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SERVICE MANUAL

SERVICE MANUAL SECTION ECE-13 BRAKE SYSTEM Model: 7600 Model: 8600 Model: 9800 S04053 2010

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TABLE OF CONTENTS

TABLE OF CONTENTS
1. DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1. RESERVOIR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2. STOP LIGHT SWITCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3. LOW PRESSURE INDICATOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4. FOOT VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5. QUICK RELEASE VALVE (QRV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6. PARKING BRAKE VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7. TRAILER CONTROL VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8. RELAY VALVE AND ANTILOCK TRACTION RELAY VALVE (R-12 AND ATR-6). . . . . . . . . . . . . . . . 1.9. ANTILOCK MODULATOR VALVE (M-32). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10. SPRING BRAKE MODULATING VALVE (SR-7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11. AIR DRYER (AD-IS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12. SOLENOID PACK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.13. INVERSION VALVE (TR-3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14. AIR LINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.15. PUSH TO CONNECT FITTINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16. AIR PRESSURE GAUGES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.17. TEST VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18. VALVE SILENCER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3 3 3 4 4 4 4 4 4 5 5 5 5 5 5 6 6 6

2. REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.1. RESERVOIR 7600/8600. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Reservoir - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Reservoir - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.2. RESERVOIR 9800. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Reservoir - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10 Reservoir - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 2.3. PRESSURE SWITCHES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Pressure Switches - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 Pressure Switches - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 2.4. FOOT VALVE (7600/8600). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Foot Valve (7600/8600) - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Foot Valve (7600/8600) - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 2.5. FOOT VALVE (9800). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Foot Valve (9800) - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 Foot Valve (9800) - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 2.6. QUICK RELEASE VALVE (QRV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Quick Release Valve (QRV) - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Quick Release Valve (QRV) - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 2.7. PARKING BRAKE VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Parking Brake Valve - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Parking Brake Valve - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 2.8. TRAILER CONTROL VALVE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Trailer Control Valve - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Trailer Control Valve - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 2.9. ANTILOCK TRACTION RELAY VALVE (ATR-6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Antilock Traction Relay Valve (ATR-6) - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 Antilock Traction Relay Valve (ATR-6) - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22 2.10. ANTILOCK MODULATOR VALVE (M-32). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Antilock Modulator Valve (M-32) - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23 Antilock Modulator Valve (M-32) - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

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TABLE OF CONTENTS

TABLE OF CONTENTS (CONT.)


2.11. SPRING BRAKE MODULATING VALVE (SR-7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Spring Brake Modulating Valve (SR-7) - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Spring Brake Modulating Valve (SR-7) - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 2.12. AIR DRYER (AD-IS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Air Dryer (AD-IS) - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 Air Dryer (AD-IS) - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26 2.13. SOLENOID PACK (7600/8600). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Solenoid Pack (7600/8600) - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 Solenoid Pack (7600/8600) - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28 2.14. INVERSION VALVE (TR-3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Inversion Valve (TR-3) - Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Inversion Valve (TR-3) - Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 2.15. PUSH TO CONNECT FITTINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 Push to Connect Tube- Removal/Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30 TORQUE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

ii

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DESCRIPTION

1. DESCRIPTION

1. DCM (DRIVER CONTROL MODULE) 2. STOPLIGHT SWITCH (NORMALLY OPEN) 3. PARK BRAKE WARNING LIGHT SWITCH (NORMALLY CLOSED) 4. PARKING BRAKE VALVE 5. TRAILER CONTROL VALVE 6. SPRING BRAKE MODULATING VALVE (SR-7) 7. MODULATOR VALVE 8. TEST VALVE 9. QUICK RELEASE VALVE 10. RELAY VALVE (R-12) 11. RESERVOIR (PRIMARY BRAKING CIRCUIT ONE REAR BRAKE) 12. RESERVOIR (SECONDARY BRAKING PARK BRAKE)

13. RESERVOIR (PRIMARY BRAKING CIRCUIT TWO FRONT BRAKE) 14. SOLENOID 15. TO CAB AIR SUSPENSION AND ACCESSORIES 16. RESERVOIR (AUXILIARY) 17. INVERSION VALVE (TR-3) 18. AIR COMPRESSOR 19. AIR DRYER (AD-IS) 20. PRESSURE SWITCH 21. FOOT VALVE 22. PRIMARY BRAKING CIRCUIT ONE REAR BRAKE CIRCUIT 23. PRIMARY BRAKING CIRCUIT TWO FRONT BRAKE CIRCUIT 24. SECONDARY BRAKING PARK BRAKE CIRCUIT 25. TRAILER CONTROL/SUPPLY CIRCUIT 26. AUXILIARY CIRCUIT

Figure 1

ECE-13 Brake System Diagram (7600/8600)


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DESCRIPTION

1. FOOT VALVE 2. CRUISE CONTROL SWITCH (NORMALLY CLOSED) 3. STOPLIGHT SWITCH (NORMALLY OPEN) 4. CAB MANIFOLD PORT LOCATION 5. AIR PRESSURE GAUGE SENDING UNIT 6. PARKING BRAKE VALVE 7. PARK BRAKE WARNING LIGHT SWITCH (NORMALLY CLOSED) 8. TRAILER CONTROL VALVE 9. SPRING BRAKE MODULATING VALVE (SR-7) 10. MODULATOR VALVE (M-32) 11. TEST VALVE 12. QUICK RELEASE VALVE (QRV) 13. RELAY VALVE (R-12) 14. RESERVOIR (PRIMARY BRAKING CIRCUIT ONE REAR BRAKE) Figure 2

15. RESERVOIR (SECONDARY BRAKING PARK BRAKE) 16. RESERVOIR (PRIMARY BRAKING CIRCUIT TWO FRONT BRAKE) 17. RESERVOIR (AUXILIARY) 18. INVERSION VALVE (TR-3) 19. AIR COMPRESSOR 20. AIR DRYER (AD-IP) 21. PRIMARY BRAKING CIRCUIT ONE REAR BRAKE CIRCUIT 22. PRIMARY BRAKING CIRCUIT TWO FRONT BRAKE CIRCUIT 23. SECONDARY BRAKING PARK BRAKE CIRCUIT 24. TRAILER CONTROL/SUPPLY CIRCUIT 25. AUXILIARY CIRCUIT

ECE-13 Brake System Diagram (9800)

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RESERVOIR

DESCRIPTION

Economic Commission for Europe (ECE) regulations describe a set of internationally agreed, standardized technical requirements for vehicles, parts, and equipment of motor vehicles. ECE-13 regulations apply to a motor vehicles braking system. Air brake equipment for the 7600, 8600, and 9800 vehicles provides a means of controlling brakes through a medium of compressed air. The air system consists of various components required to maintain a supply of air, direct the ow of air, and convert the energy of compressed air into mechanical force to apply the brakes.

1.1. RESERVOIR
The reservoir is an air storage tank; its function is to provide compressed air for braking. All reservoirs should have a manual drain cock or a drain valve. Manual drains are of two styles, one is a brass hand turn style valve; the other is a cable pull style valve. The brass turn style valve has a brass body tted with a tapered brass key. The drain cock is open when the handle is parallel to the drain cock body and closed when the handle is at right angles to the body. The pull cable style is much the same, but uses a pull cable for remote opening of valve and will only drain when the cable is being pulled. Drain cocks and drain valves are installed in the bottom or in the end of each reservoir in the air brake system to provide a convenient means of draining condensation.

1.2. STOP LIGHT SWITCH


The stop light switch is an electro/pneumatic switch, which operates in conjunction with the foot valve and stop 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 brake system, are both equipped with a stop light switch. If a failure should occur in either system, the system that continues 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 the air pressure in the primary braking circuit one rear brake, or the primary braking circuit two front brake system is below approximately 448.2 kPa to 482.6 kPa (65 to 70 psi) of pressure. Operating as an air-controlled switch of an electrical circuit, the low pressure indicator automatically sounds a buzzer when the air pressure drops to approximately 448.2 kPa to 482.6 kPa (65 to 70 psi). The warning will be both visible (light) and audible (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 foot operated valve with two separate supply and delivery circuits. The valve provides the driver with graduated control for applying and releasing 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 and 8600 is a suspended valve mounted to the dash panel. The foot valve used on the 9800 is a treadle valve mounted 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 from the air chambers it is connected to. It is mounted close to the chambers it serves. In its standard conguration, the valve is designed to deliver 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 noise reducing 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 on the instrument panel; the single lever valve applies and releases the parking brake for the tractor and trailer at the same time.

1.7. TRAILER CONTROL VALVE


The purpose of the trailer control valve is to control the dual-line trailer brake system in conjunction with the tractor 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-12 relay valve is the standard valve on the 7600, 8600, and 9800 vehicles. The R-12 relay valve in an air brake system functions as a relay station to speed up the application and release of the brakes. The valve is normally mounted at the rear of the vehicle in proximity to the chambers it serves. The valve operates as a remote controlled brake valve that delivers or releases air to the chambers in response to the control air delivered to it from the foot brake valve or other source. The R-12 relay valve is equipped with a noise reducing silencer. The optional relay valve in place of the R-12 relay valve, is the ATR-6 traction relay valve and is a service relay valve tted with a modied cover containing a control solenoid. It contains both air and electric components to provide the service braking and traction control (differential braking) as well as ESP advanced stability system ABS functions. When the ABS controller operates the ATR-6 valve, for example during an antilock traction event, the control solenoid is energized and permits delivery air to be supplied to the antilock modulator valve and used as required by the controller. The ATR-6 traction relay valve is equipped with a noise reducing silencer.

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 electrical solenoids for control. The solenoids provide the electro-pneumatic interface between the antilock controller electronics and the air brake system. The modulator is used to control the braking function during antilock activity. 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 spring brake actuator, and performs the following functions: Provides a quick application of the spring brake actuator when 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 brake system. 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 desiccant cartridge, purge reservoir, governor, safety valve, heater, pressure protection valves, and a noise reducing silencer. The air dryer (AD-IS) collects and removes air system contaminants in solid, liquid, and vapor form before they enter the brake system. It provides clean, dry air to the components of the brake system, which increases the life of the system and reduces maintenance costs.

1.12. SOLENOID PACK


The solenoid pack on the 7600 and 8600 comes in many congurations, depending on specic vehicle application. The solenoid pack is mounted on the frame rail and receives an air supply from the auxiliary air reservoir. Depending on the application, each solenoid in the solenoid pack will control an individual component such as the air horn, cab suspension, air suspension, etc. When a solenoid in the solenoid pack receives an electrical signal, it converts the electrical signal to pneumatic force to operate the specic component that it controls.

1.13. INVERSION VALVE (TR-3)


The purpose of the inversion valve (TR-3) is to drain air pressure away from the park brake reservoir, while the system is charging to working pressure, thus allowing the primary brake system circuit one and circuit two reservoirs 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 tubing comes 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 are not 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 engine temperature 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 tting bites into the air line to hold it rmly in place. The tting O-ring seals the tube to the tting body, valve or manifold 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 the 7600, 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 air system. The amount of air pressure in the primary braking circuit one rear brakes and the primary braking circuit two front brakes will be shown separately.

1.17. TEST VALVE


Test valves are commonly placed at key areas in the air system and are used to connect air pressure diagnostic equipment 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 noise made 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 sure the engine ignition is in the off position and the transmission is in neutral (or park, if automatic transmission). Set the parking brake, chock the wheels, and disconnect the batteries at the negative terminal before doing any service procedures on the engine or vehicle. WARNING To prevent personal injury or death, always drain all air reservoir pressure. The reservoirs 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 any work. WARNING To prevent personal injury or death, always disconnect power source before working on electrical equipment. NOTE Before performing any work on the brake components, be sure to perform these basic procedures: 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 the reservoir (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 Push To Connect Fittings, page 30).

1. NUT 2. MOUNT BRACKET 3. RESERVOIR (PRIMARY BRAKING CIRCUIT ONE REAR BRAKE) 4. RESERVOIR CABLE Figure 3

5. RESERVOIR (PRIMARY BRAKING CIRCUIT TWO FRONT BRAKE) 6. RESERVOIR (AUXILIARY) 7. RESERVOIR (SECONDARY BRAKING PARK BRAKE) Reservoirs 7600/8600

4. Remove the two reservoir cables and nuts securing reservoir in place. 5. Remove the reservoir from mount brackets.

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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 ttings to the replacement reservoir noting, their location and position. 1. Install reservoir to the mount brackets and, with aid of an assistant, install two reservoir cables and nuts (Figure 3, Items 1, 2, 3, and 4). Tighten nuts to 4.5 Nm (40 lbf-in). 2. Install air lines to reservoir, noting previous previously installed reference tags (See Push To Connect Fittings, page 30). 3. Ensure all drain valves and air lines are tightened and secured. 4. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.

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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 the reservoir (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 Push To Connect Fittings, page 30).

1. RESERVOIR CABLE AND NUT 2. RESERVOIR (SECONDARY BRAKING PARK BRAKE) 3. AIR LINES (LOCATION) 4. RESERVOIR (PRIMARY BRAKING CIRCUIT ONE REAR BRAKE) Figure 4

5. MOUNT BRACKET 6. RESERVOIR (PRIMARY BRAKING CIRCUIT TWO FRONT BRAKE/AUXILIARY)

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 ttings to the replacement reservoir, noting their location and position. 1. Install reservoir to the mount brackets and, with aid of an assistant, install two reservoir cables and nuts (Figure 4, Items 1, 4, and 5). Tighten nuts to 4.5 Nm (40 lbf-in). 2. Install air lines to reservoir, noting previously installed reference tags (See Push To Connect Fittings, page 30). 3. Ensure all drain valves and air lines are tightened and secured. 4. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.

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REMOVAL AND INSTALLATION

PRESSURE SWITCHES

2.3. PRESSURE SWITCHES


NOTE All stop light switches and air pressure gauge switches are removed and installed in the same or similar manner as described in the procedures below. Pressure Switches - Removal 1. Drain air from the reservoirs.

1. ELECTRICAL CONNECTOR 2. PRESSURE SWITCH Figure 5

3. COUPLING 4. AIR LINE 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. Connect electrical connector to pressure switch (Figure 5, Items 1 and 2). 3. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.

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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 the pushrod/clevis at the factory and tightens the jam nut to lock that position. Any attempt to adjust this in the eld may result in the pushrod/clevis length being too long and cause the brake pedal to press against the pedal stop which in turn could cause brake drag. Foot Valve (7600/8600) - Removal 1. Drain air from the reservoirs.

1. COTTER PIN 2. CLEVIS 3. FOOT VALVE Figure 6 2. Remove cotter pin from clevis pin. 3. Remove clevis pin and disconnect clevis from brake pedal.

4. BRAKE PEDAL 5. CLEVIS PIN Foot Valve Clevis Pin

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13

REMOVAL AND INSTALLATION

FOOT VALVE (7600/8600)

1. NUT 2. AIR LINE Figure 7

3. FOOT VALVE 4. DASH PANEL Foot Valve (7600/8600)

4. Tag and mark all air lines connected to the foot valve. 5. Disconnect the air lines from foot valve (See Push To Connect Fittings, page 30). 6. Remove the four mounting nuts securing foot valve to dash panel. 7. Remove the foot valve. Foot Valve (7600/8600) - Installation NOTE If a different foot valve is to be installed than the one removed, transfer the ttings to the replacement valve, noting their location and position. 1. Install foot valve and secure with four mounting nuts (Figure 7, Items 1 and 3). Torque mounting nuts to 23 to 31 Nm (17 to 23 lbf-ft). 2. Attach clevis to brake pedal and secure with clevis pin (Figure 6, Items 2, 4, and 5). 3. Secure clevis pin with cotter pin (Figure 6, Items 1 and 5). 4. Connect the air lines to foot valve, noting previously installed reference tags (See Push To Connect Fittings, page 30). 5. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.

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FOOT VALVE (9800)

REMOVAL AND INSTALLATION

2.5. FOOT VALVE (9800)


Foot Valve (9800) - Removal 1. Drain air from the reservoirs.

1. AIR LINE 2. PRESSURE SWITCH AND ELECTRICAL CONNECTOR Figure 8

3. DUAL ACTION VALVE

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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15

REMOVAL AND INSTALLATION

FOOT VALVE (9800)

1. COTTER PIN AND PIVOT PIN 2. FOOT PEDAL 3. FOOT VALVE Figure 9

4. FOOT VALVE PEDESTAL 5. NUT AND STUD 6. BOLT, WASHER, AND NUT Foot Valve (9800)

6. Remove the cotter pin and pivot pin from the foot pedal. Remove the foot pedal. 7. Remove the three foot valve mounting nuts from the studs. 8. Remove the foot valve. 9. Remove the three bolts, washers, and nuts from the foot valve pedestal. 10. Remove the foot valve pedestal. Foot Valve (9800) - Installation NOTE If a different foot valve is to be installed than the one removed, transfer the ttings and pressure switches to the replacement foot valve, noting their location and position. 1. Install the foot valve pedestal and secure with the three bolts, washers, and nuts (Figure 9, Items 3, 4, and 6). Tighten bolts to 19 to 20 Nm (14 to 15 lbf-ft). 2. Install the foot valve and secure with the three nuts (Figure 9, Items 3 and 5). Tighten nuts to 19 to 20 Nm (14 to 15 lbf-ft). 3. Position the foot pedal on the dual brake pedestal and secure with the pivot pin and cotter pin (Figure 9, Items 1, 2, and 4). 4. Connect the air lines to foot valve, noting previous reference tags (See Push To Connect Fittings, page 30).

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FOOT VALVE (9800)

REMOVAL AND INSTALLATION

5. Connect the electrical connectors to the pressure switches, noting previously installed reference tags (Figure 8, Item 2). 6. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.

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17

REMOVAL AND INSTALLATION

QUICK RELEASE VALVE (QRV)

2.6. QUICK RELEASE VALVE (QRV)


Quick Release Valve (QRV) - Removal 1. Drain air from the reservoirs.

1. QUICK RELEASE VALVE (QRV) 2. BOLT AND NUT Figure 10

3. AIR LINE 4. SILENCER Quick Release Valve (QRV)

2. Tag and mark all air lines connected to the quick release valve. 3. Disconnect the air lines from quick release valve (See Push To Connect Fittings, page 30). 4. Remove two bolts and nuts from quick release valve. 5. Remove quick release valve. Quick Release Valve (QRV) - Installation NOTE If a different quick release valve is to be installed than the one removed, transfer the ttings to the replacement valve, noting their location and position. 1. Install quick release valve and secure with two bolts and nuts (Figure 10, Items 1 and 2). Torque nuts to 28 to 35 Nm (21 to 26 lbf-ft). 2. Connect the air lines to quick release valve noting previously installed reference tags (See Push To Connect Fittings, page 30). 3. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.

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PARKING BRAKE VALVE

REMOVAL AND INSTALLATION

2.7. PARKING BRAKE VALVE


Parking Brake Valve - Removal 1. Drain air from the reservoirs. 2. Tag and mark all air lines connected to the parking brake valve.

1. MOUNTING SCREW 2. PARKING BRAKE VALVE Figure 11

3. AIR LINE Parking Brake Valve

3. Remove two mounting screws from parking brake valve. 4. Remove the air lines from the parking brake valve; remove the valve (See Push To Connect Fittings, page 30). Parking Brake Valve - Installation NOTE If a different parking brake valve is to be installed than the one removed, transfer the ttings to the replacement valve, noting their location and position. 1. Connect air lines to parking brake valve noting previously installed reference tags (See Push To Connect Fittings, page 30). 2. Position the parking brake valve and secure with the two mounting screws (Figure 11, Items 1 and 2). 3. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.

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19

REMOVAL AND INSTALLATION

TRAILER CONTROL VALVE

2.8. TRAILER CONTROL VALVE


Trailer Control Valve - Removal 1. Drain air from the reservoirs. 2. Tag and mark all air lines connected to the trailer control valve.

1. NUT AND WASHER 2. AIR LINE Figure 12

3. TRAILER CONTROL VALVE 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 Control Valve - Installation NOTE If a different trailer control valve is to be installed than the one removed, transfer the ttings to the replacement valve, noting their location and position. 1. Install the trailer control vale and secure with the four nuts and washers (Figure 12, Items 1 and 3). Tighten nuts to 20 Nm (15 lbf-ft). 2. Connect air lines to trailer control valve noting previously installed reference tags (See Push To Connect Fittings, page 30). 3. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.

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ANTILOCK TRACTION RELAY VALVE (ATR-6)

REMOVAL AND INSTALLATION

2.9. ANTILOCK TRACTION RELAY VALVE (ATR-6)


NOTE The antilock traction relay valve (ATR-6) removal and installation instructions are described in the following procedures. The relay valve ( R-12) is removed and installed in the same manner described with the exception of disconnecting and connecting an electrical connector. The relay valve ( R-12) does not have an electrical connector to disconnect/connect. Antilock Traction Relay Valve (ATR-6) - Removal 1. Drain air from the reservoirs.

1. ELECTRICAL CONNECTOR 2. AIR LINE 3. ANTILOCK TRACTION RELAY VALVE (ATR-6) Figure 13

4. BOLT AND NUT

Antilock 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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21

REMOVAL AND INSTALLATION

ANTILOCK TRACTION RELAY VALVE (ATR-6)

Antilock Traction Relay Valve (ATR-6) - Installation NOTE If a different relay valve is to be installed than the one removed, transfer the ttings to the replacement valve, noting their location and position. 1. Install antilock traction relay valve to mount bracket and secure with two bolts and nuts (Figure 13, Items 3 and 4). Torque nuts to 28 to 35 Nm (21 to 26 lbf-ft). 2. Connect ve air lines to antilock traction relay valve noting previously installed reference tags (See Push To Connect Fittings, page 30). 3. Connect electrical connector to antilock traction relay valve (Figure 13, Items 1 and 3). 4. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.

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ANTILOCK MODULATOR VALVE (M-32)

REMOVAL AND INSTALLATION

2.10. ANTILOCK MODULATOR VALVE (M-32)


Antilock Modulator Valve (M-32) - Removal 1. Drain air from the reservoirs.

1. ELECTRICAL CONNECTOR 2. AIR LINE 3. ANTILOCK MODULATOR VALVE (M-32) Figure 14

4. BOLT AND NUT 5. SILENCER

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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23

REMOVAL AND INSTALLATION

ANTILOCK MODULATOR VALVE (M-32)

Antilock Modulator Valve (M-32) - Installation NOTE If a different antilock modulator valve is to be installed than the one removed, transfer the ttings to the replacement valve, noting their location and position. 1. Install antilock modulator valve and secure with two bolts and nuts (Figure 14, Items 3 and 4). Torque nuts to 10 to 15 Nm (7 to 11 lbf-ft). 2. Connect the air lines to antilock modulator valve noting previously installed reference tags (See Push To Connect Fittings, page 30). 3. Connect electrical connector to antilock modulator valve (Figure 14, Items 1 and 3). 4. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.

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SPRING BRAKE MODULATING VALVE (SR-7)

REMOVAL AND INSTALLATION

2.11. SPRING BRAKE MODULATING VALVE (SR-7)


Spring Brake Modulating Valve (SR-7) - Removal 1. Drain air from the reservoirs.

1. AIR LINE 2. SPRING BRAKE MODULATING VALVE (SR-7) Figure 15

3. MOUNT BRACKET 4. NUT 5. SILENCER

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 the replacement valve, noting their location and position. 1. Install spring brake modulating valve to mount bracket and secure with two nuts (Figure 15, Items 2, 3, and 4). Tighten nuts to 56 to 68 Nm (41 to 50 lbf-ft). 2. Connect the air lines to spring brake modulating valve noting previously installed reference tags (See Push To Connect Fittings, page 30). 3. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.

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25

REMOVAL AND INSTALLATION

AIR DRYER (AD-IS)

2.12. AIR DRYER (AD-IS)


Air Dryer (AD-IS) - Removal 1. Drain air from the reservoirs. 2. Tag and mark all air lines connected to the air dryer. 3. Disconnect the air lines from air dryer (See Push To Connect Fittings, page 30).

1. AIR DRYER (AD-IS) 2. NUT Figure 16

3. SILENCER 4. MOUNT BRACKET Air Dryer (AD-IS)

4. Disconnect electrical connectors from air dryer. 5. Remove four nuts and remove air dryer from mount bracket. Air Dryer (AD-IS) - Installation NOTE If a different air dryer is to be installed than the one removed, transfer the ttings to the replacement dryer, noting their location and position. 1. Install air dryer (AD-IS) to mount bracket and secure with four nuts (Figure 16, Items 1, 2, and 4). Torque nuts to 4.5 Nm (40 lbf-in). 2. Connect electrical connectors to air dryer (Figure 16, Item 1).

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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). 4. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.

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27

REMOVAL AND INSTALLATION

SOLENOID PACK (7600/8600)

2.13. SOLENOID PACK (7600/8600)


Solenoid Pack (7600/8600) - Removal 1. Drain air from the reservoirs.

1. SOLENOID 2. SOLENOID PACK 3. BOLT Figure 17

4. ELECTRICAL CONNECTOR 5. AIR LINE 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 the replacement solenoid, noting their location and position. 1. Install solenoid pack and secure with two bolts (Figure 17, Items 2 and 3). Tighten bolts to 28 to 35 Nm (21 to 26 lbf-ft). 2. Connect the air lines to solenoid pack noting previously installed reference tags (See Push To Connect Fittings, page 30). 3. Connect electrical connector to solenoid pack (Figure 17, Items 2 and 4). 4. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.
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INVERSION VALVE (TR-3)

REMOVAL AND INSTALLATION

2.14. INVERSION VALVE (TR-3)


Inversion Valve (TR-3) - Removal 1. Drain air from the reservoirs.

1. AIR LINE 2. BOLT AND NUT Figure 18

3. INVERSION VALVE (TR-3) 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) - Installation NOTE If a different inversion valve is to be installed than the one removed, transfer the ttings to the inversion valve, noting their location and position. 1. Install the inversion valve and secure with the two bolts and nuts (Figure 18, Items 2 and 3). Tighten nuts to 11 to 14 Nm (8 to 10 lbf-ft). 2. Connect the air lines from inversion valve noting previously installed reference tags (See Push To Connect Fittings, page 30). 3. Allow reservoirs to ll with air, check connections for leaks, and ensure proper operation.

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29

REMOVAL AND INSTALLATION

PUSH TO CONNECT FITTINGS

2.15. PUSH TO CONNECT FITTINGS


WARNING Do not attempt to disassemble push to connect ttings with air pressure in the system. Failure to drain system of air pressure before removing components may cause personal injury or death. Push to Connect Tube- Removal/Installation

1. TUBE RELEASE TOOL 2. AIR LINE Figure 19

3. COLLET Air Line Tube Release Tool (P/N 1698698C1)

NOTE The tube release tool (P/N 1698698C1) is available through Navistar parts. 1. Drain air from the reservoirs. 2. Use the air line release tool (Figure 19, Item 1) to remove the air line. Do this by placing it around the air line. 3. Push down on the release tool, and then pull on the air line. Pushing the tool depresses the tting collet, allowing it to release the air line. 4. Inspect the port for any debris or contaminants or for a lose or damaged internal tube support. Remove any debris or contaminants that are found. If a lose or damaged tube support is found, then replace the tting, valve or manifold. 5. Inspect the air line end for external scratches, burrs, or cracks. If it is damaged, trim the damaged portion using the tube cutter (1698701C1 supplied in the tool kit) or replace the air line; do not reuse a damaged end.

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PUSH TO CONNECT FITTINGS

REMOVAL AND INSTALLATION

6. If the tting, valve or manifold has a plugged port, remove the shipping plug with the plug removal tool (P/N 1698699C1 supplied in the tool kit). This can be done by inserting and pushing the removal tool between the collect head and the head of the plug depressing the collet, and then pulling out the plug. 7. To install the tube into the tting, use a push-push-pull motion, pushing the tube through the collet until it bottoms out, and then pull back on the tube to ensure the collet bites into the tube. 8. Test to make sure the assembly is free from leaks using a soap solution and clean, dry air at system pressure. NOTE Use the air line cutter to ensure that the cut is square within 15 to help prevent leakage. Do not use a dull or heavy cutting tool such as side cutters, pocket knife or hacksaw, which could collapse (atten) the air line or create O-ring damaging burrs. Do not use the air line cutter to cut anything other than nylon air line tubing. Replace the blade or cutter if the cutting edge becomes dull.

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31

TORQUE

TORQUE
Table 1 Figure No. (Item No.) Figures 3 and 4 (Item 1) Figure 7 (Item 1) Figure 9 (Item 5) Figure 9 (Item 6) Torque Chart Nm 4.5 23 to 31 19 to 20 19 to 20 lbf-ft/in 40 lbf-in 17 to 23 lbf-ft 14 to 15 lbf-ft 14 to 15 lbf-ft

Location Reservoir Cable Nut Foot Valve (7600/8600) Nut Foot Valve (9800) Nut Foot Valve (9800) Pedestal Bolt and Nut

Figure 10 (Item 2)

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) Figure 16 (Item 2) Figure 15 (Item 4)

Antilock Modulator Valve Bolt and Nut Air Dryer Nut Spring Brake Modulating Valve Nut

10 to 15 4.5 56 to 68

7 to 11 lbf-ft 40 lbf-in 41 to 50 lbf-ft

Figure 17 (Item 3)

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

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