FMVSS 121

TP-121V-05
March 12, 2004
U.S. DEPARTMENT OF TRANSPORTATION
NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION
LABORATORY TEST PROCEDURE
FOR
FMVSS No. 121
Air Brake Systems
ENFORCEMENT
Office of Vehicle Safety Compliance
Room 6111, NVS-220
400 Seventh Street, SW
Washington, DC 20590
TP-121V-05
OVSC LABORATORY TEST PROCEDURE

TABLE OF CONTENTS
PAGE
1. PURPOSE AND APPLICATION ................................................................................ 1
2. SECURITY................................................................................................................. 2
3. GOOD HOUSEKEEPING .......................................................................................... 2
4. TEST SCHEDULING AND MONITORING ................................................................ 3
5. GOVERNMENT FURNISHED PROPERTY............................................................... 3
6. FACILITY AND EQUIPMENT .................................................................................... 3
7. CALIBRATION OF TEST INSTRUMENTS ................................................................ 4
8. PHOTOGRAPHIC DOCUMENTATION ..................................................................... 5
9. DEFINITIONS ............................................................................................................ 7
10. TEST EXECUTION.................................................................................................. 12
10.1 VERIFICATION OF REQUIRED EQUIPMENT ............................................. 12
10.2 LABORATORY TESTS ................................................................................. 15
10.3 ROAD TESTS ............................................................................................... 29
11. REPORTS .............................................................................................................. 44
12. DATA SHEETS ...................................................................................................... 49
13. VEHICLE CONDITION REPORT ........................................................................... 77
14. LABORATORY NOTICE OF TEST FAILURE ........................................................ 80
15. MONTHLY STATUS REPORT............................................................................... 81

TP-121V-05
REVISION CONTROL LOG
FOR OVSC LABORATORY
TEST PROCEDURES
TP-121V-05
AIR BRAKE SYSTEMS
VEHICLE TEST
TEST PROCEDURE FMVSS 121V
REV. EFFECTIVE DESCRIPTION

No. DATE AMENDMENT DATE
01 2/6/74 Minor update
02 3/16/78 Minor update
03 9/12/97 60FR13216 3-1-97 Braking-in-a-curve, Truck Tractors
04 6/4/99 Minor revisions
05 3/12/04 68FR 47485 10-10-03 Braking-in-a-curve, Trucks and buses
06
07
08
09
TP-121V-05 1
1. PURPOSE AND APPLICATION
The Office of Vehicle Safety Compliance (OVSC) provides contractor

laboratories with Laboratory Test Procedures as guidelines for obtaining
compliance test data. The data are used to determine if a specific vehicle or item
of motor vehicle equipment meets the minimum performance requirements of the
subject Federal Motor Vehicle Safety Standard (FMVSS). The purpose of the
OVSC Laboratory Test Procedures is to present a uniform testing and data
recording format, and provide suggestions for the use of specific equipment and
procedures. If any contractor views any part of an OVSC Laboratory Test
Procedure to be in conflict with a Federal Motor Vehicle Safety Standard
(FMVSS) or observes deficiencies in a Laboratory Test Procedure, the contractor
is required to advise the Contracting Officer's Technical Representative (COTR)
and resolve the discrepancy prior to the start of compliance testing.
Every contractor is required to submit a detailed test procedure to the COTR

before initiating the compliance test program. The procedure must include a
step-by-step description of the methodology to be used. The contractor=s test
procedure shall contain a complete listing of test equipment with make and
model number and a detailed check-off sheet. The list of test equipment shall
include instrument accuracy and calibration dates. All equipment shall be
calibrated in accordance with the manufacturer=s instructions. There shall be no
contradictions between the Laboratory Test Procedure and the contractor=s in-
house test procedure. Written approval of the in-house test procedures shall be
obtained from the COTR before initiating the compliance test program. The
OVSC Laboratory Test Procedures are not intended to limit or restrain a
contractor from developing or utilizing any testing techniques or equipment that
will assist in procuring the required compliance test data. These Laboratory Test
Procedures do not constitute an endorsement or recommendation for use of any
product or method. However, the application of any such testing technique or
equipment is subject to prior approval of the COTR.
NOTE: The OVSC Laboratory Test Procedures, prepared for the limited purpose
of use by independent laboratories under contract to conduct compliance tests
for the OVSC, are not rules, regulations or NHTSA interpretations regarding the
meaning of a FMVSS. The Laboratory Test Procedures are not intended to limit
the requirements of the applicable FMVSS(s). In some cases, the OVSC
Laboratory Test Procedures do not include all of the various FMVSS minimum
performance requirements. Recognizing applicable test tolerances, the
Laboratory Test Procedures may
TP-121V-05 2
1. PURPOSE AND APPLICATION....Continued
specify test conditions that are less severe than the minimum requirements of the
standard. In addition, the Laboratory Test Procedures may be modified by the
OVSC at any time without notice, and the COTR may direct or authorize
contractors to deviate from these procedures, as long as the tests are performed
in a manner consistent with the standard itself and within the scope of the
contract. Laboratory Test Procedures may not be relied upon to create any right
or benefit in any person. Therefore, compliance of a vehicle or item of motor
vehicle equipment is not necessarily guaranteed if the manufacturer limits its
certification tests to those described in the OVSC Laboratory Test Procedures.
2. SECURITY
The contractor shall provide appropriate security measures to protect the OVSC
test vehicles, items of motor vehicle equipment, and Government Furnished
Property (GFP) from unauthorized personnel during the entire compliance testing
program. The contractor is financially responsible for any acts of theft and/or
vandalism that occur during the storage of test vehicles, items of motor vehicle
equipment and GFP. Any security problems that arise shall be reported by
telephone to the Industrial Property Manager (IPM), Office of Contracts and
Procurement, within one working day after the incident. A letter containing
specific details of the security problem will be sent to the IPM (with copy to the
COTR) within two working days.
The contractor shall protect and segregate the data that evolves from compliance
testing before and after each vehicle or item of motor vehicle equipment test. No
information concerning the vehicle or equipment item safety compliance testing
program shall be released to anyone except the COTR, unless specifically
authorized by the COTR or the COTR's Group Supervisor or Division Chief.
No individuals, other than contractor personnel directly involved in the

compliance testing program, shall be allowed to witness any vehicle or
equipment item compliance test unless specifically authorized by the COTR.
3. GOOD HOUSEKEEPING
Contractors shall maintain the entire vehicle or item of motor vehicle equipment,
compliance testing area, test fixtures and instrumentation in a neat, clean and
painted condition with test instruments arranged in an orderly manner consistent
with good test laboratory housekeeping practices.
TP-121V-05 3
4. TEST SCHEDULING AND MONITORING
The contractor shall submit a test schedule to the COTR prior to testing. Tests
shall be completed as required in the contract. Scheduling shall be adjusted to
permit sample motor vehicles to be tested to other FMVSS as may be required
by the OVSC. All testing shall be coordinated with the COTR to allow monitoring
by OVSC personnel.
5. GOVERNMENT FURNISHED PROPERTY (GFP)
ACCEPTANCE OF TEST VEHICLE
The Contractor is responsible for accepting test vehicles as GFP in accordance

with the contract and in-house test procedures. The Contractor shall conduct a
thorough inspection of the test vehicle at the time of delivery and acceptance.
The results of the inspection shall be recorded on a Vehicle Condition Form and
faxed to the COTR within 72 hours of the vehicle’s arrival at the Contractor’s test
facility.
STORAGE
Government furnished property shall be segregated from Contractor’s property

and stored in a secured area.
6. FACILITY AND EQUIPMENT
TEST TRACK REQUIREMENTS
A. Service and Emergency Stopping Distance Tests
Tests shall be conducted on a straight 12 ft (+2 in/-0 in) wide roadway with
a peak friction coefficient (PFC) of 0.9 (dry Portland cement concrete or
equivalent surface). The PFC shall be measured using an American
Society for Testing and Materials (ASTM) E1136 standard reference test
tire, in accordance with ASTM Method E1337-90, at a speed of 40 mph.
The track shall be flat within 1% grade in all directions.
B. Stability and Control Tests
Tests shall be conducted on a 500-ft radius curved (measured at the

center) 12 ft (+2 in/-0 in) wide roadway with a PFC of 0.5. The PFC shall
be measured for tangent points along the length of the curve using an
ASTM E1136 standard reference test tire, in accordance with ASTM
Method E1337-90, at a speed of 40 mph, with water delivery.
TP-121V-05 4
6. FACILITY AND EQUIPMENT....Continued
The track shall be flat within 1% grade in all directions. The arc length
must be at least 300 ft and a 100 ft approach to the arc is recommended
to properly align the vehicle to the lane.
C. Parking Brake Tests
(1) Grade Holding Test - shall be conducted on clean dry Portland

cement concrete or equivalent surface and have a grade of 20%
(+0 , -1%)
(2) Static Draw Bar Test - shall be conducted on clean, dry and level
Portland cement concrete or equivalent surface
CONTROL TRAILER
The control trailer is an un-braked flatbed semi-trailer which has a single axle
with a gross axle weight rating (GAWR) of 18,000 lb. and a length of 258 ± 6
inches when measured from the transverse centerline between the axle to the
centerline of the kingpin.
7. CALIBRATION OF TEST INSTRUMENTS
Before the contractor initiates the safety compliance test program, a test
instrumentation calibration system will be implemented and maintained in
accordance with established calibration practices. The calibration system shall be
set up and maintained as follows:
A. Standards for calibrating the measuring and test equipment will be stored
and used under appropriate environmental conditions to assure their
accuracy and stability.
B. All measuring instruments and standards shall be calibrated by the

contractor, or a commercial facility, against a higher order standard at
periodic intervals not to exceed twelve (12) months. Records, showing the
calibration traceability to the National Institute of Standards and
Technology (NIST), shall be maintained for all measuring and test
equipment.
TP-121V-05 5
7. CALIBRATION OF TEST INSTRUMENTS…Continued
C. All measuring and test equipment and measuring standards will be labeled
with the following information:
(1) Date of calibration
(2) Date of next scheduled calibration
(3) Name of the technician who calibrated the equipment
D. A written calibration procedure shall be provided by the contractor that

includes as a minimum the following information for all measurement and
test equipment:
(1) Type of equipment, manufacturer, model number, etc.
(2) Measurement range
(3) Accuracy
(4) Calibration interval
(5) Type of standard used to calibrate the equipment (calibration

traceability of the standard must be evident)
E. Records of calibration for all test instrumentation shall be kept by the

contractor. All such records shall be readily available for inspection when
requested by the COTR. The calibration system will need the acceptance
of the COTR before the test program commences.
F. Standards for calibrating the measuring and test equipment shall be

stored and used under appropriate environmental conditions to assure
their accuracy and stability.
8. PHOTOGRAPHIC DOCUMENTATION
STILL PHOTOGRAPHS
The final test report shall have 8" X 10" color photographs that are properly
focused for clear images. A tag, label or placard identifying the test vehicle
model and NHTSA number shall appear in each photograph and be legible. Each
photograph shall be labeled as to subject matter. As a minimum the following
photographs shall be included:
TP-121V-05 6
8. PHOTOGRAPHIC DOCUMENTATION
A. *Frontal view of the vehicle
B. *Right side view of the vehicle
C. *Left side view of the vehicle
D. *Rear view of the vehicle
E. Vehicle Certification Label Tire information label (if not part of certification
label)
F. Service reservoir(s)
G. Supply reservoir(s)
H. Front and Rear Brake chamber(s) including automatic slack adjusters
I. ABS brake system components
J. All test instrumentation
* at LLVW and GVWR
In the event of a possible nonconformance, additional photographs shall be taken

to document the area of concern.
VIDEO COVERAGE
Videotape coverage of the following tests shall be included with each final test
report.
*A. Stability and Control
Pan view of the vehicle braking in all FOUR stops for both GVWR and
LLVW configurations.
*B. Service Brake
Pan view of one (preferably, the first) of six stops which shows the vehicle
met all requirements, OR, all six stops which show the vehicle did not
meet all requirements, for each configuration tested under chapter 10 of
this test report
TP-121V-05 7
8. PHOTOGRAPHIC DOCUMENTATION…..Continued
*C. Emergency Brake
Pan view of one (preferably, the first) of six stops which shows the vehicle
met all requirements, OR, all six stops which show the vehicle did not
meet all requirements, for each configuration tested under chapter 10 of
this test report
D. Parking Brake (Grade Holding Only)
Videotape both LLVW and GVWR configurations with the vehicle facing up
the grade and the vehicle facing down the grade for the complete 5 minute
duration of each test. The first minute shall consist of a close-up view of
the area where the marked tire contacts the ground. The next three
minutes shall consist of a full view of the vehicle on the grade. The final
minute shall consist of the view of the tire-to-ground interface with a
measurement of vehicle’s translation from the original location, if any.
* NOTE: Videotape shall clearly display the vehicle, track and lane
markers throughout the duration of the braking run from the onset of the
first brake application to the point at which the vehicle stops.
9. DEFINITIONS
AIR BRAKE SYSTEM
A system that uses air as medium for transmitting pressure or force from driver
control to service brake, including air-over-hydraulic system, but not including a
system that uses compressed air or vacuum only to assist driver in applying
muscular force to hydraulic or mechanical components.
ANTILOCK BRAKE SYSTEM (ABS)
Portion of service brake system that automatically controls the degree of

rotational wheel slip during braking by:
A. Sensing rate of angular rotation of wheels
B. Transmitting signals regarding rate of wheel angular rotation to one or

more controlling devices that interpret those signals and generate
responsive controlling output signals
C. Transmitting those controlling signals to one or more modulators that

adjust brake actuating forces in response to those signals.
TP-121V-05 8
9. DEFINITIONS....Continued
AUTO TRANSPORTER
A truck and a trailer designed for use in combination to transport motor vehicles,
in that the towing vehicle is designed to carry cargo at a location other than fifth
wheel and to load this cargo only by means of the towed vehicle.
AXLE SYSTEM
Arrangement of wheels that lay across vehicle in a line that is perpendicular to

longitudinal centerline of vehicle.
BRAKE CHAMBER HOUSING
The case that encloses a brake chamber
COMMON DIAPHRAGM
A single brake chamber diaphragm that is a component of the parking,

emergency, and service brake systems.
DIRECTLY CONTROLLED WHEEL
A wheel for which the degree of rotational wheel slip is sensed, either at that
wheel or on the axle shaft for that wheel and corresponding signals are
transmitted to one or more modulators that adjust the brake actuating forces at
that wheel.
EMERGENCY BRAKE
A mechanism designed to stop a motor vehicle after failure of the service brake
FULL –TREADLE BRAKE APPLICATION
A brake application in which the treadle valve pressure in any of the valve’s
output circuits reaches 85 psi within 0.2 seconds after the application is initiated,
or in which maximum treadle travel is achieved within 0.2 seconds after the
application is initiated
GROSS AXLE WEIGHT RATING (GAWR)
The value specified by the vehicle manufacturer as the load-carrying capacity of

a single axle system, as measured at the tire-ground interfaces.
TP-121V-05 9
GROSS VEHICLE WEIGHT RATING (GVWR)
Value specified by the manufacturer as the loaded weight of a single vehicle.
Unless otherwise specified, vehicles are loaded to GVWR as follows:
A. Trucks are loaded to GVWR using axle loads proportional to respective

gross axle weight ratings (GAWR). In the case where ballast cannot be
positioned without exceeding GAWR, reduce amount of ballast so that
axle load equals specified GAWR, maintaining load proportioning as
closely as possible to specified proportioning.
B. Truck tractors to be loaded to GVWR using single axle un-braked control

trailer. Center of gravity of all ballast on control trailer located directly
above kingpin. Load distribution to be in proportion to tractor's GAWRs,
with trailer axle as close as possible to 4,500 pounds. Adjust load
distribution by altering fifth wheel position. In case where tractor fifth
wheel cannot be adjusted as specified without exceeding a GAWR, reduce
amount of ballast so that axle load equals specified GAWR, maintaining
load proportioning as close as possible to specified proportioning.
C. Actual vehicle test weight to be within + 0%, - 2% of the weight specified in

A or B. Axle weights to be within  2% of their proportional share of test
weight. Ballast to be located as close as possible to longitudinal centerline
of control trailer or truck load frame.
HEAVY HAULER TRAILER
Trailer with one or more of following characteristics:
A. Brake lines are designed to adapt to separation or extension of vehicle

frame; or
B. Body consists only of platform whose primary cargo-carrying surface is not

more than 40 inches above ground in unloaded condition, except that it
may include sides that are designed to be easily removable and a
permanent front-end structure.
TP-121V-05 10
INITIAL BRAKE TEMPERATURE (IBT)
The average temperature of the service brakes on the hottest axle of a vehicle
0.2 mile before any brake application.
BRAKING INTERVAL
The distance measured from the start of one brake application to the start of the
next brake application.
LIGHTLY LOADED VEHICLE WEIGHT (LLVW)
The unloaded vehicle weight (UVW) plus up to 500 pounds (including driver,
observer, and instrumentation). Liftable axles shall be lifted for LLVW tests. For
safety, a rollbar structure less than 1,000 lb may be added to the vehicle.
MAXIMUM DRIVE-THROUGH SPEED
The highest possible constant speed at which the vehicle can be driven through
200 feet of the arc of a low Mu 500-foot radius curve without leaving a 12-foot
wide lane.
MOTOR VEHICLE
Any vehicle driven or drawn by mechanical power manufactured primarily for use
on public streets, roads, and highways, except vehicle operated exclusively on
rail or rails.
PARKING BRAKE
A mechanism designed to prevent movement of a stationary motor vehicle.
PEAK FRICTION COEFFICIENT (PFC)
The ratio of the maximum value of longitudinal force to simultaneous vertical

force occurring prior to wheel lockup, as braking torque is progressively
increased, as measured using procedure in ASTM E 1337.
SNUB
The braking deceleration of a vehicle from higher speed to lower speed that is
greater than zero.
TP-121V-05 11
STOPPING DISTANCE
The distance traveled by a vehicle from the start of the brake application to the
point where the vehicle stops.
TRAILER CONVERTER DOLLY
A trailer chassis equipped with one or more axles, the lower half of a fifth wheel
and a drawbar.
TRUCK
A vehicle with motive power designed primarily for transportation of property or

special purpose equipment.
TRUCK TRACTOR
A truck designed primarily for towing other vehicles and not so constructed as to
carry a load other than a part of weight of vehicle and the load so drawn.
UNLOADED VEHICLE WEIGHT (UVW)
The weight of vehicle with maximum capacity of all fluids necessary for operation
of the vehicle, but without cargo, occupants, or accessories that are ordinarily
removed from the vehicle when they are not in use.
VEHICLE COMBINATION WEIGHT (VCW)
The combined weight of the towing vehicle and the vehicle being towed.
WHEEL LOCKUP
100% wheel slip.

TP-121V-05 12
10. TEST EXECUTION
10.1 VERIFICATION OF REQUIRED EQUIPMENT - Visual Inspections
A. Brake Distribution (S5.1.8, S5.2.2)
Verify that all wheels of the vehicle are equipped with service brakes.
B. Automatic Brake Adjustment (S5.1.8, S5.2.2)
Check that all brakes are equipped with automatic brake adjusters, and if
equipped with adjustment indicators, that the indicators are visible from a
location adjacent to or underneath the vehicle.
C. Antilock Brake System (S5.1.6.1, S5.2.3.1)
(1) For truck tractors manufactured after March 1, 1997;
(a) Verify that the vehicle is equipped with an ABS system.
(b) Verify that the wheels of at least one front and one rear axle
are directly controlled and that the wheels of at least one
axle are independently controlled.*
(2) For trucks and buses manufactured after March 1, 1998:
(a) Verify that the vehicle is equipped with an ABS system.
(b) Verify that the wheels of at least one front and one rear axle
are directly controlled by locating the wheel speed sensing
device(s).*
(3) For trailers and trailer converter dollies manufactured after March 1,
1998, verify that the vehicle is equipped with an ABS system.
(4) For semi-trailers and trailer converter dollies, verify that the wheels
of at least one axle are directly controlled by locating wheel speed
sensing device(s).*
(5) For full trailers, verify that the wheels of at least one front and one
rear axle are directly controlled by locating wheel speed sensing
device(s).*
*NOTE – The NHTSA COTR shall provide Contractor with technical data from the
manufacturer that will be used to assist the Contractor in verifying the above.
TP-121V-05 13
10. TEST EXECUTION....Continued
D. Antilock Malfunction Warning Signal (S5.1.6.2, S5.2.3.2, S5.2.3.3, S5.5.1)
(1) For truck tractors manufactured after March 1, 1997 and for trucks
and buses manufactured after March 1, 1998:
(a) Turn ignition to "On" or "Run" position and check for

activation followed by deactivation of the visual signal after
ignition is turned on.
(b) Verify that the visible warning signal is in the driver's forward
field of view.
(c) Verify that the vehicle is equipped with an electrical circuit

that provides continuous power to the antilock system(s) on
any towed vehicles whenever the ignition switch is in the
“On” or “Run” position*.
(2) For truck tractors and single unit vehicles designed to tow another
air-braked vehicle manufactured after March 1, 2001
(a) Turn ignition to "On" or "Run" position and check for

activation followed by deactivation of the visual signal for the
trailer ABS after ignition is turned on.
(b) Check that the visible warning signal is in the driver's forward
field of view.
(c) Verify that the vehicle is equipped with a circuit that is

capable of transmitting a malfunction signal from the antilock
system(s) on any towed vehicles*.
(3) For trailers and trailer converter dollies manufactured after March 1,
1998 but before March 1, 2009;
Verify that the vehicle is equipped with an external warning

indicator lamp and check for activation followed by deactivation of
the warning indicator after power is supplied to the ABS system.
TP-121V-05 14
E. Service Reservoir Check (S5.1.2, S5.1.2.4, S5.2.1)
(1) Truck tractors, trucks, and buses
(a) Visually check for one or more service reservoir systems.
(b) Visually check for an automatic condensate drain valve for

each service reservoir, or a supply reservoir between the
service system and the air pressure source.
(c) Visually check for automatic operation of condensate valve,

if present, in accordance with manufacturer's specifications.*
Describe method of operation.
(d) Verify that all reservoirs have a drain valve that can be
manually operated.
(2) Trailers
(a) Visually check for one or more reservoirs to which the air is
delivered from the towing vehicle.
(b) Verify that all reservoirs have a drain valve that can be
manually operated.
F. Parking Brake System Control (S5.6.4)
(1) Verify that parking brake control is separate from the service brake
control.
(2) Verify that parking brake control is readily accessible to, and
operable by, a person seated in the normal driving position.
(3) Check that the parking brake control is identified in a manner that
specifies the method of operation.
(4) FOR TOWING VEHICLES - Connect vehicle to a trailer equipped

with parking brakes. Operate the parking brake control. Verify that
the trailer’s parking brakes apply and release as a result of the
operation of the parking brake control.
TP-121V-05 15
10.2 LABORATORY TESTS
A. Service Reservoir Air Pressure Gauge Accuracy, Compressor Cut-in and

Cut-out {Truck Tractors, Trucks, and Buses} (S5.1.1.1, S5.1.4)
(1) While seated in the normal driving position and in a normal driving
posture, verify that the service brake system air pressure gauge is
readily visible.
(2) Install a calibrated pressure transducer (e.g., a test gauge) with a

digital readout, as close as practicable to the service reservoir of
the system to be tested. Check to assure that there are no leaks in
the system.
(3) Exercise the test gauge at least 3 cycles over the entire range up to
the compressor cut-out pressure before performing the actual
measurement.
(4) Build pressure in reservoir system to compressor cut-out and

record test gauge reading.
(5) Turn off vehicle engine.
(6) Open condensate drain valve in reservoir slightly to slowly

decrease pressure. Record vehicle pressure gauge reading and
test gauge reading at 20 psi decrements until the vehicle pressure
gauge reaches 10 psi.
(7) Subtract vehicle pressure gauge readings from test gauge pressure
readings at each interval. Verify that the vehicle pressure gauge
error is less than or equal to +/- 7% of the compressor cut-out
pressure recorded in (4). Record on data sheet.
(8) Re-pressurize reservoir system to compressor cut-out.
(9) With engine idling, open condensate drain valve in reservoir slightly
to slowly decrease pressure.
(10) Record test gauge reading at compressor cut-in.
(11) Verify that compressor cut-in pressure is 100 psi or greater for
trucks and 85 psi or greater for buses. Record on data sheet.
TP-121V-05 16
(12) Repeat test with pressure transducer in other service reservoir

system.
B. Warning Signal -- Service Reservoir Air Pressure {Truck Tractors, Trucks,

and Buses} (S5.1.5)
(1) Install pressure transducers in each service reservoir
(2) With engine and ignition “Off”, bleed service brake system pressure
below 60 psi
(3) Turn ignition to "On" or "Run" and check activation of the visible
signal and activation of the audible signal if installed.
(4) While seated in the normal driving position, verify that the warning
signal is visible within the driver's forward field of view.
(5) Start engine and allow the service brake reservoir system pressure
to build to compressor cut-out. As the reservoir system pressure
rises, verify the deactivation of the visible signal, and if installed, the
deactivation of the audible signal at some pressure above 60 psi.
(6) Turn off vehicle engine.
(7) After engine rotation has stopped, and prior to the service brake
reservoir pressure falling to 60 psi, turn ignition to "On" or “Run”.
(8) Slowly bleed the service brake reservoir system pressure. As the
air pressure falls, verify the activation of the visible signal and, if
installed, the activation of the audible signal. Record pressure at
activation.
C. Service Brake Stop Lamp Switch Actuation {Truck Tractors, Trucks, and
Buses} (S5.1.7)
(1) Install a transducer to measure service brake chamber air pressure

in the chamber closest to the service brake control.
(2) Install instrumentation that is capable of detecting when the stop

lamps are energized.
TP-121V-05 17
(3) Slowly depress the service brake control.
(4) Determine the pressure at which stop-lights were energized.

Record pressure.
(5) Repeat determination while depressing the control rapidly.
(6) Verify that the lamp actuates at a pressure of 6 psi or less. Record
on data sheet.
D. Compressor Recharge Rate {Truck Tractors, Trucks, and Buses} (S5.1.1)
(1) Set the parking brakes. Place calibrated transducers in the service
reservoirs and pressurize the system to cut-out pressure.
(2) Turn off any air-operated accessories. Lower the air pressure in the
system to 70 psi or less.
(3) Operate engine at vehicle manufacturer's maximum recommended

RPM (fully depress accelerator). Towing vehicles are not placed in
the towing position.
(4) Determine the time necessary to increase the reservoir pressure

from 85 psi to 100 psi.
(5) Repeat tests two additional times.
(6) Determine and record average of the three time measurements.
(7) Calculate the Required Reservoir Capacity by multiplying twelve

(12) times the combined volume of the brake chambers.
(8) Determine the Actual Reservoir Capacity from the Reservoir

Volume Test (Section E.)
(9) Verify that average time to increase the air pressure in the
reservoirs is less than or equal to:
Actual Reservoir Capacity x 25
Required Reservoir Capacity
TP-121V-05 18
E. Reservoir Volume (S5.1.2.1, S5.2.1.1)
(1) Determine the volume of one of each type of reservoir as follows;
(a) Fill the reservoir completely with water at 100 psi and weigh.
(b) Empty the water and weigh again. Take care that all water is
removed
(c) Determine the volume of the reservoir (27.7 cubic inches per
pound).
(2) Record identification numbers.
(3) Based on the number of each type of reservoir, determine the total
reservoir volume.
(4) Determine the volume of at least one of each type or size of brake
chamber using the table in Data Sheet No. 5 if possible. If not,
determine the volume as follows;
(a) Fill the brake chamber with water at a pressure of 100 psi
and weigh.
(b) Completely empty the brake chamber of water.
(c) Determine the volume of the brake chamber.
(5) Record identification numbers.
(6) Based on number of each type of chamber, determine the total

chamber volume.
(7) Determine the ratio of total reservoir volume to total chamber

volume.
(8) Verify the following;
(a) For truck tractors, trucks, and buses, the ratio of total
reservoir volume to total chamber volume shall be equal to
or greater than 12.
(b) For trailers, the ratio of total reservoir volume to total

chamber volume shall be equal to or greater than 8.
TP-121V-05 19
F. Service Reservoir Hydrostatic Test (S5.1.2.2, S5.2.1.2)
NOTE: Since this test is potentially a destructive test, proper safety

precautions should be observed. Consult the COTR for disposition of test
reservoirs. Proper shielding of the test reservoir is recommended in the
event the reservoir should rupture during the test. Under no
circumstances should the tested reservoirs be placed in service on a
vehicle.
At least one of each reservoir size and type not identified by the same part
number will be tested. If the reservoir has multiple compartments, all
compartments will be pressurized at the same time.
(1) Determination of test pressure.
(a) For truck tractors, trucks and buses:
(i) Determine the compressor cut-out pressure
(ii) If compressor cut-out pressure times 5 is greater than

500 psi, use this pressure for tests. Otherwise, use
500 psi.
(b) For trailers and converter dollies use 500 psi.
(2) Record part number.
(3) Measure the reservoir circumference at a minimum of three

locations along the longitudinal axis of the reservoir tank.
(4) Hydrostatically pressurize reservoir at an average pressurization

rate between 1 psi/sec and 5 psi/sec until test pressure is reached
or reservoir is ruptured.
(5) Maintain test pressure for 10 minutes, then relieve pressure.
(6) Measure reservoir circumference at the same three locations

defined previously.
TP-121V-05 20
(7) Record any increase in circumference, evidence of stress, leaks,

rupture, or loss of pressure.
(8) Verify whether permanent circumferential deformation exceeds 1%

or pressure loss exceeds 5 psi.
G. Service Reservoir System Air Loss Test (S5.1.2.3, S5.2.1.4)
(1) Locate check valve or equivalent devices that protect reservoirs

from air loss.
(2) Fully charge air reservoir system
(a) For truck tractors, trucks and buses, charge system to

compressor cut-out pressure
(b) For trailers, charge system to 100 psi
(3) Record pressure in each service reservoir system
(4) Check for proper functioning of the check valve or equivalent

device
(a) For Truck tractors, trucks, and buses, follow the

manufacturer’s recommendation for checking the check
valve or equivalent device for proper function without
disconnecting any air line or fitting. Describe method and
technique used.
(b) For Trailers, disconnect the supply line coupling.
(5) Record pressure in each service reservoir system after 10 minutes.
(6) Verify that the pressure drop is less than or equal to 10 psi after 10
minutes.
H. Towing Vehicle Protection System {Vehicles Designed to Tow Another Air

Braked Vehicle} (S5.1.3)
(1) Connect vehicle to a trailer.
(2) Open condensate drain valves until all reservoirs are empty.
TP-121V-05 21
(3) Install pressure transducers in the service reservoirs of the towing

vehicle and the trailer.
(4) Start engine and allow air pressure to build up to the compressor
cut-out pressure. Record this value.
(5) Fully open a condensate drain valve(s) in the trailer’s service

reservoir(s). Record towing vehicle pressure as pressure in the
trailer’s reservoirs drop.
I. Brake Actuation and Release Timing (S5.3.3, S5.3.4)
(1) For vehicles designed to tow another vehicle equipped with air
brakes, install a 50 in3 reservoir connected to the rear control line
coupling.
(2) For vehicles equipped with an antilock system, provide power to the
antilock system.
(3) Install a pressure transducer at the brake chamber under test. All
plumbing associated with this installation should be as short as
possible. Restrictions, sharp bends in lines, or any plumbing
techniques that cause unnecessary changes in the flow path of the
air to the pressure sensor must be avoided. After the pressure
transducer has been installed, a leak check should be performed
and all leaks corrected.
(4) Pressurize system to a reservoir pressure of 100 psi
(5) Measure apply and release times for at least one chamber on each
axle and, for vehicles designed to tow another vehicle equipped
with air brakes, for the 50 in3 reservoir.
(a) For truck tractors, trucks, and buses
(i) Install a device to detect the first movement of the test

vehicle brake control in such a manner that its
operation does not affect the operation of the brake
control.
TP-121V-05 22
(ii) Depress service brake control as rapidly as practical

with operator’s foot and measure time from first
movement of the brake control until the brake
chamber pressure reaches 60 psi.
(iii) Continue to hold the brake control until the chamber

reaches 95 psi.
(iv) Once the pressure in the chamber has achieved 95

psi, release brake control as rapidly as practical and
measure time from the first movement of the brake
control until the brake chamber pressure drops to 5
psi.
(b) For trailers and converter dollies:
(i) Connect supply and control couplings to trailer test rig

shown in Figure 1.
(ii) Apply service brakes and measure time from first

movement of the brake control valve until the
chamber pressure reaches 60 psi.
(iii) Continue to apply the brake until the chamber

reaches 95 psi.
(iv) Once the pressure in the chamber has achieved 95

psi, release service brakes and measure time from
first movement of the brake control valve until the
chamber pressure drops to 5 psi. Refer to Figure 2.
(c) Repeat application and release an additional two times,

ensuring the reservoirs are completely recharged per (d)
between applications.
TP-121V-05 23
Figure 1
Figure 2
TP-121V-05 24
(6) If the test vehicle is equipped with an antilock system, it shall also
be tested under each of the following conditions (test to be
performed not less than 10 seconds after inducing described
conditions):
(a) Without primary power to the antilock system.
(b) With the antilock control valve rendered inoperative by

means of the wheel speed sensor open circuited and short
circuited
(7) Verify that the apply and release times are not more than the
values in the chart below;
Brake Actuation and Release Times – Requirement
At the Control-line Gladhands

At the Brake Chamber w/50 cubic in reservoir
Vehicle Type
Apply Release Apply Release
Truck and Buses Not 0.45 sec 0.55 sec N/A N/A
Designed to Tow Another
Vehicle
Not later than the

Truck Tractors and 0.45 sec 0.55 sec fastest brake 0.75 sec
Single Units Designed to chamber or not
Tow Another Vehicle more than 0.35
sec*
Trailers Not Designed to 0.50 sec 1.00 sec N/A N/A

Tow Another Vehicle
Not later than the 1.10 sec

Trailer Converter Dollies 0.55 sec 1.10 sec fastest brake
chamber or not
more than 0.55
sec*
Not later than the
Trailers Designed to Tow 0.60 sec 1.20 sec fastest brake 1.00 sec
Another Vehicle chamber or not
more than 0.50
sec*
* - at the option of the manufacturer

TP-121V-05 25
J. Control Signal Pressure Differential {Converter Dollies and Trailers

Designed to Tow Another Vehicle Equipped with Air Brakes} (S5.3.5)
(1) Insert a 0.032 inch thick disc with a fixed orifice of 0.0180 inch (no.
77 drill bit) in the control line between the trailer test rig coupling
and the vehicle’s control line input coupling. The trailer test rig is to
be connected to an air source with the regulator set to 100 psi
throughout test (see Figures 1 and 2).
(2) Connect a 50 in3 reservoir to the output control line coupling.
(3) Place a transducer in the 50 in3 reservoir and in the input control
line coupling.
(4) Pressurize the system so that all reservoirs are at 100 psi.
(5) Apply vehicle brakes using trailer test rig until pressure in 50 in3
reservoir achieves 95 psi, then release brakes continuously
recording pressures throughout the application and release.
(6) Requirement:
Verify the following:
The differential between the input and output pressure shall —
(a) Not exceed 1 psi for input pressures between 5 and 20 psi
(b) Not exceed 2 psi for input pressures between 20 and 40 psi
(c) Be between 0.95 times the input pressure and 1.05 times the
input pressure for input pressures equal to or greater than 40
psi
K. Parking Brake System Application and Holding (S5.6.3.2)
(1) Induce loss of air pressure in service brake system(s) by opening a

manual condensate drain valve.
(2) Verify that the parking brakes are held in the applied position solely
by mechanical means. (Note: Use the manufacturer’s technical
data provided by the COTR).
TP-121V-05 26
L. Parking Brake Accumulation of Actuation Energy (S5.6.6)
(1) Jack a wheel that has a brake equipped with a parking brake off of
the floor so that the wheel may be turned by hand.
(2) If the vehicle is designed to tow another vehicle equipped with air
brakes, connect a 50 in3 reservoir to the rear supply line coupling.
(3) Pressurize reservoir system
(a) For trucks, truck tractors, and buses, build air pressure in the
system until the reservoir system pressure is above 100 psi,
then turn engine off.
(b) For trailers use the supply line portion of the trailer test rig
(see Figures 1 and 2) to pressurize the supply line to 100
psi.
(4) Induce loss of air pressure in service brake system by opening a

manual condensate valve in one service reservoir.
(5) Apply parking brake
(a) For trucks, truck tractors, and buses, actuate the parking
brake control.
(b) For trailers, vent the front supply line coupling to

atmosphere.
(6) Verify that the parking brakes have applied by confirming that the
wheel is no longer free to rotate.
(7) Thirty (30) seconds after initiation of the parking brake application,
release parking brake.
(8) Verify that the parking brakes have released by noting that the
wheel is free to rotate.
(9) Thirty (30) seconds after initiation of parking brake release, reapply
the parking brake.
(10) Verify that the parking brakes have applied by confirming that the
wheel is no longer free to rotate.
(11) Fail other reservoir and repeat test.

TP-121V-05 27
M. Modulated Emergency Braking System {Truck Tractors, Trucks, and

Buses} (S5.7.2, S5.7.3(c))
(1) Start engine and allow the service brake reservoir system pressure
to build to compressor cut-out pressure.
(2) With engine “off”, open condensate valve on one of the service
reservoirs until pressure in that reservoir reaches zero.
(3) Apply and release the service brake control and verify that the
emergency brakes apply and release.
(4) For vehicles designed to tow another air braked vehicle - Monitor
the pressure at the control and supply line couplings to verify that
the brakes on any towed vehicle equipped with air brakes apply and
release with the service brake control. Record on data sheet.
(5) Fail other service reservoir and repeat test.
N. Emergency Braking System {Trailer Converter Dolly} (S5.8.1(b))
(1) Verify that the trailer converter dolly has a parking brake system.
(2) If it does not have a parking brake system;
(a) Pressurize the reservoirs to 20 psi.
(b) Vent the supply line coupling to atmosphere.
(c) Verify that the service brakes apply.
O. Parking Brake System Automatic Application {Trailers} (S5.8.3)
(1) Jack a wheel that has a brake equipped with a parking brake off of
the floor so that the wheel may be turned by hand.
(2) If trailer is designed to tow a vehicle equipped with air brakes,

install a 50 in3 reservoir to the rear supply line coupling.
(3) Install a pressure transducer or gauge in the front supply line

coupling.
(4) Install a pressure regulator between the air source and the front
supply line coupling.
TP-121V-05 28
(5) Pressurize the supply line and allow the reservoir pressure to build
to, and stabilize at, 100 psi.
(6) Set the pressure regulator at 70 psi.
(7) Induce loss of air pressure in service brake system(s) by opening a

manual condensate drain valve in one service reservoir.
(8) Verify that the wheel is free to rotate for all pressures above 70 psi
in the supply line.
TP-121V-05 29
10.3 ROAD TESTS
A. General Test Conditions
(1) Ambient air temperature must be between 32 °and 100° F.

.
(2) Wind velocity shall not exceed 15 mph. Stops must not be made
with a tail wind component in excess of 5 mph.
(3) All vehicle openings (doors, windows, hood, etc.) must be closed
except as required for instrumentation purposes.
(4) Unless otherwise specified, the brake control can be applied and
modulated at any desired rate.
(5) For truck tractor tests that utilize the control trailer, a 50 in3
reservoir shall be attached to the tractors control gladhand. Tractor
protection valve to be in the bobtail position for bobtail tests and the
towing position for towing the control trailer
(6) Except for the parking brake grade holding test, the roadway shall
be flat with no more than a 1% grade in all directions including
crown.
(7) Tires must be inflated to the maximum cold pressure specified by

the vehicle manufacturer for the gross vehicle weight rating.
(8) The IBT must be between 150EF and 200EF for each stability and
control, service and emergency stop. Brake temperature just prior
to any parking brake test must be between 150EF and 200EF.
Warm brakes to the required temperature by making 40 to 20 mph
snubs at 10 ft/sec2 .
(9) Automatic adjusters must remain activated for the duration of the
test.
(10) Brakes may be adjusted, per the vehicle manufacturer's procedure,

at specified points in the test sequence.
(11) Individual brake lining temperatures should be less than 200EF

when being adjusted or checked.
TP-121V-05 30
(12) The air system reservoir pressure must be at compressor governor

cut-out pressure (+0/-10 psi) within 0.2 miles before the beginning
of any stability and control and service or emergency brake stop or
just prior to any parking brake test.
(13) Vehicles equipped with an interlocking axle system or front wheel

drive system capable of being manually engaged by the driver,
shall be tested with the system disengaged.
(14) The driver may steer as necessary to stay within the lane.
(15) Vehicle speed is to be +0, -2 mph of the specified test speed.
B. Test Sequence (S5.3.1)
TRUCK TRACTORS
(1) Burnish
(2) Stability and control test at GVWR
(3) Stability and control test at LLVW
(4) Manual brake adjustment allowed
(5) Service brake stopping distance test at GVWR
(6) Parking brake test at GVWR
(8) Service brake stopping distance tests at LLVW
(9) Emergency brake stopping distance tests at LLVW
(10) Parking brake test at LLVW
(11) Final Inspection

TP-121V-05 31
TRUCKS AND BUSES
(1) Burnish
(2) Service brake stopping distance tests at GVWR
(3) Emergency brake stopping distance tests at GVWR
(4) Parking brake test at GVWR
(5) Stability and Control at LLVW
(7) Service brake stopping distance tests at LLVW
(8) Emergency brake stopping distance tests at LLVW
(a) Primary reservoir failure

(b) Secondary reservoir failure
(c) Primary control line failure
(9) Parking brake test at LLVW
(10) Final Inspection
C. Burnish (S6.1.8)
(1) Road conditions should be dry. Slightly wet is permissible but

discontinue burnish when noticeable splash and spray occurs.
(2) Install brake lining thermocouples (see Figure 3).
(3) Install thermocouple readout, decelerometer, and velocity

measurement device.
TP-121V-05 32
(4) Load vehicle to GVWR so that wheels do not lock during burnish
snubs. Truck tractors shall be loaded by coupling to a control
trailer. The vehicle combination weight shall equal the GVWR of the
truck tractor. The ballast on the control trailer shall be located so
that the truck tractor's wheels do not lock during burnish snubs. For
safety, a roll bar structure less than 1,000 lb may be added to the
vehicle.
(5) Adjust brakes per the vehicle manufacturer's recommendation.
(6) Burnish the brakes by making 500 snubs between 40 mph and 20
mph.
(a) Maintain a deceleration rate of 10 ft/sec2, or at the vehicle's

maximum deceleration rate if less than 10 ft/sec2, with
transmission in gear appropriate for speed. (If provided,
manual retarders should be in off position.)
(b) Except where an adjustment is indicated, after each brake

application accelerate to 40 mph and maintain that speed
until making the next brake application at a point 1 mile from
the initial point of the previous brake application. If the
vehicle cannot attain a speed of 40 mph in 1 mile, continue
to accelerate until the vehicle reaches 40 mph or until the
vehicle has traveled 1.5 miles from the initial point of the
previous brake application, whichever occurs first.
(7) The brakes may be adjusted, as specified by the vehicle

manufacturer, up to three times during the burnish procedure.
(8) Driver Breaks
(a) Driver breaks during the procedure should be minimized and

recorded on the data sheets.
(b) Driver breaks should not occur within any 25 snub

sequence.
(c) Each 25th snub can be a complete stop in order to record

data.
TP-121V-05 33
(9) Test Data Recording
Brake lining temperatures and brake application pressure to

maintain a 10 ft/sec2 deceleration should be recorded at each 25th
brake snub.
(10) Adjust brakes at the conclusion of the burnishing in accordance

with the vehicle manufacturer's recommendation. Record
adjustment data on data sheets.
D. Stability and Control (S5.3.6)
(1) Test Track
(a) Install vertical markers (such as cones) on a 20 ft spacing

with the inside edge of the markers placed on the 12 ft wide
lane boundaries.
(b) Begin water delivery to ensure a wet surface during the test.
(2) Instrumentation and equipment
(a) Adjust vehicle weight to appropriate load condition as per

test sequence. For the lightly loaded tests, an additional
1000 lb can be allotted for vehicles that require a roll bar.
(b) Install fifth wheel or other velocity measurement device.
(c) Install trigger switch to measure (detect) start of braking (first

brake control movement).
(d) Install a pressure transducer to measure brake primary

control line pressure or device to measure full displacement
of brake control.
(e) Install recording device to record start of braking and primary

control line pressure (or full brake control displacement) as a
function of time.
TP-121V-05 34
(3) Maximum drive-through speed and braking speed determination
(a) Starting with the vehicle in the center of the lane, attempt to
drive through the curved 500 ft radius test lane at a constant
speed.
(b) Increase or decrease speed in subsequent runs as

necessary until the maximum drive-through speed is
determined to the nearest whole mph increment. Do not
exceed 40 mph.
(c) Verify maximum drive-through speed at least once by

repeating runs at 1 mph above the previously determined
value.
(d) Take 75% of the maximum drive-through speed and round

this value to the nearest whole mph increment to determine
test speed for braking runs
(4) Braking Runs
(a) Starting with the vehicle in the center of the lane, make four
full brake application stops from the test speed determined in
the previous step.
(b) Make the brake applications after the front end of the vehicle
has traveled at least 60 ft in the curved lane on the test
surface.
(c) Vehicle speed at which the brakes are applied should be

within -1.0 to +0.5 mph of the test speed.
(5) Requirement
Verify that the vehicle remained within the 12-foot lane without any
part of the vehicle leaving the roadway in at least three of the four
runs. Record on data sheet.
TP-121V-05 35
Figure 3
TP-121V-05 36
E. Service Brake Stopping Distance Test (S5.3.1.1)
(1) Instrumentation and Equipment
(a) Install device to measure or monitor individual wheel lock-up.
(b) Install pressure gauge/transducer to measure brake control

line pressure.
(c) Install device to measure speed at first movement of brake

control and distance from first movement of brake control
until vehicle stops.
(d) Install instrumentation to display brake temperatures to

driver.
(e) Adjust vehicle weight to appropriate load condition as per

test sequence.
(2) Braking Runs
Conduct six stops from 60 mph trying to achieve the shortest

stopping distance while maintaining the vehicle within the
lane. If the speed attainable in 2 miles is less than 60 mph,
the stops will be made from a speed that is a multiple of 5,
which is 4 to 8 mph less than the speed attainable in 2 miles.
(3) Wheel Lockup Provisions
(a) At vehicle speeds above 20 mph, any wheel on a non-

steerable axle other than the two rearmost non-liftable, non-
steerable axles may lock up for any duration.
(b) At vehicle speeds above 20 mph, one wheel on any axle or

two wheels on any tandem may lock up for any duration.
TP-121V-05 37
(c) At vehicle speeds above 20 mph, any wheel not permitted to

lock above in (A) or (B) may lock up repeatedly, with each
lockup occurring for a duration of 1 second or less.
(d) At vehicle speeds of 20 mph or less, any wheels may lock up

for any duration.
(4) Requirement
Verify that the stopping distance for at least one stop shall be not
more than the distance specified in the appropriate column of
Table 1.
F. Emergency Brake Stopping Distance Test (S5.7.1)
(1) Instrumentation and Equipment
(a) Install a solenoid valve in largest port in the appropriate air

reservoir.
(b) Install a pressure gauge/transducer to measure brake

control line pressure.
(2) Conduct 6 stops from 60 mph while trying to achieve the shortest
stopping distance while maintaining the vehicle in the lane. If the
vehicle speed attainable in 2 miles is less than 60 mph, the vehicle
shall stop from a speed that is a multiple 5 mph between 20 and 60
mph, which is 4 to 8 mph less than the speed attainable in 2 miles.
(a) Activate the solenoid valve to vent pressure to atmosphere.
(b) Initiate the stop within 5 seconds after the low pressure
warning is activated.
(3) Repeat for the other reservoir system.
(4) Repeat with the solenoid in the trailer supply line and the trailer
control line vented to atmosphere for trucks other than truck
tractors that are also towing vehicles (GVWR only).
TP-121V-05 38
(6) Repeat with the control line to the rear vented to atmosphere at the
brake control valve.
(7) Requirement
Verify that the stopping distance for at least one stop shall be not
more than the distance specified in the appropriate column of
Table 1.
TABLE 1
STOPPING DISTANCE REQUIREMENTS
Emergency Brake
Service Brake Stopping Distance Stopping Distance
Unloaded All
Loaded Loaded Truck Loaded Vehicles Unloaded
and Single Tractors Truck Except Truck
Vehicle Unloaded Unit and Tractors Truck Tractors
Speed Busses Trucks Single Tractors
(mph) Unit
Trucks
20 32 35 38 40 83 85
25 49 54 59 62 123 131
30 70 78 84 89 170 186
35 96 106 114 121 225 250
40 125 138 149 158 288 325
45 158 175 189 200 358 409
50 195 216 233 247 435 504
55 236 261 281 299 520 608
60 280 310 335 355 613 720
TP-121V-05 39
G. Parking Brake Chamber Application Pressure
(1) Determine the parking brake chamber application pressure.
(2) Install pressure transducers in parking brake chambers.
(3) Install a device to indicate the first movement of parking brake

control.
(4) For vehicles designed to tow a vehicle equipped with air brakes,
install a 50 in3 reservoir to the rear supply line coupling.
(5) Pressurize reservoirs to 100 psi.
(6) Actuate the parking brake control and record the pressure at the
parking brake chambers three seconds after actuation of control.
(7) Use the parking brake chamber pressure recorded after three
seconds in the appropriate parking brake test (static retardation
force or grade holding). If the pressure after three seconds is less
than or equal to 3 psi, use a pressure of 0 psi.
H. Static Retardation Force Test (S5.6.1)
(1) Install a pull device, load cell, and wheel rotation measurement
device.
(2) If the parking brake chamber pressure was greater than 3 psi,
install a pressure regulator and a method of supplying air at the
recorded pressure to the parking brake chambers to be tested.
(3) Position the vehicle on a level dry Portland cement concrete or

equivalent surface in line with the pull cable.
(4) Connect the pull cable so that the cable is level within ±5 degrees.
(5) Mark the tires on braked wheels at the point of tire/ground contact
and at 90, 180, and 270 degrees from that point.
(6) Disable the parking brake chambers on axle(s) other than the axle
being tested.
TP-121V-05 40
(7) Throughout the sequence, warm the brakes as necessary to

achieve the specified IBT.
(8) Place vehicle transmission in neutral.
(9) Charge the brake system reservoirs to compressor governor cut-

out pressure.
(10) Turn engine off.
(11) Apply parking brakes.
(12) Pull vehicle forward at a maximum rate of 4 ft/min until the wheel
rotates 90 degrees. Release parking brakes.
(13) Repeat steps (8) through (12) starting from 90, 180, and 270
degrees of wheel rotation.
(14) Repeat (8) through (13) except pull the vehicle in the rearward
direction.
(15) Record peak pull force for each 90 degrees of wheel rotation.
(16) Requirement
(A) For vehicles other than a truck tractor that is equipped with
more than two axles, the quotient —
Static Retardation Force

GAWR
shall not be less than 0.28 for any axle other than a
steerable front axle.
(B) For truck tractors equipped with more than two axles,
the quotient —
StaticRetardationForce
GVWR
shall not be less than 0.14.

TP-121V-05 41
I. Grade Holding Test (S5.6.2)
NOTE: The weight of the truck-tractor/test trailer combination (GCW) is

GREATER than the tractor GVWR. If the combination will not park on the
test grade at the GCW, reduce the weight to equal truck-tractor GVWR
and retest.
(1) Install a device to measure vehicle movement on the grade.
(2) If the parking brake chamber pressure was greater than 3 psi,
install a pressure regulator and a method of supplying air at the
recorded pressure to the parking brake chambers to be tested.
(3) Warm brakes, as necessary, to achieve specified IBT.
(4) Charge brake system reservoirs to compressor governor cut-out

pressure.
(5) Ascend 20% grade (+0%,-1%) of dry smooth Portland cement

concrete or equivalent surface.
(6) Apply and hold service brakes to the minimum level necessary to
hold vehicle stationary.
(7) Place vehicle transmission in neutral.
(8) Turn engine off.
(9) Apply parking brakes.
(10) Release service brakes.
(11) Record initial movement of vehicle, if any, that takes place after
release of service brakes until vehicle becomes stationary.
(12) Record vehicle movement, if any, on grade after 5 minutes.
(13) Repeat the test with the vehicle descending the grade.
TP-121V-05 42
J. For Vehicles with a Common Diaphragm (S5.6.7)
(1) Install instrumentation necessary for appropriate parking brake test

(i.e., static retardation force or grade holding).
(2) Install pressure transducers at all service reservoirs.
(3) Install a tee in the air line supplying the brake chamber such that
two legs of the tee connect the air supply with the chamber and the
third leg is vented to the atmosphere through a metering valve.
(4) For vehicles designed to tow a vehicle equipped with air brakes,
install a 50 in3 reservoir on the rear supply line.
.
(5) Set vehicle parking brakes and reduce pressures in all reservoirs to
zero.
(6) Partially open the metering valve to induce a leak in the system.
(7) Attempt to release parking brakes.
(a) For truck tractors, trucks, and buses, run engine at idle and
hold parking brake control in release position.
(b) For trailers, connect the trailer’s front supply line coupling to
the trailer test rig supply line coupling with the trailer test rig
regulator set at 100 psi.
(8) Adjust leakage rate
(a) If parking brakes release, adjust metering valve to increase

rate of leakage.
(b) If parking brakes do not release and the reservoir pressures

have stabilized, adjust metering valve to decrease rate of
leakage. Pressures can be considered stabilized if pressure
change is less that 2 psi in one minute.
(9) Repeat (5) through (8) until maximum leak rate at which brakes can
be released is established.
(10) Fully pressurize system (compressor cut-out for truck tractors,

trucks, and buses; 100 psi for trailers)
TP-121V-05 43
(11) Apply parking brakes and remove air source. Record reservoir
pressures until pressures reach zero.
(a) For truck tractors, trucks, and buses, turn engine off and
apply parking brake control.
(b) For trailers, vent front supply line coupling.
(12) Determine and record leakage rate in psi per minute by dividing 90
by the number of minutes (measured to the nearest 0.01) that
elapsed from the time the reservoir pressure was 95 psi until the
reservoir pressure was 5 psi.
(13) Adjust the metering valve to increase leakage rate. Repeat (10)
through (12) until a leak rate of three times the level determined in
step (9) has been established.
(14) Without changing metering valve, conduct appropriate parking

brake test (i.e., static retardation force or grade holding).
K. Final Inspection
(1) Inspect brake system for structural integrity.
(2) Verify that all brakes lines are connected and brakes operate.
(3) Verify brake adjustment is within manufacturers limits.

TP-121V-05 44
11. REPORT
REPORT COVER PAGES FORMAT
FRONT COVER
A heavy paperback cover (or transparency) shall be provided for the protection of
the final report. The information required on the cover is as follows:
(1) Final Report Number such as 121V-ABC-0X-001, where:
121 is the FMVSS tested (“V” denotes Vehicle road tests)

ABC are the initials for the test laboratory
0X is the Fiscal Year of the test program (of 9X before year 2000)
001 is the Group Number (001 for the 1st test, 002 for the 2nd test, etc.)
(2) Final Report Title And Subtitle such as:
SAFETY COMPLIANCE TESTING FOR FMVSS 121

Air Brake Systems
******************
Name of Vehicle Manufacturer
Model Year, Make and Model of Vehicle
NHTSA Vehicle No. or Test Number
(3) Contractor's Name and Address such as:
COMPLIANCE TESTING LABORATORIES, INC.

4335 West Dearborn Street
Detroit, Michigan 48090
NOTE: DOT SYMBOL WILL BE PLACED BETWEEN ITEMS (3) AND (4)
(4) Date of Final Report completion
(5) The words "FINAL REPORT"

TP-121V-05 45
11. REPORT....Continued
(6) The sponsoring agency's name and address as follows:
U. S. DEPARTMENT OF TRANSPORTATION
National Highway Traffic Safety Administration
Safety Assurance
Room 6111 (NVS-220)
FIRST PAGE AFTER FRONT COVER
A disclaimer statement and an acceptance signature block for the COTR shall be
provided as follows:
This publication is distributed by the U. S. Department of

Transportation, National Highway Traffic Safety Administration,
in the interest of information exchange. The opinions, findings
and conclusions expressed in this publication are those of the
author(s) and not necessarily those of the Department of
Transportation or the National Highway Traffic Safety
Administration. The United States Government assumes no
liability for its contents or use thereof. If trade or manufacturers'
names or products are mentioned, it is only because they are
considered essential to the object of the publication and should
not be construed as an endorsement. The United States
Government does not endorse products or manufacturers.
Prepared By:
Approved By:
Approval Date:
FINAL REPORT ACCEPTANCE BY OVSC:
Accepted By:
Acceptance Date:
TP-121V-05 46
SECOND PAGE AFTER FRONT COVER
A completed Technical Report Documentation Page (Form DOT F 1700.7) shall

be completed for those items that are applicable with the other spaces left blank.
Sample data for the applicable block numbers of the title page follows.
Block 1 — REPORT NUMBER

121V-ABC-9X-001 or 121V-ABC-0X-001 (after year 1999)
Block 2 — GOVERNMENT ACCESSION NUMBER

Leave blank
Block 3 — RECIPIENT'S CATALOG NUMBER

Leave blank
Block 4 — TITLE AND SUBTITLE

Final Report of FMVSS 121 Compliance Testing of 200X Ace Truck,
NHTSA No. CX0701
Block 5 — REPORT DATE

March 1, 200X
Block 6 — PERFORMING ORGANIZATION CODE

ABC
Block 7 — AUTHOR(S)
John Smith, Project Manager
Bill Doe, Project Engineer
Block 8 — PERFORMING ORGANIZATION REPORT NUMBER

ABC-DOT-XXX-001
Block 9 — PERFORMING ORGANIZATION NAME AND ADDRESS

ABC Laboratories
405 Main Street
Detroit, Ml 48070
Block 10 — WORK UNIT NUMBER

Leave blank
TP-121V-05 47
Block 11 — CONTRACT OR GRANT NUMBER

DTNH22-0X-D-12345
Block 12 — SPONSORING AGENCY NAME AND ADDRESS

US Department of Transportation
National Highway Traffic Safety Administration
Mail Code: NVS-220, Room 6111
Block 13 — TYPE OF REPORT AND PERIOD COVERED

Final Test Report
Feb. 15 to Mar. 15, 200X
Block 14 — SPONSORING AGENCY CODE

NVS-220
Block 15 — SUPPLEMENTARY NOTES

Leave blank
Block 16 — ABSTRACT
Compliance tests were conducted on the subject axle assembly in
accordance with the specifications of the Office of Vehicle Safety
Compliance Test Procedure No. TP-121V-OX for the determination of
FMVSS 121 compliance. Test failures identified were as follows:
None
NOTE: Above wording must be shown with appropriate changes made for
a particular compliance test. Any questions should be resolved with the
COTR.
Block 17 — KEY WORDS

Compliance Testing
FMVSS 121
TP-121V-05 48
Block 18 — DISTRIBUTION STATEMENT

Copies of this report are available from —
NHTSA Technical Information Services (TIS)
Mail Code: NPO-230, Room 5108
Telephone No. (202) 366-4946
Block 19 — SECURITY CLASSIFICATION OF REPORT

Unclassified
Block 20 — SECURITY CLASSIFICATION OF PAGE

Unclassified
Block 21 — NUMBER OF PAGES

Add appropriate number
Block 22 — PRICE
Leave blank
TP-121V-05 49
12. DATA SHEETS
DATA SHEET No.1
VEHICLE INFORMATION DATA
TEST VEHICLE INFORMATION:
Year/Make/Model/BodyType_________________________________________
VIN:____________________________________________
NHTSA NO.:____________ Build Date:________________________________
ENGINE DATA: Type: (Diesel, gas, other)_________

cylinders CID Liter cc
TRANSMISSION: speed manual automatic overdrive
AXLE CONFIGURATION:__________
ODOMETER READING: _______ km (miles).
OPTIONS:_______________________________________________________
________________________________________________________________
________________________________________________________________
________________________________________________________________
WHEELBASE mm (in):
AERODYNAMIC TREATMENTS: Yes ______ No ______
BRAKES:
Type1 Size Make Lining (Edge Code)

Axles:
1 ________________
2 ________________
3 ________________
1
Cam, disc, wedge, etc.
TP-121V-05 50
12. DATA SHEETS ...Continued
BRAKE DRUM/ROTOR:
Type2 Make Dust Shields Installed?

Axles:
1
3 ________________
2
Cast or composite drum, vented or non-vented rotor, etc.
ACTUATION DETAILS:
AIR CHAMBERS SLACK ADJUSTERS

Length or
Make Type3 Wedge angle Mfr Cam Rotation4
Axles:
1
3
3
Size and diaphragm or piston
4
Same or opposite to forward wheel rotation
TIRES
Static Loaded Radius
Pressure Size Make Model Measured Databook
(psi)
Axles:
1 ______
2 ______
3 ______
REMARKS:
TP-121V-05 51
12. DATA SHEETS ....Continued
ABS:
Mfr: Model: Configuration:__________
FRONT SUSPENSION:
Type: Make: Model:_____________
REAR SUSPENSION:
Type: Make: Model:____________
Rear Axle Spread, (in): Overall Width (SAE J693):
FIFTH WHEEL:
Fifth Wheel Height Relative to Ground, mm (in): __________

Fifth Wheel Position, mm (in)5: ______________
5
Relative to rear axle(s) centerline (include sketch if necessary)
AIR SYSTEM:
Compressor Capacity (cfm): ________________
Cut-out (psi): Cut-in (psi): _______________
Crack Pressure Ratings (psi)5:_________________________
1st Axle: 2nd Axle:_________________
3rd Axle: Treadle Valve6:______________

5
Relative to rear axle(s) centerline (include sketch if necessary)
6
Total crack pressures between treadle valve and brake chambers
TP-121V-05 52
AIR TANK VOLUMES. (cu. in.):
Supply: Primary: Secondary: _______
Auxiliary: Isolated From Service? Yes/No
TEST WEIGHTS (lbs):
LLVW Burnish Fully Loaded (GVWR)

Axle:
1
Total:
Control
Trailer:
Total:
(truck tractor and control trailer)
REMARKS:
TP-121V-05 53
12. DATA SHEETS.....Continued
DATA SHEET No. 2

VERIFICATION OF REQUIRED EQUIPMENT
Vehicle: NHTSA Vehicle No.:___________
Date: Technician: ________
SERVICE BRAKES
All Wheels Equipped with Brakes Yes No
All Brakes Equipped with Automatic Brake Adjusters Yes No
Brake Adjustment Indicators are visible from a location

adjacent to or beneath the vehicle Yes No
ANTILOCK BRAKE SYSTEM
Antilock System Installed Yes No
Proper axle control Yes No
Comments:
Antilock Warning Signal within Drivers Field-of-View Yes No
SERVICE RESERVOIRS
No. of Reservoirs
Automatic Condensate drain valve(s) or supply reservoir Yes No
Automatic Operation of condensate drain valve Yes No
Each Reservoir has a Drain Valve

which can be Manually Operated Yes No
PARKING BRAKES
Parking Brake Control Separate from Service Brake Control Yes No

TP-121V-05 54
12. DATA SHEETS....Continued
DATA SHEET No. 2

VERIFICATION OF REQUIRED EQUIPMENT
Parking Brake Control Accessible from Operator’s Seat Yes No
Parking Brake control is identified in a manner

that specifies its operation Yes No
Parking Brake Control Operates Parking Brakes

of Towed Vehicle N/A Yes No
REMARKS:
TP-121V-05 55
12. DATA SHEETS …..Continued
DATA SHEET No. 3

SERVICE RESERVOIR AIR PRESSURE GAUGE ACCURACY
Vehicle: NHTSA Vehicle No.: _______
Date: Technician:_________
SYSTEM 1
Compressor Cut-out:____________
7 % of Compressor Cut-out:____________
Compressor Cut-in:________________
Pressure Readings
Nominal Level Test Gauge Veh. Press. Gauge Error

100
80
60
40
20
REMARKS:
TP-121V-05 56
DATA SHEET No. 3

SERVICE RESERVOIR AIR PRESSURE GAUGE ACCURACY
SYSTEM 2
Compressor Cut-out:___________________
7 % of Compressor Cut-out:______________
Compressor Cut-in:____________________
Pressure Readings
Nominal Level Test Gauge Veh. Press. Gauge Error

100
80
60
40
20
AIR PRESSURE WARNING SIGNAL
Visible Signal within Drivers Field of View Yes No
Audible Signal Installed Yes No
Pressure when Signal Deactivates psi
Pressure when Signal Activates psi
STOP LAMP
Pressure at Which Stop Lamp Activated:
Slow Brake Application psi
Rapid Brake Application psi
Both activation pressures are 6 psi or less Yes No

REMARKS:
TP-121V-05 57
DATA SHEET No. 4

COMPRESSOR RECHARGE RATE
Vehicle: NHTSA Vehicle No.: _________
Date: Technician:_________
COMPRESSOR RECHARGE RATE
Time from 85 to 100 psi

Primary Secondary
Run 1
Run 2
Run 3
Avg
Recharge rate meets requirement Yes No
REMARKS:
TP-121V-05 58
DATA SHEET No. 5

SERVICE RESERVOIR VOLUME TEST
Vehicle: NHTSA Vehicle No.:_________

Date: Technician:________
SERVICE RESERVOIR VOLUME TEST
Reservoir Weight of Reservoir Weight of Reservoir Reservoir Volume

Identification with Water without Water (Weight of Water ×
Number (lb) (lb) 27.7)
BRAKE CHAMBERS
Chamber Weight of Chamber Weight of Chamber Chamber Volume
Identification with Water without Water (Weight of Water ×
Number (lb) (lb) 27.7)
Brake Chamber Rated Volumes

Type Full Stroke (in) Rated Volume (cu. In.)
9 1.75 – 2.10 25
12 1.75 – 2.10 30
14 2.25 – 2.70 40
16 2.25 – 2.70 46
18 2.25 – 2.70 50
20 2.25 – 2.70 54
24 2.50 – 3.20 67
30 2.50 – 3.20 89
36 3.00 – 3.60 135
Total Reservoir Volume_________
Total Chamber Volume_________
Ratio of Total Reservoir Volume to Total Chamber Volume ____________
TP-121V-05 59
DATA SHEET No. 6

RESERVOIR CIRCUMFERENCE MEASUREMENTS
Vehicle: NHTSA Vehicle No.: __________
Date: Technician: ___________
SERVICE RESERVOIR HYDROSTATIC TEST
Test Pressure = psi
RESERVOIR CIRCUMFERENCE MEASUREMENTS
Location 1 Location 2 Location 3

Before Pressure Applied
After Pressure Applied
Change (Percent)
Initial Pressure Final Pressure
Pressure Loss
REMARKS: (Note any leaks, ruptures, evidence of stress)

TP-121V-05 60
DATA SHEET No. 6

RESERVOIR AIR LOSS
Method of Inducing Failure:

Primary Secondary
Pressure in Air System Prior to Inducing Failure ____
Pressure in Air System 10 minutes

After Inducing Failure
REMARKS:
TP-121V-05 61
DATA SHEET No. 7

TOWING VEHICLE PROTECTION
Vehicle: NHTSA Vehicle No.:_____________
Date: Technician:__________
TOWING VEHICLE PROTECTION

Trailer Reservoir Towing Vehicle Primary Towing Vehicle Secondary
Pressure Reservoir Pressure Reservoir Pressure
100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0
Pressure at which protection valve activates: psi

TP-121V-05 62
DATA SHEET No. 8

BRAKE ACTUATION AND RELEASE TIMES
Date: Driver: Technician:__________
BRAKE ACTUATION AND RELEASE TIMES
Run Axle 1 Axle 2 Axle 3 50 in3 Reservoir

No.
Apply Releas Apply Releas Apply Releas Apply Releas
(sec) e (sec) (sec) e (sec) (sec) e (sec) (sec) e (sec)
1
2
3
Avg
CONTROL SIGNAL PRESSURE DIFFERENTIAL
Maximum pressure difference between input coupling and 50 in3 reservoir:
for input pressures between 5 and 20 psi
for input pressures between 20 and 40 psi
for input pressures above 40 psi
REMARKS:
TP-121V-05 63
DATA SHEET No. 9
PARKING BRAKE AND EMERGENCY BRAKE OPERATION:
PARKING BRAKE APPLICATION AND HOLDING
Parking brakes held in place by mechanical means Yes No
PARKING BRAKE ACCUMULATION OF ENERGY
Parking brakes apply after release with leak Yes No
MODULATED EMERGENCY BRAKING SYSTEM

(Truck Tractors, Trucks, and Buses Only)
Emergency brakes modulated by service brake control Yes No
Trailer brakes modulated by service brake control N/A Yes No
EMERGENCY BRAKING SYSTEM

(Trailer Converter Dollies Only)
Does dolly have parking brakes Yes No
If no, do service brakes apply when supply

line vented to atmosphere Yes No
PARKING BRAKE SYSTEM AUTOMATIC APPLICATION

(Trailers Only)
Parking brakes remain released for pressures above 70 psi Yes No
Parking brakes apply for pressures below 70 psi Yes No

REMARKS:
TP-121V-05 64
DATA SHEET No. 10

BURNISH
Vehicle: NHTSA Vehicle Number: ___________
BURNISH TEST WEIGHT: AXLE 1: ____________ AXLE 2: ____________

Driver No. Date Odometer Start Odometer End
1
2
3
4
ADJUSTMENT LEVELS
Measured Stroke (in.)
SNUB 1L 1R 2L 2R 3L 3R
Initial 0
1st
2nd
3rd
Final
REMARKS:
TP-121V-05 65
DATA SHEET No. 10
BURNISH
Initial Average Initial Brake Temperatures ºF Ambient
Snub # Speed Cntrl Decel Temp. Driver Date
1L 1R 2L 2R 3L 3R
mph Press. fps2 ºF Initials
1 40
25 40
50 40
75 40
100 40
125 40
150 40
175 40
200 40
225 40
250 40
275 40
300 40
325 40
350 40
375 40
400 40
425 40
450 40
475 40
500 40
TP121V-05 66
DATA SHEET No. 11

STABILITY & CONTROL
GVWR LLVW
Maximum Drive Through Speed mph
75% of Max Drive Through Speed mph
Stop Initial Apply Approx. Number

No. Speed Time Dist. Out Markers Comments
(mph) (sec) of Lane (ft) Hit
1
2
3
4
Ambient Temp.: ºF
Wind Speed: mph
Direction:
REMARKS:
TP121V-05 67
DATA SHEET No. 12

SERVICE BRAKE STOPPING TEST
Vehicle: NHTSA Vehicle No.:__________
Date: Driver: Observer:_____________
BRAKE STROKE MEASUREMENTS at 85 psi (in)
Axle 1 Left/Right /
Axle 2 Left/Right /
Axle 3 Left/Right /
GVWR LLVW
60 MPH OR – MPH SERVICE BRAKE STOPS
Actual Corrected
Application Initial Stopping Stopping In Wheel
Pressure Speed Distance Distance 12 Lock-up
Stop (psi) (mph) (feet) per SAE foot Indication Comments
J299 Lane
1
2
3
4
5
6
Ambient Temp.:_____°F Wind Speed:_____mph Direction:______

TP121V-05 68
DATA SHEET No. 13
PRIMARY RESERVOIR FAILURE

60 MPH OR--MPH EMERGENCY BRAKE STOPS
Vehicle: NHTSA Vehicle No.:______________
Date: Driver: Observer: ________
PRIMARY RESERVOIR FAILURE

60 MPH OR--MPH EMERGENCY BRAKE STOPS
Actual Corrected
J299 Lane
1
2
3
4
5
6
Ambient Temp.: ºF
Wind Speed: mph
Direction:
REMARKS:
TP121V-05 69
DATA SHEET No. 14
SECONDARY RESERVOIR FAILURE

60 MPH OR--MPH SERVICE BRAKE STOPS
Date: Driver: Technician:________________
SECONDARY RESERVOIR FAILURE

60 MPH OR--MPH SERVICE BRAKE STOPS
Actual Corrected
J299 Lane
1
2
3
4
5
6
Ambient Temp. °F
Wind Speed: mph
Direction:_________________
REMARKS:
TP121V-05 70
DATA SHEET No. 15
PRIMARY CONTROL LINE FAILURE

60 MPH EMERGENCY BRAKE STOPS
Actual Corrected
J299 Lane
1
2
3
4
5
6
Ambient Temp:. °F
Wind Speed: mph
Direction:___________________
REMARKS:
TP121V-05 71
DATA SHEET No. 16
TRAILER CONTROL AND SUPPLY LINE FAILURE FOR TRUCK TRACTORS

60 MPH EMERGENCY BRAKE STOPS
Actual Corrected
J299 Lane
1
2
3
4
5
6
Ambient Temp.: ºF
Wind Speed: mph
Direction:
REMARKS:
TP121V-05 72
DATA SHEET No. 17

PARKING BRAKE TEST
Date: Technician:________________
Parking Brake Chamber Application Pressure Determination
AXLE #
RUN PRESSURE IN PARKING CHAMBER AFTER 3 SECONDS (PSI)

NUMBER
LEFT RIGHT
1
2
3
AVERAGE
If average pressure is less than or equal to 3 psi, use 0 psi
REMARKS:
TP121V-05 73
DATA SHEET No.18

PARKING BRAKE TEST
Static Retardation Force
Parking Brake Chamber Pressure psi
AXLE # DRAWBAR PULL — PEAK FORCE DURING WHEEL ROTATION
Brake Temperature Before Forward Pull: Before Reverse Pull:
Pull 0º - 90º 90º - 180º 180º - 270º 270º - 360º

Direction Rotation Rotation Rotation Rotation
FORWARD
REVERSE
Brake Temperature After Forward Pull: After Reverse Pull:
AXLE # DRAWBAR PULL — PEAK FORCE DURING WHEEL ROTATION
Brake Temperature Before Forward Pull: Before Reverse Pull:
Pull 0º - 90º 90º - 180º 180º - 270º 270º - 360º

Direction Rotation Rotation Rotation Rotation
FORWARD
REVERSE
Brake Temperature After Forward Pull: After Reverse Pull:
REMARKS:
TP121V-05 74
DATA SHEET No. 19

PARKING BRAKE TEST
Grade Holding
GVWR LLVW
Parking Brake Chamber Pressure psi
Control Movement
Initial Brake Pressure to to Become
GVWR Temperature Hold Vehicle Stationary Stationary on Grade
LLVW (ºF) (psi) on Grade for 5 minutes
(inches)
Yes No
Up Grade
Down Grade
REMARKS:
TP121V-05 75
DATA SHEET No. 20

FINAL INSPECTION
BRAKE STROKE MEASUREMENTS AT 85 PSI (INCHES)
Axle 1 Left/Right / _____
SERVICE BRAKES
All Brakes Structurally Intact Yes No
All Brakes Function Properly Yes No
All Brakes Adjusted Within Manufacturers Recommendation Yes No

Overall Condition of Test Vehicle:
Tires replaced: ___Yes ____No
New Brake Linings: Axle #1 ___Yes ___No
Axle #2 ___Yes ___No
Axle #3 ___Yes ___No
Additional Comments:
TP121V-05 76
13. REPORT OF VEHICLE CONDITION FORM
A "Report of Vehicle Condition" form must be submitted to the COTR with the
copies of the Final Test Report. The first page of the form shall be completed
when the test vehicle arrives at the testing laboratory. The second page of the
form is completed after the test. The forms shall be LEGIBLE (hand written
forms are unacceptable) and COMPLETE (all information requested is filled out).
TP121V-05 77
REPORT OF VEHICLE CONDITION

PAGE 1
U.S. Department
Office of Vehicle Safety Compliance/ NVS-221
of Transportation
National Highway
400 7th St., SW, Rm 6111
Traffic Safety Washington, DC 20590
Administration
The test vehicle is to be inspected upon arrival at the laboratory. The laboratory will report the arrival of
the vehicle and any findings from the inspection to the OVSC within 24 hours.
TEST LAB INFORMATION

Lab Name
& Address:
Contact:
Phone:
VEHICLE INFORMATION
PRICE:
NHTSA NO: COLOR:
YEAR: VIN:
MAKE: CONTRACT NO: DTNH22-
MODEL: DEALER NAME:
VEH TYPE : FMVSS TO BE TESTED TO:
VEHICLE ARRIVAL
DELIVERY DATE: ODOMETER
READING:
CONDITION:
RECORDED BY: DATE:

APPROVED BY: DATE:
TP121V-05 78
REPORT OF VEHICLE CONDITION

PAGE 2
TEST COMPLETION
Arrival Date:
Odometer Reading:
Date of Reading:
Can the vehicle be driven? (YES/NO)
List all equipment removed from the test vehicle, if any.
List any equipment added to the test vehicle?
Overall Vehicle Condition:
RECORDED BY: DATE:

APPROVED BY: DATE:
TP121V-05 79
14. LABORATORY NOTICE OF TEST FAILURE
An apparent test failure shall be communicated by telephone to the COTR within

24 hours with written notification mailed within 48 hours (Saturday and Sundays
excluded). A Laboratory Notice of Test Failure with a copy of the particular
compliance test data sheet(s) and preliminary data plot(s) shall be included. In
the event of a test failure, a post-test calibration check of some of the critically
sensitive test equipment and instrumentation may be required for verification of
accuracy. The necessity for the calibration shall be at the COTR’s discretion and
shall be performed without additional costs to the OVSC.
LABORATORY NOTICE OF TEST FAILURE TO OVSC

FMVSS No. 121, AIR BRAKE SYSTERMS TEST DATE:_________________________
LABORATORY:__________________________________________________________________
CONTRACT NO.: ; DELV. ORDER NO.:__________________________
LAB. PROJECT ENGINEER'S NAME:________________________________________________
VEH. MY/MAKE/MODEL:__________________________________________________________
VEH. BODY STYLE: ; BUILD DATE:____________________________
VEH. NHTSA NO.: ; VIN:_____________________________________________
TEST FAILURE DESCRIPTION:____________________________________________________
______________________________________________________________________________
______________________________________________________________________________
S121 REQUIREMENT, PARAGRAPH § _____________________________________________
NOTIFICATION TO NHTSA (COTR):_________________________________________________
DATE: BY: _______________________________________________
REMARKS:
TP121V-05 80
15. MONTHLY STATUS REPORT
The Contractor shall submit a Monthly Status Report to the COTR within the first week of each month. The Monthly
Status Report shall be submitted until all vehicles are disposed of. Below is a sample format for the report. (Contractors
may use other formats than presented below. However, all of the information that is requested in the example below
must be reported to the COTR.)
Test Program:_______ Contract Number:____________ Fiscal Year:______ Laboratory: ______ Report Date: ________
Vehicle Date
Date Initial Pass Date of Condition Final Vehicle
Test NHTSA Of Odometer Test Or Final Report Invoice Invoice Odometer Is
Vehicle No. Delivery Reading Date Fail Report Date No. Date Reading Disposed
1

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TP-121V-05

March 12, 2004

U.S. DEPARTMENT OF TRANSPORTATION

NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION

LABORATORY TEST PROCEDURE

FMVSS No. 121

Air Brake Systems

OVSC LABORATORY TEST PROCEDURE

1. PURPOSE AND APPLICATION ................................................................................ 1

3. GOOD HOUSEKEEPING .......................................................................................... 2

4. TEST SCHEDULING AND MONITORING ................................................................ 3

5. GOVERNMENT FURNISHED PROPERTY............................................................... 3

6. FACILITY AND EQUIPMENT .................................................................................... 3

7. CALIBRATION OF TEST INSTRUMENTS ................................................................ 4

8. PHOTOGRAPHIC DOCUMENTATION ..................................................................... 5

10. TEST EXECUTION.................................................................................................. 12

10.1 VERIFICATION OF REQUIRED EQUIPMENT ............................................. 12

10.2 LABORATORY TESTS ................................................................................. 15

10.3 ROAD TESTS ............................................................................................... 29

11. REPORTS .............................................................................................................. 44

12. DATA SHEETS ...................................................................................................... 49

13. VEHICLE CONDITION REPORT ........................................................................... 77

14. LABORATORY NOTICE OF TEST FAILURE ........................................................ 80

15. MONTHLY STATUS REPORT............................................................................... 81

TEST PROCEDURE FMVSS 121V

REV. EFFECTIVE DESCRIPTION

01 2/6/74 Minor update

02 3/16/78 Minor update

03 9/12/97 60FR13216 3-1-97 Braking-in-a-curve, Truck Tractors

04 6/4/99 Minor revisions

05 3/12/04 68FR 47485 10-10-03 Braking-in-a-curve, Trucks and buses

The Office of Vehicle Safety Compliance (OVSC) provides contractor

Every contractor is required to submit a detailed test procedure to the COTR

No individuals, other than contractor personnel directly involved in the

5. GOVERNMENT FURNISHED PROPERTY (GFP)

ACCEPTANCE OF TEST VEHICLE

The Contractor is responsible for accepting test vehicles as GFP in accordance

Government furnished property shall be segregated from Contractor’s property

6. FACILITY AND EQUIPMENT

TEST TRACK REQUIREMENTS

A. Service and Emergency Stopping Distance Tests

B. Stability and Control Tests

Tests shall be conducted on a 500-ft radius curved (measured at the

C. Parking Brake Tests

(1) Grade Holding Test - shall be conducted on clean dry Portland

7. CALIBRATION OF TEST INSTRUMENTS

B. All measuring instruments and standards shall be calibrated by the

(1) Date of calibration

(2) Date of next scheduled calibration

(3) Name of the technician who calibrated the equipment

D. A written calibration procedure shall be provided by the contractor that

(1) Type of equipment, manufacturer, model number, etc.

(2) Measurement range

(4) Calibration interval

(5) Type of standard used to calibrate the equipment (calibration

E. Records of calibration for all test instrumentation shall be kept by the

F. Standards for calibrating the measuring and test equipment shall be

A. *Frontal view of the vehicle

B. *Right side view of the vehicle

C. *Left side view of the vehicle