Brakemaster® air dryers

24

Service procedures Turbo-2000

Purge Valve Service Kit #235

Warning: Read and follow safety precautions found on page 17 before proceeding

Symptom

1. Dryer won’t exhaust

2. Air leak at exhaust port during the:

a) Charge mode

b) Stand-by mode

3. Pressure slow or no build

4. Compressor cycles rapidly

Operational check

Symptom #1:

Start engine and build to cutout pressure. If dryer does not exhaust proceed as follows:

1. Check for air pressure in line connecting D2 governor to control port of air dryer. If no pressure is present in line, service D2 governor.

2. Check for blockage at exhaust port of air dryer.

3. If items 1 and 2 are OK, replace purge valve #235.

Symptom #2A & #3:

Start engine and build air pressure. During the charge cycle, check for air leaking at exhaust port of dryer. If air is leaking from exhaust port proceed as follows:

1. No air pressure should be present in line connecting D2 governor and dryer purge valve during charge cycle. If there is, service D2 governor.

2. If item 1 is OK, replace purge valve #235

Symptom #2B & #4:

Start engine and build to cut out pressure. Stop engine. Allow one minute for purge air to discharge dryer. If air continues to discharge from exhaust port of dryer, replace purge valve #235.

Note: Air discharge could also be due to worn check valve or turbo valve. Refer to pages 27 and 28 for service procedures on these valves.

con’t...

Purge valve replacement

1. Disconnect air line at control port.

2. Remove the two fasteners that attach the purge valve retainer. Remove the retainer.

3. Remove the purge valve assembly from the purge cavity and discard.

Note: If there is excessive oil in the cavity, compressor may require servicing.

4. Clean the cavity thoroughly.

5. Remove the three (3) o-rings from retainer and discard.

6. Using lubricant supplied, lightly grease the new o-rings.

7. Install on the retainer the two- (2) thickest o-rings then install the third (thinner) o-ring.

8. Install the new filter screen in the purge cavity open end out.

Note: If air dryer is equipped with oil separator

DO NOT install filter screen.

9. Apply a light coating of grease around the o-ring seat on valve assembly. Install the thin o-ring on the purge valve seat.

10. Aligning the valve exhaust port with the air dryer exhaust port, install the purge valve assembly. Use care not to dislodge the o-ring from its seat.

Warning: If the air dryer purge valve port does not align with air dryer exhaust port, air dryer will not exhaust!

11. Install retainer.

12. Apply a light coating of grease on the threads of the two retainer bolts.

13. Install two retainer bolts. Tighten to 10-15 ft. lb.

14. Reconnect the control line to air dryer control port.

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25

26


Regeneration Valve Service Kit #223


Symptom

1. Water in tanks.

2. No purge air flow.


Symptom #1 & #2:

Start engine and build to cut-out pressure. Stop engine. After initial exhaust, air should flow with decreasing intensity out the exhaust port for approximately 45 seconds. If air fails to flow, replace regeneration valve kit

#223.

Regeneration valve replacement

1. Drain the air system.

2. Disconnect the air line at air dryer purge tank port.

3. Remove regeneration valve nut.

4. Remove and discard o-ring, spring and spindle.

5. Clean nut and cavity.

6. Position new spindle in the cavity with spring pocket side out.

Install spring.

7. Using grease supplied, apply a light coating on o-ring.

Install o-ring on nut.

8. Apply light coating of grease on nut threads.

Install nut and tighten to 60 ft. lb.

9. Re-connect air line to air dryer purge tank port.


Check Valve Service Kit #238


Symptom

1. Dryer frequently exhausts.

2. Air continually flows from exhaust port when compressor is in standby mode.

3. Wet tank pressure drops rapidly.

Note: The above symptoms could also lead to turbo valve replacement.

A malfunctioning turbo valve will tend to allow pressure to drop to cut-in pressure within seconds on

E-Type dryers.


Symptom #1, #2, & #3:

Start engine and build to cut out pressure. Stop engine. Allow one minute for purge air to discharge dryer. If air continues to discharge from exhaust port of dryer, replace check valve #238.

Note: Air discharge could also be due to worn purge valve or check valve.

Turbo valve replacement

1. Drain air system.

2. Disconnect air line from outlet port.

3. Remove check valve nut.

4. Remove and discard o-ring, spring, spindle, and ball.

Note: If there is excessive oil in the check valve cavity, compressor may require servicing.

5. Clean nut and cavity area.

6. Install new ball in cavity. Next, position spindle with spring pocket facing out. Install spring.



8. Apply a light coating of grease to threads of nut.


9. Re-connect air line to air dryer outlet port.

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28


Turbo Valve Service Kit #228


Symptom



3. System pressure drops very rapidly.

Note: The above symptoms could also lead to Check valve replacement.


Symptom #1, #2, & #3:

Start engine and build to cut out pressure. Stop engine. Allow one minute for purge air to discharge dryer. If air continues to discharge from exhaust port of dryer, replace turbo valve #228.

Note: Air discharge could also be due to worn purge valve

or check valve.



2. Disconnect the heater wiring.

3. Disconnect the inlet and control lines from their respective ports.

4. Remove 8 bolts from bottom cap and set aside. Discard gasket.

5. Remove turbo nut, valve stop and valve and discard.

6. Clean cavity area thoroughly.

7. Lightly coat the 2 (small) o-ring surfaces and install on piston.

Carefully install valve in cavity with tapered side up.

8. Place valve stop on top of valve concave side down.

9. Lightly lube (large) o-ring and place on nut.

Install flat seal into nut.

10. Install nut and tighten to 40-45 ft. lb.

11. Place gasket on bottom cap aligning all holes. Locate bottom cap so that inlet port is directly below outlet port. Install the 8 bolts.

Tighten bolts to 20-25 ft. lb. or 25-30 ft. lb. if equipped with oil separator.

12. Re-connect inlet and control lines to their respective ports.

13. Re-connect heater wiring.


Dessicant Cartridge Service Kit

#T224 & #T224-P


Symptom

1. Regular service interval.

2. Water or contamination in tanks.


Symptom #1 & #2

Desiccant cartridge requires regular servicing at intervals determined by compressor duty cycle or type of driving conditions. Typical service intervals are:

Line haul

Inner city

3 years

2 years

Refuse/transit 1 year

Off highway 1 year

Using T224-P with extra filtration will protect desiccant longer and lengthening service intervals. Add 1 year to above chart. The above is a guideline only. Drain tanks on regular basis. If moisture exists, replace cartridge.

Desiccant cartridge replacement

* Steps required for service kit T224-P only.

1. Relieve all system air pressure.

2. * Disconnect heater lead wire from air dryer.

3. * Disconnect inlet and control lines from their respective ports.

4. Using a strap wrench, turn the desiccant cartridge counterclockwise and remove. Discard.

4a. If cartridge spins without loosening, place a thin blade between cartridge gasket and base to break seal. If not,

4b. strike cartridge with a center punch or ball nose at the lower end where the diameter is slightly larger. This binds components together.

5. Remove and discard o-ring from adapter plate stud and filter element

(if present).

6. * Remove eight (8) 3/8" hex head bolts from bottom cap and set aside.

7. * Remove bottom cap assembly.

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8. * Remove filter plate (if present) and gasket(s) from bottom cap and discard.

9. * Clean bottom cap sump cavity, gasket surface and inside of adapter plate castings of oil and contaminants.

10. * Service of turbo valve is recommended at this time also. Refer to service procedures on page 25.

11. * Place new gasket on bottom cap bolt flange.

12. * Place new filter plate into bottom cap cavity. Position filter plate cavity, as shown in Fig. 1, with arrow pointed toward inlet port of bottom cap.

13. * Re-install bottom cap assembly to adapter plate casting.

14. * Torque (8) bolts to 25-50 ft. lbs.

15. Clean top surface of adapter plate and threaded stud.

16. * Position a new filter element around cartridge stud and onto adapter plate.

17. Using grease supplied, apply a light coating of grease onto o-ring.

Install o-ring onto threaded stud.

18. Important for easy removal: Apply a generous coat of grease on the new desiccant

cartridge gasket surface.

19. Thread new cartridge onto stud turning clockwise. When gasket contacts adapter plate, tighten cartridge 1/2 turn. Do not overtighten!

20. * Re-connect airlines to air dryer inlet and control ports.

21. * Re-connect heater lead wire.

Note: Cartridge Stud Kit #619140 available if stud needs replacing.


Early model Late model

2

Heater Service Kit #248,

#249, #619110, #619111

Warning: Read and follow safety precautions found on page 17 before proceeding.

Symptom

1. Dryer won’t exhausts

2. Exhaust port leak.

3. Cannot build pressure.


Note: Thermostat must be cooled to at least

35 degrees F to check.

1. Closed ohmmeter circuit indicates heater is functioning.

2. Open ohmmeter circuit indicates faulty heater assembly.

Heater assembly replacement

1. Disconnect heater leads.

2. Remove set screw (if present) holding heater element in casting.

3. Remove two screws attaching heater cover and/or thermostat to casting.

4. Remove heater/thermostat assembly and discard.

5. Thoroughly clean entire heater/thermostat area.

6. Apply a light coating of anti-seize to the heater element and thermostat cavity.

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7. Insert heater element into hole and twist slightly to spread anti-seize.

7.1 Early Models (#248 or #249; orange and blue wires)

7..1.1 Install new set screw (if required) until snug

(DO NOT OVER TIGHTEN) Screw will protrude from bottom cap about 1/8”.

7..1.2 Insert thermostat into position in thermostat cavity.

7..1.3 Coil lead wires around heater cover posts allowing wires to protrude through slots in cover.

7..1.4 Place two (2) 6-32 x 1-1/8 screws in heater cover and attach the thermostat.

Note: If heater cover is not used, use short screws and wire clamps to secure thermostat and wires.

7..1.5 Fill heater cover through

1

/

4

” hole with non-corrosive RTV.

7..1.6 Connect blue heater wire to a good chassis ground.

7..1.7 Connect orange wire to ignition switch.

7..1.8 Seal and route heater wires carefully.

7.2.11 Late Models (#619110 or #619111); plug style connection

7.1.2.1. Slide o-ring over heater and thermostat into position around connector flange.

7.1.2.2. Slide heater and thermostat into position in cavity.

7.1.2.3. Ensure thermostat sits flat in cavity.

7.1.2.4. Place foam cube on top of thermostat and bring heater connector into position over heater.

7.1.2.5. Secure heater assembly using the

(2) 8-32 x 1/2” screws.

7.1.2.6. Reconnect Metri-Pak connector to male plug.

Note: If heater lead wire with male plug needs to be replaced or is not in vehicle wire harness it is available in Kit #619900.

Turbo-2000 Notes:

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33

34

HD-2000 parts list

A 610237

B 223

C 610077

D 610110

E T224

E-1 T224-P

F 610236

G 238

H 619089

619090

I 235

J

248 12V 75W

249 24V 75W

J

619110 12V 75W

619111 24V 75W

K 619900

L 610024

M 619115

N 619140

O 619091

Component identification

Regeneration valve nut

Regeneration valve kit

Body gasket

Seal retainer

Desiccant cartridge

Desiccant cartridge filtration plus

Check valve nut

Check valve kit

Bottom cap assy 12V

Bottom cap assy 24V

Purge valve kit

Heater kit early models

(Orange and blue wires)

Heater kit late models

(Plug style connection)

Wire harness

Safety valve 175 psi

Mounting bracket

Cartridge stud

Mid-section with valves

Bold part numbers represent suggested stock service components

HD

620550

620554

620552

620556

221

HD w/ filtration plus option

Air dryer part number description

Description

620350

620354

620352

620356

221

Dryer/tank 12V

Dryer/tank 24V

Air dryer 12V

Air dryer 24V

Purge tank

For right-hand models see parts list on pages 139 & 140.

HD-2000 service schematic

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35

HD-2000 normal operation/cycles – use with naturally aspirated and Discharge

Line Unload compressors

Air flows from the compressor into the air dryer. Air flows past filters and desiccant bed, stripping moisture and contaminants from the air and exits the dryer to the purge tank and to the wet tank.

The reservoir line from the wet tank to the governor is always pressurized.

When pressure reaches cut-out (typically 120-125 psi), the governor sends air signal through the governor line to the air dryer opening purge valve. The check valve is closed via back pressure from the wet tank. Then, air in the purge tank re-enters the dryer and passes through the desiccant bed taking away moisture, and is expelled out the bottom of the air dryer.*

When the pressure drops to cut-in (typically 90-95 psi), the air in the UNL line evacuates out the exhaust port of the governor closing purge valve and once again flows from the compressor into the air dryer.

Charge cycle Purge cycle

36

Clean/dry air Atmospheric pressure Dirty/wet charged air Dirty/wet purged air

Note: Approx. 95PSI gov cut in, 120PSI gov cut out

*DLU compressors will continue to pump into air dryer and out exhaust port.

Trouble-shooting HD-2000

Review HD-2000 normal operation / cycles prior to trouble-shooting

Problem: air continually leaks from the exhaust port during compressor standby mode

Possible cause Remedy

Worn check valve

Worn purge valve seal

Clean cavity and replace check valve assembly #238

Clean cavities and replace purge valve assembly #235

Problem: system air pressure drops rapidly

Possible cause

Fittings are loose or damaged

Air reservoir, tubing, or hoses are damaged

Remedy

Tighten and/or replace as necessary

Repair or replace as necessary

Worn check valve




Problem: air leaks from the exhaust port during compressor charge mode


Worn purge valve

Dirt/foreign material is stuck in the purge valve

Clean cavities and replace the purge valve assembly #235


D2 governor malfunctioning

Heater assembly malfunctioning (>32 degrees)

Replace D2 governor

Replace heater assembly #246(12V), 247(24V),

248(12V), 249(24V), 619110(12V) or 619111(24V)

Problem: air compressor runs continuously (system pressure will not build)

Possible cause


Remedy

Tighten or replace loose or damaged fittings

Repair or replace damaged items Air reservoir, tubing, or hoses are damaged

Air compressor needs to be serviced or replaced

Worn purge valve

The air compressor capacity is too low for vehicle

Line between governor and air compressor is blocked

The safety valve is malfunctioning

Ice has formed in the purge valve


Rebuild or replace the air compressor


Install larger air compressor

Replace the line or remove the blockage

Replace the safety valve #610024

Replace heater assembly #246(12V), 247(24V), 248(12V), 249(24V),

619110(12V) or 619111(24V)

Replace D2 governor

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Problem: air dryer does not exhaust during compressor standby mode


Line between the air governor and the air dryer

Worn purge valve


Install or replace the air line, or control port is missing, leaking, or damaged.

Tighten the fittings.


Heater is malfunctioning

Purge valve sleeve is misaligned


619110(12V) or 619111(24V)

Replace heater assembly #246(12V), 247(24V), 248(12V),

249(24V), 619110(12V) or 619111(24V)

Align purge valve sleeve

Problem: safety valve opens

Possible cause

Air dryer check valve is blocked

Air brake system is blocked down stream from the air dryer

Air compressor governor is malfunctioning

Blocked desiccant cartridge


Remedy

Clean cavity and replace the check valve assembly #238

Remove blockage or replace the necessary components

Replace the compressor D2 governor

Replace cartridge #T224 and upgrade to filtration plus T224-P**


Problem: water accumulation in air system (tanks)


Desiccant is contaminated

Air compressor capacity is too low for vehicle

Malfunctioning regeneration valve

Replace desiccant cartridge #T224

Install larger air compressor and replace desiccant cartridge #T224

Clean cavity and replace regeneration valve assembly #223

Install or replace the air line, or tighten the fittings Line between the purge tank and the air dryer control port is missing, leaking, or damaged

Line between the compressor and air dryer too short line

Fit new line with a minimum length of 6 feet copper

(insufficient pre-cool) or 12 feet of steel braided Teflon

®

.*

Refer to vehicle manufacturer for specific test procedures for non-related air dryer components.

*Teflon® is a registered trademark of E.I. DUPONT

**Air compressor service may be required to address excessive oil blow-by

Service procedures HD-2000



Symptom

1. Dryer won’t exhaust.


a) Charge mode

b) Stand-by mode

3. Pressure slow or no build.

4. Compressor cycles rapidly.


Symptom #1:





Symptom #2A & #3:

Start engine and build air pressure. During the charge cycle, check for air leaking at exhaust port of dryer. If air is leaking from exhaust port, proceed as follows:

1. No air pressure should be present in line connecting

D2 governor and dryer purge valve during charge cycle.

If there is, service D2 governor.

2. If item 1 is OK, replace purge valve #235

Symptom #2B & #4:


Note: Air discharge could also be due to worn check valve.

Refer to page 42 for service procedure. On “Discharge

Line Unload” systems air will flow from exhaust port of dryer when engine is running and compressor is in

stand-by mode.

2

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40 con’t...



2. Remove the two fasteners that attach the purge valve retainer.

Remove the retainer.


3. Remove the purge valve assembly from cavity and discard.






Note: If air dryer is equipped with oil separator

DO NOT install filter screen.






13. Install two retainer bolts. Tighten to 10-15ft.lb.

Re-connect air line to control port.


Regeneration Valve Service

Kit #223


Symptom

1. Water in tanks.



Symptom #1 & #2:

Start engine and build to cut-out pressure. Stop engine. After initial exhaust, air should flow with decreasing intensity out the exhaust port for approximately 45 seconds. If air fails to flow, replace regeneration valve kit #223.

Regeneration valve replacement


2. Disconnect the air line at air dryer purge tank port.

3. Remove regeneration valve nut.

4. Remove and discard o-ring, spring and spindle.

5. Clean nut and cavity.

6. Position new spindle in the cavity with spring pocket side out. Install spring.

7. Using grease supplied, apply a light coating on o-ring. Install o-ring on nut.

8. Apply light coating of grease on nut threads.


9. Re-connect air line to air dryer purge tank port.

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41

42




Symptom





Symptom #1, #2, & #3:


Note: Air discharge could also be due to worn purge valve.

Check valve replacement











Reinstall nut and tighten to 60 ft. lb. Re-connect air line to air dryer outlet port.


Dessicant Cartridge

Service Kit #T224 & # T224-P


Symptom



Note: If there is excessive oil present,

compressor may require servicing

to T224-P upgrade.


Symptom #1 & #2

Desiccant cartridge requires regular servicing at intervals determined by compressor duty cycle or type of driving conditions. Typical service intervals are:

Line haul

Inner city

3 years

2 years

Refuse/transit 1 year

Off highway 1 year

Using T224-P with extra filtration will protect desiccant longer and lengthening service intervals. Add 1 year to above chart. The above is a guideline only. Drain tanks on regular basis. If moisture exists, replace cartridge.


* Steps required for service kit T224-P only.


2. * Disconnect heater lead wire from air dryer.

3. * Disconnect inlet and control lines from their respective ports.

4. Using a strap wrench, turn the desiccant cartridge counterclockwise and remove.

Discard.



5. Remove and discard o-ring from adapter plate stud and filter element (if present).

6. * Remove eight (8) 3/8" hex head bolts from bottom cap and set aside.

7. * Remove bottom cap assembly.

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8. * Remove filter plate (if present) and gasket(s) from bottom cap and discard.

9. * Clean bottom cap sump cavity, gasket surface and inside of adapter plate castings of oil and contaminants.

10. * Place new gasket on bottom cap bolt flange.

11. * Place new filter plate into bottom cavity. Position filter plate in cavity, as shown in Fig. 1, with arrow pointed toward inlet port of bottom cap.

12. * Re-install bottom cap assembly to adapter plate casting.

13. * Torque (8) bolts to 25-30 ft. lbs.


15. * Position a new filter element around cartridge stud and onto adapter plate.

16. Using grease supplied, apply a light coating of grease onto o-ring. Install o-ring onto threaded stud.

17. Important for easy removal: Apply a generous coat of grease on the new desiccant cartridge gasket surface.

18. Thread new cartridge onto stud turning clockwise. When gasket contacts adapter plate, tighten cartridge

1

/

2

turn. Do not overtighten.

19. * Re-connect airlines to air dryer inlet and control ports.

20. * Re-connect heater lead wire.




2

Heater Service Kits #248,

#249, #619110, #619111

Warning: Read and follow safety precautions found on page 17 before proceeding.

Symptom





Note: Thermostat must be cooled to at least 35 degrees F to check.


2. Open ohmmeter circuit indicated faulty heater assembly.









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46 con’t...

7.1 Early models (#248 or #249; orange and blue wires)

7..1.1 Install new set screw (if required) until snug (DO NOT OVER TIGHTEN)

Screw will protrude from bottom cap about 1/8”.



7..1.4 Place two (2) 6-32 x 1-1/8” screws in heater cover and attach the thermostat.

Note: If heater cover is not used,use short screws and wire clamps to secure thermostat and wires.


1/4”

hole with non-corrosive RTV.



7..1.8 Seal and route heater wires carefully.

7.2.11 Late Models (#619110 or #619111 plug style connection)



7.1.2.3. Ensure thermostat sits flat in cavity.


7.1.2.5. Secure heater assembly using the

(2) 8-32 x1/2” screws.

7.1.2.6. Reconnect Metri-Pak connector to male plug.

Note: If heater lead wire with male plug needs to be replaced or is not in vehicle wire harness, it is available in kit #619900

HD-2000 Notes:

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47

48

Dual Turbo-2000 dryer parts list

*H.C. Dual Turbo-2000 dryer parts list may be found on page 68.

A 619930

A 619922

B 619911

C 610077

D

E

610069

F 619928

G 238

H

H

I

T224-P

619932

619934

235

J

619110 12V 75W

619111 24V 75W

K 619935

L 619740

M 619938

N 619980

O 619140

Q 619920

R 619921

S 619910

S

T

T

619925

619912

619924


Manifold

Manifold w/valves & fitting for 2-line version


Body gasket

Seal retainer

Note: four retainers per dryer, two on either side/1 per box

Desiccant cartridge with filtration plus package

Check valve nut

Check valve kit

Valve housing, complete with valves

& 12V heater

Valve housing, complete with valves

& 24V heater

Purge valve kit note: two valves per dryer, one on either side/1 per box

12 Volt heater kit


Wire harness

Safety valve (200 psi)

Inlet check valve kit note: two valves per dryer, one on either side/1 per box.

Mounting bracket

Cartridge stud

Mid-section L.H.

Mid-section R.H.

Air control valve - 3 fitting design

Air control valve - 2 fitting design

MLT 12 Volt

MLT 24 Volt


620910 (620912*)

620920 (620924*)

620922

* Use 2 T224-P cartridges


12V w/cartridges (w/o cartridges*)

24V w/cartridges (w/o cartridges*)

24V w/12V MLT & Special Mounting Bracket

Dual Turbo-2000 service schematic

2

49

Normal Dual Turbo-2000 air dryer operation/cycle

1. The Micro Logic Timer (MLT) controls drying and regeneration cycles of the Dual Turbo-2000 air dryer by energizing and de-energizing the Air Control Valve of air dryer at 90-second intervals.

An indicator light on MLT will be “on” during energized cycle and “off” during the de-energized cycle. *

2. The air dryer’s Air Control Valve controls air flow direction through the dryer during the compressor’s charge mode (pumping). During this charge mode, one dryer cartridge is drying air and other cartridge is being regenerated.

3. During the compressor charge mode there will be a light flow of air from ONE exhaust port of air dryer. This is normal, regeneration air flow and should be present ONLY when the

compressor is in charge mode (pumping). The air flow will alternate (every 90-seconds) from one exhaust port to the other in conjunction with the MLT cycles. When the air dryer cycle alternates during the compressor charge mode (pumping), there will be a momentary burst of air from one of the air dryer exhaust ports. This is normal.

* MLT is polarity sensitive and will not operate if power (+) and ground (-) leads are switched

50

Side View

Bottom View

Clean/dry air

Atmospheric pressure

Dirty/wet charged air

Dirty/wet purged air

Trouble-shooting Dual Turbo-2000

See H.C. Dual Turbo-2000 trouble-shooting for H.C. Dual Turbo-2000 on page 71

Review Dual Turbo-2000 normal operation / cycles prior to trouble-shooting on page 50

Problem: air continually flows from the exhaust port during compressor standby mode


Worn check valve Clean cavity and replace check valve assembly #238

Problem: system/wet tank air pressure drops rapidly

Possible cause



Worn check valve


Remedy




Replace governor

Problem: air compressor moves into the standby mode but cycles rapidly






Worn check valve



Replace governor

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Problem: heavy air flow from one or both exhaust ports during compressor charge mode.

Note: alternating “light” air flow from exhaust ports during compressor charge mode is normal, regeneration air flow

Possible cause

Worn purge valve or dirt/foreign material is stuck in the purge valve

Worn inlet check valve

Ice has formed in purge and/or inlet check valves, heater assembly malfunctioning

Remedy


Clean cavity and replace valve assembly #619915

Replace heater assembly #619110(12V) or valves

619111(24V)






Repair or replace damaged items

The air compressor needs to be serviced or replaced Rebuild or replace the air compressor

Worn purge valve or dirt/foreign material is stuck in the purge valve


Clean cavity and replace the purge valve assembly #235

Install larger air compressor




Worn inlet check valve

Ice has formed in purge and/or inlet check valves, heater assembly malfunctioning


Air line (tubing) connecting dryer manifold and air control valve missing or damaged


Clean cavity and replace valve assembly #619915

Replace heater assembly #619110(12V) or 619111(24V)

Replace D2 governor

Repair/replace air line (tubing)

con’t...

Problem: air dryer does not exhaust during compressor charge mode


Micro Logic Timer (MLT) malfunctioning

Air control valve malfunction

Replace MLT #619912 (12V) or 619924 (24V)

Replace air control valve #619910 (3 fittings) or 619925

(2 fittings)


Align exhaust ports in purge valve and valve housing

Worn purge valve

Exhaust ports in purge valve and valve housing not aligned

Air line (tubing) connecting air control valve and valve housing and/or manifold damaged or missing



Repair/replace air line(s) (tubing)

Replace heater assembly #619110(12V) or 619111(24V)

Replace heater assembly #619110(12V) or

619111(24V)


Possible cause

Air dryer outlet check valve is blocked

Remedy

Clean cavity and replace the check valve assembly #238.

Air brake system is blocked down stream of air dryer

Air compressor governor malfunctioning


Replace compressor D2 governor

Air compressor unloader valve malfunctioning Replace compressor unloader valve

Blocked desiccant cartridge(s)


Air dryer inlet check valve(s) is blocked

Replace cartridge(s) #T224-P(s)


Clean cavity and replace the inlet check valve assembly #619915

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Possible cause


Micro Logic Timer (MLT)

Air control valve malfunction

Malfunctioning regeneration valve(s)

Air line (tubing) connecting air control valve and valve housing and/or manifold damaged or missing

Line between the compressor and air dryer too short

(insufficient pre-cool)

Remedy

Replace desiccant cartridge #T224-P

Replace both cartridge and filters

Replace MLT #619912 (12V) or #619924 (24V) malfunctioning

Replace air control valve #619910 (3 fittings) or

#619925 (2 fittings)

Clean cavity and replace regeneration valve(s) #619911

Repair/replace air line(s) (tubing) copper line or 12 feet of steel braided Teflon

®

Fit new line with a minimum length of 6 feet

Refer to vehicle manufacturer for specific test procedures for non related air dryer components.

*Teflon® is a registered trademark of E.I. DUPONT.

Service procedures Dual Turbo-2000

Purge Valve Service Kit #235,

Note: two (2) valves in dryer/1 per kit

Warning: Before proceeding read and follow safety precautions found on page 17. Review description of “Normal” Dual Turbo-2000 Air

Dryer operation/cycle on page 50.

Symptom

1. Dryer won’t exhaust during charge cycle.

2. Large air leak at exhaust port(s) during the charge mode.

Note: A light flow of air from one exhaust port during charge cycle is normal, regeneration air flow.



Symptom #1:

Start engine and build system pressure. If dryer does not exhaust, during the charge cycle, proceed as follows:

1. Check for blockage at exhaust port(s) of air dryer.

2. If item 1 OK, check and replace, if necessary, purge valve #235.

Note: Failure of dryer to exhaust could also be due to malfunctioning MLT Valve. Refer to page 64-66 for service procedure on this item.

55

2

56 con’t...

Symptom #2 & #3:

Start engine and build air pressure. During the charge cycle, check for large air leak at exhaust port(s) of dryer. If large amount of air is leaking from exhaust port proceed as follows:

1. Check and replace, if necessary, purge valve #235.

Note: Large air leak could also be due to worn inlet check valve. Refer to page 56 for service on this valve.

Purge valve replacement (Two places)


2. Remove the purge valve assembly and o-ring from the purge cavity and discard.





6. Install on the retainer the two (2) larger o-rings then install the third

(smaller) o-ring.

7. Apply a light coating of grease around the o-ring seat on valve assembly.

Install the thin o-ring on the purge valve seat.

8. Insert valve assembly into cavity. Insure that valve exhaust port is aligned with air dryer exhaust port. Use care not to dislodge the o-ring from its seat.







Warning: Before proceeding read and follow safety precautions found on page 17.

Review description of “Normal” Dual

Turbo-2000 Air Dryer operation/cycle on page 50.

Symptom


2. System/wet tank air pressure drops rapidly.

2


Symptom #1 & #2

Start engine and build system air pressure to cutout pressure then shut off engine. Allow at least 90 seconds for dryer to cycle through regeneration cycle. Check for air leak at exhaust ports with soap/water solution. If air leak is detected replace check valve #238.



2. Disconnect air line from dryer outlet port.



5. Clean nut and check valve cavity thoroughly.

Note: If there is excessive oil in the cavity the desiccant cartridges and filters require servicing.

6. Install new ball into cavity.

7. Install spindle, with spring pocket out, into cavity.

8. Place spring into spring pocket of spindle.

9. Apply a light coating of grease onto o-ring and place onto check valve nut.

10. Apply light coating of grease to nut threads. Install nut and tighten to 60 ft. lbs. torque.

11. Re-connect air line to outlet port.

57

58


Regeneration Valve Service Kit

#619911, Note: two (2) valves in dryer/1 per kit

Warning: Before proceeding read and follow safety precautions found on page 17. Review description of “Normal” Dual Turbo-2000

Air Dryer operation/cycle on page 50.

Symptom


Note: A light flow of air from exhaust port(s) during charge cycle is normal, regeneration air flow.

2. Water in air tanks.


Symptom #1 & #2:

Start engine and build air pressure. During the charge cycle

(compressor pumping), check for air flow at exhaust port(s) of dryer. If no air flow is present replace regeneration valves

#619911.

Regeneration valve replacement (two valves)

1. Disconnect air line from outlet port of air dryer.

2. Remove eight (8) socket head bolts fastening manifold to adaptor castings.

3. Remove manifold from adaptor castings.

4. Remove and discard o-rings, springs and regeneration valves.

5. Clean valve cavities in adaptor castings.

6. Position new valve spindles into cavities with spring pockets out.

7. Position springs into valves.

8. Lubricate new o-rings and install onto manifold bosses.

9. Position manifold onto adaptor castings ensuring o-rings are properly positioned in bores.

10. Install eight (8) socket head bolts and tighten to 50-60 in. lbs. Torque.

11. Reconnect air line to outlet port.


Inlet Check Valve Service Kit #619938,


Warning: Before proceeding read and follow safety precautions found on page 17. Review description of “Normal” Dual


Symptom

1. Large air leak at exhaust port(s) during the charge mode.

Note: A light flow of air from one exhaust port during charge cycle is normal, regeneration air flow.



Symptom #1 & #2:

Start engine and build air pressure. During the charge cycle, check for large air leak at exhaust port(s) of dryer. If large amount of air is leaking from exhaust port, proceed as follows:

1. Check and replace, if necessary, inlet check valve #619915

Note: Large air leak could also be due to worn #235

Purge Valve. Refer to page 55 for service on this valve.

59

2

60 con’t...

Inlet Check valve replacement (Two places)

1. Remove two

1

/

4

" bolts that fasten the inlet check valve retainer to valve hsg. and removed retainer.

2. Remove the inlet check valve spindle from the inlet cavity and discard.

Note: If there is excessive oil in cavity, compressor may require servicing.


4. Remove two (2) or one (1) o-ring(s) from seal retainer.

5. Install new o-ring on seal retainer.

Note: Only one (1) o-ring is required for proper function. The one (1) o-ring

must be in groove located closest to retainer flange.

6. Lubricate all o-rings on new valve spindle and seal retainer before installing in housing.

7. Lubricate bores in valve housing.

8. Install valve spindle assembly into housing bore small end first and spring to outside as shown in drawing.

9. Make sure spindle is completely engaged in cavity and moves freely.


11. Apply grease to threads of retainer bolts.

12. Install retainer bolts and tighten to 10-15 ft. lbs.


Desiccant Cartridge Service

Kit #T224-P, Note: two (2) cartridges on dryer/1 per kit

Warning: Before proceeding read and follow safety precautions found on page 17

2


Symptom



Symptom #1 & #2

Dessicant cartridge requires regular servicing at intervals determined by compressor duty cycle or type of operating conditions. Typical service intervals are:

Inner City Transit 2 years

Inner City Refuse 2 years

Off Highway 2 years

Desiccant Cartridge, Filter Element and Internal Filter Plate Replacement


2. Disconnect heater lead wire from air dryer.

3. Disconnect air line from dryer inlet port.

4. Using a strap wrench, turn the desiccant cartridge counterclockwise and remove.

Discard.



5. Remove and discard o-ring from adapter plate studs and filter elements (if present).

6. Remove four (4) 3/8" allen head bolts located at top of adapter plate castings.

7. Remove twelve (12) 3/8" hex head bolts attaching bottom valve housing to adapter plate castings.

8. Remove bottom valve housing assembly.

61

62 con’t...

9. Remove two filter plates, gaskets and o-rings

(late model version only) and discard.

10. Clean valve housing sump, gasket surface and inside of two (2) adapter plate castings of oil and contaminates.

11. Place new gasket or o-ring at each valve housing bolt flange.

12. Place new filter plate into each valve housing cavity. Position filter plates in cavities, as shown in Fig. 1, with arrows pointed toward front of valve housing.

13. Re-install valve housing assembly to adapter plate castings.

14. Torque (16) bolts to 25-30 ft. lbs.

15. Clean top surface of adapter plates and threaded studs.

16. Position new filter element around each stud and onto adapter plate.

17. Using grease supplied, apply a light coating of grease onto o-ring. Install o-ring onto threaded studs.


19. Thread new cartridge onto studs turning clockwise. When gasket contacts adapter plate, tighten cartridge

1

/

2

turn. Do not overtighten!

20. Re-connect air line top air dryer inlet port.

21. Re-connect heater lead wire.


Heater Service Kit

#619110 (12V) & #619111 (24V)


Symptom






35 degrees F to perform test.

Conduct continuity test by using an Ohmmeter or Test Light. Attach one lead of test device to one terminal of heater connector and other lead of test device to other terminal of heater connector. The test light should light or Ohmmeter indicates continuity. If there is NO continuity, replace heater/thermostat assembly.


1. Disconnect heater lead wire.

2. Remove two screws attaching heater connector to casting.



5. Slide o-ring over heater and thermostat into position around connector flange.



8. Place thermostat into position in cavity and ensure thermostat sits flat in cavity.

9. Place foam cube on top of thermostat and bring heater connector into position over cavity.

10. Secure heater connector using the (2) 8-32 x 1/2" screws.

11. Reconnect Metri-Pak connector to male plug.

Note: If heater lead wire with male plug needs to be replaced or is not in vehicle wire harness, it is available in Kit #619935.

63

2


64

Air Control Valve

Service Kit #619910 & #619925

Warning: Before proceeding read and follow safety precautions found on page 17. Review description of “normal” Dual


Symptom

1. Dryer won’t exhaust during charge cycle to allow regeneration air flow at 90 second intervals.

Note: A light flow of air from ONE exhaust port during charge cycle is normal regeneration air flow.


Operational check:

Drain tanks, check for excessive oil and water

con’t...

Symptom #1 & #2

Start engine and begin building system air pressure. After approximately 90 seconds into charge cycle, an exhaust burst should occur from one exhaust port. If exhaust does not occur proceed as follows:

1. During the charge cycle, turn the brass screw located on air valve (see Fig. 1 on page

64), to the right (screw slot will be in horizontal position). If exhaust air burst does not occur, replace valve. If exhaust does occur, turn screw back to original position

(screw slot must be in vertical position for normal operation) and proceed to step 2.

2. Failure of dryer to exhaust could also be due to malfunctioning purge valve or MLT.

Refer to pages 50 & 55 respectively for service of these items.

Air control valve replacement

1. Un-plug electrical connector from MLT/Valve.

2. Remove three (3) air lines (Kit #619910) or two (2) air lines

(Kit #619925) connected to fittings in air valve (Ref. Fig 1 on page 64).

3. Remove retaining nut holding MLT assembly to valve stem and remove MLT assembly from valve. Set aside nut and MLT for later re-assembly.

4. Remove three (3) screws holding valve to manifold. Remove valve and discard.

5. Install air valve #619910 (three fittings) as follows:

a. Install three (3) push connect fittings to open ports of new air valve.

b. Secure air valve to manifold with three (3) screws.

Torque screws to 15-20 in. lbs.

c. Re-connect air line from manifold to front port of air valve.

d. Re-connect two remaining air lines to back ports of valve.

OR

5. Install air valve #619925 (two fittings) as follows:

a. Install two (2) push connect fittings to open ports of new air valve.

b. Place small o-ring at small hole on top of valve body.

c. Position air valve against bottom of manifold, insuring the small o-ring fits into counter bore located on bottom of manifold.

d. Secure air valve to manifold with three (3) screws. Torque screws to 15-20 in. lbs.

e. Re-connect two air lines to back ports of valve.

6. Re-assemble MLT assembly to valve stem and secure with retaining nut.

7. Re-connect electrical plug to MLT.

2

65

66


Micro Logic Timer (MLT)

Service Kit: #619912 (12V), #619924 (24V)


Review description of “normal” Dual Turbo-2000

Air Dryer operation/cycle on page 50.

Symptom

1. Dryer won’t exhaust during charge cycle to allow regeneration air flow at 90 second intervals.

Note: A light flow of air from ONE exhaust port during charge cycle is normal regeneration air flow.



Symptom #1 & #2

Start engine and begin building system air pressure. After approximately 90 seconds into charge cycle, an exhaust air burst should occur from one exhaust port.

Note: No exhaust air burst will occur during compressor stand-by or non charge cycle. If exhaust air burst does not occur during charge cycle, proceed as follows:

1. Insure that power is present at MLT connector and that all electrical connections are properly connected.

Note: MLT is polarity sensitive and will not operate if power (+) and ground

(-) leads are switched. The MLT energizes and de-energizes air valve at 90 second intervals. An indicator light on MLT will be on during energize cycle and off during de-energized cycle. If all electrical connections are good replace MLT.

2. Failure of dryer to exhaust could also be due to malfunctioning purge valve and Air Control Valve. Refer to pages 55 and 64 respectively for service of these items.

MLT Replacement

1. Un-plug electrical lead wire from MLT connector.

2. Remove retaining nut holding MLT to valve stem and remove MLT from valve. Set aside nut for later re-assembly.

3. Re-assemble new MLT to valve stem and secure with retaining nut.

4. Re-connect electrical plug to MLT.

Dual Turbo-2000 Notes:

2

67

68

H.C. Dual Turbo-2000 parts list

A 619933

B 619913

C 610077

D 610069

E T224-P

F 619928

G 238

H

619972

619974

I 235

J 619110

619111

K 619900

L 619740

M 619938

N 619980

O 619140

619973

619979


Manifold/mid-section assembly (with valves)


Note: Two valves per dryer, one on either side

Body gasket

Seal retainer

Note: Four retainers per dryer, two on either side

Desiccant cartridge with Filtration Plus

Check valve nut

Check valve kit

Valve housing, complete w/valves, 12V heater & housing bolts

Valve housing, complete w/valves, 24V heater & housing bolts

Purge valve kit

Note: Two valves per dryer, one on either side



Wire harness


Inlet check valve kit

Note: Two valves per dryer, one on either side

Mounting bracket

Cartridge stud

Control line service kit (not shown)

Service kit contains (2) T224-P, (2) 235, (2) 619938, (1) 238, (1) 619111,

(1) 619740 & (12) housing bolts


620930

620980

620982

620984

620986

619228


24 V DLU application w/o purge tanks; min 600 cu.in. purge volume required

12 V with 2 #221 purge tanks

12 V without purge tanks; min 600 cu.in. purge volume required

24 V without purge tanks; min 600 cu.in. purge volume required

24 V with 2 #221 purge tanks

Purge tank kit w/690 cu.in. purge volume

H.C. Dual Turbo-2000 service schematic

2

69

70

H.C. Dual Turbo-2000 normal operation / cycles – use with high output compressors

Air flows from the compressor into the air dryer. Air flows past filters and both desiccant beds stripping moisture and contaminants from air and exits dryer to the purge tank(s) and to the wet tank.

If two purge tanks are used, T air lines to allow air to flow to both tanks simultaneously. The reservoir line from the wet tank to the governor is always pressurized.

When pressure reaches cut-out (typically 120-125 psi), the governor sends air signal through the governor line to the air dryer opening both purge valves and closing both inlet check valves. The check valve is closed via back pressure from wet tank. Then, air in the purge tank(s) re-enters the dryer and passes through both desiccant beds taking away moisture and is expelled out bottom exhaust ports of air dryer. Turbo boost from the compressor is checked at inlet check valve of dryer.

When the pressure drops to cut-in (typically 90-95 psi), the air in the UNL line evacuates out the exhaust port of the governor closing purge valves and opening inlet check valves and once again air flows from the compressor into the air dryer.

SKF Brakemaster

®

H.C. Dual Turbo-2000 air dryer service schematic

Trouble-shooting H.C. Dual Turbo-2000

See Dual Turbo-2000 trouble-shooting for Dual Turbo-2000 on page 51

Review H.C. Dual Turbo-2000 normal operation / cycles prior to trouble-shooting on page 70

Problem: air continually leaks from the exhaust port during compressor standby mode


Worn check valve

Worn inlet check valves

Worn purge valve seals


Clean cavity and replace inlet check valve assemblies #619938

Clean cavity and replace purge valve assemblies #235





Worn check valve






Clean cavity and replace inlet check valve assembly #619938








Worn check valve



Clean cavity and replace inlet check valve assemblies #619938



Replace governor




Worn purge valves

Dirt/foreign material is stuck in the purge valves


Heater assembly malfunctioning (>32 degrees)

Clean cavities and replace purge valve assemblies #235

Clean cavity and replace valve assemblies #235

Replace D2 governor

Replace heater assembly #619110(12V) or #619111(24V)

2

71

72 con’t...


Possible cause



The air compressor needs to be serviced or replaced

Remedy




Worn purge valves Clean cavity and replace the purge valve assemblies #235

The air compressor capacity is too low for vehicle Install larger air compressor








Replace D2 governor



The line between the air governor and the air dryer control port is missing, leaking, or damaged

Install or replace the air line, or tighten the fittings

Worn purge valves



Purge valve sleeves are misaligned




Align purge valve sleeves


Possible cause

Air dryer check valve is blocked

Air brake system is blocked down stream of air dryer

Air compressor governor malfunctioning



Remedy



Replace compressor D2 governor

Replace cartridge #T224-P*


*Air compressor service may be required to address excessive oil blow-by.

con’t...





Malfunctioning regeneration valves

Replace both desiccant cartridges #T224-P

Install larger air compressor and replace desiccant cartridges #T224-P

Clean cavity and replace regeneration valve assemblies #619913

Install or replace the air line, or tighten the fittings The line between the purge tank and the air dryer control port is missing, leaking, or damaged

Line between the compressor and air dryer too short

Fit new line with a minimum length of 6 feet copper line or (insufficient pre-cool) 12 feet of steel braided Teflon ® *


* Teflon® is a registered trademark of E.I. DuPont.

2

73

74

Service procedures H.C. Dual Turbo-2000



Symptom

1. Dryer won’t exhaust

2. Air leak at exhaust ports during the:

a) Charge mode

b) Stand-by mode

3. Slow or no pressure build

4. Compressor cycles rapidly


Symptom #1:


1. Check for air pressure in line connecting D2 governor to T-fitting on air dryer. If no pressure is present in line, service D2 governor.

2. Check for blockage at exhaust ports of air dryer.

3. If items 1 and 2 are OK, replace both purge valves #235.

Note: No exhaust could also be an obstructed regeneration valve #619913.

Symptom #2A & #3:

Start engine and build air pressure. During the charge cycle, check for air leaking at exhaust ports of dryer. If air is leaking from one or both exhaust ports proceed as follows:

1. No air pressure should be present in line connecting D2 governor and dryer purge valve during charge cycle. If there is, service D2 governor.

2. If item 1 is OK, replace one or both purge valves #235

Symptom #2B & #4:

Start engine and build to cut out pressure. Stop engine. Allow one minute for purge air to discharge dryer. If air continues to discharge from exhaust port of dryer, replace one or both purge valves #235.

Note: Air discharge could also be due to worn check valve or inlet check valve. There are two inlet check valves.

con’t...


1. Disconnect air line at each control port.















14. Reconnect the control line to air dryer control port.

2

75

76


Regeneration Valve Service Kit #619913


Symptom

1. Water in tanks.



Symptom #1 & #2:

Start engine and build to cut-out pressure. Stop engine. After initial exhaust, air should flow with decreasing intensity out both exhaust ports for approximately 45 seconds. If air fails to flow, replace the affected regeneration valve kit #619913.

Note: Water in tanks could also be due to worn purge valve, or

T-224-P dessicant cartridges are ready for service. No purge air could be attributed to governor or purge valve.

Regeneration valve replacement (two valves)

1. Disconnect air line from outlet port of air dryer.

2. Remove eight (8) socket head bolts fastening manifold to adaptor castings.

3. Remove manifold from adaptor castings.

4. Remove and discard o-rings, springs and regeneration valves.

5. Clean valve cavities in adaptor castings.

6. Position new valve spindles into cavities with spring pockets out.

7. Position springs into valves.

8. Lubricate new o-rings and install onto manifold bosses.

9. Position manifold onto adaptor castings ensuring o-rings are properly positioned in bores.

10. Install eight (8) socket head bolts and tighten to 50-60 in. lbs. Torque.

11. Reconnect air line to outlet port.




Symptom




2


Symptom #1, #2, & #3:


Note: Air discharge could also be due to worn purge valve or inlet check valve. The affected inlet check valve would be located on side of air dryer.














77


78

Inlet Check Valve Service Kit #619938,



Symptom

1. Air leak at exhaust port(s) during the charge mode.



Symptom #1 & #2:

Start engine and build air pressure. During the charge cycle, check for air leak at exhaust port(s) of dryer. If air is leaking from exhaust port, proceed as follows:

1. Check and replace, if necessary, inlet check valve #619938

Note: Air leak could also be due to worn #235

Purge Valve. Refer to page 74 for service on this valve.

con’t...

Inlet Check valve replacement (Two places)

1. Remove two

1

/

4

" bolts that fasten the inlet check valve retainer to valve hsg. and removed retainer.

2. Remove the inlet check valve spindle from the inlet cavity and discard.

Note: If there is excessive oil in cavity, compressor may require servicing.


4. Remove two (2) or one (1) o-ring(s) from seal retainer.

5. Install new o-rings on seal retainer. Three (3) o-rings are required.

6. Lubricate all o-rings on new valve spindle and seal retainer before installing in housing.

7. Lubricate bores in valve housing.

8. Install valve spindle assembly into housing bore small end first and spring to outside as shown in drawing.

9. Make sure spindle is completely engaged in cavity and moves freely.


11. Apply grease to threads of retainer bolts.

12. Install retainer bolts and tighten to 10-15 ft. lbs.

2

79

80


Desiccant Cartridge Service

Kit #T224-P, Note: two (2) cartridges on dryer/1 per kit

Warning: Before proceeding read and follow safety precautions found on page 17


Symptom



Symptom #1 & #2

Dessicant cartridge requires regular servicing at intervals determined by compressor duty cycle or type of operating conditions. Typical service intervals are:

Inner City Transit 2 years

Inner City Refuse 2 years

Off Highway 2 years

Desiccant Cartridge, Filter Element and Internal Filter Plate

Replacement


2. Disconnect heater lead wire from air dryer.

3. Disconnect air line from dryer inlet port.

4. Using a strap wrench, turn the desiccant cartridge counterclockwise and remove. Discard.



5. Remove and discard o-ring from adapter plate studs and filter elements (if present).

con’t...

6. Remove four (4) 3/8" allen head bolts located at top of adapter plate castings.

7. Remove twelve (12) 3/8" hex head bolts attaching bottom valve housing to adapter plate castings.

8. Remove bottom valve housing assembly.

9. Remove two filter plates, gaskets and o-rings

(late model version only) and discard.

10. Clean valve housing sump, gasket surface and inside of two (2) adapter plate castings of oil and contaminates.

11. Place new gasket or o-ring at each valve housing bolt flange.

12. Place new filter plate into each valve housing cavity. Position filter plates in cavities, as shown in Fig. 1, with arrows pointed toward front of valve housing.

13. Re-install valve housing assembly to adapter plate castings.

14. Torque (16) bolts to 25-30 ft. lbs.

15. Clean top surface of adapter plates and threaded studs.

16. Position new filter element around each stud and onto adapter plate.

17. Using grease supplied, apply a light coating of grease onto o-ring.

Install o-ring onto threaded studs.


19. Thread new cartridge onto studs turning clockwise. When gasket contacts adapter plate, tighten cartridge

1

/

2

turn. Do not

overtighten!

20. Re-connect air line top air dryer inlet port.

21. Re-connect heater lead wire.

2

81

82


Heater Service Kit

#619110 (12V) & #619111 (24V)


Symptom






35 degrees F to perform test.

Conduct continuity test by using an Ohmmeter or Test Light. Attach one lead of test device to one terminal of heater connector and other lead of test device to other terminal of heater connector. The test light should light or Ohmmeter indicates continuity. If there is NO continuity, replace heater/ thermostat assembly.


1. Disconnect heater lead wire.

2. Remove two screws attaching heater connector to casting.



5. Slide o-ring over heater and thermostat into position around connector flange.



8. Place thermostat into position in cavity and ensure thermostat sits flat in cavity.

9. Place foam cube on top of thermostat and bring heater connector into position over cavity.

10. Secure heater connector using the (2) 8-32 x1/2" screws.

11. Reconnect Metri-Pak connector to male plug.

Note: If heater lead wire with male plug needs to be replaced or is not in vehicle wire harness, it is available in Kit #619935.

H.C. Dual Turbo-2000 Notes:

2

83

Turbo-3000 parts list

A 238

B 610236

C 610077

D 619086

619112

619087

619113

E 228

F 610069

G 235

H T334

I 610024

J

248 12V 75W

249 24V 75W

J

619110 12V 75W

619111 24V 75W

K 619900

L 619115

M 619140

N 619091

619093


Check valve kit

Check valve nut

Body gaskets

Bottom cap assembly 12V STD

Bottom cap assembly 12V E-Type

Bottom cap assembly 24 STD

Bottom cap assembly 24 E-Type

Turbo valve kit

Seal retainer

Purge valve kit

Desiccant cartridge kit


Heater kit early models

(Orange and blue wires)

Heater kit late models


Wire harness

Mounting bracket

Cartridge stud kit

Mid-section with valves STD

Mid-section with valves E-Type


STD

620640

620642

E Type*

Dryer part number description

Description

620540

620542

Dryer 12V

Dryer 24V

*Holset SS E-Type and QE compressor

84

For right-hand models see parts list on pages 139 & 140.

Turbo-3000 service schematic

2

85

Turbo-3000 normal operation/cycles – light duty applications only

Air flows from the compressor into the air dryer. Air flows past filters and desiccant bed stripping moisture and contaminants from air and exits dryer to the wet tank. The reservoir line from the wet tank to governor is always pressurized.

When pressure reaches cut-out (typically 120-125 psi), the governor sends an air signal through the governor line to the air dryer opening the purge valve and closing the turbo valve. The check valve is closed via back pressure from the wet tank. Then, regeneration air contained in cartridge passes through the desiccant bed taking away moisture and is expelled out bottom of air dryer. Turbo boost from the compressor is checked at inlet of dryer with closed turbo valve. E-Type dryers provide back pressure to the compressor during stand-by. This feature is not intended for use for any compressor other than Holset E-Type compressors.

When the pressure drops to cut-in (typically 90-95 psi), the air in the UNL line evacuates out the exhaust port of the governor closing purge valve and opening turbo valve and once again flows from the compressor into the air dryer.


86

Clean/dry air Atmospheric pressure Dirty/wet charged air Dirty/wet purged air


Trouble-shooting Turbo-3000 dryer

Review Turbo-3000 normal operation / cycles prior to trouble-shooting on page 86

Problem: air continually leaks from the exhaust port in compressor standby mode


Worn check valve

Worn turbo valve


Clean cavities and replace check valve assembly #238

Clean cavities and replace turbo valve assembly #228



Possible cause



Worn check valve

Worn turbo valve


Remedy




Clean cavity and replace turbo valve assembly #228

Clean cavity and replace purge valve assembly #235

Problem: air compressor goes into the standby mode but cycles rapidly




Worn check valve

Worn turbo valve




Clean cavities and replace turbo valve assembly #228



Replace D2 governor




Worn purge valve

Dirt/foreign material is stuck in purge valve


Heater assembly malfunctioning (>32˚ F)



Replace D2 governor


249(24V), 619110(12V) or 619111(24V)

2

87

88 con’t...







Rebuild or replace the air compressor Air compressor needs to be serviced or replaced

Worn purge valve


Air line between governor and air compressor is blocked


Install larger air compressor and upgrade to Turbo-2000






Replace D2 governor


249(24V), 619110(12V) or 619111(24V)



Install or replace the air line or tighten the fittings Line between the air governor and the dryer control port is missing, leaking or damaged

Worn purge valve



Replace heater assembly #246(12V), 247(24V), 248(12V) 249(24V),

619110(12V) or 619111(24V)


Purge valve sleeve is misaligned


619110(12V) or 619111(24V)

Align purge valve sleeve

Problem: the safety valve opens

Possible cause

The air dryer check valve is blocked

The air system is blocked down stream from the air dryer

Malfunctioning D2 governor



Remedy

Clean cavity and replace the check valve assembly #238

Remove blockage or replace necessary components

Replace the D2 governor

Replace cartridge #T334


con’t...


Possible cause


Remedy

Replace desiccant cartridge #T334 or upgrade to

Turbo-2000


Line length between the compressor and air dryer

(insufficient pre-cool)

Air dryer capacity is too low for compressor

Install larger air compressor and upgrade to

Turbo-2000

Fit new line with a minimum length of 6 feet copper or 12 feet of steel braided Teflon

Upgrade to Turbo-2000

Note: Turbo-3000 is rated up to 15 cfm


®

2

89

90




Symptom



a) Charge mode

b) Stand-by mode




Symptom #1:


1. Check for air pressure in line connecting D2 governor to control port of air dryer. If no pressure is present in line, service

D2 governor.



Symptom #2A & #3:

Start engine and build air pressure. During the charge cycle check for air leaking at exhaust port of dryer. If air is leaking from exhaust port, proceed as follows:

1. No air pressure should be present in line connecting D2 governor and control port during charge cycle. If there is, service D2 governor.

2. If item 1 is OK, replace purge valve #235.

Symptom #2B & #4:


Note: Air discharge could also be due to worn check valve or turbo valve. Refer to pages 92 and 93 for service procedures on these valves.

con’t...





Note: If there is excessive oil in the cavity, compressor may require servicing and/or upgrade to Turbo-2000.




7. Install on the retainer the two (2) thickest o-rings then install the third (thinner) o-ring.








14. Reconnect air line to control port.

2

91

92




Symptom




Note: The above symptoms could also lead to turbo valve replacement. A malfunctioning turbo valve will tend to allow pressure to drop to cut-in pressure within seconds on E-Type style air dryers.


Symptoms #1, #2, #3


Note: Air discharge could also be due to worn purge valve or turbo valve.











8. Apply a light coating of grease to threads of nut. Install nut and tighten to 60 ft. lb.





Symptom




Note: The above symptoms could also lead to Check valve replacement.


Symptom #1, #2 & #3

Start engine and build to cut out pressure. Stop engine. Allow one minute for purge air to discharge dryer. If air continues to discharge from exhaust port of dryer, replace turbo valve #228.

Note: Air discharge could also be due to worn purge valve or check valve.





4. Remove 8 bolts from bottom cap and set aside.

Discard gasket.



7. Lightly coat the 2 (small) o-ring surfaces and install on piston. Carefully install valve in cavity with tapered side up.





11. Place gasket on bottom cap aligning all holes.

Locate bottom cap so that inlet port is directly below outlet port. Install (8) bolts. Tighten bolts to 20-25 ft. lb. or 25-30 ft. lb. if equipped with oil separator.

12. Re-connect inlet and control lines to air dryer.


93

2

94


Dessicant Cartridge

Service Kit #T334


Symptom


2. Water in tanks.


Symptom #1 & #2

Desiccant cartridge requires regular servicing at intervals determined by compressor duty cycle or type of driving conditions.

Check air reservoirs on regular basis opening drain valves.

If moisture exists, replace cartridge #T334.



2. Using a strap wrench, turn the desiccant cartridge counterclockwise and remove it. Discard.

3. Remove and discard o-ring from adapter plate stud.

Note: If there is excessive oil present, compressor may require servicing and/or an oil separator, kit #619650 may be required. Upgrade to Turbo-2000 may also be needed.



Install o-ring on stud.

6. Apply a generous coat of grease on the new desiccant cartridge gasket surface.

7. Thread new cartridge onto stud turning clockwise.

When gasket contacts adapter plate, tighten cartridge 1/2 turn.

DO NOT OVER-TIGHTEN.




2

Heater Service Kits #248,

#249, #619110, #619111


Symptom





Note: thermostat must be cooled to at least 35 degrees F to check.


2. Open ohmmeter circuit indicates faulty heater assembly.









95

96 con’t...

7.1 Early Models (#248 or #249; orange and blue wires)

7..1.1 Install new set screw (if required) until snug (Do not overtighten!) Screw will protrude from bottom cap about 1/8".



7..1.4 Place two (2) 6-32 x 1-1/8" screws in heater cover and attach the thermostat.



1/4

" hole with non-corrosive RTV.



7..1.8 Seal and route heater wires carefully

7.2.11 Late Models (#619110 or #619111 plug style connection)




7.1.2.3. Ensure thermostat sits flat in cavity


7.1.2.5. Secure heater assembly using the (2) 8-32 x 1/2" screws.

7.1.2.6. Reconnect Metri-Pak connector to male plug

Note: If heater lead wire with male plug needs replaced or is not in vehicle wire harness, it is available in Kit #619900.

Turbo-3000 Notes:

2

97

98

Turbo-AC parts list

A 610077

B 610271

C 610705

D 610069

E 610029

F 238

G 610229

H 240

I 239

J 610076

K 261

L

619086 12V

619087 24V

M 610024

N 235

P

Q 610851

Q 619115

R

S

619900

230

228


Body gaskets

Large spring

Die cast body

Seal retainer

Top cap nut

Check valve kit

Top cap

Filter replacement

Filter service kit

Packing ring gasket

Deflector kit

Bottom cap assembly


Purge valve kit

Heater kit, short elem.

Vertical installation

Heater kit, long elem.

Horizontal Installation

Heater kit (shown)


Wire harness

Bracket assembly (old style, not shown)

Mounting bracket (late model shown)

Feed-back line, Holset E & QE type compressor

Turbo valve kit


Dryer part number description

620570

Turbo-AC, 12V, STD

620572

Turbo-AC, 24V, STD

620580 Turbo-AC, 12V Holset compatible

620578 Turbo-AC, 24V Holset compatible

For right-hand models see parts list on page 140.

Turbo-AC service schematic

2

99

Turbo AC normal operation/cycles

Air flows from the compressor into the air dryer. Air flows up through the body and is cooled by fins.

Cooled air releases moisture that accumulates at bottom sump of air dryer. Clean, dry air then exits dryer to the wet tank. The reservoir line from the wet tank to the governor is always pressurized.

When pressure reaches cut-out (typically 120-125 psi), the governor sends air signal through the governor line to the air dryer opening purge valve and closing turbo valve, expelling accumulated moisture and contaminates. The check valve is closed via back pressure from the wet tank. E-Type dryers provide back pressure to the compressor during stand-by. This feature is not intended for use for any compressor other than Holset E-Type compressors.

When the pressure drops to cut-in (typically 90-95 psi), the air in the UNL line evacuates out the exhaust port of the governor closing purge valve and opening turbo valve, and once again flows from the compressor into the air dryer.


100

Clean/dry air

Atmospheric pressure

Dirty/wet charged air Dirty/wet purged air


Trouble-shooting Turbo-AC dryer

Review the Turbo-AC normal operation / cycles prior to trouble-shooting on page 100



Worn purge valve Clean cavity and replace the purge valve assembly #235

Dirt/foreign material is stuck in purge valve Clean cavity and replace the purge valve assembly #235


Ice has formed in purge valve

Replace D2 governor


619110(12V) or 619111(24V)







Air compressor needs to be serviced or replaced

Worn purge valve





Install larger air compressor and upgrade to Turbo-2000


619110(12V) or 619111(24V)

Replace the line or remove the blockage Line between governor and air compressor is blocked




Replace D2 governor valve

Problem: air continually leaks from the exhaust port in compressor standby mode


Worn check valve

Worn turbo valve











Worn check valve

Worn turbo valve





2

101

102 con’t...


Possible cause


Remedy



Worn check valve

Worn turbo valve






Replace D2 governor




Worn purge valve

Dirt/foreign material is stuck in purge valve




Heater assembly malfunctioning

(>32 degrees)

Replace D2 governor


249(24V), 619110(12V)

Service procedures Turbo-AC



Symptom


2. Air leak at exhaust port during

a) Charge mode

b) Stand-by mode




Symptom #1

Start engine and build to cutout pressure. If dryer does not exhaust, proceed as follows:




Symptom #2A & #3:

Start engine and build air pressure. During the charge cycle check for air leaking at exhaust port of dryer. If air is leaking from exhaust port, proceed as follows:

1. No air pressure should be present in line connecting D2 governor and control port during charge cycle. If there is service D2 governor.

2. If item 1 is OK, replace purge valve #235.

Symptom #2B & #4:


Note: Air discharge could also be due to worn check valve or turbo valve.

Refer to pages 105 and 106 for service procedures on these valves.



2. Remove the two fasteners that attach the purge valve retainer.

Remove the retainer.


2

103

104 con’t...





7. Install on the retainer the two (2) thickest o-rings then install the third (thinner) o-ring.




Warning: If the air dryer purge valve port does not align with air dryer exhaust port, air dryer will not exhaust.




14. Reconnect air line to control port.




Symptom




Note: The above symptoms could also lead to turbo valve replacement. A malfunctioning turbo valve will tend to allow pressure to drop to cut-in pressure within seconds on E-Type style air dryers.


Symptom #1, #2, & #3:

Disconnect line at control port and plug. Start engine and build to cut-out pressure. Stop engine. Apply soapy solution around exhaust port. If soap bubbles exist, replace check valve #238.








6. Install new ball in cavity.

7. Next, position spindle with spring pocket facing out. Install spring.



9. Apply a light coating of grease to threads of nut. Install nut and tighten to 60 ft. lbs.


2

105

106




Symptom




Note: The above symptoms could also lead to check valve replacement.


Symptom #1, #2, & #3:

Disconnect line at control port and plug. Start engine and build to cut-out pressure. Stop engine. Apply soapy solution around exhaust port. If soap bubbles exist, replace turbo valve #228.





4. If air dryer is equipped with external feed-back line, disconnect this line at inlet port of dryer.

5. Remove (8) bolts from bottom cap and set aside.

Discard gasket.



8. Lightly coat the (2) (small) o-ring surfaces and install on piston.

Carefully install valve in cavity with tapered side up.





12. Place gasket on bottom cap aligning all holes.

Locate bottom cap so that inlet port is directly below outlet port. Install the 8 bolts. Tighten bolts to 20-25 ft. lb. or

25-30 ft. lb. if equipped with oil separator.

13. Re-connect inlet and control lines to respective ports.

14. Re-connect external feed-back line if air dryer is so equipped.



Early model - Vertical Early model - Horizontal

2

Heater Service Kits #246, #247,

#248, #249, #619110, #619111


Symptom





Note: Thermostat must be cooled to at least 35 degrees F to check.

1. Closed ohmmeter circuit indicates heater is functioning

2. Open ohmmeter circuit indicated faulty heater assembly.

107

108 con’t...

Late model









7.1 Early models (orange & blue lead wires, Kit #246 or #247 vertical mount, Kit #248 or #249 horizontal mount).

7..2.1. Install new set screw until snug

(Do not overtighten!) Screw will protrude from bottom cap about 1/8".

7..2.2. Coil wires around heater cover posts allowing wires to protrude through slots.

7..2.3. Place two (2) 6-32 x 1-1/8" screws in heater cover and attach the thermostat.


7..2.4. Fill heater cover, through 1/4" hole, with non-corrosive RTV.

7..2.5. Connect blue heater wire to a good chassis ground.

7..2.6. Connect orange wire to ignition switch.

7..2.7. Seal and route heater wires carefully.

7.2.1. Late Models (#619110 or #619111; plug style connection)

7..2.1. Slide o-ring over heater and thermostat into position around connector flange.

7..2.2. Slide heater and thermostat into position in cavity.

7..2.3. Ensure thermostat sits flat in cavity.

7..2.4. Place foam cube on top of thermostat and bring heater connector into position over heater.

7..2.5. Secure heater assembly using the (2) 8-32 x 1/2" screws.

7..2.6. Reconnect Metri-Pak connector to male plug.

Note: If heater lead wire with male plug needs to be replaced or is not in vehicle wire harness, it is available in

Kit #619900.

Turbo-AC Notes:

2

109

Brakemaster® air dryers

Service procedures Turbo-2000

Purge Valve Service Kit #235

Symptom

Operational check

Symptom #1:

Symptom #2A & #3:

Symptom #2B & #4:

Purge valve replacement

Service procedures Turbo-2000

Regeneration Valve Service Kit #223

Symptom

Operational check

Symptom #1 & #2:

Regeneration valve replacement

Service procedures Turbo-2000

Check Valve Service Kit #238

Symptom

Operational check

Symptom #1, #2, & #3:

Turbo valve replacement

Service procedures Turbo-2000

Turbo Valve Service Kit #228

Symptom

Operational check

Symptom #1, #2, & #3:

Turbo valve replacement

Service procedures Turbo-2000

Dessicant Cartridge Service Kit

#T224 & #T224-P

Symptom

Operational check

Symptom #1 & #2

Desiccant cartridge replacement

Service procedures Turbo-2000

Early model Late model

Heater Service Kit #248,

#249, #619110, #619111

Symptom

Operational check

Heater assembly replacement

Turbo-2000 Notes:

HD-2000 parts list

A 610237

B 223

C 610077

D 610110

E T224

E-1 T224-P

F 610236

G 238

H 619089

619090

I 235

J

248 12V 75W

249 24V 75W

J

619110 12V 75W

619111 24V 75W

K 619900

L 610024

M 619115

N 619140

O 619091

Regeneration valve nut

Regeneration valve kit

Body gasket

Seal retainer

Desiccant cartridge

Desiccant cartridge filtration plus

Check valve nut

Check valve kit

Bottom cap assy 12V

Bottom cap assy 24V

Purge valve kit

Heater kit early models

(Orange and blue wires)

Heater kit late models

(Plug style connection)