Sundaram-Clayton Limited

2
Sundaram-Clayton Limited

SCHEMATIC LAYOUT - DUAL FULL AIR BRAKE SYSTEM SINGLE - AXLE VEHICLE
 DRYING AND DISTRIBUTION UNIT

SC 160 HS COMPRESSOR

HOSE ASSEMBLY 23 21
FROM ENGINE INTAKE AIR FILTER
24 22

TO EXHAUST BRAKE AIR CYLINDER WITH MAGNETIC VALVE

DUAL BRAKE VALVE

STOP LIGHT SWITCH LPI SWITCH

DRAIN VALVE RESERVOIRS - CUSTOMER’S SUPPLY

DRAIN VALVE
GRADUATED HAND CONTROL VALVE

LPI SWITCH

HOSE ASSEMBLY

RG2 RELAY VALVE

RG2 RELAY VALVE

RG2 RELAY VALVE

HOSE ASSEMBLY
TY20 BRAKE CHAMBER HOSE ASSEMBLY

HOSE ASSEMBLY

HOSE ASSEMBLY HOSE ASSEMBLY SLACK ADJUSTER

SLACK ADJUSTER
SLACK ADJUSTER TY24/24 SPRING BRAKE ACTUATOR

TY20 BRAKE CHAMBER

Sundaram-Clayton Limited

HOSE ASSEMBLY

HOSE ASSEMBLY HOSE ASSEMBLY

SLACK ADJUSTER
SLACK ADJUSTER

HOSE ASSEMBLY
SLACK ADJUSTER

SCHEMATIC LAYOUT - DUAL FULL AIR BRAKE SYSTEM MULTI - AXLE VEHICLE

3

DUAL BRAKE SYSTEM
The Dual Brake system is a split system of air
brakes to actuate front and rear foundation
brakes separately / independantly , thereby,
ensuring partial braking for the vehicle, in the event
of failure in air system in any of one these
circuits. (Front or Rear). This system can be of full
air brake system or Air assisted hydraulic
brake system.
THE SYSTEM

The compressor draws air from engine inlet
mainfoid and compressed air is pumped into the
sensing reservoir through the Unloader Valve with
Tyre lnflator or Air Dryer.

The Air Dryer/ Unloader Valve with Tyre lnflator
ensures unidirectional flow of compressed
air into the system apart from regulating the
system pressure.

The sensing reservoir delivery is connected to
the inlet of Quadruple System Protection Valve.

The Quadruple System Protection Valve has one
inlet and four independent delivery lines.
* Two out of the four delivery lines are
connected to Port 21(Primary) and port
22(Secondary) and aids preferential
charging of compressed air for service
brake application.
* The third line (Port 23- Auxiliary) is used for
parking brake application in the Rear by
actuating the Spring brakes.
* The fourth line (Port 24- Auxiliary)
provides compressed air for actuating the
auxiliary systems like engine exhaust
brake, air horn, air suspension, wiper etc.
4
Sundaram-Clayton Limited

Port 21 of Quadruple System Protection Valve is
connected to the primary Reservoir and inturn the
delivery of this reservoir is connected to the Primary
Inlet of Dual Brake Valve (Port 11)

Port 22 of Quadruple System Protection Valve is
connected to the secondary Reservoir and inturn the
delivery of this reservoir is connected to the
secondary Inlet of Dual Brake Valve (Port 12)

The Primary delivery of Dual Brake Valve (Port 21) is
connected to the Service port of Spring Brake
Actuators. (Port 11) in the rear.

The Secondary delivery of Dual Brake Valve (Port
22) is directly connected to the Brake Chambers in
the Front.

Port 23 of Quadruple System Protection Valve is
connected to the inlet of Graduated Hand Control
Valve and its delivery to the Spring Brake port (12) of
the Spring Brake Actuators in the Rear.

Low Pressure Indicator Switches, one each are
fitted on the Primary and Secondary inlet port of Dual
Brake Valve and one in the Delivery port of
Graduated Hand Control Valve to provide warning in
the event of drop in air pressure below safe value.

Stop Light Switches, one each are secured in the
delivery ports of Primary and Secondary of Dual
Brake Valve to leave warning to the rear coming
vehicles as and when brake is applied.

If the system is with Unloader Valve with Tyre
Inflator, air filter is fitted between the Primary /
Secondary inlet of Dual Brake Valve and its
respective reservoirs.


The output rods of the Brake chambers and
Spring brake actuators in the front and rear
axles respectively are connected to the
foundation brakes through Slack adjusters.

Exhaust Brake System :
Mechanical arrangement
Port 24 of the Quadruple System Protection Valve
is connected to the Exhaust Brake Air
Cylinder through Air Exhaust Brake Valve / Foot
Control Valve.
* An Isolator valve is fitted in between any
one of these valves and Exhaust Brake Air
Cylinder to facilitate the exhaust brake
inoperative whenever not required.
* Air exhaust brake valve is coupled to the
brake pedal arrangement to enable
exhaust brake application initially and
service brakes subsequently.
* The foot control valve is fitted in the floor
board to enable exhaust brake actuation
as and when required by the driver.
Electro - pneumatic arrangement
Alternatively, a Magnetic valve is secured onto the
exhaust brake air cylinder and the terminals of the
same connected to the limit switch which is coupled
to the brake pedal also facilitates exhaust brake
application initially and service brake subsequently.
SERVICE BRAKES

Initial Charging
* As the system starts charging, the
preferential arrangement in the Quadruple
System Protection Valve allows air into
Service Reservoirs (Primary / Secondary).
Sundaram-Clayton Limited
* As the pressure reaches above opening
pressure of auxiliaries in the system, the
auxiliary lines start charging.
* As long as the system pressure is below the
opening pressure of the Auxiliaries, the hand
brake is inoperative and the Spring Brakes are in
applied condition.
* As soon as the compressor starts
pumping air into the system and the system
pressure is below the opening pressure of the
auxiliaries, the low pressure indicator switch
continues to give warning.
* The warning from the Low Pressure
Indicator switch stops when the system
pressure reaches above opening pressure
of the Auxiliaries and with the lever of
Graduated Hand Brake Valve in ‘Brakes
off ‘ position.
* In this position, the Spring brakes in the
Rear are fully released.

Service Brakes Application
* When the Dual Brake Valve pedal is depressed,
compressed air from the Primary Reservoir is
fed into the Service port (11) of the Spring
brake actuators through the Dual brake valve
primary and applies the brakes in the rear.
* Simultaneously, compressed air in the Secondary
reservoir is fed into the brake chambers through
the Dual Brake valve secondary and applies
the brakes in the front.
* Application of brakes in Front and Rear is
simultaneous and the Stop Light Switches inturn
closes the contacts & switching-on the warning.
5

* The Foundation Brakes are actuated by the
slack Adjusters connected to the output rod
of the brake chambers and Spring brake
actuators in the Front and Rear Brakes
respectively.

Service Brakes releasing
* On release of the load on the pedal of Dual
brake valve, air from Service port 11 of Spring
brake actuators is exhausted by Dual brake
valve allowing the brakes to release in the rear.
* During the same time, air from theBrake
chambers is exhausted through theDual brake
valve; thus releasing the brakes in the Front.
* Release of the brakes in Front and Rear axles
is simultaneous and the StopLight Switches
inturn opening the contacts & switching-off the
warning.

PARKING BRAKES (Emergency Brakes)
1. Release :
As the system pressure builds above the
setting pressure of the auxiliaries and
Graduated hand brake valve lever in
‘BRAKESOFF’ position, compressed air is
admitted to the Spring brake port (12) of
Spring brake actuators; thus releasing the
Spring brake in the Rear.
2. Application :
For Emergency / Parking brake
appliction, Graduated Hand Controlvalve lever is
placed in ‘BRAKES ON’postion, allowing air
from the Spring brake port (12) of Spring brake
actuators to exhaust through Graduated hand
control valve; thus the heavy coil Spring
expands and applies Spring brakes in theRear.
6
Sundaram-Clayton Limited

PRIMARY FAILURE
When the Primary circuit fails, air pressure in the
Secondary system helps to apply brakes in the Front
axle.

SECONDARY FAILURE
When the Secondary circuit fails, air pressure in the
Primary system helps to apply brakes in the Rear.

AUXILIARY SYSTEM

Exhaust Brake System :
Mechanical arrangement ( with air exhaust
brake valve)
Port 24 of the Quadruple system protection valve is
connected to the exhaust brake Air cylinder
through Air exhaust brake valve.
Air exhaust brake valve is coupled to the brake pedal
arrangement to enable exhaust brake application
initially and service brakes subsequently.
Mechanical arrangement (with Foot
control valve)
Port 24 of the Quadruple system protection valve is
connected to the exhaust brake Air cylinder through
Foot control valve.
The foot control valve is fitted in the floor board to
enable exhaust brake actuation as and when required
by the driver.
Electro- pneumatic arrangement
Port 24 of the Quadruple system protection valve is
connected to the exhaust brake air cylinder
securing a Magnetic valve and operated through a
limit switch fitted below the brake pedal arrangement.
This arrangement will enable exhaust brake
application initially and service brakes subsequently.
 Sundaram-Clayton Limited

AIR BRAKE ACTUATION ASSEMBLIES

AIR COMPRESSORS

This helps to generate compressed air needed for

the operation of the braking system. improper

operation of the compressor could result in the

system being deprived of adequate air pressure which

is essential for braking.

The inlet of the compressor is connected to the

SC 230 COMPRESSOR (COMET RANGE)
engine inlet manifold. The delivery is connected
to the braking system.

These compressors are splash lubricated and

the lubricating oil line is connected to the

engine lubricating system.

The cylinder head houses reed valves

arrangement.

The piston assembly comprises a piston, two

compression rings, one steel rail oil control ring,

a gudgeon pin and two circlip which arrest the

HIGH SPEED SC 160 COMPRESSOR (TCL)
lateral movement of the gudgeon pin in the

piston bore.

The compressor is driven by the engine.

SC 160 COMPRESSOR (HINO)

7
 Sundaram-Clayton Limited

UNLOADER VALVE WITH TYRE INFLATOR

This valve ensures the system pressure at the desired limit and also charging the circuit, when the system
pressure drops to cut in pressure. Any excess pressure built in the system due to malfunctioning of this unit could

result in severe damage to the system components downstream or at times could even cause a burst. The

malfunction could also result in the system not getting charged when the pressure drops down which could result
in inadequate braking.

It is provided with a Non return valve to prevent back flow of compressed air from the system Reservoir.

A filter element is also provided to prevent dust / dirt entry into the system.

A built in Safety valve feature facilitates exhaust of compressed air in the event of failure of the unloading

mechanism.

The unit also facilitates tyre inflation by diverting air from the compressor.

8
 Sundaram-Clayton Limited

AIR DRYER

The compressed air delivered by compressor flows by the return of the pressurised air from the Purge
through a filter and a bed of Desiccant which tank. (Regeneration Cycle)
provides dirt free clean and moisture free dry air to
Tyre inflator provision in the valve helps to
the system.
inflate the Tyres.
The Air dryer has an integrated Unloader valve with
Optionally, the Air dryer can also be fitted with an
Tyre inflator provision which regulates the system
electrical heater operated from the vehicle’s battery
pressure within a pre-set value. (Charging Cycle)
to prevent freezing of water in cold weather.
When the pre-set pressure is reached in the system,
Control port of Air dryer provides signal for unloading
the compressor is unloaded thereby expelling the
compressor if fitted with unloading device in the
condensed water and impurities from the desiccant
cylinder head.
and the filter respectively

9
 Sundaram-Clayton Limited

DRYING AND DISTRIBUTION UNIT (DDU)

Concept and function face of the desiccant beads . A portion of the dried air
Drying and distribution unit (DDU) combines the func- is stored in the purge volume contained in the sheet
tion of the Air dryer with unloader valve, purge tank metal purge tank . During unloading cycle , the
(fitted with the air dryer) and the Quadruple System Unloader exhausts the compressor delivery air to
Protection Valve (QSPV). the atmosphere.

Operations Non return valve present in the DDU body and QSPV

DDU consists of an aluminium body on which the body does not allow any back flow from service reser-

purge tank , integral unloader valve, integral QSPV voirs. Because of pressure difference between the air

and the tyre inflator are mounted.The exhaust is pressure stored in the purge volume and below desic-

fitted with a silencer. Internally , air path consists of cant bed, the pressurized dry air from the purge

a coalescent filter which removes the oil and other volume expands and flows back through a small

contaminants from the compressed air and a orifice in the purge valve over the desiccant bed.This

desiccant bed , which removes the moisture from expansion and flow of dried air in the reverse direction

the air. collects the moisture adsorbed by the desiccant

during the charging cycle , regenerating the desic-

During Charging , the compressor pumps air into cant. The moisture collected by the desiccant ,

the service reservoirs . The water molecules in condensed water , oil and other contaminants are

the air get adsorbed on microscopic pores on the sur- also exhausted to atmosphere in each unloading cycle.

10
 Sundaram-Clayton Limited

QUADRUPLE SYSTEM PROTECTION VALVES

This assembly is vital for Dual Brake System.

It charges FOUR lines from a common

Compressor and prevent back flow of

compressed air from any line.

In the event of failure of any one of the lines, this valve

helps the Compressor continuing to charge the

active circuits.

PISTON TYPE Two elements connected to the Primary and

Secondary Service Reservoirs are preferentially

charged from Zero onwards till a safe value of

pressure is reached.

The lines connected to Third and Fourth

elements get charging of compressed air only then.

The Third line caters Hand brake application while

Fourth line for actuating the auxiliaries.

This valve also helps to maintain the other lines infact

to their operating pressure.

Malfunctioning of this unit will defeat the

purpose of safe Dual Brake System itself.

DIAPHRAGM TYPE

11
 Sundaram-Clayton Limited

DUAL BRAKE VALVE

This valve gradually charges and exhausts

compressed air from Brake Chambers and Spring

Brake Actuators independently from Front and Rear

brakes respectively.

Dual Brake Valve has TWO brake valves (Primary

and Secondary) assembled in tandem.

When the brake is applied the plunger moves the

primary piston downwards closing the exhaust

passage and subsequently opening primary Inlet

valve; thus admitting compressed air in the

delivery line connected to the Spring brake actuators

in the Rear and applies the brakes.

Simultaneously, the compressed air in the delivery

DUAL BRAKE VALVE port of the Dual brake valve is also communicated to
the Secondary piston which moves the secondary

piston downwards.

This causes the closure of exhaust passage by the

secondary piston and subsequently opens the Inlet

valve of secondary; thus admitting compressed air in

the delivery line connected to the brake chambers in

the Front and applies the brakes.

When the brake is released, the inlet valves in the

primary and the secondary close the inlet passage

and open the exhaust passage allowing the

compressed air from the Brake Chambers and Spring

Brake Actuators to atmosphere; thus releasing the

service brakes from Front and Rear independantly.

DUAL BRAKE VALVE (Reduced Bias)

12
 Sundaram-Clayton Limited

GRADUATED HAND CONTROL VALVE SPRING BRAKE ACTUATOR

DIAPHRAGM

(With Exhaust Banjo Arrangement)

Spring Brake Actuator produces necessary braking

force at the Foundation brakes in Service and

parking / hand brake applications.

This unit has a Diaphragm type brake chamber

operating Service brakes connected Port 11 and a

Spring brake operating the parking / hand brake

connected port 12.

When the air pressure is applied to the service port

11, diaphragm flexes and operates the push rod which

inturn moves the Slack adjuster to operate the ‘S’

(With Exhaust Filter Arrangement)
Cam.
This valve charges and exhausts compressed air
gradually from Spring Brake Actuators for The Spring brake portion is filled with compressed air

releasing and applying the parking or emergency during normal working condition keeping the heavy

brakes. coil spring in compressed position. When the hand

brake valve is operated, air pressure from the Spring

The Inlet of this valve is connected in port 23 line of
brake portion (Port 12) is exhausted to atmosphere
Quadruple System Protection Valve and the delivery
and the heavy coil Spring pushes the push rod through
to the Spring brake port (12) of Spring Brake
the Diaphragm and the brakes are applied.
Actuators.

13

BRAKE CHAMBER
This unit is used in air brakes system and when
supplied with compressed air produces braking force
at the foundation brakes.
When the air pressure is applied to the service port,
diaphragm flexes and operates the push rod which
inturn moves the Slack adjuster to operate the ‘S’
Cam.
SLACK ADJUSTER
The function of the Slack adjuster is to transmit the
braking torque to the ‘S’ Cam and to facilitate
adjustment of the clearance between the brake lining
and the brake drum.
In the normal working condition, the Slack Adjuster
is a lever transmitting the brake chamber force to the
camshaft of the foundation brakes.
14
Sundaram-Clayton Limited
For adjusting the brakes, the worm shaft lock is
pressed in fully to relieve the hexagon of the worm
shaft and worm shaft is rotated. This rotation causes
the cam shaft to rotate and adjust the clearance
between the lining and the drum. The lock is
released after the adjustment is achieved.
RESERVIOR
Pull the ring of the Drain valve on each Reservoir
preferably daily so that all condensations are ejected
out. If the vehicle is fitted with Air filter, drain the
condensate regularly and clean filter elements
preferably once every six months.
LOW PRESSURE INDICATOR SWITCH
Low Pressure Indicator Switches are also fitted one
in each of the Primary and Secondary inlet auxiliary
ports of Dual brake valve and one in the Delivery port
of Graduated Hand Control Valve to provide warning
through beeper or warning light in the event of drop in
air pressure below safe value even in any one of the
circuits.
It is a throw away switch and needs replacement
when failed.
STOP LIGHT SWITCH
Stop Light switches are secured one in each of the
delivery ports of primary and Secondary of Dual Brake
valve to leave warning to the rear
coming vehicles as and when Service brake is
applied.
It is a throw away switch and needs replacement
when failed.
AIR BRAKE SYSTEM TESTING AND
SERVICEABILITY :
 Sundaram-Clayton Limited

AIR BRAKE SYSTEM TESTING AND SERVICEABILITY

Air Dryer / DDU : Reservoirs :

Inspection
Pull the ring of the drain valve on each Reservoir
Check the air lines / DDU / Air Dryer
preferably daily to eject out the Condensate, if
mounting bolts for tightness. Ensure that the air
fitted with unloader valve with tyre inflator. In these
Inlet line is in good condition.
vehicles, remove the Air filters and clean the filter
Operating Test
element thoroughly preferably once in
Drain the Reservoir and check for presence of
every 6 months.
moisture / water collection in the reservoir. Pres-
ence of moisture is indication of requirement of Warning systems :

changing the desiccant cartridge. Low pressure indicator switch

Run the engine and build up air pressure. Low

Drain the Reservoir and start the engine . Charge
pressure indicator must sound through beeper or
the system until the unit cuts out. Record the
warning light remain lighted until the dash board
pressure reading of the dash board gauge.
gauges reaches the set value of the switch.
Ensure the correctness of the gauge before

commencing the test. If the pressure setting is Stop Light switch

different to the recommended value adjust the Apply the service brakes and hold the brake pedal.
pressure setting screw. Check for the Stop lights in the rear remain lighted.

Pressure build up test :

Repeat the test until the correct pressure set-

ting is achieved . For the purpose of setting Run the engine at full speed and build up air

the pressure, it may be required to deplete the pressure from Zero. Time required to raise air

reservoir by applying brakes a few times. pressure to Low pressure switch setting should not

exceed three minutes.

Leakage test
Unloader valve with Tyre inflator setting test :

Run the engine. Unloader valve with Tyre inflator

Charge the system to just below the ‘Cut-out’ pres-
should cut-out, stopping further compression, at
sure and stop the engine.Apply soap solution on
maximum pressure setting. Reduce air pressure by
the entire unit to check for air leakage. Air leak of
series of brake applications. Unloader valve with Tyre
25mm soap bubble is permissible. Excessive
inflator should cut-in resuming compression at
air leak , if noticed , the assembly needs to be
minimum pressure setting.
attended.

Ensure that the airline connections are free

from air leak.
15
 Sundaram-Clayton Limited

Quadruple System Protection valve test :

slowly raise. After 4 bar approximately both the

Park the vehicle in hand brake released condition. gauges will raise together.

Build air pressure to cut-out and switch off the
At 6 bar pressure approximately both

engine. the gauges will dip and stabilise as Spring brakes

are now released.

Deplete air pressure in the Sensing tank

(MainReservoir). Air pressure drop by 0.5 bar is System behavior with engine switched off :

Permissible in both the gauges in one hour.

When Hand brake valve is operated few

Deplete air pressure in the Front brake times, both gauges will drop upto 4.5 bar

Reservoir (Secondary Reservoir). Air approximately and stabilise.

pressure drop by 0.5 bar in one hour is

In case of intermittent humming noise at
permissible in the gauge connected to
Quadruple system protection valve,check for leak
Rear brake Reservoir (Primary Gauge)
in the delivery circuits of the valve and other

Repeat this test after charging the connected assemblies only. The noise is not due

system in the Rear brake Reservoir to any defect in the system protection valve.

(Primary Reservoir). Air pressure drop by 0.5

bar in one hour is permissible in the gauge

connected to Front brakeReservoir (Secondary

Gauge)

Keeping the Graduated hand control

valve in brakes -off position, deplete air pressure

in all Reservoirs and check for free rotation of

rear wheels. Spring brakes should not apply.

Operate Hand brake and hand brakes

should come on only now. If the system does not

pass the above test, Quadruple System

Protection Valve must be attended.

System behavior while building air pressure

from Zero :

One of the gauges will raise 2.5 to 4 bar

pressure approximately, while other gauge will

16
 Preventive Maintenance Schedule for Dual brake system assemblies - with Unloader valve with Tyre Inflator Fitment
SI. No. Product Daily Weekly Monthly Once in 3 months Once in 6 months Once in a year Once in TWO years

1 SC 160 / 230 Check for lub. Oil leak in Clean cylinder head and Overhaul compressor
Single Cylinder connections. Check inlet hose decarbonise if necessary. using Major Repair kit.
Compressor for deteration and change if Change piston rings if
necessary. necessary.
Check compressor performance
2 Unloader Valve Check for performance. Clean the filter and refit. Overhaul the unit using
with Tyre Inflator Pressure differential Replace the filter if recommended Repair kit.
should not exceed 1.3 bar necessary.
3 Air Filter During PDI remove and Remove the Filter Remove the Filter element, Overhaul the unit using
check the filter element, clean clean thoroughly and refit recommended Repair kit.
element thoroughly and refit Replace Filter element, if reqd.
4 Quadruple Drain Sensing Reservoir and Overhaul the unit using
System watch for pressure drop in recommended Repair kit.
Protection Valve the gauges to detect Non
return valve leak.
5 Reservoir Charge the system
to cut-out pressure.
Drain the Reservoirs
thoroughly.
6 Dual Brake Valve Check for free Check Gaiter for Overhaul the unit using
movement of plunger. damage / deterioration recommended Repair kit.
and replace Gaiter if
necessary.
7 Spring Brake Lubricate Fork and pin. Check the condition of Overhaul the unit using
Actuator Check for free breather tube and recommended Repair kit.
movement of push rod ensure clips are
by applying and secured properly at
releasing brakes both ends.
8 Brake Chamber Lubricate Fork and pin. Overhaul the unit using
Check for free recommended Repair kit.
movement of push rod
by applying and
releasing brakes.
9 Slack Adjuster Lubricate using Apply the brakes and Overhaul the unit using
Helvium No. 3 check for the angle recommended Repair kit.
Grease. between the arm and
push rod. Adjust the
brakes if reqd. and ensure
the angle is 90 degree.
10 Graduated Hand Check lever for proper Check Gaiter and knob for Overhaul the unit using
Control Valve locking in brakes damage and replace, if recommended Repair kit.
‘ON/OFF’ positions. necessary.
11 Low Pressure Check for proper
Indicator Switch working of beeper.
12 Stop Light Check for proper
Switch working of stop lights.
Sundaram-Clayton Limited

13 Hose Assembly Check for crack / Replace the assembly

deterioration / rubbing marks

Note.
1. Check the mounting nuts and bolts for adequate tightness once in 3 months
2. All the lines , joints and the assemblies should be free from excessive air leak.
3. Ensure that the angle between push rod and Slack Adjuster is 90 degree or + 5 and - 0 degreein brakes fully applied condition.
If the angle is less than 90 degree, then the push rod travel is more and needs immediate brake adjustment.
 Preventive Maintenance Schedule for Dual brake system assemblies - with Air Dryer/DDU Fitment
SI. No. Product Daily Weekly Monthly Once in 3 months Once in 6 months Once in a year Once in TWO years

1 SC 160 / 230 Check for lub. oil leak in Clean cylinder head and Overhaul compressor
Single Cylinder connections. decarbonise if necessary. using Major Repair kit.
Compressor Check inlet hose for Change piston rings if
deteration and change if reqd. necessary.
Check compressor
performance.
2 Air Dryer/DDU Check for moisture / Check for performance. Clean the filter and refit. Overhaul the unit using
water collection in the Pressure differntial Replace the filter if recommended Major Repair kit
Sensing Reservoir. If should not exceed 1.3 necessary by using minor Replace Desiccant
water collection is bar Repair Kit Cartridge.
noticed, replace the
Desiccant cartridge.
3 Quadruple System Check for Gaiter Drain Sensing Reservoir and Overhaul the unit using
Protection Valve condition and replace if watch for pressure drop in recommended Repair kit.
necessary. the gauges to detect Non
return valve leak.
4 Reservoir Drain the reservoirs
and check for moisture / water
collection. If noticed, the
Desiccant cartridge in the Air
Dryer /DDU should be replaced
5 Dual Brake Valve Check for free Check Gaiter for Overhaul the unit using
movement of damage / deterioration recommended Repair kit.
plunger. and replace Gaiter if
necessary.
6 Spring Brake Lubricate Fork and pin. Check Check the condition of breather Overhaul the unit using
Actuator for free movement of push rod tube and ensure clips are recommended Repair kit.
by applying and secured properly at
releasing brakes both ends.
7 Brake Chamber Lubricate Fork and Pin. Overhaul the unit using
Check for free recommended Repair kit.
movement of push rod
by applying and
releasing brakes
8 Slack Adjuster Lubricate using Apply the brakes and Overhaul the unit using
Helvium No. 3 check for the angle recommended Repair kit.
Grease.
Adjust the brakes if reqd. and
ensure the angle is 90 degree
between the arm and push rod.
9 Graduated Hand Check lever for proper Check Gaiter and knob for Overhaul the unit using
Control Valve locking in brakes’ damage and replace, if recommended Repair kit.
ON/OFF’ positions. necessary.
10 Low Pressure Check for proper
Indicator Switch working of beeper.
11 Stop Light Switch Check for proper
Sundaram-Clayton Limited

working of stop lights.

12 Hose Assembly Check for crack / Replace the assembly
deterioration / rubbing marks.
Note:
1. Check the mounting nuts and bolts for adequate tightness once in 3 months
2. All the lines , Joints and the assemblies should be free from excessive air leak.
3. Ensure that the angle between push rod and Slack Adjuster is 90 degree or + 5 and - 0 degree in brakes fully applied condition.
If the angle is less than 90 degree, then the push rod travel is more and needs immediate brake adjustment.
 Sundaram-Clayton Limited

MOST IMPORTANT

Drain the reservoirs thoroughly, if the vehicle is fitted with
Unloader valve with Tyre Inflator on daily basis.

Before moving the vehicle and the parking brakes in applied

condition, start the engine and build air pressure to Unloader
valve with tyre inflator / Air dryer / DDU cut - out.

Then, release the hand brake and observe the warning in

the beeper is put off.

Apply the service brake and check for glowing of rear brake
lights.

PRECAUTION
In a running vehicle, in the event of total depletion of air in
the service brake circuits,the brakes will not apply
automatically.

The driver has to operate Hand brake for applying the

brakes.
 Sundaram-Clayton Limited

SCL/MKT / Jun / 06 / 2500

Plant - II , Plot No : 3 (SP) ,3rd Main Road,Ambattur Industrial Estate, Chennai - 600 058, INDIA.
Phone : (91) 44 - 2623 8000, 4224 2000 Fax : (91) 44 - 2624 1278, 2623 8009
Website : www.sundaram-clayton.com