DAF CF Braking System Service Manual
DAF CF Braking System Service Manual
DAF CF Braking System Service Manual
ΧΦ65/75/85 series
TECHNICAL DATA
Structure
0
DIAGNOSTICS
1
BRAKE DIAGRAMS FOR THE FULLY PNEUMATIC BRAKE SYSTEM
2
EBS BRAKE SYSTEM BRAKE DIAGRAMS
3
OPERATION OF BRAKE COMPONENTS
4
BRAKE SYSTEM AND COMPONENTS
5
BRAKING PERFORMANCE AND BRAKE EQUALISATION
6
©
200423 DW23241603
https://www.truck-manuals.net/
https://www.truck-manuals.net/
6 TECHNICAL DATA
ΧΦ65/75/85 series Contents
CONTENTS
0 Technical data
Page Date 0
1. BRAKE SYSTEM AND COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200423
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . . 200423
1.2 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16 . . . . 200423
1.3 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19 . . . . 200423
©
200423 1
https://www.truck-manuals.net/
TECHNICAL DATA 6
Contents ΧΦ65/75/85 series
©
2 200423
https://www.truck-manuals.net/
6 TECHNICAL DATA
ΧΦ65/75/85 series Brake system and components
Often used:
1 energy supply (pressure)
2 energy discharge (outgoing command)
3 bleeding
4 control connection (incoming command)
Little used:
0 suction connection
5 vacant
6 vacant
7 anti-freeze connection
8 lubricating oil connection
9 coolant connection
Second digit
If there are several connections with the same
function, a 2nd digit will be added immediately
after the 1st one.
Application example: empty/load relay valve
Meaning:
1 air compressor energy supply
2 energy discharge (command) to the next
component
41 control connection (incoming)
42 second control connection (incoming)
©
200423 1-1
https://www.truck-manuals.net/
TECHNICAL DATA 6
Brake system and components ΧΦ65/75/85 series
Compressor
0 CF65 series
Type
Make: Knorr SWC 9057
Version: 1 cylinder, water cooled, 255 cc
CF75/85 series
Type
Make: Wabco 911 504 ...
Version: 2 cylinder, water cooled
©
1-2 200423
https://www.truck-manuals.net/
6 TECHNICAL DATA
ΧΦ65/75/85 series Brake system and components
23
A B
21 3 23 25
0
H M
6.2
D U 6.3
P
6.4
1 L P
F 6.5
N J K P
U 6.6
6.7
C
21
1
E 0 24 26 22
G
6.1
6.2
12 3
R600702
R Q
2 1 1 2
A B
23 29 11 21 3 23 25
H M
6.2
D U 6.3
P
6.4
L P
F 6.5
21 N J K P
U 6.6
6.7
C
1
E 0 24 26 22
G
6.1
6.2
12 3
R600703
Knorr ZB4548 - II38799F, ZB4579 - K000395 versions (used on front-axle leaf suspension)
©
200423 1-3
https://www.truck-manuals.net/
TECHNICAL DATA 6
Brake system and components ΧΦ65/75/85 series
0
supply pressure in circuit 1, connection 21 9.8 - 10.6 bar
supply pressure in circuit 2, connection 22 9.8 - 10.6 bar
supply pressure in circuit 3, connection 23 8.1 - 8.5 bar
supply pressure in circuit 3, connection 25 7.9 - 8.5 bar
supply pressure in circuit 4, connection 24 9.8 - 10.6 bar
supply pressure in circuit 4, connection 26 9.8 - 10.6 bar
4V
3V
2V
1V
0V
0 2 4 6 8 10 12 P21.22(bar)
R600701
©
1-4 200423
https://www.truck-manuals.net/
6 TECHNICAL DATA
ΧΦ65/75/85 series Brake system and components
p21/22 [bar]
P22 (P11=0)
Make: Knorr DX 61A 11
Pressure difference between 10
circuits 1 and 2 0.25 bar 9
Actuating pressure difference 8
between circuits 1 and 2 0.2 bar 7
21
6
22
5
Inshot 0.2–0.1
Stroke (mm)
4
3
2
1
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14
20
60
100
140
180
220
260
N 380–20N
R600542
Connection 11 circuit 1 supply
Connection 12 circuit 2 supply
Connection 21 circuit 1 braking pressure
Connection 22 circuit 2 braking pressure
R600704
©
200423 1-5
https://www.truck-manuals.net/
TECHNICAL DATA 6
Brake system and components ΧΦ65/75/85 series
p2 [bar]
9
8
p41= 3 bar
7 p42
6
5
4
3 p41= 0.3 bar
p42
2
1
1:
1
0.6–0.2
0 1 2 3 4 5 6 7 8 9 10
p4 [bar]
R600705
Note:
If the vehicle has EBS, the brake light switch is
located in the foot brake valve.
©
1-6 200423
https://www.truck-manuals.net/
6 TECHNICAL DATA
ΧΦ65/75/85 series Brake system and components
P2(bar)
Maximum reduction ratio 1 : 1.5 9
Actuating pressure 0.25 bar
8
6
Application: FAT vehicle P42 = P41
5
.5
1:1
4
2
P42 = 0
1
0 1 2 3 4 5 6 7 8 9 10
+
0,25 0,1 P41(bar)
R600328
Type 10
Make: Wabco 973 011 107
P2(bar)
6
Application: FAD vehicle P42 = P41
FAC vehicle 5
FAX vehicle
FAL vehicle 4
3
7
1:2.
2
P42 = 0
1
0 1 2 3 4 5 6 7 8 9 10
+
0,25 0,1 P41(bar)
R600330
©
200423 1-7
https://www.truck-manuals.net/
TECHNICAL DATA 6
Brake system and components ΧΦ65/75/85 series
Relay valve
0 Version for parking brake 9
P2 (bar)
Make: Knorr AC 577A
Fitted with silencer 8
0 1 2 3 4 5 6 7 8 9
P4 (bar)
R 600363
Relay valve
Version for service brake
Make: Wabco 973 011 009 10
Fitted with internal filter and silencer 9
0
8,9 -0,2
8
P2 (bar)
0 1 2 3 4 5 6 7 8 9 10
0,5 –0,1 P4 (bar)
R 600602
©
1-8 200423
https://www.truck-manuals.net/
6 TECHNICAL DATA
ΧΦ65/75/85 series Brake system and components
Relay valve
Version for service brake
Make: Wabco 973 011 008 0
10 0
Fitted with internal filter and silencer 9,2 -0,2 9
8
7
6
5
4
3
2
1
0 1 2 3 4 5 6 7 8 9 10
MAX. 0,2
R600640
ABS valve
Resistance of magnet coil (at approx. 25C) 10 - 20 ohm
Electrical connections
1. magnet coil bleed point
2. mass
3. magnet coil air admission point 1
2 3
2 1
1 2 3
R600370
©
200423 1-9
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TECHNICAL DATA 6
Brake system and components ΧΦ65/75/85 series
1 2
3
R600484
P22(bar)
Explanation of graph 8
B Curve of intact circuit 1, circuit 2, or failure in
circuit 1 or circuit 2 7
C Setting range, braking pressure advance
6 P11/12 = 8bar
P43 = 8bar
5
Advance
Input pressure 3 bar 4
C B
Output pressure 3 bar
(corresponds to 0.6 bar 3
advance = factory setting) 2,2 + 0,2
0 2
C
Advance adjustment 1
6
P11/12 = 8bar
5
0 1 2 3 4 5 6 7 8 9
6,3 P43(bar)
R600332
©
1-10 200423
https://www.truck-manuals.net/
6 TECHNICAL DATA
ΧΦ65/75/85 series Brake system and components
Safety valve
Type
Make: Voss 0 268 874 200
0
Opening pressure reading approx. 16 bar
R600706
©
200423 1-11
https://www.truck-manuals.net/
TECHNICAL DATA 6
Brake system and components ΧΦ65/75/85 series
Brake lining
Drum brakes
TYPE NOTES
DAF 2100 Installed on LHD vehicles
DAF 3100 Installed on RHD vehicles
Beral 1561 09N044 leading rear axle (used on FTP vehicle)
M6002
©
1-12 200423
https://www.truck-manuals.net/
6 TECHNICAL DATA
ΧΦ65/75/85 series Brake system and components
TYPE NOTES
DAF 1200 Fitted to all vehicles
Brake drum
General
A brake drum may be used until the inside
diameter has reached the maximum permissible
value, as specified in the table below.
As soon as this diameter is exceeded, the brake
drum must be replaced.
©
200423 1-13
https://www.truck-manuals.net/
TECHNICAL DATA 6
Brake system and components ΧΦ65/75/85 series
Brake pad
maximum brake pad A
thickness (C) 30 mm C B
0 minimum lining thickness (E) 2 mm
minimum brake pad thickness (F),
with 9 mm rear plate thickness (D) 11 mm
replacing:
all brake pads at the same time for each axle,
and with the specified lining only. D E
R600489
Brake caliper
Y-X
A
R600708 R600712
©
1-14 200423
https://www.truck-manuals.net/
6 TECHNICAL DATA
ΧΦ65/75/85 series Brake system and components
Brake disc
maximum brake disc
thickness (A) 0 45 mm
A 0
C B
minimum brake disc thickness (B)
(rejection dimension, disc needs
to be replaced) 37 mm
minimum thickness, turning
dimension 40 mm
Note: D E
If it is established during brake pad replacement
that the brake thickness is less than or equal to
39 mm, the brake disc must also be replaced.
R600489
a
A1 crazy cracking.
B1 cracks running to the centre up to 1.5 mm max. 0,75 x a
wide and deep, max. 0.75 x friction surface max. 1,5 mm
width (a).
C1 unevenness in the disc surface up to
1.5 mm.
D1 C1
Not permissible:
D1 through-going cracks.
R600471
©
200423 1-15
https://www.truck-manuals.net/
TECHNICAL DATA 6
Brake system and components ΧΦ65/75/85 series
SAFETY VALVE
Attachment 72 Nm
6 3 2 1 4 5
R600520
BRAKE DISC
Locking plate attachment bolts 30 Nm
©
1-16 200423
https://www.truck-manuals.net/
6 TECHNICAL DATA
ΧΦ65/75/85 series Brake system and components
BRAKE CYLINDER
Attachment nuts
Release bolt
195 Nm
45 Nm
0
Release bolt (version with indication pin) 75 Nm
BLOW-OFF VALVE
Attachment 25 Nm
Air compressor
There are two types of compressors: one version
used in production until 2002-47 and one version
used in production from 2002-48.
Compressors can be identified as follows:
1 1 2
R600743
©
200423 1-17
https://www.truck-manuals.net/
TECHNICAL DATA 6
Brake system and components ΧΦ65/75/85 series
0 1
5
3 4
7
8 2
6
R600742
5
1
3 4
7
8 2
6
R600742
©
1-18 200423
https://www.truck-manuals.net/
6 TECHNICAL DATA
ΧΦ65/75/85 series Brake system and components
1.3 LUBRICANTS
Brake calliper
0
Knorr SB7000
20
18 21
19
17
1
3 22
6a
4 6
7
5 16
8
15
14
11
10 2
9
R600746
©
200423 1-19
https://www.truck-manuals.net/
TECHNICAL DATA 6
Brake system and components ΧΦ65/75/85 series
Knorr SN7000
0 20
21
18
5 19
17
1
22
6 6a
3 7
4 16
8 23
15
11 14
10
R600755
©
1-20 200423
https://www.truck-manuals.net/
6 TECHNICAL DATA
ΧΦ65/75/85 series Braking performance and brake equalisation
©
200423 2-1
https://www.truck-manuals.net/
TECHNICAL DATA 6
Braking performance and brake equalisation ΧΦ65/75/85 series
Graph explanation 1 2
1 Brake force per wheel (N) F (N) 295/60R22,5
3
27000 27"-165
2 Tyre size
26000
3 Type of brake cylinder + brake lever length 25000
15000
8 Reference line of the measured braking force 14000
11000
10000
9000
8000
7000
6000
5000
4000
3000
2 2,5 3 3,5 4 4,5
P (bar)
4 5 6
R600879
©
2-2 200423
https://www.truck-manuals.net/
6 TECHNICAL DATA
ΧΦ65/75/85 series Braking performance and brake equalisation
F (N) 235/75R17,5
0
6000
9"-125
5500
5000
4500
4000
3500
3000
2500
2000
2 2,5 3 3,5 4 4,5
P (bar)
R600865
©
200423 2-3
https://www.truck-manuals.net/
TECHNICAL DATA 6
Braking performance and brake equalisation ΧΦ65/75/85 series
0 F (N) 295/60R22,5
27000 27"-165
26000
25000
24000
24"-165
23000
22000 24"
21000
22"
20000
19000
18000
17000
16000
16"
15000
14000
13000 14"
12000
11000 12"
10000
9000
8000
7000
6000
5000
4000
3000
2 2,5 3 3,5 4 4,5
P (bar)
R600866
©
2-4 200423
https://www.truck-manuals.net/
6 TECHNICAL DATA
ΧΦ65/75/85 series Braking performance and brake equalisation
F (N) 255/70R22,5 0
27000 27"-165
26000
25000
24000
24"-165
23000
22000 24"
21000
20000 22"
19000
18000
17000
16000
16"
15000
14000
13000 14"
12000
11000 12"
10000
9000
8000
7000
6000
5000
4000
3000
2 2,5 3 3,5 4 4,5
P (bar)
R600867
©
200423 2-5
https://www.truck-manuals.net/
TECHNICAL DATA 6
Braking performance and brake equalisation ΧΦ65/75/85 series
0 F (N) 315/60R22,5
27000
27"-165
26000
25000
24000
23000 24"-165
22000
24"
21000
20000
22"
19000
18000
17000
16000
15000 16"
14000
13000 14"
12000
11000 12"
10000
9000
8000
7000
6000
5000
4000
3000
2 2,5 3 3,5 4 4,5
P (bar)
R600868
©
2-6 200423
https://www.truck-manuals.net/
6 TECHNICAL DATA
ΧΦ65/75/85 series Braking performance and brake equalisation
F (N) 275/70R22,5 0
27000
26000 27"-165
25000
24000
23000
24"-165
22000
24"
21000
20000
22"
19000
18000
17000
16000
15000 16"
14000
13000
14"
12000
11000
12"
10000
9000
8000
7000
6000
5000
4000
3000
2 2,5 3 3,5 4 4,5
P (bar)
R600869
©
200423 2-7
https://www.truck-manuals.net/
TECHNICAL DATA 6
Braking performance and brake equalisation ΧΦ65/75/85 series
0 F (N) 385/55R22,5
27000
26000
25000 27"-165
24000
23000
22000 24"-165
21000
24"
20000
19000 22"
18000
17000
16000
15000
16"
14000
13000
12000 14"
11000
12"
10000
9000
8000
7000
6000
5000
4000
3000
2 2,5 3 3,5 4 4,5
P (bar)
R600870
©
2-8 200423
https://www.truck-manuals.net/
6 TECHNICAL DATA
ΧΦ65/75/85 series Braking performance and brake equalisation
F (N) 305/70R22,5 0
27000
26000
25000
27"-165
24000
23000
22000
24"-165
21000
24"
20000
19000
22"
18000
17000
16000
15000
14000 16"
13000
12000 14"
11000
10000 12"
9000
8000
7000
6000
5000
4000
3000
2 2,5 3 3,5 4 4,5
P (bar)
R600871
©
200423 2-9
https://www.truck-manuals.net/
TECHNICAL DATA 6
Braking performance and brake equalisation ΧΦ65/75/85 series
0 F (N) 315/70R22,5
27000
26000
25000
27"-165
24000
23000
22000
24"-165
21000
20000 24"
19000
22"
18000
17000
16000
15000
14000 16"
13000
12000 14"
11000
10000 12"
9000
8000
7000
6000
5000
4000
3000
2 2,5 3 3,5 4 4,5
P (bar)
R600872
©
2-10 200423
https://www.truck-manuals.net/
6 TECHNICAL DATA
ΧΦ65/75/85 series Braking performance and brake equalisation
F (N) 295/80R22,5 0
27000
26000
25000
24000 27"-165
23000
22000
21000 24"-165
20000
24"
19000
18000 22"
17000
16000
15000
14000
16"
13000
12000
14"
11000
10000 12"
9000
8000
7000
6000
5000
4000
3000
2 2,5 3 3,5 4 4,5
P (bar)
R600873
©
200423 2-11
https://www.truck-manuals.net/
TECHNICAL DATA 6
Braking performance and brake equalisation ΧΦ65/75/85 series
0 F (N) 11R22,5
27000
26000
25000
24000
27"-165
23000
22000
21000
24"-165
20000
24"
19000
18000
22"
17000
16000
15000
14000
16"
13000
12000
14"
11000
10000
12"
9000
8000
7000
6000
5000
4000
3000
2 2,5 3 3,5 4 4,5
P (bar)
R600874
©
2-12 200423
https://www.truck-manuals.net/
6 TECHNICAL DATA
ΧΦ65/75/85 series Braking performance and brake equalisation
F (N) 385/65R22,5 0
27000
26000
25000
24000
27"-165
23000
22000
21000
24"-165
20000
19000 24"
18000
22"
17000
16000
15000
14000
16"
13000
12000
14"
11000
10000
12"
9000
8000
7000
6000
5000
4000
3000
2 2,5 3 3,5 4 4,5
P (bar)
R600875
©
200423 2-13
https://www.truck-manuals.net/
TECHNICAL DATA 6
Braking performance and brake equalisation ΧΦ65/75/85 series
0 F (N) 315/80R22,5
27000
26000
25000
24000
23000 27"-165
22000
21000
20000 24"-165
19000 24"
18000
22"
17000
16000
15000
14000
16"
13000
12000
11000 14"
10000
12"
9000
8000
7000
6000
5000
4000
3000
2 2,5 3 3,5 4 4,5
P (bar)
R600876
©
2-14 200423
https://www.truck-manuals.net/
6 TECHNICAL DATA
ΧΦ65/75/85 series Braking performance and brake equalisation
F (N) 12R22,5 0
27000
26000
25000
24000
23000 27"-165
22000
21000
20000 24"-165
19000 24"
18000
17000
22"
16000
15000
14000
13000 16"
12000
11000 14"
10000
12"
9000
8000
7000
6000
5000
4000
3000
2 2,5 3 3,5 4 4,5
P (bar)
R600877
©
200423 2-15
https://www.truck-manuals.net/
TECHNICAL DATA 6
Braking performance and brake equalisation ΧΦ65/75/85 series
0 F (N) 13R22,5
27000
26000
25000
24000
23000
22000 27"-165
21000
20000
24"-165
19000
18000 24"
17000
22"
16000
15000
14000
13000
16"
12000
11000
14"
10000
9000 12"
8000
7000
6000
5000
4000
3000
2 2,5 3 3,5 4 4,5
P (bar)
R600878
©
2-16 200423
https://www.truck-manuals.net/
6 DIAGNOSTICS
CF65/75/85 series Contents
CONTENTS
Page Date
1. DISC BRAKE CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . 200324
1.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . 200324
2. DRUM BRAKE CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . 200324
2.1 Fault-finding table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . 200324
1
ᓻ 200324 1
https://www.truck-manuals.net/
DIAGNOSTICS 6
Contents CF65/75/85 series
2 ᓻ 200324
https://www.truck-manuals.net/
6 DIAGNOSTICS
CF65/75/85 series Disc brake construction
ᓻ 200324 1-1
https://www.truck-manuals.net/
DIAGNOSTICS 6
Disc brake construction CF65/75/85 series
1
Difference in tyre size Check tyres
Different brake cylinder diameters Check brake cylinder diameters
Broken springs in brake cylinders Check brake cylinders
Leaking brake cylinders Check brake cylinders
Fouled brake cylinders Check brake cylinders for fouling
Excessive stub axle bearing play Check stub axle bearing play
Excessive steering ball joint play Check steering ball joint play
Excessive shackle pin play Check shackle pin play
Incorrect vehicle combination Check vehicle combination
Incorrect ABS operation Check ABS operation
Brake pad stuck in the brake calliper. Incorrect Check the play between brake pads and brake
play between brake pads and brake carrier carrier
1-2 ᓻ 200324
https://www.truck-manuals.net/
6 DIAGNOSTICS
CF65/75/85 series Disc brake construction
ᓻ 200324 1-3
https://www.truck-manuals.net/
DIAGNOSTICS 6
Disc brake construction CF65/75/85 series
1
Incorrect setting of load sensing valve Check setting of load sensing valve
Incorrect vehicle combination or front axle/rear Check vehicle combination or front axle/rear
axle combination axle combination
Defective trailer vehicle brake system Check trailer vehicle brake system
Air pressure in spring brake cylinders too low Check air pressure in spring brake cylinders
during driving, dragging brakes with the parking brake valve in the driving
position
Dragging brakes because parking brake is not Check release of parking brake
released
Dirt under foot brake valve/floor mat too high Check for free movement of foot brake valve
Contaminated/blocked brake valve vents Check valve vents
Brake pad stuck in the brake calliper. Incorrect Check the play between brake pads and brake
play between brake pads and brake carrier carrier
Incorrect setting of the trailer vehicle control Check setting of the trailer vehicle control
valve/trailer vehicle reaction valve valve/trailer vehicle reaction valve
1-4 ᓻ 200324
https://www.truck-manuals.net/
6 DIAGNOSTICS
CF65/75/85 series Drum brake construction
ᓻ 200324 2-1
https://www.truck-manuals.net/
DIAGNOSTICS 6
Drum brake construction CF65/75/85 series
1
Difference in tyre pressure Check/correct tyre pressure
Difference in tyre size Check tyres
Different quality of brake linings Check brake linings
Incorrect turning of the brake linings, brake Check brake lining contact pattern
lining is incorrectly positioned against the brake
drum
Different brake shoe return springs, too slack Check brake shoe return springs
Brake linings affected by grease or oil Check seals and/or cam rollers for excess
grease or oil
Damaged brake lining surface Check brake linings
Non-tapered brake linings Check brake linings
Different brake cylinder diameters Check brake cylinder diameters
Broken springs in brake cylinders Check brake cylinders
Leaking brake cylinders Check brake cylinders
Fouled brake cylinders Check brake cylinders for fouling
Defective brake adjuster(s) Check automatic brake adjuster
Incorrectly set brake adjuster travel Check brake adjuster travel setting
Brake camshaft freedom of movement Check brake camshaft freedom of movement
Excessive stub axle bearing play Check stub axle bearing play
Excessive steering ball joint play Check steering ball joint play
Excessive shackle pin play Check shackle pin play
Incorrect vehicle combination Check vehicle combination
Incorrect ABS operation Check ABS operation
2-2 ᓻ 200324
https://www.truck-manuals.net/
6 DIAGNOSTICS
CF65/75/85 series Drum brake construction
1
System pressure too low Check pressure regulator setting
Air leaks in the brake system Check the brake system for leaks
Insufficient braking power/poor condition of Check trailer vehicle
trailer vehicle brake system
Pinched brake lines Check/replace brake lines
Brake cylinder stroke too large Check automatic brake adjuster
Frozen brake system Check brake system
Brake components affected by road salt Check brake components for fouling
Fouled brake cylinders Check brake cylinders for fouling
Incorrect brake cylinder diameter Check brake cylinders
Brake linings affected by grease or oil Check seals and/or cam rollers for excess
grease or oil
Incorrect turning of the brake linings, brake Check brake lining contact pattern
lining is incorrectly positioned against the brake
drum
Damaged brake lining surface Check brake linings
Poor quality of brake linings Check brake linings
Glazed brake linings Check brake linings
Damaged brake shoes Check brake shoes
Seized brake shoe bearing Check brake shoe bearing
Loose brake camshaft bearing Check brake camshaft bearing
Worn cam rollers/cam roller bearing Check cam rollers/cam roller bearing
Incorrect operation/setting of load sensing valve Check operation/setting of load sensing valve
Incorrect vehicle combination Check vehicle combination
Incorrect ABS operation Check ABS operation
ᓻ 200324 2-3
https://www.truck-manuals.net/
DIAGNOSTICS 6
Drum brake construction CF65/75/85 series
2-4 ᓻ 200324
https://www.truck-manuals.net/
6 DIAGNOSTICS
CF65/75/85 series Drum brake construction
1
Thermal overload of non-locking axle brake Check non-locking axle brake linings
linings
Incorrect or non-reconditioned brake linings Check brake linings
Blunt tool used during turning of the brake Check brake linings
linings
Different or poorer quality brake drums Check brake drums
Hardened areas in the brake drum due to Check/replace brake drums
thermal overload
Loose brake camshaft bearing Check brake camshaft bearing
Worn cam rollers/cam roller bearing Check cam rollers/cam roller bearing
Incorrect system pressure due to incorrect Check the pressure regulator setting
pressure regulator setting
Defective trailer vehicle brake system Check trailer vehicle brake system
Incorrect vehicle combination Check vehicle combination
Incorrect ABS operation Check ABS operation
Tyres have too little profile Check profile
ᓻ 200324 2-5
https://www.truck-manuals.net/
DIAGNOSTICS 6
Drum brake construction CF65/75/85 series
1
Incorrect foot brake valve stop bolt setting Check foot brake valve setting
(residual pressure)
Incorrect setting of load sensing valve Check setting of load sensing valve
Incorrect vehicle combination or front axle/rear Check vehicle combination or front axle/rear
axle combination axle combination
Defective trailer vehicle brake system Check trailer vehicle brake system
Highly contaminated brakes, seized brake shoe Check brake shoe freedom of movement, clean
pivot points brakes
Different/incorrect quality of brake linings Check brake linings
Return spring too slack or broken Check return spring
Defective brake adjuster Check automatic brake adjuster
Cracked brake drums Check length and depth of the cracks in the
brake drums
Air pressure in spring brake cylinders too low Check air pressure in spring brake cylinders
during driving, dragging brakes with the parking brake valve in the driving
position
Dragging brakes because parking brake is not Check release of parking brake
released
Dirt under foot brake valve/floor mat too high Check for free movement of foot brake valve
Contaminated/blocked brake valve vents Check valve vents
2-6 ᓻ 200324
https://www.truck-manuals.net/
6 DIAGNOSTICS
CF65/75/85 series Drum brake construction
1
Poorer quality of brake drums Check quality/make of brake drums
Incorrect wheel tightening procedure Tighten wheels according to tightening
procedure
Highly contaminated brakes Clean brakes
Incorrect quality of brake linings Replace brake linings
Incorrect turning of the brake linings, brake Check brake linings
lining is incorrectly positioned against the brake
drum
Loose brake camshaft bearing Check brake camshaft bearing
Brake drums reconditioned more than Replace brake drums
maximum permitted diameter
Incorrect operation of double-check function in Check brake system double-check function
the brake system
ᓻ 200324 2-7
https://www.truck-manuals.net/
DIAGNOSTICS 6
Drum brake construction CF65/75/85 series
1
Highly contaminated brakes Clean brakes
Poor quality of brake linings Check quality/make of brake linings
Frozen or rusted brakes released by using Replace brake linings
force
Incorrect turning of the brake linings Blunt tool Check/replace brake linings
used during turning
Rivet pressure too high during installation of Apply correct rivet pressure during installation
brake linings on brake shoes of brake linings on brake shoes
Rivet pressure too low during installation of Apply correct rivet pressure during installation
brake linings on brake shoes Loose brake lining of brake linings on brake shoes
on brake shoe
Incorrect sequence when applying rivets during Follow correct sequence when installing the
installation of brake linings on brake shoes brake lining
Deformed and/or damaged brake shoes Check/replace brake shoes
Damaged lining due to broken return spring Check return spring
2-8 ᓻ 200324
https://www.truck-manuals.net/
6 DIAGNOSTICS
CF65/75/85 series Drum brake construction
ᓻ 200324 2-9
https://www.truck-manuals.net/
DIAGNOSTICS 6
Drum brake construction CF65/75/85 series
2-10 ᓻ 200324
https://www.truck-manuals.net/
6 BRAKE DIAGRAMS FOR FULLY PNEUMATIC BRAKE SYSTEM
CF65/75/85 series Contents
CONTENTS
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . 200324
1.1 Brake diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . 200324
2. BRAKE DIAGRAMS FOR FULLY PNEUMATIC BRAKE SYSTEM . . . . . . . . . . . 2-1 . . . . 200324
2.1 Legend, brake diagrams for the fully pneumatic brake system . . . . . . . . . . . 2-1 . . . . 200324
2.2 Brake diagrams for fully pneumatic brake system . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . 200324
ᓻ 200324 1
https://www.truck-manuals.net/
BRAKE DIAGRAMS FOR FULLY PNEUMATIC BRAKE SYSTEM 6
Contents CF65/75/85 series
2 ᓻ 200324
https://www.truck-manuals.net/
6 BRAKE DIAGRAMS FOR FULLY PNEUMATIC BRAKE SYSTEM
CF65/75/85 series General
1. GENERAL
1.1 BRAKE DIAGRAMS
ᓻ 200324 1-1
https://www.truck-manuals.net/
BRAKE DIAGRAMS FOR FULLY PNEUMATIC BRAKE SYSTEM 6
General CF65/75/85 series
1-2 ᓻ 200324
https://www.truck-manuals.net/
6 BRAKE DIAGRAMS FOR FULLY PNEUMATIC BRAKE SYSTEM
CF65/75/85 series Brake diagrams for fully pneumatic brake system
ᓻ 200324 2-1
https://www.truck-manuals.net/
BRAKE DIAGRAMS FOR FULLY PNEUMATIC BRAKE SYSTEM 6
Brake diagrams for fully pneumatic brake system CF65/75/85 series
2-2 ᓻ 200324
https://www.truck-manuals.net/
6 BRAKE DIAGRAMS FOR FULLY PNEUMATIC BRAKE SYSTEM
CF65/75/85 series Brake diagrams for fully pneumatic brake system
R600614
18
62
2
4
B259
B258
1
16
21
22
1
21
2
11
12
33
2
2
4
1
7
53
62
62
62
11
11
1
49
49
21
12
12
62
19
14
14
11
11
62
62
25
22
23
B
A
B257
2
2
21
B256
p p
C
u u
26
11
35
1
29
24
42
2
12 23
41
1
1
62
64
2
1
0
ᓻ 200324 2-3
https://www.truck-manuals.net/
2
4x2 FA
2-4
62 7
C 16 18
62 23 29 11 21 11 21
12 22
u u
0 2 1 p p23
12 22
64 7
1 25
4 24 26
B
A
BRAKE DIAGRAM R600615
53
41 42
1 2 21
19 1
35 22 4 4
33 22 62
1 2
41 42 43
1 2
Brake diagrams for fully pneumatic brake system
22 2
12
12
46 7
12
14 49
https://www.truck-manuals.net/
B257 B259
1 2 11 12 11 2 1
62 B237
62
1 2
12
62
62 62 2
1 2 2 1 11
11
11 12 11
BRAKE DIAGRAMS FOR FULLY PNEUMATIC BRAKE SYSTEM
14 49
B256 B258
R600615
6
CF65/75/85 series
ᓻ 200324
62
6
7 6x4 FTT
C
7 18
16
ᓻ 200324
62 11 21 11 21
4 12 23 29 22
u u
0 2 1 p p 23
12 22
64 7
1 25
4 24 26
CF65/75/85 series
B
A
BRAKE DIAGRAM R600616
53
4
21 1
1 2 19
33 10
22
2
11 12 4
41 42 43 21 2
62
22 11
4 1 2
12
46 12 7 1 2
12
2
4 33
33 1 2
49
https://www.truck-manuals.net/
2
49 B259
12 11 2 1
14
B257
1 2 11 12 62
62
62
62 62
2 1
1 2 14 12 11
11 12
49
B258
B256 49
R600616
Brake diagrams for fully pneumatic brake system
BRAKE DIAGRAMS FOR FULLY PNEUMATIC BRAKE SYSTEM
2-5
2
2
62
7
2-6
8x2 FAC
C
7 18
16
62 11 21 11 21
4 12 23 29 22
u u
0 2 1 p p 23
12 22
64 7
1 25
4 24 26
B 7
A
BRAKE DIAGRAM R600768
53
41 42
21 1
1 2 19
22
2 35 62
22 4
41 42 43 2
4
22 11
12 1 2 1 2
Brake diagrams for fully pneumatic brake system
46 12 7 2
12
B259
11
33 2 11
33 2 1
4 12
1 2
33 1 2
49
4
2 33 2 11
https://www.truck-manuals.net/
49 4
14 10
12 11
B257
1 2 14 11 12 1 12
62 1 2
62 B237
62 62 62 33 1 11
10
1 2
14 11 12 2 12
12 11
BRAKE DIAGRAMS FOR FULLY PNEUMATIC BRAKE SYSTEM
49 12
B256 49 14 2 1
4 2
11
1 2 33
B258
R600768
6
CF65/75/85 series
ᓻ 200324
62
6
7 8x2 FAC
C
7 18
16
ᓻ 200324
62 11 21 11 21
4 12 23 29 22
u u
0 2 1 p p 23
12 22
64 7
1 25
4 24 26
CF65/75/85 series
B 7
A
BRAKE DIAGRAM R600618
41 42 53
1 2
19 21 1
2 35
4 33 11 12 4
1 2 21 2
62
2 4 1 2
33
1 2
1 2
2
49 33
B257 49
https://www.truck-manuals.net/
1 2 14 11 12
12 11
14 B259
2 1
62
62
62
1 2
11 12 62
14 62
2 1
49 12 11 14
B256
4
1 2
49
33 B258
R600618
Brake diagrams for fully pneumatic brake system
BRAKE DIAGRAMS FOR FULLY PNEUMATIC BRAKE SYSTEM
2-7
2
2
62
7 8x4 FAD
2-8
C
7 18
16
62 11 21 11 21
4 12 23 29 22
u u
0 2 1 p p 23
12 22
64 7
1 25
4 24 26
B 7
A
BRAKE DIAGRAM R600619
41 42 53
1 2
21 1
10
35 19
2
11 12 4
21 2
62
4 4 1
Brake diagrams for fully pneumatic brake system
33 2
33 1 2 1 2
1 2 2 2
4 33
49
49
https://www.truck-manuals.net/
B257 14
1 2 11 12
B259
12 11 2 1
14
62 62
62
1 2
14 11 12 62
62
2 1
BRAKE DIAGRAMS FOR FULLY PNEUMATIC BRAKE SYSTEM
49 14 12 11
B256
4
1 2
49
33 B258
R600619
6
CF65/75/85 series
ᓻ 200324
62
6
7 6x4 FTT
C
7 18
16
ᓻ 200324
62 11 21 11 21
4 12 23 29 22
u u
0 2 1 p p 23
12 22
64 7
1 25
4 24 26
CF65/75/85 series
B
A
BRAKE DIAGRAM R600769
53
41 42
21 1
1 2 19
10
22
2 35
11 12 4
41 42 43 21 2
62
22 11
4 1 2
12
46 12 7 1 2
12
2
4 33
33 1 2
49
https://www.truck-manuals.net/
2 B259
49 11
12 11 2 1 2
14
B257 12
1 2 11 12 62
1 2
62
62 B237
62 62 11
2 1 2
1 2 14 12 11
12
11 12
49
B258
B256 49
R600769
Brake diagrams for fully pneumatic brake system
BRAKE DIAGRAMS FOR FULLY PNEUMATIC BRAKE SYSTEM
2-9
2
2
62
7 8x4 FAD
2-10
C
7 18
16
62 11 21 11 21
4 12 23 29 22
u u
0 2 1 p p 23
12 22
64 7
1 25
4 24 26
B 7
A
BRAKE DIAGRAM R600770
41 42 53
1 2
21 1
10
35 19
2
11 12 4
21 2
62
4 4 1
Brake diagrams for fully pneumatic brake system
33 2
33 1 2 1 2
1 2 2 2
4 33
49
49
https://www.truck-manuals.net/
B257 14
1 2 11 12 B259
11
12 11 2 1 2
14
62 62 12
62 1 2
1 2
11 12 62 B237
14 62 11
2 1 2
BRAKE DIAGRAMS FOR FULLY PNEUMATIC BRAKE SYSTEM
49 14 12 11
B256 12
4
1 2
49
33 B258
R600770
6
CF65/75/85 series
ᓻ 200324
6 EBS BRAKE SYSTEM BRAKE DIAGRAMS
ΧΦ65/75/85 series Contents
CONTENTS
3 EBS brake sy stem brake diagrams
Page Date
3
3.1 Legend, EBS brake system brake diagrams . . . . . . . . . . . . . . . . . . . . . . . 3-1 . . . . . 200402
3.2 EBS-2 brake system brake diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 . . . . . 200402
© 200402 1
https://www.truck-manuals.net/
EBS BRAKE SYSTEM BRAKE DIAGRAMS 6
Contents ΧΦ65/75/85 series
2 © 200402
https://www.truck-manuals.net/
6 EBS BRAKE SYSTEM BRAKE DIAGRAMS
ΧΦ65/75/85 series General
1. GENERAL
1.1 BRAKE DIAGRAMS
© 200402 1-1
https://www.truck-manuals.net/
EBS BRAKE SYSTEM BRAKE DIAGRAMS 6
General ΧΦ65/75/85 series
1-2 © 200402
https://www.truck-manuals.net/
6 EBS BRAKE SYSTEM BRAKE DIAGRAMS
ΧΦ65/75/85 series EBS brake system brake diagrams
© 200402 2-1
https://www.truck-manuals.net/
EBS BRAKE SYSTEM BRAKE DIAGRAMS 6
EBS brake system brake diagrams ΧΦ65/75/85 series
Note:
- Two-way valve (10) only fitted on 6x2
vehicles with ASR.
- Two-way valve (11) only fitted on vehicles
with brake drums on the rear axle.
- Redundancy valve (B306) not fitted on 4x2
vehicles, FT version.
- ASR cut-off valve (B309) only fitted on 6x2
vehicles with ASR.
2-2 © 200402
https://www.truck-manuals.net/
6 EBS BRAKE SYSTEM BRAKE DIAGRAMS
ΧΦ65/75/85 series EBS brake system brake diagrams
3
- With air-sprung front axle
R600407 4x2 vehicle, FA version:
- With trailer connection
- With drum brakes on the rear axle
R600408 6x2 vehicle, FT(.) /FA(.) version:
- With trailer connection
- With disc brakes on the rear axle
- With ASR
R600409 6x2 vehicle, FT(.) /FA(.) version:
- With trailer connection
- With disc brakes on the rear axle
- Without ASR
R600410 6x2 vehicle, FT(.) /FA(.) version:
- With trailer connection
- With drum brakes on the rear axle
- With ASR
R600684 6x2 vehicle, FT(.) /FA(.) version:
- With trailer connection
- With disc brakes on the rear axle
- Without ASR
- Situation with spring brake cylinder on front axle
R600685 6x2 vehicle, FTP/FAR version with axle load ratio 11.5/6.7:
- With trailer connection
- With disc brakes on the rear axle
- Without ASR
R600686 6x2 vehicle, FTP/FAR version with axle load ratio 11.5/6.7:
- With trailer connection
- With disc brakes on the rear axle
- With ASR
R600757 4x2 vehicle, FT version
- With trailer connection
- With disc brakes on the rear axle
- With independent trailer brake
© 200402 2-3
https://www.truck-manuals.net/
3
62 7
2-4
4x2 FT
21
62 29 11 11 21
4 12 23 22
u u
0 2 1 p p 23
12 22
64 25
7
1
4 24 26
B
A
Brake diagram R600405
F628
EBS brake system brake diagrams
52
4
21
1
1 2
p
u 22
B307 42 43 4
2 B308 33
22 11 1 2
12 p
u
21 2
7
12
EBS BRAKE SYSTEM BRAKE DIAGRAMS
19
https://www.truck-manuals.net/
14 49
B257
1 2 11 12 11
22 13
62 12
62 s
u
ecu p
u
n
62
62 11 D879
©
1 2 62 21
11 12 11
14 49
B256 R600405
6
200402
ΧΦ65/75/85 series
©
C
6
2
4x2 FA
5 2 62 7
1 1 2
200402
62 21 11 21
4 12 23 29 11
u u 22
0 2 1 p p 23
12 22
64 7
1 25
4 24 26
ΧΦ65/75/85 series
B
Brake diagram R600406
F628
53
4
21 1
1 2
p
u
2
B307 4
33
1 2
19
42
1 2 B306
https://www.truck-manuals.net/
14 49
B257
1 2 11 12 11
22 13
62 12
62 s
u
ecu p
u
n
62
62 11 D879
1 2 62 21
11 12 11
14 49
B256 R600406
EBS BRAKE SYSTEM BRAKE DIAGRAMS
2-5
EBS brake system brake diagrams
3
3
62 7
2-6
4x2 FA
21
62 29 11 11 21
4 12 23 22
u u
0 2 1 p p 23
12 22
64 25
7
1
4 24 26
B
A
Brake diagram R600407
F628
EBS brake system brake diagrams
52
4 19
21 1
1 2
p
u 22
B307 42 43 4
2 B308 33
22 11 1 2
12 p
u
21 2
7
12
EBS BRAKE SYSTEM BRAKE DIAGRAMS
11
42
1 2 B306
https://www.truck-manuals.net/
14 49
B257
1 2 11 12 11
22 13
62 12
62 s
u
ecu p
u
n
62
62 11 D879
21
©
1 2 62
11 12 11
14 49
B256 R600407
6
200402
ΧΦ65/75/85 series
©
6
62 7 6x2
21 FT(.)/ FA(.)
62 29 11 11 21
4 12 23 22
u u
200402
0 2 1 p p 23
12 22
64 25
7
1
4 24 26
B
ΧΦ65/75/85 series
A
Brake diagram R600408
F628
52
4
21 1
1 2
p
u 22
B307 42 43 4
2 B308 33
22 11 1 2
12 p
u
21 2
7
12
19
42
1 2 B306
10
https://www.truck-manuals.net/
14 49 11 12
B257 2
1 2 11 12 11 14 11
22 13
62 12
62 s
u
ecu p
u
n
62
62 11 D879
1 2 62 21
11 12 11 14
B309 1 2
14 11 11 12 10
49 2
B256
R600408
EBS BRAKE SYSTEM BRAKE DIAGRAMS
2-7
EBS brake system brake diagrams
3
3
C
2
2-8
6x2
5 2 62 7
1 1 2 FT(.)/FA(.)
62 21 11 21
4 12 23 29 11
u u 22
0 2 1 p p 23
12 22
64 25
7
1
4 24 26
B
Brake diagram R600409
F628
EBS brake system brake diagrams
52
4
21 1
1 2
p
u 22
B307 42 43 4
2 B308 33
22 11 1 2
12 p
u
EBS BRAKE SYSTEM BRAKE DIAGRAMS
21 2
7
12 42
19 1 2 B306
https://www.truck-manuals.net/
14 49 11
B257 14
1 2 11 12 11
22 13
62 12
62 s
u
ecu p
u
n
62
62 11 D879
62 21
©
1 2
11 12 11
14
14 11
49
B256 R600409
6
200402
ΧΦ65/75/85 series
©
6
62 7
6x2
21 FT(.)/FA(.)
62 29 11 11 21
4 12 23 22
200402
u u
0 2 1 p p 23
12 22
64 25
7
1
4 24 26
B
ΧΦ65/75/85 series
A
Brake diagram R600410
F628
52
4 19
21 1
1 2
p
u 22
B307 42 43 4
2 B308 33
22 11 1 2
12 p
u
21 2
7
12
11 42
1 2 B306
10
https://www.truck-manuals.net/
14 49 11 12
B257 2
1 2 11 12 11 14 11
22 13
62 12
62 s
u
ecu p
u
n
62
62 11 D879
1 2 62 21
11 12 11 14
B309 1 2
14 11 11 12 10
49 2
B256
R600410
EBS BRAKE SYSTEM BRAKE DIAGRAMS
2-9
EBS brake system brake diagrams
3
3
62 7 6x2
2-10
62 29 11 21 11 21
FT(.)/FA(.)
4 12 23
u u 22
0 2 1 p p 23
12 22
64 25
7
1
4 24 26
B
A
Brake diagram R600684
F628
EBS brake system brake diagrams
52
4
21
1
1 2
p
u 22
B307 42 43 4
2 B308 33
22 11 1 2
12 p
u
21 2
7
12
19
EBS BRAKE SYSTEM BRAKE DIAGRAMS
4 42
1 2 1 2 B306
2
https://www.truck-manuals.net/
49 49 11
33 14
B257
1 2 11 12 12 11
22 13
62 12
62 s
u
ecu p
u
n
62
62 11 D879
62 21
©
1 2
11 12 12 11
14
11
49 49
B256 R600684
6
200402
ΧΦ65/75/85 series
©
6
62 7
6x2
29 11
62 21 11 21 FTP/FAR
4 12 23
u u 22
200402
0 2 1 p p 23
11,5/6,7
12 22
64 25
7
1
4 24 26
B
ΧΦ65/75/85 series
A
Brake diagram R600685
F628
52
4 42
21 1
1 2 1 2 B306
p
u 22
B307 42 43 4
2 B308 33
22 11 1 2
12 p
u
21 2
7
12
19 33
2 1
22 13
https://www.truck-manuals.net/
12
s
u
14 49 11 ecu p
u
n
B257 14
11 12 11 11 D879
1 2
21
62
62
62 1
1 2 62
11
62 4
12 11 2
14 2e 33
11
14 49
B256 R600685
2-11
EBS BRAKE SYSTEM BRAKE DIAGRAMS
EBS brake system brake diagrams
3
3
62 7 6x2
2-12
21 FTP/FAR
62 29 11 11 21
4 12 23 22
u u
0 2 1 p p 23 11,5/6,7
12 22
64 25
7
1
4 24 26
B
A
Brake diagram R600686
F628
52
EBS brake system brake diagrams
4 42
21
1
1 2 1 2 B306
p
u 22
B307 42 43 4
2 B308 33
22 11 1 2
12 p
u
21 2
7
12
19 33
2 1
EBS BRAKE SYSTEM BRAKE DIAGRAMS
22 13
https://www.truck-manuals.net/
12
s
u
14 49 11 ecu p
u
n
B257 11
1 2 11 12 11 14 D879
21
62
62
62 1
1 2
©
1 2 62
11
62 4
12 11 14 2
2e 33
11
B309
14 49
B256 R600686
6
200402
ΧΦ65/75/85 series
©
6
62 7 4x2 FT
21
62 29 11 11 21
4 12 23 22
u u
200402
0 2 1 p p 23
12 22
64 25
7
1
4 24 26
B
ΧΦ65/75/85 series
A
Brake diagram R600757
F628
52
4
15
21 1
1 2 2 1
p
u 22
B307 42 43 4
2 B308 33
22 11 1 2
12 p
u
21 2
7
18
12 19
https://www.truck-manuals.net/
14 49
B257
1 2 11 12 11
22 13
62 12
62 s
u
ecu p
u
n
62
62 11 D879
1 2 62 21
11 12 11
14 49
B256 R600757
2-13
EBS BRAKE SYSTEM BRAKE DIAGRAMS
EBS brake system brake diagrams
3
EBS BRAKE SYSTEM BRAKE DIAGRAMS 6
EBS brake system brake diagrams ΧΦ65/75/85 series
2-14 © 200402
https://www.truck-manuals.net/
6 EBS BRAKE SYSTEM BRAKE DIAGRAMS
ΧΦ65/75/85 series EBS-2 brake system brake diagrams
© 200402 3-1
https://www.truck-manuals.net/
EBS BRAKE SYSTEM BRAKE DIAGRAMS 6
EBS-2 brake system brake diagrams ΧΦ65/75/85 series
Note:
- Two-way valve (10) only fitted on 6x2
vehicles with ASR.
- Two-way valve (11) only fitted on vehicles
with brake drums on the rear axle.
- Redundancy valve (B306) not fitted on 4x2
vehicles, FT version.
- ASR cut-off valve (B309) only fitted on 6x2
vehicles with ASR.
3-2 © 200402
https://www.truck-manuals.net/
6 EBS BRAKE SYSTEM BRAKE DIAGRAMS
ΧΦ65/75/85 series EBS-2 brake system brake diagrams
3
- With air-sprung front axle
R600836 4x2 vehicle, FA version:
- With trailer connection
- With drum brakes on the rear axle
R600837 6x2 vehicle, FT(.) /FA(.) version:
- With trailer connection
- With disc brakes on the rear axle
- With ASR
R600838 6x2 vehicle, FT(.) /FA(.) version:
- With trailer connection
- With disc brakes on the rear axle
- Without ASR
R600839 6x2 vehicle, FT(.) /FA(.) version:
- With trailer connection
- With drum brakes on the rear axle
- With ASR
R600840 6x2 vehicle, FT(.) /FA(.) version:
- With trailer connection
- With disc brakes on the rear axle
- Without ASR
- Situation with spring brake cylinder on front axle
R600841 6x2 vehicle, FTP/FAR version with axle load ratio 11.5/6.7:
- With trailer connection
- With disc brakes on the rear axle
- Without ASR
R600842 6x2 vehicle, FTP/FAR version with axle load ratio 11.5/6.7:
- With trailer connection
- With disc brakes on the rear axle
- With ASR
R600843 4x2 vehicle, FT version
- With trailer connection
- With disc brakes on the rear axle
- With independent trailer brake
© 200402 3-3
https://www.truck-manuals.net/
3
62 7
3-4
4x2 FT
21
62 29 11 11 21
4 12 23 22
u u
0 2 1 p p 23
12 22
64 25
7
1
4 24 26
B
A
Brake diagram R600834
F628
EBS-2 brake system brake diagrams
52
4
21
1
1 2
p
u 22
B307 42 43 4
2 B308 33
22 11 1 2
12 p
u
21 2
7
12
EBS BRAKE SYSTEM BRAKE DIAGRAMS
19
https://www.truck-manuals.net/
14 49
B257
1 2 11 12 11
22 13
62 12
62 s
u
ecu p
u
n
62
62 11 D879
©
1 2 62 21
11 12 11
14 49
B256 R600405
6
200402
ΧΦ65/75/85 series
©
C
6
2
4x2 FA
5 2 62 7
1 1 2
200402
62 21 11 21
4 12 23 29 11
u u 22
0 2 1 p p 23
12 22
64 7
1 25
4 24 26
ΧΦ65/75/85 series
B
Brake diagram R600835
F628
53
4
21 1
1 2
p
u
2
B307 4
33
1 2
19
42
1 2 B306
https://www.truck-manuals.net/
14 49
B257
1 2 11 12 11
22 13
62 12
62 s
u
ecu p
u
n
62
62 11 D879
1 2 62 21
11 12 11
14 49
B256 R600406
EBS BRAKE SYSTEM BRAKE DIAGRAMS
3-5
EBS-2 brake system brake diagrams
3
3
62 7
3-6
4x2 FA
21
62 29 11 11 21
4 12 23 22
u u
0 2 1 p p 23
12 22
64 25
7
1
4 24 26
B
A
Brake diagram R600836
F628
EBS-2 brake system brake diagrams
52
4 19
21 1
1 2
p
u 22
B307 42 43 4
2 B308 33
22 11 1 2
12 p
u
21 2
7
12
EBS BRAKE SYSTEM BRAKE DIAGRAMS
11
42
1 2 B306
https://www.truck-manuals.net/
14 49
B257
1 2 11 12 11
22 13
62 12
62 s
u
ecu p
u
n
62
62 11 D879
21
©
1 2 62
11 12 11
14 49
B256 R600407
6
200402
ΧΦ65/75/85 series
©
6
62 7 6x2
21 FT(.)/ FA(.)
62 29 11 11 21
4 12 23 22
u u
200402
0 2 1 p p 23
12 22
64 25
7
1
4 24 26
B
ΧΦ65/75/85 series
A
Brake diagram R600837
F628
52
4
21 1
1 2
p
u 22
B307 42 43 4
2 B308 33
22 11 1 2
12 p
u
21 2
7
12
19
42
1 2 B306
10
https://www.truck-manuals.net/
14 49 11 12
B257 2
1 2 11 12 11 14 11
22 13
62 12
62 s
u
ecu p
u
n
62
62 11 D879
1 2 62 21
11 12 11 14
B309 1 2
14 11 11 12 10
49 2
B256
R600408
EBS BRAKE SYSTEM BRAKE DIAGRAMS
3-7
EBS-2 brake system brake diagrams
3
3
C
2
3-8
6x2
5 2 62 7
1 1 2 FT(.)/FA(.)
62 21 11 21
4 12 23 29 11
u u 22
0 2 1 p p 23
12 22
64 25
7
1
4 24 26
B
Brake diagram R600838
F628
EBS-2 brake system brake diagrams
52
4
21 1
1 2
p
u 22
B307 42 43 4
2 B308 33
22 11 1 2
12 p
u
EBS BRAKE SYSTEM BRAKE DIAGRAMS
21 2
7
12 42
19 1 2 B306
https://www.truck-manuals.net/
14 49 11
B257 14
1 2 11 12 11
22 13
62 12
62 s
u
ecu p
u
n
62
62 11 D879
62 21
©
1 2
11 12 11
14
14 11
49
B256 R600409
6
200402
ΧΦ65/75/85 series
©
6
62 7
6x2
21 FT(.)/FA(.)
62 29 11 11 21
4 12 23 22
200402
u u
0 2 1 p p 23
12 22
64 25
7
1
4 24 26
B
ΧΦ65/75/85 series
A
Brake diagram R600839
F628
52
4 19
21 1
1 2
p
u 22
B307 42 43 4
2 B308 33
22 11 1 2
12 p
u
21 2
7
12
11 42
1 2 B306
10
https://www.truck-manuals.net/
14 49 11 12
B257 2
1 2 11 12 11 14 11
22 13
62 12
62 s
u
ecu p
u
n
62
62 11 D879
1 2 62 21
11 12 11 14
B309 1 2
14 11 11 12 10
49 2
B256
R600410
EBS BRAKE SYSTEM BRAKE DIAGRAMS
3-9
EBS-2 brake system brake diagrams
3
3
62 7 6x2
3-10
62 29 11 21 11 21
FT(.)/FA(.)
4 12 23
u u 22
0 2 1 p p 23
12 22
64 25
7
1
4 24 26
B
A
Brake diagram R600840
F628
52
EBS-2 brake system brake diagrams
4
21
1
1 2
p
u 22
B307 42 43 4
2 B308 33
22 11 1 2
12 p
u
21 2
7
12
19
EBS BRAKE SYSTEM BRAKE DIAGRAMS
4 42
1 2 1 2 B306
2
https://www.truck-manuals.net/
49 49 11
33 14
B257
1 2 11 12 12 11
22 13
62 12
62 s
u
ecu p
u
n
62
62 11 D879
62 21
©
1 2
11 12 12 11
14
11
49 49
B256 R600684
6
200402
ΧΦ65/75/85 series
©
6
62 7
6x2
29 11
62 21 11 21 FTP/FAR
4 12 23
u u 22
200402
0 2 1 p p 23
11,5/6,7
12 22
64 25
7
1
4 24 26
B
ΧΦ65/75/85 series
A
Brake diagram R600841
F628
52
4 42
21 1
1 2 1 2 B306
p
u 22
B307 42 43 4
2 B308 33
22 11 1 2
12 p
u
21 2
7
12
19 33
2 1
22 13
https://www.truck-manuals.net/
12
s
u
14 49 11 ecu p
u
n
B257 14
11 12 11 11 D879
1 2
21
62
62
62 1
1 2 62
11
62 4
12 11 2
14 2e 33
11
14 49
B256 R600685
3-11
EBS BRAKE SYSTEM BRAKE DIAGRAMS
EBS-2 brake system brake diagrams
3
3
62 7 6x2
3-12
21 FTP/FAR
62 29 11 11 21
4 12 23 22
u u
0 2 1 p p 23 11,5/6,7
12 22
64 25
7
1
4 24 26
B
A
Brake diagram R600842
F628
52
EBS-2 brake system brake diagrams
4 42
21
1
1 2 1 2 B306
p
u 22
B307 42 43 4
2 B308 33
22 11 1 2
12 p
u
21 2
7
12
19 33
2 1
EBS BRAKE SYSTEM BRAKE DIAGRAMS
22 13
https://www.truck-manuals.net/
12
s
u
14 49 11 ecu p
u
n
B257 11
1 2 11 12 11 14 D879
21
62
62
62 1
1 2
©
1 2 62
11
62 4
12 11 14 2
2e 33
11
B309
14 49
B256 R600686
6
200402
ΧΦ65/75/85 series
©
6
62 7 4x2 FT
21
62 29 11 11 21
4 12 23 22
u u
200402
0 2 1 p p 23
12 22
64 25
7
1
4 24 26
B
ΧΦ65/75/85 series
A
Brake diagram R600843
F628
52
4
15
21 1
1 2 2 1
p
u 22
B307 42 43 4
2 B308 33
22 11 1 2
12 p
u
21 2
7
18
12 19
https://www.truck-manuals.net/
14 49
B257
1 2 11 12 11
22 13
62 12
62 s
u
ecu p
u
n
62
62 11 D879
1 2 62 21
11 12 11
14 49
B256 R600757
3-13
EBS BRAKE SYSTEM BRAKE DIAGRAMS
EBS-2 brake system brake diagrams
3
EBS BRAKE SYSTEM BRAKE DIAGRAMS 6
EBS-2 brake system brake diagrams ΧΦ65/75/85 series
3-14 © 200402
https://www.truck-manuals.net/
6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series Contents
CONTENTS
Page Date
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 . . . . 200324
1.1 Overview drawing, Knorr SB7000 disc brake construction . . . . . . . . . . . . . . 1-2 . . . . 200324
1.2 Overview drawing, Knorr SN7000 disc brake construction . . . . . . . . . . . . . . 1-4 . . . . 200324
2. DESCRIPTION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . 200324
2.1 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 . . . . 200324
2.2 Safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 . . . . 200324
2.3 Air supply unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 . . . . 200324
2.4 Water blow-off valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 . . . . 200324
2.5 Foot brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 . . . . 200324
2.6 Relay valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 . . . 200324
2.7 Empty/load relay valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 . . . 200324
2.8 Brake light switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 . . . 200324
2.9 Load sensing valve, air suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 . . . 200324
4
2.10 Load sensing valve, leaf suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 . . . 200324
2.11 ABS valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 . . . 200324
2.12 Two-way valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 . . . 200324
2.13 ASR solenoid valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 . . . 200324
2.14 Emergency filling/test connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27 . . . 200324
2.15 Brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28 . . . 200324
2.16 Parking brake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 . . . 200324
2.17 Low-pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33 . . . 200324
2.18 Spring brake cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 . . . 200324
2.19 Trailer vehicle control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37 . . . 200324
2.20 Coupling head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41 . . . 200324
2.21 Automatic brake adjuster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 . . . 200324
2.22 Disc brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44 . . . 200324
2.23 Quick-release coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 . . . 200324
ᓻ 200324 1
https://www.truck-manuals.net/
OPERATION OF BRAKE COMPONENTS 6
Contents CF65/75/85 series
2 ᓻ 200324
https://www.truck-manuals.net/
6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series General
1. GENERAL
ᓻ 200324 1-1
https://www.truck-manuals.net/
OPERATION OF BRAKE COMPONENTS 6
General CF65/75/85 series
20
18 21
19
17
1
3 22
6a
4 6
7
5 16
8
15
14
11
10
9
R600746
1-2 ᓻ 200324
https://www.truck-manuals.net/
6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series General
Legend
1 Brake saddle
2 Brake saddle carrier
3 Rubber bearing bush
4 Socket head screw
5 Guide sleeve
6 Cap
7 Copper bearing bush
8 Guide sleeve
9 Clamping strip
10 Bellows
11 Socket head screw
14 Bellows
15 Washer
16 Bearing bushes
17 Brake pad
18 Attachment bracket
19 Lock washer
20 Pin
21 Retainer clip 4
22 Thrust pieces with bellows
ᓻ 200324 1-3
https://www.truck-manuals.net/
OPERATION OF BRAKE COMPONENTS 6
General CF65/75/85 series
20
21
18
19
4 5
17
22
6 6a
3 7
4 16
8 23
15
11 14
10
R600755
1-4 ᓻ 200324
https://www.truck-manuals.net/
6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series General
Legend
1 Brake saddle
2 Brake saddle carrier
3 Rubber bearing bush
4 Socket head screw
5 Guide sleeve
6 Cap
6a Adapter
7 Copper bearing bush
8 Guide sleeve
10 Protective cover
11 Socket head screw
14 Bellows
15 Washer
16 Bearing bushes
17 Brake pad
18 Attachment bracket
19 Lock washer
20 Pin
21 Retainer clip 4
22 Thrust pieces with bellows
23 Sealing rings
ᓻ 200324 1-5
https://www.truck-manuals.net/
OPERATION OF BRAKE COMPONENTS 6
General CF65/75/85 series
1-6 ᓻ 200324
https://www.truck-manuals.net/
6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series Description of components
2. DESCRIPTION OF COMPONENTS
2.1 COMPRESSOR
CF65 series
The compressor is a single-cylinder design of
225 cm3 with a water-cooled cylinder head. The
compressor is mounted on the left side of the
engine against the flywheel housing.
The compressor is driven via a gear wheel from
the camshaft gear on the flywheel side of the
engine.
CF75/85 series
The compressor is a two-cylinder design of
440 cm3 with a water-cooled cylinder head. The
compressor is mounted on the right side of the
engine against the timing gear case.
The compressor is driven by the camshaft gear
via a gear wheel. 4
The compressor has a so-called energy-saving
function.
When the air-pressure system has reached the
set pressure, the pressure regulator in the air
dryer will send a pressure signal back to the
compressor head via port 23.
In the compressor head, a plunger operates two
valves which connect the inlet and exhaust
valves inside the compressor head.
The compressed air is then constantly pumped
internally from one cylinder to the other.
This energy-saving function has a positive effect
on the engine efficiency.
If the pressure regulator switches off to fill up
the air-pressure system, the plunger will move
the two valves into their initial position, making it
possible for the compressor to supply pressure
again.
ᓻ 200324 2-1
https://www.truck-manuals.net/
OPERATION OF BRAKE COMPONENTS 6
Description of components CF65/75/85 series
Purpose
The purpose of the safety valve is to limit the
pressure build-up to a given value.
Operation
The compressor air enters at L and arrives at
spring-loaded ball 1. When the pressure
exceeds the pre-set value, the ball will be lifted
from its seat. The excess air is vented to the
atmosphere via bores E.
When the pressure drops below the pre-set
value, the ball will close again.
L
R600050
2-2 ᓻ 200324
https://www.truck-manuals.net/
6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series Description of components
Purpose
The air supply unit is a combination of an air
dryer, pressure regulator and four-circuit safety
valve and has the following functions:
- removing water, oil and other foreign matter
from the air, even before they enter the
brake system;
- setting the system pressure by means of a
built-in pressure regulator;
- limiting the pressure build-up to a given
value;
- splitting the brake system into four circuits
and, should one circuit fail, protecting the
other circuits against running empty.
4
R600359
4
1/12 21
a 12
23 14
8 13
15
17
19
18
c 16
10
b 9
5 11 7 6
R600457
ᓻ 200324 2-3
https://www.truck-manuals.net/
OPERATION OF BRAKE COMPONENTS 6
Description of components CF65/75/85 series
A B
23 21 3 23 25
H U
6.2
D P 6.3
6.4
F 1 K
6.5
U 6.6
P
6.7
C
21
1
E 0 24 26 22
G
6.1
6.2
12 3 24
R600580
M L
2 1 1 2
A B
23 29 11 21 3 23 25
H U
6.2
D P 6.3
6.4
F K
6.5
21 P
U 6.6
6.7
C
1
E 0 24 26 22
G
6.1
6.2
12 3
R600581
2-4 ᓻ 200324
https://www.truck-manuals.net/
6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series Description of components
5 11 7 6
R600457
ᓻ 200324 2-5
https://www.truck-manuals.net/
OPERATION OF BRAKE COMPONENTS 6
Description of components CF65/75/85 series
Regenerating
A regeneration tank is no longer necessary,
because the air inside the circuits is used.
A built-in pneumatic time switch controls the
regeneration process:
- throttle 5 determines the amount of air
- throttle 6 determines the length of time.
3
Via throttle 6, air is admitted to chamber ‘b’ and
air is also admitted to chamber ‘c’ via bore 7 in A
piston 9. On cut-out by the pressure regulator, 1
blow-off valve 8 is opened and chamber ‘c’ is 29
vented via bore 7. Piston 9 is moved to the right 21
against the pressure of spring 10 as a result of 2
the difference in pressure between chambers ‘b’
and ‘c’. This releases the piston 9 from its seat 4
(11) and air from the system will flow in the 1/12 21
4
opposite direction through the filter element via a 12
23 14
throttle 5. At the same time, pressure is reduced
in chamber ‘b’ via throttle 6. The piston (9) 8 13
moves to the left until it abuts the seat (11). 15
17
Regeneration is now complete. 19
18
c 16
10
b 9
5 11 7 6
R600457
2-6 ᓻ 200324
https://www.truck-manuals.net/
6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series Description of components
R600476
6.2
U 6.3
P
6.4
6.5
U 6.6
P
6.7
24 26 22
R600477
ᓻ 200324 2-7
https://www.truck-manuals.net/
OPERATION OF BRAKE COMPONENTS 6
Description of components CF65/75/85 series
Purpose
The purpose of the water blow-off valve is to
enable any condensate in the air reservoir or air
pipes to be drained and, if necessary, to vent
the system.
Operation
The valve is kept closed by the spring and the
reservoir pressure. By pushing the pin
sideways, the valve is lifted off the seat, allowing
condensate and compressed air to escape.
When the pin is released, the valve is closed.
Check that no other components are present
under the blow-off plug, as these could get
fouled during the blow-off process.
4
R600046
2-8 ᓻ 200324
https://www.truck-manuals.net/
6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series Description of components
Purpose
The purpose of the foot brake valve is to allow
sensitive aeration and venting of both service
brake circuits, independently of each other.
R600379
Operation
The foot brake valve consists of an upper
section (circuit 1) and a lower section (circuit 2);
both have a connection point for the reservoir
pipe (11 and 12 respectively) and a connection
point for the brake line (21 and 22 respectively).
If the pedal is depressed, push rod 1, spring
retainer 2 and rubber graduating spring 3 will
exert force on graduating piston 4. The
1
graduating piston moves downwards, closes off
exhaust 5 and opens inlet 10. The supply
pressure at connection point 11 flows via
chamber A and connection 21 to the brake 2
3
cylinders of circuit 1. 4
At the same time, compressed air flows via bore A 10
5
D into chamber B above graduating piston 7, 6 B
which is forced downwards as a result. Exhaust 11 21 D
9 is closed and inlet 8 opened. Via chamber C 7
and connection 22, the supply pressure at 9
connection 12 flows to the brake cylinders in C
circuit 2. 12 22
8
Fig.2
R600748
ᓻ 200324 2-9
https://www.truck-manuals.net/
OPERATION OF BRAKE COMPONENTS 6
Description of components CF65/75/85 series
2-10 ᓻ 200324
https://www.truck-manuals.net/
6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series Description of components
Purpose
The purpose of the relay valve is to allow fast
aeration and venting of the spring brake
cylinders and brake cylinders, shortening the
brake reaction/release time.
Note:
The hysteresis of the relay valve used for the
parking brake is greater and therefore is not
suitable for use in the service brake.
1 6
5
R600491
ᓻ 200324 2-11
https://www.truck-manuals.net/
OPERATION OF BRAKE COMPONENTS 6
Description of components CF65/75/85 series
Purpose
The purpose of this valve is to adjust the brake
pressure to the front axle depending on the
output pressure from the ALR valve of the rear
axle.
4 R600049
2-12 ᓻ 200324
https://www.truck-manuals.net/
6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series Description of components
1 2
3
R600494
ᓻ 200324 2-13
https://www.truck-manuals.net/
OPERATION OF BRAKE COMPONENTS 6
Description of components CF65/75/85 series
Purpose
The purpose of the brake light switch is to
operate the brake lights when braking.
Operation
The brake light switch is mounted in the air pipe
in a conventional brake system, and in an
EBS system in the foot brake valve (see brake
diagrams).
The brake light switch consists of a diaphragm
(1) with a fixed core (2), which in rest position is
kept in its lower position by a spring (3).
In the rest position, the spring also forces
movable contact 4 downwards. As soon as the
brakes are applied, pressure beneath the
diaphragm forces the diaphragm with the fixed
4 core upwards, against the pressure of the
spring. The movable contact also moves
upwards, and the switch is activated.
If the pressure beneath the diaphragm falls
away, spring 3 ensures that the initial position is
restored. The switch must be installed in a
vertical position, with the terminals uppermost.
4
2
1
R 600105
2-14 ᓻ 200324
https://www.truck-manuals.net/
6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series Description of components
Purpose
Automatic control of the braking force is
dependent on the pressure in the bellows and
therefore on the load condition of the vehicle.
Thanks to the integrated relay valve, the brake
cylinders are aerated and vented quickly.
41 42
43
i g d m o n
4
s F
D E
C
A 4
G C
c b
r B
j f
e l
1 2
k
h
3
R600455
Operation
The control valve is activated by the pressure of
the left and right bellows via connection points
41 and 42. The actuated piston (i) that moves
against the pressure of spring ‘j’ brings the
tappet (g) to a position that corresponds to the
load condition. The arithmetic average of the
bellows pressure on the left and right is the
determining factor in this.
ᓻ 200324 2-15
https://www.truck-manuals.net/
OPERATION OF BRAKE COMPONENTS 6
Description of components CF65/75/85 series
2-16 ᓻ 200324
https://www.truck-manuals.net/
6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series Description of components
41 42
43
i g d m o n
a
s F
D E
C
A 4
G C
c b
r B
4
j f
e l
1 2
k
h
3
R600455
ᓻ 200324 2-17
https://www.truck-manuals.net/
OPERATION OF BRAKE COMPONENTS 6
Description of components CF65/75/85 series
4
hose to it, the bellows will be pneumatically
closed, allowing the valve to be operated with a
random test pressure.
2-18 ᓻ 200324
https://www.truck-manuals.net/
6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series Description of components
Purpose
Automatic control of the brake force depends on
the deflection of the springs and therefore on
the loading condition of the vehicle. Thanks to
the integrated relay valve, the brake cylinders
are aerated and vented quickly.
p q g d m o n
a
F
D E
C
A 4 4
G C
c b
i B
f
e l
j
1 2
k
h
3
R600456
Operation
The control valve is attached to the chassis and
connected to the rear axle by means of a rod.
With unloaded vehicles, the distance between
the regulator and the axle is largest and the
lever (j) points fully downwards. When the
vehicle is loaded, this distance decreases and
the lever moves upwards, towards full load
position.
Pin ‘i’ rotates with the lever and moves to the
right via the control groove in bearing cover ‘p’
as a result. Rod ‘q’ brings the tappet (g) in a
position that corresponds with the loading
condition.
ᓻ 200324 2-19
https://www.truck-manuals.net/
OPERATION OF BRAKE COMPONENTS 6
Description of components CF65/75/85 series
2-20 ᓻ 200324
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6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series Description of components
p q g d m o n
a
F
D E
C
A 4
G C
c b
i B
f
e l
j
4
1 2
k
h
3
R600456
ᓻ 200324 2-21
https://www.truck-manuals.net/
OPERATION OF BRAKE COMPONENTS 6
Description of components CF65/75/85 series
4
pressure if lever ‘j’ is in too low a position due to
a fault. The factory setting of this bolt must not
be changed.
2-22 ᓻ 200324
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6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series Description of components
R600264
ᓻ 200324 2-23
https://www.truck-manuals.net/
OPERATION OF BRAKE COMPONENTS 6
Description of components CF65/75/85 series
4 build up.
By activating the magnet coil 10 at the same
time, bore 16 opens and bore 23 closes. 5
15
By opening bore 16, the pressure under
diaphragm 6 can be reduced via the vent. The 1 7
pressure in the brake chamber can now escape
via connection point 2, chamber 20 and an 15
internal bore to the vent. 2
11
Maintaining pressure at connecting point 2 9
By deactivating magnet coil 10, the input 20
pressure can be guided via a bore past magnet
22
coil 10 into chamber 19 under diaphragm 6, thus 23
sealing off diaphragm 6. 10
The pressure in the brake chamber can now no 6
longer be guided to the vent via chamber 20. 12
This keeps the pressure in the brake chamber 19
constant. 16
1
2
20
23
10 6
12
19
16
R600019
2-24 ᓻ 200324
https://www.truck-manuals.net/
6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series Description of components
ᓻ 200324 2-25
https://www.truck-manuals.net/
OPERATION OF BRAKE COMPONENTS 6
Description of components CF65/75/85 series
4
D
C
3 R600601
2-26 ᓻ 200324
https://www.truck-manuals.net/
6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series Description of components
R600495
ᓻ 200324 2-27
https://www.truck-manuals.net/
OPERATION OF BRAKE COMPONENTS 6
Description of components CF65/75/85 series
Purpose
The purpose of the brake cylinder is to apply the
brake shoes or pads to the brake drum/disc.
Operation
When the foot brake valve is operated,
compressed air is admitted at the pressure side
of diaphragm 1. Diaphragm 1 and push rod 2
are pushed outwards against the pressure of the
spring. As a result, the brake shoes are forced
against the brake drum via a lever mechanism.
The air on the other side of the diaphragm can
escape via vent holes and the clearance around
the push rod.
When the brakes are released, coil spring 3 will
4
force the push rod and the diaphragm back to
their initial position.
When the brakes are released, the brake
cylinder will always draw in ambient air on the
non-pressure side. When the brakes are R600505
released the push rod should return fully to its
initial position. The triggering pressure should
not exceed 0.5 bar.
2
R600506
2-28 ᓻ 200324
https://www.truck-manuals.net/
6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series Description of components
Operation 8
The parking brake valve has 3 positions: 2
1. driving
2. parking 3 9
3. test 4
5 10 4
6
1
21
1 21 22
22
3
R600397
Driving
With the handle in the driving position, there is a
through connection in the valve for the supply
pressure (connection point 1) to the connection
points for spring brake cylinders 21 and trailer
vehicle 22. The vent is now closed.
The output pressure at connection points 21 and
22 is now approx. 8.5 bar (see graph).
Emergency braking
If the handle is pulled a little backwards against
the spring pressure, tappet 3 will move
downwards via eccentric 2. The chamber at
connection point 21 can now be vented and as a
result the pressure at connection point 21 will
drop. Via the bore in valve 10 the pressure at
connection point 22 will also drop. Spring 4
forces piston 5 down until valve 6 comes into
contact with the seal collar of tappet 3. A state
of equilibrium has now been achieved.
When the handle is moved against stop 7, the
vent will remain open, so that the spring brakes
and the trailer vehicle brakes will be applied to
their maximum (max. emergency-brake
position).
ᓻ 200324 2-29
https://www.truck-manuals.net/
OPERATION OF BRAKE COMPONENTS 6
Description of components CF65/75/85 series
Parking
When the handle is pulled past stop 7, it is
locked in position.
Connection points 21 and 22 will remain
pressureless, so that the spring brakes and the
trailer vehicle brakes are still applied to their
maximum.
Test
When the handle is moved beyond the parking
position, cam 8 will move tappet 9 downwards,
causing the bore in valve 10 to be closed and
the valve to be lifted from its seat.
The supply pressure can now be passed to
connection point 22, via a bore in piston 5. As a
result, the trailer vehicle brakes will be released.
Connection point 21 remains vented, so that the
spring brakes keep the parking brake shoes
4 applied.
The combination is now braked only by the force
exerted by the spring brake cylinders on the
truck. It can now be checked whether the
combination remains motionless when the trailer
vehicle brakes are not applied. When the handle
is released, it will automatically return to the
parking position.
Releasing the brakes 1 21 22
When the handle is once again moved fully
forwards, tappet 3 will move upwards, seat 3
R600399
against valve 6 and push the valve from its seat
in piston 5. As a result, the supply pressure can
reach connection points 21 and 22.
2-30 ᓻ 200324
https://www.truck-manuals.net/
6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series Description of components
1 2
3
R600095
Driving
With the handle in the driving position, there is a
through connection in the valve for the supply
pressure (connection point 1) to the connection
points for spring brake cylinders 21 and trailer
vehicle 22. The vent is now closed.
The output pressure at connection points 21 and
22 is now approx. 8.5 bar (see graph).
Emergency braking
If the handle is pulled a little backwards against
the spring pressure, tappet 3 will move
downwards via eccentric 2. The chamber at
connection point 21 can now be vented and as a
result the pressure at connection point 21 will
drop. Via the bore in valve 10 the pressure at
connection point 22 will also drop. Spring 4
forces piston 5 down until valve 6 comes into
contact with the seal collar of tappet 3. A state
of equilibrium has now been achieved.
When the handle is moved against stop 7, the
vent will remain open, so that the spring brakes
and the trailer vehicle brakes will be applied to
their maximum (max. emergency-brake
position).
ᓻ 200324 2-31
https://www.truck-manuals.net/
OPERATION OF BRAKE COMPONENTS 6
Description of components CF65/75/85 series
Parking
When the handle is pulled past stop 7, it is
locked in position.
Connection point 21 is still pressureless.
Connection point 22 is connected to the
reservoir connection via a bore in piston 5 and
valve 10, which has been pushed from its seat
by tappet 9. The combination is now braked only
by the force exerted by the spring brake
cylinders on the truck.
Releasing the brakes
When the handle is once again moved fully
forwards, tappet 3 will move upwards, seat
against valve 6 and push the valve from its seat
in piston 5. As a result, the supply pressure can
reach connection points 21 and 22.
2-32 ᓻ 200324
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6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series Description of components
Purpose
The purpose of the low-pressure switch is to
switch off the warning lights when a pre-set
pressure is reached.
1. Diaphragm
2. Switch
3. Contact
4. Contact
5. Thrust pin
3 4
4
2
5
1
R 600106
Operation
If the pre-set pressure in the air pipe is reached,
the existing connection of both contacts 3 and 4
is cut off by diaphragm 1. If the pressure falls
below the pre-set value, both contacts are
connected again.
ᓻ 200324 2-33
https://www.truck-manuals.net/
OPERATION OF BRAKE COMPONENTS 6
Description of components CF65/75/85 series
Purpose 11
The purpose of the spring brake cylinder is to
force the brake pads/shoes against the
disc/drum when the service or parking brake is
operated.
Operation, spring brake cylinder
The spring brake cylinder consists of two parts:
a part for the service brake, which is designed
as a normal brake cylinder, and a part for the
parking brake, being a spring brake cylinder.
Normal position during driving.
The air reservoirs must be at a safe pressure 12
before you start driving. If this is not the case, a
warning signal (e.g. a buzzer) will be
4 transmitted.
If this pressure is admitted to the spring brake
cylinder, the piston will compress the powerful 11
spring. The push rod is no longer under load
and will go into the non-braked position due to
the operation of the spring, etc.
Service brake
Because the brake cylinder and the spring brake
cylinder are separate, the spring brake cannot
affect the operation of the service brake.
When the service brake is applied, the powerful
spring continues to be compressed, while there
is air pressure on the diaphragm of the brake
cylinder. When the foot brake valve is operated,
12
the compressed air passes through connection
point 11 into the chamber behind the diaphragm.
The diaphragm with push rod is pushed out
against the spring pressure.
The air on the other side of the diaphragm can 11
escape via vent holes. When the brakes are
released, the spring forces the push rod and the
diaphragm back into their original position.
12
R600507
2-34 ᓻ 200324
https://www.truck-manuals.net/
6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series Description of components
Parking brake 11
Connection point 12 is vented.
The powerful spring then forces the piston with
the piston tube against the diaphragm, so that
the push rod is forced outwards. Here, use is
made of the continuously available energy of the
compressed, powerful spring.
Release tool, spring brake cylinder with
unscrewable release bolt
If, due to a failure, no compressed air is
available in the spring brake cylinder, the vehicle
brakes are automatically applied.
But it must still be possible to tow the vehicle. 12
The spring brake cylinder is therefore fitted with
a release bolt at the rear. By turning this bolt
anticlockwise using a spanner, the powerful
spring will be compressed.
4
As the bolt is provided with a thrust bearing, the 11
torque required is not more than 20 - 40 Nm.
Do not use a pneumatic spanner for this
purpose.
Because the spring brakes have
been released mechanically, the
parking brake can no longer be
applied.
12
R600507
ᓻ 200324 2-35
https://www.truck-manuals.net/
OPERATION OF BRAKE COMPONENTS 6
Description of components CF65/75/85 series
4 applied.
2-36 ᓻ 200324
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6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series Description of components
Purpose
The purpose of the trailer vehicle control valve is
to pass on the brake commands from the truck
to the trailer vehicle.
41
22
42
12 43
11
4
R600335
Operation
Driving
Connection point 11 is connected with a
reservoir and connection point 43 with the
parking brake valve. Both are pressurised and in
a state of equilibrium. The service coupling head
communicates with the ambient air via
connecting point 22, valve 8 and the vent with
damper.
R600340
ᓻ 200324 2-37
https://www.truck-manuals.net/
OPERATION OF BRAKE COMPONENTS 6
Description of components CF65/75/85 series
Pressure build-up
Circuit 1, connection point 41, and circuit 2,
connection point 42, are pressurised by the foot
brake valve.
This pushes down the pistons (1 and 2), causing
valve 8 to close the outlet and open the inlet.
The supply pressure at connection point 11 can
now flow via valve 8 to connection point 22,
(yellow) trailer service coupling head, and will
cause the drawn vehicle to brake.
Adjusting
When a pre-set output pressure has been
reached at connection point 22, this pressure
will once again force the piston (5) upwards,
thus closing valve 8.
2-38 ᓻ 200324
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6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series Description of components
Pressure build-up
If the foot brake valve is used to build up
pressure at connection points 41 and 42, the
output pressure at connection point 22 will also
move piston 5 upwards, closing valve 8.
There is now a state of balance between the
input pressure at connection point 41 and the
output pressure at connection point 22.
Change
If adjusting screw 6 is turned clockwise, for
example, spring retainer 4 will be moved
downwards, further compressing the spring
underneath it. Therefore, if the operating
pressure at connection points 41 and 42 remain
the same, a higher adjusting pressure will be
needed under piston 5. This adjusting pressure
is also on the yellow coupling head. 4
This increase of service pressure to the trailer
vehicle in relation to the brake pressure from the
truck is called brake pressure advance.
For the setting procedure, see “Inspection and
adjustment”.
R600340
ᓻ 200324 2-39
https://www.truck-manuals.net/
OPERATION OF BRAKE COMPONENTS 6
Description of components CF65/75/85 series
Emergency brake
When the parking brake valve is moved into the
locking position, connection point 43 will be
gradually vented.
Piston 9 moves upwards and valve 8 is opened.
Depending on the drop in pressure at
connection point 43, a pressure build-up will
occur at connection point 22. When a pre-set
value has been reached, valve 8 will close so
that a state of equilibrium is achieved.
Parking brake
When the parking brake valve is in its maximum
position, i.e. the position at which the lever is
blocked, connection point 43 is vented. As a
consequence, there is still an output pressure at
connection 22.
4
Protection against breakage of service line
During braking pressure will be built up on
connection point 22. The air needed for this is
supplied from connection point 11.
If the service line is broken, pressure will not
build up in chamber E, which will cause piston 9
to move up and close against the bottom of
valve 8. The supply from connection point 11
stagnates, causing pressure to be delivered R600340
from connection point 12.
The pressure in the reservoir pipe drops and the
trailer vehicle brakes are applied.
2-40 ᓻ 200324
https://www.truck-manuals.net/
6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series Description of components
Application
With spring-loaded valve. Fitted in the
dual-circuit brake system of versions with trailer
connections.
If these automatic coupling heads are applied,
there is no need for an air cock.
Purpose
Connecting the air brake system of the tractive
unit with that of the trailer vehicle.
Operation
Spring-loaded valve 2 in the coupling head
ensures that the system is isolated from the
ambient air.
When coupling, turn the counter head until the
claws of the two heads rest against the stop
under the locking plates. This will prevent the 4
coupling head from disengaging spontaneously.
Because the two sealing rings (1) are pressed 1
against each other, the spring-loaded valve
remains open so that an air-tight connection is
achieved. When the heads are uncoupled, the
spring-loaded valve will seal off the pipe on the
tractive unit. 2
The coupling head is equipped with a safety
cam. This is to prevent different coupling heads
being coupled to one another.
If no trailer vehicle is hooked up, the cover of
the coupling head must be closed, to avoid
fouling.
R600101
ᓻ 200324 2-41
https://www.truck-manuals.net/
OPERATION OF BRAKE COMPONENTS 6
Description of components CF65/75/85 series
Purpose
The purpose of the automatic brake adjuster is
to automatically compensate for any excessive
play between the brake lining and the brake
drum caused by brake lining wear. As a result,
the cylinder travel during braking remains more
or less constant.
1. Housing
2. Bearing
3. Pinion of overrunning clutch
4. Spring of overrunning clutch
5. Conical ring of overrunning clutch
6. Worm shaft 1
7. Pivot bearing
4
8. Screw cap 2
9. Gear
10. Rack
3
11. Spring retainer 4
12. Spring 10
13. Screw cap 5
14. Control plate 12
6 13
Angle A: the angle corresponding to the basic
brake stroke. 7
8
Operation
Lining wear causes extra clearance between
10 A 14
lining and drum. This is adjusted during the
return stroke of the brake adjuster. B
The brake cylinder stroke is composed of the
following three components:
R600017
- the basic brake stroke, which corresponds
to the normal clearance between lining and
drum;
- the additional stroke, which corresponds to
the additional clearance between lining and
drum due to lining wear;
- the elastic stroke due to the elasticity of
drum, lining, shoes and brake camshaft.
2-42 ᓻ 200324
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6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series Description of components
4
During the return stroke, the rack is pulled
downwards by the upper edge of the notch. The
pinion now turns in the opposite direction, so
that the overrunning clutch drives worm shaft 6
and the brake is adjusted.
Elastic stroke
During the elastic part of the stroke, the
considerable force transmitted pushes worm
shaft 6 axially against spring 12. This will cause
the worm shaft to become disengaged from the
conical clutch.
As a result, the conical clutch will be able to turn
freely over a certain distance during the return
travel, until clutch and worm shaft are
re-engaged, without driving the worm shaft.
From that moment, any rotation of the pinion will
once again adjust the length of stroke. As a
result of this construction, the elasticity of the
component involved will not be instrumental in
adjusting the stroke.
ᓻ 200324 2-43
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OPERATION OF BRAKE COMPONENTS 6
Description of components CF65/75/85 series
Variants
The disc brake construction consists of the
brake disc and the brake calliper. There are two SB7000
variants of this construction:
- Knorr SB7000, recognisable by the divided
housing between the brake cylinder and the
brake pad holder and the rubber sleeve.
- Knorr SN7000, recognisable by the
undivided housing between the brake
cylinder and the brake pad holder and the
steel cap.
The Knorr SN7000 construction used on all
disc-brake front axles and on air-sprung rear
axles. On leaf-sprung rear axles the Knorr
4 SB7000 construction is used. Operation of the
two variants is identical. Only overhauling and
SN7000
the parts of the brake calliper differ.
R600707
Operation
Brakes
This disc brake works using a pneumatic brake 1
chamber or spring brake cylinder. 5 4
If the brake is applied, the brake cylinder push
rod presses against the eccentrically mounted
lever (1).
Via bridge 2 and threaded bushes 3, the brake
pad is pressed against the brake disc (4) at two
points on the inside.
Due to the reaction force (F2) at the eccentric,
the floating brake saddle (5) will also press the 3 2
opposite brake pad with the same force (F2).
R600486
2-44 ᓻ 200324
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6 OPERATION OF BRAKE COMPONENTS
CF65/75/85 series Description of components
Adjusting 3
One of the two threaded bushes (3) is equipped
with the mechanics for automatic adjustment of
the play between the brake pads and brake
disc.
This adjuster and the eccentric have teeth (6) 7
that engage each other.
If the play is too great, the adjuster (8) will be
rotated by these teeth the next time the brakes
are applied, so that the play will be reduced.
Under normal conditions, the adjuster will push
against the brake pad before rotation can take
place. However, if rotation does take place, it 6
will be absorbed by a slip coupling.
The rotation of the adjuster is transferred by
means of a chain (7) to the other adjuster.
By removing a rubber cap (9) where the
automatic adjuster is located, a hexagon is
4
9
revealed. Using a ring spanner, the play can be
manually set by adjusting this hexagon.
8
3
R600487
Wear indicator
The wear sensor, which is fitted on the
adjustment mechanism of the brake calliper,
contains a series connection of a resistor and a
switch (1). The switch is normally closed and the
circuit has a resistance equal to the value of the
resistor. When the brake pads are worn, the 1
circuit is interrupted.
This is the signal for the VIC system to activate
the ‘brake pad wear’ warning symbol on the
instrument panel.
R600488
ᓻ 200324 2-45
https://www.truck-manuals.net/
OPERATION OF BRAKE COMPONENTS 6
Description of components CF65/75/85 series
4 5
4
8
6 7
9
10
R600365
2-46 ᓻ 200324
https://www.truck-manuals.net/
6 TECHNICAL DATA
ΧΦ65/75/85 series Contents
CONTENTS
0 Technical data
Page Date
5
2.12 Check and adjust input and output pressures of the air supply unit . . . . . 2-19 . . . . 200423
2.13 Check air dryer regeneration function in the air supply unit. . . . . . . . . . . . 2-20 . . . . 200423
2.14 Check the 4-circuit security valve of the air supply unit . . . . . . . . . . . . . . . 2-20 . . . . 200423
2.15 Inspecting the automatic slack adjuster. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22 . . . . 200423
2.16 Inspecting the disc brake automatic slack adjuster . . . . . . . . . . . . . . . . . . 2-24 . . . . 200423
2.17 Inspection, brake drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 . . . . 200423
2.18 Inspection, drum linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26 . . . . 200423
2.19 inspection, brake pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 . . . . 200423
2.20 inspection, brake discs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31 . . . . 200423
2.21 Inspection, brake calliper play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 . . . . 200423
2.22 Brake adjustment, drum brake version . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34 . . . . 200423
2.23 Brake adjustment, disc brake version . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35 . . . . 200423
2.24 Inspection, air tightness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 . . . . 200423
©
200423 1
https://www.truck-manuals.net/
TECHNICAL DATA 6
Contents ΧΦ65/75/85 series
Page Date
3.23 Removing and installing bellows with
Knorr SB7000 brake calliper thrust piece . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 . . . . 200423
3.24 Removing and installing bellows with
Knorr SN7000 brake calliper thrust piece . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 . . . . 200423
3.25 Removing and installing bronze bearing bush of
Knorr SB7000 brake calliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50 . . . . 200423
3.26 Removing and installing bronze bearing bush of
Knorr SN7000 brake calliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52 . . . . 200423
3.27 Removing and installing rubber bearing bush of
Knorr SB7000 brake calliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-55 . . . . 200423
3.28 Removing and installing rubber bearing bush of
Knorr SN7000 brake calliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-56 . . . . 200423
3.29 Removing and installing bellows of bronze bearing bush of
Knorr SB7000 brake calliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58 . . . . 200423
3.30 Removing and installing bellows of bronze bearing bush of
Knorr SN7000 brake calliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60 . . . . 200423
©
2 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Safety instructions
1. SAFETY INSTRUCTIONS
1.1 SAFETY INSTRUCTIONS
©
200423 1-1
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Safety instructions ΧΦ65/75/85 series
©
1-2 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Inspection and adjustment
Note:
5
If, when draining the air reservoirs,
they appear to hold an excessive quantity
of oil, check the condition of the compressor
and check the compressor for the presence
of carbon deposits in the compressor pipes.
©
200423 2-1
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Inspection and adjustment ΧΦ65/75/85 series
Note:
If excessive values are measured, the inside of
the air-dryer housing and the silencer on the
bleed vent should first be cleaned. Then repeat
the inspection.
5
3. Remove the compressor control pipe (1)
which is connected to connection point (23)
of the air dryer. Then seal the opening at
connection point (23).
R600521
Note:
If the pressure measured is too high,
this indicates that there are excessive
carbon deposits in the compressor pipe.
The cause could be poor condition of the
compressor (oil consumption).
R600249
©
2-2 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Inspection and adjustment
©
200423 2-3
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Inspection and adjustment ΧΦ65/75/85 series
}
1.
Remain at a safe distance from
rotating and/or moving components.
5
(blows off), the pressure gauge should fall
to approximately 0 bar.
R600249
©
2-4 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Inspection and adjustment
©
200423 2-5
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Inspection and adjustment ΧΦ65/75/85 series
VALVOLA VUOTO-CARICO
VALVULA VACIO-CARGA
p43
axle brake circuit, the box beneath the valve
VALVE CHARGE-VIDE
EMPTY-LOAD VALVE
LAST-LEER VENTIEL
MEEREGELVENTIEL
illustration will be blank. Throughout the column,
1 = 1 : 1.5
p1
p2
W475 721 003 0
a value of 8.1 bar has been filled in for "delivery
p4
5
instead of the relay valve mentioned, the box will
contain a pressure ratio, e.g."i = 1 : 1,5".
p43
The "delivery pressure p2" of axle "1" then
PRESSION COUSSIN
PRESION FUELLES
These values can be used to check the brake
bar
BALG DRUCK
0.2
0.5
1.3
1.8
2.3
4.2
4.9
5.6
2
the inspection/adjustment below at the same
time. To do this, connect a pressure gauge to the
1
test connection of one of the front axle brake
AUSGESTEUERTER DRUCK
cylinders.
UITGESTUURDE DRUK p2
DELIVERY PRESSURE
PRESSION DELIVREE
PRESION DE SALIDA
PRESSIONE USCITA
3
bar
±0.4 ±0.2
2.0
2.1
2.8
3.5
4.3
7.3
8.3
8.3
2
5.7
5.8
6.0
6.3
6.6
7.7
8.1
8.1
1
G
x104 N
CARICO ASSE
AXLE LOAD
CARGA EJE
10.0
11.5
13.0
ACHSLAST
1.8
2.5
4.0
5.0
6.0
2
ASLAST
R600472
©
2-6 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Inspection and adjustment
Inspection/adjustment
1. Check that the correct valve has been fitted
(see instruction plate). 41 42
43
4
2. Connect a pressure gauge (4) to the test
connection close to connection 1/4 on the 1/4
load sensing valve (input pressure).
1 2
3. Connect a pressure gauge (2) to the test s
connection on one of the brake cylinders 2
(service brake connection) of the rear axle.
6.
process.
Note:
When depressurising the simulation
connection (pressure gauge 43), the air hose
must remain connected to prevent the
(actual) bellows pressure from accidentally
activating the valve.
The small socket head screw in the centre of
the valve must not be adjusted.
R600478
©
200423 2-7
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Inspection and adjustment ΧΦ65/75/85 series
Note:
When depressurising the simulation
connection (pressure gauge 43), the air hose
must remain connected to prevent the
(actual) bellows pressure from accidentally
©
2-8 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Inspection and adjustment
L = 140 mm
VALVOLA VUOTO-CARICO
a value of 8.1 bar has been filled in for "delivery
a = 15 ±2
VALVULA VACIO-CARGA
G=11.0
pressure p2" under axle "1".
VALVE CHARGE-VIDE
EMPTY-LOAD VALVE
LAST-LEER VENTIEL
MEEREGELVENTIEL
If the vehicle is equipped with a control valve
i = 1 : 1.5
W475 721 004 0
p4 = 8.0 bar
L
contain a pressure ratio, e.g."i = 1 : 1.5".
p1
p2
1396041
The "delivery pressure p2" of axle "1" then
p4
indicates variable readings.
These values can be used to check the brake
pressure values of the front axle and to carry out p3
PRESSION COUSSIN
the inspection/adjustment below at the same
PRESION FUELLES
time. To do this, connect a pressure gauge to the
bar
BALG DRUCK
cylinders.
Inspection/adjustment
AUSGESTEUERTER DRUCK
UITGESTUURDE DRUK p2
PRESSION DELIVREE
PRESION DE SALIDA
PRESSIONE USCITA
1.8
1.8
2.2
3.1
6.4
7.6
8.2
8.2
2
CARGA EJE
10.0
11.5
13.0
ACHSLAST
1.8
2.0
3.0
4.0
8.0
2
ASLAST
R600479
©
200423 2-9
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Inspection and adjustment ΧΦ65/75/85 series
Note:
The small socket head screw in the centre of
the valve must not be adjusted.
2
R600781
©
2-10 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Inspection and adjustment
1 2
5 5
3
R600904
1 2
3
R600905
©
200423 2-11
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Inspection and adjustment ΧΦ65/75/85 series
©
2-12 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Inspection and adjustment
5
parking brake actuating pressure) or 0.5 bar
(service brake), without there being any
noticeable pressure on connection point (2). R600490
From this point, the pressures in both
pressure gauges must increase identically.
The pressure on the gauge connected
to point (2) should not rise in jumps.
Both gauges should indicate a value
corresponding to the graph. See "Technical
data".
©
200423 2-13
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Inspection and adjustment ΧΦ65/75/85 series
5
7. Repeat the last three points, but now for
connecting point (41).
R600340
©
2-14 200423
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6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Inspection and adjustment
Note:
The pressure ratio between prime mover and
drawn vehicle is 10 : 8 (10 bar system pressure
for prime mover and 8 bar system pressure for
drawn vehicle).
5
applied, the output pressure at connection point
(2) should be 2.4 + 0.6 = 3.0 bar.
1. Connect a pressure gauge (1) to the test
connection for the load sensing valve and
a pressure gauge (2) to the service coupling
head.
©
200423 2-15
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Inspection and adjustment ΧΦ65/75/85 series
Note:
The pressure at which the readings are taken
must always be built up. If the specified pressure
is exceeded, bleed off sufficient air, and once
again allow the pressure to build up. 41 3 bar
6 mm
R600341
©
2-16 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Inspection and adjustment
©
200423 2-17
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Inspection and adjustment ΧΦ65/75/85 series
1 2
3
R600095
©
2-18 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Inspection and adjustment
2.12 CHECK AND ADJUST INPUT AND OUTPUT PRESSURES OF THE AIR
SUPPLY UNIT
R600480
Adjusting trailer vehicle system pressure
1. Fit a pressure gauge to the trailer supply
connection (red connection).
R600652
©
200423 2-19
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Inspection and adjustment ΧΦ65/75/85 series
2.13 CHECK AIR DRYER REGENERATION FUNCTION IN THE AIR SUPPLY UNIT
2.14 CHECK THE 4-CIRCUIT SECURITY VALVE OF THE AIR SUPPLY UNIT
Check pressure build-up on circuits 1, 2, 3 and 4
1. Lower the pressure in the system to 0 bar.
2. Connect pressure gauges to circuits 1, 2,
5 3.
3 and 4.
Pressurise the circuits using the compressor
(engine speed approx. 1000 rpm).
4. The pressure in circuits 1, 2 and 4 will
gradually increase. Once the opening
pressure of circuit 3 has been reached
(see "Technical Data"), the pressure in
circuit 3 will increase.
5. If no more pressure builds up (cut-out
pressure reached), the supply pressure in
circuits 1, 2, 3 and 4 must meet the stipulated
value (see "Technical Data").
Checking circuit 1
1. Turn off the engine and simulate a leak in
circuit 1.
2. The pressure in circuit 2 and 4 may not fall
below the specified closing pressure of
circuit 1. See "Technical data".
Checking circuit 2
1. Make sure the leak in circuit 1 is remedied
and pressurise the system again.
2. Turn off the engine and simulate a leak in
circuit 2.
3. The pressure in circuit 1 and 4 may not fall
below the specified closing pressure of
circuit 2. See "Technical data".
©
2-20 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Inspection and adjustment
Checking circuit 3
1. Make sure the leak in circuit 2 is remedied
and pressurise the system again.
2. Turn off the engine and simulate a leak in
circuit 3 for the trailer circuit (connection
point 23).
3. The pressure in circuit 1.2 and 4 may not fall
below the specified closing pressure of
circuit 3. See "Technical data".
4. The pressure in circuit 3 for the parking brake
circuit (connection point 25) must remain
secured by the check valve.
Checking circuit 4
1. Make sure the leak in circuit 3 is remedied
and pressurise the system again.
2. Turn off the engine and simulate a leak in
3.
circuit 4.
The pressure in circuit 1 and 2 may not fall
5
below the specified closing pressure of
circuit 4. See "Technical data".
©
200423 2-21
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Inspection and adjustment ΧΦ65/75/85 series
5
adjuster is moved during braking.
- Fix the control plate in this position using
the attachment nut on the fixed bracket.
- Check the internal slip using a torque
wrench.
©
2-22 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Inspection and adjustment
©
200423 2-23
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Inspection and adjustment ΧΦ65/75/85 series
Note:
Never turn the hexagonal adjusting bolt
without using an adapter. The adapter
5
is a torque safety and will break off when
the torque is too high. Without the use
of an adapter the mechanics in the brake
calliper may become damaged when
the torque is too high, so that replacement
of the brake calliper may be necessary.
©
2-24 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Inspection and adjustment
5
- seized brakes
- jammed brake shafts or brake cylinders
- insufficient clearance between brake lining
and brake drum with new brake linings
- continuous application of the service brake
whilst driving.
Cracks that are permissible must be capable of
being removed when the drum is reconditioned. 50
See "Technical data".
If the cracks cannot be completely removed 0.7
during reconditioning of the brake drums,
accelerated brake lining wear can be expected.
If the brakes are once again thermally
overloaded, the edges of the cracks will rise
again, which will result in premature wear of the
lining, due to abrasion.
A brake drum may also show burns and local
hardened spots, also caused by high
temperatures.
Where the structure of the brake drum material
has changed, these burns must be removed by
reconditioning and grinding.
If the spots cannot be removed, braking will
always be accompanied by vibrations.
The brake linings will always first show rough
wear grooves at the respective spots.
A brake drum may be used until the internal
diameter has reached the maximum value. R 6 00 128
©
200423 2-25
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Inspection and adjustment ΧΦ65/75/85 series
}
see "Technical data".
Always fit the same type of brake
linings to a vehicle.
©
2-26 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Inspection and adjustment
5
moisture on the assembly face.
Incorrect bearing surface
The surface is no longer smooth. The lining no
longer has a sufficient mounting surface at the
edges of the rivet recess and ruptures during
riveting. The lining could be released from the
shoe and lifted. As a result, the clearance
between lining and drum decreases or
disappears completely.
Even when the brakes are not applied,
the temperature of the brake increases and,
as a result, heat cracks may occur in the bearing
surface of the brake drum.
Bearing pattern
When turning the brake lining, the lining will bear
on the radius of the drum with the entire brake
surface. Such a bearing pattern guarantees the
best possible breaking performance from the
beginning. The turning of the brake lining may be
carried out on a brake lining lathe, or with a
special dummy back plate on a special lathe.
The bearing pattern of the brake lining can be
improved by turning the brake lining to a diameter
which is max. 1.0 mm smaller than the drum
diameter. So, in the case of a brake drum
diameter of 420 mm the brake lining should be
turned to a max. diameter of 419 mm.
R600129
©
200423 2-27
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BRAKE SYSTEM AND COMPONENTS 6
Inspection and adjustment ΧΦ65/75/85 series
5
R600130
R600131
©
2-28 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Inspection and adjustment
R600132 5
1
4
A
6
R600481
©
200423 2-29
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Inspection and adjustment ΧΦ65/75/85 series
A
R600730
©
2-30 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Inspection and adjustment
Note:
The brake discs may be turned.
See "Technical data".
©
200423 2-31
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Inspection and adjustment ΧΦ65/75/85 series
General inspection
1. Push and pull the brake calliper back and
forth several times in the axial direction (A).
This requires considerable effort.
R600709
©
2-32 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Inspection and adjustment
X
R600710
Y
7. Fit the brake pads. D
R600711
©
200423 2-33
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BRAKE SYSTEM AND COMPONENTS 6
Inspection and adjustment ΧΦ65/75/85 series
R600253
©
2-34 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Inspection and adjustment
5
Never turn the hexagonal adjusting bolt
without using an adapter. The adapter
is a torque safety and will break off when the
torque is too high. Without the use of an
adapter the mechanics in the brake calliper
may become damaged when the torque
is too high, so that replacement of the brake
calliper may be necessary.
©
200423 2-35
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Inspection and adjustment ΧΦ65/75/85 series
Air tightness
If the brake system of a vehicle has been charged
to the maximum pressure, it should generally be
possible to drive the vehicle away after a period
of 16 hours of uninterrupted standstill, without
first having to charge the brake system to
sufficient operating pressure.
This implies a maximum pressure drop of approx.
0.4 bar per hour at normal system pressure.
Note:
Always connect auxiliary consumers and
accessories to circuit 4.
©
2-36 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
5
the bore as necessary.
Note:
If the plug is not removed from the socket,
the quick-release coupling (plug and socket)
can be re-fitted as an assembly. The socket
does not then have to be replaced.
R600367
©
200423 3-1
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
5
2
3
4
5
8
6 7
9
10
R600365
R600404
©
3-2 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
R600369
R600368
©
200423 3-3
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
5 Note:
If the connection is not fully locked, the upper
O-ring of the plug is still visible. If there is
pressure, there will also be an audible
escape of air.
R600366
©
3-4 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
Note:
When removing the remainder of the pipe,
do not use any sharp objects. This is to avoid
damaging the pipe connector. Damage to
the pipe connector could result in leakage.
Remove the remainder of the pipe using heat
5
or the "cutting point" of a soldering iron.
W602009
©
200423 3-5
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
©
3-6 200423
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6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
5
5. Remove the attachment nuts and take the
spring brake cylinder from the support.
Note:
Prevent dirt from entering the disc brake
construction and cover the opening.
©
200423 3-7
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
©
3-8 200423
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6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
Disc brakes
Note:
The automatic slack adjuster of the brake calliper
should not be removed. If defective, the brake
calliper should be replaced.
Drum brakes
Note:
It is possible that during the installation
of the slack adjuster the brake camshaft will
be pushed inwards. This can be prevented
by fitting a bolt in the brake camshaft, so that
during installation of the slack adjuster the
brake camshaft can be held in position. C
B
R600141
©
200423 3-9
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
R600142
©
3-10 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
R600143
©
200423 3-11
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
11. Note:
Never use a pneumatic tool for tightening the
A
jack screws.
Tighten them evenly by hand. This brings the
brake drum to pressure. Use a copper punch
to work the brake drum from the hub.
Use lifting gear to remove the brake drum.
©
3-12 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
©
200423 3-13
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
3.8 REMOVAL AND INSTALLATION, BRAKE SHOES 1354, 1355T REAR AXLE
R600145
©
3-14 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
©
200423 3-15
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
5
1
R600636
R600637
©
3-16 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
R600638
R600633
R600634
©
200423 3-17
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
5 R600635
©
3-18 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
R600133
5
1. Replace the brake lining when it has worn
down to the wear indicator or to
approximately 1 mm above the rivet head.
The thickness can be measured via the
inspection holes in the back plates.
The brake lining should also be replaced
if oil or grease has worked into it.
M6002
M6012
©
200423 3-19
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
0.8
5 1.5
R=
R=
0.5
1.5
3.5
R=
ca ø11
R600135
Riveting
1. Place the lining on the brake shoe. If the
0 DAF
linings are so marked, mount the 00 200
F 2 0
"draaipuntzijde" marking at the pivoting end DA dra
e aip
ijd u
of the brake shoe and the "remnokzijde" o kz nt
n
de
re
Note:
If these markings are not there, mount the
thin side of the lining at the pivoting end and
the thick side of the lining at the camshaft
end.
R600147
©
3-20 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
R600138
©
200423 3-21
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
R600139
©
3-22 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
5
R600148
©
200423 3-23
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
5
Here too, the spindle may not be fitted more
than three times.
After the spindle is fitted three times on the
other side of the brake shoe, the brake shoe
R600149
MUST be renewed.
©
3-24 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
R600152
©
200423 3-25
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
A2
A1<A2
5
A1
7 7 6 5 8 4 1 2 3 a 1
R600153
4. Move the loose wedge (1) back so that the
halves of the pulling piece (2), which are kept
together by the O-ring, are joined.
©
3-26 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
R600154
6. Using nut (4), screw the wedges as far as
possible inwards. Tighten the nut finger-tight.
©
200423 3-27
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
R600185
Note:
The oil seal on the wheel brake end should
form a seal, whilst the oil seal on the slack
adjuster end should be able to discharge
grease from the bracket.
©
3-28 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
5
the back plate. Thoroughly clean all other
parts.
©
200423 3-29
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
5
attachment bolts to the specified torque.
See "Technical data".
©
3-30 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
©
200423 3-31
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
Note:
To be certain that the air dryer is functioning
properly, the air reservoirs should regularly be
checked for condensation.
©
3-32 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
Artikelnummer
Reference
Teilenummer
Référence
1391510
Eerstvolgende vervanging
Next change
Nächster Wechsel
Prochain remplacement
R600523
©
200423 3-33
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
Note:
Never turn the hexagonal adjusting bolt
without using an adapter. The adapter is
a torque safety and will break off when the
torque is too high. Without the use of an 12
adapter the mechanics in the brake calliper 12
may become damaged when the torque is
too high, so that replacement of the brake R600462
Note:
If the brake pads have wear end indicators,
they must be removed at the same time as the
brake pads, including accessories.
©
3-34 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
©
200423 3-35
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
5
2. Position the brake disc on the hub.
©
3-36 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
R600466
R600720
R600720
©
200423 3-37
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
5
4
R600721
R600467
©
3-38 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
R600765
1. Remove the brake pads.
©
200423 3-39
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
calliper carrier.
5
4
R600721
©
3-40 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
T17 1 2 3 T17 1 2 3
2
T17 1
T2
R600766
8. Assemble a punch from the special tool set
(DAF no. 1329495) by means of T2 (only the
handle) and T17.
13. Fit the plug for the brake pad wear indicator.
©
200423 3-41
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
Note:
Starting in production week 2002-25,
the attachment of the brake calliper against
the stub axle (front axles) may have been
changed on models with disc brakes.
Five bolts are now used instead of six bolts.
The bolt hole for the "6th bolt" is then still
fitted in the brake calliper carrier, but not in
the stub axle.
©
3-42 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
Note:
Unscrew the thrust pieces a maximum of
30 mm. Do not screw them completely out of
the brake calliper, as the brake calliper
assembly would then have to be replaced.
Note:
Never turn the hexagonal adjusting bolt
without using an adapter. The adapter is a
torque safety and will break off when the
torque is too high. Without the use of an
adapter the mechanics in the brake calliper
5
may become damaged when the torque is R600468
too high, so that replacement of the brake
calliper may be necessary.
Note:
Do not insert the screwdriver too deeply into
the brake calliper. This could damage the
seat of the inner seal of the thrust pieces.
These cannot be replaced and the brake
calliper would then have to be replaced.
161
R600469
©
200423 3-43
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
Fitting bellows
Note:
Do not screw the adjusters entirely out of the B
brake calliper, as the entire brake calliper
would then have to be replaced.
R600465
Note:
The operations described above can also be B
performed if the brake calliper has been 13
removed. In that case an additional pin (8)
from the special tool set (DAF no. 1329494)
must be used, since the brake disc cannot be
used for support.
R600464
©
3-44 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
Note:
Unscrew the thrust pieces a maximum of
30 mm. Do not screw them completely out of
the brake calliper, as the brake calliper
assembly would then have to be replaced.
Note:
Never turn the hexagonal adjusting bolt
without using an adapter. The adapter
is a torque safety and will break off when the
torque is too high. Without the use of an
adapter the mechanics in the brake calliper
may become damaged when the torque
5
is too high, so that replacement of the brake
calliper may be necessary.
30 m
m
R600713
©
200423 3-45
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
Note:
Do not insert the screwdriver (3) too deeply
into the brake calliper. This could damage 6 3
the seat (6) of the inner seal (5) of the thrust
pieces. These cannot be replaced and the
brake calliper would then have to be
replaced.
5
3. Press the thrust pieces (2) off the adjusters
with the disassembly fork (3), special tool set
(DAF no. 1329495).
R600714
©
3-46 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
3
5
R600715
©
200423 3-47
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
6
R600716
R600718
©
3-48 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
R600717
©
200423 3-49
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
1
3
5
2
R600723
R600727
4
R600728
©
3-50 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
R600726
1
3
2
R600723
©
200423 3-51
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
1
3
5
2
R600723
R600727
T12
T13
T14
R600759
©
3-52 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
4
R600728
T14 5
T8
T13
T16
R600760
©
200423 3-53
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
D D D
7 7
5 a b c
R600758
3. Tighten the brass nut (T14) of the bearing
bush extractor (D) as far as the stop so as to
push in the bronze bush (7) (a, b). Then
tighten the steel bolt of T16 as far as the stop
so as to lock the bronze bush (c). Loosen the
steel bolt of T16 by 20 mm axially, rotate the
tool T16 by 60 and tighten the steel bolt of
T16 as far as the stop (c). Remove the
bearing bush extractor (D).
1
3
2
R600723
©
3-54 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
F G
5
R600599
R600600
©
200423 3-55
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
T21
5 T20
T6
T22
R600763
R600729
©
3-56 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
T18
T20
T19
T22
5
R600762
©
200423 3-57
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
1
3
5
2
R600723
4 3 5
3
5
R600724
1. Clean the bronze bearing bush (4) in the
brake calliper.
©
3-58 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
5
R600725
©
200423 3-59
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
1
3
5
2
R600723
4 3 5
3
5
R600724
1. Clean the bronze bearing bush (4) in the
brake calliper.
©
3-60 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Removal and installation
T10
T7
R600761
5
4 3 5
3
5
R600724
4. Place a new bellows (3) in the sleeve (5)
of the assembled press.
©
200423 3-61
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Removal and installation ΧΦ65/75/85 series
R600725
1
3
2
R600723
©
3-62 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Disassembly and assembly
Removal, diaphragm
1. Turn the brakes back until the spring in the
brake chamber is under tension.
Installation, diaphragm
1. Fit the new diaphragm and brake chamber
5
half. (Pay attention to the markings or the
small drainage hole.)
3. Screw the lock nut onto the push rod until the
spring in the brake chamber is slightly
tensed.
©
200423 4-1
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Disassembly and assembly ΧΦ65/75/85 series
R600197
R600194
©
4-2 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Disassembly and assembly
R600195
5
Assembly, brake chamber
1. Apply pressure to connection point (12)
(min. 6.0 bar).
R600195
©
200423 4-3
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Disassembly and assembly ΧΦ65/75/85 series
R600197
R600198
R600199
©
4-4 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Disassembly and assembly
R600200
R600201
©
200423 4-5
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Disassembly and assembly ΧΦ65/75/85 series
5 7.
auxiliary tool over the spring.
R600204
©
4-6 200423
https://www.truck-manuals.net/
6 BRAKE SYSTEM AND COMPONENTS
ΧΦ65/75/85 series Disassembly and assembly
15. Fit the flexible bleed pipe with the sinter filter
fitted at the brake chamber side. Ensure that
the filter is correctly mounted in the flexible
bleed pipe, to prevent any dirt from entering
the spring brake section.
R600197
©
200423 4-7
https://www.truck-manuals.net/
BRAKE SYSTEM AND COMPONENTS 6
Disassembly and assembly ΧΦ65/75/85 series
©
4-8 200423
https://www.truck-manuals.net/
6 BRAKING PERFORMANCE AND BRAKE EQUALISATION
ΧΦ65/75/85 series Contents
CONTENTS
6 Braking performance and brake equalisation
Page Date
©
200423 1
https://www.truck-manuals.net/
BRAKING PERFORMANCE AND BRAKE EQUALISATION 6
Contents ΧΦ65/75/85 series
©
2 200423
https://www.truck-manuals.net/
6 BRAKING PERFORMANCE AND BRAKE EQUALISATION
ΧΦ65/75/85 series General
1. GENERAL
1.1 INTRODUCTION
Note:
Trucks and trailer vehicles may be fitted with an
EBS brake system or a non-EBS brake system
(conventional brake system).
©
200423 1-1
https://www.truck-manuals.net/
BRAKING PERFORMANCE AND BRAKE EQUALISATION 6
General ΧΦ65/75/85 series
G G
m.a m.a
Z Z
Fn Fn Fn Fn Fn
F F F F F
Gd Gd Gd Gd Gd
R600023
G weight
m = mass
©
1-2 200423
https://www.truck-manuals.net/
6 BRAKING PERFORMANCE AND BRAKE EQUALISATION
ΧΦ65/75/85 series General
R600024
a a
©
200423 1-3
https://www.truck-manuals.net/
BRAKING PERFORMANCE AND BRAKE EQUALISATION 6
General ΧΦ65/75/85 series
©
1-4 200423
https://www.truck-manuals.net/
6 BRAKING PERFORMANCE AND BRAKE EQUALISATION
ΧΦ65/75/85 series General
6
p = 0.5 - 1.0 - 1.5 - 2.0 - 3.0 - 4.0 - 5.0 bar
©
200423 1-5
https://www.truck-manuals.net/
BRAKING PERFORMANCE AND BRAKE EQUALISATION 6
General ΧΦ65/75/85 series
m1 + m2 +...... m 1+ m 2+......
F1+F2+F3
X 100 %
p
R
R m1+ m2+......
R L
F1+F2+F3
L
L
F1 F2 F3
L R L R L R
0.5 %
1.0 %
1.5 %
6 2.0
3.0
%
%
4.0 %
5.0 %
F1+F2+F3
X 100 %
p
R
R R F1+F2+F3 m1+ m2+......
L
L L
F1 F2 F3
L R L R L R
0.5 %
1.0 %
1.5 %
2.0 %
3.0 %
4.0 %
5.0 %
R600119
©
1-6 200423
https://www.truck-manuals.net/
6 BRAKING PERFORMANCE AND BRAKE EQUALISATION
ΧΦ65/75/85 series General
Note:
1 kg = 10 newtons (N)
©
200423 1-7
https://www.truck-manuals.net/
BRAKING PERFORMANCE AND BRAKE EQUALISATION 6
General ΧΦ65/75/85 series
20
10
0
0 1 2 3 4 5 bar
p
%
40
30
20
10
0
0 1 2 3 4 5 bar
p
R600022
©
1-8 200423
https://www.truck-manuals.net/
6 BRAKING PERFORMANCE AND BRAKE EQUALISATION
ΧΦ65/75/85 series General
a %
100
90
80
EBS
70
60
EBS EBS
50
40
6
30
20
10
0
0 1 2 3 4 5 6 7 8
P (bar)
R600881
The "EC band" indicates the limits within which
the deceleration value must lie.
The "EC band" applies to:
- tractor with conventional brake system
- semi-trailer with conventional or EBS brake
system
©
200423 1-9
https://www.truck-manuals.net/
BRAKING PERFORMANCE AND BRAKE EQUALISATION 6
General ΧΦ65/75/85 series
a %
100
90
80
70 EBS
60
EBS EBS
50
6 40
30
20
10
0
0 1 2 3 4 5 6 7 8
P (bar)
R600880
The "EC band" indicates the limits within which
the deceleration value must lie.
The "EC band" applies to:
- truck with conventional brake system.
- trailer with conventional or EBS brake
system.
Note:
The following applies to mid-axle trailers fitted
with air brakes:
The permissible ratio between the deceleration
and the pressure at the yellow coupling head of
a laden mid-axle trailer with air brakes should be
within the two areas derived from the EC band
for a laden truck/trailer combination, for which the
vertical scale has been multiplied by 0.95.
©
1-10 200423
https://www.truck-manuals.net/
6 BRAKING PERFORMANCE AND BRAKE EQUALISATION
ΧΦ65/75/85 series Inspection and adjustment
Note:
The test bench function and deceleration
measurement can be carried out on a vehicle with
the EBS system in fully laden state, if desired.
©
200423 2-1
https://www.truck-manuals.net/
BRAKING PERFORMANCE AND BRAKE EQUALISATION 6
Inspection and adjustment ΧΦ65/75/85 series
6
vehicle.
- The pressure ratio control between front and
rear axles is not active (pressure ratio 1:1).
- The command pressure to the drawn vehicle
has a reading in the middle of the EC brake R600883
band.
- The brake functions such as deceleration
control, wheel slip control etc. are switched
off.
Condition for being able to activate the test
function
At least one of the axles must have a wheel
speed lower than 2 km/h. On all other axles,
the wheel speed must be lower than 12 km/h.
Note:
This means that both on a vehicle which has not
been on the test bench (stationary vehicle) and
on a vehicle that has been on the test bench,
the test function can be activated.
©
2-2 200423
https://www.truck-manuals.net/
6 BRAKING PERFORMANCE AND BRAKE EQUALISATION
ΧΦ65/75/85 series Inspection and adjustment
Note:
- If during application of the brake pedal
the contact is turned on, the test function
will remain active even if the brake pedal
is then released.
- The test function will be automatically
switched off if the condition is no longer
met or if, when the contact is on,
the contact is switched off when the
brake pedal is not being applied.
©
200423 2-3
https://www.truck-manuals.net/
BRAKING PERFORMANCE AND BRAKE EQUALISATION 6
Inspection and adjustment ΧΦ65/75/85 series
Note:
On a tractor/drawn vehicle combination the
values for the drawn vehicle may be slightly
lower than those for the prime mover.
The deceleration values for the truck and the
drawn vehicle of a truck/trailer combination
should be the same. The reason for this lies
in the dynamic axle load displacement,
which on semi-trailers causes a transfer of
weight to the tractive unit, whereas on
trailers it does not cause a transfer of weight
to the tractive unit.
Note:
For optimum interchangeability of vehicles,
the correct choice between these two
alternatives must be made.
©
2-4 200423
https://www.truck-manuals.net/
6 BRAKING PERFORMANCE AND BRAKE EQUALISATION
ΧΦ65/75/85 series Inspection and adjustment
©
200423 2-5
https://www.truck-manuals.net/
BRAKING PERFORMANCE AND BRAKE EQUALISATION 6
Inspection and adjustment ΧΦ65/75/85 series
Note:
The EBS trailer vehicle must be correctly
Note:
On a tractor/semi-trailer combination the
values for the drawn vehicle may be slightly
lower than those for the tractor. The
deceleration values for the truck and the
drawn vehicle of a truck/trailer combination
should be the same. The reason for this lies
in the dynamic axle load displacement,
which on semi-trailers causes a transfer of
weight to the tractive unit, whereas on
trailers it does not cause a transfer of weight
to the tractive unit.
©
2-6 200423
https://www.truck-manuals.net/
6 BRAKING PERFORMANCE AND BRAKE EQUALISATION
ΧΦ65/75/85 series Inspection and adjustment
©
200423 2-7
https://www.truck-manuals.net/
BRAKING PERFORMANCE AND BRAKE EQUALISATION 6
Inspection and adjustment ΧΦ65/75/85 series
©
2-8 200423
https://www.truck-manuals.net/
6 BRAKING PERFORMANCE AND BRAKE EQUALISATION
ΧΦ65/75/85 series Inspection and adjustment
Note:
The EBS system on the truck has a system that
automatically adjusts the brake pressures.
It is not possible to adjust it. If the EBS system
has not stored an error code and the brakes
of the truck are in proper condition, the cause
of the brake troubles must be sought in the
condition and sizing of the brakes of the trailer
vehicle. If an improvement of comfort (pulling
or pushing) is desired for low brake 6
decelerations, this is possible by changing
the pressure pulse control of the trailer vehicle.
©
200423 2-9
https://www.truck-manuals.net/
BRAKING PERFORMANCE AND BRAKE EQUALISATION 6
Inspection and adjustment ΧΦ65/75/85 series
©
2-10 200423
https://www.truck-manuals.net/