2007 Workshop Manual - S1-UNAE03A-2 PDF

S1-UNAE03A-2.
book 1 ページ２００６年２月９日　木曜日　午後６時１７分
FOREWORD
This workshop manual has been prepared to provide information regarding repair procedures on Hino Trucks.
Applicable for HINO 145, 165, 185, 238, 258, 268, 338 series, equipped with J05D-TA, J08E-TA and J08E-TB engine
When making any repairs on your vehicle, be careful not to be injured through improper procedures.
As for maintenance items, refer to the Owner's Manual.
All information and specifications in this manual are based upon the latest product information available at the time of printing.
Hino Motors Sales U.S.A., Inc. reserves the right to make changes at any time without prior notice.
Please note that the publications below have also been prepared as relevant service manuals for the components and systems
in these vehicles.
Manual Name Pub. No.

Chassis Workshop Manual S1-UNAE03A 1/2
J05D-TA Engine Workshop Manual S5-UJ05E03A
J08E-TA, TB Engine Workshop Manual S5-UJ08E03A
S1-UNAE03A-2.book 2 ページ２００６年２月９日　木曜日　午後６時１７分
CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL

Use this chart to the appropriate chapter numbers for servicing your particular vehicle.
MANUAL NO. S1-UNAE03A 2/2 (U.S.A.), S1-CNAE03A 2/2 (CANADA)
MODELS HINO HINO HINO HINO HINO HINO HINO

CHAPTER
(Production Model 145 165 185 238,258 268 308 338
Code) (NA6J) (NB6J) (NC6J) (ND8J) (NF8J) (NV8J)
(NE8J) (NJ8J)
GENERAL INTRODUCTION GN02-001
CL02-002
CLUTCH MAIN UNIT CL02-001
CL02-003
CLUTCH CONTROL CL03-001
TRANSMISSION MAIN UNIT TR02-002 TR02-001
AUTOMATIC TRANSMISSION TR04-001 TR04-002 TR04-003
TRANSMISSION/TRANSFER CONTROL TR06-001
PROPELLER SHAFT PP02-001
DIFFERENTIAL CARRIER DF02-001 DF02-002
BRAKE EQUIPMENT BR01-001 BR01-002 BR01-001 BR01-002
SERVICE BRAKE BR02-001 BR02-002 BR02-001 BR02-002
ABS & ASR BR03-001 BR03-002 BR03-001 BR03-002

BR07-001,
PARKING BRAKE BR07-001, BR07-002 — BR07-002 —
STEERING EQUIPMENT SR01-001
STEERING UNIT SR02-001
POWER STEERING SR03-001
FRONT AXLE AX02-001
REAR AXLE AX03-001
WHEEL & TIRE AX04-001
SUSPENSION SU02-001
CHASSIS FRAME FC02-001
CAB CA02-001
ELECTRICAL EQUIPMENT EL01-001
ELECTRIC WIRE EL02-001
BRAKE CONTROL DN03-001 DN03-002 DN03-001 DN03-002
This manual does not contain items on half-tone dot meshing.

INDEX: CHASSIS GROUP 1/4
GENERAL INTRODUCTION
CLUTCH EQUIPMENT
CLUTCH MAIN UNIT
WORKSHOP CLUTCH CONTROL
MANUAL TRANSMISSION EQUIPMENT
TRANSMISSION MAIN UNIT
TRANSFER MAIN UNIT
AUTOMATIC TRANSMISSION
P.T.O. (POWER TAKE-OFF)
TRANSMISSION / TRANSFER CONTROL
PROPELLER SHAFT EQUIPMENT
PROPELLER SHAFT
DIFFERENTIAL EQUIPMENT
DIFFERENTIAL CARRIER
BRAKE EQUIPMENT
SERVICE BRAKE
ABS & ASR

ES START (EASY & SMOOTH START) SYSTEM
EXHAUST BRAKE
RETARDER BRAKE
PARKING BRAKE
STEERING EQUIPMENT
STEERING UNIT
POWER STEERING
AXLE EQUIPMENT
FRONT AXLE
REAR AXLE
WHEEL & TIRE
SUSPENSION EQUIPMENT
SUSPENSION
CHASSIS EQUIPMENT
CHASSIS FRAME
COUPLER (5TH WHEEL)
PINTLE HOOK
CAB EQUIPMENT
CAB
ELECTRICAL EQUIPMENT
ELECTRIC WIRE
HYBRID SYSTEM
ENGINE CONTROL
FUEL CONTROL
BRAKE CONTROL
SUSPENSION CONTROL
CAB EQUIPMENT CONTROL
OTHERS
ABS & ASR (ABS : HYDRAULIC) BR03–1
BR03 ABS & ASR (ABS : HYDRAULIC) BR03-001
ABS ...........................................................BR03-2
OVERVIEW...................................................... BR03-2
COMPOSITION AND OPERATION ................. BR03-3
FUNCTION ...................................................... BR03-6
PRECAUTIONS WHEN DRIVING VEHICLES
EQUIPPED WITH ABS .................................... BR03-7
OVERVIEW AND FUNCTION.......................... BR03-8
BR03–2 ABS & ASR (ABS : HYDRAULIC)
ABS
OVERVIEW
EN0680103C100001
ABS is a system that makes effective use of the friction between the tires
and the road surface to maintain vehicle stability while the brakes are being
applied and for stopping the vehicle.
Applying the brakes forcefully on a slippery road surface can cause the
wheels to be locked, due to excessive braking force. This causes the vehi-
cle to lose stability because the locked wheels lose resistance in the lateral
direction. More specifically, if the front wheels are locked, it becomes
impossible to steer the vehicle, and if the rear wheels are locked, the rear of
the vehicle may fishtail from side to side.
Also, when wheel-locking occurs, it is not possible to make effective use of
friction between the tires and the road surface. This may cause the braking
distance to be increased.
ABS uses wheel sensors mounted on the axles to constantly monitor the
rotation of the wheels. If any of the wheels is starting to lock up, the ABS
computer sends signals to the ABS modulator and immediately adjusts the
brake pressure to prevent wheel-locking.
In this way, ABS maintains the stability of the vehicle while stopping by
making effective use of the friction between the tires and the road surface.
COMPOSITION AND OPERATION

EN0680103C100002
The ABS system is comprised of sensor rings mounted on the wheels, the
ABS computer, which receives signals from the wheel sensors that monitor
the rotational speed of the wheels and outputs control signals to maintain
the appropriate braking force; ABS modulator, which increase or decrease
the braking force, based on the control signals; the warning lamp, which
gives an alarm if the system malfunctions; the piping, wire harnesses, etc.,
that link together the various units that compose the system.
Pulse signals transmitted by the sensor rings mounted on the wheel hubs,
rotated together with the wheels, and the wheel sensors mounted near sen-
sor ring on the axles are sent to the ABS computer. The ABS computer
then calculates the wheels' rotational speed, acceleration, deceleration,
and amount of slippage, based on these signals.
If the limit values for the wheel's deceleration, or slippage ratio are
exceeded, the ABS computer immediately transmits signals to the ABS
modulator to adjust any excess braking force.
• ABS system operates as following table.
FRONT AXLE REAR AXLE
Independently control Independently control

CONTROL SYSTEM
right and left wheels right and left wheels
1. SYSTEM COMPOSITION DIAGRAM
ABS COMPUTER
ECU
BRAKE BRAKE
ABS INDICATOR LAMP
HYDRAULIC MASTER CYLINDER

BOOSTER
ABS
HYDRAULIC MODULATOR
BRAKE LINE ASSEMBLY
HYDRAULIC BRAKE LINE
BRAKE BRAKE
SENSOR ABS SENSOR CABLE

ASSEMBLY
SAPH068010300001
2. ABS CONTROL FLOWCHART
INPUT SIGNALS ABS COMPUTER OUTPUT SIGNALS
FRONT RIGHT FRONT RIGHT PRES-

WHEEL SENSOR SURE MAINTENANCE
SOLENOID VALVE
FRONT LEFT FRONT RIGHT PRES-

SURE REDUCTION
WHEEL SENSOR SOLENOID VALVE
REAR RIGHT FRONT LEFT PRES-

ABS COMPUTER SURE MAINTENANCE
REAR LEFT FRONT LEFT PRES-

SURE REDUCTION
REAR RIGHT PRES-

SURE MAINTENANCE
SOLENOID VALVE
REAR RIGHT PRES-

SURE REDUCTION
SOLENOID VALVE
REAR LEFT PRESSURE

MAINTENANCE SOLE-
NOID VALVE
REAR LEFT PRESSURE

REDUCTION SOLE-
NOID VALVE
ABS MOTOR RELAY
ABS WARNING LIGHT
MALFUNCTION CODE
(DIAGNOSTIC CODE)
SAPH068010300002
BR03_001.fm 5 ページ２００６年２月２０日　月曜日　午前９時３分
BASIC PRINCIPLE
Based on its relationship with the slip ratio, which is determined from the
wheels' rotational speed and the vehicle's speed, ABS controls the brake
force so that it will be most effective.
When the driver applies the brakes, the rotation of the wheels is controlled
and the vehicle speed drops. However, the momentum of the vehicle
attempts to push it forward further even though the rotation of the wheels is
being braked. At this point, slipping will occur if there is a gap between the
wheels' rotational speed and the vehicle's speed. The slip ratio is a value
that indicates the rate of slippage.
Vehicle's speed - Wheel's rotational speed

Slip ratio = 100 %
Vehicle's speed
Slip ratio 0 % : No slipping between the wheels and the
road surface
100 % : Wheels locked
The graph shown at left shows the relationship between the friction coeffi-
cient of the tires and of the road surface and the slip ratio.
In an ABS-equipped vehicle, the brake force is controlled to ensure that it is
within the range where the friction coefficient is high (shaded portion of the
graph) without locking the wheels. This ensures efficient braking perfor-
mance.
SAPH068010300004
OPERATION
The ABS computer calculates the wheel speed and wheel acceleration
speed for each of the 4 wheels, from 4 speed sensor signals, and deter-
WHEEL SPEED mines the wheel slip conditions. And depending on these conditions, con-
HIGH VEHICLE BODY SPEED
trol signals are output to the ABS actuator solenoid valves in 3 modes
SPEED
(pressure increase, pressure maintenance, and pressure reduction). Con-

trol signals are output independently to the front and rear wheels and to the
LOW left and right wheels.
ACCELERATION
0
WHEEL
SPEED
Ð
CONTROL SIGNAL
PRESSURE
REDUCTION
PRESSURE
MAINTENANCE
PRESSURE
INCREASE
WHEEL CYLINDER
FLUID PRESSURE
HIGH
0
TIME
SAPH068010300005
FUNCTION
EN0680103C100003
FAIL-SAFE FUNCTION
This ABS system is equipped with a fail-safe function that causes the ABS
warning light on the instrument panel to light and to restore the normal
(non-ABS) brake system, should an ABS malfunction occur.
Note that the ABS system consists of two independent circuits. Should a
malfunction occur for whatever reason in the electrical circuits, that sys-
tem's ABS is switched off and the normal brake system is restored while
ABS control continued for the other system. This configuration is designed
to minimize the effects of any malfunction on ABS function.
PRECAUTIONS WHEN DRIVING VEHICLES EQUIPPED WITH ABS

EN0680103F100001
Electronically, ABS uses the coefficient of friction (the amount of traction) between the tires and the road surface to monitor the
speed of each wheel. If one or more wheels indicates the possibility of locking, resulting in fishtailing or other loss of stability,
ABS enables the vehicle to be brought to a stop. Even with ABS, however, a driver must operate the vehicle in a safe manner
and recognize the following points with respect to the operation of ABS.
CHECK POINTS REMEDIAL ACTIONS
Even with ABS, the braking distance on a wet or slippery

road will be longer than on a dry road, and if the road
surface is covered with ice, snow or gravel, the braking Even with ABS, always drive safely, tak-
distance will be even greater. ing into consideration the road and traffic
conditions and the condition of your tires,
including tire type and tire wear. Always
keep a safe distance from any vehicle
ABS does not operate when the vehicle is starting, ac-
being driven in front of you.
celerating or turning, and will not assist in maintaining
directional stability or steerability or in shortening the brak-
ing distance.
Even if the ABS is operational, where the coefficient of If engine braking causes instability or fish-
friction is very low, such as on an icy roadway, skidding, tailing, the clutch should be engaged or
inability to steer, and instability may occur because of the transmission shifted to neutral, to pre-
insufficient traction by the tires. vent the application of the engine brak-
ing to the drive wheels.
Where engine braking, as a result of downshifting, oc-
curs on a surface with a low coefficient of friction, such Vibrations and noise during the operation
as ice, the drive wheels may lock, causing fishtailing or of ABS are not malfunctions. Remain calm
vehicle instability. ABS does not operate unless the brake and continue to steer the vehicle in an
pedal is applied. appropriate manner.
When ABS is activated, the driver may experience a small If the warning lamp lights again when you
amount of vibration (especially if the road surface be- reach a speed of about 6 km/h
tween the left and right tires is different) and difficulty in (4 mile/h), the ABS system may not be
steering. Also, the operation of the ABS may generate functioning properly. Have it inspected and
some noise. repaired if necessary. *The warning lamp
can be reset by turning off the engine
The ABS warning light will come on when you turn the while the vehicle is at rest. If the warning
starter switch to the "on" position. It stays on briefly and lamp fails to go out after the engine is re-
then turns off automatically. If the light does not come started and the speed indicated above is
on, have your vehicle inspected and serviced immedi- reached, or if it lights frequency while the
ately at your nearest Hino service dealer. vehicle is being driven, the ABS must be
inspected.
OTHER CHECKPOINTS REGARDING HANDLING

1. When washing the vehicle, take care not to direct high-pressure streams of water at the ABS modulator, harnesses,
or connectors. Also, under no circumstances should the ABS computer or electrical relays be exposed to water.
2. Be very careful not to damage the ABS wire harness when removing snow, ice, mud or other material from the outside or
underside of the vehicle.
3. All electronic and radio equipment installed on the vehicle must be mounted as far away from the ABS computer and wire
harness as possible. Installation of certain electronic and radio equipment can also cause the ABS computer to malfunction.
All such equipment must also conform to all applicable laws. If you wish to install a radio or other electronic equipment,
please contact your Hino service representative.
SAPH068010300006
OVERVIEW AND FUNCTION

EN0680103C100004
ABS COMPUTER
Based on pulse signals from the wheel sensors, the ABS computer
mounted in the vehicle calculates and evaluates the slip ratio and the accel-
eration/deceleration speed of the wheels. Based on the results, it sends
signals to the modulator assembly as necessary, causing them to operate
and apply the brakes to maintain the slippage of the wheels within the opti-
mal range.
During braking, the fluid pressure applied to the brake cylinder is regulated
to prevent the wheels from locking. The brakes are applied so as to main-
tain the slippage of the wheels within the optimal range.
Regardless of whether the vehicle is stopped or being driven, and whether
or not the brakes are being applied, the circuit consisting of the wheel sen-
sors, modulator assembly, ABS computer, and wire harnesses are con-
stantly being checked by the ABS computers' fail-safe circuit. If some sort
of malfunction occurs, the fail-safe circuit warns the driver by lighting the
ABS warning light. At the same time, the ABS system that is experiencing
the malfunction is shut off and braking is restored to normal (non-ABS)
operation.
NOTICE
Modified label: 199 is applied following model.
model: HINO 145, 165, 238, 268,308 (NA, NB, ND, NE, NF)
Modified label: 198 is applied
model: HINO 185 (NC)
Pay close attention to prevent misuse when replacing.
SAPH068010300007
ABS MODULATOR ASSEMBLY
1. Overview
• The ABS modulator is mounted between the Hydro booster and wheel
cylinder. It controls the fluid pressure to the wheel cylinder, regulating
the pressure according to signals from the computer in three modes:
pressure maintenance, pressure reduction, and pressure increase.
SAPH068010300008
SAPH068010300009
2. Operation
(1) During Normal Braking (ABS is not operating)
• Since there is no control signal input from the ABS computer, the
pressure maintenance solenoid valve port A is open, and the pres-
sure reduction solenoid valve port B is closed. Accordingly, when the
fluid pressure generated by the Hydro booster rises according to the
fluid pressure from the master cylinder produced when the brake
pedal is depressed, brake fluid is fed through port A to the wheel cyl-
inder. Brake fluid is not sent to the pump side at this time because of
the check valve 1 installed on that side. Then, when the brake pedal is
released, the wheel cylinder brake fluid is returned to the master cylin-
der through the pressure maintenance solenoid valve port A to the
Hydro booster.
Each Port Status
ABS computer signal Port status
Pressure mainte-
OFF Port A: Open
nance solenoid valve
Pressure reduction
OFF Port B: Closed
solenoid valve
SAPH068010300010
(2) During ABS Braking

a. Pressure Reduction Mode
• When the wheels are about to lock, the pressure maintenance sole-
noid valve port A closes and the pressure reduction solenoid valve
port B opens according to control signals from the ABS computer.
Accordingly, the wheel cylinder brake fluid is fed through the pressure
reduction solenoid valve port B to the reservoir, reducing the wheel
cylinder fluid pressure. While the ABS is in operation, the ABS com-
puter outputs a normal operating signal to the pump, which pumps out
the brake fluid that accumulates in the reservoir and returns it to the
Hydro booster.
Each Port Status
Pressure mainte-
ON Port A: Closed
Pressure reduction
ON Port B: Open
solenoid valve
SAPH068010300011
b. During Pressure Maintenance

• When the wheel cylinder fluid pressure is reduced or increased to the
required fluid pressure, the pressure maintenance solenoid valve port
A and the pressure reduction solenoid valve port B simultaneously
close according to control signals from the ABS computer. This closes
both the Hydro booster side and reservoir side oil routes, maintaining
the wheel cylinder fluid pressure.
Each Port Status
Pressure mainte-
ON Port A: Closed
Pressure reduction
OFF Port B: Closed
solenoid valve
SAPH068010300012
c. During Pressure Increase

• When the wheel cylinder fluid pressure needs to increase rapidly, the
pressure maintenance solenoid valve port A opens and the pressure
reduction solenoid valve port B closes according to control signals
from the ABS computer. This condition is the same as the normal con-
dition, and Hydro booster brake fluid is fed to the wheel cylinder, caus-
ing the wheel cylinder fluid pressure to rise. If there is any brake fluid
remaining in the reservoir at this time, it is pumped out by the pump
and sent to the wheel cylinder. The speed of the pressure increase is
controlled by combination of the pressure increase and the pressure
maintenance.
Each Port Status
Pressure mainte-
OFF Port A: Open
Pressure reduction
OFF Port B: Closed
solenoid valve
SAPH068010300013
WHEEL SENSOR
These sensors are mounted facing the sensor rings on each wheel on the
front and rear axles.
The wheel sensors are electromagnetic sensors consisting of a permanent
magnet core with a coil of wire wrapped around it. The frequency of the
pulse signals generated by magnetic inductance between the sensors and
the sensor rings they face is proportional to the rotational speed of the
wheels. These pulse signals are sent to the ABS computer and are used to
determine the wheels' rotational status.
SAPH068010300014
SENSOR RING
Hub fitted type
The sensor rings are press-fitted into the insides of the wheel hubs of each
wheel or integrated in the brake rotor on the front and rear axles, and they
face the wheel sensors described in the preceding section. The sensor
rings are made of a magnetic material, and teeth are cut into the surface
which faces the wheel sensor at regular intervals.Also, when the sensor
ring performs one complete rotation, the sensor generates pulse signals
corresponding to the number of teeth.
SAPH068010300015
Sensor ring position and number of teeth
145 165 185 238 268 308

Model
NA NB NC ND NE NF
Position Hub fitted Rotor integrated
Front
Teeth No. 70 80 80 100
Position Hub fitted Rotor integrated
Rear
Teeth No. 70 80 100
SAPH068010300016
CLAMPING BUSHING
The wheel sensors are held in place through friction by clamping bushings
that are inserted into the mounting brackets. If they are assembled properly
(the clamping bushings should be pushed in to place so that the stoppers
on the clamping bushings come in contact with the holder), the clamping
bushings serve to eliminate the need to adjust the clearance between the
wheel sensors and sensor rings.
SAPH068010300017
WARNING LAMP
The ABS is equipped with the following warning light.
SAPH068010300018
1. ABS WARNING LIGHT

• This lamp indicates the status of the ABS. It lights once when the
starter switch is turned on and automatically goes off if the ABS is
functioning normally. If a malfunction occurs in the ABS while the vehi-
cle is being driven, the light comes on to alert the driver.
Also used as the diagnostic display light.
NOTICE
Trouble shooting and Testing of the ABS refer to MERITOR WABCO
Maintenance Manual.Cab-Mounted ECU and D Version Hydraulic ABS.
WHEEL SENSOR WIRE HARNESSES

Each wheel sensor wire harness employs a two-conductor twisted wire
cable. Its function is to protect the wheel sensor signals, which are vital to
the proper operation of the ABS, from electromagnetic interference. Under
no circumstances should any part of the wheel sensor wire harness be cut
or connected to any other wire. In the event that the wire harness should
become cut, have it replaced by an authorized Hino dealer.
SAPH068010300019
DIAGNOSIS SWITCH OF ABS SYSTEM

It is positioned at the side of diagnosis connector in the instrument panel of
driver seat front side.
By switching the starter key "ON" and pushing to "ON" this ABS diagnosis
switch, which is led to the diagnosis mode, the ABS warning light flashes on
and off to inform the trouble codes.
NOTICE
ABS diagnosis switch reverts automatically to "OFF" position.
SAPH068010300020
ABS WIRE HARNESSES
1. Front axle ABS wire harness

• The wire harness that runs from the side frame to the front axle wheel
sensor must absorb the steering angle of the front wheel and the
movement of the chassis springs. It is therefore necessary to always
maintain an optimal spacing between the clips.
SAPH068010300021
• The optimal spacing between the clips is achieved when the wheel
sensor connectors are attached in the regular locations shown in the
diagram such that the sensor cabling within the frame is not loose.
When disassembling and reassembling, confirm that the connector
and sensor cable layout is appropriate.
SAPH068010300022
2. Rear axle ABS wire harness

• The wheel sensor wire harness is arranged so that the left and right
wheel sensor wire harnesses are near each other. Therefore, special
care should be taken not to make incorrect connections if the har-
nesses have been removed for inspection or repairs. If incorrect con-
nections are made, it will interfere with the functioning of the ABS. For
this reason, caution plates indicating "LEFT" and "RIGHT" are affixed
to the wire harnesses. Be sure to check when connecting the har-
nesses. The wheel sensor wire harnesses, just like the front axle har-
nesses, must absorb the movement of the chassis springs. It is
therefore necessary to always maintain an optimal spacing between
the clips.
When disassembling and re-assembling, confirm that the connector is
secured in its proper place as shown in the diagram and that the sen-
sor cables in the frame and over the axle are not hanging loosely.
SAPH068010300023
HANDLING WIRE HARNESSES

• The various sensors, valves, relays and wire harness connections to
the ABS computer employ multipolar harness connectors suitable for
use with the weak currents used by electronic circuitry. Be very careful
when handling them.
1. Place the starter switch on "LOCK" before unplugging the har-

ness connectors.
2. When unplugging the harness connectors, release the lock, hold

the housing and unplug it straight as much as possible.
3. Do not pull holding the wire harness or pull with excessive force.
Doing so can cause the pins of the harness connectors to be
deformed.
4. Remove unnecessary connectors and do not plug them.
5. When inspecting using a circuit tester, insert the test probe from
the wire harness side.
Never insert the test probe from the pins of harness connectors
as this can cause bad contacts.
SAPH068010300024
6. When unplugging the harness connectors, do not allow water,

oil, dust, or any other liquid or substance to get on the terminals
as they can cause bad contacts.
7. Be careful not to allow water, oil, dust, or any other liquid or sub-
stance to get on any component.
8. When plugging the harness connector, insert it completely and

confirm that the harness connector lock is engaged.
ADDITIONAL PRECAUTIONS
1. Make sure the model's starter switch is in the OFF position

before unplugging the harness connector from the ABS com-
puter.
2. Make sure to unplug all the harness connectors from the ABS
computer before performing welding on the chassis or body of
the vehicle. Also be careful that welding sputter does not get
onto the harnesses.
3. When cleaning the interior of the model, make sure water does
not get onto the ABS computer, various relays, connectors, or
any other component.
4. Use of a circuit tester

• If a circuit tester is being used, always use one with an internal resis-
tance greater than 100 kΩ inside the voltage measurement range.
5. Installation of a radio or other electronic equipment

• All electronic and radio equipment installed on the vehicle must be
mounted as far away from the ABS computer and wire harness as
possible. Installation of certain electronic and radio equipment can
also cause the ABS computer to malfunction. All such equipment
must also conform to all applicable laws. If you wish to install a radio
or other electronic equipment, please contact your Hino service repre-
sentative.
6. Quick battery charge

• When charging batteries using a quick charger, do it with both battery
terminals removed.
7. Installation of electrical equipment inside of the cab

• When installing an air conditioner or other electrical equipment inside
of the cab, be careful not to damage the engine, chassis, and wire
harnesses inside the cab. Moreover, do not forget to plug the harness
connectors unplugged during the installation.
ABS & ASR (ABS : FULL AIR) BR03–1
ABS & ASR (ABS : FULL AIR)

BR03
BR03-002
ABS ...........................................................BR03-2
OVERVIEW...................................................... BR03-2
COMPOSITION AND OPERATION ................. BR03-3
FUNCTION ...................................................... BR03-6
PRECAUTIONS WHEN DRIVING VEHICLES
EQUIPPED WITH ABS .................................... BR03-7
OVERVIEW AND FUNCTION.......................... BR03-8
INSPECTION (FRONT WHEEL BRAKE) ...... BR03-13
INSPECTION (REAR WHEEL BRAKE)......... BR03-14
BR03–2 ABS & ASR (ABS : FULL AIR)
ABS
OVERVIEW
EN0680203C100001
ABS is a system that makes effective use of the friction between the tires
and the road surface to maintain vehicle stability while the brakes are being
applied and for stopping the vehicle.
Applying the brakes forcefully on a slippery road surface can cause the
wheels to be locked, due to excessive braking force. This causes the vehi-
cle to lose stability because the locked wheels lose resistance in the lateral
direction. More specifically, if the front wheels are locked, it becomes
impossible to steer the vehicle, and if the rear wheels are locked, the rear of
the vehicle may fishtail from side to side.
Also, when wheel-locking occurs, it is not possible to make effective use of
friction between the tires and the road surface. This may cause the braking
distance to be increased.
ABS uses wheel sensors mounted on the axles to constantly monitor the
rotation of the wheels. If any of the wheels is starting to lock up, the ABS
computer sends signals to the ABS control valve and immediately adjusts
the brake pressure to prevent wheel-locking.
In this way, ABS maintains the stability of the vehicle while stopping by
making effective use of the friction between the tires and the road surface.
SAPH068020300001
1 Wheel speed sensors 3 Relay valve

2 ABS modulator valves 4 ECU
COMPOSITION AND OPERATION

EN0680203C100002
The ABS system is comprised of sensor rings mounted on the wheels. The
ABS computer, which receives signals from the wheel sensors that monitor
the rotational speed of the wheels and outputs control signals to maintain
the appropriate braking force; ABS control valves, which increase or
decrease the braking force, based on the control signals; the warning lamp,
which gives an alarm if the system malfunctions; the piping, wire har-
nesses, etc., that link together the various units that compose the system.
Pulse signals transmitted by the sensor rings mounted on the wheel hubs,
rotated together with the wheels, and the wheel sensors mounted near sen-
sor ring on the axles are sent to the ABS computer. The ABS computer
then calculates the wheels' rotational speed, acceleration, deceleration,
and amount of slippage, based on these signals.
If the limit values for the wheel's deceleration, or slippage ratio are
exceeded, the ABS computer immediately transmits signals to the ABS
control valves to adjust any excess braking force.
This ABS system controls the four wheels, front, rear, right, and left, inde-
pendently.
1. SYSTEM COMPOSITION DIAGRAM
SAPH068020300002
1 Brake valve 5 ABS computer

2 Brake chamber 6 Wheel sensor
3 Relay valve 7 ABS warning light
4 ABS control valve A From air tank
2. ABS CONTROL FLOWCHART
INPUT SIGNALS ABS COMPUTER OUTPUT SIGNALS
Front left wheel sensor
Front right wheel sensor ABS control valve for

front left wheel
Rear left wheel sensor

ABS control valve for
front right wheel
Rear right wheel sensor

rear left wheel
ABS COMPUTER

rear right wheel
Malfunction code
(diagnostic code)
ABS warning light
SAPH068020300003
BASIC PRINCIPLE
Based on its relationship with the slip ratio, which is determined from the
wheels' rotational speed and the vehicle's speed, ABS controls the brake
force so that it will be most effective.
When the driver applies the brakes, the rotation of the wheels is controlled
and the vehicle speed drops. However, the momentum of the vehicle
attempts to push it forward further even though the rotation of the wheels is
being halted. At this point, slipping will occur if there is a gap between the
wheels' rotational speed and the vehicle's speed. The slip ratio is a value
that indicates the rate of slippage.
Vehicle's speed - Wheel's rotational speed

Slip ratio = 100 %
Vehicle's speed
Slip ratio 0 % : No slipping between the wheels and the

road surface
100 % : Wheels locked
The graph shown at left shows the relationship between the friction coeffi-
cient of the tires and of the road surface and the slip ratio.
In an ABS-equipped vehicle, the brake force is controlled to ensure that it is
within the range where the friction coefficient is high (shaded portion of the
graph) without locking the wheels. This ensures efficient braking perfor-
mance.
SAPH068020300005
OPERATION
The ABS control characteristics line graph at left illustrates how the vehi-
cle's speed, the wheels' rotational speed, the wheel acceleration/decelera-
tion, and the air pressure at the ABS control valve outlet change over time
after the brakes are applied.
When the brakes are applied, the vehicle's speed and the wheels' rotational
speed drop and at the same time, the wheel acceleration/deceleration
speed also drops. At point T1, a gap begins to open between the wheels'
rotational speed and the vehicle's speed. Passing on point T2, the ABS
computer detects that the wheels are beginning to lock and is lowering the
outlet air pressure of the ABS control valve to prevent wheel locking from
occurring.
At point T3, the wheel acceleration/deceleration speed is starting to return
to normal one, and the ABS computer stops lowering the air pressure at the
ABS control valve outlet and maintains it at a constant level.
At point T5, the wheels' rotational speed and the vehicle's speed are about
the same. The ABS computer detects that the wheels are no longer likely to
be locked and increases the air pressure at the ABS control valve outlet.
The above processes is repeated over and over until the vehicle comes to a
complete stop.
SAPH068020300006
FUNCTION
EN0680203C100003
FAIL-SAFE FUNCTION
This ABS system is equipped with a fail-safe function that causes the ABS
warning light on the instrument panel to light and to restore the normal
(non-ABS) brake system, should an ABS malfunction occur.
Note that the ABS system consists of two independent circuits. Should a
malfunction occur for whatever reason in the electrical circuits, that sys-
tem's ABS is switched off and the normal brake system is restored while
ABS control continued for the other system. This configuration is designed
to minimize the effects of any malfunction on ABS function.
PRECAUTIONS WHEN DRIVING VEHICLES EQUIPPED WITH ABS

EN0680203F100001
Electronically, ABS uses the coefficient of friction (the amount of traction) between the tires and the road surface to monitor the
speed of each wheel. If one or more wheels indicates the possibility of locking, resulting in fishtailing or other loss of stability,
ABS enables the vehicle to be brought to a stop. Even with ABS, however, a driver must operate the vehicle in a safe manner
and recognize the following points with respect to the operation of ABS.
CHECK POINTS REMEDIAL ACTIONS
Even with ABS, the braking distance on a wet or slippery Even with ABS, always drive safely, tak-
road will be longer than on a dry road, and if the road ing into consideration the road and traffic
surface is covered with ice, snow or gravel, the braking conditions and the condition of your tires,
distance will be even greater. including tire type and tire wear. Always
keep a safe distance from any vehicle
being driven in front of you.
ABS does not operate when the vehicle is starting, ac-
celerating or turning, and will not assist in maintaining
directional stability or steerability or in shortening the brak-
If engine braking causes instability or fish-
ing distance.
tailing, the clutch should be engaged or
Even if the ABS is operational, where the coefficient of
the transmission shifted to neutral, to pre-
friction is very low, such as on an icy roadway, skidding,
vent the application of the engine brak-
inability to steer, and instability may occur because of
ing to the drive wheels.
insufficient traction by the tires.
If the air pressure becomes low and the

Where engine braking, as a result of downshifting, oc- air pressure warning lamp comes on and
curs on a surface with a low coefficient of friction, such a buzzer sounds, immediately stop the
as ice, the drive wheels may lock, causing fishtailing or vehicle in a safe place. Begin driving
vehicle instability. ABS does not operate unless the brake again only after the return to normal air
pedal is applied. pressure.
If the ABS engages, the vehicle's air consumption rate Vibrations and noise during the operation
will be higher than usual. of ABS are not malfunctions. Remain calm
and continue to steer the vehicle in an
appropriate manner.
When ABS is activated, the driver may experience a small
amount of vibration (especially if the road surface be-
tween the left and right tires is different) and difficulty in If the warning lamp lights again when you
steering. Also, the operation of the ABS may generate reach a speed about 6 km/h (4 mph)
some noise. the ABS system may not be functioning
properly. Have it inspected and repaired
The ABS warning light will come on when you turn the if necessary *
starter switch to the "on" position. It stays on briefly and The warning lamp can be reset by turn-
then turns off automatically. If the light does not come ing off the engine while the vehicle is at
on, have your vehicle inspected and serviced immedi- rest. If the warning lamp fails to go out
ately at your nearest HIno service dealer. after the engine is restarted and the speed
indicated above is reached, or if it lights
frequency while the vehicle is being
driven, the ABS must be inspected.
OTHER CHECKPOINTS REGARDING HANDLING

1. When washing the vehicle, take care not to direct high-pressure streams of water at the ABS valves, harnesses, or connec-
tors. Also, under no circumstances should the ABS computer or electrical relays be exposed to water.
2. Be very careful not to damage the ABS wire harness when removing snow, ice, mud or other material from the outside or
underside of the vehicle.
3. All electronic and radio equipment installed on the vehicle must be mounted as far away from the ABS computer and wire
harness as possible. Installation of certain electronic and radio equipment can also cause the ABS computer to malfunction.
All such equipment must also conform to all applicable laws. If you wish to install a radio or other electronic equipment,
please contact your Hino service representative.
SAPH068020300007
OVERVIEW AND FUNCTION

EN0680203C100004
1. ABS COMPUTER
Based on pulse signals from the wheel sensors, the ABS computer
mounted in the vehicle calculates and evaluates the slip ratio and the accel-
eration/deceleration speed of the wheels. Based on the results, it sends
signals to the ABS control valves as necessary, causing them to operate
and apply the brakes to maintain the slippage of the wheels within the opti-
mal range.
During braking, the air pressure applied to the brake chambers is regulated
to prevent the wheels from locking. The brakes are applied so as to main-
tain the slippage of the wheels within the optimal range.
Regardless of whether the vehicle is stopped or being driven, and whether
or not the brakes are being applied, the circuit consisting of the wheel sen-
sors, control valves, ABS computer, and wire harnesses are constantly
being checked by the ABS computers' fail-safe circuit. If some sort of mal-
function occurs, the fail-safe circuit warns the driver by lighting the ABS
warning light. At the same time, the ABS system that is experiencing the
malfunction is shut off and braking is restored to normal (non-ABS) opera-
tion.
SAPH068020300008
2. ABS CONTROL VALVES

(1) Overview
ALSO AVAILABLE WITH • The ABS control valves are positioned in the brake air circuit on the
AIR OUT OPEN-STYLE CONNECTOR
way to brake chambers. Based on signals from the ABS computer,
they adjust the air pressure sent to the brake chambers in one of three
AIR IN
modes: pressure increase, pressure reduction, or pressure mainte-
nance.
BAYONET-STYLE
CONNECTOR
SAPH068020300009
SAPH068020300010
(2) Operation
PRESSURE INCREASE a. PRESSURE INCREASE MODE
14 5 • When the driver steps on the brake pedal, air from the relay valve
VALVE OPERATING STATUS
10
enters through inlet port (6), pushes open diaphragm (5), passes
through outlet port (9), and flows into the brake chamber. At this point,
6
3
solenoid coil (1) is not energized, so solenoid valve (3) is closed and
9
pilot chamber (14) is open to the atmosphere. Also, solenoid coil (2) is
13
also not energized, so solenoid valve (4) is closed. As a result, air
passes through pilot hole (10) and enters pilot chamber (12). It then
pushes up diaphragm (11) and closes exhaust valve (13).
1
2
4 12 11
Solenoid valve for driving inlet

OFF
STATUS
valve 3
Solenoid valve for driving
OFF
exhaust valve 4
PRESSURE
Brake chamber
pressure
0 TIME
SAPH068020300011
b. PRESSURE REDUCTION MODE

PRESSURE REDUCTION
• When solenoid coil (1) is energized, solenoid valve (3) opens and air
14 5
also flows into pilot chamber (14). It pushes down on diaphragm (5),
shutting off chambers (7) and (8). At the same time, solenoid coil (2)
is also energized. This causes solenoid valve (4) to open and the
7 operating air from pilot chamber (12) passes through exhaust port
3 9 (15) and is released into the atmosphere. Consequently, the air from
8
the outlet port (9) side (brake chamber) pushes down on diaphragm
(11) and air is released into the atmosphere. This causes the air pres-
sure of the brake chamber to decrease.
1
2
12
4 15 11
ON
STATUS
valve 3
ON
exhaust valve 4
PRESSURE
Brake chamber
pressure
0 TIME
SAPH068020300012
c. PRESSURE MAINTENANCE MODE

PRESSURE MAINTENANCE
• When solenoid coil (1) is energized, solenoid valve (3) opens and air
14 5 flows through chamber (7) and acts on pilot chamber (14). On the
10 other hand, since solenoid coil (2) is not energized, solenoid valve (4)
is closed and air flows through pilot hole (10) and acts on pilot cham-
3 ber (12). This causes diaphragms (5) and (11) to shut off their air pas-
8 sages, and the chamber (8) pressure, that is to say the air acting on
the brake chamber, is maintained at the pressure that was current
when the switch from the pressure reduction mode to the pressure
maintenance mode took place.
1
2
11
12
4

ON
STATUS
valve 3
OFF
exhaust valve 4
PRESSURE
Brake chamber
pressure
0 TIME
SAPH068020300013
3. WHEEL SENSORS
These sensors are mounted, facing the sensor rings on each wheel on the
front and rear axles.
The wheel sensors are electromagnet sensors consisting of a permanent
magnet core with a coil of wire wrapped around it.
The frequency of the pulse signals generated by magnetic inductance
between the sensors and the sensor rings they face is proportional to the
rotational speed of the wheels. These pulse signals are sent to the ABS
computer and are used to determine the wheels, rotational status.
SAPH068020300014
SAPH068020300015
4. SENSOR RINGS
The sensor rings are press-fitted into the insides of the wheel hubs of each
wheel on the front and rear axles, and they face the wheel sensors
described in the preceding section. The sensor rings are made of a mag-
netic material, and teeth are cut into the surface which faces the wheel sen-
sor at regular intervals. Also, when the sensor ring performs one complete
rotation, the sensor generates pulse signals corresponding to the number
of teeth.
SAPH068020300016
5. CLAMPING BUSHINGS
The wheel sensors are held in place through friction by clamping bushings
that are inserted into the mounting brackets. If they are assembled properly,
the clamping bushings serve to eliminate the need to adjust the clearance
between the wheel sensors and sensor rings.
SAPH068020300017
6. WHEEL SENSOR HARNESSES

Each wheel sensor wire harness employs a two-conductor twisted wire
cable. Its function is to protect the wheel sensor signals, which are vital to
the proper operation of the ABS system, from electromagnetic interference.
Under no circumstances should any part of the wheel sensor wire har-
nesses be cut or connected to any other wire.
SAPH068020300018
7. ABS WARNING LIGHT

The status of the ABS system is indicated.
It lights when the starter switch is turned "ON" and automatically goes off
[USA] [CANADA]
when the system functions correctly.
or If malfunction occurs in the ABS system while the vehicle is being driven,
the light comes on to alert the driver.
However, when a defects code is eliminated after repairing it and the starter
ABS switch is turned "ON", the light will remain lit until the vehicle speed reaches
about 6 km/h {4 mile/h}.
Then, note that even when the warning light is lit, the ABS system, unaf-
fected by the malfunction, continues to operate. Also, the brake whose ABS
system experiences the malfunction is reverted to normal braking operation
SAPH068020300019 without ABS.
When a Diagnosis switch is turned "ON", this light will goes on and off,
which indicates defect code.
8. DIAGNOSIS SWITCH OF ABS SYSTEM

It is positioned at the side of diagnosis connector in the instrument panel of
driver seat front side.
By switching the starter key "ON" and pushing to "ON" this ABS diagnosis
switch, which is led to the diagnosis mode, the ABS warning light flashes on
and off to inform the trouble codes.
NOTICE
ABS diagnosis switch reverts automatically to "OFF" position.
SAPH068020300020
INSPECTION (FRONT WHEEL BRAKE)

EN0680203H300001
1. INSPECTION OF ONLY WHEEL SENSOR

(1) With a tester, measure the resistance of wheel sensor.
Standard: 900-2,000 Ω
(2) When the measured value is out of the basic standard, change the
wheel sensor as it might be considered presumably to be abnormal.
SAPH068020300021
2. INSPECTION OF THE SENSOR RING.

(1) Make a visual inspection to check for damage or deformation of the
sensor ring, and also to make sure it is not coming loose from the
wheel hub.
(2) If any damage or malformation is discovered, replace the sensor ring.
(3) If the sensor ring is coming loose from the wheel hub, use a dolly
block and press it in with a press again.
SAPH068020300022
3. INSPECTION OF THE CLAMPING BUSHING.

(1) Make sure that wheel sensor is securely fixed.
(2) Change the clamping bushing when it can be pulled off or pushed in
with a weak force.
SAPH068020300023
4. MOUNTING THE SENSOR RING

(1) Place the sensor ring on the wheel hub and use the dolly block and a
press to evenly pressure mount it.
NOTICE
Warming up the sensor ring with hot water will make it easier to pres-
sure mount it. Do not use a gas burner or the like to warm the sensor
ring. Doing so could cause malformation of the sensor ring.
(2) After pressure mounting it, check for flutter of the sensor ring in the
axle direction.
Assembly standard: Less than 0.2 mm {0.0078 in.}
SAPH068020300024
5. MOUNTING THE WHEEL HUB AND BRAKE DRUM

(1) Refer to CHAPTER, FRONT AXLE.
NOTICE
If the wheel sensors are mounted, hammering on the wheel hubs and
the like on that axle could cause internal damage to the wheel sen-
sors. Either mount the tire and then tap on the tire or tap on the wheel
hub after removing the right and left wheel sensors.
6. MOUNTING THE WHEEL SENSOR

(1) Push in the clamping bushing until the stopper makes contact with the
knuckle's wheel sensor holder.
(2) Apply a light coating of chassis grease to the hub of the wheel sensor.
Then push it forcefully into the clamping bushing until you feel that the
wheel sensor has made contact with the sensor ring.
NOTICE
When inserting the wheel sensor, do not tap on it with a hammer or
attempt to pry it into place with a screwdriver, or the like. Doing so
could damage the wheel sensor.
(3) Slowly turn the wheel hub and brake drum and confirm that they move
SAPH068020300025
smoothly.
(4) Mount the drum dust cover.
7. INSPECT THE WHEEL SENSOR

(1) Arrange the wire harness.
(2) With a circuit tester, confirm the output voltage of the wheel sensor
(By rotating the tire by one time for 2 seconds)
Standard: more than 200 mV
(Range of Alternating Current Voltage)
SAPH068020300026
INSPECTION (REAR WHEEL BRAKE)

EN0680203H300002
1. INSPECTION OF ONLY WHEEL SENSOR

(1) With a tester, measure the resistance of wheel sensor.
Standard: 900-2,000 Ω
(2) When the measured value is out of the basic standard, change the
wheel sensor as it might be considered presumably to be abnormal.
SAPH068020300027
2. INSPECTION OF THE SENSOR RING.

(1) Make visual inspection to check for damage or deformation of the
sensor ring, and also to make sure it is not coming loose from the
wheel hub.
(2) If any damage or malformation is discovered, replace the sensor ring.
(3) If the sensor ring becomes loose from the wheel hub, use a dolly
block and a press to pressure mount it again.
SAPH068020300028
3. INSPECTION OF THE CLAMPING BUSHING.

(1) Make sure that the wheel sensor is securely fixed.
(2) Change the clamping bushing when it can be pulled off or pushed in
with a weak force.
4. MOUNTING THE WHEEL SENSOR

(1) Push in the clamping bushing until the stopper makes contact with the
wheel sensor holder.
SAPH068020300029
(2) Push the wheel sensor fully in the wheel sensor holder with hands
until the wheel sensor makes contact with the clamping bushing.
NOTICE
When inserting the wheel sensor, do not tap on it with a hammer or
attempt to pry it into place using a screwdriver, or the like. Doing so
could damage the wheel sensor.
SAPH068020300030
5. MOUNTING THE SENSOR RING

(1) Place the sensor ring on the wheel hub and use the dolly block and a
press to evenly pressure mount it.
NOTICE
Warming up the sensor ring with hot water will make it easier to pres-
sure mount it. Do not use a gas burner or the like to warm the sensor
ring. Doing so could cause malformation of the sensor ring.
(2) After pressure mounting it, check for flutter of the sensor ring in the
axle direction.
Assembly standard: Less than 0.2 mm {0.0078 in.}
SAPH068020300031
6. MOUNTING THE WHEEL HUB AND BRAKE DRUM

(1) Refer to CHAPTER REAR AXLE.
NOTICE
• Be careful not to push back the wheel sensor too far when
mounting the wheel hub and brake drum. Also, make sure they
are straight so that you do not bump the tip of the wheel sensor.
• When inserting the outer hub bearing, avoid tapping on it with a
hammer as this will expose the wheel sensor to bumps. Insert
the outer hub bearing carefully with a lock nut.
7. INSPECT THE WHEEL SENSOR

(2) With a circuit tester, confirm the output voltage of the wheel sensor
(By rotating the tire by one time for 2 seconds)
Standard: more than 200 mV
(Range of Alternating Current Voltage)
(3) In case of out of the standard range at 2), remove the dust cover
located on the back plate unit. Then push the wheel sensor by using a
round end bar until the sensor contacts with the sensor ring.
NOTICE
Do not tap with a hammer or turn when pushing the wheel sensor.
This may damage the wheel sensor.
(4) Mount the axle shaft to the wheel hub and tighten the bolt on the axle
shaft.
Refer to CHAPTER, REAR AXLE.
8. ABS WIRE HARNESSES

(1) Front axle ABS wire harnesses
• The front axle chassis harnesses, particularly the ones that pass over
the front axle and extend as far as the wheel sensors, must absorb
the movement when the wheels are turned and when the springs
move. It is therefore necessary to always maintain an optimal spacing
between the clips.
In addition, if there is a large amount of variation in the spacing
between the clips, the wheel sensor harnesses can come into contact
with tire chains and sustain damage.
The wire harness for the front axle wheel sensor extends directly from
the clip on top of the king pin cover to the frame. In particular, make
sure that the distance between the clip on top of the king pin cover
and the clip on the frame side is as indicated in the diagram below.
There are markings on the wheel sensors in cases where the wheel
sensor harness clips are in locations where the relative movement is
particularly great. These places should be inspected regularly to
ensure that the clip positions are still meeting with the same marking.
SAPH068020300032
(2) Rear axle chassis harness

• The rear axle chassis harnesses is arranged so that the left and right
wheel sensor harnesses are near each other. Therefore, special care
should be taken not to make incorrect connections if the harnesses
have been removed for inspection or repairs.
If incorrect connections are made, it will interfere with the functioning
of the ABS system. For this reason, caution plates indicating "LEFT"
and "RIGHT" are affixed to the harnesses. Be sure to check when
connecting the harnesses. (The left harness is on the left side of the
vehicle when viewed from the behind and facing toward the front, and
the right harness is on the right side of the vehicle.)
The wheel sensor harnesses are arranged along the top of the rear
axle housing. Therefore, make sure to allow sufficient harness length
between the chassis and the rear axle so that the harnesses can
absorb the up-and-down motion of the rear axle.
SAPH068020300033
HANDLING WIRE HARNESSES

• The various sensors, valves, relays and wire harness connections to
the ABS computer employ multipolar harness connectors suitable for
use with the weak currents used by electronic circuitry. Be very careful
when handling them.
1. Place the starter switch on "LOCK" before unplugging the har-

ness connectors.
2. When unplugging the harness connectors, release the lock, hold

the housing and unplug it straight as much as possible.
3. Do not pull holding the wire harness or pull with excessive force.
Doing so can cause the pins of the harness connectors to be
deformed.
4. Remove unnecessary connectors and do not plug them.
5. When inspecting using a circuit tester, insert the test probe from
the wire harness side.
Never insert the test probe from the pins of harness connectors
as this can cause bad contacts.
SAPH068020300034
6. When unplugging the harness connectors, do not allow water,

oil, dust, or any other liquid or substance to get on the terminals
as they can cause bad contacts.
7. Be careful not to allow water, oil, dust, or any other liquid or sub-
stance to get on any component.
8. When plugging the harness connector, insert it completely and

confirm that the harness connector lock is engaged.
ADDITIONAL PRECAUTIONS
1. Make sure the model's starter switch is in the OFF position

before unplugging the harness connector from the ABS com-
puter.
2. Make sure to unplug all the harness connectors from the ABS
computer before performing welding on the chassis or body of
the vehicle. Also be careful that welding sputter does not get
onto the harnesses.
3. When cleaning the interior of the model, make sure water does
not get onto the ABS computer, various relays, connectors, or
any other component.
4. Use of a circuit tester

• If a circuit tester is being used, always use one with an internal resis-
tance greater than 100 kΩ inside the voltage measurement range.
5. Installation of a radio or other electronic equipment

• All electronic and radio equipment installed on the vehicle must be
mounted as far away from the ABS computer and wire harness as
possible. Installation of certain electronic and radio equipment can
also cause the ABS computer to malfunction. All such equipment
must also conform to all applicable laws. If you wish to install a radio
or other electronic equipment, please contact your Hino service repre-
sentative.
6. Quick battery charge

• When charging batteries using a quick charger, do it with both battery
terminals removed.
7. Installation of electrical equipment inside of the cab

• When installing an air conditioner or other electrical equipment inside
of the cab, be careful not to damage the engine, chassis, and wire
harnesses inside the cab. Moreover, do not forget to plug the harness
connectors unplugged during the installation.
PARKING BRAKE (BOSCH 9") BR07–1
PARKING BRAKE (BOSCH 9")

BR07
BR07-001
PARKING BRAKE ASSEMBLY ................BR07-2

DATA AND SPECIFICATIONS ......................... BR07-2
DESCRIPTION ................................................ BR07-2
TROUBLESHOOTING ..................................... BR07-4
COMPONENT LOCATOR................................ BR07-6
OVERHAUL ..................................................... BR07-8
INSPECTION AND REPAIR .......................... BR07-11
ADJUSTMENT............................................... BR07-12
BR07–2 PARKING BRAKE (BOSCH 9")
PARKING BRAKE ASSEMBLY

DATA AND SPECIFICATIONS
EN0680307I200001
Parking brake type Duo-Duty mechanical brake, internal epanding acting type
Parking brake control type Lever type control with control cable
Drum inside diameter 228.6 mm {9.0 in.}
Brake lining Width 76.2 mm {3.0 in.}
DESCRIPTION
EN0680307C100001
SAPH068030700001
1 Parking brake lever 5 Parking brake cable

2 Knob 6 Parking brake switch
3 Brake lever bracket 7 Parking brake assembly
4 Bolt 8 Knob cover (If so equipped)
SAPH068030700002

TROUBLESHOOTING
EN0680307F300001
Symptom Possible cause Remedy/Prevention

Not enough braking force Excessively large drum-to-lining clear- Readjust the lever knob.
ance.
Maladjusted control linkage. Readjust.
Burnt lining. Repair or replace.
Worn lining. Replace.
Shoes are too dirty with water, dust, Disassemble and clean.
etc.
Linings are soaked with oil. Replace.
The brake drum is cracked or heavily Replace the drum.
scored.
Lining gets burnt easily Not enough drum-to-lining clearance. Readjust.
Shoe or drum is distorted. Repair or replace.
Springs are broken. Replace.
Squeals or groans Glazed lining. Remove glaze from lining using emery
paper.
Misalignment of parts. Correct misalignment by tightening
any loose brake or drum mounting
bolts.
Dirt in drum. Remove drum and clean out lining
dust and dirt.
Worn out lining. Check for lining worn down to rim or
debris embedded in lining - replace
both shoe and lining assemblies, if
necessary.
Bent or misaligned shoe. Check for misaligned shoe rubbing
against the drum - replace both shoe
and lining assemblies, if necessary.
Clicks or noises Excessive clearance. Adjust lining to drum clearance.
Eccentric or wobbling drum. Inspect drum runout. Also check for
worn or loose bearing on main shaft.
Check drum mounting bolts for tight-
ness. Tighten as needed.
Excessive linkage friction or binding at Check linkage pivot points and cam-
camshaft ball. shaft ball for rust, binding, or lack of
lubrication. Clean and lubricate all
pivot points.
The brake shoes or backing plate is Check the brake shoes, return springs,
loose. and backing plate mounting bolts.
Tighten, repair, or replace, as needed.
There is dirt inside the brake drum. Remove the brake drum and clean it.
Also clean the other brake parts.
Cannot release the parking brake The brake cable is too tight. Adjust the brake lever knob.
The brake shoe return springs are Check the return springs. Install them
missing, detached, or broken. or replace them as needed.
The parking brake lever in the cab is Check the parking brake lever assem-
binding. bly for damage or corrosion. Repair or
replace as needed.
Water inside the cable when cold Replace the cable.
weather.

Grabbing Brake lubricant or transmission oil on Replace both shoe and lining assem-
lining. blies. Clean oil and excess brake lubri-
cation from brake and drum. Replace
faulty oil seal at main shaft.
Excessive drum runout. Reduce the drum runout to
0.015in.(0.38 mm) max. or replace
drum, if needed.
COMPONENT LOCATOR
EN0680307D100001
PARKING BRAKE LEVER
SAPH068030700003
1 Parking brake lever 5 Parking brake switch

2 Knob 6 Bolt
3 Brake lever bracket 7 Knob cover (If so equipped)
4 Clevis 8 Bolt
Tightening torque Unit: N⋅m {kgf⋅cm, lbf⋅ft}

A 42-62 {430-630, 31-46} B 1.1-1.9 {12-19, 0.9-1.4}
PARKING BRAKE
SAPH068030700004
1 Brake shoe assembly 6 Bolt

2 Support plate assembly 7 Nut
3 Shoe to shoe spring 8 Lock washer
4 Shoe return spring 9 Camshaft and lever assembly
5 Brake drum

B 110-130 {1120-1330, 81-96}* E 405-475 {4130-4840, 300-350}
C 54-65 {550-665, 40-48} F 18-26 {185-265, 13-19}
D 110-135 {1120-1380, 81-100}
*Tightening to ALLISON 2200RDS/2500RDS automatic transmission, apply Tree Bond locking agent No. TB1305.
OVERHAUL
EN0680307H200001
1. REMOVAL OF BRAKE AND DISASSEMBLY

(1) Remove the universal joint trunnion bolts, and lower the propeller
shaft to the floor (Refer to propeller shaft section).
(2) Remove the bolts that hold the drum to the companion flange, and
remove the drum.
(3) Remove companion flange.
• Remove the nut that holds the companion flange to main shaft, and
remove the companion flange (Eaton FS-4205 manual transmission).
• Remove the bolt that holds the companion flange to the main shaft,
and remove the companion flange (ALLISON 2200RDS/2500RDS
automatic transmission).
SAPH068030700005
(4) Remove the bolts that hold the parking brake assembly to the trans-
mission case, and remove the parking brake assembly with camshaft
and lever assembly.
SAPH068030700006
(5) To disassemble brake, remove the two shoe return springs and the
shoe-to-shoe spring. A spring removing tool (# Gen. 2059, or equiva-
lent) as shown in Figure A, should be used to remove the return
springs. After return springs have been removed, spread the free
ends of the shoes apart to remove the shoes from the lower anchor
pin. Remove shoe-to-shoe spring.
(6) Clean grease and dust from the brake parts. Use care to prevent
grease or oil from getting on the linings. If the linings have been con-
taminated with oil or grease, they must be replaced with new shoe
and lining assemblies.
SAPH068030700007
SAPH068030700008
2. INSPECTION OF BRAKE PARTS

(1) Inspect the springs for deformed hooks, fatigue cracks, and loss of
spring tension. The springs, when not assembled on the brake,
should not show any opening between the coils. It is recommended
that new springs be installed when shoe and lining assemblies are
replaced.
(2) Check the support plate for distortion, fatigue cracks or loose anchor
pins.
(3) Inspect the brake linings. Measure dimension between linings surface
and rivets heads. If the smallest one is less than 0.03 in. (0.8 mm),
replace both shoes and linings.
(4) Inspect the camshaft and lever assembly for fatigue cracks, worn
cams at the shoe web contact surfaces, worn camshaft ball or clevis
hole, and distorted lever.
(5) Inspect the drum for scoring, fatigue cracks or distortion.
(6) Replace any damage, broken, worn or questionable parts.
3. BRAKE LUBRICATION
(1) Coat the areas noted in Step 2 below with Lubriplate grease.
Heat resistance grease

(MIL-G-22615/23549/21164)
(NLGI No. 2 or No. 3)
! DANGER
Use only a light coating of grease at points specified. Excess grease
can melt from brake heat and drip on drum and lining surfaces. This
will cause reduced brake performance.
SAPH068030700009 (2) Lubricate brake at:
a. Camshaft lugs and ball.
b. Support plate shoe-guide lugs and shoe bearing surfaces.
c. Support plate anchor pins.
d. Contact surfaces at both ends of the shoe web. Use caution to
keep lubricant off the linings.
4. REASSEMBLY OF THE BRAKE AND REINSTALLATION

(1) Install the ends of the green shoe-to-shoe spring, into lower holes of
the brake shoe webs.
(2) Spread open upper (applying) ends of the shoes and assemble lower
ends of the shoes over shoulder of lower anchor pin with a twisting
motion of the shoes.
Insert the shoe webs between guide lugs and bearing surfaces of the
support plate, move upper ends of the shoe webs to the upper anchor
pin.
(3) With the upper ends of the shoe webs against the upper anchor pin,
install the two return springs. Install short hooks of springs into upper
SAPH068030700010
holes of the brake shoe webs and hook opposite ends of the springs
over the upper anchor pin nib. On heavy duty brakes (with red and
brown springs), springs must be installed over anchor pin nib with
open end of hooks toward centerline of brake to provide proper clear-
ance for camshaft. A spring installing tool, Bosch No. BPD-41938F4
(or equivalent tool), should be used to prevent damage to the spring.
SAPH068030700011
(4) The brake shoe assemblies must be square within 0.004 in. per inch
of lining width. Shoe assemblies that are badly out-of-square will drag
(rub against the drum) causing heat damage to the lining. Check shoe
squareness by placing the brake assembly on a flat surface, as in Fig-
ure B, and check shoe assemblies with a square as shown, or prefer-
ably with a dial indicator. To correct an out-of-square shoe, remove
shoe assemblies and bend shoe guide lug slightly in vice in direction
necessary to correct misalignment. Reassemble and recheck square-
ness. Shoe assemblies must be free to move within the slot provided
by the guide lug and the shoe bearing surfaces.
SAPH068030700012
(5) Reinstall the brake assembly to the mounting flange and align the
camshaft ball in the pivot hole of transmission rear cover, and the cam
lugs between the brake shoe webs.
The brake must be installed as a compete unit, including the cam and
lever.
a. Clean all foreign matter, nicks or burrs from the mounting surfaces
of the flange and brake support plate. The support plate must fit
snugly on the flange.
b. Coat ball and cam portions of the camshaft with Lubriplate
grease.
Heat resistance grease

(MIL-G-22615/23549/21164)
(NLGI No. 2 or No. 3)
INSPECTION AND REPAIR

EN0680307H300001
Unit: mm {in.}
Inspection item Standard Limit Remedy Inspection procedure
Brake lining: — 0.76 Replace. Measure

Lining thickness {0.03}
Brake drum: 228.6 229.3 Replace. Measure

Inside diameter1 {9.0} {9.03}
ADJUSTMENT
EN0680307H300002
1. INSTALL THE CABLE

(1) Connect the inner wire to the parking brake and fix the cable to the
cab floor with nut.
(2) Pulling up the clevis with specified force, fix the center of clevis at
specified distance A.
Pull up force: 30-70 N (3-7 kgf, 6.5-16 lbf)
Distance A: 141-144 mm (5.55-5.67 in.)
(3) Set the cable connection pin at specified distance B by turn the knob.
Distance B: 33 mm (1.3 in.)
(4) Connect the clevis to the parking brake lever.
2. ADJUST THE PARKING BRAKE LEVER

(1) Removal of the knob-cover. (If so equipped)
(2) Pull up the parking brake lever twice or more.
(3) Adjust pull up force of the parking brake lever to specified force by
turn the knob.
Pull up force: 220-270 N (22-28 kgf, 50-60 lbf)
(4) Release the parking brake lever. Turn the parking brake drum by hand
to see that the brake shoes are not dragging.
(5) Check operation, holding and releasing of the parking brake by oper-
ating the parking brake lever.
SAPH068030700015
3. BRAKE BURNISHING
(1) Burnishing of lining
When replacing lining or drum of parking brake with new parts, be
sure to perform lapping by the following procedure.
Braking force may be extremely lowered without lapping, so be sure to
perform the lapping.
NOTICE
Apply parking brake burnishing only after replacing the lining and in
an emergency when the vehicle is moving.
a. Release parking brake and turn adjusting knob until a control
force becomes to approximately 18 kgf (40lbf).
b. Mark ten (10) stops from 16 km/h (10 mph) on a dry, hard surface
road using only parking brake to stop vehicle.
c. After each stop, release parking brake and drive vehicle at 32 km/
h (20 mph) for 4 km (2.5 miles) to cool the brake.
d. After operation, adjust hand lever adjusting knob.
(2) Confirmation of parking brake application.
After completing all-brake adjustment, stop the vehicle on a safe slope
or using a brake tester, confirm whether the parking brake is securely
applied.
PARKING BRAKE (MERITOR 10" & 12") BR07–1
PARKING BRAKE (MERITOR 10" & 12")

BR07
BR07-002
PARKING BRAKE ASSEMBLY ................BR07-2

DATA AND SPECIFICATIONS ......................... BR07-2
DESCRIPTION ................................................ BR07-2
TROUBLESHOOTING ..................................... BR07-3
COMPONENT LOCATOR................................ BR07-5
OVERHAUL ..................................................... BR07-7
INSPECTION AND REPAIR .......................... BR07-11
ADJUSTMENT............................................... BR07-12
BR07–2 PARKING BRAKE (MERITOR 10" & 12")
PARKING BRAKE ASSEMBLY

EN0680407I200001
10" x 3" Model 12" x 3" Model
Parking brake type Duplex Cam mechanical brake, internal expanding acting type
Parking brake control type Lever type control with control cable
Drum inside diameter 254.0 mm {10.0 in.} 304.8 mm {12.0 in.}
Brake lining Width 76.2 mm {3.0 in} Width 76.2 mm {3.0 in}
DESCRIPTION
EN0680407C100001
SAPH068040700001

SAPH068040700002

TROUBLESHOOTING
EN0680407F300001

Not enough braking force Excessively large drum-to-lining clear- Readjust the lever knob.
ance.
Maladjusted control linkage. Readjust.
Burnt lining. Repair or replace.
Worn lining. Replace.
Shoes are too dirty with water, dust, Disassemble and clean.
etc.
Linings are soaked with oil. Replace.
The brake drum is cracked or heavily Replace the drum.
scored.
Lining gets burnt easily Not enough drum-to-lining clearance. Readjust.
Shoe or drum is distorted. Repair or replace.
Springs are broken. Replace.

Squeals or groans Glazed lining. Remove glaze from lining using emery
paper.
Misalignment of parts. Correct misalignment by tightening
any loose brake or drum mounting
bolts.
Dirt in drum. Remove drum and clean out lining
dust and dirt.
Worn out lining. Check for lining worn down to rim or
debris embedded in lining - replace
both shoe and lining assemblies, if
necessary.
Bent or misaligned shoe. Check for misaligned shoe rubbing
against the drum - replace both shoe
and lining assemblies, if necessary.
Clicks or noises Excessive clearance. Adjust lining to drum clearance.
Eccentric or wobbling drum. Inspect drum runout. Also check for
worn or loose bearing on main shaft.
Check drum mounting bolts for tight-
ness. Tighten as needed.
Excessive linkage friction or binding at Check linkage pivot points and cam-
camshaft ball. shaft ball for rust, binding, or lack of
lubrication. Clean and lubricate all
pivot points.
The brake shoes or backing plate is Check the brake shoes, return springs,
loose. and backing plate mounting bolts.
Tighten, repair, or replace, as needed.
There is dirt inside the brake drum. Remove the brake drum and clean it.
Also clean the other brake parts.
Cannot release the parking brake The brake cable is too tight. Adjust the brake lever knob.
The brake shoe return springs are Check the return springs. Install them
missing, detached, or broken. or replace them as needed.
The contact points between the brake Check the area, and clean and lubri-
shoe webs and the actuator strut are cate as needed.
corroded or dirty (MERITOR brake).
The parking brake lever in the cab is Check the parking brake lever assem-
binding. bly for damage or corrosion. Repair or
replace as needed.
Water inside the cable when cold Replace the cable.
weather.
Grabbing Brake lubricant or transmission oil on Replace both shoe and lining assem-
lining. blies. Clean oil and excess brake lubri-
cation from brake and drum. Replace
faulty oil seal at main shaft.
Excessive drum runout. Reduce the drum runout to
0.015in.(0.38 mm) max. or replace
drum, if needed.
COMPONENT LOCATOR
EN0680407D100001
PARKING BRAKE LEVER
SAPH068040700003
1 Parking brake lever 5 Parking brake switch

2 Knob 6 Bolt
3 Brake lever bracket 7 Knob cover (If so equipped)
4 Clevis 8 Bolt

A 42-62 {430-630, 31-46} B 1.1-1.9 {12-19, 0.9-1.4}
PARKING BRAKE
SAPH068040700004
1 Brake drum 7 Backing plate

2 Shoe return spring 8 Bolt
3 Brake shoe assembly 9 Nut
4 Actuator strut 10 Lock washer
5 Lever 11 Washer
6 Cam

B 110-132 {1120-1350, 81-97} F 645-710 {6570-7240, 475-525}
C 48-68 {490-690, 35-50} G 54-65 {550-665, 40-48}
D 110-135 {1120-1380, 81-100} H 160-225 {1630-2290, 120-165}
E 18-26 {185-265, 13-19}
OVERHAUL
EN0680407H200001
REMOVAL
1. REMOVAL OF THE 10" x 3" PARKING BRAKE

MODEL HINO 145 (NA6J), HINO 165 (NB6J), HINO 185 (NC6J)
EQUIPPED WITH AISIN 450 AUTOMATIC TRANSMISSION
(1) Remove the nuts that hold the propeller shaft flange yoke and remove
the flange yoke, then lower the propeller shaft to the floor (Refer to
propeller shaft section of this manual).
(2) Remove the bolts that hold the drum to the companion flange, and
remove the drum.
(3) Remove companion flange.
Remove the nut that holds the companion flange to main shaft, and
remove the companion flange. (Refer to automatic transmission sec-
tion of this manual).
SAPH068040700005 (4) Remove the bolts that hold the parking brake assembly to the trans-
mission case, and remove the parking brake assembly.
2. REMOVAL OF THE 12 x 3" PARKING BRAKE

MODEL HINO 238 (ND8J), HINO 368 (NE8J), HINO 308 (NF8J)
EQUIPPED WITH Eaton FS5406 MANUAL TRANSMISSION
(1) Remove the nuts that hold the propeller shaft flange yoke and remove
the flange yoke and brake drum to companion flange, then lower the
propeller shaft to the floor (Refer to propeller shaft section).
(2) Remove the drum.
(3) Remove the nut that holds the companion flange to main shaft, and
remove the companion flange.
(4) Remove the bolts and nuts that hold the parking brake assembly to
the transmission case, and remove the parking brake assembly.
SAPH068040700006
DISASSEMBLY
1. DISASSEMBLE DCM BRAKE
! WARNING
• Some brake linings contain asbestos fibers, a cancer and lung
disease hazard. Some brake linings contain non-asbestos fibers,
whose long-term effects to health are unknown. You must use
caution when you handle both asbestos and non-asbestos mate-
rials.
• To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
• Block the wheels to prevent the vehicle from moving. Support
SAPH068040700007 the vehicle with safety stands. Do not work under a vehicle sup-
ported only by jacks. Jacks can slip and fall over. Serious per-
sonal injury can result.
(1) Make sure the vehicle is on a level surface.
(2) Place blocks under the wheels not being serviced to keep the vehicle
from moving.
(3) Raise the vehicle so that the wheels to be serviced are off the ground.
Support the vehicle with safety stands.
(4) Disconnect the drive shaft using standard procedures.
(5) Release the brake.
(6) Remove the brake drum using standard procedures.
(7) Remove the nut and washer that hold the cam to the lever.
(8) Remove the cam and the lever.
(9) Use a brake shoe return spring removal tool to remove the two or four
brake shoe return springs from the ends of the brake shoes. Discard
the springs and replace them with new springs at assembly.
(10) Remove both brake shoes and mark them to identify their original
position at assembly.
(11) Remove the actuator strut.
NOTICE
Make a note of how the brake backing plate is mounted. Use the posi-
tion of the cam as the reference point.
(12) If complete disassembly is necessary, remove the four brake backing
plate capscrews and washers.
(13) Clean and inspect all parts.
2. CLEAN GROUND OR POLISHED PARTS

! WARNING
• To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance or service.
• If you use cleaning solvents, hot solution tanks or alkaline solu-
tions incorrectly, serious personal injury can occur. To prevent
serious personal injury, follow the instructions supplied by the
manufacturer of these products. Do NOT use gasoline to clean
parts. Gasoline can explode and cause serious personal injury.
! CAUTION
• Do not use cleaning solvents on hydraulic seals, boots or pis-
tons. Cleaning solvents can damage these components. Protect
the brake lining from solvents, lubricants, rust inhibitors, or
other contaminants of that can change the friction properties of
the lining. Contaminated linings MUST be replaced.
• Use only solvent cleaners to clean ground or polished metal
parts. Hot solution tanks or water and alkaline solutions will
damage these parts. Isopropyl alcohol, kerosene or diesel fuel
can be used for this purpose.
• If required, use a sharp knife to remove gasket material from
parts. Be careful not to damage the ground or polished surfaces.
(1) Use a cleaning solvent to clean ground or polished parts and sur-
faces. Kerosene or diesel fuel can be used for this purpose. DO NOT
USE GASOLINE.
(2) DO NOT clean ground or polished parts in a hot solution tank or with
water, steam or alkaline solutions. These solutions will cause corro-
sion of the parts.
3. CLEAN PARTS WITH ROUGH FINISHES

(1) Rough parts can be cleaned with the ground or polished parts.
(2) Rough parts also can be cleaned in hot solution tanks with a weak
alkaline solution.
(3) Parts must remain in the hot solution tanks until they are completely
cleaned and heated.
4. DRY CLEANED PARTS

(1) Parts must be dried immediately after they are cleaned.
(2) Dry parts with clean paper or rags, or compressed air.
5. PREVENT CORROSION AND RUST ON CLEANED PARTS

(1) Apply axle lubricant to the cleaned and dried metal parts that are to
be immediately assembled.
(2) If parts are to be stored, apply a special material that prevents rust
and corrosion to all surfaces.
INSPECTION
1. INSPECT PARTS
It is important that you carefully inspect all parts before assem-
bly starts. Check all parts for wear or damage and repair or
replace them as required. Replacement of these parts now can
prevent problems with assembly later.
(1) Check all castings and backing plates for cracks, loose rivets and cor-
rect alignment. Replace all damaged parts.
(2) Check all adjusting bolts, guide pins and pawl pins for corrosion and
wear. Replace or repair damage parts.
Check brake shoes for rust, expanded rivet holes, broken welds and
correct alignment. Replace damaged shoed.
(3) Check anchors, anchor pins and shoe bushings for wear or damage.
Replace as necessary.
(4) Replace all shoe return springs at time of brake overhaul.
(5) Check the brake drums for cracks, severe heat checking, heat spot-
ting, scoring, pitting and distortion. Replace damaged brake drums.
2. MINOR INSPECTION: MECHANICAL BRAKES

(1) Check lining wear. Lining wear must be even on both shoes.
(2) Check the lining to brake drum contact pattern. Contact must be the
same on both shoes.
(3) Check the operation of the brake by actuating and releasing the brake
control and observing the actuation and release.
(4) Check the brake adjustment.
3. MAJOR INSPECTION: MECHANICAL BRAKES

Major inspection must be made at every reline and when there is
poor brake performance.
(1) Check all the points described in the minor inspection procedures.
(2) Check for worn or corroded areas where components contact or slide
against each other.
(3) Replace all shoe return springs.
(4) Check the cam (if used) for wear, rust, bending and seizing.
(5) Check the actuator lever for rest, bending, seizing or other damage.
(6) Check the spider or backing plate for looseness and elongated mount-
ing holes.
(7) Check for loose or broken lining rivets.
(8) Check for grease or oil on the lining. DO NOT reuse contaminated lin-
ings.
(9) Check the brake shoes for bending and rust.
(10) Check the actuator pawl, if used, for wear and correct alignment.
(11) Check the brake drums for wear and damage.
(12) Before assembly, lubricate the sliding parts with a thin layer of Meritor
specification 0-661 brake lubricant such as Texaco Thermatex EP-2
grease or equivalent listed on page BR07-10
ASSEMBLY
1. ASSEMBLE DCM BRAKE
! CAUTION
Do not permit grease to contact the brake drum or linings. Grease on
the linings can cause poor brake performance. Contaminated linings
MUST be replaced.
(1) Before assembly, apply a thin layer Meritor specification 0-616 brake
lubricant such as Texaco Thermatex EP-2 grease or equivalent (listed
on below) to the following parts:
a. Cam head face and journals.
b. Both sides of the backing plate at the cam hole.
SAPH068040700008
(2) If it was removed, install the brake backing plate in the dame position
as marked in Step 10 of the Disassembly Section. Tighten the four
capscrews to the specifications set by the OEM.
(3) Install the brake shoes in the same position as marked in Step 8 of the
Disassembly Section with the web ends in position on the backing
plate bosses.
(4) Use a brake shoe installation tool to install the four new brake shoe
return spring at the ends of the brake shoes.
(5) Assemble the cam through the backing plate, lever, lock washer and
nut. Tighten the nut to give an end play of 0.001" to 0.010" (0.025-
0.254 mm) as measured with a feeler gauge between the backing
plate and the lever.
(6) Install the actuator strut with the pressure points against the shoe web
pressure points and the cam head in position in the slot of the strut.
(7) Assemble the brake drum and drive shaft using standard procedures.
LUBRICATION
Meritor Specification 0-616:
Standard Oil of Ohio Sohio #101
Texaco Thermatex EP-2


EN0680407H300001
Unit: mm {in.}
Brake lining: — 0.8 Replace. Measure

Lining thickness {0.03}
Brake drum: 10" x 3" 254 254.8 Replace. Measure

Inside diameter brake {10} {10.035}
12" x 3" 304.8 305.6 Replace.

brake {12} {12.035}
ADJUSTMENT
EN0680407H300002
1. INSTALL THE CABLE

(1) Connect the inner wire to the parking brake and fix the cable to the
cab floor with nut.
(2) Pulling up the clevis with specified force, fix the center of clevis at
specified distance A (See figure on page BR07-6).
Pull up force: 175-215 N (18-22 kgf, 39-48 lbf)
Distance A: 141-144 mm (5.55-5.67 in.)
(3) Set the cable connection pin at specified distance B (See figure on
page BR07-6) by turning the knob.
Distance B
10" x 3" parking brake and AISIN A450 ATM
B = 49 mm (1.93 in.)
12" x 3" parking brake and Eaton FS5406 MTM
B = 63 mm (2.48 in.)
(4) Connect the clevis to the parking brake lever.
2. ADJUST THE PARKING BRAKE LEVER

(1) Removal of the Knob-cover. (If so equipped)
(2) Pull up the parking brake lever twice or more.
(3) Adjust pull up force of the parking brake lever to specified force (See
SAPH068040700011
below) by turning the knob.
Pull up force
10" x 3" parking brake and AISIN A450 ATM
220-270 N (22-28 kgf, 50-60 lbf)
12" x 3" parking brake and Eaton FS5406 MTM
320-370 N (33-38 kgf, 72-83 lbf)
(4) Release the parking brake lever. Turn the parking brake drum by hand
to see that the brake shoes are not dragging.
(5) Check operation, holding and releasing of the parking brake by oper-
ating the parking brake lever.
3. BRAKE BURNISHING
(1) Burnishing of lining
When replacing lining or drum of parking brake with new parts, be
sure to perform lapping by the following procedure.
Braking force may be extremely lowered without lapping, so be sure to
perform the lapping.
NOTICE
Apply parking brake burnishing only after replacing the lining and in
an emergency when the vehicle is moving.
a. Release parking brake and turn adjusting knob until a control
force becomes approximately 18 kgf (40lbf).
b. Mark ten (10) stops from 16 km/h (10 mph) on a dry, hard surface
road using only parking brake to stop vehicle.
c. After each stop, release parking brake and drive vehicle at 32 km/
h (20 mph) for 4 km (2.5 miles) to cool the brake.
d. After operation, adjust hand lever adjusting knob.
(2) Confirmation of parking brake application.
After completing all-brake adjustment, stop the vehicle on a safe slope
or using a brake tester, confirm whether the parking brake is securely
applied.
STEERING EQUIPMENT SR01–1
STEERING EQUIPMENT
SR01
SR01-001
STEERING SYSTEM................................. SR01-2

TROUBLESHOOTING ..................................... SR01-2
SR01–2 STEERING EQUIPMENT
STEERING SYSTEM
TROUBLESHOOTING
EN07Z1101F300001

Hard steering or poor return of Bent steering shaft, sliding shaft or col- Replace parts.
steering wheel to center umn
Universal joint oscillates or catches. Replace universal joint in the assem-
bly.
Column bearing does not revolve or Replace parts.
catch.
Lack of lubrication in steering linkage. Lubricate.
Wheel alignment is incorrect. Refer to chapter FRONT AXLE.
Power steering system is faulty. Refer to chapter POWER STEERING.
Tire air pressure is too low. Adjust properly.
Steering wheel shimmy Steering system linkage is loose. Tighten properly.
Too much wear or play in steering link- Replace parts.
age (spline and ball joints).
Other front axle problems. Refer to chapter FRONT AXLE.
Power steering gear badly adjusted. Refer to chapter POWER STEERING.
The wheels are out of balance. Balance the wheels.
Wheel wobbles. Replace wheel.
Tire air pressure is not uniform or suffi- Adjust tire pressure.
cient.
Distorted disc wheel. Replace parts.
Abnormal noises Lack of lubrication in steering linkage. Lubricate.
Power steering system is faulty. Refer to chapter POWER STEERING.
STEERING UNIT SR02–1
STEERING UNIT
SR02
SR02-001
STEERING LINKAGE ............................... SR02-2

DESCRIPTION ................................................ SR02-2
COMPONENT LOCATOR................................ SR02-3
SPECIAL TOOL ............................................... SR02-4
OVERHAUL ..................................................... SR02-4
INSPECTION AND REPAIR ............................ SR02-9
SR02–2 STEERING UNIT
STEERING LINKAGE
DESCRIPTION
EN07Z0702C100001
SAPH07Z070200001
1 Steering wheel 5 Steering gear unit

2 Horn button 6 Pitman arm
3 Steering column assembly 7 Drag link
4 Dust cover
COMPONENT LOCATOR
EN07Z0702D100001
SAPH07Z070200002
1 Steering wheel 8 Steering column assembly

2 Horn button 9 Dust seal
3 Combination switch body 10 Steering shaft universal joint assembly
4 Spiral cable 11 Dust cover
5 Windshield wiper switch 12 Lubrication fitting
6 Light control switch 13 Column upper cover
7 Nut 14 Column lower cover

A 48.5-77.5 {500-800, 37-57}
SPECIAL TOOL
EN07Z0702K100001
Prior to starting a steering linkage overhaul, it is necessary to have these special tools.
Illustration Part number Tool name Remarks
09650-1341 STEERING WHEEL PULLER
09650-1260 PITMAN ARM PULLER
OVERHAUL
EN07Z0702H200001
IMPORTANT POINTS - DISASSEMBLY
1. REMOVE THE STEERING WHEEL.

(1) Loosen the torx bolt for fixing the horn button using torx wrench.
(2) Remove the horn button from the steering wheel.
SAPH07Z070200005
(3) Remove the connector for the horn.
CONNECTOR FOR HORN
SAPH07Z070200006
(4) Remove the steering wheel lock nut.

(5) Use the special tool or commercial tool to remove the steering wheel
as shown in the figure.
SST: Steering Wheel Puller (09650-1341)
NOTICE
• Before removing the steering wheel from the steering shaft,
make aligning marks on both so that they can be assembled in
the same position.
• Because the puller hole is made of aluminum and it is easily
damaged, screw the puller bolt deeply.
SAPH07Z070200007 (6) Fix the rotating part of spiral cable with tape etc. to prevent the spiral
cable from rotating.
2. REMOVE THE PITMAN ARM.

(1) Remove the nut and pinch bolt from the pitman arm.
(2) Using the special tool, remove the pitman arm from the sector shaft.
SST: Pitman Arm Puller (09650-1260)
SAPH07Z070200008
IMPORTANT POINTS - ASSEMBLY
1. ASSEMBLE THE STEERING SHAFT.
2. INSTALL THE DUST BOOT.
3. ASSEMBLE THE STEERING SHAFT.

(1) Before assembling, apply chassis grease to the spline of the sliding
yoke, and after assembling also fill grease through lubrication fitting.
When replacing parts: 240 g (8.8 oz)
When replenishing parts: 15 g (0.5 oz)
SAPH07Z070200009
NOTICE
When assembling, take care not to damage the steering shaft spline.
Apply chassis grease to the boundary of the dust boot and steering
shaft.
4. INSTALL THE STEERING WHEEL.

CONNECTOR FOR HORN
(1) Set front axles toward rectilinear direction.
LOCK PIN (NEW)
(2) When spiral cable is new, make sure that the lock pin is seated in the
spiral cable assembly and the seal is not cut. When spiral cable is
reused, make sure that the neutral position of the spiral cable does
SEAL (NEW) not get out of position.
SPIRAL
CABLE
FRONT
SAPH07Z070200010
NOTICE
When there is no lock pin though the spiral cable is new, or when the
seal is cut though there is a lock pin, or when the neutral position of
the spiral cable gets out of position in reuse, turn the spiral cable
counterclockwise lightly. And turn it back clockwise by 4 rotations at
the point of beginning of the hard steering. Then match the neutral
position marks on the upper side of the spiral cable assembly.
(3) Pass the spiral cable through the steering wheel opening area and set
the steering wheel straight to install it with nut. When the spiral cable
is new, remove the lock pin. When it is reused, remove the tape etc.
NEUTRAL POSITION MARK
for fixing the rotation of the spiral cable.
SAPH07Z070200011
(4) Tighten the set screw for fixing the horn button after pushing it in by
using a torx wrench.
Tightening Torque:
6.5-13.5 N⋅m {66-138, 4.8-9.9 kgf⋅cm}
SAPH07Z070200012
5. IF NECESSARY, REPLACE THE DRAG LINK DUST SEAL.

(1) Press or tap on the flanged foot portion of the seal to remove it from
the socket assembly. If you use a screwdriver to loosen the seal, be
careful not to damage the sealing face of the socket forging.
SAPH07Z070200013
(2) Wipe off all grease and foreign material from around the ball stud and
socket throat. Do not use any type of cleanser to remove the grease.
SAPH07Z070200014
(3) Using #2 NLGI extreme pressure, lithium-based, moly-filled,

heavy duty grease, grease the socket throat and stud ball. Then fill
the new boot seal 3/4 full with the same grease.
SAPH07Z070200015
(4) Position the socket assembly in a large vise, or on a press so that the
ball stud is perpendicular to the socket stem.
SAPH07Z070200016
(5) Press on the new boot seal using the tool described on below. The
seal is in place when the flanged portion is seated on the machined
section (sealing face) of the socket forging.
TOOL REQUIRED: A section of tubing with the inside diameter as
close to the outside diameter of the boot seal (middle section) as pos-
sible.
The inside corner of the tube should be radiused (rounded) or cham-

fered (angled) so it will not cut the rubber during the press-on opera-
tion.
! CAUTION
SAPH07Z070200017
DO NOT over-press the seal; over-pressing could cause it to deform
and seal improperly. DO NOT use a screwdriver, chisel, punch, etc. on
the flanged foot of the seal for installation.
6. INSTALL THE PITMAN ARM.

(1) Align the marks on the pitman arm and sector shaft.
(2) Spread open the split end of the arm. Push the arm.
(3) Install the pinch bolt and nut. Tighten the nut specified torque.
Tightening Torque:
Model: HINO 145, 165, 185 (NA, NB, NC): 220-250 N⋅m {2,244-
2,551 kgf⋅cm, 162-184 lbf⋅ft}
Model: HINO 238, 258, 268, 308, 338 (ND, NE, NF, NV): 375-415
N⋅m {3,827-4,235 kgf⋅cm, 277-306 lbf⋅ft}
NOTICE
In case of reusing bolt or nut, apply oil to the nut contact surface and
SAPH07Z070200018
thread.
7. INSTALL THE DRAG LINK.

(1) Connect the drag link with the pitman arm and with the knuckle arm.
NOTICE
• At this time, make sure that the arrow "FRONT" or numeral on
the drag link is positioned toward the front of vehicle.
• When handling the drag link, take care not to damage the dust
seal.
(2) Tighten the slotted nuts of the ball studs at both ends of the link to the
specified torque, and then secure the nuts with the cotter pins.
Tightening Torque:
SAPH07Z070200019 Model: HINO 145, 165, 185 (NA, NB, NC): 95-115 N⋅m {969-1,173
kgf⋅cm, 70-85 lbf⋅ft}
Model: HINO 238, 258, 268, 308, 338 (ND, NE, NF, NV): 136-170
N⋅m {1,388-1,735 kgf⋅cm, 100-125 lbf⋅ft}
NOTICE
When algining the castlenut cut parts with the cotter pin fitting hole,
make it by turning the nut to torque in the increasing direction. Don't
turn in the decreasing direction.
8. INSPECT THE STEERING SYSTEM FOR OPERATING ABILITY.

(1) Place the front wheels on turn tables.
(2) Make sure that the steering wheel turns smoothly without any jolts or
abnormal resistance when the steering wheel is turned full range.
SAPH07Z070200020
(3) Check the steering wheel free play while engine is idling.
FREE PLAY Wheel Free Play: 0-35 mm {0-1.377 in.}
(4) If wheel free play exceeds 0-35 mm {0-1.377 in.}, turn the set screw
clockwise to decrease wheel free play and counterclockwise to
increase it.
! WARNING
Excessive steering wheel free play may adversely affect vehicle han-
dling. This can result in personal injury and/or property damage.
SAPH07Z070200021
(5) Measure the steering wheel turning force. Use a spring balancer to
measure the steering wheel turning force.
NOTICE
Measure the steering wheel turning force while the engine is idling.
Turning force:20 N {2.0 kgf, 4.4 lbf}
SAPH07Z070200022
(6) The steering wheel must be locked securely in any position up, down,
forward and backward.
! WARNING
Before moving the vehicle, tighten the lever securely and try to move
the steering wheel up and down, and forward and backward to make
sure that it is locked securely. Never try to adjust the steering wheel
position while the vehicle is moving. Any adjustment of the steering
wheel while driving can cause the driver to lose control, and result in
personal injury and/or property damage.
(7) Check to see that the combination switch is operating properly.
SAPH07Z070200023

EN07Z0702H300001
Unit: mm {in.}
Steering wheel: — — Replace, if neces- Visual check

Cracks, distortion and sary.
damage
Steering wheel serration: — — Replace, if neces- Visual check

Wear and damage sary.
Steering column assem- — — Replace, if neces- Visual check

bly: Bent, oscillation and sary
cracks
Drag link: Cracks and dam- — — Replace the Visual check

age whole drag link
Ball joint: Play assembly or
Dust seal: Damage replace only dust
cover.
Pitman arm internal splines — — Replace, if neces- Visual check

for: sary
• severe wear, corro-
sion and fretting
• twisted splines
• missing splines
! WARNING
If twisted or missing splines are found, be sure to inspect all internal
steering gear components carefully for signs of impact damage. Fol-
low the procedure in the chapter power steering gear unit.
POWER STEERING SR03–1
POWER STEERING
SR03
SR03-001
POWER STEERING GEAR UNIT ............. SR03-2

DATA AND SPECIFICATIONS ......................... SR03-2
DESCRIPTION ................................................ SR03-3
OPERATION .................................................... SR03-4
COMPONENT LOCATOR................................ SR03-6
TORQUE CHART ............................................ SR03-8
HAZARD WARNING DEFINITIONS ................ SR03-8
DISCLAIMER ................................................... SR03-9
PATENTS ......................................................... SR03-9
MAINTENANCE TIPS...................................... SR03-9
ON-VEHICLE SERVICE ................................ SR03-11
RESEAL & REPAIR ....................................... SR03-21
SR03–2 POWER STEERING
POWER STEERING GEAR UNIT

EN07Z0703I200001
HINO 145, 165, 185 HINO 238, 258, 268, 308, 338
Vehicle model
(NA6J, NB6J, NC6J) (ND8J, NE8J, NJ8J, NF8J, NV8J)
Manufacture TRW Automotive
Power steering gear unit model TAS40 TAS65
Type Integral hydraulic power steering gears
Gear ratio 20.4
NOTICE
• Poppet valve adjustment is needed when the following occurs.
(1) Reducing the turning angle.
(2) Reducing the toe in.
• Readjustment
Refer to [Poppet Readjustment-Single Gears] part on page SR03-17 and the following parts are needed.
Poppet adjusting screw and lock nut assembly.
TRW CSS part number 021407X1
SAPH07Z070300001
DESCRIPTION
EN07Z0703C100001
3
4
2
SAPH07Z070300002
1 Rotary Valve This device provides responsive steering control.

These unloading valves are automatically set to furnish power steering pump protec-
2 Poppets (optional)
tion and reduce pressure to unload steering linkage at vehicle axle stop settings.
3 Recirculating Balls Combine high mechanical efficiency with smooth operation.
4 Dirt & Water Seals Lip-type seals on both input and output shafts.
5 Torsion Bar Provides positive valve centering with definitive "feel of the road".
SR03-001.fm 4 ページ２００６年２月２０日　月曜日　午前９時１５分
OPERATION
EN07Z0703C100002
Left Hand Lead Right Hand Lead
Right Hand Turn
Steering Wheel Input:

Clockwise Rotation
Straightline Running
No Steering Action
Left Hand Turn
Steering Wheel Input:

Counter-Clockwise Rotation
Supply Pressure
Return Pressure
SAPH07Z070300003
APPROVED HYDRAULIC FLUIDS

Automatic Transmission Fluid Dexron II Mobil ATF 210
Automatic Transmission Fluid Type "E" or "F" Mobil Super 10W-40 Motor Oil
Chevron 10W-40 Premium Blue 2000-SAE 15W-40
Chevron Custom 10W-40 Motor Oil *Shell Rotella T30W
Chevron Torque 5 Fluid *Shell Rotella T SAE 30
Exxon Nuto H32 Hydraulic Fluid Texaco 10W-40
Fleetrite PSF (Can #990625C2) Texaco TL-1833 Power Steering Fluid
Ford Spec. M2C138CJ Union 10W-40
Mack EO-K2 Engine Oil Union 15W-40
Unocal Guardol 15W-40 Motor Oil
The steering system should be kept filled with one of the above fluids. Fluids marked with an asterisk (*) have not been
approved for use with TRW's pump.
! WARNING
Completely flush the steering system with one of the recommended fluids above only. Do not mix oil types. Any mix-
ture or any unapproved oil could lead to seal deterioration and leaks. A leak could ultimately cause the loss of fluid,
which could result in a loss of power steering assist.
SPECIFICATION NUMBERS
The steering gear

specification number and
date code are stamped on a
machined surface opposite
the input shaft of every TAS
gear. Newer gears include a
serial number.
Spec. No Step Bore Identifier An example date code
TAS65001A would be 29097; this means
29097S01B27
the gear was built on the
Date Code Serial Number 290th day of 1997.
An "A" included at the end of

the specification number
indicates a step bore
housing.
SAPH07Z070300004
COMPONENT LOCATOR
EN07Z0703D100001
TAS SERIES EXPLODED VIEW
1. STEP BORE
48
47
49
46
41
45
42
59/60
52/53 63
52A 41
37
34
22
61 23A
24
26
23A
27
22
28
29
30 19
31 21
20
18
17
9
8
16
15
13
56
15 57
12 58
34
11
10
Short "V" Construction 9
8
7
31 6
32
28 5
27
54/55 4
3
2
20
21
1
19
SAPH07Z070300005
1 Bolts (4-Valve Housing) *31 Torx Screws (2-Cap/Strap)

*2 Dirt and Water Seal *32 Ball Return Guide Strap
*3 Retaining Ring 34 Housing
*4 Seal (Input Shaft) 35 Grease Fitting
5 Valve Housing 37 Roller Bearing
*6 Seal Ring (Valve Housing) *41 Seal (2-Output)
*7 Seal Ring (Valve Housing) 42 Sector Shaft
*8 Seal Ring (2) 43 Adjusting Screw (Sector Shaft)
*9 O-ring (2) 44 Retainer (Adjusting Screw)
*10 Seal Ring *45 Gasket (Side Cover)
*11 O-ring (Valve Housing) 46 Side Cover Assembly
12 Thrust Washer (Thick) 47 Jam Nut
13 Input Shaft, Valve, Worm Assy. 48 Special Bolts (6 or 8-Side Cover)
15 Thrust Bearing (1 or 2) *49 Vent Plug (Side Cover)
16 Thrust Washer (Thin) 50 Bleed Screw (Manual)
17 Bearing Adjuster 51 Plug (Auto Bleed)
*18 Adjuster Locknut 52 Fixed Stop Screw (Poppet)
19 Rack Piston 52A Fixed Stop Screw (Poppet-Alt)
*20 Teflon Seal Ring 53 Washer (Stop Screw)
*21 O-ring (Back up; Rack Piston) 54 Auxiliary Port Plug (2)
22 Poppet Seat and Sleeve Assy. (2) *55 O-ring (2-Aux. Port Plug)
23 Poppet (2) 56 Relief Valve Cap
24 Poppet Spring *57 O-ring (Relief Valve)
26 Push Tube 58 Relief Valve (2 piece)
27 Balls 59 Service Poppet Adjusting Screw
28 Ball Return Guide Halves (2) 60 Service Sealing Jam Nut
*29 Seal (Cap) *61 Dirt & Water Seal (Trunnion)
30 Ball Return Guide Cap 63 Retaining Ring
TORQUE CHART
EN07Z0703A200001
Part Name Item # Torque Range Dry Torque Range Lubricated

Auxiliary cylinder plug 54 25-35 lbf⋅ft (34-48 N⋅m)
Ball return guide cap/strap bolts 31 31 14-22 lbf⋅ft (19-29 N⋅m)
Bearing adjuster 17 11-15 lbf⋅ft (15-20 N⋅m)*
Locknut 18 101-122 lbf⋅ft (137-165 N⋅m)**
Manual bleed screw 50 40-50 lbf⋅in. (3.1-3.7 N⋅m)
Plug, auto bleed 51 38-58 lbf⋅ft (52-79 N⋅m)
Poppet sleeve assembly 22 16-20 lbf⋅ft (22-27 N⋅m)
Poppet sealing nut, service 60 33-37 lbf⋅ft (45-50 N⋅m)
Poppet fixed stop screw 52 38-42 lbf⋅ft (52-57 N⋅m)
Poppet fixed stop screw 52A 38-58 lbf⋅ft (52-79 N⋅m)
Relief valve cap 56 25-35 lbf⋅ft (34-48 N⋅m)
Sector shaft adjusting screw jam
47 40-45 lbf⋅ft (54-61 N⋅m)
nut
Side cover bolts (TAS40) 48 108-128 lbf⋅ft (147-174 N⋅m)
Side cover bolts (TAS55, 65, 85) 48 160-180 lbf⋅ft (217-244 N⋅m)
Valve housing bolts (TAS40, 55, 65) 1 75-85 lbf⋅ft (102-115 N⋅m)
Valve housing bolts (TAS85) 1 108-128 lbf⋅ft (147-174 N⋅m)
* After tightening to this torque value, the adjuster must be backed off 1/4 to
1
/2 of a turn as described in step (24) on page SR03-49.
**Torque value indicated is using recommended tools.
Special tools can be purchased through:

SPX Corporation
Kent-Moore Tool Group
28635 Mound Road
Warren, MI 48092
1-800-328-6657
HAZARD WARNING DEFINITIONS

EN07Z0703A100001
! WARNING
A warning describes hazards or unsafe practices which could result
in severe personal injury or death.
! CAUTION
A caution describes hazards or unsafe practices which could result in
personal injury or product or property damage.
NOTICE
A note gives key information to make following a procedure easier or
quicker.
DISCLAIMER
EN07Z0703A200002
This Service Manual has been prepared by TRW Commercial Steering

Division for reference and use by mechanics who have been trained to
repair and service steering components and systems on heavy commercial
vehicles. TRW Commercial Steering Division has exercised reasonable
care and diligence to present accurate, clear and complete information and
instructions regarding the TRW Commercial Steering TAS Series Integral
Power Steering Gears. Since this is a general Service Manual, the photo-
graphs and illustrations may not look exactly like the steering gear being
serviced. The procedures, therefore, must be carefully read and under-
stood before servicing.
If inspection or testing reveals evidence of abnormal wear or damage to the

TAS steering gear or if you encounter circumstances not covered in the
Manual, Stop-Consult the vehicle manufacturer's Service Manual and
warranty. Do not try to repair or service a TAS steering gear which has
been damaged or includes any part that shows excessive wear unless
the damaged and worn parts are replaced with original TRW replace-
ment and service parts and the unit is restored to TRW's specifica-
tions for the TAS steering gear.
It is the responsibility of the mechanic performing the maintenance, repairs

or service on a particular TAS steering gear to (a) inspect the steering gear
for abnormal wear and damage, (b) choose a repair procedure which will
not endanger his/her safety, the safety of others, the vehicle, or the safe
operation of the vehicle, and (c) fully inspect and test the TAS steering gear
and the vehicle steering system to ensure that the repair or service of the
steering gear has been properly performed and that the steering gear and
system will function properly.
PATENTS
EN07Z0703A200003
TRW Commercial Steering Division TAS power steering gears are covered
by several United States and foreign patents, either issued or pending.
TRW Inc., 1998
MAINTENANCE TIPS
EN07Z0703A200004
Never high-pressure wash or steam clean a power steering gear while

on or off the vehicle. Doing so could force contaminants inside the
gear and cause it to malfunction.
Make sure vehicle wheel cut or clearances meet manufacturer's specifica-

tions, and make sure pitman arm timing marks are aligned properly to pre-
vent internal bottoming of the steering gear.
Regularly check the fluid and the fluid level in the power steering reser-
voir.
Keep tires inflated to correct pressure.
Never use a torch to remove pitman arm.
Investigate and immediately correct the cause of any play, rattle, or

shimmy in any part of the steering system.
Make sure the steering column is aligned properly.

Encourage drivers to report any malfunctions or accidents that could

have damaged steering components.
Step Bore Gear
Corrosion Inhibiting
Grease Barrier
Dirt and
Bearing
Water Seal
High-Pressure
Output Seal
SAPH07Z070300006
Do not attempt to weld any broken steering component.

Replace the component with original equipment only.
Do not cold straighten, hot straighten, or bend any steering system

component.
Always clean off around the reservoir filler cap before you remove it.
Prevent dirt or other foreign matter from entering the hydraulic system.
Investigate and correct any external leaks, no matter how minor.
Replace reservoir filters according to requirements.
If you feel the vehicle is developing excessively high hydraulic fluid tem-
peratures, consult with your vehicle manufacturer for recommendations.
Maintain grease pack behind the output shaft dirt and water seal as a gen-
eral maintenance procedure at least twice a year, in the Spring and Fall.
Standard Gear Grease fitting is provided in housing trunnion. Use only NLGI grade 2 multi-
Corrosion Inhibiting
Grease Barrier
purpose chassis lube, and use only a hand operated grease gun on fitting.
Add grease until it begins to extrude past the sector shaft dirt and water
seal.
Dirt and
Water Seals Bearing High-Pressure
Output Seal
SAPH07Z070300007
ON-VEHICLE SERVICE
EN07Z0703C100003
1. FILLING AND AIR BLEEDING THE SYSTEM

! CAUTION
Make sure poppets are set correctly before beginning this procedure.
(1) Fill the reservoir nearly full. Do not steer. Start and run the engine for
10 seconds, then shut it off. Check and refill the reservoir. Repeat at
least three times, checking the reservoir each time.
! CAUTION
Do not allow the fluid level to drop significantly or run out of the reser-
voir. This may induce air into the system.
(2) Start the engine and let it idle for 2 minutes. Do not steer. Shut off the
engine and check the fluid level in the reservoir. Refill as required.
(3) Start the engine again. Steer the vehicle from full left to full right sev-
eral times. Add fluid, as necessary, to the full line on the dip stick.
Automatic bleed systems should now be free from trapped air. Man-
ual bleed systems continue with step (4).
Auto Bleed Plug

Do Not Remove
SAPH07Z070300008
(4) With engine idling, steer from full left turn to full right turn several
Manual Bleed Screw times. Stop steering and loosen the manual bleed screw about one
turn. Allow air and aerated fluid to "bleed out" until only clear fluid is
seen. Close the bleed screw, refill the reservoir if required.
Repeat step (4) three to four times until all the air is discharged.
Torque manual bleed screw to 45 lbf⋅in.
! CAUTION
Do not turn steering wheel with bleed screw loosened.
SAPH07Z070300009
2. INPUT SHAFT SEAL REPLACEMENT

This procedure uses the vehicle's power steering pump to force out
the input shaft seal. To use this procedure, the power steering pump
should have a minimum of 1,500 psi available.
(1) Disconnect return line from the steering gear and plug the line. Also
cap the return port of the gear with a high pressure fitting.
SAPH07Z070300010
(2) Remove the steering column from the gear input shaft.
SAPH07Z070300011
(3) Remove the dirt and water seal from the steering gear. Save this seal
to match the new seal to the correct size.
SAPH07Z070300012
(4) Wipe out the grease and then remove the spiral retaining ring. Use a
screwdriver inserted into the notch formed in the end of the ring. Be
careful not to scratch the bore with the screwdriver.
SAPH07Z070300013
(5) Slip the steering column back onto the input shaft with the pinch bolt
installed, but not tightened.
SAPH07Z070300014
(6) Tie or wrap a shop towel around the input shaft area and place a drip
pan under the vehicle to catch the oil.
SAPH07Z070300015
(7) Add fluid as necessary, to the full line on the dip-stick. Do not mix fluid
types.
! WARNING
Any mixture of fluid types, or use of any unapproved fluid could lead
to seal deterioration and leaks. A leak could ultimately cause the loss
of fluid, which could result in a loss of power steering assist.
SAPH07Z070300016
(8) With the vehicle in neutral, momentarily turn the starter (quickly turn
off the engine if it starts).
(9) Remove the shop towel. Disconnect the steering column, and remove
the input shaft seal.
SAPH07Z070300017
(10) Check the seal area of the valve housing for any seal fragments.
Remove any that are found.
SAPH07Z070300018
(11) Check the seal for heat damage. If the seal is stiff and brittle, and not
pliable like the new seal, it is probably heat damaged. Determine and
fix the cause of excessive heat in the vehicle.
New Seal
Heat Damaged Seal
SAPH07Z070300019
(12) Put clean grease 406038 on the inside dia. of the new input shaft
seal, and place it over the input shaft. With the small dia. of tool
J37073 against the seal, tap the tool until the tool shoulder is square
against the valve housing. Remove any seal material that may have
sheared off in the seal bore or retaining ring groove.
! CAUTION
Do not use a socket to install this seal because you will not be able to
control seal installation depth, possibly causing a leak.
SAPH07Z070300020
(13) Insert new retaining ring into the groove.
SAPH07Z070300021
(14) Pack the end of the valve housing bore around the input shaft with
grease 406038. Choose the correct size dirt & water seal by compar-
ing the choices to the old seal, or by measuring the major diameter of
the input shaft serrations (see chart below). Apply more grease
406038 to the new dirt & water seal and install it over the input shaft.
Seat it in the groove behind the serrations and against the valve hous-
ing.
Seal Part No. Serration Size Major Serration Dia.

478044 13/16" x 36 0.807 / 0.799
478060 7/8 x 36 0.866 / 0.857
SAPH07Z070300022
478050 1" x 36 0.987 / 0.977
478050 1" x 79 1.008 / 1.000
(15) Reconnect the steering column to the input shaft and tighten the pinch
bolt to torque level specified.
SAPH07Z070300023
(16) Reconnect the return line to the steering gear return port.
SAPH07Z070300024
(17) Air bleed the system using the procedure on page SR03-11.
3. SECTOR SHAFT ADJUSTMENT

This adjustment can only be completed on the vehicle if the adjusting
screw jam nut is accessible. This nut is located on the side cover.
Photos in this section were taken on a mock frame rail for clarity.
(1) With the engine on, rotate the steering wheel (input shaft) until the
timing mark on the sector shaft lines up with the mark on the housing.
The line on the sector shaft should be at a 90° angle from the input
shaft. The sector shaft is now on its "center of travel". Turn the vehicle
off.
SAPH07Z070300025
(2) Remove the drag link from the pitman arm.

! CAUTION
To avoid resetting the poppets, do not rotate the input shaft more than
11/2 turns from the "center of travel" position while the drag link is dis-
connected.
SAPH07Z070300026
(3) From the "center of travel" position, grasp the pitman arm and gently
try to rotate it back and forth. If looseness or lash is felt at this point,
the sector shaft is out of adjustment.
SAPH07Z070300027
(4) Loosen the jam nut.

NOTICE
If the gear is removed from the vehicle to adjust the lash:
• Leave the pitman arm connected to the gear.
• Best option is to follow the Final Adjustment procedure on page
SR03-53.
• Alternate option is to continue with step (5) of this procedure.
SAPH07Z070300028
(5) If no lash was detected in step (3), turn the shaft adjusting screw
counterclockwise until you feel lash at the output shaft.
SAPH07Z070300029
(6) Slowly turn the shaft adjusting screw clockwise until you feel no lash
at the output shaft without using more than 10 lbf⋅ft (14 N⋅m) of torque.
From this position, turn the screw clockwise 1/8 to 3/16 of a turn more.
Hold the adjusting screw in place, and tighten the jam nut. Final jam
nut torque 43 lbf⋅ft (58 N⋅m).
SAPH07Z070300030
(7) Turn the steering wheel 1/4 turn each side of center, then back to cen-
ter and recheck the pitman arm for lash. You should feel no lash; if
there is lash, repeat steps (4), (6) and (7).
SAPH07Z070300031
(8) Reconnect the drag link to the pitman arm according to manufac-
turer's specifications.
! CAUTION
Maintain grease in the sector shaft bearing through the grease fitting
in the housing using only a hand operated grease gun. Add grease
until it begins to extrude past the dirt and water seal. Do not use a
power grease gun because it will supply grease too fast; this could
adversely affect the high pressure seal and contaminate the hydraulic
fluid.
SAPH07Z070300032
4. POPPET READJUSTMENT-SINGLE GEARS

This resetting procedure will work in most cases with at least 13/4
hand-wheel-turns from each side of center. If you're making a large
reduction in wheelcut and this procedure does not work, you may
have to replace or internally reset the poppets using the procedure
described in the Poppet Component section of this Service Manual.
(1) Set the axle stops to vehicle manufacturer's wheelcut or clearance
specifications.
Start the engine and allow the vehicle to idle for 5-10 minutes to warm
the hydraulic fluid. Shut off the engine.
SAPH07Z070300033
(2) If a new poppet adjusting screw and nut are being used, turn the
screw into the non-sealing end of the jam nut until the drive end of
screw is flush with the nut.
Your steering gear will have either a fixed stop bolt or an adjusting
screw. If the adjusting screw is already part of the steering gear, back
the nut off of the adjusting screw until it is flush with the end of the
adjusting screw.
SAPH07Z070300034
(3) Make sure the engine is off and the road wheels are in straight ahead
position. Remove and discard the poppet fixed stop bolt (if equipped)
and washer (if equipped) from the lower end of the housing.
If the unit has a poppet adjusting screw and sealing nut that need to
be replaced, remove and discard them.
SAPH07Z070300035
(4) Turn the adjusting screw and sealing nut assembly, without rotating
the nut on the screw, into the housing until the nut is firmly against the
housing using a 7/32" Allen wrench. Tighten the sealing nut against
the housing.
! CAUTION
If the drive end of the screw is below the face of the nut, the poppet
seat flange will break during step (7)d.
SAPH07Z070300036
(5) Refill the system reservoir with approved hydraulic fluid.

! CAUTION
Do not mix fluid types. Mixing of transmission fluid, motor oil, or other
hydraulic fluids will cause seals to deteriorate faster.
SAPH07Z070300037
(6) Place a jack under the center of the front axle and jack up the front
end of the vehicle so the steer axle tires are off the ground.
SAPH07Z070300038
(7) Push upper poppet out to prepare it for setting

a. Start the engine and let it run at idle speed.
b. Note which output shaft timing mark is nearest the housing piston
bore.
c. Turn the steering wheel in the direction that makes this timing
mark move toward the adjusting screw just installed. Turn in this
direction until axle stop contact is made.
d. Pull hard on the steering wheel (put up to 40 lb rim pull on a 20"
dia. steering wheel) after the axle stop is contacted.
SAPH07Z070300039
(8) Set upper poppet

a. Turn the steering wheel in the opposite direction (end of timing
mark away from adjusting screw) until the other axle stop is con-
tacted.
b. Pull hard on the steering wheel (put up to 40 lb rim pull on a 20"
dia. steering wheel).
c. Release the steering wheel and shut off the engine.
SAPH07Z070300040
(9) Loosen the sealing nut and back out the adjusting screw until 1" is
past the nut. Tighten the sealing nut against the housing.
! CAUTION
Do not hold the steering wheel at full turn for more than 10 seconds at
a time; the heat build-up at pump relief pressure may damage compo-
nents.
SAPH07Z070300041
(10) Set lower poppet

a. Start the engine and let it idle.
b. Turn the steering wheel in the original direction (end of timing
mark toward adjusting screw), until axle stop contact is made.
c. Hold the steering wheel in this position (with up to 40 lb rim pull)
for 10 seconds, then release.
Repeat this hold and release process as many times as neces-
sary while completing step (11).
SAPH07Z070300042
(11) Position adjusting screw

a. With steering wheel held tightly at full turn loosen the jam nut and
hold it in place with a wrench.
b. Turn the adjusting screw in (clockwise) using finger-pressure
only (don't use a ratchet), until the Allen wrench stops. Do not
attempt to turn it in further. Pause the turning-in process each
time the driver releases the steering wheel; continue turning only
while the wheel is held at full turn.
c. Back off the adjusting screw 31/4 turns and tighten the sealing nut.
Torque sealing nut to 35 lbf⋅ft (47.5 N⋅m).
SAPH07Z070300043
(12) The poppets have now been completely reset.

Lower the vehicle. Check the reservoir and fill if required.
! WARNING
The length of the adjusting screw beyond the nut must be no more
than 11/16" for proper thread engagement.
NOTICE
The length of adjusting screw beyond the sealing nut may be different
for each vehicle.
RESEAL & REPAIR

EN07Z0703H300001
1. DISASSEMBLY PREPARATION
Stop the vehicle with wheels pointed straight ahead.
Clean off all outside dirt from around fittings and hose connections
before you remove the gear.
Remove input and output shaft connections per vehicle manufac-

turer's instructions.
! WARNING
When using a chisel to spread a pinch bolt-type pitman arm boss for
assembly or removal from the shaft, maintain a firm grip on the chisel
at all times. Failure to do this may result in the chisel flying loose
which could cause an injury. Never leave the chisel wedged in the pit-
man arm boss. If you cannot remove the pitman arm from the shaft
with a chisel and your hands, remove the chisel from the arm boss
and use a puller only to remove pitman arm.
! CAUTION
• Do not use a hammer on the pitman arm to remove it from sector
shaft as internal damage to steering gear could result. Be sure
there is no spreading wedge left in the pitman arm boss before
tightening pitman arm clamp bolt after assembly on sector shaft.
Do not pound the universal joint or input shaft coupling on or off
the input shaft as internal damage to the steering gear can
result.
• Unless the poppet adjuster seat and sleeve assemblies (22) are
to be removed and replaced or reset for automatic poppet adjust-
ment, or a manual adjustment with a service poppet adjuster
screw (59) and nut (60) is anticipated, do not allow the input shaft
on a steering gear with the automatic poppet adjustment feature
to rotate more than 1.5 input shaft revolutions from "straight
ahead position" when the output shaft is disconnected from the
vehicle steering linkage; this could disrupt the poppet setting
achieved at initial installation. The steering gear is in the
"straight ahead position" when the timing marks on the end of
the housing trunnion and sector shaft are aligned.
Remove the supply and return lines from the gear, and immediately
plug all port holes and fluid lines.
! WARNING
TAS steering gears can weigh up to 110 pounds dry. Exercise caution
when you remove, lift, carry, or fix in a bench vise.
Remove the steering gear from the vehicle and take it to a clean work
surface.
Clean and dry the gear before you start to disassemble it.
As you disassemble the gear, clean all parts in clean, OSHA approved
solvent, and air blow-dry them only.
! WARNING
• Because they are flammable, be extremely careful when using
any solvents. Even a small explosion or fire could cause injury
or death.
• Wear eye protection and be sure to comply with OSHA or other
maximum air pressure requirements.
! CAUTION
Never steam clean or high-pressure wash hydraulic steering compo-
nents. Do not force or abuse closely fitted parts. Use care that bearing
and sealing surfaces are not damaged by the assembly and disas-
sembly procedures.
Keep each part separate to avoid nicks and burrs.
Discard all seals, o-rings, and gaskets removed from the gear.
Replace them with new parts only.
The steering gear should be identified to the vehicle from which it was
removed. The poppet adjuster seat and sleeve assemblies are set for
that particular vehicle only.
2. DISASSEMBLY
(1) Put the steering gear in a vise, clamping firmly against the housing
mounting flange or boss. Input shaft should be horizontal; side cover
and valve housing are accessible for disassembly.
! CAUTION
Do not clamp against body of housing. If mounting boss or flange is
not accessible, fabricate and attach a mounting plate to the housing
mounting bosses.
SAPH07Z070300044
(2) Prepare for fluid drainage and unplug hydraulic ports.
SAPH07Z070300045
(3) Rotate the input shaft until the timing mark on the end of the sector
shaft is in line with the timing mark on the end of the housing. This will
position the sector shaft for removal.
SAPH07Z070300046
(4) Remove any paint or corrosion from the exposed area of the sector
shaft (42).
SAPH07Z070300047
(5) Tape the serrations and bolt groove of the sector shaft with one layer
of masking tape. The tape should not extend onto the sector shaft
bearing diameter.
SAPH07Z070300048
(6) Remove the sector shaft adjusting screw jam nut (47).
SAPH07Z070300049
(7) Be prepared for more fluid drainage and remove the six or eight spe-
cial bolts (48) from the side cover (46).
SAPH07Z070300050
(8) Be prepared for more fluid drainage and remove the side cover and
sector shaft assembly from the gear.
You may start the shaft and cover assembly removal by tapping the
end of the shaft lightly with a soft mallet or wooden hammer handle.
SAPH07Z070300051
(9) Remove and discard the side cover gasket (45).
SAPH07Z070300052
(10) Remove and discard the vent plug (49).
SAPH07Z070300053
(11) Screw sector shaft adjusting screw (43) clockwise through the side
cover and pull the sector shaft out of the side cover.
SAPH07Z070300054
(12) Clamp the side cover in a vise. Place a standard 5/8" or 11/16"-3/8 drive
socket in the center of the side cover. pry the seal (41) out with a roll-
ing head pry bar, using the socket for support. Discard the seal and
remove the socket.
! CAUTION
Don't damage the bore or DU bushing when removing the seal.
SAPH07Z070300055
(13) Inspect the sector shaft assembly for damaged adjusting screw
threads. The retainer (44) must be securely staked in place. The
adjusting screw must rotate by hand with no perceptible end play
(lash).
SAPH07Z070300056
(14) If equipped, remove relief valve cap (56), o-ring (57) and two-piece
relief valve (58) from the valve housing. Discard the o-ring.
SAPH07Z070300057
(15) Remove and discard the dirt & water seal (2, 2B or 2C) from the input
shaft (13 or 13A). Save this seal for comparison with the new seal.
SAPH07Z070300058
(16) Clean any paint or corrosion from the exposed area of the input shaft.
SAPH07Z070300059
(17) Remove the four torx head valve housing bolts (1).
SAPH07Z070300060
(18) Be prepared for more fluid drainage and remove the rack piston sub-
assembly. Place the assembly on a clean cloth. For the TAS85 it may
help to rotate the input shaft to move the rack piston toward the lower
end of the housing. This will force the valve housing to exit the main
housing.
! CAUTION
The set position of poppet seat and sleeve assemblies (22) must not
be disturbed if the poppets are not going to be replaced or reset dur-
ing disassembly.
SAPH07Z070300061
NOTICE
If your gear is short "V" construction, the rack piston seal is on the
end of the rack piston farthest from the input shaft. Remove the seal
before removing the valve housing assembly to prevent the Teflon
rack piston seal ring (20) from "hanging up" when it exits the housing.
Expose the seal through the sector shaft cavity, then cut and remove
the seal ring from the rack piston.
SAPH07Z070300062
(19) Remove and discard the valve housing seal rings (6 & 7).
! CAUTION
Do not remove the input shaft, valve worm assembly or balls from the
rack piston until the ball return guides are removed as damage to the
ball guides will occur.
SAPH07Z070300063
(20) Remove and discard the two special sealing screws (31). Remove the
ball return cap (30) and seal (29), or strap (32), discard the seal. (cap
type)
SAPH07Z070300064
(21) Bend down the two tabs (tangs) that are against the hex head bolts.
Remove two bolts and the clip. Discard the clip. (clip type)
SAPH07Z070300065
(22) Make sure the rack piston is on a cloth so the steel balls that fall out
won't roll very far. Remove ball return guide halves (28) by carefully
inserting a screwdriver between the rack piston and guides.
NOTICE
Left hand ball return guide halves are copper plated for identification
and right hand guides are not plated.
Retain the guides for reassembly.
SAPH07Z070300066
(23) Remove the steel balls (27) from the rack piston (19) by rotating the
input shaft, valve worm assembly until the balls fall out. Place the balls
and return guides in a cup or other container. Count the balls, and
make sure all have been removed.
! CAUTION
The steel balls are a matched set. If any are lost, the set must be
replaced by service balls. Number of factory balls installed: TAS40-29,
TAS55-31 (30 if date code is 337-89 or earlier), TAS65-32, TAS85-34.
SAPH07Z070300067
(24) Remove the input shaft, valve/worm, valve housing subassembly from
the rack piston.
SAPH07Z070300068
(25) Cut and remove the Teflon seal ring (20) and o-ring (21) from the rack
piston if not removed during disassembly step (18) NOTICE.
SAPH07Z070300069
(26) Push poppet stems, they should spring back. Push poppet seat, it
should not move by hand. If components are bent or broken, poppet
stems don't spring back, or poppet seat moves by hand, go to Poppet
Component Replacement section on page SR03-40. Otherwise,
proceed to step (27).
NOTICE
TRW recommends the poppet adjuster seat and sleeve assemblies
(22) not be removed unless replacement of poppet components is
required.
SAPH07Z070300070
(27) Inspect valve housing/worm screw subassembly for heat damage or

bearing roughness. If these conditions are present, or if there was
excessive internal leakage, or if preload adjustment is required, go to
Valve Housing/Worm Screw Disassembly procedures on page
SR03-43. If not, proceed to step (28).
SAPH07Z070300071
SAPH07Z070300072
(28) Remove and discard the dirt and water seal (61).
SAPH07Z070300073
(29) Remove the retaining ring (63) through the side cover opening. Then
insert a screwdriver through the trunnion opening, and carefully push
the seal (41) out without damaging the sealing area of the bore.
Discard the seal.
SAPH07Z070300074
(30) Inspect the roller bearing (37) for brinelling or spalling. If replacement
is required, go to Roller Bearing Replacement-Step Bore on page
SR03-51. If not, proceed to step (31).
SAPH07Z070300075
(31) Inspect the following for damage:
• Poppet fixed stop screw (52 or 52A) and washer (53) if equipped.
• Poppet adjusting screw (59) and sealing nut (60)
• Auto-bleed plug (51)
• Manual bleed screw (50)
• Auxiliary port plugs (54) and o-rings (55)
If any are damaged, go to Replace Housing Ports, Plugs and

Screws on page SR03-52. If not, proceed to the Inspection Section.
SAPH07Z070300076
3. INSPECTION
Make sure all sealing surfaces and seal cavities are free from
nicks and corrosion. Any nicked or corroded surface requires
part replacement to ensure proper sealing.
Wash all parts in clean, OSHA approved solvent. Air blow them
dry only.
! WARNING
or death.
• Any of the following conditions present in the steering gear indi-
cates impact damage.
Condition Area
Brinelling • Ball track grooves of rack piston

• Ball track grooves of worm screw
• Bearing area of sector shaft
• Thrust washers and bearings in valve
housing
Cracks or Breaks • Bearing area of sector shaft

• Sector shaft teeth
• Rack piston teeth
• Housing
• Thrust washers and bearings in valve
housing
• Worm screw
Twisted serrations • Output shaft serrations
If one of these conditions is found in one component, be sure to

inspect all components carefully for signs of impact damage.
Replace components noted in individual inspection steps below
if you suspect impact damage. Failure to replace all damaged
components could result in a serious vehicle accident.
(1) Inspect the rack piston (19) teeth for cracks or obvious damage. If
teeth are damaged, replace the rack piston, sector shaft (42) and set
of balls (27).
SAPH07Z070300077
(2) Inspect the rack piston (19) ball track grooves for brinelling or spalling.
If either condition exists, replace the input shaft, valve/worm assem-
bly, valve housing, rack piston subassembly and balls.
SAPH07Z070300078
(3) Inspect the sealing area of input shaft and valve (13 or 13A) for nicks,
and damage. Inspect for discoloration from excess heat. Inspect input
shaft ball-track grooves for brinelling or spalling. If any of these condi-
tions exist, replace the input shaft, valve worm assembly, valve hous-
ing and balls. Also replace rack piston if brinelling or spalling is found.
SAPH07Z070300079
(4) Inspect the housing (34) cylinder bore. Some scoring marks are nor-
mal. If there was internal leakage greater than 1 gal/mm (3.8 L/min),
make sure there are no damaged seals before replacing the housing.
SAPH07Z070300080
(5) Inspect the housing faces for nicks that would prevent proper sealing.
Replace the gear housing if these nicks are present and cannot be
easily removed with a fine-tooth flat file without changing the dimen-
sional characteristics.
SAPH07Z070300081
(6) Inspect side cover (46) DU bushing for damage. Also check side cover
bushing to sector shaft clearance. If damage exists, or if clearance
exceeds .008" (0.20 mm) replace side cover/bushing assembly.
SAPH07Z070300082
(7) Inspect the sector shaft (42) bearing and sealing areas and sector
teeth contact surfaces for brinelling, spalling or cracks. Run your fin-
gernail edge across these areas to detect steps. Remove masking
tape from the shaft and inspect for twisted or otherwise damaged ser-
rations. If any of these conditions exist, replace the sector shaft.
NOTICE
A service sector shaft will come assembled with the adjusting screw
(43) and retainer (44).
SAPH07Z070300083
4. ASSEMBLY PREPARATION
Wash all parts in clean, OSHA approved solvent. Air blow-dry

them only.
! WARNING
or death.
Replace all seals, seal rings, and gaskets with new ones each
time you disassemble the gear.
TRW Commercial Steering Division makes complete seal kits

available. These parts can be purchased through most OEM
parts distributors. Contact your local dealer for availability.
5. ASSEMBLY
(1) Assemble new seal (41) onto bearing and seal tool (short end) so the
lip with the garter spring is toward the shoulder of the tool. Working
from the side cover side of the housing, pilot the seal tool into the
washer and bearing and press with a force of 100-800 lb (445-3,560
N) until the seal is seated firmly.
Install the inside retaining ring (63) from the side cover opening. Seat
the ring firmly in the retaining ring groove.
SAPH07Z070300084
(2) Install the dirt & water seal (61) with the bearing and seal tool (long
end), making sure it is not cocked. Press the seal only until it seats
against the bearing, don't push it in farther.
Liberally pack the roller bearing and new seals with clean, high tem-
perature industrial grease, Exxon Unirex* RS460.
*Trademark of Exxon Oil Corp.
SAPH07Z070300085
(3) Lightly oil new seal ring (7) and assemble in valve housing mounting
face groove.
Oil new seal ring (6) and assemble in valve housing mounting face
groove.
SAPH07Z070300086
(4) Install a new backup o-ring (21) and then a new Teflon seal ring (20)
on rack piston (19). Do not over-stretch these rings as you install
them. Do not allow the Teflon seal ring to be twisted.
SAPH07Z070300087
(5) Apply clean oil to housing cylinder bore. Place the rack piston (19) in
the housing piston bore with ball return guide holes up.
SAPH07Z070300088
(6) Insert the worm screw into the rack piston close to maximum depth,
without the valve housing making contact with the poppet stem. Insert
two 7/16"-14 All threads through valve housing bolt holes and tighten
into housing to support the worm screw. Line up rack piston ball guide
holes with the worm ball track grooves by rotating the input shaft.
SAPH07Z070300089
(7) Assemble the ball return guide halves (28) into the rack piston until
seated, rotate the input shaft slightly if necessary.
! WARNING
Do not seat guides with a hammer.
Damage to guides can result in subsequent lockup or loss of steering.
! CAUTION
• If a new rack piston (19) or a new input shaft, valve, worm subas-
sembly (13 or 13A) is being assembled, the balls (27) removed
from the unit must be discarded and a service ball kit utilized.
The balls in a service ball kit are sized to function in the ball
SAPH07Z070300090 track guide path as altered by component replacement.
• When using the service ball kit, use the correct quantity of ser-
vice balls: TAS40-29, TAS65-32.
(8) Hold the ball return guides (28) firmly in place during this entire
procedure. Insert as many of the steel balls as you can through the
hole in the top of the ball return guides. Rotate the input shaft to pull
the balls down and around the ball track guide path. Continue until the
correct number of balls are in the ball track guide path.
! WARNING
• Hold down the ball return guides until cap or clip is reinstalled.
Failure to hold the guides will result in a trapped ball or balls,
which could cause a vehicle accident. If the ball guides become
unseated (raise up) at any time, repeat the procedure starting at
step (5).
SAPH07Z070300091
• The correct number of balls are required for proper gear opera-
tion.
Count the balls and insert each carefully as in step (7).
TAS40 TAS65
Original 29 32
Service 29 32
! CAUTION
• Do not allow valve housing to contact the poppet stem or move
more than 21/2 inches (69.1 mm) from upper end of rack piston
during these procedures. This could incorrectly reset the pop-
pet, or back out worm beyond closed ball loop, trapping balls.
• Remove any fluid present in the two screw holes. Fluid in these
holes could cause improper clamp load when torquing the cap or
strap screws.
(9) Place a new ball return guide cap seal (29) in the seal groove of the
cap (30). Make sure the seal makes full contact with the rack piston
surface. Install two new Allen or Torx head screws (31) and torque
each screw alternately until a final torque of 18 lbf⋅ft (24.5 N⋅m) is
achieved.
! CAUTION
Ball cap seal is greased to hold seal in groove while assembling.
Be sure not to trap the seal outside of the groove during reassembly.
SAPH07Z070300092
(10) If your gear was equipped with the ball return guide strap (32), or if it
was equipped with the clip, install the new ball return guide strap.
Position it on the rack piston, install two new Allen or Torx head
screws (31) and torque each screw alternately until a final torque of
18 lbf⋅ft (24.5 N⋅m) is achieved.
SAPH07Z070300093
(11) Rotate the input shaft from one end of travel to the other without con-
tacting the poppet stem to the valve housing, and without moving the
valve housing face more than 21/2" (69.1 mm) from input end (upper
end) of rack piston. If you cannot rotate the input shaft, remove the
balls and reassemble them.
! WARNING
If you install a gear on a vehicle with the worm shaft unable to rotate,
the gear will not function correctly. Steering and gear failure may
result.
SAPH07Z070300094
(12) Apply clean oil to Teflon seal ring (20) on rack piston. Make sure there
is a space of 3/8-1/2" (10.0-13.0 mm) between valve housing (5) and
poppet stem to prevent poppet contact at either end. Remove the All
Threads, and push the rack piston assembly into the housing with the
rack piston teeth toward the sector shaft cavity. Line up the valve
housing cylinder feed hole with the gear housing feed hole. Make sure
both o-rings in the valve housing remain in position.
! CAUTION
• Do not damage the seal ring (19) while installing the rack piston
into housing. If the seal ring end of rack piston enters the hous-
ing first, the seal ring will be destroyed when the rack is
SAPH07Z070300095 removed.
• The poppet seat and sleeve assemblies (22) must not bottom
against the internal poppet stops in the steering gear until the
gear is installed on the vehicle and the poppet adjustment proce-
dures are performed.
(13) Lubricate and install the four valve housing bolts (1) into the housing.
Torque the bolts alternately to 80 lbf⋅ft (108.5 N⋅m).
SAPH07Z070300096
(14) If the gear is equipped with a relief valve, assemble a new o-ring (57)
on relief valve cap (56). Assemble the small end of tapered spring
onto the pin on the relief valve cartridge and insert the assembly (58),
(large end of tapered spring end first) into the relief valve cap cavity.
Turn the relief valve cap as assembled into the valve housing and
torque to 30 lbf⋅ft (41 N⋅m).
SAPH07Z070300097
(15) Lightly oil DU bushing. Do not grease.
! CAUTION
This bearing is sealed and will receive no lubrication from the hydrau-
lic fluid in the gear. Failure to use the proper grease could result in
premature bearing wear.
SAPH07Z070300098
(16) Grease and assemble new seal (41) onto installation tool so the side
with the garter spring is against the shoulder of the tool. Pilot the tool
into the side cover (46) with a force of 100-800 lb (445-3560 N) until it
is seated against the bearing or bushing.
! CAUTION
Make sure the OD of the seal, and the ID of the bore are free from
grease and dust, for proper engagement of the seal.
SAPH07Z070300099
(17) Lightly oil short bearing area of sector shaft. Do not grease.
SAPH07Z070300100
(18) Insert the sector shaft (42) into the side cover subassembly (46), and
screw the sector shaft adjusting screw (43) counterclockwise into the
side cover until the screw reaches solid height.
Rotate the adjusting screw clockwise one half turn so the side cover
will rotate freely on the sector shaft.
SAPH07Z070300101
(19) Install the sector shaft adjusting screw jam nut (47) onto the sector
shaft adjusting screw (43) a few threads. Final adjustment will be
made later.
SAPH07Z070300102
(20) Press the new vent plug (49) into the hole provided in the side cover
until the plug is bottomed.
! WARNING
Do not weld or otherwise plug this hole in any permanent manner.
This is a safety vent which functions only if the side cover seal fails. If
the seal fails and the plug cannot vent, the steering gear may lock-up
or otherwise malfunction.
SAPH07Z070300103
(21) Apply clean grease to the new side cover gasket (45) to hold it in
place and assemble it onto the side cover (46).
SAPH07Z070300104
(22) There are four teeth on the rack piston. Rotate input shaft to position
the rack piston so the space between the second and third tooth is in
the center of the sector shaft opening. This will center the rack piston
for assembly of sector shaft.
! WARNING
If the rack piston is not centered when sector shaft is installed, gear
travel will be severely limited in one direction. This could result in an
accident.
SAPH07Z070300105
(23) Clean off any old tape on the serrations. Reapply one layer of mask-
ing tape. Install the sector shaft assembly into the housing. The center
tooth of the sector shaft must engage the center space (between the
second and third tooth) of the rack piston, with side cover gasket in
place.
! CAUTION
If the serrations are not properly taped, they will damage the output
seal (38) in housing, causing the seal to leak.
SAPH07Z070300106
(24) Install bolts in positions 3 and 4 first, by hand. Install the remaining
special side cover bolts (48) into the side cover and torque them in the
sequence shown. If bolts must be replaced, use bolts of the same
6 1
design, type and length as those you removed. Do not use a substi-
tute.
4 3
Lubricate side cover bolts and torque TAS40 bolts to 118 lbf⋅ft (160
2 5 N⋅m), TAS65 bolts to 170 lbf⋅ft (230 N⋅m).
TAS40, 65
SAPH07Z070300107
(25) Remove tape from the sector shaft.
SAPH07Z070300108
clean, high temperature industrial grease, Exxon Unirex* RS460.
Apply more of the grease to the inside of a new dirt and water seal (2,
2B or 2C) and install it over the input shaft. Seat the seal in the groove
behind the serrations and against the valve housing.
This step may have already been completed if you disassembled the
valve housing and worm screw for repair.
Proceed to Final Adjustments on page SR03-53.

SAPH07Z070300109
6. POPPET COMPONENT REPLACEMENT

(1) If the poppet assemblies are to be removed for replacement, place
rack piston in a soft-jawed vise.
SAPH07Z070300110
(2) Slide special tool #J36452-A over the seat of poppet adjuster seat and
sleeve assembly (22) and engage tool in the slots in the threaded
sleeve. Hit the end of the tool firmly four or five times with a 2 lb
sledge hammer to loosen Loctite.
! CAUTION
Poppet adjuster seat and sleeve assemblies (22) are retained by Loc-
tite applied to the threads which makes the assemblies difficult to
remove.
SAPH07Z070300111
(3) With a ratchet applied to the tool, turn one adjuster seat and sleeve
assembly out of the rack piston. If the ratchet does not turn easily,
strike the adjuster removal tool again with a hammer. If the engaging
tangs won't stay in place while torquing, it might be necessary to hold
in place with an arbor press while applying loosening torque. Discard
poppet seat and sleeve assembly.
SAPH07Z070300112
(4) Remove the two poppets (23 or 23A), spring (24), and push tube (26).
Some gears will also have a spacer rod (25) to be removed.
SAPH07Z070300113
New Design Spring
Poppet Poppet
Poppet Seat
Poppet Seat and

Poppet
Push Tube Sleeve Assembly
Sleeve
SAPH07Z070300114
(5) Remove and discard remaining poppet seat and sleeve assembly only
if required.
NOTICE
It is possible to reset one poppet adjuster seat and sleeve assembly
for automatic poppet adjustment while it is in the rack piston if one
adjuster seat and sleeve assembly and the poppets, spring, spacer
rod and push tube are removed.
SAPH07Z070300115
(6) If one poppet seat and sleeve assy. (22) was left in rack piston, it can
be reset for automatic poppet adjustment by inserting a 3/8" (9.52 mm)
diameter X 6" (152.4 mm) drill rod down through the poppet seat hole
at the opposite end of the rack piston and against the adjuster seat to
press the seat in until it bottoms against the adjuster sleeve.
SAPH07Z070300116
(7) Carefully apply Locquic "T" primer to the threads in poppet holes, and
threads on the new seat and sleeve assemblies (22). Allow to dry for
ten minutes; then carefully apply Loctite RC680 to same threads.
! CAUTION
Do not allow Loctite or Locquic to get on the adjuster seat component
of the adjuster seat and sleeve assembly. The poppets will not func-
tion properly.
SAPH07Z070300117
(8) Place rack piston (19) in a soft-jawed vise and turn one new poppet
adjuster seat and sleeve assembly (22), (slotted end out) into the pop-
pet hole in one end of rack piston.
! WARNING
• Wear eye protection while assembling poppets, as spring loaded
poppets could eject and cause eye injury.
• Do not use the spacer with the new poppet design. You must
install the spacer with the old poppet design.
SAPH07Z070300118
(9) From the other end of the poppet hole in the rack piston, install: one
poppet (23A), poppet spring (24), push tube (26), other poppet (23A),
and the other new poppet adjuster seat and sleeve assembly (22).
The new components will stack up as shown below.
Torque both poppet seat and sleeve assemblies to 18 lbf⋅ft (25 N⋅m).
Return to step (27), page SR03-29.
SAPH07Z070300119
SAPH07Z070300120
7. VALVE HOUSING/WORM SCREW DISASSEMBLY

(1) With worm vertical, place the valve housing, input shaft, valve/worm
assembly in a vise.
SAPH07Z070300121
(2) Unstake the valve housing (5) where it was upset into the adjuster
locknut (18) slot. Also unstake adjuster nut from adjuster (17).
SAPH07Z070300122
(3) Turn bearing adjuster locknut (18) out of the valve housing.
SAPH07Z070300123
(4) Turn bearing adjuster (17) out of the valve housing.
SAPH07Z070300124
(5) Remove and discard seal ring (8) and o-ring (9) from bearing adjuster.
SAPH07Z070300125
(6) Remove the input shaft, valve/worm assembly (13 or 13A) from the
valve housing.
SAPH07Z070300126
(7) Remove thin thrust washer (16) and thrust bearing (15) from input
shaft.
SAPH07Z070300127
(8) Remove thick thrust washer (12) and thrust bearing (15) from valve
housing.
! CAUTION
Input shaft, valve worm assembly must not be disassembled further.
The components were a select fit at assembly and are available only
as part of this subassembly. If disassembled further, the subassembly
must be replaced.
SAPH07Z070300128
(9) For alternate construction TAS65 gears, remove spacer sleeve (14),
thin washer (16), thrust bearing (15) and thick washer (12).
! WARNING
If the TAS65 gear has a ball bearing and ball race in the valve housing,
remove them and call TRW for disposition. Do not rebuild the gear.
SAPH07Z070300129
(10) Remove and discard seal rings (10) and (8) and o-rings (11) and (9)
from valve housing (5).
SAPH07Z070300130
(11) Turn over valve housing and remove retaining ring (3).
SAPH07Z070300131
(12) Tap input shaft seal (4) out of valve housing. Discard seal.
! CAUTION
Exercise special care when removing seal (4) to prevent damaging the
valve housing seal bore.
NOTICE
The valve housing also utilizes a ball plug for manufacturing pur-
poses that must not be removed.
SAPH07Z070300132
(13) Inspect the sealing areas of input shaft and valve (13 or 13A) for nicks
and run your fingernail edge across the sealing surfaces to detect
steps. Inspect for discoloration from excess heat. Inspect input shaft
ball-track grooves for brinelling or spalling. If any of these conditions
exist, you must replace the input shaft, valve/worm assembly, valve
housing and balls. Also replace rack piston if brinelling or spalling is
found.
SAPH07Z070300133
(14) Inspect the thrust bearing (15) rollers for any deterioration. Inspect
thrust washers (12 & 16) for brinelling, spalling, or cracks. Replace
any part with these conditions.
Alternate Construction TAS65: If spacer sleeve (14) is damaged,

replace the input shaft/valve/worm subassembly and use thick
washer and roller bearing only during reassembly.
SAPH07Z070300134
(15) Place valve housing (5) firmly in a vise so the input shaft, valve/worm
assembly (13 or 13A) can be assembled vertically with the worm end
up.
! CAUTION
Do not clamp against threaded port hole or relief valve hole sealing
faces when placing valve housing in vise.
SAPH07Z070300135
(16) Oil and assemble a new o-ring (9) into its counterbore in valve hous-
ing.
SAPH07Z070300136
(17) Lightly oil and assemble new o-ring (11) and new seal ring (10) into
the large diameter seal ring groove in valve housing, bending and
working them in and smoothing them out as necessary.
SAPH07Z070300137
(18) Install roller thrust bearing (15) and then the thick washer (12) (square
side out) onto input shaft end of input shaft, valve, worm subassembly,
seating them against the input shaft thrust face.
SAPH07Z070300138
(19) Alternate construction TAS65: Assemble spacer sleeve (14) onto

input shaft with radiused side toward valve. Make sure sleeve is
square. Assemble thin washer (16), thrust bearing (15) and thick
washer (12) onto input shaft behind spacer sleeve.
! CAUTION
If you are replacing the input shaft/valve/worm assembly, discard
spacer sleeve and thin washer.
SAPH07Z070300139
(20) Lightly oil and assemble new seal ring (8) onto input shaft and against
the thick thrust washer (12) to hold the bearing components in place.
SAPH07Z070300140
(21) Dip the input end of the input shaft, valve, worm assembly (13 or 13A)
into oil up to the worm lead. Assemble the input shaft end of the
assembly into the valve housing (5) until it is firmly seated.
SAPH07Z070300141
(22) Apply oil and assemble the other thrust bearing (15) then the thin
thrust washer (16) over the ball groove end of worm, and seat them
against the shoulder of input shaft, valve, worm assembly.
SAPH07Z070300142
(23) Lightly oil a new o-ring (9) and assemble into the seal groove in bear-
ing adjuster (17). Oil and work a new seal ring (8) into the same
groove and smooth it out.
NOTICE
Be sure the valve housing, adjuster locknut and bearing adjuster
threads are clean and free of any staking burrs that would impede the
locknut from turning freely on adjuster or the adjuster turning freely in
valve housing.
SAPH07Z070300143
(24) Lightly oil and assemble bearing adjuster (17) over worm and into
valve housing. Torque adjuster to 13 lbf⋅ft (18N⋅m) indicated torque
using a torque wrench inserted in adjuster tool #J37070. This will seat
the components. Back off adjuster 1/4 to 1/2 of a turn.
SAPH07Z070300144
(25) Lightly oil and assemble new locknut (18) onto bearing adjuster (17)
with radius (slightly rounded) side down. Tighten slightly to keep the
bearing adjuster in place.
SAPH07Z070300145
(26) Reverse assembly in vise so the worm end is down. With an inch
pound torque wrench on the input shaft, note torque required to rotate
the input shaft 360° in each direction. Tighten the bearing adjuster to
increase the maximum torque at the input shaft 5-10 lbf⋅in. (.5-1.0
N⋅m) over that which was previously noted.
SAPH07Z070300146
(27) Again reverse the assembly in vise. Torque locknut while holding
bearing adjuster in position established in step (26) with appropriate
adjuster tool. When using a torque wrench in locknut tool J37464, the
torque wrench reading should be 112 lbf⋅ft (152 N⋅m).
NOTICE
The bearing adjuster, locknut and valve housing flange should be
flush. If not, the seal ring (8) or o-ring (9) may be out of position;
which will result in axial lash.
SAPH07Z070300147
(28) Recheck input shaft torque. It should match torque measured in step
(26). Repeat steps (26) and (27) if necessary.
SAPH07Z070300148
(29) Stake valve housing into the clockwise most corner of two opposing
slots in locknut (18). Stake the locknut into the adjuster (17) in two
places (180° apart) at threaded area. Choose areas that have not
been previously staked.
After staking, torque required to rotate input shaft must be between 5-

10 lbf⋅in. (.5-1.0 N⋅m) greater than the torque noted in step (26).
Torque value must not exceed 22 lbf⋅in. (2.5 N⋅m). Unstake and
readjust if necessary.
SAPH07Z070300149
(30) Reposition worm screw/valve housing subassembly in soft-jawed

vise, clamping tightly against valve housing, so the worm screw is
pointing down.
SAPH07Z070300150
(31) Apply clean grease (Exxon Unirex* RS460) to the outside and inside
diameters (fill cavity between the lips) of the new input shaft seal (4)
and assemble it, garter spring side first over the input shaft. Align seal
in the valve housing seal bore.
Assemble seal installer tool #J37073, small diameter end first, over
the input shaft and against the seal. Tap the seal installer tool until the
tool shoulder is squarely against the valve housing. This will correctly
position the seal in the housing bore just beyond the retaining ring
groove.
Remove any seal material that may have sheared off and is in seal
SAPH07Z070300151
bore and retaining ring groove.
! CAUTION
The input shaft seal must be square in the seal bore and installed to
the correct depth.
(32) Insert new retaining ring (3) into its groove in valve housing.
SAPH07Z070300152
clean, high temperature industrial grease, Exxon Unirex* RS460.
Apply more of the grease to the inside of a new dirt and water seal (2,
2B or 2C) and install it over the input shaft. Seat the seal in the groove
behind the serrations and against the valve housing.
SAPH07Z070300153
8. ROLLER BEARING REPLACEMENT-STEP BORE

(1) If roller bearing (37) in housing needs to be replaced, place the bear-
ing removal end (long end) of the bearing and seal tool against the
trunnion end of the bearing and press it out of the side cover end of
the bearing bore. Discard bearing.
SAPH07Z070300154
(2) Press the roller bearing (37) into the housing from the side cover end
of the bearing bore until it is seated against the step bore. Be sure the
housing is square with the press base and the bearing is not cocked.
! CAUTION
Use the bearing installation end of the tool (short end). If the bearing
removal end of the bearing & seal tool is used to press in bearing, the
cage on the new bearing may be damaged.
NOTICE
If the unmachined trunnion face is not square, use shims to square it
before pressing in the bearing.
SAPH07Z070300155
Return to step (30), page SR03-30.
9. REPLACE HOUSING PORTS, PLUGS, SCREWS, FITTINGS

(1) If damaged, remove and replace the poppet fixed stop screw (52 or
52A) and washer (53) if equipped. Replace with poppet fixed stop
screw (52A), discard the washer. Torque to 48 lbf⋅ft (65 N⋅m).
SAPH07Z070300156
(2) If damaged, remove poppet adjusting screw (59) and sealing nut (60)
without allowing the nut to change its position on the screw.
Assemble the new nut onto the new adjusting screw, matching its
position to the nut and screw removed. Torque sealing nut to 35 lbf⋅ft
(47 N⋅m).
SAPH07Z070300157
(3) If damaged, remove and replace automatic bleed plug (51). Torque to
48 lbf⋅ft (65 N⋅m).
If damaged, remove and replace permanent auxiliary port plugs (54)

and o-rings (55). Assemble new o-rings (55) on port plugs and torque
to their respective ports in the housing or valve housing to 30 lbf⋅ft (41
N⋅m).
SAPH07Z070300158
(4) If damaged, remove and replace manual bleed screw (50). Torque to
45 lbf⋅in. (3.4 N⋅m).
Return to inspection section, page SR03-31.
SAPH07Z070300159
10. FINAL ADJUSTMENTS

(1) To center the steering gear, rotate input shaft, valve worm assembly
(13 or 13A) until the timing mark on the end of the sector shaft (42) is
in line with the timing mark on the end of housing trunnion.
! CAUTION
Do not rotate the input shaft more than 1.5 revolutions from center
position until the steering gear is installed, during poppet setting pro-
cedure. Doing so could make the automatic poppets inoperative,
which would require disassembly of steering gear to reposition pop-
pet seat and sleeve assemblies.
SAPH07Z070300160
NOTICE
• Initial poppet contact will occur at less than one input shaft rota-
tion in one direction from steering gear center position, if new or
reset poppet adjuster seat and sleeve assemblies are assembled
in the unit.
• Worm preload adjustment was set when input shaft, valve and
worm were assembled into valve housing.
(2) With adjusting screw jam nut (47) loose, turn sector shaft adjusting
screw (43) clockwise to provide 45-50 lbf⋅in. (5-5.5 N⋅m) of torque
required to rotate the input shaft, valve/worm assembly (13 or 13A)
through one half turn (180°) each side of center.
NOTICE
This procedure will properly mesh and seat the rack piston and sector
shaft teeth for final adjustments.
SAPH07Z070300161
(3) Turn sector shaft adjusting screw (43) counterclock-wise one half turn
and note maximum torque required to rotate the input shaft, valve/
worm assembly through one half turn (180°) each side of center.
SAPH07Z070300162
(4) Adjust sector shaft adjusting screw (43) clockwise to increase maxi-
mum torque noted in step (3) by 7 lbf⋅in. (.8 N⋅m). Tighten jam nut
(47) firmly against side cover while holding the adjusting screw in
position. Final torque jam nut to 43 lbf⋅ft (58 N⋅m) and check input
shaft, valve/worm assembly torque again. Readjust if input shaft
torque exceeds 40 lbf⋅in. (4.5 N⋅m).
SAPH07Z070300163
FRONT AXLE (MFS) AX02–1
FRONT AXLE (MFS)

AX02
AX02-001
FRONT AXLE (MFS)................................. AX02-2

DATA AND SPECIFICATIONS ......................... AX02-2
TROUBLESHOOTING ..................................... AX02-4
COMPONENT LOCATOR................................ AX02-6
SERVICE NOTES .......................................... AX02-10
SPECIAL TOOLS........................................... AX02-11
INTRODUCTION ........................................... AX02-17
INSPECTION ................................................. AX02-18
DISASSEMBLY .............................................. AX02-24
PREPARE PARTS FOR ASSEMBLY ............. AX02-31
ASSEMBLY .................................................... AX02-39
ADJUSTMENT............................................... AX02-51
LUBRICATION AND MAINTENANCE ........... AX02-60
MAINTENANCE............................................. AX02-64
AX02–2 FRONT AXLE (MFS)
FRONT AXLE (MFS)

EN08Z0602I200001
HINO 145, 165,

HINO 238, 258,
185 HINO 268, 308 HINO 268, 308 HINO 338
Vehicle Model 268
(NA6J, NB6J, (NE8J, NF8J) (NJ8J, NV8J) (NV8J)
(ND8J, NE8J)
NC6J)
Front axle series No. MFS-6 MFS-8 MFS-10 MFS-10 MFS-12
Reversed Elliot Reversed Elliot Reversed Elliot Reversed Elliot Reversed Elliot
Axle beam type
"I" beam "I" beam "I" beam "I" beam "I" beam
As rolled nor- As rolled nor- As rolled nor- As rolled nor- As rolled nor-
Axle beam material
malized steels malized steels malized steels malized steels malized steels
Brake disc or drum location Inboard Inboard Inboard Outboard Outboard
Two tapered Two tapered Two tapered Two tapered Two tapered
Wheel bearing
roller bearings roller bearings roller bearings roller bearings roller bearings
Lubrication of wheel bearing

(Amount of grease or oil in a grease grease or oil grease or oil grease or oil grease or oil
hub as shown, below)
tapered roller tapered roller tapered roller tapered roller tapered roller
King pin thrust bearing
bearing bearing bearing bearing bearing
Camber (deg) 0.25 0.25 0.25 0.25 0.25
King pin
Wheel (deg) 9.25 9.25 6.25 6.25 6.25
angle
alignment
Caster (deg) 3.5 3.5 3.5 3.5 3.5
Toe-in (mm) 0.5-2.5 1.0-3.0 1.5-3.5 1.5-3.5 1.5-3.5
Inner
(deg) 52 51 51 51 51
Knuckle turn
turning Outer
(deg) 36.3 36.8 37.6 37.6 37.6
turn
IDENTIFICATION
VIEW OF AXLE
BEAM FACING VEHICLE
MODEL AND CUSTOMER

SPECIFICATION NUMBER
NUMBER
MODEL MFS-12-143A-N
CUSTOMER NO 01X21A62
ASSY PLANT & SERIAL NO AVF 9521109
DATE 01327
AXLE ASSEMBLY
AXLE PLANT AND
ASSEMBLY TAG SERIAL NUMBER
DATE EXAMPLE
1000319d
SAPH08Z060200003
KPI Drop KPI Drop

(inches) (inches) (inches) (inches) Major Design Variation
13 = 68.0 3.74 53 = 72.0 3.74 A = Conventional Knuckle
16 = 68.0 3.60 62 = 65.24 3.74 B = Integral Tie Rod Arm
21 = 69.0 3.30 63 = 65.25 3.74 C = Integral Tie Rod Arm and
22 = 69.0 3.50 75 = 60.0 2.50 Manufacturing
24 = 69.0 5.00 85 = 67.5 2.50
Torque Plate Location
33 = 71.0 3.74 86 = 67.5 3.60 D = Integral Tie Rod Arm, Spider
N = N.A.
43 = 71.5 3.74 92 = 68.5 3.50 and Unitized Wheel End S = S.A.
44 = 71.5 5.00 94 = 68.5 5.00 E = Fabricated Axle with E = Europe
51 = 72.0 3.30 Conventional Knuckle A = Australia/Asia
Axle Spec. Number

M F S - XX - 0 0 0 X - N X XXX
M = Meritor
F = Front Brake Type

B = “B” Frame Brake L Q Plus TM Cam Brake
=
S = Non-Drive Steer Axle C = Air Disc Brake N =
None
D = Wedge Brake (Dual P =
“P” Series Cam Brake
GAWR Pounds or Tonnes Air Chambers) Q =
“Q” Series Cam Brake
E = Wedge Brake (Dual R Cast Plus TM Brake
=
Ref: Target Market
Hydraulic Cylinders) S =
Wedge Brake (Single
F = Wedge Brake (Single Air Chamber)
Beam, King Pin, Bushing Variation Hydraulic Cylinder) T = “T” Series Cam Brake
1 = Straight King Pins — Easy Steer™ Bushing G = DuraPark ® Hydraulic W = “W” Series Cam
2 = Tapered King Pins — Needle Bearings Drum Brake
3 = Alloy Beam Material, India H = Quadraulic Disc
4 = Straight King Pins — Bronze Bushing K = DiscPlus™ Air Disc
SAPH08Z060200004
TROUBLESHOOTING
EN08Z0602F300001
FRONT NON-DRIVE STEER AXLE DIAGNOSTIC TABLE
Condition Cause Correction

Tire wear out quickly Tire have incorrect air pressure. Place specified air pressure in tires.
or have uneven tire
Tire out-of-balance. Balance or replace tires.
tread wear.
Incorrect tandem axle alignment. Align tandem axles.
Incorrect toe-in setting. Adjust toe-in specified setting.
Incorrect steering arm geometry. Service steering system as necessary.
Excessive wheel end play exists. Readjust wheel bearing.
Vehicle is hard to steer. Power steering system pressure low. Repair power steering system.
Steering gear linkage not assembled correctly. Assemble steering gear correctly.
Steering linkage needs lubrication. Lubricate steering linkage.
King pins binding. Replace tie rod ends.
Incorrect steering arm geometry. Service steering system as necessary.
Caster out-of-adjustment. Adjust caster as necessary.
Tie rod ends hard to move. Replace tie rod ends.
Worn thrust bearing. Replace thrust bearing.
Tie rod ends are Tie rod ends require lubrication. Lubricate ends of cross tube. Make sure
worn and require lubrication schedule is followed.
replacement.
Severe operating conditions. Increase frequency of inspection and
lubrication intervals.
Damaged boot on tie rod end. Replace boot.
SAPH08Z060200001
Condition Cause Correction

Bent or broken cross Too much pressure in the power steering
tube, tie rod end ball system, pressure exceeds vehicle Adjust power steering system to specified
stud, steering arm or equipment manufacturer's specification. pressure.
tie rod end.
Power steering system cut-off pressure, out Adjust power steering system to specified
Component requires
of adjustment. pressure.
replacement.
Vehicle operated under severe conditions. Verify that vehicle is operated correctly.
Add-on type of power steering system not Correctly install add-on power steering
installed correctly. system.
Steering gear overtravel poppets incorrectly Check for correct operation or adjust overtravel
set or malfunctioning. of poppets to vehicle equipment manufacturer's
specifications.
Axle stops incorrectly set. Set axle stops to vehicle equipment
manufacturer's specification.
Worn or broken Drag link fasteners tightened higher than Tighten drag link fasteners to specified torque.
steering ball stud. vehicle equipment manufacturer specified.
Lack of lubrication or incorrect lubricant. Lubricate linkage with specified lubricant.
Power steering stops out-of-adjustment. Adjust stops to specified dimension.
Worn king pins and Worn or missing seals and gaskets. Replace seals and gaskets.
king pin bushings. Incorrect lubricant. Lubricate axle with specified lubricant.
Axle not lubricated at scheduled frequency. Lubricate axle at scheduled frequency.
Incorrect lubrication procedures. Use correct lubrication procedures.
Lubrication schedule does not match Change lubrication schedule to match
operating conditions. operating conditions.
Vibration or shimmy Caster out-of-adjustment. Adjust caster.
of front axle during Wheels and/or tires out-of-balance. Balance or replace wheels and/or tires.
operation.
Worn shock absorbers. Replace shock absorbers.
SAPH08Z060200002
COMPONENT LOCATOR
EN08Z0602D100001
1. AXLE WITH A CONVENTIONAL WHEEL END
40
37
39 36
51
38
6 7
44a
38
46 45 40 1 2
44b 39
42 8 9
47 3 12 10
49 48 41
50 43
13
56
11
55
53 61 4
5 14
54 58
52
17
16 15
60
59
57 19
A 20
21
27 45
29 22 18
25 24 23
26
28 12
31
33 13
11
35 34
30
10
32
B 8 9
63a 6 7
65
63b
63c
62
64
66
1003427f
SAPH08Z060200005
A Double Nut 36 Axle Beam

B Single Nut 37 Shims
1 Cotter Pin 38 Tapered Draw Key
2 Drag Link-to-Steering Arm Castle Nut 39 Threaded Draw Key
3 Steering Arm 40 Threaded Draw Key Nut
4 Key 41 Thrust Bearing and Flat-Type Bearing Seal
5 Ball Stud 42 Thrust Bearing and Cover-Type Bearing Seal
6 Capscrew and Washer 43 Integral Thrust Bearing and Oil Seal
7 Grease Fitting 44a Steering Arm-to-Knuckle Castle Nut
8 Greaseable Knuckle Cap 44b Steering Arm-to-Knuckle Castle Nut, Flared
9 Sealed Knuckle Cap Base
10 Gasket 45 3/4-Inch Stop Bolt
TM
11 Easy Steer King Pin Bushing 46 3/4-Inch Jam Nut
12 Bronze King Pin Bushing 47 1/2-Inch Stop Bolt
13 Nylon King Pin Bushing 48 1/2-Inch Jam Nut
14 Knuckle 49 3/4-Inch Adapter
15 King Pin Bushing Seal 50 Washer
16 Tie Rod Arm-to-Knuckle Castle Nut 51 Cotter Pin
17 Cotter Pin 52 Square Key
18 King Pin 53 Woodruff Key
19 Hub Grease Seal 54 Knuckle Tie Rod Arm
20 Inner Wheel Bearing Cone 55 Cotter Pin
21 Inner Wheel Bearing Cup 56 Tie Rod Arm-to-Tie Rod End Castle Nut
22 Stud 57 Tie Rod End
23 Hub 58 Clamp Bolt
24 Outer Wheel Bearing Cup 59 Clamp Lock Nut
25 Outer Wheel Bearing Cone 60 Cross Tube Clamp
26 Adjusting Nut 61 Cross Tube
27 Pierced Lock Ring 62 Knuckle with Integral Tie Rod Arm and Torque
28 Lock Washer Plate
29 Wheel Bearing Nut 63a Old Style Threaded Knuckle Cap
30 "D" Washer 63b New Style Threaded Knuckle Cap
31 Adjusting Nut 63c Round Threaded Knuckle Cap
32 Cotter Pin 64 Bolt-On Steering Arm
33 Gasket 65 Steering Arm Capscrew
34 Hubcap 66 Knuckle with Integral Tie Rod Arm
35 Capscrew and Washer
2. TORQUE SPECIFICATIONS
Front Non-Drive Axles with Conventional Ends
1 2
5
6
3
4
7
10
11 12
11
1000403d
SAPH08Z060200006
Front Axle with Conventional Wheel-End Torque Specifications

Torque Range
Item Description Size lb-ft Nm
1 Steering Arm-to-Drag Link Nut 5/8"-16 60-115 82-155
5/8"-18 60-115 92-155
3/4"-16 90 -170 123-230
7/8"-14 160 -300 217-407
2 Knuckle Cap Capscrew 5/16"-18 20-30 28-40
3 Steering Arm-to-Knuckle Nut 7/8"-14 250-450 339-610
1"-14 390-725 529-982
1-1/8"-12 550-1025 746-1389
1-1/4"-12 775-1450 1051-1965
1-1/2"-12 1350-2525 1831-3423
4 Draw Key Nut 30-45 41-61
5 3/4" Stop Screw Adapter 65-115 88-155
7/16"-20
6 1/2" Stop Screw Lock/Jam Nut 50-75 68-101
7 3/4" Stop Screw Lock/Jam Nut 65-85 88-115
8 Tie Rod Arm-to-Tie Rod End Nut 7/8"-14 160-300 217-406
1"-14 250-450 339-610
1-1/8"-12 350-650 475-881
1-1/4"-12 500-675 678-915
9 Cross Tube Clamp Nut 5/8"-11 40-60 55-81
3/4"-10 155-175 211-237
10 Tie Rod Arm-to-Knuckle Nut 7/8"-14 250-450 339-610
1"-14 390-725 529-982
1-1/8"-12 550-1025 746-1389
1-1/4"-12 775-1450 1051-1965
1-1/2"-12 1350-2525 1831-3423
11 Threaded Knuckle Cap 2.00"-20
70-90 95-122
1-5/8"-20
12 Steering Arm Knuckle Bolt 3/4"-16 360-470 490-638
M16 x 2.0 215-265 290-360
SAPH08Z060200007
SERVICE NOTES
EN08Z0602A100001
BEFORE YOU BEGIN

.
1. Read and understand all instructions and procedures before you

begin to service components.
2. Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent seri-
ous personal injury, damage to components, or both.
3. Follow your company's maintenance and service, installation, and
diagnostics guidelines.
4. Use special tools when required to help avoid serious personal injury
and damage to components.
1. HAZARD ALERT MESSAGES AND TORQUE SYMBOLS

! WARNING
A Warning alerts you to an instruction or procedure that you must fol-
low exactly to avoid serious personal injury and damage to compo-
nents.
! CAUTION
A Caution alerts you to an instruction or procedure that you must fol-
low exactly to avoid damage to components.
2. OBTAIN ADDITIONAL MAINTENANCE AND SERVICE INFORMA-

TION
(1) On the Web
Visit the DriveTrain PlusTM by ArvinMeritor Tech Library at arvinmeri-
tor.com to easily access product and service information. The Library
also offers an interactive and printable Literature Order Form.
3. OBTAIN TOOLS AND SUPPLIES SPECIFIED IN THIS MANUAL

Call ArvinMeritor's Commercial Vehicle Aftermarket at 888-725-9355
to obtain Meritor tools and supplies.
SPX Kent-Moore, 28635 Mound Road, Warren, Michigan, 48092. Call

the company's customer service center at 800-345-2233, or visit their
website at spxkentmoore.com.
Tiger Tools. Call the company's customer service center at 800-661-

4661, or visit their website at tigertool.com.
For Owatonna Tools, contact OTC Tool and Equipment Division, 655
Eisenhower Drive, Owatonna, Minnesota, 55060.
Great Lakes Tool Specialties, 8530 M-89, Richland, Michigan, 49083.

Call the company's customer service center at 800-877-9618 or 616-
629-9628.
For Snap-On tools, contact your local Snap-On dealer.

SPECIAL TOOLS
EN08Z0602K100001
To obtain these tools, refer to the Service Notes on page AX02-10.
Table U: Special Tools

Owatonna
SPX Kent-Moore Tool Snap-On®
Description Tool Number Number Tool Number Great Lakes Tool References
King Pin Remover 4240 4240 20 Ton: — “Draw Keys, King Pin Caps,
CG430HYB King Pins and Steering
35 Ton: CG730HY Knuckle” on page AX02-26
1
King Pin Bushing “King Pin Bushings”
Service Kit on page AX02-30
“King Pin Bushings ”
on page AX02-39
Basic Service Kit PT 4375-A — — —
MFS-6 PT-4370-110 — — —
FC and MFS-7 PT-4370-120 — — —
and -8
Seal Installer — — — Meritor Front Axle “Inner Knuckle Bore King Pin
Seal Installer Kit Seals” on page AX02-42
1
Use the Basic Service Kit along with the correct axle series kit.
SAPH08Z060200009
1. DIMENSIONS FOR BUSHING REMOVAL AND INSTALLATION TOOL
2.5”
(63 MM)
SUITABLE
LENGTH
1000364b
Axle Model Dimension X Dimension Y

Number (± 0.001-inch) (± 0.025 mm ) (± 0.001-inch) (± 0.025 mm )
MFS 6 1.228 31.191 1.350 34.290
MFS 7
1.493 37.922 1.618 41.097
MFS 8
MFS 10 1.786
45.364 1.911 48.539
MFS 12 1.786
SAPH08Z060200010
2. BUSHING REAMER DIMENSIONS
REMOVABLE
PILOT
OPTIONAL
A B CREAMER
E = D + 2"
D (50.8 MM)
2.5" (63 MM) MINIMUM
MATERIAL: HIGH SPEED STEEL
NUMBER OF BLADES: USE 10-14 BLADES
CUT OF BLADES: RIGHT-HAND CUT,
LEFT-HAND FLUTE
LENGTH OF BLADES: 2.50" (63.5 MM)
1000049d
Lower Pilot Diameter Blade Diameter Upper Pilot

Dimension A Dimension B Diameter C Low er Pilot Upper Pilot
(± 0.001-inc h or (± 0.0005-i nch or (± 0.001-inc h or Length Length Minimum
± 0.0245 mm ) ± 0.0127 m m) ± 0.0245 mm ) Dimension D Dimension E
Axle Model inch mm inch mm inch mm inch mm inch mm
MFS 6 1.2225 31.0515 1.2360 31.4325 1.2320 31.2928 6.75 171.45 8.75 222.25
MFS 7
1.4875 37.7825 1.5015 38.1381 1.4960 37.9984 8.90 226.06 10.90 276.86
MFS 8
MFS 10
1.7800 45.2120 1.7955 45.6057 1.7900 45.4660 10.25 260.35 12.25 311.15
MFS 12
SAPH08Z060200011
3. WHEEL-END SEAL DRIVER APPLICATION CHART

(1) MFS-6 AXLE
2 3
6
9 7
8
14
10
11
12
13
4004354a
1 5.9” (150 MM) 5 0.75” (19 MM) 9 R 0.2” (5 MM) 12 1.77” (45 MM)
2 1.02” (26 MM) 6 1.85” (47 MM) 10 1.5” (38 MM) 13 3.66” (93 MM)
3 R 0.2” (5 MM) 7 R 0.06” (1.5 MM) 11 1.1” (28 MM) 14 R 0.08” (2 MM)
4 0.13” (8 MM) 8 2.26” (57.3 MM) ± 0.01. (0.25 MM)
SAPH08Z060200012
(2) MFS-8 AXLE
9
8
10
4
6 7
5
3 2 12 13 14
1
11
21
20 15
19
16
17
18
4004353a
1 0.75” (19.1 MM) 7 R 0.5” (12.7 MM) 13 3.29” (83.57 MM) 18 2” (50.8 MM)
2 1.5” (38.1 MM) DIAMETER 8 0.25” (6.35 MM) X 45˚ TYP 14 4.5” (114 MM) 19 10” (254 MM)
3 2” (50.8 MM) DIAMETER 9 0.25” (6.35 MM) X 60˚ 15 R 0.25” (6.35 MM) 20 5” (127 MM)
4 0.06”(1.52 MM) X 45˚ 10 0.03” (0.76 MM) X 45˚ 16 0.1” (2.54 MM) 21 0.5” (12.7 MM)
TYP 11 1” (25 MM) DIAMETER-8.5” 17 0.75” (19.1 MM) 22 6” (152.4 MM)
5 R 0.13” (3.3 MM) (216 MM) DEEP SPHERE RADIUS
6 COARSE KNURL 12 2.16” (54.8 MM) DIAMETER
SAPH08Z060200013
(3) MFS-10 AXLE
8
7
6 9
5 4 10 11 12 13 14
1
2
15
16
17
18
19
20
21
4004351a
1 0.13” (3.3 MM) RADIUS (2) 7 0.25” (6.35 MM) X 45˚ CHAMFER 12 2.62/2.622” (66.55/66.6 MM) 17 2.85” (72.4 MM)
2 0.6” (1.52 MM) X 45 CHAMFER (2) 8 0.03” (0.76 MM) X 45˚ CHAMFER (2) DIAMETER 18 3.5” (88.9 MM)
3 6” (152.4 MM) SPHERE RADIUS 9 0.12” (3.05 MM) X 0.13” (3.3 MM) 13 4.5” (114 MM) DIAMETER 19 7.5” (190.5 MM)
± 0.25. (6.35 MM) CHAMFER 14 5” (127 MM) DIAMETER 20 8” (203.2 MM)
4 2” (50.8 MM) DIAMETER 10 1.5” (38.1 MM) DIAMETER 15 2.25” (57.2 MM) 21 8.75” (222.25 MM)
5 2.5” (63.5 MM) DIAMETER 11 2” (50.8 MM) 16 2.75” (69.9 MM)
6 COARSE KNURL
SAPH08Z060200014
(4) MFS-12 AXLE
6 8 9
5 4 10 11 12 13 14 15
1
2
16
17
18
19
20
21
22
23
4004352a
1 0.13” (3.3 MM) RADIUS (2) 8 0.06” (1.52 MM) R-2PLS 14 4.4” (111.76 MM) DIAMETER 20 2.62” (69.85 MM)
2 0.06” (1.52 MM) X 45˚ CHAMFER (2) 9 0.12” (3.05 MM) X 30˚ 15 4.865” (123.57 MM) DIAMETER 21 2.75” (69.85 MM)
3 6” (152.4 MM) SPHERE RADIUS ^2.5 10 0.25” (6.35 MM) R 16 5.38” (136.65 MM) DIAMETER 22 3.5” (88.9 MM)
4 2” (50.8 MM) 11 1.5” (38.1 MM) DIAMETER 17 0.03” (0.76 MM) R. MAX. 23 7.5” (190.5 MM)
5 2.5” (63.5 MM) DIAMETER 12 2” (50.8 MM) DIAMETER 18 2.25” (57.15 MM) 24 8.” (203.2 MM)
6 COARSE KNURL 13 2.60/2.622” (66.55/66.6 MM) 19 2.5” (63.5 MM) 25 8.75” (222.25 MM)
7 0.03” (0.76 MM) X 45˚ CHAMFER (2) DIAMETER
SAPH08Z060200015
INTRODUCTION
EN08Z0602A100002
1. HAZARD ALERT MESSAGES

Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent seri-
ous personal injury, damage to components, or both.
! WARNING
To prevent serious eye injury, always wear safe eye protection when
you perform vehicle maintenance or service.
2. DESCRIPTION
The descriptions and procedures contained in this maintenance man-
ual are applicable to all Meritor front non-drive steer axles.
Meritor front non-drive steer axles in this manual feature the following
components.
3. TIE ROD ARM, KNUCKLE AND KING PIN

DRIVER SIDE The right tie rod arm is a mirror image of the left, and they are linked
by the cross tube assembly. An integral tie rod design is used on Easy
Steer PlusTM and MFS axles.
STEERING
ARM CURBSIDE
The right knuckle and king pin assembly is similar to the left, except
KNUCKLE that it does not have a steering arm attached to it as in a manual
TIE steering system.
ROD
TIE ARM
ROD
END TIE ROD CROSS
TUBE ASSEMBLY A power steering system requires a steering arm in various applica-
CONVENTIONAL NON-DRIVE STEER AXLE 1000318c tions for attachment of the auxiliary assist cylinder to the right knuckle.
SAPH08Z060200016
4. STEERING KNUCKLE
Steering knuckles are rated according to the capacity of the front axle.
All models use straight king pins. Three types of king pin bushings are
used: nylon, bronze and Easy SteerTM.
The brake spider has been combined into the knuckle of the Easy
Steer PlusTM axle.
5. STEERING ARMS
The steering arm, usually a forged component, converts the drag link
force into a turning movement through the left king pin and the
knuckle. Bolt-on steering arms are used on Easy Steer PlusTM and
MFS modular axles.
6. PITMAN ARM
The Pitman arm converts the output torque from the steering gear into
the control force applied to the drag link. This linkage component con-
nects the steering gear to the linkage at the center link end.
INSPECTION
EN08Z0602F200001
HAZARD ALERT MESSAGES

Read and observe all Warning and Caution hazard alert messages in this
publication. They provide information that can help prevent serious per-
sonal injury, damage to components, or both.
! WARNING
Park the vehicle on a level surface. Block the wheels to prevent the
vehicle from moving. Support the vehicle with safety stands. Do not
work under a vehicle supported only by jacks. Jacks can slip and fall
over. Serious personal injury and damage to components can result.
Replace damaged or out-of-specification axle components. Do not

bend, repair or recondition axle components by welding or heat-treat-
ing. A bent axle beam reduces axle strength, affects vehicle operation
and voids Meritor's warranty. Serious personal injury and damage to
components can result.
Before inspecting axle components, verify that the correct tools are avail-
able. Using the correct tools will ensure safety and provide the most accu-
rate results.
• Dial indicator
• Tire blocks
• Jack
• Safety stands
• Pry bar
• Torque wrench
1. RECOMMENDATION
Meritor believes that the wheel attachment clamp joint must be care-
fully maintained with:
• Correct hardware.
• Clean, flat, uncontaminated mounting surfaces.
• Correct nut torquing and retorquing practices.
Meritor believes that installing a wheel separator plate may make it

more difficult to ensure correct wheel clamp with use over time. Refer
to the wheel separator plate manufacturer's recommended wheel stud
nut torque maintenance practices.
Meritor further believes that the use of more than one wheel separator
plate in a wheel end is inappropriate and that a wheel separator plate
should never be installed between the hub and the drum. This prac-
tice is expressly prohibited with Meritor axle models MFS-12, FF-981,
FF-982, FF-983, FF-984, FF-986 and FF-987.
Therefore, Meritor recommends that vehicle owners who install and

use wheel separator plates should also increase the frequency of their
wheel-end maintenance, consistent with wheel separator plate manu-
facturer's recommended practices, so they are confident that the
intended wheel attachment clamp integrity is maintained.
In addition, Meritor recommends that the users of wheel separator

plates should contact the wheel separator plate manufacturers to
obtain recommendations and approval for any special application or
more demanding environments (i.e., use at elevated temperature
ranges or frequent stop-start cycling) which may also potentially affect
the integrity of the wheel attachment system.
2. INSPECT PARTS
(1) Fasteners
a. Verify that all fasteners are tightened to the specified torque.
b. Use a torque wrench to check the torque. As soon as the fastener
starts to move, record the torque. Correct if necessary.
c. Replace any worn or damaged fasteners.
(2) Wear and Damage
Inspect the parts of the axle for wear and damage. Look for bent or
cracked parts. Replace all worn or damaged parts.
(3) Pivot Points
Verify that pivot points are not loose. Verify that the pivot points are
lubricated.
(4) Operation
Verify that all the parts move smoothly through the complete turning
radius.
(5) Tire Wear
Inspect the tires for wear patterns that indicate suspension damage or
misalignment. Correct if necessary.
(6) Steering Arm Bolts
DRAW KEY NUT Check the torque on all bolt-on steering arm bolts every 200,000
30-45 LB-FT (41-61 N·m)
miles (320 000 km).
(7) Draw Key Nuts
On axles with either conventional or unitized wheel ends, tighten the
draw key nuts to 30-45 lb-ft (41-61 N⋅m) at the following intervals.
• After the first 6,000 miles (10 000 km) of new vehicle operation
• Every 36,000 miles (58 000 km) of operation
1000004b
SAPH08Z060200017
3. STEERING KNUCKLE VERTICAL END PLAY
End Play Specifications
New or Rebuilt Axles 0.001-0.025-inch (0.025-0.635 mm)

In-Service Axles 0.001-0.065-inch (0.025-1.650 mm)
(1) Axles with Conventional Wheel Ends

a. Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving. Set the parking brake.
b. Use a jack to raise the vehicle until the front wheels are off the
ground. Support the front axle with safety stands.
c. Install a dial indicator with the base on the I-beam and the tip on
the top knuckle cap.
1000321c
SAPH08Z060200018
d. Place a pry bar between the boss for the tie rod arm and the I-
beam. Push the knuckle to the BOTTOM of vertical travel.
e. Set the dial indicator on ZERO.
f. Use the pry bar to push the knuckle UPWARD. Record the read-
ing on the dial indicator.
PRY BAR • If the reading is ZERO: Remove the knuckle. Refer to "Draw Keys,
King Pin Caps, King Pins and Steering Knuckle" on page AX02-26.
Remove the shims from the shim pack. Refer to "Knuckle to the Axle
Beam" on page AX02-43.
• If the reading is more than the correct end play: Remove the
1000004c knuckle. Refer to "Draw Keys, King Pin Caps, King Pins and Steering
SAPH08Z060200019
Knuckle" on page AX02-26. Add shims to the shim pack. Refer to
"Knuckle to the Axle Beam" on page AX02-43.
4. UPPER AND LOWER KING PIN BUSHINGS

(1) Wheel-to-Hub Mounting
To help determine the cause of movement and looseness, first check
the wheel-to-hub mounting.
a. Verify that the wheel is mounted correctly and all wheel-end fas-
teners and hardware are tightened to the correct specification.
b. Apply the service brake to lock the hub and spindle together.
• If movement is detected: The king pin or king pin bushings should
be inspected. Refer to the procedure below.
• If applying the service brake eliminates the movement: Proceed
to "Unitized Wheel Ends", "Detailed Inspection" to determine the unit-
ized wheel-end hub end play.
(2) Axles with Conventional and Unitized Wheel Ends

b. Use a jack to raise the vehicle until the wheels are off the ground.
Support the vehicle with safety stands.
c. Check the upper king pin bushing for wear. Install a dial indicator
with the base on the I-beam and the tip against the side of the top
of the knuckle.
CONVENTIONAL WHEEL END — DRIVER SIDE
d. Set the dial indicator to ZERO.
1000323d
SAPH08Z060200020
e. Move the top of the tire side-to-side TOWARD and AWAY from the
vehicle.
• If the dial indicator moves a total of 0.010-inch (0.254 mm): The
upper bushing is worn or damaged. Replace both bushings in the
knuckle. Refer to "King Pin Bushings" on page AX02-30, "Inspection"
on page AX02-35 and "King Pin Bushings" on page AX02-39.
f. Check the lower king pin bushing. Install a dial indicator so that
the base is on the I-beam and that the tip is against the side of the
CONVENTIONAL WHEEL END — FRONT VIEW CURBSIDE
bottom of the knuckle.
1000324d g. Set the dial indicator to ZERO.
h. Move the bottom of the tire side-to-side TOWARD and AWAY from
SAPH08Z060200021 the vehicle.
• If the dial indicator moves a total of 0.010-inch (0.254 mm): The
lower bushing is worn or damaged. Replace both bushings in the
knuckle. Refer to "King Pin Bushings" on page AX02-30, "Inspection"
on page AX02-35 and "King Pin Bushings" on page AX02-39.
5. TIE ROD AND CROSS TUBE ASSEMBLY

NOTICE
Do not grease the tie rod assembly before you perform the inspection.
BALL/STUD
You may not be able to detect loose or worn tie rod ends during oper-
ation. Under normal operating conditions, wear occurs over time. The
preload bearings inside each tie rod end provide less resistance,
which can affect steering control, front tire wear and other axle com-
BALL/STUD
ponents.
NATURAL
PIVOT
WEAR Regularly-scheduled inspection and maintenance helps to minimize
the effects of tie rod end wear on the vehicle.
BALL/STUD
NATURAL
BEARING
WEAR
SOLID STEEL
BEARING SURFACE 1003401f
SAPH08Z060200022
(1) Park the vehicle on a level surface with the wheels STRAIGHT. Block
the wheels to prevent the vehicle from moving. Set the parking brake.
(2) Raise the vehicle so that the front wheels are off the ground. Support
the vehicle with safety stands. Do not use a jack to support the vehi-
cle.
(3) With the engine off, turn the wheels from full left to full right. Return to
the straight-ahead position. This step will require more force for vehi-
cles with the power steering off.
TIE TIE
CROSS
ROD ROD
TUBE
ARM END 1000325b
SAPH08Z060200023
(4) Check the tie rod boot for cracks, tears or other damage. Also check
Cracked or torn boot requires the boot seals for damage. Replace the entire tie rod end if the boot is
entire tie rod end replacement. damaged or missing.
! WARNING
Verify that a cotter pin is installed through the tie rod end, and the tie
rod end nut is tightened to the correct torque specification. Replace a
missing cotter pin and tighten a loose tie rod end nut. A missing cot-
ter pin or loose tie rod end nut can cause loss of steering control.
Serious personal injury and damage to components can result.
4000283b
SAPH08Z060200024
(5) Check that the tie rod nut is installed and secured with a cotter pin.
Missing cotter pin
indicates unsafe • If the cotter pin is missing: Tighten the tie rod end nut to the correct
condition and requires
immediate replacement. specification. Install a new cotter pin. Always tighten the tie rod nut to
the specified torque when setting the cotter pin. Refer to page AX02-
8. Do not back-off the nut to insert the cotter pin.
STEERING
KNUCKLE 4000284a
SAPH08Z060200025
(6) Check that the tie rod end is threaded correctly into the cross tube
Tie rod end installed
deeper than the end of and installed deeper than the end of the cross tube slot. The tie rod
the cross tube slot. end must be visible the entire length of the cross tube slot.
TIE ROD Tie rod threads

CROSS must be visible
TUBE SLOT the entire length
END of the cross tube slot. 4000285a
SAPH08Z060200026
(7) Check that the grease fittings are installed. Replace a damaged
grease fitting.
ALTERNATE
GREASE
FITTING
• If the tie rod ends are non-greaseable: Do not install a grease fit-
LOCATIONS ting.
(8) By hand or using a pipe wrench with jaw protectors to avoid gouging
the cross tube, rotate the cross tube toward the FRONT of the vehicle
and then toward the REAR. After rotating, center the cross tube
between the stop positions.
• If the cross tube will not rotate in either direction: Replace both tie
4000289a rod ends.
(9) Position yourself directly below the ball stud socket. Using both hands,
SAPH08Z060200027 grasp the assembly end as close to the socket as possible, no more
than 6-inches (152.4 mm) from the end.
! CAUTION
Only use your hands to check for movement or looseness of the tie
rod assembly. Do not use a crow bar, pickle fork or two-by-four. Do not
apply pressure or force to tie rod assembly ends or joints. Do not rock
the tires with the vehicle on the ground or with the wheels raised.
Damage to components can result.
(10) Apply hand pressure of approximately 100 pounds in a vertical PUSH
and PULL motion several times. Check for any movement or loose-
ness at both tie rod ends.
• If there is any movement in the tie rod assembly: Replace both tie
rod ends.
Push. ! CAUTION
Replace bent or damaged cross tubes with original equipment parts
of the same length, diameter and threads. Do not attempt to
straighten a bent cross tube. Damage to components can result.
Check movement
by hand. Pull.
4000287a
SAPH08Z060200028
(11) Inspect the cross tube and clamps for damage.

CROSS
TUBE • If the cross tube is bent or cracked: Replace it. Use original equip-
CLAMP ment parts of the same length, diameter and threads.
• If the clamps are damaged: Replace them.
• If either clamp has become welded to the cross tube: Replace the
entire cross tube assembly. Use original equipment parts of the same
length, diameter and threads.
CRACK
DAMAGE
4000288a
SAPH08Z060200029
6. DEPARTMENT OF TRANSPORTATION ROADSIDE TIE ROD

ASSEMBLY REPLACEMENT CRITERIA
When the roadside check indicates tie rod movement of 1/8-inch (3
mm) or more, immediately remove the vehicle from service to replace
the tie rod.
• If the roadside check is less than 1/8-inch (3 mm) tie rod end
movement: The vehicle does not need to be immediately removed
from a service run. Schedule a major out-of-service inspection and
maintenance as soon as possible.
DISASSEMBLY
EN08Z0602H200001

! WARNING
Use a brass or leather mallet for assembly and disassembly proce-

dures. Do not hit steel parts with a steel hammer. Pieces of a part can
break off and cause serious personal injury.
REMOVAL
1. WHEEL ENDS
(1) Axles with conventional wheel ends.
b. Raise the front of the vehicle until the front wheels are off the
floor. Support the vehicle with safety stands.
c. Use the correct size socket to remove the capscrews that fasten
the cap to the hub. Remove the cap and the gasket.
d. Remove the fasteners for the wheel bearings.
.
DOUBLE NUT AND LOCK ADJUSTMENT

1. For double nut and lock fasteners, bend the tabs of the flattened lock
PIERCED washer away from the wheel bearing nut and the adjusting nut.
WHEEL LOCK RING
BEARING
NUT
2. Remove the wheel bearing nut, the lock washer, the pierced lock ring
and the adjusting nut from the knuckle.
e. Remove the outer wheel bearing cone from the hub. Remove the
ADJUSTING
wheel, tire, hub and drum as an assembly.
WHEEL
NUT f. Remove the brake components.
BEARING
NUT LOCK g. Remove the oil seal from the hub. Remove the inner wheel bear-
WASHER 1000354c ing cone.
h. Inspect the wheel bearings. Refer to "Wheel Bearings" on page
SAPH08Z060200030
AX02-36.
2. DRAG LINK
(1) Remove the cotter pins from the ball studs. Remove the nuts from the
ball studs.
(2) Disconnect the drag link from the Pitman arm and the steering arm.
Inspect the drag link. Refer to "INSPECTION" on page AX02-35.
DRAG STEERING
PITMAN LINK
ARM ARM 1000349b
SAPH08Z060200031
3. STEERING ARM
(1) Axles with a keyed steering arm.
a. Remove the cotter pin and nut that fasten the steering arm to the
drag link. Disconnect the steering arm from the drag link.
STEERING
ARM COTTER b. Remove the cotter pin and nut that fasten the steering arm to the
PIN
knuckle.
c. Remove the steering arm from the knuckle. If necessary, use a
leather or plastic mallet to tap on the end of the arm and separate
the arm from the knuckle.
d. Remove the key from the steering arm. Inspect the steering arm.
Refer to "INSPECTION" on page AX02-35.
NUT KEY
4000693a
SAPH08Z060200032
(2) Axles with a bolt-on steering arm.

a. Remove the two steering-arm-to-knuckle capscrews from the
knuckle assembly.
b. Remove the steering arm from the knuckle. If necessary, use a
leather or plastic mallet to tap the outside of the arm and separate
the arm from the knuckle.
c. Remove the steering arm. Inspect the steering arm. Refer to
"INSPECTION" on page AX02-35.
1000025c
SAPH08Z060200033
4. TIE ROD ARMS, TIE ROD ENDS AND CROSS TUBE

! WARNING
Support the tie rod assembly during maintenance and service to pre-
vent serious personal injury and damage to components. If the cross
tube clamps are tack-welded, do not remove the tack weld during tie
rod assembly removal. If you remove the tack weld, clamp force is
reduced. Replace the cross tube if the weld is broken. Loss of steer-
ing control, serious personal injury and damage to components can
result.
! CAUTION
Do not heat the arm to remove the tie rod assembly. Heating the tie
rod arm will soften parts. Damage to components will result.
(1) Axles with Removable Tie Rod Arms
a. Remove the cotter pins and nuts that fasten each tie rod end to
the tie rod arms.
b. Disconnect the cross tube assembly from the tie rod arms. If avail-
TIE ROD able, use a tie rod end puller to separate the tie rod end from the
ARM
tie rod arm.
c. Remove the cotter pin and nut that fastens the tie rod arms in the
TIE ROD
END
knuckle.
d. Remove the tie rod arms from the knuckle. If necessary, use a
leather or plastic mallet to tap on the end of the rod. Remove the
1000351b key.
SAPH08Z060200034
e. If necessary, use this procedure to remove the tie rod ends.

BOTTOM VIEW
.
CROSS TIE a. Mark the position of each tie rod end in the cross tube. Count and
TUBE ROD END
record the number of threads that appear outside of the cross tube.
b. Remove the bolts and nuts from the clamp on the cross tube. Rotate
the cross tube clamp to remove the nuts and bolts from the clamp.
c. Remove the tie rod ends from the cross tube.
TUBE
SLOT MARKS 1000027b
SAPH08Z060200035
f. Inspect the parts. Refer to "INSPECTION" on page AX02-35.
CLAMP
BOLT
AND
NUT 1000353b
SAPH08Z060200036
(2) Axles with integral tie rod arms.

a. Remove the cotter pins and nuts that fasten each tie rod end to
the tie rod arms.
b. Disconnect the cross tube assembly from the tie rod arms. If avail-
able, use a tie rod end puller to separate the tie rod end from the
tie rod arm. If necessary, use a leather or plastic mallet to tap on
the tie rod end to loosen and remove it.
TIE
ROD c. If necessary, use this procedure to remove the tie rod ends.
.
ARM 1. Mark the position of each tie rod end in the cross tube. Count and
TIE
ROD record the number of threads that appear outside of the cross tube.
END 1000026b 2. Remove the bolts and nuts from the clamp on the cross tube. Rotate
SAPH08Z060200037
the cross tube clamp to remove the nuts and bolts from the clamp.
3. Remove the tie rod ends from the cross tube.
d. Inspect the parts. Refer to "INSPECTION" on page AX02-35.
5. DRAW KEYS, KING PIN CAPS, KING PINS AND STEERING

KNUCKLE
(1) Axles with bolt-on king pin caps.
a. Remove the wheel ends as described in this section.
b. Vent the air from the brake system. Disconnect the air lines from
the brakes.
c. Remove the brake components.
d. Remove the tie rod arms and the steering arm from the knuckle.
Refer to the procedure in this section.
e. Remove the capscrews that fasten the king pin caps to the top
and the bottom of the knuckle. Remove the caps and the gasket.
KNUCKLE
CAP
f. Remove the plain or the threaded draw keys. Refer to below
GASKET Table.
Threaded or Plain Draw Keys
Threaded Draw Keys Plain Draw Keys
All other axle models FC-901, FC-921, FE-970, FF-971

and FL-901
1000356b
SAPH08Z060200038
• For plain draw keys: Use a brass hammer and a steel drift to remove
the draw key. Place the drift onto the small, "D"-shaped end of the key.
1000390b
SAPH08Z060200039
• For threaded draw keys: Perform the following procedure.

DRAW g. Loosen the threaded draw key lock nut until the top of the lock nut
KEY is even with the end of the draw key.
NUT
h. Use a brass drift and a hammer to hit the end of the draw key.
i. Remove the nut from the draw key. Remove the draw key from the
knuckle.
j. If you're not replacing the bushings, use the following procedure
to prevent damaging the bushings during king pin removal.
k. Use a brass drift and a hammer to remove the king pins from the
knuckle.
1000358b l. Remove any flaring on the drift that touches the bushings.
SAPH08Z060200040 m. Wrap tape to a thickness of 1/16-inch (1.5 mm) onto the end of
the drift.
n. If the king pin is hard to remove, use a hydraulic king pin remover.
Refer to "Special Tools" in Section 11. To obtain this tool, refer to
the Service Notes page on the front inside cover of this manual.
o. Remove the knuckle from the axle beam.
! WARNING
Wear gloves when you remove or install shims. Shims have sharp
edges that can cause serious personal injury.
KING PIN
1000359b
SAPH08Z060200041
p. While wearing gloves, remove the shims, the thrust bearing and
KNUCKLE
SHIMS,
the seal from the beam and knuckle.
BETWEEN
KNUCKLE q. Inspect the parts. Refer to "INSPECTION" on page AX02-35.
AND BEAM
THRUST BEARING
AND SEAL 1000360b
SAPH08Z060200042
(2) Axles with threaded king pin caps.

a. Remove the wheel end as described in this section.
b. Vent the air from the brake system. Disconnect the air lines from
CAP the brakes.
c. Remove the brake components. Refer to the brake manufacturer's
procedures.
d. Remove the steering arm from the knuckle, if applicable.
e. Remove the top and bottom king pin caps.
1000030b
SAPH08Z060200043
f. Use the following procedure to remove the upper and lower draw
keys from the knuckle.
g. Loosen the draw key nut. Use a brass drift and a hammer to hit
the end of the draw key.
HAMMER 1000031b
SAPH08Z060200044
h. Remove the nut from the draw key. Remove the draw key from the
knuckle.
NUT DRAW
KEY 1000032b
SAPH08Z060200045
i. If you're not replacing the bushings, use the following procedure

to prevent damage to the bushings during king pin removal.
BRASS j. Use a hammer and brass drift to remove the king pins from the
DRIFT
TOOL knuckle.
k. Remove any flaring on the drift that touches the bushings.
l. Wrap tape to a thickness of 1/16-inch (1.5 mm) onto the end of
the drift.
KING
PIN 1000033b
SAPH08Z060200046
m. If the king pin is hard to remove, use a hydraulic king pin remover.
Refer to "Special Tools" on page AX02-11. To obtain this tool,
refer to the Service Notes on page AX02-10.
! WARNING
Wear gloves when you remove or install shims. Shims have sharp
edges that can cause serious personal injury.
n. While wearing gloves, remove the integral thrust bearing and
KNUCKLE SHIMS, seal, and the shims from the beam and knuckle.
BETWEEN
KNUCKLE
AND BEAM
THRUST
BEARING
AND SEAL
Use gloves.
1000034b
SAPH08Z060200047
o. Remove the knuckle from the axle beam. Inspect the parts. Refer
to "INSPECTION" on page AX02-35.
INTEGRAL THRUST
BEARING SEAL
ASSEMBLY
1000035b
SAPH08Z060200048
6. KING PIN BUSHINGS

! WARNING
Observe all warnings and cautions provided by the press manufac-
turer to avoid damage to components and serious personal injury.
(1) Axles with Conventional Wheel Ends — Nylon Bushings
CONVENTIONAL
KING a. Remove and discard the lower king pin seal.
PIN b. Turn the knuckle upside down and remove the upper king pin
SEAL
seal. Remove the old bushings.
1000361b
SAPH08Z060200049
c. Remove the top and the bottom bushings from the knuckle bore.
NYLON
BUSHING
1000375c
SAPH08Z060200050
(2) Axles with Conventional Wheel Ends — Easy SteerTM and Bronze
Bushings
a. Remove and discard the lower king pin seal.
b. Turn the knuckle upside down and remove the upper king pin
seal. Remove the old bushings.
NOTICE
For some axles, you can remove the bushings with a bushing service
kit. Refer to "Special Tools" on page AX02-11.
c. Make a tool to remove the bushings. Refer to "Special Tools" on
page AX02-11.
d. Place the knuckle in a vise. Use a press with a five-ton capacity.

The knuckle must not move when the bushings are removed.
e. Install the tool into the upper king pin bushing. Press the upper
king pin bushing from the knuckle bore.
f. Turn the knuckle upside down and install the tool into the lower
UPPER king pin bushing. Press the lower bushing from the knuckle bore.
KING PIN
BUSHING
POSITION OF BUSHINGS
IN KNUCKLE
LOWER
KING PIN
BUSHING
1000363b
SAPH08Z060200051
PREPARE PARTS FOR ASSEMBLY

EN08Z0602A100003
REPLACE
1. WORN OR DAMAGED PARTS

Do not repair or recondition front axle components. Replace damaged
or out-of-specification components. All major components are heat-
treated and tempered.
Do not perform the following operations on front axle components.
• Weld steering arms, tie rod arms, knuckles, king pins, axle beams, tie
rod assemblies, hubs, drums or brakes.
• Hot- or cold-bend the knuckles, steering arms, tie rod arms, ball
studs, axle beams or tie rod assemblies.
• Drill holes in the axle beam for the king pins.
• Drill draw key holes in the knuckle.
• Spray-weld bearing diameters onto the knuckles or into the machined
bores.
• Disassemble the unitized wheel end.
• Mill or machine any components.
! WARNING
Solvent cleaners can be flammable, poisonous and cause burns.
Examples of solvent cleaners are carbon tetrachloride, and emulsion-
type and petroleum-base cleaners. Read the manufacturer's instruc-
tions before using a solvent cleaner, then carefully follow the instruc-
tions. Also follow the procedures below.
• Wear safe eye protection.
• Wear clothing that protects your skin.
• Work in a well-ventilated area.
• Do not use gasoline, or solvents that contain gasoline. Gasoline
can explode.
• You must use hot solution tanks or alkaline solutions correctly.
Read the manufacturer's instructions before using hot solution
tanks and alkaline solutions. Then carefully follow the instruc-
tions.
! CAUTION
Do not use hot solution tanks or water and alkaline solutions to clean
ground or polished parts. Damage to parts can result.
2. CLEAN, DRY AND INSPECT PARTS

(1) Ground or Polished Parts
Use a cleaning solvent to clean the ground or polished parts and sur-
faces. Kerosene or diesel fuel can be used for this purpose. DO NOT
USE GASOLINE.
Do NOT clean ground or polished parts in a hot solution tank or with

water, steam or alkaline solutions. These solutions will cause corro-
sion of the parts.
(2) Rough Parts
Rough parts can be cleaned with the ground or polished parts. Rough
parts also can be cleaned in hot solution tanks with a weak alkaline
solution. Parts must remain in the hot solution tanks until they are
completely cleaned and heated.
(3) Dry Cleaned Parts

Parts must be dried immediately after cleaning. Dry parts with clean
paper or rags, or compressed air. Do not dry bearings by spinning
with compressed air.
(4) Prevent Corrosion on Cleaned Parts
Apply a light oil to cleaned and dried parts that are not damaged and
are to be immediately assembled. Do NOT apply oil to the brake lin-
ings or the brake drums.
If the parts are to be stored, apply a good corrosion preventative to all

surfaces. Do NOT apply the material to the brake linings or the brake
drums. Store the parts inside special paper or other material that pre-
vents corrosion.
NOTICE
All tapered joints must be clean and dry with no lubrication or corro-
sion preventative applied to the mating surfaces.
INSTALLATION
1. NEW FASTENERS WITH PRE-APPLIED ADHESIVE PATCHES

(1) Clean the oil and dirt from the threaded holes. Use a wire brush to
remove the old patch material. There is no special cleaning required.
! CAUTION
Do not apply adhesives or sealants onto new fasteners with pre-
applied adhesive patches or into the threaded holes. If other adhe-
sives or sealants are used, the new adhesive will not function cor-
rectly. Damage to components can result.
(2) Assemble the parts using the new pre-applied adhesive fasteners.
NOTICE
There is no drying time required for fasteners with pre-applied adhe-
sive.
(3) Tighten the fasteners to the required torque value for that size fas-
tener. Refer to "Front Non-Drive Axles with Conventional Wheel
Ends", "Torque Specifications" on page AX02-8.
2. ORIGINAL OR USED FASTENERS USING MERITOR SPECIFICA-

TION 2297-C-7049 LIQUID ADHESIVE, LOCTITE 680 ADHESIVE
OR EQUIVALENT
! WARNING
Take care when you use Loctite adhesive to avoid serious personal
injury. Read the manufacturer's instructions before using this prod-
uct. Follow the instructions to prevent irritation to the eyes and skin.
(1) Clean the oil, dirt and old adhesive from all threads and threaded
holes. Use a wire brush.
! CAUTION
Do not apply adhesive to the fastener threads. Air pressure in the hole
will push the adhesive out as the fastener is installed. Damage to
NOTICE
There is no drying time required for Meritor specification 2297-C-7049
liquid adhesive, Loctite 680 adhesive or equivalent.
(2) Apply four or five drops of Meritor liquid adhesive, Loctite 680 adhe-
AXLE WITH BOTTLE SPINDLE
sive or equivalent into each threaded hole or bore only.
Add four to five
drops of adhesive (3) Tighten the fasteners to the required torque value for that size fas-
into bore. Torque fastener
to specifications. tener. Refer to "Front Non-Drive Axles with Conventional Wheel
1000365b
SAPH08Z060200052
3. CHECK THE TORQUE VALUES OF DRI-LOC, FASTENERS NOT

REQUIRING REMOVAL
If Dri-Loc fasteners do not require removal from components, use
the following procedure to check the fasteners for the correct torque
value.
Apply the minimum amount of torque required for that size fastener.
Refer to page AX02-8. The fastener must not rotate.
• If the fastener rotates: Remove the fastener from the component.
Inspect the fastener and the hole for wear and damage. Repair as
necessary.
• If the fastener and the hole are in good condition: Apply adhesive
into the threaded hole. Follow the procedure to install old Dri-Loc
fasteners.
INSPECTION
1. AXLES WITH CONVENTIONAL AND UNITIZED WHEEL ENDS

! WARNING
Use only dye penetrant inspection techniques on unitized wheel-end
hub units. Be careful not to get penetrant fluids into the bore of the
hub unit. Do not use fluid immersion-based crack inspection tech-
niques. The fluids can enter the joint between the inner bearing cones
through the bore of the hub unit and damage the lubricant. Serious
personal injury and damage to components can result.
Refer to the following guidelines to carefully inspect all disassembled

parts before assembly.
(1) Inspect and replace any parts that are worn, cracked or damaged.
Check for cracks using dye penetrant, magnetic flux or fluorescent
particle testing methods. Follow the inspection product manufacturer's
procedures.
(2) Remove the old bushing from the knuckle. Measure the upper knuckle
bore inside diameter at two locations. Always use a micrometer and a
telescoping gauge when taking knuckle bore measurements. Some
rounding of the top and bottom bore edges is acceptable.
(3) Measure the bore in four positions and at two locations. The two loca-
tions must be 90 degrees opposite each other.
MEASUREMENT • If the average measurement is more than the knuckle bore maxi-
PROCEDURE mum diameter specification on page AX02-36: Replace the
knuckle.
Measure here,
then rotate 90 .
UPPER
And repeat BORE
here.
Do same
down here. 1000366b
SAPH08Z060200053
(4) Repeat this procedure for measuring the lower knuckle bore. Refer to
the knuckle bore maximum diameter on page AX02-36.
Measure bushing bore

• If measurements at either the upper or lower knuckle bores
in four positions exceed the knuckle bore maximum diameter on page AX02-36:
(90˚ opposed). Replace the knuckle.
(5) Measure the king pin bushing inside diameter using a micrometer and
a telescoping gauge.
KING PIN
BUSHING • If the average inside diameter measurement is greater than the
MEASUREMENT king pin bushing maximum inner diameter on page AX02-36:
CONVENTIONAL
Install a new bushing.
1000367c
SAPH08Z060200054
(6) Measure the inner diameter of the new bushing after installation and
reaming in four positions and at two locations. The two locations must
be 90 degrees opposite each other.
• If the average measurement is more than the king pin bushing
maximum inner diameter specification on page AX02-36: Replace
the bushing.
(7) Measure the inner bore diameter of the axle beam. Rounding at the
Measure bore in
four positions
top and bottom of the beam is acceptable. Measure the axle beam
(90 opposed). bore at four positions and at two locations. Refer to the guidelines
0.5" below.
(12.7 MM)
AXLE BEAM
a. 0.5-inch (12.7 mm) below the top of the bore.
MEASUREMENT
b. 0.5-inch (12.7 mm) above the bottom of the bore.
• If the average measurement is greater than the axle beam bore
maximum diameter in Table D: Replace the entire axle beam.
0.5"
(12.7 MM)
1000368b
SAPH08Z060200055
Axle Wear Limits Specifications
Model Number Knuckle Bore Maximum Axle Beam Bore Maximum King Pin Bushing Maxi-
Diameter Diameter mum Inner Diameter
MFS 6 1.3615 in. (34.582 mm) 1.2380 in. (31.4450 mm) 1.2365 in. (31.4070 mm)
MFS 7
1.6295 in. (41.389 mm) 1.5040 in. (31.4450 mm) 1.5020 in. (38.1510 mm)
MFS 8
MFS 10
1.9220 in. (41.389 mm) 1.7960 in. (45.6180 mm) 1.7980 in. (45.6692 mm)
MFS 12
2. WHEEL BEARINGS
WORN Inspect the wheel bearings when the hub is removed from the knuckle
RADIUS
spindle.
Remove all lubricant from the bearings, knuckle, hub and hubcap.
Inspect the cup, the cone and the rollers and cage of all bearings. If
any of the following conditions exist, you must replace the bearing.
WORN • The center of the large diameter end of the rollers is worn level or
SURFACE 1000369c below the outer surface.
• The radius at the large diameter end of the rollers is worn to a sharp
SAPH08Z060200056
edge.
• There is a visible roller groove in the cup or the cone inner race sur-
faces. The groove can be seen at the small or large diameter end of
both parts.
• There are deep cracks or breaks in the cup, the cone inner race or the
CRACK WEAR GROOVE roller surfaces.
• There are bright wear marks on the outer surface of the roller cage.
• There is damage on the rollers and on the surfaces of the cup and the
cone inner race that touch the rollers.
• There is damage on the cup and the cone inner surfaces that touch
the rollers.
1000370b
SAPH08Z060200057
WEAR MARKS
1000465b
SAPH08Z060200058
ETCHING AND PITTING
1000372b
SAPH08Z060200059
SPALLING
AND
FLAKING
1000373d
SAPH08Z060200060
3. TIE ROD GREASE FITTINGS

GREASE (1) If a grease fitting is missing, install a new one. Do not install a fitting if
FITTING
ALTERNATE the tie rod end is a non-greaseable design.
LOCATION
1003414a
SAPH08Z060200061
(2) Tighten all grease fittings to 10 lb-ft (13.558 N⋅m).

GREASE FITTING
ALTERNATE LOCATION
TORQUE WRENCH
USED TO TIGHTEN
GREASE FITTING
TO SPECIFICATION 1003415b
SAPH08Z060200062
ASSEMBLY
EN08Z0602H200002
KING PIN BUSHINGS
1. BRONZE AND EASY STEERTM — KING PIN BUSHING INSTALLA-

TION WITHOUT A PRESS AXLES WITH CONVENTIONAL
NOTICE
For some axles you can install the bushings without a press. Use a
bushing service kit to install and ream the bushings. Refer to "Special
Tools" on page AX02-11.
Bronze and Easy SteerTM bushings have an interference fit in the
knuckle bores and require a bushing installation tool. Refer to "Special
Tools" on page AX02-11. To obtain this tool, refer to the Service Notes
on page AX02-10.
(1) Place the new bushing into the upper knuckle bore. On MFS-7 and -8
INSTALLATION front axles, the bushing hole must be aligned with the grease fitting
TOOL
UPPER KNUCKLE hole in the knuckle bore.
1/8" (3 MM) GREASE
DEPTH FITTING
INSTALLATION HOLES
BUSHINGS
LOWER KNUCKLE
1/8" (3 MM)
DEPTH
INSTALLATION 1000376c
SAPH08Z060200063
(2) Use the installation tool to start the bushing 1/8-inch (3 mm)
EASY STEERTM TYPE BUSHINGS
STRAIGHT into the upper bore.
UPPER KNUCKLE —
OUTSIDE
0.352-0.382"
a. On Easy SteerTM bushings and for MFS axles, press the bushing
(8.94-9.70 MM) to a depth of 0.352-0.382-inch (8.94-9.70 mm) below the top of
the upper knuckle bore or until the grease fitting holes are
aligned.
BUSHINGS
LOWER KNUCKLE —
OUTSIDE
0.352-0.382"
(8.94-9.70 MM) 1000377c
SAPH08Z060200064
b. On bronze bushings, press the bushing to a depth of 0.135-0.165-

BRONZE TYPE BUSHINGS inch (3.5-4.0 mm) above the bottom of the upper bore.
(3) Turn the knuckle over so that the bottom of the knuckle is UP. The
INSIDE bore must be parallel to the top of the press.
0.135-0.165"
(3.5-4.0 MM) (4) Place the new bushing into the lower knuckle bore. On MFS-7 and -8
front axles, the bushing hole must be aligned with the grease fitting
BUSHINGS hole in the knuckle bore.
INSIDE
0.135-0.165"
(3.5-4.0 MM)
1000378c
SAPH08Z060200065
INSTALLATION STRAIGHT into the lower bore.
TOOL
UPPER KNUCKLE
1/8" (3 MM) GREASE a. On Easy SteerTM bushings and for MFS axles, press the bushing
DEPTH FITTING to a depth of 0.352-0.382-inch (8.94-9.70 mm) below the top of
INSTALLATION HOLES the lower knuckle bore, as viewed with the knuckle upside down
or until the grease fitting holes are aligned.
BUSHINGS b. On bronze bushings, press the bushing to a depth of 0.135-0.165-
inch (3.5-4.0 mm) above the bottom of the lower bore, as viewed
LOWER KNUCKLE with the knuckle upside down.
1/8" (3 MM)
DEPTH
INSTALLATION 1000376c
SAPH08Z060200066
(6) Ream the bushings. Refer to "Ream the King Pin Bushings" on page
EASY STEERTM TYPE BUSHINGS
AX02-41.
UPPER KNUCKLE —
OUTSIDE
0.352-0.382"
(8.94-9.70 MM)
BUSHINGS
LOWER KNUCKLE —
OUTSIDE
0.352-0.382"
(8.94-9.70 MM) 1000377c
SAPH08Z060200067
BRONZE TYPE BUSHINGS

2. BRONZE AND EASY STEERTM KING PIN BUSHING INSTALLA-
TION WITH A PRESS — AXLES WITH CONVENTIONAL AND
INSIDE UNITIZED WHEEL ENDS
0.135-0.165" (1) Install the top king pin bushing first.
(3.5-4.0 MM)
! WARNING
BUSHINGS
Observe all warnings and cautions provided by the press manufac-
INSIDE turer to avoid damage to components and serious personal injury.
0.135-0.165"
(3.5-4.0 MM) (2) Place the knuckle in a press with the top of the knuckle toward the top
1000378c of the press. The top of the bores must be parallel to the top of the
SAPH08Z060200068
press.
(3) Place the new bushing into the upper knuckle bore. On MFS-7 and -8
hole in the knuckle bore.
(4) Use the installation tool to press the bushing 1/8-inch (3 mm)
STRAIGHT into the upper bore. Release the pressure.
to a depth of 0.352-0.382-inch (8.94-9.70 mm) below the top of
the upper knuckle bore or until the grease fitting holes are
aligned.
inch (3.5-4.0 mm) above the bottom of the upper bore.
(5) Turn the knuckle over so that the bottom of the knuckle is UP. The
bore must be parallel to the top of the press.
(6) Place the new bushing into the lower knuckle bore. On MFS-7 and -8
hole in the knuckle bore.
STRAIGHT into the lower bore. Release the pressure.
to a depth of 0.352-0.382-inch (8.94-9.70 mm) below the top of
the lower knuckle bore, as viewed with the knuckle upside down
or until the grease fitting holes are aligned.

inch (3.5-4.0 mm) above the bottom of the lower bore, as viewed
with the knuckle upside down.
(8) Ream the bushings. Refer to "Ream the King Pin Bushings", "Installa-
tion" below.
3. REAM THE KING PIN BUSHINGS

(1) Axles with Conventional and Unitized Wheel Ends — Bronze and
Easy SteerTM Bushings
! CAUTION
Use a fixed reamer to ream the king pin bushings. Do not hone or bur-
nish the bushings. Damage to the bushings will result.
NOTICE
Reamer tools are available from SPX Kent-Moore. Refer to "Special
Tools" on page AX02-11. To obtain these tools, refer to the Service
Notes on page AX02-10.
a. Place the knuckle in a vise with brass jaws.
Push down lightly.
b. Slide the pilot of the reamer through the top bushing until the
reamer blades touch the bushing.
REAMING UPPER BUSHING
1000380b
SAPH08Z060200069
Push down lightly.
1000047b
SAPH08Z060200070
(2) Rotate the reamer with a light DOWNWARD pressure. Do not apply
Push down lightly. too much force. Rotate the reamer smoothly.
(3) After cutting the top bushing, guide the reamer into the bottom bush-
REAMING ing. Do not allow the tool to drop to the bottom bushing. Repeat Step
UPPER
BUSHING (2) and Step (3).
(4) Slide the reamer out of the bottom bushing.
• If the reamer must be removed through the top bushing: Rotate
the tool in the opposite cutting direction.
1000381c
SAPH08Z060200071
(5) Clean all material from the bushings.

Push down lightly.
1000048b
SAPH08Z060200072
4. INNER KNUCKLE BORE KING PIN SEALS

Both upper and lower
inside seal lips must a. Place the top of the knuckle into a vise with brass jaws. The bot-
be away from bore.
tom of the knuckle must be TOWARD you.
b. Place the seal into the bottom of the top knuckle bore. The lip of
the seal must be AWAY from the bore.
1000382b
SAPH08Z060200073
c. Place the end cap for the knuckle on top of the seal. Slide the king
KING PIN pin through the opposite knuckle bore. Use the king pin to install
the seal.
• For bronze bushings: The bottom of the seal must touch the bush-
ing.
CAP
1000383c
SAPH08Z060200074
• For Easy SteerTM and nylon bushings: The top of the seal must be
MACHINED even with the top of the knuckle.
SURFACE SEAL
d. Turn the knuckle over in the vise. The jaws of the vise must hold
the bottom of the knuckle, and the top of the knuckle must be
toward you.
e. Place the seal into the top of the bottom knuckle bore. The lip of
the seal must be AWAY from the bore.
f. Repeat Step "C" of this procedure.
KNUCKLE BUSHING g. After installing the Easy SteerTM bushings, the top of the seal
BORE must be even with the inner machined surface of each knuckle
1000384b bore.
SAPH08Z060200075 h. Turn the knuckle over to the UP position. Place the seal lightly into
the inner bore. The seal lip must be AWAY from the bore.
i. Use a seal installer tool to press the seal firmly into the knuckle
bore. The top of the seal must be even with the inner machined
surface of each knuckle bore.
5. KNUCKLE TO THE AXLE BEAM

! WARNING
a. Clean the bores of the knuckle and the axle beam.
NOTICE
SEAL TYPES
COVER
The one-piece thrust bearing with an integrated grease seal is com-
FLAT
pletely interchangeable with the two-piece design. It has a specified
top and bottom orientation.
BEARING b. Install the seal onto the thrust bearing. The surface with the inner
RETAINER
diameter seal must be on the top. The surface with the outer
diameter seal must be on the bottom.
SEAL .
a. On cover-type seals: Install the seal over the open end of the bearing.
BEARING CAGE,
BEARING
b. On flat-type seals: Install the seal over the closed part of the bearing.
OPEN SIDE UP
RETAINER
1000385a
SAPH08Z060200076
TOP INNER
DIAMETER
SEAL
TOP
BOTTOM
INTEGRATED
GREASE SEAL 1000386b
SAPH08Z060200077
c. Install the seal and thrust bearing assembly on the inner knuckle.
The seal must face UPWARD toward the beam. The top inner
diameter will contact the bottom of the axle beam.
! WARNING
Wear gloves when you install the shims. Shims have sharp edges that
can cause serious personal injury.
d. Inspect the shims for damage before installation.
.
INTEGRAL THRUST a. Replace damaged shims with the same size shims, or in combination,
BEARING SEAL
ASSEMBLY that allow the least amount of knuckle end play.
1000387b b. If a new shim pack is required, select the amount of shims that will
SAPH08Z060200078 give the least amount of end play.
e. After inspection, place the shims on top of the axle beam bore
machined surface. Align the shims for king pin installation.
f. Place the knuckle onto the axle beam.
g. Place a pry bar between the steering arm boss and the axle
beam. Lift the knuckle and slide the shim pack between the top of
PRY
BAR the beam and the knuckle.
h. Align all the bores. If the bores are not aligned, the parts will be
damaged when the king pin is installed.
i. Remove the pry bar.
j. Before installing the king pin into the top of the knuckle, apply the
multi-purpose grease onto the bottom half of the king pin.
SHIM 1000388b
SAPH08Z060200079
k. Verify that you can see the word "TOP," which is stamped on the
king pin.
“TOP”
l. Rotate the king pin so that the two draw key slots of the pin cor-
KING PIN rectly align with the draw key slots in the knuckle.
m. Install the king pin into the TOP of the knuckle and through the
area where the shims are located. Do not force the pin through
the top bushing.
1000389b
SAPH08Z060200080
n. If required, use a hammer and a brass drift to apply direct force to

the king pin for seating it into the lower knuckle bore.
o. Seat the top draw key into the front of the beam. Refer to Table
below. Seat the bottom draw key into the back of the beam by
striking it with a hammer and drift. The keys must align with the
slots of the king pin. Do not install or tighten the lock nuts before
checking the knuckle end play.

1000357a
SAPH08Z060200081 All other axle models FC-901, FC-921, FE-970, FF-971 and FL-
901
6. CHECK STEER KNUCKLE VERTICAL END PLAY

a. Strike the boss of the knuckle with a rubber mallet to move the
parts into position.
1000391b
SAPH08Z060200082
b. Turn the knuckle to the straight-ahead position.

c. Attach a dial indicator. Place the base onto the knuckle. Place the
tip onto the center of the king pin. Set the dial indicator to ZERO.
MAGNETIC
BASE LOCATED
AT EITHER PLACE 1000392b
SAPH08Z060200083
d. Use one of the following methods to measure the end play.

• Place a pry bar between the knuckle and the top of the axle center.
Push the knuckle up and measure the end play.
1000393b
SAPH08Z060200084
• Place a block of wood and a hydraulic jack under the bottom of the
knuckle. Raise the knuckle until the pointer on the dial indicator stops.
e. Repeat Step c and Step d with the axle in the full RIGHT and full
LEFT positions.
f. Record the reading on the dial indicator.
• If the knuckle binds or ZERO end play is measured: Remove the
shims from the shim pack.
• If the reading is more than the correct specification shown in
Table below: Add shims to the shim pack.
WOOD
BLOCK
End Play Specifications
New or Rebuilt Axles 0.001-0.025-inch (0.025-0.635 mm)

In-Service Axles 0.001-0.065-inch (0.025-1.650 mm)
1000394a
SAPH08Z060200085
7. DRAW KEY LOCK NUTS

! WARNING
! CAUTION
Verify that the draw key is installed completely or the lock nut is tight-
ened to 30-45 lb-ft (41-61 N⋅m). If not installed correctly, the king pin
and the axle beam will be damaged.
All other axle models FC-901, FC-921, FE-970, FF-971 and FL-901
(1) Plain Draw Keys — Axles with Conventional and Unitized Wheel Ends
Use a hammer and a brass drift to install the draw key into the axle
beam and knuckle. The key must be installed 1/32-1/8-inch (1-3 mm)
below the outer surface of the beam.
1000390a
SAPH08Z060200086
(2) Threaded Draw Keys — Axles with Conventional and Unitized Wheel
CONVENTIONAL Ends
Tighten nut to
30-45 lb-ft Install the lock nut and tighten it to 30-45 lb-ft (41-61 N⋅m).
(41-61 N·m).
1000396c
SAPH08Z060200087
8. KING PIN CAPS

(1) Bolt-On King Pin Caps
a. Install new gaskets and the caps onto the top and the bottom of
CAP
the knuckle. Install the capscrews and the washers and tighten to
GASKET 20-30 lb-ft (28-40 N⋅m).
b. Connect the tie rod arm to the knuckle. Refer to "Tie Rod Arms,
Tie Rod Ends and Cross Tube Assembly" on page AX02-48.
1000397b
SAPH08Z060200088
(2) Threaded King Pin Caps

! WARNING
When you apply some silicone gasket materials, a small amount of
acid vapor is present. To prevent serious personal injury, ensure that
the work area is well-ventilated. Read the manufacturer's instructions
before using a silicone gasket material, then carefully follow the
instructions. If a silicone gasket material gets into your eyes, follow
the manufacturer's emergency procedures. Have your eyes checked
by a physician as soon as possible.
a. Apply the sealant, part number 2297-D-7076, onto the threads. To

obtain these supplies, refer to the Service Notes on page AX02-
10.
b. Install the threaded king pin caps onto the top and the bottom of
the knuckle.
c. Tighten the king pin caps to 70-90 lb-ft (95-120 N⋅m).
d. Connect the tie rod end assembly to the integral knuckle arm.
Refer to "Tie Rod Arms, Tie Rod Ends and Cross Tube Assembly"
on page AX02-48.
1000061d
SAPH08Z060200089
9. AXLES WITH KEYED STEERING ARM
STEERING (1) Press the key into the slot in the arm. Install the steering arm into the
COTTER
ARM
PIN
knuckle.
(2) Install the nuts. Tighten to the specified torque. Refer to "Front Non-
Drive Axles with Conventional Wheel Ends", "Torque Specifications"
on page AX02-9.
(3) Install the cotter pins. If necessary, tighten the nut until the holes are
aligned. Do not loosen the nut to install the cotter pin.
(4) Lubricate the drag link end that connects to the steering arm. Refer to
NUT KEY "Ball Studs on the Steering Arm, the Tie Rod Arm Ends and the Drag
4000693a Link" on page AX02-62.
SAPH08Z060200090 (5) Check for correct operation.
10. AXLES WITH BOLT-ON STEERING ARM

! WARNING
uct. Follow the instructions carefully to prevent irritation to the eyes
and skin.
(1) Use a wire brush to remove old Loctite adhesive from capscrew
bolts and internal threads of the knuckle. Reapply Meritor specifica-
tion 2297-C-7049 liquid adhesive or Loctite 680 adhesive. At least
half of the thread area must be covered.
(2) Insert the bolts through the steering arm. Hand-start the bolts into the
knuckle assembly.
(3) Tighten the arm bolts to the following specification.
215-265 LB-FT (290-360 N·m) (MFS-6)
360-470 LB-FT (490-638 N·m) (MFS-7 AND MFS-8)
300-450 LB-FT (406-610 N·m) (ALL OTHER AXLES) • MFS-6 axles: 215-265 lb-ft (290-360 N⋅m)
• MFS-7 or MFS-8 axles: 360-470 lb-ft (490-638 N⋅m)
• All other axles: 300-450 lb-ft (406-610 N⋅m)
1000062b
SAPH08Z060200091
11. INSTALL THE TIE ROD ENDS INTO THE CROSS TUBE
NOTICE
The cross tube has right-hand threads on the right side of the vehicle
and left-hand threads on the left side of the vehicle.
Tie rod end is

installed past TIE ROD The replacement cross tube must be the same length and diameter
cross tube slot. END as the original tube. Use the thread count as a guide. Install the tie rod
ends into the threaded cross tube ends to the approximate depth
marked during the tie rod assembly removal.
BOTTOM
VIEW
TUBE MARKS
SLOT CROSS
TUBE 1003281c
SAPH08Z060200092
If you are installing new tie rod ends, thread the tie rod ends to the
approximate original depth inside the cross tube.
A
Both tie rod ends must be installed into the cross tube deeper than the
A=B
end of the cross tube slot.
When assembling
the tie rods into (1) Verify that the tab on the clamp is firmly seated against the end of the
the cross tube, B cross tube.
equalize the (2) Install the nuts and the bolts into the clamps. Tighten to the specified
thread depth
at both ends. torque. Refer to "Front Non-Drive Axles with Conventional Wheel
1003418b
SAPH08Z060200093 • If the tab on the clamp is tack-welded: Do not remove the tack
weld. If you remove the tack weld, you will reduce the clamping force.
12. TIE ROD ARMS, TIE ROD ENDS AND CROSS TUBE ASSEMBLY
(1) Axles with Removable Tie Rod Arms
NOTICE
If a different size tie rod arm is installed, the steering geometry is
changed and may cause tire wear. Contact the ArvinMeritor Customer
Service Center at 800-535-5560.
a. Press the key into the slot in the arm. Install the tie rod arm into
the knuckle.
b. Install the nut onto the tie rod arm. Tighten to the specified torque.
KNUCKLE
TIE ROD ARM Refer to "Front Non-Drive Axles with Conventional Wheel Ends",
"Torque Specifications" on page AX02-9.
c. Install the cotter pins. If necessary, tighten the nut slightly,
TIE ROD
increasing the final torque value until the holes are aligned. Do
END
not loosen the nut to install the cotter pin.
NOTICE
The cross tube has right-hand threads on one end and lefthand
1003284b threads on the other end.
SAPH08Z060200094
d. If removed, install the tie rod ends into the cross tube to the posi-
tion marked during removal. Thread the ends equally into the
cross tube to the required length.
e. Install the nuts and the bolts into the clamps. Tighten to the speci-
Tie rod end is
installed past
fied torque. Refer to "Front Non-Drive Axles with Conventional
TIE ROD
cross tube slot. END Wheel Ends", "Torque Specifications" on page AX02-9.
BOTTOM VIEW
TUBE
SLOT
CROSS MARKS
TUBE 1003281a
SAPH08Z060200095
f. Rotate the cross tube clamp to remove the nuts and bolts from the
clamp. Tighten the nut to engage the locking element of the nut
CLAMP CROSS TUBE
TIE ROD with the bolt. The clamp and tie rod end must be free to rotate.
END The clamp tab must be firmly seated against the cross tube.
g. Clean and dry the tie rod taper and the tie rod arm taper hole.
h. Install the tie rod ends into the tie rod arms. The threaded portion
of the tie rod end must be installed into the cross tube beyond the
end of the slot. The clamp tab must be firmly seated against the
cross tube.
i. Install the nuts onto the tie rod ends. Tighten to the specified
BOLT
AND NUT 1003283b torque. Refer to "Front Non-Drive Axles with Conventional Wheel
SAPH08Z060200096 Ends", "Torque Specifications" on page AX02-9.
j. Install the cotter pins. If necessary, tighten the nut until the holes
are aligned. Do not loosen the nut to install the cotter pin.
k. Check and, if necessary, adjust the toe. Refer to "Measure and
Adjust the Toe" on page AX02-58.
13. CROSS TUBE AND TIE ROD ENDS

(1) Axles with Integral Tie Rod Arms
NOTICE
The cross tube has right-hand threads on one end and lefthand
threads on the other end.
a. If the tie rods have been removed, reinstall the tie rod ends into
CROSS TIE ROD the cross tube to the position marked during removal. Thread the
TUBE END ends equally into the cross tube to the required length.
b. Install the nuts and the bolts into the clamps. Tighten to the speci-
fied torque. Refer to "Front Non-Drive Axles with Unitized Wheel
TUBE MARKS
SLOT 1000064c
SAPH08Z060200097
c. Rotate the cross tube clamp to remove the nuts and bolts from the
clamp. Tighten the nut to engage the locking element of the nut
ROTATING CLAMP with the bolt. The clamp and tie rod end must be free to rotate.
The clamp tab must be firmly positioned against the cross tube.
BOLT AND NUT 1000065b
SAPH08Z060200098
d. Clean and dry the tie rod end taper and the tie rod arm taper hole.
e. Install the tie rod ends into the tie rod arm. The threaded portion
of the tie rod end must be installed into the cross tube beyond the
end of the cross tube slot.
f. Install the nuts onto the tie rod ends. Tighten to the specified
torque. Refer to "Front Non-Drive Axles with Unitized Wheel
TIE ROD
ARM g. Install the cotter pins. If necessary, tighten the nut until the holes
are aligned. Do not loosen the nut to install the cotter pin.
TIE ROD
END h. Check and, if necessary, adjust the toe. Refer to "Measure and
1000066b Adjust the Toe" on page AX02-58.
SAPH08Z060200099
14. DRAG LINK

(1) Connect the drag link to the steering arm. Connect the drag link to the
Pitman arm.
(2) Install the nuts. Tighten to the specified torque. Refer to "Front Non-
Drive Axles with Conventional Wheel Ends", "Torque Specifications"
on page AX02-9.
(3) Install the cotter pins. If necessary, tighten the nut until the holes are
aligned. Do not loosen the nut to install the cotter pin.
(4) Lubricate the drag link. Refer to "Ball Studs on the Steering Arm, the
Tie Rod Arm Ends and the Drag Link" on page AX02-62.
PITMAN DRAG (5) Check for correct operation.
ARM LINK STEERING
ARM 1000402b
SAPH08Z060200100
15. BRAKE COMPONENTS AND WHEEL ENDS

a. Install the brake assembly onto the knuckle. Lubricate the wheel
bearings. Refer to "Grease-Lubricated Wheel Bearings" on page
AX02-63 or "Oil-Lubricated Wheel Bearings" on page AX02-63.
b. Install the outer wheel bearing cone into the hub. Install the
adjusting nut.
c. Adjust the wheel bearings. Refer to "Check and Adjust Wheel
Bearings" on page AX02-52.
d. Install the cap and the gasket onto the hub. Install the capscrews
and tighten to 20-30 lb-ft (27-41 N⋅m).
e. Install the wheel and tire assembly. Lower the vehicle to the
ground. Check for correct operation.
f. Check and adjust the toe. Refer to "Measure and Adjust the Toe"
on page AX02-58.
ADJUSTMENT
EN08Z0602H600001

! WARNING
1. INSPECTION BEFORE ALIGNMENT

(1) Parts
Refer to "Inspect Parts" on page AX02-19.
(2) Wheels and Tires
a. Verify that the tires are inflated to the specified pressure.
b. Verify that the front tires are the same size and type.
c. Verify that the lug nuts are tightened to the specified torque.
d. Verify that the wheels are balanced.
e. Check for bent or damaged wheels.
(3) Front Suspension
a. Verify that all fasteners are tightened to the specified torque.
b. Inspect the leaf springs for wear and damage.
c. Inspect the shock absorbers for wear and damage.
(4) Rear Axle and Rear Suspension
Front tire wear can be caused by the rear axle. If the outer edge of
one front tire is worn and the inner edge of the other front tire is worn,
check the following.
a. All fasteners are tightened to the specified torque.
b. The leaf springs are not worn or damaged.
c. The bushings in the leaf springs are not worn or damaged.
d. The torque rods, if used, are correctly adjusted.
e. The frame is not bent.
2. FRONT WHEEL ALIGNMENT

(1) Check the front wheel alignment:
a. Every 200,000 miles (320 000 km) or 24 months (normal mainte-
nance).
b. When the vehicle does not steer correctly.
c. To correct a tire wear condition.
(2) Minor Front Wheel Alignment
Perform a minor front wheel alignment for all normal maintenance
conditions using the following procedure.
a. Inspect all systems that affect the wheel alignment. Refer to
"Inspection Before Alignment" in above 1.
b. Check and adjust the wheel bearings or wheel bearing end play
for the unitized wheel end.
c. Check and adjust the toe.
(3) Major Front Wheel Alignment
Perform a major front wheel alignment to correct steering and tire
wear conditions using the following procedure.
a. Inspect all systems that affect the wheel alignment. Refer to
"Inspection Before Alignment" in above 1.
b. Check and adjust the wheel bearings.
c. Check and adjust the maximum turn angle.
• If the vehicle has power steering: Check and adjust the pressure
relief in the power steering system. Refer to "Adjust the Pressure
Relief in the Power Steering System, Set the Maximum Turn Angle"
on page AX02-55.
d. Check and adjust the turning radius angle. Refer to "Turning
Radius Angle" on page AX02-56.
e. Check the king pin, or steering axis, inclination. Refer to "King Pin
Inclination" on page AX02-57.
f. Check the camber angle. Refer to "Camber Angle" on page AX02-
57.
! CAUTION
g. Check and adjust the caster angle. Refer to "Caster Angle" on
page AX02-58.
h. Check and adjust the toe. Refer to "Measure and Adjust the Toe"
on page AX02-58.
3. CHECK AND ADJUST WHEEL BEARINGS

! WARNING
(1) Park the vehicle on a level surface. Block the wheels to prevent the
vehicle from moving. Set the parking brake.
(2) Raise the vehicle so that the wheels are off the floor. Support the vehi-
cle with safety stands.
(3) Remove the capscrews and remove the gasket and the cap from the
hub.
(4) Verify that the brake drum and the hub fasteners are tightened to the
manufacturer's specifications.
(5) Attach a dial indicator with the magnetic base at the bottom of the hub
or the brake drum. Adjust the dial indicator so that the pointer is
With the indicator
mounted at the against the center of the knuckle. Set the dial indicator on ZERO.
bottom, push and
pull at the side NOTICE
of the tire. Do not push or pull at the top and bottom of the hub or drum, which
can affect the end play measurement.
(6) Measure the end play by pushing and pulling on each side of the hub
or drum while looking at the dial indicator. The end play is the total
travel observed.
1000333c
• If the end play is 0.001-0.005-inch (0.025-0.127 mm): The bearings
do not need adjustment.
SAPH08Z060200101
• If the end play is not 0.001-0.005-inch (0.025-0.127 mm): Adjust
the wheel bearings.
(7) On double nut and lock fasteners: Bend the lock washer off the
wheel bearing nut. Remove the wheel bearing nut, the lock washer
PIERCED and the pierced lock ring.
OUTER LOCK
WHEEL RING
BEARING ! WARNING
NUT
CAP Use a torque wrench to tighten or loosen adjusting nuts. Do not use a
hammer to directly hit adjusting nuts, or to hit a chisel or drift placed
ADJUSTING
against them. Damaged adjusting nuts can prevent you from obtain-
WHEEL
NUT ing correct wheel bearing end play, which can affect vehicle operation
BEARING NUT and cause the wheels to separate from the vehicle. Serious personal
LOCK WASHER,
BEND ONTO OUTER injury and damage to components will result.
CAPSCREW WHEEL BEARING NUT 1000354d
SAPH08Z060200102
(8) Use a torque wrench to tighten the adjusting nut to 100 lb-ft (136 N⋅m)
while rotating the tire in both directions.
(9) Loosen the nut completely. Tighten the nut to 20 lb-ft (27 N⋅m) while
rotating the tire.
1. Tighten nut to 100 lb-ft (136 N·m).
2. Loosen nut completely.
1000336a
SAPH08Z060200103
(10) For axles with single nut fasteners, perform the following procedure.
a. Back off the adjusting nut 1/8 turn.
b. Rotate the nut in either direction to line up a slot with the closest
Single Nut Fasteners: Back off nut 1/8 turn. cotter pin hole in the spindle.
Double Nut and Lock Fasteners:
c. Install a new cotter pin into the nut.
Back off nut 1/3 turn.
d. Measure the end play. The end play must be 0.001-0.005-inch
(0.025-0.127 mm). Refer to Step (4) and Step (5). Readjust if nec-
essary.
(11) For axles with double nut and lock fasteners, perform the following
procedure.
b. Install the pierced lock ring, the lock washer and the wheel bear-
ing nut.
c. For wheel bearing nuts in sizes from 1-1/8-inches up to 2-5/8-
inches (2.86-6.67 cm), tighten to 200-300 lb-ft (271-407 N⋅m). For
wheel bearing nuts 2-5/8-inches (6.67 cm) and more, tighten to
250-400 lb-ft 339-542 N⋅m).
essary.
e. If the end play is to specification, bend the washer to at least one
flat edge of the outer wheel bearing nut.
(12) Install the gasket and the cap onto the hub. Install the capscrews and
tighten to 20-30 lb-ft (27-41 N⋅m).
SAPH08Z060200104
(13) Lower the vehicle to the ground. Check for correct vehicle operation.
4. MAXIMUM TURN ANGLE ADJUSTMENT

! CAUTION
Do not exceed the maximum turn angle specified by the vehicle manu-
facturer. If the angle is exceeded, the steering arms, the cross tube
and the tie rod ends will be damaged.
The stop bolt on the back of the knuckle controls the maximum turn
angle. If the stop bolt is missing, bent or broken, the system requires
adjustment. Use the mechanical stop in the steering system to adjust
the pressure relief.
Check the angle if the front tires rub against the frame or if the steer-
STOP
REFERENCES TO KNUCKLE BOLT ing gear has been serviced. Use an alignment machine to check the
FOR STOP BOLT ADJUSTMENT
angle.
• For power steering systems: The stop bolt should NOT touch the
beam. The stop bolt should always have a minimum clearance of 1/8-
MAXIMUM TURN 1/8" inch (3 mm) when the knuckle is in the full-turn position as shown in
ANGLE SPACER
figure.
NOTICE
JAM 1/8" (3 MM) If the steering system is out-of-adjustment, inspect the steering arm
NUT CLEARANCE
BETWEEN STOP
for damage. Use a magnetic particle or liquid dye penetrant inspec-
BOLT AND BOSS 1000338d tion procedure to inspect the steering arm. Pay particular attention to
SAPH08Z060200105 the bend, the taper and the area near the ball stud.
(1) Two-Piece Steering 3/4-Inch Stop Bolt, Includes Unitized
a. Place a 1/8-inch (3 mm) spacer between the stop bolt and the
boss on the axle beam.
b. Turn the steering wheel until the boss on the axle beam touches
STOP
REFERENCES TO KNUCKLE BOLT the spacer in front of the stop bolt. Measure the turn angle.
FOR STOP BOLT ADJUSTMENT
c. If the maximum turn angle does not meet vehicle manufacturer's
specifications, correct the maximum angle.
• In a power steering system: Adjust the pressure relief.
MAXIMUM TURN 1/8"
ANGLE SPACER • In a manual steering system: Follow the guidelines and specifica-
tions from the vehicle manufacturer.
d. When the maximum turn angle is correct:
JAM 1/8" (3 MM) .
NUT CLEARANCE a. Loosen the stop bolt jam nut.

BETWEEN STOP
BOLT AND BOSS 1000338d b. Insert a 1/8-inch (3 mm) spacer and adjust the stop bolt.
SAPH08Z060200106 c. Tighten the jam nut on conventional knuckles to 65-85 lb-ft (68-101
N⋅m).
(2) Four-Piece Steering 1/2-Inch Stop Bolt, Conventional Only
a. Place the washer onto the adapter.
b. Apply adhesive patch material into the 3/4-inch (19 mm) knuckle
bore stop screw adapter hole.
c. Install the adapter with the washer into the threaded knuckle cav-
ity.
d. Tighten the adapter to 85-115 lb-ft (115-155 N⋅m).
e. Start the jam nut onto the 1/2-inch (12.7 mm) bolt, and install the
bolt and jam nut assembly into the adapter.
f. Place a 1/8-inch (3 mm) spacer between the stop bolt and the
boss on the axle beam.
g. Turn the steering wheel until the boss on the axle beam touches
the spacer in front of the stop bolt. Measure the turn angle.
h. If the maximum turn angle does not meet vehicle manufacturer's
specifications, adjust the maximum turn angle.
• In a power steering system: Adjust the pressure relief.
• In a manual steering system: Follow guidelines and specifications
from the vehicle manufacturer.
i. Proceed to the following instructions when the maximum turn
FOUR-PIECE 1/2" angle is correct.
STEERING STOP BOLT
.
a. Loosen the stop bolt jam nut.

AXLE
MAXIMUM BEAM b. Insert a 1/8-inch (3 mm) spacer between the stop bolt and the axle
TURN ANGLE BOSS beam boss with the steering arm in the full-turn position.
1/8" c. Tighten the jam nut 50-75 lb-ft (68-101 N⋅m).
WASHER (3 MM)
1/2" SPACER
(12.7 MM)
STOP BOLT
FOUR-PIECE STOP
JAM NUT
BOLT ASSEMBLY
ADAPTER 1000340c
SAPH08Z060200107
5. ADJUST THE PRESSURE RELIEF IN THE POWER STEERING

SYSTEM, SET THE MAXIMUM TURN ANGLE
! CAUTION
In power steering systems, the hydraulic pressure should relieve or
"drop off" at the end of the steering stroke, with 1/8-inch or 3 mm min-
imum clearance at the stop bolt. If the pressure does not relieve, the
components of the front axle will be damaged.
KNUCKLE POSITION AFTER PITMAN The pressure relief in the power steering system stops or reduces
ARM/CYLINDER STOPS RESET STOP BOLT forces applied to the axle when the wheel is moved in the full-turn
position.
Check the pressure relief if the steering arm is damaged or the power
MAXIMUM steering gear is serviced.
TURN ANGLE
Two types of systems are used to adjust the pressure relief.

1/8"
JAM NUT (3 MM)
1/8" (3 MM)
CLEARANCE
BETWEEN STOP SPACER • Mechanical stop on the Pitman arm or in the assist cylinder
BOLT AND BOSS 1000341d • Hydraulic pressure relief in the power steering gear
SAPH08Z060200108
! CAUTION
Meritor does not recommend a power steering system that does not
have mechanical stops or pressure relief before the maximum turn
angle is obtained. Damage to the axle can result.
(1) Mechanical Stop
Use the mechanical stop in the steering system to adjust the pressure
relief. Do not use the stop bolt on the knuckle alone to adjust the pop-
pet valve pressure relief.
! CAUTION
Use a pressure gauge to verify that the pressure drops from the maxi-
mum system delivery pressure to gear box manufacturing recommen-
dation BEFORE the full turning angle is achieved. If the pressure does
not drop, damage to the front axle components will result.
Steering systems with mechanical stops are adjusted when the
wheels are turned to the full-right and full-left turn positions. The stop
travel is set at 1/8-inch (3 mm) before the stop bolt contacts the axle
beam boss.
(2) Hydraulic Pressure Relief in the Steering Gear
KNUCKLE POSITION FOR
POPPET VALVE SETTING NOTICE
The stop bolt should always have a minimum clearance of 1/8-inch (3
AXLE mm) between the stop bolt and the axle beam boss.
STOP
BEAM
BOLT
BOSS
1/8"
Hydraulic steering gears with poppet valves are adjusted with a
(3 MM) spacer between the stop bolt in the knuckle and the boss on the axle
SPACER
beam. The poppet valves are adjusted to stop or reduce steering
1/8"
(3 MM) forces from the 1/8-inch (3 mm) specified distance between the beam
CLEARANCE boss and the spacer.
BETWEEN STOP
BOLT AND BOSS 1000342d
SAPH08Z060200109 6. TURNING RADIUS ANGLE
When turning, the inner wheel must turn at a greater angle than the outer
CENTER LINE OF TURNING RADIUS OR
ACKERMAN ANGLE wheel. This angle is the turning radius angle, often called the Ackerman
FRONT AXLE
angle.
Check the turning radius angle with the radius plates on the alignment
CENTER LINE equipment. To determine correct turning radius angle specification, refer to
CENTER LINE OF OF CHASSIS
REAR AXLE "Data and Specifications" on page AX02-2.
• If the angle is not within specifications: Premature tire wear will
occur. Inspect the knuckle, tie rod arms, tie rod ends and cross tube
for wear or damage. Service as necessary.
1000343b
SAPH08Z060200110
7. KING PIN INCLINATION

NOTICE
KING King pin, or steering axis inclination, is the angle measured between
PIN
CAMBER INCLINATION the center line of the king pin and the vertical position, as viewed from
ANGLE
the front of the vehicle.
KING PIN The king pin inclination and the camber angle are designed into the axle to
INCLINATION
ANGLE place the tire tread center line in contact with the road. This reduces steer-
ing effort and improves directional stability.
Use an alignment machine to check the king pin inclination angle. Refer to
"Data and Specifications" on page AX02-2.
1000344d
SAPH08Z060200111
The king pin inclination is not adjustable. If the inclination is not at the spec-
ified angle, check the axle beam and knuckle for damage. Service as nec-
essary.
8. CAMBER ANGLE
! WARNING
Camber is the angle of the tire with respect to the ground. Camber is
POSITIVE positive when the distance between the top of the wheels is greater
CAMBER than the distance at the ground.
A small amount of positive camber is built into the knuckle, because

ZERO OR NEUTRAL camber changes with load. This results in a zero camber angle when
LOAD
the vehicle is operated at normal load.
If camber is out of specification by more than 1-1/2 degrees, rapid or

uneven tire wear will occur. Bias ply tires will show excess camber
1000345c easily, while with vehicles equipped with radial tires, excess camber
SAPH08Z060200112 will not be as evident.
The camber angle is not adjustable. The camber angle is machined

into both the axle beam and the knuckle. If the camber angle is not at
the specified angle, check the axle beam and the steering knuckle for
damage. Service as necessary.
Use an alignment machine to check the camber angle. Refer to "Data

and Specifications" on page AX02-2. Following Table I gives the spec-
ification Meritor builds into the axle, but always use the specification
from the vehicle manufacturer.
Table I: Camber Angle Recommendations
NEW CAMBER SPECIFICATION
Axles with Assembly Dates:
• September 1, 1992 (92245) or later with no "P" suffix
Conditions Left and Right Sides
Camber angles machined into axles

• Hubs not installed.
+1/4° Nominal
• Axle not installed in vehicle.
• Load not applied on axle.
Camber angles of axles equipped with hubs +1/4° (± 7/16°)

• Axle not installed in vehicle. or
+11/16° to -3/16°
• Load not applied on axle.
(final reading)
Camber angles under load
+3/16° to -11/16°
• Axle installed in vehicle. (final reading)
9. CASTER ANGLE
Caster is the FORWARD or REARWARD tilt of the king pin center line
NEGATIVE POSITIVE
CASTER CASTER when viewed from the side of the vehicle. The caster angle is the
angle from the vertical position to the center line of the king pin. If the
top of the king pin axis is toward the rear of the vehicle, the caster is
FORWARD
CASTER
positive. A slight positive caster creates a self-aligning action that
helps to stabilize the vehicle after turning and stabilizes it for driving
straight ahead.
Always use an alignment machine to check the caster angle.
1000346b If the caster is greater than specification, steering effort can increase
SAPH08Z060200113 a shimmy condition.
The caster angle is controlled by tapered shims installed under the

leaf springs. Adjust the caster according to the specifications.
Caster specifications, refer to "Data and Specifications" on page

AX02-2.
10. MEASURE AND ADJUST THE TOE

Toe is the relationship of the distance between the front of the front
tires and the rear of the front tires.
When the front distance is less than the rear distance, the wheels are
"toed in." Toe-in is designed into the vehicle to counteract the ten-
dency of the tires to toe-out when the vehicle is driven.
Incorrect toe will result in rapid tire wear.

! WARNING
(2) Use jacks to raise vehicle so that front tires are off the ground. Sup-
port the front axle with safety stands.
(3) Use paint or chalk to mark the center area of both front tires around
the complete outer surface of the tire.
(4) Place the pointers of a trammel bar on the marks of each tire. Rotate
the tires. Verify that a straight line is marked on the outer surface of
the tire.
(5) Lower the vehicle to the floor. Do not measure toe with the front axle
in the raised position. The weight of the vehicle must be on the front
axle when toe is measured. Move the vehicle FORWARD and BACK-
WARD 10 feet (3 meters).
(6) Place the trammel bar at the back of the tires. Raise the pointers so
that the pointers are level with the spindles. Align the pointers with the
marks on the tires. Measure and record the distance between the
pointers.
(7) Repeat Step (6) for the front of the tires.
(8) To obtain the toe measurement, subtract the distance reading
1000347a between the front of the tires from the distance reading between the
SAPH08Z060200114 back of the tires.
(9) Use the following procedure if the toe measurement is not within the
FRONT OF VEHICLE correct specifications shown in below Table.
A
DIMENSION
Toe Specifications
TOP VIEW
Unloaded Vehicles 1/16-inch (1.587 mm) ±1/32-
inch (0.794 mm)
Loaded Vehicles 1/32-inch (0.794 mm) ±1/32-
inch (0.794 mm)
B
B MINUS A EQUALS TOE 1000348e a. Loosen the tube clamp nut and bolt on each end of the cross
SAPH08Z060200115 tube.
b. Turn the cross tube until the specified toe distance is obtained.
c. The threaded portion of the tie rod end must be installed into the
cross tube beyond the point where the tube slot stops.
d. Tighten the nut and bolt on each end of the cross tube to the
specified torque. Refer to "Front Non-Drive Axles with Conven-
tional Wheel Ends", "Torque Specifications" in page AX02-9.
(10) Repeat Step (1) through Step (8) to check the toe dimension.
LUBRICATION AND MAINTENANCE

EN08Z0602A200001
LUBRICATION
Read and observe all Caution and Warning safety alerts below and those
that precede instructions or procedures you will perform.
! WARNING
Front Non-Drive Axle Greasing Intervals and Specifications

Greasing Meri tor Outside
Component Interval Grease Specification NL GI Grade Grease Type Temperature
King Pins and Bushings, 100,000 miles Multi-Purpose O-617- A 1 or 2 Lithium 12 Refer to the grease
Thrust Bearings, Ball (160 000 Grease or Hydroxystear at manufacturer’s
Studs on Steering Arm, kilometers) or e or Lithium specifications for
Tie Rod Ends, and Drag O-617- B
1
once a year, Complex the temperature
Link whichever comes service limits.
first
Unitiz ed Wheel End No Lube to Hub Unit sealed for NONE DO NOT
life of component LUBRICATE
1
Applies to ball studs on Easy SteerPlus axles. Sealedaxles require in spection of the boot on the ballstud every 100,000 miles (160 000 km) for wear and
damage. Service as necessary.
Wheel-End Oil Change Intervals and Specifications

On-Highway Operation
Inter vals Off-Highway Operation Inter vals Outside Temperature
˚F ˚C
Check Oil Petroleum Oil Check Oil Petroleum Meritor Military Oil
Level Change Level Oil Change Specification Specification Description Min. Max. Min. Max.
1,000 Whichever 1,000 miles Whichever O-76-A, MIL-L-2105-D GL-5, SAE 10 None 12 None
miles comes first: (1600 comes first: Gear Oil 85W/140
(1600 Seals replaced. kilometers Seals O-76-D, MIL-L-2105-D GL-5, SAE -15 None - 26 None
kilometers) replaced.
Brakes relined Gear Oil 80W/90
100,000 miles Brakes O-76-E, MIL-L-2105-D GL-5, SAE - 40 None - 40 None
(160 000 relined. Gear Oil 75W/90
kilometers) Once a year
O-76-J, MIL-L-2105-D GL-5, SAE - 40 36 - 40 2
Once a year Gear Oil 75W
Heavy-Duty MIL-L-210-B, - API -CD, -CE, 10 None 12 None
Engine Oil C, -D or -E -SF or -SG
SAE 40 or
50 1
Heavy-Duty MIL-L -210-B , API -CD, -CE, - 15 None - 26 None
Engine Oil -C, -D or -E -SF or -SG
SAE 30 2
1
Current designations are acceptable. Multi-weight engine oils are acceotable if the SAE rating ends in a 40 or 50.
2
Current designations are acceptable. Multi-weight engine oils are acceotable if the SAE rating ends in a 30.
SAPH08Z060200008
1. TIE ROD END

This procedure refers to all tie rod ends on Meritor non-drive steer
axles.
(2) Turn the vehicle wheels to the STRAIGHT position.
Point wheels straight ahead.
1003405a
SAPH08Z060200116
(3) Wipe the grease fitting, seal and boot clean with shop towels.
Always clean off grease
fittings prior to applying lube. (4) Attach either a hand or air pressure grease gun to the grease fitting. If
using air pressure, do not exceed 150 psi (1035 kPa).
(5) Apply grease into the grease fitting. Discolored old grease should
come out of the purge holes near the boot crimp or bellows area, typi-
cally three or more places.
(6) If the tie rod end is designed for lube service and it does not accept
grease:
GREASE
FITTING
ALTERNATE
LOCATION 1003422b
SAPH08Z060200117
a. Remove the grease fitting.

b. Inspect the threaded grease fitting hole in the tie rod end and
remove any obstructions.
c. Install a new grease fitting.
d. Continue the lubrication procedure.
Apply grease into all grease fittings where required.

1003423b
SAPH08Z060200118
(7) Apply grease until all old grease is purged from the boot.
NON-REMOVABLE AND ALL-WEATHER

BOOT SEAL TIE ROD ENDS
SLIDING SEAL TIE
ROD ENDS
TRW — LUBE
O & S — LUBE PURGES FROM
PURGES FROM THREE BOOT BASE IN EVEN,
HOLES TOP OF BOOT SMALL STREAMS
TRW — LUBE PURGES
EVENLY FROM BASE OF BOOT
URRESKO — LUBE PURGES O & S — LUBE O & S — NON-GREASEABLE

FROM TOP OF BOOT PURGES FROM THREE
HOLES TOP OF BOOT 1003424d
SAPH08Z060200119
2. KING PINS
a. Park the vehicle on a level surface. Block the wheels to keep the
TOP vehicle from moving. Set the parking brake.
SIDE GREASE
GREASE FITTING
FITTING
b. Verify that the tires touch the ground. DO NOT RAISE THE VEHI-
CLE.
c. Clean off all grease fittings prior to lubrication.
d. Lubricate the king pins through the top and the bottom grease fit-
tings.
e. Apply lubricant until new lubricant comes from between the upper
Lube must shim pack and thrust bearing seal.
come from f. Apply lubricant into the bottom fitting until new lubricant purges
here. 1000327b and fills the thrust bearing.
SAPH08Z060200120
3. BALL STUDS ON THE STEERING ARM, THE TIE ROD ARM ENDS
AND THE DRAG LINK
b. Verify that the tires touch the ground. DO NOT RAISE THE VEHI-
CLE.
c. Clean off all grease fittings prior to lubrication.
d. Apply lubricant until new lubricant comes from the boot.
CONVENTIONAL 4. GREASE-LUBRICATED WHEEL BEARINGS

NOTICE
This procedure applies to hubs with grease-lubricated wheel bear-
Lube must ings.
come from here.
a. Park the vehicle on a level surface. Block the wheels to keep the
GREASE vehicle from moving. Set the parking brake.
FITTING
1000329a b. Remove the tire and wheel assembly. Remove and disassemble
the hub. Refer to "Wheel Ends" on page AX02-24.
SAPH08Z060200121
c. Remove the old lubricant from all parts. Discard the seals. Inspect
the wheel bearings for wear or damage. Replace worn or dam-
aged bearings. Refer to "Wheel Bearings" on page AX02-36.
d. Force the specified lubricant from the large end of the cones into
LUBE the cavities between the rollers and cage. Pack the hub between
the bearing cups with lubricant to the level of the smallest diame-
ter of the cups.
e. Install the inner and outer bearing cones into the cups in the hubs.
The bearing cups must be pressed tight against the shoulder in
the hubs.
f. Install new wheel seals into the hubs.
g. Install the hub and the wheel and tire assembly. Install the outer
wheel bearing cone into the hub. Install the adjusting nut.
1000330b h. Adjust the wheel bearings. Refer to "Check and Adjust Wheel
SAPH08Z060200122 Bearings" on page AX02-52.
5. OIL-LUBRICATED WHEEL BEARINGS

NOTICE
This procedure applies to hubs with oil-lubricated wheel bearings.
a. Check the level on the cap. If the oil level is not at the specified
level on the cap, remove the fill plug.
b. Add the specified oil until the oil is at the specified level.
OIL
LEVEL 1000331c
SAPH08Z060200123
MAINTENANCE
EN08Z0602G100001
1. TIGHTEN DRAW KEY NUTS

CONVENTIONAL NOTICE
This procedure applies to all except 901, 903 and 970 Series axles.
Tighten draw key These axles do not use a draw key. Refer to the identification tag on
nut to 30-45 lb-ft the front of the axle beam.
(41-61 N·m).
Tighten the nuts on the side of the knuckle that hold the draw keys to
30-45 lb-ft (41-61 N⋅m) at the following times.
• After the first 6,000 miles (10 000 km) of new vehicle operation
• Every 36,000 miles (58 000 km) of operation
1000332b
SAPH08Z060200124 2. CHECK THE STEERING ARM BOLTS
! WARNING
uct. Follow the instructions carefully to prevent irritation to the eyes
and skin.
(1) Check the steering arm bolts for minimum torque. Refer to below
Table.
Steering Arm Bolts Torque Specifications
Axle Torque lb-ft (N⋅m)

MFS-6 215-265 (290-360)
MFS-7 or MFS-8 360-470 (490-638)
All other axles 300-450 (406-610)
• If steering arm bolt torque has fallen below minimum torque:

a. Remove the bolts. Clean all the threads. Install new Loctite 680
adhesive, Meritor part number 2297-K-5523.
b. Tighten the bolts to specification.
(2) Check the steering arm bolt torque every 200,000 miles (320 000 km)
or 24 months.
(3) Refer to "Check the Torque Values of Dri-Loc Fasteners Not Requir-
ing Removal" on page AX02-34 for Dri-Loc fastener installation pro-
cedures.
REAR AXLE AX03–1
REAR AXLE
AX03
AX03-001
REAR AXLE .............................................. AX03-2

COMPONENT LOCATOR................................ AX03-9
SPECIAL TOOLS........................................... AX03-13
DISASSEMBLY .............................................. AX03-17
PREPARE PARTS FOR ASSEMBLY ............. AX03-20
ASSEMBLY .................................................... AX03-24
ADJUSTMENT............................................... AX03-35
LUBRICATION AND MAINTENANCE ........... AX03-37
AX03–2 REAR AXLE
REAR AXLE
EN08Z0603I200001
Type Full-floating axle shaft
Housing Banjo type, with extension tubes welded on both ends
Type of drive Hotchkiss drive
MODEL AXLE MODEL
HINO 145, 165 (NA6J, NB6J) MS-12-113
HINO 185 (NC6J) RS-13-120
HINO 238, 258 (ND8J) RS-17-145
HINO 268 (NE8J) RS-19-145
HINO 308, 338 (NF8J, NV8J) RS-21-145
HINO 338 (NV8J) RS-23-160
SAPH08Z060300001
NOTICE
All models use oil-lubricated wheel bearings.
REAR AXLE AX03–3
IDENTIFICATION
AXLE IDENTIFICATION TAG INFORMATION
Model No. . . . . . . . . . . . . . . . . . . .
Customer No. . . . . . . . . . . . . . . . .
Serial No. . . . . . . . . Plant . . . . . . . .

Ratio . . . . . . . . . . . .
IDENTIFICATION TAG
LOCATION OF THE IDENTIFICATION TAG, OR STAMP

NUMBER, FOR THE AXLES. LOCATION IS
DETERMINED FROM THE LEFT DRIVER SIDE
LOOKING TOWARD THE FRONT OF THE VEHICLE.
A
B
A — FRONT ENGINE DRIVE — RIGHT REAR, NEXT
TO COVER
B — REAR ENGINE DRIVE — LEFT OR RIGHT REAR,
NEXT TO DRIVE UNIT
1002704c
SAPH08Z060300002
AX03–4 REAR AXLE
GAWR HOUSING WALL

xx = GAWR (000) Pounds or Tonnes 0 = Cast
(dependent on mfg. location) 1 = TBD
2 = 0.31 in. (8 mm)
3 = 0.37/0.39 in. (9.5/10.0 mm)
4 = 0.43 in. (11 mm)
RELATIVE 5 = 0.50/0.51 in. (12.7/13.0 mm)
AXLE MODEL TYPE GEARING SIZE 6 = 0.56 in. (14.3 mm)
OR SERIES 7 = TBD
S= Single Rear (Solo)
8 = 0.63 in. (16 mm)
X= Front Drive Steer 0 = No Gearing
9 = TBD
D= Fwd Rear w/IAD 1 = 292/347
N= Fwd Rear less IAD 2 = 337/387
P= Fwd Rear w/Pump 3 = TBD
CARRIER VARIATION
R= Rear Rear 4 = 381/432
T= Tandem Drive 5 = 415/432 A= Aluminum
Z= Tridem Drive 6 = 432/457 D= Ductile
C= Coach 7 = 457 M= Ductile Rear (Amboid)
H= High Entry 8 = 460/498 N= No Carrier Ratio 1 Ratio 2
R= Ductile Front Drive Axle
Carrier (Right Hand)
T = Ductile Telma
M S - xx - 1 4 x x N - x - N 123 - xxxx - xxxx

AXLE TYPE
0 = No Carrier
1 = Single Speed MFG LOCATION SPEC NUMBER
2 = Two Speed
M = Meritor N= North America Includes: TRACK, PARKING
3 = Helical Dbl Red
S= South America BRAKE, OTHER
4 = Salisbury
E= Europe
5 = Planetary Dbl Red
A= Australia/Asia/Africa
6 = Hub Reduction
7 = Portal
9 = Single Speed with Torque
Output Limited Engine
WHEEL END/BRAKE A TTACHMENT/DIFFERENTIAL BRAKE TYPE

A= Conventional Spindle/Conventional Brake/Standard Differential B = Reaction Beam Disc Brake (B-Frame)
B= Conventional Spindle/Conventional Brake/DCDL C = Air Disc Brake
C= Conventional Spindle/Conventional Brake/NoSPIN® D = Wedge Brake (Dual Air Chambers)
D= Conventional Spindle/Conventional Brake/Other Differential E = Wedge Brake (Dual Hydraulic Cylinders)
E= Unitized Spindle/Conventional Brake/Standard Differential F = Wedge Brake (Single Hydraulic Cylinder)
F= Unitized Spindle/Conventional Brake/DCDL G= DuraPark Hydraulic Drum
G= Unitized Spindle/Conventional Brake/NoSPIN® H = Quadraulic Disc
H= Unitized Spindle/Conventional Brake/Other Differential K = Disc Plus Air Disc
J = Conventional Spindle/Integral Brake/Standard Differential L = Q Plus™ Cam Brake
K= Conventional Spindle/Integral Brake/DCDL N = None
L = Conventional Spindle/Integral Brake/NoSPIN® P = “P” Series Cam Brake
M= Conventional Spindle/Integral Brake/Other Differential Q= “Q” Series Cam Brake
N= Unitized Spindle/Integral Brake/Standard Differential R = Cast Plus™ Brake
P= Unitized Spindle/Integral Brake/DCDL S = Wedge Brake (Single Air Chamber)
Q= Unitized Spindle/Integral Brake/NoSPIN® T = “T” Series Cam Brake
R= Unitized Spindle/Integral Brake/Other Differential W= “W” Series Cam Brake
S= Bolt on Conventional Spindle/Conventional Brake/No Differential
4004362a
MS Series Rear Drive Axle

SAPH08Z060300003
REAR AXLE AX03–5
BRAKE TYPE
GEARING TYPE B = Reaction Beam Disc Brake (B-Frame)
1 = Single Speed C = Air Disc Brake
2 = Two Speed MAIN DIFFERENTIAL NEST TYPE D = Wedge Brake (Dual Air Chambers)
3 = Helical Double-Reduction B= Special Differential E = Wedge Brake (Dual Hydraulic Cylinders)
4 = Salisbury Single Speed C= Driver Controlled Differential Lock F = Wedge Brake (Single Hydraulic Cylinder)
5 = Planetary Double-Reduction F= Standard Differential G= DuraPark Hydraulic Drum
6 = Hub Reduction H= High Traction® Differential H = Quadraulic Disc
N= No-SPIN® K = Disc Plus Air Disc
L = Q Plus™ Cam Brake
N = None
P = “P” Series Cam Brake
Q= “Q” Series Cam Brake
NOMINAL AXLE LOAD R = Cast Plus™ Brake
RATING (GAWR) MANUFACTURING
LOCATION S = Wedge Brake (Single Air Chamber)
In thousands of pounds. Individual T = “T” Series Cam Brake
forward and rear axles of a tandem A= Australia W= “W” Series Cam Brake
set (D, N, P, R) are rated as single B= Brazil (Braseixos)
axles. A tandem set (T) is rated as C= India
the combination of the two axles D= Mexico (Dirona) AXLE SPECIFICATION NUMBER
and a tridem set (Z) as the E= Europe (C.V.C.)
combination of the three axles. Identi es speci c customer axle
M= Europe (Maudslay) con gur ations (variations from the
N= U.S.A. original axle design). For information
about the variation, refer to the Bill of
Materials for that speci c axle model.
Meritor
RR 20 1 4 5 N C Q F* 123
HUB TYPE
A = Aluminum
C = Cast Spoke Wheel
F = Ferrous
N = None
AXLE TYPE *NOTE: This position will be used to designate hub only
until more than three digits are required to designate
C = Single Rear Drive Axle, Coach axle speci cation.
D = Forward-Rear Axle of a Drive Tandem
with Inter-Axle Differential
F = Front Drive Axle AXLE DESIGN VARIATION
N = Forward-Rear Axle of a Drive Tandem or Indicates axle design level or variation, (e.g., RS 23 161
Tridem without Inter-Axle Differential has a thicker wall housing than the RS 23 160). For
P = Forward-Rear Axle of a Drive Tandem CARRIER TYPE information, refer to the Bill of Materials for that speci c axle
with Inter-Axle Differential and Pump Carrier size. Larger numbers model. (Also refer to Tridem Axle Note 2 below.)
R = Rear-Rear Axle of a Drive Tandem indicate a higher GCW rated
S = Single Rear Drive Axle carrier; i.e., larger ring gear, etc. NOTE 1:
T = Tandem Drive Axle Set (Also refer to Tridem Axle Note 2 If a complete axle designation is not required, use the rst se ven
below) positions of the model designation to identify the basic axle model.
Z = Tridem Drive Axle Set
RS 17 145 = Single Rear Drive, 17,000 lbs., Single Speed, 15"
Ring Gear, 145 Carrier Model.
RT 52 380 = Tandem Drive Axle Set, 52,000 lbs., Helical
NOTE 2, FOR TRIDEM AXLES ONLY: Double-Reduction, 19.62" Ring Gear, 380 Carrier
For a Tridem Drive Axle Set (RZ), the number Model.
in the sixth position designates the carrier in RZ 60 164 = Tridem Drive Axle Set, 60,000 lbs., Single Speed,
the rst axle . The number in the seventh Includes a 160 Series Forward Rear or First Axle
position designates the carriers in the second and a 145 Series Tandem Axle Set as the Second
and third axles. and Third Axles.
4002694a
RS Series Rear Drive Axle
SAPH08Z060300004
AX03–6 REAR AXLE
SAPH08Z060300005
REAR AXLE AX03–7
TROUBLESHOOTING
EN08Z0603F300001

Read and observe all Warning and Caution hazard alert messages in this publication. They provide information that can help
prevent serious personal injury, damage to components, or both.
! WARNING
To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service.
1. TROUBLESHOOTING DIAGNOSTIC CHART

Significant wheel end component wear may enable the ABS warning light and cause a fault code to be set. Slow return of
the steering wheel to its neutral position following completion of a turn may be another indication of wheel end component
wear.
Wheel-End Component Troubleshooting

Condition Cause Correcti on
Tires wear out quickly or have uneven tire Tires have incorrect air pressure. Place the specified air pressure in the tires.
tread wear. Tires are out-of-balance. Balance or replace the tires.
Tandem axle alignment is incorrect. Align the tandem axles.
Toe-in setting is incorrect. Adjust the toe-in to the specified setting.
Steering arm geometry is incorrect. Service the steering system as necessary.
Wheel end play is excessive. Readjust the wheel bearings.
Vehicle is hard to steer. Power steering system pressure is low. Repair the power steering system.
Steering gear linkage is not assembled Assemble the steering gear correctly.
correctly.
Steering linkage needs lubrication. Lubricate the steering linkage.
King pins are binding. Replace the king pins.
Steering arm geometry is incorrect. Service the steering system as necessary.
Caster is out-of-adjustment. Adjust the caster as necessary.
Tie rod ends are hard to move. Replace the tie rod ends.
Thrust bearing is worn. Replace the thrust bearing.
Tie rod ends are wo rn and require Tie rod ends require lubrication. Lubricate the ends of the cross tube. Verify
replacement. that the lubrication schedule is followed.
Operating conditions are severe. Increase the frequency of inspection and
lubrication intervals.
Boot on the tie rod end is damaged. Replace the boot.
SAPH08Z060300006
AX03–8 REAR AXLE
Condition Cause Correcti on

Bent or broken cross tube, tie rod end ball Too much pressure exists in the power
Adjust the power steering system to the
stud, steering arm or tie rod end. steering system. Pressure exceeds the
specified pressure.
Component re quires replacement. vehicle manufacturer’s specification.
Power steering system cut-off pressure is Adjust the power steering system to the
out of adjustment. specified pressure.
Vehicle is operated under severe Verify that the vehicle is operated correctly.
conditions.
Add-on type of power steering system is Correctly install the add-on power steering
not installed correctly. system.
Steering gear overtravel poppets are Check for correct operation or adjust the
incorrectly set or malfunctioning. overtravel of the poppets to the vehicle
manufacturer’s specifications.
Axle stops are incorrectly set. Set the axle stops to the vehicle
manufacturer’s specification.
Worn or broken steering ball stud. Drag link fasteners are tightened higher Tighten the drag link fasteners to the vehicle
than the vehicle manufacturer specified. manufacturer’s specified torque.
Lubrication is lacking or incorrect. Lubricate the linkage with the specified
lubricant.
Power steering stops are Adjust the stops to the specified dimension.
out-of-adjustment.
Worn king pins and k ing pin bushings. Seals and gaskets are worn or missing. Replace the seals and gaskets.
Lubricant is incorrect. Lubricate the axle with the specified
lubricant.
Axle is not lubricated at the scheduled Lubricate the axle at the scheduled
frequency. frequency.
Use of incorrect lubrication procedures. Use the correct lubrication procedures.
Lubrication schedule does not match Change the lubrication schedule to match the
operating conditions. operating conditions.
Vibration or shimmy of fro nt axle during Caster is out-of-adjustment. Adjust the caster.
operation. Wheels or tires are out-of-balance. Balance or replace the wheels or tires.
Shock absorbers are worn. Replace the shock absorbers.
SAPH08Z060300007
REAR AXLE AX03–9
COMPONENT LOCATOR
EN08Z0603D100001
1. MS-12-113 (REACTION BEAM — B-FRAME DISC BRAKE)
16
18
19
14
13
12
10
15
11
17
9
8
7
6
5
3
2
4004242a
SAPH08Z060300008
1 Capscrew 11 Disc Brake Rotor

2 Axle Shaft 12 Inner Race
3 RTV Gasket Material 13 Inner Wheel Bearing
4 Capscrew and Washer 14 Oil Seal
5 Outer Wheel Bearing Jam Nut 15 Spindle
6 Tabbed Lock Washer 16 Reaction Beam Brake Caliper Assembly
7 Outer Wheel Bearing Adjusting Nut 17 Backing Plate
8 Outer Wheel Bearing 18 Integral Caliper Bracket
9 Outer Race 19 ABS Sensor
10 Hub
AX03–10 REAR AXLE
2. RS-19-145 AND RS-13-120 (QUADRAULICTM DISC BRAKE)
18 16
19
12
11
17
15
14
13
2 1
20
10
9
8
7
6
5
4
3
4004249a
SAPH08Z060300009
1 Nut and Star Lock Washer 11 Hub

2 Tapered Dowel 12 Disc Brake Rotor
3 Axle Shaft 13 Inner Race
4 Gasket 14 Inner Wheel Bearing
5 Outer Wheel Bearing Jam Nut 15 Oil Seal
6 Tabbed Lock Washer 16 Reaction Beam Caliper Assembly
7 Pierced Lock Ring with Keyway Tab 17 Spindle
8 Outer Wheel Bearing Adjusting Nut 18 ABS Sensor
9 Outer Wheel Bearing 19 Knuckle
10 Outer Race 20 Backing Plate
REAR AXLE AX03–11
3. RS-21-145 (Q PLUSTM CAM BRAKE)
17 13
16
15 12
14
3 2 1
18
11
10
9
8
7
6
5
4
4004350a
SAPH08Z060300010
1 Brake Drum 10 Outer Wheel Bearing

2 Nut and Star Lock Washer 11 Outer Race
3 Tapered Dowel 12 Hub
4 Axle Shaft 13 Q PlusTM Cam Brake Assembly
5 Gasket 14 Inner Race
6 Outer Wheel Bearing Jam Nut 15 Inner Wheel Bearing
7 Tabbed Lock Washer 16 Oil Seal
8 Pierced Lock Ring with Keyway Tab 17 Spindle
9 Outer Wheel Bearing Adjusting Nut 18 Backing Plate
AX03–12 REAR AXLE
4. TORQUE SPECIFICATIONS
(1) MFS, MS and RS Series Wheel-End Components
Conventional Wheel-End Torque Specifications
Initial Axle Shaft

Adjusting Jam Nut Rotor Rotor Atta ch Axle Shaft Fastener
Axle Hub and Drum or Drum or Nut Torque Torque Atta ch Bolt Bolt Torque Fastener Torque
Model Rotor Assembly Hub Rotor Lb-Ft (N m) Lb-Ft (N m) Size Lb-Ft (N m) Size Lb-Ft (N m)1
MS113 16159741000 15974 123618 100-150 1/2-13 75/100 M12x1.75 85-95
(136-203) (115-129)
16159751000 15975 123624
RS13 16159731000 15973 123617 9/16-12 100/ 125 1/2-20 75-115

(102-156)
RS17 16157191000 15719 123557 100-200
(136-339)
RS19
RS21 1415675107MTB 15675 123207 – – 5/8-18 150-230
(203-312)
16159431000 15943 123574 – –
1
Refer to Axle Division recommendations.
SAPH08Z060300011
REAR AXLE AX03–13
SPECIAL TOOLS
EN08Z0603K100001
1. WHEEL-END SEAL DRIVER APPLICATION

To obtain these tools, call Arvin Meritor's Commercial Vehicle Aftermarket at 888-725-9355 to obtain Meritor tools and
supplies.
(1) MS-12-113 AXLE
6
2
1
15 8
7
9
14 10
13
12
11
4004346a
1 2.17” (55 MM) 5 0.2” (5 MM) 9 R 0.06” (1.5 MM) 13 8.22” (82 MM) ± 0.004 (0.1 MM)
2 0.079” (2 MM) RADIUS 6 0.06” (1.5 MM) 10 R 0.06” (1.5 MM) 14 2.49” (63.3 MM)
3 5.9” (150 MM) 7 1.02” (26 MM) 11 R 0.2” (5 MM) 15 1.57” (40 MM)
4 1.18” (30 MM) 8 0.55” (14 MM) 12 4.96” (126 MM) 16 1.5” (38 MM)
SAPH08Z060300012
AX03–14 REAR AXLE
(2) RS-17-145 AND RS-19-145 AXLE
5 7 10
8
4 6
11
3 2 13 14 15 16 17
1
12
18
19
20
21
22
23
24
25
26
4004345a
1 6” (152.4 MM) SPHERE RADIUS 9 0.25” (6.35 MM) X 45˚ 16 5.25” (133.1 MM) DIAMETER 22 4.25” (107.95 MM)
2 1.75” (44.45 MM) DIAMETER 10 0.03” (0.76 MM) X 45˚ 17 5.63” (143 MM) DIAMETER 23 6.25” (158.75 MM)
3 2.25” (57.15 MM) DIAMETER 11 0.06” (1.52 MM) R-TYP 18 3.5” (88.9 MM) 24 11” (279.4 MM)
4 0.06” (1.52 MM) X 45˚ TYP 12 0.25” (6.35 MM) RADIUS 19 0.25” (6.35 MM) X 30˚ 25 11.25” (285.75 MM)
5 0.06” (1.52 MM) X 45˚ 13 1.25” (31.75 MM) 20 3.25” (82.55 MM) 26 11.75” (298.45 MM)
6 0.13” (3.3 MM) RADIUS 14 2.75” (69.85 MM) 21 3.37” (85.6 MM) 27 12.5” (317.5 MM)
8 0.5” (12.7 MM) RADIUS
SAPH08Z060300013
REAR AXLE AX03–15
(3) RS-13-120 AXLE
7 8 9
5 4 10 11 12 13 14 15
1
2 26
16
17
18
19
20
21
22
25
24
23
4004342a
1 0.13” (3.3 MM) RADIUS (2) 9 0.6” (1.52 MM) R-TYP 16 4.75” (120.65) DIAMETER 22 2.25” (57.15 MM)
2 0.06” (1.524 MM) X 45˚ 10 0.25” (6.35 MM) 17 0.25” (6.35 MM) X 30˚ 23 3” (76.2 MM)
CHAMFER (2) 11 1.5” (38.1 MM) DIAMETER 18 1.43” (36.32 MM) 24 7” (177.8 MM)
3 6” (152.4 MM) SPHERE RADIUS ± 12 2.38” (60.45 MM) DIAMETER 19 1.63” (41.4 MM) 25 7.5” (190.5 MM)
0.25” (6.35 MM) 13 2.87/2.872” (72.9/72.95 MM) 20 2” (50.8 MM) 26 8.25” (209.55 MM)
4 2” (50.8 MM) DIAMETER DIAMETER 21 2.1” (53.34 MM) 27 45˚
5 2.5” (63.5 MM) DIAMETER 14 3.26” (82.8 MM) DIAMETER
7 0.25” (6.35 MM) X 45˚ CHAMFER
8 0.12” (3.05 MM) R, POLISH
SAPH08Z060300014
AX03–16 REAR AXLE
(4) RS-21-145 AXLE (CAM BRAKE AND DISC BRAKE)
8
9
6 10
4
7
3 5
11
3 2 12 13 14 15 16 17
1
19
18
20
21
22
23
24
25
26
27
28
29
4004344a
1 6” (152.4 MM) SPHERE RADIUS 10 0.02” (0.5 MM) X 45˚ CHAMFER (2) 17 5.875” (149.225 MM) 24 2.81” (71.374 MM)
2 1.75” (44.45 MM) 11 0.12” (3.05 MM) RADIUS DIAMETER 25 3.62” (91.95 MM)
3 2.25” (57.15 MM) DIAMETER 12 0.25” (6.35 MM) RADIUS 18 6.25” (158.75 MM) 26 5.75” (146.05 MM)
4 0.06” (1.524 MM) X 45˚ TYP 13 1.25” (31.75 MM) DIAMETER DIAMETER 27 10.5” (266.7 MM)
5 0.06” (1.524 MM) X 45˚ TYP 14 3.25” (82.55 MM) DIAMETER 19 0.25” (6.35 MM) X 30˚ 28 10.75” (273.1 MM)
6 0.13” (3.302 MM) RADIUS 15 3.745” (95.123 MM) DIAMETER 20 2.75” (69.85 MM) 29 11.25” (285.75 MM)
7 COARSE KNURL 16 5.775” (146.685 MM) DIAMETER 21 60˚ 30 12” (304.8 MM)
8 0.5” (12.7 MM) RADIUS 22 0.11” (2.79 MM)
9 0.25” (6.35 MM) X 45˚ 23 2.75” (69.85 MM)
SAPH08Z060300015
REAR AXLE AX03–17
DISASSEMBLY
EN08Z0603H200001
MS AND RS SERIES WHEEL END — REAR DRIVE

AXLE
1. MS-12-113 — REACTION BEAM (B-FRAME) DISC BRAKE

MS-12-113
(REACTION BEAM – B-FRAME DISC BRAKE) (2) Raise the vehicle until the wheels are off the ground. Support the
OIL vehicle with safety stands.
SEAL INNER (3) Remove the tire and wheel assembly.
WHEEL
BEARING 3
(4) Remove the four fasteners securing the reaction beam disc brake cal-
INNER iper assembly to the torque plate.
RACE HUB (5) Remove the caliper assembly from the knuckle.
(6) Remove the eight fasteners securing the axle shaft to the hub.
Remove the axle shaft.
(7) Remove the fastening hardware securing the wheel bearings.
CAPSCREW
a. Bend back the tabs of the tabbed lock washer holding the outer
wheel bearing jam nut.
b. Remove the outer wheel bearing jam nut, the tabbed lock washer
OUTER and the outer wheel bearing adjusting nut from the spindle.
RACE (8) Carefully rock the hub from side-to-side to free the outer wheel bear-
OUTER WHEEL ing. Remove the outer wheel bearing. Remove the hub and rotor
BEARING JA M
LOCK NUT assembly.
ADJUSTING
NUT
WASHER RTV
AXLE
(9) Using a seal puller, remove the inner wheel bearing oil seal from the
GASKET
MATERIAL FLANGE hub. Discard the seal.
4004357a (10) Remove the inner wheel bearing.
(11) Inspect the bearings, races and spindle for signs of damage. Refer to
PREPARE PARTS FOR ASSEMBLY on page AX03-20 to 23.
SAPH08Z060300016 NOTICE
Worn or damaged wheel-end components must be replaced as a set.
(12) If damage to either race is observed, tap out the inner and outer races
with a brass drift and discard.
(13) Use the correct cleaning solution to remove the old lubricant from all
parts. Refer to PREPARE PARTS FOR ASSEMBLY on page AX03-20
to 23.
AX03–18 REAR AXLE
2. RS-19-145 — QUADRAULICTTM DISC BRAKE

(2) Raise the vehicle until the wheels are off the ground. Support the
RS-19-145 AND RS-13-120
(QUADRAULICTM DISC BRAKE) vehicle with safety stands.
OIL
INNER
(3) Remove the tire and wheel assembly.
SEAL
WHEEL (4) Remove the four fasteners securing the QuadraulicTM disc brake cali-
BEARING per assembly to the torque plate.
INNER
HUB (5) Remove the caliper assembly from the torque plate.
RACE NUT AND
STAR LOCK (6) Remove the 12 nut fasteners and star lock washers securing the axle
WASHER shaft to the hub.
TAPERED NOTICE
DOWEL These nuts cannot be reused and must be replaced during assembly.
(7) Tap the axle shaft flange on the strike bars to loosen the tapered dow-
els.
OUTER (8) Remove the tapered dowels, axle shaft and gasket.
RACE
(9) Remove the fastening hardware securing the wheel bearings.
LOCK a. Bend back the tabs of the tabbed lock washer holding the outer
OUTER WHEEL
RING JA M
BEARING wheel bearing jam nut.
LOCK NUT
ADJUSTING WASHER GASKET b. Remove the outer wheel bearing jam nut, the tabbed lock washer,
NUT AXLE
FLANGE
the pierced lock ring with keyway tab and the outer wheel bearing
4004358a
adjusting nut from the spindle.
(10) Carefully rock the hub from side-to-side to free the outer wheel bear-
ing. Remove the outer wheel bearing. Remove the hub and rotor
assembly.
SAPH08Z060300017
hub. Discard the seal.
(12) Remove the inner wheel bearing.
(13) Inspect the bearings, races and spindle for signs of damage. Refer to
PREPARE PARTS FOR ASSEMBLY on page AX03-20 to 23.
NOTICE
to 23.
REAR AXLE AX03–19
3. RS-21-145 — Q PLUSTM CAM BRAKE

(2) Raise the vehicle until the wheels are off the ground. Support the
RS-21-145 (Q PLUSTM CAM BRAKE) vehicle with safety stands.
OIL (3) Remove the tire and wheel assembly.
INNER
SEAL
WHEEL (4) Cage the brake chamber.
BEARING
(5) Remove the brake drum.
INNER HUB
RACE (6) Remove the eight nuts and star lock washers securing the axle shaft
NUT AND to the hub.
STAR LOCK
WASHER (7) Tap the axle shaft flange on the strike bars to loosen the tapered dow-
els.
TAPERED (8) Remove the tapered dowels, axle shaft and gasket.
DOWEL
(9) Remove the fastening hardware securing the outer wheel bearing.
a. Bend back the tabs of the tabbed lock washer holding the outer
OUTER wheel bearing jam nut.
RACE b. Remove the outer wheel bearing jam nut.
OUTER WHEEL LOCK c. Remove the tabbed lock washer, the pierced lock ring with key-
BEARING RING JA M
NUT way tab and the outer wheel bearing adjusting nut from the spin-
LOCK
ADJUSTING
WASHER GASKET dle.
NUT AXLE (10) Carefully rock the hub from side-to-side to free the outer wheel bear-
FLANGE
ing. Remove the outer wheel bearing and hub.
4004361a
hub. Discard the seal.
(12) Remove the inner wheel bearing.
SAPH08Z060300018
(13) Inspect the bearings, races and spindle for signs of damage.
NOTICE
to 23.
AX03–20 REAR AXLE
PREPARE PARTS FOR ASSEMBLY

EN08Z0603H200002

! WARNING

1. REPLACE WORN OR DAMAGED PARTS

Do not repair or recondition wheel-end components. Replace dam-
aged, worn or out-of-specification components. Do not mill or
machine any components.
! WARNING
Solvent cleaners can be flammable, poisonous and cause burns.
Examples of solvent cleaners are carbon tetrachloride, and emulsion-
type and petroleum-base cleaners. Read the manufacturer's instruc-
tions before using a solvent cleaner, then carefully follow the instruc-
tions. Also follow the procedures below.
• Wear safe eye protection.
• Wear clothing that protects your skin.
• Work in a well-ventilated area.
• Do not use gasoline, or solvents that contain gasoline. Gasoline
can explode.
• You must use hot solution tanks or alkaline solutions correctly.
Read the manufacturer's instructions before using hot solution
tanks and alkaline solutions. Then carefully follow the instruc-
tions.
! CAUTION
Do not use hot solution tanks or water and alkaline solutions to clean
ground or polished parts. Damage to parts can result.
REAR AXLE AX03–21
2. CLEAN, DRY AND INSPECT PARTS

(1) Ground or Polished Parts
a. Use a cleaning solvent to clean the ground or polished parts and
surfaces. Kerosene or diesel fuel can be used for this purpose.
DO NOT USE GASOLINE.
b. Do NOT clean ground or polished parts in a hot solution tank or
with water, steam or alkaline solutions. These solutions will cause
corrosion of the parts.
c. Thoroughly clean the hub cavity with spray degreaser. The cavity
must be free of any metal chips or dirt.
d. To remove grease from a wheel end, use a stiff fiber brush, not
steel, and kerosene or diesel fuel, not gasoline. Allow the parts to
dry. Note that any solvent residue must be completely wiped dry
since it may either dilute the grease or oil or prevent the lubricant
from correctly adhering to the wheel-end components.
e. Clean and inspect the wheel bearings, race, spindle bearing jour-
nals and hub. Bearings should be cleaned in a suitable non-flam-
mable solvent and dried with either compressed air or a lint-free
rag.
NOTICE
If compressed air is used, do not spin dry the bearings as the rollers
may score due to lack of lubricant. Ensure that the air line is moisture
free.
3. ROUGH PARTS
Rough parts can be cleaned with the ground or polished parts. Rough
parts also can be cleaned in hot solution tanks with a weak alkaline
solution. Parts must remain in the hot solution tanks until they are
completely cleaned and heated.
4. DRY CLEANED PARTS

Parts must be dried immediately after cleaning. Dry parts with clean
paper or rags, or compressed air. Do not dry bearings by spinning
with compressed air.
5. PREVENT CORROSION ON CLEANED PARTS

Apply a light oil to cleaned and dried parts that are not damaged and
are to be immediately assembled. Do NOT apply oil to the brake lin-
ings or the brake drums.
If the parts are to be stored, apply a good corrosion preventative to all

surfaces. Do NOT apply the material to the brake linings or the brake
drums. Store the parts inside special paper or other material that pre-
vents corrosion.
NOTICE
All tapered joints must be clean and dry with no lubrication or corro-
sion preventative applied to the mating surfaces.
AX03–22 REAR AXLE
INSPECTION WHEEL-END COMPONENTS
1. FOLLOWING DISASSEMBLY AND CLEANING OF THE WHEEL-

END COMPONENTS, INSPECT THE SPINDLE JOURNALS, HUB
AND WHEEL BEARINGS FOR SIGNS OF WEAR AND DAMAGE.
NOTICE
Damage to either the wheel bearing or race will require replacement of
both bearings and races as a set.
2. INSPECT THE CUP, THE CONE AND THE ROLLERS AND CAGE
OF THE WHEEL BEARINGS FOR THE FOLLOWING DEFECTS.
• Cracked or broken separators
• Broken or cracked rollers
• Flaked areas on rollers or races
• Spalled rollers or races
• Overheated bearings
• Brinelled races
• Scored or etched rollers or races
• Pitting of rollers or races
• Wear bands on critical surfaces
• Rust or corrosion on critical surfaces
WORN If any of the following conditions exist, you must replace the bearing.
RADIUS
• The center of the large diameter end of the rollers is worn level or
below the outer surface.
• The radius at the large diameter end of the rollers is worn to a sharp
edge.
WORN
SURFACE
1000369c
SAPH08Z060300019
• There is a visible roller groove in the cup or the cone inner race sur-
faces. The groove can be seen at the small or large diameter end of
both parts.
• There are deep cracks or breaks in the cup, the cone inner race or the
CRACK WEAR GROOVE roller surfaces.
1000370b
SAPH08Z060300020
REAR AXLE AX03–23
• There are bright wear marks on the outer surface of the roller cage.
WEAR MARKS
1000465b
SAPH08Z060300021
• There is damage on the rollers and on the surfaces of the cup and the
cone inner race that touch the rollers.
ETCHING AND PITTING
1000372b
SAPH08Z060300022
• There is damage on the cup and the cone inner surfaces that touch
the rollers.
SPALLING
AND
FLAKING
1000373d
SAPH08Z060300023
AX03–24 REAR AXLE
ASSEMBLY
EN08Z0603H200003
MS AND RS SERIES WHEEL END — REAR DRIVE

AXLE
1. MS-12-113 — Reaction Beam (B-Frame) Disc Brake

(1) Lubricate both the inner and outer wheel bearings. Dip the wheel
bearings into the same lubricant as used in the differential carrier
housing. Refer to LUBRICATION AND MAINTENANCE on pages
MS-12-113 AX03-37 to 38.
(REACTION BEAM – B-FRAME DISC BRAKE)
OIL • If race or wheel bearing replacement is required as a result of
SEAL INNER damage observed during the disassembly procedure: Replace
WHEEL
BEARING these components as a set. If necessary, drive new inner and outer
INNER bearing races into the hub.
RACE HUB (2) Insert the inner wheel bearing into the hub bore.
(3) Install a new oil seal using the correct seal driver. Refer to SPECIAL
TOOLS on pages AX03-13 to 16.
(4) Carefully install the hub and rotor assembly onto the spindle. Ensure
CAPSCREW
that the assembly is correctly seated.
! CAUTION
Do not assemble dry. Damage to wheel end components may result.
OUTER
RACE
(5) Before the outer wheel bearing is installed, fill the wheel cavity with
OUTER WHEEL the same lubricant as used in the differential carrier housing. Typically,
BEARING JA M
LOCK NUT one-half pint of lubricant is required.
ADJUSTING RTV
NUT
WASHER
AXLE
(6) Insert the outer wheel bearing into the hub bore.
GASKET
MATERIAL FLANGE (7) Secure the hub and rotor assembly on the spindle with the outer
4004357a wheel bearing adjusting nut. Tighten finger-tight.
(8) Tighten the outer wheel bearing adjusting nut to 100 lb-ft (136 N⋅m)
while rotating the hub in both directions. This will ensure correct bear-
SAPH08Z060300024
ing-to-hub bore contact. Refer to TORQUE SPECIFICATIONS on
page AX03-12.
(9) Back off the outer wheel bearing adjusting nut one full turn.
(10) Retighten the outer wheel bearing adjusting nut to 50 lb-ft (68 N⋅m)
while rotating the hub.
(11) Back off the outer wheel bearing adjusting nut 1/3 turn.
(12) Install a new tabbed lock washer onto the spindle.
(13) Install the outer wheel bearing jam nut. Tighten to 100-150 lb-ft (136-
203 N⋅m). Refer to TORQUE SPECIFICATIONS on page AX03-12.
(14) Measure bearing end play with a dial indicator. Bearing end play
should be 0.001-0.005-inch (0.025-0.127 mm). Refer to ADJUST-
MENT on pages AX03-35 to 36.
(15) If necessary, adjust bearing end play to obtain the correct dial indica-
tor reading. Refer to ADJUSTMENT on pages AX03-35 to 36.
(16) Bend two opposed lock washer tabs over the outer wheel bearing jam
nut to lock it in position.
(17) Apply a bead of RTV gasket material around the circumference of the
inside surface of the axle shaft flange.
(18) Install the axle shaft with eight capscrews. No flat or lock washers are
required. Tighten to 85-95 lb-ft (115-130 N⋅m) .
(19) Install the reaction beam (B-frame) disc brake caliper assembly onto
the torque plate with four fasteners and washers. Tighten to 81-96 lb-
ft (110-130 N⋅m). Refer to TORQUE SPECIFICATIONS on page
AX03-12.
(20) Check the rear end differential fluid level by removing the oil fill plug
from the carrier or housing bowl. If necessary, add the specified fluid
through the carrier or housing bowl oil fill hole. Fill so that the fluid
level is even with the bottom of the fill plug hole.
REAR AXLE AX03–25
2. RS-19-145 AND RS-13-120 — QUADRAULICTM DISC BRAKE

(1) If removed during the previous wheel-end disassembly procedure,
install the torque plate and backing plate onto the knuckle.
RS-19-145 AND RS-13-120

(QUADRAULICTM DISC BRAKE) bearings into the same lubricant as used in the differential carrier
OIL
INNER housing. Refer to LUBRICATION AND MAINTENANCE on pages
SEAL
WHEEL AX03-37 to 38.
BEARING
• If race or wheel bearing replacement is required as a result of
INNER
RACE HUB NUT AND damage observed during the disassembly procedure: Replace
STAR LOCK these components as a set. If necessary, drive new inner and outer
WASHER
bearing races into the hub.
TAPERED (3) Insert the inner wheel bearing into the hub bore.
DOWEL (4) Install a new oil seal using the correct seal driver. Refer to SPECIAL
(5) Carefully install the hub and rotor assembly onto the spindle. Ensure
OUTER
that the assembly is correctly seated.
RACE
! CAUTION
LOCK
OUTER WHEEL
RING
Do not assemble dry. Damage to wheel end components may result.
BEARING JA M
LOCK NUT
ADJUSTING WASHER GASKET (6) Before the outer wheel bearing is installed, fill the wheel cavity with
NUT AXLE the same lubricant as used in the differential carrier housing. Typically,
FLANGE one-half pint of lubricant is required.
4004358a (7) Insert the outer wheel bearing into the hub bore.
(8) Secure the hub and rotor assembly on the spindle using the outer
wheel bearing adjusting nut. The adjusting nut must be installed so
SAPH08Z060300025 that the nipple faces outward toward the axle shaft flange. Tighten fin-
ger-tight.
page AX03-12.
(13) Install the pierced lock ring so that the inner tab locks into the spindle
keyway and the outer wheel bearing adjusting nut nipple engages one
of the through holes on the lock ring.
339 N⋅m) . Refer to TORQUE SPECIFICATIONS on page AX03-12.
NOTICE
For axle model RS-13-120, tighten the outer wheel bearing jam nut to
100-150 lb-ft (136-203 N⋅m)
(19) Install the axle shaft and gasket.
(20) Install the tapered dowels.
(21) Secure the axle shaft with 12 star lock washers and 12 new nuts.
Tighten to 75-115 lb-ft (102-156 N⋅m).
(22) Install the QuadraulicTM disc brake caliper assembly onto the torque
plate with four fasteners and washers. Tighten to 320-360 lb-ft (435-
AX03–26 REAR AXLE
3. RS-21-145 — Q PLUSTM CAM BRAKE

bearings into the same lubricant as used in the differential carrier
housing. Refer to LUBRICATION AND MAINTENANCE on pages
AX03-37 to 38.
RS-21-145 (Q PLUSTM CAM BRAKE)
OIL INNER
• If race or wheel bearing replacement is required as a result of
SEAL WHEEL damage observed during the disassembly procedure: Replace
BEARING these components as a set. If necessary, drive new inner and outer
INNER HUB bearing races into the hub.
RACE
NUT AND (2) Insert the inner wheel bearing into the hub bore.
STAR LOCK
WASHER (3) Install a new oil seal using the correct seal driver. Refer to SPECIAL
TAPERED
DOWEL
(4) Carefully install the hub assembly onto the spindle. Ensure that the
assembly is correctly seated.
! CAUTION
OUTER Do not assemble dry. Damage to wheel end components may result.
RACE
OUTER WHEEL LOCK (5) Before the outer wheel bearing is installed, fill the wheel cavity with
BEARING RING JA M
NUT the same lubricant as used in the differential carrier housing. Typically,
LOCK
ADJUSTING
WASHER GASKET one-half pint of lubricant is required.
NUT AXLE (6) Insert the outer wheel bearing into the hub bore.
FLANGE
(7) Secure the hub assembly on the spindle using the outer wheel bear-
4004361a
ing adjusting nut. The adjusting nut must be installed so that the nip-
ple faces outward toward the axle shaft flange. Tighten finger-tight.
SAPH08Z060300026
page AX03-12.
(12) Install the pierced lock ring so that the inner tab locks into the spindle
keyway and the outer wheel bearing adjusting nut nipple engages one
of the through holes on the lock ring.
(18) Install the axle shaft and gasket.
(19) Install the tapered dowels.
(20) Secure the axle shaft with eight star lock washers and nuts. Tighten to
150-230 lb-ft (203-312 N⋅m).
(21) Install the brake drum onto the hub.
REAR AXLE AX03–27
4. STUDS AND NUTS

The following warnings are to alert you to stud and nut conditions and
maintenance procedures that can affect your safety and the integrity
of the vehicle and its components.
Carefully read the warnings before you install disc wheels.

! WARNING
Replace bent, loose, broken or stripped studs. When you replace a
stripped stud, always replace the stud on each side of the stripped
stud as well. Even if the adjoining studs are not cracked, they have
sustained fatigue damage, which can cause the wheels to loosen and
separate from the vehicle. Serious personal injury and damage to
Always replace a serrated stud, bolt, with a new one. Do not reuse a
serrated stud, which will not tighten correctly and can cause the
wheels to loosen and separate from the vehicle. Serious personal
injury and damage to components can result.
Do not apply paint to mounting surfaces, studs or nuts. Paint

decreases a fastener assembly's capability to maintain clamp load,
which can cause wheels to loosen and separate from the vehicle. Seri-
ous personal injury and damage to components can result.
Ensure that you do not damage the stud threads. Damaged threads
will not allow the stud to provide the required clamp load to support
the wheel retention system. The wheels can loosen and separate from
the vehicle. Serious personal injury and damage to components can
result.
Check that stud standout is correct for stud-piloted wheels. If stand-

out exceeds specifications even though the correct torque is used,
the cap nut can bottom against the hub stud and loosen both wheels
and the brake drum, which will cause the wheels to separate from the
vehicle. If standout is too short, the cap nut will overload and crack,
causing the inner and dual wheels to separate from the vehicle. Seri-
ous personal injury and damage to components can result.
Install right-hand studs onto the right side of the vehicle and left-hand
studs onto the left side of the vehicle. Studs that are not installed cor-
rectly can loosen, which can cause the wheels to loosen and separate
from the vehicle. Serious personal injury and damage to components
can result.
Do not lubricate the studs or nut threads. Lubricants will not enable
you to tighten the fasteners correctly, which causes excessive clamp
load. The studs can break and cause the wheels to loosen and sepa-
rate from the vehicle. Serious personal injury can result.
Install aluminum wheel nuts onto an aluminum disc wheel. Do not

install steel wheel nuts. Steel wheel nuts can damage an aluminum
wheel or cause the dual wheels to loosen and separate from the vehi-
cle. Serious personal injury and damage to components can result.
Install steel wheel nuts onto steel wheels. Do not install aluminum
wheel nuts. The extension on an aluminum wheel nut can bottom
against the hub flange or brake drum before the disc wheel is
clamped correctly, which can cause the wheels to separate from the
vehicle. Serious personal injury and damage to components can
result.
AX03–28 REAR AXLE
Install the nuts with the correct thread size onto the studs. A nut with
an incorrect thread size will not turn freely on the stud or will fit
loosely on the stud. The thread can strip, which can cause loss of
clamp load. The wheels can loosen and separate from the vehicle.
Install the correct wheel system components for the application. Do

not mix wheel system components. The wheels can loosen and sepa-
rate from the vehicle. Serious personal injury and damage to compo-
nents can result.
Add two drops of oil between the nut flange and the hex portion of the
swivel area at each installation if you reinstall the two-piece flange
nuts that have been in service. Without lubrication, the fasteners may
not produce adequate clamp load, and the wheel(s) can loosen and
separate from the vehicle. Serious personal injury and damage to
(1) Check the studs. Repair or replace loose, bent, stripped or broken
CORRECT: studs.
STUD STANDOUT
(2) Check for correct serrated stud standout.
a. Figure shows correct standout.
b. Figure shows incorrect standout.
4001688a
SAPH08Z060300027
INCORRECT: STUD TOO LONG;

BOTTOMS IN CAP NUT
4001689a
SAPH08Z060300028
INCORRECT: STUD
TOO SHORT; INADEQUATE
SUPPORT FOR CAP NUT
4001690a
SAPH08Z060300029
REAR AXLE AX03–29
(3) Serrated studs do not usually interchange with those in various hub
part numbers. Check the application. Call ArvinMeritor's Customer
Service Center at 800-535-5560 for more information.
(4) Check for R and L stamped in the end of the stud. Install right-hand
studs onto the right side of the vehicle, and left-hand studs onto the
RIGHT- AND LEFT-HAND left side of the vehicle.
FASTENERS
(5) Some manufacturers color code studs. Check the manufacturer's
instructions to verify the color code used.
(6) Install the correct nut into all applications. Do not install rusty, galled
R L or worn nuts. Ensure that you use the correct nuts in the following
installations.
• Install 33 mm hex two-piece flange nuts into ISO 285.75 mm bolt cir-
4001691a
cle diameter (BC) and ISO 335 mm BC systems.
• Install 1-1/2-inch hex two-piece flange nuts into a 275 mm system with
SAPH08Z060300030
M22 x 1.5 serrated studs. Do not install 1-1/2-inch hex two-piece
flange nuts onto M22 x 1.5 serrated studs when 33 mm two-piece hex
nuts are used on the CentroMount-8TM system.
(7) Install aluminum wheel nuts onto aluminum wheels. Do not install
CORRECT: ALUMINUM WHEEL steel wheel nuts. An aluminum wheel nut has an extension to accom-
NUT ON ALUMINUM WHEEL modate the thickness of the aluminum.
4001692a
SAPH08Z060300031
INCORRECT: STEEL WHEEL NUT

ON ALUMINUM WHEEL
4001693a
SAPH08Z060300032
(8) Install steel wheel nuts onto steel wheels. Do not install aluminum
CORRECT: STEEL WHEEL NUT wheel nuts. The extension of the aluminum wheel nut can bottom
ON STEEL WHEEL
against the hub flange or brake drum before the disc is clamped cor-
rectly.
4001694a
SAPH08Z060300033
AX03–30 REAR AXLE
(9) Install nuts with the correct thread size onto the studs. A correct
INCORRECT: ALUMINUM WHEEL NUT thread size enables the nut to turn freely on the stud. An incorrect nut
ON STEEL WHEEL
will fit very loosely on the stud thread, which can cause the thread to
strip.
(10) Check the extension of the stud through the nut after you tighten the
nut to the specified torque.
• If less than two threads extend through the nut, or more than 3/8-
inch (9.5 mm) of the stud extends through the nut: Check all parts
to verify that they are correct for the wheel system you will install onto
the vehicle.
4001695a
SAPH08Z060300034
REAR AXLE AX03–31
(11) Ensure that the nut and wheel mate correctly. Ensure that you install
the correct components onto the wheel systems.
• If the wheel has a ball seat bolt hole pattern: The nut must have a
spherical surface that seats in the ball seat.
• If the wheel has a cylindrical bolt hole pattern: The nut must have
a flat surface that seats against the wheel.
CORRECT: BALL SEAT WHEEL ON BALL SEAT HUB
INCORRECT: HUB-PILOTED WHEEL ON BALL

SEAT HUB
4001697b
SAPH08Z060300035
CORRECT: HUB-PILOTED WHEELS ON

HUB-PILOTED HUB
INCORRECT: BALL SEAT WHEELS ON

HUB-PILOTED HUB
4001699b
SAPH08Z060300036
AX03–32 REAR AXLE
(12) Follow the disc wheel manufacturer's fastener tightening sequence

1 1 when you install fasteners to help ensure a higher and more uniform
10 8
6 3
clamp load. Always check fasteners at the wheel manufacturer's rec-
3 6
ommended service intervals.
1 2
5
4 5 4 (13) Add two drops of oil between the nut flange and the hex portion of the
4 7
7 9 swivel area at each installation if you reinstall the two-piece flange
2 2
5 6 nuts that have been in service. Do not oil the stud or nut threads.
3 8
(14) Retighten all wheel nuts on all systems at 50-100 miles (80-160 km)
to the correct torque specifications.
STUD-PILOTED AND HUB-PILOTED
SINGLE AND DUAL WHEELS (15) Use the correct installation tools.
4001686a
(16) Ensure that the gross weight does not exceed gross vehicle weight
SAPH08Z060300037 (GVW). Ensure that the axle loads do not exceed gross axle weight
ratings (GAWR).
STUD REPLACEMENT PROCEDURES

! WARNING
Do not use a hammer to remove or install studs. A hammer can cause
impact damage to the bearing raceway, which will reduce bearing life.
Ensure that you do not damage stud threads during installation pro-
cedures. Damaged threads will not allow the stud to provide the
required clamp to support the wheel retention system. The wheels
can loosen and separate from the vehicle. Serious personal injury and
damage to components can result.
If a stud is stripped and needs replacement, use one of the following proce-
dures.
1. PREFERRED METHOD — REPLACING STUDS WITH THE HUB

INSTALLED ONTO THE VEHICLE
! WARNING
vehicle from moving.
(2) Raise the vehicle so that the front wheels are off the ground. Support
the vehicle with safety stands.
(3) Mark the wheel and hub relationship. Remove the wheel and tire
assembly. Use a paint stick to mark the wheel studs you are remov-
ing. Do not reuse the studs.
4000521a
SAPH08Z060300038
REAR AXLE AX03–33
(4) If necessary, back off the brake at the slack adjuster until the brake
shoes retract and the drum clears the linings.
4000522a
SAPH08Z060300039
4000523a
SAPH08Z060300040
(6) Use a 1/2-inch (12.7 mm) drive impact wrench and a ball joint removal
kit to remove the studs.
4000524a
SAPH08Z060300041
(7) Use a crocus cloth to clean all the flat surfaces on the wheel band
hub.
(8) Position the new studs into the hub. Align the stud knurls with the
impressions in the hub stud hole.
! WARNING
Do not lubricate studs or nut threads. Lubricants will not enable you
to tighten fasteners correctly, which causes excessive clamp load.
Studs can break and cause wheels to loosen and separate from the
vehicle. Serious personal injury can result.
4000525a
SAPH08Z060300042
AX03–34 REAR AXLE
(9) Add two drops of oil between the body and flange on the stud nuts. Do
not use more than two drops of oil.
FLANGE Apply oil here.
! WARNING
Install nuts with the correct thread size onto the studs. A nut with an
incorrect thread size will not turn freely on the stud or will fit loosely
on the stud. The thread can strip, which can cause loss of clamp load.
NUT THREADS The wheels can loosen and separate from the vehicle. Serious per-
sonal injury and damage to components can result.
NUT BODY
4000527a
SAPH08Z060300043
(10) Position the nuts onto the studs. Use a 1/2-inch (12.7 mm) drive
impact wrench to draw the stud into the hub. Do not exceed 300 lb-ft
(408 N⋅m).
4000528a
SAPH08Z060300044
(11) Use a 0.0015-inch (0.0381 mm) feeler gauge to check that the stud is
correctly seated.
• If the stud is not correctly seated: Remove the stud, clean all surfaces
and install a new stud as described previously.
• If the stud is still not correctly seated: Replace the hub.
(12) Remove all the nuts. Install the wheel and tire assembly.
(13) Discard all removed studs.
4000530a
SAPH08Z060300045
REAR AXLE AX03–35
ADJUSTMENT
EN08Z0603H600001

! WARNING
1. CHECK AND ADJUST WHEEL BEARINGS

The most accurate bearing end play measurement is obtained with
the brake drum and tires removed.
• If the brake drum and tires are installed and the bearing end play
is greater than 0.003-inch (0.0762 mm): Remove the brake drum
and the tire-wheel assembly. Recheck bearing end play.
! WARNING
(2) Raise the vehicle so that the wheels are off the floor. Support the vehi-
cle with safety stands.
(3) Remove the capscrews and remove the gasket and the cap from the
hub.
(4) Verify that the brake drum and the hub fasteners are tightened to the
manufacturer's specifications.
(5) Attach a dial indicator with the magnetic base at the bottom of the hub
or the brake drum. Adjust the dial indicator so that the pointer is
With the indicator
mounted at the against the center of the knuckle. Set the dial indicator on ZERO.
bottom, push and
pull at the side NOTICE
of the tire. Do not push or pull at the top and bottom of the hub or drum, which
can affect the end play measurement.
(6) Measure the end play by pushing and pulling on each side of the hub
or drum while looking at the dial indicator. The end play is the total
travel observed.
1000333c
• If the end play is 0.001-0.005-inch (0.025-0.127 mm): The bearings
do not need adjustment.
SAPH08Z060300046
• If the end play is not 0.001-0.005-inch (0.025-0.127 mm): Adjust
the wheel bearings.
(7) On double nut and lock fasteners: Bend the lock washer off the
wheel bearing nut. Remove the wheel bearing nut, the lock washer
PIERCED and the pierced lock ring.
OUTER LOCK
WHEEL RING
BEARING ! WARNING
NUT
CAP Use a torque wrench to tighten or loosen adjusting nuts. Do not use a
hammer to directly hit adjusting nuts, or to hit a chisel or drift placed
ADJUSTING
against them. Damaged adjusting nuts can prevent you from obtain-
NUT ing correct wheel bearing end play, which can affect vehicle operation
WHEEL
BEARING NUT and cause the wheels to separate from the vehicle. Serious personal
LOCK WASHER,
BEND ONTO OUTER
injury and damage to components will result.
CAPSCREW WHEEL BEARING NUT 1000354d
SAPH08Z060300047
(8) Use a torque wrench to tighten the adjusting nut to 100 lb-ft (136 N⋅m)
while rotating the tire in both directions.
AX03–36 REAR AXLE
(9) Loosen the nut completely. Tighten the nut to 20 lb-ft (27 N⋅m) while
rotating the tire.
(10) Perform the following adjustment procedure.
2. Loosen nut completely. b. Install the pierced lock ring, the lock washer and the wheel bear-
3. Tighten nut to 20 lb-ft (27 N·m). ing nut.
c. For wheel bearing nuts in sizes from 1-1/8-inches up to 2-5/8-
inches (2.86-6.67 cm), tighten to 200-300 lb-ft (271-407 N⋅m). For
wheel bearing nuts 2-5/8-inches (6.67 cm) and more, tighten to
250-400 lb-ft (339-542 N⋅m)
essary.
e. If the end play is to specification, bend the washer to at least one
flat edge of the outer wheel bearing nut.
1000336a
SAPH08Z060300048
(11) Install the gasket and the cap onto the hub. Install the capscrews and
tighten to 20-30 lb-ft (27-41 N⋅m).
(12) Lower the vehicle to the ground. Check for correct vehicle operation.
REAR AXLE AX03–37
LUBRICATION AND MAINTENANCE

EN08Z0603H600002
1. OIL-LUBRICATED WHEEL BEARINGS, DRIVE AXLE HUBS WITH-

OUT FILL HOLES
(1) Park the vehicle on a level surface. Place blocks under the wheels to
TYPICAL OIL-LUBRICATED WHEEL BEARINGS prevent the vehicle from moving.
(2) Add the specified amount of lubricant through the carrier or housing
bowl oil fill hole.
(3) Tilt the axle to the right and to the left to let the oil flow into the hub
cavities. Keep the axle tilted for one minute in each position.
(4) With the axle in the level position, add the specified oil so that the
(5) Install and tighten the fill plug.
OIL RESERVOIR 402155a

SAPH08Z060300049
AX03–38 REAR AXLE
2. LUBRICATION INTERVALS AND SPECIFICATIONS
Wheel-End Axle Greasing Intervals and Specifications
Meritor NLGI Grease Typical Outside

Greasing Inter val Grease Specification Grade Descriptio n Application Temperature
Whichever comes first: Multi-Purpose O-617-A, 1 or 2 Lithium Wheel Refer to the grease
Replacing Seals Grease1 preferred, or 12-Hydroxy Bearings manufacturer’s
O-617-B, Stearate or Hubs specifications for
Relining Brakes
acceptable Lithium the temperature
On-Highway: 30,000 miles Spindle
Complex service limits.
(48 000 km)
On/Off Highway and Off-Highway:
Twice a year
1
Meritor recognizes that industry trends are moving toward increased selection and usage of synthetic grease in vehicle maintenance. However, some seals
are known to expandwhen in contact with synthetic grease. Consult your local Meritor representative for synthetic grease application references before using
any syntheticgrease when performing wheel-end service and maintenance.
Wheel-End Oil Change Intervals and Specifications

Operation On-Highway Off-Highway
Check Oil Level 1,000 miles (1600 km) 1,000 miles (1600 km)
Petroleum Oil Change Whichever comes first. Seals replaced. Brakes relined. Whichever comes first. Seals replaced. Brakes
100,000 mi les (160 000 km). Once a year. relined. Once a year.
Synthetic Oil Change Whichever comes first. Seals replaced. Brakes relined. Whichever comes first. Seals replaced. Brakes
100,000 mi les (160 000 km). Once a year. relined. Once a year.
Approved Lubricants
Outside Temperature
Military/SAE ˚F ˚C
Meritor Specifications Specifications Oil Description Min. Max. Min. Max.
O-76-A Gear Oil MIL-PRF-2105-E GL-5, SAE 85W/140 10 None 12 None
O-76-D Gear Oil and SAEJ2360 GL-5, SAE 80W/90 15 None 26 None
O-76-E Gear Oil GL-5, SAE 75W/90 40 None 40 None
O-76-J Gear Oil GL-5, SAE 75 40 35 40 2
O-76-M Full-Synthetic Oil GL-5, SAE 75W/140 40 None 40 None
O-76-N Full-Synthetic Oil GL-5, SAE 75W/90 40 None 40 None
Heavy-Duty Engine Oil MIL-L-2104 E or F A.P.I. -CD, -CE, -SG, -SH or 10 None 12 None
-SJ SAE 40 or 50 11
Heavy-Duty Engine Oil MIL-L-210 E or F A.P.I. -CD, -CE, -SG, -SH or 15 None 26 None
-SJ SAE 3022
1
Current designations are acceptable. Multi-grade engine oils are acceptable if the SAE rating ends in 40 or 50.
2
Current designations are acceptable. Multi-grade engine oils are acceptable if the SAE rating ends in 30.
SAPH08Z060300050
WHEEL & TIRE AX04–1
WHEEL & TIRE

AX04
AX04-001
WHEEL AND TIRE.................................... AX04-2

DESCRIPTION ................................................ AX04-3
SPECIAL TOOL ............................................... AX04-6
PRECAUTIONS ............................................... AX04-7
INSPECTION ................................................... AX04-8
INSPECTION AND REPAIR ............................ AX04-9
SAE, JIS, TYPE WHEEL......................... AX04-10

OVERHAUL ................................................... AX04-10
AX04–2 WHEEL & TIRE
WHEEL AND TIRE

EN08Z0604I200001
TIRE SIZE TIRE LOAD LIMITS (LBS.) AT VARIOUS COLD INFLATION PRESSURES (PSI)
DESIGNATION (The pressure is minimum for the load)
D:DUAL
S: SINGLE 35 40 45 50 55 60 65 70 75 80
*1,765 *2,150 *2,470

D 1,360 1,490 1,625 1,865 1,985 2,210 2,320
(C) (D) (E)
215/85R16
*1,940 *2,335 *2,680
S 1,495 1,640 1,785 2,050 2,180 2,430 2,550
(C) (D) (E)
TIRE SIZE TIRE LOAD LIMITS (LBS.) AT VARIOUS COLD INFLATION PRESSURES (PSI)
DESIGNATION (The pressure is minimum for the load)
D: DUAL
S: SINGLE 70 75 80 85 90 95 100 105 110 115 120
*3,000 *3,415 *3,750

D 2,720 2,860 3,115 3,245 3,490 3,615
(E) (F) (G)
225/70R19.5
*3,195 *3,640 *3,970
S 2,895 3,040 3,315 3,450 3,715 3,845
(E) (F) (G)
*3,860 *4,300 *4,540

D 3,415 3,515 3,655 3,940 4,075 4,345
(F) (G) (H)
245/70R19.5
*4,080 *4,540 *4,805
S 3,640 3,740 3,890 4,190 4,335 4,620
(F) (G) (H)
*4,805
D 3,525 3,705 3,860 4,040 4,205 4,410 4,525 4,685
(G)
255/80R22.5
*5,205
S 3,870 4,070 4,300 4,440 4,620 4,805 4,975 5,150
(G)
*5,070 *5,675 *6,005

D 4,095 4,300 4,540 4,690 4,885 5,260 5,440 5,795
(F) (G) (H)
295/75R22.5
*5,510 *6,175 *6,610
S 4,500 4,725 4,940 5,155 5,370 5,780 5,980 6,370
(F) (G) (H)
*4,410 *4,940 *5,355

D 3,860 4,045 4,230 4,585 4,760 5,075 5,210
(E) (F) (G)
10R22.5
*4,675 *5,205 *5,675
S 4,080 4,280 4,480 4,850 5,025 5,360 5,515
(E) (F) (G)
*5,205 *5,840 *6,005

D 4,380 4,580 4,760 4,950 5,415 5,625 5,895 5,950
(F) (G) (H)
11R22.5
*5,510 *6,175 *6,610
S 4,530 4,770 4,990 5,220 5,730 5,950 6,320 6,465
(F) (G) (H)
NOTICE
Attached *mark show maximum recommended load (LBS.)
Load range letters and corresponding PLY ratings
(C= 6 PLY, D= 8 PLY, E= 10 PLY, F= 12 PLY, G= 14 PLY, H= 16 PLY, J= 18 PLY)
Tires for vehicles in highway service
Tire load limits at various cold infalation pressures
DESCRIPTION
EN08Z0604C100001
SAPH08Z060400001
WHEEL AND TIRE

1 Tire 3 Valve
2 Disc wheel
TROUBLESHOOTING
EN08Z0604F300001

Excessive wear on edges of tread Under inflated tires Properly inflate with the recommended
pressure.
Vehicle overloading Correct as required by Factory spec.
High speed cornering Correct as required by Factory spec.
Incorrect wheel alignment Set to the correct specifications.
Tires show excessive wear in center Tires overinflated Properly inflate with the recommended
of tread pressure.

Excessive tire wear Improper tire pressure Properly inflate with the recommended
pressure.
Incorrect tire wheel usage Install the correct tire wheel combina-
tion.
Bent wheel Repair or replace.
Front end out of alignment Align front end.
Loose, worn or damaged steering link- Inspect, repair or replace as required
age, joints, suspension components,
bushing or ball joints
Wheel hopping (vehicle vibration Rocks or debris wedged between dual Remove the rocks and the debris.
and rough steering) disc wheels
(Disc wheels) Out-of-balance tire and/or hub and Determine the out-of-balance compo-
drum nent and balance or replace.
Improper positioning of the side ring Reassemble with ring split, opposite
split (180 degrees) to the valve opening to
improve the balance.
Wheel hopping (vehicle vibration Loose or worn drive line or suspension Identify the location of vibration care-
and rough steering) fully. Then repair or replace the loose
(Vehicle) or worn parts. (Refer to PROPELLER
SHAFT for vehicle vibration.)
Wobbling (vehicle vibration and Bent or distorted due to the overload- Replace the wheel.
rough steering) ing or improper handling
(Disc wheels) Loose mountings, damaged studs, Replace worn or damaged parts.
wheel nuts, enlarged stud holes, worn Clean mounting surfaces.
or broken hub face, or foreign material
on mounting surfaces
Wobbling (vehicle vibration and Improper alignment Have vehicle aligned.
rough steering) Loose, worn or broken suspension Repair or replace.
(Vehicle) parts
Cracked or broken wheel discs Metal fatigue resulting from overload- Replace wheel.
(cracks develop in the wheel disc ing
from hand hole to hand hole, from
hand hole to rim, or from hand hole
to stud hole.)
Damaged hub bolt holes (hub bolt Loose wheel mounting • Replace wheel and check the
holes become worn, elongated or installation of correct hub bolt
deformed, metal builds up around and nuts.
hub bolt hole edges, cracks develop • Check the cracked or broken hub
from hub bolt hole to hub bolt hole.) bolt-replace.
• Check the worn hub face-
replace.
• Check the broken or cracked
hub-replace.
• Clean mounting surfaces (Re-
torque the wheel nuts periodi-
cally.)
• Rust streaks fanning out from
hub bolts holes: indicates that the
wheel nuts are or have been
loose.

Tire slippage on rim (Disc wheels) Improper storage or operating condi- Correct as required.
tions
Poor maintenance Follow the proper maintenance proce-
dures.
Rust, corrosion or bead seating Correct as required.
Loss of pressure Follow the proper maintenance proce-
dures.
Tire mounting difficulties Mismatched tire and rim sizes Correct as required.
(Wheel rims) Defective or mismatched rings for the Correct as required.
rim
Tires overinflated Properly inflate with the recommended
pressure.
Corrosion and dirt Correct as required.
Loose inner wheel Excessive hub bolt standout from the Replace with the proper length hub
mounting face of hub allowing the bolt.
wheel nut to bottom out
Improper torque Follow the recommended torque pro-
cedure.
Wrong inner nut Use correct inner nuts.
Broken hub bolts Loose wheel nuts Replace the hub bolt and follow the
proper torque procedures.
Overloading Replace the hub bolt.
Stripped threads Excessive clamp load Replace hub bolt and follow the proper
torque procedures.
Rust streaks from hub bolt holes Loose wheel nuts Check complete assembly, replace
damaged parts and follow the proper
torque procedures.
Damaged inner or outer wheel nuts Loose wheel assembly Replace wheel nuts. Check the proper
torque procedures.
Frozen inner or outer wheel nuts Corrosion or damage Replace wheel nuts and hub bolts.
SPECIAL TOOL
EN08Z0604K100001
Prior to starting a wheel and tire overhaul, it is necessary to have these special tools.
Illustration Part number Tool name Remarks
09609-1210 LEVER
09609-1220 RUBBER HAMMER

PRECAUTIONS
EN08Z0604C100002
! WARNING
Failure to comply with the following procedures may result in faulty positioning of the tire and/or rim parts, and can
cause the assembly to burst with an explosive force sufficient to cause death or serious personal injury.
1. DEFLATION AND DISASSEMBLY

(1) Always check the tire/rim assembly for the proper components seating prior to the removal from the vehicle.
(2) Always deflate the tire by removing the valve core prior to removing the wheel from vehicle or disassembling of the com-
ponents.
(3) Never position your body in front of the rim during deflation.
(4) Always follow the assembly and disassembly procedures outlined in this instruction manual and obtain safety literature
from the Authorities.
(5) Never use a steel hammer to assemble or disassemble the rim components. Use a lead, brass, or plastic type mallet.
2. RIM INSPECTION
(1) Always select the proper tire size and construction to match the rim or wheel rating and size.
(2) Never use damaged, worn, or corroded rims, wheels, or mounting hardware.
(3) Always clean and repaint lightly rusted rims.
(4) Never use a rim or wheel component you cannot identify.
3. ASSEMBLY AND INFLATION

(1) Always inflate the tire in a safety cage or use a portable lock ring guard. Use a clip-on type air chuck with a remote valve
so that you can stand clear during the tire inflation.
(2) Never re-inflate or add inflation pressure to a tire that has been run flat or seriously under inflated without removing and
checking for rim damage.
(3) Tire pressure should be checked while cold. Do not bleed air from tires while hot. This will result in an under inflated con-
dition. Under inflated tires build up excessive heat due to overdeflection that may result in sudden tire deterioration, caus-
ing severe handling problems.
(4) Never hammer on the components of an inflated or partially inflated assembly.
INSPECTION
EN08Z0604H300001
1. GENERAL INSPECTION
(1) Check the tire tread wear (groove depth) and tire damage. If the slip
sign on the tire tread comes out, replace the tire.
Groove depth (Remaining groove)
General running: 1.6 mm {0.063 in.}
SAPH08Z060400004
(2) Check the air pressure.

If improper, inflate the tire to the proper pressure as previously
described in this chapter.
SAPH08Z060400005
2. CHECK RUNOUT IN THE TIRE AND WHEEL RIM.

NOTICE
Eliminate any flat spots in the tire by driving the vehicle a little.
(1) Jack up the vehicle and the check the runout in the tire and wheel rim.
Unit: mm {in.}
Tire Wheel rim
Lateral runout Less than 2.5 {0.098} Less than 1.8 {0.071}
Radial runout Less than 2.5 {0.098} Less than 1.8 {0.071}
SAPH08Z060400006
(2) If the wheel rim does not conform to the runout limits, try re-mounting
the wheel in a different position.
(3) If the wheel rim is still not within 1.8 mm {0.072 in.} of runout, then
replace it with a new rim.
(4) If the tire does not conform to runout standards, reinstall it in a differ-
ent position on the rim.
3. WHEEL AND TIRE BALANCING.

(1) Driving with a rim or tire that is unbalanced may cause the vehicle and
steering wheel to shimmy, and will produce an abnormal tire wear.
In this situation, we recommend that you should balance the wheels.
SAPH08Z060400007 • Static balancing
This is relatively effective when operating at low speeds; however, if
operating at high speeds, dynamic balancing is recommended.
• Dynamic balancing
Please balance the wheels, using a balancing machine.

EN08Z0604H300002
Unit: mm {in.}
Tire: — — Replace, if neces- Visual check

Damage, foreign matter, sary.
etc.
Tubeless tire: — — Replace, if neces- Visual check

Damage sary.
Wheel (Tubeless tire): — — Replace, if neces- Visual check

Cracks and deformation sary.
Rim (Tubeless tire): — — Replace, if neces- Visual check

Damage sary.
Pipe, nut and O-ring of — — Replace, if neces- Visual check

the valve (tubeless tire): sary.
Damage
SAE, JIS, TYPE WHEEL

OVERHAUL
EN08Z0604H200001
IMPORTANT POINT– REMOVAL
1. REMOVE THE WHEEL AND TIRE.

(1) Loosen the wheel nuts, but do not remove them.
(2) Raise the vehicle until the tire clears the floor.
(3) Remove the wheel nuts and tire from the hub and drum.
On dual tires, the inner wheel nuts will also have to be removed for the
inner tire to be removed.
Direction of wheel nut

Model Wheel position
threads
SAPH08Z060400013 Right side of vehicle Right-hand threads
HINO145 (NA)
Left side of vehicle Left-hand threads
EXCEPT FOR
Both side vehicle Right-hand threads
HINO145 (NA)
NOTICE
• Be sure to apply the wheel stoppers in the front or rear tires.
• The wheel nuts on the right side of the vehicle have right hand
threads, and those on the left side have left hand threads.
(HINO 145 (NA) model only)
IMPORTANT POINT - DISASSEMBLY
1. DISASSEMBLE THE WHEEL AND TIRE (TUBELESS).

(1) Make certain the tire is completely deflated with the valve core
removed.
(2) With the tire lying flat, loosen both beads with the special tool or by
standing on the tire with your heels close to the rim.
SST: Rubber hammer (09609-1220)
SAPH08Z060400014
(3) With the wide side of the rim down, lubricate the top bead.
(4) With the stops toward the rim, insert the spoon ends of the special
tools about 250 mm {10 in.} apart. Holding the bead in the well with
one foot, pull one tool towards the center of the rim.
SST: Lever (09609-1210)
SAPH08Z060400015
(5) Hold the tool in position with one foot and pull the second tool toward
the center of the rim. Progressively work the bead off the rim, taking
additional bites with the tools as necessary.
SAPH08Z060400016
(6) Stand the assembly in a vertical position.

Lubricate the second bead.
(7) At the top of the assembly, insert the straight end of the tool between
the bead and back the flange of the rim at about 45 degrees angle.
Turn the tool so that it is perpendicular to the rim. Pry the second
bead off.
SAPH08Z060400017
IMPORTANT POINTS – ASSEMBLY
1. ASSEMBLY OF WHEEL AND TIRE (TUBELESS).

(1) Be sure that the right valve is used and is properly installed in the rim.
Valve nut tightening torque

Tire size designation
N⋅m {kgf⋅cm, lbf⋅in}
215/85R16 11.3-14.1 {115-144, 100-125}
225/70R19.5 2.8-5.1 {29-52, 25-45}
SAPH08Z060400018
245/70R19.5 4.5-6.2 {46-63, 40-55}
255/80R22.5
295/75R22.5
4.0-6.2 {40-63, 35-55}
10R22.5
11R22.5
(2) Inspect the rim to ensure that the bead seats are clean and smooth.
(3) Place the rim on the floor with the wide side down and lubricate the
first bead of the tire and upper bead seat of the rim.
(4) Push the first bead into the well of the rim and onto the rim as far as
possible.
With the special tool, hammer the first bead so that the bead gets over
the rim flange.
SAPH08Z060400019
(5) Insert the lever between the rim flange and the tire bead and then
raise the lever so that the bead gets over the rim flange.
SST: Lever (09609-1210)
SAPH08Z060400020
(6) With the special tool, hammer the tire tread so that the bead and the
rim will be seated.
(7) Inflate the tire as described in this chapter, making certain that all the
safety precautions are followed. Check for leakage.
SAPH08Z060400021
IMPORTANT POINT – INSTALLATION
1. INSTALL THE WHEEL AND TIRE.

(1) Be sure to check all parts and replace any parts that are overly worn
or damaged. Clean and remove any foreign matter from hub bolts,
wheel nuts and wheel side is contacting with the brake drum.
SAPH08Z060400022
(2) Apply lubricant (engine oil or grease) to the thread part of the hub
bolts and wheel nuts.
SAPH08Z060400023
(3) Rotate the wheel if necessary and check to see that the hub bolts are
in the center of the wheel's hub bolt holes, then tighten the wheel nuts
lightly.
NOTICE
The wheel nuts on the right side of the vehicle have right hand
threads, and those on the left side have left hand threads.
(HINO 145 (NA) model only)
SAPH08Z060400024
(4) Using a wheel nut wrench, tighten the wheel nuts in accordance with
specified torque using diagonal method.
Tightening torque
MODEL STUD
N⋅m {kgf⋅cm, lbf⋅ft}
390-470
HINO145 (NA) JIS 6 STUDS
{4,010-4,800, 290-347}
HINO165 (NB), 185 215-235

ISO 8 STUDS
(NC), 238, 258 (ND) {2,200-2,400, 160-175}
HINO238 (ND), 268

610-675
(NE, NJ), 308 (NF), ISO 10 STUDS
{6,230-6,910, 450-500}
338 (NV)
NOTICE
Tighten the wheel nuts with several repetitions in the tightening order
so as to reach the proper torque evenly and gradually.
! WARNING
The specified torque refers to torque tightening of wheel nuts. Incor-
rect tightening can cause the wheel to come off while driving. This
can result in death, personal injury and/or property damage due to the
loss of vehicle control.
SAPH08Z060400025 When the vehicle, wheels, or wheel nuts are new, the wheel nuts
should be checked and tightened with specified torque at 100, 500
and 1,000 miles to confirm they are not loosen and correctly tight-
ened. The tightening torque should be checked with the proper torque
wrench.
2. THE FOLLOWING ORDER AND INSTRUCTIONS ARE NECES-

SARY FOR INSTALLING DUAL TIRES.
(1) Installation procedures for the inner wheel nuts are the same as in 1.
through 4. above.
(2) Installation procedures for the outer wheel nuts are the same as
above.
(3) When only the outer wheel is replaced, first tighten all the inner wheel
nuts to the specified torque. Then mount the outer wheel and tighten
all the outer wheel nuts to the specified torque.
NOTICE
• Install the dual rear wheels with their valve stems positioned at
180 degrees apart to facilitate inflation.
• Tighten all the inner nuts and outer nuts according to the above-
mentioned procedures.
3. WHEEL AND TIRE BALANCING

(1) Driving with a rim or tire that is unbalanced may cause the vehicle and
steering wheel to shimmy, and will produce an abnormal tire wear.
In this situation, we recommend that you should balance the wheels.
• Static balancing
This is relatively effective when operating at low speeds; however, if
operating at high speeds, dynamic balancing is recommended.
• Dynamic balancing
Please balance the wheels, using a balancing machine.
SUSPENSION SU02–1
SUSPENSION
SU 02
SU02-001
LEAF SUSPENSION ASSEMBLY ............ SU02-2

DATA AND SPECIFICATIONS ......................... SU02-2
DESCRIPTION ................................................ SU02-4
TROUBLESHOOTING ..................................... SU02-7
COMPONENT LOCATOR................................ SU02-8
OVERHAUL ................................................... SU02-13
INSPECTION AND REPAIR .......................... SU02-17
AIR SUSPENSION ASSEMBLY ............. SU02-19

DATA AND SPECIFICATIONS ....................... SU02-19
DESCRIPTION .............................................. SU02-20
TROUBLESHOOTING ................................... SU02-21
COMPONENT LOCATOR.............................. SU02-22
OVERHAUL ................................................... SU02-23
INSPECTION AND REPAIR .......................... SU02-27
SU02–2 SUSPENSION
LEAF SUSPENSION ASSEMBLY

EN09Z0702I200001
FRONT SUSPENSION Unit: mm {in.}
HINO 238, 258

HINO 308
(ND8J)
HINO 145 HINO 165 HINO 185 (NF8J)
Model HINO 268
(NA6J) (NB6J) (NC6J) HINO 338
(NE8J)
(NV8J)
(NJ8J)
Type Taper-leaf springs with double acting shock absorber
Span 1,200 {47.24} 1,200 {47.24} 1,200 {47.24} 1,470 {57.88} 1,470 {57.88}
Width 76.2 {3.00} 76.2 {3.00} 76.2 {3.00} 76.2 {3.00} 76.2 {3.00}
Dimensions
of leaf 16.76 {0.66} 16.76 {0.66} 16.76 {0.66} 20.01 {0.788} 20.01 {0.788}
springs: Thickness
16.76 {0.66} 16.76 {0.66} 16.76 {0.66} 20.01 {0.788} 20.01 {0.788}
of leaves
— — — — 20.01 {0.788}
Type Double acting Double acting Double acting Double acting Double acting
Shock Stroke 208 {8.19} 208 {8.19} 208 {8.19} 255 {10.04} 255 {10.04}
absorbers: Min. length 420 {16.53} 420 {16.53} 420 {16.53} 390 {15.35} 390 {15.35}
Max. length 628 {24.72} 628 {24.72} 628 {24.72} 645 {25.4} 645 {25.4}
Type Torsion ber Torsion ber Torsion ber — —

Stabilizer
Diameter 32 {1.26} 32 {1.26} 32 {1.26} — —
(opt):
Length 289.5 {11.40} 289.5 {11.40} 289.5 {11.40} — —
REAR SUSPENSION Unit: mm {in.}
HINO 238, 258

HINO 308
(ND8J)
HINO 145 HINO 165 HINO 185 (NF8J) HINO 338
Model HINO 268
(NA6J) (NB6J) (NC6J) HINO 338 (NV8J)
(NE8J)
(NV8J)
(NJ8J)
Type Semi-elliptic main and auxiliary helper-leaf spring
Span 1,300 {51.18} 1,300 {51.18} 1,300 {51.18} 1,300 {51.18} 1,300 {51.18} 1,300 {51.18}
Width 76.2 {3.00} 76.2 {3.00} 76.2 {3.00} 76.2 {3.00} 76.2 {3.00} 76.2 {3.00}
Dimensions 10.7 {0.423} 12.0 {0.473} 13.4 {0.527} 14.17{0.558} 14.99 {0.590} 15.88 {0.625 }
of main leaf
springs: Thickness of 10.2 {0.401} 10.7 {0.423} 12.0 {0.473} 13.4 {0.527} 9.65{0.380} —
leaves — 10.2 {0.401} 10.7 {0.423} 9.65{0.383} 10.2 {0.401} 10.2 {0.401}
— 9.14 {0.360} 10.2 {0.401} 10.2 {0.401} — —
Span 900 {35.44} 900 {35.44} 900 {35.44} 900 {35.44} 900 {35.44} 900 {35.44}
Dimensions
of auxiliary Width 76.2{3.00} 76.2{3.00} 76.2{3.00} 76.2{3.00} 76.2{3.00} 76.2{3.00}
leaf springs:
Thickness 17.83 {0.702} 17.83 {0.702} 17.83 {0.702} 17.83 {0.702} 17.83 {0.702} 17.83 {0.702}
SUSPENSION SU02–3
HINO 238, 258

HINO 308
(ND8J)
HINO 145 HINO 165 HINO 185 (NF8J) HINO 338
Model HINO 268
(NA6J) (NB6J) (NC6J) HINO 338 (NV8J)
(NE8J)
(NV8J)
(NJ8J)
Double act- Double act- Double act- Double act- Double act- Double act-
Type
ing ing ing ing ing ing
Shock
absorbers Stroke 280 {11.02} 280 {11.02} 280 {11.02} 242 {9.53} 242 {9.53} 242 {9.53}
(opt): Min. length 389 {15.31} 389 {15.31} 389 {15.31} 432 {17.01} 432 {17.01} 432 {17.01}
Max. length 689 {27.12} 689 {27.12} 689 {27.12} 674 {26.53} 674 {26.53} 674 {26.53}
Type — — — Torsion ber Torsion ber Torsion ber

Stabilizer
Diameter — — — 48 {1.89} 48 {1.89} 48 {1.89}
(opt):
Length — — — 550 {21.65} 550 {21.65} 550 {21.65}
SU02–4 SUSPENSION
DESCRIPTION
EN09Z0702C100001
FRONT SUSPENSION
SAPH09Z070200001
1 Leaf spring assembly 5 Shackle

2 Shock absorber 6 Spring pin
3 Spring bumper 7 Stabilizer (Opt.)
4 U-bolt
REAR SUSPENSION
SAPH09Z070200002
1 Spring pin 4 Main leaf spring assembly

2 Auxiliary leaf spring assembly 5 Spring pad
3 U-bolt 6 Shock absorber (Opt.)
SUSPENSION SU02–5
FRONT SUSPENSION
SAPH09Z070200003
1 Leaf spring assembly 4 U-bolt

2 Shock absorber 5 Shackle
3 Spring bumper 6 Spring pin
REAR SUSPENSION
SAPH09Z070200004
1 Spring pin 4 Main leaf spring assembly

2 Auxiliary leaf spring assembly 5 Spring pad
3 U-bolt 6 Shock absorber (Opt.)
SU02–6 SUSPENSION
FRONT SUSPENSION
SAPH09Z070200005
1 Leaf spring assembly 4 U-bolt

2 Shock absorber 5 Shackle
3 Spring bumper 6 Spring pin
REAR SUSPENSION
SAPH09Z070200006
1 Stabilizer (Opt.)
SUSPENSION SU02–7
TROUBLESHOOTING
EN09Z0702F300001

Rough ride Broken leaves Replace the leaves. Check the load
capacity rating.
Cracked or damaged Replace the leaves. Check the load
capacity rating.
Overloading Decrease the load.
Heavy sway Inoperative shock absorber Replace the shock absorber.
Leaves broken at the center bolt Loosen U-bolts Replace the leaves and tighten the U-
hole bolts to specified torque.
Squeaking of the leaves Friction between the leaves Apply chassis grease between leaves.
SU02–8 SUSPENSION
COMPONENT LOCATOR
EN09Z0702D100001
FRONT SUSPENSION
for Hino 145,165,185 (NA,NB,NC)
Standard front suspension 12

SAPH09Z070200007
1 U-bolt 11 Shock absorber bracket

2 Spring bumper 12 Shock absorber pin
3 Spring pad 13 Cushion (If so equipped)
4 Lock nut 14 Cushion washer (If so equipped)
5 Spring pin 15 Holder sub assembly (If so equipped)
6 U-bolt nut 16 Holder (If so equipped)
7 Caster shim 17 Stabilizer sub assembly (If so equipped)
8 Leaf spring assembly 18 Rubber bushing (If so equipped)
9 Shackle 19 Stabilizer lever (If so equipped)
10 Shock absorber

A 472-502 {4813-5118, 348-370} D 370-472 {3773-4813, 273-348} for HINO238-338 (ND-
NV)
B 107-147 {1091-1498, 79-108} for HINO145-185 (NA- E 180-240 {1836-2447, 133-177}
NC)
B 169-227 {1724-2314, 125-167} for HINO238-338 (ND- F 91-149 {928-1519, 67-109}
NV)
SUSPENSION SU02–9
C 210-294 {2142-2998, 155-216} G 73-109 {745-1111, 54-80}

D 223-335 {2274-3416, 165-247} for HINO145-185 (NA- H 35-51 {357-520, 26-37}
NC)
SU02–10 SUSPENSION
REAR SUSPENSION
SAPH09Z070200008
1 U-bolt 9 Rear spring upper seat

2 Spring pad 10 Rear spring lower seat
3 Flange bolt 11 U-bolt nut
4 Auxiliary leaf spring 12 Bushing
5 Spring pin 13 Rear bracket sub assy (If so equipped)
6 Lubrication fitting 14 Shock absorber (If so equipped)
7 Thrust washer 15 Shock absorber bracket (If so equipped)
8 Leaf spring assembly 16 Cushion washer (If so equipped)

A 73-109 {745-1111, 54-80} C 490-734 {4997-7484, 362-541} for HINO238-338 (NA-
NC)
B 35-51 {357-520, 26-37} for HINO145-185 (NA-NC) D 73-109 {745-1111, 54-80} for HINO145-185 (NA-NC)
B 107-147 {1092-1498, 79-108} for HINO238-338 (ND- D 180-240 {1836-2447, 133-176} for HINO238-338 (ND-
NV) NV)
SUSPENSION SU02–11
C 390-584 {3977-5955, 288-430} for HINO145-185 (NA-

NC)
SAPH09Z070200009
1 U-bolt 8 Slotted nut

2 U-bolt nut 9 Stabilizer bar
3 Rear bracket sub assy 10 Stabilizer bar sleeve
4 Rubber bushing 11 Stabilizer lever
5 Stabilizer link pin 12 Stabilizer bar sleeve
6 Stabilizer lever sub assy 13 Stabilizer link pin
7 Stabilizer lever 14 Stabilizer bracket sub assembly

A 180-240 {1836-2447, 133-176} C 490-734 {4997-7484, 362-541}
B 53-89 {541-907, 39-65} D 107-147 {1091-1498, 79-108}
OVERHAUL
EN09Z0702H200001
IMPORTANT POINTS - DISMOUNTING
1. SUPPORT THE FRAME WITH STANDS

(1) Park the vehicle on level ground.
(2) Be sure to block the wheels before dismounting.
SAPH09Z070200010
(3) Jack up the axle, and support the frame with stands.
(4) Remove the tires.
SAPH09Z070200011
2. REMOVAL OF THE U-BOLT

(1) Remove the shock absorber.
(2) Support the axle with a jack.
(3) Remove the U-bolt mounting nuts.
NOTICE
When cutting off the U-bolts (due to rusted threads) with a torch,
never direct the flame toward the leaves or allow sparks to come in
contact with the leaves.
SAPH09Z070200012
3. REMOVAL OF THE SPRING PIN (FRONT SUSPENSION)

(1) Use a brass rod to remove the spring pins from the shackle and spring
bracket.
SAPH09Z070200013
4. REMOVAL OF THE SPRING PIN (REAR SUSPENSION)

(1) Remove the lubrication fitting and spring pin lock bolt.
SAPH09Z070200014
(2) Use a brass rod to remove the spring pins from the shackle and spring
bracket.
SAPH09Z070200015
1. REPLACEMENT OF THE EYE BUSHING (REAR SUSPENSION)

(1) Use a suitable tool to press out the old eye bushing.
(2) Use a suitable tool to press in the new eye bushing.
SAPH09Z070200016
2. DISASSEMBLY OF THE LEAF SPRING

! WARNING
When removing the center bolt lock nut, the spring leaves may jump.
Care should be taken to avoid possible personal injury.
(1) Remove the clip bolts.
(2) Use a vice or an arbor press to hold the leaf spring near the center
bolt.
(3) Remove the center bolt.
(4) Loosen the vice or arbor press slowly, and separate the leaves.
SAPH09Z070200017
IMPORTANT POINTS - ASSEMBLY
1. ASSEMBLY OF THE LEAF SPRING

! WARNING
When clamping the spring leaves, they may jump. Care should be
taken to avoid possible personal injury.
(1) Apply coating on the leaf after removing rust, and apply chassis
grease on both surfaces of leaves.
SAPH09Z070200018
(2) Align the leaf holes then secure the leaves with a vice or an arbor
press.
(3) Insert the center bolt and tighten the lock nut.
Tightening Torque:
90-100 N⋅m {918-1020 kgf⋅cm, 66-74 lbf⋅ft}
NOTICE
When reassembling the leaf spring, replace the center bolt with a new
one.
SAPH09Z070200019
(4) Tighten the clip bolts.

Tightening Torque:
20 N⋅m {205 kgf⋅cm, 15 lbf⋅ft}
NOTICE
When tightening the clip bolts, use a new clip bolts.
(5) Use a punch to peen the thread of the clip bolts.
SAPH09Z070200020
IMPORTANT POINTS - MOUNTING
1. INSTALLATION OF THE SPRING PIN (REAR SUSPENSION)

(1) Use a copper hammer to install the spring pin with thrust washers.
NOTICE
Apply chassis grease on the surface of the eye bushing and spring
pin before installing.
(2) Install the spring pin lock bolt and nut.
SAPH09Z070200021
2. LUBRICATION (REAR SUSPENSION)

(1) Lubricate the following parts with chassis grease.
• Spring pins
• Auxiliary spring slide seats
HINT
Do not apply chassis grease to other parts and Front suspension.
SAPH09Z070200022
3. INSTALLATION OF THE U-BOLT

(1) Put the caster shim on the front axle I-beam part of the each side. (For
front suspension)
(2) Lift the axle using a jack and align the hole of the leaf spring center
bolt and the hole of the axle I-beam.
NOTICE
Axle and suspension assembly are heavy, therefore be careful when
handling them.
SAPH09Z070200023
(3) Put the spring pads and bumper rubbers on the leaf springs.
(4) Set the U-bolts so that they catch the spring pads and tighten the U-
bolt nuts temporarily.
SAPH09Z070200012
(5) Tighten the U-bolt nuts (4 pieces) alternately right and left and
equally.
After repeating this operation 3 to 5 times, tighten the nuts to the
1 3 specified torque.
FRONT
Tightening Torque: N⋅m {kgf⋅cm, lbf⋅ft}
HINO 145, 165, 185 HINO 238, 258, 268, 308, 337
Model
(NA, NB, NC) (ND, NE, NF, NV)
223-335 370-472
2 4 Front
{2,274-3,416, 165-247} {3,773-4,813, 273-348}
390-584 490-734
Rear
SAPH09Z070200024 {3,977-5,955, 288-430} {4,997-7,484, 362-541}

EN09Z0702H300001
Unit: mm {in.}
Spring pin: Outside Rear 31.66 {1.246} 31.30 Replace. Measure

diameter {1.232}
Clearance between spring pin 0.125 0.5 Replace the pin Measure
and eye bushing {0.0049} {0.0197} and/or bushing.
Thrust washer: 3.0 {0.118} 2.5 Replace. Measure

Wear {0.0984}
Leaf: — More than Replace. Measure

Damage and wear 15%
Spring bumper: — — Replace, if neces- Visual check

Damage and wear sary.
U-Bolt: — — Replace, if neces- Visual check

Damage sary.
Shock absorber: — — Replace, if neces- Visual check

Operation, oil leak and dam- sary.
age
Cushion: — —
Damage and wear
Shock absorber pin and — —

bracket:
Damage and wear
Shackle: — — Replace, if neces- Visual check

Damage sary.
Stabilizer Bar: Replace, if neces- Visual check

Damage sary.
(If so equipped)
Stabilizer Sleeve:
Wear
(If so equipped)
Stabilizer Bushing:
Wear
(If so equipped)
Slide Seat: — 2 {0.08} Replace. Measure: thickness from bolt

Wear head as shown below.
Helper Bracket: 6 {0.236} 2 {0.08} Replace. Measure: thickness

Wear
AIR SUSPENSION ASSEMBLY

EN09Z0702I200002
REAR SUSPENSION
Model HINO 268, 338 (NJ8J, NV8J)
Type HENDRICKSON AL-V

DESCRIPTION
EN09Z0702C100002
REAR SUSPENSION
SAPH09Z070200036
1 Spring hanger 5 Height control valve

2 Main support member 6 Quick align base
3 Air spring 7 Transverse torque rod
4 Shock absorber
TROUBLESHOOTING
EN09Z0702F300002

Abnormal sound occurs from the Eccentric wear of the shock absorber Replace the pin and/or rubber bush-
spring while driving. fitting pin ing.
Uncomfortably (Rolling and pitch- Deflection and damage of the bushings Replace the main support member or
ing) of the main support member or the the bushing of the transverse rod.
transverse rod
Faulty of the shock absorber Replace the shock absorber.
Faulty of the height control valve Repair the heght control valve.
Vibration of the steering wheel, and Deflection of the bushing in the main Replace the main support member or
the car shake support member or the transverse rod the bushing of the transverse rod.
Looseness of the transverse rod Replace the lock nut and tighten with
bracket bolt the specified torque.
Vehicle height is not adjusted cor- Faulty of the height control Repair the parts.
rectly
COMPONENT LOCATOR
EN09Z0702D100002
REAR SUSPENSION
H F 16 E
M 14 13
J
2 1
9
G
10
15 8
J
5
L
M K
C
6
3 7 D
B
11
4
12
N A
SAPH09Z070200037
1 Air spring 10 Link

2 Cross channel 11 Spring hanger
3 Main support member 12 Bottom cap
4 Spring seat 13 Inner reinforcement plate
5 U-bolt 14 Outer reinfocement plate
6 Top pad 15 Transverse rod
7 Lower shock absorber bracket 16 Upper shock absorber bracket
8 Shock absorber X From air tank
9 Height control valve

A 545-611 {5558-6230, 402-450} H 26-40 {266-407, 20-29}
B 285-365 {2907-3721, 211-269} J 13-17 {133-173, 10-12}
C 27-41 {276-418, 20-30} K 13-17 {133-173, 10-12}
D 215-245 {2193-2498, 159-180} L 160-220 {1632-2243, 118-162}
E 69-95 {704-968, 51-70} M 160-220 {1632-2243, 118-162}
F 160-220 {1632-2243, 118-162} N 500-600 {5099-6118, 369-442}
G 215-245 {2193-2498, 159-180}
OVERHAUL
EN09Z0702H200002
1. SUPPORT THE FRAME WITH STAND.

(1) Park the vehicle on level ground.
(2) Be sure to block the wheels before dismounting.
SAPH09Z070200010
(3) Jack up the axle, and support the frame with the stand.
SAPH09Z070200038
2. DISCONNECT THE SUSPENSION FROM REAR AXLE

(1) Remove the U-bolt lock nuts and washers.
(2) Remove the U-bolts, bottom cap, and top pad.
(3) Remove the lock nuts and washers which connect the cross channel
to both the main support members.
(4) Lift cross channel off the main support member with jacks.
SAPH09Z070200039
3. REMOVE OF MAIN SUPPORT MEMBERS

(1) Release air pressure from the air springs.
(2) Remove the height control valve link from the valve by removing the
nut and the lock washer.
SAPH09Z070200040
(3) Remove the quick align bolts, lock nuts washers, and quick align
SPRING bases from the spring hanger.
HANGER
(4) Remove the main support member assembly.
BOLT
QUICK ALIGN BASE NUT & WASHER
SAPH09Z070200041
4. REMOVE OF CROSS CHANNEL

(1) Remove the lock nuts and washers which connect the air spring to
cross channel.
(2) Raise the cross channel by using jack if requires.
SAPH09Z070200042
5. REMOVAL OF AIR SPRING

(1) Remove the air line from the air spring seat.
(2) Remove the brass air fittings from the air spring , if necessary.
(3) Remove the lock nuts and washers which connect the air spring to the
upper air spring frame hanger.
(4) Remove the air spring.
(5) Remove the air spring frame hanger, if necessary.
SAPH09Z070200043
6. REMOVE OF SHOCK ABSORBER FRAME HANGER BRACKET

(1) Remove the lock nuts and washers at both ends of the shock
absorber.
(2) Remove the shock absorber completely from the chassis.
(3) Remove the lock nuts and washers which connect the shock absorber
bracket to the frame.
(4) Remove the shock absorber bracket.
SAPH09Z070200044
7. REMOVE OF SHOCK ABSORBER LOWER BACKET

(1) Remove the shock absorber completely from the chassis.
(2) Remove the shock absorber lower bracket.
SAPH09Z070200045
8. REMOVAL OF TRANSVERSE ROD

(1) Remove the lock nuts and washers which connect the transverse rod
INNER to the frame.
REINFORCEMENT
PLATE
(2) Remove the lock nuts and washers which connect to the axle bracket.
(3) Use Owatonna Tool Company’s tool set to remove and install the
TRANSVERSE transverse rod bushings. Follow their instructions.
ROD
OUTER
REINFORCEMENT
PLATE
SAPH09Z070200046
1. INSTALLATION OF TRANSVERSE ROD

(1) Assemble the washer and lock nut to the bolt. Tighten the lock nut to
specified torque.
(2) install the back up plates.
B (3) Position the straddle mount end of torque rod at the transverse rod to
A the frame, tighten the lock nuts to specified torque.
NOTICE
All the nuts and bolts are lock type. Therefore these are not reuseable.
You should install a new one.
SAPH09Z070200047
2. INSTALL OF MAIN SUPPORT MEMBERS AND AIR SPRING

(1) Installation is in the reverse order of removal.
NOTICE
Tighten fasteners to specified torque. Refer to on page SU02-19, or
Torque Requirements card on the right frame.
3. CHECK THE AIR LEAKAGE.

(1) Apply soapy water for each joint of air line and sharge the com-
TORQUE
REQUIREMENTS pressed air of 780 kPa {8.0 kgf/cm2, 110 lbf/in.2} then check the leak-
CARD age.
4. ADJUSTMENT OF THE VEHICLE HEIGHT

NOTICE
• Adjustment should be done only after assembling.
• Adjustment should be done with the air pressure of 71-86 kPa
{7.0-8.5 kgf/cm2, 99-120 lbf/in.2}, keeping on supplying the air
SAPH09Z070200048
while rotating the engine at the idle speed.
(1) Measure the shock absorber length between upper and lower pins.
Assembly standard: 606.4 mm {23.9 in.}

(2) If the shock absorber length is not the assembly standard, adjust the
extension rod length, so that the shock absorber length is the assem-
bly standard.
EXTENSION ROD
｝
606.4mm
｛
SAPH09Z070200049

EN09Z0702H300002
Unit: mm {in.}
Air spring: — — Replace, if neces- Visual check

Wear, damage and crack sary.
Main support member: — — Replace, if neces- Visual check

Crack and damage sary.
Bushing: — —
Wear, damage and crack
Cross channel: — — Replace, if neces- Visual check

Crack and damage sary.
Spring seat: — — Replace, if neces- Visual check

Wear, damage and crack sary.
U-Bolt: — — Replace, if neces- Visual check

Damage sary.
Pad: — —
Shock absorber: — — Replace, if neces- Visual check

Operation,oil leak and damage sary.
Upper and lower brackets: — —

Crack and damage
Transverse rod: — — Replace, if neces-

Crack and damage sary. Visual check
Transverse rod bushings: — —

Chassis Reinforcement: — —
Crack and damage
Spacer plate: — —
Crack and damage
CHASSIS FRAME FC02–1
CHASSIS FRAME
FC02
FC02-001
CHASSIS FRAME ..................................... FC02-2

TROUBLESHOOTING ..................................... FC02-2
INSPECTION ................................................... FC02-2
REPAIRS.......................................................... FC02-3
FC02–2 CHASSIS FRAME
CHASSIS FRAME
TROUBLESHOOTING
EN10Z1102F300001

Frame distortion (Vehicle inclina- Flattening or breakage of springs on Replace spring
tion) one side
Incorrect mounting (Attachment of Correct mounting
heavy weight on one side of the vehi-
cle)
Bent frame Overloading or concentrated weight on • Correct load
rear end of frame • Correct with frame correction
device
Frame cracking or rivets breaking Wrong body mounting Correct mounting
Overloading • Improvement of the usage
• Reinforce with stiffener
INSPECTION
EN10Z1102H200001
1. CLEAN THE FRAME

NOTICE
While inspecting or repairing, stop the engine and block the wheels.
When cleaning with a steam cleaner, use safety goggles.
SAPH10Z110200001
2. PLACE THE VEHICLE ON A FLAT SURFACE, HANG A WEIGHT

FROM EACH MEASURING POINT ON THE FRAME, AND MARK
THE FLOOR BELOW THE WEIGHT.
SAPH10Z110200002
3. INSPECT THE FRAME FOR BENDING, TWISTING OR OTHER

DEFORMATION.
4. CHECK THE TIGHTENESS OF THE RIVETS, AND BOLTS.
SAPH10Z110200003
REPAIRS
EN10Z1102H200002
1. FRAME ALIGNMENT
(1) Correct the frame alignment.
SAPH10Z110200004
2. CRACKING OF THE FRAME

(1) Clean the area around the cracks with a steam cleaner, soap and
water, or a solvent.
NOTICE
When cleaning with a steam cleaner, use safety goggles.
SAPH10Z110200001
3. REPAIRING OF FRAME CRACKS

(1) Perform the procedure for preventing the enlargement of cracks.
NOTICE
Do not make drill holes on the frame flanges except when repairing
the cracks.
SAPH10Z110200005
(2) Make the V-shape groove with a grinder along the frame crack
according the following table.
Unit: mm {in.}
t x° s a
4.5 {0.18} 90 1.0 {0.039} 0
6 {0.24} 70 1.0 {0.039} 0
7 {0.28} 70 1.5 {0.059} 1 {0.039}
8 {0.31} 70 1.5 {0.059} 1 {0.039}
9 {0.35} 70 1.5 {0.059} 1 {0.039}
SAPH10Z110200006 10 {0.39} 60 1.5 {0.059} 1 {0.039}
12 {0.47} 60 1.5 {0.059} 1 {0.039}
16 {0.63} 60 2.0 {0.079} 1 {0.039}
(3) Use an electric welder.

Refer to page FC02-7 for WELDING CONDITION (WHEN WELD-
ING ROD IS USED).
! WARNING
• Disconnect the negative battery ground cable before using arc
welding equipment.
• While welding, make sure that there are no flammable materials
such as oil, rags, etc. around. As welded parts becomes
extremely hot and sparks are present, make sure that there are
no items such as harnesses, tubes, pipes, suspension compo-
nent, etc. which may be damaged.
SAPH10Z110200007
• If material is allowed to sputter onto the spring leaf during weld-
ing its strength will be significantly diminished. It should there-
fore be covered with a protective sheet. Also, for the same
reason, the spring leaf should never be used as a ground for arc
welding.
• When arc welding, ventilate or wear antitoxic mask for noxious
gas.
• To prevent burns, electric shock and gas poisoning during arc
welding, wear a helmet, apron, antitoxin mask, safety goggles,
arm coverings, leg covering, safety boots and gloves.
(4) After welding, shake the grinder crosswise the bead line A, along
CORRECT WRONG
direction B, to polish the welded area as illustrated in C.
Grind and polish the bead line A so that the frame surface becomes
even.
C B
SAPH10Z110200008
(5) Reinforcement patching method.

Patch-plate with ends squared off rather than tapered can cause dam-
CORRECT WRONG
age.
The patching plate thickness should be the same as the frame.
LESS
THAN 30º
SAPH10Z110200009
CORRECT WRONG
SAPH10Z110200010
CORRECT WRONG
SAPH10Z110200011
(6) Be sure to fasten the bolts at the hole locations of ups and downs (use
rivets or perform the plug welding).
CORRECT WRONG
SAPH10Z110200012
(7) Diameter of plug welding hole.

NOTICE
Prohibit plug welding on the flange.
25 PLUG WELDING
d
t t dφ
3.2 15
4.5 15
6 18
8 18
SAPH10Z110200013
10 18
(8) Interval of the holes
a ≥50+d/2
e1 e1 b≥ 3d
e1e2≥701+a
a d
dφ: 18or less
b b d
e2
SAPH10Z110200014
(9) Method of welding on the flange.

CORRECT WRONG
DO NOT WELD HERE

40 20
30
25
30
SAPH10Z110200015
CORRECT WRONG
PROHIBIT WELDING
THE BRACKET
AROUND THE HOLE
OVER 30 mm {1.2 in.}
SAPH10Z110200016
(10) In welding, be sure that there is no undercut A or overlap B of the

bead and pin hole.
CORRECT WRONG
NOTICE
An experienced professional welder should always perform the weld-
A ing since a poor welding job on the frame can cause damage.
SAPH10Z110200017
WELDING CONDITION (WHEN WELDING ROD IS USED)
Electric current (Unit: A)
Rod dia φ 3.2 mm {0.126 in.} 4mm {0.157 in.} 5 mm {0.197 in.}
Vertical Vertical Vertical

Welding position Flat Flat Flat
overhead overhead overhead
Weld Metal (Hot roll plate)

Tensile strength; 621 MPa
{63 kgf/mm2, 89.6 lbf/in.2}
Welding Rod
Tensile strength; 539 MPa 100-150 90-140 140-200 130-180 190-270 —
{55 kgf/mm2, 78.2 lbf/in.2}
Illuminate type (JIS D8016
AWS E8018) Coated elec-
Mechanical trode
property of Weld Metal (Hot roll plate)
weld metal Tensile strength; 539 MPa
& rod {55 kgf/mm2, 78.228 lbf/
in.2}
Welding Rod
Tensile strength; 490 MPa 90-140 80-130 141-190 110-160 180-250 —
{50 kgf/mm2, 71.116 lbf/
in.2}
Illuminate type (JIS D4301
AWS E6019)
Coated electrode
NOTICE
• Diameter of welding rod φ3.2 mm {0.126 in.} or φ4 mm {0.157 in.} -
plate thinner than 5 mm {0.197 in.}
• Diameter of welding rod φ4 mm {0.157 in.} or φ5 mm {0.197 in.} -
plate thicker than 6 mm {0.236 in.}
CAB CA02–1
CAB
CA02
CA02-001
CAB ASSEMBLY ......................................CA02-2 REPLACEMENT............................................ CA02-45

DATA AND SPECIFICATIONS ......................... CA02-2 AFFIXING WEATHERSTRIP PROCEDURE . CA02-46
TROUBLESHOOTING ..................................... CA02-3
DISMOUNTING AND MOUNTING .................. CA02-4 FRONT BUMPER ................................... CA02-50
INSPECTION AND REPAIR ............................ CA02-7 COMPONENT LOCATOR ............................. CA02-50
HOOD ........................................................CA02-8
COMPONENT LOCATOR................................ CA02-8
OVERHAUL ..................................................... CA02-9
FRP REPAIR PROCEDURE.......................... CA02-12
GELCOAT REPAIR PROCEDURE ................ CA02-17
DOOR ......................................................CA02-20
COMPONENT LOCATOR.............................. CA02-20
OVERHAUL ................................................... CA02-21
SEAT .......................................................CA02-24
INSTRUMENT PANEL ............................CA02-28

DISMOUNTING AND MOUNTING ................ CA02-29
HEATER AND AIR CONDITIONER ........CA02-30

AIR CONDITIONING SYSTEM ...............CA02-31

SPECIFICATION DATA .................................. CA02-31
PRECAUTIONS REGARDING REFRIGERANT
(HFC134A)..................................................... CA02-31
PRECAUTIONS FOR REPLENISHING THE
REFRIGERANT GAS .................................... CA02-32
PRECAUTIONS FOR REMOVING/INSTALLING THE AIR
CONDITIONER.............................................. CA02-33
RECOVERY AND REPLENISHMENT OF
REFRIGERANT ............................................. CA02-35
MAINTENANCE............................................. CA02-39
REPLACEMENT ............................................ CA02-41
DISMOUNTING AND MOUNTING ................ CA02-43
WINDSHIELD ..........................................CA02-44
CA02–2 CAB
CAB ASSEMBLY
EN11Z0302I200001
CAB
Cabin Engine hood
All steel welded construction, safety Tilt hood, made of FRP.

Type
glass fitted to all windows
Tilt system Less Torsion bar
Tilt angle — 75°
1 2
7 6
SAPH11Z030200001
1 Windshield glass 5 Cab body

2 Roof 6 Head light
3 Door 7 Radiator grille
4 Hood
CAB CA02–3
TROUBLESHOOTING
EN11Z0302F300001
HOOD TILT
Hood does not tilt up. Hood mounting hook does not release. Inspection of hood mounting hook.
Oil damper does not release. Inspection of oil damper mechanism.
Damaged torsion bar Replace torsion bar.
Hood tilting is difficult. Tilt up force is weak. Replace torsion bar.
Hood does not lock to hood mount- Mounting hook does not operate. Replace mounting hook.
ing member. Hood mounting cushion is not correctly Correct installation of hood mounting.
installed.
DOOR
Door does not close properly. Door is not adjusted Adjust door installation.
Striker is not adjusted Adjustment of shim for door lock striker
Damaged door lock Replace door lock.
Door does not lock by inside lock Deformation of rod Replace rod.
knob. Rod is disconnected Connect rod.
Door does not lock by key. Rod is disconnected Connect rod.
Damaged lock cylinder Replace lock cylinder.
Door does not open by outside han- Outside handle push rod is not Adjust push rod.
dle. adjusted.
Door does not open by inside han- Inside handle is not installed properly. Install inside handle properly.
dle. Deformation of rod Replace rod.
Rod is disconnected. Connect rod.
Inside handle does not return to its Interference between rods. Replace rod.
normal position. Inside handle is not installed properly. Adjust inside handle.
Return spring is damaged. Replace inside handle.
Door window goes down while driv- Window is not in the glass holder. Repair.
ing. Regulator is damaged. Replace regulator.
Regulator makes abnormal noise Window sill weather strip is installed Install properly or replace clips.
while driving. improperly.
CA02–4 CAB
BLOWER
Malfunction of blower when power Blown fuse Change fuse or check for short circuit.
is ON. Malfunction in heater relay Inspect relay.
Malfunction of heater blower switch Inspect power switch.
Malfunction of register Check register.
Blower motor malfunction Replace motor.
Damaged electrical wiring or poor Repair as necessary.
grounding
DISMOUNTING AND MOUNTING

EN11Z0302H100001
1. BEFORE DISMOUNTING THE CAB

(1) Be sure to block the front wheels.
(2) Disconnect the battery cable from the battery ground terminal.
(3) Tilt the engine hood.
(4) Drain engine coolant, clutch fluid, brake fluid and refrigerant of the air
conditioner.
2. CAB INSIDE
(1) Hydro brake model: Remove the box of parking brake control lever
and remove the cable retainer spring and pin.
SAPH11Z030200002
(2) Manual transmission: Remove the transmission control lever assem-

bly with dust boot.
Auto-transmission: Remove the cover and cable of the auto-transmis-
sion control assembly.
SAPH11Z030200003
CAB CA02–5
3. CAB FRONT SIDE

(1) Remove the heater hose, pipe for air conditioner, air cleaner and
bracket.
SAPH11Z030200004
(2) Remove the cab-chassis harness box lid and disconnect all the con-
nectors of the harness connected to the cab and chassis.
SAPH11Z030200005
(3) Disconnect the steering shaft

Make alignment marks on both the steering shaft and shaft spline.
Then remove the tightening nut and disconnect the shaft yoke from
the steering gear assembly.
SAPH11Z030200006
(4) Hydro brake, manual transmission:

Disconnect the brake pipe from the Hydro Max and the clutch pipe
from the master cylinder. Disconnect its hose.
Full air brake, manual transmission:
Disconnect the brake tube from the brake valve and the spring brake
control valve. Disconnect the clutch pipe from the master cylinder.
SAPH11Z030200007
CA02–6 CAB
4. DISMOUNT CAB
(1) Remove the mounting rubber nuts. (4 places)
SAPH11Z030200008
(2) Using a crane or hoist, bring the cab lifting device to slight tension.
(3) Lift the cab and set the cab on a cab stand.
! WARNING
Never go under the cab while lifting or suspending the cab.
5. MOUNT CAB
HINT
Mounting takes place in the reverse order of dismounting, so please
pay attention to the following points.
SAPH11Z030200009
(1) Discrimination of the mounting rubber.
Front Mounting Rear Mounting

Model
Upper Lower Upper Lower
HINO 14, 16, 18 Blue ← Yellow ←
(NA, NB, NC) φ10-1 φ10-2 φ10-1 φ10-2
HINO 23, 25, 26, 30, 33 Pink ← Green ←
(ND, NE, NJ, NF, NV) φ10-1 φ10-2 φ10-1 φ10-2
Nut Tightening Torque:

T=213-227N⋅m {2,173-2,316kgf⋅cm, 157-167ft⋅lbf}
SAPH11Z030200010 (2) Connect the pipes to the brake valve and the clutch master cylinder.
• Tighten flare nuts and tapered joints to the specified tightening torque
shown below.
Pipe or joint Flare Nut Tapered joint

diameter φ6.35mm 1/4 in. 3/8 in. 1/2 in.
Tight- N⋅m 20-30 20-30 29-39 39-49

ening kgf⋅cm 204-306 204-306 296-398 398-500
Torque ft⋅lbf 15-22 15-22 21-29 29-36
Material Steel pipe Aluminum Copper
(3) Connect the steering shaft.

The steering shaft should be aligned to the marks.
CAB CA02–7

EN11Z0302H100002

Visual check
Check the mounting rubber for Replace, if

— —
deformation. necessary.
Visual check
Repair or
Check the cab for damage and
— — Replace, if
crack.
necessary.
CA02–8 CAB
HOOD
COMPONENT LOCATOR
EN11Z0302D100001
SAPH11Z030200013
1 Hood 6 Torsion bar

2 Radiator 7 Oil damper
3 Head light, Front & Side turn light 8 Chassis frame
4 Hinge 9 Front bumper
5 Stopper wire 10 Torsion bar bracket

A 34.5-51.5 {352-526, 25-38} B 46-68 {469-694, 34-50}
CAB CA02–9
OVERHAUL
EN11Z0302H200001
1. BEFORE DISMOUNTING THE HOOD

(1) Be sure to block the front wheels.
2. REMOVE BUMPER FROM CHASSIS FRAME
3. TILT HOOD
4. REMOVE OIL DAMPER

(1) While complete opening the hood, remove the upper and lower nuts
from the ball joints of the oil damper.
SAPH11Z030200014
5. SUPPORT THE HOOD

• By supporting the hood using a crane or hoist, adjust the hood tilt
angle so that the torsion bar is free.
Refer to page CA02-11 for illustration.
! WARNING
Never go under the hood without supporting the hood with a crane or
hoist otherwise the hood could come down and cause severe per-
sonal injury.
! CAUTION
When hoisting the hood, be careful of deformation of the hood.
SAPH11Z030200015
6. REMOVE TORSION BAR

(1) Remove the left and right torsion bar bracket.
(2) Remove the two torsion bars.
SAPH11Z030200016
CA02–10 CAB
7. REMOVE STOPPER WIRE

(1) Using a crane or hoist, hold the hood before removing the stopper
wire.
(2) Remove the bolts and nuts from the stopper wire.
SAPH11Z030200017
8. REMOVE HINGE
(1) Remove the flange bolts and nuts from the hinge sub assembly on the
chassis frame.
SAPH11Z030200018
CAB CA02–11
9. INSTALL HOOD
HINT
Installation takes place in the reverse order of the removal. Please pay
attention to the following points.
(1) Using a crane or hoist, support the hood.
(2) Match the hole of hinge and hinge sub assembly.
Tighten the flange bolts and nuts.
(3) Install the stopper wire between the hood bracket and the radiator
frame.
(4) Install the torsion bar.
NOTICE
Torsion bar should be inserted perfectly to the holes and the clamping
brackets.
SAPH11Z030200019
(5) Install the oil damper.

CA02–12 CAB
FRP REPAIR PROCEDURE

EN11Z0302H200002
1. REPAIR MATERIAL
Material Main composition Note
Unsaturated polyester
.
a. Polyester resin
b. Hardener for polyester Methylethyl ketone
c. Glass mat Peroxyacid
d. Acetone Acetone
e. Putty Unsaturated polyester
f. Putty hardener Methylethyl ketone
Peroxyacid
g. Compound (rubbed finely)
h. Waxes (twinkle)
i. Masking tape Adhesive tape (18 mm wide)
j. Waste paper
k. Rag White knit goods
l. Sandpaper #240, 360, 800
2. PRECAUTION (except i., j., k., l.)

(1) Keep flames and sparks away from work area as repair materials are
highly flammable.
(2) Keep repair materials in a tightly covered container and well ventilated
place out of direct sunlight.
(3) Label the container containing the hazardous material.
(4) After the procedure, clean at once your hands, fingers, tools etc. using
acetone.
(5) Mix the hardener properly;
Polyester resin: Hardener: 1%—3%
Putty: Hardener: 1%—3%
(6) While preparing repair materials, prevent contamination of mixture by
foreign substances, in particular water or metal compounds.
(7) Dispose of solvent and resin wisely in accordance with Environmental
and Safety Regulations.
CAB CA02–13
3. MAIN TOOLS
Tool Form Use
for wide grinding or cutting
Hand grinder (or disc sander)
for V–groove cutting or small grinding

Hand router
to spray repair gel coat
Spray gun
to mix resin and hardener or compound

paints (2 pcs)
Polyethylene vessel
Scissors (or cutter) — for cutting glass mat
Infrared lamp — for heating repair part
for applying putty
Putty knife
Brush — for impregnating resin
Rubber gloves — anti-solvent type
Patch rubber — flatten

CA02–14 CAB
4. REPAIR METHOD
(1) Possible Repair Area
a. Resin crack or paint damage can be repaired if area is less than
60mm (2.4 in.) in length.
b. A broken edge or cracked corner more than 10mm2 (0.016in.2)
cannot be repaired.
c. In the case where there are many areas to repair, it must be
decided whether repair work is required or not.
NOTICE
A cracked or broken area on the hood which is located at a major
stress point, which requires frequent repairing due to strength (in par-
ticular the circumference of hole) and area size, needs to be replaced.
(2) Repair method.
Symptom Repair method Note
(1) Scratch or a) Grind around damage. This purpose is to flatten around the
crack on the damage and to increase fitting of the
gelcoat surface • Sandpaper #120-#400 putty.
• Grind lightly (Create a
small area as possible
around the damage)
b) Apply putty Apply putty with small convex.

Compound the resin and hardener sufficiently.
• Press putty strongly into

the crack with putty knife.
• Apply putty in grinding
area.
c) Dry the putty In case of incomplete drying, putty

Using an infrared lamp, dry the putty to harden perfectly under peels off while grinding.
80°C (177°F).
d) Grinding Apply sandpaper to uneven areas.

Using sandpaper (#400-#1000), grind lightly on the putty.
e) Finishing
Using compound etc. finish up buffing.
CAB CA02–15
(2) Crack in resin a) Back side grinding Grind area as small as possible
Using a hand grinder or router, grind the back side of the
crack.
(Overlay on the b) Overlay Mix hardener perfectly.

back side.) Cut two glass mats larger than grinding area, impregnate per- Clean the repair place using acetone
fectly with polyester resin and place it on the repair area with- before overlaying.
out a wrinkle and air bubble.
c) Dry resin In case of improper drying, putty peels

Refer to (1)-c). off while sanding.
d) Grinding Use patch rubber to flatten repair area.

Grind using hand grinder or router and then sandpaper #120
to #400.
e) If there is a pinhole or air bubble, apply methods(1)-b) to - Grind using #400 sandpaper.
d).
f) V-groove cutting on the front side

Using a hand router, cut a V-groove on the front side.
g) Finish on the front side

Apply methods (1)-a) to e).
CA02–16 CAB
(3) Broken resin a) Grind back side

Grind back side using hand grinder or router.
(Overlay from b) Overlay

back side.) Refer to (2)-b) but use 4 sheets of glass mats. Apply masking
tape in order that resin does not flow to front surface while
overlaying.
c) Apply methods (2)-c) to -d).
d) Apply methods (1)-a) to -e).

CAB CA02–17
GELCOAT REPAIR PROCEDURE

EN11Z0302H200003
Trouble Cause Check item, solution
Spiderweb-like cracking Impact Handling precautions when mold is removed / Do not hit
the mold with a hammer.
Gelcoat film is too thick.
Mold defect.
Bending force Gelcoat film is too thick.

Too much resin in mixture.
The laminate itself is too thin.
Tension during hardening process
Mold removal check
Mold check
Mold is dirty.
1. CRACKS
• Defects in the gelcoat appear as hairline cracks, spiderweb-like
cracks, and other types of cracks. Although most of these cracks are
produced by impact, they sometimes occur when an external force is
added to an extreme twisting force or when parts that do not fit dimen-
sionally are force-fitted, causing cracks to appear when the parts are
put into use. In particular, spiderweb-like cracks occur due to localized
impact.
SAPH11Z030200032
• These cracks are repaired with the same method that is used to repair
scratches. Before starting the repair work, it is important to carefully
check the rest of the parts. Cracks in the surface are often an indica-
tion of serious internal defects, so, naturally, it is dangerous to over-
look them. Why the damage has occurred must be thoroughly
investigated. Simply repairing the gelcoat surface may in some cases
result in a serious accident. In other words, the FRP under the part
that received a strong impact or force may also be damaged or the
back may have been blanched and lost its strength.
CA02–18 CAB
2. SCRATCHES AND CRACKS IN THE GELCOAT LAYER

• There are several ways to repair shallow scratches in the gelcoat
layer, such as:
(1) Rub off scratches using a rubbing compound.
(2) Lightly sand the gelcoat with #600 waterproof sandpaper and then
remove scratches with sandpaper and a compound and buff the sur-
face.
(3) Sand off scratches with a compound applied to #600 waterproof
sandpaper.
With scratches that can be repaired with the above methods, the over-
all smoothness of the surface can be maintained.
• In the case of deep scratches in the gelcoat layer
Careless handling during processing may produce deep scratches or
cracks in the gelcoat layer. If such scratches were removed with sand-
paper, the gelcoat layer would be sanded off, exposing the base mate-
rial, or a deep groove would be formed in the sanded area. Such
scratches are therefore repaired by applying gelcoat putty or a gelcoat
resin.
(4) The repair procedure is as follows (Figure 2).

a. Thoroughly clean the area to be repaired with acetone.
b. With particularly deep scratches, a knife or rotary file should be
used to grind the scratch into a V-shaped groove, since gelcoat
resin or putty will not reach the bottom of the scratch.
c. Wipe the ground area with acetone and remove soil and dust.
d. Pour gelcoat resin into the groove or fill the groove with putty
using a putty knife. Be careful not to get resin or putty on areas
outside the groove. If the scratched surface is relatively flat, the
gelcoat resin will flow into the scratch easily. If the surface is verti-
cal or steeply inclined, however, the resin will run out of the
scratch, so the resin should be applied carefully with a pallet knife
or similar tool. Gelcoat resins are relatively thixotropic, so they do
not flow readily.
e. After the resin or putty has hardened, sand it with #400 - #600
waterproof sandpaper wrapped around a block of wood.
f. Finish by polishing with a compound.
SAPH11Z030200033
HINT
In case that gelcoat is not available, urethane paint can be used for
repaires.
CAB CA02–19
3. SPIDERWEB-LIKE CRACKS FORMED BY A BLOW OR OTHER

IMPACT
• Most spiderweb-like cracks are formed by impact; for instance, when
the inside surface is hammered to remove the mold, or when an
abnormal shock is imparted to the inside surface during other work
procedures.
SAPH11Z030200034
• This is a difficult job because the cracks are not individual lines, so the
entire damaged area must be ground and repaired.
Figure 3
(1) The range of the spiderweb-like cracks is indicated by a dotted line in
the figure.
(2) Grind the area marked by the dotted line using a rotary file or sander.
(3) Cover the sanded area with gelcoat putty.
(4) Sand the putty with #400 — #600 waterproof sandpaper wrapped
around a block of wood.
(5) Finish by polishing with a compound.
HINT
In case that gelcoat is not available, urethane paint can be used for
repaires.
CA02–20 CAB
DOOR
COMPONENT LOCATOR
EN11Z0302D100002
SAPH11Z030200035
1 Lock cylinder 9 Inside upper trim

2 Weather strip 10 Door frame
3 Outside handle 11 Armrest
4 Striker 12 Door assist grip
5 Door lock 13 Outer oscillate-proof
6 Regulator 14 Glass run weather strip
7 Inside hole cover 15 Ashtray (driver side only)
8 Inside trim 16 Inside handle

A 4.4-6.6 {45-67, 3.3-4.8} D 2.0-3.0 {20-30, 1.5-2.1}
B 7.2-10.8 {74-110, 5.4-7.9} E 7.2-10.8 {74-110, 5.4-7.9}
C 10.8-20.2 {110-206, 8.0-14.8} F 18-26 {184-264, 13.3-19.0}
CAB CA02–21
OVERHAUL
EN11Z0302H200004
1. REMOVE REGULATOR HANDLE. (Without power window)

(1) Use a piece of cloth to catch the two ends of the retainer ring and pull
the cloth back and forth as shown, to remove the ring.
SAPH11Z030200036
2. REMOVE INSIDE TRIM.

(1) Remove the parts listed below.
CLIP POSITION (Refer to the DOOR COMPONENT LOCATOR)
a. Ashtray
b. Armrest
c. Inside upper trim
d. Inside handle
REMOVE TRIM
e. Door assist grip
RAISING UP.
(2) Pull off the inside trim.
SAPH11Z030200037
3. REMOVE WINDOW.
(1) Disconnect regulator from window channel.
SAPH11Z030200038
4. REMOVE DOOR LOCK.

(1) Disconnect the lock cylinder from the door lock.
CLAMP (2) Remove the lock cylinder.
(3) Remove the door lock with rods.
SAPH11Z030200039
CA02–22 CAB
5. SERVICE HOLE COVER AND REGULATOR INSTALLING

(1) Stick butyl rubber tape along lower tangent line of the drain hole of the
door.
(2) Insert the regulator handle with retainer ring into the regulator.
6. DOOR HINGE ADJUSTMENT

(1) Tilt the hood.
SAPH11Z030200040
(2) Make vertical and horizontal adjustments by loosening the hinge bolts
on the door.
SAPH11Z030200041
(3) Make depth adjustments by loosening the hinge bolts on the body.
SAPH11Z030200042
7. STRIKER ADJUSTMENT
(1) Check the engagement between the door lock and the striker. Make
the top and bottom contact even.
(2) Perform adjustment so that the outside of the door and the outside of
the rear quarter panel are flush with each other. After adjustment,
properly tighten the bolts.
NOTICE
When adjusting the door in the vertical direction, do not force into
alignment by using the door lock striker.
SAPH11Z030200043
CAB CA02–23
SAPH11Z030200044
CLEARANCES BETWEEN BODY AND DOOR Unit: mm {in.}

E 5.8-8.8 {0.23-0.35} I 14.6-18.6 {0.57-0.73}
F 12.5-16.5 {0.50-0.64} J 5.8-8.8 {0.23-0.35}
G 5.0-9.0 {0.20-0.35} K 11.8-15.8 {0.46-0.62}
H 12.5-16.5 {0.50-0.64} L 17.3-23.3 {0.68-0.92}
CA02–24 CAB
SEAT
COMPONENT LOCATOR
EN11Z0302D100003
DRIVER'S SEAT
SAPH11Z030200045
1 Seat back 4 Seat adjuster handle

2 Seat cushion 5 Seat suspension (If so equipped)
3 Seat reclining knob 6 Seat leg
A 17.5-32.5 {179-331, 13-23} B 11.8-14.7 {120-150, 9-11}
C 19.6-27.4 {200-280, 14.5-20}
D 26.5-48 {270-490, 19.5-35.5}
CAB CA02–25
ASSISTANT'S SEAT
SAPH11Z030200047
1 Seat back 3 Seat tilt adjuster handle

2 Seat cushion

A 17.5-32.5 {179-331, 13-23} D 29.4-44.1 {300-450, 22-32.5}
B 19.6-27.4 {200-280, 14.5-20} E 11.8-14.7 {120-150, 9-11}
C 26.5-48 {270-490, 19.5-35}
CA02–26 CAB
SUSPENSION SEAT (IF SO EQUIPPED)
SAPH11Z030200048
1 Seat suspension 2 Air tube

CAB CA02–27
SEAT BELT
SAPH11Z030200049
1 Outer seat belt (Driver's seat) 5 Center seat belt

2 Seat belt guide 6 Inner seat belt (Assistant's seat)
3 Seat belt cover 7 Outer seat belt (Assistant's seat)
4 Inner seat belt (Driver's seat)

A 29-55 {296-560, 22-40}
CA02–28 CAB
INSTRUMENT PANEL
COMPONENT LOCATOR
EN11Z0302D100004
SAPH11Z030200050
1 Pedal bracket support 8 Switch board panel

2 Upper panel 9 Cluster finish panel
3 Instrument panel cross member 10 Cluster housing
4 Gusset 11 Cluster bezel
5 Lower center cover 12 Upper right cover
6 Lower right cover 13 Side cover
7 Panel upper cover 14 Cup holder (If so equipped)
CAB CA02–29

A 2.8-3.2 {29-32, 2.1-2.3} D 11.5-20.5 {117-209, 8.5-15.1}
B 1.5-2.5 {16-25, 1.2-1.8} E 12-22 {122-224, 8.8-16.2}
C 7.5-16.5 {77-168, 5.6-12.1} F 2.8-3.2 {29-32, 2.1-2.3}

EN11Z0302H100003
1. BEFORE REMOVING THE INSTRUMENT PANEL.

(1) Disconnect the battery cable from the battery ground terminal.
2. REMOVE THE UPPER RIGHT COVER.

(1) Remove the lower bolt on the upper right cover.
(2) Pull the upper right cover toward you, remove the 4 clips of this side.
! CAUTION
• When pulling the upper right cover, be careful not to damage the
clips.
• Be sure to remove the 4 clips of this side beforehand because
pulling out the upper right cover at one time may damage it.
SAPH11Z030200051
(3) Pull the upper right cover straight with both hands to remove the inner
clip and remove the upper right cover.
SAPH11Z030200052
3. REMOVE THE SWITCH BOARD PANEL.

(1) Remove the throttle control knob.
(2) Remove the bolt and pull out the switch board panel.
PIN
REMOVE THE THROTTLE CONTROL KNOB.
SAPH11Z030200053
CA02–30 CAB
HEATER AND AIR CONDITIONER

COMPONENT LOCATOR
EN11Z0302D100005
SAPH11Z030200054
1 Blower assembly 3 Control panel assembly

2 Air conditioner assembly

A 3.9-4.9 {40-50, 2.9-3.6} C 1.4-2.4 {14-24, 1.0-1.7}
B 3.9-4.9 {40-50, 2.9-3.6}
CAB CA02–31
AIR CONDITIONING SYSTEM

SPECIFICATION DATA
EN11Z0302H100004
Refrigerant HFC 134a

Oil for air conditioning compressor. ND-OIL 8
PRECAUTIONS REGARDING REFRIGER-

ANT (HFC134A)
EN11Z0302H300001
1. COMPATIBILITY
The HFC134a system and R12 system do not have compatible
cooling cycle components, compressor oil, and other parts.
2. ABOUT THE NEW REFRIGERANT (HFC134A)

(1) Always use HFC134a. If the wrong refrigerant gas is used, the air
conditioner compressor may lock up due to poor lubrication.
3. ABOUT THE COMPRESSOR OIL

(1) Always use compressor oil for HFC134a (ND-OIL8). If compressor oil
for R12 is used in a compressor for HFC134a, the service life of the
compressor will be severely shortened due to poor lubrication.
Reference
Compressor oil for HFC134a: ND-OIL8
Compressor oil for R12: ND-OIL6
(2) Compressor oil for HFC134a (ND-OIL8) has high moisture-absorbing
characteristics. When disassembling the air conditioner, therefore,
immediately plug openings with a plug or vinyl tape to keep outside air
away from the oil.
(3) Compressor oil for HFC134a (ND-OIL8) has an adverse effect on
acrylic and ABS resins. When replenishing the compressor oil, there-
fore, do not allow the oil to splatter.
(4) Do not allow compressor oil for HFC134a (ND-OIL8) to stick to
painted surfaces, for it may cause the paint to peel.
4. ABOUT THE O-RINGS

(1) O-rings for HFC134a and O-rings for R12 have different materials,
gauges, and other characteristics, so using the wrong O-ring may
result in a gas leak. Always use an O-ring for HFC134a.
5. PRECAUTIONS FOR EVACUATING AIR

(1) When a vacuum pump for R12 is used to evacuate air and it is left on
after the vacuum has been formed, the pump oil (for R12) may flow
back into the HFC134a system. Always use an adapter equipped with
a solenoid valve.
CA02–32 CAB
6. CHECKING FOR REFRIGERANT GAS LEAKS

(1) The conventional halide torch type leak tester uses a reaction with
chlorine to detect a refrigerant leak. It cannot be used to detect an
HFC134a gas leak, therefore, not only because HFC134a contains no
chlorine but also because the tester breaks down the sucked-in
HFC134a and produces a toxic substance. Also, a conventional elec-
tric gas leak tester may not be sensitive enough to detect an
HFC134a gas leak because HFC134a gas has smaller molecules
than R12 gas. A halogen leak detector must therefore be used to
detect an HFC134a gas leak.
(2) Detecting a refrigerant gas leak with the engine running is difficult
SAPH11Z030200055 because a gas leak would be diluted by air from the fan, blower, and
other sources. Be sure to set the starter switch to the LOCK position
when checking for a refrigerant gas leak.
PRECAUTIONS FOR REPLENISHING THE

REFRIGERANT GAS
EN11Z0302H500001
1. WHAT TO DO IF REFRIGERANT GAS GETS IN YOUR EYES

(1) Do not rub your eyes with your hands or a handkerchief.
(2) Immediately wash your eyes with clean water for at least 15 minutes
and then see an eye specialist as soon as possible.
2. PRECAUTIONS FOR HANDLING REFRIGERANT GAS (SERVICE

CAN)
(1) Do not apply heat directly to the can or immerse it in hot water, for this
will cause the pressure inside the can to rise and burst the can. If the
can must be warmed up, use running water that is no hotter than
40°C.
(2) Do not drop or impart shock to the service can.
(3) Do not open the valve on the high-pressure side of the gauge mani-
fold while the engine is running, because it may cause high-pressure
gas to flow back into the service can and burst the can.
(4) Do not hold the service can close to your face while handling it.
Always wear safety goggles when working with the refrigerant gas.
CAB CA02–33
PRECAUTIONS FOR REMOVING/INSTALL-

ING THE AIR CONDITIONER
EN11Z0302H200005
1. PRECAUTIONS FOR CHANGING O-RINGS

(1) Always replace an old O-ring with a new O-ring for HFC134a when
you remove a pipe or hose.
(2) Use a toothpick or other soft implement to remove the O-ring so that
you do not damage the pipe or hose.
SAPH11Z030200056
2. PRECAUTIONS FOR CONNECTING PIPES AND HOSES

(1) Coat the O-ring with compressor oil (ND-OIL8) when making a pipe or
hose connection.
(2) Pipe joints in the HFC134a system have a cylindrical surface seal, so
you can feel them snap together when they are assembled.
NOTICE
Use compressor oil for HFC134a (ND-OIL8) to coat O-rings for
HFC134a. Do not use a penetrating type lubricating oil (mineral oil) or
other oil.
(3) When connecting pipes, use the tightening torques shown in the fol-
lowing table.
SAPH11Z030200057
NOTICE
Insufficient or excessive torque can cause a refrigerant gas leak due
to an improperly installed or broken O-ring. Always use the specified
tightening torque.
Tightening torque
Connection Tube size or Bolt size
N⋅m (kgf⋅cm)
φ8 tube 12—15 (120—150)
Nut type D1/2 tube 20—25 (200—250)
D5/8 tube 30—35 (300—350)
M6 bolt in receiver (4T) 4.0—7.0 (40—70)

Block joint
Above other M6 bolt (6T) 8.0—12 (80—120)
SAPH11Z030200058
CA02–34 CAB
3. REPLENISHING THE COMPRESSOR OIL

(1) When replacing a functional part
When replacing a functional part (condenser, evaporator, etc.), supply
the amount of new compressor oil shown in the following table.
NOTICE
• Use compressor oil for HFC134a (R134a)
• Compressor oil for HFC134a (R134a) has an adverse effect on
acrylic and ABS resins. When replenishing the compressor oil,
therefore, do not allow the oil to splatter.
Compressor oil replacement

SAPH11Z030200059
Replace parts
Compressor Condenser Evaporator Receiver Tubes
10cc (per one
Oil replacement amount (as follows) 40cc 40cc 10cc
tube)
(2) When changing the compressor oil

A new compressor is filled with the amount of oil required by its oper-
ating cycle. When changing the compressor, therefore, take out the
extra oil contained in the new compressor.
NOTICE
• Compressor oil for HFC134a (R134a) readily absorbs moisture,
so it should be sealed immediately after it has been used.
• When transferring compressor oil to an oil can, be sure to use an
oil can that has been labeled for HFC134a (R134a) use.
SAPH11Z030200060
CAB CA02–35
RECOVERY AND REPLENISHMENT OF

REFRIGERANT
EN11Z0302H500002
1. RECOVERING THE REFRIGERANT (HFC134A)

(1) Connect a gauge manifold to the air conditioner piping service valve
and the refrigerant gas recovery unit, and then open the valves on the
low-pressure and high-pressure sides and recover the refrigerant gas.
(2) Once the gas has been recovered, close the gauge manifold valves
(low-pressure side and high-pressure side).
2. REPLENISHING THE REFRIGERANT (HFC134A)

(1) Evacuate air to form a vacuum.
a. Connecting the gauge manifold
(a) Connect charging hoses to the low-pressure and high-pres-
sure service valves.
• Red hose on high-pressure side (H mark)
• Blue hose on the low-pressure side (L mark)
(b) Connect the middle charging hose on the gauge manifold
(green hose) to a vacuum pump.
NOTICE
• Do not get the low-pressure and high-pressure sides mixed up.
• In some models, the service valve is installed on the compres-
sor.
SAPH11Z030200061
CA02–36 CAB
b. Forming a vacuum
(a) Open the gauge manifold high-pressure valve (HI) and low-
pressure valve (LO).
(b) Turn on the vacuum pump and evacuate air until a vacuum is
formed (10 minutes).
(c) When the low-pressure gauge scale reading equals or
exceeds -0.1MPa (-750mmHg), close the high-pressure and the
low-pressure valves and turn off the vacuum pump.
NOTICE
If the pump is switched off before the gauge manifold valves are
closed, air will get into the system.
SAPH11Z030200062
c. Airtightness check (1) (using the gauge needle)

(a) Leave the gauge manifold high-pressure and low-pressure
valves closed (for 5 minutes) and make sure that the gauge nee-
dle does not return to the zero point.
NOTICE
If the gauge needle returns to the zero point, it means that air is leak-
ing out somewhere. Check and adjust the pipe joints and then re-form
the vacuum and check for airtightness.
SAPH11Z030200063
CAB CA02–37
d. Airtightness check (2) (using refrigerant)

Add a small quantity of refrigerant and then check for airtightness
using a gas leak detector.
(a) Remove the charging hose connected to the vacuum pump
(green hose) and connect it to a service can.
(b) Remove the air inside the charging hose (green).
• Tighten the service can valve handle and open the hole in the service
can; then open the valve.
• Press the butterfly valve on the gauge manifold so that the air inside
the hose is expelled by the refrigerant pressure. Continue until you
hear the whooshing sound of refrigerant escaping.
NOTICE
• At this time, the gauge manifold high-pressure and low-pressure
valves should both be closed.
• Be careful not to get refrigerant on your hands (or they may get
frostbitten).
SAPH11Z030200065
(c) Open the gauge manifold high-pressure valve and supply

refrigerant until the low-pressure gauge reading reaches 0.1MPa
(1kgf/cm2).
(d) Close the high-pressure valve once the refrigerant has been
replenished.
(e) Carefully check for air leakage using a gas leak detector.
Repair any leaks that you find.
NOTICE
Be sure to use a gas leak detector for HFC134a (R134a) when check-
ing for gas leaks.
SAPH11Z030200064
CA02–38 CAB
(2) Replenish the refrigerant.

a. Supplying refrigerant from the high-pressure side
(a) With the engine stopped, open the gauge manifold high-pres-
sure valve and the service can valve, and fill about one service
can with refrigerant.
NOTICE
• Never run the compressor at this time. Running the compressor
is extremely dangerous because refrigerant will flow back into
the hose or the service can, causing the hose to rupture or the
can to burst.
• Do not run the compressor without any refrigerant in the system;
otherwise, the compressor may seize.
• Do not open the gauge manifold low-pressure valve, for this will
cause the liquid refrigerant to get sucked into the compressor,
where it will be compressed and possibly damage the compres-
sor valve.
(b) Close the gauge manifold high-pressure valve and the service
can valve.
b. Supplying refrigerant from the low-pressure side
SAPH11Z030200066
(a) Make sure the gauge manifold high-pressure valve is closed.

(b) Set the following vehicle conditions.
• Turn on the engine and open all the vehicle doors.
• Turn the air conditioner on.
• Set the temperature control lever to the maximum cooling setting.
• Set the blower switch to the HI position.
• Run the engine at 1500rpm approximately.
(c) Open the gauge manifold low-pressure valve and the service
can valve, supply the stipulated amount of refrigerant.
• Refrigerant quantity: 450±50g
(d) Once the refrigerant has been replenished, close the gauge
manifold low-pressure valve and the service can valve and stop
the engine.
NOTICE
• Never open the gauge manifold high-pressure valve (HI) at this
time. Opening the valve is extremely dangerous because it will
cause high-pressure gas to flow back into the charging hose or
the service can, causing the hose to rupture or the can to burst.
• Never turn the service can upside down. If the can is turned
upside down, liquid refrigerant will get sucked into the compres-
sor, where it will be compressed and possibly damage the com-
pressor valve.
SAPH11Z030200067
Keep the can upright and supply refrigerant in a gaseous state.
CAB CA02–39
(3) Checking the amount of refrigerant supplied

a. Using the gauge manifold
(a) Set the following conditions.
• Open all the vehicle doors.
• Set the temperature control to the maximum cooling setting.
• Set the blower speed to the HI position.
• Set the outside air/room air selector lever to the room air position.
• Run the engine at 1500rpm.
NOTICE
• Determination is made with the pressure on the high-pressure
side no greater than 1.86MPa (19kgf/cm2).
• If the outside air temperature is high (above 40°C) and the pres-
sure on the high-pressure side drops below 1.86MPa (19kgf/cm2)
when you are setting the judgment criteria:
((a)) Open all the doors and set the blower speed to the LO posi-
tion.
((b)) Use an indoor workplace or work outdoors in the shade.
Carry out the procedure in steps 1 and 2 above and then deter-
mine the refrigerant quantity with the pressure no greater than
1.86MPa (19kgf/cm2).
(b) Check the gauge manifold reading.
• If it is normal
((a)) Pressure on low-pressure side 0.15—0.25MPa (1.5—2.5 kgf/
cm2)
((b)) Pressure on high-pressure side 1.37—1.57MPa (14—16 kgf/
cm2)
NOTICE
• The gauge manifold reading may vary somewhat depending on
conditions.
• Too much refrigerant can lead to problems such as faulty cooling
or overheating.
SAPH11Z030200068
ENGINE MODEL:J05D
MAINTENANCE
EN11Z0302H600001
ADJUSTING
IDLER PULLEY BOLT b
B 1. ADJUSTING THE V-BELT TENSION
LOCK NUT a
! CAUTION
After a new belt has been installed it may loosen during its initial
break-in period. Run the engine for 3—5 minutes, therefore, and re-
adjust the belt tension.
CRANKSHAFT COMPRESSOR PULLEY (1) Loosen the idler pulley lock nut and adjust the V-belt tension (measur-
PULLEY FOR AIR CONDITIONING ing point: B) until it is within the prescribed range, by turning the
SAPH11Z030200069 adjusting bolt with the special tool.
CA02–40 CAB
SST:
ENGINE MODEL:J08E CRANKSHAFT Compression gauge (09444-1210)
COMPRESSOR B PULLEY or belt tension gauge (Denso product No. 95506-00090)
PULLEY FOR AIR
CONDITIONING
Amount of deflection:
Use 09444-1210
Standard value 11mm (0.434 in.) [Reference force applied to belt:

IDLER
PULLEY 98N (10kgf, 22lb)]
Tension: Use Denso product No. 95506-00090
ADJUSTING LOCK NUT a Standard value: [330N (34kgf, 75lbf)]
BOLT b
(2) Tighten the idler pulley lock nut.
SAPH11Z030200070
Tightening Torque:
41N⋅m (420kgf⋅cm)
(3) Make sure the adjusting bolt is tight and locked in place.
Tightening Torque:
5.9N⋅m (60kgf⋅cm)
2. CLEANING THE AIR FILTER

(1) Removing the outside air filter
(2) Removing the inside air filter
The air filter is located at the bottom of the blower assembly. Remove
it by bending it and pushing it downward at the same time.
SAPH11Z030200071
(3) Cleaning the air filter

• Clean the filter every 5000km.
• Set the starter key to the LOCK position. If the key is in the ON or
ACC position, the wiper motor will operate and your fingers may get
caught in the wiper linkage.
• Clean the air filter by washing it with water or blowing it with com-
pressed air.
• If you wash the filter, make sure it is completely dry before you re-
install it.
INSIDE FILTER
SAPH11Z030200072 3. WASHING THE CONDENSER
(1) The condenser fins have to be washed periodically because problems
such as reduced cooling efficiency and corrosion may occur if the fins
are clogged with dirt or dust.
! CAUTION
• Make sure the air conditioner is off when you wash the con-
denser.
• Do not use a brush, for strong brushing may crush the fins.
• Wash the condenser carefully so that you do not damage the
fins.
• Do not use a detergent.
• Give the condenser a thorough cleaning if the vehicle has been
driven in coastal areas or on roads that have been salted to pre-
vent freezing.
CAB CA02–41
REPLACEMENT
EN11Z0302H100005
1. REPLACING THE DRYING AGENT IN THE MODULATOR

(1) Remove the filter with hexagon wrench and then take out and replace
the drying agent.
The plastic screw cannot be re-used. Be sure to replace it with a new
one.
SAPH11Z030200073
2. HVAC (HEATER AND A/C UNIT)

(1) Replacing the heater core
a. Remove the instrument panel center lower cover and AS lower
cover.
b. Remove the blower assembly.
c. Remove the heater pipe clips and pull out the end of the heater
pipe.
d. Remove the heater core.
SAPH11Z030200074
CA02–42 CAB
(2) Replacing the evaporator

a. Remove the instrument panel center lower cover and AS lower
cover.
b. Remove the blower assembly.
c. Remove the HVAC.
d. Remove the cooler piping (interior).
e. Remove the bracket below the piping through-hole.
f. Remove the expansion valve and cover.
g. Remove the evaporator.
SAPH11Z030200075
(3) Replacing the blower resistor and power transistor

a. Remove the two mounting bolts.
SAPH11Z030200076
3. BLOWER ASSEMBLY
(1) Replacing the motor
a. Remove the cooling hose.
b. Remove the three bolts holding the motor in place.
SAPH11Z030200077
4. HEATER CONTROL
(1) Replacing the illumination bulb
a. Remove the center cluster.
b. Remove the control knob and A/C switch.
c. Remove the heater control panel (claw connection).
d. Remove the illumination bulb.
SAPH11Z030200078
CAB CA02–43

EN11Z0302H100006
IMPORTANT POINTS - MOUNTING

NOTICE
• Should not bend the Inner cable when cable route.
• Set the cable at pulled state and make sure the link to boss. Set
position is as follows.
Cable Color Position
A: Mode control BLUE FACE
B: Temperature control NATURAL MAX COOL
C: Inside and outside air control BLACK OUTSIDE
SAPH11Z030200079
CA02–44 CAB
WINDSHIELD
COMPONENT LOCATOR
EN11Z0302D100006
SAPH11Z030200080
1 Weatherstrip 3 Back window

2 Windshield glass
CAB CA02–45
REPLACEMENT
EN11Z0302H100007
1. BEFORE REPLACING THE WINDSHIELD.

(1) Remove the windshield wiper.
2. REMOVE THE WINDSHIELD.

LIP (1) Cut the lip of the weatherstrip with a knife.
(2) The windshield is heavy so remove it using at least two persons.
SAPH11Z030200081
3. MOUNTING THE WINDSHIELD.

(1) Clean the weatherstrip, mounting flange of cab and contact surface of
the window.
(2) Repair any wavy area at the mounting flange as necessary.
(3) Insert the working string as shown in the figure.
STRING
WEATHERSTRIP
SAPH11Z030200082
(4) Pull the working string from the interior of the cab, and gradually
install the lip of the weatherstrip on the mounting flange.
(5) During this operation, knock the glass from outside. Use soapy water
as necessary.
(6) After installing the glass properly, knock the glass from inside and out-
side.
SAPH11Z030200083
4. INSTALL THE WINDSHIELD WIPER.

(1) Install the wiper arm.
NOTICE
The assistance side wiper is marked yellow for discrimination.
SAPH11Z030200084
CA02–46 CAB
AFFIXING WEATHERSTRIP PROCEDURE

EN11Z0302H300002
1. REMOVE THE CORNER WINDSHIELD WEATHERSTRIPS (79413-

1470A) FROM THE WINDSHIELD GLASS ASSY. (79410-2511A).
(REFER TO FIGURE 1.)
SAPH11Z030200085
2. CLEANING THE GLASS

Using a nap-free cloth or felt and a cleaning solvent, clean the
glass flange areas where the weatherstrip has been removed,
and remove grease, oil, water, dirt, and foreign substances from
the joining surfaces. (Refer to Figures 2-1 and 2-2.)
SAPH11Z030200086
NOTICE
• Cleaning solvent: (Isopropyl) alcohol
• Always keep the cleaning solvent in a clean container.
Avoid the use of a cleaning solvent that is obviously dirty.
• For the cleaning cloth, use a clean cloth, gauze, felt, or other
equivalent material that is free of stains.
• Always use a clean surface of the cleaning cloth and use a fresh
cloth for every glass you clean.
• Add cleaning solvent to the cleaning cloth so that when the cloth
is forcefully squeezed the solvent does not drip out.
SAPH11Z030200087
3. CLEANING THE WEATHERSTRIP: GLASS SIDE AND BODY SIDE

Using a cloth and a cleaning solvent, clean the glass areas where
the weatherstrip has been removed, removing grease, oil, water,
dirt, and foreign substances.
NOTICE
• Always keep the cleaning solvent in a clean container. Avoid the
use of a cleaning solvent that is obviously dirty.
cloth for every weatherstrip you clean.
CAB CA02–47
4. DRY THE SOLVENT

After completing steps 2 and 3, allow the glass to dry for at least
3 minutes so that the cleaning solvent has fully dried.
NOTICE
After the cleaning solvent has been applied (and while it is drying), be
careful not to allow oil, water, dirt, or foreign substances to stick to
the solvent.
5. APPLYING PRIMER: GLASS AND WEATHERSTRIP (GLASS SIDE

AND BODY SIDE)
Apply a uniform coat of primer to the indicated area.
NOTICE
• After applying the primer, make sure oil, water, or foreign sub-
stances do not stick to the primer.
• Primer: Sika Activator, made by Japan Sika Co., Ltd.
• Application temperature range: +5°C—+25°C
• Storage method: Keep primer in a sealed container in a cool,
dark place.
• Storage period: 12 months (unopened)
Use primer within one month after it has been opened.
6. WIPE THE PRIMED AREA WITH A DRY CLOTH WITHIN 30 SEC-

ONDS AFTER APPLYING THE PRIMER.
7. AFTER WIPING THE PRIMER WITH A DRY CLOTH, ALLOW IT TO

DRY FOR AT LEAST 10 MINUTES (IF THE TEMPERATURE IS 15°C
OR HIGHER) OR 30 MINUTES (IF THE TEMPERATURE IS BELOW
15°C).
NOTICE
Be careful not to allow water, dirt, or foreign substances to stick to the
primed surface.
8. FIT THE REMOVED WEATHERSTRIP ONTO THE GLASS (as it

was prior to the start of work.)
9. APPLYING ADHESIVE: GLASS AND WEATHERSTRIP

Apply adhesive between the glass and the weatherstrip. (For
details, refer to the assembly diagram.)
NOTICE
• Do not use an adhesive whose expiration date has passed.
• Storage conditions: 0 - 40°C, indoor storage
• Adhesive: Silkaflex 250-2
• Apply a suitable amount of adhesive to the range indicated in the
diagram (so that adhesive sticks out from the edge of the weath-
erstrip).
• With the weatherstrip securely fitted on the glass, proceed to the
next task (check and repair, including corners).
10. WASHING OFF THE ADHESIVE: GLASS SIDE

Remove the adhesive and primer sticking out from the edge of
the weatherstrip.
(1) Scrape off adhesive with a pallet knife.
(2) Wipe the scraped area with a cloth dipped in a cleaning agent.
NOTICE
• Work as quickly as possible.
• Use a clean cloth or equivalent material and use a clean surface
of the cloth at all times.
CA02–48 CAB
11. CLEANING THE BODY

Using a cloth dipped in a cleaning solvent, clean the area where
the weatherstrip and glass have been removed, and remove
grease, oil, water, dirt, and foreign substances.
NOTICE
• Always keep the cleaning solvent in a clean container.
Avoid the use of a cleaning solvent that is obviously dirty.
cloth for every weatherstrip you clean.
• Before cleaning, remove adhesive or weatherstrip stuck to the
body.
12. APPLYING PRIMER: BODY SIDE

Apply a uniform coat of primer to the indicated area.
NOTICE
• After applying the primer, make sure oil, water, or foreign sub-
stances do not stick to the primer.
• Primer: Sika Activator, made by Japan Sika Co., Ltd.
• Application temperature range: +5°C—+25°C
• Storage method: Keep primer in a sealed container in a cool,
dark place.
• Storage period: 12 months (unopened)
Use primer within one month after it has been opened.
13. WIPE THE PRIMED AREA WITH A DRY CLOTH WITHIN 30 SEC-
ONDS AFTER APPLYING THE PRIMER.
14. AFTER WIPING THE PRIMER WITH A DRY CLOTH, ALLOW IT TO

DRY FOR AT LEAST 10 MINUTES (IF THE TEMPERATURE IS 15°C
OR HIGHER) OR 30 MINUTES (IF THE TEMPERATURE IS BELOW
15°C).
NOTICE
Be careful not to allow water, dirt, or foreign substances to stick to the
primed surface.
15. APPLYING LUBRICANT

Apply a lubricant for installation to the body flange.
NOTICE
• Use a detergent as the lubricant.
• Do not allow detergent to get on the surfaces where adhesive
has been applied.
16. FIT THE GLASS IN PLACE ON THE BODY.

CAB CA02–49
17. APPLYING ADHESIVE: WEATHERSTRIP AND BODY

Apply adhesive between the body and the weatherstrip. (For
details, refer to the assembly diagram.)
NOTICE
• Do not use an adhesive whose expiration date has passed.
• Storage conditions: 0—40°C, indoor storage
• Adhesive: Silkaflex 250-2
• Apply a suitable amount of adhesive to the area indicated in the
diagram (so that adhesive sticks out from the edge of the weath-
erstrip).
18. WASHING OFF THE ADHESIVE: BODY SIDE

Remove the adhesive and primer sticking out from the edge of
the weatherstrip.
(1) Scrape off adhesive with a pallet knife.
(2) Wipe the scraped area with a cloth dipped in a cleaning agent.
NOTICE
• Work as quickly as possible.
• Use a clean cloth or equivalent material and use a clean surface
of the cloth at all times.
CA02–50 CAB
FRONT BUMPER
COMPONENT LOCATOR
EN11Z0302D100007
1. STANDARD SETTING
SAPH11Z030200088
1 Bumper sub assembly 3 Corner bumper

2 Bumper stay

A 104-156 {1061-1592, 77-115} B 13-29 {133-296, 10-21}
CAB CA02–51
2. IN FRONT SETTING
SAPH11Z030200089
1 Bumper sub assembly 4 Bumper protector

2 Bumper stay 5 Bumper protector bracket
3 Corner bumper

A 104-156 {1061-1592, 77-115} B 13-29 {133-296, 10-21}
ELECTRICAL EQUIPMENT EL01–1
ELECTRICAL EQUIPMENT
EL01
EL01-001
ELECTRICAL PARTS ............................... EL01-2

DATA AND SPECIFICATIONS ..........................EL01-2
COMPONENT LOCATOR.................................EL01-3
TROUBLESHOOTING ....................................EL01-12
GENERAL INSTRUCTION .............................EL01-13
HANDLING PRECAUTION .............................EL01-18
INSPECTION ..................................................EL01-19
INSPECTION AND ADJUSTMENT ................EL01-38
SPEEDOMETER CONVERSION RATE LIST
........................................................................EL01-40
EL01–2 ELECTRICAL EQUIPMENT
ELECTRICAL PARTS
EN12Z0301I200001
ELECTRICAL SYSTEM
Voltage Direct current 12 volts
Ground Negative (-) ground
BULB WATTAGE RATING
Head light 60/55W
Clearance light and BULE TYPE 5W

Identification light LED TYPE 1.54W (Replace with unit)
Front turn signal light 27W
Front side turn signal light 5W
Front side maker light 8W
Dome light 8W
Rear turn signal light 27W
Stop/tail light 27/8W
Back up light 27W
License plate light 8W
GAUGE TYPE
Fuel Coil type
Coolant temperature Coil type
Tachometer Coil type
Speedometer Coil type
Air pressure Coil type

COMPONENT LOCATOR
EN12Z0301D100001
PARTS INSTALLED POSITION
PARTS INSTALLED PARTS INSTALLED
Air conditioner relay AISIN A450 ATM ECU
ATM neutral relay ABS ECU (Full air brake)
ATM starter relay ABS ECU (MYDRO MAX brake)
Daytime light relay Daytime running light ECU

ECU lack, behind the
Head light dimmer relay Stop and turn controller instrument panel
lower RH cover
Head light main relay U2 ECU
Heater relay (Air conditioner) Wiper relay
Fuse and relay block, Pulse converter

Horn relay behind the instrument (MTM, ALLISON 2000RDS/
panel lower RH cover 2500RDS & 3000RDS ATM)
Mirror heater relay (If so equipped) Combination meter Meter cluster
Power accessory relay Light and turn switch
Power relay No.1 Starter switch Steering column
Power relay No.2 Wiper and retarder switch
Power relay No.3 Horn switch Steering wheel
Tail light relay No.1 Van light switch
Tail light relay No.2 Mirror heater switch (If so equipped)

Switch board panel,
Power accessory relay No.2 Auto cruising switch under the combina-
tion meter
ABS motor relay Rheostat
ATM back light relay Set resume switch
Heater relay (Glow plug) Buzzer off switch

(If so equipped) Relay block, rear side (Full air brake and wheel parking)
of the battery box Spring brake switch
Starter relay
(Full air brake and wheel parking)
U2 actuator power relay Spare power source (Live) Behinde the instru-
ment panel lower cen-
U2 actuator power relay Blower motor ter cover
U2 ECU main relay Heater and cooler unit
Air conditioner switch Monitor module (HYDRO MAX brake)
Blower switch Water level warning relay
Cigarette lighter Courtesy switch front LH

Cab rear pillar
Daytime light diode Instrument panel Courtesy switch front RH
Idling volume
Pressure switch
Radio/Audio unit
ABS Diagnosis switch Back mirror light (If so equipped)
Heater back mirror LH

Diagnosis connector
(If so equipped) Back mirror
Heater back mirror RH

DST-1 Connector
(If so equipped)
Pedal bracket
Warning buzzer Water temperature sender Engine front side
Clutch interlock switch Boost sensor
Exhaust clutch switch EGR valve 1
Stop light switch EGR valve 2
Accelerator sensor Steering support Glow plug (If so equipped)
Wiper motor Front panel Injector 1
Selector (MD) Injector 2
Overdrive switch Injector 3
ATM mode switch ATM selector lever or

(ALLISON 2200RDS/2500RDS console Injector 4
ATM) Engine left side
A450 ATM diode Injector 5
Parking brake switch Parking brake lever Injector 6
Washer motor Washer tank PC sensor
Power window motor drivers seat

Starter
(If so equipped)
Door
Power window motor passengers
Suction control valve
seat (If so equipped)
Dome light LH VNT controller

Roof inside
Dome light RH Block heater (If so equipped)
Antenna Oil pressure switch Engine right side
ID light center Cylinder angle sensor
ID light LH NE sensor (Engine speed sensor)

Roof outside Engine rear side
ID light RH Fuel temperature sensor 1
Roof clearance light LH Alternator
Roof clearance light RH Air flow sensor Air cleaner
Front turn light LH Horn (Low) Air cleaner bracket
Front turn light RH Coolant level switch Radiator upper tank
Fuel filter level sensor Fuel filter, outside of

Head light LH
Hood (If so equipped) the frame side rail LH
Head light LH Fuel filter heater sensor at cab back
Side turn light LH Fuel sender Fuel tank
Side turn light RH

Air gauge sensor front

Back light switch (EATON MTM)
(Full air brake)
Air gauge sensor rear

Neutral switch (EATON MTM) Manual transmission
(Full air brake)
Air tank
Low pressure switch No.1
Speed sensor (EATON MTM)
(Full air brake)
Neutral start switch Low pressure switch No.2

(AISIN A450 ATM) (Full air brake)
Oil temperature switch Frame, inside of the

Van light connector
(AISIN A450 ATM) side rail RH
Frame, inside of the

Solenoid temperature switch ABS modulator (HYDRO MAX
side rail LH, at cab
(AISIN A450 ATM) A450 ATM brake)
back
Air drier (Full air brake) Frame, outside of the

SPEED SENSOR side rail LH, at cab
back
Vehicle speed sensor Frame, inside of the

Spare power source (Tail) 1
(AISIN A450 ATM) side rail RH rear
Frame, inside of the

ALLISON 2200RDS/2500RDS Frame,
Spare power source (Tail) 2 side rail RH, at the 3rd
ATM ECU No.3 crossmember
crossmenber
Engine speed sensor

(ALLISON 2200RDS/2500RDS Modulator front LH (Full air brake)
ATM)
Main transmission Frame, outside of the

(ALLISON 2200RDS/2500RDS ABS sensor front LH (Full air brake) side rail LH, at front
ATM) axle
Neutral start backup ABS sensor front LH (HYDRO MAX

2200RDS/2500RDS
(ALLISON 2200RDS/2500RDS brake)
ATM
ATM)
Output speed sensor

(ALLISON 2200RDS/2500RDS Modulator rear LH(Full air brake)
ATM)
Frame, outside of the
Turbine speed sensor
side rail LH, at rear
(ALLISON 2200RDS/2500RDS ABS sensor rear LH (Full air brake)
axle
ATM)
Frame, ABS sensor rear LH

ALLISON 3000RDS ATM ECU
No.3 crossmember (HYDRO MAX brake)
Engine speed sensor

Modulator front RH (Full air brake)
(ALLISON 3000RDS ATM)
Output speed sensor
3000RDS ATM ABS sensor front RH (Full air brake) side rail RH, at front
(ALLISON 3000RDS ATM)
axle
Transmission main ABS sensor front RH
(ALLISON 3000RDS ATM) (HYDRO MAX brake)

Differential switch Rear combination light RH
side rail RH rear end
Flow switch HYDROMAX unit, Modulator rear RH (Full air brake)

pedal bracket outside Frame, outside of the
Motor pump (HYDRO MAX brake) ABS sensor rear RH (Full air brake)
side rail RH, at rear
ABS sensor rear RH axle
Motor relay (HYDRO MAX brake)
(HYDRO MAX brake)
Frame, outside of the Connector, block heater power Rear side of the bat-
Rear combination light LH
side rail LH rear end source tery box
ECU RACK
WINDSHIELD WIPER
DAYTIME RUNNING
CONTROLLER
LIGHT ECU
TURN SIGNAL
FLASHER
PULSE ADJUST ECU
AISIN A450 ABS ECU

ATM ECU
ENGINE ECU (U2)
SAPH12Z030100001
INSTRUMENT PANEL LOWER CENTER
WATER LEVEL
WARNING
CONTROLLER
BLOWER ASSEMBLY
HYDROMAX
BRAKE CONTROLLER
AIR CONDITIONER
ASSEMBLY
SAPH12Z030100002
RELAY PANEL
SAPH12Z030100003
1 Daytime running light relay 14 Mirror heater relay (If so equipped)

2 Head light dimmer relay 16 3000RDS starter relay/2200RDS/2500RDS neautral
relay
3 Head light main relay 17 Power relay No.1
4 Parking indicator relay 19 Power relay No.2
5 Air horn relay 20 Power relay No.3
6 Horn relay 21 Power accessory relay
7 Parking buzzer off relay 32 Tail light relay No.1
8 Air conditioner relay 33 Tail light relay No.2
9 Heater relay (Air conditioner)
POSITION OF THE POWER SUPPLY TERMINAL FOR EXTRA EQUIPMENT (CAB SIDE)
SPARE POWER
SOURCE CONNECTOR
(FOUR PIECE CONNECTOR)
SAPH12Z030100004
POSITION OF THE POWER SUPPLY TERMINALS FOR EXTRA EQUIPMENT (CHASSIS SIDE)
A B
No.3 CROSSMEMBER
REAR COMBINATION
LIGHT
SPARE POWER SOURCE
CONNECTOR
(THREE PIECE CONNECTOR)
SPARE POWER SOURCE

CONNECTOR (TWO PIECE CONNECTOR)
SAPH12Z030100005
TROUBLESHOOTING
EN12Z0301F300001
STARTING SYSTEM
Engine does not operate (Starter Poor contact condition Clean or replace contacts.
switch)
Engine does not operate (Battery) Open circuit in harness Check and correct.
Short circuit between electrodes Replace battery.
Poor contact condition of battery termi- Clean or retighten.
nal
Engine does not operate (Engine oil) Improper viscosity oil Change oil.
Engine does not operate (Starter Defective or poor contact of starter Repair or replace.
relay) relay
Engine does not operate (Starter) Starter does not operate Repair or replace. Refer to chapter
STARTER.
HEAD LIGHT CIRCUIT

Head light does not turn on (Head Bulb burned out Replace bulb.
light) Not grounded Check the grounding.
Broken wire Repair wire.
Head light does not turn on (Fuse) Fuse burned out Replace fuse.
Head light does not turn on (Head Defective relay Replace relay.
light relay)
Head light does not turn on (Light- Broken wire between relay and switch Repair wire.
ing switch) Defective switch Replace switch.
TURN SIGNAL CIRCUIT

Turn signal does not work (Turn sig- Bulb burned out Replace bulb.
nal light) Not grounded Check the grounding.
Turn signal does not work (Fuse) Fuse burned out Replace fuse.
Turn signal does not work (Turn sig- Not grounded Check the grounding.
nal flasher) Defective flasher Replace flasher.
Turn signal does not work (Turn sig- Broken wire between fuse and switch Repair wire.
nal switch) Defective switch Replace switch.
TAIL AND LICENSE PLATE LIGHT CIRCUIT

Tail and license plate light does not Bulb burned out Replace bulb.
turn on (Light) Not grounded Check the grounding.
Tail and license plate light does not Fuse burned out Replace fuse.
turn on (Fuse)
Tail and license plate light does not Defective relay Replace relay
turn on (Tail light relay)
Tail and license plate light does not Broken wire between fuse and switch Replace wire.
turn on (Lighting switch) Defective switch Replace switch.
GENERAL INSTRUCTION
EN12Z0301C100001
! CAUTION
Be sure to disconnect the ground cable before servicing the electrical
circuits except for testing on-vehicle.
1. WIRING CODE
(1) Wiring colors are indicated by a code.
B : Black Lg : Light green

Br : Brown O : Orange
G : Green R : Red
Gr : Gray V : Violet
L : Blue W : White
P : Pink Y : Yellow
(2) The first letter indicates the ground wire color and second letter indi-
cated the strip color.
SAPH12Z030100006
(3) Arabic numerals indicates the cross sectional area of wire.
Example: 3 indicates 3 mm2 {0.0047 in2}
2. CONNECTOR
(1) The connector consists of the male and female connectors.
Male and female connectors are classified according to the shape of
the terminals in the connector.
Male and female connectors are provided with a lock, so that they can
not be separated easily.
To separate the connectors, unlock the lock, then hold one connector
with one hand and the other one with the other hand, and pull each
other.
NOTICE
When the connector is disconnected by pulling the wires, the connec-
tion between the terminals and the wires will be damaged.
SAPH12Z030100007
(2) Removing the terminal from the connector.

a. Insert a miniature screwdriver or a terminal puller between termi-
nal and connector, and unlock the lock between terminal and con-
nector.
b. When the lock has been released, pull the wire to remove the ter-
minal.
(3) Installing the terminal in the connector.
a. Insert the terminal into the connector until it clicks.
b. Pull the wire to confirm correct lock engagement
SAPH12Z030100008
3. FUSE
(1) The power supply must be switched off for fuse replacement.
Use a proper amperage fuse.
NOTICE
Wire burning may be caused when a fuse with an excessively large
current capacity is used.
If the fuse should blow frequently, investigate the cause and correct it.
SAPH12Z030100009
4. FUSIBLE LINK
(1) The cause of an overload current should be determined and corrected
before a melted fusible link is replaced.
A melted fusible link can be determined by swollen or melted insula-
tion of the link.
SAPH12Z030100010
5. DIODE
(1) Diode allows the flow of electric current in only one direction.
SAPH12Z030100011
RELAY (TYPE, NAME AND INSPECTION)

TYPE-1: Tail light relay No.1
Tail light relay No.2
Power accessory relay
Power relay No.1
Power relay No.2
Power relay No.3
ATM starter relay (MD)
Head light main relay
Head light dimmer relay
Daytime light relay
SAPH12Z030100012
Mirror heater relay
Horn relay
Heater relay
U2 ECU main relay
U2 actuator power relay
ATM back light relay (MD)
ATM neutral relay (LCT)
Parking indicator relay
Air horn relay
Parking buzzer off relay
TYPE-2: Air conditioner relay
TYPE-3: ABS motor relay
TYPE-4: Fuel heater relay (Power accessory relay No.2)
TYPE-5: Starter relay
TYPE-6: Heater relay (Glow plug)
1. TYPE-1 AND TYPE-2 INSPECTION

(1) Apply voltage to terminals;
12V to terminal 1,
85920-2720 Ground to terminal 2.
85920-2740 5 3 (2) Under normal condition, terminals 3 and 5 switch on.
2 5 3
1 2
SAPH12Z030100013
2. TYPE-3 INSPECTION
12V to terminal 1,
5 3 (2) Under normal condition, terminals 3 and 5 switch on.
2 5 3
1 2
SAPH12Z030100014
3. TYPE-4 AND TYPE-5 INSPECTION

85920-2760 12V to terminal 1,
Ground to terminal 2.
28300-1280 5 3
5 (2) Under normal condition, terminals 3 and 5 switch on.
1 2 1 2
SAPH12Z030100015
4. TYPE-6 INSPECTION
12V to terminal 1,
5 3 (2) Under normal condition, relay switches the continuity from terminals 3
5
and 4 to 3 and 5.
1 2 1 2
SAPH12Z030100016
HANDLING PRECAUTION
EN12Z0301C100002
BATTERY
HYDROMETER ! WARNING
• Since the batteries produce explosive hydrogen gas, do not
allow any open or electric sparks near the batteries.
• The batteries produce explosive gas and contain corrosive sulfu-
ric acid. A battery explosion, contact with electrolyte, or an elec-
trical short can result in personal injury and/or property damage.
• Always shield your eyes or wear safety goggles when working on
the batteries. Do not let electrolyte, which is sulfuric acid, come
in contact with eyes, skin, or clothing. Since electrolyte is corro-
SAPH12Z030100017 sive acid, it can damage skin and clothing. If acid should contact
your skin, eyes or clothing, immediately flush the contact area
thoroughly with water and get medical treatment immediately.
• When working on the batteries, be sure to remove any metal
accessories from your arms. Do not lean over the batteries.
• This vehicle has a 12-volt, negative grounds system. Make sure
that any other vehicle used for jump starting also has a 12-volt,
negative ground system. Do not attempt to jump start when you
are not sure of the voltage or ground of the other vehicle.
1. MAINTENANCE-FREE BATTERY
(1) The hydrometer on the top of the battery provides a guide regarding
condition of the change and the electrolyte level.
(2) Check the battery condition by the hydrometer color.
.
a. Good condition
Green eye (DELPHI battery):
Blue eye (FURUKAWA battery):
b. Charging necessary
Dark eye.
NOTICE
Do not refill the battery with water.
2. BATTERY CHARGING
NOTICE
If the electrolyte level is below the specified level, replace the battery.
If it is within the specified level, the battery can be recharged.
• Be careful of the following points.
(1) While the battery is being charged, ensure that the temperature of the
electrolyte does not rise above 45°C {113°F}.
(2) While the battery is being charged, be particularly careful to keep it
away from sources of fire.
(3) The amount of electrolyte must be within the specified level.
SAPH12Z030100018 3. CLEANING THE BATTERY

• If the terminals at the top of the battery are dirty, clean them with cold
water or lukewarm water.
• Apply a light coating of grease to the terminals to prevent them from
rusting so as to prevent faulty contact.
4. CONNECTING THE BATTERY CABLES
• Tighten the cables securely to prevent improper contact between the
cables and the battery terminals.
• Be very careful not to connect the (+) and (-) leads in reverse.
(Because this may cause damage to the equipment and batteries)
INSPECTION
EN12Z0301H300001
REMOVAL PROCEDURE FOR OUTSIDE FUSIBLE LINK

OUTSIDE FUSIBLE LINK BOX
CLAW BAR BOX
1. Push the lock lever and disconnect the claw bar. (2 portions)
2. Remove the box cover while lifting two lock plate.
LOCK PLATE
LOCK LEVER
SAPH12Z030100065
POWER SUPPLY CIRCUIT

TERMINAL A
1. FUSIBLE LINK BLOCK INSPECTION
(1) Check the voltage between fusible link block terminal A and chassis
body ground.
(2) Under normal condition, the voltage is about 12V.
(3) If it is not correct, check the battery cable, wiring harness, etc.
• Battery cable (Open circuit, loosen connection, etc.)
• Wiring harness (Open circuit, etc.)
• Battery (Discharged)
SAPH12Z030100019
A B B A A B B A B A
A: GROUP A TERMINAL (FROM BATTERY)

B: GROUP B TERMINAL (TO EACH ELECTRICAL PARTS)
SAPH12Z030100020
2. FUSE BLOCK INSPECTION

(1) Check the voltage between group A terminals of fuse block and cab
body ground.
(2) Under normal condition, the voltage is about 12V.
(3) If it is not correct, check the circuit from battery to fuse.
• Coupler connection between cab harness and chassis harness
• Coupler connection of each electrical parts
• Cab harness and chassis harness
(Open circuit, against short, etc.)
• Fusible link burn out
ENGINE STARTING CIRCUIT
1. STARTER SWITCH INSPECTION

(1) Check the continuity between terminals.
M2 ACC
ST B M1
SAPH12Z030100021
Terminals
B ACC M2 M1 ST
Switch position
LOCK
ACC
ON
ST
SAPH12Z030100022
2. STARTER RELAY INSPECTION

Refer to page EL01-16.
HEAD LIGHT CIRCUIT
1. COMBINATION SWITCH INSPECTION

SAPH12Z030100023
Lighting (ON, OFF): Hazard warning:
Terminals Terminals
EL LT LH HF HL HR HT
Switch position Switch position
OFF OFF
TAIL ON
TAIL AND HEAD
Windshield wiper and washer:
Lighting (HIGH, LOW): Terminals
WW EW WI WL WH
Terminals EP Switch position
ED DL DU
Switch position OFF
PASSING WIPER: INT
LOW BEAM LOW
HIGH BEAM HIGH
WASHER: ON
Turn signal:
Terminals
BT TL TR
Switch position
LEFT
OFF
RIGHT
SAPH12Z030100024
2. HEAD LIGHT RELAY INSPECTION

Refer to page EL01-16.
DAY TIME RUNNING

LIGHT ECU
HEAD HEAD
LAMP LAMP
LO HI
RLY RLY
HLO
6
ECU-B +B
3
BATT
E
2
DIM
4
M SW
ECU-M M
12
IND
5
HI BEAM
LL LH RL RH IND
OIL LP
PRESSURE
LP H
7
DRL
1
HI
8
DAY TIME
LIGHT & LIGHT & CHG- LAMP RLY
TURN SW1 EL LT LH TURN SW2 ED DL DU EP 9
OFF HF PKB
11
T HL D-RY
15
H HU
OIL PKB
PRESSURE SW
SW PKB CHG- HI H HLO IND DIM +B
CONNECTED TO
TAIL LAMP RELAY E DRL
D-RY M
SAPH12Z030100025
3. DAYTIME RUNNING LIGHT ECU INSPECTION

(1) Wire the daytime running light ECU, bulbs, battery and others as
shown in figure (See page EL01-22).
(2) Check operation of daytime running light ECU.
Engine stopping
Lighting switch positon OFF or Tail Head light
Pass Pass
Dimmer switch position Low High Low High
ing ing
Headlight low beam Off Off Off On Off On
Headlight high beam Off Off On Off On On
Engine running
Lighting switch positon OFF or Tail Head light
Pass Pass
Dimmer switch position Low High Low High
ing ing
Parking Dim Dim
Headlight brake off on on
Off On Off On
low beam Parking
Off Off
brake pull
Headlight high beam Off Off On Off On On
TURN SIGNAL, HAZARD, STOP CLEARANCE, TAIL

AND LICENSE PLATE LIGHT CIRCUIT
5 4 3 2
12 11 10 9 8 7
E/G ECU
FLASHER ASSY
8
FUSE 15A
12
RY3 RY4
FLASHER
FUSE 10A
RY1 RY2 CONTROL
CIRCUIT
STOP LIGHT
RELAY RY3 RY4
3
12V
BATT
STOP LIGHT RY2 RY2
SW.
7 2 4 5 9 10 11
T/S SW. H/W SW.
L R
(FENDER)
(FENDER)
SIDE TURN
INDICATOR
INDICATOR
SIDE TURN
R/COMB
R/COMB
F/TURN
F/TURN
27W 27W 5W LED LED 5W 27W 27W

L R
SAPH12Z030100026
1. TURN SIGNAL FLASHER INSPECTION

(1) Wire the turn signal flasher, bulbs, battery and fuse as shown in fig-
ure.
(2) Under normal condition, bulbs turn on and off.
NOTICE
Take care of quantity when installing bulbs.
TURN SIGNAL: 27W x 2 pcs, 5W x 1 pcs,

LED x 1pcs
HAZARD WARNING: 27W x 4 pcs, 5W x 2 pcs,
LED x 2 pcs
2. STOP LIGHT SWITCH INSPECTION (HINO 268, 338 (NJ8J, NV8J)

MODEL)
SAPH12Z030100027
Terminals
1 2
Switch position
PUSH
FREE
SAPH12Z030100028
3. STOP LIGHT SWITCH INSPECTION (EXCEPT FOR HINO 268, 338

(NJ8J, NV8J) MODEL)
(1) Check the continuity between terminals
Push the plunger: continuity
SAPH12Z030100029
DOME LIGHT
1. DOME LIGHT INSPECTION

(1) Apply voltage to terminals and check the bulbs lighting.
SAPH12Z030100030
2. COURTESY SWITCH INSPECTION

(1) Check the continuity between terminal and body ground.
Between terminals
PUSH No continuity
FREE Continuity
SAPH12Z030100031
WINDSHIELD WIPER CIRCUIT
1. WIPER MOTOR INSPECTION

(1) Apply 12V to terminals, the motor should operate as below.
NOTICE
Connect termianl LW to a 10A fuse and 12V power source. Connect
wiper motor body to negative terminal of power source. If the fuse
burns out or the motor does not operate, replace the motor.
SAPH12Z030100032
Terminals
LW LB L LR
Switch position
OFF
LOW
HIGH
SAPH12Z030100033
2. WASHER PUMP INSPECTION

(1) Check the continuity between terminals of the motor.
If no continuity, replace washer tank and pump assembly.
NOTICE
Do not apply voltage to the pump motor with an empty washer tank, or
the motor will be damaged.
SAPH12Z030100034
GAUGE, METER AND WARNING CIRCUIT
1. FUEL GAUGE SENDER UNIT INSPECTION

(1) Measure resistance between terminals.
Float position F 1/2 E

Resistance: Ω 0-1.2 29.5-32.5 146.5-153.5
SAPH12Z030100035
2. COOLANT TEMPERATURE GAUGE SENDER UNIT INSPECTION

(1) Warm up the sender gauge and measure the resistance between the
terminal and the body ground.
Temperature 75°C {167°F} 100°C {212°F}

Resistance:Ω 79-92 35.5-42.5
SAPH12Z030100036
3. AIR PRESSURE GAUGE SENSOR INSPECTION

(1) Wire the air puressure gauge sensor and voltmeter as shown in fig-
ure.
(2) Apply voltage terminal; 5 V to terminal 3
(3) Apply air pressure
(4) Check voltage between terminal 1 and 2
Air pressure Voltage

0 MPa {0 kgf/cm2, 0 lbf/in2} 0.1 V
1.6 MPa {16.3 kgf/cm2, 232 lbf/in2} 0.9 V
SAPH12Z030100037
4. VEHICLE SPEED SENSOR INSPECTION

(Model equipped with AISIN A450 automatic transmission)
(1) Wire the vehicle speed sensor, resistor and electric tester or voltmeter
as shown in figure.
(2) Rotate the shaft of vehicle speed sensor by hand.
(3) Check voltage
(4) Under normal condition, voltage changes from less than 1.5 V to more
than 11.5 V frequently.
SAPH12Z030100038
5. REVOLUTION SENSOR INSPECTION

If the revolution sensor is normal, there will be continuity between the
terminals.
SAPH12Z030100039
HYDRO MAX
IG BRAKE CONTROLLER
IG
BUZZER POWER
CPU 3 7
BUZZER
+B
IG
STOP LAMP SW
WARNING INDICATOR
+B
(RED) BRAKE SW
5 8
MOTOR RELAY
BUZZER
FLOW SW
1
FLOW SW
DIFFERENCE
PRESSURE SW.
M
2
MOTOR MONITOR
GND 3 2 1
6 4
BLANK 8 7 6 5 4
SAPH12Z030100040
6. HYDRO MAX BRAKE CONTROLLER INSPECTION

(1) Wire the HYDRO MAX brake controller, buzzer, motor relay and oth-
ers as shown in figure.
(2) Check operation
a. When IG on, an alarm is carried out by motor monitor low voltage.
If the motor monitor is low voltage after high voltage, warning
stops.
b. An alarm is carried out by high voltage of motor monitor and IG
on.
c. An alarm is carried out by opening of motor monitor circuit and IG
on.
d. Electric power is supplied to the motor relay coil with IG on or
brake switch on.
NOTICE
"IG on" means starter switch is turned on.
7. AIR PRESSURE SWITCH INSPECTION (MODEL HINO 268, 338

(NJ8J, NV8J) MODEL)
(1) Apply air pressure.
(2) Check the continuity between terminal and body ground.
Between terminals
Less than 490 kPa {5.0 kgf/cm2
Continuity
71 lbf/in2}
More than 490 kPa {5.0 kgf/cm2
No continuity
71 lbf/in2}
SAPH12Z030100041
8. OIL PRESSURE SWITCH INSPECTION

(1) Start engine and disconnect the coupler.
(2) Check the continuity between terminal and engine ground.
SAPH12Z030100042
Engine
Terminal ground
Engine stop
Engine running
SAPH12Z030100043
9. CHECK THE OPERATION OF THE COOLANT LEVEL WARNING

SENSOR.
(1) Using an ohmmeter, measure the resistance between the terminal
and ground at the indicated coolant temperatures.
If resistance is not within specifications, replace the gauge unit.
Resistance
Dry condition Over 1MΩ
Wet condition Under 10kΩ
SAPH12Z030100044
10. CHECK THE OPERATION OF THE COOLANT LEVEL WARNING

CONTROLLER.
(1) When the resistance of the coolant level sensor indicates less than
10kΩ, the coolant level warning controller does not operate, and when
it is more than 30kΩ, it is operational and the buzzer rings.
(2) When the voltage of the power is 12V and the temperature is 20°C —
5°C (68° — F41°F) the voltage and the resistance of sensor operates
as follows, (Rx=The resistance of coolant level sensor)
• When Rx indicates infinity,Voltage (Vout) comes to less than 1.5V and
the buzzer rings.
• When Rx indicates 0Ω, voltage (Vout) is nearly equal to the voltage of
the power, the buzzer does not ring.
(3) When the connector of coolant level sensor is taken off, the warning
lamp lights.
(4) When terminal No.5 is taken off and is connected to the ground, Rx
indicates almost 0Ω.
Unless it is as noted above, replace the coolant level sensor.
SAPH12Z030100045
11. PARKING BRAKE SWITCH INSPECTION (EXCEPT FOR HINO

268, 338 (NJ8J, NV8J) MODEL)
1 2
SAPH12Z030100066
Terminal
1 2
Switch position
PUSH
FREE
SAPH12Z030100047
12. CHECK THE OPERATION OF THE WARNING BUZZER.

(1) Apply 12V D.C. across the terminals and check that the buzzer
sounds.
If it does not, replace the buzzer.
SAPH12Z030100048
POWER WINDOW CIRCUIT (IF SO EQUIPPED)
1. DRIVER'S SIDE SWITCH INSPECTION

IG PU PD (E)
+B DD DU B2 E WL
SAPH12Z030100049
DRIVER'S SIDE: ASSISTANT'S SIDE: LOCK SWITCH OFF POSITION

Terminals Terminals
+B DU DD E +B PU PD E WL
Switch position Switch position
CLOSE
CLOSE
OFF
OFF
OPEN
ASSISTANT'S SIDE: LOCK SWITCH ON POSITION

Terminals
+B PU PD E WL
Switch position OPEN
CLOSE
OFF
OPEN
SAPH12Z030100050
2. ASSISTANT'S SIDE SWITCH INSPECTION

D SD U SU IG
SAPH12Z030100051
Terminals
SU U IG D SD
Switch position
CLOSE
OFF
OPEN
SAPH12Z030100052
3. POWER WINDOW MOTOR INSPECTION

(1) Check the continuity between terminals. If there is no continuity,
replace the motor.
(2) Apply 12V to terminals, inspect the motor operation as below.
1 2 2 1
PASSENGER SIDE DRIVER SIDE
SAPH12Z030100053
Terminals
Direction of rotation 1 2
(View from out put shaft)
CLOCKWISE + -
COUNTERCLOCKWISE - +
SAPH12Z030100054
HEATER AND COOLER CIRCUIT
1. BLOWER SWITCH INSPECTION

SAPH12Z030100055
Terminals
E C M1 M2 H P P
Switch position
OFF
1
2 LAMP
3
4
SAPH12Z030100056
2. COOLER CONTROL SWITCH

Between terminals
PUSH Continuity
FREE No continuity
SAPH12Z030100057
3. CONDENSER ASSEMBLY INSPECTION

(1) Check continuity between terminals.
SAPH12Z030100058
Terminal
LB WB LY
Switch position
OFF
LO
HIGH
SAPH12Z030100059
4. POWER RELAY No.2 INSPECTION

Refer to page EL01-13
BACK UP LIGHT CIRCUIT
1. BACK UP LIGHT SWITCH INSPECTION

Between terminals
PUSH Continuity
FREE No continuity
PRE-HEATING CIRCUIT (IF SO EQUIPPED)
1. GLOW PLUG INSPECTION

(1) Check continuity between terminal and body ground.
(2) Under normal condition, the terminal and body ground should show
continuity.
SAPH12Z030100060
BLOCK HEATER CIRCUIT (IF SO EQUIPPED)
1. BLOCK HEATER INSPECTION

(1) Check continuity between terminal 1 and 2.
SAPH12Z030100061
INSPECTION AND ADJUSTMENT

EN12Z0301H300002
ADJUSTMENT OF PULSE ADJUST COMPUTER

HINT
This is a device that enables a fine-tuning of compensating ratio of
speedometer without modifying the speedometer driven gear of the
transmission.
1. CONNECTING INPUT TOOL

(1) Remove the instrument panel cover of assistant seat side in the cabin.
(2) Remove the seal around the screws by using a tool with a sharp point
end.
SAPH12Z030100062
(3) Remove the screws and then the cover of pulse adjust computer.
(4) If you disconnected the wire harness connector of the vehicle when
removing the cover of pulse adjust computer, connect again the wire
harness connector.
(5) Connect the input tool connector.
SST: Input tool (09630-2400)
SAPH12Z030100063
2. THE METHOD OF WRITING IN OR READING OUT THE CONVER-

SION RATE
NOTICE
The vehicle condition at writing in or reading out: Starter switch is
turned on.
(1) Reading out the conversion rate.
a. The "RD/STP" key is pushed.
b. Reading out the conversion rate correctly, "GOOD" is indicated
and buzzer is rung for three seconds, then the conversion rate
which is written in the pulse adjust computer is indicated.
(Reading out incorrectly, "bad 0" is indicated and buzzer is rung.
In this case, put the connector again.)
c. It becomes a condition of writing the conversion rate when the set
key is pushed after reading out the conversion rate.
HINT
Refer to operation manual which belongs to input tool for details.
(2) Writing in the conversion rate.
a. While the condition of inputting the conversion rate (" *.****" indi-
cation), the conversion rate is inputted by pushing the ten keys or
[UP] [DOWN] key.
If the conversion rate is inputted, omit the decimal point.
eg. When you want to input the conversion rate "1.8210", push
the ten key as "18210".
SAPH12Z030100064
NOTICE
Refer to the following "Pulse conversion rate table".
b. If the set key is pushed, the input value is decided.
When it is inputted correctly, the buzzer is rung and the display
becomes the same condition before inputting with ten keys.
c. The "WR/STR" key is pushed.

Writing in the conversion rate correctly, "GOOD" is indicated and
the buzzer is rung for three seconds, then the conversion rate
which contained an error and which was actually written in the
pulse converter is indicated.
Writing it incorrectly, "bad 0" is indicated and buzzer is rung.
In this case, write it correctly again.
3. DISCONNECTING INPUT TOOL

(1) Turn the starter switch to "LOCK" position.
(2) Disconnect the input tool connector and mount the cover of pulse
adjust computer.
(3) Apply new seal (83179-1140) on the screws to seal them.
(4) Write conversion rate on a new caution plate (conversion rate record
seal (76588-3800) and stick it on the place.
(5) Mount the instrument panel cover of assistant seat side.
SAPH12Z030100063
SPEEDOMETER CONVERSION RATE LIST

EN12Z0301H300003
EATON FS-4205A, FS-5406A, FS6406A MANUAL TRANSMISSION SERIES

REAR AXLE GEAR RATIO
TIRE SIZE RADIUS 2.93 3.07 3.15 3.21 3.31 3.42 3.58 3.73 3.90 3.91 4.10 4.11
215/85R16 0.374 0.798 0.761 0.742 0.728 0.706 0.683 0.653 0.627 0.599 0.598 0.570 0.569
225/70R19.5 0.395 0.843 0.804 0.784 0.769 0.746 0.722 0.690 0.662 0.633 0.631 0.602 0.601
245/70R19.5 0.407 0.868 0.829 0.808 0.792 0.768 0.744 0.710 0.682 0.652 0.650 0.620 0.619
9R22.5 0.470 1.003 0.957 0.933 0.915 0.887 0.859 0.821 0.788 0.753 0.751 0.716 0.715
255/80R22.5 0.475 1.013 0.967 0.943 0.925 0.897 0.868 0.829 0.796 0.761 0.759 0.724 0.722
275/80R22.5 0.491 1.047 1.000 0.974 0.956 0.927 0.897 0.857 0.823 0.787 0.785 0.748 0.747
10R22.5 0.492 1.050 1.002 0.976 0.958 0.929 0.899 0.859 0.824 0.788 0.786 0.750 0.748
295/75R22.5 0.493 1.052 1.004 0.978 0.960 0.931 0.901 0.861 0.826 0.790 0.788 0.751 0.750
11R22.5 0.508 1.084 1.034 1.008 0.989 0.959 0.928 0.887 0.851 0.814 0.812 0.774 0.772

TIRE SIZE RADIUS 4.30 4.33 4.56 4.63 4.78 4.88 4.89
215/85R16 0.374 0.543 0.540 0.512 0.505 0.489 0.479 0.478
225/70R19.5 0.395 0.574 0.570 0.541 0.533 0.516 0.506 0.505
245/70R19.5 0.407 0.591 0.587 0.558 0.549 0.532 0.521 0.520
9R22.5 0.470 0.683 0.678 0.644 0.634 0.614 0.602 0.601
255/80R22.5 0.475 0.690 0.686 0.651 0.641 0.621 0.608 0.607
275/80R22.5 0.491 0.714 0.709 0.673 0.663 0.642 0.629 0.627
10R22.5 0.492 0.715 0.710 0.674 0.664 0.643 0.630 0.629
295/75R22.5 0.493 0.716 0.712 0.676 0.665 0.644 0.631 0.630
11R22.5 0.508 0.738 0.733 0.696 0.686 0.664 0.651 0.649
ALLISON 2200RDS AND 2500RDS, 3000RDS AUTOMATIC TRANSMISSION SERIES

TIRE SIZE RADIUS 4.11 4.88 5.13 5.29 5.38 5.57 5.63 5.86
245/70R19.5 0.407 1.238 1.043 0.992 0.962 0.946 0.913 0.904 0.868
9R22.5 0.470 1.430 1.204 1.145 1.111 1.092 1.055 1.044 1.003
255/80R22.5 0.475 1.445 1.217 1.158 1.123 1.104 1.066 1.055 1.013
10R22.5 0.492 1.497 1.260 1.199 1.163 1.143 1.104 1.093 1.050
295/75R22.5 0.493 1.500 1.263 1.201 1.165 1.146 1.107 1.095 1.052
11R22.5 0.508 1.545 1.302 1.238 1.201 1.181 1.140 1.128 1.084
NOTICE
The models listed below might be equipped with AISIN 450-43L automatic transmission as an option, and compensa-
tion of speedometer would be enforced by the speedometer gear ratio, not by the pulse converter.
REAR AXLE SPEEDOMETER

MODEL TIRE SIZE
GEAR RATIO GEAR RATIO
HINO 145 (NA) 215/85R16 5.13 18/5
HINO 165 (NB) 225/70R19.5 5.86 17/5
HINO 185 (NC) 225/70R19.5 5.86 17/5
EL02_001.fm 1 ページ２００６年２月１０日　金曜日　午後６時２８分
ELECTRIC WIRE EL02–1
ELECTRIC WIRE
EL02
EL02-001
DIAGRAM.................................................. EL02-2
HOW TO USE THIS CHAPTER........................EL02-2
SPECIFICATION SYMBOL LIST ......................EL02-7
DIAGRAM .......................................................EL02-12
POSITION OF CONNECTOR.........................EL02-90
CONNECTOR ...............................................EL02-113
CONNECTOR LIST ......................................EL02-127
EL02–2 ELECTRIC WIRE
DIAGRAM
HOW TO USE THIS CHAPTER
EN12Z0302J100001
• In this chapter, "specification symbols" are used as prefix of each wiring diagram in order to specify the circuits that are
different in accordance with the models and specifications. For further detail on how to use this chapter, refer to "1.
Description of specification symbol list" and "2. Description of wiring diagram".
.
1. Description of specification symbol list
a b c d
Specification
Circuit name Specifications Page
symbol
Models equipped with 6 cylinder engine

(Model ND8J, NE8J, NF8J, NV8J)
A POWER SUPPLY CIRCUIT EL02-12
(Model NA6J, NB6J, NC6J)
Models equipped with 4 cylinder engine and

manual transmission (MTM)
ENGINE STARTING CIRCUIT-1 :
MODELS EQUIPPED WITH Models equipped with 6 cylinder engine and
B EL02-17
EATON FS SERIES MTM AND MTM
AISIN A450 ATM
Models equipped with AISIN A450 automatic
transmission (ATM)
ENGINE STARTING CIRCUIT-2 : Models equipped with ALLISON 3000RDS auto-

MODELS EQUIPPED WITH matic transmission
C ALLISON 2200RDS/2500RDS EL02-17
Models equipped with ALLISON 2200RDS and
AND 3000RDS ATM
2500RDS ATM

D GROUND CIRCUIT EL02-18
Models equipped with glow plugs on 4 cylinder

engine (as option)
E GLOW PLUG CIRCUIT EL02-20
engine (as option)

F CHARGING CIRCUIT EL02-20

G SPARE POWER SOURCE CIR- EL02-22
CUIT Models equipped with 6 cylinder engine
SAPH12Z030200001
.
a. Circuit name
Designates the circuit names on the wiring diagram.
b. Specification symbol
This is the symbol of the specification listed on the "Specifications" column. On the wiring diagram, this symbol is pre-
fixed to all the wiring type mark (example: 0.85 W-R).
Each wiring is installed only on the vehicles of the specifications that the relevant specification symbol designates.
c. Specifications
Describes the contents of specifications that each specification symbol designates. All the wirings are classified
according to the specifications listed here.
d. Page
Indicates the page where the relevant wiring diagram is found.
2. Description of wiring diagram
K
0.85 W-R
0.50 R-L 0.50 R-L
0.50 R-W 0.50 R-W

CAB SIDE WIRING
0.85 R-
(FLS+)
C7N
(HR)
C4A
(HL)
C4B
C4N
(TR)
C4P
(TL)
12 3
HF HL HR HT BT TL TR BC CL CR C8C
9
(TSWL)
2 OFF L
1
ON 3 N
C8B
10
(TSWR)
C49
(HF)
R 11 2 4 7 5
(STPR)
(STPL)
C85
C84
C4M
(BT)
0.50 B- C7W
(E)
C88
(TLPL)
C87
(TLPR)
0.50 B-
0.85 R-W
0.50 B-G
0.50 B-R
0.50 B-
0.85 B-G
0.85 B-R
0.85 Y-
1.8A
1.8A
(MTUR)
(MTUL)
E0Q
E0R
&C1 2.00 B- &C4
#L8
#L7
#A8
#LA
#L9
G3
(CAB1) (CAB4)
MAIN W/H c d
FR W/H
0.50 B-R #L9
0.50 B-W #LA
0.50 R-W #L7
#L8
#A8
0.85 W-R
0.50 B-G
0.50 B-R
0.50 R-W
AP9 APA
0.50 Y-
0.50 Y-
j k
(STL+) (STR+)
0.85 W-R
0.75 W-
#26
#27
#28
#13
#12
FR W/H
HOOD W/H
#26
1.25 B-W #27
0.85W-R #28
#12
#13
0.85 W-R
(11LD)
A0W
1.25 B-R
1.25B-W
1.25B-R
CHASSIS SIDE WIRING
1.25 Y-
To fuse turn
(15A)
(SML+)
(SML+)
(STN+)
(STN+)
(FTR+)
(FTL+)
C4Q
C4S
C1S
C26
C28
C1J
1.25 W-R
1.25 R-W
1.25 O-
6 7 8 9
(BLP+)
(S/L+)
(T/L+)
C1G
C1N
C1P
C27
(STN-)
C4R
(FTL-)
C4T
(FTR-)
C29
(STN-)
1.25B-
1.25B-
1.25B-
1.25B-
Tail, Stop, Back

Licence Turn
10
#29
HOOD W/H
FR W/H
0.85 B- #29
C1M
(RCB-)
&1B 3.00 B- &1A

1.25 B- (CAS2) (CAS1)
SAPH12Z030200036
This is the circuit name.
K STOP AND TURN LIGHT CIRCUIT 10 Rear combination light LH
1 Stop and turn controller 11 Rear combination light RH
2 Wiper and retarder switch 12 Stop light relay
3 Light and turn switch 13 STP AT diode
4 Stop light switch
5 Junction a To A450 ATM ECU
6 Side turn light LH (Fender) b To Monitor module (HYDRO MAX)
7 Front turn light LH c To Combination meter (Meter)
8 Front turn light RH d To Combination meter (Meter)
9 Side turn light RH (Fender) e To Fuse tail light (Head & tail light)
This is name of the parts on the diagram and the

number corresponds to that on the diagram.
Specification symbol ( , ,etc.)
Each wiring is installed to the vehicles relevant to the specification that the specification symbol designates.
SAPH12Z030200002
3. Position of connector
• The position of an electrical equipment connector of the wiring diagram (example:M-2) in the car can be seen.
M-1
M-2
M-4 M-3
M-1: Dome light LH

M-2: Dome light RH L M
To FR/H (Fuse R/LP)
M-3: Courtesy switch front LH #AA
(10)
M-4: Courtesy switch front RH
0.85 W-G
0.85 W-G
CAB SIDE WIRING
(+24V)
K9G
#73
MAIN
W/H
ROOF To DST-1 connecter
W/H DLL-
#73
D1R
0.85 W-G
DLL+
D1Q
0.85 W-G
A81
To fuse back light
(71LD) 1
5.2A
(DLR+)
(DLL+)
0.50 R-L
D1Q
D1T
DLL-
D1U
Connector No. 1 2 DLR+

D1T
#LB
MAIN W/H
2
FR W/H
D1R
D1U
(DLL-)
(DLL-)
#LB
0.85 R-L
0.85 R-L
0.85 G-
0.85 G-
For EATON MTM only LH+

Body Body D01
L-1 earth earth
3
#74
NRC
ROOF W/H
(+)
MAIN W/H
1
0.85 R-L #74
CHASSIS SIDE WIRING
NRD
(-)
RH+
0.85 O-
#53
D02
1.25 O-
To Back LIGHT MAIN W/H
FLOOR W/H 4
#53
For ATM only NK4

b
#15
(NO)
0.85 R-L
0.85 R-L
FR W/H
RR W/H
#15
(RH+)
(LH+)
DO1
DO2
3 4
(BLP+)
AP8
+ -
NRC NRD
c
(Caution) Terminal : male
1 Body Body
earth earth
SAPH12Z030200153
EL02_001.fm 5 ページ２００６年２月１３日　月曜日　午後４時２７分
4. Connector
• The shape, the color, and the part No. of electrical equipment connectors are listed in order of the connector No. The
position of the connector can be seen (example:M-2).
Connector : M-3 Connector : M-4

Connector : M-1 Connector : M-2 Color : White Color : White
Color : White Color : White Part No. : 82580-6170 Part No. : 82580-6170
Part No. : 82580-3360 Part No. : 82580-3360
Connector : N-1
Color : White
Part No. : 82560-2990
Position of connectors M
M-1
M-2
M-4 M-3
M-1: Dome light LH

M-2: Dome light RH
M-3: Courtesy switch front LH
SAPH12Z030200154
EL02_001.fm 6 ページ２００６年２月１３日　月曜日　午後４時２５分
5. Connector List
• The connector No. can be used as the keyword to search for the page on which a connector (example:M-2) is listed.
Three-dimensional
Wiring
Diagram Connector connector diagram
Electrical equipment name diagram
symbol No. (Position of connec-
listing page
tor) listing page
K-1 Stop and turn controller EL02-36, EL02-37 EL02-96
K-2 Wiper and retarder switch EL02-36, EL02-37 EL02-96
K-3 Light and turn switch EL02-36, EL02-37 EL02-96
K-4 Stop light switch EL02-37 EL02-96
K-5 Junction EL02-37 EL02-92
K-6 Side turn light LH (Fender) EL02-37 EL02-96
K-7 Front turn light LH EL02-37 EL02-96

K
K-8 Front turn light RH EL02-37 EL02-96
K-9 Side turn light RH (Fender) EL02-37 EL02-92, EL02-96
K-10 Rear combination light LH EL02-36, EL02-37 EL02-96
K-11 Rear combination light RH EL02-36, EL02-37 EL02-96
K-12 Stop lamp relay EL02-36, EL02-37 EL02-108
K-13 STP AT diode EL02-36, EL02-37 EL02-100
L L-1 Back light switch EL02-38 EL02-95
M-1 Dome light LH EL02-38 EL02-97
M-2 Dome light RH EL02-38 EL02-97

M
M-3 Courtesy switch front LH EL02-38 EL02-97
M-4 Courtesy switch front RH EL02-38 EL02-97
N-1 Washer motor EL02-39 EL02-96
N N-2 Wiper relay EL02-39 EL02-96
N-3 Wiper motor EL02-39 EL02-96
SAPH12Z030200155
SPECIFICATION SYMBOL LIST

EN12Z0302J100002
Specification
symbol

(Model ND8J, NE8J, NF8J, NV8J)
A POWER SUPPLY CIRCUIT EL02-12
(Model NA6J, NB6J, NC6J)

manual transmission (MTM)
ENGINE STARTING CIRCUIT-1 :
MODELS EQUIPPED WITH Models equipped with 6 cylinder engine and
B EL02-17
EATON FS SERIES MTM AND MTM
AISIN A450 ATM
transmission (ATM)
ENGINE STARTING CIRCUIT-2 : Models equipped with ALLISON 3000RDS auto-

MODELS EQUIPPED WITH matic transmission
C EL02-17
ALLISON 2200RDS/2500RDS Models equipped with ALLISON 2200RDS and
AND 3000RDS ATM 2500RDS ATM

D GROUND CIRCUIT EL02-18

engine (as option)
E GLOW PLUG CIRCUIT EL02-20
engine (as option)

F CHARGING CIRCUIT EL02-20

SPARE POWER SOURCE CIR-
G EL02-22
CUIT
Specification
symbol
Models equipped with center parking brake
Models equipped with wheel parking brake and

full air brake
Models equipped with 4 cylinder engine, EATON

METER CIRCUIT FS series MTM and HYDRO MAX brake.
H EL02-24
(CAB SIDE)
Models equipped with 6 cylinder engine, and
EATON FS series MTM
Models equipped with AISIN A450 ATM
Models equipped with ALLISON 2200RDS/

2500RDS and 3000RDS ATM
Models equipped with 6 cylinder engine, EATON

FS series MTM and full air brake
Models equipped with center parking brake
Models equipped with wheel parking brake and

full air brake
METER CIRCUIT
I Models equipped with 4 cylinder engine and EL02-28
(CHASSIS SIDE)
EATON FS series MTM

EATON FS series MTM
Models equipped with ALLISON 2200RDS/

2500RDS and 3000RDS ATM
HEAD LIGHT AND TAIL LIGHT Models equipped with wheel parking brake
CIRCUIT
J EL02-32
(WITH DAYTIME RUNNING Models equipped with center parking brake
LIGHT)
Models equipped with back mirror light (as
option)
Models equipped with power window (as option)

Specification
symbol

EATON FS series MTM

EATON FS series MTM
STOP AND TURN LIGHT CIR- Models equipped without stop light relay
K EL02-36
CUIT
Models equipped with stop light relay
Models equipped with stop light relay and diode

for ALLISON 2200RDS, 2500RDS, 3000RDS
ATM
Models equipped with stop light relay for full air

brake
Models equipped with stop light relay for HYDRO

Max brake
L BACK LIGHT CIRCUIT Models equipped with 4 cylinder engine and EL02-38
EATON FS series MTM

EATON FS series MTM
M ROOM LIGHT CIRCUIT Common to all models EL02-38
N WIPER AND WASHER CIRCUIT Common to all models EL02-39
O MIRROR HEATER CIRCUIT Common to all models (as option) EL02-40
P HORN CIRCUIT Common to all models EL02-41
Q CIGARETTE LIGHTER CIRCUIT Common to all models EL02-42
Common to all models (as option)

R POWER WINDOW CIRCUIT EL02-43
Models equipped with power window (as option)
S AUDIO CIRCUIT Common to all models EL02-44
Common to all models

MANUAL AIR CONDITIONER
T Models equipped with 4 cylinder engine EL02-46
CIRCUIT
Specification
symbol

COMMON RAIL CIRCUIT-1
(CAB SIDE) : MODELS
U Models equipped without stop light relay EL02-48
EQUIPPED WITH 6 CYLINDER
ENGINE

(CHASSIS SIDE) : MODELS
V Models equipped without stop light relay EL02-52
ENGINE

(CAB SIDE) : MODELS
W Models equipped without stop light relay EL02-56
ENGINE

(CHASSIS SIDE) : MODELS
X Models equipped without stop light relay EL02-60
ENGINE
Y COMMON RAIL CIRCUIT-3 Common to all models EL02-64
Models equipped with ATM

Z COMMON RAIL CIRCUIT-4 EATON FS series manual transmission EL02-66

EATON FS series MTM
AA COMMON RAIL CIRCUIT-5 Common to all models EL02-67
ABS CIRCUIT-1
AB Models equipped with full air brake EL02-68
(FOR FULL AIR BRAKE)

ABS CIRCUIT-2 HYDRO MAX brake
AC EL02-70
(FOR HYDRO MAX BRAKE) Models equipped with 6 cylinder engine and
HYDRO MAX brake

HYDRO MAX brake
AD HYDRO MAX BRAKE CIRCUIT EL02-72
HYDRO MAX brake
AE CIRCUIT-1 : EQUIPPED WITH EL02-74
transmission
AISIN A450 ATM
Specification
symbol
Models equipped with ALLISON 2200RDS and

AUTOMATIC TRANSMISSION 2500RDS ATM
CIRCUIT-2 : EQUIPPED WITH
AF Models equipped without stop light relay EL02-76
ALLISON 2200RDS/2500RDS
ATM
Models equipped with ALLISON 3000RDS ATM

AG CIRCUIT-3 : EQUIPPED WITH Models equipped without stop light relay EL02-78
ALLISON 3000RDS ATM
AH AIR DRIER CIRCUIT Common to all models EL02-80
DIAGNOSIS CONNECTER (9P)

AI Common to all models EL02-80
CIRCUIT

DIAGNOSIS CONNECTER
AJ Models equipped with 6 cylinder engine EL02-81
(16P) CIRCUIT
CAN COMMUNICATION CIR- —

AK Common to all models EL02-82
CUIT
AL WIRE-TO-WIRE CONNECTOR — Common to all models EL02-84

DIAGRAM
EN12Z0302J100003
A
2.00 W-G
2.00 B-R
2.00 B-R
2 L
O A O S
0.50 B-O
STA SW C C N T
K C
A9W A9X 0.50B-L A3K
B
(10+) 10A (10LD) (B) A3L(ACC) 0.50 W-G
ACC
LIGHT1 AHU(M2) 0.50 B-Y
M
A8G
A0D
(S+)
(S+)
A0Y C01 A3J(ST) 0.50 W-R
A0F
A8J
2.00 B-Y
(B)
(B)
ST
5A (12LD) (S+)
LIGHT2
A10 C05
3 4
b
1
A8K
(LD)
A8H
(S-)
A0G
(LD)
A0E
(S-)
5A (13LD) (S+)
BUS BAR No.2

AEL
(BUS1)BUS BAR No.1 (BUS2)
CAB SIDE WIRING
2.00 B-Y
5A 10A
3.00 R-W
P-BAT1
P-BAT2
BUS BAR No.4
(1H+)
(16+)
(17+)
(19+)
(73+)
ABW
A5Q
A9Y
AA2
A15
10A 5A 5A 15A 15A 5A 10A 10A 10A

0.50 G-W
A2B
(64LD)
A2A
(65LD)
PWR ACC
STARTER
PWR RLY
METER
WIPER
WIPER
%B0
RADIO
U2 (M)
HORN
(FUSE)
2.00 W-R
0.30 B-R
2.00 B-Y
AGK (PAC1)
D5D (VLP+)
A16
(16LD)
A9Z
(17LD)
AA3
(19LD)
A5R
(73LD)
ABX
(1HLD)
AA5
(1ALD)
AAD
(1FLD)
AAF
(1GLD)
AA7
(1BLD)
(FUSE)
K4C (SSWS)
N6D (CL2+) (M/T)
H9Z (PWR)
H01 (IR+)
E01 (M+)
SPARE
%B1
U03 (B)
0.50 B-O
NWM (A450)
FUSE
c d 30A
N57 (LCT)
H44
NJZ (MD)
(+)
3.00 B-R
f g h i j k
ae af #BH (AIR) (FLS+)

ag ah ai aj
#F4 (HYD) S1V
ad
(+24V)
(NO+)
(VV1)
#A3 G4H
#A7 CD7
#A8 C7N
#AA K9G
(+B)
#A2 H78
#A5 C03
(B)
(B)
e
MAIN W/H
#AH
#AG
#AE
#A1
#A4
#A6
FR W/H
#AH
#AG
#A1
#A2
#AE
#A3
#A4
#A5
#A6
#A7
#A8
#F4
#BH
#AA
0.50 B-O 0.50 B-L

3.00 R-W 3.00 R-
60A TAIL A30 (LD)
3.00 W-L
#3Q (24) (+)A37 40A HTR A38 (LD) 3.00 W-L
ak
#3P (23) (ALT)AJG 140A ALT AJF (BAT) 15.00 B-R
CHASSIS SIDE WIRING
al
3.00 W- 3.00 W- P/W 30A
(LD)A36 STRT A4M (LD) (B) A3V
60A aq
3.00 W-G 3.00 W-G (LD)A2U MAIN2 40A H-LP A2Y (LD) 2.00 W-R 2.00 B-W
40A
S05 (B) (LD)A2W ABS 30A MAIN1 A2S (LD) 3.00 B-R 3.00 B-R
am 40A
2.00 W-R 2.00 W-R (LD)A34 ACC 30A STOP LIGHT A12 (14LD)
10A
3.00 B-Y 3.00 R- (LD)A32 P-BAT 40A TURN A0W (11LD)
15A AE0 (91LD)
L32 L33 2.00 L-R AHY AHX 2.00 L-B (62LD)A24 20A ABS (LIVE)
(F/SH)
SBU (NO)
1.25 B-
(F/FH) (LD) (B) FUEL HEATER 10A U2. MAIN au BRK-S

AHV A1E (31LD) (B) K7M 5A A18 (MTM) SBH
10 AHW
(S-) (S+)
AIR BRAKE:15A
ar av SBL (MT+) A17
(21+) HYD-S (21LD)
ax
HYDRO BRAKE:30A 15A ROOM LIGHT A22 (61LD)
S06 (LD) A19 5A A1A (MTM) SBV
9 15A U2. ACT A1G (32LD) (B) KBJ
as
aw
(22+) (22LD)
ay
&1E 3.00 B-
an 10A ATM(LIVE) A26 (63LD) (BAT1) N3A
(CAS2) at
ao
A4V (S) 8 (LD)A4K GLOW 60A (MD:N1K)
SBT (B) (+)A3B BRK

ap 140A
SAPH12Z030200013
A POWER SUPPLY CIRCUIT

1 Fuse and relay block B a To Head light
2 Starter switch b To Head light
3 Power accessory relay c To Spare power source (Live)
4 Power relay No.1 d To Van switch
5 Power relay No.2 e To Starter relay exciter
6 Tail light relay No.1 f To Cigarette lighter, Radio
7 Tail light relay No.2 g To Wiper
8 Relay block No.2 h To Common rail (M)
9 Power accessory relay No.2 i To Wiper and washer
10 Fuel filter heater sensor j To Horn
11 Power relay No.3 k To Meter & Fuel filter level sensor
A
2.00 W-G
2.00 B-Y
BUS BAR No.3 1
3.00 R-W AEM
(BUS3)
A0Y 0.50 B-R 0.50 B-R

ac
(12LD)
C14
(S+)
AOM
A0H
C4Y
(S+)
(S+)
A0K
AOP
C16
C50
(S+)
(B)
(B)
(B)
(B)
5 6 7 11
A0L
(LD)
A0J
(S-)
C17
(LD)
C15
(S-)
C51
(LD)
C4Z
(S-)
AOQ
(LD)
AON
(S-)
0.50 G-R
BUS BAR No.4
y z aa
(51+) 3.00 W-R
C4F 0.50 G-R
A5A 3.00 B-R
0.85 B-L
AEN (BUS5)
(15+) (B)
(LD) C04
(LD) C08
A13 C03
BUS BAR No.6
(41+)
(43+)
A1X
A54
(LT)
(52+)
A1Z
ab
(66+)
A2B
5A 5A 10A 10A 10A 10A 10A 10A 15A 15A 5A 5A 20A 15A
0.50 B-
DRY RLY
A5V AIR CON
A1Y DIM RH
10A
ABS(M)
TAIL/LP
ATM(M)
A57 DIM LH
A5T M/HTR
P-TAIL
HEAD
HEAD
A5P AIR/D
P-IGN
A81 B/LP
BRK
RH
A1W LH
(66LD)
AAB
(1DLD)
AA9
(1CLD)
N38 (IG1) (LCT) ABV

NWN(A450) (1ELD)
A55
(41LD)
(42LD)
(43LD)
(44LD)
(71LD)
(72LD)
(74LD)
A14
(15LD)
A20
(51LD)
A5B
(52LD)
(75LD)
A2C
C35 (LOW+)
C30 (LOW+)
AGQ (PTL2)
AGM (PIG1)
(CAB2)
2.00 B- &C2
S1Q (IGN)
SBJ (IGN)
H79 (+IG)
C36 (HI+)
C31 (HI+)
N27(MD)
H64 (+B)
C0L (S+)
NRC (+)
U0C (+)
EC7 (+)
l m n o p q r s t u bb v w x ba
(CAB3)
&C3
A3X (B)
az
(STATER CABLE)
15.00 B-R
(+(3))
(+(1))
(+(2))
AJD
A4B A4A
BATTERY3
BATTERY2
BATTERY1
A49 A48
(BTOB CABLE) (BTOB CABLE)

(-(1))
AJE
(-(3))
(-(2))
(BATT GND CABLE)
BATTERY GND
SAPH12Z030200014
l To Brake ECU (HYDRO MAX) t To Air drier

m ABS ECU (AIR and HYDRO MAX) u To Mirror heater
n To ATM (A450, 2200RDS/2500RDS, 3000RDS) v To DRL relay exciter
o To Head light (Main) RH w To Clearance light, tail light, cab nighttime lighting,
p To Head light (Main) LH ID light, mirror light, rheostat, licence plate light
q To Head light (Dimmer) RH x To Spare power source (Light)
r To Head light (Dimmer) LH y To Head light main relay (Head light)
s To Back light z To Head light dimmer relay (Head light)
DRY RLY H-LP DIM RLY H-LP MAIN RLY PWR1 RLY PWR2 RLY PWR ACC RLY
S- S- S-
COM C06 C02
B LD B LD B LD B B B LD B LD
C0N C0P C07 C08 C03 C04 A0F A0K A0P A0Q A8J A8K S+
S+ S+ S+
A8G
C0L C05 C01
PKB IND RLY A/D
(HYD ONLY) AIR HORN RLY HORN RLY
S- S- S-
EHM ADQ U02
B NC B LD B LD SPARE A/D
EHN EHP ADR ADS U03 U04
S- S+ S+ 15A 72LD
EHL ADP U01 5A A5P
TAIL LP RLY1 B/LP
CAB SIDE WIRING
PKB BZ RLY
(HYD ONLY) A/C RLY HTR RLY S- 10A 10A 71LD
C15 A81
S- S- S- LD M/RR
C17 15A
E9Y G4L G4G S+ 15A 74LD
B NC B LD B LD C14 A5T
20A
E9Z EA0 G4M G4N G4H G4J A/C
PART A
S+ S+ S+ TAIL LP RLY2 5A 75LD
A5T
E9X G4K G4F
S-
C4Z
LD
C51 S+
C4Y
SPASE
FUSE 30A FUSE
HTR MIRR RLY %B0 %B1
S-
H63
+B LD (PART B) PULLER
H64 H65
S+
H62
ATM STA RLY
S-
NJY
B NO
NJZ NK0
S+
NJX 3000RDS
1(1/2)
CHASSIS SIDE WIRING
SAPH12Z030200015
aa To Head light main relay RH aj To Room light, radio (Backup), A/C, crock, DRL con-
ab To Combination switch troller, diagnosis tool
ac To Fuse light ak To Alternator
ad To Power window al To Alternator
ae To Heater am To ABS motor relay
af To Head light main relay (Head light, daytime light) an To Power accessory relay No.2 (Power supply)
ag To Stop light ao To Heater relay (Glow plug)
ah To Turn and hazard light ap To Motor relay (HYDRO MAX)
ai To ABS valve (AIR and HYDRO MAX) aq To Starter relay (Engine starting)
A
(PART B)
ATM NEUT RLY
S-
IGN N0A
10+ 10A 10LD B LD
A9W A9X N0B N0C
LIGHT 1 S+
N09
12LD
5A A0Y
LIGHT 2 DRL 2200RDS/2500RDS

13LD
5A A10
DRL HEAD RH STA P-BAT 1

PART A
15+ 15LD 41LD 41+ 16+ 16LD 64LD
A13 5A A14 A55 10A A54 A15 10A A16 A28 5A
WIP HEAD LH PWR RLY WIP P-BAT 2

1H+ 1HLD 42LD 17+ 17LD 1FLD 65LD
ABW 15A ABX A1W 10A A9Y 5A A9Z AAD 10A A2A 10A
DIM RH ACC RLY HORN
43LD 43+ 19+ 19LD 1GLD 10A
A1Y 10A A1X AA2 5A AA3 AAF
DIM LH RADIO MET
44LD 73+ 73LD 1BLD
A57 10A A5Q 15A A5R AA7 10A
U2 (M)
1ALD
AA5 5A
TAIL ATM(M)
51LD 51+ 1ELD
A20 20A A1Z ABV 10A
ABS(M)
1CLD 5A
AA9
P-TAIL P-IGN BRK
52LD 15A 52+ 66+ 66LD 1DLD
A5B A5A A2B 10A A2C AAB 5A
AT HYD
1(2/2)
SAPH12Z030200016
ar To U2 ECU main relay ax To Cab harness (Monitor module)

as To U2 actuator power relay ay To Cab harness (ABS ECU X2)
at To ATM (3000RDS, 2200RDS/2500RDS) az To Starter (Engine starting)
au To Motor relay (HYDRO MAX) ba To Spare power source (Starter switch ON)
av To Motor relay bb To DRL controller, power window, air conditioner
(DRL: Daytime running light)
aw To ABS motor relay
A
CAB SIDE WIRING
ACC M2
A3L AHU
B ST
A3K A3J
FOR 2200RDS / 2500RDS , 3000RDS

AIR:15A
HYD:30A FOR HYD-MAX
ROOM LIGHT
STOP LIGHT
LD LD LD
U2.MAIN
A4M A2Y A2S
U2.ACT
14LD 11LD 91LD 31LD 61LD 32LD 63LD
TURN
ABS
ATM
A12 A0W AE0 A1E A22 A1G A26
START
BAT
MAIN
H-LP
60A
40A
40A
AJF
10A
15A
10A
15A
15A
10A
LD LD
A30 A38
GLOW
140A
BRK
140A
60A
HTR
TAIL
60A
40A
ALT
LD +
A4K A3B
FUEL HTR
20A
MAIN2
P-BAT
ACC
ABS
P/W
30A
40A
30A
30A
40A
+ ALT
A37 AJG 62LD HYD
LD LD LD LD LD A24
CHASSIS SIDE WIRING
HYD A36 A2U A2W A34 A32 S-

AHW
C BRK-S S-
A3W B LD
21LD 5A 21+
B S04 AHX AHY
NK3 B LD
SW E A18 A17 HYD S05 S06 S+ S+
A3T A3U NO AHV
HYD-S NK4 S03
B 22LD 5A 22+ S+ S- ABS MTR RLY PWR ACC2 RLY
A3V A1A A19 NK1 NK2
S-
ST RLY AT B/LP KBH
RLY B LD
KBJ KBP S+
F B KBG
A4W K7M U2 ACT RLY
SW L E
A4X A4Y K7N
S+ S-
S K7K K7L
A4V
U2 ECU
HTR RLY MAIN RLY
FOR A450 , 2200RDS / 2500RDS , 3000RDS
8
F/FH F/SH
L32 L33
CONNECT
AND SUPPLY
10
CONNECT
AND SUPPLY
82586-1070 82560-3840
SAPH12Z030200017
B C
To Fuse starter
To Fuse starter
(Power supply)
(Power supply)
Sub starter
Sub starter
%B7
(STA)
%B7
(STA)
A16
A16
(16LD)
(16LD)
CL2+
N6D
0.50 W-
0.50 W-
CL2-
N6E
CAB SIDE WIRING
1 0.50 W-B
(CL2+)
N6D
(S+)
NJX
NJZ
(B)
1 1
NJY
(S-)
NK0
(N0)
N6E
(CL2-)
0.50 W-B
0.50 B-R
0.50 B-
0.50 W-B %DA 0.50 W-B %DA
(JC) To U2 J/C (JC) To U2 J/C
0.50 W-B %DB (Common rail) 0.50 W-B %DB (Common rail)
(JC) (JC)
(G3JC)
(NRF)
%DY
&E4
#AB
#AB
To U2 J/C J/C (G3)
MAIN W/H (Common rail 4) MAIN W/H
0.50 W-B #AB
FR W/H FR W/H
0.50 W-B #AB

NWL To NSS
(NSN) (A450)
To A4M 3.00 B- To A4M 3.00 B-

FL Starter FL Starter
(SW)
(LD) CONNECT (LD) CONNECT

CONNECT AND SUPPLY CONNECT AND SUPPLY
(SW)
A3V
A3V
A3T
A3T
AND SUPPLY AND SUPPLY

(B)
(B)
C C
A3Y A3Y
2 2
CHASSIS SIDE WIRING
8.00 B-R A3W

(C)
A3U
(E)
A3W
(C)
A3U
(E)
82586-1070 82586-1060 82586-1070 82586-1060

3 (LDT) (MDT) 3 (2200RDS/2500RDS) (3000RDS)
8.00 B-R
STARTER CABLE STARTER CABLE

A3Y
A3Y
0.50 B-
0.50 B-
A48 A3X A48 A3X

To Battery 2 To Battery 2
(+(1)) (B) (+(1)) (B)
3 &1E 3.00 B- AHW 3 &1E 3.00 B- AHW

G3 G3
(CAS2) (S-) (CAS2) (S-)
Engine GND Engine GND
SAPH12Z030200018
B ENGINE STARTING CIRCUIT-1 : MODELS EQUIPPED C ENGINE STARTING CIRCUIT-2 : MODELS EQUIPPED
WITH EATON FS SERIES MTM AND AISIN A450 ATM WITH ALLISON 2200RDS/2500RDS AND 3000RDS
ATM
1 ATM starter relay
1 Clutch interlock switch 2 Starter relay
2 Starter relay 3 Starter
3 Starter
D
a b c d e f g h i j k
C0P
(LD)
CJ4
(E)
C4E
(EL)
EC9
(GND)
C4L
(EP)
C4M
(BT)
H45
(-)
H4B
(EW)
C49
(HF)
H05
(IR-)
C7W
(E)
2.00B-
2.00B-
G03
(BSW)
D5F
(VLI-)
H63
(S-)
AEN
(BUS5)
KD3
(CIL-)
H7G
(E)
C23
(RCL-)
H4Z
(HMI-)
H9T
(RH-)
L2X
(SRI-)
H9R
(LH-)
G23
(GND)
G0H
(GND)
l m n o p q r s t u v w x
y z aa ab ac
CAB SIDE WIRING
I0B
(GND)
S2B
(G45A) (GND)
K0D
(G45A) (CASE)
E1C
(G45A) (PCE)
K4X
(AT)
1
(G45A)
&D5
&D3
&D2
&D1
(CAB1)
(CAB2)
(RAD)
&CA
&C1
&C2
J/C (G4.G5-a)
&DC
(G45A)
ah ai aj ak al
E1W
(E)
S02
(-)
K0B
(CGD1)
K2G
(GND)
E07
(MGE)
CAB GND DR 1 CAB GND DR 2 G3-AUDIO

0.85BR-
am an ao
NPE
(GND1)
NPY
(GND2)
K1V
(PGD1)
K9H 0.85BR-
To DST-1
(SGND)
#G1
#G2
#G3
CAB GND (G3)
#G2
#G3
#G1
&C5
(CAB5)
2.00BR-
2.00BR-
2.00BR-
2.00BR-
& 1D (G4-A)
N3C
(GND2) ap
N3B
(GND1)
CHASSIS SIDE WIRING
Weld splice (G4-a) NXC

aq
(SPS-)
E1A
ar
(SPS-) aw
N1J
(GND2)
AHW
as
N1H
(GND1)
E22
at
(FSDE)
3.00B-
KVA
au
(VNTG)
E20
av
(WLE)
3.00B- &1G
Chassis frame
3.00B-
Fr
(CAS1)
(CAS2)
(CAS2)
&1A
&1B
&1E
&1H
(CAS4)
CHASS GND (G3) CHASS GND (NO1/C) To BATT CABLE- CHASS GND CHASS GND
SAPH12Z030200019
D GROUND CIRCUIT
1 Junction connector (J/C) earth j To Wiper relay (Wiper and washer)
k To Stop and turn controller (Stop and turn)
a To DRL relay (Head light) l To Electric thermo sensor (Manual A/C)
b To DRL ECU (Head light) m To Van light switch (Spare power source)
c To Light and turn switch (Head light) n To Heater mirror relay
d To Rheostat (Meter) o To Wiper relay (Power supply)
e To Light and turn switch (Head light) p To Auto cruise switch (Common rail)
f To Turn switch (Turn and hazard) q To Drives seat master switch (Power window)
g To Cigarette lighter (Cigarette lighter) r To Identification light (Head light)
h To Wiper switch (Wiper and washer) s To Mirror heater switch (Mirror heater)
i To Wiper switch (Turn and hazard) t To Heater back mirror RH (Head light)
2.00B-
2.00B-
2.00B-
(G3JC)
&E1
J/C (G3)
(CAB3)
(CAB4)
&C3
&C4
&E4
(G3JC)
&E5
(G3JC)
&E6
(G3JC)
&EA
(G3JC)
EATON, 2200RDS
/2500RDS, 3000RDS
CAB GND P2 CAB GND P1
AT 2200RDS/2500RDS
(N/C-)
MD
(AT+)
E2M
N5E
NJY
N5F
(E2)
U08
U06
(S-)
G45A G45A G45A G3JC

&D1 &D2 &D3 &E6
G45A G45A G3JC G3JC G3JC G3JC

ad ax ay ae af ag &DC &D5 &E4 &E5 &E1 &EA
Rr
2.00B-
(CAS3)
(CAS3)
&1C
&1K
CHASS GND (R/AX) CHASS GND (END/C)
SAPH12Z030200104
u To Set resume switch (Common rail) aj To U2 ECU

v To Drives seat master switch (Power window) or ak To Diagnosis connector (9P)
Heater mirror LH (Head light) al To Combination meter
w To Blower switch (Manual A/C) am To AISIN A450 ATM
x To Air conditioner switch (Manual A/C) an To AISIN A450 ATM
y To Audio main (Audio) ao To U2 ECU
z To ABS ECU (ABS full air &ABS HYDRO MAX) ap To ALLISON 2200RDS and 2500RDSATM
aa To U2 ECU (Common rail) aq To Speed sensor (EATON MTM)
ab To Pulse converter (Meter) ar To Speed sensor (AISIN A450 ATM)
ac To U2ECU as To ALLISON 3000RDS ATM
ad To ATM starter relay at To fuel sender
ae To ATM mode switch au To Vent control (U2 ECU)
af To Perking brake switch av To Coolant level switch
ag To ALLISON 3000RDS ATM selector aw To Power accessory No.2
ah To Cool warning relay ax To Horn (Lo)
ai To ABS diagnosis switch ay To Horn (Hi)
E F
To U2 ECU To Meter
(Common rail) (Charge light)
KVP
(GRY2)
E0D
(MCHG)
CAB SIDE WIRING
0.30 W-
#AD
#AC
MAIN W/H MAIN W/H

FR W/H FR W/H
#AD
#AC
0.50 B-W
0.50 B-W
To
FL Alanator
8.00 B- A37 (+)
8.00 B- (ALT)
A4K 3.00 B-L

AJG
To
0.50 W-
0.50 W-
FL GROW
(LD)
(SW)
A4V
A4X
(S)
CHASSIS SIDE WIRING
1
#3K
#3Q
A4W
(F)
A4Y
#3P
(L)
Engine wire harness RH

2
3.00 B-R
#3Q
#3P
#3K
A43
(L)
B
0.85 B-
A4Z A40
A4Z
1
(B)
(B) ALTERNATOR
%12
2 2 (B) HEAVY DUTY
Altenator sub harness
23 24
&1E 3.00 B- AHW #3P #3Q
G3 To Rear
(CAS2) (S-) harness
CHASS GND (CHASS
Engine ground
(Body earth)
(NO.1) GND R/AX) Altenator body 2
SAPH12Z030200021
E GLOW PLUG CIRCUIT F CHARGING CIRCUIT

1 Heater relay 1 Alternator
2 Glow plug

To FUSE P-BAT2 To FUSE P-BAT1 To FUSE P-TAIL To FUSE P-IGN

A2A
(65LD)
A28
(64LD)
A5B
(52LD)
A2C
(66LD)
1.25 W-L
1.25 W-
1.25 G-
0.85 L-
CAB SIDE WIRING
(VLP+)
D5D
OFF
1 ON
(PAC1)
(PIG1)
D5E
(VLP-)
D5F
(VLI-)
AGM
AGK
VLP-
D5E
VLI-
D5F
VLP+
D5D 2 PAC1 3
1.25 W-
PIG1
1.25 B-
AGK AGM
1 2 3
&C2 2.00 B- &C3 #AF
(CAB2) (CAB3)
#AJ
MAIN W/H
FR W/H
#AF
#AJ
PTL1
AGP
5
1.25 W-L
1.25 W-L
1.25 W-
1.25 W-
CONNECT
AND SUPPLY
CHASSIS SIDE WIRING
FR W/H RR W/H
CAP 1.25 W-L #16 #16
82585-1270
1.25 W-L
PSW1 No.3 Crossmember End Crossmember

AM6 PTL2
(PTL2)
(PTL1)
(PSW1)
AGQ
AGQ
AGP
AM6
4 CONNECT 6
AND SUPPLY CONNECT
AND SUPPLY
4 6 5
CAP
CAP
82585-1270
82585-1270
SAPH12Z030200022
G SPARE POWER SOURCE CIRCUIT

1 Van light switch 6 Spare power source (Tail) 2
2 Spare power source (Battery) 7 Spare power source (Back)
3 Spare power source (Starter switch ON) 8 Spare power source (Side turn LH)
4 Van light connector 9 Spare power source (Side turn RH)
5 Spare power source (Tail) 1
MAIN W/H
FR W/H
TO BUCK LIGHT SWITCH TO STOP & TURN CONTROLLER
( 10 )
#LA
(9)
(NO)
#L9
NK4
NRD
(-)
MT AT
#15
0.50 B -W
0.50 B -W
0.50 B -R
0.50 B -R
FR W/H
RR W/H
#15
BLP+
AP8
#26
#27
(B)
(B)
STL+ STR+
0.50 B -W
0.50 B -W
0.50 B -R
0.50 B -R
AP9 APA
TO FR TURN RH
CONNECT
TO FR TURN LH
AND SUPPLY
7
8,9 CONNECT
1.25 O-
AND SUPPLY
CAP
(BLP+)
1.25 O-
82585-1270
C1Q
(STR+)
(STL+)
APA
AP9
82584-1640
TO BACK LIGHT RH
8 9
(BLP+)
AP8
SAPH12Z030200023
H
b c d e f as g i j k l m
KD2
(CIL+)
G0G
(IND+)
G5Y
(P1)
I0A
(ILLM)
L2W
(SRI+)
#AA
(10)
AA7
(1BLD)
E2J
(N/O+)
#MG
(16)
C17
(IND)
KVQ
(GLOW)
3
(LIGHT)
(GND)
0.85 W-G
0.50 W-G
0.50 W-B
(+)
%CE
(FUSE)
0.50 W-B %CB
(FUSE) n o
EC9
EC8
EC7
%CD
(FUSE)
C88
(TLPL)
C87
(TLPR)
0.85 W-R A20
a
(51LD)
(+24V)
0.85 B-
K9G
0.85 W-R h
0.85 R- 0.50 R-
(MM+B) E4Q
(MTUL) E0Q
(MTUR) E0R
(MPRH) E0S
(MHBM) E0T
1
(MI+) E04
(M+) E01
(SP+) E1J
G3
&C1 2.00 B- &C4
(CAB1) (CAB4)
0.50 W-B
For ALLISON
2200RDS/2500RDS ATM A A SP F T
6 3000RDS ATM
CAB SIDE WIRING
and EATON MTM

0.50 W-B
0.50 W-B
E1B
TM
(PC+) E1D
Low fuel level
High beem
E7F (PCO+)
Pre heat
Turn RH
Turn LH
(PCO4)
E1F
(PC1+)
0.50 BR- E1C
(PCE)
0.50 Y-
(MWTT)
(MARR)
(MARE)
(SPMP)
(MARF)
(MAR+)
(MFLS)
(MTM)
(MGE)
(VPLS)
(VPLS)
(G45A)
(ME)
(E7F)
%DR
NXD
NXE
&D2
E1N
E6R
E6U
E0A
E6S
E6E
E6T
E6F
E07
E02
p 0.50 Y-L
q r s 0.50 W-B
0.50 Y-L 0.30 G-Y
0.50 BR-
0.50 BR-
0.30 B-Y
(TACH)
0.30 Y-G
0.30 Y-R
0.30 Y-B
E1V
(NE+)
8
0.30 Y-
NPN
(+)
ao
K0Z
To U2 ECU
0.50 Y-R
E1
1X
0.85 BR- K9H
(SGND)
t u
(LD)
LSW)
E1W
0.30 V-R E1Y
(E)
0.50 Y- %DE
E
(WL
(JC)
NPQ %DG 0.30 BR-
am
(SP1) (JC) 7 0.30 BR-
(GND1)
0.50 Y-
(0233)
%DF
#G1
#P2
(JC)
#MC
#MA
#MB
#M5
#M6
#M7
#M8
#M9
#M1
#M2
an ap
#M5
#M6
#M7
#M8
#M9
#MA
#MB
#MC
#M1
#M2
CHASSIS SIDE WIRING
&1D
(G4-A)
(FSD+)
ar
E21
&1D
0.50 BR-
(SPS+)
(SPS-)
(G4-A) L4F
NXC
NXB
14
(ASRS)
(SPSP)
(ASR+)
(ASFS)
(SPS+)
(SSP2)
(ASF+)
(ASR-)
(SPS-)
(ASF-)
(WLE)
(WL+)
E6W
EED
E1A
E6X
E6V
E6Y
E6Z
E1Z
E18
E19
E70
E20
(G4-A)
E22
(G4-A) (FSDE)
&1D
10 Pulse converter is used

&1D
for 2200RDS/2500RDS W/S

11 ATM, 3000RDS ATM 12 13 15 (G4&G5)
and EATON MTM
To W/H (G4&G5)
SAPH12Z030200024
H METER CIRCUIT (CAB SIDE)

1 Combination meter 11 Speed sensor (Except for EATON MTM, Allison
2 Rheostat 2200RDS and 2500RDS, 3000RDS ATM)
3 U2 J/C No.1 12 Air gauge sensor front (For full air brake)
4 Warning buzzer 13 Air gauge sensor rear (For full air brake)
5 Parking brake switch 14 Fuel sender
6 Pulse converter (For ALLISON 2200RDS/2500RDS 15 Coolant level switch
ATM, 3000RDS ATM, EATON MTM) 16 Fuel filter level sensor
7 U2 J/C 17 Oil pressure switch
8 Coolant warning relay 18 Low pressure switch No.1 (For full air brake)
9 U2 J/C 19 Low pressure switch No.2 (For full air brake)
10 Speed sensor (For EATON MTM) 20 Spring brake switch (For full air brake)
Fuse radio
73LD
A5R
1.25 W-L H44 Cigarette
For center
parking brake (+) lighter
U2 J/C 1
(Meter)
0.85 W-L
0.50 W-B
0.50 W-B
0.50 W-B
4
0.30 Y-B E2H E2G
(WBZ) (WBZ+) 24
(MFFL) EDM
(S+)
E9X
(MBZ) E03
(B)
E9
0.85 W
0.50 W
22
EAO
E9Y
(S-)
(NC)
0.50 Y-
Weter level warning
EHN
EHL
Brake pressure
Motor indicator
Cheak engine
Parking brake
Range inhibit
A/T Oil temp
Oil pressure
Air pressure
Boost alarm
23
Auto cruise
Check A/T
Fuel level
0.50 W-G
O/D Off
Charge
Cruise
0.85 W-R EHM
EHP
(S-)
(NC)
ABS
0.50 W-G
CAN
(N/O+)
E2J
0.50 Y-
(MCHG)
(MENG)
(MODF)
(MCRS)
(MTCR)
(MMT+)
(MABS)
(MOLP)
(MAOT)
(BRKP)
(MCAT)
(MPAK)
(MINH)
EE6 (MTR-)
(MMT-)
(MWL)
(MIIR)
5
E4M
E4L
0.50 B-
0.85 B- E2K
(N/O-)
SBE
E0V
0.50 V-W E88
E0D
E2Y
E66
E61
E5X
E0M
E0K
E0H
E0F
EE7
E0E
al
(BTS) E0W
0.50 Y- (MTWL)
Twist Twist
Twist Twist
(TEMP)
(TEMP)
(DGLP)
(CRLP)
(FSLP)
(CE/G)
0.60 Y-R
(CHK)
(CHK)
(IHT)
(WL)
NQ8
N1U
NPT
N1S
S1S
N32
N30
N31
A43
K50
K53
K0L
0.30 V-
(L)
ah
(DPS+)
SBP
(G3JC)
0.30 Y-R L2Z
(OLSW)
v w x y z aa ab ac ae af
ad
&EA
(CAN+)
(CAN-)
(CAN)
(CAN)
(PKB)
0.50 Y- (PKB)
%BB
%BL
#CG
#CH
ag
CJC
CJC
9 J/C G3
0.30 Y-R %C1 (Ground)
CJB (+B) ai aj ak
aq %C2
(CHG-)
(BRL) 0.50 W-B %CE
0.50 P- U2 J/C 1
(Meter)
#MG
(FUSE)
#MH
#MD
#ME
#MF
#M4
#MH
#M4
#MD
#ME
#MF
#MG
(PSW+)
(BSW+)
(SW1+)
(SW2+)
(OIL+)
E2R
E2N
E2U
E2P
E2V
(F/FG)
(F/FS)
(F/FF)
L4D
L4E
L4F
17 18 19 20 21
E3J
(SW1-)
E3K
(SW2-)
E7U
(PSW-)
E7T
(BSW-)
16 Body ground
&1A 0.30 B- &1B
G3 To RR/H
(CAS1) (CAS2)
&1C 2.00 B- &1K
R/AX G3 End/C
(CAS3) (CAS3)
SAPH12Z030200025
21 Buzzer off switch (For full air brake and wheel park- f To set resume switch (Common rail)
ing) g To Front harness fusible link room light (Power sup-
22 Parking brake buzzer off relay (For center parking) ply)
23 Parking brake indicator off relay (For center park- h To Diagnosis connector (16P)
ing)
24 Parking brake off diode (For center parking) i To Fuse meter (Power supply)
j To Parking brake switch (Meter)
a To Fuse tail light (Power supply) k To Buzzer off switch (Meter)
b To Auto cruising switch (Common rail) l To DRL ECU (Head light and tail light)
c To A/C switch (Manual A/C) m U2 ECU (Common rail) (For grow plug only)
d To Blower switch (Manual A/C) n To Turn LH, stop and turn controller (Stop and turn)
e To Audio (Audio) o To Turn RH, stop and turn controller (Stop and turn)
+ GND LIGHT
SPMP MTM MI+ M+ MM+B EC7 EC9 EC8
E1N E0A E04 E01 E4Q
ME MGE MARE MFLS MWTT MARF MARR MAR+

E02 E07 E6S E6E E6F E6T E6U E6R 2
1-1
FULL AIR FULL AIR
HYD A450 HYD

3000RDS, 2200RDS
/2500RDS, EATON
CAB SIDE WIRING
MCHG MABS MTR- BRKP MPRH

E0D E0K EE6 EE7 E0S KUY KUX #UG KUV KUW #UP L2J L2H K2X #PA
%AA %AB %AC %AD %AE %AF %DN %DM %DL %DP
MWL MMT+ MMT-
E88 E4L E4M KRY #UY KTU KRB KTR #U4 FUSE FUSE FUSE
%AG %AH %AJ %AK %AL %AM %CB %CD %CE
1-2 JC JC JC K6D K6E #P5 JC JC JC

%D1 %D2 %D3 %AN %AP %AQ %D7 %D8 %DA
AT
2200RDS/2500RDS, 3000RDS
3
2200RDS/2500RDS, 3000RDS
WBZ+ WBZ-
SPI+ MOLP MCAT MTCR MCRS MBZ MFFL MTUR E2G E2H
E1J E0H E0V E61 E5X E03 EDM E0R
MINH MODE MAOT MENG MHBM MIIR MPAK MTUL

E2Y E66 E0W E0M E0T E0F E0E E0Q 4
1-3
A450 AIR
2200RDS/2500RDS
CHASSIS SIDE WIRING
SAPH12Z030200026
p To U2 ECU (Common rail) z To ATM ECU TCM-J1 (2200RDS/2500RDS ATM)

q To ATM ECU TCM-J1 (2200RDS and 2500RDS ATM) aa To Alternator (Power source)
r To ATM ECU-V (3000RDS ATM) ab To ATM ECU TCM-J1 (2200RDS/2500RDS ATM)
s To J/C (G4 and G5 ground) ac To A450 ECU O/D off (A450 ATM)
t To U2 ECU (Common rail) ad To U2 ECU (Common rail) (For auto cruise)
u To ATM ECU (A450 ATM) ae To U2 ECU (Common rail)
v To ATM ECU-V (3000RDS ATM) af To ECU X1 (ABS)
w To ATM ECU TCM-J1 (2200RDS/2500RDS ATM) ag To Differential switch (HYDRO MAX)
x To ATM ECU (A450 ATM) ah To U2 ECU (Common rail)
y To ATM ECU-V (3000RDS ATM) ai To A450 ECU (Diagnosis connecto)
+
E1V
LD WLSW E
N/O- N/O+ E1X E1Y E1W
E2K E2J
8
5
PCO+ PCO4 PC+

E1D E7F E1B
PC1+ PCE
E1F E1C
A450
A K A
KLJ KLK KLL
JC JC JC JC JC JC JC JC JC
%DB %DC %DD %DE %DF %DG %DH %DJ %DK 24
K45 NRF NTSW K2Y K46 E7F K6L
%DW %DY %DX %DU %DT %DR %DS
1.5A
+B DRL
%C1 %C2
EATON
7,9 85902-1210
SAPH12Z030200027
aj To 2200RDS/2500RDS ECU or 3000RDS ECU ao To DST-1

ak To DRL ECU (Daytime) ap To Water temperature sender (Common rail)
al To Monitor module (HYDRO MAX) aq To DRL ECU (Head light and tail light)
am To ATM ECU (A450 ATM) ar To Weld splice (W/S) (G4 and G5 ground)
an To Front wiring harness
I
b c d e f as g i j k l m
3
%CE
(FUSE)
(LAMP)
(GND)
2 %CB
(+)
(FUSE) n o
%CD
(FUSE)
EC9
EC8
EC7
(+24V)
K9G
h
0.50 R-
(MM+B) E4Q
(MTUL) E0Q
(MTUR) E0R
(MPRH) E0S
(MHBM) E0T
1
(MI+) E04
(M+) E01
(SP+) E1J
G3
&C1 2.00 B- &C4
(CAB1) (CAB4)
0.50 W-B
A A SP F T
6
CAB SIDE WIRING
0.50 W-B
0.50 W-B
E1B
TM
(PC+) E1D
Low fuel level

(PCO+)
High beem
E7F
Pre heat
Turn RH
Turn LH
(PCO4)
E1F
(PC1+)
E1C
(PCE)
p q r s
(MWTT)
(MARR)
(MARE)
E1N (SPMP)
(MARF)
(MAR+)
(MFLS)
(MTM)
(MGE)
(ME)
0.50 Y-R
E6R
E6U
E0A
E6S
E6E
E6T
E6F
E07
E02
To U2 ECM ao
E1V
8
(+)
K9H
(SGND)
%DE
0.50 Y-R
(JC) E1X
%DG t u ap
am
(JC) 7 (LD)
(WLSW)
E1Y
E1W
(E)
%DF
#MC
#MA
#MB
#M5
#M6
#M7
#M9
#M1
#M8
(JC)
an
#M2
#M9
#M5
#M6
#M7
#M8
#MA
#MB
#MC
#M1
#M2
&1D
0.85 BR-
(G4-A)
0.50 Y-G
0.50 B-Y
0.50 B-Y
0.85 Y-R
0.50 Y-R
ar
0.50 Y-B
&1D
(G4-A)
CHASSIS SIDE WIRING
0.50 BR-
0.50 V-R
0.50 W-B
0.50 BR-
(FSD+)
0.50 Y-R
0.50 Y-
0.50 G-
#1H
#1K
0.50 Y-
#1J
E21
FR W/H
0.50 Y-R
0.50 Y-B
RR W/H
0.50 Y-
For 14
E70 0.50 Y-G #1H
#1K
E6Z 0.50 Y-R #1J
EATON 0.50 W-B 0.50 BR-

MTM
(FSDE)
E22
E6Y 0.50 Y-B
(SPS+)
(SPS-)
(WLE)
(WL+)
NXB
NXC
E1Z
0.50 BR-
E20
(ASRS)
(ASR+)
(ASFS)
(SPS+)
(SSP2)
(SPSP)
(ASF+)
(ASR-)
(SPS-)
(ASF-)
Except for LCT ATM

E6W
(G4-A)
EED
E1A
E6X
E6V
E18
E19
or MD ATM
&1D
orEATON MTM For Air brake

15
10
(G4-A)
Pulse converter is used W/S

&1D
11 for LCT2400/2000
ATM,MD3060P ATM 12 13 (G4&G5)
and EATON MTM

To W/H (G4&G5) 0.50 W-B
SAPH12Z030200028
I METER CIRCUIT (CHASSIS SIDE)

1 Combination meter 11 Speed sensor (Except for EATON MTM, Allison
2 Rheostat 2200RDS and 2500RDS, 3000RDS ATM)
3 U2 J/C No.1 12 Air gauge sensor front (For full air brake)
4 Warning buzzer 13 Air gauge sensor rear (For full air brake)
5 Parking brake switch 14 Fuel sender
6 Pulse converter (For ALLISON 2200RDS/2500RDS 15 Coolant level switch
ATM, 3000RDS ATM, EATON MTM) 16 Fuel filter level sensor
7 U2 J/C 17 Oil pressure switch
8 Coolant warning relay 18 Low pressure switch No.1 (For full air brake)
9 U2 J/C 19 Low pressure switch No.2 (For full air brake)
10 Speed sensor (For EATON MTM) 20 Spring brake switch (For full air brake)
EL02_001.fm 29 ページ２００６年２月１３日　月曜日　午後４時２分
Fuse radio
73LD
U2 J/C 1
A5R
(Meter)
E2H 4 E2G H44
(+)
Cigarette
lighter
(WBZ) (WBZ+)
(S+)
E9X
24
(B)
E9
(MFVL) EDM
(MBZ) E03
22
E9Y
(S-)
EAO
(NC)
EHN
EHL
Weter level warning
Brake pressure
23
Motor indicator
Cheak engine
Parking brake
Range inhibit
A/T Oil temp
Oil pressure
Air pressure
Boost alarm
EHM
(S-)
EHP
(NC)
Auto cruise
Check A/T
Fuel level
O/D Off
Charge
Cruise
ABS
(N/O+)
E2J
CAN
5
E2K
(N/O-)
(MCHG)
(MENG)
(MODF)
(MCRS)
(MTCR)
(MMT+)
(MABS)
(MOLP)
(MAOT)
(BRKP)
(MCAT)
(MPAK)
(MINH)
EF6 (MTR-)
(MMT-)
(MWL)
(MIIR)
(G3JC)
E4M
E4L
&EA
E0V
E88
E0D
E2Y
E66
E61
E5X
E0M
E0K
E0H
E0F
EE7
E0E
al
E0W
J/C G3
aa ab ac ae af ah (Ground)
ad
(OLSW)
KVQ
0.30Y-R
v w x y z
ag 9 ai aj ak
%CE
(FUSE)
U2 J/C 1
(Meter)
aq %C1
(+B)
#MG
#MH
#MD
#ME
#MF
#M4
%C2
(BRL)
#MH
0.50 Y- #M4
#MD
#ME
0.50 W-G #MF
0.50 W-B #MG
0.50 V-
0.50 Y-R
3.00 B- &1A
(CAS1)
0.50 Y-
0.50 V-
0.50 P-
ENG/H FR W/H
#1G
#43
#1M
#1N
#1P
(CAS2)
0.50 B-
FR W/H
%1B
RR W/H
RH
(SW1+)
0.50 W-B
#43
#1G
#1M
#1N
E2N
#1P
0.50 V-
0.50 Y-
(PSW+)
(BSW+)
(SW2+)
(OIL+)
E2R
E2U
E2P
E2V
18
(F/FG)
(F/FS)
L4D
L4E
L4F
(SW1-)
17 19 20 21
E3J
0.50 B-
0.50 B- E3K
(SW2-)
E7T
(BSW-)
0.50 B- E7U
(PSW-)
16 Body ground 0.50 W-G

&1A 0.30 B- &1B
G3 To RR/H
(CAS1) (CAS2) &1C 2.00 B- &1K
R/AX G3 End/C
(CAS3) (CAS3)
SAPH12Z030200029
21 Buzzer off switch (For full air brake and wheel park- f To set resume switch (Common rail)
ing) g To Front harness fusible link room light (Power sup-
22 Parking brake buzzer off relay (For center parking) ply)
23 Parking brake indicator off relay (For center park- h To Diagnosis connector (16P)
ing)
24 Parking brake off diode (For center parking) i To Fuse meter (Power supply)
j To Parking brake switch (Meter)
a To Fuse tail light (Power supply) k To Buzzer off switch (Meter)
b To Auto cruising switch (Common rail) l To DRL ECU (Head light and tail light)
c To A/C switch (Manual A/C) m U2 ECU (Common rail) (For grow plug only)
d To Blower switch (Manual A/C) n To Turn LH, stop and turn controller (Stop and turn)
e To Audio (Audio) o To Turn RH, stop and turn controller (Stop and turn)
I
CAB SIDE WIRING
HEAVY DUTY
SPS+ SPS- ASF- ASFS ASF+

NXB NXC E6W E6X E6V
10
12
CHASSIS SIDE WIRING
HEAVY DUTY
SPS+ SPS-
NXB NXC ASR- ASRS ASR+
E6Z E70 E6Y
10
13
SPS- SPS+
E1A E18 FSDE FSD+
E22 E21
SPSP SSP2
E19 EED
11 14
SAPH12Z030200030
p To U2 ECU (Common rail) z To ATM ECU TCM-J1 (2200RDS/2500RDS ATM)

q To ATM ECU TCM-J1 (2200RDS and 2500RDS ATM) aa To Alternator (Power source)
r To ATM ECU-V (3000RDS ATM) ab To ATM ECU TCM-J1 (2200RDS/2500RDS ATM)
s To J/C (G4 and G5 ground) ac To A450 ECU O/D off (A450 ATM)
t To U2 ECU (Common rail) ad To U2 ECU (Common rail) (For auto cruise)
u To ATM ECU (A450 ATM) ae To U2 ECU (Common rail)
v To ATM ECU-V (3000RDS ATM) af To ECU X1 (ABS)
w To ATM ECU TCM-J1 (2200RDS/2500RDS ATM) ag To Differential switch (HYDRO MAX)
x To ATM ECU (A450 ATM) ah To U2 ECU (Common rail)
y To ATM ECU-V (3000RDS ATM) ai To A450 ECU (Diagnosis connecto)
WLE WL+ SW2+ SW2-

E20 E1Z E2P E3K
15 19
PSW+ PSW-
F/FS F/FF E2V E7U
L4E L4F
F/FG
L4D 20
16
SW1+ SW1- BSW+ BSW-

E2N E3J E2U E7T
18 21
SAPH12Z030200031
aj To 2200RDS/2500RDS ECU or 3000RDS ECU ao To DST-1

ak To DRL ECU (Daytime) ap To Water temperature sender (Common rail)
al To Monitor module (HYDRO MAX) aq To DRL ECU (Head light and tail light)
am To ATM ECU (A450 ATM) ar To Weld splice (W/S) (G4 and G5 ground)
an To Front wiring harness as To horn switch (For air horn only)
0.50 B-R A0Y

(12LD)
To light 1
A5V 0.50 R-L #67
2.00 W-R
a b
2.00 W-R
0.50 R-Y
(75LD) (DSW1)
c
DST-1
E0T
(MHBM)
#AA 0.85 W-G K9G
To FR
(13LD)
(10) (+24V)
(S+)
(S+)
C07
C05
C03
C01
A10
(B)
(B)
0.50 W-G
0.30 R-B
0.50 R-L
1 To light 2 2
C04
(LD)
C02
(S-)
C08
LD)
C06
(S-)
3.00 W-B
(L
C
C
(
0.50 R-G
(iND)
CJD
(+B)
CJ5
CJ7
(iG)
A13
RLY
(15LD) (15+)
CAB SIDE WIRING
2.00 W-R
3.00 W-G
3 DRL
A14 CJ8 6
3
+B
12
M
5
IND
CJB
DIM 9
(H-LP) CHG
0.50 R-Y (CHG-)
CJ6
(DIM)
4
MAIN 4 11
CJC
PKB (PKB)
C9C 15
(41+)
(43+)
A54
A1X
RLY
(SBSW) 13 8 7 1 2
LO HI H DRL E
0.50W-G
2.00R-
Dimmer RH
Dimmer LH
3
0.50L-
Head RH
Head LH
CJE
(LO)
CJA
(HI)
CJ9
(H)
CJ3
(DRL)
CJ4
(E)
A55
(41LD)
A1W
(42LD)
A1Y
(43LD)
A57
(44LD)
0.50 R-G
C0N
(S+)
(DL)
C0L
C4J
(B)
0.50R-W
2.00 R-W
ED DL DU EP
2.00 R-G
2.00 R-
2.00 R-B
2.00 B-
5
2.00 R-
HF
6
C0M
(S-)
C0P
(LD)
HL
HU
0.50R-W
C4K
(DU))
C4L
(EP)
#A5
C4H
(ED)
#L2
#L1
#L4
#L3
MAIN W/H
FR W/H
0.50 B-
#A5
#L2
#L1
#L4
#L3
2.00 B-
2.00 R-W
CHW
2.00 R-G
2.00 R-B
2.00 R-L
2.00 W-
2.00 G-
2.00 R-
2.00 R-
(A)
0.50L-B
7
CHX
(K)
#24
#23
#21
#22
(LD)
A2Y
FR W/H FR W/H
CHASSIS SIDE WIRING
n HOOD W/H HOOD W/H

#24
2.00 R-B #23
2.00 R-W #21
2.00 R-G #22
#L5
2.00 R-
#L5
LOW+)
LOW+)
HI+)
HI+)
2.00 R-
2.00 R-
35
36
31
30
C3
C3
C3
C3
(H
(H
(L
(L
LO HI HI LO
17 16
#25
FR W/H
HOOD W/H
C37
(E-)
C32
(E-)
#25
2.00 R-
2.00 R-
SAPH12Z030200032
J HEAD LIGHT AND TAIL LIGHT CIRCUIT (WITH DAYTIME RUNNING LIGHT)
1 Head light dimmer relay 11 ID light LH
2 Head light main relay 12 ID light center
3 Fuse and relay block B 13 ID light RH
4 Daytime running light ECU 14 Roof clearance light LH
5 Daytime light relay 15 Roof clearance light RH
6 Light and turn switch 16 Head light LH
7 Daytime running light diode 17 Head light RH
8 Light and turn switch
9 Back mirror light RH a To Fuse Air con (Power source)
10 Back mirror light LH b To Power window master switch (Power window)
EC7 0.85 W-R A20

f g
(+) (51LD) G3 GND
9
&C3
(CAB3)
MAIN W/H DOOR RH W/H DOOR RH W/H MAIN W/H
#M4 0.50 Y-R E0H 0.85 W-R #61 #61 0.75 W- H9
9S H9
9T 0.75 B- #65 #65 0.85 B-
d e
(4) (MOLP) (RH
H+) (R
RH-)
2.00 B-
#69
(DSW3)
0.85 W-R
0.85 W-R
DOOR LH W/H MAIN W/H
0.50 Y-R
0.75 B- #69 #69 2.00 B-
(CAB2)
h
2.00 B-
&C2
10
E0E
(MPAK)
DOOR LH W/H
MAIN W/H #62 #62 0.75 W- H9
9Q H9R
H 0.75 B-
(LH
H+) (L
LH-)
H7G
(E)
0.50 Y-
MAIN W/H #71 #71 ROOF W/H 0.85 W-R
j i
0.50 Y-
11
0.85 B- C4
45 C44
C 0.85 W-R
E0E
(MPAK)
(ID--) (ID+)
0.50 Y-
12
(N/G+)
E2L
0.85 B- C43 C42

C 0.85 W-R
(ID--) (ID+)
l
13
0.50 Y-
0.85 B- C4
41 C40
C 0.85 W-R
(ID--) (ID+)
G3 m
14
&C4
(CAB4)
C15
(S-)
0.85 B- C23 C22

C
#ME
(RCL--) (R
RCL+)
(14)
15
k 0.85 B- C25 C24 0.85 W-R
2.00 B-
0.50 B- (RCL--) (R
RCL+)
#72
2.00 B- ROOF W/H

2.00 B-
0.50 B-
8 MAIN W/H
#72
OFF
H
0.85 B-
(CAB1)
C4
4E
EL
&C1
(EL
L)
C
C4F
LT
(L
LT)
0.50L-B C4G &C2 &C3
LH
To G3
(LH
H) (CAB2) 2.00 B- (CAB3)
SAPH12Z030200033
c To Combination meter (Meter) i To Drivers seat power window switch (Power win-
dow)
d To Oil pressure switch (Meter) j To Meter
e To Combination meter (Meter) k To spring brake switch (Meter)
f To Rheostat (Meter) l To Parking brake switch (Meter)
g To Fuse tail light (Power source) m To Tail light relay (Power source)
h To Combination meter (Meter) n To Fusible link head light (H-LP) (Power source)
+B DIM IND H-LP H HI CHG PKB

CJ5 CJ6 CJ7 CJ8 CJ9 CJA CJB CJC
DRL E EL LH
CJ3 CJ4 C4E C4G
IG SBSW
CJD C9C
ED DU EP LT DL TR TL BT
C4H C4K C4L C4F C4J C4P C4N C4M
4
8
CAB SIDE WIRING
EL LH RH+
C4E C4G H5X
ED DU EP LT DL TR TL BT RH+ RH-
C4H C4K C4L C4F C4J C4P C4N C4M H9S H9T
6 9
A K
CHW CHX LH+
H5Z
LH+ LH-
7 H9Q H9R
1.5A 10
85902-1200
CHASSIS SIDE WIRING
LOW+ LOW+
C35 C30
HI+ E- HI+ E-
C36 C37 C31 C32
17 16
SAPH12Z030200034
ID+ ID-
C44 C45
11
RCL+ RCL-
C22 C23
14
ID+ ID-
C42 C43
12
RCL+ RCL-
C24 C25
15
ID+ ID-
C40 C41
13
SAPH12Z030200035
K
0.85 W-R
0.50 R-L 0.50 R-L
0.50 R-W 0.50 R-W

CAB SIDE WIRING
0.85 R-
(FLS+)
C7N
(HR)
C4A
(HL)
C4B
C4N
(TR)
C4P
(TL)
12 3
HF HL HR HT BT TL TR BC CL CR C8C
9
(TSWL)
2 OFF L
1
ON 3 N
C8B
10
(TSWR)
C49
(HF)
R 11 2 4 7 5
(STPR)
(STPL)
C85
C84
C4M
(BT)
0.50 B- C7W
(E)
C88
(TLPL)
C87
(TLPR)
0.50 B-
0.85 R-W
0.50 B-G
0.50 B-R
0.50 B-
0.85 B-G
0.85 B-R
0.85 Y-
1.8A
1.8A
(MTUR)
(MTUL)
E0Q
E0R
&C1 2.00 B- &C4
#L8
#L7
#A8
#LA
#L9
G3
(CAB1) (CAB4)
MAIN W/H c d
FR W/H 0.50 B-R #L9
0.50 B-W #LA
0.50 R-W #L7
#L8
#A8
0.85 W-R
0.50 B-G
0.50 B-R
0.50 R-W
AP9 APA
0.50 Y-
0.50 Y-
j k
(STL+) (STR+)
0.85 W-R
0.75 W-
#26
#27
#28
#13
#12
FR W/H
HOOD W/H
#26
1.25 B-W #27
0.85W-R #28
#12
#13
0.85 W-R
(11LD)
A0W
1.25 B-R
1.25B-W
1.25B-R
CHASSIS SIDE WIRING
1.25 Y-
To fuse turn
(15A)
(SML+)
(SML+)
(STN+)
(STN+)
(FTR+)
(FTL+)
C4Q
C4S
C1S
C26
C28
C1J
1.25 W-R
1.25 R-W
1.25 O-
6 7 8 9
(BLP+)
(S/L+)
(T/L+)
C1G
C1N
C1P
C27
(STN-)
C4R
(FTL-)
C4T
(FTR-)
C29
(STN-)
1.25B-
1.25B-
1.25B-
1.25B-
Tail, Stop, Back

Licence Turn
10
#29
HOOD W/H
FR W/H
0.85 B- #29
C1M
(RCB-)
&1B 3.00 B- &1A

1.25 B- (CAS2) (CAS1)
SAPH12Z030200036
K STOP AND TURN LIGHT CIRCUIT 10 Rear combination light LH

1 Stop and turn controller 11 Rear combination light RH
2 Wiper and retarder switch 12 Stop light relay
3 Light and turn switch 13 STP AT diode
4 Stop light switch
5 Junction a To A450 ATM ECU
6 Side turn light LH (Fender) b To Monitor module (HYDRO MAX)
7 Front turn light LH c To Combination meter (Meter)
8 Front turn light RH d To Combination meter (Meter)
9 Side turn light RH (Fender) e To Fuse tail light (Head & tail light)
K
0.50 W-L
5
COB
CO9
TLPL STP+ TLPR STPR
(S+)
LD S+
(B)
C88 C7P C87 C84
C0C C09
%AL NQ2 12 STPL SSIG TSWL TSWR E FLS+

C85 CHU C8C C8B C7W C7N B S-
0.85 R-
a C0B C0A
(KTR) (BK)
COC
(LD)
COA
(S-)
%AM SBK
(#U4) (BRSW)
b 1 12
JC
0.50 W-B
WW EW
0.85 R- H4A H4B
e A K
HL HR WI WL WH HF C9D C9E
0.50 W-B C4A C4B H4C H4D H4E C49
A20
(51LD)
2 13
%D3
0.50 W-L
(JC)
0.85 W-R
1.5A
C9E
EL LH
%D1
(K)
(JC) 5 C4E C4G
ED DU EP LT DL TR TL BT
13 C4H C4K C4L C4F C4J C4P C4N C4M
0.75 W-B %D2

(JC)
85902-1200
(BSW1) 3
C9D
(A)
0.50 W-B
K4E
EC7
0.85 W-R
(+)
f (NO+)
CD7
#CD
#DP
#A7
#L6
4
CD8
(NO-)
#L6
#CD
#DP
#A7
0.85 W-R
0.50 B-
0.75 B-
0.85 W-R
0.75 W-
0.50 W-L
0.50 W-L
&1C 2.00 B- &C4 A450 HYDR

(CAB1) (CAB4)
#11
2200RDS/2500RDS,
FR W/H 3000RDS, EATON
RR W/H
1.25 W-R #11
KUY KUX #UG KUV KUW #UP L2J L2H K2X #PA
(STOP)
(STOP)
(14LD)
N1R
N34
A12
NO+ KRY #UY KTU KRB KTR #U4 FUSE FUSE FUSE
NO+ CD7 %AG %AH %AJ %AK %AL %AM %CB %CD %CE
CD7
g h i NO- JC JC JC K6D K6E #P5 JC JC JC
NO- CD8 %D1 %D2 %D3 %AN %AP %AQ %D7 %D8 %DA
CD8
1.25 W-R 2200RDS/
1.25 O- 1.25 O- 4 4 2500RDS,
3000RDS 5
To Back LP SW
1.25 O-
(BLP+)
(S/L+)
(T/L+)
C1W
C1Q
C1X
STN+ STN- SML+ FTL- FTL+ SML+ FTR- FTR+

G3 C1J C4R C4Q C1S C4T C4S
C26 C27
Tail, Stop, Back
&1K
(CAS3)
Licence Turn
7 8
6
11
2.00 B-
BLP+ RCB- BLP+ RCB-

C1G C1M C1Q C1V
C1V
(RCB-)
STN+ STN- T/L+ S/L+ T/L+ S/L+

C28 C29 C1N C1P C1W C1X
(CAS3)
9 10 11
&1C
1.25 B-
SAPH12Z030200037
f To Rheostat (Meter) i To Fuse stop light (Stop & turn light)

g To 2200RDS/2500RDS ATM j To Spare power source (Side turn LH)
h To 3000RDS ATM k To Spare power source (Side turn RH)
L M
To FR/H (Fuse R/LP)
#AA
(10)
0.85 W-G
0.85 W-G
CAB SIDE WIRING
(+24V)
K9G
#73
MAIN
W/H
ROOF To DST-1 connecter
W/H DLL-
#73
D1R
0.85 W-G
DLL+
D1Q
0.85 W-G
A81
To fuse back light
(71LD) 1
5.2A
(DLR+)
(DLL+)
0.50 R-L
D1Q
D1T
DLL-
D1U
1 2 DLR+
D1T
#LB
MAIN W/H
2
FR W/H
D1R
D1U
(DLL-)
(DLL-)
#LB
0.85 R-L
0.85 R-L
0.85 G-
0.85 G-
For EATON MTM only LH+

Body Body D01
earth earth
3
#74
NRC
ROOF W/H
(+)
MAIN W/H
1
0.85 R-L #74
CHASSIS SIDE WIRING
NRD
(-)
RH+
0.85 O-
#53
D02
1.25 O-
To Back LIGHT MAIN W/H
FLOOR W/H 4
#53
For ATM only NK4

b
#15
(NO)
0.85 R-L
0.85 R-L
FR W/H
RR W/H
#15
(RH+)
(LH+)
DO1
DO2
3 4
(BLP+)
AP8
+ -
a NRC NRD
(Caution) Terminal : male
1 Body Body
earth earth
SAPH12Z030200038
L BACK LIGHT CIRCUIT M ROOM LIGHT CIRCUIT

1 Back light switch 1 Dome light LH
2 Dome light RH
a To Spare power source (Back) 3 Courtesy switch front LH
b To ATM back light relay 4 Courtesy switch front RH
A450 ATM
2200RDS/2500RDS ATM
3000RDS ATM
To Fuse To Fuse
wiper wiper
10A 15A
E
AAD
(1FLD)
ABX
(1HLD)
H23
+
H22
1
FLOOR W/H MAIN W/H
0.50 L- #54 #54 0.50 L-
2.00 L-Y
0.50 L-
2.00 L-
H22
(+)
1 M IRSI
H08
IRSL IRSH
H07 H06
IRHL
H03
IRHI PWR
H02 H9Z
(WIPS)
(PWR)
IR- IRMS WIPS IR+

(IR+)
C8H
H9Z
H01
H05 H04 C8H H01

H23
(E)
H08 H03 2.00 L-B

(IRSI) (IRHL) 2
0.50 L-R
H07 2 H02 2.00 L-R

(IRSL) (IRHI)
CAB SIDE WIRING
H06
H05
(IR-)
H04
(IRMS)
(IRSH)
#55
FLOOR W/H
MAIN W/H
(HIGH)
#55
(LOW)
H17
H18
HIGH LOW
H17 H18
2.00 L-W
0.50 L-O
0.50 L-R
0.50 L-Y
HI LO
2.00 B-
0.50 L-
INT RUN
M H19 H21
3 H21
(RUN) 3
(WW)
H4A
(WH)
(WL)
H4C
H4D
H4E
(WI)
H19
(INT)
W E W W W
W W I L H
OFF
4 INT
LO
HI
WASHER Body
earth WW EW
H4A H4B
H4B
(EW)
HL HR WI WL WH HF
C4A C4B H4C H4D H4E C49
0.50 B-
&C1 2.00 B- &C4

To
G3 (CAB1) (CAB4)
SAPH12Z030200039
N WIPER AND WASHER CIRCUIT

1 Washer motor
2 Wiper relay
3 Wiper motor
4 Wiper and retarder switch
To Fuse
back light
A5T
(74LD)
HM-
H4X
HMI- HM+
0.85 R-L H4Z H4W
To Cab 1
GND G3
&C3
(CAB3)
(HM+)
H4W
OFF
1
0.85 R-L
2.00 B-
ON
H4X
H4Z
(HM-)
(HMI-)
1.25 B- LH+
H5Z
0.85 L-
(CAB2)
LH+ LH-
&C2
H9Q H9R
3
CAB SIDE WIRING
(S+)
(+B)
H62
H64
2
H63
(S-)
H65
(LD)
RH+
H5X
0.85 B-
RH+ RH-
H9S H9T
0.85 R-B
0.85 R-B
To &C2 &C3 To 4
GND GND
DR1 (CAB2) 2.00 B- (CAB3) DR2
J/C (G3)
#64
#63
MAIN W/H MAIN W/H
(DOOR LH) (DOOR RH)

#64
#63
0.75 R-B
0.75 R-B
(RH+)
(LH+)
H5X
H5Z
3 4
SAPH12Z030200040
O MIRROR HEATER CIRCUIT

1 Mirror heater switch
2 Mirror heater relay
3 Heater back mirror LH
4 Heater back mirror RH
To Fuse horn
ELECTRIC HORN AIR HORN
(Meter circuit)
To Rheostat
To Fuse
horn
AAF
(I GLD)
EC8
(LAMP)
AAF
(1GLD)
AAF
(1GLD)
0.50 W-G
0.50 W-G
0.50 W-G
0.85 R
0.50 W-G
U03
(B)
0.50 W-G
To Horn relay
CAB SIDE WIRING
G5Y
(PT)
U01
(S+)
U03
(B)
0.50 R
To Brower SW
1
conditioner)
ADP
ADR
(Manual air
(S+)
(B)
U02
(S-)
U04
(LD)
Air horn relay
ADQ
(S-)
ADS
(LD)
0.50 LG-B
0.50 LG-
0.50 G-
(COM)
6
(ILL+)
USH
U8T
(HORN)
OFF
CAB SIDE WIRING
COM AIR I LL+ I LL+

U0B
0.50 G-B
U8T U8U USH USJ
HORN
U0B ON
2 6
0.50 B- U8U
(AIR)
0.50 B- USJ
(ILL+)
2
2.00 B-
(CAB2)
(CAB3)
&C2
Body &C3
0.50 G- earth
#H1
CAB GRAND DR2 CAB GRAND P2
U05
U07
(B)
(B)
#H1
B B
U07 U05
4 3
0.50 G-B
U06
U08
(L)
(L)
L L
U08 U06 HMV+ HMVE
CHASSIS SIDE WIRING
U09 U0A
(HMV+)
0.50 G- 3 4
U09
0.50 B-
7 7
U0A
(HMVE)
(G3JC)
&E5
G45A G45A G45A G3JC

0.50 B-
&D1 &D2 &D3 &E6
5 G45A G45A G3JC G3JC G3JC G3JC

&DC &D5 &E4 &E5 &E1 &EA
AHW 3.00 B-
&E1
(G3JC)
To Power supply
(S-)
(GAS2)
5
&1E
&C2 &C3
(CAB2) (CAB3) CHASS GRAND
CAB GRAND DR2 CAB GRAND P2
SAPH12Z030200041
P HORN CIRCUIT
1 Horn relay
2 Horn switch
3 Horn (Low)
4 Horn (High)
5 Junction (G3)
6 Horn switch (Air)
7 Horn (Air)
EL02_001.fm 42 ページ２００６年２月１４日　火曜日　午後６時０分
To Fuse
radio
A5R
(73LD)
1.25 W-L
H44
(+)
-
H45
1 +
H44
H45
1
(-)
CAB SIDE WIRING
1.25 B-
&C1 2.00 B- &C4

To G3
Cab GND
(CAB1) (CAB4)
SAPH12Z030200151
Q CIGARETTE LIGHTER CIRCUIT

1 Cigarette lighter
R
To Fuse
Air Conditioner
#A2 #A2 A36
0.50 R-L A5V

(71LD)
To FL P/W
MAIN W/H FR W/H (LD)
DSO DSC +IG
H7F H79
2.00 W-
H7E
E DB DM DMC +B
H7G H7A H7C H7B H78
#67
#68
PB PSC PMC PSO PMO
1 MAIN W/H
DOOR W/H
H7H H7N H7K H7M H7J
0.50 R-L #67
2.00 W- #68
2
(+IG)
(+B)
H79
H78
1
Main
RLY H7A 2.00 L-
(DB)
CLOSE
OPEN
W/L
#6A
SW
(DOOR LH)
Passengers seat switch MAIN W/H
CLOSE
OPEN
#6A
Drivers seat
switch
2.00 L-
CAB SIDE WIRING
(DMO)
2.00W-B H7F
(DSC)
2.00B-W H7E
(DSO)
(E)
(DMC)
H7G
H7C
H7B
To back H9R
mirror light (LH-)
2.00 B-
#6C
#6B
#6F
(DOOR LH) MAIN W/H
MAIN W/H (DOOR RH)
#69
2.00 L-W #6B
2.00 L-B #6C
#6F
(DOOR LH)
MAIN W/H
#69
#6D
#6E
2.00 L-R
2.00 L-Y
2.00 B-
2.00 L-
MAIN W/H
(DOOR RH)
2.00 W-B #6D
2.00 B-W #6E
To G3 &C2 &C3
cab GND
(CAB2) 2.00 B- (CAB3)
(PSO)
(PSC)
H7M
H7N
H7H
2
CLOSE
OPEN
(PB)
2.00 L-Y H7K
2.00 L-R H7J

(PMC)
(PMO)
PWM1 PWM2 PWM3 PWM4

H46 H47 H48 H49
3 (CLOSE) (CLOSE)
4
M M
H46 (PWM1) H47 (PWM2) H49 (PWM4)
Passengers
Drivers seat
3 H48 (PWM3) seat
4
SAPH12Z030200042
R POWER WINDOW CIRCUIT

1 Drivers seat master switch
2 Passengers seat sub switch
3 Power window motor drivers seat
4 Power window motor passengers seat
To FL To Rheostat
Room light A5R 1.25 W-L H44 (Meter) To Fuse tail
To Fuse To Cigalette
radio (73LD) (+) lighter
#AA
EC8
(I0)
(LIGHT)
(51LD)
A20
0.85 W-G
1
0.50 W-G
0.85 W-R
0.85 W-R
1.25 W-L
(+24V)
0.85 R-
085 R-
K9G
To Diagnosis
connector (16P)
G5Y
EC7
(P1)
(+)
SPR2 SPL2 ACC + To Blower sw To Rheostat
I0F I0H I0C I09 (Air conditioner) (Meter)
SPR1 SPL1 GND LILL ILLM

I0E I0G I0B I0L I0A
(ILLM)
(ACC)
(KILL)
I0C
I0A
I09
I0L
(+)
2㧔+HUQGSWKRRGF
CAB SIDE WIRING
AM/FM/CD
2
AMFMTAPE㧔+HUQGSWKRRGF
I0B
Body
(GND) earth
(SPR2)
I0G
(SPL1)
I0H
(SPL2)
(SPR1)
I0F
I0E
ACC SPL2 SPR2

I0C I0H I0F
GND ILLM KILL + SPL1 SPR1

I0B I0A I 0 L I 0㧥 I 0 G I0E
0.50 P-G
0.50 P-B
0.50 P-L
2.00 B-
0.50 P-
2
(FRE)
(RAU)
(FLE)
(FR+)
(FL+)
&CA
I04
I03
I01
I02
FLE FL+
I04 I03
3 4
3 FRE FR+
I02 I01
SAPH12Z030200043
S AUDIO CIRCUIT
1 Antenna
2 Radio/Audio unit
3 Front speaker LH
4 Front speaker RH

1
G4H G4J 2.00 L-W
(B) (LD)
G4F G4G 0.50 L-B
(S+) (S-)
0.50 W-G
#AA 0.85 W-G K9G

0.50 R-L
To FL To Diagnosis
room light (+24V) connector
(I0) 0.50 R-L
To Rheostat EC8 0.85 R-

(Meter)
(LIGHT) 0.50 L-W
2.00 L-W
A5V 0.50 R-L #67

To Fuse To P/W
CAB SIDE WIRING
Air conditioner SW G02 (ASW)
G08
(75LD) (DSW1) Electric
(+)
thermo sensor
AMP
G5W (AC)
2.00 W-L
(BSW)
G03
3 M
4
2.00 L-B G09

(GND)
2 H M2 M1 C E
OFF
0.50 B-
Blower rheostat LO
M1
G0D M2
HI
(+)
G0K
(HI)
G0E
(M2)
G0F
(M1)
G0L
(LO)
G23
(GND)
G5Z
(P2)
G5Y
(PI)
G0C
(M1)
(M2)
G0B
2.00 L-B
2.00 L-W
2.00 B-
0.85 B-
2.00 L-R
&C2 2.00 B-
#A3
(CAB2) 0.50 L-B

#A3
AC ASW
CHASSIS SIDE WIRING
G5W G02 GND LO M2 M1 P1 P2

G09 G0L G0E G0F G5Y G5Z
+ M2 M1 BSW HI GND
G0D G0B G0C G03 + G0K G23
G08
2 3 4
(LD)
A38
To FL heater
(Power supply)
SAPH12Z030200044
T MANUAL AIR CONDITIONER CIRCUIT

1 Heater relay
2 Heater and cooler unit
3 Blower motor
4 Blower switch
5 Air conditioner switch
6 Air conditioner relay
7 Pressure switch
8 Compressor
0.50 W-G
6
G4M G4N
(B) (LD)
0.50 R-L G4K G4L
(S+) (S-)
0.85 R-
0.50 L-W
0.50 L-W
2.00 L-W
(IND+)
(A/C)
G0G
G0N
G0P
(+)
(PC+)
G0S
GND LED
G0H
IND+ OFF A / C +
5
High&low pressure cut

G0G G0M G0P G0N
Night time
light
Dimmer
unit PC+ GND
5 G0S G0Q 7
7
(GND)
(OFF)
G0H
G0M
0.50 L-B
(GND)
G0Q
0.85 B-
0.50 L-R
2.00 B- &C3
To G3
#E2
0.50 L-B (CAB3)
Model
ND8J,NE8J 0.50 L-R
#E2
NF8J,NV8J
0.50 L-
#41
#42
Model
NA6J,NB6J,NC6J
FR W/H FR W/H
ENG/harness ENG/harness
RH LH
#41
#42
G0Y
(+)
8 Magnetic
clutch
(E/G)
SAPH12Z030200045
9
8
7
6
5
4
3
2
1
U
11
10
CHASSIS SIDE WIRING CAB SIDE WIRING
EL02_001.fm
1.25 BR-
a
&1D #G3 #G3
EL02–48
(G4-A)
To Weld
splice G4
(GND)
J/C G4
#G1
FR W/H
(GND1)
#AC 0.50 B-W
U2 ECU
MAIN W/H
RLY
48 ページ
(12)
Injector 1
&D3
To Heater
To Weld &1D
(Glow plug)
0.50 L-B
(G45A)
#U1 KUZ
splice G4 (G4-A)
KV6 #U1 (EGR1)
EGR valve 2
EGR valve 1
L/R1
EGR
(ECR1)
U2 junction 2
U2 junction 1
Idling volume
0.85 BR-
VNT controller
KVH
Air flow sensor

Junction signal
8
(LSC1)
#U2 0.50 L-R KVB
For Glow
KVJ #U2 (EGS1)
1.25 BR-
1.25 BR-
0.50 BR-
0.50 BR-
0.50 B-W
EGR
(LSS1) (GRY1) KVN
Accelerator sensor
L/SSR1
KVG
K9H
(SGND)
(LSV1) (GRY2) KVP
KV7 #U3 #U3 0.50 L- KV1 (EGR2) (PGD3) KRA
L/R2
EGR
To DST-1
(ECR2)
K1W
b
KVL #U4 #U4 0.50 L-W KRB (AGD3) (PGD2)

(A450 ATM)
To A450 ECU
9
(LSC2)
#U5 0.50 L-R KVC K1V
KVM #U5 (EGS2) (PGD1)
EGR
(LSS2)
L/SSR2
K0D
E0S
E0A
E0M
NPN
KVK #U6 #U6 0.50 L-Y KRR (AVC3) (CASE)

(NE+)
(MTM)
(MENG)
(LSV2)
0.50 W-
0.50 W-
(CGD1) K0B
Twist
Twist
#46 #46 KVA KV8 #U7 #U7 0.50 GR-L K6V (CANH) (CGD2) K0C 0.50 BR-
(MPRH) For Glow
(VNTG) (VNTH)
#U8 0.50 Y-L K6W
10
#47 #47 KVO KV9 #U8 (CANL) (GLOW) KVQ 0.50 LG-
(VNTV) (VNTL)
0.50 G-
２００６年２月１０日　金曜日　午後６時２８分
KTU 0.50 G- #2J #2J (BALP) K54

(AFT-)
KTT 0.50 G-B #2K #2K 0.50 G-B KUN (AFT+) (TACH) K0Z 0.50 G-
ENG W/H
(AFT+)
KTQ 0.50 G-W #2L #2L 0.50 G-W KUM (AFSG) (CE/G) K0L 0.50 V-W
5
(AFSG)
KTR 0.50 L-W #2M #2M 0.50 L-W L2P (AGD6)
(JC)
%DB
(JC)
%DC
(JC)
%DD
U
(AFGD)
1
KTS 0.50 W- #2N #2N

3
(AFVB) AIR FLOW W/H MAIN W/H

K89 #UB #UB 1.25 Y-B K5N (INJ6) (DGSW) K0H KE4
(IJ6-) (+)
ELECTRIC WIRE
#UC 1.25 R- 1.25 R- K5Y
16
K8A #UC (I2+S) (ISOK) K6U K9E
(IJ6+) (ISOK)
K87 #UD #UD 1.25 G- K5M (INJ5)
(CA2H) KRG %BD
DST-1
(IJ5-)
(CAN+)
Except for
#UE 1.25 R-
15
A450 ATM
K88 #UE
14 Injector 4
13 Injector 3
12 Injector 2
16 Injector 6
15 Injector 5
Twist
Twist
(IJ5+) (CA2L) KRH %BN

K85 #UF #UF 1.25 B-W K5S (INJ4) (CAN+)
(IJ4-)
(VS) K6L 0.50 Y- %DS E7F
1.25 V-
#UG 1.25 R- K5X
14
K86 #UG (IJ2+)
c
(IJ4+) (K6L) (PCO4)

K84 #UH #UH 1.25 Y- 1.25 Y- K5W (I1+S) %DR E19
d
(IJ3-) (E7F) (SPSP)

#UJ 1.25 L- K5P
13
K83 #UJ (INJ3)
(+BF1) L2H
(IJ3+)
17 Suction control valve

18 Cylinder angle sensor
K82 #UK #UK 1.25 Y-
(+BF2) L2J
(IJ2-)
#UL 1.25 R-B
12
K81 #UL K5R (INJ2)
20 Water temperature sender

A450 ATM
21 Fuel temperature sensor 1

(IJ2+)
K80 #UM #UM 1.25 Y- K5V (IJ1+)
(IJ1-)
COMMON RAIL CIRCUIT-1 (CAB SIDE) : MODELS EQUIPPED WITH 6 CYLINDER ENGINE
#UN 1.25 W- K5U
11
K7Y #UN (INJ1)
(VB3) KU6
(IJ1+)
2
19 NE sensor (Engine speed sensor)

(VB2) K08
0.50 G-R KUW
(SCVH) (VB1) K07
%AD
%AF
%AE
(#UP)
(KUV)
#UP 0.50 G-R 0.50 G-R KUV

(KUW)
KV2 #UP (SCVH)

(MRL2) K57
(SCVH)
#UQ 0.50 G-Y
17
KV4 #UQ 0.50 G-Y KUX (SCVL)
(MRL1) K56
(SCVL)
0.50 G-Y KUY (SCVL)
(#UG)
%AC
(KUX)
%AB
(KUY)
%AA
SAPH12Z030200046
2
0.50 W-
0.50 W-
0.50 G-
0.50 W-
0.50 L-Y
0.50 L-Y
0.85 L-B
0.85 L-B
0.85 L-B
0.50 W-
0.50 W-
0.85 L-B
0.85 L-B
0.85 L-B
0.50 L-Y
0.50 L-Y
N6E (CL2-)
To Clutch interlock SW (ENG start)
%DA (JC) NK0 (NO)
To ATM starter relay MD ATM (ENG start)
%D9 (JC)
%DB (JC) #AB g
e
%D7 (JC) 0.50 W-B (1I)
0.50 L-W %A7 (K4D)
K2X
(CLT+)
2 0.50 L-W %A8 (K4C)
%A9 0.50 L-W AA5
f
(AA5) (1ALD)
4
K0G
K4D
K4C
%DL (K2X)
%DM(L2H)
%DN (L2J)
(ST)
(SWSS)
(SSWS)
1
(GGND)
(GVCC)
(THW+)
K4E (BSW1)
(NESD)
(AGD2)
(AGD1)
(AGD5)
(AGD4)
(PCR2)
(PCR1)
(ACS2)
(ACS1)
(AVC2)
(AVC1)
(AVC5)
(AVC4)
(NE1+)
(THF+)
(NE1-)
(G3+)
(PIM)
(IVS)
2
(#PA)
KTE
KQW
KRT
K7Z
K0S
K0R
KRY
K0U
K0Y
K6E
K6D
KRQ
KRP
K6G
KRX
KUQ
KTD
K62
K5Z
KUG
K4R
KRS
%DP
0.50 W-B
%D1
(JC)
0.50 Y-B
0.50 Y-B
0.50 W-L
0.50 G-
C0A (S-)
o
0.50 GR-G
0.50 G-O
0.50 G-Y
h NIR (STOP) %D3
2 2 i
N34 (JC)
%AG %AP
2
E6F
(MWTT)
0.50 BR-W
0.01 DR-N
0.50 LG-R
0.50 BR-R
%A3 %A4
0.50 LG-B
0.50 BR-B
0.50 G-W
0.50 G-O
0.50 G-R
0.50 G-O
0.50 G-B
0.50 G-Y
0.50 W-L
0.50 BR-
(KRY) (K6E)
0.50 LG-
0.50 Y-G
0.50 Y-G
0.50 Y-R
%D2
(JC)
(K90) (KRS)
0.50 Y-
%AH %AN
%A1 %A6
(#UY) (K6D)
%AJ %AQ (KUG) (K8Y)
%A2 %A5 0.75 W-B
(KTU) (#P5)
0.50 W-
(K31) (K2Z)
0.50 G-O
(SSIG)
0.50 G-Y
(NO+)
CHU
CD7
4 4
0.50 G-
j p
0.50 Y-B
0.50 G-
0.50 W-
K8Y
K8Z
K2Z
K91
K93
K92
K90
K31
K30
0.50 W- KCZ
(C0M) k
0.50 W- KD4
(VCC2)
(GND2)
(SIG2)
(VCC1)
(GND1)
(SIG1)
(GND)
(SIG)
(+)
(STCM)
6 7
#UW
#UR
#UU
#US
#UV
#UY
#PC
#UT
#PB
#P1
#P2
#P3
#P5
#P6
#P7
#P8
#P9
#PA
#UR
#US
#UT
#UU
#UV
#UW
#UY
#P1
#P2
#P3
#P5
#P6
#P7
#P8
#P9
#PA
#PB
#PC
24
KBP KBJ A1G
m
(LD) (B) (32LD)
KBH KBG
(S-) (S+)
25
#3M
(21)
K7N K7M A1E

(E) (B) (31LD) n
K7L K7K A1E
E25 (WTMP)
KUJ (MREG)
E23 (WTM+)
KUK (MRES)
KUL (MREV)
E24 (WTM-)
K8M (PCR+)
X8P (THF+)
(S-) (S+) (31LD)

K8N (PCR-)
X8Q (THF-)
K2C (GND)
K8P (PCR)
K2A (VCC)
K8V (NE+)
K8U (NE-)
K2B (SIG)
NRE
l
(+)
- + - +
SIG
GND
VCC
VCC
SIG
GND
18 19 20 21 22 23
SAPH12Z030200047
22 PC sensor f To Fuse U2 (M) (Power supply)

23 Boost sensor g To Exhaust clutch switch (Common rail 4)
24 U2 actuator power relay h To Combination meter (Meter)
25 U2 ECU main relay i To Front harness (2200RDS/2500RDS ATM or
3000RDS ATM)
j To Stop and turn ECU (Stop and turn)
a To Front harness (G4) k To FS Cruise (Common rail 3)
b To Combination meter (Meter) l To Neutral switch (EATON) (Common rail 4)
c To Pulse converter (Meter) m To Fuse U2 main (15A) (Power supply)
d To Speed sensor (Meter) n To Fuse U2 main (10A) (Power supply)
e To ATM starter relay (Engine starting) o To Stop light relay
NE1- NE1+ NESD +BF2 I1+S IJ1+ INJ3 INJ2 INJ1 PGD1
K0S K0R K7Z L2J K5W K5V K5P K5R K5U K1V
BSW2 STOP ST SSWSGLOW FSLP CRLP EGR2 EGR1

K44 K1X K0G K4C KVQ K50 K53 KV1 KUZ
BSW1CRSW AVC4 SWSS AGD5 AGD4 PIM EGS1 AVC1 AVC2 AVC3 AFSG PCR1 G3+ AGD6
K4E K1Z KRS K4D KTD KUG K6G KVB KRP KRQ KRR KUM K6D KQW L2P
DGSW NUSW AVC5 EGS2 AGD3 AGD2 AGD1 GVCC PCR2 GGND
K0H K45 KUQ KVC KRB KRY KRX KRT K6E KTE
6 cylinder
1-1 1-4
CAB SIDE WIRING
+BF1 MRL2 MRL1 CGD2 CGD1 GRY2 GRY1 I2+S IJ2+ PGD3 PGD2 INJ5 INJ6 INJ4
L2H K57 K56 K0C K0B KVP KVN K5Y K5X KRA K1W K5M K5N K5S
CE/G SET CLSW SCVH SCVH SCVL SCVL

K0L K4A K46 KUW KUV KUY KUX
CA2L CA2H RES PTO AT A450, 2200RDS CANL CANH THW+

KRH KRG K49 K4T K4X K6W K6V K0U
/2500RDS, 3000RDS
OLSW THF+
L2Z K0Y
1-2 1-5
VB3 VB2 VB1

KU6 K08 K07
TACH
K0Z
VS ASCS ACS2 ACS1 ISOK

K6L K4S K62 K5Z K6U
AFT+ IVS CASE

KUN K4R K0D
1-3
CHASSIS SIDE WIRING
SAPH12Z030200048
p To Stop light switch

HYD 3000RDS, 2200RDS / 2500RDS, EATON A450

A450
EATON
KUY KUX #UG KUV KUW #UP L2J L2H K2X #PA JC JC JC JC JC JC JC JC JC
%AA %AB %AC %AD %AE %AF %DN %DM %DL %DP %DB %DC %DD %DE %DF %DG %DH %DJ %DK
CONNECT
AND SUPPLY K45 NRF NTSW K2Y K46 E7F K6L
KRY #UY KTU KRB KTR #U4 FUSE FUSE FUSE %DW %DY %DX %DU %DT %DR %DS
JC JC JC K6D K6E #P5 JC JC JC +B DRL

%D1 %D2 %D3 %AN %AP %AQ %D7 %D8 %DA %C1 %C2
EATON
2 3000RDS , EATON CONNECT

3
2200RDS / 2500RDS , 3000RDS AND SUPPLY
3P+3P+4P
82550-1080
AFVB AFGD AFSG AFT- AFT+

3P+3P+4P CONNECT KTS KTR KTQ KTU KTT
AND SUPPLY
82550-1080 5
3P+3P+4P
82550-1080
VCC2 GND2 SIG2 VCC1 GND1 SIG1

A450 K91 K93 K92 K8Y K90 K8Z
6
KUG K31 K90 KRS K2Z K8Y CAN- CAN- CAN- CAN- CAN-
%A1 %A2 %A3 %A4 %A5 %A6 %BP %BN %BM %BL %BK
K4D K4C AA5 CAN+ CAN+ CAN+ CAN+ CAN+

%A7 %A8 %A9 %BG %BD %BC %BB %BA
4 +
K2Z
SIG
K30
GND
K31
3000RDS , 2200RDS / 2500RDS , A450
SAPH12Z030200049
9
8
7
6
5
4
3
2
1
V
11
10
EL02_001.fm
a
&1D #G3 #G3
EL02–52
(G4-A)
To Weld
splice G4
(GND)
J/C G4
#G1
To Weld
FR W/H
#AC
(GND1)
U2 ECU
MAIN W/H
RLY
52 ページ
(12)
Injector 1
&D3
To Heater
(Glow plug)
&1D
KVE KV6
splice G4 (G4-A)
0.50 L-B #U1
(G45A)
#U1 KUZ (EGR1)
EGR valve 2
EGR valve 1
L/R1
EGR
(EGV1) (EGR1)
U2 junction 2
U2 junction 1
Idling volume
0.85 BR-
VNT controller
KVH
Air flow sensor

Junction signal
8
(LSG1)
KVJ 0.50 L-R #U2 #U2 KVB (EGS1)
EGR
(LSS1) (GRY1) KVN
Accelerator sensor
L/SSR1
KVG
(SGND)
K9H
(LSV1) (GRY2) KVP
KVF KV7 0.50 L- #U3 #U3 KV1 (EGR2) (PGD3) KRA
L/R2
EGR
To DST-1
(EGV2) (EGR2)
0.50 L-W K1W
b
KVL 0.50 L-W #U4 #U4 KRB (AGD3) (PGD2)

(A450 ATM)
To A450 ECU
9
(LSG2)
KVM 0.50 L-R #U5 #U5 KVC (EGS2) (PGD1) K1V
EGR
(LSS2)
L/SSR2
E0S
E0A
K0D
E0M
0.50 L-Y
NPN
KVK 0.50 L-Y #U6 #U6 KRR (AVC3) (CASE)

(NE+)
(MTM)
(MENG)
(LSV2)
0.50 W-
0.50 W-
1.25 BR- (CGD1) K0B
#46 #46 KVA KV8 #44 #44 0.50 GR-L #U7 #U7 K6V (CANH) (CGD2) K0C
(VNTG) (VNTH)
(MPRH) For Glow
#47 #45 0.50 Y-L #U8
10
Twist
Twist
Twist
Twist
#47 KV0 KV9 #45 #U8 K6W (CANL) (GLOW) KVQ
２００６年２月１３日　月曜日　午後４時３分
(VNTV) (VNTL)
0.50 G-
KTU #2J #2J (BALP) K54

(AFT-)
KTT #2K #2K KUN (AFT+) (TACH) K0Z
ENG W/H
(AFT+)
KTQ #2L #2L KUM (AFSG) (CE/G) K0L
5
(AFSG)
KTR #2M #2M L2P (AGD8)
(JC)
%DB
(JC)
%DC
(JC)
%DD
FR W/H
V
(AFGD)
ENG W/H
1
KTS #2N #2N

3
(AFBV)
K89 K89 K89 1.25 Y-B #UB #UB K5N (INJ8) (DGSW) K0H KE4
(IJ6-) (+)
ELECTRIC WIRE
K8A 1.25 R- #UC
16
K8A K8A #UC K5Y (12+S) (ISOK) K6U K9E
(IJ6+) (ISOK)
K87 K87 K87 1.25 G- #UD #UD K5M (INJ5)
(CA2H) KRG %DB
DST-1
(IJ5-)
(CAN+)
Except for
K88 1.25 R- #UE
15
A450 ATM
12 Injector 2
16 Injector 6
14 Injector 4
13 Injector 3
15 Injector 5
K88 K88 #UE
(IJ5+) (CA2L) KRH %BN
K85 K85 K85 1.25 B-W #UF #UF K5S (INJ4) (CAN+)
3
(IJ4-)
K86 1.25 R- #UG (VS) K6L %DS E7F
14
K86 K86 #UG K5X (IJ2+)
1.25 W-
c
(IJ4+) (KBL) (PCO4)

K84 K84 K84 1.25 Y- #UH #UH K5W (I1+S) %DR E19
d
(IJ3+) (E7F) (SPSP)

K83 1.25 L- #UJ
13
K83 K83 #UJ K5P (INJ3)
(+BF1) L2H

(IJ3-)

K82 K82 K82 1.25 Y- #UK #UK
(IJ2+) (+BF2) L2J
K81 1.25 R-B
12
K81 K81 #UL #UL K5R (INJ2)

A450 ATM
(IJ2-)
K80 K80 K80 1.25 Y- #UM #UM K5V (IJ1+)
(IJ1+)
11
K7Y K7Y K7Y 1.25 W- #UN #UN K5U (INJ1)
(VB3) KU6
(IJ1-)
19 NE sensor (Engine speed sensor)

2
COMMON RAIL CIRCUIT-1 (CHASSIS SIDE) : MODELS EQUIPPED WITH 6 CYLINDER ENGINE
(VB2) K08
KUW
(VB1) K07
%AF
ENG wiring
%AE
%AD
harness LH
(#UP)
(SCVH)
(KUV)
(KUW)
KV2 #3U #3U 0.50 G-R #UP #UP KUV (SCVH)

(MRL2) K57
(SCVH)
17
KV4 #3V #3V 0.50 G-Y #UQ #UQ KUX (SCVL)
(MRL1) K56
(SCVL)
KUY (SCVL)
(#UG)
%AC
(KUX)
%AB
(KUY)
%AA
SAPH12Z030200050
FR W/H
ENG W/H
2
g
2 %DA (JC)
N6E (CL2-)
NK0 (NO)
K7X
(CLT+)
%D9 (JC)
%DB (JC) #AB
e %A7 (K4D)
%D7 (JC) 0.50 W-B (1I)
4
K4D
K4C
%DL (K2X)
%DM(L2H)
%A8 (K4C)
%DN (L2J)
K0G
%A9 AA5
f
(AA5) (1ALD)
(ST)
(SWSS)
(SSWS)
2
(GGND)
(GVCC)
(THW+)
K4E (BSW1)
(NESD)
(AGD2)
(AGD1)
(AGD5)
KUG (AGD4)
(PCR2)
(PCR1)
(ACS2)
(ACS1)
(AVC2)
(AVC1)
(AVC5)
(AVC4)
(NE1+)
(THF+)
(#PA)
(NE1-)
%DP
(G3+)
(PIM)
GR-G (IVS)
0.50 W-B
%D1
KTE
KQW
KRT
K7Z
K0S
K0R
KRY
K0U
K0Y
K6E
K6D
KRQ
KRP
K6G
KRX
KUQ
KTD
K62
K5Z
KRS
0.50 W-L
(JC)
C0A (S-)
o
2 2 NIR (STOP) %D3
%AG h %AP %A3 %A4 i 2
N34 (JC)
(KRY) (K6E) (K90) (KRS)
0.50 LG-
E6F
(MWTT)
%AH %AN %A1 %A6 CHU 0.50 W-L
%D2
(JC)
(KUG) (K8Y)
(#UY)
%AJ
(K6D)
%AQ 4 %A2 %A5 4 (SSIG) CD7
(NO+)
0.75 W-B
K8Y
K8Z
K2Z
K91
K93
K92
K90
K31
K30
(KTU) (#P5) (K31) (K2Z) j p
0.50 W- KCZ
(VCC2)
(GND2)
(SIG2)
(VCC1)
(GND1)
(SIG1)
(GND)
(SIG)
(+)
(C0M) k
#UW
#UR
#UU
#US
#UV
#UY
#PC
#UT
#PB
7
#P1
#P2
#P3
#P5
#P6
#P7
#P8
#P9
0.50 W- KD4
#PA
6 (STCM)
#UR
#US
#UT
#UU
#UV
#UW
#UY
#P1
#P2
#P3
#P5
#P6
#P7
#P8
#P9
#PA
#PB
#PC
0.50 BR-W
0.01 DR-N
0.50 BR-R
0.50 BR-B
0.50 G-O
0.50 G-Y
0.50 BR-
0.50 L-G
0.50 G-
0.50 Y-
0.50 W-
0.50 G-
0.50 LG-R
0.50 LG-B
0.50 L-Y
0.85 L-B
0.50 Y-G
0.50 Y-R
0.50 Y-R
0.50 Y-B
#3W
#3R
#3S
#3X
#3T
FR W/H
ENG wiring
harness RH 24
#3R
#3S
#3T
#3X
#3W
KBP KBJ 2.00 W-L A1G

m
(LD) (B) (32LD)
KBH KBG 0.50 B-R
(S-) (S+)
25
#3M
(21)
K7N K7M 1.25 B-R A1E

(E) (B) (31LD) n
K7L K7K 0.50 B-R A1E
E25 (WTMP)
KUJ (MREG)
E23 (WTM+)
KUK (MRES)
KUL (MREV)
E24 (WTM-)
K8M (PCR+)
K8R (THF+)
(S-) (S+) (31LD)

K8N (PCR-)
K8Q (THF-)
K2C (GND)
K8P (PCR)
K2A (VCC)
K8V (NE+)
K8U (NE-)
K2B (SIG)
0.50 L-Y
NRE
l
(+)
- + - +
SIG
GND
VCC
VCC
SIG
GND
18 19 20 21 22 23
SAPH12Z030200051
22 PC sensor f To Fuse U2 (M) (Power supply)

23 Boost sensor g To Exhaust clutch switch (Common rail 4)
24 U2 actuator power relay h To Combination meter (Meter)
3000RDS ATM)
V
CAB SIDE WIRING
HEAVY DUTY
SWP
EGR1 LSG1 LSV1 LSS1 EGV1 IJ5- IJ5+ IJ2+ IJ2-

KV6 KVH KVG KVJ KVE K87 K88 K82 K81
8 IJ3- IJ3+ IJ4+ IJ4-

K83 K84 K86 K85
CHASSIS SIDE WIRING
IJ6- IJ6+ IJ1+ IJ1-

K89 K8A K80 K7Y
11,12,13,14,15,16
EGR2 LSG2 LSV2 LSS2 EGV2
KV7 KVL KVK KVM KVF
VNTH VNTV
KV8 KV0 SCVH SCV2 MRES MREG MREV
KV2 KV4 KUK KUJ KUL
VNTL VNTG
KV9 KVA
18
17
10
SAPH12Z030200052
p To Stop light switch

PCR- PCR PCR+

K8N K8P K8M CONNECT
AND SUPPLY
NE- NE+
K8U K8V
19 22
82823-1180
WTM+ WTM-
E23 E24
GND SIG VCC CONNECT
WTMP K2C K2B K2A
AND SUPPLY
E25
20 23
82823-1180
THF- THF+
K8Q K8R
21
SAPH12Z030200053
9
8
7
6
5
4
3
2
1
W
11
10
EL02_001.fm
&1D #G3 #G3 1.25 BR-
To
EL02–56
(G4-A)
DST-1
To Weld
(GND)
J/C G4
splice (G4)
To Weld
K9H
U2 ECU
#AC 0.50 B-W
56 ページ
splice (G4)
RLY
Injector 2
Injector 1
(12)
(SGND)
&D3
To Heater
(Glow plug)
(G45A)
EGR valve 1
&1D
U2 junction 2
U2 junction 1
(G4-A)
Idling volume
VNT controller
Air flow sensor
Junction signal
0.85 BR-
For Glow
1.25 BR-
1.25 BR-
0.50 BR-
0.50 BR-
0.50 B-W
KV6 #U1 #U1 0.50 L-B KUZ (EGR1) (GRY1) KVN
Accelerator sensor
L/R1
EGR
(EGR1)
(GRY2) KVP
(GND1)
#G1
KVH #U4 #U4 0.50 L-W KRB (AGD3)
8
(LSG1)
KVJ #U2 #U2 0.50 L-R KVB (EGS1) (PGD3) KRA a
EGR
(LSS1)
L/SSR1
KVG #U6 #U6 0.50 L-Y KRR (AVC3) (PGD2) K1W
b
(A450 ATM)
(LSV1)
To A450 ECU
#U3 0.50 L- KVI (EGR2) (PGD1) K1V

E0S
E0A
K0D
E0M
NPN
#U5 0.50 L-R KVC (EGR5) (CASE)

(NE+)
(MTM)
(MENG)
0.50 W-
(CGD1) K0B
Twist
Twist
KVA KV8 #U7 #U7 0.50 GR-L K6V (CANH) (CGD2) K0C 0.50 BR-
(VNTG) (VNTH)
(MPRH) For Glow
9
KV0 KV9 #U8 #U8 0.50 Y-L K6W (CANL) (GLOW) KVQ 0.50 LG-
(VNTV) (VNTL)
0.50 G-
KTU 0.50 G- #2J #2J

(AFT-)
KTT 0.50 G-B #2K #2K 0.50 G-B KUN (AFT+) (TACH) K0Z 0.50 G-
(AFT+)
KTQ 0.50 G-W #2L #2L 0.50 G-W KUM (AFSG) (CE/G) K0L 0.50 V-W
5
(AFSG)
KTR 0.50 L-W #2M #2M 0.50 L-W L2P (AGD6)
(JC)
%DB
(JC)
%DC
(JC)
%DD
(AFGD)
W
KTS 0.50 W- #2N #2N

3
(AFVB) Sub W/H

K86 #UG #UG 1.25 R- 1.25 R- K5W (I1+S) (DGSW) K0H KE4
(IJ4+) (+)
ELECTRIC WIRE
13
K85 #UF #UF 1.25 B- K5S (INJ4) (ISOK) K6U K9E
(IJ4-) (ISOK)
K84 #UH #UH 1.25 Y- 1.25 Y- K5Y (12+S)
(CA2H) KRG %DB
DST-1
(IJ3+)
(CAN+)
Except for
12
A450 ATM
K83 #UJ #UJ 1.25 L- K5P (INJ3)
13 Injector 4
12 Injector 3
Twist
Twist
(IJ3-) (CA2L) KRH %BN
19 PC sensor
K82 #UK #UK 1.25 Y- K5X (IJ2+) (CAN-)
3
(IJ2+)
20 Boost sensor
(VS) K6L 0.50 Y- %DS E7F
11
K81 #UL #UL 1.25 R-B K5R (INJ2)
1.25 W-
c
(IJ2-) (KBL) (PCO4)

K80 #UM #UM 1.25 R- K5V (IJ1+) %DR E19
d
(E7F) (SPSP)
(IJ1+)
10
K7Y #UN #UN 1.25 W- K5U (INJ1)
(+BF1) L2H
(IJ1-)
16 Engine speed sensor

2
(+BF2) L2J
21 U2 actuator power relay

A450 ATM
0.50 G-R KUW

%AF
%AE
%AD
(#UP)
(SCVH)
(KUV)
(KUW)
KV2 #UP #UP 0.50 G-R 0.50 G-R KUV (SCVH)
COMMON RAIL CIRCUIT-2 (CAB SIDE) : MODELS EQUIPPED WITH 4 CYLINDER ENGINE
(SCVH)
14
KV4 #UQ #UQ 0.50 G-Y 0.50 G-Y KUX (SCVL) (VB3) KU6
(SCVL)
0.50 G-Y KUY (SCVL) (VB2) K08
(#UG)
%AC
(KUX)
%AB
(KUY)
%AA
(VB1) K07
2
0.50 G-
0.50 W-
(MRL2) K57
KUJ #UR #UR 0.50 BR-B KTE (GGND)
(MRL1) K56
(MREG)
KUK #US #US 0.50 BR-W KQW (G3+)
15
(MRES)
KUL #UT #UT 0.50 BR-R KRT (GVCC)
SAPH12Z030200054
(MREV)
0.50 W-
0.50 W-
0.50 L-Y
0.50 L-Y
0.85 L-B
0.85 L-B
0.85 L-B
0.50 W-
0.50 W-
0.85 L-B
0.85 L-B
0.85 L-B
0.50 L-Y
0.50 L-Y
N6E (CL2-)
%DA (JC) NK0 (NO)
To ATM starter relay MD ATM (MD)
%D9 (JC)
%D8 (JC) #AB g
e
%D7 (JC) 0.50 W-B (1I)
0.50 L-W %A7 (K4D)
K2X
(CLT+)
2 0.50 L-W %A8 (K4C)
%A9 0.50 L-W AA5
f
(AA5) (1ALD)
4
K0G
K4D
K4C
%DL (K2X)
%DM(L2H)
%DN (L2J)
(ST)
(SWSS)
(SSWS)
(THW+)
K4E (BSW1)
(NESD)
(AGD2)
(AGD1)
(AGD5)
(AGD4)
(PCR2)
(PCR1)
(ACS2)
(ACS1)
(AVC2)
(AVC1)
(AVC5)
(AVC4)
(NE1+)
(THF+)
(NE1-)
(PIM)
(IVS)
2
(#PA)
K7Z
K0S
K0R
KRY
K0U
K0Y
K6E
K6D
KRQ
KRP
K6G
KRX
KUQ
KTD
K62
K5Z
KUG
K4R
KRS
%DP
0.50 W-B
%D1
(JC)
0.50 Y-B
0.50 Y-B
0.50 G-
0.50 W-L
C0A (S-)
o
2
0.50 GR-G
0.50 G-O
0.50 G-Y
h NIR (STOP) %D3
%AG 2 i
N34 (JC)
(KRY)
%AP
2
E6F
(MWTT)
%AH
0.01 DR-N
0.50 LG-R
%A3 %A4
0.50 LG-B
0.50 G-W
0.50 G-O
0.50 G-R
0.50 G-O
0.50 G-B
0.50 G-Y
0.50 W-L
0.50 BR-
(K6E)
0.50 LG-
0.50 Y-G
0.50 Y-G
0.50 Y-R
%D2
(JC)
(#UY) (K90) (KRS)
0.50 Y-
%AN
%AJ %A1 %A6
(K6D)
0.50 W-
(KTU) (KUG) (KBY)
%AQ
%A2 %A5 0.75 W-B
(#P5)
(K31) (K2Z)
0.50 G-O
(SSIG)
0.50 G-Y
(NO+)
0.50 W-
CHU
CD7
4 4
0.50 G-
j p
0.50 Y-B
0.50 G-
K8Y
K8Z
K2Z
K91
K93
K92
K90
K31
K30
0.50 W- KCZ
(C0M) k
0.50 W- KD4
(VCC2)
(GND2)
(SIG2)
(VCC1)
(GND1)
(SIG1)
(GND)
(SIG)
(+)
(STCM)
6 7
#UW
#UU
#UV
#UY
#PC
#PB
#P1
#P2
#P3
#P5
#P6
#P7
#P8
#P9
#PA
#UU
#UV
#UW
#UY
#P1
#P2
#P3
#P5
#P6
#P7
#P8
#P9
#PA
#PB
#PC
21
KBP KBJ A1G
m
(LD) (B) (32LD)
KBH KBG
(S-) (S+)
22
#3M
(21)
K7N K7M A1E

(E) (B) (31LD) n
K7L K7K A1E
E25 (WTMP)
E23 (WTM+)
E24 (WTM-)
K8M (PCR+)
X8P (THF+)
(S-) (S+) (31LD)

K8N (PCR-)
X8Q (THF-)
K2C (GND)
K8P (PCR)
K2A (VCC)
K8V (NE+)
K8U (NE-)
K2B (SIG)
NRE
l
(+)
- + - +
SIG
GND
VCC
VCC
SIG
GND
16 17 18 19 20
SAPH12Z030200055

3000RDS ATM)
f To Fuse U2 (M) (Power supply) p To Stop light switch
g To Exhaust clutch switch (Common rail 4)
h To Combination meter (Meter)
NE1- NE1+ NESD +BF2 I1+S IJ1+ INJ4 INJ1 PGD1

K0S K0R K7Z L2J K5W K5V K5S K5U K1V
BSW2 STOP ST SSWSGLOW FSLP CRLP EGR2 EGR1

K44 K1X K0G K4C KVQ K50 K53 KV1 KUZ
BSW1CRSW AVC4 SWSS AGD5 AGD4 PIM EGS1 AVC1 AVCZ AVC3 AFSG PCR1 G3+ AGD6
K4E K1Z KRS K4D KTD KUG K6G KVB KRP KRQ KRR KUM K6D KQW L2P
DGSW NUSW AVC5 EGS2 AGD3 AGD2 AGD1 GVCC PCR2 GGND
K0H K45 KUQ KVC KRB KRY KRX KRT K6E KTE
6 cylinder
1-1 1-4
CAB SIDE WIRING
+BF1 MRL2 MRL1 CGD2 CGD1 GRY2 GRY1 I2+S IJ2+ PGD3 PGD2 INJ2 INJ3
L2H K57 K56 K0C K0B KVP KVN K5Y K5X KRA K1W K5R K5P
CE/G SET CLSW SCVH SCVH SCVL SCVL

K0L K4A K46 KUW KUV KUY KUX
CA2L CA2H RES AT CANL CANH THW+

KRH KRG K49 K4X K6W K6V K0U
AT
OLSW THF+
L2Z K0Y
1-2 1-5
VB3 VB2 VB1

KU6 K08 K07
TACH
K0Z
VS ACS2 ACS1 ISOK

K6L K62 K5Z K6U
AFT+ IVS CASE

KUN K4R K0D
1-3
CHASSIS SIDE WIRING
SAPH12Z030200056
A450 HYD
KUY KUX #UG KUV KUW #UP L2J L2H K2X #PA
AFVB AFGD AFSG AFT- AFT+
KRY #UY KTU KRB KTR #U4 FUSE FUSE FUSE KTS KTR KTQ KTU KTT
JC
%D1
JC
%D2
JC
%D3
K6D
%AN
K6E
%AP
#P5
%AQ
JC
%D7
JC
%D8
JC
%DA
5
2
2200RDS/2500RDS, 3000RDS
A450
JC JC JC JC JC JC JC JC JC
%DB %DC %DD %DE %DF %DG %DH %DJ %DK
VCC2 GND2 SIG2 VCC1 GND1 SIG1
K91 K93 K92 K8Y K90 K8Z
K45 NRF NTSW K2Y K46 E7F K6L
%DW %DY %DX %DU %DT %DR %DS
+B DRL
6
%C1 %C2
3
A450
+ SIG GND
K2Z K30 K31
KUG K31 K90 KRS K2Z K8Y CAN- CAN- CAN- CAN- CAN-
%A1 %A2 %A3 %A4 %A5 %A6 %BP %BN %BM %BL %BK
K4D
%A7
K4C
%A8
AA5
%A9
CAN+ CAN+ CAN+ CAN+ CAN+
%BG %BD %BC %BB %BA
7
4
3000RDS, 2200RDS/2500RDS, A450
SAPH12Z030200057
9
8
7
6
5
4
3
2
1
X
11
10
EL02_001.fm
&1D #G3 #G3
To
EL02–60
(G4-A)
DST-1
To Weld
(GND)
J/C G4
splice (G4)
#AC
To Weld
K9H
U2 ECU
RLY
60 ページ
(12)
splice (G4)
Injector 2
Injector 1
(SGND)
&D3
To Heater
(Glow plug)
(G45A)
EGR valve 1
&1D
U2 junction 2
U2 junction 1
(G4-A)
Idling volume
VNT controller
Air flow sensor
Junction signal
0.85 BR-
KVE KV6 0.50 L-B #U1 #U1 KUZ (EGR1) (GRY1) KVN
Accelerator sensor
L/R1
EGR
(EGV1) (EGR1)
(GRY2) KVP
(GND1)
#G1
KVH 0.50 L-W #U4 #U4 KRB (AGD3)
(LSG1)
8
KVJ 0.50 L-R #U2 #U2 KVB (EGS1) (PGD3) KRA a
EGR
(LSS1)
L/SSR1
KVG 0.50 L-Y #U6 #U6 KRR (AVC3) (PGD2) K1W
b
(A450 ATM)
(LSV1)
To A450 ECU
(PGD1) K1V
0.50 W-
1.25 BR-
E0S
E0A
(CASE) K0D
E0M
NPN
(NE+)
(MTM)
FR W/H
(MENG)
(CGD1) K0B
ENG W/H RH
#46 #46 KVA KV8 #44 #44 0.50 W- #U7 #U7 K6V (CANH) (CGD2) K0C 0.50 BR-
(VNTG) (VNTH)
(MPRH) For Glow
9
Twist
Twist
Twist
Twist
#47 #47 KV0 KV9 #45 #45 0.50 B- #U8 #U8 K6W (CANL) (GLOW) KVQ
(VNTV) (VNTL)
KTU #2J #2J
FR W/H
(AFT-)
KTT #2K #2K KUN (AFT+) (TACH) K0Z
ENG W/H RH
(AFT+)
KTQ #2L #2L KUM (AFSG) (CE/G) K0L
5
(AFSG)
KTR #2M #2M L2P (AGD6)
(JC)
%DB
(JC)
%DC
(JC)
%DD
X
(AFGD)
1
KTS #2N #2N

3
(AFVB) Sub W/H

K86 K86 K86 1.25 R- #UG #UG K5W (I1+S) (DGSW) K0H KE4
(IJ4+) (+)
13
ELECTRIC WIRE
K85 K85 K85 1.25 B- #UF #UF K5S (INJ4) (ISOK) K6U K9E
(IJ4-) (ISOK)
K84 K84 K84 1.25 Y- #UH #UH K5Y (12+S)
(CA2H) KRG %DB
DST-1
(IJ3+)
(CAN+)
Except for
12
A450 ATM
K83 K83 K83 1.25 L- #UJ #UJ K5P (INJ3)
13 Injector 4
12 Injector 3
(IJ3-) (CA2L) KRH %BN
19 PC sensor
K82 K82 K82 1.25 Y- #UK #UK K5X (IJ2+) (CAN+)
3
(IJ2+)
20 Boost sensor
(VS) K6L %DS E7F
11
K81 K81 K81 1.25 R-B #UL #UL K5R (INJ2)
1.25 W-
c
(IJ2-) (KBL) (PCO4)

K80 K80 K80 1.25 Y- #UM #UM K5V (IJ1+) %DR E19
d
(IJ1+) (E7F) (SPSP)
10
K7Y K7Y K7Y 1.25 W- #UN #UN K5U (INJ3)
(+BF1) L2H
(IJ1-)

2
(+BF2) L2J
21 U2 actuator power relay

FR W/H
ENG W/H
KUW
0.50 G-

A450 ATM

%AF
%AE
%AD
(#UP)
(SCVH)
(KUV)
(KUW)
KV2 #3U #3U 0.50 G-R #UP #UP 0.50 G-R KUV (SCVH)
(SCVH)
14
KV4 #3V #3V 0.50 G-Y #UQ #UQ 0.50 G-Y KUX (SCVL) (VB3) KU6
(SCVL)
KUY (SCVL) (VB2) K08
COMMON RAIL CIRCUIT-2 (CHASSIS SIDE) : MODELS EQUIPPED WITH 4 CYLINDER ENGINE
(#UG)
%AC
(KUX)
%AB
(KUY)
%AA
(VB1) K07
2
(MRL2) K57
KUJ 0.50 BR- #UR #UR KTE (GGND)
(MRL1) K56
(MREG)
KUK 0.50 Y- #US #US KQW (G3+)
15
(MRES)
KUL 0.50 G- #UT #UT KRT (GVCC)
SAPH12Z030200058
(MREV)
N6E (CL2-)
%DA (JC) NK0 (NO)
%D9 (JC)
%D8 (JC) #AB
e
4 g
%D7 (JC) (1I) %A7 (K4D)
%A8 (K4C)
2
K2X
(CLT+)
K0G
K4D
K4C
%A9 AA5
f
(AA5) (1ALD)
%DL (K2X)
%DM(L2H)
%DN (L2J)
(ST)
(SWSS)
(SSWS)
(THW+)
(BSW1)
(NESD)
(AGD2)
(AGD1)
(AGD5)
(AGD4)
(PCR2)
(PCR1)
(ACS2)
(ACS1)
(AVC2)
(AVC1)
(AVC5)
(AVC4)
(NE1+)
(THF+)
(NE1-)
(PIM)
(IVS)
2
0.50 W-B
(#PA)
K7Z
K0S
K0R
KRY
K0U
K0Y
K6E
K6D
KRQ
KRP
K6 G
KRX
KUQ
KTD
K62
K5Z
KUG
K4R
KRS
K4E
%DP
%D1
0.50 W-L
(JC)
2 2 o
C0A (S-)
%AG %AP NIR (STOP) %D3

h i 2
0.50 G-O
(KRY) (K6E) N34 (JC)

%AH %AN %A3 %A4
E6F
(MWTT)
(#UY) (K6D) (K90) (KRS)

CHU 0.50 W-L
%D2
(JC)
%AJ %AQ %A1 %A6
(KUG) (KBY) (SSIG) CD7 0.75 W-B
(KTU) (#P5)
4 %A2 %A5 4 (NO+)
K8Y
K8Z
K2Z
K91
K93
K92
K90
K31
K30
(K31) (K2Z) j p
KCZ
(VCC2)
(GND2)
(SIG2)
(VCC1)
(GND1)
(SIG1)
(GND)
(SIG)
(+)
(C0M) k
#UW
#UU
#UV
#UY
#PC
#PB
7
#P1
#P2
#P3
#P5
#P6
#P7
#P8
#P9
#PA
6 KD4
(STCM)
#UU
#UV
#UW
#UY
#P1
#P2
#P3
#P5
#P6
#P7
#P8
#P9
#PA
#PB
#PC
0.01 DR-N
0.50 LG-B
0.50 L-Y
0.50 G-B
0.50 G-Y
0.50 LG-
0.50 LG-
0.50 Y-G
0.50 Y-R
0.50 Y-R
0.50 Y-B
0.50 W-
0.75 L-
0.50 G-
0.50 G-
0.50 P-
0.50 V-
21
#3W
1.25 W-
#3R
#4C
KBP KBJ A1G

#3S
#3X
#4A
#4B
2.00 W-L
#3T
m
(LD) (B) (32LD)
FR W/H FR W/H KBH KBG 0.50 B-R
ENG wiring ENG wiring (S-) (S+)
harness LH harness LH
#3R
#3S
#3T
#3X
#3W
#4A
#4B
#4C
#3M
22
(21)
K7N K7M 1.25 B-R A1E

(E) (B) (31LD)
E25 (WTMP)
n
E23 (WTM+)
E24 (WTM-)
K8M (PCR+)
X8R (THF+)
K8N (PCR-)
X8Q (THF-)
K2C (GND)
K7L K7K 0.50 B-R A1E

K8P (PCR)
K2A (VCC)
K8V (NE+)
K8U (NE-)
K2B (SIG)
(S-) (S+) (31LD)

0.50 L-Y
- + - +
SIG
GND
VCC
VCC
SIG
GND
NRE
l
(+)
16 17 18 19 20
SAPH12Z030200059

3000RDS ATM)
f To Fuse U2 (M) (Power supply) p To Stop light switch
g To Exhaust clutch switch (Common rail 4)
h To Combination meter (Meter)
X
CAB SIDE WIRING
MRES MREG MREV THF+

EGR1 LSG1 LSV1 LSS1 EGV1 KUK KUJ KUL THF-
KV6 KVH KVG KVJ KVE K8Q K8R
8 15 18
HEAVY DUTY
SWP
CHASSIS SIDE WIRING
IJ1- IJ2-
K7Y K81
PCR- PCR PCR+

IJ1+ IJ4+ IJ2+ IJ3+ K8N K8P K8M CONNECT
K80 K86 K82 K84 NE- NE+ AND SUPPLY
K8U K8V
K85
IJ4-
K83
IJ3-
16 19
10,11,12,13
82823-1180
WTM+ WTM-
E23 E24
SCVH SCV2 GND SIG VCC CONNECT
KV2 KV4 K2C K2B K2A
WTMP AND SUPPLY
E25
14 20
17
82823-1180
SAPH12Z030200060

U2 J/C1
%DP
(#PA)
To Comb meter 0.85 R-
(Meter)
To Air flow SSR KTS

(Common rail) (AFVB) 0.50 W-
E61
(MTCR)
E5X
(MCRS)
0.50 W-
0.50 W-
0.85 R-
L2W L2X
(NC+)
(SRI+) (SRI-)
CLU
(COM)
KD5
3
(CIL+)
(FSC)
To Rheostat EC8 0.85 R- G5Y
KDO
To Blower SW
KCZ
KD2
KD4
CAB SIDE WIRING
Set (SET) (Meter) (Manual A/C)

(STCM) KD6 (LIGHT) (P1)
4 Resume (RSM) Free
0.50 V-G
(NC-)
0.50 V-Y
CLV
2 Push
KD3
(CIL-)
0.50 W-G
0.50 W-B
0.50 W-L
0.85 B-
0.85 BR-B
&C2 2.00 B- &C3

G3
(CAB2) (CAB3)
0.85 B-
K44
K4A
K1Z
K50
K53
K49
(FSLP)
(CRLP)
(BSW2)
(RES)
(SET)
(CRSW)
0.50 BR-B
0.50 W-
#1W
#PA
#PA
#1W
0.85 W-
0.50 BR-B
CHASSIS SIDE WIRING
#1Y
#1X
#1Y
#1X
0.85 BR-B CLV CLU 0.85 W- 1.25 W-

KBP #47 #47 KVO
To U2 ACT power relay To VNT controller
(NC-) (NC+) (LD) (VNTV)
5
ENG W/H
SAPH12Z030200061
Y COMMON RAIL CIRCUIT-3 FS CRUISE

1 U2 ECU
2 Set resume switch
3 Auto cruising switch
4 Break switch (NC) (HYDRO MAX)
5 Break switch (NC) (Full air)
SRI- SET
L2X KD5
RSM STCM SRI+

KD6 KD4 L2W
2
NC+
CLU
NC-
CLV
4
COM CIL+ FSC CIL-
KCZ KD2 KD0 KD3
NC+ NC-
CLU CLV
SAPH12Z030200062
All models Models equipped Models equipped

with manual transmission with automatic transmission
CLT+
K2X
CLT-
K2Y
(NUSW)
(NUSW)
(CLSW)
(STOP)
(STOP)
(OLSW)
(AT)
K1X
0.50 B-R K45
K4X
K1X
K45
CAB SIDE WIRING
L2Z
K46
0.50 B-R
0.50 B-L
5mA
N1N To (2200/2500,
2200/2500,
0.50 L-R %DT (NOUT) 3000 RDS ECU)
(K46)
%DU 0.50 L-R
3 %DW
3 NJX
(S+)
To ATM Starter RLY
(ENG Start)
%DW (K45)
(K2Y)
(CLT-)
K2Y
0.50 BR-
(K45)
0.50 B-L
%DY %DY %DY NWR Neutral starter SW
3 (NRF) (NTSW)
%DX
(NRSW) (NRF) (NSNL) (A450 ATM)
2 NPG A450 ECU
(N) (A450 ATM)
0.50 B-R
0.50 B-R
0.50 W- K2X
(CLT+)
0.50 B-R
(MOLP)
(STOP)
(STOP)
(G45A)
(SIG)
(SIG)
(K2X)
%B6
%B5
%B6
%B5
&D1
%DL
U2
NEUT SIG
NEUT SIG
NEUT SIG
ENG Stop
J/C1
J/C
%DP
(#PA)
EARTH
E0H
(G4, G5-a)
#PD
#PA
To Comb meter
(Meter)
#PA
#PD
0.85 B-R
0.85 B-R
CHASSIS SIDE WIRING
NRF
(-)
4
(+)
0.85 W- NRE
+ -
NRE NRF
4
To U2 KBP 1.25 W- #47 To Common rail
ACT
PWR (VNT Cntrol)
(LD) (7)
RLY
SAPH12Z030200063
Z COMMON RAIL CIRCUIT-4 AUTOMATIC TRANSMISSION

1 U2 ECU
2 Exhaust clutch switch
3 U2 junction 2
4 Neutral switch
a
2
1
EL02_001.fm
FR W/H
MAIN W/H
67 ページ
Idle volume
P.T.O signal
%CH 0.50 R - B K4F (PTO)
P.T.O Accel sensor

(+B) (+B / Open input )
+B
%CH
AA COMMON RAIL CIRCUIT-5 P.T.O

U2 - ECU
(Janction Connector Signal )

K31 0.50 G - O %A2 %A1 KUG (AGD4)
a
(GND) (K31) (KUG)
(Janction Connector Signal )

K2Z 0.50 G - Y %A4 %A4 KRS (AVC4)
a
(+) (K2Z) (KRS)
AA
ELECTRIC WIRE
0.50 G - Y
0.50 G - O
K97 (GND)
K95 (VCC)
2
K96 (SIG) 0.50 R - L K4S (ASCS)

K95
VCC
2
SIG
K96
K97
GND
SAPH12Z030200064
EL02–67
6
5
4
3
2
1
EL02_001.fm
EL02–68
AE0 1.25 L- #BH #BH 1.25 L-
15A
(91LD)
To ABS (Live)
68 ページ
Twist
Twist
S2P 0.50 BR- K2E
11 J1708(+)
(SAE+) (+)
ABS ECU F
ABS ECU E
S24 0.50 B-R K2F
10 J1708(-)
To DIAG
connector
(DST-) (-)
14 WXH relay
Modulator front LH
Modulator front RH
S1V
ABS sensor front LH

8 Valve power
ABS Diagnosis switch

(VVI)
1
S1Q 0.50 L-R AA9
7 ECU power
(IGN) (1CLD)
AB ABS CIRCUIT-1 FULL AIR BRAKE

S1S 0.50 Y- E0K
15 Warning
light (WL) (MABS)
(M)(Power source) (Meter)
To Fuse ABS To ABS light
&1A
12
3
(CAS1)
N
CHK
S84
9 Valve GND S01 0.50 Y-

(VV1-)
S02 (+)
3.00 B-
(ABS)
N1P
(ABS)
N33
(-)
S2B 0.50 BR-
4 ECU GND
To
(GND) 1.5A
DST-1
8
7
9
AB
10
11
&D5 0.50 BR-
(MD' ATM)
K9H
To MD ECU
To LCT ECU
0.50 BR-
To J/C
(G45A)
(LCT2400/2000)
(SGND)
(G4.G5-a)
ELECTRIC WIRE
&1B
(CAS2)
0.50 B-
0.50 B-
0.85 BR- #G1
(GND1)
To G3
To
FR/H
2
S1A
1
GND
(GND)
S19 0.50 Y- #B1 #B1 0.50 Y- S1N
4
AV 6 FL AV
Modulator rear LH
(DV) (FLDV)
Modulator rear RH
S18 0.50 BR-W #B2 #B2 0.50 BR-W S2R
ABS sensor rear LH
ABS sensor rear RH

EV 3 FL EV
ABS sensor front RH

(HV) (FLHV)
#B3 #B3
Twist
Twist
S2E 0.50 B-R 0.50 B-R S1L

12 FL SSR
(SFL+) (FLS+)
5
S2F 0.50 W-R #B4 #B4 0.50 W-R S1K
15 FL SSR
(SFLE) (FLS-)
S17
Twist
Twist
1
GND
(GND)
S16 0.50 BR-R #B5 #B5 0.50 BR-R S87
6
AV 4 FR AV
(DV) (FRDV)
S15 0.50 BR-Y #B6 #B6 0.50 BR-Y S88
3
EV 1 FREV
(HV) (FRHV)
Twist
Twist
Twist
Twist
S2G 0.50 Y- #B7 #B7 0.50 Y- S1X

10 FR SSR
(SFR+) (FRS+)
7
S2H 0.50 B- #B8 #B8 0.50 B- S1Y
13 FR SSR
(SFRE)
SAPH12Z030200065
(FRS-)
AB
17 RR Sensor
18 RR Sensor
11 RL Sensor
14 RL Sensor
RR AV
RL EV
RL AV
RREV
5
8
DST- IGN GND
S24 S1Q S2B
S1U
(RLDV)
S29
(RLHV)
S2C
(RLS+)
S2D
(RLS-)
S28
(RRDV)
S1T
(RRHV)
S20
(RRS+)
S1Z
(RRS-)
SAE+ VVI
S2P S1V
WL VVI-
S1S S84
Twist Twist
1
0.50 GR-R
0.50 L-W
0.50 L-R
0.50 L-Y
0.50 Y-R
0.50 W-
0.50 R-
0.50 L-
FRS- FRS+ FRDV FRHV

S1Y S1X S87 S88
RRS+ RLS- RLS+ RRHV RLDV RLHV

S20 S2D S2C S1T S1U S29
Twist Twist
RRS- FLS- FLS+ RRDV FLDV FLHV
S1Z S1K S1L S28 S1N S2R
+ -
S01 S02
3
#BG
#BC
#BD
#BA
#BB
#BE
#BF
#B9
#B9
#BA
#BB
#BC
#BD
#BE
#BF
#BG
DV DV
S19 S1F
Twist Twist
HV GND HV GND
0.50 GR-R
S18 S1A S1E S1G

0.50 L-W
0.50 L-R
0.50 L-Y
0.50 Y-R
0.50 W-
0.50 R-
0.50 L-
4 8
Twist Twist HEAVY DUTY HEAVY DUTY
#1C
#1D
#1E
#1A
#1B
#1F
#18
#19
SWP SWP
FR W/H SFLE SFL+ SRLE SRL+

S2F S2E S2K S2J
RR W/H
#1C
#1D
#18
0.50 GR-R #19
#1E
#1F
#1A
#1B
5 9
0.50 L-W
0.50 L-R
0.50 L-Y
0.50 Y-R
0.50 W-
0.50 R-
0.50 L-
DV DV
S16 S1C
0.85 B-
HV GND HV GND
0.85 B- S15 S17 S1B S1D
(SRRE)
(SRR+)
(SRLE)
(SRL+)
6 10
(GND)
(GND)
(NV)
(HV)
(HV)
S2M
S1G
(DV)
S1D
S1C
S1E
S2K
S1B
S1F
S2L
S2J
HEAVY DUTY HEAVY DUTY
SWP SWP
GND
GND
&1C 2.00 B- &1K

EV
EV
AV
AV
To G3 SFRE SFR+ SRRE SRR+

(CAS3) (CAS3) S2H S2G S2M S2L
1 2 3 1 2 3
8 9 10 11 7 11
SAPH12Z030200066
6
5
4
3
2
1
EL02_001.fm
2.00 L-
AE0 2.00 L- #F4 #F4 2.00 L-
EL02–70
30A
(91LD)
Twist
Twist
To ABS (Live)
S2P 0.50 BR- K2E
6 J1708(+)
70 ページ
(SAE+) (+)
To G3
S24 0.50 B-R K2F
5 J1708(-)
To DIAG
connector
(DST-) (-)
ABS ECU X3
ABS ECU X2
ABS ECU X1
(S-)
S1V
AHW
1 Valve power
(VVI)
ABS motor relay

S1Q 0.50 L-R AA9
2 ECU power
HYDRO MAX unit 1

(IGN) (1CLD)
To Fuse
To G3
3.00 B-
ABS diagnosis switch

0.50 L-
2
0.50 L- Warning S1S 0.50 Y- E0K
18
light (WL) (MABS)
To ABS
&1A
ABS(M) light (Meter)
(CAS1)
N
CHK
A1A
S01 0.50 Y-
(CAS2)
&1E
(+)
S02
HYD-S
S2B
(ABS)
N33
3.00 B-
4
12 ECU GND (-)
A19
(GND)
(22LD) 5A (22+)
3.00 B-
AC ABS CIRCUIT-2 HYDRO MAX BRAKE

Motor SBV
8
monitor (MTM)
(LCT ATM)
(A450 ATM)
3.00 L-
(CAS2)
&1B
To ATM ECU
0.50 B-
K9H
5
#F1 #F1 0.50 L-
0.50 BR-
0.50 BR-B (SGND)
SBY S04 S03 0.50 BR-
1 Motor- &D5 0.50 BR-

(MT-) (S-) (S+)
(G45A)
To J/C
(G4-a)
SBX 3.00 L- S06 S05
2 Motor+
(MT+) (LD) (B)
(GND1)
(GND)
SBF
0.85 BR- #G1
6 7
3.00 L-B
9
8
7
3 GND
AC
10
11
12
monitor
module
(LD)
A2W
6 GND
To HYD Max
#F5 #F5 0.50 BR-B

7 GND
To
0.85 BR-
ELECTRIC WIRE
FL ABS
SBZ 0.85 BR- #FM #FM 0.85 BR- S84
8 GND 3 GND
(GND1) (VV1-)
0.50 Y-
S19 0.50 Y- #F9 #F9 0.50 Y- S1N
13 FL AV 1 FL AV
(DV) 0.50 BR-W (FLDV)
S18 0.50 R-W #F8 #F8 0.50 BR-W S2R
12 FL EV 2 FL EV
(HV) (FLHV)
0.50 L-B
S16 0.50 L-B #FJ #FJ 0.50 L-B S87
5 FR AV 4 FR AV
HYDRO MAX unit 3

HYDRO MAX unit 2
(DV) 0.50 L-W (FRDV)
ABS sensor rear LH

ABS sensor rear RH
S15 0.50 L-W #FH #FH 0.50 L-W S88
ABS sensor front LH

ABS sensor front RH
4 FR EV 5 FR EV
(HV) (FRHV)
3
0.50 L-R
S1F 0.50 L-R #FG #FG 0.50 L-R S1U
1 RL AV 7 RL AV
(DV) 0.50 L-Y (RLDV)
S1E 0.50 L-Y #FR #FR 0.50 L-Y S29
2 RL EV 8 RL EV
(HV) (RLHV)
0.50 L-O
S1C 0.50 L- #FQ #FQ 0.50 L-O S28
10 RR AV 10 RR AV
(DV) 0.50 BR-B (RRDV)
S1B 0.50 LG- #FP #FP 0.50 BR-R S1T
11 RR EV 11 RR EV
(HV) (RRHV)
SC0 1.25 B- SBW

1 GND 15 Pump RLY
(GND2) (MTR)
8
12 EXH RLY
&1B 3.00 B- &1A
SAPH12Z030200067
To G3
(CAS2) (CAS1)
AC
RR SSR
RR SSR
FR SSR
FR SSR
RL SSR
RL SSR
FL SSR
FL SSR
1
1
6
RLS+ FRS+ FLS+
S2C S1X S1L
(FLS+)
S1K
(FLS-)
(FRS+)
S1Y
(FRS-)
(RLS+)
S2D
(RLS-)
(RRS+)
S1Z
(RRS-)
S1L
S1X
S2C
S20
RLS- FRS- FLS-
S2D S1Y S1K
RRS- RRS+
S1Z S20
Twist Twist Twist Twist

1
0.50 GR-R
0.50 W-R
0.50 B-R
0.50 Y-R
0.50 W-
0.50 R-
0.50 B-
0.50 Y-
VVI RRDV RLDV FRDV FLDV

S1V S28 S1U S87 S1N
MTM DST- IGN RRHV RLHV FRHV FLHV

SBV S24 S1Q S1T S29 S88 S2R
WL GND SAE+ MTR VVI-
S1S S2B S2P SBW S84
2 3
+ -
S01 S02
4
#FN
#FE
#FS
#FK
#FF
#FA
#F7
#FL
HEAVY DUTY
#FE
#FN
#F7
#FF
#FL
#FS
#FA
#FK
MT+ SWP
Twist Twist SBX
MT- SFLE SFL+
9
0.50 GR-R
SBY S2F S2E

0.50 Y-R
0.50 W-
0.50 W-
0.50 R-
0.50 B-
0.50 B-
0.50 W-
6
Twist Twist
Twist Twist HEAVY DUTY
#1A
#1B
#18
#19
0.50 W-R
0.50 B-R
SWP
0.50 W-
0.50 W-
0.50 B-
0.50 B-
0.50 B-
0.50 Y-
FR W/H
RR W/H DV
S16
HV
S15 S1E
HV DV
S1F
SFRE
S2H
SFR+
S2G 10
#18
#19
#1A
#1B
GND1
Twist Twist SBZ
Twist Twist
0.50 GR-R
DV HV HV DV
0.50 Y-R
0.50 W-
0.50 R-
S19 S18 S1B S1C HEAVY DUTY
SWP
Twist Twist 7 SRLE

S2K
SRL+
S2J 11
(SRRE)
(SRR+)
(SFRE)
(SRLE)
(SFR+)
(SRL+)
(SFLE)
(SFL+)
S2M
S2G
S2H
S2K
S2E
S2F
S2L
S2J
HEAVY DUTY
GND2 SWP
SC0
SRRE
S2M
SRR+
S2L 12
9 10 11 12 8
SAPH12Z030200068
5
4
3
2
1
EL02_001.fm
EL02–72
To FL BRK
72 ページ
(+)
A3B
Motor relay
Flow switch
Motor pump
Monitor module
(AWG10)
8.00 B-R
Differential switch
(B)
%21
3
2
3.00 B-R
SBL 3.00 L- SBU
1
SBT
AD HYDRO MAX SYSTEM CIRCUIT

(MT+) (NO) (B) 0.85 Y-
SBS SBR 0.85 Y- #F3 #F3 0.50 Y- SBG
5 Motor RLY
(S-) (S+) (MTR)
5BE 0.50 Y-G EE6
Body earth (CAB dash panel)

3 Motor
indicator
meter
(MTWL) (MTR-)
Body GND
8.00 L-
To COMB.
0.85 L-B
0.50 L-B
0.50 L-B #F2 #F2 0.50 L-B SBC

1 Flow SW
(FLSW)
%22 BRK S 0.50 L-
3.00 L- A17 A18 0.50 L- #FB #FB 0.50 L- SBH
6 Motor
(21+) 5A (21LD) (MTM) monitor
SBM
(FLS+)
(21+)
SBJ 0.50 L-Y AAB
AD
7 Power
brake
To ABS
4
(IGN) (1DLD)
To Fuse
ECU(HYD)
2 Brake
indicator
S2B
ELECTRIC WIRE
(GND)
(G45A)
0.50 BR- &D5
SBK 0.50 R-
8 Brake SW
To J/C
(BRSW)
0.50 BR- SBF

4 GND
5
Hyd-Max
(GND)
SBP
(DPS+)
(#U4)
%AM
0.50 Y-R
0.50 Y-R #F6 #F6 0.50 Y-R
To U2 JC
EE7
(BRKP)
(Meter)
Comb meter
SAPH12Z030200069
AD
FLSW MTM MTWL

SBC SBH SBE
GND MTR IGN BRSW

SBF SBG SBJ SBK
B
SBT
S- S+ FLS+
SBS SBR SBM
NO
SBU
4
2
MT+
SBL
DPS+
SBP
3 5
SAPH12Z030200070
AE
a 2
E66
(MODF)
NX5
(-)
NX6
(+)
%AL 0.50 R-
To U2 JC
(KTR)
ABV 0.50 W-L
0.50 L-B
0.50 B-
To ATM (M)
(Power supply) (1ELD)
&EA 0.85 B-
To J/C G3
(G3 JC) 0.50 V-Y
0.50 W-L
A16 0.50 W-
To Starter
(Power supply) (16LD) 0.50 V-Y N7X N7Y 0.50 L-B
(A) (K)
3
CAB SIDE WIRING
E2M To PKB SW
(OD1)
(Meter)
NPD
NQ2
NPK
(BK)
(IG)
(N/C-)
1 33 12
E0W 0.50 Y-G NQ8

1
c 40 3 30 4 31 32 6 34 17 44 43
(MAOT) (BTS)
NPF
(P)
NPZ
(R)
NPG
(N)
NQ0
(D)
NQ1
(2)
NPH
(L)
NPQ
(SP1)
NPP
(SP2+)
NQA
(SP2-)
NQ9
(SGND)
0.50 Y-G
A81 0.50 R-L #67

b d
0.01 DR-N
0.50 B-R
0.50 L-O
0.50 L-R
(71LD)
0.50 L-B
0.50 L-Y
(DSW1)
0.50 W-
0.50 B-
0.50 L-
050 Y-
0.50 R-L
%DG
%DY 0.50 B-R f
e (JC)
(NRF)
#TC
#TD
#TB
#LB
#T2
#T3
#T4
#T5
#T6
#T7
#T8
#T9
#TA
#LB
#T2
#T3
#T4
#T5
#T6
#T7
#T8
#T9
#TA
#TB
#TC
#TD
0.50 L-B
0.50 R-L
To Starter RLY
0.01 DR-N
(ENG Starter)
0.50 L-W
0.50 B-R
0.50 L-R
0.50 L-B
0.50 L-Y
0.50 W-
0.50 G-
0.50 L-
0.50 P-
0.50 V-
A3T
(SW)
0.50 W-B
CHASSIS SIDE WIRING
NK3
NK1
(S+)
(B)
0.85 Y-
4
NK4
(NO)
NK2
(S-)
#3N
(22)
(NSRL)
(NSNL)
(NSDL)
(NSPL)
(SP2+)
(NS2L)
(NSLL)
(TSW)
(SP2-)
(NSN)
(NSC)
NWW
(NSB)
NWM
NWK
NWV
NWQ
NWN
NWR
NWU
NWP
NWS
NWT
NWL
RL
NL
DL
PL
2L
LL
0.50 O-
0.50 B-
SP2+
B
BTS
SP2-
5 LL
2L
#15
g
(5)
DL
6
T/M Case GND
NL 7
&1E 3.00 B- AHW RL
To G3
(CAS2) (S-)
PL
Connectors on ATM
SAPH12Z030200071
AE AUTOMATIC TRANSMISSION CIRCUIT-1 : EQUIPPED WITH AISIN A450 ATM

1 A450 ECU a To OD-OFF light & ignition (Meter)
2 Overdrive switch b To Fuse back light (Power supply)
3 A450 ATM diode c To ATM oil temperature light (Meter)
4 ATM back light relay d To Power window drivers seat master switch (Power
5 Oil temperature switch window)
6 Neutral start switch e To U2 J/C (Common rail 4)
7 Vehicle speed sensor f To U2 J/C (Meter)
8 Solenoid temperature switch g To Back light switch (Back light)
h To ABS ECU (ABS 2 HYDRO MAX)
i To ABS light (Meter)
AE
To DST-1 To U2 J/C To U2 J/C To CAN

(DST-1) (Common rail)
NE+ SP2+ VA ATF+ DGLP ST S2 S1

KS2
(TC)
%DK
(JC)
%DD
(JC)
NPN NPP NPR NPS NPT NPV NPW NPX
%BM
(CAN-)
%BC
(CAN+)
SGND SP2- VC ATF- SDG SDL SLT- SLT+
NQ9 NQA NQB NQD NQE NQF NQG NQH
Twist
1-1
0.50 L-W
0.50 G-
0.50 G-
0.50 P-
0.50 V-
0.50 V-Y
Twist
IG GND1 P N L
NPD NPE NPF NPG NPH
GND2 R D 2 BK
NPY NPZ NQ0 NQ1 NQ2
(DGLP)
(SDG)
(NE+)
NPM
NQC
(DG)
NQE
NQB
NPN
NPR
(VC)
NPT
(VA)
(E2)
1-2
23 14 49 15 19 46 47
1
27 26 25 52 20 48 54 53 41 2 29
NPX
(S1)
NPW
(S2)
NPV
(ST)
NQF
(SDL)
NPS
(ATF+)
NQD
(ATF-)
NQH
(SLT+)
NQG
(SLT-)
N33
(ABS)
NPE
(GND1)
NPY
(GND2)
OD1 DG
NPK NPM
SP1 BTS ABS

NPQ NQ8 N33
10A
1-3
0.50 L-W
0.50 W-L
0.85 BR-
0.85 BR-
0.50 L-O
0.50 L-R
0.50 R-L
0.50 L-B
0.50 L-Y
0.50 B-L
0.50 Y-
- + A K
NX5 NX6 N7X N7Y
S1S 0.50 Y- E0K

h i
(WL) (MABS) 2 3
#TM
#TG
#TH
#G2
#TE
#TK
#TF
#TL
#TJ
#TE
#TF
#TG
#TH
#TJ
#TK
#TL
#TM
#G2
0.50 BR-
SP2+ SP2-
TSW NWV NWW
0.50 L-W
NWK
0.50 W-L
0.50 L-R
0.50 R-L
0.50 L-B
0.50 L-Y
0.50 L-Y
0.50 B-L
5 7
(ATF+)
(G4-A)
(SLT+)
(ATF-)
(SDL)
(SLT-)
NWX
NWY
NWZ
(ST)
NX0
NX1
NX2
NX3
NX4
&1D
(S1)
(S2)
S1
S2
ST
SDL
ATF+
ATF-
SLT+
SLT-
To Weld splice G4 NSLL NS2L NSDL SLT+ ST S2 S1

NWU NWT NWS NX3 NWZ NWY NWX
NSPL NSNL NSRL NSC SLT- ATF+ ATF- SDL

NWP NWR NWQ NWN NX4 NX1 NX2 NX0
NSN NSB
NWL NWM
8
(Shift & lockup solenoid) (Oil temp.sensor linear solenoide)
8 6
Connectors on ATM
SAPH12Z030200072
7
6
5
4
3
2
1
AF
CHASSIS SIDE WIRING CAB SIDE WIRING EL02_001.fm
EL02–76
#CG #CG E4L
(MMT+)
To
N53
N4S
N4R
N4Q
SL+A
SOLD
SOLC
PSWC
Meter
#CH #CH E4M
(CAN+)
%CF
Twist
Twist
(MMT-)
76 ページ
NXF
E2
28
(H)
N56
N54
N55
N4X
N4U
Twist
Twist
SOLF
(CAN+)
5
NXG
(L)
N4L
O1L
N4V
N4P
N4N
N4W N4M
SOLI
CAN CAN
PSWR SL+B
SLGB
SUMT SOLB
PSWD SLGA
PSWE SOLA
(CAN-)
Twist
Twist
%CG
ID
(CAN-)
N52
N4T
SOLE
ATM mode switch
Main transmission
1
ATM back light relay

Twist
Twist
Output speed sensor

Engine speed sensor
#CF #CF %BM
Turbine speed sensor

(CAN-)
4
#CE #CE %BC
To J/C SIG
N4F N4E
(CAN+)
SPT- SPT+
(CAN circuit)
45
Twist
Twist
N4E 0.85 B- N3G
A
80
(SPT+) (SPT+)
4
N4F 0.85 Y- N3H
B
20
(SPT-) (SPT-)
ALLISON 2200RDS/2500RDS ATM ECU

O9W 0.85 R-B
AT+
N5F
N5H
INJ+
O9V
38
(NSOU) (NSIN)
N4W 0.85 G-W N3Y
8
3
18
54
(SUMT) (SUMT)
AT-
AF
N5G
N56 0.85 G-B N4A
11
77
(PSWR) (PSWR)
N55 0.85 G- N49
6
57
(PSWE) (PSWE)
N54 0.85 G-R N48
7
3
79
(PSWD) (PSWD)
0.85 P-
ON
N53 N47
OFF
4
17
(PSWC) (PSWC) N5G 0.85 B- &E6
0.85 L- To Earth J/C (G3)
N52 N46 N35 0.85 L-B #C5 #C5 0.50 L-B N5F (AT-) (G3JC)
ELECTRIC WIRE
24
76
42
(I D) (I D) (ECO) (AT+)
O1L 0.85 G-L O1K N5H
19
74
(SOL I) (SOL I) (INJ+)
N4U 0.85 V- N3W
10
78
(SOLF) (SOLF)
N4T 0.85 LG- N3V
3
51
(SOLE) (SOLE)
N4S 0.85 Y-R N3U
2
33
(SOLD) (SOLD)
5
N4R 0.85 Y-G N3T
1
STOP LP RLY
52
(SOLC) (SOLC)
N4P 0.85 R-Y N3R
17
36
(SLGB) (SLGB)
N4Y 0.85 L-Y N42 NXE 0.85 Y-R #C3 #C3 0.30 Y-R E1F To Pulse converter
22
73
25 (Meter)
REV
(NSA) (NSA) (VPLS) (PC I +)
8PLS/
N4Z 0.85 L-R N43
21
53
(NSB) (NSB)
N50 0.85 L-B N44
20
14
(NSC) (NSC)
AUTOMATIC TRANSMISSION CIRCUIT-2 : EQUIPPED WITH ALLISON 2200RDS/2500RDSATM

N51 0.85 L-W N45 N1R 0.85 W-L #CD #CD 0.30 W-L C9D To STP AT diode
1
23
34
(Stop/Turn)
ECU
0.50 W-L
(NSP) (NSP) (STOP) (A)

function off
N4N 0.85 R-W N3Q
15
55
(SLGA) (SLGA)
N4L 0.85 R- N3N
14
11
(SOLA) (SOLA)
N4M 0.85 G-Y N3P N1U 0.85 Y-B #C7 #C7 0.30 Y-B E0V To Check ATM light (-)
16
71
29
(SOLB) (CHK) (MCAT) (Meter)

(SOLB)
N4X 0.85 R-G N3Z
9
58
SAPH12Z030200073
(E2) (E2)
EL02_001.fm
N31 0.85 V- #C9 #C9 0.30 V- E2Y To Inhibit light
24
(IHT) (MINH) (Meter)
Twist
Twist
N0X 0.85 W- N2P
A
60
(SPO+) (SPO+)
77 ページ
6
N0W 0.85 R- N2C
B
40
(SPO-) (SPO-)
N1S 0.85 Y-G #C8 #C8 0.30 Y-G E0W To ATM oil temperature
64
(TEMP) (MAOT) light (-) (Meter)
Twist
Twist
N0V 0.85 BR- N2B
A
59
(SPE+) (SPE+)
7
N0U 0.85 B-R N2A N1P 0.85 Y- #C6 #C6 0.50 Y-
B
39
21
(ABS)
0.50 W-L
(SPE-) (SPE-)
E0K 0.50 Y- S1S To ABS ECU

METER
(MABS) (WL) (ABS air HYD)
7
6
N0V N0U
N0X N0W
SPE+ SPE-
SPO+ SPO-
C1G To Rear COMB
N1M 0.85 L-B 0.50 O- #15 #15 (BLP+) LH (Back light)
65
C1Q
(ROUT) (BLP+)
(S-)
NK2
(NO)
NK4
1
2
N2P
N2C
SPO-
N3H
N3G
SPT-
(B)
(S+)
NK1
NK3
N2B
N2A
SPE-
SPO+ SPE+
0.50 R-L #LB #LB 0.50 R-L A81 To Back light
N48
(71LD) (Power supply)
E2
N3Z
O9V
NSIN
N27 0.85 W-L 0.50 W-L #C4 #C4 0.50 W-L
63
(IG)
N49
PSWE
N47
N3W N4A
SPT+ PSWD SOLF PSWR
PSWC
N3R
SLGB
ID
N46
AF
N3Q
(1ELD)
ABV
N45
N3Y
NSP
N1N N3A 0.85 W-B A26
SLGA SUMT
To ATM
41
10
N44
O1K
NSC
SOL I
(NOUT) (BAT1) (63LD) (Power supply)
ELECTRIC WIRE
N43
N3U
NSB
SOLD
N42
NSA
N3T
N1K 0.85 W-B
To ATM (M)
70
(BAT1)
(Power supply)
N3V
SOLC SOLE
N3P
N3N
SOLB
SOLA
To U2 ECU
N1J 0.85 BR-
69
1
(GND2)
K45
N1K
N3A
GND
(NUSW)
N1H 0.85 BR- &1D
N1J
BAT1 GND2
(GND1) (G4-A)
W/S G4
N1U
CHK
(K45)
%DW
N1H NXG
BAT1 GND1 CAN-
NXF
&1G &1G
CAN+
U2 J/C2
cable-
To Battery
%DY
(NRF)
0.85 B-R #C1 #C1 0.50 B-R 0.50 B-R NJX To ATM
starter relay
N1M
(S+)
NXE
VPLS
N1S
ROUT TEMP
N31
I HT
IG
N27
N35
ECO
N1R
STOP
N1P
N1N
ABS
NOUT
SAPH12Z030200074
EL02–77
AG
To DIAG
(DIAG connector 9P)
To ATM (M) ABV
K2E
(+)
K2F
(-)
(Power supply) (1ELD)
Twist
0.50 BR-
0.50 B-R
6
To J/C Signal CAN CAN
(CAN circuit) Twist (H) (L)
0.50 W-L
CAB SIDE WIRING
(CAN+)
%CJ 3 8 15 11 5 12 13 14
%BC
%BM
(CAN-)
(DAG+) %CK
O9G
(CASH)
O9H
(CASL)
O9N
(SPWM)
O9L
(GNDS)
O9K
(I GS)
O9J
(BATS)
To Meter (DAG-)
Twist
E4L
(MMT+)
E4M
(MMT-)
0.50 BR-
0.50 B-R
Twist
0.50 BR-
0.50 B-R
Twist
0.50 L-
Twist
(SAE+)
Twist
(DST-)
S2P
S24
Twist
Twist
Twist
CASH GNDS
ABS ECU O9G O9L
CASL BATS I GS SPWM

Twist Twist O9H O9J O9K O9N
#CG
#CH
#CE
#CF
#D4
#D5
#D1
6
#CG
#CH
#CE
#CF
#D4
#D5
#D1
SWP
Twist Twist
OLEV SPT+ SPT- SUMT SOLB SOLA SL+F E2
Twist N18 N1F N1G N0Y N16 N17 N1E N19
0.85 L-
%CG
0.85 BR-
0.85 B-R
(CAN-) C3 ID SL+A SOLD SOLC SL+B

%CF N1C N1A N12 N13 N14 N15
(CAN+) SOLF SOLG SOLE VC

N1D N0Z N11 N1B
Twist Twist
2
Twist 3
(EPWM)
(CAN+)
(CAN-)
(SCI+)
(SCI-)
NXG
O9M
NXF
N28
N29
CHASSIS SIDE WIRING
28 8 32 72 34
CAN CAN
49 (H) (L) 1
CAN
SHIELD
20 80 16 76 77 54 58 31 36 52 11 33 55 71 12 74 51 37
N2Z
(SPT-)
N2N
(SPT+)
N2F
(OLEV)
N2H
(I D)
N2K
(C3)
N2R
(SUMT)
N2G
(E2)
N2M
(SL+F)
N2E
(SOLA)
N2D
(SOLB)
N2Y
(SL+B)
N2X
(SOLC)
N2W
(SOLD)
N2V
(SL+A)
N2J
(VC)
N2U
(SOLE)
N2S
(SOLG)
N2L
(SOLF)
Twist
0.85 R-W
0.85 R-G
0.85 L-W
0.85 BR-
0.85 B-R
0.85 R-Y
0.85 L-O
0.85 L-R
0.85 R-L
0.85 B-L
0.85 L-B
0.85 L-Y
0.85 Y-G
0.85 Y-R
0.85 Y-B
0.85 O-
0.85 P-
0.85 L-
Twist
(SUMT)
(SOLG)
(SOLC)
(SOLD)
(OLEV)
(SOLA)
(SOLB)
(SOLE)
(SOLF)
(SL+B)
(SL+A)
(SL+F)
(SPT+)
(SPT-)
N1G
(VC)
N1C
N1D
N1A
(I D)
(C3)
N0Y
N1E
N1B
N1F
(E2)
N0Z
N18
N19
N17
N16
N15
N14
N13
N12
N11
Remark: Above numbers 14 13 15 20 3 18 19 11 4 5 1 9 2 6 16 8 10 12

show 20 pins connector of
transmission side (pair sub
harness), but don't show
terminal position of this connector.
2 3
SAPH12Z030200075
AG AUTOMATIC TRANSMISSION CIRCUIT-3 : EQUIPPED WITH ALLISON 3000RDS ATM

1 ALLISON 3000RDS ATM ECU
2 Transmission TRANS2
3 Transmission TRANS1
4 Output speed sensor
6 Selector
EL02_001.fm
N1U 0.85 Y-B #DH #DH 0.30 Y-B E0V To Check A/T light (-)
29
(CHK) (MCAT) (Meter)
5
79 ページ
NOW NOX
NOU NOV
SPE- SPE+
SPO- SPO+
N1S 0.85 Y-G #DJ #DJ 0.30 Y-G E0W
To A/T oil temperature light (-)
64
(TEMP) (MAOT) (Meter)
Twist
Twist
N0X 0.85 W- N2P
A
60
(SPO+) (SPO+) NXE 0.85 Y-R #DN #DN 0.30 Y-R E1F To Pulse converter
4
25
N0W 0.85 R- N2C (VPLS) (PC I+) (Meter)
B
40
(SPO-) (SPO-)
N1R 0.85 W-L #DP #DP 0.30 W-L C9D To STP AT diode
1
(STOP) (A) (Stop/turn)
Twist
Twist
N0V 0.85 B- N2B
A
59
E0K 0.50 Y- S1S To ABS ECU
(SPE+) (SPE+)
5
N0U 0.85 W- N2A (MABS) (WL) (ABS AIR (CAB))
0.50 BR-
0.50 W-L
B
0.50 W-B
39
(SPE-) (SPE-) N1P 0.85 Y- #DK #DK 0.50 Y-
21
(ABS)
%DY %DW To U2 ECU
(NRF) (K45)
N1N 0.85 B-R #DL #DL 0.50 B-R
41
0.50 B-R To ATM
N2P
N2C
SPO-
(NOUT) starter relay
N2Z
N2N
SPT-
(Starting)
SPT+
N2B
N2A
SPE-
SPO+ SPE+
E2
N2G
1
N1M 0.85 L-B 0.50 O- #15 #15 C1G To Rear
i
65
COMB LH
N2L
(BLP+) (Back light)
(ROUT)
C3
N2K
N2E
SOLF SOLA
(S-)
NK2
(NO)
NK4
ID
N2F
N2H
(BLP+)
C1Q
OLEV
AG
N2W N2R
SOLD SUMT
(B)
(S+)
NK1
NK3
N2U
AT Back light relay
SOLE
O9M N2X
0.50 R-L #LB #LB 0.50 R-L
EPWM SOLC
ELECTRIC WIRE
To Back light
(Power supply)
N28
N2D
SCI+
VC
N2J
N29
SCI-
N27 0.85 W-L 0.50 W-L #D3 #D3
N2S
N2M
SL+F
63
SOLB SOLG
(IG)
N2V
N2Y
SL+A
SL+B
1
N3A 0.85 W-B
10
N1K
N3A
(BAT1)
N1J
BAT1 GND2
N1K 0.85 W-B 0.85 W-B #D2 #D2
N1U
CHK
70
(BAT1)
N1H NXG
BAT1 GND1 CAN-
NXF
CAN+
N1J 0.85 B-
(63LD)
A26
69
(GND2)
#G1 #G1 0.85 BR- K9H
N1M
N1H 0.85 B-
9
NXE
(SGND)
VPLS
To DIAG
(GND1)
N1S
ROUT TEMP
(Power supply)
To ATM battery
(connector 16P)
IG
N27
(G4-A)
&1D
&1G &1G
N1R
STOP
N1P
N1N
ABS
G4
NOUT
W/S
SAPH12Z030200076
To Battery cable-
EL02–79
AH AI
To Fuse room light #AA 0.85 W-G K9G Diagnosis Connector

(Power supply) (16P)
(10) (+24V)
0.50 W-G
To Fuse air driver
(Power supply)
1
K2D
+12V
(72LD)
A5P
(VB)
N6S Twist Twist %BG
CAN+
(CAN+) (CAN+) Diagnosis Connector
N6T %BP (16P)
CAN-
(CAN-) (CAN-)
CAB SIDE WIRING
N6U
CAN Shild
(CANS)
K2E Twist Twist S2P
1708+
(+) (SAE+) To ABS ECU
K2F S24
1708-
(-) (DST-)
K2G
0.50 GR-W
GND
0.50 BR-
(GND)
Twist Twist N28
(SCI+) To ATM ECU
N29 (For 3000RDS AT)
0.50 BR-
(SCI-)
CAN-
CANS N6T
N6U CAN+
N6S
+ GND VB
K9H 0.85 BR- #G1 K2E K2G K2D
To DST-1 To FR/H
-
(SGND) (GND1) K2F
#E1
1
#E1
0.50 GR-W
CHASSIS SIDE WIRING
U0C
(+)
- +
U0D UOC
1
1
(-)
U0D
0.50 B-
&1A 3.00 B- &1B

To G3
(CAS1) (CAS2)
SAPH12Z030200077
AH AIR DRIER CIRCUIT AI DIAGNOSIS CONNECTER (9P) CIRCUIT

1 Air drier 1 Diagnosis connector (9P)
AJ
+24V TC CAN-
K9G KS2 KS4
ISOK CAN+ SGND +

K9E KS3 K9H KE4
0.50 R-W K0H
01 (+) KE4 To U2 ECE
(DGSW)
02 1
03 1
04
05 (SGND) K9H
Twist Twist
06 (CAN+) KS3 %BA (CAN+) CAN H line
CAB SIDE WIRING
07 (ISOK) K9E To J/C SIGNAL

(CAN circut)
08
%BK (CAN-) CAN L line
09
2
0.85 BR-
0.50 G-
10
11
%DJ
(JC)
%DK
(JC)
%DH
(JC)
12
13
0.50 G- K6U
14 (CAN-) KS4 To U2-ECU
(ISOK)
15 (TC) KS2
NQE
16 (+24V) K9G (SDG)
To A450 ATM ECU
NPM
(DG)
0.85 W-G
#G1
#AA
#G1
#AA
CHASSIS SIDE WIRING
0.85 W-G
0.75 W-B
(G4-A)
&1D
(61LD)
A22
To Fuse room light

W/S G4 (Power supply)
SAPH12Z030200078
AJ DIAGNOSIS CONNECTOR (16P) CIRCUIT

1 Diagnosis connector (16P)
2 U2 junction 2
AK
METER
LO
HI
(MMT+)
(MMT-)
E4M
E4L
Twist
0.50 P-
0.50 V-
Twist
Twist
(CAN+) %BB
(CAN-) %BL
J/C Signal
CAN HI line
CAN LO line
CAB SIDE WIRING
(CAN+)
(CAN+)
(CAN+)
(CAN+)
(CAN-)
(CAN-)
(CAN-)
(CAN-)
%BC
%BM
%BG
%BP
%BA
%BK
%BD
%BN
Twist
0.50 P-
0.50 P-
0.50 P-
0.50 V-
0.50 V-
0.50 V-
0.50 P-
0.50 P-
0.50 P-
0.50 V-
0.50 V-
0.50 V-
Twist
Twist

%CU 0.50 V-
(CAN-)
%CT 0.50 P-
(CAN+)
Twist
(CASH)
(CAN+)
(CAN+)
(CA2H)
(CASL)
(CA2L)
(CAN-)
(CAN-)
0.50 P-
0.50 P-
0.50 V-
0.50 V-
NQB
KRG
NPR
KRH
O9G
(VC)
O9H
N6S
(VA)
N6T
KS3
KS4
Twist
1 2 3 4 Selector
Commonrail (Allison 3000RDS)
Twist Twist
#CG
#CH
#CE
#CF
#CG
#CH
#CE
#CF
Twist Twist
CHASSIS SIDE WIRING
0.50 P-
0.50 P-
0.50 V-
0.50 V-
Twist Twist
%CG
(CAN-)
%CF
(CAN+)
Twist
Twist
0.85 P- NXF
(CAN+)
0.85 V- NXG 5
(CAN-)
SAPH12Z030200079
AK CAN COMMUNICATION CIRCUIT

1 A450 ATM ECU
4 U2 ECU
5 2200RDS/2500RDS, 3000RDS ATM ECU
AK
CAN-
CANS N6T
N6U CAN+
N6S
NE+ SP2+ VA ATF+ DGLP ST S2 S1
NPN NPP NPR NPS NPT NPV NPW NPX + GND VB
K2E K2G K2D
SGND SP2- VC ATF- SDG SDL SLT- SLT+
NQ9 NQA NQB NQD NQE NQF NQG NQH -
K2F
1
2
+BF1 MRL2 MRL1 CGD2 CGD1 GRY2 GRY1

L2H K57 K56 K0C K0B KVP KVN
+24V TC CAN-
K9G KS2 KS4
CE/G SET CLSW
K0L K4A K46
ISOK CAN+ SGND + PTO

K9E KS3 K9H KE4 CA2L CA2H RES AT
KRH KRG K49 K4T K4X
OLSW
L2Z
3 4
BPWR OP6 DISP CAN+ MODE PRTY BT8 BT4 BT2 BT1 IG SPWR SCI+
N21 N26 N24 NXF N23 N1W N1X N1Y N1Z N20 N27 N22 N28
GND CHK CAN- SCI-

N25 N1U NXG N29
SAPH12Z030200152
EL02_001.fm 84 ページ２００６年２月１３日　月曜日　午前９時５５分
AL
MT + 3000RDS
A450
EATON
2200RDS / 2500RDS, 3000RDS
CAB SIDE WIRING
U21 U22 4 BSF2 11 7 11 6 7 8 18 15 5

U238 13 17 U234 U228 #1W #LB #L7 #AB #M6 #M7 #M8 #AJ #AF #M5
#U1 #U2
#P7 #AD #MH #L4 #P3 #UU
1
#A1 5 10 U23 6 CAN CAN CAN CAN 17 12 U242 U241 7
1 U24 U236 U237 U239 U223 U224 U225 10 U229
#AA #U3 # L 6 # C E # C F # C G # C H # A H # A C # P B # PA # A 7
#L1 #U4 #P5 #P6 #P8 #UP #UQ #L5 #UR #LA #UV
9 U243 U25 8 2 4 8 6
3 U26 U27 U28 U240 16 1 4 U226 U227 U230 #A8
#L3 #U6 #U7 #AG #M1 #M4 #L9 #US #UT #UW #PC #U5 #L8 #A2 #A4 #A6
#U8 #P9
2 GND1 U244 5 14 3
2 HMV+ GND3 2 U231 U232 U233 #G1 #PD #A5 #AE #A3
#L2 #E2 #H1 #G3 #M2 #UY #P1 #P2
1 2
MT
EATON
A450 MT + 3000RDS
2200RDS / 2500RDS, 3000RDS

CHASSIS SIDE WIRING
U228 U234 4 17 13 U238 U22 U21 5 15 18 8 7 6 11 7 11 BSF2

#UU #P3 #L4 #MH #AD #P7 #U2 #U1 #M5 #AF #AJ #M8 #M7 #M6 #AB #L7 #LB #1W
1
#A1
U229 10 U225 5 U224 U223 U239 U237 U237 U24 1 7 U241 U242 12 17 CAN CAN CAN CAN 6 U23 10
#UV #LA #UR #L5 #UQ #UP #P8 #P6 #P5 #U4 #L1 # A 7 # PA # P B # A C # A H # C H # C G # C F # C E #L6 #U3 #AA
U230 U227 U226 9 4 1 16 U240 U28 U27 U26 3 6 8 4 2 8 U25 U249

#UW #UT #US #L9 #M4 #M1 #AG #P9 #U8 #U7 #U6 #L3 #A6 #A8 #A4 #A2 #L8 #U5 #PC
U233 U232 U231 2 GND3 HMV-1 2 2 3 14 5 U244 GND1

#P2 #P1 #UY #M2 #G3 #H1 #E2 #L2 #A3 #AE #A5 #PD #G1
6 cylinder
1 2
SAPH12Z030200080
AL WIRE-TO-WIRE CONNECTOR
1 Cab harness to chassis front harness STD 1 2 Cab harness to chassis front harness STD 2
AL
13 5 3 2
#BD #B5 #F3 #F2
17 1 4 1
#BH #E1 #F4 #F1
14 15 13 9 7 6 11 10 9 8 7 6
#BE #BF #MD #M9 #B7 #B6 #FB #FA #F9 #F8 #F7 #F6
9 1 12 5
#B9 11 16 14 12 10 8 3 #B1 #FC 20 19 18 17 16 5 14 #F5
#BB #BG #ME #MC #MA #B8 #B3 #FL #FK #FJ #FH #FG #FF #FE
10 2 21 26 25 24 23 22 13
#BA 12 15 16 11 4 #FM #FD
#BC #MF #MG #MB #B4 #B2 #FS #FR #FQ #FP #FN
3 4
5 13 2 3
#B5 #BD #F2 #F3
1 17 1 4
#E1 #BH #F1 #F4
6 7 9 13 15 14 6 7 8 9 10 11
#B6 #B7 #M9 #MD #BF #BE #F6 #F7 #F8 #F9 #FA #FB
1 9 5 12
#B1 3 8 10 12 14 16 11 #B9 #F5 14 15 16 17 18 19 20 #FC
#B3 #B8 #MA #MC #ME #BG #BB #FE #FF #FG #FH #FJ #FK #FL
2 10 13 21
#B2 4 11 16 15 12 #FD 22 23 24 25 26
#B4 #MB #MG #MF #BC #BA #FN #FP #FQ #FR #FS #FM
3 4
SAPH12Z030200081
3 Cab harness to ABS harness (For Full air brake) 4 Cab harness to ABS harness (For HYDRO MAX
brake)
AL
11A4 GND2
CAB SIDE WIRING
#TB #G2
U221 U219 U216 U214 U212 2A4 10A4
#UM #UK #UG #UE #UC 12A4 14A4 15A4 16A4 17A4 #T2 #TA
#TC #TE #TF #TG #TH
U222 U220 U217 U218 GND7 U215 U213 U211 3A4 4A4 5A4 6A4 7A4 8A4 9A4
#UN #UL #UH #UJ #G7 #UF #UD #UB 13A4 18A4 19A4 20A4 21A4 #T3 #T4 #T5 #T6 #T7 #T8 #T9
#TD #TJ #TK #TL #TM
5 7
6
6 cylinder
6 cylinder
GND2 11A4
CHASSIS SIDE WIRING
#G2 #TB
U212 U214 U216 U219 U221 10A4 2A4
#UC #UE #UG #UK #UM 17A4 16A4 15A4 14A4 12A4 #TA #T2
#TH #TG #TF #TE #TC
U211 U213 U215 GND7 U218 U217 U220 U222 9A4 8A4 7A4 6A4 5A4 4A4 3A4
#UB #UD #UF #G7 #UJ #UH #UL #UN 21A4 20A4 19A4 18A4 13A4 #T9 #T8 #T7 #T6 #T5 #T4 #T3
#TM #TL #TK #TJ #TD
6 cylinder 5 7
6
SAPH12Z030200082
5 Cab harness to injector harness 7 Cab harness to A450 ATM-2 harness

6 Cab harness to A450 ATM-1 harness
AL
1LC 7LC 2MD 17MD

#C1 #C7 #D2 #DH
6MD 7MD 8MD 9MD
2LC 4LC 10LC 3LC 8LC 1MD 4MD 20MD 22MD 18MD #D6 #D7 #D8 #D9
#C2 #C4 #CA #C3 #C8 #D1 #D4 #DL #DN #DJ
10MD 11MD 12MD 13MD 14MD 15MD 16MD
13LC 5LC 12LC 6LC 9LC 23MD 5MD 3MD 19MD #DA #DB #DC #DD #DE #DF #DG
#CD #C5 #CC #C6 #C9 #DP #D5 #D3 #DK
10
8 9
7LC 1LC 17MD 2MD

#C7 #C1 #DH #D
9MD 8MD 7MD 6MD
8LC 3LC 10LC 4LC 2LC 18MD 22MD 20MD 4MD 1MD #D9 #D8 #D7 #D6
#C8 #C3 #CA #C4 #C2 #DJ #DN #DL #D4 #D1
16MD 15MD 14MD 13MD 12MD 11MD 10MD
9LC 6LC 12LC 5LC 13LC 19MD 3MD 5MD 23MD #DG #DF #DE #DD #DC #DB #DA
#C9 #C6 #CC #C5 #CD #DK #D3 #D5 #DP
10
8 9
SAPH12Z030200083
8 Cab harness to 2200RDS/2500RDS ATM-1 harness 10 Cab harness to 3000RDS ATM-2 harness
9 Cab harness to 3000RDS ATM-1 harness
AL
SWP SWP
ID+1 ID-2 2 1 3
DSW1 DSW5 DSW4 HTR1 PSW1 PSW3 HTR1 #71 #72
#67 #6B #6A #64 #6D #6F #63 #2K #2J #2L
WAS2 WAS1 CTY1
DOM1 DOM2
#55 #54 #53
DSW2 DSW6 B/M1 DSW3 PSW2 B/M1 HTR2 4 5
#73 #74
#68 #6C #62 #69 #6E #61 #65 #2M #2N
13 14
11 12 15
CAB SIDE WIRING
Heater mirror
Power window Power window
SWP SWP 3 1 2
HTR1 DSW4 DSW5 DSW1 ID-2 ID+1 #2L #2J #2K
HTR1 PSW3 PSW1 #72 #71
#64 #6A #6B #67 CTY1 WAS1 WAS2
#63 #6F #6D #53 #54 #55 5 4
DSW3 B/M1 DSW6 DSW2 DOM2 DOM1 #2N #2M
HTR2 B/M1 PSW2 #74 #73
#69 #62 #6C #68 #65 #61 #6E
11 14
12 13 15
Power window
Heater mirror
SAPH12Z030200084
11 Cab main harness to door LH harness 14 Cab main harness to floor harness
12 Cab main harness to door RH harness 15 Cab main harness to sub air flow harness
13 Cab main harness to roof harness
AL
Air brake
SWP SWP
18 17 19 16 21 23 22
#1J #1H #1K #1G #1M #1P #1N BSR1 9 8 11 10 2 1 4 3
#1X #19 #18 #1B #1A #22 #21 #24 #23
13 9 8 11 10
#1D #19 #18 #1B #1A 1 2 3 5 6 5 8 7
#11 #12 #13 #15 #26 #25 #28 #27
6 BS2R
12 15 14 1 2 3 5
#1C #1F #1E #11 #12 #13 #15 #16 #1Y
6 9
#16 #29
16
17 18
Air brake
Air brake
SWP SWP
10 11 8 9 3 4 1 2
#1A #1B #18 #19 #23 #24 #21 #22
22 23 21 16 19 17 18 5 3 2 1 7 8 5 6
BSR1 #1N #1P #1M #1G #1K #1H #1J #15 #13 #12 #11 #27 #28 #25 #26
#1X
10 11 8 9 13 6 9
#1A #1B #18 #19 #1D #16 #29
BSR2 6
5 3 2 1 14 15 12
#1Y #16 #15 #13 #12 #11 #1E #1F #1C
17 18
16
Air brake
SAPH12Z030200085
16 Chassis front harness to chassis rear harness 18 Chassis front harness to headlight harness
(For Full air brake)
17 Chassis front harness to chassis rear harness
(For HYDRO MAX brake)
EL02_001.fm 90 ページ２００６年２月１３日　月曜日　午前１０時４分
POSITION OF CONNECTOR
EN12Z0302J100004
Position of connector A
A-2
A-2: Starter switch
SAPH12Z030200105
Position of connectors B,C,E,F
E-2
B-3 C-3
F-2
B-1
B-1: Clutch interlock switch
B-3: Starter
C-3: Starter
E-2: Glow plug
F-2: Alternator Output (in case of J08E Engine)
SAPH12Z030200106
Position of connectors G,AA
G-2 G-3
(T-2)
AA-1 AA-2
G-2 : Spsre power source (Battery) AA-1: P.T.O. signal

G-3 : Spsre power source (Starter switch ON) AA-2: P.T.O. Accel sensor
SAPH12Z030200107
Position of connectors G
G-5
G-7
G-6
G-4
G-8 G-9
G-4: Van light connector G-7: Spare power source (Back)

G-5: Spare power source (Tail) 1 G-8: Spare power source (Side turn LH)
G-6: Spare power source (Tail) 2 G-9: Spare power source (Side turn RH)
SAPH12Z030200108
Position of connectors H,K
H-24
K-5 H-3
H-7 H-9
H-3: U2 J/C No.1 K-5: Junction
H-7: U2 J/C
H-9: U2 J/C
H-24: Parking brake off diode
SAPH12Z030200109
Position of connectors H
H-4
H-6
H-5 H-8
H-4: Warning buzzer
H-5: Parking brake switch
H-6: Pulse converter (For ALLISON 2200RDS/2500RDS ATM,3000RDS ATM,EATON MTM)
H-8: Coolant warning relay
SAPH12Z030200110
Position of connectors G,H,O,Q,Y
H-2 H-1-1 H-1-2 H-1-3
Y-3
Y-2 G-1 O-1 Q-1
G-1: Van light switch H-2: Rheostat Y-3: Auto cruising switch
H-1-1: Combination meter O-1: Mirror heater switch
H-1-2: Combination meter Q-1: Cigarette lighter
H-1-3: Combination meter Y-2: Set resume switch
SAPH12Z030200111
Position of connectors I
I-21 I-20
I-20: Spring brake switch (For full air brake)

I-21: Buzzer switch (For full air brake and wheel parking)
SAPH12Z030200112
Position of connectors J
J-4
J-6 J-8
J-4: Daytime running light ECU

J-6: Light and turn switch
J-8: Light and turn switch
SAPH12Z030200113
Position of connectors J
J-15
J-7 : Daytime running light diode

J-11: ID light LH
J-12: ID light center J-7 J-11 J-12 J-13 J-14
J-13: ID light RH
J-14: Roof clearance light LH
J-15: Roof clearance light RH
SAPH12Z030200114
EL02_001.fm 95 ページ２００６年２月１３日　月曜日　午前１０時５分
Position of connectors J,O
O-4 J-10
J-17 J-16 O-3 J-9
J-9 : Back mirror light RH O-3 : Heater back mirror LH

J-10: Back mirror light LH O-4 : Heater back mirror RH
J-16: Head light LH
J-17: Head light RH
SAPH12Z030200115
Position of connectors A,I,L

I-13 I-19
I-14 I-10
I-15
A-10
I-16
L-1 I-11 I-12 I-18
I-10: Speed sensor (For EATON MTM) I-15: Coolant level switch
I-11: Speed sensor I-16: Fuel filter level sensor
(Except For EATON MTM, Allison I-18: Low pressure switch No.1 (For full air brake)
2200RDS and 2500RDS,3000RDS ATM) I-19: Low pressure switch No.2 (For full air brake)
I-12: Air gauge sensor front (For full air brake) L-1 : Back light switch
I-13: Air gauge sensor rear (For full air brake)
I-14: Fuel sender A-10 : Fuel filter heater sensor
SAPH12Z030200116
Position of connectors K
K-11
K-9
K-10
K-6
K-8 K-7
K-6: Side turn light LH (Fender) K-9: Side turn light RH (Fender)
K-7: Front turn light LH K-10: Rear combination light LH
K-8: Front turn light RH K-11: Rear combination light RH
SAPH12Z030200117
Position of connectors K,N
K-3 N-4 K-2
K-1 N-2
N-1 K-4 N-3
K-1: Stop and turn controller N-1: Washer motor

K-2: wiper and retarder switch N-2: Wiper relay
K-3: Light and turn switch N-3: Wiper motor
K-4: Stop light switch N-4: Wiper and retarder switch
SAPH12Z030200118
Position of connectors M
M-1
M-2
M-1: Dome light LH M-4 M-3

M-2: Dome light RH
M-3: Courtesy switch front LH
SAPH12Z030200119
Position of connector P
P-2 OR P-6
P-2: Horn switch

P-6: Horn switch (Air)
SAPH12Z030200120
Position of connectors R
R-2
R-4
R-1
R-3
R-1: Drivers seat master switch

R-2: Passengers seat sub switch
R-3: Power window motor drivers seat
R-4: Power window motor passengers seat
SAPH12Z030200122
Position of connectors S
S-3 S-2 S-4
S-2: Radio/Audio unit

S-3: Front speaker LH
S-4: Front speaker RH
SAPH12Z030200123
Position of connectors T
T-4 T-5 T-2 T-3
T-2: Heater and cooler unit

T-3: Blower motor
T-4: Blower switch
T-5: Air conditioner switch
SAPH12Z030200124
Position of connector P,T
P-7
T-7
P-4 P-3
P-3: Horn (Low)
P-4: Horn (High)
P-7: Horn (Air)
T-7: Pressure switch
SAPH12Z030200125
Position of connectors K,U
U-1-5 U-1-4
U-1-2 U-1-1 U-1-3
U-6 K-13 U-4

U-1-1: U2 ECU U-4: junction signal
U-1-2: U2 ECU U-6: Accelerator sensor
U-1-3: U2 ECU K-13: STP AT diode
U-1-4: U2 ECU
U-1-5: U2 ECU
SAPH12Z030200126
Position of connectors U,W
W-2
U-2
U-3 W-3
U-2: U2 junction 1 W-2: U2 junction 1

U-3: U2 junction 2 W-3: U2 junction 2
SAPH12Z030200127
Position of connector U
U-5
U-5: Air flow sensor

SAPH12Z030200128
Position of connector U
U-7
U-7: Idling volume
SAPH12Z030200129
Position of connectors V
V-22 V-21 V-18
V-9
V-8
V-20
V-19
V-17
V-23
V-10 V-11 V-12 V-13 V-14 V-15 V-16
V-8: EGR valve 1 V-14: Injector 4 V-20: Water temperature sender

V-9: EGR valve 2 V-15: Injecto r5 V-21: Fuel temperature sensor 1
V-10: VNT controller V-16: Injector 6 V-22: PC sensor
V-11: Injector 1 V-17: Suction control valve V-23: Boost sensor
V-12: Injector 2 V-18: Cylinder angle sensor
V-13: Injector 3 V-19: NE sensor (Engine speed sensor)
SAPH12Z030200130
Position of connectors W
W-1-5 W-1-4
W-1-2 W-1-1 W-1-3
W-6 W-4
W-1-1: U2 ECU W-4: junction signal
W-1-2: U2 ECU W-6: Accelerator sensor
W-1-3: U2 ECU
W-1-4: U2 ECU
W-1-5: U2 ECU
SAPH12Z030200131
Position of connector W
W-5
W-5: Air flow sensor

SAPH12Z030200132
Position of connector W
W-7
W-7: Idling volume

SAPH12Z030200133
Position of conectors X
X-15
X-16
X-20
X-8
X-18
X-17 X-14
X-8: EGR valve X-14: Suction control valve

X-10 X-11 X-12 X-13 X-19
X-10: Injector 1 X-15: Cylinder angle sensor
X-11: Injector 2 X-16: Engine speed sensor
X-12: Injector 3 X-17: Water temperature sender
X-13: Injector 4 X-18: Fuel temperature sensor
X-19: PC sensor
X-20: Boost sensor
SAPH12Z030200134
Position of connector Z
Z-2
Z-2: Exhaust clutch switch
SAPH12Z030200135
EL02_001.fm 105 ページ２００６年２月１３日　月曜日　午後４時５６分
Position of connector Z
Z-4
Z-4: Neutral switch
SAPH12Z030200136
Position of connectors D1,AB,AC,AI,AJ
AC-2 AC-3
AC-1 AB-2 AB-1
AI-1 AC-4 AB-3 AJ-1 D-1 P-5
D-1: Junction connector (J/C) earth AB-3: ABS Diagnosis switch AI-1: Diagnosis connector (9P)
P-5: Junction (G3) AC-1: ABS ECU x1 AJ-1: Diagnosis connector (16P)
AB-1: ABS ECU E AC-2: ABS ECU x2 AC-4: ABS Diagnosis switch
AB-2: ABS ECU F AC-3: ABS ECU x3
SAPH12Z030200137
Position of connector AB
AB-10 AB-11
AB-6 AB-7
AB-8 AB-9
AB-4 AB-5
AB-4: Modulator front LH AB-8: Modulator rear LH

AB-5: ABS sensor front LH AB-9: ABS sensor rear LH
AB-6: Modulator front RH AB-10: Modulator rear RH
AB-7: ABS sensor front RH AB-11: ABS sensor rear RH
SAPH12Z030200138
Position of connector AC
AC-7 AC-12
AC-10
AC-11
AC-9 AC-8 AC-6
AC-6: HYDRO MAX unit 1 AC-10: ABS sensor front RH

AC-7: HYDRO MAX unit 2 AC-11: ABS sensor rear LH
AC-8: HYDRO MAX unit 3 AC-12: ABS sensor rear RH
AC-9: ABS sensor front LH
SAPH12Z030200139
EL02_001.fm 107 ページ２００６年２月１３日　月曜日　午前１０時６分
Position of connector AD
AD-1
AD-1: Monitor module
SAPH12Z030200140
Position of connectors AD
AD-5 AD-4
AD-3
AD-2
AD-2: Motor relay
AD-3: Motor pump
AD-4: Flow switch
AD-5: Differential switch
SAPH12Z030200141
EL02_001.fm 108 ページ２００６年２月１３日　月曜日　午後４時８分
Position of connectors K,AE,AF
K12 AE-1-2 AE-1-3 AE-1-1
AE-2 AF-3
K-12: Stop light relay AE-1-1: A450 ECU AE-2: Over drive switch
AE-1-2: A450 ECU AF-3: ATM mode switch
AE-1-3: A450 ECU
SAPH12Z030200142
Position of connector AE
AE-3
AE-3: A450 ATM diode
SAPH12Z030200143
Position of connectors AE
AE-7
AE-5
The right bottom
AE-6 AE-8
AE-5: Oil temperature switch

AE-6: Neutral start switch
AE-7: Vehicle speed sensor
AE-8: Solenoid temperature switch
SAPH12Z030200144
Position of connectors AF
AF-1
The right bottom
AF-5
AF-7
In the left
AF-4 AF-6
In the left The left bottom
AF-1: ALLISON 2200RDS/2500RDS ATM ECU AF-6: Out put speed sensor
AF-4: Turbine speed sensor AF-7: Engine speed sensor
AF-5: Main transmission
SAPH12Z030200145
EL02_001.fm 110 ページ２００６年２月１４日　火曜日　午後６時４分
Position of connectors AG
AG-3 AG-1
AG-2
AG-5
AG-4
AG-1: ALLISON 3000 RDS ATM ECU
AG-2: Transmission TRANS2
AG-3: Transmission TRANS1
AG-4: Output speed sensor
AG-5: Engine speed sensor
SAPH12Z030200147
Position of connector AG
AG-6
AG-6: Selector
SAPH12Z030200146
Position of connector AH
AH-1
AH-1: Air drier
SAPH12Z030200148
Position of connectors AL
AL-3 OR AL-4 AL-5
AL-1
AL-2
AL-1: Cab harness to chassis front harness STD 1

AL-2: Cab harness to chassis front harness STD 2
AL-3: Cab harness to ABS harness (For Fuel air breke)
AL-4: Cab harness to ABS harness (For HYDRO MAX brake)
AL-5: Cab harness to injector harness AL-7 OR AL-10 AL-6 OR AL-8 OR AL-9
AL-6: Cab harness to A450 ATM-1 harness
AL-7: Cab harness to A450 ATM-2 harness
AL-8: Cab harness to 2200RDS/2500RDS ATM-1 harness
AL-9: Cab harness to 3000RDS ATM-1 harness
AL-10: Cab harness to 3000RDS ATM-2 harness
SAPH12Z030200149
Position of connectors AL
AL-15 AL-16 AL-17
AL-13
AL-14
AL-12
AL-11: Cab main harness to door LH harness

AL-12: Cab main harness to door RH harness
AL-13: Cab main harness to roof harness AL-18 AL-11
AL-14: Cab main harness to floor harness
AL-15: Cab main harness to sub air flow harness
AL-16: Chassis front harness to chassis rear harness (For Full air brake)
AL-17: Chassis front harness to chassis rear harness (For HYDRO MAX brake)
AL-18: Chassis front harness to headlight harness
SAPH12Z030200150
CONNECTOR
EN12Z0302J100005
Connector : A-2 Connector : A-10

Color : Black Color : Dark Gray
Part No. : 82580-6060 Part No. : 82560-3830 , 82560-3840
Connector : B-1 Connector : B-3 Connector : C-3

Color : Dark Gray Color : Black Color : Black
Part No. : 82560-3030 Part No. : 82580-6720 Part No. : 82580-6720
Connector : D-1 Connector : E-2

Color : White Color : White
Part No. : 82580-8740 Part No. : 82580-6730
Connector : F-2 Connector : G-1 Connector : G-2

Color : Black Color : Blue Color : -----
Connector : G-3 Connector : G-4 Connector : G-5 Connector : G-6

Color : ----- Color : Black Color : White Color : White
Part No. : 9784-04050 Part No. : 82580-4240 Part No. : 82580-4240 Part No. : 82580-4240
SAPH12z030200090
Connector : G-7 Connector : G-8 Connector : G-9

Color : Black Color : White Color : White
Connector : H-1-1 Connector : H-1-2 Connector : H-1-3 Connector : H-2

Color : Blue Color : White Color : White Color : Black
Connector : H-3 Connector : H-4 Connector : H-5 Connector : H-6

Color : White Color : Black Color : Black Color : White
Connector : H-7 Connector : H-8 Connector : H-9

Color : White Color : White Color : White
Connector : H-24 Connector : I-10

Color : ------ Color : Black
Part No. : 82560-4180 , 85902-1210 Part No. : 82560-1990
: 82560-2530
OR
SAPH12Z030200091
Connector : I-11 Connector : I-12 Connector : I-13 Connector : I-14

Color : Black Color : Black Color : Black Color : Black
Connector : I-15 Connector : I-16 Connector : I-18 Connector : I-19

Color : Gray Color : Dark Gray Color : Black Color : Black
Connector : I-20 Connector : I-21 Connector : J-4

Color : Dark Gray Color : Black Color : White
Connector : J-6 Connector : J-7 Connector : J-8 Connector : J-9

Color : Black Color : Black Color : Black Color : White

Color : White Color : Black Color : Black Color : Black
SAPH12Z030200092

Connector : K-1 Connector : K-2 Connector : K-3 Connector : K-4

Color : Black Color : White Color : Black Color : Black
: 82828-1310
OR

Color : White Body Color : Gray Color : Black Color : Black

Color : Gray Color : Black Color : Black Color : White
Connector : K-13 Connector : L-1

Color : Black Color : Black
Part No. : 82560-3800 Part No. : 82828-1210
SAPH12Z030200093
Connector : M-1 Connector : M-2 Connector : M-3 Connector : M-4

Color : White Color : White Color : White Color : White
Connector : N-1 Connector : N-2 Connector : N-3 Connector : N-4

Color : White Color : Black Color : White Color : White
Connector : O-1 Connector : O-3 Connector : O-4

Color : White Color : White Color : White
Connector : P-2 Connector : P-3 Connector : P-4 Connector : P-5

Color : White Color : Black Color : Black Color : White
Connector : P-6 Connector : P-7 Connector : Q-1

Color : Black Color : Black Color : White
SAPH12Z030200094
Connector : R-1 Connector : R-2 Connector : R-3 Connector : R-4

Color : White Color : White Color : Gray Color : Black
Connector : S-2 Connector : S-3 Connector : S-4

Color : White Color : Black Color : Black
Connector : T-2 Connector : T-3 Connector : T-4 Connector : T-5

Color : Black Color : Black Color : Black Color : White
Connector : T-7 Connector : U-1-1 Connector : U-1-2

Color : Gray Color : White Color : White
Connector : U-1-3 Connector : U-1-4 Connector : U-1-5 Connector : U-2

SAPH12Z030200095
Connector : U-3 Connector : U-4 Connector : U-5 Connector : U-6

Color : White Color : White Color : Black Color : Black
Connector : U-7 Connector : V-8 Connector : V-9

Color : Blue Color : Black Color : Black
Connector : V-10 Connector : V-11 Connector : V-12 Connector : V-13

Color : Black Color : Gray Color : Gray Color : Gray

Color : Gray Color : Gray Color : Gray Color : Gray

Color : Black Color : Black Color : Gray Color : Dark Gray
SAPH12Z030200096
Connector : V-22 Connector : V-23 Connector : W-1-1

Color : Black Color : Black Color : White
Connector : W-1-2 Connector : W-1-3 Connector : W-1-4 Connector : W-1-5

Connector : W-2 Connector : W-3 Connector : W-4 Connector : W-5

Color : White Color : White Color : White Color : Black
Connector : W-6 Connector : W-7 Connector : X-8

Color : Black Color : Blue Color : Black
Connector : X-10 Connector : X-11 Connector : X-12 Connector : X-13

Color : Gray Color : Gray Color : Gray Color : Gray
SAPH12Z030200097
Connector : X-14 Connector : X-15 Connector : X-16 Connector : X-17

Color : Gray Color : Black Color : Black Color : Gray
Connector : X-18 Connector : X-19 Connector : X-20

Color : Dark Gray Color : Black Color : Black
Connector : Y-2 Connector : Y-3 Connector : Y-4 Connector : Y-5

Color : Brown Color : Black Color : White Color : Black
Connector : Z-2 Connector : Z-4 Connector : AA-1

Color : Dark Gray Color : White Color : ------
Connector : AA-2 Connector : AB-1 Connector : AB-2

Color : Black Color : Black Color : Dark Gray
SAPH12Z030200098
Connector : AB-3 Connector : AB-4 Connector : AB-5 Connector : AB-6

Connector : AB-7 Connector : AB-8 Connector : AB-9 Connector : AB-10

Connector : AB-11 Connector : AC-1 Connector : AC-2

Color : Black Color : Gray Color : Black
Connector : AC-3 Connector : AC-4 Connector : AC-6 Connector : AC-7

Color : Gray Color : Black Color : White Color : Black
Connector : AC-8 Connector : AC-9 Connector : AC-10 Connector : AC-11

Color : Gray Color : Black Color : Black Color : Black
SAPH12Z030200099
Connector : AC-12 Connector : AD-1 Connector : AD-2

Connector : AD-3 Connector : AD-4 Connector : AD-5

Connector : AE-1-1 Connector : AE-1-2 Connector : AE-1-3 Connector : AE-2

Color : Dark Gray Color : Dark Gray Color : Dark Gray Color : White
Connector : AE-3 Connector : AE-5 Connector : AE-6 Connector : AE-7

Color : Black Color : Gray Color : Black Color : Dark Gray
Connector : AE-8 Connector : AF-1 Connector : AF-3

Color : Gray Color : Black Color : White
SAPH12Z030200100
Connector : AF-4 Connector : AF-5 Connector : AF-6 Connector : AF-7

Color : Black Color : Gray Color : Black Color : Black
Connector : AG-1 Connector : AG-2 Connector : AG-3 Connector : AG-4

Connector : AG-5 Connector : AG-6 Connector : AH-1

Connector : AI-1 Connector : AJ-1

Part No. : 82560-1920 Part No. : 82560-4320
Connector : AK-1 Connector : AK-2 Connector : AK-3 Connector : AK-4

Color : Dark Gray Color : Black Color : Black Color : White
SAPH12Z030200101
Connector : AK-5 Connector : AL-1

Color : Black Color : White
Part No. : 82560-1940 Parts No. : 82560-2110 , 82560-2120
Connector : AL-2 Connector : AL-3

Parts No. : 82560-2130 , 82560-2140 Parts No. : 82560-2070 , 82560-2080

Parts No. : 82560-2070 , 82560-2080 Parts No. : 82560-2260 , 82560-2270

Color : White Color : Gray
Parts No. : 82560-2610 , 82560-2620 Parts No. : 82560-2610 , 82560-2620

Part No. : 82560-2610 , 82560-2620 Part No. : 82560-2610 , 82560-2620
SAPH12Z030200102

Color : Gray Color : Black
Parts No. : 82560-4210 , 82560-4220 Parts No. : 82560-3450 , 82560-3460

Color : Black Color : White
Parts No. : 82560-3430 , 82560-3440 Parts No. : 82580-6050 , 82580-6060

Color : Gray Color : Black
Parts No. : 82580-7130 , 82580-7140 Parts No. : 82580-8410 , 82580-8420

Parts No. : 82560-1320 , 82560-1330 Parts No. : 82560-3470 , 82560-3480
Connector : AL-18
Color : Black
Parts No. : 82560-3470 , 82560-3480
SAPH12Z030200103
CONNECTOR LIST
EN12Z0302J100006
Three-dimensional
Wiring
listing page
tor) listing page
A-2 Starter switch EL02-12, EL02-16 EL02-90

A
A-10 Fuel filter heater sensor EL02-12, EL02-16 EL02-95
B-1 Clutch interlock switch EL02-17 EL02-90

B
B-3 Starter EL02-17 EL02-90
C C-3 Starter EL02-17 EL02-90
D D-1 Junction connector (J/C) earth EL02-18, EL02-19 EL02-105
E E-2 Glow plug EL02-20 EL02-90
F F-2 Alternator Output (in case of J08E Engine) EL02-20 EL02-90
G-1 Van light switch EL02-22 EL02-93
G-2 Spare power source (Battery) EL02-22 EL02-91
G-3 Spare power source (Starter switch ON) EL02-22 EL02-91
G-4 Van light connector EL02-22 EL02-91
G G-5 Spare power source (Tail) 1 EL02-22 EL02-91
G-6 Spare power source (Tail) 2 EL02-22 EL02-91
G-7 Spare power source (Back) EL02-23 EL02-91
G-8 Spare power source (Side turn LH) EL02-23 EL02-91
G-9 Spare power source (Side turn RH) EL02-23 EL02-91
EL02-24, EL02-25,
H-1-1 Combination meter EL02-93
EL02-26
EL02-24, EL02-25,
EL02-26
EL02-24, EL02-25,
EL02-26
H-2 Rheostat EL02-24, EL02-26 EL02-93
H-3 U2 J/C No.1 EL02-24, EL02-26 EL02-92

H H-4 Warning buzzer EL02-25, EL02-26 EL02-92
H-5 Parking brake switch EL02-25, EL02-27 EL02-92
Pulse converter (For ALLISON 2200RDS/

H-6 EL02-24, EL02-27 EL02-92
2500RDS ATM,3000RDS ATM,EATON MTM
H-7 U2 J/C EL02-24, EL02-27 EL02-92
H-8 Coolant warning relay EL02-24, EL02-27 EL02-92
H-9 U2 J/C EL02-25, EL02-27 EL02-92
H-24 Parking brake off diode EL02-25, EL02-27 EL02-92

Three-dimensional
Wiring
listing page
tor) listing page
I-10 Speed sensor (For EATON MTM) EL02-28, EL02-30 EL02-95
Speed sensor (Except For EATON MTM, Alli-

I-11 EL02-28, EL02-30 EL02-95
son 2200RDS and 2500RDS,3000RDS ATM)
I-12 Air gauge sensor front (For full air brake) EL02-28, EL02-30 EL02-95
I-13 Air gauge sensor rear (For full air brake) EL02-28, EL02-30 EL02-95
I-14 Fuel sensor EL02-28, EL02-30 EL02-95
I I-15 Coolant level switch EL02-28, EL02-31 EL02-95
I-16 Fuel filter level sensor EL02-29, EL02-31 EL02-95
I-18 Low pressure switch No.1 (For full air brake) EL02-29, EL02-31 EL02-95
I-19 Low pressure switch No.2 (For full air brake) EL02-29, EL02-31 EL02-95
I-20 Spring brake switch (For full air brake) EL02-29, EL02-31 EL02-93
Buzzer switch (For full air brake and wheel

I-21 EL02-29, EL02-31 EL02-93
parking)
J-4 Daytime running light ECU EL02-32, EL02-34 EL02-94
J-6 Light and turn switch EL02-32, EL02-34 EL02-94
J-7 Daytime running light diode EL02-32, EL02-34 EL02-94
J-8 Light and turn switch EL02-33, EL02-34 EL02-94
J-9 Back mirror light RH EL02-33, EL02-34 EL02-95
J-10 Back mirror light LH EL02-33, EL02-34 EL02-95
J J-11 ID light LH EL02-33, EL02-35 EL02-94
J-12 ID light center EL02-33, EL02-35 EL02-94
J-13 ID light RH EL02-33, EL02-35 EL02-94
J-14 Roof clearance light LH EL02-33, EL02-35 EL02-94
J-15 Roof clearance light RH EL02-33, EL02-35 EL02-94
J-16 Head light LH EL02-32, EL02-34 EL02-95
J-17 Head light RH EL02-32, EL02-34 EL02-95

EL02_001.fm 129 ページ２００６年２月１４日　火曜日　午後６時４分
Three-dimensional
Wiring
listing page
tor) listing page
K-1 Stop and turn controller EL02-36, EL02-37 EL02-96
K-2 Wiper and retarder switch EL02-36, EL02-37 EL02-96
K-3 Light and turn switch EL02-36, EL02-37 EL02-96
K-4 Stop light switch EL02-37 EL02-96
K-5 Junction EL02-37 EL02-92
K-6 Side turn light LH (Fender) EL02-36, EL02-37 EL02-96
K K-7 Front turn light LH EL02-36, EL02-37 EL02-96
K-8 Front turn light RH EL02-36, EL02-37 EL02-96
K-9 Side turn light RH (Fender) EL02-36, EL02-37 EL02-92, EL02-96
K-10 Rear combination light LH EL02-36, EL02-37 EL02-96
K-11 Rear combination light RH EL02-37 EL02-96
K-12 Stop lamp relay EL02-37 EL02-108
K-13 STP AT diode EL02-37 EL02-100
L L-1 Back light switch EL02-38 EL02-95
M-1 Dome light LH EL02-38 EL02-97
M-2 Dome light RH EL02-38 EL02-97

M
M-3 Courtesy switch front LH EL02-38 EL02-97
M-4 Courtesy switch front RH EL02-38 EL02-97
N-1 Washer motor EL02-39 EL02-96
N-2 Wiper relay EL02-39 EL02-96

N
N-3 Wiper motor EL02-39 EL02-96
N-4 Wiper and retarder switch EL02-39 EL02-96
O-1 Mirror heater switch EL02-40 EL02-93
O O-3 Heater back mirror LH EL02-40 EL02-95
O-4 Heater back mirror RH EL02-40 EL02-95
P-2 Horn switch EL02-41 EL02-97
P-3 Horn (Low) EL02-41 EL02-99
P-4 Horn (High) EL02-41 EL02-99

P
P-5 Junction (G3) EL02-41 EL02-105
P-6 Horn switch EL02-41 EL02-97
P-7 Horn (Air) EL02-41 EL02-99
Q Q-1 Cigarette lighter EL02-42 EL02-93

EL02_001.fm 130 ページ２００６年２月１４日　火曜日　午後６時５分
Three-dimensional
Wiring
listing page
tor) listing page
R-1 Drivers seat master switch EL02-43 EL02-98
R-2 Passengers seat sub switch EL02-43 EL02-98

R
R-3 Power window motor drivers seat EL02-43 EL02-98
R-4 Power window motor passengers seat EL02-43 EL02-98
S-2 Radio/Audio unit EL02-44 EL02-98
S S-3 Front speaker LH EL02-44 EL02-98
S-4 Front speaker RH EL02-44 EL02-98
T-2 Heater and cooler unit EL02-46 EL02-99
T-3 Blower motor EL02-46 EL02-99
T T-4 Blower switch EL02-46 EL02-99
T-5 Air conditioner switch EL02-47 EL02-99
T-7 Pressure switch EL02-47 EL02-99
EL02-48, EL02-49,
U-1-1 U2 ECU EL02-100
EL02-50
EL02-48, EL02-49,
U-1-2 U2 ECU EL02-100
EL02-50
EL02-48, EL02-49,
U-1-3 U2 ECU EL02-100
EL02-50
EL02-48, EL02-49,
U-1-4 U2 ECU EL02-100
EL02-50
EL02-48, EL02-49,
U U-1-5 U2 ECU EL02-100
EL02-50
EL02-48, EL02-49,
U-2 U2 junction 1 EL02-100
EL02-51
U-3 U2 junction 2 EL02-48, EL02-51 EL02-100
U-4 junction signal EL02-49, EL02-51 EL02-100
U-5 Air flow sensor EL02-48, EL02-51 EL02-101
U-6 Accelerator sensor EL02-49, EL02-51 EL02-100
U-7 Idling volume EL02-49, EL02-51 EL02-101

Three-dimensional
Wiring
listing page
tor) listing page
V-8 EGR valve 1 EL02-52, EL02-54 EL02-102
V-9 EGR valve 2 EL02-52, EL02-54 EL02-102
V-10 VNT controller EL02-52, EL02-54 EL02-102
V-11 Injector 1 EL02-52, EL02-54 EL02-102

V
V-17 Suction control valve EL02-52, EL02-54 EL02-102
V-18 Cylinder angle sensor EL02-53, EL02-54 EL02-102
V-19 NE sensor (Engine speed sensor) EL02-53, EL02-55 EL02-102
V-20 Water temperature sendor EL02-53, EL02-55 EL02-102
V-21 Fuel temperature sensor 1 EL02-53, EL02-55 EL02-102
V-22 PC sensor EL02-53, EL02-55 EL02-102
V-23 Boost sensor EL02-53, EL02-55 EL02-102
EL02-56, EL02-57,
W-1-1 U2 ECU EL02-102
EL02-58
EL02-56, EL02-57,
W-1-2 U2 ECU EL02-102
EL02-58
EL02-56, EL02-57,
W-1-3 U2 ECU EL02-102
EL02-58
EL02-56, EL02-57,
W-1-4 U2 ECU EL02-102
EL02-58
EL02-56, EL02-57,
W W-1-5 U2 ECU EL02-102
EL02-58
EL02-56, EL02-57,
W-2 U2 junction 1 EL02-100
EL02-59
W-3 U2 junction 2 EL02-56, EL02-59 EL02-100
W-4 junction signal EL02-57, EL02-59 EL02-102
W-5 Air flow sensor EL02-56, EL02-59 EL02-103
W-6 Accelerator sensor EL02-57, EL02-59 EL02-102
W-7 Idling volume EL02-57, EL02-59 EL02-103

Three-dimensional
Wiring
listing page
tor) listing page
X-8 EGR valve EL02-60, EL02-62 EL02-104
X-10 Injector 1 EL02-60, EL02-62 EL02-104
X-14 Suction control valve EL02-60, EL02-62 EL02-104

X
X-15 Cylinder angle sensor EL02-60, EL02-62 EL02-104
X-16 Engine speed sensor EL02-61, EL02-62 EL02-104
X-17 Water temperature sendor EL02-61, EL02-62 EL02-104
X-18 Fuel temperature sensor 1 EL02-61, EL02-62 EL02-104
X-19 PC sensor EL02-61, EL02-62 EL02-104
X-20 Boost sensor EL02-61, EL02-62 EL02-104
Y-2 Set resume switch EL02-64, EL02-65 EL02-93

Y
Y-3 Auto cruising switch EL02-64, EL02-65 EL02-93
Z-2 Exhaust clutch switch EL02-66 EL02-104

Z
Z-4 Neutral switch EL02-66 EL02-105
AA-1 P.T.O. signal EL02-67 EL02-91

AA
AA-2 P.T.O. Accel sensor EL02-67 EL02-91
AB-1 ABS ECU E EL02-68, EL02-69 EL02-105
AB-2 ABS ECU F EL02-68, EL02-69 EL02-105
AB-3 ABS Diagnosis switch EL02-68, EL02-69 EL02-105
AB-4 Modulator front LH EL02-68, EL02-69 EL02-106
AB-5 ABS sensor front LH EL02-68, EL02-69 EL02-106
AB AB-6 Modulator front RH EL02-68, EL02-69 EL02-106
AB-7 ABS sensor front RH EL02-68, EL02-69 EL02-106
AB-8 Modulator rear LH EL02-69 EL02-106
AB-9 ABS sensor rear LH EL02-69 EL02-106
AB-10 Modulator rear RH EL02-69 EL02-106
AB-11 ABS sensor rear RH EL02-69 EL02-106

EL02_001.fm 133 ページ２００６年２月１３日　月曜日　午後５時１分
Three-dimensional
Wiring
listing page
tor) listing page
AC-1 ABS ECU x1 EL02-71 EL02-105
AC-2 ABS ECU x2 EL02-70, EL02-71 EL02-105
AC-3 ABS ECU x3 EL02-70, EL02-71 EL02-105
AC-4 ABS Diagnosis switch EL02-70, EL02-71 EL02-105
AC-6 HYDRO MAX unit 1 EL02-70, EL02-71 EL02-106
AC AC-7 HYDRO MAX unit 2 EL02-70, EL02-71 EL02-106
AC-8 HYDRO MAX unit 3 EL02-70, EL02-71 EL02-106
AC-9 ABS sensor front LH EL02-71 EL02-106
AC-10 ABS sensor front RH EL02-71 EL02-106
AC-11 ABS sensor rear LH EL02-71 EL02-106
AC-12 ABS sensor rear RH EL02-71 EL02-106
AD-1 Monitor module EL02-72, EL02-73 EL02-107
AD-2 Motor relay EL02-72, EL02-73 EL02-107
AD AD-3 Motor pump EL02-72, EL02-73 EL02-107
AD-4 Flow switch EL02-72, EL02-73 EL02-107
AD-5 Differential switch EL02-72, EL02-73 EL02-107
AE-1-1 A450 ECU EL02-74, EL02-75 EL02-108
AE-1-2 A450 ECU EL02-74, EL02-75 EL02-108
AE-1-3 A450 ECU EL02-74, EL02-75 EL02-108
AE-2 Over drive switch EL02-74, EL02-75 EL02-108
AE AE-3 A450 ATM diode EL02-74, EL02-75 EL02-108
AE-5 Oil temperature switch EL02-74, EL02-75 EL02-109
AE-6 Neutral start switch EL02-74, EL02-75 EL02-109
AE-7 Vehicle speed sensor EL02-74, EL02-75 EL02-109
AE-8 Solenoid temperature switch EL02-75 EL02-109
AF-1 ALLISON 2200RDS/2500RDS ATM ECU EL02-76, EL02-77 EL02-109
AF-3 ATM mode swtich EL02-76 EL02-108
AF-4 Turbine speed sensor EL02-76 EL02-109

AF
AF-5 Main transmission EL02-76 EL02-109
AF-6 Out put speed sensor EL02-77 EL02-109
AF-7 Engine speed sensor EL02-77 EL02-109

Three-dimensional
Wiring
listing page
tor) listing page
AG-1 ALLISON 3000 RDS ATM ECU EL02-78, EL02-79 EL02-110
AG-2 Transmission TRANS 2 EL02-78 EL02-110
AG-3 Transmission TRANS 1 EL02-78 EL02-110

AG
AG-4 Output speed sensor EL02-79 EL02-110
AG-5 Engine speed sensor EL02-79 EL02-110
AG-6 Selector EL02-78 EL02-110
AH AH-1 Air drier EL02-80 EL02-111
AI AI-1 Diagnosis connector (9P) EL02-80 EL02-105
AJ AJ-1 Diagnosis connector (16P) EL02-81 EL02-105
AL-1 Cab harness to chassis front harness STD 1 EL02-84 EL02-111
AL-2 Cab harness to chassis front harness STD 2 EL02-84 EL02-111
Cab harness to ABS harness (For Full air

AL-3 EL02-85 EL02-111
brake)
Cab harness to ABS harness (For HYDRO

AL-4 EL02-85 EL02-111
MAX brake)
AL-5 Cab harness to injector harness EL02-86 EL02-111
AL-6 Cab harness to A450 ATM-1 harness EL02-86 EL02-111
AL-7 Cab harness to A450 ATM-2 harness EL02-86 EL02-111
Cab harness to 2200RDS/2500RDS ATM-1

AL-8 EL02-87 EL02-111
harness
AL AL-9 Cab harness to 3000RDS ATM-1 harness EL02-87 EL02-111
AL-10 Cab harness to 3000RDS ATM-2 harness EL02-87 EL02-111
AL-11 Cab main harness to door LH harness EL02-88 EL02-112
AL-12 Cab main harness to door RH harness EL02-88 EL02-112
AL-13 Cab main harness to roof harness EL02-88 EL02-112
AL-14 Cab main harness to floor harness EL02-88 EL02-112
AL-15 Cab main harness to sub air flow harness EL02-88 EL02-112
Chassis front harness to chassis rear har-

AL-16 EL02-89 EL02-112
ness (For Full air brake)
Chassis front harness to chassis rear har-

AL-17 EL02-89 EL02-112
ness (For HYDRO MAX brake)
AL-18 Chassis front harness to headlight harness EL02-89 EL02-112

BRAKE CONTROL (ABS : HYDRAULIC) DN03–1
BRAKE CONTROL (ABS : HYDRAULIC)

DN03
DN03-001
ABS ...........................................................DN03-2
TROUBLESHOOTING ..................................... DN03-2
DN03–2 BRAKE CONTROL (ABS : HYDRAULIC)
ABS
TROUBLESHOOTING
EN1680103H500001
BEFORE YOU BEGIN

This manual provides maintenance and service instructions for Meritor
WABCO's hydraulic ABS for medium-duty trucks, buses and motor home
chassis. Before you begin procedures:
.

2. Read and observe all Caution and Warning safety alerts that precede
instructions or procedures you will perform. These alerts help to avoid
damage to components, serious personal injury, or both.
1. SAFETY ALERTS, TORQUE SYMBOL AND NOTES
! WARNING A Warning alerts you to an instruc-

tion or procedure that you must fol-
low exactly to avoid serious
personal injury and damage to
components.
! CAUTION A Caution alerts you to an instruc-

tion or procedure that you must fol-
low exactly to avoid damage to
components and possible serious
injury.
NOTICE A Note provides information or

suggestions that help you correctly
service a component.
2. ACCESS INFORMATION ON ARVINMERITOR'S WEB SITE

Additional maintenance and service information for ArvinMeritor's commer-
cial vehicle systems component lineup is also available at www.arvinmeri-
tor.com.
To access information, click on Products & Services/Tech Library Icon/HVS

Publications. The screen will display an index of publications by type.
SAPH168010300001
SYSTEM LAYOUT
A typical Meritor WABCO Hydraulic ABS with cab-mounted ECU is illustrated below.
ECU
BRAKE BRAKE
ABS INDICATOR LAMP
HYDRAULIC MASTER CYLINDER

BOOSTER
ABS
HYDRAULIC MODULA TOR
BRAKE LINE ASSEMBLY
HYDRAULIC BRAKE LINE
BRAKE BRAKE
SENSOR ABS SENSOR CABLE

ASSEMBLY 1004681a
SAPH168010300002
SYSTEM COMPONENTS
The following components make up the Meritor WABCO Hydraulic ABS.
D VERSION
CAB ECU
ELECTRONIC CONTROL UNIT (ECU)
• Processes sensor signals and generates solenoid valve commands to
reduce, maintain or reapply brake pressure.
• The ECU is cab-mounted.
.
1004683a
SAPH168010300003
1. ECU Identification
NOTICE
D VERSION
Do not open the ECU. Opening the ECU to gain access to the internal
components will void the warranty.
1004680a
SAPH168010300004
MODULATOR ASSEMBLY
• Houses the ABS solenoid control valves (one inlet valve and one out-
let valve per wheel), a pump motor and two accumulators.
• Contains brake fluid and must be handled with appropriate care. It
should not be exposed to impact loads, excessive vibrations or com-
pressed air blown into the hydraulic ports.
1004684a
SAPH168010300005
SENSOR WITH MOLDED SOCKET

• Measures the speed of a tooth wheel rotating with the vehicle wheel.
• Produces an output voltage proportional to wheel speed.
1004685a
SAPH168010300006
SENSOR SPRING CLIP

• Holds the wheel speed sensor in close proximity to the tooth wheel.
1004686a
SAPH168010300007
TOOTH WHEEL
• A machined or stamped ring mounted to a machined surface on the
hub of each ABS-monitored wheel.
1004687a
SAPH168010300008
SENSOR EXTENSION CABLES

• Two-wire cable with molded-on connector.
• Connects the wheel speed sensor to the ECU.
1004688a
SAPH168010300009
ABS INDICATOR LAMP

• Located on vehicle dash.
• Alerts drivers to a possible system fault.
• Used by service personnel to display blink codes.
• ABS indicator lamp is not provided by Meritor WABCO.
1004689a
SAPH168010300010
DIAGNOSTICS SOFTWARE
• A PC-based diagnostics program.
• Displays system faults and wheel speed data, tests individual compo-
nents, verifies installation wiring and more.
• Runs in Windows95, 98 or NT.
• To order, call 800-535-5560.
NOTICE
An RS232 to J1708 converter box is required.
1004690a
SAPH168010300011
SYSTEM WIRING INFORMATION

NOTICE
Wiring may vary, according to the vehicle. Refer to the vehicle specifi-
cations for specific wiring diagrams. A typical Meritor WABCO 4S/4M
Hydraulic ABS wiring diagram.
1. PIN NUMBERS AND LOCATIONS

Refer to page DN03-29 for Modulator Assembly Connector Pin Assign-
ments
CAB
1 4 7 1 4 7 10 13 16 1 4 7 10 13
2 5 8 2 5 8 11 14 17 2 5 8 11 14
3 6 9 3 6 9 12 15 18 3 6 9 12 15
9-Pin ECU Connector 18-Pin ECU Connector 15-Pin ECU Connector

Pin Circuit Pin Circuit Pin Circuit
Number Description Number Description Number Description
1 Left Front Sensor 1 +12 Battery 1 Left Front Outlet V alve
2 Left Front Sensor 2 +12 Ignition 2 Left Front Inlet V alve
3 Right Rear Sensor 3 Not Used 3 Ground
4 Right Front Sensor 4 Not Used 4 Right Front Outlet V alve
5 Right Front Sensor 5 SAE J1587 (-) 5 Right Front Inlet V alve
6 Right Rear Sensor 6 SAE J1587 (+) 6 Not Used
7 Left Rear Sensor 7 Not Used 7 Left Rear Outlet V alve
8 Left Rear Sensor 8 Motor Monitor 8 Left Rear Inlet V alve
9 Not Used 9 Not Used 9 Not Used
10 Not Used 10 Right Rear Outlet V alve
11 Not Used 11 Right Rear Inlet V alve
12 Ground 12 Retarder Relay
13 Not Used 13 Not Used
14 Not Used 14 Not Used
15 Jumper 15 Pump Relay
16 Not Used
17 Not Used
18 ABS Indicator Lamp
and Blink Code Switch
1004691a
SAPH168010300012
DN03–8
M
RECIRCULATION PUMP
S1-UNAE03A-2.book 8 ページ
MOTOR MONITOR
86
87
PUMP RELAY
SENSOR SENSOR SENSOR SENSOR 30 REAR REAR FRONT FRONT
REAR REAR FRONT FRONT 85 RIGHT LEFT RIGHT LEFT
RIGHT LEFT RIGHT LEFT
ABS MODULA TOR UNIT

30A
Ð
12V IV OV IV OV IV OV IV OV
+
15 30
INDEPENDENT IGNITION
FUSED IGNITION SWITCH
CONNECTION
12 AWG
(E.G. USED FOR
2.
25A 11 10 2 1 4 5 12 13 8 7 6 3
5A OTHER WARNING 5A
CIRCUITRY)
２００６年２月９日　木曜日　午後６時１７分
MAX. 2W
12 AWG
(ORANGE)
ABS
INDICATOR
IGNITION
LAMP
BLINK CODE
SWITCH
DIAGNOSTICS SAE J1587 "A"-LINE

DIAGNOSTICS SAE J1587 "B"-LINE
MOTOR MONITOR
ABS INDICATOR LAMP
GROUND
PUMP RELAY
RETARDER RELAY
REFERENCE GROUND
2x18 AWG TWISTED

2x18 AWG TWISTED
2x18 AWG TWISTED

2x18 AWG TWISTED
BRAKE CONTROL (ABS : HYDRAULIC)
6 3 8 7 5 4 2 1 8 2 18 12 1 6 5 11 10 8 7 5 4 2 1 3 12 15
15
1 4 7 1 4 7 10 13 16 1 4 7 10 13
2 5 8 2 5 8 11 14 17 2 5 8 11 14
3 6 9 3 6 9 12 15 18 3 6 9 12 15
CAB
4S/M D VERSION HYDRAULIC ABS WIRING DIAGRAM
1004692a
SAPH168010300013
SYSTEM DIAGNOSTICS
Use Meritor WABCO's PC-based diagnostic program, TOOLBOX Software,
or standard blink codes to diagnose hydraulic ABS faults. Information for
using standard blink codes appears on page DN03-12 of this manual.
1. TOOLBOX SOFTWARE
NOTICE
For complete instructions for using this program, refer to the User's
Manual, TP-99102. Contact Meritor WABCO at 800-535-5560 for infor-
mation about TOOLBOX Software.
If you have TOOLBOX Software installed on your computer, use it to

identify system faults. Then, follow the on-screen repair information
to make the necessary repairs or replacements.
To display D version Hydraulic ABS faults, use the pull-down menu or

the HABS icon to select HABS (Hydraulic ABS) from the Main Menu .
The Hydraulic ABS Main Menu will appear.
SAPH168010300014
1004696a
SAPH168010300015
Select the View ECU Faults icon or select Display Faults to use the pull-
down menu. This will display the Fault Information screen.
The Fault Information Screen contains a description of the fault. Repair

instructions for each fault appear at the bottom of the screen.
Faults that occur after the screen is displayed will not appear until a screen
update is requested. Use the UPDATE button to refresh the fault informa-
tion table.
1004697a
After making the necessary repairs, use the CLEAR FAULTS button to clear
SAPH168010300016 the fault. Use the update button to refresh the fault information table and
display the new list of faults.
2. BLINK CODE DIAGNOSTICS

(1) Definitions
ABS Indicator Lamp: This lamp, located on the vehicle dash, serves
two purposes:
a. Alerts drivers or service personnel to a possible fault in the
hydraulic ABS, as follows:
IF ... the ABS indicator lamp comes on briefly then goes OFF
when the ignition is turned ON . . . . . there are no active or
stored faults in the hydraulic ABS
1004698a
IF ... the ABS indicator lamp comes on and stays on AFTER the
SAPH168010300017
ignition is turned ON
and
IF ... The vehicle is driven in excess of 4 mph (6 km/h) . . . There

may be an active fault in the hydraulic ABS 5
and
Goes OFF after the vehicle is driven in excess of 4 mph (6
km/h) . . . There may be a stored fault in the hydraulic
ABS 5
b. Displays diagnostic blink codes for easy servicing.
Blink Code: A series of blinks or flashes that describe a particu-

lar ABS system condition. (Refer to Table D [cab-mounted] for
blink code identification.)
Blink Code Diagnostics: The ability of the Meritor WABCO ECU

to sense faults in the ABS system and to define these faults via
blink codes.
Blink Code Switch: A momentary switch that activates blink

code diagnostic capabilities. Usually, it is mounted under the dash
or on the steering column. Refer to the vehicle specifications for
type and location.
Clearing Fault Codes: The process of erasing faults from the

ECU memory bank. (Refer to Table C.)
Fault Code: An ABS condition (fault) detected and stored in

memory by the Meritor WABCO ECU and displayed by blink code.
System faults may be Active or Stored.
Active Fault: A condition that currently exists in the ABS system;

for example, a sensor circuit malfunction on the left front steering
axle. An active fault must be repaired before you can display
additional faults. Once an active fault has been repaired, it

becomes a stored fault.
Stored Fault: A condition that caused the system to register a

fault, but is not currently active. For example, a loose wire that
corrected itself. A stored fault can also be an active fault that has
been corrected (refer to Active Fault).
Table C describes the method of distinguishing between active

and stored faults and explains how to clear them.
3. USING BLINK CODE DIAGNOSTICS

Follow the steps listed in Table C to use blink code diagnostics. Refer to
page DN03-13 and 14 for blink code illustrations.
Table C: Identifying D-Version Hydraulic ABS Blink Codes

Troubleshooting with Blink Code Diagnostics
Mode Procedure System Response Action
Step I. Possible responses:
Turn Ignition ON. 1. ABS indicator lamp comes No recognizable active faults in
on momentarily then goes the ABS. No action required.
out, indicating System O.K.
2. ABS indicator lamp does Inspect wiring. Inspect bulb.
not light, indicating Make necessary repairs.
possible wiring fault or
burned-out bulb.
3. ABS indicator lamp stays
on, indicating:
Fault, or faults, in the Continue with blink code
system. diagnostics. (Go to Step II.)
Sensor fault during last Continue with blink code
operation. diagnostics. (Go to Step II.)
DIAGNOSTIC
Faults cleared from ECU, Drive vehicle lamp will go out

but vehicle not driven. when vehicle reaches 4 mph
(6 km/h).
ECU disconnected. Connect ECU.
Step II. ABS indicator lamp begins Determine if fault is active or
Press and hold Blink Code flshing two-digit blink code(s). stored:
Switch for one second, then Active Fault: Lamp will
release. repeatedly display one code.
Stored Fault: Lamp will display
code for each stored fault then
stop blinking. Faults will be
displayed one time only.
Step III. First Digit: 1 - 8 flashes, Find deÞnition for blink code on
Pause (1-1/2 seconds). blink code chart.
Count the flashes to Second Digit: 1 - 8 flashes,
determine the blink code. Pause (4 seconds).
Step IV. Active Fault. Make the necessary repairs.
Turn Ignition OFF .
Repair and Record faults. Stored Faults. Record for future reference.
Step V. ABS Indicator Lamp flashes All stored faults successfully
eight times. cleared. Turn ignition OFF .
Turn Ignition ON. Turn ignition ON. The indicator
Clear Faults from memory: lamp will stay on. This is
CLEAR
Press and hold blink code because the ECU is looking for
switch for at least three wheel speed. Drive the vehicle
seconds, then release. at a speed of 4 mph (6 km/h).
Once the ECU senses wheel
speed, the lamp will go off.
Eight flashes not received. Active faults still exist, repeat
Steps I through V .
* If you receive a blink code that is not identified in Table D , contact the Customer Support
Center at 800-535-5560.
SAPH168010300018
4. BLINK CODES ILLUSTRATED
1 Second Active Fault

Hold
1-8 Flashes 1-6 Flashes
Pause Pause Pause Pause
Continues until
1.5 s 1.5 s 4s 1.5 s ignition is turned off
Light ON 1st Digit 2nd Digit Repeat of Blink Code
(2) (3) (2) (3)
Blink Code 2-3: Fault in ABS modulator

valve, right rear drive axle.
1 Second Stored Faults

Hold
Displays all stored
Off Pause
faults once last fault
Pause Pause Pause
1.5 s 1.5 s 4s 1.5 s stored is displayed first
Light ON 1st Digit 2nd Digit 1st Digit 2nd Digit
1st Stored Fault 2nd Stored Fault
(5) (2) (3) (4)
Blink Code 5-2: Sensor signal erratic,

left front steer axle.
3-4: Too much sensor gap,
left rear drive axle.
1 Second System O.K.

Hold
Pause Pause
Blink Code 1-1: System OK
1.5 s 1.5 s
Light ON (1) (1)
S = Seconds
1002021b
SAPH168010300019
Note: After faults are cleared and

vehicle is started, ABS lamp will stay
3 Second Faults Cleared on until vehicle is driven over 4 mph (6 km/h).
Hold
Continues
Pause Pause Pause Pause Pause
until ignition
1.5 s 4s 4s 4s 4s is turned off
Light ON 8 Quick Blinks = Faults Cleared System System System System
Status Status Status Status
(2) (2) (2) (2)
Code 2
3 Second
Faults Not Cleared (Active Faults Still Exist)
Hold
Continues
until ignition
4s 4s 4s 4s is turned off
Light ON System System System System
Status Status Status Status
(2) (2) (2) (2)
S = Seconds
1002022a
SAPH168010300020
(1) Use the information in Table D, D Version Hydraulic ABS Blink Codes (Cab-Mounted ECU), to identify a fault, check
for proper volt or ohm measurements and repair the fault.
a. Identify and record the blink code. Blink codes are identified in Columns 1 and 2.
b. Test the pins indicated. Pin locations to be tested are listed in Column 3.
c. Compare the measurement received against the correct volt or ohm measurement listed in Column 4.
d. Follow the instructions listed in Column 5.
Table D: D Version Hydraulic ABS Blink Codes (Cab-Mounted ECU)
SAPH168010300021
SAPH168010300022
SAPH168010300023
5. TESTING THE SYSTEM

This section of the manual contains information for testing the hydrau-
lic ABS with TOOLBOX Software, as well as procedures for conduct-
ing standard air and electrical tests.
! WARNING
Exhaust gas contains poison. When testing a vehicle with the engine
running, test in a well-ventilated area or route the exhaust hose out-
side.
To avoid serious personal injury, keep away, and keep test equipment
away, from all moving or hot engine parts.
Refer to, and follow, the vehicle manufacturer's Warnings, Cautions
and Service Procedures.
When testing, set the parking brake and place the gear selector in
NEUTRAL (manual transmission) or PARK (automatic transmission)
unless otherwise directed.
(1) Meritor WABCO TOOLBOX Software
Use TOOLBOX Software to verify the activation of various system
components:
Turn valves, pump and retarder relay on and off (Valve Activation
Menu). Turn ABS indicator lamp on and off (Miscellaneous Output
Activation Menu). Reset components in ECU memory.
NOTICE
For complete instructions for using this program, refer to the User's
Manual, TP-99102. Contact Meritor WABCO at 800-535-5560 for infor-
mation about TOOLBOX Software.
(2) Valve, Pump and Retarder Relay Activation
To activate the ABS valves, pump or retarder relay, select HABS
(Hydraulic ABS) from the Main Menu. The Hydraulic ABS Main
Menu will appear.
1004696a
SAPH168010300024
Select the Valve Activation icon or select Component Tests, then

Valves to use the pull-down menu. This displays the Valve Activation
screen.
1004700a
SAPH168010300025
1004701a
SAPH168010300026
The Valve Activation screen lets you activate the four valves, the
pump and the retarder relay. In addition to checking for proper activa-
tion, this screen provides an easy way to make sure the valves are
wired properly — and that wiring is not reversed. Component activa-
tion status appears in the status box of this screen.
(3) ABS Indicator Lamp Activation
To activate the ABS indicator lamp, select HABS (Hydraulic ABS) from
the Main Menu. The Hydraulic ABS Main Menu will appear.
1004702a
SAPH168010300027
Select the Miscellaneous Output Activation icon or select Component

Tests to use the pull-down menu figure to display the Actuate Miscel-
laneous Output screen.
This screen provides a check of the ABS indicator lamp. In addition, it

provides a way to check either inlet or outlet activity of the valves,
pump or retarder relay. Component activation status appears in the
status box of this screen.
1004703a
SAPH168010300028
(4) Reset Memorized

This is an automatic default and cannot be de-selected. It indicates
the ECU has memorized the installed retarder relay. Once the ECU
has seen a retarder, it expects to see it every time the vehicle is pow-
ered up.
Because there are times when an ECU is moved to another vehicle —

or during diagnostic testing — you may want the ECU to disregard
1004704a this learned component. Use the Reset Memorized command for this
purpose.
SAPH168010300029
Select Component Tests from the Hydraulic ABS Main Menu.

Then, select Reset Memorized from the pull-down menu to reset the
Learned Component screen.
1004705a
SAPH168010300030
6. STANDARD TESTING
(1) Test Equipment: Volt-Ohm Meter (VOM)
Use of a VOM with automatic polarity sensing is recommended. This
eliminates the concern of the polarity of the meter leads during volt-
age measurements.
(2) System Requirements and Component Tests
a. Tire Size Range
For proper hydraulic ABS operation, front and rear tire sizes must
be within 16% of each other.
Contact the Meritor WABCO Customer Support Center at 800-

535-5560 if you plan a tire size difference greater than ±8%.
Calculate the tire size with the following equation:
! CAUTION
When troubleshooting or testing the ABS system, do not damage the
connector terminals.
(3) Voltage Check
Voltage must be between 9.5 and 14 volts for the 12-volt hydraulic
ABS to function properly.
Check voltage as follows:

a. Turn ignition ON.
b. Check for proper voltage:
Cab-mounted ECU: Pins 12 and 1 and 12 and 2 on the 18-pin

connector.
If voltage is not between 9.5 and 14 volts, verify proper wiring

connections. Make corrections as required.
7. STANDARD COMPONENT TESTING

(1) ABS Indicator Lamp
If the ABS indicator lamp does not come on after the ignition is turned
on, or it comes on but does not go out after three seconds, check all
ABS fuses or circuit breakers and replace if necessary. Check the wir-
ing to the ABS diagnostic switch and the indicator lamp and repair or
replace the wiring as required. When checking the indicator lamp, fol-
low these steps:
a. Check voltage potential at the lamp socket.
b. Check continuity of the wires to the socket.
c. Replace the bulb.
NOTICE
A complete wiring diagram for 4S/4M D-version hydraulic ABS
appears in page DN03-8.
(2) ABS Blink Code Switch
When testing the ABS Diagnostic switch:
a. Check the resistance between the terminals while cycling the
switch. A lack of resistance is an indication of a faulty switch.
b. Check the continuity of the wires to the switch:
Cab-mounted ECU: Pins 18 and 12 on the 18-pin connector.

(3) Sensor Adjustment
On steering axles, the sensor is typically accessible on the in-board
side of the steering knuckle.
On drive axles, the sensor is typically accessible on the in-board side

of the rear axle spindle.
To adjust the sensor, push the sensor in until it contacts the tooth
wheel:
• Do not pry or push sensors with sharp objects
• Sensors will self-adjust during wheel rotation.
NOTICE
No gap is allowable at installation. During normal operation a gap not
to exceed 0.04-inch is allowable.
(4) Sensor Output Voltage Test
Sensor output voltage must be at least 0.2 volts AC at 30 rpm. Test
the sensor output voltage as follows:
a. Turn ignition OFF.
b. Disconnect the ECU. To measure voltage at the pins on the ECU
connector, disconnect the sensor from the sensor extension
cable.
! WARNING
Block the wheels to prevent the vehicle from moving. Support the
vehicle with safety stands. Do not work under a vehicle supported
only by jacks. Jacks can slip and fall over. Serious personal injury can
result.
c. Put blocks under the front and rear tires to stop the vehicle from
moving.
d. Raise the vehicle off the ground. Put safety stands under the axle.
e. Rotate wheel by hand at 30 rpm (1/2 revolution per second).
f. Measure the voltage at the pins indicated in Table F.
Table F: Sensor Check Pins
Sensor Cab-Mounted
Pins (9-Pin Connector)
Left Front 1 and 2
Right Front 4 and 5
Left Rear 7 and 8
Right Rear 3 and 6
(5) Sensor Resistance

The sensor circuit resistance must be between 900 and 2000 ohms.
Measure resistance at the sensor connector, or at the pins on the
ECU connector, as follows:
b. To measure resistance at the pins on ECU connector, disconnect
the ECU connector from the ECU.
To measure resistance at the sensor connector, disconnect the

sensor from the sensor extension cable.
c. Measure output at the pins indicated in Table F, Sensor Check
Pins.
If measurement is not between 900 and 2000 ohms, replace the

sensor.
COMPONENT REMOVAL AND INSTALLATION
1. SENSORS: WHEEL SPEED SENSOR REPLACEMENT — FRONT

AXLE
Meritor WABCO specifications call for a sensor lubricant with the fol-
lowing characteristics:
Lube must be mineral oil-based and contain molydisulfide. It should

have excellent anti-corrosion and adhesion characteristics and be
capable of continuous function in a temperature range of -40°C to
300°F (-40° to 150°C).
(1) Removal
! WARNING
Block the wheels to prevent the vehicle from moving. Support the
vehicle with safety stands. Do not work under a vehicle supported
only by jacks. Jacks can slip and fall over. Serious personal injury can
result.
To avoid damage to the electrical system or ABS components, when

welding on an ABS-equipped vehicle disconnect the power connector
from the ECU.
a. Apply the parking brakes. Chock the rear tires to prevent vehicle
movement.
If necessary, raise the front tires off the ground. Put safety stands
under the axle.
b. Disconnect the fasteners that hold the sensor cable to other com-
ponents.
c. Disconnect the sensor cable from the chassis harness.
d. Remove the sensor from the sensor holder. Twist and pull the
sensor to remove it from the sensor bracket. Do not pull on the
KNUCKLE-MOUNTED cable.
SENSOR
1004706a
SAPH168010300032
(2) Installation
a. Connect the sensor cable to the chassis harness.
b. Install the fasteners used to hold the sensor cable in place.
c. Apply a Meritor WABCO-recommended lubricant to the sensor
spring clip and sensor.
d. Install the sensor spring clip. Make sure the spring clip tabs are on
the inboard side of the vehicle.
e. With the tabs on the inboard side, push the sensor spring clip into
the bushing in the steering knuckle until the clip stops.
f. Push the sensor completely into the sensor spring clip until it con-
tacts the tooth wheel.
g. Fasten the sensor cable with tie wraps every 12 inches. Properly
bundle and store excess cable in the sub frame.
h. Remove the blocks and safety stands.
i. Perform a voltage output check to ensure proper installation.
Refer to "Sensor Output Voltage Test" in page DN03-22.
2. WHEEL SPEED SENSOR REPLACEMENT REAR AXLE

(1) Removal
a. Apply the parking brake. Chock the front tires to prevent vehicle
movement.
b. Raise the rear tires off of the ground. Put safety stands under the
axle.
c. If the rear tire must be removed to gain access to the sensor,
release the parking brake to release the brake shoe.
Remove the wheel and tire assembly from the axle.
Remove the sensor from the mounting block in the axle housing.
Use a twisting motion if necessary. Do not pull on the cable.
d. Disconnect the sensor cable from the chassis harness.
e. Remove the sensor cable from any cable clamps or clips.
f. Remove the sensor spring clip from the sensor bracket.
(2) Installation
a. Connect the new sensor cable to the chassis harness.
b. Press the sensor spring clip into the sensor bracket, located on
the rear axle, until it stops. Make sure the tabs are on the inboard
side.
c. Apply a Meritor WABCO-recommended lubricant to the sensor.
d. Push the sensor completely into the spring clip until it contacts the
tooth wheel.
e. Reattach the sensor cable to the cable clamps or clips.
f. Fasten the sensor cable with tie wraps every 12 inches. Properly
bundle and store excess cable in the sub frame.
BUNDLE g. Replace the tire, remove the safety stands, lower the vehicle and
EXCESS remove the chocks from the front tires.
CABLE
h. Perform a voltage output check to ensure proper installation.
Refer to "Sensor Output Voltage Test" in page DN03-22.
1004707a
SAPH168010300033
3. MODULATOR ASSEMBLY
(1) Modulator Assembly Removal
! CAUTION
The modulator assembly contains hydraulic brake fluid, a caustic
substance. Remove the valve carefully so that fluid does not leak and
cause skin irritation or damage to components.
a. Apply the parking brakes. Chock the front and rear tires to prevent
vehicle movement.
b. Place a container under the modulator assembly to catch leaking
brake fluid.
c. Disconnect the electrical harness connectors from the modulator
assembly.
d. Mark the six brake lines for ease of installation. Disconnect the
lines from the modulator assembly.
e. Remove the three mounting capscrews, washers and nuts that
attach the modulator assembly and bracket assembly to vehicle.
NOTICE
Whenever any hydraulic system fitting is loosened or disconnected,
the entire system must be bled to remove any air that may have
entered.
f. Remove the modulator assembly and bracket.
(2) Modulator Assembly Installation
a. Position the modulator assembly and bracket in place on the vehi-
cle.
b. Tighten the three mounting nuts.
Tightening torque
15N⋅m (153kgf.cm,132 lb-in)
c. Connect and tighten brake line connections as follows:
• Two small (MI0XI) adapters:
• Four large (MI2XI) adapters:
d. Bleed the brake system, per the following instructions.
e. Connect the electrical harnesses to the modulator assembly.
4. BRAKE BLEEDING PROCEDURES

(1) General
The following brake bleeding methods explain how to bleed the
hydraulic ABS modulator assembly during installation, or in the event
of air in the brake system. There are instructions for both pressure
and manual bleeding procedures.
These instructions include the procedure for bleeding both the master
1004708a cylinder and the brake system. In some cases, for example, if you are
replacing only the modulator assembly, it may not be necessary to
SAPH168010300037 bleed the master cylinder. If you have any questions, please contact
the Meritor Service Center at 800-535-5560.
NOTICE
The modulator assembly must be handled with appropriate care and
should not be exposed to excessive impact or compressed air at the
hydraulic ports prior to assembly.
! WARNING
Failure to bleed the system whenever any hydraulic system fitting is
loosened or disconnected will allow air to remain in the system. This
will prevent the hydraulic pressure in the brake system from rising
enough to apply the brakes properly. This will cause the stopping dis-
tance to increase and can result in serious personal injury.
Properly discard hydraulic brake fluid that is removed from the brake
system. Hydraulic brake fluid that is removed can be contaminated
and can cause damage, loss of braking and serious personal injury.
Use only the type of hydraulic brake fluid specified by the equipment
manufacturer. Do not use or mix different types of hydraulic brake
fluid. The wrong hydraulic brake fluid will damage the rubber parts of
the brake caliper and can cause damage, loss of braking and serious
personal injury.
NOTICE
Use DOT 3 or DOT 4 hydraulic brake fluid. Refer to the vehicle specifi-
cations to determine which fluid to use.
! CAUTION
Hydraulic brake fluid is a caustic substance. Contact with hydraulic
brake fluid can cause skin irritation. Do not let hydraulic brake fluid
touch any painted surfaces, as it will remove the paint. Hydraulic
brake fluid may also damage certain non-metal surfaces. Do not let
fluid get on brake pads, shoes, rotors or disks.
(2) Pressure Fill and Bleed
Pressure fill and bleeding is the preferred method for bleeding the
service brake system. It requires the use of a special pressure
bleeder kit, consisting of a tank, pressure pump and valve, gauge, tub-
ing and adapter. These kits are available from a number of manufac-
1004709a
turers and include instructions for use.
SAPH168010300034
(3) Pressure Fill and Bleed Procedure:

a. Apply the parking brake and chock the tires. Turn the ignition OFF
and disconnect the battery terminals.
NOTICE
The ignition must remain off for the entire bleeding procedure; ener-
gizing the unit during bleeding must be impossible.
b. Fill the pressure bleeder with new DOT 3 or DOT 4 hydraulic
brake fluid. Refer to the vehicle specifications to determine which
fluid to use.
c. Follow the manufacturer's instructions to connect the pressure
bleeder to the brake master cylinder reservoir.
d. Set filling pressure to 20 to 30 psi (1.5 to 2.0 bar).
e. Turn on bleeding equipment until fluid level in reservoir reaches
approximately 0.875-inches (20 mm).
f. Release pressure for 3 to 5 seconds. Apply pressure for 5 to 10
seconds.
g. Repeat Steps 5 and 6 approximately 10 times. After releasing the
pressure, air bubbles should rise up into the reservoir.
! WARNING
Do not let the brake master cylinder fluid get below the minimum level
during the bleeding operation. Keep the master cylinder reservoir
filled with new DOT-approved brake fluid, as specified by the original
equipment manufacturer. Failure to keep the brake reservoir level
above minimum could result in more air entering system, making it
impossible to effectively bleed the system.
h. Bleed the brake system:
• Set filling pressure to 20 to 30 psi (1.5 to 2.0 bar).
• Put a wrench on the brake actuator bleeder fitting. Start with the far-
thest from the modulator, (typically the right rear), then attach a length
of clear plastic tubing to the bleeder fitting. Make sure the tube fits
snugly.
i. Submerge the tubing in a container of clean hydraulic brake fluid.
NOTICE
Both the tubing and container must be able to withstand the effects of
hydraulic brake fluid.
1004710a
SAPH168010300035 Loosen the bleeder fitting until the fluid begins to flow (about 3/4
turn). Let the hydraulic fluid flow out of the fitting until it is free of
air bubbles.
j. Tighten firmly to secure the fitting.
k. Repeat Steps 5 through 8 to bleed the remaining three brake
actuators. Bleed in sequence of the longest to shortest circuit
from the modulator assembly.
l. Turn off bleeding equipment and remove pressure. Remove
bleeding device and check fluid level in reservoir. Fill if required.
Replace reservoir cap and dispose of used brake fluid.
m. Remove wheel chocks.
(4) Manual Bleeding Procedure:
a. Apply the parking brake and chock the tires. Turn the ignition OFF
and disconnect the battery terminals.
NOTICE
The ignition must remain off for the entire bleeding procedure; ener-
gizing the unit during bleeding must be impossible.
b. Fill the reservoir with DOT 3 or DOT 4 hydraulic brake fluid. Refer
to the vehicle specifications to determine which fluid to use.
c. Depress the brake pedal five times using the stroke between 1/3
travel and maximum travel in 5 seconds.
d. Release the pedal for 5 to 10 seconds. Air bubbles will rise into
the reservoir while depressing and releasing pedal.
e. Repeat Steps 3 and 4 another three times, or until sufficient pedal
resistance is felt.
! WARNING
Do not let the brake master cylinder fluid get below the minimum level
during the bleeding operation. Keep the master cylinder reservoir
filled with new DOT-approved brake fluid as specified by the original
equipment manufacturer. Failure to keep the brake reservoir level
above minimum could result in more air entering system, making it
impossible to effectively bleed the system.
f. Bleed the brake system. Put a wrench on the brake actuator
bleeder fitting. Start with the farthest from the modulator, (typically
the right rear), then attach a length of clear plastic tubing to the
bleeder fitting. Make sure the tube fits snugly.
g. Submerge the tubing in a container of clean brake fluid.
NOTICE
Both the tubing and container must be able to withstand the effects of
brake fluid.
h. Depress the brake pedal 10 to 15 times, using the maximum avail-

able stroke.
i. Loosen the bleeder fitting until the fluid begins to flow, (about 3/4
turn), while depressing the brake pedal through its maximum
available stroke.
j. Tighten the fitting firmly prior to releasing the brake pedal.
k. Repeat Steps 6 through 8 several times until the discharged fluid
is free of air bubbles.
l. Repeat Steps 3 through 9 to bleed the remaining three brake
actuators. Bleed in sequence of the longest to the shortest circuit
from the modulator.
m. Check the travel of the brake pedal. If a firm resistance is felt the
manual bleeding procedure is complete.
n. Check the fluid level in reservoir and fill if required. Replace reser-
voir cap and dispose of used brake fluid.
o. Remove wheel chocks.
Modulator Assembly Connector Pin Assignment
HARNESS MODULATOR ASSEMBLY

CONNECTOR PINOUT CONNECTOR PINOUT
5 4 3 2 1 1 2 3 4 5
9 8 7 6 6 7 8 9
PUMP
13 12 11 10 10 11 12 13
CONNECTOR
MAIN
+
GROUND
-
Pin Pin
Number Circuit Description Number Circuit Description
1 Outlet Valve RL 8 Reference Ground
2 Inlet Valve RL 9 -----
3 ----- 10 Outlet Valve RR
4 Inlet Valve FR 11 Inlet Valve RR
5 Outlet Valve FR 12 Inlet Valve FL
6 ----- 13 Outlet Valve FL
1004711a
7 -----
SAPH168010300036
BRAKE CONTROL (ABS : FULL AIR) DN03–1
BRAKE CONTROL (ABS : FULL AIR)

DN03
DN03-002
ABS ...........................................................DN03-2
TROUBLESHOOTING ..................................... DN03-2
DN03–2 BRAKE CONTROL (ABS : FULL AIR)
ABS
TROUBLESHOOTING
EN1680203F100001
BEFORE YOU BEGIN

This manual provides instructions for Meritor WABCO's anti-lock braking
system for trucks, tractors and buses. Before you begin procedures:
.

2. Read and observe all Caution and Warning safety alerts that precede
instructions or procedures you will perform. These alerts help to avoid
damage to components, serious personal injury, or both.
1. SAFETY ALERTS, TORQUE SYMBOL AND NOTES
! WARNING A Warning alerts you to an instruction or pro-

cedure that you must follow exactly to avoid
serious personal injury and damage to com-
ponents.
! CAUTION A Caution alerts you to an instruction or pro-

cedure that you must follow exactly to avoid
damage to components and possible serious
injury.
NOTICE A Note provides information or suggestions

that help you correctly service a component.
2. ACCESS INFORMATION ON ARVINMERITOR'S WEB SITE

Additional maintenance and service information for ArvinMeritor's
commercial vehicle systems component lineup is also available at
www.arvinmeritor.com.
To access information, click on Products & Services/Tech Library

Icon/HVS Publications. The screen will display an index of publica-
tions by type.
3. ADDITIONAL INFORMATION
Call ArvinMeritor's Customer Service Center at 800-535-5560 to
order the following item.
• Drivetrain PlusTM by ArvinMeritor Technical Electronic Library on CD.
Features product and service information on most Meritor, ZF Meritor
and Meritor WABCO products. $20. Order TP-9853.
SAPH168020300001
ABS CONFIGURATION
4
3
1 2
A
B
1002004c
A. Air Lines 1. Wheel Speed Sensors 3. Relay Valve
B. Electrical Lines 2. ABS Modulator Valves 4. ECU
4S/4M Configuration
SAPH168020300002
SYSTEM COMPONENTS
The ECU is the brain of the ABS system. It receives information from the
sensors and sends signals to the ABS valves. The ECU is cab-mounted.
NOTICE
Do not open the ECU. Opening the ECU to gain access to the internal
components will void the warranty.
SAPH168020300003
A tooth wheel (A) is mounted at, or cast in, the hub of each sensed wheel,
with a sensor (B) installed so that its end is against the tooth wheel. A sen-
sor clip (C) holds the sensor in place at the tooth wheel.
NOTICE
The sensor and clip must be greased with Meritor WABCO-recom-
mended lubricant. Refer to "Sensor Lube Specification" page DN03-24
for lube specification.
1002009b
SAPH168020300004
An ABS modulator valve controls air pressure to each affected brake dur-
ing an ABS event. The modulator valve is usually located on a frame rail or
Also available with cross member near the brake chamber. The modulator valve is available in
2
open-style connector .
bayonet-style or open-style connector.
1
BAYONET-STYLE
CONNECTOR
1. Air In (Port 1)
2. Air Out (Port 2)
SAPH168020300005
Sensor cables connect the sensor to the ECU.
1002013a
SAPH168020300006
ABS modulator valve cables connect the modulator valve to the ECU.
1002012a
SAPH168020300007
TOOLBOX Software is a PC-based diagnostics program that can display

wheel speed data, test individual components, verify installation wiring and
more. Runs in Windows 95, 98 and NT. An RS232 to J1708 convertor box
is required. Versions 3.2 and higher support E version ABS.
Available from SPX (Kent-Moore), 800-328-6657

SAPH168020300008
The MPSI Pro-Link 9000 with a multiple protocol cartridge (MPC) and
Meritor WABCO applications card, version 2.0 or higher, provides diagnos-
tic and testing capabilities for the E version ABS.
NOTICE
The Power Line Carrier Communication (PLC) functions of E version
ABS cannot be tested with the Pro-Link.
1002014a
Available from SPX (Kent-Moore), 800-328-6657
SAPH168020300009
System Diagnostics
Use any of the following methods to diagnose E version ABS:
• TOOLBOX Software, version 3.2 or higher, a PC-based ABS diagnos-
tic and testing program that runs in Windows 95, 98 or NT
• Blink Codes — Tractor ABS only
• MPSI Pro-Link with MPC and Meritor WABCO applications card, ver-
sion 2.0 or higher
• OEM Diagnostic Displays (Refer to the Vehicle Operator's Manual)
Information about TOOLBOX Software, MPSI Pro-Link and Blink Codes fol-
lows. If you have any questions about system diagnostics, please contact
ArvinMeritor's Customer Service Center at 800-535-5560.
1. TOOLBOX SOFTWARE
NOTICE
For complete instructions for using TOOLBOX Software, refer to the
User's Manual.
If you have TOOLBOX Software installed on your computer, use it to
identify system faults. Then, follow the on-screen repair information to
make the necessary repairs or replacements.
To display E version ABS faults:

(1) Connect the computer to the vehicle:

SERIAL
CABLE • Attach the cable from your computer to the J1708 to RS232 converter
box.
• Attach the diagnostic cable (Deutsch) to the vehicle.
TO VEHICLE
J1587 J1708-TO-RS232
CONNECTOR CONNECTOR
SAPH168020300010
(2) Select TOOLBOX Software from Desktop or from the Windows Start
Menu to display the TOOLBOX Main Menu.
SAPH168020300011
(3) From the Main Menu, select Tractor ABS Diagnostics, or use the pull
down menu to make your selection. The ABS Main Screen will
appear.
SAPH168020300012
SAPH168020300013
(4) From the ABS Main Screen, select the Faults icon, or use the pull
down menu to display the faults from the ECU.
NOTICE
If there are Faults in the system (YES in existing or stores fields) dou-
ble-click on the YES to display Fault Information.
SAPH168020300014
(5) The Fault Information Screen contains a description of the fault.

Repair instructions for each fault appear at the bottom of the screen.
NOTICE
Faults that occur after the screen is displayed will not appear until a
screen update is requested. Use the Update button at the bottom of
the screen to refresh the fault information table.
(6) After making the necessary repairs, use the Clear Faults button at
the bottom of the screen to clear the fault. Use the Update button to
refresh the fault information table and display the new list of faults.
2. BLINK CODE DIAGNOSTICS (TRACTOR ABS ONLY)

SAPH168020300015
(1) Definitions
Before using blink code diagnostics, you should be familiar with a few
basic terms. If you used previous versions of Meritor WABCO's blink
code diagnostics, review these definitions to identify major changes.
ABS Indicator Lamp: This lamp serves two purposes: it alerts driv-
ers to an ABS tractor fault and it is used during diagnostics to display
the blink code.
Blink Code: A series of blinks or flashes that describe a particular

ABS system fault or condition.
Blink Code Cycle: Two sets of flashes with each set separated by a
one-and-one-half second pause. Blink codes are defined in Blink
Code Identification in this section.
Blink Code Switch: A momentary switch that activates blink code

diagnostic capabilities. Switch types and locations vary, depending on
the make and model of the vehicle.
Clear: The process of erasing faults from the ECU.
Diagnostics: The process of using blink codes to determine ABS

system faults.
Fault: An ABS malfunction detected and stored in memory by the

Meritor WABCO ECU. System faults may be Active or Stored.
Active Fault: A condition that currently exists in the ABS system; for
example, a sensor circuit malfunction on the left front steering axle.
An active fault must be repaired before it can be cleared from memory
— and before you can display additional blink code faults.
Stored Fault: There are two types of stored faults:

a. A repaired active fault that has not been cleared from the ECU.
b. A fault that occurred but no longer exists. For example, a loose
wire that makes intermittent contact. Because stored faults are
not currently active they do not have to be repaired before they
can be cleared from memory.
Meritor WABCO recommends you keep a record of these faults
1 2 for future reference.
System Configuration Code: One digit code displayed during

the clear mode. Blink codes for common ABS system configura-
4S/4M tions are shown in figure.
1. Number of Flashes
2. ABS Configuration
1002020c
SAPH168020300016
3. DIAGNOSTIC MODE
To enter the diagnostic mode, press and hold the blink code switch for
one second, then release.
4. CLEAR MODE
To erase faults from the ECU, you must be in the clear mode. To enter
the clear mode, press and hold the blink code switch for at least three
seconds, then release.
If the system displays eight quick flashes followed by a system config-

uration code, the clear was successful. Stored ABS faults have been
cleared from memory.
If you do not receive eight flashes, there are still active faults that must
be repaired before they can be cleared.
5. BLINK CODE DIAGNOSTICS
Troubleshooting with Blink Code Diagnostics

Mode Procedure System Response Action
Step I. Possible responses:
Turn Ignition ON A. ABS indicator lamp comes on No recognizable active faults in the
momentarily then goes out, ABS. No action required.
indicating System O.K.
B. ABS indicator lamp does not light, Inspect wiring. Inspect bulb. Make
indicating possible wiring fault or necessary repairs.
burned-out bulb.
C. ABS indicator lamp stays on,

indicating:
• Fault, or faults, in the system. Continue with blink code diagnostics.

(Go to Step II.)
• Sensor fault during last Continue with blink code diagnostics.

operation. (Go to Step II.)
• Faults cleared from ECU, but Drive vehicle lamp will go out when
DIAGNOSTICS
vehicle not driven. vehicle reaches 4 mph (6 km/h).
• ECU disconnected. Connect ECU.
Step II. ABS indicator lamp begins flashing Determine if fault is active or stored:
Press and hold Blink Code Switch two-digit blink code(s). Active Fault: Lamp will repeatedly
for one second, then release. display one code.
Stored Fault: Lamp will display code
for each stored fault then stop
blinking. Faults will be displayed one
time only.
Step III. First Digit: 1 - 8 flashes, Pause Find definition for blink code on blink
(1-1/2 seconds). code chart.
Count the flashes to determine
the blink code. Second Digit: 1 - 6 flashes, Pause
(4 seconds).
Step IV. Active Fault. Make the necessary repairs. Repeat

Turn Ignition OFF . Steps I, II, and III until System O.K.
code (1-1) received.
Repair and Record faults. Stored Faults. Record for future reference.
NOTE: Last fault stored is first fault
displayed.
Step V. ABS Indicator Lamp flashes eight All stored faults successfully cleared.
times. Turn ignition OFF.
CLEAR
Turn Ignition ON.
Clear Faults from memory: Press Eight ßashes not received. Active faults still exist, repeat Steps I
and hold blink code switch for at through V.
least three seconds, then release.
SAPH168020300017
6. BLINK CODES ILLUSTRATED
1 Second Active Fault

Hold
1-8 Flashes 1-6 Flashes
Continues until
1.5 s 1.5 s 4s 1.5 s ignition is turned off
Light ON 1st Digit 2nd Digit Repeat of Blink Code
(2) (3) (2) (3)
Example:
Blink Code 2-3: Fault in ABS modulator
valve, right rear drive axle.
1 Second Stored Faults

Hold Displays all stored
Off
faults once − last fault
1.5 s 1.5 s 4s 1.5 s stored is displayed first
Light ON 1st Digit 2nd Digit 1st Digit 2nd Digit
1st Stored Fault 2nd Stored Fault
(5) (2) (3) (4)
Example:
Blink Code 5-2: Sensor signal erratic,
left front steer axle.
3-4: Too much sensor gap,
left rear drive axle.
1 Second System O.K.

Hold
Pause Pause
Blink Code 1-1: System OK
1.5 s 1.5 s
Light ON (1) (1)
S = Seconds 1002021b
SAPH168020300018
Note: After faults are cleared and

3 Second vehicle is started, ABS lamp will stay
Faults Cleared on until vehicle is driven over 4 mph (6 km/h).
Hold
Continues until
Pause Pause Pause Pause Pause ignition is
1.5 s 4s 4s 4s 4s turned off
Light ON 8 Quick Blinks = Faults Cleared System ID System ID System ID System ID
(2) (2) (2) (2)
System Configuration Code 2: 4S/4M System
3 Second
Faults Not Cleared (Active Faults Still Exist)
Hold
Pause Pause Pause Pause Continues until ignition
4s 4s 4s 4s is turned off
Light ON System ID System ID System ID System ID
(2) (2) (2) (2)
S = Seconds
1002022
SAPH168020300019
WORKING WITH BLINK CODES
1. BLINK CODE CONDITIONS

When using blink code diagnostics, the following conditions could occur:
Blink Code Conditions
Condition Reason Action
ABS indicator lamp does not come on at Loose or burned-out bulb. Check bulb.
ignition. Check connections.
Make necessary repairs.
Voltage not within acceptable range Check connections.

(9.5-14.0 volts). Measure voltage.
Make necessary repairs.
Can't use blink code diagnostics; ABS indi- Switch not held for proper length of Repeat procedure, hold switch for
cator lamp will not go off when blink code is time: proper length of time.
activated. 1 Second — Diagnostics Mode
3 Seconds — Clear All Mode
Improper or faulty wiring. Inspect and repair wiring.
Eight Flashes not received after blink code Active Faults still exist. Identify active faults, then make neces-
switch pressed for at least three seconds, sary repairs. Turn ignition OFF, then
then released. repeat Blink Code Diagnostics.
2. BLINK CODE IDENTIFICATION

Use the following information to identify the blink code:
Blink Code Identification
First Digit (Type of Fault) Second Digit — Specific Location of Fault
1 No faults 1 No faults
2 ABS modulator valve 1 Right front steer axle (curb side)

3 Too much sensor gap 2 Left front steer axle (driver's side)
4 Sensor short or open 3 Right rear drive axle (curb side)
5 Sensor signal erratic/tire size 4 Left rear drive axle (driver's side)
6 Tooth wheel 5 Right rear/additional axle (curb side)*
6 Left rear/additional axle (driver's side)*
7 System function** 1 J1939 datalink

2 ATC valve
3 Retarder relay (third brake)
4 ABS indicator lamp
5 ATC configuration
6 ATC prop./dif lock/stop valve
8 ECU 1 Low power supply

2 High power supply
3 Internal fault
4 System configuration error
5 Ground
* Tandem, lift, tag or pusher axle depending upon the type of suspension.
** If this code continues after all repairs have been made — or if you receive a code for a component that is not
installed on the vehicle — it may be necessary to reconfigure the ECU. Refer to the Reconfiguration Procedure
described in page DN03-29. TOOLBOX Software may also be used to reconfigure the ECU (refer to page DN03-
29). Contact ArvinMeritor's Customer Service Center at 800-535-5560 for reconfiguration information.
3. BLINK CODE TROUBLESHOOTING AND REPAIR
Blink Code Action Required Reference
2-1 2-4 Check ABS modulator valve, valve cable, and connectors. Refer to "Valve Tests," page DN03-24.
2-2 2-5 Verify 4.0-9.0 ohms resistance (ABS modulator valve).
2-3 2-6
3-1 3-4 Adjust wheel sensor to touch tooth wheel. Refer to "Sensor Adjustment," page DN03-23,
3-2 3-5 Check sensor gap. "Sensor Output Voltage Test," page DN03-23, and
3-3 3-6 Check for loose wheel bearings or excessive hub runout. "Component Tests and Functions," DN03-18.
Verify minimum 0.2 volts AC output @ 30 rpm.
4-1 4-4 Check sensor, sensor cable, and connectors. Repair or replace as needed.
4-2 4-5 Verify 900-2000 ohms resistance.
4-3 4-6
5-1 5-5 Check for tire size mismatch or tooth wheel difference. Refer to "Tire Size Range," page DN03-22.
5-2 5-6 Check sensor, sensor cable, and connector for intermit-
5-3 5-7 tent contact.
6-1 6-4 Check for damaged tooth wheel. Repair or replace as needed.
6-2 6-5
6-3 6-6
7-1* Check for proper J1939 data link connection. Refer to wiring diagram in page DN03-28.
Verify wheel spin on each axle.
7-2* Check ATC Valve, valve cables, and connectors. Refer to "Valve Tests," page DN03-24.
Verify 7.0-14.0 ohms resistance.
7-3* Check retarder (third brake) connections. Refer to wiring diagram in DN03-28.
7-4* Check ABS indicator light connections.

Verify blink code switch was activated longer than 16 sec-
onds.
7-5* Verify proper ATC set-up.
7-6* Verify accuracy of blink code and clear from ECU mem- Refer to "Blink Code Diagnostics (Tractor ABS
ory. only)," page DN03-10.
8-1 Check for low voltage. Refer to wiring diagram in page DN03-28 and "Volt-
Check vehicle voltage, fuse, and supply to ECU (9.5-14.0 age Check," page DN-03-23.
volts).
8-2 Check for high voltage. Refer to "Voltage Check," page DN03-23, and "Blink
Check vehicle voltage (9.5-14.0 volts). Code Diagnostics (Tractor ABS only)," page DN03-
Verify accuracy of blink code and clear from ECU mem- 10.
ory.
8-3 Verify accuracy of blink code and clear from ECU mem- Refer to "Blink Code Diagnostics (Tractor ABS
ory. only)" and "Clear Mode," page DN03-10.
8-4 Verify all ECU connectors are in place. Contact ArvinMeritor's Customer Service Center at
Verify accuracy of blink code and clear from ECU mem- 800-535-5560.
ory.
If code does not clear, it may be necessary to replace the
ECU.
8-5 Check all ABS, ECU and ATC valve grounds. Refer to wiring diagram in page DN03-28.
* If this code continues after all repairs have been made — or if you receive a code for a component that is not
installed on the vehicle — it may be necessary to reconfigure the ECU. Refer to the Reconfiguration Procedure
described in DN03-29. TOOLBOX Software may also be used to reconfigure the ECU (refer to page DN03-29).
Contact ArvinMeritor's Customer Service Center at 800-535-5560 for reconfiguration information.
PRO-LINK DIAGNOSTICS
NOTICE
You must use Multiple Protocol Cartridge (MPC) and Meritor WABCO
application card, version 2.0 or higher, with E version ECUs. The PLC
functions of E version ABS cannot be tested with the Pro-Link.
The Pro-Link 9000 may be used in place of blink code diagnostic proce-
dures.
The following Pro-Link information applies to E version ECUs. Refer to

Maintenance Manual 28 if you are using the Pro-Link with C version ECUs
or Maintenance Manual 30 if you are using the Pro-Link with D version
ABS.
1. DIAGNOSTIC PROCEDURE
(1) Slide the MPC into the Pro-Link keypad until the connection is tight.
Then, insert the Meritor WABCO applications card into the cartridge.
(2) Chock the wheels, apply the parking brake, and make sure ignition
power is off.
(3) Locate the 6-pin diagnostic receptacle in the vehicle cab. Insert the 6-
pin connector from the Pro-Link into the receptacle.
(4) Turn the ignition to the ON/RUN position. The Pro-Link screen should
power up. If the Pro-Link does not power up, or if the screen indicates
NO DATA RECEIVED:
• Check connections.
• Make sure the cartridge is properly connected to the Pro-Link keypad.
• Verify 9.5-14.0 volts DC power and ground at the connector and ABS
ECU.
• Check the fuse panel for a blown fuse.
• Check for proper wiring in the diagnostic connector.
(5) Refer to the Pro-Link manual for complete diagnostic instructions.
The Pro-Link 9000 is available from Kent-

Moore, 800-328-6657.
2. PRO-LINK SCREENS
This information provides basic screen explanations for the Pro-Link
9000 with an MPC and Meritor WABCO application card. For com-
plete operating instructions and test information, refer to the Pro-Link
manual.
(1) Fault Information Screens:
Existing Faults: Use these screens to identify existing faults. The Pro-
Link screen displays a written description of the fault, including the
location on the vehicle where each exists. As long as there is an
active (existing) fault in the system, the Pro-Link will not let you clear
faults.
Stored Faults: Use these screens to identify faults stored in the ECU
memory. Stored faults may be existing faults that have been repaired,
or faults that existed for a short time, then corrected themselves. After
displaying the stored faults, the Pro-Link lets you erase them from
memory. All stored faults are cleared at one time.
J1939 DATALINK VERIFICATION — PRO-LINK 9000

The Pro-Link diagnostic tool may be used to verify J1939 datalink connection. If you do not have a Pro-Link, you can use the
blink code switch to verify this connection.
1. Turn ignition ON. Press blink code switch 1.

IGNITION ON
hold for 3 seconds. OFF ON
3 Second Hold
A. ATC indicator lamp will come on and stay A.

on for the entire test. ATC
If vehicle is not equipped with ATC, the

ATC indicator lamp will not come on.
B. ABS indicator lamp will come on and blink B.
8 times.
If the lamp does not blink 8 times, there 8 Quick Blinks = Faults Cleared
are faults that must be cleared before you
continue with this test.
Pause Pause
Continues
C. The eight quick flashes will be followed by C. 4s 4s During Test
the system configuration code. A 4S/4M
(2 blinks) system is identified here. System ID System ID System ID
(2) (2) (2)
The system configuration code will
continue during the entire test.
2. Activate the J1939 engine torque reduction 2.
code, as follows:
1000
A. Step on the accelerator. Bring the engine A.

IDLE
to 1000 rpm. RPM
Leave your foot on the accelerator during

the entire test.
B. While engine is at 1000 rpm, press the B.
blink code switch twice, as follows:
Press for one second
1 Second 1 Second Pause
Pause
Release for one second Hold Hold
Press for one second

Release for one second
C. The engine will go to idle for C. 1000 1000
approximately 10 seconds and then return IDLE IDLE
to 1000 rpm. RPM RPM
3. Turn ignition OFF . 3.

OFF ON
Test complete, engine torque reduction
command verified.
SAPH168020300020
1. COMPONENT TEST SCREENS

These screens help you test ABS components. Select this function
from the Tractor ABS/ATC menu.
ABS VALVES
ATC
ABS INDICATOR LAMP
ABS TRAILER INDICATOR LAMP
ATC INDICATOR LAMP
ABS/ATC SWITCHES
SENSORS
ENGINE DATALINK
RETARDER RELAY
RETARDER DATALINK
VEHICLE VOLTAGES
Select the appropriate function. Each screen has instructions to

guide you through the test. Refer to the Pro-Link Manual for com-
plete instructions.
2. PRO-LINK 9000 DISPLAY

With some ECUs, the Pro-Link will display system information —
components or options supported by the ECU. Access these screens
through System Setup (main ABS menu).
The following screens illustrate:

• A 4S/4M ABS/ATC system
• Where the ECU has not recognized a retarder relay
• Where the ECU has recognized a J1939 datalink
• The ECU is capable of supporting ABS and ATC switches.
NOTICE
Yes indicates the ECU is capable of supporting these options. These
may or may not be installed on the vehicle.
TRACTOR ABS/ATC
SYSTEM INFORMATION
SENSORS 4
MODULATORS 4
ATC VALVE YES

RETARDER RELAY NO
J1939 YES
DIFF LOCK NO
ABS SWITCH YES
ATC SWITCH YES
3. SYSTEM INFORMATION
(1) TOOLBOX Software Display
NOTICE
Refer to page 15 of this manual for instructions for running TOOLBOX
Software, or refer to the Software Owner's Manual, TP-99102, for com-
plete instructions.
The quickest method of verifying system information is the TOOLBOX Soft-
ware ABS Main Screen.
This screen provides information about the current state of Meritor WABCO
ABS. ECU information is read once from the ECU and does not change. All
other information (e.g., wheel sensors, control status, voltages, faults and
SAPH168020300021
road speed) is read and updated continuously.
The status of ABS switches and lamps, as well as other data, may also be
observed from this screen.
4. COMPONENT TESTS AND FUNCTIONS

(1) TOOLBOX Software
NOTICE
Refer to page 15 of this manual for instructions for running TOOLBOX
Software, or refer to the Software Owner's Manual, TP-99102, for com-
plete instructions.
Use TOOLBOX Software to display wheel speeds, cycle ABS valves,

SAPH168020300022
activate ABS and ATC lamps, including the trailer ABS lamp, and turn
the retarder relay on or off. In addition, the J1939 engine datalink con-
nection may be quickly verified by using TOOLBOX Software.
(2) Wheel Speed
Select the wheel speed icon or use the pull down menu from the ABS
Main Screen to display wheel speed data in both numeric and graphi-
cal form. This data may be shown in RPM or MPH format and in verti-
cal or horizontal graphs. Select the appearance and style from the
options menu.
SAPH168020300023
(3) Valve Activation
Select the valve icon or use the pull down menu to select and cycle
individual ABS valves. Then listen to ensure the correct valve is
cycling. This is helpful when verifying proper operation, installation
and wiring.
SAPH168020300024
(4) Lamp Activation

Select the lamp icon or use the pull down menu to turn the tractor and
trailer ABS and/or the ATC (wheel spin) lamps on or off. This is helpful
when verifying proper operation, installation and wiring of the lamps to
the ECU.
SAPH168020300025
(5) Data Link Activation

Select the Engine Data Link icon from the Main ABS Screen or use
the pull down menu to send a "limit engine torque" command to the
engine or a "disable retarder" command to the retarder.
SAPH168020300026
(6) Component Tests and Functions (Pro-Link)

These screens help you test ABS components. Select this function from the Tractor ABS/ATC menu.
TRACTOR COMP TESTS

— SELECTIONS —
↑ VEHICLE VOLTAGES ↓
Select the appropriate function. Each screen has instructions to guide you through the test. Refer to the Pro-Link Manual
for complete instructions.
The following definitions explain the function of each test.
Component Test Function
Vehicle Voltages Monitors the voltage signals powering the ECU.
ABS Valves Cycles the valves, one at a time. With brake pedal applied, you should hear
four short air exhausts, then one long air pressure hold. A menu selection
lets you choose from four or six valves. This test is used to verify valve loca-
tions and proper wiring.
NOTICE
The treadle must be applied to pressurize the brake chambers.
ATC Checks the ATC valve. You will hear a click as the valve cycles.
NOTICE
TOOLBOX Software or the Pro-Link may be used to shut off ATC for
dynamometer testing.
ABS Tractor Lamp Monitors the commanded (on/off) states of the ABS tractor lamp. Follow the
screen prompts (1 On, 2 Off) to change the status of the lamp on the instru-
ment panel.
ABS Trailer Lamp Monitors the commanded (on/off) states of the ABS trailer lamp. Follow the
ment panel.
ATC Tractor Lamp Monitors the commanded (on/off) states of the ATC tractor lamp. Follow the
ment panel.
ABS/ATC Switches Checks the status of ABS and ATC/Deep Snow and Mud switches on the
instrument panel.
Sensors Monitors the input to the ECU from the wheel. Vehicle must be stationary
and wheels must be rotated during this test.
Engine Datalink Checks wiring connections and response between the engine and the ECU.
Retarder Relay Activates the relay to verify function (a click will be heard). This test also
checks wiring connections.
Retarder Datalink Checks wiring connections and retarder response between the retarder and
the ECU.
a. Tire Size Range

For proper ABS/ATC operation with the standard ECU, front and
rear tire sizes must be within ± 14% of each other. When this tire
size range is exceeded without electronically modifying the ECU,
the system performance can be affected and the indicator lamp
can illuminate.
Call Meritor WABCO at 800-535-5560 if you plan a tire size differ-

ence greater than 14%.
Calculate the tire size with the following equation:
5. TESTING COMPONENTS
! CAUTION
When troubleshooting and testing the ABS system, do not damage
the connector terminals.
(1) Voltage Check
Measure voltage at the pins indicated in Table C.
• Voltage must be between 9.5 and 14.0 volts.
• The ignition must be turned ON for this test.
Table C: Voltage check pins
ECU Connector Pins
Universal 14-Pin 4 and 9

9 and 4
Basic 14-Pin 7 and 4

8 and 9
Frame-mounted X1-Grey 1 and 12

2 and 11
NOTICE
Pin locations are illustrated in figure (Frame) and figure (Basic and
Universal).
VIEW INTO ECU CONNECTOR

UNIVERSAL
BASIC
1 4 7 10 13 1 4 7 10 13 16 1 4 7 10 13
2 5 8 11 14 2 5 8 11 14 17 2 5 8 11 14
3 6 9 12 15 3 6 9 12 15 18 3 6 9 15
15 18 14
SAPH168020300028
(2) Location of Sensors
On steering axles, the sensor is accessible on the in-board side of the
steering knuckle.
On drive axles, the drum assembly may have to be pulled to gain

access to the sensor.
(3) Sensor Adjustment
• Push the sensor in until it contacts the tooth wheel.
• Do not pry or push sensors with sharp objects.
• Sensors will self-adjust during wheel rotation.
(4) Sensor Output Voltage Test
Voltage must be at least 0.2 volts AC at 30 rpm.
b. Disconnect the appropriate connector from the ECU (refer to wir-
ing diagram).
c. Rotate wheel by hand at 30 rpm (1/2 revolution per second).
d. Measure voltage at the pins indicated in Table D.
• If the minimum output voltage is less than 0.2, push the corresponding
sensor toward the tooth wheel, then repeat the measurement.
Table D: Sensor Check Pins
ECU Sensor Connector Pins
Basic LF 18-Pin 12 and 15

RF 18-Pin 10 and 13
LR 18-Pin 11 and 14
RR 18-Pin 17 and 18
(5) Sensor Resistance

The sensor circuit resistance must be between 900 and 2000 ohms.
Resistance can be measured at the sensor connector, or at the pins
on the ECU connector. To measure resistance:
b. To measure resistance at the sensor connector, disconnect the
ECU connector from the ECU. To measure resistance at the sen-
sor connector, disconnect the sensor from the sensor extension
cable.
c. Measure output at the pins indicated in Table D.
VALVE TESTS
1. ABS MODULATOR VALVE

Measure resistance across each valve solenoid coil terminal and
ground on the ABS valve to ensure 4.0 to 9.0 ohms.
• If the resistance is greater than 9.0 ohms, clean the electrical contacts
Bayonet-Style Connector in the solenoid. Check the resistance again.
• To check the cable and the ABS valve as one unit, measure resis-
tance across the pins on the ECU connector of the harness. Check
the diagram of the system you are testing for pin numbers. (Refer to
1 page DN03-28.)
1. Exhaust Solenoid (blue wire)

2. Inlet Solenoid (brown wire)
3. Ground Terminal
SAPH168020300029
COMPONENT REMOVAL AND INSTALLATION
1. VALVES
• ABS Modulator Valves
• ATC Valve
• ABS Valve Package (Front or Rear)
Modulator Valves
Relay Valve or Quick Disconnect Valve
ATC Valve
2. SENSOR LUBE SPECIFICATION

Meritor WABCO specifications call for a sensor lubricant with the fol-
lowing characteristics:
Lube must be mineral oil-based and contain molydisulfide. It should

have excellent anti-corrosion and adhesion characteristics, and be
capable of continuous function in a temperature range of -40° to
300°F (-40° to 150°C).
! WARNING
Release all air from the air systems before you remove any compo-
nents. Pressurized air can cause serious personal injury.
! CAUTION
Use the following procedures to avoid damage to the electrical sys-
tem and ABS/ATC components.
When welding on an ABS- or ABS/ATC-equipped vehicle

is necessary, disconnect the power connector from the
ECU.
3. WHEEL SPEED SENSOR REMOVAL — FRONT AXLE

To remove the sensor from the front axle:
! WARNING
over. Serious personal injury can result.
(1) Put blocks under the rear tires to stop the vehicle from moving. Apply
the parking brake.
(2) If necessary, raise the front tires off the ground. Put safety stands
under the axle.
(3) Disconnect the fasteners that hold the sensor cable to other compo-
nents.
(4) Disconnect the sensor cable from the chassis harness.
(5) Remove the sensor from the sensor holder. Use a twisting motion if
necessary. Do not pull on the cable.
1002036a
Knuckle-Mounted Sensor
SAPH168020300030
4. WHEEL SPEED SENSOR INSTALLATION — FRONT AXLE

To replace the sensor in the front axle:
(1) Connect the sensor cable to the chassis harness.
(2) Install the fasteners used to hold the sensor cable in place.
(3) Apply a Meritor WABCO recommended lubricant to the sensor spring
clip and sensor.
(4) Install the sensor spring clip. Make sure the spring clip tabs are on the
inboard side of the vehicle.
(5) Push the sensor spring clip into the bushing in the steering knuckle
until the clip stops.
(6) Push the sensor completely into the sensor spring clip until it contacts
the tooth wheel.
NOTICE
After installation, there should be no gap between the sensor and the
tooth wheel. During normal operation, a gap of up to 0.04-inch is
allowable.
(7) Remove the blocks and safety stands.
5. WHEEL SPEED SENSOR REMOVAL— REAR AXLE

To remove the sensor in the rear axle:
! WARNING
(1) Put blocks under the front tires to stop the vehicle from moving.
(2) Raise the rear tire off the ground. Put safety stands under the axle.
(3) Release the parking brake and back off the slack adjuster to release
the brake shoes.
(4) Remove the wheel and tire assembly from the axle.
(6) Remove the sensor from the mounting block in the axle housing. Use
a twisting motion if necessary. Do not pull on the cable.
(7) Remove the sensor spring clip from the mounting block.
(8) Disconnect the fasteners that hold the sensor cable and the hose
clamp to other components.
(9) Disconnect the sensor cable from the chassis harness.
6. WHEEL SPEED SENSOR INSTALLATION—REAR AXLE

1 (1) Apply a Meritor WABCO recommended lubricant to the sensor spring
2
clip and sensor.
(2) Install the sensor spring clip. Make sure the spring clip tabs are on the
inboard side of the vehicle.
(3) Push the sensor spring clip into the mounting block until it stops.
4 3 NOTICE
After installation, there should be no gap between the sensor and the
tooth wheel. During normal operation, a gap of up to 0.04-inch is
allowable.
(4) Push the sensor completely into the sensor spring clip until it contacts
the tooth wheel.
(5) Insert the sensor cable through the hole in the spider and axle hous-
ing flange. Route the cable to the frame rail. Be sure to route the cable
in a way that will prevent pinching or chafing and will allow sufficient
movement for suspension travel.
(6) Connect the sensor cable to the chassis harness.
(7) Install the fasteners that hold the sensor cable in place.
1002037a (8) Install the brake drum on the wheel hub.
(9) Complete the installation per vehicle manufacturer's manual.
1. Spring Clip
2. Sensor Holder
3. Spring Clip Tab
4. Sensor
SAPH168020300031
7. ABS MODULATOR VALVE

(1) Removal
a. Turn ignition switch to the OFF position, apply parking brake.
! WARNING
b. Put blocks under the front and rear tires to stop the vehicle from
2 1 moving.
c. If necessary, raise the vehicle off the ground and put safety
stands under the axle.
d. Disconnect the wiring connector from the ABS valve.
e. Disconnect the air lines from Ports 1 (air supply) and 2 (air dis-
charge) of the ABS valve.
f. Remove the two mounting capscrews and nuts.
g. Remove the ABS valve.
1002038a
1. Port 1 (Air In)
2. Port 2 (Air Out)
SAPH168020300032
(2) Installation
! CAUTION
Moisture can affect the performance of all ABS/ATC systems, as well
as the standard braking system. Moisture in air lines can cause air
lines to freeze in cold weather.
.
To install the ABS modulator valve:

a. Install the ABS valve with two mounting capscrews and nuts. Tighten
the capscrews per the manufacturer's recommendation.
b. Connect the line to the brake chambers to Port 2 of the ABS valve.
Connect the air supply line to Port 1 of the ABS valve.
c. Connect the wiring connector to the ABS valve. Hand tighten only.
d. Remove the blocks and stands.
e. Test the installation. (Refer to below.)
f. Checking the installation
.
To test the modulator valve:

a. Apply the brakes. Listen for leaks at the modulator valve.
b. Turn the ignition on and listen to the modulator valve cycle. If the valve
fails to cycle, check the electrical cable connection. Make repairs as
needed.
c. Drive the vehicle. Verify that the ABS indicator lamp operates prop-
erly.
WIRING DIAGRAM
1. BASIC ECU (CAB-MOUNTED)
BASIC
1 4 7 10 13 16 1 4 7 10 13
2 5 8 11 14 17 2 5 8 11 14
3 6 9 12 15 18 3 6 9 15
18 14
SAPH168020300033
TP
J1587 B 10 10 J1587 B
J1587 A 11 11 J1587 A
SAE SAE TP
J1939 3 TR-WL 2 J1939 1 J1939 L 1 1 J1939 L
H L J1939 H 3 3 J1939 H
BATTERY 8 14 AWG 15A AMP 8 BAT
ECU+ 7 5A AMP 7 IGN
ATC 6 ABS 5 ECU- 4 86 30
14 PIN CONNECTOR
TO 3RD BRAKE
3RD BRAKE 14
TRAILER 2 85 87 87A
GND 9 BAT 8 ECU+ 7 WARNING 14
TRAILER WARNING LAMP
LAMP 2
ATC LAMP
ATC LAMP 13 13
TRACTOR WARNING LAMP
SAE SAE TRACTOR 15 15
JUMPER 12 J1587 11 J1587 10 WARNING
A B BLINK CODE
LAMP SWITCH
ATC
SWITCH
ATC SWITCH 6
ABS OFF ROAD SWITCH
ABS 3RD ATC ABS OFF 5
LAMP 15 BRK
14 LAMP
13 ROAD
ECU- 4 4
GND 9 9
BACK VIEW OF HARNESS CONNECTOR

GND*
INLET 1 1 IV
INLET INLET INLET VALVE 16 AWG GND RIGHT FRONT
VALVE 3 VALVE 2 VALVE
1 ABS VALVE
OUTLET 4 4 OV
VALVE
INLET 3 3 IV
LEFT FRONT
VALVE 16 AWG GND
ABS VALVE
OUTLET OUTLET OUTLET OUTLET 6 6 OV
VALVE 6 VALVE 5 VALVE 4
VALVE
INLET 2 2 IV
VALVE LEFT REAR
16 AWG GND
18 PIN CONNECTOR
ABS VALVE
OUTLET 5 5 OV
OUTLET INLET VALVE
VALVE 9 VALVE 8 DIF- 7
DIF- 7
INLET 8 8 IV
VALVE 16 AWG GND RIGHT REAR
ABS VALVE
OUTLET 9 9 OV
SENSOR 11
VALVE
SENSOR 12 SENSOR 10 TP
SENSOR 10 10 RIGHT FRONT
SENSOR
SENSOR 13 13
TP
SENSOR 11 11 LEFT REAR
SENSOR
SENSOR 15
SENSOR 14 14 DIF
SENSOR 14 SENSOR 13 TP VALVE
SENSOR 12 12 LEFT FRONT
SENSOR 15 15 SENSOR
DIF+ 16
TP
SENSOR 18 SENSOR 17 DIF+ 16 SENSOR 17 17 RIGHT REAR
SENSOR
SENSOR 18 18
BACK VIEW OF HARNESS CONNECTOR
1. Momentary Switch
2. Optional Equipment
3. Twisted Pair = TP
4. All unmarked wires should be 16 or 18 AWG.
5. All fuses should be blade type.
*All connected to a common star ground.
SAPH168020300034
RECONFIGURATION PROCEDURE
1. HOW TO RECONFIGURE AN ECU (E VERSION)

Before reconfiguring the ECU, contact ArvinMeritor's Customer
Service Center at 800-535-5560 for additional information.
E version ECUs memorize the following components if they are con-

nected at power-up:
• ATC valve
• Retarder relay
• Datalink SAE J1939
Once these components have been memorized, the ECU will look for them
at each power-up. If memorized component is not present, the ECU will
record a fault. For example, if an ATC valve memorized, but is not present
at the next power-up, the ECU records a fault. This can occur if an ECU is
moved from one truck to another and one or more of the memorized com-
ponents are not available on the new truck. If this occurs, use TOOLBOX
Software to reconfigure the ECU. If you do not have TOOLBOX Software,
follow the Manual Reconfiguration instructions listed on DN03-30.
2. TOOLBOX SOFTWARE
NOTICE
For complete instructions for using TOOLBOX Software, refer to the
TOOLBOX User's Manual, TP-99102.
To reconfigure the ECU with TOOLBOX Software, use the Reset Memo-
rized command.
Select Reset Memorized from the pull down menu to tell the ECU to reset
the memorized or "learned" components.
3. MANUAL RECONFIGURATION
Action Result Reason

1. Turn ignition ON. ABS lamp displays the ABS system Stored faults cleared, no active faults
2. Press and hold blink switch for at conÞguration code*: present. Continue with reconfiguration.
least three seconds. O One blink: 6S/6M NOTE: The reconfiguration procedure
O Two blinks: 4S/4M can not be conducted if there are active
NOTE: Do not hold this switch longer faults present. These must be repaired
than seven seconds. O Four blinks: 6S/4M before proceeding with the
* The ABS lamp may display eight quick reconfiguration.
flashes before the system configuration
code begins.
Observe the ABS and A TC lamps. ATC lamp comes on and stays on. A complete A TC system including an
ATC lamp is installed. If not, the A TC
lamp will not come on.
ABS lamp will continuously blink the ECU reconfiguring the system.
system configuration code. The ECU checks the following
components and reprograms itself based
on the new system:
O ATC valve
AND/OR
O Retarder relay
AND/OR
O Datalink J1939
While the configuration code is flashing, ABS lamp displays four quick flashes , Successfully reconfigured.
press the blink code switch three times followed by a continuous display of the
(one second each, with a one second system configuration code.
pause between each).
NOTE: System configuration code
Turn ignition OFF . continues until ignition is turned OFF.
SAPH168020300035
A system reconfiguration is illustrated below:
IGNITION ON
1s 1s 1s
SWITCH
3 Second 1s 1s
Hold
ATC Reset Continues
Confirmation until
Pause Pause Pause Pause Pause Pause Pause power is
1.5 s 4s 4s 4s 4s 4s 4s turned off
System ID System ID System ID System ID System ID System ID
(2) (2) (2) (2) (2) (2)
ATC
ATC Lamp - Dyno Function (remains lit for entire test)
Light ON*
*ATC Lamp will light only if ATC is connected.
SAPH168020300036
Hino Motors Sales U.S.A., Inc.

2555 Telegraph Road, Bloomfield Hills, MI 48302-0954
Telephone: (248)-648-6400
PRINTED IN JAPAN
Pub.No. S1-UNAE03A 2/2 '06.02

2007 Workshop Manual - S1-UNAE03A-2 PDF

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book 1 ページ ２００６年２月９日 木曜日 午後６時１７分

Manual Name Pub. No.

CHAPTER REFERENCES REGARDING THIS WORKSHOP MANUAL

MODELS HINO HINO HINO HINO HINO HINO HINO

GENERAL INTRODUCTION GN02-001

CLUTCH CONTROL CL03-001

TRANSMISSION MAIN UNIT TR02-002 TR02-001

AUTOMATIC TRANSMISSION TR04-001 TR04-002 TR04-003

TRANSMISSION/TRANSFER CONTROL TR06-001

PROPELLER SHAFT PP02-001

DIFFERENTIAL CARRIER DF02-001 DF02-002

BRAKE EQUIPMENT BR01-001 BR01-002 BR01-001 BR01-002

SERVICE BRAKE BR02-001 BR02-002 BR02-001 BR02-002

ABS & ASR BR03-001 BR03-002 BR03-001 BR03-002

STEERING EQUIPMENT SR01-001

STEERING UNIT SR02-001

POWER STEERING SR03-001

FRONT AXLE AX02-001

REAR AXLE AX03-001

WHEEL & TIRE AX04-001

CHASSIS FRAME FC02-001

ELECTRICAL EQUIPMENT EL01-001

ELECTRIC WIRE EL02-001

BRAKE CONTROL DN03-001 DN03-002 DN03-001 DN03-002

This manual does not contain items on half-tone dot meshing.

INDEX: CHASSIS GROUP 1/4

CLUTCH MAIN UNIT

WORKSHOP CLUTCH CONTROL

MANUAL TRANSMISSION EQUIPMENT

TRANSMISSION MAIN UNIT

TRANSFER MAIN UNIT

P.T.O. (POWER TAKE-OFF)

TRANSMISSION / TRANSFER CONTROL

PROPELLER SHAFT EQUIPMENT

ABS & ASR

INDEX: CHASSIS GROUP 2/4

ES START (EASY & SMOOTH START) SYSTEM

WHEEL & TIRE

COUPLER (5TH WHEEL)

INDEX: CHASSIS GROUP 3/4

INDEX: CHASSIS GROUP 4/4

CAB EQUIPMENT CONTROL

ABS & ASR (ABS : HYDRAULIC) BR03–1

BR03 ABS & ASR (ABS : HYDRAULIC) BR03-001

BR03–2 ABS & ASR (ABS : HYDRAULIC)

ABS & ASR (ABS : HYDRAULIC) BR03–3

COMPOSITION AND OPERATION

FRONT AXLE REAR AXLE

Independently control Independently control

1. SYSTEM COMPOSITION DIAGRAM

HYDRAULIC MASTER CYLINDER

SENSOR ABS SENSOR CABLE

BR03–4 ABS & ASR (ABS : HYDRAULIC)

2. ABS CONTROL FLOWCHART

INPUT SIGNALS ABS COMPUTER OUTPUT SIGNALS

FRONT RIGHT FRONT RIGHT PRES-

FRONT LEFT FRONT RIGHT PRES-

REAR RIGHT FRONT LEFT PRES-

REAR LEFT FRONT LEFT PRES-

REAR RIGHT PRES-

REAR RIGHT PRES-

REAR LEFT PRESSURE

book 1 ページ２００６年２月９日　木曜日　午後６時１７分