Iveco TRALIS EBS2 Repair Manual

ELECTRONICALLY
CONTROLLED BRAKING
SYSTEM EBS 2/ESP/EBL
STRALIS AT/AD/AS
”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
Print 603.93.321 -1
st
Ed. 2004
B.U. TECHNICAL PUBLISHING Iveco Technical Publications Lungo Stura Lazio , 15 10156 Turin - Italy
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
Pneumatic system ­EBS 2/ESP/EBL brakes
SYMBOLS FOR AIR/HYDRAULIC SYSTEM
CIRCUIT DIAGRAMS
(TANKS AND ACCUMULATORS) 5..........
SYMBOLS FOR AIR/HYDRAULIC SYSTEM
CIRCUIT DIAGRAMS (VALVES) 6............
SYMBOLS FOR AIR-HYDRAULIC SYSTEM
DIAGRAMS (TANKS AND
ACCUMULATORS) 12......................
SYMBOLS FOR AIR/HYDRAULIC SYSTEM
CIRCUIT DIAGRAMS (CONVERTERS,
CYLINDERS AND CALLIPERS) 13.............
SYMBOLS FOR AIR/HYDRAULIC SYSTEM
CIRCUIT DIAGRAMS
(CALLIPERS AND CYLINDERS) 14............
1
Page
SYMBOLS FOR AIR/HYDRAULIC SYSTEM
CIRCUIT DIAGRAMS (SEMI-COUPLINGS
AND COUPLING CONNECTORS) 15.........
SYMBOLS FOR AIR/HYDRAULIC SYSTEM
CIRCUIT DIAGRAMS (SEMI-COUPLINGS
AND COUPLING CONNECTORS) 16.........
SYMBOLS FOR AIR/HYDRAULIC SYSTEM
CIRCUIT DIAGRAMS
(INDICATORS AND SWITCHES) 17..........
SYMBOLS FOR AIR/HYDRAULIC SYSTEM
CIRCUIT DIAGRAMS (BRAKES) 18............
PIPINGS AND FITTINGS 19....................
- In general 19.............................
- Rigid pipings reflanging 19...................
- Rigid pipings bending 20....................
- Rigid pipings cutting 20.....................
- Flexible pipings replacement with traditional
fittings 21...............................
- Flexible pipings replacement with quick
connection fittings 22......................
EBS 2 (ELECTRONIC BRAKE SYSTEM) 24.........
- EBS Benefits 24..........................
- Tractor and trailer compatibility at any time 24..
- Complete fault-diagnosis structures 24........
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2
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
S
TRALIS AT/AD/AS
OPERATING LOGIC 25.......................
BRAKE SYSTEM 25...........................
AUXILIARY BRAKE INTEGRATION 27...........
- 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 Logic 29.......................
- Braking system evolution 29................
BRAKING SYSTEMS 30........................
Page
Page
- EBS 2 working diagram for 6x2 vehicles (trucks)
with CURSOR 10/13 engine 41.............
- EBS 2 working diagram for 6x2 vehicles (trucks)
with CURSOR 10/13 engine 42.............
- EBS 2 working diagram for 6x2 vehicles (trucks)
with CURSOR 10/13 engine 43.............
- EBS 2 system components location on vehicle
(tractors variant) 44.......................
- ABS-EBL system components location
(tractors variant) 45.......................
DESCRIPTION 46............................
- Service braking 46........................
- Emergency braking 46.....................
- Exhaust brake 46.........................
- Parking brake 46.........................
- ABS-EBL working diagram for 4x2 vehicles
(trucks and tractors, not inclu ding HR)
with CURSOR 8 (F2B) engine 30............
- Working diagram for 6x2 vehicles (tractors)
with CURSOR 8 (F2B) engine 31............
- ABS-EBL working diagram for 6x2 vehicles
(tractors) with CURSOR 8 (F2B) engine 32....
- 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) engine 35
- ABS-EBL working diagram for 6x2C vehicles
(trucks) with CURSOR 8 (F2B) engine 36......
- ABS-EBL workin g diagram for stand alone 6x2
vehicles (trucks) with CURSOR 8 (F2B) engine 37
- EBS 2 working diagram for 4x2 vehicles (tractors)
with CURSOR 10/13 engine 38.............
BRAKES 46.................................
- Front an d rear disk brakes
(KNORR SN7 type) 46....................
FAULT DIAGNOSIS 47.......................
- Diagnosis Instruments 47...................
- Cluster Diagnosis 48......................
- EBS 2 theoretical scheme 63................
TIGHTENING TORQUES 68...................
TOOLS 70.................................
SPECIFICATIONS AND DATA -
PNEUMATIC SYSTEM 77....................
SPECIFICATIONS AND DATA - BRAKES 82......
CHECKS ON MAIN COMPONENTS
OF BRAKE SYSTEM 83......................
MAIN COMPONENTS OF THE BRAKING
SYSTEM 85...............................
- Compressor 85..........................
- EBS 2 working diagram for 4x2 T/FP-CT vehicles
- Head locking screw tigh tn ess 85.............
(tractors) with CURSOR 10/13 engine 39.....
- Fault diagnosis 86.........................
- EBS 2 working diagram for 6x2 vehicles (tractors)
with CURSOR 10/13 engine 40.............
Base - May 2004 Print 603.93.321
- A.P.U. (Air Processing Unit) 86..............
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
3
OPERATION 88.............................
- 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 heads 95........................
- Electropneumatic modulator
(vehicles with EBS 2) 96...................
- Operation 98............................
- Redundancy valve (for 4x2 and 6x2 trucks) 99..
- ABS solenoid valve 99.....................
- Dual stop valve 99........................
- Triple servo control valve
(vehicles without EBS) 99..................
- Predominance control 100..................
- Fault Diagnosis 100........................
- Trailer drive servo-assisted distributor
(vehicles with EBS 2) 101...................
Page
Page
- Speed sensor 107.........................
- Phonic wheels 107.........................
- Electronic control unit 107..................
- Pressure sensor 107........................
- 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 device 109.........................
- Repairs 109..............................
- Fault Diagnosis 109........................
DISC BRAKES KNORR TYPE (CALIPER SN7) 110...
- Operation 111............................
CHECKS 111.................................
- Checking the automatic play recovery sy stem
efficiency 111.............................
- Brake caliper components 112...............
- Check of braking seals thickness 113...........
OVERHAULING FRONT DISC BRAKES 114........
- Operation 102............................
- Pressure test point valve 104.................
- 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 valve 106................
- Fault Diagnosis 106........................
- Check valve (vehicles suited to towing) 106.....
- Low-pressure switch 106....................
- Electro-pneumatic valve for ASR 107..........
- Replacing brake lin ings 114..................
- Removing and refitting brake callipers 117.......
- Removal 117.............................
- Refitting 118..............................
- Removing and refitting wheel hubs 118.........
- Removal 118.............................
- Refitting 119..............................
BRAKE CALIPER OVERHAUL 120................
- Disassembly 120..........................
- Componentpartcleaningandcheck 121.......
- Assembly 121............................
OVERHAULING REAR DISC BRAKES 123.........
- Replacing brake lin ings 123..................
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4
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
S
TRALIS AT/AD/AS
OVERHAULING BRAKE DISCS 126...............
TURNING AND GRINDING BRAKE DISCS 126.....
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Base - May 2004 Print 603.93.321
STRALIS AT/AD/AS
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS
(TANKS AND ACCUMULATORS)
DESCRIPTION SYMBOL
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
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6
AIR SYSTEM - BRAKES EBS 2/ESP/EBL

SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)

DESCRIPTION SYMBOL
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
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STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)
DESCRIPTION SYMBOL
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
11 12
U
MS
12
32783 32784 32785
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8
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)
DESCRIPTION SYMBOL
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
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STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)
DESCRIPTION SYMBOL
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
41 43
42
41 43
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
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10
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)
DESCRIPTION SYMBOL
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
1 2
4
1
2
2
1
LEVELLING VALVE
LEVELLING VALVE
LEVELLING VALVE WITH BUILT-IN TRAVEL LIMITER
HAND OPERATED SUSPENSION RAISING CONTROL VALVE
1
21 22
12
12 23
11
21
2423
21 22
32788
32787
Base - May 2004 Print 603.93.321
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)
DESCRIPTION SYMBOL
2
PROPORTIONAL CONTROL VALVE
1
13
HAND OPERATED SUSPENSION CONTROL VALVE WITH ELECTRICAL MONITORING
12 22
42
41
2111
11
ELECTROPNEUMATIC VALVE
ELECTROPNEUMATIC VALVE
ELECTROPNEUMATIC VALVE
HYDRAULIC MODULATOR FOR ABS
AUGMENTER VALVE
1
3
12
12
21
1
VR HZ2
ABS
22
HZ1VL
HL HR
4
1
2
32788
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12
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
TRALIS AT/AD/AS
S

SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (TANKS AND ACCUMULATORS)

DESCRIPTION SYMBOL
COMPRESSED AIR TANK
BRAKE FLUID RESERVOIR
AIR SPRING
32789
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STRALIS AT/AD/AS
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS
(CONVERTERS, CYLINDERS AND CALLIPERS)
DESCRIPTION SYMBOL
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
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14
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS
(CALLIPERS AND CYLINDERS)
DESCRIPTION SYMBOL
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
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STRALIS AT/AD/AS
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS
(SEMI-COUPLINGS AND COUPLING CONNECTORS)
DESCRIPTION SYMBOL
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
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16
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS
(SEMI-COUPLINGS AND COUPLING CONNECTORS)
DESCRIPTION SYMBOL
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
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STRALIS AT/AD/AS
SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS
(INDICATORS AND SWITCHES)
DESCRIPTION SYMBOL
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
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18
AIR SYSTEM - BRAKES EBS 2/ESP/EBL

SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (BRAKES)

DESCRIPTION SYMBOL
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 2004 Print 603.93.321
STRALIS AT/AD/AS

799512 PIPINGS 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 pipings in the following 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 603.93.321 Base - 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 2004 Print 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 603.93.321 Base - 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
FITTING TIGHTENIG 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 2004 Print 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.
FITTING SEALING RINGS THREADING DIMENSIONS
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 603.93.321 Base - 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 2004 Print 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 603.93.321 Base - 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 2004 Print 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 603.93.321 Base - 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 2004 Print 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 - HR cursor 8/10/13 EBL Disc/Drum
AT/AD/AS - 6x4 cursor 10/13 EBL Disc/Drum
FRONT AXLE
braking pressure
REAR AXLE
braking pressure
CONTROL UNIT
AIM
Slip = 0
Braking intensity request
Wheel speed
Engine Type of system Type of brakes
IN
AT/AD (no HR) cursor 8 EBL Disc/Disc
AT/AD mechanical
suspensions
cursor 10 EBL Disc/Disc
AT/AD/AS cursor 10 EBS Disc/Disc
AS cursor 13 EBS Disc/Disc
Print 603.93.321 Base - May 2004
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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
valve - 13. Trailer system low pressure switch — 6.4 bars -
14. Trailer half couplings for tractors - 15. Trailer coupling half joints
for FP-CT carts and tractors - 16. Parking system one-way valve - 17. Duplex control valve - 18. Rear axle combined cylinder -
19. Rear axle disk brake assembly - 20. Rear axle phonic wheel - 21. Rear axle speed sensor - 22. Rear axle ABS solenoid
valves - 23. EBL pressure sensor - 24. Dual stop valve - 25. Rear axle brake control relay valve - 26. ASR control solenoid valve
- 27. Controlled pressure valve with no return for ASR — 7.5 bars - 28. ABS electronic control unit - 29. Front axle brake
control relay valve - 30. Front axle ABS solenoid valve - 31. Front axle diaphragm brake cylinder - 32. Front axle disc brake
assembly - 33. Front axle phonic wheel - 34. Front axle speed sensor - 35. Front axle parking brake - 36. Brake light control
microswitch - 37. Microswitch for EDC control unit - 38. 14 bar safety valve - A. To the air suspension system - B. To the
service system - * Optional.
Base - May 2004 Print 603.93.321
88748
STRALIS AT/AD/AS
s
AIR SYSTEM - BRAKES EBS 2/ESP/EBL

Working diagram for 6x2 vehicles (tractors) with CURSOR 8 (F2B) engine

Legend
1 A.P.U. unit
2. Manual condensate bleeding valve
3. 30-litre air reservoir
4. 20 - litre air reservoir
5. 15-litre air reservoir
6. Pressure check socket
7. Retaining valve
8. Manual control distributor for parking brake
9. Low pressure switch
10. Manual control distributor for trailer brake (optional)
11. Three-control servo-distributor
12. Low pressure switch
13. Half-coupling ”ISO”
14. Stop light control microswitch
15. EDC control unit microswitch
16. Phonic wheel
17. Rev sensor
18. Combined brake cylinder
19. Rear disk brake assembly
20. Membrane brake cylinder
21. Relay valve
22. ABS solenoid valve
23. Pressure sensor
24. Electronic control unit
25. Duplex distributor
26. Membrane cylinder
27. Disc brake assembly
28. Axle emergency brake
29. Compressor
30. 14 bar safety valve (optional) A. To air suspensions
B. To services
*Optional
31
Print 603.93.321 Base - May 2004
agr
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32
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
TRALIS AT/AD/AS
S
ABS-EBLworkingdi
Figure 28
mfor6x2 vehicles(t
ctors
ith CURSOR 8(F2B)engine
Base - May 2004 Print 603.93.321
88749
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL

Working diagram for 6x2 vehicles (trucks) with CURSOR 8 (F2B) engine and with CURSOR 10 engine (F3A with mechanical suspensions)

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. + 20 l.
7. Manual discharge valve
8. Air test point
9. Parking m anual control valve
10. Handbrake low pressure switch turned on — 6.4 bars
11. Parking control relay valve
12. Trailer slowing manual control valve
13. Trailer brake servo control valve
14. Trailer system low pressure switch — 6.4 bars
15. Trailer half-couplings
16. Parking system one-way valve
17. Duplex control valve
18. Load ratio relay valve for added axle braking
19. Diaphragm cylinder
20. Additional axle disk brake assembly
21. Rear axle combined cylinder
22. Rear axle disk brake assembly
23. Rear axle phonic wheel
24. Rear axle speed sensor
25. Added axle suspension air springs
26. Added axle load ratio dual stop valve
27. Rear axle ABS solenoid valves
28. EBL pressure sensor
29. ABS electronic control unit
30. Rear axle brake control relay valve
31. Dual stop valve
32. Controlled pressure valve with no return for ASR — 7 bars
33. ASR control solenoid valve
34. Front axle brake control relay valve
35. Front axle ABS solenoid valve
36. Front axle diaphragm brake cylinder
37. Front axle phonic wheel
38. Front axle speed sensor
39. Front axle disc brake assembly
40. Axle emergency brake
41. Brake light control microswitch
42. Microswitch for EDC control unit
43. 14 bar safety valve (optional) A. To the air suspension system B. To the service system *Optional
For CM vehicles only
J Version with ASR Y Version without ASR
33
Print 603.93.321 Base - May 2004
agr
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34
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
TRALIS AT/AD/AS
S
ABS-EBLworkingdi
mfor6x2 vehicles(trucks
with CURSOR 8 (F2B) engine and with CURSOR 10 engine (F3A with mechanical suspensions)
Figure 29
Base - May 2004 Print 603.93.321
88750
agr
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STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
35
ABS-EBLworkingdi
Figure 30
mforstandalone 4x2 vehicles(trucks
ith CURSOR 8(F2B)engine
88751
1. Compressor - 2. Air processing unit - 10.5 bars - 3. Air tank - 20 l. - 4. Air tank - 30 l. - 5. Manual discharge valve - 6. Air test
point - 7. Parking manual control valve - 8. Handbrake low pressure switch turned on — 6.4 bars - 9. Parking system one-way valve -
10. Duplex control valve - 11. Rear axle combined cylinder - 12. Rear axle disc brake assembly - 13. Rear axle phonic wheel -
14. Rear axle speed sensor - 15. Rear axle ABS solenoid valves - 16. EBL pressure sensor - 17. Dual stop valve -
18. Rear axle brake control relay valve - 19. ASR control solenoid valve - 20. Controlled pressure valve with no return for ASR —
7.5 bars - 21. ABS electronic control unit - 22. Front axle brake control relay valve - 23. Front axle ABS solenoid valve -
24. Front axle diaphragm brake cylinder - 25. Front axle disc brake assembly - 26. Front axle phonic wheel - 27. Front axle speed
sensor - 28. Front axle parking brake - 29. Brake light control microswitch - 30. Microswitch for EDC control unit - 31. 14 bar safety
valve - A. To the air suspension system - B. To the service system - * Optional.
Print 603.93.321 Base - May 2004
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36
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
TRALIS AT/AD/AS
S
ABS-EBLworkingdi
Figure 31
mfor6x2C vehicles(trucks
ith CURSOR 8(F2B)engine
1. A.P.U. unit - 2. Manual condensate bleeding valve - 3. 20-litre air reservoir - 4. 20 -litre air reservoir - 5. 30-litre air reservoir -
6. Pressure check socket - 7. Retaining valve - 8. Cutoff valve - 9. Manual control distributor for parking brake - 10. Low pressure switch - 11. Parking control relay valve - 12. Stop light control microswitch - 13. EDC control unit microswitch - 14. Phonic
wheel - 15. Rev sensor - 16. Disc brake assembly - 17. Combined brake cylinder - 18. Disc brake assembly - 19. Membrane
brake cylinder - 20. Relay valve - 21. ABS solenoid valve - 22. Pressure sensor - 23. Electronic control unit - 24. Duplex
distributor - 25. Membrane cylinder - 26. Disc brake assembly - 27. Axle parking brake - 28. 14 bar safety valve -
29. Compressor - A. To air suspensions - B. To services - * Optional.
Base - May 2004 Print 603.93.321
88752
agr
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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 -
10. Parking system one-way valve - 11. Duplex control valve - 12. Load ratio relay valve for added axle braking- 13. Diaphragm cylinder - 14. Added axle drum brake assembly - 15. Rear axle combined cylinder - 16. Rear axle disc brake assembly -
17. Rear axle phonic wheel - 18. Rear axle speed sensor - 19. Added axle suspension air springs - 20. Added axle load ratio dual stop valve- 21. Rear axle ABS solenoid valves - 22. EBL pressure sensor - 23. ABS electronic control unit - 24. Rear axle brake
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 603.93.321 Base - 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 -
12. Trailer brake servo control valve - 13. Rear axle combined cylinder - 14. Rear axle disc brake assembly -
15. Rear axle phonic wheel - 16. Rear axle speed sensor - 17. Rear axle brake control electro-pneumatic modulator -
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 2004 Print 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 -
12. ISO half coupling - 13. Trailer brake servo control valve - 14. Rear axle combined cylinder - 15. Rear axle disc brake assembly - 16. Rear axle phonic wheel - 17. Rear axle speed sensor - 18. Rear axle brake control
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 603.93.321 Base - 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 -
12. Trailer brake servo control valve - 13. Rear axle combined cylinder - 14. Rear axle disc brake assembly -
15. Rear axle phonic wheel - 16. Rear axle speed sensor - 17. Relay valves - 18. Intermediate axle diaphragm cylinder -
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.
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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 -
12. Trailer brake servo control valve - 13. Redundant solenoid valve - 14. Rear axle combined cylinder - 15. Rear axle disc brake assembly - 16. Rear axle phonic wheel - 17. Rear axle speed sensor - 18. Rear axle brake control
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
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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
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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
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AIR SYSTEM - BRAKES EBS 2/ESP/EBL

EBS 2 system components location on vehicle (tractors variant)

Figure 38
TRALIS AT/AD/AS
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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
servo-assisted distributor - 10. APU - 11. Membrane brake cylinder - 12. ABS solenoid valve -
13. Compressor - A. Real component location 5, 6, 9 and 10.
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ABS-EBL system components location (tractors variant)

Figure 39
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
45
88759
1. Trailer-only brake hand-operated control valve - 2. Parking brake hand-operated control valve - 3. Electronic control unit -
4. Duplex distributor - 5. Compressor - 6. Relay valve - 7 . Pedal switch for exhaust brake control - 8. ABS solenoid valve -
9. Diaphragm brake cylinder - 10. Front disc brake assembly - 11. Phonic wheel - 12. Wheel revolution sensor - 13. Trailer
drive servo-assisted distributor - 14. A.P.U. - 15. Pressure test point - 16. Air tanks - 17. Phonic wheel - 18. Wheel revolution
sensor - 19 Rear disc brake assembly - 20. Combined brake cylinder - 21. Relay valve - 22. Check valve - 23. Electropneumatic
valve for ASR - 24. Semi-coupling.
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AIR SYSTEM - BRAKES EBS 2/ESP/EBL

DESCRIPTION

Service braking

BRAKES

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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.
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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).
!
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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
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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 y IandIb 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).
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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
FMI OC ACT
Displays the fault code number Indicates the type of fault Fault frequency meter Fault 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.
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AIR SYSTEM - BRAKES EBS 2/ESP/EBL
SECTION 2
Main operating trouble of the brake system:
7 Parking brake release delayed. 8 Trailer parking brake release delayed.
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.
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1
POOR OR ABNORMAL
SYSTEM CHARGE
Air system pipes leak or burst Close or replace the worn or damaged fittings. Re-
YES
NO
place the burst o r damaged pipes.
Inefficient air compressor operation Overhaul or replace the air compressor.
YES
NO
Inefficient A.P.U. operation Overhaul or replace the A.P.U.
YES
2
POOR OR ABNORMAL SERVICE
BRAKING OF THE REAR AXLE
Air system pipes leak or burst Close or replace the worn or damaged fittings. Replace
YES
the burst or damaged pipes.
(continued)
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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)
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AIR SYSTEM - BRAKES EBS 2/ESP/EBL
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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 cylinders Overhaul or replace the diaphragm brake cylinders.
YES
NO
Inefficient operation of the automatic clearance recovery device
YES
Replace the complete brake calliper.
(continued)
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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)
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AIR SYSTEM - BRAKES EBS 2/ESP/EBL
Brake linings worn and/or vitrified Overhaul or replace the brake linings.
YES
NO
Inefficient operation of the trailer brakes Overhaul the trailer brakes.
YES
NO
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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 vitrified Overhaul or replace the brake linings.
YES
(continued)
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AIR SYSTEM - BRAKES EBS 2/ESP/EBL
Inefficient operation of the relay valve Overhaul or replace the relay valve.
YES
NO
55
Inefficient operation of the rear brakes Overhaul the rear brakes.
YES
POOR OR NO TRAILER
6
PARKING BRAKING
Air system pipes leak or burst Close 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 vitrified Overhaul or replace the trailer brake linings.
YES
NO
Inefficient operation of the trailer brakes
YES
Overhaul the trailer brakes.
(continued)
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AIR SYSTEM - BRAKES EBS 2/ESP/EBL
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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 burst Close or replace the worn or damaged fittings. Replace
YES
NO
the burst or damaged pipes.
Inefficient operation of the relay valve Overhaul or replace the relay valve
YES
NO
Inefficient operation of the combined brake cylinders Overhaul 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 brakes Overhaul the rear brakes.
YES
(continued)
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AIR SYSTEM - BRAKES EBS 2/ESP/EBL
TRAILER PARKING BRAKE
8
RELEASE DELAYED
Air system pipes leak or burst Close 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 brakes Overhaul 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 valve Overhaul or replace the Duplex control valve
YES
(continued)
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AIR SYSTEM - BRAKES EBS 2/ESP/EBL
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Inefficient operation of the front brakes Overhaul the front brakes.
NO
Inefficient operation of the rear brakes Overhaul the rear brakes.
NO
YES
YES
Inefficient operation of the triple control servo control Overhaul or replace the triple control servo control.
YES
10
INSUFFICIENT TRAILER
RETARDER BRAKING
Air system pipes leak or burst Close 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.
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AIR SYSTEM - BRAKES EBS 2/ESP/EBL
59
11
OF THE BRAKE LININGS
Inefficient operation of the Duplex control valve Overhaul 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 valve Overhaul 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)
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AIR SYSTEM - BRAKES EBS 2/ESP/EBL
-
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Wrong wiring of the electric circuit of the indicator light Find 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 light Find 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 linings Replace 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)
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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
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AIR SYSTEM - BRAKES EBS 2/ESP/EBL
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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)
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AIR SYSTEM - BRAKES EBS 2/ESP/EBL
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TRALIS AT/AD/AS
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Pin — EBS 2 central unit output
Figure 46
X1 connector
87770
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
65
PIN CABLE FUNCTION
1 0000 Earth
2 7720 Battery-directed power supply positive
3 7710 Battery-directed power supply positive
4 8847 Locked power supply positive
5 -- --
6 2299 K line for diagnosis connector (pin 4)
7 GN/VE CAN «L» line
8 -- --
9 WS/BI CAN «H» line
10 0048 Negative from ASR cutoff switch
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AIR SYSTEM - BRAKES EBS 2/ESP/EBL
X2 connector (positioning to the left with respect to forward ride)
PIN CABLE FUNCTION
1 0024 Negative for RH front wheel wear sensor (pin 3 - BR/MA - pin C)
2 6024 Positive for RH front wheel wear sensor (pin 2 - GE/GI - pin B)
3 0226 Negative for LH front wheel wear sensor (pin 3 - BR/MA - pin C)
4 6026 Positive for LH front wheel wear sensor (pin 2 GE/GI - pin B)
5 9920 Positive for RH front ABS feed solenoid valve (pin 3)
6 6025 Signal from RH front wheel wear sensor (pin 1 - SW/NE - pin A)
7 9918 Positive for RH front ABS exhaust solenoid valve (pin 1)
8 6027 Signal from LH front wheel wear sensor (pin 1 - SW/NE - pin A)
9 9921 Positive for LH front ABS feed solenoid valve (pin 3)
10 5571 RH front sensor
11 9919 Positive for LH front ABS exhaust solenoid valve (pin 1)
12 5571 RH front sensor
13 0118 Negative for RH front ABS solenoid valve (pin 2)
14 5570 LH front sensor
15 0122 Negative for LH front ABS solenoid valve (pin 2)
16 5570 LH front sensor
87771
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X3 connector (positioning to the right with respect to forward ride)
PIN CABLE FUNCTION
1 WS/BI CAN «H» line to SAS steering angle sensor (pin 4) (opt) 2 WS/BI CAN «H» line to half trailer connector (pin 6) 3 WS/BI CAN «H» line to ESC module (pin 3) (opt) 4 GN/VE CAN «L» line to half trailer connector (pin 7) 5 GN/VE CAN «L» line to SAS steering angle sensor (pin 3) (opt) 6 8275 Positive for SAS steering angle sensor (pin 1) (opt) 7 GN/VE CAN «L» line to ESC module (pin 4) (opt) 8 8270 Positive for ESC module (pin 1) (opt)
9 -- -­10 -- -­11 WS/BI CAN «H» line to rear axle modulator (pin 3 - 61) 12 0217 Negative for rear axle redundant solenoid valve 13 -- -­14 9217 Positive for rear axle redundant solenoid valve 15 GN/VE CAN «L» line to rear axle modulator (pin 4 - 61) 16 7740 Positiveforrearaxlemodulator(pin1-61)
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Pin-out of rear axle p ressure modulator 61 connector
PIN CABLE FUNCTION
1 77401 Positive from EBS central unit (CBU) (pin 16 — X3) 2 0000 Earth 3 WS/BI CAN «H» line to EBS central unit (CBU) (pin 11 — X3) 4 GN/VE CAN «L» line to EBS central unit (CBU) (pin 15 — X3)
62 connector
PIN CABLE FUNCTION
1 -- Right rear wheel r.p.m. sensor 2 -- Right rear wheel r.p.m. sensor
63 connector
PIN CABLE FUNCTION
1 -- Left rear wheel r.p.m. sensor 2 -- Left rear wheel r.p.m. sensor
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
67
66 connector
PIN CABLE FUNCTION
1 SW/NE Signal from RH rear wheel wear sensor (pin 1 - pin A) 2 GE/GI Positive for RH rear wheel wear sensor (pin 2 - pin B) 3 BR/MA
Negative for RH rear wheel wear sensor (pin 3 - pin C)
67 connector
PIN CABLE FUNCTION
1 SW/NE Signal from LH rear wheel wear sensor (pin 1 - pin A) 2 GE/GI Positive for LH rear wheel wear sensor (pin 2 - pin B) 3 BR/MA Negative for LH rear wheel wear sensor (pin 3 - pin C)
68 connector
PIN CABLE FUNCTION
1 6046 Positive for trailer drive valve pressure sensor (pin 1) 2 0026 Negative for trailer drive valve pressure sensor (pin 2) 3 6047 Signal from trailer drive valve pressure sensor (pin 3) 4 9046 Positivefortrailerdriveproportional solenoid valve (pin 4) 5 0046 Negative for trailer drive proportional solenoid valve (pin 5)
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AIR SYSTEM - BRAKES EBS 2/ESP/EBL
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TIGHTENING TORQUES

PART TORQUE
Nm (kgm)
Compressor
Nut fixing pulley 200 (20.4)
Combined brake cylinder (for disc brakes)
Nuts for bolts fixing cylinder to brake calliper 180 + 30 (18.3 + 0.3)
Manual brake release screw (type 14 — front disc brakes) max 35 (max 3.6)
Manual brake release screw (type 20/27 — rear disc brakes) max 70 (max 7.1) Fixing fittings 40 ± 5 (4 ± 0.5)
Diaphragm brake cylinder (for disc brakes)
Nut for fixing cylinder to brake calliper 180 + 30 (18 + 3) Fixing fittings 40 ± 5 (4 ± 0.5)
Fixing fittings
- BENDIX cylinder
- KNORR-BREMSE cylinder
- WABCO cylinder
17.5 ± 2.5 40 ± 5 45 ± 5
Front axle disc brakes 5876-57080/DI
Self-locking hex screw M20 x 1.5 fixing brake callipers 615.5 ± 61.5 Nut fixing wheels 665.5 ± 66.5 (67.8 ± 6.7) Self-locking hex screw to fix brake disc to wheel hub 281.5 ± 13.5 (28.7 ± 1.3) Self-locking hex screw M16 x 1.5 to fix brake calliper mount to stub axle 313.5 ± 15.5 (32 ± 1.6) Threaded plug for wheel hub cover 55 ± 5 (5.5 ± 0.5) Ring nut fixing wheel bearings 515.5 ± 24.5 (52.6 ± 2.5) Cylindrical head screw with hex socket to lock wheel bearing adjustment clamp 27.5 ± 2.5 (2.8 ± 0.2) Cover for wheel hub 130 ± 10 (13 ± 1)
Front axle disc brakes 55080/DI
Nut fixing wheel
600
+50
-20
Hex screw to fix brake disc to wheel hub 281.5 ± 13.5 (28.7 ± 1.3)
Threaded plug for wheel hub cover
55 ± 5 (5.5 ± 0.5)
Nut fixing wheel bearings 515.5 ± 24.5 (52.6 ± 2.5)
Cover for wheel hub
130 ± 10 (13 ± 1)
Screw fixing nut 27.5 (2.8)
Screw fixing mount 289.5 ± 14.5 (29.5 ± 1.5)
Screw fixing brake calliper 615 ± 61 (62.7 ± 6.2)
Spread a bead of sealant solely on the mating surface of the hub cover, using the specific metering device. Protect the threaded
part. Use LOCTITE sealant type 574.
(1.7 ± 0.2)
(4 ± 0.5)
(4.5 ± 0.5)
(62.7 ± 6.2)
+5
(61.2 )
-2
Base - May 2004 Print 603.93.321
STRALIS AT/AD/AS
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
TIGHTENING TORQUES
PART TORQUE
Nm (kgm)
Added rear axle disc brakes 56082/I
Nut fixing wheels
Screw fixing drive shaft flange • * 90 ± 10 (9.2 ± 1)
Ring nut fastening wheel hub bearing 932 ± 98 (95 ± 10)
Screw fixing brake disc to wheel hub 281.5 ± 13.5 (28.7 ± 1.3)
Nut for screw fixing brake calliper to mount 615.5 ± 61.5 (62.7 ± 6.2)
Nut for screw fixing brake calliper mount 289.5 ± 14.5 (29.5 ± 1.5)
Apply LOCTITE 243 sealant onto the thread * Spread the drive shaft / wheel hub contact surface with sealant type IVECO 1905685 (LOCTITE 14780)
MS 13-175 rear axle disc brakes
Nut fixing wheels
Screw fixing drive shaft flange * 262 ± 27
Ring nut fastening wheel hub 932 ± 98 (95 ± 10)
Screw fixing brake disc to wheel hub 281.5 ± 13.5 (28.7 ± 1.3)
Screw fixing brake calliper to mount 615.5 ± 61.5 (62.7 ± 6.2)
Nut for screw fixing brake calliper mount 289.5 ± 14.5 (29.5 ± 1.5)
665 ± 61.5 (67.8 ± 6.2)
665.5 ± 61.5 (67.8 ± 6.2) (26.7 ± 2.7)
69
* Spread the flange / wheel hub contact surface with sealant type IVECO 1905685 (LOCTITE 14780)
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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 2004 Print 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 2004 Print 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
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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 2004 Print 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
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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)
Dial gauge with magnetic base
Base - May 2004 Print 603.93.321
STRALIS AT/AD/AS
4x2veh
icl
Total
AIR SYSTEM - BRAKES EBS 2/ESP/EBL

SPECIFICATIONS AND DATA - PNEUMATIC SYSTEM

DESCRIPTION
Compressor
- WABCO 412 352 008 Sin gle cylinder
Capacity
Bore
Stroke 62 mm
Head c ooling Water
Max. continuous rpm 3000 r.p.m.
Max. working pressure
- KNORR-BREMSE 2W630R Twin cylinder
Capacity 628 cm
Bore 86 mm
Stroke 54 mm
Head c ooling Water
Max. continuous rpm 3060 r.p.m.
Max. working pressure 14 bar
352 cm
85 mm
14 bar
3
3
77
A.P.U.
- KNORR Z 007035
Safety valve opening pressure 13.0 + 4 bar
Max. working pressure 13.0 bar
Disconnecting pressure 10.5 + 0.2 bar
Duty temperature -40 to +80 °C
- KNORR Z 007036
Safety valve opening pressure 14.5 + 4.0 bar
Max. working pressure 13.0 bar
Disconnecting pressure 12.5 + 0.2 bar
Duty temperature
-40 to +80 °C
Air tanks
es
Tank capacity
15L
20L 30L 80L
Total
capacity
P/FP-CT 2 1 70
FP-D 1 1 50
T/P/FP - LT/FP-CT 2 1 70
6x2 P vehicles YP/YPS/YPT/YFP/YFS/YTN
3 1 90
Y/FP-D/FS-D 2 1 70
6x2 C vehicles X/P/FP TX/P
2
1
2
1
1
70 85
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78
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
DESCRIPTION
Manual discharge valve
- Type: VOSS 520 899 750 0 - TECHNOMATIK TP 1609.00.00
Maximum working pressure 13 bar
ABS duplex control valve
- KNORR - BREMSE DX 60 A
Supply pressure 10.5 bar
Working pressure 10.5 bar
Relay valve for parking
- KNORR - BREMSE AC574AXY
Maximum working pressure 10.2 bar
Automatic and graduated release coupling heads
- BOSCH - KNORR - BREMSE - WABCO
Working pressure 8.5 bar
S
TRALIS AT/AD/AS
EBS2 rear axle electro-pneumatic graduated release
- WABCO 480 104 000 0
Maximum working pressure 15 bar
Terminal voltage 24
Max. terminal current 10A / 10 bar
CBU (Central Brake Unit)
- WABCO 480 020 010 0
Feed pressure 12,7 bar
Maximum working pressure 13 bar
Terminal voltage 24 ± 8V
Current absorption 0,5 ÷ 11 A
ABS solenoid valve
- WABCO 472 195 055 0
Maximum working pressure
Voltage
- KNORR BREMSE IC 57664
Maximum working pressure
Voltage
13 bar
24 V
10,2 bar
24 V
+6
-9,5
V
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STRALIS AT/AD/AS
DESCRIPTION
EBS 2 trailer servo control valve
- WABCO 480 204 002 0
Supply pressure
Max. working pressure
Voltage
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
8.5 bar
13 bar
+8
V
24
-6,5
79
Max. permanent voltage between orifice 6.4 and 6.5
Max. current
Outlet pressure
Parking brake control valve (vehicles suited for towing)
- KNORR - BREMSE DPM 60 EY
Supply and working pressure 8.5 bar
Travel of control lever (discharge) with start of emergency braking (point of resistance)
Parking braking
Test braking to chec k supply to triple control valve
Parking brake control valve (standby vehicles)
- KNORR - BREMSE DPM 61 EY
Supply and working pressure 8.5 bar
Travel of control lever (discharge) with start of emergency braking (point of resistance)
Parking braking
Test braking to chec k supply to triple control valve
Dual stop valve (for vehicles with ABS/EBL)
8V
1.4A
8,5 bar
67º
73º
86º
67º
73º
- WABCO 434 208 029 - WABCO 434 500 003 0
Supply pressure 10 bar
ABS trailer triple servo control valve
- WABCO 973 009 0130 - KNORR - BREMSE AC 597 B
Supply pressure
Predominance
Differential control pressure (pipes 41 and 22) 2.5
Pressure test point valve
Maximum working pressure 12.5 bar
ASR control normally-closed solenoid valve
- WABCO 472 170 606 0
Working pressure
Maximum supply pressure
Voltage
Current
8.5 bar
0.2 bar
+0.3
bar
-0.5
5.5 ÷ 11 bar
13 bar
24 V
0.69 Amp
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80
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
DESCRIPTION
Redundant valve (for vehicles with EBS 2)
- WABCO 472 173 226 0
Working pressure
Maximum supply pressure
Voltage
Current
ABS electronic control unit
- BOSCH 446 004 320
Supply voltage 24 Volt
ESP electronic central unit (optional on tractors only)
- WABCO 446 065 005 0
Supply voltage 24
Combined brake cylinder (for front disc brake)
- Type 20 - 22 - 24: KNORR - BREMSE Z 003479
- Type 22 - 24: KNORR - BREMSE Z 003480
Maximum working pressure
- fitting 11
- fitting 12
Minimum stroke
0 ÷ 11 bar
13 bar
24 V
0.69 A
+8
Volt
-12
10.7 bar
8.5 bar
64 mm
S
TRALIS AT/AD/AS
Diaphragm brake cylinder (for added axle disc brake)
- Type 12: KNORR - BREMSE IC 72561
Maximum working pressure
Minimum stroke
- Type 14: KNORR - BREMSE IC 72563
Maximum working pressure
Minimum stroke
Combined brake cylinder (for rear disc brake)
- Type 20/27 KNORR - BREMSE IC 68086
Maximum working pressure
- fitting 11
- fitting 12
Minimum stroke
Pressure sensor
- WABCO 441 040 015 - 441 044 002 0
Supply voltage
Measurement range
Low-pressure switch
10.7 bar
57 mm
10.7 bar
57 mm
10.7 bar
8.5 bar
64 mm
8 - 32 V
0 - 10 bar
- F 130 46 S - F 130 47 S
Trip pressure
Base - May 2004 Print 603.93.321
6.6 ± 0.2 bar
STRALIS AT/AD/AS
DESCRIPTION
On-off valve (For Sweden only)
- WABCO 434 205 061
Working pressure 10 bar
Controlled pressure valve
- WABCO 434 100 199 - KNORR - 1B 435 47 - BENDIX VPC 4M
Opening pressure 7
One-way valve
- PEL 50 473 - C
Working pressure
Backpressure
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
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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
- normal S mm
- minimum permissible S mm
21
2
Brake disc diameter mm 432
Brake disc thickness:
- normal S mm
S
- minimum permissible S mm
37 (4 mm each side)
45
Operating clearance G mm 0.5 to 1
FRONT AXLES
WHEEL HUBS
5876/2/4/5 - 55080/DI-57080/DI
5886/5
Wheel hub bearings 2 with tapered rollers
56082/DI
2 with tapered rollers
Unit-Bearing
Hub bearing end float mm max 0.16 -
Hub bearing end float adjustment
Not adjustable
Tightening ring nut to torque
Rolling torque da Nm 0.50 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 hub kg
0.30 ()
-
Quantities are referred to axles.
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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
DESCRIPTION TASK
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 valve Apply 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)
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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 2004 Print 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 790510 Compressor

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.

Head locking screw tightness

Figure 48
A
73821
B
A = single-cylinder compressor B = 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

TROUBLE POSSIBLE CAUSE REMEDY
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 torque Lock 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 2004 Print 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
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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
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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 603.93.321 Base - May 2004
90
AIR SYSTEM - BRAKES EBS 2/ESP/EBL
Figure 52
S
TRALIS AT/AD/AS
a
000701t
Base - May 2004 Print 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.
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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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AIR SYSTEM - BRAKES EBS 2/ESP/EBL
793110 Duplex 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)

TROUBLE POSSIBLE CAUSE REMEDY
Air leaks from the outlet hole
Control valve with abnormal self-limitation
Vibration during braking Spring wear Overhaul 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 circuit Replace the switch.
It fails to open the electric circuit Replace 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 function of parameters detected from various components;
- proportional relay valve, which modulates pressure at
front axle;
- Back up valve assuring braking even in case of electric
failure.
88762
Pneumatic connections Electric connections
11 - From axle air tank 6.1 - Cab inner side X1 connector
12 - From axle air tank 6.2 - Connector X2 on cab outer side
(positioning to the left with respect to forward ride)
21 - To ABS solenoid valve 6.3 - 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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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
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AIR SYSTEM - BRAKES EBS 2/ESP/EBL
95

793331 Relay 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)

TROUBLE POSSIBLE CAUSE REMEDY
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

798510 Coupling 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.
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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 connections Electric 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”
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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 -
2, 21, 22, 23. Outlets - 3. Exhaust - 4. Redundant connection - 42. Control pressure
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AIR SYSTEM - BRAKES EBS 2/ESP/EBL

Operation

Braking phase
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
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