Chequeo Frenos Scania

10:03-01
Issue 3 en
Testing brake system
Applies to vehicles without EBS
ã Scania CV AB 2001, Sweden

1 585 418
Contents
Contents
General Information .................................................................................. 5
Equipment .................................................................................. 6
Location of components ................................................................................ 10
Test connection ................................................................................ 12
Checking pressure gauges ................................................................................ 14
Operating pressure, integrity,

overflow valve (39) Test stage 1 ............................................................. 18
Anti-freeze unit Test stage 2 ............................................................. 22
Four-circuit protection valve types

1, 3 Test stage 3a ........................................................... 24
Four-circuit protection valve types

2, 4, 5 Test stage 3b ........................................................... 28
Parking brake, emergency brake,

pressure limiting valve (58b), relay
valve Test stage 4 ............................................................. 32
Warning lamps and sensors Test stage 5 ............................................................. 36
Front and rear brake circuit Test stage 6 ............................................................. 38
Maximum service pressure Test stage 7 ............................................................. 40
Service brake valve Test stage 8 ............................................................. 42
Brake starting pressure, disc brake Test stage 9a ........................................................... 44
Brake starting pressure, drum

brake Test stage 9b ........................................................... 46
Rear circuit relay valve Test stage 10 ........................................................... 48
Front circuit relay valve Test stage 11 ........................................................... 50
Front circuit pressure limitation Test stage 12 ........................................................... 52
2 ã Scania CV AB 2001, Sweden 10:03-01

Contents
Trailer relay valve Test stage 13 ........................................................... 54
Load-sensing valve, air

suspension Test stage 14a ......................................................... 56
Load-sensing valve, leaf-spring

suspension Test stage 14b ......................................................... 58
Dump feature, trailer relay valve Test stage 15 ........................................................... 62
Test connection on 6x4s with US-

adapted brake system ................................................................................ 64
Emergency brake valve (93) Test stage 16 ........................................................... 65
Supply dump valve (59) Test stage 17 ........................................................... 67
Basic setting and stroke Test stage 18 ........................................................... 68
Brake linings, drum brake Test stage 19 ........................................................... 68
Brake linings and brake discs Test stage 20 ........................................................... 68
10:03-01 ã Scania CV AB 2001, Sweden 3

General Information
Brake testing
General Information
The test programme is intended for use during

brake system troubleshooting and inspection.
For the relevant test stages for the various
levels of inspection, see main group 0,
Inspection instructions.
The programme is structured so that the whole
system can be tested by circuit or individual
components.
The test programme assumes access to
appropriate test equipment, see the
"Equipment" section.
During the test, readings must be recorded in a
report. See Testing the brake system, Report,
Vehicles without EBS.
IMPORTANT! Before conducting the brake

test, apply the brake heavily 5 - 10 times.
Make sure the pressure gauges being used are
checked and calibrated.

Equipment
Equipment
1 Measuring panel 98 600

The panel comprises three pressure gauges
0-2.5 bar, permanently fixed in a metal
casing.
A Plexiglas disk permanently screwed to the
metal casing protects the pressure gauges
from the front. The connection to each
pressure gauge contains a damping device
and a T-pipe equipped with a 3/8" insert
nipple and a safety valve, part no. 293 542,
set to 2.5 bar.
2 Measuring panel 99 399

Two built-in pressure gauges, 0-15 bar,
without safety valve.
3 Pressure gauge 99 215

A loose pressure gauge 0-15 bar, without
safety valve.
4 Adapter 99 401

Equipment
5 Relief valve 98 703

The relief valve is designed to control the
other pressure gauges.
6 Pressurising hose with connections,

98 243
The hose is equipped with a cap nut at one
end and a threaded adapter connection at the
other. It also has a check valve and a test
connection. The hose is used when charging
the compressed air system of the vehicle
with workshop air.
7 Connecting hose 99 164

Fabric-reinforced plastic hose with cap nut
at one end and quick coupling at the other.
The hoses are used to connect the pressure
gauges to the test connections. The hoses
may be spliced with connector 98 706, e.g.
when testing trailer brakes.

Equipment
8 Connector for connecting hose 98 706

The connectors are used to connect the
connecting hoses, e.g. when testing trailer
brakes.
9 In-house manufactured tools
Duo-Matic, ISO and BSI kits can be ordered

to brake testing trolley 588 477. See tool
sheet 588 477 for component parts.
Due to the various designs of trailer brake
couplings, hoses 98 605 are supplied
without couplings. Connect the couplings as
follows:
• Duo-Matic coupling:
Drill out the rivets holding the plate on the

cover using a 5 mm drill. Cut a thread using
an M6 tap and attach the handle with an
M6x12 mm bolt. Make two versions, one
for trucks and one for tractors. Use handle
99 402 for trucks.
• ISO coupling:
Use a T-union WR 1/4" and test connection

215 619.

Equipment
• Duo-Matic coupling, trailer section

Equipped with a test connection in the feed
line connection.
1 Feed line
4 Control line
• ISO coupling, trailer section

Equipped with a test connection in the feed
line connection.
1 Supply cable (red)

4 Control cable (yellow)
• BSI connection, trailer section

Location of components

3 Compressor 20d Manual control valve, trailer brake circuit 58a Pressure limiting valve (6.5 bar for exhaust
4 Brake chamber 23 Double check valve brake, 7.3 bar for others)
7b Air tank, parking brake and trailer brake 25 Trailer brake coupling 58b Pressure limiting valve (8 bar), parking
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circuit brake and trailer brake circuit (7.3 bar for
26 (O10) Indicating instrument, front circuit US-adapted brake systems)
7c Air tank, front circuit pressure
58c Two-stage pressure limiting valve (9.3 bar)
7d Air tank, rear circuit 26 (O11) Indicating instrument, rear circuit for 12.2 bar systems
7k Air tank, air dryer pressure
60 Four-circuit protection valve
10a (T4) Low pressure indicator for supply 27 Spring brake chamber
61d Manual control valve, parking brake circuit
pressure, parking brake circuit 28 Filler nipple, parking brake circuit
65 Manifold fitting
10b (T3) Low pressure indicator for service 32 Drain valve
pressure, parking brake circuit 74 (H4) Air dryer with integrated pressure
35 Safety valve (19 bar) regulator
12 Service brake valve 36 Air tanks, air suspension 79 Brake protection valve
13 Safety valve (14.3 bar) 39 Overflow valve 81 V81) TC Solenoid valve
16 (T1) Pressure sensor with monitor, front 49 Load-sensing valve
circuit 83 (V1) Exhaust brake solenoid valve
51 (V3-6, V46-47) Control valve ABS 84 (N1) Buzzer
16 (T2) Pressure sensor with monitor, rear
circuit 52 Interlock valve W6 Warning lamp, low circuit pressure
17 (B1) Brake light switch 55 Test connection / filler nipple W7 Warning lamp, parking brake
18 Quick release valve 57 Trailer relay valve

19 Relay valve, rear circuit
19b Relay valve, parking brake circuit
11
Test connection
Test connection
A colour-coded brake circuit diagram is available in the electronic version of this
booklet as well as in main group 10, Testing brake system, Test connection.
F Parking brake circuit

D Trailer brake circuit
E Accessory circuit
A Supply circuit
B Front circuit
C Rear circuit

Socket No. Circuit of feature to be tested Location
1 Charging with workshop air In left-hand step
1A Measuring supply circuit pressure (on vehicles with 12.2 bar On the air suspension air tank, in front of the overflow valve
10:03-01
system)
Must not be used for charging with workshop air
2 Rear circuit, supply pressure Adjacent to service brake valve
3 Rear circuit, service pressure In centre valve assembly, bottom connection (R)
4 Parking and trailer brake circuit supply pressure Adjacent to service brake valve
5 Front circuit, brake pressure On right-hand front wheel brake chamber, on vehicles with
ABS on both sides
6 Rear circuit, brake pressure On the rear brake chambers
7 Parking brake, service pressure On the rear spring brake chambers
8 Trailer brake, service pressure For test connections connected to trailer brake coupling, see
In-house manufactured tools
9 Front circuit service pressure In centre valve assembly, top connection (F)
10 Rear circuit load-sensing valve bellows pressure Beside solenoid valve block for air suspension
11 Four-circuit protection valve, accessory circuit One of the outputs on coupling 65, select one of the couplings.
Note: Fit a test connection on the appropriate coupling
12 Front circuit, supply pressure Adjacent to service brake valve

13 Trailer brake, supply pressure For test connections connected to trailer brake coupling, see
In-house manufactured tools
14 Supply circuit, check valve in overflow valve 39 On the air suspension air tank, behind the overflow valve
Test connection
13
14
Checking pressure gauges
IMPORTANT! The pressure gauges must be
used in a suspended position, in the same way as
when they are set to zero.
Note: Always check that the cables and

connections in the circuits are airtight.
Multimeter with converter from measuring set 99 362 and adapter 99 401

Connection diagram for checking 2.5 bar Connection diagram for checking 15 bar Adjusting screw on pressure gauges
pressure gauges pressure gauges
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Equipment/Pressure gauges
2.5 bar 15 bar
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3 off 3 off
Test measures pressure gauge Cause of fault / action

2.5 bar 15 bar
2.5 bar pressure gauges
- Connect adapter 99 401 to the pressure reduction valve.
- Connect the adapter to the converter. Then connect the
converter to multimeter 588 093.
- Set the multimeter to direct current voltage and turn on the
converter.
- Zero the multimeter by turning the converter set screw
marked zero.
- Zero the indicators on the pressure gauges.
- Turn the knob anticlockwise until the relief valve is closed.

- Connect the air hose from the workshop air system to the
relief valve.
- Connect the three hoses from the relief valve to each
pressure gauge.
- Turn the relief valve knob clockwise until the pressure 1.0
gauges and the multimeter show approx. 1.0 bar. The
voltage reading shown in the multimeter window
corresponds to the pressure in bar.
- Check that the pressure gauges show the same. Check that the pressure gauge value agrees with
the value on the multimeter with a tolerance of +/-
0.025 bar/V. If it does not, return the pressure
gauge for calibration.
15
16
Test measures pressure gauge Cause of fault / action
2.5 bar 15 bar
- Raise the air pressure using the relief valve to 1.5 and
2.0 bar and check that the pressure gauges and the
multimeter correspond.
- Increase air pressure to 2.5 bar, at which point the safety 2.5 The opening pressure is adjusted by turning the
valves should open. adjusting sleeves on the safety valves.
15 bar pressure gauges

- Set the displays to zero.
- Connect an air hose to each pressure gauge.
- Turn the knob clockwise until the pressure gauges show 5 5.0
bar.
- Check that the pressure gauges correspond. Check that the pressure gauge value agrees with
the value on the multimeter with a tolerance of +/-
0.1 bar/V. If it does not, return the pressure gauge
for calibration.
- Raise the air pressure to 6 and 7 bar and check that the
pressure gauges correspond.

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18
1. Testing operating pressure, seal integrity and check valve in overflow valve (39)
Test stage 1
Note the reading in the report accompanying

this booklet.
2.5 bar 15 bar

-- 3 off

12
10 2526
100668
Test connection 1A and 14 Test connection 1 Test connection 12
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Test measure Test connection (bar) Cause of fault / action
12 1A
Vehicles with load handling tanks
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- Connect 15 bar pressure gauge to test connections 12, 1 and 1A.
- Start the engine and charge the system.
- Check the relief pressure at test connection 1A by noting when the
pressure at test connection 1 drops.
- Check the pressure limiting valve (58c) at test connection 12. 9.1 - 9.5 12.0 - 12.4
- Decrease the system pressure by draining the first load handling tank.
- Note the pressure at test connection 1A when the compressor starts to 10.4 - 11.5
charge. The compressor starts charging when the pressure rises at test
connection 1. Calculate the pressure difference to obtain the operating
range of the compressor.
Checking the check valve in the overflow valve (39)

- Move the pressure gauge from test connection 1A to test connection 14.
- Drain the first load handling tank.
- The pressure at test connection 14 must not drop. If the pressure at test connection 14
drops, the overflow valve (39) must be

replaced.
Vehicles without load handling tanks

- Connect 15 bar pressure gauges to test connections 12 and 1.
- Start the engine and charge the system.
- Check the relief pressure at test connection 12 by noting when the 9.1 - 9.5
pressure at test connection 1 drops.
- Decrease the system pressure by repeatedly depressing the brake pedal.
- Note the pressure at test connection 12 when the compressor starts to 7.9 - 8.9
charge. The compressor starts charging when the pressure rises at test
connection 1. Calculate the pressure difference to obtain the operating
range of the compressor.
Test stage 1
19
20
12 1A
Test stage 1
Seal integrity
- Fill the system to operating pressure.
- Fully depress the brake pedal. Wait 30 seconds. Read and record the
pressure.
- Keep the pedal depressed a further 1 minute.
- Read and record the pressure. < 0.2 bar If pressure drop is greater, the leak
drop must be repaired before continuing the
test.

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22
2. Checking anti-freeze unit
Test stage 2
! WARNING!
Release the air from the system before removing the

desiccant container

Haldex design 1 Haldex design 2 Wabco
Air dryer Resistance

Haldex and Wabco 5.0 - 7.5 ohm at temp < + 7 °C
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Test measure Cause of fault / action
Air dryer When the compressor is relieving load,
- Note the function check in the brake test report. the drain valve should open. The air in
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the dryer should then be evacuated.
- Check that the drain valve in the bottom of the dryer does not leak when the compressor is charging.
Evacuation takes up to 40 seconds.
Checking the heater element
- Start the engine and check whether there is a supply voltage in the connector to the air dryer heater
element, 24 - 28.8 volts
Air dryer temperature below +7 ° Rectify the air dryer if it is not
- Start the engine and feel to see if the underside of the dryer heats up within a minute. The temperature operating in accordance with the test
should rise to 20 °C, which is the switch-off temperature of the thermostat. stages, see main group 10 in the
Service Manual, Supply circuit
Air dryer temperature above +7 °
components.
- Remove the P2/H contact in the central electric unit.
- Connect a multimeter set for measuring resistance between ground and the green wire marked 61C on pin
12 in the H contact.
- Place the multimeter on top of the instrument panel with its display window facing the windscreen.
- Tilt the cab or drop down the bonnet. Remove the cover over the air dryer.
- Remove the desiccant container.
- Cool down the air dryer as illustrated using e.g. cooling spray until it is below + 7 °C, which is the opening
temperature of the thermostat. Spray at intervals to allow time for the cold to propagate through the

material.
- Measure the resistance at the contact.
Test stage 2
23
24
3a. Testing four-circuit protection valve type 1 and type 3
Test stage 3a
2.5 bar 15 bar

-- 3 off
10_2704
Type 1 Wabco Type 3 Knorr

4
12
100315
100668
Test connections 2, 4 and 12
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Test connection 1
1 2 4 11 12
Checking the opening pressure
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The only circuit that needs to be tested is the parking brake
circuit, since legal provisions state that it must not be
charged before the service brake circuits have reached
emergency brake pressure.
- Evacuate the system.
- Connect 15 bar pressure gauges to test connection 2. 4 and
12.
- Charge the system and check that the pressure in the front > 5.0 > 5.0 If the value is incorrect, replace
and rear circuit is at least 5 bar before the parking brake the valve.
circuit clearly opens.
Checking closing pressure
Front circuit and rear circuit

- Charge the system to at least 7.5 bar and make sure the
compressor is in charging mode.

- Connect 15 bar pressure gauges to the rear circuit test
connection 2, the front circuit test connection 12 and test
connection, filler nipple 1.
- Drain the accessory circuit.
- Check that the pressure in the rear circuit and the front 0.0 > 4.0 > 4.0 If the value is incorrect, replace
circuit is not below 4 bar. and the test connection, filler the valve.
nipple drops to zero.
Test stage 3a
25
26
1 2 4 11 12
Test stage 3a
Parking brake circuit and accessory circuit

- Charge the system to at least 7.5 bar and make sure the
compressor is in charging mode.
- Connect 15 bar pressure gauges to the parking brake circuit
test connection 4, the accessory circuit test connection 11
and test connection, filler nipple 1.
- Drain the rear circuit by fitting a pressurising hose to test
connection 2.
- Check that the pressure in the parking brake circuit and the 0.0 > 4.0 > 4.0 If the value is incorrect, replace
accessory circuit is not below 4 bar. and the test the valve.
connection, filler nipple drops to zero. The pressure in the
parking brake circuit will continue to drop because it does
not have a check valve.

10:03-01
28
3b. Testing four-circuit protection valve type 2, 4 and 5
Test stage 3b
2.5 bar 15 bar

-- 3 off
Types 2, 4 and 5 are similar. The difference

between them is that there is a bypass function
in types 4 and 5 that drains the parking brake
circuit if the rear circuit is empty. Type 5 has
increased opening pressure and is found on T-
vehicles with disc brakes.
Types 2, 4, 5 Wabco Types 4 and 5 Wabco
Type 4 is present as from chassis number:
Scania Södertälje 1 261 040

Scania Nederland
Scania Angers 4
Type 5 is present from 2001-09, T-vehicles with

disc brakes.
12
100668
Test connection 1 Test connections 2, 4 and 12
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1 2 4 11 12
Checking the opening pressure
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The only circuit that needs to be tested is the parking brake
circuit, since legal provisions state that it must not be
charged before the service brake circuits have reached
emergency brake pressure.
- Evacuate the system.
- Connect 15 bar pressure gauges to test connections 2, 4 and
12.
- Charge the system and check that the pressure in the front > 5.0 > 5.0 If the value is incorrect, replace
and rear circuit is at least 5 bars before the parking brake the valve.
circuit clearly opens.
Checking closing pressure
Front circuit
- Connect a 15 bar pressure gauge to the test connection,
filler nipple 1.
- Charge the system to at least 8.5 bar and make sure the > 4.0 If the value is incorrect, replace
compressor is in charging mode. Drain the front circuit and the valve.
read off the pressure gauge.

Rear circuit
compressor is in charging mode. Drain the rear circuit and the valve.
read off the pressure gauge.
Parking brake circuit
compressor is in charging mode. Drain the parking brake the valve.
circuit and read off the pressure gauge.
Accessory circuit
compressor is in charging mode. Drain the accessory the valve.
circuit and read off the pressure gauge.
Test stage 3b
29
30
1 2 4 11 12
Test stage 3b
Bypass function, types 4 and 5 only.

- Apply the parking brake.
- Charge system to relief pressure.
- Connect 15 bar pressure gauges to parking brake circuit
test connection 4 and rear circuit test connection 2.
- Drain the rear circuit.
- Check that the pressure in the parking brake circuit does 0.0 < 5.0 If the value is incorrect, replace
not exceed the specified value and that the rear circuit drops the valve.
to 0.

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32
4. Testing parking brake / emergency brake and function of pressure limiting valve
Test stage 4
(58b) and relay check valve
2.5 bar 15 bar

-- 3 off
Filler nipple 28
Interlock valve 52
Test connection 4

Test connection 7 Test connection 8
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7 8 4
Pressure limiting valve (58B)
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- Charge the system. Close the air supply.
- Read the pressure gauge at test connection 4. 7.7 - 8.3 Incorrectly adjusted pressure limiting
(7.0 - 7.6) valve.
Parking brake-emergency brake
- Place chocks in front of and behind at least two wheels.
- Connect 15 bar pressure gauges to test connections 4, 7 and
8.
If the vehicle does not have a trailer relay valve (57), only
one pressure gauge should be connected to test connection
7.
- Charge system to relief pressure. Close the air supply.
1 Parking brake in drive position. 7.4 - 8.2 0.0 Test connection 7: Incorrectly
(The values in brackets only apply to vehicles with US- (6.7 - 7.5) adjusted pressure limiting valve
adapted brake systems.) (58b) or faulty parking brake valve
(61d).
2 Lever to full emergency brake position. 0.0 6.6 - 7.6 Test connection 8: Incorrectly
(6.0 - 7.0) adjusted pressure limiting valve

(58b) or faulty parking brake valve
(61d) or trailer relay valve (57).
3 Lever in parking position. (Valve without check 0.0 0.0
position)
Lever to parking position. (Valve with check position) 0.0 6.6 - 7.6
4 Lever to test position. 0.0 0.0
Test stage 4
33
34
7 8 4
Test stage 4
Check valve in relay valve for parking brake Pressure rise at test connection 4
- Apply the parking brake. indicates defective check valve in
parking brake relay valve.
- Evacuate air from the parking brake circuit via test
connection 4.
- Put the parking brake in drive position. A large pressure drop at test
- Connect 15 bar pressure gauges to test connections 4 and 7. connection 7 indicates a leak in the
control circuit or brake chambers.
- Press in the interlock valve 52 if fitted and charge the 6.0 - 8.0 0.0
parking brake circuit to 6-8 bar via filler nipple 28.
- Read the pressure gauge at test connection 7. The pressure
must not drop more than 1 bar in 1 minute.

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36
5. Checking warning lamps and sensors
Test stage 5
2.5 bar 15 bar

-- 1 off
12
P
BRAKE
AIR 100315

Test connections 2, 4 and 12
10_2277
Test measures Test connection (bar) Cause of fault / action
12 2 4
Front circuit
- Charge the system with air.
- Check that the displays in the cab show full system
pressure.
- Connect the pressure gauge to test connection 12.
- Disconnect the sensors from test connections 2 and 4.
- Drain the front circuit tank (7c) until the warning lamp 4.5 - 5.5 Fault in the sensor, lamp or buzzer.
comes on and the buzzer sounds.
- Check that the display in the cab shows the correct
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pressure.
Test measures Test connection (bar) Cause of fault / action
12 2 4
Rear circuit
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- Drain the rear circuit tank (7d) until the warning lamp 4.5 - 5.5 Fault in the sensor, lamp or buzzer.
comes on and the buzzer sounds.
- Check that the display in the cab shows the correct
pressure.
Parking brake circuit (feed)
- Drain the parking tank (7b) until the warning lamp comes 4.5 - 5.5 Fault in the sensor, lamp or buzzer.
on and the buzzer sounds.
Parking brake circuit (control)
- Charge the system.
- Apply the parking brake.

- Check that the parking brake lamp comes on. Fault in the sensor or lamp.
Test stage 5
37
38
6. Testing front and rear brake circuit
Test stage 6
Note: When measuring increasing pressure you may only depress the brake pedal or keep it still. If the brake pedal is released when measuring
increasing pressure, the test result will be incorrect.
When measuring falling pressure you may only release the brake pedal or keep it still. If the brake pedal is depressed when measuring falling
pressure, the test result will be incorrect.
2.5 bar 15 bar

2 off --

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5 6
- Connect the pressure gauges to test connections 5 and 6.
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If the vehicle has a rear load-sensing valve, it must be set to
fully open. On vehicles with leaf suspension this is done by
releasing the springs on the load-sensing valve. On vehicles
with air suspension, the rear air suspension is evacuated.
- Measure the difference between the front and rear circuits. Maximum permitted If the value is incorrect, check the brake protection
Note this down. deviation between front valve (79). If pressure rises or drops in steps, one
and rear circuits is 0.3 bar. or more of the valves could soon cause problems.

Test stage 6
39
40
7. Testing maximum service pressure
Test stage 7
2.5 bar 15 bar

-- 3 off

Applies to tractors with front circuit
Test connection 2 pressure limitation
1 Earth
2 Left indicator
Test connection 5 Test connection 6 3 Right indicator
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5 6
- Connect the pressure gauges to test connections 5 and 6 for
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the front and rear circuits and test connection 2.
If the vehicle has a rear load-sensing valve, it must be set to
fully open. On vehicles with leaf suspension this is done by
releasing the springs on the load-sensing valve. On vehicles
with air suspension, the rear air suspension is evacuated.
Note: If the vehicle has brake reduction in the front circuit, Tip! With a trailer connected to the vehicle, it
disconnect the reduction. Do this by connecting the trailer means that the electrical connection between the
to the tractor. vehicle and trailer is connected or that a 21 W lamp
is connected to the right-hand or left-hand
indicator circuits on the trailer.
- Release the parking brake.
- Start the engine and charge the system to relief pressure.
- Fully depress the brake pedal.
- Read the pressure gauges. Note this down. The recorded If the service pressure deviates more than 1 bar, the
pressure must not deviate more than 1 bar from the supply load-sensing valve, relay valve, service brake
pressure at test connection 2. valve and brake protection valve must be checked.

- Note the values for the front and rear circuits (test
connections 5 and 6). The difference between the circuits
must be no more than 0.5 bar.
Test stage 7
41
42
8. Testing service brake valve
Test stage 8
2.5 bar 15 bar

2 off --
Test connections 3 and 9
10:03-01
3 9
10:03-01
- Brake in 5 steps according to point 6 on the report.
- Measure the difference between the front and rear circuits. See the readings in Testing If pressure rises or drops in steps, the service brake
Make a note in the report. the brake system, Report, valve is sticking and could soon cause problems.
main group 10.

Test stage 8
43
44
9a. Testing brake starting pressure, disc brake
Test stage 9a
Specifications
Brake starting pressure

Brake starting pressure 0.3 -0.5 bar
Maximum difference right-left per axle 0.2 bar
2.5 bar 15 bar

1 off --

10:03-01
5 6
10:03-01
- Connect the pressure gauge to the test connections, 5 on Note the readings in the brake test report, point 9.
the front axle and 6 on the rear axle. The maximum brake starting pressure must lie
- Jack up the vehicle so that the wheel to be measured spins between 0.3 - 0.5 bar, regardless of chamber size.
freely. Rectify the brakes if the starting pressure or the
difference between the axles is higher than
- Rotate the wheel.
specification, as this indicates binding brake
- Ask a colleague to slowly depress the brake pedal. calipers. See main group 10 in the Service Manual,
- Read the manometer when the brakes begin to apply. 0.3 - 0.5 0.3 - 0.5 Disc Brakes.
- Measure on all wheels.

Test stage 9a
45
46
9b. Testing brake starting pressure, drum brake
Test stage 9b
Specifications
Brake starting pressure

Brake starting pressure, with vibration damper 0.4 - 0.6 bar
Brake starting pressure, without vibration damper 0.2 - 0.4 bar
Maximum difference right-left per axle 0.2 bar
2.5 bar 15 bar

1 off --

10:03-01
5 6
- Connect the pressure gauge to the test connections, 5 on Note the readings in the brake test report, point 9.
10:03-01
the front axle and 6 on the rear axle. Rectify the brakes if the starting pressure or the
- Jack up the vehicle so that the wheel to be measured spins difference between the axles is higher than
freely. specification. See main group 10 in the Service
Manual, Wheel brake components for drum brakes.
- Rotate the wheel.
- Ask a colleague to slowly depress the brake pedal.
- Read the manometer when the brakes begin to apply.
With vibration damper, regardless of chamber size. 0.4 - 0.6 0.4 - 0.6
Without vibration damper, regardless of chamber size. 0.2 - 0.4 0.2 - 0.4
- Measure on all wheels.

Test stage 9b
47
48
10. Testing rear circuit relay valve Note: When measuring increasing pressure you may only depress the
brake pedal or keep it still. If the brake pedal is released when
measuring increasing pressure, the test result will be incorrect.
Test stage 10
Test stage 10a, see Testing the brake system, Report in main group 10,
applies to vehicles with relay valve 0.2 bar opening pressure. When measuring falling pressure you may only release the brake
Test stage 10b, see Testing the brake system, Report in main group 10, pedal or keep it still. If the brake pedal is depressed when measuring
applies to vehicles with relay valve 0.4 bar opening pressure. falling pressure, the test result will be incorrect.
Vehicles with double front axles, US-adapted brake systems or 4x2s,

6x4s without load-sensing valve and with 8" rear brake drums have relay
valves with 0.42 bar opening pressure. For more information and
introduction times, see main group 10 Front and rear circuit
components.

2.5 bar 15 bar
2 off --
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3 6
10:03-01
If the vehicle has a rear load-sensing valve, it must be set to fully
open. On vehicles with leaf suspension this is done by releasing
the springs on the load-sensing valve. On vehicles with air
suspension, the rear air suspension is evacuated.
- Measure the difference between the pressure in front of and See the readings in Testing If the values are incorrect, check the brake
behind the relay valve. the brake system, Report, protection valve (79).
main group 10.
If pressure at test connection 6 rises or drops
in steps, the relay valve may soon cause
problems.

Test stage 10
49
50
11. Testing front circuit relay valve
Test stage 11

2.5 bar 15 bar
2 off --
10:03-01
5 9
10:03-01
- Measure the difference between the pressure before and See the readings in Testing the brake If pressure at test connection 5 rises or
after the relay valve (19c). system, Report, main group 10. drops in steps, the relay valve (19c) may
soon cause problems.

Test stage 11
51
52
12. Testing front circuit pressure limitation
Test stage 12
This test stage is only used for short tractors P/R 4x2 and 4x4 with axle distance 3.7 m and shorter, from chassis number SS1240180 and SN4393275
onwards, which have pressure limiting valve 66a in the front circuit. The pressure limiting valve reduces the brake pressure in the front circuit when
driving without a trailer. For more information see main group 10 in the Workshop manual, Reducing brake pressure in the front circuit.
2.5 bar 15 bar

-- 1 off

1 Earth
2 Left indicator
Test connection 5 3 Right indicator
10:03-01
Test measure Test connection Cause of fault / action
(bar)
5
10:03-01
Without trailer connected to the vehicle

- Fully depress brake pedal.
- Read pressure gauge at test connection 5.
Vehicle with 20" front brake chamber. 5.8 - 6.2 If the pressure gauge at test connection 5 shows 8.0 -
9.0 bar, pressure is not limited. The valve does not
activate. Check the valve and wiring.
Vehicle with 24" or 30" front brake chamber. 4.8 - 5.2 If the values deviate from the default value, adjust the
pressure limiting valve.
With trailer connected to vehicle Tip! With a trailer connected to the vehicle, it means that
- Fully depress brake pedal. the electrical connection between the vehicle and trailer is
connected or that a 21 W lamp is connected to the right-
- Read pressure gauge at test connection 5. 8.0 - 9.0
hand or left-hand indicator circuits on the trailer.
- Test both right-hand and left-hand indicator circuits.

Test stage 12
53
54
13. Testing trailer relay valve
Test stage 13

2.5 bar 15 bar

2 off --
10:03-01
3 8
10:03-01
- Brake in 5 steps according to point 13 on the report. See the readings in Testing The pressure level set at the factory at 0.3 bar should
Measure the deviation between test connections 3 and 8. the brake system, Report, normally not be changed. For more information on
Make a note in the report. main group 10. settings, see main group 10 Trailer brake circuits,
Components.
If pressure at test connection 8 rises or drops in steps,
the trailer relay valve may soon cause problems.

Test stage 13
55
56
14a. Testing rear circuit load-sensing valve, air suspension
Test stage 14a
2.5 bar 15 bar

2 off 2 off
Example of alignment chart

1 P1 Incoming pressure must be 6.0 bar.

Test connection 3 2 Rear axle or bogie load x 1000 kg.
Test connection 10
3 Air pressure in rear bellows P3.
4 Outlet pressure P2.
5 Alignment chart part number.
Outgoing pressure P2 can be read at a particular rear axle/
bogie load 2 and an air pressure value in the rear bellows P3.
The alignment chart for the load-sensing valve is located on
the inside of the door to the compartment above the passenger
seat.
Location of alignment chart for load-

Test connection 6 sensing valve
10:03-01
3 6 10
Checking maximum reduction
10:03-01
- Connect 2.5 bar pressure gauges to test connections 6 and
10, and a 15 bar pressure gauge to test connection 3.
- Enter the following bellow pressure via the control box. If If the bellows pressure cannot be reached in this
the bellows pressure increases, disconnect the pressure way, disconnect the link arm to the levelling valve
gauge. arm and block the arm in drive position during the
1.0 bar for 4x2s, 4x4s 1.0 test.
0.5 bar for others 0.5
- Depress the brake pedal until the pressure gauge at test 6.0
connection 3 shows 6.0 bar.
- Read the pressure gauge at test connection 6. Note this 1.6 - 1.9 To adjust load-sensing valve, see main group 10
down. Front and rear circuits, Components
Checking brake pressure

- Enter the following bellow pressure via the control box. If
the bellows pressure increases, disconnect the pressure
gauge.

min. 1.5 bar for 4x2s, 4x4s 1.5
min. 0.8 bar for others 0.8
- Read the pressure gauge at test connection 6. Check the To adjust load-sensing valve, see main group 10
alignment chart in the vehicle. Front and rear circuits, Components
Checking the brake protection valve (79)

- Connect a 15 bar pressure gauge to test connection 6.
- Evacuate the rear air suspension.
- Depress the brake pedal until the pressure gauge at test 6.0 5.8 - 6.1 Fault in the brake protection valve.
Test stage 14a
57
58
14b. Testing rear circuit load-sensing valve, leaf-spring suspension
Test stage 14b
2.5 bar 15 bar

-- 2 off
Example of alignment chart

1 The vehicle type determines which line should be read.
Test connection 3 The A line for tractors, the B line for trucks.
2 Arm length R is determined by the spring configuration.
3 P1 Incoming pressure from the service brake valve must
be 6.0 bar.
4 Rear axle or bogie load x 1000 kg
5 At a particular rear axle / bogie load, A or B line and
arm length are obtained from the arm length above the
zero position and P2 Outgoing pressure (6). The
topmost digit in each column indicates the arm length.
6 Outlet pressure P2.
Location of alignment chart for load- 7 Alignment chart part number.
sensing valve
Test connection 6
10:03-01
3 6
Checking the valve
10:03-01
- Connect 15 bar pressure gauges to test connections 3 and 6.
- Remove the link to the load-sensing valve arm. The valve
then sets itself to maximum position, no reduction.
- Read the pressure gauge at test connection 6. Note this 5.8 - 6.0 If the pressure gauge at test connection 6 shows less
down. than 5.8 bar, there is a fault in the load-sensing
- Read the arm vertical travel (R) between the maximum and valve.
minimum positions on the alignment chart in the cab.
- Tie up the arm on the half vertical travel (R/2).
down. than 2.7 bar or more than 2.9 bar, there is a fault in
- Tie up the arm on the vertical travel minimum position the load-sensing valve.
(maximum position - R), as shown on the alignment chart,
not the minimum position of the valve..

down. than 1.5 bar or more than 1.7 bar, there is a fault in
- Install the link to the load-sensing valve arm. the load-sensing valve.
Test stage 14b
59
60
3 6
Test stage 14b
Checking the setting

- Check the arm length as shown on the alignment chart.
- In order to read the alignment chart, the vehicle must be
loaded until the desired rear axle / bogie load is reached.
- Depress the brake pedal until the pressure gauge at test If the reading deviates by more than +/-10 % from
connection 3 shows 6.0 bar. the alignment chart, the link system between the
- Read the pressure gauge at test connection 6. Note this drive shaft and the valve must be adjusted. To adjust
down. Compare the reading with the alignment chart. the link system, see main group 10 Front and rear
circuits, Components.

10:03-01
62
15. Testing trailer relay valve dump feature
Test stage 15
2.5 bar 15 bar

-- 1 off

BSI connector Test connection 13 with in-house manufactured Example of test connection 13 and in-house
tools for vehicles with Duo-Matic coupling. manufactured tools for vehicles with ISO coupling.
10:03-01
(bar)
13
10:03-01
- Make a tool as described in In-house manufactured tools. The outlet of
the service connection should not be obstructed.
- Place chocks in front of and behind the wheels.
- Connect the tool and pressure gauge to test connection 13.
- Charge the system with air. The pressure gauge should now show full
supply pressure.
- Quickly depress the brake pedal fully. The supply pressure should drop to < 1.5 If the value is incorrect, the trailer relay valve
less than 1.5 bar in maximum two seconds. must be replaced.

Test stage 15
63
Test connection on a US-adapted brake system
Test connection on 6x4s with US-adapted brake system

A colour-coded brake circuit diagram is available in the electronic version of this booklet as well as
in main group 10, Testing brake system, Test connection.
F Parking brake circuit

D Trailer brake circuit
E Accessory circuit
A Supply circuit
B Front circuit
C Rear circuit

16. Testing emergency brake valve (93)
10:03-01
Note: The test stage applies only to vehicles with US-adapted brake systems.
2.5 bar 15 bar

-- 2 off

7 8
Checking parking brake function

- Parking brake lever to drive position. 6.7 - 7.5 0.0
- Parking brake lever to full emergency brake position. 0.0 6.5 - 7.5
- Parking brake lever to parking position. 0.0 0.0
Test stage 16
65
66
7 8
Test stage 16
Checking the emergency brake function

- Evacuate the rear circuit completely.
- Slowly depress the brake pedal fully.
- The pressure in the parking brake chamber should slowly If pressure is greater than 0 bar, check that neither
drop to 0 bar. relay valve 19b, the double check valve, nor the
emergency brake valve is sticking.

10:03-01
17. Testing supply dump valve (59)
10:03-01
Note: The test stage only applies to vehicles with brake systems adapted to USA, Australia and New Zealand.
2.5 bar 15 bar

-- 1 off

(bar)
13
Checking the venting feature
- Charge the brake system to relief pressure.
- Check the supply cable to the trailer.

Parking brake level to drive position. Pressure Faulty parking brake valve.
Parking brake lever to full emergency brake position. Pressure
Parking brake lever to parking position. No pressure The supply dump valve is sticking.
Remove the interlock valve (28) Pressure
Test stage 17
67
Test stage 18, 19, 20
18. Basic setting and stroke

For Work description and Specifications see Maintenance instructions in Group 0.
19. Checking brake lining thickness, drum brakes

20. Checking brake discs and brake lining thickness,

disc brakes

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10:03-01

Testing brake system

Applies to vehicles without EBS

ã Scania CV AB 2001, Sweden

Location of components ................................................................................ 10

Test connection ................................................................................ 12

Checking pressure gauges ................................................................................ 14

Operating pressure, integrity,

Anti-freeze unit Test stage 2 ............................................................. 22

Four-circuit protection valve types

Four-circuit protection valve types

Parking brake, emergency brake,

Warning lamps and sensors Test stage 5 ............................................................. 36

Front and rear brake circuit Test stage 6 ............................................................. 38

Maximum service pressure Test stage 7 ............................................................. 40

Service brake valve Test stage 8 ............................................................. 42

Brake starting pressure, disc brake Test stage 9a ........................................................... 44

Brake starting pressure, drum

Rear circuit relay valve Test stage 10 ........................................................... 48

Front circuit relay valve Test stage 11 ........................................................... 50

Front circuit pressure limitation Test stage 12 ........................................................... 52

2 ã Scania CV AB 2001, Sweden 10:03-01

Trailer relay valve Test stage 13 ........................................................... 54

Load-sensing valve, air

Load-sensing valve, leaf-spring

Dump feature, trailer relay valve Test stage 15 ........................................................... 62

Test connection on 6x4s with US-

Emergency brake valve (93) Test stage 16 ........................................................... 65

Supply dump valve (59) Test stage 17 ........................................................... 67

Basic setting and stroke Test stage 18 ........................................................... 68

Brake linings, drum brake Test stage 19 ........................................................... 68

Brake linings and brake discs Test stage 20 ........................................................... 68

10:03-01 ã Scania CV AB 2001, Sweden 3

The test programme is intended for use during

IMPORTANT! Before conducting the brake

10:03-01 ã Scania CV AB 2001, Sweden 5

1 Measuring panel 98 600

2 Measuring panel 99 399

3 Pressure gauge 99 215

6 ã Scania CV AB 2001, Sweden 10:03-01

5 Relief valve 98 703

6 Pressurising hose with connections,

7 Connecting hose 99 164

10:03-01 ã Scania CV AB 2001, Sweden 7

8 Connector for connecting hose 98 706

9 In-house manufactured tools

Duo-Matic, ISO and BSI kits can be ordered

Drill out the rivets holding the plate on the

Use a T-union WR 1/4" and test connection

8 ã Scania CV AB 2001, Sweden 10:03-01

• Duo-Matic coupling, trailer section

• ISO coupling, trailer section

1 Supply cable (red)

• BSI connection, trailer section

10:03-01 ã Scania CV AB 2001, Sweden 9

10 ã Scania CV AB 2001, Sweden 10:03-01

ã Scania CV AB 2001, Sweden

F Parking brake circuit

12 ã Scania CV AB 2001, Sweden 10:03-01