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Symptoms are exactly what I was experiencing when my unloader had the black tar looking goo on it you see in the photo. Solvent alone didn't cut it, I used some 400 grit sandpaper until both mating surfaces shined like new. That's when I realized the cap has rubber seals in it, be carefull.

Yep, sounds like when the 24V jump occurred, perhaps there may have been some damage done. A misconnection somewhere would be the likely cause.

On the boxes I have seen with the black epoxy, you would be lucky to extract anything from that. That stuff is as hard as a rock and takes weeks to dissolve and by then the plastic, etc. is destroyed. I used to inspect automotive sensor failures using that method. I'm sure you can order a...

I'll draw you up a diagram to make your own FS box, stay tuned...

Took it out for a Sunday drive and it's operating perfectly now. I have been draining the air tanks after each use trying to keep condensation blown out.

Glad this info is helpful. One thing I failed to mention is that on mine, when the ground is properly connected, I hear a lower volume buzzer when just the parking brake is set and the parking brake lamp is flashing, and the volume will increase for a low air alarm when that lamp...

Electrical Engineer here, The failsafe I have is a green plastic housing which I know has a circuit board, components, relays, and the like. At least a digital 555 timer IC circuit for the buzzer and lamp oscillation. They filled it after assembly with black epoxy resin so it's very difficult...

My PPV valve is on the bottom, front end of the wet air tank which is the tank the air dryer feeds into. My valve has a round adjustment handle on it, i'm guessing to set the threshold pressure.

When in doubt, change em all out. That's how I do.

gotcha.

I also notice you mentioned your unloader "was a beast to put back together"? Why so? I have the A1 Cummins 250 and re-assembly was quite simple for me. Perhaps the difficulty is an indicator that a mistake was made in re-assembly? Do you have a diagram to confirm parts placement? I remember...

If it won't build air with the governor tube disconnected from the unloader, then either the unloader is malfunctioning or the compressor is not making air. My money is on the unloder valve intermitently malfunctioning. When compressors don't make air odds are it's not an intermitent thing.

When the governor senses high pressure(130psi), it directs air pressure to the unloader through a tube which pushes open the unloader valve. All of the air the compressor makes then escapes out the unloader outlet port. When the pressure drops below the low pressure threshold(90psi), the...

How many presses of the pedal should it normally take before your primary is below 90 and the air warning activates?

He said he took the govenor apart. Could have changed the build and blow off threshold psi. He says it's dumping air fast when the brake is pushed.

Glad it didn't blow up! Something is dumping alot of air when the brake pedal is depressed. I would start looking at the brake pedal and everywhere else for air leaking using the folowing method. Fill a spray bottle with soapy water, grab flashlight and find a helper. Air up the truck to...

It was great meeting the local folks before the parade. This was a great 1st parade for us with a huge turnout and excellent weather...

The PPV valve is located on the front bottom side of the wet air tank. It looks like an adjustable valve with a round handle on one end. I just got done solving some air problems, you may want to have a look at this if you haven't seen it...

Thanks for your response 98G, spot on. I was shocked to realize all three symptoms were from a single cause but it makes perfect sense when looking at the air diagram in hindsight. Stuck PPV starves the governor for air which keeps the unloader making air. Removed the PPV and it didn't look...

Still having air issues, now of another sort. I took it for a few drives to get it up to operating temperature and the air performance was excellent. We were thinking unsticking the unloader would be the end of our air problems. Everything was working normal. Blowing off at 120+...