R&I Air Brake System

Diagram 9.
FH 6x4
R&I Air Brake system

1
Pama Mechanic Development Program
Diagram 9. FH 6x4

2
Air Compressor
Fungsi
• Mengkompressi udara bertekanan redah ke bertekanan tinggi (menaikan tekanan udara)
• Mensirkulasikan udara bertekan di dalam brake system dan perlengkapan lain.
2COMP850
Cylinder 2
3
Displacement 600 cm
3
Capacity 680 dm /min
Counter pressure 800 kPa (8 bars)
Speed of 2000 r/min

3
Air Compressor
1. Bolt 25. Piston ring

2. Bottom cover 26. Gasket
3. Nut 27. Stud
4. Main bearing bushing 28. Pivot arm
5. Crankcase 29. Guide pin
6. Crankshaft 30. Guide pin
7. O-ring 31. Intake valve
8. End cover, bearing housing 32. Valve body, lower
9. Bolt 33. Gasket
10. Plug 34. Valve body, upper
11. Gasket 35. Outlet valve
12. ESS plunger 36. Holder
13. O-ring 37. Spacer sleeve
14. O-ring, open 38. Bolt
15. Spring 39. Gasket
16. Guide pin 40. Bolt
17. Bolt 41. Holder
18. Lock washer 42. Intake valve
19. Connecting rod, bearing cap 43. Valve seating
20. Bushing 44. Cylinder head
21. Lock ring 45. Bolt
22. Piston 46. Gasket
23. Gudgeon pin 47. Plug
24. Oil scraper ring 48. Bolt

4
Working Position
1 Intake valve
2 Intake valve
2 Intake valve
3 Outlet hole, intake valve

4 Outlet valve

5
Isnin Barokah-
Barokah-I/materi training/volvo
training/volvo
Air Governor/unloading valve (Energy Saving System)
Fungsi
• Untuk mengatur udara yang akan di compresikan oleh compressor ke air feed system
1. Bolt 25. Piston ring

2. Bottom cover 26. Gasket
3. Nut 27. Stud
4. Main bearing bushing 28. Pivot arm
5. Crankcase 29. Guide pin
6. Crankshaft 30. Guide pin
7. O-ring 31. Intake valve
8. End cover, bearing housing 32. Valve body, lower
9. Bolt 33. Gasket
10. Plug 34. Valve body, upper
11. Gasket 35. Outlet valve
12. ESS plunger 36. Holder
13. O-ring 37. Spacer sleeve
14. O-ring, open 38. Bolt
15. Spring 39. Gasket
16. Guide pin 40. Bolt
17. Bolt 41. Holder
18. Lock washer 42. Intake valve
19. Connecting rod, bearing cap 43. Valve seating
20. Bushing 44. Cylinder head
21. Lock ring 45. Bolt
22. Piston 46. Gasket
23. Gudgeon pin 47. Plug
24. Oil scraper ring R&I48.
AirBolt
Brake system
6
Energy Saving System
Working position
2 Intake valve
1 Intake valve 3 Outlet hole, intake valve

2 Intake valve 4 Outlet valve
Unloading position
3 Outlet hole, intake valve
5 Unloading plunger
6 Unloading chamber

7
Isnin Barokah-
training/volvo
Brake Chamber
Fungsi
Merubah energy udara berekanan (air pressure) ke energy mechanical
1. Inlet from brake valve

2. Screw
3. Pressure side
4. Clamp
5. Diaphragm
6. Spring side
7. Return spring
8. Thrust rod
9. Fork

8
Brake Chamber
1. Inlet from brake valve

5. Diaphragm
7. Return spring
8. Thrust rod

9
Air Reservoir (dry and primary tank)
DRY TANK
Fungsi : Tangki untuk memisahkan udara terhadap air lewat air dryer
PRIMARY TANK
Fungsi : Tangki pertama yang berfungsi untuk manampung udara
bertekanan
5. Dry tank
6. Primary tank

10
Brake Valve (Pos.34)
Fungsi
Untuk mempercepat operating evacuation udara ke brake cylinders pada saat foot brake
valve digunakan
1. Inlet from circuit tank

2. Outlet to brake cylinders
3. Outlet, air evacuation for releasing brakes
4. Inlet from footbrake valve

11
Brakes not applied

5. Relay plunger
6. Valve
7. Drilling which provides brake pressure below valve 6
8. Spring

12
Brakes applied

5. Relay plunger
6. Valve

13
Brakes applied, relay valve in balanced position

5. Relay plunger
6. Valve
7. Drilling which provides brake
pressure below valve 6

14
Brakes released


15
Exhaust Brake
Fungsi
Untuk memperlambat / mengerem laju kendaraan dengan cara menghambat putaran
engine

16
Exhaust Pressure Governor
Is9’03

17
Isnin Barokah-
training/volvo
Exhaust Brake
Is9’03

18
Isnin Barokah-
training/volvo
Active Engine Brake
Is9’03

19
Isnin Barokah-
training/volvo
Spring Chamber Brake
Fungsi
• Merubah energi udara bertekanan menjadi energi mechanical
• Pada saat tekanan udara mencukupi atau tekanan udara mampu melawan spring loaded
berfungsi untuk membebaskan brake sehingga unit bisa berjalan
• Pada saat tekanan udara drop berfungsi sebagai brake, spring loaded
bekerja menekan brake

20
Spring Chamber Brake
1. Fork
2. Cylinder, service brakes
3. Cylinder, parking brake
4. Thrust rod
5. Return spring
6. Diaphragm
7. Ventilation tube
8. Plunger rod
9. Plunger
10. Brake spring
11. Brake release bolt
12. Cover
1. Fork
2. Cylinder, service brakes
3. Cylinder, parking brake
4. Thrust rod
5. Return spring
6. Diaphragm
7. Ventilation tube
8. Plunger rod
9. Plunger
10. Brake spring
11. Brake release bolt
12. Cover R&I Air Brake system
21
Parking and Driving Position
Parking Position
Driving Position

22
Application of service brakes & Towing and repair positions
Application of service brakes
Towing and repair positions

23
Quick Release Valve
Fungsi
Untuk membuka aliran udara secara cepat sehingga memungkinkan udara di dalam
cylinder brake cepat terbuang pada saat parking brake difungsikan atau saat foot brak
dilepas
1. Outlet, brake cylinder

2. Housing
3. Cover
4. Inlet, footbrake valve
5. Diaphragm
6. O-ring
7. Outlet, evacuation

24
Quick Release Valve Function
Parking brake released
Applying parking brake
1. Outlet, brake cylinder 5. Diaphragm

2. Housing 6. O-ring
3. Cover 7. Outlet, evacuation
4. Inlet, footbrake valve
25
Relay Valve (Pos.31)
Fungsi
Untuk mempercepat operating evacuation udara ke brake cylinders (spring barke) pada
saat parking barke di release


26
Brakes not applied

5. Relay plunger
6. Valve
7. Drilling which provides brake pressure below valve 6
8. Spring

27
Brakes applied

5. Relay plunger
6. Valve

28
Brakes applied, relay valve in balanced position

5. Relay plunger
6. Valve
7. Drilling which provides brake
pressure below valve 6

29
Brakes released


30
Foot Brake Valve
Fungsi
Untuk mengendalikan atau mengatur udara yang dikirim ke valve brake
3 Air evacuation
11 Inlet from circuit tank, rear brakes
12 Inlet from circuit tank, front brakes
21 Outlet to rear brake circuit
22 Outlet to front brake circuit

31
Foot Brake Valve
1. Rubber cover
2. Reaction plunger
3. Air evacuation
4. Rubber spring
5. Spring
6. Rod
7. Valve
8. Spring
9. Air drilling
10. Relay plunger
11. Inlet from circuit tank, rear brakes
12. Inlet from circuit tank, front brakes
13. Spring
14. Valve
15. Spring
16. Seat
17. Plunger seat
18. Seat
19. Plunger seat
20. Thrust pin
21. Outlet to rear brake circuit
22. Outlet to front brake circuit

32
Brake pedal not depressed, driving position
3. Air evacuation
7. Valve
14. Valve

33
Brake pedal partly depressed, soft braking
2. Reaction plunger
3. Air evacuation
7. Valve
9. Air drilling
10. Relay plunger
14. Valve
20. Thrust pin

34
Brake pedal partly depressed, balanced braking
2. Reaction plunger
3. Air evacuation
7. Valve
9. Air drilling
10. Relay plunger
14. Valve
20. Thrust pin

35
Brake pedal fully depressed, full braking position
2. Reaction plunger
3. Air evacuation
7. Valve
9. Air drilling
10. Relay plunger
14. Valve
20. Thrust pin

36
Pressure loss in rear or front brake circuit
2. Reaction plunger
3. Air evacuation
7. Valve
9. Air drilling
10. Relay plunger
14. Valve
20. Thrust pin

37
Blocking Valve
Fungsi
Sebagai alat pengaman agar brake tidak release dengan sedirinya tanpa di control oleh
driver disaat unit sedang parkir atau saat pengisian udara.
1. Cover
2. Thrust spring
3. Circlip
4. Washer
5. O-ring
6. Plunger
7. Valve
8. Thrust spring
9. Inlet from tank
10. Drilling
11. Washer
12. Rubber rings
13. Control rod
14. Nut
15. Outlet to parking brake control
16. Housing

38
Blocking Valve Function
Safety position, air system charging up
Driving position, parking brake released
Position, pressure below 4.0 bar
6. Plunger
7. Valve
9. Inlet from tank
12. Rubber rings
13. Control rod
15. Outlet to parking brake control

39
Hand Control Valve, Parking Brake
Fungsi
• Untuk me release parking brake prime over dan service brake pada trailer
• Menutup atau membuang udara spring brake prime mover dan mensuplai
udara ke trailer brake pada saat unit parkir/berhenti
• Sebagi emergenci brake
3 Outlet for air evacuation

11 Inlet from parking brake tank via blocking valve
21 Outlet to relay valve for parking brake
22 Outlet to control valve for trailer brakes

40
Hand Control Valve, Parking Brake
1. Handle
2. Locking sleeve
3. Outlet for air evacuation
4. Roller
5. Intermediary
6. Lifting cam of roller 4
7. Plunger
8. Plunger spring
9. Valve seat
10. Valve
11. Inlet from parking brake tank via blocking valve
12. Valve spring
13. Valve spring
14. Valve
15. Valve seat
16. Adjusting screw
17. Plunger spring
18. Plunger
19. Spring
20. Plunger
21. Outlet to relay valve for parking brake
22. Outlet to control valve for trailer brakes
23. Drilling
41
Lever in position A, driving position

7. Plunger
10. Valve
14. Valve
18. Plunger
20. Plunger
23. Drilling

42
Lever in position between A and B, soft braking

14. Valve
18. Plunger
20. Plunger

43
Lever between positions A and B, balanced
position

10. Valve
14. Valve
18. Plunger
20. Plunger
23. Drilling

44
Control lever in position B

10. Valve
14. Valve
18. Plunger
20. Plunger
23. Drilling

45
Control lever in position C

4. Roller
5. Intermediary
7. Plunger
9. Valve seat
10. Valve
20. Plunger
23. Drilling

46
Four Way Protection Valve
Fungsi
Untuk melindungi / mempertahankan tekanan udara di dalam circuit bila terjadi
kebocoran pada salah satu bagian
1 Inlet from primary tank

21 Outlet to air tank, rear brake circuit
22 Outlet to air tank, front brake circuit
23 Outlet to air tank, parking brake circuit
24 Outlet to distributor nipple for extra equipment

47
1 Inlet from primary tank 1

Circlip
5
2 Rubber plug 1
Washer
3 Adjusting screw 6
1
4 Spring guide Check valves
7
5 Spring 2
Outlet to air tank, rear brake circuit
1
6 Cover 2
Outlet to air tank, front brake circuit
2
7 Spring guide
2
Outlet to air tank, parking brake circuit
8 Diaphragm 3
2 Outlet to distributor nipple for extra
9 Valve 4 equipment
10 Spring A Bypass valve
11 Housing
B Bypass valve
12 Check valve
C Bypass valve
13 Spring
14 Seal D Bypass valve

48
Charging Phase
6-6.3 bar

49
By Pass Check Function


50
Pressure drop, inlet 1 Leakage in circuit (21) or (22

21 Outlet to air tank, rear brake circuit 24 Outlet to distributor nipple for extra equipment
51
Leakage in circuit (23) or (24)

52
Load Sensing Valve
Fungsi
Untuk mengatur air pressure ke brake chamber berdasarkan berat beban/muatan yang
dibawa

53
Load Sensing Valve
Specification
Volvo P/N 1628953
Type with in-built relay valve
Lever angle 30o/clockwise
Max operating press 1000 kPa (10 bar)
Basic pressure 60 + 10 kPa (0.6 + 0.1 bar)

54
Two-way Valve (Pos.30)
Fungsi
Untuk mengarahkan air pressure menuju satu arah dengan dua operating impluse yang
berbeda
1. Inlet
2. Inlet
3. Outlet
4. Plunger
5. Rubber seal

55
Two-way Valve
Operating air to inlet (1), inlet (2) no pressure
Operating air to inlet (2), inlet (1) no pressure
1. Inlet
2. Inlet
3. Outlet

56
Air Dryer (Pos.2a)
Fungsi
Untuk mengeringkan dan membersihkan udara dari air compressor sebelum masuk ke air
system (brake and pneumatic system)
Charging function
1. Filter
2. Drying compound
3. Filter
4. Compressor port (Port on air drier is marked IN)
5. Primary reservoir port (Port on air drier is marked 21)
6. Regeneration reservoir port (Port on air drier is marked 22)
7. Non-return valve (Port on air drier is marked 5)
8. Silencer

57
Air Dryer
Pressure relief function
7. Non-return valve
9. Pressure regulator
10. Pressure relief valve
11. Port and silencer for pressure relief function
Air dryer operation

58
Air Dryer
Charging-up phase
Cycling phase
1. Compressor
2. Inlet
3. Air dryer
4. Outlet
5. Dry tank
6. Primary tank
7. Regulator
8. Drain valve
9. Check valve R&I Air Brake system
59
Air Dryer
Air dryer operation

60
Dry Air Pressure
Adalah
Udara bertekanan yang telah dipisahkan dengan air (udara murni), udara ini telah
melewati air dryer dan dry tank

61
Wet Air Pressure
Adalah
Tekanan udara yang masih mengandung air, tekanan ini berada diantara compressor
dengan air dryer dan dry tank

62
Regulating Air Pressure (Pos.4)
Adalah alat untuk mengatur tekanan udara didalam circuit air brake system
1. Housing
2. Valve spring
3. Valve
4. Plunger
5. Sealing ring
6. Washer
7. Reaction spring
8. Spring guide
9. Circlip
10. Rubber gaiter
11. Lock nut
12. Adjusting screw
13. Spacer
14. Washer
15. Spring
16. Sealing ring
17. Valve tube
18. Sealing ring

63
Regulating Operation
Charging up phase Of-loading phase
3. Pressure valve
4. Plunger
7. Reacting spring
17. Valve tube
A. Inlet
B. Outlet
C. Outlet

64
Front Wheel Circuit
Adalah
Circuit air brake system yang digunakan untuk
pengereman roda depan primover
5 Quick release valve

5b Pilot valve (PIVENT)
5c Two-stage control valve (RVENT-2)
10 Footbrake valve
11 Compressed air tanks, front wheel circuit
29 Load-sensing valve with mechanical control and built-in relay valve
29a Load-sensing valve with pneumatic control and built-in relay valve
35 3/2-way valve (bogie lift valve)
A Control valve, trailer brakes

65
Rear Wheel Circuit
Adalah
Circuit air brake system yang di gunakan untuk pengereman
roda belakang prime mover
10 Footbrake valve
12 Compressed air tanks, rear wheel circuit
Load-sensing valve with mechanical control and built-in
29
relay valve
Load-sensing valve with pneumatic control and built-in
29a
relay valve
33 Brake cylinders, driven wheels, spring brake cylinders
A Control valve, trailer brakes
F Two-way valve (only with trailer brake hand control)
Load-sensing valve with mechanical control without

29b
built-in relay valve
33 Brake cylinders, driven wheels, spring brake cylinders
Brake cylinders, trailing wheels and rear driven
33a wheels, single diaphragm cylinders, for vehicles with
air suspension, spring brake cylinders
34 Relay valve, service brakes, rear wheels 6x2, 8x2 66
Barometric Pressure
Adalah
Dasar atau pembanding untuk menentukan ukuran tekanan udara, disini yang dimaksud
adalah atmospheric pressure

67

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Diagram 9.

R&I Air Brake system

R&I Air Brake system

1. Bolt 25. Piston ring

R&I Air Brake system

3 Outlet hole, intake valve

R&I Air Brake system

1. Bolt 25. Piston ring

1 Intake valve 3 Outlet hole, intake valve

3 Outlet hole, intake valve

R&I Air Brake system

1. Inlet from brake valve

R&I Air Brake system

1. Inlet from brake valve

R&I Air Brake system

R&I Air Brake system

1. Inlet from circuit tank

R&I Air Brake system

1. Inlet from circuit tank

R&I Air Brake system

1. Inlet from circuit tank

R&I Air Brake system

1. Inlet from circuit tank

R&I Air Brake system

1. Inlet from circuit tank

R&I Air Brake system

R&I Air Brake system

R&I Air Brake system

R&I Air Brake system

R&I Air Brake system

R&I Air Brake system

R&I Air Brake system

Application of service brakes

Towing and repair positions

R&I Air Brake system

1. Outlet, brake cylinder

R&I Air Brake system

Parking brake released

Applying parking brake

1. Outlet, brake cylinder 5. Diaphragm

1. Inlet from circuit tank

R&I Air Brake system

1. Inlet from circuit tank

R&I Air Brake system

1. Inlet from circuit tank

R&I Air Brake system

1. Inlet from circuit tank

R&I Air Brake system

1. Inlet from circuit tank

R&I Air Brake system

R&I Air Brake system

R&I Air Brake system

R&I Air Brake system

R&I Air Brake system

R&I Air Brake system

R&I Air Brake system

R&I Air Brake system

R&I Air Brake system

Driving position, parking brake released

Position, pressure below 4.0 bar

R&I Air Brake system

3 Outlet for air evacuation