2005 Workshop Manual S1-UNAE01B 2

S1-UNAE01A_2.
book 1 ページ２００４年５月２１日金曜日午後４時９分
FOREWORD
This workshop manual has been prepared to provide information regarding repair procedures on Hino Trucks.
Applicable for HINO 145, 165, 185, 238, 268, 338 series, equipped with J05D-TA, J08E-TA and J08E-TB engine
When making any repairs on your vehicle, be careful not to be injured through improper procedures.
As for maintenance items, refer to the Owner's Manual.
All information and specifications in this manual are based upon the latest product information available at the time of printing.
Hino Motors Sales U.S.A., Inc. reserves the right to make changes at any time without prior notice.
Please note that the publications below have also been prepared as relevant service manuals for the components and systems
in these vehicles.
Manual Name Pub. No.

Chassis Workshop Manual S1-UNAE01B 1/4
J05D-TA Engine Workshop Manual S5-UJ05E01B
J08E-TA, TB Engine Workshop Manual S5-UJ08E01B
FOREWORD2.fm 2 ページ２００４年５月２５日火曜日午前９時１８分
CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL

Use this chart to the appropriate chapter numbers for servicing your particular vehicle.
MANUAL NO. S1-UNAE01B 2/4 (U.S.A.), S1-CNAE01B 2/4 (CANADA)
MODELS HINO HINO HINO HINO HINO HINO HINO

CHAPTER
(Production Model 145 165 185 238 268 308 338
Code) (NA6J) (NB6J) (NC6J) (ND8J) (NF8J) (NV8J)
(NE8J) (NJ8J)
GENERAL INTRO- GN02-001
CLUTCH MAIN UNIT CL02-001 CL02-002
CLUTCH CONTROL CL03-001
TRANSMISSION MAIN UNIT TR02-001
AUTOMATIC TRANSMISSION TR04-001 TR04-002 TR04-003
TRANSMISSION/TRANSFER CONTROL TR06-001
PROPELLER SHAFT PP02-001
DIFFERENTIAL CARRIER DF02-001
BRAKE EQUIPMENT BR01-001 BR01-002 BR01-001 BR01-002
SERVICE BRAKE BR02-001 — BR02-001 —
ABS (ANTI-LOCK BRAKE SYSTEM) BR03-001 BR03-002 BR03-001 BR03-002

BR07-001,
PARKING BRAKE BR07-001, BR07-002 — BR07-002 —
STEERING EQUIPMENT SR01-001
STEERING UNIT SR02-001
POWER STEERING SR03-001
FRONT AXLE AX02-001
REAR AXLE AX03-001
WHEEL & TIRE AX04-001
SUSPENSION SU02-001
CHASSIS FRAME FC02-001
CAB CA02-001
ELECTRICAL EQUIPMENT EL01-001
ELECTRIC WIRE EL02-001
This manual does not contain items on half-tone dot meshing.

INDEX2-1.fm 1 ページ２００４年５月２６日水曜日午前９時２６分
INDEX: CHASSIS GROUP 1/4
GENERAL INTRODUCTION
CLUTCH EQUIPMENT
CLUTCH MAIN UNIT
WORKSHOP CLUTCH CONTROL
MANUAL TRANSMISSION EQUIPMENT
TRANSMISSION MAIN UNIT
TRANSFER MAIN UNIT
AUTOMATIC TRANSMISSION
P.T.O. (POWER TAKE-OFF)
TRANSMISSION / TRANSFER CONTROL
PROPELLER SHAFT EQUIPMENT
PROPELLER SHAFT
DIFFERENTIAL EQUIPMENT
DIFFERENTIAL CARRIER
BRAKE EQUIPMENT
SERVICE BRAKE
ABS (ANTI-LOCK BRAKE SYSTEM)
ES START (EASY & SMOOTH START) SYSTEM

EXHAUST BRAKE
RETARDER BRAKE
PARKING BRAKE
STEERING EQUIPMENT
STEERING UNIT
POWER STEERING
AXLE EQUIPMENT
FRONT AXLE
REAR AXLE
WHEEL & TIRE
SUSPENSION EQUIPMENT
SUSPENSION
CHASSIS EQUIPMENT
CHASSIS FRAME
COUPLER (5TH WHEEL)
PINTLE HOOK
CAB EQUIPMENT
CAB
INDEX2-2.fm 1 ページ２００４年５月２６日水曜日午前９時２８分
ELECTRICAL EQUIPMENT
ELECTRIC WIRE
ENGINE CONTROL
FUEL CONTROL
BRAKE CONTROL
SUSPENSION CONTROL
CAB EQUIPMENT CONTROL
OTHERS
BR01_001.fm 1 ページ２００４年５月２５日火曜日午前９時６分
BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE) BR01–1
BRAKE EQUIPMENT (MODELS WITH HYDRAULIC

BR 01
BRAKE) BR01-001
SERVICE BRAKE ASSEMBLY.................BR01-2

DESCRIPTION ................................................ BR01-2
DIAGRAM ........................................................ BR01-3
TROUBLESHOOTING ..................................... BR01-4
BRAKE SYSTEM AIR BLEEDING................... BR01-9
POWER STEERING SYSTEM AIR BLEEDING
....................................................................... BR01-11
BRAKE TEST ................................................ BR01-12
BR01–2 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE)
SERVICE BRAKE ASSEMBLY

DESCRIPTION
EN0600101C100001
Type of service brake Hydraulic disc type wheel brake with ABS and hydraulic booster (HYDRO-MAX)
HYDRO-MAX The Hydro-Max is a hydraulically powered brake booster which provides power
assist for applying hydraulic brakes. The booster reduces the pedal effort required
to apply the brakes as compared to a non-power system.
The hydraulic booster is comprised of an open center valve and reaction feed back
mechanism, a power piston, a 12 volt backup pump and an integral flow switch. It
is powered by either the power steering pump or other hydraulic source. The
backup pump provides a secondary power source for the hydraulic booster and is
controlled by the integral flow switch.
The master cylinder is a split system type with separate fluid chambers, pistons
and outlet ports for the front and rear brake circuits. A differential pressure switch
is equipped.
Refer to DIAGRAM on page BR01-3
ABS (Anti-Lock Braking System) The ABS system comprises of sensor rings mounted on the wheels. The ABS
computer receives signals from wheel sensors that monitor the rotational speed of
the wheels and sends out signals to maintain the appropriate braking force. The
ABS modulator maintains the appropriate braking force based on the control sig-
nals.
Refer to ABS section BR03.
Hydraulic disc brake Model: HINO 145, 165, 185 (NA6J, NB6J, NC6J (Front))
Two-Piston floating Caliper
Model: HINO 238, 268, 308, 185 (ND8J, NE8J, NF8J, NC6J (Rear))
Four-Piston fixed mount Caliper.
NOTICE
Above components were made by the following manufacturer’s;
HYDRO-MAX: BOSCH
ABS MODULATOR: MERITOR WABCO
DISC BRAKE CALIPER: MERITOR
When overhauling or replacing the ABS modulator and disc brake caliper, refer to the manufacturer's maintenance
manual.
DIAGRAM
EN0600101J100001
PUMP GEAR : POWER STEERING FLUID LINE

: ELECTRICAL CIRCUIT
HYDRO-MAX : BRAKE PIPE
CONTROLER : BRAKE HOSE
POWER STEERING
RELAY
FLOW
SW
BRAKE SW
RESERVOIR
HYDRO
PRESSURE SW MAX
M
SPEED SENSOR SPEED SENSOR
FRONT BRAKE ABS REAR BRAKE

MODULATOR
ABS
SPEED SENSOR ECU SPEED SENSOR
SAPH06ABC0100001
TROUBLESHOOTING
EN0600101F300001
Symptom Possible cause Remedy/Prevention

No response upon working the Insufficient seal of master cylinder sec- Replace master cylinder assembly.
pedal or there is the feeling of step- ondary cup.
ping on sponge.(Air trapped in the
brake lines.) Insufficient air bleeding Bleed air from brake line.

No response upon working the Vapor lock in brake system Bleed air from brake.
pedal or there is the feeling of step- Leakage of fluid from brake system Tighten further or replace gasket, O-
ping on sponge. ring, cup, etc.
Poor quality brake fluid or improper Drain the system, flush and refill with
fluid (low boil point) the recommended fluid.

Brake fluid decreases. Leakage of brake fluid from brake sys- Tighten further or replace gasket, O-
tem ring, etc.
Leakage of brake fluid from master cyl- Replace master cylinder assembly.
inder
Worn pad Replace pad if it is worn to limit. Refill
brake fluid.

Excessive pedal travel (though Insufficient brake fluid in the master Search the cause of insufficient fluid,
there is response upon working the cylinder repair or replace it.Then refill fluid and
pedal). bleed air.
Air trapped in the brake lines. Bleed air from brake lines.
Leakage of fluid from brake system Check the leak point, repair or replace.
Poor quality brake fluid or improper Drain the system, flush and refill with
fluid. the recommended fluid.
Contamination of the brake fluid. Replace the brake system and refill
with the recommended fluid.
Insufficient seal of the master cylinder Replace master cylinder assembly.
cup.

Unequal or unstable braking. Pad is wet with grease or fluid Replace the pad.
Defective pad material (improper com- Replace the pad.
bination)
Nonuniform pad contact Correct.
Excessive abrasion loss of rotors Correct or replace.
Distorted rotors Correct or replace.
Loose hub bearing Adjust or replace the bearing.
Improper or unequal pneumatic pres- Adjust to proper pneumatic pressure.
sure of tire
Clogging of brake system Replace, the pipe, hose, etc.
Abnormal piston operation of the disc Check the piston seal.
brake.

Brake drags or does not release. Improper return of master cylinder pis- Replace master cylinder assembly
ton
Clogging of brake system Replace the pipe, hose, etc.
Constricted master cylinder reservoir Clean vent passage in reservoir cap
vent
Self applied booster (fluid flow too Repair or replace power steering
high) pump
Soft or swollen master cylinder seals Flush out old brake fluid then replace
due to brake fluid contamination master cylinder and add new brake
fluid
Clogging compensating valve of mas- Replace master cylinder assembly
ter cylinder
Improper return of brake pedal Repair or replace.
Improper return of brake booster piston Replace booster assembly.
Improper installation pad Check the installed condition of the
pad. Repair.
Improper return of caliper piston Repair or replace

Not enough braking, or too much Pad is wet with grease or fluid Replace the pad
pedal resistance.(Wheel brake and Improper contact of rotor and pad Correct.
rotor)
Improper pad material or glazed pad Correct.
Deformation or hardening of rotor Correct or replace.
Excessively worn pad Replace.
Glazed rotor Correct.

Not enough braking, or too much Leakage of brake fluid from brake sys- Tighten further or replace gasket.
pedal resistance.(Control system tem
pipings)

Not enough braking, or too much Improper operation of power steering Repair or replace.
pedal resistance.(Lack of power pump
steering pump pressure) Clogging of brake system Replace pipe, hose, etc.

Not enough braking, or too much Check the pipe joints for tightness Repair.
pedal resistance.(Not enough power There is a rupture or twist in the pipe Replace.
steering pump pressure or rise of leading to the power steering pump
power steering pump pressure)
The hose is ruptured or collapsed Replace.
Power steering pump relief valve set- Replace power steering pump
ting too low
Fluid contamination Drain, flush and refill system, replace
booster or master cylinder as appropri-
ate and power steering reservoir filter
as necessary.

Not enough braking, or too much Lack of brake fluid Supply brake fluid periodically.
pedal resistance. Improper power steering pump Replace
Stuck piston in the master cylinder Replace master cylinder assembly
Insufficient power steering fluid Refill to proper level
Air trapped in the power steering fluid Search the cause, refill the fluid and
or brake fluid bleed air.
Binding brake pedal linkage Overhaul and lubricate
Worn or damaged brake booster Replace booster assembly
Leakage around the check ball in the Replace the backup pump
backup pump

Brake squeal. Improper pad material or glazed pad. Replace pad
Pad back plate contact with rotor Replace pad
Deformation or wear of rotor Repair or replace.
Intrusion of foreign matter between Clean the surface of pad or replace.
rotor and pad
Loose hub bearing Adjust or replace bearing.
Hardening of pad surface Replace pad
Different pad Replace proper pad
Rotor is wet with grease, fluid and dust Check the leakage position and repair.
Clear the rotor.

Impossible to bleed air completely. Piston cup of master cylinder sucks in Replace master cylinder assembly
air
Improper tightness of joints of brake Tighten further or replace gasket.
system.

Pulsating brake pedal ABS operation Feature of ABS operation (No prob-
lem)
Wheel bearings loose or worn Readjust or replace
Excessive rotor thickness variation Repair or replace

Decreasing pedal travel Clogging of the compensating valve of Replace master cylinder assembly
master cylinder
Swollen pressure seals of master cylin- Replace master cylinder assembly
der
Improper return of the master cylinder Replace master cylinder assembly
piston

Delay pedal return Broken return spring Replace master cylinder assembly
Restricted fluid return line of the power Remove the obstruction and replace
steering or hydraulic pump the line.
Swollen power piston seal of the Replace booster assembly
booster

Backup pump operates continu- Abnormal brake switch Replace
ously Abnormal monitor module Replace
Abnormal relay Replace
Abnormal flow switch Remove switch components, clean
and inspect for damage or contamina-
tion and replace if necessary
Binding pedal linkage Disassemble and lubricate

Backup pump does not operate Abnormal brake switch Replace
Abnormal monitor module Replace
Abnormal relay Replace
Abnormal flow switch Remove switch components, clean
and inspect for damage or contamina-
tion and replace if necessary
Binding pedal linkage Disassemble and lubricate
Abnormal backup pump Replace backup pump
Abnormal battery Recharge or replace

Power steering pump is noisy Insufficient power steering fluid Refill proper level
Air trapped in the power steering fluid Bleed air from power steering system
Contamination in the power steering Replace power steering pump and
fluid fluid.

Severe reaction to pedal pressure Throttle valve cut in spring defective. Replace booster assembly
(Grabby brakes) Binding brake pedal linkage. Disassemble and lubricate
Incorrect pads, or pads loose on plate. Replace pads. Be sure pads are tight
on caliper.
Grease or brake fluid on pad. Repair grease seal or caliper as
required. Replace pads in axle sets.
Loose caliper on caliper mounting Retighten
bracket.

Leakage between booster and mas- Primary pressure seal or backup ring Replace master cylinder assembly
ter cylinder of the master cylinder is worn or dam-
aged
Seal or O-ring of the booster end cap Replace booster assembly
assembly is worn or damaged

Leakage from booster or power Seal between backup pump and Replace the seals
steering pump booster is worn or damaged
Backup pump mounting screw is loose. Retighten
Booster housing or power steering Replace booster assembly or power
pump is worn or damaged steering pump
Backup pump is worn or damaged Replace backup pump
Seal of the booster flow switch is worn Replace flow switch seals
or damaged
NOTICE
Troubleshooting of the disc wheel brake refer to MERITOR Maintenance Manual.
BRAKE SYSTEM AIR BLEEDING

EN0600101F300002
1. PREPARATION
(1) Apply the parking brake and block the wheels.
Turn the starter switch to “LOCK” position and disconnect the battery
terminals.
NOTICE
The starter switch must remain at “LOCK” position for the entire
bleeding procedure.
(2) Fill the reservoir with new DOT 3 or DOT 4 hydraulic brake fluid.
2. AIR BLEEDING
(1) Depress the brake pedal five times using the stroke between 1/3
travel and maximum travel in 5 seconds.
(2) Release the pedal for 5 to 10 seconds. Air bubbles will rise the reser-
voir while depressing and releasing pedal.
(3) Repeat Steps (1) and (2) another three times, or until sufficient pedal
resistance is felt.
! WARNING
Do not let the brake master cylinder fluid get below the minimum level
during the bleeding operation. Failure to keep the brake reservoir
level above minimum could result in more air entering system, mak-
ing it impossible to effectively bleed the system.
(4) Bleed the brake system. Put a wrench on the brake actuator bleeder
fitting. Start with the farthest from the modulator, (typically the right
rear), then attach a length of clear plastic tubing to the bleeder fitting.
Make sure the tube fits snugly.
(5) Submerge the tubing in a container of clean brake fluid.
NOTICE
Both the tubing and container must be able to withstand the effects of
brake fluid.
(6) Depress the brake pedal 10 to 15 times, using the maximum available
stroke.
(7) Loosen the bleeder fitting until the fluid begins to flow, (about 3/4
turn), while depressing the brake pedal through its maximum available
stroke.
(8) Tighten the fitting firmly prior to releasing the brake pedal.
(9) Repeat Steps (4) through (6) several times until the discharged fluid is
free of air bubbles.
(10) Repeat Steps (1) through (7) to bleed the remaining three brake actu-
ators. Bleed in sequence of the longest to the shortest circuit from the
modulator.
SAPH06ABC0100002
(11) Check the travel of the brake pedal. If a firm resistance is felt the man-
ual bleeding procedure is complete.
(12) Check the fluid level in reservoir and fill if required. Replace reservoir
cap and dispose of used brake fluid.
SAPH06ABC0100003
POWER STEERING SYSTEM AIR BLEED-

ING
EN0600101H200001
1. FILL THE OIL RESERVOIR WITH POWER STEERING FLUID.

NOTICE
• Use only specified fluid.
• Do not overfill the oil reservoir.
• Replace old fluid with new fluid after overhauling power steering
gear unit or power steering pump.
• Specified fluid....Refer to recommended lubricant list.
! WARNING
Do not use brake fluid. Mixing brake fluid with power steering fluid
will damage the seals and O-rings in the Hydro-Max booster, the
power steering pump and power steering gear unit, resulting in possi-
ble steering loss.
2. JACK UP THE FRONT AXLE AND SUPPORT THE FRAME WITH

STANDS.
NOTICE
Block the rear wheels.
SAPH06ABC0100004
3. TURN THE STEERING WHEEL FULLY IN BOTH DIRECTIONS

SEVERAL TIMES.
4. CHECK THE FLUID LEVEL IN THE OIL RESERVOIR.

(1) Add fluid, if necessary.
! WARNING
When checking the fluid level of the power steering reservoir or add-
ing fluid to the reservoir, be careful not to contaminate fluid with dirt
in the reservoir. Fluid contaminated with dirt can result in a shorter
life of the pump, and can result in personal injury and/or property
damage due to improper operation of relief valve, central valve, etc.
SAPH06ABC0100005
5. START THE ENGINE AND TURN THE STEERING WHEEL FULLY

IN BOTH DIRECTIONS SEVERAL TIMES WITH ENGINE IDLING.
NOTICE
The fluid in the oil reservoir should be continuously replenished while
air bleeding so that the oil reservoir never becomes empty.
6. RETURN THE STEERING WHEEL TO STRAIGHT AHEAD.
SAPH06ABC0100006
7. CHECK THE BRAKE OPERATION

(1) Release the parking brake.
(2) Turn the starter switch to “ON” position (engine is not running). The
brake pressure warning light and buzzer should come on. Depress
the brake pedal, and the backup pump should start.
(3) Start the engine and depress the brake pedal. The brake pressure
warning light and buzzer should not come on, and the backup pump
should not start. If they come on there is a malfunction. See trouble-
shooting to find the problem.
8. RECHECK THE FLUID LEVEL WHEN THE ENGINE IS STOPPED.

(1) If necessary, add or decrease the power steering fluid to match
between "MAX" and "MIN".
! CAUTION
If air bleeding is not done properly, and the engine is stopped, power
steering fluid could overflow from the reservoir.
MAX.
MIN.
SAPH06ABC0100007
BRAKE TEST
EN0600101F300003
Measure the braking effect of each wheel on the brake tester. If no brake
tester is on hand, perform the brake test from low speed 5—10 km/h (3.1—
3.6 miles/h) and check the braking performance. Also check to see that
there are no irregularities in general.
S1-UNAE01A_2.book 1 ページ２００４年５月２１日金曜日午後４時９分
BRAKE EQUIPMENT (MODELS WITH FULL AIR BRAKE) BR01–1
BR01 BRAKE EQUIPMENT (MODELS WITH FULL AIR

BRAKE) BR01-002
SERVICE BRAKE ASSEMBLY.................BR01-2

DESCRIPTION ................................................ BR01-2
DATA AND SPECIFICATIONS ......................... BR01-3
DIAGRAM ........................................................ BR01-5
AIR DRYER (NABCO DU-3) .....................BR01-9

DESCRIPTION ................................................ BR01-9
COMPONENT LOCATOR.............................. BR01-10
OVERHAUL ................................................... BR01-12
INSPECTION AND REPAIR .......................... BR01-14
BRAKE VALVE AND PEDAL..................BR01-15

OVERHAUL ................................................... BR01-15
BR01–2 BRAKE EQUIPMENT (MODELS WITH FULL AIR BRAKE)
SERVICE BRAKE ASSEMBLY

DESCRIPTION
EN0600201C100001
Type of service brake Full air, S-cam brake (Q-plus) with automatic adjuster.
Air charging system Air charging is from piston type air compressor and air flow is directed and
controlled by a pressure regulator, the necessary valves, and lines as
required.
This system is provided two kinds of air dryer, that are made by NABCO
and by BENDIX.
Pressure sensor and air pressure warning switch are used for indicating
the pressure level in the system.
Service brake control system Two independent lines for front and rear wheels with air flow controlled by
a brake valve, and each line comprises of a group of valves and brake
chambers (one/wheel).
Two stop lamp switches (one/line) are used to operate the stop lamps.
Spring brake control system Single line for rear spring brake chambers.
The line comprises a control valve which controls air flow, the other neces-
sary valve and spring brake chambers.
A stop lamp switch is used to turn ON the stop lamps.
A parking brake switch is used to turn OFF the warning buzzer and to turn
ON the parking brake warning lamp.
ABS (Anti-Lock Braking System) The ABS system comprises sensor rings mounted on the wheels, the ABS
computer which receives signals from wheel sensors that monitor the rota-
tional speed of the wheels and sends out signals to maintain the appropri-
ate braking force, the ABS control valves which increase or decrease the
braking force based on the control signals.
Refer to ABS section BR03.
NOTICE
See "DIAGRAM" of the following page on the component parts
(Valves, Switches, etc.) used in easy system.
DATA AND SPECIFICATIONS

EN0600201I200001
Parts name Maker Model ⋅ specification Refer to
Front axle wheel brake MERITOR Front: 15 x 4 Q-Plus Cam Brake MERITOR Wheel Equipment Disc
with Cast Spider, automatic slack Wheel Hubs Maintenance Manual
adjuster (Slack length: 5.5, type: MM-99100,
handed) Cam Brakes Maintenance Manual 4,
Drum: 15 in. Outboad mounted Automatic Slack Adjuster Mainte-
nance Manual 4B
Front Brake chamber MGM C20 20 x 2.25 in. standard MGM Brake Service Manual
Rear axle wheel brake MERITOR Front: 16.5 x 7Q-Plus Cam Brake MERITOR Wheel Equipment Disc
with Cast Spider, automatic slack Wheel Hubs Maintenance Manual
adjuster (Slack length: 5.5, type: MM-99100,
handed) Cam Brakes Maintenance Manual 4,
Drum: 16.5 in. Outboad mounted Automatic Slack Adjuster Mainte-
nance Manual 4B
Rear Spring brake chamber MGM TR3030 3030 x 2.50 in. standard MGM Brake Service Manual
Brake valve Bendix E-8P Bendix Service Data SD-03-830
Check valve Bendix SC-3 Bendix Service Data SD-03-2205
Spring brake control valve Bendix PP-DC Bendix Service Data SD-03-3619
Spring brake valve Bendix SR-1 Bendix Service Data SD-03-4508
Double check valve Bendix DC-4 Bendix Service Data SD-03-2202
Spring brake relay valve Bendix R-14 (No.102859) Bendix Service Data SD-03-1064
Rear relay valve Bendix R-14 (No.102860) Bendix Service Data SD-03-1064
Pressure regulator Bendix D-2 Cut IN/OUT: 105/125 psi Bendix Service Data SD-01-503
Protection valve Bendix PR-4 Closing pressure: 85 psi Bendix Service Data SD-03-2010
Safety valve Bendix ST-4 Do not disassemble
Air dryer Bendix AD-IP Bendix Service Data SD-08-2414
Air dryer NABCO DU-3 See page BR01-9

Brake chamber setting

10˚ 10˚
Bolt center line
Front axle
Chamber clamp bolt

insert direction
Rear axle
22˚ 22˚
SAPH06ABC0100033
DIAGRAM
EN0600201J100001
MODEL: HINO 268 (NJ8J) AND 338 (NV8J) FULL AIR BRAKE
CAB SIDE CHASSIS SIDE

A1 ( 15)
15
B2 (1/4")
3
5 8
17 A3 (1/2")
12
MADE BY 24 7
BENDIX
B1 (1/4")
B3 (1/4") 19
D1 (1/2")
CASE OF BENDIX AIR DRIER
E5 (1/2")
14
L8 (3/8")
A1 ( 15) 16
B2 (1/4")
C2 ( 12)
E7 (1/4")
E2 (3/8")
E4 (1/2")
E6 (1/2")
L4 (3/8")
12 23 23
L5 (3/8")
1 4 4
2 P
E1 (1/2")
9 (20L) 10 (24L)
E3 (1/2")
C1 (1/2")
S 13 7 19
7 L7 (3/8") L6 (3/8") 11
L2 (3/8")
L1 (3/8")
(1/2")
A4 (1/2")
A5
6 22
L3 (3/8")
5 8 (24L)
D1 (1/2")
A3 (1/2")
7
3 MADE BY 15
20 17 NABCO
21
G1 (1/4")
RUBBER HOSE
STEEL PIPE
NYLON TUBE
SAPH06ABC0100054
1 Brake valve 13 Double check valve

2 Stop lamp switch 14 Relay valve (for spring brake)
3 Brake chamber - Front 15 Brake chamber-Rear
4 Air pressure sensor 16 Relay valve (for service brake)
5 Air dryer 17 ABS control valve - Front
6 Spring brake control valve 18 Pressure regulator
7 Check valve 19 ABS control valve - Rear
8 Air tank - Water separator 20 Air suspension seat
9 Air tank - Front 21 Air suspension protection valve
10 Air tank - Rear 22 Safety valve
11 Spring brake valve 23 Low pressure switch
12 Air compressor 24 Pressure regulator
MODEL: HINO 268 (NJ8J) AND 338 (NV8J) FULL AIR BRAKE (WITH AIR SUSPENSION)
CAB SIDE CHASSIS SIDE

A1 ( 15)
15
B2 (1/4")
3
5 8
17 A3 (1/2")
12
MADE BY 24 7
BENDIX
B1 (1/4") 27
B3 (1/4") 19
D1 (1/2")
CASE OF BENDIX AIR DRIER
E5 (1/2")
R3 (3/8")
14
L8 (3/8") 26
A1 ( 15) 16
B2 (1/4")
C2 ( 12)
E7 (1/4")
R4 (3/8")
E2 (3/8")
E4 (1/2")
E6 (1/2")
L4 (3/8")
12 23 23
L5 (3/8")
1 4 4
2 P
E1 (1/2")
9 (20L) 10 (24L)
E3 (1/2")
C1 (1/2")
S 13 7
7 L7 (3/8") L6 (3/8") 11 19 27
L2 (3/8")
L1 (3/8")
(1/2")
A4 (1/2")
A5
6 22 25
L3 (3/8")
5 8 (24L)
R1 (3/8")
R2 (3/8")
D1 (1/2")
A3 (1/2")
7
3 MADE BY
20 17 NABCO
15
21
G1 (1/4")
RUBBER HOSE
STEEL PIPE
NYLON TUBE
SAPH06ABC0100055
1 Brake valve 15 Brake chamber-Rear

2 Stop lamp switch 16 Relay valve (for service brake)
3 Brake chamber - Front 17 ABS control valve - Front
4 Air pressure sensor 18 Pressure regulator
5 Air dryer 19 ABS control valve - Rear
6 Spring brake control valve 20 Air suspension seat
7 Check valve 21 Air suspension protection valve
8 Air tank - Water separator 22 Safety valve
9 Air tank - Front 23 Low pressure switch
10 Air tank - Rear 24 Pressure regulator
11 Spring brake valve 25 Protection valve
12 Air compressor 26 Leveling valve
13 Double check valve 27 Air suspension bellows
14 Relay valve (for spring brake)
TROUBLESHOOTING
EN0600201F300001

Not enough braking (Wheel brake Lining is wet with grease or oil Replace lining.
and drum) Improper contact of drum and lining Correct.
Improper lining material or hardening Replace lining.
lining
Deformation or hardening of drum Correct or replace.
Excessively worn lining Replace.
Improper adjustment of shoe clearance Check automatic slack adjuster.
Not enough braking (Control sys- Leakage of compressed air from brake Tighten further or replace gasket.
tem) system
Lack of compressed air pressure due Use properly.
to excessive use.
Improper operation of air compressor Repair or replace.
Improper operation of brake valve Repair or replace.
Improper operation of relay valve Repair or replace.
Improper operation of spring brake Repair or replace.
control valve
chamber
Clogging of brake system Replace pipe, hose, etc.
Unequal or unstable braking (Wheel Lining is wet with grease or oil Replace lining.
brake and drum) Defective lining material (Improper Replace lining.
combination)
Non-uniform lining contact Correct.
Non-uniform brake chamber rod stroke Check automatic slack adjuster.
Distorted drums Correct or replace.
Excessive abrasion of drums Correct or replace.
Unequal or unstable braking (Con- Clogging of brake system Replace pipe, hose, etc.
trol system)
Unequal or unstable braking (Oth- Loose hub bearing Adjust or replace bearing.
ers) Improper or unequal pneumatic pres- Adjust to proper pneumatic pressure.
sure of tire
Brake drags or does not release Improper adjustment of shoe clearance Check automatic slack adjuster.
(Wheel brake and drum) Defective shoe return spring Replace.
Brake drags or does not release Lack of pedal play Adjust.
(Control system) Improper return of brake pedal Repair or replace.
Improper operation of brake valve Repair or replace.
Improper operation of relay valve Repair or replace.
Leakage of air pressure from brake Tighten connections further or replace
system gaskets.
control valve
chamber
Improper operation of air compressor Repair or replace.
Clogging of brake system Replace pipe, hose, etc.

Brake squeal (Wheel brake and Improper lining material or glazed lin- Replace lining.
drum) ing
Loose lining rivet Replace or tighten the rivet further.
Lining rivet in contact with drum Replace lining and rivet.
Deformation or wear of drum Repair or replace.
Intrusion of foreign matter between Clean the surface of lining or replace.
drum and lining
Brake squeal (Others) Loose hub bearing Adjust or replace bearing.
AIR DRYER (NABCO DU-3)

EN0600201I200002
Type Purge tank, desiccant, auto-purge valve.

Air and Water discharging time (Reclamation cycle) Approx. 50 sec.
DESCRIPTION
EN0600201C100002
SAPH06ABC0100056
1 Chamber (Purge tank) 14 Plug

2 Case cover 15 Pressure regulator
3 Check valve 16 Adjusting screw
4 Spring 17 Piston
5 Body 18 Piston spring
6 Desiccant case A Outlet (Dried air to air tank)
7 Filter B Orifice
8 Desiccant C Inlet (From air compressor)
9 Oil separator filter D Purged air
10 Valve body E Dehumidification
11 Valve spring F Reclamation
12 Piston G To purge valve
13 Purge valve
COMPONENT LOCATOR
EN0600201D100001
SAPH06ABC0100036
1 O-ring 16 Filter plate

2 Cover 17 Filter
3 Piston 18 Desiccant
4 Valve spring 19 Desiccant case
5 Valve body 20 Oil separator filter
6 Purge valve 21 Body
7 Silencer case 22 Valve stopper
8 Silencer plate 23 Governor valve
9 Silencer 24 Piston assembly
10 Retainer ring 25 Exhaust stem spring
11 Exhaust cover 26 Exhaust stem
12 Chamber 27 Pressure regulator assembly
13 Check valve 28 Valve seat
14 Case cover 29 Plate
15 Set spring 30 Heater (If so equipped)
Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}

A 2.0-3.9 {20-40, 1.5-2.9} D 6.9-7.8 {71-79, 5.2-5.7}
B 3.9-6.9 {40-70, 2.9-5.0} E 17.7-27.5 {180-280, 13-20}
C 4.9-5.9 {50-60, 3.7-4.3}
OVERHAUL
EN0600201H200001
IMPORTANT POINTS - ASSEMBLY
1. LUBRICATION
C (1) When assembling the air dryer, use new O-ring, gasket and seal.
(2) Apply grease (lithium base) to each sliding surface of the component
parts and O-ring groove.
A • A: O-ring
• B: Sliding surface
2. BEFORE TIGHTENING THE BOLT WITH SPECIFIED TIGHTENING

A TORQUE, TAP ALL OVER THE OUTER SURFACE OF THE DESIC-
CANT CASE WITH A PLASTIC HAMMER.
• C: Bolt
A IMPORTANT POINTS - MOUNTING

A
B
1. INSPECTION
(1) Operate the engine and raise the air pressure until the air discharge
from the purge valve, then stop the engine.
(The pressure reaches the valve opening pressure of the air pressure
regulator).
.
a. Check to see that there is no air leakage from the purge valve.
SAPH06ABC0100037
2. ADJUSTMENT
(1) Loosen the adjusting screw until the rod spring tension is released,
and start and idle the engine to charge the air for the air tank.
(2) Tighten the adjusting screw gradually till the air pressure gauge indi-
cate valve opening pressure shown below and the air starts to dis-
charge from purge valve.
Governor valve opening pressure: 880kpa {9.0 kgf/cm2, 128 lbf/
in2.}
SAPH06ABC0100038
(3) Tighten the adjusting screw lock nut.
SAPH06ABC0100039
(4) Watch the air pressure gauge needle and see that it stops at the valve
closing pressure shown below.
Governor valve closing pressure: 780 kpa {8.0 kgf/cm2, 114 lbf/
in2.}
SAPH06ABC0100040
INSPECTION AND REPAIR

EN0600201H300001
Inspection Item Standard Limit Remedy Inspection Procedure
Check valve and valve — — Replace, If nec- Visual check

seat surface: essary.
Wear and damage
Valve body sliding surface — — Replace, If nec- Visual check

and purge valve seat sur- essary.
face:
Wear and damage
Piston sliding surface: — — Replace, If nec- Visual check

Wear and damage essary.
Purge valve seat surface: — — Replace, If nec- Visual check

Wear and damage essary.
Desiccant: — Discolored, Replace. Visual check

Contamination and deteri- more than 1/5
oration of the quantity.
BRAKE VALVE AND PEDAL

OVERHAUL
EN0600201H200002
IMPORTANT POINTS - DISMOUNTING
1. DISCONNECT THE NYLON TUBE FROM THE BRAKE VALVE AND

CLUTCH PIPE FROM THE MASTER CYLINDER
2. REMOVE THE CLUTCH MASTER CYLINDER AND DISCONNET

THE STEERING SHAFT
3. REMOVE THE PEDAL BRACKET ASSEMBLY

(1) Loosen the bolts and remove the pedal bracket assembly.
SAPH06ABC0100046
4. REMOVE THE BRAKE PEDAL.

(1) Tap the shaft lightly using a brass rod and a hammer, remove the
brake pedal from the pedal bracket assembly.
NOTICE
Do not pull out the shaft because the brake pedal and the clutch pedal
are installed by one shaft.
5. DISCONNET THE PUSH ROD JOINT FROM THE BRAKE PEDAL

LEVER
6. REMOVE THE BRAKE VALVE ASSEMBLY

SAPH06ABC0100047
IMPORTANT POINTS - MOUNTING
1. INSTALL THE BRAKE VALVE ASSEMBLY

Install the brake valve assembly with the 4 nuts.
Tightening Torque:
18-26 N⋅m{184-265 kgf⋅cm, 13-19 lbf⋅ft}
2. CONNECT THE PUSH ROD JOINT TO THE BRAKE PEDAL LEVER

NOTICE
A: The boot has to be securely fit into the groove of the push rod.
B: After assembling boot into the pedal bracket.
Make sure that the projection of the boot all around is seen above the
surface of the pedal bracket.
SAPH06ABC0100048
3. INSTALL THE BRAKE PEDAL

(1) Apply thinly lithium grease, Fuji sunlight 2000 or its equivalent to the
pedal bushing.
(2) Install the shaft into the pedal bracket and the pedal.
(3) Insert 2 snap ring to the pedal shaft.
4. INSTALL THE PEDAL BRACKET ASSEMBLY

Install the pedal bracket assembly with bolts.
Tightening Torque:
18-26 N⋅m{184-265 kgf⋅cm, 13-19 lbf⋅ft}
SAPH06ABC0100049
5. INSTALL THE CLUTCH MASTER CYLINDER AND THE STEERING
SHAFT
6. CONNECT THE NYLON TUBE TO THE BRAKE VALVE CONNEC-

TOR
Tightening Torque:
φ3/8: 35-45 N⋅m{375-459 kgf⋅cm, 26-33 lbf⋅ft}
φ1/2: 50-60 N⋅m{510-612 kgf⋅cm, 37-44 lbf⋅ft}
NOTICE
• When assembling the nylon tubes be careful not press down
them by foot, and pinch them between other parts and so on.
• When fitting the joint to the nylon tube, be careful not to fold the
tube. If it is folded or damaged, replace it with new one.
7. INSPECT THE BRAKE PEDAL PLAY

(1) Make sure that the installing hight of the brake pedal "C" and the
pedal play "B".
B: 2-5 mm {0.0788-0.1968 in.}
C: 164.6-174.6 mm {6.48-6.87 in.}
SAPH06ABC0100050
(2) If the pedal play is out of the standard value, loosen the lock nut and
turn the push rod to adjust the pedal play to the standard value.
NOTICE
If you have loosened the push rod lock nut for the adjustment,
retighten it securely.
Tightening Torque:
17.5-32.5 N⋅m{179-332 kgf⋅cm, 12.9-24 lbf⋅ft}
SAPH06ABC0100051
8. ADJUST AND INSPECT THE STOP LIGHT SWITCH

(1) After installing bushing to the switch bracket, insert the stop light
switch then twist it clockwise while making contact with the tip of the
switch and the buffer, and fix it.
(2) After installing the switch, when releasing the brake pedal, make sure
there is no contact between the switch and buffer.
Confirm the operation of the switch surely.
SAPH06ABC0100052
(3) Check the clearance between stop lamp switch and buffer.
"D": 0.5-1.5 mm {0.0197-0.0590 in.}
SAPH06ABC0100053
Revised 09-02
Cam Brakes
Maintenance Manual 4
16.5-Inch
Q PlusTM Brake
with a Stamped Spider
• Q PlusTM
• Cast PlusTM
• Q Series
• P Series
• T Series
Service Notes
Before You Begin

Service Notes
Access Product and Service Information
on Our Website
This manual describes the correct service and
repair procedures for Meritor cam brakes. Before Visit the DriveTrain PlusTM by ArvinMeritor Tech
you begin procedures: Library at arvinmeritor.com to access and order
product and service information.
1. Read and understand all instructions and
procedures before you begin to service
components. To Order Information by Phone
2. Read and observe all Caution and Warning Call ArvinMeritor’s Customer Service Center at
safety alerts that precede instructions or 800-535-5560 to order the following publications.
procedures you will perform. These alerts help Automatic Slack Adjuster (Maintenance
to avoid damage to components, serious Manual 4B)
personal injury, or both.
Q PlusTM LX500 and MX500 Cam Brakes
3. Follow your company’s maintenance and (Maintenance Manual MM-96173)
service, installation, and diagnostics
guidelines. Q and Q PlusTM Cam Brake Maintenance
(Video T-90233V)
4. Use special tools when required to help avoid
serious personal injury and damage to Meritor Automatic Slack Adjuster Installation
components. and Maintenance (Video T-90234V)
New Generation Automatic Slack Adjuster
Safety Alerts, Torque Symbol and Notes (Video T-9443V)
Drivetrain PlusTM by ArvinMeritor Technical
A Warning alerts you to an Electronic Library on CD. Features product
WARNING instruction or procedure and service information on most Meritor,
that you must follow ZF Meritor and Meritor WABCO products.
exactly to avoid serious $20. Order TP-9853.
personal injury.
How to Order Tools, Supplies and Brake
A Caution alerts you to an
CAUTION instruction or procedure Conversion Kits
that you must follow Call ArvinMeritor’s Commercial Vehicle
exactly to avoid damage to Aftermarket at 888-725-9355 to order tools and
components. supplies specified in this manual. You also can
A torque symbol alerts you order the following brake conversion kits.
to tighten fasteners to a A kit to convert Q Series cam brake shoes
specified torque value. (except models with cast shoes) to Q Series
brakes with “quick change” shoes
NOTE A Note provides
information or suggestions A kit to convert standard 16.5-inch Q Series cam
that help you correctly brakes to Q PlusTM cam brakes
service a component.
Table of Contents
Asbestos and Non-Asbestos Fibers Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Section 1: Exploded Views
15- and 16.5-Inch Q PlusTM and Q Series Cam Brakes with Cast Spiders . . . . . . . . . . . . . . . . . . . . . . . . .2
16.5-Inch Q PlusTM Cam Brake with a Stamped Spider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
15-Inch Q Series Cam Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
16.5-Inch P Series Cam Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
15-Inch T Series Cam Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Section 2: Introduction
Cam Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Q PlusTM
Q Plus LX500 and Q Plus MX500
Cast PlusTM
Q Series Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
P Series
T Series
Differences Between Q Plus and Q Series Cam Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Section 3: Removal and Disassembly
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Wheel Components
Automatic Slack Adjuster
Brake Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Check Cam-to-Bushing Radial Free Play and Axial End Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Remove the Automatic Slack Adjuster and Camshaft
Section 4: Prepare Parts for Assembly
Clean and Dry Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Corrosion Protection
Inspect Parts
16.5-Inch Brake Shoes Only
Automatic Slack Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Camshafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Section 5: Installation and Assembly
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Camshaft
Replace a Q Series Camshaft with a Q Plus Camshaft
Replace a Hammerclaw Camshaft with a Standard Q Plus Camshaft
Shoe Return Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Automatic Slack Adjuster onto the Camshaft
Welded Clevis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Threaded Clevis
Adjust the Clevis Position on the Chamber Push Rod
Brake Slack Adjuster Position (BSAP) Method for Standard Stroke and Long Stroke Chambers . . . .22
Brake Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Drum and Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Table of Contents
Section 6: Adjust the Brakes

Adjust the Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Measure Free Stroke
Commercial Vehicle Safety Alliance (CVSA) Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Measure Push Rod Travel (Adjusted Chamber Stroke)
Alternate Method to Measure Push Rod Travel (Adjusted Chamber Stroke) . . . . . . . . . . . . . . . . . . . . 28
CVSA North American Out-of-Service Criteria Reference Tables
Section 7: Reline the Brakes
Important Information on Linings and Primary Shoe Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Use the Correct Lining Material
Single Axles
Tandem Axles
Combination Friction Linings
Primary Shoe Locations
Section 8: Maintenance and Service
Lubrication and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Camshaft Bushings
Rollers and Anchor Pins
Anti-Seize Compound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Factory-Installed Automatic Slack Adjusters on Q Plus LX500 and
MX500 Cam Brake Packages
Maintenance Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
On-Highway Linehaul Applications
Off-Highway Linehaul Applications
Section 9: Inspection
Before You Return the Vehicle to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Section 10: Recommended Periodic Service
Recommended Periodic Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Adjust the Brakes
Lubrication
Reline the Brakes
Inspection
Major Overhaul
Section 11: Torque Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Section 12: Cam Brake Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Asbestos and Non-Asbestos Fibers
ASBESTOS FIBERS WARNING NON-ASBESTOS FIBERS WARNING

The following procedures for servicing brakes are recommended to reduce The following procedures for servicing brakes are recommended to reduce
exposure to asbestos fiber dust, a cancer and lung disease hazard. Material Safety exposure to non-asbestos fiber dust, a cancer and lung disease hazard. Material
Data Sheets are available from ArvinMeritor. Safety Data Sheets are available from ArvinMeritor.
Hazard Summary Hazard Summary
Because some brake linings contain asbestos, workers who service brakes must Most recently manufactured brake linings do not contain asbestos fibers. These brake
understand the potential hazards of asbestos and precautions for reducing risks. linings may contain one or more of a variety of ingredients, including glass fibers,
Exposure to airborne asbestos dust can cause serious and possibly fatal diseases, mineral wool, aramid fibers, ceramic fibers and silica that can present health risks if
including asbestosis (a chronic lung disease) and cancer, principally lung cancer and inhaled. Scientists disagree on the extent of the risks from exposure to these
mesothelioma (a cancer of the lining of the chest or abdominal cavities). Some studies substances. Nonetheless, exposure to silica dust can cause silicosis, a non-cancerous
show that the risk of lung cancer among persons who smoke and who are exposed to lung disease. Silicosis gradually reduces lung capacity and efficiency and can result in
asbestos is much greater than the risk for non-smokers. Symptoms of these diseases serious breathing difficulty. Some scientists believe other types of non-asbestos fibers,
may not become apparent for 15, 20 or more years after the first exposure to asbestos. when inhaled, can cause similar diseases of the lung. In addition, silica dust and
ceramic fiber dust are known to the State of California to cause lung cancer. U.S. and
Accordingly, workers must use caution to avoid creating and breathing dust when international agencies have also determined that dust from mineral wool, ceramic fibers
servicing brakes. Specific recommended work practices for reducing exposure to and silica are potential causes of cancer.
asbestos dust follow. Consult your employer for more details.
Accordingly, workers must use caution to avoid creating and breathing dust when
Recommended Work Practices servicing brakes. Specific recommended work practices for reducing exposure to
non-asbestos dust follow. Consult your employer for more details.
1. Separate Work Areas. Whenever feasible, service brakes in a separate area away
from other operations to reduce risks to unprotected persons. OSHA has set a maximum Recommended Work Practices
allowable level of exposure for asbestos of 0.1 f/cc as an 8-hour time-weighted average
and 1.0 f/cc averaged over a 30-minute period. Scientists disagree, however, to what 1. Separate Work Areas. Whenever feasible, service brakes in a separate area away
extent adherence to the maximum allowable exposure levels will eliminate the risk of from other operations to reduce risks to unprotected persons.
disease that can result from inhaling asbestos dust. OSHA requires that the following 2. Respiratory Protection. OSHA has set a maximum allowable level of exposure for
sign be posted at the entrance to areas where exposures exceed either of the maximum silica of 0.1 mg/m3 as an 8-hour time-weighted average. Some manufacturers of non-
allowable levels: asbestos brake linings recommend that exposures to other ingredients found in non-
DANGER: ASBESTOS asbestos brake linings be kept below 1.0 f/cc as an 8-hour time-weighted average.
CANCER AND LUNG DISEASE HAZARD Scientists disagree, however, to what extent adherence to these maximum allowable
exposure levels will eliminate the risk of disease that can result from inhaling non-
AUTHORIZED PERSONNEL ONLY
asbestos dust.
RESPIRATORS AND PROTECTIVE CLOTHING
ARE REQUIRED IN THIS AREA. Therefore, wear respiratory protection at all times during brake servicing, beginning
with the removal of the wheels. Wear a respirator equipped with a high-efficiency
2. Respiratory Protection. Wear a respirator equipped with a high-efficiency (HEPA) (HEPA) filter approved by NIOSH or MSHA, if the exposure levels may exceed OSHA or
filter approved by NIOSH or MSHA for use with asbestos at all times when servicing manufacturers’ recommended maximum levels. Even when exposures are expected to
brakes, beginning with the removal of the wheels. be within the maximum allowable levels, wearing such a respirator at all times during
3. Procedures for Servicing Brakes. brake servicing will help minimize exposure.
a. Enclose the brake assembly within a negative pressure enclosure. The enclosure 3. Procedures for Servicing Brakes.
should be equipped with a HEPA vacuum and worker arm sleeves. With the a. Enclose the brake assembly within a negative pressure enclosure. The enclosure
enclosure in place, use the HEPA vacuum to loosen and vacuum residue from the should be equipped with a HEPA vacuum and worker arm sleeves. With the enclosure
brake parts. in place, use the HEPA vacuum to loosen and vacuum residue from the brake parts.
b. As an alternative procedure, use a catch basin with water and a biodegradable, b. As an alternative procedure, use a catch basin with water and a biodegradable,
non-phosphate, water-based detergent to wash the brake drum or rotor and other non-phosphate, water-based detergent to wash the brake drum or rotor and other
brake parts. The solution should be applied with low pressure to prevent dust from brake parts. The solution should be applied with low pressure to prevent dust from
becoming airborne. Allow the solution to flow between the brake drum and the becoming airborne. Allow the solution to flow between the brake drum and the
brake support or the brake rotor and caliper. The wheel hub and brake assembly brake support or the brake rotor and caliper. The wheel hub and brake assembly
components should be thoroughly wetted to suppress dust before the brake shoes components should be thoroughly wetted to suppress dust before the brake shoes
or brake pads are removed. Wipe the brake parts clean with a cloth. or brake pads are removed. Wipe the brake parts clean with a cloth.
c. If an enclosed vacuum system or brake washing equipment is not available, c. If an enclosed vacuum system or brake washing equipment is not available,
employers may adopt their own written procedures for servicing brakes, provided carefully clean the brake parts in the open air. Wet the parts with a solution applied
that the exposure levels associated with the employer’s procedures do not exceed with a pump-spray bottle that creates a fine mist. Use a solution containing water,
the levels associated with the enclosed vacuum system or brake washing and, if available, a biodegradable, non-phosphate, water-based detergent. The
equipment. Consult OSHA regulations for more details. wheel hub and brake assembly components should be thoroughly wetted to
d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA for use suppress dust before the brake shoes or brake pads are removed. Wipe the brake
with asbestos when grinding or machining brake linings. In addition, do such work in parts clean with a cloth.
an area with a local exhaust ventilation system equipped with a HEPA filter. d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA when
e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a grinding or machining brake linings. In addition, do such work in an area with a local
HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic exhaust ventilation system equipped with a HEPA filter.
solvents, flammable solvents, or solvents that can damage brake components as e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a
wetting agents. HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic
solvents, flammable solvents, or solvents that can damage brake components as
4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or wetting agents.
by wet wiping. NEVER use compressed air or dry sweeping to clean work areas. When
you empty vacuum cleaners and handle used rags, wear a respirator equipped with a 4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter
HEPA filter approved by NIOSH or MSHA for use with asbestos. When you replace a or by wet wiping. NEVER use compressed air or dry sweeping to clean work areas.
HEPA filter, wet the filter with a fine mist of water and dispose of the used filter with care. When you empty vacuum cleaners and handle used rags, wear a respirator equipped
with a HEPA filter approved by NIOSH or MSHA, to minimize exposure. When you
5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or replace a HEPA filter, wet the filter with a fine mist of water and dispose of the used filter
smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped with care.
with a HEPA filter to vacuum work clothes after they are worn. Launder them separately.
5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or
Do not shake or use compressed air to remove dust from work clothes.
smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped
6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with a HEPA filter to vacuum work clothes after they are worn. Launder them separately.
with care, such as in sealed plastic bags. Consult applicable EPA, state and local Do not shake or use compressed air to remove dust from work clothes.
regulations on waste disposal. 6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters
with care, such as in sealed plastic bags. Consult applicable EPA, state and local
Regulatory Guidance regulations on waste disposal.
References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the
United States, are made to provide further guidance to employers and workers Regulatory Guidance
employed within the United States. Employers and workers employed outside of the References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the
United States should consult the regulations that apply to them for further guidance. United States, are made to provide further guidance to employers and workers
employed within the United States. Employers and workers employed outside of the
United States should consult the regulations that apply to them for further guidance.
Maintenance Manual 4 Copyright 2002

Revised 09-02 ArvinMeritor, Inc. Page 1
Section 1
Exploded Views
Section 1 Views
Exploded
24
23
1
22
10
11 21
2 8 7
20
3
18 19
4
17
15 16
13 14
12
11
9 10
7 8
6
5
15- and 16.5-Inch Q PlusTM and Q Series Cam Brakes with Cast Spiders
Item Description Item Description
1 Shoe and Lining Assembly 13 Cast spider — brake

2 Spring — shoe retaining 14 Seal — chamber bracket
3 Bushing — anchor pin 15 Bracket — camshaft and chamber
4 Anchor Pin — brake shoe 16 Capscrew — chamber bracket
5 Camshaft — “S” head 17 Fitting — grease
6 Washer — camhead 18 Washer — camshaft (thick)
7 Seal — camshaft (grease) 19 Slack Adjuster — automatic
8 Bushing — camshaft 20 Washer — spacing
9 Pin — return spring 21 Snap Ring — camshaft
10 Roller — brake shoe 22 Dust Shield
11 Retainer — shoe roller 23 Capscrew — dust shield
12 Spring — brake shoe return 24 Plug
Copyright 2002 Maintenance Manual 4

Page 2 ArvinMeritor, Inc. Revised 09-02
Section 1
Exploded Views
21
22
10 22
1 11 20
2 15 18
26
25
23
19
27
24
13 17
3
14
4 15
8
7
16
23
6 12 11
5
9
21
10
1
16.5-Inch Q PlusTM Cam Brake with a Stamped Spider
1 Shoe and Lining Assembly 15 Capscrew — Grade 8

2 Spring — shoe retaining 16 Plug — pipe
3 Bushing — anchor pin 17 Washer — camshaft (thick)
4 Anchor Pin — brake shoe 18 Slack adjuster — automatic
5 Camshaft — “S” head 19 Washer — spacing
6 Washer — camhead 20 Snap ring — camshaft
7 Orange seal — camshaft 21 Dust shield
8 Bushing — camshaft 22 Capscrew — dust shield
9 Pin — return spring 23 Washer (4) — hard
10 Roller — brake shoe 24 Nut (4) — Grade 8
11 Retainer — shoe roller 25 Bushing — camshaft
12 Spring — brake shoe return 26 Seal — camshaft
13 Stamped spider — brake 27 Washer — spacing (thin)
14 Bracket — camshaft and chamber

Section 1
Exploded Views
11
8 9 10
4 3
4
3
2
22
1 7
21
6 20
15 18
17
13
12 27
26
24 25
16 19
14 23
15-Inch Q Series Cam Brakes
1 Camshaft 15 Spring — shoe return

2 Washer — camhead 16 Rollers — brake shoe
3 Seal — camshaft (grease) 17 Anchor Pins — brake shoe
4 Bushing — camshaft 18 Plate — support
5 Bracket — camshaft 19 Backing Plate
6 Nut — camshaft bracket 20 Washer — anchor pin
7 Grease Fitting 21 Nut — anchor pin
8 Washer — spacing 22 Dust Shield
9 Slack Adjuster — automatic 23 Bolt — shoe clip
10 Spacers — camshaft 24 Bolt — camshaft bracket
11 Snap Ring — camshaft 25 Nut — clip to backing plate
12 Spring — shoe retaining 26 Capscrew — dust shield
13 Shoe and Lining Assembly 27 Nut — dust shield
14 Clips — anti-rattle

Section 1
Exploded Views
22
2
20
21
19
18
3 1 10
9 18
17
4
6 5
16
4 13
14 15
10
11
9 12
8
16.5-Inch P Series Cam Brakes
1 Spider — brake 12 Roller — cam

2 Shoe and Lining Assembly 13 Seal — camshaft bracket
3 Spring — brake shoe return 14 Bracket — camshaft and chamber
4 Snap Ring — anchor pin 15 Capscrew — camshaft bracket
5 Anchor Pin — brake shoe 16 Fitting — grease
6 Bushing — anchor pin 17 Slack Adjuster — automatic
7 Camshaft — “S” head 18 Washer — spacing
8 Washer — camhead 19 Snap Ring — camshaft
9 Seal — camshaft (grease) 20 Dust Shield
10 Bushing — camshaft 21 Capscrew — dust shield
11 Pin — return spring 22 Plug

Section 1
Exploded Views
11
10
8 9
4
6
20
4 6 7 21
5
3
2
1
19
18
16
15
17
22
23
12 14
13
15-Inch T Series Cam Brakes
1 Camshaft 13 Spring — anti-rattle

2 Washer — camhead 14 Rod — anti-rattle
3 Seal — camshaft (grease) 15 Shoe and Lining Assembly
4 Bushing 16 Spring — shoe return
5 Bracket — camshaft and chamber 17 Roller — brake shoe
6 Lockwasher — bracket 18 Snap Ring — anchor pin
7 Nut — bracket 19 Anchor Pin — brake shoe
8 Washer — spacing 20 Washer — anchor pin
9 Slack Adjuster — automatic 21 Nut — anchor pin
10 Washer — spacer 22 Backing Plate
11 Snap Ring — camshaft 23 Capscrew — dust shield
12 Retainer — anti-rattle spring
Figure 0.1

Section 2
Introduction
Cam Brakes
Section 2
Introduction
Figure 2.2
Q PlusTM
Figure 2.1
More lining thickness increases service life and
mileage between relines.
A redesigned S-cam and heavy-duty shoe
return spring allow additional shoe travel.
An improved camshaft bushing contributes to
longer service life.
The trailer axle version of the 16.5 x 7.0-inch
Q Plus brake uses a heavy-duty, bolt-on
camshaft bushing. Cast PlusTM
Figure 2.3
Figure 2.1 The Cast Plus brake is spec’d for heavy-duty,
off-highway and people-mover applications.
Uses Meritor’s Q Plus cam brake linings, that
provide increased service life and mileage
between relines.
A redesigned S-cam and heavy-duty shoe
return spring allow additional shoe travel.
An improved camshaft bushing contributes to
longer service life.
The brake uses Meritor’s cast P Series brake
shoe design.
Q Plus LX500 and Q Plus MX500 Figure 2.3

Figure 2.2
For complete maintenance and service
information on Meritor’s Q Plus LX500 and MX500
cam brakes, refer to Maintenance Manual
MM-96173, Q PlusTM LX500 and MX500 Cam
Brakes. To obtain this publication, refer to the
Service Notes page on the front inside cover of
this manual.
The Q Plus LX500 cam brake and the
Q Plus MX500 cam brake both include
an Extended Lube Feature and Meritor
factory-installed automatic slack adjusters.
The Q Plus MX500 cam brake also includes all
features found in the Q Plus LX500 brake plus
special long life brake shoes and linings.

Section 2
Introduction
Q Series Brakes T Series

Figure 2.4 Figure 2.6
Open anchor pins for “Quick Change” service. 15-inch diameter with 3.5-inch and 4-inch
widths for smaller capacity axles.
Single web shoe (15-inch only).
0.438-inch thick lining.
Two shoe retainer springs in addition to the
shoe return springs.
Available in 16.5-inch diameter with 5, 6, 7, Figure 2.6
8.625 and 10-inch widths with 0.75-inch tapered
brake lining.
Available in 15.0-inch diameter for front
non-drive axle applications.
Figure 2.4
P Series
Figure 2.5
16.5-inch and 18-inch diameters with 7-inch
wide cast shoes.
0.75-inch tapered brake lining.
Figure 2.5

Section 2
Introduction
Differences Between Q Plus and Q Series Cam Brakes
Q Plus Components Q Series Components
FMSI NO. 4707 FMSI NO. 4515G

28 RIVET HOLES 32 RIVET HOLES
PLUS-SHAPED HOLES (+)
IN TABLE IN TABLE
STAMPED IN TABLE MERITOR BULGE
MERITOR NO BULGE 16.5 Q SERIES
16.5 Q PLUS ON WEB
ON WEB
16.5 Q PLUS 16.5 Q SERIES

STAMPED ON WEB STAMPED ON WEB
SHOE TAG
16.5" X 7" Q SHOE SHOE TAG
16.5" X 7" Q PLUS SHOE
CAM PART NUMBER DEEPER POCKET

TIP TO TIP = 4.25" LOCATED HERE CAM PART NUMBER 1.378 DIA.
TIP TO TIP = 4.22" LOCATED HERE
1.18 DIA. 16.5

INCREASED
Q PLUS
LIFT
LOCATED HERE 16.5" Q CAMSHAFT (1.5" DIA.-10 OR 28 SPLINES)
16.5" Q PLUS CAMSHAFT (1.5" DIA.-28 SPLINES)
FMSI NO. 4702 16 RIVET HOLES IN TABLE

FMSI NO. 1308 USED WITH
USED WITH SPIDER 14 RIVET HOLES BACKING PLATE
MERITOR
15 Q PLUS NO BULGE IN TABLE MERITOR
ON WEB 15 Q PLUS BULGE ON WEB
15 Q PLUS SINGLE WEB
STAMPED
ON WEB 15 Q PLUS
DOUBLE WEB STAMPED ON WEB
15" X 4" Q PLUS SHOE 15" X 4" Q SHOE
CAM PART NUMBER DEEPER

CAM 1.164 DIA.
TIP TO TIP = 3.38" LOCATED HERE POCKET
TIP TO TIP = 3.25" PART NUMBER
LOCATED HERE
0.988 DIA.
16 INCREASED
Q PLUS LIFT
LOCATED HERE 15" Q CAMSHAFT (1.25" DIA.-10 OR 24 SPLINES)
15" Q PLUS CAMSHAFT (1.5" DIA.-28 SPLINES)
Camshafts Shoes Return Springs

Q Plus Q Plus Heavy-duty (blue)
Q Plus Q Series Standard
Q Q Series Standard

Section 3
Removal and Disassembly
Section 3 and Disassembly

Removal
ASBESTOS AND NON-ASBESTOS Automatic Slack Adjuster
FIBERS WARNING For complete maintenance and service information
Some brake linings contain asbestos fibers, a on Meritor’s automatic slack adjuster, refer to
cancer and lung disease hazard. Some brake Maintenance Manual 4B, Automatic Slack
linings contain non-asbestos fibers, whose Adjuster. To obtain this publication, refer to the
long-term effects to health are unknown. You Service Notes page on the front inside cover of
must use caution when you handle both asbestos this manual.
and non-asbestos materials. Refer to Page 1 in this
manual for hazard summaries and recommended CAUTION
work practices.
You must disengage a pull pawl or remove a
conventional pawl before you rotate the manual
WARNING adjusting nut, or you’ll damage pawl teeth. A
To prevent serious eye injury, always wear safe damaged pawl will not allow the slack adjuster to
eye protection when you perform vehicle automatically adjust brake clearance. Damage to
maintenance and service. components can result. Replace a damaged pawl
before returning the vehicle to service.
Park the vehicle on a level surface. Block the
wheels to prevent the vehicle from moving. 1. Disengage the pull pawl. Use a screwdriver or
Support the vehicle with safety stands. Do not equivalent tool to pry the pull pawl at least
work under a vehicle supported only by jacks. 1/32-inch to disengage the teeth. Figure 3.1.
Jacks can slip or fall over. Serious personal injury If the slack adjuster has a conventional
and damage to components can result. pawl: Remove the pawl. Figure 3.1.
2. Use a wrench to turn the manual adjusting nut
Removal COUNTERCLOCKWISE until the brake shoes
are fully retracted, and the lining clears the
Wheel Components drum. Figure 3.2.
1. Park the vehicle on a level surface.
2. Block the wheels to prevent the vehicle from Figure 3.1
moving.
3. Raise the vehicle, so that the area you will
service is off of the ground. Support the PAWL
vehicle with safety stands.
PRY UP
WARNING
CONVENTIONAL PULL PAWL
Before you service a spring chamber, carefully PAWL
follow the manufacturer’s instructions to
compress and lock the spring to completely
release the brake. Verify that no air pressure
remains in the service chamber before you
proceed. Sudden release of compressed air can
cause serious personal injury and damage to
components.
4. If the brake has spring chambers, carefully

cage and lock the spring, so that the spring
cannot actuate during assembly.

Section 3
COUNTERCLOCKWISE
WARNING Figure 3.4

When you remove a clevis pin that has a spring,
hold the spring with pliers. The spring can
disengage from the clevis with enough force to
cause serious personal injury.
3. Remove both clevis pins, and retainer clips or

cotter pins. Move the slack adjuster away from
the clevis.
4. Follow the manufacturer’s instructions to
remove the wheel and drum from the axle.
Brake Shoes
Figure 3.5
All Q Plus and Q Series 15-Inch and 16.5-Inch
Brakes
1. Push down on the bottom brake shoe. Pull on
the cam roller retainer clip to remove the
bottom cam roller. Figure 3.3.
2. Lift the top brake shoe and pull on the cam
roller retainer clip to remove the top cam
roller.
3. Lift the bottom shoe to release the tension on
the brake shoe return spring. Figure 3.4.
4. Rotate the bottom shoe to release the tension
on the brake shoe retainer springs. Figure 3.5.
5. Remove the shoe retainer springs and the
brake shoes.

Section 3
P Series and Cast Plus Brakes 3. Rotate the top shoe to release the tension on
the brake shoe return spring. Remove the
Some trailer axle P Series brakes have anchor pins shoe. Figure 3.9.
that are secured with lock pins. You can use a steel
rod to make a tool to drive out the lock pins. 4. Remove the bottom anchor pin. Refer to
Figure 3.6. Step 2. Remove the bottom shoe. If necessary,
remove the cam rollers. Figure 3.10.
Figure 3.6
Figure 3.8
TRAILER AXLE BRAKE
LOCK
PINS
5"
1/8"
3/16" 9/32"
NOTE: The current anchor pin arrangement is

shown in Figure 3.7. Older P Series brakes can
include additional parts. Figure 3.9
1. Remove the anchor pin snap ring, washer,

retainer, felts, seals or capscrews as required.
Figure 3.7
BUSHING
1225-B-496 SNAP RING
1229-D-2942
(0.093")
ANCHOR PIN
1259-N-1132
(CAST SHOE)
1259-M-1131
(STAMPED SHOE) Figure 3.10
WASHER
1229-B-1848
(0.060")
WARNING
Use a brass or leather mallet for assembly and
disassembly procedures. Do not hit steel parts
with a steel hammer. Pieces of a part can break
off and cause serious personal injury.
2. Remove the top anchor pin with a brass drift.

Figure 3.8.

Section 3
T Series Cam Brakes Remove the Automatic Slack Adjuster

1. Remove the anti-rattle spring retainer and and Camshaft
spring from the anti-rattle rod. 1. Remove the snap ring, washers and spacers
2. Push down on the bottom brake shoe to from the camshaft.
provide enough clearance to remove the 2. Remove the automatic slack adjuster from the
bottom cam roller. Remove the roller. camshaft.
3. Lift the top brake shoe. Remove the top cam If the slack adjuster has a “quick connect”
roller. Remove the anchor pin snap ring and clevis, and the gap between the clevis and
the anchor pin. clevis collar exceeds 0.060-inch (1.52 mm):
4. Rotate the bottom shoe to release the tension Remove the clevis from the push rod.
on the brake shoe retainer springs. Remove 3. Remove the camshaft from the spider. Use the
the shoe retainer springs and the brake shoes. correct size driver to remove the camshaft
bushings from the spider and spider bracket.
Check Cam-to-Bushing Radial Free Play
and Axial End Play
Before you remove the automatic slack adjuster
and camshaft, move the camshaft as shown in
Figure 3.11. Use a feeler gauge to verify that the
cam-to-bushing radial free play and axial end play
are within specification.
If radial free play movement is less than
0.030-inch (0.76 mm): Do not replace the
bushings and seals.
If radial free play movement exceeds
0.030-inch (0.76 mm): Replace the bushings and
seals.
If axial end play movement exceeds 0.060-inch
(1.52 mm): Remove the snap ring. Add an
appropriate number of spacing washers
between the slack adjuster and snap ring to
achieve the correct specification of
0.005-0.060-inch (0.127-1.52 mm).
Figure 3.11

Section 4
Prepare Parts for Assembly
Section 4Parts for Assembly

Prepare
WARNING
1. If you assemble parts immediately after you
To prevent serious eye injury, always wear safe
clean them: Lubricate parts with grease to
eye protection when you perform vehicle
prevent corrosion. Parts must be clean and dry
maintenance or service.
before you lubricate them.
ASBESTOS AND NON-ASBESTOS 2. If you store parts after you clean them: Apply
FIBERS WARNING a corrosion-preventive material. Store parts in
a special paper or other material that prevents
Some brake linings contain asbestos fibers, a corrosion.
cancer and lung disease hazard. Some brake
linings contain non-asbestos fibers, whose
long-term effects to health are unknown. You Inspect Parts
must use caution when you handle both asbestos 1. Check the spider for expanded anchor pin
and non-asbestos materials. Refer to page 1 in holes and for cracks. Replace damaged spiders
this manual for hazard summaries and and anchor pin bushings.
recommended work practices.
2. Check the camshaft bracket for broken welds,
cracks and correct alignment. Replace
WARNING damaged brackets.
Solvent cleaners can be flammable, poisonous 3. Check anchor pins for corrosion and wear.
and cause burns. Examples of solvent cleaners are Replace worn or damaged anchor pins.
carbon tetrachloride, and emulsion-type and 4. Check brake shoes for rust, expanded rivet
petroleum-base cleaners. Read the manufacturer’s holes, broken welds and correct alignment.
instructions before using a solvent cleaner, then Replace a shoe with any of the above
carefully follow the instructions. Also follow the conditions.
procedures below.
Wear safe eye protection. 16.5-Inch Brake Shoes Only
Wear clothing that protects your skin. Anchor pin holes must not exceed 1.009-inches
(25.63 mm) in diameter. The distance from the
Work in a well-ventilated area.
center of the anchor pin hole to the center of the
Do not use gasoline, or solvents that contain roller hole must not exceed 12.779-inches
gasoline. Gasoline can explode. (32.46 cm). Replace brake shoes with
measurements that do not meet specifications.
You must use hot solution tanks or alkaline
solutions correctly. Read the manufacturer’s 1. Check the camshaft for cracks, wear and
instructions before using hot solution tanks corrosion. Check the cam head, bearing
and alkaline solutions. Then carefully follow the journals and splines. Replace worn or
instructions. damaged camshafts.
2. Inspect the large and small clevis pins for wear
CAUTION or damage. Replace worn or damaged parts.
Do not use hot solution tanks or water and
alkaline solutions to clean ground or polished
parts. Damage to parts can result.
Clean and Dry Parts

Use soap and water to clean non-metal parts. Dry
parts immediately after cleaning with soft, clean
paper or cloth, or compressed air.

Section 4
Figure 4.1
CAUTION
Always replace used clevis pin retainer clips with
new ones when you service an automatic slack
adjuster or chamber. Do not reuse retainer clips.
Discard used clips. When you remove a retainer
clip, it can bend or “gap apart” and lose retention.
damage to components can result.
NOTE: If you remove cotter pins from a slack

adjuster during maintenance and service
procedures, Meritor recommends that you install
clevis pin retainer clips at assembly.
3. Inspect clevis pin retainer clips or cotter pins Automatic Slack Adjuster
for wear or damage. Replace worn or damaged
retainer clips or cotter pins. Do not reuse clevis 1. If the slack adjuster has a “quick connect”
pin retainer clips. Always replace used retainer clevis, check the gap between the clevis and
clips with new ones. Discard used clips. the collar.
If the gap exceeds 0.060-inch (1.52 mm):
WARNING Replace the clevis with a one-piece threaded
Do not operate the vehicle with the brake drum clevis.
worn or machined beyond the discard dimension 2. Check the clevis pins, clips and bushing in the
indicated on the drum. The brake system may not slack adjuster arm for wear and damage.
operate correctly and damage to components and Replace worn or damaged parts. Check the
serious personal injury can result. bushing’s diameter to ensure it does not
exceed 0.531-inch (13.5 mm).
4. Use the following procedure to inspect the
brake drums. If the bushing diameter exceeds 0.531-inch
(13.5 mm): Replace the bushing.
A. Check the brake drums for cracks, severe
heat checking, heat spotting, scoring,
pitting and distortion. Replace drums as CAUTION
required. Do not turn or rebore brake You must disengage a pull pawl or remove a
drums, which decreases the strength and conventional pawl before rotating the manual
heat capacity of the drum. adjusting nut, or you will damage the pawl teeth.
A damaged pawl will not allow the slack adjuster
B. Measure the inside diameter of the drum
to automatically adjust brake clearance. Replace
in several locations with a drum caliper
damaged pawls before putting the vehicle in
or internal micrometer. Figure 4.1. Replace
service.
the drum if the diameter exceeds the
specifications supplied by the drum
manufacturer. NOTE: When you service an automatic slack
adjuster with a conventional pawl, replace the
5. Check dust shields for wear and damage. Repair conventional pawl with a pull pawl.
or replace worn or damaged parts as necessary.
3. Disengage the pull pawl. Use a screwdriver or
equivalent tool to pry the pull pawl at least
1/32-inch to disengage the teeth. Figure 4.2.
If the slack adjuster has a conventional
pawl: Remove the pawl. Figure 4.2.

Section 4
22 TURNS
PAWL
PRY UP
CONVENTIONAL PULL PAWL
PAWL
ROTATE GEAR 360°
5. Re-engage the pull pawl. Remove the

CAUTION screwdriver or equivalent tool. The pull pawl
will re-engage automatically.
Only turn the adjusting nut counterclockwise
when you check gear torque on an automatic If the slack adjuster has a conventional
slack adjuster. If you turn the adjusting nut pawl: Install the pawl assembly into the
incorrectly, you will damage the pawl teeth. A housing. Tighten the capscrew to 12-17 lb-ft
damaged pawl will prevent the slack adjuster (16-23 N•m). T
from automatically adjusting clearance between
the linings and drum. Damage to components can NOTE: If necessary, install a camshaft into the
result. slack adjuster gear to minimize grease flow
through the gear holes.
4. Use a lb-in torque wrench and turn the
adjusting nut COUNTERCLOCKWISE 6. Use a grease gun to apply Meritor lubricant
(Figure 4.3) to rotate the gear 360 degrees specification O-616-A, O-692 or O-645 to the
(22 turns of the wrench) as you read the slack adjuster grease fitting, until grease flows
torque scale on the wrench. The value should from around the camshaft splines and pawl
remain at less than 25 lb-in (2.83 N•m) as you assembly. Refer to Section 8 for more
rotate the gear. lubricant information.
If the torque value remains less than
25 lb-in (2.8 N•m) as you rotate the gear: Camshafts
The slack adjuster is operating correctly.
NOTE: Install new camshaft bushings and seals
If the torque value exceeds 25 lb-in whenever you install a new camshaft.
(2.8 N•m) as you rotate the gear: The slack
adjuster is not operating correctly.
1. Tighten all spider bolts to the correct torque.
Disassemble the slack adjuster. Check that
Figure 4.4. T
it’s assembled correctly. Check that parts are
aligned correctly. 2. Use a seal driver to install new camshaft seals
and new bushings into the cast spider and
camshaft bracket.
If the brake has a stamped spider: Install
both bushings into the bracket. Install the
seals with the seal lips toward the slack
adjuster. Figure 4.5.

Section 4
If the Camshaft Bracket Has Been Removed

Install the chamber bracket seal and bracket onto
the spider. Tighten the capscrews to the correct
torque. Figure 4.4. T
Figure 4.4
Bolt
Size Torque
7/16"-20 60-75 lb-ft 81-102 N•m
1/2"-20 85-115 lb-ft 115-156 N•m
9/16"-18 130-165 lb-ft 176-224 N•m
5/8"-18 180-230 lb-ft 244-312 N•m
Figure 4.5
Figure 4.6
SEAL SEAL
LIP LIP
SPIDER
CAMSHAFT
BRACKET

Section 5
Installation and Assembly
Section 5 and Assembly

Installation
Figure 5.1
WARNING
Do not use the straight-center bar shoe return

spring with the Q Plus camshaft. The shoe spring
can interfere with the camshaft and affect braking
performance. Serious personal injury and damage
to components can result.
ASBESTOS AND NON-ASBESTOS

FIBERS WARNING
Some brake linings contain asbestos fibers, a Replace a Q Series Camshaft with a
cancer and lung disease hazard. Some brake Q Plus Camshaft
long-term effects to health are unknown. You All Front and Drive Axle 16.5-Inch Q Series Brakes
must use caution when you handle both asbestos When you replace a Q Series camshaft with a
and non-asbestos materials. Refer to page 1 in this Q Plus camshaft, continue to follow maintenance
manual for hazard summaries and recommended and service procedures for a Q Series brake and a
work practices. Q Plus camshaft.
CAUTION Replace a Hammerclaw Camshaft with a

Standard Q Plus Camshaft
Only install a Q Plus camshaft in a Q Plus brake.
A Q Series hammerclaw camshaft will not provide Front Axles Only
enough clearance between the brake shoe and
the brake drum. Brake drag and damage to A standard Q Plus camshaft and a shoe return
components can result. spring with an offset center bar replaces the
hammerclaw Q Series camshaft and shoe
To install a new brake drum so that it fits correctly return spring with a straight center bar on
over a Q Plus brake shoe, you must install a Q Plus 16.5 x 5-inch and 6-inch Q Series cam brake.
camshaft to prevent damage to components. Figures 5.2 and 5.3.
A Q Plus camshaft has deeper roller pockets than
Installation a Q Series camshaft and has “Q Plus” forged into
one of the pockets. You may notice a larger gap
Camshaft between the brake lining and the drum after you
assemble the brake shoe and shoe return spring
1. Install the cam head thrust washer onto the
with an offset center bar. Figure 5.4. The excess
camshaft. Apply Meritor specification
gap will be eliminated when you correctly adjust
O-617-A or O-617-B grease to the camshaft
the brake.
bushings and journals.
1. Follow Steps 1 and 2 under Q Plus and
2. Install the camshaft through the spider and
Q Series 16.5-Inch Brakes in this section
bracket so that the camshaft turns freely by
to replace a Q Series hammerclaw
hand. Figure 5.1.
camshaft with a standard Q Plus
camshaft.
2. Continue to follow service and maintenance
procedures for a Q Plus camshaft and
Q Series brake.

Section 5
Figure 5.2 Shoe Return Spring

Install the new offset shoe return spring with the
open end of the spring hooks toward the camshaft.
Figure 5.5.
Figure 5.5
OFFSET SPRING
(MERITOR PART
2258-Y-1273)
STANDARD Q PLUS CAM
Q PLUSTM
CAM
NEW INSTALLATION
OFFSET RETURN
Figure 5.3 Install the spring SPRING
with the open end of (MERITOR PART
the hook TOWARD the 2258-Y-1273)
cam head.
Automatic Slack Adjuster onto the

STRAIGHT SPRING Camshaft
(MERITOR PART
2258-R-642) 1. Check the camshaft and bushings and seals
HAMMERCLAW for wear and corrosion. Turn the camshaft by
Q SERIES CAM hand to check for smooth operation. Repair or
replace parts as required.
2. Apply the service brake and spring brake
several times. Check that the chamber return
Figure 5.4 spring retracts the push rod quickly and
completely. If necessary, replace the return
The initial lining to drum spring or the air chamber.
clearance with a Q Plus
camshaft is increased with 3. Verify that the new automatic slack adjuster is
both shoes fully retracted. the same length as the one you are replacing.
Refer to Table A.
OFFSET Table A: Chamber and Automatic Slack
SPRING
Adjuster Sizes
Length of Slack Adjuster Size of Chamber

(Inches) (Square Inches)
5 9*, 12*, 16, 20, 24, 30
5-1/2 9*, 12*, 16, 20, 24, 30, 36
6 24, 30, 36
6-1/2 30, 36
* Use an auxiliary spring on slack adjusters used with these
size chambers. A size 9 or 12 chamber return spring cannot
supply enough spring tension to completely retract the
slack adjuster.

Section 5
WARNING CAUTION
Before you service a spring chamber, carefully You must disengage a pull pawl or remove a
follow the manufacturer’s instructions to conventional pawl before rotating the manual
compress and lock the spring to completely adjusting nut, or you will damage the pawl teeth.
release the brake. Verify that no air pressure A damaged pawl will not allow the slack adjuster
remains in the service chamber before you to automatically adjust brake clearance. Replace
proceed. Sudden release of compressed air can damaged pawls before putting the vehicle in
cause serious personal injury and damage to service.
components.
9. Disengage the pull pawl or remove a
4. If the vehicle has spring brakes, follow the conventional pawl. Turn the manual adjusting
chamber manufacturer’s instructions to nut to align the holes in the slack adjuster arm
compress and lock springs to completely and clevis. Figure 5.6.
release the brakes. Verify that no air pressure
remains in the service chambers.
Figure 5.6
CAUTION
Most Meritor automatic slack adjusters
manufactured after January 1990 have lubrication
holes in the gear splines. Do not operate the ALIGN
actuator rod before you install the slack adjuster. HOLES
Lubricant can pump through the holes and onto Disengage a
the splines. Damage to components can result. pull pawl or
remove a
5. If the automatic slack adjuster gear has a conventional
10-tooth spline, apply Meritor specification pawl.
O-637 (part number 2297-U-4571) anti-seize
compound, or equivalent. This specification is
a corrosion-control grease. Do not mix this
grease with other greases.
NOTE: Install the slack adjuster so that you can

remove a conventional pawl or disengage a pull
pawl when you adjust the brake.
6. Install the slack adjuster onto the camshaft.

Position the slack adjuster so that you can
access the pawl when you adjust the brake.
7. Verify that camshaft axial end play is
0.005-0.060-inch (0.127-1.52 mm).
If axial end play exceeds 0.060-inch
(1.52 mm): Remove the snap ring. Add an
appropriate number of spacing washers to
achieve the correct specification.
8. Install the clevis onto the push rod.

Section 5
Welded Clevis Threaded Clevis

1. Check the clevis position. Apply Meritor
specification O-637 (part number 2297-U-4571) Adjust the Clevis Position on the
anti-seize compound or equivalent to the large Chamber Push Rod
and small clevis pins. This specification is a
corrosion-control grease. Do not mix this Automatic Slack Adjuster Template Method for
grease with other greases. Standard Stroke Chambers Only
CAUTION WARNING
Always replace used clevis pin retainer clips with Meritor provides a slack adjuster template for
new ones when you service an automatic slack truck and tractor, trailer, and coach drum brakes.
adjuster or chamber. Do not reuse retainer clips. These templates are not interchangeable. You
Discard used clips. When you remove a retainer must use the correct template when you install
clip, it can bend or “gap apart” and lose retention. the clevis.
Damage to components can result. If you use the wrong template, the automatic
slack adjuster will not adjust the brakes correctly.
NOTE: Meritor recommends that you replace Under-adjustment can increase stopping
cotter pins with clevis retainer clips at assembly. distances. Over-adjustment can cause the linings
to drag. Serious personal injury and damage to
2. Install new clevis pin retainer clips or cotter components can result.
pins to secure the clevis pins. Retainer clips
must be fully installed and positioned around 1. Install the large clevis pin through the large
the side of the clevis pin. Figure 5.7. clevis pin hole in the correct slack adjuster
template for the drum brake you’re servicing.
Figure 5.8.
Figure 5.7
CLEVIS LARGE CLEVIS PIN
AND RETAINER CLIP LARGE CLEVIS PIN Figure 5.8
RETAINER CLIP
ACTUATOR MERITOR PART
ROD 2257-D-1174
Color of Part
SMALL CLEVIS PIN Template Number Applications
RETAINER CLIP Dark brown TP-4786 Truck or tractor drum brake
MERITOR PART
SMALL CLEVIS PIN Tan TP-4787 Trailer drum brake
2257-C-1173
AND RETAINER CLIP White TP-4781 Coach drum brake
The clevis pin retainer Measure slack

clips must be fully adjuster
installed and positioned arm length.
around the side
of clevis pin.
CAMSHAFT CENTER

Section 5
2. Select the hole at the small end of the 5. Verify that the push rod does not extend
template that matches the slack adjuster arm through the clevis more than 1/8-inch
length. Position and hold the hole on the (12.7 mm).
center of the camshaft.
If the push rod extends through the clevis
3. Look through the small clevis pin slot on the more than 1/8-inch (12.7 mm): Cut the push
template to see if the small clevis hole rod, or install a new air chamber and push
completely aligns within the slot. rod.
If the small clevis hole doesn’t align within 6. Tighten the jam nut against the clevis to the
the slot: Adjust the clevis until you can see torque specification in Table B. T
the small clevis pin hole within the slot.
Figure 5.9. Table B: Jam Nut Torque Specifications
Threads Torque
Figure 5.9
1/2-20 20-30 lb-ft (27-41 N•m)
THREADED
CLEVIS 5/8-18 35-50 lb-ft (48-68 N•m)
SLOT Brake Slack Adjuster Position (BSAP)

Method for Standard Stroke and Long
Stroke Chambers
CAMSHAFT END
When you install the slack adjuster, verify that the
BSAP chamber dimension matches the table in
Figure 5.11.
4. Verify that thread engagement between the Figure 5.11

clevis and push rod is 1/2-5/8-inch 3.750" AND 3.812"
BRACKET OFFSET
(12.7-15.9 mm). Figure 5.10. BSAP +
– 0.125"
SLACK
Figure 5.10 LENGTH
5.00"
5.50"
MINIMUM 1/2" 6.00"
6.50"
Standard Stroke Long Stroke

THREADED Chamber Clevis Chamber Clevis
CLEVIS (1.38") 1.38" (1.30") 1.30"
MAXIMUM 1/8" Slack
Adjuster
Size
5.00" 2.75" 2.25"
5.50" 2.75" 2.25"
6.00" 2.75" 2.25"
6.50" 2.62" 2.25"
± 0.125" Tolerance. You must use the correct clevis with
the correct chamber type.
Correct positions of the automatic slack adjuster are
3.750-inch and 3.812-inch offsets only. For other
bracket offsets, refer to the vehicle manufacturer's
specifications.

Section 5
Brake Shoes Figure 5.14

NOTE: Meritor recommends that you replace
springs, rollers, anchor pins and cam bushings at
each reline.
WEBS
Q Plus and Q Series 16.5-Inch Brakes SQUEEZE
“EARS”
1. Place the upper brake shoe into position on
the top anchor pin. Hold the lower brake shoe
on the bottom anchor pin. Install two new
brake shoe retaining springs. Figure 5.12.
2. Rotate the lower brake shoe forward. Install a
new brake shoe return spring with the open
end of the spring hooks toward the camshaft. 4. Push the camshaft roller retainer into the
Figure 5.13. brake shoe until the “ears” lock into the shoe
3. Pull each brake shoe away from the camshaft web holes. Figure 5.15.
to enable you to install the camshaft roller and 5. Use Meritor specification grease O-617-A or
roller retainer. Press the retainer “ears” to fit O-617-B to lubricate the camshaft roller pin
into the retainer between the brake shoe webs. and anchor pin. Figure 5.16.
Figure 5.14.
Figure 5.15
Figure 5.12
WEB
HOLE
PUSH
Figure 5.16
Figure 5.13
Q PLUS AND P SERIES
Lubricate Lubricate
here only. entirely.
CAM
Do not ANCHOR PIN
lubricate here.
CAM ROLLER PIN

Section 5
Q Series 15-Inch Cam Brake P Series and Cast Plus Cam Brakes
1. Install the anchor pins, washers and nuts to 1. Install the anchor pin bushings. If necessary,
the spider if these parts were removed align the holes in the bushings with the holes
previously. Tighten the anchor pin nuts to in the spider.
325-375 lb-ft (441-509 N•m).
2. Install a new cam roller and cam roller
2. Install a new brake shoe return spring with the retainers.
open end of the spring hooks toward the 3. Install the lower brake shoe in position on the
camshaft. Install the brake shoes onto the spider.
anchor pins. Figure 5.17.
4. Use a hammer and brass drift to install the
3. Hold the bottom brake shoe in position. Install anchor pin. If necessary, align the groove on
the shoe return spring. Pull the brake shoe the anchor pin with the holes in the spider and
away from the camshaft to enable you to bushing.
install the camshaft roller and roller retainer.
5. Install the anchor pin washers, felts, seals,
4. Use Meritor specification grease O-617-A or retainers and snap rings, if required. Install
O-617-B to lubricate the camshaft roller pin lock pins or lock screws, if required. Tighten
and anchor pin. Figure 5.18. the screws to 10-15 lb-ft (13.6-20.3 N•m).
6. Install a new shoe return spring onto the brake
Figure 5.17 shoe. Figure 5.19. Place the upper brake
SHOE shoe into position over the spider. Repeat
RETAINER Steps 4 and 5.
RETURN SPRING
SPRING 7. Lubricate the camshaft roller pin and anchor
pin with Meritor specification O-617-A or
O-617-B grease. Figure 5.16.
Figure 5.19
ANCHOR
CAM PINS
ROLLERS
Figure 5.18
Q AND T SERIES
Do not Lubricate
lubricate here. entirely.
CAM
Lubricate here only. ANCHOR PIN
CAM ROLLER PIN

Section 5
T Series Cam Brake

1. Install the anchor pins, washers and nuts onto
the backing plate if these parts were
previously removed. Tighten the anchor pin
nuts to 185-350 lb-ft (251-475 N•m).
2. Install the anti-rattle rod. Install the brake shoe
onto the anchor pins and anti-rattle rod.
3. Install the anchor pin snap rings, anti-rattle
spring and anti-rattle retainer spring onto the
anti-rattle rod.
4. Pull the brake shoe away from the camshaft to
enable you to install the brake shoe roller.
Install a new brake shoe return spring onto the
brake shoe.
5. Lubricate the camshaft roller pin and anchor
pin with Meritor specification grease O-617-A
or O-617-B. Figure 5.18.
Drum and Wheel

Follow the manufacturer’s instructions to install
the drum and wheel onto the axle.

Section 6
Adjust the Brakes
Sectionthe
Adjust 6 Brakes
Measure Free Stroke
WARNING
To prevent serious eye injury, always wear safe CAUTION
conventional pawl before rotating the manual
adjusting nut, or you will damage the pawl teeth.
ASBESTOS AND NON-ASBESTOS A damaged pawl will not allow the slack adjuster
FIBERS WARNING to automatically adjust brake clearance. Replace
Some brake linings contain asbestos fibers, a damaged pawls before putting the vehicle in
cancer and lung disease hazard. Some brake service.
long-term effects to health are unknown. You 1. Disengage a pull pawl. Use a screwdriver or
must use caution when you handle both asbestos equivalent tool to pry the pull pawl at least
and non-asbestos materials. Refer to page 1 in 1/32-inch to disengage the teeth.
this manual for hazard summaries and If the slack adjuster has a conventional
recommended work practices. pawl: Remove the pawl.
2. Use a wrench to turn the manual adjusting nut
WARNING COUNTERCLOCKWISE until the brake shoes
are fully retracted, and the lining clears the
Before you service a spring chamber, carefully drum. Figure 6.1. Then back-off the adjusting
follow the manufacturer’s instructions to nut one-half turn in the opposite direction.
compress and lock the spring to completely
release the brake. Verify that no air pressure 3. Measure the distance from the center of the
remains in the service chamber before you large clevis pin to the bottom of the air
proceed. Sudden release of compressed air can chamber while the brake is released. The
cause serious personal injury and damage to measurement you obtain is “X” in Figure 6.2.
components. 4. Use a pry bar to move the slack adjuster and
position the linings against the drum (brakes
Adjust the Brakes applied). Measure the same distance again
while the brakes are applied. The
When you perform preventive maintenance measurement you obtain is “Y” in Figure 6.2.
procedures on an in-service brake, check both the
free stroke and adjusted chamber stroke. Refer to
Commercial Vehicle Safety Alliance (CVSA) CAUTION
Guidelines to Measure Push Rod Travel (Adjusted Do not set free stroke shorter than 1/2-5/8-inch
Chamber Stroke) in this section. (12.7-15.9 mm) for drum brakes. If the
Free stroke sets the clearance between the linings measurement is too short, linings can drag.
and drum. The in-service free stroke may be Damage to components can result.
slightly longer than 1/2-5.8-inch (12.7-15.9 mm)
specified in this procedure. This is not a concern if 5. Subtract “X” from “Y” to obtain the in-service
the adjusted chamber stroke is within the limits free stroke. The measurement must be
shown in Table C and Table D in this section. 1/2-5/8-inch (12.7-15.9 mm) for drum brakes.
Figure 6.2.
If the free stroke measurement is not within
specification: Turn the adjusting nut
COUNTERCLOCKWISE 1/8 turn to adjust
free stroke. Figure 6.2. Follow the steps
above to check free stroke again, until the
measurement is within specification.

Section 6
Adjust the Brakes
6. Re-engage the pull pawl by removing the Commercial Vehicle Safety Alliance
screwdriver or equivalent tool. The pull pawl
will re-engage automatically. (CVSA) Guidelines
If the slack adjuster has a conventional Measure Push Rod Travel (Adjusted
pawl: Install the pawl assembly into the
housing. Tighten the capscrew to 12-17 lb-ft
Chamber Stroke)
(16-23 N•m). Use the following procedure to check in-service
push rod travel (adjusted chamber stroke) on truck
7. If the brakes have spring chambers, carefully
and tractor brakes.
release the springs. Test the vehicle before you
return it to service.
NOTE: Hold the ruler parallel to the push rod and
measure as carefully as possible. A measurement
Figure 6.1 error can affect CVSA re-adjustment limits. CVSA
states that “any brake 1/4-inch or more past the
re-adjustment limit, or any two brakes less than
1/4-inch beyond the re-adjustment limit, will be
cause for rejection.”
1. The engine must be OFF. If the brake has a

spring chamber, follow the manufacturer’s
instructions to release the spring. Verify that
DISENGAGE no air pressure remains in the service section
PAWL of the chamber.
2. Verify that pressure is 100 psi (689 kPa) in the
air tanks. Determine the size and type of brake
chambers on the vehicle.
Figure 6.2 3. With the brakes released, mark the push rod
MEASURE “FREE STROKE” where it exits the chamber. Measure and
“Y”
record the distance. Have another person
“X” apply and hold the brakes on full application.
Figure 6.4.
4. Measure push rod travel (adjusted chamber
FREE STROKE = “Y” MINUS “X” stroke) from where the push rod exits the
Drum brake free stroke must be brake chamber to your mark on the push rod.
1/2-5/8" (12.7-15.9 mm). Measure and record the distance. Figure 6.4.
Disc brake free stroke must be
3/4-7/8" (19.1-22.2 mm). 5. Subtract the measurement you recorded in
Step 3 from the measurement you recorded in
Step 4. The difference is push rod travel
(adjusted chamber stroke).
Figure 6.3 6. Refer to Table C or Table D to verify that the
stroke length is correct for the size and type of
Disengage
air chambers on the vehicle.
pull pawl
or remove If push rod travel (adjusted chamber stroke)
conventional is greater than the maximum stroke shown
pawl. in Table C or Table D: Inspect the slack
SHORTEN adjuster and replace it, if necessary.
STROKE
LENGTHEN
STROKE

Section 6
Adjust the Brakes
Figure 6.4 Table C: “Standard Stroke” Clamp-Type Brake

Chamber Data
Mark push rod here
to measure stroke. Outside
Diameter Brake Adjustment
Type (inches) Limit (inches)
6 4-1/2 1-1/4
• Spring brakes 9 5-1/4 1-3/8

released 12 5-4/16 1-3/8
As short as
• Service brakes 16 6-3/8 1-3/4 possible without
not applied 20 6-25/32 1-3/4 lining to drum
contact
24 7-7/32 1-3/4
STROKE 30 8-3/32 2
100 psi (689 kPa) in air 36 9 2-1/4
tank — engine OFF
Table D: “Long Stroke” Clamp-Type Brake

Chamber Data
• Spring brakes
released Outside
• Service brakes Diameter Brake Adjustment Limit
applied Type (inches) (inches)
16 6-3/8 2.0
20 6-25/32 2.0 As short as
Alternate Method to Measure Push Rod 24 7-7/32 2.0
possible without
lining to drum
Travel (Adjusted Chamber Stroke) 24* 7-7/32 2.5 contact
Use the CVSA procedure, except in Steps 3 and 4, 30 8-3/32 2.5
measure the distance from the bottom of the air * For 3" maximum stroke type 24 chambers.
chamber to the center of the large clevis pin on
each of the brakes.
CVSA North American Out-of-Service

Criteria Reference Tables
Information contained in the following tables is for
reference only. Consult the CVSA’s Out-of-Service
Criteria Handbook for North American Standards,
Appendix A. Visit their website at http://64.35.82.7/
to order the handbook.

Section 7
Reline the Brakes
Sectionthe
Reline 7 Brakes
Single Axles
WARNING
Always reline both wheels of a single axle at the
To prevent serious eye injury, always wear same time.
safe eye protection when you perform vehicle
maintenance or service. Always install the same linings and drums on both
wheels of a single axle.
FIBERS WARNING Tandem Axles
Some brake linings contain asbestos fibers, a Always reline all four wheels of a tandem axle at
cancer and lung disease hazard. Some brake the same time.
linings contain non-asbestos fibers, whose Always install the same linings and drums on all
long-term effects to health are unknown. You four wheels of a tandem axle.
must use caution when you handle both asbestos
and non-asbestos materials. Refer to page 1 in Combination Friction Linings
this manual for hazard summaries and
CAUTION
Important Information on Linings When you install combination friction linings, you
and Primary Shoe Locations must install the primary lining on the primary
brake shoe. If you install combination friction
linings incorrectly, damage to components will
Use the Correct Lining Material result. Carefully follow instructions included with
Use the lining material specified by the vehicle the replacement linings.
manufacturer. This will help to ensure that the
brakes perform correctly and meet Department of You can combine brake linings, which means that
Transportation (DOT) performance regulations. the linings you install on the primary shoe will
have a different friction rating than the linings you
ALso note that the drums and linings on a front install on the secondary shoe.
axle can be different than drums and linings on a
rear axle. Figure 7.1. However, you must install the primary lining on
the primary shoe. Carefully follow the instructions
included with the replacement combination
Figure 7.1 linings.
TANDEM AXLES FRONT AXLE
Primary Shoe Locations
The first shoe past the camshaft in the direction of
wheel rotation is the primary shoe. Figure 7.2. The
primary shoe can be either at the top or bottom
position, depending on the location of the
camshaft.
If the camshaft is behind the axle, the top shoe is
Both wheel ends of each axle must the primary shoe.
have identical drums and lining.
If the cam is in front of the axle, the top shoe is the
primary shoe.

Section 7
Reline the Brakes
Figure 7.2
RIGHT WHEEL ROTATION
WHEEL ROTATION WHEEL ROTATION
CAM BEHIND AXLE CAM IN FRONT OF AXLE
LEFT WHEEL ROTATION
WHEEL ROTATION WHEEL ROTATION
CAM IN FRONT OF AXLE CAM BEHIND AXLE

Section 8
Maintenance and Service
Section 8
Figure 8.1
WARNING
Q AND T SERIES
To prevent serious eye injury, always wear
Do not Lubricate
lubricate here. entirely.

FIBERS WARNING
Some brake linings contain asbestos fibers, a
CAM
cancer and lung disease hazard. Some brake Lubricate here only. ANCHOR PIN
CAM ROLLER PIN
long-term effects to health are unknown. You
must use caution when you handle both asbestos
and non-asbestos materials. Refer to page 1 in
this manual for hazard summaries and Figure 8.2
Q PLUS AND P SERIES
Lubricate Lubricate
WARNING here only. entirely.
During lubrication procedures, if grease flows

from the seal near the camshaft head, replace the
seal. Remove all grease or oil from the camshaft
head, rollers and brake linings. Always replace
linings contaminated with grease or oil, which CAM
can increase stopping distances. Serious personal Do not ANCHOR PIN
lubricate here.
injury and damage to components can result. CAM ROLLER PIN
Lubrication and Maintenance

NOTE: Refer to Table E in this section for grease Inspect and lubricate the automatic slack adjuster
specifications. according to one of the schedules below. Use the
schedule that requires the most frequent
Camshaft Bushings inspection and lubrication, and whenever you
reline the brakes. Refer to Table F in this section for
Meritor recommends that you install new grease specifications.
camshaft bushings whenever you install a new
camshaft. Vehicle manufacturer’s schedule
Lubricate through the fitting on the bracket or Fleet’s schedule

spider until new grease flows from the inboard Every six months
seal.
A minimum of four times during the life of
Rollers and Anchor Pins the linings
When the brake is disassembled, or when

necessary, lubricate the anchor pins and rollers
where these parts touch the brake shoes.
Do not allow grease to contact the area of the
camshaft roller that touches the camshaft head.
Figures 8.1 and 8.2.

Section 8
Anti-Seize Compound
Use anti-seize compound on the clevis pins of all
automatic slack adjusters.
For a conventional automatic slack adjuster, use
anti-seize compound on the slack adjuster and
camshaft splines, if the slack adjuster gear does
not have a grease groove and holes around its
inner diameter.
Factory-Installed Automatic Slack

Adjusters on Q Plus LX500 and MX500
Cam Brake Packages
Q Plus LX500 and MX500 cam brake packages
include factory-installed automatic slack adjusters
that do not have grease fittings. Also, lubrication
intervals are different than intervals for
conventional slack adjusters.
For complete maintenance and service
information for Meritor’s LX500 and MX500 cam
brakes, refer to Maintenance Manual MM-96173.
To obtain this publication, refer to the Service
Notes page on the front inside cover of this
manual.

Section 8
Table E: Cam Brake Grease Specifications
Meritor Outside
Components Specification NLGI Grade Grease Type Temperature
Retainer Clips O-616-A 1 Clay Base Down to –40°F (–40°C)
Anchor Pins O-617-A 1 Lithium Refer to the grease
Rollers (Journals Only) or
12-Hydroxy manufacturer’s
Stearate or specifications for the
Camshaft Bushings O-617-B 2 Lithium Complex temperature service limits.
O-645 2 Synthetic Oil, Down to –65°F (–54°C)
Clay Base
O–692 1 and 2 Lithium Base Down to –40°F (–40°C)
Camshaft Splines Any of Above See Above See Above See Above
O-637* 1-1/2 Calcium Base Refer to the grease
manufacturer’s
O-641 — Anti-Seize specifications for the
temperature service limits.
Table F: Automatic Slack Adjuster Grease Specifications
Meritor Outside
Component Specification NLGI Grade Grease Type Temperature
Automatic Slack O-616-A 1 Clay Base Down to –40°F (–40°C)
Adjuster
O-692 1 and 2 Lithium Base Down to –40°F (–40°C)
O-645 2 Synthetic Oil, Down to –65°F (–54°C)
Clay Base
Clevis Pins Any of Above See Above See Above See Above
O-637* 1-1/2 Calcium Base Refer to the grease
manufacturer’s
O-641 — Anti-Seize specifications for the
temperature service limits.
* Do not mix Meritor grease specification O-637 (part number 2297-U-4571), a calcium-base, rust-preventive
grease, with other greases.
Maintenance Intervals Off-Highway Linehaul Applications

At least every four months when you replace
On-Highway Linehaul Applications the seals and reline the brakes.
Q Plus, Cast Plus and Q Series Brakes Every two weeks during the first four-month
period, inspect for hardened or contaminated
Every 100,000 miles (160 000 km) or every grease and for the absence of grease to help
six months, whichever comes first. determine lubrication intervals.
P Series Brakes Lubricate more often for severe-duty
Every 50,000 miles (80 000 km) or every applications.
six months, whichever comes first.

Section 9
Inspection
Section 9
Inspection
Figure 9.1
WARNING
TANDEM AXLES FRONT AXLE
To prevent serious eye injury, always wear
Before You Return the Vehicle to

Service
1. Check the complete air system for worn hoses
and connectors. With air pressure at 100 psi Both wheel ends of each axle must
(689 kPa), brakes released and engine off, loss have identical drums and lining.
of tractor air pressure must not exceed two psi
a minute. Total tractor and trailer loss must not
exceed three psi per minute.
Figure 9.2
2. Check to see that the air compressor drive belt
is tight. Air system pressure must rise to
approximately 100 psi (689 kPa) in two
minutes.
3. The governor must be checked and set to “A”
the specifications supplied by the vehicle
manufacturer.
“L”
4. Both the tractor and trailer air systems must
match the specifications supplied by the ”AL“ FACTOR = A x L
vehicle manufacturer. A = AIR CHAMBER AREA
L = LENGTH OF SLACK ADJUSTER
5. Both wheel ends of each axle must have the
same linings and drums. All four wheel ends
of tandem axles also must have the same
linings and drums. It is not necessary for the
front axle brakes to be the same as the rear
driving axle brakes. Figure 9.1.
6. Always follow the specifications supplied by
the vehicle manufacturer for the correct lining
to be used. Vehicle brake systems must have
the correct friction material and these
requirements can change from vehicle to
vehicle.
7. The return springs must retract the shoes
completely when the brakes are released.
Replace the return springs each time the
brakes are relined. The spring brakes must
retract completely when they are released.
8. The air chamber area multiplied by the length
of the automatic slack adjuster is called the
“AL” factor. This number must be equal for
both ends of a single axle and all four ends of
a tandem axle. Figure 9.2.

Section 10
Recommended Periodic Service

Section 10
Major Overhaul
Perform a major overhaul at every second reline,
Adjust the Brakes or as necessary. Replace shoe return springs.
Replace damaged or worn parts with genuine
NOTE: Adjust the wheel bearings before you Meritor parts. Check components for the following
adjust the brakes. conditions.
Spiders for distortion and loose bolts
Clean, inspect and adjust the brakes every time
you remove a wheel hub. Anchor pins for wear and correct alignment
Adjust the brakes when the chamber stroke Brake shoes for wear at anchor pin holes or
exceeds CVSA limits in Table C and Table D in roller slots
Section 6.
Camshafts and camshaft bushings for wear
Adjust the brake as frequently as necessary for
Brake linings for grease on the lining, wear and
correct operation.
loose rivets or bolts
Check for correct lining-to-drum clearance, push
Drums for cracks, deep scratches or other
rod travel and brake balance.
damage
Lubrication Figure 11.1
Refer to Table E and Table F in Section 8 to
lubricate the brakes and automatic slack adjuster.
Reline the Brakes
CAUTION
Reline the brakes when the lining thickness is
0.25-inch (6.3 mm) at the thinnest point. The
rivets or bolts must not touch the drum. Damage
to components will result.
Meritor recommends that you replace springs,

rollers, camshaft bushings and anchor pins at
each reline.
Reline the brake when the lining thickness is
0.25-inch (6.3 mm) at the thinnest point.
Replace shoe retainer springs, check the drum,
and perform a major inspection when you reline
the brakes.
Inspection
Refer to Section 8 for inspection guidelines.

Section 11
Torque Table
Section Table
Torque 11
HOLD DOWN CLIP (2) CAM BRACKET MOUNTING (4)

(some models) PUSH ROD LOCK NUT (1)
0.500"-13 thread 0.625"-18 thread
0.250"-28 thread Grade 8 = 90-120 lb-ft (122-163 N•m)
105-135 lb-in (12-15 N•m) 25-50 lb-ft (34-68 N•m)
Grade 5 = 65-100 lb-ft (88-136 N•m)
0.500"-20 thread
0.625"-18 thread 20-30 lb-ft (27-41 N•m)
DUST SHIELD Plain nut = 150-190 lb-ft (203-258 N•m)
MOUNTING (4) or (6) Lock nut = 130-165 lb-ft (176-224 N•m)
(some models)
0.312"-18 thread
12-20 lb-ft (16-27 N•m)
Add camshaft spacing
0.375"-16 thread washers so that slack
Grade 8 = 30-50 lb-ft (41-68 N•m) adjuster is aligned
Grade 5 = 25-35 lb-ft (34-47 N•m)
with air chamber clevis.
ANCHOR PIN
SET SCREW (2)
(some models)
0.375"-16 thread
10 lb-ft (14 N•m)
minimum
ANCHOR PIN (2)

(T brake only)
0.750"-16 thread
185-350 lb-ft (250-474 N•m)
(15 X 4 Q brake only)

325-375 lb-ft (441-509 N•m)
GREASE FITTING (1)
(some models)
BRAKE MOUNTING BOLTS 1/8" dryseal
3-5 lb-ft (4-7 N•m)
Grade 8 bolts with lock nuts and two
hardened washers on each bolt.
Bolt
Size Torque AIR CHAMBER MOUNTING (2)
Add camshaft spacing
7/16"-20 60-75 lb-ft (81-102 N•m)
1/2"-20 85-115 lb-ft (115-156 N•m)
washers to provide no
9/16"-18 130-165 lb-ft (176-224 N•m) more than 0.060" (1.52 mm)
5/8"-18 180-230 lb-ft (244-312 N•m) end play.
Grade 8 Nuts and Hard Flat Washers

Chamber Size 9 12 16 20 24 30 36 Spring Chamber
Bendix 20-30 lb-ft 30-45 lb-ft 45-65 lb-ft 65-85 lb-ft
(27-41 N•m) (41-61 N•m) (61-88 N•m) (88-115 N•m)
Haldex 35-50 lb-ft (48-68 N•m) 70-100 lb-ft (95-136 N•m)
MGM 35-40 lb-ft (48-54 N•m) 133-155 lb-ft (180-210 N•m)
Anchorlok/Haldex 130-150 lb-ft (177-203 N•m)

Section 12
Cam Brake Tips
Air Chambers
Section
Cam Brake
12 Tips
Linings
To ensure correct brake balance, all brake Insist on the same brand of quality OEM friction
chambers on the same axle must be the same size lining material to help ensure fewer relines and
and type to help ensure a balanced brake system compatibility with your present system.
for maximum lining wear and drum life.
Replacement Parts
Brake Kits Always use OEM quality standard parts. Meritor
Meritor brake shoes, rollers, camshafts and shoe brakes work as a system, and when you replace
return springs are designed to perform as a original parts with “will-fit” parts, you can
system. Always install OEM spec-level compromise the performance of the entire system.
components during maintenance or when you
upgrade from standard to long-life brakes to Return Springs
help ensure correct brake performance and Replace cam brake return springs at every cam
maximum lining life. brake reline. The return spring is critical to
alignment, accurate return of the brake away from
Cam Heads the drum and correct automatic slack adjustment.
Cam heads can look the same, but that doesn’t
mean they will perform the same in your brake Trailer Cam Brakes
system. Two cam head profiles can appear to be Long-life bushings require correct lubrication for
identical, but very small differences in cams from maximum performance and bushing life. Although
different manufacturers can be significant enough you do not have to replace spider cam bushings
to affect the performance of your brakes. To on trailer axles as frequently, Meritor recommends
ensure a balanced brake system and optimum that you lubricate the bushings at least four times
lining and drum life, always install the correct during the life of your brake lining.
replacement cam.
Automatic Slack Adjusters
Cam Rollers
“Automatic” doesn’t mean maintenance-free.
To avoid flat spots, lubricate a cam roller Properly installed and lubricated automatic slack
directly in the web roller pocket and not at the adjusters help to ensure maximum brake system
cam-to-roller contact area. Flat spots can affect performance.
brake adjustment and result in premature brake
wear or reduced braking performance. Never mix automatic slack adjusters on the same
axle. When you replace automatic slack adjusters,
Drums always use replacement parts that were originally
To help ensure balanced braking, even lining and designed for the brake system to help ensure even
drum wear, and correct function of the automatic brake wear, balanced braking and maximum brake
slack adjuster, do not install a cast drum and a performance.
centrifuse drum on the same axle.
A cast drum and a centrifuse drum each absorbs
and dissipates heat differently. When drum types
and weights are mixed, different rates of heat
absorption and dissipation occur that can effect
the brake system.
Hardware
When you service cam brakes, replace all the
springs, anchor pins, bushings and rollers — not
just the shoe return springs — to help ensure
maximum braking performance.

Meritor Heavy Vehicle Systems, LLC Information contained in this publication was in effect at the time the publication was approved for printing and is
2135 West Maple Road subject to change without notice or liability. Meritor Heavy Vehicle Systems, LLC, reserves the right to revise the
Troy, MI 48084 USA information presented or discontinue the production of parts described at any time.
800-535-5560
arvinmeritor.com Copyright 2002 Maintenance Manual 4
ArvinMeritor, Inc. Revised 09-02
All Rights Reserved Printed in the USA 16579/24240
Revised 03-98

Maintenance Manual 4B
Service Notes
This publication provides maintenance and service procedures for Meritor’s automatic slack adjuster. The
Service Notes
information contained in this publication was current at the time of printing and is subject to revision
without notice or liability.
1. You must understand all procedures and instructions before you begin maintenance and service
procedures.
2. You must follow your company’s maintenance and service guidelines.
3. You must use special tools, when required, to avoid serious personal injury and damage to
components.
Meritor uses the following notations to alert the user of possible safety issues and to provide information
that will help to prevent damage to equipment and components.
WARNING NOTE: A NOTE indicates an operation, procedure

or instruction that is important for proper service.
A WARNING indicates a procedure that A NOTE can also supply information that will
you must follow exactly to avoid serious help to make service quicker and easier.
personal injury.
CAUTION
A CAUTION indicates a procedure that This symbol indicates that you must tighten
you must follow exactly to avoid damaging fasteners to a specific torque.
equipment or components. Serious personal
injury can also occur.
Visit Our Web Site Videos

Visit the Technical Library section of Automatic Slack Adjuster Installation and
www.meritorauto.com for additional product Maintenance
and service information on Meritor’s Video 90234.
heavy vehicle systems component lineup.
New Generation Automatic Slack Adjuster
Video T-9443V.
Technical Electronic Library on CD
The CD includes product and service How to Order
information on Meritor’s heavy vehicle systems Call Meritor’s Customer Service Center at
component lineup. $20. Order TP-9853. 800-535-5560.
Meritor Brakes That Use Automatic

Slack Adjusters
r Cam brakes, including Q PlusTM LX500 and
MX500 and Cast PlusTM cam brakes
r Air disc brakes
Table of Contents
Asbestos and Non-Asbestos Fibers Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Meritor’s Automatic Slack Adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
How the Automatic Slack Adjuster Works
Pressed-In, Sealed Actuator Boot on Meritor Automatic Slack Adjusters Manufactured from
July 1998
Factory-Installed Automatic Slack Adjusters on Q PlusTM LX500 and MX500 Cam Brake Packages
Handed and Unhanded Slack Adjusters
Pull Pawls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Clevis Types and Thread Sizes
Section 2: Remove the Slack Adjuster from the Camshaft
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Section 3: Disassembly
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Prepare Parts for Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Clean Parts
Dry Parts After Cleaning
Inspect Parts
Section 5: Assembly
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Section 6: Install the Slack Adjuster Onto the Camshaft
Installing the Slack Adjuster Onto the Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Section 7: Adjust the Brakes
Check Brake Chamber Push Rod Stroke and Adjust the Clevis Position . . . . . . . . . . . . . . . . . . . . . . . . .15
Brake Slack Adjuster Position (BSAP) Method
Automatic Slack Adjuster Templates
Measure the Slack Adjuster
Install a Threaded Clevis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Free Stroke Measurement
Section 8: Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Commercial Vehicle Safety Alliance (CVSA) Guidelines to Measure Push Rod Travel
(Adjusted Chamber Stroke) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Alternate Method for Determining Push Rod Travel (Adjusted Chamber Stroke)
Commercial Vehicle Safety Alliance (CVSA) North American
Out-of-Service Criteria Reference Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Section 10: Lubrication and Maintenance
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Anti-Seize Compound
Factory-Installed Automatic Slack Adjusters on Q PlusTM LX500 and MX500 Cam Brake Packages
Maintenance
Inspections and Lubrication
At Brake Reline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Slack Adjusters Manufactured Before 1993
BR01_002.fm 64 ページ２００４年５月２４日月曜日午後３時２８分

ASBESTOS FIBER WARNING NON-ASBESTOS FIBERS WARNING

The following procedures for servicing brakes are recommended to reduce exposure to The following procedures for servicing brakes are recommended to reduce exposure to
asbestos fiber dust, a cancer and lung disease hazard. Material Safety Data Sheets are non-asbestos fiber dust, a cancer and lung disease hazard. Material Safety Data Sheets are
available from Meritor. available from Meritor.

Because some brake linings contain asbestos, workers who service brakes must understand Most recently manufactured brake linings do not contain asbestos fibers. These brake
the potential hazards of asbestos and precautions for reducing risks. Exposure to airborne linings may contain one or more of a variety of ingredients, including glass fibers, mineral
asbestos dust can cause serious and possibly fatal diseases, including asbestos (a chronic wool, aramid fibers, ceramic fibers and silica that can present health risks if inhaled.
lung disease) and cancer, principally lung cancer and mesothelioma (a cancer of the lining of Scientists disagree on the extent of the risks from exposure to these substances.
the chest or abdominal cavities). Some studies show that the risk of lung cancer among Nonetheless, exposure to silica dust can cause silicosis, a non-cancerous lung disease.
persons who smoke and who are exposed to asbestos is much greater than the risk for Silicosis gradually reduces lung capacity and efficiency and can result in serious breathing
non-smokers. Symptoms of these diseases may not become apparent for 15, 20 or more difficulty. Some scientists believe other types of non-asbestos fibers, when inhaled, can
years after the first exposure to asbestos. cause similar diseases of the lung. In addition, silica dust and ceramic fiber dust are known
Accordingly, workers must use caution to avoid creating and breathing dust when servicing to the State of California to cause lung cancer. U.S. and international agencies have also
brakes. Specific recommended work practices for reducing exposure to asbestos dust determined that dust from mineral wool, ceramic fibers and silica are potential causes of
follow. Consult your employer for more details. cancer.
Accordingly, workers must use caution to avoid creating and breathing dust when servicing
Recommended Work Practices brakes. Specific recommended work practices for reducing exposure to non-asbestos dust
follow. Consult your employer for more details.
1. Separate Work Areas. Whenever feasible, service brakes in a separate area away from
other operations to reduce risks to unprotected persons. OSHA has set a maximum allowable Recommended Work Practices
level of exposure for asbestos of 0.1 f/cc as an 8-hour time-weighted average and 1.0 f/cc
averaged over a 30-minute period. Scientists disagree, however, to what extent adherence to 1. Separate Work Areas. Whenever feasible, service brakes in a separate area away from
the maximum allowable exposure levels will eliminate the risk of disease that can result from other operations to reduce risks to unprotected persons.
inhaling asbestos dust. OSHA requires that the following sign be posted at the entrance to 2. Respiratory Protection. OSHA has set a maximum allowable level of exposure for silica
areas where exposures exceed either of the maximum allowable levels: of 0.1 mg/m3 as an 8-hour time-weighted average. Some manufacturers of non-asbestos
DANGER: ASBESTOS brake linings recommend that exposures to other ingredients found in non-asbestos
CANCER AND LUNG DISEASE HAZARD brake linings be kept below 1.0 f/cc as an 8-hour time-weighted average. Scientists
AUTHORIZED PERSONNEL ONLY disagree, however, to what extent adherence to these maximum allowable exposure levels
RESPIRATORS AND PROTECTIVE CLOTHING will eliminate the risk of disease that can result from inhaling non-asbestos dust.
ARE REQUIRED IN THIS AREA. Therefore, wear respiratory protection at all times during brake servicing, beginning with
2. Respiratory Protection. Wear a respirator equipped with a high-efficiency (HEPA) filter the removal of the wheels. Wear a respirator equipped with a high-efficiency (HEPA)
approved by NIOSH or MSHA for use with asbestos at all times when servicing brakes, filter approved by NIOSH or MSHA, if the exposure levels may exceed OSHA or
beginning with the removal of the wheels. manufacturers’ recommended maximum levels. Even when exposures are expected to be
within the maximum allowable levels, wearing such a respirator at all times during brake
3. Procedures for Servicing Brakes. servicing will help minimize exposure.
a) Enclose the brake assembly within a negative pressure enclosure. The enclosure 3. Procedures for Servicing Brakes.
should be equipped with a HEPA vacuum and worker arm sleeves. With the a) Enclose the brake assembly within a negative pressure enclosure. The enclosure
enclosure in place, use the HEPA vacuum to loosen and vacuum residue from the should be equipped with a HEPA vacuum and worker arm sleeves. With the
brake parts. enclosure in place, use the HEPA vacuum to loosen and vacuum residue from the
b) As an alternative procedure, use a catch basin with water and a biodegradable, brake parts.
non-phosphate, water-based detergent to wash the brake drum or rotor and other b) As an alternative procedure, use a catch basin with water and a biodegradable,
brake parts. The solution should be applied with low pressure to prevent dust from non-phosphate, water-based detergent to wash the brake drum or rotor and other
becoming airborne. Allow the solution to flow between the brake drum and the brake parts. The solution should be applied with low pressure to prevent dust from
brake support or the brake rotor and caliper. The wheel hub and brake assembly becoming airborne. Allow the solution to flow between the brake drum and the
components should be thoroughly wetted to suppress dust before the brake shoes brake support or the brake rotor and caliper. The wheel hub and brake assembly
or brake pads are removed. Wipe the brake parts clean with a cloth. components should be thoroughly wetted to suppress dust before the brake shoes
c) If an enclosed vacuum system or brake washing equipment is not available, or brake pads are removed. Wipe the brake parts clean with a cloth.
employers may adopt their own written procedures for servicing brakes, provided c) If an enclosed vacuum system or brake washing equipment is not available,
that the exposure levels associated with the employer’s procedures do not exceed carefully clean the brake parts in the open air. Wet the parts with a solution applied
the levels associated with the enclosed vacuum system or brake washing with a pump-spray bottle that creates a fine mist. Use a solution containing water,
equipment. Consult OSHA regulations for more details. and, if available, a biodegradable, non-phosphate, water-based detergent. The
d) Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA for use wheel hub and brake assembly components should be thoroughly wetted to
with asbestos when grinding or machining brake linings. In addition, do such work in suppress dust before the brake shoes or brake pads are removed. Wipe the brake
an area with a local exhaust ventilation system equipped with a HEPA filter. parts clean with a cloth.
e) NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a d) Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA when
HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic grinding or machining brake linings. In addition, do such work in an area with a local
solvents, flammable solvents, or solvents that can damage brake components as exhaust ventilation system equipped with a HEPA filter.
wetting agents. e) NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a
4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or by HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic
wet wiping. NEVER use compressed air or dry sweeping to clean work areas. When you solvents, flammable solvents, or solvents that can damage brake components as
empty vacuum cleaners and handle used rags, wear a respirator equipped with a HEPA filter wetting agents.
approved by NIOSH or MSHA for use with asbestos. When you replace a HEPA filter, wet the 4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or by
filter with a fine mist of water and dispose of the used filter with care. wet wiping. NEVER use compressed air or dry sweeping to clean work areas. When you
5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or empty vacuum cleaners and handle used rags, wear a respirator equipped with a HEPA filter
smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped with a approved by NIOSH or MSHA, to minimize exposure. When you replace a HEPA filter, wet the
HEPA filter to vacuum work clothes after they are worn. Launder them separately. Do not filter with a fine mist of water and dispose of the used filter with care.
shake or use compressed air to remove dust from work clothes. 5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or
6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped with a
care, such as in sealed plastic bags. Consult applicable EPA, state and local regulations on HEPA filter to vacuum work clothes after they are worn. Launder them separately. Do not
waste disposal. shake or use compressed air to remove dust from work clothes.
6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with
Regulatory Guidance care, such as in sealed plastic bags. Consult applicable EPA, state and local regulations on
References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the United waste disposal.
States, are made to provide further guidance to employers and workers employed within the
United States. Employers and workers employed outside of the United States should consult Regulatory Guidance
the regulations that apply to them for further guidance. References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the United
States, are made to provide further guidance to employers and workers employed within the
United States. Employers and workers employed outside of the United States should consult
the regulations that apply to them for further guidance.
1
BOOT
RETAINING BOOT
CLAMP
SMALL
CLEVIS PIN
ACTUATOR ROD
PISTON RETAINING Meritor Automatic
LARGE
CLEVIS PIN
RING ACTUATOR Slack Adjuster
ROLLER (PIN) ASSEMBLY
RETAINER CLIP
ACTUATOR PISTON Current Models:
ACTUATOR
January 1993 or Later
(ADJUSTING SLEEVE)
SMALL
LARGE CLEVIS PIN
CLEVIS PIN RETAINER
CLIP
STRAIGHT HOUSING
OR OFFSET
CLEVIS
WORM GEAR
BUSHING
GASKET MANUAL
ADJUSTING
NUT (END
PULL PAWL ASSEMBLY OF WORM)
(Replaces all previous pawl assemblies.)
WORM
RETAINING
RING
FACE WORM
NOTE: Parts shown in this box are SEAL GREASE
not serviceable or interchangeable SEAL
with parts from earlier models. GEAR
GREASE
RETAINER/SEAL FITTING
BOOT BOOT
RETAINING SMALL
CLAMP CLEVIS PIN Models Before
ACTUATOR ROD
January 1993
PISTON RETAINING
RING ACTUATOR
COTTER ASSEMBLY
ROLLER (PIN)
PIN
ACTUATOR PISTON
GEAR
ACTUATOR
RETAINING
(ADJUSTING SLEEVE) THRUST RING
GEAR WASHER
LARGE
COTTER SEAL
CLEVIS PIN
PIN
BUSHING
STRAIGHT OR
OFFSET CLEVIS GASKET
PULL PAWL ASSEMBLY

(Replaces all previous pawl assemblies.) HOUSING
THRUST WASHER WORM GEAR

MANUAL
ADJUSTING NUT
GEAR GEAR (END OF WORM)
RETAINING WORM
RING GEAR GREASE RETAINING
SEAL FITTING RING
WORM
GREASE SEAL
2
ii
Meritor Automatic
PUSH LARGE
ROD CLEVIS
Slack Adjuster
PIN LARGE CLEVIS PIN
BRAKE AIR CLEVIS RETAINER CLIP Cutaway View
CHAMBER
SMALL CLEVIS PIN
RETAINER CLIP
SMALL CLEVIS PIN
JAM ACTUATOR ROD

NUT
BOOT
COLLAR
BOOT RETAINING
HOUSING CLAMP
PISTON
ROLLER (PIN) RETAINING RING
ACTUATOR ACTUATOR PISTON

(ADJUSTING SLEEVE)
PULL PAWL ASSEMBLY

Correct position for “unhanded” design.
Shown 90˚ out of position for handed design.
GEAR
GASKET
WORM
GREASE FITTING WORM RETAINING

RING
GEAR RETAINER/SEAL WORM GREASE SEAL
MANUAL ADJUSTING
NUT (END OF WORM)
Offset Clevis for

Front Axle Slack Adjuster
OFFSET CLEVIS CLEVIS

LARGE COTTER COLLAR
CLEVIS PIN PIN SPRING
Use with
type 9 and 12
air chambers. LARGE
CLEVIS
PIN
ACTUATOR ROD
SPRING SLACK
ADJUSTER
SMALL ARM
CLEVIS PIN
3
Section 1
Introduction
Meritor’s Automatic
Section 1
Introduction
Pressed-In, Sealed Actuator Boot on
Slack Adjuster Meritor Automatic Slack Adjusters
Manufactured from July 1998
NOTE: As of January 1993 some parts of Meritor’s
A pressed-in, sealed actuator boot is standard
automatic slack adjuster are no longer serviceable
equipment on Meritor automatic slack adjusters
and are not interchangeable with parts from earlier
models. Refer to Exploded View, pages 2 and 3, for manufactured from July 1998.
more information. The boot features a metal retaining ring with
additional material that extends beyond the base
How the Automatic Slack of the retainer and forms a seal once the boot is
pressed into the slack adjuster body.
Adjuster Works
r Meritor part numbers will not change.
Meritor’s automatic slack adjuster automatically
adjusts the clearance between the brake lining and r All application information is printed on the
the brake drum (rotor). When linings wear, this slack adjuster’s identification tag.
clearance increases and causes the chamber push r A counterbore is machined into the slack body
rod to move a greater distance to apply the brakes. for easier installation of the press-in boot.
When you install an automatic slack adjuster, you
set the brake chamber stroke measurement, which Factory-Installed Automatic Slack
is the correct clearance between the linings and
drum (rotor). Figure 1.1.
Adjusters on Q PlusTM LX500 and
During operation, if the chamber stroke exceeds
the design limit, the automatic slack adjuster will Q Plus™ LX500 and MX500 brake packages
automatically adjust the push rod’s return stroke to include factory-installed automatic slack adjusters
control clearance between the lining and drum that do not have grease fittings, and lubrication
(rotor) and reset the stroke to the correct length. intervals differ from conventional slack adjusters.
Refer to Maintenance Manual MM-96173,
Figure 1.1 Q Plus™ LX500 and MX500 Cam Brakes, for
complete information. Call Meritor’s Customer
Service Center at 800-535-5560 to order this
publication.
Handed and Unhanded Slack Adjusters

There are two automatic slack adjuster designs:
HANDED and UNHANDED. For most applications,
install a HANDED automatic slack adjuster so that
the pawl faces INBOARD on the vehicle.
The pawl can be on either side or on the front of
the slack adjuster housing. Figure 1.2.
Figure 1.2
UNHANDED
HANDED
Figure 1.2A Figure 1.2B

PAWL
CONVENTIONAL
PRY UP
PAWL PULL PAWL
4
Section 1
Introduction
Pull Pawls One-Piece Threaded Clevis

Pull pawls are spring loaded. Pry the pull pawl at Most of Meritor’s automatic slack adjusters,
least 1/32-inch to disengage the teeth. Figure 1.2B. including the factory-installed slack adjusters on
When you remove the pry bar, the pull pawl will the new Q Plus™ LX500 and MX500 cam brakes,
re-engage automatically. have a one-piece threaded clevis.
r The clevis has a threaded hole for the push rod.
Replace Conventional Pawls with Figure 1.4.
Pull Pawls r The one-piece threaded clevis can be straight
When you service an automatic slack adjuster, or offset.
replace a conventional pawl with a pull pawl. r All service replacement automatic slack
Figure 1.2A and Figure 1.2B. Install the slack adjusters have one-piece threaded clevises.
adjuster so that you can remove the conventional
pawl or disengage the pull pawl when you adjust
the brake. Figure 1.4
OFFSET
Clevis Types and Thread Sizes CLEVIS
NOTE: Meritor’s automatic slack adjusters and

clevises are designed to be used as a system.
Always replace original components with genuine
Meritor replacement parts. Although parts from
other manufacturers can look the same, significant
STRAIGHT
differences can exist that can affect brake system CLEVIS
performance.
“Quick Connect” Clevis

THREADS
Some models of Meritor’s automatic slack adjuster
have a “Quick Connect” clevis. Figure 1.3.
r A “Quick Connect” clevis is a three-piece Thread Sizes
assembly that cannot be separated after it
is assembled. Straight and offset clevises are available in two
thread sizes (including metric threads) to match
r The collar has a threaded hole for the push rod. push rod threads.
r A “Quick Connect” clevis can be straight or
offset. Use an offset clevis when more clearance Table A: Thread Sizes
is necessary between the air chamber and the
tire on the front axle. Chambers Thread Sizes
9, 12, 16 1/2"-20 UNF
Figure 1.3
20, 24, 30, 36 5/8"-18 UNF
CLEVIS
RETAINING
RING GROOVE
RETAINING RING
“QUICK CONNECT”
COLLAR
THREADS
5
Section 2
Remove the Slack Adjuster from the Camshaft
Removal
Section 2the Slack Adjuster from the Camshaft
Remove
CAUTION
WARNING conventional pawl before rotating the manual
To prevent serious eye injury, always wear safe adjusting nut, or you will damage the pawl teeth.
eye protection when you perform vehicle A damaged pawl will not allow the slack adjuster
maintenance or service. to automatically adjust brake clearance. Replace
WARNING service.
When you work on a spring chamber, carefully 5. Use a wrench to turn the manual adjusting nut
follow the service instructions of the chamber in the direction shown in Figure 2.1. Move the
manufacturer. Sudden release of a compressed slack adjuster away from the clevis.
spring can cause serious personal injury.
Figure 2.1
WARNING
Block the wheels to prevent the vehicle from
moving. Support the vehicle with safety stands.
Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal
injury can result.
1. If the brake has a spring brake, compress and
lock the spring, so that the brake is released
completely. Check that no air pressure remains
in the service half of the air chamber.
2. If it is necessary to raise the vehicle, use a jack
and support the vehicle with safety stands.
WARNING
When you remove a clevis pin that has a spring, 6. Remove the snap ring and washers from the
hold the spring with pliers. The spring can camshaft. Remove the slack adjuster from the
disengage from the clevis with enough force to camshaft.
7. Remove the clevis from the push rod if the gap
3. Remove both clevis pins. between the clevis and the collar of a “Quick
4. Remove a conventional pawl or disengage a Connect” clevis exceeds 0.060-inch (1.52 mm).
pull pawl: Use a screwdriver or equivalent tool You do not have to remove the clevis if it is in
to lift the button of a pull pawl assembly at good condition.
least 1/32-inch from the actuator.
6
Section 3
Disassembly
Disassembly
Section 3
Disassembly 8. Remove the pin from the rod and piston, if
necessary. Figure 3.3.
WARNING Figure 3.3
PIN
1. Cut the clamp and remove it from the boot.
Use a new clamp and boot when you assemble
the slack adjuster. PISTON
2. Remove the boot from the housing. Pull the

actuator assembly from the housing.
Figure 3.1.
ACTUATOR ROD
Figure 3.1
NOTE: You do not have to remove the slack

adjuster arm bushing unless it is worn or
“egg-shaped.”
9. Inspect the condition and fit of the slack
adjuster arm bushing.
10. If necessary, install a new bushing onto the
clevis pin. Use the clevis pin and mallet to
drive out the old bushing while you drive in the
new bushing.
NOTE: Steps 11 through 21 apply only to

3. Use a small screwdriver to push down on one automatic slack adjusters manufactured BEFORE
side of the piston retaining ring to force the January 1993. The gear set and seals are not
ring out of the groove. Figure 3.2. serviceable on automatic slack adjusters
4. Extend the coils of the ring. manufactured AFTER January 1993. Refer to the
exploded views on pages 2 and 3 of this manual
5. Use pliers to unwind the ring and pull it out of for more information.
the groove. Figure 3.2.
11. Use a small screwdriver to remove the grease
Figure 3.2 seal from around the worm bore. Figure 3.4.
Discard the seal. Use a new seal when you
assemble the slack adjuster.
Pull ring out.
Push ring down.
Figure 3.4
6. Use a new ring when you assemble the slack

adjuster.
7. Pull the actuator rod, piston and pin from the
actuator.
7
Section 3
Disassembly
12. Use snap ring pliers to remove the retaining 17. Unwind the ring by hand and pull it out of the
ring from the worm bore. Figure 3.5. groove. Figure 3.7.
NOTCH
13. Use a wrench to turn the manual adjusting nut 18. Remove the thrust washer.
and wind the worm out of the bore. Figure 3.6.
CAUTION
Figure 3.6 Push one seal out of one side of the slack adjuster
housing and the other seal out of the other side of
the housing to avoid damaging the seals.
19. Push the gear out of the housing only far
enough to enable you to remove one gear seal.
20. Push the gear out of the opposite side of the
housing and remove the other seal.
21. Inspect the seals. Discard damaged seals.
14. Remove the retaining rings and thrust washers

from both sides of the gear.
15. Fit a small screwdriver into the notch at the
end of the retaining ring.
16. Remove the end of the retaining ring from the
groove.
8
Section 4

Prepare
Inspect Parts
1. You must carefully inspect all slack adjuster
WARNING parts, including pawl teeth, for wear and
To prevent serious eye injury, always wear safe damage before you assemble the slack
eye protection when you perform vehicle adjuster.
maintenance or service. 2. Replace any part that is worn or damaged.
WARNING Corrosion Protection

Solvent cleaners can be flammable, poisonous and
cause burns. Examples of solvent cleaners are NOTE: Parts must be clean and dry before you
carbon tetrachloride, emulsion-type cleaners and lubricate them.
petroleum-based cleaners. To avoid serious
personal injury when you use solvent cleaners, 1. If you assemble parts immediately after you
you must carefully follow the manufacturer’s clean them: Lubricate parts with grease to
product instructions and these procedures: prevent corrosion. Parts must be clean and dry
before you lubricate them.
r Wear safe eye protection.
2. If you store parts after you clean them: Apply a
r Wear clothing that protects your skin. corrosion-preventive material. Store parts in a
r Work in a well-ventilated area. special paper or other material that prevents
corrosion.
r Do not use gasoline, or solvents that contain
gasoline. Gasoline can explode.
r You must use hot solution tanks or alkaline
solutions correctly. Follow the manufacturer’s
instructions carefully. CAUTION
Always replace used clevis pin retainer clips with
new ones when servicing the automatic slack
CAUTION adjuster or chamber. Do not reuse clevis pin
Do not use hot solution tanks or water and retainer clips after removing them. Discard used
alkaline solutions to clean ground or polished clips. When removed for maintenance or service,
parts. Damage to parts will result. clevis pin retainer clips can be bent or “gapped
apart” and can lose retention. Damage to
components can result.
CAUTION
Only use solvent cleaners on metal parts. Damage Check the clevis pins and the bushing in the arm of
to parts will result. the slack adjuster. Replace the pins if they are
worn. Replace the bushing if its diameter exceeds
0.531-inch (13.5 mm).
Clean Parts
1. Use solvent cleaners to clean all automatic
slack adjuster parts that have ground or
polished surfaces; for example, the gear, the
worm and the inner bores of the housing.
2. Use soap and water to clean non-metal parts.
3. Use soft paper or cloth that is free from dirt, oil
or abrasives to dry the parts completely.
Dry Parts After Cleaning

Dry the parts immediately after cleaning. Dry parts
with clean paper or rags, or compressed air.
9
Section 5
Assembly
Assembly
Section 5
Assembly 6. Push the gear out of the opposite side of the
housing only until the other seal groove is
visible. Repeat Steps 4 and 5 to install the
WARNING second seal.
eye protection when you perform vehicle 7. Lubricate a thrust washer with grease that
maintenance or service. meets Meritor’s specifications. Refer to
Section 10. Install the washer around the gear.
NOTE: Steps 3 through 11 apply only to automatic 8. Expand the retaining ring coil. Install one end
slack adjusters manufactured BEFORE January of the coil into the groove in the outer diameter
1993. The gear set and seals are not serviceable on of the gear. Work around the gear and press
automatic slack adjusters manufactured AFTER the coil into the groove. Figure 5.2.
January 1993. If you are working on a current
model, skip to Step 10.
Figure 5.2
Refer to exploded view in the front of this manual
for more information.
1. Remove any corrosion-preventive material that
may have been applied to the parts you will
assemble.
2. Use grease to lubricate the gear bore in the
housing.
CAUTION
Follow Steps 3, 4 and 5 exactly when you install
the seals so that the sharp edges of the worm
bore will not damage the seals.
3. Install the gear straight into the bore in the
housing without the seals, keeping one seal 9. Repeat Steps 7 and 8 for the opposite side of
groove outside of the housing. the gear.
4. Install a seal into the groove. Figure 5.1. 10. Install the worm into the bore. Turn the
adjusting nut to wind the worm completely
into the bore. Figure 5.3.
Figure 5.1
Figure 5.3
5. Lubricate the seal with grease that meets

Meritor’s specifications. Compress the seal in
its groove. Push the gear into the housing.
10
Section 5
Assembly
11. Use snap ring pliers to install the retaining ring 13. If you removed the pin, install it into the rod
into the worm bore. and piston. Figure 5.6.
CAUTION Figure 5.6

Install the seal with the lips OUTSIDE of the bore
and the metal retainer INSIDE of the bore to
prevent contamination from entering the slack
PIN
adjuster housing. Damage to components can
result. Figure 5.4.
PISTON
CAUTION
Do not hit the seal after it reaches the bottom of
the bore. Damage to seal will result.
12. Place the seal directly over the worm bore. Use
ACTUATOR ROD
a hammer and 1-3/16-inch (30.2 mm) diameter
seal driver to install the seal straight into the
bore. Figure 5.5.
Figure 5.4 14. Install the actuator rod and piston assembly
into the actuator (adjusting sleeve).
15. Slide the piston retaining ring over the rod.
16. Extend the coils of the ring.
17. Use a small screwdriver to press one end of
the ring into the groove. Figure 5.7.
Figure 5.7
OUTSIDE INSIDE START BOTTOM COIL RING IN GROOVE
Figure 5.5
18. Keep the coil extended. Press on the ring and

work around the groove until the ring is in the
groove completely.
19. Check to ensure that the ring is installed
correctly in the groove. You cannot pull the
piston out of the actuator if the retaining ring is
installed correctly.
11
Section 5
Assembly
20. Install the actuator assembly into the housing 28. As you turn the adjusting nut in the direction
so that the actuator slides along the worm shown in Figure 5.8, read the torque scale and
splines. rotate the gear 360 degrees (22 turns of the
wrench).
21. Slip the boot over the actuator rod.
NOTE: Do not seal the boot to the tapered part of Figure 5.8
the actuator rod.
22 TURNS
r If the rod has a groove: The top of the boot
must fit into the groove.
r If the rod does not have a groove: Use
silicone sealant to seal the top of the boot to
the round part of the rod.
22. Fasten the bottom of the boot to the housing
with a retaining clamp.
23. Conventional Pawl: Install the pawl assembly ROTATE GEAR 360°
into the housing. Tighten the capscrew to a
torque of 15-20 lb-ft (20-27 N•m).
24. Pull Pawl: Remove the screwdriver or
equivalent tool. The pull pawl will re-engage
automatically. 29. The torque value must remain less than
25 lb-in (2.83 N•m) during the complete
25. Use a grease gun to lubricate the slack adjuster 360-degree rotation of the gear.
through the grease fitting. If necessary, install a
camshaft into the slack adjuster gear to 30. If the torque value remains less than 25 lb-in
minimize grease flow through the gear holes. (2.8 N•m): The slack adjuster is working
correctly.
26. Apply lubrication that meets Meritor’s
specifications until new grease purges from 31. If the torque value exceeds 25 lb-in (2.8 N•m):
around the camshaft splines and from the pawl The slack adjuster is not working correctly.
assembly. Refer to Section 10. Disassemble the slack adjuster.
r Check that the slack adjuster is assembled
CAUTION correctly.
In Step 28 turn the adjusting nut only in the
direction shown in Figure 5.8. If you turn the r Check that parts are aligned correctly.
adjusting nut in the opposite direction while the
pawl is installed, you will damage pawl teeth.
Damaged teeth prevent automatic adjustment.
Replace damaged pawls before putting the vehicle
in service.
27. Use a torque wrench that measures lb-in.
12
Section 6
Install the Slack Adjuster Onto the Camshaft
Installing the Slack Adjuster

Sectionthe
Install 6 Slack Adjuster Onto the Camshaft
WARNING
Onto the Camshaft When you work on a spring chamber, carefully
follow the service instructions of the chamber
WARNING manufacturer. Sudden release of a compressed
To prevent serious eye injury, always wear safe spring can cause serious personal injury.
eye protection when you perform vehicle 7. If the brake has a spring brake, compress and
maintenance or service. lock the spring to completely release the brake.
No air pressure must remain in the service half
WARNING of the air chamber.
moving. Support the vehicle with safety stands. CAUTION
Do not work under a vehicle supported only by Most Meritor automatic slack adjusters
jacks. Jacks can slip and fall over. Serious personal manufactured after January 1990 have lubrication
injury can result. holes in the gear splines. Do not operate the
1. Check the camshaft and bushings and seals for actuator before you install the slack adjuster.
wear and corrosion. Lubricant can pump through the holes and onto
the splines. Damage to components can result.
2. Turn the camshaft by hand to check for smooth
operation. 8. If the automatic slack adjuster gear has a
10-tooth spline, apply anti-seize compound to
3. Repair or replace parts as required. the slack adjuster and cam splines. Use Meritor
4. Apply the service brake and spring brake specified O-637, Southwest SA 8249496 or
several times. Check that the chamber return equivalent lubricants.
spring retracts the push rod quickly and
completely. If necessary, replace the return NOTE: Install the slack adjuster so that you can
spring or the air chamber. remove a conventional pawl or disengage a pull
pawl when you adjust the brake.
5. The new automatic slack adjuster must be the
same length as the one you are replacing. 9. Install the slack adjuster onto the camshaft.
Table B below shows the length of slack Position the slack adjuster so that you can
adjuster that is used with each brake chamber remove the pawl when you adjust the brake.
size. 10. If necessary, install spacing washers and the
6. Place blocks in front of and behind the snap ring at a maximum clearance of
vehicle’s wheels to prevent it from moving. 0.062-inch (1.57 mm).
11. Install the clevis onto the push rod. Do not
Table B: Chamber and Automatic Slack tighten the jam nut against the clevis.
Adjuster Sizes
Length of Size of
Slack Adjuster Chamber
(Inches) (Square Inches)
5 9*, 12*, 16, 20, 24, 30
5-1/2 9*, 12*, 16, 20, 24, 30, 36
6 24, 30, 36
6-1/2 30, 36
*Use an auxiliary spring on slack adjusters used with these
size chambers. A size 9 or 12 chamber return spring cannot
supply enough spring tension to completely retract the slack
adjuster.
13
Section 6
Install the Slack Adjuster Onto the Camshaft
CAUTION CAUTION
You must disengage a pull pawl or remove a Always replace used clevis pin retainer clips with
conventional pawl before rotating the manual new ones when servicing the automatic slack
adjusting nut, or you will damage the pawl teeth. adjuster or chamber. Do not reuse clevis pin
A damaged pawl will not allow the slack adjuster retainer clips after removing them. Discard used
to automatically adjust brake clearance. Replace clips. When removed for maintenance or service,
damaged pawls before putting the vehicle in clevis pin retainer clips can be bent or “gapped
service. apart” and can lose retention. Damage to
components can result.
12. Disengage the pawl. Turn the manual adjusting
nut to align the holes in the slack adjuster arm 15. Install new clevis pin retainer clips to hold the
and the clevis. Figure 6.1. clevis in place. Figure 6.2.

CLEVIS LARGE CLEVIS PIN
AND
RETAINER CLIP
ACTUATOR LARGE CLEVIS PIN

ROD RETAINER CLIP
P/N 2257-D-1174
ALIGN
HOLES
Disengage a pull pawl

or remove a SMALL CLEVIS PIN
RETAINER CLIP
conventional pawl.
P/N 2257-C-1173
SMALL CLEVIS PIN
AND RETAINER CLIP
13. If the slack adjuster has a welded clevis: Apply

anti-seize compound to the two clevis pins. The clevis pin
Install the clevis pins through the clevis and retainer clips
the slack adjuster. must be fully
installed and
14. If the slack adjuster has a threaded clevis: positioned
Refer to Section 7. around the SIDE
of clevis pin.
14
Section 7
Adjust the Brakes
Check Brake Chamber Push

Sectionthe
Adjust 7 Brakes
Automatic Slack
Rod Stroke and Adjust the Adjuster Templates
Clevis Position Order the correct automatic slack adjuster template from
Meritor’s Customer Service Center at 800-535-5560.
WARNING
To prevent serious eye injury, always wear safe CAUTION
eye protection when you perform vehicle There are five different installation templates for
maintenance or service. Meritor automatic slack adjusters (Figure 7.2). The
templates are NOT interchangeable. You MUST
NOTE: You cannot adjust the clevis position on a use the correct template and you MUST adjust the
chamber push rod that is equipped with a welded clevis position as described below. If you use the
clevis. wrong template and install the clevis in the wrong
position, the slack adjuster will not adjust the
There are two methods you can use to adjust the brake correctly. If the slack adjuster under-adjusts,
clevis position on a chamber push rod that is then stopping distances are increased. If the slack
equipped with a threaded clevis: adjuster over-adjusts, then the linings may drag
r The Brake Slack Adjuster Position (BSAP) and damage the brake.
method for standard and long stroke chambers.
r Meritor’s automatic slack adjuster template Measure the Slack Adjuster
method for standard stroke chambers only.
NOTE: For long stroke chambers, use the BSAP
method to measure the automatic slack adjuster.
Brake Slack Adjuster Position
(BSAP) Method 1. Use the correct Meritor automatic slack
adjuster template to measure the length of the
When installing the automatic slack adjuster, verify slack adjuster. The marks by the holes in the
that the BSAP dimension of the chamber matches small end of the template indicate the length of
the table in Figure 7.1. the slack adjuster. Figure 7.2.

3.750" AND 3.812"
BRACKET OFFSET
BSAP ± 0.125"
Color of Part Use to Install

Template Number Slack Adjusters On
Dark TP-4786 Truck or tractor drum brake
SLACK brown
LENGTH
5.00" Tan TP-4787 Trailer drum brake
5.50" White TP-4781 Coach drum brake
6.00"
6.50" Green TP-4788 Disc brake with offset clevis
SLACK ADJ. ± 0.125" LONG Yellow TP-4789 Disc brake with straight clevis
SIZE BSAP STROKE
5.00" 2.75" - Measure slack
5.50" 2.75" 2.25" adjuster
6.00" 2.75" - arm length.
6.50" 2.62" -
Correct position of automatic slack adjuster:
3.750" and 3.812" offsets only. For other
bracket offsets, refer to the vehicle
manufacturer's specifications. CAMSHAFT CENTER
15
Section 7
Adjust the Brakes
Install a Threaded Clevis Table C: Jam Nut Torque Specifications

1. Install the large clevis pin through the large
holes in the template and the clevis. Threads Torque
1/2-20 20-30 lb-ft (27-41 N•m)
2. Select the hole in the template that matches
the length of the slack adjuster. Hold that hole 5/8-18 35-50 lb-ft (48-68 N•m)
on the center of the camshaft.
3. Look through the slot in the template. If Free Stroke Measurement
necessary, adjust the position of the clevis until
the small hole in the clevis is completely CAUTION
visible through the template slot. Figure 7.3. You must disengage a pull pawl or remove a
conventional pawl before rotating the manual
Figure 7.3 adjusting nut, or you will damage the pawl teeth.
A damaged pawl will not allow the slack adjuster
THREADED
CLEVIS
to automatically adjust brake clearance. Replace
service.
NOTE: During preventive maintenance on an

SLOT in-service brake, check both the free stroke as
described below and the adjusted chamber stroke
as described in Section 9.
CAMSHAFT END
On some applications, you may find the in-service
free stroke to be slightly longer than specified in
Step 5. However, this is not necessarily a concern,
as long as the adjusted chamber stroke is within
the limits shown in the Commercial Vehicle Safety
4. Check for these specifications: Alliance (CVSA) charts on page 20.
r Thread engagement between the clevis and 1. Disengage a pull pawl or remove a
the push rod must be at least 1/2-inch conventional pawl.
(12.7 mm). Figure 7.4. 2. Turn the adjusting nut in the direction shown in
r The push rod must not extend through the Figure 7.5 until the linings touch the drum, and
clevis more than 1/8-inch (3.18 mm). If then turn the adjusting nut in the opposite
necessary, cut the push rod, or install a new direction:
push rod with a new air chamber. r 1/2 turn for drum brakes
5. Tighten the jam nut against the clevis to torque r 3/4 turn for disc brakes
specifications in Table C.
Figure 7.5
Figure 7.4
MINIMUM 1/2"
MAXIMUM 1/8"
Disengage a
pull pawl or remove
THREADED CLEVIS a conventional pawl.
16
Section 7
Adjust the Brakes
3. Measure the distance from the center of the 6. If it is necessary to adjust the stroke, turn the
large clevis pin to the bottom of the air adjusting nut 1/8 turn in the direction shown in
chamber while the brake is released. Refer to Figure 7.7 and check the stroke again. Continue
“X” in Figure 7.6. to measure and adjust the stroke until it is
adjusted correctly.
4. Use a pry bar to move the slack adjuster so
that the linings are against the drum (applying 7. Release a pull pawl or install a conventional
the brakes). Measure the same distance again pawl.
while the brakes are applied. Refer to “Y” in
Figure 7.6. Figure 7.7
CAUTION Disengage a
Do not set free stroke shorter than specifications. pull pawl or
If free stroke is too short, linings can drag and remove a
damage the brake. conventional
pawl.
5. The difference between measurement “X” and
measurement “Y” is the free stroke, which sets SHORTEN
the clearance between the linings and drum. STROKE
LENGTHEN
Free stroke must be within the following STROKE
specifications. Figure 7.6.
r Drum Brakes:
1/2-inch – 5/8-inch (12.7-15.9 mm)
r Disc Brakes:
3/4-inch – 7/8-inch (19.1-22.2 mm)
Figure 7.6 WARNING

MEASURE “FREE STROKE” When you work on a spring chamber, carefully
“Y” manufacturer. Sudden release of a compressed
“X” spring can cause serious personal injury.
8. If the brake has spring chambers, carefully
release the spring.
9. Test the vehicle to ensure that the brake
system is operating correctly before you return
the vehicle to service.
FREE STROKE = “Y” MINUS “X”

Drum brake free stroke must be
1/2" – 5/8" (12.7-15.9 mm).
Disc brake free stroke must be
3/4" – 7/8" (19.1-22.2 mm).
17
Section 8
Diagnostics
Section 8
Diagnostics
Symptoms Possible Causes Corrective Actions

Adjusted stroke is The slack adjuster part number is incorrect. Check with WD or OEM.
too long.
The clevis angle is incorrect. Use correct template or BSAP setting
No adjustment. to install clevis correctly.
Excessive wear exists between the clevis and Replace with threaded clevis.
collar (more than 0.060” [1.52 mm]).
The jam nut at the clevis is loose. Tighten to specification.
There is a worn clevis pin bushing in slack Replace bushing.
arm (ID larger than 0.53" [13.46 mm]).
There is a weak or damaged air chamber Replace return spring or air chamber.
spring. Spring force must be at least
32 lb (142.4 N) at first push rod movement.
The spring brake does not retract fully. Repair or replace spring brake.
There are worn or damaged teeth on the pawl Replace pawl or actuator.
or actuator.
High torque is required to rotate worm when Rebuild or replace slack adjuster.
slack is removed from vehicle.
In service slack maximum worm torque:
45 lb-in (5.09 N•m)
New or rebuilt slack maximum worm torque:
25 lb-in (2.83 N•m)
Excessive looseness exists between the Replace powershaft, gear or automatic
splines of the camshaft and the slack adjuster slack adjuster as needed.
gear.
A cam brake has worn components (cam Replace components.
bushing, for example).
Adjusted stroke is OEM replacement linings are not installed. Use Meritor-approved linings.
too short. Linings exhibit excessive swell or growth.
Linings drag. The slack adjuster part number is incorrect. Check with WD or OEM.
The clevis angle is incorrect. Use correct template to install
clevis correctly.
The jam nut at the clevis is loose. Tighten to specification.
The spring brake does not retract fully. Repair or replace spring brake.
The manual adjustment is incorrect. Adjust brake. Refer to Section 7.
Poor contact exists between the linings and Repair or replace drums or linings.
the drum. The drum is out-of-round.
Brake temperature is not even. Correct brake balance.
Figure 8.1
18
Section 9
Inspection
Commercial Vehicle Safety

Section 9
Inspection 4. With the brakes released, mark the push rod
where it exits the chamber. Figure 9.1.
Alliance (CVSA) Guidelines to Measure and record the distance.
Measure Push Rod Travel 5. Have another person apply and hold the brakes
(Adjusted Chamber Stroke) one full application. Figure 9.1.
6. Measure push rod travel distance (adjusted
Use the following procedures to check in-service chamber stroke) from where the push rod exits
push rod travel (adjusted chamber stroke) on truck the brake chamber to your mark on the push
or tractor air brakes with automatic slack adjusters. rod. Measure and record the distance.
Hold the ruler parallel to the push rod and measure Figure 9.1.
as carefully as possible. An error in measurement 7. To determine push rod travel (adjusted
can affect CVSA re-adjustment limits, which state chamber stroke): Subtract the measurement
that “any brake 1/4-inch or more past the you obtained in Step 4 from the measurement
re-adjustment limit, or any two brakes less than you obtained in Step 6. The difference is the
1/4-inch beyond the re-adjustment limit will be push rod travel (adjusted chamber stroke).
cause for rejection.”
r Push rod travel (adjusted chamber stroke)
WARNING must not be greater than the stroke length
shown in the CVSA reference charts for the
To prevent serious eye injury, always wear safe size and type of air chamber you are
eye protection when you perform vehicle inspecting.
r If push rod travel (adjusted chamber stroke)
WARNING is greater than the maximum stroke shown
in the CVSA reference charts, inspect the
When you work on a spring chamber, carefully slack adjuster and replace it if necessary.
manufacturer. Sudden release of a compressed
spring can cause serious personal injury. Alternate Method for Determining
1. The engine must be OFF. If the brake has Push Rod Travel (Adjusted
spring chambers, carefully release the spring. Chamber Stroke)
2. Check the gauges in the cab to ensure that air Use the above procedure, except in Step 4 and
pressure in the tanks is 100 psi (689 kPa). Step 6, measure the distance from the bottom of
3. Determine the size and type of brake chamber the air chamber to the center of the large clevis pin
you are inspecting. on each of the brakes.
Figure 9.1
Mark push rod here STROKE

to measure stroke.
• Spring brakes • Spring brakes

released released
• Service brakes 100 psi (689 kPa) in air • Service brakes
not applied tank — engine OFF applied
19
Section 9
Inspection
Commercial Vehicle Safety Alliance (CVSA) North American

Out-of-Service Criteria Reference Charts
NOTE: A brake found at the adjustment limit is not
a violation.
Table D: “Standard Stroke” Clamp-Type

Brake Chamber Data
Outside
6 4-1/2 1-1/4
9 5-1/4 1-3/8
Should be
12 5-4/16 1-3/8 as short as
16 6-3/8 1-3/4 possible
without
20 6-25/32 1-3/4 lining to
24 7-7/32 1-3/4 drum
contact
30 8-3/32 2
36 9 2-1/4
* For 3" maximum stroke type 24 chambers
Table E: “Long Stroke” Clamp-Type

Brake Chamber Data
Outside
16 6-3/8 2.0 Should be
as short as
20 6-25/32 2.0
possible
24 7-7/32 2.0 without
lining to
24* 7-7/32 2.5 drum
30 8-3/32 2.5 contact
20
Section 10
Lubricants
Section 10 and Maintenance
Lubrication
Table F: Conventional Automatic Slack Adjuster Grease Specifications

Meritor NLGI Outside
Component Specification Grade Grease Type Temperature
Automatic Slack O-616-A 1 Clay Base Down to -40°F (-40°C)
Adjuster
O-692 1 and 2 Lithium Base Down to -40°F (-40°C)
O-645 2 Synthetic Oil, Clay Down to -65°F (-54°C)
Base
Clevis Pins Any of Above See Above See Above See Above
O-637 1-1/2 Calcium Base Refer to the grease
manufacturer’s specifications
O-641 — Anti-Seize for the temperature service
limits.
Anti-Seize Compound Maintenance

Meritor lubricant specification O-637 (part number
2297-U-4571) is a corrosion control grease. Do not Inspections and Lubrication
mix this grease with other greases. This
compound is also available from the Southwest Inspect and lubricate the slack adjuster according
Petro-Chemical Division of Witco Chemical to one of the following schedules. Use the
Corporation, 1400 South Harrison, Olathe, KS schedule that gives the most frequent inspection
66061, as “Corrosion Control,” part number and lubrication. Also inspect and lubricate the
SA 8249496. slack adjuster whenever you reline the brakes.
r Use anti-seize compound on the clevis pins of r The schedule of chassis lubrication used by
all slack adjusters. your fleet.
r Also use anti-seize compound on the automatic r The schedule of chassis lubrication
slack adjuster and cam splines if the slack recommended by the chassis manufacturer.
adjuster gear has no grease groove and holes r Every six months.
around its inner diameter.
r A minimum of four times during the life of
the linings.
Factory-Installed Automatic Slack
Adjusters on Q PlusTM LX500 and
Q Plus™ LX500 and MX500 cam brake packages
include factory-installed automatic slack adjusters
that do not have grease fittings, and lubrication
intervals differ from conventional slack adjusters.
Refer to Maintenance Manual No. MM-96173,
Q Plus™ LX500 and MX500 Cam Brakes, for
complete information. Order this publication by
calling Meritor’s Customer Service Center at
800-535-5560.
21
Section 10
At Brake Reline Slack Adjusters Manufactured

1. Before you perform brake maintenance, check Before 1993
the free stroke and the adjusted chamber 1. Remove the slack adjuster when these
stroke as described in Section 7. conditions are apparent:
2. If the free stroke is not correct, refer to the r The grease is dry or contaminated.
Diagnostics table on page 18 to correct the
stroke before you adjust the chamber stroke. r The pawl or actuator is worn.
3. Inspect the boot for cuts or other damage. If 2. Disassemble the slack adjuster.
the boot is cut or damaged, remove the pawl
3. Replace any worn or damaged parts.
and inspect the grease.
4. Use new seals and a new boot when you
4. If the grease is in good condition, replace the
assemble the unit.
damaged boot with a new boot.
5. Use a grease gun to lubricate the slack adjuster
through the grease fitting. If necessary, install a
camshaft into the slack adjuster gear to
minimize grease flow through the gear holes.
6. Lubricate until new grease purges from around
the inboard camshaft splines and from the
pawl assembly.
7. Measure the gap between the clevis and the
collar on a “Quick Connect” clevis. Replace the
clevis if the gap exceeds 0.060-inch (1.52 mm).
Figure 10.1.
Figure 10.1
0.060" (1.52 MM) MAXIMUM

GAP BETWEEN
COLLAR AND CLEVIS
22
2135 West Maple Road subject to change without notice or liability. Meritor Heavy Vehicle Systems, LLC, reserves the right to revise the
Troy, MI 48084 USA information presented or discontinue the production of parts described at any time.
800-535-5560
arvinmeritor.com Copyright 1998 Maintenance Manual 4B
C
Standard Stroke Model
C
C VMRS# 13-010-034
A
B
X
E
D F
SERVICE CHAMBERS
P/N Series 1412 1416 1420 1427 1430 1436

Model C12 C16 C20 C24L C30 C36
Size 12 16 20 24 30 36
Stroke 1.75" 2.25" 2.25" 2.50" 2.50" 3.00"
Part Number 1412001 1416001 1420001 1427001 1430001 1436001
Wt.(Lbs.) 3.8 5.9 7.55 8.4 10.12 15.88
A 3.84 4.43 4.16 4.42 4.43 5.12
B 3.13 3.64 3.41 3.67 3.69 4.52
C 5.69 6.59 6.92 7.34 8.19 9.25
D 3.00 3.00 4.75 4.75 4.75 4.75
E 7/16" - 14UNC 7/16" - 14UNC 5/8" - 11UNC 5/8" - 11UNC 5/8" - 11UNC 5/8" - 11UNC
F 1/2" - 20UNF 1/2" - 20UNF 5/8" - 18UNF 5/8" - 18UNF 5/8" - 18UNF 5/8" - 18UNF
Inlets 3/8" - NPTF 3/8" - NPTF 3/8" - NPTF 3/8" - NPTF 3/8" - NPTF 3/8" - NPTF
X - Min. (in the caged position) 4.00" 4.00" 8.00" 8.00" 8.00" 8.00"
Note: Product information and specifications subject to change without notice.
#
C
C Model Features
• Low Profile Design • Heavy-Duty Nylon Reinforced Diaphragms
• Formed Steel Pressure Cap - Epoxy-Coated • Top and Side Air Ports - 3/8" NPTF
• Formed Steel Non-Pressure Chamber - Epoxy-Coated • Center Hole Shield
Replacement Parts
P/N Series 1412 1416 1420
Model C12 C16 C20
1 Kit - NP Chamber (b) 9015207 9015136 9015046
2 Kit - Nuts & Bolts 9003002 9003001 9003001
11 3 Clamp Band Assembly 8216012 8216018 8216020
4 Diaphragm 8017112 8017116 8017120
5 Kit - Push-Rod Assembly (b) 9064018 9064019 9064001
SERVICE CHAMBERS
2 6 Return Spring 8068007 8068008 8068002
7 Kit - Center Hole Shield N/A N/A N/A
3 8 NP Chamber Assembly 8215142 8215023 8215169
4 9 Kit - Nuts & Washers 9002003 9002003 9002001
10 Hex Nut - Yoke 8130011 8130011 8130004
11 Pressure Cap (2-inlets/steel) (a) 8010040 8210013 8210010
5 OPTIONAL ITEMS
Yoke Assembly Refer to Replacement Parts Section 7
Boot & Retainer Refer to Replacement Parts Section 7
P/N Series 1427 1430 1436

1
6
Model C24L C30 C36
1 Kit - NP Chamber (b) 9015117 9015050 9015049
2 Kit - Nuts & Bolts 9003001 9003001 9003001
3 Clamp Band Assembly 8216025 8216045 8216036
4 Diaphragm 8017141 8017730 8017836
8
5 Kit - Push-Rod Assembly (b) 9064002 9064003 9064004
9
6 Return Spring 8068002 8068002 8068003
10 7 Kit - Center Hole Shield N/A 9065002 N/A
8 NP Chamber Assembly 8215105 8215501 8215036
9 Kit - Nuts & Washers 9002001 9002001 9002001
10 Hex Nut - Yoke 8130004 8130004 8130004
11 Pressure Cap (2-inlets/steel) (a) 8210002 8210003 8010009
OPTIONAL ITEMS
Note: (a) Type 12 pressure cap is 1 side-inlet/cast aluminum.
(b) To ensure correct stroke alert positioning, these kits must be used only on the designated MGM
Brake units.
For additional replacement parts, refer to Replacement Parts Section 7.

#!
TR
Combination Single/Piggyback
VMRS# 13-004 VMRS# 13-004-001
D
B Piggyback Plus Kit

VMRS# 13-004-001
DOUBLE DIAPHRAGM
F
E
G
C
P/N Series 3420 3427 3429 3434 3430 3433 3437

Model TR2024 TR2424L TR2430L TR3024 TR3030 TR3036 TR3636
Size 2024 2424 2430 3024 3030 3036 3636
Stroke 2.25" 2.50" 2.50" 2.50" 2.50" 2.50" 3.00"
P/N Combination 3420051 3427051 3429051 3434051 3430051 3433051 3437051
P/N Single/Piggyback 3420001 3427001 3429001 3434001 3430001 3433001 (a) 3437001
P/N Piggyback Plus Kit N/A 3427008 3429008 N/A 3430008 N/A N/A
Wt.Combination (Lbs.) 15.9 16.6 18.5 18.3 20.0 26.5 30.8
Wt. Single (Lbs.) 9.6 9.5 11.6 9.7 11.6 18.3 20.2
A 8.31 8.52 9.04 8.47 9.04 9.86 11.13
B 6.16 6.36 6.91 6.12 6.66 7.52 8.38
C 6.9 7.38 7.38 8.31 8.31 8.31 9.25
D 7.34 7.34 8.21 7.34 8.21 9.18 9.18
E 4.75"
F 5/8" - 11UNC
G 5/8" - 18UNF
Inlets 3/8" - NPTF
X - Min. (in the caged position) 8.00" (b)
Note: (a) This model must be used only in combination with MGM Brakes heavy-duty weld reinforced mounting base or 8 gauge non-pressure housing.
(b) For Transit and Hendrickson Intraax / Vantraax Suspension applications refer to page 76.
Product information and specifications subject to change without notice.

TR
TR Model Features
• Tamper Resistant Design • Weatherseal™ Plug
(U.S. Patent No. 5,067,391) • Heavy-Duty Steel Non-Pressure Chamber
• Molded Nitrile Rubber Push-Rod Air Seal (8-Gauge Standard on Type 3030 & 3036 Aftermarket Models)
• Center Hole Shield (6-Gauge Standard on Type 36 Models)
• Externally Stored Release Bolt • Stroke Alert
• Epoxy-Coated Head, Non-Pressure • Polymer Push-Rod Guides
Chamber and Lower Push-Rod Assembly • Heavy-Duty Nylon Reinforced Diaphragms
• 360 Aluminum Center Case • Heavy-Duty Nylon Reinforced Neoprene Diaphragms (Optional)
• Long Life Power Spring
7 Center Hole Shield
DOUBLE DIAPHRAGM
11 Permits visual inspection of
stroke alert but prevents
12 entry of contaminants.
Replacement Parts
13 P/N Series 3420 3427 3429 3434 3430 3433 3437
Model TR2024 TR2424L TR2430L TR3024 TR3030 TR3036 TR3636
1 Kit - NP Chamber (b) 9015160 9015161 9015161 9015050 9015050 9015050 9015049
14 2 Kit - Nuts & Bolts 9003001 9003001 9003001 9003001 9003001 9003001 9003001
3 Clamp Band Assembly 8216020 8216025 8216025 8216045 8216045 8216045 8216036
2 4 Diaphragm 8017120 8017141 8017141 8017730 8017730 8017730 8017836
5 Kit - Push-Rod Assembly (b) 9064001 9064002 9064002 9064003 9064003 9064003 9064004
3 6 Return Spring 8068002 8068002 8068002 8068002 8068002 8068002 8068003
4 7 Kit - Center Hole Shield 9065002 9065002 9065002 9065002 9065002 9065002 9065002
8 NP Chamber Assembly 8215169 8215105 8215105 8215501 8215501 8215501 8215036
9 Kit - Nuts & Washers 9002001 9002001 9002001 9002001 9002001 9002001 9002001
5
10 Hex Nut - Yoke 8130004 8130004 8130004 8130004 8130004 8130004 8130004
1 11 Kit - Weatherseal™ Plug 9019005 9019005 9019005 9019005 9019005 9019006 9019006
12 Kit - Release Bolt 9007003 9007003 9007003 9007003 9007003 9007009 9007009
6 13 Piggyback 3420001 3427001 3429001 3434001 3430001 3433001(a) 3437001
14 Kit - Piggyback Plus N/A 3427008 3429008 N/A 3430008 N/A N/A
OPTIONAL ITEMS
8
9 Note: (a) This model must be used only in combination with MGM Brakes heavy-duty weld reinforced mounting
base or 8 gauge non-pressure housing.
10 (b) To ensure correct stroke alert positioning, these kits must be used only on the designated MGM Brake
units.
For additional replacement parts, refer to Replacement Parts Section 7.

MODEL TR SERIES
MODEL TR-T SERIES
MGM Brakes Service Manual MODEL TR-TS SERIES
MODEL TR-HD SERIES
MODEL TR-LP3 SERIES
For: Tamper Resistant S-Cam Double Diaphragm Combination Service and Spring Brake Chambers
The MGM Brakes Tamper Resistant spring brake chambers are an important part of your braking system. While they do not require scheduled
servicing, it is good preventative maintenance to make the following routine inspections while they are in the shop for regular servicing of other
components or at a minimum of every 50,000 miles.
WARNING: YOUR MGM BRAKES TAMPER RESISTANT SPRING BRAKE HAS BEEN
FACTORY SEALED FOR YOUR PROTECTION. THERE ARE NO USER-SERVICEABLE
PARTS INSIDE THE SPRING BRAKE CHAMBER. IF YOU EXPERIENCE ANY DAMAGE
OR FAILURE OF YOUR SPRING BRAKE CHAMBER, REMOVE EITHER THE ENTIRE Figure 1
ACTUATOR AS IN SECTION (3) OF THIS MANUAL, OR THE SINGLE (PIGGYBACK) AS IN A
SECTION (5) OF THIS MANUAL. SEE SECTION (8) OF THIS MANUAL FOR DISPOSAL
INSTRUCTIONS. NEVER ATTEMPT TO DISASSEMBLE THE SPRING BRAKE CHAMBER
AS SERIOUS PERSONAL INJURY COULD RESULT FROM ACCIDENTAL SUDDEN
RELEASE OF THE HIGH ENERGY SPRING.
SECTION (1): RECOMMENDED INSPECTION POINTS

C
The plastic END CAP on all “TR” and “TR-T” models requires no positioning or maintenance, but
A must be snapped tightly into place. Inspect the cap for damage and replace as necessary.“TR-T”
units equipped with a breather tube and the white WEATHER SEAL END CAP must be equipped
with a rubber O-ring (Figure 12) to ensure proper sealing of the spring chamber. Operating units
equipped with the BREATHER TUBE without the END CAP or DUST CAP securely in place E
will void the MGM Brakes warranty without remedy.
Visually inspect the exterior surfaces of the unit for signs of damage from outside sources, corrosion D
B and/or rust. If any of these are seen or suspected, cautiously remove the complete combination
chamber by following the directions in Section (3) of this manual. Per CVSA out of service criteria F
any non-manufactured hole or crack will place the vehicle out of service. (Not Shown)
Model “TR” Series
Inspect SERVICE BRAKE CLAMP RING to be sure it is securely in place and damage free. If any
C damage is seen or suspected, cautiously remove the complete piggyback/spring brake chamber
by following directions in Section (5) of this manual. MGM Brakes recommends 30-35 Lbs.-Ft.
torque on CLAMP BOLTS.
Check to ensure the MOUNTING STUD NUTS are tightened to 133-155 Lbs.-Ft. torque
D (clockwise) and washers are in place between the nut and bracket.
Figure 2
A
Inspect air lines, hoses and fittings attached to chamber. Replace any damaged or leaking parts.
E MGM Brakes recommends the fittings be tightened to 25-30 Lbs.-Ft. torque into the
chamber air inlet ports.
IMPORTANT - Inspect the air ports to determine the model of brake. Round ports denote (2.50 inch)
standard stroke model, square ports denote (3.00 inch) long stroke model. This information is
important when replacing the service diaphragm and determining the chamber’s rated stroke.
F
Inspect the PUSH-ROD to be sure it is working free, not bent, not binding and is square to the C
chamber bottom within ±3° in any direction at any point in the stroke of the chamber. If the PUSH-
ROD is not square, make corrections by repositioning the chamber on the mounting bracket and/
or by shimming the slack adjuster to the right or left on the camshaft as required.
G
Inspect the YOKE ASSEMBLY being sure YOKE PIN is installed and locked into place with a I
COTTER PIN. Replace any damaged, worn or missing parts. MGM Brakes recommends the
YOKE LOCKNUT be tightened to 25-50 Lbs.-Ft. torque. (Not Shown) E
On units equipped with a DUST BOOT, check the BOOT for damage and replace as necessary. F
H (Not Shown).
D
On units equipped with an external BREATHER TUBE (Figure 2) be sure both ends of the connector
I tube are engaged a minimum of 1/2-inch into each of the flexible elbows. The tube must be glued Model “TR-T” Series
to both of the elbows with a high quality rubber adhesive or secured with a clamp that may be
purchased with the MGM Brakes BREATHER TUBE KIT. These units must be mounted with the
BREATHER TUBE in the upper half of the non-pressure chamber facing away from the road
surface (Figure 10).
IMPORTANT: Failure to operate any MGM Brakes Model Series “TR-T” or TR-TS” chamber Figure 3
without the EXTERNAL BREATHER TUBE and END CAP with O-ring being present and in
good condition will void the MGM Brakes Warranty without remedy.
SECTION (2): MANUAL RELEASE - PARKING BRAKES

(a) Before releasing the parking brakes, chock wheels of the vehicle to prevent a runaway.
(b) Remove the plastic end cap from the spring brake chamber (Figure 3).
(c) Using a 3/4 inch (15/16-inch for TR3036 and TR3636 models) wrench, unscrew the release-nut
and remove the nut, flat washer, and release-bolt from their storage pocket on side of chamber
for all “TR” series brakes (Figure 4).
IMPORTANT: If these parts are not stored on the chamber, they must be obtained from vehicle
tool box or service department, as the piggyback/spring brake cannot be manually released Figure 4
without them.
(d) Insert the release-bolt into the centerhole of the head (Figure 5) and, being sure that the formed
end of the bolt has entered the hole in the piston inside the chamber, continue to insert the bolt
until it bottoms out.
IMPORTANT: If you are not absolutely sure of correct bolt-to-piston engagement, repeat this
step until you are sure.
(e) Turn the release-bolt 1/4 turn clockwise and pull the bolt out to lock the formed end into the piston.
IMPORTANT: If the bolt does not lock into the piston in less than 1/2 inch outward movement,
repeat steps (d) and (e) until you are sure it does lock.
(f) Holding the bolt locked into the piston, install the flat washer and the release nut on the end of the
release-bolt, and turn down the nut against the flat washer until finger tight (Figure 6). Figure 5
(g) Using a 3/4 inch (15/16 inch for TR3036 and TR3636 models) handwrench (DO NOT USE
AN IMPACT WRENCH) turn the release-nut clockwise until the following length of bolt
extends above the nut (Figure 7).
3.25 inch - Type 2430 Chamber 4.00 inch - Type 3036 Chamber
3.25 inch - Type 3030 Chamber 4.00 inch - Type 3636 Chamber
WARNING: DO NOT EXCEED THESE LENGTHS AND DO NOT EXCEED 50 Lbs.-Ft. TORQUE
ON RELEASE NUT AT ANY TIME OR DAMAGE MAY OCCUR WHICH COULD PREVENT
ANY FUTURE CORRECT MANUAL-RELEASING OF THE PIGGYBACK SPRING BRAKE
CHAMBER.
NOTES:
* For easier manual-releasing, apply 90-125 psi air pressure to inlet port marked
“SPRING BRAKE” before Step (d) above, but be sure to exhaust all air pressure after Step (g) Figure 6
is completed.
* To reactivate the piggyback/spring brake from its manually-released position, reverse the
order of Steps (a) through (g) above.
* When re-installing the release-bolt, flat washer and release-nut into the storage pocket,
MGM Brakes recommends 10 Lbs.-Ft. torque on nut against the flat washer (See
Figure 11).
SECTION (3): REMOVAL AND INSTALLATION INSTRUCTIONS FOR

“COMBINATION CHAMBERS”
NOTE: Refer to Section (7) before removing air brake chamber to be replaced to ensure that the brake
chamber being replaced was properly installed with the correct rod length.
(a) Determine the manufacturer of the single (piggyback) spring brake or combination chamber Figure 7
to be removed from the vehicle and, following that manufacturer’s instructions exactly, manually
release the spring brake completely. (Instructions for all MGM Brakes Model Series “TR”,
“TR-T” and single (piggyback) spring brakes having removable bolts are given in Section (2) of Measure
this manual. (Service Manuals for all other design series of MGM Brakes piggyback spring
brakes are also available upon request to MGM Brakes.)
(b) Remove the cotter pin from the yoke pin, knock out the yoke pin, and remove both air lines
from the assembly.
IMPORTANT: Be sure to mark the air line from the inlet port marked “SPRING BRAKE” for later
re-installation reference.
Figure 8 (c) Using a 15/16 inch wrench, unscrew hex nuts on mounting bolts and cautiously remove the old
chamber from the mounting bracket.
Y (d) Follow procedure to cut the service push-rod to proper length (Refer to Section 4).
X (e) Remove the hex nut and the flat washers on the mounting bolts of the new chamber, clean
the face of the mounting bracket and install the chamber on the bracket with close attention
given to positioning the chamber air inlet ports for correct alignment to the vehicle lines. Then
install one flat washer and hex nut on each mounting bolt and using a 15/16 inch hand
wrench (DO NOT USE AN IMPACT WRENCH), tighten nuts to MGM Brakes recommended
133-155 Lbs-Ft. torque.
IMPORTANT: If it is required to repostition the air inlet ports to assure proper mating and
alignment with vehicle air lines, refer to Section (5) of this manual and follow Steps (c) through
(f) very carefully.
IMPORTANT: When installing any MGM Brakes model with the breather tube it is mandatory to
position the non-pressure chamber end of the breather tube in upper half of chamber facing
Figure 9 away from the road surface (Figure 10). Failure to comply will void the MGM Brakes Warranty
on these models.
(f) Reconnect yoke to the slack adjuster, being sure that the correct diameter and length of yoke
pin is installed into the correct hole in the slack adjuster. Secure the yoke pin with a new
cotter pin.
IMPORTANT: When making a reconnection to an automatic slack adjuster follow the vehicle
manufacturer’s recommendations for installation and set-up.
(g) Inspect the push-rod to be sure that it is working free, not bent, not binding an is square
to the chamber bottom within ±3° in any direction at any point in the stroke of the chamber.
If the push-rod is not square, make corrections by repositioning the chamber on the mounting
bracket and/or by shimming the slack adjuster to the right or left on the camshaft as required.
(h) Apply a non-hardening sealing compound to the hose fittings and re-install both of the air
lines to the chamber being sure each is mated to the correct air inlet port according to the
markings made earlier. MGM Brakes recommends the fittings be tightened to 25-30
Figure 10 Breather Tube Lbs.-Ft. torque into the chamber air-inlet ports.
Yes Yes (i) Using the vehicle system air, charge the spring brake with full line pressure (minimum 100
psi). Spray only soapy water or leak detection solution (NEVER ANY TYPE OF OIL!) to the
air line fittings and inspect for air leaks. If bubbles appear, tighten fittings slightly, but not over
30 Lbs.-Ft. torque.
IMPORTANT: If the service brake clamp ring was loosened to reposition air inlet ports in Step(e)
above, apply air to the spring brake and then apply and hold foot brake treadle valve down to charge
No No
the service brake chamber. Test for air leaks around the circumference of the service clamp ring
using soapy water or leak detection solution. If bubbles appear, firmly tap the circumference of the
Road Surface
clamp ring with a hammer and retighten the clamp nuts until leaks cease (Figure 19). MGM Brakes
recommends 30-35 Lbs-Ft. torque on clamp hex nuts. Completely exhaust air from both of the
chambers when complete.
(j) With air pressure now exhausted from the service chamber, but still applied on the spring
brake, remove release-nut, washer and release-bolt for all “TR” models. Replace these parts
in their storage pocket (Figure 4) on chamber (or in vehicle tool box if storage pocket is not
present on chamber) and tighten nut against flat washer to 10 Lbs.-Ft. torque.
(k) Replace the END CAP properly (Figure 13). Operating units equipped with the EXTERNAL
BREATHER TUBE without the END CAP and O-RING securely in place will void the
Figure 11 MGM Brakes Warranty without remedy.
IMPORTANT: If chamber is fitted with an external breather tube be sure both ends of the
connector tube are engaged a minimum of 1/2 inch into each of the flexible elbows. The tube
must be glued to both of the elbows with a high quality rubber adhesive or secured with a
clamp that may be purchased with the MGM Brakes Breather Tube Kit. These units must be
mounted with the BREATHER TUBE in the upper half of the non-pressure chamber facing
away from the road surface (Figure 10).
WARNING: AFTER REPLACEMENT OF ANY BRAKE CHAMBER, THE CHAMBER PUSH-

ROD STROKE AND ACTUATING ALIGNMENT MUST BE CHECKED TO ASSURE CORRECT
INSTALLTION AND FOUNDATION BRAKE ADJUSTMENT. IT IS VERY IMPORTANT TO
RECOGNIZE THAT NO FOUNDATION ADJUSTMENTS CAN BE MADE AT EITHER THE
SPRING BRAKE CHAMBER, OR AT THE SERVICE BRAKE CHAMBER, AND THAT ALL
“STROKE ADJUSTMENTS” MUST BE MADE AT THE SLACK ADJUSTER ACCORDING
TO THE SPECIFIC RECOMMENDATIONS OF THE FOUNDATION BRAKE MANUFACTURER
OR THE VEHICLE MANUFACTURER.
SECTION (4): PROCEDURE TO CUT THE SERVICE PUSH-ROD TO Figure 12

PROPER LENGTH
WARNING: DO NOT ATTEMPT TO SERVICE OR DISASSEMBLE THE SPRING CHAMBER OR

ANY SPRING BRAKE ACTUATOR. A LARGE SPRING IN THE SPRING CHAMBER HAVING
EXTREME FORCE COULD CAUSE SERIOUS BODILY INJURY IF IT WERE SUDDENLY
RELEASED DUE TO INADVERTENT REMOVAL OF THIS CLAMP OR TAMPER RESISTANT
HEAD.
IMPORTANT: Place blocks under wheels to prevent vehicle runaway before removing air brake
actuators.
(a) REMOVE WORN OR NON-FUNCTIONAL UNIT FROM VEHICLE: Determine manufacturer and
model of unit to be replaced. Refer to that manufacturer’s service manual for caging and removal
instructions.
(b) Make sure the spring chamber of the removed actuator is fully released (power spring caged)
Figure 13
and the service brake push-rod is fully retracted to zero stroke position (i.e., brake fully released).
(c) Measure and record the “X” and “Y” dimensions (Figure 8).
“X” Dimension - The dimension from bottom of actuator to end of push-rod.
“Y” Dimension - The dimension from bottom of actuator to centerline of yoke pin.
NOTE: If for some reason the spring chamber power spring cannot be caged and fully released, then
the “X” and “Y” dimensions will need to be measured from another actuator of the exact type from the
same vehicle provided it is retracted to its zero stroke position (brake fully released) and was operating
correctly.
(d) Before marking push-rod to be cut on a new unit, be sure the spring chamber and push-rod are
fully retracted to the zero position. (This may be done with the manual caging bolt or by applying
90-100 psi air pressure to the spring chamber air inlet port.)
(e) Take measured “X” dimension from the removed unit and mark push-rod of new unit from the
bottom of the actuator.
(f) Thread yoke jam nut past mark on push-rod. Align bottom edge of nut with mark.
(g) Use a sharp hack-saw and cut push-rod on the mark (Figure 9). Figure 14
(h) After cutting rod, thread jam nut off to clean up the thread.
(i) Thread jam nut back onto the push-rod a suffient length to allow assembly of the yoke.
(j) Thread yoke onto the push-rod. Yoke from removed unit may be reused provided yoke pin hole
is not worn. Adjust yoke to the same “Y” dimension as measured from the removed unit. Apply
Adhesive
(k) Hold yoke to prevent it from turning and tighten locknut against yoke 25-35 Lbs.-Ft. torque. Here
TO INSTALL NEW UNIT ON VEHICLE: Refer to MGM Brakes Service Manual for the model that is
being installed.
SECTION (5): REMOVAL AND INSTALLATION INSTRUCTIONS FOR SINGLE

(PIGGYBACK) SPRING BRAKES
The removal and installation of a single spring brake chamber (without removal of the service brake 1/2-inch
chamber) can be made easier by “locking off” the service chamber piston. To do this apply the service Minimum
brake by applying the driver’s foot brake treadle valve and, while applied, clamp vise-grip pliers on Engagement
push-rod so that vice-grips abut mounting bracket to prevent rod from retracting when air pressure is
released (Figure 15).
(a) Determine manufacturer of the single spring brake to be removed from the vehicle and, following
that manufacturer’s instructions exactly, manually release the spring brake completely. (Instructions Figure 15
for all MGM Brakes Model Series “TR”, “TR-T” and single spring brakes having removable
release bolts are given in Section (2) of this manual. (Service Manuals for all other design series
of MGM Brakes single spring brakes are also available upon request to MGM Brakes.)
(b) Remove both air lines from the chamber.
IMPORTANT: Be sure to mark the air line from the inlet port marked “SPRING BRAKE” for later
re-installation reference.
(c) On all MGM Brakes models fitted with external breather tubes (Figure 2), disconnect the tube
and elbow from the service chamber housing (Figure 18).
(d) Using a 9/16 inch wrench or socket, remove the clamp nuts on the service clamp ring. Then,
Figure 16
while holding the single spring brake securely in place, remove the clamp ring to allow removal of
the single brake from the service chamber (Figure 16).
IMPORTANT: At this time take the opportunity to inspect all parts in the service chamber
(especially the diaphragm) and replace the return spring, and any other parts which may be
damaged or worn. Use only genuine MGM Brakes Engineered replacement parts!
(e) Make sure the new single (piggyback) spring brake is fully released as outlined in Section (2) of
this manual. Position the diaphragm in the bottom recess of the chamber (Figure 17) and, with
very close attention taken to assure all mating parts are aligned straight and the air lines are
positioned to mate with the vehicle air supply lines, replace the service clamp ring (Figure 16).
(f) Re-install the clamp bolts and nuts. Alternately tighten each nut in 5-10 Lbs.Ft. torque
increments while constantly rechecking mating parts alignment. (If re-alignment is required,
loosen clamp nuts and repeat Step (e) above). Firmly tap around circumference of the clamp
ring with a hammer to assure the full seating of the clamp (Figure 19) and tighten the nuts to
30-35 Lbs-Ft. torque.
(g) Apply a non-hardening sealing compound to the hose fittings and re-install both of the air lines to
the chamber, being sure each is mated to the correct air inlet port according to the markings
Figure 17
made earlier. MGM Brakes recommends the fittings be tightened to 25-30 Lbs.-Ft. torque
into the chamber air inlet ports.
(h) Using the vehicle system air, charge the spring brake with full line pressure (minimum 100 psi).
Spray only soapy water or leak detection solution (NEVER ANY TYPE OF OIL!) to the air line
fittings and inspect for air leaks. If bubbles appear, tighten fittings slightly, but not over
30 Lbs.-Ft. torque.
(i) With the spring brake still fully charged with full line pressure, apply and hold foot brake treadle
valve down to charge the service brake chamber.
IMPORTANT: At this time, remove the vise-grip pliers (Figure 15) from the service push-rod so that the
piston can return to a normal position in the chamber. Now test for air leaks around the circumference
of the service clamp ring by spraying with soapy water or leak detection solution. If bubbles appear,
firmly tap the circumference of the clamp ring with a hammer and retighten the clamp nuts until leaks
cease (Figure 19). MGM Brakes recommends 30-35 Lbs.-Ft. torque on the clamp hex nuts.
(j) On all MGM Brakes models fitted with an EXTERNAL BREATHER TUBE, wipe the open end
of the connector tube clean to be sure that no oil is present, apply a high quality rubber cement
Figure 18 to the tube and re-insert tube into flexible elbow a minimum 1/2 inch engagement (Figure 14).
If the old single unit was not equipped with an EXTERNAL BREATHER TUBE, drill a 1/2 inch
diameter hole 1 inch from the top of the non-pressure chamber (Figure 18), at a point closest
to the centerline between the air ports, but in the upper half of the chamber facing away from
Apply the road surface (Figure 10). Remove any burrs around the hole, install a new rubber elbow
Adhesive in the non-pressure chamber, wipe the open end of connector tube clean to be sure no oil is
Here present. Apply a high quality rubber cement to the tube and insert the tube into the flexible
elbow with a minimum 1/2 inch engagement (Figure 18).
IMPORTANT: These units must be mounted with the BREATHER TUBE in the upper half of the non-
1/2-inch pressure chamber facing away from the road surface (Figure 10) and the tube glued or clamped securely
Minimum into the rubber elbows (Figure 14). Failure to comply with these installation instructions will void the
Engagement MGM Brakes Warranty without remedy.
(k) With air pressure exhausted from the service chamber, but with line pressure still on the spring
brake, remove the release nut, washer and bolt for all “TR” models. Replace these parts in their
1/2-inch storage pocket (Figure 4) on the chamber (or in the vehicle tool box if a storage pocket is not on
Diameter Hole the chamber) and tighten the nut against the flat washer to 10 Lbs.-Ft. torque.
(l) Replace the end cap properly (Figure 13). Operating these units without the END CAP
Figure 19 securely in place will void the MGM Brakes Warranty without remedy.
SECTION (6): REMOVAL AND INSTALLATION INSTRUCTIONS FOR

“SERVICE BRAKE DIAPHRAGM”
(a) Follow all instructions given in Section (5) of this manual and install the new diaphragm
in Step (5-e). Use only genuine MGM Brakes Engineered replacement diaphragms!
WARNING: WHEN SERVICING A 3-INCH “LONG STROKE” MODEL BRAKE, BE SURE TO REPLACE
WITH THE CORRECT DIAPHRAGM. INSTALLATION OF A STANDARD (2.50 INCH) STROKE
DIAPHRAGM IN A 3-INCH “LONG STROKE” CHAMBER COULD RESULT IN CATASTROPHIC
FAILURE OF THE UNIT.
IMPORTANT: It may not be necessary to disconnect the air lines from the spring brake during this procedure as long as correct and straight parts
alignment can be obtained during the re-assembly operations.
SECTION (7): CAM BRAKE ADJUSTMENT - ALL MODELS SPRING BRAKE AND SERVICE BRAKE
ACTUATORS.
NOTE: The last half of an air chamber stroke is less efficient than the first half. Therefore, the following adjustments are recommended
for maximum efficiency when using manually adjusted slack adjusters.
BRAKES “OFF” - NOT APPLIED PROPERLY - ADJUSTED BRAKES “ON” - APPLIED
Angle must always be greater than 90° due to various slack To check brake adjustment, apply 90 to 100 psi air pressure to the
adjuster lengths and installation setups. (Refer to axle or service chamber. Consult the vehicle manufacturer for the correct
OEM manufacturer’s manual for recommended angle). angle between the slack adjuster arm and push-rod and/or the
push-rod length. This is necessary since different dimensions are
Stroke should be as short as possible with no lining to drum
required for automatic or manual slacks, various slack lengths and
contact.
different slack adjuster manufacturers.
Effective Approx. Maximum “B” MV/MA
IMPROPERLY ADJUSTED BRAKES “ON” - APPLIED Type Area Diaphragm Rated Stroke Stroke with Recommended
(Maximum recommended readjustment stroke has been exceeded) (SQ. IN.) O.D. of Chamber Brakes Readjustment
Adjusted Stroke
MGM Brakes “Stroke Alert” Inches MM Inches MM Inches MM
(Excessive Stroke Warning) 9 9 5.00 125 1.75 45 SHOULD 1.35 35
12 12 5.50 140 1.75 45 BE AS 1.35 35
16 16 6.00 150 2.25 57 SHORT AS 1.75 45
16L 16 6.00 150 2.50 64 POSSIBLE 2.00 51
20 20 6.50 165 2.25 57 WITHOUT 1.75 45
20L 20 6.50 165 2.50 64 LINING TO 2.00 51
24 24 7.00 175 2.25 57 DRUM 1.75 45
24L 24 7.00 175 2.50 64 CONTACT 2.00 51
24LP3 24 7.00 175 3.00 76 2.50 64
30 30 8.00 200 2.50 64 2.00 51
30LP3 30 8.00 200 3.00 76 2.50 64
36 36 9.00 230 3.00 76 2.25 57
SOURCE: MVMA (Motor Vehicle Manufacturers Association)
See chart on right for recommended
readjustment stroke
Note: The push-rod must remain perpendicular to the bottom surface of the
non-pressure chamber (NPC) within ±3° zero to full stroke.
SECTION (8): RECOMMENDED SPRING BRAKE ACTUATOR DISARMING PROCEDURE
WARNING: THIS PROCEDURE MUST BE STRICTLY ADHERED TO. NEVER ATTEMPT TO REMOVE THE SPRING
CHAMBER CLAMP RING FROM A DOUBLE DIAPHRAGM ACTUATOR OR THE SPRING CHAMBER RETAINING RING
FROM A PISTON ACTUATOR. BOTH ACTUATORS EMPLOY A HIGH ENERGY POWER SPRING THAT COULD CAUSE
SERIOUS BODILY INJURY IF THE SPRING WERE SUDDENLY RELEASED DUE TO IMPROPER DISASSEMBLY.
All retired spring brake actuators must be safely disarmed before they are disposed of to prevent serious personal injury
from accidental sudden release of the high energy spring (as much as 2700 Lbs. of force) in the parking chamber. To
disarm the unit, remove it from the vehicle following the instructions in Section (3) for combination chambers, or Section (5)
for single/piggyback chambers. Be sure to release the brake per Section (2) of this manual. Never attempt to remove the
head which contains the power spring. Observe all safety precautions. Place the unit in a steel *container and use an
acetylene torch to cut a hole through the head housing the power spring. Cut completely through at least two spring coils.
The steel container must have openings to expose the head where it is to be cut with the acetylene torch and it must be
strong enough to prevent parts from hurtling out should the unit suddenly separate before it is safely disarmed. It is the
users responsibility to ensure the steel container is safe.
*Information concerning a suitable container is available through your MGM Brakes Representative.
Form #5011
MGM Brakes A Division of Indian Head Industries, Inc.
© 1991 MGM Brakes - Revised 1/2000
All Rights Reserved
8530 Cliff Cameron Drive • Charlotte, NC 28269-9786 • (704) 547-7411 • (800) 527-1534 • (704) 547-9367 Fax Printed in U.S.A.
e-mail: mail@mgmbrakes.com • www.MGMBrakes.com
BR01_002.fm 98 ページ２００４年５月２４日月曜日午後３時２８分
SD-03-830
E-8P & E-10P DUAL BRAKE VALVES
TREADLE
TREADLE
MOUNTING
PLATE MOUNTING
PLATE
VALVE
SUPPLY SUPPLY
(4) DELIVERY
(4)
DELIVERY
(4)
VALVE
AUXILLIARY
SUPPLY EXHAUST
EXHAUST
FIGURE 1 - E-8P FIGURE 2 - E-10P
DESCRIPTION
Refer to Figures 4, 5 and 6 for item numbers referenced in Valve is generally used on busses, where smooth brake
parenthesis. applications contribute to passenger comfort.
The E-8P (Figure 1) and E-10P (Figure 2) Dual Brake Valves The circuits in the E-8P/E-10P Dual Brake Valves are
are floor mounted, treadle operated type brake valves with identified as follows: The No. 1 or primary circuit is that
two separate supply and delivery circuits for service (pri- portion of the valve between the spring seat which contacts
mary and secondary) braking, which provides the driver with the plunger and the relay piston; the No. 2 or secondary
a graduated control for applying and releasing the vehicle circuit is that portion between the relay piston and the
brakes. exhaust cavity.
The E-10P Dual Brake Valve (Figure 2) is similar to the E-8P The primary circuit of the valve is similar in operation to a
Dual Brake Valve except that a metal coil spring (5) housed standard single circuit air brake valve and under normal op-
in an upper body assembly replaces the rubber spring (27) erating conditions the secondary circuit is similar in operation
used in the E-8P valve. The use of a metal coil spring (and to a relay valve.
the upper body assembly) provides greater treadle travel
Both primary and secondary circuits of the brake valve use
and, therefore, provides the driver with a less sensitive "feel"
a common exhaust protected by an exhaust diaphragm.
when making a brake application. The E-10P Dual Brake
1
MV-3 TP-5 TRACTOR
TRAILER
CONTROL
SLACK
SPRING
BRAKE
SLACK
(E-8P OR E-10P)
DUAL BRAKE QUICK
RELEASE
DOUBLE
CHECK
GOVERNOR
AIR DRYER BP-R1
BOBTAIL
PROPORTIONING
SUPPLY
RESERVOIR
COMPRESSOR #1 SERVICE
#2 SERVICE
FIGURE 3 - TYPICAL PIPING SCHEMATIC
16 18
19 25
15 27 26
28 22
23 UPPER BODY
33
DEL - 1
24
17 31
SUP - 1
20 21
30 14
LOWER BODY
32
SUP - 2
BODY ATTACHING
SCREWS
13
DEL -2
10
EXHAUST COVER
ATTACHING SCREWS
11
9 12
FIGURE 4 - E-8P SECTIONAL VIEW

2
OPERATION - Refer to Figure 3 BALANCED: NO. 2 OR SECONDARY CIRCUIT

When the air pressure on the delivery side of the relay pis-
APPLYING: NORMAL OPERATION - NO. 1 OR
ton (20) approaches that being delivered on the primary side
PRIMARY CIRCUIT PORTION
of the relay piston, the relay piston moves closing the sec-
When the brake treadle is depressed, the plunger exerts ondary inlet valve and stopping further flow of air from the
force on the spring seat (26), graduating spring (23), and supply line through the valve. The exhaust remains closed
primary piston (22). The primary piston, which contains the as the secondary delivery pressure balances the primary
exhaust valve seat, closes the primary exhaust valve. As delivery pressure.
the exhaust valve closes, the primary inlet valve is moved off
its seat allowing primary air to flow out the No. 1 or primary When applications in the graduating range are made, a bal-
delivery port. anced position in the primary circuit is reached as the air
pressure on the delivery side of the primary piston (22) equals
APPLYING: NORMAL OPERATION - NO. 2 OR the effort exerted by the driver's foot on the treadle. A bal-
SECONDARY CIRCUIT anced position in the secondary portion is reached when air
pressure on the secondary side of the relay piston (20) closely
When the primary inlet valve (33) is moved off its seat, air is approaches the air pressure on the primary side of the relay
permitted to pass through the bleed passage and enters the piston.
relay piston cavity. The air pressure moves the relay piston
(20), which contains the exhaust seat, and closes the sec- When the brake treadle is fully depressed, both the primary
ondary exhaust valve. As the secondary exhaust valve closes, and secondary inlet valves remain open and full reservoir
the inlet valve (13) is moved off its seat allowing the second- pressure is delivered to the actuators.
ary air to flow out the delivery of the same circuit. Because
of the small volume of air required to move the relay piston RELEASING: NO. 1 OR PRIMARY CIRCUIT
(20), action of the secondary circuit of the valve is almost With the brake treadle released, mechanical force is re-
simultaneous with the primary circuit portion. moved from the spring seat (26), graduating spring (23), and
primary piston (22). Air pressure and spring load moves the
APPLYING: LOSS OF AIR IN THE NO. 2 OR primary piston, opening the primary exhaust valve, allowing
SECONDARY CIRCUIT air pressure in the primary delivery line to exhaust out the
Should air be lost in the No. 2 or secondary circuit, the No. exhaust port.
1 or primary circuit will continue to function as described
above under Normal Operation: No.1 or Primary Circuit Por-
RELEASING: NO. 2 OR SECONDARY CIRCUIT
tion. With the brake treadle released, air is exhausted from the
primary circuit side of the relay piston (20). Air pressure and
APPLYING: LOSS OF AIR IN THE NO. 1 OR spring load move the relay piston, opening the secondary
PRIMARY CIRCUIT exhaust valve, allowing air pressure in the secondary deliv-
Should air be lost in the primary circuit, the function will be ery line to exhaust out the exhaust port.
as follows: As the brake treadle is depressed and no air
PREVENTIVE MAINTENANCE
pressure is present in the primary circuit supply and deliv-
ery ports, the primary piston (22) will mechanically move Important:Review the warranty policy before performing
the relay piston (20) , allowing the piston to close the sec- any intrusive maintenance procedures. An extended war-
ondary exhaust valve and open the secondary inlet valve ranty may be voided if intrusive maintenance is performed
and allow air to flow out the secondary delivery port. during this period.
BALANCED: NO. 1 OR PRIMARY CIRCUIT Because no two vehicles operate under identical conditions,
maintenance and maintenance intervals will vary. Experi-
When the primary delivery pressure acting on the primary ence is a valuable guide in determining the best maintenance
piston (22) equals the mechanical force of the brake pedal interval for any one particular operation.
application, the primary piston (22) will move and the pri-
mary inlet valve (33) will close, stopping further flow of air Visually check for physical damage to the brake valve such
from the primary supply line through the valve. The exhaust as broken air lines and broken or missing parts.
valve remains closed preventing any escape of air through Every 3 months, or 25,000 miles or 900 operating hours:
the exhaust port.
Clean any accumulated dirt, gravel, or foreign material away
from the heel of the treadle, plunger boot, and mounting
plate.
3
Using light oil, lubricate the treadle roller, roller pin, and hinge Refer to figures 4, 5 and 6 for item numbers referenced in
pin. parenthesis.
Check the rubber plunger boot for cracks, holes or deterio- REMOVAL
ration and replace if necessary. Also, check mounting plate 1. Chock the vehicle wheels or park the vehicle by
and treadle for integrity. mechanical means. (Block and hold vehicle by means
Apply 2 to 4 drops of oil between plunger and mounting other than air brakes.) Drain all air system reservoirs.
plate - do not over oil! 2. Identify and disconnect all supply and delivery lines at
the brake valve.
Every year, or 100,000 miles, or 3,600 operating hours:
3. Remove the brake valve and treadle assembly from the
Disassemble, clean parts with mineral spirits, replace all vehicle by removing the three cap screws on the outer
rubber parts, or any part worn or damaged. Check for proper bolt circle of the mounting plate. The basic brake valve
operation before placing vehicle in service. alone can be removed by removing the three cap screws
on the inner bolt circle.
SERVICE CHECKS
DISASSEMBLY(Figures 4, 5 and 6)
OPERATING CHECK
1. If the entire brake valve and treadle assembly was re-
Check the delivery pressure of both primary and secondary moved from the vehicle, remove the three cap screws
circuits using accurate test gauges. Depress the treadle to securing the treadle assembly to the basic brake valve.
several positions between the fully released and fully ap- 2. Remove the screw (9) securing the exhaust diaphragm
plied positions, and check the delivered pressure on the (10) and washer (11) to the exhaust cover (12).
test gauges to see that it varies equally and proportionately
3. Remove the four screws that secure the exhaust cover
with the movement of the brake pedal.
(12) to the lower body.
After a full application is released, the reading on the test 4. Remove the secondary inlet and exhaust valve assem-
gauges should fall off to zero promptly. It should be noted bly (13) from the lower body.
that the primary circuit delivery pressure will be about 2 PSI
5. Remove the four hex head cap screws securing the lower
greater than the secondary circuit delivery pressure with
body to the upper body and separate the body halves.
both supply reservoirs at the same pressure. This is normal
for this valve. 6. Remove the rubber seal ring (14) from the lower body.
7. For E-8P only:While applying thumb pressure to the
Important:A change in vehicle braking characteristics or a
primary piston (22), lift out and up on the three lock tabs
low pressure warning may indicate a malfunction in one or
of the primary piston retainer (15).
the other brake circuit, and although the vehicle air brake
system may continue to function, the vehicle should not be 8. For E-10P only:While depressing spring seat (7), re-
operated until the necessary repairs have been made and move retaining ring (8). Remove spring seat (7) and coil
both braking circuits, including the pneumatic and mechani- spring (5).
cal devices, are operating normally. Always check the vehicle Caution:Before proceeding with the disassembly, re-
brake system for proper operation after performing brake fer to Figures 3 and 4 and note that the lock nut (16)
work and before returning the vehicle to service. and stem (17) are used to contain the primary pis-
ton return spring (for E-8P:23, for E-10P:6), stem
LEAKAGE CHECK spring (19), and the relay piston spring (21). The com-
1. Make and hold a high pressure (80 psi) application. bined force of these springs is approximately 50
2. Coat the exhaust port and body of the brake valve with a pounds and care must be taken when removing the
soap solution. lock nut as the spring forces will be released. It is
recommended that the primary piston and relay pis-
3. Leakage permitted is a one inch bubble in 3 seconds. If
ton be manually or mechanically contained while the
the brake valve does not function as described above or
nut and stem are being removed.
leakage is excessive, it is recommended that it be re-
placed with a new or remanufactured unit, or repaired 9. Using a 3/8” wrench, hold the lock nut (16) on the threaded
with genuine Bendix parts available at authorized Ben- end of the stem (17). Insert a screwdriver to restrain the
dix parts outlets. stem, remove the lock nut (16), spring seat, (18) and
stem spring (19).
10. For E-10P only:Remove adapter (1) and o-ring (4).
Remove the primary piston (2) from adapter (1) and o-
ring (34) from the primary piston (2).
4
16 8
18
19
7
25
15
5
27 26 16
18
22
19
34
28
23 6
UPPER
BODY
UPPER
BODY 1
33
33 4
32 32
21
21
24 24
31
31
20
20
30 30
17 17
14 14
LOWER
LOWER BODY
BODY
BODY
BODY ATTACHING
13 ATTACHING 13 SCREWS
SCREWS (QTY. 4)
(QTY. 4)
12 12
10 10
EXHAUST
11 EXHAUST COVER
COVER 11
ATTACHING
9 ATTACHING SCREWS
SCREWS 9
(QTY. 4)
(QTY. 4)
FIGURE 5 - E-8P BRAKE VALVE - EXPLODED VIEW FIGURE 6 - E-10P BRAKE VALVE - EXPLODED VIEW
5
FIGURE 5 - E-8P BRAKE VALVE - EXPLODED VIEW FIGURE 6 - E-10P BRAKE VALVE - EXPLODED VIEW
6
11. Remove the relay piston (20), relay piston spring (21), 6. Place relay piston spring (21) in concave portion of relay
primary piston (E-8P: 22, E-10P: 2) and primary piston piston (20) and install relay piston through primary inlet/
return spring (E-8P: 23, E-10P: 6) from the upper body. exhaust assembly (33) into under side of upper body.
Use care so as not to nick seats. 7. For E-10P only:Install o-ring (4) on adapter (1) and
12. A small washer (24) will be found in the cavity of the install adapter on upper body. Install o-ring (34) on pri-
lower side of the primary piston (for E-8P: 22, for E- mary piston (2).
10P: 2). 8. Place screwdriver, blade up, in vise. Insert stem (17)
13. For E-8P only:Disassemble the primary piston by ro- through the relay piston upper body sub assembly, slide
tating the spring seat nut (25) counterclockwise. this assembly over the blade of the secured screwdriver,
Separate the spring seat nut, spring seat (26), and rub- engage the screwdriver blade in the slot in the head of
ber spring (27) and remove the piston o-ring (28). the stem.
14. Remove the large and small o-rings (30 & 31) from the 9. Place the washer (24) over the stem (17) and on top of
relay piston (20). the relay piston (20).
15. Remove the retaining ring (32) securing the primary inlet 10. Install primary return spring (E-8P: 23, E-10P: 6) in up-
and exhaust valve assembly (33) in the upper body and per body piston bore.
remove the valve assembly. 11. For E-8P only:Install the primary piston rubber spring
sub assembly (steps 4 & 5) over the stem, into the up-
CLEANING AND INSPECTION
per body piston bore. For E-10P:Install primary piston
1. Wash all metal parts in mineral spirits and dry. sub-assembly (reference step 7).
2. Inspect all parts for excessive wear or deterioration. 12. Compress piston(s) (For E-8P:the relay piston (20), for
3. Inspect the valve seats for nicks or burrs. E-10P: the primary and relay pistons (2 & 20)) and re-
4. Check the springs for cracks or corrosion. taining ring into the upper body from either side and hold
compressed, either manually or mechanically. See the
5. Replace all rubber parts and any part not found to be
cautionary note under step 8 in the Disassembly
serviceable during inspection, use only genuine Bendix
section of this manual.
replacement parts.
13. Place the stem spring (19) (E-8P: place over the spring
ASSEMBLY seat nut (25)), the spring seat (18) (concave side up)
Prior to reassembling, lubricate all o-rings, o-ring grooves, and lock nut (16) on the stem (17). Torque to 20 - 30
piston bores, and metal to metal moving surfaces with Dow inch pounds.
Corning 55 o-ring lubricant (Bendix piece number 291126). 14. For E-8P only:Install the primary piston retainer (15)
over the piston, making certain all three lock tabs have
Note: All torques specified in this manual are assembly
engaged the outer lip of the body.
torques and can be expected to fall off, after assembly is
accomplished. Do not retorqueafter initial assembly 15. For E-10P only:Install coil spring (5), spring seat (7),
torques fall. and retaining ring (8) .
16. Replace the rubber seal ring (14) on the lower body.
1. Install the primary inlet and exhaust assembly (33) in
the upper body and replace the retaining ring (32) to 17. Install the 4 hex head cap screws securing the lower
secure it. Be sure the retaining ring is seated completely body to the upper body. Torque to 30 - 60 inch pounds.
in its groove. 18. Install the secondary inlet and exhaust valve assembly
2. Install the large and small o-rings (30 & 31) on the relay (13) on the lower body.
piston (20). 19. Install the screws that secure the exhaust cover (12) to
3. For E-8P only:Install o-ring (28) in the primary piston the lower body. Torque to 20 - 40 inch pounds.
(22) o-ring groove. 20. Secure the screw (9) holding the exhaust diaphragm
4. For E-8P only:Install the rubber spring (do not lubri- (10) and the diaphragm washer (11) to the exhaust cover
cate) (27), concave side down in the primary piston (22) (12). Torque to 5 - 10 inch pounds.
and place the spring seat (26), flat side up, over the 21. Install all air line fittings and plugs making certain thread
rubber spring. sealant material does not enter valve.
5. For E-8P only:Install the primary piston spring seat nut
VALVE INSTALLATION
(25), with its hex closest to the spring seat, and rotate
clockwise until the top surface of the spring seat is even 1. Install the assembled brake valve on the vehicle.
with the top surface of the piston. Set aside.
7
2. Reconnect all air lines to the valve using the identifica-

tion made during VALVE REMOVAL step 1.
3. After installing the brake valve assembly, perform the
“OPERATION AND LEAKAGE CHECKS” before plac-
ing the vehicle in service.
IMPORTANT: MAINTENANCE PRECAUTIONS

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. Drain 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 used to prevent personal in-
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 a component until you have read and
thoroughly understand the recommended proce-
dures. Use only the proper tools and observe all
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 machining or welding should not
be attempted unless specifically approved and
stated by the vehicle or component manufacturer.
11. Prior to returning the vehicle to service, make cer-
tain all components and systems are restored to
their proper operating condition.
8
SD-03-2205
®
SC-3 IN-LINE SINGLE CHECK VALVES
INLET OUTLET
SPRING
INLET OUTLET
(ONE SC-3
MODEL
FEATURES
THIS 1/16”
PIPE PLUG)
WAFER-TYPE
CHECK VALVE
FIGURE 2 - SC-3 SINGLE CHECK VA

LVE: WAFER-TYPE
FIGURE 1 - SC-3 SINGLE CHECK VALVES (EXTERIOR AND CROSS-SECTIONAL VIEWS)
DESCRIPTION
The SC-3 In-Line Single Check Valve is a device placed in INLET
an air line to allow air flow in one direction only and to prevent
flow of air in the reverse direction. SPRING
The two types of SC-3 In-Line Single Check Valves are:

1. The wafer-style type (Figure 2).
2. The ball type (Figure 3).
OUTLET
An arrow indicating the direction of air flow is found on the
body of the valve.
OUTLET BALL
OPERATION
Air flow in the normal direction moves the check valve from FIGURE 3 - SC-3 ANGLE CHECK VALVE: BALL TYPE
its seat, and the flow is unobstructed. Flow in the reverse (EXTERIOR AND CROSS-SECTIONAL VIEWS)
direction is prevented by the seating of the ball or wafer-type
disc, which is caused by a drop in up-stream air pressure Replace any check valves leaking or showing signs of wear
and assisted by the spring. or deterioration. Check for proper operation.
PREVENTATIVE MAINTENANCE OPERATION & LEAKAGE CHECKS

Every six months, 1800 operating hours or every 50,000 NOTE: Depending upon installation, it may be easier or
miles inspect all parts. necessary to completely remove check valves so that the
following checks may be made.
1
With air pressure present at outlet side of check valve and 4. Following the vehicle manufacturer’s recommended
the inlet side open to atmosphere, coat the open end of the procedures, deactivate the electrical system in a manner
check valve with soap suds; a 1" bubble in 5 seconds is that removes all electrical power from the vehicle.
permissible. 5. When working in the engine compartment the engine
If the check valve does not function as described, or leakage should be shut off. Where circumstances require that
is excessive, it is recommended that it be replaced with a the engine be in operation, EXTREME CAUTIONshould
new genuine Bendix part available at any Bendix parts outlet. be used to prevent personal injury resulting from contact
with moving, rotating, leaking, heated, or electrically
REMOVAL charged components.
Block and hold vehicle by means other than air brakes. 6. Never connect or disconnect a hose or line containing
pressure; it may whip. Never remove a component or
Completely drain all reservoirs. plug unless you are certain all system pressure has
Disconnect air lines at single check valve and remove. been depleted.
7. Never exceed recommended pressures and always wear
DISASSEMBLY/ASSEMBLY safety glasses.
Note: There are no Disassembly/Assembly procedures for 8. Do not attempt to install, remove, disassemble or
SC-3 valves. They are non-serviceable items. If a valve does assemble a component until you have read and
not meet the Operational and Leakage tests, it should be thoroughly understand the recommended procedures.
replaced at any authorized Bendix parts outlet. Use only the proper tools and observe all precautions
pertaining to use of those tools.
TESTING AND TROUBLESHOOTING 9. Use only genuine Bendix replacement parts,
Perform “Operating and Leakage Checks”. components, and kits. Replacement hardware, tubing,
hose, fittings, etc. should be of equivalent size, type,
IMPORTANT! PLEASE READ and strength as original equipment and be designed
When working on or around a vehicle, the following specifically for such applications and systems.
general precautions should be observed: 10. Components with stripped threads or damaged parts
1. Park the vehicle on a level surface, apply the parking should be replaced rather than repaired. Repairs requiring
brakes, and always block the wheels. machining or welding should not be attempted unless
specifically approved and stated by the vehicle or
2. Stop the engine when working around the vehicle.
component manufacturer.
3. If the vehicle is equipped with air brakes, make certain
11. Prior to returning the vehicle to service, make certain all
to drain the air pressure from all reservoirs before
components and systems are restored to their proper
beginning ANY work on the vehicle.
operating condition.
BW1892 © 2002 Bendix Commercial Vehicle Systems LLC. All rights reserved. 3/2002 Printed in U.S.A
2
SD-03-3619
®
PP-DC PARK CONTROL VALVE

SUPPLY
DELIVERY SUPPLY
DELIVERY
EXHAUST
EXHAUST
COVER
BUTTON
BUTTON
FIGURE 1 - PP-DC PARK CONTROL VALVE
DESCRIPTION OPERATION
GENERAL
The PP-DC park control valve is a push-pull, manually
operable on/off valve. It is dash board-mounted and provides The PP-DC receives its supply of air from the primary
in-cab control of truck or bus parking brakes. service reservoir or the secondary service reservoir,
whichever is at the higher pressure. When the button is
The valve is pressure sensitive-it automatically moves from pushed in, the valve delivers air to the spring brake chambers
the applied to the exhaust position if total system pressure (usually through a spring brake valve such as the Bendix
drops below 20 to 30 psi. Also, manually pulling the button SR-1 and a relay or quick release valve). The air releases
will apply the parking brakes. the spring brakes for normal vehicle operation.
The PP-DC body is made of molded black acetal copolymer, To apply the parking brakes, the button is pulled out, which
and the cover is available in two mounting variations (see exhausts the PP-DC delivery and releases air from the
Figure 1). The valve is designed to accept 1/4" P.T. fittings spring brake chambers.
or push-to-connect fittings that use SAE J844D nonmetallic
air brake tubing. If total system pressure drops below 20 to 30 psi, the valve
will automatically “pop out,” which removes the hold- off air
Ports: in the chambers and applies the spring brakes.
Port Embossed I.D.
Primary Reservoir Supply Supply 11 PARKING BRAKES RELEASED
Secondary Reservoir Supply Supply 12 To release the parking brakes, the push-pull button is pushed
Delivery Delivery 21 in. The PP-DC plunger moves, closing the exhaust port
Exhaust Exhaust 3 with the exhaust seal and allowing the plunger o-ring to move
Operating pressure: 150 psi max. past the guide spool. Supply air then travels out the delivery
Operating temperature: -40° to 200°F port to release the brakes.
Basic valve weight: Approximately .8 lbs. Note that Figure 3 shows the primary service reservoir
supplying the PP-DC. The double check valve diaphragm
has sealed the secondary reservoir supply port and allows
air to pass from the primary reservoir into the PP-DC.
1
DEL.
PP-DC
SR-1
SUPPLY (PRIMARY
RESERVOIR)
EXH.
SUPPLY (SECONDARY
RESERVOIR) ANTI-CMPD.
LINE
SERVICE QR-1C
RELAY VALVE
FIGURE 2 - TYPICAL 4 X 2 TRUCK SCHEMATIC WITH PP-DC PARK CONTROL VALVE
If primary service reservoir pressure drops below secondary

service reservoir pressure, the double check valve reacts
4. When working in the engine compartment the engine
as shown in Figure 4. It seals the primary service reservoir
should be shut off. Where circumstances require that
supply port and supplies the PP-DC with air from the
the engine be in operation, EXTREME CAUTION should
secondary service reservoir. As is shown, the push-pull button
be used to prevent personal injury resulting from contact
remains in and the spring brakes remain released.
with moving, rotating, leaking, heated, or electrically
PARKING BRAKES APPLIED charged components.
5. Never connect or disconnect a hose or line containing
Figure 5 shows the PP-DC in the parking-brakes-applied
pressure; it may whip.
position. This will occur if the driver manually pulls out the
push- pull button or if total system pressure drops to below 6. Never remove a component or plug unless you are certain
20 to 30 psi. all system pressure has been depleted.
When the button “pops out,” the exhaust seal moves to
safety glasses.
open the exhaust port to atmosphere, allowing delivery line
pressure to exhaust. The plunger o-ring moves to seal off 8. Do not attempt to install, remove, disassemble or
supply pressure. Spring brake hold-off air is exhausted assemble a component until you have read and
through the spring brake relay valve. thoroughly understand the recommended procedures.
Use only the proper tools and observe all precautions
IMPORTANT! PLEASE READ pertaining to the use of those tools.
9 Use only genuine Bendix replacement parts, components
When working on or around a vehicle, observe the following
and kits. Replacement hardware, tubing, hose, fittings,
general precautions.
etc. should be of equivalent size, type and strength as
1. Park the vehicle on a level surface, apply the parking original equipment and should be designed specifically
brakes, and always block the wheels. for such applications and systems.
2. Stop the engine when working around the vehicle. 10. Components with stripped threads or damaged parts
3. Drain the air pressure from all reservoirs before should be replaced rather than repaired. Repairs
beginning ANY work on the vehicle. requiring machining or welding should not be attempted
unless specifically approved and stated by the vehicle
or component manufacturer.
2
BUTTON
PLUNGER O-RING
PLUNGER
GUIDE SPOOL
SECONDARY
SERVICE RESERVOIR
DELIVERY
SUPPLY
EXHAUST
SEAL
PRIMARY SERVICE EXHAUST

RESERVOIR
FIGURE 3 - SPRING BRAKES RELEASED (PRIMARY RESERVOIR SUPPLY)
BUTTON
PLUNGER O-RING
PLUNGER
GUIDE SPOOL
SECONDARY
SERVICE RESERVOIR
DELIVERY
SUPPLY
EXHAUST
SEAL

RESERVOIR
FIGURE 4 - SPRING BRAKES RELEASED (SECONDARY RESERVOIR SUPPLY)
3
PLUNGER O-RING BUTTON
PLUNGER
GUIDE SPOOL
SECONDARY
SERVICE RESERVOIR
DELIVERY
SUPPLY
EXHAUST
SEAL

RESERVOIR
FIGURE 5 - PARKING BRAKES APPLIED
PREVENTIVE MAINTENANCE LEAKAGE TEST

1 . Every 3 months; 25,000 miles; or 900 operating hours; 1. Supply the valve with 120 psi from the primary reservoir
or during the vehicle chassis lubrication interval, make supply port. With the button out, coat the exhaust port
the visual inspections noted in “SERVICE CHECKS.” and the plunger stem with a soap solution. Leakage
2. Every 12 months; 100,000 miles; or 3600 operating should not exceed a 1" bubble in 5 seconds. There
hours, perform “OPERATIONAL AND LEAKAGE should be no leakage from the secondary reservoir
TESTS.” supply port.
2. With the button out, supply the valve with 120 psi from
SERVICE CHECKS
the secondary reservoir supply port. There should be
1. Remove any accumulated contaminants. Visually no leakage from the primary reservoir supply port.
inspect the valve’s exterior for excessive wear or physical
3. With the button in, coat the exhaust port and the plunger
damage. Repair/replace as necessary.
stem with a soap solution. Leakage at both areas should
2. Inspect all air lines connected to the valve for signs of not exceed a 1” bubble in 3 seconds.
wear or physical damage. Repair/replace as necessary.
OPERATIONAL TEST
3. Test air line fittings for excessive leakage. Repair/replace
as necessary. 1. With the button out, supply either supply port with 120
psi of air. Then push the button in. Air pressure should
LEAKAGE AND OPERATIONAL TESTS rise in the delivery volume equivalent to supply pressure.
To perform the following tests, connect two separate 120 2. Pull the button out. Delivery pressure should exhaust to
psi air sources to the PP-DC supply ports. Tee an accurate 0 psi.
test gauge into the supply lines, and provide for a means to 3. Build each supply source to 120 psi. Decrease supply
control supply line pressure. Connect a small volume with a pressure at the secondary service reservoir supply port
gauge to the delivery port. at a rate of 10 psi per second. Primary supply pressure
and delivery pressure should not drop below 100 psi.
4
BUTTON
SCREW
COVER
CHECK VALVE SEAT

GUIDE
SPOOL
2 7
BODY
3 8
PLUNGER
STEM
PLUNGER 9
INDEX TABS
FIGURE 6 - EXPLODED VIEW
5
Repeat the test for decreasing primary service reservoir CLEANING & INSPECTION
pressure.
1. Wash all metal parts in mineral spirits and thoroughly
4. Build each supply source to 120 psi. Then decrease dry.
both supply pressures to below 20 to 30 psi. The button
2. Inspect all re-usable parts for excessive wear or
should automatically “pop” out when pressure drops
damage. Inspect the body for gouges or deep scuffing.
within that range.
Replace key numbers 1-9 (and any parts not determined
If the PP-DC fails to function as described, or if leakage is usable) with genuine Bendix replacements.
excessive, repair the valve or replace it at the nearest
authorized Bendix Commercial Vehicle Systems parts outlet. ASSEMBLY
REMOVAL Before assembly, lubricate all o-rings, o-ring grooves, rubbing
surfaces and bores with Bendix silicone lubricant (Pc. No.
1. Identify and mark or label all air lines and their
connections on the valve. 291126) or equivalent.
2. Remove the PP-DC from the vehicle and save the 1 . Place check valve(9) into its seat in the body with its flat
mounting hardware. surface facing upward. If necessary, reach into the
body to make sure the valve is seated evenly in the
INSTALLATION bore.
1. Install the PP-DC in its location on the dashboard. Using 2. Install o-rings(7) and (8) on the check valve seat and
the mounting hardware saved in “REMOVAL,” secure install the check valve seat into the body. Make sure the
the valve to the vehicle. seat is fully seated-its surface should be even with the
body’s surface.
2. Reconnect all air lines to the valve using the identification
made in “REMOVAL.” 3. Install plunger spring(6) into the body. Make sure it
stands upright and is seated properly in the body bore.
3. Perform “OPERATIONAL AND LEAKAGE TESTS”
(It should surround the protrusion or “lip” at the bottom
before placing the vehicle back in service.
of the body bore.)
DISASSEMBLY 4. Install o-rings(2), (3), (5) and exhaust seal(4) onto the
plunger. Then install the plunger into the body. Line up
The following disassembly and assembly procedures are
the plunger’s index tabs with the spaces in the body
for reference only. Always have the appropriate
bore for ease of installation.
maintenance kit on hand and use its instructions in lieu of
those presented here. Refer to Figure 6 throughout the 5. Install o-ring(1) onto the guide spool. Then install the
procedure. guide spool over the plunger and into the body. Press
the guide spool into place firmly.
1. Turn the button counterclockwise to remove it from the
6. Place the cover onto the body and secure with its four
plunger stem.
screws. Torque to 35 in. lbs.
2. Remove the four screws that secure the cover to the
7. Thread the button clockwise onto the plunger stem. It
body, and remove the cover.
should take approximately 3 full button revolutions to
3. Pull the plunger stem to remove the plunger and the install it on the plunger. The protrusions on the side of
guide spool from the body. the plunger should line up with the button grooves. Push
4. Remove plunger spring(6) and discard. on the button a number of times to make sure the plunger
5. If necessary, use a screwdriver to carefully remove the moves freely throughout its range of motion.
check valve seat from the body. Be sure not to damage NOTE: BEFORE PLACING THE VEHICLE BACK INTO
the check valve seat or the body. SERVICE, PERFORM THE “LEAKAGE AND
6. Remove and discard check valve seat o-rings(7) and (8). OPERATIONAL TESTS” IN THIS MANUAL.
7. Turn the body upside down and gently tap it on a flat
surface to remove check valve(9). Discard the check
valve.
8. Remove the guide spool from the plunger. Remove and
discard o-ring(1) from the guide spool.
9. Remove and discard o-rings(2), (3) and (5) from the
plunger. Also remove and discard exhaust seal(4).
6
6'
®
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SD-03-2202*
®
*FORMERLY SD-03-67
DOUBLE CHECK VALVES
DELIVERY DELIVERY
SUPPLY
SUPPLY
SUPPLY
SUPPLY
DELIVERY
DELIVERY O-RING
SHUTTLE
VALVE VALVE
CAP DISC
O-RING
CAP VALVE
SHUTTLE GUIDE
GUIDE
BODY BODY
FIGURE 1 - DOUBLE CHECK VALVE (SHUTTLE TYPE) FIGURE 2 - DOUBLE CHECK VALVE (DISC TYPE)
DESCRIPTION of the shuttle or disc will reverse if the pressure levels are
reversed. Double Check Valves are designed so that the
Double Check Valves are used in an air brake system to
shuttle or disc can never impede the backflow of air in the
direct a flow of air into a common line from either of two
exhaust mode.
sources, whichever is at the higher pressure. They may be
used for directing air flow for specific functions or to select Figure 3 (see page 2) illustrates a typical use of a Double
the higher pressure of either of two sources of air as a sup- Check Valve to control a given device, such as trailer brakes,
ply source. from either of two control sources.
Bendix manufactures two types of Double Check Valves: Figure 4 (see page 2) illustrates a typical use of a Double
shuttle and disc. Although the valves are somewhat different Check Valve to supply air to a system or systems from
physically, the same function is performed by both types. either of two separate sources, whichever is at the greater
The difference in the design of the two valves is that the pressure level. In this type of installation the pressure
shuttle type has a movable shuttle to seal off the lower differential to which the valve is subjected may under certain
pressure source, whereas the disc type has a movable disc. conditions be minimal. It is therefore suggested that
performance of the Double Check Valve will be optimized if
OPERATION it is mounted in the horizontal position.
As air under pressure enters either end of the Double Check
Valve (inlet port) the moving shuttle or disc responds to the PREVENTIVE MAINTENANCE
pressure and seals the opposite port, assuming it is at a Every 3,600 operating hours, 100,000 miles, or yearly,
lower pressure level than the other. The air flow continues disassemble, clean and inspect all parts. Install new parts
out the delivery port of the Double Check Valve. The position if they show signs of wear or deterioration.
1
3. Apply and hold a full foot brake valve application.

Check exhaust port of Trailer Control Valve for leakage
Reservoir
with soap solution. Permissible leakage is a one inch
bubble in five seconds (100 sccm). (Note: On some
Brake Valve vehicles, an exhaust line is connected to the exhaust
port and piped outside the cab in which case it may
be necessary to disconnect this line to make leakage
To Trailer check.)
Brakes B. If Double Check Valve is to be bench tested or tested on
the vehicle, two separately controlled air supplies must
Trailer Hand be connected to the inlet ports.
Control Valve Double 1. Install an accurate test gauge in the outlet port or in
Check a line from outlet port.
Valve
2. Apply and release air to one inlet port and note that
gauge registers application and release.
FIGURE 3 - DOUBLE CHECK VALVE: CONTROL OF
SYSTEM FROM EITHER OF TWO CONTROL SOURCES 3. Repeat by applying and releasing air to other inlet
port.
4. Leakage check should be performed at inlet ports of
valve in the following manner:
a. Disconnect line from one inlet port.
PP-7
b. Apply air to other inlet port and coat opposite
inlet port with soap solution. Permissible leakage
is a one inch bubble in five seconds (100 sccm).
PP-1
c. Repeat Step “b” applying air to other inlet port
Trailer Supply
while checking opposite inlet port for leakage.
If the Double Check Valve does not function as described or
Spring Brake Control
if leakage is excessive, it is recommended that the valve be
repaired or replaced with genuine Bendix parts. The following
Double Check instructions should prove helpful:
Reservoir Valve
DISASSEMBLY
1. Remove end cap(s) from valve.
Reservoir
2. Remove grommets (if applicable).
3. Remove shuttle and/or shuttle guide, disc and/or disc
FIGURE 4 - DOUBLE CHECK VALVE: SYSTEM WITH TWO guide (depending upon type of valve).
SUPPLY SOURCES
CLEANING AND INSPECTION
1. Clean all metal parts in a cleaning solvent.
SERVICE CHECKS
2. Inspect all metal parts for signs of cracks, wear or
OPERATING AND LEAKAGE TEST deterioration. Replace all parts not considered
serviceable.
A. When the Double Check Valve is used in conjunction
with a Trailer Control Valve, the following operating and 3. Replace all rubber parts.
leakage test can be made:
ASSEMBLY
1. Apply and release foot brake valve and note that the
1. Install disc guide, disc and/or shuttle and shuttle guide.
brakes apply and release on both tractor and trailer.
2. Coat all static seals such as o-rings, grommets, etc.
2. Apply and release the Trailer Control Valve and note
with BW 650M Silicone lubricant (BW 291126). It is not
that only the trailer brakes apply and release. With
necessary to lubricate shuttles or discs.
trailer control valve applied check exhaust port of
foot brake valve for leakage with soap solution. 3. Install grommets.
Permissible leakage is a one inch bubble in five 4. Install end cap(s).
seconds (100 sccm).
2
TESTING OF REBUILT DOUBLE CHECK VALVE plug unless you are certain all system pressure has
been depleted.
Perform operating and leakage tests as described in “Service
Checks” section.
safety glasses.
IMPORTANT! PLEASE READ: 8. Do not attempt to install, remove, disassemble or
thoroughly understand the recommended procedures.
general precautions should be observed:
Use only the proper tools and observe all precautions
1. Park the vehicle on a level surface, apply the parking pertaining to use of those tools.
brakes, and always block the wheels.
9. Use only genuine Bendix replacement parts,
2. Stop the engine when working around the vehicle. components, and kits. Replacement hardware, tubing,
3. If the vehicle is equipped with air brakes, make certain hose, fittings, etc. should be of equivalent size, type,
to drain the air pressure from all reservoirs before and strength as original equipment and be designed
beginning ANY work on the vehicle. specifically for such applications and systems.
4. Following the vehicle manufacturer’s recommended 10. Components with stripped threads or damaged parts
procedures, deactivate the electrical system in a manner should be replaced rather than repaired. Repairs requiring
that removes all electrical power from the vehicle. machining or welding should not be attempted unless
5. When working in the engine compartment the engine specifically approved and stated by the vehicle or
should be shut off. Where circumstances require that component manufacturer.
the engine be in operation, EXTREME CAUTION should
be used to prevent personal injury resulting from contact 11. Prior to returning the vehicle to service, make certain all
with moving, rotating, leaking, heated, or electrically components and systems are restored to their proper
charged components. operating condition.
6. Never connect or disconnect a hose or line containing
pressure; it may whip. Never remove a component or
3
4
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SD-01-503*
®
*FORMERLY SD-01-16
D-2 GOVERNOR
16 4
UPPER SPRING 14 13
ADJUSTING RETAINING WASHER 12
SEAT SCREW
1 3 RING O-RING
RETAINING LOCKNUT 11
RING PISTON
COVER
17 10
PRESSURE SETTING 2 INLET/
SPRING BODY EXHAUST
VALVE
19 LOWER
SPRING SEAT
EXHAUST 18
PORT SPRING GUIDE
19 LOWER
SPRING SEAT
8 O-RING 9
6 INLET/EXHAUST
12 O-RING COVER VALVE
EXHAUST
UNLOADER 5 STEM SPRING
MOUNTING EXHAUST
PORTS (3) HOLES 15
STEM
(2) RETAINING
8 RING
O-RING
7
9 FILTERS
INLET/EXHAUST
RESERVOIR VALVE SPRING
PORTS (3) 15
10 RETAINING 11
INLET/EXHAUST RING PISTON
VALVE
FIGURE 1 - D-2 GOVERNOR
BLUE CLEAR
NONMETALIC NONMETALIC BLACK 5
WITH O-RING RUBBER 5
11
11
15
20
O-RING NONMETALIC METALIC
FIGURE 2 - TYPES OF COVERS FIGURE 3 - TYPES OF PISTONS
DESCRIPTION
The D-2 Governor, operating in conjunction with the unloading D-2 governors are provided with mounting holes which allow
mechanism, automatically controls the air pressure in the direct mounting to the compressor or remote mounting.
air brake or air supply system between a maximum (cut-
Porting consists of three reservoir ports (1/8 inch P.T.),
out) pressure and a minimum (cut-in) pressure. The
three unloader ports (1/8 inch P.T.) and one exhaust port (1/
compressor runs continually while the engine runs, but the
actual compression of air is controlled by the governor 8 inch P.T.).
actuating the compressor unloading mechanism which stops
or starts the compression of air when the maximum or
minimum reservoir pressures are reached.
1
OPERATION adjusting stem has been sheared off, this is a nonserviceable

governor and must be replaced with a new or remanufactured
Reservoir air pressure enters the D-2 Governor at one of its unit.
reservoir ports and acts on the piston and inlet/exhaust valve.
As the air pressure builds up, the piston and valve move A. Remove the top cover from the governor.
together against the resistance of the pressure setting spring. B. Loosen the adjusting screw locknut.
When the reservoir air pressure reaches the cut-out setting C. To raise the pressure settings, turn the adjusting screw
of the governor, the exhaust stem seats on the inlet/exhaust counter-clockwise. To lower the pressure settings,
valve, closing the exhaust passage, and then opens the turn the adjusting screw clockwise. Note: Be careful
inlet passage. Reservoir air pressure then flows around the not to overadjust. Each 1/4 turn of the adjusting screw
inlet valve, through the passage in the piston and out the raises or lowers the pressure setting approximately 4
unloader port to the compressor unloading mechanism. Air psi.
also flows around the piston which is slightly larger at the
D. When proper adjustment is obtained, tighten the
upper end. The added force resulting from this larger area
adjusting screw locknut and replace the cover.
assures a positive action and fully opens the inlet valve.
(Note: The pressure range between cut-in and cut-out is not
As the system reservoir air pressure drops to the cut-in adjustable.)
setting of the governor, the force exerted by the air pressure
on the piston will be reduced so that the pressure setting LEAKAGE TEST
spring will move the piston down. The inlet valve will close
Leakage tests on the D-2 governor should be made in both
and the exhaust will open. With the exhaust open, the air in
cut-in and cut-out positions.
the unloader line will escape back through the piston, through
the exhaust stem and out the exhaust port. CUT-IN POSITION
PREVENTIVE MAINTENANCE Apply soap solution around the cover and to the exhaust
port. Slight bubble leakage permitted. Excessive leakage
Important Note: Review the warranty policy before
indicates a faulty inlet valve or lower piston o-ring.
performing any intrusive maintenance procedures. An
extended warranty may be voided if intrusive maintenance CUT-OUT POSITION
is performed during this period.
Apply soap solution around the cover and to the exhaust
Every 6 months, 50,000 miles or 1800 operating hours, port. Slight bubble leakage permitted. Excessive leakage
perform operating and leakage tests. indicates a faulty exhaust valve seat, exhaust stem o-ring,
or o-ring at the top of the piston.
SERVICE TESTS
If the governor does not function as described or leakage is
OPERATING TESTS excessive, it is recommended that it be replaced with a new
Start the vehicle engine and build up air pressure in the air or remanufactured unit, or repaired with genuine Bendix parts
brake system and check the pressure registered by a dash available at authorized Bendix parts outlets.
or test gauge at the time the governor cuts-out, stopping the
compression of air by the compressor. The cut-out pressure IMPORTANT! PLEASE READ:
should be in accordance with the pressure setting of the
When working on or around air brake systems and
piece number being used. (Common cut-out pressures are
components, the following precautions should be ob-
between 105-125 psi.) With the engine still running, make a
served:
series of brake applications to reduce the air pressure and
observe at what pressure the governor cuts-in the 1. Park the vehicle on a level surface, apply the park-
compressor. As in the case of the cut-out pressure, the cut- ing brakes, and always block the wheels.
in pressure should be in accordance with the pressure setting 2. Stop the engine when working around the vehicle.
of the piece number being used. (Common cutting pressures 3. If the vehicle is equipped with air brakes, make
are between 90-105 psi.) certain to drain the air pressure from all reservoirs
Never condemn or adjust the governor pressure settings before beginningany work on the vehicle.
unless they are checked with an accurate test gauge or a 4. Following the vehicle manufacturer’s recom-
dash gauge that is registering accurately. If the pressure mended procedures, deactivate the electrical
settings of the D-2 Governor are inaccurate or it is necessary system in a manner that removes all electrical
that they be changed, the adjustment procedure follows. power from the vehicle.
Note: If the governor cover is marked nonadjustable and the
2
5. When working in the engine compartment the en- hand grip cover from the top and pull up with thumb until
gine should be shut off. Where circumstances cover disengages from the governor body. If top cover on
require that the engine be in operation,extreme governor is made of rubber or clear nonmetallic material
caution should be used to prevent personal injury unscrew cover until it releases from the adjusting screw
resulting from contact with moving, rotating, leak- (4) of governor. Remove o-ring (20, Figure 2) if present.
ing, heated, or electrically charged components. Note: O-ring (20) is used on Hi-Temp and waterproof
6. Never connect or disconnect a hose or line con- governors only.
taining pressure; it may whip. Never remove a 4. With a pair of retaining ring pliers, remove the spring
component or plug unless you are certain all sys- assembly retaining ring (1) and save.
tem pressure has been depleted. 5. Pull the adjusting screw (4) and spring assembly out of
7. Never exceed recommended pressures and always the governor body (2).
wear safety glasses. Note: Disassembly of the spring assembly normally is
8. Do not attempt to install, remove, disassemble or not required. (Reuse and do not wash the assembly
assemble a component until you have read and because lubrication may be removed.) If Disassembly
thoroughly understand the recommended proce- of the spring assembly is necessary, the following in-
dures. Use only the proper tools and observe all structions apply; otherwise, proceed to Step 6.
precautions pertaining to use of those tools. Remove the lock nut (3), then the hex-shaped upper
9. Use only genuine Bendix replacement parts, com- spring seat (16) from the adjusting screw (4). Remove
ponents, and kits. Replacement hardware, tubing, the pressure setting spring (17), lower spring seat (19),
hose, fittings, etc. should be of equivalent size, type, spring guide (18) and the other lower spring seat (19)
and strength as original equipment and be designed from the adjusting screw (4).
specifically for such applications and systems. 6.
Gently tap the open end of the valve body on a flat sur-
10. Components with stripped threads or damaged face to remove the exhaust stem (5), the exhaust stem
parts should be replaced rather than repaired. spring (6), and piston assembly (11). Items 5 and 11
Repairs requiring machining or welding should not may be made of metal or nonmetallic material.
be at tempted unless specifically approved and 7. Remove and discard the two o-rings (8) on the piston
stated by the vehicle or component manufacturer. O.D. and with a hooked wire remove and discard the o-
11. Prior to returning the vehicle to service, make cer- ring (12) from the piston l.D. On nonmetallic piston,
tain all components and systems are restored to washer (13) and retaining ring (14) may be removed to
their proper operating condition. facilitate removal of o-ring (12).
8. If piston assembly is nonmetallic (Figure 3), use a small
REMOVING AND INSTALLING screwdriver and carefully insert blade of screwdriver be-
REMOVING tween two of the ears of the retainer ring in the bottom of
the piston (11) and pry retainer ring (15) out of the piston
1. Block and hold vehicle by means other than air brakes.
and discard. Remove inlet/exhaust valve spring (9) and
2. Drain air brake system. the inlet/exhaust valve (10) and discard. If piston as-
3. If the governor is compressor-mounted type, disconnect sembly is metallic, disengage inlet/exhaust valve spring
reservoir air line. If the governor is remote- mounted, dis- (9) from recess in bottom of piston (11), remove inlet/
connect both the unloader and reservoir air lines. exhaust valve spring (9), and the inlet exhaust valve (10)
4. Remove governor mounting bolts, then governor. and discard.
Caution:Prior to disassembly, it is required to have the 9. Remove and discard filters (7) from unloader and reser-
proper maintenance kit available to replace parts to be voir ports in governor body.
discarded during disassembly. CLEANING AND INSPECTION
DISASSEMBLY 1. Clean all remaining parts in mineral spirits.
1. Clean the governor exterior of dirt and grease. 2. Inspect body for cracks or other damage. Be particu-
2. If the governor cover is marked nonadjustable and the larly careful that all air passages in the body, exhaust
adjusting screw has been sheared off, this is a stem, and piston are not obstructed.
nonserviceable governor and must be replaced with a 3. Check springs for cracks, distortion, or corrosion.
new or remanufactured unit. 4. Replace all parts which are worn or damaged.
3. If the governor has a blue nonmetallic cover, (refer to
Figure 2) hold governor with one hand, with the other
3
ASSEMBLY screw head is approximately 1-7/8 inches. Install the

lock nut (3).
Prior to assembly, lubricate the two lower body bores, all o-
rings and o-ring grooves with lubricant provided. Note:Also 9. Install the adjusting screw (4) and spring assembly into
spring guide and adjusting screw (if disassembled). the governor body (2).
1. Install o-ring (12) in piston (11). Replace washer (13) 10. Install retaining ring (1) making certain that it seats com-
and retaining ring (14) on nonmetallic piston if removed pletely into the groove in the governor body (2).
during disassembly. If cover provided in kit is black rubber, (refer to Figure 2)
2. Drop the inlet/exhaust valve (10) into place at the bot- install by pushing it onto the adjusting screw.
tom of the piston (11). If cover provided in kit is clear nonmetallic, install o-ring
3. Nonmetallic Piston:Install the inlet/exhaust valve spring (20) and screw cover onto the adjusting screw. Tighten
(9) with the small end against the valve, place the retain- until cover bottoms on governor body. Note: O-ring (20)
ing ring (15) on top of the large end of the valve spring (9) is used only on Hi-Temp and waterproof governors. If
[concave side of retaining ring (15) facing away from pis- cover provided in kit is blue nonmetallic place cover over
ton (11)], press into piston with thumb, making sure ears one edge of top of governor; with index finger catch knob
of retaining ring (15) are seated into piston (11) as far as on top of cover and pull until cover snaps into place.
possible. Note: Nonmetallic cover should be at room temperature
Note: Do not use a press or hammer to install retaining for ease of assembly. Do not attempt to force cover on
ring. Excessive force may damage the piston. square to the governor body.
Metallic Piston:Install the inlet/exhaust valve spring 12. Install filters (7) in governor body. The head of a pencil
(9) with the small end against the valve. Press the spring makes a satisfactory installation tool.
down until the larger coiled end snaps into the recess INSTALLATION
inside the piston (11).
1. If the governor is compressor-mounted, clean the mount-
4. Install the piston o-rings (8) on the piston (11). ing pad on both the compressor and governor. Clean
5. Install the exhaust stem spring (6) in the piston (11) with connecting line, or lines. Be certain the unloading port
the large coil end next to the piston. is clear and clean. If the governor is mounted remotely,
6. Install the exhaust stem (5) through spring (6) and into it should be positioned so that its exhaust port points
piston (11). down. It should be mounted higher than the compressor
so that its connecting lines will drain away from the gov-
7. Install assembled piston (11) into the governor body (2).
ernor.
8. If the spring assembly was not disassembled, proceed
2. Install governor.
to Step 9. If the spring assembly was disassembled,
the following instructions apply: install on the adjusting 3. If compressor-mounted type, use the governor mounting
screw (4) in this order; lower spring seat (19), spring gasket provided.
guide (18), spring seat (19), pressure setting spring (17), 4. Connect air lines to governor.
hex-shaped upper spring seat (16). Screw the upper 5. Perform operating and leakage tests as outlined under
spring seat onto the adjusting screw until the distance Service Tests section.
from the top of the seat to the bottom of the adjusting
4
SD-03-2010*
®
PRESSURE PROTECTION VALVES *Formerly SD-03-55
DESCRIPTION to delay filling of auxiliary reservoirs to insure a quick

build-up of brake system pressure.
The pressure protection valve is a normally closed, pressure
control valve which can be referred to as a non-exhausting The PR-2 and PR-4 pressure protection valves have one 1/
sequence valve. These valves are used in many different 4" N.P.T.F. supply port and one 1/4" N.P.T.F. delivery port
applications. An example would be in an air brake system which are identified. Both valves are provided with two 9/
to protect one reservoir, or reservoir system from another, 32" mounting holes through the body. The closing pressure
by closing automatically at a preset pressure should a of the PR-2 is externaIly adjustable while the PR-4 has a
reservoir system failure occur. The valves can also be used fixed setting.
SPRING
CAP
INLET PISTON
VALVE
CHECK
VALVE
PR-3 OR PR-4 PR-3
PRESSURE
SPRING CAP REGULATING
SPRING
PISTON PLUG
EXHAUST
VENT
PISTON PISTON PLUG
O-RING
PISTON
O-RING VALVE STEM
VALVE PISTON
INLET
INLET SPRING VALVE SPRING
PORT RETAINER
INLET
DELIVERY VALVE
PORT
PR-4 PR-2
1
OPERATION 4. (PR-3 only) Build pressure up again and shut off engine.
Slowly exhaust air from the supply side of the PR-3.
Air entering the supply port is initially prevented from flowing
The gauge on the delivery side of the valve should
out the delivery port by the inlet valve which is held closed
remain at the highest pressure previously attained.
by the pressure regulating spring above the piston. When
sufficient air pressure builds beneath the piston to overcome LEAKAGE CHECKS
the setting of the regulating spring, the piston will move, 1. Build up the air system to full pressure and shut off the
causing the inlet valve to unseat (open), and allow air to engine.
flow out the delivery port. As long as air pressure at the
2. Apply a soap solution around the cap of the pressure
supply port and beneath the piston remains above the
protection valve. A one-inch bubble in three seconds or
specified closing pressure, the inlet valve will remain open.
longer is acceptable. PR-3 - No leakage permissible at
NOTE: The PR-2 and PR-4 closing pressure is noted on bottom of valve.
the label affixed to the valve. Opening pressures of 3. Drain the air pressure from the delivery side of the
the valves are higher than closing pressures. The pressure protection valve and disconnect the air line to
pressure ranges are noted below: it.
PR-2-Opening pressure 15-20 psi higher than 4. Apply a soap solution to the delivery port. A one inch
closing pressure. bubble in five seconds or more is acceptable.
PR-3 & PR-4-Opening pressure approx. 10 psi higher GENERAL

than closing pressure. If the pressure protection valve does not operate as
described or leakage is excessive, it is recommended that
PR-3-Check valve will retain maximum pressure in
a replacement be obtained at the nearest authorized Bendix
downstream reservoir.
Commercial Vehicle Systems Company distributor.
If for any reason system air pressure is decreased below
the specified closing pressure, the regulating spring will REMOVING AND INSTALLING
move the piston closing the inlet valve. The remaining air REMOVING
pressure at either the supply or delivery side, (depending 1. Block or hold the vehicle by means other than air brakes.
upon where the pressure drop has occurred) will be retained.
2. Drain all system reservoirs individually, to 0 psi.
PREVENTIVE MAINTENANCE 3. Disconnect and identify (supply and delivery) the air
Every three months, 900 operating hours or 25,000 miles, lines leading to and from the pressure protection valve.
whichever if first, it is recommended that the operation and 4. Remove the mounting bolts, if any, that secure the valve.
leakage checks described in this manual be performed. INSTALLING
OPERATING AND LEAKAGE CHECKS 1. Re-install the mounting bolts and secure the replacement
valve to the vehicle.
OPERATING CHECKS
2. Reconnect the supply delivery air lines to the proper
1. Provide a pressure gauge and drain valve at the supply
ports of the replacement valve.
side and delivery side of the pressure protection valve
being checked. GENERAL
2. Build up the air system to full pressure and shut off the After installing a replacement valve, it is recommended that
engine. the operating and leakage checks be performed as outlined
3. While watching the gauges on the supply and delivery in this manual. If the closing pressure does not conform to
sides of the valve, slowly begin to exhaust pressure from that shown on the valve label or in the vehicle or a different
the delivery side. Note that both gauges will show setting is desired, the PR-2 may be adjusted by loosening
pressure loss until the closing pressure of the pressure the locknut and tightening or loosening the adjusting cap as
protection valve is reached. required; however, if the proper setting cannot be attained
The pressure protection valve should close at by moderate adjustment of the cap, the valve may have the
approximately ( ± 5 psi) the pressure indicated on the wrong spring and will have to be exchanged for the correct
valve’s label or in the vehicle handbook. The gauge on valve. The PR-3 and PR-4 are not adjustable.
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.
2
IMPORTANT! PLEASE READ AND FOLLOW 7. Never exceed recommended pressures and always
THESE INSTRUCTIONS TO AVOID PERSONAL wear safety glasses.
INJURY OR DEATH. 8. Do not attempt to install, remove, disassemble or
thoroughly understand the recommended
general precautions should be observed at all times:
procedures. Use only the proper tools and observe
1. Park the vehicle on a level surface, apply the all precautions pertaining to use of those tools.
parking brakes, and always block the wheels.
9. Use only genuine Bendix replacement parts,
2. Stop the engine when working around the vehicle. components, and kits. Replacement hardware,
3. If the vehicle is equipped with air brakes, make tubing, hose, fittings, etc. should be of equivalent
certain to drain the air pressure from all reservoirs size, type, and strength as original equipment and
before beginningANY work on the vehicle. be designed specifically for such applications and
4. F o l l o w i n g the vehicle manufacturer’s systems.
recommended procedures, deactivate the electrical 10. Components with stripped threads or damaged
system in a manner that removes all electrical parts should be replaced rather than repaired.
power from the vehicle. Repairs requiring machining or welding should not
5. When working in the engine compartment the be attempted unless specifically approved and
engine should be shut off. Where circumstances stated by the vehicle or component manufacturer.
require that the engine be in operation, EXTREME 11. Prior to returning the vehicle to service, make
CAUTION should be used to prevent personal injury certain all components and systems are restored
resulting from contact with moving, rotating, to their proper operating condition.
l e a k in g , h e a t e d , o r e l e c t r ic a l ly c h a rg e d
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.
3
SD-08-2414
®
AD-IP INTEGRAL PURGE AIR DRYER
DESICCANT
CARTRIDGE SADDLE
MOUNTING
BRACKET
MOUNTING
STRAP
SAFETY VALVE CONTROL

PORT
LOWER
MOUNTING
BRACKET
DELIVERY SUPPLY
PORT CARTRIDGE HEATER & THERMOSTAT PORT
BOLT CONNECTOR
FIGURE 1 - AD-IP INTEGRAL PURGE AIR DRYER
Air Connection Port ID Function/Connection

DESCRIPTION CON 4 ...................... Control Port (purge valve control
The function of the AD-IP Integral Purge Air Dryer is to collect & turbo cutoff).
and remove air system contaminants in solid, liquid and SUP 11 .................... Supply Port (air in).
vapor form before they enter the brake system. It provides DEL 2 ...................... Delivery Port (air out).
clean, dry air to the components of the brake system which
increases the life of the system and reduces maintenance
AD-IP DI “DROP IN” MODEL
costs. Daily manual draining of the reservoirs is eliminated. In addition to the standard AD-IP, the AD-IP DI (Drop In) is
also offered. It is a specialized version designed especially
The AD-IP Air Dryer consists of a desiccant cartridge secured
for air systems that use either the Holset (Cummins) Type
to a die cast aluminum end cover with a single, central bolt.
E or QE air compressor. These Holset compressors utilize
The end cover contains a check valve assembly, safety valve,
an unusual unloading system that requires that air pressure
heater and thermostat assembly, three pipe thread air
remain in the discharge line during the entire unloaded cycle
connections and the purge valve assembly. The removable
of the compressor. To accomplish this, Holset compressors
purge valve assembly incorporates the purge valve
rely on air “feedback” from the supply reservoir as shown in
mechanism and a turbo charger cutoff feature that is designed
Figure 3B. When an air dryer is installed the direct “feedback”
to prevent loss of engine “turbo” boost pressure during the
from the supply reservoir is interrupted and an alternate
purge cycle of the AD-IP air dryer. For ease of serviceability,
source for “feedback” pressure must be provided. A standard
all replaceable assemblies can be replaced without removal
AD-IP air dryer can be installed however a separate
of the air dryer from its mounting on the vehicle.
“feedback” line with a single check must be installed as
The AD-IP has three female pipe thread air connections shown in Figure 3B.
identified as follows:
1
DISCHARGE LINE SUPPLY

RES.
HOLSET COMPRESSOR
FIGURE A
HOLSET TYPE E & QE COMPRESSORS - NO AIR DRYER
STANDARD AD-IP AIR

FEEDBACK SPECIAL DISCHARGE DRYER
LINE PORT FTG. W/
FEEDBACK LINE
CONNECTION CHECK
VALVE SUPPLY
RES.
HOLSET
COMPRESSOR
FEEDBACK LINE
DISCHARGE W/CHECK VALVE
PORT FIGURE B
STANDARD AD-IP AND HOLSET TYPE E & QE COMPRESSORS
HOLSET
COMPRESSOR
LOWER
MTG. BRKT.
(PARTIAL) FEEDBACK
LINE
SPECIAL DISCHARGE
PORT FTG. W/ AD-IP DI W/FEEDBACK SUPPLY
FEEDBACK LINE LINE & CHECK VALVE RES.
CONNECTION END COVER FIGURE C
BOTTOM VIEW AD-IP DROP IN AND HOLSET TYPE E & QE COMPRESSORS
FIGURE 2 - AD-IP DROP IN AIR DRYER FOR HOLSET FIGURE 3 - AD-IP AND HOLSET TYPE E & QE
COMPRESSORS COMPRESSORS
The AD-IP Drop In model incorporates the feedback line and After exiting the end cover, the air flows into the desiccant
single check as an integral part of the dryer and eliminates cartridge. Once in the desiccant cartridge air first flows
the need for these components as shown in Figures 2 & 3C. through an oil separator located between the outer and inner
shells of the cartridge. The separator removes water in liquid
OPERATION form as well as oil and solid contaminants.
GENERAL Air, along with the remaining water vapor, is further cooled
as it exits the oil separator and continues to flow upward
The AD-IP air dryer alternates between two operational modes
between the outer and inner shells. Upon reaching the top
or “cycles” during operation: the Charge Cycle and the Purge
of the cartridge the air reverses its direction of flow and enters
Cycle. The following description of operation is separated
the desiccant drying bed. Air flowing down through the column
into these “cycles” of operation.
of desiccant becomes progressively dryer as water vapor
CHARGE CYCLE(refer to Figure 4) adheres to the desiccant material in a process known as
“ADSORPTION.” The desiccant cartridge using the
When the compressor is loaded (compressing air) adsorption process typically removes most of the water vapor
compressed air, along with oil, oil vapor, water and water from the pressurized air.
vapor flows through the compressor discharge line to the
supply port of the air dryer body. Dry air exits the bottom of the desiccant cartridge and flows
through the center of the bolt used to secure the cartridge to
As air travels through the end cover assembly, its direction the end cover. Air flows down the center of the desiccant
of flow changes several times, reducing the temperature, cartridge bolt, through a cross drilled passage and exits the
causing contaminants to condense and drop to the bottom air dryer delivery port through the delivery check valve.
or sump of the air dryer end cover.
2
OIL
SEPARATOR
DESICCANT
BED
PURGE
ORIFICE
PURGE
CONTROL VOLUME
PORT
PURGE
CONTROL SUPPLY
LINE PORT
GOVERNOR
DELIVERY
CHECK
VALVE
PURGE
TURBO VALVE DISCHARGE
COMPRESSOR ENGINE CUTOFF PORT
TURBO EXHAUST
VALVE
FIGURE 4 - AD-IP CHARGE CYCLE
Dry air flowing through the center of the desiccant cartridge The initial purge and desiccant cartridge decompression lasts
bolt also flows out the cross drilled purge orifice and into the only a few seconds and is evidenced by an audible burst of
purge volume. air at the AD-IP exhaust.
The air dryer will remain in the charge cycle until the air The actual reactivation of the desiccant drying bed begins
brake system pressure builds to the governor cutout setting. as dry air flows from the purge volume through the purge
orifice in the desiccant cartridge bolt, then through the center
PURGE CYCLE(refer to Figure 5) of the bolt and into the desiccant bed. Pressurized air from
As air brake system pressure reaches the cutout setting of the purge volume expands after passing through the purge
the governor, the governor unloads the compressor (air orifice; its pressure is lowered and its volume increased.
compression is stopped) and the purge cycle of the air dryer The flow of dry air through the drying bed reactivates the
begins. When the governor unloads the compressor, it desiccant material by removing the water vapor adhering to
pressurizes the compressor unloader mechanism and the it. Generally 30 seconds are required for the entire purge
line connecting the governor unloader port to the AD-IP end volume of a standard AD-IP to flow through the desiccant
cover control port. The purge piston moves in response to drying bed.
air pressure causing the purge valve to open to the The delivery check valve assembly prevents air pressure in
atmosphere and the turbo cutoff valve to close off the supply the brake system from returning to the air dryer during the
of air from the compressor (this will be further discussed in purge cycle. After the 30 second purge cycle is complete
the Turbo Cutoff Feature section). Water and contaminants the desiccant has been reactivated or dried. The air dryer is
in the end cover sump are expelled immediately when the ready for the next charge cycle to begin. However the purge
purge valve opens. Also, air which was flowing through the valve will remain open and will not close until air brake
desiccant cartridge changes direction and begins to flow system pressure is reduced and the governor signals the
toward the open purge valve. Oil and solid contaminants compressor to charge the system.
collected by the oil separator are removed by air flowing
from the purge volume through the desiccant drying bed to
the open purge valve.
3
OIL
SEPARATOR
DESICCANT
BED
PURGE
ORIFICE
PURGE
CONTROL VOLUME
PORT
PURGE
CONTROL
LINE SUPPLY
PORT
GOVERNOR
DELIVERY
CHECK
VALVE
PURGE
COMPRESSOR ENGINE TURBO VALVE DISCHARGE
TURBO CUTOFF EXHAUST PORT
VALVE
FIGURE 5 - AD-IP PURGE CYCLE
TURBO CUTOFF FEATURE(Refer to Figure 6) At the onset of the purge cycle, the downward travel of the
purge piston is stopped when the turbo cutoff valve (tapered
The primary function of the turbo cutoff valve is to prevent portion of purge piston) contacts its mating metal seat in
loss of engine turbocharger air pressure through the AD-IP the purge valve housing. With the turbo cutoff valve seated
in systems where the compressor intake is connected to (closed position), air in the compressor discharge line and
the engine turbocharger. The turbo cutoff valve also removes AD-IP inlet port cannot enter the air dryer. In this manner
the “puffing” of air out the open purge exhaust when a naturally the turbo cutoff effectively maintains turbo charger boost
aspirated, single cylinder compressor, equipped with an inlet pressure to the engine.
check valve, is in use.
PREVENTIVE MAINTENANCE
PURGE Important:Review the warranty policy before performing
VOLUME any intrusive maintenance procedures. An extended warranty
may be voided if intrusive maintenance is performed during
this period.
CONTROL
PORT Because no two vehicles operate under identical conditions,
maintenance and maintenance intervals will vary. Experience
is a valuable guide in determining the best maintenance
SUPPLY
PORT interval for any one particular operation.
Every 900 operating hours, or 25,000 miles or three (3)

months:
TURBO 1. Check for moisture in the air brake system by opening
CUTOFF
VALVE reservoirs, drain cocks, or drain valves and checking for
presence of water. If moisture is present, the desiccant
PURGE
VALVE cartridge may require replacement; however, the following
conditions can also cause water accumulation and
FIGURE 6 - AD-IP TURBO CUTOFF should be considered before replacing the desiccant:
4
DESICCANT
BED
OIL
SEPARATOR
DESICCANT
CARTRIDGE
HEATER & AD-IP END
PURGE THERMOSTAT COVER
ORIFICE CONNECTOR
PURGE
CONTROL VOLUME
PORT LOCKING LATCH
(MUST BE INSERTED UNTIL IT
SUPPLY SNAPS OVER THE MATING
PORT CHECK CONNECTOR ON AD-IP
VALVE
TURBO SIDE VIEW

CUTOFF WEATHERPROOF
VALVE ACCORDIAN
TOP VIEW SEAL
PURGE DELIVERY
VALVE PORT
CARTRIDGE
BOLT
A two lead wire harness with attached weather resistant connector is

FIGURE 7 - AD-IP AIR DRYER SECTIONAL VIEW supplied with all replacement and retrofit AD-IP air dryers. One of the
two leads is connected to the engine “kill switch” or ignition while the
other must be connected to a good vehicle ground. A fuse is installed
A. An outside air source has been used to charge the in the lead carrying vehicle power; install a 10 amp fuse for 12 volt
system. This air does not pass through the drying heaters and a 5 amp fuse for the 24 volt heater.
bed.
Use 14 AWG wire if it is necessary to lengthen the wire harness leads.
B. Air usage is exceptionally high and not normal for a Make certain all splices are weatherproofed. Tie wrap or support all
highway vehicle. electrical wires leading to the AD-IP.
This may be due to accessory air demands or some
unusual air requirement that does not allow the com- FIGURE 8 - AD-IP HEATER AND THERMOSTAT
pressor to load and unload (compressing and CONNECTOR
non-compressing cycle) in a normal fashion. Check
for high air system leakage.
C. The air dryer has been installed in a system that 2. Visually check for physical damage to the AD-IP such
has been previously used without an air dryer. The as chaffed or broken air and electrical lines and broken
system will be saturated with moisture and several or missing parts.
weeks of operation may be required to dry it out. 3. Check mounting bolts for tightness. Re-torque to 270-
D. Location of the air dryer is too close to the air com- 385 inch pounds.
pressor. Refer to Locating AD-IP On Vehicle section. 4. Perform the Operation & Leakage Tests listed in this
E. In areas where more than a 30 degree range of tem- publication.
perature occurs in one day, small amounts of water
WARNING!
can temporarily accumulate in the air brake system
due to condensation. Under these conditions, the This air dryer is intended to remove moisture and other
presence of small amounts of moisture is normal contaminants normally found in the air brake system.
and should not be considered as an indication that Do not inject alcohol, anti-freeze, or other de-icing
the dryer is not preforming properly. substances into or upstream of the air dryer. Alcohol is
removed by the dryer, but reduces the effectiveness of
Note: A small amount of oil in the system is normal and the device to dry air. Use of other substances can
should not be considered as a reason to replace the damage the air dryer and may void the warranty.
desiccant cartridge; oil stained desiccant can function
adequately.
5
OPERATION & LEAKAGE TESTS for the 12 volt heater assembly and 6.0 to 9.0 ohms
1. Test the delivery port check valve assembly by building for the 24 volt heater assembly.
the air system to governor cutout and observing a test Warm the thermostat and heater assembly to over
air gauge installed in the #1 reservoir. Check all lines 90 degrees Fahrenheit and again check the resis-
and fittings leading to and from the air dryer for leakage tance. The resistance should exceed 1000 ohms. If
and integrity. Note the pressure on the air gauge after the resistance values obtained are within the stated
governor cutout pressure is reached, a rapid loss of limits, the thermostat and heater assembly is oper-
pressure could indicate a failed delivery port check valve. ating properly. If the resistance values obtained are
This can be confirmed by shutting the engine off, draining outside the stated limits, replace the heater and ther-
system pressure to a point below governor cutin (usually mostat assembly.
not less than 95 psi), draining residual air pressure in
the compressor discharge line and removing the plug REBUILDING THE AD-IP AIR DRYER
adjacent to the air dryer delivery port from the end cover.
GENERAL
With air pressure present at the air dryer delivery, apply
a soap solution to the opening where the plug was If, after completing the routine operation and leakage tests,
removed and note that leakage does not exceed a 1 it has been determined that one or more components of the
inch bubble in 1 second. If leakage is excessive repair air dryer requires replacement or maintenance, refer to the
the check valve. following list to find the appropriate kit(s).
2. Check for excessive leakage around the purge valve. When rebuilding or replacing components of the air dryer
With the compressor in loaded mode (compressing air), use only genuine Bendix parts. For ease in servicing, the
apply a soap solution to the purge valve exhaust port AD-IP has been designed so that any of the following
and observe that leakage does not exceed a 1 inch maintenance kits can be installed without removing the air
bubble in 1 second. If the leakage exceeds the dryer from the vehicle.
maximum specified, repair the purge valve assembly.
3. Close all reservoir drain cocks. Build up system pressure MAINTENANCE KITS AVAILABLE:
to governor cutout and note that AD-IP purges with an 065624 ................ SERVICE NEW DESICCANT CARTRIDGE KIT
audible escape of air. “Fan” the service brakes to reduce This kit contains the parts necessary to change the
system air pressure to governor cut-in. Note that the desiccant cartridge only.
system once again builds to full pressure and is followed
109493 ........ REMANUFACTURED DESICCANT CARTRIDGE KIT
by an AD-IP purge.
This kit contains the parts necessary to change the
4. Check the operation of the end cover heater and
desiccant cartridge only.
thermostat assembly during cold weather operation as
follows: 5001247 ........................................ MOUNTING BRACKET KIT
A. Electric Power to the Dryer This kit contains the upper and lower brackets as well as
the necessary hardware items to mount them.
With the ignition or engine kill switch in the ON
position, check for voltage to the heater and ther- 109498 ............................................... CARTRIDGE BOLT KIT
mostat assembly using a voltmeter or test light. Contains a replacement desiccant cartridge bolt and related
Unplug the electrical connector at the air dryer and o-rings.
place the test leads on each of the pins of the male
5003547 .............. PURGE VALVE HOUSING MAINTENANCE KIT
connector. If there is no voltage, look for a blown
fuse, broken wires, or corrosion in the vehicle wir- This kit contains the parts necessary to rebuild the purge
ing harness. Check to see if a good ground path valve housing.
exists. 800404 .................................................... PURGE VALVE KIT
B. Thermostat and Heater Operation This kit contains the parts necessary to replace the purge
Note: These tests are not required except in cold valve.
weather operation. 065626 ....... SERVICE NEW PURGE VALVE HOUSING ASSEMBLY
Turn off the ignition switch and cool the thermostat Contains a service new assembly and related components
and heater assembly to below 40 degrees Fahren- to accomplish replacement.
heit. Using an ohmmeter, check the resistance 109494 ............... DELIVERY CHECK VALVE MAINTENANCE KIT
between the electrical pins in the air dryer connec-
This kit contains the parts necessary to replace the delivery
tor half. The resistance should be 1.5 to 3.0 ohms
port check valve.
6
109495 & 109496 ..................... HEATER & THERMOSTAT KIT service and parts replacement does not require
Contains a replacement heater and thermostat assembly removal of the air dryer from the vehicle.
and related components required for replacement. 1. Park the vehicle on a level surface and prevent movement
by means other than the brakes.
IMPORTANT: MAINTENANCE PRECAUTIONS
2. Drain all reservoirs to 0 p.s.i. — Caution:Compressor
When working on or around a vehicle, the following discharge line may still contain residual pressure.
general precautions should be observed. 3. Identify and disconnect the three air lines from the end
1. Park the vehicle on a level surface, apply the cover and note the position of end cover ports relative to
parking brakes, and always block the wheels. the vehicle.
2. Stop the engine when working around the vehicle. 4. Unplug the vehicle wiring harness from the heater and
3. Drain the air pressure from all reservoirs before thermostat assembly connector on the end cover
beginning ANY work on the vehicle. assembly.
4. Following the vehicle manufacturer’s recom- 5. Remove the four bolts that secure both the upper and
mended procedures, deactivate the electrical lower mounting brackets to the vehicle, and remove the
system in a manner that removes all electrical air dryer from the vehicle.
power from the vehicle. 6. Mark the relationship of the saddle bracket (5) to the
5. When working in the engine compartment the en- end cover assembly (6). Remove the 5/16" cap screw
gine should be shut off. Where circumstances (1), washer (2), and nut (3) securing the upper mounting
require that the engine be in operation, EXTREME strap (4) to the saddle bracket (5). Remove the upper
CAUTION should be used to prevent personal in- mounting strap (4) from the end cover assembly (6).
jury resulting from contact with moving, rotating, 7. Mark the relationship of the lower bracket (9) to the end
leaking, heated, or electrically charged com- cover assembly (6). Remove the two 3/8" end cover cap
ponents. screws (7) and two washers (8) that retain the lower
6. Never connect or disconnect a hose or line con- mounting bracket (9) to the end cover (6).
taining pressure; it may whip. Never remove a
component or plug unless you are certain all sys-
DISASSEMBLY
tem pressure has been depleted. The following disassembly and assembly procedure is
7. Never exceed recommended pressures and always presented for reference purposes and presupposes that a
wear safety glasses. major rebuild of the AD-IP is being undertaken. The
replacement parts and maintenance kits available generally
8. Do not attempt to install, remove, disassemble or
do not require full disassembly. The instructions provided
with these parts and kits should be followed in lieu of the
thoroughly understand the recommended proce-
instructions presented here. Refer to Figure 9 during
dures. Use only the proper tools and observe all
disassembly.
precautions pertaining to use of those tools.
9. Use only genuine Bendix replacement parts, Caution: While performing service on the AD-IP air dryer, it
components, and kits. Replacement hardware, is not recommended that a clamping device (vise, C-clamp,
tubing, hose, fittings, etc. should be of equivalent etc.) be used to hold any die cast aluminum component as
size, type, and strength as original equipment and damage may result. To hold the end cover, install a pipe
be designed specifically for such applications and nipple in the supply port and clamp the nipple into a vise.
systems. 1. Using an adjustable or socket wrench, loosen the
10. Components with stripped threads or damaged desiccant cartridge bolt (10), then separate the desiccant
parts should be replaced rather than repaired. cartridge (11) from the end cover (6). Pull the desiccant
Repairs requiring machining or welding should not cartridge bolt out of the end cover (6).
be attempted unless specifically approved and Caution: Disassembly of the desiccant cartridge
stated by the vehicle or component manufacturer. assembly should not be attempted! Detail parts for the
11. Prior to returning the vehicle to service, make cartridge are not available and the cartridge contains a
certain all components and systems are restored 150# spring which can not be mechanically caged.
to their proper operating condition. 2. Remove both o-rings (12 & 13) from the desiccant
cartridge bolt.
AD-IP REMOVAL
This air dryer removal process is presented in the event it
becomes necessary to replace the entire air dryer. Normal
7
ITEM# DESCRIPTION
1 5/16” Cap Screw
2 5/16” Lock Washer
3 5/16” Nut
4 Mounting Strap
11
5 Saddle Bracket
6 End Cover
7 3/8” Cap Screw
8 3/8” Lock Washer
9 Lower Mounting Bracket
10 Cartridge Bolt
11 Desiccant Cartridge
12 O-ring
13 O-ring
14 Retaining Ring
4 1 15 Purge Valve Cartridge Assembly
16 Shoulder Bolt
17 Exhaust Diaphragm
18 Purge Valve
2 19 Purge Valve Housing
5
20 Purge Valve Piston
3
21 O-ring
22 Piston Return Spring
33 23 O-ring
24 O-ring
25 Retaining Ring
26 Perforated Plate
6 27 Check Ring Spring
28 Check Valve
29 O-ring
30 Retaining Ring
30 31 Heater & Thermostat Assembly
32 31
32 O-ring
33 Safety Valve Assembly
29 9
28
27 12 20
26
13 8
25 21
7
22
23 24
19
10 18 15
17
14
16 14
FIGURE 9 - AD-IP EXPLODED VIEW
8
3. Remove the retaining ring (14) that secures the purge 1. Install the o-ring (21) in its groove on the O.D. of the
valve assembly (15) in the end cover (6). purge piston (20). Place the return spring (22) in the
4. Remove the 1/4" shoulder bolt (16) from the bottom of bore of the purge valve housing (19), then insert the purge
the purge valve housing assembly (19) using a 3/8" piston (20) into the I.D. of the spring (22).
socket wrench and a large blade screw driver, inserted 2. Install and center the exhaust diaphragm (17) over the
in the slot on top of the purge piston (20). Remove the shoulder bolt (16) making certain that the diaphragm ID
exhaust diaphragm (17), and the purge valve (18) from is over the bolt shoulder. Then install the purge valve
the purge valve housing (19). (18) on the shoulder bolt making certain its metal support
5. Remove the o-rings (23 & 24) from the purge valve housing side is against the diaphragm (17).
(19). 3. Push the purge piston (20) into the housing (19) until it
6. Remove the purge piston (20) and the return spring (22). bottoms and insert a large blade screw driver in the
piston’s slotted head. While depressing the purge piston
7. Remove the o-ring (21) from the purge piston (20).
with the screw driver, install the shoulder bolt (16) with
8. Remove the retaining ring (25) that secures the delivery exhaust diaphragm (17) and purge valve (18) in the piston.
check valve assembly in the end cover (6). Remove and Torque the shoulder bolt (17) to between 60-80 in. lbs.
separate the perforated plate (26), spring (27), check
4. Install the two o-rings (23 & 24) on the purge valve housing
valve body (28) and o-ring (29).
(19) placing each in its appropriate location. Install the
9. Remove the retaining ring (30) that secures the heater assembled purge valve housing in the end cover (6) while
and thermostat assembly (31) in the end cover (6). Gently making certain the purge valve housing is fully seated
pull the heater and thermostat (31) out of the end cover against the end cover. Secure the purge valve housing in
(6) and remove the o-ring (32). the end cover using the retaining ring (14). Make certain
10. Using a 9/16” wrench, remove the safety valve assembly the retaining ring is fully seated in its groove in the end
(33) from the end cover (6). cover (6).
5. Using a 9/16” wrench, install the safety valve assembly
CLEANING & INSPECTION
(34) into the end cover (6).
1. Using mineral spirits or an equivalent solvent, clean and
6. Install the o-ring (29) on the check valve body (28) and
thoroughly dry all metal parts except the desiccant
push the o-ring down, over the 3 guide lands until it is in
cartridge.
the o-ring groove of the check valve body (28). Install the
2. Inspect the interior and exterior of all metal parts that check valve spring (27) on the check valve body so that
will be reused for severe corrosion, pitting and cracks. the small coils of the spring slip over the check valve
Superficial corrosion and or pitting on the exterior portion body. Install the assembled check valve body, o-ring,
of the end cover is acceptable. and spring (27, 28 & 29) in the end cover (6) so that the
3. Inspect the bores of both the end cover and the purge o-ring rests on its seat in the end cover (6) and the spring
valve housing for deep scuffing or gouges. is visible.
4. Make certain that all purge valve housing and end cover 7. Install the perforated plate (26), in the end cover (6) and
passages are open and free of obstructions. secure the check valve assembly using the retaining
5. Inspect the pipe threads in the end cover. Make certain ring (25). Make certain the retaining ring is fully seated
they are clean and free of thread sealant. in its groove in the end cover (6).
6. Inspect the purge valve housing bore and seats for 8. Install the o-ring (32) on the heater and thermostat
excessive wear and scuffing. assembly (31). After making certain the sponge rubber
cushion is positioned between the connector body and
7. Inspect the purge valve piston seat for excessive wear.
thermostat, gently push the heater and thermostat
8. Make certain that the purge orifice in the cartridge bolt assembly (31) into the end cover (6), making certain
is open and free of obstructions. the heating element enters the small diameter bore in
9. Inspect all air line fittings for corrosion. Clean all old the larger heater and thermostat bore in the end cover
thread sealant from the pipe threads. (6). Secure the heater and thermostat assembly in the
10. All o-rings removed should be discarded and replaced body using the retaining ring (30). Make certain the
with new o-rings provided in appropriate kit(s). retaining ring is fully seated in its groove in the end cover
(6).
ASSEMBLY 9. Install both o-rings (12 & 13) on the desiccant cartridge
Prior to assembly, coat all o-rings, o-ring grooves, and bores bolt (10) and using a twisting motion, insert the
with a generous amount of silicone grease. (Refer to Figure assembled desiccant cartridge bolt in the end cover (6).
9 during assembly unless otherwise advised.)
9
10. Install the desiccant cartridge (11) on the end cover (6) vehicles in use today will meet these basic requirements
making certain the cartridge is properly seated and flush however, some may not. Examples of vehicles that may not
on the end cover. meet the requirements include, refuse trucks, city coaches,
Note: It may be necessary to rotate the cartridge slightly bulk trailer unloading operations and other high air
until the anti-rotation lugs are properly aligned and allow consumption systems. While the AD-IP air dryer can be
the cartridge to rest flush against the end cover. used on these vehicles the standard installation procedure
presented in this manual may require modification to assure
11. Using an adjustable wrench or a socket, tighten the
proper operation and service life. Consult your local
desiccant cartridge bolt (10), to secure the desiccant
authorized Bendix parts outlet or sales representative for
cartridge (11) to the end cover (6). Torque the desiccant
additional information.
cartridge bolt to 50 foot pounds.
Caution:Do not over torque. Charge Cycle Time— The AD-IP air dryer is designed to
provide clean, dry air for the brake system. When a vehicle’s
AD-IP INSTALLATION air system is used to operate non-brake air accessories it
1. Using the relationship marks made during step 7 of the is necessary to determine that, during normal daily operation
“AD-IP REMOVAL”, install the lower mounting bracket the compressor should recover from governor “cut-in” to
(9) on the end cover (6) and secure it using the two 3/8” governor “cutout” (usually 100 psi to 120 psi) in 90 seconds
cap screws and washers (7 & 8). Torque the cap screws or less at engine RPMs normal to the vehicle vocation. If the
to 300-360 inch pounds. recovery time consistently exceeds this limit, it may be
2. Using the relationship marks made during step 6 of the necessary to “bypass” the air accessory responsible for the
AD-IP Removal Procedure, install the saddle bracket high air usage. Consult your local authorized Bendix parts
(5) and mounting strap (4) on the end cover (6), and outlet or sales representative for additional information.
using the 5/16" cap screw (1), washer (2), and nut (3) Purge Cycle Time— During normal vehicle operation, the
secure the strap to the saddle bracket. Tighten the 5/ air compressor must remain unloaded for a minimum of 30
16" nut on the upper mounting bracket. Torque to 60- seconds. This minimum purge times is required to ensure
100 in lbs. complete regeneration of the desiccant material. If the purge
3. Install the AD-IP on the vehicle using the four bolts that time is occasionally shorter than the times specified, no
secure both the upper and lower mounting brackets. permanent ill effect should be expected, however, if the purge
4. Reconnect the three airlines to the proper ports on the time is consistently less than the minimum, an accessory
end cover (identified during step 3 of the AD-IP Removal). bypass system must be installed. Contact the nearest
authorized Bendix parts outlet or Bendix representative for
5. Reconnect the vehicle wiring harness to the AD-IP heater
additional information. Note: Reservoir Volume - Total vehicle
and thermostat assembly connector by plugging it into
reservoir volume can impact the Charge and Purge Cycle
the air dryer connector until its lock tab snaps in place.
time. The chart below can be used as a guide in determining
6. Before placing vehicle back into service, perform the if additional help is required.
Operation and Leakage Tests stated elsewhere in this
manual.
Total Vehicle Reservoir Air Dryer Model
RETROFITTING THE AD-IP AIR DRYER Volume (Cu. In.)
Less than 9,000 .......................... Standard AD-IP
GENERAL
Greater than 9,000 ............... AD-9 Extended Purge or Contact
The following retrofit instructions are presented for reference
purposes only since Bendix aftermarket retrofit and
Bendix Commercial Vehicle Systems LLC
replacement air dryers are packaged with the most up-to-
date installation instructions. The instructions packaged with
the AD-IP should be followed in lieu of those presented here. Air Compressor Size— Although the AD-IP air dryer can
The preceding portion of this manual deals with “in-service” be used in conjunction with larger compressors, it was
repair and or replacement of the AD-IP air dryer. The portion designed primarily for units rated for up to 30 CFM. It is
of the manual that follows is concerned with installing an recommended that when using the AD-IP air dryer with a
AD-IP on a vehicle not previously equipped with one. compressor which has a rated displacement exceeding 30
CFM that an authorized Bendix parts outlet or Bendix
VEHICLE APPLICATION REQUIREMENTS marketing representative be contacted for assistance.
The basic application requirements presented here apply to Holset “E or QE” Type Air Compressors - In order for
a standard air dryer installation. The majority of highway these Holset compressors to function properly when installed
10
with an AD-IP air dryer, the required Holset feed back line
and single check valve must be used. The standard AD-IP MOUNTING
can be used with a separate feedback line and single check STRAP
OR the AD-IP DI (Drop In) model can be used. With AD-IP 5/16" Cap Screw
DI in use the separate feed back line and single check valve
can be eliminated since these components are part of the
air dryer. Refer to Figures 2 & 3.
VEHICLE PREPARATION
1. Park the vehicle on a level surface and prevent movement
by means other than the brakes. NUT SADDLE
BRACKET
2. Drain all reservoirs to 0 p.s.i. LOCKWASHER
LOCATING AD-IP ON VEHICLE

END COVER
1. The AD-IP air dryer must be mounted vertically (purge MOUNTING HOLES
exhaust toward road surface) outside the engine (4)
compartment in an area of air flow while the vehicle is in
motion. The AD-IP must not be exposed to direct wheel
splash. If the air dryer is located directly behind the axle, LOWER
a mud flap is required. MOUNTING
BRACKET
2. Maintain a minimum clearance of 12" between the air
dryer and any potential heat source (e.g. vehicle exhaust).
If this is not feasible, a heat shield must be used. FIGURE 10 - AD-IP BRACKET INSTALLATION
3. Make certain that adequate clearance from moving
components (e.g. drive shaft, suspension, pitman arm, consideration the piping connections required to install
etc.) is provided. the AD-IP air dryer and use those that will best position
4. Locate the air dryer on vehicle so that a minimum of 1/ the unit for ease of installation. Utilizing the two cap
2” inch clearance above the air dryer is available to allow screws and washers provided with the AD-IP air dryer
desiccant cartridge removal. A minimum of 8” inches retrofit unit, attach the lower mounting bracket and torque
clearance below the air dryer is required to allow for to 300-360 in. lbs
desiccant cartridge bolt removal. Note: The bracket mounting holes in the end cover may
5. When choosing the mounting location for the AD-IP, note not be pre-tapped. In this case the mounting bolt will
the discharge line length requirements stated under the self tap the holes on initial installation.
heading Connecting the Air Lines, elsewhere in this 2. Assemble the mounting strap and saddle bracket as
manual. illustrated, by utilizing the 5/16" cap screw, lock washer,
Important Note:Under normal operating conditions, the and nut provided. Place the upper bracket strap in the
maximum inlet air temperature for the AD-IP air dryer is end cover channel provided for it, then install the saddle
150 degrees Fahrenheit. bracket and secure the strap to the saddle bracket using
the 5/16" cap screw, lock washer, and nut provided. Install
6. If possible locate the AD-IP so that the purge exhaust
but do not tighten the cap screw at this time. Orient the
does not expel contaminants on vehicle components. If
strap and saddle bracket so that it is in a flat plane with
this is not feasible, the purge exhaust may be redirected
the lower bracket. Torque the 5/16" nut to 60-100 in. lbs.
away from the vehicle by installing an optional special
to tighten strap onto the shell.
exhaust cover (part number 112609). The exhaust cover
is available as a separate item from authorized Bendix Note: A universal mounting plate (Pc. No. 248478) is
parts outlets. A 1 inch ID hose can be clamped on this available to facilitate the mounting of the AD-IP air dryer
special exhaust cover to allow the exhaust to be to the vehicle. It can be obtained through an authorized
redirected. Bendix parts outlet.
3. Components and location used to mount the AD-IP on
MOUNTING THE AD-IP(Refer to Figure 10) the vehicle must be rigid enough to minimize air dryer
1. Install the lower mounting bracket on the AD-IP air dryer. vibration.
To accomplish this, it will be necessary to choose two, 4. Mount the AD-IP air dryer on the vehicle using 3/8" bolts
of the four available, mounting holes. To determine which (grade 5 min.) and washers. Torque to 25 ft. lbs. (300
two holes to utilize to attach the lower bracket, take into inch pounds.)
11
4. Compressor discharge line lengths and inside diameter

requirements are dependent on the vehicle application
GOVERNOR
PURGE CONTROL and are as follows:
LINE TO CON PORT
Typical P & D, School Bus and Line Haul
The minimum discharge line length is 6 feet and the maximum is 16 feet.
Discharge Minimum Other Requirements
Line Length Line
AD-IP
AIR 6.0 - 9.5 ft. ................... 1/2 in. ............... None
DRYER 9.5 - 12.0 ft. .................. 1/2 in. ............... Last 2-3 feet, including the supply
port fitting, must be insulated with
DISCHARGE
LINE TO SUP 1/2 inch thick closed cell
PORT polyethylene pipe insulation.
HEATER & SUPPLY RES. 12.0 - 16.0 ft. ................ 5/8 in. ............... Last 2-3 feet, including the supply
THERMOSTAT port fitting, must be insulated with
LEAD TO DELIVERY LINE 1/2 inch thick closed cell
IGNITION FROM DEL PORT polyethylene pipe insulation.
SWITCH HEATER &
FUSE THERMOSTAT ON AD-IP
If the discharge line length must be less than 6 feet or greater
10 AMP - 12 VOLT LEAD TO
5 AMP - 24 VOLT GROUND than 16 feet, contact your local Bendix Brakes representative or
authorized parts outlet for further information.
FIGURE 11 - AD-IP INSTALLATION
CONNECTING THE AIR LINES High Duty Cycle Vehicles
PURGE CONTROL LINE (City Transit Bus, Refuse Trucks etc.)
The minimum discharge line length is 10 feet and the maximum is 16 feet.
1. Install a Purge Control air line having a minimum inside
Discharge Minimum Other Requirements
diameter of 3/16 inches between the AD-IP end cover Line Length Line
control port and an unused unloader port on the governor. 10.0 - 16.0 ft. ................ 1/2 in. ............... None
The control line must be connected directly to the
If the discharge line length must be less than 10 feet or greater
governor and not in series with automatic drain valves, than 16 feet, contact your local Bendix Brakes representative or
lubrication systems, etc. authorized parts outlet for further information.
2. The control line should slope downward to the end cover
without forming sharp bends or “dips”. DELIVERY LINE
1. Install an air line of the same approximate I.D. as the
COMPRESSOR DISCHARGE LINE compressor discharge line between the AD-IP air dryer
GENERAL: delivery port and the first (supply) reservoir. This line
should also slope downward to the reservoir, if possible.
While minimum diameters are specified, larger line diameters
generally improve performance and life and reduce EXHAUST LINE
temperatures, particularly in severe applications. 1. If it is necessary to direct AD-IP air dryer discharge
1. The compressor discharge line material should be wire contaminants away from vehicle components it will be
braided “Teflon” hose, copper tubing or a combination of necessary to purchase a special exhaust cover for the
both. AD-IP air dryer (Pc. No. 112609) and install on the unit.
2. The compressor discharge line should slope downward A 1 inch (25.4 mm) I.D. hose can be clamped on the
from the compressor discharge port to the AD-IP air dryer special AD-IP air dryer exhaust cover.
supply port without forming water traps, kinks or WIRING THE HEATER/THERMOSTAT
restrictions. Crossovers from one side of the frame rail
1. The air dryer is available with either a 12 or 24 volt heater
to the other, if required, should occur as close as possible
which uses 90 watts of power. Determine the vehicle’s
to the compressor.
electrical system voltage and make certain that the air
3. Extension fittings and combination fittings (i.e. two supply dryer that is to be installed contains the same voltage
fittings coupled together) must not be installed at the heater. The air dryer’s part number can be used to
AD-IP supply port. A straight fitting installed at the AD- determine the air dryers heater voltage requirement. The
IP supply port is preferred; however a 45 deg., or a 90 heater voltage can also be identified by the color of the
deg. fitting can be used in that order of preference. Make heater assembly connector as described in the table
certain the fitting orientation does not cause the below.
compressor discharge line to “run uphill” to the air dryer
supply port.
12
Air Dryer Heater Air Dryer Connector If the AD-IP is being installed on a vehicle that did not
Voltage Identification
previously have an air dryer or air system aftercooler, a
12 Volts .............................. White, (No other markings)
separate feedback line and single check valve must be
24 Volts .............................. Gray, or White w/Red Dot
installed
A two lead, 24 inch, wire harness with attached weather
resistant connector is supplied with all retrofit and If the AD-IP is replacing an older style air dryer or air system
replacement AD-IP air dryers. Connect one of the two leads aftercooler that did not incorporate an integral “Turbo Cutoff”
of the wire harness to the engine kill or ignition switch. The device, the Holset ECON valve must be removed. The
remaining lead of the wire harness must be connected to a feedback line and single check valve must remain in place.
good vehicle ground (not to the air dryer or its mounting AD-IP “Drop In” Model(Refer to Figure 3C)
bracket). A fuse must be installed in the power carrying wire;
install a 10 amp fuse for 12 volt heaters and a 5 amp fuse for If the AD-IP “Drop In” is being installed on a vehicle that did
a 24 volt heater. not previously have an air dryer or air system aftercooler, no
additional considerations are necessary. Install the AD-IP
3. Use 14 gauge wire if it is necessary to lengthen the wire DI in the manner described in the previous section.
harness provided with the AD-IP air dryer. Make certain
all wire splices are waterproofed using the splice kit If the AD-IP DI is replacing a standard AD-IP or air dryer or
provided with all aftermarket AD-IP air dryers. air system aftercooler which incorporated an integral “Turbo
4. Tie wrap or support all electrical wires leading to the AD- Cutoff” device, the old feedback line and single check valve
IP air dryer at 6 - 8 inch intervals. must be removed.
Note: Wires should have sufficient slack and not If the AD-IP DI is replacing an older style air dryer or air
completely taught. system aftercooler that did not incorporate an integral “Turbo
Cutoff” device, the Holset ECON valve and the old feedback
line and single check valve must be removed.
FRAME RAIL
STAR WASHER
TESTING THE AD-IP
1/4" or 3/8"
NUT EYELET Before placing the vehicle in service, perform the following
tests.
1. Close all reservoir drain cocks.
2. Build up system pressure to governor cutout and note
GROUND that the AD-IP air dryer purges with an audible escape
LEAD
of air.
3. “Fan” 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 at the AD-IP
WEATHERPROOF air dryer exhaust.
POWER LEAD
SPLICE 4. It is recommended that the following items be tested for
leakage to assure that the AD-IP air dryer will not cycle
WIRE HARNESS excessively.
CONNECTOR
14 GAGE POWER WIRE (TO AIR DRYER) (A) Total air system leakage (See Bendix publication
FROM VEHICLE
BW-5057 “Air Brake Handbook.”)
FIGURE 12 - WIRING - REMOTE POWER & LOCAL (B) Compressor unloader mechanism.
GROUND
(C) Governor.
INSTALLING AD-IP WITH HOLSET (D) Drain cock and safety valve in first (supply) reservoir.
COMPRESSOR (E) All air connections leading to and from the first
(supply) reservoir.
GENERAL
The vehicle installation guidelines presented in the previous
section apply to all AD-IP air dryer installations. Vehicles
equipped with the Holset Type E or QE compressor require
the following additional considerations.
Standard AD-IP(Refer to Figure 3B)
13
AD-IP AIR DRYER TROUBLESHOOTING CHART

SYMPTOMS CAUSE REMEDY
1. Dryer is constantly A. Excessive system A. Test for excessive system leakage.
“cycling” or purging. leakage. Allowable leakage:
Single vehicle - 1 psi/minute either service
reservoir.
Tractor trailer - 3 psi/minute either service
reservoir.
B. Excessive leakage in B. Using soap solution, test for leakage at fittings,
fitting, hoses and tubing drain cock or valve (if any) and safety valve in
connected to the first reservoir. Repair or replace as necessary.
compressor, air dryer
and first reservoir.
C. Defective check valve C. Test check valve. Build system pressure to

assembly in AD-IP air governor cut-out. Wait 2 minutes for
dryer end cover. completion of purge cycle. Using soap solution
at exhaust of purge valve, leakage should not
exceed a 1 inch bubble in less than five
seconds. Replace as necessary.
D. Defective governor. D. Test governor for proper cut-in and cut-out
pressures and excessive leakage in both
positions.
E. Compressor unloader E. Remove air strainer or fitting from compressor
mechanism leaking inlet cavity. With compressor unloaded, check
excessively. for unloader piston leakage. Slight leakage
permissible.
F. Holset “E” type F. Test the Holset E Compressor unloader system
compressor. with feedback line and check valve for proper
operation. Make certain Holset ECON is not in
use with the AD-IP air dryer, if so, remove and
retest.
G. Rapid cycling of the G. With gauge installed at RES port of governor,
governor due to air pressure should not drop below “Cut-In”
starvation at the RES pressure at the onset of the compressor
port of the governor. “Unloaded” cycle. If pressure drops, check for
“kinks” or restrictions in line connected to RES
port. Line connected to RES port on governor
must be same diameter, or preferably larger
than, lines connected to UNL port(s) on
governor.
2. Water in vehicle A. Improper discharge line A. Refer to section entitled Connecting the Air
reservoirs. length or improper line Lines and check line size and length.
material. Maximum air
dryer inlet temperature
is exceeded.
B. Air system charged B. If system must have outside air fill provision,
from outside air source outside air should pass through air dryer. This
(outside air not passing practice should be minimized.
through air dryer).
14
AD-IP AIR DRYER TROUBLESHOOTING CHART (Continued)

2. Water in vehicle C. Air dryer not purging C. See cause and remedy for Symptom #5.
reservoirs (continued). (see Symptom #5).
D. Purge (air exhaust) time D. Check causes and remedies for Symptom #1.
insufficient due to
excessive system
leakage (see causes for
Symptom #1).
E. Excessive air usage - E. Charge Cycle Time - The AD-IP is designed to
Air dryer not compatible provide clean, dry air for the brake system.
with vehicle air system When a vehicle’s air system is used to operate
requirement (Improper non-brake air accessories it is necessary to
determine that; during normal, daily operation
air dryer/vehicle
the compressor should recover from governor
application). “cut-in” to governor “cut-out” (usually 100 psi to
120 psi) in 90 seconds or less at engine RPM’s
commensurate with the vehicle vocation. If the
recovery time consistently exceeds this limit, it
may be necessary to “bypass” the air accessory
responsible for the high air usage. An example
of where a by-pass system would be required is
when the compressor is used to pressurize a
tank trailer for purposes of off-loading product.
Consult your local authorized Bendix parts
outlet or sales representative for additional
information.
Purge Cycle Time - During normal vehicle
operation, the air compressor must remain
unloaded for a minimum of 30 seconds. This
minimum purge time is required to ensure
complete regeneration of the desiccant material.
If the purge time is consistently less than the
minimum, an accessory by-pass system must
be installed. Consult your local authorized
Bendix parts outlet or sales representative for
additional information.
Air Compressor Size - Although the AD-IP can
be used in conjunction with larger compressors,
it was designed primarily for units rated for up to
30 CFM. It is recommended that when using the
AD-IP with a compressor which has a rated
displacement exceeding 30 CFM that an
authorized Bendix parts outlet or Bendix
marketing representative be contacted for
assistance.
F. Air by-passes desiccant F. If vehicle uses Holset compressor, inspect
cartridge assembly. feedback check valve for proper installation and
operation.
Replace desiccant cartridge. Make sure
desiccant cartridge assembly is properly
installed and sealing rings are in place on
mounting surface of desiccant cartridge.
G. Desiccant requires G. Replace desiccant cartridge assembly.
replacement.
15

3. Safety valve on air A. Desiccant cartridge A. Check compressor for excessive oil passing
dryer “popping off” or plugged. and/or correct compressor installation. Repair
exhausting air. or replace as necessary. Replace desiccant
cartridge.
B. Defective discharge B. Test to determine if air is passing through
check valve in end check valve. Repair or replace.
cover of the AD-IP.
C. Defective fittings, hose C. Check to determine if air is reaching first
or tubing between air reservoir. Inspect for kinked tubing or hose.
dryer and first reservoir. Check for undrilled or restricted hose or tubing
fittings.
D. Excessive pressure D. Increase volume in discharge line. Add a ping
pulsations from tank (small reservoir).
compressor. (Typical
single cylinder type).
E. Safety valve setting E. Reduce system pressure or obtain a higher

lower than the setting safety valve.
maximum system
pressure.
4. Constant exhaust of air A. Air dryer purge valve A. With compressor loaded, apply soap solution on
at air dryer purge valve leaking excessively. purge valve exhaust, to test for excessive
exhaust or unable to leakage. Repair purge valve as necessary.
build system pressure. B. Defective governor. B. Check governor for proper “cut-in”, “cut-out”
(Charge mode.) pressure and excessive leakage in both
positions. Repair or replace as necessary.
C. Purge control line C. Purge control line must be connected to
connected to reservoir unloader port of governor.
or exhaust port of
governor.
D. Purge valve frozen D. Test heater and thermostat as described in

open - faulty heater and Preventative Maintenance Section.
thermostat, wiring,
blown fuse.
E. Excessive system E. See Symptom #1’s Cause and Remedy A.

leakage.
F. Purge valve stays open F. Repair purge valve and housing.
- supply air leaks to
control side.
5. Can not build system A. Inlet and outlet air A. Connect compressor discharge to air dryer
air pressure. connections reversed. supply port. Reconnect lines properly.
B. Check valve between B. Test check valve for proper operation. Repair
air dryer and first or replace as necessary.
reservoir.
C. Kinked or blocked C. Check to determine if air passes through
(plugged) discharge line. discharge line. Check for kinks, bends,
excessive carbon deposits, or ice blockage.
16

5. Can not build system D. Excessive bends in D. Discharge line should be constantly sloping
air pressure. discharge line (water from compressor to air dryer with as few bends
collects and freezes). as possible.
E. Refer to Symptom 4, E. Refer to Symptom 4, Rememdies E & F.
causes E & F.
6. Air dryer does not A. Broken, kinked, frozen, A. Test to determine air flows through purge
purge or exhaust air. plugged or disconnected control line when compressor unloaded. Check
purge control line. for undrilled fittings. (See Symptom #4,
Remedy C.)
B. Faulty air dryer purge B. After determining air reaches purge valve
valve. (Remedy A above), repair purge valve.
C. See Causes, B. E, G for C. Refer to Remedies B. E, G for Symptom #4.
Symptom #4.
7. Desiccant material A. This symptom is almost A. See Causes and Remedies for Symptoms 1, 2,
being expelled from air always accompanied by 3, 4 and 5.
dryer purge valve one or more of
exhaust (may look like Symptoms 1, 2, 3, 4 and
whitish liquid or paste 5. See related causes
for these Symptoms
or small beads.)
above.
- OR - B. Vibration should be held to minimum. Add
B. Air dryer not securely
Unsatisfactory mounted. (Excessive bracket supports or change air dryer mounting
desiccant life. vibration.) location if necessary.
C. Malfunctioning or C. Replace desiccant cartridge assembly.
saturated desiccant
cartridge.
D. Compressor passing D. Check for proper compressor installation; if
excessive oil. symptoms persist, replace compressor.
E. Desiccant cartridge not E. Check the torque on the desiccant cartridge to
assembled properly to end cover attachment. Refer to assembly
end cover. (Loose section of this data sheet.
attachment)
8. “Pinging” noise A. Single cylinder A. A slight “pinging” sound may be heard during
excessive during compressor with high system build up when a single cylinder
compressor loaded pulse cycles. compressor is used. If this sound is deemed
cycle. objectionable, it can be reduced substantially
by increasing the discharge line volume.
This can be accomplished by adding an
additional four feet of discharge line or adding
a 90 cubic inch reservoir between the
compressor and the AD-IP air dryer.
IMPORTANT: Do not exceed the line lengths
requirements specified in this manual.
9. Constant seepage of A. Defective check valve A. Refer to Remedy C, Symptom #1.
air at air dryer purge assembly in AD-IP air
valve exhaust (non- dryer end cover.
charging mode.) B. Leaking Turbo Cutoff B. Repair or replace purge valve assembly.
valve.
C. Leaking purge valve C. Repair or replace purge valve assembly.
control piston o-ring.
17

10. The air dryer purge A. Compressor fails to A. Faulty governor installation; no air line from
piston cycles rapidly in “unload”. governor to compressor or line is kinked or
the compressor restricted. Install or repair air line.
unloaded (non-
compressing) mode.
Additional Troubleshooting Information

The Troubleshooting procedure presented on pages 18 and 19 has been excerpted from a laminated card entitled:
Troubleshooting Charging and Air Supply Systems. The complete card can be obtained from authorized Bendix parts
outlets under literature number BW1779. It is presented here because of the air dryers connection to the supply air system
and for convenience. The procedure is not all inclusive but rather represents the most commonly encountered complaints.
GOVERNOR STANDARD SINGLE CHECK VALVE LOW PRESSURE

(USED W/INTEGRAL PURGE AIR INDICATOR
DRYERS)
DASH
CONVENTIONAL GAUGE
SUPPLY SYSTEM SAFETY REAR

VALVE
& INTEGRAL PURGE
SUPPLY
TWO CYL.
AIR DRYER COMPRESSOR
AIR DRYER FRONT
STANDARD SINGLE
CHECK VALVE
SAFETY
GOVERNOR VALVE DASH
GAUGE
HOLSET TYPE AIR LOW

"E & QE" DRYER REAR PRESSURE
INDICATOR
COMPRESSOR
WITH ECON SUPPLY
HOLSET
VALVE “E OR QE”
COMPRESSOR FRONT
HOLSET
ECON VALVE SPECIAL STANDARD SINGLE
SINGLE CHECK CHECK VALVE DRAIN COCK
("CHOKE" IN INLET)
SAFETY LOW PRESSURE

GOVERNOR VALVE INDICATOR
HOLSET TYPE DASH

"E & QE" AIR DRYER REAR GAUGE
COMPRESSOR
W/O ECON SUPPLY
HOLSET
VALVE “E OR QE”
COMPRESSOR
FRONT
SPECIAL SINGLE CHECK -
SINGLE CHECK PROTECTION VALVE
("CHOKE" IN INLET) (USED W/SYSTEM SINGLE CHECK VALVE (USED
PURGE AIR DRYERS) W/INTEGRAL PURGE AIR DRYERS)
18
COMPLAINTS COMMON TO THE CHARGING & AIR SUPPLY SYSTEM
Complaint: Can Not Build System Pressure Supply system component leakage: drain system, install gauge and
• Discharge line plugged or restricted: see Common Test 1. shop air hose in place of drain cock in supply reservoir. Fill system to
120 psi, shut off shop air and check leakage on following components
• Air pressure trapped between governor and compressor in order presented:
unloaders: see Common Test 2.
• Compressor unloader leakage
• Blow Leakage at Air Dryer Exhaust: see Common Test 3.
• Drain system, remove governor from comp. plug governor UNL
Complaint: Air system Builds Too Slow port and re-test. If leakage OK repair comp. unloader mechanism
• Discharge line restricted: see Common Test 1. or replace comp. If leakage NOT OK then next.
• Discharge line leakage: see Common Test 5. • Holset ECON valve (used with Holset Type "E & QE" comp.) missing,
malfunctioning, leaking.
• Air Leaking at Air Dryer Exhaust: see Common Test 3.
• Is ECON valve required but missing? If YES, install, along with
• Compressor head gasket failure: apply soap solution around
special Holset check valve w/choke. If NO and ECON valve present
cylinder head. If leakage between head and block noted repair or
replace ECON valve and special check valve. If NO and ECON not
replace comp.
required then next
• Air pressure trapped between governor and compressor
• Air dryer leakage: Remove line from air dryer inlet and with 120 psi
unloaders: see Common Test 2.
in supply res. soap exhaust and inlet port of air dryer. If leakage
• Air system leakage: see Common Test 4. greater than 1 inch bubble in 1 second at exhaust port, repair or
Complaint: Can Not Build System Pressure Above "X" psi. replace check valve (on dryers with integral purge volume) or
replace body assy. on system purge air dryers. If leakage greater
• Blow leakage at compressor unloaders: remove all hardware from than 1 inch bubble in 1 second at inlet port, repair or replace purge
comp. inlet then remove governor. With 120 psi shop air applied to valve assy. (on dryers with integral purge volume) or replace
comp. unloader port listen for leakage at inlet. If noted, repair leak turbo cut -off valve on system purge air dryers.
or replace comp.
Complaint: System Pressure Goes to 150+ psi
• Incorrect setting on governor: verify Safety Valve operation. Drain
air from system, remove or disconnect governor from comp. and • Drain air system to 0 psi, remove/disconnect governor from comp.
install gauge in governor unloader (UNL) port. Build system Start engine and note air pressure rise on dash gauges. Apply 120
pressure and note when pressure on dash gauge and test gauge psi shop air to comp. unloader port. If air pressure continues to
are equal. Should be equal at maximum setting of governor. rise, repair comp. unloaders or replace comp. If air ceases to rise,
repair or replace governor.
• Discharge line leakage: see Common Test 5.
Complaint: Low Pressure Warning After Only 1 or 2
• Air system leakage: see Common Test 4. Applications
• Compressor head gasket failure: apply soap solution around • Brakes out of adjustment: adjust brakes.
cylinder head. If leakage between head and block noted repair or
replace comp. • Excessive system leakage on service (application) side of system:
Build system pressure to 120 psi and shut off engine. With park
Complaint: Air Dryer Cycles "ON & OFF" Constantly brakes released, make full service application and note dash gauges
This complaint caused by leakage, either Service system or Supply for 2 minutes. Pressure drop on either gauge should not exceed 4
system. Service system leakage is shown on dash gauges Supply psi. (2 psi per min.) If pressure drop excessive, find leakage in
system leakage is not. Note: System purge air dryers will purge more service system, if OK, then next.
often than those with integral purge volume. • Incorrect low pressure switch in use or setting incorrect: Build
Service system leakage: see Common Test 4. system to 120 psi. Engine OFF ignition ON, slowly drain air pressure
from one service reservoir. Low pressure warning on at minimum
60 psi, maximum 10-15 psi less than governor cut-in pressure.
TESTS COMMON TO MORE THAN ONE COMPLAINT
1. Discharge plugged or restricted repair or replace Air Dryer heater and thermostat. If voltage NOT OK,
• Connect temporary discharge line from comp. discharge port to supply Repair or replace the vehicle wire connected to Air Dryer. Retest build-
res. & re-check build-up. If build-up OK replace plugged discharge line. up.
If build-up NOT OK go to next cause. • If build-up still NOT OK or temp. above 32 deg. F, replace Air Dryer purge
2. Air pressure trapped between governor and compressor valve assembly.
• Verify Safety Valve operation then remove or disconnect governor from 4. Air system leakage
comp. & check build-up. • Build system Pressure to governor cut-out, wait 2minutes for dryer purge
• If build-up OK, repair or replace governor or line between gov. and comp. completion. Note pressures on dash gauges then watch dash gauges
• If build-up NOT OK repair or replace comp. for 2 minutes. Leakage not to exceed 2 psi in 2 mins. for truck, bus, tractor
3. Blow Leakage at Air Dryer Exhaust (no trailer).
• Drain all air from Supply reservoir then remove control air line from Air • If leakage NOT OK on gauges, find leak(s) in service and park system
Dryer, plug line and plug control port in Air Dryer. Re-check build-up. and repair. Retest and if system purge air dryer in use and still not OK
• If build-up OK, repair or replace governor or line between governor and repair or replace dyer.
Air Dryer • If leakage OK on gauges, drain air from supply reservoir, remove drain
• If build-up NOT OK, and below 32 deg. F, turn ignition ON and allow cock and install air gauge. Build system air in supply reservoir and note
heater to warm Air Dryer then check build-up. If NOT OK, remove wire leakage. If OK continue checking. If NOT OK find leaks and repair.
(connector or terminal) from Air Dryer. Using test light, check wire end 5. Discharge line leakage
or terminal for battery voltage with vehicle ignition ON. If voltage OK, • Soap cover on flex discharge line, if leakage noted replace line.
• Soap fittings to check leakage, tighten as needed.
IMPORTANT: The Complaints, Causes and Remedies presented here should not be considered as the only situations possible. They
are only meant to represent the most commonly encountered. It may be necessary to perform additional trouble shooting using the more
detailed information presented in service manuals for the specific components.
19
BW1811 © 2002 Bendix Commercial Vehicle Systems LLC All rights reserved. 3/2002 Printed in U.S.A.
20
SERVICE BRAKE BR02–1
SERVICE BRAKE
BR 02
BR02-001
HYDRAULIC BRAKE ................................BR02-2

INSPECTION AND ADJUSTMENT ................. BR02-2
HYDRO-MAX HYDRAULIC BRAKE BOOSTER

AND MASTER CYLINDER .......................BR02-5
DESCRIPTION ................................................ BR02-5
PRINCIPLE OF OPERATION .......................... BR02-7
COMPONENT LOCATOR................................ BR02-9
HYDRO-MAX BOOSTER........................BR02-10
OVERHAUL ................................................... BR02-10
MASTER CYLINDER ..............................BR02-17

OVERHAUL ................................................... BR02-17
PRESSURE TESTS ...................................... BR02-19
ABS MODULATOR .................................BR02-20

DATA AND SPECIFICATIONS ....................... BR02-20
DESCRIPTION .............................................. BR02-20
DISC BRAKE CALIPER..........................BR02-21

DATA AND SPECIFICATIONS ....................... BR02-21
DESCRIPTION .............................................. BR02-22
BR02–2 SERVICE BRAKE
HYDRAULIC BRAKE
INSPECTION AND ADJUSTMENT
EN06ABC02H200001
1. REMAINING THICKNESS OF PAD.

Inspect the pad thickness. If the pad thickness is less than the
service limit or if it is forseen that it may be worn to the service
limit before the next inspection, replace it with a new one.
Tow piston type
Assembly Standard: 15.5 mm {0.610 in}
Service Limit: 3.2 mm {0.125 in}
Four piston type
Assembly Standard: 18.5 mm {0.728 in}
Service Limit: 3.2 mm {0.125 in}
! WARNING
If a pad which has become thinner than the limit is left unreplaced, the
rotor may be damaged by the pad back-plate and the braking force will
be badly degraded. Be sure to check carefully the worn state of the
brake pad of all wheels.
2. BRAKE FLUID LEAK AND POWER STEERING FLUID LEAK

(1) Check for fluid leaks.
a. Fluid leaks from lines.
With the brake pedal depressed, visually check for leaks of brake
fluid from the brake hydraulic line including the pipes, connection,
hoses, etc. If any leak is found, repair or replace with the corre-
sponding parts.
b. When checking for leaks, check also the following items and
repair or replace with the corresponding parts as required.
a) Check that the pipes and hoses are not hitting or rubbing other
parts. Check that the pipe clips are not loose.
b) Check that the pipes have no cracks and that they have not
become rusty.
c) Check that the hoses are not deteriorated, deformed, or swol-
len.
NOTICE
As a general rule, the brake hoses should be replaced with new ones
every year. When any defects as above have been found, replace
immediately with new ones.
c. Fluid leaks from components other than lines.
If the pedal stroke gradually increases as the brake pedal is kept
pressed (in the worst case the brake pedal reaches the cab floor),
a probable cause is that there is an internal leak in any one of the
following components;
• Master cylinder
• Hydraulic booster
• Caliper piston in wheel brake
3. BRAKE FLUID
When the brake fluid is used for a long time, water may get into
the brake fluid and its boiling point may become low, thereby
causing a possibility of vapor lock which is very dangerous.
Replace old brake fluid with fresh brake fluid (Use DOT3 or DOT4
brake fluid) every year.
(1) Hydraulic brake fluid color check
• Check the color of the brake fluid in the brake fluid reservoir.
• Check that the color is as specified by FMVSS116 (transparent or
amber).
• Replace the brake fluid if it has become discolored.
• Probable causes of discoloration are as follows:
.
a. Thermal load
b. Aging
c. Oxidation
d. Ingression of mineral oil
(2) Brake fluid level check.
Check the fluid level of the brake fluid reservoir which is located under
the hood on the driver side of the vehicle. Fluid level should be within
1 inch below bottom of ring. Replenish reservoir with DOT3 or DOT4
brake fluid to bottom of ring if fluid level drops below 1 inch.
NOTICE
Be sure to use clean brake fluid. Note that if a foreign substance is
mixed with the brake fluid, components of the brake line may be dam-
aged and their functions may be degraded, thereby causing insuffi-
cient braking force.
• Before removing the brake fluid reservoir cap, clean the vicinity
SAPH06ABC0200001 of the cap.
• If foreign matter has settled on the bottom of the reservoir, clean
the reservoir.
• Check that the container and tools used for brake fluid replenish-
ment are clean. If they are dusty or dirty, clean them.
• Be sure to clean the strainer of the reservoir when replacing the
brake fluid.
• Brake fluid is highly hygroscopic, and absorbs moisture. Be sure
to securely tighten the caps of the containers to prevent entry of
moisture.
• Do not leave the reservoir cap removed for a long time.
• When replenishing or replacing brake fluid outdoors on a rainy
day, exercise care so that no water gets into the brake fluid.
• Pay attention that no mineral oil is mixed into brake fluid. Mineral
oil will cause swelling of the rubber parts of the brake line, caus-
ing insufficient braking force.
• Do not mix different types of brake fluid.
4. BRAKE PRESSURE WARNING LIGHT

(1) Check for brake pressure warning light failure.
If the brake pressure warning light does not turn on when the starter
switch is turned to the ON position, the light has burned out. Replace
any burned out light with a new one.
SAPH06ABC0200002
(2) Check the differential pressure switch.

Purposely loosen either the front or rear brake line.
Start the engine, depress the brake pedal and confirm that the warn-
ing lights up. Confirm warning light condition with other brake line
(front and rear). If in both conditions the warning light comes on, the
differential pressure switch is normal.
SAPH06ABC0200003
HYDRO-MAX HYDRAULIC BRAKE BOOSTER AND MASTER

CYLINDER
EN06ABC02I200001
Manufacturer BOSCH
Type HYDRO-MAX II and master cylinder
Master cylinder diameter 50.80 mm {2.00 in}
DESCRIPTION
EN06ABC02C100001
SAPH06ABC0200004
SAPH06ABC0200005
1 Reservoir cap with diaphragm 9 Check valve seat

2 Differential pressure switch 10 Check ball
3 Tube seat 11 Hydro-Max booster assembly
4 Master cylinder assembly 12 Check ball retainer
5 Flow switch 13 Adapter
6 O-ring 14 Face seal
7 Flow piston 15 Backup pump
8 Flow piston spring 16 Backup pump relay
NOTICE
The above parts can be replaced if necessary. Any malfunctions to master cylinder or Hydro-max booster assembly
requires complete assembly replacement.
PRINCIPLE OF OPERATION
EN06ABC02C100002
1. HYDRO-MAX BOOSTER
During normal system operation, fluid flow from a hydraulic
power source (the power steering pump) enters the inlet port of
the Hydro-Max booster, flows through the power piston, around
the throttle valve and through the flow switch, exiting through
the outlet port.
Force applied to the brake pedal by the vehicle operator is multi-
plied by the lever ratio of the pedal mechanism to move the pedal
rod of the booster. This movement closes the throttle valve
which restricts flow. This restriction of flow, which results in a
pressure increase acting on the power piston, applies an ampli-
fied force to the master cylinder primary piston. A reaction pis-
ton, inside the power piston subassembly, provides the driver
"pedal feel" during an application of the brake pedal.
Fluid flow through the flow switch opens the backup pump elec-
trical circuit during normal operation. A separate check valve in
the backup pump prevents back-flow through the pump during
normal power applications. In the event normal flow from the
power source is interrupted, the backup pump provides the
power at a reduced rate for stopping. Upon flow interruption, the
Integral flow switch closes, energizing a relay, providing electri-
cal power to the backup pump.
During backup operation, the pump re-circulates fluid within the
booster assembly with pressure built on demand via the throttle
valve. Fluid is retained within the booster by the inlet port check
valve.
2. MASTER CYLINDER
The primary circuit is separated from the secondary hydraulic
circuit. Hydraulic leakage in one circuit does not affect the func-
tion of the other circuit.
A differential pressure switch is available. It illuminates a light on
the dash panel to warn when there is a pressure differential
between the primary and secondary brake circuits caused by a
leak in one circuit. This may occur when one circuit leaks or is
improperly bled.
SAPH06ABC0200006
NOTICE
This illustration is a representative model. For operation reference.
COMPONENT LOCATOR
EN06ABC02D100001
SAPH06ABC0200007
1 Brake hose 14 Stop light switch

2 Brake hose clip 15 Stop light switch cover
3 Brake pipe bracket 16 Return spring
4 Brake pipe 17 Bushing
5 Sub harness 18 Brake pedal
6 Harness clamp 19 Collar
7 Hydro-Max booster and master cylinder 20 Pedal pad
8 Retainer 21 Power steering fluid reservoir
9 Plane washer 22 Hose clamp
10 Clevis pin 23 Power steering fluid hose
11 Pedal bracket 24 Power steering fluid pipe
12 Seal 25 Pipe clamp
13 Shaft

A 20-30 {204-305, 15-22} D 33.9-40.7 {346-415, 25-30}
B 18-26 {184-265, 14-19} E 22-34 {224-346, 16-25}
C 18-26 {184-265, 14-19}
HYDRO-MAX BOOSTER
OVERHAUL
EN06ABC02H200002
IMPORTANT POINT - DISMOUNTING

! CAUTION
The Hydro-Max booster and the master cylinder use two distinctly dif-
ferent incompatible hydraulic fluids. They must not be mixed. Using
the incorrect fluid will permanently damage the seals and can cause
malfunctioning brakes.
1. BEFORE DISMOUNTING THE HYDRO-MAX BOOSTER.

(1) Be sure to block the wheels.
(2) Disconnect the battery cable from the battery ground terminal.
SAPH06ABC0200008
2. DISCONNECT THE HARNESS CONNECTORS AND HARNESS.

(1) Disconnect the connectors of differential pressure switch, flow switch,
backup pump sub harness and relay.
(2) Remove the sub harness from the backup pump terminal.
3. DISCONNECT THE HYRDAULIC HOSE AND PIPE FROM THE

HYDRO-MAX BOOSTER.
Drain the power steering fluid.
SAPH06ABC0200009
4. DISCONNECT THE MASTER CYLINDER.

HINT
• By removing the brake pipe bracket or brake hose clips, it is pos-
sible to remove the Hydro-Max booster without removing the
master cylinder from the vehicle.
• It is not necessary to disconnect the brake pipes from the master
cylinder.
(1) Remove the brake pipe bracket or brake hose clips.
(2) Remove the nuts to disconnect the master cylinder.
SAPH06ABC0200010
5. REMOVE THE HYDRO-MAX BOOSTER.

(1) Remove the stop lamp switch cover.
(2) Remove the clevis pin to disconnect the brake pedal, stop light switch
and push rod.
(3) Remove the Hydro-Max booster tightening nuts.
(4) Move the master cylinder forward to allow for the Hydro-Max booster
removal and support it in that position.
(5) Remove the Hydro-Max booster.
SAPH06ABC0200011
IMPORTANT POINS - DISASSEMBLY
1. REMOVE THE BACKUP PUMP.

(1) Remove the two tightening bolts.
(2) Remove the backup pump and adapter.
! CAUTION
Do not damage the contact surface.
NOTICE
The power steering fluid will drain out from Hydro-Max booster.
(3) Remove and discard the four face seals.
SAPH06ABC0200012 (4) Remove the check ball. (If necessary)
2. REMOVE THE FLOW SWITCH ASSEMBLY.

(1) Remove the flow switch.
(2) Remove and discard the O-ring from the flow switch.
(3) Using a small magnet, remove the flow piston and spring.
SAPH06ABC0200013
3. REMOVE THE INLET CHECK VALVE.

O-RING (1) Using a hook wire remove and discard the inlet check valve seat with
O-ring from inlet port.
CHECK VALVE SEAT
(2) Remove the check ball.
CHECK BALL 4. USE CLEAN POWER STEERING FLUID FOR CLEANING THE
REUSED PARTS AND NEW SEALS.
! CAUTION
Do not use brake fluid.
SAPH06ABC0200014

O-RING
1. INSTALL THE INLET CHECK VALVE.
CHECK VALVE SEAT (1) Install the check ball to inlet port.
(2) Lubricate and install the O-ring in the inlet check seat.
CHECK BALL (3) Install the inlet check valve seat.
SAPH06ABC0200015
2. INSTALL THE FLOW SWITCH ASSEMBLY.

(1) Install the flow spring and piston.
(2) Lubricate and install the O-ring in the flow switch.
(3) Install the flow switch.
Tightening Torque:
2.3-4.5 N⋅m{23-45 kgf⋅cm, 20.4-39.8 lbf⋅in}
SAPH06ABC0200016
3. INSTALL THE BACKUP PUMP

(1) Install the check ball in the delivery port (If removed). If not replaced,
make sure the check ball is in the delivery port.
(2) Lubricate and install the four face seals in the adapter and backup
pump.
(3) Install the adapter and backup pump.
NOTICE
Ensure that the delivery ports for hydraulic pump, adaptor and Hydro-
Max booster correspond during installation.
Do not confuse mating surfaces.
Install the backup pump in its proper position.
SAPH06ABC0200017 (4) Tighten the two bolts.
Tightening Torque:
24.5-33.9 N⋅m {250-345 kgf⋅cm, 18-25 lbf⋅ft}
1. INSTALL THE HYDRO-MAX BOOSTER.

(1) Install the Hydro-Max booster and tighten the nuts.
Tightening Torque:
33.9-40.7 N⋅m {346-415 kg⋅cm, 25-30 lbf⋅ft}
(2) Install the clevis pin to connect the brake pedal, stop light switch and
push rod.
(3) Install the stop light switch cover.
SAPH06ABC0200018
SAPH06ABC0200019
2. CONNECT THE MASTER CYLINDER.

(1) Connect the master cylinder to Hydro-Max booster and tighten the
nuts.
Tightening Torque:
33.9-40.7 N⋅m {346-415 kgf⋅cm, 25-30 lbf⋅ft}
(2) Install the brake pipe bracket or brake hose clips.
SAPH06ABC0200020
3. CONNECT THE HYRDAULIC HOSE AND PIPE FROM THE

HYDRO-MAX BOOSTER.
(1) Connect hydraulic pipe and tighten the flare nut.
Tightening Torque:
22-34 N⋅m {224-346 kgf⋅cm, 16-25 lbf⋅ft}
SAPH06ABC0200021
(2) Connect hydraulic hose and tighten the clamp.

Tighten the clamp until dimension L=4-5 mm (0.16-0.19 in).
SAPH06ABC0200022
4. CONNECT THE HARNESS CONNECTORS AND HARNESS.

(1) Install the sub harness to the backup pump terminal.
(2) Connect the connectors of differential pressure switch, flow switch,
backup pump sub harness and relay.
5. CONNECT THE BATTERY CABLE TO THE BATTERY GROUND

TERMINAL.
6. BLEEDING OF HYDRO-MAX SYSTEM.

Refer to POWER STEERING SYSTEM AIR BLEEDING of chapter
"BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE)"
SAPH06ABC0200023
BR01-11.
! WARNING
Any Hydro-Max booster or brake hydraulic line removed or discon-
nected should be properly bled before attempting to move the vehicle,
as the braking force will not be sufficient.
7. BLEEDING OF BRAKE HYDRAULIC SYSTEM

If the master cylinder was removed, bleed the brake hydraulic
system.
Refer to BRAKE SYSTEM AIR BLEEDING of chapter "BRAKE
EQUIPMENT (MODELS WITH HYDRAULIC BRAKE)" BR01-9.
8. BRAKE PEDAL HEIGHT

Check that the pedal height H. from the floor is within the stan-
dard dimension.
Standard: 152.5-162.5 mm {6.0-6.3 in}
SAPH06ABC0200024
MASTER CYLINDER
OVERHAUL
EN06ABC02H200003
IMPORTANT POINTS-DISMOUNTING
! WARNING
If the brake pressure warning light continues to light up after the
engine has started, the vehicle should not be operated for safety rea-
sons. During normal driving a longer stopping distance is required so
extreme caution should be taken as there is a risk of personal injury
or property damage.
SAPH06ABC0200025
1. BLOCK THE WHEELS.
2. DISCONNECT THE BRAKE PIPES.

(1) Drain the fluid from the master cylinder into a container.
(2) Disconnect the brake pipe from the master cylinder.
NOTICE
Observe the position of the brake pipe to master cylinder before
removal to prevent mix-up during assembly.
(3) Cover the pipe end to prevent entry of foreign matter.
SAPH06ABC0200026
3. DISCONNECT THE MASTER CYLINDER.

(1) Remove the tightened nuts.
(2) Disconnect the master cylinder.
SAPH06ABC0200027
1. INSTALL THE PRESSURE DIFFERENTIAL SWITCH.

Tightening Torque:
1.1-1.7 N⋅m {11-17 kgf⋅cm, 9.7-15 lbf⋅in}
SAPH06ABC0200028
2. INSTALL THE TUBE SEAT.

(1) If the tube seat was removed, install the new parts.
Press the tube seat by using a tube nut.
Make sure the seat is completely inserted in the bottom.
(2) Check installation condition of the sealing surface.
If necessary, clean and rinse the master cylinder ports to remove any
metal fragments.
TUBE SEAT
TUBE NUT
SAPH06ABC0200029
1. CONNECT THE MASTER CYLINDER.

(1) Connect the master cylinder to Hydro-Max booster.
(2) Tighten the nut.
Tightening Torque:
33.9-40.7 N⋅m {346-415 kgf⋅cm, 25-30 lbf⋅ft}
SAPH06ABC0200030
2. CONNECT THE BRAKE PIPES.

(1) Remove cover from the pipe end.
(2) Connect the brake pipe to the master cylinder.
Tightening Torque:
20-30 N⋅m {204-305 kgf⋅cm, 15-22 lbf⋅ft}
3. BRAKE SYSTEM AIR BLEEDING.

Refer to BRAKE SYSTEM AIR BLEEDING of chapter "BRAKE
EQUIPMENT (MODELS WITH HYDRAULIC BRAKE) BR01-09.
SAPH06ABC0200031
PRESSURE TESTS
EN06ABC020000001
1. CHECK THE BRAKE LINE PRESSURE.

(1) To measure the brake line pressure, install a 0 to 13,800 kPa {140 kgf/
cm2, 2,000 lbf/in2} gauge to the brake caliper.
(2) Depress the brake pedal while the engine is not running.
The backup pump should start and produce pressure approximately
5,515 kPa {56 kgf/cm2, 800 lbf/in2}.
(3) Warm-up the engine until the power steering fluid reaches normal
operating temperature.
(4) Depress the brake pedal while the engine is at idling speed.
The pressure should be approximately 12,400 kPa {126 kgf/cm2,
1,800 lbf/in2}.
2. AIR BLEEDING
(1) Remove the pressure gauge.
(2) Bleed air from the pressure gauge installed line.
ABS MODULATOR
EN06ABC020000002
Manufacturer MERITOR WABCO

Type Hydraulic ABS modulator
DESCRIPTION
EN06ABC020000003
SAPH06ABC0200032
NOTICE
For removal and installation of ABS MODULATOR. refer to chapter "ABS (ANTI-LOCK BRAKE SYSTEM)" BR03 of
MERITOR WABCO Maintenance Manual 39.
DISC BRAKE CALIPER

EN06ABC020000004
Manufacturer MERITOR
Type Tow-Piston, Caliper Four-Piston, Caliper
Vehicle Model HINO 145 (NA6J) : Front, Rear HINO 185 (NC6J) : Rear
HINO 165 (NB6J) : Front, Rear HINO 238 (ND8J) : Front, Rear
HINO 185 (NC6J) : Front HINO 268 (NE8J) : Front, Rear
HINO 308 (NF8J) : Front, Rear
DESCRIPTION
EN06ABC020000005
2-PISTON FLOATING CALIPER
SAPH06ABC0200033
NOTICE
For overhaul or replacement of parts, refer to MERITOR maintenance manual MM-0328.
4-PISTON FIXED MOUNT CALIPER
SAPH06ABC0200034
NOTICE
For overhaul or replacement of parts, refer to MERITOR maintenance manual MM-2075.
Maintenance Manual MM-0328

Reaction Beam Hydraulic Disc Brake
Caliper Assembly
Issued 10-03
Service Notes
About This Manual ArvinMeritor’s Customer Service Center

This manual provides instructions for the Meritor reaction beam Call ArvinMeritor’s Customer Service Center at 800-535-5560.
hydraulic disc brake caliper assembly.
Technical Electronic Library on CD
Before You Begin The DriveTrain Plus™ by ArvinMeritor Technical Electronic Library
on CD contains product and service information for most Meritor,
1. Read and understand all instructions and procedures before
you begin to service components. ZF Meritor LLC and Meritor WABCO products. $20. Specify
TP-9853.
2. Read and observe all Warning and Caution hazard alert
messages in this publication. They provide information that can How to Obtain Tools and Supplies Specified
help prevent serious personal injury, damage to components,
in This Manual
or both.
Call ArvinMeritor’s Commercial Vehicle Aftermarket at
3. Follow your company’s maintenance and service, installation,
888-725-9355 to obtain Meritor tools and supplies.
and diagnostics guidelines.
4. Use special tools when required to help avoid serious personal
injury and damage to components.
Hazard Alert Messages and Torque Symbols

WARNING
A Warning alerts you to an instruction or procedure that you
must follow exactly to avoid serious personal injury and
damage to components.
CAUTION
A Caution alerts you to an instruction or procedure that you
must follow exactly to avoid damage to components.
@ This symbol alerts you to tighten fasteners to a specified torque

value.
How to Obtain Additional Maintenance and

Service Information
On the Web
Visit the DriveTrain Plus™ by ArvinMeritor Tech Library at
arvinmeritor.com to easily access product and service information.
The Library also offers an interactive and printable Literature Order
Form.
Information contained in this publication was in effect 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.
Meritor Maintenance Manual MM-0328

Contents
pg. i Asbestos and Non-Asbestos Fibers

1 Section 1: Exploded View
2 Section 2: Introduction
Operation
3 Section 3: Removal and Disassembly
Hazard Alert Messages
Removal
Pads
4 Caliper
Rotor
Disassembly
Caliper
5 Removal
Guide Pin
6 Section 4: Prepare Parts for Assembly
Clean, Dry and Inspect Parts
Clean Parts
Dry and Inspect Parts
7 Section 5: Assembly and Installation
Assembly
Caliper
8 Installation
Guide Pin
Rotor
9 Caliper
Pad
Bleed the Brakes
10 Section 6: Maintenance
Maintenance
Cleaning and Inspection
11 Section 7: Troubleshooting
Brakes
13 Section 8: Specifications
Torque Specifications

The following procedures for servicing brakes are recommended to reduce exposure to The following procedures for servicing brakes are recommended to reduce exposure to
asbestos fiber dust, a cancer and lung disease hazard. Material Safety Data Sheets are non-asbestos fiber dust, a cancer and lung disease hazard. Material Safety Data
available from ArvinMeritor. Sheets are available from ArvinMeritor.
Because some brake linings contain asbestos, workers who service brakes must understand the Most recently manufactured brake linings do not contain asbestos fibers. These brake linings may
potential hazards of asbestos and precautions for reducing risks. Exposure to airborne asbestos contain one or more of a variety of ingredients, including glass fibers, mineral wool, aramid fibers,
dust can cause serious and possibly fatal diseases, including asbestosis (a chronic lung disease) ceramic fibers and silica that can present health risks if inhaled. Scientists disagree on the extent
and cancer, principally lung cancer and mesothelioma (a cancer of the lining of the chest or of the risks from exposure to these substances. Nonetheless, exposure to silica dust can cause
abdominal cavities). Some studies show that the risk of lung cancer among persons who smoke silicosis, a non-cancerous lung disease. Silicosis gradually reduces lung capacity and efficiency
and who are exposed to asbestos is much greater than the risk for non-smokers. Symptoms of and can result in serious breathing difficulty. Some scientists believe other types of non-asbestos
these diseases may not become apparent for 15, 20 or more years after the first exposure to fibers, when inhaled, can cause similar diseases of the lung. In addition, silica dust and ceramic
asbestos. fiber dust are known to the State of California to cause lung cancer. U.S. and international
Accordingly, workers must use caution to avoid creating and breathing dust when servicing agencies have also determined that dust from mineral wool, ceramic fibers and silica are potential
brakes. Specific recommended work practices for reducing exposure to asbestos dust follow. causes of cancer.
Consult your employer for more details. Accordingly, workers must use caution to avoid creating and breathing dust when servicing
brakes. Specific recommended work practices for reducing exposure to
Recommended Work Practices non-asbestos dust follow. Consult your employer for more details.
1. Separate Work Areas. Whenever feasible, service brakes in a separate area away from other Recommended Work Practices
operations to reduce risks to unprotected persons. OSHA has set a maximum allowable level of
exposure for asbestos of 0.1 f/cc as an 8-hour time-weighted average and 1.0 f/cc averaged over 1. Separate Work Areas. Whenever feasible, service brakes in a separate area away from other
a 30-minute period. Scientists disagree, however, to what extent adherence to the maximum operations to reduce risks to unprotected persons.
allowable exposure levels will eliminate the risk of disease that can result from inhaling asbestos 2. Respiratory Protection. OSHA has set a maximum allowable level of exposure for silica of 0.1
dust. OSHA requires that the following sign be posted at the entrance to areas where exposures mg/m3 as an 8-hour time-weighted average. Some manufacturers of non-asbestos brake linings
exceed either of the maximum allowable levels: recommend that exposures to other ingredients found in non-asbestos brake linings be kept
DANGER: ASBESTOS below 1.0 f/cc as an 8-hour time-weighted average. Scientists disagree, however, to what extent
CANCER AND LUNG DISEASE HAZARD adherence to these maximum allowable exposure levels will eliminate the risk of disease that can
AUTHORIZED PERSONNEL ONLY result from inhaling non-asbestos dust.
RESPIRATORS AND PROTECTIVE CLOTHING Therefore, wear respiratory protection at all times during brake servicing, beginning with the
ARE REQUIRED IN THIS AREA. removal of the wheels. Wear a respirator equipped with a high-efficiency (HEPA) filter
2. Respiratory Protection. Wear a respirator equipped with a high-efficiency (HEPA) filter approved by NIOSH or MSHA, if the exposure levels may exceed OSHA or manufacturers’
approved by NIOSH or MSHA for use with asbestos at all times when servicing brakes, beginning recommended maximum levels. Even when exposures are expected to be within the maximum
with the removal of the wheels. allowable levels, wearing such a respirator at all times during brake servicing will help minimize
3. Procedures for Servicing Brakes. exposure.
a. Enclose the brake assembly within a negative pressure enclosure. The enclosure should be 3. Procedures for Servicing Brakes.
equipped with a HEPA vacuum and worker arm sleeves. With the enclosure in place, use the a. Enclose the brake assembly within a negative pressure enclosure. The enclosure should be
HEPA vacuum to loosen and vacuum residue from the brake parts. equipped with a HEPA vacuum and worker arm sleeves. With the enclosure in place, use the
b. As an alternative procedure, use a catch basin with water and a biodegradable, non- HEPA vacuum to loosen and vacuum residue from the brake parts.
phosphate, water-based detergent to wash the brake drum or rotor and other brake parts. b. As an alternative procedure, use a catch basin with water and a biodegradable, non-
The solution should be applied with low pressure to prevent dust from becoming airborne. phosphate, water-based detergent to wash the brake drum or rotor and other brake parts.
Allow the solution to flow between the brake drum and the brake support or the brake rotor The solution should be applied with low pressure to prevent dust from becoming airborne.
and caliper. The wheel hub and brake assembly components should be thoroughly wetted to Allow the solution to flow between the brake drum and the brake support or the brake rotor
suppress dust before the brake shoes or brake pads are removed. Wipe the brake parts and caliper. The wheel hub and brake assembly components should be thoroughly wetted to
clean with a cloth. suppress dust before the brake shoes or brake pads are removed. Wipe the brake parts
c. If an enclosed vacuum system or brake washing equipment is not available, employers may clean with a cloth.
adopt their own written procedures for servicing brakes, provided that the exposure levels c. If an enclosed vacuum system or brake washing equipment is not available, carefully clean
associated with the employer’s procedures do not exceed the levels associated with the the brake parts in the open air. Wet the parts with a solution applied with a pump-spray
enclosed vacuum system or brake washing equipment. Consult OSHA regulations for more bottle that creates a fine mist. Use a solution containing water, and, if available, a
details. biodegradable, non-phosphate, water-based detergent. The wheel hub and brake assembly
d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA for use with components should be thoroughly wetted to suppress dust before the brake shoes or brake
asbestos when grinding or machining brake linings. In addition, do such work in an area with pads are removed. Wipe the brake parts clean with a cloth.
a local exhaust ventilation system equipped with a HEPA filter. d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA when grinding or
e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a HEPA machining brake linings. In addition, do such work in an area with a local exhaust ventilation
filter when cleaning brake parts or assemblies. NEVER use carcinogenic solvents, system equipped with a HEPA filter.
flammable solvents, or solvents that can damage brake components as wetting agents. e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a HEPA
4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or by wet filter when cleaning brake parts or assemblies. NEVER use carcinogenic solvents,
wiping. NEVER use compressed air or dry sweeping to clean work areas. When you empty flammable solvents, or solvents that can damage brake components as wetting agents.
vacuum cleaners and handle used rags, wear a respirator equipped with a HEPA filter approved 4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or by wet
by NIOSH or MSHA for use with asbestos. When you replace a HEPA filter, wet the filter with a fine wiping. NEVER use compressed air or dry sweeping to clean work areas. When you empty
mist of water and dispose of the used filter with care. vacuum cleaners and handle used rags, wear a respirator equipped with a HEPA filter approved
5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or smoke. by NIOSH or MSHA, to minimize exposure. When you replace a HEPA filter, wet the filter with a
Shower after work. Do not wear work clothes home. Use a vacuum equipped with a HEPA filter to fine mist of water and dispose of the used filter with care.
vacuum work clothes after they are worn. Launder them separately. Do not shake or use 5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or smoke.
compressed air to remove dust from work clothes. Shower after work. Do not wear work clothes home. Use a vacuum equipped with a HEPA filter to
6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with care, vacuum work clothes after they are worn. Launder them separately. Do not shake or use
such as in sealed plastic bags. Consult applicable EPA, state and local regulations on waste compressed air to remove dust from work clothes.
disposal. 6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with care,
such as in sealed plastic bags. Consult applicable EPA, state and local regulations on waste
Regulatory Guidance disposal.
References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the United States, Regulatory Guidance
are made to provide further guidance to employers and workers employed within the United
States. Employers and workers employed outside of the United States should consult the References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the United States,
regulations that apply to them for further guidance. are made to provide further guidance to employers and workers employed within the United
States. Employers and workers employed outside of the United States should consult the
regulations that apply to them for further guidance.
Meritor Maintenance Manual MM-0328 i

1 Exploded View
1 Exploded View
Figure 1.1
GUIDE PIN
BLEED SCREW HOLE CAP
DUST CAP BRIDGE
BOLT
CALIPER
BODY
PISTON
SEAL
DUST BOOT
BRIDGE
INNER
PAD
GUIDE
PIN BOLT
GUIDE PIN
SLEEVE
GUIDE PIN
BOOT
PAD
RETAINING BOLT
PLATE
CARRIER
OR SADDLE
OUTER
PAD
4001496b
Meritor Maintenance Manual MM-0328 1

2 Introduction
Operation
2 Introduction
The reaction beam hydraulic disc brake caliper assembly consists of

a caliper housing and carrier, or saddle. The carrier is bolted directly
to the torque plate. The torque plate is bolted onto the axle or may
be integral with the axle. The caliper assembly slides on sealed and
lubricated guide pin sleeves projecting from the carrier.
Hydraulic fluid pressure is applied to the rear of the pistons. The
pistons move outward and push the inner pad onto the rotor.
Figure 2.1. The caliper assembly slides on the guide pin sleeves and
brings the outer pad into contact with the rotor. The clamp load on
both sides of the rotor is equal when the brake is applied. When the
hydraulic pressure is released, the piston’s seal retracts the pistons.
Figure 2.1
4001497a
Figure 2.1
2 Meritor Maintenance Manual MM-0328

3 Removal and Disassembly
Hazard Alert Messages 2. Remove the master cylinder reservoir filler cap. Check the
brake fluid level in the reservoir. If necessary, remove fluid to

Read and observe all Warning and Caution hazard alert messages in
keep the reservoir from overflowing when compressing pistons
this publication. They provide information that can help prevent
into the caliper.
serious personal injury, damage to components, or both.
3. Remove the pad retaining plate bolt and remove the pad
WARNING retaining plate. Figure 3.1.
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance and service. Figure 3.1
PAD
RETAINING BOLT
ASBESTOS AND NON-ASBESTOS FIBERS PLATE
WARNING
Some brake linings contain asbestos fibers, a cancer and lung
disease hazard. Some brake linings contain non-asbestos
fibers, whose long-term effects to health are unknown.
You must use caution when you handle both asbestos and
non-asbestos materials. 4003809a
Figure 3.1
Removal
4. Remove the inner pad.
WARNING
Park the vehicle on a level surface. Block the wheels to 5. Compress the caliper pistons. Figure 3.2. Check that the piston
prevent the vehicle from moving. Support the vehicle with boots are not damaged.
safety stands. Do not work under a vehicle supported only by
jacks. Jacks can slip and fall over. Serious personal injury and Figure 3.2
damage to components can result.
1. Park the vehicle on a level surface. Block the wheels to prevent

the vehicle from moving.
2. Use a jack to raise the vehicle so that the wheels to be serviced
are off the ground. Support the vehicle with safety stands.
3. Remove the wheel and tire assembly according to the vehicle
manufacturer’s recommendation.
Pads
1. Visually inspect all brake pads. Replace pads when the lining
reaches 0.08-inch (2.0 mm) thickness. 4001499a
If you replace the pads: Replace all disc brake pads on
Figure 3.2
the same axle at the same time to maintain original brake
balance.
6. Remove the outer pad. Slide the caliper assembly, if necessary,
If a complete vehicle pad replacement is not necessary to remove the outer pad.
or desirable: Replace the pads on both wheel ends on the
same axle.

Caliper Disassembly
1. Disconnect the flexible hose from the caliper.
Caliper
2. Remove the caliper assembly by removing the four bolts
1. Do not loosen or remove the guide pin bolts unless you are
attaching the carrier to the axle and place it on a suitable
replacing the guide pin bolts or sleeves. Refer to the guide pin
workbench. Figure 3.3.
removal procedure in this section.
Figure 3.3
2. Remove the pads. Refer to the pad removal procedure in this
section.
3. Use a block of wood to prevent the pistons from hitting the
caliper bridge when you remove them. Figure 3.4.
Figure 3.4
Keep your hands clear

of both pistons.
4001501a
Figure 3.3
3. Open the bleed screw. Allow the fluid to drain through the
bleed tubes into an appropriate container. Do not reuse the
brake fluid drained from the system.
4001502a
Rotor
Figure 3.4
NOTE: The resurfaced rotor thickness must exceed the minimum
thickness dimension stamped or cast into the rotor. Replace the 4. Gradually apply compressed air to the inlet ports to remove
rotor if necessary. each piston. Do not completely remove the first piston from the
caliper body until the second piston has loosened enough to
1. Check the rotor while assembled to the hub and mounted on remove them both. If you remove the first piston, you cannot
the axle spindle. The lateral runout of the rotor friction surfaces build enough air pressure inside the caliper body to loosen the
should not exceed 0.01-inch (0.25 mm) total indicator reading second piston.
(TIR). The thickness variation of the rotor should not exceed
0.0012-inch (0.0300 mm). 5. Remove the piston dust boots and seals.
If the lateral runout or the thickness variation exceeds 6. Remove the guide pin hole caps. Remove and discard the
the above values: Resurface or replace the rotor. caliper bridge bolts. Do not reuse these bolts. Remove the
caliper bridge. Figure 3.5.
2. Remove the caliper. Refer to the caliper removal procedure in
this section.
3. Remove the hub and rotor assembly from the axle according to
the vehicle manufacturer’s procedure.
4. Remove the bolts that secure the hub to the rotor.

Figure 3.5
2. Support the caliper body. Remove the bolts from the carrier.
Remove the caliper body.
3. Remove the socket head guide pin bolts while holding the
guide pin sleeves. Figure 3.7.
Figure 3.7
4001503a
Figure 3.5
7. Remove the guide pin dust boots. Slide the caliper body off the
guide pins. Remove the guide pin dust boots.
Removal 4001505a
Guide Pin Figure 3.7
NOTE: Guide pin bolts should not be removed unless you are 4. Remove the guide pin sleeves. Remove the guide pin dust
replacing the guide pin sleeves or bolts. boots.
1. Remove the guide pin hole caps. Figure 3.6. Loosen both bolts
in the carrier.
Figure 3.6
4001504a
Figure 3.6

4 Prepare Parts for Assembly
Hazard Alert Messages 2. Use a wire brush to clean fastener and fitting threads.
4 Prepare Parts for Assembly
Read and observe all Warning and Caution hazard alert messages in 3. Remove mud and dirt on the linings. Replace all linings
this publication. They provide information that can help prevent contaminated with oil or grease.
WARNING 1. Use soft, clean paper or cloth rags to completely dry parts
To prevent serious eye injury, always wear safe eye protection immediately after you clean them.
when you perform vehicle maintenance or service.
2. Carefully inspect all parts for wear or damage before you
ASBESTOS AND NON-ASBESTOS FIBERS assemble them.
WARNING 3. Repair or replace worn or damaged parts.
Some brake linings contain asbestos fibers, a cancer and lung
disease hazard. Some brake linings contain non-asbestos Corrosion Protection
fibers, whose long-term effects to health are unknown.
1. Apply DOT 3 brake fluid to cleaned, dried parts. Be careful that
You must use caution when you handle both asbestos and
you do not apply the brake fluid to the linings or rotor. Verify
non-asbestos materials.
that the linings and rotor are clean of brake fluid or other dirt
and grease.
2. If you will store the parts, apply a special material, which
Clean Parts prevents corrosion and rust, to all surfaces. Store parts inside
special paper or other material that prevents rust and
WARNING corrosion.
Solvent cleaners can be flammable, poisonous and cause
burns. Examples of solvent cleaners are carbon tetrachloride,
and emulsion-type and petroleum-base cleaners. Read the
manufacturer’s instructions before using a solvent cleaner,
then carefully follow the instructions. Also follow the
procedures below.
Wear safe eye protection.
Wear clothing that protects your skin.
Work in a well-ventilated area.
Do not use gasoline, or solvents that contain gasoline.
Gasoline can explode.
You must use hot solution tanks or alkaline solutions
correctly. Read the manufacturer’s instructions before
using hot solution tanks and alkaline solutions. Then
carefully follow the instructions.
CAUTION
Do not use hot solution tanks or water and alkaline solutions to
clean ground or polished parts. Damage to parts can result.
1. Use new heavy-duty DOT 3 brake fluid or equivalent, clear

methylated spirits or isopropyl alcohol to clean parts.

5 Assembly and Installation

Figure 5.2
WARNING
ASBESTOS AND NON-ASBESTOS FIBERS

4001507a
WARNING
Some brake linings contain asbestos fibers, a cancer and lung Figure 5.2
disease hazard. Some brake linings contain non-asbestos
fibers, whose long-term effects to health are unknown. 4. With assistance, open up the dust boot and slide the piston
You must use caution when you handle both asbestos and through the dust boot and down the bore. Figure 5.3. Ensure
non-asbestos materials.
that the piston does not trap or cut the dust cover. Release the
dust boot, pucker it to release any trapped air and settle it into
Assembly the groove in the piston.
Caliper Figure 5.3
1. Use new heavy-duty DOT 3 or equivalent brake fluid to

Ensure that the piston
lubricate parts. does not trap or cut
the dust cover.
2. Install a new piston seal into the caliper body groove.
Figure 5.1.
Figure 5.1
4001508a
4001506a
Figure 5.3
Figure 5.1
5. Repeat the same procedure with the other piston.

3. Install the dust boot into the caliper body groove. Figure 5.2.
6. Install the guide pin dust boots into the caliper body. Verify that
they are located correctly by gently pulling.
7. Use the special grease provided to grease the bores and inside
the sleeves.

8. Support the carrier. Slide the guide pins through the dust boots Rotor
into their bores in the caliper body. Install the dust boots into
their grooves in the guide pin sleeves. NOTE: Do not resurface a new replacement rotor.
9. Position and support the bridge against the caliper body.
1. Examine the rotor for corrosion, grooving and deep crazing.
Use new bridge bolts and tighten them to 70-85 lb-ft Surface crazing is acceptable. Repair or replace as necessary.
(95-115 N폷m).@
Resurface rotors and use as required. Discard rotors that
require resurfacing equal to or below the discard dimension
Installation shown on the rotor.
Guide Pin 2. Remove all scale and rust from around the edge of the rotor.
Do not damage the dust boots. Place a scraper against the
1. Install the guide pin dust boots into the caliper body. Verify that
caliper body and rotate the rotor to remove most of the
they are located correctly by gently pulling.
corrosion. Use an emery cloth to finish cleaning the rotor.
2. Use the special grease provided to grease the bores and inside Figure 5.5.
the sleeves.
Figure 5.5
3. Install the guide pin bolts into the sleeves and slide them
carefully through the dust boots into the bores. Place the dust
boots into their groove in the sleeves.
4. Install the caliper body onto the carrier. Hand-tighten the guide
pin bolts. Verify that the caliper slides easily on the sleeves.
First tighten the bolt on the side marked with the “T” or “>”
symbol to 70-85 lb-ft (95-115 N폷m). Figure 5.4. Tighten the
other bolt to 70-85 lb-ft (95-115 N폷m).@
Figure 5.4
4001500a
Figure 5.5
3. Verify that the mating surfaces of the hub and rotor are clean
4003781a
and free of rust build-up.
BOSS
4. Install the bolts that secure the hub to the rotor.
Figure 5.4
5. Install the hub and rotor assembly onto the axle according to
5. Verify that the caliper slides easily on the sleeves. If necessary, the vehicle manufacturer’s procedure.
loosen the guide pin bolts, slide the caliper and re-tighten the 6. Install the caliper. Refer to the caliper installation procedure in
bolts. this section.
6. The caliper body must be installed as far down the guide pins 7. Check the rotor for lateral runout.
as possible. Tap or screw in the guide pin hole caps.
If the lateral runout exceeds 0.010-inch (0.25 mm):
The rotor may be rotated to a different mounting hole
position on the hub to reduce the value.

Caliper
1. Install the caliper assembly by installing the four bolts to
the carrier and axle. Tighten the bolts to 81-96 lb-ft
(110-130 N폷m).@
2. Install the pads per the procedure in this section.
3. Slide the caliper assembly inboard. Inspect the piston dust
boots.
If the dust boots are damaged or cracked: Inspect the
pistons for corrosion. Replace the pistons and seals as
necessary.
If the pistons are not damaged or corroded: New dust
boots can be installed.
Pad
1. Clean the pad slide faces prior to installing the pads.
2. Carefully install the new inner pad with the lining material
against the rotor. Slide the caliper assembly outboard. Install
the new outer pad.
3. Install the pad retaining plate and bolts. Tighten the bolts to
6.6-8.9 lb-ft (9-12 N폷m).@
4. Repeat the procedure for all other calipers on the vehicle.
Bleed the Brakes

1. Connect the hydraulic lines. Bleed the brakes. Apply the pedal
two or three times.
2. Check and fill the fluid reservoir with heavy-duty DOT 3 or
equivalent brake fluid as required. Install the filler cap.
3. Repeat the procedure for all the other calipers on the vehicle.
4. Check all connections for fluid leakage.
5. Install the wheel and tire assembly.
6. Remove the safety stands. Lower the vehicle. Remove the
blocks.
7. Road test the vehicle. Brake gently several times from
50-30 mph (80-50 km/h). Avoid heavy braking for the
first 100 miles (160 km).

6 Maintenance
Hazard Alert Messages 4. Check the guide pin dust boots for damage. Inspect the guide
6 Maintenance
pin sleeves for corrosion and damage. Replace parts as

necessary.
serious personal injury, damage to components, or both. 5. Use a lint-free rag to clean the guide pin bores.
WARNING
Maintenance
1. Check the pads for wear every 10,000 miles (15 000 km) or at
the preventive maintenance schedule. Install new pads when
the lining thickness has worn to 0.08-inch (2.0 mm).
2. Never allow the lining to wear below 0.059-inch (1.5 mm).
3. Examine all brake lines and flexible hoses for leaks, corrosion,
fretting and damage every 10,000 miles (15 000 km) or at the
preventive maintenance schedule.
4. Change the brake fluid every two years. Use only heavy-duty
DOT 3 brake fluid or equivalent.
5. At each pad change, examine the pistons, piston boots and
guide pin boots for damage. If there is any damage, check the
condition of the pistons and guide pin sleeves. Replace parts
as necessary.
Cleaning and Inspection

1. Use new heavy-duty DOT 3 brake fluid or equivalent, clear
methylated spirits or isopropyl alcohol to clean parts.
WARNING
Use only the recommended fluid when cleaning brake parts.
Use of gasoline, paraffin or any other mineral-based fluid is
dangerous.
2. Remove the bleed screws from the caliper body. Inspect the
piston bores for damage, scuffing and corrosion. Use wire wool
or emery cloth to clean corrosion outboard of the seal. Badly
corroded pistons must be replaced.
3. If the piston bores are not serviceable, install a new caliper
body complete with piston seals and dust boots onto the
original caliper bridge. Install new bridge bolts and tighten to
70-85 lb-ft (95-115 N폷m).@

7 Troubleshooting

7 Troubleshooting
WARNING
Brakes
Conditions Possible Causes Correction

Excessive Pedal Effort Pads worn below minimum thickness Install new pads.
Faded, overheated condition, glazed pads, blued Replace the rotor and reface pads if sufficient
or heat-checked rotors lining remains.
Grease, oil or brake fluid on linings Install new pads in the axle sets.
Seized or frozen pistons Disassemble the calipers and free pistons, or
replace the caliper.
Pedal Pulsation (Brake Excessive lateral runout of brake rotor Check with a dial indicator. Install a new rotor if the
Roughness or Chatter) runout exceeds the maximum specified.
Excessive out-of-parallelism of brake rotor Check the parallelism or rotor thickness variation
with a micrometer. Resurface the rotor or install a
new rotor if the parallelism exceeds the maximum
allowed.
Loose or worn steering or suspension parts Replace the parts and realign.
Excessive front bearing clearance Readjust the bearing to specifications.
Vehicle Pulls to One Side Brake fluid, oil or grease on linings Install new pads in the axle sets.
Unmatched linings, uneven lining wear, distorted Install new pads in the axle sets.
pads
Rough rotor surfaces on one rotor Resurface or replace the rotor in the axle sets.
Seized or frozen pistons Disassemble the caliper and repair or replace.
Loose caliper mounting bolts Tighten to specifications.
Uneven tire pressure, tread wear or size, right Equalize to the recommended pressures. Install
to left the correct size tires with good tread.
Excessive rotor parallelism or runout Resurface or replace the rotor.
Restricted hose or line Examine the hoses and lines, and replace as
necessary.
Front end out of alignment Reset the alignment.

7 Troubleshooting

Leaky Caliper Cylinder bore surface scored or corroded Disassemble the calipers, clean the bore and
replace the seals and boots.
Caliper piston seal damaged or worn Disassemble the calipers and install new seals and
boots.
Caliper piston damaged Replace the piston.
No Braking Effect or Reservoir fluid level low Check for causes of fluid leak, repair as required
Excessive Pedal Travel and refill the reservoir. Bleed the system as
needed.
Air in the hydraulic system Bleed the system.
Bleed screw loose or open Bleed the system and tighten the bleed screw.
Caliper piston seal damaged Disassemble the caliper and replace the piston
seals. Replace the piston if it is damaged.
Excessive rotor runout or bent rotor Check the rotor with a dial indicator. Install a new
rotor if the runout exceeds the maximum specified.
Worn or excessively loose wheel bearings Adjust or replace the bearings as needed.
Low quality brake fluid Drain and clean the system. Replace with the
recommended brake fluid.
Weak brake hose that expands under pressure Replace the hoses.
Brake Noise (Chatter) Excessive lateral runout of rotor Check the runout with a dial indicator. Install a new
rotor if the runout exceeds the maximum specified.
Lack of rotor parallelism Check the parallelism with a micrometer.
Resurface or install a new rotor as required.
Loose wheel bearing Readjust the bearing to the specified torque.
Brake Noise (Scraping) Rust or mud build-up on edges of rotor and on Clean or replace as necessary.
caliper housing
Worn pad or pad installed backward Replace the pads in the axle sets only with the
friction surface against the rotor.
Incorrect caliper alignment permitting rotor to Correct the alignment.
scrape on housing
Brake Noise (Groan) Pressure on the brake pedal too light Slightly increase the pedal effort to eliminate the
noise.
Brake Noise (Rattle) Excessive clearance between the shoe and caliper Install new pads.
Pad retainer plate missing or not correctly Install a new pad retainer spring or position it
positioned correctly.
Brake Noise (Squeal) Glazed pads Resurface or replace the pads in the axle sets only.
Weak pad retainer spring Install a new pad retainer spring.
Pad wear indicator contacting rotor Install new pads in the axle sets only.
Foreign material embedded in linings Replace the pads in the axle sets only.

8 Specifications
Torque Specifications
8 Specifications
Description Specification
Inlet Port, Inverted Flare Nut, M10 5.2-9.6 lb-ft (7-13 N폷m)
Pad Retainer Plate Bolt, M8 6.6-8.9 lb-ft (9-12 N폷m)
Bleed Screw, M10 5.2-9.6 lb-ft (7-13 N폷m)
Saddle-to-Axle, M12 81-96 lb-ft (110-130 N폷m)
Guide Pin Bolt, M12 Socket Head Capscrew 70-85 lb-ft (95-115 N폷m)
Bridge Bolt, M12 Socket Head Capscrew 70-85 lb-ft (95-115 N폷m)
Rotor-to-Hub Bolt, 1/2″ 75-100 lb-ft (101.7-135.6 N폷m)
Description Specification
Brake Pad —
Thickness Above Metal (New) 0.61″ (15.5 mm)
Minimum Thickness Above Metal (Discard) 0.08″ (2 mm)
Brake Fluid — High-Performance Brake Fluid DOT 3 or DOT 4
Rotor —
Thickness (New) 1.18″ (30 mm)
Thickness (Discard) 1.04″ (26.4 mm)

Meritor Heavy Vehicle Systems, LLC

2135 West Maple Road Printed in USA
Troy, MI 48084 USA
800-535-5560 Copyright 2003 Issued 10-03
arvinmeritor.com ArvinMeritor, Inc. Maintenance Manual MM-0328 (16579/24240)
Issued 01-01
$2.50
Four-Piston Quadraulic
TM
Disc Brake Caliper

Service Notes
Before You Begin

Service Notes
Access Information on
This manual provides maintenance and service ArvinMeritor’s Web Site
procedures for Meritor’s four-piston quadraulic Additional maintenance and service information
disc brake calipers. Before you begin procedures: for ArvinMeritor’s commercial vehicle systems
1. Read and understand all instructions and component lineup is also available at
procedures before you begin to service www.arvinmeritor.com.
components. To access information, click on Products &
2. Read and observe all Caution and Warning Services/Tech Library Icon/HVS Publications.
safety alerts that precede instructions or The screen will display an index of publications
procedures you will perform. These alerts help by type.
to avoid damage to components, serious
personal injury, or both. Additional Information
3. Follow your company’s maintenance and Call ArvinMeritor’s Customer Service Center at
service, installation, and diagnostics 800-535-5560 to order the following item.
guidelines.
4. Use special tools when required to help avoid Electronic Library on CD. Features product
serious personal injury and damage to and service information on most Meritor,
components. ZF Meritor and Meritor WABCO products.
$20. Order TP-9853.
Safety Alerts, Torque Symbol
and Notes
A Warning alerts you to an

WARNING instruction or procedure
that you must follow
exactly to avoid serious
personal injury and

CAUTION instruction or procedure
exactly to avoid damage to
components and possible
serious injury.
A torque symbol alerts you

to tighten fasteners to a
specified torque value.

information or suggestions
that help you correctly
1
Table of Contents
Asbestos and Non-Asbestos Fibers Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Section 1: Exploded Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Product Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Four-Piston Quadraulic Disc Brake Caliper
Caliper
Support
Hub/Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Section 3: Disassembly
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Brake Pads
Replace Brake Pads
Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Rotor
Disassemble and Overhaul the Brake Caliper
Clean, Dry and Inspect Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Clean Parts
Apply Corrosion Protection
Section 5: Assembly and Installation
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Brake Caliper
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Rotor
Caliper
Brake Pads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Assemble the Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Inspect Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Caliper
Caliper Mounting Plate
Brake System Bleeding Procedure
Section 7: Troubleshooting
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Section 8: Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
BR02_001.fm 44 ページ２００４年５月２４日月曜日午後３時３３分

asbestos dust.
1
Section 1
Exploded Views
Section 1 Views
Exploded
Previous Style
SPRING HEX
BOLT
LINING
ASSEMBLY
PISTON HEAT
BUTTON SHIELD
HEAD BOLT
PISTON
SEAL DUST DUST
SPACER BOOT
LINING BOOT PISTON
SEAL
HEAT
SHIELD
PISTON
CALIPER
HOUSING
Current Style
SPRING HEX
BOLT
LINING
ASSEMBLY
PISTON
BUTTON
HEAD BOLT
PISTON DUST
SEAL DUST BOOT PISTON
SPACER
LINING BOOT SEAL
PISTON
CALIPER
HOUSING
2
Section 2
Introduction
Product Features
Section 2
Introduction
Current Style Previous Style
Four-Piston Quadraulic Disc Metric caliper bolts SAE caliper bolts
Brake Caliper Caliper housing halves held Caliper housing halves held
together by bolts in blind together by bolts and nuts
Meritor’s quadraulic disc brakes have a holes in the bridge area. in the bridge area.
four-piston, fixed-mount caliper design for use on
both front and rear drive axles. An installation Integral piston/heat shield Separate piston and heat
includes four major components — the caliper shield
assembly, support assembly, hub/rotor assembly Phenolic piston Metal piston
and the attaching hardware.
The inboard pistons apply the inboard pads and
the outboard pistons apply the outboard pads. Caliper
Two sizes of calipers are used, 2.520-inch (64 mm) The caliper assembly consists of two halves
and 2.756-inch (70 mm). assembled with four bolts and washers.
Features of the caliper include: It includes four hydraulic piston bores, two
Designed for hydraulic brake systems. brake pads, two stainless steel lining rail covers
installed with button head bolts, a pad retainer
Hard-mounted to the anchor plate to eliminate spring and bolt, bleeder screw and crossover
caliper and anchor plate replacement. tube.
Designed with hardened stainless steel
The piston bores contain the pistons, piston
mounting surfaces, high temperature piston
seals and piston boots.
boot compound, sealed bleeder screws and
full-coverage zinc plating. The crossover tubes connect the two halves of
the caliper piston to supply brake fluid to the
Compatible with anti-lock braking systems
outboard pistons.
(ABS) and existing hydraulic systems.
Helps to increase lining life. How to Identify the Caliper
Can be adapted to fit most vehicles with a Check for an assembly number on the side of
hydraulic system that supplies to 1,800 psi the caliper.
(12,402 kPa).
Available in 33,000 lbs maximum GVWR Support
(4 x 70 mm) and maximum 24,000 lbs GVWR
(4 x 64 mm). The support assembly includes the ABS sensor
bracket attached with two screws. It also has
provisions to mount an optional splash shield
to protect the rotor and brake assembly from
road contamination. When the ABS system is not
used or the sensor is mounted through the axle
flange, the supports are not equipped with the
sensor bracket.
PREVIOUS STYLE CURRENT STYLE
3
Section 2
Introduction
Hub/Rotor
The hub and rotor assemblies consist of a
hub and rotor, fitted with bearing cups and
wheel attachment studs.
There are two types of rotors used — a
U-shaped rotor and a hat-shaped rotor.
Some rotors are equipped with a cast-in ABS
speed sensor tooth wheel, typically with
100 slots. Some rotors have separate ABS
speed sensor tooth wheels attached to the rotor
with bolts.
Front hub/rotor assemblies can have various
ABS speed sensor tooth wheels such as: a
separate ring mounted to the inboard end of the
hub, ABS teeth integral to the rotor, or a
separate ABS ring attached to the rotor by
bolts.
There are various hub configurations offered
to accept the 19.5-inch (495.3 mm) eight-hole
wheels, as well as 22.5-inch (571.5 mm) 10-hole
wheels with the hub piloted or stud piloted
system.
Figure 1.1
Figure 2.1
4
Section 3
Disassembly
Section 3
Disassembly
Figure 3.1
WARNING
To prevent serious personal injury, always wear
maintenance or service. BRAKE PAD
RETAINER
SPRING BOLT
Removal
Brake Pads
1. Visually inspect all brake pads. Replace pads
when the remaining lining reaches 1/8-inch
(3.175 mm) thickness.
If you replace pads: Replace all disc brake
pads at the same time to maintain original
brake balance.
If a complete vehicle pad replacement is Figure 3.2
not necessary or desirable: Replace the
pads on both wheel ends on the same axle.
Replace Brake Pads

1. Raise and support the vehicle.
2. Remove the wheel and tire assembly
according to manufacturer’s recommendation.
3. Remove the master cylinder reservoir filler
cap. Check the brake fluid level in the
reservoir. If necessary, remove fluid to keep
the reservoir from overflowing when
compressing pistons into the caliper.
4. Remove the pad retainer spring bolt.
Figure 3.1.
5. Compress the caliper pistons. Figure 3.2. Figure 3.3
6. Remove the brake pads. Figure 3.3.
BRAKE PAD
5
Section 3
Disassembly
Brake Caliper Figure 3.5
WARNING
wheels to prevent the vehicle from moving.
Support the vehicle with safety stands. Do not
work under a vehicle supported only by jacks.
BRAKE
Jacks can slip and fall over. Serious personal TUBE
injury can result.
1. Raise and support the vehicle.

2. Remove the tire and wheel assembly
according to manufacturer’s instructions.
3. Remove the brake hose hold down clamp bolt,
if equipped. Figure 3.4.
4. Remove the brake hose/tube from the caliper.
5. Remove four caliper-to-support assembly
bolts. Figure 3.6. Do not disassemble the four
bolts joining the two halves of the caliper.
Figure 3.4
CALIPER-TO-SUPPORT
BOLTS
BRAKE HOSE
HOLD DOWN
CLAMP BOLT
6
Section 3
Disassembly
Support 3. Remove the hub/spoke wheel and rotor

assembly from the axle according to vehicle
1. Remove the caliper from vehicle as described manufacturer’s recommendation.
in Brake Caliper in this section.
4. Remove the hub-to-rotor attachment fasteners
2. Remove the splash shield if installed from the (hat-shaped rotor). For the U-shaped rotor,
support. remove the studs holding the hub and rotor.
3. Remove the hub and rotor assembly according
to vehicle manufacturer’s recommended Disassemble and Overhaul
service procedure. the Brake Caliper
4. Remove the ABS sensor. 1. Remove the brake caliper. Refer to Brake
5. Remove the support-to-axle mounting bolts. Caliper in this section.
Figure 3.7. 2. Drain all fluid from the caliper.
3. Push all four pistons to the bottom of their
Figure 3.7 bores.
4. Remove the piston boots by prying the metal
ring portion of the boot out of the bore with a
MOUNTING screwdriver. Use care to avoid damage to the
BOLT piston or bore. Discard the boots.
NOTE: The C-clamp must be between the pistons

on the opposite side so they may move to the
wood block without striking the C-clamp. Cover
pistons with shop rag to prevent brake fluid spray.
5. Place a block of wood (7-5/8 x 3-1/2 x

2-9/16-inches thick) between the caliper
pistons. Figure 3.8. Use a C-clamp to hold the
block of wood against the pistons on one side
of the caliper.
Rotor
Figure 3.8
NOTE: The thickness of the resurfaced rotor
must exceed the minimum thickness dimension
stamped or cast into the rotor. Replace if
necessary.
1. Check the rotor while assembled to the hub or WOOD

BLOCK
spoke wheel and mounted on the axle spindle.
The lateral runout of the rotor friction surfaces
should not exceed 0.015-inches (0.381 mm)
total indicator reading (TIR). The thickness
variation of the rotor should not exceed
0.0012-inches (0.0300 mm).
If the lateral runout and/or the thickness
variation exceed the above values:
Resurface or replace the rotor.
2. Remove the caliper. Refer to Brake Caliper in
this section.
7
Section 3
Disassembly
8. To remove the pistons from the other side of

WARNING the caliper, place the block of wood now over
the empty bores (from where the pistons have
When you use compressed air to remove the
been removed) with a thick sheet of rubber
pistons form the caliper bore, do not place your
hands or fingers near the bore to catch or protect (3/8-inch) between the wood and the caliper
the pistons. Serious personal injury can result. bores.
NOTE: Use the C-clamp to hold the block of

CAUTION wood in position against the empty bores. The
C-clamp must be between the pistons on the
When you remove the pistons from the caliper opposite side so they may move out to the wood
bore, only direct enough compressed air into the block without striking the C-clamp. Cover pistons
caliper brake fluid inlet to ease the pistons out of with a shop rag to prevent brake fluid spray.
the bore. Do not exceed 25 psi (172 kPa). Damage
to components will result. 9. Apply low air pressure (no more than 25 psi
[172 kPa]) to the fluid port in the caliper to
6. Apply low air pressure (no more than 25 psi move the caliper pistons out to the wood
[172 kPa]) to the fluid port in the caliper to block.
move the caliper pistons out to the wood
block. Figure 3.9. 10. With the pistons in contact with the wood
block, there will be a small amount of seal
7. With the pistons in contact with the wood engagement remaining. Remove the C-clamp
block, there will be a small amount of seal and the wood block. The pistons may now be
engagement remaining. Remove the C-clamp removed by hand. Figure 3.10.
and the wood block. The pistons may now be
removed by hand.
Figure 3.10
Figure 3.9
AIR
SUPPLY
CALIPER
PISTON
8
Section 3
Disassembly
11. Remove the piston seals with a non-metallic

device and discard them. Figure 3.11. Do not
knick, scratch or otherwise scar piston bores
or seal grooves.
NOTE: Do not hone the caliper bores. Pistons are

not available for honed caliper bores. If the caliper
bores are excessively scored or corroded, install a
new caliper.
Figure 3.11
9
Section 4

Prepare
WARNING
1. Use soft, clean paper or cloth rags or
To prevent serious eye injury, always wear safe compressed air to completely dry parts
eye protection when you perform vehicle immediately after you clean them.
2. Carefully inspect all parts for wear or damage
Solvent cleaners can be flammable, poisonous and before you assemble them.
cause burns. Examples of solvent cleaners are 3. Repair or replace worn or damaged parts.
carbon tetrachloride, emulsion-type cleaners and
petroleum-based cleaners. To avoid serious
personal injury when you use solvent cleaners, Apply Corrosion Protection
you must carefully follow the manufacturer’s
1. Apply a thin layer of brake grease to cleaned,
instructions and these procedures:
dried parts. Be careful that you do not apply
Wear safe eye protection. the grease to the linings or rotor.
Wear clothing that protects your skin. 2. If you will store the parts, apply a special
material, which prevents corrosion and rust, to
Work in a well-ventilated area. all surfaces. Store parts inside special paper or
Do not use gasoline or solvents that contain other material that prevents rust and
gasoline. Gasoline can explode. corrosion.
You must use hot solution tanks or alkaline Figure 4.1
solutions correctly. Carefully follow the
manufacturer’s instructions.

Clean Parts
For Ground or Polished Metal Parts
CAUTION
Do not use hot solution tanks or water and
alkaline solutions to clean ground or polished
parts. Damage to parts will result.
Use a cleaning solvent or kerosene or diesel fuel

to clean ground or polished metal parts or
surfaces.
For Rough Metal Parts

Use a cleaning solvent or a weak alkaline solution
in a hot solution tank to clean rough metal parts.
If you use a hot solution tank, follow the
instructions below.
1. Leave the rough parts in the tank until they are
completely cleaned and heated.
2. Remove the rough parts from the tank.
3. Wash the parts with water until you remove
the alkaline solution.
10
Section 5
Assembly and Installation
Section 5 and Installation

Assembly
Figure 5.1
WARNING
Assembly
Brake Caliper
CALIPER
NOTE: When using compressed air, use air lines BORE
that are completely free of oil and moisture.
All brake parts must be clean and completely
dried of cleaning fluid. Use ONLY ArvinMeritor
replacement parts to ensure proper caliper
performance.
1. Clean caliper, caliper piston bores and fluid Figure 5.2

ports with solvent. Use compressed air to
clean out and dry grooves and passages. CALIPER
PISTON
2. Dip new piston seals in new, clean DOT 3
hydraulic brake fluid and install in piston seal
groove in caliper piston bores. Make sure that
they are properly seated. Apply a thin film of
silicon grease or brake fluid to the caliper bore
seal land between the piston boot and seal
groove. Apply the grease or brake fluid around
the entire circumference of the caliper bore.
Figure 5.1.
3. Apply DOT 3 hydraulic brake fluid to the
outside of the caliper pistons and install them
in caliper bores, making sure that they are
square to the bore. Figure 5.2.
4. Be careful not to cock the caliper pistons and
press them into the bores. Figure 5.3. Figure 5.3
11
Section 5
5. Install the piston boots over the projecting

ends of the pistons and press the ring side of
Installation
the boots into the boot bore. Figure 5.4. An old
bearing cup equal to the boot ring size helps Rotor
install the boots. Make sure the piston boot
bead is seated back against the shoulder of the NOTE: Do not resurface a new replacement rotor.
projecting end of the piston. Boots for the
64 mm and 70 mm pistons are color-coded. 1. To install, reverse the removal processes,
6. If required, replace the two stainless steel making sure that the mating surfaces of the
wear rails by removing the button head bolts. hub or spoke wheel and rotor are clean and
free of rust build-up.
NOTE: Inspect the caliper prior to reinstalling it 2. Check the rotor for lateral runout. If the lateral
onto the support. Pistons must be fully retracted runout exceeds 0.015-inches (0.381 mm), the
into the caliper. Piston boots must be fully seated rotor may be rotated to a different mounting
in the caliper boot grooves. hole position on the hub or spoke wheel to
reduce the value.
Figure 5.4
Caliper
1. Inspect the caliper for leakage, damage or
defects to piston seals or pistons. If leakage,
damage or defect is found, caliper
disassembly may be required. Figure 5.5.
2. To install, reverse the removal process.
Figures 5.6 and 5.7.
PISTON 3. Bleed the brake system and road test the
BOOT vehicle.
Figure 5.5
12
Section 5
NOTE: The inboard and outboard brake pads

Figure 5.6 are identical, except when they are equipped with
a mechanical wear sensor.
4. Install the brake pads. Ensure that the friction

surface is against the rotor. Install the pad
retainer spring and tighten the bolt to 30 lb-ft
(40 N•m) of torque. Figure 5.8. T
BRAKE NOTE: Brake pad clearance adjustment is

TUBE automatic.
5. Fill the master cylinder reservoir with new,

clean, high-performance DOT 3 brake fluid or
equivalent. Make several brake applications to
move the brake pistons and linings out into
contact with the brake rotors.
6. Recheck master cylinder reservoir and
Figure 5.7 top off as necessary to manufacturer’s
recommended level.
7. Bleed the brake system.
8. Install the tire and wheel assembly according
to the manufacturer’s instructions.
BRAKE HOSE
HOLD DOWN 9. Lower the vehicle and road test for correct
CLAMP BOLT operation.
Figure 5.8
BRAKE PAD
RETAINER
SPRING BOLT
Brake Pads
1. Inspect the rotor for scoring, warping, cracks,
bluing, heat spots or other damage or defects
and minimum thickness. Repair or replace if
necessary.
2. Inspect the disc brake calipers for leakage,
damage or defects to piston boots, seals or
pistons. Replace or repair the parts as
required.
3. Clean and inspect the lining rail covers. If they
are worn, they must be replaced.
13
Section 5
Assemble the Support

1. Install the support mounting bolts. Tighten the
bolts to the specified torque. Refer to Section 8.
Figure 5.9. T
Figure 5.9
MOUNTING
BOLT
2. Install the ABS sensor. Tighten the bolt to

8 lb-ft (11 N•m). T
3. Install the hub and rotor assembly according
to vehicle manufacturer’s recommended
service procedure.
4. Install the splash shield, if equipped.
5. Install the caliper as described in Caliper in
this section.
14
Section 6
Inspection
Section 6
Inspection If these conditions are evident: Use a crocus
WARNING cloth to remove stains or corrosion. Clean
the caliper bore after using a crocus cloth. Do
not use abrasives, including an emery cloth.
maintenance or service. If you cannot remove stains and corrosion
from the caliper bore: Replace the caliper.
Inspect Parts Caliper Mounting Plate
Caliper 1. Inspect caliper mounting plate area for rust,
corrosion. Replace a damaged or worn
1. Clean the area around the brake hose. Use mounting plate.
brake parts cleaner.
2. Use a wire brush to clean the caliper mounting
2. Inspect the heat shields (previous style only) area.
for wear and damage. Replace worn or
damaged shields. 3. Inspect the mounting plate for cracks or
elongated bolt holes.
3. Inspect the caliper lining spacers for wear and
damage. Replace worn or damaged spacers. If these conditions are evident: Replace
the mounting plate.
4. Inspect the housing for cracks or damage.
Replace a cracked or damaged housing. Brake System Bleeding Procedure
Refer to manufacturer’s service information for
CAUTION ABS bleeding instructions.
The OUTSIDE diameter of the piston is the 1. Check the master cylinder reservoir and fill, if
caliper’s primary sealing surface and is necessary, with DOT 3 or DOT 4 brake fluid.
manufactured to very close tolerances. Replace
a piston if the OUTSIDE diameter is damaged. 2. Bleed brakes in the following order: right rear,
Do not refinish or use abrasives, including an left rear, right front and left front.
emery cloth, on the piston. Damage to 3. Each four-piston caliper is equipped with two
components can result. bleeder screws. Loosen the inner bleeder
screw (which is always on the top) and purge
5. Inspect the OUTSIDE diameter of the pistons the air. Tighten it loosely.
for scoring, nicks, corrosion, wear and 4. Open the outer bleeder screw and purge the
damage. air and tighten the bleeder screw to 9-12 lb-ft
If any of these conditions are evident: (12.2-16.3 N•m). T
Replace the pistons. Do not refinish or 5. Now again open the inner bleeder screw and
use abrasives. purge the air and tighten the bleeder screw to
6. Inspect the caliper bore for scoring, nicks, 9-12 lb-ft (12.2-16.3 N•m). T
corrosion, wear and damage. 6. Repeat this procedure for all other brakes in
the sequence specified in Step 2.
If any of these conditions are evident:
Replace the caliper. 7. Test brakes prior to returning vehicle to
service. A firm pedal should be felt during
brake application.
CAUTION
Use a crocus cloth to remove minor stains and
corrosion from the caliper bore. Do not use
abrasives, including an emery cloth. If you cannot
remove minor stains and corrosion, replace the
caliper bore to avoid damage to components.
7. Inspect the caliper bore for minor stains and

corrosion.
15
Section 7
Troubleshooting
Brakes
Section 7
Troubleshooting
Excessive Pedal Effort Pads worn below minimum thickness Install new pads.
Faded, overheated condition, glazed pads, Replace the rotor and/or reface pads if sufficient
“blued” or heat-checked rotors lining remains.
Grease, oil and/or brake fluid on linings Install new pads in axle sets.
Seized or frozen pistons Disassemble calipers and free pistons, or replace

caliper.
Pedal Pulsation (Brake Excessive lateral runout of brake rotor Check with dial indicator. Install new rotor if runout
Roughness or Chatter) exceeds the maximum specified.
Excessive out-of-parallelism of brake rotor Check the parallelism (rotor thickness variation)
with micrometer and resurface the rotor, or install
new rotor if the parallelism exceeds the maximum
allowed.
Loose or worn steering or suspension parts Replace parts and realign.
Excessive front bearing clearance Readjust the bearing to specifications.
Vehicle Pulls to One Side Brake fluid, oil and/or grease on linings Install new pads in axle sets.
Unmatched linings, uneven lining wear, Install new pads in axle sets.
distorted pads
Rough rotor surfaces on one rotor Resurface or replace rotor in axle sets.
Seized or frozen pistons Disassemble caliper and repair or replace.
Loose caliper mounting bolts Tighten to specifications.
Uneven tire pressure, tread wear or size, Equalize to recommended pressures. Install correct
right to left size tires with good tread.
Excessive rotor parallelism or runout Resurface or replace rotor.
Restricted hose or line Examine the hoses and lines, and replace as
necessary.
Front end out of alignment Reset alignment.
Leaky Caliper Cylinder bore surface scored or corroded Disassemble calipers, clean bore and replace seals
and boots.
Caliper piston seal damaged or worn Disassemble calipers and install new seals and
boots.
Caliper piston damaged Replace piston.
16
Section 7
Troubleshooting
Brakes
No Braking Effect or Reservoir fluid level low Check for causes of fluid leak, repair as required
Excessive Pedal Travel and refill the reservoir. Bleed system as needed.
Air in the hydraulic system Bleed the system.
Bleeder screw loose or open Bleed the system and tighten the bleeder screw.
Caliper piston seal damaged Disassemble the caliper and replace the piston
seals. Replace piston if damaged.
Excessive rotor runout or bent rotor Check rotor with dial indicator. Install new rotor if
runout exceeds maximum specified.
Bad or excessively loose wheel bearings Adjust or replace bearings as needed.
Poor quality brake fluid Drain and clean system. Replace with
recommended brake fluid.
Weak brake hose that expands under pressure Replace defective hoses.
Brake Noise — Chatter Excessive lateral runout of rotor Check the runout with a dial indicator. Install new
rotor if the runout exceeds the maximum specified.
Lack of rotor parallelism Check the parallelism with a micrometer. Resurface

or install new rotor as required.
Loose wheel bearing Readjust the bearing to specified torque.
Brake Noise — Scraping Rust or mud build-up on edges of rotor and Clean or replace as necessary.
on caliper housing
Worn pad or pad installed backward Replace pads in axle sets only with friction surface
against the rotor.
Faulty caliper alignment permitting rotor to Correct the alignment.

scrape on housing
Brake Noise — Groan Pressure on the brake pedal too light Slightly increase the pedal effort to eliminate noise.
Brake Noise — Rattle Excessive clearance between the shoe and Install new pads.
caliper
Pad retainer spring missing or not properly Install new pad retainer spring or position correctly.
positioned
Brake Noise — Squeal Glazed pads Resurface or replace pads in axle sets only.
Weak pad retainer spring Install new pad retainer spring.
Pad wear indicator contacting rotor Install new pads in axle sets only.
Foreign material embedded in linings Replace pads in axle sets only.
17
Section 8
Torque Specifications
Section Specifications
Torque 8
Description Specification
ABS Sensor Bolts — 5/16-18 9-12 lb-ft (12.2-16.3 N•m)
Brake Hose Hold Down Clamp Bolt — 5/16-18 9-12 lb-ft (12.2-16.3 N•m)
Banjo Bolt 30-40 lb-ft (40.8-54.4 N•m)
Pad Retainer Spring Bolt — M10x1.5x16 28-32 lb-ft (38.1-43.5 N•m)
Caliper-to-Support Bolts — M20 320-360 lb-ft (435.2-489.6 N•m)
Cross Over Tube Nuts — 7/16-24 9-12 lb-ft (12.2-16.3 N•m)
Bleed Screw — 7/16-24 9-12 lb-ft (12.2-16.3 N•m)
Lining Rail Covers — M8x1.25x14 12-18 lb-ft (16.3-24.5 N•m)
Rotor to Hub Bolt (9/16-12 bolt) 100-125 lb-ft (136.0-170.0 N•m)
Rotor to Hub Bolt (9/16-18) with Lock Nuts 70-95 lb-ft (95.2-129.2 N•m)
Rotor to Hub Bolt (9/16-18) with Plain Nuts 130-165 lb-ft (176.8-224.4 N•m)
Support to Axle
(5/8-18 bolt) 190-250 lb-ft (258.4-340.0 N•m)
(9/16-18 bolt) 130-165 lb-ft (176.8-224.4 N•m)
Description Specification
Brake Pad —
Thickness Above Metal (New) 0.73" (18.5 mm)
Minimum Thickness Above Metal (Discard) 0.125" (3.2 mm)
Brake Fluid — High-Performance Brake Fluid DOT 3 or DOT 4
Rotor Diameter — 15.38" (390.7 mm)

Thickness (New) 1.54" (39.1 mm)
Thickness (Discard) 1.42" (36.1 mm)
18
2135 West Maple Road subject to change without notice or liability. ArvinMeritor Commercial Vehicle Systems reserves the right to revise
Troy, MI 48084 USA the information presented or discontinue the production of parts described at any time.
800-535-5560
www.arvinmeritor.com Copyright 2001 Maintenance Manual MM-2075
ArvinMeritor, Inc. Issued 01-01
BR02_001.fm 64 ページ２００４年５月２４日月曜日午後３時３４分
ABS (ANTI-LOCK BRAKE SYSTEM) (HYDRAULIC;MERITOR WABCO MAKE) BR03–1
ABS (ANTI-LOCK BRAKE SYSTEM)

BR03
(HYDRAULIC;MERITOR WABCO MAKE) BR03-001
ABS ...........................................................BR03-2
OVERVIEW...................................................... BR03-2
COMPOSITION AND OPERATION ................. BR03-3
FUNCTION ...................................................... BR03-6
PRECAUTIONS WHEN DRIVING VEHICLES
EQUIPPED WITH ABS .................................... BR03-7
OVERVIEW AND FUNCTION.......................... BR03-8
BR03–2 ABS (ANTI-LOCK BRAKE SYSTEM) (HYDRAULIC;MERITOR WABCO MAKE)
ABS
OVERVIEW
EN0600103C100001
ABS is a system that makes effective use of the friction between the tires
and the road surface to maintain vehicle stability while the brakes are being
applied and for stopping the vehicle.
Applying the brakes forcefully on a slippery road surface can cause the
wheels to be locked, due to excessive braking force. This causes the vehi-
cle to lose stability because the locked wheels lose resistance in the lateral
direction. More specifically, if the front wheels are locked, it becomes
impossible to steer the vehicle, and if the rear wheels are locked, the rear of
the vehicle may fishtail from side to side.
Also, when wheel-locking occurs, it is not possible to make effective use of
friction between the tires and the road surface. This may cause the braking
distance to be increased.
ABS uses wheel sensors mounted on the axles to constantly monitor the
rotation of the wheels. If any of the wheels is starting to lock up, the ABS
computer sends signals to the ABS modulator and immediately adjusts the
brake pressure to prevent wheel-locking.
In this way, ABS maintains the stability of the vehicle while stopping by
making effective use of the friction between the tires and the road surface.
COMPOSITION AND OPERATION

EN0600103C100002
The ABS system is comprised of sensor rings mounted on the wheels, the
ABS computer, which receives signals from the wheel sensors that monitor
the rotational speed of the wheels and outputs control signals to maintain
the appropriate braking force; ABS modulator, which increase or decrease
the braking force, based on the control signals; the warning lamp, which
gives an alarm if the system malfunctions; the piping, wire harnesses, etc.,
that link together the various units that compose the system.
Pulse signals transmitted by the sensor rings mounted on the wheel hubs,
rotated together with the wheels, and the wheel sensors mounted near sen-
sor ring on the axles are sent to the ABS computer. The ABS computer
then calculates the wheels' rotational speed, acceleration, deceleration,
and amount of slippage, based on these signals.
If the limit values for the wheel's deceleration, or slippage ratio are
exceeded, the ABS computer immediately transmits signals to the ABS
modulator to adjust any excess braking force.
• ABS system operates as following table.
FRONT AXLE REAR AXLE
Independently control Independently control

CONTROL SYSTEM
right and left wheels right and left wheels
1. SYSTEM COMPOSITION DIAGRAM
ABS COMPUTER
ECU
BRAKE BRAKE
ABS INDICATOR LAMP
HYDRAULIC MASTER CYLINDER

BOOSTER
ABS
HYDRAULIC MODULATOR
BRAKE LINE ASSEMBLY
HYDRAULIC BRAKE LINE
BRAKE BRAKE
SENSOR ABS SENSOR CABLE

ASSEMBLY
SAPH06ABC0300001
2. ABS CONTROL FLOWCHART
INPUT SIGNALS ABS COMPUTER OUTPUT SIGNALS
FRONT RIGHT FRONT RIGHT PRES-

WHEEL SENSOR SURE MAINTENANCE
SOLENOID VALVE
FRONT LEFT FRONT RIGHT PRES-

SURE REDUCTION
WHEEL SENSOR SOLENOID VALVE
REAR RIGHT FRONT LEFT PRES-

ABS COMPUTER SURE MAINTENANCE
REAR LEFT FRONT LEFT PRES-

SURE REDUCTION
REAR RIGHT PRES-

SURE MAINTENANCE
SOLENOID VALVE
REAR RIGHT PRES-

SURE REDUCTION
SOLENOID VALVE
REAR LEFT PRESSURE

MAINTENANCE SOLE-
NOID VALVE
REAR LEFT PRESSURE

REDUCTION SOLE-
NOID VALVE
ABS MOTOR RELAY
ABS WARNING LIGHT
MALFUNCTION CODE
(DIAGNOSTIC CODE)
SAPH06ABC0300026
BASIC PRINCIPLE
Based on its relationship with the slip ratio, which is determined from the
wheels' rotational speed and the vehicle's speed, ABS controls the brake
force so that it will be most effective.
When the driver applies the brakes, the rotation of the wheels is controlled
and the vehicle speed drops. However, the momentum of the vehicle
attempts to push it forward further even though the rotation of the wheels is
being braked. At this point, slipping will occur if there is a gap between the
wheels' rotational speed and the vehicle's speed. The slip ratio is a value
that indicates the rate of slippage.
Vehicle's speed - Wheel's rotational speed

Slip ratio = 100 %
Vehicle's speed
Slip ratio No slipping between the wheels and the
0%:
road surface
100 % : Wheels locked
The graph shown at left shows the relationship between the friction coeffi-
cient of the tires and of the road surface and the slip ratio.
In an ABS-equipped vehicle, the brake force is controlled to ensure that it is
within the range where the friction coefficient is high (shaded portion of the
graph) without locking the wheels. This ensures efficient braking perfor-
mance.
SAPH06ABC0300004
OPERATION
The ABS computer calculates the wheel speed and wheel acceleration
speed for each of the 4 wheels, from 4 speed sensor signals, and deter-
WHEEL SPEED mines the wheel slip conditions. And depending on these conditions, con-
HIGH VEHICLE BODY SPEED
trol signals are output to the ABS actuator solenoid valves in 3 modes
SPEED
(pressure increase, pressure maintenance, and pressure reduction). Con-

trol signals are output independently to the front and rear wheels and to the
LOW left and right wheels.
ACCELERATION
0
WHEEL
SPEED
Ð
CONTROL SIGNAL
PRESSURE
REDUCTION
PRESSURE
MAINTENANCE
PRESSURE
INCREASE
WHEEL CYLINDER
FLUID PRESSURE
HIGH
0
TIME
SAPH06ABC0300005
FUNCTION
EN0600103C100003
FAIL-SAFE FUNCTION
This ABS system is equipped with a fail-safe function that causes the ABS
warning light on the instrument panel to light and to restore the normal
(non-ABS) brake system, should an ABS malfunction occur.
Note that the ABS system consists of two independent circuits. Should a
malfunction occur for whatever reason in the electrical circuits, that sys-
tem's ABS is switched off and the normal brake system is restored while
ABS control continued for the other system. This configuration is designed
to minimize the effects of any malfunction on ABS function.
PRECAUTIONS WHEN DRIVING VEHICLES EQUIPPED WITH ABS

EN0600103F100001
Electronically, ABS uses the coefficient of friction (the amount of traction) between the tires and the road surface to monitor the
speed of each wheel. If one or more wheels indicates the possibility of locking, resulting in fishtailing or other loss of stability,
ABS enables the vehicle to be brought to a stop. Even with ABS, however, a driver must operate the vehicle in a safe manner
and recognize the following points with respect to the operation of ABS.
CHECK POINTS REMEDIAL ACTIONS
Even with ABS, the braking distance on a wet or slippery

road will be longer than on a dry road, and if the road
surface is covered with ice, snow or gravel, the braking Even with ABS, always drive safely, tak-
distance will be even greater. ing into consideration the road and traffic
conditions and the condition of your tires,
including tire type and tire wear. Always
keep a safe distance from any vehicle
ABS does not operate when the vehicle is starting, ac-
being driven in front of you.
celerating or turning, and will not assist in maintaining
directional stability or steerability or in shortening the brak-
ing distance.
Even if the ABS is operational, where the coefficient of If engine braking causes instability or fish-
friction is very low, such as on an icy roadway, skidding, tailing, the clutch should be engaged or
inability to steer, and instability may occur because of the transmission shifted to neutral, to pre-
insufficient traction by the tires. vent the application of the engine brak-
ing to the drive wheels.
Where engine braking, as a result of downshifting, oc-
curs on a surface with a low coefficient of friction, such Vibrations and noise during the operation
as ice, the drive wheels may lock, causing fishtailing or of ABS are not malfunctions. Remain calm
vehicle instability. ABS does not operate unless the brake and continue to steer the vehicle in an
pedal is applied. appropriate manner.
When ABS is activated, the driver may experience a small If the warning lamp lights again when you
amount of vibration (especially if the road surface be- reach a speed of about 6 km/h
tween the left and right tires is different) and difficulty in (4 mile/h), the ABS system may not be
steering. Also, the operation of the ABS may generate functioning properly. Have it inspected and
some noise. repaired if necessary. *The warning lamp
can be reset by turning off the engine
The ABS warning light will come on when you turn the while the vehicle is at rest. If the warning
starter switch to the "on" position. It stays on briefly and lamp fails to go out after the engine is re-
then turns off automatically. If the light does not come started and the speed indicated above is
on, have your vehicle inspected and serviced immedi- reached, or if it lights frequency while the
ately at your nearest Hino service dealer. vehicle is being driven, the ABS must be
inspected.
OTHER CHECKPOINTS REGARDING HANDLING

1. When washing the vehicle, take care not to direct high-pressure streams of water at the ABS modulator, harnesses,
or connectors. Also, under no circumstances should the ABS computer or electrical relays be exposed to water.
2. Be very careful not to damage the ABS wire harness when removing snow, ice, mud or other material from the outside or
underside of the vehicle.
3. All electronic and radio equipment installed on the vehicle must be mounted as far away from the ABS computer and wire
harness as possible. Installation of certain electronic and radio equipment can also cause the ABS computer to malfunction.
All such equipment must also conform to all applicable laws. If you wish to install a radio or other electronic equipment,
please contact your Hino service representative.
SAPH06ABC0300006
OVERVIEW AND FUNCTION

EN0600103C100004
ABS COMPUTER
Based on pulse signals from the wheel sensors, the ABS computer
mounted in the vehicle calculates and evaluates the slip ratio and the accel-
eration/deceleration speed of the wheels. Based on the results, it sends
signals to the modulator assembly as necessary, causing them to operate
and apply the brakes to maintain the slippage of the wheels within the opti-
mal range.
During braking, the fluid pressure applied to the brake cylinder is regulated
to prevent the wheels from locking. The brakes are applied so as to main-
tain the slippage of the wheels within the optimal range.
Regardless of whether the vehicle is stopped or being driven, and whether
or not the brakes are being applied, the circuit consisting of the wheel sen-
sors, modulator assembly, ABS computer, and wire harnesses are con-
stantly being checked by the ABS computers' fail-safe circuit. If some sort
of malfunction occurs, the fail-safe circuit warns the driver by lighting the
ABS warning light. At the same time, the ABS system that is experiencing
the malfunction is shut off and braking is restored to normal (non-ABS)
operation.
NOTICE
Modified label: 199 is applied following model.
model: HINO 145, 165, 238, 268,308 (NA, NB, ND, NE, NF)
Modified label: 198 is applied
model: HINO 185 (NC)
Pay close attention to prevent misuse when replacing.
SAPH06ABC0300007
ABS MODULATOR ASSEMBLY
1. Overview
• The ABS modulator is mounted between the Hydro booster and wheel
cylinder. It controls the fluid pressure to the wheel cylinder, regulating
the pressure according to signals from the computer in three modes:
pressure maintenance, pressure reduction, and pressure increase.
SAPH06ABC0300008
SAPH06ABC0300009
2. Operation
(1) During Normal Braking (ABS is not operating)
• Since there is no control signal input from the ABS computer, the
pressure maintenance solenoid valve port A is open, and the pres-
sure reduction solenoid valve port B is closed. Accordingly, when the
fluid pressure generated by the Hydro booster rises according to the
fluid pressure from the master cylinder produced when the brake
pedal is depressed, brake fluid is fed through port A to the wheel cyl-
inder. Brake fluid is not sent to the pump side at this time because of
the check valve 1 installed on that side. Then, when the brake pedal is
released, the wheel cylinder brake fluid is returned to the master cylin-
der through the pressure maintenance solenoid valve port A to the
Hydro booster.
Each Port Status
ABS computer signal Port status
Pressure mainte-
OFF Port A: Open
nance solenoid valve
Pressure reduction
OFF Port B: Closed
solenoid valve
SAPH06ABC0300010
(2) During ABS Braking

a. Pressure Reduction Mode
• When the wheels are about to lock, the pressure maintenance sole-
noid valve port A closes and the pressure reduction solenoid valve
port B opens according to control signals from the ABS computer.
Accordingly, the wheel cylinder brake fluid is fed through the pressure
reduction solenoid valve port B to the reservoir, reducing the wheel
cylinder fluid pressure. While the ABS is in operation, the ABS com-
puter outputs a normal operating signal to the pump, which pumps out
the brake fluid that accumulates in the reservoir and returns it to the
Hydro booster.
Each Port Status
Pressure mainte-
ON Port A: Closed
Pressure reduction
ON Port B: Open
solenoid valve
SAPH06ABC0300011
b. During Pressure Maintenance

• When the wheel cylinder fluid pressure is reduced or increased to the
required fluid pressure, the pressure maintenance solenoid valve port
A and the pressure reduction solenoid valve port B simultaneously
close according to control signals from the ABS computer. This closes
both the Hydro booster side and reservoir side oil routes, maintaining
the wheel cylinder fluid pressure.
Each Port Status
Pressure mainte-
ON Port A: Closed
Pressure reduction
OFF Port B: Closed
solenoid valve
SAPH06ABC0300012
c. During Pressure Increase

• When the wheel cylinder fluid pressure needs to increase rapidly, the
pressure maintenance solenoid valve port A opens and the pressure
reduction solenoid valve port B closes according to control signals
from the ABS computer. This condition is the same as the normal con-
dition, and Hydro booster brake fluid is fed to the wheel cylinder, caus-
ing the wheel cylinder fluid pressure to rise. If there is any brake fluid
remaining in the reservoir at this time, it is pumped out by the pump
and sent to the wheel cylinder. The speed of the pressure increase is
controlled by combination of the pressure increase and the pressure
maintenance.
Each Port Status
Pressure mainte-
OFF Port A: Open
Pressure reduction
OFF Port B: Closed
solenoid valve
SAPH06ABC0300013
WHEEL SENSOR
These sensors are mounted facing the sensor rings on each wheel on the
front and rear axles.
The wheel sensors are electromagnetic sensors consisting of a permanent
magnet core with a coil of wire wrapped around it. The frequency of the
pulse signals generated by magnetic inductance between the sensors and
the sensor rings they face is proportional to the rotational speed of the
wheels. These pulse signals are sent to the ABS computer and are used to
determine the wheels' rotational status.
SAPH06ABC0300014
SENSOR RING
Hub fitted type The sensor rings are press-fitted into the insides of the wheel hubs of each
wheel or integrated in the brake rotor on the front and rear axles, and they
face the wheel sensors described in the preceding section. The sensor
rings are made of a magnetic material, and teeth are cut into the surface
which faces the wheel sensor at regular intervals.Also, when the sensor
ring performs one complete rotation, the sensor generates pulse signals
corresponding to the number of teeth.
SAPH06ABC0300015
Sensor ring position and number of teeth
145 165 185 238 268 308

Model
NA NB NC ND NE NF
Position Hub fitted Rotor integrated
Front
Teeth No. 70 80 80 100
Position Hub fitted Rotor integrated
Rear
Teeth No. 70 80 100
SAPH06ABC0300016
CLAMPING BUSHING
The wheel sensors are held in place through friction by clamping bushings
that are inserted into the mounting brackets. If they are assembled properly
(the clamping bushings should be pushed in to place so that the stoppers
on the clamping bushings come in contact with the holder), the clamping
bushings serve to eliminate the need to adjust the clearance between the
wheel sensors and sensor rings.
SAPH06ABC0300027
WARNING LAMP
The ABS is equipped with the following warning light.
SAPH06ABC0300017
1. ABS WARNING LIGHT

• This lamp indicates the status of the ABS. It lights once when the
starter switch is turned on and automatically goes off if the ABS is
functioning normally. If a malfunction occurs in the ABS while the vehi-
cle is being driven, the light comes on to alert the driver.
Also used as the diagnostic display light.
NOTICE
Trouble shooting and Testing of the ABS refer to MERITOR WABCO
Maintenance Manual.Cab-Mounted ECU and D Version Hydraulic ABS.
WHEEL SENSOR WIRE HARNESSES

Each wheel sensor wire harness employs a two-conductor twisted wire
cable. Its function is to protect the wheel sensor signals, which are vital to
the proper operation of the ABS, from electromagnetic interference. Under
no circumstances should any part of the wheel sensor wire harness be cut
or connected to any other wire. In the event that the wire harness should
become cut, have it replaced by an authorized Hino dealer.
SAPH06ABC0300018
DIAGNOSIS SWITCH OF ABS SYSTEM

It is positioned at the side of diagnosis connector in the instrument panel of
driver seat front side.
By switching the starter key “ON” and pushing to “ON” this ABS diagnosis
switch, which is led to the diagnosis mode, the ABS warning light flashes on
and off to inform the trouble codes.
NOTICE
ABS diagnosis switch reverts automatically to “OFF” position.
SAPH06ABC0300028
ABS WIRE HARNESSES
1. Front axle ABS wire harness

• The wire harness that runs from the side frame to the front axle wheel
sensor must absorb the steering angle of the front wheel and the
movement of the chassis springs. It is therefore necessary to always
maintain an optimal spacing between the clips.
SAPH06ABC0300019
• The optimal spacing between the clips is achieved when the wheel
sensor connectors are attached in the regular locations shown in the
diagram such that the sensor cabling within the frame is not loose.
When disassembling and reassembling, confirm that the connector
and sensor cable layout is appropriate.
SAPH06ABC0300020
2. Rear axle ABS wire harness

• The wheel sensor wire harness is arranged so that the left and right
wheel sensor wire harnesses are near each other. Therefore, special
care should be taken not to make incorrect connections if the har-
nesses have been removed for inspection or repairs. If incorrect con-
nections are made, it will interfere with the functioning of the ABS. For
this reason, caution plates indicating "LEFT" and "RIGHT" are affixed
to the wire harnesses. Be sure to check when connecting the har-
nesses. The wheel sensor wire harnesses, just like the front axle har-
nesses, must absorb the movement of the chassis springs. It is
therefore necessary to always maintain an optimal spacing between
the clips.
When disassembling and re-assembling, confirm that the connector is
secured in its proper place as shown in the diagram and that the sen-
sor cables in the frame and over the axle are not hanging loosely.
SAPH06ABC0300021
HANDLING WIRE HARNESSES

• The various sensors, valves, relays and wire harness connections to
the ABS computer employ multipolar harness connectors suitable for
use with the weak currents used by electronic circuitry. Be very careful
when handling them.
1. Place the starter switch on "LOCK" before unplugging the har-

ness connectors.
2. When unplugging the harness connectors, release the lock, hold

the housing and unplug it straight as much as possible.
3. Do not pull holding the wire harness or pull with excessive force.
Doing so can cause the pins of the harness connectors to be
deformed.
4. Remove unnecessary connectors and do not plug them.
5. When inspecting using a circuit tester, insert the test probe from
the wire harness side.
Never insert the test probe from the pins of harness connectors
as this can cause bad contacts.
SAPH06ABC0300022
6. When unplugging the harness connectors, do not allow water,

oil, dust, or any other liquid or substance to get on the terminals
as they can cause bad contacts.
7. Be careful not to allow water, oil, dust, or any other liquid or sub-
stance to get on any component.
8. When plugging the harness connector, insert it completely and

confirm that the harness connector lock is engaged.
ADDITIONAL PRECAUTIONS
1. Make sure the model's starter switch is in the OFF position

before unplugging the harness connector from the ABS com-
puter.
2. Make sure to unplug all the harness connectors from the ABS
computer before performing welding on the chassis or body of
the vehicle. Also be careful that welding sputter does not get
onto the harnesses.
3. When cleaning the interior of the model, make sure water does
not get onto the ABS computer, various relays, connectors, or
any other component.
4. Use of a circuit tester

• If a circuit tester is being used, always use one with an internal resis-
tance greater than 100 kΩ inside the voltage measurement range.
5. Installation of a radio or other electronic equipment

• All electronic and radio equipment installed on the vehicle must be
mounted as far away from the ABS computer and wire harness as
possible. Installation of certain electronic and radio equipment can
also cause the ABS computer to malfunction. All such equipment
must also conform to all applicable laws. If you wish to install a radio
or other electronic equipment, please contact your Hino service repre-
sentative.
6. Quick battery charge

• When charging batteries using a quick charger, do it with both battery
terminals removed.
7. Installation of electrical equipment inside of the cab

• When installing an air conditioner or other electrical equipment inside
of the cab, be careful not to damage the engine, chassis, and wire
harnesses inside the cab. Moreover, do not forget to plug the harness
connectors unplugged during the installation.
NOTICE
ANTI- LOCK BRAKE SYSTEM of this model is applied to MERITOR
WABCO ABS system. Detail of the ABS refer to MERITOR WABCO
Maintenance Manual 39 For D Version Hydraulic ABS with cab-
mounted ECU and without retarder relay.
Hydraulic ABS
for Medium-Duty
Trucks, Buses and
Motor Home Chassis
Maintenance Manual 39
Revised 09-00
For D Version Hydraulic ABS
Service Notes
Before You Begin

Service Notes
This manual provides maintenance and service ArvinMeritor’s Web Site
instructions for Meritor WABCO’s hydraulic ABS Additional maintenance and service information
for medium-duty trucks, buses and motor home for ArvinMeritor’s commercial vehicle systems
chassis. Before you begin procedures: component lineup is also available at
1. Read and understand all instructions and www.arvinmeritor.com.
procedures before you begin to service To access information, click on Products &
components. Services/Tech Library Icon/HVS Publications. The
2. Read and observe all Caution and Warning screen will display an index of publications by
safety alerts that precede instructions or type.
procedures you will perform. These alerts help
personal injury, or both.
3. Follow your company’s maintenance and
service, installation, and diagnostics
guidelines.
4. Use special tools when required to help avoid
serious personal injury and damage to
components.

and Notes

personal injury and
serious injury.
Table of Contents
Asbestos and Non-Asbestos Fibers Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .ii

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Maintenance Manual Information
How Hydraulic ABS Works
ECU Identification
System Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Electronic Control Unit (ECU)
Modulator Assembly
Sensors
ABS Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Section 2: Troubleshooting and Testing
General Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
System Wiring Information
System Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Meritor WABCO TOOLBOX Software
Blink Code Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Definitions
Using Blink Code Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Testing the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Meritor WABCO TOOLBOX Software
Standard Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Test Equipment: Volt-Ohm Meter (VOM)
Will System Requirements and Component Tests
Tire Size Range
Voltage Check
Standard Component Testing
ABS Indicator Lamp
ABS Blink Code Switch
Sensor Adjustment
Sensor Output Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Sensor Resistance
Section 3: Component Replacement
Component Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Sensors
Modulator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Brake Bleeding Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Pressure Fill and Bleed
Section 4: Appendix A
Modulator Assembly Connector Pin Assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31


Because some brake linings contain asbestos, workers who service brakes must Most recently manufactured brake linings do not contain asbestos fibers. These brake
understand the potential hazards of asbestos and precautions for reducing risks. linings may contain one or more of a variety of ingredients, including glass fibers,
Exposure to airborne asbestos dust can cause serious and possibly fatal diseases, mineral wool, aramid fibers, ceramic fibers and silica that can present health risks if
show that the risk of lung cancer among persons who smoke and who are exposed to lung disease. Silicosis gradually reduces lung capacity and efficiency and can result in
asbestos is much greater than the risk for non-smokers. Symptoms of these diseases serious breathing difficulty. Some scientists believe other types of non-asbestos fibers,
may not become apparent for 15, 20 or more years after the first exposure to asbestos. when inhaled, can cause similar diseases of the lung. In addition, silica dust and
ceramic fiber dust are known to the State of California to cause lung cancer. U.S. and
Accordingly, workers must use caution to avoid creating and breathing dust when international agencies have also determined that dust from mineral wool, ceramic fibers
servicing brakes. Specific recommended work practices for reducing exposure to and silica are potential causes of cancer.
Recommended Work Practices servicing brakes. Specific recommended work practices for reducing exposure to
sign be posted at the entrance to areas where exposures exceed either of the maximum silica of 0.1 mg/m 3 as an 8-hour time-weighted average. Some manufacturers of non-
asbestos dust.
with the removal of the wheels. Wear a respirator equipped with a high-efficiency
2. Respiratory Protection. Wear a respirator equipped with a high-efficiency (HEPA) (HEPA) filter approved by NIOSH or MSHA, if the exposure levels may exceed OSHA or
filter approved by NIOSH or MSHA for use with asbestos at all times when servicing manufacturers’ recommended maximum levels. Even when exposures are expected to
becoming airborne. Allow the solution to flow between the brake drum and the becoming airborne. Allow the solution to flow between the brake drum and the
that the exposure levels associated with the employer’s procedures do not exceed with a pump-spray bottle that creates a fine mist. Use a solution containing water,
d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA for use suppress dust before the brake shoes or brake pads are removed. Wipe the brake
an area with a local exhaust ventilation system equipped with a HEPA filter. d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA when
HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic exhaust ventilation system equipped with a HEPA filter.
solvents, flammable solvents, or solvents that can damage brake components as e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a
wetting agents. HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic
solvents, flammable solvents, or solvents that can damage brake components as
you empty vacuum cleaners and handle used rags, wear a respirator equipped with a 4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter
with a HEPA filter approved by NIOSH or MSHA, to minimize exposure. When you
5. Worker Clean-Up . After servicing brakes, wash your hands before you eat, drink or replace a HEPA filter, wet the filter with a fine mist of water and dispose of the used filter
with a HEPA filter to vacuum work clothes after they are worn. Launder them separately.
5. Worker Clean-Up . After servicing brakes, wash your hands before you eat, drink or
6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters with a HEPA filter to vacuum work clothes after they are worn. Launder them separately.
regulations on waste disposal. 6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters
ii
Section 1
Introduction
Overview
Section 1
Introduction During an ABS stop, a solenoid valve in the
modulator assembly is rapidly pulsed; that is, it
Meritor WABCO Hydraulic Anti-lock Braking opens and closes several times per second to
System (ABS) is an electronic wheel speed control the brake pressure. When this occurs,
monitoring and control system used on drivers may notice a pulsation of the brake pedal.
medium-duty trucks, buses and motor home An ABS indicator lamp on the vehicle dash alerts
chassis equipped with a hydraulic brake system. the driver to a possible system fault and provides
There are two systems available, C and D version blink code information to diagnose the system.
hydraulic ABS. D version ECUs are available in If the ABS indicator lamp comes on during normal
both cab- and frame-mounted versions. Figure 1.1. vehicle operation, drivers may complete their trip,
but are instructed to have their vehicles serviced
as soon as possible.
Figure 1.1
D VERSION
In the unlikely event of an ABS system
FRAME-MOUNTED malfunction, the ABS in the affected wheel will be
ECU disabled and will return to normal braking. The
other sensed wheels will retain their ABS function.
ECU Identification
NOTE: Do not open the ECU. Opening the ECU to
gain access to the internal components will void
the warranty.
It’s easy to determine the hydraulic ABS version

D VERSION
CAB-MOUNTED installed on the vehicle by looking at the ECU.
ECU C version system ECUs are larger than D version
ECUs. (Refer to Figure 1.1.)
C VERSION ECU
(CAB-MOUNTED ONLY) 1004679a If the ECU is easily visible, look at the part number
identification tag. D version ECUs will have a D
designation printed on the tag. There is no letter
designation on C version ECUs. Figure 1.2.
Maintenance Manual
Information
Figure 1.2
This manual contains service information for
the Meritor WABCO D version cab- and
frame-mounted hydraulic ABS. If you are servicing D VERSION
a C version hydraulic ABS, you will need
Maintenance Manual 38.
To determine which version hydraulic ABS is
installed on the vehicle you are servicing, please
refer to the ECU Identification portion of this
manual. If you are not able to identify the version,
or to request service literature, please contact the
Meritor Customer Service Support Center at
800-535-5560.
1004680a
How Hydraulic ABS Works
ABS wheel sensors detect wheel speeds. The
sensors generate signals that are transmitted to an
Electronic Control Unit (ECU). If the wheels start to
lock, the ECU signals the modulator assembly to
regulate the brake pressure of each locking wheel.
MM39
Revised 09-00 Page 1
Section 1
Introduction
System Layout
A typical Meritor WABCO Hydraulic ABS with cab-mounted ECU is illustrated below. Figure 1.3.
Figure 1.3
ECU
BRAKE BRAKE
ABS INDICATOR LAMP

BOOSTER
ABS
HYDRAULIC MODULATOR
BRAKE LINE ASSEMBLY
BRAKE BRAKE

ASSEMBLY 1004681a
A typical Meritor WABCO Hydraulic ABS with frame-mounted ECU is illustrated below. Figure 1.4.
Figure 1.4
ECU
BRAKE BRAKE
ABS INDICATOR LAMP

BOOSTER
ABS
HYDRAULIC MODULATOR
BRAKE LINE ASSEMBLY
BRAKE BRAKE

ASSEMBLY
1004682a
MM39
Page 2 Revised 09-00
Section 1
Introduction
System Components r Contains brake fluid and must be handled with

appropriate care. It should not be exposed to
The following components make up the Meritor impact loads, excessive vibrations or
WABCO Hydraulic ABS. compressed air blown into the hydraulic ports.
Electronic Control Unit (ECU) Sensors

Sensor with Molded Socket
Figure 1.5
D VERSION
CAB ECU Figure 1.7
D VERSION
FRAME ECU
1004683a
1004685a
r Processes sensor signals and generates
solenoid valve commands to reduce, maintain
or reapply brake pressure. r Measures the speed of a tooth wheel rotating
r Mounting locations vary, depending upon the with the vehicle wheel.
vehicle. Refer to the vehicle specifications for r Produces an output voltage proportional to
the exact location. Cab- and frame-mounted wheel speed.
versions available.
Sensor Spring Clip
Modulator Assembly
Figure 1.8
Figure 1.6
1004686a
1004684a
r Holds the wheel speed sensor in close

r Houses the ABS solenoid control valves (one proximity to the tooth wheel.
inlet valve and one outlet valve per wheel), a
pump motor and two accumulators.
MM39
Section 1
Introduction
Tooth Wheel ABS Indicator Lamp
1004687a 1004689a
r A machined or stamped ring mounted to a r Located on vehicle dash.

machined surface on the hub of each
ABS-monitored wheel. r Alerts drivers to a possible system fault.
r Used by service personnel to display blink
Sensor Extension Cables codes.
r ABS indicator lamp is not provided by
Meritor WABCO.
Figure 1.10
Figure 1.12
$98.00
TOOLBOX
SOFTWARE
▲▲▲
▲▲▲▲▲
▲
▲▲ O R W A B ▲
MER ▲
▲▲ O
T
▲▲▲▲ ▲▲▲▲
C
▲▲▲
TOOLBOX E
I
Easy-StopTM Trailer ABS Diagnostics

▲
▲▲▲▲▲▲
Hydraulic
K N O W
ABS Diagnostics
SOFTWAR
Pneumatic ABS Diagnostics (D Version)
WH
▲▲
1004688a
O
T T
▲
A
▲▲
YO U ▲▲ D
▲▲
▲▲▲▲▲▲▲N E E
1004690a
r Two-wire cable with molded-on connector.
r Connects the wheel speed sensor to the ECU.
r A PC-based diagnostics program.
r Displays system faults and wheel speed data,
tests individual components, verifies
installation wiring and more.
r Runs in Windows® 95, 98 or NT.
r To order, call 800-535-5560.
NOTE: An RS232 to J1708 converter box is

required.
MM39
Section 2
Troubleshooting and Testing
General Maintenance
Section 2
System Wiring Information
Information NOTE: Refer to Table A for ECU pin identification.
There is no regularly scheduled maintenance
required for Meritor WABCO D Version Hydraulic Wiring may vary, according to the vehicle. Refer to
ABS. However, ABS does not change current the vehicle specifications for specific wiring
vehicle maintenance requirements. For example, it diagrams. A typical Meritor WABCO 4S/4M
is important that the vehicle brake fluid level be Hydraulic ABS wiring diagram appears in
properly maintained. Figure 2.1.
Table A: Wiring Refer to Appendix A for Modulator Assembly Connector Pin

Assignments
Pin Numbers and Locations (Cab-Mounted ECU) CAB
1 4 7 1 4 7 10 13 16 1 4 7 10 13
2 5 8 2 5 8 11 14 17 2 5 8 11 14
3 6 9 3 6 9 12 15 18 3 6 9 12 15
9-Pin ECU Connector 18-Pin ECU Connector 15-Pin ECU Connector

Pin Circuit Pin Circuit Pin Circuit
Number Description Number Description Number Description
1 Left Front Sensor 1 +12 Battery 1 Left Front Outlet Valve
2 Left Front Sensor 2 +12 Ignition 2 Left Front Inlet Valve
3 Right Rear Sensor 3 Not Used 3 Ground
4 Right Front Sensor 4 Not Used 4 Right Front Outlet Valve
5 Right Front Sensor 5 SAE J1587 (–) 5 Right Front Inlet Valve
6 Right Rear Sensor 6 SAE J1587 (+) 6 Not Used
7 Left Rear Sensor 7 Not Used 7 Left Rear Outlet Valve
8 Left Rear Sensor 8 Motor Monitor 8 Left Rear Inlet Valve
9 Not Used 9 Not Used 9 Not Used
10 Not Used 10 Right Rear Outlet Valve
11 Not Used 11 Right Rear Inlet Valve
12 Ground 12 Retarder Relay
13 Not Used 13 Not Used
14 Not Used 14 Not Used
15 Jumper 15 Pump Relay
16 Not Used
17 Not Used
18 ABS Indicator Lamp
and Blink Code Switch 1004691a
MM39
Page 6
MM39
M
RECIRCULATION PUMP
Figure 2.1
MOTOR MONITOR
86
Section 2
87
PUMP RELAY
SENSOR SENSOR SENSOR SENSOR 30 REAR REAR FRONT FRONT
REAR REAR FRONT FRONT 85 RIGHT LEFT RIGHT LEFT
펁
펁
펁
펁
RIGHT LEFT RIGHT LEFT
ABS MODULATOR UNIT
(Cab-Mounted ECU)
30A
–
12V IV OV IV OV IV OV IV OV
+
２００４年５月２１日
15 30
INDEPENDENT IGNITION
金曜日
FUSED IGNITION SWITCH

CONNECTION
12 AWG
(E.G. USED FOR 11 10 2 1 4 5 12 13 8 7 6 3
5A OTHER WARNING 5A 25A
CIRCUITRY)
MAX. 2W
12 AWG
(ORANGE)
午後４時９分
ABS
INDICATOR
IGNITION
LAMP
BLINK CODE
4S/4M D Version Hydraulic ABS Wiring Diagram
SWITCH
ABS INDICATOR LAMP
MOTOR MONITOR
GROUND
DIAGNOSTICS SAE J1587 “B”-LINE
DIAGNOSTICS SAE J1587 “A”-LINE
REFERENCE GROUND
RETARDER RELAY
PUMP RELAY
2x18 AWG TWISTED

2x18 AWG TWISTED
2x18 AWG TWISTED

2x18 AWG TWISTED
6 3 8 7 5 4 2 1 8 2 18 12 1 6 5 11 10 8 7 5 4 2 1 3 12 15
15
1 4 7 1 4 7 10 13 16 1 4 7 10 13
2 5 8 2 5 8 11 14 17 2 5 8 11 14
3 6 9 3 6 9 12 15 18 3 6 9 12 15
CAB
1004692a
Revised 09-00
Section 2
Table B: Wiring Refer to Appendix A for Modulator Assembly Connector Pin

Assignments
Pin Numbers and Locations (Frame-Mounted ECU) FRAME
Black X-2 Connector Gray X-1 Connector Green X-3 Connector

Pin Circuit Pin Circuit Pin Circuit
Number Description Number Description Number Description
1 SAE J1587 (–) 1 X 1 X
2 +12 Ignition 2 Ground 2 X
3 +12 Battery 3 Left Front Inlet Valve 3 Left Rear Sensor
4 Warning Lamp Relay 4 Right Front Inlet Valve 4 Right Front Sensor
5 X 5 Left Rear Inlet Valve 5 Left Front Sensor
6 Pump Relay 6 Right Rear Inlet Valve 6 Right Rear Sensor
7 Retarder Relay 7 Right Rear Outlet Valve 7 Right Rear Sensor
8 ABS Indicator Lamp 8 Left Rear Outlet Valve 8 Left Front Sensor
and Blink Code Switch 9 Right Front Outlet Valve 9 Right Front Sensor
9 Ground 10 Left Front Outlet Valve 10 Left Rear Sensor
10 Motor Monitor 11 X 11 X
11 +12 Battery 12 X 12 X
12 SAE J1587 (+)
1004693a
MM39
Page 8
MM39
Figure 2.2
TOTAL RESISTANCE OF PUMP CONNECTION
Section 2
INCLUDING PLUG CONNECTORS AND RELAY
CONTACT: R < 0.03Ω M

USE A WIRE GAUGE OF 16 AWG WHERE NOT SPECIFIED.
RECIRCULATION PUMP
MOTOR MONITOR
12 AWG 86
87
PUMP RELAY
30
85
２００４年５月２１日
TOTAL RESISTANCE
INCLUDING CONTACT (Frame-Mounted ECU)
SENSOR SENSOR SENSOR SENSOR REAR RIGHT REAR LEFT FRONT RIGHT FRONT LEFT AND CRIMP RESISTANCE:
REAR RIGHT REAR LEFT FRONT RIGHT FRONT LEFT R < 0.017Ω
30A
金曜日
ABS MODULATOR UNIT

12V
15 30
INLET
INLET
INLET
INLET
+
VALVE
VALVE
VALVE
VALVE
VALVE
VALVE
VALVE
VALVE
OUTLET
OUTLET
OUTLET
OUTLET
IGNITION
SWITCH
午後４時９分
5A 5A
12 AWG
INDEPENDENTLY
FUSED CIRCUIT 25A
11 10 2 1 4 5 12 13 9 8 7 6 3
UES MAX. 2W
(ORANGE)
4S/4M D Version Hydraulic ABS Wiring Diagram
14 AWG
PUMP RELAY 85 30
MOTOR MONITOR
ABS
87a
86
TOTAL RESISTANCE
GROUND 14 AWG
REFERENCE GROUND
DIAGNOSTICS SAE J1587 “B” – LINE
DIAGNOSTICS SAE J1587 “A” – LINE
INDICATOR LAMP
RETARDER
INCLUDING CONTACT AND

14 AWG TWISTED PAIR WIRES
2x18 AWG TWISTED

2x18 AWG TWISTED
2x18 AWG TWISTED
2x18 AWG TWISTED
CRIMP RESISTANCE: R < 0.04Ω
ABS INDICATOR LAMP
BLINK CODE
SWITCH
7 6 10 3 9 4 8 5 6 7 5 8 4 9 3 10 2 7 6 10 2 4 8 9 11 3 12 1
12-PIN CONNECTOR (GREEN) 12-PIN CONNECTOR (GREY) 12-PIN CONNECTOR (BLACK)

FRAME
Revised 09-00
Section 2
System Diagnostics Figure 2.4

Use Meritor WABCO’s PC-based diagnostic
program, TOOLBOX Software, or standard blink
codes to diagnose hydraulic ABS faults.
Information for using standard blink codes
appears on page 11 of this manual.
Meritor WABCO
TOOLBOX Software
NOTE: For complete instructions for using this
program, refer to the User’s Manual, TP-99102.
Contact Meritor WABCO at 800-535-5560 for
information about TOOLBOX Software.
If you have TOOLBOX Software installed on your

computer, use it to identify system faults. Then,
follow the on-screen repair information to make
the necessary repairs or replacements.
To display D version Hydraulic ABS faults, use the 1004696a
pull-down menu or the HABS icon Figure 2.3 to
select HABS (Hydraulic ABS) from the Main Menu.
The Hydraulic ABS Main Menu will appear.
Select the View ECU Faults icon or select Display

Faults to use the pull-down menu. Figure 2.5. This
will display the Fault Information screen.
Figure 2.6.
Figure 2.3
1004697a
Figure 2.6
1004698a
MM39
Section 2
The Fault Information Screen contains a 2. Displays diagnostic blink codes for
description of the fault. Repair instructions for easy servicing.
each fault appear at the bottom of the screen.
Blink Code: A series of blinks or flashes that
Faults that occur after the screen is displayed will describe a particular ABS system condition.
not appear until a screen update is requested. Use (Refer to Table D [cab-mounted] or Table E
the UPDATE button to refresh the fault information [frame-mounted] for blink code identification.)
table.
Blink Code Diagnostics: The ability of the Meritor
After making the necessary repairs, use the CLEAR WABCO ECU to sense faults in the ABS system
FAULTS button to clear the fault. Use the update and to define these faults via blink codes.
button to refresh the fault information table and
display the new list of faults. Blink Code Switch: A momentary switch that
activates blink code diagnostic capabilities.
Usually, it is mounted under the dash or on the
Blink Code Diagnostics steering column. Refer to the vehicle
specifications for type and location.
Definitions Clearing Fault Codes: The process of erasing faults
from the ECU memory bank. (Refer to Table C.)
ABS Indicator Lamp: This lamp, located on the
vehicle dash, serves two purposes: Fault Code: An ABS condition (fault) detected and
stored in memory by the Meritor WABCO ECU and
1. Alerts drivers or service personnel to a displayed by blink code. System faults may be
possible fault in the hydraulic ABS, as follows: Active or Stored.
IF . . . the ABS indicator lamp comes on briefly Active Fault: A condition that currently exists
then goes OFF when the ignition is in the ABS system; for example, a sensor
turned ON . . . . . there are no active or circuit malfunction on the left front steering
stored faults in the hydraulic ABS axle. An active fault must be repaired before
IF . . . the ABS indicator lamp comes on and you can display additional faults. Once an
stays on AFTER the ignition is turned ON active fault has been repaired, it becomes a
stored fault.
and
Stored Fault: A condition that caused the
The vehicle is driven in excess
system to register a fault, but is not currently
of 4 mph (6 km/h) . . . There may be
active. For example, a loose wire that
an active fault in the hydraulic ABS
corrected itself. A stored fault can also be an
IF . . . ABS indicator lamp comes on and active fault that has been corrected (refer to
stays on Active Fault).
and Table C describes the method of distinguishing
Goes OFF after the vehicle is driven in between active and stored faults and explains
excess of 4 mph (6 km/h) . . . There how to clear them.
may be a stored fault in the
hydraulic ABS
MM39
Section 2
Using Blink Code Diagnostics

Follow the steps listed in Table C to use blink code diagnostics. Refer to Figure 2.7 for blink code
illustrations.
Table C: Identifying D-Version Hydraulic ABS Blink Codes
Troubleshooting with Blink Code Diagnostics
Mode Procedure System Response Action
Step I. Possible responses:
Turn Ignition ON. 1. ABS indicator lamp comes No recognizable active faults in
on momentarily then goes the ABS. No action required.
out, indicating System O.K.
2. ABS indicator lamp does Inspect wiring. Inspect bulb.
not light, indicating Make necessary repairs.
possible wiring fault or
burned-out bulb.
3. ABS indicator lamp stays
on, indicating:
r Fault, or faults, in the Continue with blink code
system. diagnostics. (Go to Step II.)
r Sensor fault during last Continue with blink code
operation. diagnostics. (Go to Step II.)
DIAGNOSTIC
r Faults cleared from ECU, Drive vehicle — lamp will go out

but vehicle not driven. when vehicle reaches 4 mph
(6 km/h).
r ECU disconnected. Connect ECU.
Step II. ABS indicator lamp begins Determine if fault is active or
Press and hold Blink Code flashing two-digit blink code(s). stored:
Switch for one second, then Active Fault: Lamp will
release. repeatedly display one code.
Stored Fault: Lamp will display
code for each stored fault then
stop blinking. Faults will be
displayed one time only.
Step III. First Digit: 1 - 8 flashes, Find definition for blink code on
Pause (1-1/2 seconds). blink code chart.
Count the flashes to Second Digit: 1 - 8 flashes,
determine the blink code. Pause (4 seconds).
Step IV. Active Fault. Make the necessary repairs.
Turn Ignition OFF.
Repair and Record faults. Stored Faults. Record for future reference.
Step V. ABS Indicator Lamp flashes All stored faults successfully
eight times. cleared. Turn ignition OFF.
Turn Ignition ON. Turn ignition ON. The indicator
Clear Faults from memory: lamp will stay on. This is
CLEAR
Press and hold blink code because the ECU is looking for
switch for at least three wheel speed. Drive the vehicle
seconds, then release. at a speed of 4 mph (6 km/h).
Once the ECU senses wheel
speed, the lamp will go off.
Eight flashes not received. Active faults still exist, repeat
Steps I through V.
* If you receive a blink code that is not identified in Table D or Table E, contact the Customer Support
Center at 800-535-5560.
MM39
Section 2
Using Blink Code Diagnostics, Continued

Blink Codes Illustrated
Figure 2.7
1 Second Active Fault

Hold
1-8 Flashes 1-6 Flashes
Pause Pause Pause Pause
Continues until
1.5 s 1.5 s 4s 1.5 s ignition is turned off
Light ON 1st Digit 2nd Digit Repeat of Blink Code
(2) (3) (2) (3)
Blink Code 2-3: Fault in ABS modulator

valve, right rear drive axle.
1 Second Stored Faults

Hold
Displays all stored
Off faults once – last fault
1.5 s 1.5 s 4s 1.5 s stored is displayed first
Light ON 1st Digit 2nd Digit 1st Digit 2nd Digit
1st Stored Fault 2nd Stored Fault
(5) (2) (3) (4)
Blink Code 5-2: Sensor signal erratic,

left front steer axle.
3-4: Too much sensor gap,
left rear drive axle.
1 Second System O.K.

Hold
Pause Pause
Blink Code 1-1: System OK
1.5 s 1.5 s
Light ON (1) (1)
S = Seconds
1002021b
MM39
Section 2
Note: After faults are cleared and

vehicle is started, ABS lamp will stay
3 Second Faults Cleared on until vehicle is driven over 4 mph (6 km/h).
Hold
Continues
Pause Pause Pause Pause Pause
until ignition
1.5 s 4s 4s 4s 4s is turned off
Light ON 8 Quick Blinks = Faults Cleared System System System System
Status Status Status Status
(2) (2) (2) (2)
Code 2
3 Second
Faults Not Cleared (Active Faults Still Exist)
Hold
Continues
until ignition
4s 4s 4s 4s is turned off
Light ON System System System System
Status Status Status Status
(2) (2) (2) (2)
S = Seconds
1002022a
MM39
Section 2

Use the information in Table D, D Version 2. Test the pins indicated. Pin locations to be
Hydraulic ABS Blink Codes (Cab-Mounted ECU) or tested are listed in Column 3.
Table E, D Version Hydraulic ABS Blink Codes
(Frame-Mounted ECU), to identify a fault, check 3. Compare the measurement received against
for proper volt or ohm measurements and repair the correct volt or ohm measurement listed in
Column 4.
the fault.
1. Identify and record the blink code. Blink codes 4. Follow the instructions listed in Column 5.
are identified in Columns 1 and 2.
Table D: D Version Hydraulic ABS Blink Codes (Cab-Mounted ECU)
CAB
Ignition Key ON to determine ABS
blink code fault Ignition Key OFF to test system (except where noted)
1 2 3 4 5
Correct Volt
Fault Pins to be Ohm Meter
Code Problem Area Connector Tested Readings Action
1-1 System OK None required
2-1 Right Front 15-pin IV 5 and 3 Inlet valve: Check electrical

Solenoid valve (inlet or outlet 6.5 ± 0.5 resistance of
valve) failure in modulator, ohms affected valve
wiring harness or inside ECU OV 4 and 3 Outlet valve: wiring to ground
3.5 ± 0.5 at ECU vehicle
2-2 Left Front 15-pin IV 2 and 3 ohms connector and at
Solenoid valve (inlet or outlet modulator plug.
valve) failure in modulator,
wiring harness or inside ECU OV 1 and 3 Check voltages at
wiring harness
2-3 Right Rear 15-pin IV 11 and 3 and connectors.
Solenoid valve (inlet or outlet Voltage of ground
valve) failure in modulator, connector should
wiring harness or inside ECU OV 10 and 3 be approximately
0 volts. Make
2-4 Left Rear 15-pin IV 8 and 3 necessary repairs.
Solenoid valve (inlet or outlet
wiring harness or inside ECU OV 7 and 3
2-7 Reference to ground 15-pin 3 to chassis 0 ohms Check ABS

interrupted ground ground
connections.
Make necessary
repairs.
IV = Inlet Valve
OV = Outlet Valve
MM39
Section 2

Table D: D Version Hydraulic ABS Blink Codes (Cab-Mounted ECU), Continued
CAB
1 2 3 4 5
Correct Volt
3-1 Right Front 9-pin 4 and 5 Greater than Check for sensor
sensor — Air gap .2 volts AC adjustment.
at 30 RPM Check for
3-2 Left Front 9-pin 1 and 2 excessive wheel
sensor — Air gap (Rotate bearing endplay.
wheel 1/2 Repair or replace
3-3 Right Rear 9-pin 3 and 6 revolution as needed.
sensor —- Air gap per second)
3-4 Left Rear 9-pin 7 and 8

sensor — Air gap
4-1 Right Front 9-pin 4 and 5 900-2000 Check electrical

sensor — Electrical fault ohms resistance of
affected sensor
4-2 Left Front 9-pin 1 and 2 and wiring at ECU
sensor — Electrical fault connector and at
harness plugs.
4-3 Right Rear 9-pin 3 and 6 Repair or replace
sensor — Electrical fault as needed.
4-4 Left Rear 9-pin 7 and 8
sensor — Electrical fault
5-1 Right Front Check for tire size
wheel — Erratic wheel speed mismatch or
tooth wheel
5-2 Left Front difference. Check
wheel — Erratic wheel speed sensor, sensor
cable and
5-3 Right Rear connector for
wheel — Erratic wheel speed intermittent
5-4 Left Rear contact. Repair or
wheel — Erratic wheel speed replace as
needed.
7-3 Retarder Relay 15-pin 12 to chassis 50-200 ohms Verify proper
ground connections to
relay. (Refer to
wiring diagram.)
7-4 ABS warning lamp 18-pin 18 and 2 10-200 ohms Check bulb.
Repair or replace
as needed.
MM39
Section 2

Table D: D Version Hydraulic ABS Blink Codes (Cab-Mounted ECU), Continued
CAB
1 2 3 4 5
Correct Volt
7-7 Recirculation pump does not 15- and Link pin 15 12 volts if Check the
switch off. 18-pin on 15-pin linked recirculation
connector pump wiring, the
OR and pin 1 on 0 volts if not pump relay and
the 18-pin linked fuse and pump
Recirculation pump does not
switch on (low level with act). connector. connections.
Measure Repair or replace
OR between as needed. If
Recirculation pump motor pin 8 on the pump does not
locked. 18-pin run when pins are
connector linked, replace
7-8 Recirculation pump relay and chassis modulator
sticks. ground. assembly.
Do not hold
for more
than one
minute.
8-1 No voltage to ABS solenoid 18-pin 1 and 12 12 volts DC Check the valve
valves. relay, fuse and
wiring. Repair or
replace as
needed.
8-2 Continuous supply to ECU Check for proper
with ignition off. wiring
connections.
Make necessary
repairs. If
problem persists,
replace ECU.
8-3 Internal ECU Fault Replace ECU.
MM39
Section 2

Table E: D Version Hydraulic ABS Blink Codes (Frame-Mounted ECU)
FRAME
1 2 3 4 5
Correct Volt
1-1 System OK None required
2-1 Right Front Gray IV 4 and 2 Inlet valve: Check electrical

Solenoid valve (inlet or outlet X-1 6.5 ± 0.5 resistance of
valve) failure in modulator, ohms affected valve
wiring harness or inside ECU OV 9 and 2 Outlet valve: wiring to ground
3.5 ± 0.5 at ECU vehicle
2-2 Left Front Gray IV 3 and 2 ohms connector and at
Solenoid valve (inlet or outlet X-1 modulator plug.
wiring harness or inside ECU OV 10 and 2 Check voltages at
wiring harness
2-3 Right Rear Gray IV 6 and 2 and connectors.
Solenoid valve (inlet or outlet X-1 Voltage of ground
valve) failure in modulator, connector should
wiring harness or inside ECU OV 7 and 2 be approximately
0 volts. Make
2-4 Left Rear Gray IV 5 and 2 necessary repairs.
Solenoid valve (inlet or outlet X-1
wiring harness or inside ECU OV 8 and 2
2-7 Reference to ground Gray 2 to chassis 0 ohms Check ABS

interrupted X-1 ground ground
connections.
Make necessary
repairs.
IV = Inlet Valve
OV = Outlet Valve
MM39
Section 2

Table E: D Version Hydraulic ABS Blink Codes (Frame-Mounted ECU), Continued
FRAME
1 2 3 4 5
Correct Volt
3-1 Right Front Green 4 and 9 Greater than Check for sensor
sensor — Air gap X-3 .2 volts AC adjustment.
at 30 RPM Check for
3-2 Left Front Green 5 and 8 excessive wheel
sensor — Air gap X-3 (Rotate bearing endplay.
wheel 1/2 Repair or replace
3-3 Right Rear Green 7 and 6 revolution as needed.
sensor —- Air gap X-3 per second)
3-4 Left Rear Green 3 and 10

sensor — Air gap X-3
4-1 Right Front Green 4 and 9 900-2000 Check electrical

sensor — Electrical fault X-3 ohms resistance of
affected sensor
4-2 Left Front Green 5 and 8 and wiring at ECU
sensor — Electrical fault X-3 connector and at
harness plugs.
4-3 Right Rear Green 7 and 6 Repair or replace
sensor — Electrical fault X-3 as needed.
4-4 Left Rear Green 3 and 10
sensor — Electrical fault X-3
5-1 Right Front Check for tire size
wheel — Erratic wheel speed mismatch or
tooth wheel
5-2 Left Front difference. Check
wheel — Erratic wheel speed sensor, sensor
cable and
5-3 Right Rear connector for
wheel — Erratic wheel speed intermittent
5-4 Left Rear contact. Repair or
wheel — Erratic wheel speed replace as
needed.
7-3 Retarder Relay Black 7 to chassis 50-200 ohms Verify proper
X-2 ground connections to
relay. (Refer to
wiring diagram.)
7-4 ABS warning lamp Black 8 and 2 10-200 ohms Check bulb.
X-2 Repair or replace
as needed.
MM39
Section 2

Table E: D Version Hydraulic ABS Blink Codes (Frame-Mounted ECU), Continued
FRAME
1 2 3 4 5
Correct Volt
7-7 Recirculation pump does not Black Link pins 6 12 volts if Check the
switch off. X-2 and 3. linked recirculation
pump wiring, the
OR Measure 0 volts if not
pump relay and
between linked
Recirculation pump does not fuse and pump
pin 10 and
switch on (low level with act). 12 volts DC connections.
chassis
Repair or replace
OR ground. Turn Ignition as needed. If
Do not hold ON pump does not
Recirculation pump motor
locked. for more run when pins are
than one linked, replace
7-8 Recirculation pump relay minute. modulator
sticks. assembly.
8-1 No voltage to ABS solenoid Black 3 and 9 12 volts DC Check the valve
valves. X-2 relay, fuse and
wiring. Repair or
replace as
needed.
8-2 Continuous supply to ECU Check for proper
with ignition off. wiring
connections.
Make necessary
repairs. If
problem persists,
replace ECU.
8-3 Internal ECU Fault Replace ECU.
MM39
Section 2
Testing the System Figure 2.8

This section of the manual contains information
for testing the hydraulic ABS with TOOLBOX
Software, as well as procedures for conducting
standard air and electrical tests.
WARNING
Exhaust gas contains poison. When testing a

vehicle with the engine running, test in a
well-ventilated area or route the exhaust
hose outside.
To avoid serious personal injury, keep away, and

keep test equipment away, from all moving or hot
engine parts.
1004696a
Refer to, and follow, the vehicle manufacturer’s
Warnings, Cautions and Service Procedures.
When testing, set the parking brake and place the Figure 2.9
gear selector in NEUTRAL (manual transmission)
or PARK (automatic transmission) unless
otherwise directed.
Meritor WABCO
TOOLBOX Software
Use TOOLBOX Software to verify the activation of
various system components:
Turn valves, pump and retarder relay on and
1004700a
off (Valve Activation Menu). Turn ABS
indicator lamp on and off (Miscellaneous
Output Activation Menu). Reset components in
ECU memory. Figure 2.10
NOTE: For complete instructions for using this

program, refer to the User’s Manual, TP-99102.
Contact Meritor WABCO at 800-535-5560 for
information about TOOLBOX Software.
Valve, Pump and Retarder

Relay Activation
To activate the ABS valves, pump or retarder relay,
select HABS (Hydraulic ABS) from the Main Menu.
The Hydraulic ABS Main Menu will appear.
Figure 2.8.
Select the Valve Activation icon or select 1004701a
Component Tests, then Valves to use the
pull-down menu. Figure 2.9. This displays the
Valve Activation screen. Figure 2.10.
MM39
Section 2
The Valve Activation screen lets you activate the This screen provides a check of the ABS indicator
four valves, the pump and the retarder relay. In lamp. In addition, it provides a way to check either
addition to checking for proper activation, this inlet or outlet activity of the valves, pump or
screen provides an easy way to make sure the retarder relay. Component activation status
valves are wired properly — and that wiring is not appears in the status box of this screen.
reversed. Component activation status appears in
the status box of this screen. Reset Memorized
ABS Indicator Lamp Activation This is an automatic default and cannot be
de-selected. It indicates the ECU has memorized
To activate the ABS indicator lamp, select HABS the installed retarder relay. Once the ECU has seen
(Hydraulic ABS) from the Main Menu. The a retarder, it expects to see it every time the
Hydraulic ABS Main Menu will appear. Figure 2.8. vehicle is powered up. Figure 2.13.
Select the Miscellaneous Output Activation icon or Because there are times when an ECU is moved to
select Component Tests to use the pull-down another vehicle — or during diagnostic testing —
menu Figure 2.11 to display the Actuate you may want the ECU to disregard this learned
Miscellaneous Output screen. Figure 2.12. component. Use the Reset Memorized command
for this purpose.
Select Component Tests from the Hydraulic ABS
Figure 2.11
Main Menu. Then, select Reset Memorized from
the pull-down menu to reset the Learned
Component screen. Figure 2.14.
Figure 2.13
1004702a
Figure 2.12
1004704a
Figure 2.14
1004705a
1004703a
MM39
Section 2
Standard Testing Standard Component Testing

Test Equipment: Volt-Ohm ABS Indicator Lamp
Meter (VOM) If the ABS indicator lamp does not come on after
Use of a VOM with automatic polarity sensing the ignition is turned on, or it comes on but does
is recommended. This eliminates the concern not go out after three seconds, check all ABS fuses
of the polarity of the meter leads during or circuit breakers and replace if necessary. Check
voltage measurements. the wiring to the ABS diagnostic switch and the
indicator lamp and repair or replace the wiring as
required. When checking the indicator lamp,
System Requirements and follow these steps:
Component Tests 1. Check voltage potential at the lamp socket.
2. Check continuity of the wires to the socket.
Tire Size Range 3. Replace the bulb.
For proper hydraulic ABS operation, front and
rear tire sizes must be within 16% of each other. NOTE: A complete wiring diagram for 4S/4M
D-version hydraulic ABS appears in Figure 2.1.
Contact the Meritor WABCO Customer Support
Center at 800-535-5560 if you plan a tire size
difference greater than ±8%. ABS Blink Code Switch
Calculate the tire size with the following equation: When testing the ABS Diagnostic switch:
펁 펂
1. Check the resistance between the terminals
RPM Steer while cycling the switch. A lack of resistance is
% Difference = – 1 x 100
RPM Drive an indication of a faulty switch.
RPM = tire revolutions per mile 2. Check the continuity of the wires to the
switch:
Cab-mounted ECU: Pins 18 and 12 on the
CAUTION 18-pin connector.
When troubleshooting or testing the ABS system, Frame-mounted ECU: Pins 8 and 9 on the
do not damage the connector terminals. black connector.
Voltage Check Sensor Adjustment

Voltage must be between 9.5 and 14 volts for the On steering axles, the sensor is typically
12-volt hydraulic ABS to function properly. accessible on the in-board side of the steering
Check voltage as follows: knuckle.
1. Turn ignition ON. On drive axles, the sensor is typically accessible

on the in-board side of the rear axle spindle.
2. Check for proper voltage:
To adjust the sensor, push the sensor in until it
Cab-mounted ECU: Pins 12 and 1 and 12 and 2 contacts the tooth wheel:
on the 18-pin connector.
r Do not pry or push sensors with
Frame-mounted ECU: Pins 9 and 3 and 9 and 2 sharp objects
on the black connector.
r Sensors will self-adjust during
If voltage is not between 9.5 and 14 volts, wheel rotation.
verify proper wiring connections. Make
corrections as required. NOTE: No gap is allowable at installation. During
normal operation a gap not to exceed 0.04-inch
is allowable.
MM39
Section 2
Sensor Output Voltage Test To measure resistance at the sensor connector,

disconnect the sensor from the sensor
Sensor output voltage must be at least 0.2 volts extension cable.
AC at 30 rpm. Test the sensor output voltage
as follows: 3. Measure output at the pins indicated in
Table F, Sensor Check Pins.
1. Turn ignition OFF.
If measurement is not between 900 and
2. Disconnect the ECU. To measure voltage at the 2000 ohms, replace the sensor.
pins on the ECU connector, disconnect the
sensor from the sensor extension cable.
WARNING
jacks. Jacks can slip and fall over. Serious
personal injury can result.
3. Put blocks under the front and rear tires to

stop the vehicle from moving.
4. Raise the vehicle off the ground. Put safety
stands under the axle.
5. Rotate wheel by hand at 30 rpm
(1/2 revolution per second).
6. Measure the voltage at the pins indicated in
Table F.
Table F: Sensor Check Pins

Cab- Frame-
Mounted Mounted
Pins (9-Pin Green
Sensor Connector) Connector
Left Front 1 and 2 5 and 8
Right Front 4 and 5 4 and 9
Left Rear 7 and 8 3 and 10
Right Rear 3 and 6 7 and 6
Sensor Resistance
The sensor circuit resistance must be between 900
and 2000 ohms. Measure resistance at the sensor
connector, or at the pins on the ECU connector,
as follows:
1. Turn ignition OFF.
2. To measure resistance at the pins on ECU
connector, disconnect the ECU connector from
the ECU.
MM39
Notes
MM39
Section 3
Component Replacement
Component Removal
Section 3 Replacement
Component 4. Remove the sensor from the sensor holder.
Twist and pull the sensor to remove it from the
and Installation sensor bracket. Do not pull on the cable.
Figure 3.1.
Sensors
Figure 3.1
Sensor Lube Specification
Meritor WABCO specifications call for a sensor KNUCKLE-MOUNTED
lubricant with the following characteristics: SENSOR
Lube must be mineral oil-based and contain

molydisulfide. It should have excellent
anti-corrosion and adhesion characteristics and be
capable of continuous function in a temperature
range of –40˚ to 300˚F (–40˚ to 150˚C).
Wheel Speed Sensor Replacement —

Front Axle
Removal 1004706a
WARNING
Installation
eye protection when you perform vehicle 1. Connect the sensor cable to the chassis
maintenance or service. harness.
2. Install the fasteners used to hold the sensor
Block the wheels to prevent the vehicle from cable in place.
Do not work under a vehicle supported only by 3. Apply a Meritor WABCO-recommended
jacks. Jacks can slip and fall over. Serious personal lubricant to the sensor spring clip and sensor.
injury can result. 4. Install the sensor spring clip. Make sure the
spring clip tabs are on the inboard side of
To avoid damage to the electrical system the vehicle.
or ABS components, when welding on an
ABS-equipped vehicle disconnect the power 5. With the tabs on the inboard side, push the
connector from the ECU. sensor spring clip into the bushing in the
steering knuckle until the clip stops.
1. Apply the parking brakes. Chock the rear tires 6. Push the sensor completely into the sensor
to prevent vehicle movement. spring clip until it contacts the tooth wheel.
If necessary, raise the front tires off the 7. Fasten the sensor cable with tie wraps every
ground. Put safety stands under the axle. 12 inches. Properly bundle and store excess
2. Disconnect the fasteners that hold the sensor cable in the sub frame. Figure 3.2.
cable to other components. 8. Remove the blocks and safety stands.
3. Disconnect the sensor cable from the 9. Perform a voltage output check to ensure
chassis harness. proper installation. Refer to “Sensor Output
Voltage Test” in Section 2.
MM39
Section 3
Wheel Speed Sensor Replacement — Figure 3.2

Rear Axle
Removal
BUNDLE
1. Apply the parking brake. Chock the front tires EXCESS
to prevent vehicle movement. CABLE
2. Raise the rear tires off of the ground. Put

safety stands under the axle.
3. If the rear tire must be removed to gain access
to the sensor, release the parking brake to
release the brake shoe.
Remove the wheel and tire assembly from the
axle. 1004707a
4. Remove the sensor from the mounting block

in the axle housing. Use a twisting motion if
necessary. Do not pull on the cable. 7. Replace the tire, remove the safety stands,
lower the vehicle and remove the chocks from
5. Disconnect the sensor cable from the the front tires.
chassis harness.
8. Perform a voltage output check to ensure
6. Remove the sensor cable from any cable proper installation. Refer to “Sensor Output
clamps or clips. Voltage Test” in Section 2.
7. Remove the sensor spring clip from the
sensor bracket.
Installation
1. Connect the new sensor cable to the
chassis harness.
2. Press the sensor spring clip into the sensor
bracket, located on the rear axle, until it stops.
Make sure the tabs are on the inboard side.
3. Apply a Meritor WABCO-recommended
lubricant to the sensor.
4. Push the sensor completely into the spring clip
until it contacts the tooth wheel.
5. Reattach the sensor cable to the cable
clamps or clips.
6. Fasten the sensor cable with tie wraps every
12 inches. Properly bundle and store excess
cable in the sub frame. Figure 3.2.
MM39
Section 3
Modulator Assembly Modulator Assembly Installation

1. Position the modulator assembly and bracket
Modulator Assembly Removal in place on the vehicle. Figure 3.3.
CAUTION
Figure 3.3
The modulator assembly contains hydraulic brake
fluid, a caustic substance. Remove the valve
carefully so that fluid does not leak and cause
skin irritation or damage to components.
1. Apply the parking brakes. Chock the front and

rear tires to prevent vehicle movement.
2. Place a container under the modulator
assembly to catch leaking brake fluid.
3. Disconnect the electrical harness connectors
from the modulator assembly.
4. Mark the six brake lines for ease of
installation. Disconnect the lines from the
modulator assembly.
5. Remove the three mounting capscrews,
washers and nuts that attach the modulator
assembly and bracket assembly to vehicle.
NOTE: Whenever any hydraulic system fitting is

loosened or disconnected, the entire system must
be bled to remove any air that may have entered.
6. Remove the modulator assembly and bracket.
1004708a
2. Tighten the three mounting nuts to 132 lb-in

(15 N•m).
3. Connect and tighten brake line connections as
follows:
r Two small (MI0XI) adapters:
108 lb-in (12 N•m).
r Four large (MI2XI) adapters:
132 lb-in (15 N•m).
4. Bleed the brake system, per the
following instructions.
5. Connect the electrical harnesses to the
modulator assembly.
MM39
Section 3
Brake Bleeding Procedures

CAUTION
General Hydraulic brake fluid is a caustic substance.
Contact with hydraulic brake fluid can cause skin
The following brake bleeding methods explain irritation. Do not let hydraulic brake fluid touch
how to bleed the hydraulic ABS modulator any painted surfaces, as it will remove the paint.
assembly during installation, or in the event of air Hydraulic brake fluid may also damage certain
in the brake system. There are instructions for non-metal surfaces. Do not let fluid get on brake
both pressure and manual bleeding procedures. pads, shoes, rotors or disks.
These instructions include the procedure for
bleeding both the master cylinder and the brake Pressure Fill and Bleed
system. In some cases, for example, if you are
replacing only the modulator assembly, it may not Pressure fill and bleed is the preferred method for
be necessary to bleed the master cylinder. If you bleeding the service brake system. It requires the
have any questions, please contact the Meritor use of a special pressure bleeder kit, consisting of
Service Center at 800-535-5560. a tank, pressure pump and valve, gauge, tubing
and adapter. These kits are available from a
NOTE: The modulator assembly must be handled number of manufacturers and include instructions
with appropriate care and should not be exposed for use. Figure 3.4.
to excessive impact or compressed air at the
hydraulic ports prior to assembly.
Figure 3.4
WARNING
Failure to bleed the system whenever any
hydraulic system fitting is loosened or
disconnected will allow air to remain in the
system. This will prevent the hydraulic pressure
in the brake system from rising enough to apply
the brakes properly. This will cause the stopping
distance to increase and can result in serious
personal injury.
Properly discard hydraulic brake fluid that is

removed from the brake system. Hydraulic brake
fluid that is removed can be contaminated and can
cause damage, loss of braking and serious
personal injury.
1004709a
Use only the type of hydraulic brake fluid specified
by the equipment manufacturer. Do not use or mix
different types of hydraulic brake fluid. The wrong
hydraulic brake fluid will damage the rubber parts
of the brake caliper and can cause damage, loss of
braking and serious personal injury.
NOTE: Use DOT 3 or DOT 4 hydraulic brake fluid.

Refer to the vehicle specifications to determine
which fluid to use.
MM39
Section 3
Pressure Fill and Bleed Procedure: NOTE: Both the tubing and container must be
able to withstand the effects of hydraulic brake
1. Apply the parking brake and chock the tires. fluid.
Turn the ignition OFF and disconnect the
battery terminals.
Figure 3.5
NOTE: The ignition must remain off for the
entire bleed procedure; energizing the unit
during bleeding must be impossible.
2. Fill the pressure bleeder with new DOT 3 or

DOT 4 hydraulic brake fluid. Refer to the
vehicle specifications to determine which fluid
to use.
3. Follow the manufacturer’s instructions to
connect the pressure bleeder to the brake
master cylinder reservoir.
4. Set filling pressure to 20 to 30 psi (1.5 to
2.0 bar).
5. Turn on bleed equipment until fluid level in
reservoir reaches approximately 0.875-inches
(20 mm).
6. Release pressure for 3 to 5 seconds. Apply
pressure for 5 to 10 seconds.
1004710a
7. Repeat Steps 5 and 6 approximately 10 times.
After releasing the pressure, air bubbles
should rise up into the reservoir.
Loosen the bleeder fitting until the fluid begins
to flow (about 3/4 turn). Let the hydraulic fluid
WARNING flow out of the fitting until it is free of air
Do not let the brake master cylinder fluid get bubbles.
below the minimum level during the bleeding 10. Tighten firmly to secure the fitting.
operation. Keep the master cylinder reservoir
filled with new DOT-approved brake fluid, as 11. Repeat Steps 5 through 8 to bleed the
specified by the original equipment manufacturer. remaining three brake actuators. Bleed in
Failure to keep the brake reservoir level above sequence of the longest to shortest circuit
minimum could result in more air entering from the modulator assembly.
system, making it impossible to effectively bleed 12. Turn off bleed equipment and remove
the system. pressure. Remove bleed device and check fluid
level in reservoir. Fill if required. Replace
8. Bleed the brake system: reservoir cap and dispose of used brake fluid.
r Set filling pressure to 20 to 30 psi (1.5 to 13. Remove wheel chocks.
2.0 bar).
r Put a wrench on the brake actuator bleeder Manual Bleed Procedure:
fitting. Start with the farthest from the 1. Apply the parking brake and chock the tires.
modulator, (typically the right rear), then Turn the ignition OFF and disconnect the
attach a length of clear plastic tubing to the battery terminals.
bleeder fitting. Make sure the tube fits
snugly. NOTE: The ignition must remain off for the
9. Submerge the tubing in a container of clean entire bleed procedure; energizing the unit
hydraulic brake fluid. Figure 3.5. during bleeding must be impossible.
MM39
Section 3
2. Fill the reservoir with DOT 3 or DOT 4 14. Check the fluid level in reservoir and fill if
hydraulic brake fluid. Refer to the vehicle required. Replace reservoir cap and dispose of
specifications to determine which fluid to use. used brake fluid.
3. Depress the brake pedal five times using the 15. Remove wheel chocks.
stroke between 1/3 travel and maximum travel
in 5 seconds.
4. Release the pedal for 5 to 10 seconds. Air
bubbles will rise into the reservoir while
depressing and releasing pedal.
5. Repeat Steps 3 and 4 another three times, or
until sufficient pedal resistance is felt.
WARNING
Do not let the brake master cylinder fluid get
below the minimum level during the bleeding
operation. Keep the master cylinder reservoir
filled with new DOT-approved brake fluid as
specified by the original equipment manufacturer.
Failure to keep the brake reservoir level above
minimum could result in more air entering
system, making it impossible to effectively bleed
the system.
6. Bleed the brake system. Put a wrench on the

brake actuator bleeder fitting. Start with the
farthest from the modulator, (typically the right
rear), then attach a length of clear plastic
tubing to the bleeder fitting. Make sure the
tube fits snugly.
7. Submerge the tubing in a container of clean
brake fluid. Figure 3.5.
NOTE: Both the tubing and container must be

able to withstand the effects of brake fluid.
8. Depress the brake pedal 10 to 15 times, using

the maximum available stroke.
9. Loosen the bleeder fitting until the fluid begins
to flow, (about 3/4 turn), while depressing the
brake pedal through its maximum available
stroke.
10. Tighten the fitting firmly prior to releasing the
brake pedal.
11. Repeat Steps 6 through 8 several times until
the discharged fluid is free of air bubbles.
12. Repeat Steps 3 through 9 to bleed the
remaining three brake actuators. Bleed in
sequence of the longest to the shortest circuit
from the modulator.
13. Check the travel of the brake pedal. If a firm
resistance is felt the manual bleeding
procedure is complete.
MM39
Section 4
Appendix A
Section 4 A
Appendix
Modulator Assembly Connector Pin Assignment
HARNESS MODULATOR ASSEMBLY

CONNECTOR PINOUT CONNECTOR PINOUT
5 4 3 2 1 1 2 3 4 5
9 8 7 6 6 7 8 9
PUMP
13 12 11 10 10 11 12 13
CONNECTOR
MAIN
+
GROUND
-
1004711a
Pin Pin
Number Circuit Description Number Circuit Description
1 Outlet Valve RL 8 Reference Ground
2 Inlet Valve RL 9 –––––
3 ––––– 10 Outlet Valve RR
4 Inlet Valve FR 11 Inlet Valve RR
5 Outlet Valve FR 12 Inlet Valve FL
6 ––––– 13 Outlet Valve FL

7 –––––
MM39
Meritor WABCO Information contained in this publication was in effect at the time the publication was approved for
Vehicle Control Systems printing and is subject to change without notice or liability. Meritor WABCO reserves the right to revise
3331 West Big Beaver Road, Suite 300 the information presented or discontinue the production of parts described at any time.
Troy, MI 48084 USA
800-535-5560 Copyright 2000 Maintenance Manual 39
meritorwabco.com ArvinMeritor, Inc. Revised 09-00
ABS (ANTI-LOCK BRAKE SYSTEM) (FULL AIR; MERITOR WABCO MAKE) BR03–1
ABS (ANTI-LOCK BRAKE SYSTEM) (FULL AIR;

BR03
MERITOR WABCO MAKE) BR03-002
ABS ...........................................................BR03-2
OVERVIEW...................................................... BR03-2
COMPOSITION AND OPERATION ................. BR03-3
FUNCTION ...................................................... BR03-6
PRECAUTIONS WHEN DRIVING VEHICLES
EQUIPPED WITH ABS .................................... BR03-7
OVERVIEW AND FUNCTION.......................... BR03-8
INSPECTION (FRONT WHEEL BRAKE) ...... BR03-12
INSPECTION (REAR WHEEL BRAKE)......... BR03-14
BR03–2 ABS (ANTI-LOCK BRAKE SYSTEM) (FULL AIR; MERITOR WABCO MAKE)
ABS
OVERVIEW
EN0600203C100001
ABS is a system that makes effective use of the friction between the tires
and the road surface to maintain vehicle stability while the brakes are being
applied and for stopping the vehicle.
Applying the brakes forcefully on a slippery road surface can cause the
wheels to be locked, due to excessive braking force. This causes the vehi-
cle to lose stability because the locked wheels lose resistance in the lateral
direction. More specifically, if the front wheels are locked, it becomes
impossible to steer the vehicle, and if the rear wheels are locked, the rear of
the vehicle may fishtail from side to side.
Also, when wheel-locking occurs, it is not possible to make effective use of
friction between the tires and the road surface. This may cause the braking
distance to be increased.
ABS uses wheel sensors mounted on the axles to constantly monitor the
rotation of the wheels. If any of the wheels is starting to lock up, the ABS
computer sends signals to the ABS control valve and immediately adjusts
the brake pressure to prevent wheel-locking.
In this way, ABS maintains the stability of the vehicle while stopping by
making effective use of the friction between the tires and the road surface.
SAPH06ABC0300040
1 Wheel speed sensors 3 Relay valve

2 ABS modulator valves 4 ECU
COMPOSITION AND OPERATION

EN0600203C100002
The ABS system is comprised of sensor rings mounted on the wheels. The
ABS computer, which receives signals from the wheel sensors that monitor
the rotational speed of the wheels and outputs control signals to maintain
the appropriate braking force; ABS control valves, which increase or
decrease the braking force, based on the control signals; the warning lamp,
which gives an alarm if the system malfunctions; the piping, wire har-
nesses, etc., that link together the various units that compose the system.
Pulse signals transmitted by the sensor rings mounted on the wheel hubs,
rotated together with the wheels, and the wheel sensors mounted near sen-
sor ring on the axles are sent to the ABS computer. The ABS computer
then calculates the wheels' rotational speed, acceleration, deceleration,
and amount of slippage, based on these signals.
If the limit values for the wheel's deceleration, or slippage ratio are
exceeded, the ABS computer immediately transmits signals to the ABS
control valves to adjust any excess braking force.
This ABS system controls the four wheels, front, rear, right, and left, inde-
pendently.
SYSTEM COMPOSITION DIAGRAM
SAPH06ABC0300041
1 Brake valve 5 ABS computer

2 Brake chamber 6 Wheel sensor
3 Relay valve 7 ABS warning light
4 ABS control valve A From air tank
ABS CONTROL FLOWCHART
INPUT SIGNALS ABS COMPUTER OUTPUT SIGNALS
Front left wheel sensor
Front right wheel sensor ABS control valve for

front left wheel
Rear left wheel sensor

ABS control valve for
front right wheel
Rear right wheel sensor

rear left wheel
ABS COMPUTER

rear right wheel
Malfunction code
(diagnostic code)
ABS warning light
SAPH06ABC0300042
BASIC PRINCIPLE
Based on its relationship with the slip ratio, which is determined from the
wheels' rotational speed and the vehicle's speed, ABS controls the brake
force so that it will be most effective.
When the driver applies the brakes, the rotation of the wheels is controlled
and the vehicle speed drops. However, the momentum of the vehicle
attempts to push it forward further even though the rotation of the wheels is
being halted. At this point, slipping will occur if there is a gap between the
wheels' rotational speed and the vehicle's speed. The slip ratio is a value
that indicates the rate of slippage.
Vehicle's speed - Wheel's rotational speed

Slip ratio = 100 %
Vehicle's speed
Slip ratio 0 % : No slipping between the wheels and the

road surface
100 % : Wheels locked
The graph shown at left shows the relationship between the friction coeffi-
cient of the tires and of the road surface and the slip ratio.
In an ABS-equipped vehicle, the brake force is controlled to ensure that it is
within the range where the friction coefficient is high (shaded portion of the
graph) without locking the wheels. This ensures efficient braking perfor-
mance.
SAPH06ABC0300044
OPERATION
The ABS control characteristics line graph at left illustrates how the vehi-
cle's speed, the wheels' rotational speed, the wheel acceleration/decelera-
tion, and the air pressure at the ABS control valve outlet change over time
after the brakes are applied.
When the brakes are applied, the vehicle's speed and the wheels' rotational
speed drop and at the same time, the wheel acceleration/deceleration
speed also drops. At point T1, a gap begins to open between the wheels'
rotational speed and the vehicle's speed. Passing on point T2, the ABS
computer detects that the wheels are beginning to lock and is lowering the
outlet air pressure of the ABS control valve to prevent wheel locking from
occurring.
At point T3, the wheel acceleration/deceleration speed is starting to return
to normal one, and the ABS computer stops lowering the air pressure at the
ABS control valve outlet and maintains it at a constant level.
At point T5, the wheels' rotational speed and the vehicle's speed are about
the same. The ABS computer detects that the wheels are no longer likely to
be locked and increases the air pressure at the ABS control valve outlet.
The above processes is repeated over and over until the vehicle comes to a
complete stop.
SAPH06ABC0300045
FUNCTION
EN0600203C100003
FAIL-SAFE FUNCTION
This ABS system is equipped with a fail-safe function that causes the ABS
warning light on the instrument panel to light and to restore the normal
(non-ABS) brake system, should an ABS malfunction occur.
Note that the ABS system consists of two independent circuits. Should a
malfunction occur for whatever reason in the electrical circuits, that sys-
tem's ABS is switched off and the normal brake system is restored while
ABS control continued for the other system. This configuration is designed
to minimize the effects of any malfunction on ABS function.
PRECAUTIONS WHEN DRIVING VEHICLES EQUIPPED WITH ABS

EN0600203F100001
Electronically, ABS uses the coefficient of friction (the amount of traction) between the tires and the road surface to monitor the
speed of each wheel. If one or more wheels indicates the possibility of locking, resulting in fishtailing or other loss of stability,
ABS enables the vehicle to be brought to a stop. Even with ABS, however, a driver must operate the vehicle in a safe manner
and recognize the following points with respect to the operation of ABS.
CHECK POINTS REMEDIAL ACTIONS
Even with ABS, the braking distance on a wet or slippery Even with ABS, always drive safely, tak-
road will be longer than on a dry road, and if the road ing into consideration the road and traffic
surface is covered with ice, snow or gravel, the braking conditions and the condition of your tires,
distance will be even greater. including tire type and tire wear. Always
keep a safe distance from any vehicle
being driven in front of you.
ABS does not operate when the vehicle is starting, ac-
celerating or turning, and will not assist in maintaining
directional stability or steerability or in shortening the brak-
If engine braking causes instability or fish-
ing distance.
tailing, the clutch should be engaged or
Even if the ABS is operational, where the coefficient of
the transmission shifted to neutral, to pre-
friction is very low, such as on an icy roadway, skidding,
vent the application of the engine brak-
inability to steer, and instability may occur because of
ing to the drive wheels.
insufficient traction by the tires.
If the air pressure becomes low and the

Where engine braking, as a result of downshifting, oc- air pressure warning lamp comes on and
curs on a surface with a low coefficient of friction, such a buzzer sounds, immediately stop the
as ice, the drive wheels may lock, causing fishtailing or vehicle in a safe place. Begin driving
vehicle instability. ABS does not operate unless the brake again only after the return to normal air
pedal is applied. pressure.
If the ABS engages, the vehicle's air consumption rate Vibrations and noise during the operation
will be higher than usual. of ABS are not malfunctions. Remain calm
and continue to steer the vehicle in an
appropriate manner.
When ABS is activated, the driver may experience a small
amount of vibration (especially if the road surface be-
tween the left and right tires is different) and difficulty in If the warning lamp lights again when you
steering. Also, the operation of the ABS may generate reach a speed about 6 km/h (4 mph)
some noise. the ABS system may not be functioning
properly. Have it inspected and repaired
The ABS warning light will come on when you turn the if necessary *
starter switch to the "on" position. It stays on briefly and The warning lamp can be reset by turn-
then turns off automatically. If the light does not come ing off the engine while the vehicle is at
on, have your vehicle inspected and serviced immedi- rest. If the warning lamp fails to go out
ately at your nearest HIno service dealer. after the engine is restarted and the speed
indicated above is reached, or if it lights
frequency while the vehicle is being
driven, the ABS must be inspected.
OTHER CHECKPOINTS REGARDING HANDLING

1. When washing the vehicle, take care not to direct high-pressure streams of water at the ABS valves, harnesses, or connec-
tors. Also, under no circumstances should the ABS computer or electrical relays be exposed to water.
2. Be very careful not to damage the ABS wire harness when removing snow, ice, mud or other material from the outside or
underside of the vehicle.
3. All electronic and radio equipment installed on the vehicle must be mounted as far away from the ABS computer and wire
harness as possible. Installation of certain electronic and radio equipment can also cause the ABS computer to malfunction.
All such equipment must also conform to all applicable laws. If you wish to install a radio or other electronic equipment,
please contact your Hino service representative.
SAPH06ABC0300046
OVERVIEW AND FUNCTION

EN0600203C100004
1. ABS COMPUTER
Based on pulse signals from the wheel sensors, the ABS computer
mounted in the vehicle calculates and evaluates the slip ratio and the accel-
eration/deceleration speed of the wheels. Based on the results, it sends
signals to the ABS control valves as necessary, causing them to operate
and apply the brakes to maintain the slippage of the wheels within the opti-
mal range.
During braking, the air pressure applied to the brake chambers is regulated
to prevent the wheels from locking. The brakes are applied so as to main-
tain the slippage of the wheels within the optimal range.
Regardless of whether the vehicle is stopped or being driven, and whether
or not the brakes are being applied, the circuit consisting of the wheel sen-
sors, control valves, ABS computer, and wire harnesses are constantly
being checked by the ABS computers' fail-safe circuit. If some sort of mal-
function occurs, the fail-safe circuit warns the driver by lighting the ABS
warning light. At the same time, the ABS system that is experiencing the
malfunction is shut off and braking is restored to normal (non-ABS) opera-
tion.
SAPH06ABC0300047
2. ABS CONTROL VALVES

(1) Overview
ALSO AVAILABLE WITH • The ABS control valves are positioned in the brake air circuit on the
AIR OUT OPEN-STYLE CONNECTOR
way to brake chambers. Based on signals from the ABS computer,
they adjust the air pressure sent to the brake chambers in one of three
AIR IN
modes: pressure increase, pressure reduction, or pressure mainte-
nance.
BAYONET-STYLE
CONNECTOR
SAPH06ABC0300048
SAPH06ABC0300049
(2) Operation
PRESSURE INCREASE a. PRESSURE INCREASE MODE
14 5 • When the driver steps on the brake pedal, air from the relay valve
VALVE OPERATING STATUS
10
enters through inlet port (6), pushes open diaphragm (5), passes
through outlet port (9), and flows into the brake chamber. At this point,
6
3 solenoid coil (1) is not energized, so solenoid valve (3) is closed and
9
pilot chamber (14) is open to the atmosphere. Also, solenoid coil (2) is
13 also not energized, so solenoid valve (4) is closed. As a result, air
passes through pilot hole (10) and enters pilot chamber (12). It then
pushes up diaphragm (11) and closes exhaust valve (13).
1
2
4 12 11
Solenoid valve for driving inlet

OFF
STATUS
valve 3
Solenoid valve for driving
OFF
exhaust valve 4
PRESSURE
Brake chamber
pressure
0 TIME
SAPH06ABC0300050
b. PRESSURE REDUCTION MODE

PRESSURE REDUCTION
• When solenoid coil (1) is energized, solenoid valve (3) opens and air
14 5
also flows into pilot chamber (14). It pushes down on diaphragm (5),
shutting off chambers (7) and (8). At the same time, solenoid coil (2)
is also energized. This causes solenoid valve (4) to open and the
7 operating air from pilot chamber (12) passes through exhaust port
3 9 (15) and is released into the atmosphere. Consequently, the air from
8
the outlet port (9) side (brake chamber) pushes down on diaphragm
(11) and air is released into the atmosphere. This causes the air pres-
sure of the brake chamber to decrease.
1
2
12
4 15 11
ON
STATUS
valve 3
ON
exhaust valve 4
PRESSURE
Brake chamber
pressure
0 TIME
SAPH06ABC0300051
c. PRESSURE MAINTENANCE MODE

PRESSURE MAINTENANCE
• When solenoid coil (1) is energized, solenoid valve (3) opens and air
14 5 flows through chamber (7) and acts on pilot chamber (14). On the
10 other hand, since solenoid coil (2) is not energized, solenoid valve (4)
is closed and air flows through pilot hole (10) and acts on pilot cham-
3 ber (12). This causes diaphragms (5) and (11) to shut off their air pas-
8
sages, and the chamber (8) pressure, that is to say the air acting on
the brake chamber, is maintained at the pressure that was current
when the switch from the pressure reduction mode to the pressure
maintenance mode took place.
1
2
11
12
4

ON
STATUS
valve 3
OFF
exhaust valve 4
PRESSURE
Brake chamber
pressure
0 TIME
SAPH06ABC0300052
3. WHEEL SENSORS
These sensors are mounted, facing the sensor rings on each wheel on the
front and rear axles.
The wheel sensors are electromagnet sensors consisting of a permanent
magnet core with a coil of wire wrapped around it.
The frequency of the pulse signals generated by magnetic inductance
between the sensors and the sensor rings they face is proportional to the
rotational speed of the wheels. These pulse signals are sent to the ABS
computer and are used to determine the wheels, rotational status.
SAPH06ABC0300053
SAPH06ABC0300054
4. SENSOR RINGS
The sensor rings are press-fitted into the insides of the wheel hubs of each
wheel on the front and rear axles, and they face the wheel sensors
described in the preceding section. The sensor rings are made of a mag-
netic material, and teeth are cut into the surface which faces the wheel sen-
sor at regular intervals. Also, when the sensor ring performs one complete
rotation, the sensor generates pulse signals corresponding to the number
of teeth.
SAPH06ABC0300055
5. CLAMPING BUSHINGS
The wheel sensors are held in place through friction by clamping bushings
that are inserted into the mounting brackets. If they are assembled properly,
the clamping bushings serve to eliminate the need to adjust the clearance
between the wheel sensors and sensor rings.
SAPH06ABC0300056
6. WHEEL SENSOR HARNESSES

Each wheel sensor wire harness employs a two-conductor twisted wire
cable. Its function is to protect the wheel sensor signals, which are vital to
the proper operation of the ABS system, from electromagnetic interference.
Under no circumstances should any part of the wheel sensor wire har-
nesses be cut or connected to any other wire.
SAPH06ABC0300057
7. ABS WARNING LIGHT

The status of the ABS system is indicated.
It lights when the starter switch is turned "ON" and automatically goes off
[USA] [CANADA]
when the system functions correctly.
or If malfunction occurs in the ABS system while the vehicle is being driven,
the light comes on to alert the driver.
However, when a defects code is eliminated after repairing it and the starter
ABS switch is turned "ON", the light will remain lit until the vehicle speed reaches
about 6 km/h {4 mile/h}.
Then, note that even when the warning light is lit, the ABS system, unaf-
fected by the malfunction, continues to operate. Also, the brake whose ABS
system experiences the malfunction is reverted to normal braking operation
SAPH06ABC0300058 without ABS.
When a Diagnosis switch is turned "ON", this light will goes on and off,
which indicates defect code.
8. DIAGNOSIS SWITCH OF ABS SYSTEM

It is positioned at the side of diagnosis connector in the instrument panel of
driver seat front side.
By switching the starter key “ON” and pushing to “ON” this ABS diagnosis
switch, which is led to the diagnosis mode, the ABS warning light flashes on
and off to inform the trouble codes.
NOTICE
ABS diagnosis switch reverts automatically to “OFF” position.
SAPH06ABC0300059
INSPECTION (FRONT WHEEL BRAKE)

EN0600203H300001
1. INSPECTION OF ONLY WHEEL SENSOR

(1) With a tester, measure the resistance of wheel sensor.
Standard: 900-2,000 Ω
(2) When the measured value is out of the basic standard, change the
wheel sensor as it might be considered presumably to be abnormal.
SAPH06ABC0300060
2. INSPECTION OF THE SENSOR RING.

(1) Make a visual inspection to check for damage or deformation of the
sensor ring, and also to make sure it is not coming loose from the
wheel hub.
(2) If any damage or malformation is discovered, replace the sensor ring.
(3) If the sensor ring is coming loose from the wheel hub, use a dolly
block and press it in with a press again.
SAPH06ABC0300061
3. INSPECTION OF THE CLAMPING BUSHING.

(1) Make sure that wheel sensor is securely fixed.
(2) Change the clamping bushing when it can be pulled off or pushed in
with a weak force.
SAPH06ABC0300062
4. MOUNTING THE SENSOR RING

(1) Place the sensor ring on the wheel hub and use the dolly block and a
press to evenly pressure mount it.
NOTICE
Warming up the sensor ring with hot water will make it easier to pres-
sure mount it. Do not use a gas burner or the like to warm the sensor
ring. Doing so could cause malformation of the sensor ring.
(2) After pressure mounting it, check for flutter of the sensor ring in the
axle direction.
Assembly standard: Less than 0.2 mm {0.0078 in.}
SAPH06ABC0300063
5. MOUNTING THE WHEEL HUB AND BRAKE DRUM
(1) Refer to CHAPTER, FRONT AXLE.
NOTICE
If the wheel sensors are mounted, hammering on the wheel hubs and
the like on that axle could cause internal damage to the wheel sen-
sors. Either mount the tire and then tap on the tire or tap on the wheel
hub after removing the right and left wheel sensors.
6. MOUNTING THE WHEEL SENSOR

(1) Push in the clamping bushing until the stopper makes contact with the
knuckle's wheel sensor holder.
(2) Apply a light coating of chassis grease to the hub of the wheel sensor.
Then push it forcefully into the clamping bushing until you feel that the
wheel sensor has made contact with the sensor ring.
NOTICE
When inserting the wheel sensor, do not tap on it with a hammer or
attempt to pry it into place with a screwdriver, or the like. Doing so
could damage the wheel sensor.
(3) Slowly turn the wheel hub and brake drum and confirm that they move
SAPH06ABC0300064
smoothly.
(4) Mount the drum dust cover.
7. INSPECT THE WHEEL SENSOR

(1) Arrange the wire harness.
(2) With a circuit tester, confirm the output voltage of the wheel sensor
(By rotating the tire by one time for 2 seconds)
Standard: more than 200 mV
(Range of Alternating Current Voltage)
SAPH06ABC0300065
INSPECTION (REAR WHEEL BRAKE)

EN0600203H300002
1. INSPECTION OF ONLY WHEEL SENSOR

(1) With a tester, measure the resistance of wheel sensor.
Standard: 900-2,000 Ω
(2) When the measured value is out of the basic standard, change the
wheel sensor as it might be considered presumably to be abnormal.
SAPH06ABC0300066
2. INSPECTION OF THE SENSOR RING.

(1) Make visual inspection to check for damage or deformation of the
sensor ring, and also to make sure it is not coming loose from the
wheel hub.
(2) If any damage or malformation is discovered, replace the sensor ring.
(3) If the sensor ring becomes loose from the wheel hub, use a dolly
block and a press to pressure mount it again.
SAPH06ABC0300067
3. INSPECTION OF THE CLAMPING BUSHING.

(1) Make sure that the wheel sensor is securely fixed.
(2) Change the clamping bushing when it can be pulled off or pushed in
with a weak force.
4. MOUNTING THE WHEEL SENSOR

(1) Push in the clamping bushing until the stopper makes contact with the
wheel sensor holder.
SAPH06ABC0300068
(2) Push the wheel sensor fully in the wheel sensor holder with hands
until the wheel sensor makes contact with the clamping bushing.
NOTICE
When inserting the wheel sensor, do not tap on it with a hammer or
attempt to pry it into place using a screwdriver, or the like. Doing so
could damage the wheel sensor.
SAPH06ABC0300069
5. MOUNTING THE SENSOR RING

(1) Place the sensor ring on the wheel hub and use the dolly block and a
press to evenly pressure mount it.
NOTICE
Warming up the sensor ring with hot water will make it easier to pres-
sure mount it. Do not use a gas burner or the like to warm the sensor
ring. Doing so could cause malformation of the sensor ring.
(2) After pressure mounting it, check for flutter of the sensor ring in the
axle direction.
Assembly standard: Less than 0.2 mm {0.0078 in.}
SAPH06ABC0300070
6. MOUNTING THE WHEEL HUB AND BRAKE DRUM
(1) Refer to CHAPTER REAR AXLE.
NOTICE
• Be careful not to push back the wheel sensor too far when
mounting the wheel hub and brake drum. Also, make sure they
are straight so that you do not bump the tip of the wheel sensor.
• When inserting the outer hub bearing, avoid tapping on it with a
hammer as this will expose the wheel sensor to bumps. Insert
the outer hub bearing carefully with a lock nut.
7. INSPECT THE WHEEL SENSOR

(2) With a circuit tester, confirm the output voltage of the wheel sensor
(By rotating the tire by one time for 2 seconds)
Standard: more than 200 mV
(Range of Alternating Current Voltage)
(3) In case of out of the standard range at 2), remove the dust cover
located on the back plate unit. Then push the wheel sensor by using a
round end bar until the sensor contacts with the sensor ring.
NOTICE
Do not tap with a hammer or turn when pushing the wheel sensor.
This may damage the wheel sensor.
(4) Mount the axle shaft to the wheel hub and tighten the bolt on the axle
shaft.
Refer to CHAPTER, REAR AXLE.
8. ABS WIRE HARNESSES

(1) Front axle ABS wire harnesses
• The front axle chassis harnesses, particularly the ones that pass over
the front axle and extend as far as the wheel sensors, must absorb
the movement when the wheels are turned and when the springs
move. It is therefore necessary to always maintain an optimal spacing
between the clips.
In addition, if there is a large amount of variation in the spacing
between the clips, the wheel sensor harnesses can come into contact
with tire chains and sustain damage.
The wire harness for the front axle wheel sensor extends directly from
the clip on top of the king pin cover to the frame. In particular, make
sure that the distance between the clip on top of the king pin cover
and the clip on the frame side is as indicated in the diagram below.
There are markings on the wheel sensors in cases where the wheel
sensor harness clips are in locations where the relative movement is
particularly great. These places should be inspected regularly to
ensure that the clip positions are still meeting with the same marking.
SAPH06ABC0300071
(2) Rear axle chassis harness

• The rear axle chassis harnesses is arranged so that the left and right
wheel sensor harnesses are near each other. Therefore, special care
should be taken not to make incorrect connections if the harnesses
have been removed for inspection or repairs.
If incorrect connections are made, it will interfere with the functioning
of the ABS system. For this reason, caution plates indicating "LEFT"
and "RIGHT" are affixed to the harnesses. Be sure to check when
connecting the harnesses. (The left harness is on the left side of the
vehicle when viewed from the behind and facing toward the front, and
the right harness is on the right side of the vehicle.)
The wheel sensor harnesses are arranged along the top of the rear
axle housing. Therefore, make sure to allow sufficient harness length
between the chassis and the rear axle so that the harnesses can
absorb the up-and-down motion of the rear axle.
SAPH06ABC0300072
HANDLING WIRE HARNESSES

• The various sensors, valves, relays and wire harness connections to
the ABS computer employ multipolar harness connectors suitable for
use with the weak currents used by electronic circuitry. Be very careful
when handling them.
1. Place the starter switch on "LOCK" before unplugging the har-

ness connectors.
2. When unplugging the harness connectors, release the lock, hold

the housing and unplug it straight as much as possible.
3. Do not pull holding the wire harness or pull with excessive force.
Doing so can cause the pins of the harness connectors to be
deformed.
4. Remove unnecessary connectors and do not plug them.
5. When inspecting using a circuit tester, insert the test probe from
the wire harness side.
Never insert the test probe from the pins of harness connectors
as this can cause bad contacts.
SAPH06ABC0300073
6. When unplugging the harness connectors, do not allow water,

oil, dust, or any other liquid or substance to get on the terminals
as they can cause bad contacts.
7. Be careful not to allow water, oil, dust, or any other liquid or sub-
stance to get on any component.
8. When plugging the harness connector, insert it completely and

confirm that the harness connector lock is engaged.
ADDITIONAL PRECAUTIONS
1. Make sure the model's starter switch is in the OFF position

before unplugging the harness connector from the ABS com-
puter.
2. Make sure to unplug all the harness connectors from the ABS
computer before performing welding on the chassis or body of
the vehicle. Also be careful that welding sputter does not get
onto the harnesses.
3. When cleaning the interior of the model, make sure water does
not get onto the ABS computer, various relays, connectors, or
any other component.
4. Use of a circuit tester

• If a circuit tester is being used, always use one with an internal resis-
tance greater than 100 kΩ inside the voltage measurement range.
5. Installation of a radio or other electronic equipment

• All electronic and radio equipment installed on the vehicle must be
mounted as far away from the ABS computer and wire harness as
possible. Installation of certain electronic and radio equipment can
also cause the ABS computer to malfunction. All such equipment
must also conform to all applicable laws. If you wish to install a radio
or other electronic equipment, please contact your Hino service repre-
sentative.
6. Quick battery charge

• When charging batteries using a quick charger, do it with both battery
terminals removed.
7. Installation of electrical equipment inside of the cab

• When installing an air conditioner or other electrical equipment inside
of the cab, be careful not to damage the engine, chassis, and wire
harnesses inside the cab. Moreover, do not forget to plug the harness
connectors unplugged during the installation.
NOTICE
ANTI- LOCK BRAKE SYSTEM of this model is applied to MERITOR
WABCO ABS system.
Detail of the ABS refer to MERITOR WABCO Maintenance Manual MM-
0112 For E Version ECUs, 12-Volt systems with Basic Cab-mounted
ECU 4S/4M and tractor ABS.
Without: Automatic Traction Control (ATC), OFF-Road ABS, ABS Valve
Package, Frame- mounted ECU, Trailer ABS Indicator Lamp and Uni-
versal ECU.
$2.50
TR
A
C
TO
R
A
B
S
Anti-Lock Braking System
(ABS) for Trucks, Tractors
and Buses
Revised 04-01
• For E Version ECUs
• 12-Volt Systems
Service Notes
Before You Begin

Service Notes
This manual provides instructions for Meritor ArvinMeritor’s Web Site
WABCO’s anti-lock braking system for trucks, Additional maintenance and service information
tractors and buses. Before you begin procedures: for ArvinMeritor’s commercial vehicle systems
1. Read and understand all instructions and component lineup is also available at
procedures before you begin to service www.arvinmeritor.com.
components. To access information, click on Products &
2. Read and observe all Caution and Warning Services/Tech Library Icon/HVS Publications. The
safety alerts that precede instructions or screen will display an index of publications by
procedures you will perform. These alerts help type.
personal injury, or both. Additional Information
3. Follow your company’s maintenance and Call ArvinMeritor’s Customer Service Center at
service, installation, and diagnostics 800-535-5560 to order the following item.
guidelines.
4. Use special tools when required to help avoid Electronic Library on CD. Features product
serious personal injury and damage to and service information on most Meritor,
components. ZF Meritor and Meritor WABCO products.
$20. Order TP-9853.
and Notes

personal injury and
serious injury.
-2
Table of Contents
Asbestos and Non-Asbestos Fibers Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
How ABS Works
ABS Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
ABS Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Trailer ABS Indicator Lamp
ABS Modulator Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Valve Arrangement Option
ABS Valve Packages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
ABS Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Off-Road ABS
Automatic Traction Control (ATC)
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Section 2: Automatic Traction Control (ATC)
ATC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Deep Snow and Mud Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
ATC Components
Section 3: Troubleshooting & Testing
General Maintenance Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
System Diagnostics
TOOLBOX Software
Blink Code Diagnostics (Tractor ABS only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Diagnostic Mode
Clear Mode
Blink Code Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Working with Blink Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Blink Code Troubleshooting and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Pro-Link® Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Diagnostic Procedure
Pro-Link Screens
J1939 Datalink Verification — Pro-Link 9000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Pro-Link 9000 Display
Component Tests and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Tire Size Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Testing Components
Voltage Check
Location of Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Sensor Adjustment
Sensor Output Voltage Test
Sensor Resistance
Dynamometer Testing Vehicles with ATC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Valve Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
ABS Modulator Valve
ATC Valve
Table of Contents
Section 4: Component Replacement

Component Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Valves
Sensor Lube Specification
Sensors
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
ABS Modulator Valve
ATC Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Front or Rear ABS Valve Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
ATC Valve on the Rear ABS Valve Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Appendix I: System Configuration Layouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Appendix II: Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Appendix III: Additional ABS Information
Troubleshooting Guide — Meritor WABCO ABS Valve Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Reconfiguration Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
How to Reconfigure an ECU (E Version)
TOOLBOX Software
Manual Reconfiguration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

asbestos dust.
MM-0112
Notes
MM-0112
Section 1
Introduction
Contents
Section 1
Introduction The ECU receives and processes signals from the
wheel speed sensors. When the ECU detects a
This manual contains service information for wheel lockup, the unit activates the appropriate
E version Meritor WABCO Anti-Lock Braking modulator valve, and air pressure is controlled.
System (ABS) and ABS with Automatic Traction In the event of a malfunction in the system, the
Control (ATC) for trucks, tractors and buses. ABS in the affected wheel(s) is disabled; that
E version ABS incorporates Power Line Carrier wheel still has normal brakes. The other wheels
Communication (PLC), an optional feature that keep the ABS function.
allows tractor/trailer communication. For the
driver, this means that a trailer ABS indicator lamp Two ABS indicator lamps, one for tractor and one
located on the vehicle dash will come on if a fault for trailer, let drivers know the status of the
occurs in the trailer ABS — if the trailer is system. The tractor ABS lamp is also used to
equipped with PLC. display tractor blink code diagnostics. Figure 1.2.
The location of the ABS indicator lamps vary,
NOTE: For diagnostic and testing procedures for depending on the make and model of the vehicle.
systems with C version ECUs, use Maintenance Blink code diagnostics information for trailer ABS
Manual 28. For D version ECUs, use Maintenance is not included in this manual. Use Maintenance
Manual 30. The ABS version is marked on the Manual 33 for Meritor WABCO Easy-Stop™ Trailer
ECU. Figure 1.1. If you cannot identify the ECU ABS for trailer diagnostics.
version installed on your vehicle, contact
ArvinMeritor’s Customer Service Center at
800-535-5560.
Figure 1.2
Figure 1.1
4 1002000a
3
1. Manufacturing Information NOTE: Do not open the ECU. Opening the ECU
2. Part Number to gain access to the internal components will
3. ECU Version void the warranty.
4. ABS Configuration
How ABS Works

Meritor WABCO ABS is an electronic system that
monitors and controls wheel speed during
braking. The system works with standard air brake
systems.
ABS monitors wheel speeds at all times and
controls braking during wheel lock situations. The
system improves vehicle stability and control by
reducing wheel lock during braking.
MM-0112
Section 1
Introduction
Figure 1.3 ABS Configuration

NOTE: With E Basic, 4S/4M is the only
configuration used.
The ABS configuration is defined by the number

of wheel end sensors and modulator valves. There
are three common ABS configurations used with
1 2 E version ECUs:
4S/4M (4 wheel speed sensors,
4 modulator valves) Figure 1.4.
4 modulator valves)
3
6 modulator valves)
1. Universal ECU
2. Frame-mounted ECU
3. Basic ECU
Figure 1.4
1
4
3
1 2
A
B
1002004c
A. Air Lines 1. Wheel Speed Sensors 3. Relay Valve
B. Electrical Lines 2. ABS Modulator Valves 4. ECU
4S/4M Configuration
NOTE: Typical illustrations in this manual use the 4S/4M configuration as a sample. Layouts for 4S/4M,
6S/4M, and 6S/6M configurations are included in Appendix I.
MM-0112
Section 1
Introduction
ABS Indicator Lamp

The ABS indicator lamp works as follows:
Ignition ON Normal Operation ABS lamp comes on at System is O.K.

ignition momentarily for a
bulb check, then goes out.
After servicing ABS ABS lamp does not go out at When vehicle is driven at
ignition. speeds above 4 mph (6 km/h),
OFF ON lamp goes out. System is O.K.
Off-road ABS operation. Refer ABS lamp flashes during The vehicle’s normal ABS
to “Off-Road ABS” in this vehicle operation. function is being modified
section. due to road conditions.
Existing Fault ABS lamp does not go out at Lamp does not go out at
ignition. speeds above 4 mph
(6 km/h) — a fault exists in
the ABS system.
NOTE: If the ECU senses a tractor ABS fault during normal vehicle operation, the ABS indicator lamp will
come on and stay on.
Trailer ABS Indicator Lamp

The trailer ABS indicator lamp on vehicle dash applies to Trailer ABS only. The lamp is controlled by a signal
to the tractor ECU, sent over the power line (PLC function). When a trailer ABS fault is detected, an ON
message is sent, when no fault is detected, the ECU receives an OFF message. Table A illustrates trailer ABS
lamp operation at power-up, or ignition on. Table B depicts lamp responses that occur during operation.
Lamp turn ON and OFF messages do not turn the lamp ON or OFF instantly. The delay between the receipt
of the message and the lamp response time is intentional. It prevents erratic lamp activity.
NOTE: For doubles or triples, the lamp does not distinguish between trailers. A system fault in any of the
trailers will activate the trailer ABS indicator lamp.
Table A: Dash-mounted Trailer ABS Indicator Lamp Operation — Bulb Check (Information for Drivers)
Status of Trailer ABS

Signal from trailer to tractor ECU Lamp on vehicle dash Explanation
Single or Multiple Trailers Trailer ABS lamp comes on Bulb Check performed AND
at ignition, OFF message is Trailer ABS system is OK. In
message OFF OFF OFF OFF OFF OFF OFF
detected within three this case, the lamp is ON for
seconds of ignition, Trailer a Bulb Check only.
lamp on ABS lamp goes out.
lamp off 0.5
sec
Single or Multiple Trailers Trailer ABS lamp does not No Bulb Check, trailer
come on within three added after initial
message No ON or OFF messages
seconds of ignition. power-up, system OK.
There was no trailer PLC
lamp on OFF OFF message for at least three
0.5 seconds following ignition
lamp off sec ON.
ign on t > 3 sec
ON = Turn ON message to “trailer ABS” lamp

OFF = Turn OFF message to “trailer ABS” lamp
Removing a trailer with a Fault will cause ABS lamp to turn off. Remember to have trailer with fault repaired as soon as possible
before returning to service.
MM-0112
Section 1
Introduction
Table B: Dash-mounted Trailer ABS Indicator Lamp Operation (Information for Service Technicians)
Status of Trailer ABS

Signal from trailer to tractor ECU Lamp on vehicle dash Explanation Action
Single or Multiple Trailers Trailer ABS lamp does Not using the PLC Use lamp
message No ON or OFF messages not come on within three system (no trailer on side of
seconds of ignition. connected) or trailer not trailer to
lamp on equipped with PLC or identify
0.5 fault in PLC system. fault. Make
lamp off sec necessary
Single Trailer Trailer ABS lamp comes Trailer ABS fault(s) repairs.
message OFF OFF OFF ON ON ON ON ON on. occurred during
operation and still exists.
lamp on
0.5
lamp off
sec
Multiple Trailers/Dollies
OFF OFF OFF ON ON ON ON
lamp on
0.5
lamp off sec
Single Trailer Trailer ABS lamp comes Trailer ABS fault None
message ON ON OFF OFF OFF OFF OFF OFF on but goes out after occurred during
2.5 seconds after fault is operation and the fault
lamp on detected. was corrected.
0.5 t + 2.5
lamp off sec
Multiple Trailers/Dollies
ON ON OFF OFF OFF OFF OFF OFF
lamp on
0.5 t + 2.5
lamp off sec
Single Trailer ABS lamp is off, comes ABS fault existed, then Use lamp
message
on, then goes off, signal was lost because on side of
ON ON ON No ON or OFF messages 10 seconds after loss of trailer disconnected or trailer to
lamp on messages. PLC fault. identify
0.5 fault. Make
lamp off sec
t t + 10 sec necessary
repairs.
Multiple Trailers/Dollies ABS fault existed, then
message trailer with fault lost
OFF OFF OFF OFF OFF OFF OFF
ON ON signal because trailer
lamp on was disconnected or PLC
0.5 t + 2.5 fault.
lamp off sec
Single Trailer to Multiples ABS lamp is on and There was a fault in
message stays on when a new existence before the new
OFF OFF OFF
ON ON ON ON ON ON
trailer with no new fault trailer was added AND
lamp on is added. the ignition was not
lamp off 0.5 turned off before the
sec trailer was added.
Single Trailer to Multiples ABS lamp is on and ABS fault was in
ON ON ON stays on when a new existence before the new
message ON ON ON ON ON ON trailer with a new fault is trailer was added AND
added. the ignition was not
lamp on turned off before the
lamp off
0.5 trailer was added AND
sec the new trailer has an
ABS fault.
ON = Turn ON message to “trailer ABS” lamp

OFF = Turn OFF message to “trailer ABS” lamp
Removing a trailer with a Fault will cause ABS lamp to turn off. Remember to have trailer with fault repaired as soon as possible
before returning to service.
MM-0112
Section 1
Introduction
ABS Modulator Valves Figure 1.5

Modulator valves control the air pressure to each 1
affected brake during an ABS function.
Valve Arrangement Option 3 1

In Figure 1.4 on page 4, the modulator valves on
the rear axle are mounted separately and a relay
valve is used to deliver air pressure to the
modulator valves. There is also an optional valve A
2
package available from Meritor WABCO, the ABS
Valve Package, which may be found on certain
vehicle models. The ABS valve package may be
used on all D and E version units, including D and 2 4
E Basic, and is available for front or rear axle
installation.
Easy Listening Tip!
To make sure the ABS valves are working — just 1
listen! Refer to Figure 1.5.
1. Apply the brakes.
2. Turn on the ignition. 4 1
3. Wait for the ABS indicator lamp to come on.

4. Listen to the valves cycle one by one, as B
follows: 2
2 5
NOTE: In previous versions of ABS, the valves
are cycled diagonally. Diagonal cycling does
not occur with E version ABS.
3 6
4M (channel) valve cycle order:
1–2–3–4 1002006d
6M (channel) valve cycle order:
1–2–3–4–5–6 A. 4M Channel
B. 6M Channel
1. Cab
2. Curbside
MM-0112
Section 1
Introduction
ABS Valve Packages

The front ABS valve package combines a quick release valve with two ABS modulator valves and is
mounted in the front of the vehicle. The rear ABS valve package combines a service brake relay valve with
two ABS modulator valves and is mounted in the rear of the vehicle. The valve package — front or rear —
must be mounted near the brake chambers it serves. Figure 1.6.
Figure 1.6
x
x xxxx x
xxxx x xxxx
xxxx
5
6
2
001 20/98
472 500 30. 0
MADE IN GERMANY
3
A
B
1002007e
A. Air Lines
B. Electrical Lines
1. Rear ABS Valve Package
2. Wheel Speed Sensors
3. Front ABS Valve Package
4. ECU
5. Tractor ABS Indicator Lamp
6. Trailer ABS Indicator Lamp
4S/4M Configuration
MM-0112
Section 1
Introduction
ABS Sensors
ABS sensor systems consist of a tooth wheel
mounted on the hub of each monitored wheel and
a sensor installed so that its end is against the
tooth wheel. The sensor continuously sends wheel
speed information to the ECU. A sensor clip holds
the sensor in place at the tooth wheel.
The type of axle determines sensor mounting
location:
Steering axle sensors are installed in the
steering knuckle or in a bolted-on bracket.
Drive axle sensors are mounted in a block
attached to the axle housing or in a bolted-on
bracket.
Off-Road ABS
On some vehicles, an off-road ABS function may
be selected. Off-road ABS improves vehicle
control and helps reduce stopping distances in
off-road conditions or on poor traction surfaces
such as loose gravel, sand and dirt. This option is
not available on 4S/4M Frame-mounted ECUs.
NOTE: On vehicles equipped with an off-road

switch, the off-road ABS mode is manually
selected by the driver. On some vehicles, the
off-road mode may be fully automatic. Refer to the
vehicle specifications for information about the
off-road ABS feature.
The ABS indicator lamp on the dash will flash

while the vehicle is in the off-road mode. This
alerts the driver that the vehicle’s normal ABS
function is being modified.

ATC is an option with Basic and Frame-mounted
E version ECUs. It is available with all Universal
ECUs. ATC can be used with individual valves, or
with an integrated ABS/ATC valve package.
Section 2 describes ATC in detail.
MM-0112
Section 1
Introduction
System Components
Figure 1.7
The ECU is the brain of the ABS system. It receives

information from the sensors and sends signals to
the ABS valves. ECUs are available for cab- or
2
Frame-mounted applications. Basic and Universal
1
ECUs are cab-mounted. Figure 1.7.
1. Universal ECU
2. Frame-mounted ECU
3. Basic ECU
Figure 1.8
A tooth wheel (A) is mounted at, or cast in, the
hub of each sensed wheel, with a sensor (B)
installed so that its end is against the tooth wheel.
A sensor clip (C) holds the sensor in place at the
tooth wheel. Figure 1.8.
NOTE: The sensor and clip must be greased with

Meritor WABCO-recommended lubricant. Refer to
“Sensor Lube Specification” in Section 4 for lube
specification.
1002009b
Figure 1.9
Also available with
2
open-style connector.
1 An ABS modulator valve controls air pressure to

each affected brake during an ABS event. The
modulator valve is usually located on a frame rail
or cross member near the brake chamber. The
BAYONET-STYLE modulator valve is available in bayonet-style
CONNECTOR
(Figure 1.9) or open-style connector.
1. Air In (Port 1)
2. Air Out (Port 2)
MM-0112
Section 1
Introduction
Figure 1.10
Also available with

open-style connectors. The ABS valve package is an alternative to
xxxxx
xxxxx xxxxx
individual valves.
xxxxx
The rear ABS valve package combines two

modulator valves and one service relay valve.
Figure 1.10.
1002011a
Figure 1.11
Also available with
open-style connectors.
The front ABS valve package combines two

modulator valves and a quick release valve.
Figure 1.11.
001 20/98
472 500 30. 0
MADE IN GERMANY
1003359a
Figure 1.12
Sensor cables connect the sensor to the ECU.

Figure 1.12.
1002013a
MM-0112
Section 1
Introduction
Figure 1.13
ABS modulator valve cables connect the

modulator valve to the ECU. Figure 1.13.
1002012a
Figure 1.14
Includes Spanish and French Versions$98.00
TOOLBOX
SOFTWARE
▲▲▲
▲▲▲▲▲
▲
▲▲ O R W A B ▲
TOOLBOX Software is a PC-based diagnostics
program that can display wheel speed data, test
MER ▲
▲▲ O
T individual components, verify installation wiring

▲▲▲▲ ▲▲▲▲
C
▲▲▲
TOOLBOX E
I
Easy-StopTM Trailer ABS Diagnostics and more. Runs in Windows® 95, 98 and NT. An
▲
▲▲▲▲▲▲
Hydraulic ABS Diagnostics

KN O W
RS232 to J1708 convertor box is required.

SOFTWAR
Pneumatic ABS Diagnostics (D and E Versions)
Versions 3.2 and higher support E version ABS.

WH
▲▲
T T
▲
A
▲▲
YO U▲▲ D
▲▲
▲▲▲▲▲▲▲ N E E
Available from SPX (Kent-Moore), 800-328-6657
Figure 1.15
The MPSI Pro-Link® 9000 with a multiple protocol
cartridge (MPC) and Meritor WABCO applications
card, version 2.0 or higher, provides diagnostic
and testing capabilities for the E version ABS.
Figure 1.15.
NOTE: The PLC functions of E version ABS cannot

be tested with the Pro-Link.
1002014a
Available from SPX (Kent-Moore), 800-328-6657
MM-0112
Section 2
ATC
Section 2 Traction Control (ATC)
Automatic
Figure 2.2
Automatic Traction Control (ATC) is available as an
option on all E version ABS ECUs and is standard
on most. ATC can be used with individual valves,
or with an integrated ABS/ATC valve package.
ATC helps improve traction when vehicles are
on slippery surfaces by reducing drive wheel
overspin. ATC works automatically in two different
ways:
1. If a drive wheel starts to spin, ATC applies air
pressure to brake the wheel. This transfers
engine torque to the wheels with better
traction.
2. If all drive wheels spin, ATC reduces engine 1002016a
torque to provide improved traction.
Individual ATC Valve
ATC turns itself on and off, drivers do not have to
select this feature. If drive wheels spin during
acceleration, the ATC indicator lamp comes on,
indicating ATC is active. It goes out when the drive Figure 2.3
wheels stop spinning. Figure 2.1.
Figure 2.1
Normal Vehicle Excessive Wheel Spin Wheels Stop

Operation ATC Operational Spinning 1002017b
(ATC Lamp is Off) (ATC Lamp Comes On) (ATC Lamp Goes Out)
1002015a ABS/ATC Valve Package
NOTE: Some vehicle manufacturers may refer to

ATC as Anti-Spin Regulation (ASR).
If ATC is installed, there will be an indicator lamp

on the vehicle dash or instrument panel marked
ATC or ASR.
If the ATC lamp goes out before the ABS lamp,
there is no ATC.
An ATC installation may use an individually
mounted valve, or the valve may be part of the
ABS valve package. Figures 2.2 and 2.3.
MM-0112
Section 2
Deep Snow and Mud Switch ATC Components

A deep snow and mud option switch is included ATC may be used with individual ABS modulator
with ATC. This function increases available valves, or installed with the ABS Valve Package.
traction on extra soft surfaces like snow, mud or
gravel, by slightly increasing the permissible When installed with individual ABS modulator
wheel spin. valves, an ATC solenoid valve is mounted on the
frame or cross member, near the rear of the
Drivers use a deep snow and mud switch to select vehicle.
this feature. When this function is in use, the ATC
When it is part of the ABS valve package, an ATC
indicator lamp blinks continuously. Figure 2.4.
valve is attached to the relay valve.
A cable connects the ECU to the ATC valve.
Figure 2.4
ATC components are illustrated in Figure 2.5.
Figure 2.5
Or
1 2
1002018a
Switch and lamp locations will vary, depending on

the vehicle make and model.
Here’s how the Deep Snow and Mud feature 3
works: 1002019a
1. ATC Valve (also available with open-style connector)

Function 2. ABS/ATC Valve Package
3. Cable
Driver System Not
Action Response Active Active
Press deep ATC lamp X
snow and blinks
mud switch continuously
Press switch ATC lamp X

again stops blinking
NOTE: Turning off the ignition will also deactivate

the deep snow and mud feature.
MM-0112
Section 3
Troubleshooting & Testing
General Maintenance
Section 3
Figure 3.1
Information SERIAL
CABLE
There is no regularly scheduled maintenance
required for the Meritor WABCO ABS or ABS/ATC.
However, ABS does not change current vehicle
maintenance requirements.
LAMP CHECK
To make sure the ABS tractor lamp is operating,
drivers should check the lamp every time the TO VEHICLE
J1587
vehicle is started. When the vehicle is started, CONNECTOR
J1708-TO-RS232
the ABS lamp should come on momentarily. If it CONNECTOR
does not come on, it could mean a burned-out
bulb.
2. Select TOOLBOX Software from Desktop or
from the Windows Start Menu to display the
System Diagnostics TOOLBOX Main Menu. Figure 3.2.
Use any of the following methods to diagnose
E version ABS: Figure 3.2
TOOLBOX Software, version 3.2 or higher, a
PC-based ABS diagnostic and testing program
that runs in Windows 95, 98 or NT
Blink Codes — Tractor ABS only
MPSI Pro-Link with MPC and Meritor WABCO
applications card, version 2.0 or higher
OEM Diagnostic Displays (Refer to the Vehicle
Operator’s Manual)
Information about TOOLBOX Software, MPSI
Pro-Link and Blink Codes follows. If you have any
questions about system diagnostics, please
contact ArvinMeritor’s Customer Service Center at
800-535-5560.
TOOLBOX Software
NOTE: For complete instructions for using
TOOLBOX Software, refer to the User’s Manual.
If you have TOOLBOX Software installed on your

computer, use it to identify system faults. Then,
follow the on-screen repair information to make
the necessary repairs or replacements.
To display E version ABS faults:
1. Connect the computer to the vehicle:
Attach the cable from your computer to the
J1708 to RS232 converter box.
Attach the diagnostic cable (Deutsch) to the
vehicle. Figure 3.1.
MM-0112
Section 3
3. From the Main Menu, select Tractor ABS 4. From the ABS Main Screen, select the Faults
Diagnostics, or use the pull down menu to icon, or use the pull down menu to display the
make your selection. Figure 3.3. The ABS Main faults from the ECU. Figure 3.5.
Screen will appear. Figure 3.4.
NOTE: If there are Faults in the system (YES in
existing or stores fields) double-click on the YES to
Figure 3.3 display Fault Information.
Figure 3.5
5. The Fault Information Screen contains a

Figure 3.4 description of the fault. Repair instructions for
each fault appear at the bottom of the screen.
Figure 3.6.
Figure 3.6
NOTE: Faults that occur after the screen is

displayed will not appear until a screen update is
requested. Use the Update button at the bottom of
the screen to refresh the fault information table.
6. After making the necessary repairs, use the

Clear Faults button at the bottom of the screen
to clear the fault. Use the Update button to
refresh the fault information table and display
the new list of faults.
MM-0112
Section 3
Blink Code Diagnostics System Configuration Code: One digit code

displayed during the clear mode. Blink codes for
(Tractor ABS only) common ABS system configurations are shown in
Figure 3.7.
Definitions
Before using blink code diagnostics, you should Figure 3.7
be familiar with a few basic terms. If you used
previous versions of Meritor WABCO’s blink code 1 2
diagnostics, review these definitions to identify
major changes. 6S/6M - 6x2
ABS Indicator Lamp: This lamp serves two
purposes: it alerts drivers to an ABS tractor fault 6S/6M - 6x4
and it is used during diagnostics to display the
blink code. 4S/4M
Blink Code: A series of blinks or flashes that
describe a particular ABS system fault or 6S/4M
condition.
1002020c
Blink Code Cycle: Two sets of flashes with each set
separated by a one-and-one-half second pause. 1. Number of Flashes
Blink codes are defined in Blink Code Identification 2. ABS Configuration
in this section.
Blink Code Switch: A momentary switch that
activates blink code diagnostic capabilities. Switch Diagnostic Mode
types and locations vary, depending on the make
To enter the diagnostic mode, press and hold the
and model of the vehicle.
blink code switch for one second, then release.
Clear: The process of erasing faults from the ECU.
Diagnostics: The process of using blink codes to Clear Mode
determine ABS system faults.
To erase faults from the ECU, you must be in the
Fault: An ABS malfunction detected and stored in clear mode. To enter the clear mode, press and
memory by the Meritor WABCO ECU. System hold the blink code switch for at least three
faults may be Active or Stored. seconds, then release.
Active Fault: A condition that currently exists in If the system displays eight quick flashes followed
the ABS system; for example, a sensor circuit by a system configuration code, the clear was
malfunction on the left front steering axle. An successful. Stored ABS faults have been cleared
active fault must be repaired before it can be from memory.
cleared from memory — and before you can
If you do not receive eight flashes, there are still
display additional blink code faults.
active faults that must be repaired before they can
Stored Fault: There are two types of stored faults: be cleared.
A. A repaired active fault that has not been
NOTE: The clear mode is also used to disable the
cleared from the ECU.
ATC function.
B. A fault that occurred but no longer exists.
For example, a loose wire that makes
intermittent contact. Because stored faults
are not currently active they do not have to
be repaired before they can be cleared
from memory.
Meritor WABCO recommends you keep a record
of these faults for future reference.
MM-0112
Section 3
Blink Code Diagnostics

Troubleshooting with Blink Code Diagnostics
Mode Procedure System Response Action

Step I. Possible responses:
Turn Ignition ON A. ABS indicator lamp comes on No recognizable active faults in the
momentarily then goes out, ABS. No action required.
indicating System O.K.
B. ABS indicator lamp does not light, Inspect wiring. Inspect bulb. Make
indicating possible wiring fault or necessary repairs.
burned-out bulb.
C. ABS indicator lamp stays on,

indicating:
Fault, or faults, in the system. Continue with blink code diagnostics.

(Go to Step II.)
Sensor fault during last Continue with blink code diagnostics.

operation. (Go to Step II.)
Faults cleared from ECU, but Drive vehicle — lamp will go out when
DIAGNOSTICS
vehicle not driven. vehicle reaches 4 mph (6 km/h).
ECU disconnected. Connect ECU.
Step II. ABS indicator lamp begins flashing Determine if fault is active or stored:
Press and hold Blink Code Switch two-digit blink code(s). Active Fault: Lamp will repeatedly
for one second, then release. display one code.
Stored Fault: Lamp will display code
for each stored fault then stop
blinking. Faults will be displayed one
time only.
Step III. First Digit: 1 - 8 flashes, Pause Find definition for blink code on blink
Count the flashes to determine (1-1/2 seconds). code chart.
the blink code. Second Digit: 1 - 6 flashes, Pause
(4 seconds).
Step IV. Active Fault. Make the necessary repairs. Repeat

Steps I, II, and III until System O.K.
Turn Ignition OFF.
code (1-1) received.
Repair and Record faults. Stored Faults. Record for future reference.
NOTE: Last fault stored is first fault
displayed.
Step V. ABS Indicator Lamp flashes eight All stored faults successfully cleared.
Turn Ignition ON. times. Turn ignition OFF.
CLEAR
Clear Faults from memory: Press Eight flashes not received. Active faults still exist, repeat Steps I
and hold blink code switch for at through V.
least three seconds, then release.
MM-0112
Section 3
Blink Codes Illustrated

Figure 3.8
1 Second Active Fault

Hold
1-8 Flashes 1-6 Flashes
Continues until
1.5 s 1.5 s 4s 1.5 s ignition is turned off
Light ON 1st Digit 2nd Digit Repeat of Blink Code
(2) (3) (2) (3)
Example:
Blink Code 2-3: Fault in ABS modulator
valve, right rear drive axle.
1 Second Stored Faults

Hold Displays all stored
Off faults once – last fault
1.5 s 1.5 s 4s 1.5 s stored is displayed first
Light ON 1st Digit 2nd Digit 1st Digit 2nd Digit
1st Stored Fault 2nd Stored Fault
(5) (2) (3) (4)
Example:
Blink Code 5-2: Sensor signal erratic,
left front steer axle.
3-4: Too much sensor gap,
left rear drive axle.
1 Second System O.K.

Hold
Pause Pause
Blink Code 1-1: System OK
1.5 s 1.5 s
Light ON (1) (1)
S = Seconds
1002021b
Continued on next page.
MM-0112
Section 3
Blink Codes Illustrated (Continued)
Note: After faults are cleared and

3 Second vehicle is started, ABS lamp will stay
Faults Cleared on until vehicle is driven over 4 mph (6 km/h).
Hold
Continues until
Pause Pause Pause Pause Pause ignition is
1.5 s 4s 4s 4s 4s turned off
Light ON 8 Quick Blinks = Faults Cleared System ID System ID System ID System ID
(2) (2) (2) (2)
System Configuration Code 2: 4S/4M System
3 Second
Faults Not Cleared (Active Faults Still Exist)
Hold
Pause Pause Pause Pause Continues until ignition
4s 4s 4s 4s is turned off
Light ON System ID System ID System ID System ID
(2) (2) (2) (2)
S = Seconds
1002022
Working with Blink Codes

Blink Code Conditions
When using blink code diagnostics, the following conditions could occur:
Blink Code Conditions
Condition Reason Action

ABS indicator lamp does not come on at Loose or burned-out bulb. Check bulb.
ignition.
Check connections.
Make necessary repairs.
Voltage not within acceptable range Check connections.

(9.5-14.0 volts).
Measure voltage.
Make necessary repairs.
Can’t use blink code diagnostics; ABS Switch not held for proper length of Repeat procedure, hold switch for proper
indicator lamp will not go off when blink time: length of time.
code is activated. 1 Second — Diagnostics Mode
3 Seconds — Clear All Mode
Improper or faulty wiring. Inspect and repair wiring.
Eight Flashes not received after blink Active Faults still exist. Identify active faults, then make
code switch pressed for at least necessary repairs.
three seconds, then released.
Turn ignition OFF, then repeat Blink Code
Diagnostics.
MM-0112
Section 3
Blink Code Identification

Use the following information to identify the blink code:
Blink Code Identification
First Digit (Type of Fault) Second Digit — Specific Location of Fault

1 No faults 1 No faults
2 ABS modulator valve 1 Right front steer axle (curb side)

3 Too much sensor gap 2 Left front steer axle (driver’s side)
4 Sensor short or open 3 Right rear drive axle (curb side)
5 Sensor signal erratic/tire size 4 Left rear drive axle (driver’s side)
6 Tooth wheel 5 Right rear/additional axle (curb side)*
6 Left rear/additional axle (driver’s side)*
7 System function** 1 J1939 datalink

2 ATC valve
3 Retarder relay (third brake)
4 ABS indicator lamp
5 ATC configuration
6 ATC prop./dif lock/stop valve
8 ECU 1 Low power supply

2 High power supply
3 Internal fault
4 System configuration error
5 Ground
* Tandem, lift, tag or pusher axle depending upon the type of suspension.
** If this code continues after all repairs have been made — or if you receive a code for a component that is not
installed on the vehicle — it may be necessary to reconfigure the ECU. Refer to the Reconfiguration Procedure
described in Appendix III. TOOLBOX Software may also be used to reconfigure the ECU (refer to Appendix III).
Contact ArvinMeritor’s Customer Service Center at 800-535-5560 for reconfiguration information.
MM-0112
Section 3
Blink Code Troubleshooting and Repair

Blink Code Action Required Reference
2-1 2-4 Check ABS modulator valve, valve cable, and connectors. Refer to “Valve Tests,” page 34.
2-2 2-5 Verify 4.0-9.0 ohms resistance (ABS modulator valve).
2-3 2-6
3-1 3-4 Adjust wheel sensor to touch tooth wheel. Refer to “Sensor Adjustment,”
3-2 3-5 Check sensor gap. page 32, “Sensor Output Voltage
Test,” page 32, and “Component
3-3 3-6 Check for loose wheel bearings or excessive hub runout. Tests and Functions,” page 27.
Verify minimum 0.2 volts AC output @ 30 rpm.
4-1 4-4 Check sensor, sensor cable, and connectors. Repair or replace as needed.
4-2 4-5 Verify 900-2000 ohms resistance.
4-3 4-6
5-1 5-4 Check for tire size mismatch or tooth wheel difference. Refer to “Tire Size Range,” page 31.
5-2 5-5 Check sensor, sensor cable, and connector for intermittent contact.
5-3 5-6
6-1 6-4 Check for damaged tooth wheel. Repair or replace as needed.
6-2 6-5
6-3 6-6
7-1* Check for proper J1939 data link connection. Refer to wiring diagram in
Appendix II.
Verify wheel spin on each axle.
7-2* Check ATC Valve, valve cables, and connectors. Refer to “Valve Tests,” page 34.
Verify 7.0-14.0 ohms resistance.
7-3* Check retarder (third brake) connections. Refer to wiring diagram in
7-4* Check ABS indicator light connections. Appendix II.
Verify blink code switch was activated longer than 16 seconds.

7-5* Verify proper ATC set-up.
7-6* Verify accuracy of blink code and clear from ECU memory. Refer to “Blink Code Diagnostics
(Tractor ABS only),” page 17.
8-1 Check for low voltage. Refer to wiring diagram in
Check vehicle voltage, fuse, and supply to ECU (9.5-14.0 volts). Appendix II and “Voltage Check,”
page 31.
8-2 Check for high voltage. Refer to “Voltage Check,” page 31,
Check vehicle voltage (9.5-14.0 volts). and “Blink Code Diagnostics (Tractor
ABS only),” page 17.
Verify accuracy of blink code and clear from ECU memory.
8-3 Verify accuracy of blink code and clear from ECU memory. Refer to “Blink Code Diagnostics
(Tractor ABS only)” and “Clear
Mode,” page 17.
8-4 Verify all ECU connectors are in place. Contact ArvinMeritor’s Customer
Verify accuracy of blink code and clear from ECU memory. Service Center at 800-535-5560.
If code does not clear, it may be necessary to replace the ECU.

8-5 Check all ABS, ECU and ATC valve grounds. Refer to wiring diagram in
Appendix II.
* If this code continues after all repairs have been made — or if you receive a code for a component that is not
installed on the vehicle — it may be necessary to reconfigure the ECU. Refer to the Reconfiguration Procedure
described in Appendix III. TOOLBOX Software may also be used to reconfigure the ECU (refer to Appendix III).
Contact ArvinMeritor’s Customer Service Center at 800-535-5560 for reconfiguration information.
MM-0112
Section 3
Pro-Link® Diagnostics Pro-Link Screens

This information provides basic screen
NOTE: You must use Multiple Protocol Cartridge explanations for the Pro-Link® 9000 with an MPC
(MPC) and Meritor WABCO application card, and Meritor WABCO application card. For
version 2.0 or higher, with E version ECUs. The complete operating instructions and test
PLC functions of E version ABS cannot be tested information, refer to the Pro-Link manual.
with the Pro-Link.
Fault Information Screens:
The Pro-Link® 9000 may be used in place of blink
code diagnostic procedures. Existing Faults: Use these screens to identify
existing faults. The Pro-Link screen displays a
The following Pro-Link information applies to written description of the fault, including the
E version ECUs. Refer to Maintenance Manual 28 if location on the vehicle where each exists. As long
you are using the Pro-Link with C version ECUs or as there is an active (existing) fault in the system,
Maintenance Manual 30 if you are using the the Pro-Link will not let you clear faults.
Pro-Link with D version ABS.
Stored Faults: Use these screens to identify faults
stored in the ECU memory. Stored faults may be
Diagnostic Procedure existing faults that have been repaired, or faults
1. Slide the MPC into the Pro-Link keypad until that existed for a short time, then corrected
the connection is tight. Then, insert the themselves. After displaying the stored faults, the
Meritor WABCO applications card into the Pro-Link lets you erase them from memory. All
cartridge. stored faults are cleared at one time.
2. Chock the wheels, apply the parking brake,
and make sure ignition power is off.
Pro-Link Display
Depending upon the ECU being tested, the
3. Locate the 6-pin diagnostic receptacle in the
Pro-Link screen will display certain options or
vehicle cab. Insert the 6-pin connector from
components only when recognized by the ECU.
the Pro-Link into the receptacle.
These include:
4. Turn the ignition to the ON/RUN position. The
ATC, ATC Indicator Lamps, Trailer ABS Indicator
Pro-Link screen should power up.
Lamp, ATC Valve
If the Pro-Link does not power up, or if the
Engine Datalink
screen indicates NO DATA RECEIVED:
Retarder Relay
Check connections.
Retarder Datalink
Make sure the cartridge is properly
connected to the Pro-Link keypad.
Verify 9.5-14.0 volts DC power and ground
at the connector and ABS ECU.
Check the fuse panel for a blown fuse.
Check for proper wiring in the diagnostic
connector.
5. Refer to the Pro-Link manual for complete
diagnostic instructions.
The Pro-Link® 9000 is available from

Kent-Moore, 800-328-6657.
MM-0112
Section 3
J1939 Datalink Verification — Pro-Link 9000

The Pro-Link diagnostic tool may be used to verify J1939 datalink connection. If you do not have a
Pro-Link, you can use the blink code switch to verify this connection.
1. Turn ignition ON. Press blink code switch — 1.

IGNITION ON
hold for 3 seconds. OFF ON
3 Second Hold
A. ATC indicator lamp will come on and stay A.

on for the entire test. ATC
If vehicle is not equipped with ATC, the

ATC indicator lamp will not come on.
B. ABS indicator lamp will come on and blink B.
8 times.
If the lamp does not blink 8 times, there 8 Quick Blinks = Faults Cleared
are faults that must be cleared before you
continue with this test.
Pause Pause
Continues
C. The eight quick flashes will be followed by C. 4s 4s During Test
the system configuration code. A 4S/4M
(2 blinks) system is identified here. System ID System ID System ID
(2) (2) (2)
The system configuration code will
continue during the entire test.
2. Activate the J1939 engine torque reduction 2.
code, as follows:
1000
A. Step on the accelerator. Bring the engine A.

IDLE
to 1000 rpm. RPM
Leave your foot on the accelerator during

the entire test.
B. While engine is at 1000 rpm, press the B.
blink code switch twice, as follows:
Press for one second
1 Second 1 Second Pause
Pause
Release for one second Hold Hold
Press for one second

Release for one second
C. The engine will go to idle for C. 1000 1000
approximately 10 seconds and then return IDLE IDLE
to 1000 rpm. RPM RPM
3. Turn ignition OFF. 3.

OFF ON
Test complete, engine torque reduction
command verified.
MM-0112
Section 3
Component Test Screens

These screens help you test ABS components.
Select this function from the Tractor ABS/ATC
menu.
ABS VALVES
ATC
ABS INDICATOR LAMP
ABS TRAILER INDICATOR LAMP
ATC INDICATOR LAMP
ABS/ATC SWITCHES
SENSORS
ENGINE DATALINK
RETARDER RELAY
RETARDER DATALINK
VEHICLE VOLTAGES
Select the appropriate function. Each screen has
instructions to guide you through the test. Refer to
the Pro-Link Manual for complete instructions.
MM-0112
Section 3
System Information Pro-Link 9000 Display

With some ECUs, the Pro-Link will display system
TOOLBOX Software Display information — components or options supported
by the ECU. Access these screens through System
NOTE: Refer to page 15 of this manual for Setup (main ABS menu).
instructions for running TOOLBOX Software, or
refer to the Software Owner’s Manual, TP-99102, The following screens illustrate:
for complete instructions. A 4S/4M ABS/ATC system
The quickest method of verifying system Where the ECU has not recognized a retarder
information is the TOOLBOX Software ABS Main relay
Screen. Figure 3.9. Where the ECU has recognized a J1939 datalink
The ECU is capable of supporting ABS and ATC
Figure 3.9 switches.
NOTE: Yes indicates the ECU is capable of

supporting these options. These may or may not
be installed on the vehicle.
TRACTOR ABS/ATC
SYSTEM INFORMATION
SENSORS 4
MODULATORS 4
ATC VALVE YES

RETARDER RELAY NO
J1939 YES
DIFF LOCK NO
This screen provides information about the ABS SWITCH YES
current state of Meritor WABCO ABS. ECU ATC SWITCH YES
information is read once from the ECU and does
not change. All other information (e.g., wheel
sensors, control status, voltages, faults and road
speed) is read and updated continuously.
The status of ABS switches and lamps, as well as
other data, may also be observed from this screen.
MM-0112
Section 3
Component Tests and Functions Figure 3.11
TOOLBOX Software
NOTE: Refer to page 15 of this manual for
instructions for running TOOLBOX Software, or
refer to the Software Owner’s Manual, TP-99102,
for complete instructions.
Use TOOLBOX Software to display wheel speeds,

cycle ABS valves, activate ABS and ATC lamps,
including the trailer ABS lamp, and turn the
retarder relay on or off. In addition, the J1939
engine datalink connection may be quickly verified
by using TOOLBOX Software.
Wheel Speed
Select the wheel speed icon or use the pull down Figure 3.12
menu from the ABS Main Screen to display wheel
speed data in both numeric and graphical form.
This data may be shown in RPM or MPH format
(Figure 3.10) and in vertical or horizontal graphs
(Figures 3.11 and 3.12). Select the appearance and
style from the options menu.
Figure 3.10
MM-0112
Section 3
Valve Activation Data Link Activation

Select the valve icon or use the pull down menu to Select the Engine Data Link icon from the Main
select and cycle individual ABS valves. Then listen ABS Screen or use the pull down menu to send a
to ensure the correct valve is cycling. This is “limit engine torque” command to the engine or a
helpful when verifying proper operation, “disable retarder” command to the retarder.
installation and wiring. Figure 3.13. Figure 3.15.
Lamp Activation
Select the lamp icon or use the pull down menu to
turn the tractor and trailer ABS and/or the ATC
(wheel spin) lamps on or off. This is helpful when
verifying proper operation, installation and wiring
of the lamps to the ECU. Figure 3.14.
Figure 3.14
MM-0112
Section 3
Disable or Enable ATC

Select the Disable ATC icon or use the pull down
menu on the ABS Main Screen to send the
command to the ECU to disable automatic traction
control. ATC will remain disabled until the enable
command is sent — or until the vehicle ignition is
cycled. Always disable ATC for dynamometer
testing. Figure 3.16.
Figure 3.16
Select the Enable ATC icon or use the pull down

menu on the ABS Main Screens to send a
command to the ECU to enable ATC. This is the
normal state of the ECU. Figure 3.17.
Figure 3.17
NOTE: The status bar on the ABS Main Screen

reflects the current status of the ATC function;
enabled, disabled or N/A (not available).
MM-0112
Section 3
Component Tests and Functions (Pro-Link)

These screens help you test ABS components.
Select this function from the Tractor ABS/ATC
menu.
TRACTOR COMP TESTS

— SELECTIONS —
앖 VEHICLE VOLTAGES 앗
Select the appropriate function. Each screen has

instructions to guide you through the test. Refer to
the Pro-Link Manual for complete instructions.
The following definitions explain the function of each test.
Component Test Function

Vehicle Voltages Monitors the voltage signals powering the ECU.
ABS Valves Cycles the valves, one at a time. With brake pedal applied, you should hear four short air
exhausts, then one long air pressure hold. A menu selection lets you choose from four or six
valves. This test is used to verify valve locations and proper wiring.
NOTE: The treadle must be applied to pressurize the brake chambers.
ATC Checks the ATC valve. You will hear a click as the valve cycles.
NOTE: TOOLBOX Software or the Pro-Link may be used to shut off ATC for dynamometer testing.
ABS Tractor Lamp Monitors the commanded (on/off) states of the ABS tractor lamp. Follow the screen prompts
(1 On, 2 Off) to change the status of the lamp on the instrument panel.
ABS Trailer Lamp Monitors the commanded (on/off) states of the ABS trailer lamp. Follow the screen prompts
ATC Tractor Lamp Monitors the commanded (on/off) states of the ATC tractor lamp. Follow the screen prompts
ABS/ATC Switches Checks the status of ABS and ATC/Deep Snow and Mud switches on the instrument panel.
Sensors Monitors the input to the ECU from the wheel. Vehicle must be stationary and wheels must be
rotated during this test.
Engine Datalink Checks wiring connections and response between the engine and the ECU.
Retarder Relay Activates the relay to verify function (a click will be heard). This test also checks wiring
connections.
Retarder Datalink Checks wiring connections and retarder response between the retarder and the ECU.
MM-0112
Section 3
Tire Size Range Testing Components

For proper ABS/ATC operation with the standard
ECU, front and rear tire sizes must be within ± 14% CAUTION
of each other. When this tire size range is
When troubleshooting and testing the ABS
exceeded without electronically modifying the
system, do not damage the connector terminals.
ECU, the system performance can be affected and
the indicator lamp can illuminate.
Call Meritor WABCO at 800-535-5560 if you plan a
Voltage Check
tire size difference greater than 14%. Measure voltage at the pins indicated in Table C.
Calculate the tire size with the following equation: Voltage must be between 9.5 and 14.0 volts.
The ignition must be turned ON for this test.
% Difference = RPM Steer – 1 x 100 Table C: Voltage Check Pins
RPM Drive
ECU Connector Pins
RPM — tire revolutions per mile
Universal 14-Pin 4 and 9
9 and 4
Basic 14-Pin 7 and 4
8 and 9
Frame-mounted X1-Grey 1 and 12
2 and 11
NOTE: Pin locations are illustrated in Figure 3.18

(Frame) and Figure 3.19 (Basic and Universal).
Figure 3.18
X1-GRAY X2-BLACK
VIEW INTO ECU CONNECTOR
2
6
1
1
11
10
12
12
11
10
7
9
X4-BROWN
(ONLY FOR 6 CHANNEL) X3-GREEN
2
6
1
1
11
10
12
12
11
10
7
9
Figure 3.19
VIEW INTO ECU CONNECTOR
UNIVERSAL
BASIC
1 4 7 10 13 1 4 7 10 13 16 1 4 7 10 13
2 5 8 11 14 2 5 8 11 14 17 2 5 8 11 14
3 6 9 12 15 3 6 9 12 15 18 3 6 9 15
15 18 14
MM-0112
Section 3
Location of Sensors Table D: Sensor Check Pins
On steering axles, the sensor is accessible on the ECU Sensor Connector Pins
in-board side of the steering knuckle.
Universal LF 18-Pin 12 and 15
On drive axles, the drum assembly may have to RF 18-Pin 10 and 13
be pulled to gain access to the sensor. LR 18-Pin 11 and 14
RR 18-Pin 17 and 18
Sensor Adjustment LR (3rd Axle) 15-Pin 2 and 5
Push the sensor in until it contacts the tooth RR (3rd Axle) 15-Pin 11 and 14
wheel. Basic LF 18-Pin 12 and 15
Do not pry or push sensors with sharp objects. RF 18-Pin 10 and 13
LR 18-Pin 11 and 14
Sensors will self-adjust during wheel rotation.
RR 18-Pin 17 and 18
Sensor Output Voltage Test Frame- LF X2 — Black 7 and 8

mounted RF X2 — Black 5 and 6
Voltage must be at least 0.2 volts AC at 30 rpm.
LR X3 — Green 1 and 2
1. Turn ignition OFF. RR X3 — Green 3 and 4
2. Disconnect the appropriate connector from the LR (3rd Axle) X4 — Brown 3 and 4
ECU (refer to wiring diagram). RR (3rd Axle) X4 — Brown 5 and 6
3. Rotate wheel by hand at 30 rpm (1/2 revolution

per second).
Sensor Resistance
4. Measure voltage at the pins indicated in
Table D. The sensor circuit resistance must be between 900
and 2000 ohms. Resistance can be measured at
If the minimum output voltage is less than the sensor connector, or at the pins on the ECU
0.2, push the corresponding sensor toward connector. To measure resistance:
the tooth wheel, then repeat the
measurement. 1. Turn ignition OFF.
2. To measure resistance at the sensor connector,
disconnect the ECU connector from the ECU.
To measure resistance at the sensor connector,
disconnect the sensor from the sensor
extension cable.
3. Measure output at the pins indicated in
Table D.
MM-0112
Section 3
Dynamometer Testing Vehicles 2. Remove Power
with ATC Remove the ABS circuit breaker/fuse or

remove the ECU power connector to disable
the ABS and ATC.
WARNING After testing, re-install the circuit breaker/
The automatic traction control (ATC) function fuse and the ATC will automatically
must be disabled before any type of reactivate the first time the vehicle power is
dynamometer testing is conducted on the vehicle. applied to the ECU.
If the ATC is not disabled, the vehicle ATC may
3. TOOLBOX Software
actuate and cause the vehicle to move forward
without warning to the operator. If the vehicle At the ABS Main Menu, select the Disable ATC
moves forward unexpectedly, the vehicle may icon or use the pull down menu to send the
cause damage or injuries to individuals who are in command to the ECU to disable the ATC. Refer
the path of the vehicle. to the TOOLBOX Software Owner’s Manual for
complete instructions for using TOOLBOX.
ATC will remain disabled until the enable
CAUTION command is sent or the vehicle ignition is
Do not cycle the vehicle ignition while the vehicle cycled.
is on a dynamometer. Cycling the vehicle ignition
After testing, ATC will automatically
will enable the ATC.
reactivate the first time the vehicle ignition
is cycled.
Vehicles with ATC must have the ATC disabled to
test the vehicle on a dynamometer. To disable the 4. MPSI Pro-Link
ATC use one of the following methods:
Refer to the MPSI Pro-Link Owner’s Manual for
1. Blink Code Switch instructions.
Press and hold the blink code switch for at ATC will remain disabled until the enable
least three seconds. (Refer to Blink Code command is sent or the vehicle ignition is
Diagnostics (Tractor ABS only) and Clear Mode cycled.
in this section for a description of how the
blink code display will appear.)
Once the system configuration code begins, is cycled.
ATC has been disabled.
The ATC lamp comes on and stays on while
ATC is disabled.
ATC will remain disabled until the vehicle
ignition is cycled.
is cycled.
MM-0112
Section 3
Valve Tests ATC Valve

Measure resistance across the two electrical
ABS Modulator Valve terminals on the ATC valve to ensure 7.0 to
14.0 ohms. Figure 3.21.
Measure resistance across each valve solenoid
coil terminal and ground on the ABS valve to If the resistance is greater than 14.0 ohms, clean
ensure 4.0 to 9.0 ohms. Figure 3.20. the electrical contacts on the solenoid. Check
the resistance again.
If the resistance is greater than 9.0 ohms, clean
the electrical contacts in the solenoid. Check the To check the cable and ATC valve as one unit,
resistance again. measure resistance across the pins on the ECU
connector of the harness. Check the diagram of
To check the cable and the ABS valve as one the system you are testing for pin numbers.
unit, measure resistance across the pins on the (Refer to Appendix II.)
ECU connector of the harness. Check the
diagram of the system you are testing for pin
numbers. (Refer to Appendix II.) Figure 3.21
Figure 3.20
Open-Style Connector
NOTE: Refer to Appendix III for ABS Valve

3
Package Troubleshooting Guide.
1. Ground Terminal
2. Exhaust Solenoid (blue wire)
3. Inlet Solenoid (brown wire)
Bayonet-Style Connector

3. Ground Terminal
MM-0112
Section 4
Component Removal
Section 4 Replacement
Component
Sensors
and Installation Wheel Speed Sensor Removal —
Front Axle
Valves
To remove the sensor from the front axle:
ABS Modulator Valves
ATC Valve WARNING
ABS Valve Package (Front or Rear) Park the vehicle on a level surface. Block the
— Modulator Valves wheels to prevent the vehicle from moving.
— Relay Valve or Quick Disconnect Valve work under a vehicle supported only by jacks.
Jacks can slip and fall over. Serious personal
— ATC Valve
injury can result.
Sensor Lube Specification 1. Put blocks under the rear tires to stop the
vehicle from moving. Apply the parking brake.
Meritor WABCO specifications call for a sensor
lubricant with the following characteristics: 2. If necessary, raise the front tires off the
ground. Put safety stands under the axle.
Lube must be mineral oil-based and contain
molydisulfide. It should have excellent 3. Disconnect the fasteners that hold the sensor
anti-corrosion and adhesion characteristics, and cable to other components.
be capable of continuous function in a
temperature range of –40° to 300°F (–40° to 150°C). 4. Disconnect the sensor cable from the chassis
harness.
5. Remove the sensor from the sensor holder.
WARNING Use a twisting motion if necessary. Do not pull
To prevent serious eye injury, always wear safe on the cable. Figure 4.1.
Figure 4.1
Release all air from the air systems before you
remove any components. Pressurized air can
CAUTION
Use the following procedures to avoid damage to
the electrical system and ABS/ATC components.
When welding on an ABS- or ABS/ATC-equipped

vehicle is necessary, disconnect the power
connector from the ECU.
1002036a
Knuckle-Mounted Sensor
MM-0112
Section 4
Wheel Speed Sensor Installation — 8. Disconnect the fasteners that hold the sensor
Front Axle cable and the hose clamp to other
components.
To replace the sensor in the front axle:
9. Disconnect the sensor cable from the chassis
1. Connect the sensor cable to the chassis harness.
harness.
2. Install the fasteners used to hold the sensor Wheel Speed Sensor Installation —
cable in place. Rear Axle
3. Apply a Meritor WABCO recommended 1. Apply a Meritor WABCO recommended
lubricant to the sensor spring clip and sensor. lubricant to the sensor spring clip and sensor.
4. Install the sensor spring clip. Make sure the 2. Install the sensor spring clip. Make sure the
spring clip tabs are on the inboard side of the spring clip tabs are on the inboard side of the
vehicle. vehicle.
5. Push the sensor spring clip into the bushing in 3. Push the sensor spring clip into the mounting
the steering knuckle until the clip stops. block until it stops.
6. Push the sensor completely into the sensor
NOTE: After installation, there should be no gap
spring clip until it contacts the tooth wheel.
between the sensor and the tooth wheel. During
normal operation, a gap of up to 0.04-inch is
NOTE: After installation, there should be no gap allowable.
between the sensor and the tooth wheel. During
normal operation, a gap of up to 0.04-inch is
4. Push the sensor completely into the sensor
allowable.
spring clip until it contacts the tooth wheel.
Figure 4.2.
7. Remove the blocks and safety stands.
Wheel Speed Sensor Removal — Figure 4.2

Rear Axle 1
2
To remove the sensor from the rear axle:
WARNING
Park the vehicle on a level surface. Block the 4 3
injury can result.
1. Put blocks under the front tires to stop the

vehicle from moving.
2. Raise the rear tire off the ground. Put safety
stands under the axle.
3. Release the parking brake and back off the
slack adjuster to release the brake shoes.
1002037a
4. Remove the wheel and tire assembly from the axle.
1. Spring Clip
5. Remove the brake drum. 2. Sensor Holder
3. Spring Clip Tab
6. Remove the sensor from the mounting block 4. Sensor
in the axle housing. Use a twisting motion if
necessary. Do not pull on the cable.
7. Remove the sensor spring clip from the
mounting block.
MM-0112
Section 4
5. Insert the sensor cable through the hole in the

Figure 4.3
spider and axle housing flange. Route the
cable to the frame rail. Be sure to route the 2 1
cable in a way that will prevent pinching or
chafing and will allow sufficient movement for
suspension travel.
6. Connect the sensor cable to the chassis
harness.
7. Install the fasteners that hold the sensor cable
in place.
8. Install the brake drum on the wheel hub.
9. Complete the installation per vehicle
manufacturer’s manual.
1002038a
Valves
1. Port 1 (Air In)
2. Port 2 (Air Out)
ABS Modulator Valve
Removal Installation
1. Turn ignition switch to the OFF position, apply
parking brake. CAUTION
Moisture can affect the performance of all
WARNING ABS/ATC systems, as well as the standard
braking system. Moisture in air lines can cause air
Park the vehicle on a level surface. Block the lines to freeze in cold weather.
Support the vehicle with safety stands. Do not To install the ABS modulator valve:
Jacks can slip and fall over. Serious personal 1. Install the ABS valve with two mounting
injury can result. capscrews and nuts. Tighten the capscrews
per the manufacturer’s recommendation.
2. Put blocks under the front and rear tires to 2. Connect the line to the brake chambers to
stop the vehicle from moving. Port 2 of the ABS valve. Connect the air supply
3. If necessary, raise the vehicle off the ground line to Port 1 of the ABS valve.
and put safety stands under the axle. 3. Connect the wiring connector to the ABS
4. Disconnect the wiring connector from the ABS valve. Hand tighten only.
valve. 4. Remove the blocks and stands.
5. Disconnect the air lines from Ports 1 (air 5. Test the installation. (Refer to below.)
supply) and 2 (air discharge) of the ABS valve.
Figure 4.3.
Checking the Installation
6. Remove the two mounting capscrews and
nuts. To test the modulator valve:
7. Remove the ABS valve. 1. Apply the brakes. Listen for leaks at the
modulator valve.
2. Turn the ignition on and listen to the
modulator valve cycle. If the valve fails to
cycle, check the electrical cable connection.
Make repairs as needed.
3. Drive the vehicle. Verify that the ABS indicator
lamp operates properly.
MM-0112
Section 4
ATC Valve 7. Remove the two mounting capscrews and

nuts. Remove the ATC valve.
Removal
Installation
1. Turn ignition switch to the OFF position. Apply
parking brake. 1. Install the ATC valve with two mounting
capscrews and nuts.
WARNING Tighten the capscrews per the manufacturer’s

recommendation.
wheels to prevent the vehicle from moving. 2. Connect the air supply, discharge, and treadle
Support the vehicle with safety stands. Do not lines to Ports 1, 2, and 3 of the ATC valve.
work under a vehicle supported only by jacks. 3. Connect the harness connector to the ATC
Jacks can slip and fall over. Serious personal valve. Hand tighten only.
injury can result.
4. Remove blocks and stands.
2. Put blocks under the front and rear tires to 5. Test the installation. (Refer to below.)
3. If necessary, raise the vehicle off the ground. Checking the Installation
Put safety stands under the axle. To test the ATC valve:
4. Relieve line pressure by bleeding the air from 1. Start vehicle.
the appropriate supply tank.
2. Fully charge reservoirs with air. Shut off
5. Disconnect the wiring from the ATC valve. vehicle.
6. Disconnect the air lines from Port 1 (air 3. Apply brakes.
supply), Port 2 (air discharge), and Port 3
(treadle) of the ATC valve. Figure 4.4. 4. Listen for air leaks at ATC valve.
5. Release brakes.
Figure 4.4 6. Activate ATC valve using the MPSI tool.
1 2 7. Disconnect MPSI tool.
8. Drive the vehicle. Verify that the ATC indicator
4
3
1002039a
1. Air Lines
2. Port 1 (Air Supply)
3. Air Line
4. Port 3 (Treadle)
5. Valve Control Do Not Open
6. Port 2 (Air Discharge)
MM-0112
Section 4
Front or Rear ABS Valve Package

WARNING
Removal and Replacement — Complete Block the wheels to prevent the vehicle from
Package moving. Support the vehicle with safety stands.
Figure 4.5: Front ABS Valve Package jacks. Jacks can slip and fall over. Serious
Figure 4.6: Rear ABS Valve Package personal injury can result.
1. Put blocks under tires to stop the vehicle from

Figure 4.5 moving.
1 2. If necessary, raise the tires off the ground.
2
3. Drain air from all system air tanks.
4. Remove all air lines and connections from
ABS valve package.
5. Remove mounting bolts from the valve
package — remove the valve package from
vehicle.
001 20/98
6. Replace the ABS valve package: Tighten bolts
3
472 500 30. 0
MADE IN GERMANY
to OE recommendation. Remove blocks and
4 3
safety stands as necessary.
7. Test the installation. (Refer to page 37.)
1003362a
1. Supply Port 1/2” NPT Removal and Replacement —

2. Quick Release Valve
3. 1/2” NPT Delivery Ports Component Valves
4. Modulator Valve
(Refer to Figure 4.7)
1. Remove ABS valve package from vehicle.
Figure 4.6 2. Use a 6 mm Allen wrench to loosen and
2 remove the Allen head bolts.
3
1 4 Figure 4.7
1
6
5
5 001 20/98
472 500 30. 0 1
MADE IN GERMANY
7
1003361a 2
xxxxx
xxxxx xxxxx
1. ABS Modulator Valve

xxxxx
2. Relay Valve
3. Control Port 1/4” NPT
4. ABS Modulator Valve
5. Delivery Ports 1/2” NPT
6. Supply Port 1/2” NPT
7. Delivery Ports 3/8” NPT 1002041c
1. Allen Head Bolts

2. 13-15 lb-ft (18-20 N•m)
MM-0112
Section 4
3. Carefully separate ABS modulator valve(s) 4. Relieve line pressure by bleeding the air from
from the relay or quick release valve. the appropriate supply tank.
4. Remove and discard old O-rings. Lubricate 5. Disconnect the wiring from the ATC valve.
replacement O-rings with grease provided.
6. Disconnect supply air line from the adapter
5. Plug any unused ports on the replacement and the treadle air line from the ATC valve.
valve(s).
7. Use a 5 mm Allen wrench to remove the two
6. Attach ABS modulator valve(s) to the relay screws that hold the adapter piece to the relay
valve. Torque the Allen head bolts to valve portion of the valve package.
13-15 lb-ft (18-20 N•m). T
Use a 6 mm Allen wrench to remove the two
7. Replace the ABS valve package: Tighten bolts mounting bolts that hold the ATC valve to the
to OE recommendation. Remove blocks and adapter piece. Remove the ATC valve from the
safety stands as necessary. adapter piece. Remove the ATC valve.
8. Check the valves for leaks: Remove the adapter piece, seal, and O-rings
from the valve package. Figure 4.8.
Modulator valve(s) (Refer to page 37.)
Relay or quick release valve (Refer to
page 42.) Figure 4.8
1
ATC Valve on the Rear ABS
Valve Package 2
Removal 3
NOTE: If there is enough room to work, it is not 4

necessary to remove the valve package from the
7
vehicle before replacing the ATC valve. If the valve 5
package must be removed, follow the instructions
for removing and replacing the ABS Valve Package
that appear in this section of the manual.
When installing the new ATC valve on the valve

package, you must use the new O-rings, seals, 6
mounting bolts, and lubricant included with the
replacement kit.
1. Turn ignition switch to the OFF position, apply 1002042a
parking brake.
1. Mounting Bolts
2. ATC Valve
WARNING 3. Treadle Air Line
4. Seal
Park the vehicle on a level surface. Block the 5. O-rings
wheels to prevent the vehicle from moving. 6. Supply Air Line
7. Adapter
injury can result.
2. Put blocks under the front and rear tires to

3. If necessary, raise the vehicle off the ground.
Put safety stands under the axle.
MM-0112
Section 4
Installation Figure 4.10

1. Clean and lubricate the small adapter piece
O-ring. Install O-ring on adapter piece. xxxxx
xxxxx xxxxx
xxxxx
Use the two new M8 Allen head bolts to attach

the ATC valve to the adapter piece. Use a
6 mm Allen head tool to tighten to 12-13 lb-ft
(18-20 N•m). Figure 4.9. T
Figure 4.9 1
1 1002044a
2 1. Relay Valve Supply Port
5 NOTE: Use Meritor WABCO-recommended

3
lubricant.
4
3. Use the two M6 Allen head bolts to attach the
adapter to the relay valve. Use a 5 mm Allen
head tool to tighten to 4-5 lb-ft (6-8 N•m).
Figure 4.11. T
Figure 4.11
1002043a 2 3
1 4
1. Mounting Bolts 12-13 lb-ft (18-20 N•m)
2. ATC Valve
3. Seal
4. Adapter
5. O-ring
2. Lubricate the replacement seal and install it in 6

5
Port 2 of the ATC valve.
Lubricate the large replacement O-ring and 1002045a
install it in the groove of the relay valve supply
port. Figure 4.10.
1. Supply Port
2. ATC Valve and Adapter
3. Control Port
4. ABS Valve Package
5. O-ring (Installed)
6. Mounting Bolts 4-5 lb-ft (6-8 N•m)
MM-0112
Section 4
4. Connect the supply air line to the supply port

on the adapter. Connect the treadle air line to
the control port on the ATC valve.
5. Attach the wiring connector to the ATC valve.
Hand tighten only.
6. Remove blocks and stands.
7. Test the installation. (See below.)
Checking the Installation

To test the valves:
1. Start vehicle.
2. Fully charge reservoirs with air. Shut off
vehicle.
3. Apply brakes.
4. Listen for air leaks at all valves.
5. Drive the vehicle. Verify that the ABS indicator
MM-0112
Appendix I
System Configuration Layouts
E Version Standard or Basic 4S/4M ABS

Appendix
System Configuration
I Layouts
E Version 6S/6M ABS
2 2
3
3
1
1
A
B A
C 1003363c B
C 1003365c
A. Air Lines A. Air Lines

B. Elec. Lines B. Elec. Lines
C. Lamps (Up to three: ABS, Trailer ABS, ATC) C. Lamps (Up to three: ABS, Trailer ABS, ATC)
1. Valve Package Installation (Front) 1. Valve Package Installation (Front)
2. Valve Package Installation (Rear) 2. Valve Package Installation (Rear)
3. Lamps 3. Lamps
E Version 6S/4M ABS
A
B
C 1003364c
A. Air Lines
B. Elec. Lines
C. Lamps (Up to three: ABS, Trailer ABS, ATC)
1. Valve Package Installation (Front)
2. Valve Package Installation (Rear)
3. Lamps
MM-0112
Appendix I
System Configuration Layouts
E Version 4S/4M ABS/ATC E Version 6S/6M ABS/ATC
2 2
3
3
1
1
A A
B B
C 1003366c C 1003368c
A. Air Lines A. Air Lines

B. Elec. Lines B. Elec. Lines
C. Lamps (Up to three: ABS, Trailer ABS, ATC) C. Lamps (Up to three: ABS, Trailer ABS, ATC)
1. Valve Package Installation (Front) 1. Valve Package Installation (Front)
2. Valve Package Installation (Rear) 2. Valve Package Installation (Rear)
3. Lamps 3. Lamps
E Version 6S/4M ABS/ATC
A
B
C 1003367c
A. Air Lines
B. Elec. Lines
C. Lamps (Up to three: ABS, Trailer ABS, ATC)
1. Valve Package Installation (Front)
2. Valve Package Installation (Rear)
3. Lamps
MM-0112
Appendix II
Wiring Diagrams
ECU Connector Pin Assignments

Appendix
Wiring Diagrams
II
Basic ECU (Cab-mounted)
BASIC
1 4 7 10 13 16 1 4 7 10 13
2 5 8 11 14 17 2 5 8 11 14
3 6 9 12 15 18 3 6 9 15
18 14
Universal ECU (Cab-mounted)
UNIVERSAL
1 4 7 10 13 1 4 7 10 13 16 1 4 7 10 13
2 5 8 11 14 2 5 8 11 14 17 2 5 8 11 14
3 6 9 12 15 3 6 9 12 15 18 3 6 9 15
15 18 14
Frame-mounted ECU
X1-GRAY X2-BLACK
2
6
1
1
11
10
12
12
11
10
7
9
X4-BROWN
(ONLY FOR 6 CHANNEL) X3-GREEN
2
6
1
1
11
10
12
12
11
10
7
9
MM-0112
Appendix II
Wiring Diagrams
Basic ECU (Cab-mounted)
TP
J1587 B 10 10 J1587 B
J1587 A 11 11 J1587 A
SAE SAE TP
J1939 3 TR-WL 2 J1939 1 J1939 L 1 1 J1939 L
H L J1939 H 3 3 J1939 H
BATTERY 8 14 AWG 15A AMP 8 BAT
ECU+ 7 5A AMP 7 IGN
ATC 6 ABS 5 ECU- 4 86 30
14 PIN CONNECTOR
TO 3RD BRAKE
3RD BRAKE 14
TRAILER 2 85 87 87A
GND 9 BAT 8 ECU+ 7 WARNING 14
TRAILER WARNING LAMP
LAMP 2
ATC LAMP
ATC LAMP 13 13
TRACTOR WARNING LAMP
SAE SAE TRACTOR 15 15
JUMPER 12 J1587 11 J1587 10 WARNING
A B BLINK CODE
LAMP SWITCH
ATC
SWITCH
ATC SWITCH 6
ABS OFF ROAD SWITCH
ABS 3RD ATC ABS OFF 5
LAMP 15 BRK
14 LAMP
13 ROAD
ECU- 4 4
GND 9 9
BACK VIEW OF HARNESS CONNECTOR

GND*
INLET 1 1 IV
INLET INLET INLET VALVE 16 AWG GND RIGHT FRONT
VALVE 3 VALVE 2 VALVE
1 ABS VALVE
OUTLET 4 4 OV
VALVE
INLET 3 3 IV
LEFT FRONT
VALVE 16 AWG GND
ABS VALVE
OUTLET OUTLET OUTLET OUTLET 6 6 OV
VALVE 6 VALVE 5 VALVE 4
VALVE
INLET 2 2 IV
VALVE LEFT REAR
16 AWG GND
18 PIN CONNECTOR
ABS VALVE
OUTLET 5 5 OV
OUTLET INLET VALVE
VALVE 9 VALVE 8 DIF- 7
DIF- 7
INLET 8 8 IV
VALVE 16 AWG GND RIGHT REAR
ABS VALVE
OUTLET 9 9 OV
SENSOR 11
VALVE
SENSOR 12 SENSOR 10 TP
SENSOR 10 10 RIGHT FRONT
SENSOR
SENSOR 13 13
TP
SENSOR 11 11 LEFT REAR
SENSOR
SENSOR
SENSOR 14 14 DIF
15 SENSOR 14 SENSOR 13 TP VALVE
SENSOR 12 12 LEFT FRONT
SENSOR 15 15 SENSOR
DIF+ 16
TP
SENSOR 18 SENSOR 17 DIF+ 16 SENSOR 17 17 RIGHT REAR
SENSOR
SENSOR 18 18
1. Momentary Switch
2. Optional Equipment
3. Twisted Pair = TP
4. All unmarked wires should be 16 or 18 AWG.
5. All fuses should be blade type.
*All connected to a common star ground.
MM-0112
Appendix II
Wiring Diagrams
Universal ECU (Cab-mounted)

TP
J1587 B 10 10 J1587 B
J1587 A 11 11 J1587 A
SAE SAE TP
J1939 3 TR-WL 2 J1939 1 J1939 L 1 1 J1939 L
H L J1939 H 3 3 J1939 H
BATTERY 8 14 AWG 15A AMP 8 BAT
ECU+ SEE 7 14 AWG 10 AMP 7 IGN
ATC 6 ABS 5 ECU- 4 NOTE 86 30
14 PIN CONNECTOR
NOTE: 4 valve uses 5 AMP
6 valve uses 10 AMP
TO 3RD BRAKE
(as shown)
3RD BRAKE 14
TRAILER 2 85 87 87A
GND 9 BAT 8 ECU+ 7 WARNING 14
TRAILER WARNING LAMP
LAMP 2
ATC LAMP
ATC LAMP 13 13
TRACTOR WARNING LAMP
SAE SAE TRACTOR 15 15
JUMPER J1587 11 J1587 10 WARNING
A B BLINK CODE
LAMP SWITCH
ATC
SWITCH
ATC SWITCH 6
ABS OFF ROAD SWITCH
ABS 3RD ATC ABS OFF 5
LAMP 15 BRK
14 LAMP
13 ROAD
ECU- 4 4
GND 9 9

GND*
INLET 2 L1 1
VALVE 3 SENSOR
OUTLET
6 SENSOR 5 L2 4
15 PIN CONNECTOR
VALVE
NOT L3
NOT USED 9
USED 9 I/O-OV 8 7
SENSOR 2 2
3RD AXLE
SENSOR 5 5 LEFT SENSOR
INLET 3 3 IV
INLET 12 SENSOR 11 10 3RD AXLE
L4 16 AWG GND LEFT ABS VALVE
VALVE OUTLET 6 6 OV
SENSOR 11 11
3RD AXLE
SENSOR 14 14 RIGHT SENSOR
OUTLET 15 SENSOR 14 L5 13
VALVE INLET 12 12 IV 3RD AXLE
16 AWG GND RIGHT ABS VALVE
OUTLET 15 15 OV
INLET 1 1 IV
INLET INLET INLET VALVE 16 AWG GND RIGHT FRONT
VALVE 3 VALVE 2 VALVE
1 ABS VALVE
OUTLET 4 4 OV
VALVE
INLET 3 3 IV
LEFT FRONT
VALVE 16 AWG GND
ABS VALVE
OUTLET OUTLET OUTLET OUTLET 6 6 OV
VALVE 6 VALVE 5 VALVE 4
VALVE
INLET 2 2 IV
VALVE LEFT REAR
16 AWG GND
18 PIN CONNECTOR
ABS VALVE
OUTLET 5 5 OV
OUTLET INLET VALVE
VALVE 9 VALVE 8 DIF- 7
DIF- 7
INLET 8 8 IV
VALVE 16 AWG GND RIGHT REAR
ABS VALVE
OUTLET 9 9 OV
SENSOR 11
VALVE
SENSOR 12 SENSOR 10 TP
SENSOR 10 10 RIGHT FRONT
SENSOR
SENSOR 13 13
TP
SENSOR 11 11 LEFT REAR
SENSOR
SENSOR
SENSOR 14 14 DIF
15 SENSOR 14 SENSOR 13 TP VALVE
SENSOR 12 12 LEFT FRONT
SENSOR 15 15 SENSOR
DIF+ 16
TP
SENSOR 18 SENSOR 17 DIF+ 16 SENSOR 17 17 RIGHT REAR
SENSOR
SENSOR 18 18
1. Momentary Switch *All connected to a common star ground.

3. Twisted Pair = TP
MM-0112
Appendix II
Wiring Diagrams
Frame-mounted ECU
+12V
IGN
15AMP
14 AWG +12V
TP SENSOR
(6S/4M AND 6S/6M ONLY) 14 AWG +12V
R3RD
10AMP
6 7 14 AWG GND
OUTLET 14 AWG GND
ABS VALVE
5 8 16 AWG COMMON RIGHT 3RD
(6S/6M ONLY) GND
INLET BLINK CODE 12 1
SWITCH
4 9
TP 86 85
SENSOR
(6S/4M AND 6S/6M ONLY) 11 2
L3RD 30 87A ABS LAMP
3 10 BLINK CODE GND
87
LAMP ATC SWITCH
OUTLET (OPTIONAL) 10 3
ABS VALVE
2 11 16 AWG COMMON LEFT 3RD
ABS OFF ROAD SWITCH (6S/6M ONLY) ATC LAMP TP
INLET J1587 -B 9 4
J1587 +A
1 12 TO RETARDER 30 86
GND 8 5
TO RETARDER 87A 85 RETARDER

X4-BROWN 7 6
(FOR 6 CHANNEL ONLY)
TP
J1939 - H
TRAILER WL J1939 - L
X1-GRAY
12 1
6 7
ATC OUTLET INLET
16 AWG COMMON ABS VALVE ABS VALVE COMMON 16 AWG

5 8 11 2
RIGHT REAR LEFT FRONT
INLET OUTLET
4 9 10 3
TP
SENSOR OUTLET
RIGHT REAR
ABS VALVE
3 10 RIGHT FRONT COMMON 16 AWG 9 4
OUTLET INLET
2 11 16 AWG COMMON ABS VALVE 8 5
LEFT REAR
INLET TP
SENSOR
1 12 LEFT FRONT 7 6
TP
SENSOR TP
SENSOR
LEFT REAR RIGHT FRONT
X3-GREEN X2-BLACK
2. TP = Twisted Pair
MM-0112
Appendix III
Additional ABS Information
Troubleshooting Guide — Meritor WABCO ABS Valve Package

Appendix
AdditionalIII
ABS Information
This Troubleshooting Guide is a reference tool to help identify possible malfunctions of the ABS
modulator or relay valves. It does not take the place of diagnostic tests or other service instructions.
ABS Valve Package Troubleshooting Guide
Condition Possible Cause Recommended Action

Air constantly leaks from exhaust port of Internal relay valve problem. Replace the relay valve.
relay valve.
Air leaks from exhaust port of ABS Parking brake problem. Service appropriate component.
modulator valve or relay valve when OR — Refer to manufacturer’s service
parking brake is released. manual for instructions.
Anti-compound 2-way check valve
problem.
Rear service brakes releasing slowly Kinked air line. Inspect/repair lines, brakes.
(brakes dragging). Dirt buildup inside relay valve.
If condition is not corrected:
Replace relay valve.
Valves don’t cycle at power-up. Broken wire. Check wires and connections.
OR OR — Make repairs as needed.
Indicator lamp comes on (blink code or Loose or broken terminal connection.
diagnostic tool indicates electrical
Corroded connector pins. If condition is not corrected:
problem with ABS valve). Measure resistance across each valve
OR
solenoid coil terminal and ground on
Problem with solenoid. the ABS modulator valve to ensure
4.0 to 8.0 ohms.
Open-Style Connector — If greater than 8.0 ohms, clean
valve and repeat measurement.
— If cleaning does not solve
problem, replace the ABS
1 modulator valve.
— If less than 4.0 ohms, replace ABS
modulator valve.
2
1. Ground Terminal
Bayonet-Style Connector

3. Ground Terminal
ABS valve package damaged. Road Hazards. Replace complete ABS valve package
OR or individual component as required.
Vehicle Damage.
MM-0112
Appendix III
Reconfiguration Procedure TOOLBOX Software

NOTE: For complete instructions for using
How to Reconfigure an ECU TOOLBOX Software, refer to the TOOLBOX User’s
(E Version) Manual, TP-99102.
Before reconfiguring the ECU, contact To reconfigure the ECU with TOOLBOX Software,
ArvinMeritor’s Customer Service Center at use the Reset Memorized command.
800-535-5560 for additional information. Select Reset Memorized from the pull down menu
to tell the ECU to reset the memorized or
“learned” components.
E version ECUs memorize the following
components if they are connected at power-up:
ATC valve
Retarder relay
Datalink SAE J1939
Once these components have been memorized,
the ECU will look for them at each power-up. If a
memorized component is not present, the ECU
will record a fault. For example, if an ATC valve is
memorized, but is not present at the next
power-up, the ECU records a fault. This can occur
if an ECU is moved from one truck to another and
one or more of the memorized components are
not available on the new truck. If this occurs, use
TOOLBOX Software to reconfigure the ECU. If you
do not have TOOLBOX Software, follow the
Manual Reconfiguration instructions listed on
page 51.
MM-0112
Appendix III
Manual Reconfiguration
Action Result Reason

1. Turn ignition ON. ABS lamp displays the ABS system Stored faults cleared, no active faults
2. Press and hold blink switch for at configuration code*: present. Continue with reconfiguration.
least three seconds. One blink: 6S/6M NOTE: The reconfiguration procedure
NOTE: Do not hold this switch longer Two blinks: 4S/4M can not be conducted if there are active
faults present. These must be repaired
than seven seconds. Four blinks: 6S/4M before proceeding with the
* The ABS lamp may display eight quick reconfiguration.
flashes before the system configuration
code begins.
Observe the ABS and ATC lamps. ATC lamp comes on and stays on. A complete ATC system — including an
ATC lamp — is installed. If not, the ATC
lamp will not come on.
ABS lamp will continuously blink the ECU reconfiguring the system.
system configuration code.
The ECU checks the following
components and reprograms itself based
on the new system:
ATC valve
AND/OR
Retarder relay
AND/OR
Datalink J1939
While the configuration code is flashing, ABS lamp displays four quick flashes, Successfully reconfigured.
press the blink code switch three times followed by a continuous display of the
(one second each, with a one second system configuration code.
pause between each).
NOTE: System configuration code
Turn ignition OFF. continues until ignition is turned OFF.
A system reconfiguration is illustrated below:
IGNITION ON
1s 1s 1s
SWITCH
3 Second 1s 1s
Hold
ATC Reset Continues
Confirmation until
Pause Pause Pause Pause Pause Pause Pause power is
1.5 s 4s 4s 4s 4s 4s 4s turned off
System ID System ID System ID System ID System ID System ID
(2) (2) (2) (2) (2) (2)
ATC
ATC Lamp — Dyno Function (remains lit for entire test)
Light ON*
*ATC Lamp will light only if ATC is connected.

1003371a
MM-0112
Meritor WABCO Information contained in this publication was in effect at the time the publication was approved for
Vehicle Control Systems printing and is subject to change without notice or liability. ArvinMeritor Commercial Vehicle Systems
3331 West Big Beaver Road, Suite 300 reserves the right to revise the information presented or discontinue the production of parts described at
Troy, MI 48084 USA any time.
800-535-5560
www.arvinmeritor.com Copyright 2001 Maintenance Manual MM-0112
PARKING BRAKE (BOSCH 9") BR07–1
PARKING BRAKE (BOSCH 9")

BR07
BR07-001
PARKING BRAKE ASSEMBLY ................BR07-2

DESCRIPTION ................................................ BR07-2
OVERHAUL ..................................................... BR07-8
ADJUSTMENT............................................... BR07-12
BR07–2 PARKING BRAKE (BOSCH 9")
PARKING BRAKE ASSEMBLY

EN0600107I200001
Parking brake type Duo-Duty mechanical brake, internal epanding acting type
Parking brake control type Lever type control with control cable
Drum inside diameter 228.6 mm {9.0 in.}
Brake lining Width 76.2 mm {3.0 in.}
DESCRIPTION
EN0600107C100001
SAPH06ABC0700015
1 Parking brake lever 5 Parking brake cable

2 Knob 6 Parking brake switch
3 Brake lever bracket 7 Parking brake assembly
4 Bolt
SAPH06ABC0700016

3 Brake lever bracket 7 Nut
4 Bolt 8 Parking brake assembly
TROUBLESHOOTING
EN0600107F300001

Not enough braking force Excessively large drum-to-lining clear- Readjust the lever knob.
ance.
Maladjusted control linkage. Readjust.
Burnt lining. Repair or replace.
Worn lining. Replace.
Shoes are too dirty with water, dust, Disassemble and clean.
etc.
Linings are soaked with oil. Replace.
The brake drum is cracked or heavily Replace the drum.
scored.
Lining gets burnt easily Not enough drum-to-lining clearance. Readjust.
Shoe or drum is distorted. Repair or replace.
Springs are broken. Replace.
Squeals or groans Glazed lining. Remove glaze from lining using emery
paper.
Misalignment of parts. Correct misalignment by tightening
any loose brake or drum mounting
bolts.
Dirt in drum. Remove drum and clean out lining
dust and dirt.
Worn out lining. Check for lining worn down to rim or
debris embedded in lining - replace
both shoe and lining assemblies, if
necessary.
Bent or misaligned shoe. Check for misaligned shoe rubbing
against the drum - replace both shoe
and lining assemblies, if necessary.
Clicks or noises Excessive clearance. Adjust lining to drum clearance.
Eccentric or wobbling drum. Inspect drum runout. Also check for
worn or loose bearing on main shaft.
Check drum mounting bolts for tight-
ness. Tighten as needed.
Excessive linkage friction or binding at Check linkage pivot points and cam-
camshaft ball. shaft ball for rust, binding, or lack of
lubrication. Clean and lubricate all
pivot points.
The brake shoes or backing plate is Check the brake shoes, return springs,
loose. and backing plate mounting bolts.
Tighten, repair, or replace, as needed.
There is dirt inside the brake drum. Remove the brake drum and clean it.
Also clean the other brake parts.
Cannot release the parking brake The brake cable is too tight. Adjust the brake lever knob.
The brake shoe return springs are Check the return springs. Install them
missing, detached, or broken. or replace them as needed.
The parking brake lever in the cab is Check the parking brake lever assem-
binding. bly for damage or corrosion. Repair or
replace as needed.
Water inside the cable when cold Replace the cable.
weather.

Grabbing Brake lubricant or transmission oil on Replace both shoe and lining assem-
lining. blies. Clean oil and excess brake lubri-
cation from brake and drum. Replace
faulty oil seal at main shaft.
Excessive drum runout. Reduce the drum runout to
0.015in.(0.38 mm) max. or replace
drum, if needed.
COMPONENT LOCATOR
EN0600107D100001
PARKING BRAKE LEVER
SAPH06ABC0700017
1 Parking brake lever 4 Clevis

3 Brake lever bracket 6 Bolt

A 42-62 {430-630, 31-46}
PARKING BRAKE
SAPH06ABC0700018
1 Brake shoe assembly 6 Bolt

2 Support plate assembly 7 Nut
3 Shoe to shoe spring 8 Lock washer
4 Shoe return spring 9 Camshaft and lever assembly
5 Brake drum

B 110-130 {1120-1330, 81-96}* E 405-475 {4130-4840, 300-350}
C 54-65 {550-665, 40-48} F 18-26 {185-265, 13-19}
D 110-135 {1120-1380, 81-100}
*Tightening to ALLISON LCT 2400/2000 automatic transmission, apply Tree Bond locking agent No. TB1305.
OVERHAUL
EN0600107H200001
1. REMOVAL OF BRAKE AND DISASSEMBLY

(1) Remove the universal joint trunnion bolts, and lower the propeller
shaft to the floor (Refer to propeller shaft section).
(2) Remove the bolts that hold the drum to the companion flange, and
remove the drum.
(3) Remove companion flange.
• Remove the nut that holds the companion flange to main shaft, and
remove the companion flange (Eaton FS-4205 manual transmission).
• Remove the bolt that holds the companion flange to the main shaft,
and remove the companion flange (ALLISON LCT2400/2000 auto-
matic transmission).
SAPH06ABC0700019
(4) Remove the bolts that hold the parking brake assembly to the trans-
mission case, and remove the parking brake assembly with camshaft
and lever assembly.
SAPH06ABC0700020
(5) To disassemble brake, remove the two shoe return springs and the
shoe-to-shoe spring. A spring removing tool (# Gen. 2059, or equiva-
lent) as shown in Figure A, should be used to remove the return
springs. After return springs have been removed, spread the free
ends of the shoes apart to remove the shoes from the lower anchor
pin. Remove shoe-to-shoe spring.
(6) Clean grease and dust from the brake parts. Use care to prevent
grease or oil from getting on the linings. If the linings have been con-
taminated with oil or grease, they must be replaced with new shoe
and lining assemblies.
SAPH06ABC0700021
SAPH06ABC0700022
2. INSPECTION OF BRAKE PARTS

(1) Inspect the springs for deformed hooks, fatigue cracks, and loss of
spring tension. The springs, when not assembled on the brake,
should not show any opening between the coils. It is recommended
that new springs be installed when shoe and lining assemblies are
replaced.
(2) Check the support plate for distortion, fatigue cracks or loose anchor
pins.
(3) Inspect the brake linings. Measure dimension between linings surface
and rivets heads. If the smallest one is less than 0.03 in. (0.8 mm),
replace both shoes and linings.
(4) Inspect the camshaft and lever assembly for fatigue cracks, worn
cams at the shoe web contact surfaces, worn camshaft ball or clevis
hole, and distorted lever.
(5) Inspect the drum for scoring, fatigue cracks or distortion.
(6) Replace any damage, broken, worn or questionable parts.
3. BRAKE LUBRICATION
(1) Coat the areas noted in Step 2 below with Lubriplate grease.
Heat resistance grease

(MIL-G-22615/23549/21164)
(NLGI No. 2 or No. 3)
! DANGER
Use only a light coating of grease at points specified. Excess grease
can melt from brake heat and drip on drum and lining surfaces. This
will cause reduced brake performance.
SAPH06ABC0700023 (2) Lubricate brake at:
a. Camshaft lugs and ball.
b. Support plate shoe-guide lugs and shoe bearing surfaces.
c. Support plate anchor pins.
d. Contact surfaces at both ends of the shoe web. Use caution to
keep lubricant off the linings.
4. REASSEMBLY OF THE BRAKE AND REINSTALLATION

(1) Install the ends of the green shoe-to-shoe spring, into lower holes of
the brake shoe webs.
(2) Spread open upper (applying) ends of the shoes and assemble lower
ends of the shoes over shoulder of lower anchor pin with a twisting
motion of the shoes.
Insert the shoe webs between guide lugs and bearing surfaces of the
support plate, move upper ends of the shoe webs to the upper anchor
pin.
(3) With the upper ends of the shoe webs against the upper anchor pin,
install the two return springs. Install short hooks of springs into upper
SAPH06ABC0700024
holes of the brake shoe webs and hook opposite ends of the springs
over the upper anchor pin nib. On heavy duty brakes (with red and
brown springs), springs must be installed over anchor pin nib with
open end of hooks toward centerline of brake to provide proper clear-
ance for camshaft. A spring installing tool, Bosch No. BPD-41938F4
(or equivalent tool), should be used to prevent damage to the spring.
SAPH06ABC0700010
(4) The brake shoe assemblies must be square within 0.004 in. per inch
of lining width. Shoe assemblies that are badly out-of-square will drag
(rub against the drum) causing heat damage to the lining. Check shoe
squareness by placing the brake assembly on a flat surface, as in Fig-
ure B, and check shoe assemblies with a square as shown, or prefer-
ably with a dial indicator. To correct an out-of-square shoe, remove
shoe assemblies and bend shoe guide lug slightly in vice in direction
necessary to correct misalignment. Reassemble and recheck square-
ness. Shoe assemblies must be free to move within the slot provided
by the guide lug and the shoe bearing surfaces.
SAPH06ABC0700027
(5) Reinstall the brake assembly to the mounting flange and align the
camshaft ball in the pivot hole of transmission rear cover, and the cam
lugs between the brake shoe webs.
The brake must be installed as a compete unit, including the cam and
lever.
a. Clean all foreign matter, nicks or burrs from the mounting surfaces
of the flange and brake support plate. The support plate must fit
snugly on the flange.
b. Coat ball and cam portions of the camshaft with Lubriplate
grease.
Heat resistance grease

(MIL-G-22615/23549/21164)
(NLGI No. 2 or No. 3)

EN0600107H300001
Unit: mm {in.}
Inspection item Standard Limit Remedy Inspection procedure
Brake lining: — 0.76 Replace. Measure

Lining thickness {0.03}
Brake drum: 228.6 229.3 Replace. Measure

Inside diameter1 {9.0} {9.03}
ADJUSTMENT
EN0600107H300002
1. INSTALL THE CABLE

(1) Connect the inner wire to the parking brake and fix the cable to the
cab floor with nut.
(2) Pulling up the clevis with specified force, fix the center of clevis at
specified distance A.
Pull up force: 30-70 N (3-7 kgf, 6.5-16 lbf)
Distance A: 141-144 mm (5.55-5.67 in.)
(3) Set the cable connection pin at specified distance B by turn the knob.
Distance B: 33 mm (1.3 in.)
(4) Connect the clevis to the parking brake lever.
2. ADJUST THE PARKING BRAKE LEVER

(1) Pull up the parking brake lever twice or more.
(2) Adjust pull up force of the parking brake lever to specified force by
turn the knob.
Pull up force: 220-270 N (22-28 kgf, 50-60 lbf)
(3) Release the parking brake lever. Turn the parking brake drum by hand
to see that the brake shoes are not dragging.
(4) Check operation, holding and releasing of the parking brake by oper-
ating the parking brake lever.
3. BRAKE BURNISHING
(1) Burnishing of lining
When replacing lining or drum of parking brake with new parts, be
sure to perform lapping by the following procedure.
Braking force may be extremely lowered without lapping, so be sure to
SAPH06ABC0700026
perform the lapping.
NOTICE
Apply parking brake burnishing only after replacing the lining and in
an emergency when the vehicle is moving.
a. Release parking brake and turn adjusting knob until a control
force becomes to approximately 18 kgf (40lbf).
b. Mark ten (10) stops from 16 km/h (10 mph) on a dry, hard surface
road using only parking brake to stop vehicle.
c. After each stop, release parking brake and drive vehicle at 32 km/
h (20 mph) for 4 km (2.5 miles) to cool the brake.
d. After operation, adjust hand lever adjusting knob.
(2) Confirmation of parking brake application.
After completing all-brake adjustment, stop the vehicle on a safe slope
or using a brake tester, confirm whether the parking brake is securely
applied.
BR07-002.fm 1 ページ２００４年５月２４日月曜日午後２時５６分
PARKING BRAKE (MERITOR 10" & 12") BR07–1
PARKING BRAKE (MERITOR 10" & 12")

BR07
BR07-002
PARKING BRAKE ASSEMBLY ................BR07-2

DESCRIPTION ................................................ BR07-2
OVERHAUL ..................................................... BR07-7
ADJUSTMENT............................................... BR07-14
BR07–2 PARKING BRAKE (MERITOR 10" & 12")
PARKING BRAKE ASSEMBLY

EN0600207I200001
10" x 3" Model 12" x 3" Model
Parking brake type Duplex Cam mechanical brake, internal expanding acting type
Parking brake control type Lever type control with control cable
Drum inside diameter 254.0 mm {10.0 in.} 304.8 mm {12.0 in.}
Brake lining Width 76.2 mm {3.0 in} Width 76.2 mm {3.0 in}
DESCRIPTION
EN0600207C100001
SAPH06ABC0700031

4 Bolt
SAPH06ABC0700032

4 Bolt
TROUBLESHOOTING
EN0600207F300001

Not enough braking force Excessively large drum-to-lining clear- Readjust the lever knob.
ance.
Maladjusted control linkage. Readjust.
Burnt lining. Repair or replace.
Worn lining. Replace.
Shoes are too dirty with water, dust, Disassemble and clean.
etc.
Linings are soaked with oil. Replace.
The brake drum is cracked or heavily Replace the drum.
scored.
Lining gets burnt easily Not enough drum-to-lining clearance. Readjust.
Shoe or drum is distorted. Repair or replace.
Springs are broken. Replace.

Squeals or groans Glazed lining. Remove glaze from lining using emery
paper.
Misalignment of parts. Correct misalignment by tightening
any loose brake or drum mounting
bolts.
Dirt in drum. Remove drum and clean out lining
dust and dirt.
Worn out lining. Check for lining worn down to rim or
debris embedded in lining - replace
both shoe and lining assemblies, if
necessary.
Bent or misaligned shoe. Check for misaligned shoe rubbing
against the drum - replace both shoe
and lining assemblies, if necessary.
Clicks or noises Excessive clearance. Adjust lining to drum clearance.
Eccentric or wobbling drum. Inspect drum runout. Also check for
worn or loose bearing on main shaft.
Check drum mounting bolts for tight-
ness. Tighten as needed.
Excessive linkage friction or binding at Check linkage pivot points and cam-
camshaft ball. shaft ball for rust, binding, or lack of
lubrication. Clean and lubricate all
pivot points.
The brake shoes or backing plate is Check the brake shoes, return springs,
loose. and backing plate mounting bolts.
Tighten, repair, or replace, as needed.
There is dirt inside the brake drum. Remove the brake drum and clean it.
Also clean the other brake parts.
Cannot release the parking brake The brake cable is too tight. Adjust the brake lever knob.
The brake shoe return springs are Check the return springs. Install them
missing, detached, or broken. or replace them as needed.
The contact points between the brake Check the area, and clean and lubri-
shoe webs and the actuator strut are cate as needed.
corroded or dirty (MERITOR brake).
The parking brake lever in the cab is Check the parking brake lever assem-
binding. bly for damage or corrosion. Repair or
replace as needed.
Water inside the cable when cold Replace the cable.
weather.
Grabbing Brake lubricant or transmission oil on Replace both shoe and lining assem-
lining. blies. Clean oil and excess brake lubri-
cation from brake and drum. Replace
faulty oil seal at main shaft.
Excessive drum runout. Reduce the drum runout to
0.015in.(0.38 mm) max. or replace
drum, if needed.
COMPONENT LOCATOR
EN0600207D100001
PARKING BRAKE LEVER
SAPH06ABC0700041
1 Parking brake lever 4 Clevis

3 Brake lever bracket 6 Bolt

A 42-62 {430-630, 31-46}
PARKING BRAKE
SAPH06ABC0700042
1 Brake durum 7 Backing plate

2 Shoe return spring 8 Bolt
3 Brake shoe assembly 9 Nut
4 Actuator strut 10 Lock washer
5 Lever 11 Washer
6 Cam

B 110-132 {1120-1350, 81-97} F 645-710 {6570-7240, 475-525}
C 48-68 {490-690, 35-50} G 54-65 {550-665, 40-48}
D 110-135 {1120-1380, 81-100} H 160-225 {1630-2290, 120-165}
E 18-26 {185-265, 13-19}
OVERHAUL
EN0600207H200001
1. REMOVAL OF THE 10" x 3" PARKING BRAKE

MODEL HINO 145 (NA6J), HINO 165 (NB6J), HINO 185 (NC6J)
EQUIPPED WITH AISIN 450 AUTOMATIC TRANSMISSION
(1) Remove the nuts that hold the propeller shaft flange yoke and remove
the flange yoke, then lower the propeller shaft to the floor (Refer to
propeller shaft section of this manual).
(2) Remove the bolts that hold the drum to the companion flange, and
remove the drum.
(3) Remove companion flange.
Remove the nut that holds the companion flange to main shaft, and
remove the companion flange. (Refer to automatic transmission sec-
tion of this manual).
SAPH06ABC0700043 (4) Remove the bolts that hold the parking brake assembly to the trans-
mission case, and remove the parking brake assembly.
2. REMOVAL OF THE 12 x 3" PARKING BRAKE

MODEL HINO 238 (ND8J), HINO 368 (NE8J), HINO 308 (NF8J)
EQUIPPED WITH Eaton FS5406 MANUAL TRANSMISSION
(1) Remove the nuts that hold the propeller shaft flange yoke and remove
the flange yoke and brake drum to companion flange, then lower the
propeller shaft to the floor (Refer to propeller shaft section).
(2) Remove the drum.
(3) Remove the nut that holds the companion flange to main shaft, and
remove the companion flange.
(4) Remove the bolts and nuts that hold the parking brake assembly to
the transmission case, and remove the parking brake assembly.
SAPH06ABC0700045
3. MAINTENANCE MANUAL PUBLISHED BY MERITOR
SAPH06ABC0700034
SAPH06ABC0700035
SAPH06ABC0700047
SAPH06ABC0700037
SAPH06ABC0700038

EN0600207H300001
Unit: mm {in.}
Inspection item Standard Limit Remedy Inspection procedure
Brake lining: — 0.8 Replace. Measure

Lining thickness {0.03}
Brake drum: 10" x 3" 254 254.8 Replace. Measure

Inside diameter brake {10} {10.035}
12" x 3" 304.8 305.6 Replace.

brake {12} {12.035}
ADJUSTMENT
EN0600207H300002
1. INSTALL THE CABLE

(1) Connect the inner wire to the parking brake and fix the cable to the
cab floor with nut.
(2) Pulling up the clevis with specified force, fix the center of clevis at
specified distance A (See figure on page BR07-6).
Pull up force: 175-215 N (18-22 kgf, 39-48 lbf)
Distance A: 141-144 mm (5.55-5.67 in.)
(3) Set the cable connection pin at specified distance B (See figure on
page BR07-6) by turn the knob.
Distance B
10" x 3" parking brake and AISIN A450 ATM
B = 49 mm (1.93 in.)
12" x 3" parking brake and Eaton FS5406 MTM
B = 63 mm (2.48 in.)
(4) Connect the clevis to the parking brake lever.
2. ADJUST THE PARKING BRAKE LEVER

(1) Pull up the parking brake lever twice or more.
(2) Adjust pull up force of the parking brake lever to specified force (See
below) by turn the knob.
SAPH06ABC0700046
Pull up force
10" x 3" parking brake and AISIN A450 ATM
220-270 N (22-28 kgf, 50-60 lbf)
12" x 3" parking brake and Eaton FS5406 MTM
320-370 N (33-38 kgf, 72-83 lbf)
(3) Release the parking brake lever. Turn the parking brake drum by hand
to see that the brake shoes are not dragging.
(4) Check operation, holding and releasing of the parking brake by oper-
ating the parking brake lever.
3. BRAKE BURNISHING
(1) Burnishing of lining
When replacing lining or drum of parking brake with new parts, be
sure to perform lapping by the following procedure.
Braking force may be extremely lowered without lapping, so be sure to
perform the lapping.
NOTICE
Apply parking brake burnishing only after replacing the lining and in
an emergency when the vehicle is moving.
a. Release parking brake and turn adjusting knob until a control
force becomes to approximately 18 kgf (40lbf).
b. Mark ten (10) stops from 16 km/h (10 mph) on a dry, hard surface
road using only parking brake to stop vehicle.
c. After each stop, release parking brake and drive vehicle at 32 km/
h (20 mph) for 4 km (2.5 miles) to cool the brake.
d. After operation, adjust hand lever adjusting knob.
(2) Confirmation of parking brake application.
After completing all-brake adjustment, stop the vehicle on a safe slope
or using a brake tester, confirm whether the parking brake is securely
applied.
COLOPHON2.fm 1 ページ２００４年５月２５日火曜日午前１０時２１分
Hino Motors Sales U.S.A., Inc.

25 Corporate Drive, Orangeburg, N.Y. 10962
Telephone: (845)-365-1400
PRINTED IN JAPAN
Pub.No. S1-UNAE01B 2/4 '04.05


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book 1 ページ ２００４年５月２１日 金曜日 午後４時９分

Manual Name Pub. No.

CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL

MODELS HINO HINO HINO HINO HINO HINO HINO

GENERAL INTRO- GN02-001

CLUTCH MAIN UNIT CL02-001 CL02-002

CLUTCH CONTROL CL03-001

TRANSMISSION MAIN UNIT TR02-001

AUTOMATIC TRANSMISSION TR04-001 TR04-002 TR04-003

TRANSMISSION/TRANSFER CONTROL TR06-001

PROPELLER SHAFT PP02-001

DIFFERENTIAL CARRIER DF02-001

BRAKE EQUIPMENT BR01-001 BR01-002 BR01-001 BR01-002

SERVICE BRAKE BR02-001 — BR02-001 —

ABS (ANTI-LOCK BRAKE SYSTEM) BR03-001 BR03-002 BR03-001 BR03-002

STEERING EQUIPMENT SR01-001

STEERING UNIT SR02-001

POWER STEERING SR03-001

FRONT AXLE AX02-001

REAR AXLE AX03-001

WHEEL & TIRE AX04-001

CHASSIS FRAME FC02-001

ELECTRICAL EQUIPMENT EL01-001

ELECTRIC WIRE EL02-001

This manual does not contain items on half-tone dot meshing.

INDEX: CHASSIS GROUP 1/4

CLUTCH MAIN UNIT

WORKSHOP CLUTCH CONTROL

MANUAL TRANSMISSION EQUIPMENT

TRANSMISSION MAIN UNIT

TRANSFER MAIN UNIT

P.T.O. (POWER TAKE-OFF)

TRANSMISSION / TRANSFER CONTROL

PROPELLER SHAFT EQUIPMENT

ABS (ANTI-LOCK BRAKE SYSTEM)

ES START (EASY & SMOOTH START) SYSTEM

INDEX: CHASSIS GROUP 2/4

WHEEL & TIRE

COUPLER (5TH WHEEL)

INDEX: CHASSIS GROUP 3/4

INDEX: CHASSIS GROUP 4/4

CAB EQUIPMENT CONTROL

BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE) BR01–1

BRAKE EQUIPMENT (MODELS WITH HYDRAULIC

SERVICE BRAKE ASSEMBLY.................BR01-2

BR01–2 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE)

SERVICE BRAKE ASSEMBLY

BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE) BR01–3

PUMP GEAR : POWER STEERING FLUID LINE

FRONT BRAKE ABS REAR BRAKE

BR01–4 BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE)

Symptom Possible cause Remedy/Prevention

Symptom Possible cause Remedy/Prevention

Symptom Possible cause Remedy/Prevention

Symptom Possible cause Remedy/Prevention

Symptom Possible cause Remedy/Prevention

BRAKE EQUIPMENT (MODELS WITH HYDRAULIC BRAKE) BR01–5

book 1 ページ２００４年５月２１日金曜日午後４時９分