I

AIR BRAKE SYSTEM TROUBLESHOOTING

SYMPTOM CAUSE REMEDY

S,.. Compressor
Passes excessWe oil Restricted oil return Make sure oil return line is free of kinks and sharp bends. Minimum return line should be 5/8"
O.D. or 1/2" 1.0. Make sure oil return in compressor and mating engine surfaces are clear and
aligned. Use caution when using gasket sealant.
Excessive ring wear Check air intake to make sure air is properly fillered. Check discharge line for restriction or carbon
build up. Clean or replace as necessary. Check compressor cooling system. Min. water line - 1/2"
0 .0 . Min flow rate - 2.5 gaVmin at engine governor speed. Water temp. 200• F max.
Restricted air intake Check engine or compressor air cleaner - replace as necessary.
Excessive engine crankcase pressure. Test for excessive engine crankcase pressure. Clean breather or rep{ace positive crankcase
ventilation valve.
Excessive build up and recovery lime (85-100 PSI in 40 Excessive air leak in system Check air valves for leaks at exhaust ports. Check lines for cracks or leaks at fittings.
seconds with engine at foll governed RPM)
Restricted air discharge line. or sticking Check discharge line tor restrictions and carbon build-up. Clean or replace line as necessary.
reservoir inlet check valve
Unloader valves sticking Clean and lubricate. If plungers are bent, replace with new unloader kit.
Faulty or mis-adjusted air governor Replace governor.
Faulty compressor drive Check pulley to make sure belt is not slipping. If gear driven check gear. Replace tt worn.
Noisy compressor Loose drive gear or pulley Check compressor drive system. Tighten if necessary. Torque the crankshalt nut to 100 It. lbs.
maximum. Do not use impact wrench.
Excessive worn drive gear Inspect drive gear and coupling. Fiber gears should be replaced when compressor is changed.
Pumps beyond cut-out Faulty or mis-adjusted governor or Test governor for proper operation. Inspect air lines to and from governor tor kinks and
governor is improperly installed restrictions. Replace tt necessary.
Unloader valves sticking Clean and lubricate. If unloader stems are worn, replace.
Governor
Flutters Restricted reservoir line Check governor reservoir line for kinks, restriction. Clean or replace line as necessary.
Out of adjustment Only adjust after making sure gauge is accurate. To raise pressure setting, tum adjustment screw
counter-ctockwise. To lower pressure setting. tum adjusting screw clockwise (1/4 tum= 416 PSI.)
Excessive air leak in system See #1 cause - Excessive air leak.
Air Dryer
Dryer is constanUy cycting or purging Defective governor Check governor for proper ·cut-out" pressure. Repair or replace governor.
Defective check valve between dryer and Repair or replace as necessary.
first tank
Kinked or plugged discharge Check to see that air is passing through compressor discharge line. Check for kinks, bends or
excessive carbon build up. Clean or replace discharge line.
Excessive air leak in system See #1 cause - Excessive air leak.
Dryer does not purge or exhaust air Line between governor and dryer kinked, Check lo make sure air nows through purge control line When compressor is unloaded. Clean or
plugged or frozen replace purge control line.
Faulty heater or thermostat {allowing purge Repair or replace thermostat/heater.
valve to freeze)
Faulty purge valve. Alter determining air reaches purge valve. repair or replace purge valve.
Supply Reservoir
Excessive water accumulation Failure to drain tank Drain tank daily. Install air dryer or automatic drain valve.
Ex~ive oil accumulation Compressor passing excessive oil See #1.
Contaminaied air dryer desiccant cartridge Replace desiccant cartridge.
Front Brake Reservoir
Excessive oil or waler accumulation See il4
Loses air pressure See #8 and #11

Rear Brake Reservoir

Excessive oil or water accumulaUon See#4
Loses air pressure · See #8 and #11

Safety Valve
Pops off at 150 PSI System pressure too high Check governor •cut-out' setting. Readjust if necessary or replace governor if faulty
Plugged governor sensing line Clean or replace line.
Pops off below 150 PSI Faulty safety valve Replace valve #7.
Will not function Faulty safety valve Test with shop air at 150 PSI. Replace valve tt ,t does not pop off al 150 PSI.

One-Way Check Valve •

Allows air to bleed back to suoo!v reservoir Dirtv or faullv one-wav check valve Replace valve #8.

Page 10 QUALITY HEAVY DUTY PARTS

 AIR BRAKE SYSTEM TROUBLESHOOTING
·- - - ------- - -
~ Low Pressure Switch
Will not operate at pressures below 60 PSI Faulty buzzer or light Repair or replace #9.
Faulty dash gauge Repair or replace #10.
Buzzer or light will not operate Bad ground connection Check all wiring and ground lo buzzer, light and low pressure switch.

In>- Dash Gauge

Improper reading Faulty dash gauge Calibrate or replace gauge #10.

~ Two-Way Check Valve

Front or rear brake reservoir loses air pressure Check valve not seating properly Replace valve # 11 .

~ Two-Way Check Valve

Foot valve leaks at exhaust port when hand valve is applied. Check valve not seating properly Replace valve #12 or #19.
Hand valve leaks at exhaust port when fool valve is applied. Check valve not seating properly Replace valve #12.

~ Limiting and Quick Release Valve

Front breaks release 100 slowly Possible contamination in valve Replace valve #t 3.
Severe front brake application. Faulty valve Replace valve # t 3.
Leaks al exhaust port. Bad diaphragm in valve Replace valve #13.

~ Foot Valve
Leaks at exhaust wilh all brakes released. Leak in anti-compounding system Check #21 (Springbrake Valve) for bad double check valve causing back flow
to foot valve. Repair or replace #21 .
Leaks al exhaust with hand valve applied and foot valve released. Faulty two-way check valve Replace check valve #12 or #19.
Leaks at exhaust with foot brake applied. Possible conlarninalion in valve or faulty foot valVe Replace foot valve #14.
Brakes not modulating properly. Firs! no brakes, then on all at once. Faulty relay valve Replace relay valve #23.

bl>- Traller Hand Control Valve

Leaks at exhaust when only foot valve is applied. Faulty two-way check valve Replace check valve #12.
Leaks at exhaust port when in applied or released position. Faulty hand control valve Replace hand control valve #15.

11),, Trailer Charge Dash Valve

(red octagon knob)
Will not automatically pop out When air pressure is below 40 PSI. Faulty dash valve Replace dash valve #1 6.
Trailer brakes will not immediately apply When valve is pulled. Dash valve nol exhausting properly Replace dash valve #16.
Faulty tractor proteclion valve If dash valve wiTI exhaust, replace tractor protection valve #20.
Leaks at exhaust port Faulty dash valve Replace dash valve # 16.

D>, Tractor-Trailer Park Valve

(yellow diamond knob)
Leaks at exhaust port. Faulty par1< valve Replace valve #17.
Par1<ing brakes will not release. Defective springbrake valve Replace valve #21 .
Par1<ing brakes will not apply. Defective springbrake valve Replace vaJve #21.
Defective springbrake See #24.
n:,.. Tractor Park Valve
(round blue knob)
Leaks at exhaust port. Faulty par1< value Replace valve #18.
Tractor parking brakes will not release. Defective springbrake vaJve Replace valve #21 .
Tractor par1<ing brakes will not apply. Defective springbrake valve Replace valve #21 .
Defective springbrake See #24.
~ Double Check Valve with Stop Light Switch
Brake lights w!ll not come on when foot brake Is applied. Contamination in valve Replace valve #19.
Bad wiring or bulb Repair or replace as needed.
!:Ji,- Tractor Protection Valve
Will not respond to trailer charge valve. Will not shut off air in tractor Defective tractor proteclion valve Replace valve #20.
serv,ce line when trailer air pressure is below 45 PSI.

fi),- Sprtngbrake Valve

Will not allow modulating control of springbrakes via fool valve atter Faulty valve Replace valve #21.
loss of service brake air pressure.
Leaks at exhaust. Contamination in valve Replace valve #21 .

~ Sprtngbrake ControVAetay Valve

Leaks at exhaust pon. Contamination in valve Repla.ce vaJve #22.
Slow application or release of springbrakes. Piston in springbrake control valve is sticking. Replace valve #22.
Possible problem wilh springbrake, eg: misaligned
push rod and slack adjuster See #24 , #27.
~ Service Brake Relay Valve
Leaks at exhaust pon with springbrakes released. Possible leak at center seal in springbrake Replace with new piggy back.
Leaks at exhaust port with service brake applied. Contamination in valve Replace relay valve #23.
Faulty relay valve Replace relay valve #23.
~ Tandem Sprlngbrakes
Service brakes are slow to apply. Problem wilh relay valve 1123 or springbrake valve #21 Replace valve(s) #21 & #23.
Possible problem with foundation brakes Check linings. S-cams, rollers and return springs.
Brakes not properly adjusted See #27.
Restriction or leak in air line Repair or replace.
Service brake leaks Diaphragm failure Replace diaphragm.
Par1< brake slow to apply or release Faulty springbrake control valve Replace #22.
Diaphragm failure Replace piggy back.
Leak in air system - not enough air pressure Repair leak.
Broken return spring Replace service chamber
Broken barren spring Replace piggy back.
Springbrake leaks when par1<ing brakes are released. Center seal leaking in brake Replace piggy back. Leak may be heard at relay valve #22.

fJ;,,,- Trailer Air Reservoir

Excessive oil or water accumulation See #4

~ Sprlngbrake Valve
Leaks al exhaust porL Faulty or contaminated valve Replace #26.
Stow application or release of trailer par1< brakes. Possible problem with springbrake See #24. Par1< brake slow to apply or release.

llJ>- Service Chamber

Leaks Diaphragm failure Replace diaphragm.
Slow to apply or release. Faulty relay valve Replace relay valve #23.
R estriction in air line Repair or replace line .
Faulty quick release valve Replace #13.
Possible problem wilh foundation brakes Check linings, &<:ams. rollers and return springs.
Brakes not properly adjusted

Page 11
QUALITY HEAVY DUTY PARTS
 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 vehicle's 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, lubricati ng or rel ining. -Brakes need adjusting, lubri cating or relini ng. Engine Stopped and Brakes Released
-Low air pressure in the brake system (below 60 -Improper al(le mounting. -Leaking brake valve.
psi). -Grease on brake li ni ng - rel ine brakes. -Leaking tu bing or hoses.
-Brake valve delivery pressure below normal. -B rake shoe return spring broken. -Compressor discharge valves leaking.
-Wrong size actuators and/or slack adjusters. -Brake drum out of round. -Governor leaking.
-Fail ure of part of a dual air system. -B rake chamber diaphragm failure. -Excessive leakage elsewhere in the air brake supply
-If remote mounted brake valve, check linkage. -Wrong brake lining. system.
-Broken lack adj uster or fo undation brake parts. -Inadequate reservoir volume - hi gh 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 wi th brakes applied. -Governor out of adjustment brake cylinder.
-Restricted tubing or hose. -Slipping compressor drive belt. -Valve lefr open.
-Treadle travel restricted . -Faulty compressor. -Leaking brake valve.
-If remote mounted brake valve. check linkage. -Broken supply line. -Leaki ng tubing or hose line.
-Excessive water in reservoirs.
3.) Brakes Release Too Slowly -Inadequate reservoir vol ume.
-B rakes need adjusting or lubricating. 9.) Air Pressure Rise To Normal
-Brake valve not returni ng to fully released Too Slowly
position. -Excessive valve or fitting leakage. 13.) Compressor Knocks Continously
-Restricted tubi ng or hose. -Excessive reservoir volume . or Intermittently
-Exhaust pon of brake valve, quick release valve, or -Clogged compressor air strainer.
-Loo e drive pulley.
relay valve restricred or plugged. -Engine speed too slow.
-Back lash in drive gears or drive coupling.
-Faulty brake valve, quick release valve, or relay -Compressor discharge valve or inlet valves
-Worn or burnt out bearings.
valve. leaking.
-Excessive carbon deposits in compressor cylinder
-If remote mounted brake val ve, check linkage. -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 cyli nder head or 14.) Safety Valve ''Blows Oft"
-Restricted or broken rubing or hose. discharge line.
-Safety valve out of adjustment.
-Faulty brake valve.
-Air pressure in the air brake system above normal
If remote mounted brake valve. check linkage.
due to faulty unloader mechanism or faulty governor.
10.) Air Pressure Rises Above Normal
5.) Brakes Do Not Release -Faulry air gauge ( registeri ng incorrectly).
-Brake rigging binding. -Governor out of adjustment.
-Faul ty governor and safety valve.
15.) Excessive Oil or Water in the
-B rake not in fu ll y released position.
-Faulty brake valve or re lay valve. -Restriction in Line between governor and Brake System
-Restricted or collapsed tubing or hose. compressor or re tricted unloading valve. -Reservoirs not being drained oftem enough.
-if remote mounted brake valve, check linkage. -Too much clearance at compressor unloader -Compressor passi ng excessive oil.
valves or compressor unloading mechanism stuck -Compressor air trainer restricted.
6.) Brakes Grab or Erratic Brake in closed position. -Excessive engine oil pressure.
-Back pressw·e from engine crankcase.
-Grease on brake lining = reline brakes.
-Excessive oil (fl ooding) in compressor crankca e.
-Faulty brake valve or relay valve.
-Brake rigging binding.
-No vehicle load = h.igb brake pressure.

Page 12 QUALITY HEAVY DUTY PARTS

 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 vehicle's 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.
-Brake rigging binding. -Grease on brake lining - reline brakes.
system of the towing vehicle for its air
-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. -Lealci.ng 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.
- o air pressure in ai r 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. -Leaking brake chamber diaphragm.
-Brakes need adjusting, lubricating or relining. -Brake rigging binding. -Leaking tubing or hose.
-Tractor protection valve not in "normal" position. -Relay emergency valve in emergency position. -Hose uncoupled or leaking hose coupling.
-Faulty relay emergency valve. -Fau lty 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 10.) Excessive Leakage with Relay
psi). or not placed in " normar· position.
-Brake valve delivery pressure in towing vehicle Emergency Valve in Emergency Position
below normal. -Faulty relay emergency vah·e.
6.) Brakes Grab
-Restricted tubing or hose. -Grease on brake lining - reline brakes.
-Wrong size actuators. 11.) Excessive Oil and Water Present
-Brake rigging binding.
-Faulry relay emergency valve. in the Air Brake System.
2.) Brakes Apply Too Slowly -Faulry 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.

Page 13
QUALITY HEAVY DUTY PARTS
 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. Defecti ve 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 passe 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 mate1ial 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 I- 1/2' of flex hose for each I ' 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 fi 1ter. 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 conu·ol 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/beater.
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.

Page 14 QUALITY HEAVY DUTY PARTS