Section Air System

Number KM805020

Date 04/17/2013

2013 Air System Service Manual

 ©2013 PACCAR Corporation

Confidentiality Notice: This document and the information contained herein is proprietary. It shall not be
reproduced, copied or disclosed, in whole or in part, or used for manufacture without the written permission
of PACCAR. You are hereby notified that any dissemination of this information is strictly prohibited.

ii KM805020 (04/17/2013)
Air System

Table of Contents

Safety . . . . . . . . . . . . . 1
Applies To . . . . . . . . . . . 2
Exploded View . . . . . . . . . 3
What's New . . . . . . . . . . 4
General Information 5
Special Tools . . . . . . . . . . 6
Specifications . . . . . . . . . 7
How It Works . . . . . . . . . . 8
Maintenance . . . . . . . . . . 9
Disassembly / Assembly . . . . 10
Inspection . . . . . . . . . . . 11
Troubleshooting . . . . . . . . 12
Glossary . . . . . . . . . . . . 13
Index . . . . . . . . . . . . . 14

KM805020 (04/17/2013) iii

iv KM805020 (02/28/2012)
Air System 1

1 Safety
General Safety Instructions . . . . . . 1 - 2

KM805020 (04/17/2013) 1-1

1 Air System
General Safety Instructions
WARNING!
Do not attempt to modify, alter, repair or discon-
nect any component of the air system. Repairs
or modifications to the air system, other than what
is described in this section, should only be per-
formed by an authorized dealer. Failure to comply
may result in death or personal injury.
WARNING!
Prior to the removal of any air system component,
always block and hold the vehicle by a secure
means other than the vehicle's own brakes. De-
pleting air system pressure may cause the vehicle
to roll unexpectedly resulting in an accident caus-
ing death or personal injuries. Keep hands away
from chamber push rods and slack adjusters, they
may apply as system pressure drops.
WARNING!
These procedures require servicing the vehicle
with the parking brakes released. The vehicle
must be parked on a completely flat/level surface
with both front wheels chocked on both sides.
Failure to adequately chock the wheels may lead
to the vehicle rolling into someone/something,
causing an accident and possible serious per-
sonal injury and/or equipment damage.
WARNING!
Chamber push rods and slack adjusters will move
as air system pressure drops in the spring brake
chambers and as the parking or service brakes
are cycled. To avoid possible injury or property
damage, keep hands and objects away from brake
system components when performing these pro-
cedures.
WARNING!
After completing any repairs to the air system, al-
ways test for air leaks, and check the brakes for
safe operation before putting the vehicle in ser-
vice. Failure to comply may result in death, per-
sonal injury, equipment or property damage.
1-2
WARNING!
Never connect or disconnect a hose or line con-
taining air pressure. It may whip as air escapes.
Never remove a component or pipe plug unless
you are certain all system pressure has been de-
pleted. Failure to comply may result in death, per-
sonal injury, equipment or property damage.
WARNING!
Never exceed recommended air pressure and al-
ways wear safety glasses when working with air
pressure. Never look into air jets or direct them
at anyone. Failure to comply may result in death,
personal injury, equipment or property damage.
WARNING!
Never attempt to disassemble a component un-
til you have read and understood recommended
procedures. Some components contain powerful
springs and injury can result if not properly disas-
sembled. Use only proper tools and observe all
precautions pertaining to use of those tools. Fail-
ure to comply may result in death, personal injury,
equipment or property damage.
WARNING!
Completely bypassing a Bendix® AD-IS air dryer
will bypass the system’s pressure protection
valves. This could lead to loss of air pressure
or damage to the vehicle’s air system, which
could cause an accident involving death or per-
sonal injury. Always adhere to the manufacturer’s
procedure if it is necessary in an emergency to
temporarily bypass an AD-IS-series air dryer.
Failure to comply may result in death, personal
injury, equipment or property damage.
WARNING!
If the supply and service tanks are not drained
at the recommended frequency, water could en-
ter the air lines and valves. This could cause cor-
rosion or blockage, which could compromise the
brake system safety and potentially cause an ac-
cident involving death or personal injury.
KM805020 (04/17/2013)
Air System 1

WARNING!
Do not attempt to work on the electric over air
(EOA) components without first disconnecting the
negative battery cable from the battery and insu-
lating it. Servicing the EOA system with batteries
connected could cause an electrical shock or in-
jury from energized components. Failure to com-
ply may result in death, personal injury, equipment
or property damage.

KM805020 (04/17/2013) 1-3

1-4 KM805020 (04/17/2013)
Air System 2

2 Applies To
Model Chart . . . . . . . . . . . . . 2 - 2

KM805020 (04/17/2013) 2-1

 2 Air System

Model Chart
Kenworth Model T680

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Air System 3

3 Exploded View
Air Solenoid Bank . . . . . . . . . . . 3 - 2

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3 Air System

Air Solenoid Bank

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Air System 4

4 What's New
Introduction . . . . . . . . . . . . . 4 - 2
Solenoid Bank . . . . . . . . . . . . 4 - 3
Brake System . . . . . . . . . . . . . 4 - 4

KM805020 (04/17/2013) 4-1

 4 Air System

Introduction
The air system in this vehicle has been redesigned
to reduce the amount of air lines entering into the
cab. The result is fewer sources for air leaks.

The air subsystems, controlled through dash

switches, are monitored and controlled by the
cab electronic unit. This interactivity provides
feedback to the operator when an air system is
detecting problems.

The new design is characterized by a significantly

smaller air manifold at the cab front wall (footwell)
and the lack of air lines running directly to a switch.
Most notably, the vehicle will have an Air Solenoid
Bank which is located outside of the cab, around
the driver’s side front cab mount.

For improved serviceability, the front brake valve

(relay or quick release) is located on the bottom
side of the front cross member (under the cooling
module).

4-2 KM805020 (04/17/2013)

Air System 4

Solenoid Bank

The solenoid bank can hold up to 10 solenoids,

this eliminates the need for BOC junction block.
Solenoids are individually replaceable.

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 4 Air System

Brake System

Front brake valves are relocated to radiator

crossmember to improve serviceability.

4-4 KM805020 (04/17/2013)

Air System 5

5 General Information
Air Piping Schematic . . . . . . . . . 5 - 2
Air Compressor . . . . . . . . . . . . 5 - 4
Air Dryer . . . . . . . . . . . . . . . 5 - 5
Air Solenoids . . . . . . . . . . . . . 5 - 6
Electric Over Air (EOA) . . . . . . . . 5 - 8
Brake System Description . . . . . . 5 - 10
Charging Trailer Air Reservoir With
Tractor Parking Brakes Applied . . 5 - 13
Releasing Only The Trailer Parking
Brakes . . . . . . . . . . . . . . 5 - 14

KM805020 (04/17/2013) 5-1

 5 Air System

Air Piping Schematic

Brake System

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Air System 5

Accessory

KM805020 (04/17/2013) 5-3

 5 Air System

Air Compressor
All compressors, regardless of make or model, run
continuously while the engine is running.

System pressure is controlled by the governor

which (acting in conjunction with the unloading
mechanism in the compressor cylinder block)
starts and stops compression of air by loading or
unloading the compressor when pressure in the
system reaches a minimum of 690 kPa (100 psi)
or a maximum of 827 kPa (120 psi).

5-4 KM805020 (04/17/2013)

Air System 5

Air Dryer
The air dryer is a device used to remove moisture
and contaminants from the air coming from the
engine compressor. The air dryer is needed
because air from the compressor contains water
vapor and oil that can shorten the life of the air
system components.

Two types of air dryers may be used on vehicles:

• The aftercooler type removes moisture and
contaminants by forcing the hot air against a
finned aluminum body, causing the air to cool
and moisture and oil to separate from it. The
aftercooler type of air dryer should be installed
in an area of sufficient air flow, and away from
engine exhaust heat.
• The desiccant type uses a chemical
that collects and absorbs moisture and
oil. The desiccant type does not require
greater-than-normal air flow, but should
also be kept clear of the engine or exhaust
environment.

Both types of air dryer are provided with a

means of expelling the accumulated water and
contaminants (an ejector valve).

KM805020 (04/17/2013) 5-5

 5 Air System
Air Solenoids
Air solenoids are the devices that translate the
electrical signal into physical change that controls
the air pressure in various circuits. The air
solenoids are mounted to a bracket outside the
cab.
The solenoids are designed to stack on each other
so that they share a common air supply rail which
reduces the amount of air lines on the vehicle. Air
solenoids used on the vehicle are both of Latching
and Non-latching types.
5-6
• Latching: Requires a signal voltage to close
or open a solenoid. Will remain in position
if power is disconnected. Physically, these
require 2 spots on the bank compared to a
non-latching valve.
• Non-latching: Requires constant 12V to
change a valve from its normal position. Will
revert back to its normal position if power is
disconnected.
KM805020 (04/17/2013)
Air System 5

For safety reasons, certain circuits are designed

with latching type solenoid valves. These circuits
include but are not limited to:
1. Air suspension dump (tractor and trailer)
2. 2 speed rear axle control
3. Liftable axle controls (both on the vehicle and
on the trailer)
4. Workbrakes for winches

NOTE
General air accessories may be installed as either
latching or non-latching solenoids. This is depen-
dent on what the customer and/or body builder in-
stalls.

KM805020 (04/17/2013) 5-7

 5 Air System
Electric Over Air (EOA)
Electric over air describes a new design where
switches use electrical signals to control air
actuated devices instead of the old design where
the air valve and the switch were one unit.
Electric Over Air (EOA) switches initiate electrical
signals to actuate air valves in order to activate
and deactivate air functions (such as: suspension
dumps, differential locks, PTO switches, trailer
switches, etc.).
The electric signal is sent to the Cab Electronic
Control Unit (CECU) and is processed into a digital
instruction. That data is sent to the chassis node
which then processes the digital instruction and
activates the proper air solenoid. The air solenoid
takes the supplied voltage and opens/closes an
air valve.
The EOA system reduces the number of air
lines running into the cab; by having a single
air supply to a bank of solenoids. This helps
5-8
improve reliability and reduces diagnostic time;
the solenoid bank is mounted on the left hand cab
support.
The only air connections behind the dash are for
the air gauges, pressure sensors, tractor park
brake and trailer air supply.
There are a total of eight available EOA general
function switches with four additional hardwired
lifter/pusher axle switches. The eight general
switches are inputs into the CECU while the four
hardwired switches are wired directly to the air
solenoids (bypassing the CECU).
WARNING!
Do not attempt to work on the electric over air
(EOA) components without first disconnecting the
negative battery cable from the battery and insu-
lating it. Servicing the EOA system with batteries
connected could cause an electrical shock or in-
jury from energized components. Failure to com-
ply may result in death, personal injury, equipment
or property damage.
KM805020 (04/17/2013)
Air System 5

PTO Types
There are three different types of PTOs supported
in the EOA software implementation.

Single Acting PTOs — These types of PTOs

have a single air control. A single chassis node
output controls the air solenoid. The presence air
pressure engages the PTO, and the lack of air
pressure at the control port disengages the PTO
from the driveline.

Double Acting PTOs — These types of PTOs

have a dual air control. One air port controls the
engagement, and another air port controls the
disengagement. This can be achieved one of two
ways:
• A Single Acting PTO is configured. The
engage air control port is connected to the
chassis node output and a pilot inversion valve
in the chassis air plumbing is connected to the
second disengage air control port.
• Two chassis node outputs control the PTO.
One chassis node output and solenoid is
connected to the engage air control port of
the PTO and one chassis node output and
solenoid is connected to the disengage air
control port.

Reversible PTOs — These types of PTOs have

three different operational states:
• Inactive, not engaged to driveline, no air
control ports active.
• Main Direction, engaged to driveline, main air
control port pressurized.
• Opposite Direction, engaged to driveline,
opposite air control port pressurized.

The CECU software is written as part of a

3-position switch design strategy. This 3-position
switch prevents the possibility that both inputs are
active at the same time.

KM805020 (04/17/2013) 5-9

 5 Air System
Brake System Description
The dual air braking system is composed of the
following:
• Three reservoirs - Supply, Front service, and
Rear service
• A dual-valve brake treadle
• A spring brake valve capable of controlling
variable spring brake pressure (full truck only)
• Single and double check valves to protect each
brake circuit in the event either circuit loses air
When the air system is pressurized, the front and
rear service reservoirs supply air to their respective
brake circuits. Both brake circuits supply air to
the spring brakes and the trailer brakes, thereby
offering extra protection in the event either one
of the circuits loses air pressure. If either circuit
should lose air pressure it is immediately isolated
from the rest of the air system by the action of
the single and double check valves. Modulating
antilock valves (if installed) serve the dual purpose
of controlling brake action in direct proportion to
brake application pressure and preventing wheel
lockup in the event of an impending skid.
5 - 10
Normal Service Brake Application
Movement of the brake treadle actuates the dual
brake valves, allowing air from the front and rear
reservoirs to flow through the respective delivery
ports.
On full trucks only, as brake pressure is applied, air
in the front brake circuit is simultaneously supplied
to the spring brake relay valve, but as long as
there is normal supply pressure in the rear brake
circuit no movement of the internal components of
the spring brake valve takes place, and the spring
brakes will not be activated. Anticompounding
of the spring brakes is prevented by means of a
hose from the forward rear modulator valve to the
service port of the spring brake relay valve.
On tractors the spring brake relay valve is
replaced with a QR-1C quick release valve.
Anticompounding of the spring brakes is
accomplished by means of a connection from the
forward rear modulator valve to the supply port of
the quick release valve.
Air in the rear brake circuit goes directly from
the rear service relay valve to the rear modulator
valves, where it is metered to the service brake
chambers.
When the brake treadle is released, air pressure
from all brake chambers is exhausted through the
respective relay valves.
KM805020 (04/17/2013)
Air System 5

ABS Loss Of Front Brake Circuit

If, due to operating conditions, a brake application
causes either wheel on the same axle to begin
skidding, wheel speed sensors immediately signal
the antilock controller in the modulator assembly.
The controller responds instantly by signaling
the solenoids in the modulator which activate
the air valves, reducing application pressure as
needed to prevent the wheels from locking up. If
this over-riding correction is effective, application
pressure is allowed to build up to the original input.
If air pressure is lost in the front brake circuit,
action of the check valves will protect the entire
rear brake circuit from any loss of air. Only the
front brakes will be inoperative. The rear service
brakes will function normally. The rear brake
circuit will supply air to the trailer brakes.

Any malfunction of the antilock system on one or

more axles will cause the system to fail-safe, and
the panel-mounted amber warning light will come
on, indicating both a malfunction, and automatic
shut-down of the system. If the air system is intact
(indicated by the pressure gauges), the service
brakes will continue to function normally, but
without benefit of the antilock feature.

NOTE
If one wheel on any driven axle continues to slip or
spin for approximately 4 seconds, this will cause
the antilock controller for that axle to go into the
fail-safe mode, and the warning light will give a
shutdown signal. In this case, the antilock system
can be turned back on, and the warning light ex-
tinguished, by turning the key switch Off and On,
after the vehicle has been brought to a full stop.
When the key switch is turned back on, the warn-
ing light will illuminate and remain on for 3 to 5
seconds This is a built-in function test of the warn-
ing light.

CAUTION
Do not attempt to recycle the antilock system by
turning the keyswitch OFF and ON until the vehicle
has been brought to a full stop and the parking
brakes set. Failure to do so could adversely affect
steering and braking control, and may result in loss
of vehicle control and an injury accident.

KM805020 (04/17/2013) 5 - 11
 5 Air System

Loss Of Rear Brake Circuit Total Loss Of System Air Pressure

If air is lost in the rear brake circuit, the check A total loss of air pressure in the braking system
valves protect the front brake circuit. For full will cause the spring brakes on the truck/tractor
trucks, when the rear brake circuit pressure drops and trailer to actuate.
below 379 kPa (55 psi), the reservoir port in the
spring brake valve no longer senses pressure.
Now, when a service application is made, air in
the front brake circuit goes simultaneously to the
front brakes and the control port of the spring
brake valve. The spring brake valve responds by
exhausting the spring brake chambers through
the relay valve, in proportion to the amount of
pressure delivered by the brake valve. Release of
the brake valve treadle allows stand-off pressure
to build up in the spring brake chambers and
retract the springs; thus, modulated control of
the spring brakes offers braking action similar to
the service brakes. For tractors, a double check
valve will insure that the trailer brakes remain
operative by the front brake circuit. The tractor
rear brakes will not operate. WARNING! Do not
operate the vehicle in the event of a malfunction in
any air circuit. The vehicle should not be operated
until the system is repaired and both braking
circuits, including all pneumatic and mechanical
components, are working properly. Loss of system
air can cause the service brakes to not function
resulting in the sudden application of the spring
brakes causing wheel lock-up, loss of control or
overtake by following vehicles. You could be in an
accident and severely injured.

5 - 12 KM805020 (04/17/2013)
Air System 5

Charging Trailer Air Reservoir With

Tractor Parking Brakes Applied

NOTE
The yellow parking brake holds a tractor-trailer
combination without applying the service brakes
when charging the trailer air system.

WARNING!
A service brake application may be needed to pre-
vent vehicle movement.

Connect the tractor air lines to the trailer, then

complete this procedure.
1. With the yellow and red control in Out position
and the trailer hand brake control in the Off
position, push In the red control. This charges
the trailer air system and releases the trailer
parking brakes. The tractor parking brakes
are still applied.
2. Charge the trailer air system and verify that
both front and rear service air pressure
gauge(s) indicate at least 690 kPa (100 psi).
3. Push In the yellow control. This releases the
tractor parking brakes.
4. Check for proper operation of the service
brakes before proceeding.

KM805020 (04/17/2013) 5 - 13
 5 Air System

Releasing Only The Trailer Parking

Brakes
• With the red and yellow control in the Out
position, push In the red control. This releases
only the trailer parking brakes.
• With the red and yellow control in the In
position:
° Pull out the yellow control. This applies
the tractor parking brakes. The red control
will pop out automatically, applying the
trailer parking brakes. To release the trailer
parking brakes, push In the red control.
° While holding In the red control, pull Out
the yellow control. This applies the tractor
parking brakes without reapplying the
trailer parking brakes.

5 - 14 KM805020 (04/17/2013)
Air System 7

7 Specifications
Front Brake Air Piping . . . . . . . . . 7 - 2
Air Solenoid Bank . . . . . . . . . . . 7 - 3
Axle Lift Control Options . . . . . . . 7 - 4
Air Sensor . . . . . . . . . . . . . . 7 - 5
Air Manifold Connections . . . . . . . 7 - 6

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7 Air System

Front Brake Air Piping

1. 90° BULK - #8 FLARE 16. FAM TO BULKHEAD PIPING 31. BRACKET-TRAILER ABS
2. NUT - SAE HEXAGON JAM, 3/4" 17. BULKHEAD TO CHAMBER PIPING 32. JUMPER HOSE
3. WASHER - SAE PLAIN, 3/4" 18. VALVE-ASSEMBLY 33. DASH LABEL
4. WASHER - STAR, 3/4" 19. SUSPENSION HOSE 34. FRAME LABEL
5. WASHER - HARDENED, 1/2" 20. CONV. FTG 35. STEERING LABEL
6. LOCKNUT - NYLON INSERT, M12 21. TEE OR UNION 36. AIR SYSTEM LABEL
7. BRACKET-ROUTING, AID 22. ESP PRESSURE SENSOR 37. J-BLOCK
8. FASTENER - THREADED, EXT (M6 X 25) 23. ESP YAW RATE SENSOR 38. FTG-FRONT
9. CLIP - FIR TREE ASSY 24. ABS MANUAL 39. FTG-BALANCE
10. MOUNT-CABLE TIE, HEAVY DUTY 25. TRAILER JUMPER HOSE 40. BALANCE
11. PIPING 26. VALVE-PMV, BENDIX 41. TO FAM
12. MODULATOR HOSE 27. FTG-90° ELBOW, PTCe 42. BOLT
13. FITTING 28. FTG-90° ELBOW, FLARE 43. NUT
14. JUMPER 29. BOLT-5/16" X 3 1/4"
15. FRAME DRILLING 30. WASHER-FLAT

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Air System 7

Air Solenoid Bank

1. M8 Screw
2. M8 Screw
3. EOA Bracket
4. Solenoid Assembly

KM805020 (04/17/2013) 7-3

 7 Air System

Axle Lift Control Options

Axle Lift Control Options

Option Primary Gauge Secondary Gauge Regulator Switch

1 Dash Mounted None Dash Mounted Dash Mounted

2 Dash Mounted L/H of Drivers Seat Under Drivers Door Dash Mounted
3 Dash Mounted BOC Lower L/H Corner BOC Lower L/H Corner BOC Lower L/H Corner
4 BOC Drivers Side None BOC Drivers Side BOC Drivers Side
5 Dash Mounted BOC Lower L/H Corner BOC Lower L/H Corner Dash Mounted
6 Dash Mounted Tie Strapped to Rail Tie Strapped to Rail Dash Mounted
7 Dash Mounted L/H of Drivers Seat Under Drivers Door Under Drivers Door
8 Lift Axles Controlled by Drive Axle Suspension

7-4 KM805020 (04/17/2013)

Air System 7

Air Sensor
Air Sensor Locations

KM805020 (04/17/2013) 7-5

 7 Air System

Air Manifold Connections

Interior Label

7-6 KM805020 (04/17/2013)

Air System 7

Bulkhead Label

AIR SUPPLY (HOT) HOSES

COMPRESSOR
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
MOISTURE REMOVAL
1001 COMPRESSOR EQUIPMENT W/AIR DRYER CHASSIS BLACK
1002 COMPRESSOR WET TANK W/O AIR DRYER CHASSIS BLACK
COMPRESSOR COMPRESSOR
1003 GOVERNOR UNLOADER PORT STANDARD CHASSIS BLACK
GOVERNOR,
1004 COMPRESSOR COMPRESSOR STANDARD CHASSIS BLACK
*Hose color refers to the color of the actual hose. It does not refer to the color that may be painted over the hose during the assembly process

AIR SUPPLY (HOT) HOSES

AIR DRYER
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
PRIMARY REAR DRY RAPID PRESSURE
1101 AIR DRYER TANK BUILDUP CHASSIS ORANGE
SUPPLY TANK OR AIR
1102 DRYER REMOTE FITTING SYSTEM CHARGE CHASSIS BLACK
CHECK VALVE ON
1103 WET TANK ECON VALVE WITH ECON VALVE CHASSIS BLACK
UNLOADER PORT OF
1104 AIR DRYER ECON VALVE WITH ECON VALVE CHASSIS BLACK
1105 AIR DRYER REAR DRY TANK STANDARD CHASSIS ORANGE
1106 WET TANK REAR DRY TANK WITH WET TANK CHASSIS BLACK
MOISTURE REMOVAL
1107 EQUIPMENT FORWARD DRY TANK STANDARD CHASSIS GREEN
1108 WET TANK FORWARD DRY TANK WITH WET TANK CHASSIS GREEN

KM805020 (04/17/2013) 7-7

 7 Air System

AIR SUPPLY (HOT) HOSES

AIR DRYER
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
GOVERNOR,
1109 WET TANK COMPRESSOR WITH WET TANK CHASSIS BLACK
GOVERNOR,
1110 AIR DRYER COMPRESSOR STANDARD CHASSIS BLACK
TRANSMISSION AIR AUTOMATED
1112 AIR DRYER TANK TRANSMISSION CHASSIS BLACK
TRANSMISSION AIR FREEDOMLINE
1113 WET TANK TANK TRANSMISSION CHASSIS BLACK
*Hose color refers to the color of the actual hose. It does not refer to the color that may be painted over the hose during the assembly process

AIR SUPPLY (HOT) HOSES

FORWARD DRY
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
1201 FORWARD DRY TANK EVERFLOW UNIT AIR SENSING LINE CHASSIS GREEN
HEIGHT CONTROL
1202 FORWARD DRY TANK VALVE CAB SUSPENSION CHASSIS GREEN
CUMMINS VG TURBO
1203 FORWARD DRY TANK AIR FILTER CUMMINS VG TURBO CHASSIS BLACK
FOOT VALVE
1205 FORWARD DRY TANK SECONDARY SUPPLY LOWER HALF CAB/CHASSIS GREEN
1206 FORWARD DRY TANK AUTO RVS CYLINDER PUSHER W/AUTO RVS CHASSIS GREEN
SECONDARY AIR
1207 FORWARD DRY TANK CIM PORT IB PRESSURE CHASSIS GREEN
1208 FORWARD DRY TANK FORWARD DRY TANK W/MULTIPLE TANKS CHASSIS GREEN
PUSHER
SUSPENSION W/PUSHER AXLE
1209 FORWARD DRY TANK SOLENOID SUSPENSION CHASSIS GREEN
PUSHER
SUSPENSION W/PUSHER AXLE
1210 FORWARD DRY TANK SYNCHRO VALVE SUSPENSION CHASSIS GREEN
W/PUSHER AXLE
1211 FORWARD DRY TANK RELAY, RIDE BAG SUSPENSION CHASSIS GREEN
REAR DRY TANK
DOUBLE CHECK
1212 FORWARD DRY TANK VALVE W/SBM CHASSIS GREEN
1213 FORWARD DRY TANK SR-7 RELAY VALVE W/SR-7 CHASSIS GREEN
FRONT SERVICE
1214 FORWARD DRY TANK RELAY VALVE FRONT BRAKES CHASSIS GREEN
AUXILIARY W/ AUXILIARY
1215 FORWARD DRY TANK TRANSMISSION TRANSMISSION CAB/CHASSIS GREEN
1216 FORWARD DRY TANK CAB MANIFOLD STANDARD CHASSIS GREEN
AUXILIARY
AIR MANIFOLD
(ACCESSORY
1217 FORWARD DRY TANK SUPPLY) STANDARD CHASSIS GREEN
W/PUSHER AXLE
1218 FORWARD DRY TANK RELAY, PUSHER AXLE SUSPENSION CHASSIS GREEN
FRONT PRESSURE W/FLIP VALVE TO
1219 FORWARD DRY TANK REDUCING VALVE ALL/REAR BRAKES CHASSIS GREEN
NEWAY CNTRLD BY
1220 FORWARD DRY TANK RELAY, RATIO VALVE REAR AXLE CHASSIS GREEN

7-8 KM805020 (04/17/2013)

Air System 7

AIR SUPPLY (HOT) HOSES

FORWARD DRY
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
HAND VALVE TO
1221 FORWARD DRY TANK HAND VALVE SUPPLY BRAKES CAB GREEN
1222 FORWARD DRY TANK RELAY, FRONT AXLE STANDARD CHASSIS GREEN
DIFFERENTIAL,
INTER-AXLE EATON 2 SPEED WITH
1223 FORWARD DRY TANK CONTROL PROTECTION CHASSIS GREEN
FRONT PRESSURE W/FLIP VALVE TO
1224 REDUCING VALVE FLIPPER VALVE ALL/REAR BRAKES CAB BLACK
POWERTRAIN
1225 FORWARD DRY TANK RETARDER ENGINE BLACK
*Hose color refers to the color of the actual hose. It does not refer to the color that may be painted over the hose during the assembly process

AIR SUPPLY (HOT) HOSES

REAR DRY
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
1301 REAR DRY TANK ASR/HSA/ECA VALVE HILL START AID CHASSIS ORANGE
PRIMARY AIR
1302 REAR DRY TANK CIM PORT IA PRESSURE CHASSIS ORANGE
RAPID PRESSURE
1303 REAR DRY TANK (#1) REAR DRY TANK (#2) BUILDUP CHASSIS ORANGE
1304 REAR DRY TANK AUTO RVS CYLINDER TAG/W AUTO RVS CHASSIS ORANGE
1305 REAR DRY TANK SBM W/SBM VALVE CHASSIS ORANGE
LIFT AXLE RELAY W/TAG AXLE
1306 REAR DRY TANK VALVE SUPPLY SUSPENSION CHASSIS ORANGE
TAG SUSPENSION
1307 REAR DRY TANK SOLENOID W/TAG SUSPENSION CHASSIS ORANGE
1308 REAR DRY TANK RELAY, REAR BRAKE STANDARD CHASSIS ORANGE
FOOT VALVE PRIMARY
1309 REAR DRY TANK SUPPLY STANDARD CAB/CHASSIS ORANGE
SPRING BRAKE
1310 REAR DRY TANK INVERSION VALVE STANDARD CHASSIS ORANGE
REAR PRESSURE W/FLIP VALVE TO
1311 REDUCING VALVE FLIPPER VALVE ALL/REAR BRAKES CAB BLACK
*Hose color refers to the color of the actual hose. It does not refer to the color that may be painted over the hose during the assembly process

AIR SUPPLY (HOT) HOSES

BRAKES
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
DOUBLE CHECK PARKING/TRAILER 1 OR 3 VALVE
1401 VALVE SUPPLY VALVE PARKING CAB BLACK
FOOT VALVE PRIMARY PARK VALVE PRIMARY PARK VALVE PRIMARY
1402 SUPPLY SUPPLY SUPPLY CAB ORANGE
FOOT VALVE (TOP CIM PORT IB TEE/CAB PRIMARY AIR
1403 HALF) MANIFOLD PRESSURE CAB ORANGE
FOOT VALVE CIM PORT IA TEE/CAB SECONDARY AIR
1404 (BOTTOM HALF) MANIFOLD PRESSURE CAB GREEN
DOUBLE CHECK RELAY, SPRING
1405 VALVE BRAKE W/SBM CHASSIS YELLOW
FOOT VALVE PARK VALVE PARK VALVE
1406 (BOTTOM HALF) SECONDARY SUPPLY SECONDARY SUPPLY CAB/CHASSIS GREEN
*Hose color refers to the color of the actual hose. It does not refer to the color that may be painted over the hose during the assembly process

KM805020 (04/17/2013) 7-9

 7 Air System

AIR SUPPLY (HOT) HOSES

MANIFOLD
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
GOVERNOR
CONTROL FLIP VALVE
1501 CAB MANIFOLD SUPPLY PORT AIR THROTTLE CAB BLACK
PARK CONTROL
VALVE (2 VALVE) OR
DBL CHECK VALVE (1 REAR DRY TANK
1502 CAB MANIFOLD OR 3 VALVE) SUPPLY CAB ORANGE
AIR THROTTLE
1503 CAB MANIFOLD TREADLE VALVE W/AIR THROTTLE CAB GREEN
HEATER AIR AIR OPERATED
1504 CAB MANIFOLD CONTROL HEATER CONTROLS CAB GREEN
TRANSFER CASE
SHIFTER INVERSION
1505 CAB MANIFOLD VALVE W/TRANSFER CASE CHASSIS GREEN
TRANSMISSION AIR
1506 CAB MANIFOLD TRANSMISSION SUPPLY CHASSIS BLACK
TRANSMISSION AIR
1507 CAB MANIFOLD TRANSMISSION SUPPLY CHASSIS BLACK
REAR PRESSURE
1508 CAB MANIFOLD REDUCING VALVE CHASSIS BLACK
AIR SHUTDOWN
1509 CAB MANIFOLD SOLENOID HILL START AID CHASSIS GREEN
PARK CONTROL
VALVE (2 VALVE) OR
DBL CHECK VALVE (1 FORWARD DRY TANK
1510 CAB MANIFOLD OR 3 VALVE) SUPPLY CAB GREEN
HAND VALVE
TO SERVICE
1511 CAB MANIFOLD HAND VALVE SUPPLY BRAKES/ACCESSORY CAB GREEN
HAND VALVE TO
1512 CAB MANIFOLD HAND VALVE SUPPLY TRAILER BRAKES CAB GREEN
FAN CLUTCH (VIA ELECTRIC OVER AIR
1513 CAB MANIFOLD SOLENOID) FAN CLUTCH CAB/ENGINE GREEN
AIR SLIDING FIFTH W/ AIR SLIDING FIFTH
1514 CAB MANIFOLD WHEEL VALVE WHEEL CAB GREEN
PRESSURE
PROTECTION VALVE,
1515 CAB MANIFOLD JIFFLOX JIFFLOX CAB BLACK
1516 CAB MANIFOLD AIR SEAT DRIVER SIDE CAB BLACK
1517 CAB MANIFOLD AIR HORN VALVE STANDARD CAB GREEN
DUMP VALVE SUPPLY W/ SUSPENSION
1518 CAB MANIFOLD PORT DUMP CAB BLACK
PRESSURE
1519 CAB MANIFOLD PROTECTION VALVE BULK UNLOAD CAB BLACK
PRESSURE
1520 CAB MANIFOLD REDUCING VALVE BRAKESAVER CAB BLACK
PRESSURE BULK UNLOAD OR
1521 CAB MANIFOLD REGULATOR LIFT AXLE CAB/CHASSIS GREEN
1522 CAB MANIFOLD AIR SEAT PASSENGER SIDE CAB BLACK
1523

7 - 10 KM805020 (04/17/2013)
Air System 7

AIR SUPPLY (HOT) HOSES

MANIFOLD
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
INTERAXLE
DIFFERENTIAL LOCK W/ INTERAXLE
1524 CAB MANIFOLD VALVE DIFFERENTIAL LOCK CAB GREEN
TRACTION CONTROL W/MANF CONTROL
1525 CAB MANIFOLD TOGGLE LIMITING CAB GREEN
EXHAUST AIR
1526 CAB MANIFOLD MANIFOLD AFTERTREATMENT CAB GREEN
EXHAUST BRAKE
1527 CAB MANIFOLD SOLENOID VALVE AFTERTREATMENT ENGINE GREEN
*Hose color refers to the color of the actual hose. It does not refer to the color that may be painted over the hose during the assembly process

AIR SUPPLY (HOT) HOSES

OTHER
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
1601 AIR DRYER AUXILIARY AIR TANK AUXILIARY AIR TANK CHASSIS BLACK
1602 SERVICE TANK CAB TILT PUMP CAB TILT CHASSIS BLACK
LIFT AXLE RELAY LIFT AXLE RELAY
1603 VALVE SUPPLY VALVE SUPPLY MULTIPLE LIFT AXLES CHASSIS GREEN/ORANGE
FOOT VALVE AIR ACCESSORY
1604 (AUXILIARY PORT) CAB MANIFOLD SUPPLY CAB GREEN
*Hose color refers to the color of the actual hose. It does not refer to the color that may be painted over the hose during the assembly process

AIR SUPPLY (HOT) HOSES

SUSPENSION
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
MANIFOLD, REAR
1701 SERVICE HAND VALVE SUPPLY AIR SUSPENSION CAB ORANGE
REAR HEIGHT
CONTROL VALVE
1702 AIR DRYER (LEVELING VALVE) AIR SUSPENSION CHASSIS PURPLE
FORWARD OR REAR
1703 DRY TANK LEVELING VALVE AIR SUSPENSION CHASSIS GREEN/ORANGE
LEVELING
VALVE/DUMP VALVE
1704 (LH) RIDE BAG, LH REAR AIR SUSPENSION CHASSIS PURPLE
HEIGHT CONTROL
1705 AIR DRYER VALVE CAB SUSPENSION CHASSIS PURPLE
FRONT AIR
1706 FORWARD DRY TANK LEVELING VALVE SUSPENSION CHASSIS GREEN
FRONT HEIGHT FRONT AIR
1707 AIR DRYER CONTROL SUSPENSION CHASSIS PURPLE
SUPPLY TANK
(AD-IS AIR DRYER,
FORWARD DRY/REAR
1708 DRY) LEVELING VALVE AIR SUSPENSION CHASSIS PURPLE
*Hose color refers to the color of the actual hose. It does not refer to the color that may be painted over the hose during the assembly process

KM805020 (04/17/2013) 7 - 11
 7 Air System

AIR SUPPLY (HOT) HOSES

TRANSMISSION
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
TRANSMISSION AIR FREEDOMLINE
1801 TANK TRANSMISSION ECU TRANSMISSION CHASSIS BLACK
TRANSMISSION AIR TRANSMISSION FREEDOMLINE
1802 TANK CLUTCH SOLENOID TRANSMISSION CHASSIS BLACK
*Hose color refers to the color of the actual hose. It does not refer to the color that may be painted over the hose during the assembly process

AIR SUPPLY (HOT) HOSES

RUSSIAN AIR
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
MULTI-CIRCUIT
PROTECTION VALVE
1901 SUPPLY TANK (MCP VALVE) RUSSIAN AIR TANK CHASSIS BLACK
MULTI-CIRCUIT
1902 PROTECTION VALVE FRONT SERVICE TANK RUSSIAN AIR TANK CHASSIS GREEN
MULTI-CIRCUIT
1903 PROTECTION VALVE REAR SERVICE TANK RUSSIAN AIR TANK CHASSIS ORANGE
MULTI-CIRCUIT SECONDARY/EMERGENCY
1904 PROTECTION VALVE AIR TANK RUSSIAN AIR TANK CHASSIS YELLOW
MULTI-CIRCUIT
1905 PROTECTION VALVE TRAILER AIR TANK RUSSIAN AIR TANK CHASSIS RED
EMERGENCY AIR RELAY, SPRING
1906 TANK BRAKE RUSSIAN AIR TANK CHASSIS YELLOW
TRAILER CONTROL
1907 TRAILER AIR TANK VALVE RUSSIAN AIR TANK CHASSIS RED
1908 TRAILER AIR TANK #1 TRAILER AIR TANK #2 RUSSIAN AIR TANK CHASSIS RED
*Hose color refers to the color of the actual hose. It does not refer to the color that may be painted over the hose during the assembly process.

BRAKE HOSES
FRONT BRAKE
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
RH PMV/BRAKE
2001 RELAY VALVE CHAMBER DRIVING STEER AXLE CHASSIS ORANGE
LH PMV/BRAKE
2002 RELAY VALVE CHAMBER DRIVING STEER AXLE CHASSIS ORANGE
LH PMV/BRAKE
2003 RELAY VALVE CHAMBER DRIVING STEER AXLE CHASSIS GREEN
RH PMV/BRAKE
2004 RELAY VALVE CHAMBER DRIVING STEER AXLE CHASSIS GREEN
FRONT BRAKE
LIMITING VALVE OR
2005 DOUBLE CHECK QRV FRONT CHASSIS GREEN
FRONT AXLE LIMITING
VALVE/QUICK
FOOT VALVE RELEASE VALVE OR FRONT SERVICE
2006 (BOTTOM HALF) R-14 RELAY VALVE BRAKES CAB/CHASSIS GREEN
LH FOOT VALVE DOUBLE CHECK
2007 (BOTTOM HALF) VALVE LH FRONT CHASSIS GREEN
RH FOOT VALVE DOUBLE CHECK
2008 (BOTTOM HALF) VALVE RH FRONT CHASSIS GREEN
FRONT AXLE LIMITING W/MANF CONTROL
2009 ATC VALVE VALVE LIMITING CAB/CHASSIS BLACK

7 - 12 KM805020 (04/17/2013)
Air System 7

BRAKE HOSES
FRONT BRAKE
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
DIFFERENTIAL
LOCK OR TRACTION FRONT AXLE LIMITING W/MANF CONTROL
2010 CONTROL VALVE VALVE LIMITING CAB/CHASSIS BLACK
TRACTION CONTROL W/MANF CONTROL
2011 CAB MANIFOLD TOGGLE LIMITING CAB GREEN
FRONT AXLE LIMITING
VALVE OR QUICK
2012 RELEASE SBM (SR-1) VALVE W/SBM VALVE CHASSIS GREEN
SERVICE BRAKE SERVICE BRAKE
2013 CHAMBER CHAMBER WEDGE BRAKES CHASSIS BLACK
FOOT VALVE FRONT AXLE LIMITING
SECONDARY VALVE OR QUICK
2014 DELIVERY RELEASE CHASSIS GREEN
FRONT AXLE LIMITING RELAY, FORWARD
2015 VALVE SERVICE CONTROL CHASSIS GREEN
FRONT AXLE LIMITING
VALVE OR QUICK LH PMV/BRAKE
2016 RELEASE CHAMBER STANDARD CHASSIS GREEN
FRONT AXLE LIMITING
VALVE OR QUICK RH PMV/BRAKE
2017 RELEASE CHAMBER STANDARD CHASSIS GREEN
FRONT AXLE LIMITING
2018 RELAY, FRONT AXLE VALVE CHASSIS GREEN
*Hose color refers to the color of the actual hose. It does not refer to the color that may be painted over the hose during the assembly process.

BRAKE HOSES
REAR BRAKE
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
RELAY, FORWARD QR-1C OF SBM RELAY
2101 REAR VALVE ANTI-COMPOUNDING CHASSIS ORANGE
QR-1C OF SBM RELAY
2102 RELAY, REAR BRAKE VALVE ANTI-COMPOUNDING CHASSIS ORANGE
SR-7 RELAY VALVE
2103 SERVICE RELAY BALANCE PORT FULL TRUCK CHASSIS ORANGE
LH FOOT VALVE (TOP DOUBLE CHECK
2104 HALF) VALVE LH REAR CHASSIS ORANGE
FOOT VALVE PRIMARY REAR SERVICE
2105 DELIVERY RELAY, REAR BRAKE BRAKES CHASSIS ORANGE
RH FOOT VALVE (TOP DOUBLE CHECK
2106 HALF) VALVE RH REAR CHASSIS ORANGE
SERVICE BRAKE SERVICE BRAKE
2107 CHAMBER CHAMBER WEDGE BRAKES CHASSIS BLACK
2108 RELAY, SINGLE REAR ANCHOR ELBOW STANDARD CHASSIS ORANGE
SERVICE BRAKE
RELAY, SERVICE CHAMBER, FORWARD
2109 BRAKE REAR AXLE STANDARD CHASSIS ORANGE
SERVICE BRAKE
RELAY, SERVICE CHAMBER, REAR
2110 BRAKE REAR AXLE STANDARD CHASSIS ORANGE
FOOT VALVE (TOP QUICK RELEASE
2111 HALF) VALVE CAB/CHASSIS ORANGE

KM805020 (04/17/2013) 7 - 13
 7 Air System

BRAKE HOSES
REAR BRAKE
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
DOUBLE CHECK QUICK RELEASE W/O TRAILER
2112 VALVE VALVE CONNECTIONS CAB/CHASSIS ORANGE
*Hose color refers to the color of the actual hose. It does not refer to the color that may be painted over the hose during the assembly process.

BRAKE HOSES
SPRING BRAKE
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
DOUBLE CHECK
2201 VALVE SBM VALVE 330 W/SBM CAB/CHASSIS BLACK
PARK BRAKE
2202 CONTROL FIREWALL BULKHEAD EXHAUST CAB BLACK
FOOT VALVE
SECONDARY SPRING BRAKE
2203 DELIVERY INVERSION VALVE FULL TRUCK CHASSIS GREEN
RELAY, SPRING
2204 SBM DELIVERY PORT BRAKE FULL TRUCK CHASSIS YELLOW
RELAY, SERVICE
2205 BRAKE SBM BALANCE PORT FULL TRUCK CHASSIS ORANGE
PARKING CONTROL
PARK BRAKE VALVE CONTROL
2206 CONTROL PORT W/DUAL STEER CAB YELLOW
SPRING BRAKE
INVERSION VALVE,
OR SPRING BRAKE
QUICK RELEASE, OR
PARK BRAKE ANTI-COMPOUNDING
2207 CONTROL PORT DOUBLE CHECK SPRING BRAKES CAB/CHASSIS YELLOW
2208 SBM VALVE SBM RELAY VALVE W/SBM VALVE CHASSIS YELLOW
SPRING BRAKE DOUBLE CHECK
2209 RELAY, CONTROL VALVE CHASSIS YELLOW
SPRING BRAKE
RELAY, SPRING CHAMBER, FORWARD
2210 BRAKE REAR AXLE STANDARD CHASSIS YELLOW
SPRING BRAKE
RELAY, SPRING CHAMBER, REAR
2211 BRAKE REAR AXLE STANDARD CHASSIS YELLOW
*Hose color refers to the color of the actual hose. It does not refer to the color that may be painted over the hose during the assembly process.

BRAKE HOSES
TRAILER BRAKES
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
TRACTOR
PROTECTION VALVE CIM PORT 2B, 3A OR AIR APPLICATION
2301 OR DOUBLE CHECK 3B GAUGE CHASSIS BLACK
TRACTOR CHASSIS INTERFACE TRAILER
2302 PROTECTION VALVE MODULE APPLICATION GAUGE CAB BLACK
FOOT VALVE DOUBLE CHECK TRAILER
2303 (BOTTOM HALF) VALVE CONNECTIONS 362 CAB GREEN
DOUBLE CHECK DOUBLE CHECK TRAILER
2304 VALVE VALVE CONNECTIONS 362 CAB BLACK
TRACTOR W/TRAILER
2305 HAND VALVE PROTECTION VALVE CONNECTIONS CAB BLUE

7 - 14 KM805020 (04/17/2013)
Air System 7

BRAKE HOSES
TRAILER BRAKES
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
DOUBLE CHECK TRACTOR W/TRAILER
2306 VALVE PROTECTION VALVE CONNECTIONS CAB/CHASSIS BLUE
TRACTOR GLADHAND, W/TRAILER
2307 PROTECTION VALVE EMERGENCY CONNECTIONS CAB/CHASSIS RED
TRACTOR W/TRAILER
2308 PROTECTION VALVE GLADHAND, SERVICE CONNECTIONS CAB/CHASSIS BLUE
TRAILER SUPPLY TRACTOR
2309 VALVE PROTECTION VALVE STANDARD CAB RED
TP VALVE (W/TRAILER
FOOT VALVE CONN) DBL CHECK
2310 (BOTTOM HALF) (W/O TRAILER CONN) STANDARD CAB GREEN
TP VALVE (W/TRAILER
FOOT VALVE (TOP CONN) DBL CHECK
2311 HALF) (W/O TRAILER CONN) STANDARD CAB ORANGE
BRAKE
PROPORTIONING
TRACTOR VALVE (BPR-1)
2312 PROTECTION VALVE CONTROL PORT CHASSIS BLACK
FRONT AXLE
TRACTOR LIMITING VALVE (LQ-5)
2313 PROTECTION VALVE CONTROL PORT CHASSIS BLACK
*Hose color refers to the color of the actual hose. It does not refer to the color that may be painted over the hose during the assembly process.

BRAKE HOSES
LIFT AXLES
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
SPRING BRAKE
RELAY, SPRING CHAMBERS, LIFT
2401 BRAKE AXLE LIFT AXLE CHASSIS YELLOW
SERVICE BRAKE
RELAY, SERVICE CHAMBERS, LIFT
2402 BRAKE AXLE LIFT AXLE CHASSIS GREEN/ORANGE
RELAY, SERVICE
BRAKES OR LQ-5
CONTROL PORT
FOOT VALVE PRIMARY (PUSHER OR TAG
2403 DELIVERY AXLE) LIFT AXLE CHASSIS ORANGE
REAR DRY TANK OR
DEAD AXLE SERVICE
RELAY VALVE SUPPLY
2404 PORT LQ-5 CONTROL PORT LIFT AXLE CHASSIS BLACK
RELAY, TAG AXLE
2405 RELAY, REAR BRAKE CONTROL W/TAG AXLE CHASSIS ORANGE
LIFT AXLE RELAY
FRONT AXLE LIMITING VALVE CONTROL W/TURNER
2406 VALVE PORT SUSPENSION CHASSIS GREEN
*Hose color refers to the color of the actual hose. It does not refer to the color that may be painted over the hose during the assembly process.

KM805020 (04/17/2013) 7 - 15
 7 Air System

BRAKE HOSES
OTHER
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
SERVICE BRAKE AUTO NEUTRAL AK
2501 FLIPPER VALVE STATUS SWITCH FUNCTION CAB/CHASSIS BLACK
END OF FRAME
BOOST-A-LOAD
2502 REAR DRY TANK SUPPLY LINE BOOST-A-LOAD CHASSIS ORANGE
END OF FRAME
REAR RELAY VALVE BOOST-A-LOAD
2503 CONTROL PORT CONTROL LINE BOOST-A-LOAD CHASSIS ORANGE
HAND VALVE TO
HAND VALVE OR DOUBLE CHECK REAR/ALL/ OR WB
2504 TOGGLE VALVE VALVE OR TP-5 VALVE W/ESP CAB BLACK
FOOT VALVE
SECONDARY
2505 DELIVERY TRANSDUCER STABILITY CONTROL CAB GREEN
FOOT VALVE PRIMARY
2506 DELIVERY TRANSDUCER STABILITY CONTROL CAB ORANGE
2507 FRONT BRAKE RELAY TRAILER MODULATOR STABILITY CONTROL CHASSIS BLUE
TRACTOR
PROTECTION VALVE
2508 TRAILER MODULATOR OR DOUBLE CHECK STABILITY CONTROL CAB/CHASSIS BLUE
TRACTOR STOP LIGHT
PROTECTION VALVE SWITCH/BRAKE W/ OR W/O TRAILER
2509 OR DOUBLE CHECK APPLICATION CONNECTIONS CAB BLUE
W/O TRAILER
DOUBLE CHECK DOUBLE CHECK CONNECTIONS,
2510 VALVE VALVE W/HAND VALVE CAB BLACK
DOUBLE CHECK GAUGE, REAR BRAKE W/REAR BRAKE
2511 VALVE OR TP VALVE APPLICATION APPLICATION GAUGE CAB ORANGE
GLADHAND, SERVICE W/TOWING
2512 (TOWING) RELAY, REAR BRAKE GLADHANDS CHASSIS BLUE
GLADHAND,
EMERGENCY W/TOWING
2513 (TOWING) REAR DRY TANK GLADHANDS CHASSIS RED
FRONT TOW
CONNECTION
GLADHAND OR
DOUBLE CHECK W/TOWING
2514 VALVE STOPLIGHT SWITCH GLADHANDS CHASSIS BLACK
FOOT VALVE (TOP DOUBLE CHECK W/O TRAILER
2515 HALF) VALVE CONNECTIONS CAB ORANGE
HAND VALVE OR BVA-85 VALVE OR W/FLIP VALVE TO ALL
2516 TOGGLE VALVE REAR RELAY VALVE BRAKES CAB/CHASSIS BLACK/ORANGE
ANCHOR ELBOW/AIR
2517 CAB MANIFOLD APPLICATION GAUGE CAB BLACK
DOUBLE CHECK W/FLIP VALVE TO
2518 FLIPPER VALVE VALVE (FR) ALL/REAR BRAKES CAB BLACK
DOUBLE CHECK W/FLIP VALVE TO
2519 FLIPPER VALVE VALVE (QRV) ALL/REAR BRAKES CAB BLACK

7 - 16 KM805020 (04/17/2013)
Air System 7

BRAKE HOSES
OTHER
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
W/HAND VALVE TO
DOUBLE CHECK DOUBLE CHECK REAR & TRAILER
2520 VALVE (REAR) VALVE (FRONT) CONN. CAB BLACK
*Hose color refers to the color of the actual hose. It does not refer to the color that may be painted over the hose during the assembly process.

BRAKE HOSES
RUSSIAN AIR
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
EMERGENCY AIR DASH HAND BRAKE
2601 TANK VALVE RUSSIAN AIR CAB/CHASSIS YELLOW
RELAY, SPRING
2602 HAND VALVE BRAKE RUSSIAN AIR CAB/CHASSIS YELLOW
FOOT VALVE (TOP TRAILER CONTROL
2603 HALF) VALVE RUSSIAN AIR CAB/CHASSIS ORANGE
FOOT VALVE TRAILER CONTROL
2604 (BOTTOM HALF) VALVE RUSSIAN AIR CAB/CHASSIS GREEN
TRAILER CONTROL
2605 HAND VALVE VALVE RUSSIAN AIR CAB/CHASSIS RED
MULTI-CIRCUIT AIR ACCESSORY RUSSIAN AIR
2606 PROTECTION VALVE MANIFOLD ACCESSORY CAB GREEN
PRESSURE AIR ACCESSORY RUSSIAN AIR
2607 PROTECTION VALVE MANIFOLD ACCESSORY CAB GREEN
FRONT AIR SYSTEM
FOOT VALVE AIR PRESSURE RUSSIAN AIR FRONT
2608 SECONDARY SUPPLY GAUGE SERVICE CAB/CHASSIS GREEN
FOOT VALVE PRIMARY VARIABLE LOAD RUSSIAN AIR REAR
2609 DELIVERY VALVE SERVICE CAB ORANGE
FOOT VALVE PRIMARY REAR SYSTEM AIR RUSSIAN AIR REAR
2610 SUPPLY PRESSURE GAUGE SERVICE CAB ORANGE
VARIABLE LOAD RELAY, SERVICE RUSSIAN AIR REAR
2611 VALVE BRAKES SERVICE CHASSIS ORANGE
TRAILER CONTROL
FOOT VALVE PRIMARY VALVE OR SUPPLY RUSSIAN AIR REAR
2612 DELIVERY DUMP VALVE SERVICE CHASSIS ORANGE
SECONDARY AIR
TANK (FORWARD SPRING BRAKE RUSSIAN AIR
2613 DRY) RELAY SECONDARY/PARKING CHASSIS GREEN
SECONDARY AIR
TANK (FORWARD PARK BRAKE RUSSIAN AIR
2614 DRY) CONTROL VALVE SECONDARY/PARKING CHASSIS GREEN
PARK BRAKE SPRING BRAKE RUSSIAN AIR
2615 CONTROL RELAY SECONDARY/PARKING CAB/CHASSIS YELLOW
DOUBLE CHECK
FRONT AXLE QUICK VALVE (FRONT RUSSIAN AIR
2616 RELEASE VALVE SPRING BRAKES) SECONDARY/PARKING CHASSIS GREEN
DOUBLE CHECK
SPRING BRAKE VALVE (FRONT RUSSIAN AIR
2617 RELAY SPRING BRAKES) SECONDARY/PARKING CHASSIS YELLOW
FRONT SPRING
FRONT SPRING BRAKE ANCHOR RUSSIAN AIR
2618 BRAKE ANCHOR TEE COUPLING SECONDARY/PARKING CHASSIS YELLOW

KM805020 (04/17/2013) 7 - 17
 7 Air System

BRAKE HOSES
RUSSIAN AIR
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
FRONT SPRING SPRING BRAKE
BRAKE ANCHOR CHAMBER, FRONT RUSSIAN AIR
2619 COUPLING AXLE SECONDARY/PARKING CHASSIS BLACK
TRAILER HAND DOUBLE CHECK RUSSIAN AIR TRAILER
2620 BRAKE VALVE VALVE PIPING CAB BLACK
TRAILER CONTROL DOUBLE CHECK RUSSIAN AIR TRAILER
2621 VALVE VALVE PIPING CAB BLACK
SUPPLY DUMP
TRAILER CONTROL VALVE AND TRAILER RUSSIAN AIR TRAILER
2622 VALVE CONTROL VALVE PIPING CAB RED
EMERGENCY RUSSIAN AIR TRAILER
2623 SUPPLY DUMP VALVE GLADHAND PIPING CHASSIS RED
TRAILER AND TRAILER HAND RUSSIAN AIR TRAILER
2624 ACCESSORY TANK BRAKE VALVE PIPING CAB/CHASSIS BLACK
SUPPLY DUMP
TRAILER AND VALVE AND TRAILER RUSSIAN AIR TRAILER
2625 ACCESSORY TANK CONTROL VALVE PIPING CAB BLACK
FOOT VALVE
SECONDARY TRAILER CONTROL RUSSIAN AIR TRAILER
2626 DELIVERY VALVE PIPING CAB GREEN
SPRING BRAKE TRAILER CONTROL RUSSIAN AIR TRAILER
2627 CONTROL VALVE VALVE PIPING CAB RED
*Hose color refers to the color of the actual hose. It does not refer to the color that may be painted over the hose during the assembly process.

ACCESSORY
OTHER
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
PRESSURE BRAKESAVER
3001 REDUCING VALVE SOLENOID VALVE BRAKESAVER CAB BLACK
BRAKESAVER BRAKESAVER
3002 SOLENOID VALVE CONTROL VALVE BRAKESAVER CAB BLACK
DOUBLE CHECK GAUGE, RETARDER
3003 VALVE PRESSURE BRAKESAVER CAB BLACK
DOUBLE CHECK RETARDER VALVE
3004 VALVE HOUSING BRAKESAVER CAB BLACK
CTIS FRONT
3005 DELIVERY FRONT AXLE EATON CTIS CHASSIS BLACK
3006 CTIS REAR DELIVERY REAR AXLE (S) EATON CTIS CHASSIS BLACK
DOUBLE CHECK
3007 ASR/HSA/ECA VALVE VALVE HILL START AID CHASSIS ORANGE
3008 AIR HORN VALVE AIR HORN STANDARD CAB/CHASSIS BLACK
FIFTH WHEEL LOCK W/ AIR SLIDING FIFTH
3009 VALVE FIFTH WHEEL WHEEL CAB/CHASSIS BROWN
WINCH CLUTCH W/ AIR OPERATED
3010 VALVE WINCH WINCH CAB/CHASSIS BLACK
FAN CLUTCH
3011 SOLENOID FAN CLUTCH STANDARD ENGINE BLACK
W/ AIR OPERATED
3012 TRAILER HOOK VALVE TRAILER HOOK PINTLE HOOK CHASSIS BLACK
MECH VARIABLE
3013 REAR DRY TANK TIMING SUPPLY CHASSIS BLACK

7 - 18 KM805020 (04/17/2013)
Air System 7

ACCESSORY
OTHER
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
TRANSMISSION MECH VARIABLE
3014 SUPPLY PORT TIMING SUPPLY CHASSIS BLACK
DRIVE TRAIN
3015 COMPONENT AIR VENT FILTER CHASSIS BLACK
AIR VALVE EXHAUST
3016 PORT FIREWALL BULKHEAD CAB BLACK
3017 ACCESSORY VALVE END OF FRAME ACCESSORY 1 CHASSIS BLACK
AIR THROTTLE AIR THROTTLE
3018 TREADLE VALVE CONTROL CYLINDER W/AIR THROTTLE CAB BLACK
CTIS PCU TRAILER
3019 DELIVERY TRAILER AXLE (S) EATON C.T.I.S CHASSIS BLACK
ADDITIONAL AIR
3020 PRESSURE GAUGE 1 CAB/CHASSIS BLACK
ADDITIONAL AIR
3021 PRESSURE GAUGE 2 CAB/CHASSIS BLACK
3022 ACCESSORY VALVE END OF FRAME ACCESSORY 2 CAB/CHASSIS BLACK
3023 ACCESSORY VALVE END OF FRAME ACCESSORY 3 CAB/CHASSIS BLACK
WINCH BRAKE W/ AIR OPERATED
3024 CONTROL VALVE WINCH BRAKE WINCH CAB/CHASSIS BLACK
CONTROL VALVE DOUBLE CHECK
3025 DELIVERY PORT VALVE CAB/CHASSIS BLACK
AIR THROTTLE DOUBLE CHECK
3026 TREADLE VALVE VALVE CAB BLACK
DOUBLE CHECK AIR THROTTLE
3027 VALVE CONTROL CYLINDER TURNER/HI-STEER CAB BLACK
JIFFLOX AIR BAG GAUGE, AIR
CONTROL VALVE PRESSURE AND
3028 OUTLET PORT QUICK DISCONNECT JIFFLOX CAB BLACK
PRESSURE TELESCOPING TELESCOPING
3029 PROTECTION VALVE DRAWBAR SUPPLY DRAWBAR CHASSIS BLACK
TELESCOPING TELESCOPING
3030 DRAWBAR DELIVERY FIREWALL BULKHEAD DRAWBAR CAB/CHASSIS BLACK
GOVERNOR
CONTROL FLIP VALVE REGULATOR "IN"
3031 SUPPLY PORT PORT AIR THROTTLE CAB BLACK
REGULATOR "OUT" VHSLS GOVERNOR
3032 PORT SUPPLY PORT AIR THROTTLE CAB BLACK
SPEED HEWITT
FRONT SERVICE TANK LIMITER ACTUATING
3033 (FORWARD DRY) CYLINDER CHASSIS GREEN
TRANSMISSION
SLAVE VALVE "P" SYNCHRO VALVE LOW RANGE
3034 PORT CONTROL PORT INTERLOCK CHASSIS BLACK
SYNCHRO VALVE
CONTROL PORT
OR OVERSPEED LOW RANGE
3035 REAR DRY TANK SHUTDOWN VALVE INTERLOCK CHASSIS ORANGE
OVERSPEED
SHUTDOWN W/ OVERSPEED
3036 SOLENOID SHUTDOWN VALVE SHUTDOWN ENGINE BLACK

KM805020 (04/17/2013) 7 - 19
 7 Air System

ACCESSORY
OTHER
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
CAB MANIFOLD OR
3037 AIR DRYER FLIPPER VALVE CAB GREEN
3038 TOGGLE DELIVERY FIREWALL BULKHEAD V/S GOVERNOR CAB BLACK
AIR THROTTLE
3039 TREADLE VALVE FORWARD DRY TANK TURNER/HI-STEER CAB/CHASSIS BLACK
AIR THROTTLE
3040 TREADLE VALVE SOLENOID VALVE AIR THROTTLE CAB BLACK
3041 AUTO RVS CYLINDER AUTO RVS CYLINDER MULTIPLE AUTO RVS CHASSIS PURPLE
3042 FORWARD MANIFOLD RAPID DUMP VALVE KINGPIN RELEASE CAB GREEN
KINGPIN RELEASE
3043 RAPID DUMP VALVE PULL VALVE KINGPIN RELEASE CAB BROWN
KINGPIN RELEASE
3044 PULL VALVE FIFTH WHEEL KINGPIN RELEASE CAB/CHASSIS BROWN
CENTRAL TIRE
INFLATION (CTIS)
3045 WET TANK PSU SUPPLY UNIT EATON C.T.I.S CHASSIS BLACK
CTIS FRONT AXLE CTIS LH FRAME
3046 MANIFOLD BULKHEAD EATON C.T.I.S CHASSIS BLACK
CTIS FRONT AXLE CTIS RH FRAME
3047 MANIFOLD BULKHEAD EATON C.T.I.S CHASSIS BLACK
CTIS FORWARD CTIS REAR REAR
REAR AXLE FRAME AXLE FRAME
3048 MANIFOLD MANIFOLD EATON C.T.I.S CHASSIS BLACK
CTIS DRIVE AXLE
3049 FRAME MANIFOLD CTIS AXLE MANIFOLD EATON C.T.I.S CHASSIS BLACK
DOUBLE CHECK
3050 VALVE PRESSURE SWITCH BRAKESAVER CAB BLACK
PRESSURE
3051 RIDE BAG, LEFT REAR TRANSDUCER STABILITY CONTROL CHASSIS PURPLE
EMERGENCY AIR
3052 TANK CAB MANIFOLD RUSSIAN AIR CHASSIS RED
AIR CLEANER W/ AIR FILTER
3053 AIR CLEANER RESTRICTION GAUGE RESTRICTION GAUGE CAB/ENGINE BLACK
PRESSURE PRESSURE
3054 PROTECTION VALVE REDUCING VALVE BULK UNLOAD CAB/CHASSIS BLACK
PRESSURE PRESSURE
3055 REDUCING VALVE REGULATOR BULK UNLOAD CAB/CHASSIS BLACK
PRESSURE
3056 REGULATOR RELAY VALVE BULK UNLOAD CAB/CHASSIS BLACK
PRESSURE
3057 REGULATOR GAUGE BULK UNLOAD CAB/CHASSIS BLACK
AIR SHUTDOWN ENGINE OVER-SPEED ENGINE AIR
3058 SOLENOID SHUT-DOWN VALVE SHUTDOWN ENGINE BLACK
*Hose color refers to the color of the actual hose. It does not refer to the color that may be painted over the hose during the assembly process.

7 - 20 KM805020 (04/17/2013)
Air System 7

ACCESSORY
LIFT AXLE
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
DEAD AXLE RIDE
BAG RELAY VALVE
PRESSURE AND LIFT BAG DUMP
3101 PROTECTION VALVE VALVE SUPPLY PORTS LIFT AXLE CHASSIS PURPLE
DEAD AXLE DUMP
VALVE DELIVERY
3102 PORTS LIFT BAGS LIFT AXLE CHASSIS PURPLE
STEERABLE PUSHER
SOLENOID VALVE
3103 AIR SUPPLY SUPPLY PORT LIFT AXLE CHASSIS PURPLE
STEERABLE PUSHER
SOLENOID VALVE PRESSURE
DELIVERY PORT OR REDUCING VALVE
NON-STEERABLE AND CRUISE
DEAD AXLE AIR CONTROL SOLENOID
3104 SUPPLY ASSEMBLY SUPPLY LIFT AXLE CHASSIS PURPLE
DEAD AXLE
PRESSURE AXLE LIFT VALVE
3105 REDUCING VALVE SUPPLY PORT LIFT AXLE CHASSIS PURPLE
RIDE BAG PRESSURE
DEAD AXLE LIFT REGULATOR VALVE
VALVE DELIVERY AND LIFT BAG DUMP
3106 PORT VALVE PILOT PORT LIFT AXLE CHASSIS PURPLE
PUSHER
PRESSURE SUSPENSION
3107 REGULATOR GAUGE/VALVE LIFT AXLE CAB/CHASSIS PURPLE
GAUGE, TAG
PRESSURE SUSPENSION
3108 REGULATOR PRESSURE LIFT AXLE CAB/CHASSIS PURPLE
FORWARD REAR OR
PUSHER AXLE RELAY SINGLE REAR RELAY
VALVE CONTROL VALVE CONTROL
3113 PORT PORT WITH FRONT BRAKES CHASSIS ORANGE
FORWARD REAR OR
PUSHER AXLE RELAY SINGLE REAR RELAY
VALVE CONTROL VALVE CONTROL WITHOUT FRONT
3114 PORT PORT BRAKES CHASSIS GREEN
SYNCHRONIZING
3116 VALVE LIFT BAG LIFT AXLE CHASSIS PURPLE
3117 RELAY, RIDE BAG RIDE BAG LIFT AXLE CHASSIS PURPLE
PRESSURE
3118 REDUCING VALVE RELAY, RIDE BAG TURNER/HI-STEER CHASSIS PURPLE
FORWARD NORMALLY
OPEN SOLENOID
3119 FORWARD DRY TANK VALVE TURNER TANDEM CHASSIS GREEN
FORWARD NORMALLY
OPEN SOLENOID PRESSURE
3120 VALVE REDUCING VALVE TURNER TANDEM CHASSIS PURPLE

KM805020 (04/17/2013) 7 - 21
 7 Air System

ACCESSORY
LIFT AXLE
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
REAR NORMALLY
PRESSURE OPEN SOLENOID
3121 REDUCING VALVE VALVE TURNER TANDEM CHASSIS PURPLE
NORMALLY CLOSED
3122 REGULATOR VALVE SOLENOID VALVE TURNER TANDEM CHASSIS PURPLE
NORMALLY CLOSED
3123 SOLENOID VALVE RELAY, RIDE BAG TURNER TANDEM CHASSIS PURPLE
NEWAY PUSHER
CNTRLD BY REAR
3124 SOLENOID VALVE RELAY, RATIO VALVE AXLE CAB/CHASSIS PURPLE
NEWAY PUSHER
CNTRLD BY REAR
3125 RELAY, RATIO VALVE PRESSURE GAUGE AXLE CAB/CHASSIS PURPLE
FORWARD RELAY, FORWARD
PRESSURE SUSPENSION RIDEWELL TANDEM
3126 REGULATOR CONTROL LIFT CHASSIS PURPLE
FORWARD
SYNCHRONIZATION
VALVE OR NORMALLY LIFT BAG, FORWARD RIDEWELL TANDEM
3127 OPEN SOLENOID LIFT AXLE LIFT CHASSIS PURPLE
FORWARD
PRESSURE FORWARD RIDEWELL TANDEM
3128 REDUCING VALVE REGULATOR LIFT CHASSIS PURPLE
REAR NORMALLY REAR PRESSURE RIDEWELL TANDEM
3129 CLOSED SOLENOID REDUCING VALVE LIFT CHASSIS PURPLE
REAR
REAR NORMALLY SYNCHRONIZATION RIDEWELL TANDEM
3130 OPEN SOLENOID VALVE LIFT CHASSIS PURPLE
RELAY, REAR
REAR PRESSURE SUSPENSION RIDEWELL TANDEM
3131 REGULATOR CONTROL LIFT CHASSIS PURPLE
REAR
SYNCHRONIZATION
VALVE OR NORMALLY RIDEWELL TANDEM
3132 OPEN SOLENOID REAR LIFT BAG LIFT CHASSIS PURPLE
REAR PRESSURE PRESSURE RIDEWELL TANDEM
3133 REDUCING VALVE REGULATOR LIFT CHASSIS PURPLE
FORWARD
FORWARD NORMALLY PRESSURE RIDEWELL TANDEM
3134 CLOSED SOLENOID REDUCING VALVE LIFT CHASSIS PURPLE
FORWARD NORMALLY FORWARD
OPEN SOLENOID SYNCHRONIZATION RIDEWELL TANDEM
3135 VALVE VALVE LIFT CHASSIS PURPLE
CENTER NORMALLY
CLOSED SOLENOID CENTER PRESSURE RIDEWELL TANDEM
3136 VALVE REDUCING VALVE LIFT CHASSIS PURPLE
CENTER NORMALLY CENTER
OPEN SOLENOID SYNCHRONIZATION RIDEWELL TANDEM
3137 VALVE VALVE LIFT CHASSIS PURPLE

7 - 22 KM805020 (04/17/2013)
Air System 7

ACCESSORY
LIFT AXLE
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
RELAY, CENTER
CENTER REGULATOR SUSPENSION RIDEWELL TANDEM
3138 VALVE CONTROL LIFT CHASSIS PURPLE
CENTER
SYNCHRONIZATION LIFT BAG, CENTER RIDEWELL TANDEM
3139 VALVE LIFT AXLE LIFT CHASSIS PURPLE
CENTER PRESSURE CENTER PRESSURE RIDEWELL TANDEM
3140 REDUCING VALVE REGULATOR LIFT CHASSIS PURPLE
CHASSIS INTERFACE TURNER
3141 RIDE BAG MODULE SUSPENSION CHASSIS PURPLE
FORWARD GAUGE, FORWARD
PUSHER/TAG RIDE PUSHER/TAG
3142 BAG PRESSURE DUAL LIFT AXLE CAB/CHASSIS PURPLE
REAR PUSHER/TAG GAUGE, REAR LIFT
3143 RIDE BAG AXLE PRESSURE DUAL LIFT AXLE CAB/CHASSIS PURPLE
PRESSURE PUSHER/TAG HAND
3144 PROTECTION VALVE VALVE W/NEWAY CAB VARIES
3145 RIDE BAG PRESSURE GAUGE LIFT AXLE 1 CAB/CHASSIS PURPLE
3146 RIDE BAG PRESSURE GAUGE LIFT AXLE 2 CAB/CHASSIS PURPLE
3147 RIDE BAG PRESSURE GAUGE LIFT AXLE 3 CAB/CHASSIS PURPLE
3148 RIDE BAG PRESSURE GAUGE LIFT AXLE 4 CAB/CHASSIS PURPLE
PRESSURE
3149 REGULATOR RELAY, RIDE BAG LIFT AXLE 1 CHASSIS PURPLE
PRESSURE
3150 REGULATOR RELAY, RIDE BAG LIFT AXLE 2 CHASSIS PURPLE
PRESSURE
3151 REGULATOR RELAY, RIDE BAG LIFT AXLE 3 CHASSIS PURPLE
PRESSURE
3152 REGULATOR RELAY, RIDE BAG LIFT AXLE 4 CHASSIS PURPLE
*Hose color refers to the color of the actual hose. It does not refer to the color that may be painted over the hose during the assembly process.

ACCESSORY
PTO
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
PTO CYLINDER
3201 PTO VALVE (ENGAGE/DISENGAGE) SINGLE ACTING PTO CAB/CHASSIS BLACK
PTO INVERSION PTO DISENGAGE
3202 VALVE CYLINDER DOUBLE ACTING PTO CHASSIS BLACK
PTO CYLINDER,
3203 FIRST PTO VALVE ENGAGE DOUBLE ACTING PTO CAB/CHASSIS BLACK
PTO ENGAGE
3204 SECOND PTO VALVE CYLINDER DOUBLE ACTING PTO CAB/CHASSIS BLACK
PTO REAR DRIVE
3205 REAR DRIVE TOGGLE ENGAGE PTO REAR DRIVE CHASSIS BLACK
PTO CYLINDER
3206 FIRST PTO VALVE (ENGAGE/DISENGAGE) SINGLE ACTING PTO CAB/CHASSIS BLACK
PTO CYLINDER,
3207 FIRST PTO VALVE DISENGAGE DOUBLE ACTING PTO CAB/CHASSIS BLACK
PTO CYLINDER,
3208 SECOND PTO VALVE DISENGAGE DOUBLE ACTING PTO CAB/CHASSIS BLACK
PTO ENGAGE TRANSMISSION HP
3209 (TRANSFER CASE) RANGE SHIFT KIT HP RANGE SHIFT KIT CHASSIS BLACK

KM805020 (04/17/2013) 7 - 23
 7 Air System

ACCESSORY
PTO
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
PTO CYLINDER
3210 SECOND PTO VALVE (ENGAGE/DISENGAGE) SINGLE ACTING PTO CAB/CHASSIS BLACK
*Hose color refers to the color of the actual hose. It does not refer to the color that may be painted over the hose during the assembly process.

ACCESSORY
REAR AXLE
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
DIFFERENTIAL LOCK FRONT AXLE
3300 VALVE DIFFERENTIAL LOCK W/FRONT DRIVE AXLE CHASSIS BLACK
INTERAXLE DIFFERENTIAL SHIFT W/ INTERAXLE
3301 DIFFERENTIAL VALVE CYLINDER DIFFERENTIAL LOCK CAB/CHASSIS SILVER
FORWARD REAR
INTERAXLE AXLE LOCKOUT EATON 2 SPEED
3302 DIFFERENTIAL VALVE VALVE SUPPLY TANDEM CAB/CHASSIS SILVER
TWO SPEED AXLE W/ OR W/O TRANSFER
3303 VALVE TWO SPEED SHIFTER CASE CAB/CHASSIS SILVER
TRACTION CONTROL QUICK RELEASE
OR CROSSLOCK VALVE OF SHIFT
3304 VALVE CYLINDER CAB/CHASSIS SILVER
W/ INTERAXLE
DIFFERENTIAL LOCK
INTERAXLE TWO SPEED AXLE AND 2-SPEED REAR
3305 DIFFERENTIAL VALVE VALVE AXLE CAB/CHASSIS SILVER
FORWARD REAR
DIFFERENTIAL LOCK AXLE DIFFERENTIAL
3306 VALVE LOCK CHASSIS BLACK
SYNCHRO VALVE OR DIFFERENTIAL
NORMALLY OPEN LOCK OR TRACTION
3307 SOLENOID VALVE CONTROL VALVE RS AXLE DIFF-LOCK CAB/CHASSIS SILVER
3308 REAR DRY TANK 2-SPEED AXLE TANDEM ONLY CHASSIS SILVER
SYNCHRONIZING
3309 DIFF-LOCK SWITCH VALVE RS AXLE DIFF-LOCK CAB/CHASSIS SILVER
FORWARD
FORWARD MAIN DIFF SYNCHRONIZATION
3310 LOCK VALVE VALVE DUAL CONTROL CAB/CHASSIS SILVER
FORWARD
SYNCHRONIZATION DIFFERENTIAL LOCK,
VALVE OR NORMALLY FORWARD REAR
3311 OPEN SOLENOID AXLE DUAL CONTROL CHASSIS SILVER
REAR
REAR MAIN DIFF SYNCHRONIZATION
3312 LOCK VALVE VALVE DUAL CONTROL CAB/CHASSIS SILVER
REAR
SYNCHRONIZATION REAR DRIVE
VALVE OR NORMALLY DIFFERENTIAL LOCK
3313 OPEN SOLENOID SHIFTER DUAL CONTROL CHASSIS SILVER
2-SPEED SHIFT AXLE INTERLOCK
3314 INTERLOCK PIN CONTROL VALVE EATON 2 SPEED CAB/CHASSIS SILVER
DIFFERENTIAL LOCK CENTER REAR AXLE
3315 VALVE DIFFERENTIAL LOCK W/FRONT DRIVE AXLE CHASSIS BLACK
*Hose color refers to the color of the actual hose. It does not refer to the color that may be painted over the hose during the assembly process.

7 - 24 KM805020 (04/17/2013)
Air System 7

ACCESSORY
SUSPENSION
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
DUMP VALVE OR
AIR SUSPENSION INVERSION VALVE
3401 VALVE PILOT PORT AIR SUSPENSION CAB/CHASSIS PURPLE
LEVELING
VALVE/DUMP VALVE
3402 (LH) RIDE BAG, LH REAR AIR SUSPENSION CHASSIS PURPLE
LEVELING
VALVE/DUMP VALVE
3403 (RH) RIDE BAG, RH REAR AIR SUSPENSION CHASSIS PURPLE
GAUGE, LH
SUSPENSION
3404 LH AIR BAG PRESSURE AIR SUSPENSION CHASSIS PURPLE
GAUGE, RH
SUSPENSION
3405 RIDE BAG, RH REAR PRESSURE AIR SUSPENSION CHASSIS PURPLE
NORMALLY CLOSED PRESSURE
3407 SOLENOID VALVE REDUCING VALVE TURNER/HI-STEER CHASSIS PURPLE
NORMALLY OPEN SYNCHRONIZING W/TURNER
3408 SOLENOID VALVE VALVE SUSPENSION CHASSIS PURPLE
RIDE BAG, LH
3409 LH REAR AIR BAG FORWARD AIR SUSPENSION CHASSIS PURPLE
3410 LEVELING VALVE (LH) DUMP VALVE AIR SUSPENSION CHASSIS PURPLE
RIDE BAG, RH
3411 RIDE BAG, RH REAR FORWARD AIR SUSPENSION CHASSIS PURPLE
3412 LEVELING VALVE (RH) DUMP VALVE AIR SUSPENSION CHASSIS PURPLE
SUSPENSION
DIFFERENTIAL LOCK PROPORTIONING
3413 VALVE VALVE AIR SUSPENSION CHASSIS SILVER
SUSPENSION HAND SUSPENSION AIR
3414 VALVE BAG/GAUGE NEWAY SUSPENSION CAB/CHASSIS PURPLE
PRESSURE SUSPENSION
3415 WM-318 REDUCING VALVE REGULATOR CHASSIS PURPLE
FORWARD DRIVE
FORWARD DRIVE AXLE TRACTION EQ W/ TRACTION
3416 TRACTION EQ VALVE SHIFTER CONTROL CHASSIS SILVER
REAR DRIVE AXLE
REAR DRIVE TRACTION EQ W/ TRACTION
3417 TRACTION EQ VALVE SHIFTER CONTROL CHASSIS SILVER
HEIGHT CONTROL RIDE BAG, CAB
3418 VALVE SUSPENSION CAB SUSPENSION CHASSIS PURPLE
RIDE BAG, CAB RIDE BAG, CAB
3419 SUSPENSION SUSPENSION CAB SUSPENSION CHASSIS PURPLE
LEVELING VALVE RIDE BAG, RH FRONT AIR
3420 (FRONT) FORWARD SUSPENSION CHASSIS PURPLE
LEVELING VALVE RIDE BAG, LH FRONT AIR
3421 (FRONT) FORWARD SUSPENSION CHASSIS PURPLE
REAR SUSPENSION
3422 AIR BAG LOAD SENSING VALVE RUSSIAN AIR CHASSIS PURPLE
DUMP VALVE OVER
3423 SOLENOID VALVE INFLATION PORT AIR SUSPENSION CHASSIS PURPLE
*Hose color refers to the color of the actual hose. It does not refer to the color that may be painted over the hose during the assembly process.

KM805020 (04/17/2013) 7 - 25
 7 Air System

ACCESSORY
TRANSFER CASE
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
FRONT AXLE TRANSFER CASE
3501 DECLUTCH VALVE ENGAGE PORT ENGAGE CAB/CHASSIS BLACK
FRONT DRIVE AXLE TRANSFER CASE
3502 VALVE NEUTRAL SHIFT UNIT W/TRANSFER CASE CAB/CHASSIS BLACK
TWO SPEED SHIFT TRANSFER CASE
VALVE (TRANSFER HIGH-LOW SHIFT
3503 CASE) UNIT W/TRANSFER CASE CHASSIS SILVER
FRONT AXLE
FRONT AXLE DECLUTCH PORT
3504 DECLUTCH VALVE (ENGAGE/DISENGAGE) W/TRANSFER CASE CAB/CHASSIS BLACK
TRANSFER CASE
3505 CONTROL VALVE TRANSFER CASE ENGAGE CHASSIS BLACK
TRANSFER CASE
3506 CONTROL VALVE TRANSFER CASE DISENGAGE CHASSIS BLACK
WABCO CONTROL MULTI-POSITION AIR
3507 VALVE PORT #1 CYLINDER PORT #4
WABCO CONTROL MULTI-POSITION AIR
3508 VALVE PORT #2 CYLINDER PORT #1
FRONT AXLE TRANSFER CASE
3509 DECLUTCH VALVE DISENGAGE PORT DISENGAGE CAB/CHASSIS BLACK
PILOT AIR CONTROL MANIFOLD,
3510 VALVE TRANSMISSION CHASSIS BLACK
PILOT AIR CONTROL TRANSFER CASE W/WABCO DUAL
3511 VALVE DISENGAGE PORT CONTROLS CAB/XMSN BLACK
TRANSFER CASE AUXILIARY 2 OR 3 POSITION
3512 VALVE TRANSMISSION SHIFT CAB/CHASSIS BLACK
TRANSFER CASE AUXILIARY
3513 VALVE TRANSMISSION 3 POSITION SHIFT CAB/CHASSIS BLACK
*Hose color refers to the color of the actual hose. It does not refer to the color that may be painted over the hose during the assembly process.

ACCESSORY
TRANSMISSION
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
DEEP REDUCTION
3601 VALVE TRANSMISSION DEEP REDUCTION CHASSIS BLACK
TRANSMISSION LOCK
3602 VALVE TRANSMISSION CHASSIS BLACK
CONVERTER LOCK
3603 VALVE CONVERTER CHASSIS BLACK
MANIFOLD, REAR
SERVICE OR DEEP REDUCTION
3604 TRANSMISSION VALVE, SUPPLY DEEP REDUCTION CHASSIS BLACK
TRANSMISSION W/WABCO DUAL
3605 SHIFT TOWER PORT 2 SHUTTLE VALVE CONTROLS CAB/XMSN BLACK
TRANSMISSION W/WABCO DUAL
3606 SHIFT TOWER PORT 3 SHUTTLE VALVE CONTROLS CAB/XMSN BLACK
TRANSMISSION W/WABCO DUAL
3607 SHIFT TOWER PORT 5 SHUTTLE VALVE CONTROLS CAB/XMSN BLACK
TRANSMISSION W/WABCO DUAL
3608 SHIFT TOWER PORT 6 SHUTTLE VALVE CONTROLS CAB/XMSN BLACK

7 - 26 KM805020 (04/17/2013)
Air System 7

ACCESSORY
TRANSMISSION
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
MANIFOLD, TRANSFER CASE W/WABCO DUAL
3609 TRANSMISSION ENGAGE PORT CONTROLS CAB/XMSN BLACK
TRANSMISSION
3610 FIREWALL BULKHEAD SHUTTLE VALVE HIGH SHIFT RANGE CHASSIS SILVER
*Hose color refers to the color of the actual hose. It does not refer to the color that may be painted over the hose during the assembly process.

MISCELLANEOUS NON-AIR
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
SOLENOID EXHAUST
4001 PORT PTO DUMP PORT HYDRAULIC PTO CHASSIS BLACK
TRANSMISSION MAIN
4001 PRESSURE PORT SOLENOID IN PORT HYDRAULIC PTO CHASSIS BLACK
SOLENOID CYLINDER
4002 PORT PTO CONTROL PORT HYDRAULIC PTO CHASSIS BLACK
4002 TRANSMISSION PTO LUBE PORT HYDRAULIC PTO CHASSIS BLACK
TRANSMISSION
4003 PRESSURE PORT PRESSURE GAUGE AUTO TRANSMISSION CAB/ENGINE BLACK
TRANSMISSION OIL
4004 TRANSMISSION COOLER/FILTER CHASSIS BLACK
TRANSMISSION OIL TRANSMISSION OIL
4005 FILTER COOLER/FILTER CHASSIS BLACK
TRANSMISSION OIL
4006 COOLER TRANSMISSION CHASSIS BLACK
TRANSMISSION CHASSIS INTERFACE
4007 PRESSURE PORT MODULE AUTO TRANSMISSION ENGINE/CHASSIS BLACK
MANIFOLD
4101 ENGINE MANIFOLD PRESSURE GAUGE CAB/ENGINE BLACK
OIL PRESSURE
4102 ENGINE BLOCK CIM PORT 2A GAUGE ENGINE/CHASSIS BLACK
CIM PORT 2B, 3A OR MANIFOLD
4103 ENGINE MANIFOLD 3B PRESSURE GAUGE ENGINE/CHASSIS BLACK
GAUGE, OIL
4104 ENGINE BLOCK PRESSURE LUBE OIL LINES ENGINE BLACK
WATER FILTER
4105 ENGINE BLOCK (SUPPLY) WATER LINE
WATER FILTER
4106 (DELIVERY) ENGINE BLOCK WATER LINE
SINGLE/MAIN
STEERING GEAR
POWER STEERING OR HYDRAULIC
4201 PUMP CYLINDER POWER STEERING CHASSIS BLACK
SINGLE/MAIN
STEERING GEAR
OR HYDRAULIC POWER STEERING
4202 CYLINDER RESERVOIR POWER STEERING CHASSIS BLACK
POWER STEERING
4203 RESERVOIR PUMP SUPPLY POWER STEERING CHASSIS BLACK
POWER STEERING POWER STEERING
4204 PUMP BYPASS RESERVOIR POWER STEERING CHASSIS BLACK

KM805020 (04/17/2013) 7 - 27
 7 Air System

MISCELLANEOUS NON-AIR
HOSE NUMBER FROM TO APPLICATION HOSE LOCATION HOSE COLOR*
MAIN POWER
STEERING
HYDRAULIC
4205 RESERVOIR SLAVE CYLINDER POWER STEERING CHASSIS BLACK
SLAVE GEAR
MAIN STEERING (PRESSURIZED FOR
4206 GEAR RH TURN) POWER STEERING CHASSIS BLACK
SLAVE GEAR
MAIN STEERING (PRESSURIZED FOR
4207 GEAR LH TURN) POWER STEERING CHASSIS BLACK
STEERING VALVE "L" ANCHOR END PORT
4208 PORT ON RAM POWER STEERING CHASSIS BLACK
STEERING VALVE "RT" ROD END PORT ON
4209 PORT RAM POWER STEERING CHASSIS BLACK
CAB TILT PUMP, PULL CAB TILT CYLINDER,
4301 PORT PULL PORT CAB TILT CHASSIS BLACK
CAB TILT LATCH OR
CAB TILT CYLINDER, CAB LIFT OFF ASSIST
4302 PUSH PORT CYLINDER CAB TILT CHASSIS BLACK
CAB TILT PUMP, PUSH CAB TILT CYLINDER,
4303 PORT PUSH PORT CAB TILT CHASSIS BLACK
*Hose color refers to the color of the actual hose. It does not refer to the color that may be painted over the hose during the assembly process.

7 - 28 KM805020 (04/17/2013)
Air System 9

9 Maintenance
Air Compressor . . . . . . . . . . . . 9 - 2

KM805020 (04/17/2013) 9-1

 9 Air System

Air Compressor
CAUTION
Should it be necessary to drain the engine cool-
ing system to prevent damage from freezing, the
compressor must also be drained at cylinder head
and block to prevent damage to that component.

Every 3 Months Or 40,000 km (25,000 Miles)

Inspect compressor air filter element, if so

equipped, and replace element if clogged. Check
compressor mounting and drive for alignment and
belt tension. Adjust if necessary.

Every 6 Months Or 80,000 km (50,000 Miles)

Remove compressor discharge valve cap nuts

and check for presence of excessive carbon.
If excessive carbon is found, clean or replace
the compressor cylinder head. Also, check
compressor discharge line for carbon, and clean
or replace the discharge line if necessary.

Every 12 Months Or 160,000 km (100,000 Miles)

Disassemble compressor and thoroughly clean

and inspect all parts. Repair or replace all worn
or damaged parts, or replace compressor with a
factory exchange unit.

9-2 KM805020 (04/17/2013)

Air System 10

10 Disassembly/Assembly
Push-to-Connect Fittings . . . . . . 10 - 2
Solenoid Bank Replacement - Aero . . 10 - 4
Solenoid Valve Replacement . . . . . 10 - 5
Brake Valve Replacement . . . . . . 10 - 6

KM805020 (04/17/2013) 10 - 1
10 Air System

Push-to-Connect Fittings
DO's DON'Ts
Tighten by hand. Make final adjustment with wrench at the hex. Avoid using wrench on push-to-connect end.

Achieve a square cut and clean edge. Avoid Drastic angle cutting which can lead to an improper seal.

Use the Legris or equivalent tube cutter. Avoid using side cutters, knife or a dull tool to cut tubing. Avoid burrs,
dirt, and anything that can hinder full flow.

Allow adequate bend radius of tube. Avoid kinking the tubing and side load against the collet which can
cause leaks.

Push the tubing until it bottoms out. Holding and sealing is accomplished Avoid contaminating substances in fittings and cartridges.
instantaneously.

• A. Tube support
• B. Tube insertion

10 - 2 KM805020 (04/17/2013)
Air System 10

Connection Disconnection
Achieve a square cut edge with a tube cutter. Make sure there is no air flow.

Push the tubing until it bottoms out. Holding and sealing is accomplished With no button - Press disconnect tool against collet, then pull tube out.
instantaneously.

• A. Keep collet depressed

• B. Remove tube
With button - Depress the manual release button, then pull the tube out.
• A. Tube support
• B. Tube insertion
Pull on tubing to verify gripping action.
• A. Keep collet depressed
• B. Remove tube

KM805020 (04/17/2013) 10 - 3
10 Air System

Solenoid Bank Replacement - Aero
10. Install the new solenoid bank and tighten the
M8 bolts.
11. Connect the air supply line to the solenoid
bank.
12. Reinstall the chassis node and connect the
electrical connectors.
13. Charge the air system and check for leaks.
14. Verify the operation of the replaced solenoid
bank.

1. Park the truck on a level surface and block the

tires.
2. Empty the air system.
3. Disconnect the electrical connectors.
4. Open the hood.
5. Remove the chassis node from the common
bracket that holds both the chassis node and
the solenoid bank.
6. Remove the bolts that hold the common
bracket to the cast overbell foot. these are
vertically positioned and they will have to be
raised out of the way to remove the bracket.
These bolts will not come out of the assembly.
7. Reach in and remove as many electrical
connectors as possible. Additionally,
disconnect as many air lines as possible (blind
reach, single hand). After most of the air
lines have been disconnected, reposition the
solenoid bank and allow it to drop down just
below the top of the frame rail. Doing this will
provide access to the remainder of the air lines
connected to the farthest lines from reach.
8. Once all of the lines have been disconnected,
the whole solenoid bank and bracket can be
dropped from the vehicle and taken to a shop
workbench.
9. Remove M8 bolts, then the solenoid bank.

10 - 4 KM805020 (04/17/2013)
Air System 10

Solenoid Valve Replacement 7. Install the new solenoid and tighten the Torx or
Phillips square drive screws.
8. Connect the electrical connector.
9. Charge the air system and check for leaks.
10. Verify the operation of the replace solenoid.

NOTE
If equipped with an upper bank of solenoids, the
upper bank needs to be removed to service any of
the lower bank solenoids.

1. Park the truck on a level surface and block the

tires.
2. Empty the air system.
3. Disconnect the electrical connector.
4. Remove the bank of solenoids from the
bracket it is mounted on.
5. Remove the Torx or Phillips square drive
screws on each side of the solenoid being
replaced.

NOTE
There are tamper proof screws on one side of each
solenoid. These are intentional, do not attempt to
remove these screws.

6. Twist the valve to unseat it from the adjacent

valve. Remove the solenoid from the solenoid
bank.

KM805020 (04/17/2013) 10 - 5
10 Air System

Brake Valve Replacement

1. Valve, PMV 8. 90° Elbow 15. M10 Flat Washer

2. Valve, Quick Release 9. 90° Elbow 16. M6 Locking Nut
3. Bracket, ABS Valves 10. 90° Elbow 17. M8 Screw
4. Bracket, ABS Valves 11. 90° Elbow 18. 5/16 x 6 Bolt
5. Tubing 12. 90° Elbow 19. 5/16 Flat Washer
6. 45° Elbow 13. 90° Elbow 20. 5/16 Locknut
7. 90° Elbow 14. Hex Bolt 21. Plug or 45° Elbow

1. Park the truck on a level surface and block the

tires.
2. Empty the air system.
3. Remove the supply and or control lines.
4. Remove the two nuts mounting the assembly
to the radiator crossmember.
5. With the valve assembly loose, remove the
ABS modulator connectors on the forward side
of the module. This will complete the removal
process.
6. Repair or replace components as necessary.
7. Install ABS modulator connectors with
assembly in near installed position.
8. Slide assembly into place and re-install nuts to
secure module to radiator crossmember.

10 - 6 KM805020 (04/17/2013)
Air System 11

11 Inspection
Dual Air System Function Test . . . . 11 - 2

KM805020 (04/17/2013) 11 - 1
11
Dual Air System Function Test
Conduct this test at least every 3 months or if
there is any indication of a potential problem.
Park the vehicle on level ground and block the
wheels. Have an assistant open drain valves
and, where required, observe brake action at the
wheels. If a malfunction occurs during this test,
do not move the vehicle until the problem has
been corrected. Engine should be Off with the key
switch to the ON or Run position.
NOTE
Tractor air system must be connected to trailer.
Sequence No. 1— Checking Truck Or Tractor
Dual System Operation
1. Pull out panel-mounted air control valve(s).
2. Charge air system to 827 kPa (120 psi). Check
front and rear service air gauges for equal
pressure ± 34 kPa (5 psi).
3. Stop the engine. Push in YELLOW parking
brake valve.
4. Open front service reservoir drain valve. Front
service air gauge indicates pressure drop.
Rear service air gauge indicates no pressure
drop.
NOTE
When bleeding front or rear reservoir; if both ser-
vice air gauges indicate a pressure drop determine
the cause and correct it Do not proceed with test
until the problem has been corrected.
As front service pressure drops to
approximately 483 kPa (70 psi), the low
pressure warning light should come on. Allow
front service pressure to drop to 0.
5. Depress brake treadle valve while assistant
watches brake action at the wheels. Only rear
brakes apply. There is no front braking action.
6. For truck with YELLOW parking control only:
Continue making brake applications until spring
brakes apply automatically at approximately
241 - 310 kPa (35 - 45 psi). YELLOW parking
brake control will pop out automatically.
For vehicle with YELLOW parking brake
control and RED trailer air supply control only:
Continue making brake applications until RED
trailer air supply control pops out automatically
11 - 2
Air System
at approximately 138 - 207 kPa (20 - 30 psi).
With continued brake application the YELLOW
parking brake control will pop out automatically
at approximately 138 kPa (20 psi).
7. Close front service reservoir drain valve, start
engine and charge air system to full pressure.
8. Stop the engine.
Push in YELLOW parking brake valve.
9. Open rear service reservoir drain valve. Rear
service air gauge should indicate pressure
drop. Front service air gauge should indicate
no pressure drop. As rear service pressure
drops to approximately 483 kPa (70 psi), the
low pressure warning light should come on.
Allow rear service pressure to drop to 0.
NOTE
The spring brakes should not apply automatically.
10. When rear service reservoir is completely
empty, depress brake treadle valve while
assistant watches brake action at the front
wheels.
11. For truck with YELLOW parking control only:
Continue making brake applications until spring
brakes apply automatically at approximately
241- 310 kPa (35 - 45 psi). YELLOW parking
brake control will pop out automatically.
For vehicle with YELLOW parking brake
control and RED trailer air supply control only:
Continue making brake applications until RED
trailer air supply control pops out automatically
at approximately 138 - 206 kPa (20 - 30 psi).
With continued brake application the YELLOW
parking brake control will pop out automatically
at approximately 138 kPa (20 psi).
If brake system has functioned normally, proceed
with Sequence No. 2.
Sequence No. 2— Checking Valve Operation
1. Pull Out panel mounted air control valve(s).
2. Charge air system to 827 kPa (120 psi). Check
front and rear service air gauges for almost
equal pressure.
NOTE
Recharge the air system to 827 kPa (120 psi), if
the air pressure in either front or rear service air
systems drops to 483 kPa (70 psi) at any time dur-
ing the following test.
KM805020 (04/17/2013)
Air System 11

3. Push In RED control. Only the trailer parking

brakes release. Pull Out RED control. Trailer
parking brakes should apply.
4. Push In YELLOW control. Only the tractor
parking brakes release. Pull Out YELLOW
control. Tractor parking brakes apply.
5. Push In RED control. Only the trailer parking
brakes release. Push In YELLOW control. The
tractor parking brakes release.
6. Pull Out YELLOW control. The tractor
parking brakes apply and the RED control
automatically pops out, applying the trailer
parking brakes.
7. Push In the YELLOW control and then push In
the RED control. The tractor and trailer parking
brakes release. Pull Out the RED control
which applies only trailer parking brakes. The
YELLOW control stays in.
8. Pull Out the YELLOW control. This applies the
tractor parking brakes. The function test for
the dual air system is complete.

KM805020 (04/17/2013) 11 - 3
11 - 4 KM805020 (04/17/2013)
Air System 12

12 Troubleshooting
Symptom Based Diagnostics . . . . 12 - 2
EOA Solenoids . . . . . . . . . . . 12 - 3

KM805020 (04/17/2013) 12 - 1
12
Symptom Based Diagnostics
Tractor System
Symptom
A. Rapid loss of system air
pressure when engine is stopped leaking.
and brakes are released.
B. Rapid loss of system air
pressure with engine stopped
and brakes applied fully.
4. Relay valve leaking.
C. Indicated system air pressure 1. Reservoir drain cock open.
remains below normal.
D. System air pressure build-up
too slow.
E. Braking action weak.
F. Brakes apply too slowly.
12 - 2
Possible Cause
1. Fitting, hose line, or tubing
2. Foot-controlled dual brake
valve leaking.
3. Relay valve leaking.
4. Governor leaking.
5. Compressor discharge valve
leaking.
1. Fitting, hose line, or tubing
leaking.
2. Brake chamber leaking.
3. Foot-controlled dual brake
valve leaking.
2. Compressor drive belt slipping.
3. System air pressure gauge
defective.
4. Crosscheck with other system
press gauge).
5. Check Symptom column for
condition A.
6. Governor out of adjustment.
1. Engine idling too slowly.
2. Compressor air filter clogged.
3. Check Symptom column for
condition A.
4. Compressor worn.
1. Brakes need adjustment or
relining.
2. Brake mechanism needs
lubrication.
3. Brake mechanism defective.
4. Brake system air pressure low.
5. Brake valve delivery pressure
low.
6. Brake hose line or tubing
restricted.
1. Check Symptom column for
condition B.
2. Brake hose line or tubing
restricted.
Symptom
G. Brakes release too slowly.
H. Brakes will not release.
I. Brakes will not apply.
NOTE
The following chart is applicable to the trailer brake
system only.
Trailer System
Symptom
A. Loss of system air pressure
with application of emergency air leaking.
only.
B. Loss of system air pressure
with application of service brakes. leaking.
C. Braking action weak.
D. Brakes apply too slowly.
E. Brakes release too slowly.
F. Brakes will not release.
G. Brakes will not apply.
Air System
Possible Cause
1. Foot-controlled brake
valve treadle not returning to
full-release position.
2. Brake hose line or tubing
restricted.
3. Relay valve or dual brake
valve defective.
1. Brake mechanism binding.
2. Relay valve or dual brake
valve defective.
3. Spring brake stand-off
pressure lost.
1. System air pressure lost.
2. Hose line or tubing broken or
restricted.
3. Relay valve or dual brake
valve defective.
Possible Cause
1. Fitting, hose line or tubing
2. Relay valve leaking.
3. Brake chamber leaking.
1. Fitting, hose line or tubing
2. Relay valve leaking.
3. Brake chamber leaking.
1. Brakes need adjustment or
relining.
2. Brake mechanism needs
lubrication.
3. Brake mechanism defective.
1. Hose line or tubing restricted.
3. Check Symptom column for
condition B.
1. Hose line or tubing restricted.
2. Relay valve defective.
1. Brake mechanism binding.
2. Relay valve defective.
1. Trailer brake system not
properly connected to trailer air
system.
2. Relay valve defective.
3. Hose line or tubing restricted.
KM805020 (04/17/2013)
Air System 12

EOA Solenoids

1. Supply Side
2. Control Side

Check for air leaks at the supply side and between

the solenoids.

Check for voltage at the control side.

KM805020 (04/17/2013) 12 - 3
12 - 4 KM805020 (04/17/2013)
 Index
D
Disassembly/Assembly Safety
Brake Valve General safety
Replacement .... 10-6 instructions ........1-2
Push-to-Connect Specifications
Fittings ........... 10-2 Air manifold
Solenoid Valve connections .......7-6
Replacement .... 10-5 Air Solenoid Bank......7-3
Axle lift control options 7-4
E Front Brake Air Piping.7-2
Electric Over Air (EOA) T
PTO Types ..............5-9
Exploded View Troubleshooting
Air solenoid bank.......3-2 EOA solenoids ....... 12-3
Symptom based
G diagnostics ...... 12-2
General Information W
Air compressor .........5-4
Air dryer .................5-5 What's New
Air piping schematic ...5-2 Brake system ...........4-4
Air solenoids ............5-6 Introduction .............4-2
Brake system Solenoid bank ..........4-3
description ....... 5-10
Charging trailer air
reservoir with tractor
parking brakes
applied ........... 5-13
Electric Over Air
(EOA)...............5-8
Releasing only the trailer
parking brakes .. 5-14

I
Inspection
Dual air system function
test................ 11-2

M
Maintenance
Air compressor .........9-2

P
PTO Types.................5-9

(04/17/2013) Index - 1