DuraStar® Series — Medium Conventional Body Builder Diagrams (CT-471) October, 2010 Cautions - Of themanyrequirements ofFMVSS121,two andrelated systems. manufactured onor after March1, 1975 mustcomplywitha compr The Federal Department of Transportation's Motor Safety Certification ProceduresForDOTFMVSS-121 Air BrakeModifications A BRAKES DuraStar and air flow design ofthe system. manufacturer. Thefirstconcernisthe center ofgravity locati CAUTION: CAUTION: CAUTION: LL M ODELS FMVSS-121 AirBrakeS FMVSS-121 Air-operated auxiliary Air reservoirsmaybe relocated provid If wheelbasealterationsaremadetoInte • • • • • • • • necessarily be restri necessarily be to reach and release the brakes, itisobvi parts areavailablefrom Internationaltruckdealers. Pressure protection valvesare required where shown and documentationcompliance ornon-co of (through contacting your loca DO NOT DO NOT DO NOT DO NOT DO NOT DO NOT DO NOT the wheelbase.Forwhee useair taplocations other thansh those alter braketo port line location. bendssharpor allowother constrictionsinhosing. fittings or piping , with lines air to alterations make exceed the minimum orwheelbase maximum availablefrom th bendssharpor allowother constrictionsinhosing. fittings or piping hose, with lines air to alterations make ® SERIES ystem Modifications cted. Consult FMVSS-121 for crit FMVSS-121 for cted. Consult attachments maybeaddedtoInternatio lbases longer orsh lbases are of primary concern between the l Internationaldealer). mpliance with FMVSS-121 for the specific mpliance withFMVSS-121for ing theseguideli ous that the tubing design is very critic isvery design tubing the that ous on a truckusedfor compliancetestingand the secondinvolve rnational orter thanthos – 149 – Standard 121 required that virtually all equipped witha own on thesedrawings for thesemodels. ehensive setofdesign and performance parameters concerning the International will be available to Internationalwillbeavailable eria for timeallowed forap eria Since the FVMSS-121 has very specific e availablefromthefa nes arefollowed: should bemountedwith the vent new port All downward. ofsizes other than those currently inuseon the truck. ofsizes other than those currently inuseon the truck. with FMVSS-121brakes: nal FMVSS-121v e factory for thatmodel after lengthening or shortening manufacturer andthe al and that the allowable sources for air t ply andrelease of brakes. ctory, Internationalw situation at an additional cost. provide certification testingand provide certification ehicles ifyou: criteria for the time allowed for air body and alliedequipm ill provide verbal opinio ill provide s the tubing ir brakes and ap must ent air n October, 2010 DuraStar® Series — Medium Conventional Body Builder Diagrams (CT-471) NOTE: Install the airtanks so that the drainvalves Install the brake pipesinpo • Preferably, use bent brake pipesinsteadof elbow unions • Avoid joints, preferably change the entirebrake pipe. • • Make sure that the brakecircuits arenot altered. Before anypa • observed: Should itbenecessary tomodify the brakingsystem, forexampl Safety Measures Brake Restrictions A DuraStar CAUTION: LL M connections concerned, or makeasketch showing theoriginal routing. ODELS On truckswithABSbrakes,thesensorcablemust not When abrakepipeisrepl ® sitions wherethey are protected against damage andheat. SERIES aced orjointed,useon stillfunctionwelland areeasy toreach. – 150 be jointed. If necessary,be jointed. it so asnotto affect the brakeapplication/release times. e in connection with awheelbase alteration, the following must rt ofthe braking systemisdi ly genuineInternationalpa must becompletelyreplaced. smantled, mark thebrake pipes a rts ofthecorrecttype. always be nd DuraStar® Series — Medium Conventional Body Builder Diagrams (CT-471) October, 2010 (with Truck BrakeSystemCode04085) Full PowerHydraulicBrakeSystemSchematic DuraStar ® SERIES – 151 – 04_0081 October, 2010 DuraStar® Series — Medium Conventional Body Builder Diagrams (CT-471) (with Truck BrakeSystemCode04091) Antilock AirBrake DuraStar Speed Sensor (4) ABS Wheel Safety Valve ABS Modulator ABS Modulator Valve Valve Service Brake System Schematic Service Brake Chamber Chamber Governor Wet Tank Air Dryer Low Pressure Gauge Pressure Air Switch ® SERIES Check Valve Park BrakeControlValve Park Foot Valve Gauge Pressure Air Low Pressure Switch Low Pressure Secondary Stop E-8P Light Switch Primary Stop Light Switch Drain Valve Secondary Tank Primary Tank ABS Control – 152 Module Modulator Valve Spring Brake Pressure Protection Valve Relay Valve Air Accessory Solenoid Module ABS Modulator Valve ABS Modulator Valve Key: suspensions, transmissions, etc. accessories such as air Extra port for non-solenoid air Service Brake Chamber Spring Brake Chamber Electrical Circuits Electrical Circuit Primary Circuit Circuit Secondary controlled accessories. controlled air various for supply Air Valve elease R Quick Valve elease R Quick 04_0102 DuraStar® Series — Medium Conventional Body Builder Diagrams (CT-471) October, 2010 Be installed inamanner that prevents itfrom contacting the v Be suitably secured against chafing, kinking, orother mechanical damage. • Be longand flexible enough to accommodate without damage all normal motions ofthe part towhich it is attached. • Be installed inamanner that insures proper • Be designed and constructed ina manner that insures proper, adequate, and continued functioning of the tubing orhose. • • Carrier SafetyRegulations Pocketbook, section 393.45, should be followed: If modifications are made to International vehicleswith the Routing Guidelines A DuraStar LL M ODELS ® SERIES continued functioning ofthe tubingorhose. addition or re-routing of tubingaddition thefollowingguidelinesor re-routingof in found – 153 – ehicle's exhaust systemor anyothersourceofhigh temperature the Federal Motor s. October, 2010 DuraStar® Series — Medium Conventional Body Builder Diagrams (CT-471) The primaryairreservoirdedicated hasa port foratwo-port • Air-Operated AuxiliaryAttachments A DuraStar Ifalloftheports onthe PPVareutilized, then aQualityConnect • The PPV willcome installed fromthefactoryifan airsuspens • LL M dealer. the vehicle, then thisport isplugged fromthe factory. APP recommended tee - 3/8-inchx teerecommended(Internat x3/8-inch stem use the port. suspension dump, etc.). Depending onvehicle ordered features; o ODELS ® SERIES – 154 V canbe ordered fromanInter 04_0005 pressure protection valve(PPV). Ifnoair-operated features are ion or otherair-operated device isordered (i.e.,fifth wheel s ional part number 2024458C1) – can be ordered froman Internatio tee shouldbeinstalled into ne port may beopen. Ifthis is the case, then unplug thatport national dealerifa PPVisneeded. the oneofusedports. Th e lide, air ordered on and 04_0006 nal DuraStar® Series — Medium Conventional Body Builder Diagrams (CT-471) October, 2010 color isused. To assure standardization of tubingusedon International vehi service, a kitisavailable with toolsforeach port and tube size used byInternational. into the tube to hold it firmly in placeandafittingO-ringwhic holdtointo thetube itfirmly PTCor an plastic fitting) fitting The majority oftubefitting connections intheairbraked chas Tube FittingInstallationInstructions A DuraStar LL M Orange OR Secondary Brakesystem Secondary OR Orange ODELS upeP 1stTag Delivery PL Purple elwY Spring Air Suspension Brake System,Cab YL Yellow Brown BN Air Suspension system, 2nd Pusher Delivery Pusher system, 2nd Suspension Air BN Brown re NPrimaryBrakesystem GN Green White WH Solenoid Pack Supply Load Sensing Gauge,1stTagSensing PackSupplyLoad Solenoid Supply WH White ivrSIL Silver lc BK Black Color Abbreviation Where Used Where Abbreviation Color leB Trailer Delivery 1stPusher Service, BL Blue e DTrailer emergency RD Red a TN Tan ® (fitting threaded into an airbrakecomponent). SERIES Wet tankGovernor to WetAir Dryerto Tank Air Horn Air Seat MV-3, PPDCExhaust Governor toDryer Governor Supply PDL control,2ndPusher Two-speed axle Traction differential Locking differential, Supply 1st Pusher h seals the tube to the valve, manifold or tee body to preven sis utilizeaQuality Connect fitt cles, the following table illust – 155 – Both of thesefitting types are comprised of rates tubingcolor, abbreviations ing (fitting integraling (fitting toanai r brakecomponent or a collet whichbites t leakage.t To aidin andwhere that October, 2010 DuraStar® Series — Medium Conventional Body Builder Diagrams (CT-471) Push downon therelease tool, then pull on the tube. Pushing the Use thetube release tool(see graphic 1 below) to remove the tube. • • Removal ofTube fromFitting Removal andInsertionProcedures A DuraStar 1– Remove Tube 1– Test to makesurethe assembly is free fromleaks using a • Lubricate the tubeend and install ittothe correct insertion depth (seegraphic 3below). Install thetube bypushing it str • Installing Tube IntoThe Fitting thetube Inspect end forexternal scratches, burrs,orcracks. • Preparation of Tube forInstallation IMPORTANT: LL M leak exceeding theabove specification is stillpresent,remove and replace the valve, manifold or tee. bubble test,leakageshould not exceedasoapbubble(1 of1/2-inch fitting. Thefitting. insertion depthmarkshouldbeflushwiththe face is secured inthe fitting. (see graphic 2below)orreplace thetube. installingtube. the Sometimes the brass tube support will be pulled outof the fitting wh ODELS WARNING: air line tubing. Replace the blade or thebladeor linetubing.Replace air whichcouldcollapse orhack saw pocket knife (flatten) cutters, (supplied inthetoolkit) tubecutter Use the of airpressure before removing components maycause personal injury ordeath. Do not attempt todisassemble tubing from fittings with air pressure in the system. Failure todrainsystem ® SERIES 04_007 for Tubing inQCorPTCFittings cutter ifthecuttingedgebecomesdull. cutter 2 –Prepare for Installation DO NOT to ensure that the cut is square within 15 within thecutissquare to ensurethat reuse a damagedend. – 156 soap solution and clean, dryair at system pressure. When performing the tube or create O-ring damaging burrs. Do not use the tube notusethetube Do damagingburrs. createO-ring thetubeor If it isdamaged, trimthedamaged portion off at an insertion ofthe fitting(see graphic3below). Gently tug onthetube to tool depresses the fitting collet, allowing itto release th 2 mm) in 3 seconds with system air pressureseconds3 of100to130system air with mm) in ps 2 en the tubeisremoved.Besureto reinstall a tubesuppor ° to help prevent leakage. Do notusea tohelppreventleakage.Do 04_008 3–Install Tube theFitting into dull or heavy cutting tool such as side side heavycutting toolsuchas dull or cutter to cut anything other than nylon tocutanythingother cutter aight into the make sureit e tube. depth mark mark depth t when a i. Ifa 04_009 DuraStar® Series — Medium Conventional Body Builder Diagrams (CT-471) October, 2010 Air BrakeTubing –FrontSection A DuraStar LL M ODELS ANCHOR FITTING SUPPLY TO 1/2" ORANGE ® SERIES TO FITTING FOOT VALVE SUPPLY FROM 1/2" ORANGE – 157 – MODULATOR VALVE SUPPLY TO 1/2" ORANGE SUPPLY TO 1/2" ORANGE ANCHOR FITTING MODULATOR VALVE SUPPLY TO 1/2" ORANGE MODULATOR VALVE TO SPRINGBRAKE 3/8" ORANGE 04_0010 October, 2010 DuraStar® Series — Medium Conventional Body Builder Diagrams (CT-471) Air BrakeTubing –Rear A DuraStar LL M ODELS VALVE TO RELAY VALVE RELAY TO VALVE SIGNAL LINEFROMFOOT 3/8" GREEN TO RELAY VALVE SUPPLY FROMPRIMARY AIRTANK 5/8" GREEN(4x2);3/4"(6x4) Section –Tractor Brakes ® SERIES MODULATOR VALVE RELAY VALVE TO DELIVERY FROM 5/8" GREEN – 158 3/8" YELLOW MODULATOR VALVE RELAY VALVE TO DELIVERY FROM 5/8" GREEN 04_0011 DuraStar® Series — Medium Conventional Body Builder Diagrams (CT-471) October, 2010 Air BrakeTubing – Rear A DuraStar LL M ODELS TO QRV INVERSION VALVE DELIVERY FROM 3/8" YELLOW MODULATOR VALVE RELAY VALVE TO DELIVERY FROM 5/8" GREEN Section –Truck Brakes ® SERIES VALVE TO MODULATORVALVE DELIVERY FROM RELAY 5/8"GREEN – 159 – RELAY VALVE FOOT VALVE TO SIGNAL LINEFROM 3/8" GREEN OFRELAY VALVE TO BOTTOM PORT TANK TO RELAY VALVE SUPPLY FROMPRIMARY AIR 5/8" GREEN(4x2);3/4"(6x4) TO RELAY VALVE INVERSION VALVE SIGNAL LINEFROM 3/8" GREEN INVERSION VALVE TOX FITTING SIGNAL LINEFROM 3/8" ORANGE CONTROL VALVE SPRING BRAKE DELIVERY FROM 3/8” YELLOW 04_0012 October, 2010 DuraStar® Series — Medium Conventional Body Builder Diagrams (CT-471) Inside Cab&FootValve Plumbing A DuraStar LL M ODELS General Informationbook. schematic intheCT-400 please refertotheappropriate For connectionsnotshown, Supply toSpringBrakeControl Valve 3/8" Orange Supply fromSecondaryAirTank toFootValve 5/8" Orange ® SERIES – 160 Exhaust fromSpringBrakeControlValve 3/8" Black Supply fromPrimaryAirTank toFootValve 5/8" Green Delivery from Spring Brake Control ValveDelivery fromSpringBrakeControl 3/8" Yellow Dash Panel Supply toSpringBrakeControl Valve 3/8" Green 04_0013 DuraStar® Series — Medium Conventional Body Builder Diagrams (CT-471) October, 2010 Hydraulic ControlUnitPlumbing A DuraStar LL M ODELS leftrearbrake 1/4" tubeto ® brake right rear 1/4" tubeto SERIES service) Service Manualpriorto accumulators (seeISIS High pressurebrake cylinder (primary) 1/4" tubetomaster (secondary) master cylinder 1/4" tubeto – 161 – Back ofcabcrossmember 1/4" tubetorightfrontbrake cylinder reservoir 5/8" tubetomaster 1/4" tubetoleftfrontbrake 04_0014 October, 2010 DuraStar® Series — Medium Conventional Body Builder Diagrams (CT-471) With hydraulic brakes, the park brake assembly isattached to t Assembly Parking Brake A DuraStar cable. Dueto the construction of the cables, itisnot possible to alter the length. LL M ODELS With HydraulicBrakes ® SERIES BRAKE PARK – 162 he rear axle. Itismechanically actuated through the use of a t LEVER BRAKE PARK 04_0015 hree-section hree-section DuraStar® Series — Medium Conventional Body Builder Diagrams (CT-471) October, 2010 Air ABSECU(ElectricalControlUnit) A DuraStar LL M ODELS ® SERIES – 163 – ECU PASSENGER PANELINSTRUMENT SIDE 04_0016 October, 2010 DuraStar® Series — Medium Conventional Body Builder Diagrams (CT-471) With BrakesandAirEffectsRight Hydraulic Air Tank Location A DuraStar LL M ODELS ( E xcept 4x4) ® SERIES (455) 17.91 (504030) and Left( (504030) and (REF) 29 (672) (219) 8.62 CREW CAB DIA [Right Shown; Left Opposite] 504616) SideMounted – 164 EXT. CAB 26.60 66 (176) (676) 504616 504030 26.46 REG. CAB (660) 25.98 6.93 (REF) (220) 8.68 8.68 10.87 (276) FWD 04_0017 DuraStar® Series — Medium Conventional Body Builder Diagrams (CT-471) October, 2010 With AirBrakesLeft(508 Air Tank Location A DuraStar LL M ODELS FRONT (644.1 25.4 ) 003) SideMountedUnderBa A STD CAB B BACK OF (207.8) ® 8.2 E SERIES 508003 ++ BACK OF EXT CAB 35.4 (899.2 ) ttery Box,BackofCab BACK OF CREW CAB F C – 165 – + 04_0018 D Key 25(1.)14.9(379.2) 23.9(606.6) 12.5(318.3) 3.8 (96.7) D C . 123 5.4(137.4) 24.2(614.7) 1.6(41.7) 5.6 (142.3) 21.8(553.7) E 4.1 (103.8) B A 05(093 41.3(1048.3) 40.5(1029.3) F 8.5" Tank 11" Tank 11" Tank 8.5" Inch (Millimeter) Inch October, 2010 DuraStar® Series — Medium Conventional Body Builder Diagrams (CT-471) With AirBrakesLeft(504 Air Tank Location A DuraStar LL M (644.1) ODELS 25.4 FRONT B A 602) SideMountedUnder (969.9) 38.2 (880.2) ® 34.7 STD CAB BACK OF SERIES 504602 ++ (188.8) C 7.4 Battery Box,UnderCab EXT CAB BACK OF E D – 166 BACK OF CREW CAB + 04_0019 Key D 12.5 (318.3) 14.9 (379.2) 14.9 (96.7) 3.8 (318.3) 12.5 (102.4) 4.0 D C E 3.5 (89.9) 2.3 (59.0) 2.3 (614.7) 24.2 (41.7) 1.6 (89.9) 3.5 (553.7) 21.8 E (103.8) 4.1 B A 8.5" Tank 11" Tank 11" Tank 8.5" Inch (Millimeter) DuraStar® Series — Medium Conventional Body Builder Diagrams (CT-471) October, 2010 With AirBrakesLeft(504615) Air Tank Location M DuraStar ODELS LP, 4x2 Side Mounted, Back of Cab, SideMounted,Backof ® SERIES FWD With 19.5"Dia.Wheels 25.33 25.98 (643) (660) (219) 8.62 – 167 – 11 (859) (151) (REF) 5.96 DIA REG. CAB CAB EXT. 33.83 CREW CAB 15 (212) (155) 6.12 17.91 (455) 504615 8.34 (REF) 04_0020 October, 2010 DuraStar® Series — Medium Conventional Body Builder Diagrams (CT-471) With (5 AirBrakesRight Air Tank Location A DuraStar (606.6) 23.9 LL M ODELS FRONT B C A 504603 (except4x4) (188.8) (970.8) (880.2) 38.2 7.4 34.7 STD CAB BACK OF 04603) Side MountedUnder 04603) Side +++ +++ E ® D BACK OF EXT CAB SERIES CREW CAB BACK OF 04_0021 Battery Box, Under Cab Battery Box,Under Key 25(1.)14.9(379.2) 3.8(96.7) 12.5(318.3) (102.4) 4.0 D C . 8.)2.3(59.0) 24.2(616.7) 1.6(41.7) 3.5 (89.9) 21.8(553.7) E (103.8) 4.1 B A – 168 ."Tn 11" Tank Tank 8.5" Inch (Millimeter) Inch DuraStar® Series — Medium Conventional Body Builder Diagrams (CT-471) October, 2010 Codes 04EBD, 04EBS, and 04EBT Codes 04EBD,04EBS,and Air DryerLocation A DuraStar LL M ODELS LOCATION CODES ® ATR O ONE FRAME MOUNTED BATTERY BOX MOUNTED SERIES 13.19 35 (361) (335) 04EBT 8.40 504393 04VBC (213) (243) 9.58 – 169 – 4B 04EBD 04EBS 14.21 504396 504395 12.74 (324) 12.00 (305) 13.50 12.65 (343) (321) 504396 504395 04EBT 12. (308) 11 504396 504395 11.7 (299) 04_0022 12.50 (318) 9 (215) 8.46 October, 2010 DuraStar® Series — Medium Conventional Body Builder Diagrams (CT-471) Air Dryer 04EBD with Loc Air Dryer04EBDwith Air DryerLocation A DuraStar LL M ODELS ation Code504396– ® FWD SERIES Mounted LeftSideInside BACK OF STD CAB 504396 04EBD +++++ ++ (368.5 14.5 – 170 BACK OF (660.40 STD CAB 26.00 ) Rail,BackofRegCab ) (111.5 4.4 ) BACK OF STD CAB 18.00 (457.20 ) + + 04_0023 DuraStar® Series — Medium Conventional Body Builder Diagrams (CT-471) October, 2010 Air Dryer 04EBS with Locat Air Dryer04EBSwith Air DryerLocation A DuraStar LL M ODELS ion Code504395–M FWD ® SERIES ounted Right Side Inside Ra ounted RightSideInside 25.98 (660) (REF) 2.31 (59) CAB REG. – 171 – 4.72 (120) il, Back of StandardCab il, Backof CAB EXT. 504395 04EBS CAB CREW 17.91 (455) (REF) 04_0024 October, 2010 DuraStar® Series — Medium Conventional Body Builder Diagrams (CT-471) Air Dryer 04EBS with Locat Air Dryer04EBSwith Air DryerLocation A DuraStar LL M ODELS (except4x4) (REF) ion Code504396–Mount ® SERIES 45 (660) (455) 17.91 CAB CREW ed LeftSideInsideRail, CAB EXT. 14.78 (375) – 172 REG. CAB 4.72 (120) 25.98 BackofStandardCab 04EBS 504396 (REF) FWD 04_0025 DuraStar® Series — Medium Conventional Body Builder Diagrams (CT-471) October, 2010 Air Dryer04EBTwithLocationCode Air DryerLocation A DuraStar LL M ODELS ® SERIES FWD s 04VBC or 504393 – Mounted s 04VBCor504393–Mounted (660) 25.98 8.48 (215) (REF) – 173 – Left Side,BackofBa CAB REG. 4.30 (109) (21) .8 4 CAB EXT. ttery Box,UnderCab CREW CAB 504393 04EBT 04VBC 17.91 (455) (REF) 04_0026