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man-006 installation & service manual for fitment of sibs® onto

Contents

1. 48 Detailed Parts Inspection Brake 90 Brake Pads and Rotor Rotor Carrier 51 Wheel Bearings and Seals 52 EMMA Park Brake tnter tenni 57 57177 CRM 59 SIBS EMMA Troubleshooting Guide Page 3 006 REV 0 INSTALLATION amp SERVICING OF 51855 ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION ASB Advanced Braking Pty Ltd About this Manual This manual applies to the Sealed Integrated Braking System 51852 for TOYOTA HILUX vehicles It details how to fit the SIBS correctly While every effort has been made to address all the issues involved please advise Advanced Braking Technology of any errors or omissions and suggestions to improve the manual Vehicle Applications KUNT1 Series 3L Diesel Rear brakes only KUN2 Series 3L Diesel Full SIBS system KUN3 Series 3L Diesel Full SIBS system GGN 2 Series 4L Petrol Full SIBS system All variants must be fitted with 16 rims Rim 6 00JJ x 16 Steel Toyota P N 42611 OK250 Web page The most up to date version of the Manual can be downloaded from the web page www advancedbraking com On the right hand side click on
2. Advanced Braking Pty Ltd MAN 006 INSTALLATION amp SERVICE MANUAL FOR FITMENT OF 5185 ONTO TOYOTA HILUX VEHICLES SBY Change Revision Issue Issue Comments Approved Revision Date j _ 16 11 07 Initial Release Page 1 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION ABI Advanced Braking Pty Ltd About This Manual Vehicle Applications Web Page Terminology Contact Information 4 Important Information Installation of SIBS Safety Labels Storage e 5 Introduction Introduction to SIBS 6 Special Tools Special Tools Required During Installation 9 Inspection and Pre Installation Check SUGGESTIONS and Preparation a a a 10 SIBS Front Brake Assembly Drawing Exploded 11 Parts List 12 SIBS Rear Brake Assembly Drawing Exploded 14 UES e 15 SIBS Key Hydraulic and Electrical Components ee 17 Installation Procedures Installation Sequence a nnn nnns nnns 18 Installation of SIBS Brakes Front
3. 50 YANNI 068T ST W3HSVM YAddOD 98TE bC qaad 2402 DNISNOH YALNO 610Z Zb 810 2 SNISNOH 331000 8 06 Ct 01115 ONILNNOW Uva 0S8cC vc O80T ST NO QVd a3 vig SNIU O c00c cv YOLOY TSTT ST AlddIN 0S0c cv SNTdV3g TCOE ST guva 1 S 0v TO TWAS 14VHS LS0C cv ONTavad LINN GANIHOVW 0466 10 1104 0 TO H3HSVM SNTISdS 8STE TO 90ZE T0 5 ZOEE TO 1109 8 0 0 1108 1109 80b T0 WS ONISNOH LT106 2t sav HLIM 0006 29 dnd 3SVvau5 14 5 31XV 09ST ST J ddIN 3SV335 0202 104406 1V3S A Sv0C Cb Twas 1134 v00c cv H3AOO 1V3S vTOC Cv 1 T33HM 0806 41 098c vc NOV QVd a vua 800c cv NOLSId SDIAYAS 4606 10 334111 7607 10 SNTH O OSIA avd ASSY 4 SAIS ASB Advanced Braking Pty Ltd Parts list SIBS rear brake assembly To suit Hilux vehicles with and without ABS Part number 70 3006 42 9039 42 9038 42 9030 42 9000 42 9027 42 9017 42 2057 42 2053 42 2052 42 2050 42 2045 42 2018 42 2019 42 2020 42 2014 42 2011 42 2008 42 2004 42 2002 42 2001 24 4030 24 3186 24 2010 24 2
4. 5 1 Remove the 4 backing plate mounting nuts Remove the 4 nuts Pull out the axle shaft Take care not to damage the oil seal in the differential housing Oil seal in differential housing ABS rear axle shown oil seal in differential housing is mounted further inboard on ABS models Remove the OE brake pipes from the tee piece to the brake Remove the clamps from the brake pipes as these will be re used Remove the park brake cable by undoing the restraining bolts down the chassis Disconnect the switch and remove the park brake lever in the cabin Page 23 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBI Advanced Braking Pty Ltd 4 Install SIBS brakes rear axle shaft assemblies Installation is reverse of removal 4 1 The rear brake assemblies are supplied with M14 retractor bolts fitted to the spring cover These retract the EMMA piston and keep the springs compressed during shipment and assembly Do not remove the retractor bolts until after the EMMA system is connected and fully functional The vehicle should not be driven until the retractor bolts have been removed Rear brake assembly showing 4 x retractor bolts Do not remove retractor bolts until AFTER EMMA pump has been installed and is functioning correctly 4 2 Remove the 4 nuts and washers fitted to the studs on the bearing
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6. 13DVdS NIvad TcO ST guva duH lvdag YOUNIW SI A18W3SSV QNVH 1 NMOHS 18IW3SSV 1441 LNO H 3 LON TcOc cv GANIHOVW 1109 5 YANNI 010Z Zb 6007 2 15 YANNI HOSN3S SEV 0206 Zv k006 Zb 135vdS L 06 Ct 1795 LSNA anH xENNA LAN 06 Ct H1 ITANNA ITAONNA 2606 29 OEET ST Md TIIJ T0 Cb NOLSId SDIAYAS cT06 cv A18IN3SSV 90c TO 1109 100 1 T33HM cTOC CV Warguvo 1v3s cOTC TO ONTY O OSOE ST 0026 10 1104 ZOb T0 Was 14VHS 080T ST 4802 10 6607 10 SNTH O 9L0t TO W3HSVM 4 TSTT ST AlddIN DNISNOH YALNO LNO H ZZOZ ZH 02 YALNO 1 4 098c vc NOV QVd a Vua TT0 cb 6006 CNN INH LNOUS x NNY INH 1 1606 29 0 TO u3HSVM 45 0951 1 31ddIN 3SV315 2066 10 v00c cv 11049 0266 10 WAS Sv0C Cb 110d SNISNOH 1194 LT06 Ct dv LSNA 0c0c cv 1V3S A 8206 10 1104 8STE TO YaHSVM 80t TO TWaAS SNISNOH 0S8c vc NO QVd c00c cv WOLON OSIA LNOU ASSV 4 XNITH SAIS ASB Advanced Braking Pty Ltd
7. AXLE HOUSING SHOWN FOR CLARITY LOCATION FIT 0 015 MIN 0 075 MAX ET LOS MIN 0 08 MAX DETAIL C SCALE 2 1 To change a wheel bearing e Cold chisel and remove the bearing retainer on the axle shaft e Press the shaft through the bearing assembly e Remove the outer housing from the bearing carrier e Using suitable tools pull the bearing out of the bearing carrier assembly This should take the bearing collar pressed into the bearing carrier Drilling or chiseling of the bearing collar may be required Page 54 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBI 407m Advanced Braking Pty Ltd To assemble a new rear wheel bearing e Use the following new components 42 3057 Machined unit bearing 42 2052 Bearing collar 42 2053 Bearing retainer o 01 4075 Shaft seal e Prepare a bearing carrier assembly o Install a new shaft seal into the bearing carrier o Install a new Machined unit bearing Pack the bearing with grease prior to installation Timken recommend the use of a No 2 grease with an EP additive Note The bearing cup is attached to the bearing along the rib ring using adhesive It may become detached as this is only to aid with assembly If this happens the bearing can still be used as long as the cup is matched to the correct cone and rib ring o Insert a new bearing retainer as shown O O
8. Product Name SIBS COOLING FLUID Classified as hazardous according to criteria of NOHSC Remove all sources of ignition Increase ventilation Evacuate all unnecessary personnel Wear full protective equipment and clothing to minimise exposure If possible contain the spill Place inert non combustible absorbent material onto spillage Use clean non sparking tools to collect the material and place into a suitable labelled container If large quantities of this material enter the waterways contact the Environmental Protection Authority or your local Waste Management Authority 7 HANDLING AND STORAGE Handling Storage Repeated or prolonged contact with this material should be avoided in order to lessen the possibility of skin disorders It is essential that all who come into contact with this material maintain high standards of personal hygiene ie washing hands prior to eating drinking or going to the toilet Build up of mists in the working atmosphere must be prevented Combustible C1 liquid for storage and handling purposes Store in a cool dry well ventilated area out of direct sunlight Avoid sparks flames and other ignition sources Store away from incompatible materials such as materials that support combustion oxidising materials Reference should be made to Australian Standard AS1940 The storage and handling of flammable and combustible liquids 8 EXPOSURE CONTROLS PERSONAL PROTECTION Exposure Limits Resp
9. This EMMA system has one solenoid valve and internal cartridge filtration Functionality of this system is SOFT ue STOP only whereby a modulated FILTER SOLENOID BEI brake application occurs as the k VALVE pressure dumps via a relief valve 02 1005 EMMA PUMP HARNESS ASSY This is the system typically fitted to 100 series Landcruisers and the photo shows the system in situ Note the position of the pressure switch has moved otherwise the components remain the same as 02 1007 above PRESSURE SWITCH Procedure 1 Lift the bonnet locate the EMMA unit 2 Clean thoroughly around the relief valve and other hydraulic components Note A small amount of ATF leakage through the cap is normal however excessive leakage should be investigated 3 Using a 11 16 spanner loosen the locknut at the top of the relief valve TAF 010 Rev04 Page 3 15 11 2007 SBT os Advanced Braking Pty Ltd If only a small adjustment is required 4 Using a 3 16 Allen key turn the adjusting screw only 74 of a turn o CLOCKWISE to INCREASE Relief Valve Pressure Setting This will INCREASE the delay in EMMA brake application o ANTI CLOCKWISE to REDUCE Relief Valve Pressure Setting This will DECREASE the delay in EMMA brake application 5 Tighten the locknut and test drive the vehicle Adjust again if necessary Adjustment of relief valve using 11 16 spanner and 3 16 Allen key If a
10. UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION Material Safety Data Sheet Page lof 4 Infosafe No LPUSZ Issue Date January 2005 ISSUED by SAFEEFFE Product Name SIBS COOLING FLUID Classified as hazardous according to criteria of NOHSC 1 IDENTIFICATION OF THE SUBSTANCE PREPARATION AND COMPANY Product Name SIBS COOLING FLUID Product Use Coolant for Sealed Integrated Braking System Company Name SAFE EFFECT PTY LTD Address PO Box 632 Balcatta WA 6914 Australia Emergency Tel FOL 18279240 2713 Telephone Tel 61 8 9240 2713 Fax 61 9 9240 1577 Number Fax 2 COMPOSITION INFORMATION ON INGREDIENTS Ingredients Name CAS Proportion Liquid Hydrocarbons QUOS S Paraffins amp Naphthenes Ingredients determined Not required Balance not to De hazardous 3 HAZARDS IDENTIFICATION Classified as hazardous according to NOHSC criteria Not classified as dangerous goods according to the ADG Code Risk Phrases R65 Harmful may cause lung damage if swallowed Safety Phrases 562 If swallowed do not induce vomiting seek medical advice immediately and show this container or label 4 FIRST AID MEASURES Inhalation Remove the source of contamination or move the victim to fresh air Ensure airways are clear and have qualified person give oxygen through a facemask if breathing is difficult If irritation develops and persists seek medical attention Ingestion DO NOT induce vomiting Immediately wash ou
11. refer to page 34 Refer Toyota Repair Manual for diagnosis Adjust to correct pressures Replace brake line refer to page 18 Isolate damaged seals and replace components and SIBS oil Replace or repair refer to page 46 Replace brake pads lightly scour all rotors with 240 grit wet and dry sandpaper or Perform SIBS optimum performance procedure TBN 018 UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION Advanced Braking Pty Ltd SIBS EMMA TROUBLESHOOTING GUIDE Brakes judder and or pulsing pedal during braking EMMA park brake will not release Oil leaks from EMMA spring covers Damaged brake rotor or brake pads resulting from loss of SIBS oil from housing Cab door open either side Circuit breaker protecting motor has tripped EMMA park brake hydraulic system faulty EMMA control switch will not operate Seals damaged worn or backup rings fitted incorrectly Page 63 Check and identify cause and replace damaged components Close door and or check door switch Investigate cause of current overload and rectify Reset circuit breaker Check system operating pressure If insufficient pressure check for hydraulic system leaks replace faulty components Check amp replace EMMA control switch and wiring Replace or reassemble seals Refer to page 55 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES
12. 8 x M6 bolts and torque to 15Nm Note the seal cover should be rigidly bonded to the outer housing to ensure it imparts stiffness to the brake assembly Page 47 006 REV 0 INSTALLATION amp SERVICING OF 518595 ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBI 407m Advanced Braking Pty Ltd Inspection Maintenance Strip Down All brake parts should be examined thoroughly and brake pads rotors piston brake fluid seals and oil dust seals replaced during reassembly if required With the fitting of new piston O rings a slight binding of the brake may occur until seals have bedded Therefore replacing seals on both side of the axle is recommended Procedure Remove the wheel e Clean the external surface of the brake prior to disassembly e Drain the SIBS Fluid from the brake housing by removing the drain plugs from the inner housings Important When removing the outer housing on the rear brake assemblies there should be no spring force on the outer housing Use the EMMA pump to hold off the spring force and install the retractor bolts The hydraulic pressure can then be released Hint if the EMMA pump is disconnected not working use a manual hydraulic pump e g Enerpac Remove the outer housing the same process is used for the front and rear brake assemblies e Remove the Toyota grease cup using a screwdriver and a hammer e Remove the housing bolts around the
13. ABS pulse wheels and retainers are OE components Use the SIBS bearing carrier 42 2003 and seal 01 4075 Page 53 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION ASB Advanced Braking Pty Ltd 21 Figure 11a Arrangement of Timken unitized bearing in SIBS rear brake assemblies The OD of the bearing is restrained by a bearing collar pressed into the bearing carrier Pd V L emt DENDO S 4 Ss gt m Bearing collar on axle shaft n Eg A shaft seal is located in front of the bearing in the carrier LITT 710 The bearing is pressed onto the shaft A retaining collar is pressed onto the axle shaft after the bearing NNNNNNNNN u aa m a Bearing retainer pressed into bearing carrier 77 0 3 MIN GAP 0 9 MAX LS loa ae BEARING MUST f BE FULLY PRESSED Figure 1 1 b AGAINST HERE Closer view of Timken unitized bearing assembly Parts used POSITIVE CLAMPIN REQUIRED HERE AT ALL TIMES 24 in M exe 42 2050 Bearing carrier 42 3057 Machined unit bearing 42 2052 Bearing collar TENIS IT 42 2053 Bearing retainer rage Gee 01 4075 Shaft seal
14. EMMA brake engagement time is excessive adjust relief valve If no change consider changing EMMA filter o Ensure service brakes are functioning correctly and the vehicle is not pulling to one side Change oil and perform TBN 018 Optimum performance procedure to rectify vehicle pulling Minor service 5 000 7 500 km depending on conditions Complete two weekly service Put vehicle on hoist and remove wheels Inspect felt seals replace as required Inspect for leaking housing seals replace as required Drain SIBS oil from all four brakes Perform Optimum performance procedure TBN 018 try to get even temperature on all four brakes to ensure all friction surfaces are restored Allow brakes to cool Replace SIBS oil with 800ml of fluid per housing Refer to Figures 1 amp 2 for location of fill amp drain plugs Inspect for leaking housing seals replace as required Test drive o EMMA brakes refer above o Service brakes refer above Any issues that are not rectified by above procedure may require removal of outer housing for further investigation Major service 20 000 50 000km 12 months Put vehicle on hoist and remove wheels Page 39 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBI 407 Advanced Braking Pty Ltd e Remove outer housing using recommended practice e Measure pad wear Replace pad
15. Hilux x TAF 010 Rev04 Page 1 15 11 2007 ABI Advanced Braking Pty Ltd Technical Bulletin TBN 019 Product EMMA Brake Subject Adjustment of EMMA relief valve to change the delay in application of EMMA Brake Summary e his procedure specifically relates to the newer EMMA manifolds with one solenoid valve o With this system there is no HARD STOP option only the SOFT STOP option o When EMMA brake application is called for either by pressing the operator button or triggering the interlock when fitted a modulated brake application occurs as the pressure dumps via a relief valve o This Procedure can be used to negate the effect of the relief valve to provide a HARD STOP only This is only recommended when the vehicle is operated at low speed as full EMMA application at higher speeds will cause the rear wheels to lock e The Procedure can also be used to adjust the EMMA relief valve if the application of the EMMA v brake is either too rapid causing the brakes to lock or too slow e The relief valve is typically set to 350psi Recommended tools To carry out this procedure the following items will be required 1 Spanner 11 16 2 Allen key 3 16 oi TAF 010 Rev04 Page 2 15 11 2007 osi ka SGS SBI 407 Advanced Braking Pty Ltd Description 02 1007 EMMA PUMP HARNESS ASSY This is the system typically fitted to 78 79 series Landcruisers as well as Hilux models
16. Refer Figure 8 below Front BUW note position x uum Brake fluid this side Rear service piston Front service piston Figure 8 O ring and BUW arrangement on service pistons e Install pistons into housing Ensure the bleed nipples are open IMPORTANT The two service piston o rings are dissimilar materials Only use Silicone grease to lubricate the o rings and bores prior to assembly Detailed parts inspection Brake Housings e Ensure the brake housings are still firmly bolted to the axle or spindle o Check for signs of leakage o Replace mounting gasket bolts and lock tabs if required Use Brakeclean to clean piston bores Inspect for signs of corrosion wear or pitting Use fine emery paper 2400 grit to remove any corrosion e Smear piston bores with Silicone grease after cleaning Do not use brake fluid or SIBS fluid for this purpose Page 50 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBI 407m Advanced Braking Pty Ltd Housing bolts Check heads of housing bolts In corrosive environments it is recommended that all housing bolts be replaced Note stainless steel bolts cap screws are available as an alternative SAF P N 01 3237 Brake Pads Brake pads replacement Front Wheel Rear Wheel Original thickness 14 0 mm Original thickness 14 0 mm Replace if 11 0 mm Replace if 12 5 mm
17. Remove the fill plug and fill the system with fresh SIBS Fluid through this port using only SIBS Fluid Fill each brake assembly with 800ml of SIBS fluid E FIGURE 2 Rear brake drain and filler plug locations FIGURE 1 Front brake drain and filler plug locations SIBS Fluid Volume in Brake Assemblies e Each Front Assembly 0 8 litre e Each Rear Assembly 0 8 litre Page 43 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBI Advanced Braking Pty Ltd Grease felt seal N e Figure 3 Rotor carrier grease nipple o Remove wheels Apply grease and rotate hub axle shaft slowly Minimum 5 pumps every two weeks Grease nipple Note check state of felt seal and replace if necessary 8 x M6 Seal cover bolts Changing the felt seal 3 M5 felt seal support bolts Apply Caterpillar Contact Cement P N 5H2471 or equivalent Brake to be fully assembled to axle or Knuckle prior to installing Apply clean good quality machine oil to seal surface after adhesive has cured Figure 4 Changing the felt seal e Loosen and remove the 3 x 5 felt seal support bolts e Remove the used seal e Clean the bore Check for signs of leaking of the main housing seal If the housing seal requires changing follow the procedure set out below e Apply contact cement to the surface o
18. SPRING APPLIED HYDRAULIC RELEASE PARK BRAKE gt 0 ISSUED FOR FIRST RELEASE Pe 10 0 Eve _ Advanced Braking Technology Ltd TLE LCVS MANUAL RELEASE PROPRIETARY DOCUMENT TOLERANCES UNLESS SPECIFIED DIMENSIONS IN MILLIMETRES UNLESS OTHERWISE STATED THIS DOCUMENT REMAINS THE PROPERTY OF ADVANCED O PLACES 10 1PLACE 0 25 MATERIAL pate P2710707 T oo BRAKING TECHNOLOGY Pty Ltd AND MAY NOT BE COPIED OR 2 PLACES 015 ANGLES 0 5 REPRODUCED IN WHOLE OR PART OR COMMUNICATED TO SURFACE FINISH u t SS OTHER PARTIES WITHOUT THE PERMISSION OF ADVANCED 5 pate 00 uen BRAKING TECHNOLOGY Pty 2007 Description TAF 010 04 ABT Advanced Braking Pty Ltd To Quick Release Page 4 The original hydraulic line running under the vehicle from the EMMA pump in the engine bay to the EMMA brake at the rear is replaced by a 3 way valve and 3 hoses The photo left shows the 3 way valve bracketed to the underside of the vehicle below the cab The pipe to the Quick Release connector runs up into the vehicle cab The pipe to the brake continues back to the EMMA brake at the rear The 3 way valve handle is shown in the photo on the left in its fixed location on the cab floor The handle is in the position for normal vehicle operation The red arrow shows the handle movement required to isolate the EMMA pump circuit and allow th
19. around and use the return on the seal cover to fit over the return on the steel cassette seal Note the words OIL SIDE and AIR SIDE that are printed on the cassette seal o Using longer M6 bolts and nuts walk the cassette seal into the bore of the outer housing by tightening the nuts diagonally opposite each other approx 1 turn each IMPORTANT Ensure the seal goes in straight Page 46 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION Advanced Braking Pty Ltd Outer housing Figure 5 Installation of housing seal Cassette seal shown SAF P N 01 4083 Flip the seal retainer and use longer M6 bolts and nuts not shown to walk the seal into the housing bore Ensure the seal goes in straight Seal retainer Note orientation is flipped to Cassette seal SAF P N 01 4083 facilitate installation of cassette seal Use longer M6 bolts and nuts to walk the housing seal in straight e Continue tightening the nuts until the top surface of the seal is flush with the outer housing e Remove the seal cover e The seal cover must now be installed in the correct orientation Refer to Figure 3 e Clean the surfaces of the outer housing and seal cover that will be in contact e Apply LOCTITE 515 to the seal cover surface that will be in contact with the outer housing Install the
20. assembly and disassembly of the brake units Note it may also be necessary to manufacture other spacers for pressing bearings seals and locking collars SST Toyota rear axle shaft special tool Toyota P N 09521 25011 Bearing puller Toyota P N 09710 30021 Page 9 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBT J Advanced Braking Pty Ltd Inspection and Pre Installation Check Remove the parts from their packaging and carefully check that the kit contains all the parts listed on the delivery document Familiarize yourself with each part and learn where it goes Keep the parts clean at all times WARNING A SIBS unit must not be contaminated with any external matter that may adversely affect its operation and reliability Suggestions e Inspect each brake and supplied items against the packing list included in the shipment e Ensure all items are included as described e Ensure all components remain in their original packaging until required for assembly e Thoroughly read the Service Manual Familiarize yourself with the tools required and prepare them for use familiarize yourself with the parts of the brake and the process required for fitting each brake and control system e Ensure complete cleanliness of all brake components and the working environment around the vehicle e Ensure no contamination of the brake as
21. carrier assembly Remove 4 x nuts and washers fitted to the mounting studs on the bearing carrier assembly These are left on during shipping to ensure the inner housing and bearing carrier remains sealed Page 24 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION Advanced Braking Pty Ltd Remove any tape that may be wrapped around the spline on the axle shaft This is applied to protect the spline during shipping 4 3 If fitting to an ABS vehicle install the ABS pulse wheel and retainer 4 3 1 On the OE assembly measure the distance from the back of the bearing carrier to the start of the pulse wheel 4 3 2 Install the pulse wheel and retainer on to the SIBS assembly up to the same position Measure the position from the bearing carrier to the pulse wheel on the OE axle shaft assembly Install the pulse wheel and bearing retainer to the SIBS axle shaft assembly to the same position 4 4 Install a new oil seal in the differential housing d Install a new oil seal in the differential housing Toyota recommends the use of a special tool Toyota P N 09950 60020 Page 25 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBI 407mm Advanced Braking Pty Ltd 4 5 Install a new o ring to the spigot of the diffe
22. however is labelled in accordance with the National Occupational Health and Safety Commission s National Code of Practice for the Labelling of Workplace Substances 16 OTHER INFORMATION SDS History MSDS Creation January 2005 End Of MSDS SBI Advanced Braking Pty Ltd Service History Record Sheet SERVICED BY ACTIVITY DATE ODOMETER READING SERVICE KM Page 68 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBI 40 7m Advanced Braking Pty Ltd Notes Page 69 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBT 9 Advanced Braking Pty Ltd Appendix Included in this Appendix are the following documents Technical Bulletins TBN 019 Adjustment of EMMA Relief Valve TBN 032 Fitment of EMMA Manual Release System Page 70 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBI Advanced Braking Pty Ltd Technical Bulletin TBN 019 Product EMMA Brake Subject Adjustment of EMMA relief valve to change the delay in application of EMMA Brake Change Revision Issue Revision Issue Date Comments 00 30 August 2006 Initial Release 01 15 November 2007 Updated to include
23. maintenance for a SIBS system in a Toyota HILUX vehicle application as detailed above All information contained in this manual is based on the latest SIBS product information available at the time of publication Advanced Braking Technology Ltd reserves the right to change the manual at any time without prior notice This manual should be read in conjunction with the appropriate Toyota chassis manual for further information on removal of any standard Toyota components Advanced Braking Technology welcomes any queries or feedback on the contents of this manual Installation of SIBS SIBS must be installed by a qualified tradesperson who has undergone the required training by ABT and has been licensed by ABT to do so The silica gel sachets must be removed from the brake assemblies prior to installation Safety Labels Advanced Braking Technology provides customers with Safety Labels that are required to be placed prominently in any vehicle fitted with SIBS Storage of SIBS All SIBS units are protected against corrosion and may be stored for up to 3 months before installation Plugs are fitted in the brake fluid inlet ports of housings these should be kept in place during storage or shipping to prevent corrosion Any SIBS that remains unfitted for a period longer than 3 months must be inspected thoroughly before use Page 5 006 REV 0 INSTALLATION amp SERVICING OF 51855 ON TOYOTA HILUX VEHICLES UNCONTROLLE
24. nstallation Manual You may be asked for a username and password Username 5 85 Password resellers note case sensitive Technical Bulletins relevant to the system are also posted in this area Terminology SIBS Sealed Integrated Braking System EMMA Electronically Modulated Mechanically Applied SIBS Fluid Specially formulated cooling fluid used in SIBS brakes Service Brake Brakes applied when driving Park Brake Brakes applied when vehicle is parked Emergency Brake Brakes applied in an emergency PECB Park Emergency Control Box Contact information Advanced Braking Pty Ltd Unit 1 3 McDonald Street West Email info advancedbraking com Osborne Park W A 6017 Web www advancedbraking com AUSTRALIA Phone 61 0 8 9273 4800 Postal address Fax 61 0 8 9201 9986 PO BOX 1177 Osborne Park WA 6916 Page 4 MAN 006 REV 0 INSTALLATION amp SERVICING SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION ASB Advanced Braking Pty Ltd Important Information Ownership of SIBS The SIBS Patent and Trademarks are owned by Advanced Braking Technology Ltd Manual Information This manual has been prepared to assist customers maintenance personnel and operators of SIBS It should be read thoroughly and understood to ensure that the product is installed utilised and maintained properly This manual provides instructions for the retrofitting installation service and
25. the pump of any foreign matter If this is not successful investigate the check valve on the side of the pump as foreign material may become stuck under the valve and hold it open preventing the pump from building pressure 5 10 With the EMMA brake released i e pressure in the system remove the retractor bolts and replace with plugs to prevent ingress of water and dirt into the spring cavity 6 Bleed the service brakes Use standard workshop procedure Ensure the brake fluid level in the master cylinder does not run dry Service brake bleed nipples on rear Note housings e There is 1 service brake bleed nipple per front brake e There are 2 service brake bleed nipples per rear brake e Bleed the load proportioning valve Page 37 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBI 407 Advanced Braking Pty Ltd 7 Adjustment of the Relief Valve The relief valve can be adjusted if required to change the delay in application of the EMMA Brake The procedure for this adjustment is detailed in Technical Bulletin TBN 019 which can be found in the Appendix at the back of this document 8 Adjust the load proportioning valve 8 1 Correct operation of SIBS requires a functioning and correctly set Load Sensing Proportioning Valve LSPV For the adjustment procedure follow that set out in the standard To
26. water traps used in reverse the inlet from the brake is at the bottom and the outlet to the paper type filter is at either position 1 or 3 at the top 4 10 1 Locate a suitable position to install the expansion chambers Drill holes as required Use the M8 nuts and bolts provided Ensure that the expansion chambers will not be impacted by the axle even during extreme axle movements Note breather pipes cross over LH breather is connected to RH brake as shown 4 10 2 Drill holes in the under tray and use the M8 nuts and bolts to provided to mount the expansion chambers 4 10 3 Fit the red hose to the bottom of the chambers Note the LH breather hose feeds into the bottom of the RH expansion chamber Ensure there is sufficient length of hose when the vehicle is on the hoist the axle will be at its lowest position 4 10 4 Fit a length of 5 16 ID black fuel hose to the top barbs of both rear expansion chambers at ports no 2 or 3 and join with a tee piece see figure below Page 27 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBI Advanced Braking Pty Ltd _ pu Barbs at position no 2 Tee piece hose connector D 5 to suit 5 16 hose anas 4 10 5 Run the outlet from the tee piece to a paper type in line fuel filter mount filter as high on the vehicle as possible Use the 50mm half sa
27. 06 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBI J Advanced Braking Pty Ltd Both front assemblies provide service braking only The rear assemblies provide service brake EMMA park brake and emergency brake All the service pistons are actuated by a brake master cylinder the pistons are applied by disc springs and released by hydraulic pressure from a standalone pump unit This system is referred to as an Electronically Modulated Mechanically Applied EMMA fail safe braking mechanism system Page 7 006 REV 0 INSTALLATION amp SERVICING OF 51855 ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBI Advanced Braking Pty Ltd Special Tools The following items shown are required for the installation of a full SIBS brake set Dowel Guide Pins M10 x 1 5 Master Cylinder Setup Tool Manufacture From Long Bolts Toyota Part Number 09737 00013 Only required if master cylinder is replaced LSPV Gauge Set Nutserts amp Insertion Tool Toyota Part Number 09709 29018 Textron Part Number 39006 28035 Page 8 006 REV 0 INSTALLATION amp SERVICING OF 51855 ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION ABI Advanced Braking Pty Ltd Vacuum Pressure Gauge Other tools may be required during
28. 19 Rear 23 Installation of EMMA System nn nn nn aaaaT a 29 EMMA System Electrical Schematic J n aaa 30 Check EMMA System Operation I I I nn narsa sa 36 Bleed EMMA System sse terrre 37 Bleed Service Brak8S uuuuu TE 37 Adjustment Of EMMA Relief Valve eee 38 Adjustment Of Load Proportioning Valve 38 Servicing Procedures Service Intervals a 39 Recommended Parts E dU vam 40 Torque of Critical Bolts and Nuts a 41 PMCS USC M c 42 Handling and Disposal of SIBS Fluid e 43 Replacing SIBS Fluid Fluid Volumes ee nne 43 Changing Grease Felt Seal r aa 44 Changing Housing UN UE 45 Page 2 006 REV 0 INSTALLATION amp SERVICING SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION ASB Advanced Braking Pty Ltd Inspection Maintenance Strip Down Procedure
29. 860 24 2850 24 2815 15 4060 15 4050 15 3750 15 3050 15 3021 15 2781 15 2530 15 2080 15 1890 N N EMMA cover plug Nut Rear mounting stud Hilux rear axle shaft Hilux rear axle shaft with _ Circlip Dust cap Machined unit bearing Bearing retainer Bearing collar Bearing carrier Felt seal Rear outer housing RH Rear outer housing LH V seal support Wheel stud Rotor carrier Service piston Seal cover Rotor Inner housing RH Inner housing LH O ring EMMA minor EMMA feed EMMA piston Brake pad ACW Brake pad CW Link pipe O ring EMMA major O ring EMMA major Disc spring Dowel pin Breather barb Spring cover Retractor bolt Spring cover gasket Copper washer UJ 09 Page 15 Qty 4 IN Ns OO T s N Supplied separately with kit Fitted on Installation Manufactured from OE part standard bearing Manufactured Manufactured Manufactured Manufactured Manufactured Manufactured Manufactured Manufactured Inner housing Manufactured Manufactured MAN 006 REV 0 INSTALLATION amp SERVICING OF 51855 ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION ASB Advanced Braking Pty Ltd 10 1 1 1 4 1 1 1 4 3 Feltseal cover 3 Feltseal cover 4 Mounting 12 2 _ Rotor carrier 8 Seal cover 8 S
30. A covers to avoid bending of the cover or pistons To remove the EMMA covers the rear inner housings should be removed from the axle e Ensure that the retractor bolts are installed and tight in the spring covers compressing the EMMA springs This can be easily achieved by charging the EMMA system prior to Installing the retractor bolts e Clamp the flexible service hose to the rear axle to prevent leakage of brake fluid Disconnect brake pipes and hoses from the housing e Remove mounting lock nuts Remove inner housing e Remove the outer spring cover bolts by undoing slowly in sequence e Discard spring cover bolts e Once allten bolts are removed the retractor bolts can be wound out in sequence one turn at a time relieving tension on EMMA springs e Lift off the spring cover e Remove the disc springs Check for cracking and replace as required On installation ensure the springs are well greased Page 57 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBI Advanced Braking Pty Ltd e Inspect for signs of ATF in with the disc springs as this will indicate there is a leakage of ATF past the large EMMA o ring e Push out the EMMA park brake pistons and check O ring seal for damage or wear Hint manufacture a slide hammer from a retractor bolt for this purpose e Clean and inspect EMMA piston bores for corrosion pitt
31. BS fluid Brakes drag Incorrectly adjusted Refer to Toyota Repair vacuum booster master Manual for adjustment cylinder push rod Brakes shudder at very Additives in SIBS fluid Replace fluid end of stop only have broken down and lost effectiveness Page 61 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION ASB Advanced Braking Pty Ltd SIBS EMMA TROUBLESHOOTING GUIDE Issue Description Possible Cause Solution Brakes are not releasing fully after operation Vehicle pulls to one side during braking MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES Seized or jammed service piston Seized or jammed EMMA piston Blocked or damaged brake line Damaged brake rotor nub assembly EMMA park brake hydraulic system faulty Faulty master cylinder Incorrect tyre pressures Blocked or damaged brake line Contamination of SIBS oil damaged oil seals Seized or jammed pistons Damaged brake pads or polished rotor Page 62 Replace or repair Refer to page 46 Replace or repair Refer to page 55 Replace brake line refer to page 18 Replace brake rotor and hub assembly refer to page 46 Check system operating pressure and hydraulic system leaks Check for leaks in system and fluid lines Check for correct operation of EMMA Charge Module
32. Brake pads should be free of damage distortion and or blocked grooves Before reusing brake pads it is recommended to lightly buff the surface of the pads with 240 grit wet and dry sand paper This will help ensure consistent brake performance Ensure front brake pads are 14 groove 24 2850 amp 24 2860 WARNING Thickness of rear brake pads is critical Brake pads below replacement thickness will result in increased travel of EMMA piston and reduced braking force Rotor Inspect the spline for damage or wear Replace rotor if the teeth of the spline are visibly stepped Before replacing the rotor lightly buff both friction surfaces of the rotor using 240 grit wet and dry sand paper This will help ensure consistent brake performance Rotor carrier e Inspect hub spline for damage and wear Replace hub if the teeth of the spline are visibly stepped e Inspect wheel and drive studs for damage Replace as required Page 51 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION Advanced Braking Pty Ltd Wheel bearings and seals The rear bearing carrier seal the rear axle shaft oil seal and the front bearing carrier seal are essential to seal the SIBS brake units for effective operation Any bearing grease or differential oil which mixes with the SIBS Fluid may reduce braking efficiency During assembly the re
33. D COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION Advanced Braking Pty Ltd Introduction Figure 1 Exploded assembly diagram of a typical rear SIBS brake Your Sealed Integrated Braking System SIBS shown above as exploded view in figure 1 is a unique new product leading the way in motion control technology SIBS is an enclosed single rotor high speed disc brake It provides greater reliability in a compact enclosed package SIBS design and development is primarily concerned with e Safety e Advanced Technology e Simplicity A SIBS is simple to install simple to operate and increases reliability significantly It utilizes conventional actuation and can be applied to any rotary equipment large or small industrial or automotive on and off road A SIBS incorporates a service brake a park brake and an emergency brake into a single brake It is an Australian invention that is patented worldwide It is the only brake in the world that is able to perform consistently every time regardless of its environment while requiring minimal maintenance throughout its life under the most demanding braking applications A SIBS set comprises four individual brakes Each fully sealed brake consists of a sliding rotor brake pads and a small quantity of specially formulated SIBS fluid Because it is fully sealed there is no ingress of foreign substances and brake debris is not released into the atmosphere Page 6 MAN 0
34. ERSION lO JO IO ON Bias Ll I JON F66L S FLA 3INSV S3ONVHAITOL SNOISNAIMIG L321d33 NI 0 4202 20 Va HSINIA 39V43ns S32V1d Z 9010 61 ALVA Nad of OF ISHIONW lt 10 900061 Naaj Sr sior eaoviaz 141915 ASIMYSHLO 5541 SAYLAWITINN NI SNOISNAWIC 1315419345 SS31Nf SH3ONVH310 LL 14 5 30 VWW3 OILVW3HOS TvOIl31O313 JILL pq Abojouysa Bulyeig paoueApy 3JSv3132 1634 404 990551 O 441316 31IHM N333O M UD JLIHM M 341316 31IHM 3f118 M I8 44 ug A38MO AO 4019 Ig MOTI3A A N338O uo J 3OVv18 38 SANO TOO JAIM AN4941 JUIN zUJUJ S 0 ASN 551 4 NISVO SedHIO TIY 404 WWE L L ASN SNOILOJNNOO JOLIOW 4 4 zulu S r ASN SS3N3VH AVE 3NION3 V 4 3614 3dAL 3Q V 18 TIVWS 105 OL 3I3d1OH 3515 Q31v3s 55344405 3dOIQ AGNIONI S103 GIONHIOS JATVA 13ddOd N3dO ATIVWYON NO 9 5 GIONH3IOS YOLOW Ol41313 AZL dWNd NOLIOW MOD GION31OS A F1 6 SNONNILNOD V NIW AVJ 83AO3ONVHO 310d JIONIS GION3IOS Ar 1 6 SNONNILNOD V NIW AV 133 N3dO ATIVW3ON 31Od 319NIS 55344405 3GOId HLM TIOO GION3IOS A Y l 6 INIJANO 5 001 NIW SNONNILNOD V 05 NIW N3dO ATIVW3ON 310d JIONIS POW 006 POW 08 N3349 031 4 141 1 1 8 3415
35. HARD STOP only is required 6 Using a 3 16 Allen key turn the adjusting screw ANTI CLOCKWISE as far as the adjustment will allow this relief valve has a minimum setting of 100psi f Tighten the locknut 8 Test drive the vehicle If EMMA brake application is still delayed the filter unit may need changing WARNING It is not recommended to operate a vehicle at high speed with the minimum pressure setting on the relief valve as full EMMA brake application at high speed will cause the rear wheels to lock Prepared by otuart Millgate Approved by Andrew Miller Chief Engineer Issue Date 15 November 2007 Issue Revision 01 Advanced Braking Pty Ltd Unit 1 3 McDonald Street West Tel 61 08 9273 4800 Osborne Park WA 6017 Fax 61 08 9201 9986 AUSTRALIA Email info perth advancedbraking com PO Box 1177 Web www advancedbraking com Osborne Park WA 6916 TAF 010 Rev04 Page 4 15 11 2007 ABI Advanced Braking Pty Ltd Technical Bulletin TBN 032 Product EMMA Brake Subject Fitment of EMMA Brake Manual Release System Change Revision IssueRevision lssueDate Comments 0 16 November 2007 Initial Release 010 04 Page 1 15 11 2007 SBT oe Advanced Braking Pty Ltd Technical Bulletin TBN 032 Product EMMA Brake Subject Fitment of EMMA Brake Manual Release System Summary The Manual Release System allows the EMMA Brak
36. O Figure 13a o Slide bearing carrier assembly over axle as shown o Apply Loctite 515 between housing and bearing carrier Page 55 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION ABTT Advanced Braking Pty Ltd Figure 13b o Slide on the bearing retainer o Timken recommend that the bearing and retainer are pressed at the same time o Press onto axle using an appropriately sized spacer and the Toyota tool P N 09521 25011 Figure 13c o Press bearing and bearing retainer firmly against the axle shaft Figure 13d o Finally attach the flange nuts to the mounting studs and the circlip to the axle Page 56 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION ABI 407m Advanced Braking Pty Ltd Figure 14 To install ABS pulse wheel on ABS models o Measure the position from the bearing carrier to the pulse wheel on the OE axle shaft assembly Install the pulse wheel and bearing retainer to the SIBS axle shaft assembly to the same position EMMA Park Brake Inspection Inspection of EMMA pistons Belleville washers and replacement of EMMA piston o rings and back up rings will only be required every second Major service Note the EMMA covers are under spring tension Take care when removing EMM
37. Parts list SIBS front brake assembly To suit Hilux vehicles with and without ABS Part number Comment 42 9036 Spacer KUN2 1 OE part 42 9028 Hub adjusting nut KUN3 42 9037 Hub dust seal OE part Knuckle RH Manufactured from OE Knuckle LH 1 part Knuckle RH ABS Knuckle LH ABS 42 9017 OE part 42 9012 Bearing assembly Manufactured from OE part 42 9009 Hub front KUN2 1 Manufactured from OE 42 9031 Hub front part 42 9020 ABS sensor front 42 2045 Manufactured 42 2022 Front outer housing RH 42 2021 Mounting bolt machined Manufactured 42 9018 42 9017 OEpat 006 42 2045 0 6 Manufactured 00 42 2021___ Manufactured 0006 42 2014 Wheel stud 6 Manufactured 42 2010 Inner housing RH 15 9021 Breather barbo 00011 0 00 15 1560 Grease nipple 1 15 1341 jJDrinpug M 15 1331 1 1 m 15 1151 Bleed nippe 1 15 1080 O ring Housing 1 01 4083 Housing seal tS 01 4073 5 1 j Page 12 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBI Advanced Braking Pty Ltd 01 3220 Housingbolt 12 01 3158 Washr 018 Sealcover 000000 01 3078 re ee 01 2102 O ring Inner housing mounting 01 2099 O 29 EH 4 4 Sericepis
38. VICING SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBI Advanced Braking Pty Ltd 2 Install red breather hose This prevents build up of pressure within the brake under severe driving conditions 2 7 1 Measure 1 5m of red breather hose 1 4 ID and cut 2 2 Install red breather hose onto the hose connector on the inner housing 2 3 Restrain the hose to the hose connector with jubilee type hose clamp 2 4 Feed the hose up the inner guard and into the engine bay 2 5 Restrain the hose to the service brake hose clip with a cable tie 2 7 6 Restrain the hose to the inner guard with p clamp C Restrain red breather hose Ensure the hose will not rub on any suspension components at full lock Cable tie hose to service brake hose clip K B Hose clamp Restrain red breather hose at the top of the inner guard Use a p clamp fitted to the chassis C P clamp 2 8 Install expansion chambers Expansion chambers allow the brake to vent without allowing ingress of dirt The expansion chambers are diesel water traps used in reverse the inlet from the brake is at the bottom and the outlet to the paper type filter is at either position 1 or 3 at the top Page 21 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBI Advanced Braking P
39. allation Procedures Installation Sequence SIBS brakes for Toyota Hilux are supplied assembled onto the front steering knuckle and rear axle shaft The installation sequence is as detailed below Install front SIBS knuckle assemblies left amp right Install rear SIBS axle shaft assemblies left amp right EMMA Engine Bay Pump Assembly under the bonnet EMMA PECB and Cabin Harness inside cabin Bleeding of the EMMA system Bleeding the service brake system Test drive followed by a second bleed of the service brakes Page 18 006 REV 0 INSTALLATION amp SERVICING OF 51855 ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION ASB Advanced Braking Pty Ltd Installation of SIBS brakes front 1 Remove the OE steering knuckle assembly Note procedure below is a truncated version of that found in the Toyota manual if in doubt refer to Toyota manual Remove front wheel Remove front speed sensors if ABS vehicle Remove brake line Disconnect tie rod end sub assembly 1 4 1 Remove cotter pin amp nut x pue Toyota manual showing special tool to disconnect tie lt lt rod end from steering knuckle 2 NI 1 5 Remove the 2 bolts and disconnect the suspension arm from the steering knuckle 1 6 Remove the clip and nut from the upper arm assembly gt Toyota manual showing special VTE s M tool to disconnect the ste
40. ar axle shaft oil seal must always be replaced Replace the rear bearing carrier seal or the front bearing carrier seal when the rear pressed assembly or front pressed assembly are overhauled Front wheel bearings and seals Figure 9 On the front SIBS the standard Toyota bearing a double taper roller bearing in a bearing carrier is modified to accept an additional seal running on the top surface The seal spins with the hub and is located in position via a seal carrier To change the bearing follow the procedure set out in the Toyota Manual Be sure to re use a modified Toyota bearing 42 9012 and standard Toyota locking collars and ABS pulse wheels Inner hub and seal where fitted Use a new seal 01 4073 in the seal carrier bolted to the hub Page 52 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION ASB Advanced Braking Pty Ltd SIBS front seal carrier bolted to hub Modified Toyota 42 2012 2 4 front bearing assembly 42 9012 SIBS front hub seal 01 4073 i HOUSING ORING Rear wheel bearings and seals Figure 10 The rear SIBS brake on Toyota Hilux KUN2 amp 3 vehicles uses unitised taper roller bearings The bearing is manufactured from a Timken bearing and should only be purchased from ABT The outer bearing retainer locking collar and bearing carrier are also manufactured by ABT
41. ddle to mount the paper type fuel filter This will ensure the brake will not breath dirt or water which is detrimental to the operation of the brake Paper type in line fuel filter mounted at the top of the tray behind the driver Page 28 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION ASB Advanced Braking Pty Ltd 5 Installation of the EMMA system Note when fitting optional Manual Release system in addition to pump refer to TBN 032 which is included in the Appendix at the back of this document CZ Fitment of EMMA unit KUN26R shown fitment in LH vehicles may differ 5 1 EMMA pump manifold and bracket assembly is shipped complete with wiring harness Check that the relay is fully encased with Plasti dip as this prevents corrosion of this part 5 2 Mount the EMMA pump manifold amp bracket assembly using the components provided 5 3 Study the wiring diagram overleaf Note the following 5 3 1 The heavy gauge red wire from the relay must be connected to constant 12V in the power box 5 3 2 Earth the heavy gauge green white wire from the motor 5 3 3 Earth the two small gauge black wires from the solenoid amp pressure switch Page 29 006 REV 0 INSTALLATION amp SERVICING OF 51855 ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST V
42. e manual release system to be operated 15 11 2007 ABT Advanced Braking Pty Ltd From EMMA Pump X TAF 010 Rev04 Page 5 The blue arrow in the photo left Shows the direction of fluid flow during normal vehicle operation Fluid is pumped from the EMMA pump to the brake The green arrow in the photo left shows the direction of fluid flow during manual release of the EMMA brake Fluid is pumped from the hand pump to the EMMA brake ath les 15 11 2007 S 3 9 TAF 010 04 ASB Advanced Braking Pty Ltd From 3 way valve eee 11901 wend 3531138 0 OL 6 The quick release connector is shown located between the driver and passenger seats next to the EMMA brake control The photo left shows the hand pump and mating half of the quick release connector 15 11 2007 SBT e Advanced Braking Pty Ltd Procedure Lift the bonnet disconnect the battery Locate EMMA unit and clean thoroughly around the hydraulic connections Disconnect hydraulic pipe running from pump to T piece on rear axle Locate 3 way valve in suitable position on cab floor drill holes if required and fix using brackets Connect a hose from the pump to 3 way valve and another from the 3 way valve to the T piece 6 Connect the hose with the Quick release connector to the 3 way valve and t
43. e to be released in the case of a power failure in the vehicle eg flat battery preventing the EMMA system pump from operating It will not be possible to move the vehicle if the EMMA Brake is not released The system consists of a hand pump a quick release coupling a three way valve hoses and fittings The hand pump can be either permanently fitted between the seats of the vehicle or can be coupled when needed to the system via a quick release coupling The three way valve can be fitted under the driver s or passenger s seat There are three hoses running from the three way valve one to the manifold one to the hand pump or quick release coupling and one to the T piece on the rear differential When the Manual Release System needs to be used the operator rotates the lever of the three way valve closing the circuit between the EMMA pump and EMMA brake and opens the circuit between the hand pump and the EMMA brake The hand pump is then operated until the SIBS park brake emergency brake is released and the vehicle can be moved i TAF 010 Rev04 Page 2 15 11 2007 osi ka SGS comments PARTNUMBER Jo STANDARD HYDRAULIC SCHEMATIC EXISTING SY STEM 02 1008 1 HANDFUMP MANUALRELEASE QUICK RELEASE HAND PUMP ENZED GFC 1 8 AND COUPLING VALVE COUPLING MANUAL RELEASE VALVE 8 OFF PISTONS HAND PUMP QUICK RELEASE COUPLING EMMA PUMP VALVE MOUNTED a UNDER SEAT
44. eal cover 2 Service piston O ring wiper 2 Service piston Page 16 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION I woy Gure1qpadueapegyuad ojul 1866 1026 8 0 19 ajlwisoey 426 8 0 19 euoudaja 9169 VM Jed auloqst 1111 X08 04 pr1 0 04 99 Guryeug paoueApy 581 1504 1109 VM 16d 2010080 199215 P EUOGIW L yun Leg 101 650 NIY ONN 94 2 Burue 681672 8 ONN 91 2 gu 982 Zh D ss wey jo ed xn iH Aeq 920 00 9L 0 6 Aeq jo ueq dup yeaq JNU 010720 12007 0 OMS auNSSald GOO ZO 2 11 0209 20 2 sjees syoq ofueq aren quuessy Jale ea s pnpu j O SYA gs zogo OL X AND 800920 6 UN ewe plousjos 7009 20 8 UMOUS 2001 20 1 ETC MEE EM goo pwe bDndeowo 2 0640 9 qu abpuyes soy 1 09 0 S q a ssMwAwog 05 10 ee aoea 220940 e tu sem Avo GOL Z rc 2060 O ALD uonduoseg _ N d ASB Advanced Braking Pty Ltd Inst
45. ering BE knuckle from the suspension 5 lt a AY 7s upper arm 0 Z EM 1 7 Remove the front steering knuckle assembly Page 19 006 REV 0 INSTALLATION amp SERVICING OF 51865 ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBI 407m Advanced Braking Pty Ltd 2 Install SIBS front knuckle assembly Installation is reverse of removal and is the same for LH and RH steering knuckle assemblies 2 1 Install the upper arm with the nut Torque nut to 110Nm Install the clip Note if holes in cotter pin are not aligned tighten the nut a further 60 2 2 Install the lower suspension arm onto the steering knuckle via the two bolts Torque bolts to 160Nm 2 3 Install tie rod end sub assembly Install the tie rod end nut Torque nut to 49Nm Install a new cotter pin Note if holes in cotter pin are not aligned tighten the nut a further 60 2 4 Install front stabilizer link assembly Torque nut to 7ONm 2 5 Install front ABS speed sensor 2 5 1 Torque on speed sensor bolt 8 0Nm 2 5 2 Install 3 x clamps Torque on bolts 13Nm 2 6 Install front brake hose into the clip and new brake pipe A into the inner housing Install front brake hose into the clip Install the new brake pipes into the inner housings 42 2027 Brake pipe front LH LCV5 42 2028 Brake pipe front RH LCV5 Page 20 MAN 006 REV 0 INSTALLATION amp SER
46. f the felt seal that will be in contact with the housing Caterpillar contact cement P N 5H2471 or equivalent e Install felt seal and allow cement to cure e Apply some machine oil to the felt seal to lubricate the sliding surfaces Page 44 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBI 40 7m Advanced Braking Pty Ltd Changing the housing seal Important When changing the housing seal on the rear brake assemblies there should be no spring force on the outer housing Use the EMMA pump to hold off the spring force and install the retractor bolts The hydraulic pressure can then be released Hint if the EMMA pump is disconnected not working use a manual hydraulic pump e g Enerpac The outer housing does not need to be removed to change the housing seal There are several different housing seals that may be used The procedure for installation is similar Remove felt seal o Undo 3 5 bolts that locate the felt seal support and remove o Undo 8 x M6 bolts that locate seal cover and remove Felt seal should be glued to seal cover e Remove the housing seal Hint use TEK screws to lever out if required e Clean outer housing bore and seal cover using Brakeclean e Ensure the seal surface is free of corrosion If necessary place in a lathe and buff with fine wet and dry emery paper 2400 grit or finer This is im
47. hen route it into the vehicle cab 7 Bleed EMMA brakes and check operation aa E Operation of Manual Release System Ensure hand pump is full of AT Fluid Connect hand pump using Quick release connector Turn 3 way valve handle to manual release position Close valve on hand pump to allow pumping Pump hand pump upto 700 1000 psi to release EMMA brake Move vehicle as required Turn 3 way valve back to normal vehicle operation position to engage EMMA brakes Release pressure in handpump then disconnect Bleed EMMA brake system before recommencing normal vehicle operation A D cop pers WARNING The 3 way valve must not be turned to the manual release position during normal vehicle operation as the EMMA brake has been bypassed and will not function Prepared by otuart Millgate Approved by Andrew Miller Chief Engineer Issue Date 16 November 2007 Issue Revision 0 Advanced Braking Pty Ltd Unit 1 3 McDonald Street West Tel 61 08 9273 4800 Osborne Park WA 6017 Fax 61 08 9201 9986 AUSTRALIA Email info perth advancedbraking com PO Box 1177 Web www advancedbraking com Osborne Park WA 6916 O TAF 010 Rev04 Page 7 15 11 2007 osil ka SGS
48. ic hose down the left hand chassis rail Secure along the way with p clamps Ee f pr 1 m 2 5 x E a w 4 h i E Hydraulic hose running down LH chassis rail secured with p clamps 5 6 2 Bolt hydraulic tee piece to rear differential housing 7 16 JIC tee piece fitted to rear differential housing viewed from the rear Use existing M8 captive nut for the purpose 0 6 3 Run the two hydraulic hoses to the left hand and right hand brake 5 6 4 Connect the hose to the EMMA pump Page 35 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBI Advanced Braking Pty Ltd 5 7 Check EMMA system operation 5 7 1 Reconnect the battery 5 2 Shut the door Description of operation The Red Operator Button is wired into the ignition so that the vehicle key is needed to release the brakes However the yellow or black Momentary Release Button allows the brakes to be released ina situation where the key is not available but only as long as the button remains depressed This prevents the brakes being left off The Red Green LED in the centre of the control provides a visual indication of the circuit operation To Release the EMMA Brakes e With the ignition ON check the LED display is RED If it
49. ing or wear e While the spring cover is removed inspect the link pipe Replace with Stainless alternative 24 2815 if required 24 2010 EMMA Piston 15 4050 O ring EMMA Large 15 4060 Backup Ring EMMA Large 24 4030 O ring EMMA Small Figure 15 EMMA Piston O rings and backup ring assembled 01 4051 Backup Ring EMMA Small The O rings and backup rings must be installed as shown in above figure Figure 16a Rear inner housing Figure 16b EMMA piston installation With spring cover removed inspect Link pipe Assembly is the reverse of the above procedure e O rings and BUW s are included in kit 42 4001 O ring kit for one rear brake LCV5 e Ensure the o rings and BUW are correctly installed on the EMMA pistons refer to figure below Grease o rings BUW s and pistons with e Push pistons into housing Care should be taken to ensure the BUW s are not pinched during assembly Page 58 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBI 407m Advanced Braking Pty Ltd e Grease the Belleville spring washers with bearing grease e Stack Belleville spring washers 8 per piston as shown in Figure 17 below Note springs must be stacked correctly to ensure correct brake application e Place gasket and spring cover over springs e Fit retractor bolts to the pistons Carefully wind down in sequence
50. int on Heavy gauge red wire from the relay to constant 12V in the power box 5 4 Feed the grey and red wires through the firewall into the cabin Note on some vehicles where the pump is mounted in front of the radiator there may be some extension required of the harness Use Deutsch 2 pin connectors for this purpose Grey and red wire inside black sheath poked through firewall Use one of existing grommets Ensure grey and red wires from the engine harness are connected to the same wires on the cabin harness Use the Deutsch connectors supplied 4 2 Right hand drive vehicle shown 0 4 1 Route the cabin harness to the Hirschman plug in the centre console in the old park brake lever position 5 4 2 Connect the engine harness to cabin harness using Deutsch 2 pin connectors Note sometimes sectioning of the harness into two halves will be required during installation as the harnesses are manufactured as one item Fit Deutsch connector at the section point 5 4 3 Splice the grey wire of the harness to the green wire of the old handbrake switch Page 31 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION Advanced Braking Pty Ltd Route the cabin harness to the black Hirschman plug in the centre console in the old park brake lever position Note the brown wire to be spliced into the drive
51. iratory Protection Eye Protection Hand Protection Body Protection Eng Controls Other Information No exposure standards have been established for this material by the National Occupational Health And Safety Commission NOHSC Avoid breathing of vapours or mists Where ventilation is inadequate and vapours or mists are generated the use of an approved respirator with filter complying with AS NZS 1715 and AS NZS 1716 is recommended however final choice of appropriate breathing protection is dependant upon actual airborne concentrations and the type of breathing protection required will vary according to individual circumstances Expert advice may be required to make this decision Reference should be made to Australian Standards AS NZS 1715 Selection Use and Maintenance of Respiratory Protective Devices and AS NZS 1716 Respiratory Protective Devices Safety glasses with side shields goggles as appropriate recommended Final choice of appropriate eye face protection will vary according to individual circumstances i e methods of handling or engineering controls and according to risk assessments undertaken Eye protection should conform with Australian New Zealand Standard AS NZS 1337 Eye Protectors for Industrial ApplIXOSDIOn Wear gloves of impervious material Final choice of appropriate gloves will vary according to individual circumstances i e methods of handling or according to risk assessments undertaken Reference shou
52. is not push the Red Operator Button in This indicates the system is reset e Now gently twist the Red Operator Button clockwise 715 and pull The LED display should change to GREEN indicating brake release is in operation e Full brake release is indicated when the Brake Warning Light in the dashboard goes out However the vehicle should be able to be moved very soon 1 2seconds after the pump starts to run gt x E 5 8 Engage the pump using the control box If it does not work ensure the door is open amp check the connections using the wiring diagram 5 9 Bleed the EMMA system 5 9 1 the pump 5 9 2 Bleed the EMMA system of each rear inner housing assembly using the 2 bleed nipples on each rear housing Page 36 MAN 006 REV 0 INSTALLATION amp SERVICING OF 51855 ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION Advanced Braking Pty Ltd Note e There are 2 EMMA bleed nipples on the rear inner housings e These are the two outside bleed nipples in the group of 3 at the top of the brake EMMA bleed nipples WARNING Note 1 Bleeding the EMMA system may cause the pump to run dry under load resulting in damage 2 Pump is designed for intermittent use when bleeding do not run the pump continuously for more than 10 s 5 9 3 If the EMMA pump cycles release and engage the system several times to try to clear
53. iston o rings Does not include main housing seal or felt seal 01 4083 Cassette seal Main housing seal 2 2 4 4 42 2045 Felt seal 4 Felt grease seal Page 40 MAN 006 REV 0 INSTALLATION amp SERVICING 51855 ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION Advanced Braking Pty Ltd 00 3321 siBS Cooling Fluid 20L 2211 LL 02 7005 Pressure swith 11 EMMA hydraulic system 01 5071 Filter element 3 EMMA hydraulic system 15 1151 Bleed nipple 15 1330 Fill plug LEN cum Drain th megne with magnet 45 4361 4361 Hose breather breather kur emm 12 jeu per brake assy manm _ 10 required per rear brake See 45 2530 2530 Retractor bolt bolt a H j 70306 Pugemma 8e o 01 7016 Relay 60Amp dioded 1 EMMA electrical system az oo O 42 2014 Stud wheel M12 LCV5 24 4962 Kit brake pads for two front or rear LEM brakes 24 2815 Brake pipe service link 42 2026 Hose 1 hydraulic EMMA supply 1 LCV5 422024 BrakepiperearLHLCVS tf 42 2025 BrakepiperearRHLCVS J4 O 24 2826 Brake pipe rear RH TLC100 1 42 2027 Brake pipe frontLHLEV5S J4 y O 42 2028 Brake pipe front RH LCV5 tf 121111 Torque of critical bolts amp nuts 01 3220 M10 Housing bolts 61Nm 42 9039 M12 Locknuts 5Nm 01 3078 M6 Seal cover bolts 15Nm XX XXXX Wheel nuts 90N
54. ld be made to AS NZS 2161 1 Occupational protective gloves Selection use and maintenance Wear appropriate clothing including chemical resistant apron where clothing is likely to be contaminated It is advisable that a local supplier of personal protective clothing is consulted regarding the choice of material Natural ventilation should be sufficient however where vapours or mists are generated the use of a local exhaust ventilation system drawing vapours mists away from workers breathing zone is recommended No biological limit allocated 9 PHYSICAL AND CHEMICAL PROPERTIES Appearance Melting Point Boiling Point Solubility in Water Specific Gravity 20 1 pH Value Vapour Pressure Viscosity Clear and bright liquid Not available 236305796 Immiscible qd Xd cgo me Not applicable 3 pa gez 4 cSt 08 40 C 13 4990 0 100 Material Safety Data Sheet Page 3of 4 Infosafe No LPUSZ Issue Date January 2005 ISSUED by SAFEEFFE Product Name SIBS COOLING FLUID Classified as hazardous according to criteria of NOHSC Flash Point 105 C Opened cup Flammability Classified as a Class Cl COMBUSTIBLE LIQUID for the purpose of storage and handling in accordance with the requirements of AS1940 Remove all sources of heat and ignition Ignition Temperature 232 C ASTM 659 Flammable Limits Not available LEL Flammable Limits Not available UEL 10 STABILITY AND REACTIVITY S
55. m 15 1330 15 1341 Fill drain plugs apply PTFE tape Hand tight 15 1151 Bleed nipples Hand tight 01 5080 Tube nuts Hand tight 01 3302 M5 Seal support bolts Hand tight Page 41 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION Advanced Braking Pty Ltd Master Cylinder an PERS EE s k b L L J Cooling Fluid 287 Fill plug Brake housings Page 42 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION Advanced Braking Pty Ltd Handling and disposal of SIBS Fluid Refer to SIBS Fluid Material Safety Data Sheet Appendix for handling instructions SIBS Fluid must be disposed of in accordance with all Regulatory and Environmental regulations Replacing SIBS Fluid Draining SIBS Fluid Remove the drain plug see Figures 1 amp 2 from a brake assembly and drain SIBS Fluid into a drain pan ready for disposal WARNING The use of any fluid other than SIBS Fluid will void the warranty and may cause brake failure resulting in injury or death The brakes must be drained and filled with new SIBS Fluid if they remain totally immersed in water for lengthy periods Before refilling with SIBS Fluid ensure that the drain plug has been cleaned and fitted with new thread sealant tape
56. m ignition barrel assembly Blue wire from harness already spliced to black yellow 5 4 8 Splice the brown wire into the drivers door open switch Ensure the wire will not be impacted by the drivers feet Page 33 006 REV 0 INSTALLATION amp SERVICING OF 518565 ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION Advanced Braking Pty Ltd Splice the brown wire into the drivers door open switch Run the wire under the drivers seat and floor matt away from any possible damage by the drivers feet 5 5 Control box 5 5 1 Find a suitable location to fix the control box firmly to the centre console Depending on centre console type this may require some modification of the plastic centre console Z Mounting of control box on dual cab Mounting of control box in single cab Hilux Some modification of the centre Hilux console is required Firmly fasten the control box to the floor using the Mounts in place of park brake lever fasteners and bracket provided Note the park brake lever is still shown in this photo should be removed refer to 2 16 5 5 2 Fit black Hirschman plug from cabin harness into control box Page 34 MAN 006 REV 0 INSTALLATION amp SERVICING OF 51855 ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBI Advanced Braking Pty Ltd 9 6 Hydraulics 5 6 1 Run the long hydraul
57. one turn at a time Note if the bolts are tightened individually the EMMA piston may retract from the bore e Install spring cover retaining bolts same as housing bolts In corrosive environments it is advised to use new bolts or the stainless alternative 01 3237 e he spring cover retaining bolts should be tightened evenly to 61Nm 45 Ib ft Belville washers x 8 stack as shown pe 2 EMMA Piston Rear Housing Minor Bore Figure 17 Arrangement of Belleville springs 8 springs are stacked in series behind each EMMA piston Total of 32 springs required per rear brake assembly EMMA Filter The FILTER ELEMENT 01 5071 in the EMMA manifold should be changed at regular intervals Safe Effect recommends changing every 1 000 hours Page 59 MAN 006 REV 0 INSTALLATION amp SERVICING 51855 ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION Figure 18 Position of Filter Element on typical manifold Pump is mounted on rear left hand side of bonnet on right hand drive vehicles Position of pump on left hand drive vehicles may differ SBI Advanced Braking Pty Ltd FILTER ELEMENT 01 5071 is fitted to the side of the manifold as shown in Figure 18 above To replace Use a large wrench and loosen the filter element Remove the two top bolts and spacers from the bracket and loosen the bottom bolt Swing bracket away from the firewall Wipe the filter to remo
58. osion Replace as required Remove service pistons from inner housings Inner housings do not need to be removed from the vehicle Apply a bar clamp on the rubber brake hoses to stop fluid loss Loosen the bleeder nipples Remove the four 47 mm service pistons front housings and two 53 mm pistons rear housings Clamp the groove on the inside of the piston with inside pliers can be made from flat steel bar e Service piston o rings amp BUW s refer Figure 8 o Each rear service piston has two o rings a primary EPDM o ring of 3 53mm cross section and a wiper VITON o ring of 1 78mm cross section o Each front service piston has two o rings and a BUW a primary EPDM o ring of 5 33mm cross section with a PTFE BUW note orientation of BUW and a wiper VITON o ring of 1 78mm cross section Assembly service pistons and seals front and rear brakes e Clean the service piston bores with Brakeclean Buff with fine emery paper 2400 to remove any corrosion e O ring kits are available 42 4000 front brake 42 4001 rear brake e Lubricate housing bore with Silicone grease Page 49 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBI Advanced Braking Pty Ltd e Fito rings to pistons Lubricate with Silicone grease e The primary pistons of the front brake have back up washers Ensure these are installed in the correct orientation
59. outer edge of the brake housing outer cover and remove cover insert the 2 special M10 locating bolts with head removed as used in the installation of SIBS Braking System e Remove the 2 x M8 x 1 25 x 45LG socket head screws that locate the rotor carrier to the hub axle shaft e Insert these two bolts into the 2 threaded jacking holes in the rotor carrier Note longer M8 x 1 25 bolts may be Figure 7 required to fully jack off the rotor Removal of outer housing rotor carrier carrier from the hub axle shaft 48 MAN 006 REV 0 INSTALLATION amp SERVICING 518589 ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBI 407m Advanced Braking Pty Ltd e Remove the rotor carrier outer housing outer pads amp rotor as one assembly Hint 1 Use M10x1 5 dowel pins to assist the removal of the outer housing 2 Prevent the two inner housing pads from falling have a colleague use a steel rule to retain them in the housing CAUTION When the rotor and pads are removed they must be marked carefully and returned to their original locations Mismatching may cause loss of brake efficiency accelerated wear and or increased pedal stroke THE BRAKE PADS ARE DIRECTIONAL Treat brake pads carefully to avoid damaging the friction material Once the outer housing has been removed remove the brake pads from the inner housing e Inspect the housing bolts for corr
60. portant to provide a smooth seal surface and is especially important when installing a single lip shaft seal non cassette type e Ensure there are no sharp edges on the lead in for the rotor carrier This is especially important when fitting a single lip shaft seal e lf fitting seal framed cassette seal SAF P N 01 4083 do the following o Place cassette seal air side down o Run some LOCTITE 290 wik in around the edge of the seal at the join of the two steel components as this is a potential leak path o Allow LOCTITE to go off o This process will prevent SIBS fluid from by passing the seal lip by weeping through the join of the two steel components Apply wik in Loctite 290 to full p LOCTITE WICK IN diameter of seal casing Allow to cure Figure 4 Oil side Preparing cassette seal SAF P N 01 4083 for installation Page 45 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBI Advanced Braking Pty Ltd Apply LOCTITE 290 wik in to full diameter of seal casing as shown This will seal potential leak path Figure 4 Cont e If fitting the all rubber cassette seal or single lip shaft seal follow the same procedure as below e Apply LOCTITE 515 to housing bore e Install the seal refer to Figure 5 o The seal cover doubles as the installation tool for the cassette seal Flip the seal cover
61. rential housing Install a new o ring 4 6 Install the red breather hose 4 6 1 Cut a 1 5m length of the breather hose 4 6 2 Install one end into the hose connector on the inner housing and restrain with a jubilee type hose clamp Install red breather hose to the hose connector on the inner housing Note retractor bolts not shown however these should still be in place refer 4 1 4 7 Carefully slide the SIBS brake and axle shaft assembly into the diff housing Take care not to damage the oil seal 4 8 Align the housing such that the three bleed nipples are at the top The spring cover that houses the stack of Belleville washers should be biased towards the front of the vehicle Orientation of rear inner housings Top Position the housing such that e bleed nipples at the top e Spring cover is biased towards the front of the vehicle Note retractor bolts not shown however these should still be in place refer 4 1 Front of vehicle Page 26 006 REV 0 INSTALLATION amp SERVICING OF 51855 ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION SBI J Advanced Braking Pty Ltd 4 9 Install the washers and locknuts to the mounting studs Tighten the M12 locknuts to G9Nm Tighten locknuts to G9ONm 4 10 Install the expansion chambers Expansion chambers allow the brake to vent without allowing ingress of dirt The expansion chambers are diesel
62. ron Protection Avoid contaminating waterways drains sewers or ground Mobility No data available for this specific product Persistence No data available for this specific product Degradability Bioaccumulation No data available for this specific product Ecotoxicity No data available for this specific product 13 DISPOSAL CONSIDERATIONS Dispose of waste according to federal E P A and state regulations Assure conformity with all applicable regulations 14 TRANSPORT INFORMATION Not classified as a Dangerous Good according to the Australian Code for the Transport of Dangerous Goods by Road and Rail U N Number None Allocated Proper Shipping None Allocated Name DG Class None Allocated Material Safety Data Sheet Page 4o0f 4 Infosafe No LPUSZ Issue Date January 2005 ISSUED by SAFEEFFE Product Name 5185 COOLING FLUID Classified as hazardous according to criteria of NOHSC Hazchem Code None Allocated Packing Group None Allocated 15 REGULATORY INFORMATION Risk Phrase R65 Harmful may cause lung damage if swallowed Safety Phrase 562 If swallowed do not induce vomiting seek medical advice immediately and show this container or label Poisons Schedule 212 Hazard Category Harmful Packaging amp Labelling requirements of the Standard for Uniform Scheduling of Drugs and Labelling Poisons do not apply to a poison that is packed and sold solely for industrial laboratory or manufacturing purposes
63. rs door open switch and the grey wire to be spliced into the green wire of the old handbrake switch 5 4 4 Earth the black wire from the Hirschman plug end of the harness in a Suitable location Earth the black wire in a suitable location on the body Position shown here is in the passenger foot well below the dashboard Note the red and white wires of the harness running to the centre console lt a Black wire 5 4 5 Run the green and blue wires from the Hirschman plug end of the harness up to the steering wheel console Remove shroud at base of steering wheel 5 4 6 Splice green wire with sealed fuse holder into the red white wire out of the ignition barrel assy This wire picks up constant 12V to operate the EMMA system Page 32 006 REV 0 INSTALLATION amp SERVICING OF 51855 ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION Advanced Braking Pty Ltd Blue and green wires routed to Green wire spliced into red white wire out of steering column Note sealed ignition barrel assembly fuse holders check these are fitted with 7 5Amp mini blade type fuses 5 4 7 Splice the blue wire with sealed fuse holder into the thick black yellow wire coming out of the ignition barrel assembly This wire picks up ignition live to operate the EMMA system Image showing blue wire with sealed fuse holder spliced to thick black yellow wire fro
64. s if below specified limits o Original thickness 14mm o Front replace if thickness 11mm o Rear replace if thickness 12 5mm o Note when replacing pads it is desirable to replace all pads across an axle to ensure consistent performance e Check components and replace seals o Replace service piston o rings o Inspect service pistons and service piston bores for corrosion or pitting Replace if necessary o Inspect EMMA pistons for leakage and change o rings if necessary Replace EMMA piston o rings every second Major service e Replace housing bolts e Inspect rotor carrier and rotor spline Replace if spline teeth of either component are visibly stepped or there is excessive play in the fit of the two components Note the splines of the rotor and rotor carrier should engage smoothly and slide under load There should be minimal wobble between components e Replace wheel bearings and wheel bearing seals e Inspect seal surface axle shaft and hubs restore with speedi sleeves if corroded or pitted e Flush EMMA hydraulic system with ATF e Change EMMA filter Recommended parts holding per 10 vehicles PIN 42 4000 O ring kit for one front brake LCV5 Required for Major service Includes housing o ring service piston o rings Does not include main housing seal or felt seal 42 4001 O ring kit for one rear brake LCV5 Required for Major service Includes housing o ring service and EMMA p
65. semblies occurs during installation e Follow the points in the manual as described if you are not sure check the Manual e Place each brake close to the vehicle adjacent to the axle where the brake is to be fitted ensuring that they cannot by contaminated by any foreign material Preparation Make sure all the tools equipment and brake components are readily available Before starting installation check that 1 the battery is disconnected 2 the vehicle is standing safely on a hoist 3 the original Toyota brakes have been removed refer to Toyota manual a remove rear axle shaft assemblies b if fitting fronts remove the front steering knuckle assemblies the handbrake cable and lever have been removed the required amount of SIBS fluid is available an empty drain pan is available oo ex Page 10 006 REV 0 INSTALLATION amp SERVICING OF 51855 ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION V000 Cv ON LYVd WOY 0414 1006 fia ADOTIONHOAL 1002 80 Q39NVAQV 40 NOISSINYAd IHL LNOHLIM S3l L vd H3HLO OL GALVOINNWWOD LHVd HO 3 T10OHM NI 0 000 Q3ldOO 38 LON AVN ANY PH ADOTONHOAL dO ALH3dOSd JHL SNIVIN3H LN3IADOOG SIHL 9ud LNAWNDO00 ASV L3THdO d 1 Somuga Burseig paaueapy Js ANH 8c06 ct 9806 Zb
66. t mouth with water Seek immediately medical attention Skin Remove contaminated clothing Wash gently and thoroughly with water and non abrasive soap Ensure contaminated clothing is washed before re use or discard If irritation develops seek medical attention Eye If contact with the eye s occur wash with copious amounts of water holding eyelids s open Take care not to rinse contaminated water into the non effected eye If irritation develops and persists seek medical attention First Aid Facilities Eye wash and normal washroom facilities Advice to Doctor Treat symptomatically Other Information For advice contact a Poisons Information Centre Phone eg Australia 131 126 New Zealand 03 4747 000 Not after May 2005 or 0800 764 766 or a doctor at once 5 FIRE FIGHTING MEASURES Extinguishing Media Water fog carbon dioxide foam or dry chemical Do NOT use water jets Cool fire exposed containers with water spray Specific Hazards Combustible C1 liquid Fire exposed container may rupture explode Hazardous Under fire conditions this product may emit toxic and or irritating fumes Combustion Products including oxides of carbon Precautions in Self Contained Breathing Apparatus S C B A and full protective clothing connection with Fire should be worn to minimise exposure 6 ACCIDENTAL RELEASE MEASURES Material Safety Data Sheet Page 2 of 4 Infosafe No LPUSZ Issue Date January 2005 ISSUED by SAFEEFFE
67. tability Stable under normal conditions Hazardous Will Polymerization Materials to Avoid Strong oxidising agents Hazardous Thermal decomposition and combustion produce noxious fumes containing oxides Decomposition of carbon Products Hazardous Reaction Reacts with oxidising agents Conditions to Avoid Heat direct sunlight open flames or other sources of ignition 11 TOXICOLOGICAL INFORMATION Toxicology No toxicity data is available for this material Information Inhalation May cause irritation to the mucous membrane and upper airways where material is heated and is used in poorly ventilated areas Symptoms may include headache dizziness and nausea Ingestion Harmful may cause lung damage if swallowed Subsequent to ingestion or vomiting small amounts of liquid aspirated into the respiratory system may cause severe pulmonary injury that may lead to death May also cause irritation to the gastrointestinal system Symptoms may include nausea vomiting diarrhoea and abdominal pain Skin May cause irritation in contact with the skin which may result in redness and itchiness possibly leading to dermatitis Eye May cause eye irritation resulting in redness stinging and excessive tearing Chronic Effects Prolonged or repeated contact with this material may result in skin irritation possibly leading to dermatitis 12 ECOLOGICAL INFORMATION No ecological data is available for this material Envi
68. ton Service piston 01 2085 O ring wiper 14 jSemicepiston Page 13 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION 20062 A9010NHO31 SNDIVHg JO 56 IHL LNOHLIM SIILYYd YSHLO O1 GALVOINNWWOD LYYd HO 3 1OHM NI 002 11 80 2 E E Q3ldOO 38 LON AVN ANY PH Aid ADOTONHOAL 0 8600 Q39NVAQGV dO ALH3dOSd JHL SNIVIN3H LN3IACIOOG SIHL ON LNAWNDO0 ASV L3THdO ld pr Abouysay Guyer Se J9VIAI YOUNIW SI 1glN4SSV QNVH 1331 NMOHS A 18lIN3SSV LHOTS V3 3 LON W3NIV L33 9NT3V38 SC06 Cv WVds YOSNAS 58 9206 cv OS TV 114 S3 DIH3A SAV 3LON TTCE TO YAHSVM 6 06 Ct LAN TSOv TO YONIW VIAIA3 YIHSYM drbiOvVg 402 2 YINIVLIJY 0 0b vc YONIW VlAIA3 SNIN O Lc06 CV 090b ST VIAIN3 YIHSYM OSZE ST SNT3dS 510 080 ST LAYSVS ONTYdS O SC ST 1104 NIVaG 0TOC vc I8 2 ST NOLSId VWWA ONTYdS ST8C vc 3dId 900 02 O ET ST S T1d YAO VIAIN3 1115 Ov8T ST 11089 33A0O ONTYdS OSOb ST HOCVIA WWW SNIM O SNISNOH YANNI 1002 29 000c Cv
69. ty Ltd 2 8 1 Locate a suitable position against the inner guard in the engine bay 2 8 2 Use existing M8 captive nuts or install new ones using the M8 Nutserts provided 2 8 3 Bolt the expansion chambers using M8 bolts provided Use washers behind the chamber if the guard is not flat at this point 2 8 4 Fit a short length of black 5 16 ID fuel hose to either position 1 or 3 at the top of the chamber Run this hose to a paper type fuel filter 2 8 5 Restrain the fuel filter as high as possible under the bonnet Use the 50mm half saddles provided Use existing captive nuts or install new ones using the M8 Nutserts Expansion chamber and paper type fuel filter mounted under the bonnet Note positions may vary depending on availability of space Expansion chamber bolts to the EMMA bracket on right hand drive model vehicles e g KUN26R On left hand drive vehicles locate a suitable position and mount the chamber as per the instructions above Page 22 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION Advanced Braking Pty Ltd Installation of SIBS brakes rear 3 6 3 7 3 8 Remove rear axle shaft assemblies Remove the rear wheel Remove the speed sensors if ABS is fitted Disconnect the service brake line Disconnect the park brake cable Remove the axle shaft with backing plate
70. ve dirt and prevent contamination of the fluid when the filter is removed Remove used filter and replace Re install bracket Ensure the wiring harness fitted near the pump unit will not rub on the bracket Page 60 MAN 006 REV 0 INSTALLATION amp SERVICING OF SIBS ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION ABI Advanced Braking Pty Ltd SIBS EMMA TROUBLESHOOTING GUIDE Issue Description Possible Cause Solution Low brake pedal Faulty master cylinder Refer to Toyota or Repair Manual for Incorrect adjustment of fault diagnosis booster Input output rods Excessive brake pedal Leaking or damaged Replace brake line refer travel Sudden or brake line to page 18 creeping and loss of braking efficiency Air in the brake system Bleed the brake system refer to pages 34 Replace piston and Damaged service piston seals refer to page 47 Spongy brake pedal Air in the brake Bleed the brake system system refer to pages 34 Hard brake pedal Vacuum booster or Check vacuum vacuum pump faulty pressure not leaking Damaged brake pads or Replace brake pads polished rotor lightly scour all rotors with 240 grit wet and dry sandpaper Excessive force required to operate the brake pedal and loss of braking efficiency Glazing of pads and rotor Alternative method Perform SIBS optimum performance procedure TBN 018 and refill brakes with fresh SI
71. yota Manual Use the Toyota LSPV Gauge Toyota P N 09709 209017 8 2 Install LSPV Gauge into front and rear bleed ports 8 3 Raise the front brake pressure to 80 kg cm2 1138psi 8 4 Rear brake pressure on SIBS should read HEAVY DUTY 70 6 kg cm2 996 85 psi STANDARD DUTY 65 6 kg cm2 925 85 psi 8 5 Test drive the vehicle the front brakes should ALWAYS lock before the rear brakes Adjust again if necessary 9 Fit warning labels SIBS brakes are supplied with two OPERATOR CAUTION labels MAN Z a Fit the SIBS warning labels in prominent positions easily visible by the operator and any mechanic working on the vehicle 10 Check for any leaks Test drive the vehicle 11 Bleed the service brakes for a second time Page 38 006 REV 0 INSTALLATION amp SERVICING OF 51865 ON TOYOTA HILUX VEHICLES UNCONTROLLED COPY IF PRINTED CHECK WEBSITE FOR LATEST VERSION ABI Advanced Braking Pty Ltd Servicing Procedures Service Intervals Two weekly service Check brake fluid level in master cylinder and top up as required Check ATF fluid level in EMMA pump and top up as required Put vehicle on hoist and remove wheels Inspect brakes for leaks Grease felt seal via grease nipple approx 3 pumps whilst rotating hub axle shaft Re fit wheels and test drive Check for correct operation of EMMA brake and service brakes o Ensure EMMA brake release and engagement times are not excessive If

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