TP-0357

Issued 09-03

Meritor WABCO Inversion

Issued
1TP-0357
Technical
09-03 Bulletin
Relay Valve (IR-2)

Technical Bulletin

Hazard Alert Messages Inversion Relay Valve (IR-2)

Read and observe all Warning and Caution hazard alert messages in The inversion relay valve (IR-2) combines the functions of two air
this publication. They provide information that can help prevent brake system valves:
serious personal injury, damage to components, or both. 앫 A relay valve

WARNING 앫 An inversion valve with anti-compounding protection

To prevent serious eye injury, always wear safe eye protection Under normal conditions, the IR-2 responds to a control signal from
when you perform vehicle maintenance or service. a dash-mounted parking brake control valve to supply or exhaust air
from the spring brake chambers, thereby applying the spring
Park the vehicle on a level surface. Block the wheels to brakes. In the event of a primary air system failure, the IR-2 makes
prevent the vehicle from moving. Support the vehicle with a modulated application of the spring brakes by means of the foot
safety stands. Do not work under a vehicle supported only by valve. A typical IR-2 valve installation is shown in Figure 1.
jacks. Jacks can slip and fall over. Serious personal injury and
damage to components can result.

Release all air from the air systems before you remove any
components. Pressurized air can cause serious personal
injury.

Do not attempt to open or disassemble the inversion relay

valve. This valve has an internal spring that may be damaged
by opening the valve. In addition, internal spring forces may
cause serious personal injury.

Overview
Access Product and Service Information
For additional information about Meritor WABCO’s inversion relay
valve, please contact the ArvinMeritor Customer Service Center at
800-535-5560. Literature covering the complete Meritor WABCO
product line is posted on our website, [Link].
Figure 1

AIR
FROM
INLET
FILTER

SECONDARY
RESERVOIR

ACC PRIMARY
RESERVOIR
WET
SUPPLY LINE
TANK
PURGE PARKING BRAKE
TANK CONTROL LINE

4003018b

Figure 1

Installation Figure 2

Guidelines
NOTE: If you are installing the inversion relay valve on an existing
installation, you must first remove the old valve. Refer to the valve
replacement procedure in this bulletin for instructions.

1. Mount the valve.

앫 Refer to the vehicle manufacturer’s specifications for
specific mounting requirements.
EXHAUST
4003006a
앫 Select a flat mounting surface. The mounting surface must
be within 0.010-inch (0.25 mm) of flat. Figure 2

앫 For best timing results, mount the valve near the spring
brakes it will serve.
앫 Mount the valve with the exhaust port facing down within
30° of vertical.
앫 Use 8 mm mounting hardware to attach the valve to the
mounting surface. Tighten to 15 ± 2 lb-ft (20 ± 3 N폷m).
Figure 2. @

TP-0357
Issued 09-03 (16579/24240)
Page 2 Copyright ArvinMeritor, Inc., 2003 Printed in the USA
2. Connect the air lines as indicated in Table A. Valve ports are Troubleshooting
identified in Figure 3.
앫 Make sure all unused supply and delivery ports are Function Tests
plugged. Non-Failure Mode
앫 Look at the air line installation to make sure all air lines are When the vehicle’s primary air system is functioning correctly, the
correctly installed and that all connections are secure. IR-2 valve passes reservoir air to the spring brake chambers as
directed by the park brake valve. To test this operation:
Figure 3

1. Park the vehicle and apply the parking brakes. Place blocks
PORT 42 under the tires to prevent the vehicle from moving.
PORT 43
2. Follow standard shop procedures to install a test gauge in the
PORT 11
delivery line of the valve or at the spring brake chamber.
PORT 21 PORT 41
3. Fully charge the air brake system to 105-130 psi
(724-896 kPa).
PORT 12

PORT 22 4. Release the parking brakes by pushing in the dash-mounted

park brake knob.
PORT 23
EXHAUST PORT 24 4003007a 5. Check the pressure reading. The test gauge pressure reading
should be 90-105 psi (621-724 kPa).
Figure 3
6. Apply the parking brakes by pulling out the dash-mounted park
brake knob. The IR-2 will exhaust all air in the spring brake
Table A: IR-2 Valve Port Identification chambers, applying the spring brakes.
IR-2 Valve Port Assignments If the IR-2 valve does not function as described, check the
Port Function Typical Line Size installation. Make sure all air lines are correctly routed. Check
the connections for leaks. Make the necessary repairs and
11 Reservoir ports 1/2" O.D. Tube
retest. If the problem persists, it may be necessary to replace
12 the valve. If you have any questions or need additional
NOTE: If the system includes
assistance, contact the ArvinMeritor Customer Service Center
a line with blended air from
at 800-535-5560.
both tanks through a double
check valve, only one supply Anti-Compounding
line is connected to the valve.
Plug the remaining port. The anti-compounding feature occurs if the service brakes are
applied while the spring brakes are already applied. If this occurs,
21 Delivery ports to spring brake 3/8" I.D. Hose
the valve will deliver air to the spring brake chambers to release the
22 chambers. If the vehicle has
spring brakes. To test this function:
only two spring brakes, plug
23 1. Park the vehicle. Do not apply the parking brakes. Place blocks
the remaining two ports.
24 under the tires to prevent the vehicle from moving.
41 Control port to primary 3/8" O.D. Tube or 2. Follow standard shop procedures to install a test gauge in the
brake circuit Push-to-Connect delivery line of the valve or at the spring brake chamber.
42 Control port to secondary 3/8" O.D. Tube or 3. Fully charge the air brake system to 105-130 psi
brake circuit Push-to-Connect (724-896 kPa).
43 Control port to park brake 3/8" O.D. Tube or
4. Apply the parking brakes by pulling out the dash-mounted park
valve Push-to-Connect
brake knob. The IR-2 will exhaust all air in the spring brake
chambers, applying the spring brakes.

TP-0357
(16579/24240) Issued 09-03
Printed in the USA Copyright ArvinMeritor, Inc., 2003 Page 3
5. Make a service brake application by stepping on the foot Air Leakage
valve. This will send reservoir service brake air to the spring
Replace the IR-2 valve if leakage exceeds 175 sccm.
brakes.
6. Check the pressure gauge to ensure reservoir pressure NOTE: If accurate measurement equipment is not available,
is delivered to the spring brakes, thus indicating the replace any valve that has a clearly audible air leak.
anti-compounding feature is functional.
Leak Test
If the IR-2 valve does not function as described, check the
installation. Make sure all air lines are correctly routed. Perform a leak test to check for air leakage at the air line
Check the connections for leaks. Make the necessary connections.
repairs and retest. If the problem persists, it may be 1. Place blocks under the tires to prevent the vehicle from
necessary to replace the valve. If you have any questions or moving.
need additional assistance, contact the ArvinMeritor
Customer Service Center at 800-535-5560. 2. Drain air from all system tanks.
3. Close the reservoir drain cocks.
Failed Primary System Function
4. Start the vehicle. Allow air system pressure to build to
If there is a loss of the primary system air, the valve will respond
cut-out pressure while the engine idles.
to the remaining signal from the secondary brake system. When
secondary pressure increases to 10 psi (69 kPa), the valve will 앫 If the vehicle is equipped with an air dryer: There
begin to exhaust air from the spring brake chambers. The spring will be a purge or strong blast of air from the air dryer,
brake chambers will be exhausted, fully applying the brakes, followed by a mild flow which will last 10-25 seconds
before the secondary service pressure exceeds 75 psi (517 kPa). when cut-out pressure is reached.
To test this function:
5. Apply a soap solution to each connection that contains
1. Place blocks under the tires to prevent the vehicle from pressurized air. Check the connections for soap solution
moving. bubbles.

trim line = 6 picas in

2. Follow standard shop procedures to install a test gauge in 앫 No soap bubbles: Connections are sealed.
the delivery line of the valve or at the spring brake chamber.
앫 Soap bubbles: Connections are not sealed.
3. Fully charge the air brake system to 105-130 psi
(724-896 kPa). Connection Seal Repair

4. Drain the air from the primary reservoir. To repair connection seals:

5. Make a service brake application by stepping on the foot 1. Drain all reservoirs.
valve. This exhausts air from the spring brakes. 2. Remove the leaking connection.
6. Check the pressure reading. The test gauge should read 3. Inspect the connections and ports for damaged threads or
0 when the secondary service pressure exceeds 70 psi cracks. Replace if necessary.
(483 kPa).
4. Apply pipe sealant to the pipe thread connection.
If the IR-2 valve does not function as described, check the
installation. Make sure all air lines are correctly routed. NOTE: Repeat the leak test until all connections are sealed.
Check the connections for leaks. Make the necessary
repairs and retest. If the problem persists, it may be Ensure that tubes are cut squarely to avoid damage to seals
necessary to replace the valve. If you have any questions or during insertion into push-to-connect fittings.
need additional assistance, contact the ArvinMeritor
Customer Service Center at 800-535-5560.

TP-0357
Issued 09-03 (16579/24240)
Page 4 Copyright ArvinMeritor, Inc., 2003 Printed in the USA
 Procedures
Valve Replacement
1. Place blocks under the tires to prevent the vehicle from
moving
2. Identify, mark and disconnect all air lines from the valve.
3. Remove the mounting hardware that holds the valve to the
vehicle.
4. Remove the old valve from the vehicle.
5. Install the replacement IR-2 valve. Refer to the installation
guidelines in this bulletin for installation instructions.
6. Reconnect the pneumatic lines. Refer to Table A for more
information.

NOTE: All lines must be reinstalled in the same location

they were in before they were removed. Refer to the vehicle
manufacturer’s service manual for complete instructions.

7. Apply 105-130 psi (724-896 kPa) minimum air system

pressure. Test the installation, following the function tests
procedures in this bulletin.
trim line = 6 picas in

TP-0357
(16579/24240) Issued 09-03
Printed in the USA Copyright ArvinMeritor, Inc., 2003 Page 5
Meritor WABCO Information contained in this publication was in effect at the time the publication was approved for printing and is subject to
Vehicle Control Systems change without notice or liability. Meritor WABCO reserves the right to revise the information presented or discontinue the
3331 West Big Beaver Road, Suite 300 production of parts described at any time.
Troy, MI 48084 USA
Copyright 2003 TP-0357
800-535-5560
ArvinMeritor, Inc. Issued 09-03
[Link]
All Rights Reserved Printed in the USA 16579/24240