EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 1

SECTION 14
79 Air system
52 Brakes

Page

GRAPHIC SYMBOLS FOR AIR-HYDRAULIC

SYSTEM DIAGRAMS (MISCELLANEOUS AND
GENERATORS) . . . . . . . . . . . . . . . . . . . . . . . 5

GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM

DIAGRAMS (VALVES) . . . . . . . . . . . . . . . . . . 6
GRAPHIC SYMBOLS FOR AIR-HYDRAULIC
SYSTEM DIAGRAMS (TANKS AND
ACCUMULATORS) . . . . . . . . . . . . . . . . . . . . 12
GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM
DIAGRAMS (CONVERTERS, CYLINDERS AND
CALLIPERS) . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM
DIAGRAMS (CALLIPERS AND CYLINDERS) 14

GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM

DIAGRAMS (HALF-COUPLINGS AND
COUPLING HEADS) . . . . . . . . . . . . . . . . . . . 15

GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM

DIAGRAMS (HALF-COUPLINGS AND
COUPLING HEADS) . . . . . . . . . . . . . . . . . . . 16

GRAPHIC SYMBOLS FOR AIR-HYDRAULIC

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

GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM

DIAGRAMS (BRAKES) . . . . . . . . . . . . . . . . . . 18
PIPES AND FITTINGS . . . . . . . . . . . . . . . . . . . . . 19

- General information . . . . . . . . . . . . . . . . . . . . . 19

- Flaring rigid pipes . . . . . . . . . . . . . . . . . . . . . . . 19

- Bending rigid pipes . . . . . . . . . . . . . . . . . . . . . . 20

- Cutting rigid pipes . . . . . . . . . . . . . . . . . . . . . . 20

- Replacing the flexible hoses with conventional

fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
- Replacing flexible hoses with quick-
coupling fittings . . . . . . . . . . . . . . . . . . . . . . . . 22

BRAKING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 24
- Working diagram for 4x2 - 4x4 vehicles designed
for towing with ABS-ASR device . . . . . . . . . . . 24
- Working diagram for isolated 6x4 vehicles with
ABS-ASR device . . . . . . . . . . . . . . . . . . . . . . . 25
- Working diagram for 6x4 - 6x6 vehicles designed
for towing with ABS-ASR device . . . . . . . . . . . 26
2 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

Page Page

- Working diagram for isolated 8x4x4 - 8x8x4 SPECIFICATIONS AND DATA - BRAKES . . . . . . . 59
vehicles with ABS-ASR device . . . . . . . . . . . . . 27
CHECKS ON MAIN COMPONENTS OF
- Working diagram for 8x4x4 - 8x8x4 vehicles THE BRAKING SYSTEM . . . . . . . . . . . . . . . . . 62
designed for towing with ABS-ASR device . . . 28
CHECKS ON MAIN COMPONENTS OF THE
BRAKING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 28/1 BRAKING SYSTEM . . . . . . . . . . . . . . . . . . . . . 63
- Working diagram for 4x2 - 4x4 vehicles designed - Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . 65
for towing with ABS-ASR device . . . . . . . . . . . 28/1
- Head locking screw tightness . . . . . . . . . . . . . . 65
- Concept diagram for 6x4 vehicles isolated with
EBL devices . . . . . . . . . . . . . . . . . . . . . . . . . . . 28/2 - Electronic control unit . . . . . . . . . . . . . . . . . . . 66
- Working diagram for 6x4 - 6x6 vehicles designed - A.P.U. (Air Processing Unit) . . . . . . . . . . . . . . 66
for towing with EBL device . . . . . . . . . . . . . . . 28/3
- Triple servo control valve . . . . . . . . . . . . . . . . 67
- Concept diagram for 8x4x4 - 8x8x4 vehicles
isolated with EBL devices . . . . . . . . . . . . . . . . 28/4 - Predominance control . . . . . . . . . . . . . . . . . . . 67
- Working diagram for 8x4x4 - 8x8x4 vehicles - Knorr Bremse AC 597B . . . . . . . . . . . . . . . . . 67
designed for towing with EBL device . . . . . . . . 28/5

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- Wabco 973 009 013 . . . . . . . . . . . . . . . . . . . . 67
- Layout on vehicle of main components of
braking system . . . . . . . . . . . . . . . . . . . . . . . . . 29 - Duplex control valve . . . . . . . . . . . . . . . . . . . . 68
- Layout on vehicle of main components of - Coupling heads . . . . . . . . . . . . . . . . . . . . . . . . 69
ABS-ASR system . . . . . . . . . . . . . . . . . . . . . . . 30
- Check valve
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 (vehicles suited to towing) . . . . . . . . . . . . . . . 69
- Service braking . . . . . . . . . . . . . . . . . . . . . . . . 31 - Parking brake hand control valve
(vehicles suited to towing) . . . . . . . . . . . . . . . 69
- Emergency braking . . . . . . . . . . . . . . . . . . . . . 31
- Safety valve (”for Sweden”) . . . . . . . . . . . . . . . 70
- Retarding braking . . . . . . . . . . . . . . . . . . . . . . 31
- Parking brake hand control valve
- Parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . 31 (isolated vehicles) . . . . . . . . . . . . . . . . . . . . . . 70
- ABS (Anti-Lock Brake System) . . . . . . . . . . . . 31 - Diaphragm brake cylinder . . . . . . . . . . . . . . . . 71
- ASR (Anti-Slip Regulator) system . . . . . . . . . . 32 - Combined brake cylinder . . . . . . . . . . . . . . . . 71
- EBL (Electronic Brakes Limiter) . . . . . . . . . . . . 32 - Combined cylinder emergency braking device 71
BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 - Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
- Front disc brakes type KNORR: SB7; SN7 - Relay valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
(for vehicles with partial traction) . . . . . . . . . . 32
- Pressure reduction unit . . . . . . . . . . . . . . . . . . 72
- Front brakes (for four-wheel drive vehicles)
and rear brakes type MERITOR Duo - duplex - Engine brake switch . . . . . . . . . . . . . . . . . . . . . 73
Ø 410x180 and 410x200 . . . . . . . . . . . . . . . . 32
- Dual servo control valve . . . . . . . . . . . . . . . . . 73
FAULT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . 32/1
- Brake anti-lock control valve . . . . . . . . . . . . . . 74
- Diagnosis Instruments . . . . . . . . . . . . . . . . . . . 32/1
- ASR electropneumatic valve . . . . . . . . . . . . . . 74
- ABS Troubleshooting . . . . . . . . . . . . . . . . . . . 32/3
- Speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . 74
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . 45
- Phonic wheels . . . . . . . . . . . . . . . . . . . . . . . . . 74
TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
BRAKE REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
SPECIFICATIONS AND DATA -
PNEUMATIC SYSTEM . . . . . . . . . . . . . . . . . . 54
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 3

Page

FRONT DISC BRAKES SB7 TYPE

(VEHICLES WITH PARTIAL TRACTION) . . . 75

TYPE SN7 DISK BRAKES . . . . . . . . . . . . . . . . . . . . 75/1

- SB7 type brake operation . . . . . . . . . . . . . . . . 76

CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
- Efficiency of automatic clearance recovery . . . 76

- Brake lining thickness . . . . . . . . . . . . . . . . . . . . 77

- Replacing brake linings . . . . . . . . . . . . . . . . . . . 78
- Removing and refitting brake callipers SB7 . . . 80

- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
- Removing and refitting wheel hubs . . . . . . . . . 81

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- Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

- Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

OVERHAULING BRAKE CALLIPERS SB7 . . . . . . . 82

- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

- Cleaning and checking component parts . . . . . 83

- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

OVERHAULING BRAKE DISCS . . . . . . . . . . . . . . . 84

TURNING AND GRINDING BRAKE DISCS ON

THE BENCH . . . . . . . . . . . . . . . . . . . . . . . . . . 85

TURNING AND GRINDING BRAKE DISCS ON

THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . 85

DRUM BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
FRONT BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

- Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
- Turning drums . . . . . . . . . . . . . . . . . . . . . . . . . 89
- Replacing brake linings . . . . . . . . . . . . . . . . . . . 89

- Turning brake linings . . . . . . . . . . . . . . . . . . . . 90

- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

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EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 5

GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS

(MISCELLANEOUS AND GENERATORS)
DESCRIPTION SYMBOL

HYDRAULIC FLOW

PNEUMATIC FLOW

ELECTRIC DUCT

POSSIBLE ROTATION

CONNECTED PIPES CROSSING

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PRESSURE TEST POINT

QUICK COUPLING

COCK

1 2
COCK WITH DISCHARGE

SILENCER

COMPRESSOR 0 2

0 2
ENERGY SAVING COMPRESSOR
4

VACUUM PUMP 3 2

HYDRAULIC PUMP 0 2

MANUAL HYDRAULIC PUMP

32780
6 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS

(VALVES)
DESCRIPTION SYMBOL

CONDENSATE SEPARATOR

FILTER 1 2

DRIER 1 2

4
DRIER 21 1
22

DRIER WITH INTEGRATED 21 1

REGULATOR 22
23

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AUTOMATIC CONDENSATE
BLEED VALVE

CONTROLLED CONDENSATE
BLEED VALVE

MANUAL CONDENSATE
BLEED VALVE

7
CONTROLLED ANTI-FREEZE 1 2

AUTOMATIC ANTI-FREEZE
1 2

21 23
PRESSURE REGULATOR WITH 1
INDEPENDENT CIRCUIT
22 24

PRESSURE REGULATOR 1 21

PRESSURE REGULATOR 1 21
23

PRESSURE REGULATOR
(GOVERNOR) 1 2

PRESSURE RELIEF VALVE 1 2

32782 32783
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 7

GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS

(VALVES)
DESCRIPTION SYMBOL

PROPORTIONAL REDUCTION
VALVE 1 2

ADAPTING VALVE 1 2

21 23
4-CIRCUIT SAFETY VALVE 1
22 24
21
3-CIRCUIT SAFETY VALVE 1 23
22
21
2-CIRCUIT SAFETY VALVE 1
22

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AIR INTAKE VALVE WITH NO
RETURN 1 2

AIR INTAKE VALVE WITH LIMITED

RETURN 1 2

SAFETY VALVE

CHECK VALVE 1 2

2
CHECK VALVE 2

1
2
TWIN STOP VALVE
11 12

U
DIFFERENTIAL TWIN STOP VALVE
M S

CHOKE VALVE WITH QUICK

RETURN 1 2

CHOKE VALVE

32783 32784 32785

8 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS

(VALVES)
DESCRIPTION SYMBOL

QUICK DISCHARGE VALVE 1 2

BRAKE CONTROL VALVE

11 A 21

12 P 22

BRAKE CONTROL VALVE

11 21

BRAKE CONTROL VALVE 11 21

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4
12 22

PARKING BRAKE CONTROL VALVE 21

11 22

PARKING BRAKE CONTROL VALVE

1 2

BRAKE CONTROL 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
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 9

GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS

(VALVES)
DESCRIPTION SYMBOL

41 42
SERVO CONTROL VALVE
1 2

SERVO CONTROL VALVE FOR

SINGLE LINE
1 2

41 42 43
TRIPLE VALVE CONTROLLING
TRAILER BRAKE
1 2

42
41 43
TRIPLE VALVE CONTROLLING

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TRAILER BRAKE WITH
INCORPORATED SERVO SWITCH 11 22
12

BRAKING LOAD APPORTIONING 1 2

VALVE

11 21
TWIN BRAKING LOAD
12 22
APPORTIONING VALVE

12
BRAKING LOAD APPORTIONING 21
11
VALVE WITH BY-PASS

BRAKING LOAD APPORTIONING 1 2

VALVE WITH INTEGRATED RELAY

4
4

BRAKING LOAD APPORTIONING

VALVE WITH INTEGRATED RELAY 1 2
WITH PNEUMATIC CONTROL

41 42

32786 32787
10 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS

(VALVES)
DESCRIPTION SYMBOL

BRAKING LOAD APPORTIONING

1 2
VALVE WITH PNEUMATIC
CONTROL
41 42

BRAKING LOAD APPORTIONING 1 2

VALVE WITH PNEUMATIC
CONTROL
4

PROPORTIONAL REDUCTION
1 2
VALVE

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INTERLOCKED PROPORTIONAL
REDUCTION VALVE
1 2

2
TRAVEL LIMITING VALVE 1

LEVELLING VALVE

21 22

1 2
LEVELLING VALVE

12 23
LEVELLING VALVE WITH
INTEGRATED TRAVEL LIMITER 11 21

SUSPENSION LIFTING MANUAL 23 24

CONTROL VALVE
21 22

32787 32788
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 11

GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS

(VALVES)
DESCRIPTION SYMBOL
2
42
GRADUAL CONTROL VALVE
41
1

13

ELECTRIC CONTROL SUSPENSION 11 21

MANUAL CONTROL VALVE
12 22
1 3

ELECTRO-PNEUMATIC VALVE
1 2

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ELECTRO-PNEUMATIC VALVE 1 2

ELECTRO-PNEUMATIC VALVE 21
1 22

VR ABS HZ2
HYDRAULIC MODULATOR FOR ABS VL HZ1

HL HR
4

BOOSTER VALVE
1 2

32788
12 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS

(TANKS AND ACCUMULATORS)
DESCRIPTION SYMBOL

COMPRESSED AIR TANK

BRAKE FLUID TANK

AIR SPRING

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32789
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 13

GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS

(CONVERTERS, CYLINDERS AND CALLIPERS)
DESCRIPTION SYMBOL

VACUUM SERVO BRAKE

VACUUM SERVO BRAKE

TWIN CIRCUIT MASTER CYLINDER

SINGLE CIRCUIT MASTER CYLINDER

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AIR-HYDRAULIC CONVERTER

AIR-HYDRAULIC CONVERTER

HYDRAULIC BRAKE CYLINDER

OPERATING CYLINDER

BRAKE CYLINDER

SPRING CYLINDER

COMBINED BRAKE CYLINDER

FIXED DISC BRAKE CALLIPER

32790 32791
14 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS

(CALLIPERS AND CYLINDERS)
DESCRIPTION SYMBOL

FLOATING DISC BRAKE CALLIPER

FLOATING DISC BRAKE CALLIPER

WITH PARKING

MECHANICAL FLOATING DISC

BRAKE CALLIPER

SERVO CLUTCH

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SERVO CLUTCH

32791
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 15

GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS

(HALF-COUPLINGS AND COUPLING HEADS)
DESCRIPTION SYMBOL

A
”ISO” HALF-COUPLING

M
ISO VERSION

A
”ISO” HALF-COUPLING

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VERSION WITH ISO COUPLINGS

A
”CUNA” HALF-COUPLING
B

ITALIAN VERSION

M
”CUNA” HALF-COUPLING
A

A
”NATO” HALF-COUPLING

M
NATO VERSION

32792 32793
16 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS

(HALF-COUPLINGS AND COUPLING HEADS)
DESCRIPTION SYMBOL

4
1 5
2 3

V
Z
A

VERSION WITH SINGLE LINE

A
M
HALF-COUPLING
V
Z
A

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VERSION WITH SINGLE LINE

12

22

HALF-COUPLING 4

VERSION WITH SINGLE LINE

12
A
22
M
HALF-COUPLING 4

1 2

VERSION WITH SINGLE LINE

32793
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 17

GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS

(INDICATORS AND SWITCHES)
DESCRIPTION SYMBOL

PRESSURE GAUGE

PRESSURE GAUGE

PRESSURE TRANSMITTER

LIGHT BULB

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MECHANICAL CONTROL SWITCH

PRESSURE SWITCH

LOW PRESSURE SWITCH

AUDIBLE WARNING

SENSOR

32794
18 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

GRAPHIC SYMBOLS FOR AIR-HYDRAULIC SYSTEM DIAGRAMS

(BRAKES)
DESCRIPTION SYMBOL

SINGLE HYDRAULIC BRAKE

TWIN HYDRAULIC BRAKE

DUAL-SERVO HYDRAULIC BRAKE

DUAL-SERVO HYDRAULIC BRAKE

WITH PARKING

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SINGLE CAM-OPERATED BRAKE

TWIN DUAL CAM OPERATED BRAKE

32795
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 19

799512 PIPES AND FITTINGS

General information Figure 3

There are currently two kinds of pipes for the braking system
of industrial vehicles:
- Flexible hoses of polyamide with a single or twin layered
structure with the following diameters (Ø 6 - 8 - 10 - 12
- 16 mm) supplied as spares in metres.
- Rigid metal pipes of the following diameters (Ø 4.75 -
6.35 - 8-10 - 12 mm). The pipes from Ø 4.75 to Ø 10 mm
are supplied as spares in straight lengths of 4 - 5 - 6 m,
whereas ones over 10 mm are supplied as spares already
cut, bent and flared.

31973
Flaring rigid pipes
Deburr the pipe (1), fit the coupling (2) on it and place it
Figure 1 between the blocks (3) in contact with the pin (5). Lock the
pipe (1) with the screw (4).

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Figure 4

C 31971

DEPICTION OF FLANGING RIGID PIPES 31974

Flaring type A Put the pin (4) back in its neutral position. Screw down the
screw (1) until the matrix (2) comes into contact with the
Figure 2 blocks (3) thereby shaping the end of the pipe (5).

Flaring type B

Figure 5

31972

On the press 99386523 (3) set the blocks (1) so that the
punched numbers, showing the diameter of the pipe to
process, are facing the matrix (2). The choice of the matrix (2)
depends on the diameter of the pipe to flange. Furthermore, 31975

each matrix (2) has punched on it the diameter of the pipe for Mount on the press 99386523 (1) the matrix (2).
which it can be used. For flaring, keep to the above instructions for A-type flaring.
20 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

Flaring type C

Figure 6 Figure 9

31976 31979

Key onto the pipe (1) the nut (2) and ring (3). Position the pipe (1) in the tool (3) and, using the lever (2), bend
the pipe.

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Figure 7 Figure 10

31980

31977
To free the pipe (2) from the tool (3), use the lever (1).
Mount the fitting (2) and tighten so that the ring (3, Fig. 6) locks
on the pipe (1).

Bending rigid pipes Cutting rigid pipes

Figure 8 Figure 11

31978 31981

Position the pipe (2) in the tool (3) 99386523 and close the
Mount the tool (1) 99386523 choosing parts (2) and (3) screw (1). Holding the pipe (2) still, turn the tool (3) until the
according to the diameter of the pipes to bend. pipe is cut completely.
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 21

After cutting the pipe, deburr and shape the end as described - Flare the supporting ring on mounting on the vehicle or at
above. the work bench on a fitting.
- The pressure applied and the final distance of the front
Turning the tool (3) around the pipe (2), the screw (1) edge of the pressure ring from that of the strengthening
! loosens. To cut the pipe completely, it is then bushing must be as listed in the chart as given in the table.
necessary to tighten the screw (1) gradually as it
loosens.

Replacing the flexible hoses with conventional In the event of bad assembly, never reuse the pipe
! after extracting the bushing and the supporting ring.
fittings
Keep meticulously to the following instructions:
Pipe Distance between Assembly
Figure 12 bushing edge and pressure
mm ring N/mm2
mm (*)
6x1 from 1 to 1.5 0.040
Twin layer
8x1 from 2 to 2.5 0.050

10 x 1.5 from 2 to 2.5 0.050

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Single layer 12 x 1.6 from 2 to 2.5 0.060

16 x 2.34 from 3 to 3.5 0.060

10397

- Use only type approved pipes;

- Check the state of the spare pipe, which must show no sign (*) See reference h, Figure 14.
of cracking or cuts;
- Cut the pipe to 90º to the axis with the specific pipe-cutting
clamp 99387050 to the necessary length;
Insert the following on the pipe, in sequence: Figure 14
- nut (3), pressure ring (2) (its greater thickness must face the
nut (3)) and the strengthening bushing (1);
- the bushing must be in perfect condition (showing no sign
of buckling or hammering).

Figure 13

10399

10398
1. Strengthening bushing - 2. Pressure ring - 3. Nut -
FITTING THE STRENGTHENING BUSHING 4. Fitting - 5. Pipe - h. Distance between bushing edge
A = CORRECT FITTING and ring edge (see table).
B = WRONG FITTING Insert the end of the pipe, thus prepared, into the body of the
fitting so that the flange of the strengthening bushing rests in
the specific seat:
- Key the strengthening bushing with the tool 99372219
ensuring contact between its flange and the end of the pipe; - To close the nut on the fitting, screw it initially by hand and
then complete tightening with the right box wrench
- Make sure that the end of the pipe goes into the rake race inserted in the torque wrench, to be set according to the
obtained in the flange;
required tightening torque.
22 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

The pipe is fitted on the vehicle by taking some important Replacing flexible hoses with quick-coupling
procedures into account: fittings
- The bends must observe minimum radii so as to avoid
choking;
Rotary fittings:
Diameter of pipes Minimum radius of curvature
mm mm Figure 16

6x1 ≈ 40

8x1 ≈ 50

10 x 1.5 ≈ 60

12 x 1.6 ≈ 75

16 x 2.34 ≈ 100

Make sure that the pipes are not in contact with sharp
! edges or metal parts or with sources of heat, but are at 39306
a safe distance of at least 15 mm from them.

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Screw the fitting into the threaded seat on the pneumatic valve
and lock it to the tightening torque given in the table.
- In addition, when crossing the chassis side members, or
metal parts, check that the holes they pass through are
lined with rubber grommets that are in a good state of Adjustable fittings:
repair.
- Never slide the pipe over sharp edges that would risk Figure 17
cutting it.
- Having to secure the pipe onto existing conduits, take into
account the additional heat it may be subjected to (power
steering duct); in this case the pipe needs to be protected
with shields.
- After making the connection, check that the pipe, between
fixings, is not taut, but slightly slackened to recover the
greater changes in temperature, especially for short
sections.
- Before mounting, carefully clean the pipes by blowing
compressed air to ensure system operation.

Figure 15 39307

- Check that the seal (1) is in the right seat.

- Screw down the fitting till you feel the gasket is resting on
the valve.
- Adjust the fitting appropriately and, holding the adjustable
part still, lock the hex nut to the tightening torque given
in the table.

13132
Rotary and adjustable fittings:
- Protect the pipes in the event of grinding or welding on the THREAD TIGHTENING TORQUE (Nm ± 10%)
vehicle; for this purpose, in the cab there is a sticker giving
the precautions to observe with the utmost attention to
avoid damage. M 10 x 1.0 mm 22

M 12 x 1.5 mm 24
For greater safety and working convenience it is
! recommended to disconnect the pipes during these M 14 x 1.5 mm 28
operations.
M 16 x 1.5 mm 35
On completing assembly, check the seal of all the gaskets
(unions, fittings etc.). M 22 x 1.5 mm 40
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 23

Figure 18 Figure 20

39308

- Insert the pipe (2) by hand into the fitting (1), with a
variable force from 30 to 120 Nm according to the
diameter of the pipe so that the reference mark L1 is
positioned inside the fitting while the reference mark L2
33977
is visible.
- Use only type-approved pipes;
Figure 21
- Check the state of the spare pipe, on which there must
be no cracking or cuts;

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- Cut the pipe to 90º, with a max error of 15º to the axis,
using the specific pipe-cutting clamp 99387050 to the
necessary length;
Figure 19

33978

When removing the fittings (1) from the pneumatic

components, check the state of the seal (2), replace it if
necessary.

A
FITTING DIMENSIONS
33976
THREADING OF SEALS

A = Marking to identify pipe limit M 10 x 1.0 10.1 x 1.6

- Mark the pipe clearly and indelibly (in ink), with two M 12 x 1.5 11.0 x 2.0
reference marks on both diametrically opposite faces of
M 14 x 1.5 -
the pipe for an angle ² 75º, positioned at lengths L1 and
L2 to ensure correct assembly. M 16 x 1.5 15.0 x 2.0

M 22 x 1.5 -
The lengths L1 and L2 vary depending on the diameter
! of the pipe and should be measured from the longest
portion of the pipe (see Figure 18).

0 -0,5 -0,5 Every time a pipe is detached from the quick coupling,
D L L1 L2 it is necessary to replace this fitting or coupling. Quick
+0,5 +1 +1 !
(mm) (mm) (mm) (mm) couplings are supplied complete as spares.

6 19.8 17 22

8 20.5 18 23 Quick couplings and conventional fittings, like the

flexible hoses used with the quick couplings and the
12 25 22 28 ! flexible hoses used with the threaded fittings, are not
interchangeable.
16 27.1 24 30
24 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

BRAKING SYSTEM
Working diagram for 4x2 - 4x4 vehicles designed for towing with ABS-ASR device
Figure 22

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71273

1. E.S. Compressor - 2. A.P.U. - 3. Manual condensate discharge valve - 4. Trailer air tank 20 l - 5. Rear axle air tank 20 l -
6. Front axle air tank 20 l - 7. Pressure test point - 8. Dual control relay valve - 9. Parking brake hand control valve - 10. Switch
for parking brake on indicator - 11. Trailer slowing hand control valve (optional) - 12. Triple servo control valve for trailer
braking - 13. Low pressure switch - 14. ”ISO” half-coupling for truck - 15. ”ISO” half-coupling for tractor - 16. Dual control
valve - 17. Brake light switch - 18. Engine brake control switch - 19. Diaphragm brake cylinder - 20. Phonic wheel - 21. Wheel
speed sensor - 22. Double drum brake assembly - 23. Combined brake cylinder - 24. ABS solenoid valve -
25. Pressure sensor - 26. Twin stop valve - 27. Single-control relay valve - 28. Electronic control unit - 29. Controlled pressure
check valve - 30. A.S.R. solenoid valve - 31. Disk brake assembly (*) - 32. Membrane brake cylinder (•) (optional for 4x2
vehicles) - 33. Drum brake assembly (•) (optional for 4x2 vehicles) - 34. Low pressure switch - 35. Pressure gauge - A.
Services
(*) vehicles 4x2
(•) vehicles 4x4
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 25

Working diagram for isolated 6x4 vehicles with ABS-ASR device

Figure 23

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71845
1. E.S. Compressor - 2. A.P.U. - 3. Manual condensate discharge valve - 4. Trailer air tank 20 l - 5. Rear axle air tank 20 l -
6. Front axle air tank 20 l - 7. Dual control relay valve - 8. Parking brake hand control valve - 9. Switch for parking brake on
indicator - 10. Dual control valve - 11. Brake light switch - 12. Engine brake control switch - 13. Diaphragm brake cylinder -
14. Phonic wheel - 15. Wheel speed sensor - 16. Double drum brake assembly - 17. Combined brake cylinder - 18. ABS
solenoid valve - 19. Pressure sensor - 20. Twin stop valve - 21. Single-control relay valve - 22. Electronic control unit -
23. Controlled pressure check valve - 24. A.S.R. solenoid valve - 25. Disk brake assembly - 26. Membrane brake cylinder
(optional) - 27. Drum brake assembly (optional) - 28. Low pressure switch - 29. Pressure gauge - A. Services
26 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

Working diagram for 6x4 - 6x6 vehicles designed for towing with ABS-ASR device

Figure 24

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71274

1. E.S. Compressor - 2. A.P.U. - 3. Manual condensate discharge valve - 4. Trailer air tank 20 l - 5. Rear axle air tank 20 l -
6. Front axle air tank 20 l - 7. Pressure test point - 8. Dual control relay valve - 9. Parking brake hand control valve - 10.
Switch for parking brake on indicator 11. Trailer slowing hand control valve (optional) - 12. Triple servo control valve for
trailer braking - 13. Low pressure switch - 14. ”ISO” half-coupling for truck - 15. ”ISO” half-coupling for tractor - 16. Dual
control valve - 17. Brake light switch - 18. Engine brake control switch - 19. Diaphragm brake cylinder - 20. Phonic wheel -
21. Wheel speed sensor - 22. Double drum brake assembly - 23. Combined brake cylinder - 24. ABS solenoid valve -
25. Pressure sensor - 26. Twin stop valve - 27. Single-control relay valve - 28. Electronic control unit - 29. Controlled
pressure check valve - 30. A.S.R. solenoid valve - 31. Disk brake assembly (*) - 32. Membrane brake cylinder (•) (optional for
6x4 vehicles) - 33. Drum brake assembly (•) (optional for 6x4 vehicles) - 34. Low pressure switch - 35. Pressure gauge - 36.
Adapter valve - A. Services
(*) vehicles 6x4
(•) vehicles 6x6
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 27

Working diagram for isolated 8x4x4 - 8x8x4 vehicles with ABS-ASR device

Figure 25

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71846

1. E.S. Compressor - 2. A.P.U. - 3. Manual condensate discharge valve - 4. Trailer air tank 20 l - 5. Rear axle air tank 20 l -
6. Front axle air tank 20 l - 7. Dual control relay valve - 8. Parking brake hand control valve - 9. Switch for parking brake on
indicator - 10. Dual control valve - 11. Brake light switch - 12. Engine brake control switch - 13. Diaphragm brake cylinder -
14. Phonic wheel - 15. Wheel speed sensor - 16. Double drum brake assembly - 17. Combined brake cylinder - 18. ABS
solenoid valve - 19. Pressure sensor - 20. Twin stop valve - 21. Single-control relay valve - 22. Electronic control unit -
23. Controlled pressure check valve - 24. A.S.R. solenoid valve - 25. Disc brake assembly - 26. Adapter valve - 27. Diaphragm
brake cylinder (optional) - 28. Double drum brake assembly - 29. Low pressure switch - 30. Pressure gauge - A. Services
28 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

Working diagram for 8x4x4 - 8x8x4 vehicles designed for towing with ABS-ASR device

Figure 26

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71275

1. E.S. Compressor - 2. A.P.U. - 3. Manual condensate discharge valve - 4. Trailer air tank 20 l - 5. Rear axle air tank 20 l -
6. Front axle air tank 20 l - 7. Pressure test point - 8. Dual control relay valve - 9. Parking brake hand control valve -
10. Switch for parking brake on indicator 11. Trailer slowing hand control valve (optional) - 12. Triple servo control valve for
trailer braking - 13. Low pressure switch - 14. ”ISO” half-coupling for truck - 15. ”ISO” half-coupling for tractor - 16. Dual
control valve - 17. Brake light switch - 18. Engine brake control switch - 19. Diaphragm brake cylinder - 20. Phonic wheel -
21. Wheel speed sensor - 22. Double drum brake assembly - 23. Combined brake cylinder - 24. ABS solenoid valve -
25. Pressure sensor - 26. Twin stop valve - 27. Single-control relay valve - 28. Electronic control unit - 29. Controlled
pressure check valve - 30. A.S.R. solenoid valve - 31. Disc brake assembly - 32. Adapter valve - 33. Diaphragm brake cylinder
(optional) - 34. Double drum brake assembly (optional) - 35. Low pressure switch - 36. Pressure gauge - A. Services
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 28/1

BRAKING SYSTEM
Working diagram for 4x2 - 4x4 vehicles designed for towing with ABS-ASR device
Figure 26/1

cardiagn.com
78270

1. E.S. Compressor - 2. A.P.U. - 3. Manual condensate discharge valve - 4. Trailer air tank 20 l - 5. Rear axle air tank 20 l -
6. Front axle air tank 20 l - 7. Pressure test point - 8. Dual control relay valve - 9. Parking brake hand control valve - 10.
Switch for parking brake on indicator - 11. Trailer slowing hand control valve (optional) - 12. Triple servo control valve for
trailer braking - 13. Low pressure switch - 14. ”ISO” half-coupling for truck - 15. ”ISO” half-coupling for tractor - 16. Dual
control valve - 17. Brake light switch - 18. Engine brake control switch - 19. Diaphragm brake cylinder (*) - 20. Phonic wheel
- 21. Wheel speed sensor - 22. Double drum brake assembly - 23. Combined brake cylinder - 24. ABS solenoid valve -
25. Pressure sensor - 26. Twin stop valve - 27. Single-control relay valve - 28. Electronic control unit - 29. Controlled
pressure check valve (*) - 30. Membrane brake cylinder (•) (optional for 4x2 vehicles) - 31. Drum brake assembly (•)
(optional for 4x2 vehicles) - 32. Low pressure switch - 33. Pressure gauge - A. Services - B. Services
(*) vehicles 4x2
(•) vehicles 4x4
28/2 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

Concept diagram for 6x4 vehicles isolated with EBL devices

Figure 26/2

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78271

1. E.S. Compressor - 2. A.P.U. - 3. Manual condensate discharge valve - 4. Trailer air tank 20 l - 5. Rear axle air tank 20 l -
6. Front axle air tank 20 l - 7. Pressure test point - 8. Dual control relay valve - 9. Parking brake hand control valve - 10.
Switch for parking brake on indicator - 11. Duplex distributor - 12. Stop lights switch - 13. Engine brake control switch - 14.
Membrane brake cylinder - 15. Phonic wheel - 16. Wheel r.p.m. sensor - 17. Duo-Duplex drum brake assembly - 18.
Combined brake cylinder - 19. A.B.S. solenoid valve - 20. Pressure sensor - 21. Single-control relay valve - 22. Electronic
central unit - 23. Disk brake assembly - 24. Membrane brake cylinder (optional) - 25. Drum brake assembly - 26. Low
pressure switch - 27. Pressure gauge - A. Services - B. Services
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 28/3

Working diagram for 6x4 - 6x6 vehicles designed for towing with EBL device

Figure 26/3

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78272

1. E.S. Compressor - 2. A.P.U. - 3. Manual condensate discharge valve - 4. Trailer air tank 20 l - 5. Rear axle air tank 20 l -
6. Front axle air tank 20 l - 7. Pressure test point - 8. Dual control relay valve - 9. Parking brake hand control valve - 10.
Switch for parking brake on indicator 11. Trailer slowing hand control valve (optional) - 12. Triple servo control valve for
trailer braking - 13. Low pressure switch - 14. ”ISO” half-coupling for truck - 15. ”ISO” half-coupling for tractor - 16. Dual
control valve - 17. Brake light switch - 18. Engine brake control switch - 19. Diaphragm brake cylinder - 20. Phonic wheel -
21. Wheel speed sensor - 22. Double drum brake assembly - 23. Combined brake cylinder - 24. ABS solenoid valve -
25. Pressure sensor - 26. Single-control relay valve - 27. Electronic central unit - 28. Disk brake assembly (*) - 29. Membrane
brake cylinder (•) (optional for 6x4 vehicles) - 30. Drum brake assembly (•) (optional for 6x4 vehicles) - 31. Low pressure
switch - 32. Pressure gauge - A. Services - B. Services
(*) vehicles 6x4
(•) vehicles 6x6
28/4 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

Concept diagram for 8x4x4 - 8x8x4 vehicles isolated with EBL devices

Figure 26/4

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78273

1. E.S. Compressor - 2. A.P.U. - 3. Manual condensate discharge valve - 4. 20 litre trailer air tank (in alternative to two 30
litre air tanks) - 5. Rear axle air tank 20 l - 6. Front axle air tank 20 l - 7. Dual control relay valve - 8. Parking brake hand
control valve - 9. Switch for parking brake on indicator - 10. Dual control valve - 11. Duplex distributor - 12. Stop lights
switch - 13. Engine brake control switch - 14. Membrane brake cylinder - 15. Phonic wheel - 16. Wheel r.p.m. sensor - 17.
Duo-Duplex drum brake assembly - 18. Combined brake cylinder - 19. A.B.S. solenoid valve - 20. Pressure sensor - 21.
Single-control relay valve - 22. Electronic central unit - 23. Disk brake assembly (*) - 24. Adapter valve - 25. Membrane
brake cylinder (•) (optional for 8x4x4 vehicles) - 26. Duo-Duplex drum brake assembly (•) (optional for 8x4x4 vehicles) -
27. Low pressure switch - 28. Membrane - A. Services - B. Services
(*) vehicles 8x4x4
(•) vehicles 8x8x4
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 28/5

Working diagram for 8x4x4 - 8x8x4 vehicles designed for towing with EBL device

Figure 26/5

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78274

1. E.S. Compressor - 2. A.P.U. - 3. Manual condensate discharge valve - 4. Trailer air tank 20 l - 5. Rear axle air tank 20 l -
6. Front axle air tank 20 l - 7. Pressure test point - 8. Dual control relay valve - 9. Parking brake hand control valve -
10. Switch for parking brake on indicator 11. Trailer slowing hand control valve (optional) - 12. Triple servo control valve for
trailer braking - 13. Low pressure switch - 14. ”ISO” half-coupling for truck - 15. ”ISO” half-coupling for tractor - 16. Dual
control valve - 17. Brake light switch - 18. Engine brake control switch - 19. Diaphragm brake cylinder - 20. Phonic wheel -
21. Wheel speed sensor - 22. Double drum brake assembly - 23. Combined brake cylinder - 24. ABS solenoid valve -
25. Pressure sensor - 26. Single-control relay valve - 27. Electronic control unit - 28. Disk brake assembly (*) - 29. Adapter
valve - 30. Membrane brake cylinder (•) (optional for 8x4x4 vehicles) - 31. Duo-Duplex drum brake assembly (•) (optional
for 8x4x4 vehicles) - 32. Low pressure switch - 33. Pressure gauge - A. Services - B. Services
(*) vehicles 8x4x4
(•) vehicles 8x8x4
28/6 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

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EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 29

Layout on vehicle of main components of braking system

Figure 27

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71843

1. Adapter valve - 2. Relay valve - 3. Manual condensate discharge valve - 4. Tanks - 5. Dual control relay valve - 6. Rear axle
combined brake cylinder - 7. Rear axle diaphragm brake cylinder - 8. Triple servo control valve for trailer braking - 9. ”ISO”
half-coupling - 10. Rear axle double drum brake assembly - 11. Relay valve - 12. Twin stop valve - 13. A.P.U. - 14. Tanks -
15. Manual condensate discharge valve - 16. Front axle diaphragm brake cylinder (drum brakes) - 17. Front axle double drum
brake assembly - 18. Front axle diaphragm brake cylinder (disc brakes) - 19. Front axle disc brake assembly - 20. Tank - 21.
Engine brake control pedal - 22. Twin control valve - 23. E.S. compressor - 24. Parking brake hand control valve (isolated
vehicles) - 25. Parking brake hand control valve for vehicles suited for towing - 26. Manual control valve for slowing trailer.
30 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

Layout on vehicle of main components of ABS-ASR system

Figure 28

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71844

1. ”Phonic” wheel - 2. Wheel speed sensor - 3. Brake anti-lock control valve - 4. ASR electropneumatic valve -
5. Electronic control unit
 EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 31

DESCRIPTION

Service braking ABS (Anti-Lock Brake System)

Pedal-operated, pneumatic, acting on all the wheels and on the The braking of a moving vehicle and the conseguent
trailer or half-trailer. deceleration and stopping distances depend above all on the
It is composed of two independent sections, one for activating grip between the surfaces of the tyres and the road.
the braking elements of the front axle, the other for activating
With a fully efficient braking system, a further improvement in
the braking elements of the rear axle.
braking can only be achieved by acting on the friction of the tyres
A third section, interlocked with the two sections of the control
or on the grade of the road surface.
valve, is envisaged for braking the trailer. The twin control valve
with electronic transmitter controls the two independent When faced with especially tricky situations, such as poor grip
sections and the trailer servo control valve in its turn governs due to a wet or icy road surface, the driver is forced to
the above-mentioned interlocked section. moderate use of the brakes in order to avoid partially locking
The division of the air system, if one section breaks down, one or more wheels, with the risk of skidding dangerously.
permits the others to remain efficient.
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
Emergency braking available grip is made full use of.
Even in the case of emergency braking, the system makes it
Emergency braking makes it possible to slow down the vehicle possible to keep direction, that is to turn the steering wheel to
and stop it within a safety distance, even if the braking system avoid obstacles with no risk of skidding.
has broken down.

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It should be interpreted as a partial service brake that, thanks In short, the anti-lock brake system (ABS):
to the dual circuit, anyhow acts on one of the two axles. - Prevents the wheels locking when the vehicle is braking, no
matter what grip is available on the road.
- Shortens stopping distances.
Retarding braking - Provides safety for the driver who can keep the vehicle’s
The I.T.B. (Iveco Turbo Brake) engine brake used on Cursor stability and direction.
engines is composed of a hydraulically controlled mechanism
that cancels the exhaust valve clearance. By applying this
mechanism, at the end of the compression phase, a few degrees
before the T.D.C., the exhaust valves open slightly with a
consequent reduction in the pressure formed in the cylinder.
This takes advantage of the braking torque of the compression
phase but without having the following return thrust on the
piston.

Parking brake

Mechanical, actuated by a manual control valve at the limit stop,

acting on the tractor’s rear wheels by discharging air from the
spring section of the pneumatic cylinders and from the control
section of the servo control valve causing the wheels of the
trailer or half-trailer to lock.
From the driving seat, it is possible to check whether the tractor
is able, with the trailer unrestrained, to ensure the effectiveness
of the parking brake of the tractor trailer assembly.
 32 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

BRAKES
ASR (Anti-Slip Regulator) system Front disc brakes type KNORR: SB7; SN7 (for
vehicles with partial traction)
The driving wheels of an industrial vehicle slipping during
acceleration has harmful consequences, such as a reduction in The discs are keyed onto the wheel hubs and equipped with
the force of traction, loss of grip between tyres and road ventilation fins that permit lowering the high temperature
surface with conseguent loss of control over the vehicle. generated under the braking action.
The function of the ASR is to prevent undesired wheel slip, An electric lead is sunk in the brake linings and connected to an
both when accelerating and on bends, especially on icy or indicator light on the dashboard to signal brake lining wear.
slippery roads, or for ”off-road” use in mud and water. The phonic wheels of the ABS device are keyed onto the wheel
hubs.
In short, the ASR anti-slip regulator system:
- Prevents the driving wheels slipping, both on starting and
when travelling, with differential braking on the wheels
and, if necessary, optimizing the engine torque.
- Keeps an optimal value of traction when the vehicle is on
roads with a low grip coefficient.
- Improves stability especially on bends with a low grip
coefficient.
- Limits tyre wear.

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EBL (Electronic Brakes Limiter) Front brakes (for four-wheel drive vehicles)
and rear brakes type MERITOR Duo - duplex
The EBL function checks the rear axle wheel ”slip”, comparing Ø 410x180 and 410x200
it with the speed of the wheels of the front axle.
The control unit input data are the wheel speed and braking Each braking assembly is composed of a body housing the
pressure measured by the pressure sensor installed upstream adjustment pins, control pins and wedge units.
from the rear axle ABS modulators. The wedge units are operated by the stem of the cylinders that
On the basis of these values, the control unit calculates the in their turn are operated by compressed air.
speed of the vehicle, the rear axle wheel ”slip” and the The wedge unit rollers, as they travel, cause the control pins to
minimum deceleration contemplated. expand that, overcoming the resistance of the shoe return
The EBL function is activated when the driver applies an springs, bring the shoes up to the drum to actuate braking. The
excessive braking force for the conditions of load on the vehicle, adjustment and control pins are made integral with the brake
thereby reducing the braking force on the rear axle. body by two pins that fit into a side slot. When the braking
action ends, there is no air pressure in the diaphragm section of
the combined brake cylinders and so the action of the wedge
unit return and shoe return springs take the wedge units back
into the starting position.
A sensor is screwed onto one of the two shoes forming the
brake. This sensor indicates the state of wear of the brake linings.
When the sensor wire comes into contact with the drum, the
brake lining wear indicator light blinks in the cab.
When the sensor wire gets broken, due to further wear of the
brake linings, the wear indicator light stays on, thereby indicating
the linings have reached their maximum wear limit.
 EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 32/1

FAULT DIAGNOSIS

Fault diagnosis comprises two sections:

- The first one concerns faults that may be identified by the ABS control unit directly. These faults are mainly of an electric —
electronic — pneumatic nature.
- The second one, organized by symptoms, describes the possible faults the electronic control unit cannot identify directly. These
faults are mainly of a mechanical — pneumatic nature.

SECTION I
ABS system troubleshooting can be performed with the Cluster or with the diagnosis instruments Modus, IWT and IT 2000.
These 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

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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.
32/2 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

Figure 28/1

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78400
 Fault warning lamps
Blink
Type of error ABS ASR Possible failures and system reaction Failure reported by the driver Recommended repairing
Code
Yellow Yellow
EUROTRAKKER CURSOR 13

2+1 Front RH modulator ABS disabled. Wheel lock during braking.

Positive short circuit. X Front RH wheel incorrect braking. Check wiring and connectors.
ABS Troubleshooting

Open circuit. Front RH wheel modulation disabled. Front RH wheel incorrect braking. Check front RH modulator efficiency.

Negative short circuit. Front RH wheel tends to lock.

2+2 Front LH modulator: ABS disabled. Wheel lock during braking.
Positive short circuit. Front LH wheel incorrect braking. Check wiring and connectors.
X
Open circuit. Front LH wheel modulation disabled. Front LH wheel incorrect braking. Check front LH modulator efficiency.

Negative short circuit. Front LH wheel tends to lock.

2+3 Rear RH modulator ABS disabled. Wheel lock during braking.
Positive short circuit. Rear RH wheel incorrect braking. Check wiring and connectors.
X
Open short circuit. Rear RH wheel modulation disabled. Rear RH wheel incorrect braking. Check rear RH modulator efficiency.

Negative short circuit.. Rear RH wheel tends to lock..

2+4 Rear LH modulator ABS disabled. Wheel lock during braking.
Positive short circuit. Rear LH wheel incorrect braking. Check wiring and connectors.
X
Open circuit. Rear LH wheel modulation disabled. Rear LH wheel incorrect braking. Check rear LH modulator efficiency.

Negative short circuit. Rear LH wheel tends to lock.

AIR SYSTEM - BRAKES
32/3

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 32/4
Fault warning lamps
Blink
Type of error ABS ASR Possible failures and system reaction Failure reported by the driver Recommended repairing
Code
Yellow Yellow
3+1 Front RH sensor excessive magnetic X Front RH wheel modulation disabled. Front RH wheel incorrect braking. Check and adjust clearance between sensor and
gap. phonic wheel
AIR SYSTEM -

Front RH wheel tends to lock. Check phonic wheel wobble.

BRAKES

Check bearing clearance.

Excessive skidding detected by front Check and adjust clearance between sensor and
RH sensor. phonic wheel.

Check front RH modulating valve.

Front RH sensor signal too low. Check and adjust clearance between sensor and
phonic wheel.

Check wiring and connectors.

Check if sensor signal is compatible.

3+2 Excessive magnetic gap. X Front LH wheel modulation disabled. Front LH wheel incorrect braking. Check and adjust clearance between sensor and
phonic wheel.

Front LH wheel tends to lock. Check phonic wheel wobble.

Check bearing clearance.

Excessive skidding detected by front Check and adjust clearance between sensor and
LH sensor. phonic wheel.
Check front LH modulating valve.
Front LH sensor signal too low. Check and adjust clearance between sensor and
phonic wheel.
Check wiring and connectors.
Check if sensor signal is compatible.
EUROTRAKKER CURSOR 13

cardiagn.com
 Fault warning lamps
Blink
Type of error ABS ASR Possible failures and system reaction Failure reported by the driver Recommended repairing
Code
Yellow Yellow

3+3 Rear RH sensor excessive magnetic X Rear RH wheel modulation disabled. Rear RH wheel incorrect braking. Check and adjust clearance between sensor
EUROTRAKKER CURSOR 13

gap. and phonic wheel.

Rear RH wheel tends to lock. Check phonic wheel wobble.

Check bearing clearance.
Excessive skidding detected by rear RH Check and adjust clearance between sensor
sensor. and phonic wheel.
Check rear RH modulating valve.
Rear RH sensor signal too low. Check and adjust clearance between sensor
and phonic wheel.
Check wiring and connectors.
Check if sensor signal is compatible.

3+4 Rear LH sensor excessive magnetic X Rear LH wheel modulation disabled. Rear LH wheel incorrect braking. Check and adjust clearance between sensor
gap. and phonic wheel.

Rear RH wheel tends to lock. Check phonic wheel wobble.

Check bearing clearance.
Excessive skidding detected by rear LH Check and adjust clearance between sensor
sensor. and phonic wheel.
Check rear LH modulating valve.
Rear LH sensor signal too low. Check and adjust clearance between sensor
and phonic wheel.
Check wiring and connectors.
Check if sensor signal is compatible.
AIR SYSTEM - BRAKES
32/5

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 32/6
Fault warning lamps
Blink
Type of error ABS ASR Possible failures and system reaction Failure reported by the driver Recommended repairing
Code
Yellow Yellow
AIR SYSTEM -

4+1 Front RH sensor:

Positive short circuit. X Front RH wheel modulation disabled. Front RH wheel incorrect braking. Check sensor wiring.
Negative short circuit. Front RH wheel tends to lock. Replace sensor if damaged.
BRAKES

Open circuit.
Short circuit between the two sensor
wires.
4+2 Front LH sensor: Front LH wheel incorrect braking.
Positive short circuit. X Front LH wheel modulation disabled. Check sensor wiring.
Negative short circuit. Front LH wheel tends to lock. Replace sensor if damaged.
Open circuit.
Short circuit between the two sensor
wires.
4+3 Rear RH sensor:
Positive short circuit. X Rear RH wheel modulation disabled. Rear RH wheel incorrect braking. Check sensor wiring.
Negative short circuit. Rear RH wheel tends to lock. Replace sensor if damaged.
Open circuit.
Short circuit between the two sensor
wires.
4+4 Rear LH sensor:
Positive short circuit. X Rear LH wheel modulation disabled. Rear LH wheel incorrect braking. Check sensor wiring.
Negative short circuit. Rear LH wheel tends to lock. Replace sensor if damaged.
Open circuit.
Short circuit between the two sensor
wires.
EUROTRAKKER CURSOR 13

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5+1 Front RH sensor:
Wrong tyre dimensions. X Front RH wheel modulation disabled. Front RH wheel incorrect braking. Check correct tyre circumference.
Front RH wheel tends to lock Check phonic wheel correct tooth number.
Wrong sensor connection. Check and restore correct sensor connection.
EUROTRAKKER CURSOR 13

Speed signal faulty. Check wiring and connectors.

Check if sensor signal is compatible.
Signal frequency too high. Check wiring and connectors.
Replace electronic control unit if error persists.
5+2 Front LH sensor:

Wrong tyre dimensions. X Front LH wheel modulation disabled. Front LH wheel incorrect braking. Check correct tyre circumference.
Front LH wheel tends to lock Check phonic wheel correct tooth number.
Wrong sensor connection. Check and restore correct sensor connection.
Speed signal faulty. Check wiring and connectors.
Replace electronic control unit if error persists.
Signal frequency too high. Check wiring and connectors.
Replace electronic control unit if error persists.

5+3 Rear RH sensor:

Wrong tyre dimensions. X Rear RH wheel modulation disabled. Rear RH wheel incorrect braking. Check correct tyre circumference.
Rear RH wheel tends to lock. Check phonic wheel correct tooth number.
Wrong sensor connection. Check and restore correct sensor connection.
Speed signal faulty. Check wiring and connectors.

Check if sensor signal is compatible.

Signal frequency too high. Check wiring and connectors.
Replace electronic control unit if error persists.
AIR SYSTEM - BRAKES
32/7

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 32/8
Fault warning lamps
Blink
Type of error ABS ASR Possible failures and system reaction Failure reported by the driver Recommended repairing
Code
Yellow Yellow
5+4 Rear LH sensor:
AIR SYSTEM -

Wrong tyre dimensions. X Rear LH wheel modulation disabled. Rear LH wheel incorrect braking. Check correct tyre circumference.

Rear LH wheel tends to lock. Check phonic wheel correct tooth number.
BRAKES

Wrong sensor connection. Check and restore correct sensor connection.

Speed signal faulty. Check wiring and connectors.

Check if sensor signal is compatible.

Signal frequency too high. Check wiring and connectors.

Replace electronic control unit if error persists.

6+1 Wrong front RH phonic wheel. X Front RH wheel modulation disabled. Front RH wheel incorrect braking. Check if phonic wheel is damaged and replace
it.
Front RH wheel tends to lock Check and ad just clearance between sensor
and phonic wheel.

6+2 Wrong front LH phonic wheel X Front LH wheel modulation disabled. Front LH wheel incorrect braking. Check if phonic wheel is damaged and replace
it.
Front LH wheel tends to lock Check and ad just clearance between sensor
and phonic wheel.

6+3 Wrong rear RH phonic wheel. X Rear RH wheel modulation disabled. Rear RH wheel incorrect braking. Check if phonic wheel is damaged and replace
it.
Front LH wheel tends to lock Check and ad just clearance between sensor
and phonic wheel.
EUROTRAKKER CURSOR 13

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 Fault warning lamps
Blinkk
Bli
Type of error ABS ASR Possible failures and system reaction Failure reported by the driver Recommended repairing
Code
Yellow Yellow

6+4 Wrong rear LH phonic wheel. X Rear LH wheel modulation disabled. Rear LH wheel incorrect braking. Check if phonic wheel is damaged and replace it.
EUROTRAKKER CURSOR 13

Rear LH wheel tends to lock Check and ad just clearance between sensor and
phonic wheel.

7+1 No CAN line communication. X Impossible to disengage engine brake. Rear axle tends to skid. Check CAN line wiring.

CAN line open circuit. ASR disabled. Check EDC control unit.
CAN line short circuit.
No communication with EDC control @ X
unit for too long.

(@ - only if ASR is missing)

7+1 No communication with control unit X Impossible to disengage engine brake. Rear axle tends to skid. Check CAN line wiring.
Retarder for too long. Impossible to disengage retarder. Check EDC control unit.
No communication with control unit ASR disabled. Check Retarder control unit.
EDC for too long

ASR valve:
7 +2 Positive short circuit. X Rear axle ASR braking disabled. Rear axle tends to skid. Check ASR valve wiring.
Open circuit. X Rear axle ASR braking disabled. Rear axle tends to skid. Check ASR valve wiring.
Negative short circuit.
AIR SYSTEM - BRAKES
32/9

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 Fault warning lamps
32/10

Blinkk
Bli
Type of error ABS ASR Possible failures and system reaction Failure reported by the driver Recommended repairing
Code
Yellow Yellow

7+3 Retarder disengagement control relay:

AIR SYSTEM -

Positive short circuit. X Impossible to disengage retarder.. Rear axle tends to lock. Check disengagement relay wiring (pin 14 con.
X1).
BRAKES

Negative short circuit.

Open circuit.

7+4 Failure warning lamp faulty. Failure warning lamp not working. Warning lamp off at initial check. Check wiring and warning lamp.

7+5 Wrong ASR configuration. X ASR completely disabled. Rear axle tends to skid.. Check control unit configuration.

7+7 Pressure sensor: X EBL disabled. Rear axle tends to lock. Check wiring and pressure sensor integrity.
Positive short circuit.
Negative short circuit.
Open circuit.

8+1 Control unit low power supply voltage X ABS disabled. No ABS check. Check power supply wiring and fuse integrity.
or open circuit.

8+2 Voltage too high. X ABS / ASR disabled. No ABS / ASR check. Check battery and alternator power supply.

8+3 Control unit inside errors. X ABS / ASR disabled. No ABS / ASR check. Replace electronic control unit.

8+4 Tyre wrong parameters X ABS disabled. No ABS check. Check tyre dimension parameters.
Replace electronic control unit.

8+5 No negative connection. X ABS disabled. No ABS check. Check signal integrity to pins 4 and 9 of X1
connector.
Check earth connection efficiency.
EUROTRAKKER CURSOR 13

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 EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 33

SECTION 2

Main operating trouble of the brake system:

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.
7 - Parking brake release delayed. 14 - Noisy brakes.
8 - Trailer parking brake release delayed.

POOR OR ABNORMAL
1

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SYSTEM CHARGE

Air system pipes leak or burst. Close or replace the worn or damaged fittings.
YES Replace 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

POOR OR ABNORMAL SERVICE

2
BRAKING OF THE REAR AXLE

Air system pipes leak or burst. Close or replace the worn or damaged fittings.
YES Replace the burst or damaged pipes.

(continued)
34 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

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

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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 automatic clearance recovery Replace the complete brake calliper.
device. YES

(continued)
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 35

POOR OR ABNORMAL SERVICE

3
BRAKING OF THE FRONT AXLE

Air system pipes leak or burst. Close or replace the worn or damaged fittings.
YES Replace the burst or damaged pipes.

NO

Inefficient operation of the Duplex control valve. Overhaul or replace the Duplex control valve.
YES

NO

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Brake linings worn and/or vitrified. Overhaul or replace the brake linings.
YES

NO

Inefficient operation of the front brakes. Overhaul the front brakes.

YES

NO

Inefficient operation of the relay valve. Overhaul or 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)
36 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

Inefficient operation of the ABS solenoid valve. - Check the electric wiring.
YES
- Replace the ABS solenoid valve.

POOR OR ABNORMAL TRAILER

4 SERVICE BRAKING

Air system pipes leak or burst. Close or replace the worn or damaged fittings.
YES Replace the burst or damaged pipes.

NO

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Inefficient operation of the triple control servo control Overhaul or replace the triple control servo control
valve. YES valve.

NO

Inefficient operation of the Duplex control valve. Overhaul or replace the Duplex control valve.
YES

NO

Inefficient operation of the A.P.U. Overhaul or replace the A.P.U.

YES

NO

Brake linings worn and/or vitrified. Overhaul or replace the brake linings.
YES

NO

Inefficient operation of the trailer brakes. Overhaul the trailer brakes.

YES

(continued)
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 37

POOR OR NO
5
PARKING BRAKING

Air system pipes leak or burst. Close or replace the worn or damaged fittings.
YES Replace the burst or damaged pipes.

NO

Inefficient operation of the combined brake cylinders. Overhaul or replace the combined brake cylinders.
YES

NO

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Inefficient operation of the parking brake manual con- Overhaul or replace the lever.
trol valve (lever). YES

NO

Brake linings worn and/or vitrified. Overhaul or replace the brake linings.
YES

NO

Inefficient operation of the relay valve. Overhaul or replace the relay valve.
YES

NO

Inefficient operation of the rear brakes. Overhaul the rear brakes.

YES

(continued)
38 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

POOR OR NO TRAILER
6 PARKING BRAKING

Air system pipes leak or burst. Close or replace the worn or damaged fittings.
YES Replace the burst or damaged pipes.

NO

Inefficient operation of the triple control servo Overhaul or replace the triple control servo control
control valve. YES valve.

NO

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Replace broken or damaged piping. Overhaul or replace the lever.
YES

NO

Trailer brake linings worn and/or vitrified. Overhaul or replace the trailer brake linings.
YES

NO

Inefficient operation of the trailer brakes. Overhaul the trailer brakes.

YES

NO

Inefficient operation of the trailer control servo control - Check the electric wiring.
valve. YES
- Replace the trailer control servo control valve.

(continued)
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 39

PARKING BRAKE
7
RELEASE DELAYED

Air system pipes leak or burst. Close or replace the worn or damaged fittings.
YES Replace the burst or damaged pipes.

NO

Inefficient operation of the relay valve. Overhaul or replace the relay valve.
YES

NO

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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

Inefficient operation of the rear brakes. Overhaul the rear brakes.

YES

(continued)
40 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

TRAILER PARKING BRAKE

8 RELEASE DELAYED

Air system pipes leak or burst. Close or replace the worn or damaged fittings.
YES Replace the burst or damaged pipes.

NO

Inefficient operation of the triple control servo control Overhaul or replace the triple control servo control
valve. YES valve.

NO

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Inefficient operation of the parking brake manual con- Overhaul or replace the lever.
trol valve (lever). YES

NO

Inefficient operation of the trailer brakes. Overhaul the trailer brakes.

YES

THE VEHICLE SKIDS

9 WHEN BRAKING

Air system pipes leak or burst. Close or replace the worn or damaged fittings.
YES Replace the burst or damaged pipes.

NO

Inefficient operation of the Duplex control valve. Overhaul or replace the Duplex control valve.
YES

(continued)
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 41

Inefficient operation of the front brakes. Overhaul the front brakes.

YES

NO

Inefficient operation of the rear brakes. Overhaul the rear brakes.

YES

NO

Inefficient operation of the triple control servo control. Overhaul or replace the triple control servo control.
YES

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INSUFFICIENT TRAILER
10 RETARDER BRAKING

Air system pipes leak or burst. Close or replace the worn or damaged fittings.
YES Replace the burst or damaged pipes.

NO

Inefficient operation of the A.P.U. Overhaul or replace the A.P.U.

YES

NO

Inefficient operation of the triple control servo control Overhaul or replace the triple control servo control
valve. YES valve.

NO

Inefficient operation of the parking brake manual con- Overhaul or replace the lever.
trol valve (lever). YES
42 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

EARLY WEAR OF THE

11 BRAKE LININGS

Inefficient operation of the Duplex control valve. Replace broken or damaged piping.
YES

NO

Inefficient operation of the brakes. Overhaul the brakes.

YES

NO

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Inefficient operation of the triple control servo control Overhaul or replace the triple control servo control
valve. YES valve.

NO

Inefficient operation of the relay valve. Overhaul or replace the relay valve.
YES

BRAKE SYSTEM
12 WARNING LIGHT ON

Air system pipes leak or burst. Close or replace the worn or damaged fittings.
YES Replace the burst or damaged pipes.

NO

Inefficient operation of the A.P.U. Overhaul or replace the A.P.U.

YES

(continued)
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 43

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

PARKING BRAKE INDICATOR LIGHT ON

13 WITH LEVER IN DRIVING POSITION

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

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NO

Inefficient operation of the parking brake manual con- Overhaul or replace the lever.
trol valve (lever). YES

NO

Inefficient operation of the A.P.U. Overhaul or replace the A.P.U.

YES

14 NOISY BRAKES

Worn brake linings. Replace the brake linings.

YES

NO

Foreign bodies between the brake linings and discs (disc Remove the foreign bodies between the brake linings
brakes). YES and discs.

(continued)
44 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

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 Turn or if necessary replace the drums.
brakes). YES

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EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 45

TIGHTENING TORQUES

PART TORQUE
Nm (kgm)
Compressor
Compressor type Knorr-Bremse 2W460R of 464cm3
Screws fixing head 30 (3)
+1 +1
Nut fixing pulley 190 - 0 (19 -0 )

Combined brake cylinder

Ring nut fixing brake cylinder 315 ± 15 (31.5 ± 1.5)
Manual unrestraining screw (in service position) 35 ±5 (3.5 ± 0.5)

Diaphragm brake cylinder (for disc brakes)

Nuts for screws fixing cylinder to brake calliper 180 ± 20 (18 ± 2)

Diaphragm brake cylinder (for drum brakes)

Ring nut fixing brake cylinder 315 ± 15 (31.5 ± 1.5)

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Nut fixing clamp retaining cylinder cover 8±1 (0.8 ± 0.1)

5886/D axle front disk brakes

Ring nut fixing wheel bearings 515.5 ± 24.5 (51.5 ± 2.4)
Cylindrical head screws with hex socket to lock wheel bearing adjustment clamp 27.5 ± 2.5 (2.7 ± 0.2)
Self-locking hex screws to fix brake callipers to mount 615.5 ± 61.5 (61.5 ± 6.1)
Self-locking hex screw to fix brake calliper mount to stub axle 312.5 ± 16.5 (31.2 ± 1.6)
Hex screw fixing brake disc to wheel hub 281.5 ± 13.5 (28.1 ± 1.3)
Cover for wheel hub * TYPE A 133.5 ± 13.5 (13,3 ± 1,3)
TYPE B ♦ 130± 10 (13 ± 1)
Tapered threaded plug for wheel hub cover * TYPE A
27 ± 2 (2.7 ± 2 )
-

5886/2D axle drum brakes

Ring nut fixing wheel bearings 515 ± 30 (51±3)
Cylindrical head screws with hex socket to lock wheel bearing adjustment clamp 27 ± 3 (2.7±0.3)
Cover for wheel hub (axle 5886) * TYPE A 133 ± 14 (13.3 ± 1.4)
TYPE B ♦ 130 ± 10 (13±1)
Tapered threaded plug for wheel hub cover (axle 5886) * TYPE A 27 ± 2 (2.7 ± 0.2)
TYPE B ♦ 50 ± 2
* See on page 81 (Figure 74) for cover type
♦ Only deposit a sealant bead on hub cover ledge surface, using proper dispenser.
Protect threaded portion.
Use LOCTITE TYPE 574 sealant.
45/1 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

TIGHTENING TORQUES

PART TORQUE
Nm (kgm)
Rear axles drum brakes 452191/2D - 453291/2D - 452146/2D - 451391/2D
Drum securing screw 25 ± 3 (2.5 ± 0.3)
Cover securing screw J 50 ± 5 (5 ± 0.3)
Flat-head screw 25 ± 3 (2.5 ± 0.3)
Wheel securing nut 615 ± 35 (61.5 ± 3.5)
J Apply LOCTITE 573 on thread

5985/2D axle drum brakes

+50 +5
Wheel securing nut 600 - 20 (60 -2 )
Brake support securing screw 362.5 ± 33.5 (36.2 ± 3.3)
Cover securing screw 49 ± 5 (4.9 ± 0.5)
Support securing screw 25 ± 3 (2.5 ± 0.3)

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RT 153E/2D rear axle drum brakes
Drum securing screw 40 ± 4 (4 ± 0.4)
Brake support tightening screw (29 ± 1,3)
289 ± 13.5
(29 ± 1.3)
Half shaft flange securing screw (23,2 ± 2,4)
232.4 ± 24.5
(23.2 ± 2.4)
Ring nut for wheel hub bearings ♦ 392.3 (40)

♦ See ”Rear axles” section for correct adjustment

EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 45/2

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 46 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

TOOLS

TOOL No. DESCRIPTION

99301001 Grinding and turning machine for brake discs and drums

99301005 Brake disc turning device

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99301006 Brake shoe turning device

99305079 Brake shoe turning device

99305121 Hot air device

99321024 Hydraulic trolley to remove and refit wheels

EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 47

TOOLS

TOOL No. DESCRIPTION

99341003 Single-acting bridge (rear axles 452194/2D - 451391/2D -

453291/2D)

99341015 Clamp (rear axles 412191/2D - 451391/2D - 453291/2D -

452146/2D - RT 153E/2D)

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99341020 Pair of tie rods for grips (use with 99341023)

99341023 Grips (rear axles 452191/2D - 451391/2D - 453291/2D)

99345049 Reaction block for extractors (drive axle 5985/2D)

99345053 Reaction block for extractors (drive axle 5985/2D, rear axle
452146/2D)
48 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

TOOLS

TOOL No. DESCRIPTION

99345055 Reaction block for extractors (rear axles 452191/2D - 451391/2D

- 453291/2D - RT 153E/2D)

99345103 Tool for wheel hub mounting (RT153E/2D rear axles)

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99348001 Extractor with locking device (drive axle 5985/2D, rear axles
452146/2D - SR145E/2D - RT 153E/2D - 452191/2D - 451391/2D
- 453291/2D)

9938004 Universal male extractor from 5 to 70 mm (drive axle 5985/2D)

99354207 Wrench for wheel hub caps (front axles 5886/D - 5886/2D, drive
axle 5985/2D, 452191/2D - 451391/2D - 453291/2D -
452146/2D)

99355167 114mm wrench for wheel hub bearing adjustment nut (rear axle
RT 153E/2D)
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 49

TOOLS

TOOL No. DESCRIPTION

99356001 Wheel brake shoe adjustment wrench (rear axles 452191/2D -

451391/2D - 453291/2D - 452146/2D)

99370005 Grip for interchangeable drifts (rear axles 452191/2D - 451391/2D

- 453291/2D - 452146/2D - RT 153E/2D - 452146/2D)

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99370006 Grip for interchangeable drifts (front axles 5886/D - 5886/2D, drive
axle 5985/2D, rear axles 452191/2D - 451391/2D - 453291/2D)

99370007 Grip for interchangeable drifts (front axles 5886/D - 5886/2D, drive
axle 5985/2D, rear axles 452191/2D - 451391/2D - 453291/2D -
RT 153E/2D - 452146/2D)

99370317 Reaction lever with extension to retain flanges (front axles 5886/D
- 5886/2D, drive axle 5985/2D, rear axles 452191/2D -
451391/2D - 453291/2D - 452146/2)

99370715 Guide for fitting wheel hub (front axles 5886/D - 5886/2D, rear
axles 452191/2D - 451391/2D - 453291/2D)
50 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

TOOLS

TOOL No. DESCRIPTION

99372211 Tool to remove and refit brake shoe retainer springs

99372213 Tool for turning brake drum (use with 99301001) (drive axle
5985/2D, 452191/2D - 451391/2D - 453291/2D - 452146/2D - RT
153E/2D, front axle 5886/2D)

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99372228 Hub for positioning dismantled floating shoe turning tools on lathe
99301001

99372230 Tool for turning dismantled floating shoes (Rockwell 410) (use with
99301001 - 99372228)

99372237 Tool to mount brake calliper sliding bush guard (front axle
5886/D)

99372238 Tool to extract brake calliper thrust units (front axle 5886/D)
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 51

TOOLS

TOOL No. DESCRIPTION

99372239 Tool to mount thrust units with brake calliper guard (front axle
5886/D)

99372240 Tool to remove and refit brake calliper sliding bush guide bushings
(use with 99372237 for assembly) (front axle 5886/D)

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99372241 Tool for notching brake calliper sliding bush guide bushing (front
axle 5886/D)

99373004 Key to remove brake cylinder gasket (Rockwell) (rear axles

452191/2D - 451391/2D - 453291/2D - 452146/2D - RT
153E/2D, front axles 5985/2D - 5886/2D)

99374093 Drift to mount bearing outer races 91-134 mm (use with

99370007) (front axles 5886/2D - 5886/D, drive axle 5985/2D,
rear axles 452191/2D - 451391/2D - 453291/2D - 452146/2D -
RT 153E/2D)

99374094 Drift to mount bearing outer races 134-215 mm (use with

99370007) (rear axles 452191/2D - 451391/2D - 453291/2D -
452146/2D - RT 153E/2D, front axle 5985/2D)
52 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

TOOLS

TOOL No. DESCRIPTION

99374132 Key to mount wheel hub internal gasket (use with 99370006)
(front axles 5886/D - 5886/2D)

99374134 Key to mount wheel hub internal gasket (rear axle RT 153E/2D)

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99374161 Key to mount wheel hub internal gasket (rear axles 452191/2D -
452191/2D - 451391/2D - 453291/2D - 452146/2D)

99374377 Key to mount wheel hub internal gasket (drive axle 5985/2D)

99374451 Tool to remove and refit drive shafts (rear axles 452191/2D -
451391/2D - 453291/2D - 452146/2D)

99388001 Wrench (80 mm) for front wheel hub bearing adjustment nut
(front axles 5886/D - 5886/2D, drive axle 5985/2D)
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 53

TOOLS

TOOL No. DESCRIPTION

99389819 Torque wrench (0-10 Nm) with 1/4” square fitting

99389821 Torque wrench (0-70 Nm) with 3/8” square fitting (drive axle
5985/2D, rear axles 452191/2D - 451391/2D - 453291/2D -
452146/2D)

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99395026 Tool to check rolling torque of wheel hubs (use with torque
wrench)

99395603 Dial gauge (0 - 5 mm)

54 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

SPECIFICATIONS AND DATA - PNEUMATIC SYSTEM

DESCRIPTION

Compressor
- KNORR 2W460R
Capacity 464 cc
- KNORR - BREMSE 2W630R Twin cylinder
Capacity 628 cm3

A.P.U.
- KNORR ZB4530
Drier
Safety valve opening pressure 13.0 ± 4.0 bar
min 10 ± 0.3 bar
Regulator trip pressure
min 10 ± 0.3 bar
4-way safety valve

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Opening pressure
Section 21 - 22 ≤ 7.5
Section 23 - 24 ≤ 8 bar
Closing pressure +0.5
6.5-0 bar

Max. working pressure bar 13

Safety valve opening pressure bar 13 ± 4

Circuit 1 2 3 4 3 4
Fitting for second bar 21 22 23 24 26
7.5 + 0.2 8.0 -0
Opening pressure (The circuits 1+2 are filled first) bar 0 0.2

Opening pressure of the integrated safety valve bar > = 9.2

Static closing pressure
6.5 ± 0.25 6.5 ± 0.25
(Without compensation, with 0 bars in the circuit out of service) bar
Limiting pressure bar 8.5 -0.3 8.5 -0.5
Pressure limiter on / off pressure difference bar < = 0.65

Air tanks
Front axle 20 litres
Rear axle + trailer 20 litres
Parking 20 litres

Engine brake pedal control valve

- Type: BOSCH A 481 110 125
Maximum working pressure 12 bar
- Type: BENDIX CP6A
Maximum working pressure 13 bar
- Type: WABCO 463 036 019 0
Maximum working pressure 12 bar
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 55

SPECIFICATIONS AND DATA - PNEUMATIC SYSTEM

DESCRIPTION

Duplex control valve

- Type: KNORR DX 76 A
Supply pressure 10.5 bar
- Type: WABCO 884 010 978 0
Supply pressure 10.5 bar
- Type: KNORR DX 60A
Supply pressure 10.5 bar

Triple servo control valve

- Type: WABCO 973 009 013 0
Supply pressure 8.5 bar
Predominance 0.2
- Type: KNORR AC 597 B

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Supply pressure 8.5 bar
Predominance 0.2
Differential control pressure (pipes 42 and 22) +0.3
2.5 -0.5 bar

Parking brake control valve (vehicles suited for towing)

- Type: WABCO 961 723 117 0 - 961 723 106 0
Supply and working pressure 8.5 bar
Travel of control lever (discharge) with start of emergency braking (point of resistance) 65°
Parking braking 73°
Test braking to check supply to triple control valve 85°
- Type: KNORR DPM 95 AAX
Supply and working pressure 8.5 bar
Travel of control lever (discharge) with start of emergency braking (point of resistance) 67°
Parking braking 73°
Test braking to check supply to triple control valve 86°
Parking brake control valve (isolated vehicles)
- Type: WABCO 961 723 023 0 - 961 723 007 0
Supply pressure 8.5 bar
Travel of control lever (discharge) with start of emergency braking (point of resistance) 65°
Parking braking 73°
- Type: KNORR DPM 94 AAX
Supply pressure 8.5 bar
Travel of control lever (discharge) with start of emergency braking (point of resistance) 67°
Parking braking 73°
56 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

DESCRIPTION

Trailer retarder control valve (optional)

- KNORR DPM 96 DAX - DPM 96 AAX
Supply pressure 8.5 bar
Maximum angular travel of control lever 73°
Safety valve (”for Sweden”)
- WABCO 434 205 030 0
Maximum working pressure 11 bar
Pressure in the cylinders (under which supply is shut off) +0
4 -0.6 bar

Air pressure switch

- TDS
Working pressure max 15 bar
Setting pressure

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with increasing pressure 5.5 ± 0.5 bar

with decreasing pressure 6.6 ± 0.3 bar

Manual condensate drain valve
- Type: VOSS 5 2 08 99 75 00
Working pressure 13 bar
- Type: TECHNOMATIK TP 1609.00.00
Working pressure 13 bar
Twin control relay valve (anticompound)
- WABCO 973 011 208 0
Supply pressure max 13 bar
Outlet pressure fitting 21 -
Outlet pressure fitting 22 -
Control pressure 41/42 max 10 bar
Pressure sensor
- WABCO 441 040 015 0
Measuring principle piezo-resistive
Permissible overpressure 16 bar
Single control relay valve
- Type: KNORR AC 574 AXY
Working pressure max 10.2 bar
- Type: WABCO 973 003 008 0
Working pressure max 14 bar
Twin stop valve
- WABCO 434 208 029 0
Supply pressure max 10 bar
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 57

DESCRIPTION

Check valve with controlled pressure

- Type: BENDIX VPC 4 M
Working pressure max 20 bar
Opening pressure +0,1
7 -0.3 bar
+0.1

Closing pressure 6.3 ± 0.2 bar

- Type: WABCO 434 100 130 0
Working pressure max 20 bar
Opening pressure +0
7 -0.3 bar

- Type: KNORR 1 B 435 47

Working pressure max. 20 bar
Opening pressure adjustable 1 ÷ 10 bar
Proportional reduction valve

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- KNORR DB 2116
Reduction ratio 1.15 : 1
Pressure test point valve
- Type: RAUFOSS
Working pressure max 12.5 bar
- Type: SIRIT
Working pressure max 12,5 bar
Safety valve
- WABCO 434 608 219 0
Diaphragm brake cylinder (for disc brakes)
- Type 22: KNORR 1 C 722 35
Maximum working pressure 10.7 bar
- Type 24: KNORR 1 C 722 37
Maximum working pressure 10.7 bar
- Type 27: KNORR
Maximum working pressure -
Diaphragm brake cylinder (for drum brakes)
- Type 14: BENDIX DFR 8944 B
Maximum working pressure 8.5 bar
Sleeve length 187 mm
Stroke min. 53 mm
- Type 14: KNORR EF 141 AY
Maximum working pressure 8.5 bar
Sleeve length 152 mm
Stroke 53 mm
- Type 16: BENDIX DFR 9023 B
Maximum working pressure 8.5 bar
Sleeve length 187 mm
Stroke min. 53 mm
58 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

DESCRIPTION
- Type 16: KNORR EF 161 AY
Maximum working pressure 8.5 bar
Sleeve length 152 mm
Stroke min. 53 mm
- Type 18: BENDIX EF 180 BY
Maximum working pressure 8.5 bar
Sleeve length 180 mm
Stroke min. 53 mm
- Type 18: KNORR EF 180 AY
Maximum working pressure 8.5 bar
Sleeve length 152 mm
Stroke min. 53 mm
Combined brake cylinder

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- Type 16: KNORR 1 C 56449
Maximum working pressure 8.5 bar
Spring load 7900 N
- Type 18: KNORR 1 C 55976
Maximum working pressure 8.5 bar
Spring load 7900 N
- Type 14/24 HFL3: KNORR Z005732
Maximum working pressure 8.5 bar
- Type 16/24 HFL3: KNORR Z005733
Maximum working pressure 8.5 bar
Electronic control unit
- WABCO 446 004 320 0
Supply voltage 24 V
ABS Sensor
- WABCO 441 032 857 0 - 441 032 8540
ABS wheel anti-lock control valve
- Type: WABCO 472 195 055 0
Working pressure max 13 bar
- Type: KNORR IC 65307
Working pressure max 11.2 bar
Solenoid valve
- WABCO 472 170 606 0
Working pressure max 13 bar
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 59

SPECIFICATIONS AND DATA - BRAKES

FRONT DISC BRAKES

KNORR:
5886/D *
INTERMEDIATE ADDED
AXIS FRONT AXLE

Brake calliper cylinders:

∅ - number 2
- diameter ∅ mm 68

Brake lining thickness:

- standard S mm 21
S - minimum permissible S mm 2

∅ 436 (TYPE SB7)

Brake disc diameter ∅ mm
432 (TYPE SN7)

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Brake disc thickness:
- normal S mm 45 ± 0.1
S - minimum permissible S mm 37 (4 mm per side)

0.6 ÷ 0.9 (TYPE SB7)

Operating clearance G mm
0.5 ÷ 1 (TYPE SN7)

WHEEL HUBS

Wheel hub bearings 2 with tapered rollers

Hub bearing end float mm 0.16 max

Hub bearing end float adjustment with ring nut

Rolling torque da Nm 0.50 max.

Oil for wheel hub bearings

Tutela W 140/MDA
Litres 0.35
Quantity of oil for each hub
Kg 0.32

* On request, axle 5886/2D with Duo-Duplex drum brakes for 20” rims.
60 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

DRIVE AXLE
MERITOR DUO-DUPLEX
DUO DUPLEX FRONT AXLE
5985/2D
DRUM BRAKES 5886/2D ♦
5985M/2D
Drum diameter:
- Nominal ∅ mm 410 ÷ 410.4
- 1st uprating ∅ mm 412 ÷ 412.4
- 2nd uprating ∅ mm 414 ÷ 414.4
Brake lining thickness:
S - Nominal S mm 22.95
- 1st uprating S mm 23.95
S1* - 2nd uprating S mm 24.95
- minimum permissible S1* mm 6.95
Diameter of brake linings:
∅ - Nominal ∅ mm
408 ÷ 409
- 1st uprating ∅ mm
- 2nd uprating 410 ÷ 411
∅ mm
412 ÷ 413

Width of brake linings:

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L mm 179 ÷ 180

L
G
Clearance between brake linings
and drum:
G mm 0.5 ÷ 1.2

Maximum error of concentricity

E in the drum diameter after
turning
E mm 0.04

WHEEL HUBS

Two with tapered rollers

Wheel hub bearings
SET-RIGHT

Hub bearing end float

Not adjustable
mm

Hub bearing end float adjustment Tightening to torque with ring nut

Wheel hub bearing rolling torque 0.50 max -

Oil for wheel hub bearings

Tutela W 140/M DA
Litres 0.33 0.75
Quantity of oil for each hub
Kg 0.3 -
♦ Alternatively to front axle 5886/D with disc brakes (for vehicles with partial traction).
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 61

REAR
MERITOR DUO-DUPLEX REAR H.R. REAR AXLE
AXLE
DRUM BRAKES
451391/2D 452146/2D 452191/2D 453291/2D RT153E/2D

Drum diameter:
- Nominal ∅ mm 410 ÷ 410.4
- 1st uprating ∅ mm 412 ÷ 412.4
- 2nd uprating ∅ mm 414 ÷ 414.4
Brake lining thickness:
S - Nominal S mm 22.95
- 1st uprating S mm 23.95
- 2nd uprating S mm 24.95
S1* - minimum permissible S1* mm 6.95
Diameter of brake linings:
- Nominal ∅ mm 408 ÷ 409
∅ - 1st uprating ∅ mm 410 ÷ 411
- 2nd uprating ∅ mm 412 ÷ 413
Width of brake linings:
199 ÷ 200
L mm

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L

G
Clearance between brake linings and drum:
G mm
1 ÷ 1.25

Maximum error of concentricity in the drum

E diameter after turning
E mm 0.04

WHEEL HUBS

Two with tapered rollers

Wheel hub bearings
SET-RIGHT

Hub bearing end float

Not adjustable
mm

Hub bearing end float adjustment -

Wheel hub bearing rolling torque -

Oil for wheel hub bearings

Tutela W 140/M DA
Litres -
Quantity of oil for each hub
Kg -
62 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

CHECKS ON MAIN COMPONENTS OF THE BRAKING 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

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Air tanks for:
- Front axle
Check the seal and corrosion protection.
- Rear axle
Drain the condensate off from the tanks via the drain valve.
- Parking + Trailer
- Services

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 same time, at the automatic coupling pipe, the pressure gauge
(with check position) has to show a pressure of 7.5 bars.

Engine brake pedal Check it works properly.

control valve

Using a bleed valve or loosening a screw plug (with integrated bleed

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

(continued)
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 63

CHECKS ON MAIN COMPONENTS OF THE BRAKING SYSTEM

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 cylinders
Relay valve
act.

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Fill the tank. Connect one pressure gauge to the automatic coupling
head and one to the graduated coupling head.
A pressure of 1 bar, sent by the twin control valve, must at the
Servo control valve with triple
graduated coupling head correspond to a pressure of from 0.8 to 1.5
control for trailer braking, with
bars. Make a full braking (vehicle stationary).
modulated servo diverter
The coupling head must have available the required braking pressure
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 7.5 bars.
Check there is no air leakage from the coupling gaskets.

Disc brake calliper

Brake disc Check the wear of the brake linings, scoring and wear of the brake
disc, efficiency of the pistons, wear of the dust caps.
Brake linings

When the pressure on the pedal stops, the shoes need to return to
the rest position quickly and evenly on all the wheels.
Drum brakes
Check the clearance between shoes and drum.
Check the thickness of the brake linings.

(continued)
64 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

With the system filled, disconnect the supply to the fitting 1 and
check that the pressure at the outlets is constant.
Check that the pressure at outlet 22 is equal to the supply pressure
at the fitting 1.
Twin servo control valve Connect a pressure gauge to the controls 41 and 42 and one to the
(anticompound) outlet 21.
With the parking brake control valve on, check that the pressure at
outlet 21 is equal to the control pressure 41.
On pressing the brake pedal, check that the outlet pressure 21 is
equal to the control pressure 42.

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

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all the above cases it is necessary to replace the 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 with couplings and fittings with a soft brush and seeing there is no leakage.
engine off and under activation Air leakage corresponding to a soap bubble of Ø 25 mm in 5 seconds
pressure is tolerated, or anyhow a max. fall in pressure within 10 min. of 2%
of the disengagement pressure = 0.220.02 bar.
Seal of pneumatic system in the For 3 min. the pressure has to remain stable in the pneumatic system.
partial braking range with 3 bar This check should be made with the parking brake disengaged.
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 65

MAIN COMPONENTS OF
THE BRAKING SYSTEM
790510 Compressor Head locking screw tightness

Figure 29 Figure 30

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60231 60232

It produces compressed air needed by the braking system Following the order shown in the figure, tighten the screws
and auxiliary services. fixing the cylinder head to the required torque.
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 (noted because the seal seat Replace the piston assembly.
is shiny).
Scraper ring assembly defective. 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 120º to each other.
vertical line.
Cylinder scored or ovalized. Grind the cylinder and mount an uprated piston.
Total lack of compression Compression or suction valve damaged. Replace deteriorated parts.
Piston rings all on the same vertical line. Mount rings at 120º 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 cylin- Grind the cylinder and mount an uprated piston.
der.
Particles of carbonized oil between the intake Clean the valves.
and compression valves.
Mechanical noise Too much clearance between the small end and Check the tolerance of the couplings at issue.
pin, between the pin and hole in the piston, be-
tween the shaft and big end, between the shaft
and bushings.
Too much clearance between the piston and cy- Grind the cylinder and mount an uprated piston.
linder.
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.
66 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

526711 Electronic control unit A.P.U. (Air Processing Unit)

Figure 31 Figure 32

32370

The electronic control unit is the system’s nerve centre. 72019

Its function is to control the system’s solenoid valves

according to the signals from the wheel sensors. Its function is to keep the air clean and at the right moisture
Each channel comprises four functional circuits. The first one level in the distribution system and keep the pressure needed
is the input, which receives the analogue signals from the for the operation of the connected systems at the outlet.
sensor on the corresponding wheel, it filters them from the This component integrates the functions of 4-way pressure

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parasitic signals and converts them into digital information regulator, pressure reduction unit for parking, services and
measuring the length of the cycle. Then there is a main circuit, trailer.
which consists of a microprocessor that processes the The drier decreases the amount of moisture in the
information received from the input circuit. compressed air coming from the compressor so that no
It has a complex program permitting it to calculate the condensate accumulates in the system. The compressed air
acceleration and deceleration of the wheel and to make the flows through a granular material whose crystalline structure
logical combination of the various adjustment signals. stores the condensate water. After the regulator trips the
When necessary, it emits two control signals that are sent to regeneration air tank air regenerates the absorbent material.
the corresponding anti-lock control valve via the control unit’s The device is composed of three main parts: a cartridge
third circuit, the one for control, to adjust the braking pressure containing the absorbent material, a control section and a
appropriately. pressure regulator, which besides governing the operation of
The fourth and last circuit is the one for safety, which checks the entire system switches the device over from the ”Drying”
the efficiency of the various system components. to the ”Regeneration” phase.
If any trouble is detected, not only does it warn the driver by The function of the device is to ensure that the compressor,
switching on the warning light on the dashboard, but it also if a section breaks down, fills the tanks connected to the
automatically disconnects the entire ABS system, while sound sections with a pressure equal to the set value of the
leaving the conventional braking system efficient. section broken down.
This unit is composed of four valve assemblies all similar to
each other.

Fault Diagnosis

TROUBLE POSSIBLE CAUSE REMEDY

Too much condensate Filtering cartridge clogged. Replace the cartridge.

in the circuit

The set pressure is not Air leakage from the safety valve. Overhaul the device, replacing the worn parts.
reached in the tank
Seals worn. Overhaul the device, replacing the worn parts.

Air leaks from the out- Poor piston seal. Overhaul the device, replacing the worn parts.
let

Air leaks around the Leakage from the valves in the four sections. Overhaul the device, replacing the worn parts.
plugs

Air leaks if a section Defective operation of the check valves. Overhaul the device, replacing the worn parts if necessary or re-
breaks down place the device.
 EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 67

793332 Triple servo control valve

Figure 33 The operations to carry out to adjust the predominance of

the servo control valve type KNORR - BREMSE AC 597 B 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
predominance.

32373

Wabco 973 009 013

The device controlled by the two independent circuits of
the duplex control valve and the spring brake circuit of the Figure 35
tractor controls trailer braking.
It incorporates a device making it possible to brake the
trailer even in the event of control pipe failure.

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Predominance control
It is equipped with a predominance adjustment device.

Knorr Bremse AC 597B

Figure 34

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.
- Turning it CLOCKWISE decreases the predominance.
- Turning it ANTICLOCKWISE increases the
60255
predominance.
Fault Diagnosis
TROUBLE POSSIBLE CAUSE REMEDY
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.
68 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

793110 Duplex control valve

Figure 36 Figure 37

11 A 21

12 P 22

33545

It takes air from the tanks and distributes it to the braking

33346
elements.
It is self-limited, that is it limits the delivery of air at a set DFR 9412A DUPLEX CONTROL VALVE
PERFORMANCE DIAGRAM

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maximum pressure, the outcome of which is a greater
availability of energy and a constant maximum braking A. Outlet pressure (bar)
pressure irrespective of the pressure swings in the tanks. B. Push rod travel (mm)
Vehicles prepared as trucks have duplex control valves
mounted with the function of correcting the braking force of
the operator elements of the front axle according to the
correction made by the load apportioning valve.

Fault Diagnosis

TROUBLE POSSIBLE CAUSE REMEDY

Air leaks from the outlet Leaks from the outlet pipes due to wear of Overhaul the device, replacing the worn parts.
hole the gaskets.

Control valve with ab- Self-limitation higher or lower than as re- Set the device using the specific screw.
normal self-limitation quired.

Vibration during bra- Spring wear. Overhaul the device, replacing the worn parts.
king
Air leakage due to piston gaskets in the two Overhaul the device, replacing the worn parts.
sections.

Abnormal operation of The electric circuit does not close. Replace the switch.
the brake light switch
The electric circuit does not open. Replace the switch.
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 69

798510 Coupling heads 794310 Parking brake hand control valve

(vehicles suited to towing)

Figure 38 Figure 40

21
11 22

35352
52871

The version for the ”Graduated” pipe is equipped with a This device provides emergency and parking braking for the
yellow cover, while the version for the ”Automatic” pipe is tractor and trailer.

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equipped with a red cover and a side safety projection (1). Additionally, it makes it possible to check the braking effect
The safety projections are used to avoid coupling errors. of the tractor. This is vital when the vehicle is parked on a
steep slope.
793319 Check valve (vehicles suited to
towing)
Figure 39

1 2

33987

This permits compressed air to pass in the direction shown

by the arrow on the valve body, preventing its backflow.
Fault Diagnosis

TROUBLE POSSIBLE CAUSE REMEDY

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.
Thoroughly clean the various parts comprising it.

in the braking position Control valve, seals and valve to control Check and overhaul the device, replacing any defective parts.
component worn. Thoroughly clean the various parts comprising it.

Difficulty in turning the Interference in the control valve. Overhaul the device and moisten all the sliding parts.
control lever
70 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

Safety valve (”for Sweden”) 794310 Parking brake hand control valve
(isolated vehicles)

Figure 41 Figure 42

1 2

72103 35352

The function of this component is to supply the manual brake This device, in the tractor’s parking brake circuit, makes it
release control valve and accordingly the spring cylinders, possible to apply emergency and parking braking on the
when a safety pressure is reached in the tanks of the braking vehicle by discharging the air contained in the spring cylinders.

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system.

Fault Diagnosis

TROUBLE POSSIBLE CAUSE REMEDY

Air leaks from the outlet Piston, exhaust valve, seals worn. Clean thoroughly, check the integrity of the rubber parts and
with the control valve le- their seats.
ver in the brake release
position Overhaul the device, replacing any defective parts.

Air leaks from the outlet Piston, gasket, seals worn. Clean thoroughly, check the parts and overhaul the device, re-
with the control valve placing any defective parts.
lever in the emergency
or parking braking
position

Air leaks from the Plate, gasket, seals worn. Thoroughly clean the parts, check the seal surfaces and gasket,
control valve lever cover check the integrity of the rubber parts and their seats. Overhaul
the device, replacing any defective or worn parts and restore the
mating surfaces if necessary.

Difficulty in turning the Interference in the control valve. Thoroughly clean and check all the component parts.
control valve lever Overhaul the device, replacing any defective parts. During as-
sembly, moderately grease all the sliding parts.

If you find any defects or wear such as to impair operation, re-

place the entire device.
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 71

794911 Diaphragm brake cylinder Combined cylinder emergency braking device

Figure 43 Figure 45

35798
36745

This device transmits the force given by the compressed air, If it were not possible to supply the spring section of the
as the brake pedal is pressed, to the mechanical service combined cylinder (1) pneumatically, it is possible to release
braking device. If there is any trouble, it is necessary to replace the vehicle brake manually to permit towing. To release the
the entire cylinder. vehicle brake you need to unscrew the screw (2) fully.

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794911 Combined brake cylinder
Repairs
Figure 44 Figure 46

36744

This device is composed of two parts: a diaphragm brake for

service braking and a spring brake for parking and emergency 36476
braking if the braking system fails. Before detaching the combined cylinder from the vehicle,
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

TROUBLE POSSIBLE CAUSE REMEDY

Air leaks from the outlet Diaphragm punctured or broken. Replace the diaphragm.
or retaining clamp Diaphragm lip broken.
Retaining clamp locking screws loose. Tighten the screw.

Air leaks from the dia- Deterioration of the parts forming the Overhaul the device, replacing any worn parts.
phragm section supply spring section.
72 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

793331 Relay valve

Figure 47 This device makes it possible to accelerate the discharge of

compressed air from the section of the combined cylinder,
thereby shortening braking times.

1 2

36743

Fault Diagnosis

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TROUBLE POSSIBLE CAUSE REMEDY

Air leaks from the outlet Leakage from the introduction or from the Overhaul the device, replacing any defective parts.
with the control pipe seals.
exhausting

Air leaks from the outlet Leakage from the piston gasket or from the Overhaul the device, replacing any defective parts.
with supply in the exhaust valve.
control pipe

793321 Pressure reduction unit

Figure 48 Its purpose is to cut off the flow of compressed air to the
service when the pressure in the service reaches a certain
value (setting).

Bench setting
1 2 Mount the device on the test bench and connect the fittings
1 and 2 with pipes to the pressure gauges and supply.
Using the adjustment screw, set the pressure to the required
value, and at the same time check its seal.

34953

Fault Diagnosis

TROUBLE POSSIBLE CAUSE REMEDY

Pressure at the outlet Valve off setting. Set the device.

fitting not as set Leakage from the seals. Overhaul the device, replacing any damaged parts.
Piston and its seat defective. Replace the device.
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 73

Engine brake switch Dual servo control valve

Figure 49 Figure 50

62372 71989

This is an N.O. switch fitted on the cab floor. It supplies the This device is used, in the event of the service and parking
electronic control unit with a negative signal to engage the brakes being operated at the same time, to prevent the two
engine brake. braking forces from being applied at the same time, thereby
protecting the mechanical parts of the brake against undue

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strain. Additionally, this device permits accelerating the
discharge of compressed air from the section of the spring
brake cylinder, thereby shortening braking times.

Fault Diagnosis

TROUBLE POSSIBLE CAUSE REMEDY

Air leaks from the dis- Leakage from the introduction of the valve Replace the valve assembly or seals.
charge slit (3) with supply assembly or from the seals.
(1) and control pipes (41)
and (42) exhausting

Air leaks from the Leakage from the piston gasket or from the Replace the gasket and valve assembly.
discharge slit (3) with exhaust valve of the valve assembly.
supply in the control
pipes (41) and (42) and in
the pipes connected to
the services (21) and (22)

Air leaks from the fitting Leakage from the top piston gasket or from Replace the gasket or seal.
(41) with supply in (42) the seal.
and (41) free into the
atmosphere

Air leaks from the fitting Leakage from the top piston gasket or from Replace the gasket or seal.
(42) with supply in (41) the seal.
and (42) free into the at-
mosphere
74 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

526714 Brake anti-lock control valve 526713 Speed sensor

56712 Phonic wheels
Figure 51 Figure 53

35383
35805

This component modulates the pressure of the air in the The speed sensors and phonic wheels have the job of
brake circuit. detecting the speeds of the respective wheels.
When the electronic control unit detects the tendency of a The phonic wheel is housed on the wheel hub and turns at
wheel to lock, the valve intercepts the supply to the brake

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the same speed as the wheel. It generates alternating voltages
cylinder preventing the wheel from locking. in the sensors by induction. The frequency of these voltages
is in proportion to the speed of rotation of the respective
wheel. These voltage signals are transmitted to the control
unit to be suitably processed. A sensor and a phonic wheel
are fitted for each wheel. This arrangement makes it possible
to control an individual braking pressure for each wheel
during adjustment, optimizing travelling stability and braking
distance.
526724 ASR electropneumatic valve

Figure 52

35384

This device brakes the driving wheels, via the brake anti-lock
modulator, whenever the tendency is detected for one or
more wheels in traction to slip.
This is a normally closed valve. When the electronic control
unit detects the tendency for one or more driving wheels to
slip, it sends a signal to the solenoid valve, which energizes and
lets air pass to the brake anti-lock modulators that brake the
wheels at issue. The solenoid valve is de-energized when the
wheels reach the right degree of friction on the road surface.
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 75

BRAKE REPAIRS
5274 FRONT DISC BRAKES SB7 TYPE (VEHICLES WITH PARTIAL TRACTION)
Figure 54

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49151

SECT. A-A

49152

SB7-TYPE DISC BRAKES

1. Dry bushing - 2. Brake lining - 3. Threaded sleeve - 4. Spring cotter - 5. Brake lining retaining plate - 6. Retaining plate -
7. Pin - 8. Brake calliper - 9. Bearing plate - 10. Piston - 11. Cap - 12. Sliding bushing - 13. Rubber guide bushing -
14. Sliding pin - 15. Drive - 16. Cover - 17. Screw - 18. Chain wheel disc - 19. Chain - 20. Plug - 21. Adjustment device -
22. Protection cap - 23. Fixing clamp - 24. Sliding pin - 25. Brass guide bushing - 26. Sliding bushing - 27. Internal guard -
28. Brake disc - 29. Bridge - 30. Lever - 31. Diaphragm cylinder - 32. Pressure springs
75/1 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

TYPE SN7 DISK BRAKES

Figure 54/1

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78397

78396

1. Dry bushing - 2. Threaded sleeve - 3. Small piston - 4. Washer - 5. Spring split pin - 6. Pintle - 7. Retainer plate -
8. Bearing plate - 9. Driving pin - 10. Rubber driving bushing - 11. Sliding pin - 12. Plug - 13. Entrainer
- 14. Wear sensor - 15. Axle - 16. Chain - 17. Spring - 18. Cover - 19. Adapter - 20. Chain gear - 21. Adjustment device -
22. Cover - 23. Brass bushing - 24. Sliding pin - 25. Sliding bushing - 26. Inside protection - 27. Ring - 28. Braking gaskets -
29. Brake disc - 30. Lever - 31. Eccentric bearing
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 75/2

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 76 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

SB7 type brake operation

Braking phase Figure 56

During the braking phase, the rod of the diaphragm cylinder
(31) presses on the lever (30).
The force is transmitted to the bridge (29) via the roller in an
eccentric position in the lever (30) and through the threaded
sleeves (3) and the pistons (10) the force of reaction acts on
the internal brake lining (2).
After overcoming the clearance between the brake linings (2)
and brake disc (28), the force of reaction is transmitted to the
external brake lining (2) through the movement of the brake
calliper.
The pressure of the brake linings (2) on the brake disc (28)
generates the braking force.

Release phase
As soon as the pressure on the brake decreases, the two 49153
pressure springs (32), the bridge (29) with the threaded
sleeves (3) and the lever (30) go back into their rest position. Remove the safety plug (1).

Automatic clearance recovery

The brake is equipped with an automatic adjustment device

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Make sure the external safety plug and the seal are
that keeps the operating clearance between the brake linings
! fitted properly in order to prevent water getting
and the brake disc constant.
inside the automatic clearance recovery device.
Whenever the brake is applied, the adjustment device (21),
which is integral with the lever (30), automatically comes into
operation.
If the wear of the brake linings and brake discs causes the
functional clearance to increase, the adjustment device (21)
and the drive (15) make the threaded sleeves (3) turn so as Figure 57
to recover the increase in clearance.

CHECKS
Efficiency of automatic clearance recovery

Figure 55

60759

Using a wrench (1), turn the adjustment pinion anticlockwise

by 2-3 clicks, increasing the clearance between the brake
linings and the disc.
Apply the brakes for approximately 5-10 times and check that
the wrench (1) turns clockwise with small increases to restore
the required clearance between the disc and brake linings.
On the contrary, if the wrench does not turn, only turns on
the first application or even turns forwards and backwards, this
40570
means the clearance recovery has broken. It is therefore
necessary to replace the entire calliper, following the
Unscrew the fixing nuts (1) and with the hydraulic trolley procedure described on page 78, and refit the wheels.
99321024 (2) disconnect the wheels.
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 77

Brake lining thickness

Figure 58

49155

This operation is feasible with the wheels fitted.

Remove the safety plug (1) and check that A > 0.

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On the contrary, you need to remove the wheels and perform
a thorough check as described hereunder.

Figure 59

A1

49156

1. Brake calliper - 2. Rubber guide bushing - 3. Sliding bushing

A. Position of the sliding bushing with new linings - A1. Position of the sliding bushing with worn brake linings
(make a thorough check with the wheels off)
78 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

527417 Replacing brake linings

Figure 60 Figure 63

40569 49158

Set the vehicle on flat ground and lock the rear wheels. Loosen Disconnect the electrical connection (1) from the calliper
the nuts (1) fixing the front wheels. body.
Lift the vehicle at the front with a hydraulic lift and set it on two Remove the split pin (2), pin (3) and brake lining retaining plate
stands (2). (4).

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Figure 61 Figure 64

40570 60861

Unscrew the fixing nuts and with the aid of the hydraulic trolley Remove the plug (2), turn the adjustment unit (1)
99321024 (1) remove the wheels. anticlockwise, with a spanner, to make the pistons move back
into the calliper body and remove the brake linings (4) making
the calliper body (3) float appropriately.

Figure 62 Figure 65

49157 49160

Remove the screw (1) and the wear sensor cable retaining Press (→) on the spring (1) and remove it. Remove the wear
plate (2). sensors (2) from the brake linings (3).
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 79

Figure 66 Figure 67

49162

49161
Insert the wear sensor (2) into its seat on the brake lining (3).
Mount the spring (1) in the opposite sequence to that for
Remove dirt and rust from around the edge of the brake disc disassembly.
with a scraper or an old screwdriver (2) resting on the calliper
body, turning the disc (1).
Finish the job with abrasive cloth. Remove the remains with Figure 68

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the aid of an aspirator, or rags and a brush.
Do not use petrol or other petroleum products that could
cause trouble for the brakes.
Use only methylated spirit or isopropyl alcohol.
Carefully clean the surfaces of the braking area of the brake
disc.

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 49163
together with the bearing plate for a thorough Insert the new linings in the brake calliper (1) and check they
overhaul. slide freely in their seats.

If you find it necessary to replace the pair of brake

! linings, always replace them with a full set for each
Check that the calliper slides freely on its guides. axle.
If you find any trouble on a single brake calliper it is wise to
overhaul both brake callipers completely.
Remove the dirt from the brake calliper with a wire brush, Figure 69
without damaging the dust caps.
Clean the sliding surfaces of the brake linings.
Check the conditions of the brake disc and make sure it is not
corroded, scored or grooved. Light surface cracks are
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 springs and wear sensors, replace them
if necessary.

60864

Using the wrench (1), turn the clearance recovery pin to

obtain a clearance of no less than 0.7 mm between the brake
lining and brake disc, measured with the feeler gauge (2).
Replace the plug (3) and spread a light layer of RENOLIT
HLT2 white grease.
 80 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

527413 Removing and refitting brake callipers

SB7
Figure 72
Removal
Make sure the external safety plug and the seal are
! fitted properly in order to prevent water getting
inside the automatic clearance recovery device.

Figure 70

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).
Unscrew the nuts (4) and remove the diaphragm cylinder (3).

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49158

Make the electrical connection (1) and secure it to the calliper Figure 73
body.
Mount the plate (4), pin (3) and split pin (2).
Figure 71

49167

Remove the screws (3) and disconnect the brake calliper (1)
together with the bearing plate (2).
49165

Mount the wear sensor cable retaining plate (1).

Using the hydraulic trolley 99321024, fit on the wheels. Lower Take care when removing and carrying the calliper (1)
the vehicle. Lock the nuts fixing the wheels to the required as it is heavy and floats on the bearing plate (2).
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 Refitting
repeatedly, while the vehicle is moving, in both directions, in
order to wear in the brake linings.
For refitting, carry out the steps described for
removal in reverse order, keeping to the required
tightening torques.

Before inserting the diaphragm brake cylinder, spread

! the cap in the brake calliper operating lever with
RENOLIT HLT2 white grease.
 EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 81

520620 Removing and refitting wheel hubs

Removal
Figure 74 2 Figure 77

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 necessary,
77264
the ring (1), keeping to the description given in the ”Front axle”
Arrange, out of prevention, a container to recover oil. section.
Unscrew either plug (1) of cover (A) or inspection plug (2) of Using the adjustment ring nut, check that the thread (2) has no
cover (B). stiffness. If it has, use appropriate means to get rid of the stiffness.
Remove the opposite brake assembly, keeping the components

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separate.
Figure 75
Refitting

Make sure the surfaces of all the parts inside the hub
! are thoroughly clean, with no waste or burrs.
Lubricate the bearings with W 140/MDA oil.
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.
36407

Block rotation of the wheel hub suitably and with the wrench
Figure 78
99354207 (1) unscrew the oil cover (2).

Figure 76

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
36408
measure the end float, which must be 0.16 mm (maximum
Undo the safety screw (3). With the wrench 99388001, value).
unscrew the adjustment ring nut (2), remove the washer (4), On obtaining the required end float, lock the screw (5)
outer bearing (1) and remove the brake disc together with the retaining the adjustment ring nut (4) to the required torque.
wheel hub, spacer and internal bearing.
82 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

Figure 79 Figure 82

36412

Fit the tool 99395026 (1) onto the pins of the wheel hub and, 49169
using the torque wrench 99389819 (2), check that the rolling Remove the sliding pins (2 and 3) and take down the bearing
torque of the wheel hub is 5 Nm. plate (1), recovering the washer (4).
While protecting threaded portion, form a bead with either
IVECO n° 1905685 sealant (cover 1) or LOCTITE 574 sealant
(cover 3) on the wheel hub, on the ledge surface of cover (1

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or 3, Figure 80).
Figure 80 Figure 83

77265

Mount cover (1 or 3) depending on mounted type and tighten 60741

it at prescribed torque. Introduce lubricating oil of the required Remove the safety cap (3), using the specific drift with tool
type and quantity into the wheel hub and fit on the plug (2 o 99372240 (4), the brass bushing (2) and the rubber bushing
4). (1).
527413 OVERHAULING BRAKE CAL-
LIPERS SB7
Figure 81 Disassembly

49168

Take the brake calliper to the bench and lock it in a vice.

Remove the clamp (3) and the safety caps (1 and 2).
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 83

Figure 84
Good braking largely depends on the sliding of the
! brake calliper on the guide pins.

Check the state of wear of the brake lining retaining pins and
associated safety clips. If they are worn or out of shape, replace
the deteriorated parts.
It is wise to replace all the rubber and plastic parts as well as
the brass bushing even if they do not appear to have
deteriorated or be out of shape.

Assembly
Make sure all the components of the brake calliper are
thoroughly clean. Remove any abrasive remains with a
60742 fluff-free rag soaked in isopropyl alcohol, or the equivalent.
Using a wrench (4) and the clearance recovery device, make Spread the thread of the threaded pipe with RENOLIT HLT2
the piston (1) come out of the calliper body by at most 30 mm white grease.
(distance A).
Take the dust cap off the calliper body and, using tool

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99372238 (5), remove the thrust units (1) of the brake
calliper, together with the safety caps (3). Figure 85

The distance A must never be exceeded as the

threaded sleeves (2) are synchronized. If the threaded
! sleeves (2) run by, they lose their synchronism and the
brake calliper has to be replaced.
The internal parts of the brake calliper must never be
removed.
Therefore, never loosen or remove the screws
retaining the covers.

Cleaning and checking component parts

60743

Wash the metal parts with a solution of warm water and Fiat Using the tool 99372239 (4), mount the pistons (1) together
LCD detergent. with the safety caps (2).
Using a wire brush, remove the dirt from the calliper body, Using a wrench (3) and the clearance recovery device, make
then with a brush eliminate the remains and clean the seats of the pistons (1) go back in.
the guiding pins and sliding bushings thoroughly.
Using a synthetic brush of appropriate dimensions, remove
the remains of grease from the seats for the sliding bushings.
Carefully blow compressed air onto the calliper body. Figure 86
Thoroughly clean the sliding bushings with a rag soaked in
isopropyl alcohol, or the equivalent.
Carefully check the wear of the sliding bushings and their seats
on the brake calliper body. Check the sliding surfaces are
neither worn nor damaged.
Insert the bushings into their seats. Check they slide properly.
If they do not, replace them or, if necessary, restore their seats
on the calliper body.

60744

Mount the brass bushing (1) with the specific drift and tools
99372240 (3) and 99372239 (2).
84 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

Figure 87 Figure 89

60745 49176

Using the specific tool 99372241 (2), do the notching at the Insert the sliding bushings (2 and 8).
point (→) by the race in the calliper body to prevent the brass Mount the bearing bracket (1), inserting the washer (9), fixing
bushing (1) from moving. it with the sliding pins (3 and 7) to the required torque.
Check there are no burrs in the bushing seat; remove them Mount: the safety plug (4), safety cap (5) and secure it with the

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if there are any. clamp (6).
Spread the bushing with RENOLIT HLT2 white grease. Before mounting the brake calliper on the vehicle, make sure
it runs freely, acting on the plate (1) in both directions.

Make sure the external safety plug and the seal are
! fitted properly in order to prevent water getting
inside the automatic clearance recovery device.

Figure 88

527411 OVERHAULING BRAKE DISCS

Figure 90

60746

Mount the rubber bushing (1) so that the external ring goes
into the groove (→) using tool 99372237 (3).
Spread the bushing with SYNTHESO GL EPI synthetic green
grease.
Mount the safety cap (2), making sure the sealing lip goes into
its seat.
38597

Examine the state of wear of the surfaces of the brake discs.

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.
 EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 85

527411 TURNING AND GRINDING BRAKE 527411 TURNING AND GRINDING BRAKE
DISCS ON THE BENCH DISCS ON THE VEHICLE

Figure 91 Figure 92

35707

- Key onto the shaft of the lathe 99301001 (2) the brake
disc (1) together with the hub.
- Key onto the shaft a set of spacers that eliminate the end

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float of the assembly; screw on the locking nut and fit the 71848
mount of the lathe shaft. Remove the wheel.
Fit the tool 99301005 (1) onto the wheel hub.
- Position the tool holder (3) in line with the brake disc (1), Proceed with turning and grinding the brake disc.
then adjust the depth of the tools.
- Proceed with turning and grinding the brake disc (1), During grinding, proceed gradually, advancing the
operating with one or more passes to remove material ! wheel in sectors to remove the turning remains
depending on the scoring found. entirely.

5272 DRUM BRAKES

Figure 93
DIRECTION OF TRAVEL SECT. A-A

71781
MERITOR DUO-DUPLEX DRUM BRAKE
86 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

5272 FRONT BRAKES

Figure 96
Overhaul the brake assembly keeping to the
! procedure described for the front brakes as it is
similar.

527230 REAR BRAKES

Disassembly
Figure 94

71782

Take out the screws fixing the brake drum (1) to the wheel
hub (2). Screw two appropriate screws (⇒) into the holes in
the drum and take this out of the wheel hub.

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Figure 97

40510

Set the vehicle on level ground. Take the covers off the nuts
fixing the wheel and loosen the nuts.
Lift the vehicle at the rear and put it on stands. Position the
hydraulic trolley 99321024 under the wheels. Take out the
nuts fixing the wheels and take them off.

Figure 95

40513

Disconnect the electrical connection (1) for the cable

signalling brake lining wear.

Figure 98

39951
Fully unscrew the manual braking screw (2) of the combined
cylinder (1).

40514

Take out the shoe return springs (2).

Remove the top shoe (1).
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 87

Figure 99 Figure 102

71783
40517
Free the brake wear indicator cable (1) from the clips of the
brake plate (3) and take the cable out of the guard (2). Extract the wedge-shaped control unit (1) from the brake
Remove the bottom shoe (4). body (2).
Figure 100 Figure 103

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71841 71791

Disconnect the pipes (3 and 4) from the fittings (5 and 2) and Unscrew the guide pins (2) and take them out. Extract the
remove these from the combined cylinder (1). Using wrench adjustment unit (1) together with the thrust pin from the
99356006, loosen the fixing ring nut. Turning the combined brake body (3).
cylinder (1) anticlockwise, remove it from the brake body.
Figure 104
Figure 101

71789

71842
Disconnect the pipe (1) from the fitting (2) and remove this Unscrew the guide pins (2) and take them out.
from the diaphragm brake cylinder (4). Using wrench Extract the reaction pin (1) together with the thrust pin from
99366006, loosen the ring nut (3). Turning the diaphragm the brake body (3).
brake cylinder (4) anticlockwise, remove it from the brake
body.
88 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

Figure 105 Figure 107

71790 71786

Check the state of wear of the pin seats on the brake body (1), Extract the seal (1) from the thrust pin (2). Check the state of
if they are scored or excessively worn, replace the abnormal wear of the thrust pin (2) and of the angled surfaces (3) on
brake bodies. which the shoe opening control rollers acts.
Examine the wear of the drums to decide on their reuse.
Measure the diameter of the drums with a sliding gauge

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Figure 108
without angling the arms.
Measure the diameter at several points to establish roundness
and wear, also considering the depth of the scoring on the
braking surface.
Admitted tolerance on roundness and/or eccentricity 0.25
mm.
If you find such wear or scoring as not to permit restoring the
braking surface by turning, or clear signs of overheating,
replace the drum (see Characteristics and Data table).
Check the state of the brake shoes and replace them if
cracked.
If the braking surface of the linings shows signs of grease, you
need to find the cause and eliminate it. 38360
The minimum admitted thickness of the brake linings is 6.95
mm. Check the state of wear of the teeth of the guide pins (3), the
If you find a lower or slightly higher value, replace them. integrity of the compression springs (2) and of the copper
Check the integrity and/or efficiency of the brake lining wear washers (1).
signal cable.
Check the integrity and/or efficiency of the shoe return springs. Figure 109

Figure 106

35713

38357 Check that the wedge assemblies run smoothly and the parts
Take apart the automatic adjustment units. are not scratched.
Unscrew the adjustment bushings (3) from the adjustment
pins (2) then extract the seals (1).
Check the state of wear of the external helical teeth of the
If the parts forming the wedge units are worn, you need
adjustment bushings. Check that the bushings slide properly
! to replace the entire wedge unit.
when screwing onto the adjustment pins.
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 89

527231 Turning drums 527233 Replacing brake linings

Measure the diameter of the drums with a sliding gauge
without angling the arms. Measure the diameter at several Figure 111
points to determine the roundness and state of wear.

Figure 110

77085

Remove the worn brake linings from the shoes with the
compressed air press 99305087 (1).

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Open the tongues of clamp (6) from lower shoes,
40520
! releasing bush (7). Then, dismount gasket wear
indicator (8) with its cable.
Fit the tool 99372213 (2) in the brake drum (1).
Key this assembly onto the shaft of the lathe 99301001 (3).
Fit a set of spacers onto the shaft eliminating the end float of
the assembly. Screw down the locking nut and fit on the lathe Put the entire shoes (4) on the adjustable plate (5).
mount. With the chisel (2) in the operating head of the press (1), cut
Fit the anti-vibration band onto the brake drum. off the heads of the rivets (3).
Turn the drums, removing the necessary amount of material Eject the rivets from the shoes.
in several stages to eliminate the flaws found. Thoroughly clean the shoes by washing and blowing.
After turning, remove the brake drum from the lathe and clean
it carefully.
Figure 112

The highest permitted diameter for the drums is given

! on the drum itself.
This limit must never be exceeded as this would
impair the braking effect and the strength of the
drums.

Couple the appropriate brake linings for each single drum 17256
! according to the oversize.
Each of the vehicle’s axles must be equipped with linings Fit the supporting pin (5) on the mobile mount (4) of the press.
of the same type. Rivet the brake linings (3) onto the shoes (2) using the drift (1)
inserted in the operating head of the press.

The right way to rivet the brake linings is to start from

! the middle and gradually move towards the outside
of the braking sectors.

Mount gasket wear indicator inverting operations described

for dismounting.
90 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

Turning brake linings

Figure 113 Figure 115

71786

Grease the seal (1) and fit it on the thrust pin (2).

71849 When repairing the brakes, replace the seals of the

reaction and thrust pins.

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Fit the hub 99372228 (2) on the shaft of the lathe 99301001 !
(1). Fit the plate 99372230 (3) on the hub (2) and secure the To lubricate the components, use Rockwell RBSK
brake linings (4), making the wording ”ANCHOR 15” coincide 0253 grease.
as shown in the figure. Turn the brake linings.

Assembly Figure 116

Figure 114

38364

Fit the seals (2) on the units of the adjustment pins (1). Grease
the thread of the pins (1).
71788
Fully screw down the adjustment bushings (3) and grease
them thoroughly on the outside diameter. Grease the inside of the brake body (5).
Grease the inside diameter of the thrust pins (4). Mount the thrust pin - seal assembly (6) with the slot facing
the guiding pin (4).
Insert the thrust pin (7) into the brake body (5) and insert the
adjustment pin - seal - adjustment bushing assembly (1).

Take great care to observe the assembly order of the

! pins that has to be as illustrated in Fig. 114.

Grease and insert the guide pin assemblies (4) into the seats
on the brake body (5). Check the washers (2) are inserted and
screw down by a few turns.

The guide pins (4) need to be mounted so that the

! tips (3) slide in the seats of the holes in the brake body
(5).
EUROTRAKKER CURSOR 13 AIR SYSTEM - BRAKES 91

Figure 117 Figure 120

71784

Unscrew the adjustment unit (1) to the same extent to obtain

the diameter A, 2 mm less than the diameter of the brake
71787 drum to mount.
Using the key 99373002 (1), drive the metal rings of the seals
onto the brake assembly (2).
Figure 121

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Figure 118

40530

Grease the wedge-shaped control unit (1). Insert it in its seat,

40524 taking care that the rollers (⇒) are positioned in the sliding
Using device 99301006 (2), turn the brake linings (1). race.

Figure 119
Figure 122

71785 36757
Connect the lining wear indicator cable electrical connection Screw the ring nut (1) by hand onto the sleeve (2) as far as it
(2) helping the fixing nut on the shoe. Fit the shoes (1) in the will go.
seat. Apply non-hardening sealant type LOCTITE 573 on the first
Hook on the shoe return springs with the aid of tool few threads of the sleeve (2).
99372211 (3).
92 AIR SYSTEM - BRAKES EUROTRAKKER CURSOR 13

Figure 123 Figure 125

71841 71842

Screw the combined cylinder (1) fully down into its seat. Screw the diaphragm brake cylinder (4) fully down into its seat.
Check that the holes for the supply fittings are in the same Check that the hole for the supply fitting is in the same position
position found on removal; if they are not, unscrew the found on removal; if it is not, unscrew the diaphragm brake

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combined cylinder appropriately. Mount the fittings (2 and 5) cylinder (4) appropriately. Mount the fitting (2) on the
and connect the supply pipes (3 and 4). Supply the diaphragm diaphragm brake cylinder (4), hook up the supply pipe (1).
sections of the combined cylinder by applying the service Supply the brake cylinder by applying the service brake and
brake. With the wrench 99356006, tighten the ring nut to the with wrench 99356006 tighten the ring nut (3) to the required
required torque. Connect the brake lining wear indicator cable torque.
electrical connection. Restore the operation of the combined
cylinder (1) screwing down the screw (2, Fig. 95) fully.

Figure 126

Figure 124

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Mount the wheels and tighten the fixing nuts to the required
torque according to the diagram shown in the figure.
Mount the opposite brake assembly.
39941 Start the vehicle’s engine and run it for a sufficiently long time
to fill the system.
Screw the ring nut (1) by hand onto the sleeve (2) as far as it Brake repeatedly to wear in the brake assembly and recover
will go. Apply non-hardening sealant type LOCTITE 573 on the clearance between the brake lining and the drum when the
the first three threads of the sleeve (2). vehicle is running.