Compressed air system / Brakes, Suspension 10

Contents

COMPRESSED AIR SYSTEM ................................................................. 2

Compressed air .................................................................................. 2
Compressor ........................................................................................ 2
Air dryer .............................................................................................. 3
Couplings ........................................................................................... 3
Charging compressed air .................................................................. 4

BRAKE SYSTEM ..................................................................................... 5

Configuration...................................................................................... 5
Modification ........................................................................................ 5
Manual control valve with test position ........................................... 5

ABS .......................................................................................................... 6

TC (Traction Control) ............................................................................. 7

The eight main components of the ABS/TC system ....................... 8
TC operation in brief .......................................................................... 9
TC off-road .......................................................................................... 9

ELC (Electronic Level Control)............................................................ 10

TAG AXLE .............................................................................................. 11

Load transfer .................................................................................... 11

CONTROL BOX ..................................................................................... 12

Programming M1 and M2 ................................................................ 13
Extra control box.............................................................................. 13

CHASSIS HEIGHT ................................................................................. 14

Front .................................................................................................. 14
Rear ................................................................................................... 16
Tyres .................................................................................................. 19

© Scania CV AB 2002 1
 Compressed air system / Brakes, Suspension 10

COMPRESSED AIR SYSTEM

This chapter contains general information about the
brake and air suspension systems.
For a more detailed description of brakes and air
suspension, please refer to the Scania workshop
manual.

Compressed air
The guaranteed pressure is 8 bar.
The air tanks may be located transversely inside the
frame right at the rear or next to the battery shelf,
depending on vehicle type and wheel configuration.
The current location is shown on the maim dimension
drawings.

Compressor
The compressor has a swept volume of 600 cc,
ensuring that charging time is short.
The compressor has an ESS (”Energy Saving Sys-
tem”) relief mechanism that reduces the compressor’s
no-load power requirement by about 800 W.

Relief pressure:
With extra air tanks (load handling) 12.2 ± 0.2 bar
Control range 1.1 - 1.6 bar

Without extra air tanks 9.3 ± 0.2 bar

Control range 0.6 - 1.2 bar

2 © Scania CV AB 2002
 Compressed air system / Brakes, Suspension 10

Air dryer
The air dryer has integrated heating to prevent
freezing (engaged at +7). Capacity 800 litres/min.
Drying performance is more than adequate to cope with
extra tank capacities for cargo handling, trailers, etc.

Couplings
The compressed air hoses have unions with seals of
O-ring type.

NOTE: If the hoses are to be disconnected from a

component, the coupling must be unscrewed. The
hose cannot be simply pulled out of the union. When
changing unions on a hose the old ones must be
scrapped and new ones fitted instead.

If it is necessary to fit new unions or hoses, they can be

purchased from the Scania spare parts department which
also has a special tool for fitting unions on plastic pipes.
Part no. 587956.

Connecting extra air consuming equipment.

Connection of all extra compressed air equipment
must always be carried out after the four-circuit
protection valve at manifold fitting 65.
Manifold fitting 65 can be found at several places on
the vehicle but the most easily accessible ones are on
the right-hand frame side member and rear cross-
member.

Place for extra solenoid valves can be found on the solenoid valve holder, located
on one of the crossmembers beside the bogie / rear axle.
Valves and couplings can be purchased from Scania distributors.
© Scania CV AB 2002 3
 Compressed air system / Brakes, Suspension 10

Charging compressed air

The air dryer can be charged with air directly from
an external compressed air system through the
union located beside the left-hand boarding step.

An air union on the dashboard under the parking

100668
brake control can be used for charging the parking
brake circuit with air in connection with towing,
etc.
Consult the driver’s manual for a description of
how air can be filled from the front wheel.

Note: If the truck has an air dryer, air must only be

filled via this air dryer in order to ensure that the new
air is dried.

4 © Scania CV AB 2002
 Compressed air system / Brakes, Suspension 10

BRAKE SYSTEM
Configuration
The system has four circuits; service brake front and rear, parking brake/trailer
brake circuit and a circuit for optional equipment.

The circuits are internally protected by a four-circuit protection valve located

beside the air dryer. If any of the circuits suffers an abnormal drop in pressure,
supply is shut off to this circuit and the valve provides reduced pressure to the
remaining circuits.

All extra equipment should be coupled after the four-circuit

protection valve.
Parking and trailer components are assembled in a central valve package on the
left-hand side of the frame. The relay valves are assembled in a package on the
inside of the frame beside the rear axle.

In order to facilitate removal of the cab, cab brake equipment and the central valve
package are connected with two pairs of block couplings.

Modification
Modification of the brake system, for example after retrofitting additional tag
axles, must always be carried out by Scania’s service works.

Manual control valve with test position

1. Drive position.
1-2. Emergency brake position.
Between positions 1 and 2, air is bled from the lines to 2
the spring brake chambers and the brakes are applied
1
in proportion to how far the lever is moved towards
3
position 2. 4
If the vehicle has a trailer brake circuit, the trailer
brakes are also applied.
15
3. Parking position.
4. Test position. 11
57a

The lever is pressed down, pulled back and held in 27 4

this position. The function is then the same as for the 19

22
21
parking position except that the trailer brakes are 13
released when the line to the trailer relay valve is 7b

again pressurized.
26:1001

The purpose of this is to check that the vehicle

3
parking brake alone is capable of holding the entire
vehicle combination if the trailer brakes fail.
When the lever is released it springs back to the
parking position.
© Scania CV AB 2002 5
 Compressed air system / Brakes, Suspension 10

ABS

ABS stands for Anti-lock Braking System.

Optimum braking characteristics are achieved if both
the trailer and tractor unit are equipped with ABS.
If one part of the combination does not have ABS, it
will brake as normally with the risk of wheel-lock.

ABS ABS

26:1005
The four main components of the ABS system.
(four-circuit system)
1 2
1 ABS control valve, two front and two rear.*
2 Electronic control unit, ABS.
3 Toothed ring, two front and two rear. *
4 Wheel sensor, two front and two rear.*
*Six-circuit systems have four at the rear.
26:1007

3
The toothed ring ( 3 ) is located on the wheel hub. 4
The electromagnetic wheel sensor ( 4 ) is located
on the axle and senses wheel rotation.
The control unit ( 2 ), with the aid of the wheel
sensors, senses whether one of the wheels is about
to lock and then sends a signal to that wheel’s
control valve ( 1 ) which reduces brake pressure
sufficiently to stop the wheel locking.

6 © Scania CV AB 2002
 Compressed air system / Brakes, Suspension 10

TC (Traction Control)

Traction control prevents the driven wheels from

spinning when acceleration is too fierce.

TC works in combination with the ABS and uses the

same sensors.

© Scania CV AB 2002 7
 Compressed air system / Brakes, Suspension 10

The eight main components of the ABS/TC system

(four-circuit system).

1 ABS control valve, two front and two rear.*

2 Control unit.
3 Toothed ring, two front and two rear. *
4 Wheel sensor, two front and two rear.*
5 Solenoid valve (TC brake control), one unit for
the driven wheel pair.
6 Double check valve, one unit for the driven
wheel pair.
7 Relay valve, one unit for the driven wheel pair.
8 EDC control unit (electronically controlled fuel
injection), for TC engine control.
*Six-circuit systems have four at the rear.

8 © Scania CV AB 2002
 Compressed air system / Brakes, Suspension 10

TC operation in brief
With ABS, the control unit registers signals from the sensors about the
tendency of the wheels to lock. With TC, signals concerning whether
the wheels are about to spin are also registered (one or two wheels
show an abnormal increases in speed).

Traction control has two control circuits.

- Brake control
- Engine control

Brake control
The brake control circuit is active up to a maximum of 40 km/h and is
activated when a driven wheel spins.
The TC brake control applies the brake to the spinning wheel and
therefore basically functions as an automatic differential brake.

Engine control
Engine control is active at all speeds and is engaged when both driven
wheels are spinning at the same speed. It is also engaged when one
wheel is spinning and vehicle speed is greater than 40 km/h. Engine
control limits the supply of fuel to the engine, via the EDC control
unit, until the average speed of the driven wheels, when compared to
vehicle road speed, is within the programmed range.

Note: Malfunctions may arise if the difference in tyre

sizes between the front and rear axles is too great. See
the work description in the Workshop Manual.

TC off-road

With the TC off-road switch activated, the spin limit is increased by

10 km/h + 6 % of the normal programmed value.
This means that the driven wheels can have a comparatively higher
speed than the front wheels.

© Scania CV AB 2002 9
 Compressed air system / Brakes, Suspension 10

ELC (Electronic Level Control)

Brief description.
Electronic Level Control (ELC) is electronic control of the
air suspension level control.

Some advantages:
- Constant height when loading and unloading,
irrespective of chassis height.
- Two chassis heights, such as for two the heights of two
loading bays, can be programmed in the control unit.
- Load transfer on vehicles with liftable tag axle.

Driving
Drive level is obtained by pressing the drive level button
on the control box.
Only in exceptional circumstances may the vehicle be
driven at a height other than drive level.
When driving with snow chains, the chassis should be
raised about 65 mm.

Calibration
When a control unit or level sensor has been changed,
drive level, upper max. level and the lower mechanical
stop must be calibrated in the control unit.

Adjusting programmed parameters for tipper trucks,

etc.
On tipper trucks and trucks with a crane the air bellows
should be emptied to gain increased stability. Scania
service workshops can reprogram the air suspension
control unit with a function called ”empty air bellows” and
fit a switch for activating this function.
Other alterations to the control unit can also be carried out
for better adaptation to customer requirements.

For chassis heights, see page 14.

Always use axle stands when working

under vehicles with air suspension.

10 © Scania CV AB 2002
 Compressed air system / Brakes, Suspension 10

TAG AXLE

Operating the tag axle.

With the switch in its lower position, the tag axle is
lowered.

Tag axle lowered

With the switch in its middle position, the tag axle

is raised.

Tag axle raised

Load transfer
With the switch in its upper position, the load transfer
is requested.

Load transfer is used to temporarily obtain increased

weight on the driven axle.

Two ways to activate load transfer:

1 With a spring-back upper position, the tag axle
bellows are vented for 90 seconds.
2 Spring-back position and unlimited time.
Load transfer

The regulations concerning maximum permitted rear

axle weight and load transfer vary between different
countries. The pressure monitors and switches should be
selected to ensure that operation complies with the local
regulations.
© Scania CV AB 2002 11
 Compressed air system / Brakes, Suspension 10

CONTROL BOX

The control box is used to adjust chassis height to the

desired level. The microprocessor in the box
communicates with the control unit via digital signals.

Features:

1 Raising/lowering, front.
2 Raising/lowering, rear.
3 Not used.
4 M1 memory for selectable chassis height.
Must be used in combination with button 1 or 2. 1 2 3
5 M2 memory for selectable chassis height.
Must be used in combination with button 1 or 2.
6 Raising/lowering to normal drive level.
Must be used in combination with button 1 and/or
2.
7 Raising.
Must be used in combination with button 1 and/or 4 5 6
2.
8 Lowering.
Must be used in combination with button 1 and/or
2.
9 STOP. Interrupts features 4-6 when they have
started.
STOP is used to activate the stand-by feature. 7 8 9
This button can also be used when programming
M1 and M2.

12 © Scania CV AB 2002
 Compressed air system / Brakes, Suspension 10

Programming M1 and M2

Any two chassis heights can be programmed in

addition to the preprogrammed values.

1 Adjust chassis height to the desired level using

the control box.
2 Press the STOP button when the chassis is at the
correct level and keep it depressed while
activating either M1 or M2.
3 The chassis height is now stored in the memory
and the STOP button can be released.

Stand-by feature
The stand-by feature allows automatic level control
to work for two hours after the starter power has
been switched off.

If the truck is equipped with the stand-by feature, it

is activated by holding the STOP button depressed
when switching off the starter power.

The stand-by feature is not used in 4x2 and 6x4

without load transfer.

Extra control box

For connection, see chapter 11, electrical system.

M1 M2

STOP
26:1014

© Scania CV AB 2002 13
 Compressed air system / Brakes, Suspension 10

CHASSIS HEIGHT
If a more accurate calculation of chassis height is desired, a document on Scania’s
bodyworking home page describes how to calculate the height. Scania distributors
can also provide information on the height of a chassis.

Front
Electronically controlled air suspension, ELC (Electronic Level
Control) - Front
Chassis Chassis Front axle Dimension U Max. Max. Comment
height raised lowered

4x2 Normal AMA860 980 +220 -80

6x2
6x2*4
6x2/4
6x4
8x2/4
8x4*4
4x2 Normal AMA740 980 +187 -60
6x2
6x2*4
6x2/4
6x4
8x4*4
8x2 Normal AMA860 980 +160 -80
8x2*6
8x4
8x2 Normal AMA740 980 +160 -60
8x2*6
8x4
4x2 Low AMA860 950 +167 -80 Produced before
6x2 February 2000
6x2*4
4x2 Low AMA860 930 +187 -62 Produced after
6x2 February 2000
6x2*4
6x2/4 Low AMA860 880 +110 -60
4x2 Extra low AMA860 880 +110 -60

U, measured from top of frame to ground at front axle centre or centre

between front axles, for chassis weight with 295/80R22.5 tyres.

14 © Scania CV AB 2002
 Compressed air system / Brakes, Suspension 10

Leaf spring suspension - Front

Front axle Suspension Dimension U with Dimension U with

axle weight 3 000 kg axle weight 6 000 kg
AM620/621 2x30 1030 950
2x32 1030 960
7x15 1080 1000
AM740 2x30 1000 920
2x32 1000 930
3x29 1040 980
AM860 2x30 940 860
2x32 940 870
AM820/920 2x32 1030 970
3x29 1070 1010
4x28 1080 1030
9x15 1130 1060
AM900 2x30 1110 1030
2x32 1110 1040
3x29 1150 1090
4x28 1160 1100
AMD900 2x32 1220 1160
3x29 1230 1170

U, measured from top of frame to ground at front axle centre or centre

between front axles, at different loads with 295/80R22.5 tyres.

© Scania CV AB 2002 15
 Compressed air system / Brakes, Suspension 10

Rear
Mechanically controlled air suspension - Rear
Chassis Chassis height Rear axle Dimension V Max. Max. Comment
raised lowered
4x2 Normal ADA1100/1300 1 000 +167 -88
4x2 Low ADA1100/1300 970 +196 -59 Produced before
February 2000
4x2 Low ADA1100/1300 940 +161 -28 Produced after
February 2000

V, measured from top of frame to ground at centre of rear

axle, for chassis weight with 295/80R22.5 tyres.

Electronically controlled air suspension, ELC

(Electronic Level Control) - Rear
Chassis Chassis Rear axle Dimension V Max. Max. Comment
height raised lowered

4x2 Normal ADA1100/1300 1 000 +167 -88

6x2
6x2*4
8x2
8x2*6
4x2 Normal ADA1500P 1 000 +167 -82
6x2
6x2*4
8x2
8x2*6
6x4 Normal ADA1100/1300 1 000 +110 -69
8x4
8x4*4
6x2/4 Normal ADA1100/1300 1 000 +135 -88
8x2/4
8x2/4 Normal ADA1500P 1 000 +135 -82
4x2 Low ADA1100/1300 970 +196 -59 Produced before
6x2 February 2000
6x2*4
4x2 Low ADA1100/1300 940 +165 -30 Produced after
6x2 February 2000
6x2*4
6x2/4 Low ADA1100/1300 890 +155 -53
4x2 Extra low ADA1100/1300 870 +170 -34

V, measured from top of frame to ground at centre of rear axle (driving axle) or
bogie, for chassis weight with 295/80R22.5 tyres.

16 © Scania CV AB 2002
 Compressed air system / Brakes, Suspension 10

Leaf spring suspension - Rear 4x2

Suspension Dimension V Dimension V Comment
with axle weight with axle weight
5 000 kg 10 000 kg
3x26+2x26 1030 960 With AM900 add 78 mm
7x15+6x14 1040 980
9x15+6x14 1080 1020
12x15+6x14 1140 1070

V, measured from top of frame to ground at centre of

rear axle at different loads with 295/80R22.5 tyres.

Leaf spring suspension - Rear 6x2, 8x2

Suspension Dimension V Dimension V Comment

with bogie weight with bogie weight
5 000 kg 19 000 kg
5x22 1140 1080 For ad 3100 reduce by 30 mm
1x15+10x13 1150 1090 For ad 3100 reduce by 30 mm

V, measured from top of frame to ground at centre of

driving axle at different loads with 295/80R22.5 tyres.

© Scania CV AB 2002 17
 Compressed air system / Brakes, Suspension 10

Leaf spring suspension - Rear 6x4, 8x4

Boogie Suspension Dimension V Dimension V
with bogie weight with bogie weight
5 000 kg 19 000 kg
BT200B 4x30 1040 950
4x41 1060 1010
BT200I 4x30 1070 980
4x41 1090 1040
BT201B 4x30 1030 950
4x41 1050 1010
10x20/90 1060 990
BT201I 4x30 1090 1000
4x41 1100 1060
10x20/90 1110 1040
BT300B 12x20/90 1100 1040
10x25/90 1100 1050
H/E 10x20/100 1100 1040
12x20/100 1100 1050

V, measured from top of frame to ground at centre of bogie at

different loads with 295/80R22.5 tyres.

Leaf spring suspension - Rear 4x4

Suspension Dimension V Dimension V
with axle weight with axle weight
5 000 kg 10 000 kg
3x26+2x26 1170 1110
9x15+6x14 1200 1130
V, measured from top of frame to ground at centre
of rear axle at different loads with 295/80R22.5
tyres.

18 © Scania CV AB 2002
 Compressed air system / Brakes, Suspension 10

Leaf spring suspension - Rear 6x6

Boogie Suspension Dimension V Dimension V
with bogie weight with bogie
5000 kg weight 19000 kg
BT300I 4x41 1190 1140
12x20/90 1220 1150
10x25/90 1210 1160

V, measured from top of frame to ground at centre of

bogie at different loads with 295/80R22.5 tyres.

Tyres
For tyres other than 295/80R22.5 the chassis height
changes. Adjust the height with the value obtained
from the table below.

For more accurate calculation of chassis height a

calculation should be performed according to the
height document that will be found on Scania’s
bodyworking home page.

Tyres Dimension
295/60R22.5 -60
305/60R22.5 -55
315/60R22.5 -50
385/65R22.5 10
275/70R22.5 -40
305/70R22.5 -25
315/70R22.5 -15
275/80R22.5 -15
315/80R22.5 10
11R22.5 0
12R22.5 15
13R22.5 30
10.00R20 0
11.00R20 15
12.00R20 35
12.00R24 80

© Scania CV AB 2002 19