Trucks - Chassis and Active Safety Air Brake Systems - Go Trainer Document

Global Training – The finest automotive learning
Trucks • Chassis and Active Safety

Air Brake Systems • Go
Trainer Document
NLDB-LL246
Issue date 10.2.2011
This document is intended for use in the training only. Performed exercises cannot simply be implemented in practice.
Country-specific laws, regulations and specifications must always be observed.
The training documents are not subject to the ongoing update service. For work at the vehicle, the most up-to-date
workshop aids (e.g. EPC net, WIS net, DAS, special tool) of the manufacturer for the affected vehicle must be used.
Printed in Germany
© 2011 Copyright Daimler AG
Publisher: Global Training
This document, including all its parts, is protected under the laws of copyright. Any further processing or use requires
the previous written consent of Daimler AG. This applies in particular to reproduction, distribution, alteration, translation,
microfilming and storage and/or processing in electronic systems, including databases and online services.
Note: The term "employee" always refers to both female and male members of staff.
1511 8650 - 1st edition 10.2.2011 160

Contents
Contents
1 Orientation .................................................................................................................1
Instructions..................................................................................................................................... 1
1.1 Welcome............................................................................................................................... 2
1.2 Organization and general rules ............................................................................................. 2
1.3 Learning objectives............................................................................................................... 2
2 Legal provisions .........................................................................................................4

Instructions..................................................................................................................................... 4
2.1 Controls + brake circuits ...................................................................................................... 5
2.2 Types of brake system.......................................................................................................... 6
3 Standardization and symbols .....................................................................................7

Instructions..................................................................................................................................... 7
3.1 Brake systems in function schematics.................................................................................. 8
3.2 Symbols................................................................................................................................ 9
3.3 Using function schematics.................................................................................................. 13
4 Components for compressed air production (DE)....................................................17

Instructions................................................................................................................................... 17
4.1 Compressor ........................................................................................................................ 18
4.2 Pressure regulator .............................................................................................................. 20
4.3 Pressure regulator (10 bar), sales code BC3 ...................................................................... 22
4.4 Compressed air drier .......................................................................................................... 23
5 Practical work 1 .......................................................................................................27

Instructions................................................................................................................................... 27
5.1 Test compressor ................................................................................................................. 28
5.2 Check and adjust pressure regulator.................................................................................. 29
5.3 Test compressed air drier ................................................................................................... 30
6 Components of the compressed air system ............................................................31

Instructions................................................................................................................................... 31
6.1 Overflow valves................................................................................................................... 32
6.2 Relay valve.......................................................................................................................... 36
7 Components for pressure retention (DS) .................................................................38

Instructions................................................................................................................................... 38
7.1 Four-circuit protection valve - Introduction......................................................................... 39
7.2 Four-circuit protection valves as per ECE 13/9.................................................................. 40
NLDB-LL246 <> Trainer document I

Contents
8 Practical work 2 .......................................................................................................43

Instructions .................................................................................................................................. 43
8.1 Test of four-circuit protection valve.................................................................................... 44
8.2 Test pressure limitation in four-circuit protection valve...................................................... 46
9 Read function schematics - 1...................................................................................47

Instructions .................................................................................................................................. 47
9.1 Read function schematics (DE+DS).................................................................................... 48
10 Components of the service brake system (BBA) ......................................................50

Instructions .................................................................................................................................. 50
10.1 System design of service brake system ............................................................................. 54
10.2 Confusion during repair of the service brake system ......................................................... 56
10.3 Service brake valve ............................................................................................................ 58
10.4 Pressure ratio valve with retardation.................................................................................. 60
10.5 Brake force regulator.......................................................................................................... 62
10.6 Trailer control valve ............................................................................................................ 65
11 Practical work 3 .......................................................................................................68

Instructions .................................................................................................................................. 68
11.1 Test components of service brake system ......................................................................... 69
12 Braking effect...........................................................................................................73
Instructions .................................................................................................................................. 73
12.1 Terms related to braking effect .......................................................................................... 74
12.2 Measurement method ........................................................................................................ 75
12.3 Deceleration....................................................................................................................... 76
12.4 Braking ratio in %................................................................................................................ 78
12.5 Extrapolation of brake forces ............................................................................................. 80
13 Practical work 4 .......................................................................................................81

Instructions .................................................................................................................................. 81
13.1 Determine and evaluate braking effect............................................................................... 82
13.2 Friction value of brake test stand ....................................................................................... 88
13.3 Test condensation sensor .................................................................................................. 89
14 Read function schematics - 2...................................................................................90

Instructions .................................................................................................................................. 90
14.1 Read function schematics (BBA) ........................................................................................ 91
15 Braking effect of tractor vehicles and trailers ..........................................................92

Instructions .................................................................................................................................. 92
15.1 Complaints due to insufficient harmonization of tractor/trailer combination..................... 93
II NLDB-LL246 <> Trainer document

Contents
15.2 Evaluation possibilities ....................................................................................................... 96

15.3 Evaluation and adjustment options..................................................................................... 99
15.4 Practical examples............................................................................................................ 104
16 Parking brake .........................................................................................................106

Instructions................................................................................................................................. 106
16.1 Parking brake valves......................................................................................................... 107
16.2 Combination brake cylinder with integrated ventilation valve........................................... 112
17 Antilock brake system............................................................................................113

Instructions................................................................................................................................. 113
17.1 Introduction to ABS (anti-lock braking system)................................................................. 114
17.2 Control loop + control cycle.............................................................................................. 116
17.3 Types of control ................................................................................................................ 118
17.4 Control channels............................................................................................................... 120
17.5 Other functions................................................................................................................. 121
17.6 Electronic brake force limitation....................................................................................... 122
18 Acceleration skid control (ASR) .............................................................................123

Instructions................................................................................................................................. 123
18.1 ASR components and function ......................................................................................... 124
19 Special functions....................................................................................................125
Instructions................................................................................................................................. 125
19.1 Overload protection .......................................................................................................... 126
19.2 Frequent-stop brake ......................................................................................................... 129
20 Practical work 6 .....................................................................................................130

Instructions................................................................................................................................. 130
20.1 Adjustment possibilities as part of truck/trailer balancing............................................... 132
20.2 Practical work on the ABS ................................................................................................ 134
21 Practical work 7 .....................................................................................................138

Instructions................................................................................................................................. 138
NLDB-LL246 - Trainer preparation...............................................................................139

Daily overview............................................................................................................................. 139
Preparation table ........................................................................................................................ 152
NLDB-LL246 <> Trainer document III

1 Orientation
0 Instructions
1 Orientation
Instructions
Total time ...........................................................................................................................40 min
1.1 Welcome
Welcome from the trainer
5 min
1.2 Organization and general rules

Organizational procedures (participant list, parking...), general decisions on training
procedure, introductions
30 min
1.3 Learning objectives
The participant can understand the learning objectives of the NLDB training.
Learning objectives of NLDB training course
“Learning path” on metaplan board 5 min
Presentation of day's schedule:

Suggestion for introducing learning objectives. Visualize the training agenda (learning
objectives and chapters) as a training roadmap on a metaplan board. The chapters are
written down on metaplan cards and follow the “course of a road”. This allows the
participants to gain an overview of their training progress. If no metaplan board is
available, the training procedure may instead be presented on a flip chart.
TT_00_00_007326_FA
Marking of content relevant for the final test

The content relevant for the final test is identified with the following symbol:
@Test
NLDB-LL246 <> Trainer document 1

1 Orientation
1.1 Welcome
1 Orientation (participants)
1.1 Welcome
Welcome to the NLDB - Air Brake Systems training course.
In this training course, you will learn about the air brake system. You will have, no doubt,
already worked on the brake system and will already have some knowledge about it. Apply your
experience to the training actively and extend your practical knowledge through discussions
with colleagues. You should be aiming to become a brake specialist at your service operation!
This is because air brake systems can cause complicated problems even through simple faults.
You do not need us to tell you that only a satisfied customer comes back happily, confident in
the fact that a professional with in-depth system expertise is working on his or her vehicle.
Products of MB-Trucks TT_00_10_001407_FA
The trainer team from Global Training wishes you a fun and interesting course.
1.2 Organization and general rules

The training day begins at 8:15 and finishes at 16:15.
Training agreements:
 We make a punctual start after breaks
 Mobile phones set to “silent” or “off”
 We do not discuss things “on the side” when the group is together

After the training course you will be able to:
 Describe the legal requirements applicable to the controls and the brake circuits of a brake
system.
 Classify the different types of brake systems
 Explain the standardized symbols used in function schematics
 Explain the function of the switchable compressor
 Describe the function of the pressure regulator
2 NLDB-LL246 <> Trainer document

1 Orientation
 Describe the function of compressed air driers and recognize sources of faults on them
 Describe the function of different types of overflow valves
 Describe the function of a relay valve
 Describe the tasks and functions of four-circuit protection valves
 Check and adjust the pressure production and pressure retaining components for proper
operation in accordance with manufacturer specifications
 State the usual variants of brake system design
 Describe the tasks and functions of the service brake components e.g. service brake valve,
trailer control valve …
 Read and use function schematics
 Perform function tests on service brake system components
 Name the measuring method for determining braking effect
 Determine and evaluate braking effect in practice
In this training course, a vehicle identification number is needed for some exercises.
The reference vehicle is an Axor 1829 K 4x4. The vehicle identification number is
WDB 952 563 1L 423 884.
Axor reference vehicle TT_00_00_009902_FA

2 Legal provisions
0 Instructions
2 Legal provisions
Instructions
Total time ...........................................................................................................................20 min
2.1 Controls + brake circuits
The participant can state the legal requirements applicable to the controls of a brake
system. The participant can describe the legal requirements applicable to brake circuits.
Legal requirements for controls and brake circuits
Interactive lecture 5 min
2.2 Types of brake system
The participant can name the different types of brake systems.

The participant can name an example/the associated components of every type of brake
system.
Types of brake system: service brake system, secondary brake system, permanent brake
system, parking brake system
Exercise, exhibition with pictures of 15 min
components (e.g. Telma) and copies
from specialist books
The trainer must provide the participants with a sufficient quantity of suitable information
material/media:
e.g. Tabellenbuch Kraftfahrzeugtechnik (Automotive Technical Data Manual), Europa-
Lehrmittel, ISBN-No.: 3-9095-2125-2 or Fachkunde Kraftfahrzeugtechnik (Automotive
Engineering Expertise), Europa Lehrmittel, ISBN-No.: 3-8085-2238-0.
The participant can obtain the information required to achieve the learning objective from
these. Materials of this type are stored as files in a folder for learning sequence 1 in
accordance with the concept.
Different media in other languages can be produced during country-specific adaptation.

2 Legal provisions
2 Legal requirements (participants)

Brake systems are subject to certain regulations stipulating the design or effect, which are
listed in the EU directive. Vehicle manufacturers must build brake systems according to these
requirements.
Brake system control devices

Vehicles must have two independent brake systems or one brake system with two independent
control devices, each one able to continue to function if the other fails. The independent control
devices must act on different braking surfaces via separate transfer methods, which can be in
or on the same brake drum/brake disk.
Brake circuits
If the brake force is created by controlling accumulated energy, there must be at least two
completely independent energy reservoirs, each with its own independent transfer device. Each
energy reservoir must have a warning device. If more than two wheels can be braked, the brake
circuits must be distributed in such a way that at least two wheels can be braked that are not
on the same side of the vehicle.
@Test: exercise 3, version I + III

2 Legal provisions

Exercise 1 Complete the following exercises in groups.
a) First determine the classification of the statutory brake systems using the media provided.
Present the classification on a presentation medium such as a metaplan board.
 Service brake system (BBA)

 Secondary brake system (HBA)
 Parking brake system (PBS)
 Permanent brake system (DBA)
b) What is the task of the respective brake systems in a motor vehicle? Add this information to
the classification you produced.
 Service brake system: It must be possible to brake the vehicle to a

standstill in all operating conditions using the service brake system.
 Secondary brake system (HBA): A mean full deceleration of 2.2 m/s²
must be reached with the secondary brake, even if the control device is
used for other braking functions as well.
 Parking brake system (FBA): The parking brake system must be able to
hold the vehicle even on uphill and downhill slopes (18 %).
 Permanent brake system (DBA): The permanent brake system can be
used to generate and maintain a braking effect over a long period of
time without a noticeable power loss.
c) Add the components and systems which you are familiar with to the listed brake systems.
 Service brake system: service brake valve, relay valve, ALB valve, brake
cylinder
 Secondary brake system (HBA): secondary brake valve
 Parking brake system (FBA): parking brake valve, relay valve, spring
brake cylinder
 Permanent brake system (DBA): constant throttle, engine brake and
exhaust flap, eddy current brake, retarder

3 Standardization and symbols
0 Instructions

Instructions
Total time ...........................................................................................................................30 min
3.1 Brake systems in function schematics
The participant can identify the individual types of brake systems in function schematics.
Transition from “Types of brake system” exercise to reading of function schematics.
Task, exercise 5 min
3.2 Symbols
The participant can explain the connection designations and standardized symbols used in
function schematics.
Symbols in pneumatic function schematics
Assignment exercises 15 min
The trainer CD or DVD contains a poster template for this learning module. The posters
are hung up in the training room and the trainer will have written the solutions (see TR
document) on metaplan cards in advance. In group work, the participants assign the terms
to the symbols and present their results. Finally, the result can be transferred to the
participants' documents. The advantage of this method is that the symbols remain on
visual display in the training room throughout the entire training course. The participant
thus has an aid which can be used for reading function schematics during subsequent
exercises without the need for any further effort.
3.3 Using function schematics
The participant can explain other information on function schematics (e.g. grids,
references to other function schematics or circuit diagrams, legend).
Other information on function schematics

WIS (per group)

3 Standardization and symbols (participants)

Exercise 2 Complete the following exercise using function schematic PP42.30―W―2000―97AXA.
a) In which functional areas of the function schematic can you find the various brake systems
which you classified earlier?
Brake system Location on function schematic
Service brake system
Area BB... Areas 1A, 2A, AS
Secondary brake system
Area 1A
Parking brake system
Areas FB + 2A
Permanent brake system
Areas AK + KD

3.2 Symbols
3.2 Symbols
All function schematics are produced in accordance with Mercedes-Benz standard N31 010.
This standard governs the symbol and connection designations as well as basic symbols for
components.
When reading function schematics, note that they are drawn in the drive position!
Exercise 3 What are the meanings of the connection designation numbers on the components?
Connection designation Meaning
0
Intake connection
1
Energy supply
2
Energy outlet
3
Connection to atmosphere
4
Control connection
5
Unused
6
Electronic connection
7
Antifreeze agent connection
8
Lubricating oil connection (compressor)
9
Coolant connection (compressor)
22
Energy outlet, serial number 2
Exercise 4 In group work, assign the correct designation to the symbol. Then transfer your result to the
following table.
Symbol Designation or name
Work line
TT_4
Control line
TT_4
Hose
TT_42_60_009855_SW

3.2 Symbols
Electrical line
TT_42_60_009847_SW
Line connection
TT_4
Line crossing
TT_42_60_009852_SW
Lever
TT_42_60_009850_SW
Spring
TT_42_60_009848_SW
Muscular actuation, general

TT_42_60_009836_SW
Muscular actuation, rotational movement

TT_42_60_009837_SW
Muscular actuation, knob

TT_42_60_009851_SW
Muscular actuation, lever

TT_42_60_009842_SW
Muscular actuation, pedal

TT_42_60_009843_SW
Mechanical actuation, spring

TT_42_60_009841_SW
Mechanical actuation, button

TT_42_60_009844_SW

3.2 Symbols
Electrical actuation
TT_42_60_009840_SW
Pneumatic actuation through pressure rise

TT_42_60_009839_SW
Pneumatic actuation through pressure drop

TT_42_60_009838_SW
Detent
TT_42_60_009854_SW
Hydraulic pressure medium

TT_42_60_009845_SW
Pneumatic pressure medium

TT_42_60_009846_SW
Flow direction
TT_42_60_009857_SW
Blocked connection
TT_42_60_009849_SW
Outlet ventilation
TT_42_60_009834_SW
Assembly
TT_42_60_009835_SW
Exercise 5 Lines are shown in color on function schematics.
What is the meaning of the specified coding?

Colors and types of lines in Meaning
function schematics
Reservoir pressure
TT_42_60_009833_SW
Red

3.2 Symbols
Control pressure (reservoir pressure)
TT_42_60_009856_SW
Red
Brake pressure
TT_42_60_009833_SW
Yellow
Control pressure (brake pressure)
TT_42_60_009856_SW
Yellow
Air bellows pressure

TT_42_60_009833_SW
Blue
Control pressure (air bellows pressure)
TT_42_60_009856_SW
Blue
Electrical line
TT_42_60_009833_SW
Black


As you have already noticed, pneumatic function schematics are a useful tool. In addition to
the standardized symbols, there is further information which helps you to use them.
Exercise 6 Complete the following exercises using WIS. Use vehicle identification number
WDB 952 563 1L 423 884 for this example exercise.
a) Determine the matching function schematic for the specified vehicle identification number.
Note down your procedure and the document number.
 Enter vehicle identification number in upper field.

 In the Groups field, select Design group 42 Brakes - Hydraulic and
mechanical.
 Select information type (IA): Circuit diagrams and sub-item
Pneumatics.
 In the top window press button 2. Start search.
 The corresponding function schematic can be selected. If the vehicle-
specific equipment is required, the data card of the vehicle can be
displayed with F8.

b) In the overview of document titles, you were able to select a variety of documents. Now look
at the Validity field. Determine the missing sales codes and equipment in the table.
Sales code Equipment
B02 Brake system, antilock brake system (ABS)
B22
Parking brake for gross combination weight from 44 to 60t
No brake system (BS) with ABS and ASR
B92
No ABS
B95
B85
Brake system for England
B82
Brake system for Switzerland
B24
Frequent-stop brake with indicator lamp
B51
Independent trailer brake
B56
Coupling head at front for air replenishment
Front trailer brake connection
B55
Heated compressed air drier (single-chamber system)
B65
BB9
Pipe fracture protection
B43
2-line trailer brake (EC)
B62
Heated compressed air drier (dual-chamber system)

c) Now open the function schematic which you found. What do the following designations at the
bottom edge mean?
Designation Meaning
DE Compressed air production assembly
DS
Compressed air storage assembly
AK
Engine brake exhaust valve assembly
KD
Engine brake constant throttle assembly
DB
Pressure limitation assembly for vehicles with trailer
recognition
BB
Service brake system actuation assembly
FB
Parking brake system actuation assembly
1A
Assembly of 1st axle
2A
Assembly of 2nd axle
3A
Assembly of 3rd axle
4A
Assembly of 4th axle
AS
Trailer control assembly
A complete list of explanations can be found in WIS document

OV00.01-W-1001-29A Abbreviations for pneumatic diagrams.
d) The components of the compressed air system and brake system are identified with unique
component numbers. Enter the component designation for the specified component numbers.
Component Component
number
1.02
Dual compressor
4.05
4-circuit protection valve with integrated pressure
limitation
24.01
Pressure ratio valve with vent
18.05
Trailer control valve for 2-line brake

e) Consider function group FB on component 14.02 and the line to connection 22 found there.
What does the specification AS/18.05.43 mean?
This specification means that the marked line leads to assembly AS.
In assembly AS it leads to component 18.05. on connection 43.

4 Components for compressed air production (DE)
0 Instructions

Instructions
Total time ..........................................................................................................................55 min
4.1 Compressor
The participant can name the changes to the cylinder head through the use of
“AdvancedPowerReduction”.
APR cylinder head
Interactive lecture/exercise 10 min

Cylinder head of switchable
compressor for viewing
4.2 Pressure regulator
The participant can describe the function of the pressure regulator.

The participant can explain the function of the heater in the pressure regulator unit.
Function of pressure regulator
Exercise 10 min
4.3 Pressure regulator (10 bar), sales code BC3
The participant can name the differences in the compressed air system when the 10 bar
pressure regulator is used.
Pressure regulator in 10 bar pressure regulating system (10 bar)
Presentation 5 min
Function schematic
4.4 Compressed air drier
The participant can describe the function of the single-chamber and dual-chamber air drier.
The participant can identify sources of faults on the different compressed air driers.
Function of compressed air drier
Exercise 30 min

4.1 Compressor

(participants)
4.1 Compressor
The following work can be carried out to check the compressor for proper operation. Firstly,
the drive system can be checked. Furthermore, the line connections for oil, water and air
should not have any leaks. In addition, the delivery rate can also be checked.
APR compressor (Advanced Power Reduction)

As of the Euro 4 engines, a new cylinder head is used on the compressor. When the shutoff
pressure is attained in the compressed air system, the compressor can be “switched off” by
switching an additional valve (APR valve). This reduces the delivery rate to a large extent and
the fuel consumption can be lowered.
TT_13_10_005423_FA
TT_13_10_005424_FA
A Suction fitting C APR valve
B Pressure fitting D Residual gas connection

4.1 Compressor
Exercise 7 Complete the following exercises about the compressor.
a) Draw the symbol for a switchable compressor.
b) Which of the following complaints could affect the filling time? Mark the correct answers with
an “X”.
Answer Number Complaint
1 The V-belt of the compressor drive is making noises (screeches).
X
2 The pressure use during brake application is too high due to
improper brake adjustment.
3 The compressed air system has considerable air loss due to leaks.
X
4 Compressed air reservoirs contain a significant amount of water
X (are not drained).
5 Oil ejection is noticeable at the pressure regulator ventilation.
6 The pressure line connection at the compressor cylinder head is not

X leaktight, air blows by.
7 The pressure line to the pressure regulator is clogged with oil carbon
X (line cross section too narrow).
8 Parts of the compressed air system are not filled, perhaps because
an overflow valve is defective.
9 Valve plate in the compressor is defective.
X
10 The cooling system of the engine is losing water, coolant
X occasionally presses out of the pressure relief valve.
11 APR valve stuck or jammed.
X
c) Which of the complaints from the preceding exercise cause a longer or shorter filling time?
Enter the numbers on the lines.
Filling time Number
longer
1, 3, 6, 7, 9,11
shorter
4, 8


Note: The mode of operation of regeneration can and should be explained using the graphic in exercise f.
@Test: exercise 7, version I (refers to exercise f)
The pressure regulator is an important component of a compressed air system. The function
schematic once again supplies valuable information in this regard which can help you with
your daily work.
Exercise 8 For the exercises of this module, use function schematic PP42.30-W-2000-97AXA.
a) What is the component designation of the pressure regulator?
6.12
b) What pressure specification is specified on the component in the function schematic?
10.2 - 12.3 bar
c) What does this specification mean?
 10.2 bar is the cut-in pressure

 12.3 bar is the shutoff pressure
d) What is the task of the integrated assembly with the electrical line (bottom left)?
This illustrates the heater of the pressure regulator. It is intended to

prevent the pressure regulating valve from freezing at low temperatures
and thus protect against consequential damage in or on the compressed
air system.
e) To which component is connection 4/25 on the pressure regulator connected?
On systems with switchable compressor, connection 4/25 is connected

to connection 4 in the cylinder head of the compressor.

f) Add the switch position of the valves at the shutoff pressure to the following graphic.
TT_42_60_009865_SH
11 Energy supply (from compressor) 23 Energy outlet (tire inflation connection)

Energy outlet (compressed air reservoir
12 Energy supply (external filling) 24
for constant pressure system)
Energy outlet (to four-circuit protection
21 3 Ventilation
valve)
Energy outlet (regeneration compressed
22
air reservoir)
g) What is the maximum pressure level in compressed air reservoir 5.01 at coordinate H 12?
When the pressure regulator is adjusted correctly, a maximum pressure

of 12.3 bar is possible. The reservoir in question is also designated the
constant pressure reservoir.


Implementation of the 10 bar pressure regulation system has necessitated a few
modifications to the brake system. One feature to recognize the 10 bar pressure regulation
system is the 4-circuit protection valve, which is clearly different from that of the 12 bar
compressed air system.
Summary of the changes:
 The pressure regulator switching range has been reduced (9.3 to 10 bar).
 Discontinuation of the 12 bar compressed air reservoir
 Use of another 4-circuit protection valve without 10 bar pressure regulator (The static and
dynamic retaining pressures did not change.)
 The design pressure has been reduced from 8.5 bar to 8 bar.
 ABS vehicles are fitted with larger brake cylinders.
 To adhere to the EU braking band, the characteristic of the trailer control valve has been
adapted.
 In vehicles without trailer connection, smaller, less expensive spring accumulators are
sufficient in certain cases.


Compressed air driers extract humidity from the air supplied by the compressor. This only
involves a relative extraction of humidity. This means: “The air dried by the air drier is not
absolutely dry”. In some circumstances, however, water may still be separated out.
Example:
At a relative air humidity of 100 % and an air temperature of 50°C, the proportion of water
vapor is approx. 90 g in 1 m³ of intake air. If the temperature of the intake air volume drops to
30°C, approx. 60 g of water is separated out. This is still 0.06 l of water.
Note:
To achieve a good level of efficiency, the inlet temperature of the compressed air flowing into
the compressed air drier should not exceed 65°C.
Exercise 9 Single-chamber air drier
After shutoff pressure is reached and the engine is stopped, there is continuous venting at the
ventilation opening of the single-chamber air drier. Use the graphic to find out what the
possible causes are.
Answer Answer number Cause
1 Cartridge not leaktight
2 Shutoff pressure set too high
3 Bypass valve defective
4 Check valve not leaktight

X
5 Drain valve not leaktight (upper rubber ring)
X
6 Granulate oiled up
7 Regeneration compressed air reservoir leaky

W42.60-1006-06 W_42_60_001006_SW
1 Granulate 4 Drain valve
2 Cartridge 5 Bypass valve
3 Check valve 6 Regeneration compressed air reservoir
Exercise 10 Dual-chamber air drier

@Test: exercise 9, version I + III
In vehicles with a high air consumption, a single-chamber air drier may reach the limits of its
capacity. Therefore, dual-chamber air driers are installed in these vehicles.

W_42_60_001166_FA
During filling, there is continuous venting at the ventilation opening of the compressed air
drier. What do you think could be the causes here? Make brief notes.
During the filling operation, regeneration air continuously escapes from

the desiccant cartridge which is not involved in the drying process at the
vent.
Exercise 11 What is the main difference between single and dual-chamber air driers?
Assign the air drier functions specified in the table by crossing them off.
Air drier functions Single- Dual-chamber
chamber air air drier
drier
During the filling phase (pressure regulator switched on), some
compressed air is constantly escaping at the ventilation X
opening.
When the pressure regulator switches off, a powerful pressure
surge escapes at the ventilation opening. X X

An additional compressed air reservoir is provided for the

regeneration of the cartridge(s). X
A powerful pressure surge escapes at the vent at regular
intervals of around 1.5 minutes when the system is being filled. X
Exercise 12 Moisture in compressed air reservoirs

In isolated cases, customer complaints have been received about vehicles with single-chamber
air driers. The cause of the complaint is believed to be a relatively low number of regeneration
cycles at the compressed air drier (long filling phase, shutoff pressure is hardly ever reached).
Careful tests for possible causes should therefore be performed in the event of a complaint.
Which of the following can be the cause of inadequate regeneration of the compressed air
drier?
Answer Number Cause
1 The air consumption at the trailer is very high.
X
2 The compressed air system is not leaktight, has a high air
X consumption (shutoff pressure is barely reached).
3 The output of the compressor is inadequate.
X
4 The pressure line from compressor to pressure regulator is
X not leaktight.
5 The pressure line from the compressor to the pressure
X regulator is clogged by carbon deposits.
6 The pressure line from the regeneration compressed air
X reservoir to the compressed air drier has a kink and is
clogged.
7 The pressure regulator is not adjusted correctly (shutoff
pressure too low).
8 The pressure regulator is defective, does not shut off at
X times.
9 The pressure regulator is not adjusted correctly (shutoff
X pressure too high).
10 For the compressed air reservoir of the air suspension, the
X vehicle has a high additional volume (additional compressed
air reservoir).

5 Practical work 1
0 Instructions
5 Practical work 1
Instructions
Overall duration..................................................................................................................50 min
5.1 Test compressor
The participant can perform work on the compressor in accordance with manufacturer
specifications.
Test operations on compressor (delivery time, oil loss)
Exercises 20 min
5.2 Check and adjust pressure regulator
The participant can check the operation of the pressure regulator and evaluate the result.
The participant can adjust the pressure regulator as per manufacturer specifications.
Testing and adjustment operations on pressure regulator
Exercises 15 min
WIS + compressed air gauge
5.3 Test compressed air drier
The participant can test the operation of the compressed air drier.
Test operation of compressed air drier.
Exercises 15 min

5 Practical work 1
5.1 Test compressor
5 Practical work 1 (participants)

5.1 Test compressor
Exercise 13 Which tests can you carry out on the compressor?
a) Note down the respective operation number from the work instructions for testing the vehicle
provided.
 Check compressor for oil loss

 Check filling time, main document BE13.00-Z-9999NZ.
b) Carry out the corresponding tests on the vehicle as per the work instructions.

5 Practical work 1

@Test: exercise 1, version I
Exercise 14 Which tests can you carry out on the pressure regulator?
provided.
AR42.60-W-0020A, Check/adjust pressure regulator shutoff pressure
b) Perform the corresponding test/adjustment on the vehicle as per the work instructions.

5 Practical work 1

Exercise 15 Which tests can you carry out on the compressed air drier?
provided.
AR42.60-W-0115A, Check single-chamber compressed air drier with

integrated pressure regulator for proper operation.
b) Carry out the corresponding test on the vehicle as per the work instructions.
c) To which points do you connect a compressed air gauge for the test?
 Regeneration compressed air reservoir

 Connection 23 on compressed air drier unit

6 Components of the compressed air system
0 Instructions

Instructions
Total time ...........................................................................................................................30 min
6.1 Overflow valves
The participant can name the different types of overflow valves. The participant can
describe the mode of operation of the different overflow valves.
Types and mode of operation of overflow valves

Overflow valve for viewing
6.2 relay valve
The participant can explain the function of a relay valve.

Mode of operation of a relay valve

Relay valve for viewing

6.1 Overflow valves
6 Components of the compressed air system (participants)

6.1 Overflow valves
Overflow valves are required if the compressed air supply in compressed air reservoirs is to be
protected against air loss (defects) in connected consumers. Overflow valves can also be used
for high-priority reservoirs or for supplying compressed air. To the extent the overflow valve is
used to retain pressure, the protection occurs at the pressure at which the valve opens
(opening pressure).
The following overflow valves are available:

 Without return flow (w/o R.)
 With return flow (w. R.)
 With limited return flow (lim. R.)
Overflow valves without return flow
N_42_10_002048_SW
1 Adjustment bolt
N_42_10_002080_SH
2 Spring
3 Diaphragm
4 Check valve
Use:
Overflow valves without return flow are installed in combination with ancillary consumers that must not influence each
other when pressure is consumed.
Operating method:
If the pressure at connection 1 reaches the opening pressure, compressed air passes via the check valve to
connection 2. If there is a pressure drop at connection 1, the check valve closes and safeguards the pressure.

6.1 Overflow valves
Overflow valves with return flow
N_42_10_002051_SW
1 Adjustment bolt
N_42_10_002079_SH
2 Spring
3 Diaphragm
4 Check valve
Use:
Overflow valves with return flow are mainly used if rapid operational availability is to be achieved with volumes
connected in series.
Operating method:
The compressed air reservoir connected to connection 1 is first topped up. Once the opening pressure has been
reached, the valve opens and now the other compressed air reservoir can be topped up via connection 2. When
pressure is consumed, the pressure can flow back from connection 2 to connection 1 via the check valve.
Overflow valves with limited return flow
N_42_10_002044_SW
1 Adjustment bolt
N_42_10_002043_SH 2 Spring
3 Piston
Use:
Overflow valves with limited return flow are used if the pressure of two pressure circuits or consumers has to be
safeguarded by each other.
Operating method:
At operating pressure, the valve is completely open. If the pressure at one of the two connections drops, a pressure
compensation occurs at both connections until the valve is closed. Both pressure circuits are then separated from one
another. In case of total pressure loss at connection 2 the pressure at connection 1 drops to the clamping pressure.

6.1 Overflow valves
Exercise 16 Complete the following exercises on overflow valves.
a) How can you check the function of the overflow valve?
Empty both pressure reservoirs. Connect pressure gauge to both

pressure reservoirs. With pressure rise at connection 2 the opening
pressure is attained. Empty pressure reservoir at connection 1.
Pressure in the pressure reservoir at connection 2 must also drop.
b) The opening pressure can be altered by means of adjustment bolt 1. What steps can be taken
to lower or increase the opening pressure?
Answer Number Statement
1 Screw in bolt = lower opening pressure
2 Screw in bolt = increase opening pressure

X
3 Unscrew bolt = increase opening pressure
4 Unscrew bolt = lower opening pressure

X

6.1 Overflow valves
c)
N_42_10_002045_SW
Aö Area for opening the valve 2 Diaphragm
As Area for closing the valve 3 Piston
1 Adjustment bolt
Compare the size of the areas in the graphic. Which pressure therefore has to be greater to
counteract the spring force?
1 Opening pressure in order to open the valve
X
2 Closing pressure in order to close the valve

6.2 Relay valve
6.2 Relay valve

The relay valve is an important component of an (air) brake system. The function is also
integrated into other components. As a result, it is important to understand the mode of
operation.
TT_42_60_009869_SH
Exercise 17 Complete the following exercises about the relay valve.
a) Enter the correct name for the specified connection designations.

Connection designation Designation
1
Inlet - energy supply
2
Outlet - energy outlet
4
Inlet - control line
b) What does the arrow in the schematic diagram mean?
The arrow represents the working piston.
c) What does the small triangle on the left-hand edge of the valve mean?
It is the vent.

6.2 Relay valve
d) The broken line is not physically installed on the valve. What does this line mean?
It is an inner control line. It works as a vibration damper by acting on the

working piston, thus preventing pressure peaks.
e) Imagine the following situation: red air is present at connection 1 and connection 4 uses blue
air for control. What is the color of the air at connection 2 when the valve is actuated?
Answer Number Color
1 Magenta
2 Blue
3 Red
X
4 White
f) Which pressure can you measure at connection 2 under the following conditions?
Requirements Measurement
Connection 1 Connection 4 Connection 2 exit pressure (bar)?
reservoir pressure control pressure
(bar) (bar)
4 1
1
8 1
1
4 4
4
8 8
8
2 4
2

7 Components for pressure retention (DS)
0 Instructions

Instructions
Overall duration ..................................................................................................................45 min
7.1 Four-circuit protection valve - Introduction
The participant can understand the design of the four-circuit protection valve. (The trainer
derives its mode of operation with an exercise covering a simple overflow valve through to
a simplified illustration of the four-circuit protection valve.)
Design of four-circuit protection valve
Interactive lecture, exercise 15 min
The trainer leads the group with an interactive lecture which starts off easy and becomes
more complicated:
 1) Question: What are the various types of overflow valves?
 2) Exercise: On an available medium (flip chart/whiteboard) draw the protection of an
air tank by means of overflow valve with limited return flow, including designations
 3) Draw three further overflow valves with limited return flow – as specified under 2) –
underneath the first one you drew.
 4) Provide a central air supply for the individual subassemblies.
 5) Draw a dash-dot line around the overflow valves. You now have a very simplified
multi-circuit protection valve.
 6) The functioning of the protection can now be explained. For example: a circuit is
defective; the other circuits also lose pressure up to the closing pressure of the
overflow valve at the defective circuit.
 7) After the aforementioned explanation the trainer can now add the ECE function
(bypass) to the drawing. The presentation on the trainer DVD can be used for support
here.
7.2 Four-circuit protection valves as per ECE 13/9
The participant can explain the special features of the design of four-circuit protection
valves as per ECE 13/9.
Special features of design of four-circuit protection valve as per ECE directive 13/9
30 min

7 Components for pressure retention (DS) (participants)

Terms related to overflow valves
Opening pressure: is the pressure at which an overflow valve opens when the system is
completely empty.
Example: Connection 1 is filled + connection 2 is unpressurized. Once pressure is registered at
connection 2, the opening pressure (measured at connection 1) is attained.
Closing pressure (static retention pressure): is the pressure at which an overflow valve closes
because of a leak and thereby secures the pressure.
Example: Connection 2 loses air; the pressure (measured at connection 1) at which the valve
closes is defined as the static retaining pressure.
Dynamic retention pressure: is the pressure at which an overflow valve closes despite
postdelivery because of a leak and thereby secures the pressure.
Example: The compressor is running and a leak occurs at connection 2. The valve will secure.
The postdelivery opens the valve, which closes again because of the leak. A valve dynamic
develops, which effects a lower pressure (compared with the static retaining pressure) at
connection 1.
Exercise 18 Complete the exercise set by the trainer and transfer the results to your documents at the end.


The main function of the four-circuit protection valve is to protect against the loss of
compressed air.
The regulations of ECE directive 13/09 annex 8 state: if the supply pressure in the service
brake circuits is no longer sufficient to provide a residual braking effect of 1.3 m/s2, it must not
be possible to release the parking brake. In other words:
in the event of a complete pressure loss in supply circuit 1 with the vehicle parked and the
parking brake applied, it must no longer be possible to release the parking brake.
This version of four-circuit protection valve has been installed in series production as of the
vehicle identification number with end number K 432590.
Exercise 19
N42.10-2024-01 N_42_10_002024_SH
How is a release of the PBS prevented in the valve shown above when supply circuit 1 has no
pressure? Write down details in keywords.
When air is lost from supply circuit V1 (connected to 21), air is released
from supply circuit V3 (connected to 23) via the integrated restrictor.

Exercise 20
N42.10-2025-01 N_42_10_002025_SH
How is a release of the PBS prevented in the valve shown above when supply circuit 1 has no
pressure? Write down details in keywords.
When the supply pressure at connection 21 has dropped to less than 4.5
bar, the integrated 3/2 way valve switches over and releases air from
compressed air reservoir V3 (connected to connection 23) via a bore in
the housing.
Exercise 21 @Test: exercise 5, version I
Assign the functions to the connections and mark the appropriate fields with an “X”. Use the
Workshop Information System (WIS) for support.
Functions Connections
21 22 23 24 25 26 27 28
The pressure limiter 10 ± 0.2 bar limits
the pressure at the connections ... X X
The pressure sensors p/U transmit the
pressure to the instrument cluster to X X
display the pressure at the
connections ...
The 8.5 - 0.4 bar pressure limiter limits
the pressure at the connections ... X X X X X X
The parking brake is protected at
connection ... against automatic X
application when the pressure drops at
the auxiliary consumer (NV).
The supply for the gearshift GS and the
clutch operating system KB is protected X
at connection ...

The pressure switch (cut-out) for the V3

supply pressure warning indicator is X
connected to ...
The pressure switch (cut-out) for the
supply pressure warning indicator for the X
auxiliary consumers is connected to ...

8 Practical work 2
0 Instructions
8 Practical work 2
Instructions
8.1 Test of four-circuit protection valve
The participant can test the four-circuit protection valve as per ECE 13/9 in accordance
with manufacturer specifications.
Test of four-circuit protection valve
Exercises 40 min
8.2 Test pressure limitation in four-circuit protection valve
The participant can test the operation of the pressure limiting valves in the four-circuit
protection valve.
Test pressure limiting function in four-circuit protection valve.
Exercises 20 min

8 Practical work 2

The test of the four-circuit protection valve for functional reliability must also be performed
during mandatory inspections. The specified protection pressures must be taken into account
here.
Four-circuit protection valve from “WABCO” Four-circuit protection valve from “KNORR”
N_42_10_002025_SH
N_42_10_002024_SH
Exercise 22 Test the pressure retention of the four-circuit protection valve on the vehicle provided.
a) Find out the document number of the work instructions for testing the pressure retention of
the four-circuit protection valve. Write it down.
AR42.60-W-0050B

8 Practical work 2
b) At which measuring points (test connections) do you connect the pressure gauges for testing
pressure retention?
Answer Number Measuring point
1 Connection 21 on four-circuit protection valve
X
X
X
5 At the spring accumulator combination cylinder
6 At the red coupling head only with trailer brake

X
7 Constant pressure supply
c) Determine the specified values for the retention pressures.

Static retention pressure of BBA circuits:
_____________________________________
Static retention pressure of compressed air supply circuits 3 + 4:
_____________________________________
d) Test the four-circuit protection valve and enter the pressures measured into the table!
Test or operation step Supply Supply Supply Supply
circuit 1 circuit 2 circuit 3 circuit 4
(bar) (bar) (bar) (bar)
Establish prerequisites 10 10 8.5 8.5
Check pressure retention of circuit 1
and 2
Check warning lamps
On: _____________ or Off: _____________
Check circuit 3 pressure retention
Check warning lamps

On: _____________ or Off: _____________
Check compressed air supply in
circuit 4
Check filling sequence
Four-circuit protection valve OK?

Yes: _____________ or No: _____________

8 Practical work 2

Exercise 23 Check the operating pressures on the four-circuit protection valve on the vehicle provided.
Complete the following exercises to do so.
a) Find out the document number of the work instructions for checking the operating pressures
of the four-circuit protection valve. Write it down.
AR42.60-W-0040B
b) At which measuring points (test connections) do you connect the pressure gauges for testing
operating pressures?
Answer Number Measuring point
1 Circuit 1 test connection
X

X
X
5 Tire inflation connection
X
6 At the red coupling head
7 Constant pressure supply

X
c) Determine the specified values for the operating pressures.

Operating pressure of service brake circuit 1 + 2:
_____________________________________ bar
Operating pressure of auxiliary consumer circuit 3 + 4:
_____________________________________ bar
d) Check the operating pressures as per the work instructions and note down the results in the
following table.
Operating pressure Measurement (bar)
Circuit 1
Circuit 2
Circuit 3
Circuit 4

9 Read function schematics - 1
0 Instructions

Instructions
9.1 Read function schematics (DE+DS)
The participant can read function schematics for the pressure production and pressure
retention sections (DE+DS).
Read function schematics
Exercise 30 min
Day-end closing
Any unresolved questions of participants about the content covered can be answered.
Content mentioned can be repeated to reinforce learning.
Clarification of unresolved questions + repetition of content
Discussion 15 min

9 Read function schematics - 1 (participants)

Exercise 24 Complete the following repeat exercises using the Workshop Information System and function
schematic PP42.30-W-2000-997AXA. The vehicle identification number of your reference
vehicle is WDB 952 563 1L 423 884.
Add the missing pressure values to the respective tables.
a) Conditions: Vehicle stationary, engine running, shutoff pressure reached.

Component number Measuring point or Coordinates of Measurement (bar)
testing point measuring point
6.12 Connection 23 D8
12.3
6.12 Connection 4/25 F5
12.3
5.01 K 11
0
38.02 H 15
10.0
38.02 C 16
8.5
38.02 C 15
10.0
b) Conditions: Vehicle stationary, engine off, shutoff pressure reached, major leak at
connection 1 of component 26.07.
0
0
5.01 K 11
0
38.02 H 15
more than 4.5
38.02 C 16
0
38.02 C 15
0

c) Conditions: Vehicle stationary, engine off, shutoff pressure reached, line torn off at
connection 12 of component 13.04.
0
0
5.01 K 11
0
38.02 H 15
0
38.02 C 16
more than 4.5
38.02 C 15
more than 4.5

10 Components of the service brake system (BBA)
0 Instructions

Instructions
Overall duration ............................................................................................................... 150 min
Introduction to day 2
The participant can explain what he/she learnt on the previous day.
Repetition of first day.
20 min
10.1 System design of service brake system
The participant can describe the two usual variants of system design. The participant can
name the components of the service brake system.
The participant can name the tasks of the service brake system components.
Design of brake system.
Exercise. One group works out each 40 min

design. When completed, the group
presents their solution to the others.
TT_42_10_009903_FA

0 Instructions
TT_42_10_009904_FA
TT_42_10_009905_FA

0 Instructions
TT_42_10_009906_FA
TT_42_10_009907_FA
After completion, the groups present their results and explain them. After this, the results
can be transferred to the participants' documents.
Note:
The tasks of the components can be transferred to the participants' documents in the
respective learning modules on the components.

0 Instructions
10.2 Confusion during repair of the service brake system
The participant can explain the consequences of a faulty repair of the service brake
system.
Dual-circuit functionality of brake system
Exercise 15 min
10.3 Service brake valve
The participant can describe the function of the service brake valve. The participant knows
the different versions of a service brake valve.
Service brake valve
Exercise 15 min
10.4 Pressure ratio valve with retardation
The participant can describe the function of the pressure ratio valve. The participant can
state the model series in which the component is used.
Pressure ratio valve with retardation (braking pressure controller)
Exercise 5 min
10.5 Brake force regulator
The participant can assign the various designs of ALB valves to their type of application.
The participant can describe the function of an ALB valve.
ALB valves
Exercise 10 min
10.6 Trailer control valve
The participant can describe the functions of the trailer control valve.
Trailer control valve
Interactive lecture + exercise 45 min


(participants)
Exercise 25 Complete the following exercises about the system design of a service brake system in groups.
a) In groups, create a schematic design of a service brake system using the templates, e.g.
schematic of a service brake valve, on a metaplan board or flipchart. Use function schematic
PP 42.30-W-2000-97AXA for assistance.
Group 1 - Create a system design for a vehicle of over 12 t permissible gross weight and with
size 24 brake cylinders on the front axle.
Group 2 - Create a system design for a vehicle of less than 12 t permissible gross weight.
b) Add the tasks of the components to your system design. Use the available technical literature
for support.

c) Add the switch position of the valves to the schematic illustration of components for the
following situation:
Group 1 - The vehicle is fully loaded. The brake cylinders are receiving the full brake pressure.
Group 2 - The brake cylinders of the rear axle are receiving a brake pressure of 2.9 bar.


Exercise 26 Complete the two exercises. A colleague has carried out a repair on the brake system and
incorrectly swapped the air lines at connections 11 + 12.
a) Which brake cylinders receive pressure during a brake application?
N_42_60_002015_SW
Situation Pressure during brake application

Front axle Rear axle
Circuit V1 fails
Circuit V2 fails
X

b) Which brake cylinders receive pressure during a brake application?
N_42_60_002016_SW
Situation Pressure during brake application

Front axle Rear axle
Circuit V1 fails
Circuit V2 fails


@Test: exercise 4, version I + III. (refers to exercise c), @Test: exercise 12, version I + III (refers to exercise
d)
In the exercise on creating the system design of a brake system, you already learnt that there
are two different versions of service brake valves.
Exercise 27 Complete the following exercises about the service brake valve.
a) Write down the tasks of the service brake valve.
 Control the brake pressure supplied to the brake cylinders and trailer
control valve on a finely graduated basis
 Control the brake pressure depending on the load
b) Add the correct component number and its designation to the table for each component.
Use the Workshop Information System for help.
Service brake valve
TT_42_10_009935_FA
TT_42_10_009934_FA
Component number Component number

13.02_____________________ 13.04_____________________
Designation Designation
2-circuit service brake valve without 2-circuit service brake valve with
front axle control front axle control

c) Imagine a colleague has performed welding during a repair to a vehicle. During this work,
the line between connection 4 of the service brake valve and connection 2 of the brake force
regulator was melted accidentally and unnoticed. Upon completion of the work, the vehicle
was handed over to the customer.
With which complaint will the customer probably return to the workshop?
As a consequence of the melted line, connection 4 of the service brake

valve does not receive any pressure during brake applications. If the
vehicle is unladen, only low pressures are generally present. If the vehicle
is loaded, the pressure applied to connection 4 is higher. This would be
missing in the case described here. As a result, the higher pressure at the
front axle with the vehicle loaded would not be present.
The customer would thus probably only complain about poor braking
characteristics and poor braking effect at the front axle with the vehicle
loaded.


Pressure ratio valves are usually installed at the front axle to retard the brake pressure in the
partial brake range (not for Telligent brake systems). Pressure retardation takes place along
a sharp curve as per the characteristic. Outside the range of pressure retardation, the brake
pressure output occurs at a ratio of 1:1 to the input pressure.
Currently, the Zetros model is equipped with this type of valve for the front axle brake.
W_42_60_001010_SW
TT_42_10_009928_SW
Exercise 28
W_42_60_001011_SW

Using the graphic, determine the output pressures for the specified input pressures and note
them down in the following table. Pay attention to the characteristic of the dark shaded area.
Input pressure, PE (bar) Output pressure, PA (bar)
1 approx. 0.5
2
approx. 0.8
3
approx. 2.3
4
approx. 4.0


Brake force regulator for steel-sprung vehicles Brake force regulator for air-sprung vehicles
N_42_80_002004_SW
N_42_80_002005_SW
Static brake force regulator Dynamic brake force regulator

Static brake force regulators do not further modify the Dynamic brake force regulators modify the initial brake
initial brake pressure applied at the beginning of the brake pressure applied at the beginning of braking during
application. dynamic movement of the axle loads. These brake force
regulators are used in Mercedes-Benz trucks.
Exercise 29 Complete the following exercises about the brake force regulator chapter.
a) Write down the tasks of the brake force regulator.
 Adjust the brake pressure (at the axle being controlled) in accordance
with load

Exercise 30 Brake force regulator for steel-sprung vehicles
TT_42_80_009942_FA
Complete the following exercises about the brake force regulator on steel-sprung vehicles.
a) What is the component number of the component shown above?
Component number 26.07
b) To which components are the following pneumatic connections on the brake force regulator
connected?
Connection 1 = Connected to circuit 1 compressed air reservoir (rear axle)
Connection 2 = Connected to ABS valves of rear axle, each at connection 1
Connection 3 = Ventilation to atmosphere
Connection 4 = Connected to connection 21 of service brake valve

Exercise 31 Brake force regulator for air-sprung vehicles
W_42_80_001002_SW
Complete the following exercises about the brake force regulator on air-sprung vehicles.
a) What is the component number of the component shown above?
Component number 26.09
b) To which components are the following pneumatic connections on the brake force regulator
connected?
Connection 1 = Connected to circuit 1 compressed air reservoir (rear axle)
Connection 2 = Connected to ABS valves of rear axle, each at connection 1
Connection 3 = Ventilation to atmosphere
Connection 4 = Connected to connection 21 of service brake valve
Connection 41 = Connected to the suspension bellows of one vehicle side
Connection 42 = Connected to the suspension bellows of one vehicle side
Connection 43 = Test valve, connection for simulating a load


@Test: exercise 8, version I + III (refers to exercise c)
The trailer control valve is actuated with a dual circuit from the service brake system (BBA) and
with a single circuit from the parking brake system (PBS).
Evaluation of its operation during tests requires well-founded expertise.
TT_42_10_008514_FA
TT_42_70_009927_SW

The trailer control valve must respond immediately when the service brake valve is actuated.
The maximum response pressure is 0.2 bar.
Exercise 32 Complete the following exercises about the trailer control valve.
a) What tasks must the trailer control valve perform? Transfer the solution from the exercise in
chapter “System design of service brake system”.
The trailer control valve:

 must be able to be actuated by two circuits.
 must supply the trailer with reservoir pressure during a brake
application.
 must incorporate an emergency function. If the yellow helical line is
torn off, the red coupling head must be ventilated within 1.5 seconds
of emergency braking.
b) Which brake units are the trailer control valve connections connected to via the compressed
air lines? Place a cross next to the correct assignments in the table.
Brake devices Pneumatic connections on trailer control valve
11 21 22 41 42 43
Service brake valve,
connection 21 X
Service brake valve,
connection 22 X
Parking brake valve
X
Coupling head, red
X
Coupling head, yellow
X
Reservoir (V 3)
X

c) At which connections of the trailer control valve is pressure present as per the specified
conditions? Mark the correct pneumatic connections in the table.
Condition Pneumatic connections on trailer control valve
11 21 22 41 42 43
Service brake and parking
brake released X X X
Parking brake operated
X X X
Service brake actuated
and parking brake released X X X X X X
Reservoir pressure
released in pressure X
circuit 3, parking brake
remains released
Reservoir pressure
released in pressure
circuit 3, parking brake
was actuated
Reservoir pressure
released in pressure X X X
circuit 3, only the service
brake was actuated
Line torn off at
connection 21, service X X X X
brake actuated

11 Practical work 3
0 Instructions
11 Practical work 3
Instructions
Total time ...........................................................................................................................70 min
11.1 Test components of service brake system
The participant can test the components of the service brake system as per the work
instructions.
Function tests on service brake system components.
Exercises 70 min
WIS, pressure gauge,
commercially available tools,
folding rule

11 Practical work 3

The majority of complaints regarding brake systems are a result of excessive wear or changes
in braking behavior.
As well as troubleshooting on the vehicle, it is, of course, also necessary to check how the
vehicle is being operated by the driver. There are work instructions describing how to properly
test the components of the automatic load-dependent brake and trailer control valve.
Exercise 33 Test trailer control valve
a) Find the instructions in the Workshop Information System (WIS) for testing the trailer control
valve on the vehicle provided. Note down the number of the document.
Test trailer control valve (four vehicles without BS) - AR42.25-W-0025B
b) Test the trailer control valve as per the test points specified in the table in accordance with
the instructions and enter the pressures measured.
Carry out pressure test Pneumatic pressures in bar
with parking brake
Coupling head, red Coupling head, yellow Combination brake
cylinder
Pressure in release position
Response pressure
EC check position
Carry out pressure test Pneumatic pressures in bar

with service brake
Connection 4 on Coupling head, red Coupling head, yellow
brake force regulator
0.5
1.0
1.5
2.0

11 Practical work 3
c) Test the breakaway coupling. Make notes of your procedure.
To test the breakaway coupling

 the yellow coupling head must be opened to full diameter.
 the helical line on the towing vehicle must be stretched as far as
possible.
 the brake pedal must be fully depressed.
 the pressure at the yellow coupling head must drop within two
seconds. Compressed air may continue to flow.
Exercise 34 Test and adjust automatic load-dependent brake (ALB)
a) Find the instructions in the Workshop Information System (WIS) for testing and adjusting the
brake force regulator on the vehicle provided. Note down the number of the document.
 Check/adjust automatic load-dependent brake (ALB) (vehicles with

leaf spring suspension) - AR42.80-W-0050B
 Check/adjust automatic load-dependent brake (ALB) (vehicles with air
suspension) - AR42.80-W-0050B
b) Which measuring tools do you need for testing the brake force regulator? Mark the correct
answers with an “X”.
Measuring tools Air-sprung vehicle Steel-sprung vehicle
Scales
X
Pressure gauge
X X
Brake test stand
Workshop Information System WIS
Tape measure or folding rule for

measuring X
Adjustable pressure reducing valve
X
Pedal support

11 Practical work 3
c) To which measuring points do you connect the pressure gauge for testing the brake force
regulator?
 Brake cylinders on front axle

 Brake cylinders on rear axle
 Connection 4 on brake force regulator
d) Perform the test on the vehicle provided and enter the values you determine in the table.
Test Rear axle Front axle output Rear axle output Spring
specification load [kg] pressure [bar] pressure [bar] travel f on
lever [mm]
Specified Actual Specified Actual
No-load test
(actual
condition)
Half-load test
Full-load test
Emergency
operation
position test
Mechanical Lever on
pressure ALB
control in controller
service brake fixed in the
valve emergency
driving
position

11 Practical work 3
e) The customer complains of insufficient braking effect and increased brake wear at the front
axle. The check showed that the brake units and the setting of the automatic load-dependent
brake system were in compliance with the data on the ALB plate and therefore not a cause for
complaint. What causes could there be related to the ALB in this case?
1 ALB controller rusted tight in the partial load position.
2 The rear spring is in very poor condition e.g. very rusty.

X
3 Pins on spring attachments and spring shackles are stuck.
X
4 The rear spring was reinforced by installing additional spring leaves.
X
5 The operating pressure in the brake system does not quite comply with the
manufacturer's data.
6 When the brake pedal is fully depressed, the brake cylinders at the front
axle receive full operating pressure.

12 Braking effect
0 Instructions
12 Braking effect
Instructions
12.1 Terms related to braking effect
The participant can explain the definition of the terms deceleration and braking ratio.
The participant can name the measured quantities with which the braking effect can be
determined.
Terms related to braking effect
Exercise 5 min
12.2 Measuring method
The participant can name the measuring method for determining braking effect.
Measuring method for determining braking effect
Presentation, interactive lecture 5 min
12.3 Deceleration
The participant knows the procedure for measuring deceleration

Deceleration
12.4 Braking ratio in %
The participant can explain the method for determining the braking ratio in % for evaluating
the braking effect.
Braking ratio in %
12.5 Extrapolation of brake forces
The participant can extrapolate the brake forces for evaluating the braking effect.
Extrapolation of brake forces

12 Braking effect
12 Braking effect (participants)

You will certainly have experienced this situation during discussions in the workshop. The
discussion is about braking effect but different technical terms are used. Which technical terms
mean what exactly?
Exercise 35 Complete the following exercises.
a) First determine the unit which each technical term is measured in and enter your result in the
table.
Technical term Unit
Vehicle weight
Kilogram (kg)
Brake force
Decanewton (daN)
Deceleration
m/s2
Braking ratio
%
b) With which tools or measuring methods do you determine the results for braking effect for the
respective technical term?
Technical term Tool or measuring method
Vehicle weight
Scales
Brake force
Brake test stand
Deceleration
(Logging) decelerometer
Braking ratio
Calculated from the values for brake force and
vehicle weight

12 Braking effect
12.2 Measurement method
12.2 Measurement method

You can check the braking effect by determining
 the deceleration [m/s²]
 the brake force [N]
 the braking ratio [%]
In order to properly test brakes for their effect and evaluate the results, the following are
needed:
Good technical knowledge
Good testing and measuring equipment
Knowledge of the correct test procedure and
Expertise in the correct evaluation of test results

12 Braking effect
12.3 Deceleration
12.3 Deceleration
Measuring the deceleration of tractor vehicles

If the brake test on the brake test stand is not possible because e.g. of the vehicle dimensions,
the test must be conducted in a road trial with the decelerometer. The deceleration
measurements must be performed with great care and under consideration of the road
conditions, as well as the subsequent traffic on the road.
If this method is used, the following points must be observed:

 Install decelerometer with pedal force meter
 Dry road
 Speed approx. 50 km/h
N_42_10_001013_SW
When determining the braking effect, the permissible control force must not be exceeded.
Measuring the deceleration of trailers

For trailers that cannot be measured on the roller dynamometer, the deceleration must be
measured on the road as well.
The measurement procedure is as follows:
1. Measure deceleration of tractor vehicle with decelerometer.
2. Measure deceleration of entire tractor/trailer combination with decelerometer.

12 Braking effect
12.3 Deceleration
Example:
 Test weight of the trailer, Ga = 18000 daN
 Test weight of the tractor, Gz = 17000 daN
 Test weight of the tractor/trailer combination, Gzg = 35000 daN
 Deceleration of tractor vehicle, zz = 5 m/s2
 Deceleration of tractor/trailer combination, z zg = 5.5 m/s2
Formula for calculating total deceleration of a truck/trailer combination with example
TT_42_00_008543_SW TT_42_00_008544_SW
Exercise 36 How can the calculated results in the preceding example be shown as braking ratio in %?
Answer in brief giving reasons.
The result equals a braking ratio of approx. 59 %.

100 % corresponds to 9.81 m/s2 or approx. 10 m/s2.
5.9 m/s2 thus corresponds to approx. 59 %.
Exercise 37 With which load combination of tractor and trailer vehicle does it make sense to test the
braking effect on the trailer in a road test? Mark the correct answer with an “X”.
1 Tractor and trailer not loaded.
2 Tractor vehicle loaded with permissible gross vehicle weight,

trailer not loaded.
3 Tractor vehicle not loaded, trailer loaded with permissible
X gross vehicle weight.
4 Tractor and trailer loaded with permissible gross vehicle
X weight.

12 Braking effect

The braking ratio for the vehicle must be documented as a percentage (%) based on the weight
(test weight [m] · normal g force [a]). Brake force can then be measured in any load condition.
The permissible control force or brake pressure must not be exceeded.
N_42_10_002019_SW
Formula for braking ratio z TT_42_00_008545_SW
Formula
Explanation FM Total of all brake forces
symbol
z Braking ratio in % GM Weight of vehicle
Exercise 38 What values do you need to determine the braking ratio in % based on the test weight? Mark
the correct answer with an “X”.
Answer Number Values
1 The maximum applicable brake pressure.
2 The weight force of the vehicle

X
3 The maximum measurable brake force (just before the locking
X limit).
4 The weight force at the axles determined by the test.
X
5 The size of the tires on the vehicle at the time of the test.

12 Braking effect
Exercise 39 Which of the following statements do you consider permissible control forces for the brake
test? Mark the correct answer with an “X”.
1 Forces that must not exceed the possible braking ratio for the
X test.
2 Permissible control forces must at least be exerted in the
test.
3 The permissible control forces are forces to be measured on
the test stand.

12 Braking effect

If compliance with the required minimum braking ratio cannot be proven using the procedure
described above, the braking ratio can be determined using the permissible gross vehicle
weight (extrapolation).
Formula for extrapolation TT_42_00_008546_SW
Design pressure specified by

z Braking ratio [%] pN1...n
manufacturer [bar]
Permissible total weight of the vehicle Brake pressure applied during the brake
Gz [N], for semitrailers the sum of the p1...n test in the brake cylinder(s) of each axle
maximum permissible axle loads [N] [bar]
Brake force of the first and additional
Pressure required to apply the brake
F1...n axles, determined for the pressure p1...n 0.4 bar
linings to the brake drum/brake disk
[N]
i Ratio of design pressure/brake pressure
Example
As the following graphics show, the linear extrapolation through points 1 and 2 at different brake pressures produces
very different extrapolated results for the same brake force curve (a). The example was calculated with a design
pressure of 6.5 bar.
W_42_10_001011_SW
Exercise 40 What should you pay particular attention to when determining brake forces for extrapolation?
The wheels must not lock up and the brake forces should be determined
at a very high pressure.

13 Practical work 4
0 Instructions
13 Practical work 4
Instructions
13.1 Determine and evaluate braking effect
The participant can evaluate the response time of the wheel brake during tests.
The participant can evaluate the braking effect using the braking ratio.
Practical tests on wheel brake
Exercises 60 min
Pressure gauge, brake test
stand, scales
13.2 Friction value of brake test stand
The participant can evaluate the brake test stand with respect to friction value.
Friction value of brake test stand
Exercise 5 min
13.3 Test condensation sensor
The participant can test the condensation sensor.

Test of condensation sensor
Exercises 15 min
Multimeter, test adapter,
beaker (filled with water),
commercially available tools

13 Practical work 4

Exercise 41 Determine response time of wheel brake
a) Determine the brake forces for the specified brake pressures at the front axle for evaluating
the response time. Note them down in the following table.
Front axle
Brake pressure (bar) Left brake force (daN) Right brake force (daN)
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0

13 Practical work 4
b) Determine the brake forces for the specified brake pressures at the rear axle for evaluating
the response time. Note them down in the following table.
Rear axle
Brake pressure (bar) Left brake force (daN) Right brake force (daN)
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
c) Evaluate the response time of the wheel brake.

13 Practical work 4
Exercise 42 Determine braking power
a) Determine the brake forces for the specified brake pressures at the front axle during actuation
and release of the brake pedal. Note them down in the following table.
Front axle
Brake Left brake force (daN) Right brake force (daN)
pressure
(bar)
During actuation During release During actuation During release
(pressure buildup) (pressure release) (pressure buildup) (pressure release)
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
Draw the brake force curve during pressure buildup and release on the front axle on the
following graphic.
TT_42_00_008547_SW

13 Practical work 4
b) Determine the brake forces for the specified brake pressures at the rear axle during actuation
and release of the brake pedal. Note them down in the following table.
Rear axle
Brake Left brake force (daN) Right brake force (daN)
pressure
(bar)
During actuation During release During actuation During release
(pressure buildup) (pressure release) (pressure buildup) (pressure release)
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
Draw the brake force curve during pressure buildup and release on the rear axle on the
following graphic.
TT_42_00_008547_SW

13 Practical work 4
Exercise 43 Braking effect test - Extrapolation
a) Measure the brake forces on the vehicle provided at the highest possible brake pressure and
enter the values determined in the following table.
Brake forces (daN) Brake pressure Axle load (kg)
(bar)
Left Right
Axle 1
Axle 2
Axle 3
Axle 4
b) Extrapolate the total braking ratio and evaluate it according to legal requirements.
Design pressures and legal requirements
Design pressures in MB trucks

Vehicle model Design pressure (bar)
NG 73 6.5
SK 6.5
SK with partial air suspension 6.5
SK with full air suspension 6.5

13 Practical work 4
Actros, Atego, Axor, Zetros, Econic 8.5

Atego, Axor with 10 bar pressure regulating 8.0
system (code BC3)
Vario With trailer control dual-line brake system
(tractor vehicles) = 6.8 bar
Solo vehicles = 7.5 bar
Specified minimum braking ratio and maximum actuating forces of service brake system
(values are valid for safety inspection (SP))
Vehicle category Service brake system (BBA)
z >= (%) Fh <= (daN) Ff <= (daN)
Buses 43 70
Trucks 43 70
Trailers 25 - -
up to 25 km/h 40 (PM ≤ 8.5bar) (PM ≤ 8.5bar)
above 25 km/h
Other vehicles 25 - 70
up to 25 km/h 40 - 70
above 25 km/h
Legend
z = braking ratio
BBA = service brake
system
Ff = pedal force
Fh = manual effort
PM = pressure at
yellow coupling head
Specified minimum braking ratio and maximum actuating forces of parking brake system
(values are valid for safety inspection (SP))
Vehicle category Parking brake system (PBS)
z >= (%) Fh <= (daN) Ff <= (daN)
Buses 15 60 70
Trucks 15 60 70
Trailers 15 60 -
up to 25 km/h 15 60 -
above 25 km/h
Other vehicles 15 60 70
up to 25 km/h 15 60 70
above 25 km/h
Legend
z = braking ratio
FBA = parking brake
system
Ff = pedal force
Fh = manual effort
PM = pressure at
yellow coupling head

13 Practical work 4

This chapter describes the German regulations. Observe the respective national regulations which apply.
Brake test stands are subject to specific - sometimes national - regulations. For Germany the
current values were published in “Verkehrsblatt”, edition 9/2003. These include compliance
with the required friction value µ between the wheels and rollers of the test stand.
Specified friction values µ:

 Dry test stand rollers µ ≥ 0.7
 Wet test stand rollers µ ≥ 0.5
The µ value is defined as:
µ = FR / FN
FR = brake force measured on brake test stand
FN = normal force on brake test stand (weight of axle)
Exercise 44 Determine the friction value μ between the wheels of the front axle and the rollers of the test
stand, and decide whether the calculated µ value is OK.
Statement Value
FR
FN
Calculated µ value
Your result and finding regarding the value

13 Practical work 4

Further development of the components of the air brake system has an effect on maintenance
operations and intervals. For example, regular draining of water in the air tanks is no longer
required. To indicate a malfunction in the air dehumidification system, a condensation sensor
was developed and installed in Mercedes-Benz trucks. This condensation sensor is thus of
particular importance. If there are indications on the instrument cluster, you should have at
least made sure that the condensation sensor is operating properly.
Exercise 45 Complete the following exercises.
a) Find the corresponding instructions in the Workshop Information System (WIS) for testing the
condensation sensor and note them down.
SI42.00-W-0003A and AR42.10-W-0050A
b) Which testing and measuring tools do you need for testing the condensation sensor?
 Open end wrench (for removing the sensor from the tank)
 Multimeter
 Test adapter as per WF58.50-W-4260-04A
 (small container of water)
c) Perform the test.

0 Instructions

Instructions
14.1 Read function schematics (BBA)
The participant can read function schematics for the service brake system (BBA) section.
Exercise 40 min
Day-end closing
Any unresolved questions of participants about the content covered can be answered.
Content mentioned can be repeated to reinforce learning.
Discussion 10 min

14 Read function schematics - 2 (participants)

Exercise 46 Complete the following repeat exercises using the Workshop Information System (WIS) and
function schematic PP42.30-W-2000-97AXA. The vehicle identification number of your
reference vehicle is WDB 952 563 1L 423 884.
Add the missing pressure values to the respective tables.
a) Conditions: Vehicle loaded up to permissible gross weight and at standstill, engine off, shutoff
pressure reached, input pressure at connection 4 of brake force regulator is 8 bar.
12.3
38.02 E 50
7.7
38.02 K 50
7.7
38.02 H 53
8
38.02 K 58
8.2
38.02 C 58
8.2
35.02 F 66
8.5
35.03 H 66
8
b) Conditions: Vehicle empty and at standstill, engine off, shutoff pressure was reached, brake
pedal fully actuated with pedal support, connection 11 torn off at component 13.04.
0
38.02 E 50
more than 4.5
38.02 K 50
more than 4.5
38.02 H 53
0
38.02 K 58
0
38.02 C 58
0
35.02 F 66
0
35.03 H 66
0

15 Braking effect of tractor vehicles and trailers
0 Instructions

Instructions
Introduction to day 3
The participant can explain what he/she learnt on the previous days.
Repetition of content from second day.
15 min
15.1 Complaints due to insufficient harmonization of tractor/trailer combination
The participant can state the effects on components on the tractor vehicle and trailer.
The participant can establish a link to customer complaints.
Effects on assemblies and customer complaints with poor truck/trailer balancing.
Card question 10 min

Metaplan cards
The participants prepare their ideas and experiences on a card question. The trainer
collects them in and sorts them appropriately. The result is then transferred to the
documents.
15.2 Evaluation possibilities
The participant can explain the possibility of comparing deceleration. The participant can
explain the differences on the available evaluation diagrams. The participant can correctly
use the diagrams.
Diagrams for evaluation
15.3 Evaluation and adjustment options
The participant can evaluate a completed diagram. The participant can explain the
adjustment options.
Evaluation of completed diagrams. Adjustment options.
15.4 Practical examples
The participant can name possible fault sources based on practical examples.
Practical examples of completed braking effect diagrams.
Interactive lecture, discussion 10 min

15 Braking effect of tractor vehicles and trailers (participants)

15.1 Complaints due to insufficient harmonization of tractor/trailer
combination
TT_00_00_010275_SH
Exercise 47
a) Which components can be subject to a particular high amount of stress due to disharmonious
brake characteristics and thus high wear?
 Tires
 Wheel brakes
 Towing connections
 Trailer hitch
 A-frame towbar
 Turntable
 End crossmember
 Fifth wheel coupling
 Kingpin
b) Mark the affected assemblies on the graphic above.

Exercise 48 What types of complaints can a customer have to come to the workshop, which can be traced
to inadequately coordinated brake characteristics?
a) On the wheel brakes?
 Excessive wear
 of the brake drums
 of the brake disks
 of the brake pads
b) On the connecting devices?
 Excessive wear
 of the trailer hitch
 of the A-frame towbar
 of the fifth wheel coupling
 of the kingpin
 Cracks or loosening of attachment
 on end crossmember
 of fifth wheel
c) With respect to road safety?
 Unstable handling characteristics due to shunting or skidding
d) With respect to the usage possibilities for the individual vehicles?
 Poor compatibility due to braking characteristics

Exercise 49 @Test: exercise 15, version I + exercise 5, version III
By way of example, let's assume that the current vehicle weight of the tractor is 18,000 kg and
that of the trailer is 12,000 kg.
TT_00_00_010275_SH
Which of the listed characteristics must be as equal as possible on both vehicles during brake
applications of any kind?
Answer Characteristic
Brake forces at the wheel brakes
Brake pressure at the brake cylinders
Braking ratio in % based on the permissible gross weight
Braking ratio in % based on the current vehicle weight

X
Deceleration
X
Tire dimension


You have looked at the possible complaints resulting from inadequate harmonization of the
brakes of a tractor/trailer combination. You should proceed systematically to deduce measures
for rectifying a complaint.
Drawing the braking ratio on a diagram is something you will certainly be familiar with, but this
is only a small step in the process.
For the following exercises, we will assume that a vehicle (reference vehicle, vehicle
identification number WDB 952 563 1L 423 884) comes to you with a complaint. In your
opinion, the complaint is due to inadequate truck/trailer balancing.
Exercise 50 What conditions do you put in place before you start the actual comparison of braking forces
on the diagram?
 The vehicle must be loaded as close to the permissible gross weight as

possible.
 The wheel brakes have been visually inspected.
 All components of the brake system are operational.
Exercise 51 Which main operations will you perform before the actual test of braking effect?
a) Visual inspection of wheel brakes:
 Condition of brake drums or brake disks

 Condition of brake linings
 Ease of movement of brake shoes and brake shafts
 Condition and number of retracting springs
 Adjustment of wheel brakes
 Effective brake lever length
b) On the components of the air brake system:
 Test of response time

 Test of ability to brake gradually
 Check of positive-tolerance calibration
 Check of brake force regulator adjustment

Exercise 52 Determine the corresponding document numbers for the following operations.
a) Document number of work instructions for testing braking characteristics of tractor vehicle and
trailer:
AR42.00-W-0030-A
b) Document number for graphic illustration of braking effect of tractor vehicle and trailer:
OF42.10-W-3000-01A
Exercise 53 The diagrams are defined in an EC directive. In this directive, a distinction is made between
trucks and semitrailer tractor vehicles and between load states (laden and unladen).
You have already found out that, to process complaints effectively, vehicles loaded as heavily
as possible make diagnosis easier. As a result, only diagrams for loaded vehicles are found in
the workshop literature.
EC brake band for trucks with trailers (laden) EC brake band for semitrailer tractors with
semitrailers (laden)
TT_42_10_010276_SW TT_42_10_010277_SW
z (%) = braking ratio in % U = EC compatibility band for laden semitrailer

pm (bar) = pressure at yellow coupling head in tractor
bar V = EC compatibility band for laden semitrailer
Why are there different diagrams for evaluating trucks and semitrailer tractors?

During braking of a semitrailer tractor with trailer, the dynamic axle load
shift is more pronounced than on a truck with trailer. This fact is taken
into account in the diagrams.
TT_42_00_010278_SW


Exercise 54 Evaluation
Below you will see a completed form for evaluating the braking effect by way of example.
Example of completed form TT_42_00_010302_SW
Complete the following exercises.
a) Calculate the braking ratio in the specified example for the tractor vehicle and trailer.
Add your results directly to the form.
Permissible gross vehicle weight:

 Tractor vehicle: 18,000 kg
 Trailer: 18,000 kg
Test weight:
 Tractor vehicle: 15,850 kg
 Trailer: 14,200 kg

b) Transfer the calculated values for both vehicles to the following diagram.
TT_42_10_010276_S
c) Which main features do you pay particular attention to when evaluating the graphic
representation?
 Response pressure
 Path of curve
 Location of curve
 Range of brake pressure at yellow coupling head in range from
0.00 to 3.00 bar

Exercise 55 Adjustment options
Before this work, you have ruled out the possibility of mechanical or pneumatic faults with
appropriate tests. Then you recorded, graphically illustrated and evaluated the braking effect
of the tractor/trailer combination of your customer.
What options are available for harmonizing the braking characteristics between the
tractor vehicle and trailer?
The “positive-tolerance calibration” can be adjusted at the trailer control

valve in the tractor vehicle and at the trailer brake valve in the trailer.
Exercise 56 Effect of adjustment
The trailer control valve and trailer brake valve operate with internal relay valves. These can
be influenced by adjusting them.
The following example should illustrate this again: When 1.0 bar is applied to the control
connection, 1.0 bar is also output (with a full compressed air supply, of course).
Trailer brake valve TT_42_70_010301_SH
1 Energy supply (from red coupling head) 3 Ventilation

Control connection (from yellow
2 Energy outlet (to brake cylinders) 4
coupling head)
Energy supply and energy outlet (depending
2-1 on filling of compressed air system of
trailer)

What are the effects of adjustments at the respective valve?
a) What pressure is present for the specified pressure at the yellow coupling head with both
valves at the basic setting (positive-tolerance calibration = 0.0 bar)?
Trailer control valve Yellow coupling head (bar) Trailer brake valve
connection 41 connection 2
Positive-tolerance calibration Positive-tolerance calibration
= 0.00 bar = 0.00 bar
1.0
1.0 1.0
2.0
2.0 2.0
3.0
3.0 3.0
4.0
4.0 4.0
5.0
5.0 5.0
b) What pressure is present for the specified pressures with the trailer brake valve set to a
positive-tolerance calibration of +1.0 bar?
Use the graphic provided for help. When a positive tolerance calibration is set, the spring
tension at the adjustment valve is increased.
= 0.00 bar = +1.00 bar
1.0 1.0
2.0
2.0 2.0
3.0
3.0 3.0
4.0
4.0 4.0
5.0
5.0 5.0
6.0

c) How does the pressure behave when a positive-tolerance calibration of +1.0 bar is set at the
trailer control valve?
= +1.00 bar = +0.00 bar
1.0 1.0
0.0
2.0 2.0
1.0
3.0 3.0
2.0
4.0 4.0
3.0
5.0 5.0
4.0
Adjusting the positive-tolerance calibration only changes the position of

the braking effect in the EC brake band.


Exercise 57 What can be the cause of the graphic illustrations of braking effect in the diagrams?
a)
N_42_60_002051_SH
1 Tractor vehicle
2 Trailer
 Tractor vehicle:
 High friction value between parts
 Wheels too small
 Wheel brake cylinders too large
 Brake lever too long (with drum brakes)
 Trailer:
 Poor mechanical efficiency

b)
N_42_60_002052_SH
1 Tractor vehicle
2 Trailer
 Tractor vehicle:
 Brake force limitation by pressure limiter
 Poor adjustment of wheel brakes
 Brake cylinders have no effective travel
 ALB controller rusted tight in the partial load position
 Trailer:
 Poor friction value (oiled up or glazed)
 Wheels too large
 Brake cylinders too small
 Brake lever too short (with drum brakes)

16 Parking brake
0 Instructions
16 Parking brake
Instructions
16.1 Parking brake valves
The participant can explain the tasks of the different parking brake valves.
Parking brake valves
16.2 Combination brake cylinder with integrated ventilation valve
The participant can explain the function of the brake cylinder with integrated ventilation
valve (IBV).
The participant can describe possible symptoms of incorrect diagnosis due to the
integrated ventilation valve.
Combination brake cylinder with integrated ventilation valve (IBV)
Presentation, exercise 5 min

16 Parking brake
16 Parking brake (participants)

Preparation
Split up into three groups. In groups, complete the following exercises. Then present your
solutions to the other groups and transfer the results to your documents.
Also use function schematic PP42.30-W-2000-97AXA for help.
Exercise 58 Group 1
TT_42_20_010295_FA
What is the designation of this component?
Parking brake valve
Exercise 59 @Test: exercise 14, version I
Group 1

16 Parking brake
TT_42_20_010296_FA
a) What is the designation of this component?
Parking brake valve with trailer control
b) To which components are the pneumatic connections of the valve connected?
 Connection 11 = four-circuit protection valve connection 25

 Connection 21 = relay valve connection 4
 Connection 22 = trailer control valve connection 43
c) What effect do positions 0, I and II of the parking brake lever have?
 Position 0 = drive position

 Position I = parking brake actuated
 Position II = EC check position (parking brake actuated, trailer control
valve outputs no brake pressure at yellow coupling head)

16 Parking brake
d) What happens if the compressed air supply at connection 11 fails while the lever of the
parking brake valve is in the drive position?
The compressed air loss releases the air from the spring brake cylinders.
The vehicle is thus braked by the spring brake cylinders.
Air is also released from the connecting line to the trailer control valve.
The trailer control valve thus outputs brake pressure at the yellow
coupling head.
Exercise 60 Group 2
TT_42_20_010297_FA
Parking brake valve with pipe fracture protection

16 Parking brake

 Connection 23 = shuttle valve connection 12
c) What happens if the compressed air supply at connection 11 fails while the lever of the
Instead of compressed air being supplied via connection 11, the spring
brake cylinders are supplied with pressure from connection 12.
Exercise 61 Group 3
TT_42_20_010298_FA

16 Parking brake
Parking brake valve with trailer control and pipe fracture protection

 Connection 22 = trailer control valve connection 43
 Connection 23 = shuttle valve connection 12
c) What happens if the compressed air supply at connection 11 fails while the lever of the
Instead of compressed air being supplied via connection 11, the spring
brake cylinders are supplied with pressure. Air is released from the
connecting line to the trailer control valve. As a result, it responds to the
pressure drop and applies brake pressure to the yellow coupling head.

16 Parking brake

This brake cylinder is supplied by WABCO.
The combination brake cylinder with integrated ventilation valve can be identified externally
through the lack of an external ventilation line.
Combination brake cylinder with external ventilation Combination brake cylinder with integrated ventilation
line valve
TT_42_20_010283_FA
TT_42_20_010284_FA
1 - Integrated ventilation valve
The internal ventilation valve is integrated in the piston of the spring-loaded actuator. When it is
open, it connects the spring chamber to the unpressurized chamber of the service brake and
prevents pressure from being built up in the spring chamber when the spring-loaded piston
moves. This is important for a low release pressure. When the service brake is actuated, the
integrated ventilation valve closes as of a pressure of approx. 1.5 bar to enable faster pressure
buildup in the diaphragm part of the cylinder.
Exercise 62 At which point of the brake system does compressed air come out when the parking brake
is actuated and the service brake is simultaneously actuated with a brake pressure below
1.5 bar?
Use a parking brake function schematic for help.
The brake pressure initially passes from the diaphragm part of the
combination brake cylinder into the spring-loaded actuator part because
the parking brake is actuated i.e. unpressurized. From there, the
compressed air passes via the connecting lines to the relay valve where it
escapes at connection 3.

17 Antilock brake system
0 Instructions

Instructions
17.1 Introduction to ABS (anti-lock braking system)
The participant can describe the background to the use of ABS. The participant can explain
technical terms related to ABS.
Compulsory ABS requirement, terms “frictional connection” and “wheel slip”
17.2 Control loop + control cycle
The participant can name the components which make up an ABS control loop.
The participant can explain the sequence of an ABS control cycle.
17.3 Types of control
The participant can explain the types of control of an ABS system.

Types of control of ABS
17.4 Control channels
The participant can explain the term “control channel”

“Control channel” term
Exercise 10 min
17.5 Other functions
The participant can explain how ABS functionality is ensured in different driving situations.
ABS function when used with permanent brakes. ABS function on all-wheel drive vehicles.
17.6 Electronic brake force limitation
The participant can explain the background to the omission of the ALB controller in certain
model series.
The participant can use the relevant published documentation.
Exercise 5 min

17 Anti-lock braking system (participants)

Compulsory ABS requirement

For vehicles with initial registration as of 1.1 1991, ABS is a compulsory requirement. The task
of ABS is to prevent the wheels from locking up continuously during a brake application to keep
the vehicle maneuverable and thus controllable.
Commercial vehicle required to have ABS
Vehicle type Permissible gross weight Conditions
Trucks and semitrailer tractors Larger than 16 t If registered for trailers larger than
10 t.
Trailers Larger than 10 t
Semitrailers Larger than 10 t Total of axle loads greater than 10 t
Bus Larger than 12 t Up to 31.12. 1998
Bus Larger than 5 t As of 1999
Frictional connection and wheel slip

The task of preventing the wheels from continued locking during brake application can only be
realized if the wheels have frictional connection to the road surface.
Wheel slip when braking:
Wheel slip is the percentage difference between the
vehicle speed and wheel speed.
Wheel slip formula TT_42_30_008530_SW

N42.30-2009-11 N_42_30_002009_SW
Brake force coefficient on wet concrete

λ Wheel slip 2
μB
VF Vehicle speed 3 Lateral stability coefficient μS
VR Circumferential wheel speed 1 A Optimal slip range

Brake force coefficient on dry concrete
1
μB
Wheel slip occurs with the transfer of brake, driving and lateral forces from the wheels to the
road surface. As the diagram shows, the μ-value initially increases starting at 0 % slip. Only
when the optimal slip range (range A) has been exceeded does the µ value decrease, and thus
so does the ability to transfer the forces.
Example
100 % wheel slip at one wheel means: The vehicle is traveling and one wheel is not turning
(locked up) or the vehicle is stationary and one wheel is turning (drive wheel spinning).


@Test: exercise 13, version III
Control loop
A control loop consists of:
 Rpm sensor with sensor rotor
 ABS control unit
 ABS solenoid control valve
 Wheel brake
W_42_30_001011_SW
1 Rpm sensor 3 ABS solenoid control valve
2 ABS control unit
Control cycle
The electronics of the ABS monitor the brake response of the wheels on the road surface
during brake application. The brake pressure can be regulated in the process using the ABS
solenoid valve. This results in a control cycle which can be repeated up to five times per
second.
Exercise 63 @Test: exercise 15, version III
What happens to the brake pressure in an ABS control intervention? Add this information to
the empty fields in the area surrounded by the broken line.

Control cycle schematic TT_42_30_008531_SW
1 Apply brake pressure 3.2 no

Brake application without ABS
2 Braking effect operative 4
control
3 Locking tendency 5 Brake application with ABS control
3.1 yes
The following information should be added to the empty fields from top to bottom.
 Gradually increase brake pressure
 Maintain brake pressure
 Decrease brake pressure


Individual control (IR) Modified individual control (MIR) Select-low control
TT_42_30_008532_SW TT_42_30_008533_SW
TT_42_30_008534_SW
p (bar) Brake pressure p (bar) Brake pressure p (bar) Brake pressure

1 Left 1 Left 1 Left
2 Right 2 Right 2 Right
Note
Mercedes-Benz commercial vehicles have MIR at the front axle and IR at the drive axle.
Exception: Atego with three-channel ABS system.
Exercise 64 What controls the brake cylinder pressure in the case of ABS control?
a) With individual control?
The brake pressure is regulated individually according to the frictional

connections of the individual wheels.

b) With modified individual control?
At the start of the control intervention, the brake pressure is regulated at

the wheel brakes of an axle according to the wheel with the weaker
frictional connection. Next, the brake pressure is gradually pulsed higher
at the wheel with the higher frictional connection.
c) With select-low control?
Both wheels of an axle receive brake pressure at the level of the wheel
with weaker frictional connection.


The control channels of an ABS system in a vehicle are determined by the number of ABS
control valves. Different ABS configurations are shown here, by which the number of control
channels can be determined.
It is possible to determine the possible type of control based on the illustration.
Example: If two ABS control valves are located at the front axle and one control valve at the
rear axle, it is a three-channel system.
N_42_30_002010_SW
A ABS control valves
Exercise 65 Complete the following table about the different ABS configurations in illustrations 1 to 5 as
per the following exercises.
a) How many control channels are present?
b) Which control types may be possible at the axles?

ABS ABS ABS ABS ABS
configuratio configuratio configuratio configuratio configuratio
n1 n2 n3 n4 n5
Control channels
4 3 4 6 5
Axle 1 control type
IR/MIR IR/MIR IR/MIR IR/MIR IR/MIR
Axle 2 control type
IR/MIR SLR IR IR SLR
Axle 3 control type
IR IR IR


@Test: exercise 15, version III
ABS when used with permanent brakes

The wheels braked with a permanent brake, e.g. engine brake and retarder, must be protected
against lock-up by the ABS system. Permanent brakes are automatically switched off at the
start of an ABS control process. Once the ABS control process has ended, the permanent
brake, that remains actuated during the ABS control, is switched on again. If the wheels tend to
lock up just from the operation of the permanent brake, ABS recognizes this condition and the
system temporarily shuts off the permanent brake or the retarders are switched back in stages.
ABS when used in all-wheel drive vehicles

Interaxle differential lock shutoff: During an ABS control process the interaxle differential
lock in the transfer case is temporarily switched off to separate the individual axles in terms of
control.
ABS shutoff in all-wheel drive vehicles: While driving in difficult off-road conditions, where
the interwheel and the interaxle differential lock are required, the driver can actuate the switch
to shut off the ABS control function. The ABS warning light will illuminate and the ABS
components continue to be monitored.
N_42_30_000263_SW


Exercise 66 Your customer has an Atego with 7.5 t permissible gross weight, which was registered for the
first time in February 2010.
View the function schematic for the customer vehicle PP42.30-W-2000AB in the Workshop
Information System (WIS) and complete the following exercises.
a) What is the number of the component which controls brake pressure at the rear axle?
16.01 Air admission relay valve (coordinate F53)
b) Can the brake pressure at the rear axle of the affected vehicle be regulated according to load?
No. It is controlled only by the service brake valve. Adjustment of the

brake pressure with a brake force regulator does not take place
mechanically.
c) Is there any information in the Workshop Information System for the affected vehicle,
e.g. Service Information (SI), which explains this circumstance?
SI42.30-W-0003A

18 Acceleration skid control (ASR)
0 Instructions

Instructions
18.1 ASR components and function
The participant can name the components required for the ASR function.
The participant can explain the mode of operation of an ASR control intervention.
Components of acceleration skid control (ASR). Mode of operation of ASR.
Exercise, interactive lecture 15 min

18 Acceleration skid control (ASR) (participants)

Differential brake control

During start-off with different friction values on the wheels of the drive axle (µ-split) the wheel
with the lower friction value (µ value) spins. ASR recognizes the clear difference in rpm and
brakes the spinning wheel. By braking the individual wheel and with the help of the differential,
the greater frictional connection at the wheel with the higher friction value is used for start-off.
W_42_40_001001_SW
A ABS/ASR electronics E Brake cylinder

Differential brake valve (3/2-way solenoid
B F Sensor rotor and sensor
valve)
C Two-way valve G Brake pressure from ALB
D ABS solenoid valve H Compressed air reservoir
Exercise 67 Place an X next to the devices that are necessary for ASR in addition to ABS.
Answer Number Additional equipment
1 ABS/ASR electronics
X
2 Differential brake valve (3/2-way solenoid valve)
X
3 Two-way valve
X
4 Solenoid valve
5 Brake cylinder
6 Sensor rotor and sensor
7 Service brake valve
8 Compressed air reservoir

19 Special functions
0 Instructions
Instructions
19.1 Overload protection
The participant can explain the function of relay valve 16.05 in function schematics.
Overload protection valve
Exercise 15 min
19.2 Bus stop brake/frequent-stop brake
The participant can explain the function of the frequent-stop brake.

Frequent-stop brake
Exercise 10 min

19 Special functions (participants)

@Test: exercise 2, version III (refers to exercise d)
Exercise 68 Access function schematic PP42.30-W-2000-99NA.
a) For which vehicles is this schematic valid?
Vehicle model designation 942.30 with ABS (code B02).

Four-axle vehicles.
b) A component is shown at coordinate F59. For which equipment option is this component
installed?
U93 - only with drum brakes
c) What are the component number and designation?
Component 16.05, overload protection valve

d) For which of the specified situations is compressed air present at connection 2 of

component 16.05?
Situation Pressure at connection 2
Parking brake not engaged, service brake not engaged
X
Parking brake not engaged, service brake engaged
X
Parking brake engaged, service brake not engaged
Parking brake engaged, service brake engaged

X
Details about component 16.05 Overload protection valve
Characteristic of overload protection valve 16.05 TT_42_20_010293_SH

Detailed function schematic of overload protection valve 16.05

19.2 Frequent-stop brake
19.2 Frequent-stop brake

Exercise 69 @Test: exercise 13, version I + exercise 6, version III
TT_54_25_006907_FA
Complete the following exercises again with our reference vehicle WDB 952 563 1L 423 884.
a) Find the function schematic for the specified vehicle model designation and equipment
code B24.
PP42.60-W-2002-99D
b) What pressure is output at the wheel brakes when the frequent-stop brake switch is pressed?
3.5 bar
c) On which axles does the pressure act when the frequent-stop brake is actuated?
The brake pressure of 3.5 bar acts on the rear axles. As per the function
schematic, it acts on the second and third rear axle through actuation of
the relay valve or ALB controller.
d) What is the advantage of the frequent-stop brake system?
When stopping frequently, e.g. short-range distribution, this system can

save needed air volume.
In addition, the release of air volume takes less time than the alternative
ventilation method via the spring brake cylinder. The vehicle can thus be
set in motion more quickly.

20 Practical work 6
0 Instructions
20 Practical work 6
Instructions
Total time ........................................................................................................................ 140 min
20.1 Adjustment possibilities as part of truck/trailer balancing
The participant can make adjustments to the braking characteristics of the truck/trailer
combination in practice.
Adjustment possibilities as part of truck/trailer balancing
Exercises 40 min
20.2 Practical work on the ABS
The participant can use diagnostic equipment and special tools.

Practical work on the ABS
Exercises Star Diagnosis, HMS 90 min

measurement technology,
tool kit
Preparation of component for practical exercise

 Mark solenoid block relative to housing
 Unscrew lower section of housing
 Rotate solenoid block through 180°
 Screw lower section of housing back on
 Install ABS valve in vehicle
TT_42_00_010303_FA
1 Solenoid block
2 Marking

20 Practical work 6
0 Instructions
TT_42_00_010304_FA
1 Lower section of housing
2 Rotate solenoid block through 180 degrees
Put tools away in workshop

10 min

20 Practical work 6

Exercise 70 @Test: exercise 14, version III (refers to exercise b)
In the training course, you have already learnt the theoretical fundamentals about performing
adjustments to ensure harmonized braking between the tractor vehicle and trailer. In the
following exercises, you have the opportunity to apply this knowledge to practical work.
Complete the following exercises in the specified order.
a) First find the document in WIS which covers testing/adjustment of the trailer control valve.
Note down the number of the corresponding document.
AR42.25-W-0025B (Test trailer control valve)
b) How can you determine whether a positive-tolerance calibration is already set on the valve?
Compare the input pressure at the trailer control valve (brake force
regulator connection 4) with the brake pressure output at the yellow
coupling head.
c) Determine the following pressures through measurement on the vehicle provided.

Measuring point at connection 4 of brake Pressure at yellow coupling head (bar)
force regulator (bar)
0.5
1.0
1.5
2.0
2.5
3.0
3.5
4.0

20 Practical work 6
d) Change the positive-tolerance calibration by 0.4 bar How do you proceed?
Also see operation step 4 in work instructions AR42.25-W-0025B.

20 Practical work 6

Exercise 71 Record signal of ABS sensor
The purpose of this exercise is to teach participants how to use HMS and
Star Diagnosis.
The rpm signals of the rpm sensors can also affect the function of other systems. In order to
make sure that an rpm sensor is operating correctly, the signal can be recording using HMS
Measurement Technology.
Record a signal from an rpm sensor of your choice using the HMS measurement technology
and transfer it to your documents. Note down the details of your measurement in the following
table:
Details of vehicle test
Location of sensor
Measuring point 1
Measuring point 2
Selection on HMS
Type of oscilloscope: universal, ...
TT_42_00_010286_FA

20 Practical work 6
Exercise 72 Diagnosis options with Star Diagnosis
Access the ABS control unit using Star Diagnosis.
a) Which diagnostic options do you have with Star Diagnosis in the ABS CONTROL UNIT?
 CONTROL UNIT VERSION

 FAULT CODE:
 CURRENT
 STORED
 ACTUAL VALUES
 ACTUATION
 Control unit adaptations
 CONTROL UNIT PROGRAMMING (SDFLASH)
b) Select the ACTUAL VALUES menu. What selection options do you have?
 VEHICLE SPEEDS AT FRONT AND REAR AXLE

 THRESHOLD GAP SPEED AT FRONT AND REAR AXLE
 TIMER VALUE FOR THRESHOLD GAP SPEED AT FRONT AND REAR AXLE
 TIRE ROLLING CIRCUMFERENCE
 VOLTAGE AT TERMINALS 30 AND 15
 INTERWHEEL DIFFERENTIAL LOCK AT FRONT AXLE
 ABS SHUTOFF BUTTON (S39)
 INTER-AXLE LOCK
 TEST EQUIPMENT ACCESS DATA

20 Practical work 6
c) What selection options do you have in menu item ACTUATIONS?
In this exercise, you can select and demonstrate the menu items depending on the equipment
of the training venue. Additional exercise for participants: What effect does the Output
actuation have? Answer: actuation of the relay for differential lock shutoff.
 ABS SOLENOID VALVE WITH ROLLER DYNAMOMETER

 ABS SOLENOID VALVE WITHOUT ROLLER DYNAMOMETER
 RPM SENSORS WITHOUT ROLLER DYNAMOMETER
 RPM SENSORS AT THE FRONT AXLE WITH ROLLER DYNAMOMETER
 RPM SENSORS AT THE REAR AXLE WITH ROLLER DYNAMOMETER
 ACTUATION 'OUTPUT' (PIN X1 18/17)
d) What selection options do you have in menu item CONTROL UNIT ADAPTATIONS?
 NUMBER OF POLE WHEEL TEETH AT THE FRONT AXLE

 NUMBER OF POLE WHEEL TEETH AT THE REAR AXLE
 SYSTEM
 ASR FUNCTION
 ASR PUSHBUTTON
 ELECTRONIC BRAKE FORCE LIMITATION
 ABS SHUTOFF WITH FRONT AXLE LOCKED
 INTER-AXLE LOCK
 TIRE ROLLING CIRCUMFERENCE OF THE FRONT AXLE
 TIRE ROLLING CIRCUMFERENCE OF THE REAR AXLE
Exercise 73 Troubleshooting on ABS
On the vehicle provided, process the following customer complaint: “When braking on a
slippery road surface, the vehicle breaks away to the left.”
Note down your procedure and the results.

20 Practical work 6

21 Practical work 7
0 Instructions
21 Practical work 7
Instructions
Clarification of open questions

15 min
Final test
Explanation of trainer and carrying out of final test
40 min
Farewell
5 min

NLDB-LL246 - Trainer preparation
Daily overview

Daily overview
Time Duration Section Title Learning objective / content / work form / method Media
Day 1
1 Orientation
8:15 5 1.1 Welcome Welcome from the trainer
8:20 30 1.2 Organization and Organizational procedures (participant list, parking...), general decisions on
training procedure, introductions
general rules
8:50 5 1.3 Learning objectives The participant can understand the learning objectives of the NLDB
training.
Learning objectives of NLDB training course
“Learning path” on metaplan board
2 Legal provisions
8:55 5 2.1 Controls + brake The participant can state the legal requirements applicable to the controls
circuits of a brake system. The participant can describe the legal requirements
applicable to brake circuits.
Legal requirements for controls and brake circuits
Interactive lecture
9:00 15 2.2 Types of brake The participant can name the different types of brake systems. The
system participant can name an example/the associated components of every
type of brake system.
Types of brake system: service brake system, secondary brake system,
permanent brake system, parking brake system
Exercise, exhibition with pictures of components (e.g. Telma) and copies
from specialist books

Daily overview
9:15 5 3.1 Brake systems in The participant can identify the individual types of brake systems in
function schematics function schematics.
Transition from “Types of brake system” exercise to reading of function
schematics.
Task, exercise
9:20 15 3.2 Symbol The participant can explain the connection designations and standardized
symbols used in function schematics.
Symbols in pneumatic function schematics
Assignment exercises
9:35 10 3.3 Using function The participant can explain other information on function schematics WIS (per group)
schematics (e.g. grids, references to other function schematics or circuit diagrams,
legend).
Other information on function schematics
Interactive lecture
9:45 20 Breakfast
10:05 10 4.1 Compressor The participant can name the changes to the cylinder head through the use Cylinder head of
of “AdvancedPowerReduction”. switchable compressor for
APR cylinder head viewing
Interactive lecture/exercise
10:15 10 4.2 Pressure regulator The participant can describe the function of the pressure regulator. WIS (per work group)
The participant can explain the function of the heater in the pressure
regulator unit.
Function of pressure regulator
Exercise

Daily overview
10:25 5 4.3 Pressure regulator The participant can name the differences in the compressed air system Function schematic
(10 bar), sales code when the 10 bar pressure regulator is used.
BC3 Pressure regulator in 10 bar pressure regulating system (10 bar)
Presentation
10:30 30 4.4 Compressed air drier The participant can describe the function of the single-chamber and
dual-chamber air drier. The participant can identify sources of faults on
the different compressed air driers.
Function of compressed air drier
Exercise
11:00 10 Break
5 Practical Work 1
11:10 20 5.1 Test compressor The participant can perform work on the compressor in accordance with Once per work group =
manufacturer specifications. clock (time measurement)
Test operations on compressor (delivery time, oil loss) Blank paper (oil loss),
Exercises commercially available
tools, WIS. (wheel
chocks+extraction system)
11:30 15 5.2 Check and adjust The participant can check the operation of the pressure regulator and WIS + compressed air
pressure regulator evaluate the result. The participant can adjust the pressure regulator as per gauge
manufacturer specifications.
Testing and adjustment operations on pressure regulator
Exercises
11:45 15 5.3 Test compressed air The participant can test the operation of the compressed air drier. WIS + compressed air
drier gauge + adapter fitting
Test operation of compressed air drier. (tank
Exercises to pressure gauge)
12:00 60 Lunch

Daily overview
13:00 15 6.1 Overflow valves The participant can name the different types of overflow valves. Overflow valve for viewing
The participant can describe the mode of operation of the different
overflow valves.
Types and mode of operation of overflow valves
13:15 15 6.2 Relay valve The participant can explain the function of a relay valve. Relay valve for viewing
Mode of operation of a relay valve

13:30 15 7.1 Four-circuit The participant can understand the design of the four-circuit protection
protection valve - valve. (The trainer derives its mode of operation with an exercise covering a
simple overflow valve through to a simplified illustration of the four-circuit
Introduction
protection valve.)
Design of four-circuit protection valve
Interactive lecture, exercise
13:45 30 7.2 Four-circuit The participant can explain the special features of the design of four-circuit
protection valves as protection valves as per ECE 13/9.
per ECE 13/9 Special features of design of four-circuit protection valve as per ECE
directive 13/9
8 Practical work 2
14:15 40 8.1 Test of four-circuit The participant can test the four-circuit protection valve as per ECE 13/9 in Compressed air gauge
protection valve accordance with manufacturer specifications.
Checking 4-circuit protection valve
Exercises

Daily overview
14:55 15 Coffee
15:10 20 8.2 Test pressure The participant can test the operation of the pressure limiting valves in the Compressed air gauge
limitation in four- four-circuit protection valve.
circuit protection Test pressure limiting function in four-circuit protection valve.
valve Exercises

15:30 30 9.1 Read function The participant can read function schematics for the pressure WIS
schematics (DE+DS) production and pressure retention sections (DE+DS).
Exercise
16:00 15 Day-end closing Any unresolved questions of participants about the content covered can be
answered. Content mentioned can be repeated to reinforce learning.
Discussion

Daily overview
Day 2
8:15 20 Introduction to day 2 The participant can explain what he/she learnt on the previous day.
Repetition of first day.
8:35 40 10.1 System design of The participant can describe the two usual variants of system design. Laminated sheets with
service brake system The participant can name the components of the service brake system. schematic illustration of
The participant can name the tasks of the service brake system components
components.
Design of brake system.
Exercise. One group works out each design. When completed, the group
presents their solution to the others.
9:15 15 10.2 Confusion during The participant can explain the consequences of a faulty repair of the
repair of the service service brake system.
brake system Dual-circuit functionality of brake system
Exercise
9:30 15 10.3 Service brake valve The participant can describe the function of the service brake valve. Component for viewing
The participant knows the different versions of a service brake valve.
Service brake valve
Exercise
9:45 5 10.4 Pressure ratio valve The participant can describe the function of the pressure ratio valve. Component for viewing
with retardation The participant can state the model series in which the component is used.
Pressure ratio valve with retardation (braking pressure controller)
Exercise
9:50 10 10.5 Brake force regulator The participant can assign the various designs of ALB valves to their type of Component for viewing
application. The participant can describe the function of an ALB valve.
ALB valves
Exercise

Daily overview
10:00 20 Breakfast
10:20 45 10.6 Trailer control valve The participant can describe the functions of the trailer control valve. WIS, component for
viewing
Trailer control valve
Interactive lecture + exercise
11 Practical work 3
11:05 10 Break
11:15 70 11.1 Test components of The participant can test the components of the service brake system as per WIS, pressure gauge,
service brake system the work instructions. commercially available
Function tests on service brake system components. tools, folding rule
Exercises
12 Braking effect
12:25 5 12.1 Terms related to The participant can explain the definition of the terms deceleration and
braking effect braking ratio.
The participant can name the measured quantities with which the braking
effect can be determined.
Terms related to braking effect
Exercise
12:30 5 12.2 Measurement method The participant can name the measuring method for determining braking
effect.
Measuring method for determining braking effect
Presentation, interactive lecture
12:35 5 12.3 Deceleration The participant knows the procedure for measuring deceleration
Deceleration

Daily overview
12:40 5 12.4 Braking ratio in % The participant can explain the method for determining the braking ratio in
% for evaluating the braking effect.
Braking ratio in %
12:45 5 12.5 Extrapolation of brake The participant can extrapolate the brake forces for evaluating the braking
forces effect.
Extrapolation of brake forces
12:50 60 Lunch
13 Practical work 4
13:50 60 13.1 Determine and The participant can evaluate the response time of the wheel brake during Pressure gauge, brake test
evaluate braking tests. The participant can evaluate the braking effect using the braking stand, scales
ratio.
effect
Practical tests on wheel brake
Exercises
14:50 5 13.2 Friction value of The participant can evaluate the brake test stand with respect to friction
brake test stand value.
Friction value of brake test stand
Exercise
14:55 15 13.3 Test condensation The participant can test the condensation sensor. Multimeter, test adapter,
sensor beaker (filled with water),
Test of condensation sensor commercially available
Exercises tools
15:10 15 Coffee

Daily overview
15:25 40 14.1 Read function The participant can read function schematics for the service brake system WIS
schematics (BBA) (BBA) section.
Exercise
16:05 10 Day-end closing Any unresolved questions of participants about the content covered can be
answered. Content mentioned can be repeated to reinforce learning.
Discussion

Daily overview
Day 3
8:15 15 Introduction to day 3 The participant can explain what he/she learnt on the previous days.
Repetition of content from second day.
8:30 10 15.1 Complaints due to The participant can state the effects on components on the tractor vehicle Metaplan cards
insufficient and trailer. The participant can establish a link to customer complaints.
harmonization of Effects on assemblies and customer complaints with poor truck/trailer
balancing.
tractor/trailer
Card question
combination
8:40 10 15.2 Evaluation The participant can explain the possibility of comparing deceleration.
possibilities The participant can explain the differences on the available evaluation
diagrams. The participant can correctly use the diagrams.
Diagrams for evaluation
Interactive lecture
8:50 30 15.3 Evaluation and The participant can evaluate a completed diagram. The participant can
adjustment options explain the adjustment options.
Evaluation of completed diagrams. Adjustment options.
Interactive lecture
9:20 10 15.4 Practical examples The participant can name possible fault sources based on practical
examples.
Practical examples of completed braking effect diagrams.
Interactive lecture, discussion
9:30 20 Breakfast

Daily overview
16 Parking brake
9:50 20 16.1 Parking brake valves The participant can explain the tasks of the different parking brake valves.
Parking brake valves

10:10 5 16.2 Combination brake The participant can explain the function of the brake cylinder with
cylinder with integrated ventilation valve (IBV). The participant can describe possible
symptoms of incorrect diagnosis due to the integrated ventilation valve.
integrated ventilation
Combination brake cylinder with integrated ventilation valve (IBV)
valve
Presentation, exercise
10:15 5 17.1 Introduction to ABS The participant can describe the background to the use of ABS.
(anti-lock braking The participant can explain technical terms related to ABS.
system) Compulsory ABS requirement, terms “frictional connection” and “wheel
slip”
Interactive lecture
10:20 5 17.2 Control loop + control The participant can name the components which make up an ABS control
cycle loop. The participant can explain the sequence of an ABS control cycle.
Control loop, control cycle
Interactive lecture
10:25 5 17.3 Types of control The participant can explain the types of control of an ABS system.
Types of control of ABS

10:30 10 17.4 Control channels The participant can explain the term “control channel”
“Control channel” term

Exercise

Daily overview
10:40 5 17.5 Other functions The participant can explain how ABS functionality is ensured in different
driving situations.
ABS function when used with permanent brakes. ABS function on all-wheel
drive vehicles.
Interactive lecture
10:45 5 17.6 Electronic brake force The participant can explain the background to the omission of the ALB WIS
limitation controller in certain model series. The participant can use the relevant
published documentation.
Electronic brake force limitation
Exercise
10:50 10 Break
11:00 15 18.1 ASR components and The participant can name the components required for the ASR function.
function The participant can explain the mode of operation of an ASR control
intervention.
Components of acceleration skid control (ASR). Mode of operation of ASR.
Exercise, interactive lecture
11:15 15 19.1 Overload protection The participant can explain the function of relay valve 16.05 in function WIS
schematics.
Overload protection valve
Exercise
11:30 10 19.2 Frequent-stop brake The participant can explain the function of the frequent-stop brake. WIS
Frequent-stop brake
Exercise

Daily overview
20 Practical work 6
11:40 40 20.1 Adjustment The participant can make adjustments to the braking characteristics of the WIS, tool kit
possibilities as part of truck/trailer combination in practice.
truck/trailer Adjustment possibilities as part of truck/trailer balancing
balancing Exercises
12:20 60 Lunch
13:20 90 20.2 Practical work on the The participant can use diagnostic equipment and special tools. Star Diagnosis, HMS
ABS measurement technology,
Practical work on the ABS tool kit
Exercises
14:50 10 Put tools away in
workshop
21 Practical work 7
15:00 15 Coffee
15:15 15 Clarification of open
questions
15:30 40 Final test Explanation of trainer and carrying out of final test
16:10 5 Farewell

Preparation table
Preparation table
Vehicles
Name Details Quantity Resource No.
Axor or Atego The following equipment features are 2
required: brake system with ABS
(sales code B02), trailer brake system
(sales code B43)
Tools/equipment with MB object number

Test weighing device For determining the actual axle load 1 W 385 589 05 21 00
Compressed air test kit Pressure gauge with suitable test 2 W 360 589 00 21 00
connections for the compressed air
system
MB electrical connection set 2 W 220 589 00 99 00
Tools/equipment
Standard workshop tool kit Torx screwdriver, open end and box 1
wrench, crimper, side cutting pliers,
release tool for connectors etc.
Star Diagnosis with HMS 2
Pit 1
Vehicle jack With possibility for fitting a test scale 1
Brake test stand 1
Video projector For group work with Star Diagnosis As required
Flashlight/hand lamp As required
Repair aids
Work clothing As required
Shop towels As required
Hand washing paste As required
Hand cream As required

Preparation table
Resources/materials for preparing theory sections of training

Flipchart with markers As required
Metaplan board with As required
corresponding cards
Video projector As required
Presentation program ABS Must be Program as additional
installed on the material on CD
computer
Posters Can be written on and wipeable As required ppt presentation as
additional material
on CD
Colored pens Various colors for highlighting on B/W As required
documents
Components for viewing and demonstration (disassembly)

Pressure ratio valve with As required A 004 430 46 81
retardation
Relay valve As required A 004 429 94 44
Service brake valve with front As required A 004 431 61 05
axle control
Brake valve without front axle As required A 004 431 20 05
control
Steel suspension brake force As required A 003 431 27 12
regulator
Air suspension brake force As required A 003 431 22 12
regulator
Air suspension brake force (new generation) As required A 005 431 84 12
regulator
Material for preparation. Troubleshooting on ABS system with Star Diagnosis

ABS valve 1 per vehicle A 000 429 65 44

1511 8650 - 1st edition 10.2.2011 160

Trucks - Chassis and Active Safety Air Brake Systems - Go Trainer Document

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Global Training – The finest automotive learning

Trucks • Chassis and Active Safety

© 2011 Copyright Daimler AG

Publisher: Global Training

1511 8650 - 1st edition 10.2.2011 160

2 Legal provisions .........................................................................................................4

3 Standardization and symbols .....................................................................................7

4 Components for compressed air production (DE)....................................................17

5 Practical work 1 .......................................................................................................27

6 Components of the compressed air system ............................................................31

7 Components for pressure retention (DS) .................................................................38

NLDB-LL246 <> Trainer document I

8 Practical work 2 .......................................................................................................43

9 Read function schematics - 1...................................................................................47

10 Components of the service brake system (BBA) ......................................................50

11 Practical work 3 .......................................................................................................68

13 Practical work 4 .......................................................................................................81

14 Read function schematics - 2...................................................................................90

15 Braking effect of tractor vehicles and trailers ..........................................................92

II NLDB-LL246 <> Trainer document

15.2 Evaluation possibilities ....................................................................................................... 96

16 Parking brake .........................................................................................................106

17 Antilock brake system............................................................................................113

18 Acceleration skid control (ASR) .............................................................................123

20 Practical work 6 .....................................................................................................130

21 Practical work 7 .....................................................................................................138

NLDB-LL246 - Trainer preparation...............................................................................139

NLDB-LL246 <> Trainer document III

1.2 Organization and general rules

1.3 Learning objectives

“Learning path” on metaplan board 5 min

Presentation of day's schedule:

Marking of content relevant for the final test

NLDB-LL246 <> Trainer document 1

Products of MB-Trucks TT_00_10_001407_FA

1.2 Organization and general rules

1.3 Learning objectives

2 NLDB-LL246 <> Trainer document

Axor reference vehicle TT_00_00_009902_FA

NLDB-LL246 <> Trainer document 3

2.1 Controls + brake circuits

Interactive lecture 5 min

2.2 Types of brake system

The participant can name the different types of brake systems.

4 NLDB-LL246 <> Trainer document

2 Legal requirements (participants)

Brake system control devices

NLDB-LL246 <> Trainer document 5

2.2 Types of brake system

 Service brake system (BBA)

 Service brake system: It must be possible to brake the vehicle to a

6 NLDB-LL246 <> Trainer document

3 Standardization and symbols

3.1 Brake systems in function schematics

Task, exercise 5 min

Assignment exercises 15 min

3.3 Using function schematics

Interactive lecture 10 min

NLDB-LL246 <> Trainer document 7