Commercial Vehicle Aftermarket

Service Parts Catalog

www.wabco-auto.com
 About WABCO

THE LEADING GLOBAL SUPPLIER OF COMMERCIAL VEHICLE SAFTEY AND

EFFICIENCY TECHNOLOGIES
WABCO is a leading global supplier of
technologies and services that improve
the safety, efficiency and connectivity of
commercial vehicles. Originating from
the Westinghouse Air Brake Company
founded nearly 150 years ago, WABCO
continues to pioneer breakthrough
innovations to enable autonomous
driving in the commercial vehicle industry.
Today, leading truck, bus and trailer
brands worldwide rely on WABCO’s
differentiating technologies, including
advanced driver assistance, braking,
steering and stability control systems,
and aerodynamic solutions. In 2017,
WABCO reported sales of $3.3 billion
and has nearly 15,000 employees in
40 countries.
As a customer-centric organization,
WABCO continues to significantly
expand its field sales and service
support teams. WABCO delivers a
seamless one-stop-shop environment
for vehicle manufacturers, fleet
operators, dealers and distributors in
North America to help them capitalize
on WABCO’s ever expanding portfolio
of technology solutions.

WABCO PRODUCTS IN NORTH AMERICA

WABCO North America is located in Auburn Hills, Michigan. For more information call the WABCO Customer Care
The organization focuses on the sales of industry-leading Center at (855) 228-3203 or visit:
WABCO safety, efficiency, and connectivity technologies
■■ WABCO Global: www.wabco-auto.com
such as:
■■ WABCO North America: www.wabco-na.com
■■ Foundation Brakes: Air Disc Brakes, Hydraulic Disc
Brakes, Drum Brakes, Brake Chambers ■■ MICO, a WABCO company: www.mico.com
■■ Advanced Driver Assistance Systems: OnGuard™, ■■ R.H. Sheppard, a WABCO company: www.rhsheppard.com
OnGuardACTIVE™, OnLane™, OnLaneALERT™,
OnSide™
■■ Sheppard Steering Gears: Assemblies, Components,
Repair Kits
■■ Aerodynamic Solutions: OptiFlow™ TrailerSkirts™,
OptiFlow™ AutoTail™
■■ Air Charging and Processing: Compressors, Air Dryers
■■ Braking and Stability Control Systems: Truck and
Trailer ABS
■■ Electronic Suspension Control: ECAS
■■ Tire Pressure Monitoring: OptiTire™
Regional offices and an expansive network of field sales and
service professionals are located throughout North America.

2
WABCO Customer Value
ADVANCED SAFETY AND
DRIVER EFFECTIVENESS
WABCO leads the world in the creation and supply of
advanced braking and control systems for trucks, buses and
trailers. WABCO delivers solutions that integrate sophisticated
driver assistance technologies with braking, chassis and
suspension systems.
Connected with customers and aligned with their own
technology roadmaps, our engineering and manufacturing
teams develop new products and functionalities that provide:
■■ Greater ability to control vehicles in critical driving situations
■■ Improved driver effectiveness and comfort
■■ Advanced safety systems that contribute to vehicle
compliance with increasingly stringent safety and
performance regulations
■■ VEHICLE EFFICIENCY AND
ENVIRONMENTAL SUSTAINABILITY
WABCO is at the forefront of our industry’s drive to protect
the environment and develop greener transportation solutions.
Our vision of significant improvements in vehicle efficiency
and environmental sustainability is based on WABCO’s focus
in three key areas:
■■ Improve weight performance ratios of our products by
using lighter materials and enhancing the performance
of existing products
■■ Increase fuel savings by reducing power consumption of
braking system and related products
■■ Develop energy recovery systems that reuse energy
instead of wasting it
3
 Content

NOTES
About WABCO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 WABCO Inform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

WABCO Customer Value . . . . . . . . . . . . . . . . . . . . . . 3 WABCO Academy . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Repair note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Index Part numbers . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Choose Genuine WABCO Parts . . . . . . . . . . . . . . . . . 7

AIR DISC BRAKES

PAN™ range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 MAXXUS™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

PAN™17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 MAXX™22T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

PAN™19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Tool sets for WABCO Air Disc Brakes . . . . . . . . . . . 20

PAN™22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Maintenance of WABCO Air Disc Brakes . . . . . . . . . 22

PAN™25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

HYDRAULIC DISC BRAKES

230 VI OE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 340 VI OE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

230 VI OE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

DRUM BRAKES
230×35 SM OE/OEM . . . . . . . . . . . . . . . . . . . . . . . . 28 360×170 ZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

230×50 SM OEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 410×180 ZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

300×55 SM OEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 400×120 SM OEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

315×80 SM OE/OEM . . . . . . . . . . . . . . . . . . . . . . . . 30 400×140 SM OEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

500×160 SM OE/OEM . . . . . . . . . . . . . . . . . . . . . . . 30 410×220 ZG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

504×160 SM OE/OEM . . . . . . . . . . . . . . . . . . . . . . . 30

4
BRAKE ACTUATORS
TRISTOP™D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 TRISTOP™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

UNISTOP™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

OPTITIRE™
Advanced Tire Pressure Monitoring . . . . . . . . . . . . . . 44 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

WORKSHOP SOLUTIONS
ABS/EBS Code Reader . . . . . . . . . . . . . . . . . . . . . . 50 TPMS Manager . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Bio-Cleaning System Set . . . . . . . . . . . . . . . . . . . . . 52

MICO® PRODUCTS
691 Brake Lock Systems . . . . . . . . . . . . . . . . . . . . . . 57 Twist Brake Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Electric Activated Brake Locks . . . . . . . . . . . . . . . . . 60 Pressure Testing Devices . . . . . . . . . . . . . . . . . . . . . . 63

Cable Brake Locks . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Hydraulic Throttle Controls . . . . . . . . . . . . . . . . . . . . . 64

Lever Brake Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

5
 Notes

This catalog provides an overview of brake and OptiTire™ STRUCTURE OF THE WABCO NUMBER
components offered by WABCO for installation in a wide
range of vehicles. WABCO part numbers consist of 8 or 10 digits.
This document is only an extract from our product range.
You will find more information about our products on the 8 digit Part number
internet in our online product catalog INFORM at Assembling date
http://inform.wabco-auto.com Production date 0318 1218
40 175 072

DISCLAIMER Characteristic number

The information contained within this online catalog and Design size
the functions offered are intended to provide information Serial number
about products available for purchase from WABCO. All
reasonable efforts have been made to ensure the accuracy 10 = Drum brake
of the information. However, WABCO will not be held 12, 13, 16, 17, 18 = Spare part or Repair kit
responsible for any errors or unexpected unfulfillment of 40 = Disc brake
shipments. WABCO does not warrant the accuracy and
reserves the right to make changes to the catalog and its
functions at any time without notice. Except where otherwise 10 digit Part number  001
noted or superseded by process of law, WABCO accepts Production date 5117
no responsibility or liability for any losses or damages of 925 376 112 0
any kind arising out of the use of this online catalog or any
of its related functions. Type of device
Variant
Status digit
TERMS AND CONDITIONS OF USE
0 = New device (complete device)
This online catalog is offered on the basis of the terms and 1 = New device (subassembly)
conditions stated herein. Use of this online catalog confirms 2 = Repair kit or subassembly
the user’s acceptance of these same terms and conditions. 4 = Component part
Such acceptance allows full access to view the catalog and 7 = Replacement device
utilize its functions.

6
Repair notes Choose Genuine WABCO Parts

REPAIR SAFETY, EFFICIENCY, RELIABILITY.

Only qualified personnel of a specialist workshop only
EVERY DAY
are authorized to perform repair work on a vehicle. Genuine WABCO parts are made of high quality materials
■■ Only start the repair after you have read and and are rigorously tested before they leave our factories.
understood all information required for the repair You also have the assurance that every WABCO product
■■ Follow specifications and instructions of vehicle is reinforced by a powerful customer service network.
manufacturer Because WABCO, as a tier one supplier, works with the
■■ Use protective equipment if required (goggles, world’s leading Original Equipment Manufacturers, WABCO
respiratory protection, hearing protection, etc.) has the experience and scale to meet the most accurate
production standards.
You will find any additional documents you may need in the
product catalog INFORM at http://inform.wabco-auto.com
by entering the part number or document number:
■■ Test instructions
■■ Spare Parts Sheet
■■ General repair and test notes (815 010 109 3)

TESTING AFTER INSTALLATION

After replacing or repairing a device, a functional test
of the entire system must be performed.
Always carry out a test drive after you have completed
any work.

7
 Air Disc Brakes PAN™ range

AIR DISC BRAKES

WITH SINGLE-PISTON TECHNOLOGY
The reliable and proven single-piston technology has made
WABCO’s PAN™ range one of the most successful air disc
brake ranges. The compact design is based on the careful
combination of FEM (Finite Element Method) calculations and
single-piston technology. The result: significant vehicle weight
improvement in all classes.

RELIABILITY SERVICE
■■ Encapsulated guiding system with stable metal sealing ■■ Designed to be maintenance-free
■■ Redundant sealing systems at pin guidance and ■■ Lifetime lubrication
adjuster device ■■ Easy pad exchange
■■ Extended service intervals
■■ Less service cost

8
RELIABLE, PROVEN TECHNOLOGY WITH FEWER COMPONENTS
Technical Data PAN™17 PAN™19 PAN™22 PAN™25
Truck: 23,000 Nm /
17,000 ft lbs
Braking torque 10,000 Nm / 7,400 ft lbs 17,000 Nm / 12,500 ft lbs 25,000 Nm / 18,400 ft lbs
Trailer: 21,000 Nm /
15,500 ft lbs

Disc dimension 330×34 mm / 13×1.3 in 375×45 mm / 14.8×1.8 in 430×45 mm / 17×1.8 in 525×41 mm / 20.7×1.6 in

Pad surface area 240 cm² / 37 in² 292 cm² / 45 in² 340 cm² / 53 in² 340 cm² / 53 in²

Pad thickness 19 mm / 0.75 in 21 mm / 0.83 in 23 mm / 0.91 in 23 mm / 0.91 in

Weight (incl. pads) 23 kg / 51 lb 32 kg / 71 lb 36 kg / 79 lb 39 kg / 86 lb

Rim size 17.5 in 19.5 in & 22.5 in 22.5 in 25 in

Max. actuator size Type 20 Type 24 Type 24 Type 24

YOUR BENEFITS
■■ Light weight design
■■ Compact design for easy axle adaptation
■■ Excellent bad road resistance
■■ Heat shielded piston boots
■■ KTL technology (cathodic corrosion protection) coating
as standard corrosion protection

9
 Air Disc Brakes PAN™17

2 15

With the introduction of pneumatic 1

disc brake PAN™17 in 1996, WABCO
pionieered the control of tangential taper
wear. Since then, the patented taper wear
compensation in combination with the
advanced single-piston technology has
passed the test of time. Our success in 13
17.5” wheel applications demonstrates
the effectiveness of this technology. 12

■■ Brake pad formula: Jurid 539-20

■■ Application: IMT

OE PRODUCTION NUMBERS 14
6 11
■■ Left hand brake: 40 175 090 5 8
■■ Right hand brake: 40 175 091 13 7
12

10

Service part Part number Comments

40 175 072 Left hand brake
Brake w/o pads
40 175 073 Right hand brake
Brake pad kit 12 999 806 1, 2, 3, 4, 5
Seals and guide bolt 12 999 699VT 5, 7, 8, 9, 10, 11, 12, 13, 14
Seals for clamping unit 640 175 920 2 5, 6, 14
Pressure plate 640 175 940 2 15

Changing out the bolt kits requires tool set 640 195 522 2 & 640 175 521 2 (page 20).

10
PAN™19

19

The success of PAN™17 was followed

by the introduction of the single-piston
technology to the 19.5” class. With 2
PAN™19 WABCO set new standards
both in the trailer and in the mid-class
truck segments. At only 32 kg it is still
one of the lightest brakes of this size. 11

■■ Brake pad formula: Jurid 539-20 12

■■ Application: IMT

OE PRODUCTION NUMBERS
8
■■ Left hand brake: 40 195 027 9
10 14
■■ Right hand brake: 40 195 028
11 15
18
12

13

16

17

Service part Part number Comments

40 195 037 Left hand brake
Brake w/o pads
40 195 038 Right hand brake
Brake pad kit 12 999 737VT 2, 3, 6, 7, 10
8, 10, 11, 12, 13, 14, 15,
Seals and guide bolt 640 225 921 2
16, 17, 18
Seals for clamping unit 640 175 920 2 8, 9, 10
Pressure plate 640 195 936 2 19

Changing out the bolt kits requires tool set 640 195 522 2 & 640 195 521 2 (page 20).

11
 Air Disc Brakes PAN™22

2
17

With PAN™22 WABCO extended the

single-piston PAN™ range with a brake
for the trailer segment and trucks up
to 18 tons. Pad thickness has been
enlarged by 2 mm, resulting in extended
service intervals compared to previous 1
designs.
■■ Brake pad formula: WABCO 230
■■ Application: Hendrickson, Meritor 6
7
SERIES PART NUMBERS
■■ Left hand brake: 640 225 036 0 8
■■ Right hand brake: 640 225 037 0
14

15

6 16
7 9
13 10

12

11

Service part Part number Comments

640 225 080 0 Left hand brake
Brake w/o pads
640 225 081 0 Right hand brake
Brake pad kit 640 225 922 2 2, 3, 4, 5, 8
6, 8, 9, 10, 11, 12, 13, 14,
Seals and guide bolt 640 225 921 2
15, 16
Seals for clamping unit 640 175 920 2 14, 15, 16
Pressure plate 640 225 926 2 17

Changing out the bolt kits requires tool set 640 195 522 2 & 640 195 521 2 (page 20).

12
PAN™22

3
4

2
2

17
1

■■ Brake pad formula: Jurid 539-20

■■ Application: Ridewell, AXN, Reyco
Graning, IMT

SERIES PART NUMBERS

8
■■ Left hand brake: 40 225 011
9
■■ Right hand brake: 40 225 012

7
6
5 11

8 13
14
9

10

12

15

Service part Part number Comments

40 225 015 Left hand brake
Brake w/o pads
40 225 016 Right hand brake
Brake pad kit 12 999 796 1, 2, 3, 4, 5
5, 7, 8, 9, 10, 11, 12, 13,
Seals and guide bolt 640 225 921 2
14, 15
Seals for clamping unit 640 175 920 2 5, 6, 7
Pressure plate 640 225 926 2 17

Changing out the bolt kits requires tool set 640 195 522 2 & 640 195 521 2 (page 20).

13
 Air Disc Brakes PAN™22

2
2

17

■■ Brake pad formula: Jurid 539-20

■■ Application: Ridewell, AXN, Reyco
Graning, IMT
8
SERIES PART NUMBERS 9

■■ Left hand brake: 640 225 032 0

■■ Right hand brake: 640 225 033 0
7
6
5 11
8 13

9 14

10

12

15

Service part Part number Comments

Brake pad kit 12 999 796 1, 2, 3, 4, 5
5, 7, 8, 9, 10, 11, 12, 13,
Seals and guide bolt 640 225 921 2
14, 15
Seals for clamping unit 640 175 920 2 5, 6, 7
Pressure plate 640 225 926 2 17

Changing out the bolt kits requires tool set 640 195 522 2 & 640 195 521 2 (page 20).

14
PAN™25

4
3

The PAN™®25 brake is a pneumatic

single-piston brake. It is designed for
use in commercial vehicles on front
and rear axle as service, auxiliary and
parking brakes for 25" wheel rims.
9
Applied mainly in big and special use
vehicles like cranes, fire trucks, tractors 8
or military vehicles.
9
SERIES PART NUMBERS
■■ Left hand brake: 640 250 004 0 15
■■ Right hand brake: 640 250 005 0 14

7
6
12
15 10

13

12
11

Service part Part number Comments

Brake pad kit 640 250 921 2 1, 2, 3, 4, 5, 6
6, 7, 8, 9, 10, 11, 12, 13,
Seals and guide bolt 12 999 738VT
14, 15
Seals for clamping unit 640 175 920 2 6, 7, 8

Changing out the bolt kits requires tool set 640 195 522 2 & 640 195 521 2 (page 20).

15
 Air Disc Brakes MAXX™ range

MAXX™ BREAKTHROUGH IN PERFORMANCE AND WEIGHT REDUCTION

MAXX™ is WABCO's latest, lightest and best performing WABCO’s patented single-piston technology is the cornerstone
range of single-piston air disc brakes. of the compact MAXX™ design. Developed using advanced
finite element analysis, the new lightweight design cuts down
MAXX™ is the next, logical evolution of WABCO’s braking
unsprung mass offering payload and fuel economy benefits.In
technology - an air disc brake range that offers lower weight
combination with an efficient service concept this significantly
for even the most demanding applications. Where PAN™
improves Total Cost of Ownership (TCO) or trucks and trailers.
has been the industry benchmark, MAXX™ exceeds its
performance by up to 20%.

REDUCED STOPPING DISTANCE (FMVSS 121)

MAXXUS™ is a heavy duty air disc brake designed for wheel and axle configurations on Class 7 and 8
trucks, providing increased braking capabilities to exceed new federal stopping distance requirements.

NEW REGULATION PREVIOUS REGULATION

250′ <70k GVWR 355′

PREVIOUS AVERAGE STOPPING DISTANCE 275′-285′

CURRENT RSD DRUM BRAKES 220′-240′

WABCO AIR DISC BRAKES 210′-220′

BETTER BY DESIGN
MAXX™ brakes are the latest develop­ vehicles. The proven reliability of design offers exceptional braking
ment in WABCO’s high performance WABCO’s single-piston technology performance at a significantly lower
range of air disc brakes for commercial allied to a compact and innovative weight than previous generations.

16
SHORTER STOPPING DISTANCE AND REDUCED FUEL CONSUMPTION
Technical Data MAXXUS™ MAXX™22T
Braking torque / performance 23,000 Nm / 17,000 ft lbs 21.000 Nm / 15,500 ft lbs
Disc dimensions 430×45 mm / 16.93×1.77 in 430×45 mm / 16.93×1.77 in
Pad surface area 340 cm² / 52.7 in² 340 cm² / 52.7 in²
Pad thickness 21 mm / 0.83 in 23 mm / 0.91 in
Weight (incl. pads) 37 kg / 82 lb 32 kg / 71 lb
Rim size 22.5 in 22,5" / 22.5 in
Maximum actuator size Type 24 Typ 22 / Type 22

WABCO SERVICE KITS

THE MAXX™ SOLUTION
■■ Combination of original WABCO pads and leaf springs
leads to long product life
■■ Reduced service time due to easy brake pad replacement
with crimped springs on pad backplate
■■ Guiding system is easy to access and exchange
■■ Separate kits for pad dust shields, rotor dust shields,
boots, spreader plates and return units available

17
 Air Disc Brakes MAXXUS™

2
4

Heavy duty air disc brake MAXXUS™

7
provides an excellent downhill 8
performance and virtually no fading
or pulling. Downtime is dramatically
reduced with brake pads lasting twice
1
as long as drum linings. 7
■■ Brake pad formula: Jurid 539-20
■■ Application: Freightliner, Western
9
Star
11
SERIES PRODUCTION NUMBERS
■■ Left hand brake: 640 322 050 0
■■ Right hand brake: 640 322 051 0 14
15
16
17 12
13
9

10

12
13

Service part Part number Comments

640 322 065 0 Left hand brake
Brake w/o pads
640 322 066 0 Right hand brake
Brake pads kit 640 322 934 2 3, 4, 5, 6, 17
Seal set 640 322 932 2 7, 8
Resetting unit 640 322 927 2 14, 15, 16, 17
Pressure plate 640 322 935 2 2
Seals and guide bolt 640 322 938 2 7, 8, 9, 10, 11, 12, 13, 17

Changing out the bolt kits requires tool set 640 195 522 2 & 640 322 522 2 (page 20).

18
MAXX™22T

13
11
12

17

16

10
5
Heavy duty air disc brake MAXX™22T
is specifically designed for light and
medium duty trucks as well as trailers.
1
■■ Supports trailer applications up to 5
10 tons axleload
■■ Bidirectional adjuster mechanism
6
ensures optimal running clearance
even under extreme conditions 4
■■ Innovative lightweight design
provides ability to increase payload
■■ Brake pad formula: WABCO 230
9
8
SERIES PRODUCTION NUMBERS 3
2
■■ Left hand brake: 640 222 005 0
■■ Right hand brake: 640 222 006 0 7

3
2

Service part Part number Comments

640 222 007 0 Left hand brake
Brake w/o pads
640 222 008 0 Right hand brake
Brake pads kit 640 222 923 2 8, 11, 12, 13, 16
Seals and guide bolt 640 222 920 2 2, 3, 4, 5, 6, 7, 8, 10
Seals for clamping unit 640 175 920 2 8, 9, 10
Pressure plate 640 225 926 2 17

Changing out the bolt kits requires tool set 640 195 522 2 & 640 322 522 2 (page 20).

19
 Air Disc Brakes Tool sets for WABCO Air Disc Brakes

The WABCO caliper tool sets are modular tool sets for The WABCO caliper tool sets can be used for:
repairing WABCO calipers and adjusting the return units of
■■ Full servicing of PAN™17, 19, 22 and 25 brake calipers
truck or trailers. WABCO has designed a dedicated cranked
ratchet wrench specifically to carry out this often difficult task. ■■ Full servicing of MAXXUS™ and MAXX™ brake calipers
The tools will work with a wide range of OEM equipment,
including (but not limited to) Mercedes, MAN and Schmitz.

BASIC TOOL SET 640 195 522 2

# 10 # 11 # 12 # 13

TOOL SET 640 175 521 2 FOR PAN™17

# 14 # 15 # 16 # 17 # 18 # 19 # 20

TOOL SET 640 195 521 2 FOR PAN™19, PAN™22, PAN™25

# 21 # 22 # 25 # 26 # 27 # 28

TOOL SET 640 322 522 2 FOR MAXXUS™, MAXX™22T

# 19 # 20 # 21 # 22 # 23

# 24 # 25 # 26 # 27 # 29

20
DIFFERENTIATORS
■■ Convenient and fast servicing of MAXX™ and PAN™ ■■ Contains all the tools required to service MAXX™ and
brake calipers. The specially designed ratchet wrench PAN™ brake calipers in one place, allowing you to perform
provides excellent access to difficult to reach places all required maintenance with maximum convenience

HOW IT WORKS

1. Replace the brake pads 2. Operate the adjuster

3. Replace bushing and guide bolts (1 of 2) 4. Replace bushing and guide bolts (2 of 2)

21
 Air Disc Brakes Maintenance of WABCO Air Disc Brakes

1  IDENTIFY YOUR BRAKE 2  DETECT WEAR OUTS

Wear limits

A PAN™19, PAN™22,
OE reference Assembling
date PAN™17 MAXXUS™,
Production B Pos.
date C MAXX™22T
WABCO D
part number
mm / in mm / in
A 34 / 1.34 45 / 1.77
B 28 / 1.10 37 / 1.46
C   7 / 0.28   9 / 0.35
E
D   2 / 0.08   2 / 0.08
E   9 / 0.35 11 / 0.43

Check disc

A B Pos. Description Comment

≤ 0.75 × a
a

a Width rubbing surface -

≤ 0.5 mm A Crazing permissible

Radial cracks, width ≤ 0.5 mm
B permissible
(≤ 0.020")
D C
C Uneveness ≤ 1.5 mm (≤ 0.059") permissible
D Cracks across rubbing surface not permissible
E ≤ 0.15 mm E Disc runout ≤ 0.15 mm (≤ 0.006") permissible

3  FIND REPAIR KIT OR DOWNLOAD SERVICE MANUAL

■■ Open INFORM on http://inform.wabco-auto.com Pos. Kit name Repair
■■ Enter part number of brake caliper
A–E Pads per axle
■■ Click repair radio button
■■ Open spare repair sheet E–H Adjuster per brake
per brake, tool set
I – M, E, P, Q Guide bolts & seals
required
E, Q Seal kit per brake
R Pressure plate per brake

22
 4  ASSEMBLE USING CORRECT TORQUE
2 D
PAN™19, PAN™22,
Pos. PAN™17
C MAXXUS™, MAXX™22T
  130 ±10 Nm + 90° ±5°   130 ±10 Nm + 90° ±5°
1
1151 ±89 lbf in + 90° ±5° 1151 ±89 lbf in + 90° ±5°
  20   ±2 Nm   30   +15 Nm
B
2
177 ±18 lbf in 266 +133 lbf in
B
Observe the instructions of the brake cylinder manufacturer.
3
WABCO: 210 −30 Nm / 1,859 −266 lbf in
A

5  TESTING AFTER INSTALLATION

After replacing or repairing a brake, a functional test of the entire
system must be performed.
B
Always carry out a test drive after you have completed work.

O
H K
G
F
I
E
1

L
1

23
 Hydraulic Disc Brakes

WABCO’s Hydraulic Disc Brakes

for parking and emergency brake
applications have proven their reliability
for more than 40 years.
These brakes are ideal for installation
in a wide variety of Off-Highway Wheel
Loaders, Haulers, Lift Trucks and
Platforms as well as Rough Terrain
Cranes. The brakes are activated
automatically when the system pressure
falls below 1480 psi / 102 bar release
pressure, offering maximum safety and
reliability.

CUT AWAY AND TOP VIEW

11

1 4 3 8 10 6 7 9
2

1 Caliper
2 Guide pins
3+4 Backing plate/ Brake pad
5 Disc spring stack
6 Piston
  7 Adjuster screw
  8 Push rod
  9 Thrust ring
10 Oil chamber
11 Lock nut

24
230 VI OE

40
22

19

24
■■ Floating Caliper Disc Brake with
30 Magnet
17
30
16 ■■ Type 230 VI
30
18 30
17 9
16
8
13 7
6
5

30
2
1

Service part Part number Item number Service part Part number Item number
Brake 40 023 005 Piston 13 477 053  9

Repair kit 12 999 473VT 30 Thrust piece 13 229 167 13

Screw 18 429 151  1 Magnet 17 861 001 16

Cover 13 230 075  2 Tolerance ring 17 665 107 17

Screw 18 425 475  5 Screw 18 429 469 18

Nut 18 441 009  6 Brake pad 12 182 091 19

Ring 13 701 115  7 Bleeding valve 16 200 083 22

Set of dished plate Nut 18 444 000 24

12 303 003  8
springs
Bleeding valve 16 200 152 40

25
 Hydraulic Disc Brakes 230 VI OE

19 40

16

21
30
30 ■■ Floating Caliper Disc Brake
■■ Type 230 VI
30

15 9
8
7
11 6
5

30
2
1

Service part Part number Item number Service part Part number Item number
Brake 40 023 004 Piston 13 477 053  9

Repair kit 12 999 387VT 30 Thrust piece 13 229 146 11

Screw 18 429 151  1 Screw 18 429 469 15

Cover 13 230 075  2 Brake pad 12 182 091 16

Screw 18 425 475  5 Bleeding valve 16 200 083 19

Nut 18 441 009  6 Nut 18 444 000 21

Ring 13 701 115  7 Bleeding valve 16 200 152 40

Set of dished plate

12 303 003  8
springs

26
340 VI OE

40 15
19

24
25
20 13
30
30
■■ Floating Caliper Disc Brake with
30 Magnet
14 30 ■■ Type 340 VI
13
7
14
6

10
4
3

30

Service part Part number Item number Service part Part number Item number
Brake 40 034 005 Ring 17 665 107 14

Repair kit 12 999 521VT 30 Brake pad 12 182 121 15

Ring 13 701 116  3 Bleeding valve 16 200 083 19

Screw 18 425 476  4 Bolt 13 151 249 20

Set of dished plate Screw 13 103 013 24

12 303 004  6
springs
Sealing ring 16 500 780 25
Piston 13 477 058  7
Bleeding valve 16 200 152 40
Thrust piece 13 229 167 10
Magnet 17 861 001 13

27
 230×35 SM OE/OEM
Drum Brakes
230×50 SM OEM

21

21

Hydraulic Duo Servo Brake with

Parking Brake
■■ Diameter 230 to 310 mm /
9.06 to 12.20 in 22
■■ Torque 1,100 - 4,000 Nm / 23
820 - 3,000 ft lbs
25
■■ Wheel size 14 to 16 in
Complete brakes are no longer available.

Brake type Service part Part number

Pull spring (22) 13 301 169
230×35 SM OE/OEM
Spring plate (25) 13 306 010
Pull spring (21) 13 301 217
230×50 SM OEM
Spring plate (23) 13 302 117

28
300×55 SM OEM

3
10

Hydraulic Duo Servo Brake with

2
Parking Brake
■■ Diameter 300 mm / 11.81 in
■■ Torque 5,000 Nm / 3,700 ft lbs
Complete brakes are no longer available.
2

28

Service part Part number Service part Part number

Cable lever (9) 13 160 219 Pull spring (28) 13 301 215

Cable lever (9) 13 160 220 Strap plate (3) 13 513 029

Thrust piece (10) 13 229 171 Plug (2) 13 826 001

29
 500×160 SM OE/OEM
Drum Brakes 315×80 SM OE/OEM
504×160 SM OE/OEM

3
2
11
20
Hydraulic Duo Servo Brake with
Parking Brake
315×80 SM OE/OEM
■■ Diameter 180 to 315 mm /
7.09 to 12.40 in
■■ Torque 1,800 - 12,000 Nm /
22
15,930 - 106,200 ft lbs
24 21
■■ Wheel size 8 to 15 in

500×160 SM OE/OEM
504x160 SM OE/OEM
■■ Diameter 500 mm/19.7 in
■■ Torque 30,000 - 40,000 Nm/ 13
22,130 - 29,500 ft lbs
Complete brakes are no longer available.
14

Brake type Service part Part number Brake type Service part Part number
Adjuster (13) 12 603 135 500×160 SM OE/
Adjuster (14) 12 603 084VT
OEM
Pull spring (20) 13 301 093
504×160 SM OE/ Repair kit 12 999 739VT
Pull spring (21) 13 301 215
OEM Pull spring (21) 13 301 134
Pressure spring (22) 13 302 010
Pressure spring (-) 13 302 034
315×80 SM OE/
Strap plate (3) 13 513 068
OEM
Locking plate (24) 13 731 000
Locking plate (24) 13 731 003
Plug (2) 13 826 001
Wheel cylinder (11) 16 134 106
Sealing ring (-) 16 500 030

30
360×170 ZE
410×180 ZE

6
5
Wedge Simplex Brake 7

■■ Diameter 360 and 410 mm /

14.17 and 16.14 in 8
■■ Torque 14,000 - 23,000 Nm /
5 6
10,300 - 17,000 ft lbs
■■ Wheel size 19.5 to 22.5 in
Complete brakes are no longer available.

Brake type Service part Part number

360×170 ZE Expander unit (7) 12 739 075VT
Brake shoe (5+6) 12 258 253VT
Repair kit (6+Rivets) 12 999 442VT
Expander unit (7) 12 739 085VT
410×180 ZE
Pull spring (8) 13 301 161
Screw (-) 13 730 138
Lock nut (-) 13 551 045

31
 400×120 SM OEM
Drum Brakes
400×140 SM OEM

14

Hydraulic Duo Servo Brake with

Parking Brake Facility
■■ Diameter 400 mm / 15.75 in
■■ Torque 16,000 - 12,000 Nm /
10,800 - 8,850 ft lbs
Complete brakes are no longer available.
22

Brake type Service part Part number

400×120 SM OEM Pull spring (22) 13 301 159
400×140 SM OEM Wheel cylinder (14) 16 131 004

32
410×220 ZG

13

7 13

S-Cam Brake
■■ Diameter 410 mm / 16.14 in
■■ Torque 16,000 - 20,000 Nm /
11,900 - 14,800 ft lbs
■■ Wheel size 22.5 in
Complete brakes are no longer available. 7

14
9

4
5

Service part Part number

Repair kit (13+14) 12 999 114VT
Repair kit (4+5+6) 12 999 528VT
Brake shoe (7) 13 155 094
Brake cam shaft, length 12.7 in (9) 13 161 338VT
Brake cam shaft, length 11.7 in (9) 13 161 372
Pull spring (14) 13 301 111

33
 Brake Actuators

PROVEN IN MILLIONS OF APPLICATIONS

WABCO’s actuator technology has
been a trusted pillar of truck and
bus manufacturers for more than
four decades. There are over 3,500
actuator variants in the WABCO range,
comprising UNISTOP™ service brake
chambers, TRISTOP™D double
diaphragm spring brake chambers and
TRISTOP™ piston type spring brake
chambers.
Important distinctive features of a brake
actuator are the size, stroke, push
rod length, clevis type, port location
angle and clampband angle. Clocking
and band clamp angles are measured
clockwise, and our pushrod length is
measured from the cage.
WABCO actuation products, chosen by
many of the major truck manufacturers,
have proven their reliability in millions of
applications.

TRISTOP™D UNISTOP™ TRISTOP™

INTERNAL BREATHING VALVE (IBV)

Most WABCO actuators feature an Internal Breathing Valve
(IBV) and a coil clash-free barrel shaped power spring.
The IBV allows the brake chamber to breathe using clean
air from the service side of the chamber. Most competitor
chambers breathe with external holes in the rear housing
(Open-Hole Technology). These holes allow for contaminants
like dirt and salt to enter the spring cavity and decay the
parking spring. Protecting the parking spring is the best way to
extend the life of the brake chamber and WABCO’s IBV does
exactly that, allowing for a fully sealed parking spring.

34
REPLACEMENT
WABCO recommends replacing actuators per axle. For older When replacing cylinders, ensure correct installation as well
cylinders, the spring force of the spring chamber can be as making sure that the seal to the disc brake is not damaged.
weakened, which will cause uneven braking.

FEATURES OF THE TRISTOP™D DOUBLE DIAPHRAGM SPRING BRAKE CHAMBER

Sealing Internal Breathing Valve (IBV)

■■ Redundant in driving ■■ Provides clean and dry air
position «« Extended service life of the device
«« Extra protection against
dirt and dust impact

Spring room
Parking spring ■■ Completely powder-coated
■■ Powder-coated «« High corrosion resistance
■■ Low relaxation ensuring longer service life and
lower Total Cost of Ownership
■■ Coil-clash free design
«« Barrel-shaped parking spring with
coil-clash free design for installation
in a wide range of applications
Vulcanized diaphragm
«« Long service life Longer push rod
«« For universal applications

35
 Brake Actuators TRISTOP™D

TRISTOP™D – DOUBLE DIAPHRAGM FEATURES

SPRING BRAKE CHAMBER
The design of WABCO’s double
diaphragm spring brake chamber
provides a compact solution for air disc
brakes and S-cam brakes.
The coil clash free power spring
increases the actuator life and a variety
of connection port locations enable
customized solutions for different
vehicle applications.
■■ Service pressures up to 10 bar /
145 psi
■■ Strokes up to 75 mm / 3.0 inch
■■ Coil clash free power spring
■■ A variety of connection port
locations and threat sizes

TRISTOP™D for disc brakes

TRISTOP™D FOR DISC BRAKES

Size Stroke Push-rod length Port Clamp ring

IBV Part number
(inch) mm inch mm inch position position

18/24" 64 2.52" 15.0 0.59" IBV 0° 180° 925 347 006 0

18/24" 64 2.52" 15.0 0.59" IBV 45° 180° 925 347 007 0
18/24" 64 2.52" 15.0 0.59" IBV 135° 180° 925 347 008 0
20/24" 64 2.52" 15.0 0.59" IBV 0° 180° 925 380 002 0
20/24" 64 2.52" 15.0 0.59" IBV 45° 180° 925 380 003 0
20/24" 64 2.5" 15.0 0.59" IBV 135° 180° 925 380 004 0
20/24" 64 2.52" 15.0 0.59" IBV 0° 180° 925 380 020 0
20/24" 64 2.52" 15.0 0.59" IBV 45° 180° 925 380 021 0
20/24" 64 2.52" 15.0 0.59" IBV 135° 180° 925 380 022 0

36
TRISTOP™D

BENEFITS APPLICATION THE WABCO DIFFERENCE

■■ Extended life for brake actuator due ■■ Heavy and medium duty trucks Internal Breathing Valve (IBV) and
to highly reliable park brake module ■■ Trailers coil clash free power spring maximize
■■ Compact actuator design supported actuator life.
■■ Off-Highway
by barrel-shaped power spring
■■ High quality and cost-effective
solution enabled by shared
component architecture with road
proven TRISTOP™ actuator
■■ Inner component protection with
optional Internal Breathing Valve

Equipped with an extra long push rod

and a pre-mounted yoke, they can be
installed in a wide range of applications.

TRISTOP™D for drum brakes

TRISTOP™D FOR DRUM BRAKES - IBV VARIANTS - 20/30"… 24/30"

Push-rod length Clamp

Size Stroke Port Replacement
(incl. yoke)* Yoke ring Part number
(inch) position for
mm inch mm inch position

925 375 100 0

20/30" 75/75 2.95"/2.95" 213  8.39" - 90˚ 315˚ 925 375 110 0
925 375 101 0
925 376 100 0
24/30" 75/75 2.95"/2.95" 213  8.39" - 90˚ 315˚ 925 376 121 0
925 376 104 0
24/30" 75/75 2.95"/2.95" 213  8.39" - 0˚ 135˚ 925 376 122 0 925 376 101 0
24/30" 75/75 2.95"/2.95" 190  7.48" Yoke 90˚ 315˚ 925 376 123 0 925 376 103 0
24/30" 75/75 2.95"/2.95" 264 10.39" Yoke 90˚ 315˚ 925 376 124 0 925 376 106 0
24/30" 75/75 2.95"/2.95" 120  4.72" Yoke 0˚ 135˚ 925 376 125 0 925 376 107 0
24/30" 75/75 2.95"/2.95" 227  8.94" Yoke 90˚ 315˚ 925 376 126 0 925 376 110 0
24/30" 64/64 2.52"/2.52" 224  8.82" - 90˚ 315˚ 925 376 201 0 925 376 200 0

* Push rod stand out for variants without fork / stand out for variants with fork have been noted.
37
 Brake Actuators TRISTOP™D

TRISTOP™D for drum brakes

TRISTOP™D FOR DRUM BRAKES - IBV VARIANTS - 30/30"

Push-rod length Clamp

Size Stroke Port Replacement
(incl. yoke)* Yoke ring Part number
(inch) position for
mm inch mm inch position

925 377 100 0

30/30" 75/75 2.95"/2.95" 212  8.35" - 90˚ 315˚ 925 377 121 0
925 377 101 0
30/30" 75/75 2.95"/2.95" 212  8.35" - 35˚ 315˚ 925 377 125 0 925 377 102 0
30/30" 75/75 2.95"/2.95" 268 10.55" Yoke 90˚ 315˚ 925 377 122 0 925 377 103 0
30/30" 75/75 2.95"/2.95" 268 10.55" Yoke 0˚ 135˚ 925 377 123 0 925 377 105 0
30/30" 75/75 2.95"/2.95" 227  8.94" Yoke 90˚ 315˚ 925 377 124 0 925 377 106 0
30/30" 64/64 2.52"/2.52" 225  8.86" - 90˚ 315˚ 925 377 201 0 925 377 200 0
30/30" 63.5 2.5" 254 10.00" - 0° 180° 925 392 039 0 -

TRISTOP™D FOR DRUM BRAKES - OPEN HOLE VARIANTS (OH)

Push-rod length Clamp

Size Stroke Port Replacement
(incl. yoke)* Yoke ring Part number
(inch) position for
mm inch mm inch position

20/30" 75/75 2.95"/2.95" 251  9.88" Yoke 90˚ 315˚ 925 375 001 0 925 375 100 0
24/30" 75/75 2.95"/2.95" 279 10.98" Yoke 90˚ 315˚ 925 376 112 0 925 376 106 0
30/30" 75/75 2.95"/2.95" 288 11.34" Yoke 90˚ 315˚ 925 377 110 0 925 377 100 0
30/30" 63.5 2.5" 254 10.00" - 0° 180° 925 392 038 0 -

* Push rod stand out for variants without fork / stand out for variants with fork have been noted.

38
UNISTOP™

UNISTOP™ – SERVICE BRAKE CHAMBER FEATURES

WABCO service brake chambers, chosen by many of the major
truck manufacturers, have proven their reliability in millions of
applications. With more than 500 variants, our service brake
chambers provide a solution for almost every application.
Service pressure up to 13 bar, stroke length up to 75 mm and
various connection ports offer a wide range for disc, S-cam and
wedge brake applications.
■■ Service pressures up to 13 bar / 188 psi
■■ Strokes up to 75 mm / 3.0 inch
■■ Several push rod lengths for drum disc variants
■■ A variety of connection port locations and threat sizes
■■ High force output enables short stopping distance
■■ Customer tailored products with various options

APPLICATION
■■ Heavy, medium and light duty trucks
■■ Trailers
■■ Buses
■■ Off-Highway

UNISTOP™ for disc brakes

UNISTOP™ FOR DISC BRAKES

Size Stroke Push-rod length Port Clamp ring

Yoke Part number
(inch) mm inch mm inch position position

18 64 2.50" 15.0 0.59" - 0° 180° 400 512 003 0

18 64 2.50" 15.0 0.59" - 45° 180° 400 512 004 0
18 64 2.50" 15.0 0.59" - 135° 180° 400 512 005 0
20 65 2.56" 15.0 0.59" - 180° 180° 423 505 075 0
20 65 2.56" 15.0 0.59" - 135° 180° 423 505 150 0
20 65 2.56" 15.0 0.59" - 45° 180° 423 505 151 0
20 65 2.56" 15.0 0.59" - 0° 180° 423 505 152 0
22 65 2.56" 15.0 0.59" - 10° 180° 423 510 044 0
22 65 2.56" 15.0 0.59" - -10° 180° 423 510 045 0
22 65 2.56" 15.0 0.59" - 45° 180° 423 510 046 0
22 65 2.56" 15.0 0.59" - -45° 180° 423 510 047 0
22 65 2.56" 15.0 0.59" - 90° 0° 423 510 048 0
24 65 2.56" 15.0 0.59" - 90° -90° 423 506 183 0
24 65 2.56" 15.0 0.59" - 10° 180° 423 506 184 0
24 65 2.56" 15.0 0.59" - -10° 180° 423 506 185 0
24 65 2.56" 15.0 0.59" - 45° 180° 423 506 186 0
24 65 2.56" 15.0 0.59" - -45° 180° 423 506 187 0
24 65 2.56" 15.0 0.59" - 90° 0° 423 506 188 0
24 65 2.56" 15.0 0.59" 0° 90° 423 506 065 0

39
 Brake Actuators UNISTOP™

UNISTOP™ for drum brakes

UNISTOP™ FOR DRUM BRAKES - 16"… 24"

Size Stroke Push-rod length Port Clamp ring

Yoke Part number
(inch) mm inch mm inch position position

16 64 2.52" 57.2 2.25" Yoke 30° central crimped 423 104 015 0
16 64 2.52" 57.2 2.25" Yoke -30° central crimped 423 104 016 0
16 64 2.52" 57.2 2.25" Yoke central crimped 423 104 013 0
16 75 2.95" 38.0 1.50" - 270° 22° 30' 423 104 050 0
16 75 2.95" 38.0 1.50" - 270° 22° 30' 423 104 053 0
20 57 2.24" 37.0 1.46" Yoke 135° -90° 423 105 704 0
20 64 2.52" 57.2 2.25" Yoke central crimped 423 105 011 0
20 64 2.52" 57.2 2.25" Yoke -30° central crimped 423 105 018 0
20 64 2.52" 57.2 2.25" Yoke 30° central crimped 423 105 017 0
20 64 2.52" 25.4 1.00" - central crimped 423 105 019 0
20 64 2.52" 25.4 1.00" - 30° central crimped 423 105 023 0
20 64 2.52" 25.4 1.00" - -30° central crimped 423 105 024 0
20 75 2.95" 227.0 8.94" Yoke 180° 45° 423 105 900 0
24 75 2.95" 186.0 7.32" - 180° 45° 423 106 900 0
24 76 2.99" 57.2 2.25" Yoke 30° central crimped 423 106 007 0
24 76 2.99" 57.2 2.25" Yoke -30° central crimped 423 106 008 0
24 76 2.99" 25.4 1.00" - -30° central crimped 423 106 012 0
24 76 2.99" 25.4 1.00" - 30° central crimped 423 106 011 0
24 76 2.99" 25.4 1.00" - central crimped 423 106 010 0
24 76 2.99" 57.2 2.25" Yoke central crimped 423 106 006 0

40
UNISTOP™

UNISTOP™ for drum brakes

UNISTOP™ FOR DRUM BRAKES - 30"

Size Stroke Push-rod length Port Clamp ring

Yoke Part number
(inch) mm inch mm inch position position

30 75 2.95" 186.0 7.32" - 180° 45° 423 107 900 0

30 76 2.99" 147.3 5.80" - central crimped 423 107 027 0
30 76 2.99" 25.4 1.00" - -30° central crimped 423 107 026 0
30 76 2.99" 25.4 1.00" - 30° central crimped 423 107 025 0
30 76 2.99" 25.4 1.00" - central crimped 423 107 018 0
30 76 2.99" 57.2 2.25" Yoke -30° central crimped 423 107 017 0
30 76 2.99" 57.2 2.25" Yoke 30° central crimped 423 107 016 0
30 76 2.99" 57.2 2.25" Yoke central crimped 423 107 015 0

Size (inch) Part number

16" 423 104 351 4
30" 423 107 350 4

UNISTOP™ clamp rings for drum brakes

41
 Brake Actuators TRISTOP™

TRISTOP™ – SPRING BRAKE FEATURES

ACTUATOR PISTON TYPE
The WABCO G-Type TRISTOP™ spring brake chamber's
piston type has proven its reliability in millions of applications.
The TRISTOP™ is highly customizable due to more than
1,500 variants available for S-cam, air disc and wedge brakes.
Its internal breathing valve, high force power springs, various
release systems (standard, half, integrated) have helped set
today’s standard.
■■ Service pressures up to 13 bar / 188 psi
■■ Strokes up to 75 mm / 3.0 inch
■■ Several push rod lengths for drum brake variants
■■ A variety of connection port locations and threat sizes
■■ Clamp ring and seal variants available

TRISTOP™ for disc brakes

TRISTOP™ FOR DISC BRAKES

Size Stroke Push-rod length Port Clamp ring

IBV Yoke Part number
(inch) mm inch mm inch position position

24/24" 64/64 2.52" 15,0 0.59" IBV - 90° 0° 925 481 376 0
24/24" 64/64 2.52" 15,0 0.59" IBV - 90° -90° 925 481 375 0
24/24" 64/64 2.52" 15,0 0.59" IBV - 45° 90° 925 481 377 0
24/24" 64/64 2.52" 15,0 0.59" IBV - -45° -90° 925 481 378 0
24/30 65 2.56" 15,0 0.59" IBV - 30° 180° 925 481 016 0
24/30" 65/65 2.56" 15,0 0.59" IBV - -30° 180° 925 481 017 0

42
TRISTOP™

BENEFITS REPLACEMENT

■■ Highly customizable with more than 1,500 variants
available for air disc, S-cam or wedge brakes
■■ Highest inner component protection with optional Internal
Breathing Valve
When replacing TRISTOP™ actuators, ensure correct
installation as well as making sure that the seal to the disc
brake is not damaged.
Hazard: Never open the spring chamber housing.
The spring chamber is only to be replaced as a
complete part.

TRISTOP™ for drum brakes

TRISTOP™ FOR DRUM BRAKES

Size Stroke Push-rod length Port Clamp ring

IBV Yoke Part number
(inch) mm inch mm inch position position

20/30" 57/57 2.24" 77,0 3.03" - Yoke 30° 90° 925 320 515 0
Double clamp ring
36/30" 76/76 2.99" 217,0 8.54" - - 0° 925 323 130 0
(45° and -135°)

TRISTOP™ FOR WEDGE BRAKES

Size Stroke Push-rod length Port Clamp ring

IBV Yoke Part number
(inch) mm inch mm inch position position

20/24" 53/53 2.09" 81,0 3.19" - - 0° -135° 425 333 212 0

43
 OptiTire™ Advanced Tire Pressure Monitoring

INNOVATIVE TECHNOLOGY FOR INTEGRATED MONITORING OF

TIRE PRESSURE ON TRUCKS, BUSES AND TRAILERS
WABCO OptiTire™ is the next
generation tire pressure monitoring
solution especially developed for
commercial vehicles. OptiTire™
provides the driver with constant
updates of tire pressures directly from
each monitored wheel. OptiTire can
help prevent a tire blowout by informing
the truck driver of any leaks. (Leaks can
create low tire pressure which could
result in a blowout). In combination with
telematics, OptiTire™ also reports the
tire pressures to a web portal and warns
the fleet manager or dispatcher via SMS
or e-mail.

OPTITIRE SYSTEM TRAILER OPTITIRE SYSTEM TRACTOR

Radio Frequency Transmission Cable Connection
From Trailer To Tractor ECU

WHEEL MODULE TRAILER ECU TRACTOR ECU DISPLAY

FEATURES
■■ Reliable measurement of absolute tire pressure by wheel ■■ Tire pressure readouts can remotely be sent to dispatchers
modules via telematics
■■ Records pressure information of both truck and trailer ■■ Warning signal is shown on display in cabin in case of
■■ Analysis of the tire pressure profile critical pressure variation
– Compares parameterized thresholds
– Detects early leakage by axle comparison
■■ Tire pressure data from each tire can be sent to the driver
in the truck cabin via CAN or wireless connection to
dashboard or OptiTire™ display

44
BENEFITS APPLICATION
■■ Maximize the life of your tires by maintaining ■■ Heavy, medium and light duty truck
recommended tire pressures ■■ Trailer, semi-trailer, drawbar-trailer, central-axle-trailer
■■ Save fuel consumption by preventing under-inflation of ■■ Bus, city-bus, coach
tires
■■ Off-Highway
■■ Real-time tire pressure readouts provide drivers and
dispatchers with early warning of critical tire pressure
variation AFTERMARKET BENEFITS
■■ Early leakage detection gives drivers time to react before
■■ Easy to retrofit
tire failure causes vehicle breakdown
■■ Backward compatibility with IVTM™
■■ Spots slow punctures early, giving fleet operators a better
chance of repairing – rather than replacing – a damaged tire

Display ECU Wheel modules

FAST AND EASY RETROFIT

Retrofit can often mean ‘complicated’
but in the case of WABCO’s OptiTire™
it really couldn’t be simpler. Wireless
technology as well as easy integration
with existing systems assures
that installation of OptiTire™ can
be completed within the normal
maintenance cycle. Tires aren’t removed
from the rim in the process, and the
external sensors do not risk damaging informed about incorrect pressure either
tire integrity. In fact, fleet downtime to fit through an easily-affixed dedicated
the system is negligible. WABCO display or an integrated display
(if available).
The WABCO OptiTire™ solution uses
wheel-mounted sensors to monitor tire
pressures in real time. The information
is transmitted wirelessly to the
Electronic Control Unit; the driver is

45
 OptiTire™ Components

ELECTRONIC CONROL UNIT

446 220 100 0 960 901 050 4

Part number Description

446 220 100 0 ECU truck retrofit
446 220 110 0 ECU trailer retrofit
960 901 050 4 ECU holder

WHEEL MODULE

960 731 071 0 960 731 073 0 960 731 075 0 960 731 921 2 893 770 005 2 960 905 824 4

Part number Description

960 731 071 0 Wheel module WM2, 20° filling valve with B-shaped bracket
960 731 073 0 Wheel module WM2, 20° filling valve with T-shaped bracket
960 731 075 0 Wheel module WM2, 20° filling valve with L-shaped bracket
960 731 921 2 Wheel module WM2 replacement, 20° filling valve
893 770 005 2 Replacement connector
960 905 824 4 Balancing plate

46
Components

DISPLAY

446 221 000 0

Part number Description

446 221 000 0 Display

CONNECTING TUBE

1.6"

1.6"
" " " 1.6
.9 .9 .9 " "
13 13 13 " 5. 3 "
5. 3 4. 6

960 731 800 0 960 731 801 0 960 731 802 0 960 731 803 0 960 731 804 0 960 731 808 0
1.6
1.6 " 7.4"
"
4"
3.

1.7 "

"
" " 7.1
" 4. 3
4. 3 7.9 4.9"

960 731 816 0 960 731 821 0 960 731 822 0 960 731 823 0 960 731 825 0 960 731 827 0

Part number Description

960 731 800 0 Connecting tube, 13.9" length with 0° brass fastener
960 731 801 0 Connecting tube, 13.9" length with 90° brass fastener
960 731 802 0 Connecting tube, 13.9" length with 135° brass fastener
960 731 803 0 Connecting tube, 5.3" length with 135° brass fastener
960 731 804 0 Connecting tube, 5.3" length with 135° brass fastener
960 731 808 0 Connecting tube, 4.6" length with 90° brass fastener
960 731 816 0 Connecting tube, 4.3" length with 90° brass fastener
960 731 821 0 Connecting tube, 7.9" length with 90° brass fastener
960 731 822 0 Connecting tube, zig-zag 4.9" length with 135° brass fastener
960 731 823 0 Connecting tube, 7.1" length with 90° brass fastener
960 731 825 0 Connecting tube, 4.3" length with 90° brass fastener
960 731 827 0 Connecting tube, zig-zag 7.4" length with 135° brass fastener

47
 OptiTire™ Components

CABLE

449 376 xx0 0 449 601 060 0 449 674 xxx 0 894 600 001 2 894 607 xxx 0

Part number Description

449 376 070 0 Cable set, open end with 7pin DIN socket
449 376 250 0 Cable set, open end with 7pin DIN socket
449 601 060 0 Cable set, 4 pole diagnostic socket
449 674 273 0 Cable set trailer
449 674 306 0 Cable set trailer
894 600 001 2 Adapter cable
894 607 295 0 Cable set towing vehicle, 5-pin
894 607 390 0 Cable set towing vehicle, 7-pin with brake light connection

DIAGNOSTICS AND ACCESSORIES

815 xx0 045 3

300 200 001 0 446 300 348 0 446 301 030 0

Part number Description

247 301 730 0 Diagnostic software
300 200 001 0 TPMS Manager
446 300 348 0 Diagnostic cable
446 301 030 0 USB diagnostic interface
815 010 045 3 System description, English
815 040 045 3 System description, Spanish

48
WABCO Inform
WABCO Academy

INFORM: WABCO'S ONLINE

PRODUCT CATALOG
WABCO's online product catalog, INFORM, provides easy access
to technical documentation like product data sheets, outline
drawings, cross references, vehicle applications, repair information
and wiring diagrams. This information is connected with adequate
part numbers.
■■ Go to
http://inform.wabco-auto.com

WABCO ACADEMY - 40 YEARS OF CONSULTING AND TRAINING EXPERIENCE

For over 40 years, WABCO Academy
has been providing training and
consulting services to fleet managers,
professional drivers, garage managers
and employees, as well as parts
dealers in the office and in the field.
Our focus is on providing competent
knowledge and practical know-how,
as well as efficient and flexible training
solutions that provide immediate utility.
Eighteen training centers worldwide
as well as offerings in just about every
language serve the needs of WABCO
Academy’s international customers.
Already more than 190,000 customers
from 45 countries have successfully
completed training programs in the
four core areas of Technical Training,
Online Training, Business Training &
Consulting, and the TopDriver Program.

TECHNICAL TRAINING
From installation to diagnosis to maintenance, WABCO Academy’s technical training
program provides numerous practical and customer-specific training modules to give
our customers the practical know-how needed to survive in today’s fast-paced high-
tech world.

WABCO ONLINE TRAINING

Online Training is the easiest way to access WABCO Academy’s knowledge and training
opportunities. To do so, all you need is a computer and internet access. Wherever you are
and whenever you have the time, you can quickly log in online to take advantage of WABCO
Academy’s training courses. WABCO Online Training facilitates efficient learning, helping our
students save time and money.

ARE YOU INTERESTED?

We would be happy to design a custom training program to meet your needs and support
implementation at your business. Please visit us at www.wabco-academy.com to learn more.

49
 Workshop Solutions ABS/EBS Code Reader

The WABCO ABS/EBS Code Reader is the ideal tool for a
quick and easy diagnostic job. With this handheld tool, you
have easy access to the ECU and instant sight of fault codes,
plus access to our database for detailed information on
those fault codes, viewable from any smartphone, tablet or
computer.
The WABCO ABS/EBS Code Reader can be used for:
■■ Diagnostics of any trailer equipped with WABCO ABS or
EBS
■■ Diagnostics of any truck equipped with WABCO ABS or
EBS (only in Asia and South America)
■■ For quick pre-repair diagnostics across a fleet

Part number: 300 200 002 0

Dimensions per case: 3.11" × 4.65" × 0.73"
79 × 118 × 18,5 mm
Weight per case: 0.37 lbs
170 gr

PACKAGE COMPONENTS

Access to database for fault code information

ABS/EBS Code Reader User manual for fault code information

DIFFERENTIATORS
■■ The ABS/EBS Code Reader is a cost efficient, entry level
diagnostics device
■■ Direct online access to enhanced information behind the
codes via your smartphone, tablet or computer
■■ Lightweight and handheld, the device is highly portable,
making it suitable for workshop or roadside use
■■ Does not require an additional diagnostic interface

50
 HOW IT WORKS

1. Select the correct diagnostic cable (sold separately) to 2. Connect the cable to the vehicle (no additional diagnostic
establish trailer ECU connection interface needed)

3. Turn on the ignition to establish power supply 4. Connect the ABS/EBS Code Reader to the vehicle. The
device is powered by the vehicle automatically. Follow the
instructions on the screen access ECU error codes

5. Scan the QR Code on Code Reader with your smartphone 6. Once the code is scanned, your mobile device will
(or other mobile device). If you don’t have a mobile device, automatically be taken to our dedicated website and get
the user manual will provide a translation of the ECU code) a direct explanation of what this particular code means,
allowing you to begin the maintenance task

Multilingual interface menu, manual and website are available in 12 languages worldwide: English, Chinese,
German, Spanish, French, Portuguese, Brazilian Portuguese, Italian, Croatian, Hungarian, Czech and Turkish.

FURTHER INFORMATION

Database for trouble code translation:

https://services.wabco-auto.com/codekey/

51
 Workshop Solutions Bio-Cleaning System Set

The WABCO Bio-Cleaning System Set is the ideal workshop The WABCO Bio-Cleaning System Set can be used for:
accessory for fast-cleaning of used vehicle parts and
■■ Cleaning vehicle parts
workshop tools. The liquid cleaning products provided by
WABCO feature natural components. This makes both ■■ Cleaning workshop tools
cleaning and recycling cheaper and more convenient.

Part number: 300 100 007 0

Dimensions per case: 3.15" × 4.72" × 4.72"
80 × 120 × 120 cm
Weight per case: 366.40 lbs
166,2 kg

PACKAGE COMPONENTS

2× 500 ml
Compact Bio-Cleaning Machine 5× 20 l Bio-Cleaning Liquid Bio-Cleaning Intensive CB100

DIFFERENTIATORS
■■ The biodegradable liquid does not require recycling
■■ The ergonomic design of the machine makes cleaning
easier

52
 HOW IT WORKS

1. Open the cleaning bath, place the filter in the correct position 2. Fill the bath with WABCO Bio-Cleaning liquid, up to the
maximum level (90 litres)

3. Control and clean the two aerators (with a blade, if required) 4. Connect the device to the power supply and turn on

5. The aerators work properly when bubbles are clearly visible. 6. Clean the mesh, filter and magnetic separator regularly
The 3-way valve controls the separate distribution of the
cleaning liquid

The cleaning liquid does not require recycling, which saves money and time for any workshop.
Microorganisms will process up to 500 ml of oil and grease per day.

FURTHER INFORMATION

WABCO Bio-Cleaning System installation guide.

YOU MAY ALSO BE INTERESTED IN

■■ 20 l Canister liquid 300 100 009 4
■■ 500 ml intensive CB100 300 100 010 4

53
 Workshop Solutions TPMS Manager

The WABCO TPMS (Tire Pressure Monitoring System) The WABCO TPMS Manager can be used for:
Manager is a sensor activation and readout tool. It allows
■■ Activation / triggering of WABCO OptiTire™ sensors to
you to read and activate the external and internal sensors of
enable installation of the WABCO TPMS OptiTire™ system
the WABCO TPMS OptiTire™ system and display: ID; tire
on a vehicle
pressure; tire temperature; battery status and radio frequency.
Combining all these features, the WABCO TPMS Manager ■■ Displaying tire and sensor condition data
offers functionality and flexibility at an affordable price.

Part number: 300 200 001 0

Dimensions per case: 5.90" × 3.15" × 0.98"
150 × 80 × 25 mm
Weight per case: 0.66 lbs
0.3 kg

PACKAGE COMPONENTS

1 - TMPS Manager
2 - Charger
3 - International power adapters
4 - USB 2.0 cable
5 - CD with user manual

54
 HOW IT WORKS

1. Open the OptiTire™ diagnostics program on your computer 2. Turn on the TPMS Manager and select the sensor type that
you would like to trigger

3. Follow instructions from the diagnostics software, trigger the 4. Triggered sensors send signals to the ECU confirming
respective sensors activation and position

5. Repeat the procedure for each sensor 6. To finish the procedure, follow the instructions from the
diagnostics software

The device is designed to be used only with the WABCO OptiTire™ System and requires WABCO OptiTire™
Diagnostics Software.

FURTHER INFORMATION

Watch the OptiTire™ product video for more details.

YOU MAY ALSO BE INTERESTED IN

■■ OptiTire Electronic Control Unit (ECU) Truck 446 220 100 0
■■ OptiTire Electronic Control Unit (ECU) Trailer 446 220 110 0
■■ OptiTire External Wheel Module 960 731 011 0
55
 MICO® Products Hydraulic Brake Locks
ARTWORK TEMPLATE
NOTE: Etch aluminum and fill background
with black paint.

ABOUT MICO STRUCTURE OF THE MICO NUMBER

Since 1946, MICO Inc., a WABCO company, has been on
Sequential Part Number
the leading edge of technological innovation in hydraulic
Product Group Number
components, controls and brake systems primarily for
heavy-duty, off-highway industrial applications. Today, the Product Level Build
company is a completely integrated design, manufacturing 02-515-025
and sales operation. Its knowledge of brake system design in U.S.A. 16M033
conjunction with state-of-the-art machinery and manufacturing
processes makes it an industry leader. Year Manufacture
Location Manufactured
For more information, visit Day of Year Manufactured
www.mico.com
033 = Feb 2nd
M = Mankato
MX = Mexico

U.S.A.
Lever Brake Lock
SAMPLE
MICO Part Number 32-830-219

Electric Activated
Brake Locks Twist Brake Lock

691 Brake Lock Systems Cable Brake Locks

In addition to a well maintained and adjusted mechanical
parking brake, experience has shown that in many uses,
additional supplemental holding is necessary. This can be
done in the form of wheel chocks, outriggers, or other means
to keep all wheels that are in contact with the ground from
moving.
MICO ® Hydraulic Brake Locks are ideal for use on vehicles
with hydraulic brake systems. Typical uses are in the
construction, mining, forestry, agriculture, material handling
industries, multi-stop delivery vehicles, and recreational
vehicles, such as motor homes and off-road 4-wheel drives.
All MICO ® Brake Locks are for supplemental brake holding
and are to only be used in conjunction with a vehicle’s properly
functioning mechanical parking brake. The brake locks use
the vehicle’s service brakes as an operational supplement
to the parking brakes and are not intended to be used as the
primary parking brake or to be used for prolonged parking.
Several types of brake locks are available for use in single,
dual, split, or anti-lock brake systems. The brake lock you
select will depend on the type of brake system on the vehicle.

56
691 Brake Lock Systems

DESCRIPTION
MICO ® Brake Lock Systems lock
hydraulic pressure in the service
brakes to supplement the vehicle’s
mechanical parking brake and provide
extra holding in heavy-duty and high-
frequency applications. The 691
Brake Lock Systems consist of a small
electrohydraulic pump, remote mounted
actuator (single and/or dual), electronic
control module and small dash-mounted
user interface. The operator simply
activates a switch and the 691 system
automatically applies, monitors, and
maintains brake locking pressure.
The 691 Brake Lock significantly
enhances vehicle-holding capability
while not interfering with normal service
brake function and provides added
safety for operator, vehicle, and work
area.
In addition to operator control via the
“Lock/Release” switch on the user
interface, 691 systems can be remotely
controlled and/or interlocked using
leads in the main wiring harness.
This allows control of the brake lock
system from locations outside the
cab. As an interlock, 691 operation is
linked to other vehicle systems and
components; for example, wheelchair
lift, PTO, electrical generator, hydraulic
pump, air compressor, etc. to ensure
that whenever they are being used the
brakes are locked and the vehicle is
immobilized.

FEATURES
■■ Supplements existing parking brake for additional holding
■■ Automatically monitors and maintains optimal brake lock
system pressure
■■ Activates with the flip of a switch
■■ Can be remotely controlled
■■ Can be interlocked with other 12-volt systems
■■ Microprocessor controlled with onboard diagnostic LED’s
■■ Waterproof control module
■■ Factory provided weatherproof connectors
■■ Wide selection of models

57
 MICO® Products 691 Brake Lock Systems

691 BRAKE LOCK SYSTEM MODELS

Model Number Model Vehicle application
02-691-101 Single Brake Lock System for vehicles over 19,000 GVM
02-691-109 Single Brake Lock System for vehicles under 19,000 GVM
02-691-201 Dual Brake Lock System for vehicles over 19,000 GVM
02-691-209 Dual Brake Lock System for vehicles under 19,000 GVM
02-691-303 3-Channel Anti-Lock Brake Lock System for vehicles over 19,000 GVM
02-691-305 3-Channel Anti-Lock Brake Lock System for vehicles under 19,000 GVM
02-691-403 4-Channel Anti-Lock Brake Lock System for vehicles over 19,000 GVM optional on others

691 ACCESSORIES
Remote Reservoir
For use in brake fluid applications
MICO offers a remote reservoir kit (part number 02-600-038)
for installations where the 691 Power Unit brass breather plug
cannot be mounted in an upright position and away from dust
and dirt, or when visual monitoring of fluid level is desired.
Elbow Fittings and Straight Adapters
Simplify plumbing installation using 90° or 45° elbows and
straight adapters available from MICO. These fittings allow
more direct routing of brake tubes with fewer bends and are
handy when mounting components in close quarters.

34-350-006 90° Elbow 34-350-011 45° Elbow

Remote Reservoir Kit
7/16-20UNF 7/16-20UNF
(part number 02-600-038 37o Flare 37o Flare
includes items below)

Remote Reservoir 7/16-20UNF 7/16-20UNF

Assembly

Connector

34-350-078 Straight Adapter 34-350-079 Straight Adapter

SAE 3/8-24 SAE 7/16-24

for 3/16" Line for 1/4" Line
Tubing, 10 ft.

7/16-20UNF 7/16-20UNF
Connector 37o Seat 37o Seat

Adaptor

Wire Harness Extension

Power Unit The 11 ft. supplemental wire harness (part number 32-820-022)
Reservoir
simplifies wiring when the 691 Control Module is mounted
away from the 691 Power Unit. Uses waterproof adapters for
quick connection of the control module and power unit leads.
Nut

Power Unit
Reservoir Screw

58
691 Brake Lock Systems

691 SUB-COMPONENTS

Control
Power Module
Unit
User
Interface

Dual Single
Actuator Actuator

User Interface Control Module Power Unit Single Actuator Dual Actuator Wire Harness

System Model Control User Main Wire

Description Power Unit Actuator
Number Module Interface Harness
02-691-101 Single (1 3/4 in bore) 20-410-014 29-585-001 20-460-013 32-585-007 32-820-021
02-691-109 Single (1 1/4 in bore) 20-410-014 29-585-001 20-460-018 32-585-007 32-820-021
02-691-201 Dual (1 3/4 in bore) 20-410-014 29-585-001 20-460-012 32-585-007 32-820-021
02-691-209 Dual (1 1/4 in bore) 20-410-014 29-585-001 20-460-017 32-585-007 32-820-021
** 02-691-223 Dual (1 1/4 in bore) 20-410-014 29-585-001 20-460-018 (two) 32-585-007 32-820-021
20-460-013 (one)
*** 02-691-303 3-Channel 20-410-014 29-585-001 32-585-007 32-820-021
20-460-017 (one)
20-460-018 (one)
**** 02-691-305 3-Channel 20-410-014 29-585-001 32-585-007 32-820-021
20-460-017 (one
***** 02-691-403 4-Channel 20-410-014 29-585-001 20-460-017 (two) 32-585-007 32-820-021

** Consists of two 1 1/4 inch diameter single actuators.

*** Consists of one 1 3/4 inch diameter single actuator and one 1 1/4 inch diameter dual actuator.
**** Consists of one 1 1/4 inch diameter single actuator and one 1 1/4 inch diameter dual actuator.
***** Consists of two 1 1/4 inch diameter dual actuators.

59
 MICO® Products Electric Activated Brake Locks

DESCRIPTION
The MICO ® Brake Lock supplements
the standard parking brake of a vehicle
by using a portion of the hydraulic
service brake system. The brake lock
is installed directly into the vehicles
service brake system. It is activated by
the flip of a toggle switch located within
reach of the vehicle operator. When the
operator applies the brake pedal, the
brake lock acts as a one-way check
valve and holds pressure to the brakes
until the lock is released. Service brake
operation is not affected by the use of
the brake lock.
The MICO ® Brake Lock can be used
in many different vehicle applications,
however, it is not recommended for
use in frequent stop applications
or emergency vehicle applications.
Please contact MICO, Inc. for
assistance in choosing one of our
many other lock designs for these type
applications.

Model Number Description

Brake Lock, 12 VDC electric activated,
02-620-009
DOT 3, 4, 5 and 5.1 brake fluid
Brake Lock, 12 VDC electric activated,
02-620-172
Mineral base hydraulic oil
Brake Lock, 24 VDC electric activated,
02-620-173
DOT 3, 4, 5 and 5.1 brake fluid

BENEFITS FEATURES VEHICLE APPLICATIONS

■■ Easy to install and maintain ■■ Can be used on cab-forward or cab- ■■ Tow Trucks
■■ Does not affect normal service brake over vehicles ■■ Tilt Bed Trucks
operation ■■ Brake fluid and hydraulic oil models ■■ General Delivery
■■ Supplements standard parking brake available
■■ Lawn Service
■■ Operates with a flip of a toggle ■■ Uses standard brake line fittings
■■ Crane Hoist Trucks
switch ■■ No additional plumbing necessary
■■ Bulk Fuel Delivery

SPECIFICATIONS
Maximum operating Low pressure warning
Fluid type Toggle switch
temperature switch
Mineral base hydraulic oil models NO, 20 A @ 12 VDC
250 °F DPST, 15 A @ 12/24 VDC
and brake fluid models NO, 12 A @ 24 VDC

60
Cable Brake Locks

DUAL CABLE LOCK CABLE LOCK

MICO ® Dual Cable Locks supplement a vehicle's standard MICO ® Hydraulic Brake Locks supplement a vehicle's standard
parking brake by utilizing the hydraulic service brake system. parking brake by utilizing the hydraulic service brake system.
Incorporating two manually operated one-way check valves These brake locks are manually operated one-way check
in a single housing, dual cable locks hold fluid under pressure valves which hold pressurized fluid in the selected brakes.
in the selected brakes. Dual cable locks can hold pressure in
The Cable Lock is for use in applications where there is
two separate fluid lines. They can provide 2-wheel locking on
limited space under the dash. The lock is mounted in a remote
vehicles equipped with multi-channel anti-lock brake systems
location and operated by a cable and knob that is accessible
(ABS), or 4-wheel lock-up on dual brake systems or vehicles
on the dash.
with single channel ABS. The lock is mounted in a remote
location and operated by a cable and knob that is accessible MICO ® Hydraulic Brake Locks are ideal for use on vehicles
on the dash. in the construction, mining, forestry, agriculture, material
handling industries, multi-stop delivery vehicles, and
MICO ® Hydraulic Brake Locks are ideal for use on vehicles in
recreational vehicles, such as motorhomes and off-road
the construction, mining, forestry, agriculture, and materials
4-wheel drives.
handling industries as well as on multi-stop delivery vehicles,
and recreational vehicles.

Model Model
Description Description
Number Number
Dual Cable Lock - 3/16 and 1/4 inch fittings, Cable Lock - 3/16 and 1/4 inch fittings,
02-640-169 includes 10 foot cable, 02-640-023 includes 10 foot cable,
DOT 3, 4, 5 and 5.1 brake fluid DOT 3, 4, 5 and 5.1 brake fluid
Dual Cable Lock - 3/16 and 1/4 inch fittings,
Cable Lock, includes 10 foot cable,
02-640-202 includes 10 foot cable, 02-640-122
Mineral base hydraulic oil
Mineral base hydraulic oil

Front Wheel Lock-up

on 3-channel ABS

61
 MICO® Products Lever Brake Lock Twist Brake Lock

DESCRIPTION
MICO ® Hydraulic Brake Locks supplement a vehicle's standard parking brake by utilizing the hydraulic service brake system.
These brake locks are manually operated one-way check valves which hold pressurized fluid in the selected brakes.
MICO ® Hydraulic Brake Locks are ideal for use on vehicles in the construction, mining, forestry, agriculture, material handling
industries, multi-stop delivery vehicles, and recreational vehicles, such as motorhomes and off-road 4-wheel drives.

LEVER BRAKE LOCK TWIST BRAKE LOCK

The Lever Lock will provide a cost-effective method to The Twist Lock function is similar to the lever lock but uses a
supplement the parking brake. sealed rotary action. It is for use in applications with adverse
environments.

Model Model
Description Description
Number Number
Lever Lock - 3/16 inch and 1/4 inch fittings, Twist Lock - 3/16 inch and 1/4 inch fittings,
02-640-125 03-640-075
DOT 3, 4, 5 and 5.1 brake fluid DOT 3, 4, 5 and 5.1 brake fluid
Lever Lock - 3/16 inch and 1/4 inch fittings, Twist Lock - 3/16 inch and 1/4 inch fittings,
02-640-126 03-640-076
Mineral base hydraulic oil Mineral base hydraulic oil
Lever Lock - 1/4 inch fittings,
03-640-131 normally open interlock switch,
DOT 3, 4, 5 and 5.1 brake fluid

62
Pressure Testing Devices

QUADRIGAGE™ DIGITAL PRESSURE GAUGE

MICO ® Quadrigages™ perform four gauge functions plus read in lbs/in² (PSIG) and This versatile and economical gauge is
k­ g/cm² (bar). Continuous system pressure readings are possible through pressure the perfect choice for a wide variety of
ranges of 0-3000 PSI, 0-4000 PSI, 0-5000 PSI, or 0-6000 PSI, and vacuum. applications.
All Quadrigages™ pressure hoses are equipped with a swivel fitting that can be
connected to any accessible gauge outlet in the system to be tested. If the system FEATURES
is not equipped with gauge outlets, connect it to an outlet in the system such as a ■■ Meets ASME B40.7
bleeder fitting. If there are no outlets, a female branch tee fitting can be installed at ■■ Proof pressure is 120% of range
any point in the system where a pressure reading is desired. ■■ Burst pressure is 150% of range
■■ 1/2% terminal point accuracy
■■ IP67 weatherproof enclosure
FEATURES ■■ Standard range is 0-10,000 PSI
■■ Nine pre-programmed engineering
■■ Performs four gauge functions ■■ 1/8 inch NPTF male fitting units of measure
■■ Case is dust and moisture resistant ■■ Includes bleeder screw and ■■ Back lighting for easy viewing in low
■■ Glycerin filled models dampen convenient hanger light areas
pointer vibration and provide for ■■ Built-in pressure sensor protects low ■■ Minimum and maximum pressure
extented life range gauges from high pressure indication
■■ Stainless steel socket and sensor
■■ Compact for tool box storage ■■ Compatible with most hydraulic fluids
suitable for a variety of applications.
■■ Available with 12 or 36 inch pressure Welded sensor to socket for added
hoses durability

Standard Gauge Glycerin Filled Gauge Digital Pressure Gauge

Read in lb/in² (PSIG) and kg/cm² (bar). Read in lb/in² (PSIG) and bar (kg/cm²). Easy-to-read 5 digit LCD display
Measures 6 7/16 inch diameter. Measures 8 3/8 inch diameter. 45 standard PSI and bar ranges
3000 or 5000 PSIG maximum pressures. 4000 or 6000 PSIG maximum pressures. from -14.7 to 10,000 PSI

Hose Pressure Gauge Range (PSIG) Model

Model Description
Gauge Type Length Number
Number Vacuum Low Medium High
(inches)
42-610-028 Gauge
02-740-011 Standard 12 0-30 0-150 0-600 0-3000
Gauge (with certification
42-610-029
02-740-016 Standard 12 0-30 0-150 0-600 0-5000 of calibration)

03-740-006 Standard 36 0-30 0-150 0-600 0-3000 12-740-017 Gauge and 12" hose
12-740-018 Gauge and 36" hose
03-740-019 Standard 36 0-30 0-150 0-600 0-5000
Gauge, 12" hose,
03-740-023 Standard n\a 0-30 0-150 0-600 0-5000 12-740-019
fitting kit and case
*12-740-006 Glycerin Filled 12 0-30 0-300 0-1000 0-6000 Gauge, 36" hose,
12-740-020
*12-740-008 Glycerin Filled 36 0-30 0-300 0-1000 0-6000 fitting kit and case
42-590-002 12" hose only
*12-740-011 Glycerin Filled 36 0-30 0-300 0-1000 0-4000
42-590-003 36" hose only
* Not recommended for unpressurized airfreight shipments. 12-700-002 Fitting kit only
UNIT CONVERSION: 1 PSI = 0.06895 bar 1 kg/cm² = 0.9807 bar
63
 MICO® Products Hydraulic Throttle Controls

DESCRIPTION
MICO ® Hydraulic Throttle Controls enable you to make a direct
and simple hook-up to control engine RPM by eliminating the
necessity for troublesome mechanical linkage.
MICO ® Throttle Controls incorporate return springs in all the
actuators as well as some of the slave cylinders. The primary
function of these springs is to return the pedal to its normal
static position. MICO recommends that an external return
spring be installed at the throttle control slave cylinder push
rod location when compliance with Federal Motor Vehicle
Safety Standards FMVSS-124 is necessary.
FEATURES
■■ Available in brake fluid or hydraulic oil models
■■ Utilizes flexible tubing for reduced installation cost
■■ Adjustable pedal angle maximizes operator control and
comfort
■■ The low hydraulic pressure during operation gives the
operator a natural pedal feel feed-back
■■ Rugged die cast aluminum construction ensures reliable
and maintenance free operation

Slave Cylinder
Reservoir

Pedal, Plate and Actuator

Reservoir Reservoir

Slave Cylinder Slave Cylinder

Pedal and Pedal and Pedal and

Actuator Actuator Actuator

One Unit Hook-Up Two Unit Hook-Up

64
Hydraulic Throttle Controls

COMPLETE MODELS
Model Number Fluid Type Description Cylinder Type Repair Kit
Pedal and Actuator, Slave Cylinder
12-460-189 Brake Fluid Spring loaded slave cylinder. 12-400-023
and Reservoir
Pedal and Actuator, Slave Cylinder
12-460-190 Hydraulic Oil Spring loaded slave cylinder. 12-400-024
and Reservoir
Pedal and Actuator, Slave Cylinder
12-460-191 Brake Fluid Non-spring loaded slave cylinder. 12-400-025
and Reservoir
Pedal and Actuator, Slave Cylinder
12-460-192 Hydraulic Oil Non-spring loaded slave cylinder. 12-400-012
and Reservoir

All complete models use reservoir 20-920-006.

PEDAL AND ACTUATOR

Model Effective Effective Actuator
Fluid Type Bore Stroke Repair Kit
Number Stroke Displacement Only
12-460-185 Brake Fluid 1.250 in 0.63 in 0.56 in 0.73 in³ 12-400-007 12-460-187
12-460-186 Hydraulic Oil 1.250 in 0.63 in 0.56 in 0.73 in³ 12-400-002 12-460-188

SLAVE CYLINDER
Fluid Volume Rod End
Model Number Fluid Type Bore Stroke Repair Kit
Required for Full Stroke Thread
* 12-120-007 Brake Fluid 0.625 in 2.44 in 0.73 in³ 5/16 - 24 12-100-009
* 12-120-010 Hydraulic Oil 0.625 in 2.44 in 0.73 in³ 5/16 - 24 12-100-010
** 12-120-015 Brake Fluid 0.625 in 2.06 in 0.63 in³ 5/16 - 24 12-100-013
** 12-120-016 Hydraulic Oil 0.625 in 2.06 in 0.63 in³ 5/16 - 24 12-100-014

* Non-spring loaded slave cylinder.

** Spring loaded slave cylinder.
5° Effective Pedal Stroke - 0.48 inch movement of Slave Cylinder.

RESERVOIR
Model Number Fluid Type Capacity Fittings
Brake Fluid or Two connectors -
20-920-006 3.3 in³ - filler cap with baffle and breather
Hydraulic Oil 1/8-27NPTF Male × 1/4 Plastic Tube
Brake Fluid or
20-920-009 3.3 in³ - filler cap with baffle and breather
Hydraulic Oil
20-920-509 Brake Fluid 14.5 in³ - filler cap with diaphragm 1/4-18NPTF (interval) adaptable fitting
20-920-512 Hydraulic Oil 14.5 in³ - filler cap with diaphragm 1/4-18NPTF (interval) adaptable fitting

See MICO Form No. 80-920-001 for complete information regarding reservoirs.

65
 Index Part numbers Part number è

Part number Part number Part number Part number Part number
02-600-038  58 12 303 003   25, 26 13 151 249  27 16 131 004  32 40 175 072  10

02-620-009  60 12 303 004  27 13 155 094  33 16 134 106  30 40 175 073  10

02-620-172  60 12-460-185  65 13 160 219  29 16 200 083   25, 26, 27 40 175 090  10

02-620-173  60 12-460-186  65 13 160 220  29 16 200 152   25, 26, 27 40 175 091  10

02-640-023  61 12-460-189  65 13 161 338VT  33 16 500 030  30 40 195 027  11

02-640-122  61 12-460-190  65 13 161 372  33 16 500 780  27 40 195 028  11

02-640-125  62 12-460-191  65 13 229 146  26 17 665 107   25, 27 40 195 037  11

02-640-126  62 12-460-192  65 13 229 167   25, 27 17 861 001   25, 27 40 195 038  11

02-640-169  61 12 603 084VT  30 13 229 171  29 18 425 475   25, 26 40 225 011  13

02-640-202  61 12 603 135  30 13 230 075   25, 26 18 425 476  27 40 225 012  13

02-691-101   58, 59 12-700-002  63 13 301 093  30 18 429 151   25, 26 40 225 015  13

02-691-109   58, 59 12 739 075VT  31 13 301 111  33 18 429 469   25, 26 40 225 016  13

02-691-201   58, 59 12 739 085VT  31 13 301 134  30 18 441 009   25, 26 42-590-002  63

02-691-209   58, 59 12-740-006  63 13 301 159  32 18 444 000   25, 26 42-590-003  63

02-691-223  59 12-740-008  63 13 301 161  31 20-410-014  59 42-610-028  63

02-691-303   58, 59 12-740-011  63 13 301 169  28 20-460-012  59 42-610-029  63

02-691-305   58, 59 12-740-017  63 13 301 215   29, 30 20-460-013  59 247 301 732 0  48

02-691-403   58, 59 12-740-018  63 13 301 217  28 20-460-017  59 300 100 007 0  52

02-740-011  63 12-740-019  63 13 302 010  30 20-460-018  59 300 200 001 0   48, 54

02-740-016  63 12-740-020  63 13 302 034  30 20-920-006  65 300 200 002 0  50

03-640-075  62 12 999 114VT  33 13 302 117  28 20-920-009  65 400 512 003 0  39

03-640-076  62 12 999 387VT  26 13 306 010  28 20-920-509  65 400 512 004 0  39

03-640-131  62 12 999 442VT  31 13 477 053   25, 26 20-920-512  65 400 512 005 0  39

03-740-006  63 12 999 473VT  25 13 477 058  27 29-585-001  59 423 104 013 0  40

03-740-019  63 12 999 521VT  27 13 513 029  29 32-585-007  59 423 104 015 0  40

03-740-023  63 12 999 528VT  33 13 513 068  30 32-820-021  59 423 104 016 0  40

12-120-007  65 12 999 699VT  10 13 551 045  31 34-350-006  58 423 104 050 0  40

12-120-010  65 12 999 737VT  11 13 701 115   25, 26 34-350-011  58 423 104 053 0  40

12-120-015  65 12 999 738VT  15 13 701 116  27 34-350-078  58 423 104 351 4  41

12-120-016  65 12 999 739VT  30 13 730 138  31 34-350-079  58 423 105 011 0  40

12 182 091   25, 26 12 999 796   13, 14 13 731 000  30 40 023 004  26 423 105 017 0  40

12 182 121  27 12 999 806  10 13 731 003  30 40 023 005  25 423 105 018 0  40

12 258 253VT  31 13 103 013  27 13 826 001   29, 30 40 034 005  27 423 105 019 0  40

66
Part number # è

Part number Part number Part number Part number Part number
423 105 023 0  40 423 510 046 0  39 640 225 921 2   11, 12, 925 376 123 0  37 960 731 804 0  47
13, 14
423 105 024 0  40 423 510 047 0  39 925 376 124 0  37 960 731 808 0  47
640 225 922 2  12
423 105 704 0  40 423 510 048 0  39 925 376 125 0  37 960 731 816 0  47
640 225 926 2   12, 13,
423 105 900 0  40 425 333 212 0  43 14, 19 925 376 126 0  37 960 731 821 0  47

423 106 006 0  40 446 220 100 0  46 640 250 004 0  15 925 376 201 0  37 960 731 822 0  47

423 106 007 0  40 446 220 110 0  46 640 250 005 0  15 925 377 110 0  38 960 731 823 0  47

423 106 008 0  40 446 221 000 0  47 640 250 921 2  15 925 377 121 0  38 960 731 825 0  47

423 106 010 0  40 446 300 348 0  48 640 322 050 0  18 925 377 122 0  38 960 731 827 0  47

423 106 011 0  40 446 301 030 0  48 640 322 051 0  18 925 377 123 0  38 960 731 921 2  46

423 106 012 0  40 449 376 070 0  48 640 322 065 0  18 925 377 124 0  38 960 901 050 4  46

423 106 900 0  40 449 376 250 0  48 640 322 066 0  18 925 377 125 0  38 960 905 824 4  46

423 107 015 0  41 449 601 060 0  48 640 322 522 2  20 925 377 201 0  38

423 107 016 0  41 449 674 273 0  48 640 322 927 2  18 925 380 002 0  36

423 107 017 0  41 449 674 306 0  48 640 322 932 2  18 925 380 003 0  36

423 107 018 0  41 640 175 521 2  20 640 322 934 2  18 925 380 004 0  36

423 107 025 0  41 640 175 920 2   10, 11, 640 322 935 2  18 925 380 020 0  36
12, 13, 14, 15, 19
423 107 026 0  41 640 322 938 2  18 925 380 021 0  36
640 175 940 2  10
423 107 027 0  41 815 010 045 3  48 925 380 022 0  36
640 195 521 2  20
423 107 350 4  41 815 040 045 3  48 925 392 038 0  38
640 195 522 2  20
423 107 900 0  41 893 770 005 2  46 925 392 039 0  38
640 195 936 2  11
423 505 075 0  39 894 600 001 2  48 925 481 016 0  42
640 222 005 0  19
423 505 150 0  39 894 607 295 0  48 925 481 017 0  42
640 222 006 0  19
423 505 151 0  39 894 607 390 0  48 925 481 375 0  42
640 222 007 0  19
423 505 152 0  39 925 320 515 0  43 925 481 376 0  42
640 222 008 0  19
423 506 065 0  39 925 323 130 0  43 925 481 377 0  42
640 222 920 2  19
423 506 183 0  39 925 347 006 0  36 925 481 378 0  42
640 222 923 2  19
423 506 184 0  39 925 347 007 0  36 960 731 071 0  46
640 225 032 0  14
423 506 185 0  39 925 347 008 0  36 960 731 073 0  46
640 225 033 0  14
423 506 186 0  39 925 375 001 0  38 960 731 075 0  46
640 225 036 0  12
423 506 187 0  39 925 375 110 0  37 960 731 800 0  47
640 225 037 0  12
423 506 188 0  39 925 376 112 0  38 960 731 801 0  47
640 225 080 0  12
423 510 044 0  39 925 376 121 0  37 960 731 802 0  47
640 225 081 0  12
423 510 045 0  39 925 376 122 0  37 960 731 803 0  47

67
 REMAN SOLUTIONS

The OE Choice Restored to Performance, Enabling

Original Performance Reliability and Value Quality Repairs

Original Parts Remanufactured Parts All-Makes Repair Kits

OE Certified Premium Delivering OE Quality Aftermarket Parts OE Quality Components
Quality

About WABCO
WABCO (NYSE: WBC) is a leading global supplier of technologies and
services that improve the safety, efficiency and connectivity of commercial
vehicles. Originating from the Westinghouse Air Brake Company founded
nearly 150 years ago, WABCO continues to pioneer breakthrough
innovations to enable autonomous driving in the commercial vehicle industry.
Today, leading truck, bus and trailer brands worldwide rely on WABCO’s
differentiating technologies, including advanced driver assistance, braking,
steering and stability control systems. Powered by its vision for accident-free
driving and greener transportation solutions, WABCO also contributes to
commercial fleet efficiency. In 2017, WABCO reported sales of $3.3 billion
and has nearly 15,000 employees in 40 countries.
For more information, visit www.wabco-auto.com

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