LUCAS GIRLING SYSTEM COMPONENTS And INFORMATION

LUCAS GIRLING SYSTEMCOMPONENTS andINFORMATION

HYDRAULIC BRAKE DRUMSCONSIST OF:BACKING PLATETWO BRAKE SHOES & LINING ASSEMBLIESADJUSTER CYLINDERPARK CYLINDERBACKINGPLATELINED SHOERETAININGCLIP & TSGREEN GE ING PLATE CONTAINS TWO LINING INSPECTION HOLES(measurement of shoe to drum clearance) TWO ADJUSTER SIGHT HOLES TWO ADJUSTMENT SLOTS(manual override to increase or decrease the shoe to drumclearance)

202262XPICTUREDLEFT HANDLOADEDADJUSTING CYL201183XPARK CYLINDER201179XSHOES6”BRIDGEPORT140016SPRING KITSP7896S (140003)BRAKE CYLINDEROVERHAUL #L5489

LEFT SIDEBACKINGPLATE X1.75(for 5” Shoes)1.75(for 6” & 7” Shoes)NOSHOESNOSHOESNOSHOES203252XRIGHT SIDEBACKINGPLATE 1X1.756”202271X1.757”203249X1.625NO SHOES203251X203261X1.75(for 5” Shoes)1.75(for 6” & 7” Shoes)NO SHOESNO SHOES202261X

PARKCYLINDERINSTALLATIONINSTALLATION¾¾¾¾Put on the new gasket, 3)nuts, bolts & washers. Torque per manufacturers’ specs.Connect bridge pipe to cylinder (torque 10-15 ft. lbs) Put in bridge pipe retainer.Reinstall Spring Brake Chamber.Put on shoes, drum, tires, wheels and hub via vehicle NSTALLATIONINSTALLATION¾ Put on the new gasket, 3)nuts, bolts & washers. Torque per manufacturers’ specs.¾ Connect bridge pipe to cylinder (torque 10-15 ft. lbs) Put in bridge pipe retainer.¾ Put on shoes, drum, tires, wheels and hub via vehicle manufacturers’recommendations.

ADJUSTER CYLINDERBREAKDOWNMANUAL OVERRIDEWHEEL ASSEMBLYPISTONDUST BOOTADJUSTERSHAFTASSEMBLYPISTON SEALLOAD SPRINGGASKETSPRINGLOCATORHOUSINGREMOVAL¾ Remove and Discard Brake Fluid.Attach tube to bleeder screw, and place other end of tube in container.Unscrew bleeder screwwith one turn.pump brake pedal to remove brake fluid.¾ Remove: Wheels, Tires, Drums, Shoes & Lining¾ Remove and clean bridge pipe retainer from packing plate. Disconnect and clean bridge pipefrom adjuster cylinder¾ Remove: Bolts (3), Nuts & Washers from the adjuster Cylinder to Backing Plate and Axle Flange¾ Remove: Allen Bolts (holding Adjusting Cylinder to Backing Plate) Now remove AdjusterCylinder from Backing Plate. Gasket cannot be used again.¾ Remove: Any corrosion or rust that may have accumulated on the Backing Plate with a wirebrush

ADJUSTERCylinderCASTING #Can be foudhereA number (“5”)Stamped in thisarea identifies a1.625” cylinderA number (“6”)Stamped in thisarea identifies a1.75” cylinderADJUSTER CLYLINDER1)Adjuster CylinderAssembly2)Manual Override ASTING NUMBERBORE ��RH1.625”LH1.625”RH1.625”Has aGroovein theExpander& theAbutmentPistons1.75”Does notHave aGroove

PARK CYLINDERBREAKDOWNDUST BOOTEXPANDER PISTONRETURN SPRINGSLEEVEPINSPRING & LOCATORPISTON SEALSSNAP RINGHANDBRAKE PISTONO-RINGRETAINING RINGWASHERHOUSINGWEDGE ASSEMBLYSTOP PINGASKETABUTMENT PISTONDUST BOOTREMOVAL¾ REMOVE & discard brake fluid.¾ Attach a tube to the bleeder screw. Place other end of tube into container to catch brake fluid.Carefully pump brake pedal to eliminate brake fluid. (Dispose of brake fluid properly)¾ Remove wheels, tires, drums, shoes and lining.¾ Remove parking brake spring chamber¾ Remove bridge pipe from backing plate. Clean & disconnect bridge pipe from cylinder¾ Remove bolts (3), washers & nuts, careful to retain the park cylinder to the backing plate & axleflange¾ Remove Allen head bolts. Remove park cylinder & gasket. Do not reuse gasket.¾ Remove any corrosion or rust that may have formed with a wire brush.

Park CylinderPARK CYLINDER1)Park Cylinder XCASTING #BORE SIZE689190676891906868919061689190621.75” LH1.75” RH1.625” LH1.625” RH1.625”Expandersfor Park Cylindershave aGroove1.75”Expandersfor Park Cylindersdo not have aGroove

LEFT SIDEBACKINGPLATE CYLINDERADJUSTINGCYLINDERKITBRIDGEPORT#SPRING 2S201183XSP7871S140016SP78965203250X1.625NO 52X1.75NO 62X1.75NO INGPLATE CYLINDERADJUSTINGCYLINDERKITBRIDGEPORT#SPRING 2S201184XSP7871S140015SP78975203249X1.625NO 51X1.75NO 61X1.75NO T SIDE

LUCAS SYSTEM COMPONENTSLEFT HAND SPRING KITRIGHT HAND SPRING KITPART #PART #140003140004(ORANGE & GREEN)(WHITE & YELLOW)140016BRIDGEPORTLEFT HAND291000140015OVERRIDE WHEELASSEMBLYBRIDGEPORTRIGHT HAND

LUCAS SYSTEM COMPONENTS065147X065316XHYDRAULIC RELAYVALVECONTROL VALVEADJUSTERCYLINDERGASKETAlways use a New GasketWhen Overhauling theCylindersPARKCYLINDERGASKETRC01Applies 3-10 psi in the brake line to keeppressure on the seals in the adjuster andcylinder to help prevent leakage. Valve isworking whether vehicle is running orparked.(This will not prevent all leakage, as someleakage in this system is acceptable)

LUCAS SYSTEM COMPONENTSBrass NutAir PortBleederPortBleederPortKSH101AXSPRING BRAKEKSH202CXContains 1 Air Port &2 Bleeder PortsAIR & HYDRAULICSPRING BRAKEContains 1 Air PortAIR ONLYMQ5200180KSH5200099BLEEDER SCREWElbow Fitting with Plug

LUCAS SYSTEM COMPONENTS2771320X2771558XPump & MotorHydromaxBP1X12379XBrake PumpMini Master Cylinder

LUCAS SYSTEM COMPONENTSL5489LUCAS DURAPARK Brake Cylinder Overhaul KitSP7871SADJUSTER CYLINDER KITSP7872SPARK CYLINDER KIT

LUCAS GIRLING DRUM BRAKE ASSEMBLY TROUBLESHOOTINGSYMPTOMFluid LeakageAt theWheel CylindersPOSSIBLE CAUSES AREBUT NOT LIMITED TOIf the dust boot is damaged it will allow contaminants into the cylinder, causingscoring of the piston seal.The brake fluid is designed to absorb water caused by condensation. The fluidshould be changed every two years to avoid water contamination. Threepercent contamination can lower the boiling point by 50%. As the fluidbecomes contaminated with water condensation, the fluid looses the ability toprotect the metal parts in the system and rust will begin to form. Rust and/oroverheating due to boiling fluid will damage the piston seals causing the sealsto leak. Note: Rust tends to turn black when introduced to brake fluid and heatthus resulting in black fluid.Distortion to the piston seals can be caused as the brake system cools and thefluid returns to the master cylinder. As the fluid returns to the master cylinderreverse force can be applied to the piston seals resulting in distortion andleakage.If the KSH parking brake chamber leaks fluid into the park cylinder, the fluidwill cause the park cylinder seals to swell, resulting in leakage and fluidcontamination. Note: Some KSH parking brake chambers are air operated.CORRECTIONReplace all affected adjuster cylindersand flush the systemReplace all leaking components & allbrake lines, flush the systemthoroughly.Replace all affected adjustedcylinders.Install an RC01 check valve.Replace the affected backing plates,The KSH parking chambers andflush the system

Hydraulic Brake Systemw/ Tandem Rear Primary Hydraulic SystemLight Dotted Line2771558XSecondary Hydraulic SystemStraight LineParking Brake SystemDark Dotted Line

right side backing plate # bore size shoes 202249x 1.625 5” 202251x 1.75 5” 202261x 1.75 6” 202271x 1.75 7” 203249x 1.625 no shoes