Air Brakes Slides 2 - 095652

AIR BRAKE SYSTEM FOR HEAVY
VEHICLES
RQF Level: 8
Course no: AUTHC801
Credit: 10
Module leaders:
Patrick BANDA
Michael SHAMU
The brakes on a truck are probably its most vital
safety component
The brakes on a truck are probably its most vital safety component
Objectives
Conduct heavy vehicle brake systems repair
• Diagnose heavy vehicle pneumatic brake
system
• Conduct heavy vehicle pneumatic brake
system repair
• Perform post repair activities of heavy vehicle
pneumatic brake system
Brakes and Braking
Introduction
• To stop a vehicle, brake shoe linings are forced
against the surfaces of the brake drums, creating
friction
• This friction generates heat while reducing the
energy of revolving brake drums and wheels
• This heat is absorbed by the brake drums, which
dissipate the heat into the atmosphere
• When enough friction is created between the brake
lining and the drums, the wheels stop turning
Brakes and Braking
Example:
• If a 200-horsepower engine accelerates a vehicle to
100 km/h in one minute
• What power is needed to stop in 6 seconds (i.e. in
1/10 the time it took to reach 100 km/h)
• It requires a stopping force of 10 times the
acceleration force i.e. the equivalent of 2,000 HP
• If the vehicle had 6 wheels, each wheel would have
to provide 1/6 the braking force
• If one or two of the wheels have ineffective brakes,
the other wheels will compensate for the braking
Brakes and Braking
Example:
• Excessive braking result in heat generation which
the brake drums cannot absorb and dissipate
• This result in brake fade, brake damage and/or
brake failure
NB: Brake fade is when brakes stop operating
properly because they have become overheated
• The heat generated can cause fire
• Brake linings operate best at around 250°C and
should not exceed 425°C
Brakes and Braking
Brakes and Braking
Summary
• Distance to stop a vehicle depends on its speed and
weight, in addition to energy, heat and friction
• So;
 If weight is doubled, braking force must be doubled
 If speed is doubled, braking force must be increased
4 times
 If weight and speed are doubled, braking force
must be increased 8 times
Brakes and Braking
Use of Air Pressure
• Force can multiplied by the use of air to gain
mechanical advantage
• Air can be compressed (squeezed) into a smaller
space than it will normally occupy eg in tires
• The smaller the space into which air is squeezed,
the greater the air’s resistance to being squeezed
• This resistance creates pressure which is used to
gain mechanical advantage
Brakes and Braking
Stopping Distance
• Stopping distance consists of three factors
 Driver’s reaction time
 Brake lag
 Braking distance
• Braking distance depends on
 the ability of the brake lining to produce friction
 the brake drums to dissipate heat
 the tires to grip the road
Braking distance depends on
Brakes and Braking
Stopping Distance
• Heavy vehicles require powerful braking systems
• These are obtained by use of mechanical leverage
and air pressure
• Brakes must be used keeping in mind the heat
generated by friction
• Excessive heat reduces braking effectiveness
• The heavier the load and the faster the speed, the
greater the force needed to stop the vehicle
NB: An air brake equipped vehicle, does not always
stop immediately
Air Brake Systems
Fundamentals
• Air brakes are used in heavy vehicles due to their
reliability
• They have several advantages for large multi-trailer
vehicles
• The supply of air is unlimited, so the brake system
can never run out of its operating fluid, as hydraulic
brakes can
• Minor leaks do not result in brake failures
Advantages
• Have an air tank to store sufficient pressure to stop
the vehicle if the compressor dies
• Effective than other brakes even with a leakage
• Uses air to operate the brakes, which is easily
available
• Horns and seat adjusters can be operated better
with compressed air than hydraulics
• Air couplings are easy and accessible to connect
and disconnect than hydraulic lines
• Higher braking effect and control over the system
• Less wear and tear of parts
Disadvantages
• Generally more expensive than hydraulic brakes
• Compressed air has moisture that requires an air
dryer to remove making the system expensive
• High maintenance and repair costs
• A faulty dryer causes ice to build up in the air-brake
system in winter.
• Noise in operation which can impair hearing
• A simple leakage can cause entire system failure
• Difficult to seal
• Not applicable underwater and in extreme
temperatures
Application of Air Brake System
• Suitable where there are many trailers, high speed
heavy loaded long haul vehicles
• Applicable in locomotives
• Not suitable for small vehicles due to limited space
Components of Air Brake System
A basic air brake system that can stop a vehicle has 5
main components
• Compressor - pumps air (a governor controls it)
• Reservoir/tank - store the compressed air
• Foot valve - regulates the flow of compressed air
from reservoir when it is needed for braking
• Brake chambers and slack adjusters - transfer the
force exerted by the compressed air to mechanical
linkages
• Brake linings and drums - create the friction
required to stop the wheels
They are divided into 3 categories
a. Supply System Components
b. Control System Components
c. Actuation components
Assignment 1
In groups, discuss each of these categories
Supply System Components
• Air compressor
• Air Governor
• Air Dryer
• Reservoirs
• Single Check Valves
• Low Pressure Warning System
• Safety Valve
• Drain Valve
• Pressure Protection Valve
• Regulator Valve
• Pipes
Control System Components
• Application Valve
• Relay Valves
• Quick Release Valves
• Push Pull valves
• Double Check Valves
• Electric-Pneumatic Valves
Components of Airbrake System
Actuation components
• Foot valve
• Brake chambers
• Slack adjusters
• Brake shoes
• Brake drums
Basic Air Brake Circuit
Basic Air Brake Circuit
• The compressor pumps air to the supply reservoir
• Over pressurization of the tank is protected by a safety
valve
• The governor controls the pressure in the reservoir to the
bottom of the foot valve
• When the driver depresses the foot valve, air pressure
moves to the brake chambers
• The brake chamber push rods move the slack adjusters
which rotate the S-cams resulting in the outward
movement of brake shoes causing friction that stops the
wheels
• When the driver releases the foot valve, air in the brake
chambers is vented out via the foot valve
Basic Air Brake System
Compressor and governor valve
• The compressor is in constant drive with the engine
• When pressure in the system has reached a
predetermined level, (80 - 135 psi), it is not
necessary for the compressor to pump air
• The governor places the compressor in the
unloading stage
• Thus it controls the min and max air pressure
 The function of the air governor is to monitor system
air pressure and manage the loaded and unloaded
cycles of the compressor.
 The governor assembly can be mounted directly to

the air compressor or remotely, often on the firewall
of the engine compartment.
 A truck air system must be carefully managed at
what is called system pressure. System pressure is a
range of pressures between governed pressure
(maximum system pressure) and compressor cut-in
pressure (minimum system pressure).
 Governed pressure is usually set between 120 and
130 psi on trucks, but you should note the following:
Safety valve
• Prevents excessive air pressure to build-up in the
system in the event that the governor valve fails to
cut out the compressor
• It is located on the supply side reservoir
• It vents air to the atmosphere if the pressure in the
reservoir exceeds limit (150 psi)
Air Dryer
• Remove moisture and contamination from the air
before it enters the supply reservoirs
• The dirt is then expelled into the atmosphere using
air pressure when the governor cuts the
compressor
• This is referred to as the air dryer purge cycle
• Air dryers may be filled with moisture absorbing
substance or maybe hollow with baffles to separate
moisture from the air
• Some have a heating element to prevent moisture
Air dryer parts
Reservoirs/Tanks
• These hold a supply of compressed air
• Number and size of tanks on a vehicle depends on
 number of brake chambers
 the size of the chambers
 the parking brake configuration
• Trucks are equipped with more than one reservoir
• It gives the system a larger volume of main
reservoir air
Reservoirs/Tanks
• The first reservoir after the compressor is referred
to as the supply or wet reservoir
• Other reservoirs are known as primary and
secondary or dry reservoirs
• When air is compressed, it becomes hot and as it
cools in the reservoir, it forms condensation
• Also, if oil leaks past piston rings and mixes with this
moisture, it forms sludge (oil & water)
• The sludge accumulates in the bottom of the tank
and can affect the braking system and valves
Reservoirs/Tanks
• Reservoirs are equipped with drain valves to drain
moisture/sludge that accumulate
• All reservoirs must be drained daily to minimize the
amount of water
• To drain the reservoirs, always start with the supply
reservoir on the truck
• Open the drain completely and allow all air pressure to
escape
• This permits the moisture collected in the reservoir to
drain
• Some tanks have automatic drain valves
One-Way Check Valve
• It is installed between reservoirs
• The valve allows air to flow in one direction only
and prevents air from flowing back in the system
• The valve is spring loaded and works when pressure
at the inlet side overcomes the spring pressure and
lifts the check valve ball off its seat.
• Air then passes through the valve to the outlet
• When pressure at the outlet becomes greater than
at the inlet, the check device seats preventing air
from flowing through the valve
Air Pressure Gauge
• Vehicles with an air brake system are equipped with
reservoir air pressure gauges
• The gauges are mounted in the cab, usually on the
dashboard (80 to 135 psi)
• They indicate the air pressure in the primary and
secondary/service reservoirs
•Can be combined into a single gauge
The supply reservoir usually does not
have a gauge
Brake Application Gauge
• An additional gauge which indicates the application
air pressure when the brakes are applied
• It indicates the pressure of either a foot or hand
application
Low Pressure Warning Device
• This device warn the driver if the air pressure in the
system drops below recommended levels
• Its made up of two components, visual and audible
(a red warning light and a buzzer)
• Due to overuse or leaks, the low pressure indicator
switch will turn on a red warning light on the dash
or cause a buzzer to sound at or before 60 psi
Stop Light Switch
• The stop light switch is an air-operated electric
switch
• It turns ON the brake lights when brake are applied
Foot Valve
Foot Valve
Introduction
• It is a foot-controlled pressure regulator
• Allows the selection of air pressure needed to make
a gentle or a sudden stop
• For brake application, simply press down the brake
pedal
• If foot valve is held in one position, the pressure
delivered is constant
• Releasing the foot valve allows air to be exhausted
NB: Foot valves have the ability to maintain
application pressure even though there is a leak
Components of a Foot Valve
Foot Valve Applying
• When the treadle is depressed, the application
piston is moved down
• As the piston moves down, it pushes the exhaust
valve to close
• Air pressure is allowed to enter the foot valve
through inlet ports
• This air is directed to the brake chambers
Foot Valve Applying
Foot Valve on Hold Position
• When the brake pedal is held in same position, air
pressure has a tendency to equalize
• This causes the exhaust valve to move and close
the inlet ports
• No air pressure is allowed in or out
• In this position, the brakes stay applied
Foot Valve on Hold Position
Foot Valve Exhaust Position
• When the brakes are released, the foot valve spring
causes the application piston to retract
• By retracting, it opens the exhaust valve
• This allows air to be vented out into the
atmosphere
Foot Valve Exhaust Position
Quick Release Valve
To allow brakes to release quickly and fully by
discharging the air near the brake chambers
On release of the foot valve, the air from brake
chambers should return to the foot valve to release
the brakes
This releasing action would be slow in long wheel
base vehicles due to longer lines between the foot
valve and the rear brake chambers
Relay Valve
• The foot valve is located closer to the front wheels
than to the rear wheels
• The longer the distance from the foot valve to the
rear chambers, the more time it will take before the
rear brakes apply (brake lag)
• To correct this condition, a relay valve is installed
near the rear brake chambers
• A supply pipe is connected between the main
reservoir and the relay valve
• The air line from the foot valve to the relay valve
Relay Valve
• The air in the control line dead ends at the relay
valve
• When the foot valve is depressed, signal pressure is
send to the relay valve
• Pressure from the reservoir is then directed straight
to the rear brake chambers
• Releasing the foot valve exhausts the signal air to
the relay valve, thereby cutting of air pressure to
the rear chambers
• This in turn exhausts the air in the brake chambers
by the quick release feature of the relay valve
Front Wheel Limiting Valve (Manual/Auto)
• This is usually used in slippery roads for better steering
control
• Used to reduce the braking effort of the front wheels
• The system can be achieved by installing a control valve in
the cab and a front brake limiting valve on the front axle
• For dry road surfaces, the control valve is set to normal
(braking air pressure is normal)
• For slippery road, the control valve is set to the “slippery
road” position
• In this position, the control valve cause the limiting valve to
operate and air pressure to the front brakes is reduced to
50% that delivered to the rear brakes
Spring Parking Brakes
Introduction
• Used to hold the truck stationary during parking
• During normal braking, the brakes are applied by air
pressure and retracted by springs
• In spring parking brake, the parking brakes are
applied by spring pressure and retracted by air
pressure
• The design is such that the spring parking brake
chambers are attached to the normal brake
chambers and operate through the same linkage
• It means the effectiveness of the parking brake
Spring Brake Chamber
Operation
• A control valve (square yellow button) in the cab
allows the driver to:
 exhaust air out of the spring parking brake circuit to
apply the brakes
 or pressurize the circuit to release the parking brake
• Some systems have an additional valve (blue
button) that applies only the tractor parking brakes
and not the trailer parking brakes
• The system can also act as an emergency brake
• Air pressure is unreliable for parking
• Any leaks or failure in a hose, diaphragm or air valve result
in loss of air pressure
• Spring parking brakes are mounted on the rear axles only,
not on steering ax les
• Thus parking brakes consist of an extra chamber attached
to the rear of a service brake chamber
• The service brake chamber contains the pushrod,
diaphragm and return spring
• The added chamber has a powerful coil spring arranged so
that the spring force can be applied to the brakes through
the normal service chamber pushrod
Spring Parking Brake Chamber
• Foot brake application, air pressure is applied
against the diaphragm in a service brake chamber
• This causes the diaphragm to push the rod against
the slack adjuster to apply the brakes
• At the same time, air is supplied to compress the
coil spring of the parking brake
• For spring brake actuation, air pressure that
compress the coil spring is exhausted
• The spring then expands pushing the push rod out
against the slack adjuster to apply the brakes
NB: Parking brake coil spring is under extreme
pressure, can cause severe injury or death
Spring Parking Brake- Released
• The diagram below shows a spring parking brake
chamber in the released position
• The service brake is also in the released position
• Air at reservoir pressure has been supplied to the
spring parking brake section
• The parking brake diaphragm has inflated,
compressing the main spring
NB: The control valve (yellow button) is mounted on
the dash board
Instructions are usually im print ed on the button.
• Pushing the valve allows air pressure to flow to the
spring parking brake chambers, causing the spring
parking brakes to release
• Pulling the valve out exhausts the air pressure
against the spring parking brake chamber, causing
the brakes to apply
• Some systems use a switch, so that flipping it in one
direction applies the spring parking brakes and
flipping it in the other direction releases them
NB: Instructions are imprinted on the button/switch
Service Brakes Applied
• The driver has applied the foot valve

• Air pressure is supplied to the service brake port,
inflating the service brake diaphragm
• Air pressure in the spring parking brake chamber
keeps the spring parking brakes off
Service Brakes Applied
Spring Parking Brake Applied
• If the parking brake control valve is put in the park
position
• Air from the spring parking brake chamber is exhausted
• This causes the parking brake coil spring to expand
transmitting its force against the service brake
diaphragm, pushrod and slack adjuster applying the
brakes
NB: Avoid compounding the brakes. Always release the
spring parking brakes before making a heavy service
brake application
 It damages slack adjusters, s-cams, brake chamber
bolts, brake shoe rollers, shoes and brake drums
Spring Parking Brake Applied
Spring Parking Brake Manual Release
• Spring parking brake chambers can be manually
released (caging)
• This is done when all air is lost and the vehicle has
to be towed
NB: This is used by mechanics when making a repair
 Always block the wheels because there will be no
parking brake force at the wheel after caging
 Some chambers have a built-in release bolt while
others have a release bolt, nut and washer carried
in a bracket mounted on the chamber housing
Dual Air Systems Parking Brakes
• It has primary and secondary reservoirs
• Air is supplied to the control valve from the tank
that has the highest pressure
• It is achieved by the use of a two-way check valve
(shuttle) which draws air from the tank with the
highest pressure
• This arrangement ensures that the parking brakes
do not automatically apply if there is a total loss of
pressure from either tank
Dual Air Systems Parking Brakes
Dual Systems Partial System Failure
• If there is a loss of air from the primary tank
• The two-way check valve moves so that secondary tank
supplies the parking brake control valve
• In this case, the parking brakes do not apply
automatically
• Other trucks with dual air systems have a spring brake
modulator
• This device senses a loss of pressure in the primary
circuit
• When service brakes are applied, air is exhausted from
the parking chambers in proportion brake application
NB: This helps to bring the vehicle to a halt smoothly
Dual Systems Partial System Failure
Truck-Trailer Air Brake Systems
Introduction
• To understand the basics of truck-trailer air brake
systems, it is best to start with the trailer
• A trailer has many of the components found on a
truck except the air compressor
The trailer rely on the truck for two things:
 compressed air to fill the trailer reservoirs
 commands to apply and release brakes
• To accomplish this, two air line connections are
used
Tractor-Trailer Air Brake Systems
• Supply/emergency line (red)- supply trailer
reservoir with air at full truck reservoir pressure
• Control/service line (blue) - carry control signals
from the truck
Air Tubing and Line Colors
• Green - Supply and primary brake
system
• Red - Secondary brake system
• Brown - Parking, Emergency, Spring
brakes governor control circuit
• Black - Accessory system, suspension
system
• Blue - Suspension system some buses

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AIR BRAKE SYSTEM FOR HEAVY

 The governor assembly can be mounted directly to

• The driver has applied the foot valve

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