SIBS III FAIL SAFE BRAKE SYSTEM · 2017-05-22 · SIBS® III Maintenance Schedule The following...
1
SIBS ® III Maintenance Schedule The following table shows the recommended service intervals for SIBS ® III rear only brakes on a Toyota Landcruiser vehicle being operated in a harsh mining environment. ABT recommends each site undertake a review of the service intervals and adjust to suit their specific conditions. Pre-Start Check The pre-start check involves a quick check of the fluid levels and confirms proper brake system operation. 1. Check Brake Master Cylinder Reservoir level. Top up with brake fluid (DOT 3) as required. 2. Check EMMA ™ Pump Fluid Reservoir level. Top up with Automatic Transmission Fluid (ATF Dexron III) as required. 3. With the doors closed, ignition switch on, press the E-Stop Button. a) The ‘Red’ light on the SIBS ® Control Unit should be on. b) The Park Brake should be applied. 4. Twist and reset the E-Stop button. a) The ‘Red’ light will flash momentarily , the alarm will sound, then the ‘Green’ light will come on. b) The Park Brake should now be released. 5. Check the Park Brake applies when: a) The E-Stop is pressed. b) The door is opened. c) The key is ‘turned off’ Note: The E-Stop must be pressed and then reset between each test. 6. Conduct a road test: a) Check the Service brake (Foot Brake) firmly applies the brake. b) Drive the vehicle at approximately 10 Kph. Press the E-Stop button. The vehicle should stop within 5 metres or 3 seconds. Minor Service The Minor Service involves a general system inspection and replacement of the SIBS ® Fluid in the wheel ends. 1. General Inspections a) Check the wheel end brake for leaks. b) Check the EMMA ™ Pump for leaks. c) Check hydraulic lines for leaks or damage. d) Check all electrical connectors and wiring damage. 2. Check Brake Pad wear. Note: The Park Brake must be applied to measure Brake Pad wear. a) Remove the Protective Cap on the Pad wear Indicator (located on the EMMA ™ Spring Cover, see Figure. 4). b) The Plunger should project out from the gland fitting. The distance the plunger projects shows the remaining Brake Pad wear available (see figure. 3). c) If the Brake Pads have worn beyond the wear limit then the Brake Pads must be replaced. In this case Major Service is recommended. 3. Replace the SIBS ® Fluid: a) Drain and discard the SIBS ® Fluid from each Wheel End Brake. Note: 1 Litre of SIBS ® Fluid should be in each Wheel End. Check for leaks if this amount is low. Note: The SIBS ® Fluid should drain freely from the Brake. The SIBS ® Fluid should flow freely, if this does not occur check the SIBS ® Breather Line for blockages. b) Refit the Drain Plug using a new Sealing Washer. c) Refill the Wheel End up to the Level Plug (fill to spill). 1 Litre of SIBS ® Fluid is required for each Wheel End. 4. Conduct a ‘Vehicle Pre-Start Check’. Major Service The Major Service is conducted either to replace worn Brake Pads or as a preventative maintenance activity to ensure the continued reliable operation of the SIBS ® Brake. During the Major Service new Seals are fitted throughout the Brake and any worn components replaced. The following procedure assumes that a refurbished Wheel End is to be fitted. The refurbishment of the Brake is described in the SIBS ® III Maintenance Schedule section of the Workshop Manual, Preparing Service Exchange Units. 1. Remove the SIBS ® Wheel End for the Vehicle. a) Remove Wheel. b) Remove the Service Brake Line, the EMMA ™ Hydraulic Line and the Breather Line from the Brake. c) Remove the Axle Shaft. d) Remove the Hub Nut. e) Attach Lifting Eye (P/N: 24-2870), connect to suitable Lifting Hoist. Note: The Lifting Eye is fitted using bolt hole 5 and 7 (see Figure. 1). f) Remove the 4 Nuts that hold the Brake onto the Axle Housing. g) Lift the Brake clear from the Axle Housing using lifting hoist. The inner housing may need to be tapped with a Copper Mallet to free it from the Axle Housing. 2. Refit a refurbished Wheel End Brake and Hub to the Axle Housing (refer to Workshop Manual, Section Title: Fitting Procedure): a) Clean the Brake mounting surface on the Axle. b) Apply Loctite ® 515 ™ evenly to mounting surface. c) The Brake can now be fitted to the vehicle as a complete assembly (Housing and Hub). d) Lift the Brake onto the Axle Housing using the Lifting Eye and suitable Lifting Hoist. e) Fit and tighten the 4 Nuts that hold the Brake onto the Axle Housing (Torque: 81Nm). f) Fit the Bearing Adjustment Nut inside the Hub (to Toyota recommendations). g) Fit the Axle Shaft. h) Fit the Service Brake Line, EMMA ™ Hydraulic Line and the Breather Hose. i) Grease the V-Lip Seal. Note: Do not over grease. j) Refill the Wheel End up to the Level Plug (fill to spill). 1 Litre of SIBS ® Fluid is required for each Wheel End. 3. Replacement of Lines: a) Replace the EMMA ™ Axle Housing Link Line (P/N: 24-3209). b) Replace Breather Lines once Expansion Chambers have been drained. 4. EMMA ™ Pump: a) Remove the Automatic Transmission Fluid (ATF Dexron III) from the EMMA ™ Pump Reservoir. b) Replace the EMMA ™ Pump Filter Element (P/N: 01-5071). d) Refill the EMMA ™ Pump Reservoir with ATF Dexron III. e) Bleed the EMMA ™ system at the Wheel End. 5. Service Brake: a) Drain and replace the Brake Fluid (DOT 3) from the Master Cylinder Reservoir. b) Bleed the Service Brake at the Wheel End. 6. Final Check: a) Conduct a ‘Vehicle Pre-Start Check’. SIBS ® III FAIL SAFE BRAKE SYSTEM Toyota LandCruiser 70 Series (Australian 6 & 8 Cylinder Models) REAR BRAKE ASSY ITEM PART NO. DESCRIPTION QTY/BRAKE 1 24-5020 KIT WHEEL BEARING LCV1 (one brake) 1 2 15-1200 SEAL V-LIP 1 3 15-1470 SEAL HOUSING 1 4 24-5023 KIT SEAL HUB LCV1 (one brake) 1 5 24-0864 HUB ASSY REAR SIBS III 1 6 24-2942 BOLT HOUSING FLANGE HEAD 12 7 24-1733 HOUSING OUTER LH 1 24-1743 HOUSING OUTER RH 1 8 24-4953 KIT BRAKE PAD (one brake) 1 9 15-2630 ROTOR BRAKE 1 10 15-1080 O-RING HOUSING 1 11 24-5021 KIT SEAL SERVICE REAR LCV1 (one brake) 1 12 24-2040 PISTON SERVICE BRAKE REAR 2 13 24-5048 KIT BRAKE MOUNTING REAR SIBS III (one brake) 1 14 24-5061 HOUSING INNER REAR LH LCV1 SIBS III 1 24-5060 HOUSING INNER REAR RH LCV1 SIBS III 1 15 15-1151 BLEED NIPPLE 4 16 15-1380 BLEED NIPPLE CAP 4 17 15-1890 WASHER COPPER 1 18 24-2873 ADAPTER LINK PIPE 2 19 24-2872 LINK PIPE SERVICE BRAKE REAR 1 20 15-3021 CONNECTOR HOSE 1/4” 1 21 24-2879 HOSE BREATHER 1/4”ID REAR SIBS II 1 22 01-5175 HOSE CLAMP 1 23 01-5176 BARB HOSE W/SWIVEL NUT 1/4”ID HOSE 1 24 24-5027 KIT FILL/DRAIN PLUG SIBS II (one brake) 1 25 24-5030 KIT SEAL FILL/DRAIN PLUG SIBS II 0.1 26 02-6019 CONNECTOR JIC MALE SST 1 27 15-2250 NUT LOCK RR SPINDLE MOUNT 4 28 15-3070 WASHER FLAT HARDENED M12 4 29 15-2530 RETRACTOR BOLT 4 30 24-5031 KIT PAD WEAR INDICATOR SIBS II (one brake) 1 24-5024 KIT PAD WEAR INDICATOR SIBS II HD (one brake) 1 31 01-3446 BOLT HOUSING M10x1.5x50 10 32 24-2925 COVER SPRING EMMA RH SIBS III 1 24-2926 COVER SPRING EMMA LH SIBS III 1 33 10-3240 SPRING PIN 2 34 15-3750 DISC SPRING 3mm (STANDARD) 32 10-2030 DISC SPRING 4mm (HEAVY DUTY) 24 35 24-2010 PISTON PARK BRAKE 4 36 24-2918 GASKET SPRING COVER STATITE SIBS II 1 37 24-5051 KIT SEAL PARK BRAKE (one brake) 1 38 24-3233 PLUG SOCKET HD 3/8” BSPP 3 39 00-3221 SIBS COOLING FLUID 20 LITRES - Rear Brake Assy ITEM DESCRIPTION TORQUE SETTINGS 1 SPRING COVER BOLTS 71 Nm 2 HOUSING BOLTS 61 Nm 3 BRAKE MOUNTING NUTS 81 Nm 4 WHEEL NUTS 209 Nm ITEM NEW COMPONENT MINIMUM THICKNESS Brake Pads (Standard) 14 mm 13 mm Brake Pads (Heavy Duty) 14 mm 12 mm Brake Rotor 14.5 mm 14 mm EMMA PUMP ENCLOSURE ITEM PART NO. DESCRIPTION QTY/BRAKE 1 01-3453 SCREW HEX HD 3/8" - 16 UNC x 2" LG 2 2 01-4141 WASHER DOWTY M10 2 3 02-2045 SPACER PUMP ENCLOSURE - SIBS III 1 4 02-7019 AM SERIES WOUND MOTOR 1 5 02-1046 PUMP EMMA SIBS III 1 6 02-6024 RESERVOIR KIT 'C' TYPE PLASTIC 108 SERIES 1 7 02-2018 SPOUT C RESERVOIR 1 8 02-2051 BRACKET CLIP PUMP ENCLOSURE - SIBS III 1 9 24-2881 P-CLIP 6mm x M8 RUBBER LINED 1 10 02-6033 MANIFOLD ASSY EMMA SIBS II 1 11 02-6020 RELIEF VALVE (-10 DA) 1 12 02-6012 SCREEN 1 13 02-6032 SOLENOID VALVE SUPER COIL ASSY 1 14 02-7091 SOLENOID COIL SUPER 12VDC 1 15 01-2072 O-RING #111 ID10.77 x 2.62SECT 2 16 01-5071 FILTER ELEMENT 1 17 01-5439 WASHER COPPER 12mm 2 18 02-7125 PRESSURE SWITCH NC 550psi FALLING 1 02-7116 PRESSURE SWITCH NC 850psi FALLING 1 19 01-5048 WASHER COPPER 1/2" 1 20 01-2131 O-RING SAE ID8.89 X 1.78SECT 1 21 01-5032 BANJO BOLT HEX HD 7/16" - 20 x 2LG 2 22 02-7086 PRESSURE SWITCH NC 40psi FALLING 1 23 01-4045 SEAL DOWTY 7/16" 1 24 02-2048 PIPE PUMP ENCLOSURE - SIBS III 1 25 02-6008 ELBOW 7/16" JIC MF 1 26 24-3188 CONNECTOR MALE 7/16" UNO - 7/16" JIC 1 27 01-5180 BULKHEAD UNION W/LOCKNUT 37deg FLARE 7/16 JIC 1 28 02-0107 ENCLOSURE PUMP SIBS III 1 29 02-2054 SEAL PINCHWELD PUMP ENCLOSURE - SIBS III 1 30 02-7122 HARNESS PUMP ENCLOSURE - SIBS III 1 31 02-7100 RELAY 12V 100A/400A 1 32 02-2050 BRACKET CIRCUIT BREAKER PUMP ENCLOSURE 1 33 02-7010 CIRCUIT BREAKER 40A MANUAL RESET 1 34 02-2046 HOLDER RETRACTOR BOLT PUMP ENCLOSURE 1 ELECTRONIC HARDWARE ITEM PART NO. DESCRIPTION QTY / VEHICLE 1 02-7120 HARNESS RM CABIN CONTROL - SIBS III 1 2 02-0090 CONTROL BOX/BRACKET ASSY LCV1 1 OPTIONAL HARDWARE ITEM PART NO. DESCRIPTION QTY / VEHICLE 1 02-7131 HARNESS CABIN EXTENSION SIBS III 1 2 02-7120 HARNESS CABIN SIBS III (OPTION*) 1 3 02-7121 HARNESS CABIN EXTENSION SIBS III (OPTION*) 1 4 02-7122 HARNESS PUMP ENCLOSURE SIBS III (OPTION*) 1 5 01-9052 PROXIMITY SWITCHES 2 6 02-7123 HARNESS HSI SIBS III 1 7 24-0838 MANIFOLD ASSY HSI 1 8 02-7085 CONTROL MODULE HIGHWAY SPEED ISOLATION 1 EMMA Pump Enclosure Hydraulic and Breather Hardware Electronic Hardware Optional Hardware Torque Settings and Tightening Sequences Brake Wear Inspection and Measurements 1 3 5 4 2 8 1 2 1 2 3 4 5 1 2 3 6 7 8 9 12 10 13 14 11 15 7 6 Checking Rear Brake Pad Wear 1. Apply the Park Brake. 2. Remove the Cap on the Par Wear Indicator (found on the EMMA™ Spring Cover). 3. The Plunger should project out of the Gland Fitting . 4. The distance the Plunger projects shows the remaining Brake Pad wear available. 5. If the Brake Pads have worn beyond the wear limit then the Brake Pads must be replaced. In this case a Major Service is required. Critical Measurements Customer Service and Parts Tel: +61 (08) 9273 4800 Fax: +61 (08) 9201 9923 Email: [email protected] Web: www.advancedbraking.com Rotor 1. Clean friction surface of Rotor with brake cleaner. 2. Perform visual inspection of Rotor, ensuring no crack or hots spots are present. 3. Measure thickness of Rotor at 90 degree intervals with a calibrated Micrometer. 4. If Rotor thickness is below 14mm discard and replace. Pads 1. Clean Pad friction surface and backing plate with brake cleaner. 2. Perform visual inspection of Pads, ensuring no crumbling. 3. Measure thickness of Pads with a calibrated Micrometer 4. If Pad thickness is below recommended minimum thickness discard and replace. HYDRAULIC AND BREATHER HARDWARE ITEM PART NO. DESCRIPTION QTY / VEHICLE 1 24-3211 TUBE HYDRAULIC EMMA LH 1 2 24-3210 TUBE HYDRAULIC EMMA RH 1 3 24-6010 BRAKE PIPE REAR LH (DRUM/SIBS II) 1 4 24-2817 BRAKE PIPE REAR RH TLC 1 5 24-3209 EMMA SUPPLY HOSE 2 (WRAPPED) 1 6 01-5088 HOSE VENT ID 5/16” 1 7 01-5226 HOSE FUEL ID 1/4” 1 8 24-3224 HOSE SUPPLY EMMA P-BH SIBS III 1 9 02-6018 REAR AXLE TEE ASSY 1 10 24-0007 EXPANSION CHAMBER ABS 1 24-0005 EXPANSION CHAMBER NON ABS 11 24-2982 BRACKET EXPANSION CHAMBER REAR ABS 1 12 01-5180 BULKHEAD UNION W/LOCKNUT 37deg FLARE 7/16 JIC 1 13 24-2839 BRACKET UNION 1 14 15-3780 FILTER BREATHER 5/16” HOSETAIL 1 15 01-5094 SADDLE HALF 50MM 1 MI-046-1 SIBS III Wall Chart Toyota LandCruiser 70 Series 39 ABS Sensors (ABS Equipped Vehicles Only) ABS SENSORS ITEM KIT NO. DESCRIPTION QTY/BRAKE SET 1 24-5018 SENSOR ASSEMBLY ABS LEAD LH (24-7008) 1 2 SENSOR ASSEMBLY ABS LEAD RH (24-7007) 1 1 1 2 3 3 4 4 WHITE/BLACK YELLOW/BLACK ABOVE GROUND UNDERGROUND PRE START CHECK DAILY DAILY MINOR SERVICE EVERY 5,000 KM MONTHLY MAJOR SERVICE UP TO 2 YEARS DEPENDING ON CONDITIONS UP TO 2 YEARS DEPENDING ON CONDITIONS OPTION HARNESSES FOR HIGH SPEED ISOLATION AND/OR DOOR PROXIMITY ENABLED VEHICLES ONLY. * Figure. 1 Figure. 2 Figure. 3 Figure. 4 Figure. 5 Figure. 6
Transcript of SIBS III FAIL SAFE BRAKE SYSTEM · 2017-05-22 · SIBS® III Maintenance Schedule The following...
SIBS® III Maintenance ScheduleThe following table shows the recommended service intervals for SIBS® III rear only brakes on a Toyota Landcruiser vehicle being operated in a harsh mining environment. ABT recommends each site undertake a review of the service intervals and adjust to suit their specific conditions.
Pre-Start Check
The pre-start check involves a quick check of the fluid levels and confirms proper brake system operation.
1. Check Brake Master Cylinder Reservoir level. Top up with brake fluid (DOT 3) as required.2. Check EMMA™ Pump Fluid Reservoir level. Top up with Automatic Transmission Fluid (ATF Dexron III) as required.3. With the doors closed, ignition switch on, press the E-Stop Button. a) The ‘Red’ light on the SIBS® Control Unit should be on. b) The Park Brake should be applied.4. Twist and reset the E-Stop button. a) The ‘Red’ light will flash momentarily , the alarm will sound, then the ‘Green’ light will come on. b) The Park Brake should now be released.5. Check the Park Brake applies when: a) The E-Stop is pressed. b) The door is opened. c) The key is ‘turned off’ Note: The E-Stop must be pressed and then reset between each test.6. Conduct a road test: a) Check the Service brake (Foot Brake) firmly applies the brake. b) Drive the vehicle at approximately 10 Kph. Press the E-Stop button. The vehicle should stop within 5 metres or 3 seconds.
Minor Service
The Minor Service involves a general system inspection and replacement of the SIBS® Fluid in the wheel ends.
1. General Inspections a) Check the wheel end brake for leaks. b) Check the EMMA™ Pump for leaks. c) Check hydraulic lines for leaks or damage. d) Check all electrical connectors and wiring damage.2. Check Brake Pad wear. Note: The Park Brake must be applied to measure Brake Pad wear. a) Remove the Protective Cap on the Pad wear Indicator (located on the EMMA™ Spring Cover, see Figure. 4). b) The Plunger should project out from the gland fitting. The distance the plunger projects shows the remaining Brake Pad wear available (see figure. 3). c) If the Brake Pads have worn beyond the wear limit then the Brake Pads must be replaced. In this case Major Service is recommended.3. Replace the SIBS® Fluid: a) Drain and discard the SIBS® Fluid from each Wheel End Brake. Note: 1 Litre of SIBS® Fluid should be in each Wheel End. Check for leaks if this amount is low. Note: The SIBS® Fluid should drain freely from the Brake. The SIBS® Fluid should flow freely, if this does not occur check the SIBS® Breather Line for blockages. b) Refit the Drain Plug using a new Sealing Washer. c) Refill the Wheel End up to the Level Plug (fill to spill). 1 Litre of SIBS® Fluid is required for each Wheel End.4. Conduct a ‘Vehicle Pre-Start Check’.
Major Service
The Major Service is conducted either to replace worn Brake Pads or as a preventative maintenance activity to ensure the continued reliable operation of the SIBS® Brake. During the Major Service new Seals are fitted throughout the Brake and any worn components replaced.
The following procedure assumes that a refurbished Wheel End is to be fitted. The refurbishment of the Brake is described in the SIBS® III Maintenance Schedule section of the Workshop Manual, Preparing Service Exchange Units.
1. Remove the SIBS® Wheel End for the Vehicle. a) Remove Wheel. b) Remove the Service Brake Line, the EMMA™ Hydraulic Line and the Breather Line from the Brake. c) Remove the Axle Shaft. d) Remove the Hub Nut. e) Attach Lifting Eye (P/N: 24-2870), connect to suitable Lifting Hoist. Note: The Lifting Eye is fitted using bolt hole 5 and 7 (see Figure. 1). f) Remove the 4 Nuts that hold the Brake onto the Axle Housing. g) Lift the Brake clear from the Axle Housing using lifting hoist. The inner housing may need to be tapped with a Copper Mallet to free it from the Axle Housing.2. Refit a refurbished Wheel End Brake and Hub to the Axle Housing (refer to Workshop Manual, Section Title: Fitting Procedure): a) Clean the Brake mounting surface on the Axle. b) Apply Loctite® 515™ evenly to mounting surface. c) The Brake can now be fitted to the vehicle as a complete assembly (Housing and Hub). d) Lift the Brake onto the Axle Housing using the Lifting Eye and suitable Lifting Hoist. e) Fit and tighten the 4 Nuts that hold the Brake onto the Axle Housing (Torque: 81Nm). f) Fit the Bearing Adjustment Nut inside the Hub (to Toyota recommendations). g) Fit the Axle Shaft. h) Fit the Service Brake Line, EMMA™ Hydraulic Line and the Breather Hose. i) Grease the V-Lip Seal. Note: Do not over grease. j) Refill the Wheel End up to the Level Plug (fill to spill). 1 Litre of SIBS® Fluid is required for each Wheel End.3. Replacement of Lines: a) Replace the EMMA™ Axle Housing Link Line (P/N: 24-3209). b) Replace Breather Lines once Expansion Chambers have been drained.4. EMMA™ Pump: a) Remove the Automatic Transmission Fluid (ATF Dexron III) from the EMMA™ Pump Reservoir. b) Replace the EMMA™ Pump Filter Element (P/N: 01-5071). d) Refill the EMMA™ Pump Reservoir with ATF Dexron III. e) Bleed the EMMA™ system at the Wheel End.5. Service Brake: a) Drain and replace the Brake Fluid (DOT 3) from the Master Cylinder Reservoir. b) Bleed the Service Brake at the Wheel End.6. Final Check: a) Conduct a ‘Vehicle Pre-Start Check’.
SIBS® III FAIL SAFE BRAKE SYSTEMToyota LandCruiser 70 Series (Australian 6 & 8 Cylinder Models)
REAR BRAKE ASSYITEM PART NO. DESCRIPTION QTY/BRAKE
1 24-5020 KIT WHEEL BEARING LCV1 (one brake) 12 15-1200 SEAL V-LIP 13 15-1470 SEAL HOUSING 14 24-5023 KIT SEAL HUB LCV1 (one brake) 15 24-0864 HUB ASSY REAR SIBS III 16 24-2942 BOLT HOUSING FLANGE HEAD 12
724-1733 HOUSING OUTER LH 124-1743 HOUSING OUTER RH 1
8 24-4953 KIT BRAKE PAD (one brake) 19 15-2630 ROTOR BRAKE 1
10 15-1080 O-RING HOUSING 111 24-5021 KIT SEAL SERVICE REAR LCV1 (one brake) 112 24-2040 PISTON SERVICE BRAKE REAR 213 24-5048 KIT BRAKE MOUNTING REAR SIBS III (one brake) 1
1424-5061 HOUSING INNER REAR LH LCV1 SIBS III 124-5060 HOUSING INNER REAR RH LCV1 SIBS III 1
15 15-1151 BLEED NIPPLE 416 15-1380 BLEED NIPPLE CAP 417 15-1890 WASHER COPPER 118 24-2873 ADAPTER LINK PIPE 219 24-2872 LINK PIPE SERVICE BRAKE REAR 120 15-3021 CONNECTOR HOSE 1/4” 121 24-2879 HOSE BREATHER 1/4”ID REAR SIBS II 122 01-5175 HOSE CLAMP 123 01-5176 BARB HOSE W/SWIVEL NUT 1/4”ID HOSE 124 24-5027 KIT FILL/DRAIN PLUG SIBS II (one brake) 125 24-5030 KIT SEAL FILL/DRAIN PLUG SIBS II 0.126 02-6019 CONNECTOR JIC MALE SST 127 15-2250 NUT LOCK RR SPINDLE MOUNT 428 15-3070 WASHER FLAT HARDENED M12 429 15-2530 RETRACTOR BOLT 4
3024-5031 KIT PAD WEAR INDICATOR SIBS II (one brake) 124-5024 KIT PAD WEAR INDICATOR SIBS II HD (one brake) 1
31 01-3446 BOLT HOUSING M10x1.5x50 10
3224-2925 COVER SPRING EMMA RH SIBS III 124-2926 COVER SPRING EMMA LH SIBS III 1
33 10-3240 SPRING PIN 2
3415-3750 DISC SPRING 3mm (STANDARD) 3210-2030 DISC SPRING 4mm (HEAVY DUTY) 24
35 24-2010 PISTON PARK BRAKE 436 24-2918 GASKET SPRING COVER STATITE SIBS II 137 24-5051 KIT SEAL PARK BRAKE (one brake) 138 24-3233 PLUG SOCKET HD 3/8” BSPP 339 00-3221 SIBS COOLING FLUID 20 LITRES -
Rear Brake Assy
ITEM DESCRIPTION TORQUE SETTINGS1 SPRING COVER BOLTS 71 Nm2 HOUSING BOLTS 61 Nm3 BRAKE MOUNTING NUTS 81 Nm4 WHEEL NUTS 209 Nm
ITEM NEW COMPONENT MINIMUM THICKNESSBrake Pads (Standard) 14 mm 13 mmBrake Pads (Heavy Duty) 14 mm 12 mm Brake Rotor 14.5 mm 14 mm
EMMA PUMP ENCLOSUREITEM PART NO. DESCRIPTION QTY/BRAKE
1 01-3453 SCREW HEX HD 3/8" - 16 UNC x 2" LG 22 01-4141 WASHER DOWTY M10 23 02-2045 SPACER PUMP ENCLOSURE - SIBS III 14 02-7019 AM SERIES WOUND MOTOR 15 02-1046 PUMP EMMA SIBS III 16 02-6024 RESERVOIR KIT 'C' TYPE PLASTIC 108 SERIES 17 02-2018 SPOUT C RESERVOIR 18 02-2051 BRACKET CLIP PUMP ENCLOSURE - SIBS III 19 24-2881 P-CLIP 6mm x M8 RUBBER LINED 1
10 02-6033 MANIFOLD ASSY EMMA SIBS II 111 02-6020 RELIEF VALVE (-10 DA) 112 02-6012 SCREEN 113 02-6032 SOLENOID VALVE SUPER COIL ASSY 114 02-7091 SOLENOID COIL SUPER 12VDC 115 01-2072 O-RING #111 ID10.77 x 2.62SECT 216 01-5071 FILTER ELEMENT 117 01-5439 WASHER COPPER 12mm 2
1802-7125 PRESSURE SWITCH NC 550psi FALLING 102-7116 PRESSURE SWITCH NC 850psi FALLING 1
19 01-5048 WASHER COPPER 1/2" 120 01-2131 O-RING SAE ID8.89 X 1.78SECT 121 01-5032 BANJO BOLT HEX HD 7/16" - 20 x 2LG 222 02-7086 PRESSURE SWITCH NC 40psi FALLING 123 01-4045 SEAL DOWTY 7/16" 124 02-2048 PIPE PUMP ENCLOSURE - SIBS III 125 02-6008 ELBOW 7/16" JIC MF 126 24-3188 CONNECTOR MALE 7/16" UNO - 7/16" JIC 127 01-5180 BULKHEAD UNION W/LOCKNUT 37deg FLARE 7/16 JIC 128 02-0107 ENCLOSURE PUMP SIBS III 129 02-2054 SEAL PINCHWELD PUMP ENCLOSURE - SIBS III 130 02-7122 HARNESS PUMP ENCLOSURE - SIBS III 131 02-7100 RELAY 12V 100A/400A 132 02-2050 BRACKET CIRCUIT BREAKER PUMP ENCLOSURE 133 02-7010 CIRCUIT BREAKER 40A MANUAL RESET 134 02-2046 HOLDER RETRACTOR BOLT PUMP ENCLOSURE 1
ELECTRONIC HARDWAREITEM PART NO. DESCRIPTION QTY / VEHICLE
1 02-7120 HARNESS RM CABIN CONTROL - SIBS III 12 02-0090 CONTROL BOX/BRACKET ASSY LCV1 1
OPTIONAL HARDWAREITEM PART NO. DESCRIPTION QTY / VEHICLE
1 02-7131 HARNESS CABIN EXTENSION SIBS III 12 02-7120 HARNESS CABIN SIBS III (OPTION*) 13 02-7121 HARNESS CABIN EXTENSION SIBS III (OPTION*) 14 02-7122 HARNESS PUMP ENCLOSURE SIBS III (OPTION*) 15 01-9052 PROXIMITY SWITCHES 26 02-7123 HARNESS HSI SIBS III 17 24-0838 MANIFOLD ASSY HSI 18 02-7085 CONTROL MODULE HIGHWAY SPEED ISOLATION 1
EMMA Pump Enclosure
Hydraulic and Breather Hardware
Electronic Hardware
Optional Hardware
Torque Settings and Tightening Sequences
Brake Wear Inspection and Measurements
1
3
54
2
8
1
2
1 2 3 4
5
1
23
6 78
9
12
10
13
14
11
15
76
Checking Rear Brake Pad Wear
1. Apply the Park Brake.2. Remove the Cap on the Par Wear Indicator (found on the EMMA™ Spring Cover).3. The Plunger should project out of the Gland Fitting .4. The distance the Plunger projects shows the remaining Brake Pad wear available.5. If the Brake Pads have worn beyond the wear limit then the Brake Pads must be replaced. In this case a Major Service is required.
Critical Measurements
Customer Service and PartsTel: +61 (08) 9273 4800Fax: +61 (08) 9201 9923
Email: [email protected]: www.advancedbraking.com
Rotor1. Clean friction surface of Rotor with brake cleaner.2. Perform visual inspection of Rotor, ensuring no crack or hots spots are present.3. Measure thickness of Rotor at 90 degree intervals with a calibrated Micrometer.4. If Rotor thickness is below 14mm discard and replace.
Pads1. Clean Pad friction surface and backing plate with brake cleaner.2. Perform visual inspection of Pads, ensuring no crumbling.3. Measure thickness of Pads with a calibrated Micrometer4. If Pad thickness is below recommended minimum thickness discard and replace.
HYDRAULIC AND BREATHER HARDWAREITEM PART NO. DESCRIPTION QTY / VEHICLE
1 24-3211 TUBE HYDRAULIC EMMA LH 12 24-3210 TUBE HYDRAULIC EMMA RH 13 24-6010 BRAKE PIPE REAR LH (DRUM/SIBS II) 14 24-2817 BRAKE PIPE REAR RH TLC 15 24-3209 EMMA SUPPLY HOSE 2 (WRAPPED) 16 01-5088 HOSE VENT ID 5/16” 17 01-5226 HOSE FUEL ID 1/4” 18 24-3224 HOSE SUPPLY EMMA P-BH SIBS III 19 02-6018 REAR AXLE TEE ASSY 1
1024-0007 EXPANSION CHAMBER ABS 124-0005 EXPANSION CHAMBER NON ABS
11 24-2982 BRACKET EXPANSION CHAMBER REAR ABS 112 01-5180 BULKHEAD UNION W/LOCKNUT 37deg FLARE 7/16 JIC 113 24-2839 BRACKET UNION 114 15-3780 FILTER BREATHER 5/16” HOSETAIL 115 01-5094 SADDLE HALF 50MM 1
MI-046-1 SIBS III Wall Chart Toyota LandCruiser 70 Series
39
ABS Sensors (ABS Equipped Vehicles Only)
ABS SENSORSITEM KIT NO. DESCRIPTION QTY/BRAKE SET
124-5018
SENSOR ASSEMBLY ABS LEAD LH (24-7008) 12 SENSOR ASSEMBLY ABS LEAD RH (24-7007) 1
11 2
3
3
4
4
WHITE/BLACK YELLOW/BLACK
ABOVE GROUND UNDERGROUNDPRE START CHECK DAILY DAILY
MINOR SERVICE EVERY 5,000 KM MONTHLY
MAJOR SERVICE UP TO 2 YEARS DEPENDING ON CONDITIONS UP TO 2 YEARS DEPENDING ON CONDITIONS
OPTION HARNESSES FOR HIGH SPEED ISOLATION AND/OR DOOR PROXIMITY ENABLED VEHICLES ONLY.*
Figure. 1 Figure. 2
Figure. 3
Figure. 4
Figure. 5 Figure. 6
