ACX-1903 – Undersized Brake Chambers/ FMVSS 121 – 2008-2019 Autocar Xpeditor

SEOCONTENT-START

SAFETY RECALL BULLETIN
NHTSA RECALL 19V091, Transport Canada 2019-165
AUTOCAR, LLC SAFETY RECALL ACX-1903 April, 2019
Attention:
Service Managers/Parts Managers
Subject:
Autocar has determined that a safety defect
exists in the factory specified size of brake
chambers of certain 2008-2019 model year
Xpeditors.
Safety Recall Information:
This document contains information regarding
replacement of the brake chambers.
Vehicles Affected:
There are 273 vehicles affected,
manufactured after April 18, 2008. To
determine if a vehicle is affected by this
recall, log in to the Autocar Warranty
Management System at www.autocartruck.
com. From the main menu, select “View
Recalls/Service Programs” and look for the
Autocar recall number above. An excel
file will be accessible with the VIN list of
affected vehicles. Alternatively, to determine
if a single vehicle is affected, select “VIN
Profile” from the main menu. In the “Chassis
Number” field, enter the last 6 of the VIN.
Once the VIN profile is displayed, scroll down
to the “Recall/Service Program Information”
section to determine if the recall is open.
Autocar, LLC
4680 Pinson Valley Parkway
Center Point, AL 35215
888-318-2611
Service Responsibility:
Service sites must perform this recall on
affected vehicles at no charge to the owner
regardless of vehicle mileage, age or
ownership. If a vehicle affected by this recall
is taken into or is currently in your vehicle
inventory, or at your center for service, you
must perform this recall before the vehicle is
sold or released to the owner.
Required Parts:
(1) S7632001 KOO?
( 1) A 7630031-001 Brake Chamber
( 1) A 7630031-002 Brake Chamber
To Obtain Parts:
Ensure that you have authorization from the
customer to perform this work, and send an
e-mail to [email protected] and
include the following:
• VIN(s) (or last 6 digits of VIN(s)
• ‘Attention To’ name
• ‘Ship To’ address
Claims for Reimbursement:
Submit a claim for reimbursement in
accordance with Autocar’s Warranty
Administration Manual.
Page 1 of 23
SAFETY RECALL BULLETIN
NHTSA RECALL 19V091, Transport Canada 2019-165
AUTOCAR, LLC SAFETY RECALL ACX-1903 April, 2019
Claim Coding Information:
Labor Time Description
Operation Allowance
Code Number SRT
56421-0-07 2.0 HR
Tools Required:
Caging Tool
Wheel Chocks
Brake Chamber
Replacement
15/16″ Combination Wrench
1 /2″ Drive 15/16″ Socket
1 /2″ Drive Adjustable Torque Wrench capable
of 100-150 lb-ft
1 /2″ Drive Extension 1 0″ Long
1 /2″ Combination Wrench
9/16″ Combination Wrench
Square
Dial-Indicator
Tools as required per supplier instructions
Page 2 of23
SAFETY NOTICES:
~ WARNING
Allow the vehicle’s engine and cooling
system to cool to ambient temperature before
performing the repair procedure. A hot engine
or cooling assembly may cause burns or other
personal injury.
~ WARNING
To prevent eye injury, always wear eye protection
when performing vehicle maintenance,
service or inspection.
Before working on a vehicle, set the parking
brake, place the transmission in neutral and
block the wheels. Failure to do so can result in
unexpected vehicle movement and can cause
serious personal injury or death.
Autocar, LLC
4680 Pinson Valley Parkway
Center Point, AL 35215
888-318-2611
SAFETY RECALL BULLETIN
NHTSA RECALL 19V091, Transport Canada 2019-165
AUTOCAR, LLC SAFETY RECALL ACX-1903 April, 2019
Working on CNG/LNG Trucks
SAFETY
INSTRUCTIONS
If you store or dispense Compressed Natural
Gas (CNG) or Liquefied Natural Gas (LNG),
or if you work on CNG or LNG trucks, your
location must be fully compliant with applicable
codes, regulations and standards, including
National Fire Protection Associate (NFPA)
codes, Society of Automotive Engineers (SAE)
standards, American National Standards
Institute (ANSI) Natural Gas Vehicle (NGV)
standards, the United States Code of Federal
Regulations (CFR) and your state and local
fire and other applicable codes (including, for
example, the California Code of Regulations
and the Texas Administrative Code).
Contact your local fire department for guidance
and additional compliance information.
Technicians working on Autocar trucks with
CNG or LNG engines must be trained in the
proper repair of CNG and LNG trucks and
engines and the safe storage and dispensing
of CNG and LNG.
Autocar, LLC
4680 Pinson Valley Parkway
Center Point, AL 35215
888-318-2611
Working on CNG Fuel Systems
al WARNING
CNG fuel systems include a high pressure
(3600 psi) system for fuel storage and a low
pressure system (125 psi) for consumption by
the engine. Understanding the characteristics
of CNG and how the fuel system works will
prevent injury and damage to persons and
property.
Attempting to operate or maintain any CNG fuel
system without proper training is dangerous.
Complete training and consult instructional
bulletins from the CNG system suppliers, such
as Agility Fuel Systems’ Field Service Bulletin,
Safely Working on CNG Fuel Systems.
Welding and Hot Work Near CNG
and LNG Trucks
al WARNING
Welding, grinding and other “hot work” can
be safely performed on or near a CNG or
LNG vehicle, but certain precautions must
be followed. Understand and perform the
necessary precautions provided by the CNG
system suppliers, such as Agility Fuel Systems’
Field Service Bulletin, Welding and Hot Work
Precautions Near CNG and LNG Vehicles.
Page 3 of23
SAFETY RECALL BULLETIN
NHTSA RECALL 19V091, Transport Canada 2019-165
AUTOCAR, LLC SAFETY RECALL ACX-1903 April, 2019
CNG Cylinders
ii WARNING
CNG fuel containers must meet Federal
Motor Vehicle Safety Standard (FMVSS) 304
(Compressed Natural Gas Fuel Container
Integrity) and/or ANSI/CSA NGV2 (Basic
Requirements for Compressed Natural Gas
Vehicle Fuel Containers). Both standards
specify a detailed visual examination every
three years.
Ensure that every truck owner completes the
required inspections, in accordance with the
applicable standards and other resources, such
as the Clean Vehicle Education Foundation
and NGVAmerica’s Compressed Natural Gas
(CNG) Container Visual Inspection Advisory.
FMVSS 304 also requires that cylinders not be
used after the end of life (EOL) date provided
on the tank label. The EOL date is also
displayed in the engine compartment and at
the fueling connection of each truck. If there
is any question as to proper decommissioning
of a cylinder, contact the manufacturer, whose
name and address is also required to be on
the label.
Page4 of23
CNG Fuel Container Pressure
Relief Devices (PRDs)
ii WARNING
PRDs must be properly maintained and
positioned for safe operation of a CNG fuel
system. Missing vent caps can allow moisture
into PRDs and vent lines, which can freeze
and damage these safety components. Debris
which clogs the PRDs and/or vent lines can
prevent proper function.
PRDs must be positioned to vent upward, not
outward, from a vehicle.
Ensure that every truck owner completes
periodic inspections of the PRDs and vent lines
and systems, in accordance with guidance
provided by the system component suppliers.
Alert First Responders to CNG
and LNG
ii DANGER
In the event of a fire or other emergency, alert
first responders to the presence and location
of CNG fuel systems, tanks and dispensers.
Ensure that emergency personnel are aware
of proper precautions, such as those provided
in Agility’s First Responder Guide: CNG and
LNG Vehicle Fuel Systems.
Autocar, LLC
4680 Pinson Valley Parkway
Center Point, AL 35215
888-318-2611
SAFETY RECALL BULLETIN
NHTSA RECALL 19V091, Transport Canada 2019-165
AUTOCAR, LLC SAFETY RECALL ACX-1903
~—¢CAUTION
LOCKOUT/TAGOUT PROCEDURES
Before entering the vehicle or vehicle body,
read and follow OSHA regulations concerning
entry and working in “CONFINED SPACE”
OSHA 1910.146 and “LOCKOUT/TAGOUT”
OSHA 1910.147. Follow OSHA regulations
while performing any work on the vehicle.
The vehicle must be disabled by the following
steps before performing any work on the
vehicle:
1. Place the transmission in NEUTRAL.
2. Set the parking brake.
3. Shut the engine OFF.
4. Lock cab doors, keep the key in your
pocket. Block the wheels before
entering the body or performing
any work on the vehicle.
5. Turn the battery disconnect
switch OFF, if equipped.
6. Completely drain the air from the
primary/A system and secondary/B
system by opening the drain valves on
the air tanks themselves or by using
the drain manifold if supplied. When
draining the air tanks, do not look into
the area where air is draining. Dirt or
sludge particles may be expelled in the
air stream and can cause eye injury.
7. Place magnetic “DANGER” signs on
both cab doors before entering the body
or performing any work on the vehicle.
8. Take proper precautions before working
under the vehicle. Use ramps approved
for the weight of your vehicle, or use floor
jacks and stands. Never work under a
vehicle supported by jacks alone. Always
use jack stands to support the vehicle.
Autocar, LLC
4680 Pinson Valley Parkway
Center Point, AL 35215
888-318-2611
April, 2019
Page 5 of23
SAFETY RECALL BULLETIN
NHTSA RECALL 19V091, Transport Canada 2019-165
AUTOCAR, LLC SAFETY RECALL ACX-1903 April, 2019
Installation of New Brake Chambers
and S-Cam Brackets
1. Complete the “LOCKOUT/TAGOUT
PROCEDURES” on the preceeding
page and be sure to drain the air tanks
completely and chock the wheels.
2. Locate the brake chambers at the rear of
the vehicle (see Figure 1).
3. Starting on the left-hand side of the
vehicle, install the caging tool.
4. Remove and discard the brake chamber.
5. Install the new brake chamber
(A7630031-002). Tighten fastening nuts
to 140 lb-ft +/-10 of torque.
Note: Ref. Haldex Service Bulletin
“Recommended Procedure for
Cutting Brake Chambers Push-Rod”
on page 6 and page 7). Supplier
documentation is provided for
reference and instruction only
– supplier components are not
identified as defective or as a root
cause for the recall.
Page 6 of23
Note: Units equipped with Haldex slack
adjusters reference page 8 and
page 9. Units equipped with Meritor
slack adjusters reference pages 10
through 21. Supplier documentation
is provided for reference and
instruction only- supplier
components are not identified as
defective or as a root cause for the
recall.
6. Repeat steps 4 through 10 for the righthand
side of the vehicle utilizing the new
brake chamber (A7630031-001)
(see Figure 1 ).
7. Adjust the brakes.
8. Road test the vehicle to ensure proper
brake operation.
9. Installation is completed.
Autocar, LLC
4680 Pinson Valley Parkway
Center Point, AL 35215
888-318-2611
SAFETY RECALL BULLETIN
NHTSA RECALL 19V091, Transport Canada 2019-165
AUTOCAR, LLC SAFETY RECALL ACX-1903
Autocar, LLC
4680 Pinson Valley Parkway
Center Point, AL 35215
888-318-2611
BRAKE CHAMBER
Figure 1
April, 2019
BRAKE CHAMBER
Page 7 of23
SAFETY RECALL BULLETIN
NHTSA RECALL 19V091, Transport Canada 2019-165
AUTOCAR, LLC SAFETY RECALL ACX-1903 April, 2019
Page 8 of 23
Haldex
This procedure is applicable to Haldex Automatic and All Manual Brake Adjusters
A WARNING: Always chock wheels to prevent vehicle from moving. Vent vehicle system air pressure to zero psi.
A. When preparing to install a spring brake chamber, ensure that the unit is fully released (power spring
caged) and the service brake push-rod is fully retracted to zero stroke position. Thread the clevis jam nut
onto the push-rod
B. Place the brake chamber into the appropriate brake assembly
bracket. Tighten the holding nuts to the bracket studs
(100-140 lb. ft.).
C. Measure the distance from the centerline of the S-Cam to the
centerline of the push-rod (See Figure 2 – Dimension A). This
measurement should be equal to the length of the brake
adjuster being used. (See Figure 3 – Dimension A).
NOTE: If Dimension A – Figure 2 and
Dimension A- Figure 3 are not identical, the
chamber mounting bracket is either bent and
must be straightened or replaced, the chamber has
been mounted improperly in the bracket or the
length of the adjuster installed is incorrect.
Make any necessary corrections before going
to Step D.
D. Measure and record the length of clevis to be
used. This measurement should be taken from
the center of the clevis pin hole, to the
bottom of the yoke assembly (See Figure I).
l
L
E. Using a square, mark the push-rod at the 90° setting (See
Figure 2 – Mark #1) . From this mark, subtract the
measurement recorded in Step D and make a second mark on
the push-rod (moving toward the brake chamber mounting
surface). (See Figure 2 – Mark #2).
F. From Mark #2, measure toward the brake chamber mounting
surface the distance listed in Table I – Column “D”(See
Reverse Side) for the brake chamber type being installed. Mark
and cut the push-rod.
-continued on reverse-
Figure 1
Figure 2
~ s-CAM
Figure 3
BRAKE ADJUSTER
www.haldex.com • www.hbsna.com
Autocar, LLC
4680 Pinson Valley Parkway
Center Point, AL 35215
888-318-2611
SAFETY RECALL BULLETIN
NHTSA RECALL 19V091, Transport Canada 2019-165
AUTOCAR, LLC SAFETY RECALL ACX-1903 April, 2019
Autocar, LLC
Haldex
G. Install the clevis onto the push-rod and secure the jam nut (33-90 lb. ft.). Connect the clevis to the brake
adjuster using the clevis pin and cotter pins (See Figure 1 ). Uncage the spring brake.
H. Release spring brakes and adjust the brake adjuster to the manufacturers recommendation.
Important Note: Some automatic brake adjusters require a slightly different rod length.
Column
A
Chamber
Type
09
12
16
20
20LS*
24
24LS*
24XLS**
30
30LS*
36
• Long Stroke
Always refer to the original manufacturers installation guidelines
Table 1 – Stroke Values
Column Column
B C
Available .. Maximum”
Readjustable
Stroke stroke
1 3/4″ 1 3/8″
1 3/4″ 1 3/8″
2 1/4″ 1 3/4″
2 1/4″ 1 3/4″
2 1/2″ 2″
2 1/4″ 1 3/4″
2 1/2″ 2″
3″ 2 1/2″
2 1/2″ 2″
3″ 2 1/2″
3″ 2 1/4″
•• Extra-Long Stroke
Column
D
Set-Up
Stroke
1 3/8″
1 3/8″
1 3/8″
1 3/8″
1 1/2″
1 3/8″
1 1/2″
1 3/4″
1 1/2″
1 3/4″
1 3/4″
A D A N G E R _a A spring brake or
combination service/spring
brake must be disarmed
before disposal, or forceful
release of the compression
spring may occur In the
future without warning.
Warning: Haldex strongly
recommends routine visual
checks be performed at EACH
maintenance service interval.
Foundation brake operational
checks utilizing CVSA level 1
applied stroke criteria should
always be utilized. Manual
adjustment of automatic adjusters
can disguise hidden problems
within the foundation brake.
Brake components such as scams,
bushings, return springs,
actuators, drums and adjuster
installation MUST be within
manufacturer’s specifications.
Adjuster control arms, wear
bushings or attaching hardware
that demonstrate visual damage,
or which fail the operational
checks, MUST be replaced
immediately. Automatic Adjusters
should NEVER be operated as
manual adjusters except as may
be necessary to get the vehicle off
the road for service.
Haldex Commerdlll Vehlde Systems
Haldex Brake Products Corporation
10707 NW Airworld Drive
Kansas City, MO 64153-1215
Phone: 816-891-2470
Fax: 816-801-4198
Haldex Limited
525 Southgate Drive, Unit 1
Guelph, Ontario CAN N 1 G 3W6
Phone: 519-826-7723
Fax: 519-826-9497
L58002 US Rev 6/07 SM CM (Created 7/02) www.haldex.com www.hbsna.com
4680 Pinson Valley Parkway
Center Point, AL 35215
888-318-2611 Page 9 of23
SAFETY RECALL BULLETIN
NHTSA RECALL 19V091, Transport Canada 2019-165
AUTOCAR, LLC SAFETY RECALL ACX-1903 April, 2019
Page 10 of 23
Installation Procedures
Note: Configuration of anchor bracket and brake adjuster housing may vary,
depending upon axle. Refer to typical applications on Page 2.
Step 1 ftNote: Block wheels to prevent
vehicle from rolling. Ensure
system tank pressure is
above 100 PSI.
■ Check that the push rod is fully retracted;
apply air to release spring brake. If air is not
available, spring brake must be manually
caged back.
■ Install anchor bracket loosely as illustrated
(fig. 7).
■ Some strap brackets have two mounting
holes. Proper mounting location is
determined by the length of adjuster arm.
5″ and 5-1 /2″ adjuster arm lengths utilize
the shorter hole location while 6″ and 6-1/2″
length adjusters utilize the longer hole
locations.
■ Do not tighten anchor bracket fasteners at
this time.
■ Apply “Anti-Seize” type lubricant to camshaft
splines.
Step 2
■ Install the brake adjuster onto the camshaft
with the adjusting hex pointing away from the
brake chamber (fig. 8).
■ Secure the brake adjuster on the camshaft.
Use at least one inner washer and enough
outer washers to allow no more than .060
movement of adjuster on camshaft. (Per
TMC recommended practice RP609-A.)
Note: Do NOT pull push rod out to
meet the brake adjuster.
■ Rotate the 7/16″ adjusting hex nut
CLOCKWISE until the clevis hole lines up
with the brake adjuster arm hole.
■ Apply anti-seize to clevis pin, install and
secure with cotter pin.
Anchor Bracket
Figure7
3
Autocar, LLC
4680 Pinson Valley Parkway
Center Point, AL 35215
888-318-2611
SAFETY RECALL BULLETIN
NHTSA RECALL 19V091, Transport Canada 2019-165
AUTOCAR, LLC SAFETY RECALL ACX-1903
n
4
Autocar, LLC
Installation Procedures
Step 3
■ Rotate the control arm away from the
adjusting hex toward the air chamber, until
it comes to a definite internal stop (fig. 9).
■ Most adjusters will be equipped with an
“Installation Indicator.” Indicator must fall
within the slot for proper installation with
brakes fully released (fig. 10).
■ If the control arm position is
wrong, tight brakes will occur
(fig.11).
■ Tighten all anchor bracket fasteners (make
sure the control arm does not move from its
position while tightening fasteners).
Step 4
■ The adjuster must be manually adjusted
at this time.
■ Rotate the adjusting hex clockwise until the
lining lightly contacts the drum.
■ Then back-off the adjuster by turning the
adjusting hex counter-clockwise 1/2 of a
turn (fig. 12).
■ A minimum of 13 ft. lbs. is necessary to
overcome the internal clutch. A ratcheting
sound will be present.
■ Do Nor use an impact wrench or
internal damage will occur!
■ FINAL INSPECTION. With full service
brake application, assure that spring brakes
are released, and check that the
“Installation Indicator” is within the slotted
area. IF NOT, REPEAT Step 3.
Note: To ensure proper fit and
function, always replace both
adjuster and mounting bracket.
4680 Pinson Valley Parkway
Center Point, AL 35215
888-318-2611
Correct
(Brakes released)
Flgure10
INCORRECT
(Brakes released)
Figure11
April, 2019
Page 11 of 23
SAFETY RECALL BULLETIN
NHTSA RECALL 19V091, Transport Canada 2019-165
AUTOCAR, LLC SAFETY RECALL ACX-1903 April, 2019
~MERITOR
Technical Bulletin
Important Information
Meritor automatic slack adjusters (ASAs) should not need to be
manually adjusted in service. ASAs should not have to be adjusted
to correct excessive push rod stroke. The excessive stroke may be
an indication that a problem exists with the foundation brake, ASA,
brake actuator or other system components.
Meritor recommends troubleshooting the problem, replacing
suspect components and then confirming proper brake operation
prior to returning the vehicle into service.
In the event that a manual adjustment must be made (although not a
common practice), a service appointment and full foundation brake,
ASA, and other system component inspection should be conducted
as soon as possible to ensure integrity of the overall brake system.
For Meritor brake adjustment, refer to the brake adjustment tables
in this technical bulletin. For non-Meritor brake adjusters, refer to
the brake manufacturer’s service procedures.
Hazard Alert Messages
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.
A ASBESTOS AND NON-ASBESTOS
FIBERS 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 materials.
A WARNING
To prevent serious eye injury, always wear safe eye protection
when you perform vehicle maintenance and service.
Page 12 of 23
TP-9173
Revised 10-13
Installation and Adjustment
Procedures for Meritor Automatic
Slack Adjusters
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 or fall over. Serious personal injury and
damage to components can result.
Before you service a spring chamber, carefully follow the
manufacturer’s instructions to compress and lock the spring to
completely release the brake. Verify that no air pressure
remains in the service chamber before you proceed. Sudden
release of compressed air can cause serious personal injury
and damage to components.
You must disengage a pull pawl before rotating the manual
adjusting nut, or you will damage the pawl teeth. A damaged
pawl will not allow the slack adjuster to automatically adjust
brake clearance. Replace damaged pawls before putting the
vehicle in service.
How to Obtain Additional Maintenance,
Service and Product Information
Refer to Maintenance Manual 4, Cam Brakes and Automatic Slack
Adjusters; and Parts Catalog PB-8857, Brake, Trailer Axle and
Wheel Attaching Parts. To obtain these publications, visit Literature
on Demand at meritor.com.
Automatic Slack Adjusters
Since January 1993, some parts of Meritor automatic slack
adjusters are not serviceable or interchangeable with parts from
earlier models.
Never mix automatic slack adjusters on the same axle. Always use
replacement parts that were originally designed for the brake
system to help ensure maximum brake performance.
Autocar, LLC
4680 Pinson Valley Parkway
Center Point, AL 35215
888-318-2611
SAFETY RECALL BULLETIN
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AUTOCAR, LLC SAFETY RECALL ACX-1903 April, 2019
How an Automatic Slack Adjuster Works
When you install an automatic slack adjuster, you set the brake
chamber stroke measurement, which is the correct shoe-to-drum
clearance. Figure 1. When linings wear, this clearance increases,
and the air chamber push rod must travel farther to apply the
brakes.
When this happens, the slack adjuster will automatically adjust
during the return stroke to maintain the correct shoe-to-drum
clearance. If the air brake chamber push rod stroke is within limits
during operation, no adjustment occurs.
4002836a
Handed and Unhanded Slack Adjusters
There are two automatic slack adjuster designs: handed and
unhanded. Handing refers only to the location of the pawl, which is
used for clearance issues on the vehicle. For most applications,
install a handed automatic slack adjuster so that the pawl faces
INBOARD on the vehicle.
The pawl can be on either side or on the front of the slack adjuster
housing. Figure 2.
UNHANDED 7\
m
PULL PAWL
4002837c
Pull Pawls
Pull pawls are spring loaded. Pry the pull pawl at least 1 /32-inch to
disengage the teeth. Figure 2. When you remove the pry bar, the
pull pawl will re-engage automatically.
Clevis Types and Thread Sizes
A one-piece, threaded clevis is standard equipment on most Meritor
automatic slack adjusters, including factory-installed slack adjusters
on Q Plus™ l.X500 and MX500 cam brakes, and all service
replacement parts.
Meritor automatic slack adjusters and clevises are designed to be
used as a system. Always use genuine Meritor replacement parts.
Although parts from other manufacturers can look the same,
differences can exist that will affect brake system performance.
The threaded-type clevis is available in two different pin spacings,
1.30-inches (33 mm) and 1.38-inches (35 mm). The initial slack
adjuster set-up is unique for each pin spacing. Refer to Table E for
correct installation. Figure 3.
~» CLEVISWITH 71.3~.~~:ss~!~NG
1.30″ PIN SPACING
There is a 0.080″ (2.03 mm) difference
between the large and small clevis holes.
Notice the large pin is engaged and the
small pin is 0.080″ (2.03 mm) off.
Clevis (1 .30″) Clevis (1 .38″)
Pin Spacing Pin Spacing
1.30″ 1.38″
~~
4005004a
Threaded Clevis for Straight or Offset Applications
A threaded clevis can be either straight or offset. If service
replacement is required, replace a straight clevis with a straight
clevis and an offset clevis with an offset clevis to maintain the
correct brake design and set up. Figure 4.
TP-9173
Revised 10-13
Page 2 Copyright Merttor, Inc., 2013
(1 6579)
Printed in USA
Autocar, LLC
4680 Pinson Valley Parkway
Center Point, AL 35215
888-318-2611 Page 13 of 23
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STRAIGH
CLEVIS
Thread Sizes
THREADS 40028418
Straight and offset clevis designs are available in two common
thread sizes to match push rod threads.
Table A: Thread Sizes
Chambers
9, 12, 16
20,24, 30, 36
Thread Sizes
1/2″-20 UNF
5/8″-18 UNF
Meritor Automatic Slack Adjusters are
Color-Coded to Brake Type and Air
Chamber Size
Meritor uses either black, red, yellow, green or blue to color-code an
automatic slack adjuster’s internal actuator piston according to
brake type and air chamber size.
Meritor uses a mylar tag on the body of the current-design slack
adjuster to identify the color of the internal actuator piston.
Mylar Tag – Current Design
A mylar tag is attached to the current-design slack adjuster with a
press-in boot. The color of the actuator piston is printed on the
mylar tag. Figure 5.
Color-Coded Tie Wrap – Previous Design
On previous-design slack adjusters, a color-coded tie wrap attaches
the boot to the slack adjuster body. The tie wrap color matches the
color of the actuator piston. Figure 5.
CURRENT DESIGN
MYLAR TAG
~:@’~
COLOR-CODED TIE WRAP
PREVIOUS DESIGN
Important Note
4003395a
While in service, it is possible that the boot’s tie wrap might have
been replaced with a tie wrap of a different color than originally
installed at manufacture. If this happens, the tie wrap will not
correctly identify the brake type and air chamber size.
Meritor recommends that you remove the boot from the slack
adjuster to determine the color of the actuator piston, which
identifies the brake type and air chamber size.
For a complete color-coding list, refer to Parts Catalog PB-8857,
Brake, Trailer Axle and Wheel Attaching Parts.
When You Replace an Automatic Slack
Adjuster
The original equipment manufacturer paints the chassis and slack
adjusters, which includes the mylar tag or tie wrap, depending on
the slack adjuster model.
When you replace an automatic slack adjuster, the color of the
actuator piston on the new slack adjuster must match the color of
the actuator piston on the in-service slack adjuster you’ll replace.
Check the mylar tag or color-coded tie wrap, or remove the boot as
described below, to identify the color of the actuator piston. To
ensure a correct installation, this color must match the color of the
actuator piston on the in-service slack adjuster you’ll replace.
• If you are unsure of the color of the actuator piston on the
in-service slack adjuster: Remove the piston boot to see the
color of the actuator piston to ensure a correct installation. The
color must be the same as the new slack adjuster you’ll install.
(16579)
Printed in USA Copyright Meritor, Inc., 2013
TP-91 73
Revised 10-13
Page 3
Page 14 of 23
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Installation
NOTE: If the slack adjuster is not a Meritor automatic slack adjuster,
refer to the manufacturer’s literature for the correct service
procedures.
While in service, it is possible that the boot’s tie wrap might have
been replaced with a tie wrap of a different color than originally
installed at manufacture. If this happens, the tie wrap will not
correctly identify the brake type and air chamber size.
Meritor recommends that you remove the boot from the slack
adjuster to determine the color of the actuator piston, which
identifies the brake type and air chamber size.
When You Replace an Automatic Slack Adjuster
The original equipment manufacturer paints the chassis and slack
adjusters, which includes the mylar tag or tie wrap, depending on
the slack adjuster model.
When you replace an automatic slack adjuster, the color of the
actuator piston on the new slack adjuster must match the color of
the actuator piston on the in-service slack adjuster you’ll replace.
Check the mylar tag or color-coded tie wrap, or remove the boot as
described below to identify the color of the actuator piston. To
ensure a correct installation, this color must match the color of the
actuator piston on the in-service slack adjuster you’ll replace.
• If you are unsure of the color of the actuator piston on the
in-service slack adjuster: Remove the piston boot to see the
color of the actuator piston to ensure a correct installation. The
color must be the same as the new slack adjuster you’ll install.
For a complete color-coding list, refer to Parts Catalog PB-8857,
Brake, Trailer Axle and Wheel Attaching Parts.
1. Check the camshaft and bushings and seals for wear and
corrosion. Turn the camshaft by hand to check for smooth
operation. Repair or replace parts as required.
2. Apply the service brake and spring brake several times. Check
that the chamber return spring retracts the push rod quickly
and completely. If necessary, replace the return spring or the
air chamber.
3. Verify that the new automatic slack adjuster is the same length
as the one you are replacing. Refer to Table B.
Table B: Chamber and Automatic Slack Adjuster Sizes
Length of Slack Adjuster
Onches)
Size of Chamber
(Square Inches)
5 9, 12, 16, 20, 24, 30*
5-1/2 9, 12, 16, 20, 24, 30, 35•
6 24, 30, 36
6-1/2 30, 36
•use an auxiliary spring on slack adjusters used with size 9 and 12
chambers. A size 9 or 12 chamber return spring cannot supply
enough spring tension to completely retract the slack adjuster.
4. If the vehicle has spring brakes, follow the chamber
manufacturer’s instructions to compress and lock the springs
to completely release the brakes. Verify that no air pressure
remains in the service chambers.
A CAUTION
Most Meritor automatic slack adjusters manufactured after
January 1990 have lubrication holes in the gear splines. Do not
operate the actuator rod before you install the slack adjuster.
Lubricant can pump through the holes and onto the splines.
Damage to components can result.
5. If the automatic slack adjuster gear has a 10-tooth spline,
apply Meritor specification 0-637, part number 2297-U-4571,
anti-seize compound, or equivalent. This anti-seize compound
is a corrosion-control grease. Do not mix this grease with other
greases.
NOTE: Install the slack adjuster so that you can remove a
conventional pawl or disengage a pull pawl when you adjust
the brake.
6. Add the thick camshaft thrust washer. Install the slack adjuster
onto the camshaft. Position the slack adjuster so that you can
access the pawl when you adjust the brake.
7. Add thin camshaft spacing washers, followed by a thick
camshaft spacing washer (thick spacing washer must be next
to the snap ring). Install the snap ring.
8. Verify that camshaft axial end play on trucks and tractors is
0.005-0.060-inch (0.127-1 .52 mm). On trailers, no end play
adjustment is required. End play is controlled by the snap ring
near the cam head end of the camshaft.
• If axial end play is not 0.005-0.060-inch
(0.127-1.52 mm): Remove the snap ring. Add or remove
the appropriate number of spacing washers to achieve the
correct specification.
TP-9173
Revised 10-13
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Page 16 of 23
9. If the assembly has a “bolt-on” type camshaft, refer to
Assembly of the Slack Adjuster for a Bolted Camshaft.
10. Install the clevis onto the push rod.
11 . Disengage the pull pawl. Tum the manual adjusting nut to align
the holes in the slack adjuster arm and clevis. Figure 6.
.._ Disengage a
pull pawl.
4000354e
Assembly of the Slack Adjuster for a Bolted
Camshaft
Refer to Figure 7 for measurement location and component
description.
Place bracket washer (1229H4090) between slack and bracket.
Place the slack on the camshaft and check in this order.
1. Alignment of slack arm to chamber centerline, maximum
0.100″ mismatch.
2. Slack body to wing bracket clearance during slack actuation.
• If slack interferes with bracket: Shim between slack and
bracket washer with the following washers and repeat Step
1.
Part Number Nominal Thickness
1229-H-4090 0.104″
1229-W-2935 0.030″
1229-X-2936 0.054″
3. Use hardened camshaft step washer and spacer washers to
set up end play and slack between 0.005″ and 0.060″. Add
spacer washers between the slack body and the hardened
camshaft step washer.
Hardened Camshaft Step
Washer Part Number
1229-L -5030
1229-M-5031
Nominal Step Thickness
0.260″
0.405″
Spacer Washer Part Number
1229-W-1505
1229-D-5022
Nominal Thickness
0.090″
0.054″
Table C: Typical End Play Washer Requirements
Measured Hardened
Distance from End Camshaft Step
of Camshaft to Washer Spacer Washer
Edge of Slack Thickness Thickness
0.200″ to 0.255″ 0.260″ None
0.256″ to 0.309″ 0.260″ 0.054″
0.31 0″ to 0.345″ 0.260″ 0.090″
0.346″ to 0.400″ 0.405″ None
0.401″ to 0.454″ 0.405″ 0.054″
0.455″ to 0.490″ 0.405″ 0,090″
0.491″ to 0.539″ 0.405″ 0.054″ and 0.090″
4. Install the lock washer (WA-18) and bolt (S-2812-2, 0.50″-13
thread x 1.50″ long), then tighten bolt to 85-115 lb-ft
(115-155 N•m). 0
5. Verity end play is between 0.005-inch and 0.060-inch.
6. Actuate the brake by pulling on the slack adjuster to ensure the
cam and roller move freely and that the shoes retract when the
slack adjuster is released.
(16579)
Printed in USA Copyright Meritor, Inc., 2013
TP-9173
Revised 10-13
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Check for
wing bracket –,c—–,;-clearance.
Welded Clevis
1. Check the clevis position using the brake slack adjuster
position (BSAP) method. Refer to Table E. Apply Meritor
specttication 0-637, part number 2297-U-4571, anti-seize
compound or equivalent to the large and small clevis pins. This
anti-seize compound is a corrosion-control grease. Do not mix
this grease with other greases.
It.
—+c’ I-+—,__ MISALIGNMENT 0.100· MAX.
I I I~ EITHER SIDE OF CHAMBER CENTERLINE
SPACER
WASHER
LOCK
WASHER
HARDENED
CAMSHAFT
STEP WASHER
END OF CAM
TO
EDGE OF SLACK 4006240a
A CAUTION
Always replace used clevis pin retainer clips with new ones
when you service an automatic slack adjuster or chamber. Do
not reuse retainer clips. Discard used clips. When you remove
a retainer clip, it can bend or “gap apart” and lose retention.
Damage to components can result
2. Install new clevis pin retainer clips or cotter pins to secure the
clevis pins. Retainer clips must be fully installed and positioned
around the side of the clevis pin. Figure 8.
TP-9173
Revised 10-13
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Page 18 of 23
SMALL CLEVIS PIN
AND RETAINER CUP
Threaded Clevis
~
LARGE CLEVIS PIN
RETAINER CLIP
P/N 2257-D-1174
©J
SMALL CLEVIS PIN
RETAINER CLIP
P/N 2257-C-1173
The clevis pin re1ainer
clips must be fully
installed and positioned
around the SIDE of the
clevis pin.
4007487a
The threaded-type clevis is available in two different pin spacings,
1.30-inches (33 mm) and 1.38-inches (35 mm). Based on your pin
spacing, install the threaded clevis to the correct position using the
template or brake slack adjuster position (BSAP) method. Refer to
Table E. Figure 9.
.~ There is a 0.080″ (2.03 mm) difference
between the large and small clevis holes.
Notice the large pin is engaged and the
small pin is 0.080″ (2.03 mm) off.
Clevis (1 .30″) Clevis (1 .38″)
Pin Spacing Pin Spacing
1.30″ 1.38″
~~
4005004a
Verify That the Slack Adjuster Angle is
Correct
There are two methods for determining the correct geometry for the
slack adjuster.
A. Brake Slack Adjuster Position (BSAP)
B. Template
Trucks and Tractors Equipped with Long-Stroke
Chambers
Because of concerns regarding slack adjuster-to-axle clearances at
the end of longer strokes, Meritor has revised instructions to use the
BSAP method only. Trailers are not affected by this change. Refer to
Brake Slack Adjuster Position (BSAP) Method and Table E in this
section.
Trucks and Tractors Equipped with Standard-Stroke
Chambers; Trailers Equipped with Standard- or
Long-Stroke Chambers
You can use either the Brake Slack Adjuster Position (BSAP) method
or the template method to verify that slack adjuster angles are
correct on trucks and tractors with standard-stroke brake chambers
and trailers with standard- and long-stroke brake chambers. Refer
to Table E.
Template Method
A CAUTION
There are four different installation templates for Meritor
automatic slack adjusters. The templates are not
interchangeable. You must use the correct template and clevis
pin spacing and you must adjust the clevis position as
described below. If you use the wrong combination and install
the clevis in the wrong position, the slack adjuster will not
adjust the brake correctly. If the slack adjuster underadjusts,
then stopping distances are increased. If the slack adjuster
overadjusts, then the linings may drag and damage the brake.
1. Use the correct Meritor automatic slack adjuster template to
measure the length of the slack adjuster. The marks by the
holes in the small end of the template indicate the length of the
slack adjuster. Refer to Table E.
2. Install the large clevis pin through the large holes in the
template and the clevis.
3. Select the hole in the template that matches the length of the
slack adjuster. Hold that hole on the center of the camshaft.
4. Look through the slot in the template to see if the small clevis
hole completely aligns within the slot.
(16579)
Printed in USA Copyright Meritor, Inc., 2013
TP-9173
Revised 10-13
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• If the small clevis hole doesn’t align within the slot:
Adjust the clevis until you can see the small clevis pin hole
within the slot. Figure 1 o.
1
~~;~DED
‘
” ‘
SLOT
: / CAMSHAFT END
:U,iL-_-0 / 0 4000358a
5. Verify that the thread engagement between the clevis and push
rod is 0.5-0.625-inch (12.7-15.9 mm). Figure 11 .
MINIMUM 0.5″ (12.7 MM)
THREADED
CLEVIS ~ “”‘”‘UM:·”‘””” MMI
4000359a
6. Verify that the push rod does not extend through the clevis
more than 0.125-inch (3.2 mm).
• If the push rod extends through the clevis more than
0.125-inch (3.2 mm): Cut the push rod or install a new air
chamber and push rod.
7. Tighten the jam nut against the clevis to the torque
specification in Table D. 0
Table D: Jam Nut Torque Specifications
Threads Torque
1/2-20 20-30 lb-ft (27-41 N•m)
5/8-18 35-50 lb-ft (48-68 N•m)
8. Use the following steps to install the automatic slack adjuster.
A. Determine the clevis pin spacing.
B. Determine the brake offset.
C. Refer to Table E for the recommended installation.
TP-9173
Revised 10-13
Page 8 Copyright Meritor, Inc., 2013
4680 Pinson Valley Parkway
Center Point, AL 35215
888-318-2611
April, 2019
(16579)
Printed in USA
Page 19 of 23
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Page 20 of 23
1.38″ Clevis Pin Spacing Must Be Used with Other Bracket Offsets
± 0.125″
Slack Bracket Clevis Pin BSAP
Length Offset Spacing Installation Clevis Type
5.00″ Other 1.38″ Not Threaded
5.50″ Applicable.
6.00″
Use Template
Method.
6.50″
If your combination is not shown, please contact the Meritor
OnTrac™ Customer Call Center at 866-668-7221 .
Brake Slack Adjuster Position (BSAP) Method
Use this method to ensure the correct position of welded or
threaded clevises on standard- or long-stroke brake chambers.
When you install the slack adjuster, verity that the BSAP chamber
dimension matches the dimension shown in Table E.
Adjustment
Measure Free Stroke
When you perform preventive maintenance procedures on an
in-service brake, check both the free stroke and adjusted chamber
stroke. Refer to the procedures in this section.
Free stroke sets the clearance between the linings and drum. The
in-service free stroke may be slightly longer than 0.5-0.625-inch
(12. 7-15.9 mm) specified in this procedure. This is acceptable if the
adjusted chamber stroke is within the limits shown in Table F and
Table G.
1. Disengage a pull pawl. Use a screwdriver or equivalent tool to
pry the pull pawl at least 1 /32-inch (0.8 mm) to disengage the
teeth.
2. Use a wrench to turn the adjusting nut COUNTERCLOCKWISE
until the brake shoes contact the drum. Figure 12. Then back
off the adjusting nut in the opposite direction 1 /2 turn for drum
brakes or 3/4 turn for disc brakes.
Optional Template
Method
Refer to View C.
Template Template
Chamber Type Color Part Number Vehicle Application
Standard Dark TP-4786 Truck or Tractor Drum
Stroke or Long Brown Brake/Straight or Offset
Stroke Clevis
Tan TP-4787 Trailer Drum Brake
White TP-4781 Coach Drum Brake
Disengage pawl.
4000371e
3. Measure the distance from the center of the large clevis pin to
the bottom of the air chamber while the brake is released. The
measurement you obtain is X in Figure 13.
MEASURE FREE STROKE
FREE STROKE = Y MINUS X
Drum brake free stroke must be
0.5-0.625″ (12.7-15.9 mm).
Disc brake free stroke must be
0.75-0.875″ (19.1-22.2 mm).
4000372a
4. Use a pry bar to move the slack adjuster and position the
linings against the drum, brakes applied. Measure the same
distance again while the brakes are applied. The measurement
you obtain is Y in Figure 13.
TP-9173
Revised 10-13
Page 10 Copyright Meritor, Inc., 2013
(16579)
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Table E: Meritor Automatic Slack Adjuster Installation Instructions
SLACK~ rr•BSA•P:t0=.125″
LENGT Measure from
5.00″ the bottom of
5.50″ the air chamber
6.00″ -to the center
6.50″ , of the clevis
hole.
VIEWA
1.30″ Clevis Pin Spacing
Bracket Clevis Pin
Offset Spacing ± 0.125″
Slack Refer to Refer to BSAP
Length View A. ViewB. Installation
Template
Template Part
Color Number
5.00″ 3.75″ and 1.30″ 2.25″
5.50″ 3.81″
6.00″
6.50″
1.38″ Clevis Pin Spacing
Bracket Clevis Pin
Offset Spacing ± 0.125″
Slack Refer to Refer to BSAP
Length View A. ViewB. Installation
5.00″ 3.75″ and 1.38″ 2.75″
5.50″ 3.81″
6.00″
6.50″ 2.62″
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~rur·~ … Clevis (1.30″) Clevis (1.38″) A , o slack adjuster
Pin Spacing Pin Spacing . ~\”‘~ 1.30″ 1.38″
:-►. :—►.
~ ~ ”) –
CAMSHAFT CENTER
VIEWB VIEWC 4007050a
Optional Template
Method
Clevis Type Chamber Type Refer to View C. Vehicle Application
Threaded or Standard Grey TP-10130 Truck or Tractor Drum Brake
Welded Stroke or Long
Stroke
Optional Template
Method
Refer to View C.
Template Template
Clevis Type Chamber Type Color Part Number Vehicle Application
Threaded Standard Dark TP-4786 Truck or Tractor Drum
Stroke or Long Brown Brake/Straight or Offset
Stroke Clevis
White TP-4781 Coach Drum Brake
Dark TP-4786 Truck or Tractor Drum
Brown Brake/Straight or Offset
Clevis
White TP-4781 Coach Drum Brake
TP-9173
Revised 10-13
Copyright Meritor, Inc., 2013 Page 9
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Page 22 of 23
A CAUTION
Do not set free stroke shorter than 0.5-0.625-inch
(12.7-15.9 mm) for drum brakes. If the measurement is too
short, linings can drag. Damage to components can result.
5. Subtract X from Y to obtain the in-service free stroke. The
measurement must be 0.5-0.625-inch (12.7-15.9 mm) for
drum brakes. Figure 13.
• If the free stroke measurement is not within
specification: Turn the adjusting nut 1/8 turn in the
direction shown in Figure 14 and check the free stroke
again. Continue to measure and adjust the stroke until the
measurement is within specification.
4000373b
6. Re-engage the pull pawl by removing the screwdriver or
equivalent tool. The pull pawl will re-engage automatically.
7. II the brakes have spring chambers, carefully release the
springs. Test the vehicle before you return it to service.
Commercial Vehicle Safety Alliance
(CVSA) Guidelines
Measure Push Rod Travel or Adjusted
Chamber Stroke
Use the following procedure to check in-service push rod travel or
adjusted chamber stroke on truck and tractor brakes.
1. The engine must be OFF. II the brake has a spring chamber,
follow the manufacturer’s instructions to release the spring.
Verify that no air pressure remains in the service section of the
chamber.
2. Verify that pressure is 1 DD psi (689 kPa) in the air tanks.
Determine the size and type of brake chambers on the vehicle.
3. With the brakes released, mark the push rod where it exits the
chamber. Measure and record the distance. Have another
person apply and hold the brakes on lull application. Figure 15.
Hold the ruler parallel to the push rod and measure as carefully
as possible. A measurement error can affect CVSA
re-adjustment limits. CVSA states that “any brake 1/4-inch or
more past the re-adjustment limit, or any two brakes less than
1/4-inch beyond the re-adjustment limit, will be cause for
rejection.”
Step 1
• Service brakes
not applied
Step 3 STROKE
• Spring brakes n
released 0
• Service brakes
applied
90-100 psi (620-690 kPa)
in air tank – engine OFF
4000374b
4. Measure the push rod travel or adjusted chamber stroke from
where the push rod exits the brake chamber to your mark on
the push rod. Measure and record the distance. Figure 15.
5. Subtract the measurement you recorded in Step 3 from the
measurement you recorded in Step 4. The difference is the
push rod travel or adjusted chamber stroke.
6. Reier to Table For Table G to verify that the stroke length is
correct for the size and type of air chambers on the vehicle.
• If the adjusted chamber stroke is greater than the
maximum stroke shown in Table For Table G: Diagnose
and correct the problem.
(16579)
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TP-91 73
Revised 10-13
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Table F: Standard-Stroke Clamp-Type Brake Chamber Data
Outside Diameter Brake Adjustment
Type (inches) Limit (inches)
6 4-1/2 1-1/4
9 5-1 /4 1-3/8
12 5-4/16 1-3/8
16 6-3/8 1-3/4
20 6-25/32 1-3/4
24 7-7/32 1-3/4
30 8-3/32 2
36 9 2-1/4
Table G: Long-Stroke Clamp-Type Brake Chamber Data
Outside Diameter Brake Adjustment
Type (inches) Limit (inches)
16 6-3/8 2.0
20 6-25/32 2.0
24 7-7/32 2.0
24* 7-7/32 2.5
30 8-3/32 2.5
* For 3″ maximum stroke type 24 chambers.
Alternate Method to Measure Push Rod
Travel or Adjusted Chamber Stroke
Use the CVSA procedure, except in Steps 3 and 4, measure the
distance from the bottom of the air chamber to the center of the
large clevis pin on each of the brakes.
CVSA North American Out-of-Service Criteria
Reference Tables
Information contained in Table F and Table G is for reference only.
Consult the CVSA Out-of-Service Criteria Handbook for North
American Standards, Appendix A. Visit their website at
http:/164.35.82. 7 / to obtain the handbook.
~MERITOR
Meritor Heavy Vehicle Systems, LLC
2135 West Maple Road
Troy, Ml 48084 USA
Information contained in this publication was in effect at the time the publication was approved for printing and is subject to
change without notice or liability. Meritor Heavy Vehicle Systems, LLC, reserves the right to revise the information presented or
to disccntinue the production of parts described at any time.
866-0nTrac1 (668-7221)
meritor.com
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Copyright 2013
Meritor, Inc.
All Rights Reserved Printed in USA
TP-9173
Revised 10-13
(16579)
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