TP-20141 - Meritor WABCO

TP-20141
Revised 01-04
Meritor WABCO
Air Brake Systems
Workbook
SECONDARY
CONTROL
TO SERVICE
RELAY
PRIMARY
TANK
FROM PARK
VALVE
SIDE VIEW
INSET (A) OPTION
PRIOR TO MARCH 1, 1998 FMVSS-121 REGULATIONS
INVERSION VALVE AND QUICK RELEASE VALVE
(INCLUDES ANTI-COMPOUNDING)
ECU
INSET (A) OR (B)
xxxxx
xxxxx xxxxx
xxxxx
PRIMARY
DELIVERY
SECONDARY
CONTROL
001 20/98
472 500 30. 0
MADE IN GERMANY
TO SERVICE
RELAY
FROM PARK
VALVE
INSET (B) OPTION
SECONDARY
SUPPLY
(WET TANK)
AFTER MARCH 1, 1998 FMVSS-121 REGULATIONS
NEW INVERSION VALVE AND QUICK RELEASE VALVE
(INCLUDES ANTI-COMPOUNDING)
COLOR KEY
PRIMARY
SUPPLY
SECONDARY
PRIMARY
PARK/EMERGENCY
ABS ELECTRICAL
TRAILER CONTROL
TRAILER SUPPLY
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.
Introduction
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
앫 Air Supply
앫 Secondary Service
앫 Primary Service
앫 Parking
앫 Anti-Compounding
앫 Emergency (Prior to 3/1/98)
Air Brake System Color Key
앫 Emergency (After 3/1/98)
Tractor/Trailer Systems
앫 Tractor Parking & Trailer Air Supply
COLOR KEY
앫 Trailer Control
For additional information, call ArvinMeritor’s Customer Service Center at 800-535-5560.
1
SUPPLY
SECONDARY
PRIMARY
PARK/EMERGENCY
ABS ELECTRICAL
TRAILER CONTROL
TRAILER SUPPLY
Truck
Air Supply System
Air Supply System
Truck
SUPPLY
(WET TANK)
2
Truck
Air Supply System
Compressor ______________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
Air Dryer _________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
Supply Tank ______________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
Pressure Relief Valve ______________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
Automatic/Manual Drain Valve _____________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
Low Pressure Switch ______________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
Governor _________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
3
Truck
Secondary Service System
Secondary Service System
SECONDARY
SUPPLY
(WET TANK)
4
Truck
Secondary Service System
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_________________________________________________________
__________________________________________________________________________________
5
Truck
Primary Service System
Primary Service System
SECONDARY
SUPPLY
(WET TANK)
PRIMARY
6
Truck
Primary Service System
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 __________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
7
Truck
Parking System
Parking System
SECONDARY
SUPPLY
(WET TANK)
PRIMARY
8
Truck
Parking System
Two-Way Check Valve ____________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
Dash Valve (Yellow Diamond Knob) ________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
Quick Release Valve ______________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
Spring Brakes_____________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
9
Truck
Anti-Compounding System
Anti-Compounding System
SECONDARY
SUPPLY
(WET TANK)
PRIMARY
10
Truck
Anti-Compounding System
INLET A
CHECK
VALVE
DISC
INLET
B
DELIVERY
DELIVERY
INLET OR
CONTROL 1
DELIVERY
INLET OR
CONTROL 2
Quick Release With Two-Way Check Valve _________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
11
Truck
Emergency System (Prior to March 1, 1998)
Emergency System (Prior to March 1, 1998)
SECONDARY
SUPPLY
(WET TANK)
PRIMARY
12
Truck
Emergency System
Emergency System
CONTROL
INLET
DASH VALVE
SUPPLY
DELIVERY
TO SPRING
BRAKE
PRIMARY
RESERVOIR
SUPPLY
SECONDARY
CONTROL
PORT
SUPPLY
PORT
PRIMARY
BALANCE
PORT
DELIVERY
PORT
EXHAUST
CHECK
VALVE
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 ___________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
13
Truck
Emergency System Complete (Prior to March 1, 1998)
Emergency System Complete (Prior to March 1, 1998)
SECONDARY
SUPPLY
(WET TANK)
PRIMARY
14
Truck
Emergency System (After March 1, 1998)
Emergency System (After March 1, 1998)
SECONDARY
SUPPLY
(WET TANK)
PRIMARY
15
Truck
Emergency System Complete (After March 1, 1998)
Emergency System Complete (After March 1, 1998)
SECONDARY
SUPPLY
(WET TANK)
PRIMARY
16
Truck
Self Test (Prior to March 1, 1998)
Self Test (Prior to March 1, 1998)
SECONDARY
SUPPLY
(WET TANK)
PRIMARY
17
Truck
Self Test (After March 1, 1998)
Self Test (After March 1, 1998)
SECONDARY
SUPPLY
(WET TANK)
PRIMARY
18
Notes
19
Truck
Anti-Compounding/Emergency System
Anti-Compounding/Emergency System
SECONDARY
SUPPLY
(WET TANK)
PRIMARY
20
Truck
Anti-Compounding/Emergency System
Inversion Relay Valve With Anti-Compounding ______________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
One-Way Check Valve ____________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
21
Truck
Anti-Compounding/Emergency System
Anti-Compounding/Emergency System
SECONDARY
SUPPLY
(WET TANK)
PRIMARY
22
Truck
Anti-Compounding/Emergency System Test
Anti-Compounding/Emergency System Test
SECONDARY
SUPPLY
(WET TANK)
PRIMARY
23
Tractor
Parking and Trailer Air Supply System
Parking and Trailer Air Supply System
Tractor
SECONDARY
SUPPLY
(WET TANK)
PRIMARY
24
Tractor
Parking and Trailer Air Supply System
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 __________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
25
Tractor
Trailer Control System
Trailer Control System
SECONDARY
SUPPLY
(WET TANK)
PRIMARY
26
Tractor
Trailer Control System
Hand Control Valve _______________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
(2) Two-Way Check Valves ________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
Stoplight Switch __________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
__________________________________________________________________________________
27
Tractor
Air System Complete
Air System Complete
SECONDARY
SUPPLY
(WET TANK)
PRIMARY
28
Tractor
Self Test
Self Test
SECONDARY
SUPPLY
(WET TANK)
PRIMARY
29
Meritor WABCO Vehicle Control Systems
2135 West Maple Road
Troy, MI 48084-7121 USA
800-535-5560
meritorwabco.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
ArvinMeritor, Inc.
All Rights Reserved
Printed in USA
TP-20141
Revised 01-04
16579/22882