AviaAshokLeylandMotors,s.r.o.,Beranových140,Praha9,Letňany 444 - 1 / 9

Modification of the brake system for towing a trailer with pneumatic brakes

444S e r v i c eTechnická instrukce Technical instruction Technische weisung

7/2008D

full air brake system

No.:

Date: Type:Instruction technique

Instructión tecnica

Reason:Retrofitofadditionalbrakesystemcomponentsfortrailerwithpneumaticbrake.

Valid for:VehiclesAVIAD60-D120withfullypneumaticbrakesystemonwhichthebrakeinstallationsforpneumaticallybrakedtrailerhavenotbeenfittedintheproductionplant.

Parts to order:1x Relay valve Order No. 412-5302101x Trailer control valve Order No. 412-5300201x Manualbrakevalve OrderNo.412-5302501x Holder Order No. 410-5624072x Angularsocket"F" OrderNo.412-5378415x Fitting OrderNo.412-5377041x Fitting OrderNo.412-5377091x Fitting OrderNo.412-5377111x Plug OrderNo.412-5347011x Pipe/640mm/ OrderNo.414-5605031x Pipe/670mm/ OrderNo.414-5605031x Pipe/680mm/ OrderNo.414-5605031x Pipe/900mm/ OrderNo.414-560503

+Pipes-incompliancewithtableunderneath/lenghtdependinguponvehiclesversion/

Part denomination Ø Vehicle denomination LHD order no. G S E L N K RHD FROM TRAILER CONTROL VALVE /INLET 41/ 8 2550 2550 2550 2550 2550 2550 414-560503 -TO RELAY VALVE /INLET 41/ FROM TRAILER CONTROL VALVE /OUTLET 12/ 8 2550 2550 2550 2550 2550 2550 414-560503 -TO COUPLING HEAD /YELLOW/ FROM TRAILER CONTROL VALVE /OUTLET 12/ 12 2550 2550 2550 2550 2550 2550 414-560504 -TO COUPLING HEAD /RED/ FROM MAIN CONTROL VALVE /OUTLET 22/ 8 7660 7160 6560 5960 5460 5010 LHD 414-560503 -TO TRAILER CONTROL VALVE /INLET 42/ 7975 7475 6875 6275 5775 5325 RHD FROM CONNECTION MAN. BRAKE VALVE /INLET 22/ 8 8780 8280 7680 7080 6580 6130 414-560503 -TO TRAILER CONTROL VALVE/INLET 43/ PIPE FROM VALVE RELAY /INLET 22/ 8 10085 9585 8985 8385 7885 7340 LHD 414-560503 -FOR CONNECTING MAN. BRAKE VALVE /INLET 1/ 7250 RHD

AviaAshokLeylandMotors,s.r.o.,Beranových140,Praha9,Letňany 444 - 2 / 9

2) MotificationatLoadsensingvalve:DisconnectthePipewithFitting/pos.16/anddemounttheSwivelfittingwithAngularSockerF.

MountAngular socket F, order No.412-537841and Fitting,orderNo.412-537704.

MountbacktheoriginalPipewithFitting/pos.16/.InsertnewPipe/pos.42/order No. 414-560503and insert its ending into the mounted Fitting order No412-537704. 42

16

16

Modification:1) preparingPipesandoperationstobedoneWarning:theminimumPipesbendingradiusallowedduringtransportandhandling,measuredatinnerbendofexternalradiusis:fordiameter8-R=50mmfordiameter12-R=18mmItisnecessarytokeeptheinteriorofPipesandFittingsperfectlyclean.TheendsofPipeshave tobecutwithoutupset,upright to the longitudinalPipeaxies,withtolerance ±5°. Pipesmustbeinserteduntil thebottomoftheinsertionconnector.Connectingis tobedonemanuallybypushingandsynchroneousrotatingbothpartsuntilthebottom.Depthofthepipeinsertionis:fordiameter8-21mmfordiameter12-25mmThequalityofconnectioncheckbypullingandturningslightlyback.FixPipestooriginalclusterbytapeswherenecessarysothatitstayssteadythusavoidinganycontactswithedges.OnthelastpageofthisTechnicalInstructionisshownapictureofthefinalpipesinstallation.ForsafetyreasonstheconnectionsafterinsertionofPipesmaynotbedis-assembled.Whendemountingthefittingsthesealingisdamaged,thesealingringmustbereplacedbyanewone.

AviaAshokLeylandMotors,s.r.o.,Beranových140,Praha9,Letňany 444 - 3 / 9

3) Relay Valve:DisconnectPipeswithFittings.Demount theRelay valve fromthe vehicle.

Mount new Pipes and insertPipes positions 33, 72, 73 into Fittings.

MountanewRelayValvewheretheoriginalwasmountedorderNo.412-530210.ChecksealingandmountPipestopositions4,32,40,48.

723373

40432

48

3248

4 40

FromnewRelayValveorderNo.412-530210 demount Fittingsfrom positions 4, 32, 40, 48 /markedinred/.

AviaAshokLeylandMotors,s.r.o.,Beranových140,Praha9,Letňany 444 - 4 / 9

4) Trailer control valve Order No. 412-530020.DemounttheplugsfromtheTrai-ler control valve.Mount onto outlet 12 Fitting412-537709 and onto outlet 22Fitting412-537711.

12

MountandfixtheTrailercontrolvalveontotheframe.Spotdimen-sionsaremarkedfromthelowerframeflange inhorizontal levelandfromtheaxleaxisinverticalstraight.

Insert and connect Pipes in con-formitywiththedrawing.

34

612 71

41

22

AviaAshokLeylandMotors,s.r.o.,Beranových140,Praha9,Letňany 444 - 5 / 9

5) SafetyvalveDemount Pipewith Fitting /pos.2/. WithdrawthePipefromtheve-hicle.Mount Plug 412-534701 /pos.1/.

6) PedalBrakeControlValveDemount Pipe with Fitting /pos.13/.

2

1

DemountAngularSocketFwithSwivelpivot.MountAngularSocketFOrderNo.412-537841andFittingOr-der No.412-537704.

13

AviaAshokLeylandMotors,s.r.o.,Beranových140,Praha9,Letňany 444 - 6 / 9

AfterinsertionofnewPipesMount the Pipewith Fitting /pos. 13/Insert the Pipe end /pos. 11/ into Fitting

7) ManualbrakevalveDisconnect the Pipe connection underthecab.Pipewithends1/2pulloutofftheframe(directionfromSafetyvalve).

DemountManual brake valvefromthecab.Mount a Fitting - Order No.412-537704 onto a newMa-nual brake valve - OrderNo.412-530250.MountnewManualbrakevalveintothecab.

13

11

AviaAshokLeylandMotors,s.r.o.,Beranových140,Praha9,Letňany 444 - 7 / 9

MountHolder Order No. 410-562407Connect the pipes as per pictu-re.

Insert the Pipes PipetoManualBrakeValve/pos.1/Order No 414-560503 LHD-640mmRHD-1200mm

PipefromManualBrakeValve/pos.3/ Order No 414-560503 LHD-670mmRHD-1230mm

Pipefortrailer/pos.5/ Order No 414-560503 LHD-680mmRHD-1240mm

PipeAirBlow-off/pos.Blow-off/Order No 414-560503 LHD-900mmRHD-1400mm

1blow-off

3

5

1

35

AviaAshokLeylandMotors,s.r.o.,Beranových140,Praha9,Letňany 444 - 8 / 9

SCHEME OF NEW PIPING CONNECTON

11

15

4272

73

33

12 6

34

71 41

AviaAshokLeylandMotors,s.r.o.,Beranových140,Praha9,Letňany 444 - 9 / 9

Ing.TomášJiřičkav.r.----------------------------------

finančníředitel

Ing.JiříPůda,CSc.v.r.----------------------------------

vedoucívývoje

Ing.JaroslavHanzalv.r.----------------------------------

vedoucíútvarukvality

SCHEME OF NEW PIPING INSTALLATION

A

B

C

ED

Newlymounted Pipe springs for PipesprotectionaremarkedinRED:/pos.A/ - Order No. 414-534402 - 440 mm/pos.B/ - Order No. 414-534405 - 900 mm/pos.C/ -OrderNo. 414-534410 - 750mm OriginalPipesprings,whichcanbeusedforinstallationofnewPipes,aremarkedYELLOW.

/pos.D)-Couplinghead- - Order No. 410-531403/pos.E)-Couplinghead- - Order No 410-531402