SERVICE MANUAL SECTION ECE-13 BRAKE SYSTEM Model: 7600 Model: 8600 Model: 9800 S04053 2010
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TABLE OF CONTENTS
TABLE OF CONTENTS
1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1. RESERVOIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2. STOP LIGHT SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3. LOW PRESSURE INDICATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4. FOOT VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5. QUICK RELEASE VALVE (QRV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6. PARKING BRAKE VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7. TRAILER CONTROL VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8. RELAY VALVE AND ANTILOCK TRACTION RELAY VALVE (R-12 AND ATR-6). . . . . . . . . . . . . . . . 1.9. ANTILOCK MODULATOR VALVE (M-32). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10. SPRING BRAKE MODULATING VALVE (SR-7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11. AIR DRYER (AD-IS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12. SOLENOID PACK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13. INVERSION VALVE (TR-3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14. AIR LINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15. PUSH TO CONNECT FITTINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16. AIR PRESSURE GAUGES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.17. TEST VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18. VALVE SILENCER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 3 3 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6
2. REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.1. RESERVOIR 7600/8600. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Reservoir - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Reservoir - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.2. RESERVOIR 9800. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Reservoir - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Reservoir - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 2.3. PRESSURE SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Pressure Switches - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Pressure Switches - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 2.4. FOOT VALVE (7600/8600). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Foot Valve (7600/8600) - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Foot Valve (7600/8600) - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 2.5. FOOT VALVE (9800). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Foot Valve (9800) - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Foot Valve (9800) - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 2.6. QUICK RELEASE VALVE (QRV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Quick Release Valve (QRV) - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Quick Release Valve (QRV) - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 2.7. PARKING BRAKE VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Parking Brake Valve - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Parking Brake Valve - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 2.8. TRAILER CONTROL VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Trailer Control Valve - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Trailer Control Valve - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 2.9. ANTILOCK TRACTION RELAY VALVE (ATR-6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Antilock Traction Relay Valve (ATR-6) - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Antilock Traction Relay Valve (ATR-6) - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 2.10. ANTILOCK MODULATOR VALVE (M-32). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Antilock Modulator Valve (M-32) - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Antilock Modulator Valve (M-32) - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
TABLE OF CONTENTS
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DESCRIPTION
1. DESCRIPTION
1. DCM (DRIVER CONTROL MODULE) 2. STOPLIGHT SWITCH (NORMALLY OPEN) 3. PARK BRAKE WARNING LIGHT SWITCH (NORMALLY CLOSED) 4. PARKING BRAKE VALVE 5. TRAILER CONTROL VALVE 6. SPRING BRAKE MODULATING VALVE (SR-7) 7. MODULATOR VALVE 8. TEST VALVE 9. QUICK RELEASE VALVE 10. RELAY VALVE (R-12) 11. RESERVOIR (PRIMARY BRAKING CIRCUIT ONE REAR BRAKE) 12. RESERVOIR (SECONDARY BRAKING PARK BRAKE)
13. RESERVOIR (PRIMARY BRAKING CIRCUIT TWO FRONT BRAKE) 14. SOLENOID 15. TO CAB AIR SUSPENSION AND ACCESSORIES 16. RESERVOIR (AUXILIARY) 17. INVERSION VALVE (TR-3) 18. AIR COMPRESSOR 19. AIR DRYER (AD-IS) 20. PRESSURE SWITCH 21. FOOT VALVE 22. PRIMARY BRAKING CIRCUIT ONE REAR BRAKE CIRCUIT 23. PRIMARY BRAKING CIRCUIT TWO FRONT BRAKE CIRCUIT 24. SECONDARY BRAKING PARK BRAKE CIRCUIT 25. TRAILER CONTROL/SUPPLY CIRCUIT 26. AUXILIARY CIRCUIT
Figure 1
DESCRIPTION
1. FOOT VALVE 2. CRUISE CONTROL SWITCH (NORMALLY CLOSED) 3. STOPLIGHT SWITCH (NORMALLY OPEN) 4. CAB MANIFOLD PORT LOCATION 5. AIR PRESSURE GAUGE SENDING UNIT 6. PARKING BRAKE VALVE 7. PARK BRAKE WARNING LIGHT SWITCH (NORMALLY CLOSED) 8. TRAILER CONTROL VALVE 9. SPRING BRAKE MODULATING VALVE (SR-7) 10. MODULATOR VALVE (M-32) 11. TEST VALVE 12. QUICK RELEASE VALVE (QRV) 13. RELAY VALVE (R-12) 14. RESERVOIR (PRIMARY BRAKING CIRCUIT ONE REAR BRAKE) Figure 2
15. RESERVOIR (SECONDARY BRAKING PARK BRAKE) 16. RESERVOIR (PRIMARY BRAKING CIRCUIT TWO FRONT BRAKE) 17. RESERVOIR (AUXILIARY) 18. INVERSION VALVE (TR-3) 19. AIR COMPRESSOR 20. AIR DRYER (AD-IP) 21. PRIMARY BRAKING CIRCUIT ONE REAR BRAKE CIRCUIT 22. PRIMARY BRAKING CIRCUIT TWO FRONT BRAKE CIRCUIT 23. SECONDARY BRAKING PARK BRAKE CIRCUIT 24. TRAILER CONTROL/SUPPLY CIRCUIT 25. AUXILIARY CIRCUIT
RESERVOIR
DESCRIPTION
Economic Commission for Europe (ECE) regulations describe a set of internationally agreed, standardized technical requirements for vehicles, parts, and equipment of motor vehicles. ECE-13 regulations apply to a motor vehicles braking system. Air brake equipment for the 7600, 8600, and 9800 vehicles provides a means of controlling brakes through a medium of compressed air. The air system consists of various components required to maintain a supply of air, direct the ow of air, and convert the energy of compressed air into mechanical force to apply the brakes.
1.1. RESERVOIR
The reservoir is an air storage tank; its function is to provide compressed air for braking. All reservoirs should have a manual drain cock or a drain valve. Manual drains are of two styles, one is a brass hand turn style valve; the other is a cable pull style valve. The brass turn style valve has a brass body tted with a tapered brass key. The drain cock is open when the handle is parallel to the drain cock body and closed when the handle is at right angles to the body. The pull cable style is much the same, but uses a pull cable for remote opening of valve and will only drain when the cable is being pulled. Drain cocks and drain valves are installed in the bottom or in the end of each reservoir in the air brake system to provide a convenient means of draining condensation.
DESCRIPTION
FOOT VALVE
1.8. RELAY VALVE AND ANTILOCK TRACTION RELAY VALVE (R-12 AND ATR-6)
The R-12 relay valve is the standard valve on the 7600, 8600, and 9800 vehicles. The R-12 relay valve in an air brake system functions as a relay station to speed up the application and release of the brakes. The valve is normally mounted at the rear of the vehicle in proximity to the chambers it serves. The valve operates as a remote controlled brake valve that delivers or releases air to the chambers in response to the control air delivered to it from the foot brake valve or other source. The R-12 relay valve is equipped with a noise reducing silencer. The optional relay valve in place of the R-12 relay valve, is the ATR-6 traction relay valve and is a service relay valve tted with a modied cover containing a control solenoid. It contains both air and electric components to provide the service braking and traction control (differential braking) as well as ESP advanced stability system ABS functions. When the ABS controller operates the ATR-6 valve, for example during an antilock traction event, the control solenoid is energized and permits delivery air to be supplied to the antilock modulator valve and used as required by the controller. The ATR-6 traction relay valve is equipped with a noise reducing silencer.
DESCRIPTION
DESCRIPTION
RESERVOIR 7600/8600
1. NUT 2. MOUNT BRACKET 3. RESERVOIR (PRIMARY BRAKING CIRCUIT ONE REAR BRAKE) 4. RESERVOIR CABLE Figure 3
5. RESERVOIR (PRIMARY BRAKING CIRCUIT TWO FRONT BRAKE) 6. RESERVOIR (AUXILIARY) 7. RESERVOIR (SECONDARY BRAKING PARK BRAKE) Reservoirs 7600/8600
4. Remove the two reservoir cables and nuts securing reservoir in place. 5. Remove the reservoir from mount brackets.
RESERVOIR 7600/8600
Reservoir - Installation NOTE If a different reservoir is to be installed than the one removed, transfer the ttings to the replacement reservoir noting, their location and position. 1. Install reservoir to the mount brackets and, with aid of an assistant, install two reservoir cables and nuts (Figure 3, Items 1, 2, 3, and 4). Tighten nuts to 4.5 Nm (40 lbf-in). 2. Install air lines to reservoir, noting previous previously installed reference tags (See Push To Connect Fittings, page 30). 3. Ensure all drain valves and air lines are tightened and secured. 4. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.
RESERVOIR 9800
1. RESERVOIR CABLE AND NUT 2. RESERVOIR (SECONDARY BRAKING PARK BRAKE) 3. AIR LINES (LOCATION) 4. RESERVOIR (PRIMARY BRAKING CIRCUIT ONE REAR BRAKE) Figure 4
Reservoirs 9800
4. Remove the two reservoir cables and nuts securing reservoir in place. 5. Remove the reservoir from mount brackets.
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RESERVOIR 9800
Reservoir - Installation NOTE If a different reservoir is to be installed than the one removed, transfer the ttings to the replacement reservoir, noting their location and position. 1. Install reservoir to the mount brackets and, with aid of an assistant, install two reservoir cables and nuts (Figure 4, Items 1, 4, and 5). Tighten nuts to 4.5 Nm (40 lbf-in). 2. Install air lines to reservoir, noting previously installed reference tags (See Push To Connect Fittings, page 30). 3. Ensure all drain valves and air lines are tightened and secured. 4. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.
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PRESSURE SWITCHES
2. Disconnect electrical connector from pressure switch. 3. Disconnect pressure switch from coupling (See Push To Connect Fittings, page 30). Pressure Switches - Installation 1. Connect pressure switch to coupling (See Push To Connect Fittings, page 30). 2. Connect electrical connector to pressure switch (Figure 5, Items 1 and 2). 3. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.
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1. COTTER PIN 2. CLEVIS 3. FOOT VALVE Figure 6 2. Remove cotter pin from clevis pin. 3. Remove clevis pin and disconnect clevis from brake pedal.
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4. Tag and mark all air lines connected to the foot valve. 5. Disconnect the air lines from foot valve (See Push To Connect Fittings, page 30). 6. Remove the four mounting nuts securing foot valve to dash panel. 7. Remove the foot valve. Foot Valve (7600/8600) - Installation NOTE If a different foot valve is to be installed than the one removed, transfer the ttings to the replacement valve, noting their location and position. 1. Install foot valve and secure with four mounting nuts (Figure 7, Items 1 and 3). Torque mounting nuts to 23 to 31 Nm (17 to 23 lbf-ft). 2. Attach clevis to brake pedal and secure with clevis pin (Figure 6, Items 2, 4, and 5). 3. Secure clevis pin with cotter pin (Figure 6, Items 1 and 5). 4. Connect the air lines to foot valve, noting previously installed reference tags (See Push To Connect Fittings, page 30). 5. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.
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2. Tag and mark all pressure switches and electrical connectors connected to the foot valve. 3. Disconnect the electrical connectors from the pressure switches. 4. Tag and mark all air lines connected to the foot valve. 5. Disconnect the air lines from foot valve (See Push To Connect Fittings, page 30).
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1. COTTER PIN AND PIVOT PIN 2. FOOT PEDAL 3. FOOT VALVE Figure 9
4. FOOT VALVE PEDESTAL 5. NUT AND STUD 6. BOLT, WASHER, AND NUT Foot Valve (9800)
6. Remove the cotter pin and pivot pin from the foot pedal. Remove the foot pedal. 7. Remove the three foot valve mounting nuts from the studs. 8. Remove the foot valve. 9. Remove the three bolts, washers, and nuts from the foot valve pedestal. 10. Remove the foot valve pedestal. Foot Valve (9800) - Installation NOTE If a different foot valve is to be installed than the one removed, transfer the ttings and pressure switches to the replacement foot valve, noting their location and position. 1. Install the foot valve pedestal and secure with the three bolts, washers, and nuts (Figure 9, Items 3, 4, and 6). Tighten bolts to 19 to 20 Nm (14 to 15 lbf-ft). 2. Install the foot valve and secure with the three nuts (Figure 9, Items 3 and 5). Tighten nuts to 19 to 20 Nm (14 to 15 lbf-ft). 3. Position the foot pedal on the dual brake pedestal and secure with the pivot pin and cotter pin (Figure 9, Items 1, 2, and 4). 4. Connect the air lines to foot valve, noting previous reference tags (See Push To Connect Fittings, page 30).
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5. Connect the electrical connectors to the pressure switches, noting previously installed reference tags (Figure 8, Item 2). 6. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.
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2. Tag and mark all air lines connected to the quick release valve. 3. Disconnect the air lines from quick release valve (See Push To Connect Fittings, page 30). 4. Remove two bolts and nuts from quick release valve. 5. Remove quick release valve. Quick Release Valve (QRV) - Installation NOTE If a different quick release valve is to be installed than the one removed, transfer the ttings to the replacement valve, noting their location and position. 1. Install quick release valve and secure with two bolts and nuts (Figure 10, Items 1 and 2). Torque nuts to 28 to 35 Nm (21 to 26 lbf-ft). 2. Connect the air lines to quick release valve noting previously installed reference tags (See Push To Connect Fittings, page 30). 3. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.
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3. Remove two mounting screws from parking brake valve. 4. Remove the air lines from the parking brake valve; remove the valve (See Push To Connect Fittings, page 30). Parking Brake Valve - Installation NOTE If a different parking brake valve is to be installed than the one removed, transfer the ttings to the replacement valve, noting their location and position. 1. Connect air lines to parking brake valve noting previously installed reference tags (See Push To Connect Fittings, page 30). 2. Position the parking brake valve and secure with the two mounting screws (Figure 11, Items 1 and 2). 3. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.
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3. Remove the air lines from the trailer control valve (See Push To Connect Fittings, page 30). 4. Remove the four nuts and washers, and remove the trailer control valve. Trailer Control Valve - Installation NOTE If a different trailer control valve is to be installed than the one removed, transfer the ttings to the replacement valve, noting their location and position. 1. Install the trailer control vale and secure with the four nuts and washers (Figure 12, Items 1 and 3). Tighten nuts to 20 Nm (15 lbf-ft). 2. Connect air lines to trailer control valve noting previously installed reference tags (See Push To Connect Fittings, page 30). 3. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.
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1. ELECTRICAL CONNECTOR 2. AIR LINE 3. ANTILOCK TRACTION RELAY VALVE (ATR-6) Figure 13
2. Tag and mark all air lines connected to the trailer control valve. 3. Disconnect ve air lines from antilock traction relay valve (See Push To Connect Fittings, page 30). 4. Disconnect electrical connector from antilock traction relay valve. 5. Remove two bolts and nuts from antilock traction relay valve. 6. Remove antilock traction relay valve.
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Antilock Traction Relay Valve (ATR-6) - Installation NOTE If a different relay valve is to be installed than the one removed, transfer the ttings to the replacement valve, noting their location and position. 1. Install antilock traction relay valve to mount bracket and secure with two bolts and nuts (Figure 13, Items 3 and 4). Torque nuts to 28 to 35 Nm (21 to 26 lbf-ft). 2. Connect ve air lines to antilock traction relay valve noting previously installed reference tags (See Push To Connect Fittings, page 30). 3. Connect electrical connector to antilock traction relay valve (Figure 13, Items 1 and 3). 4. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.
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2. Tag and mark all air lines connected to the antilock modulator valve. 3. Disconnect the air lines from antilock modulator valve (See Push To Connect Fittings, page 30). 4. Disconnect the electrical connector from antilock modulator valve. 5. Remove two bolts and nuts from antilock modulator valve. 6. Remove antilock modulator valve.
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Antilock Modulator Valve (M-32) - Installation NOTE If a different antilock modulator valve is to be installed than the one removed, transfer the ttings to the replacement valve, noting their location and position. 1. Install antilock modulator valve and secure with two bolts and nuts (Figure 14, Items 3 and 4). Torque nuts to 10 to 15 Nm (7 to 11 lbf-ft). 2. Connect the air lines to antilock modulator valve noting previously installed reference tags (See Push To Connect Fittings, page 30). 3. Connect electrical connector to antilock modulator valve (Figure 14, Items 1 and 3). 4. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.
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2. Tag and mark all air lines connected to the spring brake modulating valve. 3. Disconnect the air lines from spring brake modulating valve (See Push To Connect Fittings, page 30). 4. Remove two nuts and remove spring brake modulating valve from mount bracket. Spring Brake Modulating Valve (SR-7) - Installation NOTE If a different spring brake modulating valve is to be installed than the one removed, transfer the ttings to the replacement valve, noting their location and position. 1. Install spring brake modulating valve to mount bracket and secure with two nuts (Figure 15, Items 2, 3, and 4). Tighten nuts to 56 to 68 Nm (41 to 50 lbf-ft). 2. Connect the air lines to spring brake modulating valve noting previously installed reference tags (See Push To Connect Fittings, page 30). 3. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.
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4. Disconnect electrical connectors from air dryer. 5. Remove four nuts and remove air dryer from mount bracket. Air Dryer (AD-IS) - Installation NOTE If a different air dryer is to be installed than the one removed, transfer the ttings to the replacement dryer, noting their location and position. 1. Install air dryer (AD-IS) to mount bracket and secure with four nuts (Figure 16, Items 1, 2, and 4). Torque nuts to 4.5 Nm (40 lbf-in). 2. Connect electrical connectors to air dryer (Figure 16, Item 1).
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3. Connect the air lines to air dryer noting previously installed reference tags (See Push To Connect Fittings, page 30). 4. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.
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2. Tag and mark all air lines connected to the solenoid pack. 3. Disconnect the air lines from solenoid pack (See Push To Connect Fittings, page 30). 4. Disconnect electrical connector from solenoid pack. 5. Remove two bolts from solenoid pack. 6. Remove solenoid pack. Solenoid Pack (7600/8600) - Installation NOTE If a different solenoid pack is to be installed than the one removed, transfer the ttings to the replacement solenoid, noting their location and position. 1. Install solenoid pack and secure with two bolts (Figure 17, Items 2 and 3). Tighten bolts to 28 to 35 Nm (21 to 26 lbf-ft). 2. Connect the air lines to solenoid pack noting previously installed reference tags (See Push To Connect Fittings, page 30). 3. Connect electrical connector to solenoid pack (Figure 17, Items 2 and 4). 4. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.
28 S04053 2010 NC2 Global LLC All rights reserved
2. Tag and mark all air lines connected to the inversion valve. 3. Disconnect the air lines from inversion valve (See Push To Connect Fittings, page 30). 4. Remove the two bolts and nuts. Remove the inversion valve. Inversion Valve (TR-3) - Installation NOTE If a different inversion valve is to be installed than the one removed, transfer the ttings to the inversion valve, noting their location and position. 1. Install the inversion valve and secure with the two bolts and nuts (Figure 18, Items 2 and 3). Tighten nuts to 11 to 14 Nm (8 to 10 lbf-ft). 2. Connect the air lines from inversion valve noting previously installed reference tags (See Push To Connect Fittings, page 30). 3. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.
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NOTE The tube release tool (P/N 1698698C1) is available through Navistar parts. 1. Drain air from the reservoirs. 2. Use the air line release tool (Figure 19, Item 1) to remove the air line. Do this by placing it around the air line. 3. Push down on the release tool, and then pull on the air line. Pushing the tool depresses the tting collet, allowing it to release the air line. 4. Inspect the port for any debris or contaminants or for a lose or damaged internal tube support. Remove any debris or contaminants that are found. If a lose or damaged tube support is found, then replace the tting, valve or manifold. 5. Inspect the air line end for external scratches, burrs, or cracks. If it is damaged, trim the damaged portion using the tube cutter (1698701C1 supplied in the tool kit) or replace the air line; do not reuse a damaged end.
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6. If the tting, valve or manifold has a plugged port, remove the shipping plug with the plug removal tool (P/N 1698699C1 supplied in the tool kit). This can be done by inserting and pushing the removal tool between the collect head and the head of the plug depressing the collet, and then pulling out the plug. 7. To install the tube into the tting, use a push-push-pull motion, pushing the tube through the collet until it bottoms out, and then pull back on the tube to ensure the collet bites into the tube. 8. Test to make sure the assembly is free from leaks using a soap solution and clean, dry air at system pressure. NOTE Use the air line cutter to ensure that the cut is square within 15 to help prevent leakage. Do not use a dull or heavy cutting tool such as side cutters, pocket knife or hacksaw, which could collapse (atten) the air line or create O-ring damaging burrs. Do not use the air line cutter to cut anything other than nylon air line tubing. Replace the blade or cutter if the cutting edge becomes dull.
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TORQUE
TORQUE
Table 1 Figure No. (Item No.) Figures 3 and 4 (Item 1) Figure 7 (Item 1) Figure 9 (Item 5) Figure 9 (Item 6) Torque Chart Nm 4.5 23 to 31 19 to 20 19 to 20 lbf-ft/in 40 lbf-in 17 to 23 lbf-ft 14 to 15 lbf-ft 14 to 15 lbf-ft
Location Reservoir Cable Nut Foot Valve (7600/8600) Nut Foot Valve (9800) Nut Foot Valve (9800) Pedestal Bolt and Nut
Figure 10 (Item 2)
28 to 35
21 to 26 lbf-ft
Figure 12 (Item 1)
20
15 lbf-ft
Figure 13 (Item 4)
28 to 35
21 to 26 lbf-ft
Antilock Modulator Valve Bolt and Nut Air Dryer Nut Spring Brake Modulating Valve Nut
10 to 15 4.5 56 to 68
Figure 17 (Item 3)
28 to 35
21 to 26 lbf-ft
Figure 18 (Item 2)
11 to 14
8 to 10 lbf-ft
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