Warner Electric Utility Controller Hand–Air Operated - Manual (Page 5)

5 Warner Electric • 800-825-9050 P-1395 • 819-0288
3. Install one 3-way tee in each of the primary
and secondary service system control lines.
They should be installed as close as possible
to the control valve and ahead of any other
valves in the air brake system. The tee should
provide straight-through flow for the service
brake system.
4. After installing the 3-way tees in the primary
and secondary control lines, connect the
open (right angle) port of each tee to the inlet
sides of the double check valve. (Refer to
Figure 4). The double check valve serves two
purposes: it provides a single connection
between both brake lines and the air
controller while keeping the primary and
secondary brake systems isolated.
This installation must not be
made without the double check valve to
protect the truck air brake system.
5. Install the air supply line from the outlet port
of the double check valve to the inlet port of
the controller using either 3/16-inch or 1/4-
inch diameter air supply tubing.
6. Check all tees, valves, fittings, and air lines to
assure that the entire installation, including
torque settings, is consistent with the vehicle
manufacturer’s service instructions for the
types of components used.
7. Inspect all air lines to assure that no kinks are
present. Fasten all nylon or plastic lines at
least 6 inches away from possible heat
sources.
Air Line Connection – Vehicles Equipped
with Pre-FMVSS-121 Brake Systems
Important: The customer must supply the
3-way tee and tubing needed for this
connection.
The three-way tee should be obtained from the
vehicle manufacturer’s service parts organization
and installed per the vehicle manufacturer’s
instructions.
To obtain correct tubing, measure the diameter
of the brake line tubing and determine the type
of tubing material used (normally nylon or
copper).
Note: No double check valve is needed to
connect this system.
1. Systems used before the FMVSS-121 contain
only one brake line instead of both the
primary and secondary systems.
2. Install the tee into the system at either the
front or rear brake line. The tee should
provide straight-through flow for the service
brake system.
3. Connect the open (right angle) port of the
3-way tee to the inlet side of the air controller.
4. Check all tees, fittings, valves, and air lines to
assure that the entire installation, including
torque settings, is consistent with the vehicle
manufacturer’s service instructions for the
type of components used.
5. Inspect all air lines to assure that no kinks are
present. Fasten all nylon or plastic lines at
least 6 inches away from the possible heat
sources.
C. Electrical Wire Connections
Electrical connections are required for all
installations. The customer must furnish a
sufficient amount of automotive-type, multi-
stranded, single conductor, 12 gauge (or heavier)
wire with thermo-plastic insulation (nylon,
polyvinyl chloride, etc.).
The air controller is furnished with three wires:
blue, red, and black. (Refer to Figure 5 when
wiring).
Note: Solder or crimp clamp connections are
required for connecting all three controller lead
wires. Wrap electrician’s tape around all bare
wire joints. Do Not Use twist-type connections.