Volvo Trucks North America

Greensboro, NC USA

D Service Bulletin
Date

4.2008
Trucks
Group

900
No.

077

Brakes and Air Systems

VN, VHD VERSION2
From build date 1.2007
Page

1(24)

Brakes and Air Systems

This information contains details for Brakes and Air Systems applications in VN/VHD
vehicles from 1.2007.

Note: We have attempted to cover as much information as possible. However, this

information does not cover all the unique variations that a vehicle may present. Note that
illustrations are typical but may not reflect all the variations of assembly.
All data provided is based on information that was current at time of release. However,
this information is subject to change without notice.
Please note that no part of this information may be reproduced, stored, or transmitted by
any means without the express written permission of Volvo Trucks North America, Inc.

Contents:
Specifications page 2
Front Axle Brakes page 2
Rear Axle Brakes page 3
Pneumatic Electric Interface Plate page 5
Air Solenoids (Chassis Mounted) page 8
I-Shift Hill Start Assist page 11
Secondary Function Control Solenoid Valve Pack page 9
Schematics page 12
Design and Function page 15
Air System Pressure page 16
Air Tubing and Fittings page 17
Air Tank Mounting page 20
Links:
Air Brake Routing Schematics
Return:
Brakes and Air System Index
General Index

PV776-20150313 USA30064.ihval
Volvo Trucks North America
Service Bulletin

Specifications
Front Axle Brakes
Front Axle Load
Front Axle
Load

lb
Brake Size
Variant
Brake
D Wearable
Thick-
Date
4.2008
Group
900

Chamber
No.
077

Static
Loaded
Radius Operat-
Page
2(24)

Size Variant Type Spider Lining ness Slack Size Mfg Range ing Class

5.5 12,000 FBRA100 15 x 4 inc Meritor Q+ Cast MA212 0.48 5.5 20 Haldex 17.0 - 22.2 DH10
ULH1

5.5 12,000 FBRA100 15 x 4 inc Meritor Q+ Cast R301 0.48 5.5 20 Haldex 17.0 - 22.2 DH10
ULH1

5.5 12,000 FBRA100 15 x 4 inc Meritor Q+ Cast R301 0.48 5.5 20 Haldex 17.0 - 22.2 DH10
ULH2

6.0 13,200 FBRA100 15 x 4 inc rear Meritor Q+ Cast R301 0.48 5.5 20 Haldex 17.0 - 22.0 1

6.0 13,200 FBRA125R 15 x 5 inc Meritor Q+ Cast R301 0.48 5.5 20 Haldex 17.0 - 22.0 1
ULH1

6.0 13,200 FBRA125R 15 x 5 inc Meritor Q+ Cast R201 0.48 5.5 20 Haldex 16.0 - 16.5 1
ULG1

6.0 13,200 FBRA125R 15 x 5 inc rear Meritor Q+ Cast R609 0.48 5.5 20 Haldex 17.0 - 20.6 1

6.0 13,200 FBRA125 16.5x5 inc rear Meritor Q+ Cast R301 0.60 5.5 20 Haldex 17.0-20.6 1, 2, 3

6.7 14,740 FBRA125 16.5 x 5 inc rear Meritor Q+ Cast R301 0.60 5.5 20 Haldex 17.0 - 20.6 1, 2, 3

7.5 16,500 FBRA150 16.5 x 6 inc rear Meritor Q+ Cast R301 0.60 5.5 24 Haldex 17.0 - 20.6 1, 2, 3

7.5 16,500 FBRA175 16.5 x 7 inc rear Meritor Q+ Cast R301 0.60 5.5 24 Haldex 18.022.0 1, 2, 3,

8.6 18,920 FBRA150 16.5 x 6 inc rear Meritor Q+ Cast R403 0.60 5.5 24 Haldex 18.0 - 22.0 1, 2, 3

9.1 20,000 FBRA150 16.5 x 6 inc rear Meritor Q+ Cast R403 0.60 5.5 24 Haldex 18.0 - 22.0 1, 2, 3

9.1 20,000 FBRA175 16.5x7 inc rear Meritor Q+ Cast R403 0.60 5.5 24 Haldex 18.022.0

10.0 22,000 FBRA175 16.5x7 inc rear Meritor Q+ Cast R301 0.60 5.5 30 Haldex 18.0-22.0 1, 2, 3
Volvo Trucks North America
Service Bulletin

Rear Axle Brakes

Rear Axle Load
Rear Axle Load

9
Units

19,800
Brake
Variant

RBRA175
Size

16.5 x
Brake

Variant

UL-H1
Type

Meritor Q+
D
Spider

Stamped
Lining

R301
Wearable
Thick-
ness

0.60
Date
4.2008

Slack

5.5
Group
900

Chamber

Size

30/30
Mfg
No.
077

Haldex
Static
Loaded
Radius
Range

17.0 - 22.0
Page
3(24)

Oper-
ating
Class

DH10
7

9 19,800 RBRA200 16.5 x UL-H1 Meritor Q+ Stamped R301 0.60 5.5 30/30 Haldex 17.0 - 22.0 DH10
8

9 19,800 RBRA175 16.5 x UL-H2 Meritor Q+ Cast R301 0.60 5.5 30/30 Haldex 17.0 - 22.0 DH10,
7 DH20,
DH30

10 22,000 RBRA175 16.5 x UL-H1 Meritor Q+ Stamped R301 0.60 5.5 30/30 Haldex 17.0 - 22.0 DH10
7

11.5 25,300 RBRA175 16.5 x UL-H3 Meritor Q+ Cast R403 0.60 6 30/30 Haldex 19.0 - 21.7 DH20,
7 HD DH30

13 28,600 RBRA175 16.5 x UL-H4 Meritor P * Cast * R403 0.60 6 36/36 Haldex 19.0 - 22.5 DH20,
7 DH30

14 30,800 RBRA175 16.5 x UL-H4 Meritor P * Cast * R403 0.60 6 36/36 Haldex 19.0 - 22.5 DH20,
7 DH30

17 37,400 RBRA175 16.5 x UL-H1 Meritor Q+ Cast MA212 0.60 5.5 30/30 Haldex 17.0 - 22.0 DH10
7

17 37,400 RBRA175 16.5 x UL-H1 Meritor Q+ Cast R301 0.60 5.5 30/30 Haldex 17.0 - 22.0 DH10,
7 DH20,
DH30

17 37,400 RBRA175 16.5 x UL-H2 Meritor Q+ Cast R301 0.60 5.5 30/30 Haldex 17.0 - 22.0 DH10
8

17 37,400 RBRA200 16.5x8 UL-G1 Meritor Q+ Stamped R208 0.60 5.5 30/30 Haldex 17.0-20.5 DH10

18 39,600 RBRA175 16.5 x UL-H1 Meritor Q+ Stamped R301 0.60 5.5 30/30 Haldex 17.0 - 22.0 DH10
7

18 39,600 RBRA175 16.5 x UL-H2 Meritor Q+ Cast R301 0.60 5.5 30/30 Haldex 17.0 - 22.0 DH10,
7 DH20,
DH30

20 44,000 RBRA175 16.5 x UL-H2 Meritor Q+ Cast R301 0.60 5.5 30/30 Haldex 17.0 - 22.0 DH20,
7 DH30

21 46,200 RBRA175 16.5 x UL-H1 Meritor Q+ Stamped R301 0.60 6 30/30 Haldex 17.0 - 22.0 DH10
7

21 46,200 RBRA175 16.5 x UL-H2 Meritor Q+ Cast R301 0.60 6 30/30 Haldex 17.0 - 22.0 DH10,
7 DH20,
DH30

22 48,400 RBRA175 16.5 x UL-H3 Meritor Q+ Cast R403 0.60 6 30/30 Haldex 19.0 - 21.7 DH20,
7 HD DH30

24 52,800 RBRA175 16.5 x UL-H4 Meritor P * Cast R403 0.60 6 30/30 Haldex 19.0 - 21.7 DH20,
7 DH30

26 57,200 RBRA175 16.5 x UL-H4 Meritor P * Cast * R403 0.60 6.5 36/36 Haldex 17.0 - 22.0 DH20,
7 DH30
Volvo Trucks North America
Service Bulletin

Rear Axle Load

30

32
Units

66,000

70,400
Brake
Variant

RBRA175

RBRA175
Size

16.5 x
7

16.5 x
7
Brake

Variant

UL-H4

UL-H4
Type

Meritor P *

Meritor P *
Spider

Cast *

Cast *
D
Lining

R403

R403
Wearable
Thick-
ness

0.60

0.60
Date
4.2008

Slack

6.5

6.5
Group
900

Chamber

Size

36/36

36/36
Mfg
No.
077

Haldex

Haldex
Static
Loaded
Radius
Range

19.0 - 22.5

19.0 - 22.5
Page
4(24)

Oper-
ating
Class

DH20,
DH30

DH20,
DH30

Note: * = Cast Shoes and Spiders Q1 Q+ cast front, Q+ stamped rear

Q2 Q+ cast front, Q+ cast rear
Q3 Q+ cast front, Q+ HD cast rear
Q4 Q+ cast front, P cast rear
Volvo Trucks North America
Service Bulletin

Pneumatic Electric Interface Plate

D Date
4.2008
Group
900
No.
077
Page
5(24)

W5001568
1 REAR SUP

2 FRT SUP

3 AP-TD

4 SLS

5 PARK

6 PBS

7 B-Tank

8 B-TD

9 A-Tank

10 A-TD

11 Cab Power Supply (+)

12 Cab Ground Supply (-)

Note: For further information refer to Pneumatic Electric

Interface Plate page 7.
Volvo Trucks North America
Service Bulletin

D
Date
4.2008
Group
900
No.
077
Page
6(24)

W5001567

Pneumatic Electric Interface Plate attached to

Dash Firewall

It is not recommended to use the pneumatic/electrical

pass through for pneumatics connections or other
additional pneumatic requirements. Cab floor access
should be used to add air lines into the cab as well as
using the secondary function control, solenoid valve pack
to connect to for other pneumatic needs.
Volvo Trucks North America
Service Bulletin

Pneumatic Electric Interface Plate

Port

A-Tank

B-Tank

A-TD

Park
Contains

Green 3/8" Tube

Red 3/8" Tube

Pressure Transducer

Orange 3/8" Tube

D
Functional Description

Inside of Cab A Tank Air Supply

Inside of Cab B Tank Air Supply

Date
4.2008
Group
900
No.
077

The Instrument Cluster Pressure Transducer for the R pressure gauge

The control line for the tractor/truck parking brakes

Page
7(24)

B-TD Pressure Transducer The Instrument Cluster Pressure Transducer for the F pressure gauge. The
port is supplied from the B-Tank port

PBS 25-30 psi pressure switch Park brake light switch. The port is supplied from the PARK port.

SLS 2-6 psi pressure switch The vehicles stop light switch

FRT SUP Pressure Transducer (Optional) This pressure transducer is used to report the front air suspension bellows
pressure in the instrument clusters secondary information display

AP-TD Pressure Transducer (Optional) The pressure transducer is used to control the brake application pressure gauge
in the instrument cluster. This port is supplied from the SLS port

REAR SUP Pressure Transducer (Optional) This pressure transducer is used to report the rear air suspension bellows
pressure in the instrument clusters secondary information display
Volvo Trucks North America
Service Bulletin

Air Solenoids (Chassis Mounted)

Air operated devices controlled from the cab use electric
air solenoids. The primary pack is located on the rear
of the transmission crossmember. The new package
replaces the pneumatic operated On/Off dash switches
previously used.

Functions controlled by the air solenoids include:

Air Horn
D
Date
4.2008
Group
900
No.
077
Page
8(24)

Air Suspension Dump

InterWheel and Interaxle locks

5th Wheel Slider

Lift Axles

There are up to two solenoid packs, depending on the

number of air operated devices. Each Solenoid pack can
hold up to 5 solenoids and is of modular construction.

All solenoids block air when not engaged and pass air
when engaged. As noted in the illustration below, all
of the solenoids are wired independently. For further
electrical information refer to VN/VHD Version 2 from
build date 11.2002 Electrical Schematics.

Electrical specifications for the air solenoids are as

follows:

Nominal Diameter 3mm

Operation Pressure 01 Mpa

Valve Seat Seal VITON

Temperature Range 40C - 100C

(104F - 212F)

Operational Voltage 12 3
Volvo Trucks North America
Service Bulletin

Secondary Function Control Solenoid Valve Pack

D Date
4.2008
Group
900
No.
077
Page
9(24)

W9000846

W9000847

On the second generation of the VN/VHD functions that

have been traditionally controlled with pneumatic switches
in the dashboard will now be controlled electronically
with the uses of solenoid valves. The number and
configuration of valves attached to the base plate will
vary from vehicle to vehicle depending on the available
options. The primary base plate will always be one unit
regardless whether it is a VN or VHD model. However,
during some rare cases, on the VHD, there will be a
second valve package mounted on the right frame rail.
There are currently five different methods of populating
the solenoid valve referred to in the table below.

Note: For further information refer to Secondary Function

Control Solenoid Valve Pack page 10.
Volvo Trucks North America
Service Bulletin

Secondary Function Control Solenoid Valve Pack

VN

VHD
Air Horn (Red)

Air Horn (Red)

(Black)
Primary Packs

Suspension Dump

I/O Air Cleaner

(Black)
D
5th Wheel Slide
(Yellow)

Inter Wheel
Differential Lock
(Brown)
Date
4.2008
Group
900
No.
077

Inter Axle Differential

Lock (Grey)

Inter Axle Differential

Lock (Grey)
Page
10(24)

Inner Wheel Lock

(Brown)

5th Wheel Slide

(Yellow)

Secondary Packs

VHD 1st Aux. Axle (Blue) 2nd Auxiliary Axle 3rd Auxiliary Axle (Blue) Suspension Dump (Black)
(Orange)

Air Tank Volumes

TOTAL Wet Tank Front Rear

4x2 (in) 4575 1525 1525 1525

6x4 (in) 5850 1950 1950 1950

Volvo Trucks North America
Service Bulletin
I-Shift Hill Start Assist
D Date
W5001597
DANGER
Hill Start Assist is only intended to temporarily hold
the vehicle on a grade during a vehicle launch.
The vehicle brake must be applied, independent of
Hill Start Assist, to hold the vehicle on a grade for
an extended period of time. Failure to follow this
instruction can result in loss of vehicle control and
serious personal injury or death.
Note: For basic operator information about the Hill Start
Assist feature, refer to the Operators Manual.
The Volvo I-Shift Hill Start Assist feature (option), provides
the operator with anti-rollback assistance during vehicle
launch on a hill. Hill Start Assist works by applying the
vehicles brakes when in a forward gear and starting on an
incline, or in a reverse gear when starting on a decline.
When enabled, it automatically activates when all of the
following conditions are met:
Key switch in the ignition position and the speed is
present
and the vehicle speed is equal to 0 km/h
and vehicle is in a forward gear on an incline equal to
or greater then 2%, or in a reverse gear on a decline
equal to or greater then 2%
and the service brake applied
and the Hill Start Assist disable switch is not selected
and no failures with expected J1939 communications
are present
and the function is not in a downgraded mode.
Function in a downgraded mode:
When an existing fault or loss of information from other
necessary control modules such as the Transmission
Electronic Control Unit (TECU) and the Anti-Lock
Brake System control module (ABS).
Another downgraded mode would be if braking with
active ABS, ATC or ESP is detected.
4.2008
Group
900
No.
077
Activation of the system is triggered by the release of
the service brake pedal. Once activated, brake chamber
pressure is maintained for up to three seconds or until
positive torque is identified in the drive line (which ever
occurs first). When active, the Driver Information Display
(DID) will read Hill Start Assist Active to alert the
operator of the function.
Page
11(24)
Hill Start Assist always defaults to the on position upon
vehicle start up. A momentary switch is located on the
dash for temporary deactivation of the feature but, will
re-enable if the vehicle begins another drive cycle, the
momentary switch is depressed again or the vehicle
exceeds 20 km/h (12 mph). When temporarily disabled,
the Hill Start Assist telltale in the instrument cluster will
blink. This telltale is also used to alert the driver of
a permanently disabled system, but the telltale will be
solidly illuminated in this instance.
The following components are responsible for operating
this feature:
Hill Start Assist momentary switch
Vehicle Electronic Control Unit (VECU)
Solenoids to the ABS
W5001598
Brake Control Valve Assembly (located on the left
rear frame rail forward of the axle)
The following components are used to support the
operation of this feature with input to the VECU:
Transmission Electronic Control Unit (TECU)
Brake Control Unit (ABS)
The air lines for this system should not be modified or
taped in any way. Do not attempt to use any of this
systems air lines for supplies or for signals for other
components. For more information about this feature or
its components, please contact your local dealership.
Volvo Trucks North America
Service Bulletin

Schematics
Air Line Descriptions
The following information is used for these schematics:

Lift Axle Air Circuits (from Control Side) page 13

Air Circuits (Air and Electrical) page 14

D
Date
4.2008
Group
900
No.
077
Page
12(24)

Air Circuits
Number Description

001 Tubing, 12.7 mm (1/2 in.) OD, Black

003 Tubing, 9.5 mm (3/8 in.) OD, Black

004 Tubing, 6.4 mm (1/4 in.) OD, Black

030 Tubing, 9.5 mm (3/8 in.) OD, Green

032 Tubing, 15.9 mm (5/8 in.) OD, Green

033 Tubing, 6.4 mm (1/4 in.) OD, Red

034 Tubing, 9.5 mm (3/8 in.) OD, Red

035 Tubing, 12.7 mm (1/2 in.) OD, Red

036 Tubing, 15.9 mm (5/8 in.) OD, Red

037 Tubing, 6.4 mm (1/4 in.) OD, Yellow

038 Tubing, 9.5 mm (3/8 in.) OD, Yellow

041 Tubing, 6.4 mm (1/4 in.) OD, Orange

042 Tubing, 9.5 mm (3/8 in.) OD, Orange

043 Tubing, 12.7 mm (1/2 in.) OD, Orange

045 Tubing, 6.4 mm (1/4 in.) OD, Blue

046 Tubing, 9.5 mm (3/8 in.) OD, Blue

048 Tubing, 15.9 mm (5/8 in.) OD, Blue

052 Tubing, 9.5 mm (3/8 in.) OD, Grey

053 Tubing, 6.4 mm (1/4 in.) OD, Grey

054 Tubing, 19 mm (3/4 in.) OD, Green

055 Tubing, 19 mm (3/4 in.) OD, Brown

 Service Bulletin
Volvo Trucks North America
Lift Axle Air Circuits (from Control Side)

D 4.2008
900
077
Date
Group
No.
W5001216

For air line callouts, see Air Line Descriptions page 12.

Note 1 For connection locations, see page 14.

13(24)
Page
 Service Bulletin
Volvo Trucks North America
Air Circuits (Air and Electrical)

D
4.2008
900
077
Date
Group
No.
W5001217

For air line callouts, see Air Line Descriptions page 12.

Note 1 For connection locations, see page 13;

14(24)
Page
Volvo Trucks North America
Service Bulletin

Design and Function D Date

4.2008
Group
900
No.
077
Page
15(24)

W5001362
1 Compressor 12 Front Brake Chamber
2 Governor; 2a Governor Servo Valve 13 Dash Manifold Valve
3 Air dryer 14 Quick Release Valve
4 Wet Tank 15 Trailer Hand Brake Valve
5 B System Tank 16 Manifold Tractor Protection Valve
6 A System Tank 17 Low Air Pressure Switch
7 Foot Valve 18 Air Pressure Gauge
8 Quick Release Valve 19 Accessory Manifold
9 Relay Valve 20 Pressure Protection Valve
10 ABS Modulator Valve 21 Parking/daytime Running Light Switch
11 Spring Brake Chamber 22 Stop Light Switch

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

Air System Pressure

Air pressure in the two circuits are monitored by two
pressure gauges on the right side of the instrument
panel. The gauge for the primary (rear) brake circuit is
marked with an R within a symbol and the gauge for
the secondary (front) brake circuit is marked with an F
within a symbol. The two pointers should register equal or
nearly equal pressure. By observing the gauge pointers,
the operator is forewarned in the event of a pressure
D Date
4.2008
Group
900
No.
077

Before operating the vehicle check the air gauges which

indicate air pressure. They should not register less than
7.2 bar (105 psi). Maximum pressure at any time should
not exceed 10.3 bar (150 psi).
Page
16(24)

drop in either or both of the circuits, and also may readily

identify the specific circuit.

Supply System
The supply system for the compressed air brakes
consists of the compressor (1), governor (2), air dryer
(3) and storage tanks (4, 5 and 6). Which compressor
model is installed is dependent on engine manufacturer
specification or customer choice.
A Bendix governor is standard for all compressors. The
governor is installed away from the compressor on all
vehicles with Volvo engine and Knorr compressor. For air
schematics over supply systems on other models, refer to
Group 5 air brake system schematics.

Also found in the supply system is the Purge Tank (See

Purge Tank page 16).

Compressor Relief Valve

There have been instances where problems downstream
from the compressor has produced high pressures in the
compressor resulting in damage to the head gasket. A
relief valve has been introduced on some compressors
and engine types to prevent damaging overpressure in
the compressor.
The relief valve is typically installed in the valve head or
very close to it. In the event of an overpressure, air will
be released in short bursts from the valve as it opens.
Opening pressure is set at 1.7 MPa (250 psi).

Compressor Air Supply

Normally Aspirated
The air supply for compressors installed on all Volvo
engines is normally aspirated. The intake piping is
connected to the engine air filter piping on the clean side
of the filter.
Overpressurized Aspiration
Compressors on Cummins engines have the air intake
connected to the intake manifold of the engine. The air in
the manifold is over pressurized by the turbocharger.

Purge Tank
The purge tank provides the air volume used to clean
or regenerate the Dryer at the end of each compressor
pumping cycle. It is used with the Wabco 1200P and the
CR Turbo 2000 Dryers.

On all VN models the purge volume is built into the wet

tank as a separate compartment. This is also true for all
VHD models. The separate purge tank can be used on
W5001192
VHD models, in special cases.

W5001193
Volvo Trucks North America
Service Bulletin

Air Tubing and Fittings

The schematics found in Service Manuals 56,
Compressed Air Brakes Schematics, VHD VERSION2
(from build date 11.2002), 11.2002, PV776TSP178761
and 56, Compressed Air Brakes Schematics and Routing,
VN VERSION2 (from build date 11.2002), 11.2002,
PV776TSP178762, represents the brake system as a
schematic layout or show actual routing in the vehicle.
D Date
4.2008
Group
900
No.
077
Page
17(24)

Fittings are typically of the push-connect type. To connect

or disconnect tubing is very easy, which simplifies
troubleshooting in the air system. New, simple test gauges
have been introduced for testing the valves and pressures
(See Service Manual: Air Valves and Components).
TUBING COLOR, PRIMARY
BLUE . . . . . . . . . . . . . . . . Supply System Circuit
RED . . . . . . . . . . . . . Front Service Brake Circuit
GREEN . . . . . . . . . . . Rear Service Brake Circuit
ORANGE . . . . . . . . . . . . . . Parking Brake Circuit

All tubing is made of nylon and sizes are always measured W5000377

as an outer diameter (OD). The 1/4 in. tubing is a solid
core, single ply extrusion. All other sizes are made of a
solid core, covered with a protective, colored layer with
fiber reinforcement between the layers. The cover is
treated for heat and sunlight resistance.
The fitting body is made of brass or a composite material
with brass collets. An internal O-ring seals on the outside
diameter of the tubing and the retaining collar holds the
tubing firmly in place. Straight fittings have an internal
hex grip, most others have external hex grip. A number
of valves also come with push-type connectors already
installed in the valve body.

The fitting is designed for letting the tubing rotate to

eliminate kinks. The fitting IS NOT designed for locations
with continuous movement, such as, between frame and
axle. Threads are pre-applied with sealant. A fitting can
be reused in the same port up to five times before new
sealant needs to be applied.
W5000379

In areas where great flexibility is needed, air is routed

in rubber hoses, for example, between frame and the
axles. A hose is built up of three layers of rubber and
reinforcement. Hoses are specifically made for each
installation to the correct length with crimped on fittings
on either end.
W5000378

W5000384
Volvo Trucks North America
Service Bulletin

Air Tubing Installation

To ensure a tight seal between tubing and fitting, the
tubing end needs to be cut straight. Also, inspect tubing
that has been removed for teethmarks around the
perimeter where the retaining collar holds the tubing in
place. If the marks are too deep, that is, can be easily
seen or a depression can be felt by running a fingernail
across mark, recut the tubing before reinstalling.
D
Date
4.2008
Group
900
No.
077

W5000380
Page
18(24)

Installing is done by aligning tubing in a straight line with

the fitting opening. Push until the tubing stops against the
bottom of the fitting.
W5000381

When the tubing has bottomed in the fitting, pull back to

make the collar retaining teeth engage the tubing. Do not
pull too hard, only enough to ensure that the collar has
gripped the tubing.
W5000382

Air Tubing Removal

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

To disconnect, push the tubing into the fitting until it

bottoms. Use release tool J42189 to push in the collar
and then pull out tubing while holding the collar in.

W5000580
Volvo Trucks North America
Service Bulletin

Air Tubing Repair

In the event that tubing has been severed as the result
of an accident or if tubing needs to be lengthened for
rerouting, there are certain procedures that must be
followed.

In general, there are no restrictions against repairing

D
tubing versus replacing it. A repaired tubing has the same
integrity as the rest of the system if the repairs are done
Date
4.2008
Group
900
No.
077
Page
19(24)

properly. Tube to tube fittings are available for 1/4, 3/8

and 1/2 in. tubing.

W5000582

Damage to one tube is repaired so that the repair fitting

is close to a bracket for support. Prepare the tubing as
outlined on the previous page. Push the tubing ends into
the fitting. Leak test fitting at full pressure after system
pressure has been established again.

W5000583

If a whole bundle of tubing needs to be repaired or

lengthened, make sure the fittings are staggered instead
of installed at the same length. Put the larger fittings
close to a bracket for support and the smaller fittings
further away.

W5000584
Volvo Trucks North America
Service Bulletin

Air Tank Mounting

Air Tanks are found in several locations on the VN and
VHD vehicles. The illustration shows the standard
mounting for the various air tanks.
D
Date
4.2008
Group
900
No.
077
Page
20(24)

W9000938
1 VHD Axle Back Right Side Frame Rail Option

2 VHD Axle Forward Right Side Frame Rail Option

3 I-Shift Transmission Air Tank (without PTO)

4 Left Side Only All VHD

5 Left of Right Side VN and VHD

6 Purge Tank

7 Air Dryer VN/VHD

8 Crossmember Mounted/I-Shift Transmission Air Tank

(with PTO)
Volvo Trucks North America
Service Bulletin

D Date
4.2008

Air Tank Routing for Bendix and Midland Air Dryers

Group
900
No.
077
Page
21(24)

W5001467
Volvo Trucks North America
Service Bulletin

D Date
4.2008
Group
900
No.
077
Page
22(24)

Air Tank Routing for Wabco SS1200P or Chicago Rawhide Turbo 2000 Dryers

W5001466
Volvo Trucks North America
Service Bulletin

Brake Valve D
Date
4.2008
Group
900
No.
077
Page
23(24)

W5001404

Brake Valve attached to Air Dryer

Volvo Trucks North America
Service Bulletin

Automatic Air Tank Drain Valve

Sales Code: VW-A1
D Date
4.2008
Group
900
No.
077
Page
24(24)

W9000527

Air Tank Drain Valve with Heater

1 Port A

2 Port B