DAF Braking Maintenance Manual

6

ΛΦ45/55 series

STRUCTURE

Structure

TECHNICAL DATA

DIAGNOSTICS

BRAKE DIAGRAMS FOR THE FULLY PNEUMATIC BRAKE SYSTEM

OPERATION OF BRAKE COMPONENTS

BRAKE SYSTEM AND COMPONENTS

BRAKING PERFORMANCE AND BRAKE EQUALISATION

0

1

2

3

4

5

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200436 DW23259602

6

TECHNICAL DATA

ΛΦ45/55 series

0 Technical data

CONTENTS

Page Date

1. BRAKE SYSTEM AND COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200436

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200436

1.2 Tightening torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12 . . . . 200436

1.3 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 . . . . 200436

Contents

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200436 1

TECHNICAL DATA

6

0

Contents

ΛΦ45/55 series

2

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200436

6

TECHNICAL DATA

ΛΦ45/55 series

1. BRAKE SYSTEM AND COMPONENTS

1.1 GENERAL

Coding of components

All components have been provided with number
codes.

Structure of the code
First digit

Often used:

1 Energy supply (pressure)
2 Energy discharge (outgoing command)
3Bleed
4 Control connection (incoming command)

Little used:

0 Suction connection
5Free
6Free
7 Anti-freeze connection
8 Lubricating oil connection
9 Coolant connection

Where one connection performs several
functions, additional 1
These are separated by a hyphen.

st

digits will be allocated.

Brake system and components

0

Second digit

If there are several connections with the same
function, a 2
after the 1

Application example: empty/load relay valve

Meaning:

1 Air compressor energy supply
2 Energy discharge (command) to the next

41 Control connection (incoming)
42 Second control connection (incoming)

COMPRESSOR

Knorr model

Type: LK3839
Version: 1-cylinder, liquid-cooled

nd

digit will be added immediately

st

one.

component

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200436 1-1

TECHNICAL DATA

6

0

Brake system and components

AIR SUPPLY UNIT

Front axle, leaf-sprung

A

D

F

C

1

12

A Air dryer/pressure regulator (unit)
B 4-circuit protection valve (unit)
C Filter/drying grid
D Pressure regulator
E Blow-off valve
F Pneumatic time switch for regeneration
G Heating element
H Pressure relief valve with bypass, circuit 1
J Pressure relief valve with bypass, circuit 2
K Pressure limiting valve, circuit 3
L Pressure relief valve, circuit 3
M Flowback valve, circuit 3
N Pressure relief valve with bypass, circuit 4
P Pressure sensors

E

0

G

6.1

3

6.2

21

B

2123 3 23 25

1

NJK

24

26

22

ΛΦ45/55 series

MH

L

P

P

P

U

U

R600702

6.2

6.3

6.4

6.5

6.6

6.7

Cut-out pressure of pressure regulator 10.0 ≥ 0.2 bar
Cut-in pressure of pressure regulator 1.2 ≥ 0.2 bar under cut-out pressure

Supply pressure in circuit 1, connection 21 max. 10 bar
Supply pressure in circuit 2, connection 22 max. 10 bar
Supply pressure in circuit 3, connection 23 8.5 - 0.4 bar
Supply pressure in circuit 3, connection 25 8.5 - 0.6 bar
Supply pressure in circuit 4, connection 24 max. 10 bar
Supply pressure in circuit 4, connection 26 max. 10 bar
Opening pressure of circuits 1, 2 and 4 8.5 bar
Opening pressure of circuit 3 7.0 bar
Closing pressure of circuits 1, 2 and 4 7 bar
Closing pressure of circuit 3 5.5 bar

Cut-in temperature of heating element 7C
Cut-out temperature of heating element 29C

Circuit 1 activation pressure for flowback function
of circuit 3 < 4.5 bar

1-2

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200436

6

TECHNICAL DATA

ΛΦ45/55 series

Pressure sensor reading, circuits 1 and 2
(connections 6.2 - 6.7 in the diagram above)

FOOT BRAKE VALVE

Ua(V)

5V

4V

3V

2V

1V

0V

Brake system and components

P21

bar

P22

10

9
8
7
6
5
4

3
2
1

0

123456789101112

Pressure difference between circuits 1 and 2 (be­tween 0 and 3 bar) 0.3 ≥ 0.15 bar

P21-P22 = 0,3

21

22

– 0,15

0

12024 6810

P

(bar)

21.22

R600701

bar

C (cm)

R600594

Pressure reduction in circuits 1 and 2 from 10 to
8 bar

Connection 11 circuit 1 supply
Connection 12 circuit 2 supply
Connection 21 circuit 1 braking pressure
Connection 22 circuit 2 braking pressure

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200436 1-3

TECHNICAL DATA

6

0

Brake system and components

LOAD-DEPENDENT CONTROL VALVE,
LEAF SPRING

Characteristic

LOAD-DEPENDENT CONTROL VALVE,
AIR SUSPENSION

Characteristic

0.6

10

9

p2 [bar]

8

7

6

5

4

3

2

1

–0.2

ΛΦ45/55 series

1:1

23 45678 910

10

p4 [bar]

R600704

p41

= 4.65 bar

p42

p41

= 3 bar

p42

p41

= 0.3 bar

p42

R600705

LOW-PRESSURE SWITCH

Cut-out pressure: 5.2 ≥ 0.2 bar

1-4

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200436

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TECHNICAL DATA

ΛΦ45/55 series

RELAY VALVE

Fitted with internal filter and silencer

EMPTY/LOAD RELAY VALVE

10

Brake system and components

9

8

P2 (bar)

7

6

5

4

3

2

1

10 23456789

0

P4 (bar)

R 600363

9

P2(bar)

8

7

6

5

4

3

2

1

0

Maximum reduction ratio 1 : 2.7
Actuating pressure 0.25 bar
Fitted with internal filter and silencer

P

= P

42

41

1:2.7

P

= 0

42

1

2345678910

+

0,1

0,25

P41(bar)

R600330

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200436 1-5

TECHNICAL DATA

6

0

Brake system and components

ABS VALVE

Resistance of magnet coil 15 ≥ 5 ohm at 25C

Electrical connections

1. Bleed magnet coil

2. Earth

3. Aerate magnet coil

21

3

ΛΦ45/55 series

1

2

3

123

ASR solenoid valve

1. Supply

2. Port, two-way valve

3. Bleed

TRAILER VEHICLE CONTROL VALVE

Knorr model

Type: AC 597BA

Advance

Input pressure 3 bar
Output pressure 3.2 bar
(equals 0.2 bar advance = factory setting)

R600370

1

2

3

R600484

1-6

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200436

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TECHNICAL DATA

ΛΦ45/55 series

Advance adjustment

Adjusting screw (Allen type, 6 mm)
Clockwise increases the advance
Anti-clockwise decreases the advance

Knorr model

Type: AC 597C

Advance

Input pressure 3 bar
Output pressure 3.5 bar
(equals 0.5 bar advance = factory setting)

Advance adjustment

Adjusting screw (Allen type, 6 mm)
Clockwise increases the advance
Anti-clockwise decreases the advance

PARKING BRAKE VALVE WITH TRAILER
VEHICLE CONNECTION

Brake system and components

0

Wabco model

Type: 961 723 134 0
Max. output pressure in driving position approx. 8 bar

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200436 1-7

TECHNICAL DATA

6

0

Brake system and components

PARKING BRAKE VALVE WITHOUT TRAILER
VEHICLE CONNECTION

Wabco model

Type: 961 723 036 0
Max. output pressure in driving position approx. 8 bar

ΛΦ45/55 series

BRAKE PADS

A

C

Knorr model

Maximum brake block thickness (C) 30 mm
Maximum lining thickness (E) 2 mm (at the thinnest point)
Minimum brake block thickness (F) 11 mm (at the thinnest point) with 9mm rear plate

thickness (D)

Replacing: all brake pads at the same time for each axle, and

with the specified lining only.

B

ED

F

R600489

1-8

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200436

6

TECHNICAL DATA

ΛΦ45/55 series

Wabco PAN 17 version:

Maximum brake block thickness (C) 26 mm
Maximum lining thickness (E) 2 mm (at the thinnest point)
Minimum brake block thickness (F) 9 mm (at the thinnest point) with 7mm rear plate

thickness (D)

Replacing: all brake pads at the same time for each axle, and

with the specified lining only.

Wabco PAN 19-1+ and PAN 19-2 versions:

Maximum brake block thickness (C) 30 mm
Maximum lining thickness (E) 2 mm (at the thinnest point)
Minimum brake block thickness (F) 11 mm (at the thinnest point) with 9mm rear plate

thickness (D)

Replacing: all brake pads at the same time for each axle, and

with the specified lining only.

BRAKE DISC

Brake system and components

A

C

B

0

R600489

Knorr model

Maximum brake disc thickness (A) 45 mm
Minimum brake disc thickness (B) 37 mm (rejection dimension, disc must be

replaced)

Minimum thickness, turning dimension 40 mm

Note:

If it is established during brake pad replacement
that the brake thickness is less than or equal to
39 mm, the brake disc must also be replaced.

ED

F

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200436 1-9

TECHNICAL DATA

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0

Brake system and components

The following signs of wear are permissible:

A1 Crazy cracking.
B1 Cracks running to the centre up to 1.5 mm

wide and deep, max. 0.75 x friction
surface width (a).

C1 Unevenness in the disc surface up to

1.5 mm.

Not permissible:

D1 Through-going cracks.

Wabco model

PAN 17 version:

Maximum brake disc thickness (A) 34 mm
Minimum brake disc thickness (B) 28 mm (rejection dimension, disc must be

Minimum thickness, turning dimension 30 mm

A

B

1

D

C

1

replaced)

a

ΛΦ45/55 series

1

max. 0,75 x a

max. 1,5 mm

1

R600471

The following signs of wear are permissible:

A1 Crazy cracking.
B1 Cracks running to the centre up to 1.5 mm

wide and deep,
max. 0.75 x friction surface width (a).

C1 Unevenness in the disc surface up to

1.5 mm.

Not permissible:

D1 Through-going cracks.

Brake disc wobble 0.15 mm

A Measuring distance is 35 mm

A

R600508

1-10

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200436

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TECHNICAL DATA

ΛΦ45/55 series

PAN 19-1+ and PAN 19-2 versions:

Maximum brake disc thickness (A) 45 mm
Minimum brake disc thickness (B) 38 mm (rejection dimension, disc must be

replaced)

Minimum thickness, turning dimension 40 mm

The following signs of wear are permissible:

A1 Crazy cracking.
B1 Cracks running to the centre up to 1.5 mm

wide and deep,
max. 0.75 x friction surface width (a).

C1 Unevenness in the disc surface up to

1.5 mm.

Not permissible:

D1 Through-going cracks.

Brake disc wobble 0.15 mm

A Measuring distance is 35 mm

BRAKE CALLIPER
Knorr model

Brake system and components

0

A

R600708

Brake calliper play in axial direction (direction A) 0.6 - 1.0 mm
Brake calliper play on guide bushes ("Y" - "X") max. 2.0 mm
Play between brake calliper carrier and brake

pads ("Y" - "X" direction) 0.3 - 0.9 mm

Wabco model

Play between brake pad/brake disc:
Manually adjustable brake pad/brake disc play

after fitting brake pads: 0.7 mm

Y - X

R600712

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200436 1-11

TECHNICAL DATA

6

0

Brake system and components

1.2 TIGHTENING TORQUES

The tightening torques stated in this section are
different from the standard tightening torques
stated in the overview of the standard tightening
torques. The other threaded connections not
specified must therefore be tightened to the
torque stated in the overview of standard
tightening torques.
When attachment bolts and nuts are replaced, it
is important that - unless stated otherwise - these
bolts and nuts are of exactly the same length and
property class as those removed.

QUICK-RELEASE COUPLING

Parker 20 - 30 Nm

SPRING BRAKE CYLINDER

Attachment nuts 195 Nm
Release bolt 70 Nm
Clamping strip attachment nut 40 Nm

BRAKE CYLINDER

Attachment nuts 195 Nm

ΛΦ45/55 series

BRAKE CALLIPER - BRAKE CARRIER, Knorr
model

Sliding sleeve Allen screws (SB7000) 285 Nm
Sliding sleeve Allen screws (SN7000) 180 Nm + 90
Pressure tool, guide bush bellows 8 Nm
Rubber bearing bush pressure tool (only
SN7000) 8 - 45 Nm

(1) Always use new bolts, provided with locking compound.

New bolts are supplied with locking compound already
applied.

(1)

(1)

1-12

R600744

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200436

6

TECHNICAL DATA

ΛΦ45/55 series

Brake calliper attach­ment bolts, front axle 440 Nm

(1) From production date 2003-37 there is one fitted bolt and

flange bolts are also fitted.
The fitted bolt must be fitted at the position marked by a
small hole.

(2) In the case of versions with Knorr disc brakes, the

attachment of the brake calliper against the stub axle
changed starting from production week 2002-25. Five
bolts are now used instead of six bolts. There is still a hole

th

for the 6
the stub axle.

bolt on the brake carrier, but there is no hole on

Brake calliper attach­ment bolts, rear axle 440 Nm

(1) From production date 2003-37 there is one fitted bolt and

flange bolts are also fitted.

- In the case of the 11.26 rear axle, the fitted bolt must
be fitted at the position marked "X".

- In the case of the 11.32 rear axle, the fitted bolt must
be fitted at the position marked by a small hole.

(1) (2)

(1)

Brake system and components

0

BRAKE CALLIPER - BRAKE CARRIER,
Wabco model

Locking bracket bolt (PAN 17) 20 Nm
Locking bracket bolt (PAN 19-1+ and PAN 19-2) 37 Nm
Guide bush Allen screws (PAN 17) 340 Nm
Guide bush Allen screws (PAN 19-1+ and

PAN 19-2) 300 Nm
Brake calliper attachment bolts against stub axle
or back plate (PAN 17) 213 Nm
Brake calliper attachment bolts against stub axle

or back plate (PAN 19-1+ and PAN 19-2) 470 Nm

X

R600791

©

200436 1-13

TECHNICAL DATA

6

0

Brake system and components

Tightening sequence of brake calliper
attachment bolts, Wabco model

Tightening sequence of brake calliper attachment
bolts:

6 23 1 54

BRAKE DISC

Knorr model

Locking plate attachment bolts 32 Nm

Wabco model

PAN 17 version

Brake disc attachment bolts on front axle 115 ≥ 7 Nm
Brake disc attachment bolts on rear axle 130 Nm

ΛΦ45/55 series

R600520

PAN 19-1+ and PAN 19-2 versions

Brake disc attachment bolts on front axle 210 ≥ 21 Nm
Brake disc attachment bolts on rear axle 193 Nm

1-14

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200436

6

TECHNICAL DATA

ΛΦ45/55 series

Tightening sequence of brake disc on
F36 axle

Tightening sequence of brake disc on
F48 axle

Brake system and components

0

3

9

5

1

11

8

7

12

2

6

10

4

R600732

3

16

13

9

5

1

11

8

15

4

7

12

2

6

10

14

R600731

©

200436 1-15

TECHNICAL DATA

6

0

Brake system and components

1.3 LUBRICANTS

BRAKE CALLIPER, KNORR MODEL

SB7000 version

18

ΛΦ45/55 series

20

21

19

17

1

3

4

6

5

8

10

9

12

7

16

15

14

11

13

2

22

1-16

R600541

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200436

6

TECHNICAL DATA

ΛΦ45/55 series

Renolit HLT2 (white) for parts 6, 7, 8, the
adjusters (not shown), the brake cylinder lever
and the flange surface for attachment of the
brake cylinder 1448907

Syntheso GL EP1 (green), for parts 3, 5 1448908

Brake system and components

0

©

200436 1-17

TECHNICAL DATA

6

0

Brake system and components

SN7000 version

18

ΛΦ45/55 series

20

21

19

5

17

1

6a

6

3

7

4

8

11

10

2

Renolit HLT2 (white) for parts 3, 6, 7, 8, the
adjusters (not shown), the brake cylinder lever
and the flange surface for attachment of the
brake cylinder 1448907

22

16

23

15

14

R600698

BRAKE CALLIPER, WABCO MODEL

Renolit G-BRF 2

1-18

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200436

6

DIAGNOSTICS

ΛΦ45/55 series

1 Diagnostics

CONTENTS

Page Date

1. DISC BRAKE CONSTRUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200436

1.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200436

Contents

1

©

200436 1

DIAGNOSTICS

6

1

Contents

ΛΦ45/55 series

2

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200436

6

DIAGNOSTICS

ΛΦ45/55 series

Disc brake construction

1. DISC BRAKE CONSTRUCTION

1.1 FAULT-FINDING TABLE

SYMPTOM: SQUEALING/NOISE DURING BRAKING

Possible cause Remedy

Worn brake pads Check brake pads and brake disc thickness

Loose parts Check disc brake construction

Wear/damage to hub bearing Check hub bearing play

Wear to internal parts of disc brake construction Check internal parts

Incorrect vehicle combination Check vehicle combination

Incorrect front axle / rear axle brake pressure
balance

SYMPTOM: IRREGULAR BRAKE PAD WEAR

Possible cause Remedy

Check front axle / rear axle balance

1

Fouled/corroded guide bushes Check the guide bushes

Dirt accumulation between moving parts of the disc
brake construction

Moisture and dirt on internal mechanical parts Check and clean the brake calliper seals

Brake pad stuck in the brake calliper Incorrect play
between brake pads and brake carrier

SYMPTOM: VEHICLE PULLS TO ONE SIDE DURING BRAKING

Possible cause Remedy

Difference in tyre pressure Check / correct tyre pressure

Difference in tyre size Check tyres

Different brake cylinder diameters Check brake cylinder diameters

Broken springs in brake cylinders Check brake cylinders

Leaking brake cylinders Check brake cylinders

Fouled brake cylinders Check the brake cylinders for fouling

Excessive stub axle bearing play Check stub axle bearing play

Excessive steering ball joint play Check steering ball joint play

Clean the disc brake construction

Check the play between brake pads and brake
carrier

Excessive shackle pin play Check shackle pin play

Incorrect vehicle combination Check vehicle combination

Incorrect ABS operation Check ABS operation

Brake pad stuck in the brake calliper Incorrect play
between brake pads and brake carrier

©

200436 1-1

Check the play between brake pads and brake
carrier

DIAGNOSTICS

6

1

Disc brake construction

SYMPTOM: POOR BRAKING DECELERATION

Possible cause Remedy

Overload due to excessive loading Check vehicle loading condition

System pressure too low Check pressure regulator setting

Air leakage in the brake system Check the brake system for leakage

Insufficient braking power / poor condition of trailer
vehicle brake system

Pinched brake lines Check / replace brake lines

Brake cylinder stroke too large Check automatic slack adjuster

Frozen brake system Check brake system

Brake components affected by road salt Check the brake components for fouling.

Fouled brake cylinders Check the brake cylinders for fouling

Incorrect brake cylinder diameter Check brake cylinders

Incorrect operation / setting of load sensing valve Check operation / setting of load sensing valve

Incorrect vehicle combination Check vehicle combination

Check trailer vehicle

ΛΦ45/55 series

Incorrect ABS operation Check ABS operation

Brake pad stuck in the brake calliper Incorrect play
between brake pads and brake carrier

SYMPTOM: VIBRATIONS DURING BRAKING

Possible cause Remedy

Incorrect wheel tightening procedure Tighten wheels according to tightening procedure

Non-standard wheels fitted Fit only standard wheels

Overload due to excessive loading Check vehicle loading condition

Incorrect front axle / rear axle brake pressure
balance

Wrong brake pad quality Check brake pads

Dirt/deposits on brake disc Check/clean brake disc

Loose parts Check disc brake construction

Wear/damage to hub bearing Check hub bearing play

Damage to disc brake Check thickness and condition of brake disc

Play in cab suspension Check cab suspension

Check the play between brake pads and brake
carrier

Check front axle / rear axle balance

Incorrect vehicle combination Check vehicle combination

1-2

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200436

6

DIAGNOSTICS

ΛΦ45/55 series

SYMPTOM: LOCKING OF THE BRAKES

Possible cause Remedy

Incorrect setting of load sensing valve Check setting of load sensing valve

Thermal overload of non-locking axle brake pads Check non-locking axle brake pads

Incorrect system pressure due to incorrect
pressure regulator setting

Defective trailer vehicle brake system Check trailer vehicle brake system

Incorrect vehicle combination Check vehicle combination

Incorrect ABS operation Check ABS operation

Tyres have too little tread Check tread

Brake pad stuck in the brake calliper Incorrect play
between brake pads and brake carrier

SYMPTOM: INCREASED BRAKE PAD WEAR

Possible cause Remedy

Check pressure regulator setting

Check the play between brake pads and brake
carrier

Disc brake construction

1

Overload due to excessive loading Check vehicle loading condition

Incorrect setting of load sensing valve Check setting of load sensing valve

Incorrect vehicle combination or front axle/rear
axle balance

Defective trailer vehicle brake system Check trailer vehicle brake system

Air pressure in spring brake cylinders too low
during driving, dragging brakes

Dragging brakes because parking brake is not
released

Dirt under foot brake valve / floor mat too high Check for free movement of foot brake valve

Dirty / blocked brake valve bleeders Check valve bleeders

Brake pad stuck in the brake calliper Incorrect play
between brake pads and brake carrier

Incorrect setting of the trailer vehicle control valve/
trailer vehicle reaction valve

Check vehicle combination or front axle/rear axle
balance

Check air pressure in spring brake cylinders with
the parking brake valve in the driving position

Check release of parking brake

Check the play between brake pads and brake
carrier

Check setting of the trailer vehicle control valve/
trailer vehicle reaction valve

©

200436 1-3

DIAGNOSTICS

6

1

Disc brake construction

SYMPTOM: DRAGGING BRAKES

Possible cause Remedy

Leaking foot brake valve to circuit 1 and/or 2 Check the foot brake valve for leaks

Dirt/deposits in brake calliper of disc brake Check freedom of movement of brake calliper

Brake pads turned back too tightly Check minimum brake pad play

Air pressure in spring brake cylinders too low
during driving

Output supply pressure from trailer vehicle control
valve to trailer/semi-trailer too low

Dirt under foot brake valve / floor mat too high Check for free movement of foot brake valve

Dirty / blocked brake valve bleeders Check valve bleeders

Brake pad stuck in the brake calliper Incorrect play
between brake pads and brake carrier

Check output pressure of the double-check relay
valve
Check four-circuit safety valve for dirt
Check output pressure of the parking brake valve
in the driving position

Check output supply pressure of the trailer vehicle
control valve

Check the play between brake pads and brake
carrier

ΛΦ45/55 series

1-4

©

200436

BRAKE DIAGRAMS FOR THE FULLY PNEUMATIC BRAKE SYSTEM

6

ΛΦ45/55 series

2 Brake diagrams for the fully pneumatic br ake system

CONTENTS

Page Date

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200436

1.1 Brake diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200436

2. BRAKE DIAGRAMS FOR THE FULLY PNEUMATIC BRAKE SYSTEM . . . . . 2-1 . . . . . 200436

2.1 Legend, brake diagrams for the fully pneumatic brake system . . . . . . . . . 2-1 . . . . . 200436

2.2 Brake diagrams for the fully pneumatic brake system . . . . . . . . . . . . . . . . 2-2 . . . . . 200436

Contents

2

©

200436 1

BRAKE DIAGRAMS FOR THE FULLY PNEUMATIC BRAKE SYSTEM

6

2

Contents

ΛΦ45/55 series

2

©

200436