5 Brake

Service Information
Document Title: Function Group: Information Type: Date:

Introduction 500 Service Information 2014/6/26
Profile:
Introduction
A30C has an air-hydraulic service brake system, which acts on all wheels.
The parking brake is of the air-mechanical type acting on the propeller shaft. It is applied by spring force and released by
compressed air. Service and parking brakes are disc brakes with one or more brake calipers per disc.
The engine is provided with a direct-drive, single-cylinder, water-cooled compressor and separate unloading – pressure
regulator for the compressed-air supply. The machine has two reservoirs on the tractor unit and one on the trailer unit for
storing compressed air.
The service brakes are operated through a foot brake valve which has two circuits. The brake valve regulates the brake
pressure to the air-hydraulic units the tractor unit directly and on the trailer unit via a relay valve. The air-hydraulic units have
a diaphragm which is actuated by the compressed air. The diaphragm is attached to a piston rod. This transfers force to a
piston which in turn acts on the brake fluid. The area difference between the diaphragm and the piston is large and this
boosts the pressure on the brake fluid. The brake fluid actuates the pistons in the brake calipers. The four air-hydraulic units,
two for the front axle and two for the trailer unit, have reservoirs for brake fluid. These are positioned directly on the brake
units on the trailer unit and separately with connecting hoses on the tractor unit.
When the parking brake is applied, also the longitudinal differential lock will be engaged, this in order to make the parking
brake act on more wheels.
Load and dump brake (serial No. 2901–, US 60001–)
The load and dump brake is a function which causes the trailer unit service brakes to be applied when the parking brake is
applied. This takes place provided that the air system is pressurised and that the ignition switch is in the running position.
The purpose of the load and dump brake is to improve the braking capacity of the parking brake when the machine is being
loaded or is dumping a load.
Engagement of load and dump brake, overview
Engagement, position and component parts, see [Invalid linktarget] .
WARNING
The parking brake is not dimensioned to take up the forces from a moving machine. Therefore, do not use the
parking brake as service brakes, even if the machine is equipped with a load and dump brake.
CAUTION
However, the parking brake may be used as an emergency brake, but only if the ordinary brake system has ceased to
function.
Figure 1
Load and dump brake. Engagement, position and component parts. (The item numbers refer to the item list on page
58.)
Service Information

Brake disc for service 510 Service Information 2014/6/26
brakes, checking
Profile:
Brake disc for service brakes, checking

Op nbr 51002
Torque wrench 0–200 N m (148 lbf ft)
Figure 1
1. Place the machine in service position, i.e. the machine should stand on level and hard ground. The steering joint
lock should be connected and at least one wheel blocked.
2. Remove the brake guard which is attached with two bolts. See [Invalid linktarget] .
Figure 2
Removing brake guard
3. Check the brake disc wear. See [Invalid linktarget] .
Min. thickness of service brake discs is 13 mm (0.51 in).
Figure 3
Brake caliper, complete
1. Brake piston
2. Scraper seal
3. Min. thickness (13 mm) (0.51 in)
4. Bolt on the brake guard with the two bolts.

Tightening torque: 91 N m (9.1 kgf m) (67 lbf ft).
Service Information

Brake pads for service 510 Service Information 2014/6/26
brakes
Profile:
Brake pads for service brakes

Op nbr
Torque wrench 0–200 N m (148 lbf ft)
Op. number 51001 (checking wear, all axles)

Op. number 51101 (checking front axle)
Op. number 51201 (checking wear, rear axle)
Figure 1
2. Remove the brake guard which is attached with two bolts. See [Invalid linktarget] .
Figure 2
Removing brake guard
3. Check the wear of the brake pads. See [Invalid linktarget] .

The minimum thickness of the service and parking brake pads (linings) is 3 mm (0.12 in).
CAUTION
The pads must not be worn down below a lining thickness of 3 mm (0.12 in), as the pistons in the brake
calipers and the brake discs may be damaged.
Figure 3
Minimum thickness of brake pads (linings) is 3 mm (0.12 in)
4. Bolt on the brake guard with the two bolts.

Service Information

Brake caliper, replacing 511 Service Information 2014/6/26
Profile:
Brake caliper, replacing

Op nbr
11 668 007 Stand jack (or similar equipment)
Wheel handling trolley (or similar equipment)
Op. number 51145 (Front axle)

Op. number 51245 (Rear axle)
Removing
Figure 1
2. Lift the axle with a stand jack (or alternatively with a jack and axle stand), see [Invalid linktarget] .
Figure 2
3. Remove the wheel with a wheel handling trolley or equivalent equipment, see [Invalid linktarget] and [Invalid
linktarget] .
Figure 3
Figure 4
4. Remove the brake guard.
5. Disconnect the brake pipe and remove the brake caliper. See [Invalid linktarget] .
CAUTION
Plug the connections.
Figure 5
Removing brake caliper
6. Check the brake disc as regards wear and damage.
Installing
7. Install the brake caliper.

Install the brake pipe.
8. Install the brake pads in the caliper. See [Invalid linktarget] . Apply locking fluid (medium locking) to the bolts and
install the stop. See [Invalid linktarget] .
Tightening torque: 240 N m (24 kgf m) (177 lbf ft).
Figure 6
Installing brake pad
Figure 7
Installing stops
9. Bleed the brake caliper according to [Invalid linktarget] .

NOTE!
Only the system on the axle on which work has been carried out needs to be bled.
10. Install the wheel and tighten the nuts to 800 N m (80 kgf m) (590 lbf ft). Remove the stand jack.
11. Fit the brake guard.

Tightening torque for the bolts: 90 N m (9 kgf m) (66 lbf ft).
12. Test the function.

Apply the brakes 4–5 times to check the function. If necessary increase the pressure.
Service Information

Brake discs, replacing 511 Service Information 2014/6/26
(one wheel)
Profile:
Brake discs, replacing (one wheel)

Op nbr
11 688 004 Hub nut socket
E 1751 Lifting device
E 1752 Lifting yoke
Lifting sling, 2 m (6.5 ft)
Ratchet block, 750 kg (1653 lb)
Op. number 51102 (Front axle)

Op. number 51202 (Rear axle)
Removing
Figure 1
2. Lift the axle with a stand jack (or alternatively with a jack and axle stand), see [Invalid linktarget] .
Figure 2
linktarget] .
Figure 3
Figure 4
4. Raise the axle further to prevent oil from running out of the axle housing. Empty the oil out of the hub.
5. Remove brake guard, brake pads, brake pipe and brake caliper.
CAUTION
Plug the connections.
6. Arrange the lifting device E 1751, see [Invalid linktarget] .
Figure 5
7. Insert 10 x 35 mm pins in the puller holes to protect the threads in the hub.
8. Install M12 x 120 mm guide pins in two holes. Pull off using M16 x 60 mm bolts. Pull out the planet carrier onto the
guide pins and lower it.
9. Remove the lock ring and the sun gear. Leave the half shaft in place. See [Invalid linktarget] .
Figure 6
1. Sun gear
2. Lock ring
10. Remove the lock ring and the lock washer from the end of the shaft. See [Invalid linktarget] .
Figure 7
11. Loosen and remove the hub nut using hub nut socket 11 668 004. See [Invalid linktarget]
Figure 8
12. Secure the ring gear with two large washers and two bolts. See [Invalid linktarget] .
Figure 9
Securing ring gear
13. Connect lifting yoke E 1752 to the hub and lower the hub together with the ring gear, see [Invalid linktarget]
Figure 10
14. Place the hub on the floor with the brake disc upward.
Installing
15. Remove and replace the brake disc with a new disc. Install new spring washers.
Tightening torque: 310 N m (31 kgf m) (229 lbf ft)
16. Replace seal (1), [Invalid linktarget] . If the wear ring is noticeably worn, replace it as well.
Figure 11
1. Seal
17. Lift the hub together with the ring gear into position. See [Invalid linktarget] .
Figure 12
18. Tighten the hub to approximately 600–800 N m (60–80 kgf m) (443–590 lbf ft) with the aid of hub nut socket
11 668 004 (1 metre (39 in) handle (lever),
and a force of 60–80 kg (132–176 lb)).
19. Rotate the hub 4 – 5 revolutions and loosen the hub nut 1/2 a turn.
20. Tighten the hub nut to 300 N m (30 kgf m) (221 lbf ft).
21. Adjust the indicator pin on the hub nut socket 11 668 004 so that it aligns with one of the bolt holes in the hub. See
[Invalid linktarget] .
Figure 13
22. Tighten the hub nut until the indicator pin reaches the next hole (12°) in the hub.
23. Install the lock washer and the lock ring. See [Invalid linktarget] .
CAUTION
Never loosen the hub nut to make it align with the lock washer Two different versions of the lock washer are
available.
24. Install the sun gear together with the lock ring.
25. Clean the planet carrier and the hub. Apply new sealant.
26. Install the planet carrier and a few bolts. Knock in the outer guide pins before the inner ones.
NOTE!
The guide pin slots should point in the direction of rotation of the hub, see [Invalid linktarget] . Tighten down the
bolts. Torque-tighten to 110 N m (11 kgf m) (81 lbf ft).
Figure 14
Guide pin slots in the direction of rotation of the hub.
27. Install the brake caliper. Torque-tighten to 550 N m (55 kgf m) (406 lbf ft). Install the brake pipes.
28. Install the pads. Apply locking fluid (medium locking) to the bolts and install the stop.
Tightening torque: 240 N m (24 kgf m) (177 lbf ft). Bleed the brake system, see [Invalid linktarget] .
NOTE!
Only the system on the axle on which work has been carried out needs to be bled.
29. Install brake guard and wheel. Torque-tighten the wheel nuts to 800 N m (80 kgf m) (590 lbf ft).
30. Check the oil level in the axle. Top up when required. Remove the blocks.

Service Information

Brake pads, replacing 511 Service Information 2014/6/26
Profile:
Brake pads, replacing

Op nbr
Op. number 51105 (one wheel)

Op. number 51205 (one wheel, 1st bogie axle)
Removing
Figure 1
2. Lift the axle with a stand jack (or alternatively with a jack and axle stand). See [Invalid linktarget] .
Figure 2
Figure 3
linktarget] .
Figure 4
4. Clean the brake caliper, remove the attaching bolts and the stops for the brake pads. See [Invalid linktarget] .
Figure 5
Removing stops
Figure 6
5. Place a pinch-bar, according to [Invalid linktarget] , and prize the brake pads slightly away from the disc and
remove them. See [Invalid linktarget] .
Figure 7
6. Inspect the brake disc as regards any damage and wear, see [Invalid linktarget] and [Invalid linktarget] .
Figure 8
Minimum thickness of brake pads (linings) is 3 mm (0.12 in)
Figure 9
Brake caliper, complete
1. Brake piston
2. Scraper seal
3. Min. thickness (13 mm) (0.51 in)
7. Clean the locations for the pads and around the pistons and inspect the rubber boots. Replace damaged boots.
Installing
8. Press in the pistons fully with the aid of the tools shown in figure [Invalid linktarget] , so that the new pads can be
installed.
CAUTION
Take care not to damage the scraper seals.
Figure 10
Principle diagram for pressing in pistons. Turn carefully
1. Flat bar of mild steel
9. Install the pads. Apply locking fluid (medium locking) to the bolts and install the stop.
Tightening torque: 240 N m (24 kgf m) (177 lbf ft).
10. Install the wheel and tighten the nuts to 800 N m (80 kgf m) (590 lbf ft).
11. Remove the stand jack.

Apply the brakes 4–5 times to check the function. If necessary increase the pressure.
Service Information

Brake system, 520 Service Information 2014/6/26
air bleeding
Profile:
Brake system, air bleeding

Op nbr 52037
CAUTION
Block the wheels (see [Invalid linktarget] ). Air bleeding the brake system should be carried out with the parking brake
released.
Figure 1
Connection between brake units and the brake calipers, front circuit
The machine has four air-hydraulic units.

When air bleeding, the hydraulic master cylinder of each unit should be bled first and then the cylinders in the brake
calipers.
When bleeding the brake calipers, begin with the brake caliper which has the longest brake line.
Therefore, bleed the brake calipers in the following order: A, B, C and D, see [Invalid linktarget] .
1. Run the engine to build up the pressure in the compressed-air system.
2. Depress the brake pedal.
3. Open one bleeder nipple and close it when the brake fluid no longer flows out.
4. Let up the brake pedal.
5. Repeat the procedure until brake fluid free of air flows out.
CAUTION
The bleeder nipples should be closed before the brake pedal is let up.
6. Fill brake fluid to correct level.
7. After air bleeding, press pin (2) in [Invalid linktarget] to the bottom. Measure measurement "a" and make a note of
it. Make sure that the system pressure is at approx. 800 kPa (8.0 bar) (116 psi) and press the brake pedal right
down.
Figure 2
Air-hydraulic unit
1 Bleeder nipple
2 Pin for measuring stroke
C Max. stroke 41 mm (1.61 in)
8. Use distance b to work out stroke c, see Fig 42. The stroke must not be more than 41 mm (1.61 in), when the
system has been correctly air bled.
Figure 3
Air-hydraulic unit
11 Bleeder nipple
15 Hydraulic master cylinder
21 Air cylinder
Service Information

Description 520 Service Information 2014/6/26
(serial No. 2901–, US
60001–)
Profile:
Description (serial No. 2901–, US 60001–)

The hydraulic brake system is divided in two main circuits, one for the front axle (the front circuit, see [Invalid linktarget] )
and one for the rear axles (the rear circuit, see [Invalid linktarget] ). The front axle has four brake calipers, two for each front
wheel and two air-hydraulic units. The right unit is connected to the rear right and front left brake calipers on the front axle,
see [Invalid linktarget] . The left unit is connected to the other two brake calipers. The front circuit is in this way divided into
a dual-circuit system acting diagonally on the brake calipers.
In the rear circuit there is one air-hydraulic unit for each rear axle.
Figure 1
Front circuit, principle diagram
1. Air-hydraulic unit
2. Bleeder nipple on master cylinder
3. Bleeder nipple
Figure 2
Rear circuit, principle diagram
1. Air-hydraulic unit
2. Bleeder nipple on master cylinder
3. Bleeder nipple
Service Information

Foot brake valve 525 Service Information 2014/6/26
Profile:
Foot brake valve

The foot brake valve is a dual-circuit valve, where one part controls the circuit on the tractor unit and the other part controls
the circuit on the trailer unit.
The valve is supplied with air from the air reservoirs. In the valve air pressure is adjusted to the required pressure by
depressing the pedal. The regulated air pressure is then conducted to the brake cylinders which apply the wheel brakes.
A feature of this foot brake valve design is that circuit 2 is actuated by the pressure in circuit 1 through a relay piston. This
means that the pressure difference between the two circuits is very small, but with a delay for circuit 2.
Figure 1
Foot brake valve
1 Guide with vent 20 Spring guide

2 Valve 21 O-ring
3 Connection 12, reservoir pressure circuit 2 22 O-ring
4 Compression spring, weaker 23 Lock ring
5 Piston 24 Compression spring
6 Relay piston 25 Spring guide
7 Valve 26 Washer for O-rings
8 Connection 11, reservoir pressure circuit 1 27 O-rings
9 Compression spring, stronger 28 O-ring
10 Piston 29 Lock ring
11 Rubber spring 30 O-ring for centre hole in piston
12 Rubber boot 31 O-ring for relay piston
13 Pressure piston 32 O-ring for piston
14 Bracket 33 O-ring for valve housing
15 Connection 21, brake pressure circuit 1 34 Adjusting screw
16 Upper housing 35 Thrust washer, plastic
17 Lower housing 36 O-ring for valve housing
18 Connection 22, brake pressure circuit 2 37 O-ring for piston
19 Compression spring 38 Washers and nut
Service Information

Relay valve 525 Service Information 2014/6/26
Profile:
Relay valve
The purpose of the relay valve is, when necessary, immediately to supply a large amount of air and thereby achieve a rapid
brake application.
The loss of pressure is reduced in that the air does not have to take the longer way round through a control device. Only the
flow of control air has to go through the control device and thus provide a signal to the relay valve.
Therefore, there is always one feed line and one signal line leading to a relay valve.
The relay valve is provided with a quick release function and thereby replaces a separate quick release valve.
Figure 1
Relay valve
1 Connection, input control pressure 11 Seal

2 Exhaust valve 12 Cover
3 Cover 13 Rubber washer, outlet
4 Piston seal 14 Valve pipe
5 Bolt for cover 15 Locking device
6 Valve housing 16 Washer
7 Seal 17 Compression spring
8 Connection, feed pressure from reservoir 18 Connection, output control pressure
9 Seat for inlet valve 19 Control piston
10 Inlet valve
Service Information

Automatic adjusting lever 550 Service Information 2014/6/26
Profile:
Automatic adjusting lever

The automatic adjusting lever provides self-adjustment of the parking brake in that the lever rotates the brake key as the
brake pads are worn. This means that the clearance between the brake pads and the brake disc is kept constant. The
adjusting lever consists in principle of a worm gear which is actuated by an automatic adjusting mechanism. Regarding the
main and component parts of the adjusting levers, see [Invalid linktarget] and [Invalid linktarget] .
Figure 1
Adjusting lever, component parts
1 Adjusting screw 7 Gear 13 Housing

2 Rubber ring 8 Bearing 14 Worm gear
3 Threaded cover, front 9 Worm 15 Control unit (control disc and control arm)
4 Needle bearing 10 Coiled spring 16 Gear rack
5 Clutch sleeve 11 Threaded cover, rear
6 Friction torsion spring 12 Lock rivet
Figure 2
Main parts
A. One-way clutch
B. Worm
C. Worm gear
D. Gear rack
E. Control unit (control disc and control arm)
F. Coiled spring
Service Information

Profile:
Description
The parking brake consists of an air controlled mechanical disc brake, which acts on the tractor unit propeller shaft.
Because the machine has a permanent 4-wheel drive and a longitudinal differential lock, which is automatically engaged
when the parking brake is applied, four wheels will be braked. The brake is operated with compressed air.
Figure 1
Air controlled parking brake
The parking brake is operated via a spring brake cylinder which applies the parking brake by spring force and releases it with
compressed air.
The brake pads in the brake caliper are automatically adjusted through an adjusting lever mounted between the brake
caliper and the spring brake cylinder.
When the parking brake is applied, the circuit for the longitudinal differential lock is also drained via the connecting block
and the hand control and this causes the longitudinal differential lock to be engaged.
Service Information

Parking 550 Service Information 2014/6/26
brake, replacing brake disc
Profile:
Parking brake, replacing brake disc

Op nbr 55005
11 668 007 Stand jack (or similar
optional)
E 1645 Dump body support
Figure 1
Removing
lock should be connected and at least one wheel blocked. Make sure that there is full working pressure in the
compressed-air system.
2. WARNING
It is forbidden to be under a raised dump body without first having secured it with the dump body lock or
dump body support E 1645.
Raise the dump body and secure with the dump body lock or with dump body support E 1645. Release the parking
brake (OFF position).
3. Wedge the brake caliper to the attaching plate with a screwdriver or similar to keep the parts in place. See [Invalid
linktarget] .
Figure 2
Wedging brake caliper and attaching plate
4. Remove the eight bolts for the parking brake bracket.
5. Arrange the lifting device and lift away the complete brake unit (brake caliper and spring brake cylinder). See
Figure 3
Lifting brake caliper and spring brake cylinder
6. Carefully lay the brake caliper and spring brake cylinder on the frame (weight approx. 60 kg = 132 lb). See [Invalid
linktarget] .
Figure 4
Parking brake is placed on the frame
1. Right-hand filler valve
7. Position stand jacks under the first bogie axle. Lift until it is possible to turn the wheels. See [Invalid linktarget] .
Figure 5
Lifting with jacks
8. Remove the bolted joint for the propeller shaft. Use tool 999 1566. Push in the front part of the propeller shaft to
make it shorter and swing it to one side.
NOTE!
Tie the propeller shaft to the frame.
9. Remove the brake disc. See [Invalid linktarget] .
Figure 6
Removing brake disc
Installing
10. Install the new brake disc.
11. Re-install the propeller shaft and tighten down the bolted joint. Tightening torque: 100 N m (10 kgf m) (74 lbf ft).
12. Lower the machine and remove the stand jacks.
13. Install the complete unit with the spacers positioned in the same way as they were when removing.
CAUTION
Do not tighten the bolts.
14. Remove the wedge between the caliper and the attaching plate.
15. Turn the adjusting screw on the adjusting lever clockwise until stop, see [Invalid linktarget] .
Figure 7
1. Adjusting lever
16. Apply the parking brake.
17. Tighten the bolted joint for the attaching plate.

Tightening torque: 220 22 N m (22 2.2 kgf m) (162 16 lbf ft).
18. Release the parking brake.
19. Turn the adjusting screw on the adjusting lever clockwise until stop. Then turn the adjusting screw counter-
clockwise (clicking sound) 3/4 of a turn.
20. Remove the dump body lock or the dump body support E 1645 and lower the dump body.
21. Apply and release the parking brake approx. 10 times.

Service Information

Parking brake caliper, 550 Service Information 2014/6/26
removed, reconditioning
Profile:
Parking brake caliper, removed, reconditioning

Op nbr 55013
699 9004 Handle
699 9038 Plate
699 9044 Plate
Dismantling
1. Mark housing – caliper. Remove the housing from the caliper, see [Invalid linktarget] .
Figure 1
Removing housing together with piston
2. Unscrew the piston from the shaft.
3. Drive the shaft out of the housing. Remove the wear washer and the seal.
4. Remove the large, square seal from the caliper. Clean and inspect the parts.
5. Drive the bushing out of the housing.
Assembling
6. Drive a new bushing into the housing using handle 699 9004 and plates 699 9038, 699 9044. The bushing should
be driven down 12 mm (0.47 in) below the edge, see [Invalid linktarget] .
Figure 2
Measuring bushing location
7. Replace the valve on the caliper, see [Invalid linktarget] .
Figure 3
Position of valve
8. Lubricate the parts and install the wear washer, the shaft and the seal in the housing.
9. Install the piston on the shaft.
10. Install the gasket against the housing.
11. Install the large, square seal in the yoke.
12. Apply grease to the piston and the cylinder in the caliper. Install piston together with housing in the caliper
according to earlier marking. Tighten the bolts.
Service Information

Parking brake, 550 Service Information 2014/6/26
replacing brake pads
Profile:
Parking brake, replacing brake pads

Op nbr 55014
E 1645 Dump body support
Removing
WARNING
It is forbidden to be under a raised dump body without first having secured it with the dump body lock or dump
body support E 1645.
Figure 1
lock should be connected and at least one wheel blocked. Make sure that there is full working pressure in the
compressed-air system.
2. Raise the dump body and secure with the dump body lock or with dump body support E 1645. Release the parking
brake (OFF position).
3. Wedge the brake caliper to the attaching plate with a screwdriver or similar to keep the parts in place. See [Invalid
linktarget] .
Figure 2
Wedging brake caliper and attaching plate
4. Turn the adjusting screw on the adjusting lever counter-clockwise (clicking sound).
5. Remove the eight bolts for the parking brake bracket.
6. Arrange the lifting device and lift away the complete brake unit (brake caliper and spring brake cylinder). See
Figure 3
Lifting brake caliper and spring brake cylinder
7. Carefully lay the brake caliper and spring brake cylinder on the frame (weight approx. 60 kg = 132 lb). See [Invalid
linktarget] . Remove the brake pads.
Figure 4
Parking brake is placed on the frame
1. Right-hand filler valve
CAUTION
When installing, the spacers should be positioned in the same way as they were when removing.
Installing
8. Install the new brake pads. The springs are there to keep the brake pads apart.
9. Install the complete unit with the spacers positioned in the same way as they were when removing.
CAUTION
Do not tighten the bolts.
10. Remove the wedge between the caliper and the attaching plate.
11. Turn the adjusting screw (1) on the adjusting lever clockwise until stop. See [Invalid linktarget] .
12. Apply the parking brake.
13. Tighten the bolted joint for the attaching plate.

Tightening torque: 220 22 N m (22 2.2 kgf m) (162 16 lbf ft).
14. Release the parking brake.
15. Turn the adjusting screw on the adjusting lever clockwise until stop. Then turn the adjusting screw counter-
clockwise (clicking sound) 3/4 of a turn.
16. Remove the dump body support E 1645 and lower the dump body.
17. Apply and release the parking brake approx. 10 times.

Service Information

Spring brake cylinder 550 Service Information 2014/6/26
Profile:
Spring brake cylinder

The purpose of the spring brake cylinder is to apply the parking brake with the aid of a strong spring.
The parking brake receives its supply of air from the compressor and compressed-air reservoir via the 4-way pressure
retaining valve and the parking-brake valve.
The parking brake is applied when there is atmospheric pressure at connection A, see [Invalid linktarget] .
This will cause the spring to press on the piston, which in turn presses up the pushrod and brings about a strong mechanical
application against the brake disc via the adjusting lever.
The same result is obtained with a fully charged system pressure if the compressed air at connection "A" is drained with the
parking-brake valve.
When the compressed air is admitted via connection "A", the piston is pushed back and the brake application ceases.
Figure 1
Spring brake cylinder
A. Air connection from parking brake valve
1. Brake cylinder
2. Piston
3. O-ring
4. Felt ring
5. Spring
6. Cover
7. Plug
8. Nylon bushing
9. O-ring
10. Lock nut
11. Flange nut
12. Screw
13. Rubber boot
14. Pushrod
Service Information

Spring brake cylinder 550 Service Information 2014/6/26
removed, reconditioning
Profile:
Spring brake cylinder removed, reconditioning

Op nbr 55010
WARNING
Great spring force! Remember that the spring is compressed and therefore the press piston must be released
approx. 100 mm (4 in) before the pressure of the spring is released.
Dismantling
1. Secure the spring brake cylinder in a press, see [Invalid linktarget] . Remove the bolts, the cover and the spring.
Figure 1
Dismantling and assembling spring brake cylinder
2. Remove clevis, boot, lock nuts and pushrod from the piston.
3. Drive the piston out of the cylinder.
4. Remove O-ring and bushing from the cylinder.
5. Remove piston seals and piston ring from the piston.
6. Clean and inspect the parts.
Assembling
7. Install the piston ring on the piston.
Then install O-ring and felt ring.
8. Install the O-ring and the bushing in the cylinder. The chamfered edge of the bushing toward the O-ring.
9. Apply grease to the parts.
10. Carefully wriggle the piston down into the cylinder.
11. Position the pushrod in the piston rod and install the nuts. Adjust until there is a clearance of 2.4 ±0.5 mm
0.094 ±0.020 in) between nut and piston rod, see [Invalid linktarget] .
Install boot and clevis.
Figure 2
Checking clearance, 2.4 ±0.5 mm 0.094 ±0.020 in)
12. Install the spring in the cylinder and put the cover on the spring. Press down cover and spring into the cylinder,
install the lock screws, see [Invalid linktarget] .
Service Information

Parking brake 551 Service Information 2014/6/26
valve (Hand control)
Profile:
Parking brake valve (Hand control)

It is possible gradually to apply the parking brake with the parking-brake valve control. The control is spring-loaded and
returns to the released brake position if the control is released, unless it has first been moved right over to its rear position,
parking position. In this position the lever is locked by catch (2), [Invalid linktarget] .
The parking-brake valve connections are shown in [Invalid linktarget] .
If the ordinary service brakes cease to function, the parking brake may be used as an emergency brake.
Figure 1
The parking-brake valve connections
1. Outlet to parking brake caliper and the connecting block connection marked 1 for connecting longitudinal
differential lock
2. Pressure sensor (SE6)
3. Inlet from air reservoir
4. Air bleeding
Service Information

Parking brake valve 551 Service Information 2014/6/26
Profile:
Parking brake valve
Figure 1
1 Lever 10 Attaching plate 19 Lock ring 28 Lock ring

2 Catch 11 O-ring 20 O-ring 29 Steering
3 Spring 12 Cover with guide 21 Valve 30 Piston spring
4 Rubber bellows 13 Housing 22 Valve spring 31 Spring for control rod
5 Lock plate 14 Spring pin 23 Washer 32 Control rod
6 Lifting roller 15 Exhaust 24 Valve rubber 33 Washer
7 Bolt for cover 16 Inlet 25 Piston 34 Steering
8 Spring pin 17 Venting connection 26 O-ring 35 O-ring
9 Link 18 O-ring 27 Adjusting screw
Service Information

Parking brake valve, 551 Service Information 2014/6/26
reconditioning (removed)
Profile:
Parking brake valve, reconditioning (removed)

Op nbr 55103
Dismantling
1. Pull the rubber bellows up on the control lever. Mark the intermediate piece, the bracket and the housing relative
to each other.
2. Remove the four bolts and take the control (lever) part and the housing apart.
3. From the housing remove: bracket (11), washer (12), spring (13), piston (14), valve (16), washer (19) and spring (20),
see [Invalid linktarget] .
Figure 1
4. Remove O-ring (15) from the piston. Remove rubber seal (18) and O-ring (17) from the valve.
5. Secure a 12 mm combination spanner in a vice, see [Invalid linktarget] . Position the control part in the grip on the
combination spanner. Compress the spring on the control part and remove lock ring (10), see [Invalid linktarget] .
Figure 2
1. Combination spanner 12 mm
6. Remove the components from the control part: stop washer (9), spring (8), sleeve (7), O-rings (6) and (5) and
intermediate part (4), see [Invalid linktarget] .
Figure 3
Clean and check all parts. Replace damaged and worn parts. Coat the parts with grease, e.g. Bendix Westinghouse
”Lubricant 24017”, before assembling.
Assembling
7. Check that distance A on bolt (3), is 6 mm (0.24 in), see [Invalid linktarget] .
Figure 4
A Approx. 6 mm (0.24 in)

3 Screw
8. Take control part (1) and insert rod (2) in intermediate part (4). Install O-rings (5) and (6) on the intermediate part.
Install sleeve (7), spring (8) and stop washer (9) on the rod, see [Invalid linktarget] .
9. Compress the spring and install lock ring (10), see [Invalid linktarget] and [Invalid linktarget] .
10. Install the O-ring and the rubber ring on valve (16). Install the O-ring on piston (14).
11. Install the parts in the housing: spring (20), washer (19), valve (16), piston (14), spring (13) and washer (12) and
bracket (11), see [Invalid linktarget] .
12. Assemble the control part and the housing according to earlier marking. Install the four bolts. Pull the rubber
bellows down over the intermediate piece.
Service Information

Profile:
Description
Compressed air is used for:
 Parking brake
 Differential locks
 6-wheel drive
 Retarder engagement
 Horn
 Exhaust retarder
 Seat with air suspension.
Service Information

Air compressor 561 Service Information 2014/6/26
Profile:
Air compressor
The compressor has one cylinder and is air-cooled, apart from the cylinder head which is liquid-cooled.
The force-feed lubrication of the compressor takes place through a connection to the engine force-feed lubrication system.
The oil is drained back via ducts to the engine timing gears.
Charging
During the down-stroke of the piston in the compressor a partial vacuum is created in the cylinder. This causes the plate
valve at the inlet to open and air is sucked into the cylinder through the air filter.
When the piston turns, the air is gradually compressed and the air pressure plus the force of the leaf spring closes the inlet.
During the up-stroke of the piston in the compressor air is compressed. When the pressure has risen so much that it
overcomes the spring and air pressure on top of the plate valve at the outlet, the valve opens and compressed air flows to
the wet reservoir.
Figure 1
When the piston turns and moves downward, the pressure in the cylinder is again reduced and the plate valve for the outlet
closes the connection to the wet reservoir.
Service Information

Anti-freeze reservoir 561 Service Information 2014/6/26
Profile:
Anti-freeze reservoir
This equipment is intended to reduce the risk of the condensation water, which is formed in the compressed-air system,
freezing. The reservoir should be filled to approx. 2/3rds with clean ethyl or methyl alcohol.
The reservoir is connected to the inlet duct on the compressor. Because of the partial vacuum, the air is sucked through the
filter and through the pipe which is immersed in the liquid. The air bubbles up through the liquid and evaporated alcohol,
together with the air, is drawn into the compressor and further on out into the brake system.
Figure 1
Anti-freeze reservoir
1. Atmospheric pressure
2. Liquid
3. Evaporated liquid
NOTE: When operating in areas with a permanently warm climate, where there is no risk of frost, the line to the compressor
should be blocked. This is necessary to prevent impurities from being drawn into the compressor.
Service Information

Compressor, replacing 561 Service Information 2014/6/26
Profile:
Compressor, replacing
Op nbr 56104
Hose pliers, 2 pcs
Removing
Figure 1
A. Air compressor
CAUTION
Mark the hoses before removing
1. Pinch the coolant hoses to the compressor with the aid of the two hose pliers and disconnect the hoses at the
compressor.
Disconnect the hose from the anti-freeze reservoir and the lubricating oil hose as well as the suction and pressure
hoses.
2. Remove the support for the pressure pipe.
3. Remove the compressor.

Figure 2
Air compressor
1. From air cleaner

2. From anti-freeze reservoir
3. Coolant connection
4. To wet reservoir
5. Coolant connection
6. From force-feed lubrication system
Installing
4. Install a new rubber seal between the compressor and the engine timing gears and install the compressor.
5. Connect the hoses to the compressor and remove the hose pliers. Install the pressure pipe support.
Service Information

Cut-out and cut-in 561 Service Information 2014/6/26
pressure,
checking and adjusting
Profile:
Cut-out and cut-in pressure, checking and adjusting

1. Check the cut-out pressure of the regulator by charging the compressed-air system. Read off the pressure on the
pressure gauge in the cab. The cut-out pressure should be 830–850 kPa
(8.3–8.5 bar (120–123 psi) ). When necessary, adjust the regulator to this pressure with adjusting screw (19) and
lock with the lock nut, see [Invalid linktarget] .
2. Check the cut-in pressure by slowly releasing air from the system using the brake pedal.
CAUTION
Not the wet air reservoir.
If the cut-in pressure is below approx. 700 kPa (7 bar (102 psi)), the regulator needs to be lubricated or replaced.
Service Information

General repair 561 Service Information 2014/6/26
instructions, compressor
Profile:
General repair instructions, compressor

Repair is required in case of reduced capacity, too high sound level or too high oil consumption.
Substantial carbon deposits in the cylinder head can be removed through careful scraping.
If carbon deposits appear around the pressure disc, the complete disc valve should be removed, as dismantling is not
allowed.
Figure 1
Air compressor, sectional view
The item numbers refer to [Invalid linktarget] .
Tightening torque:
Cylinder head (item 45) 31 N m (23 lbf ft)
Cylinder foot (item 25) 23 N m (17 lbf ft).

Figure 2
Air compressor, exploded view
1 Crankshaft 25 Nut M8 4 pcs

2 •O-ring 26 •Gasket
3 Bearing bushing 27 •Gasket
4 End flange 28 Suction disc
5 Nut 29 Disc valve
6 •Cylinder bolt M8x45, 4 pcs, micro-capsuled 30 •Seal ring
7 •Spring ring 31 Lock screw
8 Nut 32 Type plate
9 •Shaft seal ring 33 Groove rivet, 2 pcs
10 •Bolt M8x20 4 pcs, micro-capsuled 34 Pump bracket
11 Bearing cap 35 Cylinder bolt
12 Connecting rod 36 Drive flange
13 Oil groove ring 37 Bearing bushing
14 Piston 38 Cover
15 •Stop ring 39 Bolt M8x20, 4 pcs
16 Piston ring 40 •Gasket
17 Piston ring 41 •Gasket
18 Piston ring 42 Cylinder head
19 Piston pin 43 Lock screw M14x1.5 or M22x1.5
20 Crankcase 44 •Seal ring
21 Screw stud 45 •Bolt M8x80, 4 pcs
22 Gasket 46 •Seal ring
23 Cylinder 47 •Lock screw M26x1.5
24 •Spring ring 48 •Flange head bolt
1) Position and quantity depend on type
2) Not installed on all types
Parts, which are marked with a dot ”•” must not be re-used after dismantling. When assembling, new parts must be
used.
Service Information

Pressure regulator 561 Service Information 2014/6/26
Profile:
Pressure regulator
System without pressure, pressure build-up
Air supplied from the compressor enters at (1), passes unloading valve (7), past non-return valve (28) and out into the
system through outlet (2), see [Invalid linktarget] .
Figure 1
Pressure regulator
1 Inlet
2 Exhaust
3 Air bleeding
4 Silencer housing
5 Insert
6 Spring
7 Unloading valve with pin 17
8 Washer
9 O-ring
10 Spacer ring
11 O-ring
12 Spacer ring
13 O-ring
14 O-ring
15 Seal ring
16 Control piston
17 Pin with air ducts
18 Lock nut
19 Adjusting screw
20 Spring disc
21 Spring
22 Spring guide
23 Cover
24 Diaphragm
25 Lock ring
26 Duct
27 Spring
28 Non-return valve
29 Housing
30 Lock ring
31 Strainer
Unloading
The system is connected to control piston (16) via air duct (26). When the pressure in the system reaches 790–830 kPa (7.9–
8.3 bar) (115–120 psi), the control piston is moved against spring (21). This opens the air ducts in pin (17) and the air can
pass into the space above unloading valve (7). Unloading valve (7) is pressed against spring (6) and the air is unloaded out
through silencer housing (4) and out through air vent (3). Non-return valve (28) closes.
Pressure build-up, pressurised system
If the pressure drops to 750–790 kPa (7.5–7.9 bar) (109–115 psi), the pressure behind control piston (16) also drops. This
piston then closes the air duct in pin (17) with the aid of spring (21).
The air behind unloading valve (7) is drained out through the air duct in pin (17), above seal ring (15) between pin (17) and
control piston (16) and out into cover (23), past diaphragm (24) and out into the atmosphere.
Spring (6) presses back unloading valve (7) and closes the unloading. Thus a new pressure build-up is initiated. The pressure
regulator is designed so that, if the control piston does not open, the pressure directly actuates the unloading valve and
opens the same at approx. 1.2 MPa (12 bar) (174 psi).
Air-hydraulic brake cylinder
Figure 2
Air-hydraulic brake cylinder
11 Bleeder nipple
15 Hydraulic master cylinder
21 Air cylinder
Service Information

4-way pressure retaining 562 Service Information 2014/6/26
valve
Profile:
4-way pressure retaining valve

The purpose of the 4-way pressure retaining valve is to divide the system into circuits. In case of a leak in either of the
circuits its purpose is also to shut off the air supply to the leaking circuit and still allow the circuits, which are not leaking, to
be supplied with air from the compressor. The intact circuits therefore remain operational.
Opening pressure, all circuits 620–650 kPa (6.2–6.5 bar) (90–94 psi).
Figure 1
4-way pressure retaining valve
A Overflow valve, circuit 2 (tractor unit) 3 Housing

B Overflow valve, circuit 1 (trailer unit) 4 Spring
C Overflow valve, circuit 3 (parking brake) 5 Valve
D Overflow valve, circuit 4 (differential locks) 7 Diaphragm
E Non-return valves 8 Spring guide
F Inlet, connection 1 9 Cover
G Outlet, circuit 1 (trailer unit brakes) connection 21 10 Spring for overflow valve
H Outlet, circuit 3 (parking brake) connection 23 11 Spring guide
I Outlet, circuit 4 (differential lock, other equip.) connection 24 12 Adjusting screw
J Outlet, circuit 2 (engine unit brakes) connection 22 13 Rubber plug
14 Washer
1 Spring for non-return valve 15 Lock ring
2 Non-return valve 16 Rubber ring
Service Information

Safety valve, 562 Service Information 2014/6/26
wet reservoir
Profile:
Safety valve, wet reservoir

To protect the system against too high pressure there is a safety valve installed on the wet air reservoir. The valve consists of
a spring loaded ball which opens if the air pressure exceeds the spring pressure. The spring pressure can be adjusted with
the aid of the adjusting cap.
Safety valve, opening pressure 930 kPa (9.3 bar) (135 psi).
Figure 1
Safety valve, wet reservoir
1. Housing
2. Poppet valve
3. Compression spring
4. Lock nut
5. Adjusting cap
Service Information

Compressed-air 590 Service Information 2014/6/26
system, item list (serial No.
<emph>–2900</emph>)
Profile:
Compressed-air system, item list (serial No.

A. Tractor unit
B. Trailer unit
Feed circuit
1 Air filter
2 Anti-freeze reservoir
3 Adjusting screw for anti-freeze reservoir (metering screw)
4 Compressor
5 Pressure regulator (on 6 litre air reservoir, at back of tractor unit)
6 Air reservoir 6 litres (wet reservoir, positioned on the right behind the cab)
7 Draining valve
8 Safety valve
9 4-way pressure retaining valve
Circuit 2
7 Draining valve
10 Air reservoir 30 litres (on the right behind the cab)
11 Pressure gauge IM30, with built-in low-pressure sensors for circuits 1 and 2
12 Foot brake valve, circuits 1 and 2
13 Stop light switch SE30, circuit 2
14 Outlet for pressure checking (on air connection for brake unit)
15 Stroke indicator SE50 (on brake unit)
16 Air-hydraulic brake unit
17 Brake caliper
Circuit 1
7 Draining valve
8 Safety valve
12 Foot brake valve, circuits 1 and 2
17 Brake caliper
18 Stop light switch SE29, circuit 1 (on foot brake valve)
19 Relay valve, foot brake
20 Pressure outlet for tyre inflation (on transitional plate at the front on trailer unit frame), SE20 (mechanical)
21 Air reservoir, 30 litres (1 ft3 )
Circuit 3
22 Parking brake valve (hand control)
23 Pressure sensor SE6, control lamp, parking brake (on parking brake valve)
24 Valve block containing change-over valve and relay valve for all differential locks (on cab floor under right control
panel)
25 Pressure sensor SE107, gear-shift inhibitor at applied parking brake
26 Diaphragm cylinder, longitudinal differential lock
27 Sensor SE20 (mechanical), control lamp, longitudinal differential lock
28 Pressure outlet, unloading parking brake (on transitional plate at the front on trailer unit frame)
29 Spring brake cylinder for parking brake
Circuit 4
24 Valve block containing change-over valve and relay valve for all differential locks (on cab floor under right control
panel)
31 Foot control, retarder (with built-in pressure regulator 7.5 bar (109 psi))
32 Pressure sensor SE56, retarder (under engine hood, in front of cab)
33 Pressure sensor SE104, stop lights retarder (on MA8)
34 Solenoid valve MA8, retarder (under engine hood, in front of cab)
35 Checking point, retarder (on MA8)
36 Retarder valve and retarder (right side on transmission)
37 Horn SA2
38 Solenoid valve MA49, exhaust retarder (under engine hood, in front of cab)
39 Cylinder for exhaust retarder (optional)
40 Valve (hand control) differential lock, front axle
41 Diaphragm cylinder, engagement of differential lock, front axle
42 Pressure sensor SE18, control lamp, engagement, differential lock, front axle (on valve block 24)
43 Pressure sensor SE19, control lamp, engagement of all differential locks and 6-wheel drive (6x6) (on valve block 24)
44 Valve (foot control), 6-wheel drive (6x6), all differential locks
45 Valve (hand control), longitudinal differential lock and 6-wheel drive (6x6)
46 Diaphragm cylinder, engagement of 6-wheel drive (6x6)
47 Diaphragm cylinder, engagement of differential locks on rear axles
Service Information

Compressed-air system, 590 Service Information 2014/6/26
item list <br />(serial No.
<emph>2901–, US 60001</
emph>–)
Profile:
Compressed-air system, item list

A. Tractor unit
B. Trailer unit
Feed circuit
1 Air filter
2 Anti-freeze reservoir
3 Adjusting screw for anti-freeze reservoir (metering screw)
4 Compressor
5 Pressure regulator (on 6 litre air reservoir, at back of tractor unit)
6 Air reservoir 6 litres (wet reservoir, positioned on the right behind the cab)
7 Draining valve
8 Safety valve
9 4-way pressure retaining valve
Circuit 2
7 Draining valve
10 Air reservoir 45 litres (on the right behind the cab)
12 Foot brake valve, circuits 1 and 2. with built-in sensor for retarder engagement, SE100
13 Stop light switch SE30, circuit 2
17 Brake caliper
Circuit 1
7 Draining valve
8 Safety valve
12 Foot brake valve, circuits 1 and 2. with built-in sensor for retarder engagement, SE100
17 Brake caliper
18 Stop light switch SE29, circuit 1 (on foot brake valve)
19 Relay valve, foot brake
20 Pressure outlet for tyre inflation (on transitional plate at the front on trailer unit frame)
21 Air reservoir, 45 litres (1.6 ft3 )
Circuit 3
22 Parking brake valve (hand control)
23 Pressure sensor SE6, control lamp, parking brake (on parking brake valve)
24 Pressure sensor SE107, gear-shift inhibitor at applied parking brake
25 Pressure sensor SE116, load and dump brake at applied parking brake
26 Solenoid valve MA11, engagement of longitudinal differential lock
27 Diaphragm cylinder, longitudinal differential lock
28 Sensor SE20 (mechanical), control lamp, longitudinal differential lock
29 Pressure outlet, unloading parking brake (on transitional plate at the front on trailer unit frame)
29 Spring brake cylinder for parking brake
Circuit 4
31 Pressure-reducing valve for retarder circuit (under engine hood, in front of cab)
32 Foot control, retarder
33 Solenoid valve MA151, automatic retarder
34 Shuttle valve, retarder
35 Pressure sensor SE56, retarder (under engine hood, in front of cab)
36 Solenoid valve MA8, retarder (under engine hood, in front of cab)
37 Pressure sensor SE104, stop lights retarder (on MA8)
38 Checking point, retarder (on MA8)
39 Retarder valve and retarder (right side on transmission)
40 Horn SA2
41 Solenoid valve MA49, exhaust retarder (under engine hood, in front of cab)
42 Cylinder for exhaust retarder (optional)
43 Solenoid valve MA9, engagement of transverse differential lock, front axle
44 Diaphragm cylinder, differential lock, front axle
45 Solenoid valve MA156, for load and dump brake (optional equipment)
46 Shuttle valve for load and dump brake
47 Solenoid valve for MA12, for engagement of 6-wheel drive
48 Diaphragm cylinder, engagement of 6-wheel drive
49 Solenoid valve MA10, for engagement of differential locks on rear axles
50 Diaphragm cylinder, engagement of differential locks on rear axles
51 Diaphragm cylinder, for engagement of differential locks on rear axles
52 Pressure-reducing valve, air-suspended seat
53 Air-suspended seat
Thank you for your purchase.
Have a nice day.
file:///C|/Users/app/Documents/yeqiwen-END.txt[2014/6/26 14:30:45]

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Service Information

Document Title: Function Group: Information Type: Date:

Document Title: Function Group: Information Type: Date:

Brake disc for service brakes, checking

Torque wrench 0–200 N m (148 lbf ft)

3. Check the brake disc wear. See [Invalid linktarget] .

Min. thickness of service brake discs is 13 mm (0.51 in).

4. Bolt on the brake guard with the two bolts.

Document Title: Function Group: Information Type: Date:

Brake pads for service brakes

Torque wrench 0–200 N m (148 lbf ft)

Op. number 51001 (checking wear, all axles)

3. Check the wear of the brake pads. See [Invalid linktarget] .

4. Bolt on the brake guard with the two bolts.

Document Title: Function Group: Information Type: Date:

Brake caliper, replacing

11 668 007 Stand jack (or similar equipment)

Wheel handling trolley (or similar equipment)

Op. number 51145 (Front axle)

4. Remove the brake guard.

6. Check the brake disc as regards wear and damage.

7. Install the brake caliper.

9. Bleed the brake caliper according to [Invalid linktarget] .

11. Fit the brake guard.

12. Test the function.

Document Title: Function Group: Information Type: Date:

Brake discs, replacing (one wheel)

11 688 004 Hub nut socket

11 688 007 Stand jack (or similar equipment)

E 1751 Lifting device

E 1752 Lifting yoke

Wheel handling trolley (or similar equipment)

Lifting sling, 2 m (6.5 ft)

Ratchet block, 750 kg (1653 lb)

Op. number 51102 (Front axle)

6. Arrange the lifting device E 1751, see [Invalid linktarget] .

31. Test the function.

Document Title: Function Group: Information Type: Date:

Brake pads, replacing

11 668 007 Stand jack (or similar equipment)

Wheel handling trolley (or similar equipment)

Op. number 51105 (one wheel)

1. Flat bar of mild steel

11. Remove the stand jack.

12. Test the function.

Document Title: Function Group: Information Type: Date:

Brake system, air bleeding

The machine has four air-hydraulic units.

1. Run the engine to build up the pressure in the compressed-air system.

2. Depress the brake pedal.

4. Let up the brake pedal.

Document Title: Function Group: Information Type: Date:

Description (serial No. 2901–, US 60001–)

Document Title: Function Group: Information Type: Date:

Foot brake valve

1 Guide with vent 20 Spring guide

Document Title: Function Group: Information Type: Date:

1 Connection, input control pressure 11 Seal

Document Title: Function Group: Information Type: Date:

Automatic adjusting lever

1 Adjusting screw 7 Gear 13 Housing

Document Title: Function Group: Information Type: Date:

Document Title: Function Group: Information Type: Date:

Parking brake, replacing brake disc