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Hino 600 User Manual

Hino 600
451 pages
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FOREWORD
This workshop manual has been prepared to provide information regarding repair procedures on Hino Trucks.
Applicable for HINO 238, 258LP, 268, 338 series, equipped with J08E-VB and J08E-VC engine
When making any repairs on your vehicle, be careful not to be injured through improper procedures.
As for maintenance items, refer to the Driver’s / 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 workshop manuals for the components and sys-
tems in these vehicles.
Manual Name Pub. No.
Chassis Workshop Manual S1-UNAE11A 2/2
J08E-VB, VC Engine Workshop Manual S5-UJ08E11A
Trouble Shooting Workshop Manual
S7-UNAE11A 1/3
S7-UNAE11A 2/3
S7-UNAE11A 3/3
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Table of Contents

Questions and Answers:

Hino 600 Specifications

General IconGeneral
BrandHino
Model600
CategoryAutomobile
LanguageEnglish

Summary

FOREWORD

GENERAL INTRODUCTION (CHASSIS)

GENERAL INTRODUCTION

Overview of maintenance services and general precautions for vehicle servicing.

GENERAL PRECAUTIONS

Safety precautions to prevent death, injury, or property damage during maintenance.

IDENTIFICATION INFORMATION

Details on Vehicle Identification Number (VIN) structure and label location.

TOWING

CLEAN AIR ACT

HOW TO USE THIS WORKSHOP MANUAL

PRECAUTIONS FOR ELECTRICAL SYSTEM

PRECAUTIONS FOR ELECTRIC WELDING

SEALANT ON THE TAPERED SCREW FOR PIPING

NYLON TUBE REPLACEMENT METHOD

METRIC INFORMATION

DECIMAL AND METRIC EQUIVALENTS

SPECIFIED TORQUE FOR STANDARD BOLTS AND NUTS

SPECIFIED TORQUE FOR FLANGE BOLTS AND NUTS

RECOMMENDED LUBRICANTS

VEHICLE LIFT AND SUPPORT LOCATIONS

NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP

Precautions regarding vehicle condition, load, and weight distribution when jacking up.

NOTICE FOR USING 4 POST LIFT

Guidelines for safe operation of a 4-post lift, including tire protection and vehicle securing.

NOTICE FOR USING JACK AND SAFETY STAND

Detailed instructions for safe jacking and supporting procedures using jacks and safety stands.

INFORMATION DISPLAY

INFORMATION DISPLAY ITEMS

Description of items displayed on the information display, including ordinary and warning displays.

INFORMATION DISPLAY CONTROL SWITCH

Explanation of how to operate the information display using control switches like MODE, SELECT, and SET/RESET.

Normal display item

WARNING DISPLAY

SELF DIAGNOSIS SYSTEM

RESETTING PROCEDURE

AVAILABLE SETTING ITEMS

SYMPTOM SIMULATION

WATER SPRINKLING METHOD

HIGH ELECTRICAL LOAD METHOD

GLOSSARY

CLUTCH MAIN UNIT (EATON 1401)

CLUTCH ASSEMBLY (EATON SAS1401)

Data and specifications, description, troubleshooting, special tools, component locator, and overhaul for the Eaton SAS1401 clutch.

CLUTCH ASSEMBLY (EATON SOLO1401)

Data and specifications, component locator, overhaul, and inspection/repair for the Eaton SOLO1401 clutch assembly.

DATA AND SPECIFICATIONS

TROUBLESHOOTING

SPECIAL TOOL

COMPONENT LOCATOR

IMPORTANT POINT - MOUNTING

IMPORTANT POINT - ADJUSTMENT

CLUTCH MAIN UNIT (EATON 1402)

CLUTCH ASSEMBLY (EATON SOLO1402)

Data and specifications for the Eaton SOLO1402 clutch assembly, including material, type, and dimensions.

OVERHAUL

Important steps for dismounting and inspection/replacement of clutch components for the Eaton SOLO1402.

CLUTCH MAIN UNIT (EATON 1402)

CLUTCH ASSEMBLY (EATON SAS1402)

Data and specifications for the Eaton SAS1402 clutch assembly, including material, type, and dimensions.

TROUBLESHOOTING

Common issues with the clutch, their causes, and remedies.

SPECIAL TOOL

List of necessary special tools for clutch overhaul, including illustrations and part numbers.

COMPONENT LOCATOR

Diagram illustrating the components of the Eaton SAS1402/SOLO1402 clutch assembly with tightening torque values.

IMPORTANT POINT - MOUNTING

Step-by-step instructions for mounting the clutch assembly, including alignment and bolt tightening.

IMPORTANT POINT - ADJUSTMENT

Procedures for checking Kwik-Adjuster location and performing adjustment procedures for release bearing position and free travel.

CLUTCH CONTROL

CLUTCH CONTROL UNIT

Details on the clutch control unit, including description, inspection, and adjustment procedures.

CLUTCH PEDAL AND RELEASE UNIT

Component locator, overhaul, and inspection/repair procedures for the clutch pedal and release unit.

CLUTCH MASTER CYLINDER

Information on the clutch master cylinder, including component locator, overhaul, and inspection/repair steps.

AIR BLEEDING

CHECK AND ADJUST THE CLUTCH PEDAL PLAY

CHECK THE CLUTCH PEDAL HEIGHT AND STROKE

COMPONENT LOCATOR

OVERHAUL

INSPECTION AND REPAIR

COMPONENT LOCATOR

TRANSMISSION MAIN UNIT (EATON FS 5406/6406)

TRANSMISSION ASSEMBLY

Overview of the transmission assembly, including data, specifications, and dismounting/mounting procedures.

DATA AND SPECIFICATION

Technical data for the transmission assembly, including gear ratios, number of teeth, and oil capacity.

DISMOUNTING AND MOUNTING

Step-by-step procedures for safely dismounting and mounting the transmission, including important safety points.

AUTOMATIC TRANSMISSION (ALLISON 2200RDS, 2500RDS, 2200HS)

AUTOMATIC TRANSMISSION ASSEMBLY

General information on the automatic transmission assembly, including troubleshooting and special tools.

DISMOUNTING AND MOUNTING

Procedures for dismounting the automatic transmission, including safety warnings and steps like blocking wheels and draining fluid.

TRANSMISSION/TRANSFER CONTROL (EATON MANUAL TRANSMISSION)

TRANSMISSION CONTROL UNIT

Details on the transmission control unit, including troubleshooting, component locator, and overhaul procedures.

TROUBLESHOOTING

Common issues with manual transmission shifting and lever play, their causes, and remedies.

COMPONENT LOCATOR

Diagram of the manual transmission control components with tightening torque specifications for the isolator.

OVERHAUL

Important assembly steps for the manual transmission control, including shift lever connection and shift stroke checks.

TRANSMISSION/TRANSFER CONTROL (ALLISON AUTOMATIC TRANSMISSION)

TRANSMISSION CONTROL UNIT

Information on the transmission control unit for Allison automatic transmissions, covering troubleshooting and component location.

TROUBLESHOOTING

Troubleshooting guide for automatic transmission issues, referring to the Allison Shop Manual.

COMPONENT LOCATOR

Diagrams of the automatic transmission control system, identifying selector and shift cable assemblies.

OVERHAUL

Assembly procedures for the automatic transmission control cable, emphasizing proper installation and bending radius.

PROPELLER SHAFT (SPL 100, 140)

PROPELLER SHAFT ASSEMBLY

Overview of the propeller shaft assembly, including data, specifications, description, troubleshooting, component locator, and overhaul.

DATA AND SPECIFICATIONS

Specifications for propeller shafts, including manufacturer, type, universal joint details, and front/rear component identification.

DESCRIPTION

Exploded view of the propeller shaft assembly, identifying components like bearing assembly, cross assembly, and slip yoke.

TROUBLESHOOTING

Common causes and remedies for abnormal vibrations experienced while driving a propeller shaft.

COMPONENT LOCATOR

Diagram showing propeller shaft components and their locations, with tightening torque specifications for critical fasteners.

IMPORTANT POINT - DISMOUNTING

Crucial steps for safely disconnecting the propeller shaft from all connecting points, emphasizing alignment marks and support.

IMPORTANT POINTS - DISASSEMBLY

Detailed steps for disassembling the universal joint assembly, including snap ring removal and bearing cup extraction.

REMOVE THE MEMBER BOOT

Procedure for removing the slip member boot, including cautions about boot clamps and marking alignment.

REMOVE THE CENTER BEARING

Steps for removing the center bearing, emphasizing the midship nut and washer, and the importance of marking.

IMPORTANT POINTS - ASSEMBLY

Steps for assembling the universal joint, focusing on lubrication, bearing cup installation, and phasing marks.

SPRING TAB BOLT SPECIFICATIONS

Table detailing torque specifications for spring tab bolts based on series, thread size, and head size.

INSTALL NEW SPRING TABS AND BOLTS

Procedure for installing new spring tabs and bolts, ensuring correct torque and alignment.

BOOT CLAMP SPECIFICATIONS

Specifications for boot clamp torque based on series (SPL100, SPL140).

DIFFERENTIAL CARRIER (MERITOR RS17.19.21&23)

DIFFERENTIAL CARRIER ASSEMBLY

Data and specifications, description, troubleshooting, special tools, component locator, overhaul, and inspection/repair for the differential carrier assembly.

DRIVER-CONTROLLED MAIN DIFFERENTIAL LOCK

Procedures for overhaul and inspection/repair of the driver-controlled main differential lock mechanism.

DATA AND SPECIFICATIONS

Specifications for differential carriers, including model, axle model, gear ratios, and fluid capacity.

DESCRIPTION

Exploded view of the single-reduction differential carrier, identifying all components and their numbered parts.

Differential lock assembly

Exploded view of the differential lock assembly, identifying components like sensor switch, shift fork, and screw-in differential lock.

TROUBLESHOOTING

Common causes and remedies for abnormal noises in the differential carrier, categorized by bearing, gear, rear axle, and oil systems.

SPECIAL TOOL

Illustration and specifications for a special tool (SPX Kent-Moore J-3409-D) required for differential carrier overhaul.

COMPONENT LOCATOR

Exploded view of the differential carrier assembly, identifying numerous components with numerical labels.

FASTENER

Torque values for various fasteners including capscrews, nuts, and bolts used in the differential carrier assembly.

SAFETY ALERTS, TORQUE SYMBOL AND NOTES

Explanation of safety alert symbols (Warning, Caution, Notice) and general guidelines for servicing components.

IMPORTANT POINTS - DISMOUNTING

Crucial safety precautions and steps for removing the differential carrier from the axle housing.

DIFFERENTIAL AND RING GEAR FROM THE CARRIER

Steps for removing the differential and ring gear from the carrier, including match marking and loosening fasteners.

DISASSEMBLY OF DIFFERENTIAL AND RING GEAR ASSEMBLY

Procedures for disassembling the differential and ring gear assembly, including separating case halves and removing gears.

REMOVAL OF DRIVE PINION AND BEARING CAGE FROM THE CARRIER

Steps for removing the drive pinion and bearing cage from the carrier, with cautions about using tools and potential damage.

GEAR SETS

Information on identifying gear sets with matched parts using part numbers and tooth combination numbers.

ASSEMBLY OF DRIVE PINION, BEARINGS AND BEARING CAGE

Procedures for assembling the drive pinion, bearings, and bearing cage, emphasizing proper lubrication and press usage.

INSTALLATION OF ONE-PIECE SPIGOT BEARING ON THE DRIVE PINION WITH SNAP RING

Steps for installing a one-piece spigot bearing on the drive pinion using a snap ring.

INSTALLATION OF ONE-PIECE SPIGOT BEARING ON THE DRIVE PINION WITHOUT SNAP RING

Procedure for installing a one-piece spigot bearing on the drive pinion when snap rings are not present.

INSTALLATION OF TWO-PIECE SPIGOT BEARING ON THE DRIVE PINION

Steps for installing a two-piece spigot bearing on the drive pinion, including heating and staking procedures.

ADJUSTMENT OF PINION BEARING PRELOAD BY PRESS METHOD

Method for adjusting pinion bearing preload using a press, including pressure calculations and torque values.

ADJUSTMENT OF PINION BEARING PRELOAD BY YOKE OR FLANGE METHOD

Method for adjusting pinion bearing preload using a yoke or flange, with cautions on tool usage.

ADJUSTMENT OF SHIM PACK THICKNESS FOR A NEW DRIVE PINION

Procedure for adjusting shim pack thickness based on pinion cone variation numbers and old shim pack measurements.

INSTALLATION OF DRIVE PINION, BEARING CAGE AND SHIM PACK INTO THE CARRIER

Steps for installing the drive pinion, bearing cage, and shim pack into the carrier, ensuring proper alignment and sealant application.

DIFFERENTIAL GEARS ROTATING RESISTANCE CHECK

Procedure to check differential gears rotating resistance using a special tool and torque wrench.

INSTALLATION OF DIFFERENTIAL AND RING GEAR ASSEMBLY

Steps for installing the differential and ring gear assembly into the carrier, including cleaning and lubrication.

INSTALL THE BEARING CUPS

Instructions for installing bearing cups into the case halves using a press or mallet, ensuring correct seating.

ADJUST DIFFERENTIAL BEARING PRELOAD

Method 1 for adjusting differential bearing preload using a dial indicator and pry bars.

METHOD 2

Method 2 for adjusting differential bearing preload using a micrometer and measuring distance changes.

CHECK RING GEAR RUNOUT

Procedure to check ring gear runout using a dial indicator and compare against specifications.

RING GEAR BACKLASH ADJUSTMENT

Steps to adjust ring gear backlash to meet specifications, including checking tooth contact patterns.

CHECK GEAR SET TOOTH CONTACT PATTERNS (BACKLASH)

Procedure to check gear set tooth contact patterns by applying marking compound and observing the pattern.

ADJUST THE THRUST SCREW

Steps for adjusting the thrust screw and jam nut to set the clearance between the thrust screw and ring gear.

INSTALLATION OF DIFFERENTIAL CARRIER INTO AXLE HOUSING

Procedures for installing the differential carrier into the axle housing, including cleaning, alignment, and sealant application.

CLEAN AND INSPECT YOKES

Instructions for cleaning and inspecting yoke surfaces, including groove measurements and replacement criteria.

CLEAN GROUND AND POLISHED PARTS

Guidelines for cleaning ground or polished parts using solvents or weak alkaline solutions.

CLEAN ROUGH PARTS

Methods for cleaning rough metal parts using hot solution tanks with alkaline solutions.

CLEAN AXLE ASSEMBLIES

Procedures for cleaning axle assemblies, including steam cleaning and covering openings.

DRY PARTS AFTER CLEANING

Instructions for drying parts after cleaning, using soft rags or compressed air, with cautions about bearing rotation.

PREVENT CORROSION ON CLEANED PARTS

Guidelines for applying axle lubricant or special anti-corrosion material to cleaned parts for storage.

INSPECT PARTS

Detailed inspection of bearings (cup, cone, rollers, cage) for wear and damage, with criteria for replacement.

INSPECT PARTS (continued)

Continued inspection of bearing parts for wear marks, damage, cracks, and pitting, with a caution about replacing drive pinion and ring gear as matched sets.

INSPECT hypoid pinions and gears

Inspection of hypoid pinions and gears for wear or damage, with a caution about replacing matched sets.

REPAIR OR REPLACE PARTS

General guidelines for repairing or replacing worn or damaged parts, cleaning threads, and applying gasket material.

REMOVING FASTENERS SECURED WITH ADHESIVE

Procedure for removing fasteners secured with adhesive, including heating and loosening steps.

NEW FASTENERS WITH PRE-APPLIED ADHESIVE

Instructions for using new fasteners with pre-applied adhesive, including cleaning threaded holes and tightening to torque.

ORIGINAL OR USED FASTENERS

Procedure for cleaning and preparing original or used fasteners for reinstallation with liquid adhesive.

APPLYING ADHESIVE AND SILICONE GASKET MATERIAL

Instructions for applying Meritor specification adhesive and silicone gasket material to differential bearing bores and mounting surfaces.

APPLYING ADHESIVE AND SILICONE GASKET MATERIAL (continued)

Further instructions on applying silicone gasket material, including bead size, and assembly timing.

CARRIER-TO-HOUSING JOINT

Procedures for repairing the carrier-to-housing joint, including cleaning surfaces, installing studs, and applying gasket material.

REMOVAL OF DIFFERENTIAL CARRIER FROM THE AXLE HOUSING

Safety precautions and steps for removing the differential carrier from the axle housing, including blocking wheels and draining lubricant.

SCREW-IN STYLE DIFFERENTIAL LOCK CYLINDER

Instructions for operating the screw-in style differential lock cylinder and removing the carrier from the axle housing.

REMOVAL OF THE DIFFERENTIAL LOCK SLIDING COLLAR

Procedures for removing the differential lock sliding collar and DCDL assembly.

REMOVAL OF THE DIFFERENTIAL LOCK ASSEMBLY

Steps for removing the lock cylinder, sensor switch, and bearing adjusting rings, including match marking parts.

SCREW-IN STYLE DIFFERENTIAL LOCK ASSEMBLY INTO CARRIER

Procedures for installing the screw-in style differential lock assembly into the carrier after assembly and adjustments are complete.

INSPECTION AND REPAIR

Checks for the differential lock system, including shifting transmission to neutral and checking the indicator light.

SERVICE BRAKE (HYDRAULIC BRAKE)

HYDRAULIC BRAKE

Overview of the hydraulic brake system, including inspection and adjustment procedures.

HYDRO-MAX HYDRAULIC BRAKE BOOSTER AND MASTER CYLINDER

Data and specifications, description, principle of operation, and component locator for the Hydro-Max booster and master cylinder.

MASTER CYLINDER

Overhaul and pressure tests for the master cylinder.

ABS MODULATOR

Data and specifications, and description of the ABS modulator.

WHEEL BRAKE (TYPE: 4 PISTON)

Data and specifications, description, and troubleshooting for the 4-piston wheel brake.

REMAINING THICKNESS OF PAD

BRAKE FLUID LEAK AND POWER STEERING FLUID LEAK

BRAKE FLUID

BRAKE PRESSURE WARNING LIGHT

HYDRO-MAX HYDRAULIC BRAKE BOOSTER AND MASTER CYLINDER

DATA AND SPECIFICATIONS

Manufacturer, type, and master cylinder diameter specifications for the Hydro-Max booster and master cylinder.

DESCRIPTION

Diagram of the Hydro-Max hydraulic brake booster and master cylinder assembly, labeling key components.

COMPONENT LOCATOR

PRINCIPLE OF OPERATION

COMPONENT LOCATOR

IMPORTANT POINT-DISMOUNTING

IMPORTANT POINTS-DISASSEMBLY

REMOVE THE BACKUP PUMP

Procedures for disassembling the backup pump, flow switch assembly, and inlet check valve.

USE CLEAN POWER STEERING FLUID FOR CLEANING REUSED PARTS AND NEW SEALS

Guidance on using appropriate cleaning fluids for reused parts and new seals.

IMPORTANT POINTS-ASSEMBLY

INSTALL THE INLET CHECK VALVE

Steps for installing the inlet check valve, including lubrication and seating.

INSTALL THE FLOW SWITCH ASSEMBLY

Steps for installing the flow switch assembly, including lubrication and tightening torque.

INSTALL THE BACKUP PUMP

Steps for installing the backup pump, including check ball placement and tightening bolts.

IMPORTANT POINTS-MOUNTING

INSTALL THE HYDRO-MAX BOOSTER

Procedures for mounting the Hydro-Max booster, including tightening nuts and installing the clevis pin.

CONNECT THE MASTER CYLINDER

Steps for connecting the master cylinder to the Hydro-Max booster and tightening nuts.

CONNECT THE HYRDAULIC HOSE AND PIPE FROM THE HYDRO-MAX BOOSTER

Procedures for connecting hydraulic hoses and pipes to the Hydro-Max booster, including tightening flare nuts.

CONNECT THE HARNESS CONNECTORS AND HARNESS

CONNECT THE BATTERY CABLE TO THE BATTERY GROUND TERMINAL

BLEEDING OF HYDRO-MAX SYSTEM

BLEEDING OF BRAKE HYDRAULIC SYSTEM

BRAKE PEDAL HEIGHT

IMPORTANT POINTS-DISMOUNTING

IMPORTANT POINTS-ASSEMBLY

INSTALL THE PRESSURE DIFFERENTIAL SWITCH

Steps for installing the pressure differential switch.

INSTALL THE TUBE SEAT

Instructions for installing the tube seat, ensuring proper seating and cleaning ports.

IMPORTANT POINTS-MOUNTING

CONNECT THE MASTER CYLINDER

Steps for connecting the master cylinder to the Hydro-Max booster.

CONNECT THE BRAKE PIPES

Procedures for connecting brake pipes to the master cylinder.

BRAKE SYSTEM AIR BLEEDING

Reference to air bleeding procedures in another section.

ABS (ABS : HYDRAULIC (E VERSION))

DATA AND SPECIFICATIONS

Manufacturer and type specifications for the ABS modulator.

DESCRIPTION

Illustration of the ABS modulator, identifying the modulator valve.

DATA AND SPECIFICATIONS

TORQUE SPECIFICATIONS

TROUBLESHOOTING

REMOVAL

BRAKE CALIPER

SUPPORT

ROTOR

DISASSEMBLE AND OVERHAUL THE BRAKE CALIPER

DISASSEMBLE AND OVERHAUL THE BRAKE CALIPER (continued)

CLEAN, DRY AND INSPECT PARTS

ASSEMBLY

INSTALLATION

BRAKE PADS

ASSEMBLE THE SUPPORT

CALIPER

CALIPER MOUNTING PLATE

BRAKE SYSTEM BLEEDING PROCEDURE

BRAKE SYSTEM BLEEDING PROCEDURE (continued)

SERVICE BRAKE (FULL AIR BRAKE)

AIR DRYER AND RESERVOIR SYSTEM (MODEL: BENDIX AD-IS)

Description of the AD-IS Air Dryer and Reservoir System, including port designations and general function.

DESCRIPTION

General description of the AD-IS Air Dryer and Reservoir System, its function in cleaning air, and its components.

DIAGRAM SHOWS PRESSURE PROTECTION VALVES OPEN, E & D CLOSED

Diagram illustrating the AD-IS air dryer and reservoir system charge cycle, showing pressure protection valves.

AD-IS AIR DRYER AND RESERVOIR SYSTEM OPERATION: GENERAL (Refer to Figure 2)

General explanation of the AD-IS air dryer and reservoir system's operation, covering charge and purge cycles.

CHARGE CYCLE (Refer to Figure 2)

Detailed explanation of the charge cycle, including airflow path and contaminant removal processes.

PURGE CYCLE (Refer to Figure 3.)

Explanation of the purge cycle, including governor action, purge valve operation, and desiccant reactivation.

TURBO CUT-OFF FEATURE (Refer to Figure 3.)

Explanation of the turbo cut-off valve's function to prevent loss of engine turbocharger air pressure.

PREVENTIVE MAINTENANCE

Recommended maintenance intervals and checks for the air dryer and reservoir system, including inspecting for moisture and physical damage.

OPERATION & LEAKAGE TESTS (ALSO SEE VIDEO BW2327)

Procedures for testing air dryer and reservoir system operation and leakage, including pressure checks and purge valve tests.

REBUILDING THE AD-IS AIR DRYER AND RESERVOIR SYSTEM

General safety guidelines for rebuilding the AD-IS air dryer and reservoir system, emphasizing personal injury prevention.

Do not attempt to install, remove, disassemble or assemble a component

General precautions for working on air brake and auxiliary pressurized air systems, including draining pressure and deactivating electrical systems.

TEMPORARY AIR DRYER AND RESERVOIR SYSTEM BYPASS

Procedure for temporarily bypassing the air dryer system, including safety precautions and instructions for cleaning/reinstalling the delivery check valve.

DELIVERY CHECK VALVE CLEANING PROCEDURE

Procedure for cleaning the delivery check valve, including cleaning metal parts and o-rings.

AD-IS AIR DRYER RESERVOIR SYSTEM TROUBLESHOOTING CHART

Troubleshooting chart for common symptoms related to the AD-IS air dryer system, such as constant cycling and water in reservoirs.

Water in vehicle reservoirs.

Possible causes and remedies for water accumulation in vehicle reservoirs, including checks for discharge line length and air usage.

Safety valve on air dryer "popping off" or exhausting air.

Potential causes and remedies for the safety valve on the air dryer popping off or exhausting air.

Constant exhaust of air at air dryer purge valve exhaust or unable to build system pressure. (Charge mode.)

Troubleshooting for constant air exhaust from the purge valve or inability to build system pressure.

Cannot build system air pressure.

Causes and remedies for failure to build system air pressure, including checks for discharge lines and pressure protection valves.

Air dryer does not purge or exhaust air.

Troubleshooting steps for when the air dryer fails to purge or exhaust air.

Desiccant material being expelled from air dryer purge valve exhaust

Potential causes and remedies for desiccant material being expelled from the air dryer purge valve exhaust.

Unsatisfactory desiccant life.

Reasons for unsatisfactory desiccant life, including excessive system leakage and incorrect vehicle application.

"Pinging" noise excessive during compressor loaded cycle.

Causes and remedies for pinging noise during the compressor loaded cycle.

The air dryer purge piston cycles rapidly in the compressor unloaded (noncompressing) mode.

Troubleshooting for rapid air dryer purge piston cycling in the unloaded mode.

CHECK VALVE

DATA AND SPECIFICATIONS

Type and pressure difference specifications for spring type, wafer type check valves.

DESCRIPTION

Diagram of a spring type, wafer type check valve, illustrating inlet, outlet, spring, and wafer components.

INSPECTION AND REPAIR

PREVENTATIVE MAINTENANCE

Routine inspections for the SR-7TM valve every 6 months or 1500 operating hours.

SERVICE CHECKS

Operational tests for the SR-7TM valve, including brake application checks and leakage tests.

LEAKAGE AND OPERATIONAL TESTS

REMOVAL

IMPORTANT POINTS-MOUNTING

INSTALL THE BRAKE VALVE ASSEMBLY

Steps for installing the brake valve assembly, including tightening nuts.

CONNECT THE PUSH ROD JOINT TO THE BRAKE PEDAL LEVER

Instructions for connecting the push rod joint to the brake pedal lever.

INSTALL THE BRAKE PEDAL

Steps for installing the brake pedal, including lubrication and snap ring insertion.

INSTALL THE PEDAL BRACKET ASSEMBLY

Procedure for installing the pedal bracket assembly with bolts.

INSTALL THE CLUTCH MASTER CYLINDER AND THE STEERING SHAFT

Steps for installing the clutch master cylinder and steering shaft.

CONNECT THE NYLON TUBE TO THE BRAKE VALVE CONNECTOR

Procedure for connecting the nylon tube to the brake valve connector, including torque specifications and cautions.

INSPECT THE BRAKE PEDAL PLAY

Instructions for checking brake pedal play and installing height.

BRAKE VALVE

DATA AND SPECIFICATIONS

Type and specifications for the brake valve, including dual pistons and plunger pedal.

DESCRIPTION

Diagram of the brake valve, identifying components like pistons, springs, and diaphragms.

COMPONENT LOCATOR

INSPECTION AND REPAIR

PREVENTIVE MAINTENANCE

Routine inspections for the brake valve every 3 months, 25,000 miles, or 900 operating hours.

SERVICE CHECKS

Operating checks for the brake valve, including pressure delivery and brake pedal movement.

LEAKAGE AND OPERATIONAL TESTS

REMOVAL

DISASSEMBLY

CLEANING & INSPECTION

ASSEMBLY

SPRING BRAKE MODULATING VALVE

DESCRIPTION

Illustration of the spring brake modulating valve, indicating ports like park control, supply, delivery, and exhaust.

COMPONENT LOCATOR

INSPECTION AND REPAIR

REMOVAL

INSTALLATION

PREVENTIVE MAINTENANCE

SERVICE CHECKS

LEAKAGE AND OPERATIONAL TESTS

SERVICE BRAKE (FULL AIR BRAKE)

BRAKE CHAMBER (FRONT)

Data and specifications for the front brake chamber, including P/N Series, Model, Size, Stroke, and weight.

COMPONENT LOCATOR

Exploded view of the front brake chamber components, identifying parts like NP chamber, diaphragm, and return spring.

ASSEMBLING THE BRAKE CHAMBER

Steps for assembling the brake chamber, including diaphragm replacement, alignment marks, and bolt tightening.

INSPECTION AND REPAIR

Inspection of brake chamber components like cover, clamp, push rod, and springs for wear and damage.

BRAKE CHAMBER (REAR)

DATA AND SPECIFICATIONS

Data and specifications for the rear brake chamber, including P/N Series, Model, Size, Stroke, and weight.

DESCRIPTION

Illustration of the rear brake chamber, showing dimensions A through G and inlet types.

COMPONENT LOCATOR

Exploded view of the rear brake chamber components, identifying parts like NP chamber, diaphragm, and push-rod assembly.

INSPECTION AND REPAIR

Recommended inspection points for MGM Brakes Tamper Resistant spring brake chambers, including checking end caps, exterior surfaces, and clamp rings.

REMOVAL AND INSTALLATION INSTRUCTIONS FOR SINGLE (PIGGYBACK) SPRING BRAKES

Procedures for removing and installing single/piggyback spring brake chambers, including manual release and air line disconnection.

PROCEDURE TO CUT THE SERVICE PUSH-ROD TO PROPER LENGTH

Instructions for cutting the service push-rod to the correct length, with warnings about spring release.

REMOVAL AND INSTALLATION INSTRUCTIONS FOR SINGLE (PIGGYBACK) SPRING BRAKES (continued)

Detailed steps for removing and installing single spring brake chambers, including push-rod measurements and yoke alignment.

REMOVAL AND INSTALLATION INSTRUCTIONS FOR SINGLE (PIGGYBACK) SPRING BRAKES (continued)

Further steps for removing and installing single spring brake chambers, including yoke connection and air line connections.

CAM BRAKE ADJUSTMENT - ALL MODELS SPRING BRAKE AND SERVICE BRAKE ACTUATORS

Adjustment procedures for spring and service brake actuators, including angle checks and recommended stroke settings.

RECOMMENDED SPRING BRAKE ACTUATOR DISARMING PROCEDURE

Procedure for safely disarming spring brake actuators before disposal, emphasizing spring release and safety precautions.

WHEEL BRAKE

DATA AND SPECIFICATIONS

Data and specifications for wheel brakes, including drum inside diameter and lining width for front and rear axles.

DESCRIPTION

Diagram of the wheel brake assembly, identifying components like shoe and lining assembly, camshaft, and adjuster screw.

OVERHAUL

GENERAL

General guidelines and important points for overhauling Meritor cam brakes, including safety warnings and tool ordering information.

IMPORTANT POINTS-DISASSEMBLY

Procedures for removing wheel components, including brake shoes, springs, and camshaft.

REMOVAL (continued)

Detailed steps for removing brake shoes, including releasing springs and hold-down pins.

INSTALLING THE SHOES

Procedures for installing brake shoes, including cleaning components, applying grease, and ensuring proper orientation.

SHOE CAGE ADJUSTMENT PROCEDURES

Procedures for adjusting the shoe cage with the drum off (primary) and installed (alternate).

ADJUSTMENT WITH DRUM INSTALLED - ALTERNATE PROCEDURE

Alternate procedure for adjusting the brake shoes with the drum installed.

DISENGAGING ADJUSTER LEVER FROM ADJUSTER STAR WHEEL TO ALLOW RETRACTING THE BRAKE SHOES (LOOSEN BRAKE)

Procedure for disengaging the adjuster lever to allow retracting brake shoes, including using a special tool.

ANCHOR SCREW, LEVER AND CAM REPLACEMENT

Steps for removing and replacing the anchor screw, lever, and cam components, including torque specifications and cautions.

INSTALLING COMPONENTS

Procedures for installing new components, including anchor post threads, grease application, and adjuster cable routing.

INSTALLATION

Final installation steps for the adjuster cable and related components.

INSPECTION AND REPAIR

Inspection of brake components such as spider, camshaft bracket, anchor pins, and brake shoes for wear and damage.

16.5-INCH BRAKE SHOES ONLY

Specific inspection criteria for 16.5-inch brake shoes, including anchor pin hole diameter and roller hole distance.

RELINE THE BRAKES

Recommendations for relining brakes, including replacing springs, rollers, and checking drums.

INSPECTION AND REPAIR

Inspection and repair procedures for brake lining thickness and brake drum inside diameter.

ADJUSTMENT

Procedures for installing the parking brake cable, adjusting the parking brake lever, and burnishing the lining.

Confirmation of parking brake application.

Confirmation of proper parking brake application after adjustment.

AUTOMATIC SLACK ADJUSTER

DESCRIPTION

Diagram of an automatic slack adjuster, labeling components like push rod, clevis, actuator rod, and worm gear.

DIAGNOSTICS

Troubleshooting guide for common issues with automatic slack adjusters, such as adjusted stroke being too long or too short, and linings dragging.

COMPONENT LOCATOR

Exploded view of the automatic slack adjuster components, including clevis types and their applications.

"QUICK CONNECT" CLEVIS

Description of the "Quick Connect" clevis assembly, its features, and usage.

ONE-PIECE THREADED CLEVIS

Description of the one-piece threaded clevis, its features, and application for new Q Plus/MX500 cam brakes.

IMPORTANT POINTS-ASSEMBLY

Procedures for assembling automatic slack adjusters, including steps for installing seals, gears, and springs.

IMPORTANT POINTS-ASSEMBLY (continued)

Continued assembly steps for automatic slack adjusters, including installing retaining rings, worms, and actuator assemblies.

IMPORTANT POINTS-ASSEMBLY (continued)

Further assembly steps for automatic slack adjusters, including removing and installing seals, and inspecting components.

CLEAN PARTS

Instructions for cleaning automatic slack adjuster parts using solvent and soap/water.

DRY PARTS AFTER CLEANING

Procedures for drying cleaned parts using paper rags or compressed air.

INSPECT PARTS

Steps for inspecting slack adjuster parts, including pawl teeth, for wear or damage.

CORROSION PROTECTION

Guidelines for applying corrosion protection to parts after cleaning and before lubrication or storage.

AUTOMATIC SLACK ADJUSTERS

General information and cautions regarding automatic slack adjusters, including clevis pin retainer clips and bushing inspection.

ASSEMBLY

Assembly steps for automatic slack adjusters, including lubrication and installation of gears, seals, and thrust washers.

ASSEMBLY (continued)

Continued assembly steps for automatic slack adjusters, including retaining rings, worms, and seal installation.

ASSEMBLY (continued)

Further assembly steps for automatic slack adjusters, including installing actuator rods, pistons, and boots.

INSTALLATION

Procedures for installing the slack adjuster onto the camshaft, including checking camshaft condition and applying grease.

INSTALLATION (continued)

Further steps for installing slack adjusters, including clevis alignment and securing with retainer clips.

BRAKE SLACK ADJUSTER POSITION (BSAP) METHOD

Method for verifying BSAP dimension for automatic slack adjusters.

AUTOMATIC SLACK ADJUSTER TEMPLATES

Information on ordering and using automatic slack adjuster templates for correct installation.

MEASURE THE SLACK ADJUSTER

Procedure for measuring the slack adjuster length using a template.

INSTALL A THREADED CLEVIS

Steps for installing a threaded clevis onto the push rod, including alignment and thread engagement checks.

FREE STROKE MEASUREMENT

Procedure for measuring free stroke of the brake, including cautions about pawl engagement and lining-to-drum contact.

FREE STROKE MEASUREMENT (continued)

Continued measurement of free stroke and adjustment procedures, including checking push rod travel.

COMMERCIAL VEHICLE SAFETY ALLIANCE (CVSA) GUIDELINES TO MEASURE PUSH ROD TRAVEL (ADJUSTED CHAMBER STROKE)

CVSA guidelines for measuring push rod travel (adjusted chamber stroke) on truck and tractor air brakes.

ANTI-SEIZE COMPOUND

Information on using Meritor anti-seize compound for slack adjusters and camshaft splines.

ABS (ABS : FULL AIR)

OVERVIEW

General overview of the ABS system for full air brake vehicles, explaining its purpose.

COMPOSITION AND OPERATION

Description of the ABS system's composition and operational principles for full air brake vehicles.

FUNCTION

Explanation of ABS functions, including fail-safe and exhaust brake control.

PRECAUTIONS WHEN DRIVING VEHICLES EQUIPPED WITH ABS

Precautions for drivers operating vehicles with ABS, covering braking distances and vehicle handling.

OVERVIEW

General overview of the ABS system, explaining its function in maintaining vehicle stability.

SYSTEM COMPOSITION DIAGRAM

Diagram illustrating the ABS system composition for full air brake vehicles.

ABS CONTROL FLOWCHART

Flowchart detailing the ABS control process for full air brake systems.

BASIC PRINCIPLE

Explanation of ABS basic principles, relating slip ratio to friction coefficient and braking force.

OPERATION

Description of ABS operation modes (pressure increase, maintenance, reduction) based on wheel speed and slip conditions.

FAIL-SAFE FUNCTION

Explanation of the ABS fail-safe function in full air brake systems.

EXHAUST BRAKE CONTROL FUNCTION

Explanation of how ABS controls the exhaust brake in full air brake systems.

CHECK POINTS

Checkpoints for ABS operation in full air brake vehicles, including braking distance and handling.

REMEDIAL ACTIONS

Remedial actions for common ABS issues in full air brake vehicles, including driving precautions and warning light checks.

Operation

Explanation of ABS operation during pressure reduction and maintenance modes for full air brake systems.

WHEEL SENSORS

Description of wheel sensors used in ABS for full air brake systems.

SENSOR RINGS

Information on sensor rings used in ABS for full air brake systems.

CLAMPING BUSHINGS

Explanation of clamping bushings for ABS wheel sensors.

WARNING LIGHT

Information regarding the ABS warning light in full air brake systems.

WHEEL SENSOR WIRE HARNESSES

Details on wheel sensor wire harnesses, their function, and precautions during installation and handling.

Front axle ABS wire harness

Specifics about the front axle ABS wire harness, emphasizing proper routing and spacing for movement.

Rear axle ABS wire harness

Details on the rear axle ABS wire harness, stressing correct connections and optimal spacing for chassis spring movement.

HANDLING WIRE HARNESSES

General precautions for handling wire harnesses and connectors, including unplugging, probing, and cleaning procedures.

ADDITIONAL PRECAUTIONS

Additional safety precautions for ABS systems, including starter switch position, welding, cleaning, and electronic equipment installation.

EXHAUST BRAKE

EXHAUST BRAKE SYSTEM

Overview of the exhaust brake system, including system diagram, troubleshooting, and adjustment.

SYSTEM DIAGRAM

Diagram of the exhaust brake system for manual and automatic transmissions, showing electrical and air line connections.

TROUBLESHOOTING

Common symptoms for exhaust brake switches and valves, with possible causes and remedies.

ACCELERATOR SWITCH ADJUSTMENT

Procedures for adjusting accelerator pedal height and checking the output voltage of the accelerator pedal stroke sensor.

CLUTCH SWITCH ADJUSTMENT (MANUAL TRANSMISSION)

Adjustment procedure for the clutch switch in manual transmission systems, including clearance checks.

BRAKE CYLINDER

Data and specifications, and description of the brake cylinder, illustrating its components.

PARKING BRAKE (BOSCH 12")

PARKING BRAKE ASSEMBLY

Overview of the parking brake assembly, including data, specifications, description, troubleshooting, component locator, overhaul, inspection, and adjustment.

DATA AND SPECIFICATIONS

Specifications for the parking brake, including type, control type, drum diameter, and brake lining width.

DESCRIPTION

Diagram of the parking brake lever assembly, identifying components like parking brake lever, knob, and cable.

TROUBLESHOOTING

Common symptoms related to parking brake operation, such as light force, heavy force, or failure to release, with possible causes and remedies.

COMPONENT LOCATOR

Diagram of the parking brake lever components, identifying parts and providing tightening torque specifications.

OVERHAUL

Step-by-step instructions for removing and installing brake shoes, including safety precautions and adjuster lever procedures.

REMOVING THE SHOES

Detailed steps for removing brake shoes, including releasing springs and hold-down pins.

INSTALLING THE SHOES

Procedures for installing brake shoes, including cleaning components, applying grease, and ensuring proper orientation.

SHOE CAGE ADJUSTMENT PROCEDURES

Procedures for adjusting the shoe cage with the drum off (primary) and installed (alternate).

ADJUSTMENT WITH DRUM INSTALLED - ALTERNATE PROCEDURE

Alternate procedure for adjusting the brake shoes with the drum installed.

DISENGAGING ADJUSTER LEVER FROM ADJUSTER STAR WHEEL TO ALLOW RETRACTING THE BRAKE SHOES (LOOSEN BRAKE)

Procedure for disengaging the adjuster lever to allow retracting brake shoes, including using a special tool.

ANCHOR SCREW, LEVER AND CAM REPLACEMENT

Steps for removing and replacing the anchor screw, lever, and cam components, including torque specifications and cautions.

INSTALLING COMPONENTS

Procedures for installing new components, including anchor post threads, grease application, and adjuster cable routing.

INSTALLATION

Final installation steps for the adjuster cable and related components.

INSPECTION AND REPAIR

Inspection of brake components such as spider, camshaft bracket, anchor pins, and brake shoes for wear and damage.

16.5-INCH BRAKE SHOES ONLY

Specific inspection criteria for 16.5-inch brake shoes, including anchor pin hole diameter and roller hole distance.

RELINE THE BRAKES

Recommendations for relining brakes, including replacing springs, rollers, and checking drums.

INSPECTION AND REPAIR

Inspection and repair procedures for brake lining thickness and brake drum inside diameter.

ADJUSTMENT

Procedures for installing the parking brake cable, adjusting the parking brake lever, and burnishing the lining.

Confirmation of parking brake application.

Confirmation of proper parking brake application after adjustment.

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