1147531 - A25F-A40F Step 1

This course with instructor will give you a general overview of the products involved. Machines covered are A25F, A30F,
A35F and A40F. The course contains theoretical and practical exercises in order to increase understanding of the
systems.
TARGET GROUP:
Service technicians
LEARNING OBJECTIVES:
After the course the student can:

- Find the machine's main components.

- Describe the function and main components of the subsystems as well as how they actuate each other.

- Find and use available service information.

- Carry out checking and adjustment in accordance with instructions in the service information.

- Carry out basic troubleshooting in accordance with service information.

1
- Find and use service instructions and service programmes.
PRIOR KNOWLEDGE:
Achieved knowledge and skills in accordance with certificate[Electric Systems], [Hydraulic Systems] and [VCADS Pro].
DURATION:
32 hours

1.1
1088384 - Study guide

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 1127217 - Compressed air system

When the engine is running, the compressor is driven by the engine's timing gear. The compressor draws air through the
engine's air filter and generates a pressure in the air drier. The air drier has a filter which collects the water in the air.
Then the pressure builds up in the regeneration tank and out to the air tank. From the air tank there is a feed line to the
parking brake and a pressure retention valve. The pressure retention valve ensures the pressure in the parking brake
circuit if one or several of the other users cannot keep the pressure up. The safety valve is located before the pressure

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When the pressure to the parking brake is high enough, filling of the other circuits start. When the cut-out pressure in the
regulator has been reached, the compressor is stopped by the pressure regulator in the air drier. The control line from
the air drier to the compressor is pressurized. The cut-out valve in the compressor is acted on by and the air is pumped
around inside the compressor. At the same time, the air in the regeneration tank is led through the bottom of the air
drier's filter and out through a silencer. In this way, the air in the regeneration tank evacuates any water that the filter has
collected. The compressor does not operate until the pressure in the system drops below the cut-in pressure, then the
channel to the air drier's silencer closes and the control line to the compressor becomes pressureless, and the pressure
starts to build up again.
Components

- EPG and wastegate (D11F-D16F)

- Regeneration tank

- Operator's seat suspension

- Air drier

- Valve, parking brake

- Differential locks

- Air tank

- Horn

- Compressor

- Pressure retaining valve

- Parking brake

115.1
 1074864 - Compressor

Compressor
All articulated haulers have a compressor with feedback from the pressure regulator in the air drier. When full system
pressure is reached, a signal is sent from the pressure regulator enabling the compressor to go to a so-called power
reduction phase.
The pressure line from the pressure regulator to the compressor (arrow, A), is connected to a piston at the top of the
compressor. This piston is connected with a valve plate (grey).
The valve plate is normally in position B, during compressoroperation. When the line from the pressure regulator is
pressurized,the piston forces the valve plate to position C, which opens a channelto the top of the compressor. This
channel leads to an expansion space,which means that the compressor pumps the air to a bigger space. Inturn, this
gives lower compression and power consumption.
Whenthe system pressure drops, the pressure regulator drains the pressurein the signal line and the valve plate can
return to position B withspring force.
On machines with D11H-D16H engines, this compressoris also used to supply the EATS-system with high-pressure air.

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 1088099 - Valves, compressed air

On the F-series articulated haulers there are valves for P-brake, pressure retention, as well as transverse differential
lock installed on the front of the muffler bow, as compared to earlier series where these where located on the right cab
wall.
Components (from the top):
Parking brake's solenoid valve, MA5501
Parking brake pressure sensor, SE5501
Transverse differential lock's solenoid valve, MA4603
And down to the right:
Pressure retaining valve

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 1074866 - Parking brake

The parking brake is a disc brake acting on the propeller shaft behind the hitch. For safety reasons, the brake is applied
with spring force and released with compressed air. The longitudinal differential lock is always engaged together with the
parking brake to obtain braking action on two axles. The parking brake can hold a loaded machine on grades up to 18%.
The brake is released at approx. 5.6 bar.
When changing pads the machine shall be blocked, and load body support or load body lock shall be used. The spring
brake cylinder should be kept compressed with the caging bolt (1). The caging bolt is inserted in the hole in the cylinder
housing, behind the plastic plug (2), and is locked by turning it ¼ turn clockwise. When installing new brake pads the
automatic adjustment has to be backed up/reset. The automatic adjustment is located behind plug (3).
The parking brake is applied automatically if the pressure is lost in both the front and rear circuit. When the parking
brake is used as emergency brake, the Load & Dump brake is also applied automatically (if machine speed is above 2
km/h).
Gears cannot be activated when the parking brake is applied.

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1088117 - Compressed air diagram

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 A25F/A30F

1088121 - Brake components, overview

- Brake pump/cooling fan pump

- Brake charging valve, brake charging/cooling

- Foot brake valve

- Accumulator bank, front brake circuit

- Accumulator, servo line

- Valve block, Load & Dump brake

- Accumulator bank, rear brake circuit

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- Relay valve, rear brake circuit
- Hydraulic Tank

- Relay valve, front brake circuit

- Accumulator, servo pressure rear brake circuit

- Pressure oil filter

- Wheel brake

120.1
 A35F/A40F

1088123 - Brake components, overview

- Brake pump/cooling fan pump

- Foot brake valve

- Accumulator, servo pressure front brake circuit

- Accumulator bank, front brake circuit

- Accumulator, servo line

- Valve block, Load & Dump brake

- Accumulator bank, rear brake circuit

- Relay valve, rear brake circuit

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- Hydraulic Tank
- Brake charging valve, brake charging/cooling

- Accumulator, servo pressure rear brake circuit

- Pressure oil filter

- Wheel brake

121.1
 1074868 - Brake pedal

When the Load & Dump brake via MA5901 or Automatic brake via PWM5203, is used, a servo pressure allows to the
brake pedal's connection (A).

Positions in Fig. 2

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 A25F/A30F A35F/A40F

1088127 - Valve, brake charging

The F-series' articulated haulers do not have a brakecharging pump. Instead the brake pressure is built up with the
radiator'shydraulic pump and a Brake charging valve. The Brake charging valvecontrols the flow to the brake system or
the cooling system.
TheBrake charging valve on A25F and A30F is located on the left radiatorbow. On A35F and A40F the Brake charging
valve is located in the sameblock as PWM5201, which controls the secondary coolant pump.
When the machine starts, the pump begins to build upthe pressure in the brake system through the pressure oil filter
andto the Load & Dump brake block. In this block the oil is distributedthrough non-return valves to the tractor's and
trailer's accumulators.
The pressure increases rapidly up to the accumulators' prechargepressure, and then continues to increase slowly up to
the brake system'soperating pressure. The control light turns off first when the sensorsfor the tractor's brake
circuit(SE5201)and trailer's brake circuit(SE5202)registerthat operating pressure has been reached. Now the pump
switches todriving the cooling fan, at the same time as the brake pressure ismonitored. As soon as the operating
pressure drops under its limitvalue, the pump switches back to charge the brake pressure

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 1088129 - Load & dump brake block

The Load & Dump brake block is located on the mufflerbow. The block contains two non-return valves which also
separatethe two brake circuits. The two sensors measure the pressure in eachbrake circuit. Solenoid valve MA5901 is
used to activate the Load& Dump brake by deploying a servo pressure to the brake pedal'sconnection A, thereby
applying the wheel brakes on all wheels. Thecorresponding function is also used for the Automatic brake
function,however, proportional valve PWM5203 is used for this function.
The smaller accumulator in the servo system makes it possible tokeep the Load & Dump brake/Automatic brake
activated when theengine is not running. The brake servo pressure accumulator is pre-chargedwith 10 bar.

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 1091194 - Relay valve

Relay valves are located on the inside of the rear frame on all machines in the F-series. A relay valve is also located just
behind the hydraulic block on the tractor on A25F and A30F. By using a relay valve the delay in the brake system is
reduced, from when the pedal is pressed to when the brakes really are applied. When the deployed pressure from the
pedal reaches the servo valve via connection 3, the slide will be pressed against the spring force and open between
connection 5 and 1, and let out brake pressure to the brakes, which matches the servo pressure. When the servo
pressure disappears (pedal is let up) the slide is forced in the other direction by the spring and the pressure in the brake
is drained to tank.
Important! A25F and A30F, as well as A35F and A40F have different relay valves due to different deployed brake
pressure to the wheel brakes. To reduce the risk of mix-ups in spare parts handling the relay valves are clearly marked
with different colour and markings on the valves.

- Output brake pressure to brakes

- Breather nipple

- Connection servo pressure from brake pedal

- Tank connection

- Connection to accumulator bank 125

 1214916 - Wheel brake, dry brakes

New brake caliper compared to earlier series. One of the differences is that the material in the seals is different
compared to earlier brake calipers. Also, there is a new type of dust seal installed on the new brake caliper. The brake
caliper can be overhauled.

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 1074870 - Wheel brake, wet brakes

Brakes on A35F and A40F are hydraulically operated and oil-cooled multi-disc brakes. The brake discs are completely
surrounded by brake cooling oil. The brake piston has automatic adjustment and brake disc wear can be measured
using an indicator pin. The number of brake discs varies depending on machine and axle.

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1088134 - Hydraulic diagram, brake system

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1088138 - Hydraulic diagram, brake system

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 1088136 - Brake cooling overview

The brake cooling system on A35 and A40 is divided into two circuits; one for the tractor and one for the trailer. Brake
cooling oil is sucked from the by the two hydraulically driven brake cooling oil pumps, which are mounted in the pump
stack on the frame's left inside. Then oil is pumped out to the front axle for the front circuit and the distribution block
between the bogie axles, where it is divided between the first and second bogie axle.
On each axle there is a distribution block which distributes the cooling oil between the axle's two hubs. The axle's
temperature sensor is located on this distribution block, and it reads off the temperature of the cooling oil for the axle's
two hubs. Before the brake cooling oil reaches the heat exchanger, both circuits are mixed and then pass through a
common heat exchanger for the brake circuit. This heat exchanger is located on the left frame member, in parallel with
the transmission's heat exchanger.

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 1088144 - Brake cooling pump

The brake cooling pump is located on the inside of the front frame's left frame member. The pump is driven by a
hydraulic motor which is supplied with oil from the radiator fan pump. The secondary coolant pump is also mounted on
the same shaft. The speed (rpm) of the brake cooling pump can be controlled using a PWM-valve. A speed (rpm) sensor
on the pump shaft is used to monitor the pump rpm. The pump stack always turns with a basic rpm. This gives a small
circulation of brake cooling oil, making it possible to read off the temperatures in the brakes. The pump rpm will increase
if the temperature becomes too high, which means an increase in coolant circulation as well as brake cooling oil
circulation. Brake cooling is divided into two circuits, one for the front axle and one for the bogie axles.

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 1088142 - Brake cooling distribution block

A distribution block for brake cooling is located in the centre on the axles. The distribution blocks distribute the brake
cooling oil between the brakes. The temperature sensors for brake cooling oil are also installed on the distribution
blocks.

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 1088140 - Brake cooling heat exchanger

The heat exchanger for brake cooling is located together with the transmission oil cooler on the front frame's left frame
member. The inner heat exchanger is for the transmission and the outer is for the brake cooling.

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 1088150 - Fan pumps

The fan pumps on the F-series are of the same typeas the pumps used on the E-series and D-series, that is, axial
pistonpumps with variable displacement. As before, the pumps are controlledelectrically and displacement is adjusted
between two set values.Without electric control the pump delivers max. flow. A25F, A30F aswell as the E-series have
two 28 cc. pumps. A35F and A40F have one45 cc. pump and one 28 cc. pump. The bigger of the two also
drivescirculation of brake cooling oil as well as coolant circulation inthe secondary circuit.
The radiator's fan pump on all machinesin the F-series also provides the brake system with pressure via theBrake
charging valve that switch between brake charging and cooling.

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1088146 - Brake cooling oil system, diagram

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