Workbook Meritor WABCO Air Brake Systems
Workbook Meritor WABCO Air Brake Systems
Workbook Meritor WABCO Air Brake Systems
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001 20/98<br />
472 500 30. 0<br />
MADE IN GERMANY<br />
<strong>Workbook</strong><br />
ECU<br />
SUPPLY<br />
(WET TANK)<br />
SECONDARY<br />
PRIMARY<br />
SIDE VIEW<br />
<strong>Meritor</strong> <strong>WABCO</strong><br />
<strong>Air</strong> <strong>Brake</strong> <strong>Systems</strong><br />
INSET (A) OR (B)<br />
SECONDARY<br />
CONTROL<br />
FROM PARK<br />
VALVE<br />
TP-20141<br />
Revised 01-04<br />
PRIMARY<br />
TANK<br />
INSET (A) OPTION<br />
PRIOR TO MARCH 1, 1998 FMVSS-121 REGULATIONS<br />
INVERSION VALVE AND QUICK RELEASE VALVE<br />
(INCLUDES ANTI-COMPOUNDING)<br />
SECONDARY<br />
CONTROL<br />
TO SERVICE<br />
RELAY<br />
xxxxx xxxxx xxxxx xxxxx<br />
xxxxx xxxxx xxxxx xxxxx<br />
PRIMARY<br />
DELIVERY<br />
TO SERVICE<br />
RELAY<br />
FROM PARK<br />
VALVE<br />
INSET (B) OPTION<br />
AFTER MARCH 1, 1998 FMVSS-121 REGULATIONS<br />
NEW INVERSION VALVE AND QUICK RELEASE VALVE<br />
(INCLUDES ANTI-COMPOUNDING)<br />
COLOR KEY<br />
SUPPLY<br />
SECONDARY<br />
PRIMARY<br />
PARK/EMERGENCY<br />
ABS ELECTRICAL<br />
TRAILER CONTROL<br />
TRAILER SUPPLY
Introduction<br />
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<br />
Motor Vehicle Safety Standard 121 dictates how this is to be done for over-the-road vehicles.<br />
The purpose of this book is to help you construct <strong>Meritor</strong> <strong>WABCO</strong> Truck and Tractor air systems. It will also help you identify air system components and<br />
understand how they relate to FMVSS-121.<br />
NOTE: The systems described in this workbook are generic air brake systems.<br />
Included in this book are:<br />
Truck <strong>Systems</strong><br />
� <strong>Air</strong> Supply<br />
� Secondary Service<br />
� Primary Service<br />
� Parking<br />
� Anti-Compounding<br />
� Emergency (Prior to 3/1/98)<br />
� Emergency (After 3/1/98)<br />
Tractor/Trailer <strong>Systems</strong><br />
� Tractor Parking & Trailer <strong>Air</strong> Supply<br />
� Trailer Control<br />
For additional information, call Arvin<strong>Meritor</strong>’s Customer Service Center at 800-535-5560.<br />
1<br />
<strong>Air</strong> <strong>Brake</strong> System Color Key<br />
COLOR KEY<br />
SUPPLY<br />
SECONDARY<br />
PRIMARY<br />
PARK/EMERGENCY<br />
ABS ELECTRICAL<br />
TRAILER CONTROL<br />
TRAILER SUPPLY
Truck<br />
<strong>Air</strong> Supply System<br />
Truck <strong>Air</strong> Supply System<br />
SUPPLY<br />
(WET TANK)<br />
2
Truck<br />
<strong>Air</strong> Supply System<br />
Compressor ______________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
<strong>Air</strong> Dryer _________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
Supply Tank ______________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
Pressure Relief Valve ______________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
Automatic/Manual Drain Valve _____________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
Low Pressure Switch______________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
Governor _________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
3
Truck<br />
Secondary Service System<br />
Secondary Service System<br />
SUPPLY<br />
(WET TANK)<br />
4<br />
SECONDARY
Truck<br />
Secondary Service System<br />
Pressure Control Check Valve______________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
Secondary Service Tank ___________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
Manual Drain Valve _______________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
<strong>Air</strong> Gauge ________________________________________________________________________<br />
__________________________________________________________________________________<br />
Dual Foot Control Valve ___________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
Quick Release Valve ______________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
ABS Modulator Valve _____________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
Service Chambers_________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
Manual Slack Adjusters____________________________________________________________<br />
__________________________________________________________________________________<br />
Automatic Slack Adjusters_________________________________________________________<br />
__________________________________________________________________________________<br />
5
Truck<br />
Primary Service System<br />
Primary Service System<br />
SUPPLY<br />
(WET TANK)<br />
6<br />
SECONDARY<br />
PRIMARY
Truck<br />
Primary Service System<br />
One-Way Check Valve ____________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
Primary Service Tank______________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
Manual Drain Valve _______________________________________________________________<br />
__________________________________________________________________________________<br />
<strong>Air</strong> Gauge ________________________________________________________________________<br />
__________________________________________________________________________________<br />
Dual Foot Control Valve ___________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
Service Relay Valve _______________________________________________________________<br />
__________________________________________________________________________________<br />
ABS Modulator Valve _____________________________________________________________<br />
__________________________________________________________________________________<br />
Spring <strong>Brake</strong>s_____________________________________________________________________<br />
__________________________________________________________________________________<br />
Manual Slack Adjusters____________________________________________________________<br />
__________________________________________________________________________________<br />
Automatic Slack Adjusters_________________________________________________________<br />
__________________________________________________________________________________<br />
Two-Way Check Valve ____________________________________________________________<br />
__________________________________________________________________________________<br />
Stoplight Switch __________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
7
Truck<br />
Parking System<br />
Parking System<br />
SUPPLY<br />
(WET TANK)<br />
8<br />
SECONDARY<br />
PRIMARY
Truck<br />
Parking System<br />
Two-Way Check Valve ____________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
Dash Valve (Yellow Diamond Knob) ________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
Quick Release Valve ______________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
Spring <strong>Brake</strong>s_____________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
9
Truck<br />
Anti-Compounding System<br />
Anti-Compounding System<br />
SUPPLY<br />
(WET TANK)<br />
10<br />
SECONDARY<br />
PRIMARY
Truck<br />
Anti-Compounding System<br />
INLET A<br />
DELIVERY<br />
CHECK<br />
VALVE<br />
DISC<br />
INLET<br />
B<br />
DELIVERY DELIVERY<br />
INLET OR<br />
CONTROL 1<br />
INLET OR<br />
CONTROL 2<br />
Quick Release With Two-Way Check Valve _________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
11
Truck<br />
Emergency System (Prior to March 1, 1998)<br />
Emergency System (Prior to March 1, 1998)<br />
SUPPLY<br />
(WET TANK)<br />
12<br />
SECONDARY<br />
PRIMARY
Truck<br />
Emergency System<br />
Emergency System<br />
CONTROL<br />
INLET<br />
DASH VALVE<br />
SUPPLY<br />
SECONDARY<br />
CONTROL<br />
PORT<br />
SUPPLY<br />
PORT<br />
DELIVERY<br />
TO SPRING<br />
BRAKE<br />
PRIMARY<br />
RESERVOIR<br />
SUPPLY<br />
PRIMARY<br />
BALANCE<br />
PORT<br />
EXHAUST<br />
CHECK<br />
VALVE<br />
DELIVERY<br />
PORT<br />
Inversion Valve (Prior to March 1, 1998)<br />
<strong>Meritor</strong> <strong>WABCO</strong> Production Part Number 9718990010<br />
<strong>Meritor</strong> <strong>WABCO</strong> Service Part Number RKN28030 ___________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
New Inversion Valve (Used After March 1, 1998)<br />
<strong>Meritor</strong> <strong>WABCO</strong> Production Part Number 9718990020<br />
<strong>Meritor</strong> <strong>WABCO</strong> Service Part Number RKN28032 ___________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
13
Truck<br />
Emergency System Complete (Prior to March 1, 1998)<br />
Emergency System Complete (Prior to March 1, 1998)<br />
SUPPLY<br />
(WET TANK)<br />
14<br />
SECONDARY<br />
PRIMARY
Truck<br />
Emergency System (After March 1, 1998)<br />
Emergency System (After March 1, 1998)<br />
SUPPLY<br />
(WET TANK)<br />
15<br />
SECONDARY<br />
PRIMARY
Truck<br />
Emergency System Complete (After March 1, 1998)<br />
Emergency System Complete (After March 1, 1998)<br />
SUPPLY<br />
(WET TANK)<br />
16<br />
SECONDARY<br />
PRIMARY
Truck<br />
Self Test (Prior to March 1, 1998)<br />
Self Test (Prior to March 1, 1998)<br />
SUPPLY<br />
(WET TANK)<br />
17<br />
SECONDARY<br />
PRIMARY
Truck<br />
Self Test (After March 1, 1998)<br />
Self Test (After March 1, 1998)<br />
SUPPLY<br />
(WET TANK)<br />
18<br />
SECONDARY<br />
PRIMARY
Notes<br />
19
Truck<br />
Anti-Compounding/Emergency System<br />
Anti-Compounding/Emergency System<br />
SUPPLY<br />
(WET TANK)<br />
20<br />
SECONDARY<br />
PRIMARY
Truck<br />
Anti-Compounding/Emergency System<br />
Inversion Relay Valve With Anti-Compounding ______________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
One-Way Check Valve ____________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
21
Truck<br />
Anti-Compounding/Emergency System<br />
Anti-Compounding/Emergency System<br />
SUPPLY<br />
(WET TANK)<br />
SECONDARY<br />
PRIMARY<br />
22
Truck<br />
Anti-Compounding/Emergency System Test<br />
Anti-Compounding/Emergency System Test<br />
SUPPLY<br />
(WET TANK)<br />
SECONDARY<br />
23<br />
PRIMARY
Tractor<br />
Parking and Trailer <strong>Air</strong> Supply System<br />
Tractor Parking and Trailer <strong>Air</strong> Supply System<br />
SUPPLY<br />
(WET TANK)<br />
24<br />
SECONDARY<br />
PRIMARY
Tractor<br />
Parking and Trailer <strong>Air</strong> Supply System<br />
Module Dash Control (Yellow Diamond Knob & Red Octagon Knob) __________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
Quick Release With Two-Way Check Valve _________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
(2 Line) Tractor Protection Valve ___________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
(3 Line) Tractor Protection Valve ___________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
(Trailer Supply) Gladhand __________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
25
Tractor<br />
Trailer Control System<br />
Trailer Control System<br />
SUPPLY<br />
(WET TANK)<br />
26<br />
SECONDARY<br />
PRIMARY
Tractor<br />
Trailer Control System<br />
Hand Control Valve _______________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
(2) Two-Way Check Valves ________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
Stoplight Switch __________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
__________________________________________________________________________________<br />
27
Tractor<br />
<strong>Air</strong> System Complete<br />
<strong>Air</strong> System Complete<br />
SUPPLY<br />
(WET TANK)<br />
28<br />
SECONDARY<br />
PRIMARY
Tractor<br />
Self Test<br />
Self Test<br />
SUPPLY<br />
(WET TANK)<br />
29<br />
SECONDARY<br />
PRIMARY
<strong>Meritor</strong> <strong>WABCO</strong> Vehicle Control <strong>Systems</strong><br />
2135 West Maple Road<br />
Troy, MI 48084-7121 USA<br />
800-535-5560<br />
meritorwabco.com<br />
Information contained in this publication was in effect at the time the publication was approved for printing and is<br />
subject to change without notice or liability. <strong>Meritor</strong> <strong>WABCO</strong> reserves the right to revise the information presented<br />
or to discontinue the production of parts described at any time.<br />
Copyright 2004 TP-20141<br />
Arvin<strong>Meritor</strong>, Inc. Revised 01-04<br />
All Rights Reserved Printed in USA 16579/22882
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