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Troubleshooting United States 816-891-2470

Guide
Canada 519-672-6722
Mexico 52-81-81569500
 COMPLAINT/REMEDY COMPLAINT/REMEDY COMPLAINT/REMEDY COMPLAINT/REMEDY
COMPRESSOR SINGLE CHECK VALVE DUAL SYSTEM FOOT BRAKE VALVE SPRING PARKING BRAKE (SERVICE
1 n PUMPS BEYOND “CUT-OUT” 7 n ALLOW BLEED BACK TO SUPPLY RESERVOIR
15 n LEAKS AT EXHAUST WITH ALL BRAKES RELEASED 21 ONLY SERVICE CHAMBER SIDE OF
- Check gauge.
- Periodic Test: bleed supply reservoir and observe gauges. Check valves - Check anti-compound double check valve #20. SPRING BRAKE)
- Check governor.
should maintain rear and front reservoir pressure.
- Check inversion relay valve #18 for back flow into service control line.
- Be certain it pressurizes unloader port when above “cut-out”. n PARK BRAKE DRAGS OR WON’T RELEASE
- Check unloader/plungers. Lube, kit or change head. - Replace it if results are negative. n CAUTION: CHOCK WHEELS
- Check for: Improper adjustment, restriction or broken line.
n LEAKS AT EXHAUST WITH FOOT BRAKE APPLIED
n WON’T PUMP AIR Diaphragm failure. System pressure too low. Improper
- Foot valve defective. Repair or replace.
- Check gauge. PRIMARY & SECONDARY RESERVOIR manual release. Broken return spring (spring side). Quick

8
- Check compressor drive. n LEAKS AT EXHAUST WITH ALL PARK BRAKES SET IN PARK POSITION release of relay malfunction. Broken power spring.
- Check inlet valves and plungers. If stuck, leak will be evident at n EXCESS OIL/WATER AND FOOT BRAKE RELEASED - Replace entire unit or piggy-back emergency section.
intake when unloaded. Install unloader kit, head kit or head assembly. - Drain as required. - Foot valve defective. Repair or replace. n SLUGGISH PARK APPLICATION
n SLOW PRESSURE BUILD-UP - Check automatic drain valve on wet tank for proper operation (See #6). - Check for: Diaphragm failure. Improper manual release.
- Check gauge. Broken power spring.
- Check compressor drive. n LEAKS WHEN PRESSURIZED FOR PARK BRAKE RELEASE
- Check intake for restriction. AIR GAUGE STOP LIGHT SWITCH AND - Check for: Ruptured spring side diaphragm. Push rod seal leakage
-
-
Check discharge line for restriction.
Check unloader function. Lube or kit. 9 n INCORRECT READING 16 DOUBLE CHECK VALVE (may be evident at relay valve #19 ).
n SERVICE CHAMBER MALFUNCTION
- Check inlet and exhaust valves. Leak will be evident at intake when - Calibrate or replace. n LEAKS
unloaded. Repair or replace head. - See service brake chamber #13.
n PUMPS EXCESSIVE OIL - Replace.
n FAILS TO SIGNAL A GOOD BULB THROUGH SOUND WIRING AT 3–6 PSI
- Check oil return for restriction, kink or loop.
DOUBLE CHECK VALVE UNITES FRONT - Replace.
10
- Check for gasket sealant obstructing drain.
- Check for undersize return line (1/2” minimum).
- Check for fitting restricting drain.
BRAKE AND REAR BRAKE RESERVOIRS
- Check for intake vacuum (20” water maximum). TO FEED PARK CONTROL VALVE
- Check for excessive engine crankcase pressure (poor engine ventilation). n REAR TANK BLEED-DOWN ALSO BLEEDS FROM TANK OR VICE VERSA. PUSH-PULL PARKING BRAKE VALVE
17
- Check compressor ring wear. Exchange for service unit.
n PERIODICALLY TEST: PRESSURE SHOULD REMAIN IN ONE TANK AFTER n PARK BRAKE WON’T RELEASE
GOVERNOR THE OTHER IS DRAINED. REPLACE AS NEEDED.
-
2 n FLUTTERS
- Check gauge.
n
Check for full system pressure.
PARK BRAKE WON’T APPLY
- Repair or replace if valve will not release pressure.
- Check unloader line size (5/16” x 5’ maximum).
AIR DRYER n LEAKS AT EXHAUST PORT WITH SERVICE BRAKES APPLIED
11
- Check air actuated accessory. Is the air volume requirement greater
than governor capacity? n
- Check inversion relay valve #18.
AIR LEAKING CONSTANTLY FROM PURGE VALVE
- Check for plugged governor reservoir line. n LEAKS AT EXHAUST PORT WITH SERVICE BRAKES RELEASED
- Repair, adjust or replace governor. - Purge valve seal damaged. Replace. - Repair or replace.
n WON’T PASS AIR TO UNLOADER TO “CUT-OUT” COMPRESSOR - Purge valve frozen.
- Check governor reservoir line. n HEATER INOPERATIVE
- Repair or replace. - Blown fuse. Check fuse and replace with 8 – 10 amp fuse.
INVERSION RELAY VALVE WITH THE
LOW PRESSURE INDICATOR SWITCH
- Broken wires or poor connections. Repair or replace wiring to heater.
18 LOSS OF REAR SERVICE BRAKES,
3
n SLOW WET TANK BUILD-UP
n BUZZER OR LIGHT INOPERABLE.
- Check ground and wiring on switch and buzzer/light.
- Filter and or desiccant plugged. Service air dryer. APPLICATION OF SPRING BRAKE BY
- Replace switch or buzzer/light. USING THE EMERGENCY SECTION
n WON’T OPERATE AT PRESSURES BELOW 60 PSI SHOULD BE AVAILABLE ALONG WITH
- Check dash gauge for accuracy. QUICK RELEASE VALVE
- Replace switch or buzzer/light.
12 n LEAKS AT EXHAUST PORT WITH ALL BRAKES RELEASED
FRONT SERVICE BRAKE BY APPLYING
WET TANK - Check and replace inversion relay valve #18 if back flow occurs into FOOT VALVE
4 n EXCESS OIL ACCUMULATION n
service delivery line.
LEAKS WHEN SERVICE BRAKES ARE APPLIED
n PERIODICALLY TEST BY BLEEDING REAR SERVICE TANK AND OBSERVING
- See PUMPS EXCESSIVE OIL (above). - Repair or replace. FRONT BRAKE AND REAR SPRING BRAKE APPLICATION UPON DEPRESSING
n EXCESS WATER ACCUMULATION FOOT PEDAL. REPAIR OR REPLACE, IF AFTER CHECKING PIPING IS NOT
- Drain daily. Install automatic drain on wet tank. FUNCTIONING PROPERLY.
n DAMAGED WET TANK SERVICE BRAKE CHAMBER FOR FURTHER TECHNICAL ASSISTANCE
13
n LEAKS
- Replace.
n LEAKS - Repair or replace. CONTACT YOUR HALDEX DISTRIBUTOR, YOUR
SAFETY VALVE - Replace diaphragm.
HALDEX SALES REPRESENTATIVE OR CALL
5 - Cage park brake.
- Reset clamps. RELAY VALVE
19 (800) 643-2374 AND CHOOSE OPTION 2
n ”POPS” OFF EXCESSIVELY.
- Check system pressure. - Adjust brakes. n LEAKS AT EXHAUST PORT WITH ALL BRAKES RELEASED
- Valve operating properly if venting at 140/150 PSI n WITH SERVICE BRAKES -Check seal in spring brake for back flow of spring “hold-off” pressure TO SPEAK WITH A TECHNICAL ADVISOR.
- Check unloader/governor. APPLIED STROKE IS AT OR through service port to open exhaust on valve. Replace Spring Parking
n ”POPS” OFF AT LESS THAN 140 PSI BEYOND MAXIMUM LIMIT OF: Brake #21 Spring.
- Replace. - Type 9 1 3/8” - Check and replace inversion relay valve #18, if back flow occurs into
n LEAKS - Type 12 1 3/8” service delivery line.
- Replace. - Type 16 1 3/4” - Check reservoir port for evidence of contamination, check supply lines
- Type 20 1 3/4” for rusty fittings or carbon deposits. Repair or replace.
n WON’T FUNCTION
- Periodic Test: remove and test above 150 PSI with shop air.
- Type 24 1 3/4” Brake n LEAKS AT EXHAUST PORT WITH SERVICE BRAKES APPLIED
- Type 30 2” - Exhaust valve not seating properly. Repair or replace.
- Replace if non-functional. n SLUGGISH APPLICATION OR
Released
RELEASE
MANUAL DRAIN VALVES - Check basic brake.
6 n LEAKS
- Replace.
- Check for air line restriction/leak.
- Align linkage. 20
QUICK RELEASE AND DOUBLE CHECK
VALVE COMBINATION
- Check chamber return spring.
- Adjust brakes. Angle should approach 90° on application n FOOT VALVE EXHAUST LEAK PARK BRAKES RELEASED YELLOW DASH
AUTOMATIC DRAIN VALVES - Check for improper chamber or obstruction. CONTROL VALVE EXHAUST LEAK IN PARK POSITION AND SERVICE
n WON’T DRAIN BRAKES APPLIED
- Repair or replace. - Check anti-compound double check valve portion for feedback to foot
n or dash control valve. Repair or replace.
WON’T DRAIN IN COLD WEATHER
ABS INLINE VALVES haldex.com
n
- Replace with heated unit.
LEAKS - MALFUNCTIONS 14 n FOR COMPLETE TROUBLESHOOTING INFORMATION REFER TO L20303 US 9/19 5M WAT
- Repair or replace. MODAL POWER TK-2 INSTALLATION & SERVICE MANUAL AND/OR Printed in the USA
- Periodic Test: with system pressure stabilized (compressor unloaded) ABS DIAGNOSTIC TROUBLESHOOTING GUIDE @ haldex.com
no leak evident at discharge port - make several foot brake applications
to reduce wet tank pressure. Moisture should drain from discharge port.