Brake circuit diagram

Diagram 10. RADD - TR1/TR2, 6x4. RADD – BR, 6x4.

FSS-LEAF, RSS-LEAF, TRBR-HCF, TRBR-HCR, AIRDRY1, ABS-WHL.

See Position text for diagrams and Colour key and position text for the diagrams.

Brake circuit diagram

 Colour key and position text for the
diagrams
 1.2.3.: Front wheel circuit (dashed dark red 12 bar)
 4.5.6.: Rear wheel circuit (dashed dark blue 12 bar)
 7.8.: Parking circuit
 9.: Compressor part, primary tank part and extra air tank for air suspension 12 bar
 10.: Barometric press.
 11.: Cable to valves 5 and 5b
 12.: Socket for compressed air driven extra equipment

Position text for diagrams

 Position text for the 17. Blocking valve variants other
diagrams Hand control, parking connections may be
19. found.
1. Compressor brake
Safety valve (18 bar) for 21. Safety valve 10 bar Inlet to four-way protection
1a. P1
compressor valve
21a. Safety valve 15 bar
Air dryer with in-built P11 Port to front circuit
23. Test nipple
2a. pressure regulator and P12 Port to rear circuit
non-return valve 24. Four-way protection valve
P21 Port to front circuit
2b. Dry tank 25. Distributor nipple
P22 Port to rear circuit
The compressor's intake air 25a. Filter
3. P23 Port to parking brake
via the engine's air filter Drain valve for reservoir
26. 11.12.13.14 P24 Port to extra outlet
5. Quick release valve
For vehicles equipped
5b. Pilot valve with trailer brake, the
29. Load sensing valve
5d. Relay valve following is added:
Load sensing valve,
6. Single diaphragm cylinder 29a. controlled by bellows Control valve for trailer
A.
7. Air pressure gauge pressure brake
Low pressure indicator: Load sensing valve, B. Control lines, trailer brake
8. front and rear wheels 29b. controlled by bellows C. Supply lines, trailer brake
circuit container pressure Manual control, trailer
Low pressure indicator: 30. Two-way valve brake. Marked with line,
8a.
parking brake Relay valve for parking D. which implies only
31. available in certain
Low pressure indicator: AT- brake
8f. countries
regulator 33. Main brake cylinder
9a. Brake light contact SU. Supply (trailer)
34. Relay valve main brake
9b. Brake light contact CO. Control (trailer)
36. Solenoid valves ABS
9c. Brake light contact EM. Emergency (trailers)
Extra tank for air
Foot brake valve. P = 50. suspension vehicles, SEE. Service (trailers)
10. Primary circuit. certain variants The following electrical
S = Secondary circuit Pressure limiting valve 7.5– components are drawn
51. in the brake diagrams
Compressed air reservoir, 7.7 bar
11. Low pressure
front wheel circuit 12 bar 52a. Overflow valve 6.7–7.0 bar 200.
indicator
Compressed air reservoir, Overflow valve 10.0–10.4
12. 52b. Brake light
rear wheel circuit 12 bar bar 216A.
contact
Compressed air reservoir, 56. Air bellows
13. Brake light
parking brake 216B.
NOTE! The connection contact
Compressed air reservoir, for the four-way
14. Brake light
primary tank 12 bar protection valve 216C.
contact
Non-return valve, parking described here is the
15. Low pressure
brake most common. 218.
Depending on the indicator
Brake circuit diagram

FSS-LEAF, RSS-LEAF, UTRBRHC, AIRDRY1, RIGID

For information on colours, numbering and abbreviations respectively, see Coloured code for the pneumatic diagram, Full
component list and Abbreviations.

Component legend

1. Contact switch, brake light 7. Air compressor 14. Service brake valve

2. Pressure sensor, front brake 8. Air drier pipe 16. Parking brake valve

3. Pressure sensor, rear brake 9. Test nipple 17. Blocking valve

4. Contact switch, rear brake 10. Safety valve 19. Quick release valve

5. Contact switch, rear brake light 11. Air dryer 21. Trailer connections

6. Boost air intake 12. Air regenerator 22. Contact switch, parking brake
23. Air distributor (collector)

24. Contact switch, parking brake

25. Contact switch, parking brake

26. Drain valve

29. Four-way protection valve

33. Air reservoir, front

35. Air reservoir, rear

36. Air filter

37. Relay valve, parking brake

38. Air distributor nipple

39. 2–way valve

40. Retaining valve

41. Air reservoir, parking

44. Air reservoir, rear brake

45. Load sensing valve

48. Rear brake cylinder (double

membrane)

49. Front brake cylinder (double

membrane)

50. Rear brake cylinder (single

membrane)

A Air for seat suspension

B Air for gear selector lever

Brake circuit diagram

Coloured code for the pneumatic diagram

 Brown: Supply circuit
 Red: Front circuit
 Light blue: Suspension circuit
 Green: Parking circuit
 Dark blue: Rear circuit
 Yellow: Atmospheric pressure
 Dashed brown: Controlled pressure, supply circuit
 Dashed red: Controlled pressure, front circuit
 Dashed green: Controlled pressure, parking circuit
 Dashed dark blue: Controlled pressure, rear circuit

Full component list

1. Contact switch, brake light 16. Parking brake valve

2. Pressure sensor, front brake 17. Blocking valve 31. Air distributor (collector)

3. Pressure sensor, rear brake 18. Contact switch, trailer brake 32. Contact switch, air suspension

4. Contact switch, rear brake 19. Quick release valve 33. Air reservoir, front

5. Contact switch, rear brake light 20. Front brake cylinder (single 34. Pressure limiting valve
membrane)

6. Boost air intake 35. Air reservoir, rear

21. Trailer connections

7. Air compressor 36. Air filter

22. Contact switch, parking brake

8. Air drier pipe 37. Relay valve, parking brake

23. Air distributor (collector)

9. Test nipple 38. Air distributor nipple

24. Contact switch, parking brake

10. Safety valve 39. 2–way valve

25. Contact switch, parking brake

11. Air dryer 40. Retaining valve

26. Drain valve

12. Air regenerator 41. Air reservoir, parking

27. Air reservoir, moist

13. Relay valve, trailer 42. Level control valve

28. Pressure retaining valve for trailer

14. Service brake valve 43. Air distributor

29. Four-way protection valve

15. Trailer brake valve 44. Air reservoir, rear brake

30. Pressure sensor, air suspension
45. Load sensing valve

46. Air distributor nipple

47. Air bellows, rear suspension

48. Rear brake cylinder (double

membrane)

49. Front brake cylinder (double

membrane)

50. Rear brake cylinder (single

membrane)

51. Solenoid valve

A Air for seat suspension

B Air for gear selector lever

Abbreviations

4x2 Vehicle with 4 support FSS-LEAF Front suspension system, TRACTOR Tractor vehicle
point and 2 traction point leaf springs

TRBR- Full brake pressure control,

6x4 Vehicle with 6 support LOADSV Load sensing valve HCF trailer
point and 4 traction point

RIGID Rigid vehicle, platform type UBAS Without anti-lock brake

ABS Anti-lock brake system system

RSS-AIR point Rear suspension

AIRDRY1 Single tower air drier system, air suspension ULOADSV Without load sensing valve

FSS-AIR Front suspension system, RSS-LEAF Rear suspension system, UTRBRHC Without brake manual
air suspension leaf springs control, trailer

Air drier

AIRDRY1 VERSION2
Air drier, general
The compressor generates and supplies compressed air. The compressed air contains water, oil and other
impurities that need to be separated from the air before it reaches the pneumatic system. The purpose of the
air drier is to purify and dry the compressed air.

When compressing air, the air temperature rises. The water and oil therefore leave the compressor in the form
as vapour and will remain in this form until the temperature falls.

By reducing the air temperature, the vapour condenses into fluid. The reduction of air temperature and
condensation occurs in the cooling coil between the compressor and air drier.

In order to achieve ultimate drying capacity, the cooling coil must be designed so that the inlet air
temperature is no less than +5°C and no more than +65°C.

If the temperature is less than +5°C, the air between the compressor and air drier risks freezing. If the
temperature exceeds +65°C, the air will contain excessive water and oil vapour which negatively affects the
outlet air quality and shortens the desiccant lifespan. An inlet air temperature that is too high may damage
the inside of the air drier.

Condensation is collected in the air drier, before the desiccant, and then drained. Any remaining water and oil
is efficiently detained
(adsorption*) by the desiccant. During the relief phase, a regeneration is performed (desorption **), purifying
the desiccant of impurities.

* Adsorption = Process where water and oil molecules are adsorbed by the desiccant under high pressure.

** Desorption = The opposite to adsorption. Process where the desiccant (during a reduction of the pressure in
the relief phase) releases water and oil molecules. At the same time, a return flow of dried air is passed
through the desiccant adsorbing water and oil. The return flow is then drained out into the atmosphere via a
relief valve. This process is also called regeneration.

A certain amount of oil will show on the air drier silencer, which is normal and does not require any action.

A frost prevention device (alcohol evaporator) must not be installed upstream of the air drier.

The air drier uses outlet port 12/4 Fig. to control the POWER REDUCTION FUNCTIONS (PR functions) of the
compressor. The air driers also have integrated pressure regulators and non-return valves.

Vehicles with AIRDRY air driers have a system pressure of either 8.5 or 12 bars.

Air drier, design

The purpose of the air drier is to dry and purify the air supplied by the compressor. The air drier primarily
consists of an air drier housing with anchorage, a number of air connections, a desiccant reservoir with a ring
filter and a relief valve with a heat unit. The air drier also has an integrated pressure regulator and non-return
valve.

The air drier is equipped with a replaceable cassette (bayonet mount) containing desiccant. The complete
cassette is changed. The desiccant consists of a large number of porous pellets (granules) with extensive
moisture absorbing contact area. A frost prevention device (alcohol evaporator) must not be installed
upstream of the air drier.

In the air drier, the air first passes through a ring filter collecting water, oil and impurities which are then
drained through the relief valve in the base of the air drier when the air drier ventilates and the compressor
unloads. After this, the air flows through the drying compound container, where moisture is separated, and is
thus prevented from entering the brake system. Around the pressure relief valve, there is a thermostatically
controlled heater that prevents ice forming in the air drier in cold weather. The pressure relief valve has a
silencer, to cut the noise level during venting.

Air drier, function

The air is dried through adsorption on a granulated, highly porous drying agent. The desiccant collects
moisture when the pressurised air flows through it. To regenerate the drying agent, some of the dried air is
allowed to expand to atmospheric pressure, and flow in the reverse direction through the drying agent. The
regenerated air absorbs and transports away the moisture that was previously bound to the drying agent
through the relief valve.

Intelligent fan control (FAN-Vise)

The idle speed of the engine cooling fan (FAN-VISE) is lower than on previous fans, reducing the cooling
capacity of the cooling coil at low speeds.

To secure the cooling capacity on vehicles with this type of fan, an intelligent fan control has been introduced
that engages the fan to at least 50% when the compressor is charging.

The fan control only functions when the outside temperature is above +10°C, the engine speed exceeds 700
rpm and the speed is less than 45 km/h.

There are two ways in which the fan can detect if the compressor is charging, depending on whether it is an
air or leaf spring vehicle. On air spring vehicles, the signal is received from an existing system pressure sensor
(a low or rising pressure means that the compressor is charging). On leaf spring vehicles, the signal is
received from a pressure switch installed on the control cable between the compressor and air drier.

Air drier, charging function

The air from the compressor flows via port 1 (marked 1 in the illustration), through the fine filter (8) where it is
cleaned from impurities such as water and oil. As the air is cooled in the ring filter, some of the moisture will
condense here and be collected in the pre-drying chamber (10).

The air continues through the drying agent (9) where the actual drying takes place, to the non-return valve 7
that opens to allow air to flow via port 21(marked 2/21 in the illustration) into the compressed air system tank.
The regeneration reservoir is filled at the same time via a restrictor (11) and port 22 (marked 3/22 in the
illustration). The cleaning and pre-drying performed by the fine filter has a positive effect on the life and
efficiency of the drying agent.

During charging, there should be no air leakage through the silencer.

Air drier, relief function

When full pressure has been reached in the compressed air system, the pressure relief valve (5) is opened in
the base of the air dryer, by means of a pneumatic signal from the pressure regulator.

The air delivered by the compressor and the air in the air drier flows via the vent (4) out to the open air. In this
way, the collected condensed water and a large portion of the contamination is removed.

The dry air in the regeneration reservoir flows via port 22 (marked 3/22 in the illustration) to the restrictor (11)
where it expands to the same pressure as the surrounding air. The air then flows through the moist drying
agent (9) and frees the bound water before it flows out into the open air via the ring filter (8) and the relief
valve (5). Regeneration time is about 15 seconds. The non-return valve (7) prevents air from flowing back out
of the compressed air tanks.

Air drier, power reduction function

When the pressure regulator (6) sends a signal to the relief valve (5), a signal is also sent via port 12/4 to the
compressor's relief function Power Reduction. During the relief phase, no or only a small amount of air flows
through the air vent (4).

When the system pressure has fallen to the set value, the signal pressure is evacuated and the PR function of
the compressor is reset for charging.

Air drier, heating function

To prevent the relief valve (5) from freezing during harsh weather conditions, the air drier housing is equipped
with an electric heater (13). The heater is thermostatically controlled and connected via a generator-controlled
relay preventing the battery from running low when the engine is turned off.

Air drier, heater unit

The air drier heater is provided to prevent condensed water in the pressure relief valve from freezing. The
electric heater unit is thermostatically controlled and engages at a temperature of 7±6°C and disengages at
approx. 29.5±3°C. The output of the heater unit is approx. 90-100 W.

Air drier, checking drying function

Check regularly if there is water in the compressed air tanks and if the drier is functioning. Perform this check
by opening the drain valve in the primary tank immediately after the air drier. If there is water in the
compressed air tanks, refer to Service Information Malfunctions for Group 56.

Drain valve, compressed air reservoir

All compressed air reservoirs except the regeneration reservoir are provided with manual drain valves, which
allow condensed water to be drained from the reservoirs. Emptying should be done regularly to check the
function of the air drier and to prevent any condensed water from being carried on into the brake system.

Air drier

AIRDRY1 VERSION2
Air drier with built in pressure regulator and non-return
valve

Make..... Wabco

Type..... 1 tower

Dry tank (Regeneration reservoir) Volvo part No...... 20392304

Volume..... 6 dm³

The relief valve's heating is:

In when the temperature falls below ..... +7°C±6°C

Out when the temperature rise to above ..... +29.5°C±3.0°C

For vehicles with a system pressure of 850 kPa (8.5 bar)

Air drier, Volvo part No...... 20410157

The pressure regulator's cut-out pressure..... 830-870 kPa (8.3-8.7 bar)

Pressure regulator's cut-in pressure, lower than cut-out pressure.....

0.7 +0,5
/–0bar
For vehicles with a system pressure of 1200 kPa (12bar)

Air drier, Volvo part No...... 20410156

The pressure regulator's cut-out pressure..... 1180-1220 kPa (11.8-12.2 bar)

Pressure regulator's cut-in pressure, lower than cut-out pressure.....

0.9 +0,7
/–0bar

Air drier

AIRDRY-E
Air drier, general
The new electronic air drier works according to the same principles as it's air-controlled predecessor. The
difference is that the new air drier is controlled electronically. If the air drier should for some reason become
powerless, it will cease to function and the desiccant will become wet through, while the compressor will
continue to charge. Relief is provided via the safety valve.

By using information from the chassis electronic system, air drier and compressor management can be
optimized so that air drying can be guaranteed and fuel consumption can be reduced.
Air drier, earlier version with heater cartridge

A: Compressor. B: Cooling coil. C: Air drier D: Vehicle control unit. (VECU) E: Air system. F: Solenoid valve,
regeneration. G: Solenoid valve, relief. H :Electrical control signal, compressor. I: Electrical control signal,
regeneration. J: Check valve. K: Data links: 1587/1939. The following values are aquired via these links:
System pressure, engine speed, engine elapsed time, ambient temperature and vehicle speed. L: Power
supply to heating element. M: Thermostatically controlled heating element in relief valve.

Air drier, later version without heater cartridge

The electronically controlled air drier's heater cartridge (M, L) has, from CHID: A606749, CHID: B405545 and
CHID: CKD862786 (CKD= COMPLETE KNOCKED DOWN) been excluded. The reason being that the air drier
already has a built-in function to prevent freezing or blocking of the air drier. The function provides temporary
relief (air drier blow clean) at engine shut down. This function eliminates the problem of freezing on a
stationary vehicle.

Air driers, with and without heater cartridges, are exchangeable; they are otherwise identical. Only air driers
without heater cartridges will be supplied as spare parts.

LATER VERSION WITHOUT HEATER CARTRIDGE

A: Compressor. B: Cooling coil. C: Air drier D: Vehicle control unit. E: Air system. F: Solenoid valve,
regeneration. G: Solenoid valve, relief. H :Electrical control signal, compressor. I: Electrical control signal,
regeneration. J: Check valve. K: Data links: 1587/1939. The following values are obtained from these links:
System pressure, engine speed, engine elapsed time, ambient temperature and vehicle speed.

Electronic air drier functions

Drier control

Icon on display

A function controls the regeneration of the air drier and ensures that the air fed to the vehicle compressed air
system is dry, even after long charging periods.

The controlling strategy is based on the system monitoring the pumped air volume (charging interval) and
regenerates (return flow from the system) dependant on this volume. There is no longer a separate
regeneration tank. If one regeneration cycle is insufficient to perform a complete regeneration, the system will
remember this (even after engine shut off) and continue at the next suitable situation, until complete
regeneration has been achieved.

If the charging time is so long that there is a risk that undried air may pass through the air drier, the charging
procedure will be interrupted and a forced regeneration will be performed. When this occurs, an icon is shown
on the display to draw the drivers attention to the fact (See figure). If charging is continued anyway, there will
be a number of charging stops associated with regeneration, which means that no air is supplied to the
system before charging is finished and a normal regeneration can be performed.

The air pressure is however always sufficient for maximum brake performance and for supplying lifting power
to the air suspension. Below 8.5 bars pressure, charging will be the first priority. Above 8.5 bars pressure,
regeneration will be the first priority, however with large consumption, regeneration may be shortened. In
practice this can mean that the air pressure may temporarily be somewhat under 8.5 bar, since it can take a
few seconds to complete an ongoing regeneration.

To further improve the drying function, the memory for the volume of undried air is increased with each
engine turn off (ignition key turn to off position), which increases regeneration without the compressor
pumping air. With repeated cycling of the ignition key between driving and stop positions (as with
downloading of software), the memory for undried air can be so large that a forced regeneration is performed
the next time the engine is started. For this reason, avoid unnecessary cycling of the ignition key.

When downloading software to several control units it is best to update the vehicle control unit last. The
ignition key can normally be cycled 10–15 times without any problems.

The allowed charging volume before a forced regeneration is dependant on vehicle speed. This means that
when the vehicle is standing still, a larger volume is accepted to minimize disruption (delays) during load
handling. A lower system pressure is also allowed to generate more regeneration air before the compressor is
connected in.

If the icon is lit during load handling, i.e. change of swap body, this is probably due to manual level controls
being left in the raise position. The controls should therefore be moved to the stop position to stop
unnecessary air consumption.

Compressor control
The function controls the connection and relief periods of the compressor, while at the same time reducing
fuel consumption by allowing the compressor charging periods to occur preferentially when descending
gradients or decelerating. As a side effect, the lifespan of the compressor is increased since the average
pressure in the system is lower.

At vehicle speeds below 30 km/h, full system pressure is allowed, to guarantee that the air tanks are
completely filled prior to the vehicle entering a load depot.

At speeds over 30 km/h a reduced system pressure applies, except when descending inclines or braking (no
fuel injection) when full system pressure is allowed, i.e. the system can be filled when charging does not
require any energy from the engine.

The air system's lowest pressure is adapted to the specification of the vehicle. An air-suspended bogie vehicle,
which requires higher system pressure, will not achieve the same fuel savings as a 4x2 with air suspension.

To improve the starting characteristics of the engine, the compressor is unloaded during starting, assuming
that the system pressure is above 7 bar.

To avoid freezing or blocking of the air drier while the engine is turned off, a temporary unloading is
performed (air drier blow through) at engine switch off. The unloading is only performed if the system
pressure is above 7 bar.

A yellow warning light illuminates if the system pressure exceeds 13 bar.

Service checks
Icon on display

This function helps the service personnel and vehicle owner to plan servicing and component exchange and
thereby reduces costs. On most of today's vehicles, the desiccant is changed too often or too seldom, which
results in high costs and poor functionality. On the electronically controlled air drier, an icon is displayed (see
figure) and a yellow warning lamp lights when it is time to change the desiccant.

By using VCADS PRO: it is possible to read off the calculated remaining mileage before the next desiccant
replacement. It is also possible to read off the total amount of pumped air for the compressor, which helps
determine when to perform a capacity check on the compressor.

The charge air volume is calculated from the charging time, system pressure and rotational speed.

Calibration must be performed after exchange of desiccant or compressor (reset running time). If another size
of compressor is fitted, the parameter data must be altered. It is also possible to alter the regeneration
frequency to suit the type of driving situation. All calibration and alteration of parameter data is performed
with VCADS PRO:.

Customers who do not wish to perform calibration when changing desiccant holders, can by using VCADS PRO:
turn off this function. This however excludes the possibility of reading off the remaining mileage to the next
desiccant replacement.

To ensure good air quality, both with regard to dampness and oil content, it is important that the
correct type of desiccant cartridge is mounted. Volvos desiccant cartridge contains, in addition to
desiccant, an oil filter.

Air leakage check/warning

Icon on display

The purpose of this function is to inform the driver that the compressor is charging abnormally, which is
usually an indication of an air leak, by using an icon (see figure) and a lamp on the display.

Two levels of warning are given. A white information lamp indicates increased fuel consumption. A yellow
warning lamp plus an icon indicates a risk for increase compressor and air drier wear, which can lead to
unplanned stops if the fault is not corrected.

The checks are only performed when driving above 50 km/h.

Managing fault codes

This function handles presentation of fault information. Both direct hardware faults and faults detected via the
logic in the software are displayed. For the faults stated, an icon is displayed and a warning lamp is lit. Fault
presentation (under vehicle control unit) follows the previous architecture for handling fault codes. The fault
codes are described in service information Vehicle control unit, fault codes under function group 36.
Air drier

AIRDRY-E

Electronically controlled air drier

Type .....1 tower

Min operating pressure .....7.5 bar

Max operating pressure .....13 bar

Thermal range of continuous application .....-40°C to +65°C

Resistance to heat .....+80°C (Max)

Torque for connections

M12 x 1.5 .....21Nm (max)

M16 x 1.5 .....35 Nm (max)

M22 x 1.5 .....53 Nm (max)

Connection and disconnection pressures:

The cut-in and cut-out pressure is set via the vehicle control unit software and cannot be altered.

For the appropriate programmed value, see the table below.

Regeneration:

Recirculation from the air system is controlled via parameters set in the vehicle control unit. The default value for
recirculation is 12% - 15% depending on the air drier.
On vehicles that for some reason cannot manage to dry the air (e.g. extreme use of the compressor), the
recirculation value can be increased using VCADS-PRO.

Supply voltage.....24V

Power consumption:

- Heating.....4A

- Solenoid valves.....0.32 A (governor) / 0.50 A (regeneration)

*Relief valve heating is:

- In when the temperature drops below.....+7°C ± 6°C

- Out when the temperature rises above.....+29.5°C ± 3.0°C

*The heating function only applies to some air driers.

Cut-in and cut-out pressures, value for AIRDRY-E

Variant Low speed / Engine braking * High speed

Normal mode Protective mode ** Normal mode Protective mode **

Cut-in Cut-out Minimum cut- Maximum cut- Cut-in Cut-out Minimum cut- Maximum cut-
pressure pressure in pressure out pressure pressure pressure in pressure out pressure

ASCOP120 10.6 bar 12.0 bar 8.6 bar 12.0 bar 9.6 bar 10.6 bar 9.6 bar 10.6 bar

Standard

ASCOP120 10.6 bar 12.0 bar 8.6 bar 12.0 bar 10.6 bar 12.0 bar 9.6 bar 12.0 bar

Leaf spring EBS

ASCOP85 7.5 bar 8.5 bar 7.0 bar 8.5 bar 7.5 bar 8.5 bar 7.5 bar 8.5 bar

Leaf spring suspension

ABS / UABS

ASCOP120 10.6 bar 12.0 bar 10.6 bar 12.0 bar 10.6 bar 12.0 bar 10.6 bar 12.0 bar

Pusher

ASCOP100 9.0 bar 9.8 bar 9.0 bar 9.8 bar 9.0 bar 9.8 bar 9.0 bar 9.8 bar

Japan
* Speed lower than 30 km/h, and at higher speed in conjunction with engine braking.

** A fault code is set in the vehicle control unit, MID144 Protective mode = Control unit goes to protective mode (exceeds
time out) for air pumping and has drying of air by relieving the compressor as priority and performs forced regeneration of the
air drier. This reduces the compressors ability to pump air out to the system. Air pressure is however always ensured so that
braking power and lifting power for air suspension is retained.

Air drier
The task of the air drier is to dry and purify the air supplied by the compressor. The air drier mainly consists of
an air drier housing with attachment, a number of air connections, a drying agent container with ring filter, a
pressure relief valve and a heater. This air drier also has a built-in pressure regulator and a non-return valve.

The air drier is equipped with a replaceable cassette (screw fixing) which contains drying agent. The complete
cassette is changed. The drying agent contains a large number of balls of porous material (granulate) with a
very large surface area, which adsorbs the moisture. A frost prevention device (alcohol evaporator) must not
be installed upstream of the air drier.

In the air drier, the air first passes through a ring filter, which collects water drops, oil and contamination,
which is drained through the pressure relief valve in the base of the air drier, when the air drier is vented and
relieves pressure on the compressor. After this, the air flows through the drying compound container, where
moisture is separated, and is thus prevented from entering the brake system. Around the pressure relief
valve, there is a thermostatically controlled heater which prevents ice formation in cold weather. The pressure
relief valve has a silencer, to cut the noise level during venting.

The air is dried by adsorption on a granulated, highly porous drying agent (molecular filter). When the
compressed air flows through the drying agent, the water vapour in the air is bound to the drying agent. To
regenerate the drying agent, some of the dried air is allowed to expand to atmospheric pressure, and flow in
the reverse direction through the drying agent. In this way, the regeneration air can absorb the moisture
which was previously bound by the drying agent.

Charging function
Air from the compressor flows via port (1) and on through the ring filter (9) where it is purified from water and
oil contamination. Since the air is cooled in the ring filter, some of the moisture condenses here already, and
collects in the pre-drying chamber (11).

The air continues through the drying agent (10), where the real drying takes place, and continues on to non-
return valve (8) which opens and the air flows in via port (2) to the tank in the compressed air system. The
regeneration reservoir is filled via a restriction (12) and port (3) at the same time. The filtering and pre-drying
provided by the ring filter have a very positive influence on the service life and efficiency of the drying agent.
 1. Compressor port (Port on air drier is marked 1)
2. Primary reservoir port (Port on air drier is marked 21)
3. Regeneration reservoir port (Port on air drier is marked 22)
4. Pressure relief
5. Air signal from pressure regulator
6. Pressure relief valve
7. Pressure regulator
8. Non-return valve (Port on air drier is marked 5)
9. Ring filter
10. Drying compound
11. Pre-drying chamber
12. Restriction

Pressure relief function

When full pressure has been reached in the compressed air system, the pressure relief valve (6) is opened in
the base of the air dryer, by means of a pneumatic signal from the pressure regulator.

The air which the compressor continues to deliver, plus the air in the air drier, flow out via the pressure relief
valve (4) into the atmosphere. In this way, the collected condensate and a large portion of the contamination
is removed.

The dry air in the regeneration reservoir flows via port (3) to restriction (12) and expands to the same
pressure there as the surrounding atmosphere. After this, the air flows out through the damp drying agent
(10) and relieves it of its bound water, before it flows on and out into the atmosphere via the ring filter (9) and
pressure relief valve (6). Regeneration time is about 15 seconds. The non-return valve (8) prevents air from
flowing back out of the compressed air tanks.

1. Compressor port (Port on air drier is marked 1)

2. Primary reservoir port (Port on air drier is marked 21)
3. Regeneration reservoir port (Port on air drier is marked 22)
4. Pressure relief
5. Air signal from pressure regulator
6. Pressure relief valve
7. Pressure regulator
8. Non-return valve (Port on air drier is marked 5)
9. Ring filter
 10. Drying compound
11. Pre-drying chamber
12. Restriction

Checking the drying function

If you regularly check that there is no water in the compressed air tanks, you check whether the drier is
functioning. This check is done by opening the drain valve in the primary tank immediately after the air drier.
Leaks in the compressed air system affects the charging phase of the compressor and affects the
drying function negatively. If the drying agent gets wet, it ceases to function.

Heating
The air drier housing is provided with an electric heater (resistance heater) in the area adjacent to the
pressure relief valve (7), to prevent the pressure relief valve from freezing in unfavourable weather. The
current supplied to the heater, which is thermostatically controlled, is connected via a relay controlled by the
alternator, to prevent the battery from becoming discharged when the engine is not running.

Air drier
Air drier with built in pressure regulator and non-return valve

Designation..... LA82

Type..... 1 tower

Dry tank (regeneration reservoir) (pos. 2b) Volvo part no...... 1075397

Volume..... 6 dm³

The relief valve's heating is:

engaged when the temperature falls below..... +7°C±6°C

disengaged when the temperature rises above..... +29°C±3.5°C

For all trucks with RSS LEAF. System pressure 850 kPa, (8.5 bar)

Air drier, Volvo part no...... 8122460

The pressure regulator's cut-out pressure..... 810-890 kPa (8.1-8.9 bar)

Pressure regulator cut-in pressure, lower than cut-out pressure..... 0.8±bar

For 4x2 TRACTOR with FSS-LEAF and RSS-AIR. System pressure

1200 kPa (12 bar)

Air drier, Volvo part no...... 3172999

The pressure regulator's cut-out pressure..... 1160-1240 kPa (11.6-12.4

bar)

Pressure regulator cut-in pressure, lower than cut-out pressure.....

0.8 +0.6
/–0.5bar

56166-3 5618-03-03-04 Air drier cassett, replace

Note: The same illustrations are reused for different variants. Some details may differ from the variant you are working on. The
essential information in the illustrations is, however, always correct.

Special tools: 9992976, 9998313

1

Caution

Follow the instructions carefully to avoid personal injury and damage to the product or equipment.

Special tools: 9992976

A = 9998313

Special tools: 9998313

4
Replace the O-ring, included in Kit.
Check that the inlet in the middle from the drier insert to the drier housing is clean, otherwise the drier insert has failed or the
compressor oil consumption is too high. Abnormal carbonization in the air drier requires an inspection of the cooling coil,
56176-2 5617-06-02-02 Cooling coil, compressor, check and if necessary replacement.
Clean the drier housing internally.
Spread a thin layer of grease on the sealing surfaces and threads.

5 Install the new drier insert until it is against the housing. Tighten by hand another 1/2 turn.

6 Calibration shall be performed if the drier insert is replaced. Customers who do not wish to perform calibration when
replacing the drier insert can turn the function off with Vcads-Pro. This removes the possibility of reading off the remaining
mileage until the next drier insert replacement.

7 Connect the PC...Reset the parameter, Air drier cartridge...Close the test and disconnect PC.

56136-2 Air drier non return valve, replace

AIRDRY1 VERSION2
Special tools: 9992976

Cau
tion
Follow the instructions carefully to avoid personal injury and damage to the product or equipment.

2 Note: Make sure that the parking brake is applied.

Raise the cab.

Empty the air out of the compressed air system, use nipple 9992976.

Special tools: 9992976

3 Remove the plastic tube and nipple from the air drier port (21).

4 Screw the non-return valve out from the air drier port (21). The non-return valve consists of plastic nut,
spring and valve cone.

Clean and fit the new non-return valve.

6 Replace the nipple and tube in the air drier.

7 Carry out 56158-2 Non-return valve, check.

8 Carry out a function test. Lower the cab.

56126-2 Air drier, drier insert, replace

Special tools: 9998313

Other special equipment: 1159680

AIRDRY1
1

Cau
tion
Follow the instructions carefully to avoid injury or damage to property.
Neglect to do so may result in minor or moderate injury or damage to property.

2 Check to make sure the parking brake is applied.

3 Drain the truck compressed-air system. Tilt the cab.

4
Clean the filter container and remove it, using a filter wrench.

Special tools: 9998313

Clean the sealing surfaces and the threaded spindle.

6 Apply a thin coating of grease to the sealing ring and the threaded spindle. Screw on the container by hand
until the sealing ring is flush with the air drier housing. Then tighten the container about another one full-turn
by hand.

7 Make a note on the filter container when the change was carried out (year, month).

8 Fill the compressed air system with air until the compressor is load-relieved and the air drier is bled. Use a
leakage tracing instrument to check that the air drier is tight during charging.

Other special equipment: 1159680

9 Lower the cab.

56126-2 5618-03-02-01 Air drier, drier insert, replace

Note: The same illustrations are reused for different variants. Some details may differ from the variant you are working on. The
essential information in the illustrations is, however, always correct.

Part number: 88890086

Special tools: 9992976, 9998313

Caution

Follow the instructions carefully to avoid personal injury and damage to the product or equipment.
2 Apply the parking brake.

Special tools: 9992976

A = 9998313

Special tools: 9998313

6
Check that the inlet in the middle from the drier insert to the drier housing is clean, otherwise the desiccant reservoir has failed
or the compressor's oil consumption is too high. Abnormal carbonization in the air drier requires an inspection of the cooling
coil. Refer to: 56176-2 5617-06-02-02 Cooling coil, compressor, check and if necessary replacement.
Clean the drier housing internally.
Spread a thin layer of grease on the sealing surfaces and threads.

Note: Replace O-ring (included in the desiccant reservoir kit).

Screw in the new desiccant reservoir until it is against the housing. Tighten by hand another 1/2 turn. (approx. 20Nm).

Warning

When starting the engine with the cab tilted, make sure that the vehicle is not in gear and that the parking brake is applied.

9 Start the engine. Run the brake pressure up until the compressor disengages. Turn off the engine.
Perform a leakage check with leakage detector instrument 88890086 or use Volvo leak finder spray.

Part number: 88890086

10

11 Calibration is to be carried out when replacing desiccant reservoirs. Customers who do not wish to carry out calibration
when replacing desiccant reservoirs can shut off this function using VCADS-PRO. This removes the possibility of reading off
the remaining number of kilometers until the next desiccant reservoir replacement.

12 Connect the VCADS PC.

Reset the parameter for the desiccant reservoir.
Start calibration, wait until it is completed.
Close the test and disconnect VCADS PC.

56116-2 Air drier, replace

AIRDRY1 VERSION2
Special tools: 9992976

Cau
tion
Follow the instructions carefully to avoid personal injury and damage to the product or equipment.

2 Note: Check that the parking brake is applied.

Raise the cab.

Empty the air out of the compressed air system, use nipple 9992976.

Special tools: 9992976

3 Mark and remove the air connections to the air drier. Remove the electrical connections to the air drier
heater.

Remove the three fixing screws holding the air drier in the bracket. Lift out the air drier and place it in a vice.

5 Transfer the nipples and, if necessary, the silencer to the new air drier. Fit the nipples with new O-rings if
necessary. Use a thread sealant for nipples with a conical thread.

6 Check that the regeneration tank is free from water and oil. Clean the tank if necessary. If there is oil in the
regeneration tank, check the reason. Refer to service information Malfunctions in Group 56.

7
Fit the air connections together with new O rings in accordance with previous markings. Check that the angled
inlet pipe is angled to prevent standing water in the bend (there is a risk of freezing).

8 Connect and clamp the electrical connections to the heater.

9 Carry out 56133-2 Air drier, function check.

56116-2 5618-03-02-03 Air drier, replace

AIRDRY-E
Special tools: 9992976

Other special equipment: 88890086

Caution

Follow the instructions carefully to avoid personal injury or damage to products or equipment.

3 Check that the parking brake is applied. Tilt up the cab.

4
Special tools: 9992976

6 Mark up the air drier's air connections. If necessary, replace the sealing washers and O-rings.

7 If the replaced air drier is covered in oil or soot, the cooling coil must be checked. See 56176-2 5617-06-02-02 Cooling coil,
compressor, check and replace as needed.

Warning

When starting the engine with the cab tilted, make sure that the vehicle is not in gear and that the parking brake is applied.

9 After replacing the air drier. Fit the exhaust hose. Start the engine and fill the compressed air system until the compressor
disengages. Switch off the engine.

10 Perform a leakage check with leakage detector instrument 88890086 or use Volvo leak finder spray.

Other special equipment: 1159680

11 Remove the exhaust hose and lower the cab.

12 Calibration is to be carried out where air driers or desiccant reservoirs are replaced. Customers who do not wish to carry
out calibration when replacing air driers or desiccant reservoirs, can shut off this function. The ability to read remaining
mileage to the next desiccant change is however lost. Calibration or shut off is carried out using VCADS–PRO.

13 Connect the VCADS PC. Reset the parameter. Start calibration, wait until it is completed. Check for and if necessary
remove any fault codes. Close the test and disconnect VCADS PC.

14
When changing to a new air drier, confirm the parameter settings with VCADS–PRO in accordance with the following
information. Switch off and disconnect the PC.
A B Parameter settings
Old drier (part no.) New drier (part no.)

20466522, 20700794 20884103, 21398254, 21480094 CUB=12%

Note: This replacement (B->A) is only a temporary measure, applicable until the new type of drier can be fitted. The
drying effect will be reduced.
56130-2 Bleed valve, replace
AIRDRY-E
AIRDRY1

Cau
tion
Follow the instructions carefully to avoid personal injury or damage to the product or equipment.
Negligence can lead to minor or moderate personal injury or product damage.

Special tools: 9992976

Special tools: 9992976

War
nin
g
The draining pipe is spring loaded. Risk for personal injury. Be careful when removing the lock ring.

Remove the silencer at the bottom of the drier. If the condition of the silencer is in doubt, replace it.
On older version there is an O-ring for the pipe. This O-ring is not included in the new repair kit and may not
be reused.
Carefully bend out the relief valve and sealing, to avoid damaging the sealing surfaces.

4 Clean the housing internally. Inspect the condition of the sealing surfaces for wear, corrosion and damage. If
the condition of the air drier is in doubt, replace it.

War
nin
g
The draining pipe is spring loaded. Risk for personal injury.

Grease in the relief valve, seals and the inside of the housing. To facilitate fitting the washers, sparingly
grease them before fitting them into the milled out groove. It is important that the lock ring is locked in the
groove before fitting the draining pipe.

Note: Use only the type of grease that is supplied with the repair kit.

Cau
tion
When fitting the inner seal be careful not to damage the edges of the seal.

6 Fit the exhaust hose. Start the engine. Run the engine until the compressor and air drier are relieved.

8
Using the cooling coil filler nipple, pressurise the cooling coil with external air, to ensure that the repair work
been properly carried out.
Perform a leakage check with leakage detector instrument 1159680 or with Volvo leak finder spray. Remove
the air hose and test nipple 9992976 from the air drier.

Special tools: 9992976 1159680

Compressor

1COMP530
Compressor, general information
1COMP530 is a single-cylinder compressor. The task of the compressor is to provide both the truck and trailer
with compressed air. Compressed air is mainly used in the service brake system, but is also used for other
functions such as air suspension, ride height adjustment, gear change systems, clutch and differential lock.

Air consumption of the various models of trucks varies with their size and the amount of equipment which
uses compressed air. The compressor on the trucks included here has a cylinder and is driven by a gear wheel
directly via the engine transmission. The crankcase and the cylinder block are air-cooled, while the cylinder
head is cooled by liquid from the cooling system of the engine.

The compressor receives its lubrication via the pressure lubrication system of the engine and the main and
large end bearings are thus pressure lubricated. The small end bearing and piston are splash lubricated. The
oil used by a piston compressor to lubricate the piston and piston rings, is separated in the air drier and drains
out of the air drier during the compressor pressure relief phase (together with a considerably larger quantity
of water).

Note: A certain amount of oil will show on the air drier silencer, which is normal and does not require any
action.

Air flowing into the compressor is cleaned, dust and dirt particles being removed by the air filter of the engine.
Before the air flows into the pneumatic system, the air is dried in a separate air drier to prevent water from
getting into the system.
The air flowing from the compressor, which is frequently hotter than 150°C is directed through a coil of piping
of between 3 and 5 metres in length, to be cooled to about 60°C, before it enters the air drier. This is done to
get the highest possible efficiency in the air drier and to protect rubber components.

The size of the compressor is intended to fulfil the air requirements of the vehicle rapidly and to fill the
compressed air system. Its function can be divided into two phases; charging phase and pressure relief phase.

When the pre-set system pressure in the pressure regulator has been reached, the pressure regulator
transmits a signal to the air drier's release valve, which opens and lets out the old air together with water
collected in the air drier.

A new energy saving function Power Reduction (PR) has been introduced on these compressors. This is a relief
function that shuts off the compressor's air supply to the pneumatic system when the pre-set system pressure
in the pressure regulator is achieved. A small amount of the normal air volume will be allowed to flow from the
air drier silencer when the compressor is relieved. The PR signal to the compressor originates from the air
drier relief function.

When the system pressure has decreased to the pre-set connecting pressure, the pressure regulator closes
the release valve of the air drier which drains the PR connection, which closes the PR valve with the aid of a
return spring. The compressor now begins filling the compressed air system.

The idling speed of the electrically controlled cooling fan (FAN-VISE) is lower compared with earlier fans which
reduces the cooling capacity of the cooling loop at low speed.

In order to ensure cooling capacity in vehicles with this type of fan, an intelligent fan control has been
introduced which means that the fan is at least 50 % engaged when the compressor is charging.

The fan control only functions when the outside temperature is higher than + ºC, the engine speed is higher
than 700 r/m and the speed of the vehicle is less than 45 km/h.

There are two different ways for the fan to know when the compressor is charging, depending on whether the
vehicle has air suspension or leaf suspension. On vehicles with air suspension the signal comes from existing
system pressure sensors (low or increasing pressure means that the compressor is charging. On vehicles with
leaf suspension the signal comes from a pressure connection mounted on the control wire between the
compressor and the air drier.

Compressor, design
1COMP530 is a single-cylinder compressor used on FM and FH vehicles that require less air, e.g. tractor
vehicles and leaf spring vehicles. Its air capacity is 440 dm³/min with a back pressure of 800 kPa (8 bar) and
an engine speed of 1500 rpm. Maximum working pressure is 1300 kPa (13 bar).

The inlet and exhaust valves as well as the reed valve of the PR function are positioned underneath the
cylinder cover. The compressor's inlet and exhaust valves are of reed type that open pneumatically and close
by a spring. The exhaust valve is mounted with a holder on top of the valve plate, between the cylinder block
and cylinder head. The inlet valve is integrated in the cylinder head gasket. The PR function is controlled by a
piston rod connected to the reed valve.

The PR connection to the compressor for D12 engines is made via a steel nipple which is screwed down into
the intermediate plate of the cylinder head. On the compressor of the D9 engine, the PR connection is
screwed directly into the extension plate without a steel nipple. On this variant, the hole for the steel nipple is
plugged.

Note: Do not change these nipples for other types of standard nipples. Other types of nipples can put the PR
function at risk.

Cylinder head, cylinders with crankshaft are separate and separable units. The cylinder head is cooled by fluid
via the cooling system of the engine, while the crankshaft with the cylinder, is air-cooled. The piston has three
piston rings, two compression rings and one oil scraper ring.
The compressor is driven by a gear wheel fixed on the tapered shaft, without a Woodruff key. The compressor
flange and rear end plate of the crankshaft is fitted with bushings. The gudgeon pin is mounted directly in the
connecting rod without bushings.

The compressor has a greater cooling capacity and an integrated PR function. The cylinder head has been
made twice as large as the crankcase in order to make room for all these functions.

Compressor, function
A vacuum is created in the cylinder as the piston travels downwards and opens the inlet valve. The inlet ducts
are opened and the induction air, which has been filtered by the engine air filter, flows into the cylinder.

When the piston travels upwards, the inlet valve closes (by the pressure in the cylinder) and the induction air
is compressed.

When the piston approaches its top position and the pressure in the cylinder exceeds the pressure from the
spring and the air above the exhaust valve, the exhaust valve will open for the compressed air to pass into the
compressed air system.

Compressor, power reduction function

When the system pressure has reached the pre-set release pressure in the pressure regulator of the air drier,
the release valve opens and lets out the old air from the compressor, together with the water collected from
the air drier.

At the same time, the PR valve in the cylinder head of the compressor is activated by a pressure signal from
the pressure regulator, which causes air to be pumped to a dead volume in the cylinder head, instead of
delivering air to the compressed air system.

A small proportion of the normal amount of air from the compressor now flows out through the release valve
of the air drier and silencer, when the compressor runs released.

When the system pressure has come down to 100 kPa (1bar) the pressure regulator closes the release valve
of the air drier and drains the air pressure from the PR connection, which closes the PR valve with the help of a
return spring.

The compressor now begins charging the compressed air system.

In the PR function it is important to have the correct signal speed in order that the functions should work
satisfactorily. Signal connections which are not sealed cause the signal speed to be incorrect.

For further information on relieving the compressor, please refer to the service information Air drier for group
56.
A. Open position, compressor idle.
B. Closed position, compressor pumping.

Compressor Specification

1COMP530

Make..... WABCO 352

Type..... Piston
compressor

Number of cylinders..... 1

Cooling, cylinder head..... Fluid

Cooling, cylinder..... Air

Air capacity at a back pressure of 800 kPa (8 bar) and compressor speed of 2000
rpm..... 440 dm³/min

Max operating pressure..... 1300 kPa, (13

bar)

Max operating speed..... 3000 rpm

Cylinder bore..... 85 mm

Stroke..... 62 mm

Cylinder volume..... 352 cm³

PR function:

Cylinder stroke PR piston reed valve..... 10-15 mm

Compressor, tightening torques

Drive gear wheel..... 200-250 Nm

Nipple air outlet pipe..... 130 ± 20 Nm

Nipple, oil hose, compressor and engine block..... 25 ± 4 Nm

Cylinder head bolts 1-4. For the correct torque tightening order, see the above 25 ±2 Nm
figure.....

Cylinder head bolts 1-4. For correct tightening order and angle, see the above Tightening angle 90°
figure.....
+10
/–5
Bolts, valve plate (5-8). Please refer to the illustration below for the correct 10±1 Nm
torquing sequence:.....

Bolts, valve plate (5-8). Please refer to the above figure for the correct Tightening angle 90°
tightening angle order:.....
+10
/–5
Nipple, PR connection to compressor..... 25 ±4 Nm

Bolts, fixing, compressor..... 85 ±15 Nm

56111-2 Compressor, replace

Before perform the replacement of the air compressor, please check the information Cooling system, leak test.

1COMP530 FM12 FH12 2COM1080 VERSION2 FM12 FH12

Special tools: 9992976

Other special equipment: 9986172, 1159795, 1158957

Cau
tion
Follow the instructions carefully to avoid personal injury or damage to products or equipment.

2 Note: Apply the parking brake.

3 Empty the compressed air system, use nipple 9992976.

Special tools: 9992976

4 Remove the sound insulation from the frame.

5 Remove the PR function's plastic hose from the compressor.

6 Remove the air hose from the compressor. Loosen the brace if necessary.

7 Check that the air hose is not blocked by deposit, see service information Checking air supply system in
group 56. Replace the cooling coil if necessary.

8 Remove the hose clamp to the compressor air inlet pipe at the turbo intake pipe. Unscrew the lock brace on
the air inlet pipe and remove the inlet pipe and sealing ring.

9 Remove the engine air intake from the turbo compressor. Put the air intake onto the valve cover.

10 Clamp the compressor coolant hoses together, using hose pliers 1158957. Remove the coolant hoses from
the compressor and push them aside.

Other special equipment: 1158957

11 Remove the oil hose from the compressor.

12 Remove the compressor's retaining screws and remove the compressor with O-ring from the engine.
Empty the oil and water out of the compressor.

13 Lift up the compressor's gear wheel and secure it between soft jaw covers in a vice.

14

Remove the mounting nut and pull the gear wheel off the compressor with a puller 9986172.

Other special equipment: 9986172

15 Remove the connection nipples for the coolant hoses, the oil hose and the outlet pipe from the
compressor.

16 Clean all the components which are to be used in the new compressor. Inspect the gear wheel for damage.
If necessary, change the gear wheel.

17 Note: Clean the crankshaft end of the new compressor (exterior cone) as well as the interior cone in the gear
wheel, removing oil with the help of paper and grease-removing agent. Wipe the surfaces clean with dry paper.

18 Install the gear wheel on the compressor crankshaft, and hold the gear wheel firmly in a vice with soft jaw
covers.

19 Oil the nut flange facing the gear wheel, and tighten it. Torque the nut to 200-250 Nm, using torque
wrench 1159795.
Other special equipment: 1159795
Specifications:
225±25 Nm

20 Put in the connection nipples for the coolant hoses, the oil hose and the outlet pipe on the new
compressor. Replace old gaskets with new ones, and use thread sealing fluid on threaded unions.

Note: Some nipples have a conical thread. Do not over tighten.

21 Clean the mating surfaces on the engine and the compressor. Install a new O ring. Install the compressor
and tighten the fixing screws alternately, so that the compressor is drawn in correctly. Torque tighten the
screw union with a torque wrench 1159795. Tightening torque 85±Nm.

Other special equipment: 1159795

Specifications:
85 ±15 Nm

22 Install the coolant hoses, tighten the hose clamps and remove the hose pliers.

23 Check the oil hose to make sure there are no cracks. Replace the hose if necessary. Put the oil hose on the
compressor

Note: Check that the oil hose does not rub against adjacent components.

24 Put on the air inlet pipe with a new greased sealing ring. Put on the lock brace.

25 Put the compressor's air inlet pipe onto the turbo compressor's inlet.

26 Install the air cooler coil. Tighten the loosened clamps.

27 Put the PR function's plastic pipe onto the compressor. Check that the plastic pipe is undamaged and that
the screw fitting does not leak air. This is important in order that the PR function should function faultlessly.

28 Fill the compressed air system with air, use the nipple 9992976

Special tools: 9992976

29 Carry out 56123-3 Compressor, function and leakage check.

30 Install the sound insulation barrier on the frame.

Cooling system, leak test
Together with compressor, replace

The number of air compressors which are replaced because of water leakage is on the increase. Checks on
returned compressors which are the subject of claims shows that leakage was only found in a very small
number. The leakage could come from another part of the engine cooling system instead, such as the
thermostat housing, which is located above the air compressor.

If you suspect coolant leakage from the cooling system and / or compressor, the cooling system must be
pressure tested to find the source of any leakage. Coolant leakage can be difficult to find, so pressure test the
cooling system when the coolant is both hot and cold. Check carefully to see whether leakage occurs.

For further information about Leakage check, cooling system please refer to the Service Manual, Group 26,
Cooling system, D12A. The instructions for leakage checking of the cooling system are general, and apply to
all engine variants.

56164-4 5611-03-04-03 Cylinder head gasket, compressor, replace

1COMP530
Other special equipment: 1159795

Caution

Follow the instructions carefully to avoid personal injury or damage to products or equipment.

2 Clean the outside of the compressor.

3 Mark up the cylinder head and middle plate in relation to the compressor housing.

4 Remove all the bolts from the cylinder head. Lift the cylinder head from the compressor housing.

5 Clean the sealant surfaces on the compressor housing, middle section and cylinder head.

6
Also clean the space where the reed valves are placed. Remove the PR function nipple. Check that the PR piston to the reed
valve has its full cylinder stroke 10-15 mm by pressing the spring-loaded link arm, see the arrow in the picture. Use a blunt
instrument in order to avoid damage. Place and tighten the nipple. Tightening torque 25±4 Nm

Note: Check that the travel of the reed valve can also be made on the compressor in the vehicle.

Specifications:
10-15 mm
25 ±4 Nm

Clean the sealing surface on the compressor housing. The arrow shows where the movable part of the suction leaf should be
placed.

Suction leaf placed in the compressor housing.

Place the suction leaf in the compressor housing. The movable part of the suction leaf is placed against the somewhat larger
bevelling on the surface of the compressor housing. Check that the suction leaf is the right way round. The round hole on the
suction leaf, which can be seen in the top left of the picture, should match up with the locating pin of the reed valve in the left
of the picture, under point 15.

Place the four coarser studs in the cylinder head in order to guide gaskets and other parts during assembly.

10
Place a new gasket on the cylinder head. Check that the gasket is the right way up and that the configuration of the holes is
correct.

11

Place a new plate on the gasket. Check that the plate is the right way up and that the configuration of the holes is correct.

12

Place a new gasket on the new plate. Check that the gasket is the right way up and that the configuration of the holes is
correct.

13 Place the middle section on the cylinder head in conformity with the marks which were made during disassembly.

14 Turn the cylinder head unit over. Bolt together the cylinder head unit. Do not torque tighten them at present.

15

Suction leaf placed in the compressor housing.

Spread a thin layer of grease on the underside of the reed valve to keep it in position when you assemble the cylinder head.
Place the reed valves on the middle plate. In order to guide the reed valves, the holes should be placed on the pins which are
on the cylinder head, see arrows on the picture.

16 Put the assembled cylinder head unit on the compressor housing in conformity with the markings made earlier.

17
Note: Replace the cylinder bolts with the replacements included in the gasket kit.

Position the eight cylinder head bolts.

Tighten 1-4 to a torque of 25±2 Nm.

Tighten 1-4 at an angle of 90° +10 /–5

Tighten 5-8 to a torque of 10±1 Nm.

Tighten 5-8 at an angle of 90° +10 /–5

Torque spanner 1159795.

Other special equipment: 1159795

56163-4 5611-03-04-02 Cylinder head, compressor, replace

1COMP530
Other special equipment: 1159795

Caution

Follow the instructions carefully to avoid personal injury or damage to products or equipment.

2 Clean the outside of the compressor.

3 Remove the connection nipples for coolant and air from the old cylinder head.

4 Mark up the cylinder head in relation to the compressor housing.

5 Remove the M8 bolts from the cylinder head. Do not remove the two M6 bolts that hold the metal plate onto the cylinder
head. Lift the cylinder head and the metal plate from the compressor housing.

6 Remove the M6 bolts retaining the metal plate.

7
Clean the sealing surface on the compressor housing. The arrow shows where the movable part of the suction leaf should be
placed.

Suction leaf placed in the compressor housing.

Place the suction leaf in the compressor housing. The movable part of the suction leaf is placed against the somewhat larger
bevelling on the surface of the compressor housing. Check that the suction leaf is the right way round. The round hole on the
suction leaf, which can be seen in the top left of the picture, should match up with the locating pin of the reed valve in the left
of the picture, under point 8.

Reed valve placed on the middle plate.

Spread a thin layer of grease on the underside of the reed valve, in order to keep it in position when assembling the cylinder
head. Place the reed valve on the middle plate. In order to guide the reed valve, the holes should be placed on the pins which
are on the cylinder head, see arrows on the picture.

10 Put the new cylinder head on the middle plate of the compressor housing in conformity with the markings which were made
on the old cylinder head.

11
Note: Replace the cylinder head bolts with the replacements included in the cylinder head kit.

Position the eight cylinder head bolts.

Tighten 1-4 to a torque of 25±2 Nm.

Tighten 1-4 at an angle of 90° +10 /–5

Tighten 5-8 to a torque of 10±1 Nm.

Tighten 5-8 at an angle of 90° +10 /–5

Torque spanner 1159795.

Other special equipment: 1159795

12 Put on connection nipples for coolant and air. Use thread sealant fluid or similar.

Note: Some nipples have a conical thread. Do not over tighten.

Heater, air drier

The air drier heater is provided to prevent condensate in the pressure relief valve from freezing. The electric
heating unit is thermostatically controlled and is connected at a temperature of +6 - +7°C and is disconnected
at about 27°C. The power of the heater is in the range of 90–100 W. The current supplied to the heater, which
is thermostatically controlled, is connected via a relay controlled by the alternator, to prevent the battery from
becoming discharged when the engine is not running.

The illustration shows the heater unit for AIRDRY1

1. Electical connection
2. Thermostat
3. Heating element

56158-2 Non-return valve, check

AIRDRY VERSION2 AIRDRY1 VERSION2
Special tools: 9992976

Cau
tion
Follow the instructions carefully to avoid personal injury and damage to the product or equipment.

2 Note: Check that the parking brake is applied.

Raise the cab.

Empty the air out of the compressed air system, use nipple 9992976.

Special tools: 9992976

3 Fit nipple 9992976 on the air dryer test nipple.

Special tools: 9992976

4 Fit an exhaust hose. Start the engine. Build up the air pressure until the compressor discharges. Turn off the
engine.

5 If the non-return valve is intact, no air should leak out through the air dryer test connection when the relief
phase is complete.

6 Remove the nipple from the air dryer test connection.

7 Lower the cab. Remove the exhaust hose.

56113-3 Pressure regulator, adjust / Repairer/

AIRDRY VERSION2 AIRDRY1 VERSION2

Special tools: 9992976, 9996461, 9996465, 9996926

Cau
tion
Follow the instructions carefully to avoid personal injury and damage to the product or equipment.

2 Note: Make sure that the parking brake is applied.

Raise the cab.

Empty the air out of the compressed air system, use nipple 9992976.

Special tools: 9992976

Connect manometer 9996465 or 9996926 (depending on the vehicle system pressure) to the primary
reservoir on the vehicle using nipple 9992976 and hose 9996461.

Special tools: 9992976 9996461 9996465 9996926

4 Fit an exhaust hose. Start the engine. Build up the air pressure until the air dryer discharges air. Check the
cut-out pressure on the manometer. For the correct cut-out pressure see service information Air dryer,
specifications in group 56. Leave the engine running.

Figure A
Figure B

Adjust the relief pressure if this is incorrect. Turn clockwise to increase the pressure. Turn anti-clockwise to
reduce the pressure. On air dryer AIRDRY (Figure A), the protective cap must be removed to reach the
adjusting screw. Air dryer AIRDRY1 (Figure B) is not fitted with a protective cap.

6 Repeat the relief pressure check according to point 4.

7 Lower the system pressure slowly. Check the connection pressure. The connection pressure is the pressure
that the system has at the same moment as the relief valve closes and the compressor starts to charge the
system again. For the correct cut-in pressure see service information Air dryer, specifications in group 56.
Leave the engine running.

8 When the correct cut-in and cut-out pressures have been obtained, refit the protective cap on the air dryer
(AIRDRY).

9 Turn off the engine. Remove the measuring equipment and the exhaust hose. Lower the cab.

56113-3 Pressure regulator, adjust / Repairer/

AIRDRY / AIRDRY1
Special tools: 9992976, 9996461, 9996465, 9996926

1 Empty the compressed air system, use nipple 9992976.

Note: Make sure that the parking brake is applied.

Special tools: 9992976

Connect pressure gauge 9996465 or 9996926 (depending on the system pressure in the truck) to the primary
tank in the truck, using nipple 9992976 and hose 9996461.

Special tools: 9992976 9996461 9996465 9996926

3 Put an exhaust hose on the exhaust pipe, start the engine and run the air pressure up until the compressor
pressure is relieved. Check the pressure relief pressure on the pressure gauge. Please refer to Specifications,
air driers for the correct cut-out pressure. Leave the engine running.

4
Illustration A

Illustration B

If the pressure relief pressure is incorrect, adjust it to the correct pressure. Turn clockwise to increase
pressure, turn anti-clockwise to reduce pressure. On the AIRDRY air drier (illustration A), you have to remove
the protective cap to reach the adjustment screw. There is no protective cap on the AIRDRY1 air drier
(illustration B),

5 Repeat the check for the relief pressure, as in item 4.

6 Apply the service brakes several times, or drain the primary tank, to reduce the pressure. Reduce the
pressure slowly. When the pressure gauge needle approaches 7.5 bar in a truck with leaf springs, or 10.5 bar
in a truck with air springs, to see when the pressure gauge needle begins to move towards higher pressure
again. Note this turning point = cut-in pressure.
Please refer to Specifications, air driers for the correct cut-in pressure.

Specifications:
7.5 bar
leaf springs 10.5 bar
air springs

7 When the correct cut-in and cut-out pressure has been reached, re-install the protective cap on the AIRDRY
air drier.

8 Stop the engine. Empty the compressed air system. Remove the measurement equipment and remove the
exhaust hose.

56135-2 5619-03-02-04 Solenoid valve, air drier, replace / Repairer/

Note: As the illustrations are reused for several different variants, some details may differ from the variant you are working on.
The essential information in the illustrations is, however, always correct.

Special tools: 9998313, 9992976, 9998081, 88890086

AIRDRY-E
1

Caution

Pay particular attention to the instructions to avoid personal injury or product damage.
2

Special tools: 9992976

Warning

Use safety goggles when using compressed air.

Clean the outside of the air drier.

Make sure that no impurities enter the air drier housing.

6
Untighten desiccant reservoir using tool (A) 9998313.

Special tools: 9998313

Warning

Use safety goggles when using compressed air.

Check that the inlet in the middle from the desiccant reservoir to the drier housing is clean, otherwise the drier insert has failed
or the compressor oil consumption is too high. Abnormal carbonization in the air drier requires an inspection of the cooling
coil. Refer to 56176-2 5617-06-02-02 Cooling coil, compressor, check
Clean the inside of the air drier.
Blow all air channels clean on the solenoid valve side.

Clean the sealing surfaces. Check that the threads are not damaged. Replace O-ring (B) included in the desiccant reservoir
kit.
Spread a thin layer of grease on the housing's sealing surfaces and threads.

9
Screw the new desiccant reservoir by hand until it bottoms and a further 1/2 turn (approx.20 Nm)

10

Apply grease (A) (included in the solenoid valve kit) on the O-rings and the solenoid valve housing.
Move the cover (B) from the old solenoid valve.
Fit new O-rings in the air drier housing and the O-ring sealing in the solenoid valve housing.

Note: Be extra careful during fitting of the O-ring sealing into the solenoid valve housing.

Screw tight the solenoid valve with new screws (C) to 6±0.9 Nm with torque wrench 9998081.

Special tools: 9998081

Specifications:
6±0.9 Nm

11

Warning

When starting the engine with the cab tilted, make sure that the vehicle is not in gear and that the parking brake is applied.

Start the engine. Check that the air drier disengages.

Reduce pressure by pumping with the brake pedal until the compressor starts filling with air, check the connection and
disconnection function, see specifications.
Turn off the engine.

12 Perform a leakage test with leakage detector tool 88890086 or with Volvo's leak finder spray.

Special tools: 88890086

13 Connect the VCADS PC. Perform regeneration function test on the air drier's solenoid valve. When a click is heard, air
flows out of the silencer for approx. 10 seconds and air pressure in the primary tank is reduced.

14 Zero the parameter for the dessicant reservoir. Start calibration, wait until it is completed. Close the test and disconnect
VCADS PC.

15
Adhesive diagram for load sensing valves/ Specification/

This Service Bulletin contains instructions on how to read load sensing valves diagrams.

General
Braking system is planned in such a way that it can stop a fully loaded vehicle. When there are lesser loads on
the vehicle the brake pressure must be reduced to the same degree with the aid of a load sensing valve in the
rear brake circuit and a pilot valve (if assembled) in the front brake circuit.

There are two types of load sensing valve, one for vehicles with leaf springs and another one for vehicles with
air suspension.

Leaf springs type of valve is mechanically operated by a lever that detects movement in the rear springs and
adjusts the pressure to the brake cylinders.
In vehicles equipped with air suspension the valve detects load weight by the air pressure in the rear
suspension air bellows.

Load sensing valve output pressure operates pilot valve (if assembled).

Vehicles equipped with load sensing valve have a corresponding adhesive diagram affixed to the service cover
(FM and FH, see illustration Fig. ) or on sunblind in the passenger's side (NH).

Diagram is used in the adjustment and checking of load sensing valve.

A properly adjusted load sensing valve is a basic condition to meet legal regulations.

FM, FH Vehicles

How often should the checking and adjustment of load sensing valve be done?

Checking and adjustment of load sensing valve should be done at least once a year. Check also if control
shaft is stuck due to dirt or oxidation.

Any change in the leaf springs features affects the operation of the load sensing valve. Rust deposits between
the leaf springs or replacement of leaf springs can alter these features. Leaf springs P/N is stamped on main
leaf upper side close to the eyelet, at respective leaf spring.

Adjust load sensing valve if springs are reinforced with extra leaves. A stiffer spring makes lever movement
shorter, so lever length should be shortened for a proper movement angle.

In vehicles equipped with air suspension, P/N is stamped on the suspension air bellows. For more accurate
analysis the air bellow P/N is not enough, since suspension characteristics are determined by combined air
bellow and piston. Combined air bellow and piston have one P/N for whole set.

Dealer must check and adjust load sensing valve soon after the superstructure assembling and
before delivering the vehicle to the customer. Vehicles equipped with air suspension have
factory-supplied valves with final adjustment.

How to read the diagrams

Weigh vehicle's engine axle/bogie and write down load value on axle.

Example 1

NH 4x2 Rigid, RST-PAR1, RAD-L90.

Use noted load value on axle for instance, 7.0 ton. From 7.0 ton in the X-axis (pos. 1); reduced pressure value
in the Y-axis (pos. 3) is obtained through the Putcurve (pos. 2). In this case, 6.0 bar. Tolerance in output
pressure of load sensing valve is ±0.4 bar.
X = Load on engine axle in ton.
Y = Output pressure in bar

Example 2

FH 4x2, Tractor, RAD-A4, CHH-STD.

Use noted load value on axle for instance, 8.0 ton. From 8.0 ton in the X-axis (pos. 1); reduced pressure value
in the Y-axis (pos. 3) is obtained through the Putcurve (pos. 2). In this case 6.4 bar. Tolerance in output
pressure of load sensing valve is ±0.4 bar.

X = Load on engine axle in ton

Y = Output pressure in bar

Double check valve/ Specification/

Parking brake

Make..... ECAN

Volvo part no...... 85104850

Double check valve /Description design/

The two-way valve is used to differentiate between two control signals arriving at a valve when they originate from two
different controls

The two-way valve is fitted to parking brake circuits to prevent the service brake and parking brake from being applied
simultaneously.
Foot and hand controls /specification/
Footbrake valve (pos. 10)

Designation..... MB 4690
Volvo part no...... 1628491
Type..... 2-circuit
Connections:
11..... Inlet primary circuit
12..... Inlet secondary circuit
21..... Outlet primary circuit
22..... Outlet secondary
circuit
Max operating pressure..... 1000 kPa (10 bar)
Pressure difference between the pressure circuits over the entire pressure 10-30 kPa (0.1-0.3
area..... bar)

Hand control, parking brake (pos. 19)

Designation..... Volvo part no.

Volvo part no...... 1078958
Max operating pressure..... 1000 kPa (10 bar)
Connections:
1..... Inlet
21..... Outlet to parking brake
22..... Outlet to control valve for trailer brake
3..... Air discharge
Hand control trailer brake, only for certain countries (pos. D)

Braking with full pressure (TRBR-HCF)

Designation..... 1186643
Volvo part no...... 3986121
Min output pressure from valve at 600 kPa (6 bar) system pressure entails
unreduced brake pressure to the trailer (after the control valve)..... 0 kPa (0 bar)
Connections:
1..... Inlet
2..... Outlet to control valve
3..... Air discharge
Braking with reduced pressure (TRBR-HCR)
Designation..... 1186645
Volvo part no...... 3986120
Min output pressure entails reduced max brake pressure to the trailer 300-400 kPa (3.0-4.0 bar)
(after the control valve).....
Connections:
1..... Inlet
2..... Outlet to control valve
3..... Air discharge

Blocking valve (pos. 17)

Designation..... 434 205 0260

Volvo part no...... 1628492
The valve closes when the pressure falls below..... 340-400 kPa (3.4-4.0 bar)

56373-4 Footbrake valve, overhaul/ Repairer/

Valve removed

Part number: 1161326, 1628491

Special tools: 9992797, 9992800

Kits: 3090820

Disassemble
1
Mark the position of the housings one in relation to the other. Remove the lock ring.

Remove the discharge pipe and the valve body.

Apart the housings and remove the pistons. Inject compressed air in the plug 21 to remove the piston.

Note: Do not use pliers to remove the piston.

Remove the lock ring carefully so the spring does not fly off. Remove the valve body.

5
Remove the lock ring carefully so the spring does not fly off.

Remove the cover, the piston and the spring.

Remove the larger piston.

Use a screwdriver to pull out the rubber spring from the piston.

9
Remove the smaller piston.

Inspection
Note: Clean all the components and check them for scratches, corrosion or signs of sticking. Replace all rubber
rings. The sealing surfaces cannot show any signs of wear. Lubricate the components with grease P/N
1161326.

Assemble
10

Install the new rubber spring. Its rounded side should face upwards.

11

Install the springs, cover and larger piston lock ring. Then, install a new sealing ring.

12

Install the smaller piston, pressure pin, spring, flat washer and lock ring. Then, install the new sealing rings.

13
Install the valve body with a new sealing ring.

14

Position the spring with the larger diameter side facing upwards. Install the metal washer with new rings (the
larger diameter side facing upwards). Then, install the lock ring. Use new sealing rings.

15

Position the spring and piston in the valve.

16

Install the dust-guard, felt ring and sealing ring to the cover.

17
Position the cover on the piston and fit the cover dust-guard to the piston groove.

18

Press the piston in and install the lock ring.

Note: Fasten the valve to a vise to relieve the spring load and make it easier to install the lock ring. Make sure
the lock ring fits properly in its groove.

19

Install the smaller piston with new sealing rings.

20

Position the spring.

21

Install a new sealing ring to the plate.

Note: Sealing ring identification number should face the plate lowering face.

22

Install the plate to the housing with its lowering face upwards.

23

Position the sealing ring between housings and assemble them. Torque-tighten the bolts to 18±2 Nm (1.8±0.2
kgfm).

Specifications:
18±2 Nm
(1.8±0.2 kgfm)

24

Install the valve body, spring, metal washer with sealing rings, exhaust pipe and lock ring.

Test, adjustment
25
 (12) Intake pressure, front brake
circuit
(22) Outlet pressure, front brake
circuit
(11) Intake pressure, rear brake
circuit
(21) Outlet pressure, rear brake
circuit

Connect the footbrake valve to the test bench 9992800, as shown in the illustration.
 Thoroughly unscrew the stopcock (R).
 Close K1, K2 and K3.
 Connect the compressed air to the test bench.
 Connect the pipe (A) to the outlet (21).
 Connect the pipe (B) to the connection (11).
 Connect the pipe (C) to the connection (22).
 Connect the pipe (D) to the connection (12).
 Plug the remaining connections.

Special tools: 9992800 9992797

26

Screw in the support 9992797 to the valve.

 Adjust the pressure to 6 bar (0.6 MPa) in the pressure gauge M2 with stopcock (R).
 Using the support 9992797, lock it gradually until it reaches maximum pressure and then release it
gradually until it reaches zero.
 Perform some quickly lock and unlock.
 Check the pressure gauges M1 and M3. There must not be any delay.
 Difference in pressure between the two circuits, checked in the pressure gauges M1 and M2, must not
exceed 0.2 bar (0.02 MPa).
 Close K4.
 Check the pressure drop in the pressure gauge M2 during one minute.
 Maximum allowed pressure drop is of 0.1 bar (0.01 MPa).
 Remove the tools.
 Bleed the air from the test bench.
  Remove the pipes and nipples from the valve.

Special tools: 9992797

Specifications:
max. 0.1 bar
(0.01 MPa)

56317-2 Footbrake valve, replace/ Repairer/

1

Cau
tion
Follow the instructions carefully to avoid injury or damage to property.
Neglect to do so may result in minor or moderate injury or damage to property.

2 Drain the truck compressed-air system.

3 Lift up the front hatch. Mark and remove all pipe connections to the service brake valve with the exception
of the pipe to connection 12.
Note: This pipe is to remain connected to prevent the valve from falling out when the attachment bolts are
removed at a later stage.

4 Position the steering wheel in its straight-ahead position and push the driver's seat to its rearmost position.

5 Remove the floor moulding at the door opening.

Remove the bolts for the draught insulation panel on the left-hand and right-hand sides of the steering shaft,
also the bolts for the upper steering shaft protection.
Remove the upper steering shaft protection.

Fold the floor mat to one side at the cowl and remove the plastic nuts for both the draught insulation panels.

Remove the plastic clips for the lower steering shaft protection and remove the protection.

9
Remove the push rod for the service brake valve.

10

First remove the lower nuts from the service brake valve. Then remove the upper nuts.

11 Remove the brake pipe from connection 12 on the brake valve and lift out the valve.

12 Fit the new valve in position and connect the brake pipe to the brake valve inlet 12, using new O-rings.

13 Secure the valve in place using new nuts.

Note: Tighten the upper nuts first.

14 Fit the push rod and check that the pedal moves freely up and down without seizing.

15 Replace the O-rings on all the previously removed pipe connections.

16 Fit and tighten the pipe connections on the service brake valve according to the previously made
markings.

17 Fill the compressed air system with air.

18 Check for leaks using leak detection equipment.

Check footbrake valve function and circuit pressure variation according to operation 56388-2 Footbrake valve,
check function and system pressure differences.

Other special equipment: 1159683

19 Fit the lower steering shaft protection, using new clips if necessary.

20 Fit and secure the upper steering shaft protection. Adjust the seals at the controls.

21 Fit and secure the right-hand and left-hand draught insulation panels.

22 Re-fit and adjust the floor mat in position round the steering shaft.

23 Fit and secure the floor moulding at the cab door opening. Cover the screw holes with plastic covers.

24 Close the front hatch.

Four-circuit protection valve /description/

The four-way protection valve is used to protect the air pressure in the other circuits if a leak should occur in one of the
circuits.
If a leak occurs in one of the circuits, the four-way protection valve will stop the supply of air to that circuit, to prevent the
passage of air from the other circuits. In this way, the supply of air to the other circuits is safeguarded and the vehicle can still
be braked.

The four-way protective valve is available in two versions, a 5-port valve and a 7-port valve. Vehicles with low system
pressure (8.5 bar) use a 5-port valve, while vehicles with high system pressure (12 bar) use a 7-port valve.

The opening pressure in the new 5-port valve parking circuit (port 23) has been changed to 6.9-7.2 bar. The opening pressure
in the new 7-port valve is the same as for earlier 7-port valves, 5.5-5.8 bar.

Both valves have a new design for evacuating the parking brake circuit when the pressure in the rear brake circuit is too low.
On earlier valves, the parking brake circuit is evacuated into the free air, while it is evacuated to the rear brake circuit on the
new valves. The advantage of this change is that air does not flow out of the brake system and it eliminates the risk of
mistaking the evacuated air for a leak.

Five-port valve

Seven-port valve

Four-way protective valve, principle diagram

Four-way protective valve, 5-port low-pressure system (8.5 bar)
 P1. Inlet port
 P21. Front circuit port
 P22. Rear circuit port
 P23. Parking brake port
 P24. Port for extra equipment

Four-way protective valve, 7-port high-pressure system (12 bar)

 P1. Inlet port
 P11. Front circuit port
 P12. Rear circuit port
 P21. Front circuit port
 P22. Rear circuit port
 P23. Parking brake port
 P24. Port for extra equipment

Four-circuit protection valve /specification/

Five-port valve
Seven-port valve
For vehicles with system pressure 850 kPa, (8.5 bar) (leaf springs)

Make WABCO

Five port valve: Volvo part no...... 20452152

Opening pressure:

Service brakes, connections, 21 front circuit and 22 rear circuit..... 620-650 kPa (6.2-6.5 bar)

Parking brake, connection 23..... 690-720 kPa (6.9-7.2 bar)

Extra equipment, connection 24..... 620-650 kPa (6.2-6.5 bar)

For vehicles with 1200 kPa, (12 bar) system pressure (air springs and/or BSYS-EBS)

Make..... WABCO

Seven port valve: Volvo part no...... 20755195

Opening pressure:

Service brakes, connection 21 front circuit and 22 rear circuit..... 600-630 kPa (6.0-6.3 bar)

Parking brake, connection, 23..... 550-580 kPa (5.5-5.8 bar)

Extra equipment, connection 24 ..... 550-580 kPa (5.5-5.8 bar)

Circuit 21 22 23 24

Opening Pressure — Dynamic

(Bar) 6.3 +0 /– 5.8 +0 /–0,3
0,3

Closing Pressure — Static 0 ≥4 ≥ ≥

(Bar) 5.5 5.5
 ≥4 0 * ≥4

≥4 ≥4 0 ≥4

≥4 ≥4 ≥4 0

56365-2 Load sensing valve and pilot valve, check and adjust
/ Repairer/
Special tools: 9992976, 9996461, 9998052

RSS-LEAF, FBREG-LS, UFBREG

1

Cau
tion
Follow the instructions carefully to avoid injury or damage to property.
Neglect to do so may result in minor or moderate injury or damage to property.

2 Check that the rear spring configuration is correct.

3 Check that there is no rust between the spring leaves, that the spring leaves are not broken and that the
spring assembly has not settled.

4 Grease the spring shackle bolts and balance arm bushings and rollers.

5 Check the function of the lever and those components which influence the movement of the lever.

6 Weigh and note the actual drive axle load or bogie load.

7
On the basis of the truck drive axle load or bogie load, read off on the pressure reduction diagram how high
the output pressure from the load-sensing valve should be.
Note the pressure.
The pressure reduction diagram is mounted on the inside of the service hatch.

Cau
tion
When connecting the test union to the test outlet, it should only be tightened by hand, otherwise there
is a risk that the test outlet be damaged.

9 Connect a test union to the input pressure on the load-sensing valve.

Special tools: 9992976

10

For valve without in-built relay function

11

For valve with in-built relay function

12

Connect a test union to the spring brake cylinder service brake section at the drive axle.

Special tools: 9992976

13

If the truck is equipped with a front

control valve (FBREG-LS), the test union should be connected to the brake cylinder at the front axle.
Connect the test union according to point 14 and 15.

Special tools: 9992976

14 Connect hoses between the compressed-air instrument gauges:

 B and test union on input pressure

 C and test union on the drive axle brake cylinder
 D and test union on the front axle brake cylinder (only applies if the truck is equipped with a control
(pilot) valve)

15 If necessary adjust the length (L) of the lever to the correct measurement. Details are stated on the
pressure reduction diagram which is mounted on the inside of the truck service hatch.

16 Loosen the clamp which holds the wire at its attachment in the spring, axle or the rod between the axles.

17

Applies to load sensing valves without inbuilt relay function

Place the lever in full load position. The indicator on the shaft shall point at the lug on the housing. See
illustration.
18 Applies to load sensing valves with inbuilt relay function
The lever automatically goes to full load position when the spring is released.

19 Fill the compressed-air system with air until the compressor off-loads.

20 Apply the brake pedal using a pedal support tool until the pressure on gauge B shows 7.0 bars.

21 Check that the pressure on gauge C is 7.0 bars.

22 On trucks equipped with a control (pilot) valve (FBREG-LS), the pressure on gauge D should also be
checked.

23

Read off on the pressure reduction diagram for the control (pilot) valve how high the pressure to the front axle
should be and compare with the pressure on gauge C.

24 Apply the brake pedal until pressure on gauge B indicates 7.0 bars.

25 Turn the lever until gauge C indicates the value which was noted in point 7.
Stretch the wire and tighten the clamp.

26 Simulate a wire breakage by releasing the return spring and allowing the lever to go to the return position.
Apply the brake pedal until the pressure on gauge B indicates 7.0 bars.
The output pressure should be as follows for the truck variants stated:
RAD-L90, RADD-BR and RADD-TR1/TR2, the same as the input pressure, i.e. 7.0 bars.
RADT-AR, half that of the input pressure, i.e. 3.5 bars.

27 Remove the pedal support tool, compressed air instrument, hoses and test unions.

56332-2 Load sensing valve, replace/ Repairer/

RSS-LEAF
1

Cau
tion
Follow the instructions carefully to avoid injury or damage to property.
Neglect to do so may result in minor or moderate injury or damage to property.

2 Drain the truck compressed-air system.

3 Clean the compressed-air connections on the load-sensing valve or the combined load-sensing valve/relay
valve and mark them.

4 Disconnect the compressed-air pipes and hoses. Unhook the spring from the lever.

5 Remove the valve attachment bolts and remove the valve.

6 Move the lever and unions over to the new valve.

Use thread sealant, Part no. 1161056 and fit new O-rings.

7 Adjust the length of the lever according to the measurements stated on the pressure reduction diagram on
the inside of the service hatch.

8 Fit the new valve and tighten the attachment bolts.

9 Fit the compressed-air pipes and hoses according to the previously made markings and hook the spring onto
the lever.

10 Carry out load sensing valve check according to operation

56350-2 Load-sensing valve, check acc. to plate on door alt.

plate on service hatch/ Repairer/
Special tools: 9992976, 9996461, 9998052

Spring rear suspension (RSS-LEAF)

1
 Cau
tion
Carefully follow the instructions to avoid personal injury and damage to the product or equipment.

2 Measure the load on the rear axle or on the bogie. Write down the value.

3 Check that the rear spring assembly is correct.

4 Check the spring leaves for rust. Check for dented or distorted leaves.

5 Lubricate the shackles, anti-roll bar bushings and linkages.

6 Check that the load sensing valve lever as well as parts that affect lever movement are not stuck.

Cau
tion
Hand tight the test nipple when connecting it to the test plug to avoid damage to the test plug.

Load sensing valve with the function of built-in relay valve.

Connect the coupler 9992976 to the inlet connection of the load sensing valve, coming from the footbrake
valve.

Special tools: 9992976

9
Connect the coupler 9992976 to the brake cylinder outlet for the footbrake, on the drive axle.

Special tools: 9992976

10 Connect the flexible pipes between the air pressure gauges.

 (B) and test nipple to the load sensing valve inlet pressure.
 (C) and test nipple to the brake cylinder.

Special tools: 9996461 9998052

11 Check the lever length. The values are at the pressure reduction diagram, located at the service cover
interior (FH) or behind the passenger sun visor (NH).

12 Release the lever spring from the load sensing valve.

13

Valid for load sensing valve without built-in relay valve function.
Move lever to maximum load position. Lever indicator should point to the valve body shoulder.

14 Valid for load sensing valve with built-in relay valve function.
The lever moves automatically to maximum load position when the spring is released.

15 Charge the compressed air system until the load cut-off point of compressor. Turn the starting switch to
the drive position.

16 Depress the brake pedal to the bottom.

17 Read the pressure in the pressure gauge C and compare it with the pressure gauge 2 on the vehicle
instrument panel. Both pressure gauges should have the same pressure.

18 Couple the spring to the lever.

19 Press the brake pedal. Use a support to fasten it to the point in which the pressure gauge B reads a 7 bar
pressure (0.7 MPa).

Specifications:
7 bar
(0.7 MPa)

20
From the load on the drive axle or on the bogie, read the outlet pressure value of the load sensing valve in the
reduction diagram. Diagram is located at the service cover interior (FH) or behind the passenger sun visor
(NH).

21 Check that the value in the diagram is in accordance with the pressure gauge C.

22 Remove the support from the pedal, air pressure gauges used in the test, flexible pipes and test nipples.

Load-sensing valve Air suspension / Repairer/

Part number: 1161326, 1628955

Special tools: 9992787, 9992792, 9992800, 9992976

Kits: 3090946

Disassemble
1
Mark the position of the upper body in relation to the lower body and remove the bolts. Remove the upper
body piston along with the diaphragms.

Remove the dust-guard and the lock rings. Remove the upper body.

Remove the upper body piston.

Remove the lower body piston by blowing some compressed air into the plug.

5
Remove the adjusting device.

Remove the air bellows pressure sensor and silencer.

Remove the lock ring and remove the inner piston.

Inspection
Note: Clean all the components and check them for scratches, corrosion or signs of sticking. Replace all rubber
rings. The sealing surfaces cannot show any signs of wear. Lubricate the components with grease P/N
1161326.

Assemble
8

Install the outer valve for the upper body and install the lock ring. Use new sealing rings.

9
Install the inner valve for the upper body.

Note: Shim shoulder should face the lock ring.

10

Install the piston valve.

11

Install the sealing ring to the piston.

Note: Sealing ring lip should face upwards.

12

Install the pistons.

Note: The white piston has rounded corners in one of its inner sides, which should face the diaphragms side.

13
Install the diaphragms to the piston. Then, install the flat washer and lock ring.

14

Install the guide pipe.

15

Install the air bellows pressure sensor piston. Use new sealing rings.

16

Install the air bellows pressure sensor device.

17
Position the bushing and spring on the adjusting device cover.

Note: To make it easier to install, let adjustment completely free.

18

Fasten the assembly mounted in the previous item to a vise and position the guide, the smaller spring and the
gasket.

19

Install the valve body to the assembly fastened to the vise.

Note: Pre-adjust the adjusting bolt to approximately 35 mm.

Specifications:
35 mm

20

Install the inner driving rod.

Note: The rod casing has a guide pin which must be positioned to the rod groove.

21
Position the piston cover sealing ring.

22

Position the spring and piston.

23

Install the piston cover and lock ring.

24

Install the second piston.

25

Install the upper body piston.

26
 Install the valve bodies. Torque-tighten the bolts to 20±2 Nm (2±0.2 kgfm).

Specifications:
20±2 Nm
(2±0.2 kgfm)

27

Install the silencer.

Note: Check if pipe guide bolt is tight.

Test, adjustment
1

(1) Feed air from the compressed air network

(2) Braking pressure to the brake cylinders
(4) Braking pressure from the footbrake valve
(41) Air bellows pressure
(42) Air bellows pressure
 Test nipple for simulated pressure of the air
(43)
bellows

Connect the load sensing valve to test bench 9992800, as shown in the illustration.
 Pipe (A): Connected to connection (43) in the load sensing valve (use coupler 9992976).
 Pressure gauge M1: Adjusts pressure in the air bellows in K3.
 Pipe (B): Not used.
 Pipe (C): Connected to connection (2) in the valve (use the nipple 9992787 and plug 9992792).
 Pressure gauge M3: Braking pressure in the outlet for brake cylinders.
 Pipe (D): Connected to connection (4) in the valve (use the nipple 9992787 and plug 9992792). The
pipe must be disconnected after each test with different pressures in the air bellows. The pressure in
the air bellows must not be connected while pressure is altered to avoid incorrect measuring values.
 Pressure gauge M2: Braking pressure in the footbrake valve inlet.

Special tools: 9992800 9992976 9992787 9992792

2 Copy a diagram for the type of valve to be checked.

On Service Publications, Group 56, there are some examples on how to read the diagrams.

1. Pressure in the network for the test bench must be of at least 6.3 bar (0.63 MPa).
2. Adjust the pressure in the pressure gauge M2 with the stopcock (R) to 6 bar (0.6 MPa).
3. Adjust the air bellows pressure in the pressure gauge M1 with K3 (K1 closed) to 1 bar (0.1 MPa).
4. Connect the pipe (D) to valve connection (4).
5. Note in the diagram the pressure value read in the pressure gauge M3.
6. Disconnect the pipe (D).
7. Increase the pressure in the pressure gauge M1 with K3 to 3 bar (0.3 MPa).
8. Repeat the items 4,5, and 6.
9. Increase the pressure in the pressure gauge M1 to 5 bar (0.5 MPa).
10. Repeat the items 4,5, and 6.
11. Using a ruler, sketch a straight line as close to the points noted in the diagram as possible.

If the line exceeds the tolerance of ± 0,4 bar, adjust the valve.

Specifications:
min 6.3 bar
(0.63 MPa)

Spring length (A) = ± 110 mm

Separator number in the spring = 01

Adjusting bolt length (B) = 35 mm

Other types of adjusting bolt

After adjustment, install the adjusting bolt cap.

Load-sensing valve spring suspension /Repairer/

Part number: 1161326, 1628951

Special tools: 9992677, 9994025

Kits: 3090924

Disassemble
1
Mark the position of the upper body in relation to the lower body and remove the bolts. Remove the upper
body piston along with the diaphragms.

Remove the dust-guard and the lock rings. Remove the upper body.

Remove the upper body piston.

Remove the lower body piston by blowing some compressed air into the plug (2).

5
Remove the rod stop bolt to relieve the spring load. Remove the rod.

Remove the side cover. Disassemble the cam shaft and the spring.

Remove the lock ring and remove the inner piston.

Remove the sealing ring. If necessary, remove the bushing with the tool 9994025.

Special tools: 9994025

Inspection
Note: Clean all the components and check them for scratches, corrosion or signs of sticking. Replace all rubber
rings. The sealing surfaces cannot show any signs of wear. Lubricate the components with grease P/N
1161326.

Assemble
9 Install the new bushing with the tool 9994025.

Special tools: 9994025

10
Install the shaft sealing ring with the tool 9992677.

Note: Sealing ring lip should facing out.

Special tools: 9992677

11

Install the outer valve for the upper body and install the lock ring. Use new sealing rings.

12

Install the inner valve for the upper body.

Note: Shim shoulder should face lock ring.

13

Install the piston valve.

14
Install the sealing ring to the piston.

Note: Sealing ring lip should face upwards.

15

Install the pistons.

Note: The white piston has rounded corners in one of its inner sides, which should face the diaphragms side.

16

Install the diaphragms to the piston. Then, install the flat washer and lock ring.

17

Position the spring in the valve housing, taking note of the spring end mounting configuration.

18
Install the cam shaft following the spring stop in the shaft.

Note: Install a flat washer onto the shaft before installing it to the valve.

19

Install the rod to the shaft. Check the rod location in relation to the shaft.

20

Turn the rod 180° counterclockwise and install the stop bolt.

Specifications:
180°

21

Install the side cover using a new sealing ring.

22
Install the inner driving rod.

Note: The rod casing has a guide pin which must be positioned to the rod groove.

23

Position the piston cover sealing ring.

24

Position the spring and piston.

25

Install the piston cover and lock ring.

26
Install the second piston.

27

Install the upper body piston.

28

Install the valve bodies. Torque-tighten the bolts to 20±2 Nm (2±0.2 kgfm).

Specifications:
20±2 Nm
(2±0.2 kgfm)

29 Adjust the rod length. Refer to operation 56350-2.

Parking brake hand control /Description/

Where the blocking valve is fully depressed or fully withdrawn, the blocking valve does not drain out any air. If
the brake system for some reason leaks out air and the pressure to the blocking valve falls below 4.0 bars, it
can for a short period of time (around 30 seconds) be in an intermediate position and therefore evacuate out
the air which is in the feed lines to the blocking valve. Evacuation is through a small hole drilled in the
blocking valve. The blocking valve is designed to function in this way and such an evacuation will not lead to
replacing the parking brake valve.

If you sleep in the vehicle and have problems with this air evacuation, you can draw out the blocking valve
and in this way avoid evacuation. A withdrawn blocking valve also applies the trailer service brake. The
service brakes on the trailer are however only applied where there is pressure in the trailer brake system.

Repeated application - unloading the parking brake should result in the blocking valve releasing when the
pressure in the parking tank is below 4.0 bars. If the parking tank is emptied for other reasons, it is not certain
that the blocking valve will be activated.
56320-4 5633-04-04-05 Pressure limiter valve, overhaul /Repairer/
Removed

Part number: 1606720, 1161326

Special tools: 9992976, 9992800

Repair kit: 244815

General
1 Clean the valve and fix in a vice with soft jaws.

Remove adjusting screw, washer and non-return valve.

Turn the valve. Remove the locking ring and cover with O-ring.

Note: Pay attention to the spring tension.

4
Remove the piston. O-ring and spring plate.

Carefully remove the locking ring and remove the valve seat.

Note: Be careful not to damage the sliding surfaces of the valve.

6 Remove the valve housing from the vice. Clean and inspect the valve parts. Coat sliding surfaces, O-rings and
other parts with grease part no. 1161326 .

Part number: 1161326, 244815

Grip the valve housing in a vice with soft jaws. Press the valve seat into place with the lip facing the valve housing, and fit the
locking ring. Press with a socket.

Note: Avoid scratching the valve's sliding surfaces.

8
Fit the O-ring on the piston. Place the spring plate, with the raised centre part turned upwards, into the valve housing. Fit the
spring and piston with the O-ring.

Fit the cover and O-ring. Depress the cover and insert the locking ring.

10

Turn the valve and place the non-return valve with the lip toward the valve housing, and the washer. Screw in the adjusting
screw so that it is touching the compression spring.

Setting the valve's limiting pressure

11

Fit nipples 2976 together with suitable nipples for the valve's input and output.

Connection 1 Input pressure

Connection 2 Output pressure

Special tools: 9992976

12 See for connection of test bench 2800 .

 Connect hose B to the pressure multiplier's outlet.
 Close stopcocks K2 K3, K4 and K5.
 Connect compressed air to the pressure multiplier's inlet.
 Connect hose C to the pressure limiter valve outlet, marked 2.
 Connect hose D to the pressure limiter valve inlet, marked 1.

Special tools: 9992800

13 Setting the valve's limiting pressure:

 Open stopcock K5.
 Increase the air pressure in the test bench using the control on the pressure multiplier, until the manometer M2 shows
9.5 bar (950 kPa).
 Carefully screw in the pressure limiter valve's adjusting screw until the manometer M3 shows a pressure of 7.5-7.7
bar (750-770 kPa).
 Lock the adjusting screw with a locknut in this position.
 Close stopcock K5 and open stopcock K2 so that the valve and manometer are vented.
 Close stopcock K2 and open stopcock K5.
 Increase the pressure on manometer M2 to approx 9 bar (900 kPa) with the pressure multiplier. Check on manometer
M3 that the output pressure, 7.5-7.7 bar (750-770 kPa) is properly set.
 Close stopcock K5.
 Check for that no pressure drop occurs. Max permitted pressure drop is 0.1 bar (10 kPa) per minute.

14 Reset test bench 2800. Disconnect the compressed air from the pressure multiplier. Open stopcocks K2 and K5 so
that the test bench is vented. Disconnect the hoses from the valve and the pressure multiplier.

15 Remove the connection nipples from the pressure limiter valve.

56338-2 5633-03-02-11 Pressure limiter valve, replace /Repairer/

Part number: 1606720

Special tools: 9992976, 9996461, 9996465

Other special equipment: 9810621

Removal
1

Empty the primary tank, use nipple 2976 in the test outlet.

Special tools: 9992976

Clean around the compressed air pipe connections. Remove the compressed air pipe from the valve outlet marked 2 on the
valve housing.

3 Remove the pressure limiter valve from the primary tank. It may be necessary to remove any adjacent pipes in order to
unscrew the pressure limiter valve.

4 Grip the pressure limiter valve in a vice with soft jaws. Remove the O-ring and nipple from the compressed air valve's
connection.

Installation
5 Fit the nipple and a new O-ring to the new pressure limiter valve's connection. Apply a little thread sealant on the nipple
threads. Remove the valve from the vice.

6 Install the pressure limiter valve in the primary tank. Install the compressed air pipe and a new O-ring on the outlet marked
2. Refit any previously removed adjacent pipes.

Note: Ensure dirt does not enter into the compressed air system.

Connect a manometer 6465 with hose 6461 and nipple 2976 to one of compressed air tanks for the brake circuit tanks.
Special tools: 9992976, 9996461, 9996465

Start the engine and fill the compressed air system with air up to working pressure. Alternatively, fill the compressed air
system with pressure multiplier 9810621 connected to the air filling outlet before the air drier.

Other special equipment: 9810621

Check on manometer 6465 that the correct pressure is obtained in the brake circuit air tank. The valve's limiting pressure shall
be 7.5-7.7 bar (750-770 kPa). Check that there is no air leakage from the pressure limiter valve.

Special tools: 9996465

10 Remove the pressure gauge, hose and nipple.

Quick release valve /Specification/

Service brake, front wheel, without front load-sensing brake valve

Make..... WABCO

Volvo part no...... 3173152

Connections:

Top, M22 thread..... Inlet from foot brake valve

Side 2 pcs, M16 thread..... Outlet to brake cylinder

Base, M16 thread..... Air evacuation

Max operating pressure..... 1000 kPa (10 bar)

Quick release valve /Description/

The quick release valve is used to provide rapid brake release, i.e. rapid evacuation of the air from the brake cylinders.

The quick release valve is connected to the lines leading to the brake cylinders and in close proximity to them. It is then not
necessary to transport air long distances in order to release the brakes.

Quick release valve (front), overhaul /Repairer/

Special tools: 9992800, 9992976

VM

FH, FM and NH

VM

FH, FM and NH

3
4 Clean all of the parts. Check that the seats are not damaged. Replace all valve parts with the parts in the
repair kit.

7 Connect test nipples to valve ports 1 and 2.

Part number: 1082480 1592924 1592924

8 To connect the valve to the test bench, use nipples 9992976.

Special tools: 9992976

9

Completely unscrew the stopcock (R).

Close K2 and K5.
Open K1, K3 and K4.
Connect the compressed air to the test bench.

Special tools: 9992800

10 Using the stopcock (R), adjust the pressure in pressure gauge M2 to 6 bar.

Note: Air cannot escape from the release valve once you have started to open stopcock R.

Check that the pressure reading on pressure gauge M3 is in line with that shown on pressure gauge M2.
Close K4 when the pressure reaches 6 bar on pressure gauges M2 and M3.
Check for any drop in pressure shown on pressure gauges M2 and M3 for one minute.
The maximum permitted drop in pressure is 0.1 bar.

11 Open K4.

Note: The pressure readings on pressure gauges M2 and M3 must be 6 bar.

Disconnect pipe (D) from port 1 of the valve.

The air must be expelled via the exhaust in the lower part of the valve.
The pressure on pressure gauge M3 must drop rapidly to zero.

12 Connect pipe (D) to valve port 1 and check that the pressure shown on pressure gauges M2 and M3 is 6
bar.
Close K4.
Gradually decrease the pressure shown on pressure gauge M2 by opening K5.
Check that the pressure reading shown on pressure gauge M3 is in line with that shown on pressure gauge M2
until they reach zero.

13 Purge the air from the test bench.

14 Disconnect the pipes and nipples from the valve.

15

VM
FH, FM and NH

16

VM

FH, FM and NH

56360-2 Quick release valve (rear), overhaul/Repairer/

Part number: 8123281

Special tools: 9992800

Kits: 6889580

Disassemble
1
Disassemble the cover, diaphragm, ring and rubber pin.

2 Clean all parts. Check the seats for damages. Replace the valve parts for parts in the repair kit.

Assemble
3 Install the diaphragm, ring and rubber pin.

4 Install the valve cover.

Test, adjustment
5

Connect the quick release valve to test bench 9992800, as shown in the illustration.
 Thoroughly unscrew the stopcock (R).
 Close K1 and K5.
 Open K1, K3 and K4.
 Connect the compressed air to the test bench.
 Connect the pipe (C) to an outlet.
 Connect the pipe (D) to the inlet (1).
 Close another outlet with a plug.

Special tools: 9992800

6 Increase the pressure in pressure gauge M2 with stopcock (R) to 6 bar (0.6 MPa).

 Check that the pressure in the pressure gauge M2 follows the pressure in pressure gauge M3 and vice
versa.
 Check the pressure difference on the two pressure gauges. This difference must not be higher than 0.2
bar (0.02 MPa).
 Close K4 when pressure reaches 6 bar (0.6 MPa) on the pressure gauges M2 and M3.
 Check the pressure drop in the pressure gauge M2 and M3 during one minute.
 Maximum allowed pressure drop is of 0.1 bar (0.01 MPa).

Specifications:
max. 0.1 bar
(0.01 MPa)
7 Open K4. Pressure on the pressure gauges M2 and M3 must be of 6 bar (0.6 MPa).

 Disconnect the pipe (D) from the valve inlet.

 Drain the air through the outlet at the valve bottom.
 Pressure on the pressure gauge M3 should drop quickly to zero.

8 Connect the pipe (D) to valve inlet and check that the pressure on the pressure gauges M2 and M3 is of 6
bar (0.6 MPa).

 Close K4.
 Gradually close the pressure in pressure gauge M2 opening K5.
 Check that the pressure in the pressure gauge M2 follows the pressure gauge M3 until it reaches zero.
 Pressure difference between both pressure gauges must not be higher than 0.2 bar (0.02 MPa).

9 Bleed the air from the test bench.

10 Remove the pipes and nipples from the valve.

Regulating quick release valve/Description/

Not fitted on vehicles with disc brakes or EBS.

This valve is used to reduce the brake pressure to the front wheel service brakes.

Regulating, quick release valve/Specification/

Front wheel service brake FBREG-RP. Not fitted on vehicles with disc brakes or EBS.

Make..... WABCO

Volvo part no...... 3198756

Relay valve /Specification/

pneumatic system

Make..... WABCO

Volvo part no...... 3173150

Connections:

1..... Inlet

2..... Exhaust

3..... Air evacuation

4..... Control pressure

Max control pressure..... 1000 kPa (10 bar)

Max inlet pressure..... 1300 kPa (13 bar)

Relay valve/Description/
The relay valve is used to obtain a fast supply or evacuation of the operating air to the brake cylinders where a quick release
valve is not enough to fulfill legal requirements.

The relay valve obtains a continuous supply or air from the appropriate circuit reservoir and only requires a small amount of
control air from the foot brake valve or parking brake hand control in order to allow air to pass to the brake cylinders.
56316-2 Relay valve, overhaul/Repairer/
Part number: 1082666, 1161326

Special tools: 9992800

Kits: 3090254

Disassemble
1 Drain the vehicle compressed air system.

2 Mark the connections and disconnect the pipes and hoses from the valve.

3 Remove valve from the vehicle.

4
Clean and fasten the valve to a vise with soft jaws.

5 Mark the position of the cover and the valve housing.

Remove cover (1) and the valve piston (2).

Turn over the valve. Disassemble the safety ring (7), valve housing (6), spring (5), guide washer (4) and valve
disc (3).
8 Replace the valve parts for parts in the repair kit. Clean and check the valve housing and the remaining
parts for damage and wear.

Assemble
9 During assembly, lubricate all sliding surfaces, rubber rings, springs and valves with grease P/N 1161326.

Part number: 1161326

10 Install the valve disc (3) and guide washer (4).

Note: The guide washer teeth must be installed face down on the valve seat.

11 Install the spring (5) and valve housing (6). Install the valve housing under pressure. Install the safety ring
(7).

12 Place the valve piston (2) to the cover. Install the cover and tighten the valve with bolts.

Test, adjustment
13

Connect the parking brake relay valve to the test bench 9992800, as shown in the illustration.
 Thoroughly unscrew the stopcock (R).
 Close K1, K2 and K3.
 Open K4.
 Connect the compressed air to the test bench.
 Connect the pipe (C) to the outlet (2).
 Connect the pipe (D) to the inlet (4).
 Cover another inlet with a plug.

Special tools: 9992800

14 Increase the pressure in the pressure gauge M2 with the stopcock (R) to 7 bar (0.7 MPa).

 Close K4.
 Check the pressure drop in the pressure gauge M2 during one minute.
 Maximum allowed pressure drop is of 0.1 bar (0.01 MPa).
 Transfer the pipe (D) from inlet (4) to inlet (1).
 Open K4.
 Increase the pressure on the pressure gauge M2 to 7 bar (0.7 MPa).
 Close K4.
  Check the pressure drop in the pressure gauge M2 during one minute.
 Maximum allowed pressure drop is of 0.1 bar (0.01 MPa).

Specifications:
max. 0.1 bar
(0.01 MPa)

15 Connect the pipe (A) to the inlet (4).

 Open the stopcock (R).

 Open K2 and bleed the air from the pressure gauges M2 and M3.
 Close K2.
 Open K4 and K5.
 Carefully, open K3 and gradually increase the pressure to 6 bar (0.6 MPa) in the pressure gauge M1.
 Check that the pressure in the pressure gauge M1 follows the pressure in pressure gauge M3 and vice
versa.

Note: Pressure difference between both pressure gauges must not be higher than 0.2 bar (0.02 MPa).

16 Close K3.

 Gradually reduce the pressure in the pressure gauge M1 opening K1 carefully.

 Check that the air in the pressure gauge M3 is drained through the valve outlet (3).
 Check that the pressure in the pressure gauge M1 follows the pressure in the pressure gauge M3.

17 Bleed the air from the test bench.

18 Remove the pipes and nipples from the valve.

19 Install the valve to the vehicle. Install the pipes according to the marking done previously.

20 Fill the compressed air system and check if connections are properly sealed.

56366-4 Relay valve, overhaul /Repairer/

Removed

Part number: 1161326, 1592924, 1082480

Special tools: 9992800, 9992976

Disassemble
1 Clean the outside of the valve.

2
3

Note: Attach the valve in a vice with soft jaws.

Cleaning and checking

6 Clean all the components and check them for scratches or signs of sticking. The sealing surfaces cannot
show any signs of wear.
Replace all components included in the repair kit.
7 Lubricate the components with the grease included in the repair kit or with the grease P/N 1161326

Part number: 1161326

Assemble
8

10

Note: Install according to the mark previously done.

Test
11 Install test nipples to the all valve connections. Are necessary:
1 test nipple M16 - P/N 1592924;
2 test nipples M22 - P/N 1082480.

Part number: 1592924 1082480

12 Connect the valve to the test bench P/N 9992800. Use three nipples P/N 9992976.

Special tools: 9992800 9992976

13

To prepare the test, follow the procedure:

 Fully unscrew the stopcock R;

 Close K1, K2, K3 and K5;
 Open K4;
 Connect the air compressed pipe to the test bench (min. 0.7 MPa);
 Connect the pipe C to the output 2;
 Connect the pipe D to the output 4;
 Plug the remaining connections.

14 Test the leakage according to the procedure:

 Screw in R until the pressure gauge M2 is 7.0 bar (0.7 MPa);

 Close K4;
 Check the pressure drop in the pressure gauge M2 during one minute. Maximum allowed drop 0.1 bar
(0.01 MPa);
 Transfer the pipe D from input 4 to input 1;
 Open K4;
 Regulate the pressure on the pressure gauge M2 to 7.0 bar (0.7 MPa);
 Close K4;
 Check the pressure drop in the pressure gauge M2 during one minute. Maximum allowed drop 0.1 bar
(0.01 MPa).

15 Test the function according to the procedure:

 Connect the pipe A to the input 4;

 Unscrew R;
 Open K4 and K5;
 Screw in R until the pressure gauge M2 is 6.0 bar (0.6 MPa);
 Carefully, open K3 and gradually increase the pressure to 6.0 bar (0.6 MPa) on the pressure gauge M1;
 Check that the pressure in the pressure gauge M1 follows the pressure in the pressure gauge M3 and
vice versa. Maximum allowed difference 0.2 bar (0.02 MPa).

16 Test the discharge according to the procedure:

  Close K3;
 Gradually reduce the pressure in pressure gauge M1 opening K1 carefully;
 Check that the pressure gauge M3 indicates the air escape that occurs through the discharge valve;
 Check that the pressure in the pressure gauge M1 follows the pressure in pressure gauge M3.

17 Bleed the air from the test bench.

18 Remove the pipes and nipples from the valve.

Trailer brake control valve /Specification/

Without preset advanced braking. With integrated silencer. Not fitted on vehicles with disc brakes or EBS

Make..... WABCO

Volvo part no...... 20424431

Advance braking pressure setting..... 0-20 kPa (0-0.2 bar)

Advance braking pressure adjustable up to ..... 1.0 bar

Max operating pressure..... 1000 kPa (10 bar)

Connections:

11..... Supply air from compressed air reservoir

12..... Supply line to trailer

22..... Control line to trailer

41..... Control pressure, rear circuit

42..... Control pressure, front circuit

43..... Control pressure, parking brake valve

Control valve, trailer brakes

With preset advanced braking. With integrated silencer. Not fitted on vehicles with disc brakes or EBS.

Make..... WABCO

Volvo part no...... 20424432

Advance braking pressure setting..... 30-50 kPa (0.3-0.5 bar)

Advance braking pressure adjustable up to..... 1.0 bar

Max operating pressure..... 1000 kPa (10 bar)

Connections:

11..... Supply air from compressed air reservoir

12..... Supply line to trailer

22..... Control line to trailer

41..... Control pressure, rear circuit

42..... Control pressure, front circuit

43..... Control pressure, parking brake valve

Trailer brake control valve /description/

The control valve for the trailer brake is used to supply the trailer brake system with supply and control air. Two versions of the
he valve are available, one with preset advanced braking pressure and one without.

There is a preset advanced braking pressure setting screw. The direction of rotation that the screw is turned to increase or
reduce pressure has been changed, compared with the previous control valve.

Ports 42 and 43 on the new control valve have swapped places, compared with earlier control valves. The control valve has
also been equipped with an integrated silencer. This control valve is not fitted on vehicles with disc brakes or EBS.