SECTION 7002 – BRAKING SYSTEM 1

SECTION 7002

AIR TRAILER BRAKES

CONTENT

Description Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

SPECIFICATIONS
Air Compressor:
Location Right hand side of engine, above fuel injection pump
Drive Belt driven via crankshaft/water pump
Type Single cylinder air cooled
Speed 3,000 rev/min. Maximum
Lubrication Pressure fed from engine
Bore / Stroke 75mm x 36mm
Displacement 159 cm3
Operating Pressure 18 bar (261 lbf.in2) Maximum

System Operating Pressure 7.8–8.3 bar (113–120 lbf.in2) “Universal” and “German”
7.0–7.5 bar (101–108 lbf.in2) “Italian”

Unload (relief) Valve Setting 12 bar (174 lbf.in2) “Universal” and “German”
12 bar (174 lbf.in2) “Italian”

Low Pressure Warning Switch Operates at, 4.5–5.0 bar (65–73 lbf.in2) “Universal” and “German”
4.5–5.0 bar (65–73 lbf.in2) “Italian”

Pressure Sender
Pressure (bars) 0 2 6 10

Ohms 10 52 124 184

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

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2 SECTION 7002 – BRAKING SYSTEM

TIGHTENING TORQUES

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 SECTION 7002 – BRAKING SYSTEM 3

DESCRIPTION AND OPERATION

There are three versions of the air trailer brake
available.
These can be easily identified by the coupler
configuration at the rear of the cab.
1. Universal
A generally accepted air brake providing a dual
line system. The universal system is available
with either the straight inline connectors, Figure
1, or the side mounting type, Figure 2.

1
2. Universal with Side mounting couplers.

2
3. “German”
An air brake system designed in accordance with
German TUV specifications providing both
single and dual line operation.

3
4. “Italian”
An air brake system designed to meet Italian
legislation and providing dual line operation.

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4 SECTION 7002 – BRAKING SYSTEM

5
Air Brake Schematic Diagram
“Universal”
1. Compressor 9. Coupler – Control Line Yellow
2. Unload Valve (8 bar) 10. Coupler – Supply Line Red
3. Silencer 11. Pressure Gauge
4. 10 litre Reservoir 12. Low Pressure Warning Lamp
5. Drain Valve 13. Pressure Sender
6. Dual Line Control Valve 14. Brake Master Cylinder
7. Solenoid Valve 15. Brake Logic Head
8. Pressure Regulator 16. Brake light switches

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 SECTION 7002 – BRAKING SYSTEM 5

1 2

6
Universal Air Brake – Tube Connections
1. Control valve to left hand reservoir tube 4. Yellow coupler tube
2. Unload valve to left hand reservoir tube 5. Red coupler tube
3. Compressor to unload valve

Universal Air Brake Option (Figure 5) Brakes Engaged

Brakes Disengaged
Air from the Compressor (1) is supplied to the Unload
Valve (2) which regulates system pressure stored in
the Reservoir (4).
This pressure is supplied to the trailer via the Red
Supply Line (10) Coupler to disengage the brakes.
The air in the system also acts on the Pressure
Sender Unit (13) which supplies a variable electrical
signal to the Pressure Gauge (11) to indicate the
pressure in the system.
If the pressure drops below specified limits, the
sender incorporates a switch to illuminate the
Warning Lamp (12).
Operating the brake pedal closes the Brake
Switches (15) which sends a signal to the Solenoid
Valve (7). When energised this supplies air via the
Pressure Regulator (8) to the Control Valve (6) as
pilot pressure to initiate operation of the trailer’s
brakes via the Yellow Control Line Coupler (9).
As the tractor’s brakes are applied, Hydraulic
Pressure from the Master Cylinders (12) is
transferred via the Brake Logic Valve (13) to the
Control Valve (6) to progressively increase pressure
in the Yellow Control Line (9) to the trailer’s brake
control valve to engage the brakes in line with the
tractor brakes.

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6 SECTION 7002 – BRAKING SYSTEM

7
Air Brake Schematic Diagram
“German”
1. Compressor 10. Coupler Single Line Black
2. Unload Valve (8 bar) 11. Coupler Dual Line (Control) Yellow
3. Silencer 12. Coupler Dual Line (Supply) Red
4. Reservoir (2 x 10 litres) 13. Pressure Gauge
5. Drain Valve 14. Low Pressure Warning Lamp
6. Single Line Control Valve 15. Pressure Sender Unit
7. Dual Line Control Valve 16. Brake Master Cylinder
8. Solenoid Valve 17. Brake Logic Valve
9. Pressure Regulator

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 SECTION 7002 – BRAKING SYSTEM 7

2 3

8 7 6

8
German Air Brake – Tube Connections
1. Yellow coupler tube 5. Single line valve to right hand reservoir tube
2. Control valve to left hand reservoir 6. Red coupler tube
3. Unload valve to reservoir 7. Black coupler tube
4. Single line valve to dual line valve tube 8. reservoir to reservoir tube

“German” Air Brake Operation (figure 7) Brakes Disengaged

The German Air Trailer Brake System combines a Air from the Reservoir (4) is supplied via the Single
dual line and single line brake system and has the Line Control Valve (6) to the Black Line (10) to
addition of a second reservoir tank. disengage the trailer’s brakes.

Dual Line Braking System Brakes Engaged

Refer to Universal Braking System.
Single Line Braking System
The system functions in a similar fashion to dual line
braking except for the following.
As pressure in the Yellow Line (11) increases, it is
sensed at the Single Line Control Valve (6) to
progressively vent the air pressure supplied to the
trailer via the Black Line (10) to apply the trailer’s
brakes in line with the tractor’s brakes.

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8 SECTION 7002 – BRAKING SYSTEM

9
Air Brake Schematic System
“Italian”
1. Compressor 8. Pressure Regulator
2. Unload Valve (7 bar) 9. Pressure Gauge
3. Silencer 10. Low Pressure Warning Lamp
4. 2 off Reservoir (10 litres) 11. Pressure Sender Unit
5. Drain Valve 12. Brake Master Cylinder
6. Dual Line Control Valve 13. Brake Logic Valve
7. Solenoid Valve 14. Dual Coupler

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 SECTION 7002 – BRAKING SYSTEM
1 2
5 4
Italian Air Brake – Tube Connections
1. Control valve to left hand reservoir tube
2. Unload valve to left hand reservoir
3. Yellow coupler tube
“Italian” Air Brake Operation (Figure 9)
Brakes Disengaged
Air from the compressor (1) is supplied to the Unload
Valve (2) which regulates system pressure stored in
the Reservoir (4).
This pressure is supplied to the trailer via the Dual
Coupler (18) supply line to disengage the brakes.
The air in the system also acts on the Pressure
Sender Unit (11) which supplies a variable electrical
signal to the Pressure Gauge (9) to indicate the
pressure in the system.
If the pressure drops below specified limits the
sender incorporates a switch to illuminate the
Warning Lamp (10).
9
10
4. Reservoir to reservoir tube
5. Red coupler tube
Brakes Engaged
Operating the brake pedal closes the brake switches
(12) which sends a signal to the Solenoid Valve (7).
When energised this supplies air via the Pressure
Regulator (8) to the Control Valve (6) as pilot
pressure to initiate operation of the trailer’s brakes
via the Dual Coupler (18) control line.
As the tractor’s brakes are applied hydraulic
pressure from the Master Cylinders (12) is
transferred via the Brake Logic Valve (13) to the
Control Valve (6) to progressively increase pressure
in the Dual Coupler (14) control line to the trailer’s
brake control valve to engage the brakes in line with
the tractor brakes.
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10 SECTION 7002 – BRAKING SYSTEM

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 SECTION 7002 – BRAKING SYSTEM 11

Description Diagram Function

Ref.

Compressor B Belt driven via the crankshaft. Takes filtered air and compresses it to
supply the reservoir tank(s) with pressurised air. The compressor is
lubricated from the engine lube system.

Unload (relief) Valve A Controls the operating pressure within the system to prevent system
damage from excess pressure. Also removes any contamination
from the system during unloading.

Reservoir Tanks D&F Provides storage for the compressed air generated by the
compressor.

Brake Pedal Switch H When both brake pedal switches are operated, (both brake pedals
depressed), relay ‘A’ becomes de–energised, this cuts the voltage to
the dual line control valve solenoid.

Dual Line Control Valve G Operated via the brake pedal switch, supplies air pressure to the
Solenoid dual line control valve to establish the trailer brake pressure before
the tractor brakes become effective, thereby preventing any delay in
operation.

Dual Line Control Valve G Provides control of the two line braking system in conjunction with
the hydraulic pressure supplied from the brake master cylinder. A
mechanical connection to the handbrake provides full trailer braking
when the handbrake is applied.

Single Line Control C Controls the single line trailer brake system in conjunction with the
Valve dual line control valve and brake master cylinder pressure.

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12 SECTION 7002 – BRAKING SYSTEM

Description Diagram Function

Ref.

Pressure G Connected directly in line with the reservoir, provides an electrical

Switch/sender signal to the cab pressure gauge. When the pressure drops to
Assembly 4.5–5.0 bar (65–73 lbf.in2) or lower the switch closes and completes
the circuit to illuminate the warning lamp on the instrument cluster.

Pressure Gauge I Electrically operated gauge by a signal received from the pressure
switch/sender assembly.

Couplers E Red and yellow couplers for dual line systems. Red is the supply
coupler with full pressure available all the time.
The yellow coupler is the control line. Air pressure at the coupler is
increased as the brake pedal is depressed.
The black coupler is for single line systems. Pressure is available at
the coupler with the brake pedal released, pressure decreases as
the pedal is depressed.
The “Italian” trailer brake uses a dual coupler which has both the
supply and control lines in one coupler.

Brake Logic Valve J Ensures that trailer braking only occurs when both brake pedals are
depressed simultaneously. Hydraulic pressure from both brake
master cylinders act on a ball and plunger arrangement which then
allows pressure oil out to act on the control valve.

Regulating Valve K Provides a means for the operator to “Fine Tune” the pressure
supplied from the solenoid to the control valve dependant upon the
characteristics of the trailers brakes.

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 SECTION 7002 – BRAKING SYSTEM
Description
Instrument cluster light illuminates 1. System
when system is running.
Trailer brakes not functioning
(system air pressure okay)
Delay in trailer brake operation
System pressure too high
(exceeds 12±2 bar)
FAULT FINDING
Causes
pressure below 1. Compressor drive belt broken
4.5/3.5 bar.
2. Faulty switch or switch wiring
1. Air in braking system
2. Faulty pilot valve
3. Control valve faulty
1. Dual line solenoid failed closed 1. Disconnect wiring to solenoid.
or permanently energised.
1. Faulty unload valve
13
Remedy
2. Check system for leaks
3. Unload valve failed, stuck open
4. Compressor fault
5. Reservoir drain tap faulty
1. Disconnect wiring to switch. If
light extinguishes replace
switch. If light remains
illuminated check wiring for
short to earth.
1. Bleed brakes
1. Disconnect supply line to
control valve from pilot valve
assembly. Operate the brakes,
if oil is expelled, pilot valve is
okay. If no oil expelled remove
and inspect pilot valve.
1. Repair/replace as required
If brakes operate normally
inspect wiring for short to +12v.
If still a delay in operation after
wire disconnection replace
solenoid assembly.
2. Faulty brake switch
1. Remove valve clean/replace.
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14 SECTION 7002 – BRAKING SYSTEM

11
Air Brake Electrical System
1. Ignition Switch 7. Relay G
2. Ignition Relay (Normally Open) 8. Pressure/Sender Switch
3. Relay ’A’ (Normally Closed) 9. Pressure Gauge
4. Battery 10. Instrument Lamp Warning Lamp
5. Electronic Management Unit 11. Right Hand Brake Pedal Switch
6. Feed to Stoplamps 12. Left Hand Brake Pedal Switch

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 SECTION 7002 – BRAKING SYSTEM 15

COMPONENT REMOVAL AND

INSTALLATION

WARNING
Before removing any air system component ensure
that there is no air pressure in the system. This can
be achieved by depressing and releasing the brake
pedal several times with the engine off and draining
the air reservoirs. Also ensure that the wheels of the
tractor/trailer are chocked.

Compressor – Figure 12
1. Remove the drive belt (2).
2. Disconnect air inlet hose (6).
3. Disconnect air outlet tube (1).
4. Remove the oil drain tube (4).
5. Remove the oil inlet tube (5).
6. Remove the four compressor mounting bolts and
lift compressor away from tractor (3).
7. Reassembly is the reversal of removal, noting
the following point:

12
a. The drive belt is tensioned by moving the idler
pulley. Loosen the idler pulley pivot bolt (3) and
retighten to 6 Nm (55 lbf. in.) This low torque is
just sufficient to pinch the idler pulley assembly
against it’s bracket. Loosen the locknut (2) and
check the torque of the tensioner bolt (1). The
correct torque is 7.5 Nm (66 lbf.in.). Adjust
torque, as necessary and tighten the locknut.
Figure 13.
Retighten the pulley pivot bolt (3) to 85 Nm (62
lbf.ft.).

13
Drain the Air Reservoirs
Prior to performing any of the following operations
drain the air reservoirs to release pressure from the
system.
There is a plunger on the base of each reservoir. To
drain a reservoir, move the plunger (1) laterally, in
any direction, and allow air pressure and any
accumulated water to escape. The reservoirs will
recharge with air when the engine is restarted.

14

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16 SECTION 7002 – BRAKING SYSTEM

Unload Valve – Figure 15

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

15
Reservoir Tanks – Figure 16
NOTE: Removal of the wheel will aid removal of the
reservoir tank(s), but is not essential.
1. Remove all the tubes and hoses connected to
the tank, noting their location.
2. Loosen the strap retaining nuts and lift out the
tank.
3. Reassembly is the reversal of removal.

60–33–014 TI
16
Dual Line Solenoid – Figure 17.
1. Disconnect the electrical connector.
2. Disconnect the two air lines.
3. Remove the two retaining bolts and lift away from
the tractor.
4. Reassembly is the reversal of removal.

17
Dual Line Control Valve – Figure 18.
1. Disconnect the handbrake cable connection.
2. Disconnect hydraulic brake connection from
Pilot valve assembly, cap the end of the tube to
prevent contamination and excessive loss of
brake oil.
3. Disconnect large diameter air lines, noting
locations for reassembly.
Disconnect dual line control valve solenoid.
Remove the two retaining bolts and lift the control
valve assembly complete with bracket and solenoid
valve from the tractor.
18

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 SECTION 7002 – BRAKING SYSTEM 17

4. Reassembly is the reversal of removal, noting

the following points:–
a. When the tube is reconnected it will be
necessary to bleed the braking system.
Bleed each side of the pilot head assembly,
first, then at the bleed screw located in the
control valve.
b. Ensure the handbrake cable is adjusted
correctly after assembly:
Refer to pressure testing at the end of this
chapter for correct handbrake set up.

Pilot Head Valve Assembly – Figure 19

1. Disconnect the two tubes from the braking
system and the outlet tube to the dual line control
valve. Cap the ends of the tubes to prevent dirt
ingress.
2. Remove the single retaining bolt (1), Figure 19
and lift away from the tractor.
3. Reassembly is the reversal of removal, noting
the following point:
a. Bleed the braking system of air as described
previously.

19
Pressure Switch/Sender Assembly – Figure 20.
1. Disconnect wiring to switch.
2. Remove the switch/sender assembly from the
tee connector into the single line control valve.
3. Reassembly is the reversal of removal.

20

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18 SECTION 7002 – BRAKING SYSTEM

Single Line Control Valve – Figure 21

1. Disconnect the three air lines to the single line
control valve assembly.
2. Remove the valve to support bracket retaining
bolts and lift away from tractor.
3. Reassembly is the reversal of removal.

21
Coupler – Figure 22
1. Remove the tube from the rear of the coupler
2. Unscrew the coupler assembly from the bracket.
3. Reassembly is the reversal of removal.

22

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 SECTION 7002 – BRAKING SYSTEM 19

Air Line Removal and Installation – Figure 23

1. To remove an air pipe it is necessary to undo and
remove the complete fitting (1) from the
component. When removed the retaining clip
can then be removed to allow the pipe to be
disassembled from the fitting.

23
2. To install the push-in type air lines the following
should be observed:
• Ensure the seal (1) is correctly seated in the
bottom of the connector fitting.
• Ensure the plastic retaining clip (2) is also
correctly installed in the component
connector fitting.
• Install and tighten the connector fitting (4).
3. Firmly push the pipe connector (3) into the
component connector fitting (4).
WARNING
An air pipe should never be installed as a single item
with the component fitting. The retaining clip may not 24
seat properly and this will lead to pipe disconnection
and air leakage. Always install the fitting, seal and
retaining ring to the component and then install the
pipe into the fitting.

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20 SECTION 7002 – BRAKING SYSTEM

NOTES

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 SECTION 7002 – BRAKING SYSTEM 21

COMPONENT OVERHAUL – COUPLERS

A B

25
COUPLERS

Key to Components – Figure 25

A. Single Line Coupler B. Supply and Control Line Couplers
1. Cover 1. Screw
2. Circlip 2. Guide Piece
3. Bush 3. Spring
4. ‘O’ Ring 4. Tube
5. Valve Ring 5. Cover
6. Valve Body 6. Housing
7. ‘O’ Ring 7. Spring
8. Spring 8. Cap
9. Housing 9. Valve
10. Washer 10. ‘O’ Ring
11. Guide Piece 11. Cap
12. Washer 12. ‘O’ Ring
13. Screw 13. Thrust Piece
14. Guide
15. Screw

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22 SECTION 7002 – BRAKING SYSTEM

COMPONENT OVERHAUL – COMPRESSOR

26

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 SECTION 7002 – BRAKING SYSTEM 23

COMPRESSOR

Key to Components – Figure 26

1. Bolt 21. Seal
2. Sealing Ring 22. Washer
3. Bolt 23. Nut
4. Pressure Valve Support 24. Screw
5. Pressure Valve Plate 25. Bearing and Cover Assembly
6. Suction Valve Plate 26. ‘O’ Ring
7. Washer 27. Crankshaft
8. Bolt 28. Crankcase
9. Bush 29. Connecting Rod Bearing
10. Alternate End Housing 30. Connecting Rod
11. Screw 31. Piston Assembly
12. Cover 32. Gasket
13. ‘O’ Ring 33. Valve Assembly (complete)
14. Sealing Washer 34. Washer
15. Locking Screw 35. Bush
16. Plug 36. Gasket
17. Sealing Ring 37. Plug
18. Cap 38. Washer
19. Bolt 39. Cylinder Head
20. Washer

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24 SECTION 7002 – BRAKING SYSTEM

COMPONENT OVERHAUL – UNLOADER VALVE

27

NOTE: The filter, item 35, should be cleaned at regular intervals, depending on the operating conditions and
replaced if necessary when cleaning is no longer effective.

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 SECTION 7002 – BRAKING SYSTEM 25

UNLOADER VALVE

Key to Components – Figure 27

1. Relief Valve 20. Seal
2. Sealing Ring 21. Spring Seat
3. Adjuster Screw 22. Spring
4. Screw 23. Shims
5. Housing 24. Valve
6. ‘O’ Ring 25. Seal
7. Adjuster Block 26. ‘O’ Ring
8. Seat 27. Tapered Spring
9. Spring 28. Valve
10. Seat 29. Housing
11. ‘C’ Clip 30. Sealing Ring
12. Washer 31. Bolt
13. Plate 32. Bush
14. Spring Seat 33. Valve
15. Spring 34. Spring
16. Washer 35. Filter
17. Bolt 36. Seal
18. Circlip 37. Adaptor
19. Cover 38. Protective Cap

NOTE: After reassembly of the unloader valve it will be necessary to adjust the pressure at which the valve
unloads. Start at a low setting , i.e, the adjuster screw (3), unscrewed several turns. Observe the
pressure gauge within the cab and gradually increase the pressure, by rotating the adjuster clockwise,
until 7.0–7.5 bar (Italian) or 7.8–8.3 bar (universal/German) is indicated.

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26 SECTION 7002 – BRAKING SYSTEM

COMPONENT OVERHAUL – SINGLE LINE CONTROL VALVE

28

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 SECTION 7002 – BRAKING SYSTEM 27

SINGLE LINE CONTROL VALVE

Key to Components – Figure 28

1. Cap 15. Valve
2. Lockring 16. ‘O’ Ring
3. Diaphragm Disk 17. Lockring
4. Bolt 18. Piston
5. ‘O’ Ring 19. ‘O’ Ring
6. ‘O’ Ring 20. Bolt
7. Valve Tappet 21. ‘O’ Ring
8. Housing 22. Support
9. ‘O’ Ring 23. Spring Washer
10. Compression Spring 24. Diaphragm
11. Spring Plate 25. Bolt
12. Adjuster Screw 26. Cup Seal
13. Locknut 27. Cover
14. End Cap 28. Spring

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28 SECTION 7002 – BRAKING SYSTEM

COMPONENT OVERHAUL – DUAL LINE CONTROL VALVE

29

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 SECTION 7002 – BRAKING SYSTEM 29

DUAL LINE CONTROL VALVE

Key to Components – Figure 29

1. Vent Screw 18. Vent Screw
2. Protective Cap 19. Bolt
3. Bolt 20. Housing
4. Housing 21. Valve with Lockring
5. Lip Seal 22. Sealing Ring
6. ‘O’ Ring 23. Bolt
7. Tappet 24. ‘O’ Ring
8. ‘O’ Ring 25. Valve
9. ‘O’ Ring 26. ‘O’ Ring
10. Tappet 27. Spring
11. Washer 28. Guide
12. Spring 29. ‘O’ Ring
13. Piston 30. Circlip
14. ‘O’ Ring 31. Ball
15. Guide Ring 32. Cap
16. ‘O’ Ring 33. Bolt
17. Rod

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30 SECTION 7002 – BRAKING SYSTEM

COMPONENT OVERHAUL – SOLENOID VALVE

30
SOLENOID VALVE
Key to Components – Figure 30
1. Knurled Nut 6. Lock Washer
2. ‘O’ Ring 7. Flange
3. Housing 8. Spool
4. ‘O’ Ring 9. ‘O’ Ring
5. Cylinder Screw 10. Armature

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 SECTION 7002 – BRAKING SYSTEM 31

PRESSURE TESTING

Tractor Preparation
1. Position the tractor on a flat, level surface and in
a suitable location to allow the engine to run
during the testing.
2. Chock the wheels and ensure the parking brake
is in the OFF position.
3. To perform the test it will be necessary to obtain
the correct trailer side couplers for the system, to
couple up to the tractor connectors.

31
Use suitable fittings to connect to each trailer
side coupler a 0–10 bar, undamped (100mm),
pressure gauge. Connect the appropriately
coloured couplers to the corresponding tractor
coupler.
• “Italian” trailer brake
• “German” trailer brake
• ”Universal” trailer brake

32
Pre-Test Procedure
NOTE: For all pressure testing illustrations the
gauges represent the following coupler colours:
A = Dual line control (Yellow)
B = Single line supply (Black
C = Dual line supply (Red)
D = Cab Gauge
1. Switch tractor ignition on.
2. All test gauges, including vehicle gauge located
on the left hand ’B’ pillar, must read zero pressure
(drain tanks if required).
NOTE: Tractor ’B’ pillar gauge reads line pressure
which is the same as that shown on the red line
33
coupler gauge.
3. Low pressure warning indicator for the air brake
system must be illuminated on the instrument
cluster. Warning light located in top right hand
corner of the instrument cluster.
NOTE: All figures in ( ) refer to the Italian trailer brake
pressures, where they differ.

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32 SECTION 7002 – BRAKING SYSTEM

1. Start the tractor B

2. System should be fully pressurised within 40 to
60 seconds depending on engine rev setting (a
maximum period of 3 minutes is permitted for the
system to reach operating pressure). When the
system is fully pressurised the gauges must read
as follows:
Gauges Pressure
(Bar)
Dual Line Control (Yellow)(A) 0 C
Single Line Supply (Black) (B) 5.0 – 6.0
Dual Line Supply (Red) (C) 7.5 – 8.5 34
(6.5 – 7.5)
Cab (D) 8.0 (7.0)

NOTE: Cab gauge reads 8.0 (7.0) bar in the green

segment.

3. As the system is being pressurised, the air brake

low pressure warning light on the instrument
cluster should extinguish between 4.5 and 5.5
bar.
NOTE: Indication of malfunctioning must be
investigated and the defect rectified before
continuing with the test.

35
4. Apply tractor parking brake
The gauges must now read the following values:
Gauges Pressure
(Bar)
Dual Line Control (Yellow)(A) 7.5 – 8.5
(6.5 – 7.5)
Single Line Supply (Black) (B) 0
Dual Line Supply (Red) (C) 7.5 – 8.5
(6.5 – 7.5)
Cab (D) 8.0 (7.0)

In cases where the gauges do not exhibit the above

values, adjust the handbrake cable to the dual line 36
control valve as described on the following page.

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 SECTION 7002 – BRAKING SYSTEM 33

Handbrake Control Cable Adjustment

1. Handbrake off, system (red), (C), at full pressure
8 (7) bar (ignition on – engine off). Check yellow
gauge (A) is on zero.
2. Handbrake up four clicks – slacken dual valve
operating cable top nut.

37
3. Adjust cable (by tightening the bottom nut first on
the cable assembly) until needle on yellow gauge
(A) just starts to move, lock up top nut.
4. Check operation of handbrake.
Handbrake On = 8 (7) bar yellow
Handbrake Off = 0 bar yellow

38
Leak Test
1. Engine off – tractor parking brake applied.
2. No deterioration of the red line pressure (8 (7)
bar) must occur over a 10 minute period.
Indication of any leakage must be investigated,
the defect rectified and the test repeated.

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34 SECTION 7002 – BRAKING SYSTEM

Brake Pedal Test Procedure

1. Start the tractor. Engine revs not to exceed 1000
rev/min.
2. Do NOT apply tractor parking brake.

40
3. Release brake pedal link pin so that pedals will
work individually.
4. Apply left hand and right hand brake pedals
individually. No change in pressure readings on
test gauges must occur.

41
5. Reconnect brake pedal link pin, apply brake
pedals fully several operations until red system
pressure below 7 (6) bar – vehicle compressor
will come back on load – allow system to reach
full pressure 8 (7) bar (loud ’pop’ will be heard as
unload valve opens). Gently apply pressure to
linked pedals until both brake light switches have
just clicked on, brake lights on and 4WD indicator
on dash is illuminated. The gauges will now
record the following values:

Dual Line Systems 42

Gauges Pressure
(Bar)
Dual Line Control (Yellow)(A) 0.5 – 1.0
Single Line Supply (Black) (B) 4.5 – 5.0*
Dual Line Supply (Red) (C) 7.5 – 8.5
(6.5 – 7.5)
Cab (D) 8.0 (7.0)

* slight drop in pressure must occur

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 SECTION 7002 – BRAKING SYSTEM 35

NOTE: If the brake lights operate late into the braking

process, i.e. pedals are depressed more than 20mm
before the brake switches are switched on, no
advance braking on the air brake system will occur.
The brake switches must be reset and the brake test
performed again.

Single Line System

6. Fully apply brake pedal effort with graduated
effort. Yellow line (A), pressure must increase
evenly to a maximum of 7–8 bar. Black line (B),
pressure must decrease evenly to zero bar.

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Pressure Regulator ON/OFF Test Procedure
1. Set engine at idle revs.
2. Do NOT apply tractor parking brake.
3. With the system fully pressurised 8 (7) bar,
depress the brake pedals several times until the
pressure drops below 7 (6) bar on Red system
gauge (C) and gauge in cab.

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4. The unload valve, located on the RHS of the
engine must recharge the system to 8 (7) bar.
5. In cases where an unload valve is found to be
faulty, a new unload valve must be fitted and the
test repeated.

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36 SECTION 7002 – BRAKING SYSTEM

NOTES

6 – 66000 – 06 – 2002