B29.10-0034-09
1 | Mounting bracket of the brake pedal assembly with the servo brake and the master cylinder on the main bracket of the pillar | 14 | Double servo brake drive rod pivot shaft | |
2 | Flange bolts, attaching the pedal bracket to the main bracket of the pillar | 15 | servo brake drive rod fork | |
3 | Dual servo brake assembly bracket with master cylinder | 16 | Collar nut for actuator rod adjustment | |
4 | Flange bolts securing the support bracket of the double servo brake to the pedal support | 17 | Double servo brake drive rod | |
5 | Brake pedal | 18 | Master brake cylinder, assisted by double servo brakes | |
6 | Pedal foot support fixture (removed) | 19 | Flange nuts attaching the master cylinder to the double servo brake | |
7 | Brake pedal return spring | 20 | Double servo brake assembly | |
8 | Brake pedal limiter stop | 21 | Brake application light switch | |
9 | Brake pedal pivot shaft on the bracket | 22 | Flange nuts attaching the double servo brake to the support | |
10 | Pedal pivot shaft elastic rings (one on each side) | 23 | Feed and return lines for the brake liquid on the master cylinder | |
11 | Double servo brake drive rod pivot shaft cotterpin | |||
12 | Spacing washer | B | Brake pedal travel measured on a 360 mm radius from the joint shaft center | |
13 | Pedal pivot shaft cotter pin |
Warning | Risk of injury to skin or eyes from hydraulic fluid spraying out under pressure.Risk of poisoning from swallowing hydraulic fluid. | Depressurize hydraulic system completely before starting any work on it. Wear protective clothing and safety glasses. | |
Danger | Risk of death caused by vehicle slipping or toppling off of the lifting platform. | Align vehicle between vehicle lift columns and position the four support plates at the vehicle lift support points specified by the vehicle manufacturer. | |
1 | Place the vehicle on a flat, level location to enable safe working conditions. Chock the rear wheels to prevent the vehicle from accidentally moving. | ||
2 | Switch off the general switch. | As it deals with electronic vehicles, always follow the recommendations for this type of vehicles. | |
| Remove | ||
3 | Remove the complete brake pedal assembly along with the double servo brake and the master cylinder of the main bracket | ||
Caution | Risk of poisoning from swallowing brake fluid. Risk of injury from skin and eye contact with brake fluid | Only pour brake fluid into suitable and appropriately marked containers. Wear protective clothing and eye protection when handling brake fluid. | |
4 | Remove the steering column cover to make the access to the pedal assembly easier. | ||
5 | Protect the bottom of the cabin against brake fluid spills. | | |
6 | Drain the brake system fluid. | ||
7 | Disconnect the brake light switch wiring. Remove the servo brake pipe. Carefully disconnect the side pipes in the master cylinder. | Handle brake fluid reservoir with care. | |
Plug each line end with a small plug to prevent brake fluid spills. | |||
The inlet and return hoses to the master cylinder should be carefully removed from the connections (23) mounted on the master cylinder (18). | |||
8 | Remove the collar bolts (2) fastening the bracket (1) to the main bracket of the steering. | ||
9 | Carefully remove complete brake pedal assembly. | The brake pedal assembly will come out complete with the brackets (1) and (3), the double servo brake (20) and the master cylinder (18). | |
10 | Secure the assembly in an appropriate base for removing and installing it. | ||
11 | Remove the double servo brake with the master cylinder | ||
12 | Remove the pedal return spring (7). | ||
13 | Release the servo brake drive rod. To do so, remove the cotter pin (11), the washer (12) and pull the pivot shaft (14) out. | At this point, the double servo brake drive rod (17) with the fork (15) and the adjusting nut (16) is released from the brake pedal assembly (5). | |
14 | Remove the 4 flange bolts (4) and separate from the bracket (1) the set consisting of the bracket (3), the double servo brake (20) and the master cylinder (18). | If necessary to remove the master cylinder (18), remove the two nuts (19) and remove the master cylinder. Incorrect assembly will damage the cylinder and servo brake assembly components. | |
To remove the servo brake (20), after removing the master cylinder (18) remove the 4 nuts (22) that secure it to the bracket (3). Be careful not to get dirt inside the brake. | |||
15 | Remove the brake pedal from the bracket | ||
16 | Remove the two elastic rings (10) securing the pivot shaft. Remove the pivot shaft (9) and the brake pedal (5). | In some vehicles, instead of the elastic rings there may be plain washers and cotter pins (13) on the outside of the pivot shaft (9). | |
17 | Remove, from the pedal, the foot support fixture (6). Remove the limiter stop (8) from the brake pedal (5). | ||
| Clean | ||
18 | Clean all the components. | | |
| Check | ||
19 | Check all the components for wear or deformations, especially the pedal joint shaft (9) and the drive rod (14). Replace whatever necessary. | ||
Replace the following components: The elastic rings (10) and (11), the cotter pins (11) and (13), the spacer or spacer washers (10) and (12), the foot support trim on the pedal (6), the pedal limit stop and the return spring (7). | |||
| Install | ||
20 | Install the brake pedal on its articulation on the bracket | ||
21 | Place the pedal (5) on the bracket (1), install the lubricated pivot shaft (9), the new elastic rings (10) on both sides. Install a new foot support (6) on the pedal (5). | The inside of the pedal joint and the axle (9) should be well lubricated during assembly and the return spring hooks contacts should be well lubricated (7). | |
Molybdenum disulfide running-in paste | |||
22 | In some vehicles, instead of the elastic rings there may be plain washers and cotter pins on the outside of the pivot shaft (9). | ||
23 | If the master cylinder (18) has been removed, install it on the servo brake (20) observing the necessary recommendations. Install the master cylinder (18) with the servo brake (20) on the bracket (3). | | |
To install the servo brake (20), after installing the master cylinder (18), fit the servo brake studs to the bracket (3) and tighten the 4 nuts (22) that secure it to the bracket (3). | |||
.Nuts attaching the servo-brake to the support. | |||
24 | Prepare the drive shaft for mounting. It is formed by the rod (17), the flange nut (16) and the fork (15). | If necessary, after mounting the assembly, adjust the clearance. | |
In the assembly, lightly lubricate the semi-spherical tip contact and the joint shaft fit (14). | |||
Molybdenum disulfide running-in paste | |||
.Clearance F between actuation rod and the emitter cylinder piston, adjusted. | |||
25 | Install the servo brake assembly (20) with the master cylinder (18) onto the bracket (1). Fit the flange bolts (4) and tighten them on the bracket (1). | .Screws with fixing flange of the support bracket of the servo brake on the pedal support. | |
26 | Lubricate the pivot shaft of the rod (14) and install it with the fork (15) at the upper end of the pedal. Then install the new washer (12) and the new cotter pin (11). Install the new stop (8). | ||
27 | Adjust the servo brake drive rod clearance. | Hold the fork (15) with a wrench, loosen the nut (16) on the threads of the rod (17) and turn it by hand until you feel the back. Then, gently return the rod, move it laterally until you notice a minimum clearance and fix it with the nut(16). | |
.Slope of the clutch pedal lever | |||
.Servo-brake actuation rod nut. | |||
28 | Install the double servo brake assembly along with the master cylinder and the brake pedal on the main bracket | ||
29 | Place the assembly and secure the support (1) with the 4 screws (2) on main support. | .Nuts with fixing flange of the steering main trestle and pedals in the cab. | |
.Flange bolts, attaching the brake pedal support to the main steering bracket. | |||
30 | Connect the servo brake feed lines. Connect the feed and return lines (23) for the brake fluid to the master cylinder. | ||
31 | Connect the pressure lines of the master cylinder and tighten them to the correct torque. Connect the electrical cables to the brake pedal switch (5). | .Pipe connections on the hydraulic emitter cylinder and on the master cylinder. | |
32 | Fill the brake system with brake fluid and purge it. | ||
33 | After assembling and adjusting the brake pedal, and after purging the brake system, its travel must be represented by measure "B" . | Pedal "B" course measured in a 360 mm radius from center of articulation axle (9). | |
.Length A of the auxiliary spring | |||
.Clutch pedal stroke B | |||
34 | Install the steering column cover. | ||
35 | Check that everything is in order, remove the protection from the cab floor, turn the main switch on and perform a test drive. |