Trailer Systems

Troubleshooting Guide
SYSTEM “A” SYSTEM “F”
PRE-121 RELAY/EMERGENCY VALVE SYSTEM HOW TO USE THIS CHART MOD-I FULL FUNCTION ABS 2S/1M
The purpose of the chart is to help you solve a specific problem in the pneumatic portion of a trailer air brake system with the
assumption the foundation brake components and tractor pneumatics are in good repair.
Identify which system is malfunctioning. (Refer to how to check your system).
Identify your system from the schematics shown.
Identify the problem and select the solution recommended for that system.
CAUTION: WHEELS MUST BE BLOCKED.
CAUTION: SPRING BRAKE INSPECTION AND DISASSEMBLY MUST BE IN ACCORD WITH THE
MANUFACTURERS PROCEDURE.

HOW TO CHECK YOUR SYSTEM

The most important factor in trailer troubleshooting is to determine if the malfunction is in the vehicle’s “parking brake system” or
the “service brake system”. If the problem is “Neither air system is working”, the fault may be mechanical. All “Pre-121” or new “121”
trailers have a “parking/emergency system” and normally used “service brake system”. The parking system works from the
emergency (supply) line. The service system works from the service (control) line. You can determine if the parking emergency
brakes operate by charging and then disconnecting the tractor emergency (supply) line.
The service brakes will operate with apply and release air in the service (control) line by the tractor hand control or foot control valve.

HOW TO IDENTIFY YOUR SYSTEM

All types of trailer air brake systems can be identified for troubleshooting purposes by starting from the brake chamber or spring
brake assembly. This procedure will work for older “Pre-121” equipped trailers regardless of how many tanks and valves or types of
valves that you see. For ABS Troubleshooting, See ABS Diagnostic Troubleshooting Guide (L20293).
SYSTEM “B” If your trailer is equipped with chambers only - you are dealing with system “A” for a trailer and systems “C” and “D” for a converter SYSTEM “G”
PRE-121 RELAY/EMERGENCY VALVE SYSTEM dolly. A “four-wheel” trailer may have chambers on the steerable axle - identify axle as a dolly system “C” or “D”. If the vehicle is MOD-II ABS 4S/2M
WITH SPRING BRAKES equipped with spring brakes you must determine which hose is the “parking/emergency” and which is the “service”.
Follow the service hose from the service portion of the spring brake assembly, the hose will be connected to the service relay valve
and it is responsible for the application and release of the service brake only.
Follow the parking/emergency hose from the spring brake assembly and you will end up at the spring brake control valve. After you
have identified your system, go directly to the Problem and Solution Sections on the reverse side to remedy your situation.

SYSTEM “J”
TWO TANK - ONE VALVE TANDEM AXLE SYSTEM

For ABS Troubleshooting, See ABS Diagnostic Troubleshooting Guide (L20293).

SYSTEM “C” SYSTEM “H”
SINGLE AXLE DOLLY SYSTEM WITH CHARGING TYPE TWO TANK - THREE VALVE TANDEM SYSTEM MIDLAND RT4/RG2 (RG5) VALVES OR
RELAY/EMERGENCY VALVE SEALCO MULTI-FUNCTION WITH SERVICE RELAY VALVE

SYSTEM “D” SYSTEM “E”

TYPICAL 121 DOLLY SYSTEM WITH NON- TWO TANK - TWO VALVE SINGLE AXLE SYSTEM WITH MIDLAND
CHARGING TYPE RELAY/EMERGENCY VALVE RTF4/RG2 VALVE OR SEALCO MULTI-FUNCTION & RELAY

NOTE: Procedures suggested on this chart are merely suggested and should not be construed to be all inclusive nor should the schematics be regarded as typical of piping patterns on all vehicles.

PROBLEM SYSTEM LETTER AND SOLUTION NUMBER SOLUTION

A B C D E F G H J 1. Check service chamber at clamp housing, push rod 27. Assure spring brake is fully released with supply air at
AIR LEAK AT for damage. system pressure above 100 P.S.I. or emergency side of
spring brake.
2. Check service chamber diaphragm for rupture.
Service Brake Chamber 1-2-34 - 1-2-34 1-2-34 - - - - - 28. Excessive volume imposed in supply/emergency lines -
3. Check brake adjuster and chamber/spring brake ie: air pintle air chamber.
Spring Brake with Service Brakes Released & Park Brake Applied - 11-36-37 - - - - - - - push rod alignment for interference.
29. On a pre-121exempt trailer utilizing an emergency relay
6-11-36 6-11-36 6-11-36 6-11-36 6-11-36 6-11-36 4. Assure brake adjuster and chamber/spring brake valve, the spring brake emergency port should be
Spring Brake with Service Brakes Released & Park Brake Released - or 37 - - or 37 or 37 or 37 or 37 or 37 push rod angle 90° applied with proper adjustment. plumbed directly to the tank.
5. Check all lines, valves, reservoirs, actuators for 30. Observe and determine which specific device, fitting or
Spring Brake with Service Brakes Applied & Spring Brake Released - 6-25-36 - - 6-25-36 6-25-36 6-25-36 6-25-36 6-25-36 leakage. hose is leaking and replace.
33-36-37
Emergency Relay Valve with Service Brake Applied or Released 42 or 42 42 51 - - - - - 6. Check spring brake for damage or loose clamp. 31. Assure a leak free system by applying service brake and
7. Assure jumper hoses are not crossed. inspecting.
Emergency Relay Valve with Emergency Brake Applied 42 42 42 51 - - - - -
8 Assure functional return spring in service chamber 32. Note that some trailers may have the emergency/supply
Service Relay Valve with Service Brake Released & Spring Brake Applied - - - - 38 54 54 38 53 or spring break. line piped to a single check valve at both tanks - one
could be leaking.
Service Relay Valve with Service Brake Released & Spring Brake Released - - - - 33-38 33-54 33-54 33-38 33-53 9. Assure air chamber size and brake adjuster arm
length to original spec. 33. Check for failure in spring brake center seal.
Service Relay Valve with Service Brake Applied & Spring Brake Released - - - - 38 54 54 38 53 A. Block wheels and release park brake.
10. Assure spring brake control port has exhausted. B. Check for air pressure leakage at service port of
Spring Brake Control Valve with Spring Brake Applied or Released - - - - 40 54 54 40 53 each spring brake until the leaking assembly is
11. Check for ruptured spring brake diaphragm located. Replace leaking unit.
Trailer Service Gladhand on Disconnect (with Trailer Supply Pressurized) 42 42 42 51 24-40 54 54 24-40 53 (furthest from brake adjuster). C. If no spring brake leakage is found see #41.
Trailer Emergency Gladhand on Disconnect 42 42 42 51 or 52 - - - - - 12. Supply/emergency line must be at atmosphere. 34. Confirm and replace with Type 30 diaphragm, air
13. Assure emergency line exceeds 100 P.S.I. pressure; chamber Type 30
Trailer System Leakage Exceeds 2 P.S.I. per min. with Service Brakes Applied 30 30 30 30 30 30 30 30 30
check and maintain governor at max cut-in. 35. Confirm and replace/use rubber grommets with integral
SERV Valve with Service Brake Released & Park Brake Applied - - - - - - - - - 14. Assure air delivery to service gladhand. brackets.
SERV Valve with Service Brake Released & Park Brake Released - - - - - - - - - 15. Assure air delivery to service relay valve control port. 36. Confirm and replace with appropriate spring brake
assembly; Type 30/30 or Type 24/30. Diaphragm Type
SERV Valve with Service Brake Applied & Park Brake Released - - - - - - - - - 16. Assure air delivery to air chamber or spring brake. 24/30 PiggyBack.
SYSTEM OR COMPONENT FAILURE 17. Assure air delivery to emergency gladhand 37. Confirm and replace with Type 30/30 PiggyBack or Type
3-4-22- 3-4-22- 3-4-22- 3-4-22- 3-4-22- 3-4-22- 3-4-22- 3-4-22- 3-4-22- exceeds 100 P.S.I. 24/30 PiggyBack
Trailer Brakes Slow and Sluggish
44-45- 44-45- 44-45- 44-45- 44-45- 44-45- 44-45- 44-45- 44-45- 18. Assure air delivery to emergency relay valve 38. Confirm and replace with service relay valve 1/2 Supply
46-47 46-47 46-47 46-47 46-47 46-47 46-47 46-47 46-47 emergency port. or 3/8 Supply.
Trailer Brakes Drag 3-4-13- 3-4-13- 3-4-13- 3-4-13- 3-4-13- 19. Assure air delivery to all reservoirs at system 39. Confirm and replace with task spring brake control
3-4-13- 3-4-22- 3-4-22- 3-4-22- 22-23- 22-23- 22-23- 22-23- 22-23- working pressure. valve.
22-23-42 23-27 23-42 23-51 27-37 27-37 27-37 27-37 27-37 20. Assure air delivery to spring brake control valve 40. Confirm and replace with RT-4 spring brake control
control port. valve (replaces Sealco ratio valves).
Trailer Brakes Won't Apply (Service) 3-4-14- 3-4-14- 3-4-14- 3-4-14- 3-4-14- 3-4-14- 3-4-14- 3-4-14- 3-4-14-
16-18-19 16-18-19 16-18-19 14-18-19 15-16-19 15-16-19 15-16-19 15-16-19 15-16-19 21. Assure air delivery to control port on spring brake 41. Assure adequate trailer brake function.
(port furthest from brake adjuster).
Trailer Emergency Application Too Slow 42. Confirm and replace with emergency relay valve,
22-28 22-28 22-28 22-28 22-28 22-28 22-28 22-28 22-28 22. Assure open lines - no kinks, bends, closed shut-off 1/4 Delivery or 3/8 Delivery.
cocks, restrictions, excessive elbows.
Park/Emergency Brakes Won’t Release 7-11-17- 7-17-18- 7-17-18- 7-11-17- 7-11-13- 7-11-13- 7-11-17- 7-11-13- 43. Confirm and replace with FFV (Full Function Valve)
7-17-18- 18-19 22 19-22- 19-22- 19-22- 17-19 17-19-22- 19-22- 17-19- 23. Check for trapped service air pressure at trailer System.
19-22-42 42 42 51 40 22- 54 40 40 53 service/delivery hoses. If air pressure is noted, check
for full release of all application valves 44. Assure adequate tractor brake function.
Park/Emergency Brakes Won’t Hold 3-4-36 or 3-4-36 3-4-36 3-4-36 or 3-4-36 or 3-4-36- (tractor/truck/trailer).
3-4-19 37 19- 32 19- 32 or 37 or 37 37 37 or 37 45. Assure adequate pressure and timing balance relative to
24. Trailer brakes which have a spring brake control valve tractor/trailer application.
Park/Emergency Brakes Won’t Apply 4-12-19- 4-10-12- 4-10-12- 4-10-12- 4-10-12- 4-10-12- can be compounded by the tractor air brake system. 46. Consider addition of “FAB Valve” to accelerate trailer
4-12-19- 36 or 37 4-12-19- 4-12-19- 36 or 37- 36 or 37- 36 or 37- 36 or 37- 36 or 37- The compounding occurs when service air pressure timing.
42 -42 42 51 40 54 54 40 53 is trapped in the trailer service line by the tractor
protection valve when the supply line is released to 47. Consider use of “jumper hose analyzer” and duplex
Air Reservoir Leaks or Loose Mounting 35 35 35 35 35 35 35 35 35 atmosphere. Compounding is prevented by gauge to pin-point brake imbalance.
connecting the trailer service line to the appropriate
port of the trailer spring brake control valve through a 48. Assure full mechanical release - foundation brake.
BRAKE BALANCE tee. Early spring brake control valves are equipped
49. Assure “push-out” pressure or initial brake adjuster
4-22-45- 4-22-45- 4-22 46- 4-22 46- 4-22-45- 4-22-45- 4-22-45- 4-22-45- 4-22-45- with a shuttle valve between the supply and service
Semi-Trailer “RUNS-UP” on Tractor 46-47-49 46-47-49 47-49 47-49 46-47-49 46-47-49 46-47-49 46-47-49 46-47-49 connections at the cover. The RT-4 has a one- way
motion at 3 to 7 P.S.I. - at all brakes.
check valve which prevents supply pressure from 50. Proceed per problem “trailer brakes drag.”
Uneven Brakes 3-4-22- 3-4-22- 3-4-22- 3-4-22- 3-4-22- 3-4-22- 3-4-22- 3-4-22- 3-4-22- entering the service lines; but will allow service
31-49 31-49 31-49 31-49 31-49 31-49 31-49 31-49 31-49 pressure to vent at trailer supply coupling. Systems A, B, 51. Confirm and replace with emergency relay valve
C, D will not compound the trailer brake system if (non-charging).
Trailer Brake Lining Wear Excessive connected as shown on this chart.
48-50 27-44-50 44-50 44 27-44-50 27-44-50 27-44-50 27-44-50 27-44-50 52. Confirm and replace with pressure protection valve with
one-way check, 50 P.S.I. or 75 P.S.I.
25. Check for ruptured service brake diaphragm in spring
Trailer Brake Lining Wear Insufficient When Compared to Tractor 4-16-45- 4-16-45- 4-16-45- 4-16-45- 4-16-45- 4-16-45- 4-16-45- 4-16-45- 4-16-45- brake (clamp nearest brake adjuster) after attention to 53. Confirm and replace with full function valve (FFV). FFV
46-47-49 46-47-49 46-47-49 46-47-49 46-47-49 46-47-49 46-47-49 46-47-49 46-47-49 damage or loose clamps. has built-in anti-compounding feature.
Trailer Brakes Slow to Apply 4-19-22- 4-19-22- 4-19-22- 4-19-22- 4-19-22- 4-19-22- 4-19-22- 4-19-22- 4-19-22- 26. Proceed same as for service relay valve. 54. Confirm and replace with spring brake priority or
46-47 46-47 46-47 46-47 46-47 46-47 46-47 46-47 46-47 service brake priority (FFABS) ABS full function valve.

Trailer Brakes Slow to Release 8-22-42- 8-22-42- 8-22-42- 8-22-47- 8-22-38- 8-22-38- 8-22-38- 8-22-38- 8-22-38-
47-48 47-48 47-48 48-51 47-48 47-48 47-48 47-48 47-48 NOTE: FOR FURTHER TECHNICAL ASSISTANCE CONTACT YOUR HALDEX SERVICES
Damaged Foundation Components Due to Brake Compounding DISTRIBUTOR, DISTRICT MANAGER, A TECHNICAL SERVICE REPRESENTATIVE OR
- 29 - 24 24 54 54 24 53 CALL (800) 643 -2374 AND ASK FOR A TECHNICAL ADVISOR.

Commercial Vehicle Systems

www.haldex.com Haldex Brake Products Corporation
10707 N.W. Airworld Drive
Kansas City, MO 64153 -1215
Haldex Limited
525 Southgate Drive, Unit 1
Guelph, Ontario CANADA N1G 3W6
Phone: (816) 891- 2470 Phone: (519) 826- 7723
Fax: (816) 801-4198 Fax: (519) 826-9497

L60040 US Rev 10/08 5M CUT