Iveco Stralis AT/AD. Manual — part 236
S
TRALIS
AT/AD
2
AIR SYSTEM - BRAKES
Base - January 2003
BRAKE SYSTEM
26
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AUXILIARY BRAKE INTEGRATION
27
. . . . . . . . . .
“ABS-EBL” SYSTEM (ANTI-LOCK BRAKE SYSTEM —
ELECTRONIC BRAKE LIMITER)
28
. . . . . . . . . . .
- “ABS” (Anti-Lock Brake System)
28
. . . . . . . . . . .
- EBL (Electronic Brakes Limiter)
29
. . . . . . . . . . . .
- Operating Logic
29
. . . . . . . . . . . . . . . . . . . . . . . .
- EBS working diagram for 4x2 vehicles (tractors)
30
- EBS working diagram for 4x2 vehicles
(models: AT440S.. /FP-CT/FP-LT)
31
. . . . . . . . . .
- EBS working diagram
for 6x2 vehicles (tractors)
32
. . . . . . . . . . . . . . . .
- EBS working diagram
for 6x2 vehicles (trucks)
33
. . . . . . . . . . . . . . . . . .
- EBS working diagram
for 6x2 vehicles (trucks)
34
. . . . . . . . . . . . . . . . . .
- ABS-EBL working diagram
for 4x2 vehicles (trucks and tractors)
38
. . . . . . . .
- ABS-EBL working diagram
for 6x2C vehicles
39
. . . . . . . . . . . . . . . . . . . . . . .
- ABS-EBL working diagram
for 6x4 vehicles
40
. . . . . . . . . . . . . . . . . . . . . . . .
- ABS-EBL working diagram for stand alone
4x2 vehicles (trucks)
41
. . . . . . . . . . . . . . . . . . . .
- ABS-EBL working diagram
for 6x2 vehicles (trucks)
42
. . . . . . . . . . . . . . . . . .
- ABS-EBL working diagram for stand alone
6x2 vehicles (trucks)
44
. . . . . . . . . . . . . . . . . . . .
DESCRIPTION
45
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- Service braking
45
. . . . . . . . . . . . . . . . . . . . . . . . .
- Emergency braking
45
. . . . . . . . . . . . . . . . . . . . . .
- Exhaust brake
45
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Parking brake
45
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BRAKES
45
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Drum Brakes
45
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Disc Brakes
45
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULT DIAGNOSIS
46
. . . . . . . . . . . . . . . . . . . . . .
Page
- Diagnosis Instruments
46
. . . . . . . . . . . . . . . . . . . .
- Cluster Diagnosis
47
. . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUES
61
. . . . . . . . . . . . . . . . . .
TOOLS
64
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS AND DATA -
PNEUMATIC SYSTEM
73
. . . . . . . . . . . . . . . . . .
SPECIFICATIONS AND DATA - BRAKES
79
. . . . . .
CHECKS ON MAIN COMPONENTS
OF BRAKE SYSTEM
82
. . . . . . . . . . . . . . . . . . . .
MAIN COMPONENTS OF THE BRAKING SYSTEM
84
- Compressor
84
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Head locking screw tightness
84
. . . . . . . . . . . . . .
- Fault diagnosis
85
. . . . . . . . . . . . . . . . . . . . . . . . .
- A.P.U. (Air Processing Unit)
85
. . . . . . . . . . . . . . .
- Duplex control valve (vehicles without EBS)
86
. .
- Duplex control valve with electric transmitter
(vehicles with EBS)
86
. . . . . . . . . . . . . . . . . . . . . .
- Fault Diagnosis (vehicles without EBS)
86
. . . . . . .
- Relay valve (vehicles without EBS)
87
. . . . . . . . . .
- Proportional relay valve for front axle
(vehicles with EBS)
87
. . . . . . . . . . . . . . . . . . . . . .
- Fault Diagnosis (vehicles without EBS)
87
. . . . . . .
- Coupling heads
87
. . . . . . . . . . . . . . . . . . . . . . . . .
- Rear axle electro-pneumatic modulator
(for vehicles with EBS)
88
. . . . . . . . . . . . . . . . . . .
- Fault Diagnosis
88
. . . . . . . . . . . . . . . . . . . . . . . . .
- Redundancy valve (for 4x2 and 6x2 trucks)
89
. . .
- ABS-EBS solenoid valve
89
. . . . . . . . . . . . . . . . . .
- Dual stop valve
89
. . . . . . . . . . . . . . . . . . . . . . . . .
- Triple servo control valve
(vehicles without EBS)
89
. . . . . . . . . . . . . . . . . . .
AIR SYSTEM - BRAKES
3
S
TRALIS
AT/AD
Page
- Predominance control
90
. . . . . . . . . . . . . . . . . . .
- Fault Diagnosis
90
. . . . . . . . . . . . . . . . . . . . . . . . .
- Trailer servo control valve (vehicles with EBS)
91
.
- Pressure test point valve
91
. . . . . . . . . . . . . . . . . .
- Parking brake hand control valve
(vehicles suited to towing)
91
. . . . . . . . . . . . . . . .
- Fault Diagnosis (parking brake control valve)
91
. .
- Parking brake control manual distributor
(standby vehicles)
92
. . . . . . . . . . . . . . . . . . . . . . .
- Manual control valve to slow down the trailer
(optional extra)
92
. . . . . . . . . . . . . . . . . . . . . . . .
- Fault Diagnosis (parking brake control valve)
92
. .
- Controlled pressure valve
93
. . . . . . . . . . . . . . . . .
- Fault Diagnosis
93
. . . . . . . . . . . . . . . . . . . . . . . . .
- Check valve (vehicles suited to towing)
93
. . . . . .
- Low-pressure switch
93
. . . . . . . . . . . . . . . . . . . .
- Electro-pneumatic valve for ASR
94
. . . . . . . . . . .
- Speed sensor
94
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Phonic wheels
94
. . . . . . . . . . . . . . . . . . . . . . . . .
- Electronic control unit
94
. . . . . . . . . . . . . . . . . . .
- Pressure sensor
94
. . . . . . . . . . . . . . . . . . . . . . . .
- Diaphragm brake cylinder
(for front and added front axle disc brake)
95
. . . .
- Diaphragm brake cylinder
(for front and added front axle drum brake)
95
. .
- Combined brake cylinder
(for front and rear disc brake)
95
. . . . . . . . . . . . .
- Combined brake cylinder
(for front and rear drum brake)
95
. . . . . . . . . . . .
- Combined cylinder emergency brake
release device
96
. . . . . . . . . . . . . . . . . . . . . . . . . .
- Repairs
96
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Fault Diagnosis
96
. . . . . . . . . . . . . . . . . . . . . . . . .
DISC BRAKES KNORR TYPE (CALIPER SN7)
97
. . .
- Operation
98
. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKS
98
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
- Checking the automatic play recovery
system efficiency
98
. . . . . . . . . . . . . . . . . . . . . . . .
- Brake caliper components
99
. . . . . . . . . . . . . . . .
- Check of braking seals thickness
100
. . . . . . . . . . . .
OVERHAULING FRONT DISC BRAKES
101
. . . . . . .
- Replacing brake linings
101
. . . . . . . . . . . . . . . . . . .
- Removing and refitting brake callipers
104
. . . . . . . .
- Removal
104
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting
105
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Removing and refitting wheel hubs
105
. . . . . . . . . .
- Removal
105
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
- Refitting
106
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BRAKE CALIPER OVERHAUL
107
. . . . . . . . . . . . . . .
- Disassembly
107
. . . . . . . . . . . . . . . . . . . . . . . . . . .
- Component part cleaning and check
108
. . . . . . . .
- Assembly
108
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OVERHAULING REAR DISC BRAKES
110
. . . . . . . .
- Replacing brake linings
110
. . . . . . . . . . . . . . . . . . .
OVERHAULING BRAKE DISCS
113
. . . . . . . . . . . . .
TURNING AND GRINDING BRAKE DISCS
113
. . . .
DRUM BRAKES
114
. . . . . . . . . . . . . . . . . . . . . . . . . .
OVERHAULING THE DRUM BRAKES
115
. . . . . . . .
- Removing the rear drum brakes
115
. . . . . . . . . . . .
- Turning drums
119
. . . . . . . . . . . . . . . . . . . . . . . . .
- Replacing brake linings
120
. . . . . . . . . . . . . . . . . . .
- Assembly
120
. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S
TRALIS
AT/AD
4
AIR SYSTEM - BRAKES
Base - January 2003
32780
AIR SYSTEM - BRAKES
5
S
TRALIS
AT/AD
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
PRESSURE TEST POINT
QUICK-CONNECTION COUPLING
COCK
COCK WITH OUTLET
1
2
SILENCER
COMPRESSOR
0
2
ENERGY SAVING COMPRESSOR
0
2
4
VACUUM PUMP
3
2
HYDRAULIC PUMP
0
2
HYDRAULIC HAND PUMP
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