SECTION 33 - BRAKING SYSTEM - CHAPTER 2 1

SECTION 33 - BRAKING SYSTEM

Chapter 2 - Air Trailer Brakes
CONTENTS
Section Description Page

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
Drive belt tension 4 mm (0.16in.) deflection with a force of 40N

System Operating Pressure 8 bar (116 lbf.in2)

Unload (relief) Valve Setting 11 bar (160 lbf.in2)

Low Pressure Warning Switch Operates at,4.5 bar (65 lbf.in2)

Pressure Sender
Pressure (bars) 0 2 6 10

Ohms 10 52 124 184

Maintenance
Drain Reservoir Tanks Daily
Compressor Drive Belt Tension Every 300 hours

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33 000 TIGHTENING TORQUES

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33 000 DESCRIPTION AND OPERATION

60-33-001

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3
Air Brake Electrical System

1. Ignition Switch 8. Dual Line Solenoid Valve Assembly

2. Ignition Relay (Normally Open) 9. Pressure/Sender Switch
3. Relay ‘A' (Normally Closed) 10. Air Brake Extension Harness Connector (C050)
4. Battery 11. Pressure Gauge
5. Electronic Management Unit 12. Instrument Lamp Warning Lamp
6. Feed to Stoplamps 13. Right Hand Brake Pedal Switch
7. Relay G 14. Left Hand Brake Pedal Switch

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Description
Compressor
Unload (relief) Valve
Reservoir Tanks
Brake Pedal Switch
Dual Line Control Valve Solenoid
Dual Line Control Valve
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Fig/Ref Function
1/B Belt driven via the crankshaft. Takes filtered air and
compresses it to supply the two reservoir tanks with
pressurised air. The compressor is lubricated from
the engine lube system.
1/A Controls the operating pressure within the system to
prevent system damage from excess pressure. Also
removes any contamination from the system during
unloading.
1/D & F Provides storage for the compressed air generated
by the compressor.
1/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.
1/G Operated via the brake pedal switch, supplies air
pressure to the dual line control valve to establish the
trailer brake pressure before the tractor brakes
become effective, thereby preventing any delay in
operation.
1/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.
 SECTION 33 - BRAKING SYSTEM - CHAPTER 2
Description
Single Line Control Valve
Pressure Switch/sender Assembly
Pressure Gauge
Couplers
Control Valve Remote Pilot Head
7
Fig/Ref Function
1/C Controls the single line trailer brake system in
conjunction with the dual line control valve and brake
master cylinder pressure.
1/C Connected directly in line with the right hand
reservoir, provides an electrical signal to the cab
pressure gauge. When the pressure drops to 4.5 bar
(65 lbf.in2) or lower the switch closes and completes
the circuit to illuminate the warning lamp on the
instrument cluster.
1/I Electrically operated gauge by a signal received
from the pressure switch/sender assembly.
1/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.
11 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.
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33 000 FAULT FINDING

Description Causes Remedy

Instrument cluster light 1. System pressure below 4.5 bar. 1. Compressor drive belt broken
illuminates when system is
running. 2. Check system for leaks
3. Unload valve failed, stuck open
4. Compressor fault
5. Reservoir drain tap faulty

2. Faulty switch or switch wiring 1. Disconnect wiring to switch. If

light extinguishes replace
switch. If light remains
illuminated check wiring for
short to earth.

Trailer brakes not functioning 1. Air in braking system 1. Bleed brakes

(system air pressure okay)

2. Faulty pilot valve 1. Disconnect supply line to

control valve from pilot valve
assembly. Operate the brakes,
if oil is expelled, pilot valve is
okay. If no oil expelled remove
and inspect pilot valve.

3. Control valve faulty 1. Repair/replace as required

Delay in trailer brake operation
1. Dual line solenoid failed closed
or permanently energised.
1. Disconnect wiring to solenoid. If
brakes operate normally inspect
wiring for short to +12v. If still a
delay in operation after wire
disconnection replace solenoid
assembly.
2. Faulty brake switch

System pressure too high 1. Faulty unload valve 1. Remove valve clean/replace.
(exceeds 11 bar)

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COMPONENT REMOVAL AND INSTALLATION

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 4 4

1. Remove the drive belt (2).

2. Disconnect air inlet hose (6).
3. Disconnect air outlet tube (1).
4. Remove oil feed tube (5).
5. Remove the oil drain tube (4).
6. Remove the four compressor mounting bolts and
lift compressor away from tractor (3).
7. Reassembly is the reversal of removal, noting the
following point:
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 5
of the pulley bracket. Figure .

Unload Valve - Figure

1. Disconnect pressure feed tube from compressor
(1).
2. Disconnect outlet hose to left hand reservoir (2).
3. Remove the two retaining bolts (3) and withdraw
valve from tractor.
4. Reassembly is the reversal of removal.

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Reservoir Tanks - Figure

NOTE: Removal of the wheel will aid removal of the

reservoir tanks, but is not essential.

1. Remove all the tubes and hoses connected to the

tank, noting their location.
2. Loosen the strap retaining nuts and lift out the tank.
3. Reassembly is the reversal of removal.

Dual Line Solenoid - Figure .

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.

Dual Line Control Valve - Figure .

1. Disconnect the handbrake cable connection.
2. Disconnect hydraulic connection from Pilot valve
assembly, cap the end of the tube to prevent
contamination and excessive loss of brake oil.
3. Disconnect all air lines, noting locations for
reassembly.
4. Remove the two retaining bolts and lift the control
valve from the tractor.

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5. Reassembly is the reversal of removal, noting the

following points:-

a) When the tube is reconnected it will be necessary

to bleed the braking system. Bleed each side of
the pilot head assembly, items (1) and (3) Figure ,
first then at the bleed screw located in the control
valve, item (2) Figure .

b) Ensure the handbrake cable is adjusted correctly

after assembly:
Assemble the cable and adjust the cable until the
operating arm just begins to move, then back off
adjuster 1/2 turn to provide some cable slack. 10
Operate handbrake and ensure full travel of the
arm is achieved.

Pilot Head Valve Assembly - Figure

1. Disconnect the two tubes from the braking system
and the outlet tube to the dual line control valve.
Cap the ends of the tubes to prevent dirt ingress.

2. Remove the single retaining bolt (1), Figure and lift

away from the tractor.

3. Reassembly is the reversal of removal, noting the

following point:

a) Bleed the braking system of air as described

previously. 11

Pressure Switch/Sender Assembly - Figure .

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.

12

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Single Line Control Valve - Figure

1. Disconnect the three air lines to the single line

control valve assembly.

2. Remove the valve to support bracket retaining

bolts and lift away from tractor.

13
3. Reassembly is the reversal of removal.

Coupler - Figure

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.

14

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COMPONENT OVERHAUL - COUPLERS - Figure

A B

COUPLERS

Key to Components - Figure

A - Single Line Coupler B - Supply and Control Line Couplers

1. Cover 1. Screw
2. Circlip 2. Guide Piece
3. Bush 3. Spring
4. ‘O' Ring 4. Tube
5. Valve Ring 5. Cover
6. Valve Body 6. Housing
7. ‘O' Ring 7. Spring
8. Spring 8. Cap
9. Housing 9. Valve
10. Washer 10. ‘O' Ring
11. Guide Piece 11. Cap
12. Washer 12. ‘O' Ring
13. Screw 13. Thrust Piece
14. Guide
15. Screw

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COMPONENT OVERHAUL - COMPRESSOR - Figure

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COMPRESSOR

Key to Components - Figure 16

1. Bolt 21. Seal

2. Sealing Ring 22. Washer
3. Bolt 23. Nut
4. Pressure Valve Support 24. Screw
5. Pressure Valve Plate 25. Bearing and Cover Assembly
6. Suction Valve Plate 26. ‘O' Ring
7. Washer 27. Crankshaft
8. Bolt 28. Crankcase
9. Bush 29. Connecting Rod Bearing
10. Alternate End Housing 30. Connecting Rod
11. Screw 31. Piston Assembly
12. Cover 32. Gasket
13. ‘O' Ring 33. Valve Assembly (complete)
14. Sealing Washer 34. Washer
15. Locking Screw 35. Bush
16. Plug 36. Gasket
17. Sealing Ring 37. Plug
18. Cap 38. Washer
19. Bolt 39. Cylinder Head
20. Washer

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COMPONENT OVERHAUL - UNLOADER VALVE - Figure 17

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UNLOADER VALVE

Key to Components - Figure 17

1. Relief Valve 20. Seal

2. Sealing Ring 21. Spring Seat
3. Adjuster Screw 22. Spring
4. Screw 23. Shims
5. Housing 24. Valve
6. ‘O' Ring 25. Seal
7. Adjuster Block 26. ‘O' Ring
8. Seat 27. Tapered Spring
9. Spring 28. Valve
10. Seat 29. Housing
11. ‘C' Clip 30. Sealing Ring
12. Washer 31. Bolt
13. Plate 32. Bush
14. spring Seat 33. Valve
15. Spring 34. Spring
16. Washer 35. Filter
17. Bolt 36. Seal
18. Circlip 37. Adaptor
19. Cover 38. Protective Cap

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 8 bar is indicated.

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COMPONENT OVERHAUL - SINGLE LINE CONTROL VALVE - Figure 18

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SINGLE LINE CONTROL VALVE

Key to Components - Figure 18

1. Cap 15. Valve

2. Lockring 16. ‘O' Ring
3. Diaphragm Disk 17. Lockring
4. Bolt 18. Piston
5. ‘O' Ring 19. ‘O' Ring
6. ‘O' Ring 20. Bolt
7. Valve Tappet 21. ‘O' Ring
8. Housing 22. Support
9. ‘O' Ring 23. Spring Washer
10. Compression Spring 24. Diaphragm
11. Spring Plate 25. Bolt
12. Adjuster Screw 26. Cup Seal
13. Locknut 27. Cover
14. End Cap 28. Spring

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COMPONENT OVERHAUL - DUAL LINE CONTROL VALVE - Figure 19

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DUAL LINE CONTROL VALVE

Key to Components - Figure 19

1. Vent Screw 18. Vent Screw

2. Protective Cap 19. Bolt
3. Bolt 20. Housing
4. Housing 21. Valve with Lockring
5. Lip Seal 22. Sealing Ring
6. ‘O' Ring 23. Bolt
7. Tappet 24. ‘O' Ring
8. ‘O' Ring 25. Valve
9. ‘O' Ring 26. ‘O' Ring
10. Tappet 27. Spring
11. Washer 28. Guide
12. Spring 29. ‘O' Ring
13. Piston 30. Circlip
14. ‘O' Ring 31. Ball
15. Guide Ring 32. Cap
16. ‘O' Ring 33. Bolt
17. Rod

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COMPONENT OVERHAUL - SOLENOID VALVE - Figure 20

SOLENOID VALVE
Key to Components - Figure
1. Housing 6. Spool
2. Sealing Ring 7. ‘O' Ring
3. Cylinder Screw 8. Armature
4. ‘O' Ring 9. ‘O' Ring
5. Flange 10. Knurled Nut

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