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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 specifications and repair methods. When this is believed to have a significant 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 Specifications ......................................................................................... 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

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Except for foldouts A and B. troubleshooting and test procedures. each foldout describes a particular circuit with its valves and actuators as located in the vehicle. 2 . Foldouts A and B describe the complete brake system schematically.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. 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 specifications.

......................................................................................................................................................... 6X4............... 5/8 and 3/4 in.................. maximum ............................................................................................... 5......................... SAE J844 & FMVSS 106 Sizes: Unreinforced ......... minimum ......................................................................................................................... tractor truck tractor truck Air Tubing and Fittings TUBING Material .......................................................................................... OD Safety factor.................. OD Reinforced with fiber filament .................................................................................. 1/4 in..........................................Group 56 Specifications Specifications General Type ....... 1030 kPa (150 psi) System working temperature range ......................................................... Compressed air brakes Working pressure ........................................................... 3/8............................... Nylon (polyamide) Standard ................................ 4X2......... -40 to +90 C (-40 to +200 F)   3 ............................................................................................................................... 6X4........................... 760 to 895 kPa (110 to 130 psi) Variants: 4X2..............3:1 System working pressure.......... 1/2...........................................

in. 3/8 in. in. 90 . in. Straight. in. in. Thread M12x1. Plugs for bulkhead fitting. in. 3/8 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. 3/8 in. in. in. in. in. in. 5/8 1/2 3/8 5/8 1/2 3/8 1/4 1/2 3/8 1/4 1/4 in. thread to tube. tube to tube. in. in. in. in. in. tube to tube. in. in. 1/4 in. in. in. thread to tube. 1/4 in. 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. 1/4 to 1/4 in. in. 1/4 in. in.Group 56 Specifications FITTINGS Type Straight.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. thread to tube. in. in. threads with O-ring seal. in. Straight. 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.  90 . in.5 M10x1. Bulkhead (at pedal plate).5 M12x1. 1/2 to 1/2 in. in. 3/8 to 3/8 in. in. 8397770 8397771 8397772 8397773 8397774 8397775 8397776 8397777 8397778 4 . Pipe threads. Cyl.

 5 . in. in. in.  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. 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 and tube. 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. thread to tube. in. in. in. in. in. in. in. in. in. in. in. in. in. in. (Hex grip around base). in. 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. Part Number 8397709 8397710 8397711 8397712 8397713 8397714 8397715 8397716 8397717 8076768 Thread Branch Tee. Branch Tee. in. in. in. in. in. in. in. in. in. in. thread to tube . in. in. 90 .tube. in. in. in. in.tube. in. in.Group 56 Specifications FITTINGS Type 45 . thread to tube . in. in. in. in. in.

in. in. in. in. tube to bulkhead to tube tube (Used for stoplight switch). tube 2 . in. in.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. (Hex grip around base). in.straight. 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. in. in. 8397804 8397805 8397806 8397927 8079457 Run Tee. Tube 2 1/4 1/4 3. Tube 1 Branch Tee.4 3/8 1/2 3/8 in. in. in. in. in.4 3/8 1/2 1/4 in. in. in. in. in. in. in.90 ). in. 1/4 in. 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. Tube 3 1. in. in.  (Tube 1 .90 ). in. tube to tube . in. thread to tube . 1/4 in. in. thread to tube .4 3/8 1/2 3/8 in. in. in. in. in. in. in. in. in.straight. in. in. tube 2 . in. in. Tube 2 1. 6 . in. in. in. 1. in. in. in. in. in. in. in. in. in. 1/4 in.  (Tube 1 . in. in. in. in. in. in.tube. in.tube. in.tube.Group 56 Specifications FITTINGS Type Run Tee.

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

... To connect or disconnect tubing is very easy.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... Options Supply Circuit Circuit Circuit Circuit All tubing is made of nylon and sizes are always measured as an outer diameter (OD).. Fifth Wheel Air Cylinder YELLOW (3/8 in..... W5000379 In areas where great flexibility is needed... Air Suspension Exhaust GREY (1/4 in............ Compressor Supply.. Bobtail Balance Control BLACK (1/4 in.......) ....... All other foldouts show the brake system valves and tubing in separate circuits.) .. The cover is treated for heat and sunlight resistance..) . Interwheel YELLOW (1/4 in.. SECONDARY BLUE (1/4 in........ Interaxle GREY (3/8 in...... Foldouts A and B are schematics of the entire brake system on a 4x2 and a 6x4 vehicle................. W5000384 W5000377 The fitting body is made of brass.... The fitting IS NOT designed for locations with continuous movement.... Exhaust ORANGE (1/4 in. single ply extrusion.. simple test gauges have been introduced for testing the valves and pressures (See Service Manual: Air Valves and Components)..) .. Lock.....) ........... covered with a protective.... 8 W5000378 ........ most others have external hex grip. tubing is a solid core....... between frame and the axles.... The tubing in the foldouts are colored the same as the actual tubing in the vehicle. The fitting is designed for letting the tubing rotate to eliminate kinks... New....... The 1/4 in. for example....... A fitting can be reused in the same port up to five times before new sealant needs to be applied.......... Parking Brake TUBING COLOR....... Fittings are typically of the push-connect type......... All color on tubing and in the schematic layouts conform to the standardized color scheme listed to the right... Hoses are specifically made for each installation to the correct length with crimped on fittings on either end........ An internal O-ring seals on the outside diameter of the tubing and the retaining collar holds the tubing firmly in place.......... Trailer Hand Control BROWN (1/4 in. air is routed in rubber hoses........... Rear Service Brake ORANGE ...... Supply System RED ................. Diff........................ A hose is built up of three layers of rubber and reinforcement.... Diff...............) ... A number of valves also come with push-type connectors already installed in the valve body.) ........ All other sizes are made of a solid core.. such as. This helps the identification and troubleshooting process with less possibility for mistakes. colored layer with fiber reinforcement between the layers. Front Service Brake GREEN . which simplifies troubleshooting in the air system...) ... Lock...... between frame and axle...... Air Seat. PRIMARY BLUE ..... Threads are pre-applied with sealant... TUBING COLOR..... Straight fittings have an internal hex grip........

pull back to make the collar retaining teeth engage the tubing. WARNING Always make sure that all compressed air is removed from the air system before removing tubing or components. If the marks are too deep. 9 . W5000382 Air Tubing Removal To make removal easier. remove tubing when valve or component is still in place. Also. W5000380 W5000381 When the tubing has bottomed in the fitting. Do not pull too hard. that is. Installing is done by aligning tubing in a straight line with the fitting opening. only enough to ensure that the collar has gripped the tubing. can be easily seen or a depression can be felt by running a fingernail across mark. W5000580 To disconnect. Push until the tubing stops against the bottom of the fitting. the tubing end needs to be cut straight. push the tubing into the fitting until it bottoms. Use release tool J42189 to push in the collar and then pull out tubing while holding the collar in. inspect tubing that has been removed for “teethmarks” around the perimeter where the retaining collar holds the tubing in place. recut the tubing before reinstalling.Group 56 Design and Function Air Tubing Installation To ensure a tight seal between tubing and fitting. Compressed air has great force and can create serious personal injury.

Put the larger fittings close to a bracket for support and the smaller fittings further away.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 no restrictions against repairing tubing versus replacing it. Push the tubing ends into the fitting. A repaired tubing has the same integrity as the rest of the system if the repairs are done properly. make sure the fittings are staggered instead of installed at the same length. there are certain procedures that must be followed. 3/8 and 1/2 in. tubing. Prepare the tubing as outlined on the previous page. Tube to tube fittings are available for 1/4. In general. Leak test fitting at full pressure after system pressure has been established again. W5000583 If a whole bundle of tubing needs to be repaired or lengthened. W5000584 10 . W5000582 Damage to one tube is repaired so that the repair fitting is close to a bracket for support.

22 This schematic describes the air brake system. To separate the supply and operation systems. Use the schematic for troubleshooting and understanding the air brake system function.Parking Brake Circuit .Front Service Brake Circuit .Supply System Circuit . as listed: 16 11 11 10 13 12 10 15 7 21 8 17 14 1 2 3 18 17 9 18 10 . Colors are to current standard ( see list on page 8 ) and are separated into main groups. 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. In the vehicle.Trailer Supply . the operation system is shown with dashed lines. all tubing is solidly colored. Other locations are not representative of true location in the vehicle. All colors are as they appear on the tubing in the vehicle.Rear Service Brake 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 V560233 .

Foldout A Brake Schematic 4x2 .

Front Service Brake Circuit . Other locations are not representative of true location in the vehicle. Use the schematic for troubleshooting and understanding the air brake system function.Parking Brake Circuit . Colors are to current standard ( see list on page 8 ) and are separated into main groups. the operation system is shown with dashed lines.22 This schematic describes the air brake system.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 . To separate the supply and operation systems. 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. In the vehicle.Trailer Supply Circuit . all tubing is solidly colored. as listed: 16 11 11 10 13 12 10 15 7 21 8 17 14 1 2 3 18 17 9 18 10 .Supply System Circuit . All colors are as they appear on the tubing in the vehicle.Rear Service Brake Circuit .

1 2 3 20 4 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 .

SUPPLY ( BLACK ) 2 .V560073 3 1 2 WABCO 3 2 4 1 BENDIX ADIP 1 3 2 1 . ONLY MIDLAND PURE AIR PLUS THE LIMITED RETURN CHECK VALVE IS ONLY USED WITH WABCO AIR DRYER.CONTROL ( 1/2" BLUE ) 4 . ALL OTHERS HAVE STANDARD CHECK VALVE 6x4 2 1 4x2 3 CR TURBO 2000 .DELIVERY ( 5/8" BLUE ) 3 .FOR HOLSET COMPRS.

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 3 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 9 9 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 .

TO A SYSTEM PRESSURE GAUGE 2.PARK/DAYTIME RUNNING LIGHT SWITCH 6x4 V560212 .TO B SYSTEM PRESSURE GAUGE 3.2 1 3 4x2 1.

22 15 7 16 9 13 5 5 6 6 3 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 5 6 2 1 3 4 5 6 20 19 AIR SPRINGS BELLOWS 5 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 .

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 .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 1 20 19 SUSP.

FROM E-1 TO AIR RIDE SEATS SEE BACK OF THIS FOLDOUT FOR DETAIL V560217 .TO BRAKE APPLICATION GAUGE.

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

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1996 © Volvo Trucks North America.O.. Inc. NC 27402-6115 Volvo Trucks Canada.com PV776-TSP25323/1 7.volvotrucks. Ltd. Greensboro. Box 26115.Volvo Trucks North America. 1996 . Ontario L5T 1W8 http://www. 6490 Vipond Drive. Inc. Mississauga.volvo. P.