Greetings and salutations. I'm Marcus. I (usually) drive a 96 Mack CL700 Elite dump truck for a small gravel pit. The truck is old and beat up with lots of mechanical issues that we know how to fix. However there is an electrical issue connected to the air system that I'm not sure how to fix or even troubleshoot.
1st: When the Brake Air Pressure idiot light comes on, the brake lights come on (I'm not sure if this is what is supposed to happen, but that's the way it is.)
2nd: The idiot light used to come on at 90psi but now it comes on between 105 and 110. Which is a problem as it causes the brake lights to keep coming on when I have sufficient air.
3rd: The air compressor is super slow to air up and once it hits about 118 the dryer purges and the various air leaks slowly drain out the system and it doesn't start to refill until it drops to 90psi.
So, the more important issue (aside from fixing all the various little air leaks) is addressing the idiot light coming on too soon. I'm hoping to find out how it works, and more important how to get it to activate at the right air pressure.
Thank you in advance for any and all help that points me in the right direction,
Marcus
96 Mack CL700 Elite dump truck electrical and air issues
Discussion in 'Heavy Duty Diesel Truck Mechanics Forum' started by sirpuma, Oct 19, 2023.
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I’m not familiar with Mack, but most trucks of that vintage have pressure switches mounted in a manifold. It could be the switches are old and reading incorrectly or you may have a restriction in the line feeding the manifold.
The compressor may be worn out or the discharge line may be leaking. If a compressor is passing oil the discharge line can leak along the length and not be heard.
Break out the soapy water and start spraying everything down.
@BoxCarKidd @Big Road Skateboard may be familiar with Mack -
Thanks for the reply. I'll start tracing the lines coming off the compressor. I'm trying to think if there were any electrical wires in there. I think there was something on the air dryer, but I'll look around ... whenever I have the down time. Tis the season for everyone in our area to suddenly want rock. Like they just couldn't get their projects done in the summer. Oh no, gotta do it in the late fall just before the snows fly and while all the rain is coming down.
Maybe I can convince them to let me come in over the winter while we're down. -
My previous truck was a '96 Mack CL700. It seems the core issue might be with the pressure switch of the air brake system. This switch is designed to activate the brake warning light (and in some models, the brake lights as well) when the air pressure drops below a certain threshold, indicating a potential brake failure. If the switch is malfunctioning or incorrectly calibrated, it might erroneously signal low pressure at 105-110 psi. You'll need to check the switch's settings and recalibrate it to trigger at the correct pressure. I'd go with replacing it because it's more straightforward.
The slow air compressor build-up and frequent purging point towards potential compressor wear or issues in the air dryer system. On my Mack, similar symptoms were a precursor to compressor failure. Keep an eye out for excessive noise during operation, a sign that the compressor is struggling. For the air dryer, ensure the purge valve isn't sticking and check for any desiccant saturation or contamination, which can impede performance.
I was sick of wasting money on repairs, and I eventually upgraded to a 2016 Freightliner M2106. Fewer headaches and it's easier to handle it. Keep an eye on those used dump trucks for sale from where I got mine. They often post sweet deals.Last edited: Oct 26, 2023
sirpuma Thanks this. -
The air compressor was rebuilt a couple years ago and we replaced the entire air dryer unit last year. Any idea where that pressure switch might be? Perhaps under the dash on the firewall or behind the dash somewhere. If I have an idea where to look, when I get some downtime I can can tear into it. Sadly the outfit I work for is too small to afford anything even close to new. The Mack is the newest of our trucks and all of them has seen not only heavy use, but the owner of our company has put almost every truck we have on it's side at one time or another. We work in very challenging environments.
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