Section 8007 Trailer Brake Valves

SECTION 8007 – HYDRAULIC SYSTEMS 1
SECTION 8007
TRAILER BRAKE VALVES
CONTENT
Description Page
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Italian Trailer Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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2 SECTION 8007 – HYDRAULIC SYSTEMS
SPECIFICATIONS
Maximum Trailer Brake Pressure 50 bar (2175 lbf/in2)
Trailer Brake Disengagement Pressure (Italian Trailer Brakes only) 10–12 bar
Brake Reservoir Oil LHM
TORQUES
SPECIAL TOOLS
Trailer Brake Fitting 80000550
Pressure Gauge 250 bar (3600 lbf/in2)
Pressure Guage 40 bar (600 lbf/in2)
6–66000 – 06 – 2002
DESCRIPTION AND OPERATION

Tractors may be fitted with a hydraulically operated
trailer brake valve which operates the trailer brakes
whenever the brake system is activated by
depressing the footbrake.
Installation of the trailer brake valves varies
according to model however the principal of
operation remains the same.
120–155 model trailer brake installation
175–190 model trailer brake installation
3
For tractors marketed in Italy a modified trailer brake
valve is fitted which ensures the trailer brakes are
also applied when:–
The engine is stopped
The parking brake is applied
Output from the hydraulic pump is very low.
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1 2
5
3
4
BSE2533A
5
Trailer Brake Circuit
1. Trailer Brake Valve 4. Variable Displacement Hydraulic Pump
2. Braking Pressure 5. Remote Valves
3. Load Sense Line 6. Trailer Brakes
Oil flows from the hydraulic pump (4) and into the trailer brake valve to give a sense of feel to the
trailer brake valve (1) before flowing onto the remote operator which aids precise braking.
valves and other high pressure hydraulic circuits. The description and operation described on the
The position of the trailer brake valve in the circuit following pages is for the standard trailer brake
ensures that the trailer brake circuit has priority flow system. The additional operating features of the
over the remote valves (5) and other hydraulic high valve when fitted with the Italian features is
pressure circuits. described from page 10.
Trailer braking is proportional to the effort on the
tractor brake pedal. Feedback is provided by the
6–66000 – 06 – 2002
6
Trailer Brake Layout 120–155 Tractors
1. Remote Valves 7. Supply from Hydraulic Pump to Trailer Brake Valve
2. Feed to Trailer Brake Coupling 8. Load Sense Line
3. Outlet from Trailer Brake Valve to Remote Valves 9. Trailer Brake Valve
4. Pressure Line from Tractor Left Hand Brakes 10. Italian Trailer Brake Valve Components
5. Pressure Line from Front Tractor Brakes (Where Fitted)
6. Pressure Line from Tractor Right Hand Brakes
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7
Trailer Brake Valve Operation – Tractor Brakes Not Applied
Pump Pressure Return to Reservoir
Zero Brake Pedal Pressure

1. Control Valve and Spool 6. Throttling Orifice
2. Pressure Relief Element 7. Flow Regulating Valve
3. Piston 8. Restrictor
4. Pilot Head 9. Check Valve
5. Spring
A. Load Sensing Gallery To Implement Pump P Inlet Port from Hydraulic Pump
B To Trailer Brakes R Return to Reservoir
N Outlet Port to Implement Valves X Pressure from Tractor Brake Pedal Application
Tractor Brakes Not Applied

When the tractor brakes are not applied there is no Their is a small controlled flow of oil from the
hydraulic pressure in the circuit from the tractor implement pump through port ‘P’ of approximately
brake pedal master cylinder to ports ‘X’ of the pilot 0.6 Litres/min which passes to the reservoir through
head (4). restrictor (8), throttling orifice (6) control valve (1) and
The piston (3) is not under pressure and the control port ‘R’. The pressure drop at the throttling orifice (6)
valve (1) assumes the neutral position. holds the flow regulating valve (7) in the open flow
position allowing all remaining flow to pass from port
The trailer brake line ‘B’ is relieved to reservoir
‘P’ through port ‘N’ to the implement valves and other
through the control valve and port ‘R’.
hydraulic circuits.
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8
Trailer Brake Valve Operation – Brakes Being Applied
Pump Pressure Reduced Flow
Brake Pedal Pressure Return to Reservoir

5. Spring
B. Load Sensing Gallery To Implement Pump P Inlet Port from Hydraulic Pump
N Outlet Port to Hydraulic Circuit X Pressure from Tractor Brake Pedal Application
Tractor Brakes Being Applied–Initial application

When the tractor brake pedal is being depressed the pass through the flow regulating valve, the
pilot piston (3) is pressurised through ports ‘X’ and combination of rising oil pressure on the spring side
moves forward pushing against the pressure relief of the valve and the spring pressure moves the
element (2). As the pressure relief element moves to regulating valve to the left.
the left the control valve spool (1) similarly moves to A constant flow of oil from the implement pump
the left. passes from port ‘P’ to the trailer brake through
As the control spool moves to the left the flow of oil restrictor (8), and check valve (9). The residual flow
to reservoir through port ‘R’ is prevented in two by–passes the flow regulating valve (7) and passes
stages. First the connection between the trailer to the tractor implement valves and other hydraulic
brake line ‘B’ and return to reservoir port ‘R’ is closed. circuits through port ‘N’.
Secondly oil passing through the centre of the flow The pressure in the trailer brake line ‘B’ builds up and
regulating valve is prevented from returning to acts on the end of the control valve spool in
reservoir through the control valve and port ‘R’. As oil opposition to the pressure on the piston (3).
from the hydraulic implement pump continues to
6–66000 – 06 – 2002
9
Trailer Brake Valve Operation – Brakes Held
Pump Pressure Trapped Oil (Pressurised)

5. Spring
C. Load Sensing Gallery To Implement Pump P Inlet Port from Hydraulic Pump
Tractor Brakes Being Applied– Brakes Held

If the tractor brake pedal is kept depressed the brake returning to reservoir through the throttling orifice (6)
line ‘B’ remains blocked from the return to reservoir is now directed to port ‘N’ and the tractor implement
port ‘R’. The pressure in the trailer brake line ‘B’ valves and other hydraulic circuits.
increases until it matches the tractor braking The oil in the trailer brakes is now trapped and
pressure and acts on the end surface of the control maintained at a constant pressure until the pressure
valve spool (1) moving the spool to the right against applied to the brake pedal is changed.
the pressure being applied by the brake pedals.
When the brake pedal pressure is decreased the
The oil trapped at the spring end of the flow control spool moves to the right allowing the trapped
regulating valve (7) is now open to reservoir through oil in the trailer brake circuit to return to reservoir
port ‘R’ and the valve moves to the right preventing through port ‘R’ as shown in Figure 6. Oil in circuit
any further pump pressure oil flowing past the check ‘B’ is allowed to escape to reservoir until the pressure
valve (9) and into the trailer brake circuit ‘B’. All pump in the trailer brake circuit once again matches the
flow with the exception of a small controlled flow pressure applied to the tractor brake pedal.
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10
Trailer Brake Valve Operation – Brakes Applied With Maximum Brake Pedal Pressure
Pump Pressure Trapped Oil (Pressurised)

5. Spring
D. Load Sensing Gallery To Implement Pump P Inlet Port from Hydraulic Pump
Brakes Applied With Maximum Brake Pedal Pressure

If at any time the maximum permissible trailer further pump system pressure being directed over
braking pressure of 150 bar (2180lbf/in2) is reached, the check valve to the trailer brake circuit.
for example by pressing excessively on the tractor If the excess pressure is as a result of external
brake pedal or due to any other external forces an factors in the trailer brake system the pressure in
increase in braking pressure is prevented by the gallery ‘B’ is similarly applied to the end face of the
pressure relief element (2). control valve which momentarily moves further to the
As pressure in the trailer braking circuit increases to right opening gallery ‘B’ to reservoir through port (R).
the maximum permissible limit, the trailer brake This allows the excess pressure in the trailer brake
circuit pressure forces the control spool (1) against circuit to be vented to reservoir avoiding further
the springs in the pressure relief element (2). The increase of the braking pressure.
springs which are preset to the maximum Although the trailer brake circuit has priority over the
permissible braking pressure are compressed and implement valve hydraulic circuits the tractor
the control spool (1) moves to the right allowing the hydraulics can be used and pressurised as desired
oil trapped behind the flow regulating valve to return through all operating situations of the trailer brakes
to reservoir through port ‘R’. The flow regulating without any adverse effect.
valve now moves to the right and prevents any
6–66000 – 06 – 2002
ITALIAN TRAILER BRAKES

The unique braking mechanism on Italian trailers
automatically applies the trailer brakes whenever the
tractor engine is stopped, output from the hydraulic
pump is very low or the tractor is disconnected from
the trailer.
NOTE: The Italian trailer braking system will only
function on trailers specifically designed to the Italian
trailer braking specification. Do NOT attach trailers
which are not to the Italian specification to tractors
installed with the Italian trailer brake option. Failure
to observe this requirement may result in continual
partial engagement of the brakes on the trailer and
consequential overheating.
The internal components of the Italian trailer brake
valve are the same as the standard trailer braking
system, however an additional manifold (3) is
attached to the ‘P’ and ‘B’ ports. This manifold
contains two solenoids (1) and (2) and internal
galleries which direct oil to and from the trailer brake
circuit in accordance with the trailer braking
requirements of this system.
An oil discharge valve located in the the return port
‘R’ of the valve creates a back pressure of 10 to 12
bar in the system whenever the engine is running but
the foot brakes are not applied.
The full description and operation of the system is
described as follows. 11
6–66000 – 06 – 2002
12
Italian Trailer Brake Components
1. Delivery Solenoid 5. Manifold
2. Discharge Solenoid 6. Trailer Brake Valve
3. Trailer Brake Engaged Warning Lamp Switch 7. Low Pressure Switch
4. 10–12bar Pressure Regulating Valve 8. Sleeve
6–66000 – 06 – 2002
Engine Running Brakes Not Applied

To release the trailer braking mechanism a pressure The 11–12 bar pressure created by the oil discharge
of 11 to 12 bar (160–174lbf/in2) is required at the valve flows from the trailer brake line (B), through the
trailer brake coupling whenever the handbrake is solenoid valves (4 and 5) to the trailer brake coupler
released while the engine is running and the (12).
footbrake is not being applied. This pressure is sufficient to overcome spring (13) of
This pressure is controlled by the oil discharge valve the Italian brake actuating mechanism. As the spring
(6) which is attached to the trailer brake return to is compressed, spring (14) retracts the actuating pin
reservoir port (R). to disengage the braking mechanism on the trailer.
Oil from the implement pump flows to the trailer NOTE: At engine start–up the trailer brake indicator
brake valve (7) port ‘P’. When the brakes are not light (6) will remain illuminated until the 11 bar
applied a small flow of oil returns to reservoir through pressure necessary to disengage the braking
port (R) with the remaining flow passing from port (P) mechanism has been created. To reduce the time
to the implement valves and hydraulic lift through necessary to reach trailer brake release pressure
port N. depress the brake pedal with the parking brake lever
in the off position.
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13
Italian Trailer Brake Valve Schematic– Engine Running Brakes Not Applied
Pump Pressure Brake Pedal Pressure
Trailer Brake Release Pressure (11bar) Return To Reservoir

1. Parking Brake 9. Hydraulic Pump
2. Parking Brake Switch 10. Brake Pedal and Master Cylinder
3. Relay 11. Implement Valves and Hydraulic Lift
4. Discharge Solenoid 12. Trailer Brake Coupler
5. Delivery Solenoid 13. Spring
6. 11 bar Pressure Regulating Valve 14. Spring
7. Trailer Brake Valve 15. Trailer Brake Engaged Warning Lamp Switch
8. Low Pressure Switch 16. Trailer Brake Engaged Warning Lamp
6–66000 – 06 – 2002
Engine Running Brakes Applied

When the tractor brake pedal is depressed the
control of oil flow through the trailer brake valve (7)
is the same as described for tractors with the
standard trailer brake system, refer to Page 8 and the
outlet pressure through port ‘B’ will be 12–150bar
(174–2180lbf/in2) depending on the pressure applied
to the brake pedal.
The delivery solenoid (5) is open and the discharge
solenoid (4) is closed. Oil exiting port ‘B’ flows
through the ‘Open’ delivery solenoid valve (5) to the
trailer brake coupler (12).
When a trailer is connected to the coupler the
pressure passing through the coupling to the trailer
braking mechanism overcomes the spring force (13
and 14) and moves the actuating pin forward to apply
the brakes on the trailer.
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14
Italian Trailer Brake Valve Schematic– Engine Running Brakes Applied
Pump Pressure Brake Pedal Pressure
Trailer Braking Pressure Return To Reservoir

6–66000 – 06 – 2002
Engine Stopped or Running but with Low

Hydraulic Pump Flow.
When the engine has stopped or the output from
the hydraulic implement pump is very low the
pressure switch (8) closes. With the switch closed
the current energises the relay (3). The relay
closes and current reaches and energises the
solenoid valves (4) and (5). The delivery solenoid
(5) is now closed and discharge solenoid (4) is
open. In this condition the oil in the trailer brake
line discharges to reservoir through solenoid (4).
Their is now insufficient pressure to overcome the
spring (13) and therefore the actuating pin moves
forward to apply the brakes. Low pressure in the
trailer brake line causes the switch (15) to close
and illuminate the warning lamp (16).
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15
Italian Trailer Brake Valve Schematic– Engine Stopped or Running With Low Hydraulic Pump Flow
Pump Pressure (Less than 10 bar) Return To Reservoir
Brake Pedal Pressure

6–66000 – 06 – 2002
Engine Running and Parking Brake Applied

When the parking brake is applied the switch (2) is
closed. With the switch closed the current energises
the relay (3). The relay closes and current reaches
and energises the solenoid valves (4) and (5).
The delivery solenoid valve (5) is now closed and
discharge solenoid valve (4) is open. The 11 bar
pressure oil at port ‘B’ is blocked by delivery solenoid
valve (5) and the pressure in the trailer brake coupler
line is discharged to reservoir through discharge
solenoid valve (4).
Because there is insufficient pressure to overcome
spring (13) the actuating pin is pushed forward to
apply the brakes. The low pressure in the trailer
brake coupler line causes the trailer brake warning
lamp switch (15) to close and the in cab warning lamp
will illuminate.
NOTE: After applying the parking brake, wait
approximately 10 seconds before stopping the
engine. This will allow complete discharge of the oil
pressure in the trailer brake line to obtain full
application of the trailer brakes.
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16
Italian Trailer Brake Valve Schematic– Engine Running and Parking Brake Applied
Pump Pressure Zero Brake Pedal Pressure
Release Pressure (11bar) Return To Reservoir

6–66000 – 06 – 2002
TRAILER BRAKE VALVE PRESSURE TESTING AND FAULT FINDING
TEST CONDITIONS.
Oil temperature 40° to 50° C. Electrical system powered.
Engine speed 1000 rpm. Parking brake disengaged.
TRAILER BRAKING SYSTEM PRESSURE AND LEAK TESTS

(ALL MODELS)
1. Insert fitting no. 380000550 (1) in trailer brake
coupler and connect it to a 0 to 250 bar pressure 1
gauge from kit no.380000240.
2. Release the parking brake.
3. Apply the foot brake. The pressure gauge
reading should increase depending on pedal
effort up to 135 to 150 bar.
4. Continue to apply the foot brake for a minimum
of 10 seconds. The pressure gauge reading
should remain constant up to 150 bar.
5. Engage parking brake.
BTB0240A
17
FAULT FINDING
Problem Possible cause Correction
Pressure higher or lower than 1. Faulty trailer brake pressure Replace trailer brake valve.
specified. regulating valve.
2. Faulty hydraulic pump (9). Test Pump and identify concern.
Excess pressure peaks are 1. Oil leaks from hydraulic system Locate leaks and repair.
observed when applying the 2. Trailer brake auxiliary valve (7) Replace trailer brake auxiliary
brake pedals for 10 seconds. leaks. valve.
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TRAILER BRAKE DISENGAGEMENT PRESSURE TEST

(ITALIAN TRAILER BRAKES ONLY)
1. Insert fitting no. 380000550 (1) into the trailer
brake coupler and connect it to a 0 to 40 bar 1
pressure gauge from kit no. 380000240.
2. Release the parking brake.
3. With engine and oil as detailed for test conditions
pressure should be 10–12 bar.
4. Make sure that the in cab warning light is off.
BTB0240A
18
FAULT FINDING
Trailer brake disengagement 3. Parking brake engaged. Disengage parking brake.
pressure is less than 10 bar.
4. Trailer brake disengagement Replace valve.
pressure regulating valve
misadjusted
5. Faulty trailer brake engaged Replace switch.
warning lamp switch.
6. Faulty hydraulic pump. Test hydraulic pump.
7. Delivery solenoid valve stuck Repair or replace solenoid valve.
closed.
8. Discharge solenoid valve stuck Repair or replace solenoid valve.
open. Discharge and delivery solenoid
valves reversed.
Trailer brake disengagement 1. Trailer brake disengagement Replace valve.
pressure = 0 to 10 bar pressure valve misadjusted.
Correct trailer brake 1. Faulty trailer brake engaged Replace switch.
disengagement pressure but warning lamp switch.
warning lamp is on.
Trailer brake disengagement 1. Faulty warning lamp. Replace lamp.
pressure not correct but warning
light is off.
2. Faulty trailer brake engaged Replace switch.
warning lamp switch.
NOTE: The low pressure switch can be recognized by the red paint point between the two switch blades.
6–66000 – 06 – 2002
PARKING BRAKE ENGAGEMENT TEST

Proceed as follows:
1. Insert fitting no. 380000550 (1) in trailer brake 1
coupler and connect it to a 0 to 40 bar pressure
gauge from kit no. 380000240.
2. With engine and oil as detailed for test conditions
fully raise parking brake control lever.
3. Check if pressure is 0 bar and warning lamp is on.
BTB0240A
19
FAULT FINDING
Trailer brake disengagement 1. Faulty parking brake switch. Replace switch.
pressure does not zero when
parking brake is applied. 2. Faulty circuit relay. Replace relay.
3. Discharge solenoid valve faulty Repair or replace solenoid valve.
or stuck closed.
TRAILER BRAKE CIRCUIT SAFETY SWITCH TEST

Proceed as follows:
1. Insert fitting no. 380000550 in trailer brake 1
coupler and connect it to a 0 to 40 bar pressure
gauge from kit no. 380000240.
2. With parking brake ‘Off’ and tractor brakes not
applied, operate and hold the remote control
valve lever and allow the system pressure relief
valve to operate. Keep this position for a few
seconds and quickly release the control lever.
3. Check if parking brake disengagement pressure
remains at the specified value: 10 to 12 bar
BTB0240A
20
FAULT FINDING
Trailer brake disengagement 1. Trailer brake low pressure Replace switch.
pressure is permanently zeroed switch exceeding rated value
when operating the levers (3 ± 0.5 bar).
described above.
2. Low pressure and trailer brake Move switches to correct
engaged warning lamp switches positions.
reversed
NOTE: The low pressure switch can be recognized by the red paint point between the two switch blades.
6–66000 – 06 – 2002

Section 8007 Trailer Brake Valves

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Section 8007 Trailer Brake Valves

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SECTION 8007 – HYDRAULIC SYSTEMS 1

TRAILER BRAKE VALVES

DESCRIPTION AND OPERATION

120–155 model trailer brake installation

175–190 model trailer brake installation

Pump Pressure Return to Reservoir

Zero Brake Pedal Pressure

Tractor Brakes Not Applied

Pump Pressure Reduced Flow

Brake Pedal Pressure Return to Reservoir

Tractor Brakes Being Applied–Initial application

Pump Pressure Trapped Oil (Pressurised)

Brake Pedal Pressure Return to Reservoir

Tractor Brakes Being Applied– Brakes Held

Pump Pressure Trapped Oil (Pressurised)

Brake Pedal Pressure Return to Reservoir

Brakes Applied With Maximum Brake Pedal Pressure

ITALIAN TRAILER BRAKES

Engine Running Brakes Not Applied

Pump Pressure Brake Pedal Pressure

Trailer Brake Release Pressure (11bar) Return To Reservoir

Engine Running Brakes Applied

Pump Pressure Brake Pedal Pressure

Trailer Braking Pressure Return To Reservoir

Engine Stopped or Running but with Low

Pump Pressure (Less than 10 bar) Return To Reservoir

Brake Pedal Pressure

Engine Running and Parking Brake Applied

Pump Pressure Zero Brake Pedal Pressure

Release Pressure (11bar) Return To Reservoir

TRAILER BRAKE VALVE PRESSURE TESTING AND FAULT FINDING

TRAILER BRAKING SYSTEM PRESSURE AND LEAK TESTS

TRAILER BRAKE DISENGAGEMENT PRESSURE TEST

PARKING BRAKE ENGAGEMENT TEST

TRAILER BRAKE CIRCUIT SAFETY SWITCH TEST

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