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AIR BRAKE Interactive General Driver Education Edition (ABI-GDE) is an all-encompassing and easy-to-use educational tool for professional driver trainers, specifically designed to offer a detailed and engaging teaching experience for students learning about air brake systems in heavy vehicles. This resource covers the full spectrum of air brake knowledge, from the fundamentals of the system’s design and operation to the more intricate aspects of routine inspection, maintenance, and adjustments required for optimal performance.

With ABI-GDE, driver trainers can present a structured, consistent, and in-depth training program that ensures their students gain a thorough understanding of the essential elements of air brake systems. The interactive format and comprehensive visual aids make complex concepts more accessible and easier to grasp, promoting faster learning and better retention of critical information.

Students will not only gain theoretical knowledge but also practical insights into the real-world application of air brake systems. This enhanced understanding helps them recognize potential issues and troubleshoot effectively, leading to safer, more skilled drivers. By integrating ABI-GDE into your training program, you are investing in the success of your students, helping them to become more competent, confident, and safety-conscious drivers who can handle the operational challenges and responsibilities associated with modern heavy vehicle air brake systems.

What’s Included:

Sample Animations






Why Air Brake Training for Drivers?

A heavy vehicle’s air brakes are its single most important safety system. Although drivers in most jurisdictions are required to know something about the air brake systems employed on their vehicles, in many cases, the required curriculum is woefully inadequate. As a result many commercial vehicle drivers simply do not know enough about their vehicle’s air brakes to recognize when they are functioning properly and when they are not.

The following supports this position:

December 2008 – The American Association of Motor Vehicle Administrators
Because no driver training standards exist, many drivers are trained primarily to pass the State knowledge and skills tests. The Task Force believes a gap exists between the testing required by the CDL program and the knowledge and skills needed to safely operate a CMV.

February 2006 – NTSB Acting Chairman Mark V. Rosenker said, “We believe that more than 500,000 vehicles equipped with air brakes may be operated by drivers who have no air brake training and therefore may not be able to operate their vehicles safely. This situation needs to change – and change quickly.”

The Solution

The solution to inadequate driver knowledge regarding air brake systems is education – thorough education as opposed to just enough knowledge to acquire a CDL.  Understanding air brake systems is not difficult, provided that instructors themselves have the knowledge required to properly teach the subject and are equipped with comprehensive and effective teaching resources. Our AIR BRAKE Interactive General Driver Edition teaching resource fits and fills that requirement like no other program available.

GDE Instructor’s Reference and Presentation Guide

The GDE Instructor’s Reference and Presentation Guide is a full-color resource designed to support instructors in delivering effective and engaging GDE presentations. This comprehensive guide spans 260 pages across 12 modules, providing instructors with the tools they need to ensure their training sessions are well-structured, informative, and impactful.

The guide serves as both a step-by-step presentation aid and a technical reference. It offers detailed instructions for each section of the GDE curriculum, allowing instructors to confidently navigate the content and deliver a cohesive learning experience from start to finish.

Included within the guide are practical tips for presentation delivery, strategies for keeping students engaged, and suggestions for interactive exercises that help reinforce key concepts. The guide also highlights specific components of the air brake system and related issues, offering in-depth explanations to ensure that instructors are equipped to address any questions or challenges that may arise during training.

Whether you’re new to teaching or an experienced instructor, the GDE Instructor’s Reference and Presentation Guide ensures that every class runs smoothly, helping you deliver a thorough and consistent message while also supporting student comprehension and retention of critical air brake system knowledge.

The Multimedia Presentation

The GDE multimedia presentation includes 44 voice-narrated air brake components and system animations and 80 additional high-quality support visuals. Ultimately, your students will see, hear, and remember how an entire modern air brake functions. It’s Visual Learning at its best!

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

ABI-GDE Content

In this module students will learn 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:

The Braking Process

  • Overview of how braking systems convert kinetic energy into heat to slow or stop a vehicle.

Foundation Brake Types

  • Examination of primary brake system designs, including their functions and applications.

Drum Brakes

  • Detailed explanation of drum brake components, operation, and common use cases.

Brake Fade

  • Insights into the causes of brake fade, its impact on performance, and how to mitigate it.

Disc Brakes

  • Exploration of disc brake systems, their advantages, and their role in modern vehicles.

Brake Application Mediums

  • Analysis of the mediums used to transmit braking force, such as hydraulic fluids and air.

Fluid Dynamics

  • Study of the principles governing fluid behavior within hydraulic braking systems.

Air Dynamics

  • Examination of air pressure and flow in air brake systems.

Spring Dynamics

  • Understanding the role of springs in brake application and release.

Hydraulic Brakes

  • Overview of hydraulic brake systems, their components, and operation.

Air Brake System Operation

  • In-depth look at how air brake systems function in heavy vehicles.

Brake Lag

  • Discussion of the delay between brake application and system response.

Vehicle Speed, Weight, and Stopping Distances

  • Relationship between vehicle dynamics and braking performance.

Air System Divisions

  • Breakdown of air brake system components into subsystems and their specific functions.

Air Brake System Configuration Variables

  • Factors affecting the design and operation of air brake systems, including vehicle type and operating conditions.

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:

Compressed Air, DANGER

  • Safety precautions and risks associated with handling compressed air in brake systems.

Supply System – Introduction and Overview

  • Overview of the supply system’s purpose and its role in the air brake system.

Air Compressor Components – Drives and Mountings

  • Types of drives and mounting configurations used for air compressors.

Air Compressor Component Identification and Operation

  • Detailed identification of air compressor components and their operational principles.

Air Compressor Cooling and Lubrication

  • Methods of cooling (air or water-cooled) and lubrication systems for air compressors.

Optional Compressor Induction System (Utilizing Turbo-Charger Boost Pressure)

  • Explanation of systems that use turbocharger boost pressure to enhance compressor efficiency.

Air Dryer Types

  • Overview of various air dryer designs and their specific applications.

Desiccant Air Dryer – Component Identification and Operation

  • Function and operation of desiccant air dryers in removing moisture from compressed air.

Aftercooler Condensing Air Dryer

  • Role of aftercoolers in condensing and removing moisture from compressed air.

Supply Tank & Service Reservoirs

  • Functions of supply tanks and service reservoirs in storing and managing compressed air.

Alcohol Evaporators & Injectors

  • Use of alcohol evaporators and injectors to prevent freezing in air brake systems.

Governor

  • Operation of the governor in regulating compressor activity based on system pressure.

One-way Check Valve

  • Function of check valves in maintaining air flow direction and preventing backflow.

Safety Valve (Over-Pressure Relief Valve)

  • Importance of safety valves in releasing excess air to prevent system overpressure.

Drain Valves (Manual and Automatic)

  • Operation and maintenance of valves used to remove moisture and contaminants from air reservoirs.

Air Pressure Gauges

  • Monitoring air pressure levels to ensure safe and efficient operation.

Low Air Pressure Warning Devices

  • Identification and function of warning systems that alert drivers to low air pressure.

Supply System Operation

  • Comprehensive explanation of how the supply system operates during vehicle use.

Pressure Ranges and Rise Times

  • Normal operating pressure ranges and the time required to build pressure in 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

  • Overview and identification of the primary components of the service brake system.

Brake Control and Synchronization (Quick Release and Relay Valves)

  • Understanding how quick release and relay valves work to ensure synchronized and efficient braking.

Treadle Valve – Component Identification and Operation

  • Examination of the treadle valve, its components, and its role in converting driver input into braking force.

Brake Pedal Feel (Feedback)

  • Factors affecting brake pedal feel and how it provides feedback to the driver about braking performance.

Primary (Rear) Relay Valve

  • Role of the primary relay valve in managing rear brake operations and maintaining system efficiency.

Secondary (Front) Quick Release Valve

  • Function of the quick release valve in facilitating faster air release for front brakes.

Dry / Slippery Valve

  • Purpose and operation of the dry/slippery valve in adjusting braking force based on road conditions.

Secondary (Front) Service Brake Ratio / Limiter Valve (Limiting Valve)

  • Use of the limiter valve to regulate braking force for the front brakes, especially under specific conditions.

Brake Tubing and Hoses

  • Overview of the brake tubing and hoses, their materials, routing, and maintenance requirements.

Service Brake Chambers – How They Work, Component Identification and Operation

  • Detailed study of service brake chambers, their construction, and their role in converting air pressure into mechanical force.

Brake Chamber Stroke vs. Application Force

  • Relationship between the stroke length of brake chambers and the resulting application force.

Brake Chamber Size, Markings, Outside Diameter (OD), and Adjustment Limits

  • Understanding the specifications of brake chambers, their identification markings, and adjustment limits.

Service Brake System Operation

  • Comprehensive explanation of how the service brake system operates, from driver input to braking action.

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:

Compressed Spring, DANGER

  • Understanding the dangers of handling compressed springs in spring brake systems and the necessary safety precautions.

Spring Brake System – Introduction and Principal Components

  • Overview of the spring brake system, its purpose, and key components.

Double Check Valve Design and Operation (Shuttle-type)

  • Function and operation of shuttle-type double check valves in directing air to the correct circuit.

Park / Emergency Brake Control Valve Operation

  • Explanation of the control valve used to engage and release park and emergency brakes.

Spring Brake Chamber – Component Identification and Operation

  • Detailed identification of spring brake chamber components and their role in park and emergency braking.

Spring Brake System (Basic) with Quick Release Valve

  • Operation of a basic spring brake system that incorporates a quick release valve for faster response.

Spring Brake System with Relay Valve

  • Enhanced spring brake system using a relay valve for improved control and response.

Brake Compounding

  • Explanation of brake compounding, where service and spring brakes are applied simultaneously, and its implications.

Basic Anti-Compounding Circuit (with Standard Spring Brake Relay)

  • Introduction to anti-compounding circuits that prevent the simultaneous application of service and spring brakes.

Anti-Compounding Circuit (with Anti-Compounding Spring Brake Relay)

  • Advanced anti-compounding circuits with specialized spring brake relays for enhanced safety.

Service Brake Application Force vs. Spring Brake Application Force

  • Comparison of the forces generated by service brakes and spring brakes under various conditions.

Manual Spring Brake Caging

  • Procedure for manually caging spring brakes in emergency or maintenance scenarios.

DD-3 Brake Chambers

  • Study of DD-3 brake chambers, their unique features, and their application in spring brake systems.

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:

1. Introduction to Trailer Brake Systems

  • Overview of trailer brake systems, their purpose, and importance in heavy vehicle operations.

2. Trailer Air Supply Circuit

  • Function and layout of the trailer air supply circuit and its role in providing compressed air to the trailer.

3. Trailer Air Supply Valve – Basic Function

  • Operation of the trailer air supply valve and its role in controlling air supply to the trailer.

4. Combination Tractor Park and Trailer Air Supply Valves

  • Understanding the combined operation of tractor park and trailer air supply valves.

5. Tractor Protection Valve

  • Function of the tractor protection valve in preventing air loss from the tractor during trailer detachment.

6. Trailer Supply and Spring Brake System Operation (Tractor Section)

  • Interaction between the tractor and trailer air supply and spring brake systems.

7. Trailer Service Brake Control System Components

  • Identification and roles of components in the trailer service brake control system.

8. Trailer Service Brake Control System Operation

  • Step-by-step explanation of how the trailer service brake system operates.

9. Trailer Brake Hand Valve (Spike) – Introduction, Warning

  • Introduction to the trailer brake hand valve (spike), its uses, and associated warnings.

10. Trailer Brake Hand Valve (Spike) – Component Identification and Operation

  • Detailed identification and operation of the trailer brake hand valve (spike).

11. Trailer Supply and Service Brake Connections (Gladhands)

  • Function and proper handling of gladhands for trailer supply and service brake connections.

12. Trailer Brake System Configurations & Automatic Spring Brake Application Features

  • Overview of trailer brake system configurations and the features of automatic spring brake applications.

13. Spring Brake Priority System Component Identification & Operation

  • Function and operation of components in the spring brake priority system.

14. Service Brake Priority System Component Identification & Operation

  • Role and operation of components in the service brake priority system.

15. Trailer Relay Emergency (Pre-121) Systems – Introduction

  • Introduction to trailer relay emergency systems designed before FMVSS 121 standards.

16. Trailer Relay Emergency (Pre-121) with Service Brake Chambers ONLY

  • Operation of pre-121 trailer relay emergency systems equipped with service brake chambers only.

17. Trailer Relay Emergency (Pre-121) with Service & Spring Brake Chambers

  • Function and operation of pre-121 systems that include both service and spring brake chambers.

18. Trailer Relay Emergency (Pre-121 SERV) with Service & Spring Brake Chambers

  • Advanced pre-121 relay emergency systems featuring specific service and spring brake chamber configurations.

In this module students will learn about Foundation (Wheel) Brakes.

Topics Covered:

1. Modern Foundation Brake Designs

  • Overview of contemporary foundation brake designs and their evolution to meet performance and safety standards.

2. S-Cam Brake – Component Identification and Operation

  • Detailed identification of S-Cam brake components and their role in braking operations.
  • Explanation of the rotational motion of the S-Cam and its effect on brake shoes.

3. External (Visible) S-Cam Brake Components

  • Identification and understanding of external components such as camshafts, bushings, and brake shoe rollers.

4. Slack Adjuster – Basic Function, Leverage & Torque

  • Explanation of how slack adjusters maintain proper brake shoe-to-drum clearance.
  • Understanding leverage and torque mechanics in brake force application.

5. Slack Adjuster Types (Manual & Automatic)

  • Comparison of manual and automatic slack adjusters, their operation, and adjustment processes.

6. Wedge Brake – Component Identification and Operation

  • Study of wedge brake components, including the wedge, push rod, and brake shoes.
  • How the wedge brake applies force to brake shoes through linear motion.

7. Disc Brake – Component Identification and Operation

  • Examination of disc brake components, such as the rotor, caliper, and brake pads.
  • Operation of disc brakes, emphasizing their superior heat dissipation and braking efficiency.

In this module students will learn about Demands on the Brake System During Vehicle Operation.

Topics Covered:

The Effects of Vehicle Speed and Weight on Stopping Distances

  • Analysis of how increased speed and vehicle weight impact stopping distances.
  • The physics behind momentum and the role of the brake system in overcoming it.

Brake Lag and Stopping Distance

  • Understanding brake lag: the time delay between brake application and actual braking.
  • How brake lag contributes to overall stopping distance.

Brake Fade (A Drum Brake Phenomenon)

  • Explanation of brake fade, its causes (e.g., overheating), and its impact on drum brake performance.
  • Strategies to minimize or prevent brake fade during prolonged braking.

Brake Chamber Stroke (A Crucially Important Adjustment)

  • Importance of proper brake chamber stroke adjustment to ensure effective braking.
  • Identifying acceptable stroke limits and the implications of exceeding them.

ABS Fiction and Facts

  • Dispelling common myths about Anti-lock Braking Systems (ABS).
  • Highlighting the benefits and limitations of ABS technology.

ABS Components and Operation

  • Overview of ABS components, including sensors, control modules, and actuators.
  • Explanation of how ABS prevents wheel lockup and maintains vehicle control during braking.

In this module students will learn about Air Brake Compliance.

Topics Covered:

  1. Motor Vehicle Safety Standards
    • Overview of motor vehicle safety standards, including the Federal Motor Vehicle Safety Standards (FMVSS) and their relevance to air brake systems.
    • Understanding compliance with brake performance, testing, and maintenance regulations.
    • Role of inspections, certifications, and record-keeping in ensuring ongoing compliance with air brake standards.
  2. Vehicle Security and Personal Safety During Vehicle Inspections
    • Best practices for securing vehicles during air brake inspections to prevent accidents.
    • Safety protocols for personnel conducting inspections, including personal protective equipment (PPE) and safe working procedures around brake systems.
    • Importance of understanding the risks associated with air brake systems and how to mitigate them during inspection and maintenance activities.

This module provides students with the essential knowledge and techniques for inspecting air brake system components to ensure they function correctly and meet safety standards. The module covers various inspection procedures for different brake system components, emphasizing safety and maintenance.

Topics Covered:

Introduction to Brake System Inspections

  • Overview of the inspection process for air brake systems, including the purpose and importance of regular inspections.
  • Understanding how proper inspections help prevent brake failure, ensure vehicle safety, and comply with regulatory requirements.

Vehicle Security / Compressor Inspection

  • Procedures for securing the vehicle during brake inspections to prevent movement and ensure safety.
  • How to inspect the air compressor for wear, damage, and functionality, ensuring it operates efficiently.

Air Tanks, Lines, and Fittings, Gladhands

  • Inspecting air tanks for corrosion, leaks, and proper pressure levels.
  • Checking air lines and fittings for cracks, leaks, and signs of wear.
  • Proper inspection of gladhands, ensuring secure connections between the tractor and trailer air supply.

Brake Chambers, Slack Adjusters, and Foundation Brakes

  • Inspecting brake chambers for damage, leaks, and proper functioning of the spring brake system.
  • How to inspect slack adjusters, checking for proper adjustment, wear, and functionality in both manual and automatic types.
  • Inspecting foundation brakes, including S-Cam, disc, and wedge brakes, to ensure they are free of defects and functioning properly.

In this module students will learn about Air Brake System Functional Tests.

Topics Covered:

Air System Functional Tests: Introduction

  • Overview of functional tests to verify the proper operation of the air brake system.
  • Importance of conducting these tests regularly to ensure vehicle safety and compliance with regulations.

Initial Pressure Build & Retention

  • Testing the air system’s ability to build and maintain the correct pressure levels for safe braking operation.
  • Ensuring there are no leaks that could cause pressure loss over time.

Tractor Park System (Spring Brake)

  • Verifying the operation of the tractor’s spring brake system, ensuring that it engages and disengages correctly when required.

Tractor Service Brake System and Tractor Protection Valve

  • Conducting tests on the tractor’s service brake system to ensure it applies and releases properly.
  • Testing the tractor protection valve to confirm that it prevents air loss when the trailer is disconnected.

Low Air Warning System

  • Testing the low air warning system to ensure it activates when the air pressure falls below a safe threshold.

Pressure Rise-time Recovery (85-100 PSI) and Governor Cut-out

  • Measuring the pressure rise-time recovery from 85 PSI to 100 PSI and verifying that the governor cut-out function operates within the correct time frame.

Pressure Rise-time Recovery (50-90 PSI) and Governor Cut-out

  • Conducting tests to ensure the system recovers from 50 PSI to 90 PSI and the governor cut-out activates at the appropriate pressure level.

Compressor Cut-in

  • Verifying the compressor’s ability to cut in at the correct pressure level to ensure proper system pressure maintenance.

Supply & Service Reservoir Draining

  • Ensuring that supply and service reservoirs drain correctly to remove moisture and contaminants from the system, preventing damage to components.

Tractor Park & Service Brake (Dynamic Tests)

  • Performing dynamic tests on the tractor’s park and service brakes to ensure they provide adequate stopping power under real-world conditions.

Trailer Supply, Spring & Service Brakes

  • Verifying the functionality of the trailer’s air supply, spring, and service brakes to ensure they engage and release properly during operation.

Trailer Spring & Service Brake (Dynamic Tests)

  • Conducting dynamic tests on the trailer’s spring and service brakes to evaluate their performance under load and during driving conditions.

In this module students will learn about Inspecting Air Brake Adjustment.

Topics Covered:

  1. Brake Stroke Adjustment – Introduction (Component Wear & Brake Stroke)
    • Understanding the relationship between brake stroke and component wear in air brake systems.
    • Explanation of how improper brake stroke can lead to decreased braking efficiency and excessive wear.
  2. Brake Stroke Inspection & Adjustment (Before Checking Brake Chamber Stroke)
    • Importance of inspecting and adjusting the brake stroke before assessing brake chamber stroke.
    • Identifying signs of brake system issues that may require adjustment.
  3. Brake Stroke Inspection – Test Preparations & Equipment
    • Preparing for brake stroke inspections, including the tools and equipment needed.
    • Safety precautions and proper procedures to follow during inspection.
  4. Brake Stroke – Mark & Measure
    • Marking the brake stroke and measuring its length to assess whether it is within the acceptable range.
    • Identifying issues based on stroke measurements and knowing when adjustments are necessary.
  5. Brake Stroke – Measure and Re-measure
    • The importance of measuring the brake stroke multiple times to ensure consistency and accuracy.
    • Verifying that the brake stroke is within manufacturer specifications.
  6. Brake Stroke Indicators
    • Using brake stroke indicators to help monitor brake system adjustments and performance.
    • How these indicators can assist in identifying the need for adjustments.
  7. Automatic Slack Adjusters (12-Pack-to-Go Initiating the Auto Adjust Process)
    • Explanation of automatic slack adjusters and their role in maintaining proper brake stroke.
    • The process of initiating auto-adjustment on automatic slack adjusters and ensuring they function properly.
  8. Adjusting Manual Slack Adjusters
    • Step-by-step procedure for manually adjusting slack adjusters to maintain proper brake stroke.
    • Understanding the importance of manual adjustments and when they are necessary.

In this module students will learn about Inspecting Air Brake Adjustment.

Topics Covered:

Prepare the Vehicle and Low Air Warning Device

  • Steps to secure the vehicle and prepare it for inspection.
  • Testing the low air warning device to ensure it activates at the correct pressure level for safety.

Air Pressure Build-up Time

  • Measuring the time required for the air system to build pressure to the required operational level.
  • Understanding acceptable build-up time standards and identifying potential issues.

Air Compressor Governor Settings

  • Verifying the governor cut-in and cut-out pressures to ensure proper compressor operation.
  • Identifying and troubleshooting incorrect governor settings.

Air Loss Rate

  • Testing the air loss rate in the system when the brakes are applied and when they are not.
  • Recognizing acceptable air loss thresholds and diagnosing leaks.

Tractor (Tow Vehicle) Protection Valve

  • Testing the tractor protection valve to confirm it prevents air loss when the trailer is disconnected.
  • Ensuring the valve operates as intended during emergencies.

Automatic Application Function of the Trailer Spring (Park/Emergency) Brakes

  • Testing the trailer’s spring brakes to ensure they automatically engage when air pressure falls below a safe level.
  • Understanding the critical role of this feature in emergency braking.

Spring (Park/Emergency) Brakes – Tractor / Tow Vehicle Test

  • Verifying the proper engagement and release of the spring brakes on the tractor or tow vehicle.
  • Ensuring the brakes hold the vehicle securely when parked.

Spring (Park/Emergency) Brakes – Trailer Test

  • Testing the trailer’s spring brakes for proper operation and secure engagement during parking or emergencies.

Drain Air Tanks

  • Draining the air tanks to remove moisture and contaminants that can damage the system.
  • Inspecting the drained air for signs of oil, water, or debris that indicate maintenance needs.

For more information and to discuss your specific needs, ideas, or questions with one of our expert teaching resource developers, we encourage you to reach out to us. Our team is dedicated to creating high-quality, engaging, and effective teaching materials tailored to your unique requirements. Please don’t hesitate to contact us via:

Bryan Duross
TECHNICAL TRAINING SERVICES
Telephone: 519-621-0708
E-Mail: bduross@sentex.net

For a FREE full-version demo, Contact Us!

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