Mack AIR AND BRAKE SYSTEM SERVICE MANUAL(16-104) – PDF DOWNLOAD
FILE DETAILS:
Mack AIR AND BRAKE SYSTEM SERVICE MANUAL(16-104) – PDF DOWNLOAD
Language : English
Pages : 368
Downloadable : Yes
File Type : PDF
Size: 33.4 MB
DESCRIPTION:
Mack AIR AND BRAKE SYSTEM SERVICE MANUAL(16-104) – PDF DOWNLOAD
INTRODUCTION
SAFETY INFORMATION
Advisory Labels
Cautionary signal words (Danger-Warning-Caution) may appear in various locations throughout this manual. Information accented by one of these signal words must be observed to minimize the risk of personal injury to service personnel, or the possibility of improper service methods which may damage the vehicle or cause it to be unsafe. Additional Notes and Service Hints are used to emphasize areas of procedural importance and provide suggestions for ease of repair. The following definitions indicate the use of these advisory labels as they appear throughout the manual:
INTRODUCTION
ABOUT THIS MANUAL
- This manual assists the technician in properly diagnosing and repairing the air and brake system of a MACK Class 8 highway chassis. To provide an understanding of how an air system operates, a basic discussion of air system operation, along with a detailed explanation of air system components, is included.
- As an aid in identifying the various air system components in relation to the chassis, illustrations are used, where possible, to show the location of each component on the truck. Piping diagrams are designed to be easy to follow while accurately illustrating airflow through the system.
- Every effort has been made to ensure the accuracy of the presented information. However, due to constant product improvement, not all information is applicable to every chassis. Additionally, because of various customer-specified options, not all chassis are equally equipped. Follow recommended service and maintenance procedures to ensure air and brake system integrity and proper operation. Read and understand this manual before attempting any extensive air and brake system service or repair.
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Mack AIR AND BRAKE SYSTEM SERVICE MANUAL(16-104) – PDF DOWNLOAD
INTRODUCTION 1
SAFETY INFORMATION 2
Advisory Labels 2
Service Procedures and Tool Usage 3
EXPLANATION OF NUMERICAL CODE 4
ABOUT THIS MANUAL 5
DESCRIPTION AND OPERATION 7
AIR SYSTEM OVERVIEW 8
Air Compressor and Reservoirs 8
Dash-Mounted Pressure Gauges 9
Application Valve (Treadle Valve) 9
Brake Chambers 10
AIR SYSTEM THEORY OF OPERATION 11
System Pressurized with Parking Brakes Applied 11
System Pressurized with Parking Brakes Released 12
Applying the Service Brakes 13
Releasing the Service Brakes 14
AIR SYSTEM SAFETY FEATURES 15
Low-Pressure Warning 15
Single Check Valves 15
Double Check Valves 16
Spring Brake Modulating Relay Valve 17
Spring Brake Control Valve (LE and MR Models) 19
Redundant Signal Relay Valve 20
Anti-Compounding Circuits 22
Tractor Protection Valve 26
AIR SYSTEM COMPONENTS 27
Air Reservoir 27
Drain Valves 30
Automatic Drain Valve 30
Air Compressor 32
Governor 34
Low-Pressure Indicator Switch 36
Single Check Valves 37
Double Check Valves 38
Pressure Protection Valve 39
Stoplight Switch 40
Treadle Valve 42
Park Brake Control Module 46
Single Park Brake Control Valve with Double Check Valve 51
Push/Pull-Type Park Brake Control Valves 54
Trailer Air Supply Valve 56
Tractor Protection Valve — MR and DM Models with Full Trailer Connection 59
Tractor Protection Manifold — CXN/CHN/CH/CL/CX/CV/CT Models 62
Hand Control Valve (Trolley Valve) 65
Spring Brake Modulating Relay Valve 67
Spring Brake Control Valve 74
Quick Release Valve 82
Tractor — Rear Brake Proportioning/Front Axle Ratio Valves 83
Inversion Valve 87
Relay Valves 88
TABLE OF CONTENTS
v
Bobtail Proportioning Relay Valve 94
Hose Couplings (Glad Hands) 101
Brake Chambers 101
Single-Diaphragm Brake Chambers 102
Multiple-Diaphragm Spring Brake Chambers 104
Rotochambers 110
Long-Stroke Air Chambers 111
AIR DRYERS 113
Description 113
Air Dryer Service 115
Anchorlok “Moisture Lok” Dry Air Tank (Aftercooler Type) 115
Bendix AD-9 and AD-9 Soft Seat Air Dryers 121
Bendix AD-IP Air Dryer 126
Bendix AD-SP Air Dryer 130
CR Brakemaster Models 62 and 68 (Aftercooler Type) 134
CR Brakemaster T2000 and T3000 Air Dryers 136
Cyclo-Gard Air Dryer Models 17 and 22 140
Haldex Dry EST Air Dryer 142
Midland Pure Air Plus Air Dryer 146
ArvinMeritor™ WABCO System Saver 1000 1200 1200E and 1200P 148
Isolation (ECON) Valve 153
ANTI-LOCK BRAKE SYSTEM (ABS) 155
Introduction 155
System Overview 155
Dyno-Testing Vehicles with ATC Option 156
ANTI-LOCK BRAKE SYSTEM COMPONENTS 157
Electronic Control Unit (ECU) 157
Engine Brake Disable Relay 160
ABS Relay Panel 161
Tone Wheel 161
Wheel Speed Sensors 162
Modulator (ABS) Valve 163
ATC Valve 163
ABS Indicator Lamp 165
ATC Indicator Lamp 165
Diagnostic Blink Codes 166
ABS/ATC Diagnostic Tools 167
TROUBLESHOOTING 169
TROUBLESHOOTING BRAKE SYSTEM PROBLEMS 170
BRAKE NOISE INVESTIGATION 174
DUAL-NEEDLE TEST GAUGE 175
AIR SYSTEM DIAGNOSTIC PROCEDURES 176
Measuring Supply Pressure at the Service Brake Relay Valve (If Equipped) 176
Measuring Supply Pressure at the Treadle Valve 177
Measuring Relay Valve Control Pressure Versus Delivery Pressure 177
Measuring Drive Axle Delivery Pressure Versus Steering Axle Delivery Pressure 178
Measuring Drive Axle Control Pressure Versus Trailer Control Pressure (Tractors Only) 178
Measuring Drive Axle Delivery Pressure Versus Trailer Axle Delivery
Pressure (Tractors Only) 178
Air System Diagnostic Check 179
vi
TABLE OF CONTENTS
MAINTENANCE 181
AIR SYSTEM MAINTENANCE 182
Service Tests 182
Preventive Maintenance 183
Dual-Circuit Brake System Function Test 185
REPAIR INSTRUCTIONS 187
ANTI-LOCK BRAKE SYSTEM COMPONENT REMOVAL AND INSTALLATION 188
Front-Axle Speed Sensor Removal 188
Front-Axle Speed Sensor Installation 188
Rear-Axle Speed Sensor Removal 189
Rear-Axle Speed Sensor Installation 190
ABS Valve Removal 191
ABS Valve Installation 192
ATC Valve Removal 192
ATC Valve Installation 193
WHEELBASE CHANGES ON ABS-EQUIPPED VEHICLES 193
REPLACEMENT OF ABS CHASSIS HARNESSES 193
BRAKE ADJUSTMENT 196
Manual and Automatic Slack Adjusters 196
Slack Adjuster Maintenance 197
Slack Adjuster Lubrication 203
Adjusting Stroke 204
BRAKE SYSTEM OVERHAUL 210
Asbestos Fibers Danger 210
Non-Asbestos Fibers Danger 211
Wheel Removal 211
Drum/Rotor Inspection 212
Cam Brake Shoe Removal 216
Cam Brake Component Inspection 223
Cam Brake Shoe Installation 229
AIR SYSTEM CONTAMINANT REMOVAL 240
BALANCED AIR BRAKES ON TRACTOR/TRAILER COMBINATIONS 241
Testing for Balanced Brakes 241
AIR LINE HOSE — INSTALLATION 246
Air Fittings — Quick Disconnect 247
Air Lines — Routing 249
Air Lines — Clamping 253
Air Lines — Minimum Allowable Radius 258
SCHEMATIC & ROUTING DIAGRAMS 259
AIR SYSTEM BASIC CHASSIS AND CAB PIPING DIAGRAMS 260
CXN CHN CT Series Truck with 4S/4M ABS/ATC 265
CXN CHN CT Series Truck with 4S/4M ABS/ATC with Full Trailer Connection 266
CXN CHN CT Series Truck with 4S/4M ABS/ATC with Full Trailer Connection
and Dual Function Hand Control Valve 267
CXN CHN CT Series Tractor with 4S/4M ABS/ATC 268
CV Series Truck with 4S/4M ABS/ATC (January 1 2004 and Later) 269
CV Series Truck with 4S/4M ABS/ATC with Full Trailer Connection (January 1 2004
and Later) 270
CV Series Truck with 4S/4M ABS/ATC with Full Trailer Connection and Dual Function
Hand Control Valve (January 1 2004 and Later) 271
TABLE OF CONTENTS
vii
CV Series Truck with 4S/4M ABS/ATC (Prior to January 1 2004) 272
CV Series Truck with 4S/4M ABS/ATC with Full Trailer Connection (Prior to
January 1 2004) 273
CV Series Truck with 4S/4M ABS/ATC with Full Trailer Connection and Dual Function
Hand Control Valve (Prior to January 1 2004) 274
CV Series Tractor with 4S/4M ABS/ATC 275
CH/CL Series Truck with 4S/4M ABS/ATC 276
CH/CL Series Truck without ABS/ATC with Full Trailer Connection 277
CH/CL Series Truck with 4S/4M ABS/ATC and Full Trailer Connection 278
CH/CL Series Truck with 4S/4M ABS/ATC and Full Trailer Connection with Dual Function
Hand Control Valve 279
CH/CL Series Tractor without ABS/ATC 280
CH/CL Series Tractor with 4S/4M ABS/ATC ArvinMeritor™ WABCO “C” Version ECU 281
CH/CL/CX Series Tractor with 4S/4M ABS/ATC 282
R Series Truck without ABS/ATC 283
R Series Truck with 4S/4M ABS/ATC 284
R Series Truck without ABS/ATC with Full Trailer Connection 285
R Series Truck with 4S/4M ABS/ATC with Full Trailer Connection 286
R Series Tractor without ABS/ATC 287
R Series Tractor with 4S/4M ABS/ATC 288
R Series Truck with 4S/4M ABS/ATC with Full Trailer Connection and Dual Function
Hand Control Valve 289
DM DMM Series Truck without ABS/ATC with Full Trailer Connection 290
DM DMM Series Truck with 4S/4M ABS/ATC with Full Trailer Connection 291
MR Series Truck without ABS/ATC 292
MR Series Truck with 4S/4M ABS/ATC 293
MR Series Truck without ABS/ATC with Full Trailer Connection 294
MR Series Truck with 4S/4M ABS/ATC with Full Trailer Connection 295
MR Series Tractor without ABS/ATC 296
MR Series Tractor with 4S/4M ABS/ATC 297
LE Series Truck without ABS/ATC without Work Brake 298
LE Series Truck with 4S/4M ABS/ATC without Work Brake 299
LE Series Truck without ABS/ATC and with Work Brake 300
LE Series Truck with 4S/4M ABS/ATC with Work Brake 301
Liftable Axle Air Brake Piping — One Tag or One Pusher 302
Liftable Axle Air Brake Piping — Two Pusher Axles 303
Liftable Axle Air Brake Piping — One Tag and One Pusher Axle 304
Liftable Axle Air Brake Piping — Two Pusher Axles and One Tag Axle 305
Rear Axle Relay Valve Configuration 306
Bendix TU-FLO Piping 310
Cab Manifold Piping 311
SPECIAL TOOLS & EQUIPMENT 351
SPECIAL TOOLS 352
INDEX 353
VIDEO PREVIEW OF THE MANUAL:
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
S.M