TM02MERITOR RIDESTAR INDEPENDENT FRONT SUSPENSION (IFS) MANUAL
TM02SUSPENSION RIDE HEIGHT TRAVEL AND TIRE CLEARANCE
TM02INTRODUCTION ........................................................................................................41
TM02DESCRIPTION............................................................................................................................ 41
TM02MODEL NOMENCLATURE................................................................................................................ 41
TM02MODEL NUMBERS AND DESIGNATIONS ............................................................................................... 41
TM02SUSPENSION RIDE HEIGHT TRAVEL AND TIRE CLEARANCE .........................................43
TM02SUSPENSION RIDE HEIGHT ............................................................................................................ 43
TM02HOW TO DETERMINE THE CORRECT RIDE HEIGHT ................................................................................. 43
TM02SUSPENSION TRAVEL ................................................................................................................... 43
TM02JOUNCE AND REBOUND ................................................................................................................ 43
TM02INSPECTION..............................................................................................................44
TM02INTERVALS ............................................................................................................................... 44
TM02SHOCK ABSORBERS ..................................................................................................................... 45
TM02UPPER AND LOWER CONTROL ARM JOINTS AND BAR PIN BUSHINGS ............................................................ 46
TM02AIR SPRINGS............................................................................................................................ 47
TM02BRAKES .................................................................................................................................. 48
TM02STEERING ASSEMBLY ................................................................................................................... 48
TM02UNITIZED WHEEL ENDS ............................................................................................................... 50
TM02REMOVAL AND DISASSEMBLY .....................................................................................54
TM02REMOVAL ................................................................................................................................ 54
TM02WHEEL ............................................................................................................................. 54
TM02CALIPER ASSEMBLY ................................................................................................................ 54
TM02WHEEL ADAPTER AND ROTOR.................................................................................................... 54
TM02UNITIZED WHEEL END............................................................................................................ 55
TM02AIR SPRING ........................................................................................................................ 55
TM02SHOCK ABSORBER ................................................................................................................. 55
TM02STEERING ARM AND KNUCKLE.................................................................................................... 55
TM02UPPER AND LOWER CONTROL ARM.............................................................................................. 56
TM02DISSASSEMBLY .......................................................................................................................... 57
TM02UPPER AND LOWER CONTROL ARMS ............................................................................................ 57
TM02REMOVAL ................................................................................................................................ 58
TM02STEERING ASSEMBLY .............................................................................................................. 58
TM02DISASSEMBLY............................................................................................................................ 59
TM02IDLER ARM AND RELAY ARM ..................................................................................................... 59
TM02PREPARE PARTS FOR ASSEMBLY .................................................................................60
TM02CLEAN, DRY AND INSPECT PARTS .................................................................................................... 60
TM02GROUND OR POLISH PARTS ........................................................................................................... 60
TM02ROUGH PARTS .......................................................................................................................... 60
TM02DRY CLEANED PARTS .................................................................................................................. 60
TM02PREVENT CORROSION ON CLEANED PARTS .......................................................................................... 60
TM02INSPECTION ............................................................................................................................. 60
TM02STEERING ARM AND KNUCKLE.................................................................................................... 60
TM02TIE ROD GREASE FITTINGS ...................................................................................................... 61
TM02ASSEMBLY AND INSTALLATION ...................................................................................62
TM02ASSEMBLY ............................................................................................................................... 62
TM02UPPER AND LOWER CONTROL ARMS ............................................................................................ 62
TM02INSTALLATION ........................................................................................................................... 63
TM02UPPER AND LOWER CONTROL ARM.............................................................................................. 63
TM02STEERING ARM AND KNUCKLE.................................................................................................... 64
TM02UNITIZED WHEEL END............................................................................................................ 65
TM02WHEEL ADAPTER AND ROTOR.................................................................................................... 66
TM02CALIPER ASSEMBLY ................................................................................................................ 66
TM02AIR SPRING ........................................................................................................................ 67
TM02SHOCK ABSORBER ................................................................................................................. 67
TM02ASSEMBLY ............................................................................................................................... 68
TM02IDLER ARM AND RELAY ARM ..................................................................................................... 68
TM02STEERING ASSEMBLY .............................................................................................................. 69
TM02ADJUSTMENT ............................................................................................................72
TM02ADJUSTMENT ............................................................................................................................ 72
TM02INSPECTION BEFORE ALIGHNMENT .................................................................................................... 72
TM02MAXIMUM TURN ANGLE................................................................................................................ 72
TM02ADJUST THE PRESSURE RELIEF IN THE POWER STEERING SYSTEM, SET THE MAXIMUM TURN ANGLE ....................... 73
TM02TURNING RADIUS ANGLE .............................................................................................................. 74
TM02MEASURE AND ADJUST THE TOE...................................................................................................... 74
TM02SPECIFICATIONS .......................................................................................................76
TM02SPECIAL TOOLS .........................................................................................................77
TM02TOOL DRAWINGS ....................................................................................................................... 77
TM02INTRODUCTION AND PREVENTIVE MAINTENANCE ......................................................86
TM02REAR AXLE .............................................................................................................................. 86
TM02AXLE DESCRIPTION ..................................................................................................................... 86
TM02AXLE IDENTIFICATION TAG INFORMATION............................................................................................ 86
TM02PREVENTIVE MAINTENANCE ............................................................................................................ 86
TM02LUBRICATION SCHEDULE ............................................................................................................... 87
TM02MAGNETS AND MAGNETIC DRAIN PLUGS ....................................................................................... 87
TM02OIL LEVEL CHECK ...................................................................................................................... 87
TM02BREATHER INSPECTION................................................................................................................. 88
TM02OIL DRAIN AND REFILL................................................................................................................ 88
TM02AXLE INSPECTION....................................................................................................................... 88
TM02REAR AXLE SERVICE ..................................................................................................89
TM02INTRODUCTION.......................................................................................................................... 89
TM02AXLE SHAFT REPLACEMENT ............................................................................................................ 89
TM02REMOVAL ........................................................................................................................... 89
TM02BRASS DRIFT METHOD ........................................................................................................... 90
TM02AIR HAMMER METHOD............................................................................................................ 90
TM02INSTALLATION ........................................................................................................................... 90
TM02WHEEL BEARING ADJUSTMENT ........................................................................................................ 91
TM02DIFFERENTIAL CARRIER REPLACEMENT ............................................................................................... 92
TM02REMOVAL ........................................................................................................................... 92
TM02INSPECTION ........................................................................................................................ 92
TM02INSTALLATION ...................................................................................................................... 92
TM02DIFFERENTIAL CARRIER OVERHAUL ................................................................................................... 93
TM02REAR AXLE REPLACEMENT ............................................................................................................. 93
TM02REMOVAL PREPARATION ........................................................................................................... 94
TM02REMOVAL ........................................................................................................................... 94
TM02INSTALLATION ...................................................................................................................... 95
TM02AXLE TO C-K FRAME ATTACHMENT.............................................................................................. 96
REAR AXLE ALIGNMENT CHECKS ...................................................................................................... 96
PREPARATION....................................................................................................................... 96
AXLE TRACKING ADJUSTMENT .................................................................................................... 96
AIR SPRING ALIGNMENT AND HEIGHT CHECKS...................................................................................... 97
AIR SPRING ALIGNMENT .......................................................................................................... 97
AIR SPRING HEIGHT .............................................................................................................. 97
WHEEL END BRAKE COMPONENTS..............................................................................98
DISC BRAKE ASSEMBLY ................................................................................................................ 98
DESCRIPTION....................................................................................................................... 98
OPERATION AND MAINTENANCE .................................................................................................. 98
REAR AXLE BRAKE CHAMBERS ........................................................................................................ 98
DESCRIPTION....................................................................................................................... 98
OPERATION ......................................................................................................................... 98
EXTERNAL BREATHER TUBE....................................................................................................... 98
MANUAL RELEASE BOLT........................................................................................................... 99
MAINTENANCE...................................................................................................................... 99
24,000-MILE INTERVALS........................................................................................................ 99
REPLACEMENT ........................................................................................................................... 99
REMOVAL ........................................................................................................................... 99
INSTALLATION ...................................................................................................................... 100
SPECIFICATIONS.................................................................................................................... 100
MERITOR REAR AXLE MAINTENANCE MANUAL
EXPLODED VIEWS......................................................................................................106
59000 SERIES REAR AXLE........................................................................................................... 106
61000 SERIES REAR AXLE........................................................................................................... 108
71000 SERIES REAR AXLE........................................................................................................... 110
RC-23-160 SERIES REAR AXLE ................................................................................................... 112
T SERIES PARKING BRAKE - 5900 SERIES REAR AXLE ........................................................................... 114
MODELS COVERED...................................................................................................................... 115
DESCRIPTION............................................................................................................................ 115
REAR AXLES ............................................................................................................................ 115
CENTER AXLES .......................................................................................................................... 116
T SERIES PARKING BRAKE ............................................................................................................ 116
IDENTIFICATION ......................................................................................................................... 117
REMOVAL AND DISASSEMBLY .....................................................................................119
REMOVAL ................................................................................................................................ 119
DIFFERENTIAL CARRIER FROM THE AXLE HOUSING ................................................................................. 119
AXLE SHAFTS FROM THE AXLE HOUSING ............................................................................................ 121
HUB AND DRUM ASSEMBLY OR HUB AND ROTOR ASSEMBLY FROM THE AXLE HOUSING ........................................ 122
DISASSEMBLY............................................................................................................................ 123
HUB ASSEMBLY WITH ABS: 59000, 61000, 71000 AND RC-26-700 SERIES .......................................... 123
HUB ASSEMBLY WITHOUT ABS: 59000, 61000, 71000 AND RC-26-700 SERIES ...................................... 123
HUB ASSEMBLY WITH DRUM BRAKES: RC-23-160 SERIES ...................................................................... 124
HUB ASSEMBLY WITH DISC BRAKES: RC-23-160 SERIES ....................................................................... 124
BRAKES FROM THE HOUSING WITHOUT ABS: 59000, 61000, 71000 AND RC-26-700 SERIES....................... 125
BRAKES FROM THE HOUSING WITH ABS: 59000, 61000, 71000 AND RC-26-700 SERIES ........................... 125
DRUM BRAKES FROM THE HOUSING: RC-23-160 SERIES ....................................................................... 126
DISC BRAKES FROM THE HOUSING: RC-23-160 SERIES......................................................................... 126
REMOVAL ................................................................................................................................ 126
AXLE TUBE: 59000, 61000 AND 71000 SERIES ............................................................................... 126
PARKING BRAKE SHOES................................................................................................................ 128
CAMSHAFT ............................................................................................................................... 129
TORQUE ROD BRACKETS: 61000 SERIES AXLES WITH CAST HOUSING AND 71000 SERIES AXLES ........................ 130
PREPARE PARTS FOR ASSEMBLY .................................................................................131
CLEAN, DRY AND INSPECT PARTS .................................................................................................... 131
GROUND AND POLISHED PARTS ....................................................................................................... 131
ROUGH PARTS .......................................................................................................................... 131
DRY CLEANED PARTS .................................................................................................................. 131
PREVENT CORROSION ON CLEANED PARTS .......................................................................................... 131
INSPECT PARTS ......................................................................................................................... 131
BRAKES ............................................................................................................................. 133
BRAKE DRUMS ..................................................................................................................... 133
BUSHINGS AND LININGS .......................................................................................................... 133
CAMSHAFT .......................................................................................................................... 133
DISC BRAKE CALIPER AND BRAKE PADS ........................................................................................ 133
DISC OR ROTOR ................................................................................................................... 133
APPLYING ADHESIVE AND SILICONE GASKET MATERIAL ............................................................................ 135
SILICONE GASKET MATERIAL .......................................................................................................... 135
REPAIR WELDING ON AXLE HOUSINGS............................................................................................... 135
DO NOT BEND OR STRAIGHTEN A DAMAGED DRIVE AXLE HOUSING............................................................. 135
ASSEMBLY AND INSTALLATION ...................................................................................136
INSTALLATION ........................................................................................................................... 136
DIFFERENTIAL CARRIER INTO THE AXLE HOUSING ............................................................................. 136
POSE™ SEAL .................................................................................................................... 136
YOKE................................................................................................................................ 137
ASSEMBLY ............................................................................................................................... 138
HUB WITH W-SERIES BRAKES WITHOUT ABS: 59000, 61000, 71000 AND RC-26-700 SERIES................ 138
BRAKE TO THE HOUSING WITHOUT ABS: 59000 AND 61000 SERIES................................................... 139
HUB TO THE AXLE WITHOUT ABS: 59000, 61000, 71000 AND RC-26-700 SERIES ............................. 139
HUB WITH W-SERIES BRAKES WITH ABS: 59000, 61000, 71000 AND RC-26-700 SERIES .................... 140
HUB WITH DRUM BRAKES: RC-23-160 SERIES ............................................................................. 141
BRAKE TO THE HOUSING WITH ABS: 59000, 61000, 71000 AND RC-26-700 SERIES ........................... 141
HUB TO THE AXLE WITH ABS: 59000, 61000, 71000 AND RC-26-700 SERIES................................... 142
BRAKE TO THE HOUSING WITH DRUM BRAKES: RC-23-160 SERIES ...................................................... 143
HUB TO THE AXLE WITH DRUM BRAKES: RC-23-160 SERIES ............................................................. 143
HUB WITH DISC BRAKES: RC-23-160 SERIES............................................................................... 143
BRAKE TO THE HOUSING WITH DISC BRAKES: RC-23-160 SERIES ....................................................... 144
HUB TO THE AXLE WITH DISC BRAKES: RC-23-160 SERIES............................................................... 144
DRUM TO HUB WITH W-SERIES BRAKES: 59000, 61000 AND 71000 ................................................. 144
ADJUSTMENT ............................................................................................................................ 145
WHEEL BEARINGS ................................................................................................................. 145
INSTALLATION ........................................................................................................................... 146
AXLE TUBE: 59000 AND 61000 SERIES ..................................................................................... 146
TORQUE ROD BRACKETS: 61000 WITH CAST HOUSING AND 71000 SERIES AXLES .................................... 148
CAMSHAFT .......................................................................................................................... 148
T SERIES PARKING BRAKE ....................................................................................................... 149
LUBRICATION ............................................................................................................151
FILL THE AXLE WITH LUBRICANT ..................................................................................................... 151
DIAGNOSTICS ...........................................................................................................152
TROUBLESHOOTING ..................................................................................................................... 152
LUBRICATION ............................................................................................................153
LUBRICATION ............................................................................................................................ 153
CAMSHAFT BUSHINGS ............................................................................................................. 153
CAMSHAFT SPLINES................................................................................................................ 153
ANCHOR PINS...................................................................................................................... 153
SHOE ROLLERS .................................................................................................................... 153
AXLE ................................................................................................................................ 154
T SERIES PARKING BRAKE ....................................................................................................... 156
GREASE-LUBRICATED WHEEL ENDS ............................................................................................. 156
SPECIFICATIONS .......................................................................................................157
TORQUE SPECIFICATIONS .............................................................................................................. 157
MERITOR REAR SUSPENSION MAINTENANCE MANUAL
EXPLODED VIEW .......................................................................................................164
INTRODUCTION ........................................................................................................166
DESCRIPTION............................................................................................................................ 166
COMPONENTS ........................................................................................................................... 166
FEATURES................................................................................................................................ 166
IDENTIFICATION ......................................................................................................................... 166
SUSPENSION RIDE HEIGHT, TRAVEL AND TIRE CLEARANCE .........................................168
SUSPENSION RIDE HEIGHT ............................................................................................................ 168
MAINTENANCE MANUAL
SUSPENSION TRAVEL.................................................................................................................... 168
TIRE CLEARANCE ....................................................................................................................... 169
INSPECTION..............................................................................................................170
INTERVALS ............................................................................................................................... 170
SHOCK ABSORBERS ................................................................................................................ 170
TORQUE RODS ..................................................................................................................... 171
BAR PIN BUSHINGS ............................................................................................................... 171
REMOVAL ..................................................................................................................173
AIR SPRING ............................................................................................................................. 173
SHOCK ABSORBER ...................................................................................................................... 173
UPPER TORQUE ROD................................................................................................................... 173
LOWER TORQUE ROD .................................................................................................................. 174
INSTALLATION...........................................................................................................175
LOWER TORQUE ROD .................................................................................................................. 175
UPPER TORQUE ROD................................................................................................................... 175
SHOCK ABSORBER ...................................................................................................................... 175
AIR SPRING ............................................................................................................................. 175
SPECIFICATIONS .......................................................................................................176
ABS INDICATOR LAMP................................................................................................................. 182
COMPONENT OVERVIEW................................................................................................................ 182
ELECTRONIC CONTROL UNITS (ECU)..........................................................................184
IDENTIFICATION ......................................................................................................................... 184
ABS VALVES...............................................................................................................184
REAR AXLE VALVE ASSEMBLIES ....................................................................................................... 184
MODULATOR VALVE OPERATION MODES ............................................................................................. 185
FRONT AXLE MODULE ................................................................................................................. 185
SPEED SENSORS ........................................................................................................................ 185
WHEEL END SENSORS ................................................................................................................. 185
DIAGNOSTICS ...........................................................................................................186
GENERAL PRECAUTIONS ............................................................................................186
TROUBLESHOOTING PROCEDURES ..................................................................................................... 187
WHEEL END SPEED SENSOR.......................................................................................188
DESCRIPTION............................................................................................................................ 188
OPERATION .............................................................................................................................. 188
PREVENTIVE MAINTENANCE ............................................................................................................ 189
SERVICE CHECKS ....................................................................................................................... 189
REMOVAL ................................................................................................................................ 189
INSPECTION ............................................................................................................................. 189
SENSOR INSTALLATION ................................................................................................................. 189
OPERATIONAL TESTING ................................................................................................................ 189
TEST 1 ............................................................................................................................. 189
TEST 2 ............................................................................................................................. 190
ANTILOCK MODULATORS ...........................................................................................190
DESCRIPTION............................................................................................................................ 190
FUNCTIONAL CHECK .................................................................................................................... 190
OPERATION .............................................................................................................................. 190
NON-ANTILOCK BRAKE APPLICATION ............................................................................................ 190
NON-ANTILOCK HOLD ........................................................................................................... 191
NON-ANTILOCK EXHAUST......................................................................................................... 191
ANTILOCK OPERATION ................................................................................................................. 191
GENERAL ........................................................................................................................... 191
ANTILOCK EXHAUST ............................................................................................................... 192
ANTILOCK HOLD MODE ........................................................................................................... 192
ANTILOCK “REAPPLY” MODE ..................................................................................................... 192
PREVENTIVE MAINTENANCE ............................................................................................................ 192
GENERAL ........................................................................................................................... 192
OPERATION & LEAKAGE TESTS ....................................................................................................... 193
LEAKAGE TESTS.................................................................................................................... 193
OPERATION TESTS................................................................................................................. 193
ELECTRICAL TESTS ................................................................................................................ 193
GENERAL PRECAUTIONS ................................................................................................................ 195
MODULATOR REMOVAL ............................................................................................................ 195
MODULATOR INSTALLATION ....................................................................................................... 196
TECHNICAL INFORMATION ......................................................................................................... 196
DUAL BRAKE VALVES .................................................................................................196
DESCRIPTION............................................................................................................................ 196
OPERATION .............................................................................................................................. 197
APPLYING: NORMAL OPERATION - NO. 1 OR PRIMARY CIRCUIT PORTION ................................................. 197
APPLYING: NORMAL OPERATION - NO. 2 OR SECONDARY CIRCUIT PORTION .............................................. 197
APPLYING: LOSS OF AIR IN THE NO. 2 OR SECONDARY CIRCUIT ........................................................... 197
APPLYING: LOSS OF AIR IN THE NO. 1 OR PRIMARY CIRCUIT ............................................................... 197
BALANCED: NO. 1 OR PRIMARY CIRCUIT....................................................................................... 197
BALANCED: NO. 2 OR SECONDARY CIRCUIT ................................................................................... 198
RELEASING: NO. 1 OR PRIMARY CIRCUIT ...................................................................................... 198
RELEASING: NO. 2 OR SECONDARY CIRCUIT................................................................................... 198
PREVENTIVE MAINTENANCE ............................................................................................................ 198
SERVICE CHECKS ....................................................................................................................... 199
OPERATING CHECK ................................................................................................................ 199
LEAKAGE CHECK ................................................................................................................... 199
VALVE REMOVAL ........................................................................................................................ 199
VALVE DISASSEMBLY.................................................................................................................... 199
CLEANING AND INSPECTING............................................................................................................ 200
VALVE ASSEMBLY ....................................................................................................................... 200
VALVE INSTALLATION ................................................................................................................... 201
GENERAL PRECAUTIONS ................................................................................................................ 201
BENDIX® PP-1™ & RD-3™ PUSH-PULL TYPE CONTROL VALVES ...................................202
DESCRIPTION............................................................................................................................ 202
PREVENTIVE MAINTENANCE ............................................................................................................ 202
REMOVAL ................................................................................................................................ 202
INSTALLING .............................................................................................................................. 202
DISASSEMBLY: PP-1™ AND RD-3™ VALVES ...................................................................................... 203
OPERATING AND LEAKAGE TESTS ..................................................................................................... 203
PP-1™ AND RD-3™ VALVE ................................................................................................... 203
SPRING BRAKE VALVE ................................................................................................204
DESCRIPTION............................................................................................................................ 204
OPERATION .............................................................................................................................. 204
INITIAL AIR SYSTEM CHARGE .................................................................................................... 204
AIR BRAKE SYSTEM FULLY CHARGED............................................................................................ 204
NORMAL SERVICE RESERVOIRS 1 & 2 CHARGED .............................................................................. 204
SERVICE APPLICATION WITH LOSS OF NO. 2 RESERVOIR PRESSURE ........................................................ 204
SERVICE AAPPLICATION WITH LOSS OF NO. 1 RESERVOIR PRESSURE ....................................................... 205
PARKING ............................................................................................................................ 205
PREVENTIVE MAINTENANCE ............................................................................................................ 205
SERVICE CHECKS ....................................................................................................................... 205
OPERATING CHECKS ............................................................................................................... 205
LEAKAGE CHECK ................................................................................................................... 206
REMOVAL ................................................................................................................................ 206
DISASSEMBLY............................................................................................................................ 206
CLEANING & INSPECTION.............................................................................................................. 207
MAINTENANCE MANUAL
ASSEMBLY ............................................................................................................................... 207
TESTING THE REBUILT SR-1™ SPRING BRAKE VALVE ............................................................................ 207
AD-IS® AIR DRYER AND RESERVOIR SYSTEM.............................................................208
DESCRIPTION............................................................................................................................ 208
AD-IS® AIR DRYER AND RESERVOIR SYSTEM OPERATION ...................................................................... 208
CHARGE CYCLE .................................................................................................................... 208
PURGE CYCLE ...................................................................................................................... 209
TURBO CUT-OFF FEATURE ........................................................................................................... 210
PREVENTIVE MAINTENANCE ............................................................................................................ 210
OPERATION & LEAKAGE TESTS ................................................................................................. 211
REBUILDING THE AD-IS® AIR DRYER AND RESERVOIR SYSTEM ................................................................ 212
GENERAL SAFETY GUIDELINES ................................................................................................... 212
GENERAL ........................................................................................................................... 213
MAINTENANCE KITS AVAILABLE .................................................................................................. 213
TESTING THE AD-IS® AIR DRYER AND RESERVOIR SYSTEM .................................................................... 214
BRAKING SYSTEM PROTECTION ....................................................................................................... 214
ROADSIDE INSPECTION................................................................................................................. 214
TEMPORARY AIR DRYER AND RESERVOIR SYSTEM BYPASS......................................................................... 214
DELIVERY CHECK VALVE CLEANING PROCEDURE .................................................................................... 215
CLEANING & INSPECTION.............................................................................................................. 215
ASSEMBLY ............................................................................................................................... 215
MERITOR DX225 MAINTENANCE MANUAL
AIR DISC BRAKE INSPECTION INTERVALS AND PROCEDURES ......................................223
INTERVALS ............................................................................................................................... 223
CHECK THE PUSH ROD TRAVEL OR ADJUSTED CHAMBER STROKE LENGTH ...................................................... 223
CALIPER ASSEMBLY INSPECTION ....................................................................................................... 224
DISC OR ROTOR INSPECTION ......................................................................................................... 225
INSTALL THE BRAKE PADS ............................................................................................................. 227
INITIAL BRAKE ADJUSTMENT .......................................................................................................... 227
REMOVE THE CALIPER ASSEMBLY ..................................................................................................... 227
REPLACE THE ROTOR................................................................................................................... 227
INSTALL THE CALIPER ASSEMBLY ...................................................................................................... 228
AIR DISC BRAKE TROUBLESHOOTING ................................................................................................ 229
BENDIX ABS MAINTENANCE MANUAL
INTRODUCTION ........................................................................................................231
ANTILOCK BRAKING SYSTEM (ABS) ............................................................................232
ABS OPERATION ....................................................................................................................... 232
ABS COMPONENT FUNCTION ......................................................................................................... 233
ABS INDICATOR LAMP ................................................................................................................. 233
ABS TRAILER INDICATOR LAMP ...................................................................................................... 233
AUTOMATIC TRACTION CONTROL (ATC) SYSTEM .................................................................................. 234
ATC OPERATION ....................................................................................................................... 234
ATC INDICATOR LAMP................................................................................................................. 234
COMPONENT OVERVIEW ............................................................................................235
ELECTRONIC CONTROL UNITS (ECUS) ........................................................................237
ABS VALVES...............................................................................................................239
MODULATOR VALVE OPERATION MODES.....................................................................240
OPTIONAL FRONT AXLE MODULES .............................................................................241
DIAGNOSTICS ...........................................................................................................243
TROUBLESHOOTING PROCEDURES ...................................................................................................... 243
SYSTEM CONFIGURATIONS ........................................................................................245
TEST EQUIPMENT ......................................................................................................246
MULTIMETER ............................................................................................................................ 246
SERVICERANGER PC SOFTWARE ...................................................................................................... 246
HAND-HELD TESTER ................................................................................................................... 247
RETRIEVING DIAGNOSTIC TROUBLE CODES .......................................................................................... 248
CLEARING DIAGNOSTIC TROUBLE CODES AND/OR SYSTEM CONFIGURATION ..................................................... 250
DISABLING ATC FOR DYNO TESTING ................................................................................................ 250
SPEED SENSOR TROUBLESHOOTING ..........................................................................255
THE 17•12 SENSOR MEMORY DIAGNOSTIC TROUBLE CODE.........................................256
WHEEL END SPEED SENSOR REPAIR...........................................................................258
PRESSURE MODULATOR VALVE (PMV) TROUBLESHOOTING..........................................260
ABS MODULATOR VALVE ............................................................................................263
AUTOMATIC TRACTION CONTROL (ATC) VALVE TROUBLESH0OTING ............................264
PERFORMANCE TEST OF THE RELAY VALVE.................................................................264
ATC VALVE REMOVAL .................................................................................................266
CAB MOUNT ECU PIN IDENTIFICATION.......................................................................269
FRAME MOUNT ECU PIN IDENTIFICATION ..................................................................273
GLOSSARY.................................................................................................................277
BENDIX EC-60 MANUAL
INTRODUCTION ........................................................................................................279
COMPONENTS ...........................................................................................................280
ECU MOUNTING ........................................................................................................280
HARDWARE CONFIGURATIONS...................................................................................281
EC-60 CONTROLLERS WITH PLC .................................................................................281
EC-60 CONTROLLER INPUTS ......................................................................................281
EC-60 CONTROLLER OUTPUTS ...................................................................................282
POWER-UP SEQUENCE ...............................................................................................283
ABS OPERATION ........................................................................................................284
ATC OPERATION ........................................................................................................285
ABS PARTIAL SHUTDOWN ..........................................................................................287
RECONFIGURING EC-60 CONTROLLERS ......................................................................288
TROUBLESHOOTING ..................................................................................................289
GENERAL ................................................................................................................................ 289
BLINK CODES AND DIAGNOSTIC MODES ............................................................................................. 290
USING HAND-HELD OR PC-BASED DIAGNOSTIC TOOLS ........................................................................... 293
ACTIVE OR INACTIVE DIAGNOSTIC TROUBLE CODES................................................................................ 295
WHEEL SPEED SENSORS ............................................................................................................... 296
PRESSURE MODULATOR VALVES ....................................................................................................... 298
TRACTION CONTROL VALVES .......................................................................................................... 300
POWER SUPPLY ......................................................................................................................... 301
J1939 SERIAL COMMUNICATIONS.................................................................................................... 302
ECU..................................................................................................................................... 303
MISCELLANEOUS ........................................................................................................................ 304
WIRING ................................................................................................................................. 310
STANDARD CAB WIRING SCHEMATIC ................................................................................................. 313
PREMIUM CAB WIRING SCHEMATIC .................................................................................................. 314
STANDARD FRAME WIRING SCHEMATIC .............................................................................................. 316
PREMIUM FRAME WIRING SCHEMATIC................................................................................................ 317
GLOSSARY.................................................................................................................319
ix
MAINTENANCE MANUAL
BENDIX AD-IS AIR DRYER MANUAL
DESCRIPTION............................................................................................................323
AIR DRYER AND RESERVOIR SYSTEM OPERATION.......................................................325
GENERAL ................................................................................................................................ 325
CHARGE CYCLE ......................................................................................................................... 325
PURGE CYCLE ........................................................................................................................... 326
TURBO CUT-OFF FEATURE ............................................................................................................ 326
PREVENTIVE MAINTENANCE.......................................................................................326
OPERATION & LEAKAGE TESTS ....................................................................................................... 327
REBUILDING THE AD-IS AIR DRYER AND RESERVOIR SYSTEM .....................................328
GENERAL SAFETY GUIDELINES ........................................................................................................ 328
TESTING THE AD-IS AIR DRYER AND RESERVOIR SYSTEM ....................................................................... 330
BRAKING SYSTEM PROTECTION ....................................................................................................... 330
ROADSIDE INSPECTION................................................................................................................. 330
TEMPORARY AIR DRYER AND RESERVOIR SYSTEM BYPASS......................................................................... 330
DELIVERY CHECK VALVE CLEANING PROCEDURE .................................................................................... 331
CLEANING & INSPECTION.............................................................................................................. 332
ASSEMBLY ............................................................................................................................... 332
TROUBLESHOOTING CHART .......................................................................................333
BENDIX E-10P MANUAL
DESCRIPTION............................................................................................................339
OPERATION...............................................................................................................341
SERVICE CHECKS.......................................................................................................342
OPERATING CHECK ..................................................................................................................... 342
LEAKAGE CHECK ........................................................................................................................ 342
REMOVAL ................................................................................................................................ 342
DISASSEMBLY............................................................................................................................ 342
CLEANING AND INSPECTION ........................................................................................................... 344
ASSEMBLY ............................................................................................................................... 344
VALVE INSTALLATION ................................................................................................................... 345
GENERAL SAFETY GUIDELINES ...................................................................................345
BENDIX PP-1 & RD-3 MANUAL
DESCRIPTION............................................................................................................347
PREVENTIVE MAINTENANCE.......................................................................................347
REMOVAL ................................................................................................................................ 348
INSTALLING .............................................................................................................................. 348
DISASSEMBLY............................................................................................................................ 348
OPERATING AND LEAKAGE TESTS...............................................................................348
GENERAL SAFETY GUIDELINES ...................................................................................350
BENDIX M-32 AND M-32QR ANTILOCK MODULATORS MANUAL
DESCRIPTION............................................................................................................351
FUNCTIONAL CHECK ..................................................................................................352
OPERATION...............................................................................................................352
ANTILOCK OPERATION...............................................................................................354
GENERAL ................................................................................................................................ 354
ANTILOCK EXHAUST .................................................................................................................... 354
ANTILOCK “REAPPLY” MODE .......................................................................................................... 355
PREVENTIVE MAINTENANCE.......................................................................................356
x
TABLE OF CONTENTS
GENERAL ................................................................................................................................ 356
LEAKAGE TEST .......................................................................................................................... 356
OPERATION TEST ....................................................................................................................... 356
ELECTRICAL TESTS ..................................................................................................................... 356
MODULATOR REMOVAL ..............................................................................................357
MODULATOR INSTALLATION.......................................................................................358
TECHNICAL INFORMATION.........................................................................................358
BENDIX QUICK RELEASE VALVES MANUAL
DESCRIPTION............................................................................................................359
OPERATION...............................................................................................................359
PREVENTIVE MAINTENANCE.......................................................................................360
OPERATING AND LEAKAGE TESTS...............................................................................360
GENERAL SAFETY GUIDELINES ...................................................................................360
REMOVING AND INSTALLING......................................................................................360
BENDIX RELAY VALVES MANUAL
DESCRIPTION............................................................................................................363
OPERATION...............................................................................................................364
APPLICATION ............................................................................................................................ 364
BALANCE................................................................................................................................. 364
EXHAUST OR RELEASE.................................................................................................................. 364
ANTI-COMPOUNDING ................................................................................................................... 364
PREVENTIVE MAINTENANCE............................................................................................................. 364
OPERATIONAL LEAKAGE TEST ......................................................................................................... 364
REMOVAL AND INSTALLATION .......................................................................................................... 364
REMOVAL................................................................................................................................. 364
DISASSEMBLY............................................................................................................................ 364
CLEANING AND INSPECTION ........................................................................................................... 364
ASSEMBLY ............................................................................................................................... 367
INSTALLATION ........................................................................................................................... 367
BENDIX SPRING BRAKE VALVE MANUAL
DESCRIPTION............................................................................................................369
OPERATION...............................................................................................................369
INITIAL AIR SYSTEM CHARGE ......................................................................................................... 369
AIR BRAKE SYSTEM FULLY CHARGED................................................................................................. 369
NORMAL SERVICE....................................................................................................................... 371
LOSS OF NO. 2 RESERVOIR PRESSURE .............................................................................................. 371
LOSS OF NO. 1 RESERVOIR PRESSURE .............................................................................................. 372
PARKING ................................................................................................................................. 373
PREVENTIVE MAINTENANCE.......................................................................................373
SERVICE CHECKS ....................................................................................................................... 373
OPERATING CHECKS .................................................................................................................... 373
LEAKAGE CHECKS ....................................................................................................................... 373
REMOVAL ................................................................................................................................ 374
DISASSEMBLY............................................................................................................................ 374
CLEANING & INSPECTION.............................................................................................................. 374
ASSEMBLY ............................................................................................................................... 374
TESTING THE REBUILT SR-1 SPRING BRAKE VALVE ............................................................................... 374
OVERVIEW ................................................................................................................377

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