Service Manual Trucks

Group

56

Air Brake System Schematics and Routing VNL, VNM

PV776-TSP25323/1

Foreword
The descriptions and service procedures contained in this manual are based on design and method studies up to July 1996. The products are under continuous development. Vehicles and components produced after the above date may therefore have different specications and repair methods. When this is believed to have a signicant bearing on this manual, supplementary service bulletins will be issued to cover the changes. The new edition of this manual will update the changes. In service procedures where the title incorporates an operation number, this is a reference to an S.R.T. (Standard Repair Time). Service procedures which do not include an operation number in the title are for general information and no reference is made to an S.R.T. The following levels of observations, cautions and warnings are used in this Service Documentation: Note: Indicates a procedure, practice, or condition that must be followed in order to have the vehicle or component function in the manner intended. Caution: Indicates an unsafe practice where damage to the product could occur. Warning: Indicates an unsafe practice where personal injury or severe damage to the product could occur. Danger: Indicates an unsafe practice where serious personal injury or death could occur.

Volvo GM Heavy Truck

Greensboro, NC USA

Order number: PV776-TSP25323/1

1996 Volvo GM Heavy Truck, Greensboro, NC USA

All rights reserved. No part of this publication may be reproduced, stored in retrieval system, or transmitted in any forms by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Volvo GM Heavy Truck.

Contents
General .................................................................................................... 2 About This Manual ................................................................................ 2 Specications ......................................................................................... 3 ............................................................................................................... 3 Design and Function ............................................................................. 7 Air Brake System ..................................................................................... 7 General .................................................................................................. 7 Air Tubing and Fittings .......................................................................... 8 Air Tubing Repair ................................................................................ 10 Foldout A Brake Schematic, 4x2 Foldout B Brake Schematic, 6x4 Foldout C Supply System Routing Foldout D Front Brake System Routing Foldout E Rear Brake System Routing Foldout F Parking Brake System Routing Foldout G Trailer Brake System Routing Foldout H Accessories System Routing Foldout I Cab Air Tubing Routing

Group 56

About This Manual

General

W5000485

About This Manual

This manual is intended to give information for helping in troubleshooting the brake and air systems from point to point without having to trace the actual tubing. Except for foldouts A and B, each foldout describes a particular circuit with its valves and actuators as located in the vehicle. Foldouts A and B describe the complete brake system schematically. This manual should be used together with Service Manuals Air Brake Valves and Components and Compressors and Air Dryers which describe each component in detail together with specications, troubleshooting and test procedures.

Group 56

Specications

Specications
General
Type ............................................................................................................................................ Compressed air brakes Working pressure ......................................................................................................... 760 to 895 kPa (110 to 130 psi) Variants: 4X2, 4X2, 6X4, 6X4, tractor truck tractor truck

Air Tubing and Fittings

TUBING Material ................................................................................................................................................ Nylon (polyamide) Standard .................................................................................................................................. SAE J844 & FMVSS 106 Sizes: Unreinforced ................................................................................................................................................. 1/4 in. OD Reinforced with ber lament ............................................................................................ 3/8, 1/2, 5/8 and 3/4 in. OD Safety factor, minimum ............................................................................................................................................ 5.3:1 System working pressure, maximum ................................................................................................ 1030 kPa (150 psi) System working temperature range ................................................................................ -40 to +90 C (-40 to +200 F)
 

Group 56

Specications

FITTINGS Type Straight, thread to tube. Cyl. threads with O-ring seal. Straight, thread to tube. Pipe threads. Thread M12x1.5 M10x1.5 M12x1.5 1/2-14 1/2-14 1/2-14 3/8-18 3/8-18 3/8-18 3/8-18 1/4-18 1/4-18 1/4-18 1/8-27 N/A N/A N/A N/A N/A N/A N/A 1/8-27 1/8-27 1/4-18 1/4-18 1/4-18 3/8-18 3/8-18 3/8-18 3/8-18 1/2-14 1/2-14 1/2-14 1/2-14 NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF Tube size 1/4 in. 1/4 in. 3/8 in. 5/8 1/2 3/8 5/8 1/2 3/8 1/4 1/2 3/8 1/4 1/4 in. in. in. in. in. in. in. in. in. in. in. Part number 8077358 8397965 8397850 8397728 8397727 8397726 8397725 8397724 8397723 8397722 8397721 8397720 8397719 8397718 8079336 8079337 8079338 8397891 8397851 8077186 8077187 8397697 8397698 8397699 8397700 8397701 8397702 8397703 8397704 8397705 8397706 8397707 8397708 8076767

Straight, tube to tube.

1/4 to 1/4 in. 3/8 to 3/8 in. 1/2 to 1/2 in. 1/4 in. 3/8 in. 1/4 in. 3/8 in. 1/4 3/8 1/4 3/8 1/2 1/4 3/8 1/2 5/8 3/8 1/2 5/8 3/4 in. in. in. in. in. in. in. in. in. in. in. in. in.

Straight, tube to tube. Bulkhead (at pedal plate). Plugs for bulkhead tting. 90 , thread to tube.


90 , thread to tube (Hex grip around base)

1/8-27 1/4-18 1/4-18 1/4-18 3/8-18 3/8-18 3/8-18 1/2-14 1/2-14

NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF

1/4 1/4 3/8 1/2 1/4 3/8 1/2 3/8 1/2

in. in. in. in. in. in. in. in. in.

8397770 8397771 8397772 8397773 8397774 8397775 8397776 8397777 8397778

Group 56

Specications

FITTINGS Type 45 , thread to tube.



Thread 1/8-27 1/8-27 1/4-18 1/4-18 1/4-18 3/8-18 3/8-18 1/2-14 1/2-14 1/2-14 NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF

Tube 1 1/4 3/8 1/4 3/8 1/2 3/8 1/2 3/8 1/2 3/4 in. in. in. in. in. in. in. in. in. in. Tube 2 1/4 1/4 3/8 3/8 1/2 1/2 3/8 1/2 1/2 1/2 1/2 1/2 1/2 1/2 1/8 1/4 3/8 1/4 3/8 1/2 3/8 1/2 3/8 1/2 1/4 1/2 3/8 1/2 1/2 1/2 5/8 in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in.

Part Number 8397709 8397710 8397711 8397712 8397713 8397714 8397715 8397716 8397717 8076768

Thread Branch Tee, thread to tube and tube. 1/8-27 1/4-18 1/4-18 1/4-18 1/4-18 1/4-18 3/8-18 3/8-18 3/8-18 3/8-18 1/2-14 1/2-14 1/2-14 1/2-14 1/8-27 1/8-27 1/8-27 1/4-18 1/4-18 1/4-18 3/8-18 3/8-18 1/2-14 1/2-14 1/4-18 3/8-18 1/2-14 1/2-14 1/2-14 1/2-14 1/2-14 NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF

Tube 1 1/4 1/4 1/4 3/8 1/4 1/2 3/8 1/4 1/2 5/8 1/4 3/8 1/2 5/8 1/8 1/4 3/8 1/4 3/8 1/2 3/8 1/2 3/8 1/2 1/4 1/2 1/2 3/8 1/2 5/8 5/8 in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in.

8397729 8397730 8397731 8397732 8397733 8397734 8397735 8397736 8397737 8397738 8397739 8397740 8397741 8397742 8397849 8397779 8397852 8397780 8397781 8397782 8397783 8397784 8397785 8397786 8397763 8397764 8397765 8397766 8397767 8397768 8397769

Branch Tee, thread to tube - tube. (Hex grip around base).

Branch Tee, 90 , thread to tube - tube.

Group 56

Specications

FITTINGS Type Run Tee, thread to tube - tube.  (Tube 1 - straight; tube 2 - 90 ). Thread 1/4-18 1/4-18 1/4-18 1/4-18 1/4-18 3/8-18 3/8-18 3/8-18 3/8-18 3/8-18 3/8-18 3/8-18 1/2-14 1/2-14 1/2-14 1/2-14 1/2-14 1/2-14 1/8-27 1/4-18 1/4-18 1/4-18 3/8-18 3/8-18 1/2-14 1/2-14 NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF NPTF Tube 1 1/4 3/8 1/4 3/8 1/2 1/4 1/4 3/8 1/2 1/4 1/2 1/4 1/2 1/4 3/8 1/4 1/2 5/8 1/4 1/4 3/8 1/2 3/8 1/2 3/8 1/2 in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. Tube 2 1/4 1/4 3.8 3/8 1/2 1/4 3/8 3/8 3/8 1/2 1/2 5/8 1/4 3/8 3/8 1/2 1/2 1/2 1/4 1/4 3/8 1/2 3/8 1/2 3/8 1/2 in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. in. Part Number 8397743 8397744 8397745 8397746 8397747 8397750 8397751 8397752 8397753 8397754 8397755 8397756 8397757 8397758 8397759 8397760 8397761 8397762 8397787 8397788 8397789 8397790 8397791 8397792 8397793 8397794

Run Tee, thread to tube - tube.  (Tube 1 - straight; tube 2 - 90 ). (Hex grip around base).

Tube 1 Branch Tee, tube to tube - tube. 1.4 3/8 1/2 1/4 in. in. in. in.

Tube 2 1.4 3/8 1/2 3/8 in. in. in. in.

Tube 3 1.4 3/8 1/2 3/8 in. in. in. in. 8397804 8397805 8397806 8397927 8079457

Run Tee, tube to bulkhead to tube tube (Used for stoplight switch).

1/4 in.

1/4 in.

1/4 in.

Group 56

Design and Function

Design and Function Air Brake System

W5000581

1 2 3 4 5 6 7 8 9

Compressor Governor Air Dryer Wet Tank B System Tank A System Tank Foot Valve Quick Release Valve Relay Valve

10 11 12 13 14 15 16

ABS Modulator Valve Spring Brake Chamber Front Brake Chamber Manifold Dash Valve Quick Release Valve Trailer Hand Brake Valve Manifold Tractor Protection Valve

17 Low Air Pressure Switch 18 Air Pressure Gauge 19 Accessory Manifold 20 Pressure Protection Valve 21 Parking/Daytime Running Light Switch 22 Stop Light Switch

General
The compressed air brake system is separated into two parts: a supply system and a control system. The supply system produces, stores and supplies compressed air to the various brake valves in the system and to any air powered accessories. The control system is on the downside of an operating valve. The valve is regulating the amount of air going to an actuator or other valve. Main operating valves are Foot Valve(7), Trailer Hand Brake Valve(15) and Manifold Dash Valve(13). They regulate air pressure going to the wheel brake chambers when operated. Other operating valves outside the brake system connect to the B system tank(5). A pressure protection valve(20) protects the brake system from draining, should a problem occur in an accessory supply line. A main supply line goes to the cab, supplying air to cab components, and to the accessory manifold(19), located in the frame, supplying air to chassis components. The circuit diagram above shows components for an ABS brake system. Components 9 and 10 change depending on application and vendor types. See Service Manual Air Brake Valves and Components for more information. 7

Group 56

Design and Function

Air Tubing and Fittings

The foldouts represent the brake system as a schematic layout or show actual routing in the vehicle. Foldouts A and B are schematics of the entire brake system on a 4x2 and a 6x4 vehicle. All other foldouts show the brake system valves and tubing in separate circuits. All color on tubing and in the schematic layouts conform to the standardized color scheme listed to the right. The tubing in the foldouts are colored the same as the actual tubing in the vehicle. This helps the identication and troubleshooting process with less possibility for mistakes. TUBING COLOR, PRIMARY BLUE ...................................... Supply System RED ................................ Front Service Brake GREEN ............................ Rear Service Brake ORANGE ................................. Parking Brake TUBING COLOR, SECONDARY BLUE (1/4 in.) ...................... Air Suspension Exhaust GREY (1/4 in.) ............................ Diff. Lock, Interaxle GREY (3/8 in.) ........................... Trailer Hand Control BROWN (1/4 in.) ...................... Diff. Lock, Interwheel YELLOW (1/4 in.) ................ Fifth Wheel Air Cylinder YELLOW (3/8 in.) ........ Compressor Supply; Exhaust ORANGE (1/4 in.) ................ Bobtail Balance Control BLACK (1/4 in.) .................. Air Seat; Options Supply Circuit Circuit Circuit Circuit

All tubing is made of nylon and sizes are always measured as an outer diameter (OD). The 1/4 in. tubing is a solid core, single ply extrusion. All other sizes are made of a solid core, covered with a protective, colored layer with ber reinforcement between the layers. The cover is treated for heat and sunlight resistance.
W5000379

In areas where great exibility is needed, air is routed in rubber hoses, for example, between frame and the axles. A hose is built up of three layers of rubber and reinforcement. Hoses are specically made for each installation to the correct length with crimped on ttings on either end. Fittings are typically of the push-connect type. To connect or disconnect tubing is very easy, which simplies troubleshooting in the air system. New, simple test gauges have been introduced for testing the valves and pressures (See Service Manual: Air Valves and Components).

W5000384

W5000377

The tting body is made of brass. An internal O-ring seals on the outside diameter of the tubing and the retaining collar holds the tubing rmly in place. Straight ttings have an internal hex grip, most others have external hex grip. A number of valves also come with push-type connectors already installed in the valve body. The tting is designed for letting the tubing rotate to eliminate kinks. The tting IS NOT designed for locations with continuous movement, such as, between frame and axle. Threads are pre-applied with sealant. A tting can be reused in the same port up to ve times before new sealant needs to be applied. 8

W5000378

Group 56

Design and Function

Air Tubing Installation

To ensure a tight seal between tubing and tting, the tubing end needs to be cut straight. Also, inspect tubing that has been removed for teethmarks around the perimeter where the retaining collar holds the tubing in place. If the marks are too deep, that is, can be easily seen or a depression can be felt by running a ngernail across mark, recut the tubing before reinstalling. Installing is done by aligning tubing in a straight line with the tting opening. Push until the tubing stops against the bottom of the tting.

W5000380

W5000381

When the tubing has bottomed in the tting, pull back to make the collar retaining teeth engage the tubing. Do not pull too hard, only enough to ensure that the collar has gripped the tubing.

W5000382

Air Tubing Removal

To make removal easier, remove tubing when valve or component is still in place.

WARNING
Always make sure that all compressed air is removed from the air system before removing tubing or components. Compressed air has great force and can create serious personal injury.
W5000580

To disconnect, push the tubing into the tting until it bottoms. Use release tool J42189 to push in the collar and then pull out tubing while holding the collar in.

Group 56

Design and Function

Air Tubing Repair

In the event that tubing has been severed as the result of an accident or if tubing needs to be lengthened for rerouting, there are certain procedures that must be followed. In general, there are no restrictions against repairing tubing versus replacing it. A repaired tubing has the same integrity as the rest of the system if the repairs are done properly. Tube to tube ttings are available for 1/4, 3/8 and 1/2 in. tubing.

W5000582

Damage to one tube is repaired so that the repair tting is close to a bracket for support. Prepare the tubing as outlined on the previous page. Push the tubing ends into the tting. Leak test tting at full pressure after system pressure has been established again.

W5000583

If a whole bundle of tubing needs to be repaired or lengthened, make sure the ttings are staggered instead of installed at the same length. Put the larger ttings close to a bracket for support and the smaller ttings further away.

W5000584

10

22
This schematic describes the air brake system. All colors are as they appear on the tubing in the vehicle. Components are grouped together so that the left of the schematic represents the front of the vehicle and the right represents the rear of the vehicle. Other locations are not representative of true location in the vehicle. Use the schematic for troubleshooting and understanding the air brake system function. To separate the supply and operation systems, the operation system is shown with dashed lines. In the vehicle, all tubing is solidly colored. Colors are to current standard ( see list on page 8 ) and are separated into main groups, as listed:

16 11 11 10 13

12 10

15 7
21

8
17

14 1 2 3 18
17

18 10
- Supply System Circuit - Front Service Brake Circuit - Rear Service Brake Circuit - Parking Brake Circuit - Trailer Supply - Trailer Hand Control Circuit
Supply Operation

19
20

10 4 12 5 5 6 6 11 11

1 2 3 4 5 6 7 8

Compressor Governor Air Dryer Wet Tank B System Tank A System Tank Foot Valve Quick Release Valve

9 Relay Valve 10 ABS Modulator Valve 11 Spring Brake Chamber 12 Front Brake Chamber 13 Manifold Dash Valve 14 Quick Release Valve 15 Trailer Hand Brake Valve 16 Manifold Tractor Protection Valve

17 Low Air Pressure Switch 18 Air Gauge 19 Accessory Manifold 20 Pressure Protection Valve 21 Park/Daytime Running Light Switch 22 Stoplight Switch V560233

Foldout A
Brake Schematic 4x2

22
This schematic describes the air brake system. All colors are as they appear on the tubing in the vehicle. Components are grouped together so that the left of the schematic represents the front of the vehicle and the right represents the rear of the vehicle. Other locations are not representative of true location in the vehicle. Use the schematic for troubleshooting and understanding the air brake system function. To separate the supply and operation systems, the operation system is shown with dashed lines. In the vehicle, all tubing is solidly colored. Colors are to current standard ( see list on page 8 ) and are separated into main groups, as listed:

16 11 11 10 13

12 10

15 7
21

8
17

14 1 2 3 18
17

18 10
- Supply System Circuit - Front Service Brake Circuit - Rear Service Brake Circuit - Parking Brake Circuit - Trailer Supply Circuit - Trailer Hand Control Circuit
Supply Operation

19
20

10 4 12 5 5 6 6 11 11

1 2 3 4 5 6 7 8

Compressor Governor Air Dryer Wet Tank B System Tank A System Tank Foot Valve Quick Release Valve

9 Relay Valve 10 ABS Modulator Valve 11 Spring Brake Chamber 12 Front Brake Chamber 13 Manifold Dash Valve 14 Quick Release Valve 15 Trailer Hand Brake Valve 16 Manifold Tractor Protection Valve

17 Low Air Pressure Switch 18 Air Gauge 19 Accessory Manifold 20 Pressure Protection Valve 21 Park/Daytime Running Light Switch 22 Stoplight Switch V560228

20

5 5

6 6

1 Compressor 2 Governor 3 Air Dryer 4 Wet Tank 5 B System Tank 6 A System Tank 20 Pressure Protection Valve

Foldout B
Brake Schematic 6x4

V560073

1 2

WABCO

3 2 4 1

BENDIX ADIP

1 3 2
1 - SUPPLY ( BLACK ) 2 - DELIVERY ( 5/8" BLUE ) 3 - CONTROL ( 1/2" BLUE ) 4 - FOR HOLSET COMPRS. ONLY

MIDLAND PURE AIR PLUS

THE LIMITED RETURN CHECK VALVE IS ONLY USED WITH WABCO AIR DRYER. ALL OTHERS HAVE STANDARD CHECK VALVE

6x4
2 1

4x2

CR TURBO 2000

12 16 10 7 13 8
17

18

19
20

10 5 5 12 11 4

5 B System Tank 7 Foot Valve 8 Quick Release Valve 10 ABS Modulator Valve 12 Front Brake Chamber 17 Low Air Pressure Switch 18 Air Gauge 20 Pressure Protection Valve

Foldout C
Supply System Routing

6x4

4x2

FROM TANK TO WHEELS

V560074

11 10

11

7 9
17

18

5 4 5

6 6

10 11 11

6 A System Tank 7 Foot Brake Valve 9 Relay Valve 10 ABS Modulator Valve 11 Spring Brake Chamber 17 Low Air Pressure Indicator 18 Air Gauge

Foldout D
Front Brake System Routing

BOBTAIL PROPORTION

SPRING BRAKE BALANCE

TO BRAKE CHAMBER

RELAY VALVE

SUPPLY SERVICE

TO SPRING BRAKES QUICK RELEASE VALVE

ABS w/ ATC

ABS
ABS MODULATOR VALVE

FROM TANK TO RELAY VALVE TO FOOT VALVE

4x2

TO TRACTOR PROTECTION VALVE

6x4
V560100

11 13

11
7

21

14

5 5 6

6 6

11

11
4

5 6 9 11 13 14 21

B System Tank A System Tank Relay Valve Spring Brake Chamber Manifold Dash Valve Quick Release Valve Park/Daytime Running Light Switch

Foldout E
Rear Brake Routing

2 1 3

4x2

1- TO A SYSTEM PRESSURE GAUGE 2- TO B SYSTEM PRESSURE GAUGE 3- PARK/DAYTIME RUNNING LIGHT SWITCH

6x4
V560212

22 15 7

16

9 13

5 5

6 6

11
5 B System Tank 6 A System Tank 7 Foot Valve 9 Relay Valve 13 Manifold Dash Valve 15 Trailer Hand Brake Valve 16 Manifold Tractor Protection Valve 22 Stop Light Switch

Foldout F
Parking Brake Routing

4x2

6x4
V560216

BACK OF CAB
FAN AIR SPRINGS BELLOWS

ENGINE BRAKE ( VOLVO ONLY )

VENDOR TRANSMISSION

VOLVO TRANSMISSION

TRANSMISSION HORN
2 1 3 4

2 1

3 4

5 6

20

19
AIR SPRINGS BELLOWS

AIR SUSPENSION DUMP ( SEE FOLDOUT I )

SUSP. LEVELING VALVE

5 B System Tank 19 Accessory Manifold 20 Pressure Protection Valve

Foldout G
Trailer Brake System Routing

VENDOR TRANSMISSION

VOLVO TRANSMISSION

See Foldout I
V560220

SUP SUP DEL

SUP SUP DEL

IF W/O FULL DIFF. LOCK

SUP SUP SUP DEL

B1 A3 B3 C3 D3

SUP DEL

E1

DIFFERENTIAL LOCKS

20

19

SUSP. LEVEL VALVE

5
AIR SUSPENSION ( SEE FOLDOUT H )

FIFTH WHEEL CYLINDER

5 B System Tank 19 Accessory Manifold 20 Pressure Protection Valve

Foldout H
Accessories System Routing

TO BRAKE APPLICATION GAUGE. FROM E-1 TO AIR RIDE SEATS

SEE BACK OF THIS FOLDOUT FOR DETAIL

V560217

AIR SUSPENSION

This view shows the switches from the rear of the dashboard. Depending on what options are installed on the vehicle, the hookup to the switches changes as shown on this page. The top left configuration is when no switch is installed. Air is then piped straight to the air ride seat(s). The black tubing is marked at the end, giving the indication of which is supply from the tank and which supplies the air ride seat(s).

Foldout I
Cab Air Line Routing

AIR SUSPENSION

FIFTH WHEEL

INTERWHEEL

INTERAXLE

INTERWHEEL

INTERAXLE

FIFTH WHEEL

Volvo Trucks North America, Inc.

P.O. Box 26115, Greensboro, NC 27402-6115

Volvo Trucks Canada, Ltd.

6490 Vipond Drive, Mississauga, Ontario L5T 1W8 http://www.volvotrucks.volvo.com

PV776-TSP25323/1

7.1996

Volvo Trucks North America, Inc., 1996