AIR BRAKE Interactive Classroom Edition (ABI-CE) Course

AIR BRAKE Interactive Classroom Edition (ABI-CE)

AIR BRAKE Interactive Classroom Edition (ABI-CE) is an air brake training and teaching resource designed for air brake service instructors teaching entry to intermediate-level air brake students and service technicians. It is also well suited for advanced air brake training for drivers. ABI-CE is a complete, presentation-ready, training package that has been carefully structured to deliver a progressive and effective learning experience.

The AIR BRAKE Interactive CE package comprises a highly detailed, full-color, 12-module, 350-page Instructor’s Reference and Presentation Guide supported by a state-of-the-art multimedia presentation.

What’s Included:

Sample Animations

The Instructor’s Reference and Presentation Guide

The Instructor’s Reference and Presentation Guide is an essential resource designed to empower presenters with comprehensive reference material and a clear, step-by-step roadmap for delivering their program effectively. This guide serves as a valuable tool, ensuring that instructors can confidently present their content with precision and consistency.

By combining with the program’s powerful multimedia support animations and visuals, you are assured of a thorough, accurate, and consistent presentation by every instructor, every time!

Available Student Workbook

Enhance your AIR BRAKE Interactive Classroom experience with our high-quality, full-color, 110-page Student Workbook. Designed to perfectly align with the structure and content of your classroom presentations, this workbook serves as an invaluable resource for students, both during and after their air brake studies. Call or e-mail us for details and pricing.

The Multimedia Presentation

The Multimedia Presentation is a powerful teaching tool that brings the operation of a modern heavy vehicle air brake system to life. With 44 voice-narrated technical and mechanical animations, paired with over 75 additional technical visuals, this presentation delivers a comprehensive and engaging learning experience.

Key highlights include:

Detailed Animations: Voice-narrated animations simplify complex concepts, making them accessible and memorable.

Enhanced Understanding: Combines audio, visuals, and animations for an immersive learning experience that ensures students grasp and retain the material effectively.

Extensive Visuals: Over 75 technical visuals provide in-depth insights into the air brake system’s operation.

This is a visual learning experience that your students will understand and remember.

Presenting the Program

You can present the entire ABI-CE program (approximately 16 classroom hours) or pick and choose what subject matter you wish to contribute and what individual visual elements you want to employ. It’s up to you.

AIR BRAKE Interactive IS NOT a re-assembly of age-old air brake training material that has been around for decades. AIR BRAKE Interactive CE employs ALL NEW and ORIGINAL MATERIAL. Its content, structure, system diagrams, technical animations, and illustrations have been carefully designed and created to reflect current air brake technology. AIR BRAKE Interactive CE will provide your students with the most thorough air brake education possible. It is the most comprehensive and effective air brake teaching resource available today.

For more information on each module, click on the “v”.

ABI-CE Content

In this module, students will gain comprehensive knowledge about The Braking Process, Foundation Brake Type, Drum Brakes, Brake Fade, Disc Brakes, Brake Application Mediums, Fluid Dynamics, Air Dynamics, Spring Dynamics, Hydraulic Brakes, Air Brake System Operation, Brake Lag, Vehicle Speed, Weight and Stopping Distances, Air System Divisions, and Air Brake System Configuration Variables.

Topics Covered:

This comprehensive module covers the essential concepts and mechanics of vehicle braking systems, ensuring a thorough understanding of both foundational and advanced topics.

Basic Physics of Vehicle Motion and Braking (How Brakes Slow and Stop a Vehicle)
• How brakes work to slow and stop a vehicle.
Brake Basics – Foundation Brake Types
• Overview of the primary braking systems.
Drum Brakes – Principal Components and Basic Operation
• Key parts and functionality of drum brakes.
Brake Fade (A Drum Brake Phenomenon
• Causes, effects, and prevention of brake fade in drum brakes.
Disc Brakes – Principal Components and Basic Operation
• Understanding the components and operation of disc brakes.
How Brakes are Applied – The Mediums Used to Activate Brake Systems
• Overview of hydraulic, pneumatic, and mechanical activation methods.
Basic Fluid Dynamics (Hydraulics)
• The role of fluid dynamics in hydraulic braking systems.
Basic Air Dynamics (Pneumatics)
• Understanding air pressure dynamics in air brake systems.
Spring Dynamics
• How springs contribute to braking system performance.
Hydraulic Brakes
• Detailed operation and applications of hydraulic brakes.
Air Brakes – Basic Operation
• Components and workflow of air brake systems.
Brake Lag
• Identifying and addressing delays in brake activation.
Brake Lag and Stopping Distance
• Exploring the relationship between brake lag and overall stopping distance.
Vehicle Speed, Weight, and Stopping Distances
• How these factors influence braking performance.
Air Brake System Divisions
• Breakdown of air brake system components and their roles.
Air Brake System Configuration Variables
• Examining how different configurations impact system performance.

In this module students will learn about the DANGERS of Compressed Air, Compressed Springs and Vehicle Inspection and Maintenance Safety.

Topics Covered:

Compressed Air, DANGER
• Understanding the risks of working with compressed air systems.
• Proper handling techniques to prevent injuries or accidents.
• Recognizing and responding to compressed air system malfunctions.
Compressed Spring, DANGER
• Identifying the dangers posed by compressed springs in brake systems.
• Safe procedures for handling and servicing components under spring tension.
• Preventative measures to avoid accidents during maintenance.
Vehicle Inspection and Maintenance Safety
• Best practices for conducting safe and effective vehicle inspections.
• Maintenance protocols to ensure safety and reliability of brake systems.
• Identifying and mitigating common hazards during maintenance activities.

In this module students will learn about Service Brake Chambers and Sizes, Diaphragm Areas & Adjustment Limits, Converting Air Pressure into Mechanical Force, Stroke vs. Application Force, Slack Adjuster Types (Manual & Automatic),Leverage & Torque and S-Cam Brakes, Wedge and Disc Brakes.

Topics Covered:

Service Brake Chambers
• How they work, Component Identification and Operation
Brake Chamber Sizes and Effective Diaphragm Areas
• Understanding the relationship between chamber size and diaphragm effectiveness.
Converting Air Pressure into Mechanical Force
• Calculating force using the formula Area × Pressure = Force.
Brake Chamber Size, Markings, Outside Diameter (OD) and Adjustment Limits
• Recognizing chamber size markings and their significance.
• Determining adjustment limits based on OD specifications.
Brake Chamber Stroke vs. Application Force
• Exploring how stroke length affects the application of force.
Slack Adjuster – Basic Function, Leverage & Torque
• The role of slack adjusters in maintaining proper brake adjustment.
• Examining leverage and torque mechanics.
Slack Adjuster Types
• Differences between manual and automatic slack adjusters (Manual & Automatic)
S-Cam Brake (Component Identification and Operation)
• Identifying components and understanding the operation of S-Cam brakes.
Wedge Brake (Component Identification and Operation)
• Component identification and functionality of wedge brake systems.
Disc Brake (Component Identification and Operation)
• Component identification and operation of disc brake systems.

In this module students will learn about Air Compressors and Drives & Mountings, Cooling and Lubrication, Air Dryers, Supply Tanks & Service Reservoirs, Alcohol Evaporators & Injectors, Governor, One-way Check Valves, Safety Valves, Drain Valves, Air Pressure Gauges, Low Air Warning systems, Supply System Operation, and Pressure Ranges and Rise Times.

Topics Covered:

Supply System – Introduction and Overview
• An overview of the air supply system’s role in air brake operation.
Air Compressor Components – Drives and Mountings
• Understanding the different types of drives and how air compressors are mounted.
Air Compressor Component Identification and Operation
• Identifying key components of air compressors and their operational functions.
Air Compressor Cooling and Lubrication
• The importance of cooling and lubrication in maintaining compressor performance.
Optional Compressor Induction System (Utilizing Turbo-Charger Boost Pressure)
• How turbochargers can be used to boost compressor efficiency.
Air Dryer Types
• Overview of different air dryer systems used to remove moisture from compressed air.
Desiccant Air Dryer – Component Identification and Operation
• How desiccant air dryers work and their components.
Aftercooler Condensing Air Dryer
• The operation of aftercoolers in condensing air dryers.
Supply Tank & Service Reservoirs
• Identifying and understanding the role of supply tanks and service reservoirs in storing compressed air.
Alcohol Evaporators & Injectors
• The role of alcohol injectors in preventing moisture freeze-up in cold conditions.
Governor
• How governors regulate air pressure within the system.
One-way Check Valve
• Function of one-way check valves in maintaining unidirectional air flow.
Safety Valve (Over-Pressure Relief Valve)
• Importance of safety valves in protecting the system from over-pressurization.
Drain Valves (Manual and Automatic)
• Understanding the function of manual and automatic drain valves in removing moisture from the system.
Air Pressure Gauges
• How air pressure gauges monitor and display system pressure.
Low Air Pressure Warning Devices
• The role of warning devices in alerting the driver to low air pressure.
Supply System Operation
• Overview of how the air supply system operates within the broader air brake system.
Pressure Ranges and Rise Times
• Understanding the importance of pressure ranges and rise times in the proper functioning of the system.

In this module students will learn about the Basic Service Brake System, Brake Control and Synchronization, Treadle Valve operation, Brake Pedal (Feedback), Relay Valves, Quick Release Valves, Brake Light Switches, Service Brake System Operation and Tandem Axle Service Brake Systems.

Topics Covered:

Basic Service Brake System – Component Identification
• Identifying key components of the basic service brake system.
Brake Control and Synchronization (Quick Release and Relay Valves)
• Understanding how quick release and relay valves work to control and synchronize brake pressure.
Treadle Valve – Component Identification and Operation
• The function and operation of the treadle valve, which regulates air pressure to the brake chambers.
Brake Pedal Feel (Feedback)
• How the brake pedal feedback mechanism provides the driver with tactile information about braking force and system pressure.
Primary (Rear) Relay Valve
• The operation of the primary relay valve, which controls air flow to the rear brake chambers.
Secondary (Front) Quick Release Valve
• The role of the secondary quick release valve in rapidly exhausting air pressure from the front brake chambers.
Brake Light Switches
• How brake light switches are integrated into the system to activate the brake lights when the brake pedal is engaged.
Service Brake System Operation
• An overview of how the service brake system operates, including air flow, pressure application, and brake engagement.
Tandem Axle – Service Brake System
• Understanding how the tandem axle brake system works, with particular attention to the synchronization of braking forces across multiple axles.

In this module students will learn about the Principal Components of a Spring Brake System, Double Check Valves, Park/Emergency Brake Valves, Spring Brake Chambers, Spring Brake Systems w/ Quick Release and Relay Valves Brake Compounding, Anti-Compounding, Service Brake Application vs. Spring Brake Application Force, Manual Spring, Brake Caging.

Topics Covered:

Spring Brake System – Introduction and Principal Components
• Overview of the spring brake system and identification of its main components.
Double Check Valve Design and Operation (Shuttle-type)
• How double check valves operate to ensure proper air flow and pressure distribution in the braking system.
Park / Emergency Brake Control Valve Operation
• The role of park/emergency brake valves in controlling the application and release of the parking and emergency brakes.
Spring Brake Chamber – Component Identification and Operation
• Understanding the components and function of spring brake chambers in the system.
Spring Brake System (Basic) with Quick Release Valve
• How a basic spring brake system works with a quick release valve to efficiently apply and release the spring brakes.
Spring Brake System with Relay Valve
• The operation of a spring brake system that includes a relay valve to improve air flow and reduce brake application times.
Brake Compounding
• The process of brake compounding, where the service and spring brakes work together to increase braking efficiency.
Basic Anti-Compounding Circuit (with Standard Spring Brake Relay)
• The role of the anti-compounding circuit in preventing the service brakes from applying when the spring brakes are engaged.
Anti-Compounding Circuit (with Anti-Compounding Spring Brake Relay)
• How an advanced anti-compounding circuit works to enhance safety by preventing unwanted brake applications.
Service Brake Application Force vs. Spring Brake Application Force
• Understanding the differences between the forces involved in service brake applications and spring brake applications.
Manual Spring Brake Caging
• The process and safety procedures for manually caging spring brakes to allow for service and maintenance.

In this module students will learn about Front Service Brake Ratio / Limiter Valves, Dry / Slippery Valves and Spring Brake Systems with Quick Release and Spring Brake Valves (Inversion Valves).

Topics Covered:

Secondary (Front) Service Brake Ratio / Limiter Valve (Limiting Valve)
• The function of the front service brake ratio/limiter valve in controlling brake pressure to prevent overloading of the front brakes.
• How this valve helps balance braking forces between the front and rear axles.
Dry / Slippery Valve
• The role of dry/slippery valves in adjusting brake pressure based on road conditions.
• How these valves optimize braking performance under dry and slippery conditions to prevent wheel lockup.
Spring Brake System with Quick Release and Spring Brake Valves (Inversion Valves)
• The operation of spring brake systems with quick release and spring brake valves (also known as inversion valves).
• Understanding how these valves help manage the application and release of spring brakes efficiently, ensuring safety and reliability during operation.

This module focuses on the trailer air supply circuit, the key valves involved, and how the tractor’s protection system interacts with the trailer’s air brake system. Students will learn the components that ensure proper air supply and safe braking for both the tractor and trailer.

Topics Covered:

Tractor Protection and Trailer Supply System – Introduction
• Overview of the tractor protection system and how it works in conjunction with the trailer air supply system.
Trailer Air Supply Circuit – Component Identification
• Identifying the components of the trailer air supply circuit and their roles in the braking system.
Trailer Air Supply Valve – Basic Function
• Understanding the function of the trailer air supply valve in regulating air flow to the trailer’s brake system.
Combination Tractor Park and Trailer Air Supply Valves
• The operation of combination valves that serve both park and trailer air supply functions.
Tractor Protection Valve
• How the tractor protection valve ensures safe operation by protecting the tractor’s air system in case of trailer separation or malfunction.
Trailer Supply and Spring Brake System Operation (Tractor Section)
• The role of the tractor section in supplying air to the trailer’s brake system, including spring brake system operation and coordination between tractor and trailer brakes.

This module covers the key components and operations of the trailer service brake control system, including the double check valve, stop light switch, and trailer brake hand valve (spike). Students will learn how these components function together to ensure safe and effective trailer braking.

Topics Covered:

Double Check Valve / Stop Light Switch Function
• The role of the double check valve in maintaining consistent brake pressure.
• How the stop light switch operates to activate the trailer’s brake lights when the brakes are applied.
Trailer Service Brake Control System Components
• Identifying and understanding the components that make up the trailer service brake control system.
• How each part contributes to controlling the braking force applied to the trailer.
Trailer Service Brake Control System Operation
• How the trailer service brake control system works to synchronize braking between the tractor and trailer.
• Understanding the air flow and pressure regulation that ensures efficient and balanced braking.
Trailer Brake Hand Valve (Spike) – Introduction, Warning
• An introduction to the trailer brake hand valve (spike) and its purpose.
• The warning about its proper use and the potential dangers of misuse.
Trailer Brake Hand Valve (Spike) – Component Identification and Operation
• Identifying the components of the trailer brake hand valve (spike) and understanding its operation.
• How this valve is used to manually control the trailer’s brakes, especially in situations where automatic braking is not desirable.

In this module students will learn about Spring Brake Priority & Service Brake Priority Systems, Service Brake Priority systems using a Multi-Function Valve, Protected Reservoir System, Trailer Systems Summary, Pressure Gauges, Trailer Relay Emergency System, SERV System.

Topics Covered:

Trailer Brake Systems – Introduction
• Overview of trailer brake systems, including key components and how they interact with the tractor’s air brake system.
Spring Brake Priority System Component Identification & Operation
• Understanding the spring brake priority system, including the identification of components and how the system prioritizes spring brake operation in emergency situations.
Service Brake Priority System Component Identification & Operation
• The identification and operation of service brake priority systems, ensuring that service brakes are given precedence in normal braking situations.
Service Brake Priority (with Multi-Function Valve)
• How the service brake priority system operates using a multi-function valve, which integrates multiple functions (such as pressure regulation and valve control) in a single unit.
Protected Reservoir System
• Understanding the protected reservoir system and how it ensures the availability of air for the braking system in case of air pressure loss.
Trailer Systems Summary
• A summary of the various trailer brake systems, including their components, operation, and integration with the tractor’s braking system.
What Your Air Pressure Gauges Tell You and DON’T Tell You
• The role of air pressure gauges in monitoring the trailer brake system and understanding what they can and cannot indicate about the system’s health and performance.
Trailer Relay Emergency Systems (Introduction)
• An introduction to trailer relay emergency systems, designed to provide backup braking in the event of a system failure.
Trailer Relay Emergency System (Pre-121 with Service Brake Chambers Only)
• Understanding the operation of pre-121 trailer relay emergency systems that use service brake chambers only.
Trailer Relay Emergency System (Pre-121 with Service & Spring Brake Chambers
• The operation of pre-121 trailer relay emergency systems that integrate both service and spring brake chambers for enhanced safety and redundancy.
Trailer Relay Emergency System (SERV System w/ Service & Spring Brake Chambers)
• The SERV system’s operation, which integrates service and spring brake chambers to ensure emergency braking capability in case of air supply failure or other malfunctions.

This module introduces students to the Anti-lock Braking System (ABS), focusing on dispelling common misconceptions, understanding its components and operation, and learning how to use ABS properly for maximum safety and efficiency.

Topics Covered:

ABS Fiction and Facts
• Addressing myths and misconceptions about ABS.
• Clarifying the true benefits and limitations of ABS in vehicle braking systems.
ABS Components and Operation
• Identifying the key components of an ABS, including sensors, controllers, and modulators.
• Understanding how ABS operates to prevent wheel lockup during braking and maintain vehicle control.
ABS – Proper Use
• Best practices for utilizing ABS effectively in various driving conditions.
• The importance of maintaining steady pressure on the brake pedal rather than pumping the brakes when ABS is active.

In this module, students will learn about Personal Safety Equipment, Inspections of the Compressor, Air Tanks, Lines & Fittings, Gladhands, Foundation Brakes, Pre-Test Preparation and Air System Functional Tests including Pressure Build and Retention, Tractor Park (spring brake)Tractor Service Brake System & Tractor Protection Valve, Low Air Warning, Pressure Rise-Time Recovery, Governor Cut Out / Cut-In, Supply and Service Reservoir Draining, Tractor Park and Service Brake Dynamic Tests, Trailer Spring and Service Brake Dynamic Tests, Brake Chamber Stroke, Brake Adjustment and Mark & Measure, Measure & Re-measure Procedures, Adjusting Manual Slack Adjusters, Automatic Slack Adjusters and a review of Basic Spring and Service Brake System Function.

Topics Covered:

Visual Inspections:
Introduction and Personal Safety Equipment (In Pre-Engine-Start Procedures)
• Importance of safety gear and best practices during inspections.
Compressor Inspection
• Key steps for inspecting the air compressor and identifying potential issues.
Air Tanks, Lines and Fittings, Gladhands
• Visual checks for leaks, damage, or improper connections.
Foundation Brakes
• Inspection of brake components for wear, damage, or misalignment.
Pre-Test Preparations (Before Starting the Vehicle)
• Preparing the vehicle and systems for functional testing.
Air System Functional Tests:
Initial Pressure Build and Retention
• Assessing the system’s ability to build and retain air pressure.
Tractor Park (spring brake) System
• Testing the tractor’s spring brake for proper function.
Tractor Service Brake System (and Tractor Protection Valve)
• Evaluating service brakes and tractor protection valve operation.
Low Air Warning System
• Ensuring the warning system activates at the correct pressure levels.
Pressure Rise-Time Recovery and Governor Cut-Out
• (85 – 100 PSI and Governor Cut-Out): Measuring pressure build-up speed.
• (50 – 90 PSI and Governor Cut-Out): Confirming system efficiency during pressure recovery.
Compressor Cut-in
• Validating compressor activation and pressure maintenance.
Supply and Service Reservoir Draining
• Procedures for draining air reservoirs and checking for contamination.
Tractor Park and Service Brake Dynamic Tests
• Real-world testing of the tractor’s braking systems.
Trailer Supply, Spring, and Service Brakes
• Inspection and testing of trailer brake systems.
Trailer Spring and Service Brake Dynamic Tests
• Verifying the dynamic performance of trailer brakes.
Brake Chamber Stroke and Adjustment:
Brake Chamber Stroke (A Crucially Important Adjustment)
• Understanding the critical role of brake chamber stroke in braking performance.
Brake Stroke Inspection and Adjustment (Before Checking Brake Chamber Stroke)
• Procedures for accurate inspection and adjustment of brake stroke.
Brake Adjustment Inspection:
Brake Stroke Inspection – Introduction, Test Preparations and Equipment
• Preparing for accurate brake adjustment inspections.
Brake Stroke – Mark & Measure
• Step-by-step marking and measuring of brake stroke for accuracy.
Brake Stroke – Measure & Re-measure
• Ensuring precision in brake stroke measurements.
Brake Stroke Adjustment: – Introduction, Brake Component Wear & Brake Stroke
Adjusting Manual Slack Adjusters (adjustment procedures)
• Best practices for manually adjusting slack adjusters.
Automatic Slack Adjusters (12-Pack to Go – Initiating the Auto Adjust Process)
• How to activate and test automatic slack adjusters.
Review:
Basic Spring and Service Brake System Function
• Comprehensive review of spring and service brake system principles.
Learning Outcomes:
By the end of this module, students will be skilled in:
• Conducting thorough inspections of air brake systems.
• Performing functional tests and identifying system inefficiencies.
• Properly adjusting manual and automatic slack adjusters.
• Ensuring compliance with safety standards and optimal brake performance.