Air Brake Charging System Troubleshooting
How to use this guide:
Find the symptom(s) that you see, then move to the right to find the possible causes (“What it may indicate”) and remedies (“What you should do”).
Review the warranty policy before performing any intrusive compressor maintenance. Unloader or cylinder head gasket replacement and resealing of the bottom cover plate are usually permitted under warranty. Follow all standard safety procedures when performing any maintenance.
Look for:
Normal - Charging system is working within normal range.
Check - Charging system needs further investigation.
WARNING! Please READ and follow these instructions to avoid personal injury or death:
When working on or around a vehicle, the following general precautions should be observed at all times.
1.Park the vehicle on a level surface, apply the parking brakes, and always block the wheels. Always wear safety glasses.
2.Stop the engine and remove ignition key when working under or around the vehicle. When working in the engine compartment, the engine should be shut off and the ignition key should be removed. Where circumstances require that the engine be in operation, EXTREME CAUTION should be used to prevent personal injury resulting from contact with moving, rotating, leaking, heated or electrically charged components.
3.Do not attempt to install, remove, disassemble or assemble a component until you have read and thoroughly understand the recommended procedures. Use only the proper tools and observe all precautions pertaining to use of those tools.
4.If the work is being performed on the vehicle’s air brake system, or any auxiliary pressurized air systems, make certain to drain the air pressure from all reservoirs before beginning ANY work on the vehicle. If the vehicle is equipped with an
5.Following the vehicle manufacturer’s recommended procedures, deactivate the electrical system in a manner that safely removes all electrical power from the vehicle.
6.Never exceed manufacturer’s recommended pressures.
7.Never connect or disconnect a hose or line containing pressure; it may whip. Never remove a component or plug unless you are certain all system pressure has been depleted.
8.Use only genuine Bendix® replacement parts, components and kits. Replacement hardware, tubing, hose, fittings, etc. must be of equivalent size, type and strength as original equipment and be designed specifically for such applications and systems.
9.Components with stripped threads or damaged parts should be replaced rather than repaired. Do not attempt repairs requiring machining or welding unless specifically stated and approved by the vehicle and component manufacturer.
10.Prior to returning the vehicle to service, make certain all components and systems are restored to their proper operating condition.
11.For vehicles with Antilock Traction Control (ATC), the ATC function must be disabled (ATC indicator lamp should be ON) prior to performing any vehicle maintenance where one or more wheels on a drive axle are lifted off the ground and moving.
Symptom: | What it may indicate: | What you should do: |
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1.0 Oil Test Card | Not a valid test. |
Results |
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| û |
Bendix®
BASIC Test
ü
Discontinue using this test.
Do not use this card test to diagnose compressor "oil passing" issues. They are subjective and error prone. Use only the Bendix Air System Inspection Cup (BASIC) test and the methods described in this guide for advanced troubleshooting.
The Bendix® BASIC test should be the definitive method for judging excessive oil fouling/oil passing. (See Appendix A, on page 32 for a flowchart and expanded explanation of the checklist used when conducting the BASIC test.)
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