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Compressed Air Brakes - Groups 00

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1. W5000742 Design and Function Group 56 Bendix AD IP Group 56 CR Turbo 2000 The dryer incorporates valves for both types of compressors used A separate purge tank is used as there is no internal purge air storage Desiccant is contained in a disposable cartridge that is screwed onto the valve housing N WARNING Do not disassemble cartridge No replacement parts are available and the cartridge contains a spring under pressure which can not be mechanically caged The sudden release of the spring could cause it to be ejected violently causing serious personal injury Charge Cycle During compressor loading air flows into the supply connection of the valve housing where it expands and is cooled This causes oil and water vapor to condense and fall to the bottom After exiting the valve housing air flows into the cartridge A coalescent filter located between the outer and the inner shells separates heavier contaminants Air along with remaining water vapor is further cooled as it continues to flow upward between the outer and inner shells It then flows through the desiccant from the top to the bottom and becomes progressively drier as water vapor is adsorbed Dry air exits the bottom of the cartridge flows through the check valve and then exits the discharge connection onto the wet tank Dry air also flows through the pur
2. Wabco 1200 1200E 1200P Height Maximum width Weight Voltage Maximum compressor capacity Heater power 292 mm 11 5 in 241 mm 9 5 in 5 0 kg 11 Ib 12V 710 L min 25 cfm 100 W 277 mm 10 9 in 160 mm 6 3 in 4 1 kg 9 Ib 12V 850 L min 30 cfm 95 W Group 56 Bendix AD IP Height Maximum width Weight Voltage Maximum flow capacity Heater power Midland Pure Air Plus Height Maximum width Weight Voltage Maximum flow capacity Heater power 10 Specifications 360 mm 14 18 in 235 mm 9 27 in 13 kg 28 Ib 12V 850 L min 30 cfm 90 W 384 mm 15 1 in 236 mm 9 31 in 8 kg 18 Ib 12 V 710 L min 25 cfm 95 W Group 56 CR Turbo 2000 Height Maximum width Weight Voltage Maximum compressor capacity Heater power Specifications 413 mm 16 25 in 216 mm 8 5 in 7 5 kg 16 5 Ib 12V 850 L min 30 cfm 75 W 12 Group 56 Tools Tools Special Tools The following special equipment is used when checking air system pressure or safely disconnecting air lines Equipment is available from Kent Moore telephone 1 800 328 6657 W0001874 J 44773 Airline release tool O 4 W0001731 J 44399 Dual air pressure gauge Na W0001873 PP J 44775 Valve assembly fixture f W0001198 J 42189 Air line disconnect tool 13 14 Group 56 Design and Function Design and Function Air Brake System General System Function The supply
3. Air leaks from exhaust port during pressure build up Air dryer does not unload when the compressor unloads Purge cycle is too long more than 30 to 40 seconds Excessive amounts of water in air reservoirs Cause e Excessive fluid in reservoirs Governor faulty Excessive system leakage e Purge valve worn Dirt stuck in purge valve Frozen purge valve Governor faulty Control air lines connected to the wrong port e Purge valve is worn stuck closed or is frozen shut Tubing between governor and air dryer leaking damaged or kinked e Purge valve stuck open Turbo valve is leaking Outlet valve stuck open Desiccant saturated Insufficient purge time due to leaks in the air system Excessive temperature of air going into air dryer Air dryer not purging Troubleshooting Remedy Drain reservoirs Replace governor Check for leaks in unloader valves reservoirs tubing fittings air dryer and drain valve Clean or replace valve Clean or replace valve Check heater Replace governor Check connections against air line schematic Clean or replace purge valve Check heater Repair or replace the air tubing Replace valve Replace valve Replace valve Replace desiccant cartridge Check for leaks in supply system or in accessories Compressor runs hot inlet air to dryer maximum 65 C 150 F Check purge valve Check tubing from air dryer to the go
4. Fifth Wheel Air Cylinder Compressor Supply Exhaust Bobtail Balance Control Air Seat Options Supply Air Suspension Air Pressure Gauge KVEN K DN ALTE OSEN FLL Yo Le aiid W5000384 W5000378 37 Group 56 Air Tubing Installation To ensure a tight seal between tubing and fitting the tubing end needs to be cut straight Also inspect tubing that has been removed for teethmarks around the perimeter where the retaining collar holds the tubing in place If the marks are too deep that is can be easily seen or a depression can be felt by running a fingernail across mark recut the tubing before reinstalling Installing is done by aligning tubing in a straight line with the fitting opening Push until the tubing stops against the bottom of the fitting When the tubing has bottomed in the fitting pull back to make the collar retaining teeth engage the tubing Do not pull too hard only enough to ensure that the collar has gripped the tubing Air Tubing Removal To make removal easier remove tubing when valve or component is still in place To disconnect push the tubing into the fitting until it bottoms Use release tool J 42189 to push in the collar and then pull out tubing while holding the collar in 38 Design and Function p W5000380 W5000381 W5000382 W5000580 Group 56 Air Tubing Repair In the event that tubing has been severed as the result o
5. Fill coolant and then start engine Run the engine to check for air or liquid leaks and air compressor operation Note Maximum coolant fill rate is 2 2 gallons per minute 10 liters per minute 49 Group 56 Service Procedures 5612 03 02 05 Compressor Unloader Valve Replacement Knorr Before beginning this procedure read the General Work Practices section General Work Practices page 45 for further information See Knorr 2COMP850 page 20 for important service information before beginning this procedure See Knorr 2COMP850 page 22 for an exploded view of the Knorr compressor Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death N WARNING Do not work near the fan with the engine running The engine fan can engage at any time without warning Anyone near the fan when it turns on could be seriously injured Before turning on the ignition be sure that no one is near the fan N WARNING HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns or can permanently damage test equipment 50 Group 56 15007311 Service Procedures N WARNING Before beginning any service work on any part of the air
6. valves and remove the valve from the bracket Installation 1 Install the new valve and connect the air lines 2 Install the trailer hand brake and the manifold dash valve to the mounting plate and install the mounting plate 3 Move the dash panel into place and reconnect the lower radio support 4 Install the dash panel and the dash cover for the trailer hand brake valve and manifold dash valve 5 Install the knobs on the parking brake and the trailer supply and install the cover to the trailer hand brake valve 6 Install the instrument cluster and electrical center covers 7 Start the vehicle to build up air pressure and check the valves for leaks and proper operation 87 Group 56 Service Procedures 5631 03 02 01 Foot Brake Valve Replacement Before beginning this procedure read the General Work Practices section General Work Practices page 45 for further information 1 Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death N WARNING Always wear appropriate eye protection to prevent the risk of eye injury due to contact with engine debris or fluids Park the vehicle on a level surface with the transmission in neutral and chock the front wheels Removal 2 Remove the lower dash panel on the left side un
7. N WARNING Before beginning any service work on any part of the air system be certain that the air pressure has been released Failure to do so may cause a component to violently separate causing serious personal injury Removal 1 Chock wheels Empty compressed air system of all air Drain the coolant 2 Turn the ignition switch OFF and disconnect the battery AN CAUTION If there are other ground cables connected to the battery such as engine ECU satellite system etc disconnect those grounds first then remove the battery ground cable Electronic modules may be damaged when additional grounds are connected disconnected without the main battery ground connected Always disconnect the main battery ground last 63 Group 56 W5000756 W5000757 64 Service Procedures 3 Remove the fuel filter and O ring Remove all of the fuel lines 1 Fuel inlet line 2 Fuel supply line to head 3 Fuel vent line 4 Disconnect discharge line from the compressor Disconnect compressor intake air pipe 5 Disconnect the fuel solenoid wire 6 Remove the four fuel pump mounting bolts and fuel pump support bracket 7 Remove the two air governor mounting bolts and air tubing 8 Disconnect compressor coolant lines 9 Remove the two power steering pump mounting bolts Note Removing the power steering pump allows access to the compressor mounting bolts Group
8. Remove the unloader valve cap Remove the rectangular vee seal and O ring Use a pick if necessary to remove the seals Do not damage the groove Remove the intake manifold and gasket W5000770 68 Group 56 W5000763 Service Procedures 5 Loosen but DO NOT REMOVE the center head bolt It will hold the head assembly together Mark the head for orientation during assembly Loosen and remove the four corner head bolts Save these for reuse 6 Remove head cover and valve plate Place on a clean work surface WITH INTAKE VALVE FACING UPWARD 7 Some units have a press fit or stacked in place valve retainer If present carefully remove it Then remove the intake valve 8 Turn the head assembly over and set it on a clean surface Remove the center head bolt Save it for reuse Note that it is shorter than the four corner head bolts Remove the cover gasket head and head gasket 9 Remove the two wave washers exhaust valve retainer save for possible reuse and exhaust valve 69 Group 56 W5000769 W5000767 70 Service Procedures Installation 10 Install a new rectangular vee seal into the unloader body Note The seal must be installed with the lip facing in 11 Liberally lubricate the unloader valve bore above and below the vee seal with high temperature grease Accrolube Lubrication Teflon Grease or equivalent 12 Install a new O ring seal on the unloader valve body
9. The new purge tank provides the air volume used to clean or regenerate the Dryer at the end of each compressor pumping cycle It is used with the Wabco 1200P and the CR Turbo 2000 Dryers For replacement information see Purge Tank Replacement page 79 More information is pending 36 Design and Function W5001192 W5001193 Group 56 Air Tubing and Fittings The foldouts represent the brake system as a schematic layout or show actual routing in the vehicle Foldouts A and B are schematics of the entire brake system on a 4x2 and a 6x4 vehicle All other foldouts show the brake system valves and tubing in separate circuits All color on tubing and in the schematic layouts conform to the standardized color scheme listed to the right The tubing in the foldouts are colored the same as the actual tubing in the vehicle This helps the identification and troubleshooting process with less possibility for mistakes TUBING COLOR PRIMARY BLUE Supply System Circuit RED Front Service Brake Circuit GREEN Rear Service Brake Circuit ORANGE Parking Brake Circuit All tubing is made of nylon and sizes are always measured as an outer diameter OD The 1 4 in tubing is a solid core single ply extrusion All other sizes are made of a solid core covered with a protective colored layer with fiber reinforcement between the layers The cover is treated for heat and sunlight resistance In areas where great flexibility is needed
10. air out to the discharge pipe Unloading When the governor opens at the set cut out pressure air flows to the unloader valve The unloader piston will be pushed out to cover the air inlet opening of the compressor The compressor piston will move up and down with the air compressing and uncompressing without any air being delivered 28 Design and Function W5000927 W5000928 W5000929 Design and Function Group 56 Holset QE296 Group 56 Design and Function Air Dryer Wabco System Saver 1000 1200 Series The dryer incorporates valves for both types of compressors used Desiccant is contained in a disposable cartridge that is screwed onto the valve housing Note The Air Dryer Wabco System Saver 1200 Series P does not have a Regeneration Valve to cool air intake The System Saver relies on the Purge Tank to perform this function N WARNING Do not disassemble the cartridge No replacement parts are available and the cartridge contains a spring W5001194 under pressure which can not be mechanically caged The sudden release of the spring could cause it to be ejected violently causing serious personal injury Charge Cycle During system pressure build up compressed air passes into the air dryer where the coalescent filter removes contaminants and the air is further cooled at the outer walls of the cartridge Moisture that condenses out
11. ee ee Re ee ee Re ee ee 84 5711 03 02 01 Trailer Brake Control Valve Replacement eiseres see ese ee Ee ee ee Ge Ge Ge ee ee ee ee ee ee Ge ee 84 563 1 03 02 01 Foot Brake Valve Replaces meti pr ib 88 5631 06 02 01 Foot Brake Valve Leak Test Checking s m ea 90 VOLVO Volvo Trucks North America Inc P O Box 26115 Greensboro NC 27402 6115 Volvo Trucks Canada Ltd 5600A Cancross Court Mississauga Ontario L5R 3E9 http Awww volvotrucks volvo com PV776 TSP194846 1000 07 2003 Volvo Trucks North America Inc 2003
12. engine air filter piping on the clean side of the filter Overpressurized Aspiration Compressors on Cummins Detroit Diesel and Caterpillar engines have the air intake connected to the intake manifold of the engine The air in the manifold is overpressurized by the turbo charger 16 Design and Function W5000754 Group 56 Governor Today s governors are set from the factory No attempt to adjust the cut out and cut in pressures should be done Always replace if faulty Normal cut out pressure is 900 kPa 130 psi Cut in pressure is always 140 kPa 20 psi less than the cut out pressure The governor operating with the compressor unloading mechanism automatically controls the air pressure in the air brake or air supply system between a maximum cut out pressure and a minimum cut in pressure The compressor runs continuously while the engine runs but the actual compression of air is controlled by the governor actuating the compressor unloading mechanism which stops or starts the compression of the air when the maximum or minimum reservoir pressures are reached Reservoir air pressure enters the governor at one of its reservoir ports 1 and acts on the piston 4 and inlet exhaust valve 5 As the air pressure builds up the piston and valve move together against the resistance of the pressure setting spring When reservoir air pressure reaches the cut out setting of the governor the inlet exhaust valve
13. install them into the replacement air tank 6 Install the replacement air tank and connect the air line 7 Start the vehicle to build up the air system pressure and check for proper operation Group 56 Service Procedures 5621 03 02 01 Air Tank Replacement Before beginning this procedure read the General Work Practices section General Work Practices page 45 for further information 1 For an illustration of the various Air Tank locations on VN and VHD vehicles see Air Tank Mounting page 40 Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death Park the vehicle on a level surface with the transmission in neutral and the front wheels chocked 2 N WARNING Before beginning any service work on any part of the air system be certain that the air pressure has been released Failure to do so may cause a component to violently separate causing serious personal injury N WARNING Always wear appropriate eye protection to prevent the risk of eye injury due to contact with engine debris or fluids Drain the complete air system 3 Cut all zip ties securing the airlines and the air tank drain fitting cable 4 Disconnect any airlines using special tool J 44773 Airline Release Tool J 44773 5 Remove any air
14. line and cylinder head from the compressor and apply shop air back through the discharge port Coat the discharge valve seats with soapy water Air leaks should not exceed a one inch diameter soap bubble in 3 seconds The unloader pistons can be checked for air leaks as follows Build up the air system to governor cut out and shut the engine off Listen for escaping air at the compressor intake To pinpoint air leaks apply a small amount of oil around the unloader pistons No leaks are permitted If the compressor does not function as described above or leakage is excessive replacement is recommended 46 Group 56 Service Procedures 5611 03 02 02 Compressor Replacement Knorr Before beginning this procedure read the General Work Practices section General Work Practices page 45 for further information See Knorr 2COMP850 page 20 for important service information before beginning this procedure See Knorr 2COMP850 page 22 for an exploded view of the Knorr compressor Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death N WARNING Do not work near the fan with the engine running The engine fan can engage at any time without warning Anyone near the fan when it turns on could be seriously injured Before turning on the ignition
15. seats on the exhaust stem 6 closing the exhaust port 3 and then opens the inlet valve when the piston moves up Reservoir air flows around the inlet valve through the passage in the piston and out through the unloader port 2 to the compressor unloading mechanism As the system reservoir air pressure drops the force exerted by the air pressure on the piston will be reduced and the governor spring will push the piston down The inlet valve will close the piston will move down and open the end of the exhaust stem With the exhaust open the air in the unloader line 2 will escape back through the piston exhaust stem and out through the exhaust port 3 Design and Function W5000773 y W5000932 W5000933 17 Group 56 Design and Function Servo Valve Volvo engines equipped with the Knorr compressor have a governor located away from the compressor The governor is equipped with a servo valve for boosting the signal to the compressor The servo valve is mounted together with the governor on a panel located on the frame Depending on the model the locations are as follows VN VHD Outside of left hand frame rail behind battery box Other Inside of right hand frame rail close to rear cab support W5000765 For governors installed away from the compressor the servo valve boosts the cut out signal from the governor Normally the servo valve is closed A with air press
16. system be certain that the air pressure has been released Failure to do so may cause a component to violently separate causing serious personal injury Removal 1 Drain all coolant from system into drain pan Chock the wheels and release all air from compressed air system into an appropriate container 2 Disconnect the governor unloader line and remove fitting from unloader port Visually check unloader port for trash or corrosion Remove plug from opposite side 3 Disconnect air supply line discharge line and coolant lines from compressor head 4 Remove the eight head bolts and lift off cylinder head Remove cylinder head gasket 5 Remove the valve body and gasket 51 Group 56 52 15007340 W5000969 Service Procedures 6 Remove the pivot arms and intake valve plates Push in on ESS piston and remove guide pin Repeat for opposite side Remove ESS pistons from the bore Installation 7 Clean ESS pistons install new O rings open O ring should be closest to the spring and apply a small amount of silicone grease to prevent sticking Replace valves if necessary 8 Install pistons into the bore Adjust the piston position for installing the guide pins Press new guide pins into the pistons 9 Install new guide pins into the block Install the studs pivot arms and intake valves on the block face 10 Install the metal gasket with the red side facing downward carefully placing
17. to their seats Compression is then resumed Design and Function W5000731 25 Design and Function Group 56 Bendix 550 770 Gw f Group 56 Holset Design The Holset compressor is a single piston single stage reciprocating compressor which supplies compressed air to operate the air brakes and other air driven devices The compressor runs continually but has loaded and unloaded operating modes The operating mode is controlled by the governor and the compressor unloading assembly The compressor is flange mounted to the timing gear cover and driven by the timing gears A sleeve connects the gear with the compressor input shaft The compressor is lubricated with pressurized engine oil The oil provides both lubrication and cooling for bearings piston rings and cylinder walls The cylinder head is connected to the engine coolant system All Holset compressors in Volvo vehicles from 1994 model year have only the QE type off loading valve This makes the compressor compatible with all air dryers except the Midland Pure Air Plus Design and Function E W5000776 W5000738 W5000931 27 Group 56 Function Charging During the down stroke of the piston air enters the cylinder through the unloader body and intake valve When the piston starts the up stroke the intake valve closes The piston compresses air during the up stroke The outlet valve opens to let
18. 001049 Fig 1 Locations for the delivery air pressure gauge connections Service Procedures 6 After checking for leakage in the unapplied and applied positions make a brake application of approximately 20 psi 137 9 kPa for a delivery pressure check If a delivery air pressure gauge is available make the connection at the left rear most brake chamber The arrows in figure 1 identify the correct locations for connecting the delivery air pressure gauge Note The connection location depends on the type of brake chamber being used Note In order to maintain constant delivery pressure it may be necessary to use a block of wood or support mechanism beneath the pedal to check the foot brake valve at delivery pressure 8 If a delivery air pressure gauge is unavailable deflect the pedal to between 1 3 and 1 2 of its full travel and check for leakage using the guidelines in step 4 9 If the foot brake valve passes these three tests the valve is good 91 92 Feedback One of our objectives is that workshop personnel should have access to correct and appropriate service manuals where it concerns fault tracing repairs and maintenance of Volvo trucks In order to maintain the high standards of our literature your opinions and experience when using this manual would be greatly appreciated If you have any comments or suggestions make a copy of this page write down your comments and send them to us either via t
19. 1 Tighten fuel inlet line 1 to head 35 Nm 25 ft lb 2 Tighten supply line 2 to 35 Nm 25 ft lb 3 Tighten vent line 3 to 75 Nm 55 ft lb 35 Nm 25 ft lb 35 Nm 25 ft lb 75 Nm 55 ft lb 19 Install the wire to the fuel solenoid and tighten 20 Install the air discharge line Tighten to a torque of 75 Nm 55 ft lb 75 Nm 55 ft lb 21 Install the air compressor air intake pipe use new O rings Tighten bolts to a torque of 47 Nm 35 ft lb Tighten clamp to a torque of 5 Nm 40 in lb 47 Nm 35 ft lb 5 Nm 40 in Ib Group 56 Service Procedures 22 Install compressor air governor with the two mounting bolts and connect air tubing use new gasket Tighten to a torque of 16 Nm 12 ft lb 16 Nm 12 ft lb 23 Install fuel filter with new O ring 24 Clean the gasket surface on the engine and power steering pump before mounting Install pump with the two bolts and tighten them to a torque of 8 Nm 48 ft lb 8 Nm 48 ft lb 25 Fill the radiator with coolant Coolant fill rate is 2 1 2 gallons per minute 10 liters per minute 26 AN CAUTION Connect the main battery ground cable first If there are other ground cables connected to the battery such as engine ECU satellite system etc connect those grounds last Electronic modules may be damaged when additional grounds are connected disconnected without the main battery ground connected Always connect the main battery
20. 12 engine Disconnect the sensor in the water outlet pipe on the water pump 5 Remove all hoses and lines that are connected to the air compressor e Air discharge line e Water line Supply to the compressor e Water line Return from the compressor e 2 air lines to the air governor e Oil supply line If equipped e Oil return line If equipped 6 Note the position of all fittings and remove them Group 56 Service Procedures 7 Remove the 4 compressor mounting bolts W5000755 8 Lift and remove the air compressor Installation 9 Position the air compressor into place W5000755 10 Install and torque the 4 mounting bolts to 85 15 Nm 63 10 ft lb 85 15 Nm 63 10 ft lb 59 Group 56 i a NL A dd PAN T San age p eT a W5000754 60 Service Procedures 11 Install all fittings and reconnect all hoses and lines to the air compressor Note Torque for water line hose clamps is 3 0 5 Nm 25 4 in lb 12 Reconnect the air filter pipe to the turbo and the air supply line to the air compressor Tighten bolt and clamp assembly on the compressor air supply line to a torque of 24 4 Nm 18 3 ft lb Then hook up the air governor tubing 24 4Nm 18 3 ft lb 13 AN CAUTION Connect the main battery ground cable first If there are other ground cables connected to the battery such as engine ECU satellite system etc conn
21. 13 Use clean 15W40 oil or Accrolube Lubrication Teflon Grease or equivalent to lubricate the seal 14 Install in order into the valve plate 1 Exhaust valve retainer with the groove facing up 2 Align wave spring gaps 180 degrees from each other and place them in the exhaust valve retainer groove 15 Orient the valve plate to the valve head Use orientation marks made during removal 16 Assemble cover cover gasket head head gasket and valve plate Install the short screw with washer through the center hole Tighten the screw to a torque of 14 Nm 120 in lb 14 Nm 120 in lb Group 56 Service Procedures 17 Install the valve assembly gasket on the cylinder block Carefully place the intake valve and valve retainer in the valve plate Install the valve assembly onto the compressor block 18 Install the four valve plate assembly screws Tighten the screws to a torque of 28 Nm 21 ft lb 28 Nm 21 ft lb 19 Install the intake manifold to the valve head Install the unloader cap in the cover Place the spring in the manifold and install the unloader cover to the manifold with the four screws Tighten the screws to a torque of 27 Nm 20 ft lb Install governor to the unloader 27 Nm 20 ft lb 71 Group 56 Service Procedures 5612 03 02 02 Compressor Unloader Valve and Head Replacement Holset SS E ST Before beginning this procedure read the General Work Practices section General Work Practi
22. 56 W5000760 W5000758 Service Procedures 10 Remove the four air compressor mounting bolts and lift the air compressor away from the engine Remove all fittings from compressor Installation 11 Replace the O rings on coolant fittings and put sealant on the air fittings Tighten the fittings to a torque of 47 Nm 35 ft lb Install all air and coolant fittings with the proper sealants applied 47 Nm 35 ft lb 12 Clean the air compressor mounting surface on the engine 13 Position the air compressor crankshaft timing mark at the 12 o clock position Position the accessory drive shaft dowel pin at the 2 o clock position 14 Install the air compressor onto the engine with new mounting gaskets Tighten the bolts hand tight then tighten the bolt to a torque of 65 Nm 50 ft lb 65 Nm 50 ft lb 15 Install the coolant lines Note Replace the rubber grommet on the coolant outlet tube Tighten the coolant tube to a torque of 40 Nm 30 ft lb 40 Nm 30 ft lb 65 Group 56 W5000759 W5000756 66 Service Procedures 16 Clean the fuel pump mounting surface and install new gaskets and spider Install the fuel pump with the four mounting bolts Tighten the bolts to a torque of 47 Nm 35 ft lb 47 Nm 35 ft lb 17 Install fuel pump support bracket and tighten the bolt to a torque of 47 Nm 35 ft lb 47 Nm 35 ft lb 18 Install fuel lines hand tight
23. 56 Bendix 550 750 Design The Tu Flo air compressor is a two cylinder single stage reciprocating compressor The Tu Flo 550 750 compressor consists of two major subassemblies the cylinder head and the crankcase The cylinder head is an iron casting which houses the inlet outlet and unloader valves The cylinder head also contains the air inlet port and is designed with both top and side air outlet ports The head is mounted on the crankcase and is secured by six screws The crankcase houses the cylinder bores pistons crankshaft and main bearings and provides the flange mounting surface The compressor is driven by the engine timing gears and is operating continuously while the engine is running Actual compression of air is controlled by the compressor unloading mechanism and the governor The governor is generally mounted on the compressor or close by and maintains the brake system air pressure to a preset maximum and minimum pressure level The unloader valves are accessible from the top of the cylinder head After removing the cover plate the valves are easily serviced Design and Function W5000729 W5000730 W5000774 23 Group 56 Function Charging During the down stroke of the piston a slight vacuum is created between the top of the piston and the cylinder head causing the inlet valve to move off its seat and open Air atmospheric or pressurized flows through the air inlet port an
24. 96 e Air Dryer Bendix AD IP e Air Dryer Midland Pure Air Plus e Air Dryer CR Turbo 2000 e Air Dryer WABCO System Saver 1000 1200 1200E 1200P e Footvalve e Governor e Servo Valve e Air Tanks e Air Tubing and Fittings Group 56 Specifications Specifications Compressor Knorr 2COMP850 Designation sales designation Volvo 26 5 CFM 2COMP850 Type Piston Compressor Number of cylinders 2 Cooling cylinder head Coolant Capacity 750 L min 26 5 cfm Maximum pressure 930 kPa 135 psi Maximum operating speed 2 700 r min Bore 88 0 mm 3 46 in Stroke 50 mm 1 97 in Tightening torques Nm ft Ib Mounting flange bolts 85 15 63 10 Drive gear nut 225 25 165 20 Cylinder head bolts 31 5 41 5 23 1 Valve body bolt 31 5 41 5 23 1 Exhaust valve bolt 11 0 5 8 1 0 4 Intake valve bolt 12 1 0 8 8 0 7 Group 56 Bendix Tu Flo 550 Designation Sales designation Bendix 13 2 CFM Type Number of cylinders Cooling cylinder head Capacity Maximum pressure Maximum operating speed Bore Stroke Tightening torques Mounting flange bolts Drive gear nut Cylinder head bolts Unloader valve cover plate bolts Exhaust valve seat Intake valve seat Specifications Tu Flo 550 Piston Compressor 2 Coolant 375 L min 13 2 cfm 930 kPa 135 psi 2400 r min 70 6 mm 2 78 in 38 1 mm 1 50 in Nm ft Ib 85 15 63 10 165 13 5 110 10 53 3 4 39 2 5 23 143 17 20 110 13 80 10 110 13 80 10 G
25. Note A new unloader kit should be used when rebuilding 3 Remove the unloader cover gasket Remove unloader pistons from compressor 61 Group 56 62 Service Procedures Installation 4 Install the new springs and unloader pistons in their bores being careful not to cut the O rings Note The unloader pistons in the kit are pre lubricated with a special lubricant and do not require additional lubricant Install the unloader cover gasket Install the unloader cover and hand tighten the capscrews 6 Tighten the cover capscrews to a torque of 23 3 Nm 17 2 ft lb in a crossing pattern after first snugging all screws by hand 23 3 Nm 17 2 ft lb Group 56 Service Procedures 5611 03 02 02 Compressor Replacement Holset Before beginning this procedure read the General Work Practices section General Work Practices page 45 for further information See Holset page 27 for important service information before beginning this procedure Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death N WARNING Before beginning any service work on any part of the air system be certain that the air pressure has been released Failure to do so may cause a component to violently separate causing serious personal injury
26. Service Manual Trucks Group 560 670 Compressed Air Brakes VN VHD PV776 TSP194846 VOLVO Foreword The descriptions and service procedures contained in this manual are based on designs and methods studies carried out up to July 2003 The products are under continuous development Vehicles and components produced after the above date may therefore have different specifications and repair methods When this is believed to have a significant bearing on this manual supplementary service bulletins will be issued to cover the changes The new edition of this manual will update the changes In service procedures where the title incorporates an operation number this is a reference to an V S T Volvo Standard Times Service procedures which do not include an operation number in the title are for general information and no reference is made to an V S T The following levels of observations cautions and warnings are used in this Service Documentation Note Indicates a situation handling or circumstance which should be observed Caution Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury or damage to property Warning Indicates a potentially hazardous situation which if not avoided could result in death serious injury or major damage to property Danger Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Volvo Tr
27. air from the compressed air system 75 Group 56 W5001212 76 W5001212 Service Procedures 2 Remove the air lines 3 Remove the mounting bolts 4 Remove the fittings Installation 5 Install the fittings onto the dryer 6 Re attach the air dryer and tighten the bolts to a torque of 18 Nm 25 ft lb 18 Nm 25 ft lb 7 Install the air lines 8 Start the engine and check for air leaks Group 56 Service Procedures 5618 03 02 11 Air Dryer Desiccant Cartridge Replacement Before beginning this procedure read the General Work Practices section General Work Practices page 45 for further information See Wabco System Saver 1000 1200 Series page 30 Bendix AD IP page 32 CR Turbo 2000 page 34 and Midland Pure Air Plus page 35 for important service information before beginning this procedure See page 31 and page 33 for an exploded view of the air dryers Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death N WARNING Before beginning any service work on any part of the air system be certain that the air pressure has been released Failure to do so may cause a component to violently separate causing serious personal injury N WARNING Before beginning any service work o
28. air is routed in rubber hoses for example between frame and the axles A hose is built up of three layers of rubber and reinforcement Hoses are specifically made for each installation to the correct length with crimped on fittings on either end Fittings are typically of the push connect type To connect or disconnect tubing is very easy which simplifies troubleshooting in the air system New simple test gauges have been introduced for testing the valves and pressures See Service Manual Air Valves and Components The fitting body is made of brass An internal O ring seals on the outside diameter of the tubing and the retaining collar holds the tubing firmly in place Straight fittings have an internal hex grip most others have external hex grip A number of valves also come with push type connectors already installed in the valve body The fitting is designed for letting the tubing rotate to eliminate kinks The fitting IS NOT designed for locations with continuous movement such as between frame and axle Threads are pre applied with sealant A fitting can be reused in the same port up to five times before new sealant needs to be applied Design and Function TUBING COLOR SECONDARY BLUE 1 4 in GREY 1 4 in GREY 3 8 in BROWN 1 4 in YELLOW 1 4 in YELLOW 3 8 in ORANGE 1 4 in BLACK 1 4 in PURPLE 1 4 in Air Suspension Exhaust Diff Lock Interaxle Trailer Hand Control Diff Lock Interwheel
29. and right side sections of the lower dash panels under the steering column 5631 06 02 01 Foot Brake Valve Leak Test Checking Before beginning this procedure read the General Work Practices section General Work Practices page 45 for further information Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death N WARNING Before beginning any service work on any part of the air system be certain that the air pressure has been released Failure to do so may cause a component to violently separate which can result in serious personal injury 1 Park the vehicle on a level surface and chock the front wheels 2 Start the engine and build the system air pressure to the governor cut out pressure then stop the engine 3 Apply and release the foot brake valve twice 4 Spray the foot brake valve with soapy water and check the foot brake valve in the unapplied position When conducting this test be sure that leakage does not exceed a one inch diameter soap bubble in three seconds Note Spray all fittings and joints of the foot brake valve with soapy water before checking for leakage 5 Apply the foot brake valve to 100 application and check for leakage using the guidelines in step 4 Group 56 dup IT lt 7 W5
30. be sure that no one is near the fan N WARNING HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and or fluids can cause burns or can permanently damage test equipment N WARNING Before beginning any service work on any part of the air system be certain that the air pressure has been released Failure to do so may cause a component to violently separate causing serious personal injury Removal 1 Chock wheels Empty the compressed air system of all air Drain the coolant into an appropriate container 47 48 Group 56 Le I TED pr E A A al H lg A TA A 2 al lA A A 2 IDD oe A N W5000775 Service Procedures 2 Turn the ignition switch OFF and disconnect the battery AN CAUTION If there are other ground cables connected to the battery such as engine ECU satellite system etc disconnect those grounds first then remove the battery ground cable Electronic modules may be damaged when additional grounds are connected disconnected without the main battery ground connected Always disconnect the main battery ground last 3 Remove the air compressor supply line from the air filter piping to the turbo Then remove the air filter piping to the turbo 4 Remove all hoses and lines that are connected to the air compressor e Air dischar
31. caged The sudden release of the spring could cause it to be ejected violently causing serious personal injury Charge Cycle During compressor loading air flows into the supply connection of the valve housing where it expands and is cooled This causes oil and water vapor to condense and fall to the bottom After exiting the valve housing air flows through the coalescent filter where heavier contaminants are separated Air along with remaining water vapor is further cooled as it moves up into the cartridge It then flows through the desiccant from the top to the bottom and becomes progressively drier as water vapor is adsorbed Dry air exits the bottom of the cartridge and flows through the check valve and then exits the delivery connection on the wet tank Dry air also flows through the purge valve or orifice to fill up the purge tank Purge Cycle As air pressure reaches the cut out setting of the governor the compressor unloads and the purge cycle of the air dryer begins The governor sends air to the control connection thereby closing the turbo valve which closes off the air supply from the compressor At the same time the purge valve opens to the atmosphere Design and Function W5000747 W5000749 W5000750 35 Group 56 Purge Tank
32. ces page 45 for further information See Holset page 27 for important service information before beginning this procedure Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death N WARNING Before beginning any service work on any part of the air system be certain that the air pressure has been released Failure to do so may cause a component to violently separate causing serious personal injury N WARNING Before beginning any service work on any part of the air system be certain that the air pressure has been released Failure to do so may cause a component to violently separate causing serious personal injury Removal 1 Chock wheels Empty compressed air system of all air 72 Group 56 W5000772 W5000771 s Le ch gt W5000854 Service Procedures 2 N WARNING Always wear appropriate eye protection to prevent the risk of eye injury due to contact with engine debris or fluids Hold the unloader valve body and remove the two captive washer capscrews and the two plain washers Then remove the unloader valve body O ring seal and the rectangular ring seal 3 Remove the unloader valve cap and the unloader valve spring Then remove the intake valve seat va
33. d the open inlet valve into the cylinder As the piston begins its upward stroke the air that was drawn into the cylinder on the down stroke is being compressed Air pressure on the inlet valve plus the force of the inlet spring returns the inlet valve to its seat so it closes As the piston continues the upward stroke compressed air pushes the outlet valve off of its seat and air flows by the open outlet valve into the discharge pipe and out to the reservoirs As the piston reaches the top of its stroke and starts down the outlet valve spring and air pressure in the discharge pipe returns the outlet valve to its seat This prevents the compressed air in the discharged pipe from returning to the cylinder bore as the intake and compression cycle is repeated 24 Design and Function W5000926 Group 56 Unloading When the compressed air in the reservoir reaches the cut out pressure the governor sends air from the reservoir to the cavity above the unloader pistons The unloader pistons move down holding the inlet valves off of their seats With the inlet valves held off of their seats by the unloader pistons air is pumped back and forth between the two cylinders and the outlet valves remain closed When air pressure from the reservoir drops to the cut in setting of the governor the governor closes and exhausts the air from above the unloader pistons The unloader springs force the pistons upward and the inlet valves return
34. der the steering column 3 Remove the center and right side sections fo lower dash panels under the steering column 4 Remove the lower cover off of the steering column 88 Group 56 Service Procedures 5 N WARNING Before beginning any service work on any part of the air system be certain that the air pressure has been released Failure to do so may cause a component to violently separate which can result in serious personal injury Deplete air system pressure 6 Note Note location of air lines for replacement Disconnect air lines J 42189 7 Remove the nuts from the footvalve and remove the footvalve 8 Remove the fittings from the old footvalve and install the fittings onto the new footvalve Note Remove the fittings one at a time for proper orientation J 44775 Installation 9 Set the new footvalve into position for mounting 10 Connect the air lines to the new footvalve 11 Install the mounting nuts on the new footvalve and tighten to 24 4 Nm 18 3 ft lb 24 4Nm 18 3 ft lb 12 Start the vehicle and check for air leaks and proper operation 13 Install the lower cover to the steering column Note Refer to Service Bulletin 563 01 See Foot Brake Valve Leak Test Checking page 90 for air leak test procedure 89 Group 56 90 Service Procedures 14 Install the left side lower dash panel under the steering column 15 Install the center
35. ect those grounds last Electronic modules may be damaged when additional grounds are connected disconnected without the main battery ground connected Always connect the main battery ground first Connect the battery cable 14 Fill coolant and then start engine Look over compressor connections for possible leaks Note Maximum coolant fill rate is 2 2 gallons per minute 10 liters per minute Group 56 Service Procedures 5612 03 02 05 Compressor Unloader Valve Replacement Bendix 550 750 W5000774 Before beginning this procedure read the General Work Practices section General Work Practices page 45 for further information See Bendix 550 750 page 23 for important service information before beginning this procedure See Bendix 550 770 page 26 for an exploded view of the Bendix compressor Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death N WARNING Before beginning any service work on any part of the air system be certain that the air pressure has been released Failure to do so may cause a component to violently separate causing serious personal injury Removal 1 Chock wheels Empty compressed air system of all air 2 Remove the cover capscrews and remove the unloader cover
36. eeeteeeees Compressor Replacement cccsccceeeeeeeeeeetees Compressor Unloader Valve Replacement Compressor Cylinder Head Gasket Replacement Compressor Replacement 2 ccsssceeeeeeeeeeeeees Compressor Unloader Valve Replacement Compressor Replacement ccscceeeeseeeeeetees Compressor Unloader Valve and Head GE N OE ici Compressor Unloader Valve and Head KE ERE EEE EE EE Air Dryer Replacement issie GE ok Air Dryer Desiccant Cartridge Replacement Purge Tank Replacement sisie ei ENE ie ge Air Tank Replacement 2 nmaerssennmmmmeissnueismeiniea Governor Replacement cosita Parking Brake Valve Replacement cece Parking Brake Trailer Supply Valve Replacement di de EA ee Trailer Brake Control Valve Replacement Dash Valve Replacement esse ees ee ee ee Foot Brake Valve Replacement ees esse ee ee Foot Brake Valve Leak Test Checking Feedback Operation Numbers Group 56 General General Compressed Air Brakes W5000728 This information covers the supply system for the compressed air brakes The supply system includes compressor governor air dryer and other support valves with connecting air lines The main components covered are e Compressor Knorr 2COMP850 e Compressor Bendix Tu Flo 550 and 750 e Compressor Holset SS296 SS296 QE2
37. elefax or mailing directly to the address listed below To From Volvo Trucks North America Inc Dept 516 Service Publications 7825 National Service Road EER RE TREE ME MS RE VO EE EE P O Box 26115 Greensboro NC 27402 6115 CC aapinen aaa USA Fax 336 393 3170 Comments proposals Operation Numbers 5611 080202 Compressor REPACEMENT ia 47 56 12 03 02 05 Compressor Unloader Valve Replacement uk ASK KG Ke ek AA ag ee RR Ge AG AE hin 50 5611 03 02 04 Compressor Cylinder Head Gasket Replacement iss ee ee ee ee Re RA ee ee ee RA ee ee Re ee ee ee 54 BE 1 1 08 02 02 Compressor Replica a 57 5612 03 02 05 Compressor Unloader Valve Replacement mrrnerernvnernvnnvnnernnnnnnnnnnenenernnnernvernenerunnnsenensnnenernnnenenernrnesnn 61 be 1102 02 02 Compressor FPS isa ii RE EE N AE 63 5612 03 02 02 Compressor Unloader Valve and Head Replacement murnerernvvernvvervnernnnnvnnneenenernanevnvernvnernnnrsenenenenere 68 5612 03 02 02 Compressor Unloader Valve and Head Replacement eie ee ee ee ee Ge ee ee ee Be ee ee ee ee 72 5018 030203 GR EE AE ee oi RE Ed OE AE Oe RE IN 75 5618 03 02 11 Air Dryer Desiccant Cartridge Replacement iii 77 5621 03 02 03 Purge Tank Replacement a 79 5621 03 0201 Ar Tank EDIC ar AAA EE 81 BG 1408 02 01 Er is RI ee aal AE EE EE AA AAA 82 5516 03 02 01 Parking Brake vale REPSCSMEN iria 84 5631 03 02 02 Parking Brake Trailer Supply Valve Replacement Dash iese esse
38. es reservoirs tubing fittings air dryer and drain valve Inspect compressor drive for loose components If low running time check for proper oil pressure coolant flow and duty cycle Replace compressor Replace compressor Check fasteners and seals Replace compressor Check fastener torque replace gasket if necessary 41 Group 56 Symptom Compressor head gasket failure Compressor passes excessive amounts of oil into the air system 42 Cause Restricted discharge line or dryer cartridge loose head bolts or faulty gasket Wintertime freeze up in discharge line Restricted air inlet Restricted oil return to engine Worn piston rings due to dirt in air supply high operating temperature due to exterior dirt accumulation or low coolant flow Excessive engine crankcase pressure Runs loaded for excessive time Troubleshooting Remedy Check for restrictions bolt torque change gasket consider installing relief valve Check for low spots in the slope of the discharge line where water can collect Check pipe Check oil return for problems Check supply piping for leaks Clean compressor Check operating temperature of compressor Replace compressor Test engine crankcase pressure and check crankcase ventilation Drain reservoirs Check for leaks in supply and accessory systems Group 56 Air Dryer Troubleshooting Symptom Dryer is constantly cycling or purging
39. f an accident or if tubing needs to be lengthened for rerouting there are certain procedures that must be followed In general there are no restrictions against repairing tubing versus replacing it A repaired tubing has the same integrity as the rest of the system if the repairs are done properly Tube to tube fittings are available for 1 4 3 8 and 1 2 in tubing Damage to one tube is repaired so that the repair fitting is close to a bracket for support Prepare the tubing as outlined on the previous page Push the tubing ends into the fitting Leak test fitting at full pressure after system pressure has been established again If a whole bundle of tubing needs to be repaired or lengthened make sure the fittings are staggered instead of installed at the same length Put the larger fittings close to a bracket for support and the smaller fittings further away Design and Function W5000582 RO W5000583 QUA W5000584 39 Group 56 Air Tank Mounting Air Tanks are found in several locations on the VN and VHD vehicles The illustration shows the standard mounting for the various air tanks For Air Tank replacement instructions see Air Tank Replacement page 81 Design and Function 1 VHD Right Side frame rail Option 2 VN VHD Left Side frame rail 3 Purge Tank 40 W5001147 4 Air Dryer VN VHD 5 Crossmember Mounted VHD 6 Dual Compartment Wet Tank and Rear Brake Tank Group 56 Troub
40. ge line e Water line Supply to the compressor e Water line Return from the compressor e 2air lines to the air governor e Oil supply line 5 Note the position of the fittings and remove them Note VE D12 Unplug the sensor in the water outlet pipe on the water pump 6 Remove the 4 compressor mounting bolts Lift compressor out Installation 7 Position the air compressor into place Group 56 Service Procedures 8 Install and torque the 4 mounting bolts to 85 15 Nm 63 10 ft lb 85 15 Nm 63 10 ft lb Install all fittings and reconnect all hoses and lines to the air compressor Install coolant lines discharge line and governor tubing Note Torque for water line hose clamps is 3 0 5 Nm 25 4 in lb 0 5 Nm 3 25 4 in lb 10 Reconnect the air filter pipes from the air filter to the turbo and the air supply line to the air compressor Note Torque for bolt and clamp assembly on the compressor air supply line is 24 4 Nm 18 3 ft lb 24 4Nm 18 3 ft lb 11 A CAUTION Connect the main battery ground cable first If there are other ground cables connected to the battery such as engine ECU satellite system etc connect those grounds last Electronic modules may be damaged when additional grounds are connected disconnected without the main battery ground connected Always connect the main battery ground first Connect the battery cable 12
41. ge valve or orifice to fill the purge tank Purge Cycle As air pressure reaches the cut out setting of the governor the compressor unloads and the purge cycle of the dryer begins The governor sends air to the control connection thereby closing the turbo valve which closes off the air supply from the compressor At the same time the purge valve opens to atmosphere and expels separated contaminants in the initial air pressure release Air is also flowing from the wet tank back to pressurize the supply line via a check valve Regeneration of the desiccant takes place during the time it takes for the purge volume to slowly flow back through the purge orifice and into the desiccant bed There it removes the water vapor collected in the desiccant The regeneration takes less than a minute 34 Design and Function W5000740 W5000745 W5000746 Group 56 Midland Pure Air Plus A separate replaceable coalescent filter is used for separating out large particles This should be changed every 12 months regardless of desiccant cartridge exchange Desiccant is contained in a disposable cartridge that is screwed on to the valve housing Note Midland Pure Air Plus air dryers are not available with Holset compressors N WARNING Do not disassemble the cartridge No replacement parts are available and the cartridge contains a spring under pressure which can not be mechanically
42. ground first Connect the battery cable 27 Run the engine to check for leaks and air compressor operation Note It may be necessary to prime fuel system before running the engine 67 Group 56 Service Procedures 5612 03 02 02 Compressor Unloader Valve and Head Replacement Holset QE296 Before beginning this procedure read the General Work Practices section General Work Practices page 45 for further information See Holset page 27 for important service information before beginning this procedure See Holset QE296 page 29 for an exploded view of the Holset unloader valve Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death N WARNING Before beginning any service work on any part of the air system be certain that the air pressure has been released Failure to do so may cause a component to violently separate causing serious personal injury Removal 1 Chock wheels Empty compressed air system of all air 2 N WARNING Always wear appropriate eye protection to prevent the risk of eye injury due to contact with engine debris or fluids Hold the unloader valve body down and remove the four screws 3 Remove the valve body together with the unloader valve spring 4
43. he 2COMP850 is a twin cylinder compressor that is standard equipment on Volvo engines since 1997 The compressor has a built in unloading system ESS which stands for Energy Saving System The system reduces the power requirements for the compressor by approximately 80 when running unloaded and at the same time oil consumption is reduced The Knorr compressor is driven directly from the engine timing gears with a gear wheel attached to the tapered end of the crankshaft with a keyless fit The crankcase and cylinder block are cast as one unit and are air cooled The cylinder head is cooled by the engine cooling system The compressor is lubricated by the engine pressure lubrication system and the oil drains through the timing gear cover and back to the engine oil sump The two inlet valves which are also used for the ESS function are mounted with pivot arms on guide pins which run in grooves in the cylinder block The pivot arms are connected to the ESS system plungers via pins which are attached to the plungers and protrude above the block face through grooves in the block When unloading the plungers are pressed in with the help of compressed air from the governor and servo valve The plungers work on the pins and pivot arms pushing on the intake valves which are moved over to the unloading position 20 Design and Function W5000733 W5000969 Group 56 Function Charging When the compressor piston travels d
44. initially collects in the base of the dryer The moisture laden air then flows through the desiccant from the top to the bottom and becomes progressively drier as water vapor is adsorbed Dry air exits at the bottom of the cartridge and flows through the check valve and then exits out to the wet tank Purge Cycle When the compressor unloads the purge valve opens allowing the initial decompression of the dryer purge and expels the water collected in the base of the dryer The volume of air held in the purge tank back flows through the dessicant This flow cleans and dries the dessicant preparing it for the next cycle The air held in the purge tank is the cleanest air from the completed pumping cycle This provides a more efficient regeneration purge cycle 30 Group 56 Design and Function Air Dryer Wabco System Saver 1000 1200 Series W5001211 1 Regeneration Valve for the Wabco Air Dryer 1000 1200 1200E Series Note The Wabco Air Dryer 1200P Series does not use the Regeneration Valve 31 Group 56 Bendix AD IP This dryer is used in two configurations where one is used exclusively for the Holset compressor Because of the need for the Holset to have the discharge line fully pressurized also during the unloaded mode the dryer for the Holset compressor has a check valve arrangement that ties the wet tank pressure into the discharge line during the air dryer purge cycle N WARNING Do not disassemble cart
45. it into position Make sure that the intake valves are not trapped between the metal gasket and block face Group 56 15007321 15007323 W5000850 Service Procedures 11 Press in the ESS pistons so that the intake valves move to the unloading position and are not trapped by the metal gasket This can be done by placing a small nut behind the plug and tightening it down until the valve has moved over 12 Install the valve body on the block Make sure it is correctly positioned on the guide pins Install head gasket and head Oil the head bolt threads and install them 13 Tighten the head bolts in two steps First to a torque of 15 Nm 11 ft lb and then to the final torque of 30 33 Nm 22 24 ft lb 15 Nm 11 ft lb 30 33 Nm 22 24 ft lb 14 Remove the plugs and nuts from the ESS pistons Use a drift to press pistons in to check for proper operation indicating that the intake valves are not trapped by the metal gasket 15 Install air supply line discharge line and coolant lines to compressor head Install plug and fittings and unloader line 53 Group 56 Service Procedures 5611 03 02 04 Compressor Cylinder Head Gasket Replacement Knorr Before beginning this procedure read the General Work Practices section General Work Practices page 45 for further information 1 Before working on a vehicle set the parking brakes place the transmission in neutral and b
46. leshooting Compressor Troubleshooting Symptom Long charging time or will not build air pressure does not stop pumping Compressor builds too much or not enough air pressure Compressor constantly cycles Compressor noisy External oil or coolant leaks Cause e Intake pipe is blocked e Discharge pipe leaking or blocked e Inlet or outlet valves faulty e Unloader valves sticking e Slipping drive components e Air dryer purge valve leaking or frozen Blocked dryer cartridge e Automatic drain valve on reservoir leaking or frozen e Governor faulty e Governor faulty e Compressor fails to unload e Excessive fluid in reservoirs e Governor faulty e Compressed air system leaks e Loose drive gear or drive components e Worn compressor e Porous casting e Leaking supply lines or fittings e Cracked crankcase or head e Damaged mounting gasket between compressor and timing gear housing Troubleshooting Remedy Check pipe Check pipe and fittings for leaks blockage Replace compressor Replace unloader valves Inspect drive components Clean or thaw out the valve Replace valve if necessary Clean or thaw out the valve Replace if necessary Replace governor make sure the control tubing is Ok Replace governor Check for sticking unloader valves Test governor and inspect tubing Drain reservoirs Replace governor Checks for leaks in unloader valv
47. lock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death N WARNING Before beginning any service work on any part of the air system be certain that the air pressure has been released Failure to do so may cause a component to violently separate causing serious eye and or personal injury N WARNING Hot Engine Keep yourself clear of all moving or hot engine parts A hot engine can cause serious burns A CAUTION Before installing the replacement gaskets make sure all surfaces on the Knorr Compressor and head are clean and free of debris Chock the front wheels and release all air from the compressed air system Removal 2 Drain all coolant from the coolant system into a drain pan 3 Disconnect the governor unloader line air supply line discharge line and coolant line from the compressor head 54 Group 56 Service Procedures 4 Remove the eight head bolts and lift off the cylinder head and gasket 15007311 5 Remove the valve body and the head gasket W5001052 55 Group 56 Service Procedures 56 15007323 Installation 6 Install the head gasket between the valve body and compressor housings carefully placing it into position Note Make sure that the intake valves are not trapped between the head gasket and the compressor housing surface 7 Install the valve body on the compress
48. lve and intake valve spring 4 Remove capscrews lock washers and plain washers that hold cover and head to the cylinder block Remove cover and discard gasket 5 Remove the head and discard gasket Hold the head bottom side up and use thumb pressure to remove the exhaust valve seat assembly Remove the O ring seal from the exhaust valve seat Remove the exhaust valve 73 Group 56 74 Service Procedures 6 Remove the compression spring and wear plate from the head Installation 7 Install the new rectangular ring seal into the unloader body Note The seal must be installed with the grooved side up 8 Install the unloader cap in the body Install a new O ring seal on the unloading valve body Use clean 15W 40 oil to lubricate the seal 9 Install the wear plate and compression spring in the head Then install the exhaust valve on the exhaust valve seat 10 Install the O ring seal on the seat Use clean 15W 40 oil to lubricate the O ring seals Use hand pressure to install the exhaust valve assembly in the head 11 Use new gaskets to install the cylinder head and cover Install the flat washers lock washers and capscrews 12 Tighten the cylinder head capscrews in an alternating sequence 1 7Nm 5 ft lb 2 14 Nm 10 ft lb 3 20 Nm 15 ft lb 4 27 Nm 20 ft lb 7 Nm 5 ft lb 14 Nm 10 ft lb 20 Nm 15 ft lb 27 Nm 20 ft lb 13 Install the intake valve spring with the tang down In
49. n any part of the air system be certain that the air pressure has been released Failure to do so may cause a component to violently separate causing serious personal injury Removal 1 Drain all air from the compressed air system 77 Group 56 78 Bendix AD IP Air Dryer W5000852 Service Procedures 2 N WARNING Do not disassemble cartridge No replacement parts are available and the cartridge contains a spring under pressure which can not be mechanically caged The sudden release of the spring could cause it to be ejected violently causing serious personal injury Drain all air from the compressed air system 3 WABCO System Saver 1000 1200 Series Midland Pure Air Plus and RC Turbo 2000 air dryers only require the use of a strap wrench to replace desiccant cartridge They are spin on type cartridges On Bendix AD IP air dryers use a 1 1 8 in wrench or socket to loosen desiccant cartridge bolt Remove desiccant cartridge bolt 1 with its two O rings Installation 4 Inspect all O rings for splits cracks and possible reuse If defective replace 5 When installing new cartridge make certain the cartridge is properly seated and flush on end cover and that all sealing surfaces are clean Note For the AD IP dryer it may be necessary to rotate cartridge until anti rotation lugs align to allow cartridge to properly seat After new desiccant cartridge has been seated
50. o violently separate causing serious personal injury Removal 1 Completely drain all air from the compressed air system 2 Remove the air lines from the governor 3 Remove the two mounting bolts that hold the governor in place 4 Remove the air line fittings from the old governor Installation 5 Install the fittings to the new governor and align to the correct position for proper connection 6 Install the governor to the air compressor or bracket 7 Install the air lines to the governor fittings 8 Install the governor and tighten the bolts to a torque of 18 Nm 25 ft lb 18 Nm 25 ft lb 9 Start the engine and build up the system air pressure Check for air leaks and proper operation 83 Group 56 Service Procedures 5516 03 02 01 Parking Brake Valve Replacement For the service procedure see Dash Valve Replacement page 85 5631 03 02 02 Parking Brake Trailer Supply Valve Replacement Dash For the service procedure see Dash Valve Replacement page 85 5711 03 02 01 Trailer Brake Control Valve Replacement For the service procedure see Dash Valve Replacement page 85 84 Group 56 Service Procedures Dash Valve Replacement W5001037 Before beginning this procedure read the General Work Practices section General Work Practices page 45 for further information Before working on a vehicle set the parking brakes place the transmis
51. on General Work Practices page 45 for further information See Bendix 550 750 page 23 for important service information before beginning this procedure See Bendix 550 770 page 26 for an exploded view of the Bendix compressor Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death Ss O ore ie W5000754 57 Group 56 58 Service Procedures N WARNING Before beginning any service work on any part of the air system be certain that the air pressure has been released Failure to do so may cause a component to violently separate causing serious personal injury Removal 1 Chock wheels Empty compressed air system from all air Drain the coolant 2 Turn the ignition switch OFF and disconnect the battery AN CAUTION If there are other ground cables connected to the battery such as engine ECU satellite system etc disconnect those grounds first then remove the battery ground cable Electronic modules may be damaged when additional grounds are connected disconnected without the main battery ground connected Always disconnect the main battery ground last 3 Remove the compressor air supply piping If necessary remove any other components that are in the way 4 Note For Volvo VE D
52. or housing making sure it is correctly positioned on the guide pins Install the gasket and compressor head Oil the head bolt threads and install them 8 Torque the head bolts to 15 Nm 11 ft lb and then toa final torque of 30 33 Nm 22 24 ft lb Note To prevent warping or cracking the use of a cross method is recommended when torquing the air compressor head bolts 15 Nm 11 ft lb 30 33 Nm 22 24 ft lb 9 Remove the plug and fitting for the air governor line from the ESS Energy Saver System valve locations Using a drift press the ESS valves inward to check for proper operation Note If the ESS valves go in with ease this indicates that the intake valves are not trapped by the head gasket 10 Install the air supply line discharge line and coolant line to the compressor head Install the plug fittings and unloader line 11 Fill coolant system with coolant and start the engine Note Maximum coolant fill rate is 2 2 gallons per minute or 10 liters per minute 12 Run the engine to check for air compressor operation as well as any air or coolant leaks Note The compressor must be capable of raising the air system pressure from 585 690 kPa 85 100 psi in 25 seconds or less 585 690 kPa 85 100 psi Group 56 Service Procedures 5611 03 02 02 Compressor Replacement Bendix 550 750 Before beginning this procedure read the General Work Practices secti
53. ownward the check valve 1 and inlet valve 2 are opened by the vacuum created in the cylinder The inlet ducts are exposed and air flows into the cylinder When the piston moves upward the inlet valve 2 is closed by the pressure in the cylinder The air passes out through a hole 3 in the inlet valve and past the outlet check valve 4 into the compressed air system Unloading When the pressure in the system has reached the required level the governor and servo valve send air to the unloading plunger 5 The plunger is pressed in and moves the inlet valve so that a connection is opened to a chamber 6 in the compressor cylinder head At the same time the passage 3 to the outlet valve is closed which means that the air cannot pass out into the system When the piston travels upward the air in the cylinder is compressed and enters the chamber 6 in the cylinder head The compressed air will provide a driving force for the piston in its downward movement With the exception for losses in the form of heat which is formed during the compression phase the energy used to compress the air will be re used as the driving force when the piston travels downward This results in a compressor with ESS using very little power in the unloading position Design and Function W5000734 W5000735 W5000736 Ve Sa p E W5000737 21 Design and Function Group 56 Knorr 2COMP850 W5000727 22 Group
54. r fluids can cause burns or can permanently damage test equipment N WARNING Do not work near the fan with the engine running The engine fan can engage at any time without warning Anyone near the fan when it turns on could be seriously injured Before turning on the ignition be sure that no one is near the fan 45 Group 56 Service Procedures Inspection It is of the utmost importance that the compressor receives a clean supply of air The air strainer must be properly installed and kept clean If the compressor intake is connected to the engine air cleaner this connection must be properly installed and maintained Check the drive for proper alignment belt tension etc Inspect the oil supply and return lines Be sure these lines are properly installed and that the compressor is getting the proper supply of oil and just as important that the oil is returning to the engine Check the coolant lines to and from the compressor Check the unloader mechanism for proper operation Operation Test Vehicles manufactured after the effective dates of FMVSS 121 with the minimum required reservoir volume must have a compressor capable of raising the air system pressure from 585 690 kPa 85 7 100 psi in 25 seconds or less This test is performed with the engine operating at maximum recommended governed speed Air Leak Test Air leaks past the discharge valve can be detected as follows Remove the discharge
55. reinstall cartridge bolt with its two O rings and tighten to a torque of 68 Nm 50 ft lb 68 Nm 50 ft lb Group 56 Service Procedures 5621 03 02 03 Purge Tank Replacement W5001192 Before beginning this procedure read the General Work Practices section General Work Practices page 45 for further information See Purge Tank page 36 for important service information before beginning this procedure Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death Park the vehicle on a level surface with the transmission in neutral and the front wheels chocked 2 N WARNING Before beginning any service work on any part of the air system be certain that the air pressure has been released Failure to do so may cause a component to violently separate causing serious personal injury N WARNING Always wear appropriate eye protection to prevent the risk of eye injury due to contact with engine debris or fluids Deplete the air system pressure 3 Disconnect the air line using Special Tool J 44773 Note Observe the orientation of fitting when performing this step J 44773 4 Remove the mounting bolts to the air tank bracket 79 Group 56 80 Service Procedures 5 Remove the fittings from the air tank and
56. ridge No replacement parts are available and the cartridge contains a spring under pressure which can not be mechanically caged The sudden release of the spring could cause it to be ejected violently causing serious personal injury Charge Cycle During compressor loading air flows into the supply connection of the housing changing direction several times thereby reducing the temperature causing contaminants to condense and drop to the bottom toward the purge valve After exiting the housing air flows into the cartridge A coalescent filter located between the outer and inner shells separates heavier contaminants Air along with remaining water vapor is further cooled as it continues to flow through the desiccant from the top to the bottom and becomes progressively drier as water vapor is adsorbed Dry air exits at the bottom of the cartridge and flows through the check valve and then exits the discharge connection for the wet tank Dry air also flows through the purge orifice to fill up the purge volume storage Purge Cycle Regeneration of the desiccant takes place during the time it takes for the purge volume to slowly flow back through the purge orifice and into the desiccant bed There it removes water vapor collected by the desiccant The regeneration takes approximately 30 seconds 32 Design and Function W5000751 W5000741
57. roup 56 Bendix Tu Flo 750 Designation Sales designation Bendix 16 5 CFM Type Number of cylinders Cooling cylinder head Capacity Maximum pressure Maximum operating speed Bore Stroke Tightening torques Mounting flange bolts Drive gear nut Cylinder head bolts Unloader valve cover plate bolts Exhaust valve seat Intake valve seat Specifications Tu Flo 750 Piston Compressor 2 Coolant 470 L min 16 5 cfm 930 kPa 135 psi 2400 r min 70 6 mm 2 78 in 47 5 mm 1 87 in Nm ft lb 85 15 63 10 165 13 5 110 10 53 3 4 39 2 5 23 143 17 20 110 13 80 10 110 13 80 10 Group 56 Holset SS 296 SS 296E QE 296 Designation Sales designation Cummins 13 2 CFM Type Number of cylinders Cooling cylinder head Capacity Maximum pressure Maximum operating speed Bore Stroke Tightening torques Mounting flange bolts SS and E unloader housing bolts QE unloader housing bolts Valve plate housing bolts Air compressor support bracket bolts Fuel pump mounting bolts Specifications SS296 SS296E QE296 Piston Compressor 1 Coolant 375 L min 13 2 cfm 930 kPa 135 psi 2400 r min 92 10 mm 3 625 in 44 45 mm 1 750 in Nm ft Ib 68 50 14 10 27 20 28 21 47 35 47 35 Group 56 Air Dryer Specifications Air Dryer Wabco System Saver 1000 1200 1200E 1200P Wabco 1000 Height Maximum width Weight Voltage Maximum compressor capacity Heater power
58. sion in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death N WARNING Before beginning any service work on any part of the air system be certain that the air pressure has been released Failure to do so may cause a component to violently separate which can result in serious personal injury N WARNING Always wear appropriate eye protection to prevent the risk of eye injury due to contact with engine debris or fluids 1 Park the vehicle on a level surface and chock the wheels Make sure the vehicle is in neutral and the brakes have been released Drain the air sys tem of all air pressure Removal 2 Remove the electrical center covers Unbolt the instrument cluster and lay the instrument cluster to the side 85 Group 56 W5001038 W5001039 W5001040 86 Service Procedures 3 Pull the handle off the trailer hand brake valve and remove the trailer hand brake cover Using a small punch drive the pins out of the parking brake knob and the trailer supply knob and remove them 4 Remove the dash cover for the trailer hand brake valve and manifold dash valve and unbolt the dash panel 5 Disconnect the lower radio support and lay the dash panel over 6 Unbolt the manifold dash valve and remove the mounting plate Group 56 Service Procedures 7 Disconnect the air lines to the
59. stall the intake valve Install the intake valve seat with the flange side up Group 56 Service Procedures W5000856 14 Install the unloader valve cap spring Install a new O ring to the valve body Install the unloader valve body 15 AN CAUTION Do not overtighten these screws Compressor damage will result Hold the unloader valve body down and install the washers and screws Tighten the screws to a torque of 14 Nm 10 ft lb Install governor to the unloader body 5618 03 02 03 Air Dryer Replacement Before beginning this procedure read the General Work Practices section General Work Practices page 45 for further information See Wabco System Saver 1000 1200 Series page 30 Bendix AD IP page 32 CR Turbo 2000 page 34 and Midland Pure Air Plus page 35 for important service information before beginning this procedure See page 31 and page 33 for an exploded view of the air dryers Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death N WARNING Before beginning any service work on any part of the air system be certain that the air pressure has been released Failure to do so may cause a component to violently separate causing serious personal injury Removal 1 Drain all
60. system for the compressed air brakes consists of the compressor 1 governor 2 air dryer 3 and storage tanks 4 5 and 6 Which compressor model is installed is dependent on engine manufacturer specification or customer choice A Bendix governor is standard for all compressors The governor is installed away from the compressor on all vehicles with Volvo engine and Knorr compressor A servo valve 23 is needed for the governor when installed away from the compressor see Servo Valve page 18 for more information For air schematics over supply systems on other models refer to Group 5 air brake system schematics Also found in the supply system is the Purge Tank See Purge Tank page 36 W5000764 Compressor Relief Valve There have been instances where problems downstream from the compressor has produced high pressures in the compressor resulting in damage to the head gasket A relief valve has been introduced on some compressors and engine types to prevent damaging overpressure in the compressor The relief valve is typically installed in the valve head or very close to it In the event of an overpressure air will be released in short bursts from the valve as it opens Opening pressure is set at 1 7 MPa 250 psi W5000934 15 Group 56 Compressor Air Supply Normally Aspirated The air supply for compressors installed on all Volvo engines is normally aspirated The intake piping is connected to the
61. ucks North America Inc Greensboro NC USA Order number PV776 TSP194846 2003 Volvo Trucks North America Inc Greensboro NC USA All rights reserved No part of this publication may be reproduced stored in retrieval system or transmitted in any forms by any means electronic mechanical photocopying recording or otherwise without the prior written permission of Volvo Trucks North America Inc USA14061 Contents ETL J A EE 3 Compressed Air Brakes cursar 3 ee el EE N EE ON 5 ER ERE 5 Knair SEINE BED cascara cotiza 5 Eie MIE st EO 6 Bendix TU 750 aria Holset 55 296 55 296E QE 296 siese REENEN ed 8 A A OR ET 9 Air Dryer Wabco System Saver 1000 1200 200E 1200P ri 9 Bendi ADAP vu 10 Midland Pure Alr REE ere 10 OR WDO eee 11 TONE opus di 13 EE es ER na 13 Design and Function ee ees ee ee ee ee 15 l se Les oe iia 15 General System Function eers see ee ee 15 Eee EE teeter terete ig COMPSSSO ri 20 Khor 200MP E50 canal 20 Pandi ED REE 23 5 Se EEE 27 EEE je EE A 30 Wabco System Saver 1000 1200 Series 30 Bendik AD IP iia 32 CR TUbO 2000 ein 34 Midland Pure Air PIUS sesse RAN EKEN EL Ka 35 RE EE EN 36 Pure TANE Ma EE 36 Alf TUBING A Al Tank MONNA is Troubleshooting 0 00 0 ee ee ee ee ee Compressor Troubleshooting oococoonocnmmm m mm Air Dryer Troubleshooting iese ee ee ee ee Service Procedures sisirin General Work Practices cceeecceeeseeeeesee
62. ure from the wet tank holding the valve closed The governor sends the cut out signal to the servo valve when air pressure has reached maximum system pressure The signal activates the piston in the servo valve B which opens the valve connecting air flow from the wet tank to the compressor and air dryer The compressor will unload and the air dryer will go into its regeneration and purge cycle W5000930 18 Group 56 Servo Valve Ventilator Cap It is possible for the vent cap on the servo valve P N 8081072 see arrow page 19 to prevent air from exhausting completely trapping air in the valve This will cause the compressor to stay in the unloaded mode and or the air dryer to stay in the purge mode thus preventing the system pressure from properly building up A new vent cap design has been introduced into production If the above failure should occur the new vent cap P N 8061304 should be installed Note This vent cap P N 8061304 can be used for all models The servo valve is only installed on vehicles with Volvo engines equipped with a Knorr compressor The servo valve governor location is remote from the compressor On VN vehicles it is located between the battery box and the frame or on later models just in front of the battery box VN VHD location is on the outside of the frame rail close to the cab support Design and Function W5001007 19 Group 56 Compressor Knorr 2COMP850 Design T
63. valve bracket to allow for the removal of the air tank mount bolts 6 Remove any brackets or straps and fittings and plugs from the air tank 81 Group 56 82 Service Procedures 7 Remove the air tank from the vehicle 8 Install the fittings and plugs into the replacement air tank using pipe sealant Install the replacement air tank and start the mount bolts 10 Tighten the air tank mount bolts 11 Secure any air valves or brackets 12 Connect any airlines and secure them with zip ties 13 Start the vehicle and build the system to check for leaks and proper operation 5614 03 02 01 Governor Replacement Bendix Before beginning this procedure read the General Work Practices section General Work Practices page 45 for further information See Governor page 17 for important service information before beginning this procedure Before working on a vehicle set the parking brakes place the transmission in neutral and block the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death N WARNING Always wear appropriate eye protection to prevent the risk of eye injury due to contact with engine debris or fluids Group 56 Service Procedures N WARNING Before beginning any service work on any part of the air system be certain that the air pressure has been released Failure to do so may cause a component t
64. vernor WABCO Tubing between wet tank and air dryer kinked or blocked 43 Group 56 Troubleshooting Symptom Safety valve opens if equipped Air dryer valves freeze up 44 Cause e Output valve blocked Tubing blocked downstream from air dryer Safety valve faulty Desiccant cartridge plugged Governor faulty so compressor overcharges Heater or thermostat inoperative Remedy Clean or replace valve Check for blockage kinks or faulty components Replace valve Replace desiccant cartridge Replace governor Check fuse Check for defective wiring heater element or thermostat Group 56 Service Procedures Service Procedures General Work Practices Before working on a vehicle set the parking brakes place the transmission in neutral and chock the wheels Failure to do so can result in unexpected vehicle movement and can cause serious personal injury or death N WARNING Before beginning any service work on any part or the air system be certain that the air pressure has been released Failure to do so may cause components to violently separate causing serious eye and or personal injury N WARNING Always wear appropriate eye protection to prevent the risk of eye injury due to contact with engine debris or fluids N WARNING HOT ENGINE Keep yourself and your test equipment clear of all moving parts or hot engine parts and or fluids A hot engine and o

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