TP-20141 Revised 01-04 Workbook Meritor WABCO Air Brake Systems SECONDARY COLOR KEY SUPPLY SECONDARY PRIMARY PARK/EMERGENCY ABS ELECTRICAL TRAILER CONTROL TRAILER SUPPLY SECONDARY CONTROL PRIMARY TANK FROM PARK VALVE INSET (A) OPTION PRIOR TO MARCH 1, 1998 FMVSS-121 REGULATIONS INVERSION VALVE AND QUICK RELEASE VALVE (INCLUDES ANTI-COMPOUNDING) PRIMARY SUPPLY (WET TANK) ECU SECONDARY CONTROL TO SERVICE RELAY FROM PARK VALVE INSET (B) OPTION AFTER MARCH 1, 1998 FMVSS-121 REGULATIONS NEW INVERSION VALVE AND QUICK RELEASE VALVE (INCLUDES ANTI-COMPOUNDING) PRIMARY DELIVERY SIDE VIEW INSET (A) OR (B) TO SERVICE RELAY
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TP-20141
Revised 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
Truck
Air Supply System
TruckAir Supply System
SUPPLY(WET TANK)
Truck
Air Supply System
3
Compressor____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Air Dryer_________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Supply Tank _________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Pressure Relief Valve _________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Automatic/Manual Drain Valve__________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Low Pressure Switch ___________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Governor ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
4
Truck
Secondary Service System
Secondary Service System
SECONDARY
SUPPLY(WET TANK)
Truck
Secondary 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
Truck
Primary Service System
Primary Service System
SECONDARY
PRIMARY
SUPPLY(WET TANK)
Truck
Primary 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
Truck
Parking System
Parking System
PRIMARY
SECONDARY
SUPPLY(WET TANK)
Truck
Parking System
9
Two-Way Check Valve ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Dash Valve (Yellow Diamond Knob) _________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Quick Release Valve ______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
Spring Brakes__________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________
10
Truck
Anti-Compounding System
Anti-Compounding System
PRIMARY
SECONDARY
SUPPLY(WET TANK)
Truck
Anti-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
Truck
Emergency System (Prior to March 1, 1998)
Emergency System (Prior to March 1, 1998)
SECONDARY
PRIMARY
SUPPLY(WET TANK)
Truck
Emergency System
13
Emergency System
Inversion Valve (Prior to March 1, 1998) Meritor WABCO Production Part Number 9718990010 Meritor WABCO Service Part Number RKN28030 _________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ New Inversion Valve (Used After March 1, 1998) Meritor WABCO Production Part Number 9718990020 Meritor 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)
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 WABCOVehicle Control Systems3331 West Big Beaver Road, Suite 300Troy, MI 48084 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. ArvinMeritor Commercial Vehicle Systems reserves the right to revise the information presented or discontinue the production of parts described at any time.
Copyright 2004 TP-20141ArvinMeritor, Inc. Revised 01-04All Rights Reserved Printed in the USA 16579/24240
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