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Air Tank Capacity Requirements
airbrakes The air tank stores air pressure for the service circuit, sized to the brake chamber air volume required. Tanks are hydrostatically tested and must provide a minimum number of full brake applications.
Key Rules
- ✓Tanks are hydrostatically tested to handle at least five times cut-out pressure or 500 PSI (3,448 kPa), whichever is greater
- ✓Tank capacity must provide minimum 12 full service applications for power units
- ✓Tank capacity must provide minimum 8 full service applications for trailers
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Pressure Gauges and Low Air Alarm
airbrakes Pressure gauges measure air in the two tractor service tanks (primary and secondary). Trailer tanks receive air from the tractor tank with highest pressure. The low air alarm activates below 60 PSI.
Key Rules
- ✓The low air alarm is set to activate if air pressure drops below 60 PSI (414 kPa)
- ✓Sending units tend to activate the alarm around 70 PSI (483 kPa)
- ✓Trailer service tanks receive air from the tractor service tank with the highest pressure
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CVSA Out-of-Service Standards
airbrakes The Commercial Vehicle Safety Alliance (CVSA) standardizes commercial vehicle inspections so defects are applied equally throughout North America. The out-of-service standard for low air is defined by minimum pressure thresholds.
Key Rules
- ✓CVSA out-of-service standard is minimum 55 PSI (310 kPa) or half of governor cut-out pressure, whichever is less
- ✓If either the audible or visual warning device works, the vehicle is not placed out-of-service
- ✓CVSA standardizes inspections so defects are applied equally throughout North America
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Brake Chambers Convert Air to Force
airbrakes Brake chambers convert air pressure into mechanical force, marking the end of the air system and beginning of mechanical linkages. Two factors affect conversion: brake chamber size and applied air pressure. Force equals pressure multiplied by surface area.
Key Rules
- ✓Two factors affecting conversion are brake chamber size and applied air pressure
- ✓10 PSI (69 kPa) applies 10 pounds of force onto a single square inch
- ✓Force = air pressure multiplied by diaphragm surface area
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Brake Chamber Sizes
airbrakes Brake chambers are sized by the OEM but air pressure is controlled by the driver. Steering axles typically use Type 20 (20 sq in / 129 sq cm diaphragm); load bearing axles typically use Type 30 (30 sq in / 194 sq cm).
Key Rules
- ✓Type 20 = 20 square inches diaphragm, typical for steering axles
- ✓Type 30 = 30 square inches diaphragm, typical for load bearing axles
- ✓Brake chambers are sized by OEM; air pressure is controlled by the driver
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Control Valves Operation
airbrakes Control valves manage air flow from tank to chambers using two internal valves: an inlet (air from tank to chambers) and an exhaust (air from chambers to atmosphere). They work the same regardless of activation method.
Key Rules
- ✓When released: inlet is closed and exhaust is open, leaving chambers open
- ✓When applied: exhaust closes and inlet opens, applying service brakes
- ✓In hold/balance position: both inlet and exhaust are closed, capturing application air
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Relay Valves Reduce Air Lag
airbrakes Relay valves are installed in the axle group area to provide fast air delivery, reducing the lag that would occur if air had to travel from cab-mounted valves. They can be tank-mounted (trailers) or frame-mounted (drive axles).
Key Rules
- ✓Relays are mounted in the service tank (typical of trailers) or on the frame (typical of drive axles)
- ✓The driver sends a control signal to the top of the relay to trigger application
- ✓All vehicles must maintain air pressure control signals even with electronic braking systems
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Independent Service Brake Circuits
airbrakes Every axle group has its own independent service brake circuit and they all work essentially the same way. Some trailer OEMs fit a circuit per axle while others outfit one circuit for the complete axle group.
Key Rules
- ✓Every axle group has an independent service brake circuit
- ✓All service brake circuits work essentially the same way
- ✓A tridem axle group might have three separate service brake circuits
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Check Valves Protect Service Tanks
airbrakes Check valves protect the service tanks from air supply failure. Every service tank on every axle group is equipped with one. AD-IS systems use pressure protection valves built into the module.
Key Rules
- ✓Every service tank on every axle group is equipped with a check valve
- ✓Check valves protect service tanks from air supply failure
- ✓AD-IS systems use pressure protection valves built into the module
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Long Stroke Brake Chambers
airbrakes Long stroke chambers have more total stroke before the push plate bottoms out. They have square inlet ports and are not interchangeable with regular chambers.
Key Rules
- ✓Standard Type 30 has total stroke of 2½ inches (64mm); long stroke has 3 inches (77mm)
- ✓Long stroke chambers have square inlet ports
- ✓Long stroke chambers are not interchangeable with regular chambers
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Application Air Flow and Pressure Drop
airbrakes When brakes apply, air flows from tank to chambers and the gauge drops, but no air volume is lost from the system. When held applied, both valves stay closed maintaining chamber pressure.
Key Rules
- ✓When the control valve is first applied, air pressure in tank and gauge drops but no air volume is lost
- ✓When held applied, both inlet and exhaust valves close to maintain chamber pressure
- ✓When released, inlet closes and exhaust opens, releasing chamber air to atmosphere
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Quick Release Valves
airbrakes Quick release valves allow air to exhaust quickly from the chambers rather than travelling all the way back to the control valve. Air may also exhaust through ABS modulators if equipped.
Key Rules
- ✓Air exhausts through the quick release valve for faster release
- ✓Air may also exhaust through the ABS modulators if equipped
- ✓Quick release valves reduce release time in the service system
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Crack Pressure and Brake Timing
airbrakes Crack pressure is the control air pressure that must reach the top of a relay before it opens. Different crack pressures regulate service brake timing down the vehicle length so brakes apply in coordination.
Key Rules
- ✓Crack pressure is control air that must be delivered before the relay starts to open
- ✓Relays closer to the cab have higher crack pressures to allow control air time to reach the rear
- ✓Service line booster relays have zero crack pressure to avoid reducing the signal
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Straight Truck and Super-B Service Systems
combination In a straight truck the primary circuit (green) serves the drive axle(s) and secondary (red) serves the steering axle. In a Super-B, four axle groups have independent service circuits including tank-mounted relays for trailers.
Key Rules
- ✓Primary (green) circuit serves the drive axle(s); secondary (red) serves the steering axle
- ✓Service circuits are connected with control lines
- ✓Trailers use tank-mounted relay valves in the service circuit
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Air Line Diameters
airbrakes Large air volumes flow through larger hoses while control signals flow through smaller diameter lines for faster delivery. Different line sizes are used for different functions.
Key Rules
- ✓Tank-to-relay volume lines are typically 5/8 to 3/4 inch (16 to 19 mm)
- ✓Brake signals move through 3/8 inch (10 mm) lines; governor signals through 1/4 inch (7 mm)
- ✓Transmission signals move through 1/8 inch (4 mm) lines