Professional Documents
Culture Documents
CONTENT
33 000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
33 000 Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
33 000 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
33 000 SPECIFICATIONS
Air Compressor:
Location Right hand side of engine, above fuel injection pump
Drive Belt driven via crankshaft/water pump
Type Single cylinder air cooled
Speed 3,000 rev/min. Maximum
Lubrication Pressure fed from engine
Bore / Stroke 75mm x 36mm
Displacement 159 cm3
Operating Pressure 18 bar (261 lbf.in2) Maximum
Unload (relief) Valve Setting 11 bar (160 lbf.in2) “Universal” and “German”
10 bar (145 lbf.in2) “Italian”
Low Pressure Warning Switch Operates at, 4.5 bar (65 lbf.in2) “Universal” and “German”
3.5 bar (50 lbf.in2) “Italian”
Pressure Sender
Pressure (bars) 0 2 6 10
Maintenance
Drain Reservoir Tanks Daily
Compressor Drive Belt Tension Every 300 hours
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2 SECTION 33 – BRAKING SYSTEM – CHAPTER 2
42–62 Nm
31–46 lbf. ft
13–17
10–13
73–90
54–66
42–62 20–25
31–46 15–18
90–110
66–81
20–25
42–62
15–18
31–46
60–70
44–52
20–25
20–25 15–18
15–18
22–29
16–21
40–51
9–10 29–38
7–7.5
30–35
22–26
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SECTION 33 – BRAKING SYSTEM – CHAPTER 2 3
1. Universal
A generally accepted air brake providing a dual
line system.
1
2. “German”
An air brake system designed in accordance with
German TUV specifications providing both
single and dual line operation.
2
3. “Italian”
An air brake system designed to meet Italian
legislation and providing dual line operation.
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4 SECTION 33 – BRAKING SYSTEM – CHAPTER 2
4
Air Brake Schematic Diagram
“Universal”
1. Compressor 9. Coupler – Control Line Yellow
2. Unload Valve (8 bar) 10. Coupler – Supply Line Red
3. Silencer 11. Pressure Gauge
4. 10 litre Reservoir 12. Low Pressure Warning Lamp
5. Drain Valve 13. Pressure Sender
6. Dual Line Control Valve 14. Brake Master Cylinder
7. Solenoid Valve 15. Brake Logic Head
8. Pressure Regulator
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SECTION 33 – BRAKING SYSTEM – CHAPTER 2 5
5
Air Brake Schematic Diagram
“German”
1. Compressor 10. Coupler Single Line Black
2. Unload Valve (8 bar) 11. Coupler Dual Line (Control) Yellow
3. Silencer 12. Coupler Dual Line (Supply) Red
4. Reservoir (2 x 10 litres) 13. Pressure Gauge
5. Drain Valve 14. Low Pressure Warning Lamp
6. Single Line Control Valve 15. Pressure Sender Unit
7. Dual Line Control Valve 16. Brake Master Cylinder
8. Solenoid Valve 17. Brake Logic Valve
9. Pressure Regulator
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6 SECTION 33 – BRAKING SYSTEM – CHAPTER 2
6
Air Brake Schematic System
“Italian”
1. Compressor 8. Pressure Regulator
2. Unload Valve (7 bar) 9. Pressure Gauge
3. Silencer 10. Low Pressure Warning Lamp
4. Reservoir (10 litres) 11. Pressure Sender Unit
5. Drain Valve 12. Brake Master Cylinder
6. Dual Line Control Valve 13. Brake Logic Valve
7. Solenoid Valve 14. Dual Coupler
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SECTION 33 – BRAKING SYSTEM – CHAPTER 2 7
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8 SECTION 33 – BRAKING SYSTEM – CHAPTER 2
Compressor B Belt driven via the crankshaft. Takes filtered air and compresses it to
supply the reservoir tank(s) with pressurised air. The compressor is
lubricated from the engine lube system.
Unload (relief) Valve A Controls the operating pressure within the system to prevent system
damage from excess pressure. Also removes any contamination
from the system during unloading.
Reservoir Tanks D&F Provides storage for the compressed air generated by the
compressor.
Brake Pedal Switch H When both brake pedal switches are operated, (both brake pedals
depressed), relay ‘A’ becomes de–energised, this cuts the voltage to
the dual line control valve solenoid.
Dual Line Control Valve G Operated via the brake pedal switch, supplies air pressure to the
Solenoid dual line control valve to establish the trailer brake pressure before
the tractor brakes become effective, thereby preventing any delay in
operation.
Dual Line Control Valve G Provides control of the two line braking system in conjunction with
the hydraulic pressure supplied from the brake master cylinder. A
mechanical connection to the handbrake provides full trailer braking
when the handbrake is applied.
Single Line Control C Controls the single line trailer brake system in conjunction with the
Valve dual line control valve and brake master cylinder pressure.
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SECTION 33 – BRAKING SYSTEM – CHAPTER 2 9
Pressure Gauge I Electrically operated gauge by a signal received from the pressure
switch/sender assembly.
Couplers E Red and yellow couplers for dual line systems. Red is the supply
coupler with full pressure available all the time.
The yellow coupler is the control line. Air pressure at the coupler is
increased as the brake pedal is depressed.
The black coupler is for single line systems. Pressure is available at
the coupler with the brake pedal released, pressure decreases as
the pedal is depressed.
The “Italian” trailer brake uses a dual coupler which has both the
supply and control lines in one coupler.
Brake Logic Valve J Ensures that trailer braking only occurs when both brake pedals are
depressed simultaneously. Hydraulic pressure from both brake
master cylinders act on a ball and plunger arrangement which then
allows pressure oil out to act on the control valve.
Regulating Valve K Provides a means for the operator to “Fine Tune” the pressure
supplied from the solenoid to the control valve dependant upon the
characteristics of the trailers brakes.
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10 SECTION 33 – BRAKING SYSTEM – CHAPTER 2
Instrument cluster light illuminates 1. System pressure below 1. Compressor drive belt broken
when system is running. 4.5/3.5 bar.
2. Check system for leaks
4. Compressor fault
Delay in trailer brake operation 1. Dual line solenoid failed closed 1. Disconnect wiring to solenoid.
or permanently energised. If brakes operate normally
inspect wiring for short to +12v.
If still a delay in operation after
wire disconnection replace
solenoid assembly.
System pressure too high 1. Faulty unload valve 1. Remove valve clean/replace.
(exceeds 11 bar)
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SECTION 33 – BRAKING SYSTEM – CHAPTER 2 11
7
Air Brake Electrical System
1. Ignition Switch 7. Relay G
2. Ignition Relay (Normally Open) 8. Pressure/Sender Switch
3. Relay ’A’ (Normally Closed) 9. Pressure Gauge
4. Battery 10. Instrument Lamp Warning Lamp
5. Electronic Management Unit 11. Right Hand Brake Pedal Switch
6. Feed to Stoplamps 12. Left Hand Brake Pedal Switch
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12 SECTION 33 – BRAKING SYSTEM – CHAPTER 2
Group 33.000
WARNING
Before removing any air system component ensure
that there is no air pressure in the system. This can
be achieved by depressing and releasing the brake
pedal several times with the engine off. Also ensure
that the wheels of the tractor/trailer are chocked.
Compressor – Figure 8
1. Remove the drive belt (2). 6 1
2. Disconnect air inlet hose (5).
3. Disconnect air outlet tube (1).
5
4. Remove the oil drain tube (4).
5. Remove the four compressor mounting bolts and
lift compressor away from tractor (3). 4 2
6. Reassembly is the reversal of removal, noting
the following point:
3
60–33–012 TI
8
a. Adjust the drive belt to provide 4 mm deflection
with a force of 40N at the centre of the belt run
between tensioner and water pump. The belt is
tensioned by moving the pulley (1) within the slot
of the pulley bracket. Figure 9.
60–33–011 TI
9
Unload Valve – Figure 10
1. Disconnect pressure feed tube from compressor
(1).
2. Disconnect outlet hose to the reservoir (2).
3. Remove the two retaining bolts (3) and withdraw
valve from tractor.
4. Reassembly is the reversal of removal.
10
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SECTION 33 – BRAKING SYSTEM – CHAPTER 2 13
60–33–014 TI
11
Dual Line Solenoid – Figure 12.
1. Disconnect the electrical connector.
2. Disconnect the two air lines.
3. Remove the two retaining bolts and lift away from
the tractor.
4. Reassembly is the reversal of removal.
12
Dual Line Control Valve – Figure 13.
1. Disconnect the handbrake cable connection.
2. Disconnect hydraulic brake connection from
Pilot valve assembly, cap the end of the tube to
prevent contamination and excessive loss of
brake oil.
3. Disconnect large diameter air lines, noting
locations for reassembly.
Disconnect dual line control valve solenoid.
Remove the two retaining bolts and lift the control
valve assembly complete with bracket and solenoid
valve from the tractor.
13
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14 SECTION 33 – BRAKING SYSTEM – CHAPTER 2
14
Pressure Switch/Sender Assembly – Figure 15.
1. Disconnect wiring to switch.
2. Remove the switch/sender assembly from the
tee connector into the single line control valve.
3. Reassembly is the reversal of removal.
15
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SECTION 33 – BRAKING SYSTEM – CHAPTER 2 15
16
Coupler – Figure 17
1. Remove the tube from the rear of the coupler
2. Unscrew the coupler assembly from the bracket.
3. Reassembly is the reversal of removal.
60–33–019 TI
17
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16 SECTION 33 – BRAKING SYSTEM – CHAPTER 2
18
2. To install the push-in type air lines the following
should be observed:
• Ensure the seal (1) is correctly seated in the
bottom of the connector fitting.
• Ensure the plastic retaining clip (2) is also
correctly installed in the component
connector fitting.
• Install and tighten the connector fitting (4).
3. Firmly push the pipe connector (3) into the
component connector fitting (4).
WARNING
An air pipe should never be installed as a single item
with the component fitting. The retaining clip may not 19
seat properly and this will lead to pipe disconnection
and air leakage. Always install the fitting, seal and
retaining ring to the component and then install the
pipe into the fitting.
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SECTION 33 – BRAKING SYSTEM – CHAPTER 2 17
A B
20
COUPLERS
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18 SECTION 33 – BRAKING SYSTEM – CHAPTER 2
21
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SECTION 33 – BRAKING SYSTEM – CHAPTER 2 19
COMPRESSOR
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20 SECTION 33 – BRAKING SYSTEM – CHAPTER 2
22
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SECTION 33 – BRAKING SYSTEM – CHAPTER 2 21
UNLOADER VALVE
NOTE: After reassembly of the unloader valve it will be necessary to adjust the pressure at which the valve
unloads. Start at a low setting , i.e, the adjuster screw (3), unscrewed several turns. Observe the
pressure gauge within the cab and gradually increase the pressure, by rotating the adjuster clockwise,
until 7 bar is indicated.
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22 SECTION 33 – BRAKING SYSTEM – CHAPTER 2
23
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SECTION 33 – BRAKING SYSTEM – CHAPTER 2 23
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SECTION 33 – BRAKING SYSTEM – CHAPTER 2 25
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26 SECTION 33 – BRAKING SYSTEM – CHAPTER 2
25
SOLENOID VALVE
Key to Components – Figure 25
1. Knurled Nut 6. Lock Washer
2. ‘O’ Ring 7. Flange
3. Housing 8. Spool
4. ‘O’ Ring 9. ‘O’ Ring
5. Cylinder Screw 10. Armature
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SECTION 33 – BRAKING SYSTEM – CHAPTER 2 27
PRESSURE TESTING
Tractor Preparation
1. Position the tractor on a flat, level surface and in
a suitable location to allow the engine to run
during the testing.
2. Chock the wheels and ensure the parking brake
is in the OFF position.
3. To perform the test it will be necessary to obtain
the correct trailer side couplers for the system, to
couple up to the tractor connectors.
26
Use suitable fittings to connect to each trailer
side coupler a 0–10 bar, undamped (100mm),
pressure gauge. Connect the appropriately
coloured couplers to the corresponding tractor
coupler.
1. “Italian” trailer brake
2. “German”/”Universal” trailer brake
27
Pre-Test Procedure
NOTE: For all pressure testing illustrations the
gauges represent the following coupler colours:
A = Dual line control (Yellow)
B = Single line supply (Black
C = Dual line supply (Red)
D = Cab Gauge
1. Switch tractor ignition on.
2. All test gauges, including vehicle gauge located
on the left hand ’B’ pillar, must read zero pressure
(drain tanks if required).
NOTE: Tractor ’B’ pillar gauge reads line pressure
which is the same as that shown on the red line
28
coupler gauge.
3. Low pressure warning indicator for the air brake
system must be illuminated on the instrument
cluster. Warning light located in top right hand
corner of the instrument cluster.
NOTE: All figures in ( ) refer to the Italian trailer brake
pressures, where they differ.
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28 SECTION 33 – BRAKING SYSTEM – CHAPTER 2
30
4. Apply tractor parking brake
The gauges must now read the following values:
Gauges Pressure
(Bar)
Dual Line Control (Yellow)(A) 7.5 – 8.5
(6.5 – 7.5)
Single Line Supply (Black) (B) 0
Dual Line Supply (Red) (C) 7.5 – 8.5
(6.5 – 7.5)
Cab (D) 8.0 (7.0)
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SECTION 33 – BRAKING SYSTEM – CHAPTER 2 29
32
3. Adjust cable (by tightening the bottom nut first on
the cable assembly) until needle on yellow gauge
(A) just starts to move, lock up top nut.
4. Check operation of handbrake.
Handbrake On = 8 (7) bar yellow
Handbrake Off = 0 bar yellow
33
Leak Test
1. Engine off – tractor parking brake applied.
2. No deterioration of the red line pressure (8 (7)
bar) must occur over a 10 minute period.
Indication of any leakage must be investigated,
the defect rectified and the test repeated.
34
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30 SECTION 33 – BRAKING SYSTEM – CHAPTER 2
35
3. Release brake pedal link pin so that pedals will
work individually.
4. Apply left hand and right hand brake pedals
individually. No change in pressure readings on
test gauges must occur.
36
5. Reconnect brake pedal link pin, apply brake
pedals fully several operations until red system
pressure below 7 (6) bar – vehicle compressor
will come back on load – allow system to reach
full pressure 8 (7) bar (loud ’pop’ will be heard as
unload valve opens). Gently apply pressure to
linked pedals until both brake light switches have
just clicked on, brake lights on and 4WD indicator
on dash is illuminated. The gauges will now
record the following values:
38
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SECTION 33 – BRAKING SYSTEM – CHAPTER 2 31
39
Pressure Regulator ON/OFF Test Procedure
1. Set engine at idle revs.
2. Do NOT apply tractor parking brake.
3. With the system fully pressurised 8 (7) bar,
depress the brake pedals several times until the
pressure drops below 7 (6) bar on Red system
gauge (C) and gauge in cab.
40
4. The unload valve, located on the RHS of the
engine must recharge the system to 8 (7) bar.
5. In cases where an unload valve is found to be
faulty, a new unload valve must be fitted and the
test repeated.
41
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