Академический Документы
Профессиональный Документы
Культура Документы
AND TACTICS
General information
Contents
System pressures
Port numbers
Use IMPACT
Basic fault nding logic
Charging circuit
Rear circuit
Circuit diagram
Footbrake valve
Load sensing valve - steel suspension
Load sensing valve - graph
Load sensing valve - air suspension
Load sensing valve - graph
Spring brake chamber
Front circuit
cont.
Park circuit
Circuit diagram
Park brake control valve
Blocking valve
Connections at park brake tank
Anti-compound valve
Trailer brake control valve
Spring brake chamber
Auxiliary circuit
Circuit diagram
High pressure system
Circuit diagram
7 port MCPV
Pressure reduction - front and park
circuit
Z Cam brakes
Earlier S cam
Z cam advantages
Automatic adjustment
Brake stroke
Leading and trailing shoes
Measuring lining thickness
Shoe remove and ret
Tappet components
LH and RH components
Initial setting of brake shoes
Disc brake
????
Introduction
About this
Pocket guide
Danger,
Warning,
Caution &
Note
Replacement
parts
Specication
Copyright
General information
9
General information
Air system
High pressure
system
10
General information
High pressure
system - cont.
Low pressure
system
All pre 98 FM/FH trucks with air suspension, and all trucks
with steel suspension have a low pressure system.
On trucks with air suspension, every tank has 7.5 bar
pressure, except the wet tank which has 12.0 bar pressure.
On trucks with steel suspension, every tank has 7.5 to 8.5
bar pressure.
The low pressure system can be identied by a 5 port
MCPV.
11
General information
Air pressure
units
Port numbers
- general
12
General information
Use IMPACT
13
General information
Air is leaking from a valve.
Yes
No
14
General information
Basic air brake
fault nding
logic
15
16
Charging circuit
17
Charging circuit
23
1a
2a
24
1
14
2b
18
Charging circuit
Circuit
with steel
suspension
19
Charging circuit
23 1a
2a
24
1
14
2b
3
A
52a
52b
20
Charging circuit
Circuit with air
suspension
21
Charging circuit
1COMP530
2COMP1080
22
Charging circuit
Compressor
Power
reduction (PR)
23
Charging circuit
PR function
- twin cylinder
24
Charging circuit
Compressor
checks
25
Charging circuit
Compressor
checks - cont.
26
27
Charging circuit
3
28
Charging circuit
Air dryers
Air dryers are used to dry, clean and cool air from the
compressor.
They have a renewable cartridge lled with water absorbing
granules - desiccant. The cartridge usually has an oil
separator which helps to remove oil passed over from the
compressor. Oil contamination reduces the effectiveness of
the desiccant.
Four types of air dryer are in use - three single tower and
one twin tower. All dryers - except AIRDRY-E - use a
regeneration tank.
Single tower
1 Wabco
2 Haldex
3 Knorr
These dryers have integral pressure regulating (governor)
valves
29
Charging circuit
30
Charging circuit
Twin tower
Dryer faults
Single tower dryers should not have any air leaks from the
exhaust port when the compressor is charging.
After the dryer unloads, it can take up to 30 sec. for the
regeneration tank to discharge through the dryer exhaust.
If discharge takes too long, a fault in the non-return valve is
indicated.
31
Charging circuit
Leaks - twin
tower
32
33
Charging circuit
0
1
4
D
C
1587 / 1939
G
M
I
+ 15
34
Charging circuit
AIRDRY - E
G - Unloader & PR
J - Non-return valve
K - Data bus
L - Ignition feed
M - Heating element
35
Charging circuit
AIRDRY - E
- cont.
Air leaks
36
37
Charging circuit
1 Supply from
wet tank
P3
2 Output signal to
air dryer port 4.
P2
3 Exhaust
P1
38
Charging circuit
Governor
valve
Cut out
pressure
Cut in
pressure
39
Charging circuit
Governor
valve faults
Checking cut
out pressure
40
Charging circuit
Checking cut
in pressure
Adjusting the
pressure
Remote
mounted
valve
Integral valve
41
Charging circuit
42
Charging circuit
Pressure
limiting valve
Pre 98 types
43
Charging circuit
P1
P2
44
Charging circuit
Truck version
2 valves
Checking the
pressure
45
Charging circuit
46
Charging circuit
Multi circuit
protection
valve - MCPV
Port numbers
- pre 98
47
Charging circuit
Port numbers
- post 98:
Valve versions
- 5 port
48
Charging circuit
Version 1
Version 2
49
Charging circuit
It was then noted that, a truck parked overnight could leak
air from one of the service circuits which, again, meant
that the truck could be driven with only one service circuit
completely lled - so version 3 was introduced.
Version 3
50
Charging circuit
However, many technicians thought this leak was a fault,
and renewed the valve - so version 4 was introduced.
Version 4
This valve still has the choke valve tted but, instead of
leaking to atmosphere, the park tank drains into the rear
service tank.
This valve is in current use - all version 2 trucks have this
valve tted..
51
Charging circuit
Has the valve
got a choke
drain valve ?
Valve version 3
If park tank air now leaks from the exhaust port - in the
centre of the MCPV four elements - a choke valve is tted.
Valve version 4
If park tank air now drains into the rear service tank - a
choke valve is tted.
Note: This is a normal function of the valve - the valve is
NOT faulty.
52
Charging circuit
MCPV without
choke drain
valve
MCPV common
faults
53
Charging circuit
Note porting
differences in
this area
P1
P2
54
Charging circuit
Overow valve
Opening
pressure - to
system
Ports
55
Charging circuit
56
Charging circuit
Easy check type 52a valve
57
Charging circuit
Note porting
differences in
this area
17
P1
P2
58
Charging circuit
Type 52b
Opening
pressure - to
tank
Ports
Return ow
59
Charging circuit
60
Charging circuit
Three versions
Version 1
Version 2
Version 3
61
62
Rear circuit
63
Rear circuit
12
37
24
4
10
30
33
33
S
P
2
56
64
Rear circuit
Main
components
65
Rear circuit
P12
P22
P11
P21
66
Rear circuit
Footbrake valve
Primary circuit
67
Rear circuit
P12
P22
P11
P21
68
Rear circuit
Ports - EBS
Air leaks
- non EBS
69
Rear circuit
Port 21 pipe
Air leaks from the valve exhaust port (3) only when the
park brake is OFF:
Disconnect the pipes from ports 21 and 22.
If air is escaping from the port 21 pipe, the most likely
causes are:
- faulty anti-compound valve. Conrm by disconnecting the
pipe from the service port
- faulty trailer brake control valve. Conrm by disconnecting
the pipe from port 41.
70
Rear circuit
Port 22 pipe
71
Rear circuit
P4
P2
P1
L
P2
72
Rear circuit
Load sensing
valve
Valve with steel
suspension
The load sensing valve adjusts the air pressure to the rear
brake chambers in proportion to the load on the vehicle.
The illustration above shows the type of valve used with
steel suspension. This valve has an integral relay valve.
Note: Some very early trucks - e.g. FL6 - have separate
load sensing valve and relay valve.
Output pressure is determined by spring deection, which
is mechanically communicated to the valve via a rod and
lever (L).
Ports
Testing
73
Rear circuit
P out
+/- 0.4 bar
Lever deection - mm
80
70
60
50
40
3
2
20
f
L = 80 mm
+/- 2 mm
10
1
0
30
10 12 14 16 18 20
00
74
Rear circuit
Load sensing
valve graph steel suspension
Example
75
Rear circuit
P4
P1
P2
P3
P42
P41
76
Rear circuit
The illustration above shows the type of valve used with air
suspension. This valve has an integral relay valve.
Output pressure is determined by the pressure in the rear
air bags, which is sensed at ports (41) and (42).
Ports
Testing
77
Rear circuit
P out
+/- 0.4 bar
bar
8
4 x 2 truck
7
6
P Out
5
4
P Air bag
3
2
1
0
10 12 14 16 18 20
78
Rear circuit
Load sensing
valve graph - air
suspension 4x2
In the example above, air pressure in the rear air bags has
been measured at approx. 2 bar.
Find 2 bar on the LH scale.
Follow the horizontal line until it intersects the P Air bag
graph line.
Move vertical up to the P Out graph line.
Move left to the LH scale and read the value.
This is the pressure required in the rear brake chambers.
Note: That output pressure is governed around a constant
input pressure of approx. 7 bar.
79
Rear circuit
80
Rear circuit
81
Rear circuit
8
7
6
5
4
3
2
1
bar 0
7
6
5
4
3
2
1
0
Pusher/tag axle
Input brake
pressure is
output from
drive axle P
brake
Drive axle
Input brake
pressure - 7 bar
P Brake
P Air bag
10 12 14 16 18 20 22
82
Rear circuit
83
Rear circuit
1
Drive
P11
P12
Park
84
Rear circuit
Spring brake
chamber operation
Drive
Park
85
Rear circuit
5
Service
5
P11
P12
Mechanical release
86
Rear circuit
Service
Mechanical
release
No brakes !
-chock
wheels
87
Rear circuit
1
2
Air leak
points
88
Rear circuit
Leak check
- service
brakes
With the footbrake applied, check for leaks at the tell tale
hole, and push-rod.
Leaks from these points indicates a ruptured service
diaphragm, which can be renewed as a separate part.
Renew
diaphragm
No park
brake !
DANGER
Bolt must be screwed fully back in after repairs.
If this is not done, there will be no park brake.
Note: On new type chambers, with captive nut,
turn bolt 45 turns until it stops, and the red plunger
is fully down.
89
Rear circuit
Leak check
- park brakes
Seal (1) around the park brake piston normally prevents air
transfer from the park brake chamber to the service brake
chamber.
If this seal leaks, air will leak from the load sensing valve/
relay valve, or a brake modulator, when the park brake is
released.
90
Front circuit
91
Front circuit
11
33
12
33
2
7
24
14
33
P12
P11
10
S
P
P22
P21
33
92
Front circuit
Main components
- circuit with steel
suspension
93
Front circuit
12
22
11
21
94
Front circuit
Footbrake valve
Primary circuit
95
Front circuit
P1
2
P4
P4
P3
96
Front circuit
Quick release
valve
QRV - front
circuit
97
Front circuit
P1
P4
P4
P3
Front circuit
QRV - park
circuit
99
Front circuit
P4
P2
P2
P3
100
Front circuit
Relay valve
Like the QRV, the relay valve is located close to the brake
chambers for rapid brake application and release.
A relay valve may be tted in the front brake circuit, rear
brake circuit, park brake circuit or all circuits.
When front load sensing is tted - long wheelbase 4 axle
trucks -the QRV is replaced by a relay valve, controlled by
a pilot valve.
Relay valve
ports
101
Front circuit
P4
P2
P2
P1
P3
Brakes OFF
Brakes applying
Brakes applying
102
Front circuit
Brakes held
Brakes released
103
Front circuit
Relay valve
leaks
104
105
Front circuit
P1
P4
P2
P
106
Front circuit
Pilot valve
Ports
107
Front circuit
33
33
11
7
7
2
10
S
33
33
108
Front circuit
Main
components circuit with front
air suspension
109
Front circuit
Input pressure P= 7 bar
Pressure at front brake chambers
- bar
7
6
Signal pressure from
rear load sensing valve
- bar
5
4
110
Front circuit
Pilot valve
graph
Test points
111
Front circuit
Pilot valve
faults
112
Park circuit
113
Park circuit
13
24
14
2b
17
19
31
30
33
33
114
Park circuit
Main
components
115
Park circuit
P2
P1
P3
116
Park circuit
Park brake
control valve
- FL & Bus
Ports
Port 1 - supply
Port 2 - delivery
Port 3 - exhaust
The valve has 2 operating positions - ON and OFF.
There is no secondary, or progressive function.
117
Park circuit
118
Park circuit
Park brake
control valve
FM/FH
Ports
119
Park circuit
P2
P1
120
Park circuit
Blocking valve
Ports
121
Park circuit
15
13
1a
2
3
122
Park circuit
Connections
at park brake
tank
1a Safety valve
13 Park brake tank
15 Non-return (one-way) valve
2 Trailer brake connection
3 Park brake connection
Testing the
park brake
valve
123
Park circuit
P3
P1
P2
P2
P3
P1
P3
124
Park circuit
Anticompound
Ports
Operation
125
Park circuit
Operation cont.
Testing the
valve
Apply the park brake, and note the position of the brake
operating levers.
Watch the levers, and apply the footbrake. The levers
should not move any further in the application direction.
126
127
Park circuit
P41
P22
P43
P21
P42
128
Park circuit
Trailer brake
control valve
- early type
Ports
Port 41 - rear
Port 43 - park (port 22)
Port 42 - front
Port 22 - red trailer line
Port 21 - yellow trailer line
P - from park brake tank
Adjustment
129
Park circuit
130
Park circuit
Trailer brake
control valve version 2 trucks
Ports
Adjustment
Dump valve
131
Park circuit
Testing the trailer
brake control
valve
132
133
Park circuit
P12
134
Park circuit
Spring brake
chamber
Remember !
1 Push-rod
2 Service diaphragm return spring
3 Service brake chamber - nearest to the push rod
4 Service brake diaphragm
5 Captive nut
6 Park brake chamber piston
7 Park brake application spring
8 Park brake chamber - furthest from the push rod
9 Park brake mechanical release bolt
Park brake ON = air OUT of park chamber = spring
applies brake.
Park brake OFF = air IN to park chamber = spring
compressed.
Foot brake ON = air IN to service brake chamber = air
applies brake.
Footbrake OFF = NO air to service brake chamber.
135
Park circuit
Brake chamber
faults
136
Auxiliary Circuit
137
Auxiliary circuit
P24
24
138
Auxiliary circuit
The auxiliary circuit includes - e.g. drivers seat, clutch,
gearbox air system, air horns.
The circuit is fed from port (24) of MCPV (1), via in-line air
lter (??).
139
140
11
P21
12
P1
P11
51
2b
10
P12
P23
14
P22
P24
24
61
56
S
P
142
Air
suspension
Pressure limiting
valves
143
144
EBS
1
21
22
11
12
23
24
145
EBS
7 port MCPV
146
EBS
7 port MCPV
- cont.
Version 1
Version 2
Version 3
147
EBS
P21
P22
11
24
P11
51 new type
P12
P24
P23
S
P21
10
P11
37
51 early
type
25
13
148
EBS
Pressure
reduction - front
and park circuit
EBS
Thick lines = HIGH
pressure
Thin lines = low
pressure
11
12
P11
P23
14
2b
51
P1
P21
24
P22
P12
61
56
S
P
10
151
P21
33
37
P22
24
P11
P23
37
P1
P12
37
33
P24
13
S
P
25
30
37
31
33
33
152
EBS
Info/illust reqd
153
EBS
154
ECS
23
22
22
21
22
21
4
1/3 21
3
156
P23
P22
P1/3
P4
56
56
56
P21
Y25
P22
P22
P21
P21
P1
P1
56
Y29
52a
56
14
56
56
157
ECS
P22
P23
P21
P4
P1/3
P21
P3
P1
P1
P3
158
ECS
Ports
1/3 Supply air and drain to drive axle solenoid (port 23)
21 Delivery to LH front air bag
22 Delivery to RH front air bag
4 Supply from wet tank for solenoid valve control
159
160
Z Cam Brakes
161
Z cam brakes
162
Z cam brakes
Earlier S cam
Inefcient
Disadvantages
163
Z cam brakes
3
1
2
1
3
164
Z cam brakes
Z Cam
Even contact
area
165
Z cam brakes
166
Z cam brakes
Automatic
adjustment
167
Z cam brakes
S
168
Z cam brakes
Brake stroke
Use IMPACT
169
Z cam brakes
170
Z cam brakes
Leading and
trailing shoes
Each wheel assembly has a leading - or primary (P) shoe, and a trailing - or secondary (S) - shoe.
The linings are offset on the shoes, leaving a gap between
the end of the lining and the end of the shoe, facing the
direction of rotation.
Arrows (A) on the end of the shoe indicate the correct
direction of drum rotation.
171
Z cam brakes
172
Z cam brakes
Shoe location
173
Z cam brakes
174
Z cam brakes
Measuring lining
thickness
175
Z cam brakes
P
999 8550
P
176
Z cam brakes
CAUTION
To avoid damage to the ABS pole wheel, spring expansion
tool 999 8550 must be used.
Expanding the tool relieves spring pressure from return
pins (P), allowing them to be withdrawn and retted during
shoe remove and ret.
CAUTION
Do not apply the park brake or footbrake when the brake
drum is not tted.
The expander mechanism may be damaged.
If the drum is to be left off for a long period, wind off the
spring brake.
This will prevent damage if there is loss of air which would
normally cause the brake to come on.
177
Z cam brakes
1
2
3
4
5
250 mm
178
Z cam brakes
Tappet
components
When relining
Retraction spring
5 Tappet screw
6 Tappet seal
7 Strut
179
Z cam brakes
LH thread
RH thread
180
Z cam brakes
LH and RH
components
181
Z cam brakes
4
1
999 8386
182
Z cam brakes
Initial setting of
brake shoes
Set tappet
heads
183
Z cam brakes
184
Z cam brakes
Setting
procedure
Set trailing
shoe rst
4 Attach the setting tool to the hub, and turn the hub until
indicator wheel (3) is in line with the second row of rivets at
the abutment end of the trailing shoe.
5 Tap the shoe sideways until the indicator is at zero.
185
Z cam brakes
4
186
Z cam brakes
6 Turn the hub until the indicator wheel is in line with the
second row of rivets at the expander end of the trailing
shoe.
7 If the indicator is not at zero, turn the manual adjuster
until the indicator is at zero.
8 Re-check the abutment end reading. Continue tapping
the shoe and turning the adjuster until the indicator is at
zero at both ends of the shoe.
Set leading
shoe
187
Z cam brakes
Set leading
shoe - cont.
188
Disc Brake
189
Disc brake
Info/illust reqd
190
191
192