Anti-Lock Brake System / Accelera-Tion General

BRAKE SYSTEM
GENERAL ANTI-LOCK BRAKE SYSTEM / ACCELERA-

SPECIFICATIONS ............................................ BR -2 TION
TROUBLESHOOTING ..................................... BR -3 SLIP REGULATION
GENERAL .................................................. BR -85
FULL AIR BRAKE SYSTEM CONNECTOR CONFIGURATIONS ........... BR -91
AIR PROCESSING UNIT(A.P.U) OPERATION ............................................... BR -94
SPECIFICATION ........................................ BR -13 ABS SELF DIAGNOSIS ............................. BR -103
GENERAL DIAGNOSTICS AND TESTS ... BR -13 WHEEL SPEED SENSOR
COMPONENTS .......................................... BR -15 COMPONENT LOCATION ......................... BR -123
REPLACEMENT ........................................ BR -16 INSTALLATION ........................................... BR -125
DUAL BRAKE VALVE
COMPONENTS .......................................... BR -20 RETARDER SYSTEM
REPLACEMENT ........................................ BR -21 SPECIFICATIONS ...................................... BR -127
GRADUAL VALVE DESCRIPTION ........................................... BR -128
COMPONENTS .......................................... BR -22 SPECIAL TOOL .......................................... BR -135
GENERAL DIAGNOSTICS ........................ BR -23 ADJUSTMENT ........................................... BR -139
REPLACEMENT ........................................ BR -23 GENERAL DIAGNOSTICS AND TESTS ... BR -140
ONE TOUCH FITTING RETARDER ECU
COMPONENTS .......................................... BR -24 COMPONENTS .......................................... BR -142
REPLACEMENT ........................................ BR -25 CONNECTOR TERMINAL ......................... BR -143
RETARDER SYSTEM
BRAKE ASSEMBLY COMPONENTS .......................................... BR -145
SPECIFICATIONS ...................................... BR -26 DISASSEMBLY ........................................... BR -146
COMPONENTS .......................................... BR -27 REASSEMBLY ........................................... BR -155
DISASSEMBLY ........................................... BR -29 INSTALLATION ........................................... BR -164
INSPECTION .............................................. BR -31
REASSEMBLY ........................................... BR -34
BRAKE CHAMBER
COMPONENTS .......................................... BR -36
DESCRIPTION ........................................... BR -36
ADJUSTMENT ........................................... BR -37
REPLACEMENT ........................................ BR -37
INSPECTION .............................................. BR -44
AUTO SLACK ADJUSTER
DESCRIPTION ........................................... BR -46
COMPONENT LOCATION ......................... BR -47
COMPONENTS .......................................... BR -48
REMOVAL .................................................. BR -49
INSTALLATION ........................................... BR -50
DISASSEMBLY ........................................... BR -51
REASSEMBLY ........................................... BR -54
DISC BRAKE
OPERATION ............................................... BR -56
GENERAL DIAGNOSTICS AND TESTS ... BR -57
SPECIAL TOOLS ........................................ BR -58
COMPONENT LOCATION ......................... BR -59
COMPONENTS .......................................... BR -60
REMOVAL .................................................. BR -61
INSTALLATION ........................................... BR -61
REPLACEMENT ........................................ BR -62
INSPECTION .............................................. BR -79
BR -2 BRAKE SYSTEM
GENERAL
SPECIFICATIONS E40D674D
DESCRIPTION SPECIFICATION
Type Full air brake system
Type(Relay valve) R-12 valve(front), R-14 valve(rear)
Type Gradual valve
Parking brake Operating temperature -40 ~ 80℃
Maximum pressure 10 bar
Thickness of brake pad 9mm (with backplate)
Disc brake
Play of brake pad 0.7 ~ 1.1 mm
Drum I.D x lining width x lining thickness Ø410 x 200 x 20 mm
Type(brake cam) S-cam
Drum brake
’S’ cam base circle Ø25.4 mm
Control of play Auto slack adjuster
Type Dual brake valve
Brake pedal Max. pressure 10 bar
Temperature range -40 ~ 80℃
Air pressure 6.3 ~ 10 bar
Retarder system Type(Oil) SAE 30 type
Initial filling Approx. 25 liter
Cut-out pressure 9.1 ~ 9.5 bar
Air processing unit(APU) Opening safety valve 14~17 bar
Operating temperature -40 ~ 80℃
GENERAL BR -3
TROUBLESHOOTING E96CC729
WHEEL BRAKES
Symptom Probable cause Remedy

Poor braking Air leaks when Loosen connectors Tighten connectors
action brake pedal is
Leaky primary and secondary valves Disassemble dual brake valve
depressed
of dual brake valve to remove foreign matter or
replace inlet valve
Damaged dual brake valve O-ring Disassemble dual brake valve
and replace O-ring
Air leaks when Loosen connectors Tighten connectors
brake pedal is
Leaky primary and secondary valves Disassemble dual brake valve
released
of dual brake valve to remove foreign matter or
replace inlet valve
Low air Air leak Check air line and correct air leaks
pressure
Air pressure governor improperly adjusted Adjust air pressure governor
Air compressor malfunctioning Overhaul air compressor
No air leaks Excessive brake shoe clearance Adjust shoe clearance.
Replace brake lining if it has
worn to limit.
Oil or grease on brake lining Wash deposits off the surface
or replace brake lining
Hardened lining surface Machine brake lining surface
or replace lining
Air in fluid line Bleed the line
Worn wheel cylinder cup resulting in Replace cup
brake fluid leak
Brake drum The brake Improper return motion of the primary or Disassemble, check, and clean
overheat shoes are not secondary valve of the dual brake valve, or dual brake valve and correct
moving away exhaust port being plugged with foreign matter problem or replace
from the brake
Small brake shoe clearance Adjust shoe clearance
drum when the
brake pedal is
released (brake Weak or broken brake shoe return spring Replace return spring
dragging)
Brakes are noisy when pedal Brake lining worn to allow rivet head Replace brake lining
is depressed to be exposed
Hardened brake lining Replace brake lining
Unevenly worn brake drum inner surface Machine or replace drum
Brake shoe not in tight contact with brake lining Replace brake lining
Brake drum left loose Retighten
BR -4 BRAKE SYSTEM

Vehicle pulls to one side when Improper brake shoe clearance or brake Adjust shoe clearance.
brake pedal is depressed lining in poor contact Correct poor contact or reline
brake lining
Oil or grease on brake lining and brake Completely remove deposits
drum inner surface or reline brake lining
Brake drum runout, or left loose Correct runout.
Retighten
Adjust to specified inflation
Uneven right and left inflation pressures
pressure
Different brake lining materials used Reline brake lining or pad of
the same material
Weak or broken brake shoe return spring Replace return spring
Chassis spring U-bolt left loose Retighten
Deformed backing plate Replace backing plate
Abrupt braking action of Small brake shoe clearance Adjust shoe clearance
wheel brakes
Large brake shoe clearance Adjust shoe clearance
GENERAL BR -5
AIR DRYER

Air dryer Air tank drain Desiccant becoming ineffective Replace desiccant, oil filter,
cock drains and filter
Exhaust port Heater fails to operate and air dryer is frozen Replace heater if defective.
does not drain Replace thermostat if defective.
Air dryer Valve inoperative due to foreign matter trapped Disassemble and check valve
interior is frozen and replace valve complete
as necessary
An open-circuited heater aggravating Check heater for continuity with
heat insulating effect a multimeter and replace heater
if there is an open circuit
Heater inoperative due to defective thermostat Use following procedure to
check thermostat and replace
if found defective
• Leave thermostat under
environment 0 C or below
and check for continuity
using a multimeter.
• heat thermostat to make
sure that it turns OFF
at temperature between
0 C and 20 C .
Remove snow and ice with
Snow being packed on air dryer, lowering
care not to damage air dryer
temperature to an abnormal low
and heater wires
Heater inoperative due to heater and Connect heater and thermostat
thermostat wires left disconnected wires properly
Air leaks from Valve fails to seat properly due to Disassemble and check valve
exhaust port foreign matter and replace valve complete.
Or replace valve body if its sliding
surface is damaged.
Engine oil is Oil working up in air compressor Replace piston rings an
discharged cylinder liner
from exhaust
port
BR -6 BRAKE SYSTEM
BRAKE SYSTEM

Maximum pressure does not reach Do an fault tracing in the compressed
the brake cylinders. air system.
Damaged brake system piping or air
Repair the damage/air leaking.
leaking in the connections.
Worn brake linings. Replace brake linings.
New brake linings may provide low friction Brake linings should be properly seated. This
values on a brake testing machine. normally happens after 2000 km driving.
Brake linings with incorrect quality. Replace brake linings for original brake linings.
Check the origin of the grease and repair
Grease in the brake linings.
the leaking. Replace brake linings.
Brake drums too scratched. Grind or replace brake drums.
Glazed brake linings. Remove the glaze with sudden braking.
Weak brake action
Adjustment mechanism stuck. Lubricate adjustment mechanism.
Excessive brake stroke
Overhaul adjustment mechanism.
Automatic adjustment fails to work.
Lubricate the camshaft with grease
for chassis.
Check if the grease comes out between
Camshaft stuck in the supports. the support and the lever as well as
the draining hole.
Maximum allowable radial play : 0.5 mm.If
play is higher, replace the bushings.
Lubricate it. Maximum allowable play between
Lever fork stuck.
the fork pin and the lever : 0.1 mm.
Dust guard is damaged. Replace the dust guard.
GENERAL BR -7

Basic adjustment incorrect. Correct basic adjustment.
Replace brake linings on both sides.
Uneven wear in the brake linings.
(Check the cause of uneven wear.)
Different model brake linings assembled Replace brake linings on both sides with
on the same axle. same model brake linings.
Grease in one or more brake linings.
Brake linings poor riveted or incorrectly Replace brake linings and make sure the
assembled. new linings are properly assembled.
Brake linings should be properly seated. This
Brake linings recently assembled.
Vehicle pulls normally happens after 2000 km driving.
sideways during the
One of the brake drums more worn or
brake action. Grind or replace brake drums.
scratched than the other in the same axle.
Uneven wearing in the tires. Check the tires.
Wheel alignment angle incorrect. Align wheels.
Automatic adjusting stopped working.
Excessive play between the brake drum Overhaul brakes.
and the brake linings.
Air leaking in a brake cylinder diaphragm. Replace the diaphragm.
Air leaking in the brake cylinder piping. Repair air leaking.
Brake cylinder with incorrect dimension Replace brake cylinder with a correct
was assembled. dimension cylinder.
Brake the vehicle to warm the brakes
Humidity in the brake linings.
and let the humidity dry.
Loosen or damaged brake linings. Replace brake linings.
Incorrect quality brake linings. Replace brake linings with correct quality.
The brakes lock.
Tighten the bolts.
Loosen bolts in the brake support.
Check the cause of bolts unfastening.
Grease in one or more brake linings.
Over brake drum. Grind or replace brake drums.
Excessive dirt/dust in the brake drums. Clean brake drums and brake linings.
Incorrect quality brake linings. Replace brake linings with correct quality.
Poorly riveted brake linings, causing low
Rivet brake linings again.
Squeak in the brakes. contact with the brake shoes.
Brake linings excessively riveted.
(Cracks in the brake linings, under Replace brake linings on both sides.
the rivet heads.)
Distorted or dirty contact surface between
Brake vibrations during brake action.
the rim and the brake drum.
BR -8 BRAKE SYSTEM

Spring brake cylinders.
1. Piston stuck. 1. Overhaul brake cylinders.
2. Air leaking in the cylinder. 2. Overhaul brake cylinders.
3. Air leaking in the parking brake circuit. 3. Repair air leaking.
4. Too low air pressure in the parking 4. Check the cause of the damage
brake circuit. and repair it.
Brake release slowly
Service brake valve stuck. Overhaul valve.
Brake shoes return springs broken. Replace both return springs on the same axle.
Lock mechanism stuck. Overhaul lock mechanism.
Clean the valve outputs in the front
Poor air discharge.
and rear circuit.
Wheel brake.
1. Incorrect basic adjustment. 1. Check basic adjustment.
Check if shoes are properly assembled.
2. Using of the old pad spring. 2. Replace the new pad spring.
Steering.
Vibration in the
Poorly adjusted convergence. Check the steering system.
brakes.
Excessive play in the steering.
Wheels :
Incorrectly tightened rims in the brake drums.
Check/Replace rims.
Unbalanced wheels.
Damaged or warped rims.
DISC BRAKE
The causes of each symptom are listed with the most

common cause first, followed by the next most common
cause,etc.
Symptom detected by driver when driving Faults detected in workshop

1. Noise
2. Uneven braking
3. Brake judder
4. Hot running
5. Long response time
6. Abnormal performance
7. Cracks in disc
8. Uneven wear between brake pads on same axle
9. Unevenly worn or skew worn brake pads
GENERAL BR -9
SYMPTOM DETECTED BY DRIVER WHEN DRIVING
1. Noise
Fault detected Checks Action

Stone, ice or other foreign Check that no parts are damaged or Remove foreign object.
object in rim. defective, especially valve and rim.
Loose components. Check external influence, deformation Remove and replace components that
or damage. are worn or defective.
Change bolted joints and reassemble using
the correct method and tightening torque.
Worn brake pad. Check that brake disc is not damaged Change brake pads.
Brake pad backing plate and lies within limits. On front wheels : Brake pads front
runs against disc. wheel, replace.
On drive wheels : Brake pads, replace
rear wheel.
Worn guide sleeves in Check play, carry out : If play is too great, carry out :
brake caliper. Sliding sleeves, wear measurement On front wheels : Guide sleeve sealing,
and/or Sliding sleeves, wear replace and Guide sleeves bushings
measurement. and seals, replace.
On drive wheels : Guide sleeve sealing,
replace and Guide sleeves bushings
and seals, replace.
Damaged bearings in hub. Check play. Replace complete hub with bearing if play
is greater than permitted or if another
fault is detected in bearing.
On front wheels : Front wheel
hub,remove.(Wheel removed) and install the
front wheel hub(wheel removed.)
On drive wheels : Rear wheel hub
unit remove ,and install the front wheel
hub(wheel removed.)
2. Uneven braking

Worn brake pads. Check wear. Change brake pads.
On front wheels : Brake pads front
wheel,replace.
On drive wheels : Brake pads,replace
rear wheel.
Defective brake pads. Check brake pads with respect to Replace with original brake pads.
part number and wear. On front wheels : Replace brake pads
on front wheel.
On drive wheels : Replace the brake pads.
Grease,dirt on brake disc Check brake disc. Wash disc clean.
and/or brake pad. Check source of grease. Change brake pads if necessary.
On front wheel : Replace the brake
pads on front wheel.
On drive wheel : Replace the brake
pads on rear wheel.
Air leakage or choking Carry out footbrake valve,check function Rectify detected faults.
of air supply. and system pressure differences.
BR -10 BRAKE SYSTEM

Seized brake caliper. Check by hand that brake caliper On front wheels : Guide sleeve sealing,
can slide. replace and Guide sleeves bushings
and seals, replace.
On drive wheels : Guide sleeve sealing,
and seals, replace.
Incorrect clearance Check clearance. If the clearance is outside permitted
between brake caliper - On front wheels : Brake pad, values and the torque required to pull
and brake pads. measurement of play between round the manual adjusting screw is
outer lining plate and brake caliper. outside specifications, then replace the
- On drive wheels : Brake pad, adjusting mechanism.
measurement of play between
outer lining plate and brake caliper.
Check torque required to pull round
manual adjusting screw.
Blocked ventilation hose Check that no hoses are pinched Rectify detected faults.
from brake cylinder. or twisted.
3. Brake judder

Rust or other deposits Check that brake disc lies within Clean the brake disc.
on brake disc. given dimensions.
Run-out on brake disc. Measure run-out of brake disc. If run-out is greater than permitted, remove
the brake disc. Check splines and hub,clean
mating surfaces and refit brake disc with new
disc springs and new retaining ring.
Change brake disc if necessary.
On front wheels : Replace the brake disc.
On rear wheels : Replace the brake disc.
Thickness variation of Measure thickness of brake disc. If thickness is outside permitted limits,replace
brake disc. the brake disc.
4. Hot running

Stones and gravel prevent Inspect brake disc and brake caliper. Clean, remove stones and gravel.
return of brake pads.
Incorrect clearance - Check clearance - If the clearance is outside permitted
between brake caliper - Check torque required to pull round values and the torque required to pull
and brake pads. manual adjusting screw. round the manual adjusting screw
is outside specifications. : Replace
adjusting mechanism.
Seized brake caliper. Check by hand that brake caliper On front wheels : Guide sleeve sealings,
and seals, replace.
On drive wheels : Guide sleeve sealings,
and seals, replace.
GENERAL BR -11
5. Long response time

Air leakage or choking Check the brake valve. Rectify detected faults.
of air supply.
and seals, replace.
and seals, replace.
Seized brake mechanism. - Check torque required to pull round Recondition brake caliper if limits
manual adjusting screw. are exceeded.
- Lift off cylinder and check
seal to see of moisture has
entered the brake.
- Push by hand on lever cup and
note of lever moves easily and if it
returns by itself without seizing.
6. Abnormal performance (Faults detected in workshop)

Grease or dirt on brake Check brake disc. Wash brake disc clean.
disc or brake pad. Check source of grease. Replace brake pads if necessary.
Air leakage or choking Check the brake valve. Rectify detected faults.
of air supply.
Defective brake pads. Check brake pads with respect to Replace with original brake pads.
part number and wear. On front wheels : Replace brake pads
on front wheel.
On drive wheels : Replace the brake pads.
Seized brake mechanism. - Check torque required to pull round Recondition brake caliper if limits
manual adjusting screw. are exceeded.
- Lift off cylinder and check
seal to see of moisture has
entered the brake.
- Push by hand on lever cup and
note of lever moves easily and if it
returns by itself without seizing.
and seals, replace.
and seals, replace.
BR -12 BRAKE SYSTEM
7. Cracks in disc

Cracks in disc. Check that cracks do not exceed When cracks occur,go through items.
permitted values. 2.Uneven braking
4.Hot running
6.Abnormal performance
If permitted values are exceeded, carry
out : Replace the brake disc.
8. Uneven wear between brake pads on same axle

Uneven wear between Check as per items : As per inspection items.
brake pads on same axle 2.Uneven braking
4.Hot running
6.Abnormal performance
7.Cracks in disc.
9. Unevenly worn or skew worn brake pads

Difference in thickness - Ensure the correct brake - If brake linings are not original
between outer and inner pads are fitted. parts,replace to original brake pads.
brake pads. - Check the sliding function of the - If the brake caliper seizes :
brake caliper and make sure the Replace the guide sleeve sealings ,guide
difference in thickness between sleeves bushings and seals.
the inner and outer brake pads - Replace the ventilation hoses or filter
does not exceed 4 mm. if they are blocked.
- Make sure ventilation hoses and
filters to the brake cylinders are
not blocked or pinched.
Difference in thickness Check that the difference in thickness Clean the supporting surfaces for brake
between top edge and between the brake pads is not pads,rear of outer brake pads, pad springs
bottom edge and between greater than 4 mm and that the and brake pad retainers and make sure
front edge and rear edge guide pin play is not above permitted they are not damaged.
on brake lining. limits,carry out : Sliding sleeves, wear - If brake linings are not original parts,
measurement for values. replace to original brake pads.
- If play in guide sleeve bushings
is too great.
FULL AIR BRAKE SYSTEM BR -13
FULL AIR BRAKE SYSTEM

AIR PROCESSING UNIT(A.P.U)
SPECIFICATION E03B7732
Description Specification
Operating process Compressed air
Operating temperature -40 ~ 80℃
Opening safety valve 14~17 bar
Cut-out pressure 9.1~9.5 bar
GENERAL DIAGNOSTICS AND

TESTS ED32F82B
SAFETY CHECKS
Before working on or around air braking systems and de-

vices, the following precautions should be observed:
1. Stop the engine before working under a vehicle.
2. Always chock the wheels because depleting vehicle

air system pressure may cause the vehicle to roll.
Keep hands away from actuator push rods and slack
adjusters they may apply as system pressure drops.
3. Never connect or disconnect a hose or line containing

air pressure, it may whip as air escapes.
Never remove a device or pipe plug unless you are
sure that all system pressure has been depleted.
4. Never exceed recommended air pressure and always

wear safety glasses when working with air pressure.
Never look into air jets or direct them at anyone.
5. Never attempt to dismantle a device until you have

read and understood recommended procedures.
Some units contain powerful springs and injury can
result if not properly dismantled.
Use only correct tools and observe all precautions
relative to the use of these tools.
6. Before you begin testing the air braking system, per-

form the following checks:
1. Examine all pipe work for signs of kinks, dents,
abrasion, drying out or overheating.
2. Check attachment of all pipe work; it should be
supported so that it cannot abrade or be sub-
jected to excessive heat.
BR -14 BRAKE SYSTEM
SERVICE INTERVALS
Service Intervals Service Note

• Clean the oil separator and replace
the O-Rings Failure of the air processing unit to purge
30,000 Km (If necessary the service interval or none placement of the desiccant
can be revised, depending on the cartridge at the recommended interval can
amount of oil carryover). cause a reduction in the service interval
• Replace the desiccant cartridge. of downstream components.
1 year, 100,000 km
• Clean the oil separator, if necessary.
COMPONENTS EADDCC17
2
5
1. Filter cartridge
2. Heater plug
3. Silencer
4. Oil separator
5. Purge valve
6. Body
7. Air processing unit
7
SPYBR7001L
BR -16 BRAKE SYSTEM
REPLACEMENT EBD9051E FITTING THE CARTRIDGE
REMOVAL WITH THE AIR PROCESSING UNIT 1. Lightly lubricate the gasket at the base of the cartridge
STILL FITTED TO THE VEHICLE (A) with grease Molykote 55 M.
1. Before starting work on the vehicle please refer to the 2. Lubricate new O-ring (1) with grease Molykote M.
safety instructions.
3. Fit O-ring (1) over the cartridge retaining thread.
2. Clean the outside of the air processing unit and its
surroundings to prevent entry of dirt. 4. Screw desiccant cartridge (A) up to stop.
3. Vent the air processing unit cartridge by charging the 5. Fully tighten desiccant cartridge (A) by turning a fur-
compressed air system until the cut-out pressure of ther 1/2 turn using a suitable strap wrench.
the unloaded valve has been reached and the air pro-
cessing unit has purged. REPLACEMENT OF THE HEATER ASSEMBLY
4. Loosen the cartridge(A) by turning counter-clockwise 1. Clean the outside of the air processing unit and the
using a suitable strap wrench. surroundings of the heater area.
REMOVING THE CARTRIDGE WITH APU REMOVED 2. Unscrew electrical connector locking ring and unplug
connector.
1. Unscrew desiccant cartridge (A) counter-clockwise,
using suitable strap wrench. 3. Undo screw (2).
1 1
G 2
G
SPYBR7002L SPYBR7003L
2. Remove O-ring (1). 4. Remove heater assembly (1).
3. Wipe the body (G) with a clean rag. Protect the clean 5. Fit heater assembly (1) into body (G).
air chamber and cartridge mounting thread from dirt.
6. Tighten screw (2) to a torque of 3.5 Nm.
7. Refit the electrical connector and hand tighten the

locking ring.
REPLACEMENT OF THE SILENCER ASSEMBLY REFITTING THE AIR PROCESSING UNIT TO THE
VEHICLE
1. Remove silencer assembly (C).
1. Locate the air processing unit in its position on the
vehicle.
SPYBR7004L
2. Locate silencer assembly (C) over its spigot on the SPYBR7006L
base of the air processing unit.

2. Fit and tighten the three M12 mountings to a maxi-
3. Lightly tap the silencer assembly (C) in the direction mum torque of 25 Nm.
of the spigot so that it snaps into place.
3. Reconnect the air lines.
REMOVAL OF THE AIR PROCESSING UNIT FROM
THE VEHICLE 4. Charge the air system to cut out pressure.
1. Before starting work on the vehicle please refer to the 5. Check all fittings and seals for leakage using soap and
safety checks. water. There should be no leakage.
2. Vent the system air pressure completely. 6. Deplete the pressure in the system by operating the
foot brake repeatedly until cut-in pressure is reached.
3. Disconnect air lines after noting which port they are
connected to for correct reinstallation. 7. Ensure cut-in and cut-out pressures are correct.
4. Unscrew and remove the three M12 mountings.
SPYBR7005L
5. Remove the air processing unit and cover the ports to

prevent entry of dirt.
BR -18 BRAKE SYSTEM
REMOVAL OF THE OIL SEPARATOR UNIT FITTING THE OIL SEPARATOR
1. Clean the outside of the air processing unit and its 1. Check that the sealing surfaces of the oil separator
surroundings to prevent entry of dirt. unit (1) and the cartridge neck (not shown) are clean.
Fit the new O-rings (2 and 3 ).
2. Secure the APU either to a simple fixture or using the
mounting bolts/studs to make it stable. 2. Put 2 rods (Ø2.5 mm) into the threads for screws (4)
to guide the oil separator in to the body (G).
3. Unscrew desiccant cartridge (A) counter-clockwise,
using suitable strap wrench. C
4
1
A
5 5 G
1 4
2
G
3
G
SPYBR7009L
SPYBR7007L 3. Place the oil separator unit (1) into the body (G). Push
the unit down until it is correctly seated.
4. Remove the screws (4).
4. Fit and tighten screws (4) to a torque of 2.5 ± 0.2 Nm.
5. Remove the oil separator unit (1) by turning it
clockwise and pulling, using 2 screwdrivers or rods 5. Slightly lubricate the gasket at the base of the car-
(Ø3×100 mm), until the O-ring (2) is clear of the body tridge (A) with grease Molykote 55M.
(G).
6. Lubricate O-ring (5) with grease Molykote M.
B
7. Fit new O-ring (5) over the cartridge retaining thread.
8. Screw desiccant cartridge (A) up to stop.

1
G 9. Fully tighten desiccant cartridge (A) by turning a fur-
ther 1/2 turn using a suitable strap wrench.
2
SPYBR7008L
6. Pull the oil separator unit (1) completely clear of the

body (G).
7. Clean the oil separator unit (1) with water using a high
pressure hose or alternatively with gasoline. Also
clean the housing using a soft cloth.
DISASSEMBLING THE PURGE VALVE ASSEMBLING THE PURGE VALVE
1. Remove the retaining ring (7) while holding the cover 1. Lubricate the housing with grease Molykote 55M.
(6) against the compression spring (4).
3
2
3
2 1
1 4
5
4
5 6
7
6
7 G
G 6
9bar 9bar
SPYBR7011L
SPYBR7010L
2. Lubricate O-ring (3) and sealing ring (2) with grease
2. Remove the cover (6) carefully. Molykote M and fit to piston (1).
3. Remove the compression spring (4). 3. Make sure that the sealing ring (2) fits properly into
the groove of the piston (1).
4. Remove the piston (1).
4. Place the assembled piston (1) into the body (G).
5. Clean the housing in the body (G).
5. Place the compression spring (4) into the body (G).
6. Choose the appropriate cover (6).
7. Lubricate O-ring (5) with grease Molykote M and fit

into the groove in cover (6)
8. Place the assembled cover (6) into the housing and

press down and hold against the compression spring
(4).
9. Fit retaining ring (7) into the body (G). Make sure that
it is securely located in the groove.
BR -20 BRAKE SYSTEM
DUAL BRAKE VALVE
COMPONENTS E8F7B13E
43
38
A
34
45
8 35
32
1 37
2 41
36 39 33
40
14 10 27
3 9
4
5 11
6 12
7
44 13
18 15
19 16
20 17
21 23
22 24 42
47 25
15 48
16 26
31 46
18 19 30 20
17 21 29 28
1. Cover plate 17. Ring piston 33. Pivot pin

2. Retaining ring 18. O-ring 34. Collar 1
3. Bush piston 19. O-ring 35. Roller
4. Compression spring 1 20. Circlip 36. Cover assembly
5. Compression spring 4 21. O-ring 37. Clamping piston
6. Compression spring 5 22. Power piston 38. Pedal
7. Compression spring 2 23. O-ring 39. Stopper nut
8. Nut 24. O-ring 40. Stopper bolt
9. Washer 1 25. Guide plate 41. Clamping pedal seal
10. Circlip 26. Plate seal 42. Bolt and washer
11. Cover plate 2 27. Bolt and washer 43. Pedal rubber
12. O-ring 28. O-ring 44. Protective plug
13. Guide rod bolt 29. Exhaust socket 45. Washer 3
14. Upper housing 30. Exhaust cover 46. Circlip
15. Guide piston assembly 31. Housing base 47. Compression spring
16. Compression spring 3 32. Pin cotter 48. Push rod
* Pedal angle (A): 40 2
[CAUTION]
1.Plug the ends of the removed air pipes and the open parts of the dual brake valve.
2.Check for air leakage after installation.
SPYBR7014L
REPLACEMENT E6188331
1. Park the vehicle at the flat road.
2. Remove the battery (-) cable.
3. Disconnect the connector below the gradual valve.
SPYBR7015L
4. Remove the gradual valve with loosening the brake

pedal mounting bolt.
SPYBR7016L
5. The installation is the reverse of removal.
CAUTION
1. Brake hose is free from being twisted.
2. Lubricate the sealant for preventing dust and
water after installing the connect.
BR -22 BRAKE SYSTEM
GRADUAL VALVE
COMPONENTS EFB23EA5
C
B
A
P2 (bar) R
Lever
(Lever stroke)
Exhaust
Port1
Port2
Gradual valve
Exhaust
A: Driving condition(Lever stroke 0 )

B: Stopping condition in driving(Lever stroke 60 )
C: Conversion to parking condition by raising lever upward at "B" state(Lever stroke 85 )
R: Parking
Port 1: Air supply line

Port 2: Air delivery line for operating parking chamber
SPYBR7017L
Operating process Compressed air

Operating temperature -40 C~80 C
Max. pressure 10bar
GENERAL DIAGNOSTICS E1089F0F
Symptom Cause Remedy

Air leaks of port1, port2 Wrong tightening torque in connector Retighten to the specified torque
Defective connector Replace connector
Poor lever movement Foreign material entry Replace
Damage to inner parts
Functional malfunction Damage to inner parts Replace
Foreign material entry Replace
Insufficient air pressure supplied Check for air supply pipe
REPLACEMENT EF73CB38
1. Remove the control box assembly in driver seat left

side.
2. Remove the gradual valve with mounting bolt after

disconnecting the hose.
Release the parking Apply the parking

brake. brake.
SPYBR7018L
3. The installation is the reverse of removal.

BR -24 BRAKE SYSTEM
ONE TOUCH FITTING
COMPONENTS EB52902D
1 2 3 4
1. Body
2. Tube support
3. O-ring
4. Collet
SPYBR7019L
REPLACEMENT EEAE6A21 5. In the case of Elbow or Tee fittings, Tighten external

thread into the internal thread.(Finger Tight) Tighten
REPLACEMENT OF TUBE an additional 1 to 11/2 revolutions with a wrench.
1. Cut tubing squarely maximum of 15 angle allowable.
2. Check that port or mating part is clean and free of

debris.
3. Insert tubing into fitting until it bottoms - Push twice to

verify that tubing is inserted past collet and O-Ring.
4. Pull on tubing to verify it is fully inserted.
5. To disassemble, simply press collet, hold against

body, and pull tubing out of fitting.
6. Disassembling a tube
- Remove a foreign substance between a collet
and body using air gun. SPYBR7021L
- Push and remove the tube after contacting a col-
let to the body totally. 6. Tighten fitting, Clockwise, to Align with Tubing (Never
counter clockwise).
FITTING REPLACEMENT
1. Fitting assembly of turns methods applies differently

to each type.(Straight fittings / Elbow or tee fittings.)
2. At first, check the proper sealant on the threads.
3. In the case of Straight fittings, Tighten external thread

into the internal thread.(Finger Tight) and tighten ad-
ditional revolutions with wrench.
SPYBR7022L
7. To minimize the possibility of a leaking threaded joint

after assembling male to female pipe threads, neither
end should be backed out (loosened) once the as-
sembly has been made.
8. When disassembly fittings, untighten fitting and clean

sealant debris or foreign substance. When reassem-
bly fittings, apply sealant to thread, Dry it properly and
SPYBR7020L
tight fittings according to above Instructions.
4. For example, Tighten an additional 2 revolutions with
a wrench up to 1/2 in. male pipe thread. Above 1/2
in., 11/2 to 21/2 revolutions.
BR -26 BRAKE SYSTEM
BRAKE ASSEMBLY
DRUM BRAKE
SPECIFICATION EC8697F6
Description Specification
Brake type Full air type
Brake shoe(type) Open type
Brake size(mm) Ø410
Lining width × thickness(mm) 200×20
Brake cam(type) Spiral (S-cam)
Adjusting type Auto slack adjust
SERVICE STANDARDS
Item Standard Limit Remark

Lining thickness(mm) 20 6.5 Remaining thickness
Anchor pin O.D(mm) 37 36.85
Anchor pin bushing I.D(mm) 37 37.15
Play between anchor pin and bushing(mm) 0.05~0.12 0.25
Shoe roller bushing I.D(mm) 22 22.4
Shoe roller O.D(mm) 37 36.6
Shoe roller pin O.D(mm) 22 21.6
Play between shoe roller bushing
0.2~0.43 0.8
and roller pin(mm)
Camshaft bushing I.D(mm) 40 40.3
Camshaft O.D(mm) 40 39.7
Play between camshaft bushing and
0.15~0.22 0.6
camshaft(mm)
Return spring A Free length (mm) 252 257
Load (kg) 41~49 - Measuring at 261mm
Return spring B Free length (mm) 145 148
Load (kg) 23~28 - Measuring at 261mm
TIGHTENING TORQUE
Tightening torque
Item
kgf.m Nm Ib-ft
Chamber bracket mounting
8~12 78.5~117.7 57.9~86.8
bolt
BRAKE ASSEMBLY BR -27
COMPONENTS E79A18CC
FRONT BRAKE
135.3~154.9 11
(13.8~15.8, 99.8~114.3)
10
4 343.2~441.3
1 (35~45, 2~325.5)
6
1. Return spring pin
2. Anchor bracket
3. Camshaft
7
4. Return spring A 2
5. Shoe and lining assembly
6. Return spring B
7. Anchor pin
8. Chamber bracket
9. Brake chamber
10. ABS speed sensor
11. Auto slack adjuster
Tightening Torque : Nm (kgf.m, Ib-ft)
SPYBR7023L
BR -28 BRAKE SYSTEM
REAR BRAKE
3
4
2 14.7~19.6 2
(1.5~2, 10.91~14.54)
1 27.44~53.9 1
(2.8~5.5,
20.36~40)
1. Brake chamber
2. Drum brake
3. Rear axle
SPYBR7024L
DISASSEMBLY E0A41364
16
18
20 13
17
7
19 12
21 22 1
18
4
2 3 6 24
13
5
23
12 15
8
11
10 25 6
14
*1. Roller and retainer assembly 14. Anchor pin

2. Retainer 15. Cam shaft
3. Roller 16. Chamber bracket bolt
4. Pin roller 17. Chamber bracket bolt
*5. Shoe return spring A 18. Washer
*6. Shoe return spring B 19. Chamber bracket
7. Shoe and lining assembly 20. Oil seal
8. Rivet 21. Camshaft bushing
9. Cam lining 22. Anchor bracket
10. Anchor lining 23. Oil seal
11. Shoe assembly 24. Camshaft bushing
12. Snap ring 25. Anchor pin bushing
"*" mark means that describe disassembly and assembly in detail.
SPYBR7025L
BR -30 BRAKE SYSTEM
1. Rotate the shoe and lining assembly like ①, then re- 3. Rotate the shoe and lining assembly like ①, remove
move the roller and retainer assembly like ②. (See the return spring B like ②.(See "disassembly picture
"disassembly picture *1") *6")
CAUTION
Remove the parts using tools(ex. screwdriver).Do
not remove it by hands.
2
1
1 2
SPYBR7028L
NOTE
Clear the contaminated part because of dirty oil or
SPYBR7026L
dust.
2. Rotate the shoe and lining assembly base on the

camshaft like ①, then remove the return spring A with
narrowing the gap of return spring like ②.(See "disas-
sembly picture *5")
1 1
SPYBR7027L
INSPECTION E4F79F83 4) I.D of anchor pin bushing
1. INSPECTION Standard Limits

Inspect the each part using inspection device or
37 mm 37.15 mm
tool.Refer to specified value whether use each part
or not.If necessary, repair or replace them.
If wear of part limits the specified value,if needed, re- 5) Play of anchor pin and bushing
place the wear part or opponent part.
Although wear of part doesn’t limit the specified value Standard Limits
,it will be able to replace for maintenance.Do not use 0.05~0.12 mm 0.25 mm
again rubber parts, use the new one.
1) Abnormal state 6) I.D of shoe roller bushing

- Wear is uneven.
- Sloping wear Standard Limits
- A scar
22 mm 22.4 mm
- A crack
- A fatigue or weakening(Spring)
- Bending 7) O.D of shoe roller
- Loose assembly
- Discoloration Standard Limits
- Abnormal noise(Bearing) 37 mm 36.6 mm
- Rust
- Capacity deterioration(Lining)
8) O.D of shoe roller pin
2) Lining thickness
Standard Limits
Standard Limits(A) 22 mm 21.6 mm
20 mm 6.5 mm
9) Play of shoe roller bushing and roller pin
Standard Limits
0.2~0.43 mm 0.80 mm
A
10) I.D of camshaft bushing
Standard Limits
40 mm 40.3 mm
11) O.D of camshaft

SPYBR7029L
3) O.D of anchor pin Standard Limits

40 mm 39.7 mm
Standard Limits
37 mm 36.85 mm 12) Play of camshaft bushing and camshaft
Standard Limits
0.15~0.22 mm 0.6 mm
BR -32 BRAKE SYSTEM
13) Return spring 2. Repair and replacement

Using a drill machine, drill the jointing part of the shoe
Stan- side rivet. Remove the lining.
Item Remarks
dard(L)
1) Lining
Free 1. Drill the rivet head of shoe.Remove the rivet
252
length(mm) and disassemble the lining.
Return
Limit(mm) 257
spring A
Measuring
Load (kg) 41~49
at 261mm
Free
145
length(mm)
Return
Limit(mm) 148
spring B
Measuring
Load (kg) 23~28
at 154 mm
NOTE
If return spring length exceed the limits described in
table , replace it.
SPYBR7031L
2. Joint the parts using the rivet like below pic-

ture.
L
A Type
B Type
SPYBR7030L
SPYBR7032L
NOTE
• Riveting of lining from the center portion and
working toward the ends. Make sure that no gap
is produced between the shoe and lining.
• Clear the surface of shoe.
• Stake the rivets to 2,700 to2,900 kgf.
SPYBR7045L
SPYBR7033L
2) Anchor pin bushing

1. Remove the anchor pin bushing from the an-
chor bracket.(See the below pictures.)
2. Clear the bushing hole.
3. Insert and press the new bushing to anchor
bracket.(See the below pictures.)
4. After pressing , inner diameter must be 37~ SPYBR7220L
37.15 mm.
3) Camshaft bushing
1. Remove the oil seal from the anchor bracket.
2. Remove the camshaft bushing from the an-
chor bracket and the chamber bracket.
3. Clear the bushing hole.
4. Press the new bushing and oil seal to the
anchor bracket and chamber bracket.
5. After pressing, inner diameter must be
40~40.03 mm.
SPYBR7034L
BR -34 BRAKE SYSTEM
REASSEMBLY EFA60124
16
18
20 13
17
7
19 12
21 22 1
18
4
2 3 6 24
13
5
23
12 15
8
11
10 25 6
14
Reassembly sequency
25. Anchor pin bushing 12. Snap ring

24. Camshaft bushing 11. Shoe assembly
23. Oil seal 10. Anchor lining
22. Anchor bracket 9. Cam lining
21. Camshaft bushing 8. Rivet
20. Oil seal 7. Shoe and lining assembly
19. Chamber bracket *6. Shoe return spring B
18. Washer *5. Shoe return spring A
17. Chamber bracket bolt 4. Pin roller
16. Chamber bracket bolt 3. Roller
15. Cam shaft 2. Retainer
14. Anchor pin *1. Roller and retainer assembly
"*" mark means that describe disassembly and assembly in detail.
SPYBR7035L
NOTE ROLLER AND RETAINER ASSEMBLY
Refer to ’Inspection’ about detail contents. Assemble the roller and retainer assembly like below se-
- Assembly of brake shoe and lining quence. After assembling ,check for rotation of roller with
- Assembly of anchor pin bushing rotating the camshaft.
- Assembly of camshaft bushing
TIPS ON ASSEMBLY
CAMSHAFT BUSHING
2
1
Lubricate the grease into the bushing.
CHAMBER BRACKET BOLT
Tighten the chamber bracket bolt.(8 ~ 12 kgf.m)
CAMSHAFT
Check for rotation of camshaft after assembling the

camshaft.
SHOE RETURN SPRING B SPYBR7038L
Assemble the shoe return spring B like below sequence. CAUTION WHILE INSTALLING THE DRUM BRAKE
CAUTION
When installing the drum to the hub, tighten the
bolt to the specified torque.
Torque : 56.84~59.78 Nm(5.8~6.1 kgf.m,

42.17~44.35 lb-ft)
2
SPYBR7036L
5.8~6.1Kgf.m
SHOE RETURN SPRING A
Assemble the shoe return spring A like below sequence.
SPYBR7039L
1 1
SPYBR7037L
BR -36 BRAKE SYSTEM
BRAKE CHAMBER
COMPONENTS E5DD9687
3 4
1. Release bolt
2. Bleeder tube
3. Service chamber clamp band
4. Mounting stud nut
5. Air line 6
6. Push rod
SPYBR7040L
DESCRIPTION EA3AF933
There are no user-serviceable parts inside the spring

brake chamber. If you experience any damage or failure
of your spring brake chamber, remove either the entire
actuator or the single (piggyback).
Never attempt to disassemble the spring brake chamber
as serious personal injury could result from accidental sud-
den release of the high energy spring.
ADJUSTMENT E33CEC3B REPLACEMENT E6CB4D70
1. Visually inspect the exterior surfaces of the unit for REMOVAL OF BRAKE CHAMBER
signs of damage from outside sources, corrosion
and/or rust. If any of these are seen or suspected, 1. Ignition OFF, and Place the wooden block at the front
cautiously remove the complete combination cham- and rear side of the rear wheel.
ber.
2. Remove the chamber air hose(A). If parking brake is,
2. Check to ensure that the release bolt is seated against remove main brake air hose and parking brake air
head insert and tightened to 47~61Nm(35~45 lb-ft) hose.
torque. This ensures the parking brake will have full
stroke capability and seals release bolt threads, keep-
ing out contaminants.
3. Ensure the breather tube is securely engaged a

minimum of 0.5 inch(13 mm) into the rubber elbows
and glued together with a high quality rubber cement.
These units must be mounted with the breather tube
facing away from the road surface.
4. Check to ensure the service chamber clampband

A
is evenly seated and the clampband bolt nuts are
torqued to 41~47 Nm(30~35 lb-ft).
5. Check to ensure the mounting stud nuts are tightened

to 180~210 Nm(133~155 lb-ft) torque (clockwise) and SPYBR7041L
washers are in place between the nut and the bracket.
3. Remove the chamber with loosening the two mount-
6. Inspect air lines, hoses and fittings attached to ing bolts after removing the washer from push-rod.
the chamber. Replace any damaged or leaking
parts.MGM Brakes recommends the fittings be 4. Turn the integral release bolt counter-clockwise us-
tightened to 34~41 Nm(25~30 lb-ft) torque into the ing a 3/4-inch(19mm) socket wrench until the power
chamber air-inlet ports. spring is fully caged or compressed (Do not use an
impact wrench). Full cage position requires approxi-
7. Inspect the push-rod be sure it is working free, not mately 22~23 turns for 3 inch(76mm) stroke units.
bent, not binding and is square to the chamber bottom
within ±3 in any direction at any point in the stroke of
the chamber. If the push-rod is not square, make cor-
rections by repositioning the chamber on the mount-
ing bracket and / or by shimming the slack adjuster to
the right or left on the camshaft.
8. Inspect the yoke assembly being sure the yoke pin

is installed and locked into place with a cotter pin.
Replace any damaged, worn or missing parts. MGM
Brakes recommends the yoke jam nut be tightened to
34~68 Nm(25~50 lb-ft) torque.
9. On units equipped with a dust boot, check the boot for

tears and replace as necessary.
SPYBR7042L
BR -38 BRAKE SYSTEM
5. The parking spring is fully caged when the release 1. Manually release the spring brake completely.
bolt is up approximately 1.3 inches(33 mm) from the
run position. 2. Remove cotter pin from the yoke pin, knock out yoke
pin, and remove both airlines from the assembly.
CAUTION
Be sure to mark the air line from the air-inlet port
marked "SPRING" for reinstallation reference.
3. Using a 15/16 inch(24 mm) wrench, unscrew hex

Measure
nuts on mounting bolts and cautiously remove the old
chamber from the mounting bracket.
4. Procedure to cut service push-rod to proper length.
1) Improper installation of the new unit could result

in malfunctioning brakes or premature failure of
the braking system. Proper cam brake adjust-
SPYBR7043L ment. If the old brake chamber was properly in-
stalled, use the old brake measurement to deter-
CAUTION mine the proper rod length. If the brake being
removed was not properly installed or has been
Do not exceed this length and do not exceed 50 damaged too greatly to allow measurement, the
lb-ft(68 Nm) torque on release bolt at any time or other chamber on the same axle may be used.
damage may occur which could prevent any fur-
ther correct manual release of the spring brake 2) Replacing the spring brake
chamber. Make sure the old spring brake is manually-re-
leased fully and that the service brake push-rod
NOTE is fully retracted to zero stroke or brakes "OFF"
For easier turning of the release bolt, apply 95~125 position. Then measure and record both of the
psi(655~862 kPa) air pressure to the air-inlet port following "X" and "Y" dimensions, in inches or
marked "Spring" before Step (4) above. After caging, millimeters, outward from bottom face of service
completely exhaust air from the spring chamber. brake chamber.
REMOVAL AND INSTALLATION INSTRUCTIONS

FOR “ COMBINATION” SPRING BRAKE
CHAMBERS
CAUTION
It is important when replacing any other model air
brake actuator, both actuators on the same axle
be replaced to ensure braking stability. The park-
ing brake forces are significantly different and us-
ing two different actuators on the same axle could
cause brake pull during an emergency brake ap-
plication.
NOTE
SPYBR7044L
Refer to cam brake adjustment of this manual before
removing the air brake chamber to be replaced to en-
sure the brake chamber being replaced will be prop- "X" Dimension - The dimension from bottom of
erly installed with correct rod length. actuator to end of push-rod. : 34 ~ 40 mm
"Y" Dimension - The dimension from bottom of
actuator to centerline of yoke pin. : 65~71 mm
5. Procedure to Cut Push-Rod on New Replacement 8. Inspect the push-rod to be sure it is working free, not
Combination Chamber bent, not binding and is square to the chamber bottom
within + 3 in any direction at any point in the stroke
NOTE of the chamber. If the push-rod is not square, make
corrections by repositioning the chamber on mounting
The new service chamber push-rod must be cut to ex-
bracket and/or by shimming the slack adjuster on the
actly duplicate the original "rod-plus-yoke" length af-
camshaft as required.
ter the yoke assembly is reinstalled on the new cham-
ber’ s push-rod. Use the same procedure for mea- 9. Apply sealing compound to hose fittings and reinstall
suring the rod on the new unit as used on the unit both air lines to the chamber making sure each is
being replaced. mated to the correct air-inlet port according to mark-
ings made earlier. MGM Brakes recommends the fit-
6. Remove hex nuts and washers on mounting bolts of
tings be tightened to 25~30 lb-ft / 34~41 Nm torque
new chamber, clean face of mounting bracket and in-
into the chamber’ s air-inlet ports.
stall chamber on bracket with close attention given to
positioning chamber air-inlet ports for alignment to ve-
10. Using vehicle system air, charge spring brake with
hicle air lines. Then install one washer and hex nut
full line pressure (minimum 100 psi/690 kPa). Using
on each mounting bolt and, using a 15/16-inch/24mm
only soapy water (Never any type of oil.), inspect for
hand wrench (Do not use an impact-type wrench.)
air leaks at air lines and fittings. If bubbles appear,
Tighten nuts to 133~155 lb-ft/180~210 Nm torque.
tighten fittings slightly, but not over 25~30 lb-ft / 34~41
Nm torque.
CAUTION
- If it is required to reposition the air-inlet ports CAUTION
to assure proper mating and alignment with
- If service brake clampband was loosened to
vehicle air lines,execute carefully.
reposition air-inlet ports in Step (6) above,
- The breather tube faces away from the road
apply air to spring brake and then apply and
surface.
hold foot brake treadle valve down to charge
service brake chamber. Test for air leaks
Breather tube around circumference of service clampband
with soapy water or air leak detection liquid
solution. If bubbles appear, firmly tap cir-
cumference of clampband with hammer and
retighten clampband nuts until leaks cease.
Tightening torque is recommended to 30~35
Lb-ft /41~47 Nm torque on clampband hex
nuts.
Road surface
SPYBR7047L
7. Reconnect yoke to slack adjuster, being sure the cor-

rect diameter and length of yoke pin is installed into
the correct hole in the slack adjuster. Secure yoke
pin with a new cotter pin.
CAUTION
When reconnecting to an automatic slack ad-
juster, use the proper automatic slack adjuster. SPYBR7048L
BR -40 BRAKE SYSTEM
11. Exhaust air pressure from service brake chamber and 17. Push and close the dust cover to the hole of release
with air pressure still applied to spring brake chamber, bolt.
tighten the release bolt until it is seated against the
head insert and torqued to 35~45 lb-ft / 47~61 Nm. 18. The piston rod must remain perpendicular to the bot-
This will ensure the parking brake will have full stroke tom of the non pressure chamber within ± 3 during
capability and the release bolt threads will seal out brake actuation from zero to full stroke with the unit
contaminants. mounted to the axle bracket and the piston rod con-
nected to the slack adjuster.
CAUTION REMOVAL AND INSTALLATION FOR SINGLE
Be sure external breather tube is securely en- SPRING BRAKE CHAMBERS
gaged a minimum of 0.5 inch/13mm into the
rubber elbow and glued together with a high CAUTION
quality rubber cement. These units must be - It is important when replacing any other
mounted with the breather tube facing away from model air brake actuator with same model
the road surface. actuator that both actuators on the same axle
be replaced to ensure braking stability.
The parking brake forces are significantly dif-
Apply adhesive here ferent and using two different actuators on
the same axle could cause brake pull during
an emergency brake application.
NOTE
- The replacement of a single (piggyback) spring
brake chamber can be done without the removal
of the entire "combination" spring brake from the
Min. 13 mm
vehicle.
The procedure can be made easier by "locking
off" the service chamber push-rod. To do this, en-
gage the service brake by applying the driver’ s
SPYBR7049L foot brake treadle valve and, while applied, clamp
vise-grip pliers onto push-rod to prevent rod from
WARNING retracting when air pressure is released.
After replacement of any spring brake actuator,
the push-rod stroke and actuating alignment
must be checked to assure correct installation
and foundation brake adjustment. It is very
important to recognize that no foundation brake
adjustments can be made at either the spring
brake chamber or at the service brake chamber,
and that all “ stroke adjustments” must be made
at the slack adjuster.
12. Place the chamber unit on the chamber bracket. But

don’t use the washer between chamber and bracket.
13. Tighten the washer and nut. Tighten the nut to the
180 ~ 210 Nm torque.
SPYBR7050L
14. Torque air line fittings to 34 Nm(25 lb-ft) Maximum.
Use LOCTITE PST 565 pipe sealant or equivalent.
15. Charge the Minimum pressure, 6.2 Bar, to the cham-

ber unit.
16. Remove the release bolt.

1. Remove both air lines from chamber. 4. Make sure new single (piggyback) spring brake cham-
ber is fully released. Position diaphragm in bottom re-
CAUTION cess of chamber and, with very close attention taken
to assure all mating parts are aligned straight and the
- Be sure to mark the air line from the air-inlet air-inlet ports are positioned to mate with vehicle air
port marked "SPRING" for reinstallation ref- supply lines, replace service clampband.
erence.
2. Disconnect the tube and elbow from the service

chamber housing
SPYBR7053L
SPYBR7051L
3. Using a 9/16-inch/ 14mm wrench or socket, remove

the nuts on service clampband. Next, while hold-
ing the single (piggyback) chamber securely in place,
remove clampband, then carefully separate and re-
move the single (piggyback) chamber from the ser-
vice chamber.
SPYBR7052L
SPYBR7052L
CAUTION
- At this time take the opportunity to inspect all
parts in the service chamber (especially the
diaphragm and return spring) and replace any
parts which may be damaged or worn. Use
only genuine replacement parts.
BR -42 BRAKE SYSTEM
5. Reinstall clampband bolts and nuts. Alternately 8. On the chamber fitted with an external breather tube,
tighten each nut in 5~10 lb-ft(7~14 Nm) torque in- wipe open end of connector tube clean to be sure no
crements while constantly rechecking mating parts oil is present, apply a good quality rubber cement to
alignment. If realignment is required, loosen clamp- the tube and reinsert tube into both of the flexible el-
band nuts and repeat Step 4 above. Firmly tap bows with a minimum of 0.5 inch/13 mm engagement
around circumference of clampband with hammer to .
assure full seating of clampband and tighten nuts to
30~35 lb-ft / 41~47 Nm torque.
Apply adhesive here
Min. 13 mm
SPYBR7056L
SPYBR7055L
If old single (piggyback) spring brake was not
6. Apply sealing compound to hose fittings and reinstall equipped with an external breather tube, drill a 0.5
both air lines to chamber, making sure each is mated inch/13mm diameter hole 1 inch/ 25 mm from the top
to correct air-inlet port according to markings made ’lip’ of the non-pressure chamber, at a point closest
earlier. The fittings be tightened to 25~30 lb-ft / 34~41 to the centerline between the air-inlet ports, on the
Nm torque into the chamber’s air-inlet ports. side which will face away from the road surface.
7. Using vehicle system air, charge parking brake with

full line pressure (minimum 100 psi/690 kPa). Using
only soapy water (Never any type of oil.), inspect for Hole
air leaks at air lines and fittings. If bubbles appear, (Diameter 13mm)
tighten fittings slightly, but not over 25~30 lb-ft / 34~41
Nm torque. With spring brake still fully charged with 25mm
full line pressure, apply and hold foot brake treadle
valve down to charge service brake chamber.
CAUTION
- At this time, remove vise-grip pliers from
the service chamber push-rod so it can re-
turn to a normal position in chamber when
service brake is released. Test for air leaks SPYBR7057L
around circumference of service clampband
with soapy water or air leak detection liquid
solution.
If bubbles appear, firmly tap circumference
of clampband with hammer and retighten
clampband nuts until leaks cease. The spec-
ified tightening torque is 30~35 lb-ft /41~47
Nm torque on clampband hex nuts.
REMOVAL AND INSTALLATION FOR SERVICE

Breather tube BRAKE DIAPHRAGM
WARNING
- When servicing a 3 inch/76 mm "Long Stroke"
model brake, be sure to replace with the cor-
rect diaphragm. Installation of a standard
(2.50 inch/ 64 mm) stroke diaphragm into a
3.0 inch/ 76 mm "Long Stroke" chamber will
result in short stroking and could result in air
leaks and failure of the unit.
Road surface
1. Follow all instructions given in Section "REMOVAL
AND INSTALLATION FOR SINGLE SPRING BRAKE
SPYBR7058L CHAMBERS" of this manual, paying close attention
to positioning the new diaphragm. Use only genuine
replacement diaphragms!
Remove burrs around the hole and install a new
rubber elbow into the non-pressure chamber. Wipe
NOTE
open end of connector tube clean to be sure no oil is
present and apply a good quality rubber cement to It may not be necessary to disconnect air lines from
the tube. Insert the tube into the flexible elbow with a the spring brake during this procedure as long as cor-
minimum of 0.5 inch/13mm engagement into elbow. rect parts are used and alignment can be obtained
during reassembly operation.
Apply adhesive here
Min. 13 mm
SPYBR7059L
CAUTION
These units must be operated with the breather
tube facing away from the road surface and the
tube glued securely into the rubber elbows.
9. Exhaust air pressure from service brake chamber

and with air pressure still applied to the spring brake,
tighten the release bolt until it is seated against the
head insert and torque to 35~45 lb-ft / 47~61 Nm.
This will ensure the parking brake will have full stroke
capability and the release bolt threads will seal out
contaminants.
CAUTION
- Release bolt must be properly tightened for
correct, full functioning of the spring brake.
BR -44 BRAKE SYSTEM
INSPECTION E53B03D0
NOTE
PROCEDURE TO CUT THE SERVICE CHAMBER - If for some reason the spring chamber power
PUSH-ROD TO PROPER LENGTH spring cannot be caged and fully released, then
the "X" and "Y" dimensions will need to be mea-
WARNING sured from the other actuator on the same axle
- Do not attempt to service or disassemble the (must be same model as the one being removed),
spring chamber on any spring brake actuator. provided it is properly adjusted and operating cor-
A large spring in the spring chamber having rectly, and is retracted to its zero stroke position
extreme force could cause serious bodily in- (brake fully released).
jury if it were to suddenly be released due to
inadvertent removal of the clampband or tam- 4. Before marking push-rod to be cut on a new unit, be
perresistant head. sure the power spring is fully caged and the push-rod
is fully retracted to the zero stroke position. (This may
be done with the integral release bolt or by applying
CAUTION 90~100 psi(621~690 kPa) air pressure to the spring
- Place chocks under wheels to prevent vehi- chamber air-inlet port.)
cle movement before removing air-brake ac-
5. Take measured "X" dimension from the removed unit
tuators.
and mark push-rod of new unit from the bottom of the
actuator.
1. Remove worn or non-functional nut from Vehicle.
2. Make sure the spring chamber of the removed actua- 6. Thread yoke jam nut past mark on push-rod. Align
tor is fully released (power spring caged) and the ser- bottom edge of nut with mark.
vice brake push-rod is fully retracted to zero stroke
7. Use a sharp hack-saw and cut push-rod on the mark.
position (i.e. brake fully released).
3. Measure and record the "X" and "Y" dimensions.
SPYBR7061L
8. After cutting rod, thread jam nut off to clean up cut

SPYBR7060L
thread.
9. Thread jam nut back onto the push-rod a sufficient

"X" Dimension - The dimension from bottom of actu-
length to allow assembly of the yoke.
ator to end of push-rod.:34~40 mm
"Y" Dimension - The dimension from bottom of actu- 10. Thread yoke onto the push-rod. Yoke from removed
ator to centerline of yoke pin.:65~71 mm unit may be reused provided yoke pin hole is not worn.
Adjust yoke to the same "Y" dimension as measured
from the removed unit.
11. Hold yoke to prevent it from turning and tighten jam

nut against yoke to 34~68 Nm(25~50 lb-ft) torque.
CAM BRAKE ADJUSTMENT - ALL SPRING BRAKE 3. IMPROPERLY ADJUSTED BRAKES "ON" - AP-
AND SERVICE BRAKE ACTUATORS PLIED
Maximum recommended readjustment stroke has
1. BRAKES "OFF" - NOT APPLIED been exceeded.
Angle must always be greater than 90 due to various
slack adjuster lengths and installation setups. Free
stroke should be as short as possible with no lining to
drum contact.
SPYBR7064L
RECOMMENDED SPRING BRAKE ACTUATOR

DISARMING PROCEDURE
SPYBR7062L
All retired spring brake actuators should be safely dis-
2. PROPERLY ADJUSTED BRAKES “ ON” - AP- armed before they are disposed of to prevent serious per-
PLIED sonal injury from accidental sudden release of the high en-
To check brake adjustment, apply 90-100 psi(621-690 ergy power spring (as much as 3200 lbs(1450 kg) ) in the
kPa) air pressure to the service chamber. This is nec- spring (or parking) chamber. To disarm the unit, remove it
essary since different dimensions are required for au- from the vehicle Be sure to cage the spring.
tomatic or manual slacks.
WARNING
Never attempt to remove the head which contains
the power spring. Observe all safety precau-
tions. Place the unit in a steel container and
use an acetylene torch to cut a hole through the
head housing the power spring. Cut completely
through at least two spring coils. The steel con-
tainer must have openings to expose the head
where it is to be cut with the acetylene torch, and
it must be strong enough to prevent parts from
hurtling out should the unit suddenly separate
before it is safely disarmed. It is the user’ s
responsibility to ensure the steel container is
safe.
SPYBR7063L
BR -46 BRAKE SYSTEM
AUTO SLACK ADJUSTER
DESCRIPTION EA2C261B
The clearance between lining and brake drum becomes

wide as the use of brake is going on. Therefore, the clear-
ance of brake lining should be maintained properly by ad-
justing it. To do so, the clearance will be adjusted by using
slack adjuster in full air "S" cam brake. But bad brake per-
formance like brake slippage will occur as the stroke of
brake chamber is long due to the excess of brake lining
clearance when applying brake, in case it is not adjusted
by maintenance intervals.
This is the reason why the stroke of brake chamber in the
range of approx. 80 % or more of max. stroke has char-
acteristics that brake force decreases. It is very important
service factor to adjust brake lining clearance in full air "S"
cam brake.
The auto slack adjuster always secures stable brake per-
formance and is in pursue of stability by adjusting brake
lining automatically and maintaining proper stroke of brake
chamber. Also it is not needed for adjusting the clearance
of brake lining by the time brake lining wears out fully after
installation.
Clearance
In adjusting manually
In adjusting automatically
Time
Effect of auto slack adjuster(Comparing with manual adjuster)
SPYBR7065L
COMPONENT LOCATION EE08A951
[ Front drum brake ]

3
[ Rear drum brake ]
4
2 2
1. Drum brake(front)
2. Drum brake(rear)
3. Brake chamber
5. Rear axle
SPYBR7066L
BR -48 BRAKE SYSTEM
COMPONENTS EACF0DF8
2 18
9 13
10
1
4
12
17 3
6 12
5
7
13
15
16
11
14
1. Housing 10. Thrust washer

2. Bushing 11. Gasket
3. Worm wheel 12. O-ring
4. Worm shaft 13. Rivet
5. O-ring 14. Plastic insert
6. Needle bearing 15. Gear wheel assembly
7. Front cover 16. Control disc
8. Control unit assembly 17. Clutch
9. Coil spring 18. Rear cover
SPYBR7067L
REMOVAL EDE4B180 REAR AUTO SLACK ADJUSTER
FRONT AUTO SLACK ADJUSTER 1. Park the vehicle to the flat place in safety.
1. Park the vehicle to the flat place in safety. 2. Remove the push-rod(A) connected to the brake
chamber after removing the tire.
2. Disassemble the bracket(A) connected to ABS wiring
after removing the tire.
SPYBR7070L
SPYBR7068L 3. Remove the auto slack adjuster with loosening the

mounting bolt.
3. Remove the push-rod(A) connected to the brake
chamber.
SPYBR7071L
SPYBR7069L
4. Loosen the mounting bolt and remove the auto slack

adjuster.
BR -50 BRAKE SYSTEM
INSTALLATION EF97F86A REAR BRAKE
FRONT BRAKE 1. Pre-assemble the stopper(A) to the bracket(B).
1. Confirm to be free field return spring of brake assem-

B
bly. If it was not, to rotate S-CAM shaft to remove force
at return spring.
2. Pre-assemble bracket by using bolt on chamber A

mounting bracket S-CAM shaft.
3. Side of auto slack adjuster "→" direction must coin-

cide with operating direction, assemble it to S-CAM
shaft.
4. After assembling in S-CAM shaft, insert auto slack

adjuster arm into the push rod clevis of brake chamber
by tuning auto slack adjuster head clockwise, install
the pin afterwards.
SPYBR7072L
5. After assemble bolt, nut in side of control arm. Com-

pletely assemble the parts of pre-assembled state. 2. Direction of "→" marked on slack adjuster to be iden-
tical with that of slack adjuster’s operating when as-
6. Lining gap adjusting turn degree auto slack ad- sembling slack adjuster to ’S’ cam shaft.
juster hexagon head right(Clockwise). After the At this time stopper to be inserted into the hole of
lining touches the drum turn it couterclockwise(270 control arm.
Degree) adjusting lining gap to 0.3~0.4 mm(After
assembling drum). 3. Turn hexagonal head of slack adjuster clockwise to
insert arm into clevis of chamber push-rod and then
tighten with pin.
4. Fasten completely pre-assembled bracket.
5. Adjusting clearance : Turn hexagonal head of slack

adjuster clockwise until lining is contact on drum and
then set clearance between drum and lining to be 0.3
mm by turning hexagonal head counterclockwise.
NOTE
Above installation should be performed at release of
brake.
DISASSEMBLY EF19C03B 4. Remove gear wheel assembly.
1. Remove control unit assembly mounting screw from

housing.
SPYBR7076L
5. Using hexagonal wrench, remove rear cover, coil

SPYBR7073L spring, and thrust washer.
2. Remove control unit assembly from housing.
SPYBR7077L
SPYBR7074L
3. Remove control unit gasket from housing.
SPYBR7078L
SPYBR7075L
BR -52 BRAKE SYSTEM
6. Remove front cover and then remove O-ring, needle 8. Detach O-ring from worm wheel.
bearing, clutch wheel, and worm shaft.
SPYBR7082L
SPYBR7079L
INSPECTION E26D5923
1. Wash and clean housing, worm wheel, and control

unit assembly prior to inspection.
SPYBR7080L
7. Remove worm wheel from housing.
SPYBR7083L
SPYBR7081L
SPYBR7084L
2. Inspect damage to inside of housing and replace

housing if worn.
Housing I.D. : Max. 62.20 mm
SPYBR7087L
4. Inspect damage to worm wheel including surface con-

dition. Replace it if necessary.
SPYBR7085L
3. Install worm shaft to housing and using thickness

gage measure the clearance between worm shaft
and housing.
Clearance between worm shaft and housing:

Max. 0.25 mm
SPYBR7088L
5. Measure worm wheel O.D. and replace it if worn.
Worm wheel O.D. : Max. 61.87 mm
SPYBR7086L
SPYBR7089L
BR -54 BRAKE SYSTEM
REASSEMBLY E2692850 3. Apply grease to worm shaft and install worm shaft to
housing.
1. Apply grease to the inside of housing.
SPYBR7093L
SPYBR7090L
4. Install clutch wheel, needle bearing, O-ring, and front
2. Apply grease to worm wheel and O-ring, and install cover and tighten these to the specified torque.
worm wheel to housing.
Front cover tightening torque: 5.0 kgf.m
SPYBR7091L
SPYBR7094L
SPYBR7092L
5. Install thrust washer, coil spring, and rear cover to 7. Install gasket and control unit assembly.
housing.
SPYBR7098L
SPYBR7095L
8. Install control unit mounting screw.
NOTE
Tighten screw by pushing to the maximum extent with
a hand when installing control unit.
Control unit mounting screw: 0.3~0.4 kgf.m
SPYBR7096L
6. Install gear wheel assembly.
SPYBR7099L
SPYBR7097L
BR -56 BRAKE SYSTEM
DISC BRAKE INSPECTION POINTS
Despite the use of long-life materials, it is necessary to

OPERATION E56D3745 check some of the components regularly for their general
condition. The following points ensure a long-life and trou-
BRAKE ACTUATION ble-free operation of the disc brake. The inspection fre-
quencies specified are minimum values.
During actuation, the Push Rod of the Actuator (18/1 or
Depending on the vehicle application a more frequent
18/2) moves the Lever (19). The input forces are trans-
check of the components may be necessary. The brake
ferred via the Eccentric Bearing (20) to the Bridge (17).
pad wear must be checked visually on a regular basis,
The force is then distributed by the Bridge (17) and the two
e.g. each time the tire pressures are checked, or at least
Threaded Tubes (16) to the Tappet and Boot Assemblies
every year. At least annually inspect the pad to disc
(13) and finally to the inboard Pad (12). After overcoming
running clearance and the correct fitting and condition
the running clearance between the Pads and the Disc, the
of the Cover (10), the Cap (68a), the Cover (68c) and
reaction forces are transmitted to the outboard Pad (12).
the Adjuster Cap (37). With each Pad change check for
The clamping forces on the Pads (12) and the Disc (46)
the correct functioning of the Adjuster and the smooth
generate the braking force for the wheel.
operation of the caliper over its full range of movement.
BRAKE RELEASE Also inspect the Tappet and Boot Assemblies (13), the
Adjuster Cap (37) and the sealing elements (6a, 9, 10,
After releasing the air pressure, the Return Spring (27) 58, 68a or 68c) for correct fitting and condition.
pushes the Bridge (17) and Lever (19) back to the start
position; this ensures a running clearance between Pads DISC BRAKE IDENTIFICATION AND SERVICE KITS
and Disc is maintained.
BRAKE ADJUSTMENT
To ensure a constant running clearance between Disc and KNORR-BREMSE

Pads, the brake is equipped with a low wearing, automatic
adjuster mechanism. The Adjuster (23) operates with ev-
ery cycle of actuation due to the mechanical connection
with Lever (19). As the Pads and Disc wear, the run-
ning clearance increases. The Adjuster (23) and Turning
Device (24) turn the Threaded Tubes (16) by an amount Type of caliper
necessary to compensate for this wear. The total running KNORR-BREMSE Part No.
clearance (sum of clearance both sides of Disc) should be Axle / Vehicle manufacturer's No.
Date of manufacture
between 0.6 and 1.1 mm; smaller clearances may lead to
overheating problems.
SPYBR7100L
The following Service Kits are available.

Description Contents
Carrier 2
4a*, 5, 6a*, 6b*, 7, 9, 10, 39a*,
Guide Pins and
40, 58, 4b*, 4c*, 6b*, 6c*, 39b*,
Seals Kit
39c*, 68*, 68c*
Tappet and Boot
13, 22, 161
Kit (2 pieces)
Adjuster Cap 37(10pcs), 61(10pcs)
Pad Kit (per axle) 11, 12, 26, 37, 44, 45, 61
Air Disc Brake without Brake
Caliper Carrier (2) and Caliper without
Brake Pads (12).

TESTS EFBC7AEC
Please also refer to the relevant safety instructions for re-

pair work and service work on commercial vehicles, espe-
cially for jacking up and securing the vehicle.
Use only original Knorr-Bremse parts.
CAUTION
service brake and parking brake, as well as the
bus stop temporary hold brake, if fitted, are not
applied and that the vehicle cannot roll away.
Please follow repair manual instructions and adhere to the

wear limits of the Pads and the Discs. Use only recom-
mended tools.
CAUTION
Screw threads and tapped holes must be clean
and dry (free of lubrication and residuals of pre-
applied adhesive).
After re-fitting a wheel, please ensure that there is suffi-

cient clearance between the tire inflation valve, the caliper
and the wheel rim, to avoid damage to the valve.
CAUTION
After every service work:
Check the brake performance and the system be-
havior on a rolling road.
Check function and effectiveness.
BR -58 BRAKE SYSTEM
SPECIAL TOOLS E58D57F8
T05
Video
T13
T15
T08 T09
T07
T22
T25
T01
T06
T18 T24
T17 T14
T12
T02
Washer T04 T19 T21 T10 T20 T11 T16
SPYBR7101L
Consisting of tool
Part number Description
components.
Z004190 /(B) Press-in Tool for Tappet and Boot Assembly (13) T1, T2, T3, T4
Z004357 / (C) Pull-in Tool for Inner Boot (9) T7, T8, T10
Z004354 / (D) Pull-in/Pull-out Tool including Grooving Tool for Brass Bush (7) T8, T12, T13, T14
Ⅱ32202 / (A) Wedged Fork for removal of Tappet and Boot Assembly (13) T15
Z004197 / (H) Press-in Tool for Cover (10) T2, T17
K004515 / (M) Press-in Tool for Cover (68c) T2, T25
T5, T6, T18, T19, T20,
Z004198 / (R) Pull-in/Pull-out Tool for Rubber Bush (6a and 6b)
T21, T22
K005986 / (N) Pull-in/Pull-out Tool for Guide Sleeve (6c) T5, T6, T8, T14, T20, T21
Z003934 / (K) Press-in Tool for Cap (68) T11
Z004361 / (L) Press-in Tool for Inner Seal (22) T3, T4, T9
K004082 / (P) Ring for Tappet and Boot Assembly (13) T24
COMPONENTS LOCATION E41DAD87
34.3~40.2
[ Front disc brake ] (3.5~4.1, 25.5~29.8)
4
2
156.8~176.4
(16~18, 116.3~130.9)
3
1
1~1.1
(0.1~0.11, 0.7~0.8)
509.6~588
(52~60, 378~436.2)
509.6~588
(52~60, 378~436.2)
[ Rear disc brake ] 27.4~53.9

(2.8~5.5, 20.4~40) 6 343~441
(35~45, 254.5~327.2)
7 1. Caliper(Front)
2. Brake chamber
3. Lining wear sensor
4. Wheel speed sensor
5. Caliper(Rear)
6. Brake chamber
7. Rear axle
SPYBR7102L
BR -60 BRAKE SYSTEM
COMPONENTS E85E3993
Grease
Grease
Adhesive
1. Caliper
2. Carrier
3. Guide pin 18/2. Brake chamber
4. Guide pin 22. Inner seal
5. Guide pin 26. Spring clip
6a*). Rubber bush 37. Adjuster cap
6b*). Rubber bush 39a*) Caliper bolt
6c*). Guide sleeve 39b*) Caliper bolt
7. Brass bush 39c*) Caliper bolt
9. Inner boot 40. Caliper bolt
10. Cover 44. Pad retainer pin
11. Pad retainer 45. Washer
12. Pad(Complete) 58. Ring
12/1. Pad 61. Shear adapter
12/2. Pad holder spring 68a*) Cap
13. Tappet and boot assembly 68c*) Cover
18/1. Spring brake 161. Tappet bush
* Option
SPYBR7103L
REMOVAL E9AD64FC INSTALLATION EC59BC0D
FRONT DISC BRAKE FRONT DISC BRAKE
1. Park the vehicle on the flat place. 1. Assemble the hub drum assembly.
2. Remove the tire. 2. Assemble the brake chamber.
3. Remove the mounting bracket that is fixing wheel
3. Assemble the caliper to the spindle.
speed sensor wiring , and remove the lining wear
indicator.
4. Clear a foreign substance(dust ,grease etc.) on the
4. Remove the air hose and connector. disc brake surface.
5. Remove the disc brake assembly after removing the 5. Adjust the pad clearance(0.7~0.8 mm) using the ad-
brake chamber(A). justing screw.
6. Assemble the disc wear sensor and wheel speed sen-

A sor.
7. Check the breathing hole to the ground base on the

vehicle.
8. Assemble the air hose.
REAR DISC BRAKE
1. Assemble the wheel speed sensor to the disc brake

adapter.
2. Assemble the disc brake adapter after passing

a wheel speed sensor wire(A) through the brake
SPYBR7104L mounting flange Ø25 hole.
REAR DISC BRAKE
1. Park the vehicle on the flat place.
2. Remove the tire.
3. Remove the air hose and connector.
SPYBR7106L
3. Assemble the hub and disc brake to the axle.
SPYBR7105L 4. Install the caliper to the disc brake adapter.

4. Remove the brake chamber. 5. Assemble the chamber.
5. Remove the caliper from the disc brake adapter.
6. Clear a foreign substance(dust ,grease etc.) on the
disc brake surface.
7. Adjust the pad clearance(0.7~0.8 mm) using the ad-

justing screw.
8. Assemble the air hose.

BR -62 BRAKE SYSTEM
REPLACEMENT EEC3E5DD 5. Fully wind back the Tappet and Boot Assemblies (13)
by rotating the Shear Adapter (61) in an anti-clockwise
REMOVAL OF PAD direction.
1. Remove wheel.
CAUTION
NOTE Never turn Adjuster (23) without Shear Adapter
(61) being fitted. If the shear torque of the Shear
Before removing Pads it is strongly recommended
Adapter is exceeded, then it is designed to fail.
that the Adjuster mechanism is checked for correct
Try again with a new (unused) Shear Adapter.
operation.
With a second failure of the Shear Adapter the
2. Remove Clip (26) and Washer (45), depress the Pad Caliper must be exchanged since internal damage
Retainer (11) and remove Pin (44). is present. Do not use an open-ended spanner as
If necessary remove any in-pad wear sensor compo- this may damage the Adapter.
nents and discard.
3. When replacing the pad, replace the pad with re- oar
d
Inb
tainer(11), pad spring(12/2), pad retainer pin(44),
washer(45), spring clip(26). ard
tbo
Ou
12/2 SPYBR7108L
SPYBR7107L
4. Pull off the Adjuster Cap (37) using the tab, taking
care not to lose the Shear Adapter (61).
INSTALLATION OF PAD 5. After fitting the Pad Retainer (11) into the groove of
the Caliper (1), it must be depressed to enable the
CAUTION insertion of the Pad Retainer Pin (44).
- Never turn Adjuster (23) without Shear 6. Fit washer (45) and Spring Clip (26) to the Pad Re-
Adapter (61) being fitted. If the shear torque tainer Pin (44) (use only new parts).
of the Shear Adapter is exceeded, then it is
designed to fail. Try again with a new (un- 7. It is recommended that Pad Retainer Pin (44) is in-
used) Shear Adapter. With a second failure stalled pointing downwards.
of the Shear Adapter the Caliper must be
exchanged since internal damage is present.
Do not use an open-ended spanner as this
may damage the Adapter.
- Pads must be changed as an axle set and not
individually.
1. Clean the Pad abutments.
d
oar
Inb
ard
tbo
Ou
SPYBR7110L
8. Re-fit wheel.
NOTE
The Adjuster Cap (37) must then be replaced(use only
a new Cap) having lightly greased it with white grease.
SPYBR7109L
2. Turn the Shear Adapter (61) clockwise until the Pads

come into contact with the Disc.
3. Then turn back the Adjuster 2 clicks.
4. The hub should turn easily by hand after having ap-

plied and released the brake. SPYBR7111L
BR -64 BRAKE SYSTEM
TAPPET AND BOOT ASSEMBLIES (13) AND INNER TAPPET AND BOOT ASSEMBLIES (13) - REMOVAL
SEALS (22)
TOOL NOTE
It may be easier to remove the Caliper from the axle
1. To remove the Tappet and Boot Assembly (13) use to replace the Tappet and Boot Assemblies (13).
the Wedge Fork (A).
1. The Shear Adapter (61) must be screwed clockwise
2. To fit the Tappet and Boot Assembly (13) use the until the Boots can be reached (max. 30 mm).
Press-in Tool (B) (Part No. Z004190).
2. To remove the Tappet Boot from the Caliper bore, a
Screwdriver (B) should be used to deform the Boot
location ring.
Wedge Fork (A) Press-in Tool (B)
SPYBR7112L
3. To fit the Inner Seal (22), use the Press-in Tool (L)
(Part No. Z004361). SPYBR7114L
NOTE
The inner sealing face (see arrow X in adjacent
sketch) must not be damaged. It cannot be replaced.
Press-in Tool (L)
SPYBR7113L
SPYBR7115L
3. The Tappet and Boot Assemblies (13) can be re-

moved from the Threaded Tubes (16) by using Wedge
Fork (A).
4. Remove the old Tappet Bush (161). INNER SEALS (22) - REPLACEMENT
5. Check inner sealing face (see arrow X). 1. Fully wind back the Threaded Tubes (16) by turning
the Shear Adapter (61) anti-clockwise.
6. When replacing Tappet and Boot Assemblies (13), the
Inner Seals (22) must also be replaced. 2. Clean area of the Inner Seal (22).
THREADED TUBES (16) - INSPECTION 3. To remove the Inner Seal (22) a Screwdriver (A)
should be used.
1. Place an unworn Pad (12) into the outboard gap to
avoid loss of thread engagement of the Threaded
Tubes.
2. For the inspection of the threads, the tubes must

be screwed out (max. 30mm) by turning the Shear
Adapter (61) clockwise.
SPYBR7118L
CAUTION
The sealing face (X) for the Inner Seal (22), as well
as the Threaded Tubes (16) must not be damaged.
They cannot be replaced.
SPYBR7116L
4. Clean sealing face (X).
3. If Caliper is not installed on axle, put a spacer E(length
= 70mm) into the Caliper (1) to avoid loss of thread en- 5. Fit each Inner Seal (22) onto a Threaded Tube (16).
gagement of the Threaded Tubes (16) when screwing
them out. Check the threads for corrosion damage.
4. In case of water ingress or corrosion, the Caliper must

be replaced.
SPYBR7117L
BR -66 BRAKE SYSTEM
6. With Caliper installed on axle : TAPPET AND BOOT ASSEMBLIES (13) - FITTING
WITH CALIPER INSTALLED ON AXLE

1) Remove the Tappet Bush (161).
1. Grease threads with white grease.
2) Position Tool (L) (Part No. Z004361) with the
short strut in the position shown. 2. Screw back Threaded Tubes (16), by turning the
Shear Adapter (61) anti-clockwise.
3. The sealing seat in the caliper for Tappet and Boot

Assemblies (13) must be clean and free of grease.
4. Fit a new Tappet Bush (161) onto the spigot of each

Threaded Tube (16).
5. Position a Tappet and Boot Assembly (13) onto each

Tappet Bush.
6. Use Push-in Tool (B) (Part No. Z004190) with the

short strut (T3) for positioning and pressing in the
Boot.
SPYBR7119L
3) The Tool (L) is guided over the spigot of the

Threaded Tube (16).
4) Fully press in the Inner Seal (22) by rotating Tool

T3 using a spanner.
To check the correct fit of the Inner Seal (22),
screw out the Threaded Tubes (16) about 4-5
threads by turning the Shear Adapter (61) clock-
wise. The Inner Seal (22) must not turn.
7. With Caliper not installed on axle : SPYBR7121L
1) The fitting sequence of Inner Seal (22) does not 7. Using Tool (B) (Part No. Z004190) in reverse, with the
change. short strut (T3), each Tappet can be pressed onto its
Tappet Bush.
2) When pressing in the Inner Seal (22) however,
use the long strut (T3+T4) for Tool (L) (Part No.
Z004361).
SPYBR7122L
SPYBR7120L
8. After assembly the Tappet (13) must be free to turn in CALIPER REPLACEMENT
both directions.
TOOL
WITH CALIPER NOT INSTALLED ON AXLE
1. To fit the Cover (10) use Press-in Tool (H) (Part
1. Grease threads with white grease. No.Z004197).
2. Screw back Threaded Tubes (16), by turning the 2. To fit the Cap (68a), use the Press-in Tool (K) (Part
Shear Adapter (61) anti-clockwise. No. Z003934).
3. The sealing seat in the caliper for Tappet and Boot 3. To fit the Cover (68c), use the Press-in Tool (M) (Part
Assemblies (13) must be clean and free of grease. No. K004515).
4. Fit a new Tappet Bush (161) onto the spigot of each

Threaded Tube (16).
5. Position a Tappet and Boot Assembly (13) onto each

Tappet Bush.
6. Use Push-in Tool (B) (Part No. Z004190) with the long
strut (T3+T4) for positioning and pressing in the Boot.
Press-in Tool (K) Press-in Tool (H) Press-in Tool (M)
SPYBR7125L
CALIPER REMOVAL
1. Remove Pads.
2. Remove Actuator.
SPYBR7123L
7. Using Tool (B) (Part No. Z004190) in reverse, with the

long strut (T3+T4), each Tappet can be pressed onto
its Tappet Bush.
SPYBR7124L
8. After assembly the Tappet (13) must be free to turn in

both directions.
BR -68 BRAKE SYSTEM
REMOVAL OF THE COVER (10) REMOVAL OF THE COVER (68C)
1. Use a suitable Tool (e.g a Screwdriver) to penetrate 1. Because of the protruding Cover (68c) it must be dis-
the Cover (10). During penetration, the Cover may assembled. Use a screw driver or another suitable
move approximately 10 mm inwards. tool.
2. Do not disassemble the Cover (68c) in direction of

the Caliper since itself or components of it might be
damaged.
SPYBR7127L
REMOVAL OF CAP (68A)
1. On Calipers with Rubber Bush (6a), pull the Cap (68a)

from the Guide Pin (4) using a suitable tool.
SPYBR7126L
2. Remove Cover (10).
CAUTION
Cover (10) should be penetrated in the middle. Do
not drive the tool between Caliper bore and Cover
(10) since Caliper bore may be damaged.
SPYBR7128L
NOTE
Take care not to damage Rubber Bush (6a). If neces-
sary replace it by means of a Guide Pins and Seals
Kit.
REMOVE CALIPER FROM CARRIER 1. Fit the Caliper to the Carrier.
NOTE
Before removing the Caliper Bolts (39 and 40) en-
sure that the Caliper (1) cannot move or fall when the
Caliper Bolts are removed causing damage or injury.
1. Remove Caliper Bolts (39) and (40) and discard. They

must not be re-used.
CAUTION
Never hold the Caliper with your fingers between
Caliper and Carrier - there is a risk of injury! Do
not fasten any lifting device to the Pad Retainer
Option
(11), since this could be damaged.
SPYBR7130L
2. Screw in new Caliper Bolts (39) and (40) and tighten

to 180 Nm, then tighten by a further 90 .
Specified tightening torque : 180 N.m + 90
3. Check that the Caliper slides easily on the Guide Pins.
4. Check the position of the Inner Boot (9) on the Guide

Pin (5). According to the Caliper variant check also
the position on the Guide Pin (4) as well as the posi-
tion of Ring (58).
SPYBR7129L
2. Remove Caliper from Carrier.
CALIPER FITTING (CARRIER IS FITTED ON THE

AXLE)
NOTE
1. The correct choice of Caliper must be ensured
by checking the part number on the identification
label.
2. The replacement Caliper may have a plastic cap
or adhesive tape in the area of the actuator at-
tachment. Remove the cap or tape after installing SPYBR7131L
the caliper on the vehicle.
3. Alternatively,if the replacement Caliper has a 5. Fit Pads.
breakthrough diaphragm, it should be left in
place. 6. Check Adjuster function.
7. Attach Brake Chamber or Spring Brake.

BR -70 BRAKE SYSTEM
FITTING OF COVER (10) FITTING OF CAP (68A)
1. Caliper bore and Cover (10) must be clean and free 1. Fit the Cap (68a) using Tool (K) (Part No. Z003934)
of lubrication. and a hammer. Force the Cap (68a) into the Guide
Pin (4) until it contacts the Caliper Bolt. The seal is
2. Press in the Cover (10) using the Press-in Tool (H) achieved by the compression of the lip of the Rub-
(Part-No. Z004197) and a hammer. ber Bush (6a) between the Guide Pin (4) and Cap
(68a)(see view "Y").
3. Move the Caliper against the Carrier and hold so that
the Inner Boot (9) is in a compressed condition to
prevent air being trapped when Cover (10) is fitted.
SPYBR7134L
IF THE CALIPER AND CARRIER ASSEMBLY IS NOT

SPYBR7132L FITTED TO THE VEHICLE
FITTING OF COVER (68C) 1. Move the Caliper against the Carrier and hold using a
suitable clamping device so that the Inner Boot (9) is in
1. Caliper bore and Cover (68c) must be clean and free
a compressed condition to prevent air being trapped
of lubrication.
when Cover (10) or Cover (68c) and Cap (68a) is fit-
ted.
2. Press in the Cover (68c) using the Press-in Tool (M)
(Part-No. K004515) and a hammer.
2. Fit new Cover (10), Cover (68c) or Cap (68a) as de-
3. Move the Caliper against the Carrier and hold so that scribed above.
the Inner Boot (9) is in a compressed condition to
prevent air being trapped when Cover (68c) is fitted. Clamping device
Direction of pressure
SPYBR7135L
SPYBR7133L
3. Fit the Pads, if not already fitted.
4. Check Adjuster function.
5. Attach Brake Chamber or Spring Brake.

REPLACEMENT OF INNER BOOT (9)
TOOL
1. To fit the Inner Boot (9) use the Pull-in Tool (C) (Part
No. Z004357).
Washer
SPYBR7138L
6. Check Brass Bush (7) and if is installed Guide Sleeve

(6c) for dirt and replace if damaged.
Pull-in Tool (C) 7. Fit new Boot (9) into the Sleeve of the Tool (C) (Part
No. Z004357). See arrow B.
SPYBR7136L
8. Pay attention that the bellow-folds of Inner Boot (9)

REPLACEMENT
are positioned within the tool.
1. Remove Caliper.
9. Position Sleeve with Inner Boot (9) into the Caliper
2. Pull out Guide Pin (5). bore and pull in by hand.
3. Push out Inner Boot (9) with screwdriver. Then pull in with a maximum torque of 8 Nm.
NOTE 10. Grease Brass Bush (7) and if installed Guide Sleeve
The sealing face of Inner Boot (9) in the Caliper must (6c) with white grease.
not be damaged
11. Insert Guide Pin (5) and also Guide Pin (4c) if Guide
Sleeve (6c) is installed.
12. The lip in the end of the Inner Boot must engage in
the groove of the Guide Pin (5).
13. Pushing on the Ring (58) ensures that the Boot (9) is
engaged in the groove of the Guide Pins (5).
Option
SPYBR7137L
4. Inspect and clean contact area of Inner Boot (9).
5. Check for corrosion.(See arrow A.)
SPYBR7139L
14. Fit Caliper.

BR -72 BRAKE SYSTEM
REPLACEMENT OF GUIDE PIN BUSHES 4. Pull out Brass Bush (7) by means of a spanner or
socket.
In order to remove, fit and groove the Brass Bush (7)
use the Pull-out/Pull-in and Grooving Tool (D) (Part No. 5. Fully wind Brass Nut (T14) on to Spindle (T13).
Z004354).
6. Place new Brass Bush (7) on the Groover (T16) and
insert into caliper bore.(Sketch 1a.)
Washer
7. Screw Spindle (T13) by hand up to stop.
8. Pull in Brass Bush (7) using Brass Nut (T14) up to

stop.(Sketch 1b)
Sketch 1
Pull-in/Pull-out tool including grooving tool(D)

SPYBR7140L
1. Remove Caliper.
BRASS BUSH (7) REPLACEMENT
1. Remove Guide Pin (5) and Inner Boot (9).
2. Clean surface (X), surface (Y) and Brass Bush (7).

SPYBR7142L
3. Position Tool arrangement for pulling out of Brass

Bush (7). 9. To prevent longitudinal displacement of Brass Bush
(7) it must be grooved.(Sketch 1c)
10. To do so the Groover (T16) must be screwed in up to

stop.
Brush bush(7)
removed
11. Wind back the Groover (T16) approximately 20 mm.
12. Slacken the Brass Nut (T14) and rotate the Groover
(T16) through approximately 60 .
Brush bush(7)
installed 13. Repeat the process of grooving.
14. The new Brass Bush (7) is now grooved with the
Caliper.
15. Before removing the Tool (D), the hexagon screw of

SPYBR7141L
the Groover (T16) should be wound out approximately
20 mm.
NOTE
Ensure that Nut (T14) is located in Brass Bush (7) and 16. Check contact area of Brass Bush (7) and remove any
the end of Tube (12) is firmly located. burrs. Grease Bush (7) with white Grease.
RUBBER BUSH (6A OR 6B) AND GUIDE SLEEVE REMOVAL OF RUBBER BUSH (6A OR 6B)
(6C) - REPLACEMENT
1. Remove Guide Pin (4a or 4b).
1. Use Tool (R) (Part No. Z004198) for the assembly of
the Rubber Bush (6a or 6b). 2. Clean Caliper in the area of the Rubber Bush.Select
Disc T6 Ø39.
Washer 3. Position the Tool (R) (Part No. Z004198) as shown in

the adjacent picture. Screw on the Nut (T22) by hand.
Threaded pin
Disc
Pull-in/Pull-out tool(R)
SPYBR7143L
2. Use Tool (N) (Part No. K005986) for the assembly of

the Guide Sleeve (6c).
SPYBR7145L
Washer
4. Hold the Nut (T22) with a ring spanner and with a
suitable socket or ring spanner tighten Spindle (T20)
to remove the Rubber Bush.
Pull-in/Pull-out tool(R)
SPYBR7144L
SPYBR7146L
BR -74 BRAKE SYSTEM
REMOVAL OF GUIDE SLEEVE (6C) FITTING OF RUBBER BUSH (6A OR 6B)
1. Remove Guide Pin (4c). 1. Check bore for corrosion and clean.
2. In order to separate the tab from the Guide Sleeve 2. Unscrew Threaded Pin in the Tool (R), so that there
(6c) use a screwdriver or similar tool whose width is is no projection at the contact surface .
smaller than the tab.
Place the screwdriver as close as possible to the base 3. Push Rubber Bush (6a or 6b) into the Tool (R).
of the tab. Then separate the tab from the Guide
Sleeve (6c) by means of a screwdriver and a hammer.
Rubber bush(6a,6b)
Contact surface
Threaded pin
SPYBR7149L
SPYBR7147L 4. Position Tool (R) with Rubber Bush (6a or 6b).
3. Clean Caliper in the area of the Guide Sleeve (6c) and 5. Lightly screw on the Nut (T22) by hand.
the Pad abutment.
6. Screw in Threaded Pin until it contacts the Caliper
4. Position Tool (N) as shown in adjacent Sketch.Screw in order to adjust possible unevenness at the contact
on the Nut (T14) by hand. surface.
NOTE
Do not tilt the Rubber Bush (6a or 6b) when pulling-in.
7. Using Torque Wrench pull in Rubber Bush (6a or 6b)

until its stop.
Specified tightening torque : 8 ~ 45 Nm
8. Remove the Tool.
SPYBR7148L
5. Hold the Nut (T14) with a ring spanner and with a

suitable socket or ring spanner tighten Spindle (T20)
to remove the Guide Sleeve (6c).
SPYBR7150L
9. Grease the interior of the Rubber Bush (6a or 6b) with 3. Slightly press in the Guide Sleeve (6c) by means of
white Grease. the Nut (T14) and a hammer. The Guide Sleeve (6c)
is now adjusted.
10. Fit Guide Pins (4a or 4b) via the Pad abutment in the
Rubber Bush (6a or 6b).
SPYBR7153L
SPYBR7151L 4. Insert Tool (N) and position.
FITTING OF GUIDE SLEEVE (6C) 5. Pull on Spindle (T20) slightly by hand.
1. Check bore for corrosion and clean. 6. Hold Nut (T14) by means of an ring spanner and with
a suitable socket or an other suitable tool tighten Spin-
2. Position the Guide Sleeve (6c). dle (T20) up to stop.
Washer
SPYBR7152L
SPYBR7221L
CAUTION
Before pressing in Guide Sleeve (6c) the tab
must be in correct position. The tab must snap
in Caliper groove when Guide Sleeve (6c) is
reaching its end position.
NOTE
Caliper groove can be on left side or right side of the
caliper bore.
BR -76 BRAKE SYSTEM
7. Remove Tool (N). CARRIER REPLACEMENT
8. In order to press in the tab use a screwdriver or similar 1. If necessary remove Caliper.
tool whose width is smaller than the tab. Place the
screwdriver as close as possible to the top of the tab. 2. Remove Carrier (2) from axle.
Then press in the tab by means of the screwdriver and
a hammer.
NOTE
Do not fasten any lifting device to the Pad Re-
tainer(11), since this can be damaged.
3. Clean axle contact area.
SGVBR7959D
9. The Guide Sleeve (6c) is now secured against rotating

and axial movement.
10. Grease the interior of the Guide Sleeve (6) with white
SGVBR7960D
Grease.
11. Fit Guide Pin (4c). 4. Fit new Carrier (2) with new bolts.
5. It may be necessary, to firstly attach the Caliper.
BRAKE ACTUATOR REPLACEMENT
BRAKE CHAMBER REMOVAL
1. Disconnect air hose from Brake Chamber (18/2).
2. Unscrew Brake Chamber Mounting Nuts (see arrow

B).They must not be re-used.
SGVBR7961D
3. Remove Brake Chamber (18/2).

BRAKE CHAMBER FITTING 5. Attach Brake Chamber using new Nuts.
NOTE 6. In order not to tilt the Brake Chamber, screw Nuts

step by step alternately with a suitable tool and torque
New Brake Chambers (18/2) have drain plugs in- tighten to 180 ~210 Nm.
stalled (see arrows A). Remove lowest plug (as
viewed when Brake Chamber is installed). All other 7. Connect air hose and check for leakage.
drain holes should be plugged.
8. Make sure that hose is not twisted and that chafing is
1. Before fitting the new Brake Chamber, the sealing sur- not possible.
face (see arrow C) must be cleaned, and the Spheri-
cal Cup (19) in the Lever must be greased with white SPRING BRAKE REMOVAL
Grease.
CAUTION
2. The surface area of the flange must be damage free
and clean. Chock wheels before releasing Spring Brake.
1. Release parking brake, move Hand Control Valve to

’run’ position.
2. Screw-out Release Bolt (arrow D) with a maximum

torque of 35 Nm.
SGVBR7962D
3. The Seal, as well as the Push Rod area must be clean

and dry.
4. If the thickness of the Seal is less than 3 mm the Brake

Chamber must be replaced. SGVBR7964D
3. Release air from brake, move Hand Control Valve

Seal lever to ‘ park’ position.
Push rod 4. Disconnect air hoses from Spring Brake (18/1) (air
hoses must be free of air pressure).
5. Unscrew Spring Brake Mounting Nuts (see arrow B).

They must not be re-used.
6. Remove Spring Brake (18/1).
SPYBR7222L
BR -78 BRAKE SYSTEM
SPRING BRAKE FITTING 5. Attach Spring Brake using new Nuts.
NOTE 6. In order not to tilt the Spring Brake, screw Nuts step by
step alternately with a suitable tool and torque tighten
New Spring Brakes (18/2) have drain plugs installed to 180~210 Nm.
(see arrows A). Remove lowest plug (as viewed when
Spring Brake is installed). All other drain holes should 7. Connect air hoses, ensuring that they are replaced in
be plugged. the correct ports.
1. Before fitting the new Spring Brake, the sealing sur- 8. Make sure that hoses are not twisted and that chafing
face (see arrow C) must be cleaned, and the Spheri- is not possible.
cal Cup (19) in the Lever must be greased with white
Grease.
SGVBR7965D
2. The surface area of the flange must be damage free

and clean.
3. The Seal, as well as the Push Rod area must be clean

and dry.
4. If the thickness of the Seal is less than 3 mm the

Spring Brake must be replaced.
Push rod
Seal
SPYBR7154L
INSPECTION E06D1B32 F = Minimum allowed thickness in worn condition

for backplate and friction material.
PAD F = 11 mm.
If these minimum allowed thicknesses are reached re-
The thickness of the Pads must be checked regularly de- placement of Pads is necessary.
pendent on the usage of the vehicle. The Pads should
be checked corresponding to any legal requirements that If the disc dimension A ≤ 39 mm, it is recommended that
may apply. If a Wear Indicator has not been fitted or is not the Disc should be renewed together with the Pads.If the
connected, this should be at least every year.If friction ma- disc thickness is less than 37 mm, the disc must be re-
terial is less than 2mm,the Pads must be replaced.Minor placed.Check Disc at each change of Pads for grooves and
damage at the edges is permitted (see arrow,Sketch 1). cracks.The diagram shows possible surface conditions.
Major damage on the surface of the Pad is not permitted
(see arrow, Sketch 2).
A1 B1
max. 0.75 a
max. 1.5mm
D1 C1
A
Sketch 1
SGVBR7322D
Sketch 2
SPYBR7155L
A1 = Small cracks spread over the surface are allowed

DISC
B1 = Cracks less than 1.5mm deep or wide, running in a
Measure thickness at thinnest point. Avoid measuring Radial direction are allowed
near the edge of the disc as a burr may be present. C1 = Grooves (circumferential) less than 1.5mm deep are
allowed
D1 = Cracks going through until the cooling duct or until
the inner or outer boarder are not allowed. The Disc must
be replaced.
a = Pad contact area
NOTE
In case of surface conditions A1, B1 and C1, the Disc
can continue to be used until the minimum thickness
of 37mm is reached.
Knorr-Bremse Discs are normally service-free and grind-

ing when changing Pads is not necessary. However, grind-
ing could be useful, e.g. to increase the load-bearing sur-
face of the Pads after severe grooving on the entire friction
surface has occurred.
To meet safety requirements, the minimum thickness after
regrinding must be greater than 39 mm.
SGVBR7902D
A = Disc thickness
new condition = 45 mm
worn condition = 37 mm (the disc must be replaced)
C = Overall thickness of Pad 30mm (new condition)
D = Backplate - 9 mm
E = Minimum thickness of friction material 2mm
BR -80 BRAKE SYSTEM
BRAKE WEAR CHECK USING RUBBER BUSH (6A)
For all Disc Brakes which are equipped with a Rubber

Bush that is axially ribbed (see H in sketch).
SGVBR7903D
The condition of the Pads can be visually determined with-

out removing the road wheel, by viewing the position of the
Caliper (1) against the fixed Guide Pin (4).
New Condition (see “ X” ) : The position of Wear Indica-
tor ” G” on the Rubber Bush (6a) in new condition.
Wear Limit (see “ Z” ) : When the Rubber Bush (6a) is re-
tracted to the level “ G” of the Wear Indicator as shown,
the wheel must be removed so that the wear of the Pads
and Disc can be checked.
If necessary change the Pads and/or the Disc.
BRAKE WEAR CHECK USING CARRIER TO

CALIPER POSITION (6C)
For all Disc Brakes which are equipped with a Caliper to

Carrier marking.
SGVBR7324D
The condition of the Pads can be visually determined with-

out removing the road wheel by viewing the position of the
Caliper position (P) against the Carrier marking (R).
If the condition “ D” is reached the wheel must be
removed so that the wear of the Pads and Disc can be
checked.
If necessary change the Pads and/or the Disc.
C = shown in new condition

D = Pads and Disc must be checked with road wheel re-
moved.
BR -82 BRAKE SYSTEM
ADJUSTER CHECK 3. If the running clearance is too small or too large, the
adjuster may not be functioning correctly and should
CAUTION be checked as follows.
a. Pull off the Adjuster Cap (37) using the tag, taking
Before starting service work, ensure the service care not to lose the Shear Adapter (61).
brake and parking brake are not applied and that b. The Adjuster (23) must be turned with the Shear
the vehicle cannot roll away. Adapter (61) anti-clockwise for 2 or 3 clicks (in-
creasing running clearance).
1. Remove wheel.
2. The caliper assembly should be pushed inboard on its

Guide Pins. Using a suitable tool, press the inboard
pad (12) away from the Tappets and check the gap
between Tappet and inboard pad backplate
it should be between 0.6mm & 1.1mm.
NOTE
If the clearance is too wide, there is a danger of brake
failure.
If the clearance is too small, there is a danger of over-
heating. That may lead to consequential damage.
SGVBR7905D
CAUTION
Never turn Adjuster (23) without Shear Adapter
(61) being fitted. If the shear torque of the Shear
Adapter is exceeded, then it is designed to fail.
Try again with a new (unused) Shear Adapter.
With a second failure of the Shear Adapter the
Caliper must be exchanged since internal dam-
age is present.
Do not use an open-ended spanner as this may
damage the Adapter.
c. By applying the brake (about 2 Bar) 5~10 times

SGVBR7904D the Spanner or Socket should turn clockwise in
small increments if the Adjuster is functioning
correctly.
SGVBR7906D
CALIPER CHECKS
CAUTION
Never turn Adjuster (23) without Shear Adapter CAUTION
(61) being fitted.
Before starting service work, ensure the service
brake and parking brake are not applied and that
NOTE
the vehicle cannot roll away.
- As the number of applications increases, incre-
mental movement will decrease. 1. Caliper Running Clearance
- If the Spanner or Socket does not turn or turns By pushing and pulling the Caliper in an axial direction
only with the first application or turns forward and by hand, a movement of 0.6~1.1 mm must be possi-
backward with every application, the automatic ble. If, using hand pressure only (no tools), the Caliper
Adjuster has failed and the Caliper must be re- is not moveable, the Caliper guidance must be further
placed. examined.
- Even if Pads are not being changed, a new
Adjuster Cap (37) should be fitted having lightly 2. Caliper Movement along Guide Pins
greased it with white grease. a. Remove Pads.
- The tag of the Adjuster Cap (37) should be po- b. Clean dirt from Guide Pin.
sitioned as shown by the arrow in the adjacent c. Using hand pressure only (no tools), the Caliper
diagram. This ensures access is maintained for (1) must slide freely along the whole length of the
subsequent removal. Removal of the Adjuster Guide Pin arrangement. This should be greater
Cap with a screwdriver, for example, is not rec- than 25mm.
ommended since the seal may be damaged.
3. Rubber Bush or Guide Sleeve to Guide Pin clearance
NOTE
Before removing the wheel, note that there is no con-
tact between Caliper and axle, vehicle, chassis sec-
tions or Carrier. If necessary the Rubber Bush or
Guide Sleeve must be replaced.
a. Remove the wheel.

b. Remove Pad Retainer, but leave the Pads (12)
in the abutment. Fasten a magnetic dial-gauge
holder to the Carrier (2) on the short bearing side
of the Caliper (1).
c. Use the measuring point on the Caliper (1).
d. Press Caliper (1) in the direction of Carrier (2)
SGVBR7907D and set the dial-gauge to zero.
e. Place a suitable tool (e.g. Screwdriver) between
Carrier (2) and Caliper (1) forcing them in oppo-
site directions. Read the maximum value on the
dial-gauge.
SGVBR7908D
BR -84 BRAKE SYSTEM
f. If the short bearing side is open or closed by Cap 5. Checking of Tappet and Boot Assemblies (13)
and the distance is greater than 2.0 mm the Rub- a. If necessary remove Pads and screw the Shear
ber Bush must be replaced using a suitable kit. Adapter clockwise until the boots are clearly vis-
g. If the short bearing side is closed by Cover and ible.
the distance is greater than 1.0 mm the Guide
Sleeve must be replaced using a suitable kit. NOTE
h. Note that there must be no contact between
The tappet should not extend more than 30 mm.
Caliper and axle, vehicle, chassis sections or
Carrier. If necessary the Rubber Bush or the b. The Tappet and Boot Assemblies (13) must not
Guide Sleeve must be replaced using a suitable show any signs of damage.
kit.
i. Fit Pads.
j. Fit the wheel. NOTE
The penetration of dirt and moisture into the brake will
4. Caliper Guide Pin Seals lead to corrosion and impair the function of the Disc
a. The Guide Pin is sealed with Cover and with the Brake.
Inner Boot.
c. Check for correct location and fitment.If neces-
The Guide Pin is also sealed with Inner Boot and sary replace Tappet and Boot Assemblies.
Cover.
The components must not show any signs of damage.
Check for correct location and fitment.
NOTE
It may be necessary to remove the Pads to inspect the
Inner Boots - dependent on the amount of pad wear.
30m
m
SGVBR7909D
ANTI-LOCK BRAKE SYSTEM/ACCELERATION SLIP REGULATION BR -85
ANTI-LOCK BRAKE
SYSTEM/ACCELERATION
SLIP REGULATION
GENERAL EEE3E3D9
0.8
0.6
0.4
0.2
20 40 60 80 100% (Wheel lock)
Wheel slip
Relation between road surface friction coefficient and wheel slip
SPYBR7156L
ABS FUNCTION
Under rapid braking or slippy road condition by rain or

snow, braking a vehicle in running is apt to generate skid
condition.
The skid may decrease braking force to increase braking
distance, generate spin by traverse slipping, and/or dis-
able steering control, resulting to an accident. Therefore
the ABS system is designed to prevent from wheel locking
and slip upon braking for ensuring :
1. Stability
2. Steer ability
3. Optimum braking power and stopping distance.

• Skid : A vehicle may slip to move without wheel
rotation upon braking.
BR -86 BRAKE SYSTEM
SLIP RATE (λ ) ASR (BRAKE CONTROL) FUNCTION
Upon braking a vehicle which is running, slip rate changes When one side wheel is caught at slippery road or muddy
from 0 to 100% until the wheels are locked and the vehicle surface, the slipping wheel idles, that the vehicle is hard
stops completely. The slip rate (λ ) may be indicated as to run and powertrain (differential, axle shaft). In order to
the below : compensate idling for stability, the ASR, feature controls
λ = Vehicle speed － Wheel speed / Vehicle speed to brake the idling wheel properly and transfer the rotating
×100(%) force to the other wheel to enable launching. The ASR fea-
ture is traction control, and an extensive application of the
The slip rate (λ ) and the surface friction coefficient (μ B) ABS system. Only ASR control valves (solenoid valves)
may be correlated as the illustration. The slip rate (λ ) integrated on the ABS system to make the ASR feature.
at the max.μ B differs by the road condition but the max.
range is approx. 8~30%. The cornering force (trans- ASR EFFECT (BRAKE CONTROL)
versely slip preventing force) decreases with increasing
slip rate. Once wheels are locked, surface friction coef- Upon starting or accelerating the vehicle, a wheel may idle
ficient μ B decreases and slip friction coefficient μ S be- on a slippery road surface or so. Then the vehicle may not
comes to ’0’, and then wheels are easy to slip. start or may be unstable to incur accident. When speeds
In fact locked rear wheels generate spinning and locked of both side wheels are different, the ASR system brakes
front wheels disables steer ability. The ABS system con- operate to the faster wheel (idling wheel) to make the both
trols braking force to maintain the slip rate in the range of wheels speed same. The system does not operate at an
8~30%, in order to generate max. surface friction coeffi- above 30km/h.
cient, control slip friction coefficient at higher range, and
provide stability and steer ability.
1. Starting at a surface of which one side is frozen (ex
ABS EFFECT : bus stop) or accelerating or starting at a cornering
range, the system provides optimum drivability.
The ABS system provides stable braking under extreme
condition. Even braking rapidly on frozen or snowy road, 2. Idling wheels as well as locked wheels do not trans-
wheels are not locked and maintain max. friction with the fer driving force, to decrease steer ability and put the
road surface to provide optimum braking distance. Re- rearmost part of the vehicle out of track. The ASR
stricting the pressure in the chamber locked at the wheel system maintains the vehicle under control.
side on the road surface, the system ensures straight for-
ward motion. The driver may acquire correct alignment of 3. The system decreases wear of driving mechanism
the vehicle by adjusting the steering wheel only a little. (differential, axle) and tires.
ABS CONFIGURATION
6
1 3
5
1
3
5
5
3
1
5
4
1 3

2. ABS ECU
3. Pressure control valve (PCV)
4. ABS warning lamp
5. Brake chamber
6. Dual brake valve
SPYBR7157L
ABS/ASR CONFIGURATION
The ABS control unit is designed to accommodate the

ASR feature within modifying the size of pulse ring, wheel
speed sensor, and pressure control valve that are used for
the ABS system, are used for the ASR feature, as well.
The ABS control unit, microelectronics is extended to ac-
commodate the ASR logic. Only the solenoid valve that
sends compressed air to the corresponding cylinder to the
rear axle brake circuit when a wheel is idling, is added.
Two shuttle valves facilitate the service brake system and
the ASR operation. The front axle yaw moment restric-
tion function is built in the ABS/ASR control unit, as well.
Besides the ABS/ASR control unit has "self-diagnosis fea-
ture" or "in-car diagnosis feature". In case of system failure
during driving, the feature will enable sooner repair in the
service shop. Pressing buttons, the diagnostic lamps flash
failure codes to indicate cause of failure.
1. Air compressor 5. Low air pressure switch 14. Quick release valve
2. APU valve assembly 7. Dual brake valve 15. Exhaust brake valve
BR -88
2-1. Air drier 10. Parking brake valve 16. Speed wheel sensor
2-2. 4-circuit protection valve 11. Brake chamber 20. Check valve
3. Air reservoir 12. Spring brake chamber
CIRCUIT DIAGRAM
4. Auto drain valve 13. Solenoid valve

CIRCUIT(NON-ABS)
Hose
Suspension
Door, clutch, air gun,retarder
Brake lamp switch
Stop lamp switch
SPYBR7158L
BRAKE SYSTEM
1. Air compressor 10. Parking brake valve 16. Front package valve assembly
2. APU valve assembly 11. Brake chamber 16-1. ABS Modulator valve
2-1. Air drier 12. Spring brake chamber 16-2. R-12 Relay valve CIRCUIT(ABS)
2-2. 4-circuit protection valve 13. Solenoid valve 17. Exhaust brake valve
3. Air reservoir 14. Quick release valve 18. Speed wheel sensor
4. Auto drain valve 15. Rear package valve assembly 20. Check valve
5. Low air pressure switch 15-1. ABS Modulator valve
7. Dual brake valve 15-2. R-14 Relay valve
Hose
Suspension

ANTI-LOCK BRAKE SYSTEM/ACCELERATION SLIP REGULATION
Brake lamp switch
Stop lamp switch

BR -89
SPYBR7159L
1. Air compressor 10. Parking brake valve 15-3. ASR Solenoid valve
2. APU valve assembly 11. Brake chamber 16. Front package valve assembly BR -90
2-1. Air drier 12. Spring brake chamber 16-1. ABS Modulator valve
2-2. 4-circuit protection valve 13. Solenoid valve 16-2. R-12 Relay valve CIRCUIT(ASR)
3. Air reservoir 14. Quick release valve 17. Exhaust valve
4. Auto drain valve 15. Rear package valve assembly 18. Speed wheel sensor
5. Low air pressure switch 15-1. ABS Modulator valve 20. Check valve
7. Dual brake valve 15-2. R-14 Relay valve
Hose
PARK'G
Suspension
Brake lamp switch
Stop lamp switch
SPYBR7160L
BRAKE SYSTEM
CONNECTOR CONFIGURATIONS EF2472E7
ABS ECU CONNECTOR PIN
ABS ECU connector uses two plugs.
(18 Pins) (18 Pins)
SPYBR7169L
PIN NO PIN NAME Abbreviation PIN NO PIN NAME Abbreviation

X1-1 Ground GND X2-1 Inlet valve (FL) PCV_SL_IV
Output trailer-ABS warning
X1-2 WLT X2-2 Outlet valve (FL) PCV_SL_OV
lamp control (Low active)
Ignition switched voltage Pressure control valve
X1-3 US X2-3 PCV_SL_GND
detection Ground (FL)
X1-4 - - X2-4 Inlet valve (FR) PCV_SR_IV
Wheel speed sensor
X1-5 - - X2-5 WSS_SL+
(FL+)
Pressure control valve
X1-6 - - X2-6 PCV_SR_GND
Ground (FR)
X1-7 CAN BUS Low CAN1939_LO X2-7 Outlet valve (FR) PCV_SR_OV
Wheel speed sensor
X1-8 CAN BUS High CAN1939_HI X2-8 WSS_SL-
(FL-)
X1-9 Stop lamp switch SLS X2-9 PCV_DR_GND
Ground (RR)
X1-10 Wheel speed sensor (RR+) WSS_DR+ X2-10 Inlet valve (RR) PCV_DR_IV
Wheel speed sensor
X1-11 Wheel speed sensor (RR-) WSS_DR- X2-11 WSS_SR+
(FR+)
X1-12 Ground (ABS Warning lamp) WL_GND X2-12 PCV_DL_GND
Ground (RL)
Diagnostic communication
X1-13 DIAK_SAEB X2-13 Outlet valve (RR) PCV_DR_OV
(Low)
Diagnostic communication Wheel speed sensor
X1-14 DIAL_SAEA X2-14 WSS_SR-
(High) (FR-)
Wheel speed sensor
X1-15 - - X2-15 WSS_DL+
(RL+)
X1-16 Supply voltage UB X2-16 Inlet valve (RL) PCV_DL_IV
X1-17 Output retarder relay RET X2-17 Outlet valve (RL) PCV_DL_OV
Output ABS warning Wheel speed sensor
X1-18 WL X2-18 WSS_DL-
lamp control (RL-)
BR -92 BRAKE SYSTEM
ABS/ASR ECU CONNECTOR PIN
ABS/ASR ECU connector uses three plugs.
(18 Pins) (18 Pins) (15 Pins)
SPYBR7170L

X1-1 Ground GND X2-10 Inlet valve (RR) PCV_DR_IV
Output trailer-ABS warning Wheel speed sensor
X1-2 WLT X2-11 WSS_SR+
lamp control (Low active) (FR+)
Ignition switched voltage Pressure control valve
X1-3 US X2-12 PCV_DL_GND
detection Ground (RL)
X1-4 ASR valve ground TCV_DA_GND X2-13 Outlet valve (RR) PCV_DR_OV
Wheel speed sensor
X1-5 ASR valve TCV_DA X2-14 WSS_SR-
(FR-)
ASR switch input/output Wheel speed
X1-6 TCL/TCS X2-15 WSS_DL+
and ASR lamp sensor(RL+)
X1-7 CAN BUS Low CAN1939_LO X2-16 Inlet valve (RL) PCV_DL_IV
X1-8 CAN BUS High CAN1939_HI X2-17 Outlet valve (RL) PCV_DL_OV
Wheel speed
X1-9 Stop lamp switch SLS X2-18 WSS_DL-
sensor(RL-)
X1-10 Wheel speed sensor (RR+) WSS_DR+ X3-1 Off-road switch ORS
Output (Highside Driver)
X1-11 Wheel speed sensor (RR-) WSS_DR- X3-2 DIFF
Difflock control
Ground (ABS Warning Ground return Difflock
X1-12 WL_GND X3-3 DIFF_GND
lamp) control
Diagnostic communication Inlet valve (additional
X1-13 DIAK_SAEB X3-4 PCV_AL_IV
(Low) axle left)
Diagnostic communication
X1-14 DIAL_SAEA X3-5 Input 2 or output 2 IO2
(High)
pressure control valve
X1-15 - - X3-6 ground- Additional PCV_AL_GND
Axle Left
Outlet valve (additional
X1-16 Supply voltage UB X3-7 PCV_AL_OV
axle left)
X1-17 Output retarder relay RET X3-8 Input 3 or output 3 IO3
pressure control valve
Output ABS warning
X1-18 WL X3-9 ground- Additional PCV_AR_GND
lamp control
Axle right

Inlet valve (additional
X2-1 Inlet valve (FL) PCV_SL_IV X3-10 PCV_AR_IV
axle right)
Wheel speed sensor+
X2-2 Outlet valve(FL) PCV_SL_OV X3-11 WSS_AL+
(additional axle left)
Pressure control valve Wheel speed sensor+
X2-3 PCV_SL_GND X3-12 WSS_AR+
Ground(FL) (additional axle right)
Outlet valve (additional
X2-4 Inlet valve (FR) PCV_SR_IV X3-13 PCV_AR_OV
axle right)
Wheel speed
X2-5 Wheel speed sensor (FL+) WSS_SL+ X3-14 sensor-(additional WSS_AL-
axle left)
Wheel speed
X2-6 PCV_SR_GND X3-15 sensor-(additional WSS_A
Ground(FR)
axle right)
X2-7 Outlet valve(FR) PCV_SR_OV
X2-8 Wheel speed sensor (FL-) WSS_SL-
X2-9 PCV_DR_GND
Ground(RR)
BR -94 BRAKE SYSTEM
OPERATION E962A72E
COMPONENT FUNTION
3
1
2
1. Control unit
2. Solenoid valve
3. Pressure control valve
SPYBR7161L

The 4-channel ABS uses four wheel speed sensors.
The sensor consists of a permanent magnet con-
nected to metal rod, around which a coil has been
wound. A pulse wheel mounted to the hub induces an
alternating voltage in the sensor coil. The frequency
of the alternating voltage is managed signal in the
control unit.
2. ABS/ASR control unit

The ABS/ASR control unit is designed in digital type
and possess dual microprocessors, with the following
four features: 1. From service brake valve
2. To brake cylinder
1) Input stage 3. Pressure modulation valve
4. Exhaust valve
The unit checks the wheel speed signal
5. Solenoid valve
(pilot control of pressure modulation valve)
2) Computer 6. Solenoid valve
The computer calculates the brake slip/traction (pilot control of exhaust valve)
and wheel deceleration/wheel acceleration con- 7. Ambient air
trol signal, and energize the output stage when SPYBR7162L
wheels are about to be locked or spin.
4. Solenoid valve
3) Output stage The solenoid valves are connected with two 3/2 so-
The unit energizes interface and axle weight dis- lenoid valves that are pilot-controlled. When wheel’s
tribution unit for controlling the pressure control are about to spin, the valve energizes the axle brake
valve, the solenoid valve, and the engine control. cylinder driven by compressed air. Two control
plungers are controlled by the solenoid valves.
4) Power supply
When current is interrupted, power supply 1 is close
The unit supplies stable voltage for the control
and the cylinder connections are open outwards.
unit operation.
The built-in protective device prevents electrical
interference from applying to the vehicle electri-
cal circuit.
3. Pressure control valve (1 channel)

Each wheel is controlled by a 1 channel control valve.
The pressure control valve consists two diaphragm
type valves (for pressure modulation, and for outlet)
that are guided and controlled by the solenoid valves.
Upon normal braking, compressed air freely pass
through the pressure control valve to the brake
cylinder. If one of wheels is about to be locked, 1. From air tank
the ABS/ASR control unit energizes both solenoid 2. Control plunger
valves to lower the pressure in the brake cylinder. 3. From pressure modulation valve
The pressure modulation valve operates to modulate 4. Solenoid valve
5. Ambient air
the pressure. When the pressure is rising no current
flows in the two solenoid valves. SPYBR7163L
BR -96 BRAKE SYSTEM
ABS CONTROL
Speed
Acceleration
Slip
Brake cylinder
pressure
Valve back force
Time t
VR : Vehicle speed HV : Pressure modulation valve of pressure control valves

AR : Wheel acceleration or deceleration, : Slip AV : Pressure control exhaust valve
Pz : Brake cylinder pressure speed
<ABS operation diagram>
SPYBR7164L
When the drive press the brake pedal, the pressure is sup-
plied to the brake cylinder (or air chamber), and result to
wheel deceleration. When the brake slip is lower than the
ABS system reaction limit value, the braking power is not
controlled.
The ABS/ASR valve rises. In order to provide the most
proper pressure in the brake cylinder, the pressure de-
creases, is maintained, or increases in accordance with
friction coefficient between tires, road surface, and vehi-
cle steering. The illustration 6 indicates the ABS control
feature on wheels upon braking. At time t1, the pressure
in the brake cylinder increases and the wheel speed de-
creases. At time t2, the wheel deceleration and the slip
rate increase above the limit, and the wheel is about to be
locked. With closing the pressure modulation valve and
opening the exhaust valve, the pressure in the brake cylin-
der increases until the wheel speed increases again at
time t3. Closing the exhaust valve, the pressure is main-
tained at a certain level to time t4. Then the slip value
λ =0 approximately, and the wheel acceleration reached
the value that may raise the pressure again. Then instantly
opening and closing the pressure modulation valve, the
pressure becomes pulse-up until time t5. The wheel de-
celeration and slip is higher than the limit again, and the
pressure rise again. The control cycle repeats until the ve-
hicle stops actually.
YAW MOMENT ON THE FRONT AXLE FRICTION FORCE BETWEEN TIRE AND SURFACE
When the friction coefficients are significantly different be- Friction force between tires and road surface when other
tween right and left wheels (for example when the road is conditions are same, friction forces between tires and road
frozen at outer side), corrective control feature is applied surfaces are virtually same for starting and braking condi-
to the front axle accommodating between short braking tions. Friction force measurement (friction coefficient) dif-
distance and steering corrective value. Constraining pres- fers by road condition, weather condition, tread type, and
sure rising and braking force on wheels, the yaw moment especially braking and wheel slip. In usual, braking mo-
is restricted within the range that vehicle control is possi- tive force is within the stable area of slip curve. In general
ble under rapid braking condition. rapid braking increases brake slip and decrease friction
force. With higher brake slip, wheels have lower traverse
force for stability and steer ability of the vehicle. The ABS
system is designed primarily for stability and steer ability
Braking force coefficient ms, Traverse force coefficient
of the vehicle. Friction force on running as well as on brak-

ing relies particularly on slip between tires and road sur-
faces. With higher wheel slip, traction and running stability
decreases. With lowest wheel friction, differential function
provides driving power.
Brake slip
Braking and traverse force coefficients
Correlation between brake slip l and slip
angle a on a dry concrete surface
SPYBR7165L
BR -98 BRAKE SYSTEM
ABS/ASR CONTROL
Speed
Brake cylinder
pressure
Valve back force
ABS/ASR operation diagram
VF : Vehicle speed VR : Wheel speed PZ1.PZ2 : Braking pressure of started driving wheels in the brake cylinder
HV, HV : pressure modulation valve of pressure control valves by driving
AV, AV : exhaust valve of pressure control valves by driving wheels
SPYBR7166L
On starting and accelerating, power transfer depends on

the wheel slip between tires and road surface. When
wheel slip is lower than ASR responding limit wheel slip is
not controlled.
The ABS logic in the ABS/ASR control unit detects driving
wheels’ speed, when wheel spin is about to occur, senses
it.ASR controls driving wheels’ speed. Up to 30km/h,
when driving wheels are about to spin, wheels are braking
and wheel speed is synchronized (limited-slip differential
operation). To achieve this operation compressed air
comes from the air tank through the solenoid valves to the
brake cylinder. The corresponding pressure control valve
modulates braking pressure. When a driven wheel is
about to spin, ASR indication lamp comes on immediately
(warn slip condition). The illustration indicates starting
condition of a ASR vehicle. At time t₁ the car starts and
the driving wheels are about to spin.
At time t₂, wheel spin begins and it will brake wheels
through the control circuit. At time t₃, wheel speed ap-
proaches to the vehicle speed again and wheel braking
pressure is ’pulse-downed’.
OPERATING RANGE IN THE ABS FAULTY
SPEED SENSOR ERRORS
System configuration : Full air brake (4 sensors, 4 pres-

sure adjusting valve)
ABS control Exhaust

Warning
Failure Front Rear brake
Front left Rear left lamp
right right control
Front left speed sensor NO* IC* IC IC ○ ON
Front right speed sensor IC* NO* IC IC ○ ON
Rear left speed sensor MIC MIC NO IC ○ ON
Rear right speed sensor MIC MIC IC NO ○ ON

Mixed up speed sensors NO NO NO NO × ON
Tire size, alignment error NO NO NO NO × ON
Two speed sensor errors or one speed
NO NO NO NO × ON
sensor error and one PMV error
NOTE
IC : individual control
MIC : Modified individual control
* : MIC if affected wheel is on high μ (skid factor)
side.
O : The system part feature is operable
× : The system part feature is inoperable
BR -100 BRAKE SYSTEM
PMV ERRORS
System configuration : Full air brake
ABS control Exhaust

Warning
right right control
Valve solenoid front left shorted low or broken

NO IC IC IC ○ ON
wire or valve ground front left broken wire
Valve solenoid front right shorted low
or broken wire or valve ground front IC NO IC IC ○ ON
right broken wire
Valve solenoid rear left shorted low or broken
MIC MIC NO IC ○ ON
wire or valve ground rear left broken wire
Valve solenoid rear right shorted low or broken
MIC MIC IC NO × ON
wire or valve ground rear right broken wire
Any valve solenoid or valve ground
NO NO NO NO × ON
shorted high
Valve ground shorted low MIC MIC IC IC ○ ON
Two valve error or one valve error and
NO NO NO NO × ON
one speed sensor error
NOTE
IC : individual control
MIC : Modified individual control
× : The system part feature is inoperable
POWER SUPPLY ERRORS
ABS control Exhaust

Warning
right right control
GND shorted high or broken wire NO NO NO NO × ON

U_PMV or U_ECU over voltage or low voltage* NO NO NO NO × ON
U_PMV or U_ECU broken wire NO NO NO NO × ON
NOTE
PMV : Pressure modulation valve
× : The system pant feature is inoperable
*: Errors are reversible (can reset) provided they do
not occur during ABS cycles.
MISCELLANEOUS ERRORS
ABS control Exhaust

Warning
right right control
Internal ECU failure or internal relay

NO NO NO NO × ON
switch failure
Internal relay always ON Yes* Yes* Yes* Yes* ○ ON
RET shorted high or shorted low or
Yes* Yes* Yes* Yes* × ON
broken wire
CAN interface bus off Yes* Yes* Yes* Yes* ○ ON
CAN interface error on message ERC1 Yes* Yes* Yes* Yes* ○ ON
NOTE
* : Control mode according to selected system con-
figuration.
× : The system part feature is inoperable.
ABS SELF-DIAGNOSIS EC767085
SAFETY MONITORING
Control configuration 4S/4K IRM/IR (wheel speed sensors vehicle is controlled through 4 channels)
S : sensor K : channel IR : Each wheel of a vehicle is controlled individually

2. ABS control unit
3. 1-channel pressure control valve
4. Solenoid valve
Control diagram
SPYBR7167L
1. Safety monitoring 3. How to read the failure code

The ABS system satisfies highest safety and relia- Failure codes may be read using a Hi-scan and self-
bility requirements. Prior to starting the vehicle, mi- diagnosis by blink signals of the ABS lamp.
crocomputers perform self-diagnosis and check other
computers, and then monitor wheel spin sensor, pres-
sure modulation valve, wiring harness, and the whole
ABS system. Finding a failure the ABS system be-
comes wholly or partly inoperable and the warning
lamp comes on. The service brake system is still op-
erable.
2. Self-diagnostic feature
In addition to the safety monitoring system, the self-
diagnostic feature built in the ABS control unit enables
to remove the failure immediately and safely. Upon
failure detection by the ABS control unit, the failure
code is stored in the computer that may be read later
at a service shop. Then temporary failures including
poor contraction at plug connection may be found and
eliminated soonest.
1
Tester
2
ABS Switch
Light
SPYBR7168L
SELF-DIAGNOSIS ON A VEHICLE
1. ABS lamp
When a problem occurs in using the ABS system, the
yellow ABS lamp comes on for warning in order to
facilitate finding the trouble area by self-diagnosis.
In normal condition, the ABS lamp comes on upon
switching the battery power on and extinguished upon
starting the vehicle and during running. If a trouble
occurs in the ABS system during running, the ABS
lamp comes on even or running.
Cluster Warning lamp
SPYBR7171L
2. Diagnostic method
The blink code device reads out error codes of 16 sys-
tems that are stored in the ECU system configuration
and error memory. The device checks the brake sig-
nal, as well.
The blink codes may be read using the ASR lamp,
and troubles read with the self-diagnostic button may
be identified using the blink code table.
3. Blink code configuration

In order to operate the blink code, keep the self-di-
agnostic button pressed for two seconds and then re-
lease it.
Pressing the button once it will indicate the system
configuration and an error code. Press the self-diag-
nostic button once again to read error codes.
The ASR lamp indicates an error code each time
pressing the button.
After reading out all error codes stored in the memory
using the blink codes, the last stored code may be
read continually.
Quitting self-diagnosis for 5minutes or more, or
switching the starting key off and on again, the
self-diagnostic feature reads all information again
from the beginning, the system configuration.
Each error code including the brake signal failure, in-
cludes three blocks.
The first block may be read at 100’s digit, the second
block at 10’s digit, and the third block at 1’s digit.
(configuration block I) (configuration block II)
(warning lamp)
(1st digit) (2nd digit) (1st digit) (2nd digit)
ON
OFF
1.5s -0.5s 1.5s 4.5s
(diagnosis button)
ON
<1.5s
OFF
0.5...8s 0.5...8s
SPYBR7172L
4. Failure memory erosion

Then ABS ECU will erase all error codes when the
diagnostic push button is pressed during power on.
Ignition Switch
ON
<3s
OFF Failure memory
completely erased
Diagnosis push button
ON
OFF
SPYBR7173L
5. ERROR CODE TRANSMISSION

The ABS ECU is able to store up to 16 different errors
at a time.
The transmission of the error codes is triggered by
pressing the diagnostic push button. For each error
the component number (1st digit) and the failure mode
(2nd digit) is displayed.
Error codes of failures that have been detected dur-
ing the active power on cycle are transmitted first. A
delay time of at least 1s after power on is required be-
fore pressing the diagnostic push button. The trans-
mission of error codes can be terminated at any time
by pressing the diagnostic push button.
failure 1 failure 2
(warning lamp) compo- compo-

error error
nent no. nent no.
ON
OFF
1s 1.5s 0.5s 1.5s 4.5s
(diagnosis button)
ON
OFF
0.5...8s
SPYBR7175L
Center lower panel
Side switch box
ABS check
1 2 3 4 5 6 7 8 Data link connector

9 10 11 12 13 14 15 16
Ground K-line Power
SPYBR7176L
6. Safety device
Operate as a
Upon ABS Failed circuit
non-ABS brake
failure
Other circuits ABS operation
At least the ABS system may operate just same as a

non-ABS brake.
HI-SCAN CHECK
1. Turn the starting key off.
2. Connect a Hi-scan with the data link connector lo-

cated under the low crash pad panel.
3. Turn the starting key on.
4. Using the Hi-scan, check the diagnosis trouble code.
5. Upon repairing or correcting the problem, turn the

starting switch and clear stored error codes using the
clear key.
6. Disconnect the Hi-scan.
Center lower panel
Side switch box
ABS check
1 2 3 4 5 6 7 8 Data link connector

9 10 11 12 13 14 15 16
Ground K-line Power
SPYBR7174L
BLINK CODES
CONFIGURATION CODES
Number of
Block Digit Description
pulses
Ⅰ 1st 1 12V
2 24V
2nd 2 4 sensor/4 pressure modulation valve
15 Invalid configuration
Ⅱ 1st 1 No retarder link, No retarder relay

2 With retarder link, No retarder relay
3 No retarder link, With retarder relay
4 With retarder link, With retarder relay
2nd 2 No ASR
ERROR CODES
Blink code
Description
Comp. Error
1 2 No failure
Wheel speed sensor 2 1 Large air gap (Air gap＞0.6mm)
front left 2 2 Missing sensor signal at drive off
2 3 Bad tooth wheel, long term ABS control
2 4 Long term instability
2 5 Loss of sensor signal
2 6 Shorted low/high or broken wire or two sensors aborted

front right 3 2 Missing sensor signal at drive off
3 6 Shorted low/high or broken wire or two sensors aborted

rear left 4 2 Missing sensor signal at drive off
4 6 Shorted low/high or broken wire or two sensors shorted

rear right 5 2 Missing sensor signal at drive off
5 6 Shorted low/high or broken wire or two sensors shorted
Blink code
Description
Comp. Error
Pressure modulation 8 1 Release solenoid shorted high
valve front left 8 2 Release solenoid shorted low
8 3 Release solenoid broken wire
8 4 Valve ground broken wire
8 5 Hold solenoid shorted high
8 6 Hold solenoid shorted low
8 7 Hold solenoid broken wire
8 8 Valve configuration error
valve front right 9 2 Release solenoid shorted low
valve rear left 10 2 Release solenoid shorted low
valve rear right 11 2 Release solenoid shorted low
Pressure modulation valve, 10 10 Valve ground shorted high
valve ground 10 11 Valve ground shorted low or int. ground solenoid defective
Blink code
Description
Comp. Error
ECU internal failures 15 1 Internal (If this fault code is still present then
replace the ECU)
15 2 Internal (If this fault code is still present then
replace the ECU)
15 3 EEPROM data error (If this fault code is still
present then replace the ECU)
replace the ECU)
replace the ECU)
replace the ECU)
replace the ECU)
15 9 Invalid configuration in EEPROM (If this fault code
is still present then replace the ECU)
replace the ECU)
replace the ECU)
Power supply 16 1 Battery supply - temporary over voltage, check
alternator/voltage regulator
16 2 Battery supply - temporary low voltage/low voltage during
ABS control,check condition of battery and terminals
Battery supply - broken wire
16 3 Battery supply - power line noise/temporary
16 4 power line noise
Ignition supply - temporary over voltage,check
16 9 alternator/voltage regulator
Ignition supply - temporary low voltage, check
16 10 condition of battery and terminals
Ignition supply - Low voltage during ABS control,check
16 11 for corrosion on battery terminals
Blink code
Description
Comp. Error
Endurance braking device 17 1 Shorted to battery,check wiring to service braking device.
(Exhaust brake or retarder) Shorted to ground or broken wire,check wiring
17 2 to service braking device.
Front to rear out of range,check that correct tire sizes
17 5 are fitted and that tire pressures are correct.
Warning lamp ground shorted to battery or broken
17 10 wire,or warning lamp supply shorted to ground or
broken wire,check warning lamp wiring.
Wheel speed sensor failure in previous ’power on’
17 12 cycle.Drive vehicle to 20 km/hr,if ABS warning lamp
goes off then problem is fixed,if lamp stays on then stop
vehicle and check the fault blink codes again.
Wheel speed sensors incorrectly wired(left to right) on
17 13 front axle or rear axle,check wiring of X1 and X2 plugs.
Miscellaneous 18 3 CAN-BUS off, check CAN-BUS connections

and terminating resistor.
18 4 Timeout or invalid data on ERC1,check CAN-BUS
connections and the ECU which is generating
the ERC1 message.
OPERATING RANGE IN THE ABS/ASR FAULTY
As said, when the ECU detects failure, the ABS/ASR sys-

tem operates partly or wholly unable to operate. Partly
operating features as per failed part is as the below table.
Upon failed of two or more parts, the ABS/ASR system is
wholly inoperable.
ABS
Failed part Indication Other ABS ABS

Failed part diagonal features* diagonal
features
One of front wheel ABS warning Sensor-failed wheel side is
ON ON 1)
sensors lamp inoperable
One of rear wheel ABS warning Sensor-failed wheel side is
ON 2) OFF
sensors lamp inoperable
PCV : ground circuit ABS warning
Failed side wheel is inoperable ON ON 3)
break or short lamp
ABS warning
Short with UZ or UB OFF ON ON OFF
lamp
ABS warning
DBR relay ON ON OFF ON
lamp
ABS warning
ASR valve ON ON ON OFF
lamp
ABS warning
UB circuit break OFF ON ON OFF
lamp
ECU internal ABSwarning
OFF ON ON OFF
GND-FET failure lamp
ON : The system part feature is operable

OFF : The system part feature is inoperable
NOTE
1. ON, but slip increases
2. ON, but operates depending on normal sensors.
3. Upon front wheel pressure modulation valve fail-
ure : ON
Upon rear wheel pressure modulation valve fail-
ure : OFF
DBR : Exhaust brake or retarder, UZ : Starter key
first step power, UB : Battery power
* Diagonal feature : The ABS system is applicable in the

diagonal direction of the vehicle (FR and RL, or FL and
RR).
ABS/ASR SELF-DIAGNOSIS
SAFETY MONITORING
Control configuration 4S/4K IRM/IR (wheel speed sensors vehicle is controlled through 4 channels)
S : Sensor K : Channel IR : Each wheel of a vehicle is controlled individually

2. ABS/ASR control unit
3. 1-channel pressure control valve
4. Solenoid valve
Control diagram
SPYBR7177L
1. Safety monitoring 2. Self-diagnostic feature

The ABS/ASR system satisfies highest safety and re- In addition to the safety monitoring system, the self-
liability requirements. Prior to starting the vehicle, mi- diagnostic feature built in the ABS/ASR control unit
crocomputers perform self-diagnosis and check other enables to remove the failure immediately and safely.
computers, and then monitor wheel spin sensor, pres- Upon failure detection by the ABS/ASR control unit,
sure modulation valve, wiring harness, and the whole the failure code is stored in the computer that may be
ABS/ASR system. Finding a failure the ABS/ASR read later at a service shop. Then temporary failures
system becomes wholly or partly inoperable and the including poor contraction at plug connection may be
warning lamp comes on. The service brake system is found and eliminated soonest.
still operable.
1
Tester
2
ABS Switch
ASR
Light
SPYBR7178L
3. How to read the failure code

Failure codes may be read using a Hi-scan and self-
diagnosis by blink signals of the ASR lamp.
SELF-DIAGNOSIS ON A VEHICLE
1. ABS lamp
When a problem occurs in using the ABS system, the
yellow ABS lamp comes on for warning in order to
facilitate finding the trouble area by self-diagnosis.
In normal condition, the ABS lamp comes on upon
switching the battery power on and extinguished upon
starting the vehicle and during running. If a trouble
occurs in the ABS system during running, the ABS
lamp comes on even or running.
Detail A
SPYBR7181L
3. Blink code configuration

In order to operate the blink code, keep the self-di-
agnostic button pressed for two seconds and then re-
lease it. Pressing the button once it will indicate the
system configuration and an error code. Press the
self-diagnostic button once again to read error codes.
The ASR lamp indicates an error code each time
pressing the button.
After reading out all error codes stored in the memory
using the blink codes, the last stored code may be
SPYBR7179L read continually.
Quitting self-diagnosis for 5minutes or more, or
2. Diagnostic method switching the starting key off and on again, the
The blink code device reads out error codes of 16 sys- self-diagnostic feature reads all information again
tems that are stored in the ECU system configuration from the beginning, the system configuration.
and error memory. The device checks the brake sig- Each error code including the brake signal failure, in-
nal, as well. cludes three blocks.
The blink codes may be read using the ASR lamp, The first block may be read at 100’s digit, the second
and troubles read with the self-diagnostic button may block at 10’s digit, and the third block at 1’s digit.
be identified using the blink code table.
SPYBR7180L
4. Reading error codes

For example the below blink code indicates no brake
signal failure, the system configuration, and two error
codes, 312 and 322.
Configuration : Last-stored fault: Last-but-one stored fault :

2 312 322
Indicator lamp ON
Indicator lamp
OFF
Press button
Release button
Sketch Blink-code example
SPYBR7182L
1) Time delay from "power-on" to pressing the 5. Reset procedure

self-diagnostic button : 1.25seconds or more In order to clear out all information stored in the fault
(>1.25s) memory, "Power-On" the system with the self-diag-
nostic button pressed in, turn "Ignition-On" and wait
2) Pressed-in time of the button for reading 5seconds, and release the self-diagnostic button.
DTCs : 2seconds or more (>=2s) Then wait with "Ignition-On" for 5seconds or more and
turn "Ignition-Off". Now the system is reset.
3) Time delay from releasing the self-diagnostic but-
ton until indicating output signal : 3seconds (3s) 6. Safety measure
4) Blink code blinking time : 0.5seconds (0.5s) Operate as a

Upon ABS Failed circuit
non-ABS brake
5) Blink code time in 100’s digit and 10’s digit/10’s failure
digit and 1’s digit : 3seconds Other circuits ABS operation
6) Time interval between blink codes in 1’s digit :

1second At least the ABS system may operate just same as a
non-ABS brake.
CAUTION FOR ABS VEHICLES
1. Upon ignition on, the ABS warning lamp (yellow) shall

be on and go out at 10km/h or more after starting the
vehicle.
2. Braking normally on a normal road surface, the driver

is hard to feel the ABS effect. The ABS effect is de-
signed to feel at braking on a certain surface that
wheels are apt to be locked as slippery road-frozen,
snowy, rainy road.
NOTE
On rapid braking or braking on a slippery road, do not
pump the brake pedal as a non-ABS vehicle. Press
the pedal properly depending on situation (hard or
light) at once and continuously for optimum ABS ef-
fect.
3. An ABS vehicle an integration of the ABS system on

a non-ABS vehicle. The basic braking system shall
be maintained properly, and the ABS system cannot
improve the serviceability.
4. For optimum ABS effect, regularly put the wheel

speed sensors(A) to bottom into the pulse ring. Upon
removing the hub and drum assembly to replace the
lining/clean off dirt (lining, particles, dust, oil, etc) on
the speed sensor.
SPYBR7183L
HI-SCAN CHECK
1. Turn the starting key off.
2. Connect a Hi-scan with the data link connector lo-

cated under the side switch box trim panel.
3. Turn the starting key on.
4. Using the Hi-scan, check the self-diagnosis on a ve-

hicle.
5. Upon repairing or correcting the problem, turn the

starting switch and clear stored error codes using the
clear key.
SPYBR7180L
6. Disconnect the Hi-scan from the data link connector.
Detail A
SPYBR7181L
DTC (DIAGNOSTIC TROUBLE CODE)
NO DTC Description
1 00h No failure
2 0Ch Reserved for tire size alignment add axle left
3 10h ABS-CPU timeout
4 11h ABS-CPU run time error
5 12h Valve output signal mismatch
6 13h ABS-CPU communication checksum error
7 14h Failure on speed sensor input circuit
8 15h ABS-CPU master/slave different configuration or ROM checksum error
9 16h ABS-CPU invalid configuration in EEPROM
10 17h ABS-CPU EEPROM data error
11 18h ABS-CPU EEPROM not programmable
12 1Ah Internal relay not switchable
13 1Bh Internal relay permanently turned on
14 1Fh Reserved c3-signal plausibility check
15 20h U-ign temporary over voltage
16 21h U-ign temporary low voltage
17 22h U-ign low voltage during ABS Control
18 23h U-bat temporary over voltage
19 24h U-bat temporary low voltage
20 25h U-bat low voltage during ABS Control
21 26h U-bat broken wire
22 29h Valve ground or solenoid shunt to supply voltage
23 2Ah Valve ground or solenoid shunt to ground or int. ground switch defective
24 2Bh Reserved for timeout or invalid data on CAN-messages
25 2Eh Reserved for timeout or invalid data on CAN-messages
26 2Fh Reserved for timeout or invalid data on CAN-messages
27 30h Retarder relay shorted high
28 31h Retarder relay shorted low or broken wire
29 33h J1939 CAN bus off detected
30 34h Timeout or invalid data on ERC1
31 35h Timeout or invalid data on EEC1 / EEC2 / EEC3
32 36h Reserved for timeout or invalid data on CAN-messages
33 3Ah TC solenoid broken wire
34 3Bh TC solenoid shorted low
35 3Ch TC solenoid shorted high
36 3Dh TC valve configuration error
37 3Fh Timeout or invalid data on AUXIO
NO DTC Description
38 41h Shorted low/high or broken wire or two sensors shorted
39 45h Bad tooth wheel, long term ABS control
40 47h large air gap
41 48h Missing sensor signal at drive off
42 49h Long term instability
43 4Ah Loss of sensor signal
44 4Bh Reserved for wheel speed sensor (Taumelschlag)
45 4Ch Reserved for tire size alignment steer axle left
46 51h Hold solenoid broken wire
47 52h Hold solenoid shorted low
48 53h Hold solenoid shorted high
49 54h Valve ground broken wire.
50 55h Release solenoid broken wire
51 56h Release solenoid shorted low
52 57h Release solenoid shorted high
53 5Dh Valve configuration error
56 67h Large air gap
61 6Ch Reserved for tire size alignment drive axle right
65 74h Valve ground broken wire
70 80h ABS software not compatible with hardware
72 82h Supply voltage temporary powerline noise
73 83h Supply voltage powerline noise
75 87h Large air gap
NO DTC Description
80 8Ch Reserved for tire size alignment steer axle right
81 8Dh Unused
82 8Eh Unused
83 8Fh Unused
84 90h Unused
88 94h Valve ground broken wire
92 98h Unused
93 99h Unused
94 9Ah Unused
95 9Bh Unused
97 A0h Bad brake performance steer axle left
98 A1h Shorted low/high or broken wire or two sensors shorted
99 A2h Bad brake performance steer axle right
100 A3h Bad brake performance drive axle left
101 A4h Bad brake performance drive axle right
102 A5h Bad tooth wheel, long term ABS control
103 A6h Bad brake performance add axle left
104 A7h Large air gap
105 A8h Missing sensor signal at drive off
106 A9h Long term instability
107 AAh Loss of sensor signal
108 ABh Reserved for wheel speed sensor (Taumelschlag)
109 ACh Reserved for tire size alignment drive axle left
110 ADh Bad brake performance add axle right
111 AFh ATC brake control time limit exceeded
112 B1h Hold solenoid broken wire
113 B2h Hold solenoid shorted low
114 B3h Hold solenoid shorted high
115 B4h Valve ground broken wire
NO DTC Description
116 B5h Release solenoid broken wire
117 B6h Release solenoid shorted low
118 B7h Release solenoid shorted high
119 BDh Valve configuration error
120 CCh Reserved for tire size alignment add axle right
121 D0h Wheel speed sensor failure in previous power on cycle
122 D1h GND-WL broken wire or WL switched to ground permanently
123 D2h Tires or learned parameters (front or rear or front to rear) out of range
124 D3h Reserved for tire size alignment (wheel alignment with memory function)
125 D4h Wheel speed sensors mixed up
126 D5h Stop light switch not activated in this power on cycle
127 D6h ATC or ESP disabled or rollerbench mode active
128 D7h ABS disabled due to off road mode
129 D8h Stop light switch defective
130 D9h Reserved for booster switch defective
131 DAh Reserved for booster defective
132 DBh ABS disabled due to engaged difflock
133 DCh Difflock solenoid shorted high
134 DDh Difflock solenoid shorted low or broken wire
135 FFh Not existing error in ROM table
WHEEL SPEED SENSOR
COMPONENT LOCATION E95BFDB0
[Front drum brake]

1
2
[Front disc brake]

1
1. Front wheel speed sensor

2. Brake chamber
SPYBR7184L
[Rear drum brake]
1 2
[Rear disc brake]

2. Brake chamber
SPYBR7185L
INSTALLATION EA2E71B0 FRONT DISC BRAKE
FRONT DRUM BRAKE 1. Insert wheel speed sensor(A) by hand till it reach to
pulse ring.
1. Insert bushing(A) in the arrow direction till it is insert
on spindle all the way.
A SPYBR7187L
SPYBR7186L 2. After assembly is completed, check the wheel speed

sensor, pulse ring air gap sensor and pulse ring dam-
2. Insert sleeve on the wheel speed sensor. Then insert age.
it in the bushing.
3. Install hub & drum.
4. Insert wheel speed sensor until it touches pulse

ring.Then turn hub & drum assembly once.
5. After assembly is completed, check the wheel speed

sensor, pulse ring air gap, sensor operation and pulse
ring damage.
REAR DRUM BRAKE REAR DISC BRAKE
1. Assemble the brake assembly to the axle housing. 1. Push the wheel speed sensor(A) smoothly till reach-
ing to the pulse ring by hand.
2. Assemble the wheel speed sensor to the hole of
holder after inserting a clamping sleeve to the wheel
speed sensor holder.
3. Install the holder assembled with a wheel speed sen-

sor to the axle housing with bolt and washer.
SPYBR7189L
2. After assembly is completed, check the wheel speed

sensor, pulse ring air gap sensor and pulse ring dam-
age.
SPYBR7188L
4. Tighten the cable.
5. Push the wheel speed sensor smoothly till reaching

to the "A" by hand.
6. Assemble the hub and drum assembly.
7. Rotate hub and drum assembly by one turn after

pushing wheel speed sensor to contact on pulse ring
with Ø4 rod through Ø25 hole of brake mounting
flange.
RETARDER SYSTEM BR -127
RETARDER SYSTEM
SPECIFICATION E7D46B94
MODEL ZF-6S1901
Type 6 O.D
Brake torque(Max, Nm) 1900
Gear ratio 1st 6.32
2nd 3.62
3rd 2.15
4th 1.37
5th 1.00
6th 0.81
Reverse 5.81
Weight(without oil) Transmission (w/o retarder) 200 kg
Transmission (with retarder) 275 kg
Oil Initial oil volume (Liter) 25 liter
Oil type SAE 30 Oil
Control Electric signal and hydraulic
Operating voltage 24 V
DESCRIPTION E058689F If the system doesn’t have any fault ,monitoring display
lights up for 3 sec at ignition on. If there is a defect in
The retarder is an additional brake integrated in the trans- the electric system, the monitoring display flashes when
mission which functions hydro dynamically and with no the retarder is switched on.
wear. The retarder is conducive to more consistent and
more cost-effective driving styles. TYPE PLATE
RETARDER OPERATING LEVER The type plate contains important retarder data. It can be
found to the side of the retarder housing. The following
The operating level is consist of bromsometic, 1, 2, 3 level. items must be specified when making enquires, placing
While the retarder is operating ,the lamp is on. orders or undertaking repair work.
1 98 1 3
2
2
1. Pilot lamp(Operating lamp) 4 5

2. Brake step lever
SPYBR7190L SGVBR7066D
1 : Pilot lamp(Operating lamp) 1. Type of transmission

2 : Brake step lever
2. Retarder parts list no.
RETARDER MONITORING DISPLAY
3. Serial no. of retarder
NOTE
4. Oil volume
Check whether the retarder functions match the light
displays described below. 5. List of lubricants
When the ignition has been switched on and the re-
tarder system automatically checks that the monitor-
ing display is functioning.
SPYBR7191L
FUNCTION
The retarder is fitted to one side at the output end of the

transmission and is connected to the output shaft(1) by a
step-up stage(2). The rotor(3) and the pump(4) are driven
into ratio via the stage with a i = 1:2.
When the retarder is actuated, oil is pumped into the re-
tarder chamber, accelerated by the rotor and braked again
in the blade cavities of the stator. The braking energy cre-
ated during this is converted into thermal energy and the
braking torque produced acts on the transmission output
via the step-up and therefore acts on the vehicle’ s driv-
eline.
The heat is conveyed to the vehicle engine’ s cooling cir-
cuit via the heat exchanger(5).
Additional oil is fed from the accumulator cylinder(6) to the
circuit to obtain a rapid retarder response time.
External pipes are not required for the oil circuit when the
retarder is fitted because the hydraulic control unit(7) and
the heat exchanger(8) are integrated in the transmission
housing.
2 5
3
4
1. Step-up
2. Transmission output shaft 7
3. Rotor / stator
4. Pump
5. Heat exchanger
6. Accumulator cylinder
7. Hydraulic control unit
SPYBR7192L
CONSTITUTION OF RETADER
2 5
3
4
1. Step-up
2. Transmission output shaft 7
3. Rotor / stator
4. Pump
5. Heat exchanger
6. Accumulator cylinder
7. Hydraulic control unit
SPYBR7193L
RETARDER PROPERTY
1. Up to 500 kW braking power
2. Oil supply shared by transmission and retarder
3. Integrated transmission cooling
4. Unaltered installation length
5. Compact low weight system
6. Greater braking comfort
7. Increased safety for passengers and vehicle

RETARDER OPERATION
Thermal energy
Thermal
energy
Engine Transmission
Mechanical energy ZF retarder
Thermostat
Engine heat exchanger
SPYBR7194L
The oil in the retarder is used to create a braking effect. RETARDER PILOT LAMP
You can operate the retarder using the electronic braking
level selector. The retarder pilot lamp gives the driver a continuous sur-
Depending on the position of the braking level selector, vey of the current retarder condition. The pilot lamp comes
the retarder fills with the required quantity of oil in order to on when the retarder is activated by moving the braking
produce the desired braking torque. level selector.
The desired braking torque is reached in 0.75s after
switch-on. NOTE
Reduction of the torque, e.g. with ABS, takes about 0.3s When the retarder is switched on, the retarder pilot
from switch-off of the retarder. lamp flashes continuously if there is any fault in the
A step-up gear set on the transmission output shaft accel- electrical system.
erates a rotor.
As the rotor turns, its blades push oil into the stationary
blades of the turbine wheel where the oil is slowed.
This converts the braking energy into heat energy.
The braking torque achieved is applied to the vehicle
driveline through a helical gear set. The heat created
is dissipated through the direct-mounted oil/water heat
exchanger to the vehicle’s engine cooling water circuit.
ELECTRONIC CONTROL UNIT EST FAIL-SAFE FUNCTIONS
The Retarder is controlled by the electronic control unit. The electronic control unit comprised additional safety
This unit receives and processes various signals; functions which ensure limited Retarder operation if any
electrical component should fail (short circuit, interrup-
1. The signal from the braking level selector activates tion).
the accumulator solenoid valve and the proportional
solenoid valve. This activates the oil reservoir and the 1. Fault in braking level selector or interruption of braking
Retarded hydraulic control system. The oil contained level signals.
in the reservoir is immediately fed into the Retarder The highest braking level selectable is the level corre-
circuits. sponding to the number of intact braking level signals.
If the signal for braking level 1 fails, the Retarder is
2. The ABS signal switches the Retarder off automati- switched off.
cally.
As soon as the ABS system allows the Retarder to 2. Fault in the speed and/or temperature sensor the elec-
operate again, the Retarder is automatically switched tronic control unit reduces maximum braking power to
back on. In this case braking torque rises smoothly to braking lever 2 (even if a higher braking level is en-
the level currently set according to a specified char- gaged).
acteristic curve. This ensures the Retarder still functions, although
with reduced braking torque.
3. The signal from the electronic pulse sensor for Re-
tarder speed limits the Retarder braking power and is 3. Fault the speed and/or temperature sensor. The elec-
used to enable Bremsomat operation. tronic control unit reduces maximum braking power to
braking level 2 (even if a higher braking level is en-
4. The signal for the cooling water temperature allows gaged).
the electronic control unit to control the Retarder This ensures the Retarder still functions, although
power reduction function. this prevents the cooling with reduced braking torque.
water temperature exceeding a specified maximum
value (standard value 105 C). 4. Fault in the proportional solenoid valve The Retarder
is automatically switched off.
5. The Bremsomat or Bremsomatic signal allows
the driver to select and maintain his speed when 5. Fault in the accumulator solenoid valve No reduction
descending hills. The Retarder electronics automati- in braking power. The Retarder takes longer to re-
cally set the braking torque needed. spond.
FAULT RECOGNITION
NOTE
If the vehicle has an engine brake, this can be con- 1. Fault recognition
trolled by the Retarder as well. The Retarder pilot lamp indicates Retarder function
and also assists fault recognition.
The Retarder pilot lamp lights for 3 sec, when the
ignition is switched on (lamp check).
In the unlikely event of a failure of an electrical com-
ponent of the Retarder, this is indicated by the lamp
flashing continuously.
This informs you that only a limited braking effect or
no braking effect at all is available from the Retarder.
2. Error diagnosis
The Retarder electronic control system is capable of
diagnostic functions. Errors recognized by the Re-
tarder electronic control unit are stored in an error
memory.
During vehicle inspection, the information stored can
help you to identify any faults quickly and clearly.
HYDRAULIC DIAGRAM(RETARDER "ON")
EST Retarder level select switch
Brake light acc. to Retarder

local regulations Control lamp
Control valve Pressure relief

Pressure Regulating Safety valve valve 12 bar
elevation valve valve
Pump
Impulse sensor
Preload valve Retarder
Change over valve
Compressed. Oil tank/reservoir Sump

air
Temperature sensor
Filter
Main oil flow
Control circuit
Electr. line
SPYBR7195L
SPRING TABLE
Wire dia. Spring dia. Intensioned length

Order No. Location No. of coils
in mm in mm in mm
Retarder control unit
0732 042 402 52.5 3.0 16.5 238.0
(cooler changeover valve)
0732 042 470 7.5 1.9 15.8 31.2
(pressure relief valve)
0732 042 471 11.5 1.6 10.8 32.6
(pressure relief valve)
0732 041 247 7.5 1.4 9.4 19.6
(safety valve)
0732 042 348 8.5 1.5 18.3 52.4
(pressure increase valve)
Retarder
0732 042 403 14.5 1.6 17.6 85.0
(preload valve)
Retarder
0732 042 406 16.5 1.7 15.6 72.0
(drain valve)
ADJUSTMENT DATA
Description Dimension spec. Measuring device Remarks

Oil pump 0.03-0.05 mm Dial gauge -
Impeller Axial play
Stator-Rotor 0.05-0.1 mm Fixture and dial gauge Preload (pressure)
Axial play of taper roller bearing
SPECIAL TOOL E843E157
Tool (Number and Name) Illustration Use

1x89 122 292 Pressing out rotor and stator
Hydraulic spindle (use with 1x56 138 047)
SGVBR7070D
1x56 138 045 Guide when installing stator

Centering dis and rotor
SGVBR7071D
1x56 138 046 Installation of taper roller bearing

Adjustment fixture on stator and rotor
SGVBR7072D
1x56 138 047 Pressing out stator and rotor

Extraction fixture
SGVBR7073D
1x56 138 050 Installation of spur gear when

Ring assembling inner race
of taper roller bearing
SGVBR7074D

1x56 137 124 Installation of shaft seal
Tool (use with 1x56 138 038)
SGVBR7075D
1x56 137 974 Driving in inner race of taper

Tool roller bearing
SGVBR7076D
1x56 137 975 Installing needle sleeve in control

Tool housing and pump housing
SGVBR7077D
1x56 138 038 Installation of shaft seal

Tool (Use with 1x56 137 124)
SGVBR7078D
1X56 138 049 Pressing out stator and rotor

Tool (Use with spindle press or
hydraulic press)
SGVBR7079D

1x56 136 471 Driving retaining plate into
Tool output flange
SGVBR7080D
1x56 138 048 Installation of shaft seal on

Tool output flange.
SGVBR7081D
1x56 138 054 Bore-pressure relief valve/control

Calibration mandrel valve
SGVBR7082D
1x56 138 055 Bore-pressure increase valve

Calibration mandrel
SGVBR7083D
1X56 138 056 Bore-cooler changeover valve

Calibration mandrel
SGVBR7084D

1X56 138 057 Bore-pilot valve
SGVBR7085D
1x56 138 068 Retarder housing/control housing

Measuring plugs for retarder outlet pressure
or retarder or temperature
SGVBR7086D
1P01 138 069 Test on test bench

Test unit
SGVBR7087D
1P01 138 070 Testing electric speedometor

Test unit
SGVBR7088D
ADJUSTMENT EC67D6D7 1. Stop vehicle in horizontal position and switch off en-
gine.
OIL LEVEL CHECK
2. To drain the oil, the drain plug on the transmission
CAUTION and the drain plug on the oil filter housing should be
unscrewed.
a. To check the oil level, the retarder must not be
activated just before the vehicle is stopped.
CAUTION
b. This ensures that the transmission has the
correct oil volume. - Hot transmission oil: RISK OF BURNING.
NOTE 3. Once the oil has been drained, the drain screws
(solenoids) must be cleaned and the seals replaced.
1. In order to prevent incorrect measurements, the
oil level on transmissions fitted with a ZF-retarder 4. Refill the oil. Fill up the oil sufficiently(approx. 25
must be checked with liter),then drive the vehicle without operating the re-
- the vehicle horizontal tarder system for a little while. Check oil level again
- the engine off and if necessary, top up oil until it overflows.
- cooled transmission oil (＜ 40 C).
Regularly check the oil level. Oil over flow plug Retarder housing
oil drain point
2. During the check, look out for leaks on the:
- transmission,
- retarder,
- oil/water heat exchanger,
- associated coolant pipes.
1. Stop and park the vehicle without activating the re-

tarder.
2. The oil overflow plug should be opened during the oil

Transmission oil drain point
level check.
Retarder housing oil filter cover
3. If the oil level is below the edge of the oil overflow
SPYBR7196L
aperture, oil must be topped up at the oil overflow
aperture until it overflows.
CAUTION
4. Screw oil overflow plug back in with new seal. - Do not fill coolant into the oil inlets.
DRAINING OIL - Use the below oil.
: SAE 30 oil
CAUTION
5. Insert new filter.
The retarder must not be activated just before
stopping the vehicle for an oil change. 6. Then screw the drain plugs back in.
This ensures that the correct oil change volume
is used.
NOTE
- When changing the oil, the oil must be drained
into a suitable container and disposed of in ac-
cordance with environmental legislation.
- Always: Undertake oil change after a long jour-
ney while the transmission oil is still warm and
thin.

TESTS E0F120B1
1. Ignition ON, wait for finishing up the retarder self-di-

agnostics test.
2. Connect the Hi-scan to the vehicle.
3. Read the diagnostic trouble code.
No. DTC Description Remarks

1 A105 Accumulator charge valve output / shorted to low source
2 A106 Accumulator charge valve output / shorted to high source
3 A10A Accumulator charge valve output / disconnection
4 A305 Intarder pilot lamp output / shorted to low source
5 A306 Intarder pilot lamp output / shorted to high source
6 A30A Intarder pilot lamp output / disconnection
7 A505 Brake light output / shorted to low source
8 A506 Brake light output / shorted to high source
9 A50A Brake light output / disconnection
10 A805 Braking level selector supply output / shorted to low source
11 A806 Braking level selector supply output / shorted to high source
12 A80A Braking level selector supply output / disconnection
13 A905 Proportional valve output / shorted to low source
14 A906 Proportional valve output / shorted to high source
15 A90A Proportional valve output / disconnection
16 A909 Proportional valve output / device error
17 FA05 Proportional valve ground feedback output / shorted to low source
Proportional valve ground feedback output / shorted
18 FA06
to high source
19 AC04 Speed sensor on output shaft / no signal
20 AD0A Temperature sensor of coolant system / disconnection
21 AD07 Temperature sensor of coolant system / general short
Readback current of proportional valve output /
22 AE01
above max. threshold
Readback current of proportional valve output /
23 AE02
below min. threshold
24 CF0A Vehicle circuit voltage (key 30) / disconnection
25 AF01 Vehicle circuit voltage (key 15) / above max. threshold
26 AF02 Vehicle circuit voltage (key 15) / below min. threshold
27 B003 Braking level selector / not plausible
28 CE00 EOL Parameter / no fault symptom
29 B100 Operation hours counter checksum / no fault symptom
30 B200 Error memory - checksum / no fault symptom
No. DTC Description Remarks

31 B404 EEC2-message / no signal
32 B504 engine speed sensor / no signal
33 B600 System error / no fault symptom
34 B704 TSC1-message / no signal
35 B800 CAN- transmit register / no fault symptom
36 B909 CAN bus / device error
37 BA04 EBC1-message / no signal
38 BB00 CAN acknowledge / no fault symptom
39 BC04 EEC1-message / no signal
40 BD04 TCO1-message / no signal
41 BF04 CCVS-message / no signal
42 C004 ERC1-message / no signal
43 C104 ETC1-message / no signal
44 C304 ETP-message / no signal
45 C404 ERC1-message / no signal
46 C504 TSC1-message / no signal
47 C604 TIME/DATE-message / no signal
48 C704 HIGH RESOLUTION VEHICLE DISTANCE / no signal
49 C904 ABS-message / no signal
50 CA04 FMR1-message / no signal
51 CC04 FMR2-message / no signal
52 CD04 EPS-message / no signal
53 D004 DR_BC-message / no signal
RETARDER ECU
COMPONENTS EA4374D3
[ Retarder ECU ]
Luggage room(Left side)
1. ABS/ASR ECU
2. RETARDER ECU
3. BWS(Back warning system) unit
4. ECU Cover
SPYBR7197L
CONNECTOR TERMINAL E518F52F
Terminal Signal function

1 Battery Output(+) Accumulator charge valve operating power 24V
2 Battery Output(+) Stop lamp relay operating power
3 Battery(-) Proportional valve ECU ground
4 Battery Output(+) Proportional valve(+) output
5 Not use
6 Not use
7 Not use
8 Speed sensor Speed sensor signal input
Coolant temperature
9 Coolant temperature sensor input
sensor
10 Not use
11 Not use
12 Not use
13 Not use
14 Hi-scan K terminal
15 BREMSOMATIC Speed cruise
16 Switch terminal Retarder level 1 switch
18 Not use
19 Not use
20 Not use
21 Not use
22 CAN terminal CAN-H
23 Not use
24 -
25 Not use
26 Not use
27 ECU ground
28 ECU ground
29 Battery(+) Retarder operating lamp
30 Not use
31 Battery(+) Key On
32 Not use
33 Not use
34 Battery(-) Accumulator charge valve
35 Not use
36 Not use
Terminal Signal function

37 Temperature sensor(-) Coolant temperature sensor input
38 Not use
39 Not use
40 Not use
41 L-terminal
46 ABS ECU(-) DBR operating signal input
47 Signal Accelerator switch signal
48 -
49 CAN terminal CAN-H
50 -
51 -
52 Not use
54 Battery(+) Power
55 Battery(+) Power
56 Not use
57 Not use
RETARDER SYSTEM
COMPONENTS E071D9EA
1
6
34.3~49
(3.5~5.0, 25.5~36.4)
4
3
1. Oil reservoir
2. Pump
3. Pipe
4. Heat exchanger
5. Radiator
6. Manual transmission
SPYBR7198L
DISASSEMBLY ECCF4B54 3. Check O-ring on filter cover for damage and replace
and grease.
1. Unscrew plug(A) from oil filter housing cover.
4. Securely attach solenoid(B) to the new filter(A).
A B
A
SPYBR7046D
SPYBR7048D
2. Remover cover and pull filter out of filer housing.

5. When using new filter,grease the O-ring.
CAUTION 6. Insert new filter in filter housing.
Beware of escaping oil.Catch escaping oil in suit-
able container. 7. Use screws to fit cover.
SPYBR7047D
REMOVAL OF RETARDER FROM MAIN

TRANSMISSION.
46 Nm (5kgf·m)
8 50 Nm (5.5kgf·m)
9 50 Nm (5.5kgf·m)
12 50 Nm (5.5kgf·m) 1
2
10 50 Nm (5.5kgf·m) 3
11 4
5
6
7
B 14 13
50 Nm (5.5kgf·m)
19
18
20
A
C
17
50 Nm (5.5kgf·m)
15 50 Nm (5.5kgf·m)
16
50 Nm (5.5kgf·m)
1. Retaining plate 9. Hex screw 16. Hex screw

2. Hex screw 10. Hex scrw 17. Hex screw
3. Washer 11. Hex screw 18. Shim (thickness 1.6 to 0.9 mm, 0.1 mm steps)
4. O-ring (68x4) 12. Hex screw 19. Shim (thickness 0.6, 0.5, 0.4, 0.3, 0.2 mm)
5. Output flange 13. Hex screw (M10x215) 20. Gasket
6. Ring 14. Hex screw for cardan shaft A = Sealing face of retarder housing
7. Shaft seal 15. *Hex scrw B = Contact face for output shaft ball bearing
8. Hex screw (M10x35 / 8.8) (head with bore for wire retainer) C = Contact face for stator
SPYBR7199L
1. Release output flange (5), remove shim (3) and O-ring 3. Remove hex screws (8, 9, 10, 11, 12, 13, 15, 16 and
(4), extract flange with two-leg puller. 17) from retarder, remove retarder.
2. Remove ring (6) or, instead of ring (6), remove ring 4. Remove gasket (20) and shims (18 and 19).
gear (not shown in drawing) from output flange.
CAUTION
In the following procedure, the retarder becomes
free and may fall.
Secure retarder to prevent it from falling.
OIL PUMP REMOVAL
8 2.5kgf•m
9 2.5kgf•m
6
5
4
3
2
10
1
11
11
1. O-ring 7. Pump housing

2. Ring gear 8. Hex screw, (x4) (M8x80) TT = 23Nm
3. Shaft 9. Hex screw, (x1) (M8x30) TT = 23Nm
4. V-ring 10. Dowel pins (x2)
5. Needle sleeve 11. Mark on ring gear (ease of assembly)
6. O-ring
SPYBR7200L
1. Unscrew and remove screws (8 and 9).
2. Remove pump, pressing off with pry lever if necessary

until dowel pin (10) comes free.
3. Remove O-rings (1 and 6) from control unit housing.
4. Remove shaft (3) and ring gear (2) from pump hous-
ing.
Check the following :

No scoring permitted on ring gear, shaft and ring gear
bore in housing.
Check that pump pinion (3) is firmly located on shaft.
CONTROL UNIT HOUSING AND VALVE REMOVAL
1.1 2.1 9
2 7.2 7.3
2.2 7
1 2.3
2.4 5 6 7.1
1.2 2.5
3.1 3 17
1.3 2.2
3.3
4
8.3 8.2 8
8.1
16 10.3 10
11.5 10.2
14 11.4 10.1
16.1 11.3
16.2 11 11.2
11.1
16.3 12
15.3 13
15.2
15.1
16
15
16.3
16.2
16.1
SPYBR7201L
8 3
10 2
11
1
SPYBR7202L
1. Cooler changeover valve 9 = Hex screw (M10)

1.1 Screw plug (M48) with seal 10 = Pressure valve
1.2 Compression spring, e.g. 0732 042 402 10.1 = Screw plug (M30x1.5)
1.3 Piston 10.2 = Compression spring.
10.3 = Piston
2. Pressure relief valve (12 bar) 11 = Control valve
2.1 Screw plug (M26) with seal 11.1 = Sealing cover
2.2 Piston 11.2 = Adjusting screw
2.3 Compression spring, e.g. 0732 042 470 11.3 = Piston
Compression spring, e.g. 0732 042 471 11.4 = Compression spring
2.5 Piston 11.5 = Piston
12 = Hex screws
3 = Safety valve (14, 5 bar) 13 = Screw plug (M24x1.5) with seal
3.1 = Screw plug M12x1.5 with seal 14 = Screw plug (M24x1.5) with seal
3.2 = Compression spring. e.g. 0732 041 247 15 = Preload valve (1.5 bar)
3.3 = Ball 15.1 = Screw plug (1.5 bar) M26x1.5 with seal and
recess for compression spring.
4 = Screw plug M26 with seal 15.2 = Compression spring.
5 = Screw plug M12 (pump pressure) with seal 15.3 = Piston
6 = Screw plug M12 (control pressure) with seal 16 = Drain valve
7 = Cover 16.1 = Screw plug (M22x1.5) with seal
7.1 = Gasket 16.2 = Compression spring.
7.2 = Hex screw 16.3 = Piston
7.3 = Hex screw 17 = Needle sleeve and V-ring (for pump shaft).
8 = Proportional solenoid with control valve
8.1 = Cylindrical screw
8.2 = O-ring
8.3 = Piston (control valve)
SPYBR7203L
1. Remove retarder control unit.
2. Remove gasket (14).
NOTE
When removing the valves, ensure that the removed
pistons and piston guides are not damaged.
3. Remove the valves shown in this diagram.

Clean Loctite residue from thread on screw plugs and
threads for screw plugs.
CAUTION
Proportional solenoid (8) must not be subjected to
24V power source. Check solenoid using terminal
tester only.
Technical data - proportional solenoid (8)

Stroke 2 + 2 mm
Limit current 0.5A
Resistance at 20 C 25.0±6%Ω
Activation time 100 %
STATOR AND ROTOR REMOVAL
1
2
3
4
6
7
1= Retaining ring 6 = Rotor

2= Circlips 7 = Stator
3= Spindle (or press) 1X56 122 292 8 = Base plate or ring (ring 1X56 138 049 when
4= Pressing-out fixture 1X56 138 047 using press)
5= Pressure piece (in-house manufacture, 9 = Shaft seal
refer to tools, item 15)
SPYBR7204L
1. Release retaining ring (1) and remove (strike with When using a press, item 8 (ring) 1X56 138 049 must
chisel). be used.
If no baseplate is used, housing may become dis-
2. Remove circlips (2). torted or damaged.
3. Fit pressing-out fixture (4) with pressure piece (5). 5. Press out shaft with stator and rotor from housing.
4. Heat housing at points around circumference marked 6. Press out shaft seal (9) from housing.
with arrows to between 90 and 100 C using hot air
blower.
NOTE
When using fixture (4) with spindle (3), an appropriate
height of baseplate can be inserted instead of item8
(ring).
INPUT SPUR GEAR REMOVAL
12 2
11
3
4
5
6
7
10
1. Special hex screw 7. Ring (not fitted to all versions)

2. Shim 8. Rotor
3. Spur gear 9. Rectangular ring (piston ring)
4. Inner race of taper roller bearing 10. Baseplate or ring
5. Outer race of taper roller bearing 11. Three-leg puller
6. Stator 12. Pressure piece
SPYBR7205L
1. Clamp shaft in vice using soft chucks.
2. Remove hex screw (1) and shim (2).
3. Remove spur gear (3) using three-leg puller and pres-

sure piece.
STATOR REMOVAL
4
5
6
7
8
9
10
1. Three-leg puller 5. O-ring 9. Rectangular ring

2. Pressure piece 6. Stator 10. Ring (or baseplate)
3. Inner race of taper roller bearing 7. Ring (not fitted to all versions) 11. Impulse sensor
4. Stator housing pocket 8. Rotor
SPYBR7206L
1. Place rotor (8) on baseplate, remove stator using

three-leg puller.
2. Remove inner race of taper roller bearing.
3. Remove ring (7)
4. Remove O-ring (5) from stator.
5. Remove outer race of taper roller bearing from stator

(6)
6. Remove rectangular rings (9) from rotor (8).
7. Remove impulse sensor (11).
Technical data - impulse sensor (11)

Operating voltage Ub max 6 -15V
Current intake max. 18 mA
Tightening torque 40 Nm
Air cap sensor/impulse wheel 1.4 mm
ZF operating voltage 8V
11
SPYBR7207L
REASSEMBLY E6A95D0A
6 1. Hex screw M12x80 Powerlock (95 Nm)

2. Shim
7 3. Spur gear
8 4. Inner race of taper roller bearing
5. Outer race of taper roller bearing
6. Stator
7. O-ring
9 8. Ring (not fitted to all versions)
9. Rectangular ring (piston ring)
10
10. Rotor
SPYBR7208L
STATOR AND ROTOR ASSEMBLY 7. Heat spur shim gear (3) to approx. 85 C place cor-
rectly on rotor.
NOTE
8. Fit shim (2).
Clean all parts. Lightly coat all moving parts with oil.
9. Screw in special hex screw (1), tighten provisionally.
1. Coat rectangular rings (9) with oil, insert in annular When cooled down, tighten to 95 Nm (10.4 kgf.m)
grooves of rotor.
10. Place O-ring (7) in stator and coat lightly using grease.
2. Heat stator bore for outer race of taper roller bearing
(5) to approx. 80 C, install outer race of bearing in
stator, facing in correct direction.
3. Slide ring (8) onto stator (6).
4. Place rotor on bench (end of shaft) as shown in dia-

gram.
5. Fit stator with ring onto rotor.
6. Heat inner race of taper roller bearing (4) to approx.

100 C, slide correctly onto rotor shaft (contact face for
inner race of taper roller bearing protrudes, i.e. inner
race of bearing faces rotor). Apply light coat of oil to
inner, race of taper roller bearing.
STATOR AND ROTOR INSTALLATION
1 5
6 7
2
4
8
1. Stator 5. Rotor
2. O-ring 6. Shaft seal
3. Rectangular ring (piston ring) 7. Plate (in-house manufacture, refer to tools, item 16)
4. Retarder housing 8. Centering disc (1X56 138 045)
SPYBR7209L
1. Apply light coat of oil to rectangular ring (piston ring) 5. Press shaft seal (depending on version) to correct
and align centrally. depth using suitable tool (refer to list of tools).
2. Fit centering disc (8) to retarder housing. 6. Screw 1.5 bar preload valve (refer to control unit),
spring, seal plug (with recess for spring) and seal into
3. Heat retarder housing (4) to approx. 90 to 100 C (in retarder housing.
heating chamber at 100 C for approx. 15 mins., if
possible)
NOTE
Ensure no scoring occurs inside housing when fitting.
4. Firmly install stator (1) and rotor (5) in retarder hous-

ing until tips of arrows on cam surface of retarder
housing and stator are precisely aligned with one an-
other. Maximum tolerance 1mm.
Using manual press lever, apply pressure to stator
and rotor for approx. 5 minutes until stator locates
firmly in housing recess.
NOTE
When correctly installed, stator must be located lower
than the groove on the Sealing face (corresponds to
plate (7) supporting face.
FITTING OF TAPER ROLLER BEARING TO ROTOR

AND TAPER ROLLER BEARING ADJUSTMENT
1
2
7
3
8
4
A
6 6
9
10
5
1. Retaining ring 8. Feeler gauge

2. Circlip 9. Spur gear
3. Adjusting fixture (1X56 138 046) 10. Rotor shaft
4. Inner race of taper roller bearing A= Gap [measure at spin torque 2 ± 0.5 Nm. (22±5 kgf·cm)
5. Ring (for assembly of item 4) (1X56 138 050) Taper roller bearing must have preload of 0.05 to 0.1 mm]
6. Baseplate
7. Tightening torque to spin point [2±0.5 Nm (22±5 kgf·cm)]
SPYBR7210L
1. Fit retarder and spur gear to ring 1X56 138 050 as 6. Using feeler gauge (8), measure gap "A" and note
shown in diagram. dimension.
Circlip is supplied in 0.05 mm grades from 2.9 to 3.7
2. Heat inner race of taper roller bearing (4) to approx. mm
85 C, fit correctly on rotor shaft. Taper roller bearing must have pressure of 0.05 to
0.1 mm. This is assured if a circlip with thickness
3. Apply light coat of oil to inner race (4) of taper roller equivalent to gap "A" is fitted. At a spin torque of 2Nm,
bearing. circlip with next possible dimension can be installed.
4. Allow bearing to cool. Remove ring (5). Place Intarder 7. Fit retaining ring (1) and peen onto baseplate at 3
housing on baseplates (6). This enables spur gear (9) points (120 apart).
to rotate freely.
5. Fit adjusting fixture (3), preload inner race of taper

roller bearing until spin torque reaches 2±0.5 (22±5
kgf.cm)
VALVE ASSEMBLY AND FITTING OF CONTROL

UNIT HOUSING
1.1 2.1 9
2 7.2 7.3
2.2 7
1 2.3
2.4 5 6 7.1
1.2 2.5
3.1 3 17
1.3 2.2
3.3
4
8.3 8.2 8
8.1
16 10.3 10
11.5 10.2
14 11.4 10.1
16.1 11.3
16.2 11 11.2
11.1
16.3 12
15.3 13
15.2
15.1
16
15
16.3
16.2
16.1
35 2.7kgf.m
2.5kgf.m 47 36 2.7kgf.m
2.5kgf.m 46
8 3
37 2.7kgf.m
10 2
11kgf.m 45 38 7.8kgf.m
7.8kgf.m 44
39 7.8kgf.m 11
1
40
16.5kgf.m
42
SPYBR7211L
1. = Cooler changeover valve 9= Hex screw M10x215

1.1= Screw plug (M48) with seal 10 = Pressure valve
1.2 = Compression spring, e.g. 0732 042 402 10.1 = Screw plug (M30x1.5) with seal
1.3 = Piston 10.2 = Compression spring. e.g. 0732 042 348
10.3 = Piston
2. = Pressure relief valve (12 bar)
2.1= Screw plug (M26) with seal 11 = Control valve
2.2 = Piston 11.1 = Sealing cover
2.3 = Compression spring, e.g. 0732 042 470 11.2 = Adjusting screw
2.4 = Compression spring, e.g. 0732 042 471 11.3 = Piston
2.5 = Piston 11.4 = Compression spring
11.5 = Piston
3. = Safety valve (14.5 bar)
3.1 = Screw plug M12x1.5 with seal 12 = Hex screws
3.2 = Compression spring. e.g. 0732 041 247
3.3 = Ball 13 = Screw plug (M24x1.5) with seal
(entry to heat exchanger, oil temperature)
4. Screw plug M26 14 = Gasket (on sheet metal version, do not bend)
5. Screw plug M12 (pump pressure) with seal 15 = Preload valve (1.5 bar)
6. Screw plug M12 (control pressure) with seal 15.1 = Screw plug (1.5 bar) M26x1.5 with seal and
7. Cover recess for compression spring.
7.1 Gasket 15.2 = Compression spring. e.g. 0732 042 403
7.2 Hex screw 15.3 = Piston
7.3 Hex screw 16 = Drain valve (not on all versions)
8. Proportional solenoid with control valve 16.1 = Screw plug (M22x1.5) with seal
8.1 Cylindrical screw 16.2 = Compression spring. e.g. 0732 042 406
8.2 O-ring 16.3 = Piston
8.3 Piston (control valve) 17 = Needle sleeve and V-ring (for pump shaft).
(Install needle sleeve so that thick collar
faces pressing-in side)
Technical data proportional solenoid (8)

Stroke 2+2mm
Limit current 0.5A
Resistance at 20˚C 25.0 6%
Activation time 100%
SPYBR7212L
NOTE 2. Fit proportional solenoid (8) with O-ring (8.2) and pis-
ton (8.3).
Check compression springs against spring table.
Apply light coat of oil to moving parts. 3. Fit control unit with gasket (14).
Calibrate bores for valve pistons using calibration Tighten retaining screws to required torque.
mandrel
In all cases, check piston for ease of movement in
piston bore.
1. Install appropriate piston and compression springs in

control housing.
Apply light coat of Loctite 574 to seal plug threads and
screw in with new sealing ring. Tighten to required
torque.
MOUNTING BOLTS ON CONTROL HOUSING
Control housing Items 1 to 33
1 2
29
11
28
O1
33 12
27
30 13
32 7
26 14
25
31 6
8
9 10
24
23 5
15
22
21
O2 O2
O1
3 20 19 4 18 17 16
SPYBR7213L
Screw size Tightening torque

Item no.
O.D × pitch (mm) Nm (kgf.m)
2 M12 × 115 62 (6.8)
1, 3, 4 M2 × 120 62 (6.8)
5 M8 × 115 23 (2.5)
6, 7, 8, 9, 10 M8 × 30 23 (2.5)
11 M10 × 215 50 (5.5)
12, 13, 14, 15, 16, 17, 18, 19,
M8 × 80 23 (2.5)
20, 21, 22, 23, 24
25, 26, 27, 28, 29, 30, 31 M8 × 105 23 (2.5)
32, 33 M8 × 30 23 (2.5)
OIL PUMP REASSEMBLY AND MOUNTING
8 2.5kgf.m
9 2.5kgf.m
6
5
4
3
2
10 1. O-ring
2. Ring gear
1
3. Shaft with internal rotor
4. V-ring
5. Needle sleeve
11 6. O-ring
7. Pump housing
8. Hex screws. (x4)
11 9. Hex screw. (x1)
10. Dowel pins (x2)
11. Mark on ring gear
(for ease of assembly)
SPYBR7214L
NOTE
Apply light coat of oil to moving parts.
Once needle sleeve and V-ring have been removed
from pump housing or control unit housing, heat hous-
ing to approx. 40 C and install needle sleeve correctly
using tool 1X56 137 975 (thick collar facing press-
ing-on side).
Note that mark (dot) on ring gear (11) points upwards.
This ensures that the lug on the ring gear external
diameter points towards pump housing.
1. Install shaft (3) with internal rotor and ring gear (2) in
pump housing.
2. Install O-ring (6 and 1) in control unit housing.
3. Fit pump housing, avoiding damage to drive spigot on

shaft (3). Drive in dowel pins (10). Tighten screws to
required torque.
AXIAL PLAY MEASUREMENT (STATOR

AND GROOVED BALL BEARING ON MAIN
TRANSMISSION)
8
9
12 1
2
10 3
11 4
5
6
7
B 13
14
19
18
20
C
17
15
16
1. Retaining plate 18. Shim (thickness 1.6 to 0.9 mm. available in 0.1 mm steps)
2. Hex screw (depending on version) 19. Shim (thickness 0.6, 0.5, 0.4, 0.3, 0.2 mm)
3. Shim 20. Gasket
4. O-ring (68x4)
5. Output flange A = Sealing face of Intarder housing
6. Ring (ring or ring gear) B = Contact face for ball bearing on output shaft
7. Shaft seal (possibly already fitted) C = Gap between bearing and
8. Hex screw (M10x35/8.8) D = Gap between bearing and sealing face of basic housing
9. Hex screw GAP A - C e.g. 1.1 mm
10. Hex screw GAP A - B e.g. 10.5 mm
11. Hex screw Gap D e.g. 10.0 mm
12. Hex screw
13. *Hex screw (M10x215) TA = 50Nm Axial play :
14. Hex screw for universal shaft Axial play of stator must be 0 ± 0.05 mm
15. *Hex screw (head with bore for wire retainer Axial play of output flange bearing must be 0 to 0.1 mm.
to secure with impulse sensor)
16. Hex screw
17. Hex screw
SPYBR7215L
A A
C B
D = Gap between sealing face of basic transmission A-C = Gap between sealing face of Intarder housing and face
and face end of grooved ball bearing. end of stator must be 0 ± 0.05 mm
A-B = Gap between sealing face of Intarder housing E = Impulse gear
and face end of grooved ball bearing - must be
0 to 0.1 mm larger than dimension “D”
SPYBR7216L
NOTE thickness of steel plate gasket without corrugated

strip must be added to dimension "A"-"B")."A"-"B".
Various versions of the gasket between Intarder and Measure dimension "D" from outer race of ball
main transmission are in circulation. bearing to sealing face of main transmission, note
dimension, e.g. 10.0 mm
1. Paper gasket.
2. Paper gasket and gasket bead.
3. Steel plate gasket (with corrugated strip).

When measuring this part, do not include gasket bead
or corrugated strip.
When being measured, the paper gaskets are placed
on the Intarder housing. The steel plate gasket is
measured separately.
SPYBR7217L
4. Measure shim (19)

Shim must have play of 0 to 0.1 mm
Measure dimension "A"-"B" from sealing face (A) with
paper gasket fitted to contact face (B), note dimension
e.g. 10.5 mm
(On version with steel plate gasket, dimension "A"-"B"
is thinner by the thickness of the gasket. In this case,
INSTALLATION EC4B7646 10. Screw in impulse sensor, tightening torque 40Nm.

(4.4kgf.m)
1. Measure shim (18). Shim must be adjusted to 0.05
mm pressure and 0.05 mm play. Technical data - impulse sensor (11)
Measure dimension "A"-"C" from sealing face (A) with
Operating voltage Ub max 6 - 15V
fitted paper gasket to contact face (C), note dimen-
sion, e.g. 1.1 mm. Current intake max. 18 mA
(On version with steel plate gasket, dimension "A"-"C" Tightening torque 40 Nm (4.4 kgf.m)
is thinner by the thickness of the gasket. In this case,
the thickness of the steel plate gasket without corru- Air gap between
1.4 mm
gated strip must be added to dimension "A"-"C". sensor/impulse gear
ZF operating voltage 8V
SPYBR7218L
2. Attach corrected shims (18 and 19) to contact faces

"C" and "B" with grease.
3. Fit gasket (20) to basic transmission. On version

with gasket bead or corrugated strip, raised portion of
bead (corrugated strip) points towards Intarder hous-
ing.
Secure the gasket by inserting as many hex screws as 11
possible to the basic transmission and by screwing in
SPYBR7219L
long enough stud bolts. Fit stud bolts at the points
where through bores exist on the Intarder housing.
The stud bolts also serve as dowels when fitting the
Intarder.
4. Carefully fit Intarder to basic transmission and screw

down. Note tightening torques.
5. Slide ring (6) onto output flange.
6. Correctly install retaining screws for cardan shaft in

output flange.
(screws cannot be inserted when flange is fitted).
7. Fit output flange (5) without heating.
8. Fit O-ring (4) and shim (3).
9. Screw in hex screws (2), tighten to correct torque

and secure with retaining plate (1) using tool (refer to
transmission).
FITTING OF RESERVOIR AND TEMPERATURE FITTING OF SOLENOID VALVE TO RESERVOIR

SENSOR TO HEAT EXCHANGER
1. Slide retaining screw (2) into solenoid valve.
1. Install O-ring (3) in annular groove of reservoir. Install O-ring (4) in groove. Fit solenoid valve.
Fit reservoir to heat exchanger. Tightening torque for screws (2) is 23Nm (2.5 kgf.m)
1
Technical data - solenoid valve
2 Operating voltage 24V
3
Coil resistance Approx. 55.6 Ω (23 C)
4 5
2 3
SGVBR7217D
2. Screw temperature sensor (1) into heat exchanger,

tighten.
Max. tightening torque 40 Nm (4.4 kgf.m)
4
Technical data - Temperature sensor SGVBR7222D
at 20 C approx. 50000Ω
SGVBR7218D

Anti-Lock Brake System / Accelera-Tion General

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Anti-Lock Brake System / Accelera-Tion General

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BRAKE SYSTEM

GENERAL ANTI-LOCK BRAKE SYSTEM / ACCELERA-

Symptom Probable cause Remedy

Symptom Probable cause Remedy

Symptom Probable cause Remedy

Symptom Probable cause Remedy

Symptom Probable cause Remedy

Symptom Probable cause Remedy

The causes of each symptom are listed with the most

Symptom detected by driver when driving Faults detected in workshop

SYMPTOM DETECTED BY DRIVER WHEN DRIVING

Fault detected Checks Action

Fault detected Checks Action

Fault detected Checks Action

Fault detected Checks Action

Fault detected Checks Action

5. Long response time

Fault detected Checks Action

6. Abnormal performance (Faults detected in workshop)

Fault detected Checks Action

Fault detected Checks Action

8. Uneven wear between brake pads on same axle

Fault detected Checks Action

9. Unevenly worn or skew worn brake pads

Fault detected Checks Action

FULL AIR BRAKE SYSTEM

GENERAL DIAGNOSTICS AND

Before working on or around air braking systems and de-

1. Stop the engine before working under a vehicle.

2. Always chock the wheels because depleting vehicle

3. Never connect or disconnect a hose or line containing

4. Never exceed recommended air pressure and always

5. Never attempt to dismantle a device until you have

6. Before you begin testing the air braking system, per-

Service Intervals Service Note

REPLACEMENT EBD9051E FITTING THE CARTRIDGE

2. Remove O-ring (1). 4. Remove heater assembly (1).

7. Refit the electrical connector and hand tighten the

2. Locate silencer assembly (C) over its spigot on the SPYBR7006L

base of the air processing unit.

4. Unscrew and remove the three M12 mountings.

5. Remove the air processing unit and cover the ports to

REMOVAL OF THE OIL SEPARATOR UNIT FITTING THE OIL SEPARATOR

8. Screw desiccant cartridge (A) up to stop.

6. Pull the oil separator unit (1) completely clear of the

DISASSEMBLING THE PURGE VALVE ASSEMBLING THE PURGE VALVE

6. Choose the appropriate cover (6).

7. Lubricate O-ring (5) with grease Molykote M and fit

8. Place the assembled cover (6) into the housing and

DUAL BRAKE VALVE

1. Cover plate 17. Ring piston 33. Pivot pin

* Pedal angle (A): 40 2

1. Park the vehicle at the flat road.

2. Remove the battery (-) cable.

3. Disconnect the connector below the gradual valve.

4. Remove the gradual valve with loosening the brake

5. The installation is the reverse of removal.

A: Driving condition(Lever stroke 0 )

Port 1: Air supply line