11
Advanced Troubleshooting Guide for Air Brake Compressors
Air brake charging system:
Slow build (9.0) .....................................19 - 20
Doesn’t build air (10.0) .................................21
Air dryer:
Doesn’t purge (14.0) ....................................22
Safety valve releases air (12.0) ................... 22
Compressor:
Constantly cycles (15.0) ..............................22
Leaks air (16.0) ............................................23
Safety valve releases air (11.0) ...................21
Noisy (18.0) ................................................23
Reservoir:
Safety valve releases air (13.0) ................... 22
INDEX
Air
Coolant
Engine
Oil
Compressor leaks coolant (17.0) ...................... 23
Oil consumption (6.0) ....................................... 19
Oil Test Card results (
1.0) .................................. 14
Oil is present:
On the outside of the compressor (2.0) ....... 15
At the air dryer purge/exhaust
or surrounding area (3.0) ......................... 15
In the supply reservoir (4.0) .................. 16 - 18
At the valves (5.0) ........................................ 18
At air dryer cartridge (7.0) ............................ 19
In the ping tank or compressor
discharge aftercooler (8.0) ....................... 19
Symptom Page Number
(1) Oil Leakage at Head Gasket ........ 24
(2) System Leakage .......................... 24
(3) Compressor Discharge and
Air Dryer Inlet Temperature ...........
24
(4) Governor Malfunction ................... 24
(5) Governor Control Line .................. 25
(6) Compressor Unloader .................. 25
BASIC Test Information ................
26-28
Test Procedures
Maintenance Schedule and
Usage Guidelines (Table A) .......
13
Symptom Page Number
Maintenance & Usage Guidelines
TORQUE SPECIFICATIONS
Assembly Torques in inch pounds (in. Ibs.)
M8x1.25-6g Cylinder Head .......... 265-292 In. Lbs. (30-33 Nm)
M5x0.75-6g Unloader Cap ................... 62-71 In. Lbs. (7-8 Nm)
M8x1.25-6g Governor Adapter .... 195-213 In. Lbs. (22-24 Nm)
M8x1.25-6g Rear End Cover ....... 195-213 In. Lbs. (22-24 Nm)
M6x1.00-6g Crankcase Cover ........... 62-71 In. Lbs. (7-8 Nm)
M20x2.50-6g Crankshaft Nut 1858-2567 In. Lbs. (210-290 Nm)
Inlet Port Fittings
1 3/16"-12 UN-2B .......................... 575-637 In. Lbs. (65-72 Nm)
M27 x 2.0 ....................................... 575-637 In. Lbs. (65-72 Nm)
Discharge Port Fittings
7/8"-14 UNF-2B ............................. 460-504 In. Lbs. (52-57 Nm)
M22 x 1.5 ....................................... 195-213 In. Lbs. (22-24 Nm)
Water Port Fittings
3/4"-16 UNF-2B ............................. 319-245 In. Lbs. (36-39 Nm)
M18 x 1.5-6g ................................. 230-257 In. Lbs. (26-29 Nm)
Unloader Port Fittings
1/8"-27 NPT .............................................................. 2 - 3 TFFT
1
M10 x 1.5-6g ................................. 120-145 In. Lbs. (14-16 Nm)
Safety Valve Port
M16 x 1.5 ....................................... 230-257 In. Lbs. (26-29 Nm)
3/4"-16 UNF-2B ............................. 319-345 In. Lbs. (36-39 Nm)
7/8"-14 UNF-2A ............................. 319-345 In. Lbs. (36-39 Nm)
1/2"-14 NPT .............................................................. 2 - 3 TFFT
1
Oil Port
7/16"-20 UNF ....................................97-115 In. Lbs. (11-13 Nm)
M12 x 1.5-6g ................................. 142-159 In. Lbs. (16-18 Nm)
1
Note: TFFT = Turns From Finger Tight
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