Truck Troubleshooting Guide
Contents
1. Truck roubleshootin Guide i A 4 A ba Haldex Brake Products Corporation 10707 N W Airworld Drive Kansas City MO 64153 1215 Phone 816 891 2470 Fax 816 801 4198 a E E Commercial Vehicle Systems Haldex Limited 525 Southgate Drive Unit 1 Guelph Ontario CANADA N1G 3W6 Phone 519 826 7723 Fax 519 826 9497 oT EET A N Ss E r SECONDARY P ome amp FROM PARK VALVE PRIMARY TANK INSET A OPTION PRIOR TO MARCH 1 1998 FMVSS 121 REGULATION INVERSION VALVE AND QUICK RELEASE VALVE 9 gt rQ Y hij T soem INCLUDES ANTI COMPOUNDING COMPLAINT REMEDY compressor E PUMPS BEYOND CUT OUT Check gauge Check governor Be certain it pressurizes unloader port when above cut out Check unloader plungers Lube kit or change head E WON T PUMP AIR Check gauge Check compressor drive Check inlet valves and plungers If stuck leak will be evident at intake when unloaded Install unloader kit head kit or head assembly SLOW PRESSURE BUILD UP Check gauge Check compressor drive Check intake for restriction Check discharge line for restriction Check unloader function Lube or kit Check inlet and exhaust valves Leak will be evident at intake when unloaded Kit or exchange head E PUMPS EXCESSIVE OIL Check oil return for restriction kink or loop Check f2. AT EXHAUST PORT WITH ALL BRAKES RELEASED Check and replace 18b if back flow occurs into service delivery line E LEAKS WHEN SERVICE BRAKES ARE APPLIED Repair or replace SERVICE BRAKE CHAMBER E LEAKS Replace diaphragm Cage park brake Reset clamps Adjust brakes E WITH SERVICE BRAKES APPLIED STROKE IS AT OR BEYOND MAXIMUM LIMIT OF Type 9 1 3 8 Type 12 13 8 Type 16 13 4 Type 20 13 4 Type 24 13 4 Type 30 2 SLUGGISH APPLICATION OR RELEASE Check basic brake Check for air line restriction leak Align linkage Check chamber return spring Adjust brakes Angle should approach 90 on application Check for improper chamber or obstruction Brake Released E BRAKE ADJUSTER E SLEEVE WILL NOT DEPRESS Clean and lubricate or replace with unit dimensionally same E ADJUSTING SHAFT WILL NOT TURN Replace with unit dimensionally same E CRACKED HOUSING Check spring brake anti compound system Check air chamber size Replace if larger than original size Check direction of travel for proper position of hex nut Shown Under 12 Hex nut must face away from chamber for uni directional brake adjuster WORN CLEVIS PIN BUSHING Replace bushing RELAY VALVE E LEAKS AT EXHAUST PORT WITH ALL BRAKES RELEASED Check seal in spring brake for back flow of spring hold off pressure through service port to open exhaust on valve Replace 15 Spring Parking B
3. to reduce wet tank pressure Moisture should drain from discharge port GOVERNOR E FLUTTERS Check gauge Check unloader line size 5 16 x 5 maximum Check air actuated accessory Is the air volume requirement greater than governor capacity Check for plugged governor reservoir line Repair adjust or replace governor E WON T PASS AIR TO UNLOADER TO CUT OUT COMPRESSOR Check governor reservoir line Repair or replace i WET TANK pmm 8 5 COMPLAINT REMEDY SINGLE CHECK VALVE ALLOW BLEED BACK TO SUPPLY RESERVOIR Periodic Test bleed supply reservoir and observe gauges Check valves should maintain rear and front reservoir pressure Replace it if results are negative PRIMARY amp SECONDARY RESERVOIR E EXCESS OIL WATER Drain as required Check automatic drain valve on wet tank for proper operation See 5 air GAUGE E INCORRECT READING Calibrate or replace C DUAL SYSTEM FOOT BRAKE VALVE E LEAKS AT EXHAUST WITH ALL BRAKES RELEASED Check anti compound double check valve 16 Check 18a and 18b for back flow into service control line E CAUTION CHOCK WHEELS Repair and replace items as necessary E LEAKS AT EXHAUST WITH FOOT BRAKE APPLIED Foot valve defective Repair or replace E LEAKS AT EXHAUST WITH ALL PARK BRAKES SET IN PARK POSITION AND FOOT BRAKE RELEASED Foot valve defective Repair or replace QUICK RELEASE VALVE E LEAKS
4. ABS INLINE VALVES E FOR COMPLETE TROUBLESHOOTING INFORMATION REFER TO LITERATURE PIECES MODAL POWER TK 2 INSTALLATION amp SERVICE MANUAL L30022 AND OR ABS DIAGNOSTIC TROUBLESHOOTING GUIDE L20293 C ABS SENSORS amp EXCITER RINGS E FOR COMPLETE TROUBLESHOOTING INFORMATION REFER TO LITERATURE PIECES MODAL POWER TK 2 INSTALLATION amp SERVICE MANUAL L30022 AND OR ABS DIAGNOSTIC TROUBLESHOOTING GUIDE L20293 NOTE FOR FURTHER TECHNICAL ASSISTANCE CONTACT YOUR HALDEX DISTRIBUTOR YOUR LOCAL HALDEX SALES PROFESSIONAL OR CALL 800 643 2374 AND ASK FORA TECHNICAL ADVISOR www haldex com L60038 US Rev 10 08 5M CUT
5. OP LIGHT SWITCH E LEAKS Replace E FAILS TO SIGNAL A GOOD BULB THROUGH SOUND WIRING AT 3 6 P S I Replace INVERSION RELAY VALVE WITH THE LOSS OF REAR SERVICE BRAKES APPLICATION OF SPRING BRAKE BY USING THE EMERGENCY SECTION SHOULD BE AVAILABLE ALONG WITH FRONT SERVICE BRAKE BY APPLYING FOOT VALVE E Periodically test by bleeding rear service tank and observing front brake and rear spring brake application upon depressing foot pedal Repair or replace if after checking piping is not functioning properly E LEAKS Repair or replace BARRIER WHEEL OIL SEALS NOT SHOWN IN SCHEMATIC E OIL LEAK Check for proper glazing of the sealing lip Check serrations on O D and I D to see that sealing surfaces are dry If wet this could denote the leakage path Check area between positioning pads If wet suspect seal leak Check seal for possible damage incurred during installation Check hub bore and spindle surfaces for imperfections or irregularities Check to see that proper seal has been installed for the particular axle application CZA AIR DRYER E AIR LEAKING CONSTANTLY FROM PURGE VALVE Purge valve seal damaged Replace Purge valve frozen E HEATER INOPERATIVE Blown fuse Check fuse and replace with 8 10 amp fuse Broken wires or poor connections Repair or replace wiring to heater E SLOW WET TANK BUILD UP Filter and or desiccant plugged Service air dryer COMPLAINT REMEDY CF
6. or gasket sealant obstructing drain Check for undersize return line 1 2 minimum Check for fitting restricting drain Check for intake vacuum 20 water maximum Check for excessive engine crankcase pressure poor engine ventilation Check compressor ring wear Exchange for service unit WET TANK E EXCESS OIL ACCUMULATION See PUMPS EXCESSIVE OIL above E EXCESS WATER ACCUMULATION Drain daily Install automatic drain on wet tank E DAMAGED WET TANK Replace LOW PRESSURE INDICATOR SWITCH E BUZZER OR LIGHT INOPERABLE Check ground and wiring on switch and buzzer light Replace switch or buzzer light E WON T OPERATE AT PRESSURES BELOW 60 P S I Check dash gauge for accuracy Replace switch or buzzer light SAFETY VALVE E POPS OFF EXCESSIVELY Check system pressure Valve operating properly in venting at 140 150 P S I Check unloader governor E POPS OFF AT LESS THAN 140 P S I Replace E LEAKS Replace E WON T FUNCTION Periodic Test remove and test above 150 P S I with shop air Replace if non functional DRAIN VALVES MANUAL E LEAKS Replace DRAIN VALVES AUTOMATIC E WON T DRAIN Repair or replace E WON T DRAIN IN COLD WEATHER Replace with heated unit E LEAKS MALFUNCTIONS Repair or replace Periodic Test with system pressure stabilized compressor unloaded no leak evident at discharge port make several foot brake applications
7. rake Check and replace 18b if back flow occurs into service delivery line Check reservoir port for evidence of contamination check supply lines for rusty fittings or carbon deposits Repair or replace E LEAKS AT EXHAUST PORT WITH SERVICE BRAKES APPLIED Exhaust valve not seating properly Repair or replace QOS ET COLOR KEY E SUPPLY EEEE PRIMARY SECONDARY seeeeeeeee PARK EMERGENCY COMPLAINT REMEDY 15 SPRING PARKING BRAKE SERVICE ONLY SERVICE CHAMBER SIDE OF SPRING BRAKE E PARK BRAKE DRAGS OR WON T RELEASE Check for Improper adjustment restriction or broken line Diaphragm failure System pressure too low Improper manual release Broken return spring spring side Quick release of relay malfunction Broken power spring Replace entire unit or piggy back emergency section E SLUGGISH PARK APPLICATION Check for Diaphragm failure Improper manual release Broken power spring E LEAKS WHEN PRESSURIZED FOR PARK BRAKE RELEASE Check for Ruptured spring side diaphragm Push rod seal leakage may be evident at 14 relay valve E SERVICE CHAMBER MALFUNCTION See 12 service brake chamber QUICK RELEASE AND DOUBLE CHECK VALVE COMBINATION E FOOT VALVE EXHAUST LEAK PARK BRAKES RELEASED YELLOW DASH CONTROL VALVE EXHAUST LEAK IN PARK POSITION AND SERVICE BRAKES APPLIED Check anti compound double check valve portion for feedback to foot or dash control valve Repair or replace ST
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