*AIR BRAKING SYSTEM COMPONENTS*

#.. AIR COMPRESSOR:

-It is the compressor that pumps air from the atmosphere to the air storage tank and is driven by the
engine through a belt drive.

#.. AIR COMPRESSOR GOVERNOR:

-It is the governing device used in the air brake system that controls the compression pressure of the air
that is pumped to the air storage tank through the air compressor.

#.. AIR DRYER:

-It is the device used to remove moisture content from the air coming from the atmosphere to prevent
the lines and air storage from water condensation that can cause brake failure such as during winters
due to the freezing of that condensed water..

#.. AIR STORAGE (RESERVOIR):

-It is the tank that is used to store the compressed air sent by the compressor, this storage always has
enough amount of compressed air so that the brakes can be applied several time and also prevents the
brake failure when the air compressor shows malfunctioning.

#.. BRAKE PEDAL:

-It is the mechanism that is operated by the driver and is used to actuate the brakes in order to stop or
decelerate the vehicle. Brakes, when pressed, pushed the compressed air which in turn applies brakes to
the moving tire.

#.. DIRT COLLECTOR:

-It is the device that is placed inside a brake pipeline at a place where a branch is separated and taken
off to the triple valve which removes dirt from the air before sending it to the triple valve..
#.. BRAKE CYLINDER OR BRAKE CHAMBER:

-It is the device that consists of a cylinder and piston over which the compressed air pressure is applied
in order to push brake pads which in turn makes frictional contact with the disc or drum in order to stop
or decelerate the vehicle.

#.. BRAKE VALVE OR TRIPLE VALVE:

-The actuation and release of brake require continuous release and building of pressure inside the brake
lines and brake cylinder according to the motion of the brake pedal this is done by the triple valve used
in the air brake system.

#.. BRAKE DRUM:

Brake drum is the component through which the brake force due to frictional contact between brake
pads and drum lining is transferred to the wheel in order to stop or decelerate the vehicle, Outer surface
of the brake drum consisting of drum lining rotates with the wheel and the inner part consisting of brake
shoes stays in its state of rest when the brake pedal is not pressed.

Note – Usually brake drums are used in air brake system but with the suitable arrangement, disc brake
can also be used in the air brake system.

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Some Air Braking System Valves

#..QUICK RELEASE VALVE - is there to rapidly release air from actuators (chambers)when line pressure is
released..

#..CHECK VALVE -allow flow of air in one direction (normally fitted at the entry of the reservoir to
prevent return of air to the supply components)

#..SAFETY VALVE -protects the system from excessive buildup of air pressure in the reservoir in the
event of other valves regulating pressurised air failing )
#..PRESSURE PROTECTION VALVE -is used to isolate auxiliary air system from the brake system...this is
done to preserve air for braking in the event that the auxiliary system develops a major leak..

#..PRESSURE REDUCING VALVE/LIMITING VALVES - used in the circuit to control or provide a set
pressure lower than the system pressure

#..RELAY VALVE -it reduces brake application response time (especially pamaTruck aya with long
wheelbase ) also ..

#..RELAY EMERGENCY VALVE- speeds up the application and release of trailer brakes and also allows
automatic application of the trailer brakes in the event of air pressure in supply line to trailer reservoir
falls low..

#..DIFFERENTIAL PROTECTION VALVE -it prevents simultaneous application of service and spring brakes

#..VARIABLE LOAD VALVE/LOAD SENSING VALVE- it ensures that the brake force is proportional to the
load on the axle..

#..HAND OPERATE VALUE- generally it's made to operate the park brakes

#..DUAL FOOT VALVE -used to control the system air pressure , during application and release of the
brakes..

#..GOVERNOR VALVE- it acts as metering valve which can cause the compressor to stop or become
inactive for a moment when the set pressure reached , unlike the unloader valve it allows the pump to
operate but exhausting air into the atmosphere..

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#..Design and function

-A compressed air brake system is divided into a supply system and a control system..The supply system
compresses, stores and supplies high-pressure air to the control system as well as to additional air
operated auxiliary truck systems (gearbox shift control, clutch pedal air assistance servo, etc.).

Supply system:

-The air compressor is driven off of the engine either by crankshaft pulley via a belt or directly off of the
engine timing gears. It is lubricated and cooled by the engine lubrication and cooling systems.
Compressed air is first routed through a cooling coil and into an air dryer which removes moisture and
oil impurities and also may include a pressure regulator, safety valve and a smaller purge reservoir. As
an alternative to the air dryer, the supply system can be equipped with an anti freeze device and oil
separator. The compressed air is then stored in a reservoir (also called a wet tank) from which it is then
distributed via a four way protection valve into the front and rear brake circuit air reservoir, a parking
brake reservoir and an auxiliary air supply distribution point. The system also includes various check,
pressure limiting, drain and safety valves.

Control system:

-Th control system is further divided into two *service brake circuits:* , the *parking brake circuit* and
the *trailer brake circuit* .. This dual brake circuit is further split into *front and rear wheel circuits*
which receive compressed air from their individual reservoirs for added safety in case of an air leak..

-The service brakes are applied by means of a brake pedal air valve which regulates both circuits.

-The parking brake is the air operated spring brake type where its applied by spring force in the spring
brake cylinder and released by compressed air via hand control valve.

-The trailer brake consists of a direct two line system: the supply line and the separate control or service
line.. The supply line receives air from the prime mover park brake air tank via a park brake relay valve
and the control line is regulated via the trailer brake relay valve.

-The operating signals for the relay are provided by the prime mover brake pedal air valve, trailer service
brake hand control and the prime mover park brake hand control..

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#..When the driver of a vehicle presses the brake pedal in order to stop or decelerate the vehicle the
following processes takes place:

-When the driver starts the engine the brake compressor starts as it is driven by the engine which in turn
starts compressing the atmospheric air and through the compressor governor this compressed air with
optimum pressure is sent to the compressed air reservoir which always has some amount of air stored
from the previous cycle.

-When the driver presses the brake pedal the outlet valve of the triple valve closes and inlet valve opens
up which in turn gives passage to the compressed air from the reservoir to pass through the brake lines
of the system.

-This compressed air flowing through the brake lines is then transferred to the brake cylinder which has
a piston inside it.

-When the compressed air applies pressure over the piston inside the brake chamber, the piston moves
away from its original position which converts this pneumatic energy into the mechanical energy.

-On the wheel end of the brake cylinder, brake drums are placed inside which there is a housing of the
mechanical actuator like springs or slacks having brake pads at its outer end.

-Due to the movement of piston because of the pressure applied by the compressed air, The mechanical
actuator inside the brake drum expands which in turn pushes the brake pads in an outward direction in
order to make frictional contact with the rotating drum lines.

-With this frictional contact between brake pads and rotating, drum lines brakes are applied to the
wheels in order to stop or decelerate the vehicle.

#..APPLICATIONS

-Due to its property of preventing brake failure air brakes systems are widely used in various vehicles
but in heavy vehicles like trucks and buses due to the government vehicle regulations, the air brake
system is mandatory.

#.. It is used in railways

#..Most trucks and busses on the road today use air brake systems..
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How to adjust brakes on vehicles  with  Air braking System:

(On Manually adjusted systems,, some are automatically adjusted)

-Right, you take all necessary tools including a trolley jack or th recommended tonnage bottle jack,
scissor type of jack hariite kumatrucks rinokukuvadzisa coz th weight of th vehicle wil be too much)..

-Start th vehicle kut mweya uzare mumatank, and inspect for any air leakages, be sure the compressor &
th deshboard is working correctly, (th pressure gauge to be precise),, if th gauge is not going up but
working well together wth th compressor then locate th unloader valve, use an allen key or th correct
tool to adjust /increase pressures by screwing th adjuster in then lock it ..After all is now well, keep on
running  th engine until all th tanks are full wth air, till th release valve releases pressure ..yu then move
your truck/vehicle to a workable environment,  chock both front and rear sides of th wheels (safety is
very important when doing such exercises cause injuries or fatal myt be th result if yu not obey it),, Then
release th hand/park brake (put it on off position by moving th handbrake lever downwards or towards
th flow),, Jack up any of th rear wheel till it is off th ground zvekuti rinotenderera,, Then go underneath
th vehicle check for th slack adjuster ,use th correct size of th spanner to rotate th adjusting bolt in th
direction wch moves th push rod toward th brake booster/chamber till its tight, yu then undo th adjuster
by doing a quarter turn going opposite direction, then remove th inspection cover on th back plate of th
drum, select th correct size of th feeler gauge insert it between th shoe and th drum thru tht inspection
cover to check th clearance, if yu dnt know th manufacturers specs or if yu dnt have a feeler gauge, Try
to turn th wheel by your hands uchinzwa kut mabrake akabata sei  uye arikurema here(the wheel must
complete a revolution when turning it asi kana uine simba rekunyepedzera unoita false adjustment
nhaika)..If they are stil tight yu can redo another quarter turn till yu meet th desired position or it rotates
freely competing an obit. .Go to th next wheel do th same procedure till yu finish all th wheels.. Then
road test th vehicle or machine , move it at a reasonable speed and first apply foot brakes atleast 2
times then if they are working or actuating correctly yu then move it again and apply hand brake
ichifamba kudaro and see if th hand brake is applying correctly..If all is now well and correct, listen or
trace for any air leaks again, if theres any then yu had to attend and fix it buddy..

-But some vehicles doesnt hve th adjusting screw or bolt on th slack adjuster eg mamwe maDAF
especially kumatrailer uko..so yu loosen th nut wch locks th slack splines/teeth to th shaft, push th slack
towards th chamber then use a pipe wrench/ monkey wrench (Bhobhojani) to turn it till yu meet th
desire position ..mesh th slack to shaft on tht positon and tighten th lock nut..check kuti anenge achibata
zvakadii..

FURTHER RESEARCH IS ADVISABLE

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Non-Boosted Hydraulic Braking System*

(Shoe and drum type)

#..LAYOUT:

-Brake fluid reservoir

-Master cylinder (either single or tandem type)

-Fluid lines/tubes

-Wheel cylinders

-(or accumulator/ABS pump)

-Shoes

-Drums

#..OPERATION:

-When th driver depresses the brake pedal to make brake application, the piston in th master cylinder
exerts pressure on an enclosed column of fluid whch fills the entire brake system..

-The fluid is already in the line and tubes of this system and th addition of more fluid from th M/cylinder
builds up pressure..In accordance to PASCAL'S Law, equal pressure is exerted at all wheels, as th
pressure is transmitted thru the fluid from the master cylinder to cylinders at each wheels..
-Inside the wheel-cylinders are two pistons and the fluid enters th wheel cylndrs at th centre btwn the
pistons..

-The further th pedal is pressed, the more fluid is moved thru the master cylnder and through the tubes
leading from that cylinder..

-Th fluid must go somewhere bcoz it is almost non-compressible, so it is forced btwn the wheel cylinder
pistons wch are not fastened to anything..

-These pistons moving away from each other, are pushed against th upper ends of the brake shoes,
which in turn are pushed against the brake drums of the wheels..This wil stop the wheels from
revolving..

FURTHER RESEARCH IS ALWAYS ADVISABLE..

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RECAP_

Antilock Braking Systems (ABS)

-Most commercial vehicles use electronic Antilock Braking System (ABS) to help improve braking when
excessive wheel slip, or wheel lock-up, is detected.

-Electronic Control Units (ECUs) use patented technology to monitor wheel speeds (on all wheels
equipped with speed sensors) and use ABS modulator valves to adjust or pulse the braking force being
applied..These valves operate many times per second during an ABS event..

- ABS typically improves stability and steerability, and also reduces stopping distances on most surfaces..

-In addition to the ABS features above, some advanced ECUs have a drag torque control feature which
reduces driven-axle wheel slip (due to driveline inertia) by communicating with the engines controller
and increasing the engine torque..

Antilock Traction Control

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Types of braking systems:

-Hydraulic braking system (Non-Boosted, Boosted and Full Power)

-Electromagnetic braking system

-Servo braking system

-Pneumatic/Air braking system

-Mechanical braking system..

Categories: (Frictional type)

-Drum and shoes

-Disc and pads (caliper assembly)

-Wet/Oil brake discs

BLEEDING AIRLOCK ON A HYDRAULIC BRAKING SYSTEM

#.._SINGLE LINE_:

-START AT THE WHEEL FURTHEST FROM THE MASTER CYLINDER.

#.._TANDEM  LINE_:

-START AT THE WHEEL CLOSEST TO THE MASTER CYLINDER..

#.._BLEEDING BRAKES WITH THE AID OF A HELPER_..

-PLACE A CLEAN GLASS CONTAINER ON THE FLOOR AND PUT THE FREE END OF THE TUBE INTO IT

-POUR ENOUGH BRAKE FLUID INTO IT TO COVER THE END OF THE TUBE

-LOOSEN THE BLEED NIPPLE AND GET SOMEONE TO PUMP THE PEDAL

-WATCH THE TUBE FOR AIR BUBBLES AND ONCE IT CLEARS UP GET THE HELPER TO KEEP THE PEDAL
DEPRESSED AND CLOSE THE NIPPLE

-THE MASTER CYLINDER MIGHT EMPTY AFTER JUST A FEW PUMPS SO KEEP A EYE ON THE LEVEL AND
KEEP TOPPING UP

-MOVE ONTO THE NEXT NIPPLE FOLLOWING THE SAME PROCEDURE..

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