Service Bulletin

Volvo Trucks North America

Greensboro, NC USA Trucks
Date Group No. Release Page

4.2010 900 079 1( 5 )

Brakes and Air Systems, Compressors

VN, VHD
US 2010

Brakes and Air Systems, Compressors

This information provides details for Brakes and Air Systems applications in US 2010
VN/VHD vehicles.

Note: We have attempted to cover as much information as possible. However, this

information does not cover all the unique variations that a vehicle may present. Note that
illustrations are typical but may not reflect all the variations of assembly.

All data provided is based on information that was current at time of release. However, this
information is subject to change without notice.

Please note that no part of this information may be reproduced, stored, or transmitted by any
means without the express written permission of VOLVO Trucks North America, Inc.

Contents:
Design and Function, page 2

Return:
Brakes and Air System Index
General Index

PV776-88940165 USA37605
Volvo Trucks North America
Service Bulletin
Design and Function
Compressor
2COM1080
Compressor, General Information
2COM1080 is a two cylinder compressor. The task of the
compressor is to provide both the truck and trailer with
compressed air. Compressed air is mainly used in the
service brake system, but is also used for other functions
such as air suspension, ride height adjustment, gear
change systems, clutch and differential lock.
Air consumption of the various models of trucks varies
with their size and the amount of equipment which uses
compressed air. The compressor for the vehicles which
are covered here, have two cylinders and they are driven
by a gearwheel directly via the engine transmission. The
crankcase and cylinder block are air-cooled, while the
cylinder heads are liquid cooled via the engine cooling
system.
The compressor receives its lubrication via the pressure
lubrication system of the engine and the main and large
end bearings are thus pressure lubricated. The small end
bearing and piston are splash lubricated. The oil used by a
piston compressor to lubricate the piston and piston rings,
is separated in the air dryer and drains out of the air dryer
during the compressor pressure relief phase (together with
a considerably larger quantity of water).
Note: A certain amount of oil will show on the air dryer
silencer, which is normal and does not require any action.
Air flowing into the compressor is cleaned, dust and dirt
particles being removed by the air filter of the engine.
Before the air flows into the pneumatic system, the air is
dried in a separate air dryer to prevent water from getting
into the system.
The air flowing from the compressor, which is frequently
hotter than 150 C (302 F) is directed through a coil of
piping of between 3 and 5 meters (10 and 16 ft) in length, to
be cooled to about 60 C (140 F), before it enters the air
dryer. This is done to get the highest possible efficiency in
the air dryer and to protect rubber components.
The size of the compressor is intended to rapidly fulfil the
air requirements of the vehicle and to fill the compressed
air system. Its function can be divided into two phases;
charging phase and pressure relief phase.
Date Group No. Release Page
4.2010 900 079 2( 5 )
When the pre-set system pressure in the pressure regulator
is achieved, the pressure regulator transmits a signal to the
air dryers release valve, which opens and lets out the old
air together with water collected in the air dryer.
A new energy saving function Power Reduction (PR) has
been introduced on these compressors. This is a relief
function that shuts off the compressors air supply to the
pneumatic system when the pre-set system pressure in
the pressure regulator is achieved. A small amount of the
normal air volume will be allowed to flow from the air dryer
silencer when the compressor is relieved. The PR signal to
the compressor originates from the air dryer relief function.
When the system pressure has decreased to the pre-set
connecting pressure, the pressure regulator closes
the release valve of the air dryer which drains the PR
connection, which closes the PR valve with the aid of
a return spring. The compressor now begins filling the
compressed air system.
The idling speed of the electrically controlled cooling fan
(FAN-VISE) is lower compared with earlier fans which
reduces the cooling capacity of the cooling loop at low
speed.
In order to ensure cooling capacity in vehicles with this
type of fan, an intelligent fan control has been introduced
which means that the fan is at least 50 % engaged when
the compressor is charging.
The fan control only functions when the outside temperature
is higher than + C (+ F), the engine speed is higher than
700 r/m and the speed of the vehicle is less than 45 km/h
(28 miles/h).
There are two different ways for the fan to know when the
compressor is charging, depending on whether the vehicle
has air suspension or leaf suspension. On vehicles with air
suspension the signal comes from existing system pressure
sensors (low or increasing pressure means that the
compressor is charging. On vehicles with leaf suspension
the signal comes from a pressure connection mounted on
the control wire between the compressor and the air dryer.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 900 079 3( 5 )

Compressor, Function
A vacuum is created in the cylinders as the pistons travel
downwards and makes the inlet valves open. The inlet
ducts are opened and the induction air, which has been
filtered by the engine air filter, flows into the cylinders.

When the piston travels upwards, the inlet valve closes

(by the pressure in the cylinder) and the induction air is
compressed.

When the pistons approach their top positions and the

pressure in the cylinders exceeds the pressure from the
spring and the air above the exhaust valves, the exhaust
valves will open and the compressed air will pass into the
compressed air system.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 900 079 4( 5 )

Compressor, Power Reduction Function

When the system pressure has reached the pre-set release
pressure in the pressure regulator of the air dryer, the
release valve opens and lets out the old air from the
compressor, together with the water collected from the air
dryer

At the same time the PR valve in the cylinder head of

the compressor is activated by a pressure signal from
the pressure regulator, which leads to air being pumped
forwards and backwards between the cylinders instead of
delivering air to the compressed air system.

A small part of the normal amount of air from the compressor

now flows through the release valve of the air dryer and the
silencer when the compressor runs released.

When the system pressure has declined to 100 kPa (1bar)

the pressure regulator of the air dryers release valve closes
and drains the PR connection of air pressure, which closes
the PR valve with the help of a return spring.

The compressor now begins charging the compressed air

system.

In the PR function it is important to have the correct signal

speed in order that the function should work satisfactorily.
A signal lead that is not sealed makes the speed of the
signal incorrect.

For further information on relieving the compressor, please

refer to the service information Air dryer for group 56.

A. Open position, compressor idle.

B. Closed position, compressor pumping.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 900 079 5( 5 )

Compressor Routing and Water Separator

The compressor is routed to eventually connect with a water
separator. The water separator acts as a filter to remove
excess moisture from the air coming from the compressor.

W2003848

Compressor Routing on D11 Engine

W2003885

Compressor Routing to Water Separator