Deutsche GROVE

GMK 6250

Carrier Pneumatic System

General description:

The brake system is an air operated dual-line system to EC standards, incorporating a

split service brake system.

Service brakes:

A horizontal split, dual footbrake valve operates on all axle brake actuators. Axles 1
& 3 have standard diaphragm actuators. Axles 2, 4, 5 & 6 all have combined spring
brake actuators. A duplex (double actuator) system operates on axles 1 & 2 and
simplex (single actuator) system operates on axles 3, 4, 5, & 6. Air pressure from
reservoir V1 provides air via the upper section of the footbrake valve to axles 1 – 3,
axles 4 – 6 from air reservoir V2 via the lower section of the footbrake valve. Axles 1
– 3 are designated as circuit I and axles 4 – 6 are designated as circuit II. Two air
reservoirs are utilised for circuit I due to the duplex arrangement on axles 1 & 2
having a higher air consumption. Circuit protection, pressure reducing & relay valves
are incorporated in the circuit to comply with current regulations.

Parking brakes:

Hand operated and acting on axles 2, 4, 5 & 6. Powerful springs in the spring brake
actuators mechanically apply the foundation brakes when air is released from the
spring chambers. The air pressure for the parking circuit is from air reservoir V3.

Secondary braking:

Using the same hand control valve as for parking. The valve has three positions – a
locked park, unlocked “park-off” and unlocked “secondary-on” positions. When the
valve is moved gradually from the “park off” to secondary-on a progressive release
of air provides progressive braking. Air for this circuit is from reservoir V3.

Foundation brakes:

Perrot or Knott brake assemblies are used, both being of wedge design. The duplex
arrangement on axles 1 & 2 carries wider brake shoes at 180 mm, axles 4 – 6 being
160 mm wide. Inspection plugs on each backplate give access to lining wear
indicators (a ledge moulded into the edge of the lining).

GMK Training Information. May 98. Carrier Pneumatic System. Page 1

 Deutsche GROVE

Air supply & distribution:

A single cylinder compressor supplies air via two copper cooling coils to the air dryer,
which passes the air through a chemical agent to remove moisture. The dryer also
contains a heating element to prevent freezing. A governor (8.1 bar) & unloader
valve are also integrated into the air dryer. Once the system air pressure reaches 8.1
bar the governor valve gives a pilot signal to the unloader valve which then opens
allowing the compressor to cycle to atmosphere. A purge tank/conditioning tank,
which was charged on pressure build up will now discharge back through the
chemical agent and the debris filter to remove water and contamination through the
now open unloader valve. When the system pressure falls to about 7.8 bar the
governor valve will reset and the charge cycle will begin again. A built in safety
valve set to 10 bar will protect the system should the governor malfunction.

From the dryer air is routed to the four-circuit protection valve. The valve allows
sequential charging of the reservoirs and gives minimum air pressure circuit
protection to allow safe braking in case of a malfunction in one of the circuits. The
valve is located rearmost on a valve sub assembly between axles 3 & 4 on the chassis
lower diaphragm plate.

The primary reservoirs V1, V2 & V3 all supply their respective control and relay
valves. A signal/pilot line from the control valve (footbrake/handbrake) operates the
relay valves. All primary brake functions utilise signal/pilot control, as this is the
only way to meet the application time requirements. The relay valves operate in
proportion to the signal/pilot pressure. To achieve the necessary brake performance a
3.5 bar pressure-reducing valve is situated in the signal/pilot line of the footbrake on
axles 5 & 6. Relay valves fitted to spring brake circuits have an extra signal/pilot
connection (4.1). This serves as anti-compound protection to prevent simultaneous
application of both park and service brake as this would cause mechanical damage to
the brake assemblies. The relay valves & pressure reducing valves are all located as
three sub assemblies on the lower diaphragm plate of the main chassis.

Pressure monitoring:

Low air pressure is indicated by switches installed directly on the footbrake valve
(=41-S20 & =41-21) via warning light –H1 in the driving cab. Dual air gauges are
also installed for visual indication of reservoir pressures. A footbrake stop light
switch (=03-S8) and a park brake application warning switch (=41-S22) are installed
directly beside the respective valves.

NOTE: The respective montage/installation drawings should be consulted for

component locations.

GMK Training Information. May 98. Carrier Pneumatic System. Page 2

 Deutsche GROVE

Auxiliary/secondary consumers:

All functions are controlled by air pressure from reservoir V4 and all operate at
system air pressure. An eight or nine element sandwich type electric solenoid valve
block is used to control all functions. The solenoid valve block is located on the right
side of the carrier adjacent to the outrigger control box. Emergency operation of
individual solenoids can be carried out without electrical power by operation of the
manual override.

Solenoid functions:

Front

=41-Y6 axle/suspension blocking

=41-Y13 exhaust & engine brake (not fitted with Cummins engine)

=41-Y7 axle differential cross locks

=41-Y4 inter-axle & transfer case differential locks

=47-Y1 all wheel steering lock

=47-Y12 steering lock axles 5 & 6

=41-Y1 Transfer case range select – the solenoids

are only energised while holding the range
selection buttons.
=41-Y2
The table below shows the selection
sequence.
O = De-energised
X = Energised
=41-Y3
Solenoid function 41-Y1 41-Y2 41-Y3
Highway range O O X
Neutral X O X
Low/rough terrain range X X O

GMK Training Information. May 98. Carrier Pneumatic System. Page 3

 Deutsche GROVE

Auxiliary/secondary consumers:

Function description of solenoid actuation & air delivery:

=41-Y6 Axle/suspension blocking. Control by switch (-S3) in driving cab. This

supplies air to to six axle/suspension blocking valves, which are located between each
suspension group. Without air pressure, these valves automatically isolate the
pressure accumulators from the suspension cylinders and give a rigid but still
interactive suspension. A minimum air pressure of 5 bar is required to release the
axle/suspension blocking for hydrogas interactive suspension. A 5 bar warning
switch (=41-S61) is fitted (directly to solenoid valve) to indicate function status via
cab warning via light -H6.

=41-Y13 Exhaust & engine brake. Control by cab floor mounted switch (-S37 via
relay K26) subject to transmission lockup engagement & accelerator position. This
supplies air simultaneously to an exhaust brake flap and engages the integrated engine
brake.

=41-Y7 Axle differential cross locks. Control by switch in driving cab (-S6)
subject to low range selection of transfer case & suspension key engagement. This
supplies air to each integral air cylinders in each axle line, which engages a sliding
coupling to inhibit the differential function and give drive to both wheels. Switches
(-S1 through -S4) are installed in each actuating cylinder to indicate function status
via cab warning light -H7.

=41-Y4 Inter-axle & transfer case differential locks. Control by switch in driving
cab (-S3) subject to low range selection of transfer case & suspension key
engagement. This supplies air to integral cylinders in axles 2, 4 & transfer case,
which engages a sliding coupling to inhibit the longitudinal differentials in the
transfer case and axle 4. Axle 2 cylinder function engages axle 1 drive. Switches
(-S4 & -S54) are installed in axles 2 & 4 respectively and (-S5) in the transfer case to
indicate function status via cab warning light -H4.

=47-Y1 All wheel steering lock. Control by switch in driving cab (-S4) subject to
speed control via = 47 –K1 & output from ESX control. This supplies air to unlock
the hydraulic cylinders on axles 3 & 4. Switches -S1 & -S2 are installed in the
respective cylinders to indicate function status via cab warning light -H6.

=47-Y12 All wheel steering lock. Control by switch in driving cab (-S4) subject to
speed control via =47 –K1 & output from ESX control. This supplies air to unlock
the steering idler assembly for axles 5 & 6. A switch -S3 is installed in the steering
idler to indicate function status via cab warning light -H6.

GMK Training Information. May 98. Carrier Pneumatic System. Page 4

 Deutsche GROVE

Auxiliary/secondary consumers:

=41-Y1

=41-Y2 Transfer case range selection. Control is by push buttons in driving cab
(-S7 highway, -S8 neutral & -S9 low). This supplies a sequential air
=41-Y3 delivery to integral cylinders within the transfer case to select the
particular function. Switches (-S7 low range, -S70 highway range) are
installed in the transfer case to indicate function status via cab warning
lights -H6 low & -H8 highway.

Note: Changing ratio of the transfer box must be carried out at standstill.

GMK Training Information. May 98. Carrier Pneumatic System. Page 5