”This document provides data, characteristics, instructions and
methodology to perform repair interventions on the vehicle
and its components.
Anyhow, this document is addressed to qualified and
specialised personnel. Iveco commercial and assistance
network personnel as well as all Iveco authorised points of
assistance are specifically qualified and equipped to perform
the repair interventions that are indicated in this document.
Before performing any intervention, check to have available
the document relating to the vehicle model on which the
intervention is being performed and also make sure that all
accident prevention devices, such as, as a rough guide, goggles,
helmet, gloves, shoes, as well as work tooling, lifting and
transport tooling, etc., are available and efficient, and further
make sure that the vehicle is put such a way that an
intervention can be made in safety conditions.
Making interventions strictly observing the indications given
here, as well as using specific tooling indicated, assures a
correct repair intervention, execution timing observance and
operators’ safety.
Each repair intervention must be finalised to the recovery of
functionality, efficiency and safety conditions that are provided
by Iveco.
Each intervention, on the vehicle, that is finalised to a
modification, alteration or else, which is not authorised by
Iveco, involves the exclusion of any responsibility for Iveco,
and, in particular, where the vehicle is covered by a guarantee,
each such intervention involves an immediate lapse of the
guarantee.
Responsibility for Iveco in repair intervention execution is
excluded.
Iveco is available to provide all clarifications necessary to make
interventions, as well as to provide indications in cases and
situations not included in this document.
Data and information contained in this document could result
not to be updated owing to modifications made by Iveco at
any moment for technical or commercial reasons, or because
of the need to adapt the vehicle to law requirements in
different countries.
Inthecaseofadifferencebetweenwhatcontainedhereand
what actually found on the vehicle, please contact Iveco
network before making any intervention.”
The data contained in this publication might fail to reflect the
latest changes which the Manufacturer may introduce at any
time, for technical o r sales purposes, or to meet the
requirements of local legislation.
Copy, even partial, of text and drawings is forbidden.
Publication Edited by:
IVECO S.p.A.
Customer Service
Lungo Stura Lazio , 15
10156 Torino - Italia
- Tractor and trailer compatibility at any time24..
- Complete fault-diagnosis structures24........
Print 603.93.321Base - May 2004
2
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
S
TRALIS AT/AD/AS
OPERATING LOGIC25.......................
BRAKE SYSTEM25...........................
AUXILIARY BRAKE INTEGRATION27...........
- ESP (Electron ic Stability Program)28.........
“ABS-EBL” SYSTEM (ANTI-LOCK BRAKE SYSTEM —
ELECTRONIC BRAKE LIMITER)28............
- “ABS” (Anti-Lock Brake System)28..........
- EBL (Electron ic Brakes Limiter)29............
- Operating Logic29.......................
- Braking system evolution29................
BRAKING SYSTEMS30........................
Page
Page
- EBS 2 working diagram for 6x2 vehicles (trucks)
with CURSOR 10/13 engine41.............
- EBS 2 working diagram for 6x2 vehicles (trucks)
with CURSOR 10/13 engine42.............
- EBS 2 working diagram for 6x2 vehicles (trucks)
with CURSOR 10/13 engine43.............
- EBS 2 system components location on vehicle
(tractors variant)44.......................
- ABS-EBL system components location
(tractors variant)45.......................
DESCRIPTION46............................
- Service braking46........................
- Emergency braking46.....................
- Exhaust brake46.........................
- Parking brake46.........................
- ABS-EBL working diagram for 4x2 vehicles
(trucks and tractors, not inclu ding HR)
with CURSOR 8 (F2B) engine30............
- Working diagram for 6x2 vehicles (tractors)
with CURSOR 8 (F2B) engine31............
- ABS-EBL working diagram for 6x2 vehicles
(tractors) with CURSOR 8 (F2B) engine32....
- Working diagram for 6x2 vehicles (trucks) with
CURSOR 8 (F2B) engine and with CURSOR 10
engine (F3A with mechanical suspensions)33...
- ABS-EBL w orking diagram for 6x2 vehicles (trucks)
with CURSOR 8 (F2B) engine and w ith CURSOR 10
engine (F3A with mechanical suspensions)34...
- ABS-EBL workin g diagram for stand alone 4x2
vehicles (trucks) with CURSOR 8 (F2B) engine35
- ABS-EBL working diagram for 6x2C vehicles
(trucks) with CURSOR 8 (F2B) engine36......
- ABS-EBL workin g diagram for stand alone 6x2
vehicles (trucks) with CURSOR 8 (F2B) engine37
- EBS 2 working diagram for 4x2 vehicles (tractors)
with CURSOR 10/13 engine38.............
BRAKES46.................................
- Front an d rear disk brakes
(KNORR SN7 type)46....................
FAULT DIAGNOSIS47.......................
- Diagnosis Instruments47...................
- Cluster Diagnosis48......................
- EBS 2 theoretical scheme63................
TIGHTENING TORQUES68...................
TOOLS70.................................
SPECIFICATIONS AND DATA -
PNEUMATIC SYSTEM77....................
SPECIFICATIONS AND DATA - BRAKES82......
CHECKS ON MAIN COMPONENTS
OF BRAKE SYSTEM83......................
MAIN COMPONENTS OF THE BRAKING
SYSTEM85...............................
- Compressor85..........................
- EBS 2 working diagram for 4x2 T/FP-CT vehicles
- Head locking screw tigh tn ess85.............
(tractors) with CURSOR 10/13 engine39.....
- Fault diagnosis86.........................
- EBS 2 working diagram for 6x2 vehicles (tractors)
with CURSOR 10/13 engine40.............
Base - May 2004Print 603.93.321
- A.P.U. (Air Processing Unit)86..............
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
3
OPERATION88.............................
- Duplex control valve (vehicles without EBS)92.
- Fault Diagnosis (vehicles without EBS)92......
- CBU (Central Brake Unit)
(vehicles with EBS 2)93...................
- Relay valve (vehicles without EBS)95.........
- Fault Diagnosis (vehicles without EBS)95......
- Coupling heads95........................
- Electropneumatic modulator
(vehicles with EBS 2)96...................
- Operation98............................
- Redundancy valve (for 4x2 and 6x2 trucks)99..
- ABS solenoid valve99.....................
- Dual stop valve99........................
- Triple servo control valve
(vehicles without EBS)99..................
- Predominance control100..................
- Fault Diagnosis100........................
- Trailer drive servo-assisted distributor
(vehicles with EBS 2)101...................
Page
Page
- Speed sensor107.........................
- Phonic wheels107.........................
- Electronic control unit107..................
- Pressure sensor107........................
- Diaphragm brake cylinder (for fron t and
added front axle disc brake)108..............
- Combined brake cylinder
(for front and rear disc brake)108............
- Combined cylinder emergency brake
release device109.........................
- Repairs109..............................
- Fault Diagnosis109........................
DISC BRAKES KNORR TYPE (CALIPER SN7)110...
- Operation111............................
CHECKS111.................................
- Checking the automatic play recovery sy stem
efficiency111.............................
- Brake caliper components112...............
- Check of braking seals thickness113...........
OVERHAULING FRONT DISC BRAKES114........
- Operation102............................
- Pressure test point valve104.................
- Parking brake hand control valve
(vehicles suited to towing)104...............
- Fault Diagn osis (parking brake control valve)104.
- Parking brake control manual distributor
(standby vehicles)105......................
- Manual control valve to slow down
the trailer (optional extra)105...............
- Fault Diagn osis (parking brake control valve)105.
- Controlled pressure valve106................
- Fault Diagnosis106........................
- Check valve (vehicles suited to towing)106.....
- Low-pressure switch106....................
- Electro-pneumatic valve for ASR107..........
- Replacing brake lin ings114..................
- Removing and refitting brake callipers117.......
- Removal117.............................
- Refitting118..............................
- Removing and refitting wheel hubs118.........
- Removal118.............................
- Refitting119..............................
BRAKE CALIPER OVERHAUL120................
- Disassembly120..........................
- Componentpartcleaningandcheck121.......
- Assembly121............................
OVERHAULING REAR DISC BRAKES123.........
- Replacing brake lin ings123..................
Print 603.93.321Base - May 2004
4
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
S
TRALIS AT/AD/AS
OVERHAULING BRAKE DISCS126...............
TURNING AND GRINDING BRAKE DISCS126.....
Page
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS
(TANKS AND ACCUMULATORS)
DESCRIPTIONSYMBOL
HYDRAULIC FLOW
AIR FLOW
ELECTRICAL LINE
ABLE TO ROTATE
CROSSOVER OF CONNECTED LINES
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
5
PRESSURE TEST POINT
QUICK-CONNECTION COUPLING
COCK
COCK WITH OUTLET
SILENCER
COMPRESSOR
ENERGY SAVING COMPRESSOR
VACUUM PUMP
12
02
02
4
32
HYDRAULIC PUMP
02
HYDRAULIC HAND PUMP
32780
Print 603.93.321Base - May 2004
6
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)
DESCRIPTIONSYMBOL
CONDENSATE SEPARATOR
TRALIS AT/AD/AS
S
FILTER
DEHUMIDIFIER
DEHUMIDIFIER
DEHUMIDIFIER WITH BUILT-IN
REGULATOR
AUTOMATIC CONDENSATE
DRAIN VALVE
CONTROLLED CONDENSATE
DRAIN VALVE
HAND CONDENSATE DRAIN VALVE
CONTROLLED ANTI-ICING UNIT
12
12
4
21
1
22
21
1
22
23
7
12
AUTOMATIC ANTI-ICING UNIT
PRESSURE REGULATOR WITH
INDEPENDENT CIRCUIT
PRESSURE CONTROLLER
PRESSURE CONTROLLER
PRESSURE CONTROLLER
(GOVERNOR)
PRESSURE LIMITING VALVE
12
1
1
1
21
21
23
1
1
2
2
21
22
23
24
3278332782
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)
DESCRIPTIONSYMBOL
7
PROPORTIONAL REDUCING VALVE
MATCHING VALVE
FOUR CIRCUIT PROTECTION VALVE
THREE CIRCUIT PROTECTION
VALVE
TWO CIRCUIT PROTECTION VALVE
NON-RETURN AIR INLET VALVE
LIMITED RETURN AIR INLET VALVE
21
2
2
23
1
1
1
22
24
21
123
22
21
1
22
21
21
SAFETY VALVE
CHECK VALVE
CHECK VALVE
DOUBLE SHUT-OFF VALVE
DIFFERENTIAL DOUBLE SHUT-OFF
VALVE
THROTTLE VALVE WITH QUICK
RETURN
THROTTLE VALVE
21
2
2
1
2
1112
U
MS
12
32783 32784 32785
Print 603.93.321Base - May 2004
8
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)
DESCRIPTIONSYMBOL
TRALIS AT/AD/AS
S
DUMP VALVE
BRAKE CONTROL VALVE
BRAKE CONTROL VALVE
BRAKE CONTROL VALVE
PARKING BRAKE CONTROL VALVE
A
P
21
2111
2212
2111
2111
4
2212
21
2211
PARKING BRAKE CONTROL VALVE
BRAKE VALVE
CONTROL VALVE
CONTROL VALVE
RETARDER CONTROL VALVE
SERVO CONTROL VALVE
R
21
21
21
21
221
2313
4
21
32786
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)
DESCRIPTIONSYMBOL
4241
SERVO CONTROL VALVE
21
4
SERVO CONTROL VALVE FOR
SINGLE LINE
TRAILER BRAKING TRIPLE
CONTROL VALVE
TRAILER BRAKING TRIPLE
CONTROL VALVE WITH BUILT-IN
SERVO SWITCHING
42
4143
42
4143
12
21
21
2211
9
LOAD PROPORTIONING VALVE
DUAL LOAD PROPORTIONING
VALVE
LOAD PROPORTIONING VALVE
WITH BY-PASS
LOAD PROPORTIONING VALVE
WITH BUILT-IN RELAY
LOAD PROPORTIONING VALVE
WITH BUILT-IN RELAY WITH AIR
CONTROL
21
2111
2212
12
21
11
1
2
4
4
1
2
4241
32787
32786
Print 603.93.321Base - May 2004
10
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)
DESCRIPTIONSYMBOL
TRALIS AT/AD/AS
S
LOAD PROPORTIONING VALVE
WITH AIR CONTROL
LOAD PROPORTIONING VALVE
WITH AIR CONTROL
PROPORTIONAL REDUCING VALVE
SLAVED PROPORTIONAL
REDUCING VALVE
STROKE LIMITING VALVE
12
4241
1
2
4
12
4
1
2
2
1
LEVELLING VALVE
LEVELLING VALVE
LEVELLING VALVE WITH BUILT-IN
TRAVEL LIMITER
HAND OPERATED SUSPENSION
RAISING CONTROL VALVE
1
2122
12
1223
11
21
2423
2122
32788
32787
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)
DESCRIPTIONSYMBOL
2
PROPORTIONAL CONTROL VALVE
1
13
HAND OPERATED SUSPENSION
CONTROL VALVE WITH
ELECTRICAL MONITORING
1222
42
41
2111
11
ELECTROPNEUMATIC VALVE
ELECTROPNEUMATIC VALVE
ELECTROPNEUMATIC VALVE
HYDRAULIC MODULATOR FOR ABS
AUGMENTER VALVE
1
3
12
12
21
1
VRHZ2
ABS
22
HZ1VL
HLHR
4
1
2
32788
Print 603.93.321Base - May 2004
12
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
TRALIS AT/AD/AS
S
SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (TANKS AND ACCUMULATORS)
DESCRIPTIONSYMBOL
COMPRESSED AIR TANK
BRAKE FLUID RESERVOIR
AIR SPRING
32789
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS
(CONVERTERS, CYLINDERS AND CALLIPERS)
DESCRIPTIONSYMBOL
VACUUM BRAKE SERVO
VACUUM BRAKE SERVO
DUAL CIRCUIT MASTER CYLINDER
SINGLE CIRCUIT MASTER CYLINDER
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
13
AIR/HYDRAULIC CONVERTER
AIR/HYDRAULIC CONVERTER
HYDRAULIC BRAKE CYLINDER
SLAVE CYLINDER
BRAKE CYLINDER
SPRING CYLINDER
COMBINED BRAKE CYLINDER
FIXED DISC BRAKE CALLIPER
3279132790
Print 603.93.321Base - May 2004
14
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS
(CALLIPERS AND CYLINDERS)
DESCRIPTIONSYMBOL
FLOATING DISC BRAKE CALLIPER
FLOATING DISC BRAKE CALLIPER
WITH PARKING
MECHANICAL FLOATING DISC
BRAKE CALLIPER
SERVO CLUTCH
TRALIS AT/AD/AS
S
SERVO CLUTCH
32791
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS
(SEMI-COUPLINGS AND COUPLING CONNECTORS)
DESCRIPTIONSYMBOL
A
“ISO” SEMI-COUPLING
M
ISO VERSION
A
“ISO” SEMI-COUPLING
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
15
“CUNA” SEMI-COUPLING
“CUNA” SEMI-COUPLING
M
VERSION WITH ISO COUPLINGS
A
B
ITALIAN VERSION
M
A
A
“NATO” SEMI-COUPLING
M
NATO VERSION
32793
32792
Print 603.93.321Base - May 2004
16
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS
(SEMI-COUPLINGS AND COUPLING CONNECTORS)
DESCRIPTIONSYMBOL
4
1
5
23
V
Z
A
SINGLE LINE VERSION
A
M
SEMI-COUPLING
V
Z
A
TRALIS AT/AD/AS
S
SEMI-COUPLING
SEMI-COUPLING
SINGLE LINE VERSION
12
22
4
2
SINGLE LINE VERSION
12
22
4
1
2
SINGLE LINE VERSION
A
M
32793
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS
(INDICATORS AND SWITCHES)
DESCRIPTIONSYMBOL
PRESSURE GAUGE
PRESSURE GAUGE
PRESSURE SENDING UNIT
LAMP
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
17
MECHANICAL SWITCH
PRESSURE SWITCH
LOW PRESSURE SWITCH
AUDIBLE WARNING
SENSOR
32794
Print 603.93.321Base - May 2004
18
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (BRAKES)
DESCRIPTIONSYMBOL
SINGLE CYLINDER HYDRAULIC
BRAKE
TWIN CYLINDER HYDRAULIC BRAKE
DUAL SERVO HYDRAULIC BRAKE
DUAL SERVO HYDRAULIC BRAKE
WITH PARKING BRAKE
TRALIS AT/AD/AS
S
SINGLE CAM OPERATED BRAKE
TWIN DUAL CAM OPERATED BRAKE
32795
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
799512PIPINGS AND FITTINGS
In general
Hydraulic system pipings for industrial vehicles are currently of
two types:
- Flexible ones made of polyamide with single-layered or
double-layered structure and in the following diameters
(∅ 6-8-10-12-16 mm) equipped with spares in meters.
- Rigid metal pipingsin thefollowing diameters
(∅ 4.75-6.35-8-10-12 mm). Pipings from ∅ 4.75 to
∅ 10 mm are supplied as spares in straight 4-5-6 m crop
ends, while those exceeding 10 mm are supplied as spares
already cut, bent and reflanged.
Rigid pipings reflanging
Figure 1
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
Figure 3
31973
Burr piping (1), insert union (2) and place it between small
blocks (3) abutting pin (5). Lock piping (1) with screw (4).
Figure 4
19
A
B
C
RIGID PIPINGS REFLANGING REPRESENTATION
Reflanging type A
Figure 2
31971
31974
Take back pin (4) to its neutral position. Screw screw (1) till
matrix die (2) comes to abut against small blocks (3) thereby
shaping the piping (5) end.
Reflanging type B
Figure 5
31972
Arrange on a press 99386523 (3) small blocks (1) so that the
punched numbers, showing the piping number to be worked,
are facing the matrix die (2). The choice of the matrix die (2)
depends on the diameter of the piping to be reflanged.
Moreover, on every matrix die (2) the diameter of the piping
is punched for which the same one can be used.
Print 603.93.321Base - May 2004
Assemble matrix die (2) on press 99386523 (1).
For the reflanging process comply with what has been stated
above for reflanging type A.
31975
20
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
TRALIS AT/AD/AS
S
Reflanging type C
Figure 6
Key on piping (1) nut (2) and ring (3).
Figure 7
Figure 9
31979
31976
Place piping (1) into tool (3) and operating on lever (2) bend
the piping.
Figure 10
31977
Assemble union (2) and tighten so that ring (3, Figure 6) is
locked on piping (1).
Rigid pipings bending
Figure 8
31978
Assemble tool (1) 99386523 choosing parts (2) and (3)
depending on the diameter of pipings to be bent.
31980
In order to free piping (2) from tool (3), operate on lever (1).
Rigid pipings cutting
Figure 11
31981
Place piping (2) into tool (3) 99386523 and tighten screw (1).
Keeping piping (2) still, rotate tool (3) till the piping is
completely cut.
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
21
After having cut the piping, burr and shape the end as
previously described.
Rotating tool (3) around piping (2), screw (1) is
loosened. In order to completely cut the piping, it is
!
then necessary to tighten screw (1) when it
loosening.
Flexible pipings replacement with traditional
fittings
Strictly comply with the following instructions:
Figure 12
10397
- Use homologated pipes only;
- Check the spare pipe status, on which no cracks, cuts or
nickings must be detected;
- Cut the pipe at 90° with respect to the axis through a
suitable pipe-cutting pliers 99387050 at the necessary
length;
Insert on the pipe in the following order:
- nut (3), pressure ring (2) (its greater thickness must be
facing nut (3) and reinforcement bush (1));
- the bush must be in perfect conditions (it must not have
either distortions or hammering traces).
- Carry out abutment ring reflanging upon assembly on the
vehicle or work bench on a fitting.
- The exerted pressure and the final distance from front
pressure ring edge to reinforcement bush edge must be
those mentioned in the table below.
In case of a bad assembly, never use the pipe after
having extracted bush and abutment ring.
!
Pipe
mm
6x1
Distance between
bush edge and ring
mm (*)
from 1 to 1.5
Assembling
pressure
2
N/mm
0.040
Double-
layered
Single-
8x1
10 x 1.5
12 x 1.6
from 2 to 2.5
from 2 to 2.5
from 2 to 2.5
0.050
0.050
0.060
layered
16 x 2.34
(*) See reference h, Figure 14.
from 3 to 3.5
0.060
Figure 14
Figure 13
10399
1. Reinforcement bush - 2. Pressure ring -
3. Nut - 4. Fitting - 5. Pipe -
10398
REINFORCEMENT BUSH ASSEMBLY
A=CORRECT ASSEMBLY
B=WRONG ASSEMBLY
- Key the reinforcement bush with tool 99372219
guaranteeing the contact between its flange and the pipe
end;
- make sure that the pipe end penetrates into the suitable
rake groove obtained in the flange.
Print 603.93.321Base - May 2004
h. Distance between bush edge and ring edge (see table).
Insert the thereby-prepared piping end into the fitting body till
the reinforcement bush flange rests within the suitable seat:
- For closing the nut on the fitting, initially screw it manually
and then complete the tightening with a suitable box
wrench (complete series 99372221) inserted into the
dynamometric wrench, to be calibrated according to the
required tightening torque.
22
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
TRALIS AT/AD/AS
S
Assembly of piping on vehicle is carried out by taking into
account some important solutions:
- Bendings must comply with minimum radiusses, in order
to avoid throttlings.
Pipings diameter
mm
6x1
8x1
10 x 1.5
12 x 1.6
16 x 2.34
Minimum bending radius
mm
approx. 40
approx. 50
approx. 60
approx. 75
approx. 100
Make sure that pipings are not in contact with sharp
edges or with cutting metallic parts or with heat
!
sources, but that are distant therefrom by a minimum
safety distance of 15 mm.
- Moreover,when crossing chassis longitudinal members or
metallic parts, check that passage holes are coated with
rubber fairlead rings and that these latter ones are in good
conditions;
- Avoid that the pipe slides along cutting edges that would
risk to create nickings;
- Having to fix the piping onto already existing ducts, take
into account the supplementary heat to which it can be
subjected (hydraulic power steering duct): in such case,
the piping must be protected with guards;
- At the end of the connection, verify that the piping,
between keying and securing, is not stretched, but must
be slightly loosened to recover higher temperature
variations, particularly for short lengths;
- Before assembling, accurately clean the pipings by blowing
compressed air in order to guarantee system operation.
Flexible pipings replacement with quick
connection fittings
Rotating fittings
Figure 16
39306
Screw the fitting in the threaded seat provided on the
pneumatic valve and lock it at the tightening torque shown in
the table.
Swinging fittings
Figure 17
39307
Figure 15
- Check that the sealing ring (1) is into its suitable seat;
- screw the fitting till it is felt that the sealing gasket abuts
onto the valve;
- adequately swing the fitting and keeping the swingable
part still, lock the hexagonal nut at the tightening torque
mentioned in the table.
13132
- Protect the pipes in case of grinding or welding
operations on the vehicle; for such purpose, an adhesive
plate is applied in the cabin and shows the precautions to
be observed with utmost care to avoid damages.
Rotating and swinging fittings
FITTINGTIGHTENIG TORQUE (Nm ± 10%)
THREADING
M10x1.0mm
M12x1.5mm
22
24
For better safety and work comfortability, it is
advisable to detach the pipings during such operations.
!
At the end of the assembly, check the perfect seal of all gaskets
(unions, fittings, etc.).
Base - May 2004Print 603.93.321
M14x1.5mm
M16x1.5mm
M22x1.5mm
28
35
40
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
23
Figure 18
33977
- Use homogated pipes only;
- Check the spare pipe status, on which no cracks, cuts or
nicking must be detected;
- Cut the pipe at 90° with a max 15° error with respect to
the axis through the suitable pipe-cutting pliers 99387050
at the necessary length;
Figure 19
Figure 20
39308
- Manually insert pipe (2) into fitting (1), with a force varying
from 30 to 120 N depending on pipe diameter, so that the
notch L
is placed inside the fitting while the notch L2is
1
visible.
Figure 21
A
33976
A = Marking to identify pipe end-of-stroke
- Strongly and indelibly mark with ink two reference
notches on both diametrically-opposed pipe faces for an
angle ≥ 75°, placed at the distances of L
guarantee a correct assembly.
Dimensions L1and L2change depending on the pipe
diameter and must be measured from the longest
!
pipe part (see Figure 18).
D
(mm)
6
L
(mm)
19.8
0
+0.5
L
1
(mm)
17
-0.5
+1
and L2to
1
L
2
(mm)
22
-0.5
+1
33978
In case of disassembling of fittings (1) from pneumatic
components, check the sealing ring (2) status, and if necessary
replace it.
FITTINGSEALING RINGS
THREADINGDIMENSIONS
M 10 x 1.0
M 12 x 1.5
M 14 x 1.5
M 16 x 1.5
M 22 x 1.5
10.1 x 1.6
11.0 x 2.0
-
15.0 x 2.0
-
Every time a piping is detached from a quick
connection fitting, it is necessary to replace the fitting
!
itself. Quick connection fittings are supplied complete
as spares.
8
12
20.5
25
18
22
23
28
Quick connection and threaded fittings, as well as
flexible pipings used with quick connection fittings
!
and flexible pipings used with threaded fittings, are
16
Print 603.93.321Base - May 2004
27.1
24
30
not interchangeable.
24
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
TRALIS AT/AD/AS
S
EBS 2 (ELECTRONIC BRAKE S YSTEM)
The increase in competition in the transport sector has had the effect, among others, of constantly increasing the basic requirements
of braking systems.
The introduction of the EBS electronic brake system is the logical answer to these new needs.
It is an integrated and permanent electronic control system for the brake system of the tractor and trailer.
It supplements the ABS, ASR and EBL functions.
The system is made up of a pneumatic system and an electric system. In the system there is inserted the CBU (central brake unit),
component integrating:
- Duplex distributor, which generates electric and pneumatic signals to increase or decrease pressure in the braking system;
- electronic central unit, which has the task of managing the braking system determining deceleration values as a function of
parameters detected from various components;
- proportional relay valve, which modulates pressure at front axle.
The EBS system dialogues with the control units of the other assemblies:
Engine, Ecas, retarder and gearbox via the CAN line (VDB, Vehicle Data Bus).
EBS Benefits
Lower servicing costs.
The EBS combines many functions. The aim is to cut maintenance costs while maximizing braking safety — that is minimizing brake
lining wear.
An individual control according to the lining wear parameters on both the front and rear axles harmonizes lining wear. Distributing
the load homogeneously between all the brakes of the wheels reduces total consumption. In addition, the frequency of servicing
and changing the linings coincide. The costs of inactivity are drastically reduced.
Depending on the servicing a vehicle needs along with other factors, the owner may be able to make considerable savings. A
comparison of the maintenance costs, for the brake system, of a vehicle with EBS and one with a conventional brake system highlights
significant savings.
Tractor and trailer compatibility at any time
Harmonizing the braking processes of the entire tractor-trailer combination, especially if the combinations are frequently changed,
often with conventional means, is not satisfactory.
An inadequate balance, such as with a trailer whose braking is not sufficiently effective, will cause uneven wear of the brake linings.
The EBS will recognize all the incompatibilities between tractor and trailer, harmonizing braking automatically. When the brakes work
in the best conditions, not only are brake maintenance costs optimized, but safety and comfort are optimum too.
Complete fault-diagnosis structures
The EBS provides the owner of the vehicle with constantly updated information on the state of the brake system and the basic brakes.
This makes it possible to schedule servicing in advance. The EBS monitors all the fundamental components and functions of the brake
system.
Any defect recognized by the system is accurately highlighted. The maintenance specialist can therefore rectify the error at issue.
The high degree of safety ensured by the EBS is due to several factors:
- Lower pressure accumulation and response times for the brakes on the front, rear and trailer axles.
- Better ABS function.
- Tractor/trailer always balanced in every moment.
- Constant monitoring of the service brake system. In the event of reduced brake performance, the EBS will be able to warn the
driver.
- The integrated ASR function permits optimum vehicle stability and drive optimization.
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
OPERATING LOGIC
The purpose of the electronic control unit is to slow down the vehicle as quickly as possible, ensuring its stability and avoiding the
tendency for the wheels to lock.
To achieve this aim, while braking, the electronic control unit will be informed of the:
- required deceleration via the sensors inside the duplex control valve;
- pressures made available via the pressure sensors in the components;
- reaction on slowing down due to the pressures made available via the speed sensor signals.
The continuous monitoring and processing of this information, in relation to the set aim, will cause the modulating valves to activate
appropriately and optimize the braking action accordingly.
25
IN
Required deceleration
Braking pressure
Wheel speed
Graduated release trailer pressure
CONTROL UNIT
AIM
n Slip = 0
BRAKE SYSTEM
In a dynamic situation the effect on the vehicle will be managed in this way:
Figure 22
OUT
FRONT AXLE pressure
REAR AXLE pressure
77208
Ca. Front axle load - Cp. Rear axle load - Cr. Load on fifth wheel - Da. Front axle braking force -
Dp. Rear axle braking force - Dm. Braking force at graduated release - Ds. Semitrailer braking force -
Ffa. Resultant of braking/front axle load - Ffp. Resultant of braking/rear axle load - Ffm. Resultant of braking/load
at graduated release - Ffs. Resultant of braking/semitrailer load - a. Braking angle - Rr. Reaction on the fifth wheel -
Dec. Required deceleration - g. Acceleration due to gravity - z. Braking ratio
Print 603.93.321Base - May 2004
26
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
TRALIS AT/AD/AS
S
Generally, the EBS will tend to apply a braking force in proportion to the load on the axles, that is to maintain the same angle ”α”
for all the axles:
Da
Ca
Dp
=
Cp
=
Ds (Dm)
Cs (Cr)
=
Tag α α =
dec
=z
g
Therefore, such force will be larger as compared to required deceleration.
This, as may be seen, also holds for the semitrailer control.
If the reaction on the fifth wheel ”Rr” is not as expected, the system automatically increases or decreases the predominance at the
graduated release and ”Ffm” accordingly so as to ensure the best compatibility between the tractor and semitrailer in compliance
with current type-approval standards, as may be seen in the following compatibility diagram.
Figure 23
000987t
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
27
AUXILIARY BRAKE INTEGRATION
Commercial vehicles are normally fitted with auxiliary brakes for slowing down without causing wear, such as the exhaust brake and
intarder.
On vehicles equipped with the EBS, these devices can be integrated to ensure the vehicle slows down sooner and more effectively.
The exhaust brake/intarder action percentage is set by the driver with the lever.
The exhaust brake will be applied up to a speed of 1000 rpm, while the action of the retarder will cause the following action depending
on the position of the lever:
Figure 24
Position 0 — disengaged
001685t
Position 1 — E.B. 100%
Position 2 — E.B. 100% + Intarder 25% (20% *)
Position 3 — E.B. 100% + Intarder 50% (40% *)
Position 4 — E.B. 100% + Intarder 75% (60% *)
Position 5 — E.B. 100% + Intarder 100% (80% *)
Position 6 — E.B. 100% + Intarder 100%
These applications, always possible, will be signalled to the driver by the relevant indicator lights coming on.
*Vehicles with mechanic gearbox.
On vehicles without the optional Intarder, the auxiliary brake lever has just three positions: off, E.B. 50%, E.B. 100%.
!
On vehicles fitted with a EuroTronic gearbox, with the auxiliary brake lever on position 6, slowing down will be more
effective with the automatic gear shift down.
Switching the engine off for longer than one minute involving a change in load, tyres or ratios at the rear axle causes the adjustment
data to be lost and so a fresh period of data acquisition will be necessary for the system to be able to reactivate auxiliary brake
integration if no vehicle parameter is changed the integration will be immediately available.
If manually activating the auxiliary brakes, the next time the brake pedal is pressed will implement integration.
On releasing the brake pedal, if the manual action is compatible with the calculated action it will be kept active.
If activating the auxiliary brakes, both manual and integrated, causes the rear axle to slow down too much and a tendency for it to
lock, the EBS control unit, on detecting this situation via the speed sensors, will immediately disengage them or turn on the auxiliary
brake Slip Control.
Print 603.93.321Base - May 2004
28
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
TRALIS AT/AD/AS
S
ESP (Electronic Stability Program)
ESP function, joined to EBS abilities, controls vehicle lateral dynamics.
The main objectives of this function are:
- Improving stability, most of all in both understeering and oversteering conditions
- Reducing braking spaces in change of line conditions on slippery roads
Main central unit input data in order to achieve following objectives, are:
- signal from steering angle sensor (mounted on the steering wheel)
- signals from y aw speed and lateral acceleration sensors (integrated into the ESP module, that is mounted on the chassis and
also contains a part o f ESP software).
In order to avoid control loss, the ESP will automatically activate the brakes of one wheel per axle only trying to take the vehicle
back to correct direction. In this case, the ESP controls towing body skidding angle and slant, as well as the shift between driver’s
request and actual vehicle yaw speed. To the purpose of withstanding vehicle deceleration, the driving torque will be decreased.
In yaw control mode, the ESP very carefully controls driver’s reactions and always tries to provide relevant support.
Note: ESP function is optionally available on tractors only.
Figure 25
89009
1. ESP module - 2. Reference pin for mounting to support bracket.
“ABS-EBL” SYSTEM (ANTI-LOCK BRAKE SYSTEM — ELECTRONIC BRAKE LIMITER)
EBL function controls rear axle wheel “skidding” by comparing it to front axle wheel speed.
On the basis of wheel r.p.m.’s and braking pressure (detected by the sensor upstream from rear axle ABS modulators), the central
unit calculates vehicle speed, rear axle wheel “skidding” and minimum acceleration expected.
“ABS” (Anti-Lock Brake System)
The braking of a m oving vehicle and the according deceleration and stopping distances depend above all on the grip between the
surfaces of the tyres and the road.
With a fully efficient braking system, a further improvement in braking can only be achieved by acting on the friction of the tyres
or on the grade of the road surface.
Even in these optimum conditions, absolute braking safety is anyhow not guaranteed when faced with especially tricky situations,
such as poor grip due to a wet or icy road surface: the driver is forced to moderate use of the brakes in order to avoid partially
locking one or more wheels, with the risk of skidding dangerously.
The function of the ”ABS” is therefore to ensure vehicle stability (in all braking conditions), preventing the wheels from locking
irrespective of the state of the road surface, so as to ensure the available grip is made full use of.
Even in the case of e mergency braking, the system makes it possible to keep direction, that is to turn the steering wheel to avoid
obstacles with no risk of skidding.
In short, the anti-lock brake system (ABS):
- Prevents the wheels locking when the vehicle is braking, no matter what grip is available on the road.
- Shortens stopping distances.
- Provides safety for the driver who can keep the vehicle’s stability and direction.
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
EBL (Electronic Brakes Limiter)
The EBL function checks the rear axle wheel ”slip”, comparing it with the speed of the wheels of the front axle.
The control unit input data are the wheel speed and braking pressure measured by the pressure sensor installed upstream from
the rear axle ABS modulators.
On the basis of these values, the control unit calculates the speed of the vehicle, the vehicle’s deceleration, the rear axle wheel ”slip”
and the minimum deceleration c ontemplated.
The EBL function is activated (the rear ABS modulators maintain the set pressure) when the driver applies an excessive braking
force for the conditions of load on the vehicle, in short when the rear axle slip and vehicle deceleration thresholds are exceeded.
Operating Logic
The purpose of the electronic control unit is to slow down the vehicle as quickly as possible, ensuring its stability and avoiding the
tendency for the wheels to lock.
To achieve this aim, while braking, the electronic control unit will be informed of the:
- braking intensity required by the driver via the rear axle pressure sensor,
- reaction on slowing down due to the pressures made available via the speed sensor signals.
The continuous monitoring and processing of this information, in relation to the set aim, will cause the rear axle modulating valves
to activate appropriately and optimize the braking action accordingly.
29
Figure 26
Braking
action
Braking system evolution
Vehicle
AT/AD/AS - HRcursor 8/10/13EBLDisc/Drum
AT/AD/AS - 6x4cursor 10/13EBLDisc/Drum
FRONT AXLE
braking pressure
REAR AXLE
braking pressure
CONTROL UNIT
AIM
∆ Slip = 0
Braking intensity request
Wheel speed
EngineType of systemType of brakes
IN
AT/AD (no HR)cursor 8EBLDisc/Disc
AT/AD mechanical
suspensions
cursor 10EBLDisc/Disc
AT/AD/AScursor 10EBSDisc/Disc
AScursor 13EBSDisc/Disc
Print 603.93.321Base - May 2004
agr
a
r
a
)
30
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
BRAKING SYSTEMS
ABS-EBLworkingdi
mfor4x2 vehicles(trucksand t
with CURSOR 8 (F2B) engine
Figure 27
ctors, not includingHR
TRALIS AT/AD/AS
S
1. Compressor - 2. Air processing unit - 10.5 bars - 3. Front axle air tank - 20 l. - 4. Parking air tank - 20 l. - 5. Rear axle air tank
- 30 l. - 6. Manual discharge valve - 7. Air test point - 8. Parking manual control valve - 9. Handbrake low pressure switch
turned on — 6.4 bars - 10. Parking control relay valve - 11. Trailer slowing manual control valve - 12. Trailer brake servo control
29. Compressor - A. To air suspensions - B. To services - * Optional.
Base - May 2004Print 603.93.321
88752
agr
a
)
w
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
37
ABS-EBLworkingdi
Figure 32
mforstandalone 6x2 vehicles(trucks
ith CURSOR 8(F2B)engine
88753
1. Compressor - 2. Air processing unit - 10.5 bars - 3. Air tank - 30 l. - 4. Manual discharge valve - 5. Air tank - 20 l. - 6. Air test
point - 7. Parking manual control valve - 8. Handbrake low pressure switch turned on - 9. Parking control relay valve -
control relay valve - 25. Dual stop valve - 26. Controlled pressure valve with no return for ASR — 7 bars - 27. ASR control
solenoid valve - 28. Front axle brake control relay valve - 29. Front axle ABS solenoid valve - 30. Front axle diaphragm brake
cylinder - 31. Front axle phonic wheel - 32. Front axle speed sensor - 33. Front axle disc brake assembly - 34. Front axle parking
brake - 35. Brake light control microswitch - 36. Microswitch for EDC control unit - 37. 14 bar safety valve - 38. On-off valve -
A. To service (TN vehicles) and pneumatic suspensions (Y/P/PS/PT - Y/FP/FS/FT vehicles) system - B. To the service system -
*Optional-J Version with ASR - Y Version without ASR.
Print 603.93.321Base - May 2004
38
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
EBS 2 working diagram for 4x2 vehicles (tractors) with CURSOR 10/13 engine
Figure 33
TRALIS AT/AD/AS
S
88754
1. Compressor - 2. Air processing unit 10.5 bars - 3. Front axle air tank 20 l. - 4. Parking air tank 20 l. - 5. Rear axle
air tank 30 l. - 6. Manual discharge valve - 7. Air test point - 8. Rear axle low pressure switch for ASR - 6.6 bars -
9. Parking system one-way valve - 10. Trailer system low pressure switch - 5.5 bars - 11. Semitrailer half-couplings -
18. CBU - 19. Front axle ABS solenoid valves - 20. Front axle diaphragm brake cylinder - 21. Front axle phonic wheel -
22. Front axle speed sensor - 23. Front axle disc brake assembly - 24. Parking control relay valve - 25. On-off valve -
26. Parking manual control valve - 27. Trailer slowing manual control valve - 28. Handbrake low pressure switch
turned on - 6.6 bars - 29. 14 bar safety valve - 30. Front axle parking brake - A. To the air suspension system -
B. To the service system - * Optional.
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
EBS 2 working diagram for 4x2 T/FP-CT vehicles (tractors) with CURSOR 10/13 engine
Figure 34
39
88755
1. Compressor - 2. Air processing unit 10.5 bars - 3. Front axle air tank 20 l. - 4. Parking air tank 20 l. - 5. Rear axle
air tank 30 l. - 6. Manual discharge valve - 7. Air test point - 8. Rear axle low pressure switch for ASR - 6.6 bars -
9. Parking system one-way valve - 10. Trailer system low pressure switch - 5.5 bars - 11. Semitrailer half-couplings -
electro-pneumatic modulator - 19. CBU - 20. Front axle ABS solenoid valves - 21. Front axle diaphragm brake cylinder -
22. Front axle phonic wheel - 23. Front axle speed sensor - 24. Front axle disc brake assembly - 25. Parking control relay
valve - 26. On-off valve - 27. Parking manual control valve - 28. Trailer slowing manual control valve - 29. Handbrake
low pressure switch turned on - 6.6 bars - 30. 14 bar safety valve - 31. Front axle parking brake - A. To the air suspension
system - B. To the service system - * Optional
Print 603.93.321Base - May 2004
40
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
EBS 2 working diagram for 6x2 vehicles (tractors) with CURSOR 10/13 engine
Figure 35
TRALIS AT/AD/AS
S
88757
1. Compressor - 2. Air processing unit 10.5 bars - 3. Front axle air tank 20 l. - 4. Parking air tank 20 l. - 5. Rear axle air
tank 30 l. + 15 l. - 6. Manual discharge valve - 7. Air test point - 8. Rear axle low pressure switch for ASR - 6.6 bars -
9. Parking system one-way valve - 10. Trailer system low pressure switch - 5.5 bars - 11. Semitrailer half-couplings -
19. Intermediate axle disc brake assembly - 20. Intermediate axle suspension air springs - 21. Intermediate axle load ratio
dual stop valve - 22. Selector - 23. Rear axle braking control electro-pneumatic modulator - 24. CBU - 25. Front axle
ABS solenoid valves - 26. Front axle diaphragm brake cylinder - 27. Front axle disc brake assembly - 28. Front axle
phonic wheel - 29. Front axle speed sensor - 30. Parking control relay valve - 31. On-off valve - 32. Parking manual
control valve - 33. Trailer slowing manual control valve - 34. Handbrake low pressure switch turned on - 6.6 bars -
35. 14 bar safety valve - 36. Front axle parking brake - A. To the air suspension system - B. To the service system -
* Optional.
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
EBS 2 working diagram for 4x2 vehicl es (trucks) with CURSOR 10/13 engine
Figure 36
41
88756
1. Compressor - 2. Air processing unit 10.5 bars - 3. Front axle air tank 20 l. - 4. Parking air tank 20 l. - 5. Rear axle
air tank 30 l. - 6. Manual discharge valve - 7. Air test point - 8. Rear axle low pressure switch for ASR - 6.6 bars -
9. Parking system one-way valve - 10. Trailer system low pressure switch - 5.5 bars - 11. ISO coupling half joints -
electro-pneumatic modulator - 19. CBU - 20. Front axle ABS solenoid valves - 21. Front axle diaphragm brake cylinder -
22. Front axle phonic wheel - 23. Front axle speed sensor - 24. Front axle disc brake assembly - 25. Parking control
relay valve - 26. On-off valve - 27. Parking manual control valve - 28. Trailer slowing manual control valve -
29. Handbrake low pressure switch turned on - 6.6 bars - 30. 14 bar safety valve - 31. Front axle parking brake A. To the air suspension system - B. To the service system - * Optional
Print 603.93.321Base - May 2004
42
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
EBS 2 working diagram for 6x2 vehicl es (trucks) with CURSOR 10/13 engine
Legend
1. Compressor
2. Air processing unit - 10.5 bars
3. Air processing unit - 12.5 bars
4. Front axle air tank - 20 l.
5. Parking air tank - 20 l.
6. Rear axle air tank - 30 l. + 2 0 l.
7. Manual discharge valve
8. Air test point
9. Rear axle low pressure switch for ASR — 6.6 bars
10. Parking system one-way valve
11. Trailer system low pressure switch — 5.5 bars
12. Semitrailer half-couplings
13. Trailer brake servo control valve
14. Rear axle braking redundancy valve
15. Load ratio relay valve for added axle braking
16. Added axle diaphragm brake cylinder
17. Added axle ASR exclusion solenoid valve
18. Added axle suspension air springs
19. Added axle load ratio dual stop valve
20. Rear axle combined cylinder
21. Rear axle disc brake assembly
22. Rear axle phonic wheel
23. Rear axle speed sensor
24. Selector
25. Rear axle brake control electro-pneumatic modulator
26. CBU
27. Front axle ABS solenoid valves
28. Front axle diaphragm brake cylinder
29. Front axle disc brake assembly
30. Front axle phonic wheel
31. Front axle speed sensor
32. Parking control relay valve
33. On-off valve
34. Parking manual control valve
35. Trailer slowing manual control valve
36. Handbrake low pressure switch turned on — 6.6 bars
37. 14 bar safety valve
38. Front axle parking brake
A. To the air suspension system
B. To the service system
*Optional
•For CM vehicles only
TRALIS AT/AD/AS
S
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
EBS 2 working diagram for 6x2 vehicl es (trucks) with CURSOR 10/13 engine
Figure 37
43
88758
Print 603.93.321Base - May 2004
44
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
EBS 2 system components location on vehicle (tractors variant)
Figure 38
TRALIS AT/AD/AS
S
88760
1. CBU (Central Brake Unit) - 2. Hand distributor for parking - 3. Coupling half joints - 4. Air tanks - 5. Axle
electropneumatic modulator - 6. Relay valve for parking - 7. Air tank - 8. Spring brake cylinder - 9. Trailer drive
Pedal-operated, pneumatic, with electric control acting on all
the wheels and on the trailer.
It is composed of two independent sections, one for activating
the braking elements of the front axle, the other for activating
the braking elements of the rear axle.
The division of the air system, if one section breaks down,
permits the other to remain efficient.
Emergency braking
Emergency braking makes it possible to slow down the vehicle
and stop it within a safety distance, even if the braking system
has broken down.
It should be interpreted as a partial service brake that, thanks
to the dual circuit, anyhow acts on one of the two axles.
Exhaust brake
Front and rear disk brakes
(KNORR SN7 type)
For the disc brakes, the discs are keyed onto the wheel hubs and
equipped with ventilation fins that permit lowering the high
temperature generated under the braking action.
The brake linings are fitted with a wear indicator connected to
an indicator light on the dashboard to signal brake lining wear.
The phonic wheels of the ABS device are keyed onto the wheel
hubs.
The ”exhaust brake” function is controlled by the EDC control
unit that, depending on the required braking capacity, governs
this function in combination with the EBS and Intarder systems
(where applicable).
Parking brake
This comprises the pneumatic control of the manual control
valve, a spring cylinder acting on the rear wheel brakes, locking
them (on some versions the parking brake acts on the front
brakes too).
In the event of the supply failing, this system automatically
brakes the vehicle.
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
FAULT DIAGNOSIS
SECTION I
ABS-EBS system troubleshooting can be performed with the Cluster or with the diagnosis instruments Modus, IWT and IT 2000.
Diagnosis with the cluster makes it possible to estimate the situation of faults in the system in advance, while the diagnosis instruments
are essential to perform thorough diagnosis and operate on the single faults correctly.
Each single instrument displays the diagnosis and repair help.
Diagnosis Instruments
MODUS (Maintenance and Diagnostic System)
A computerized fault-diagnosis station dedicated to diagnosing the brake systems, air suspensions, engines and systems controlled
electronically.
The station is equipped with auxiliary functions, such as: programming electronic control units, consulting the spare parts catalogue
and service time schedules.
The vehicle has a 30-pin diagnosis socket to interface with the instrument.
IWT (IVECO Wiring Tester)
The IVECO Wiring Tester expands and integrates MODUS.
This instrument is made by IVECO to improve fault diagnosis of vehicle electric and electronic systems.
The vehicle has a 30-pin diagnosis socket to interface with the instrument; the connection between the instrument and the diagnosis
socket must be made with the cable identified as no. 4.
47
IT 2000 (IVECO Electronic Tester)
This makes it possible to take immediate action on the vehicle, identifying it with the chassis number.
It saves the results of diagnostics actions performed.
It can be used as a portable Personal Computer, too, being fitted for remote diagnosis.
By using MODUS as the mother station it is possible to update and c onfigure the IT 2000.
IT 2000 interfaces with the vehicle via a 30-pin diagnosis socket.
The diagnosis socket is positioned in central panel lower side in the cab (at passenger side).
!
Print 603.93.321Base - May 2004
48
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
Cluster Diagnosis
It is possible to access the fault memory with the ”menu” function key 2 on the steering wheel.
Figure 40
TRALIS AT/AD/AS
S
74375
With the ignition key on MAR (+15), press the ”menu” function key 2; the display will show a dialogue menu containing a list of
the available functions (e.g., Hi-Fi,phone,diagnostics,etc.).
With the yIandIb function keys, select the diagnosis function and confirm the selection with the ”OK” function key 2.
Select the ABS-EBS system with the select/confirm keys 1 and 2.
Select the ABS-EBS system with the select/confirm keys 1 and 2.
The cluster will display the first diagnostics screen.
After selecting the system, EuroTronic is displayed on a red or green background depending on whether there is any trouble.
Figure 41
74388
The diagnosis information shown on the cluster is split up on two screens:
- On the first one, it is possible to consult and scroll through all saved/present trouble.
- On the second one, it is possible to delete the intermittent errors (when you have the relevant password).
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
FIRST SCREEN
Figure 42
The information on the single faults is arranged on four columns with the following content:
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
49
74389
DTC
FMIOCACT
Displays the fault code number Indicates the type of faultFault frequency meterFault active/not active status
Two digits (hexadecimal)Two digits (hexadecimal)Three digits (hexadecimal)One character
(Y=Yes,N=No)
Troubleshooting via DTC-FMI codes described under the relevant section completes the above information. Each pair of DTC-FMI
codes is associated with a description of the fault, the possible system reaction and recommended repairs with the relevant checks.
SECOND SCREEN
Deleting Errors
To select the second screen, press ”page” on the steering wheel.
The fault display is eliminated as follows:
- Press ”+”, on the request to confirm deletion, press OK.
- Enter the required password (see the ENTERING PASSWORD paragraph).
- Press OK to confirm.
Figure 43
74390
Entering the Password
Figure 44
74378a
Select the first number of the password with the y IandIb keys.
Press OK to confirm each number.
Press a to delete the last number selected.
On completing the password, select the key symbol to confirm.
1—Poor or abnormal system charge.
2—Poor or abnormal service braking of the rear axle.
3—Poor or abnormal service braking of the front axle.
4—Poor or abnormal trailer service braking.
5—Poor or no parking braking.
6—Poor or no trailer parking braking.
9—The vehicle skids when braking.
10 —Insufficient trailer retarder braking.
11 —Early wear of the brake linings.
12 —Brake system warning light on.
13 —Parking brake indicator light on with lever in driving
position.
14 —Noisy brakes.
Electric and electronic components diagnosis must be through Modus and IWT.
TRALIS AT/AD/AS
S
1
POOR OR ABNORMAL
SYSTEM CHARGE
Air system pipes leak or burstClose or replace the worn or damaged fittings. Re-
YES
NO
place the burst o r damaged pipes.
Inefficient air compressor operationOverhaul or replace the air compressor.
YES
NO
Inefficient A.P.U. operationOverhaul or replace the A.P.U.
YES
2
POOR OR ABNORMAL SERVICE
BRAKING OF THE REAR AXLE
Air system pipes leak or burstClose or replace the worn or damaged fittings. Replace
YES
the burst or damaged pipes.
(continued)
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
NO
NO
NO
YES
YES
YES
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
51
Overhaul or replace the brake linings.Brake linings worn and/or vitrified
Overhaul the rear brakes.Inefficient operation of the rear brakes
Overhaul or replace the Duplex control valve.Inefficient operation of the Duplex control valve
NO
Inefficient operation of the ABS solenoid valve
NO
Inefficient operation of the electro-pneumatic modulator
of the rear axle (vehicles with EBS)
NO
device
YES
YES
YES
YES
Overhaul or replace the brake cylinders.Inefficient operation of the brake cylinders
- Check the electric wiring.
- Replace the ABS solenoid valve.
- Check the wiring
- Replace the electro-pneumatic modulator
Replace the complete brake calliper.Inefficient operation of the automatic clearance recovery
NO
Inefficient operation of the Duplex control valve with
electric transmitter (vehicles with EBS)
YES
- Check the wiring.
- Replace the Duplex Control Valve with electric
transmitter
(continued)
Print 603.93.321Base - May 2004
52
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
TRALIS AT/AD/AS
S
3
POOR OR ABNORMAL SERVICE
BRAKING OF THE FRONT AXLE
Air system pipes leak or burst
NO
Inefficient operation of the Duplex control valve
NO
YES
YES
YES
Close or replace the worn or damaged fittings. Replace
the burst or damaged pipes.
Overhaul or replace the Duplex control valve.
Overhaul or replace the brake linings.Brake linings worn and/or vitrified
NO
Inefficient operation of the front brakes
YES
NO
Overhaul the front brakes.
Overhaul ore replace the relay valve.Inefficient operation of the relay valve
YES
NO
Inefficient operation of the diaphragm brake cylindersOverhaul or replace the diaphragm brake cylinders.
YES
NO
Inefficient operation of the automatic clearance
recovery device
YES
Replace the complete brake calliper.
(continued)
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
53
Inefficient operation of the ABS solenoid valve
NO
Inefficient operation of the front axle relay valve
(vehicles with EBS)
NO
Inefficient operation of the Duplex control valve with
electric transmitter (vehicles with EBS)
POOR OR ABNORMAL TRAILER
4
SERVICE BRAKING
YES
YES
YES
- Check the electric wiring.
- Replace the ABS solenoid valve.
- Check the wiring
- Replace the front axle relay valve
- Check the wiring.
- Replace the Duplex Control Valve with electric
transmitter (vehicles with EBS)
Air system pipes leak or burst
NO
Inefficient operation of the triple control servo control
valve
NO
NO
Inefficient operation of the A.P.U.
YES
YES
YES
YES
Close or replace the worn or damaged fittings. Replace
the burst or damaged pipes.
Overhaul or replace the triple control servo control
valve.
Overhaul or replace the Duplex control valve.Inefficient operation of the Duplex control valve
Overhaul or replace the A.P.U.
(continued)
Print 603.93.321Base - May 2004
54
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
Brake linings worn and/or vitrifiedOverhaul or replace the brake linings.
YES
NO
Inefficient operation of the trailer brakesOverhaul the trailer brakes.
YES
NO
TRALIS AT/AD/AS
S
Inefficient operation of the electro-pneumatic modulator of the rear axle (vehicles with EBS)
POOR OR NO
5
PARKING BRAKING
Air system pipes leak or burst
NO
Inefficient operation of the combined brake cylinders
YES
YES
YES
- Check the wiring
- Replace the electro-pneumatic modulator
Close or replace the worn or damaged fittings. Replace
the burst or damaged pipes.
Overhaul or replace the combined brake cylinders.
NO
Inefficient operation of the parking brake manual control valve (lever)
NO
YES
Overhaul or replace the lever.
Brake linings worn and/or vitrifiedOverhaul or replace the brake linings.
YES
(continued)
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
Inefficient operation of the relay valveOverhaul or replace the relay valve.
YES
NO
55
Inefficient operation of the rear brakesOverhaul the rear brakes.
YES
POOR OR NO TRAILER
6
PARKING BRAKING
Air system pipes leak or burstClose or replace the worn or damaged fittings. Replace
NO
Inefficient operation of the triple control servo control valve
YES
YES
the burst or damaged pipes.
Overhaul or replace the triple control servo control
valve
NO
Inefficient operation of the parking brake manual control valve (lever)
NO
YES
Overhaul or replace the lever.
Trailer brake linings worn and/or vitrifiedOverhaul or replace the trailer brake linings.
YES
NO
Inefficient operation of the trailer brakes
YES
Overhaul the trailer brakes.
(continued)
Print 603.93.321Base - May 2004
56
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
TRALIS AT/AD/AS
S
Inefficient operation of the trailer control servo control
valve
YES
- Check the electric wiring.
- Replace the trailer control servo control valve.
PARKING BRAKE
7
RELEASE DELAYED
Air system pipes leak or burstClose or replace the worn or damaged fittings. Replace
YES
NO
the burst or damaged pipes.
Inefficient operation of the relay valveOverhaul or replace the relay valve
YES
NO
Inefficient operation of the combined brake cylindersOverhaul or replace the combined brake cylinders.
YES
NO
Inefficient operation of the parking brake manual control valve (lever)
NO
YES
Overhaul or replace the lever.
Inefficient operation of the rear brakesOverhaul the rear brakes.
YES
(continued)
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
TRAILER PARKING BRAKE
8
RELEASE DELAYED
Air system pipes leak or burstClose or replace the worn or damaged fittings. Replace
YES
NO
the burst or damaged pipes.
57
Inefficient operation of the triple control servo control
valve
NO
Inefficient operation of the parking brake manual control valve (lever)
NO
YES
YES
Overhaul or replace the triple control servo control
valve
Overhaul or replace the lever.
Inefficient operation of the trailer brakesOverhaul the trailer brakes.
YES
9
THE VEHICLE SKIDS
WHEN BRAKING
Air system pipes leak or burst
YES
NO
Close or replace the worn or damaged fittings. Replace
the burst or damaged pipes.
Inefficient operation of the Duplex control valveOverhaul or replace the Duplex control valve
YES
(continued)
Print 603.93.321Base - May 2004
58
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
TRALIS AT/AD/AS
S
Inefficient operation of the front brakesOverhaul the front brakes.
NO
Inefficient operation of the rear brakesOverhaul the rear brakes.
NO
YES
YES
Inefficient operation of the triple control servo controlOverhaul or replace the triple control servo control.
YES
10
INSUFFICIENT TRAILER
RETARDER BRAKING
Air system pipes leak or burstClose or replace the worn or damaged fittings. Replace
YES
NO
the burst or damaged pipes.
Inefficient operation of the A.P.U.Overhaul or replace the A.P.U.
YES
NO
Inefficient operation of the triple control servo control
valve
NO
Inefficient operation of the parking brake manual control valve (lever)
YES
YES
Overhaul or replace the triple control servo control
valve
Overhaul or replace the lever.
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
59
11
OF THE BRAKE LININGS
Inefficient operation of the Duplex control valveOverhaul or replace the Duplex control valve.
EARLY WEAR
YES
NO
Overhaul the brakes.Inefficient operation of the brakes
YES
NO
Inefficient operation of the triple control servo control
valve
YES
Overhaul or replace the triple control servo control
valve
NO
Inefficient operation of the relay valveOverhaul or replace the relay valve.
YES
BRAKE SYSTEM
12
Air system pipes leak or burst
WARNING LIGHT ON
NO
YES
Close or replace the worn or damaged fittings. Replace
the burst or damaged pipes.
Inefficient operation of the A.P.U.
YES
Overhaul or replace the A.P.U.
(continued)
Print 603.93.321Base - May 2004
60
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
-
TRALIS AT/AD/AS
S
Wrong wiring of the electric circuit of the indicator lightFind the wrong connection and restore the wiring.
YES
13
LIGHT ON WITH LEVER
IN DRIVING POSITION
Wrong wiring of the electric circuit of the indicator lightFind the wrong connection and restore the wiring.
PARKING BRAKE INDICATOR
YES
NO
Inefficient operation of the parking brake manual control valve (lever)
NO
YES
Overhaul or replace the lever.
Inefficient operation of the A.P.U.Overhaul or replace the A.P.U.
YES
14
NOISY BRAKES
Worn brake liningsReplace the brake linings.
YES
NO
Foreign bodies between the brake linings and discs
(disc brakes)
YES
Remove the foreign bodies between the brake linings
and discs.
(continued)
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
Brake discs off centre (disc brakes)Grind or replace the brake discs.
YES
NO
Inefficient shoe r eturn springs (drum brakes)Overhaul the rear brakes.
YES
NO
61
Excessive ovalization of the brake drums (drum brakes)
Turn or if necessary replace the drums.
YES
Print 603.93.321Base - May 2004
62
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
TRALIS AT/AD/AS
S
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
EBS 2 Working diagram
Figure 45
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
63
α
52056 Switch with built-in alarm indicator for ASR cu toff - 70403 Fuse holder for 4 fuses - 70602 Fuses — 70606 Fuse holder for 6 fuses - 72006 7-pole joint for tractor/trailer ABS/EBS electric connection - 72021 30-pole joint for conn ection to earthed diagnosis socket -
78052 Solenoid valve for ABS/EBS - 78058 Proportional valve for EBS trailer air contro l — 78061 Redundant solenoid valve (for carts only) - 86116 Body Computer Multiplex Central Unit - 86117 Front Frame Multiplex Central Unit — 86118 Rear Frame Multiplex Central
Unit — 88001 ABS/EBS system r.p.m. sensor - 88006 Modulator for EBS rear axle air pressure control - 88007 Potentiometric sensor for front wheel pad position signalling — 88008 Potentiometric sensor for rear wheel pad position signalling - 88011 Potentiometric sensor
for third axle wheel pad position signalling - 88012 SAS drive angle s ensor - Steering Angle Sensor for EBS (O ptional on tract ors) — 88013 ESC module - Electronic Stability Control for EBS (Optional on tractors)
Print 603.93.321Base - May 2004
90004
64
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
S
TRALIS AT/AD/AS
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
Pin — EBS 2 central unit output
Figure 46
X1 connector
87770
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
65
PINCABLEFUNCTION
10000Earth
27720Battery-directed power supply positive
37710Battery-directed power supply positive
48847Locked power supply positive
5----
62299K line for diagnosis connector (pin 4)
7GN/VECAN «L» line
8----
9WS/BICAN «H» line
100048Negative from ASR cutoff switch
Print 603.93.321Base - May 2004
66
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
X2 connector (positioning to the left with respect to forward ride)
PINCABLEFUNCTION
10024Negative for RH front wheel wear sensor (pin 3 - BR/MA - pin C)
26024Positive for RH front wheel wear sensor (pin 2 - GE/GI - pin B)
30226Negative for LH front wheel wear sensor (pin 3 - BR/MA - pin C)
46026Positive for LH front wheel wear sensor (pin 2 GE/GI - pin B)
59920Positive for RH front ABS feed solenoid valve (pin 3)
66025Signal from RH front wheel wear sensor (pin 1 - SW/NE - pin A)
79918Positive for RH front ABS exhaust solenoid valve (pin 1)
86027Signal from LH front wheel wear sensor (pin 1 - SW/NE - pin A)
99921Positive for LH front ABS feed solenoid valve (pin 3)
105571RH front sensor
119919Positive for LH front ABS exhaust solenoid valve (pin 1)
125571RH front sensor
130118Negative for RH front ABS solenoid valve (pin 2)
145570LH front sensor
150122Negative for LH front ABS solenoid valve (pin 2)
165570LH front sensor
87771
TRALIS AT/AD/AS
S
X3 connector (positioning to the right with respect to forward ride)
PINCABLEFUNCTION
1WS/BICAN «H» line to SAS steering angle sensor (pin 4) (opt)
2WS/BICAN «H» line to half trailer connector (pin 6)
3WS/BICAN «H» line to ESC module (pin 3) (opt)
4GN/VECAN «L» line to half trailer connector (pin 7)
5GN/VECAN «L» line to SAS steering angle sensor (pin 3) (opt)
68275Positive for SAS steering angle sensor (pin 1) (opt)
7GN/VECAN «L» line to ESC module (pin 4) (opt)
88270Positive for ESC module (pin 1) (opt)
9---10---11WS/BICAN «H» line to rear axle modulator (pin 3 - 61)
120217Negative for rear axle redundant solenoid valve
13---149217Positive for rear axle redundant solenoid valve
15GN/VECAN «L» line to rear axle modulator (pin 4 - 61)
167740Positiveforrearaxlemodulator(pin1-61)
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
Pin-out of rear axle p ressure modulator
61 connector
PINCABLEFUNCTION
177401Positive from EBS central unit (CBU) (pin 16 — X3)
20000Earth
3WS/BICAN «H» line to EBS central unit (CBU) (pin 11 — X3)
4GN/VECAN «L» line to EBS central unit (CBU) (pin 15 — X3)
* Spread the flange / wheel hub contact surface with sealant type IVECO 1905685 (LOCTITE 14780)
Print 603.93.321Base - May 2004
70
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
TOOLS
TOOL NO.DESCRIPTION
TRALIS AT/AD/AS
S
99301001
99301005
99305117
Grinding and turning machine for brake discs and drums
Brake disc turning device
Instrument to check air circuits
99321024
99322215
99341003
Hydraulic trolley to remove and refit wheels
Stand for overhauling front and rear axles
Single-acting bridge
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
TOOLS
TOOL NO.DESCRIPTION
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
71
99341016
99341017
99345049
Pair of brackets with hole
Pair of brackets with hole
Reaction block for extractors
99345053
99345055
99345103
Reaction block for puller tools
Reaction block for puller tools
Wheel hub fitting tool
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72
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
TOOLS
TOOL NO.DESCRIPTION
TRALIS AT/AD/AS
S
99348001
99354207
99355167
Extractor with locking device
Wrench for wheel hub sumps
Wrench (114 mm) for wheel hub bearing adjustment nut
99355175
99355180
99356006
Wrench (105 mm) for wheel hub bearing adjustment nut
Wrench (105 mm) for wheel hub bearing adjustment nut
Wrench to remove and refit brake cylinder ring nut
(use with 99389817)
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
TOOLS
TOOL NO.DESCRIPTION
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
73
99370005
99370006
99370007
Grip for interchangeable drifts
Grip for interchangeable drifts
Grip for interchangeable drifts
99370317
99370700
99370706
Reaction lever with extension to fasten flanges
Guide to fit wheel hub
Tool to drive in wheel hub bearing
Print 603.93.321Base - May 2004
74
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
TOOLS
TOOL NO.DESCRIPTION
TRALIS AT/AD/AS
S
99370708
99372237
99372238
Tool to drive out wheel hub bearing
Tool to mount brake caliper sliding bush guard
Tool to extract brake caliper thrust units
99372239
99372240
99372242
Tool to mount thrust units with brake caliper guard
Tool to remove and refit brake caliper sliding bush guide bushings
(use with 99372237)
Tool for notching brake caliper sliding bush guide bushing
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
TOOLS
TOOL NO.DESCRIPTION
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
75
99372243
99372244
99372245
Tool for mounting thrust pressure inner seals (use with 99372239)
and for mounting the brass bush of brake caliper guide pin (use with
99372240 and with the screw of 99372237)
Tool for mounting the rubber bush of brake caliper guide pin (use
with the screw of 99372237)
Tool for dismounting the rubber bush of brake caliper guide pin (use
with the screw of 99372237)
99374132
99374134
99387050
Installer, wheel hub inner seal (use with 99370006)
Installer, wheel hub inner seal
Cutters for polyamide pipes
Print 603.93.321Base - May 2004
76
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
TOOLS
TOOL NO.DESCRIPTION
TRALIS AT/AD/AS
S
99388001
99389816
99389817
Wrench (80 mm) for wheel hub bearing adjustment nut
Torque multiplier x 4, with square fitting, 3/4” in, 1” out
(maximum torque 2745 Nm)
Torque wrench (60-32 Nm) with 1/2” square fitting
99389819
99395026
99395684
Torque wrench from 0 to 0.9 kgm with 1/4” square fitting
Tool to check rolling torque of wheel hubs
(use with torque wrench)
Trailer automatic and handbrake engaging low-pressure switch
- F 130 48
Trip pressure
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
+0.1
bar
-0.3
12 bar
0.2 bar
5.5 ± 0.2 bar
81
Print 603.93.321Base - May 2004
82
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
Print603.93.141
SPECIFICATIONS AND DATA - BRAKES
S
TRALIS AT/AD/AS
∅
DISC BRAKES:
FRONT AXLE
5876/4/5 - 5886/5
5876/2/4
CENTRAL ADDED AXLE
REAR AXLE
REAR ADDED AXLE
55080/DI (DN8071) - 57080/DI (N8072)
MS 13-175
56082/DI (N9171)
Brake calliper cylinders:
- number
∅
-diameter∅ mm
2
68
Brake lining thickness:
S
- normalS mm
- minimum permissibleS mm
21
2
Brake disc diameter∅ mm432
Brake disc thickness:
- normalS mm
S
- minimum permissibleS mm
37 (4 mm each side)
45
Operating clearanceG mm0.5 to 1
FRONT AXLES
WHEEL HUBS
5876/2/4/5 - 55080/DI-57080/DI
5886/5
Wheel hub bearings2 with tapered rollers
56082/DI
2 with tapered rollers
Unit-Bearing
Hub bearing end floatmmmax 0.16-
Hub bearing end float adjustment
Not adjustable
Tightening ring nut to torque
Rolling torqueda Nm0.50 max.
Oil for wheel hub bearings
Tutela W 140/M-DA
(TRUCK FE-AXLE protection
only on the rear axles of vehicles
with F3A/F3B Engines)Litres
0.33 (•)
-
Quantity of oil for each hubkg
0.30 (•)
-
• Quantities are referred to axles.
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
CHECKS ON MAIN COMPONENTS OF BRAKE SYSTEM
Since the vehicle system is type approved to European code standards, it is vital to periodically check its efficiency and that of
the relevant components with the device 99305117.
These checks should be carried out with the vehicle stationary, using the compressed air of the tanks filled by the compressor,
with the engine started.
Always lock th e vehicle before doing any work. Periodically check the pressure gauges, comparing them with a sample
pressure gauge.
!
83
DEVICE
DESCRIPTIONTASK
Compressor
A.P.U.
(Air Processing Unit)
Air tanks for:
- Front axle
- Rear axle
- Parking + trailer
- Services
- For regeneration
Duplex control valve
Check the tightness of fittings and compressor fixing; make sure the
cooling fins are not dirty.
Using a bleed valve or loosenin g a screw plug (with integrated bleed
hole), check whether the air drier works properly. In this case, th e
air needs to come out of the tank without there being any trace of
condensation water.
Check t he seal and corrosion protection.
Drain the condensate off from the tanks via the drain valve.
Check that the pedal gasket is not worn, that the brake control
linkage is properly t ightened and lubricated, not out of shape. Check
that the lever housings are neither worn nor oxidized.
Pneumatic pressure
test points
Check the safety caps are on
Parking brake control valveApply the parking brake control valve till it trips; the pressure gauge on
the test point has to show pressure discharge down to 0 bar in 1 sec.
Parking brake control valve
(with check position)
At t he same time, at the automatic coupling pipe, the pressure gauge
has to show a pressure of 7.5 bars.
(continued)
Print 603.93.321Base - May 2004
84
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
S
TRALIS AT/AD/AS
Diaphragm cylinder
Combined cylinder
Relay valve
Servo control valve
with triple control
fortrailerbraking,
with modulated
servo diverter incorporated
Check its fixing, integrity and seal.
The bleed hole must be facing downwards and must not be clogged.
Check its fixing, integrity and seal.
The bleed hole must be facing downwards and must not be clogged.
Check its operation and seal, evaluatin g how fast th e brake
cylinders ac t.
Fill the tank. Connect one pressure gauge to the automatic coupling
head and one to the graduated coupling head.
A pressure of 1 bar, sent by the twin control valve, must at the
graduated coupling head correspond to a pressure of from 0.8 to 1.5
bars. Make a full braking (vehicle stationary).
The coupling head must have available the required braking pressure
or a pressure decreased by 0.5 bars. Apply the parking brake; at the
graduated coupling head, the pressure must stay unchanged or
decreased by 0.5 bars.
Coupling heads
Disc brake calliper
Brake disc
Brake linings
Check there is no dirt or damage in the c oupling guides.
After coupling is made, press the brake pedal and check the seal and
stability between the coupling heads introducing air at 8.5 bars.
Check there is no air leakage from the coupling gaskets.
Check the wear of the brake linings, scoring and wear of the brake
disc, efficiency of the pistons, wear of the dust caps.
(continued)
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
Pipes and fittings
Seal of pneumatic system
with engine off and under
activation pressure
Seal of pneumatic system in the
partial braking range with 3 bars
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
Check the metal pipes are in a perfect state, with no dents or cranks;
the polyamidepipes must have no cracking or cuts. Check moreover
they are far from sharp edges of the bodywork and chassis that could
damage them. Check that all the pipe brackets are firmly secured,
their slackening causes vibration with the ensuing risk of breakage.
Check that the polyamide pipes have not come into contact with
oil or mineral grease, rubber solvents. Press forcefully on t he brake
pedal an d check the pipes do not swell. Check there is no leakage
from the various fittings or it will be necessary to tighten them fully,
but taking care not to cause any abnormal torsion on the pipes. In
all the above cases it is necessary to replace th e relevant parts if there
is even the slightest doubt about their efficiency. Apart from their
conditions, it is advisable to replace the flexible h oses after
considerable mileage or after a lengthy period of u sin g the vehicle
in order to prevent sudden bursting due to ageing and fatigue.
This check is carried out by intro ducing air pressure into the system
of no less than 5 bars, spreading fairly dense soapy water over the
couplings and fittings with a soft brush and seeing there is no leakage.
Air leakage corresponding to a soap bubble of ∅ 25 mm in 5 seconds
is to lerated, or anyhow a max. fall in pressure within 10 min. of 2%
of the disengagement pressure = 0.22 + 0.02 bars.
For 3 min. the pressure has to remain stable in the pneumatic system.
This check s hould be made with the parking brake disengaged.
85
MAIN COMPONENTS OF THE BRAKING
SYSTEM
790510Compressor
Figure 47
73820
It produces compressed air needed to supply the pneumatic
system. Depending on the version, it may be a single- or
twin-cylinder compressor.
Following the order shown in the figure, tighten the screws
fixing the cylinder head to the required torque.
60732
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86
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
Fault diagnosis
TROUBLEPOSSIBLE CAUSEREMEDY
Oil leakage from the flange
on the outside
Oil leakage from the head
Total lack of compression
Poor efficiency
Mechanical noise
Water blow-by
Incorrect tightening torqueLock the screws to the required values.
Flange seal surfaces not perfectly flat.Check the sealing surfaces, replace any defective parts or
Gasket broken.Change the gasket.
Shaft gasket damaged.Change the gasket.
Scraper ring worn
(noted because the seal seat is shiny).
Defective assembly of the scraper ring.It should be fitted with the word TOP facing the head of
Scraper ring and piston rings all on the same
vertical line.
Cylinder scored or ovalized.Grind the cylinder and mount an uprated piston.
Compression or intake valve deteriorated.Replace deteriorated parts.
Piston rings all on the same vertical line.Mount rings at 120° to each other.
Perforation of the piston or breakage of parts
connected to the piston.
Gaskets damaged.Replace the gaskets.
Energy-saving device in open position during intake.
Piston rings worn.Replace the piston (together with piston rings).
Air leakage between cylinder and head.Replace the gasket and lock the screws with the required
Energy-saving device, intake or compression
valves deteriorated.
Excessive clearance between piston and cylinder. Grind the cylinder and mount an uprated piston.
Particles of carbonized oil between the intake
and compression valves.
Too much clearance between the small end
and pin, between the pin and hole in the piston, between the shaft and big end, be twee n
the sha ft and bushing s and betwe en the piston
and cylinder.
To much clearance between the piston and
cylinder.
Too much incrustation between the piston and
cylinder head caused by burnt oil.
Head gasket or coupling faces scored and uneven.
make them level.
Replace the piston assembly.
the compressor.
Fitat120° to each other.
Replace the piston assembly.
Replace the cylinder head.
torque.
Replace the deteriorated parts.
Clean the valves.
Check the tolerance of the couplings at issue.
Grind the cylinder and mount an uprated piston.
Clean the incrusted parts and replace the valves.
Replace the damaged parts.
S
TRALIS AT/AD/AS
A.P.U. (Air Processing Unit)
Figure 49
73913
Its function is to keep the air clean and at the right moisture level in the system.
In addition, it has to distribute and keep the pressure needed for the operation of the connected systems at the outlet.
On CM (Movable Body) vehicles, the c omponent is used with a setting of 12.5 bars, while versions below this one have a setting
of 10.5 bars.
The A.P.U. contains two pressure sensors connected with an MUX system to display the front/rear axle pressure on the Cluster.
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
Figure 50
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
87
001682t
Pneumatic connections
1-Compressor feed
24 -Pressure intake
25 -Outlet for 10.5 bar / 12.5 bar pneumatic suspension for mobile cases
23 -To compressor for Energy Saving drive
3-Exhaust into atmosphere
21 -To 10.5 bar rear axle air tank
22 -To 10.5 bar front axle air tank
23 -To trailer parking and reloading air tank and to hand distributor for 8.5 bar parking brake
24 -To 8.5 bar services tank
Thermostatic resistor connections (<7°÷>29°)
6.1 -Negative for thermostatic resistor
6.2 -Positive for thermostatic resistor
Pressure switch electric connections on four-way protection valve
6.2 -Signal
6.3 -Positive for power supply
6.4 -Negative
6.5 -Signal
6.6 -Positive for power supply
6.7 -Negative
System for signalling on cluster
By this new component, systems pressure is displayed on IVECO Colour Display in following way:
Cluster - Systems pressure
Print 603.93.321Base - May 2004
88
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
OPERATION
Figure 51
S
TRALIS AT/AD/AS
e
f
d
h
a
c
b
g
000700t
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
RE-CHARGING STEP:
(10.3 + 0.2 bar Regulator) Compressed air from compressor at feed ”1” is arranged on system ”a” safety valve (calibrated to
+4
13
bar for components limited to 10.5 bar, calibrated to 14.5+4for components calibrated to 12.5 bar), and through dedicated
channel reaches the drier filter.
Compressed air by passing throu gh the filter releases its own moisture and, so dried, will be able to reach and feed, through the
calibrated hole, the chamber of timer ”b”; at the same time it opens holding single acting valve ”c”, and in this way it can feed
outlet pressure intake 24, pressure regulator ”b”, outlet for feeding pneumatic suspension circuit 25, and through outlet 21 it
feeds the four-way protection valve by its lying beneath pressure valves and is controlled by brake system outlets 21 and 22.
On reaching ≤ 7.5 bar pressure, the controlled pressure valves of above outlets open and, therefore, rear axle braking system
21 and front axle braking system 22 are fed; at the same, time through the two single acting valves ”e”, the pressure reducing
device can be reached; since the pressure reducing device is open, this device allows pressure to pass to the controlled pressure
valves of secondary sections.
Pressure at outlet 21 feeds the safety valve ”f” of section 23, lifting it to seal position.
By further inc reasing pressure and reaching > 8 bar pressure, controlled pressure valves of secondary sections can open, and,
consequently, outlets 23 and 25 can be fed, opening dedicated single acting safety valve and outlet 24.
These s ections are fed and limited until the integrated pressure reducing device, calibrated to 8.5 bar, reaches the intervention
pressure.
When regulator calibration 10.3
+0,2
bar pressure is reached, the regulator is opened and, consequently, exhau st valve ”h”is
opened, causing a pressure drop within the drier from holding single actin g valve ”c”closing.
At the same time, through outlet 23, there will be sent the intervention pressure of the Energy Saving device integrated into
compressor head and drier filter regeneration step activation , since the slow pressure drop in timer feed chamber enables
pressure return from systems for ~20 seconds. This pressure, directed inside the filter, will assure filter regeneration and be
released into atmosphere through exhaust 3.
89
Print 603.93.321Base - May 2004
90
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
Figure 52
S
TRALIS AT/AD/AS
a
000701t
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
RE-CHARGING STEP: (12.5 + 0.2 bar regulator)
This component assures 12.3 + 0.2 bar pressure at outlet 25 of pneumatic suspension, while maintaining the same calibrations
as the former one at the outlets of the four-way protection valve.
In order to assure this functionality, it will be provided with a pressure reducing device ”a” calibrated to 10.3
+0,2
bar on outlets
21 and 22; therefore, the re-charging will be similar to the already described one but for the pressure reducing device being closed
on reaching above pressure and the regulator release occurring on reaching 12.3 + 0.2 bar pressure.
DUCT 21 FAILURE STEP
Where a failure occurs at the four-way protect ion valve main circuit, component behaviour will be as below:
The pressure drop affecting outlet 21 results in a general pressure fall throughout the component, until the controlled pressure
valve of faulty sect ion reaches 6.5 bar closing pressure.
This pressure decrease also affects regulator ”d”, which shifts and returns to the re-charging condition.
At t he same time, the pressure drop at outl et 21 causes safety valve ”f” of parking duct to shift and open on discharging, so forcing
duct 23 of protection valve to discharging, and causes the single acting valve of outlet 25 to close, so assuring pressure to be
maintained in spring cylinders and preventing tractor parking self-braking.
In this failure condition, the h alf-trailer or c on nection, if any, will on the contrary be shifted to automatic braking.
System re-charging, assured by regulator intervention, will take pressure back to the opening levels of the controlled pressure
valve of faulty section, corresponding to ≤ 7,5 bar, so assuring this pressure to be present in all the outlets of the component.
DUCT 24 FAILURE STEP
Where a failure occurs at the four-way protection valve secondary c ircuit, component behaviour will be as below:
The pressure drop affecting outlet 24 c auses the pressure reducing device to open, so affecting the whole c omponent, until the
controlled pressure valve of faulty section reaches 6.5 bar cl osing pressure.
This fact causes the pressure regulator to open and ret urn to the re-charging step.
System re-charging, assured by regulator intervention, will take pressure back to the opening levels of the controlled pressure
valve of faulty section, corresponding to > 8 bar, so assuring this pressure to be present in all the outlets of the component.
91
In t he case of any failure in protection valve, system feed is assured at pressure levels t hat guarantee system functionality ;
however, filter regeneration is not assured any more since this function is only activated when regulation pressure is
!
reached, which in a failure condition cann o t be reached any more.
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92
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
793110Duplex control valve
(vehicles without EBS)
Figure 53
73914
S
TRALIS AT/AD/AS
It takes air from the tanks and distributes it to the braking
elements.
It is self-limited, that is it limits the delivery of air at a set
maximum pressure, the outcome of which is a greater
availability of energy and a constant maximum braking
pressure irrespective of the pressure swings in the t anks.
Fault Diagnosis (vehicles without EBS)
TROUBLEPOSSIBLE CAUSEREMEDY
Air leaks from the outlet
hole
Control valve with abnormal
self-limitation
Vibration during brakingSpring wearOverhaul the device, replacing the worn parts.
Abnormal operation of the
brake light switch
Leaks from the outlet pipes due to wear of the
gaskets
Self-limitation higher or lower than as required Set the device using the specific screw.
Air leakage due to piston gaskets in the two
sections
It fails to close the electric circuitReplace the switch.
It fails to open the electric circuitReplace the switch.
Overhaul the device, replacing the worn parts.
Overhaul the device, replacing the worn parts.
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STRALIS AT/AD/AS
CBU (Central Brake Unit) (vehicles with EBS 2)
Figure 54
88761
Figure 55
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
93
This component integrates the functions of following
components:
- duplex distributor, which generates electric and
pneumatic signals to increase or decrease pressure in the
braking system;
- electronic central unit, which has the task of managing
the braking system determining deceleration values as a
functionofparametersdetected fromvarious
components;
- proportional relay valve, which modulates pressure at
front axle;
- Back up valve assuring braking even in case of electric
failure.
88762
Pneumatic connectionsElectric connections
11 -From axle air tank6.1 -Cab inner side X1 connector
12 -From axle air tank6.2 -Connector X2 on cab outer side
(positioning to the left with respect to forward ride)
21 -To ABS solenoid valve6.3 -Connector X3 on cab outer side
(positioning to the right wi th respect to forward ride)
22 -To ABS solenoid valve
23 -To trailer drive servo-assisted distributor
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94
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
Figure 56
S
TRALIS AT/AD/AS
90144
A. CBU (Central Brake Unit) - B. ABS solenoid valve - C. Servo-assisted distributor for t railer drive - V1, V3. Air tanks -
1, 11, 12. Feeds - 2, 21, 22, 23. Outlets - 3. Exhaus t - 42, 43. Control pressures
Base - May 2004Print 603.93.321
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
95
793331Relay valve (vehicles without EBS)
The device allows to speed up compressed air release from
combined cylinder section, so cutting down braking time.
Figure 57
4
21
36743
Fault Diagnosis (vehicles without EBS)
TROUBLEPOSSIBLE CAUSEREMEDY
Air leaks from the outlet
with the control pipe
exhausting
Leakage from the introductionor from the seals. Overhaul the device, replacing any defective parts.
Air leaks from the outlet
with supply in the control
pipe
798510Coupling heads
Figure 58
Leakage from the piston gasket or from the exhaust valve.
The version for the ”Graduated” pipe is equipped with a red
cover and a safety projection (1), while th e version for the
”Automatic” pipe is equipped with a yellow cover and a side
safety projection (2). The safety projections are used to avoid
coupling errors.
Overhaul the device, replacing any defective parts.
52871
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96
2
1-To(LH
)axlebrakecylind
6
1.4CANL
tiv
6
6.1/6
7.1-Positiv
e
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
Electropneumatic modulator (vehicles with EBS 2)
Figure 59
88763
Figure 60
S
TRALIS AT/AD/AS
Its task is to modulate pressure at rear axle brake cylinders.
It is provided with an electronic central unit which controls
rear r.p.m. sensors and rear axle braking gaskets wear.
This electronic central unit communicates via CAN n etwork
with the electronic central unit of the EBS that is integrated
in the CBU.
In carts, at gate 4, the redundant valve is connected enabling
pneumatic braking in the case of an electric failure.
Pneumatic connectionsElectric connections
11 -From axle air tank
12 -From axle air tank
-
er
22 -To (RH) axle brake cylinder
3-Exhaust
4-Redundant connection
61.1-Positive
61.2-Earth
61.3-CAN “H”
61.4-CAN “L”
62.1/63.1 -Speed signal
62.2/63.2 -Speed signal
66.1/67.1 -Posi
e
66.2/67.2 -Earth
66.3/67.3 -Signal
Central units
connection line
Speed sensors
Wear sensors
68.1-Positive
68.2-Earth
68.3-Signale
Trailer drive valve
68.4-CAN “H”
68.5-CAN “L”
Base - May 2004Print 603.93.321
88764
STRALIS AT/AD/AS
Figure 61
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
97
90145
A. Rear Axle Modulator - B. Redundant valve - C. CBU (Central Brake Unit) - V1. Air tank - 1, 11, 12. Feeds -
The CBU in forms the modulating valve electronic control
unit via CAN. It controls the modulating valve so that the
discharge solenoid valve is closed and t he input one is
opened.
The pressurised air will reach the brake cylinders causing the
vehicle braking.
The outlet pressure will be proportional to the control signals
and will be constantly controlled by the two built-in pressure
sensors.
Depending on the signals coming from the speed sensors,the
electronic control unit controls that the deceleration effect
corresponds to the calculated one by constantly informing
the CBU.
If the requested deceleration percentage or the grip of the
wheel on the road decrease, the electronic control unit w ill
enable the fit modulations of the braking pressure.
When the brake pedal is released, the component will
remove the braking act ion from the rear axle, disabling the
solenoid valves, which will return to the closed position on
inputs, and discharging the braking pressure.
Besides, the component electronic unit controls and
transmits to the CBU, via CAN network, the percen tage
wear status of the rear axle brake linings.
S
TRALIS AT/AD/AS
Braking in electric failure
TRACTORS
In case of electric failure, it will not be possible to brake the
rear axle as th is function is electrically enabled only. Braking
will be ensured on the front axle and on the connected
semitrailer only.
TRUCKS
In trucks, in the case of a failure of the electric system, the
redundant valve opens, enabling axle braking
Performance diagram
Figure 62
FEED PRESS URE
SUPPLIED PRESSURE
BRAKING VALUE REQUIRED
88765
Base - May 2004Print 603.93.321
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