ALLCV

Service Manual
Brakes
09.02 BRAKES

CONTENTS

CHAPTER - 09

BRAKES

Section Subject Page No.

09.0 Brakes .......................................................................................................................... 09.03

09.1 Air System .................................................................................................................... 09.03

09.1.0 Operation ........................................................................................................................................... 09.03

09.2 Data .......................................................................................................................... 09.04

09.3 Air Brake Components .............................................................................................. 09.07

09.3.0 SC 160 High Speed Water Cooled Compressor .............................................................. 09.07
09.3.0.0 Trouble Shooting .................................................................................................................................................... 09.10
09.3.1 Dual Brake Valve ............................................................................................................................ 09.11
09.3.2 R 6 Relay Valve .............................................................................................................................. 09.13
09.3.3 Brake Chamber ................................................................................................................................ 09.14
09.3.4 Spring Brake Actuator .................................................................................................................. 09.15
09.3.5 Graduated Hand Control Valve - ‘S’ Type ......................................................................... 09.18
09.3.6 Quadruple System Protection Valve (Diaphragm Type) ................................................ 09.22
09.3.7 Unloader Valve With the Inflator ............................................................................................ 09.24
09.3.8 Air Reservoir and Air Filter ...................................................................................................... 09.27
09.3.8.0 Air Filter ........................................................................................................................................................................ 09.27
09.3.9 Low Pressure Indicator Switch .................................................................................................. 09.28
09.3.10 Stop Light Switch ............................................................................................................................ 09.29
09.3.11 Pressure Reducer Valve ................................................................................................................ 09.29
09.3.12 Foot Control Valve ......................................................................................................................... 09.31

09.4 Foundation brake (simplex air wedge) system ................................................... 09.34

09.4.0 Brake Shoe Removal / Assembly .............................................................................................. 09.36
09.4.1 Expander Assembly Replacement ............................................................................................. 09.39

09.5 Exhaust Brake Butterfly Valve - Overhaul ........................................................... 09.42

09.6 Air Dryer ....................................................................................................................... 09.44

09.7 Automatic Load Sensing Valve ............................................................................... 09.47

 BRAKES 09.03

AIR PIPING LAYOUT

1. Front Brake Chamber LH

2. Air Compressor
3. Exhaust Brake Foot Valve
4. Air Gauge
5. E2 Valve
6. Parking Brake Flick Valve
7. Front Brake Chamber RH
8. Wet Tank
9. Reservoir
10. Rear Brake Chamber LH
11. Relay Valves
12. Reservoir 2
13. Load Sensing Valve
14. Rear Brake Chamber RH
15. Brake Hose
16. 6 Way Tee
17. Purge Tank
18. Air Dryer
19. Pressure Reducing Valve

09.0 BRAKES the dual brake valve. In order to overcome the

The type of brakes is simplex air wedge brakes (SAW
brakes) full air dual line system. Parking brake is flick
valve operated spring brake on rear wheels only. The
brake system can be broadly classified as.
I. Air System
II. Foundation (Simplex Air Wedge) Brake
09.1 AIR SYSTEM
The engine driven compressor has its inlet connection
from the inlet manifold of the engine. The compressor
delivery is connected to a sensing tank through an
unloader valve which regulates the system operating
pressure. Air pressure for the two independent service
brake reservoirs and spring brake circuits are divided by
the quadruple system protection valve which protects
the operative circuits. One of the secondary outlets of
system protection valve is plugged and if need arises,
this outlet can be utilised for air horn, air operated door
etc., incidentally the two non return valves provided in
this valve prevent spring brake chamber coming ‘ON’
automatically in case of failure of both service circuits in
line with international regulations.
09.1.0 Operation
A dual circuit service braking is provided by connecting
the two independent service reservoirs to the inlets of
malfunctioning of the dual brake valve, 2 Nos.
serviceable air filters are introduced in the inlet port lines
of the dual brake valve as shown in the figure above.
Periodic maintenance of air reservoir and air filters has
to be carried out for longer life of metal and rubber
components. Two independent pressure gauges are
provided in the circuits to indicate the prevailing system
pressures. Low pressure warning devices are provided
in both the circuits. One delivery of dual brake valve is
connected to the service side of the spring brake
chambers in the rear axle. Stop light switches are
provided on both service circuits to give an indication to
the vehicle coming behind during braking. The brake
chambers are mounted on the plates of the foundation
brakes.
When the pedal is depressed, air pressure from service
reservoirs flow through dual brake valve to front and
rear brake chambers which in turn actuate the
foundation brakes and during release of treadle air from
actuators is exhausted to atmosphere through dual
brake valve. In case of failure of one circuit, the other
circuit will apply the partial brake for the vehicle. In this
case maximum pressure will be restricted to the
pressure setting of system protection valve.
09.04 BRAKES

09.2 DATA

Sl. No Figure Description Data

1. Brake drum Standard Diameter Front - 360 x 140 mm

Rear - 360 x 140 mm

2. Front brake linings

(a) Thickness TC / TE 0.5" (12.7 mm)
(b) Width W1 5" (127 mm)

Rear brake linings

(a) Thickness TC / TE 0.5" (12.7 mm)
(b) Width W1 6.00" (152.4 mm)

3. Brake lining rivets

(a) Type Tubular
(b) No. of rivets 48
(c) Dia of rivets (2) 0.25" (6.35 mm)
(d) Length of rivets (L1) 0.50" (12.7 mm)
(e) Head dia (3) 0.469" (11.906 mm)

4. Recommended running
clearance C1 0.010" (0.254 mm)

5. Braking Area
(a) Front brake 595.5 sq.in (3842 sq.cm.)
(b) Rear brake 325 sq.in (2100 sq.cm.)
 BRAKES 09.05

Sl. No Figure Description Data

6. Brake chamber type

(a) Front 9
(b) Rear 9
(c) Normal working 0.75" (19.05 mm)
(d) Max. permissible working stroke S2 1.75" (44.45 mm)
(e) Max. stroke S3 2.25" (67.15 mm)

7. Effective area of diaphragm

(a) Front A1 9.89"
(b) Rear A2 9.89"

8. Air Reservoir capacity

(a) Tank 10 lts.

(b) Service tank front 15 Lts.
(c) Service tank rear 15 Lts.

9. Safety valve setting 8.25 kg/cm² (117 PSC)

10. Unloader Valve setting 6.5 kg/cm²

11. Minimum air pressure 60 psi (4.2 kg/cm²)

09.06 BRAKES

Sl. No Figure Description Data

12. Air Compressor Type

(a) Cylinder bore dia 80.018 / 80.000 mm

(b) Max. permissible ovality 0.051 mm (0.002")
(c) Max. permissible taper 0.076 mm (0.003")

13. Crank dia. 5 31.725/31.373 mm (1.290" / 1.2495")

14. Clearance small end bearing 0.011 / 0.003 mm

Clearance - Big end bearing 0.013 / 0.051 mm

15. Stroke 32 mm

16. Ring gap in bore X1 0.45 / 0.20 Compression ring

Max. Ring gap allowed 0.50/0.20 Oil ring

14. Ring side clearance C1 0.020 mm

Ring Max. allowed side
Clearance C1 0.052 mm
 BRAKES 09.07

09.3 AIR BRAKE COMPONENTS sealing purpose. The crankshaft runs in phosphor
bronze bush bearing (which is incorporated with a tin
coated collar face as thrust bearing) in the crankcase
side and aluminium end cover on the other end. the
drive end is tapered and fitted with woodruff key and
lock nut for fixing the drive pulley.

An oil seal is provided on the drive end side of the

shaft and two lubricating oil holes are provided on the
mounting flange through which pressurized oil from the
engine lubricating system is circulated into the
compressor and oil drained to the engine oil sump
through the passage provided in the mounting end
cover. Drain hole is provided on the rear end cover
and mounting end cover to relieve the oil pressure on
the oil seal.

Connecting rod made of special aluminium forging is

used without bearings at gudgeon pin and crankshaft
ends. The bigger end bore of the connecting rod has
been made as two halves and assembled to the
crankshaft with two 80mm dia piston is provided with
three compression rings and oil control ring at above
09.3.0 SC 160 High Speed Water Cooled and below the gudgeon pin portion respectively
Compressor connecting rod bolts.

80 mm dia piston is provided with three compression

Function
rings and one oil control ring at above and below the
The purpose of the compressor is to produce
gudgeon pin portion respectively .
compressed air for braking system.

Description
The single cylinder compressor is of the reciprocating
piston type and is water cooled with 80 mm dia
cylinder bore and a stroke of 32 mm to get
displacement of 160 CC. The normal working speed of
the compressor is 3000 rpm.
The compressor has a one piece crankcase cylinder
block with fins facilitating cooling and aluminium cylinder
head assembly consisting of reed valve plate assembly
and an aluminium cylinder head cover to cover the
water cooling passage. For water circulation, inlet and
delivery ports are provided in the cylinder head.
Air inlet port (flange type) is provided in the cylinder
head cover and delivery port is provided in the cylinder
head.
Inlet and delivery reeds are fixed on the steel valve
plate and two gaskets are provided on each side for
Service Check
(a) Inspection Check
* Check the tightness of compressor mounting bolts.
* Ensure that the air and water lines from air cleaner
and water circulating system are in good condition
(b) Operating Tests
* Check for noisy operation and oil leakage when
compressor is running
* Check for any leakage in water pipe joints.
* If air leakage in the remaining parts/pipe joints of
the system is not excessive, failure of compressor
to maintain the required pressure in the system
usually denotes loss of efficiency due to wear.
Another sign of wear is excessive oil passing
through the Reservoir to other equipment of brake
system. If either condition develops and inspection
shows the remainder of the system is in good
condition, the compressor must be overhauled.
09.08 BRAKES
Removing
* Block the wheels to prevent movement of the
vehicle during working.
* Remove the oil filters.
* Remove the drive belt and remove the pulley from
crankshaft after loosening the nut.
* Disconnect air and water pipes and close the open
ends of pipes to prevent dirt/dust entry.
* Remove the mounting bolts and detach the
compressor from its mounting.
* Remove the gasket from mounting end cover.
Replacing
* Locate the gasket on the mounting face of the
cylinder block.
* Install the assembly on engine mounting and secure
tightly.
* Connect the air/oil pipe and water line connections.
* Locate the drive gear on the crankshaft and ensure
that the gear key way to seat on the woodruff key
properly.
* Tighten the lock nut uniformly to a torque of 90
to 120 Nm.
* Fit the drive belts and adjust for correct tension.
* Carry out “operation tests” as given under “Service
Check”.
Dismantling
* Clean the exterior of the assembly.
* Mark the position of the cylinder head in relation
to cylinder block before dismantling.
* Unscrew the four screws
* Remove cylinder head cover. Detach the reed
valve assembly and joints from cylinder head.
* Provide identification marks on the inlet & delivery
side of the valve plate.
* Using a suitable punch, push and remove the
locating pins from the valve plate. Remove the
inlet and delivery reed valves.
* Loosen the four screws (10 A/F) and remove the
base cover plate from the cylinder block.
* Turn the crankshaft to BDC. Loosen the connecting
rod bolts (11A/F) and remove the cap.
* With draw the piston assembly through the top of
the cylinder bore.
* Remove the piston ring from the piston. If the
piston assembly is to be completely dismantled,
remove one of the circlips retaining the gudgeon
pin and press the gudgeon pin until it comes out
of the piston and connecting rod.
* Loosen the end cover screws (13 A/F) and
remove the end cover, crankshaft.
* Scrap all the old parts which are serviced in the
major repair kit.
Cleaning and Inspection
* Clean all components in cleaning solvent and blow
dry with compressed air. Ensure that no trace of
solvent is present during reassembly.
* Thoroughly clean the cylinder head, scrape carbon,
dirt and particles of old joints from all surfaces.
* Clean cylinder head cover to remove dirt and
particles.
* Clean the oil holes in the crankshaft using a piece
of wire if necessary, and flush with cleaning solvent.
Ensure that the oil hole is free from blockage.
* Clean the inlet and delivery reed valves if they are
not worn excessively.
* Clean the oil inlet passage in the mounting cover
and blow with compressed air. Ensure that the oil
hole is free from blockage.
* Crankcase
Check cylinder bore for any deep score marks and
also whether the honing pattern is visible all over
the bore. If the honing pattern is visible uniformly
all over the bore without score marks, then the
cylinder and same size piston can be used be
renewing the same size rings. Other wise the
cylinder is to be rebored and rehoned to the
finished bore sizes as given below and fitted with
oversize piston and rings.
Finished bore size after honing (mm)
Standard bore 80.018
80.000
1st O /S bore 80.268
80.250
2nd O /S bore 80.518
80.500
* When new bush is pressed in to mounting end
cover, machine the bore to 32.08 / 32.05 dia with
0.4 micro finish and do not machine the collar face.
Piston and Connecting Rod
a. Check the fit of the piston rings in the grooves.
The clearance should be within 0.052 / 0.020 mm.
b. Install the rings in the cylinder and ensure that the
free end gaps are within:
0.045 / 0.20 mm for compression rings. and 0.50
/ 0.20 mm for oil ring.
(Ensure correct bore size and proper size of rings
prior to check free gap of rings.
c. Inspect the piston, renew if scored / cracked /
damaged. Check fit of gudgeon pin in piston and
connecting rod. The pin should be a light press fit
in the piston and the clearance between the
connecting rod and the gudgeon pin should be
within 0.011 / 0.003 mm.

d. Inspect the connecting rod for cracks and damage
and the bearing bore for correct fit on the crank
shaft. Clearance between crankshaft pin and
bearing bore must not be less than 0.013mm and
not more than 0.051 mm.
e. Inspect crankshaft journal and pin dia for wear
score marks, finish and whether ovality is within
0.04mm.
Never try to recondition the crankshaft which is
specially hardened to suit high speed operation.
f. The crank shaft should be a new sliding fit in the
bearing bore on end cover and the mounting
flange side of cylinder block.
If worn excessively :
(a) renew the bush bearing and rebore to suit
crankshaft on mounting end cover (Refer
instruction of crankcase)
(b) replace aluminium end cover.
Cylinder Head
* Inspect the cylinder head for cracks and damage.
Inspect inlet and delivery reed valves and valve
plate for any wear/distortion/score marks. Replace
the reed valve assembly, if excessive wear /
distortion is observed.
* Joints
Renew all joints and sealing rings by
recommended repair kit.
* Scrap the old parts which are found to be
unserviceable.
Reassembly
* Use recommended Repair Kit to replace the parts
scrapped during dismantling and in addition, renew
all the parts which were found to be unserviceable/
defective during inspection. Lubricate all moving
parts with clean engine oil to prevent possible
damage when the engine is started and oil supply
is established.
Crankshaft and End Cover
* Insert the crankshaft in the cylinder block after
smearing a little engine oil on bush and crankshaft
journals.
* Position a sealing ring on the end cover.
Assemble the end cover to the cylinder block.
* Fit screws with washers and check for free rotation
of the crankshaft and then tighten the end cover
screws to a torque of 22Nm. (16.2 lb.ft.)
Piston Assembly
* Locate the connecting rod small end in the piston
and insert gudgeon pin fit the circlip and ensure
that the circlip is located in the piston groove
properly.
BRAKES 09.09
* Fit new rings on the piston and ensure that the
sides marked "top" are upper most and ring gaps
set at 120 degree (approx) to each other.
* Position the crankshaft in BDC and pass the piston
assembly through the top of the cylinder bore
using a ring guide and ensure that the connection
rod big end is located on the crankshaft journal.
* Place the cap on connecting rod. Fix connecting
rod bolts with new washers and tighten the
connecting rod bolts to a torque of 15 Nm.
Apply loctite 242 or equivalent to bolt thread
before assembly.
* Again check for free rotation of crankshaft.
* Apply engine oil over the crankshaft and cylinder
walls. Place and position the joint and base cover
on the sump and secure by screws and spring
washers. Tighten the screws to a torque of 9
Nm.(6.6 lb.ft.)
Cylinder Head and Reed Valves
* Fix delivery reed valve on to the valve plate using
two locating pins of 3mm dia can be pressed in
by hand. Ensure that the reed is located on same
side following the identification marks provided
during dismantling.
* Reverse the valve plate and fix the inlet reed valve
on it, using two locating pins one in each of
diameter 2 mm to 2.5 mm.
using * Apply gasket sealant LOCTITE 518 or its
equivalent on all gaskets.
* Place the delivery reed thinner joint (0.4mm) on
the top side of the valve plate and ensure that it
does not overlap with the delivery reed. Then,
place the delivery reed thicker joint (0.8 mm).
* Locate the cylinder head on the valve plate.
* Place the sealing ring on the inlet boss of cylinder
head and assemble cylinder head cover with
gasket.
* Insert 4 Nos. of set screw with washers on the
cylinder head.
* Insert the inlet reed thinner joint (0.4 mm) through
the 4 Nos. of set screws and align it ensuring that
it does not overlap with reed valve.
* Insert thicker joint (0.8 mm) on the screw and
position over the thinner joint.
* Place and position the cylinder head with cylinder
head cover on the cylinder block and tighten the 4
set screws to a torque of 22 Nm. (16.2 lb.ft.)
* Install the compressor on the engine as per
instruction giver in ‘REPLACING’ and check the
compressor performance.
NOTE: Do not apply Oil/Grease/sealing compound like
shellac on the joints the cylinder head joints
should be used as raw in as is condition and
also avoid reuse of joints once removed.
5. Check for free rotation of crankshaft during every
stage of assembly.
09.10 BRAKES
09.3.0.0 Trouble Shooting
Fault
Overheating of compressor
Compressor fails to maintain
adequate pressure in the Air
Brake System. (When tested
without any leakage in system
due to defective valve assy
and pipe joints.)
Noisy Operation
Compressor passes excessive
oil through delivery
Causes Remedy
a. Defective water circulation system. Rectify the defect in water circulation
system
b. Blockage in water passage of cylinder Clean the cylinder head / pipe lines
head / connection
a. Dirty Air cleaner Clean the air cleaner
b. Excessive carbon in the compress or Clean compressor cylinder head and
cylinder head / delivery line. decarbonize delivery line.
c. Delivery reed valve leaking and Clean / replace with new inlet /
leakage at inlet reed valve. delivery reed valve.
d. Excessive wear of cylinder / piston Rebore and fit O/S piston and rings.
rings.
e. Leak through cyl.head joints and pipe Replace joints and tighten to correct
fittings. torque values. Tighten pipe fittings
properly
a. Loose drive / mounting Tighten the gear / coupling bolts.
Check for key shearing, key way
enlarging etc. tighten mounting bolts of
compressor.
b. Worn or burnt out bearing / end Replace bearing / end cover
cover bore
c. Excessive wear of journals / bearing. Replace crankshaft and renew bearing.
a. Excessive wear in bore / rings / piston Rebore and replace with O / S piston
/ bearing. and rings and renew.
b. Dirty air cleaner Clean Air Cleaner
c. Excessive oil pressure (Normal for Rectify
engine lubricated units is 2.8 ksc to
4.2 ksc)
d. Oil return passage from engine Clean the oil return passage.
crankcase.
e. Back pressure from engine crankcase Clean the engine breather
obstructed.
f. Piston rings incorrectly installed Ensure piston rings are assembled with
“Top” mark facing top and ring gap
spaced at 120 degrees to each other.
g. Restricted Drain hole in End cover Clean the passage
h. Deep score marks in piston bore. Rebore / hone and assemble with
O/S piston and rings.

09.3.1 Dual Brake Valve
Function
Dual brake valve is used to gradually charge and
exhaust the brake actuator. Spring loaded plunger is
provided on the secondary piston to reduce the
pressure difference with upper (primary) and lower
(secondary) delivery pressure.
Description
The Dual Brake Valve mainly consists of an upper body
and a lower body in which the pistons and the spring
loaded valves are housed.
The spring loaded upper piston houses a rubber, spring
a spring seat and a stem, located in the upper body.
The stem is connected to the brake pedal. Secondary
piston is housed with spring loaded plugger inside the
lower body. The upper and the lower bodies are
provided with inlet / delivery ports of primary, secondary
and auxiliary connections, and are secured together by
four screws.
Service Check
(a) Operating Test
* Check and ensure that the pipe connection and
joints are free from air leakage when the brake is
in applied condition.
* Connect test gauges in the delivery of the primary
/ secondary lines of the brake valve and check
delivery pressures with the brake pedal fully
BRAKES 09.11
depressed. The delivery pressures registered in the
gauges should be approximately the same as the
primary / secondary dash board pressures.
* Depress the brake pedal to several positions
between fully released and fully applied positions
and check the delivery pressure registered by the
test gauges which should vary in accordance with
the brake pedal position.
(b) Leakage Tests
* Off leak
Charge the system fully and check for air leak in
pipe line joints and exhaust check of brake valve
by applying soap solution. No air leak is
permissible.
If air leak is noticed in exhaust check of brake
valve, disconnect either primary or secondary inlet
and again check air leak. Air leak noticed in either
of the line connected, leaves indication to check
and attend to primary / secondary portion of the
valve.
* On leak
Depress the brake pedal fully and check the brake
valve for exhaust leak. By holding the brake pedal
fully depressed, check the delivery pipe joints for
air leakage by applying soap solution. No air leak
is permissible.
If air leak is noticed in the exhaust, check brake
valve disconnect either primary or secondary inlet
and again check air leak. Air leak noticed in either
of the line connected, leaves indication to check
and attend only that portion of the valve.
Removing
* Block the wheel to prevent movement of the
vehicle during working.
* Brush away dirt / dust from the air line connections
and the brake valve.
* Drain the air pressure from the system.
* Disconnect the inlet / delivery pipe connections of
primary and secondary after identifying the pipe
lines to avoid wrong connection of pipes while
replacing the unit on the vehicle.
09.12 BRAKES
* Close open ends of the pipes to prevent dirt /
dust entering the air lines.
* Disconnect the electrical terminals of stop light
switches and low pressure indicator switches, if
provided.
* Loosen and remove the mounting nuts and remove
the brake valve.
Replacing
* Mount the brake valve on the vehicle and secure it
tightly.
* Connect air lines. Follow the identification of the
pipe lines to avoid wrong connection.
* Connect the electrical terminals to the stop light
switches and low pressure indicator switches, if
provided.
* Apply the service brake and check for stop light
switch function and also check for the warning from
low pressure indicator switch, when the system
pressure is below the pressure setting of the
switch.
* Carry out Operating / leakage tests’ as given
under service check’.
Dismantling
* Clean the exterior of the unit.
* Loosen and remove the stop light switches and
low pressure indicator switches, if provided.
* Disconnect brake pedal operating plunger from the
brake valve and loosen mounting bolts.
* Remove the assy from the vehicle.
* Mark the position of upper and lower bodies to
avoid wrong position of ports during assembly.
* Remove the four screws (913 A/F) which secure
the upper and lower bodies and detach the bodies
and extra cover.
Lower Body Sub Assembly
* Push the secondary piston into the bore to ensure
free movement and remove the piston from body.
* Remove the circlip and detach venting guide assy.
sealing ring, spacer, spring and valve.
* Remove the snap ring from secondary piston to
dismantle plunger and spring with washer.
Upper Body Assembly
* Remove the bottom circlip and detach the sealing
ring spacer, spring and valve.
* Remove the upper circlip and detach the boot
spacer and stem.
* Detach the primary piston sub assembly.
Primary Piston Sub Assembly
* Remove the circlip and detach the spring seat and
rubber spring.
* Remove the ‘O’ rings, sealing rings and guide rings
from the venting guide, sealing ring spacer, primary
and secondary pistons and valve bodies.
* Scrap all the old parts after replacing from the
Repair Kit.
Cleaning and Inspection
* Clean the metallic parts in cleaning solvent and
blow with dry compressed air. Ensure that no
trace of solvent is present during assembly.
* Ensure that the metering holes are free from
blockage in the upper and lower bodies.
* Check the upper and lower bodies for thread /
port face damage.
* Inspect the mounting plate, pistons, plunger and
venting guide for damage, nick marks and excessive
wear.
* Check the springs and circlips for corrosion,
distortion and permanent set.
* Scrap all the old parts which are found to be
unserviceable during inspection.
Reassembly
* Use recommended Repair Kit to replace the old
parts scrapped during dismantling and also replace
the parts found to be unserviceable during
inspection.
* Lubricate the pistons, bores of upper and lower
bodies and sealing ring spacers with Bharat MP2
grease. This grease is supplied in the Repair Kit.
* Install the new ‘O’ rings on the pistons, venting
guide and sealing ring spacers and smear with
grease.
* Install the guide rings on the primary piston and
smear with grease.
Lower Body Sub Assembly
* Place the valve, spring, sealing ring spacer and with
sealing ring on venting guide.
* Position and guide the venting guide gently in the
valve body bore.
* Secure the venting guide in the valve body with
circlip.
* Ensure that the circlip is located in the groove
properly.
* Insert the plunger into secondary piston from seat
face along with spring, seat and retain in position
by the snap ring.
* Apply grease in the secondary body bore.
* Assemble the secondary piston on the body and
press the piston in the bore for few cycles to
ensure proper alignment of valve.

Upper Body Sub Assembly
* Place the valve, spring and sealing ring spacer in
the bottom side of the upper valve body.
Position and secure with circlip.
* Ensure that the circlip is located in the groove
properly.
* Place and position Rubber spring seat in the
primary piston.
* Press in the spring seat using the mallet handle
and assemble the circlip.
* Ensure that the circlip is located in the groove
properly.
* Avoid Grease / Oil Contact with Rubber
Spring
* Insert the primary piston in the top side of the
upper valve body.
* Place the spacer (with the groove face towards
top) and boot (keeping plain portion towards top)
along with stem and secure with circlip.
* Ensure that the circlip is located in the groove
properly.
* Locate the sealing ring in the bottom groove of
the upper body and secure upper, lower bodies
and exhaust cover together by the four screws (10
A/F) by tightening to a torque of 10 Nm (7.5 lb
ft.). Ensure that the marking on valve bodies is in
line.
* Place the brake pedal assembly on the valve, align
the plunger to seat on the stem.
* Assemble the stop light switches in the auxiliary
port of the deliveries and the low pressure
indicator switches in the auxiliary post of the inlet
along with aluminium washers, if provided.
Test
* Check the assy performance on the vehicle as per
specification in Service Check.
BRAKES 09.13
09.3.2 R 6 Relay Valve
Function
Relay valve provides a means of admitting and releasing
air to and from brake chambers, in accordance with the
brake valve without passing the air for the brake
chambers through the brake valve.
Description
The assembly comprises of a body, top cover and base
cover. The top cover guides the relay piston during
operation and an exhaust valve seat screwed into the
relay piston. Piston returns on its own during exhaust
without the assistance of return spring. Inlet and
exhaust valve assembly consists of inlet and exhaust
valve spring which are retained in the valve guide by a
snap ring. The valve assembly is housed in the body
and retained by base cover with two screws.
Diaphragm type exhaust check is fitted into the base
cover to prevent dirt entry into the valve assembly.
Service Check
(a) Operating Test
* Charge the system to unloader valve cut-out
pressure.
* Apply and release the brakes several times and
check that the brake chambers respond promptly
to brake movements.
(b) Leakage Test
* Charge the system to unloader valve cut-out
pressure and stop the engine.
* Coat the top cover joint, pipe unions and exhaust
diaphragm with soap solution.
* Leakage more than 25 mm soap bubble in three
seconds is not permissible.
* Apply the appropriate control valve and recheck
for leakage as before.
Removing
* Check the wheels and release all air pressure from
the appropriate reservoir.
* Disconnect the air lines and take precautions to
prevent dirt entering the open ends of the pipes.
09.14 BRAKES

* Remove the mounting flange set screws or unscrew 09.3.3 Brake Chamber
the pipe nipple to remove the valve.
* Remove the sealing ring from the mounting flange
where applicable.
Replacing
* Position a new sealing ring in the mounting flange.
* Screw in the mounting screws or pipe nipple and
connect the piping as before.
* Open the line cock where applicable and carry out
the operating and air leakage tests as given under
‘Service Check’.
Dismantling
* Mark the top cover in relation to the body to
ensure correct reassembly.
* Remove the four set screws and take off top Function
cover, relay piston and sealing ring. Brake Chamber coverts the energy of compressed air
* Remove the cover sealing ring from the body. into mechanical force and motion necessary to operate
* Remove the two screws securing the base cover the brakes and this assembly is specially designed to
and take out the valve and guide assembly. operate the wedge brake.
* Remove the sealing rings from the valve guide.
Description
* Slide the valve spring and valve retainer off the A rubber diaphragm is housed in between pressure
valve stem by removing the snap ring.
plate and non pressure plate and retained by the clamp
* Discard all old items renewable from the Repair
ring. The push rod assembly fitted with nylon bearing(s)
Kit.
is guided in the bore of the mounting bracket which is
Reassembly welded into non pressure plate. In order to meet the
* All sliding surfaces, sealing rings and joint rings requirements for different braking forces different types
must be coated with grease.
of push rod assemblies are used in same diaphragm.
* Position the cover joint ring (15) in the body (10),
locate the sealing ring (14) correctly in the piston
(1) and insert the piston into the top cover (3). Service Check
* If a new exhaust seat (2) has to be fitted, smear (a) Inspection Check
the threads of the insert with ‘LOCTITE SCREW * Check the tightness of the mounting nuts.
LOCK’. (b) Operating Tests
* Locate the marks made before dismantling and fit * Check and ensure that the pipe connections and
the cover and set screws (4).
joints are free from leakage when service brake is
* Fit the valve retainer (6) and valve spring (7) on applied.
the inlet/exhaust valve (8) so that the rubber head
of the valve sits in the retainer. Removing
* Insert the valve into the body (10). * Operate the hand brake valve to ‘Brakes on’
* Assemble the sealing rings (9) and (12) in the condition and completely drain the system air
valve guide (11) and groove. Insert into inlet/ pressure.
exhaust valve and retain by the snap ring in
position. * Disconnect air lines after marking suitable
* Position the sealing ring in the valve guide outer identification of port position with reference to the
groove. vehicle installation for easy reinstallation.
* Slide the valve assembly so that the outer seal on * Remove the mounting bolts and remove the Brake
the valve guide butts the body and fit the base Chamber.
cover (18) by two screws (17) spring washers (16)
* Close the open ports to prevent entry of dirt.
* Locate the diaphragm exhaust (19) and cover (20)
on the base cover and screw the self tapping * Ensure that the rubber sealing ring used on
screw (21). mounting flange is retained in position inside the
* Position the filter (22) with spherical portion into carrier plate.
the reservoir port thread.
Dismantling
Test
Special Instructions
* Test the assembly as given under ‘SERVICE
CHECK’ a. Ensure the correct size of push rod assembly
(Type 7 or 9 ) as applicable for the vehicle.

b. To avoid wrong fitment provide suitable
identification on the assembly externally.
c. Entry of dust particles through brake chamber non
pressure plate side must be avoided. This needs
proper maintenance / lubrication of bearing and
sealing ring guiding in the mounting bracket bore.
d. Dimension between mounting flange and push rod
seat must be 76.5 / 75.5 brake released condition.
e. In case of any deviation in the above dimension or
damage to nylon bearings on the push rod
assembly, It is essential to replace whole push rod
assembly with bearings (which is supplied as push
rod repair kit) and do not attempt to recondition.
f. To avoid entry of dust / water always ensure
fitment of sealing ring in between brake chamber
mounting flange and carrier plate.
* Clean the exterior of the assembly.
* Loosen and remove the clamp ring bolt and nut
non pressure plate, diaphragm, push rod assembly.
Cleaning and Inspection
* Wash and clean all metal parts and blow with dry
compressed air.
* Inspect all parts for excessive wear and
deterioration.
Reassembly
* Use recommended Repair Kit to replace the old
parts. Replace all parts found to be worn out,
defective during inspection by new parts.
* Lubricate all moving parts and ‘O’ rings with Bharat
MP2 grease.
* Place the diaphragm on the Non-pressure plate
and place clamping and non pressure plate with
push rod etc. In position, Proper positioning of
non pressure plate is to be ensured.
Do not apply Grease or oil on Diaphragm
* Tighten the Clamp Ring nut and ensure 1.5 to 1.8
kgm. tightening torque.
* Fix the breather tube to connect elbows on end
cover and non pressure plate.
* Measure the push rod spring seat face from
mounting flange to check the dimension 76.5 /
75.5 (Refer Special Instruction Note (e))
BRAKES 09.15
* Push rod bearing(s) is / are not removed during
overhaul unless any damage / excess wear is
noticed. If bearings are worn out / damaged,
Use push rod assembly repair kit for proper
shimming.
* Apply grease in push rod seat.
* Fit the assembly on the vehicle and tighten the
mounting bolts.
* Adjust the brakes and check for pipe joints leak
before putting into service.
Test Procedure
* Apply the brakes and hold.
* Check for leakage around clamp ring joint and pipe
connection.
* No leakage is permissible.
09.3.4 Spring Brake Actuator
Function
To produce braking forces at the foundation brakes,
having wedge brakes arrangement. It serves the
function of service, secondary and parking brakes.
Description
The assembly is a combination of diaphragm brake
chamber and spring actuator with mechanical rear wind
off arrangement. While the diaphragm is for actuating
service brakes and spring loaded piston is for
secondary/parking brake actuation, the mechanical wind
off arrangement is for releasing the spring brake in case
of emergency viz - to release spring brakes temporarily
should occasion arise where the vehicle has to moved
after a failure in the brake system. The breather tubes
have hoses attached to them for remote outlet.
09.16 BRAKES
Service Check
(a) Inspection Check
* Check the tightness of the mounting nuts.
* Ensure that the wind off bolt is in fully tightened
condition.
(b) Operating Tests
* Check and ensure that the pipe connection and
joints are free from leakage when service brake is
applied.
* Check and ensure that the pipe connection and
joints are free from leakage when spring brake is in
released condition.
Removing
* Block the wheels and operate the hand brake
valve to ‘BRAKE OFF’ condition.
* Rotate the wind off bolt in anti-clockwise direction
such that wind off bolt comes out fully.
* Never attempt to remove the assembly
from the vehicle without winding off.
* Operate the hand brake valve to ‘BRAKES ON’
condition and completely drain the system air
pressure.
* Disconnect air lines after marking suitable
identification of port position with reference to the
vehicle installation for easy reinstallation.
* Remove the mounting bolts and remove the Spring
Brake Actuator.
* Close the open ports to prevent entry of dirt.
* Ensure that the rubber sealing ring used on
mounting flange is retained in position inside the
carrier plate.
Dismantling
Special instructions
A heavy coil spring is provided in this spring brake
actuator and this assembly is meant for operating
wedge brakes. Extra care is required while
servicing these assemblies as follows:
a. While attempting any repair on spring brake
actuator always wind off the spring brake actuator
mechanism to keep the heavy coil spring in
compressed condition.
b. Ensure the correct size of push rod assembly (type
7 & 9 ) as applicable for the vehicle.
c. To avoid wrong fitment, provide suitable
identification on the assembly externally.
d. Entry of dust particles through brake chamber non
pressure plate side must be avoided. This needs
proper maintenance/lubrication of bearing and
sealing ring guiding in the mounting bracket bore.
e. Dimension between mounting flange and push rod
seat must be 76.5/75.5 in brake released condition.
f. In case of any deviation in the above dimension or
damage to nylon bearings on the push rod
assembly, it is essential to replace whole push rod
assembly with bearings (which is supplied as push
rod repair kit) and do not attempt to recondition.
g. To avoid entry of dust/water always ensure fitment
of sealing ring in between brake chamber mounting
flange and carrier plate.
* Clean the exterior of the assembly.
* Remove the breather tube from the elbows.
* Loosen and remove the clamp ring bolt and nut,
non-pressure plate, diaphragm, push rod assembly.
* Push the spring seat into the cylinder and remove
stem plug by lifting it out using a screw driver.
* Remove the spring dowel from the hexagonal
sleeve (wind off nut) by using 6mm dia flat punch/
rod and remove the sleeve from the wind off bolt.
Unscrew the wind off bolt and remove from the
piston.

* Insert the rod (Item No 3 in fig. ) and screw in to
the spring seat boss.
* Fix the special tool sleeve on the rod as given in
instruction 6 and rotate the sleeve rod to
compress the spring fully.
* Unscrew three M6 cap screws and push the spring
into cylinder.
* Remove the ‘O’ ring from cylinder groove.
* Insert screw driver to lift the snap ring from
groove and remove the snap ring from the
cylinder.
* Remove the spring seat with spring/piston from the
cylinder and hold the spring seat suitably from
rotation.
* Rotate the special tool sleeve until the spring load
is fully released and remove the special tool sleeve
and rod to dismantle the piston, spring and end
cover.
* Remove all bearings (nylon) ‘O’ ring and seat from
piston and cylinder.
Cleaning and Inspection
* Wash and clean all metal parts and blow with dry
compressed air.
* Inspect all parts for excessive wear and
deterioration. Check cylinder bore and piston for
any score mark/crack/damage.
Reassembly
* Use recommended Repair Kit to replace the old
parts. Replace all parts found to be worn out/
defective during inspection by new parts.
* Lubricate all moving parts and ‘O’ rings with Bharat
MP2 grease.
* Fit the seal (ensuring the correct position of the
lip) and bearing on the respective grooves of the
piston.
* Fit ‘O’ ring and bearing in the respective grooves
of the cylinder.
BRAKES 09.17
* Assemble the piston into the cylinder. Care should
be taken to avoid damage to seal and ensure
proper entry of the seal into the cylinder without
folding during assembling as the cylinder bore is
having two grooves at entry portion.
* Place the main spring inside the piston and keep the
spring seat over the spring. (Lightly coat grease over
the entire spring before assembly)
* Insert the special tool rod with nylon washer into the
piston and assemble the special tool sleeve with M6
screw on to the other end of the rod.
* Hold the spring seat suitably to prevent from
rotation.
* Rotate the special tool sleeve to compress the spring
until the piston touches the face of the spring seat.
* Push spring seat fully into the cylinder.
* Insert the snap ring into the bottom groove of
cylinder.
* Insert the ‘O’ ring in the cylinder groove.
* Rotate the spring seat to get correct position of
rubber elbow.
* Fix 3 cap screws with steel washer on the spring
seat and align to the slots of the cylinder.
* Rotate the special tool sleeve to release the spring
load and remove the special sleeve from the rod and
unscrew the rod to remove.
* Fit wind off rod with nylon washer.
* Insert aluminium washer and assemble the hexagonal
sleeve (wind off nut) on the wind off bolt and drive
the spring dowel pin into hexagonal sleeve.
* Press the stem plug with ‘O’ ring on the piston.
* Place the diaphragm on the Non-pressure plate and
place clamping and non pressure plate with push rod
etc., in position. Proper positioning of non pressure
plate is to be ensured.
Do not apply Grease or Oil on Diaphragm
09.18 BRAKES

* Tighten the Clamp Ring nut and ensure 1.5 to 1.8 09.3.5 Graduated Hand Control Valve - ‘S’
kgm. tightening torque. Type

* Fix the breather tube to connect elbows on end

cover and non pressure plate.

* Measure the push rod spring seat face from

mounting flange to check the dimension 76.5/75.5
(Refer Special Instruction Note (e))

* Push rod bearing(s) is/are not to be removed

during overhaul unless nay damage/excess wear is
noticed. If bearings are worn out/damaged, use
push rod assembly repair kit for proper shimming.

* Test the unit for leak and performance (refer test

procedure)

* Apply grease in push rod seat.

* Fit the assembly on the vehicle and tighten the

mounting bolts.

* Adjust the boxes and check for pipe joints leak

before put into service.

Test Procedure

* Connect spring brake actuator port (12) with air

lines through an “ON-OFF” valve.
FUNCTION
* Apply air pressure to Spring Brake Actuator port
and check for release of piston/push rod. Operate
The purpose of this valve is to gradually charge and
the “ON-OFF” valve few times and check for free
exhaust air from spring brake actuators for releasing/
movement of piston/push rod. Operate the valve
to “ON” position and check for leak through applying the parking or emergency brakes in a truck or
breather holes on non-pressure plate, body and a tractor. Lever in the top cover assembly is provided
port 11 to check piston stem leak. with torsion spring which ensures self return to brake
released condition and locking arrangement at parking
* Connect the pipe to service port (11) through a brake applied condition.
separate “ON-OFF” valve and apply pressure to
spring brake port to keep the heavy coil spring in DESCRIPTION
compressed condition. Operate “ON-OFF” valve
of service brakes few times and check for free The valve mainly comprises of a valve body in which an
movement of push rod. inlet/exhaust, valve is housed in a floating plunger
assembly. The inlet/exhaust valve is operated by a
* Operate the valve connected to service brake to
plunger fitted with roller.
“ON” position and check for leak through
diaphragm and clamp ring joints.

The above procedure is to be adopted after

fitment on the vehicle if not tested earlier.
 BRAKES 09.19

Plunger assembly retained in the valve body by a (b) Leakage Tests

graduated spring and base cover with three set screws.
Graduating spring load can be adjusted by the grub
screw provided on the adjustment plate which is located
in between base cover and plunger guide.
The top cover assembly houses a cam, a pivot pin and
an operating lever. A torsion spring is assembled over
the cam with two guide bushes on pivot pin to return
the cam to brake released condition when sleeve is
lifted from its locking position. The lever can be locked
in brakes ‘ON’ position by spring loaded sleeve and a
knob. The top cover assembly is secured on to the
upperside of the valve body. The valve body also has
inlet, delivery and exhaust ports at the side over which
mounting bracket is fixed with suitable relief for the
fitment of adaptors. A rubber gaiter fitted in between
the top cover and the sleeve protects dust/dirt entering
the valve.
* With the lever locked in brakes ‘ON’ position,
charge the system fully.
Check for air leakage through the exhaust. No air
leak is permissible. Air leak, if noticed indicates
faulty inlet/exhaust valve or damage on valve seat.
* With the lever in brakes ‘OFF’ position, charge the
system fully and check for air leakage through
exhaust.
No air leak is permissible
If air leak is noticed, indicators faulty inlet/exhaust
valve, damage on the valve seat of the plunger or
‘O’ rings.

Service Check
Removing

(a) Operating Tests

* Release the lever to the brakes ‘OFF’ position and
charge the system to cutout pressure and stop the
engine.
Move the lever to brakes ‘ON’ position gradually.
The air should start exhausting from initial
movement of the lever from ‘OFF’ position.
Further movement will start to apply the spring
brakes.
* Operate the hand brake valve to apply the parking
brake.
* Block the wheels to prevent movement of the
vehicle during working.
* Deplete the air pressure from the system.
* Brush away dust/dirt from the air line connections
and the valve.

Move the lever completely towards brakes ‘ON’

position and lock the lever.
effectiveness of spring brakes.
* Disconnect the inlet/delivery pipe lines and close
Check for full
the open ends of the pipes to prevent dirt/dust
entry.

The air in the hand brake line should be exhausted

fully. * Mark the valve position with respect to its
mounting.
* Release the lever from ‘ON’ and move into ‘OFF’
position. Observe a sound of air passing through * Remove the mounting nuts. Remove the valve
to the spring brakes releasing it. In the final from the mounting bracket.
position of the lever in brakes ‘OFF’ condition, full
inlet pressure must be available at the delivery. Replacing

* Check for proper locking sleeve in brake applied * Fit the adaptors along with aluminium washers.
condition and when the sleeve is lifted from the
lock the lever should return to brakes ‘OFF’
* Identify the marking and locate the valve on the
position automatically.
mounting bracket. Place and secure the valve
tightly by nuts and spring washers.
09.20 BRAKES
* Connect the pipe lines to its respective ports.
* Charge air pressure and carry out ‘operating/air
leakage test’ as given under ‘Service Check’.
Dismantling
* Mark the position of the top cover assembly with
respect to the valve body.
* Remove the gaiter from its seating in the top
cover/the cap.
* Unscrew and remove the counter sunk screws, top
cover assembly.
* Only when required for replacement of any
damaged parts:
Press out the tension pin using 3 mm dia flat pin
and remove the lever, pivot pin and cam with
torsion spring from the top cover.
* unscrew mounting bracket screws and remove the
bracket.
* Unscrew the mounting screws and remove the
cover, aluminium plate, graduated spring and
plunger assembly.
* Remove the plunger and roller from valve body.
* Scrap all the old parts which are serviced in the
repair kit.
Cleaning and Inspection
* Clean all the metallic parts in cleaning solvent and
blow with dry compressed air. Ensure that no
trace of solvent is present during reassembly.
* Check the valve body, cover and plunger for excessive
wear, nick/score marks, cracks and damages.
* Check the cam for excessive wear at the mating
surfaces.
* Check the spring and torsion spring for distortion,
corrosion and permanent set.
* Check the cover and the sleeve for excessive wear
on its mating surfaces.
* Scrap all the old parts found to be unserviceable.
Reassembly
* Use recommended kit to replace the old parts
scrapped during dismantling and also replace the
parts found to be unserviceable during inspection by
new ones.
* Lubricate all the sliding parts and its mating surfaces
with Bharat MP2 grease which is supplied in the
repair kit.
* Install ‘O’ rings on the plunger.
Plunger Sub Assembly
* Place inlet/exhaust valve in the upper plunger with
valve spring.
* Locate the special washer with sealing ring in the
lower plunger.
* Hold the outer diameter of the upper and lower
plungers with rubber sheets separately.
* Screw in the lower plunger into upper plunger and
tighten fully.
* Insert the operating plunger into valve body with
circlip and conical spring.
* Insert the plunger assembly into the body and locate
the graduating spring and guide.
* Place the gasket, adjustment plate and cover on the
body and tighten the three set screws. Screw the
grub screw into the adjustment plate.
* Top Cover Sub Assembly (Only when dismantled for
any replacement of parts)
* Insert the torsion springs on to the slot provided
on the cam along with two guide bushes.
 BRAKES 09.21

* Insert the lever into the cam. Testing and Pressure Adjustment

* Ensure the position of the cam and torsion spring
to locate correctly the top cover slot.
* Press the cam into the top cover with two legs of
torsion spring guiding into the slot.
* Keep the lever in brakes ‘ON’ condition.
* Connect the inlet pipe of the vehicle to assembly.
Connect pressure gauge (0 to 10 bar) to delivery
port.

* Withdraw the lever slightly to give sufficient
clearance for inserting the pivot pin to the top
cover through the cam bore.
* Press the lever in the cam in position and align
holes in the pivot pin and lever in one line.
* Press the tension pin using suitable drift.
* If the top cover assembly is free from any defect
during the inspection, lubricate the pivot pin and
apply grease over the torsion pin to proceed for
further assembling.
* Assemble the gaiter on its groove in the sleeve,
and slide the sleeve into the lever. Assemble the
other end of the gaiter on the groove in the top
cover.
Run the engine to build up air pressure in the
system.
* Operate the lever for few cycles and check for
even rise and drop of pressure in delivery line.
* Keep the lever at brakes ‘OFF’ position and unscrew
the grub screw to reduce the delivery pressure to 5
bar when reservoir is maintained at 8 bar.
* Slowly tighten the grub screw to increase the
delivery pressure upto 7.5 bar.
* Check for any leakage in brake applied and
released condition.
* Operate the lever to brakes ‘ON’ condition and
lock.

* Place the spring in the sleeve and with a few
drops of loctite 242 or its equivalent on the
threaded portion of the lever, screw the knob on
the lever.
* Lock the lever at brakes ‘ON’ position.
* Locate the roller pin the slot of the valve body
ensuring the correct position to get required lever
position on assembly.
* The gauge at delivery pressure should read zero
which indicates proper function of the valve.
* Remove the connection and gauge and install the
assembly on the vehicle.
* Connect pipe lines and check for any leak at pipe
joints in brakes ‘OFF’ condition.

* Identify the marking and locate the top cover with

‘L’ bracket on the valve body and assemble with
four counter sunk screws.

* Operate the lever to brakes ‘ON’ and ‘OFF’

condition for few times and check for proper
locking at brakes ‘ON’ condition and self return to
brakes ‘OFF’ condition once the sleeve is lifted
from the lock position.
09.22 BRAKES
09.3.6 QUADRUPLE SYSTEM PROTECTION
VALVE (DIAPHRAGM TYPE)
Function
The function of system protection valve is to charge 4
lines from a compressor and prevent back flow of
compressed air from any one line to which the valve is
connected. In the event of failure in any one of the lines
this valve helps to maintain the other lines intact to their
opening pressure.
Description
The Valve consists of a valve body, a diaphragm
assembly, 6 spring-loaded hemispherical valves, graduating
spring and a top cover. The body has one inlet port
connecting the delivery of the compressor and 4 delivery
ports. Two ports labelled 21 and 22 are connected to
two independent reservoirs feeding air pressure to dual
brake valve. Port labelled 23 is connected to the hand
brake circuit and port 24 is connected to auxiliary circuits
like exhaust brakes, air horn, air wiper, throttle, air
suspension and pneumatically actuated door mechanisms.
The body provides valve seats for the 4 elements. Each
element has a spring-loaded hemispherical valve. A Air leak of 25mm soap bubbles in 5 seconds is
diaphragm assembly locates the valves. The top cover
locates the graduating springs and secures the
diaphragm assembly through 5 hexagonal head screws.
A dust cover is provided to prevent dust entry into the
elements.
Service Checks
a) Operating checks
1. Pressure Setting
- Deplete air pressure completely from all the lines.
- Connect a test gauge in the inlet line of the
system protection valve. ( preferably in the sensing
tank drain port).
- Connect test gauges one in each of the delivery
lines of the system protection valve.
- With any one of the service lines, start the engine
and build up air pressure, to check the opening
pressure of that element. The stabilised pressure
showing in the inlet gauge is the opening pressure
of that element.
- If the system pressure is not charged to the correct
pressure setting the valve element should be
removed, serviced and adjusted to give the correct
pressure setting.
- For setting the specified pressure, screw in all the
adjusting screws (2.5mm hexagonal socket set screw)
to higher pressure and unscrew to get the required
pressure setting. For setting the pressure in the service
element run the compressor at idling speed of the
engine.
Repeat the procedure for all other three elements and
attend to them if necessary.
Note: For service lines the gauges provided in the
dash board may be used
2. Closing Pressure of Auxiliary Elements
For checking the closing pressure of an element in the auxiliary
line, charge the system fully and release the pressure slowly by
opening that line to atmosphere. Pressure retained in the inlet
test gauge is the closing pressure of that element.
3. Closing Pressure of Service Elements
For checking the closing pressure of an element in the
service line, charge the system fully and release the
pressure by opening that line to atmosphere. The
pressure drops in the test gauge connected to the inlet
at a faster rate to a pressure and further keeps
dropping slowly. The pressure dropped suddenly to a
value is the closing pressure of that element.
b) Leakage Tests
1. Charge the system to unloader valve cut out
pressure and stop the engine.
2. Apply soap solution on the joint and dust cover and
check for air leakage. If air leak is noticed in that joint,
check valve body mating faces for nick/score marks and
damage and replace if necessary.
permissible
Non Return Valve Leak
- Connect test pressure gauges in the delivery of the
service and auxiliary lines and charge the system
fully.
- Deplete any one of the service reservoirs by
disconnecting that line.
Apply soap solution in the disconnected lines and
first check for air leak. Air leak of 25mm soap
bubbles in 5 seconds is permissible.
- No faster pressure drop is permissible in the other
test gauges of the service line and auxiliary lines.
- Excessive pressure drop in any of the test gauges
indicates non-return valve leak in that line.
- Connect that service line and repeat the above
procedure by disconnecting the other lines one by
one to detect non-return valve leak in the other lines
- Remove all the test gauges
Note: Prior to conducting air leakage tests ensure
that the entire system is free from air leak.
With the system fully charged, if system
protection valve gives rise to hissing noise, it
leaves an indication that there exists external
air leak which has to be attended to first
before conducting leak tests.
To Remove
- Block the wheels to prevent movement of the vehicle
during working.
- Brush away dust/dirt from the air line connections
and the system protection valve.
- Deplete air pressure in all the lines.
 BRAKES 09.23

QUADRUPLE SYSTEM PROTECTION VALVE

ILL.
NO. DESCRIPTION QTY.

1 SET SCREW 8
2 BASE COVER 1
3 GASKET 1
4 BODY 1
5 VALVE 6
6 SPRING 6
7 DIAPHRAGM ASSEMBLY 1
8 COMPRESSION SPRING 4
9 SPRING GUIDE 4
10 TOP COVER 1
11 PRESSURE SETTING SCREW 4
12 DUST COVER 4

- Identify the pipes with its appropriate ports and
disconnect the pipes and close the open ends of
the pipes to prevent dust/dirt entry.
- Loosen the lock nut and removes the valve with
the long adaptor. (Remove the mounting nuts and
remove the valve from the bracket where
applicable)
To Refit
- Fix the short end of the long adaptor with an
aluminium washer to the inlet port of the valve.
- Screw in the lock nut and an aluminium washer on
the long end of the adaptor and screw in the
adaptor to the sensing tank boss and secure tightly.
- (Locate the valve on the mounting bracket and
secure tightly where applicable)
- Identify the ports and connect its respective pipes.
- Carryout 'Operating / Leakage tests' as given
under "Service check."
To Dismantle
Tools required for servicing:
Spanners 10, 11, 13 A/F, a 2.5mm Allen key. No other
special tool is required
- Loosen and remove the lock nut from the long
adaptor and remove the adaptor and the washer
from the valve port.
- Remove the 4 dust covers.
- Loosen and remove the 4 pressure setting screws
- Loosen and remove the 5 hexagonal screws
securing the top cover to the body.
- Remove the springs, the spring guides the
diaphragm assembly and the 4 valves.
- Loosen and remove the 3 screws securing the
base cover to the body.
- Remove the gasket and the 2 valves.
- Scrap all the parts which are serviced in the Repair
kit.
Cleaning and Inspection
- Clean all the components with a cleaning solvent
and blow dry with compressed air. Ensure that no
trace of solvent is present in the components
during assembly.
- Thoroughly clean the body and check the valve
seats for damage, nick marks. Check the threads
for damage.
- Check the springs for distortion, and permanent
set.
Scrap All The Old Parts Which Are Found
Unserviceable
To Assemble
- Use recommended Repair kit to replace the parts
scrapped during dismantling and in addition replace
all parts which were found unserviceable/defective
during cleaning and inspection.
- Locate the springs on the hemispherical valves and
locate the valve assembly on the seat in the valve
body.
- Locate the diaphragm assembly on the valve in
proper orientation.
- Locate the pressure setting springs on the
diaphragm.
- Locate spring guides on the springs.
- Locate the top cover and secure with 5 hexagonal
screws. Tighten the screws evenly in sequence as
shown in the figure below.
- Assemble the 4 pressure setting screws on the
top cover.
- Assemble the dust covers. Use a small drift of
2mm dia and insert the cover fully to ensure that
it is properly seated.
09.24 BRAKES
09.3.7 Unloader Valve With the Inflator
Function
This unit is used to control the pressure of an air
system and to draw compressed air from the
compressor for external use such as tyre inflation. It is
provided with an Air Filter for filtration and built in
Safety Valve feature.
Description
This Valve mainly consists of Valve body, Diaphragm
assembly, Unloader plunger assembly, Non-Return valve
assembly, Tyre inflating assembly, Pressure setting spring,
Top cover and Base cover.
The Diaphragm assembly comprises of a spring loaded
valve secured on to a Governor Plunger by a spring
washer and nut with bottom follower, Diaphragm and
Top follower. The spring loaded valve seats against a
seat in the valve body.
The unloader plunger assembly consists of plunger fitted
with ‘O’ ring on one end and a Valve seat and Valve
secured by nyloc nut on the other end. The valve of
unloader plunger is spring loaded with a shim and
secured in the bottom of the valve body by base cover,
sealing ring and circlip, while the plunger is located in
the bore of valve body beneath the governor plunger.
Due to the spring load, the unloader is pushed up and
the valve seals the passage on valve seat.
The non return valve assembly comprises of spring
loaded hemi-spherical rubber valve which seats on the
valve body in the delivery passage and secured in
position by a valve strip & spring retainer.
A pressure setting spring is located in between the top
follower of diaphragm assembly & top cover. The top
cover is secured to the body by four (4) screws with
spring washers. A spring guide is located in between
the pressure setting spring and the top cover while an
adjusting screw is screwed in to the top cover with a
lock nut. In between locknut and top cover, an exhaust
flap and a cup is provided to prevent dust/dirt entry.
A tyre inflating plunger assembly is housed on the
delivery passage of valve body before the non return
valve assembly and consists of a spring loaded valve,
inflating plunger with ‘O’ ring and secured on to the
body by an adaptor with an aluminium washer. A dust
cap is also provided on the adaptor to prevent dust/
dirt entry into the tyre inflating passage when not in use.
For effective filtration of compressed air, strainer in the
inlet port and wiremesh filter with a filter retainer in
between base cover and valve body just before the
inflation; passage are also provided.

Service Check
(a) Operating Tests
Drain the reservoir and then start the engine. Charge
the system until the unit “Cuts out” and record the
reading of dash-board gauge pressure. Ensure that the
pressure gauge on the dash board gives correct reading
before commencing the test. If the pressure setting
differs, loosen the lock nut, and adjust the adjusting
screw. Repeat the test till the correct pressure setting
is achieved and then tighten the lock nut. For the
purpose of resetting, it may be required to deplete the
reservoir by applying the brakes a few times.
Connect the tyre inflator to a pressure gauge. Start the
engine and record the “blow off pressure”. Ensure that
there is no air supply through the delivery port during
the test.
Leakage Tests
Charge the system to just below the “Cut out’ pressure
and stop the engine. Apply soap solution on the entire
unit to check for air leakage. Leakage from any part of
the valve or from the air line connections is not
permissible.
Start the engine and charge the system until “Cut out”.
Stop the engine and check for air leak through exhaust
passage of base cover to detect non return valve
leakage.
Removing
1. Block the wheels to prevent movement of the
vehicle during working.
2. Brush away dirt/dust from the air line connection
and the unit.
3. Relieve the air pressure from the system.
4. Loosen the pipe clamps and disconnect the pipe
lines from the unit.
5. Close open ends of the pipes to prevent dirt/dust
entering the air lines.
BRAKES 09.25
6. For the units mounted on reservoir, unscrew the
unit with adaptor and remove the unit. If lock
nuts are provided, loosen the lock nuts first and
then unscrew adaptor.
Replacing
1. For the valves mounted reservoir:
* Fit the unit with adaptor onto the reservoir port
and tighten. Use shims to secure the unit in
correct position.
* Connect the inlet pipeline.
NOTE: The unit must be mounted always vertical with
the adjusting screw at the top.
2. Carryout ‘Operating/Leakage tests’ as given under
‘Service check’
Dismantling
1. Clean the exterior of the unit.
2. Remove the strainer from inlet port and dust cap
from the tyre inflating adaptor.
3. Loosen the locknut and remove adjusting screw,
cup and exhaust flap.
4. Loosen and remove the top cover screws, spring
washers, top cover, spring guide, pressure setting
spring and diaphragm assembly.
5. Loosen and remove the nut, spring washer, top
follower, diaphragm, bottom follower, spring and
valve from the governor plunger.
6. Loosen and remove tyre inflator adaptor, washer,
plunger, valve and spring from the valve body.
7. Remove the circlip securing the bottom cover and
take out the bottom cover, shim, spring, sealing
ring, unloader plunger assembly, wiremesh filter and
filter retainer from the valve body.
8. Loosen and remove the nyloc nut, valve and valve
seat from the unloader plunger.
09.26 BRAKES
9. Unscrew and remove the valve stop & spring
retainer, conical spring and non return valve from
the valve body.
10. Scrap all the old parts which are replaced from in
the repair kit.
Cleaning and Inspection
Clean the metallic parts in cleaning solvent and blow
with dry compressed air, Ensure that no trace of solvent
is present during reassembly.
* Ensure that the passage in Valve Body, Governor
Plunger, Top Cover are free from blockage.
* Check the valve body for thread damage, nick
marks/damage on valve seat, excessive wear/score
marks in unloader plunger bore.
* Check the unloader plunger and governor plunger
for damage / score marks.
* Check the spring and circlip for corrosion, distortion
and permanent set.
* Scrap all the old parts which are found to be
unserviceable.
Reassembly
1. Use recommended Repair kit to replace the parts
scrapped during dismantling and also replace the
parts found to be unserviceable during inspection.
2. Lubricate all the sliding parts and its contact
surfaces with Bharat MP 2 grease. This grease is
supplied in the Repair kit.
3. Install the new ‘O’ rings on the tyre inflator plunger
and unloader plunger.
4. Assemble conical spring on Non Return valve and
position the valve on its seat on valve body.
5. Secure the valve in position by screwing the valve
stop & spring retainer in the delivery port.
6. Locate the spring, valve and tyre inflator plunger in
the valve body and secure in position by tightening
the adaptor with aluminium washer to a torque of
3 to 3.5 kgm. (22 to 25 lb.ft)
7. Place the valve, spring, bottom follower, diaphragm,
top follower in governor plunger and secure by
tightening the nut with spring washer to a torque
of 0.2 to 0.25 kgm (1.5 to 2 lb.ft). Ensure for
proper orientation of diaphragm during assembly.
8. Place the diaphragm on the top of valve body by
guiding the governor plunger in the bore.
9. Place the graduating spring guide and top cover on
the diaphragm assembly and secure the top cover
with valve body by tightening four screws with
spring washer to a torque of 0.6 to 0.7 kgm (4
to 5 lb.ft).
10. Locate the valve seat & valve on the unloader
plunger by tightening the nyloc nut to a torque of
0.4 to 0.5 kgm (3 to 3.6 lb.ft).
11. Place the strainer, wiremesh filter in the bottom of
the valve body and insert the unloader plunger in
its bore of valve body.
12. Place the base cover with spring in the bottom of
the valve body and secure the base cover in its
position by a circlip. Ensure that the circlip is
located in the groove of valve body properly and
the valve lip of unloader plunger is in contact with
valve seat.
13. Fix the dust cap on tyre inflator adaptor and
strainer in the inlet port.
14. Place the exhaust flap and cup on the top cover
and screw in the adjusting screw with lock nut.
15. The pressure can be set on a test bench if
available or the unit can be installed on the vehicle
and setting of pressure can be done as explained
under “Service Check”.
 BRAKES 09.27

09.3.8 Air Reservoir and Air Filter Dismantling

Unscrew the safety valve from the reservoir. Withdraw
the valve and spring. after removing the circlip and
retaining plate.

Inspection
1. Check for cracks visually at the welded portion.
2. Check the condition of the spring and ball of
safety valve, and the ball seat. If necessary replace
safety valve.

Assembly
Description
The function of a reservoir is to provide a place to 1. Assemble the safety valve by placing the ball,
store compressed air so that there will always be an spring retaining plate and lock it by circlip.
ample supply available for immediate use in brake 2. Screw the valve body to the reservoir.
operation. It also provides storages for sufficient 3. Check for leakage.
compressed air to permit several brake applications after
the engine has stopped. Another function of reservoir is Fitment
to provide a place where the air, heated during 1. Mount the reservoir over the bracket and tighten
compression may cool and oil and water vapours the bolts and nuts.
condense.
2. Connect all the airlines and check for leakage.
The reservoir is made of sheet steel with enhanced
corrosion resistance and has electrically welded 09.3.8.0 Air Filter
seams. The heads of ends are steel stamping and are
electrically welded to the body. Metric tapped bosses
are used at openings and welded in place.
The total reservoir volume used on the vehicle is 15
litres/10 liters approximately, depending on application.
A safety valve set to blow at 130 to 160 Ib/sq. In (9.2
1. Filter body
to 11.3 kg/sq cm) is fitted on the reservoir to
2. Filter
safeguard any overloading on the compressor In the
3. Compression spring
event of the unloader valve becoming defective. A
4. Sealing ring
drain plug is fitted at the bottom of the reservoir.
5. Spring retainer
6. Lock plate
Operation
7. Split pin
It has been pointed out that the reservoir provides a
place where the condensate may collect. All compressors
must pass a certain amount of oil in order to lubricate
the cylinder walls and piston rings.
Depending on the humidity, the atmospheric air entering
the compressor contains a certain amount of water. The
oil and water normally pass into the reservoir in the
form of vapour because of heat generated during
Function
compression. After reaching the reservoir the vapour
The air Filter prevents dirt from reaching the pipe lines
cools and condense in the form of oil and water
and valves in the braking system.
emulsion and are drained off before entering the brake
system.
Description
The Air filter is line mounting type and mainly comprises
Removal
of spring loaded Nylon filter held by a Spring guide and
Disconnect air lines, and plug the open ends to exclude
locked by a Lock plate with a split pin. An ‘O’ Ring is
dirt.
provided on to the spring guide for sealing purposes.
Unscrew mounting bracket nuts and bolts and remove
reservoir.
09.28 BRAKES

Service Check 09.3.9 Low Pressure Indicator Switch

(a) Leakage Test
With full air pressure in the system, Check for air leak
in the inlet and delivery joints and at the lock plate.
No leakage is permissible.
Removing
1. Block the wheels to prevent movement of the
vehicle during working
2. Brush away dirt/dust from the pipe line and the air
filter.
3. Deplete the air pressure from the system
thoroughly.
4. Disconnect the delivery pipe line and remove the
unit.
5. Close the open end of pipe and Reservoir to
prevent dirt/dust entry.
6. Remove the adaptors fitted to the inlet and
delivery port of the air filter.
Replacing
1. Fit the adaptor with washer on the inlet and
Function:
delivery port of Air Filter and secure tightly.
To switch on the Warning lamp or buzzer in the circuit
2. Connect the inlet and delivery pipe and secure
tightly. when system air pressure drops below the set safe level
(6.0 and 6.4 ksc)
Dismantling
1. Unfold the split pin and tap it out.
Operation:
2. Press the spring guide gently and pull out the lock
In the normal running condition air pressure acting under
plate.
the Diaphragm (1) moves the Contact plate (2)
3. Scrap all old parts for which the new parts are
upwards and the contact between the Contact plate (2)
serviced in Repair kit.
and terminal (4) is kept open against the force of the
Cleaning and Inspection
spring (3)
* Clean all the metallic parts using cleaning solvent
and blow with dry Compressed air.
When the air pressure falls below the set limit, the
* Check the inlet/delivery adaptor for thread damage/
spring (3) over comes the air head load under
Crack
Diaphragm (1) and pushes the contact plate (2) down
* Check the spring for corrosion, distortion or
permanent set. closing the contact between the Terminals (4) and signal
* Scrap all the old parts which were found the warning lamp or buzzer.
unserviceable.
The spring load can be adjusted by means of adjusting
Reassembly
Screw (5) to vary the set pressure.
1. Use recommended Repair Kit to replace the old
parts scrapped during dismantling and also replace
those that are found to be unserviceable during Maintenance:
inspection by new ones. No special care is necessary during normal service.
2. Locate the ‘O’ Ring in the spring guide applying However,, check the electrical connections periodically for
recommended grease tightness this unit is not repairable.
3. Locate the filter and spring in the filter body
pressing the spring guide gently and lock with the
lock plate.
4. Locate the split pin in the lock plate and fold the
ends.
 BRAKES 09.29

09.3.10 Stop Light Switch 09.3.11 Pressure Reducer Valve

Function: Introduction
To switch on the Warning lamp when the brakes are In complete air pressure braking systems certain
applied. equipment may need lower operating air pressure while
the system air pressure is maintained at the original
Operation : level. As the name implies this valve maintains a pre-
Air pressure acts under the diaphragm (1) and pushes it
determined reduced pressure at its delivery port. It is
up overcoming the load of the spring (3). The contact
mounted generally on a bracket on the chassis. It is
plate (2) carried along with the Diaphragm (1) makes
advisable to connect the pressure reducer valve delivery
contact with the contacts on Terminals (4). The circuit
to the actuating units through an auxiliary reservoir to
closes to signal the stop warning lamp.
provided a smooth unsurged supply.

When the air pressure reduces, the spring force

overcomes the air head load under the Diaphragm (1) Description
and the Control plate (2) moves downward breaking The pressure reducer valve consists of a piston
the contact and opening the circuit. graduating spring and spring seat which are housed in a
cast aluminium body the piston is provided with two ‘O’
Maintenance : Rings. The piston is spring loaded and is held in
No special care is necessary during normal service. position by a mounting bracket which is secured to the
However, Check the electrical connections periodically for body by (3) three bolts and spring washers. The
tightness. This unit is not repairable. mounting bracket also houses an adjusting screw and a
locknut and the adjusting screw acts on a spring guide
09.30 BRAKES

located. on the spring seat. The exhaust valve is Service Check

assembled to a valve stem and this along with spring
and spring guide and the inlet valve. Seat is Operating Test
subassembled with inlet valve. The subassembly located Connect an air pressure gauge to the delivery line and
in the bottom portion of the body is provided with the admit the air pressure to the inlet of the valve. Check

rubber exhaust check diaphragm which is secured by the pressure recorded by the gauge and the valve

means of a screw and a plate. In some cases an should not vary more than ± 0.5 ksc (2.5 PSI) than

extension exhaust tube is assembled to the body and that of the indicated pressure in the identification tag if
it is not so the required pressure is to be obtained by
the exhaust air is diverted to the ground through a
the adjustment screw. Turning the screw clockwise
hose connected to the exhaust tube. An identification
increases the pressure and anti-clockwise decreases the
tag indicating the part number and pressure setting is
pressure.
provided below one of the screws securing the mounting
plate to the body.
Leakage Test
Supply air pressure to the inlet and when the set
Operation
pressure is reached on the delivery check for leaks at
the exhaust port. A 25 mm bubble in 5 seconds is
Initially the exhaust valve is kept closed and the inlet is permissible.
kept open. When air pressure enters the inlet port it
passes through the delivery port. Simultaneously, the Removing and Replacing
same air pressure is communicated underneath the
piston through a metering hole provided in the body. Removing
When pressure increases the graduating spring load is Prevent the vehicle from moving by means of blocks
overcome and once the set pressure is reached the placed behind the wheels. Brush away and clean dirt
valve attains the balancing position. During balancing from the airline connection. Drain the air system

both the inlet and exhaust valves will be in the closed completely. Disconnect airline connections from the unit

position. When the pressure in the delivery line reduces loosen the pipe clamps if provided to facilitate easy

the spring force overcomes the air pressure and open removal of the units keep the open ends of the pipes
plugged with adhesive tape to prevent external dirt
inlet valve thus admitting further air pressure into the
entering into them. Remove the driver hose unscrew
delivery until the spring load is overcome and balancing
the mounting bolts and remove the reducer valve.
is achieved again. If by any chance the air pressure at
the delivery increases above the set pressure the
Replacing
increased pressure lifts the piston up opening the
Mount the Reducer valve in position and secure tightly.
exhaust valve. Air pressure is exhausted to atmosphere
Remove the end plugs from the air lines and reconnect
until the pressure in the delivery line drops to the set
them to the unit tighten pipe clamps reconnect exhaust
pressure when the balancing position is achieved again.
diversion hose.
Thus the set pressure is maintained in the delivery line.

Dismantling
Loosen the lock nuts for the adjusting screw and
remove the adjusting screw. Loosen and remove the
 BRAKES 09.31

three screws securing the mounting plate to the body 09.3.12 Foot Control Valve
and remove the mounting plate. Remove the spring
guide spring seat graduating spring piston and the piston
return spring remove the ‘O’ ring from the piston.
Gently tap the inlet nut with a wooden mallet and
loosen the inlet nut and remove it form the body,
remove the inlet exhaust valve assembly along with the
‘O’ Ring.

Cleaning and Inspection

Clean all the metallic parts in a good cleaning solvent
and blow with dry air. Wipe clean rubber parts with
dry cloth. NEVER USE KEROSENE OR PETROL FOR
CLEANING RUBBER COMPONENTS. Check the body
for any damage or crack externally or internally. Check
the main piston bore for scratches or score marks.
Check the threads on the body for any damage check
the springs for corrosion and distortion. Check the
valves for damage or deterioration. Check the inlet
seat for score marks or damage. Check the ‘O’ Rings
for wear damage or deterioration. Rectify defective
parts if possible replace all unserviceable parts.

Reassembly
Assemble the exhaust valve to the valve stem with
a new sealing fabric washer and tighten securely
Introduction
with Nyloc Nuts. Locate the spring guide, spring
and inlet valve seat on the valve with a new
The foot-operated control valve is designed for use in
sealing fabric washer and secure tightly assemble a
air pressure exhausted brake system in this system the
new ‘O’ ring in the body and locate the inlet
exhaust valve assembly at the inlet side assemble valve controls the exhaust brake operating cylinder. The
the inlet nut and tighten to a torque of 11 kgm control valve is used solely to operate the exhaust
(79 Ib ft.) brake unit.

NOTE: Since the inlet nut seats on the inlet seat there
will be a gap between the body and the inlet
nut this should not be mistaken for a loose
inlet nut and the inlet nut should never be
overtightened to close this gap.
Description
The control valve consists mainly of a body a spring
loaded plunger and cap assembly and a rubber forced
disc type valve.

Locate the piston return spring on the body smear the

Air passages in the plunger communicate with breather
‘O’ ring grooves on the piston with grease and
port in body which is fitted with a rubber band to
assemble new ‘O’ rings in their respective grooves locate
exclude dirt.
the piston over the return spring position the gradation
spring the spring seat and spring guide over the piston
The disc valve and a return spring are retained in the
and assemble the mounting bracket and secure tightly to
the body assemble the adjusting screw and lock nut. body by a cap nut which also forms an air pressure
pipe connection.
Carryout operating and leakage test as given under
service check.
09.32 BRAKES

Operation Dismantling

When the valve cap is depressed, the plunger contacts
the disc valve which closes the air passage through the
plunger. The plunger then unseals the disc valve and
compressed air from the supply connection passes
around the valve and through the delivery port (s) to
the operating cylinder (s)
Remove grease and dirt from the exterior of the unit
depress the valve cap slightly and remove the plunger
locating screw and washer withdraw the plunger from
the body and remove the plunger spring and sealing
ring.

Unscrew the cap nut from the valve body and with
When the valve cap is released the plunger and disc
draw the spring and disc valve Remove the sealing ring
valve are raised by their respective springs when this
from the cap nut.
occurs, the disc valve re-seats in the body closing the
air inlet passage and then the plunger moves always
from the disc valve compressed air from the operating Cleaning and Inspection

cylinder (s) then exhausts through the plunger and vent

hole to atmosphere. Finish oil, metal parts in cleaning solvent and blow dry
with compressed air clean all rubber parts with a clean
Removing and Replacing cloth.

Removing Examine the valve body for cracks and other damages
check the threads in the body for damage and the
Prevent the vehicle from moving by means other than plunger bore in the body for excessive wear and scoring
the air brakes. examine the valve seat for damage.

Release all air pressure from the system.

Examine the plunger for wear and scoring and the hollow
Brush away dirt from the pipe connections disconnect
end face for damage check that the plunger moves freely
the pipes from the valve and take precautions to
in the body check that the plunger cap is secure on the
prevent dirt from entering the pipes and valves.
plunger.

Mark the valve and its mounting to ensure correct

Examine the disc valve for deterioration of the rubber
replacement and then remove the valve from the
vehicle. faces wear damage and distortion.

Replacing Check the spring for corrosion and distortion.

Aligning the marks made before removing remount the Examine the sealing rings for wear and deterioration.
valve on the vehicle.
Check the threads in the cap nut for damage.
Reconnect the air pipes to the valve as originally fitted.

Run the engine to create air pressure in the system and

check that the valve operates satisfactorily.
 BRAKES 09.33

Reassembly CAUTION

Renew all parts found to be defective during inspection
Lubricate the valve parts where necessary with Bharat
MP2 grease or equivalent grease.
Place the disc valve on the seat in the valve body and
position the spring on the valve. Lightly smear the cap
nut sealing ring with grease and fit the ring on to the
nut screw the nut into the body and tighten securely.
When working on or around brake system and
components. The following precautions should be
observed.
1. Always block vehicle wheels stop engine when
working under a vehicle.
2. Keep hands away from chamber push rods they
may apply as the system pressure drops.

Lightly smear the plunger sealing ring with grease and fit
the ring on to the plunger in the position. Lightly smear
the sliding surfaces of the plunger and plunger bores in
the body with grease place the plunger return spring on
the body and insert the plunger into the body taking
care not to damage the sealing ring. Depress the valve
cap and screw the plunger locating screw, complete with
new washer into the body and tighten securely.
3. Never connect or disconnect a hose or line
containing pressure; it may whip.
4. Never remove a component or pipe plug unless
you are certain all system pressure has been
depleted.
5. Never exceed recommended pressure and always
wear safety glasses when working.

Testing Rebuilt Air Pressure Control Valve 6.
Operate the valve several times to check that the valve
parts move freely.
Plug the side connections in the valve body and then
connect an air pressure supply of 60 Ib/sq.in. into the
connection in the cap nut. 7.
Coat the valve body and cap nut with soap solution.
The appearance of soap bubbles at the exhaust hole 8.
when the valve cap is in the released position indicates
leakage which is not permissible. Leakage indicates that
the disc valve or its seat in the body is defective.
Never attempt to disassemble a component until
you have read and understood recommended
procedures. Some components contain powerful
springs and injury can result if not properly
disassembled use only proper tools and observe all
precautions pertaining to the use of those tools.
Use only genuine replacement parts and
components.
Devices with stripped threads or damaged parts
should be replaced. Repairs requiring machining
should not be attempted.

Depress the valve cap and again check for air leakage
at the air filter gauze leakage is not permissible leakage
when the cap is depressed indicates that the disc valve
or its seat on the end of the plunger or the plunger
sealing ring is defective.

With the valve cap depressed check the body and cap
nut for leakage which is not permissible.

If the tests indicate defective parts they must be

rectified.
09.34 BRAKES
09.4 FOUNDATION BRAKE (SIMPLEX AIR WEDGE) SYSTEM
Description
The SAW brake is a leading/trailing shoe (simplex)
brake utilising a single wedge expander unit incorporating
automatic adjustment to compensate for lining wear in
service. The sealing of the unit against dirt and water
ingress is also a prominent feature. Well established
and proven design principles are used to ensure
satisfactory operation and least possible need for
maintenance.
The brake (see figure) is fitted to the front and rear
axles and the expander wedge is operated by air
actuators. The substantial torque plate incorporates cast
abutment slots in which tips of the shoes sit.
Diametrically opposite is the expander against which the
other end of the shoes rest. Shoe return springs ensure
effective retraction of the shoes after a brake application
and also provide the return load to operate the auto
adjuster. Both shoes are held against the steady rest
lugs with shoe hold down clips bolted to the torque
plate.
(ii) Operation
When brakes are applied the brake actuator push rod
pushes the wedge into the expander. This forces the
rollers apart moving the tappets outwards and thus
pressing the shoes against the drum. Upon release the
wedge will be returned by the action of the wedge
return spring and the shoes will be pulled away from
the drum by the shoe return springs.
Auto Adjustment
The adjuster maintains shoe clearance to a value
determined by the specific backlash between the gear
teeth and the adjuster sleeve and the drive ring for any
one brake application, only a specific proportion of any
tappet travel, in excess of the backlash is taken up by
the adjuster and this controls the shoe clearance in the
brakes off position the drive ring is retained in light
contact with its conical seat by the back up spring. The
shoe tip engages in the tappet clip and the shoe return
springs ensure that the tappet is fully returned against
its housing abutment.

Adjuster Function When Clearance Exceeds Backlash
BRAKES IN OFF
CONDITION
BRAKES `ON'
OPERATION
Brakes Applied (Normal Condition)
When the brake is applied the sleeve (tappet) is moved
upwards and begins to pass through the drive ring. If
the movement required to apply the shoes to the drum
is less than the axial clearance (backlash) between the
flanks of the helix on the tappet and the drive ring
teeth no adjustment will take place.
Brakes Applied (Adjustment Required)
If adjustment is required, the movement will exceed the
axial clearance (backlash), the adjuster sleeve will lift the
drive ring from its seat simultaneously the back up
spring will be pushing the drive ring back down the helix
teeth of the adjuster sleeve causing the ring to rotate
and adopt a new position on its seat.
When the brake pedal is released, the shoe return
spring causes the shoes to push back the adjuster
sleeve and adjuster screw assembly, The adjuster sleeve
helix moves through the axial clearance (backlash) In the
drive ring teeth and when the flanks of the threads
BRAKES 09.35
BRAKES `OFF'
OPERATION
meet the drive ring it is loaded into its seat in the
housing thus preventing rotation of the drive ring.
Further return movement pushes the adjuster spring
through the drive ring and the adjuster sleeve is forced
to rotate as its helix slided up the helix of the locked
drive ring. Consequently, as the adjusting screw
(threaded into the sleeve) is prevented from rotating by
the clip located against the shoe web. The effect of the
action is to increase the overall length of the adjuster
assembly similar to simple screw jack. The end result is
to take up the excess shoe to drum clearance created
by lining wear.
It is likely that different shoe to drum clearance readings
will be obtained for each shoe on each brake.
Providing that the readings taken at the abutment end
are within 0.35 mm (0.015'’) to 1.6mm (0.065'’) band,
the adjuster is functioning satisfactorily. Do not use the
manual override mechanism to equalise these clearances.
09.36 BRAKES

(iii) Do’s and Don'ts Replacement of Linings

a) Brake Assembly Standard lining thickness - At centre 16.00 mm

- At ends 12.5 mm
Do
When linings are worn upto the indicator slot or if the
1. Replace hub oil seal whenever the hub is removed linings available over the rivet is 1 mm, linings must be
or Installed. replaced.

2. Reset the shoe to drum clearances after fitting new Expander Assembly
shoes as given In Manual Override’

Whenever drums are removed check for the

Don't
deformation of anti rotation clips and for any damage
to dirt excluder.
1. Use an airline to remove dust. Use a damp rag.

(v) Recommended Lubricant

Expander/Torque Plate Assembly

At the abutment end slot resting lugs and the shoe

Do
hold down clip, graphite grease is to be applied.
1. Inspect bores and seatings for damage when
servicing. 09.4.0 Brake Shoe Removal / Assembly

2. Examine shoe steady lugs and shoe abutment slots

for wear.

3. Unwind the spring brake chamber screw fully, After

assembling the shoes wind the screw.

Don't

1. Dismantle the expander assembly.

2. Actuate the brake at the time of lining

replacement.
Removal
1. Park the vehicle on hard, level ground.
3. Skim the brake drum more than 1 mm on dia.
2. Chock road wheels.
(iv) Maintenance Procedure 3. Jack up axle and securely fit axle stands.
4. ‘Wind off’ parking brake
Brake Adjustment
5. Remove wheels and drums.

Being auto adjusted brakes practically no maintenance is

CAUTION: Do not apply brakes after brake drums
required.
have been removed.
Brake Lining Inspection
NOTE: If difficulty is experienced in removing drums,
Every 7,500 Kms, Inspection of lining thickness or once probably due to a lipped drum condition, it will
in a month/through the Inspection window is be necessary to wind off the brake adjustment
recommended. sufficiently to allow ‘the lip to clear the shoe.

Manual Override of Auto Adjuster
A manual override facility is provided to
1. Enable Initial shoe/ drum clearance to be set after
new shoes are fitted.
2. Adjust the brakes if necessary to enable the drum
to be removed.
3. Fully Adjust the brakes.
NOTE: This facility should not be used for any other
purpose.
To operate the manual override and to adjust the
mechanism, remove the dust cover quadrant at the
expander end.
Insert a screw driver through the slot of the plate
welded on to the shoe and rotate the adjuster wheel in
the direction to screw the tappet in to the housing.
Repeat on the other adjuster wheel until the shoes are
retracted sufficiently for the drum to be removed. The
use of excessive force should be avoided.
BRAKES 09.37
With the drum removed and prior to removing the
brake shoes, continue to fully wind back the adjusters.
Then rotate the adjusters one turn forward from this
position, to ensure that tappet head assemblies are not
locked back to the shoulder of the tappet screw.
NOTE: Do not attempt to remove shoe return springs
until adjuster is fully wound back - otherwise
over stretched springs will result.
Fit an elastic band or a wire around the adjuster screws
to retain them in position.
Using the special spring removal tool, remove the shoe
return springs at the expander end and abutment end.
Ease each shoe in turn from under its hold down clip
and remove. The tension exerted by the clip is fairly
high, if it does not exert adequate strength replace it
with a new clip.
Examine the dust excluders. If damaged, and any
malfunction of auto adjuster noticed, expander assembly
should be replaced.
NOTE: Do not tamper the expander assembly as it is
not meant for overhauling.
Clean the torque plate and dust cover with clear
methylated spirit or Isopropyl alcohol and allow to dry.
Use a wire brush to remove any corrosion, but take
care not to damage the rubber dirt excluder on the
expander unit.
NOTE: Do not use an airline to blow dust from brake.
Whenever possible remove dry dust with a
vacuum brush or damp rag.
Examine the tappet heads, shoe steady lugs and shoe
abutment slots in the torque plate for possible wear, If
in doubt, replace.
09.38 BRAKES
Inspection
CHECKING RUNNING CLEARANCES
Linings should not be allowed to wear down to the
rivet heads, If the linings are worn out upto the wear
indicator and the lining thickness is 1 mm above the
rivet head. The linings must be replaced.
De-rivet them carefully. Ensure that the rivet holes in
the shoe rim are not enlarged during de-riveting. Clean
the shoe rim to ensure a smooth / even surface for re-
lining. Always use genuine / approved service
replacement linings along with the rivets supplied during
relining.
Since the linings are tapered make sure that the thinner
end of the lining blocks are towards expander and
abutment ends of shoes before riveting.
Clamp the linings evenly to the shoe rim and start
riveting at the lining centre progressing outwards to the
ends of the lining segment. A flat against rivet head
and the tubular shank of the rivet should be properly
clinched.
Care should be taken, since over riveting may crack the
linings. Also ensure that no gap exists between the
lining and shoe rim.
Do not contaminate the lining surface with oil
or grease.
The shoe tips should be smooth and if in doubt the
shoe to be replaced.
Fitment of Shoes
1. Apply a thin film of grease on the shoe tips and
shoe steady lugs with graphite grease.
2. Fit the swan neck of the new abutment end of the
shoe return spring into the hole in the leading
shoe. (the swan neck may be fitted into the
trailing shoe with no detrimental effect)
3. Slide both shoes into position under the hold
down clips and centralise the shoes to the brake
manually.
Ensure that the shoe tip is seating in the slot of
the anti rotation clip.
4. Using the special spring assembly tool, lever the
hook end of the abutment end spring into the hole
in the trailing shoe.
5. Position the new expander end spring in one of
the holes in the shoe web and using the special
spring assembly tool, fit the other end of the
spring into the other shoe. Remove the elastic
band or wire fitted on to the expander assembly.
6. Manually wind out each of the adjuster bolt until
the drum can just be fitted.
After ensuring the drum size and braking surface
are free from oil or grease, fit the drums.
Important
Initial setting of the shoe to drum clearance is essential
to ensure the correct operation of the automatic
adjuster mechanism.
Check the shoe to drum clearances, if they are not
within 0.35 mm to 1.60 mm band, re-adjust to these
figures using the manual override.
Screw in the spring brake actuator wind off screw fully.
Fit the wheels.
Brake Lining Rivet
Size Dia 6 mm
Material Steel
 BRAKES 09.39

09.4.1 Expander Assembly Replacement

1. Remove the brake shoes as explained in shoe 2. Remove the protective cap fitted on to the wedge
removal. of the expander assy.

2. Remove brake actuator if it is front brakes and 3. Fit new ‘O’ ring on to expander seating dia of the
spring brake actuator if it is rear brakes. Make torque plate.
sure that the wind off screw is unscrewed fully so
that spring brake actuator is not operating. 4. Offer the expander assembly to the torque plate
ensuring it is well seated.
3. Unscrew the two elan headed bolts and remove
the expander from the torque plate. 5. Fit the two elan headed bolts and tighten them to
a torque of 18/22 Nm. (13 /16 lb.ft)
NOTE: Due to corrosion it may be necessary to
tap the expander for taking out of the 6. Refit the lined shoes as detailed in shoe removal
torque plate. Do not tap on the wedge and fitment.
for expander removal. Avoid undue
force on the expander as it will damage 7. Refit the brake actuator / spring brake actuator in
the body. the reverse order of removal. Screw in fully the
wind off screw.
4. Take out the ‘O’ ring.
8. Fit the drum and reset the shoe to drum clearance
Fitment as detailed in fitment of new shoes.
1. Clean the expander seating dia and the surface of
the torque plate, if it is rusted or any imperfections
noticed.
09.40 BRAKES

Tightening Torque Grease

Graphite grease should be used for the shoe seatings.
a) Brake mounting bolts/ nuts- Refer to
recommendations under Maintenance Chapter. Maintenance

b) Expander assembly mounting bolt - 18 /22 Nm
(13 / 16 lb.ft)
c) Hold down clip bolt - 22/28 Nm (16/20 lb.ft)
d) Dust cover (Shield) set screw - 6/10 Nm (4/7
lb.ft)
Maintenance Schedule
Observance of suitable servicing and inspection schedules
will help to ensure that the vehicle’s braking system has
optimum safety and efficiency throughout its life.
The complete replacement of the expander by a skilled
fitter should be carried out after 3 years or 3,00,000
kms, whichever occurs first or when the expander
assembly is malfunctioning.
Regular lining inspection should take place every 10,000
kms or once in a month .
NOTE: Automatic adjustment is carried out by
expander tappet adjuster assemblies only.
Each unit individually adjusts the appropriate
shoe. Although constantly pressing and
releasing the brake treadle with the vehicle
stationary may eventually achieve some
adjustment, initial setting is important. Refer
to manual over-ride of auto adjuster.
Do not apply brakes after drums have been
removed.
a) Checking of expander assembly malfunctioning;
It is likely that different shoe to drum clearance readings
will be obtained for each shoe on each brake. If the
readings taken at the abutment end are within 0.35 mm
(0.015") to 1.6 mm (0.065") band the adjuster is
functioning satisfactorily. If the clearance is more
expander assembly should be replaced.

IMPORTANT IMPORTANT
Any inspection or work carried out in line with schedules
must be done by an experienced fitter / mechanic Do not use the manual override mechanism to equalise
suitably trained to a high degree of competence relating these clearances.
to the vehicles in question.

General Maintenance Hints:

To ensure that the efficiency and performance of these B) Lining Inspection
brakes is maintained, It is essential that the following
procedures and recommendations are carried out.

IMPORTANT
Initial correct setting up of the brake after work has
been carried out will dictate service reliability and driver
satisfaction.

Failure to observe procedures may result in further work

being necessary which otherwise would not have been
required. The skilled mechanic will undoubtedly
Access to view the linings is through the inspection
recognise the need for change and amend working
holes which are protected by rubber grommets. After
practices in line with these recommendations.
checking running clearances and lining thickness, always
replace the grommets to avoid dirt and water ingress.
 BRAKES 09.41

Lining Wear

Brake linings/shoes be replaced when the lining material

is worn to a thickness of 1 mm above rivet head. A
lining thickness check should be carried out at every
7,500 kms. Failure to replace the shoes/ linings at the
correct time may result in damage to the shoes and
drums and in impaired brake efficiency.

Always fit new linings/shoes in pairs to both sides of

the vehicle. When fitting new shoes fit new shoe return
springs at the same time. The efficiency of the
automatic adjuster may be impaired by weak springs.
Also the possibility of shoes ‘hanging on’ after brake
release may be increased. A visual lining wear indicator
is provided on the edge of the lining to allow a visual
indication of minimum lining thickness when viewed
through the lining inspection holes.

Brake Carrier Assembly

Dismounting

1. Remove the brake shoe assembly as per the

procedure given in this chapter.

2. Remove the brake carrier plate (torque plate) by

removing the mounting bolts.

Mounting

Refit the brake carrier plate (Torque plate) and secure

with the mounting bolts.
09.42 BRAKES

EXHAUST BRAKE

09.5 EXHAUST BRAKE BUTTERFLY VALVE Remove the remaining butterfly valve mounting (4) and
- OVERHAUL remove the assembly from the exhaust pipe. Support
the pipe as necessary to prevent damage.
Removal
Care to be taken to prevent gasket from getting (2)
Apply the parking brake and chock the wheels damaged if possible

(Disconnect Ball joint arrangement (similar to accelerator Cleaning and Inspection

linkage joints)
Disconnect air line to actuating cylinder
Remove the bolts securing the actuating cylinder bracket
to the exhaust pipe flange and secure the assembly to
one side.
Thoroughly clean all the components, ensuring that all
traces of the old gaskets are removed from all the
flange faces.
Examine all the components for wear, damage or
excessive corrosion. Renew any faulty parts.

Reassembly
NOTE: Should it be necessary to fit a new butterfly
disc, Care should be taken to ensure that the
correct type of disc is fitted. The disc fitted to
some engines has a pressure relieving hole, the
diameter of which can vary between engine
type, and some discs have no pressure relieving
hole.
Fit new spindle sealing rings, and push the
spindle into the housing.
Check the butterfly for free and correct
movement.
Butterfly valves:
Adjust the valve prior to installing it on the vehicle.
Installation
Install the valve assembly to the exhaust pipe flanges
with new gaskets, ensuring correct alignment with the
position of the slave cylinder.
Install the actuating cylinder and bracket into position
and tighten all the flange bolts.
Hold the butterfly valve in fully open position (i.e. the
groove in the end of the spindle in line with the centre
line of the exhaust pipe)
Slacken the actuating cylinder ball lock nut and adjust
ball joint position with respect to push rod so that the
ball pin can be inserted on to the spindle lever in
above position.
BRAKES 09.43
Exhaust Brake Actuating Cylinder Overhaul
Removal
Disconnect the batteries and remove the air pipe(s)
from the actuating cylinder.
Remove one bolt retaining the cylinder to its mounting
bracket and remove the cylinder.
Dismantling
Slacken the locknut and remove the ball joint.
Remove the gaiter and retaining clip.
Remove the circlip retaining the position and rod
assembly in the cylinder body.
Remove the washer, piston stop and spring.
Remove the piston rod. Remove the piston by applying
very low air pressure to the air pipe connection on the
end of the cylinder body.
Cleaning & Inspection
Thoroughly clean the remaining components.
Examine the piston and the piston bore. Renew if
damaged or deeply grooved.
Reassembly
Fit a new seal to the piston and apply grease from the
repair kit to the seal piston, rod mushroom and the
cylinder bore. Apply the remaining grease inside the
new gaiter.
Carefully insert the piston in the cylinder bore taking
care not to damage the seal. Push the piston, to the
bottom of the bore using the piston rod.
Adjust the cylinder ball joint as detailed in ‘Exhaust
Brake Butterfly Valve Overhaul’
Installation
Fit the cylinder to its mounting bracket and securely
tighten the retaining bolts.
Fit the air pipe (s) and securely tighten.
09.44 BRAKES
09.6 AIR DRYER
Introduction
Compressed air brake systems, used widely in
commercial vehicles, experience several
operating problems due to the condensation of
water vapour present in the atmospheric air.
Though there are several methods for
Condensate removal from compressed air in
the air brake system, Air dryer has been found
to be the roost effective one. Air dryer has a
pre-filter, which cleans the compressed air and
a desiccant bed, which dries it.
Water condensation in compressed air:
Atmospheric air is a mixture of gases with the
presence of condensable water vapour. The
amount of water present in the air determines
the relative humidity of the air at a particular
temperature. When the atmospheric air is
cooled, the relative humidity of the air increases
and attains saturation. Any further cooling
causes condensation of a portion of water
vapour. However when the air is compressed
to a higher pressure, its capacity to hold water
vapour comes down.. Because of this low
water holding capacity , the compressed air in
the air brake system is always saturated and
results in accumulation of condensed water in
the air reservoir.
Problems associated with water
condensation
In air brake system, water condenses in the air
reservoirs and in metallic pipelines. There are
several problems associated with condensation
of water vapour in air brake system.
Pipeline and reservoir corrosion - leads to scale
formation and malfunctioning of valves by the
rust particles carried by compressed air.
Washing away of lubricant in valves and
actuators - increases wear and lowers life
causing frequent replacement of brake system
parts.
Deterioration of rubber products such as
diaphragms and sealing rings - results in
leakage of compressed air available for brake
applications.
Ice formation in subzero atmospheric
temperatures - leads to valve stuck up and
blockage of flow path.
These problems cause frequent need for
servicing air brake components and consequent
vehicle downtime.
Methods of moisture removal
There are several methods existing for
Condensate removal such as inclusion of an
automatic drain valve or condenser auto drain
valve apart from the manual draining of the
reservoirs daily. However all the above
methods leave the air saturated at the
compressed conditions. Over night parking
and appreciable difference between day 1 night
temperatures may lead to further condensation.
Hence the only reliable option is to reduce, the
water vapour content and prevent the
compressed air from condensing even at very
low ambient temperatures.
The air can be dried by passing the
compressed air over a bed of suitable
desiccant. The absorbed water in the desiccant
is removed by passing a portion of the dried
air in the reverse direction through the
desiccant bed at a certain interval, This is
called purging or regeneration of the desiccant.
This process will bring down the dew point of
the compressed air in the air brake system.
This principle is used in air dryers.
Air dryer for commercial vehicle brake
system:
Air dryer has become a standard fitment In air
brake systems in USA and Europe with
significant Improvements in life and reliability.
Manufacturers of air brake system components
in these countries have reportedly doubled the
warranty periods for their products where Air
dryers of their make are used. Air dryer
removes the moisture in the compressed air
before it enters the system reservoirs and
lowers the dew point of the compressed air.
It also removes a significant portion of the oil
carried over from the compressor. The
function of the Unloader valve is integrated in
the air dryer.
 BRAKES 09.45

Fig. 31

Fig. 32
09.46 BRAKES

AIR DRYER
Sl. No. Description Qty
1 Body 1
2 * Sealing Ring 1
3 Filter Retainer 1
4 * Filter 1
5 * Sealing Ring 1
6 * Desiccant Cartridge 1
7 Spring 1
8 Housing 1
9 Stiffener Plate 1
10 Steel Washer 6
11 Hexagon Screw 6
12 * Sealing Ring 1
Plunger Assembly Comprising:
13 Unloader Plunger 1
14 Compression Spring 1
15 Valve Seat 1
16 * Valve 1
17 * Hexagon Nyloc Nut 1
18 * Sealing Ring 1
19 * Silencer 1
20 Pan Head Screw 4
21 Steel Washer 4
22 * Dust Cap 1
23 Adaptor 1
24 * Sealing Ring 1
25 Tyre Inflator Plunger 1
26 * Valve 1
27 * Sealing Washer 1
28 * Spring Retainer 1
29 Tyre Inflator Spring 1
Diaphragm Assembly Comprising:
30 Governor Plunger 1
31 * Valve 1
32 Spring 1
33 Follower 2
34 * Diaphragm 1
35 Spring Washer 1
36 Hexagon Nut 1
37 Spring Guide 1
38 Top Cover 1
39 Hexagon Head Screw 4
40 * Exhaust Flap 1
41 Cup 1
42 Hexagon Nut 1
43 Adjustment Screw 1
44 Compression Spring 1
45 * Conical Spring 1
46 * Non Return Valve 1
47 * Valve Stop and Spring Retainer 1
Repair Kit consists of items marked ( *) and Grease Sachet 2 off.

Working of the Air Dryer
The compressor delivery air enters the air dryer
and passes through the filter, where most of
the oil carried over by the compressed air,
other contaminants and condensed water are
filtered from the compressed air. The
condensed water and excess oil get collected
at the bottom of the body cavity. The clean
but moist air then goes through the desiccant
bed where the water vapour gets absorbed on
the numerous molecular cavities of the
desiccant. The dry air then charges the service
reservoir and a small reservoir known as the
purge reservoir.
The Unloader valve attached to the air dryer
regulates the pressure of the system and once
the system pressure attains the preset value,
the compressor is cut out, depressurising the
air dryer and forcing the Condensate out of
the air dryer through the exhaust. The
depressurisation inside the Air dryer causes the
air from the purge reservoir to expand and go
through the desiccant bed in the reverse
direction, thereby taking away the Water
absorbed by the desiccant bed while drying.
Since the air dryer also filters the oil carried
over by the compressed air, the deterioration
of rubber products such as diaphragms and
sealing rings is avoided. This prevents the
leakage of the compressed air available for the
brake service applications.
Air dryer prevents ice formation in sub-zero
atmospheric temperatures, thus eliminating the
blockage of compressed air flow path and
valve stuck up.
Air dryer offers considerable improvement in
life and reliability of brake system and ensures
vehicle safety as whole. Air dryer reduces the
down time of the vehicles and cost of frequent
replacement of brake system parts. Though
not mandated by any regulation, air dryer has
been a standard fitment abroad due to the
tangible benefits obtained by the end user.
BRAKES 09.47
09.7 AUTOMATIC LOAD SENSING VALVE
Introduction:
The Automatic Load Sensing Valve (ALSV) has been
designed to regulate the braking force on a particular
axle in proportion to the load on that axle, and is
controlled by the variations in the spring deflection of
mechanical suspension systems. In ALSV, the regulation
of delivery pressure takes place automatically in response
to the change in the load on the axles of the vehicle
Function
The unit consists of upper and lower body, which are
bolted together encasing a control piston, an inlet /
exhaust valve arrangement and a flexible diaphragm. The
piston is integral with an arrangement called moving fin
which is free to move vertically. The inner edge of the
diaphragm is attached to the lower end of the moving
fin. The moving fin, when moving in the vertical direction,
meshes with an arrangement called stationary fin.
Depending on the extent of meshing between stationary
and moving fin, the contact area of diaphragm with the
moving fin varies .Thus, the delivered pressure, which
depends on the effective area of the diaphragm, is
determined by the vertical position of the moving fin.
The position of the piston is controlled by the inlet /
exhaust valve arrangement. The position of the inlet /
exhaust valve arrangement in turn is determined by a
tappet. The cam- follower and tappet arrangement is
controlled by a lever, which is connected to the axle
through a linkage arrangement. The relative motion
between the axle and the chassis is determined by the
vehicle suspension and the axle load.
Operation:
The ALSV is mounted on the vehicle chassis and the
operating lever is connected to the axle through a
simple linkage. When the vehicle is empty, the distance
between the axle and the ALSV is greatest and the
lever end is in its lower most position. As the vehicle is
loaded, the distance between axle and chassis decreases,
and the lever end moves upwards causing the cam to
rotate which in turn moves the tappet to a position
corresponding to the vehicle load.
When a brake application is made, air at brake line
pressure is fed through inlet port into the upper
chamber forcing the moving fin with piston downwards,
which closes delivery from exhaust and connects inlet to
delivery. The air now flows into the chamber below
diaphragm and flows out through delivery ports to
brake actuators. At the same time, air flows into
chamber above diaphragm through the opened in-shot
09.48 BRAKES

LSV Installation Details ASSY PROCEDURE FOR CONTROL ROD

WITH ARM ASSEMBLY IN LSV LINKAGE

LSV Setting Angle Details

LSV DIAL ANGLE IN DEGREE

SL. WITH BODY
MODEL CAB
NO. (FOR REFERENCE ONLY)
CAHSSIS
FSD/DSD HSD
1 Ecomet 910 - 3075 wb 7.5 10
2 Ecomet 1109 - 3600 wb (With 8.25 X 20 Tyre) 7.5 15
3 Ecomet 1109 - 3970 wb (With 8.25 x 20 Tyre) 10 17.5 20
4 Ecomet 912 - 3600 wb 7.5 12.5
5 Ecomet 912 - 4200 wb 7.5 12.5
6 Ecomet 1112 - 3600 wb (With ZF S6-36 ODGB) 10 15
7 Ecomet 1112 - 4200 wb (With ZF S6-36 ODGB) 10 15 17.5
8 Ecomet 1112 - 3600 wb (With ZF S6-36 GB) 10 15
9 Ecomet 1112 - 4200 wb (With ZF S5-36 GB) 10 15 17.5
10 Ecomet 1512 - 4250 wb 10 12.5 (Sub Frame)

valve and acts on the upper side of the diaphragm.
Thus pressures above and below the diaphragm are
equalised. This pressure control provides un-modulated
output at low inlet pressure. If the inlet pressure
increases further, the in-shot piston is pressed further
against the in-shot spring load and in-shot valve closes.
There will not be any further increase in pressure above
the diaphragm.
As the moving fin with piston moves down, the
diaphragm begins to move away from the stationary fin,
pushed away by the fanned out portion of the moving
fin. This alters the effective area of the diaphragm
supported by the moving fin with piston, until the force
under the diaphragm, which depends on the pressure
and the effective area, equals that acting on the top of
the moving fin piston and the inlet valve closes. Balance
is therefore achieved with a lower delivery pressure than
that applied at the inlet port, keeping the valve
assembly in the “lapped” condition with the inlet and
exhaust closed. The applied pressure is thus regulated in
proportion to vehicle spring deflection.
As the effective area of the diaphragm depends on the
position of the moving fin attached to the piston, which
in turn depends on the position of cam attached to
lever, the output pressure to the brake actuators will be
increased or decreased according to the load on the
axle.
When the brake is released, the pressure in the ALSV
supply line (between the Dual Brake Valve and ALSV )
falls and will result in loss of balance of air forces on
the moving fin piston. This results in unseating of the
valve from the tappet, allowing air below the diaphragm
to exhaust to atmosphere through the hollow tappet
and out of the exhaust. A silencer is provided to reduce
the noise due to exhaust.