Commercial Vehicles Air Brakes
Commercial Vehicles Air Brakes
Commercial Vehicles Air Brakes
Air Brakes
Air brake systems use a much greater force to apply the brakes
than hydraulic braking systems do. This greater force is needed
to cope with the heavy loads of commercial vehicles.
Air brake systems are more tolerant to small leaks. The smallest
leak in a hydraulic system could result in brake failure. An
air brake system includes a compressor to generate more
compressed air as needed.
Air brakes are used on heavy vehicles because they have proven
they are capable of stopping these vehicles safely.
153
Chapter 7
This diagram shows the components that are used to make the simplest
possible air brake system:
154
Air lines to allow the pressurized air to flow between the air
brake system components.
Air Brakes
The above diagram shows the most common device used to apply truck
air brakes the air brake chamber. It converts the force of compressed
air into a strong mechanical force through the pushrod and slack
adjuster.
The air brake chamber consists of a flexible diaphragm clamped between
two steel housings. The diaphragm construction is similar to a tire
sidewall, consisting of a reinforced fabric core with a rubber coating.
Other main parts are the pushrod and plate assembly, and a return
spring.
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Chapter 7
This diagram shows how air under pressure is admitted to one side of
the diaphragm, causing it to inflate. As it inflates, the diaphragm pushes
against the pushrod, plate assembly and the return spring, causing them
to move. Note the position of the slack adjuster it is now at about a 90
degree angle to the pushrod.
The amount of pushrod force is governed by the air pressure (in pounds
per square inch) and the effective surface area of the diaphragm
(in square inches). The pushrod force is exerted against the brake
mechanism, causing the brakes to apply.
The most common size air chamber used on truck drive axles and trailer
axles is a regular Type 30 clamp type chamber with 30 square inches of
effective diaphragm area.
Air chambers are very powerful. The common Type 30 regular chamber
shown in the diagram above if applied with air pressure of 100 p.s.i.
(690 kPa) develops a pushrod force of 3,000 pounds.
Air chambers are made in a number of sizes, ranging from Type 9 (with
nine square inches of effective diaphragm area) to Type 36 (with 36
square inches of effective diaphragm area). The range of sizes allows the
truck engineer to match air chamber force with axle capacity so that no
axle is under or over braked.
However, even though truck air brake system pressures are 100 p.s.i.
(690 kPa) and above, much lower air application pressure, usually less
than 20 p.s.i. (138 kPa) is used to make normal stops.
156
Air Brakes
Definition
This diagram shows the main components used in the S-cam drum
foundation brake. The air brake chamber pushrod is connected to a lever
arm called a slack adjuster. The slack adjuster is attached to a camshaft
with an S-shaped head called an S-cam. Air pressure applied to the
chamber causes the pushrod to move forward, causing the slack adjuster
to rotate the S-cam. This causes the brake linings to press against the
brake drum, causing friction, which causes the wheel to decelerate,
stopping the vehicle.
The slack adjuster is also the means of adjusting the brakes to
compensate for brake lining and brake drum wear. Brake adjustment is
important and is covered in Chapter 8 Air Brake Adjustment.
Brake shoe return springs are used to keep the brake linings away from
the drum when the air pressure is released from the air chamber.
The picture on the left shows the
brake linings mounted on the axle
housing. The brake drum on the
right is mounted on the wheel and
rotates with it.
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Chapter 7
Compressor
The first requirement of an air brake system is a means of compressing air
and storing it in reservoirs (tanks) so that it is available for instant use.
The source of the compressed air is the compressor, which takes in air
from the atmosphere and compresses (pressurizes) it. The compressed air
is then pumped through an air line to a supply reservoir.
A gear-driven compressor and
governor.
RoadSense Tip
Check belt tension by
pressing down on the
belt midway between the
pulleys. If you can press
it in more than double
the width of the belt,
the tension needs to be
adjusted.
158
Air Brakes
Oil is used for lubricating the moving parts of the compressor, just like
oil is used to lubricate the moving parts of a cars engine. Oil also helps
to cool the compressor. The compressor is usually lubricated from the
same oil as the engine of the truck or bus, though some compressors
have their own separate oil supply. It is important to check that there is
sufficient oil supply.
Diagram of an air compressor.
Since the compressor pumps air, it needs a supply of clean air to work
properly. Air from the atmosphere supplies both the truck engine and the
compressor. An air filter is used to keep this supply clean. The air filter
should be checked regularly to make sure it is not clogged, as this would
restrict air flow.
A piston-type compressor operates on a similar principle to that of the
intake and compression strokes of a typical car engine.
Intake stroke
As the piston moves down in the cylinder, it creates a lower pressure
(vacuum) within the cylinder than the atmospheric pressure outside the
compressor. With the inlet valve open, air is then drawn into the cylinder
to fill the vacuum.
159
Chapter 7
Fast Fact
Compression stroke
When the piston reaches the bottom of the cylinder it then begins to rise.
The inlet valve closes, causing the air in the cylinder to compress. As the
piston nears the top of the stroke, the discharge valve opens, and the
pressurized air is forced past the valve and into the discharge line leading
to the reservoir.
Governor
Fast Fact
Vehicle safety standards
require that the governor
must be set to restart
the compressor if the air
pressure drops below 80
p.s.i. (552 kPa).
160
Air Brakes
Fast Fact
The compressor must
be capable of building
pressure in the reservoirs
from 50 p.s.i. to 90
p.s.i. within three
minutes at a fast idle
(1,000 1,200 r.p.m.).
Governors are usually set to unload the compressor (stop the compressor
from pumping air) when the air pressure reaches about
125 p.s.i. Although the maximum pressure on different vehicles may
vary between 105 and 135 p.s.i. (724 and 931 kPa), the range between
minimum and maximum pressure should be approximately 20 p.s.i.
(138 kPa).
For example, if the maximum air pressure was 125 p.s.i., the governor
would restart the compressor if air pressure in the reservoirs dropped to
105 p.s.i. (applying the brakes several times would likely cause the air
pressure to drop to this level). At any rate, the governor must restart the
compressor if the air pressure drops below 80-85 p.s.i. (552-586 kPa).
Reservoirs
Fast Fact
Steel tanks (known as reservoirs) are used to store the compressed air
from the compressor.
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Chapter 7
RoadSense Tip
When draining reservoirs
dont just briefly open
and close the drain
cocks. Allow plenty
of time for the air to
completely drain.
Warning
Compressed air can be
dangerous if it escapes,
particularly to eyes and
to ears.
Avoid being in the direct
path of compressed air,
such as when draining
the reservoirs.
Foot Valve
Pressing on the brake pedal (called the foot valve treadle) applies the air
brakes, just like stepping on the brake pedal applies the brakes in a car.
Fast Fact
The maximum brake
application will not
exceed the pressure in
the reservoirs.
For example, if reservoir
pressure is 80 p.s.i. (552
kPa), the maximum brake
application you could
make would not exceed
80 p.s.i.
162
The treadle (pedal) of a foot valve has a springy feel that is quite different
from the feel of a hydraulic brake pedal of a car. For one thing, you really
dont have to press harder on a foot valve to apply more braking force
you simply have to press it down a bit farther. As long as the foot valve
is held in one position, the air pressure delivered to the brake system will
remain constant.
Air Brakes
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Chapter 7
Brakes released
In this simplified diagram, the drivers foot is off the brake pedal,
allowing the brakes to release. This action has caused an exhaust port in
the bottom of the foot valve to open, allowing the air that was applied
to the brake chambers to escape. Note the burst of exhaust air below the
foot valve.
The return springs in the air chambers have returned the pushrod
assembly to the released position, and the slack adjusters and S-cams
have rotated to their released position.
Brake shoe return springs (not shown) have retracted the brake linings
away from the brake drums.
164
Air Brakes
The device that made dual systems possible is the dual foot valve. It is
actually two control valves operated by a single pedal. This allows the
brake system to be divided into two completely independent sections.
Each section has its own supply, delivery and exhaust ports.
Fast Fact
Cars have had dual
braking systems since
1968 to reduce the
chance of a total brake
failure.
The two sections of the dual foot valve are named primary and
secondary. The primary section is located closest to the pedal, and in
many systems operates the drive axle brakes. The secondary section
usually operates the steering axle brakes.
When the driver applies the brakes, both sections of the dual foot valve
are activated. Air from the primary tank is applied to the rear axle brakes
and air from the secondary tank is applied to the front axle brakes.
Most dual systems use three reservoirs, a supply reservoir as before, and
two service reservoirs, one for each section of the dual system. Each
service reservoir is filled through a one-way check valve, and there are
two reservoir pressure gauges, one for each service reservoir.
Even in the event of a total failure in one or the other system, the driver
is able to make a controlled stop, using only the foot valve, although
maximum braking power will be reduced.
There are other ways of splitting a dual air brake system, but however
it is divided, if one of the systems fail, the driver is still able to make a
controlled stop.
Note the change in terminology for the reservoirs. The first reservoir (wet
tank) is called the supply reservoir. The two service reservoirs are
165
Chapter 7
RoadSense Tip
Check gauges frequently
to make sure there is
adequate air pressure to
apply the brakes.
166
Rather than having two separate reservoir gauges, many vehicles have a
single gauge with two needles, indicating the pressure in the primary and
secondary reservoirs.
As well, many vehicles have an additional gauge to indicate how much
air pressure is being applied when the foot valve is depressed.
The reservoir pressure gauge is mounted in the dashboard so that the
status of the air brake system can be monitored while driving and during
a pre-trip inspection.
Air Brakes
Fast Fact
The low air warning device must come on when air pressure drops
below 60 p.s.i. (414 kPa).
A typical low air warning device is a red warning light on the dashboard.
There may also be a buzzer.
A wig-wag.
RoadSense Tip
If the low air warning
comes on, pull over and
stop. Do not proceed
until you find out why
the low air warning
came on and until you
determine that the air
brake system is safe.
Some older vehicles are equipped with a low air warning device near the
top of the windshield that drops into the drivers view when air pressure
drops below approximately 60 p.s.i. This type
of warning device is known as a wig-wag.
Some wig-wags automatically retract when
air pressure rises above the warning level of
60 p.s.i.; some wig-wags need to be manually
pushed up to the out of view position after
the air pressure has risen above the warning
level.
When a low air warning device activates,
stop the vehicle and find the cause of the air
loss. The air pressure remaining in the system
(approximately 60 p.s.i.) will be enough to stop
the vehicle if you act promptly.
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Chapter 7
When the brakes are applied, air from the foot valve flows through the
quick release valve to the chambers in the normal manner.
When the driver releases the foot valve, only the air in the line between
the foot valve and the quick release valve is vented at the foot valve
exhaust port. The larger volume of air contained in the air chambers is
vented at the exhaust port of the quick release valve.
Note the difference in the air bursts at the foot valve and at the quick
release valve there is a much bigger burst of exhausting air at the quick
release valve.
Quick release valves may be found in a number of places in an air brake
system, including front brakes, rear brakes, spring parking brakes and any
other place that the rapid exhausting of air is required.
168
Air Brakes
Relay valve
A relay valve has been installed between the reservoir and the rear
brake chambers.
Relay valves are used to reduce the lag time when the brakes are applied,
and when they are released. They are remote controlled air valves that
respond to a control signal from the foot valve. They are usually mounted
on a frame rail close to the air chambers that they are to operate.
Relay valves are supplied with air directly from the primary or secondary
reservoirs through a large diameter air line (shown as the supply line
in the diagram) so that there is a high volume of air available for rapid
delivery to the air chambers.
The pressure of the reservoir air delivered in this way will be the same as
the control pressure delivered by the foot valve. If you make a 20 p.s.i.
(138 kPa) brake application, approximately 20 p.s.i. of air pressure would
be directed to the rear brake chambers through the relay valve.
When the driver releases the foot valve, only the air in the control line is
vented at the foot valve exhaust port. The volume of air contained in the
air chambers is vented through an exhaust port built into the relay valve.
Relay valves are designed to handle the volume requirements of two or
four air chambers. Though they are primarily found on rear axle brakes,
relay valves are sometimes found on steering axle brakes or wherever
there is a need to apply and release air rapidly.
For simplicity, quick release valves and relay valves are not shown in
the following diagrams because they do not change the basic concept of
an air brake system, but serve only to speed up the release of the brakes,
if needed.
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Chapter 7
170
Air Brakes
Parking Brakes
While air pressure does an excellent job in helping to stop a vehicle by
applying the foundation brakes, it is totally unreliable (and illegal) for
parking. If a vehicle were to be parked using only the air brakes, any
leaks in the system, or any failure in a hose, diaphragm, or air valve
would result in loss of air pressure and a possible rollaway collision.
Regulations for parking brakes require that once applied, the parking
force must be maintained by mechanical means and be unaffected by loss
of air pressure.
The most common type of parking brake in an air brake system is the
spring parking brake. The second type is known as a safety actuator and
is usually found only on some highway coaches and intercity buses.
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Chapter 7
Fast Fact
While the spring parking
brakes will apply if air
pressure falls beneath
a certain level, their
effectiveness in stopping
the vehicle or holding a
parked vehicle depends
on how well the brakes
have been kept in
adjustment.
Spring parking brakes are mounted on the rear axles only not on
steering axles. The service brake chamber contains the normal pushrod,
diaphragm and return spring. The spring parking brake section is
mounted behind the service brake chamber.
Warning
The spring in a spring
parking brake is very
powerful. If the spring
were ever to break out
of the chamber, it could
cause serious damage to
any objects or persons
in its way.
Keep away from a spring
parking brake chamber
that shows any sign of
damage, such as dents
or cracks anywhere in
the housing.
172
When you make a regular foot brake application, air pressure is applied
against the diaphragm in a service brake chamber, causing the diaphragm
to inflate, pushing the push rod out against the slack adjuster to apply the
foundation brakes.
Spring parking brakes work in the opposite way. These brakes are applied
and remain applied by mechanical spring pressure, not by air pressure.
If air pressure falls beneath the amount needed to keep the spring
compressed, the spring pushes against the push rod in the service brake
chamber, pushing the push rod out against the slack adjuster to apply the
foundation brakes (because the parking brake chambers are piggy-backed
onto the service brake chambers and operate the foundation brakes
through the same linkage).
Spring parking brake assemblies should only be serviced by qualified
personnel. The spring in a spring parking brake chamber is under
extreme pressure and could cause serious personal injury.
Air Brakes
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Chapter 7
The driver has applied the foot valve, delivering air to the service brake
port, inflating the service brake diaphragm.
174
Air Brakes
The driver has placed the parking brake control valve in the park
position. This has caused the air from the spring parking brake section to
be exhausted.
The force of the coil spring has been transmitted to the intermediate
pushrod, which in turn has pushed against the service brake diaphragm,
pushrod, and slack adjuster, applying the brakes.
RoadSense Tip
Avoid compounding the
brakes.
Always release the spring
parking brakes before
making a heavy service
brake application.
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Chapter 7
RoadSense Tip
Caging spring parking
brakes should be done
only in an emergency.
Once a spring brake
chamber is caged, there
will be no parking brake
force at that wheel.
176
This diagram shows how one type of release bolt is inserted into the
rear of the spring parking brake housing. The release bolt is then given
a quarter turn to lock it in place. Then the release nut is turned until the
spring is compressed.
Instructions for manual release are usually imprinted on the housing of
most spring parking brake chambers.
Before attempting to manually release spring parking brakes, block
the wheels to prevent the vehicle from rolling. To move a vehicle after
manually releasing the spring parking brakes call a tow truck!.
Air Brakes
Fast Fact
The effectiveness of
spring parking brakes
depends on how well the
brakes have been kept in
adjustment.
This is accomplished by the use of a two-way check valve. The air that is
delivered from the two-way check valve is frequently called blended air.
Blended air
The two-way check valve draws
air from the tank with the highest
pressure.
The two-way check valve has two inlet ports and one delivery port.
A free floating shuttle within the valve will move away from the inlet that has
the higher pressure, and the higher pressure will be supplied to the parking
brake control.
This arrangement will also ensure that the spring parking brakes will
not automatically apply if there is a total loss of air pressure in either
reservoir.
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Chapter 7
This diagram shows the benefit of the blended air supply for the parking
brake system. There has been a loss of air from the primary reservoir.
The two-way check valve shuttle has moved so that secondary reservoir
pressure supplies the parking brake control valve.
The result is that the spring parking brakes do not apply automatically.
The low air warning system has alerted the driver to the air loss, allowing
the driver to make a controlled stop using the front axle brakes.
Some vehicles with dual air systems are equipped with an optional device
called a spring brake modulator. This device senses a loss of pressure
in the primary system, and when the driver applies the service brakes,
causes air to be exhausted from the spring parking brakes in direct
proportion to the brake application. By simply applying the foot valve
normally, the driver controls the amount of spring force used to assist the
front brakes to bring the vehicle to a controlled stop.
All vehicles must meet Canadian Motor Vehicle Safety Standards for
emergency stopping, so regardless of how the dual system is arranged,
or if a spring parking brake modulator is installed, the vehicle will have
adequate braking force, even with a partially failed air system.
With all systems, after stopping, the driver can securely park the vehicle
by manually applying the parking brake control valve.
178
Air Brakes
A separate air reservoir is used for parking and the parking brake dash
control is identical in appearance and operation to the one used for
spring parking brakes.
Pulling the dash control outward simultaneously applies air pressure to
the parking diaphragm and engages the locking mechanism. The push rod
moves out, applying the brakes. The pushrod is then held in the applied
position by the locking mechanism. The vehicle is parked securely, even if
air is lost from all reservoirs.
Normally, pushing the dash control inward causes air to exhaust from the
parking diaphragm and at the same time releases the locking mechanism,
allowing the pushrod to retract. However, if more than 4 p.s.i. (27.6 kPa)
pressure has been lost from the parking reservoir, the parking brakes will
not release. A heavy service brake application must also be made, causing
the pushrod to move slightly ahead, allowing the locking mechanism to
disengage.
Because spring force is not used for parking, safety actuator parking
brakes cannot be compounded.
Note that safety actuator parking brakes will not apply automatically,
even if service reservoir pressure is drained or pumped down to zero.
Only loss of pressure in the parking reservoir will cause automatic
application.
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Chapter 7
180
The line that carries the control signal from the tractor is called the
control line. It is also commonly called the service line.
Because tractors and trailers need to be disconnected and reconnected
from time to time, the air lines are equipped with quick coupling devices
called glad hands. Each coupler resembles a human hand about to make
a handshake to give you the glad hand. Glad hands are often colourcoded a blue line or blue colouring on a glad hand is used to indicate
the control line, and red is used to indicate the supply line.
Air Brakes
RoadSense Tip
When not in use,
glad hands should be
fastened to dead-end
(dummy) couplers or to
each other to prevent
dirt and debris from
entering the air lines.
Glad hands should
also be secured to
prevent the lines from
chafing against other
components or bouncing
off the vehicle.
There are two basic types of trailer air systems those that use spring
parking brakes and those that do not. Although most current trailers
do use spring parking brakes, there are a number of earlier trailers and
converter dollies in use that are not equipped with spring parking brakes.
All trailer systems, with spring parking brakes or without, must have an
emergency stopping system that will fully apply the trailer brakes in the
event that the trailer separates from the tractor.
Trailers that are not equipped with spring parking brakes use a device
called a relay emergency valve. If this valve senses that the trailer has
broken away from the tractor, it applies the trailer service brakes with
full trailer reservoir pressure. This action is called dynamiting the trailer
brakes.
Trailers equipped with spring parking brakes use the spring force to apply
the brakes (dynamite the trailer brakes) if the trailer breaks away from
the tractor.
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Chapter 7
The relay emergency valve has drawn air from the trailer reservoir and
delivered it to the trailer service chambers at approximately the same
pressure as the control signal.
On highway trailers, one reservoir and one relay emergency valve
are used for single or tandem axles. Some tandem logging trailers are
equipped with a reservoir and a relay emergency valve for each axle.
182
Air Brakes
Warning
Small leaks in trailer
systems not equipped
with spring parking
brakes can cause the
applied pressure to be
reduced or depleted,
possibly allowing a
parked trailer to roll
away.
Always block the wheels
of a parked trailer to
ensure it cannot roll.
The trailer brakes will also be dynamited each time the glad hands are
disconnected, or when the driver closes the trailer supply valve that is
located on the tractor dashboard.
Motor vehicle safety standards require that these systems remain applied
for a minimum of 15 minutes.
It is important to follow proper procedures when coupling a tractor to
a parked trailer to prevent the trailer from moving and possibly causing
damage. Coupling procedures are detailed in Chapter 4 Skills for
Driving Trucks and Trailers.
183
Chapter 7
RoadSense Tip
You can usually tell if
you have reversed the
supply line and service
line connections:
the spring parking
brakes will not
release even when
you use the parking
brake control on the
dashboard
The system shown uses one reservoir and two air valves, a relay valve for
the service brakes, and a trailer spring brake valve that fills the reservoir
and controls the spring parking brakes.
Other systems may be equipped with one, two or three air valves and
multiple reservoirs. However, the use of more or less air valves or
additional reservoirs will not alter the basic operation of the system.
The tractor is delivering air through the supply line to the trailer
spring brake valve. The spring parking brake valve directs air to fill the
reservoir(s) and to release the spring parking brakes.
There are two types of systems:
RoadSense Tip
Always perform a tug
test after coupling the
tractor to a trailer.
Before conducting a tug
test, use a flashlight to
visually check that the
fifth wheel locking jaws
are closed and locked.
184
One type fills the reservoir(s) before releasing the spring parking
brakes.
The other type releases the spring parking brakes first, then fills
the reservoir(s).
Always perform a tug test after coupling the tractor to the trailer. Follow
the coupling procedures as shown in Chapter 4 Skills for Driving
Trucks and Trailers.
Air Brakes
This action can also be called dynamiting of the trailer brakes. The trailer
brakes will also be dynamited each time the glad hands are disconnected,
or when the driver closes the trailer supply valve that is located on the
tractor dashboard.
185
Chapter 7
Tractor protection
Fast Fact
A peace officer may
place your vehicle out
of service if the tractor
protection system allows
the tractor pressure to
drop below 20 p.s.i.
(138 kPa) without the
trailer air supply valve
automatically closing.
If the mechanical connection between the tractor and trailer were to fail,
causing the trailer to separate from the tractor, the two connecting air
lines would break. Air pressure from the tractor system would rush out
through the broken supply line, and if the driver were making a brake
application, air pressure would also rush out through the broken control
line.
To prevent the tractor air from being depleted to an unsafe level, tractors
are equipped with a tractor protection system.
A tractor protection system consists of a trailer air supply valve located
in the tractor dash, and a tractor protection valve, usually located behind
the tractor cab. All of the supply and control air delivered to the trailer
passes through the tractor protection valve.
In the event of a trailer breakaway, the tractor protection system will
automatically shut off air loss from the tractor, preserving enough
pressure for the driver to make a safe stop.
Some tractor protection systems will shut off immediately in the event
of a breakaway, but some will allow tractor pressure to drop to as low as
20 p.s.i (138 kPa) before shutting off.
Proper operation of the tractor protection system should be checked as
part of the daily pre-trip inspection.
This is the job of the dash mounted trailer air supply valve. It senses
air pressure in the supply line that carries air to the trailer system. Most
trailer air supply valves are an octagon-shaped red button.
186
Air Brakes
Hand valve
Applying the foot valve directs approximately the same application
pressure to both the tractor and trailer brakes. For example, if you make
a 20 p.s.i. foot valve application, this application pressure will be applied
to both the tractor and trailer brakes.
There are times when it may be beneficial to apply only the trailer brakes
without applying the tractor brakes, such as when coupling the tractor to
a trailer.
The hand valve allows independent
control of the trailer brakes. Some
are mounted on the steering
column, others are mounted in the
dashboard.
Warning
DO NOT use the hand
valve for parking.
When parked, apply the
tractor parking brakes,
close the trailer supply
valve and block the
trailer wheels.
This is the purpose of the hand valve. When the trailer air brake system
is fully connected to the tractor, the hand valve allows you to apply the
trailer brakes independently of the tractor.
The hand valve should not be used in normal or emergency situation
braking. Always use the foot valve for service braking.
Most hand valves are spring-loaded, just like the foot valve, so that when
you release it, it will return to the released position. Do not use the hand
valve for parking.
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Chapter 7
Bobtail tractors
Driving a tractor without a trailer attached is called bobtailing.
Driving a tractor without a trailer
attached is called bobtailing.
Because a bobtail tractor has very little weight over the rear drive
axles, it is very easy to lock up the rear brakes, even with a light brake
application.
To help prevent this unwanted lockup, and to increase control, some
tractors are equipped with a bobtail proportioning system.
This system consists of two special valves, one controlling the steering
axle brakes, and the other controlling the drive axle brakes.
When the tractor is being driven with a trailer attached, the tractor
brakes operate normally.
When bobtailing, the braking pressure to the drive axle brakes is reduced
by as much as 75 per cent, preventing the rear brakes from locking.
At the same time, the steering axle brakes receive full application
pressure.
A tractor with a bobtail proportioning system will stop in a shorter
distance and control will be increased, especially on wet or slippery road
surfaces.
Because the steering axle brakes are doing most of the braking, a higher
than normal pedal pressure is required.
188
Air Brakes
This diagram shows only the two service reservoirs, the dual foot valve,
and the components that are added to a tractor with a dual air system so
that it can safely tow a trailer with air brakes.
The components added are a trailer air supply valve, tractor protection
valve, hand control valve, and a pair of two-way check valves.
Two-way check valves are installed so that whichever brake is applied
foot valve or hand valve a control signal will be sent to the trailer.
The driver is making a foot valve application. The tractor front and rear
brakes are being applied, and a control signal is being sent to the trailer
through both of the two-way check valves.
Note that in most dual systems, the parking brake control valve (yellow
button) is interlocked with the trailer supply valve (red button) so that
applying the parking brake control valve causes all of the parking brakes
on both the tractor and trailer to apply.
Some tractors are equipped with three dashboard control valves the
parking brake control valve (yellow button), the trailer supply valve (red
button), plus a tractor parking brake valve with a round blue button that
can control the tractor parking brakes independently of the trailer brakes.
189
Chapter 7
Fast Fact
A peace officer may
place a trailer out of
service if the trailer
brakes do not apply
when the trailer air
supply valve is closed.
This diagram shows a tractor with a dual air system where there has been
a failure in the primary air system on the tractor. The low air warning
would have alerted the driver to the problem and a glance at the reservoir
gauges would confirm that only one part of the dual air system had been
lost.
The driver is making a foot valve application, causing the tractor front
brakes to apply. Application air from the secondary foot valve is also
passing through both of the two-way check valves, to the trailer control
line, signalling the trailer brakes to apply.
If it were the secondary system that had failed, a foot valve application
would apply the rear tractor brakes, directing air through both of the
two-way check valves to signal the trailer brakes to apply.
The same motor vehicle safety standards that require automatic shutoff of
the air supply to the trailer in the event that the pressure in the tractor
air system is lowered to between 20 and 45 p.s.i. (138 and 310 kPa)
apply equally to tractors with dual air systems.
Because the trailer supply valve is now supplied with blended air from
a two-way check valve, the automatic shutoff will not occur until the
service reservoir with the highest pressure is lowered to between 20 and
45 p.s.i. (138 and 310 kPa).
The automatic shutoff requirement should be checked as part of a pretrip inspection. If it doesnt function properly, the vehicle must be placed
out of service until it is repaired.
190
Air Brakes
This diagram shows how the tractor protection valve and the trailer air
supply valve act together to protect the tractor air supply from being
depleted to an unsafe level in the event that the trailer separates, causing
the connecting lines to rupture. The sudden loss of air through the
broken trailer supply line has caused the trailer air supply valve to shut
off automatically.
The driver is making a foot valve application, causing the tractor service
brakes to apply. The application pressure is also passing through both of
the two-way check valves to the tractor protection valve.
Because there is no pressure in the supply line to the trailer, the tractor
protection valve has closed the passage to the trailer control line, so no
application air can be wasted through that broken line.
If the control line separates, nothing will happen until the trailer brakes
are applied. When that happens, the tractor protection system will
activate to protect the tractor air supply.
When no trailer is connected, the trailer air supply valve will be in the
closed position. This allows the tractor to be driven bobtail so that no air
will be lost through the disconnected glad hand couplers.
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Chapter 7
wedge brakes
air-over-hydraulic brakes
Wedge brakes
This type of brake uses one or two small air chambers with wedge-shaped
pushrods. Once quite common on drive and trailer axles, wedge brakes
are now usually found only on steering axles.
RoadSense Tip
Wedge brakes should
only be adjusted or
repaired by a qualified
mechanic.
When the brakes are applied, air pressure in the brake chamber pushes
the wedge part of the pushrod between two rollers, forcing the brake
linings out to contact the brake drum.
Most wedge brakes have internal automatic adjusters. Checking proper
adjustment requires that inspection hole covers in the backing plate
be removed so that brake linings movement can be checked while the
brakes are applied and released. If either linings move more than 1/16
of an inch, or a total of 1/8 of an inch for both linings, the automatic
adjusters have failed.
Unlike conventional s-cam braking systems, drivers cant easily check the
wedge brake adjustment of a wedge brake.
Adjustment and repairs to wedge brakes should only be carried out by a
qualified mechanic.
192
Air Brakes
RoadSense Tip
Air disc brakes should
only be adjusted or
repaired by a qualified
mechanic.
This type of brake uses a rotor, or disc, that is mounted to the wheel hub
and rotates with the wheel. Two brake pads are located on either side
of the rotor. When applied, the brake pads are pressed against the rotor.
This action is similar to that of a large C clamp.
There are a number of different linkages used between the air chamber
and the operating mechanism. This illustration only shows one type,
although the principle of the others is similar.
Most air disc brakes feature an internal automatic brake adjustment
mechanism to adjust for brake pad wear. Chamber stroke limits are the
same as for automatic slack adjusters.
Unlike conventional s-cam braking systems, drivers cant easily check the
adjustment of an air disc brake.
Adjustment and repairs to air disc brakes should only be carried out by a
qualified mechanic.
193
Chapter 7
Air-over-hydraulic brakes
Air-over-hydraulic brakes are frequently found on middleweight trucks
and buses. This type of braking system combines the features of an air
brake system with that of a hydraulic braking system.
Hydraulic foundation brakes offer several advantages on commercial
vehicles of this size, including light weight, compact size and proven
automatic adjusting mechanisms.
Most middleweight commercial vehicles of this size were once powered
by gasoline engines, which supplied a source of engine vacuum so
that vacuum boosters for the hydraulic brakes could be used. The now
common diesel engine does not supply a usable vacuum, so a partial air
brake system has been adopted.
An air-over-hydraulic braking
system.
Fast Fact
An air brake endorsed
drivers licence is
required to operate most
vehicles equipped with
air-over-hydraulic brakes.
The only exception is if
the brake system does
not use an air treadle. In
this case, an air brakeendorsed drivers licence
is not required.
194
Air Brakes
RoadSense Tip
Check gauges frequently
to make sure there is
adequate air pressure to
apply the brakes.
Air dryers
Air dryers are optional devices that are installed in the compressor
discharge line between the compressor and the first reservoir. They are
designed to remove any water vapour, oil mist and carbon particles from
the air before it is delivered to the first reservoir.
Most new air brake systems include
an air dryer.
Fast Fact
Even if the air brake
system includes an air
dryer, air reservoirs
should still be drained
regularly to check for
contaminants.
RoadSense Tip
If you notice more than
just a few drops of water
when you drain the
supply reservoir, the air
dryer or compressor may
need servicing.
195
Chapter 7
Fast Fact
Even if the air brake
system includes an
alcohol evaporator or
alcohol injector, air
reservoirs must still be
drained regularly.
RoadSense Tip
Only use products
specifically designed for
use in air brake systems
in alcohol evaporators or
alcohol injectors.
196
Air Brakes
197
Chapter 7
RoadSense Tip
On vehicles equipped
with a manual front
wheel limiting valve,
keep the control in
the normal (Dry Road)
position to have normal
braking efficiency.
Under the Motor Vehicle
Act, the Slippery Road
position valve may only
be used when weather
conditions make its use
essential for safety.
Fast Fact
Spring parking brake
emergency release
systems are sometimes
called California spring
parking brake systems.
198
Air Brakes
199
Chapter 7
200
Air Brakes
RoadSense Tip
When coupling to a
trailer, always check to
see if it is equipped with
ABS.
Stopping in an emergency
with a combination
unit where the tractor
and all trailers are
ABS-equipped is quite
different than stopping
a combination where all
the units do not have
ABS.
Trucks and tractors are equipped with a dash mounted failure warning
lamp that monitors the ABS system. When the ignition switch is
first turned on, the ABS system performs a self-checking sequence.
Depending on the system, the dash lamp may light, flash briefly, then
stay lit until vehicle speed reaches 711 km/h, or light briefly, then turn
off.
If the lamp does not go out, or comes on during vehicle operation, it
is signalling that there has been a failure in the ABS system. Normal
braking is still operational, only the anti-lock feature is disabled. The
vehicle may be driven to a service depot for repairs.
201
Chapter 7
Review Questions
202
1.
2.
3.
4.
How can you tell how much air pressure is in the main
reservoirs?
5.
6.
7.
8.
9.
What are the two ways that the spring in a spring parking
brake chamber can be held in the released position?
10.
11.
12.
13.
14.
15.
16.
17.
18.