Is my Compressor broken or not???

Did you use a governor from the same manufacturer of the compressor?

I had an issue on one truck, it would always cycle, no air leaks (held air for more than 36 hours). The driver took it to four different shops while it was on the road and every time replaced the governor with a 'dealer' replacement. I got my hands on it, looked at the governor and saw that it wasn't the same as the original, the ports looked in the right spot but when I looked in the pilot line port on the original and compared to the replacements (my policy was ALWAYS get the old parts when shops work on the truck), it was different so I capped that port on the new one, put the pilot line on the opposite side and it worked. These were alliance and another supplier's parts- the original was Bendix - I took one of the new ones and the old one apart and saw there was a difference in the casting, the new ones were made to cover a lot of applications and the old one was for that compressor and that engine. .

 

I guess I cant read not sure where I came up with the Cat in your truck, But a Volvo is basically the same.

 

On my D-2 governor (Cat motor) there is an "EXH" port.. I assume for exhaust... It is capped it was that way for 7 years since I bought my truck. Should it be capped? If it to exhaust air it has to be uncapped? I assume?

 

Unless the governor is mounted on the drier the most common one is a Bendix. You will want a part number Bendix OR275491X what you will get is a new D2 governor at a reman price. Here is a link to the Bendix compressor trouble shooting. It should answer all of your questions.
http://www.bendix.com/media/documents/products_1/compressorsgovernors_1/troubleshootingguide.pdf

 

I just experience this exact issue with one of my Pete's a couple weeks ago. I pulled the unloader, cleaned it, put it back. No improvement so I figured it had to be the gov. or the purge valve in the drier. Since the drier was original to the truck (2005) I chose to get both a new drier and a new gov. Changed the gov first, no change so changed the drier and problem solved. You COULD just change the purge valve but, for the cost, you may find it better to just change the whole drier.

 

I would lean towards the unloader valve.
When you say you changed the air filter were you refering to the air drier dessicant cartridge or does your volvo have it's own air filter for the compressor that you changed.
The reason i ask is because if you haven't changed the drier dessicant cartridge it could also be the culprit.
Good luck and hope this helps.

 

I dont know about volvo engine, but my Freightliner with Mercedes every other year or so it does the problem you have, and changing the dryer or the cartidge works for me, fixes the annoying sound, why or how Dont know dont care, but it works for about a year or may be a year and half

 

I had the same problem once and it turned out to be when I replaced the govenor I accidently plugged the exhaust port, so it just kept building air