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TP-20141Revised 01-04
Workbook
Meritor WABCOAir Brake Systems
SECONDARY
472 500 30. 0
MADE IN GERMANY
001 20/98
xxxxx xxxxx
xxxxx xxxxx
xxxxx xxxxx
xxxxx xxxxx
COLOR KEYSUPPLYSECONDARYPRIMARYPARK/EMERGENCYABS ELECTRICALTRAILER CONTROLTRAILER SUPPLY
SECONDARYCONTROL
PRIMARYTANK
FROM PARKVALVE
INSET (A) OPTIONPRIOR TO MARCH 1, 1998 FMVSS-121 REGULATIONS
INVERSION VALVE AND QUICK RELEASE VALVE(INCLUDES ANTI-COMPOUNDING)
PRIMARY
SUPPLY(WET TANK)
ECU
SECONDARYCONTROL
TO SERVICERELAY
FROM PARKVALVE
INSET (B) OPTIONAFTER MARCH 1, 1998 FMVSS-121 REGULATIONS
NEW INVERSION VALVE AND QUICK RELEASE VALVE(INCLUDES ANTI-COMPOUNDING)
PRIMARYDELIVERY
SIDE VIEW
INSET (A) OR (B)
TO SERVICERELAY
Introduction
1
Introduction The purpose of an air brake system on heavy duty vehicles is to convert air pressure to mechanical energy to activate the foundation brakes. Federal Motor Vehicle Safety Standard 121 dictates how this is to be done for over-the-road vehicles.
The purpose of this book is to help you construct Meritor WABCO Truck and Tractor air systems. It will also help you identify air system components and understand how they relate to FMVSS-121.
NOTE: The systems described in this workbook are generic air brake systems.
Included in this book are:
Truck Systems
� Air Supply
� Secondary Service
� Primary Service
� Parking
� Anti-Compounding
� Emergency (Prior to 3/1/98)
� Emergency (After 3/1/98)
Tractor/Trailer Systems
� Tractor Parking & Trailer Air Supply
� Trailer Control
For additional information, call ArvinMeritor’s Customer Service Center at 800-535-5560.
Air Brake System Color Key
COLOR KEYSUPPLYSECONDARYPRIMARYPARK/EMERGENCYABS ELECTRICALTRAILER CONTROLTRAILER SUPPLY
2
TruckAir Supply System
TruckAir Supply System
SUPPLY(WET TANK)
TruckAir Supply System
3
Compressor ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Air Dryer _________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Supply Tank __________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Pressure Relief Valve __________________________________________________________________________________________________________________________________________________________________________________________________________________________________Automatic/Manual Drain Valve ___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Low Pressure Switch____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Governor _________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
4
TruckSecondary Service System
Secondary Service System
SECONDARY
SUPPLY(WET TANK)
TruckSecondary Service System
5
Pressure Control Check Valve____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Secondary Service Tank _______________________________________________________________________________________________________________________________________________________________________________________________________________________________Manual Drain Valve ___________________________________________________________________________________________________________________________________________________________________________________________________________________________________Air Gauge __________________________________________________________________________________________________________________________________________________________Dual Foot Control Valve _______________________________________________________________________________________________________________________________________________________________________________________________________________________________Quick Release Valve __________________________________________________________________________________________________________________________________________________________________________________________________________________________________ABS Modulator Valve _________________________________________________________________________________________________________________________________________________________________________________________________________________________________Service Chambers_____________________________________________________________________________________________________________________________________________________________________________________________________________________________________Manual Slack Adjusters______________________________________________________________________________________________________________________________________________Automatic Slack Adjusters___________________________________________________________________________________________________________________________________________
6
TruckPrimary Service System
Primary Service System
SECONDARY
PRIMARY
SUPPLY(WET TANK)
TruckPrimary Service System
7
One-Way Check Valve ________________________________________________________________________________________________________________________________________________________________________________________________________________________________Primary Service Tank__________________________________________________________________________________________________________________________________________________________________________________________________________________________________Manual Drain Valve _________________________________________________________________________________________________________________________________________________Air Gauge __________________________________________________________________________________________________________________________________________________________Dual Foot Control Valve _______________________________________________________________________________________________________________________________________________________________________________________________________________________________Service Relay Valve _________________________________________________________________________________________________________________________________________________ABS Modulator Valve _______________________________________________________________________________________________________________________________________________Spring Brakes_______________________________________________________________________________________________________________________________________________________Manual Slack Adjusters______________________________________________________________________________________________________________________________________________Automatic Slack Adjusters___________________________________________________________________________________________________________________________________________Two-Way Check Valve ______________________________________________________________________________________________________________________________________________Stoplight Switch ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________
8
TruckParking System
Parking System
PRIMARY
SECONDARY
SUPPLY(WET TANK)
TruckParking System
9
Two-Way Check Valve ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Dash Valve (Yellow Diamond Knob) __________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Quick Release Valve ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Spring Brakes___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
10
TruckAnti-Compounding System
Anti-Compounding System
PRIMARY
SECONDARY
SUPPLY(WET TANK)
TruckAnti-Compounding System
11
Quick Release With Two-Way Check Valve _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
INLET A
CHECKVALVEDISC
DELIVERY
INLETB
INLET OR CONTROL 1
INLET OR CONTROL 2
DELIVERY DELIVERY
12
TruckEmergency System (Prior to March 1, 1998)
Emergency System (Prior to March 1, 1998)
SECONDARY
PRIMARY
SUPPLY(WET TANK)
TruckEmergency System
13
Emergency System
Inversion Valve (Prior to March 1, 1998)Meritor WABCO Production Part Number 9718990010Meritor WABCO Service Part Number RKN28030 _________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________New Inversion Valve (Used After March 1, 1998)Meritor WABCO Production Part Number 9718990020Meritor WABCO Service Part Number RKN28032 _________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
PRIMARYBALANCEPORT
EXHAUSTCHECKVALVE
DELIVERYPORT
SUPPLYPORT
SECONDARYCONTROLPORT
DELIVERYTO SPRINGBRAKE
DASH VALVESUPPLY
PRIMARYRESERVOIRSUPPLY
CONTROLINLET
14
TruckEmergency System Complete (Prior to March 1, 1998)
Emergency System Complete (Prior to March 1, 1998)
SECONDARY
PRIMARY
SUPPLY(WET TANK)
TruckEmergency System (After March 1, 1998)
15
Emergency System (After March 1, 1998)
SECONDARY
PRIMARY
SUPPLY(WET TANK)
16
TruckEmergency System Complete (After March 1, 1998)
Emergency System Complete (After March 1, 1998)
SECONDARY
PRIMARY
SUPPLY(WET TANK)
TruckSelf Test (Prior to March 1, 1998)
17
Self Test (Prior to March 1, 1998)
SECONDARY
PRIMARY
SUPPLY(WET TANK)
18
TruckSelf Test (After March 1, 1998)
Self Test (After March 1, 1998)
SECONDARY
PRIMARY
SUPPLY(WET TANK)
Notes
19
20
TruckAnti-Compounding/Emergency System
Anti-Compounding/Emergency System
PRIMARY
SECONDARY
SUPPLY(WET TANK)
TruckAnti-Compounding/Emergency System
21
Inversion Relay Valve With Anti-Compounding ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________One-Way Check Valve ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
22
TruckAnti-Compounding/Emergency System
Anti-Compounding/Emergency System
SECONDARY
PRIMARY
SUPPLY(WET TANK)
TruckAnti-Compounding/Emergency System Test
23
Anti-Compounding/Emergency System Test
SECONDARY
PRIMARY
SUPPLY(WET TANK)
24
TractorParking and Trailer Air Supply System
TractorParking and Trailer Air Supply System
SECONDARY
PRIMARY
SUPPLY(WET TANK)
TractorParking and Trailer Air Supply System
25
Module Dash Control (Yellow Diamond Knob & Red Octagon Knob) ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Quick Release With Two-Way Check Valve ___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________(2 Line) Tractor Protection Valve ___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________(3 Line) Tractor Protection Valve ___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________(Trailer Supply) Gladhand ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
26
TractorTrailer Control System
Trailer Control System
SECONDARY
PRIMARY
SUPPLY(WET TANK)
TractorTrailer Control System
27
Hand Control Valve _____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________(2) Two-Way Check Valves______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________Stoplight Switch ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
28
TractorAir System Complete
Air System Complete
SECONDARY
PRIMARY
SUPPLY(WET TANK)
TractorSelf Test
29
Self Test
SECONDARY
PRIMARY
SUPPLY(WET TANK)
Meritor WABCO Vehicle Control Systems2135 West Maple RoadTroy, MI 48084-7121 USA800-535-5560meritorwabco.com
Information contained in this publication was in effect at the time the publication was approved for printing and is subject to change without notice or liability. Meritor WABCO reserves the right to revise the information presented or to discontinue the production of parts described at any time.
Copyright 2004 TP-20141ArvinMeritor, Inc. Revised 01-04All Rights Reserved Printed in USA 16579/22882
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