Manual y Diagnostico de Fallas de Dura Star Terra Star Trans Star, Work Star

7/30/2019 Manual y Diagnostico de Fallas de Dura Star Terra Star Trans Star, Work Star

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SERVICE MANUAL

SERVICE MANUAL SECTION

ECE-13 BRAKE SYSTEM

Model: 7600

Model: 8600

Model: 9800

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TABLE OF CONTENTS

TABLE OF CONTENTS1. DESCRIPTION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.1. RESERVOIR.................................................................................................. 31.2. STOP LIGHT SWITCH..... ...... ...... ...... ..... ...... ...... ..... ..... ...... ...... ..... ...... ...... ..... .. 3

1.3. LOW PRESSURE INDICATOR....... ....... ....... ...... ...... ...... ...... ...... ...... ...... ...... ....... . 31.4. FOOT VALVE................................................................................................. 41.5. QUICK RELEASE VALVE (QRV)...... ...... ..... ..... ...... ..... ...... ..... ..... ...... ..... ...... ..... . 41.6. PARKING BRAKE VALVE........... ...... ...... ...... ...... ...... ....... ....... ....... ....... ....... ....... 41.7. TRAILER CONTROL VALVE..... ..... ...... ..... ..... ...... ..... ..... ..... ..... ..... ..... ..... ..... ..... .. 41.8. RELAY VALVE AND ANTILOCK TRACTION RELAY VALVE (R-12AND ATR-6)... .. .. .. .. .. .. . 41.9. ANTILOCK MODULATOR VALVE (M-32).... ... .... ... .... ... .... ... ... .... ... .... ... .... ... .... ... .... 41.10. SPRING BRAKE MODULATING VALVE (SR-7)... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 51.11. AIR DRYER (AD-IS)...... ..... ...... ...... ..... ..... ...... ..... ...... ...... ...... ..... ...... ..... ..... .... 51.12. SOLENOID PACK........... ....... ....... ...... ....... ...... ...... ....... ....... ...... ....... ...... ...... ... 51.13. INVERSION VALVE (TR-3)....... ...... ...... ....... ...... ....... ....... ...... ...... ....... ...... ....... . 51.14. AIR LINE...................................................................................................... 51.15. PUSH TO CONNECT FITTINGS...... ..... ....... ...... ...... ...... ..... ....... ....... ...... ...... ...... .. 51.16. AIR PRESSURE GAUGES....... ..... ..... ..... ...... ..... ...... ...... ..... ...... ...... ..... ...... ..... ... 61.17. TEST VALVE...... ....... ....... ....... ....... ...... ....... ....... ....... ....... ...... ....... ....... ....... .. . 61.18. VALVE SILENCER.......... ...... ...... ...... ...... ...... ..... ...... ...... ...... ..... ...... ...... ...... ..... 6

2. REMOVAL AND INSTALLATION.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.1. RESERVOIR 7600/8600..... ..... ..... ..... ..... ..... ...... ...... ...... ...... ...... ..... ..... ..... ..... .... 8

Reservoir - Removal..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ...... ...... . 8Reservoir - Installation... ... ... ... ... ... ... .... .... .... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .... .... .... 9

2.2. RESERVOIR 9800...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... . 10Reservoir - Removal..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ..... ...... ...... . 10Reservoir - Installation... ... ... ... ... ... ... .... .... .... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .... .... .... 11

2.3. PRESSURE SWITCHES.................................................................................... 12Pressure Switches - Removal... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 12Pressure Switches - Installation... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 12

2.4. FOOT VALVE (7600/8600)... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 13Foot Valve (7600/8600) - Removal... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 13Foot Valve (7600/8600) - Installation... ... ... ... ... .... ... ... ... ... ... ... .... .... ... ... ... ... .... .... ... ... 14

2.5. FOOT VALVE (9800)...... ....... ....... ...... ....... ....... ....... ...... ....... ....... ....... ....... ...... .. 15Foot Valve (9800) - Removal... .... .... ... .... ... .... ... ... ... .... ... .... ... .... ... ... ... .... ... .... ... ... .. 15Foot Valve (9800) - Installation... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 16

2.6. QUICK RELEASE VALVE (QRV)...... ...... ..... ..... ...... ..... ...... ..... ..... ...... ..... ...... ..... . 18Quick Release Valve (QRV) - Removal... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 18Quick Release Valve (QRV) - Installation... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 18

2.7. PARKING BRAKE VALVE........... ...... ...... ...... ...... ...... ....... ....... ....... ....... ....... ....... 19Parking Brake Valve - Removal... ... .... ... ... .... ... ... .... ... ... ... .... ... ... .... ... ... .... ... ... ... .... . 19

Parking Brake Valve - Installation... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 192.8. TRAILER CONTROL VALVE..... ..... ...... ..... ..... ...... ..... ..... ..... ..... ..... ..... ..... ..... ..... .. 20 Trailer Control Valve - Removal.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. .. .. .. .. .. 20 Trailer Control Valve - Installation.. .. .. .. .. .. .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. .. .. .. .. 20

2.9. ANTILOCK TRACTION RELAY VALVE (ATR-6)... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 21Antilock Traction Relay Valve (ATR-6) - Removal.... .. .. ... ... .. .. .. .. .. .. .. .. .. ... .. .. ... .. .. .. .. .. .. 21Antilock Traction Relay Valve (ATR-6) - Installation.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 22

2.10. ANTILOCK MODULATOR VALVE (M-32).... ... .... ... .... ... .... ... ... .... ... .... ... .... ... .... ... .... 23Antilock Modulator Valve (M-32) - Removal... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 23Antilock Modulator Valve (M-32) - Installation.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 24

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TABLE OF CONTENTS

TABLE OF CONTENTS (CONT.)

2.11. SPRING BRAKE MODULATING VALVE (SR-7)... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 25Spring Brake Modulating Valve (SR-7) - Removal... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 25Spring Brake Modulating Valve (SR-7) - Installation.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... .. .. .. .. .. .. .. 25

2.12. AIR DRYER (AD-IS)..... ..... ...... ..... ..... ...... ..... ...... ...... ..... ..... ...... ...... ..... ...... ..... 26Air Dryer (AD-IS) - Removal..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ..... ... 26Air Dryer (AD-IS) - Installation... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 26

2.13. SOLENOID PACK (7600/8600)... ... ... ... ... .... ... ... ... ... ... ... ... .... .... ... ... ... ... ... .... ... ... ... . 28Solenoid Pack (7600/8600) - Removal... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 28Solenoid Pack (7600/8600) - Installation.. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 28

2.14. INVERSION VALVE (TR-3)...... ...... ...... ....... ...... ....... ...... ...... ....... ....... ...... ....... .. 29Inversion Valve (TR-3) - Removal... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 29Inversion Valve (TR-3) - Installation... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 29

2.15. PUSH TO CONNECT FITTINGS........ ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... . 30Push to ConnectTube- Removal/Installation.. ... .. .. ... .. .. ... .. .. .. ... .. .. ... .. .. ... .. .. ... .. .. .. ... .. .. 30

TORQUE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 32

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DESCRIPTION

1. DESCRIPTION

1. DCM (DRIVER CONTROLMODULE)

2. STOPLIGHT SWITCH(NORMALLY OPEN)

3. PARK BRAKE WARNING LIGHTSWITCH (NORMALLY CLOSED)

4. PARKING BRAKE VALVE5. TRAILER CONTROL VALVE6. SPRING BRAKE MODULATING

VALVE (SR-7)7. MODULATOR VALVE8. TEST VALVE9. QUICK RELEASE VALVE10. RELAY VALVE (R-12)11. RESERVOIR (PRIMARY

BRAKING CIRCUIT ONE REARBRAKE)

12. RESERVOIR (SECONDARYBRAKING PARK BRAKE)

13. RESERVOIR (PRIMARYBRAKING CIRCUIT TWO FRONTBRAKE)

14. SOLENOID15. TO CAB AIR SUSP ENSION

AND ACCESSORIES16. RESERVOIR (AUXILIARY)17. INVERSION VALVE (TR-3)18. AIR COMPRESSOR19. AIR DRYER (AD-IS)20. PRESSURE SWITCH21. FOOT VALVE22. PRIMARY BRAKING CIRCUIT

ONE REAR BRAKE CIRCUIT23. PRIMARY BRAKING CIRCUIT

TWO FRONT BRAKE CIRCUIT24. SECONDARY BRAKING PARK

BRAKE CIRCUIT25. TRAILER CONTROL/SUPPLY

CIRCUIT26. AUXILIARY CIRCUIT

Figure 1 ECE-13 Brake System Diagram (7600/8600)

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DESCRIPTION

1. FOOT VALVE2. CRUISE CONTROL SWITCH

(NORMALLY CLOSED)3. STOPLIGHT SWITCH

(NORMALLY OPEN)4. CAB MANIFOLD PORTLOCATION

5. AIR P RESSURE GAUGESENDING UNIT

6. PARKING BRAKE VALVE7. PARK BRAKE WARNING LIGHT

SWITCH (NORMALLY CLOSED)8. TRAILER CONTROL VALVE9. 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


15. RESERVOIR (SECONDARYBRAKING PARK BRAKE)

16. RESERVOIR (PRIMARYBRAKING CIRCUIT TWO FRONT

BRAKE)17. RESERVOIR (AUXILIARY)18. INVERSION VALVE (TR-3)19. AIR COMPRESSOR20. AIR DRYER (AD-IP)21. PRIMARY BRAKING CIRCUIT

ONE REAR BRAKE CIRCUIT22. PRIMARY BRAKING CIRCUIT

TWO FRONT BRAKE CIRCUIT23. SECONDARY BRAKING PARK

BRAKE CIRCUIT24. TRAILER CONTROL/SUPPLY

CIRCUIT

25. AUXILIARY CIRCUIT

Figure 2 ECE-13 Brake System Diagram (9800)

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RESERVOIR DESCRIPTION

Economic Commission for Europe (ECE) regulations describe a set of internationally agreed, standardizedtechnical requirements for vehicles, parts, and equipmentof motor vehicles. ECE-13 regulations apply to amotor vehicles braking system.

Air brake equipmentfor the 7600, 8600, and 9800 vehicles provides a means of controlling brakes through a

mediumof compressed air. The air systemconsists 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.

Al l reserv oi rs shou ld have a man ual dr ain cock or a drain val ve.

Manual drains are of two styles, one is a brass hand turn style valve; the other is a cable pull style valve. Thebrass turn style valve has a brass body tted with a tapered brass key. The drain cock is open when the handleis parallel to the drain cock body and closed when the handle is at rightangles to the body. The pull cablestyle is much the same, butuses a pull cable for remote opening of valve and will only drain when the cable isbeing pulled. Drain cocks and drain valves are installed in the bottomor in the end of each reservoir in the airbrake system to provide a convenient means of draining condensation.

1.2. STOP LIGHT SWITCH

The stop lightswitch is an electro/pneumatic switch, which operates in conjunction with the foot valve andstop lights by completing the electrical circuit when a brake application of 34.5 kPa (5 psi) or more is made.On trucks, the primary braking circuit one rear brake system, and the primary braking circuit two front brakesystem, are both equipped with a stop light switch. If a failure should occur in either system, the system thatcontinues to function will provide stop lights when the brakes are applied.

1.3. LOW PRESSURE INDICATOR

The low pressure indicator is a safety device designed to give an automatic warning to the driver whenever theair pressure in the primary braking circuit one rear brake, or the primary braking circuit two front brake systemis below approximately 448.2 kPa to 482.6 kPa (65 to 70 psi) of pressure. Operating as an air-controlledswitch of an electrical circuit, the low pressure indicator automatically sounds a buzzer when the air pressuredrops to approximately 448.2 kPa to 482.6 kPa (65 to 70 psi). The warning will be both visible (light) andaudible (buzzer).

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DESCRIPTION FOOT VALVE

1.4. FOOT VALVE

The foot valve is the control unit for the service air brake systems. The foot valve is a footoperated valve withtwo separate supplyand deliverycircuits. The valve provides the driver with graduated control for applying andreleasing the vehicle brakes. The foot valve is equipped with a noise reducing silencer.

The 7600 and 8600 uses a different type foot valve than the 9800. The foot valve used on the 7600 and8600 is a suspended valve mounted to the dash panel. The foot valve used on the 9800 is a treadle valvemounted to the oor board.

1.5. QUICK RELEASE VALVE (QRV)

The function of the quick release valve is to speed up the exhaust of air fromthe air chambers it is connectedto. It is mounted close to the chambers it serves. In its standard con guration, the valve is designed todeliver within 6.9 kPa (1 psi) of control pressure to the controlled device; however, for special applications,the valve is available with greater differential or zero hysteresis. The QRV valve is equipped with a noisereducing silencer.

1.6. PARKING BRAKE VALVE

The parking brake valve is a lever style non-metallic type air valve. The parking brake valve is mounted onthe instrument panel; the single lever valve applies and releases the parking brake for the tractor and trailerat the same time.

1.7. TRAILER CONTROL VALVE

The purpose of the trailer control valve is to control the dual-line trailer brake systemin conjunction with thetractor dual brake valve, and the modulated hand control valve for spring brake actuation.

1.8. RELAY VALVE AND ANTILOCK TRACTION RELAY VALVE (R-12 AND ATR-6)

The R-12relay valve is the standard valve on the 7600, 8600, and 9800 vehicles. The R-12relay valvein 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 valveoperates as a remote controlled brake valve that delivers or releases air to the chambers in response tothe control air delivered to it from the foot brake valve or other source. The R-12relay valve is equippedwith a noise reducing silencer.

The optional relay valve in place of the R-12relay valve, is the ATR-6 traction relay valve and is aservice relay valve tted with a modi ed cover containing a control solenoid. It contains both air and electriccomponents to provide the service braking and traction control (differential braking) as well as ESPadvancedstability system ABS functions. When the ABS controller operates the ATR-6 valve, for example duringan antilock traction event, the control solenoid is energized and permits delivery air to be supplied to theantilock modulator valve and used as required by the controller. The ATR-6 traction relay valve is equippedwith a noise reducing silencer.

1.9. ANTILOCK MODULATOR VALVE (M-32)

The antilock modulator valve (M-32) is a high capacity, on/off air valve that incorporates a pair of electricalsolenoids for control. The solenoids provide the electro-pneumatic interface between the antilock controllerelectronics and the air brake system. The modulator is used to control the braking function during antilockactivity. The M-32 modulator valve is equipped with a noise reducing silencer.

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SPRING BRAKE MODULATING VALVE (SR-7) DESCRIPTION

1.10. SPRING BRAKE MODULATING VALVE (SR-7)

The spring brake modulating valve (SR-7) is used in conjunction with a dual air brake system and springbrake actuator, and performs the following functions: Provides a quick application of the spring brake actuatorwhen applying the parking brake. Prevents application of service and spring brake forces at the same time.

Controls the spring brake application using the foot valve should a failure occur in the primary service brakesystem. The SR-7 valve is equipped with a noise reducing silencer.

1.11. AIR DRYER (AD-IS)

The air dryer (AD-IS) has been designed as an integrated air system consisting of a desiccantcartridge,purge reservoir, governor, safety valve, heater, pressure protection valves, and a noise reducing silencer.

The air dryer (AD-IS) collects and removes air systemcontaminants in solid, liquid, and vapor formbeforethey enter the brake system. It provides clean, dry air to the components of the brake system, which increasesthe life of the system and reduces maintenance costs.

1.12. SOLENOID PACK

The solenoid pack on the 7600 and 8600 comes in many con gurations, depending on speci c vehicleapplication. The solenoid pack is mounted on the frame rail and receives an air supply from the auxiliaryair reservoir. Depending on the application, each solenoid in the solenoid pack will control an individualcomponent such as the air horn, cab suspension, air suspension, etc. When a solenoid in the solenoidpack receives an electrical signal, it converts the electrical signal to pneumatic force to operate the speci ccomponent that it controls.

1.13. INVERSION VALVE (TR-3)

The purpose of the inversion valve (TR-3) is to drain air pressure away fromthe park brake reservoir, whilethe systemis charging to working pressure, thus allowing the primary brake systemcircuit one and circuit tworeservoirs to ll prior to the park brake reservoir.

1.14. AIR LINE

Three commonly used types of hoses or air lines are:

A. Nylon tubing commonly used in areas where engine temperature is not a issue. Nylon tubingcomes in various sizes and is often color coded to its application.

B. Rubber hose commonly used in high ex areas where engine temperature and oil exposure arenot an issue. Comes in various sizes and often has ttings crimped on the ends.

C. Copper pipe commonly used where air compressor discharge temperatures and enginetemperature are an issue.

1.15. PUSH TO CONNECT FITTINGS

Push to Connect ttings are commonly used with nylon tubing and are threadless. A collet in the ttingbites into the air line to hold it rmly in place. The tting O-ring seals the tube to the tting body, valve ormanifold to prevent leakage.

To aid in service, a tool kit (P/N 991843C91) is available with tools for each port and tube size used by the7600, 8600, and 9800 vehicles.

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DESCRIPTION AIR PRESSURE GAUGES

1.16. AIR PRESSURE GAUGES

An air pressure gauge uses pressure switches to register the amount of reservoir air pressure in the airsystem. The amount of air pressure in the primary braking circuit one rear brakes and the primary brakingcircuit two front brakes will be shown separately.

1.17. TEST VALVE

Testvalves are commonlyplaced atkey areas in the air systemandare used to connectair pressure diagnosticequipment to these areas. They each have a rubber protective cover and should be covered when not in use.

1.18. VALVE SILENCER

A valve silencer is used on an air valve exhaust port. The purpose of the silencer is to suppress the noisemade while air is being exhausted from the air valve it is attached to.

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REMOVAL AND INSTALLATION

2. REMOVAL AND INSTALLATION

WARNING

To prevent personal injury or death, park the vehicle on a at, level surface. Make surethe engine ignition is in the off position and the transmission is in neutral (or park, if automatic tr ansmission). Set t he parking brake, chock the wheels, and disconnect thebatteries at the negative terminal before doing any service procedures o n the engine or vehicle.

WARNING

To prevent personal injury or death, always drain all air reservoir pressure. Thereservoirs are isolated from each other with the use of check valves and other components. Always be certain to drain all of the reservoirs, before performing anywork.

WARNING

To prevent personal injury or death, always disconnect power source before working onelectrical equipment.

NOTE Before performing any work on the brake components, be sure to perform these basicprocedures:

1. Park the chassis on a at, level surface.

2. Place transmission in neutral (or park, if automatic transmission).

3. Set the parking brake.

4. Turn off ignition. Remove the key.

5. Install wheel chocks.

6. Disconnect the battery.

7. Drain all reservoirs of air pressure.

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REMOVAL AND INSTALLATION RESERVOIR 7600/8600

2.1. RESERVOIR 7600/8600

NOTE The removal and installation procedures that follow describe removal and installation of thereservoir (primary braking circuit one rear brake). The removal and installation procedures for the other reservoirs are the same.

Reservoir - Removal

1. Drain the air from the reservoirs.

2. Tag and mark all air lines prior to removal.

3. Disconnect air lines attached to the reservoir (primary braking circuit one rear brake) (See P ush ToConnect Fittings, page 30) .

1. NUT2. MOUNT B RACKET3. RESERV OIR (PRIMARY

BRAKING C IRCUIT ONE REARBRAKE)

4. RESERV OIR CABLE

5. RESERVOIR (PRIMARYBRAKING CIRCUIT TWOFRONT BR AKE)

6. RESER VOIR (AUXILIARY)7. RESER VOIR (SECONDARY

BRAKING PARK BRAKE)

Figure 3 Reservoirs 7600/8600

4. Remove t he two reservoir cables and nuts securing reservoir in place.

5. Remove t he reservoir from mount brackets.

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RESERVOIR 7600/8600 REMOVAL AND INSTALLATION

Reservoir - Installation

NOTE If a different reservoir is to be installed than the one removed, transfer the t t ings to thereplacement 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 ConnectFittings, 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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REMOVAL AND INSTALLATION RESERVOIR 9800

2.2. RESERVOIR 9800

NOTE The removal and installation procedures that follow describe removal and installation of thereservoir (primary braking circuit one rear brake). The removal and installation procedures for the other reservoirs are the same.

Reservoir - Removal

1. Drain the air from the reservoirs.

2. Tag and mark all air lines prior to removal.

3. Disconnect air lines attached to the reservoir (primary braking circuit one rear brake) (See P ush ToConnect Fittings, page 30) .

1. RESERVOIR CABLE AND NUT2. RESERVOIR (SECONDARY

BRAKING PARK BRAKE)3. AIR LINES (LOCATION)4. RESERVOIR (PRIMARY


5. MOUNT BRACKET6. RESERVOIR (PRIMARY

BRAKING CIRCUIT TWOFRONT BRAKE/AUXILIARY)

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 REMOVAL AND INSTALLATION

Reservoir - Installation

NOTE If a different reservoir is to be installed than the one removed, transfer the t t ings to thereplacement 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 P ush To ConnectFittings,page 30) .

3. Ensure all drain valves and air lines are tightened and secured.


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REMOVAL AND INSTALLATION PRESSURE SWITCHES

2.3. PRESSURE SWITCHES

NOTE All st op li ght switches and air pr essure gauge switches are removed and installed in the sameor si milar manner as described in the procedures below.

Pressure Switches - Removal

1. Drain air from the reservoirs.

1. ELECTRICAL CONNECTOR2. PRESSURE SWITCH

3. COUPLING4. AIR LINE

Figure 5 Pressure Switch

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. Connectelectrical connector to pressure switch (Figure 5, Items 1 and 2).


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FOOT VALVE (7600/8600) REMOVAL AND INSTALLATION

2.4. FOOT VALVE (7600/8600)

CAUTION

To prevent damage to the brake system and/or brake components, the linkage for

the Foot Brake Valve (Linkage consisting of Plunger, Plunger Guide, Pushrod, Clevis,and Jam Nut) is considered NONADJUSTABLE. Bendix sets the required length of thepushrod/clevis at the factory and tightens the jam nut t o lock that position. Any attemptto adjust this in the eld may result in the pushrod/clevis length being too long andcause the brake pedal to press against the pedal stop which in turn could cause brakedrag.

Foot Valve (7600/8600) - Removal


1. COTTER PIN2. CLEVIS3. FOOT VALVE

4. BRAKE PEDAL5. CLEVIS PIN

Figure 6 Foot Valve Clevis Pin

2. Remove cotter pin from clevis pin.

3. Remove clevis pin and disconnect clevis from brake pedal.

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FOOT VALVE (9800) REMOVAL AND INSTALLATION

2.5. FOOT VALVE (9800)

Foot Valve (9800) - Removal


1. AIR LINE2. PRESSURE SWITCH AND

ELECTRICAL CONNECTOR

3. DUAL ACTION VALVE

Figure 8 Foot Valve (9800) Air Lines and Electrical Connectors

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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REMOVAL AND INSTALLATION FOOT VALVE (9800)

1. COTTE R PIN AND PIVOT PIN2. FOOT PE DAL3. FOOT VA LVE

4. FOOT V ALVE PEDESTAL5. NUT AND STUD6. BOLT, W ASHER, AND NUT

Figure 9 Foot Valve (9800)

6. Remove t he cotter pin and pivot pin from the foot pedal. Remove the foot pedal.

7. Remove t he three foot valve mounting nuts from the studs.

8. Remove t he foot valve.

9. Remove t he three bolts, washers, and nuts from the foot valve pedestal.

10. Remove t he 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 pressureswitche s to the replacement f oot valve, noting their location and posi tion.

1. Install the footvalve pedestal and secure with the three bolts, washers, and nuts (Figure 9, Items 3, 4, and6). Tigh ten 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 to20 Nm (1 4 to 15 lbf-ft).

3. Positio n the foot pedal on the dual brake pedestal and secure with the pivot pin and cotter pin (Figure9, Item s 1, 2, and 4).

4. Connectthe air lines to footvalve, noting previous reference tags (See Push To ConnectFittings, page 30) .

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FOOT VALVE (9800) REMOVAL AND INSTALLATION

5. Connect the electrical connectors to the pressure switches, noting previously installed reference tags(Figure 8, Item 2).


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REMOVAL AND INSTALLATION QUICK RELEASE VALVE (QRV)

2.6. QUICK RELEASE VALVE (QRV)

Quick Release Valve (QRV) - Removal


1. QUICK RELEASE VALVE(QRV)

2. BOLT AN D NUT

3. AIR LINE4. SILENC ER

Figure 1 0 Quick Release Valve (QRV)

2. Tag and m ark all air lines connected to the quick release valve.

3. Disconn ect the air lines from quick release valve (See Push To Connect Fittings, page 30) .

4. Remove t wo 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 t he ttings tothe replacement valve, noting t heir location and position.

1. Install quick release valve and secure with two bolts and nuts (Figure 10, Items 1 and 2). Torque nuts to28 to 35 N m (21 to 26 lbf-ft).

2. Connect the air lines to quick release valve noting previously installed reference tags (See P ush ToConnec t Fittings, page 30) .

3. Allow r eservoirs to ll with air, check connections for leaks, and ensure proper operation.

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PARKING BRAKE VALVE REMOVAL AND INSTALLATION

2.7. PARKING BRAKE VALVE

Parking Brake Valve - Removal


2. Tag and mark all air lines connected to the parking brake valve.

1. MOUNT ING SCREW2. PARKI NG BRAKE VALVE

3. AIR LINE

Figure 1 1 Parking Brake Valve

3. Remove two mounting screws from parking brake valve.

4. Remove t he 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 rep lacement valve, noting their location and position.

1. Connec t air lines to parking brake valve noting previously installed reference tags (See Push To ConnectFittin gs, page 30) .

2. Positi on the parking brake valve and secure with the two mounting screws (Figure 11, Items 1 and 2).

3. Allow r eservoirs to ll with air, check connections for leaks, and ensure proper operation.

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REMOVAL AND INSTALLATION TRAILER CONTROL VALVE

2.8. TRAILER CONTROL VALVE

Trailer Control Valve - Removal


2. Tag and mark all air lines connected to the trailer control valve.

1. NUT AND WASHER2. AIR LINE

3. TRAILER CONTROL VALVE

Figure 12 Trailer Control Valve

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 C ontrol Valve - Installation

NOTE If a different trailer contr ol valve is to be installed than the one removed, transfer the ttings tothe replacement valve, noting t heir 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. Connectair lines to trailer control valve noting previously installed reference tags (See Push To ConnectFittings, page 30) .


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ANTIL OCK TRACTION RELAY VALVE (ATR-6) REMOVAL AND INSTALL ATION

2.9. ANTILOCK TRACTION RELAY VALVE (ATR-6)

NOTE The antilock traction relay valve (ATR-6) removal and installation instructions are describedin t he following procedures. The relay valve ( R-12) is removed and inst alled in the same manner described with the exception of d isconnecting and connecting an electrical connector. The relay valve

( R-12) does not have an electrical connector to disconnect/connect. Anti lo ck Tract ion Relay Valve (ATR-6) - Remo val


1. ELECTRICAL CONNECTOR2. AIR LINE3. ANTILOCK TRACTION RELAY

VALVE (ATR-6)

4. BOLT AND NUT

Figure 13 Antil ock Traction Relay Valve (ATR-6)

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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REMOVAL AND INSTALLATION ANTILOCK TRACTION RELAY VALVE (ATR-6)

Anti lo ck Tract io n Relay Valve (ATR-6) - Ins tal lat io n

NOTE If a different relay valve is to be installed than the one removed, transfer the ttings to thereplacement valve, noting their location and position.

1. Install antilock traction relay valve to mountbracket and secure with two bolts and nuts (Figure 13, Items 3and 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. Connectelectrical connector to antilock traction relay valve (Figure 13, Items 1 and 3).


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ANTILOCK MODULATOR VALVE (M-32) REMOVAL AND INSTALLATION

2.10. ANTILOCK MODULATOR VALVE (M-32)

An ti lock Mod ulato r Valve (M-32) - Remo val


1. ELECTRICAL CONNECTOR2. AIR LINE3. ANTILOCK MODULATOR VALVE

(M-32)

4. BOLT AND NUT5. SILENCER

Figure 14 Antilock Modulator Valve (M-32)

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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REMOVAL AND INSTALLATION ANTILOCK MODULATOR VALVE (M-32)

Anti lo ck Modul ato r Valve (M-32) - Ins tal lat io n

NOTE If a different antilock modulator valve is to be installed than the one removed, transfer the ttingsto t he 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 nutsto 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 ToConnect Fittings, page 30) .

3. Connectelectrical connector to antilock modulator valve (Figure 14, Items 1 and 3).


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SPRING B RA KE MODUL ATING VA LVE (SR-7) REMOVA L A ND INSTA LL ATION

2.11. SPRING BRAKE MODULATING VALVE (SR-7)

Spring Brake Modul ating Valve (SR-7) - Removal


1. AIR LINE2. SPRING BRAKE MODULATING

VALVE (SR-7)

3. MOUNT BRACKET4. NUT5. SILENCER

Figure 15 Spring Brake Modulating Valve (SR-7)

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 th e replacement valve, noting their location and position.

1. Install spring brake modulating valve to mountbracketand secure with two nuts (Figure 15, Items 2, 3, and4). 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 (SeePush To Connect Fittings, page 30) .


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REMOVAL AND INSTALLATION AIR DRYER (AD-IS)

2.12. AIR DRYER (AD-IS)

Ai r Dry er (AD-IS) - Remo val


2. Tag and mark all air lines connected to the air dryer.

3. Disconnect the air lines fromair dryer (See Push To Connect Fittings, page 30) .

1. AIR DRYER (AD-IS)2. NUT

3. SILENCER4. MOUNT BRACKET

Figure 16 Air Dryer (AD-IS)

4. Disconnect electrical connectors from air dryer.

5. Remove four nuts and remove air dryer from mount bracket.

Ai r Dry er (AD-IS) - Ins tal lat io n

NOTE If a different air dryer is to be installed than the one removed, transfer the t t ings to thereplacement 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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AIR DRYER (AD-IS) REMOVAL AND INSTALLATION

3. Connect the air lines to air dryer noting previously installed reference tags (See Push To Connect Fittings,page 30) .


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REMOVAL AND INSTALLATION SOLENOID PACK (7600/8600)

2.13. SOLENOID PACK (7600/8600)

Solenoid Pack (7600/8600) - Removal


1. SOLENOID2. SOLENOID PACK 3. BOLT

4. ELECTRICAL CONNECTOR5. AIR LINE

Figure 17 Solenoid Pack

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 thereplacement 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 ConnectFittings, page 30) .

3. Connectelectrical connector to solenoid pack (Figure 17, Items 2 and 4).


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INVERSION VALVE (TR-3) REMOVAL AND INSTALLATION

2.14. INVERSION VALVE (TR-3)

Inversion Valve (TR-3) - Removal


1. AIR LINE2. BOLT AND NUT

3. INVERSION VALVE (TR-3)

Figure 18 Inversion Valve (TR-3)

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) - Inst allation

NOTE If a different inversion valve is to be installed than the one removed, transfer the ttings to theinversion 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 nutsto 11 to 14 Nm (8 to 10 lbf-ft).

2. Connect the air lines frominversion valve noting previously installed reference tags (See Push To ConnectFittings, page 30) .


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REMOVAL AND INSTALLATION PUSH TO CONNECT FITTINGS

2.15. PUSH TO CONNECT FITTINGS

WARNING

Do not attempt to d isassemble push to connect ttings with air pressure in the system.Failure to drain system of air pressure before removing components may cause personalinjury or death.

Push to Connect Tube- Removal/Installation

1. TUBE RELEASE TOOL2. AIR LINE 3. COLLET

Figure 19 Air Line Tube Release Tool (P/N 1698698C1)

NOTE The tu be release tool (P/N 1698698C1) is available throu gh Navistar parts.


2. Use the air line release tool (Figure 19, Item 1) to remove the air line. Do this by placing it around theair 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. Removeany debris or contaminants that are found. If a lose or damaged tube support is found, then replacethe tting, valve or manifold.

5. Inspect the air line end for external scratches, burrs, or cracks. If it is damaged, trim the damagedportion using the tube cutter (1698701C1 supplied in the tool kit) or replace the air line; do not reusea damaged end.

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PUSH TO CONNECT FITTINGS REMOVAL AND INSTALLATION

6. Ifthe tting, valve or manifoldhas a plugged port, remove the shipping plug with the plug removal tool (P/N1698699C1 supplied in the tool kit). This can be done by inserting and pushing the removal tool betweenthe 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 colletbites into the tube.

8. Test to make sure the assembly is free from leaks using a soap solution and clean, dry air at systempressure.

NOTE Use the air lin e cutter to ensure that t he cut is square within 15 to help prevent leakage. Donot use a dull or heavy cutting tool such as side cutters, pocket knife or hacksaw, which could col lapse( 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 tubi ng. Replace the blade or cutter if the cutting edge becomes dull.

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TORQUE

TORQUE

Table 1 Torque Chart

Figure No. (Item

No.)Location Nm lbf-ft/in

Figures 3 and 4(Item 1) Reservoir Cable Nut 4.5 40 lbf-in

Figure 7 (Item 1) Foot Valve (7600/8600) Nut 23 to 31 17 to 23 lbf-ft

Figure 9 (Item 5) Foot Valve (9800) Nut 19 to 20 14 to 15 lbf-ft

Figure 9 (Item 6) Foot Valve (9800) Pedestal Boltand Nut 19 to 20 14 to 15 lbf-ft

Figure 10 (Item2) Quick Release Valve Bolt and Nut 28 to 35 21 to 26 lbf-ft

Figure 12 (Item 1) Trailer Control Valve Nut 20 15 lbf-ft

Figure 13 (Item 4) Relay Valve Bolt and Nut 28 to 35 21 to 26 lbf-ft

Figure 14 (Item 4) Antilock Modulator Valve Bolt and Nut 10 to 15 7 to 11 lbf-ft

Figure 16 (Item 2) Air Dryer Nut 4.5 40 lbf-in

Figure 15 (Item 4) Spring Brake Modulating Valve Nut 56 to 68 41 to 50 lbf-ft

Figure 17 (Item3) Solenoid Pack Bolt 28 to 35 21 to 26 lbf-ft

Figure 18 (Item 2) Inversion Valve Bolt and Nut 11 to 14 8 to 10 lbf-ft

Date post:	14-Apr-2018
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