FAULT DIAGNOSIS

Troubleshooting a problem depends on an in-depth analysis of the problem. Gather as much information as
possible to make solving it faster and easier. Attempt the easiest logical solution first. If that solution does not
work, then go to the next one in sequence. Although the troubleshooting table attempts to cover as many
common problems as possible, it is not possible to include all solutions to all problems. Factors that aid in
solving a problem include: gathering all the facts, analyzing the problem, relate problem symptoms to systems
and components and consider any recent maintenance worked performed related to the problem.

POWERPACK

Engine Assembly

Table 4-1 Engine assembly troubleshooting

Problem / Possible Causes Remedy

Excessive blow-by
Engine breather oil leak and or high oil 1. Check breather connection sealing.
steam pressure. 2. Check breather body for cracks.
3. Check engine compressibility (need
ST-100 certified Tech.) for high oil
steam pressure.
Air compressor malfunction Check air compressor blow-by (). Repair or
replace as necessary.
Turbocharger oil seal leaking Check turbocharger turbine and compressor
seals ().
Check turbocharger blow-by contribution ().
Repair or replace as necessary.
Valve stem clearance is excessive, or seals Check valve stems and seals ().
are excessively worn
Cylinder head valve guides are excessively Check the valve guides for wear (). Replace
worn cylinder head if necessary.
Piston or piston rings are excessively worn Check pistons and piston rings for wear or
or damaged. damage.
Engine difficult to start or will not start
Low fuel level. Check fuel tank level. Verify fuel gauge is
accurate. Refuel as needed.
Low fuel rail pressure Engage starting the engine for continuous 30
seconds then check fuel pressure value with
INSITE. If fuel pressure remains low, refer to
fuel system table.
Malfunctioning ECM Check for the battery voltage at the ECM
power and ground circuits. Check for faults
using INSITE
Low battery voltage
Slow cranking speed
Excessive fuel drain.
Check for air in the fuel system
Plugged fuel tank vent.
Poor fuel quality.
Excessive engine noise
Air intake or exhaust leaks
Fan is loose or damaged.
Lubricating oil is above or below
specification.
Lubricating oil pressure is low
High coolant temperature
Engine mounts worn or damaged.
Incorrect overhead adjustments
Injector malfunction
Turbocharger is worn or damaged.
Engine power output low
Air leaks
Fuel injector malfunction
Secondary fuel filter clogged.
Turbocharger seized or damaged
Air in the fuel
Incorrect overhead adjustments
Malfunctioning accelerator pedal
Check the battery voltage gauge. Replace
battery if necessary.
Minimum cranking speed must be greater
than 150 rpm.
Check suction side line and filter for loose
connections that allow air inside the fuel
system.
See section ().
Remove fuel tank cap. If engine starts,
inspect fuel tank vent for obstructions.
Operate the engine with a known good fuel
supply.
Inspect air intake and exhaust systems for
leaks.
Check the fan.
Add or drain oil as necessary.
Refer to Low lubricating oil pressure
problem.
Refer to coolant system table.
Replace engine mounts.
Measure and adjust the overhead settings.
Perform cut-out test (). Replace the injectors
as necessary.
Check the turbocharger for damage.
Measure the turbine and compressor wheel
clearances.
Inspect the air intake and exhaust systems
for leaks.
Perform cylinder cut-out test with INSITE.
Replace injectors as necessary.
Inspect and replace secondary fuel filter.
Inspect turbocharger. Repair or replace if
necessary.
Find and repair air leak. Bleed fuel system ().
Measure the overhead valve lash settings.
Adjust if necessary ().
Use INSITE to monitor accelerator pedal
position while depressing and releasing the
accelerator pedal. Verify the reading is 0

Poor fuel quality.
Engine running rough or misfires
Poor fuel quality.
Fuel injector malfunction
Fuel pump actuator malfunction
Secondary fuel filter clogged.
Air in the fuel
Incorrect overhead adjustments
Engine speed surge
Air in the fuel
Fuel pump actuator malfunction
Secondary fuel filter clogged.
Fuel injector malfunction
Turbocharger damaged
Engine starts but does not keep running
Fuel level low.
Low battery voltage.
Fuel leak.
Fuel filter or fuel suction line restricted
Air in the fuel.
Fuel lift pump malfunction
Poor fuel quality.
Engine will not shut of
Turbocharger oil seal leaking
Fuel fumes entering air intake
when pedal is released and 100 when pedal
is fully depressed.
Operate engine with known high-quality fuel.
Operate engine with known high-quality fuel.
Perform cylinder cut-out test with INSITE.
Replace injectors as necessary.
Remove actuator electric plug while the
engine is idling, if engine runs normally,
replace the actuator.
Inspect and replace secondary fuel filter.
Find and repair air leak. Bleed fuel system ().
Measure the overhead valve lash settings.
Adjust if necessary ().
Find and repair air leak. Bleed fuel system ().
Remove actuator electric plug while the
engine is idling, if engine runs normally,
replace the actuator.
Inspect and replace secondary fuel filter.
Perform cylinder cut-out test with INSITE (6-
26). Replace injectors as necessary.
Inspect turbocharger. Repair or replace if
necessary.
Refuel.
Check battery voltage. Replace battery if
necessary.
Check fuel lines, filters and connections for
leaks.
Check filter and suction line for restrictions.
Clean suction line. Replace fuel filter.
Find and repair air leak. Bleed fuel system ().
Measure fuel lift pump output pressure.
Replace if necessary.
Operate engine with known high-quality fuel.
Check the turbocharger turbine and
compressor oil seals.
Check the air intake ducts. Locate the source

ECM malfunction
FUEL SYSTEM
Table 4-2 Fuel system troubleshooting
Problem / Possible Causes
Fuel in coolant
Coolant is contaminated
Cylinder head is cracked or porous
Fuel in lubricating oil
Engine idling for too long
Fuel drain line restriction
Fuel injector malfunction
Internal fuel leaks
LUBRICATING OIL SYSTEM
Table 4-3 Lubrication system troubleshooting
Problem / Possible Causes
Lubricating oil contaminated with coolant
EGR cooler is leaking
Lubricating oil cooler malfunction
Air compressor cylinder head is cracked or
porous or gasket is leaking.
Internal coolant leaks
Turbocharger leaking coolant
Cylinder head gasket is leaking
Cylinder head is cracked or porous
Cylinder block is cracked or porous
Excessive lubrication oil consumption
Determine oil consumption rate
of the fumes. Repair as necessary.
Replace ECM.
Remedy
Drain and refill with non-contaminated coolant.
Pressure test the cylinder head ().
Engine should not remain idling for more than
10 minutes. Shut down engine or raise idle
speed.
Check fuel drain lines for restrictions. Clear or
replace the fuel lines, check valves or fuel tank
vents as necessary.
Perform a high-pressure injector return flow test
(). Replace injectors as necessary.
Inspect for leaks. Add fluorescent dye to fuel
system to locate source of fuel leaks.
Remedy
Check EGR cooler core for leaks.
Check the oil cooler.
Inspect the air compressor head and
gasket.
Refer to cooling system table.
Perform the crack detection test to
determine if bearing housing is cracked or
porous.
Remove the cylinder head and inspect for
signs of coolant leaks.
Pressure test the cylinder head ().
Inspect the cylinder block ().
Determine the amount of oil added against

External oil leak
Crankcase ventilation is obstructed
Lubricating oil does not meet specification
Lubrication change interval too long
Air compressor leaking oil into the intake
air system
Lubricating oil cooler leaking
Lubricating oil level above specification
Turbocharger oil seal leaking
Valve stem clearance is excessive, or seals
are excessively worn
Cylinder head valve guides are excessively
worn
Piston or piston rings are excessively worn
or damaged.
Lubricating oil contaminated
Identify contaminant
Fuel in the lubricating oil
Internal coolant leak.
Oil supply contaminated.
High lubricating oil pressure
Low coolant temperature
Lubricating oil change interval too long
Lubricating oil pressure sensor faulty
Oil pressure regulator faulty
Low lubricating oil pressure
Lubricating oil pressure sensor faulty
the operating hours.
Inspect the engine for external oil leaks.
Tighten the cap screws, fittings and
connection. Replace gaskets if necessary.
Check breather and vent tube. Clear vent
tube and replace breather if necessary. (3-1
3-18)
Drain and replace with correct lubricating
oil (7-37).
Check lubricating oil change interval.
Check the outlet air line for oil (12-3). Refer
to Intake air system table.
Check oil cooler for leaks.
Check oil level. Drain as necessary (7-9).
Check turbocharger turbine and
compressor seals (10-33). Repair or replace
as necessary.
Check valve stems and seals (2-4).
Check the valve guides for wear (2-4).
Replace cylinder head if necessary.
Check pistons and piston rings for wear or
damage (10-24).
Perform oil analysis (7-83).
Refer to fuel system table.
Refer to cooling system table.
Check the oil supply. Drain the oil and
replace with non-contaminated oil.
Refer to the coolant system table.
Check and replace the oil at the correct
lubricating oil change interval.
Check for faults on the lubricating oil
pressure sensor with INSITE. Replace oil
pressure sensor if necessary.
Replace oil pressure regulator (7-29).
Check for faults on the lubricating oil
pressure sensor with INSITE. Replace oil
pressure sensor if necessary.
 Lubricating oil level above or below
specification
External oil leak
Lubricating oil filter plugged
Lubricating oil does not meet specification
Incorrect oil filter
Lubricating oil is contaminated with coolant
or fuel.
Lubricating oil pressure sensor or circuit is
faulty
Lubricating oil pressure regulator faulty
Lubricating oil pump is faulty
Lubricating oil cooler is obstructed
Piston cooling nozzles damaged or not
installed correctly
High lubricating oil temperature
Low coolant temperature
Lubricating oil level above or below
specification
Lubricating oil temperature sensor or circuit
is faulty
Lubricating oil cooler is obstructed
COOLING SYSTEM
Table 4-4 Cooling system troubleshooting
Problem / Possible Causes
External coolant leak
Coolant level above specification
Check oil level. Add or drain as necessary
(7-9) (7-37).
Inspect the engine for external oil leaks.
Tighten the cap screws, fittings and
connection. Replace gaskets if necessary.
Measure and check the differential pressure
across the oil filter against specification.
Replace filter if pressure drop higher than
specification.
Drain and replace with correct lubricating
oil (7-37).
Replace with correct oil filter (18-24).
Refer to “Lubricating oil contaminated”
segment.
Check for faults on the lubricating oil
pressure sensor with INSITE. Repair or
replace as necessary (19-66).
Replace oil pressure regulator (7-29).
Insect the lubricating oil pump (7-37).
Check the oil cooler (7-3).
Check piston nozzles for damage and
correct installation (1-46).
Refer to the coolant system table.
Check oil level. Add or drain as necessary
(7-9) (7-37).
Check for faults on the lubricating oil
temperature sensor with INSITE. Repair or
replace as necessary (19-66).
Check the oil cooler (7-3).
Remedy
Check coolant level. Drain as necessary.
External leak.
Coolant hoses are restricted or
collapsed
Pressure cap is malfunctioning
Engine is overheating
Radiator overflow
Gearbox oil cooler leaking.
Internal coolant leak
Pressure cap malfunctioning
EGR cooler leaking
Air compressor head is cracked,
or gasket is leaking.
Lubricant oil contaminated with
coolant
Turbocharger bearing housing
cracked or porous
Cylinder head is cracked or
porous.
Cylinder head gasket is leaking
Cylinder block cracked or porous.
Coolant temperature above
normal
Charge air cooler fins, radiator
fins or air conditioner condenser
fins are damaged or obstructed.
Coolant level is below
specification
Incorrect distilled water and
antifreeze mixture
Fan shroud is damaged or
missing.
Fan clutch malfunction
Coolant temperature gauge or
sensor is malfunctioning
Inspect engine for leaks from seals, gasket, drain cock
and coolant lines.
Inspect radiator, gearbox oil cooler, EGR cooler and
turbocharger coolant lines.
Pressurize the coolant system if necessary to find the
source of the leak.
Inspect coolant hoses for restrictions or collapse.
Inspect pressure cap (section ).
Refer to engine troubleshooting table.
Check air compressor.
Pressure test the turbocharger, EGR cooler.
Pressure test gearbox oil cooler for leaks.
Check the radiator pressure cap.
Check EGR cooler for leaks.
Inspect air inlet and outlet lines for signs of coolant.
Replace compressor head and gasket.
Refer to lubricating oil system table.
Check turbocharger bearing housing (10-33)
Pressure test the cylinder.
Check the cylinder head gasket. Remove the cylinder
head gasket and inspect.
Inspect the cylinder block.
Inspect, clean or replace if necessary.
Check the coolant level. Check for external leaks.
Check lubricating oil for coolant contamination.
Verify the concentration of antifreeze in the water.
Add water or antifreeze to correct the concentration.
Repair, replace or install as necessary.
Check fan clutch and controls. Repair or replace as
necessary.
Test the gauge and sensor. Repair or replace as
necessary.
 Pressure cap malfunctioning.
Thermostat is malfunctioning
Coolant hose restricted, leaking
or collapsed.
Fill line or vent lines are
restricted.
Intake manifold air temperature
above specification
Lubricating oil level above or
below specification
Cooling system contaminated
with dirt.
Lubricating oil is contaminated
with coolant or fuel.
Water pump is malfunctioning
Air or exhaust gases are entering
the coolant system
Coolant contaminated with
lubricating oil or gearbox oil
Coolant supply is contaminated
Lubricating oil cooler leaking
Gearbox oil cooler leaking
Turbocharger bearing housing
cracked or porous
Cylinder head is cracked or
porous.
Cylinder head gasket is leaking
Cylinder block cracked or porous.
AIR INTAKE SYSTEM
Table 4-5 Air Intake system troubleshooting
Problem / Possible Causes
High intake air temperature
Charge air cooler fins, radiator fins or
air conditioner condenser fins are
damaged or obstructed.
Air temperature sensor faulty
Fan drive faulty
Check the pressure cap.
Check the thermostat for correct operation.
Inspect the hoses.
Check fill and vent lines for correct routing and
restrictions.
Refer to intake air system table.
Check oil level. Add or drain oil as necessary.
Clean the cooling system.
Refer to lubricating oil system table.
Check water pump for correct operation. Repair or
replace as necessary.
Check for air or exhaust gases in the coolant system.
Check coolant supply. Drain and replace with non-
contaminated coolant. Replace coolant filter.
Check the oil cooler (7-3).
Remove and inspect the gearbox oil cooler
Check turbocharger bearing housing (10-33)
Pressure test the cylinder.
Check the cylinder head gasket. Remove the cylinder
head gasket and inspect.
Inspect the cylinder block.
Remedy
Inspect, clean or replace if necessary.
Replace the air sensor
Check the fan drive and control (8-27).
 Fan shroud missing or damaged.
Exhaust gases leaking into engine
compartment.
EGR valve leaking
EGR Cooler malfunctioning.
EXHAUST SYSTEM
Table 4-6 Exhaust system troubleshooting
Problem / Possible Causes
Excessive black smoke
Significant air intake restriction
Air leak
Fuel system malfunction
High fuel inlet restriction
Intake manifold pressure or temperature
sensor or circuits faulty.
EGR valve faulty
Turbocharger malfunctioning
Inspect the shroud. Repair, replace or install.
Check the exhaust system for leaks.
Check the EGR valve for leaks (11-22).
Perform the EGR cooler leak test (11-19).
Remedy
Check if air filter is plugged. Check air intake
system for obstructions.
Check air intake system for air leaks (10-24).
Perform the “High-Pressure Leak Down
Test” (5-236).
Perform the “Fuel Inlet Restriction” test (6-
20).
Check for faults on the sensors and their
circuits with INSITE. Repair or replace as
necessary (19-66).
- Use INCITE to perform the “Aftertreatment
Diesel Particulate Filter Regeneration Test”.
- Allow the stationary regeneration procedure to
run for at least 15 minutes.
- Monitor and record the EGR differential
pressure value.
- If differential pressure is above 1.7 [kPa], inspect
the EGR differential pressure sensor ports for
restrictions.
- If there are no restrictions, replace the EGR
valve.
- Use INCITE to perform the “Aftertreatment
Diesel Particulate Filter Regeneration Test”.
- Allow the stationary regeneration procedure to
run for at least 15 minutes.
- Monitor the turbocharger Actuator Position
Measured (Percent Closed) and Enhanced
Exhaust Gas Pressure.
- Turbocharger actuator position must read above
90% and exhaust gas pressure must be equal to
or greater than 405 [kPa].
- If below, check proper operation of the actuator

Excessive blow-by
Excessive white smoke
EGR Cooler leaking internally
Fuel injector malfunction
EGR valve stuck in open position
Cylinder head is cracked or porous.
Cylinder head gasket is leaking
Poor fuel quality.
Check injector harness
COMPRESSED AIR SYSTEM
Table 4-7 Compressed air system troubleshooting
Problem / Possible Causes
Air pressure rises slowly
Restriction in air intake system
Air system leaks
Air governor malfunction or incorrect
setting
Excessive carbon buildup in compressor
(10-134).
- If actuator is operating properly, replace the
turbocharger.
Measure the crankcase pressure (14-10). If
crankcase blow-by is above specification
refer to “Excessive blow-by” segment of
Engine table.
Perform the EGR cooler leak test (11-19).
Perform cylinder cut-out test with INSITE
(6-26). Replace injectors as necessary.
- Use INSITE to perform the “Aftertreatment
Diesel Particulate Filter regeneration test for at
least 5 minutes.
- Monitor the EGR differential pressure value.
- Differential pressure must be below 3.4 [kPa], if
more repair or replace EGR valve.
Pressurize the internal fuel drain line in the
cylinder head and check for leaks (2-4).
Check the cylinder head gasket. Remove
the cylinder head gasket and inspect.
Operate the engine with a known good fuel
supply.
Check continuity of the SIGNAL and
RETURN wire from each injector to the
ECM.
Remedy
Replace air filter
Check air intake connection
Measure the intake restriction (section x.x)
Check air system components for leaks such
as:
- Air compressor gasket.
- Hoses, pipes, fittings, tanks and valves.
Check the air governor (section x.x).
If compressor does not have a governor,
frequent cycling is normal.
Clean or replace discharge line. Check
 discharge line or further downstream.
Unloader valve is malfunctioning
Inlet or exhaust valves leak.
Cycles frequently
Air system leaks.
- Air compressor gasket.
- Hoses, pipes, fittings, tanks and valves.
Air governor malfunction or incorrect
setting
Inlet or exhaust valves leak.
Air dryer purge valve is stuck
Excessive noise
Excessive carbon buildup in compressor
discharge line or further downstream.
Mounting is loose, worn or broken
Splined drive coupling is worn
Air compressor drive gear or engine gear
train is worn
Air compressor is worn or internally
damaged
turbocharger for oil leaks. Check air
compressor supply line for oil.
Check unloader valve (section).
Clean compressor cylinder head (section).
Test the compressor head inlet and exhaust
valve for leaks (section)
Check air system components for leaks such
as:
Check the air governor (section x.x).
If compressor does not have a governor,
frequent cycling is normal.
Test the compressor head inlet and exhaust
valve for leaks (section)
Lubricate or replace purge valve.
Clean or replace discharge line. Check
turbocharger for oil leaks. Check air
compressor supply line for oil.
Check air compressor mounting parts.
Tighten or replace if necessary.
Replace coupling.
Inspect the drive gear and gear train. Repair
as necessary.
Inspect the air compressor for internal
damage. Replace as necessary. Replace the
air dryer desiccant cartridge.

Gearbox Assembly

Table 4-8 Gearbox troubleshooting

Error Possible Causes Actions

Pushbutton range selector not in
“Neutral” Select “Neutral” on range
selector
Engine will not start Connector of the electronic control Establish plug connection
unit is loose
Starting interlock relay defective or Replace relay or check CAN
missing CAN signal via CAN signal
Transmission does Accelerator pedal not in idle Check accelerator
not engage any gears position or load signal too high pedal/injection pump or
adjust it
 Engine idle speed > 900 rpm Set engine idle speed
Transmission oil sump temperature Warm up engine for approx.
below –20 °C 5 minutes
Only on transmissions with Activate service or parking
additional function “Gear release”: brake
Neither service brake nor parking
brake activated
Electronic control unit in Turn off the engine and start
malfunction setting it again
Vehicle does not Oil level too low Check/correct oil level
move Transmission defective Replace transmission.
Oil level too high Check/correct oil level
Retarder engaged Deactivate retarder (via
Oil temperature too hand lever or rocker switch)
high
Transmission damage Replace transmission.
Vehicle radiator dirty Clean the radiator
Oil level too low Check/correct oil level
No retarder effect Retarder proportional valve or Check CAN signal and
solenoid valve not working, CAN retarder connector
signal not present signal

DRIVELINE

Transfer Case

Drive Shaft s

Table 4-9 Drive shafts troubleshooting

Problem Possible Cause Possible solutions

Transmission Deformed shaft. Replace the shaft.

noise and Shaft Imbalance. Perform balancing.
vibration
Loose bolts fixing shaft to Tighten bolts to
transmission output flange. specification.
Loose mounting bolts. Tighten bolts to
specification.
Propeller shaft universal joint worn. Replace universal joint.
Central mounting block worn. Replace the mounting.
Central mounting bearing worn. Replace the bearing.
Insufficient lubrication Lubricate.
Diff erenti al

Table 4-10 Diferential troubleshooting

Problem Possible Causes Possible Solutions

Noise from wheel hubs.
Noise
Noise at release.
Noise during acceleration
Noise when cornering.
Insufficient lubrication.
Worn bearings.
Splined shaft worn.
Insufficient lubrication.
Improper fitting backlash
between pinion and ring
bevel gear.
Insufficient lubrication.
Improper backlash
between planetary gears
and crown wheels.
Check for leaks then fill
to the correct level.
Replace bearings.
Replace shaft.
Check for leaks then fill
to the correct level.
Check for leaks then fill
to the correct level.
Replace the unit.

Final Drive

Table 4-11 Wheels troubleshooting

Problem Possible Causes Possible Solutions

Excessive speed over
rough surface.
Sudden acceleration
and harsh braking.
Excessive wear. Tire under-inflated.
Tire over-inflated.
Vehicle overloaded.
Uneven tire pressure.
Uneven wear. Wheel rim deformed.
Incorrect tire size.
Excessive wear Insufficient front wheel
on inner edge of toe-in
tread.
Excessive wear Excessive front wheel
Reduce speed.
Avoid sudden acceleration and
harsh braking.
Inflate tire to comply with
specification.
Deflate tire to comply with
specification.
Reduce carrying load.
Check all tires pressure. Inflate or
deflate tires to comply with
specification.
Replace wheel rim then balance
wheel.
Replace with tire of correct size
according to specification.
Adjust front wheel toe-in.
Adjust front wheel toe-in.
 on outer edge of toe-in
tread.
Excessive wear Tire under-inflated. Inflate tire to comply with
on outer edge of specification.
tread.
Excessive wear Tire over-inflated. Deflate tire to comply with
in center of specification.
tread.
Front wheel out of Balance front wheels.
balance.
Front axle tires have Check front tires pressure. Inflate
Vehicle pulls to
different pressures. or deflate tires to comply with
one side.
specification.
One of the front tires Replace worn out tire.
has excessive wear.
Table 4-12 Steering system troubleshooting

Problem / Possible causes Action

Stif steering in both directions

Low oil level Check oil level. Add as needed.
Air in the steering system Check for loose line fittings. Bleed the
system.
Low steering pump flow Replace the steering pump.
Stif steering in only one direction
Steering gearbox internal fault Replace the steering gearbox.
Stif steering when turning wheel fast
Air in the steering system Check for loose line fittings. Bleed the
system.
Low steering pump flow Replace the steering pump.
Knocking when turning steering wheel
Excessive slack in the universal joint Replace the universal joint.
Low oil level Refer to low oil level segment.
Worn ball joints Inspect ball joints for wear, replace as
needed.
Irregular steering pump flow Replace the steering pump.
Oil leakage Inspect for leaks. Replace gaskets or seals
as necessary. Bleed air out of system.
Steering wheel vibration
Unbalanced wheels Perform wheel balancing.
Air in the steering system Check for loose line fittings. Bleed the
system.
 Excessive steering wheel play
Worn ball joints or rubber mountings. Check for wear in ball joints and mountings.
Replace as necessary.
Universal joint is slack. Replace universal joint.
Steering gearbox internal fault. Repair or replace the steering gearbox.
Low oil level
Tank not covered. Install cover.
Oil leak Inspect for leaks. Replace gaskets or seals
as necessary. Bleed air out of system.
Low oil pressure
Faulty steering pump Replace steering pump.
Oil leak Inspect for leaks. Replace gaskets or seals
as necessary. Bleed air out of system.
Low oil level Refer to low oil level segment.

SUSPENSION

STEERING

PNEUMATIC

Brake

Table 4-13 Brake system troubleshooting

Problem Solution

Low pressure lamp is off  Check wiring on switch and lamp.

below 60 [psi].
Low pressure lamp is on
above 60 [psi].
Cut-out is higher or lower
than specification.
Pressure build up time
greater than 40 seconds.
 Replace switch or lamp bulb.
 Check dashboard pressure gauge with test gauge for accuracy.
 Replace switch or lamp bulb.
 Check dashboard pressure gauge with test gauge for accuracy.
 Check that unloader is operating correctly. If yes, then
repair/replace/adjust the governor as necessary.
 Check the air filter and compressor inlet line for restrictions or
damage. Clean/replace the air filter or inlet line as necessary.
 Check the compressor discharge port and line for excessive
carbon. Clean/replace if necessary. Carbon formation is an
 indication of excessive heat. Find the source of the excessive
heat and repair it.
 When the system is fully charged, and the compressor is
unloaded, listen for air leakage at the compressor inlet port. If
there is, repair/replace the unloader.
Excessive system air Check for leaks in the following:
leakage.  Supply line and fittings.
 Drain valves.
 Pressure switch for gauges one and two.
 Service brake relay valves.
 Spring brake relay valves.
 Service brake foot valve.
 Parking brake hand valve.
 Trailer control valve.
 Air processing unit.
 Governor.
 Compressor discharge line.
After repair/replacement, perform the system air leakage
test to verify proper operation.
Excessive service brake air Check for leaks in the following:
leakage.  Service brake lines and fittings.
 Service brake air reservoir drain valve.
 Pressure switch for gauge one.
 Brake chamber.
 Spring brake chamber.
 Service brake relay valves.
 Service brake foot valve.
 Trailer control valve.
After repair/replacement, perform the service brake air
leakage test to verify proper operation.
Parking brake slow to  Restrictions in the parking brake lines.
operate.  Damaged or incorrectly installed hose fittings.
 Faulty relay valve.
 Damaged or incorrectly installed spring brake chamber.
 Damaged or incorrectly installed brake caliper or pad.
Dual circuit system not  Replace the air dryer.
functional.

Table 4-14 Brake system troubleshooting 2

Serial Condition Remedy

Numbe
r
1 Compressor
Leaks air. Replace gasket.
Low air Perform overhaul.
pressure.
Leaks oil. Perform overhaul.
 Build up time is  Check the air filter and compressor inlet line for restrictions
greater than 40 or damage. Clean or replace the air filter or inlet line as
seconds.
necessary.
 Check the compressor discharge port and line for excessive
carbon. Clean or replace if necessary. Carbon formation is an
indication of excessive heat. Find the source of the excessive
heat and repair it.
 When the system is fully charged, and the compressor is
unloaded, listen for air leakage at the compressor inlet port.
If there is, repair or replace the unloader.
2 Governor
Flutters  Check gauge.
 Check unloader line size.
 Check air actuated accessories. Is the air volume
requirement greater than governor capacity?
 Check for plugged governor-reservoir line.
 Repair, adjust or replace governor.
Does not pass  Check governor reservoir line.
air to unloader  Repair or replace.
to “cut-out”
compressor
3 Air Dryer
Air leaking  Purge valve seal damaged. Replace.
constantly  Purge valve frozen. Inspect heater (see heater problems).
from vent port
Heater  Blown Fuse. Check fuse and replace with 8 – 10 [A] fuse.
Inoperative  Broken wires or poor connections. Repair or replace wiring
to heater.
Slow air Filter plugged. Service air dryer.
pressure build-
up
5 Four Circuit
Protection
Valve

2 Air Reservoir
Leaks. Repair or replace.
4 Safety Valve
Excessive  Check system pressure.
venting  Valve operating properly when venting at 140/150 [psi].
 Check unloader/governor.
 Vents at less Replace.
than 140 [psi]
Leaks Replace.
Does Not Periodic Test: Remove and test above 150 [psi] with
Function external air. Replace if non-functional.
4a Drain Valve
(Manual)
Leaks Replace.
4b Drain Valve
(Automatic)
Does Not Drain Repair or replace.
Does Not Drain Replace with heated unit.
In Cold
Weather
Leaks or Periodic Test: with system pressure stabilized
Malfunctions (compressor unloaded) no leak evident at discharge port
- make several foot brake applications to reduce wet
tank pressure. Moisture should drain from discharge
port. Repair or replace.
6 Check Valve
Allows flow Periodic Test: bleed supply reservoir and observe
back to air gauges. Check valves should maintain primary and
reservoir secondary reservoir pressure. Replace if test results are
negative.
8 Air Pressure
Gauge
Shows only Replace.
one reading
9 Foot Brake CAUTION
Valve Chock wheels then repair and/or replace items as
necessary.
Leaks from  Check seal of parking brake chamber for back-flow of spring
vent port when “hold-off” pressure through service port to open exhaust on
all brakes are
valve.
released.
 Replace parking brake chamber.
Leaks from Foot valve defective. Repair or replace.
vent port when
service brake
applied.
Leaks from Foot valve defective. Repair or replace.
vent port when
parking brakes
applied and
 service brakes
released.
10 Quick Release
Valve
Leaks when Repair or replace.
service brakes
are applied
11 Service Brake
Chamber
12 Parking Brake CAUTION
Chamber Service only service brake side of parking brake
chamber.

Any Replace parking brake chamber.

13 Relay Valve
Leaks at vent  Check seal of parking brake chamber for back-flow of spring
port with all “hold-off” pressure through service port to open exhaust on
brakes
valve.
released.
 Replace parking brake chamber.
 Check reservoir port for evidence of contamination, check
supply lines for rusty fittings or carbon deposits. Repair or
replace.
Leaks at vent Exhaust valve not seating properly. Repair or replace.
port when
service brakes
applied.

Auxiliary

CENTRAL TIRE INFLATION SYSTEM

Problem Solution

DRIVELINE CONTROL

Problem Solution

AIR CONDITION

FIRE SUPPRESSION