Iveco Stralis Ebs2 Repair Manual

ELECTRONICALLY
CONTROLLED BRAKING
SYSTEM EBS 2/ESP/EBL
STRALIS AT/AD/AS

”This document provides data, characteristics, instructionsand

methodology to perform repair interventions on the vehicle
and its components.
Anyhow, this document is addressed to qualified and
specialised personnel. Iveco commercial and assistance
network personnel as well as all Iveco authorised points of
assistance are specifically qualified and equipped to perform
the repair interventions that are indicated in this document.
Before performing any intervention, check to have available
the document relating to the vehicle model on which the
intervention is being performed and also make sure that all
accident prevention devices, such as, as a rough guide, goggles,
helmet, gloves, shoes, as well as work tooling, lifting and
transport tooling, etc., are available and efficient, and further
make sure that the vehicle is put such a way that an
intervention can be made in safety conditions.
Making interventions strictly observing the indications given
here, as well as using specific tooling indicated, assures a
correct repair intervention, execution timing observance and
operators’ safety.
Each repair intervention must be finalised to the recovery of
functionality, efficiencyand safety conditionsthat are provided
by Iveco.
Each intervention, on the vehicle, that is finalised to a
modification, alteration or else, which is not authorised by
Iveco, involves the exclusion of any responsibility for Iveco,
and, in particular, where the vehicle is covered by a guarantee,
each such intervention involves an immediate lapse of the
guarantee.
Responsibility for Iveco in repair intervention execution is
excluded.
Iveco is available to provide all clarifications necessary to make
interventions, as well as to provide indications in cases and
situations not included in this document.
Data and information contained in this document could result
not to be updated owing to modifications made by Iveco at
any moment for technical or commercial reasons, or because
of the need to adapt the vehicle to law requirements in
different countries.
In the case of a difference between what contained here and
what actually found on the vehicle, please contact Iveco
network before making any intervention.”
The data contained in this publication might fail to reflect the
latest changes which the Manufacturer may introduce at any
time, for technical or sales purposes, or to meet the
requirements of local legislation.
Copy, even partial, of text and drawings is forbidden.
Produced by:
Publication Edited by:

IVECO S.p.A.
CustomerService
LungoSturaLazio,
15
B.U. TECHNICAL PUBLISHING
10156 Torino - Italia
Iveco Technical Publications
LungoSturaLazio, 15
Print 603.93.321 - 1st Ed. 2004 10156 Turin - Italy

STRALIS AT/AD/AS AIR SYSTEM - BRAKES EBS 2/ESP/EBL 1
Pneumatic system -
EBS 2/ESP/EBL brakes
Page
SYMBOLS FOR AIR/HYDRAULIC SYSTEM

CIRCUIT DIAGRAMS
(TANKS AND ACCUMULATORS) . . . . . . . . . . 5

CIRCUIT DIAGRAMS (VALVES) . . . . . . . . . . . . 6
SYMBOLS FOR AIR-HYDRAULIC SYSTEM

DIAGRAMS (TANKS AND
ACCUMULATORS) . . . . . . . . . . . . . . . . . . . . . . 12

CIRCUIT DIAGRAMS (CONVERTERS,
CYLINDERS AND CALLIPERS) . . . . . . . . . . . . . 13

CIRCUIT DIAGRAMS
(CALLIPERS AND CYLINDERS) . . . . . . . . . . . . 14

CIRCUIT DIAGRAMS (SEMI-COUPLINGS
AND COUPLING CONNECTORS) . . . . . . . . . 15

CIRCUIT DIAGRAMS (SEMI-COUPLINGS
AND COUPLING CONNECTORS) . . . . . . . . . 16

CIRCUIT DIAGRAMS
(INDICATORS AND SWITCHES) . . . . . . . . . . 17

CIRCUIT DIAGRAMS (BRAKES) . . . . . . . . . . . . 18
PIPINGS AND FITTINGS . . . . . . . . . . . . . . . . . . . . 19
- In general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
- Rigid pipings reflanging . . . . . . . . . . . . . . . . . . . 19
- Rigid pipings bending . . . . . . . . . . . . . . . . . . . . 20
- Rigid pipings cutting . . . . . . . . . . . . . . . . . . . . . 20
- Flexible pipings replacement with traditional

fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Flexible pipings replacement with quick

connection fittings . . . . . . . . . . . . . . . . . . . . . . 22
EBS 2 (ELECTRONIC BRAKE SYSTEM) . . . . . . . . . 24
- EBS Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . 24
- Tractor and trailer compatibility at any time . . 24
- Complete fault-diagnosis structures . . . . . . . . 24
Print 603.93.321 Base - May 2004

2 AIR SYSTEM - BRAKES EBS 2/ESP/EBL STRALIS AT/AD/AS
Page Page
- EBS 2 working diagram for 6x2 vehicles (trucks)

OPERATING LOGIC . . . . . . . . . . . . . . . . . . . . . . . 25 with CURSOR 10/13 engine . . . . . . . . . . . . . 41
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 - EBS 2 working diagram for 6x2 vehicles (trucks)

with CURSOR 10/13 engine . . . . . . . . . . . . . 42
AUXILIARY BRAKE INTEGRATION . . . . . . . . . . . 27 - EBS 2 working diagram for 6x2 vehicles (trucks)
with CURSOR 10/13 engine . . . . . . . . . . . . . 43
- ESP (Electronic Stability Program) . . . . . . . . . 28
- EBS 2 system components location on vehicle
“ABS-EBL” SYSTEM (ANTI-LOCK BRAKE SYSTEM — (tractors variant) . . . . . . . . . . . . . . . . . . . . . . . 44
ELECTRONIC BRAKE LIMITER) . . . . . . . . . . . . 28
- ABS-EBL system components location
(tractors variant) . . . . . . . . . . . . . . . . . . . . . . . 45
- “ABS” (Anti-Lock Brake System) . . . . . . . . . . 28
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
- EBL (Electronic Brakes Limiter) . . . . . . . . . . . . 29
- Service braking . . . . . . . . . . . . . . . . . . . . . . . . 46
- Operating Logic . . . . . . . . . . . . . . . . . . . . . . . 29
- Emergency braking . . . . . . . . . . . . . . . . . . . . . 46
- Braking system evolution . . . . . . . . . . . . . . . . 29
- Exhaust brake . . . . . . . . . . . . . . . . . . . . . . . . . 46
BRAKING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . 30
- Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . 46
- ABS-EBL working diagram for 4x2 vehicles
(trucks and tractors, not including HR) BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
with CURSOR 8 (F2B) engine . . . . . . . . . . . . 30
- Front and rear disk brakes
(KNORR SN7 type) . . . . . . . . . . . . . . . . . . . . 46
- Working diagram for 6x2 vehicles (tractors)
with CURSOR 8 (F2B) engine . . . . . . . . . . . . 31
FAULT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . 47
- ABS-EBL working diagram for 6x2 vehicles

- Diagnosis Instruments . . . . . . . . . . . . . . . . . . . 47
(tractors) with CURSOR 8 (F2B) engine . . . . 32
- Cluster Diagnosis . . . . . . . . . . . . . . . . . . . . . . 48
- Working diagram for 6x2 vehicles (trucks) with
CURSOR 8 (F2B) engine and with CURSOR 10
engine (F3A with mechanical suspensions) . . . 33 - EBS 2 theoretical scheme . . . . . . . . . . . . . . . . 63
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . 68
- ABS-EBL working diagram for 6x2 vehicles (trucks)
with CURSOR 8 (F2B) engine and with CURSOR 10
engine (F3A with mechanical suspensions) . . . 34 TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
- ABS-EBL working diagram for stand alone 4x2 SPECIFICATIONS AND DATA -
vehicles (trucks) with CURSOR 8 (F2B) engine 35 PNEUMATIC SYSTEM . . . . . . . . . . . . . . . . . . . . 77
SPECIFICATIONS AND DATA - BRAKES . . . . . . 82

- ABS-EBL working diagram for 6x2C vehicles
(trucks) with CURSOR 8 (F2B) engine . . . . . . 36
CHECKS ON MAIN COMPONENTS
OF BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . 83
- ABS-EBL working diagram for stand alone 6x2
vehicles (trucks) with CURSOR 8 (F2B) engine 37
MAIN COMPONENTS OF THE BRAKING
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
- EBS 2 working diagram for 4x2 vehicles (tractors)
with CURSOR 10/13 engine . . . . . . . . . . . . . 38 - Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . 85
- EBS 2 working diagram for 4x2 T/FP-CT vehicles - Head locking screw tightness . . . . . . . . . . . . . 85
(tractors) with CURSOR 10/13 engine . . . . . 39
- Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . 86
- EBS 2 working diagram for 6x2 vehicles (tractors)
with CURSOR 10/13 engine . . . . . . . . . . . . . 40 - A.P.U. (Air Processing Unit) . . . . . . . . . . . . . . 86
Base - May 2004 Print 603.93.321

Page Page
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 - Speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . 107
- Duplex control valve (vehicles without EBS) . 92 - Phonic wheels . . . . . . . . . . . . . . . . . . . . . . . . . 107
- Fault Diagnosis (vehicles without EBS) . . . . . . 92 - Electronic control unit . . . . . . . . . . . . . . . . . . 107
- CBU (Central Brake Unit) - Pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . 107

(vehicles with EBS 2) . . . . . . . . . . . . . . . . . . . 93
- Diaphragm brake cylinder (for front and
- Relay valve (vehicles without EBS) . . . . . . . . . 95 added front axle disc brake) . . . . . . . . . . . . . . 108
- Fault Diagnosis (vehicles without EBS) . . . . . . 95 - Combined brake cylinder

(for front and rear disc brake) . . . . . . . . . . . . 108
- Coupling heads . . . . . . . . . . . . . . . . . . . . . . . . 95
- Combined cylinder emergency brake
- Electropneumatic modulator release device . . . . . . . . . . . . . . . . . . . . . . . . . 109
(vehicles with EBS 2) . . . . . . . . . . . . . . . . . . . 96
- Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
- Fault Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 109
- Redundancy valve (for 4x2 and 6x2 trucks) . . 99
DISC BRAKES KNORR TYPE (CALIPER SN7) . . . 110
- ABS solenoid valve . . . . . . . . . . . . . . . . . . . . . 99
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
- Dual stop valve . . . . . . . . . . . . . . . . . . . . . . . . 99
CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
- Triple servo control valve
(vehicles without EBS) . . . . . . . . . . . . . . . . . . 99 - Checking the automatic play recovery system
efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
- Predominance control . . . . . . . . . . . . . . . . . . 100
- Brake caliper components . . . . . . . . . . . . . . . 112
- Fault Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 100
- Check of braking seals thickness . . . . . . . . . . . 113
- Trailer drive servo-assisted distributor
(vehicles with EBS 2) . . . . . . . . . . . . . . . . . . . 101 OVERHAULING FRONT DISC BRAKES . . . . . . . . 114
- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 - Replacing brake linings . . . . . . . . . . . . . . . . . . 114
- Pressure test point valve . . . . . . . . . . . . . . . . . 104 - Removing and refitting brake callipers . . . . . . . 117
- Parking brake hand control valve - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

(vehicles suited to towing) . . . . . . . . . . . . . . . 104
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
- Fault Diagnosis (parking brake control valve) . 104
- Removing and refitting wheel hubs . . . . . . . . . 118
- Parking brake control manual distributor
(standby vehicles) . . . . . . . . . . . . . . . . . . . . . . 105
- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
- Manual control valve to slow down
the trailer (optional extra) . . . . . . . . . . . . . . . 105 - Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
- Fault Diagnosis (parking brake control valve) . 105 BRAKE CALIPER OVERHAUL . . . . . . . . . . . . . . . . 120
- Controlled pressure valve . . . . . . . . . . . . . . . . 106 - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 120
- Fault Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 106 - Component part cleaning and check . . . . . . . 121
- Check valve (vehicles suited to towing) . . . . . 106 - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
- Low-pressure switch . . . . . . . . . . . . . . . . . . . . 106 OVERHAULING REAR DISC BRAKES . . . . . . . . . 123
- Electro-pneumatic valve for ASR . . . . . . . . . . 107 - Replacing brake linings . . . . . . . . . . . . . . . . . . 123
Print 603.93.321 Base - May 2004

Page
OVERHAULING BRAKE DISCS . . . . . . . . . . . . . . . 126
TURNING AND GRINDING BRAKE DISCS . . . . . 126
Base - May 2004 Print 603.93.321

SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS

(TANKS AND ACCUMULATORS)
DESCRIPTION SYMBOL
HYDRAULIC FLOW
AIR FLOW
ELECTRICAL LINE
ABLE TO ROTATE
CROSSOVER OF CONNECTED LINES
PRESSURE TEST POINT
QUICK-CONNECTION COUPLING
COCK
1 2
COCK WITH OUTLET
SILENCER
COMPRESSOR 0 2
0 2
ENERGY SAVING COMPRESSOR
4
VACUUM PUMP 3 2
HYDRAULIC PUMP 0 2
HYDRAULIC HAND PUMP
32780
Print 603.93.321 Base - May 2004

SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)
DESCRIPTION SYMBOL
CONDENSATE SEPARATOR
FILTER 1 2
DEHUMIDIFIER 1 2
4
DEHUMIDIFIER 21 1
22
DEHUMIDIFIER WITH BUILT-IN 21 1

REGULATOR 22
23
AUTOMATIC CONDENSATE
DRAIN VALVE
CONTROLLED CONDENSATE
DRAIN VALVE
HAND CONDENSATE DRAIN VALVE
7
CONTROLLED ANTI-ICING UNIT 1 2
AUTOMATIC ANTI-ICING UNIT

1 2
21 23
PRESSURE REGULATOR WITH
1
INDEPENDENT CIRCUIT
22 24
PRESSURE CONTROLLER 1 21
PRESSURE CONTROLLER 1 21
23
PRESSURE CONTROLLER
(GOVERNOR) 1 2
PRESSURE LIMITING VALVE 1 2
32782 32783
Base - May 2004 Print 603.93.321

DESCRIPTION SYMBOL
PROPORTIONAL REDUCING VALVE 1 2
MATCHING VALVE 1 2
21 23
FOUR CIRCUIT PROTECTION VALVE 1
22 24
21
THREE CIRCUIT PROTECTION
1 23
VALVE
22
21
TWO CIRCUIT PROTECTION VALVE 1
22
NON-RETURN AIR INLET VALVE 1 2
LIMITED RETURN AIR INLET VALVE 1 2
SAFETY VALVE
CHECK VALVE 1 2
CHECK VALVE 2
1
2
DOUBLE SHUT-OFF VALVE
11 12
U
DIFFERENTIAL DOUBLE SHUT-OFF
VALVE M S
THROTTLE VALVE WITH QUICK

RETURN 1 2
THROTTLE VALVE
32783 32784 32785
Print 603.93.321 Base - May 2004

DESCRIPTION SYMBOL
DUMP VALVE 1 2
BRAKE CONTROL VALVE

11 A 21
12 P 22
BRAKE CONTROL VALVE

11 21
BRAKE CONTROL VALVE 11 21
4
12 22
PARKING BRAKE CONTROL VALVE 21

11 22
PARKING BRAKE CONTROL VALVE

1 2
BRAKE VALVE
1 2
CONTROL VALVE
1 2
CONTROL VALVE 21
1 22
RETARDER CONTROL VALVE

13 R 23
4
SERVO CONTROL VALVE
1 2
32786
Base - May 2004 Print 603.93.321

DESCRIPTION SYMBOL
41 42
SERVO CONTROL VALVE
1 2
SERVO CONTROL VALVE FOR

SINGLE LINE
1 2
42
41 43
TRAILER BRAKING TRIPLE
CONTROL VALVE
1 2
42
41 43
TRAILER BRAKING TRIPLE
CONTROL VALVE WITH BUILT-IN
SERVO SWITCHING 11 22
12
1 2
LOAD PROPORTIONING VALVE
11 21
DUAL LOAD PROPORTIONING
12 22
VALVE
12
LOAD PROPORTIONING VALVE 21
11
WITH BY-PASS
LOAD PROPORTIONING VALVE 1 2

WITH BUILT-IN RELAY
4
4
LOAD PROPORTIONING VALVE

WITH BUILT-IN RELAY WITH AIR 1 2
CONTROL
41 42
32786 32787
Print 603.93.321 Base - May 2004

DESCRIPTION SYMBOL

WITH AIR CONTROL
41 42

WITH AIR CONTROL
PROPORTIONAL REDUCING VALVE 1 2
4
SLAVED PROPORTIONAL
REDUCING VALVE
1 2
2
1
STROKE LIMITING VALVE
LEVELLING VALVE
21 22
1 2
LEVELLING VALVE
12 23
LEVELLING VALVE WITH BUILT-IN
TRAVEL LIMITER 11 21
HAND OPERATED SUSPENSION 23 24

RAISING CONTROL VALVE
21 22
32787 32788
Base - May 2004 Print 603.93.321

DESCRIPTION SYMBOL
2
42
PROPORTIONAL CONTROL VALVE
41
1
13
HAND OPERATED SUSPENSION 11 21
CONTROL VALVE WITH
ELECTRICAL MONITORING
12 22
1 3
ELECTROPNEUMATIC VALVE
1 2
ELECTROPNEUMATIC VALVE
1 2
ELECTROPNEUMATIC VALVE 21
1
22
VR HZ2
ABS
HYDRAULIC MODULATOR FOR ABS VL HZ1
HL HR
4
AUGMENTER VALVE
1 2
32788
Print 603.93.321 Base - May 2004

SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS (TANKS AND ACCUMULATORS)
DESCRIPTION SYMBOL
COMPRESSED AIR TANK
BRAKE FLUID RESERVOIR
AIR SPRING
32789
Base - May 2004 Print 603.93.321


(CONVERTERS, CYLINDERS AND CALLIPERS)
DESCRIPTION SYMBOL
VACUUM BRAKE SERVO
VACUUM BRAKE SERVO
DUAL CIRCUIT MASTER CYLINDER
SINGLE CIRCUIT MASTER CYLINDER
AIR/HYDRAULIC CONVERTER
AIR/HYDRAULIC CONVERTER
HYDRAULIC BRAKE CYLINDER
SLAVE CYLINDER
BRAKE CYLINDER
SPRING CYLINDER
COMBINED BRAKE CYLINDER
FIXED DISC BRAKE CALLIPER
32790 32791
Print 603.93.321 Base - May 2004


(CALLIPERS AND CYLINDERS)
DESCRIPTION SYMBOL
FLOATING DISC BRAKE CALLIPER
FLOATING DISC BRAKE CALLIPER

WITH PARKING
MECHANICAL FLOATING DISC

BRAKE CALLIPER
SERVO CLUTCH
SERVO CLUTCH
32791
Base - May 2004 Print 603.93.321


(SEMI-COUPLINGS AND COUPLING CONNECTORS)
DESCRIPTION SYMBOL
A
“ISO” SEMI-COUPLING
M
ISO VERSION
A
“ISO” SEMI-COUPLING
M
VERSION WITH ISO COUPLINGS
A
“CUNA” SEMI-COUPLING
B
ITALIAN VERSION
M
“CUNA” SEMI-COUPLING
A
A
“NATO” SEMI-COUPLING
M
NATO VERSION
32792 32793
Print 603.93.321 Base - May 2004


(SEMI-COUPLINGS AND COUPLING CONNECTORS)
DESCRIPTION SYMBOL
4
1 5
2 3
V
Z
A
SINGLE LINE VERSION
A
M
SEMI-COUPLING
V
Z
A
SINGLE LINE VERSION
12
22
SEMI-COUPLING
4
SINGLE LINE VERSION
12
A
22
M
SEMI-COUPLING
4
1 2
SINGLE LINE VERSION
32793
Base - May 2004 Print 603.93.321


(INDICATORS AND SWITCHES)
DESCRIPTION SYMBOL
PRESSURE GAUGE
PRESSURE GAUGE
PRESSURE SENDING UNIT
LAMP
MECHANICAL SWITCH
PRESSURE SWITCH
LOW PRESSURE SWITCH
AUDIBLE WARNING
SENSOR
32794
Print 603.93.321 Base - May 2004

SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (BRAKES)
DESCRIPTION SYMBOL
SINGLE CYLINDER HYDRAULIC

BRAKE
TWIN CYLINDER HYDRAULIC BRAKE
DUAL SERVO HYDRAULIC BRAKE
DUAL SERVO HYDRAULIC BRAKE

WITH PARKING BRAKE
SINGLE CAM OPERATED BRAKE
TWIN DUAL CAM OPERATED BRAKE
32795
Base - May 2004 Print 603.93.321

799512 PIPINGS AND FITTINGS

In general Figure 3
Hydraulic system pipings for industrial vehicles are currently of
two types:
- Flexible ones made of polyamide with single-layered or
double-layered structure and in the following diameters
(∅ 6-8-10-12-16 mm) equipped with spares in meters.
- Rigid metal pipings in the following diameters
(∅ 4.75-6.35-8-10-12 mm). Pipings from ∅ 4.75 to
∅ 10 mm are supplied as spares in straight 4-5-6 m crop
ends, while those exceeding 10 mm are supplied as spares
already cut, bent and reflanged.
31973
Rigid pipings reflanging Burr piping (1), insert union (2) and place it between small
blocks (3) abutting pin (5). Lock piping (1) with screw (4).
Figure 1
Figure 4
C 31971
RIGID PIPINGS REFLANGING REPRESENTATION 31974
Reflanging type A Take back pin (4) to its neutral position. Screw screw (1) till
matrix die (2) comes to abut against small blocks (3) thereby
Figure 2 shaping the piping (5) end.
Reflanging type B
Figure 5
31972
Arrange on a press 99386523 (3) small blocks (1) so that the

punched numbers, showing the piping number to be worked,
are facing the matrix die (2). The choice of the matrix die (2) 31975
depends on the diameter of the piping to be reflanged.
Moreover, on every matrix die (2) the diameter of the piping Assemble matrix die (2) on press 99386523 (1).
is punched for which the same one can be used. For the reflanging process comply with what has been stated
above for reflanging type A.
Print 603.93.321 Base - May 2004

Reflanging type C Figure 9

Figure 6
31979
31976
Place piping (1) into tool (3) and operating on lever (2) bend
Key on piping (1) nut (2) and ring (3). the piping.
Figure 7 Figure 10
31980
31977
In order to free piping (2) from tool (3), operate on lever (1).
Assemble union (2) and tighten so that ring (3, Figure 6) is
locked on piping (1).
Rigid pipings bending Rigid pipings cutting

Figure 8 Figure 11
31981
31978
Place piping (2) into tool (3) 99386523 and tighten screw (1).
Assemble tool (1) 99386523 choosing parts (2) and (3) Keeping piping (2) still, rotate tool (3) till the piping is
depending on the diameter of pipings to be bent. completely cut.
Base - May 2004 Print 603.93.321

After having cut the piping, burr and shape the end as - Carry out abutment ring reflanging upon assembly on the
previously described. vehicle or work bench on a fitting.
- The exerted pressure and the final distance from front
pressure ring edge to reinforcement bush edge must be
Rotating tool (3) around piping (2), screw (1) is
those mentioned in the table below.
! loosened. In order to completely cut the piping, it is
then necessary to tighten screw (1) when it
loosening.
In case of a bad assembly, never use the pipe after

Flexible pipings replacement with traditional having extracted bush and abutment ring.
fittings !
Strictly comply with the following instructions:
Figure 12
Pipe Distance between Assembling
bush edge and ring pressure
mm mm (*) N/mm2
6x1 from 1 to 1.5 0.040

Double-
layered 8x1 from 2 to 2.5 0.050
10 x 1.5 from 2 to 2.5 0.050
10397
Single- 12 x 1.6 from 2 to 2.5 0.060
layered
16 x 2.34 from 3 to 3.5 0.060
- Use homologated pipes only;
- Check the spare pipe status, on which no cracks, cuts or (*) See reference h, Figure 14.
nickings must be detected;
- Cut the pipe at 90° with respect to the axis through a
Figure 14
suitable pipe-cutting pliers 99387050 at the necessary
length;
Insert on the pipe in the following order:
- nut (3), pressure ring (2) (its greater thickness must be
facing nut (3) and reinforcement bush (1));
- the bush must be in perfect conditions (it must not have
either distortions or hammering traces).
Figure 13
10399
1. Reinforcement bush - 2. Pressure ring -

3. Nut - 4. Fitting - 5. Pipe -
10398 h. Distance between bush edge and ring edge (see table).
REINFORCEMENT BUSH ASSEMBLY
A = CORRECT ASSEMBLY Insert the thereby-prepared piping end into the fitting body till
B = WRONG ASSEMBLY the reinforcement bush flange rests within the suitable seat:
- Key the reinforcement bush with tool 99372219 - For closing the nut on the fitting, initially screw it manually
guaranteeing the contact between its flange and the pipe and then complete the tightening with a suitable box
end; wrench (complete series 99372221) inserted into the
dynamometric wrench, to be calibrated according to the
- make sure that the pipe end penetrates into the suitable required tightening torque.
rake groove obtained in the flange.
Print 603.93.321 Base - May 2004

Assembly of piping on vehicle is carried out by taking into Flexible pipings replacement with quick
account some important solutions: connection fittings
- Bendings must comply with minimum radiusses, in order
to avoid throttlings.
Rotating fittings
Pipings diameter Minimum bending radius
mm mm Figure 16
6x1 approx. 40
8x1 approx. 50
10 x 1.5 approx. 60
12 x 1.6 approx. 75
16 x 2.34 approx. 100
Make sure that pipings are not in contact with sharp

! edges or with cutting metallic parts or with heat 39306
sources, but that are distanttherefrom by a minimum
safety distance of 15 mm. Screw the fitting in the threaded seat provided on the
pneumatic valve and lock it at the tightening torque shown in
- Moreover,when crossing chassis longitudinal members or the table.
metallic parts, check that passage holes are coated with
rubber fairleadrings andthatthese latter ones are in good Swinging fittings
conditions;
- Avoid that the pipe slides along cutting edges that would Figure 17
risk to create nickings;
- Having to fix the piping onto already existing ducts, take
into account the supplementary heat to which it can be
subjected (hydraulic power steering duct): in such case,
the piping must be protected with guards;
- At the end of the connection, verify that the piping,
between keying and securing, is not stretched, but must
be slightly loosened to recover higher temperature
variations, particularly for short lengths;
- Before assembling, accuratelyclean thepipings by blowing
compressed air in order to guarantee system operation. 39307
Figure 15 - Check that the sealing ring (1) is into its suitable seat;
- screw the fitting till it is felt that the sealing gasket abuts
onto the valve;
- adequately swing the fitting and keeping the swingable
part still, lock the hexagonalnut at the tighteningtorque
mentioned in the table.
13132
Rotating and swinging fittings
- Protect the pipes in case of grinding or welding FITTING TIGHTENIG TORQUE (Nm ± 10%)
operations on the vehicle; for such purpose, an adhesive THREADING
plate is applied in the cabin and shows the precautions to
be observed with utmost care to avoid damages. M 10 x 1.0 mm 22
M 12 x 1.5 mm 24
For better safety and work comfortability, it is
! advisable to detach the pipingsduring such operations. M 14 x 1.5 mm 28
M 16 x 1.5 mm 35
Atthe endof the assembly, check the perfect seal of allgaskets
M 22 x 1.5 mm 40
(unions, fittings, etc.).
Base - May 2004 Print 603.93.321

Figure 18 Figure 20
39308
- Manually insert pipe (2)into fitting(1), with a force varying

from 30 to 120 N dependingon pipe diameter, so that the
notch L1 is placed inside the fitting while the notch L2 is
visible.
33977
- Use homogated pipes only;

- Check the spare pipe status, on which no cracks, cuts or Figure 21
nicking must be detected;
- Cut the pipe at 90° with a max 15 ° error with respect to
the axis through the suitable pipe-cutting pliers 99387050
at the necessary length;
Figure 19
33978
In case of disassembling of fittings (1) from pneumatic

components, check the sealing ring (2) status, and if necessary
replace it.
A
FITTING SEALING RINGS
33976
THREADING DIMENSIONS
M 10 x 1.0 10.1 x 1.6

A = Marking to identify pipe end-of-stroke
- Strongly and indelibly mark with ink two reference M 12 x 1.5 11.0 x 2.0
notches on both diametrically-opposed pipe faces for an
angle ≥ 75°, placed at the distances of L 1 and L2 to M 14 x 1.5 -
guarantee a correct assembly.
M 16 x 1.5 15.0 x 2.0
M 22 x 1.5 -
Dimensions L1 and L2 change depending on the pipe
! diameter and must be measured from the longest
pipe part (see Figure 18).
D L 0
L1 -0.5
L2 -0.5 Every time a piping is detached from a quick
+0.5 +1 +1
! connection fitting, it is necessary to replace the fitting
(mm) (mm) (mm) (mm) itself. Quick connection fittings are supplied complete
as spares.
6 19.8 17 22
8 20.5 18 23
Quick connection and threaded fittings, as well as
12 25 22 28 ! flexible pipings used with quick connection fittings
and flexible pipings used with threaded fittings, are
16 27.1 24 30 not interchangeable.
Print 603.93.321 Base - May 2004

EBS 2 (ELECTRONIC BRAKE SYSTEM)

The increase in competition in the transport sector has had the effect, among others, of constantly increasing the basic requirements
of braking systems.
The introduction of the EBS electronic brake system is the logical answer to these new needs.
It is an integrated and permanent electronic control system for the brake system of the tractor and trailer.
It supplements the ABS, ASR and EBL functions.
The system is made up of a pneumatic system and an electric system. In the system there is inserted the CBU (central brake unit),
component integrating:
- Duplex distributor, which generates electric and pneumatic signals to increase or decrease pressure in the braking system;
- electronic central unit, which has the task of managing the braking system determining deceleration values as a function of
parameters detected from various components;
- proportional relay valve, which modulates pressure at front axle.
The EBS system dialogues with the control units of the other assemblies:
Engine, Ecas, retarder and gearbox via the CAN line (VDB, Vehicle Data Bus).
EBS Benefits
Lower servicing costs.

The EBS combines many functions. The aim is to cut maintenance costs while maximizing braking safety — that is minimizing brake
lining wear.
An individual control according to the lining wear parameters on both the front and rear axles harmonizes lining wear. Distributing
the load homogeneously between all the brakes of the wheels reduces total consumption. In addition, the frequency of servicing
and changing the linings coincide. The costs of inactivity are drastically reduced.
Depending on the servicing a vehicle needs along with other factors, the owner may be able to make considerable savings. A
comparison of themaintenance costs, for the brakesystem, of a vehicle with EBSand one with a conventional brakesystem highlights
significant savings.
Tractor and trailer compatibility at any time
Harmonizing the braking processes of the entire tractor-trailer combination, especially if the combinations are frequently changed,
often with conventional means, is not satisfactory.
An inadequate balance, such as with a trailer whose braking is not sufficiently effective, will cause uneven wear of the brake linings.
The EBS will recognize all the incompatibilities between tractor and trailer,harmonizing brakingautomatically. Whenthe brakes work
in the best conditions, not only are brake maintenance costs optimized, but safety and comfort are optimum too.
Complete fault-diagnosis structures
The EBS provides the owner of the vehicle with constantlyupdated informationon the state of the brake system and the basic brakes.
This makes it possible to schedule servicing in advance. The EBS monitors all the fundamental components and functions of the brake
system.
Any defect recognized by the system is accurately highlighted. The maintenance specialist can therefore rectify the error at issue.
The high degree of safety ensured by the EBS is due to several factors:
- Lower pressure accumulation and response times for the brakes on the front, rear and trailer axles.
- Better ABS function.
- Tractor/trailer always balanced in every moment.
- Constant monitoring of the service brake system. In the event of reduced brake performance, the EBS will be able to warn the
driver.
- The integrated ASR function permits optimum vehicle stability and drive optimization.
Base - May 2004 Print 603.93.321

OPERATING LOGIC
The purpose of the electronic control unit is to slow down the vehicle as quickly as possible, ensuring its stability and avoiding the
tendency for the wheels to lock.
To achieve this aim, while braking, the electronic control unit will be informed of the:
- required deceleration via the sensors inside the duplex control valve;
- pressures made available via the pressure sensors in the components;
- reaction on slowing down due to the pressures made available via the speed sensor signals.
The continuous monitoring and processing of this information, in relation to the set aim, will cause the modulating valves to activate
appropriately and optimize the braking action accordingly.
IN OUT
Required deceleration FRONT AXLE pressure
Braking pressure REAR AXLE pressure
Wheel speed Graduated release trailer pressure
CONTROL UNIT
AIM
n Slip = 0
BRAKE SYSTEM
In a dynamic situation the effect on the vehicle will be managed in this way:
Figure 22
77208
Ca. Front axle load - Cp. Rear axle load - Cr. Load on fifth wheel - Da. Front axle braking force -
Dp. Rear axle braking force - Dm. Braking force at graduated release - Ds. Semitrailer braking force -
Ffa. Resultant of braking/front axle load - Ffp. Resultant of braking/rear axle load - Ffm. Resultant of braking/load
at graduated release - Ffs. Resultant of braking/semitrailer load - a. Braking angle - Rr. Reaction on the fifth wheel -
Dec. Required deceleration - g. Acceleration due to gravity - z. Braking ratio
Print 603.93.321 Base - May 2004

Generally, the EBS will tend to apply a braking force in proportion to the load on the axles, that is to maintain the same angle ”α”
for all the axles:
Da Dp Ds (Dm) dec
= = = Tag α  α = =z
Ca Cp Cs (Cr) g
Therefore, such force will be larger as compared to required deceleration.

This, as may be seen, also holds for the semitrailer control.
If the reaction on the fifth wheel ”Rr” is not as expected, the system automatically increases or decreases the predominance at the
graduated release and ”Ffm” accordingly so as to ensure the best compatibility between the tractor and semitrailer in compliance
with current type-approval standards, as may be seen in the following compatibility diagram.
Figure 23
000987t
Base - May 2004 Print 603.93.321

AUXILIARY BRAKE INTEGRATION

Commercial vehicles are normally fitted with auxiliary brakes for slowing down without causing wear, such as the exhaust brake and
intarder.
On vehicles equipped with the EBS, these devices can be integrated to ensure the vehicle slows down sooner and more effectively.
The exhaust brake/intarder action percentage is set by the driver with the lever.
The exhaust brake will be applied upto a speedof 1000 rpm, while the action of the retarder will cause the following action depending
on the position of the lever:
Figure 24
001685t
Position 0 — disengaged
Position 1 — E.B. 100%
Position 2 — E.B. 100% + Intarder 25% (20% *)
Position 6 — E.B. 100% + Intarder 100%
These applications, always possible, will be signalled to the driver by the relevant indicator lights coming on.
* Vehicles with mechanic gearbox.
On vehicles without the optional Intarder, the auxiliary brake lever has just three positions: off, E.B. 50%, E.B. 100%.
! On vehicles fitted with a EuroTronic gearbox, with the auxiliary brake lever on position 6, slowing down will be more
effective with the automatic gear shift down.
Switching the engine off for longer than one minute involving a change in load, tyres or ratios at the rear axle causes the adjustment
data to be lost and so a fresh period of data acquisition will be necessary for the system to be able to reactivate auxiliary brake
integration if no vehicle parameter is changed the integration will be immediately available.
If manually activating the auxiliary brakes, the next time the brake pedal is pressed will implement integration.
On releasing the brake pedal, if the manual action is compatible with the calculated action it will be kept active.
If activating the auxiliary brakes, both manual and integrated, causes the rear axle to slow down too much and a tendency for it to
lock, the EBS control unit, on detecting this situation via the speed sensors, will immediately disengage them or turn on the auxiliary
brake Slip Control.
Print 603.93.321 Base - May 2004

ESP (Electronic Stability Program)

ESP function, joined to EBS abilities, controls vehicle lateral dynamics.
The main objectives of this function are:
- Improving stability, most of all in both understeering and oversteering conditions
- Reducing braking spaces in change of line conditions on slippery roads
Main central unit input data in order to achieve following objectives, are:
- signal from steering angle sensor (mounted on the steering wheel)
- signals from yaw speed and lateral acceleration sensors (integrated into the ESP module, that is mounted on the chassis and
also contains a part of ESP software).
In order to avoid control loss, the ESP will automatically activate the brakes of one wheel per axle only trying to take the vehicle
back to correct direction. In this case, the ESP controls towing body skidding angle and slant, as well as the shift between driver’s
request and actual vehicle yaw speed. To the purpose of withstanding vehicle deceleration, the driving torque will be decreased.
In yaw control mode, the ESP very carefully controls driver’s reactions and always tries to provide relevant support.
oteESP function is optionally available on tractors only.
Figure 25
89009
1. ESP module - 2. Reference pin for mounting to support bracket.
“ABS-EBL” SYSTEM (ANTI-LOCK BRAKE SYSTEM — ELECTRONIC BRAKE LIMITER)

EBL function controls rear axle wheel “skidding” by comparing it to front axle wheel speed.
On the basis of wheel r.p.m.’s and braking pressure (detected by the sensor upstream from rear axle ABS modulators), the central
unit calculates vehicle speed, rear axle wheel “skidding” and minimum acceleration expected.
“ABS” (Anti-Lock Brake System)

The braking of a moving vehicle and the according deceleration and stopping distances depend above all on the grip between the
surfaces of the tyres and the road.
With a fully efficient braking system, a further improvement in braking can only be achieved by acting on the friction of the tyres
or on the grade of the road surface.
Even in these optimum conditions, absolute braking safety is anyhow not guaranteed when faced with especially tricky situations,
such as poor grip due to a wet or icy road surface: the driver is forced to moderate use of the brakes in order to avoid partially
locking one or more wheels, with the risk of skidding dangerously.
The function of the ”ABS” is therefore to ensure vehicle stability (in all braking conditions), preventing the wheels from locking
irrespective of the state of the road surface, so as to ensure the available grip is made full use of.
Even in the case of emergency braking, the system makes it possible to keep direction, that is to turn the steering wheel to avoid
obstacles with no risk of skidding.
In short, the anti-lock brake system (ABS):
- Prevents the wheels locking when the vehicle is braking, no matter what grip is available on the road.
- Shortens stopping distances.
- Provides safety for the driver who can keep the vehicle’s stability and direction.
Base - May 2004 Print 603.93.321

EBL (Electronic Brakes Limiter)
The EBL function checks the rear axle wheel ”slip”, comparing it with the speed of the wheels of the front axle.
The control unit input data are the wheel speed and braking pressure measured by the pressure sensor installed upstream from
the rear axle ABS modulators.
On the basis of these values, the controlunit calculates the speedof thevehicle, the vehicle’s deceleration, the rear axle wheel ”slip”
and the minimum deceleration contemplated.
The EBL function is activated (the rear ABS modulators maintain the set pressure) when the driver applies an excessive braking
force for the conditions of load on the vehicle, in short when the rear axle slip and vehicle deceleration thresholds are exceeded.
Operating Logic
The purpose of the electronic control unit is to slow down the vehicle as quickly as possible, ensuring its stability and avoiding the
tendency for the wheels to lock.
To achieve this aim, while braking, the electronic control unit will be informed of the:
- braking intensity required by the driver via the rear axle pressure sensor,
- reaction on slowing down due to the pressures made available via the speed sensor signals.
The continuous monitoring and processing of this information, in relation to the set aim, will cause the rear axle modulating valves
to activate appropriately and optimize the braking action accordingly.
Figure 26
FRONT AXLE
Braking
braking pressure IN
action
Braking intensity request
REAR AXLE
Wheel speed
braking pressure
CONTROL UNIT
AIM
∆ Slip = 0
Braking system evolution
Vehicle Engine Type of system Type of brakes

AT/AD/AS - HR cursor 8/10/13 EBL Disc/Drum
AT/AD/AS - 6x4 cursor 10/13 EBL Disc/Drum
AT/AD (no HR) cursor 8 EBL Disc/Disc
AT/AD mechanical
cursor 10 EBL Disc/Disc
suspensions
AT/AD/AS cursor 10 EBS Disc/Disc
AS cursor 13 EBS Disc/Disc
Print 603.93.321 Base - May 2004

BRAKING SYSTEMS
ABS-EBL working diagram for 4x2 vehicles (trucks and tractors, not including HR)
with CURSOR 8 (F2B) engine
Figure 27
88748
1. Compressor - 2. Air processing unit - 10.5 bars - 3. Front axle air tank - 20 l. - 4. Parking air tank - 20 l. - 5. Rear axle air tank
- 30 l. - 6. Manual discharge valve - 7. Air test point - 8. Parking manual control valve - 9. Handbrake low pressure switch
turned on — 6.4 bars - 10. Parking control relay valve - 11. Trailer slowing manual control valve - 12. Trailer brake servo control
valve - 13. Trailer system low pressure switch — 6.4 bars - 14. Trailer half couplings for tractors - 15. Trailer coupling half joints
for FP-CT carts and tractors - 16. Parking system one-way valve - 17. Duplex control valve - 18. Rear axle combined cylinder -
19. Rear axle disk brake assembly - 20. Rear axle phonic wheel - 21. Rear axle speed sensor - 22. Rear axle ABS solenoid
valves - 23. EBL pressure sensor - 24. Dual stop valve - 25. Rear axle brake control relay valve - 26. ASR control solenoid valve
- 27. Controlled pressure valve with no return for ASR — 7.5 bars - 28. ABS electronic control unit - 29. Front axle brake
control relay valve - 30. Front axle ABS solenoid valve - 31. Front axle diaphragm brake cylinder - 32. Front axle disc brake
assembly - 33. Front axle phonic wheel - 34. Front axle speed sensor - 35. Front axle parking brake - 36. Brake light control
microswitch - 37. Microswitch for EDC control unit - 38. 14 bar safety valve - A. To the air suspension system - B. To the
service system - * Optional.
Base - May 2004 Print 603.93.321

Working diagram for 6x2 vehicles (tractors) with CURSOR 8 (F2B) engine
Legend
1 A.P.U. unit
2. Manual condensate bleeding valve
3. 30-litre air reservoir
4. 20 -litre air reservoir
5. 15-litre air reservoir
6. Pressure check socket
7. Retaining valve
8. Manual control distributor for parking brake
9. Low pressure switch
10. Manual control distributor for trailer brake (optional)
11. Three-control servo-distributor
12. Low pressure switch
13. Half-coupling ”ISO”
14. Stop light control microswitch
15. EDC control unit microswitch
16. Phonic wheel
17. Rev sensor
18. Combined brake cylinder
19. Rear disk brake assembly
20. Membrane brake cylinder
21. Relay valve
22. ABS solenoid valve
23. Pressure sensor
24. Electronic control unit
25. Duplex distributor
26. Membrane cylinder
27. Disc brake assembly
28. Axle emergency brake
29. Compressor
30. 14 bar safety valve (optional)
A. To air suspensions
B. To services
* Optional
Print 603.93.321 Base - May 2004

ABS-EBL working diagram for 6x2 vehicles (tractors) with CURSOR 8 (F2B) engine
Figure 28
88749
Base - May 2004 Print 603.93.321

Working diagram for 6x2 vehicles (trucks)

with CURSOR 8 (F2B) engine and with CURSOR 10 engine (F3A with mechanical suspensions)
Legend
1. Compressor
2. Air processing unit - 10.5 bars
4. Front axle air tank - 20 l.
5. Parking air tank - 20 l.
6. Rear axle air tank — 30 l. + 20 l.
7. Manual discharge valve
8. Air test point
9. Parking manual control valve
10. Handbrake low pressure switch turned on — 6.4 bars
11. Parking control relay valve
12. Trailer slowing manual control valve
13. Trailer brake servo control valve
14. Trailer system low pressure switch — 6.4 bars
15. Trailer half-couplings
16. Parking system one-way valve
17. Duplex control valve
18. Load ratio relay valve for added axle braking
19. Diaphragm cylinder
20. Additional axle disk brake assembly
21. Rear axle combined cylinder
22. Rear axle disk brake assembly
23. Rear axle phonic wheel
24. Rear axle speed sensor
25. Added axle suspension air springs
26. Added axle load ratio dual stop valve
27. Rear axle ABS solenoid valves
28. EBL pressure sensor
29. ABS electronic control unit
30. Rear axle brake control relay valve
31. Dual stop valve
32. Controlled pressure valve with no return for ASR — 7 bars
33. ASR control solenoid valve
34. Front axle brake control relay valve
35. Front axle ABS solenoid valve
36. Front axle diaphragm brake cylinder
37. Front axle phonic wheel
38. Front axle speed sensor
39. Front axle disc brake assembly
40. Axle emergency brake
41. Brake light control microswitch
42. Microswitch for EDC control unit
43. 14 bar safety valve (optional)
A. To the air suspension system
B. To the service system
* Optional
• For CM vehicles only
J Version with ASR
Y Version without ASR
Print 603.93.321 Base - May 2004

ABS-EBL working diagram for 6x2 vehicles (trucks)

with CURSOR 8 (F2B) engine and with CURSOR 10 engine (F3A with mechanical suspensions)
Figure 29
88750
Base - May 2004 Print 603.93.321

ABS-EBL working diagram for stand alone 4x2 vehicles (trucks) with CURSOR 8 (F2B) engine
Figure 30
88751
1. Compressor - 2. Air processing unit - 10.5 bars - 3. Air tank - 20 l. - 4. Air tank - 30 l. - 5. Manual discharge valve - 6. Air test
point - 7. Parking manual control valve - 8. Handbrake low pressure switch turned on — 6.4 bars - 9. Parking system one-way valve -
10. Duplex control valve - 11. Rear axle combined cylinder - 12. Rear axle disc brake assembly - 13. Rear axle phonic wheel -
14. Rear axle speed sensor - 15. Rear axle ABS solenoid valves - 16. EBL pressure sensor - 17. Dual stop valve -
18. Rear axle brake control relay valve - 19. ASR control solenoid valve - 20. Controlled pressure valve with no return for ASR —
7.5 bars - 21. ABS electronic control unit - 22. Front axle brake control relay valve - 23. Front axle ABS solenoid valve -
24. Front axle diaphragm brake cylinder - 25. Front axle disc brake assembly - 26. Front axle phonic wheel - 27. Front axle speed
sensor - 28. Front axle parking brake - 29. Brake light control microswitch - 30. Microswitch for EDC control unit - 31. 14 bar safety
valve - A. To the air suspension system - B. To the service system - * Optional.
Print 603.93.321 Base - May 2004

ABS-EBL working diagram for 6x2C vehicles (trucks) with CURSOR 8 (F2B) engine
Figure 31
88752
1. A.P.U. unit - 2. Manual condensate bleeding valve - 3. 20-litre air reservoir - 4. 20 -litre air reservoir - 5. 30-litre air reservoir -
6. Pressure check socket - 7. Retaining valve - 8. Cutoff valve - 9. Manual control distributor for parking brake - 10. Low pressure
switch - 11. Parking control relay valve - 12. Stop light control microswitch - 13. EDC control unit microswitch - 14. Phonic
wheel - 15. Rev sensor - 16. Disc brake assembly - 17. Combined brake cylinder - 18. Disc brake assembly - 19. Membrane
brake cylinder - 20. Relay valve - 21. ABS solenoid valve - 22. Pressure sensor - 23. Electronic control unit - 24. Duplex
distributor - 25. Membrane cylinder - 26. Disc brake assembly - 27. Axle parking brake - 28. 14 bar safety valve -
29. Compressor - A. To air suspensions - B. To services - * Optional.
Base - May 2004 Print 603.93.321

ABS-EBL working diagram for stand alone 6x2 vehicles (trucks) with CURSOR 8 (F2B) engine
Figure 32
88753
1. Compressor - 2. Air processing unit - 10.5 bars - 3. Air tank - 30 l. - 4. Manual discharge valve - 5. Air tank - 20 l. - 6. Air test
point - 7. Parking manual control valve - 8. Handbrake low pressure switch turned on - 9. Parking control relay valve -
10. Parking system one-way valve - 11. Duplex control valve - 12. Load ratio relay valve for added axle braking- 13. Diaphragm
cylinder - 14. Added axle drum brake assembly - 15. Rear axle combined cylinder - 16. Rear axle disc brake assembly -
17. Rear axle phonic wheel - 18. Rear axle speed sensor - 19. Added axle suspension air springs - 20. Added axle load ratio dual
stop valve- 21. Rear axle ABS solenoid valves - 22. EBL pressure sensor - 23. ABS electronic control unit - 24. Rear axle brake
control relay valve - 25. Dual stop valve - 26. Controlled pressure valve with no return for ASR — 7 bars - 27. ASR control
solenoid valve - 28. Front axle brake control relay valve - 29. Front axle ABS solenoid valve - 30. Front axle diaphragm brake
cylinder - 31. Front axle phonic wheel - 32. Front axle speed sensor - 33. Front axle disc brake assembly - 34. Front axle parking
brake - 35. Brake light control microswitch - 36. Microswitch for EDC control unit - 37. 14 bar safety valve - 38. On-off valve -
A. To service (TN vehicles) and pneumatic suspensions (Y/P/PS/PT - Y/FP/FS/FT vehicles) system - B. To the service system -
* Optional - J Version with ASR - Y Version without ASR.
Print 603.93.321 Base - May 2004

EBS 2 working diagram for 4x2 vehicles (tractors) with CURSOR 10/13 engine
Figure 33
88754
1. Compressor - 2. Air processing unit 10.5 bars - 3. Front axle air tank 20 l. - 4. Parking air tank 20 l. - 5. Rear axle
air tank 30 l. - 6. Manual discharge valve - 7. Air test point - 8. Rear axle low pressure switch for ASR - 6.6 bars -
9. Parking system one-way valve - 10. Trailer system low pressure switch - 5.5 bars - 11. Semitrailer half-couplings -
12. Trailer brake servo control valve - 13. Rear axle combined cylinder - 14. Rear axle disc brake assembly -
15. Rear axle phonic wheel - 16. Rear axle speed sensor - 17. Rear axle brake control electro-pneumatic modulator -
18. CBU - 19. Front axle ABS solenoid valves - 20. Front axle diaphragm brake cylinder - 21. Front axle phonic wheel -
22. Front axle speed sensor - 23. Front axle disc brake assembly - 24. Parking control relay valve - 25. On-off valve -
26. Parking manual control valve - 27. Trailer slowing manual control valve - 28. Handbrake low pressure switch
turned on - 6.6 bars - 29. 14 bar safety valve - 30. Front axle parking brake - A. To the air suspension system -
B. To the service system - * Optional.
Base - May 2004 Print 603.93.321

EBS 2 working diagram for 4x2 T/FP-CT vehicles (tractors) with CURSOR 10/13 engine
Figure 34
88755
12. ISO half coupling - 13. Trailer brake servo control valve - 14. Rear axle combined cylinder - 15. Rear axle
disc brake assembly - 16. Rear axle phonic wheel - 17. Rear axle speed sensor - 18. Rear axle brake control
electro-pneumatic modulator - 19. CBU - 20. Front axle ABS solenoid valves - 21. Front axle diaphragm brake cylinder -
22. Front axle phonic wheel - 23. Front axle speed sensor - 24. Front axle disc brake assembly - 25. Parking control relay
valve - 26. On-off valve - 27. Parking manual control valve - 28. Trailer slowing manual control valve - 29. Handbrake
low pressure switch turned on - 6.6 bars - 30. 14 bar safety valve - 31. Front axle parking brake - A. To the air suspension
system - B. To the service system - * Optional
Print 603.93.321 Base - May 2004

EBS 2 working diagram for 6x2 vehicles (tractors) with CURSOR 10/13 engine
Figure 35
88757
1. Compressor - 2. Air processing unit 10.5 bars - 3. Front axle air tank 20 l. - 4. Parking air tank 20 l. - 5. Rear axle air
tank 30 l. + 15 l. - 6. Manual discharge valve - 7. Air test point - 8. Rear axle low pressure switch for ASR - 6.6 bars -
12. Trailer brake servo control valve - 13. Rear axle combined cylinder - 14. Rear axle disc brake assembly -
15. Rear axle phonic wheel - 16. Rear axle speed sensor - 17. Relay valves - 18. Intermediate axle diaphragm cylinder -
19. Intermediate axle disc brake assembly - 20. Intermediate axle suspension air springs - 21. Intermediate axle load ratio
dual stop valve - 22. Selector - 23. Rear axle braking control electro-pneumatic modulator - 24. CBU - 25. Front axle
ABS solenoid valves - 26. Front axle diaphragm brake cylinder - 27. Front axle disc brake assembly - 28. Front axle
phonic wheel - 29. Front axle speed sensor - 30. Parking control relay valve - 31. On-off valve - 32. Parking manual
control valve - 33. Trailer slowing manual control valve - 34. Handbrake low pressure switch turned on - 6.6 bars -
35. 14 bar safety valve - 36. Front axle parking brake - A. To the air suspension system - B. To the service system -
* Optional.
Base - May 2004 Print 603.93.321

EBS 2 working diagram for 4x2 vehicles (trucks) with CURSOR 10/13 engine
Figure 36
88756
9. Parking system one-way valve - 10. Trailer system low pressure switch - 5.5 bars - 11. ISO coupling half joints -
12. Trailer brake servo control valve - 13. Redundant solenoid valve - 14. Rear axle combined cylinder - 15. Rear axle
disc brake assembly - 16. Rear axle phonic wheel - 17. Rear axle speed sensor - 18. Rear axle brake control
electro-pneumatic modulator - 19. CBU - 20. Front axle ABS solenoid valves - 21. Front axle diaphragm brake cylinder -
22. Front axle phonic wheel - 23. Front axle speed sensor - 24. Front axle disc brake assembly - 25. Parking control
relay valve - 26. On-off valve - 27. Parking manual control valve - 28. Trailer slowing manual control valve -
29. Handbrake low pressure switch turned on - 6.6 bars - 30. 14 bar safety valve - 31. Front axle parking brake -
A. To the air suspension system - B. To the service system - * Optional
Print 603.93.321 Base - May 2004

Legend
1. Compressor
4. Front axle air tank - 20 l.
5. Parking air tank - 20 l.
6. Rear axle air tank - 30 l. + 20 l.
7. Manual discharge valve
8. Air test point
9. Rear axle low pressure switch for ASR — 6.6 bars
10. Parking system one-way valve
11. Trailer system low pressure switch — 5.5 bars
12. Semitrailer half-couplings
13. Trailer brake servo control valve
14. Rear axle braking redundancy valve
15. Load ratio relay valve for added axle braking
16. Added axle diaphragm brake cylinder
17. Added axle ASR exclusion solenoid valve
18. Added axle suspension air springs
19. Added axle load ratio dual stop valve
20. Rear axle combined cylinder
21. Rear axle disc brake assembly
22. Rear axle phonic wheel
23. Rear axle speed sensor
24. Selector
25. Rear axle brake control electro-pneumatic modulator
26. CBU
27. Front axle ABS solenoid valves
28. Front axle diaphragm brake cylinder
29. Front axle disc brake assembly
30. Front axle phonic wheel
31. Front axle speed sensor
32. Parking control relay valve
33. On-off valve
34. Parking manual control valve
35. Trailer slowing manual control valve
36. Handbrake low pressure switch turned on — 6.6 bars
37. 14 bar safety valve
38. Front axle parking brake
A. To the air suspension system
B. To the service system
* Optional
• For CM vehicles only
Base - May 2004 Print 603.93.321

Figure 37
88758
Print 603.93.321 Base - May 2004

EBS 2 system components location on vehicle (tractors variant)

Figure 38
88760
1. CBU (Central Brake Unit) - 2. Hand distributor for parking - 3. Coupling half joints - 4. Air tanks - 5. Axle
electropneumatic modulator - 6. Relay valve for parking - 7. Air tank - 8. Spring brake cylinder - 9. Trailer drive
servo-assisted distributor - 10. APU - 11. Membrane brake cylinder - 12. ABS solenoid valve -
13. Compressor - A. Real component location 5, 6, 9 and 10.
Base - May 2004 Print 603.93.321

ABS-EBL system components location (tractors variant)

Figure 39
88759
1. Trailer-only brake hand-operated control valve - 2. Parking brake hand-operated control valve - 3. Electronic control unit -
4. Duplex distributor - 5. Compressor - 6. Relay valve - 7. Pedal switch for exhaust brake control - 8. ABS solenoid valve -
9. Diaphragm brake cylinder - 10. Front disc brake assembly - 11. Phonic wheel - 12. Wheel revolution sensor - 13. Trailer
drive servo-assisted distributor - 14. A.P.U. - 15. Pressure test point - 16. Air tanks - 17. Phonic wheel - 18. Wheel revolution
sensor - 19 Rear disc brake assembly - 20. Combined brake cylinder - 21. Relay valve - 22. Check valve - 23. Electropneumatic
valve for ASR - 24. Semi-coupling.
Print 603.93.321 Base - May 2004

DESCRIPTION
Service braking BRAKES
Pedal-operated, pneumatic, with electric control acting on all Front and rear disk brakes
the wheels and on the trailer. (KNORR SN7 type)
It is composed of two independentsections, one for activating
the braking elements of the front axle, the other for activating Forthe disc brakes, the discs arekeyed onto the wheelhubsand
the braking elements of the rear axle. equipped with ventilation fins that permit lowering the high
temperature generated under the braking action.
The division of the air system, if one section breaks down, The brake linings are fitted with a wear indicator connected to
permits the other to remain efficient. an indicator light on the dashboard to signal brake lining wear.
The phonic wheels of the ABS device arekeyed onto the wheel
hubs.
Emergency braking
Emergency braking makes it possible to slow down the vehicle
and stop it within a safety distance, even if the braking system
has broken down.
It should be interpreted as a partial service brake that, thanks
to the dual circuit, anyhow acts on one of the two axles.
Exhaust brake
The”exhaust brake” function is controlled by the EDC control
unit that, depending on the required braking capacity, governs
this function in combination with the EBS and Intarder systems
(where applicable).
Parking brake
This comprises the pneumatic control of the manual control

valve, a spring cylinder acting on the rear wheelbrakes, locking
them (on some versions the parking brake acts on the front
brakes too).
In the event of the supply failing, this system automatically
brakes the vehicle.
Base - May 2004 Print 603.93.321

FAULT DIAGNOSIS
SECTION I
ABS-EBS system troubleshooting can be performed with the Cluster or with the diagnosis instruments Modus, IWT and IT 2000.
Diagnosis with the cluster makes it possible to estimate the situation of faults in the system in advance, while the diagnosis instruments
are essential to perform thorough diagnosis and operate on the single faults correctly.
Each single instrument displays the diagnosis and repair help.
Diagnosis Instruments
MODUS (Maintenance and Diagnostic System)
A computerized fault-diagnosis station dedicated to diagnosing the brake systems, air suspensions, engines and systems controlled
electronically.
The station is equipped with auxiliary functions, such as: programming electronic control units, consulting the spare parts catalogue
and service time schedules.
The vehicle has a 30-pin diagnosis socket to interface with the instrument.
IWT (IVECO Wiring Tester)

The IVECO Wiring Tester expands and integrates MODUS.
This instrument is made by IVECO to improve fault diagnosis of vehicle electric and electronic systems.
The vehicle has a 30-pin diagnosis socket to interface with the instrument; the connection between the instrument and the diagnosis
socket must be made with the cable identified as no. 4.
IT 2000 (IVECO Electronic Tester)

This makes it possible to take immediate action on the vehicle, identifying it with the chassis number.
It saves the results of diagnostics actions performed.
It can be used as a portable Personal Computer, too, being fitted for remote diagnosis.
By using MODUS as the mother station it is possible to update and configure the IT 2000.
IT 2000 interfaces with the vehicle via a 30-pin diagnosis socket.
The diagnosis socket is positioned in central panel lower side in the cab (at passenger side).
!
Print 603.93.321 Base - May 2004

Cluster Diagnosis
It is possible to access the fault memory with the ”menu” function key 2 on the steering wheel.
Figure 40
74375
With the ignition key on MAR (+15), press the ”menu” function key 2; the display will show a dialogue menu containing a list of
the available functions (e.g., Hi-Fi, phone, diagnostics, etc.).
With the y I and I b function keys, select the diagnosis function and confirm the selection with the ”OK” function key 2.
Select the ABS-EBS system with the select/confirm keys 1 and 2.
Select the ABS-EBS system with the select/confirm keys 1 and 2.
The cluster will display the first diagnostics screen.
After selecting the system, EuroTronic is displayed on a red or green background depending on whether there is any trouble.
Figure 41
74388
The diagnosis information shown on the cluster is split up on two screens:

- On the first one, it is possible to consult and scroll through all saved/present trouble.
- On the second one, it is possible to delete the intermittent errors (when you have the relevant password).
Base - May 2004 Print 603.93.321

FIRST SCREEN
Figure 42
74389
The information on the single faults is arranged on four columns with the following content:
DTC FMI OC ACT
Displaysthe fault codenumber Indicates the type of fault Fault frequency meter Fault active/not active status
Two digits (hexadecimal) Two digits (hexadecimal) Three digits (hexadecimal) One character
(Y = Yes, N = No)
Troubleshooting via DTC-FMI codes described under the relevant section completes the above information. Each pair of DTC-FMI
codes is associated with a description of the fault, the possible system reaction and recommended repairs with the relevant checks.
SECOND SCREEN
Deleting Errors
To select the second screen, press ”page” on the steering wheel.
The fault display is eliminated as follows:
- Press ”+”, on the request to confirm deletion, press OK.
- Enter the required password (see the ENTERING PASSWORD paragraph).
- Press OK to confirm.
Figure 43
74390
Entering the Password

Figure 44
74378a
Select the first number of the password with the y I and I b keys.
Press OK to confirm each number.
Press a to delete the last number selected.
On completing the password, select the key symbol to confirm.
Print 603.93.321 Base - May 2004

SECTION 2
Main operating trouble of the brake system: 7 — Parking brake release delayed.
8 — Trailer parking brake release delayed.
1 — Poor or abnormal system charge. 9 — The vehicle skids when braking.
2 — Poor or abnormal service braking of the rear axle. 10 — Insufficient trailer retarder braking.
3 — Poor or abnormal service braking of the front axle. 11 — Early wear of the brake linings.
4 — Poor or abnormal trailer service braking. 12 — Brake system warning light on.
5 — Poor or no parking braking. 13 — Parking brake indicator light on with lever in driving
6 — Poor or no trailer parking braking. position.
14 — Noisy brakes.
Electric and electronic components diagnosis must be through Modus and IWT.
1 POOR OR ABNORMAL
SYSTEM CHARGE
Air system pipes leak or burst Close or replace the worn or damaged fittings. Re-
YES place the burst or damaged pipes.
NO
Inefficient air compressor operation Overhaul or replace the air compressor.

YES
NO
Inefficient A.P.U. operation Overhaul or replace the A.P.U.

YES
2 POOR OR ABNORMAL SERVICE

BRAKING OF THE REAR AXLE
Air system pipes leak or burst Close o r replace the worn or damaged fittings. Replace
YES the burst or damaged pipes.
(continued)
Base - May 2004 Print 603.93.321

Brake linings worn and/or vitrified Overhaul or replace the brake linings.
YES
NO
Inefficient operation of the rear brakes Overhaul the rear brakes.

YES
NO
Inefficient operation of the Duplex control valve Overhaul or replace the Duplex control valve.
YES
NO
Inefficient operation of the brake cylinders Overhaul or replace the brake cylinders.
YES
NO
Inefficient operation of the ABS solenoid valve - Check the electric wiring.
YES
- Replace the ABS solenoid valve.
NO
Inefficient operation of the electro-pneumatic modulator - Check the wiring

of the rear axle (vehicles with EBS) YES
- Replace the electro-pneumatic modulator
NO
Inefficient operation of the automatic clearance recovery Replace the complete brake calliper.
device YES
NO
Inefficient operation of the Duplex control valve with - Check the wiring.
electric transmitter (vehicles with EBS) YES - Replace the Duplex Control Valve with electric
transmitter
(continued)
Print 603.93.321 Base - May 2004

3 POOR OR ABNORMAL SERVICE

BRAKING OF THE FRONT AXLE
Air system pipes leak or burst Close or replace the worn or damagedfittings. Replace
NO
YES
NO
YES
NO
Inefficient operation of the front brakes Overhaul the front brakes.

YES
NO
Inefficient operation of the relay valve Overhaul ore replace the relay valve.
YES
NO
Inefficient operation of the diaphragm brake cylinders Overhaul or replace the diaphragm brake cylinders.
YES
NO
Inefficient operation of the automatic clearance Replace the complete brake calliper.
recovery device YES
(continued)
Base - May 2004 Print 603.93.321

Inefficient operation of the ABS solenoid valve - Check the electric wiring.
YES
- Replace the ABS solenoid valve.
NO
Inefficient operation of the front axle relay valve - Check the wiring
(vehicles with EBS) YES - Replace the front axle relay valve
NO
Inefficient operation of the Duplex control valve with - Check the wiring.
electric transmitter (vehicles with EBS) YES - Replace the Duplex Control Valve with electric
transmitter (vehicles with EBS)
POOR OR ABNORMAL TRAILER

4 SERVICE BRAKING
Air system pipes leak or burst Close or replace the worn or damaged fittings. Replace
NO
Inefficient operation of the triple control servo control Overhaul or replace the triple control servo control
valve YES valve.
NO
YES
NO
Inefficient operation of the A.P.U. Overhaul or replace the A.P.U.

YES
(continued)
Print 603.93.321 Base - May 2004

YES
NO
Inefficient operation of the trailer brakes Overhaul the trailer brakes.

YES
NO
Inefficient operation of the electro-pneumatic modu- - Check the wiring

lator of the rear axle (vehicles with EBS) YES
- Replace the electro-pneumatic modulator
POOR OR NO
5 PARKING BRAKING
NO
Inefficient operation of the combined brake cylinders Overhaul or replace the combined brake cylinders.
YES
NO
Inefficient operation of the parking brake manual con- Overhaul or replace the lever.
trol valve (lever) YES
NO
YES
(continued)
Base - May 2004 Print 603.93.321

Inefficient operation of the relay valve Overhaul or replace the relay valve.
YES
NO

YES
POOR OR NO TRAILER
6 PARKING BRAKING
NO
Inefficient operation of the triple control servo con- Overhaul or replace the triple control servo control
trol valve YES valve
NO
NO
Trailer brake linings worn and/or vitrified Overhaul or replace the trailer brake linings.
YES
NO

YES
(continued)
Print 603.93.321 Base - May 2004

Inefficient operation of the trailer control servo control - Check the electric wiring.
valve YES
- Replace the trailer control servo control valve.
PARKING BRAKE
7 RELEASE DELAYED
NO
Inefficient operation of the relay valve Overhaul or replace the relay valve
YES
NO
Inefficient operation of the combined brake cylinders Overhaul or replace the combined brake cylinders.
YES
NO
NO

YES
(continued)
Base - May 2004 Print 603.93.321

TRAILER PARKING BRAKE

8 RELEASE DELAYED
NO
valve YES valve
NO
NO

YES
THE VEHICLE SKIDS

9
WHEN BRAKING
NO
Inefficient operation of the Duplex control valve Overhaul or replace the Duplex control valve
YES
(continued)
Print 603.93.321 Base - May 2004

Inefficient operation of the front brakes Overhaul the front brakes.

YES
NO

YES
NO
Inefficient operation of the triple control servo control Overhaul or replace the triple control servo control.
YES
INSUFFICIENT TRAILER
10 RETARDER BRAKING
NO

YES
NO
valve YES valve
NO
Base - May 2004 Print 603.93.321

EARLY WEAR
11 OF THE BRAKE LININGS
YES
NO
Inefficient operation of the brakes Overhaul the brakes.

YES
NO
valve YES valve
NO
Inefficient operation of the relay valve Overhaul or replace the relay valve.
YES
BRAKE SYSTEM
12 WARNING LIGHT ON
NO

YES
(continued)
Print 603.93.321 Base - May 2004

Wrong wiring of the electric circuit of the indicator light Find the wrong connection and restore the wiring.
YES
PARKING BRAKE INDICATOR

13 LIGHT ON WITH LEVER
IN DRIVING POSITION
Wrong wiring of the electric circuit of the indicator light Find the wrong connection and restore the wiring.
YES
NO
NO

YES
14 NOISY BRAKES
Worn brake linings Replace the brake linings.

YES
NO
Foreign bodies between the brake linings and discs Remove the foreign bodies between the brake linings
(disc brakes) YES and discs.
(continued)
Base - May 2004 Print 603.93.321

Brake discs off centre (disc brakes) Grind or replace the brake discs.
YES
NO
Inefficient shoe return springs (drum brakes) Overhaul the rear brakes.
YES
NO
Excessive ovalization of the brake drums (drum brakes) Turn or if necessary replace the drums.
YES
Print 603.93.321 Base - May 2004

Base - May 2004 Print 603.93.321

EBS 2 Working diagram

Figure 45
α
52056 Switch with built-in alarm indicator for ASR cutoff - 70403 Fuse holder for 4 fuses - 70602 Fuses — 70606 Fuse holder for 6 fuses - 72006 7-pole joint for tractor/trailer ABS/EBS electric connection - 72021 30-pole joint for connect
78052 Solenoid valve for ABS/EBS - 78058 Proportional valve for EBS trailer air control — 78061 Redundant solenoid valve (for carts only) - 86116 Body Computer Multiplex Central Unit - 86117 Front Frame Multiplex Central Unit — 861
Unit — 88001 ABS/EBS system r.p.m. sensor - 88006 Modulator for EBS rear axle air pressure control - 88007 Potentiometric sensor for front wheel pad position signalling — 88008 Potentiometric sensor for rear wheel pad position signallin
for third axle wheel pad position signalling - 88012 SAS drive angle sensor - Steering Angle Sensor for EBS (Optional on tractors) — 88013 ESC module - Electronic Stability Control for EBS (Optional on tracto
Print 603.93.321 Base - May 2004

Base - May 2004 Print 603.93.321

Pin — EBS 2 central unit output

Figure 46
87770
X1 connector
PIN CABLE FUNCTION

1 0000 Earth
2 7720 Battery-directed power supply positive
3 7710 Battery-directed power supply positive
4 8847 Locked power supply positive
5 -- --
6 2299 K line for diagnosis connector (pin 4)
7 GN/VE CAN «L» line
8 -- --
9 WS/BI CAN «H» line
10 0048 Negative from ASR cutoff switch
Print 603.93.321 Base - May 2004

87771
X2 connector (positioning to the left with respect to forward ride)

PIN CABLE FUNCTION
1 0024 Negative for RH front wheel wear sensor (pin 3 - BR/MA - pin C)
2 6024 Positive for RH front wheel wear sensor (pin 2 - GE/GI - pin B)
3 0226 Negative for LH front wheel wear sensor (pin 3 - BR/MA - pin C)
4 6026 Positive for LH front wheel wear sensor (pin 2 GE/GI - pin B)
5 9920 Positive for RH front ABS feed solenoid valve (pin 3)
6 6025 Signal from RH front wheel wear sensor (pin 1 - SW/NE - pin A)
7 9918 Positive for RH front ABS exhaust solenoid valve (pin 1)
8 6027 Signal from LH front wheel wear sensor (pin 1 - SW/NE - pin A)
9 9921 Positive for LH front ABS feed solenoid valve (pin 3)
10 5571 RH front sensor
11 9919 Positive for LH front ABS exhaust solenoid valve (pin 1)
12 5571 RH front sensor
13 0118 Negative for RH front ABS solenoid valve (pin 2)
14 5570 LH front sensor
15 0122 Negative for LH front ABS solenoid valve (pin 2)
16 5570 LH front sensor
X3 connector (positioning to the right with respect to forward ride)

PIN CABLE FUNCTION
1 WS/BI CAN «H» line to SAS steering angle sensor (pin 4) (opt)
2 WS/BI CAN «H» line to half trailer connector (pin 6)
3 WS/BI CAN «H» line to ESC module (pin 3) (opt)
4 GN/VE CAN «L» line to half trailer connector (pin 7)
5 GN/VE CAN «L» line to SAS steering angle sensor (pin 3) (opt)
6 8275 Positive for SAS steering angle sensor (pin 1) (opt)
7 GN/VE CAN «L» line to ESC module (pin 4) (opt)
8 8270 Positive for ESC module (pin 1) (opt)
9 -- --
10 -- --
11 WS/BI CAN «H» line to rear axle modulator (pin 3 - 61)
12 0217 Negative for rear axle redundant solenoid valve
13 -- --
14 9217 Positive for rear axle redundant solenoid valve
15 GN/VE CAN «L» line to rear axle modulator (pin 4 - 61)
16 7740 Positive for rear axle modulator (pin 1 - 61)
Base - May 2004 Print 603.93.321

Pin-out of rear axle pressure modulator

61 connector
PIN CABLE FUNCTION

1 77401 Positive from EBS central unit (CBU) (pin 16 — X3)
2 0000 Earth
3 WS/BI CAN «H» line to EBS central unit (CBU) (pin 11 — X3)
4 GN/VE CAN «L» line to EBS central unit (CBU) (pin 15 — X3)
62 connector
PIN CABLE FUNCTION
1 -- Right rear wheel r.p.m. sensor
2 -- Right rear wheel r.p.m. sensor
63 connector
PIN CABLE FUNCTION

1 -- Left rear wheel r.p.m. sensor
2 -- Left rear wheel r.p.m. sensor
66 connector
PIN CABLE FUNCTION

1 SW/NE Signal from RH rear wheel wear sensor (pin 1 - pin A)
2 GE/GI Positive for RH rear wheel wear sensor (pin 2 - pin B)
3 BR/MA Negative for RH rear wheel wear sensor (pin 3 - pin C)
67 connector
PIN CABLE FUNCTION

1 SW/NE Signal from LH rear wheel wear sensor (pin 1 - pin A)
2 GE/GI Positive for LH rear wheel wear sensor (pin 2 - pin B)
3 BR/MA Negative for LH rear wheel wear sensor (pin 3 - pin C)
68 connector
PIN CABLE FUNCTION

1 6046 Positive for trailer drive valve pressure sensor (pin 1)
2 0026 Negative for trailer drive valve pressure sensor (pin 2)
3 6047 Signal from trailer drive valve pressure sensor (pin 3)
4 9046 Positive for trailer drive proportional solenoid valve (pin 4)
5 0046 Negative for trailer drive proportional solenoid valve (pin 5)
Print 603.93.321 Base - May 2004

TIGHTENING TORQUES
PART TORQUE
Nm (kgm)
Compressor
Nut fixing pulley 200 (20.4)
Combined brake cylinder (for disc brakes)
Nuts for bolts fixing cylinder to brake calliper 180 + 30 (18.3 + 0.3)
Manual brake release screw (type 14 — front disc brakes) max 35 (max 3.6)
Manual brake release screw (type 20/27 — rear disc brakes) max 70 (max 7.1)
Fixing fittings 40 ± 5 (4 ± 0.5)
Diaphragm brake cylinder (for disc brakes)
Nut for fixing cylinder to brake calliper 180 + 30 (18 + 3)
Fixing fittings 40 ± 5 (4 ± 0.5)
Fixing fittings
- BENDIX cylinder 17.5 ± 2.5 (1.7 ± 0.2)
- KNORR-BREMSE cylinder 40 ± 5 (4 ± 0.5)
- WABCO cylinder 45 ± 5 (4.5 ± 0.5)
Front axle disc brakes 5876-57080/DI
Self-locking hex screw M20 x 1.5 fixing brake callipers 615.5 ± 61.5 (62.7 ± 6.2)
Nut fixing wheels 665.5 ± 66.5 (67.8 ± 6.7)
Self-locking hex screw to fix brake disc to wheel hub 281.5 ± 13.5 (28.7 ± 1.3)
Self-locking hex screw M16 x 1.5 to fix brake calliper mount to stub axle 313.5 ± 15.5 (32 ± 1.6)
Threaded plug for wheel hub cover 55 ± 5 (5.5 ± 0.5)
Ring nut fixing wheel bearings 515.5 ± 24.5 (52.6 ± 2.5)
Cylindrical head screw with hex socket to lock wheel bearing adjustment clamp 27.5 ± 2.5 (2.8 ± 0.2)
Cover for wheel hub ♦ 130 ± 10 (13 ± 1)
Front axle disc brakes 55080/DI
+50 +5
Nut fixing wheel 600 - 20 (61.2 -2 )
Hex screw to fix brake disc to wheel hub 281.5 ± 13.5 (28.7 ± 1.3)
Threaded plug for wheel hub cover 55 ± 5 (5.5 ± 0.5)
Nut fixing wheel bearings 515.5 ± 24.5 (52.6 ± 2.5)
Cover for wheel hub ♦ 130 ± 10 (13 ± 1)
Screw fixing nut 27.5 (2.8)
Screw fixing mount 289.5 ± 14.5 (29.5 ± 1.5)
Screw fixing brake calliper 615 ± 61 (62.7 ± 6.2)
♦ Spread a bead of sealant solely on the mating surface of the hub cover, using the specific metering device. Protect the threaded
part. Use LOCTITE sealant type 574.
Base - May 2004 Print 603.93.321

TIGHTENING TORQUES
PART TORQUE
Nm (kgm)
Added rear axle disc brakes 56082/I
Nut fixing wheels 665 ± 61.5 (67.8 ± 6.2)
Screw fixing drive shaft flange • * 90 ± 10 (9.2 ± 1)
Ring nut fastening wheel hub bearing 932 ± 98 (95 ± 10)
Screw fixing brake disc to wheel hub 281.5 ± 13.5 (28.7 ± 1.3)
Nut for screw fixing brake calliper to mount 615.5 ± 61.5 (62.7 ± 6.2)
Nut for screw fixing brake calliper mount 289.5 ± 14.5 (29.5 ± 1.5)
• Apply LOCTITE 243 sealant onto the thread
* Spread the drive shaft / wheel hub contact surface with sealant type IVECO 1905685 (LOCTITE 14780)
MS 13-175 rear axle disc brakes
Nut fixing wheels 665.5 ± 61.5 (67.8 ± 6.2)
Screw fixing drive shaft flange * 262 ± 27 (26.7 ± 2.7)
Ring nut fastening wheel hub 932 ± 98 (95 ± 10)
Screw fixing brake disc to wheel hub 281.5 ± 13.5 (28.7 ± 1.3)
Screw fixing brake calliper to mount 615.5 ± 61.5 (62.7 ± 6.2)
Nut for screw fixing brake calliper mount 289.5 ± 14.5 (29.5 ± 1.5)
* Spread the flange / wheel hub contact surface with sealant type IVECO 1905685 (LOCTITE 14780)
Print 603.93.321 Base - May 2004

TOOLS
TOOL NO. DESCRIPTION
99301001 Grinding and turning machine for brake discs and drums
99301005 Brake disc turning device
99305117 Instrument to check air circuits
99321024 Hydraulic trolley to remove and refit wheels
99322215 Stand for overhauling front and rear axles
99341003 Single-acting bridge
Base - May 2004 Print 603.93.321

TOOLS
99341016 Pair of brackets with hole
99341017 Pair of brackets with hole
99345049 Reaction block for extractors
99345053 Reaction block for puller tools
99345055 Reaction block for puller tools
99345103 Wheel hub fitting tool
Print 603.93.321 Base - May 2004

TOOLS
99348001 Extractor with locking device
99354207 Wrench for wheel hub sumps
99355167 Wrench (114 mm) for wheel hub bearing adjustment nut
Wrench (105 mm) for wheel hub bearing adjustment nut

99355180
Wrench to remove and refit brake cylinder ring nut

99356006 (use with 99389817)
Base - May 2004 Print 603.93.321

TOOLS
99370005 Grip for interchangeable drifts
99370317 Reaction lever with extension to fasten flanges
99370700 Guide to fit wheel hub
99370706 Tool to drive in wheel hub bearing
Print 603.93.321 Base - May 2004

TOOLS
99370708 Tool to drive out wheel hub bearing
99372237 Tool to mount brake caliper sliding bush guard
99372238 Tool to extract brake caliper thrust units
99372239 Tool to mount thrust units with brake caliper guard
99372240 Tool to remove and refit brake caliper sliding bush guide bushings
(use with 99372237)
99372242 Tool for notching brake caliper sliding bush guide bushing
Base - May 2004 Print 603.93.321

TOOLS
99372243 Tool for mounting thrust pressure inner seals (use with 99372239)
and for mounting the brass bush of brake caliper guide pin (use with
99372240 and with the screw of 99372237)
99372244 Tool for mounting the rubber bush of brake caliper guide pin (use
with the screw of 99372237)
99372245 Tool for dismounting the rubber bush of brake caliperguide pin (use
with the screw of 99372237)
99374132 Installer, wheel hub inner seal (use with 99370006)
99374134 Installer, wheel hub inner seal
99387050 Cutters for polyamide pipes
Print 603.93.321 Base - May 2004

TOOLS
99389816 Torque multiplier x 4, with square fitting, 3/4” in, 1” out

(maximum torque 2745 Nm)
99389817 Torque wrench (60-32 Nm) with 1/2” square fitting
99389819 Torque wrench from 0 to 0.9 kgm with 1/4” square fitting
99395026 Tool to check rolling torque of wheel hubs

(use with torque wrench)
99395684 Dial gauge with magnetic base
Base - May 2004 Print 603.93.321

SPECIFICATIONS AND DATA - PNEUMATIC SYSTEM

DESCRIPTION
Compressor
- WABCO 412 352 008 Single cylinder
Capacity 352 cm3
Bore 85 mm
Stroke 62 mm
Head cooling Water
Max. continuous rpm 3000 r.p.m.
Max. working pressure 14 bar
- KNORR-BREMSE 2W630R Twin cylinder

Capacity 628 cm3
Bore 86 mm
Stroke 54 mm
Head cooling Water
Max. continuous rpm 3060 r.p.m.
A.P.U.
- KNORR Z 007035
Safety valve opening pressure 13.0 + 4 bar
Max. working pressure 13.0 bar
Disconnecting pressure 10.5 + 0.2 bar
Duty temperature -40 to +80 ° C
- KNORR Z 007036
Safety valve opening pressure 14.5 + 4.0 bar
Max. working pressure 13.0 bar
Disconnecting pressure 12.5 + 0.2 bar
Duty temperature -40 to +80 ° C
Air tanks
Tank capacity Total
4 x 2 vehicles
15L 20L 30L 80L capacity
P/FP-CT 2 1 70
FP-D 1 1 50
T/P/FP - LT/FP-CT 2 1 70
6x2 P vehicles
3 1 90
YP/YPS/YPT/YFP/YFS/YTN
Y/FP-D/FS-D 2 1 70
6x2 C vehicles
X/P/FP 2 1 70
TX/P 1 2 1 85
Print 603.93.321 Base - May 2004

DESCRIPTION
Manual discharge valve

- Type: VOSS 520 899 750 0 - TECHNOMATIK TP 1609.00.00
Maximum working pressure 13 bar
ABS duplex control valve
- KNORR - BREMSE DX 60 A
Supply pressure 10.5 bar
Working pressure 10.5 bar
Relay valve for parking

- KNORR - BREMSE AC574AXY
Maximum working pressure 10.2 bar
Automatic and graduated release coupling heads

- BOSCH - KNORR - BREMSE - WABCO
Working pressure 8.5 bar
EBS2 rear axle electro-pneumatic graduated release

- WABCO 480 104 000 0
Terminal voltage 24 + 6 V
- 9,5
Max. terminal current 10A / 10 bar
CBU (Central Brake Unit)

- WABCO 480 020 010 0
Feed pressure 12,7 bar
Terminal voltage 24 ± 8 V
Current absorption 0,5 ÷ 11 A
ABS solenoid valve

- WABCO 472 195 055 0
Voltage 24 V
- KNORR BREMSE IC 57664
Maximum working pressure 10,2 bar
Voltage 24 V
Base - May 2004 Print 603.93.321

DESCRIPTION
EBS 2 trailer servo control valve

- WABCO 480 204 002 0
24 + 8 V
Voltage - 6,5
Max. permanent voltage between orifice 6.4 and 6.5 8V

Max. current 1.4A
Outlet pressure 8,5 bar
Parking brake control valve (vehicles suited for towing)

- KNORR - BREMSE DPM 60 EY
Supply and working pressure 8.5 bar
Travel of control lever (discharge) with start of emergency braking
(point of resistance) 67º
Parking braking 73º
Test braking to check supply to triple control valve 86º
Parking brake control valve (standby vehicles)

- KNORR - BREMSE DPM 61 EY
Supply and working pressure 8.5 bar
Travel of control lever (discharge) with start of emergency braking
(point of resistance) 67º
Parking braking 73º
Test braking to check supply to triple control valve
Dual stop valve (for vehicles with ABS/EBL)

- WABCO 434 208 029 - WABCO 434 500 003 0
Supply pressure 10 bar
ABS trailer triple servo control valve

- WABCO 973 009 0130 - KNORR - BREMSE AC 597 B
Predominance 0.2 bar
Differential control pressure (pipes 41 and 22) 2.5 + 0.3 bar
- 0.5
Pressure test point valve

ASR control normally-closed solenoid valve

- WABCO 472 170 606 0
Working pressure 5.5 ÷ 11 bar
Maximum supply pressure 13 bar
Voltage 24 V
Current 0.69 Amp
Print 603.93.321 Base - May 2004

DESCRIPTION
Redundant valve (for vehicles with EBS 2)

- WABCO 472 173 226 0
Working pressure 0 ÷ 11 bar
Maximum supply pressure 13 bar
Voltage 24 V
Current 0.69 A
ABS electronic control unit

- BOSCH 446 004 320
Supply voltage 24 Volt
ESP electronic central unit (optional on tractors only)

- WABCO 446 065 005 0
Supply voltage 24 + 8 Volt
- 12
Combined brake cylinder (for front disc brake)

- Type 20 - 22 - 24: KNORR - BREMSE Z 003479
- Type 22 - 24: KNORR - BREMSE Z 003480
Maximum working pressure
- fitting 11 10.7 bar
Minimum stroke 64 mm
Diaphragm brake cylinder (for added axle disc brake)

- Type 12: KNORR - BREMSE IC 72561
- Type 14: KNORR - BREMSE IC 72563
Combined brake cylinder (for rear disc brake)
- Type 20/27 KNORR - BREMSE IC 68086
Maximum working pressure
Pressure sensor
- WABCO 441 040 015 - 441 044 002 0
Supply voltage 8 - 32 V
Measurement range 0 - 10 bar
Low-pressure switch
- F 130 46 S - F 130 47 S
Trip pressure 6.6 ± 0.2 bar
Base - May 2004 Print 603.93.321

DESCRIPTION
On-off valve (For Sweden only)

- WABCO 434 205 061
Working pressure 10 bar
Controlled pressure valve

- WABCO 434 100 199 - KNORR - 1B 435 47 - BENDIX VPC 4M
Opening pressure 7 + 0.1 bar
- 0.3
One-way valve
- PEL 50 473 - C
Working pressure 12 bar
Backpressure 0.2 bar
Trailer automatic and handbrake engaging low-pressure switch

- F 130 48
Trip pressure 5.5 ± 0.2 bar
Print 603.93.321 Base - May 2004

Print603.93.141
SPECIFICATIONS AND DATA - BRAKES
DISC BRAKES: 5876/4/5 - 5886/5

FRONT AXLE 5876/2/4
CENTRAL ADDED AXLE
REAR AXLE MS 13-175
REAR ADDED AXLE 55080/DI (DN8071) - 57080/DI (N8072)
56082/DI (N9171)
Brake calliper cylinders:

∅ - number 2
- diameter ∅ mm 68
Brake lining thickness:

- normal S mm 21
S
- minimum permissible S mm 2
∅ Brake disc diameter ∅ mm 432
Brake disc thickness:

- normal S mm 45
S - minimum permissible S mm 37 (4 mm each side)
Operating clearance G mm 0.5 to 1
FRONT AXLES
WHEEL HUBS 5876/2/4/5 - 55080/DI-57080/DI 56082/DI
5886/5
2 with tapered rollers

Wheel hub bearings 2 with tapered rollers
Unit-Bearing
Hub bearing end float mm max 0.16 -
Not adjustable
Hub bearing end float adjustment
Tightening ring nut to torque
Rolling torque da Nm 0.50 max.
Oil for wheel hub bearings

Tutela W 140/M-DA
(TRUCK FE-AXLE protection
only on the rear axles of vehicles
with F3A/F3B Engines) Litres 0.33 (•) -
Quantity of oil for each hub kg 0.30 (•) -
• Quantities are referred to axles.
Base - May 2004 Print 603.93.321

CHECKS ON MAIN COMPONENTS OF BRAKE SYSTEM

Since the vehicle system is type approved to European code standards, it is vital to periodically check its efficiency and that of
the relevant components with the device 99305117.
These checks should be carried out with the vehicle stationary, using the compressed air of the tanks filled by the compressor,
with the engine started.
Always lock the vehicle before doing any work. Periodically check the pressure gauges, comparing them with a sample
! pressure gauge.
DEVICE DESCRIPTION TASK
Check the tightness of fittings and compressor fixing; make sure the
Compressor
cooling fins are not dirty.
Using a bleed valve or loosening a screw plug (with integrated bleed

A.P.U. hole), check whether the air drier works properly. In this case, the
(Air Processing Unit) air needs to come out of the tank without there being any trace of
condensation water.
Air tanks for:

- Front axle
- Rear axle Check the seal and corrosion protection.
- Parking + trailer Drain the condensate off from the tanks via the drain valve.
- Services
- For regeneration
Check that the pedal gasket is not worn, that the brake control
Duplex control valve linkage is properly tightened and lubricated, not out of shape. Check
that the lever housings are neither worn nor oxidized.
Pneumatic pressure
Check the safety caps are on
test points
Parking brake control valve Apply the parking brake control valve till it trips; the pressure gauge on
the test point has to show pressure discharge down to 0 bar in 1 sec.
Parking brake control valve At the sametime, at the automaticcoupling pipe, the pressure gauge
(with check position) has to show a pressure of 7.5 bars.
(continued)
Print 603.93.321 Base - May 2004

Check its fixing, integrity and seal.

Diaphragm cylinder
The bleed hole must be facing downwards and must not be clogged.
Check its fixing, integrity and seal.

Combined cylinder
The bleed hole must be facing downwards and must not be clogged.
Check its operation and seal, evaluating how fast the brake
Relay valve
cylinders act.
Fill the tank. Connect one pressure gauge to the automatic coupling
head and one to the graduated coupling head.
Servo control valve A pressure of 1 bar, sent by the twin control valve, must at the
with triple control graduated coupling head correspond to a pressure of from 0.8 to 1.5
for trailer braking, bars. Make a full braking (vehicle stationary).
with modulated The coupling head must have available the required braking pressure
servo diverter incorporated or a pressure decreased by 0.5 bars. Apply the parking brake; at the
graduated coupling head, the pressure must stay unchanged or
decreased by 0.5 bars.
Check there is no dirt or damage in the coupling guides.

After coupling is made, press the brake pedal and check the seal and
Coupling heads
stability between the coupling heads introducing air at 8.5 bars.
Check there is no air leakage from the coupling gaskets.
Disc brake calliper

Check the wear of the brake linings, scoring and wear of the brake
Brake disc
disc, efficiency of the pistons, wear of the dust caps.
Brake linings
(continued)
Base - May 2004 Print 603.93.321

Check the metal pipes are in a perfect state, with no dents or cranks;
the polyamide pipes must have no cracking or cuts. Check moreover
they are far from sharp edges of the bodywork and chassis that could
damage them. Check that all the pipe brackets are firmly secured,
their slackening causes vibration with the ensuing risk of breakage.
Check that the polyamide pipes have not come into contact with
oil or mineral grease, rubber solvents. Press forcefully on the brake
Pipes and fittings pedal and check the pipes do not swell. Check there is no leakage
from the various fittings or it will be necessary to tighten them fully,
but taking care not to cause any abnormal torsion on the pipes. In
all the above cases it is necessary to replacethe relevant parts if there
is even the slightest doubt about their efficiency. Apart from their
conditions, it is advisable to replace the flexible hoses after
considerable mileage or after a lengthy period of using the vehicle
in order to prevent sudden bursting due to ageing and fatigue.
This check is carried out by introducing air pressure into the system
of no less than 5 bars, spreading fairly dense soapy water over the
Seal of pneumatic system
couplings and fittings with a soft brush and seeing thereis no leakage.
with engine off and under
Air leakage corresponding to a soap bubble of ∅ 25mm in 5 seconds
activation pressure
is tolerated, or anyhow a max. fall in pressure within 10 min. of 2%
of the disengagement pressure = 0.22 + 0.02 bars.
Seal of pneumatic system in the For 3 min.the pressure has to remain stable in the pneumatic system.
partial braking range with 3 bars This check should be made with the parking brake disengaged.
MAIN COMPONENTS OF THE BRAKING Head locking screw tightness

SYSTEM
790510 Compressor Figure 48
A
Figure 47
73821
73820
60732
It produces compressed air needed to supply the pneumatic A = single-cylinder compressor
system. Depending on the version, it may be a single- or B = twin-cylinder compressor
twin-cylinder compressor. Following the order shown in the figure, tighten the screws
fixing the cylinder head to the required torque.
Print 603.93.321 Base - May 2004

Fault diagnosis
TROUBLE POSSIBLE CAUSE REMEDY
Oil leakage from the flange Incorrect tightening torque Lock the screws to the required values.
on the outside
Flange seal surfaces not perfectly flat. Check the sealing surfaces, replace any defective parts or
make them level.
Gasket broken. Change the gasket.
Shaft gasket damaged. Change the gasket.
Oil leakage from the head Scraper ring worn Replace the piston assembly.
(noted because the seal seat is shiny).
Defective assembly of the scraper ring. It should be fitted with the word TOP facing the head of
the compressor.
Scraper ring and piston rings all on the same Fit at 120° to each other.
vertical line.
Cylinder scored or ovalized. Grind the cylinder and mount an uprated piston.
Total lack of compression Compression or intake valve deteriorated. Replace deteriorated parts.
Piston rings all on the same vertical line. Mount rings at 120° to each other.
Perforation of the piston or breakage of parts Replace the piston assembly.
connected to the piston.
Gaskets damaged. Replace the gaskets.
Energy-saving device in open position during in- Replace the cylinder head.
take.
Poor efficiency Piston rings worn. Replace the piston (together with piston rings).
Air leakage between cylinder and head. Replace the gasket and lock the screws with the required
torque.
Energy-saving device, intake or compression Replace the deteriorated parts.
valves deteriorated.
Excessive clearance between piston and cylinder. Grind the cylinder and mount an uprated piston.
Particles of carbonized oil between the intake Clean the valves.
and compression valves.
Mechanical noise Too much clearance between the small end Check the tolerance of the couplings at issue.
and pin, between the pin and hole in the pis-
ton, bet ween the shaf t and big end, b etwe en
the shaf t and bush ings and bet ween the pist on
and cylinder.
To much clearance between the piston and Grind the cylinder and mount an uprated piston.
cylinder.
Too much incrustation between the piston and Clean the incrusted parts and replace the valves.
cylinder head caused by burnt oil.
Water blow-by Head gasket or coupling faces scored and un- Replace the damaged parts.
even.
A.P.U. (Air Processing Unit)

Figure 49
73913
Its function is to keep the air clean and at the right moisture level in the system.
In addition, it has to distribute and keep the pressure needed for the operation of the connected systems at the outlet.
On CM (Movable Body) vehicles, the component is used with a setting of 12.5 bars, while versions below this one have a setting
of 10.5 bars.
The A.P.U. contains two pressure sensors connected with an MUX system to display the front/rear axle pressure on the Cluster.
Base - May 2004 Print 603.93.321

Figure 50
001682t
Pneumatic connections
1 - Compressor feed
24 - Pressure intake
25 - Outlet for 10.5 bar / 12.5 bar pneumatic suspension for mobile cases
23 - To compressor for Energy Saving drive
3 - Exhaust into atmosphere
21 - To 10.5 bar rear axle air tank
22 - To 10.5 bar front axle air tank
23 - To trailer parking and reloading air tank and to hand distributor for 8.5 bar parking brake
24 - To 8.5 bar services tank
Thermostatic resistor connections (<7 ° ÷ >29 °)
6.1 - Negative for thermostatic resistor
6.2 - Positive for thermostatic resistor
Pressure switch electric connections on four-way protection valve
6.2 - Signal
6.3 - Positive for power supply
6.4 - Negative
6.5 - Signal
6.6 - Positive for power supply
6.7 - Negative
System for signalling on cluster
By this new component, systems pressure is displayed on IVECO Colour Display in following way:
Cluster - Systems pressure
Print 603.93.321 Base - May 2004

OPERATION
Figure 51
f
d
a c b
g
000700t
Base - May 2004 Print 603.93.321

RE-CHARGING STEP:
(10.3 + 0.2 bar Regulator) Compressed air from compressor at feed ”1” is arranged on system ”a” safety valve (calibrated to
13+4 bar for components limited to 10.5 bar, calibrated to 14.5+4 for components calibrated to 12.5 bar), and through dedicated
channel reaches the drier filter.
Compressed air by passing through the filter releases its own moisture and, so dried, will be able to reach and feed, through the
calibrated hole, the chamber of timer ”b”; at the same time it opens holding single acting valve ”c”, and in this way it can feed
outlet pressure intake 24, pressure regulator ”b”, outlet for feeding pneumatic suspension circuit 25, and through outlet 21 it
feeds the four-way protection valve by its lying beneath pressure valves and is controlled by brake system outlets 21 and 22.
On reaching ≤ 7.5 bar pressure, the controlled pressure valves of above outlets open and, therefore, rear axle braking system
21 and front axle braking system 22 are fed; at the same, time through the two single acting valves ”e”, the pressure reducing
device can be reached; since the pressure reducing device is open, this device allows pressure to pass to the controlled pressure
valves of secondary sections.
Pressure at outlet 21 feeds the safety valve ”f ” of section 23, lifting it to seal position.
By further increasing pressure and reaching > 8 bar pressure, controlled pressure valves of secondary sections can open, and,
consequently, outlets 23 and 25 can be fed, opening dedicated single acting safety valve and outlet 24.
These sections are fed and limited until the integrated pressure reducing device, calibrated to 8.5 bar, reaches the intervention
pressure.
When regulator calibration 10.3+0,2 bar pressure is reached, the regulator is opened and, consequently, exhaust valve ” h” is
opened, causing a pressure drop within the drier from holding single acting valve ”c” closing.
At the same time, through outlet 23, there will be sent the intervention pressure of the Energy Saving device integrated into
compressor head and drier filter regeneration step activation, since the slow pressure drop in timer feed chamber enables
pressure return from systems for ~20 seconds. This pressure, directed inside the filter, will assure filter regeneration and be
released into atmosphere through exhaust 3.
Print 603.93.321 Base - May 2004

Figure 52
000701t
Base - May 2004 Print 603.93.321

RE-CHARGING STEP: (12.5 + 0.2 bar regulator)

This component assures 12.3 + 0.2 bar pressure at outlet 25 of pneumatic suspension, while maintaining the same calibrations
as the former one at the outlets of the four-way protection valve.
In order to assure this functionality, it will be provided with a pressure reducing device ”a” calibrated to 10.3+0,2 bar on outlets
21 and 22; therefore, the re-charging will be similarto the already described one but for the pressure reducing device being closed
on reaching above pressure and the regulator release occurring on reaching 12.3 + 0.2 bar pressure.
DUCT 21 FAILURE STEP
Where a failure occurs at the four-way protection valve main circuit, component behaviour will be as below:
The pressure drop affecting outlet 21 results in a general pressure fall throughout the component, until the controlled pressure
valve of faulty section reaches 6.5 bar closing pressure.
This pressure decrease also affects regulator ”d”, which shifts and returns to the re-charging condition.
At thesame time,the pressure drop at outlet 21 causes safety valve”f ” of parkingduct to shift and open on discharging, so forcing
duct 23 of protection valve to discharging, and causes the single acting valve of outlet 25 to close, so assuring pressure to be
maintained in spring cylinders and preventing tractor parking self-braking.
In this failure condition, the half-trailer or connection, if any, will on the contrary be shifted to automatic braking.
System re-charging, assured by regulator intervention, will take pressure back to the opening levels of the controlled pressure
valve of faulty section, corresponding to ≤ 7,5 bar, so assuring this pressure to be present in all the outlets of the component.
DUCT 24 FAILURE STEP
Where a failure occurs at the four-way protection valve secondary circuit, component behaviour will be as below:
The pressure drop affecting outlet 24 causes the pressure reducing device to open, so affecting the whole component, until the
controlled pressure valve of faulty section reaches 6.5 bar closing pressure.
This fact causes the pressure regulator to open and return to the re-charging step.
System re-charging, assured by regulator intervention, will take pressure back to the opening levels of the controlled pressure
valve of faulty section, corresponding to > 8 bar, so assuring this pressure to be present in all the outlets of the component.
In the caseof any failure in protection valve,system feed is assured at pressure levels that guarantee system functionality;
! however, filter regeneration is not assured any more since this function is only activated when regulation pressure is
reached, which in a failure condition cannot be reached any more.
Print 603.93.321 Base - May 2004

793110 Duplex control valve

(vehicles without EBS)
Figure 53
It takes air from the tanks and distributes it to the braking

elements.
It is self-limited, that is it limits the delivery of air at a set
maximum pressure, the outcome of which is a greater
availability of energy and a constant maximum braking
pressure irrespective of the pressure swings in the tanks.
73914
Fault Diagnosis (vehicles without EBS)

Air leaks from the outlet Leaks from the outlet pipes due to wear of the Overhaul the device, replacing the worn parts.
hole gaskets
Control valve with abnormal Self-limitation higher or lower than as required Set the device using the specific screw.
self-limitation
Vibration during braking Spring wear Overhaul the device, replacing the worn parts.
Air leakage due to piston gaskets in the two Overhaul the device, replacing the worn parts.
sections
Abnormal operation of the It fails to close the electric circuit Replace the switch.
brake light switch
It fails to open the electric circuit Replace the switch.
Base - May 2004 Print 603.93.321

CBU (Central Brake Unit) (vehicles with EBS 2)

Figure 54 This component integrates the functions of following
components:
- duplex distributor, which generates electric and
pneumatic signals to increase or decrease pressure in the
braking system;
- electronic central unit, which has the task of managing
the braking system determining deceleration values as a
function of parameters detected from various
components;
- proportional relay valve, which modulates pressure at
front axle;
- Back up valve assuring braking even in case of electric
failure.
88761
Figure 55
88762
Pneumatic connections Electric connections

11 - From axle air tank 6.1 - Cab inner side X1 connector
12 - From axle air tank 6.2 - Connector X2 on cab outer side
(positioning to the left with respect to forward ride)
21 - To ABS solenoid valve 6.3 - Connector X3 on cab outer side
(positioning to the right with respect to forward ride)
22 - To ABS solenoid valve
23 - To trailer drive servo-assisted distributor
Print 603.93.321 Base - May 2004

Figure 56
90144
A. CBU (Central Brake Unit) - B. ABS solenoid valve - C. Servo-assisted distributor for trailer drive - V1, V3. Air tanks -
1, 11, 12. Feeds - 2, 21, 22, 23. Outlets - 3. Exhaust - 42, 43. Control pressures
Base - May 2004 Print 603.93.321

793331 Relay valve (vehicles without EBS) The device allows to speed up compressed air release from
combined cylinder section, so cutting down braking time.
Figure 57
1 2
36743
Fault Diagnosis (vehicles without EBS)

Air leaks from the outlet Leakage from the introduction or from the seals. Overhaul the device, replacing any defective parts.
with the control pipe
exhausting
Air leaks from the outlet Leakage from the piston gasket or from the ex- Overhaul the device, replacing any defective parts.
with supply in the control haust valve.
pipe
798510 Coupling heads The version for the ”Graduated” pipe is equipped with a red
cover and a safety projection (1), while the version for the
”Automatic” pipe is equipped with a yellow cover and a side
Figure 58 safety projection (2). The safety projections areused to avoid
coupling errors.
52871
Print 603.93.321 Base - May 2004

Electropneumatic modulator (vehicles with EBS 2)

Figure 59 Its task is to modulate pressure at rear axle brake cylinders.
It is provided with an electronic central unit which controls
rear r.p.m. sensors and rear axle braking gaskets wear.
This electronic central unit communicates via CAN network
with the electronic central unit of the EBS that is integrated
in the CBU.
In carts, at gate 4, the redundant valve is connected enabling
pneumatic braking in the case of an electric failure.
88763
Figure 60
88764

11 - From axle air tank 61.1 - Positive
61.2 - Earth Central units
12 - From axle air tank 61.3 - CAN “H” connection line
- o ax e ra e cy n er 61.4
. - CAN “L”
22 - To (RH) axle brake cylinder 62.1/63.1 - Speed signal

Speed sensors
62.2/63.2 - Speed signal
3 - Exhaust 66.1/67.1
. . - Positive
4 - Redundant connection 66.2/67.2 - Earth Wear sensors
66.3/67.3 - Signal
68.1 - Positive
68.2 - Earth
68.3 - Signale Trailer drive valve
68.4 - CAN “H”
68.5 - CAN “L”
Base - May 2004 Print 603.93.321

Figure 61
90145
A. Rear Axle Modulator - B. Redundant valve - C. CBU (Central Brake Unit) - V1. Air tank - 1, 11, 12. Feeds -
2, 21, 22, 23. Outlets - 3. Exhaust - 4. Redundant connection - 42. Control pressure
Print 603.93.321 Base - May 2004

Operation
Braking phase Braking in electric failure
The CBU informs the modulating valve electronic control
unit via CAN. It controls the modulating valve so that the TRACTORS
discharge solenoid valve is closed and the input one is In case of electric failure, it will not be possible to brake the
opened. rear axle as this function is electrically enabled only. Braking
will be ensured on the front axle and on the connected
The pressurised air will reach the brake cylinders causing the
semitrailer only.
vehicle braking.
The outlet pressure will be proportional to the controlsignals
TRUCKS
and will be constantly controlled by the two built-in pressure In trucks, in the case of a failure of the electric system, the
sensors. redundant valve opens, enabling axle braking
Depending on the signals coming from the speed sensors, the Performance diagram
electronic control unit controls that the deceleration effect
corresponds to the calculated one by constantly informing Figure 62
the CBU.
FEED PRESSURE
If the requested deceleration percentage or the grip of the
wheel on the road decrease, the electronic control unit will
enable the fit modulations of the braking pressure.
When the brake pedal is released, the component will
remove the braking action from the rear axle, disabling the
solenoid valves, which will return to the closed position on
inputs, and discharging the braking pressure. E
R
Besides, the component electronic unit controls and U
S
S
transmits to the CBU, via CAN network, the percentage E
R
wear status of the rear axle brake linings. P
D
E
I
L
P
P
U
S
BRAKING VALUE REQUIRED
88765
Base - May 2004 Print 603.93.321

Redundancy valve (for 4x2 and 6x2 trucks) Dual stop valve
Figure 63 Figure 65
90143 73919
This component has the task of ensuring the rear axles brake On vehicles with an ABS/EBL system,this component has the
even if the EBS is entirely out of service. task of sending the rear axle braking control relay valve the
control pressure from the duplex control valve (normal
working function). With the ASR function active, this
component will send the activation pressure from the ASR
solenoid valve. In addition, it is used on 6x2 vehicles to
transmit the pressure in the air springs, to the added axle
braking control relay valve,according to the load. On vehicles
with the EBS, it has the task of sending the pressure of the
front axle braking relay valves according to the load bearing
on the air springs of the added axle.
793332 Triple servo control valve

ABS solenoid valve (vehicles without EBS)
Figure 64 Figure 66
42
41 43
11 22
12
35805 33986
The device controlled by the two independent circuits of the

duplex control valve and the spring brake circuit of thetractor
This component modulates the air pressure in the brake controls trailer braking.
circuits. When the electronic control unit detects a tendency It incorporates a device making it possible to brake the trailer
for one of the wheels to lock, the valve shuts off the supply even in the event of control pipe failure.
to the brake cylinder, preventing the wheel from locking.
Print 603.93.321 Base - May 2004

Predominance control WABCO 9730090130

It is equipped with a predominance adjustment device.
Figure 68
KNORR - BREMSE AC 597 B

Figure 67 41
1
42
22
bar 11
12
bar
43
2 3 2
60256
The operations to carry out to adjust the predominance of

the servo control valve type WABCO 973 009013 are
performed in the following order:
- Remove the screws (2) and take off the cover (3).
- Turn the screw (1) to adjust the predominance.
60255
- Turning it CLOCKWISE decreases the predominance.
The operations to carry out to adjust the predominance of - Turning it ANTICLOCKWISE increases the predo-
the servo control valve type KNORR — BREMSE AC 597 B minance.
are performed in the following order:
- undo the screw (2) from the silencer body;
- insert an Allen wrench into the hole through the silencer
body and turn the hexagonal hole of the body (1);
- turning it CLOCKWISE increases the predominance;
- turning it ANTICLOCKWISE decreases the predo-
minance.
Fault Diagnosis
Air leaks from the outlet Leaks from the gaskets. Overhaul the device, replacing the worn parts.
when at rest
Exhaust valve and seat defective Overhaul the device, replacing the worn parts.
Outlet pressures not as Air leaks from the gaskets. Overhaul the device, replacing the worn parts.
required
Pistons and seats worn or defective. Overhaul the device, replacing the worn parts.
Springs yielded. Overhaul the device, replacing the worn parts.
Base - May 2004 Print 603.93.321

Trailer drive servo-assisted distributor (vehicles with EBS 2)

Figure 69 Valve task is to assure both all braking (service, parking,
rescue) levels and the adaptation of the prevalence to trailer.
88769
Figure 70
88766

11 - From air tank to trailer 6.1 - Positive Pressure sensor
21 - To automatic coupling joint 6.2 - Earth Pressure sensor
22 - To moderable coupling joint 6.3 - Signal Pressure sensor
42 - From (drive) CBU 6.4 - Positive Solenoid
3 - Exhaust 6.5 - Negative Solenoid
Print 603.93.321 Base - May 2004

Operation
Braking phase Parking braking
Depending on signals from CBU, servo-assisted distributor By operating the hand-operated control valve, pressure is
proportional valve is conveniently activated. discharge at control 43 of the component. This causes the
movement of the internal piston which, intercepting the relay
The enabling of the latter causes the opening of the input
closes the discharge and feed the adjustable outlet 22
valve andthe pressurised air may reach and move the control
achieving in this way the pneumatic parking of the semitrailer.
relay device and simultaneously move the adjusted
servo-switch. The control unit will be informed of the braking situation by
the built-in pressure sensor.
The movement of the control relay closes the discharge and
opens the input valve. The so-defined pressure will reach the When the hand-operate control valve position is reset, in
automatic servo control valve of the trailer through outlet 22 running conditions, the pressure to control 43 will be
and start braking. restored, The movement of the internal piston will cause the
discharge the adjustable pressure of outlet 22 and the
Through pressure sensor, CBU will be acquainted of supplied
non-braking of the semitrailer.
pressure and at the same time, through 42 command, safety
pressure arrives from CBU. Braking in electric failure
In electric failure conditions, the driver will be informed by the
In this way, the central unit integrated in CBU detects,
turning on of the light on the dashboard.
through axle speed sensors, the actual slowdown obtained
on the half trailer and, if necessary, will provide to optimise No braking electric signals will be transmitted when pressing
it by properly adapting necessary prevalence value (0.5 to the brake pedal, but the safety pressure to outlet 21 of the
1.2 bar), and will store it. control valve reaching control 42 of the servo control valve
will be ensured.
When the brake pedal will be released, the control unit will
disable the solenoidvalve causing the discharge of thecontrol This pressure will directly control the relay device, ensure the
and braking pressures. pressure to the adjusted outlet pressure 22. Braking pressure
will be proportional to the control pressure.
On releasing brake pedal, 42 command will be directly
released by CBU so having the relay lifted and moderable
pressure and half trailer breaking released.
Base - May 2004 Print 603.93.321

Braking with failure of the adjustable line Figure 72

During the braking phase with the line 22 in failureconditions,
the braking pressure is discharged in the atmosphere through µ
the line breaking. P
E
N
I
The electronic control unit is informed by the pressure L
E
sensor of the pressure drop. The electronic control unit, K
A
therefore, fully enable the control solenoid valve with no R
B
results. E
L
B
This will cause a decrease in the pressure of the automatic A
T
S
line 21 and the closing of the adjusted servo control valve U
J
which stops the input to the automatic line. D
A
E
The pressure drop in the automatic line causes the operation H
T
of the semitrailer servo control valve in automatic braking O
T
mode. E
R
U
When the brake pedal is release, the return to its position of S
S
the adjusted servo control valve allows the automatic E
R PRESSURE IN P 42 SERVICE BRAKE DUCT
P
pressure reset and the semitrailer non-braking.
88767
Performance diagram
Braking with electric signal failure
Figure 71 Figure 73
µ
P
E
2
2
N
I
P L
E E
N K
I A
L R
E B
K E
A L
R B
B A
E T
L S
B U
A J
T D
S A
U
J E
D H
A T
E O
H T
T E
R
O U
T S
E S
R E
U R
S P
S
E
R
P
PRESSURE IN P 43 SPRING BRAKE CYLINDER
CURRENT TO THE PROPORTIONAL VALVE I 43
62337 88768
Braking with electric control Parking braking
Print 603.93.321 Base - May 2004

Pressure test point valve 794310 Parking brake hand control valve
(vehicles suited to towing)
Figure 74
Figure 75
71953
79514
The pressure test points are in the pipes or tanks of the This device provides emergency and parking braking for the
pneumatic system in order to make it easier to hook up tractor and trailer.
pressure gauges for fault diagnosis. Additionally, it makes it possible to check the braking effect
of the tractor. This is vital when the vehicle is parked on a
steep slope.
Fault Diagnosis (parking brake control valve)

Air leaks from the outlet
with the control lever:
in the release position Exhaust valve, seat or seal defective Check and overhaul the device, replacing any defective
parts
in the braking position Control valve, seals and valve to control Thoroughly clean the various parts comprising it
component worn
Difficulty in turning the Interference in the control valve Overhaul the device and moisten all the sliding parts
control lever
Base - May 2004 Print 603.93.321

793336 Parking brake control manual dis- Manual control valve to slow down the trailer
tributor (standby vehicles) (optional)
Figure 77
Figure 76
73922
79515 This component, in the parking circuit between the manual

control valve and the trailer servo control valve, makes it
The apparatus, inserted into tractor parking brake circuit, possible to activate braking to slow down just the semitrailer
allows to actuate vehicle help andparking braking by releasing according to the control given by the driver. It is an optional
the air in spring cylinders. fitting and is anyhow bound by the current type-approval
regulations in the various countries.
Fault Diagnosis (parking brake control valve)

Air leaks from the outlet Piston, outlet valve, seals worn or defective. Clean thoroughly, check the rubber parts andthe seats are
with the control valve lever sound.
in the brake release position
Air leaks from the outlet Piston and associated seal defective or deterio- Clean thoroughly, check theparts and overhaul the device,
with the control valve lever rated. replacing the defective parts.
in the emergency or parking
braking position
Air leaks from the cover Plate, gasket, seals worn. Clean the parts thoroughly, check the surfaces of the
of the control valve lever gasket andseals,checkthe integrity of the rubber parts and
the relevant seats. Overhaul the device, replacing the de-
fective or worn parts, and restore the mating faces if
necessary.
Control valve lever hard Interference inside the control valve. Clean thoroughly and check all the component parts.
to turn Overhaul the device, replacing defective parts. During as-
sembly, grease all the sliding parts in moderation.
If you find any defects or wear such as to jeopardize oper-

ation, replace the complete device.
Print 603.93.321 Base - May 2004

Controlled pressure valve Its jobis to break off the flow of air to the ASR solenoid valve
when the pressure of the rear axle system falls under 7.5 bars
Figure 78 after a breakdown or too much air being drawn off.
73923
Fault Diagnosis
Vent at outlet Diaphragm leaks Overhaul the device, replacing any worn parts
Air leaks from the join be- Leakage from the diaphragm fitting
tween the two half-bodies
Vent on delivery Leakage from inlet valve or its seat Overhaul the device, replacing any worn parts
(into the atmosphere)
with supply at a lower
pressure than the setting
793319 Check valve Low-pressure switch

(vehicles suited to towing)
Figure 80
Figure 79
1 2
73924
33987
The purpose of this component is to warn the driver, with
indicator lights on the CLUSTER, and the electronic control
This permits compressed air to pass in the direction shown unit of low pressure in the system.
by the arrow on the valve body, preventing its backflow.
Base - May 2004 Print 603.93.321

526724 Electro-pneumatic valve for ASR 526711 Electronic control unit

Figure 83
Figure 81
A
35384
B
This device brakes the driving wheels, via the brake anti-lock
modulator, whenever a tendency for one or more driving
wheels to skid is detected.
The valve is normally closed.When the electronic control unit
detects a tendency to skid of one or more driving wheels, it
sends a signal to the solenoid valve, which energizes and lets
air pass to the brake anti-lock modulators that brake the
wheels. The solenoid valve de-energizes when the wheels
have reached the right degree of friction on the road surface. 88772
A = ABS — EBL electronic control unit
B = EBS 2 electronic control unit (CBU)
Its purpose is to control the brake system, producing
526713 Speed sensor deceleration in relation to the parameters detected by the
various system components.
566712 Phonic wheels
The electronic control unit is equipped with a highly
advanced self-diagnosis system and it is able to identify and
Figure 82 save any trouble, even of an intermittent nature, occurring to
the system during operation, in relation to the environmental
conditions, ensuring the most correct and reliable repairs.
EBS 2 central unit is integrated in CBU (Central Brake Unit)
and able to drive slowdown auxiliary systems (engine brake
and Retarder) optimising the intervention in such a manner
as to both assure better system operation and reduce
breaking gaskets wear.
Pressure sensor
Figure 84
35383
The speed sensors and phonic wheels have the job of
detecting the speeds of the respective wheels.
The phonic wheel is housed on the wheel hub and turns at
the same speed as the wheel. It generates alternating voltages
in the sensors by induction. The frequency of these voltages
is in proportion to the speed of rotation of the respective
52722
wheel. These voltage signals are transmitted to the control
unit to be suitably processed. A sensor and a phonic wheel In ABS/EBL systems, its job is to inform the electronic control
are fitted for each wheel. This arrangement makes it possible unit of the extent of action required by the driver.
to control an individual braking pressure for each wheel In EBS 2 systems, this component is integrated in the front
during adjustment, optimizing travelling stability and braking axle, rear axle and trailer control valves.
distance.
Print 603.93.321 Base - May 2004

794911 Diaphragm brake cylinder 794922 Combined brake cylinder

(for front and added front axle (for front and rear disc brake)
disc brake)
Figure 85 Figure 86
73926 73927
This device transmits the force given by the compressed air, This device is composed of two parts: a diaphragm brake for
as the brake pedal is pressed, to the mechanical service service braking and a spring brake for parking and emergency
braking device. If there is any trouble, it is necessary to replace braking if the braking system fails.
the entire cylinder.
Base - May 2004 Print 603.93.321

Combined cylinder emergency brake release Repairs

device Figure 88
Figure 87
36745
36476
If it were not possible to supply the spring section of the
combined cylinder (2) pneumatically, it is possible to release
the vehicle brake manually to permit towing. To release the Before detaching the combined cylinder from the vehicle,
vehicle brake you need to unscrew the screw (1) fully. carry out the manual brake release procedure for the
combined cylinder as described above.
Before removal, it is recommended to thoroughly

! clean the outer parts of dirt and other debris that on
getting inside could damage the cylinder.
If there is any trouble with the spring section of the
cylinder, do not dismantle it as this can be dangerous.
Fault Diagnosis

Air leaks from the outlet or Diaphragm punctured or broken. Replace the diaphragm
retaining clamp Diaphragm lip broken.
Retaining clamp locking screws loose. Tighten the screw
Air leaks from the dia- Deterioration of the parts forming the spring Overhaul the device, replacing any worn parts.
phragm section supply section
Print 603.93.321 Base - May 2004

5274 DISC BRAKES KNORR TYPE (CALIPER SN7)
Figure 89
78397
78396
SEC. AA
1. Dry bush - 2. Threaded hose - 3. Piston - 4. Washer - 5. Spring split pin - 6. Pin - 7. Retaining plate - 8. Supporting plate -
9. Guide pin - 10. Guide bush - 11. Sliding pin - 12. Plug - 13. Dragging device - 14. Wear sensor - 15. Rear axle- 16. Chain -
17. Spring- -18. Cover - 19. Adapter - 20. Chain gear - 21. Adjusting device- -22. Cover - 23. Brass bush - 24. Sliding pin -
25. Sliding bush - 26. Inner protection - 27. Ring - 28. Brake lining - 29. Brake disc body - 30. Lever - 31. Cam bearing.
Base - May 2004 Print 603.93.321

Operation (See previous figure)

Braking stage Figure 91
During braking, the diaphragm cylinder rod presses down on
the lever (30).
The force is transferred to the axle (15) by the bearing in an 1
off - centered position (31)
Through the threaded sleeves (2) and pistons (3), the force 2
is conveyed to the inner braking lining (28).
Once the play between brake linings (28) and brake disc (29)
has been recovered, the force is conveyed to the outer brake 4
lining (28), due to brake caliper displacement.
The brake linings (28) pressing on the brake disc (29)
produce the braking power.
Releasing stage
As soon as thepressure on thebrake is reduced, the pressure
spring (17), therear axle (15) along with threaded sleeves (2) 78622
and lever (32) go back to their original positions.
Remove the plug (4) using the tab (3) and make sure the
Automatic play recovery adapter (2) is not lost.
The brake is equipped with automatic adjustment device,
which keeps the operating play between brake linings and
Never turn the adjusting pinion (1) without fitting
brake disc constant.
! the adapter (2) first. If the adapter cut torque is
Every time the brake is operated, the adjustment device (21),
overcome, the adapter gets broken.
which is integral with the lever (32), is automatically started.
Try again with a new adapter and if also in this case
If worn brake linings and brake discs increase the operating
it gets broken, the caliper should be replaced
play, the adjustment device (21) and drag link (13) turn the
because there is an inner damage.
threaded sleeves (2) so to recover said increase in play.
The operating clearance should be between 0.6 and 1.1 mm;
lower clearances might cause overheating problems.
Figure 92
CHECKS
Checking the automatic play recovery system
efficiency
Figure 90
60759
Using a suitable wrench (1), rotate the adjustment pinion

counterclockwise by 2-3 with the adapter (2, Figure 91)
installed turns, thus increasing the play between brake linings
and brake disc.
Operate the brakes for about 5-10 times and make sure the
40570 wrench (1) moves clockwise with small increments, up to
Remove the lock nuts and wheels, using hydraulic stand complete recover of play between braking linings and brake
99321024 (1). disc.
Otherwise, i.e. if the wrench does not turn, turns just once
or turns in both directions, this means the automatic play
recovery system is faulty. Replace the caliper, following the
procedure given subsequently, then fit back the wheels.
Print 603.93.321 Base - May 2004

Brake caliper components

Figure 93
78628
1. Combined brake cylinder - 2. Membrane brake cylinder - 3. Rubber bushes - 4. Sliding pins - 5. Plug - 6. Adjusting unit
cover - 7. Adapter - 8. Guide pin - 9. Cover - 10. Sliding pin - 11. Brass bushes - 12. Carrying plate - 13. Protection cowling -
14. Ring - 15. Inner seals - 16. Bushes - 17. Plungers - 18. Brake caliper - 19. Guide pin - 20. Braking seal - 21. Spring -
22. Split pin - 23. Washer - 24. Pintle - 25. Check plate.
Base - May 2004 Print 603.93.321

Check of braking seals thickness

Figure 94
78625
1. Brake caliper - 2. Sliding bush - 3. Rubber bush - A. Bush position with new seals - A 1. Bush position with worn out
braking seals (perform an accurate check with wheels dismounted).
The condition of braking seals can be visually determined

without dismounting wheels, by checking that A > 1 mm.
Otherwise, it is needed to dismount the wheels and perform
an accurate check as described below.
Print 603.93.321 Base - May 2004

5274 OVERHAULING FRONT DISC BRAKES

527417 Replacing brake linings Figure 98
Figure 95
49158
Disconnect the electrical connection (1) from the calliper

40569
body.
Set the vehicle on flat ground and lock the rear wheels. Remove the split pin (2), pin (3) and brake lining retaining
Loosen the nuts (1) fixing the front wheels. plate (4).
Lift the vehicle at the front with a hydraulic lift and set it on
two stands (2).
No lifting devices are to be fixed to plate (4).
Figure 96 !
For vehicles with EBS

Figure 99
40570
Unscrew the fixing nuts and with the aid of the hydraulic
trolley 99321024 (1) remove the wheels.
For vehicles without EBS
Figure 97
60860
Remove the split pin (1), pin (2) and brake lining retaining
plate (3).
If plate (3) is damaged or worn out, it must be

! replaced.
No lifting devices are to be fixed on plate (3).
49157
Remove the screw (1) and the wear sensor cable retaining
plate (2).
Base - May 2004 Print 603.93.321

Figure 100 For all vehicles

Figure 103
78623
Remove the plug (3). Turn the adjustment device (1) 49161
operating on the adapter counterclockwise with a wrench, to

insert the pistons within the caliper body and extract brake Remove dirt and rust from around the edge of the brake disc
linings (4), suitably moving the caliper body (3). with a scraper or an old screwdriver (2) resting on the calliper
body, turning the disc (1).
Never operate directly on the registration pinion (1) Finish the job with abrasive cloth. Remove the remains with
without having first of all fitted the adapter (2). If the the aid of an aspirator, or rags and a brush.
! Do not use petrol or other petroleum products that could
cutting torque of the adapter is exceeded, this will
break. cause trouble for the brakes.
Test with a newadapter. If this also breaks, the caliper Use only methylated spirit or isopropyl alcohol.
must be replaced because it is damaged. Carefully clean the surfaces of the braking area of the brake
disc.

Figure 101
Visually check the conditions of the dust caps, if
! deformed or broken it is necessary to replace them.
This requires removing the brake calliper, so it is
recommended to remove the brake calliper body
together with the bearing plate for a thorough
overhaul.
Check that the calliper slides freely on its guides.

49160
If you find any trouble on a single brake calliper it is wise to
overhaul both brake callipers completely.
Press (→) on the spring (1) and remove it. Remove the wear Remove the dirt from the brake calliper with a wire brush,
sensors (2) from the brake linings (3). without damaging the dust caps.
Clean the sliding surfaces of the brake linings.
For vehicles with EBS Check the conditions of the brake disc and make sure it is not
corroded, scored or grooved. Light surface cracks are
Figure 102 acceptable, but it is necessary to grind the brake disc as
described under the relevant section heading. On the
contrary, if it is worn, replace the brake disc.
If one needs to be replaced, it is recommended to replace
both brake discs.
Check the state of the springsand wear sensors, replace them
if necessary.
60862
Press(→) on the spring (1) andremoveit. If necessary, replace

it with a new one.
Print 603.93.321 Base - May 2004


If you find it necessary to replace the pair of brake
Figure 104 linings, always replace them with a full set for each
!
axle.
Figure 107
49162
Insert the wear sensor (2) into its seat on the brake lining (3).
Mount the spring (1) in the opposite sequence to that for
disassembly.

78624
Figure 105
Using the wrench (1), act on the adaptator retriever pin to get
a play not lower than 0.7 mm between brake lining and brake
disk, which can be measured using the thickness gauge (2).
Replace the cover (4) and lubricate it with white grease
RENOLIT HLT2.
Make sure that the outer protecting plug and the seal
! ring are correctly fitted, in order to prevent water
leaks inside the play automatic retriever.
60863
Mount the spring (1) in the opposite sequence to that for

disassembly.
Figure 108
For all vehicles
Figure 106
49158
49163
Insert the new linings in the brake calliper (1) and check they Make the electrical connection (1) and secure it to the calliper
slide freely in their seats. body.
Mount the plate (4), pin (3) and split pin (2).
Base - May 2004 Print 603.93.321

For vehicles with EBS 527413 Removing and refitting brake callipers
Figure 109 Removal
Forvehicles without EBS
Figure 111
60860
Mount the plate (3), pin (2) and split pin (1). 49166
To remove the brake linings, keep to the above description in

the paragraph for replacing brake linings. Remove the clamps
(2). Disconnect the diaphragm cylinder supply pipe (1).
For vehicles without EBS Unscrew the nuts (4) and remove the diaphragm cylinder (3).
Figure 110
Nuts (4) are to be discarded.
!

Figure 112
49165
Mount the wear sensor cable retaining plate (1).

Using the hydraulic trolley99321024, fit on the wheels. Lower
the vehicle. Lock the nuts fixing the wheels to the required
torque.
Fit the safety cap onto the wheel hubs.
Proceed as described on the opposite side.
After repairing the vehicle brakes, press the brake pedal
60866
repeatedly, while the vehicle is moving, in both directions, in
order to wear in the brake linings.
To remove the brake linings, keep to the above description in
the paragraph for replacing brake linings. Remove the clamps
(2). Disconnect the diaphragm cylinder supply pipe (1).
Unscrew the nuts (4) and remove the diaphragm cylinder (3).
Disconnect the electrical connection (5) of the calliper body.
Nuts (4) are to be discarded.

!
Print 603.93.321 Base - May 2004

For all vehicles Figure 115

Figure 113
36407
Block rotation of the wheel hub appropriately and, using the

wrench 99354207 (1), unscrew the oil cover (2).
Drain off all the oil.
49167 Figure 116
Remove the screws (3) and disconnect the brake calliper (1)
together with the bearing plate (2).
Be very careful in removing and carrying the calliper

(1) as it is heavy and floating on the support plate (2).
Keep the caliper only on the outer side. Never put
your fingers between the caliper (9) and the
supporting plate.
Refitting
36408
For refitting, carry out the steps described for
removal in reverse order, keeping to the required Undo the safety screw (3). With the wrench 99388001,
tightening torques. unscrew the adjustment ring nut (2), remove the washer (4),
outer bearing(1) and removethe brakedisctogether with the
wheel hub, spacer and internal bearing.
520620 Removing and refitting wheel hubs
Figure 117
Removal
Figure 114
38596
Visually check the diameter of the gasket ring (1) has no

accidental dents or scratches.
Replace the internal gaskets of the wheel hubs and, if
77206 necessary, the ring (1), according to what described in the
“Repairing handbook”.
Rotate wheel hub in order to take screw plug (1) downwards; Using the adjustment ring nut, check that the thread (2) has
unscrew the plug and drain oil into a suitable tank. no stiffness. If it has, use appropriate means to get rid of the
stiffness.
Remove the opposite brake assembly, keeping the
components separate.
Base - May 2004 Print 603.93.321

Refitting Figure 119
Make sure the surfaces of all the parts inside the hub
! are thoroughly clean, with no waste or burrs.
Lubricate the bearings with Tutela W 140/M-DA oil
(Tutela TRUCK Fe-Axle for vehicles with rear disk
brakes).
Key the wheel hub on the stub axle together with the
brake disc. Insert the internal spacer onto the stub
axle then position the external bearing and thrust
washer.
Screw down and lock the adjustment ring nut to the
required torque.
36412
Apply tool (1) 99395026 on wheel hub stud bolts and use
Figure 118 torque meter 99389819 (2) to check whether the wheel hub
rolling torque is at the set value.
Deposit a sealing bead (Loctite type 574) exclusively

on the hub cover ledge surface and protect the
threaded part.
Tighten to torque the hub cover (1, Figure 120).
Figure 120
36411
Strike the wheel hub a few times with a mallet in an axial

direction, turn it in both directions to free the bearing rollers.
Fit the magnetic base (1) together with the dial gauge (2) on
the wheel hub. Set the pointer of the dial gauge (3) at right
angles to the shank of the stub axle.
Reset the dial gauge with a pre-load of 1.5 ÷ 2 mm.

With the aid of a lever, move the wheel hub axially and
measure the end float, which must be 0.16 mm (maximum
value).
On obtaining the required end float, lock the screw (5)
retaining the adjustment ring nut (4) to the required torque.
79068
Rotate the wheel hub until when hub cover (1) is positioned
as shown in the figure. Restore the prescribed quantity of oil
into the hubcover (1) through filling hole (2). Tighten the plug
on the hub cover (1) to the set torque.
Print 603.93.321 Base - May 2004

BRAKE CALIPER OVERHAUL Figure 124

Disassembly
Figure 121
79121
Place the brake caliper on the bench and block it in a vice. Remove
the cover (1) and make a hole in it with a Parker screw.
Figure 122
79124
Use tool 99372245 (2) (to be used with screw in tool

99372237) to disassemble the rubber sleeve (1).
Figure 125
79122
Refit the supporting plate (1) and remove the fastening screws
(2).
Figure 123
79123
79125
Remove the sliding bushes (1). Take the caliper to the press.
Insert the appropriate beater in the brass bush housing (1)
(See arrow A). Use the press to remove the bush (1).
Base - May 2004 Print 603.93.321

Figure 126
Regular braking depends mainly on the brake caliper
! sliding on the guide pins.
Check the wear conditions of the brake lining retaining pins

and the related safety pins. If they are worn or damaged,
replace the worn parts.
It is advisable to replace all rubber and plastic parts and the
brass bush even if they do notseem damaged or worn at sight.
Assembly
Make sure all the brake caliper components are perfectly
clean. Possible abrasive residuals should be removed with a
cloth soaked in isopropyl alcohol or similar.
Figure 127
60742
Place the caliper on the bench and block it in a vice. Use the
wrench (4) to operate the clearance recovery device so that
the piston (1) comes out of the caliper body for a maximum
of 30 mm (value A).
Take off the dust-guard from the caliper body and use tool
99372238 (5) to removethe thrust pressing devices (1) of the
caliper together with the protection casings (3).
Value A must not be overcome because threaded

! hoses (2) are synchronised. If the threaded hoses (2)
reach their over-travel, they loose synchronism and
the brake caliper must be replaced. The brake caliper
inner parts must never be removed.
For this reason you arerecommended non to slacken
or to remove the cover retaining screws.. 79126
Use tool 99372239 (4) (see figure A) to fit the protection

casings (2). Use the same tool 99372239 (4) fitted on the
other side (see figure B) to insert the pistons (1). Use the
Component part cleaning and check wrench (3) to operate the clearance recovery device and ad
To wash metal parts, use a solution of hotwater with Fiat LCD just the pistons (1).
detergent. Use a metal brush to remove dirt from the caliper Figure 128
body and then a little brush to remove the residuals and to
clear accurately the guide pin and the sliding bush housings.
Use a synthetic brush with the right dimensions to removethe
grease left on the sliding bush housings.
Clean the caliper body accurately with compressed air.
Use a piece of cloth soaked with isopropyl alcohol or similar
to clean the sliding bushes accurately.
Check the wear conditions of the sliding bushes and their
housings on the brake caliper body. Make sure they are not
damagedor worn, especially the sliding surfaces. Fit the bushes
in their housings and check they slide regularly.
Fit the bushes in their housings, check they slide correctly,
otherwise replace or restore their housings on the caliper
body, if needed.
79127
Use tool 99372244 (2) (to be used with the screw in tool
99372237) to assemble the rubber sleeve (1).
Print 603.93.321 Base - May 2004

Figure 129 Figure 131
79128
Use tool 99372243 (1) (to be used with tool 99372240 and 60745
use screw in tool 99372237) to assemble the brass bush (2)
in its seat, by blocking its rotation by means of a suitable tool Use the appropriate tool 99372242 (2) to carry out bruising
(3) (punch or screwdriver). in the point (→) next to the caliper body groove, in order to
prevent the brass bush (1) from moving.
Make sure there are no burrs in the bush housing, otherwise
remove them. Apply white grease RENOLIT HLT2 on the
bush.
Figure 132
Figure 130
79130
Place the caliper on the bench and block it in the vice. Fit the
protection casing (2) by means of tool (1) 99372237.
Reverse the removal order to fit the sliding bushes

! and the supporting plate.
79129
Place the caliper under the press. Use the press to fit the brass
bush (1) in its housing until is comes out of the lower side by
1 mm.
Base - May 2004 Print 603.93.321

5274 OVERHAULING REAR DISC

BRAKES Figure 135
527417 Replacing brake linings
Figure 133
72744
Place a container under the wheel hub to collect the oil.

Block wheel hub(1) rotation with the retaining tool99370317
(3).
Take out the screws (2) and extract the drive shaft (4).
39950
Figure 136
Park the vehicle on level ground. Put the parking brake lever
into the offposition and loosen the nuts fixing the rear wheels.
Using a hydraulic jack, lift the vehicle at the rear and rest it on
the special stands. Using the hydraulic trolley 99321024 (1),
take off the wheels.
Overhaul braking unit, observing — in dismounting

! and overhauling the brake caliper — the procedure
described for front disk brakes, since it is similar.
72745
Lift the notch on the ring nut (5). With wrench 99355175 (1)
Examine the state of wear of the brakediscsurfaces. If you find and multiplier 99389816 (2), take off the ring nut (5) holding
different values to the ones given in the characteristics and the wheel hub bearing. Remove the retaining ring (4).
data table, remove it as follows.
Figure 137
Figure 134
39951
72746
Fullyunscrewthe screw(2) to manuallyrelease the combined Remove the wheel hub (1). Should this prove difficult, use the
cylinder (1) and detach it from the brake calliper. extractor comprising the brackets 99341017 (2), bridge
99341003 (3) and block 99345049 (4) fitted as shown in the
figure.
Print 603.93.321 Base - May 2004

Check the state of the wheel hub bearing, rear axle housing Figure 140
sleeve and calliper mounting plate. Replace any worn or
damaged parts as described under ”Overhauling the wheel
hubs” of rear axle MS 13-175 with disc brakes.
Figure 138
72755
Screw the tool 99370700 (2) onto the sleeve (1) of the rear
axle housing.
Lubricate the outside of the tool (1) with Tutela Truck
Fe-Axle.
Figure 141
72748
Take out the screws (2) and remove the wheel hub (1) from
the brake disc (3). Turn and grind the brake disc as described
in the section or replace it if necessary.
Figure 139
72757
Fit the wheel hub (3) on the sleeve of the rear axle housing
andwiththe dial gauge (1) with a magnetic base check that the
error of concentricity of the phonic wheel (2) is no greater
than 0.2 mm. Remove the wheel hub (3).
Figure 142
72749
The phonic wheel(1) is removed from the wheelhub (2) with

general tools.
To assemble the phonic wheel, heat it to approx. 150°C and
fit it on the wheel hub (2).
On completing assembly, make sure the phonic wheel (1)
rests correctly on the hub seat.
72748
Fit the brake disc (3) onto the wheel hub (1) and screw down
the screws (2).
Base - May 2004 Print 603.93.321

Figure 143 Figure 146
72760
72758
Block rotation of the wheel hub (2) with tool 99370317 (4)
Sling the brake disc (1) with a rope and hook this onto a lift. and tighten the screws (3) fixing the brake disc (1) to the
Fit the wheel hub (2) onto the sleeve of the rear axle housing. wheel hub to the required torque.
Remove the tool 99370700 (3).
Figure 147
Figure 144
72761
Spread IVECO 1905685 sealant (LOCTITE 14780) onto the

contact surfaces, drive shaft flange and wheel hub and insert
72759 the drive shaft into the rear axle housing.
Screw down the screws (2) fixing the drive shaft (3) to the
Position the retaining ring (4) so as to insert the tab into the wheel hub and tighten with the torque wrench (4) to the
groove in the sleeve. Lastly, screw down the ring nut (5). required torque. Remove the tool 99370317 (5).
Using wrench 99355175 (1), the multiplier 99389816 (2) and
the torque wrench (3), tighten the ring nut (5) to the required Figure 148
torque.
Figure 145
39954
After overhauling and refitting the braking assembly, fit the

cylinder (1) following the procedure described for the front
brake cylinder.
74371
Supply the cylinder (1) by pressing the service brake andtighten
After tightening with a specific tool, make the cut and bend to the fixing ring nut to the required torque with the wrench
prevent the ring nut unscrewing, as shown in the figure. 99356006. Restoreoperation of the cylinders (1) governing the
The arrow shows the direction of unscrewing the ring nut. parking brake by fully screwing down the screw (2).
Print 603.93.321 Base - May 2004

527411 TURNING AND GRINDING

Figure 149 BRAKE DISCS
Figure 151
40564
Using the hydraulic trolley 99321024 fit on the wheels. Lower 35707
the vehicle. Lock the nuts fixing the rims to the required
tightening torque according to the diagram shown in the figure - Key onto the shaft of the lathe 99301001 (2) the brake
Proceed as described on the opposite side. disc (1) together with the hub.
On completing this process, start the engine to recharge the
pneumatic system. - Key onto the shaft a set of spacers that eliminate the end
Drive the vehicle in both directions, press the brake pedal float of the assembly; screw on the locking nut and fit the
repeatedly, to let the brake linings settle in. mount of the lathe shaft.
- Position the tool holder (3) in line with the brake disc (1),
then adjust the depth of the tools.
- Proceed with turning and grinding the brake disc (1),
operating with one or more passes to remove material
depending on the scoring found.
527411 OVERHAULING BRAKE DISCS Figure 152
Figure 150
38597 35704
Using thespecific grinding tool99301001(1) fittedto thelathe

Examine the state of wear of the surfaces of the brake discs. 99301001, grind both working surfaces of the brake disc.
Finding other values to the ones given in the characteristics and
data, turn and grind the brake discs or, if necessary, replace them.
Remove the screws (1) and detach the hub (2) from the disc (3).
Replace the disc (3) and refit it following the reverse
procedure to the one described above. When grinding, move the sector wheel forwards
! gradually, to remove all remains of turning.
Base - May 2004 Print 603.93.321

Iveco Stralis Ebs2 Repair Manual

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What are the symbols used to represent components in circuit diagrams?

What are the symbols used to represent components in circuit diagrams?

What steps are involved in overhauling wheel hubs?

What steps are involved in overhauling wheel hubs?

”This document provides data, characteristics, instructionsand

Publication Edited by:

STRALIS AT/AD/AS AIR SYSTEM - BRAKES EBS 2/ESP/EBL 1

SYMBOLS FOR AIR/HYDRAULIC SYSTEM

SYMBOLS FOR AIR/HYDRAULIC SYSTEM

SYMBOLS FOR AIR-HYDRAULIC SYSTEM

SYMBOLS FOR AIR/HYDRAULIC SYSTEM

SYMBOLS FOR AIR/HYDRAULIC SYSTEM

SYMBOLS FOR AIR/HYDRAULIC SYSTEM

SYMBOLS FOR AIR/HYDRAULIC SYSTEM

SYMBOLS FOR AIR/HYDRAULIC SYSTEM

SYMBOLS FOR AIR/HYDRAULIC SYSTEM

PIPINGS AND FITTINGS . . . . . . . . . . . . . . . . . . . . 19

- Rigid pipings reflanging . . . . . . . . . . . . . . . . . . . 19

- Rigid pipings bending . . . . . . . . . . . . . . . . . . . . 20

- Rigid pipings cutting . . . . . . . . . . . . . . . . . . . . . 20

- Flexible pipings replacement with traditional

- Flexible pipings replacement with quick

EBS 2 (ELECTRONIC BRAKE SYSTEM) . . . . . . . . . 24

- Tractor and trailer compatibility at any time . . 24

- Complete fault-diagnosis structures . . . . . . . . 24

Print 603.93.321 Base - May 2004

2 AIR SYSTEM - BRAKES EBS 2/ESP/EBL STRALIS AT/AD/AS

- EBS 2 working diagram for 6x2 vehicles (trucks)

BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 - EBS 2 working diagram for 6x2 vehicles (trucks)

- ABS-EBL working diagram for 6x2 vehicles

SPECIFICATIONS AND DATA - BRAKES . . . . . . 82

Base - May 2004 Print 603.93.321

STRALIS AT/AD/AS AIR SYSTEM - BRAKES EBS 2/ESP/EBL 3

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 - Speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . 107

- Duplex control valve (vehicles without EBS) . 92 - Phonic wheels . . . . . . . . . . . . . . . . . . . . . . . . . 107

- Fault Diagnosis (vehicles without EBS) . . . . . . 92 - Electronic control unit . . . . . . . . . . . . . . . . . . 107

- CBU (Central Brake Unit) - Pressure sensor . . . . . . . . . . . . . . . . . . . . . . . . 107

- Fault Diagnosis (vehicles without EBS) . . . . . . 95 - Combined brake cylinder

- Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 - Replacing brake linings . . . . . . . . . . . . . . . . . . 114

- Parking brake hand control valve - Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

- Controlled pressure valve . . . . . . . . . . . . . . . . 106 - Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . 120

- Fault Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 106 - Component part cleaning and check . . . . . . . 121

- Check valve (vehicles suited to towing) . . . . . 106 - Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

- Low-pressure switch . . . . . . . . . . . . . . . . . . . . 106 OVERHAULING REAR DISC BRAKES . . . . . . . . . 123

- Electro-pneumatic valve for ASR . . . . . . . . . . 107 - Replacing brake linings . . . . . . . . . . . . . . . . . . 123

Print 603.93.321 Base - May 2004

4 AIR SYSTEM - BRAKES EBS 2/ESP/EBL STRALIS AT/AD/AS

TURNING AND GRINDING BRAKE DISCS . . . . . 126

Base - May 2004 Print 603.93.321

STRALIS AT/AD/AS AIR SYSTEM - BRAKES EBS 2/ESP/EBL 5

SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS

CROSSOVER OF CONNECTED LINES

PRESSURE TEST POINT

HYDRAULIC HAND PUMP

Print 603.93.321 Base - May 2004

6 AIR SYSTEM - BRAKES EBS 2/ESP/EBL STRALIS AT/AD/AS

SYMBOLS FOR AIR/HYDRAULIC SYSTEM CIRCUIT DIAGRAMS (VALVES)

DEHUMIDIFIER WITH BUILT-IN 21 1