SIBS III FAIL SAFE BRAKE SYSTEM
®
Toyota LandCruiser 70 Series (Australian 6 & 8 Cylinder Models)
Rear Brake Assy
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
39
ABS Sensors (ABS Equipped Vehicles Only)
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
WHITE/BLACK
33
YELLOW/BLACK
34
35
36
37
38
39
EMMA Pump Enclosure
ITEM
1
2
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Hydraulic and Breather Hardware
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
2
1
5
4
3
11
10
9
6
7
14
8
12
13
15
Electronic Hardware
1
2
MI-046-1 SIBS III Wall Chart Toyota LandCruiser 70 Series
ITEM
1
2
3
4
5
6
7
8
9
PART NO.
24-5020
15-1200
15-1470
24-5023
24-0864
24-2942
24-1733
24-1743
24-4953
15-2630
15-1080
24-5021
24-2040
24-5048
24-5061
24-5060
15-1151
15-1380
15-1890
24-2873
24-2872
15-3021
24-2879
01-5175
01-5176
24-5027
24-5030
02-6019
15-2250
15-3070
15-2530
24-5031
24-5024
01-3446
24-2925
24-2926
10-3240
15-3750
10-2030
24-2010
24-2918
24-5051
24-3233
00-3221
KIT NO.
24-5018
PART NO.
01-3453
01-4141
02-2045
02-7019
02-1046
02-6024
02-2018
02-2051
24-2881
02-6033
02-6020
02-6012
02-6032
02-7091
01-2072
01-5071
01-5439
02-7125
02-7116
01-5048
01-2131
01-5032
02-7086
01-4045
02-2048
02-6008
24-3188
01-5180
02-0107
02-2054
02-7122
02-7100
02-2050
02-7010
02-2046
11
12
13
14
15
PART NO.
24-3211
24-3210
24-6010
24-2817
24-3209
01-5088
01-5226
24-3224
02-6018
24-0007
24-0005
24-2982
01-5180
24-2839
15-3780
01-5094
ITEM
1
2
PART NO.
02-7120
02-0090
10
REAR BRAKE ASSY
DESCRIPTION
KIT WHEEL BEARING LCV1 (one brake)
SEAL V-LIP
SEAL HOUSING
KIT SEAL HUB LCV1 (one brake)
HUB ASSY REAR SIBS III
BOLT HOUSING FLANGE HEAD
HOUSING OUTER LH
HOUSING OUTER RH
KIT BRAKE PAD (one brake)
ROTOR BRAKE
O-RING HOUSING
KIT SEAL SERVICE REAR LCV1 (one brake)
PISTON SERVICE BRAKE REAR
KIT BRAKE MOUNTING REAR SIBS III (one brake)
HOUSING INNER REAR LH LCV1 SIBS III
HOUSING INNER REAR RH LCV1 SIBS III
BLEED NIPPLE
BLEED NIPPLE CAP
WASHER COPPER
ADAPTER LINK PIPE
LINK PIPE SERVICE BRAKE REAR
CONNECTOR HOSE 1/4”
HOSE BREATHER 1/4”ID REAR SIBS II
HOSE CLAMP
BARB HOSE W/SWIVEL NUT 1/4”ID HOSE
KIT FILL/DRAIN PLUG SIBS II (one brake)
KIT SEAL FILL/DRAIN PLUG SIBS II
CONNECTOR JIC MALE SST
NUT LOCK RR SPINDLE MOUNT
WASHER FLAT HARDENED M12
RETRACTOR BOLT
KIT PAD WEAR INDICATOR SIBS II (one brake)
KIT PAD WEAR INDICATOR SIBS II HD (one brake)
BOLT HOUSING M10x1.5x50
COVER SPRING EMMA RH SIBS III
COVER SPRING EMMA LH SIBS III
SPRING PIN
DISC SPRING 3mm (STANDARD)
DISC SPRING 4mm (HEAVY DUTY)
PISTON PARK BRAKE
GASKET SPRING COVER STATITE SIBS II
KIT SEAL PARK BRAKE (one brake)
PLUG SOCKET HD 3/8” BSPP
SIBS COOLING FLUID 20 LITRES
ABS SENSORS
DESCRIPTION
SENSOR ASSEMBLY ABS LEAD LH (24-7008)
SENSOR ASSEMBLY ABS LEAD RH (24-7007)
EMMA PUMP ENCLOSURE
DESCRIPTION
SCREW HEX HD 3/8" - 16 UNC x 2" LG
WASHER DOWTY M10
SPACER PUMP ENCLOSURE - SIBS III
AM SERIES WOUND MOTOR
PUMP EMMA SIBS III
RESERVOIR KIT 'C' TYPE PLASTIC 108 SERIES
SPOUT C RESERVOIR
BRACKET CLIP PUMP ENCLOSURE - SIBS III
P-CLIP 6mm x M8 RUBBER LINED
MANIFOLD ASSY EMMA SIBS II
RELIEF VALVE (-10 DA)
SCREEN
SOLENOID VALVE SUPER COIL ASSY
SOLENOID COIL SUPER 12VDC
O-RING #111 ID10.77 x 2.62SECT
FILTER ELEMENT
WASHER COPPER 12mm
PRESSURE SWITCH NC 550psi FALLING
PRESSURE SWITCH NC 850psi FALLING
WASHER COPPER 1/2"
O-RING SAE ID8.89 X 1.78SECT
BANJO BOLT HEX HD 7/16" - 20 x 2LG
PRESSURE SWITCH NC 40psi FALLING
SEAL DOWTY 7/16"
PIPE PUMP ENCLOSURE - SIBS III
ELBOW 7/16" JIC MF
CONNECTOR MALE 7/16" UNO - 7/16" JIC
BULKHEAD UNION W/LOCKNUT 37deg FLARE 7/16 JIC
ENCLOSURE PUMP SIBS III
SEAL PINCHWELD PUMP ENCLOSURE - SIBS III
HARNESS PUMP ENCLOSURE - SIBS III
RELAY 12V 100A/400A
BRACKET CIRCUIT BREAKER PUMP ENCLOSURE
CIRCUIT BREAKER 40A MANUAL RESET
HOLDER RETRACTOR BOLT PUMP ENCLOSURE
HYDRAULIC AND BREATHER HARDWARE
DESCRIPTION
TUBE HYDRAULIC EMMA LH
TUBE HYDRAULIC EMMA RH
BRAKE PIPE REAR LH (DRUM/SIBS II)
BRAKE PIPE REAR RH TLC
EMMA SUPPLY HOSE 2 (WRAPPED)
HOSE VENT ID 5/16”
HOSE FUEL ID 1/4”
HOSE SUPPLY EMMA P-BH SIBS III
REAR AXLE TEE ASSY
EXPANSION CHAMBER ABS
EXPANSION CHAMBER NON ABS
BRACKET EXPANSION CHAMBER REAR ABS
BULKHEAD UNION W/LOCKNUT 37deg FLARE 7/16 JIC
BRACKET UNION
FILTER BREATHER 5/16” HOSETAIL
SADDLE HALF 50MM
ELECTRONIC HARDWARE
DESCRIPTION
HARNESS RM CABIN CONTROL - SIBS III
CONTROL BOX/BRACKET ASSY LCV1
QTY/BRAKE
1
1
1
1
1
12
1
1
1
1
1
1
2
1
1
1
4
4
1
2
1
1
1
1
1
1
0.1
1
4
4
4
1
1
10
1
1
2
32
24
4
1
1
3
-
Optional Hardware
1
SIBS® III Maintenance Schedule
2
5
3
ITEM
1
2
3
4
5
6
7
8
PART NO.
02-7131
02-7120
02-7121
02-7122
01-9052
02-7123
24-0838
02-7085
4
8
QTY / VEHICLE
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
QTY / VEHICLE
1
1
QTY / VEHICLE
1
1
1
1
2
1
1
1
3
Figure. 3
Figure. 2
DESCRIPTION
SPRING COVER BOLTS
HOUSING BOLTS
BRAKE MOUNTING NUTS
WHEEL NUTS
TORQUE SETTINGS
71 Nm
61 Nm
81 Nm
209 Nm
1
2
4
3
Figure. 6
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.
MAJOR SERVICE
UP TO 2 YEARS DEPENDING ON CONDITIONS
UP TO 2 YEARS DEPENDING ON CONDITIONS
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.
Figure. 4
NEW COMPONENT
14 mm
14 mm
14.5 mm
MONTHLY
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.
Critical Measurements
ITEM
Brake Pads (Standard)
Brake Pads (Heavy Duty)
Brake Rotor
EVERY 5,000 KM
Major Service
Brake Wear Inspection and Measurements
Figure. 5
MINOR SERVICE
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’.
2
1. Apply the Park Brake.
2. Remove the Cap 1 on the Par Wear Indicator (found on the EMMA™
Spring Cover).
3. The Plunger 3 should project out of the Gland Fitting 4 .
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.
DAILY
The Minor Service involves a general system inspection and replacement of the SIBS® Fluid in the wheel ends.
1
Checking Rear Brake Pad Wear
DAILY
Minor Service
Torque Settings and Tightening Sequences
ITEM
1
2
3
4
PRE START CHECK
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.
* OPTION HARNESSES FOR HIGH SPEED ISOLATION AND/OR DOOR PROXIMITY ENABLED VEHICLES ONLY.
QTY/BRAKE SET
1
1
QTY/BRAKE
2
2
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
UNDERGROUND
The pre-start check involves a quick check of the fluid levels and confirms proper brake system operation.
OPTIONAL HARDWARE
DESCRIPTION
HARNESS CABIN EXTENSION SIBS III
HARNESS CABIN SIBS III (OPTION*)
HARNESS CABIN EXTENSION SIBS III (OPTION*)
HARNESS PUMP ENCLOSURE SIBS III (OPTION*)
PROXIMITY SWITCHES
HARNESS HSI SIBS III
MANIFOLD ASSY HSI
CONTROL MODULE HIGHWAY SPEED ISOLATION
Figure. 1
ABOVE GROUND
Pre-Start Check
7
6
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.
MINIMUM THICKNESS
13 mm
12 mm
14 mm
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’.
Customer Service and Parts
Tel: +61 (08) 9273 4800
Fax: +61 (08) 9201 9923
Email: [email protected]
Web: www.advancedbraking.com