AIR BRAKE SYSTEM TROUBLESHOOTING

Page 10 QUALITY HEAVY DUTY PARTS

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 AIR BRAKE SYSTEM TROUBLESHOOTING

QUALITY HEAVY DUTY PARTS Page 11

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 AIR BRAKE SYSTEM TROUBLESHOOTING
1.) Before replacing any valve with a new or remanufactured valve, be sure to blow the air lines out either
using the vehicles own air supply or shop air. Dirt is the greatest cause of premature air valve failure.
2.) If pipe dope is used on fittings, use it sparingly. This can also get into the unit and cause a failure.
3.) When installing fittings into a remanufactured valve, do not over tighten or it will crack the casting.
4.) With the introduction of spring brakes, anti-compounding and 121 air brake systems, because a valve is
leaking air out of its exhaust, does not mean the valve is at fault. If a spring brake is leaking from the the
spring brake to the service brake side, that air will travel back up the service line and out the exhaust of the
next valve back. Before replacing a valve that has air leaking from its exhaust, disconnect the delivery lines
from that valve to determine if air is being fed back from some other valve or unit.

TRUCKS, TRACTORS and BUSES

1.) Insufficient Brakes 7.) Uneven Brakes 11.) Air Pressure Drops Quickly With
-Brakes need adjusting, lubricating or relining. -Brakes need adjusting, lubricating or relining. Engine Stopped and Brakes Released
-Low air pressure in the brake system (below 60 -Improper axle mounting. -Leaking brake valve.
psi). -Grease on brake lining - reline brakes. -Leaking tubing or hoses.
-Brake valve delivery pressure below normal. -Brake shoe return spring broken. -Compressor discharge valves leaking.
-Wrong size actuators and/or slack adjusters. -Brake drum out of round. -Governor leaking.
-Failure of part of a dual air system. -Brake chamber diaphragm failure. -Excessive leakage elsewhere in the air brake supply
-If remote mounted brake valve, check linkage. -Wrong brake lining. system.
-Broken slack adjuster or foundation brake parts. -Inadequate reservoir volume - high air demand.
2.) Brakes Apply Too Slowly
-Brakes need adjusting or lubricating.
-Low air pressure in the brake system (below 60 8.) Air Pressure Will Not Rise To Normal 12.) Air Pressure Drops Quickly With
psi). -Faulty air gauge (registering incorrectly). Engine Stopped and Brakes Fully Applied
-Insufficient brake valve delivery pressure. -Excessive valve or fitting leakage. -Leaking brake chamber, actuator, rotochamber or
-Excessive leakage with brakes applied. -Governor out of adjustment. brake cylinder.
-Restricted tubing or hose. -Slipping compressor drive belt. -Valve left open.
-Treadle travel restricted. -Faulty compressor. -Leaking brake valve.
-If remote mounted brake valve, check linkage. -Broken supply line. -Leaking tubing or hose line.
-Excessive water in reservoirs.
3.) Brakes Release Too Slowly -Inadequate reservoir volume.
-Brakes need adjusting or lubricating. 9.) Air Pressure Rise To Normal
-Brake valve not returning to fully released Too Slowly
position. -Excessive valve or fitting leakage. 13.) Compressor Knocks Continously
-Restricted tubing or hose. -Excessive reservoir volume.
-Exhaust port of brake valve, quick release valve, or
or Intermittently
-Clogged compressor air strainer.
relay valve restricted or plugged. -Loose drive pulley.
-Engine speed too slow.
-Faulty brake valve, quick release valve, or relay -Back lash in drive gears or drive coupling.
-Compressor discharge valve or inlet valves
valve. -Worn or burnt out bearings.
leaking.
-If remote mounted brake valve, check linkage. -Excessive carbon deposits in compressor cylinder
-Compressor drive belt slipping or faulty drive
head.
coupling.
4.) Brakes Do Not Apply -Worn compressor.
-No air pressure in brake system. -Excessive carbon in compressor cylinder head or
-Restricted or broken tubing or hose.
14.) Safety Valve Blows Off
discharge line.
-Faulty brake valve. -Safety valve out of adjustment.
-Air pressure in the air brake system above normal
If remote mounted brake valve, check linkage.
10.) Air Pressure Rises Above Normal due to faulty unloader mechanism or faulty governor.
5.) Brakes Do Not Release -Faulty air gauge ( registering incorrectly).
-Brake rigging binding. -Governor out of adjustment.
-Brake not in fully released position. -Faulty governor and safety valve.
15.) Excessive Oil or Water in the
-Faulty brake valve or relay valve. -Restriction in line between governor and Brake System
-Restricted or collapsed tubing or hose. compressor or restricted unloading valve. -Reservoirs not being drained oftern enough.
-If remote mounted brake valve, check linkage. -Too much clearance at compressor unloader -Compressor passing excessive oil.
valves or compressor unloading mechanism stuck -Compressor air strainer restricted.
6.) Brakes Grab or Erratic Brake in closed position. -Excessive engine oil pressure.
-Grease on brake lining = reline brakes. -Back pressure from engine crankcase.
-Faulty brake valve or relay valve. -Excessive oil (flooding) in compressor crankcase.
-Brake rigging binding.
-No vehicle load = high brake pressure.

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 AIR BRAKE SYSTEM TROUBLESHOOTING
1.) Before replacing any valve with a new or remanufactured valve, be sure to blow the air lines out either
using the vehicles own air supply or shop air. Dirt is the greatest cause of premature air valve failure.
2.) If pipe dope is used on fittings, use it sparingly. This can also get into the unit and cause a failure.
3.) When installing fittings into a remanufactured valve, do not over tighten or it will crack the casting.
4.) With the introduction of spring brakes, anti-compounding and 121 air brake systems, because a valve is
leaking air out of its exhaust, does not mean the valve is at fault. If a spring brake is leaking from the the
spring brake to the service brake side, that air will travel back up the service line and out the exhaust of the
next valve back. Before replacing a valve that has air leaking from its exhaust, disconnect the delivery lines
from that valve to determine if air is being fed back from some other valve or unit.

TRAILERS
** The air brake system of a trailer is 3.) Brakes Release Too Slowly 7.) Uneven Brakes
entirely dependent upon the air brake -Brakes need adjusting or lubricating. -Brakes need adjusting, lubricating or relining.
system of the towing vehicle for its air -Brake rigging binding. -Grease on brake lining - reline brakes.
-Exhaust port of relay emergency valve restricted or -Brake shoe return spring broken.
supply and control. Therefore, the air air plugged. -Brake drum out of round.
brake system of the towing vehicle must -Restricted tubing or hose. -Leaking brake chamber or actuator diaphragm.
be in good condition; otherwise it will be -Restricted tubing or hose.
impossible to obtain a good brake 4.) Brakes Do Not Apply -Broken slack adjuster or foundation brake parts.
-Connecting hoses to trailer crossed.
performance on the trailer. Before -Faulty relay emergency valve.
condemning the air brake system on a -Tractor protection valve not functioning properly 8.) Excessive Leakage With Brakes Released
trailer, always be sure the air brake or not in normal position (see operating instruc- -Relay emergency valve or drain valve leaking.
system on the towing vehicle is function- tions). -Leaking tubing or hose.
-No air pressure in air brake system. -Hose uncoupled or leaking hose coupling.
ing properly. The following is based on -Restricted tubing or hose.
on the assumption the tractor air brake -Hoses between tractor and trailer not connected.
system is functioning properly. 9.) Excessive Leakage With Brakes
5.) Brakes Do Not Release Fully Applied
-Connecting hoses to trailer crossed. -Faulty relay emergency valve.
1.) Insufficient Brakes -Brake valve on towing vehicle in applied position.
-Brakes need adjusting, lubricating or relining. -Leaking brake chamber diaphragm.
-Brake rigging binding. -Leaking tubing or hose.
-Tractor protection valve not in normal position. -Relay emergency valve in emergency position.
-Faulty relay emergency valve. -Hose uncoupled or leaking hose coupling.
-Faulty relay emergency valve.
-No trailer air supply - clogged emergency line. -Restricted tubing or hose.
-Low air pressure in the brake system (below 80 -Tractor protection valve not functioning properly
psi).
10.) Excessive Leakage with Relay
or not placed in normal position. Emergency Valve in Emergency Position
-Brake valve delivery pressure in towing vehicle
below normal. -Faulty relay emergency valve.
6.) Brakes Grab
-Restricted tubing or hose. -Grease on brake lining - reline brakes.
-Wrong size actuators. -Brake rigging binding. 11.) Excessive Oil and Water Present
-Faulty relay emergency valve. in the Air Brake System.
2.) Brakes Apply Too Slowly -Faulty brake valve on towing vehicle. -Reservoirs not drained often enough.
-Brakes need adjusting or lubricating. -No trailer load.
-Low air pressure in the brake system (below 80
psi).
-Brake valve delivery pressure in towing vehicle
below normal.
-Restricted tubing, hose, or line filter.
-Excessive leakage with brakes applied.
-Faulty relay emergency valve.

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 AIR BRAKE SYSTEM TROUBLESHOOTING
PROBLEM CAUSE REMEDY
1) Dryer is constantly cycling a. Excessive system leak. a. Repair air leak.
or purging. b. Defective governor. b. Check governor for proper cut-in, cut-out
c. Defective one way valve between pressure and excessive leakage. Repair or
air dryer and wet tank. replace governor.
d. Kinked or plugged discharge line. c. Check to see if air is passing through check
valve.
d. Check to see if air passes through discharge
line. Check for kinks, bends, excessive
carbon deposits. Clean or replace discharge
line.
2) Water and sludge appear a. Plugged desiccant cartridge or filter. a. Replace dessicant cartridge filter.
in wet tank. b. Improper length or material of b. Use minimum of six-foot tubing for two-
discharge line. cylinder compressor; ten-foot for one cylinder
c. Restricted purge orfice. compresssor. Flex hose can be substituted at
d. No purge cycle. a ratio of 1- 1/2 of flex hose for each 1 of
e. Compressor passing excessive oil. metal.
c. Clean orfice with small drill bit or wire.
d. See cause and remedy for problem #5.
e. Check for proper compressor installation.
Replace compressor if necessary.

3) Safety valve on air dryer a. Plugged or saturated desiccant a. See remedy 2E, replace desiccant cartridge/
opens during operation. cartridge or filter. filter.
b. Defective one way check valve. b. Check to see if air is passing through check
c. Restricted discharge line. valve. Repair or replace check valve.
c. Clean or replace air discharge line.

4) Constant leak of air from a. Purge control line connected to a. Purge control line must be connected to
purge valve. reservoir or exhaust port of governor. unloader port of governor.
b. Inlet and outlet air connections b. Compressor discharge line must be connected
reversed. to dryer inlet port.
c. Purge valve frozen open. c. Repair or replace thermostat/heater.
d. Restricted discharge line. d. Check to see if air passes through discharge
e. Faulty governor. line. Check for kinks, bends or excessive
carbon deposits.
e. Check governor for proper cut-in, cut-out
pressure and excessive leakage. Repair or
replace governor.

5) Air dryer does not purge a. Line between governor and dryer a. Check to make sure air flows through purge
or exhaust air. kinked, plugged, broken or frozen. control line when compressor is unloaded.
b. Faulty heater or thermostat. Clean or replace purge control line.
c. Faulty purge valve. b. Repair or replace thermostat/heater.
c. After determining air reaches purge valve,
repair purge valve.

6) Slow air pressure build up. a. Restricted line. a. Check to see if air passes through discharge
b. Plugged desiccant or filter. line. Check for kinks, bends or excessive
carbon deposits. Clean or replace discharge
line.
b. Replace desiccant cartridge.
7) Heater inoperative. a. Broken wire or bad connection. a. Repair or replace wiring to heater.
b. Blown fuse. b. Check fuse and replace if necessary.
c. Defective thermostat. c. Repair or replace thermostat.

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