Truck Commercial Vehicle Systems

Haldex Brake Products Corporation Haldex Limited

Troubleshooting 10707 N.W. Airworld Drive

Kansas City, MO 64153 -1215
Phone: (816) 891- 2470
525 Southgate Drive, Unit 1
Guelph, Ontario CANADA N1G 3W6
Phone: (519) 826- 7723

Guide Fax: (816) 801-4198 Fax: (519) 826-9497

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18b
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COMPLAINT/REMEDY COMPLAINT/REMEDY COMPLAINT/REMEDY COMPLAINT/REMEDY

1 COMPRESSOR 7 SINGLE CHECK VALVE 15 SPRING PARKING BRAKE (SERVICE ONLY 21 ABS INLINE VALVES
■ PUMPS BEYOND “CUT-OUT” ■ ALLOW BLEED BACK TO SUPPLY RESERVOIR
◆ Check gauge. ◆ Periodic Test: bleed supply reservoir and observe gauges. Check valves SERVICE CHAMBER SIDE OF SPRING ■ FOR COMPLETE TROUBLESHOOTING INFORMATION REFER TO LITERATURE
◆ Check governor.
◆ Be certain it pressurizes unloader port when above “cut-out”.
should maintain rear and front reservoir pressure. BRAKE) PIECES MODAL POWER TK-2 INSTALLATION & SERVICE MANUAL (L30022)
◆ Replace it if results are negative.
■ AND/OR ABS DIAGNOSTIC TROUBLESHOOTING GUIDE (L20293)
◆ Check unloader/plungers. Lube, kit or change head. PARK BRAKE DRAGS OR WON’T RELEASE
■ WON’T PUMP AIR
◆ Check gauge.
8 PRIMARY & SECONDARY RESERVOIR ◆ Check for: Improper adjustment, restriction or broken line. Diaphragm
failure. System pressure too low. Improper manual release. Broken 22 ABS SENSORS & EXCITER RINGS
■ EXCESS OIL/WATER
◆ Check compressor drive. return spring (spring side). Quick release of relay malfunction. Broken ■ FOR COMPLETE TROUBLESHOOTING INFORMATION REFER TO LITERATURE
◆ Drain as required. power spring.
◆ Check inlet valves and plungers. If stuck, leak will be evident at intake ◆ Check automatic drain valve on wet tank for proper operation (See #5). PIECES MODAL POWER TK-2 INSTALLATION & SERVICE MANUAL (L30022)
when unloaded. Install unloader kit, head kit or head assembly. ◆ Replace entire unit or piggy-back emergency section.
■ SLUGGISH PARK APPLICATION AND/OR ABS DIAGNOSTIC TROUBLESHOOTING GUIDE (L20293)
■ SLOW PRESSURE BUILD-UP
◆ Check gauge.
9 AIR GAUGE ◆ Check for: Diaphragm failure. Improper manual release. Broken power spring.
■ INCORRECT READING
◆ Check compressor drive. ■ LEAKS WHEN PRESSURIZED FOR PARK BRAKE RELEASE
◆ Calibrate or replace.
◆ Check intake for restriction. ◆ Check for: Ruptured spring side diaphragm. Push rod seal leakage (may be
◆ Check discharge line for restriction. evident at # 14 relay valve).
◆ Check unloader function. Lube or kit. 10 DUAL SYSTEM FOOT BRAKE VALVE ■ SERVICE CHAMBER MALFUNCTION NOTE: FOR FURTHER TECHNICAL ASSISTANCE CONTACT YOUR
◆ Check inlet and exhaust valves. Leak will be evident at intake when ■ LEAKS AT EXHAUST WITH ALL BRAKES RELEASED ◆ See #12 service brake chamber.
unloaded. Kit or exchange head. ◆ Check anti-compound double check valve # 16. HALDEX DISTRIBUTOR, YOUR LOCAL HALDEX SALES
■ PUMPS EXCESSIVE OIL ◆ Check #18a and 18b for back flow into service control line. PROFESSIONAL, OR CALL (800) 643-2374 AND ASK FOR A
◆ Check oil return for restriction, kink or loop. ■ CAUTION: CHOCK WHEELS - Repair and replace items as necessary. 16 QUICK RELEASE AND DOUBLE CHECK TECHNICAL ADVISOR.
◆ Check for gasket sealant obstructing drain.
◆ Check for undersize return line (1/2” minimum).
■ LEAKS AT EXHAUST WITH FOOT BRAKE APPLIED VALVE COMBINATION
◆ Foot valve defective. Repair or replace.
◆ Check for fitting restricting drain. ■ FOOT VALVE EXHAUST LEAK PARK BRAKES RELEASED YELLOW DASH
■ LEAKS AT EXHAUST WITH ALL PARK BRAKES SET IN PARK POSITION
◆ Check for intake vacuum (20” water maximum). CONTROL VALVE EXHAUST LEAK IN PARK POSITION AND SERVICE
◆ Check for excessive engine crankcase pressure (poor engine ventilation). AND FOOT BRAKE RELEASED BRAKES APPLIED
◆ Check compressor ring wear. Exchange for service unit. ◆ Foot valve defective. Repair or replace. ◆ Check anti-compound double check valve portion for feedback to foot
or dash control valve. Repair or replace.
2 WET TANK
■ EXCESS OIL ACCUMULATION
◆ See PUMPS EXCESSIVE OIL (above). 17 STOP LIGHT SWITCH
■ EXCESS WATER ACCUMULATION 11 QUICK RELEASE VALVE ■ LEAKS
◆ Drain daily. Install automatic drain on wet tank. ■ LEAKS AT EXHAUST PORT WITH ALL BRAKES RELEASED
■ ◆ Check and replace #18b if back flow occurs into service delivery line. ◆ Replace.
DAMAGED WET TANK
■ ■ FAILS TO SIGNAL A GOOD BULB THROUGH SOUND WIRING AT 3-6 P.S.I.
◆ Replace. LEAKS WHEN SERVICE BRAKES ARE APPLIED
◆ Repair or replace. ◆ Replace.
3 LOW PRESSURE INDICATOR SWITCH
■ BUZZER OR LIGHT INOPERABLE. 12 SERVICE BRAKE CHAMBER 18a INVERSION RELAY VALVE WITH THE LOSS
◆ Check ground and wiring on switch and buzzer/light. ■
◆ Replace switch or buzzer/light.
LEAKS
◆ Replace diaphragm.
OF REAR SERVICE BRAKES, APPLICATION
■ WON’T OPERATE AT PRESSURES BELOW 60 P.S.I. ◆ Cage park brake. 18b OF SPRING BRAKE BY USING THE
◆ Check dash gauge for accuracy. ◆ Reset clamps.
◆ Replace switch or buzzer/light. ◆ Adjust brakes. EMERGENCY SECTION SHOULD BE
■ WITH SERVICE BRAKES AVAILABLE ALONG WITH FRONT
4 SAFETY VALVE APPLIED STROKE IS AT OR
BEYOND MAXIMUM LIMIT OF: SERVICE BRAKE BY APPLYING FOOT
■ ”POPS” OFF EXCESSIVELY. ◆ Type 9
◆ Check system pressure. ◆ Type 12
1 3/8”
1 3/8”
VALVE
◆ Valve operating properly in venting at 140/150 P.S.I. ◆ Type 16 1 3/4” ■ Periodically test by bleeding rear service tank and observing front brake and
◆ Check unloader/governor. ◆ Type 20 1 3/4” rear spring brake application upon depressing foot pedal. Repair or replace,
■ ”POPS” OFF AT LESS THAN 140 P.S.I. ◆ Type 24 1 3/4”
if after checking piping is not functioning properly.
◆ Replace. ◆ Type 30 2”
■ LEAKS
■ ■ SLUGGISH APPLICATION OR
LEAKS ◆ Repair or replace.
◆ Replace. RELEASE
◆ Check basic brake.
■ WON’T FUNCTION ◆ Check for air line restriction/leak.
◆ Periodic Test: remove and test above 150 P.S.I. with shop air. ◆ Align linkage.
◆ Replace if non-functional. ◆ Check chamber return spring. 19 BARRIER WHEEL OIL SEALS
◆ Adjust brakes. Angle should approach 90° on application (NOT SHOWN IN SCHEMATIC)
5 DRAIN VALVES - MANUAL ◆ Check for improper chamber or obstruction.
■ ■ OIL LEAK
LEAKS
◆ Replace. ◆ Check for proper glazing of the sealing lip.
13 BRAKE ADJUSTER ◆ Check serrations on O.D. and I.D. to see that sealing surfaces are dry. If
5 DRAIN VALVES - AUTOMATIC ■ SLEEVE WILL NOT DEPRESS
◆ Clean and lubricate or replace with unit dimensionally same.
wet, this could denote the leakage path.
■ WON’T DRAIN ◆ Check area between positioning pads. If wet, suspect seal leak.
■ ADJUSTING SHAFT WILL NOT TURN
◆ Repair or replace. ◆ Check seal for possible damage incurred during installation.
◆ Replace with unit dimensionally same.
■ WON’T DRAIN IN COLD WEATHER ■ CRACKED HOUSING ◆ Check hub bore and spindle surfaces for imperfections or irregularities.
◆ Replace with heated unit.
◆ Check spring brake anti-compound system. ◆ Check to see that proper seal has been installed for the particular
■ LEAKS - MALFUNCTIONS ◆ Check air chamber size. Replace if larger than original size. axle application.
◆ Repair or replace. ◆ Check direction of travel for proper position of hex nut (Shown Under #12).
◆ Periodic Test: with system pressure stabilized (compressor unloaded) ◆ Hex nut must face away from chamber for uni-directional brake adjuster.
no leak evident at discharge port - make several foot brake applications
to reduce wet tank pressure. Moisture should drain from discharge port.
■ WORN CLEVIS PIN BUSHING
◆ Replace bushing.
20 AIR DRYER
■ AIR LEAKING CONSTANTLY FROM PURGE VALVE
6 GOVERNOR ◆ Purge valve seal damaged. Replace.
■ FLUTTERS 14 RELAY VALVE ◆ Purge valve frozen.
■ LEAKS AT EXHAUST PORT WITH ALL BRAKES RELEASED
◆ Check gauge. ■
◆ Check seal in spring brake for back flow of spring “hold-off” pressure HEATER INOPERATIVE
◆ Check unloader line size (5/16” x 5’ maximum).
◆ Check air actuated accessory. Is the air volume requirement greater through service port to open exhaust on valve. Replace #15 Spring ◆ Blown fuse. Check fuse and replace with 8 - 10 amp fuse.
than governor capacity? Parking Brake. ◆ Broken wires or poor connections. Repair or replace wiring to heater.

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◆ Check for plugged governor reservoir line.
◆ Repair, adjust or replace governor.
WON'T PASS AIR TO UNLOADER TO “CUT-OUT” COMPRESSOR
◆ 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.
■ SLOW WET TANK BUILD-UP
◆ Filter and or desiccant plugged. Service air dryer.
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■ LEAKS AT EXHAUST PORT WITH SERVICE BRAKES APPLIED
◆ Check governor reservoir line.
◆ Repair or replace. ◆ Exhaust valve not seating properly. Repair or replace.

L60038 US Rev 10/08 5M CUT