Air Brake

Systems
 Introduction
The purpose of an air brake system on heavy duty vehicles is to convert air pressure to
mechanical energy to activate the foundation brakes. Federal Motor Vehicle Safety Standard
(FMVSS) 121 dictates how this is to be done for over-the-road vehicles.
The purpose of this presentation is to help you construct Meritor WABCO Truck and Tractor air
systems. It will also help you identify air system components and understand how they relate
to FMVSS 121.
NOTE: The systems described in this workbook are generic air brake systems.
Included in this presentation are:
Truck Systems
• Air Supply Air Brake System Color Key
• Secondary Service
COLOR KEY
• Primary Service
SUPPLY
• Parking
SECONDARY
• Anti-Compounding PRIMARY
• Emergency (Prior to 3/1/98) PARK / EMERGENCY
• Emergency (After 3/1/98) TRAILER CONTROL
TRAILER SUPPLY
Tractor / Trailer Systems
• Tractor Parking & Trailer Air Supply
• Trailer Control
For additional information, call ArvinMeritor's Customer Service Center at 800-535-5560
Truck Air Supply System
Compressor
The compressor supplies all of the air for the brake
system and any accessory requiring air. Compressors
rely on the vehicle's engine to be driven, cooled,
lubricated and sometimes for an intake air source.
It works on the same principle as a piston engine.
Meritor WABCO has two models: a 318 single
* cylinder and a 636 dual cylinder. Both have reed type
valving and a sliding leaf valve unloader.
FMVSS 121 requires that a compressor be of
sufficient capacity to increase air pressure in the
supply and service reservoirs from 85 p.s.i. to
100 p.s.i. when operating at maximum R.P.M. in
approximately 25 seconds.

To prevent compressor problems always maintain an

unrestricted area at the compressor inlet and
discharge.

* Meritor WABCO has both single and twin cylinder

compressors to meet your air requirements.
Truck Air Supply System
Air Dryer
Air dryers are not required, but are common on most
air braked vehicles today. The Meritor WABCO air
dryer has a spin-on desiccant. The dryer's main job is
to remove moisture and contaminants which are
created while compressing air. Two basic styles
available: a system purge style and an external purge
style. Both systems use single cartridge designs and
are available in a 1200 and 1800 model. The system
purge style uses air from the supply (wet) and
secondary tanks to purge (back flush) the dryer. The
external purge style uses air from its own external
mounted tank which is isolated from the brake system.

All desiccant style dryers require regular

maintenance (desiccant cartridge).
Meritor WABCO also has a twin dryer available for
high air volume use vehicles, greater than 25 cfm.
Truck Air Supply System
Supply Tank
The supply tank (wet tank) is needed to collect any
moisture or contaminants not removed by the dryer
and to make up a portion of the total storage volume
required by FMVSS 121.
The supply tank can also be used to indicate when the
dryer requires service.
Note: A supply tank is not required if the primary and
secondary tanks both have automatic or manual drain
valves.
Truck Air Supply System
Pressure Relief Valve
The pressure relief valve, also known as a pop-off or
safety valve, is needed to protect the system from
excessive pressure.

Most valves are pre-set to open at 150 p.s.i.

Truck Air Supply System
Automatic / Manual Drain Valve
Drain valves (spitter valves) are required on
primary and secondary reservoirs if the vehicle is
not equipped with a supply (wet) tank. The
automatic drain valve works on an internal
pressure differential which means the valve
momentarily expels (spits) moisture every
15-18 p.s.i.. Most drain valves are equipped with a
manual drain and are available in either heated (12
volt) or non-heated versions.
Truck Air Supply System
Low Pressure Switch
Low pressure switches are required by FMVSS 121 to
give the driver a visual indication, other than a gauge,
anytime system pressure is below 60 p.s.i. when the
ignition is in the on position. By regulation it must be
visual but can be audio and visual.
Truck Air Supply System
Governor
The governor is needed to control the compressor's
out-put and purge the dryer. The governor is basically
an on / off switch, but is adjustable like a regulator.

FMVSS 121 requires that for buses built after

March 1, 1997 the cut-in pressure must be 85 p.s.i. or
greater, and for truck / tractors 100 p.s.i. or greater.

A governor's typical operating pressure range is 25

p.s.i. i.e., 130 / 105 p.s.i. (cut-out / cut-in).

When one end of the operating range is adjusted, the

other end changes approximately the same amount.
Truck Air Supply System
Discharge
UNL
RES
Should not be
more than1/4” ID

Inlet
UNL

Inlet
Delivery
Truck Secondary Service System
Pressure Control Check Valve (PCCV)
The pressure control check valve is used on the
secondary reservoir in conjunction with a system
purge style air dryer. The PCCV allows air to flow
freely into the system reservoir and back to the supply
(wet) tank above 95 p.s.i. The PCCV is typically
installed on the service reservoir in place of the one-
way check valve. The PCCV maintains minimum air
pressure in the service reservoir and allows the air
dryer to use 10 p.s.i. of air volume from the supply
(wet) tank and secondary tank during regeneration.

FMVSS 121 requires that each service reservoir

system be protected against loss of air pressure due
to failure or leakage in the system between the
service reservoirs and the source of air pressure by a
check valve or equivalent device.
Truck Secondary Service System
Secondary Service Tank
The secondary service tank is used to provide an
isolated storage area for air to be used for service and
emergency braking.

The combined volume of all service and supply

reservoirs must be at least 12 times the combined
volume of all service chambers at maximum stroke.
Truck Secondary Service System
Manual Drain Valve
The manual drain valve is required by FMVSS 121 to
be on each reservoir of an air brake system so the
driver can drain the system daily.
Truck Secondary Service System
Air Gauge
The air gauge is required by FMVSS 121 so the driver
can monitor the pressure for each service system
when seated in the normal driving position. The
manufacturer can install two separate gauges, one for
primary and one for secondary, or they can install a
duplex (dual needle) gauge.
Truck Secondary Service System
Dual Foot Control Valve
The dual foot control valve provides the driver
modulated control of the vehicle's service brakes.
There are three different styles of dual foot control
valves. One thing common to all is that the primary
section is normally the section closest to the pedal and
is mechanically applied. The secondary is the furthest
section away from the pedal and is controlled from
primary air. If primary air is not present (failed primary
system), the secondary is mechanically applied.

Generally, the primary section applies 3-5 p.s.i. of air,

prior to the secondary section starting to apply.
Most (but not all) manufacturers send secondary air to
the steer axle, primary air to the drives and dominant air
to the trailer.
Truck Secondary Service System
Quick Release Valve
The quick release valve releases air pressure from the
air chambers quickly to assist in meeting FMVSS 121
release timing requirement. Some quick release
valves are used to aid in balancing application
pressure. Ensure you are using the correct one when
replacing quick release valves.
Quick release valves may have a differential pressure.
Differential pressure is the difference between the
inlet pressure compared to the outlet pressure.

Example: This quick release valve has an approximate

3 p.s.i. differential. If you put 10 p.s.i. to the inlet, it
delivers approximately 7 p.s.i. etc.

The letters and numbers QRV-030 identify this valve.

They can be found stamped in the body next to the part
number or on the tag.
Truck Secondary Service System
ABS Modulator Valve
The ABS modulator valve modulates the air pressure
in the brake chamber if wheel lock-up is imminent.
During normal braking air passes directly through the
valve. If the ABS is actuated the valve will modulate
chamber pressure.

Additional ABS modulator valve information is

available in Meritor WABCO maintenance manuals.
Truck Secondary Service System
Service Chambers
A service chamber is used during braking and
converts air pressure to linear motion or mechanical
force.
Service chambers are available in standard and long
stroke models. Normally, the port outside diameter of
a standard stroke chamber is round. In the long
stroke stroke chamber the port outside is square plus
the chamber is identified as long stroke.

The components are not interchangeable.

Truck Secondary Service System
Manual Slack Adjusters
Manual slack adjusters convert linear motion from the
chamber to rotary motion of the s-cam.
Manual slack adjusters are used to maintain proper
brake adjustment when replacing a chamber.
Manual slack adjusters are known as either bi-directional
or uni-directional.
A bi-directional slack adjuster can be installed either way
on an s-cam. With the adjusting nut facing toward or
away from the chamber.
A uni-directional slack adjuster must be installed with the
adjuster nut facing away from the chamber or damage
could occur.
Truck Secondary Service System
Automatic Slack Adjusters
As it's name implies, the automatic slack adjuster
does everything the manual slack does, only
automatically if properly installed.
The automatic slack adjuster saves downtime. It
should be checked periodically to ensure a problem is
not present.
Automatic slack adjusters were mandated on all new
vehicles manufactured on or after
October 20, 1994.
Truck Secondary Service System

#2
Delivery
port
#2
Supply
Port
Truck Primary Service System
One-Way Check Valve
If the vehicle is equipped with a system purge style
dryer, a PCC valve is normally used on the secondary
service reservoir and a one-way check valve is used
on the primary reservoir.
A one-way check valve allows air to flow from the
supply source into the primary reservoir, but does not
allow air to flow in the opposite direction.
FMVSS 121 requires the service reservoirs to be
protected against the loss of air pressure.
If a vehicle is not equipped with a system purge style
dryer, both the primary and secondary reservoirs will
have one-way check valves.
Truck Primary Service System
Primary Service Tank
Same as secondary service system and is also used in
the primary service system.
Manual Drain Valve
Same as secondary service system and is also used in
the primary service system.
Air Gauge
Same as secondary service system and is also used in
the primary service system.
Dual Foot Control Valve
Same as secondary service system and is also used in
the primary service system.
ABS Modulator Valve
Same as secondary service system and is also used in
the primary service system.
Manual Slack Adjusters
Same as secondary service system and are also used in
the primary service system.
Automatic Slack Adjusters
Same as secondary service system and are also used in
the primary service system.
Truck Primary Service System
Service Relay Valve
A service relay is utilized to send a modulated signal
from the foot valve to the service chambers when
sending air longer distances or for better air balance.
A relay valve works much like a quick release valve
except it has a reservoir line which is not on a quick
release. The reservoir or supply line is connected
directly to a reservoir.
Whereas quick release valves may have differential
pressure relay valves may have crack pressure. Crack
pressure is similar to differential pressure except that
differential pressure is throughout the whole range of
the valve. Crack pressure is only present in a relay
during the initial stages of the application. It is the
amount of air it takes to open the valve before it
delivers any air.
Truck Primary Service System
Spring Brakes
Spring brakes enable service braking capabilities and
parking braking capabilities from a single unit.
The push rod comes out of the service side end of the
chamber.
The other end of the spring brake is known as the
spring or emergency side. Do not mess with this end.
There is a spring with approximately 1800 lbs. of force
inside this chamber. A spring brake is the most
dangerous thing on a heavy duty truck.
Spring brakes are also available in standard and long
stroke and are identified the same as service chambers.
Truck Primary Service System
Two-Way Check Valve
Two-way check valves are used in air brake systems
to monitor two pressures and deliver the highest.

Two-way check valves are available in two different

styles:

1. Shuttle-type which is mounting sensitive -

the inputs must be horizontal.
2. Diaphragm type which is not mounting
sensitive - can be installed any way.
Truck Primary Service System
Stoplight Switch
The stoplight switch is mandated by FMVSS 121 and
requires that the brake lights activate before chamber
pressure reaches 6 p.s.i.
This switch is normally open.
Truck Primary Service System

#1 Supply
#1 Delivery Port
Port
Truck Parking System
Two-Way Check Valve
FMVSS 121 states that in the event either system
(primary or secondary) fails you still must have the
capabilities of releasing the vehicle parking brakes.
The two-way check valve meets this requirement by
having both primary and secondary system pressure
at the two-way check and allowing dominant air to
flow to the dash control valve.
Truck Parking System
Dash Valve (Yellow Diamond Knob)
The dash control valve or commonly called the push-
pull valve is needed to control the release and
application of the vehicle parking brakes.
By regulation this valve must be identified as to what it
controls and how it controls it.
The standard form of operation is to push to release
and pull to apply. Releasing delivers air pressure to
the parking chamber, releasing spring force. Applying
exhausts air pressure from the parking chamber,
applying spring force.
Truck Parking System
Quick Release Valve with Double Check
FMVSS 121 states that from the instant the driver pulls
the dash valve, the parking brakes should be 100%
mechanically applied in less than 3 seconds.
Since the quick release valve always has a zero
differential it aids in meeting FMVSS 121 application
timing of the spring brakes
Truck Parking System
Spring Brakes
How a spring brake functions:
Step #1:
With no air on the spring side or the service side,
the vehicle is parked by mechanical force.
Step #2
With air pressure on the spring side only, the
parking brakes are released and the vehicle is
ready to roll.
Step #3
With air pressure on both the spring side and
the service side, the vehicle is stopped with
service air pressure.
Truck Parking System

Two Way Check

Valve
Truck Anti-Compounding System
Quick Release with Two-Way Check Valve
The quick release with two-way check valve is used for anti-
compounding but not mandated by law.
In an air brake system anti-compounding prevents the service and
the parking brakes from being applied at the same time.
The following is an example of how much force could be produced
by a spring brake.
The spring in the spring chamber produces approximately 1800
lbs. of force. If the vehicle has 30" / 30" spring brakes without
anti-compounding, is parked and the push rod is connected to a 6"
slack arm:
1800 x 6 = 10,800 in lbs. torque
At the same time, the driver steps on the brake pedal and delivers
50 p.s.i. to the service side of the spring brake:
50 p.s.i. x 30" chamber = 1500 lbs. force x 6" slack
= 9,000 in. lbs. additional = this is compounding
Truck Anti-Compounding System (Cont'd.)
Quick Release with Two-Way Check Valve (Cont'd.)
With the preceding example, having anti-compounding as the
driver applied pressure on the service side, the same pressure
would be delivered to the spring side, releasing that amount of
spring force.
Things that could possibly break if the vehicle does not have anti-
compounding:
(1) Premature cracking or breaking of brake drums
(2) Bend chamber push rods
(3) Rip the mounting studs out of the spring brakes
(4) Break slack adjusters
(5) Break spring brake mounting brackets off the axle
Truck Anti-Compounding System
Truck Emergency System
Inversion Valve (Prior to March 1, 1998)
Meritor WABCO Production Part Number 9718990010
Meritor WABCO Service Part Number RKN28030
Required on all straight trucks and buses manufactured between
1975 and March 1, 1998. Under normal conditions, this valve
does not have to work. The only time this valve must function is
when there has been a primary system failure (reservoir to zero).
At that time, the parking brakes are released with secondary air
and the vehicle has service braking with secondary air on the
steer axle. The inversion valve receives the modulated secondary
signal from the foot valve and equally releases air pressure from
the spring chamber giving the drive axle a mechanical brake
application. As the driver disengages the brakes, a secondary
signal will re-release that mechanical application.
Truck Emergency System
New Inversion Valve (Used After March 1, 1998)
Meritor WABCO Production Part Number 9718990020
Meritor WABCO Service Part Number RKN28032
The new inversion valve is required on all straight trucks and buses
and functions exactly the same as the previous valve except it will
also function with a control line failure in the primary system.
Previous valve may be used if a two control line primary relay valve
is used.
To check either valve for function on a vehicle:
(1) With the vehicle dash valve knob pushed in and wheels
blocked, build up the air system completely.
Shut vehicle off.
(2) Drain the supply (wet) tank - see if the one-way checks are
working.
(3) Drain the primary tank.
(4) Two people are needed, one in the driver's seat, the other
back by the drive axle.
(5) The driver gradually depresses the foot valve, the technician in
the back should hear air exhausting and see the chamber push
rods extending.
(6) As the driver disengages the brake pedal, the push rods should
retract.
Truck Emergency System
Meritor WABCO Production Part No. 9718990010

Add an R-12 DC?

Truck Emergency System
Meritor WABCO Production Part No. 9718990020
Tractor Parking and Trailer Air Supply
System
Module Dash Control (Yellow Diamond
Knob & Red Octagon Knob)
The two-way check for the parking system is built internally. The
yellow diamond knob controls the application of the total vehicle
parking brakes and the release of module dash control of the
tractor parking brakes. The red octagon knob controls the release
and application of the trailer parking brakes plus the fill of the
trailer service reservoirs.

Quick Release With Two-Way Check Valve

Like a straight truck system, this valve prevents two forces from
working on the foundation brakes at the same time.
Tractor Parking and Trailer Air Supply
System
Tractor protection valves in general are required by FMVSS 121 to
protect the tractor's air system from the effects of loss of air on the
trailer or loss of trailer.
Two types are available:
(2 Line) Tractor Protection Valve
Could be automatic or non-automatic style.
Automatic style (flow sensitive); If it senses a pressure drop, it
shuts off the air automatically somewhere between 75 and 100
p.s.i.
(3 Line) Tractor Protection Valve
Could be automatic or non-automatic style.
Non-automatic style (non-flow sensitive): It will not sense any
pressure drop. It relies on the dash valve popping when the line
pressure reaches about 40-45 p.s.i.
The difference between the two line and three line tractor
protection valves other than one additional air line, is that the three
line protection valve will release the trailer's parking brakes and fill
the trailer's reservoirs 35% quicker than a two line.
Tractor Parking and Trailer Air Supply
System
(Trailer Supply) Gladhand
Gladhands are the quick couplings between the tractor and trailer
in which air passes through for the trailer.
Universal and polarized gladhands are manufactured. Universal
will connect to each other. Polarized are color coded and / or
identified service and emergency.
If I had a polarized (color coded) supply gladhand, what color
would it be?
Answer - Red
Supply is emergency (Red) - control is service (Blue)
Tractor Parking and Trailer Supply System
Tractor Trailer Control System
Hand Control Valve
Hand control valves are not required by any regulation in the U.S.
or Canada.
This valve has several slang names (Trolly Valve, Spike Valve,
Johnson Bar and Broker Valve). It allows the driver to operate the
trailer service brakes without using any tractor brakes.
There are many major fleets today who spec their tractors without
hand control valves because better stopping is accomplished with
all brakes doing their share of the work.
(2) Two-Way Check Valves
If either service system (primary or secondary) on the tractor fails,
the combination vehicle will still have service braking from the
good system on the tractor as well as the trailer system.
Tractor Trailer Control System
Stoplight Switch
The stoplight switch is required by FMVSS 121 to activate the
brake lights prior to service chamber pressure reaching
6 p.s.i.
Tractor Trailer Control System
Tractor Air System Complete