SB-10054551-5707

Service Bulletin No. 13-11-01
To:

Distribution – Operations Managers, Maintenance Managers and Maintenance Personnel

From:

Bill Nygaard – Director, Service

Attachments: Kongsberg Automotive Adjustable Floor Pedal Service Manual
Affects:

All buses equipped with adjustable pedals

Date:

August 09, 2013

Prepared By:

Bill Nygaard
Director, Service

Approved By:

Dan Allen
Chief Engineer

Periodic inspection is required to maintain proper functionality of the adjustable pedals.
The instructions outlined in this Service Bulletin supersede information previously published in your
Maintenance Manual. Please review the attached manual, provide to key maintenance personnel, and update
bus preventative maintenance programs as required.
For questions regarding this NABI Service Bulletin, please contact:
Kalman Takacs – Sr. Field Service Engineer
[email protected]
256-453-7583 (mobile)

Adjustable Floor Pedal Service Manual
COMPLETE BASE ASSEMBLIES
0

► Caterpillar Throttle (45 throttle angle)
E6/E8 – 317880-005 (Integrated Connector)
E10 – 317881-004 (Integrated Connector)
0

► Cummins Throttle (45 throttle angle)
E6/E8 w/IVS – 317880-001 (700mm Lead)
E6/E8 Dual Analog – 317880-002 (700mm Lead)
E10 w/IVS – 317881-001 (700mm Lead)
E10 Dual Analog - 317881-002 (700mm Lead)
E10 Dual Analog - 317881-008 (Integrated Connector)
0

► Cummins Throttle (40 throttle angle)
E10 w/IVS – 317881-011 (700mm Lead)
E10 Dual Analog – 317881-012 (Integrated Connector)
0

► Cummins Throttle (35 throttle angle)
E6/E8 w/IVS – 317880-008 (700mm Lead)
E6/E8 Dual Analog – 317880-004 (700mm Lead Deutsch)
E6/E8 Dual Analog - 317880-010 (700mm Lead)
E10 w/IVS – 317881-005 (700mm Lead)
E10 Dual Analog - 317881-006 (700mm Lead)
0

► Cummins/Allison Hybrid (45 throttle angle)
E6/E8 - 317880-007 (Integrated Connector)
E10 - 317881-007 (Integrated Connector)

Note: all connectors are Packard
Metripak unless otherwise specified

0

► Cummins/Allison Hybrid (40 throttle angle)
E6/E8 - 317880-013 (Integrated Connector)
0

► Cummins/Allison Hybrid (35 throttle angle)
E10 - 317881-010 (Integrated Connector)
0

► DDEC V Throttle (45 throttle angle)
E10 – 317881-009 (700mm Lead)
0

► DDEC V Throttle (35 throttle angle)
E6/E8 – 317880-009 (700mm Lead)
0

► Detroit/Mercedes Throttle (45 throttle angle)
E6/E8 – 317880-003 (700mm Lead)
E10 – 317881-003 (700mm Lead)
0

► Detroit/Mercedes Throttle (35 throttle angle)
E6/E8 - 317880-006 (700mm Lead Deutsch)
Switch and Wiring Harness 6549011

2011

IS-6971310 R2

Removal and Installation Contents:
Drive Motor ................................................................................................................. page 3
Throttle ........................................................................................................................ page 4
Brake Treadle Rubber Overshoe ............................................................................... page 5
Brake Treadle .............................................................................................................. page 6
Brake Plunger ............................................................................................................. page 8

Scheduled Maintenance:
Brake Plunger ............................................................................................................. page 8
Every 3 months, 25,000 miles, or 900 operating hours:
Clean any accumulated dirt, gravel, or foreign material away from the pedal system
Follow the procedure to remove, clean, inspect, grease and install the brake plunger
(see page 8) – replace as necessary
Inspect the rubber plunger seal for cracks, holes or deterioration. (see diagram on
page 8) – replace as necessary
Inspect the pedal system mounting plate, brake and accelerator treadles for integrity
Inspect the pedal system for proper operation

Note:

This drive motor runs on 12 VDC power source (6 amp max.)
Do not lift assembly by throttle pedal

Tools Required:
Torque Wrench capable of both 30 and 110 in-lb
#3 Phillips Head Screw driver attachment for torque wrench
3/8” Hex Head driver attachment for torque wrench

2011

Page 2

IS-6971310 R2

DRIVE MOTOR REPLACEMENT
Removal
1. Disconnect the electrical connector at the
drive motor (1)

2. Slide the cable drive shaft into the
transmission

Note: it may be easier to disconnect the
electrical connector after the drive motor is
removed.

3. Slide the new drive motor over the cable
drive shaft, making sure the square end
of the cable drive shaft is fully seated in
both the transmission and the drive
motor.

2. Remove the drive motor mounting screws
(2)
3. Remove the motor by gently sliding the
motor away from the transmission making
sure to capture the cable drive shaft
connecting the drive motor to the
transmission.
4. If not done previously in #1 above,
disconnect the electrical connector at the
drive motor.
Installation
1. Connect the electrical connector to the
drive motor. (1)
Note: make sure the connector is fully locked
into position.

Item #

Part Description

Part Number

1

Drive Motor

016T-G4270

2

Screw

3809816

2011

Page 3

Note: do not force the cable drive shaft in
either the drive motor or transmission. The
square ends of the cable drive shaft should
slide freely into both the transmission and
the drive motor.
4. Align the motor with the connector
down, line up the holes for the drive
motor attaching screws and install the
screws (2). Tighten the attaching screws
to 30 in-lb.
5. Test the drive motor by activating the
adjustable pedal switch several times
while observing the adjustable unit for
smooth operation.

1

(12 volt DC; 6 amp max.)

IS-6971310 R2

THROTTLE REPLACEMENT
Removal
1. Disconnect the throttle sensor wiring lead
from the vehicle harness. (Not shown in
diagram)
Note: if applicable, be aware of the wiring
path and constraint methods so the same can
be used during installation to ensure safe and
proper constraint of the sensor wire lead
2. Remove the throttle mounting screws that
fasten the throttle to the base
3. Remove the throttle pedal
Item #

Part Description

Part Number

Throttle Assembly (450)
Caterpillar (Integrated Packard Connector)
Cummins w/IVS (700mm Flying Lead Packard)
Cummins Dual Analog (700mm Flying Lead Packard)
Cummins/Allison Hybrid (Integrated Connector Packard)
Detroit Diesel/Mercedes (700mm Flying Lead Packard)
Detroit Diesel V (700mm Flying Lead Packard)
1

Throttle Assembly (400)
Cummins w/IVS (700mm Flying Lead Packard)

75130NO-47CI-01

Throttle Assembly (350)
Cummins w/IVS (700mm Flying Lead Packard)
Cummins Dual Analog (700mm Flying Lead Packard)
Cummins Dual Analog (700mm Flying Lead Deutsch)
Cummins/Allison Hybrid (Integrated Connector Packard)
DDC/Mercedes (700mm Flying Lead Deutsch)
2

Screw

75140NO-10CP-27
75140NO-47CI-01
75140NO-47CD-00
75140NO-10CA-39
75140NO-47CI-07
75140NO-47CN-41

75120NO-47CI-01
75120NO-47CD-00
75120NO-27CD-00
75120NO-10CA-39
75120NO-27CI-07
6554414

Installation
1. Install the new throttle on the mounting plate
2. Install the throttle mounting screws and tighten them to 110 in-lb.
3. Connect the throttle sensor connector to the vehicle harness. If applicable, run the wire lead along
the same path and constrain using the same method as the pedal removed. (Not shown in diagram)
Throttle Calibration
1. Turn on the vehicle ignition without
starting the engine.
2. Cycle the throttle to full throttle and back
to idle 3 complete turns.
2011

Page 4

3. Turn off the vehicle ignition and wait 1
minute.
4. Start the vehicle and check for proper
throttle operation.
IS-6971310 R2

BRAKE TREADLE OVERSHOE REPLACEMENT
Removal and Installation
1. Remove the old rubber overshoe (1) by
gently prying out on the cover.
2. Clean the surface thoroughly to remove
any dirt or debris from the brake treadle.
3. Install the new rubber overshoe making
sure the edges are fully seated around the
outside of the treadle and locking the
rubber overshoe in place.
Note: make sure the rubber tabs on the
underside of the rubber overshoe are fully
seated through the three alignment holes in
the treadle
Item #
1

Part Description
Rubber Overshoe

Part Number
800389

Note: if applicable, be aware of the wiring path and constraint methods so the same can be used
during installation to ensure safe and proper constraint of the sensor wire lead

2011

Page 5

IS-6971310 R2

BRAKE TREADLE REPLACEMENT
Removal
1. Remove the safety clip (3) from the inside
end of the brake treadle pivot pin (2).
2. Remove the brake treadle pivot pin by
sliding it out of the brake treadle and
carrier.

2. Inspect the brake treadle pivot holes for
any wear.
Warning: If any wear is noted (elongation
and/or looseness of the holes) the brake
treadle must be replaced. A worn brake
treadle can lead to a sticking and/or
binding condition of the brake treadle.

3. Remove the brake treadle (1).
Installation
1. Inspect the brake treadle pivot pin for any
wear.
Warning: If any wear is noted on the
brake treadle pivot pin it must be
replaced. A worn brake treadle pivot pin
can lead to a sticking and/or binding
condition of the brake treadle.

Item #

2011

Part Description

3. While holding the brake treadle in
position, slide the brake treadle pivot pin
through the brake treadle and the carrier
assembly.

Part Number

1

Brake Treadle

6560716

2

Pivot Pin

6551312

3

Safety Clip

203071

Page 6

IS-6971310 R2

BRAKE TREADLE REPLACEMENT - CONTINUED
Note: Align the flat on the pivot pin (2) with the
machined relief on the outside edge of the
brake treadle (1) as shown below.
4. Install a new safety clip to the inside end
of the brake treadle pivot pin.
5. Inspect the safety clip to make sure it is
secured correctly to the brake treadle pivot
pin as shown below.
Warning: the safety clips must be fully
seated around the end of the brake
treadle pivot pin. Failure to fully seat and
lock the safety clip in place could allow
the brake treadle pivot pin to shift and
cause a binding condition of the brake
treadle. Always check to make sure the
safety clip is fully seated and locked over
the end of the brake treadle pivot pin.

2011

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IS-6971310 R2

BRAKE PLUNGER REMOVAL AND INSTALLATION
Removal
1. Adjust the assembly to a mid-travel point
to create clearance with the carrier for
plunger removal.
2. Follow the instructions (in this document)
to remove the brake treadle assembly.
3. Lift up on the moveable arm assembly and
remove the brake plunger seal (1).
4. Slide the brake plunger (2) up and out of
the bore of the valve casting bore.
5. Clean and inspect the brake plunger and
the valve casting bore for any wear,
scoring or damage.

2011

Page 8

1

Plunger Seal

Part
Number
6702214

2

Brake Plunger (fits Bendix E6/E8 valves)
Brake Plunger (fits Bendix E10 valves)

6565710
6565813

3

Grease, Bendix PN 246671

6705212

Item #

Part Description

Warning: If any wear, scoring, or
damage is noted, either the plunger
and/or valve casting (complete AFP unit)
must be replaced. Failure to replace a
damaged plunger or valve casting could
lead to a sticking condition of the brake
control.

IS-6971310 R2

BRAKE PLUNGER REMOVAL AND INSTALLATION - CONTINUED
Installation
1. Grease the inside of the valve casting
bore and the outside of the brake plunger
with the specified grease included in the
service kit.
Warning: Use only the grease specified.
This is a very specific grease that has
been fully tested and approved for this
application and cannot be substituted
with any other grease.
2. Lift up on the moveable arm and slide the
brake plunger into the valve casting bore.
3. Install the brake plunger seal making sure
it is fully seated in the seal groove in the
plunger and the valve casting.
4. Rotate the moveable arm back down so it
rests on top of the plunger.
5. Follow the instructions (in this document)
to re-install the brake treadle.
Warning: If any wear or looseness is
noted on the brake treadle pivot pin or
the brake treadle pivot holes the
component parts must be replaced. A
worn brake treadle pivot pin or brake
treadle can lead to a sticking and/or
binding condition of the brake treadle.

2011

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IS-6971310 R2