Home

Brakemaster® air dryers

1. 71 2 6 Fill heater cover through 1 4 hole with non corrosive RTV Connect blue heater wire to a good chassis ground Connect orange wire to ignition switch Seal and route heater wires carefully Late Models 619110 or 619111 plug style connection Slide o ring over heater and thermostat into position around connector flange Slide heater and thermostat into position in cavity Ensure thermostat sits flat in cavity Place foam cube on top of thermostat and bring heater connector into position over heater Secure heater assembly using the 2 8 32 x 1 2 screws 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 33 34 HD 2000 parts list Component identification B 223s Regenerationvalvekit ss O D 610110 Sealretainer o O Ce a esiema SSCS CECO 619090 Bottom cap assy 24V o O pas uewe SSCS 249 24V 75W Orange and blue wires 619111 24V75W___ Plug style connection Cd o e1091 Mid sectionwithvaves SOS Bold part numbers represent suggested stock service components Air dryer part number description HD w filtration plus Description option A For right hand models see parts list on pages 139 amp 140 HD 2000 service schematic FF 7 TES I SS AnS E or E 1 35 36 HD 2000 normal operation cycles
2. Max allowable braked axles 5 For naturally aspirated compressors or DLU Discharge Line Unload air systems only Dual dryer application call for installation details Note Filtration Plus option available on Turbo 2000 and HD 2000 air dryers SKF is a registered trademark of the SKF Group SKF Group 2013 The contents of this publication are the copyright of the publisher and may not be reproduced even extracts unless permission is granted SKF VSM NA Every care has been taken to ensure the accuracy of the information contained in this publication but no liability can be accepted for any loss or 890 N State Street damage whether direct indirect or consequential arising out of the use of the information contained herein Suite 200 Publication 457938 rev 04 13 Elgin IL 60123 Printed in U S A 1 800 882 0008 Certain image s used under license from Shutterstock com www vsm skf com
3. The solution is SKF Brakemaster air dryers With the ongoing evolution of commercial vehicles the proliferation of new pneumatic powered accessories has increased demands on vehicles compressed air systems From kneeling buses to multi axle ABS brakes new applications have raised the requirements for clean dry air straining existing technologies and creating a need for more efficient and reliable air dryers The SKF Brakemaster family of air dryers is meeting those needs In addition to units designed for conventional over the road applications the SKF Brakemaster line includes high performance air dryer units specifically designed to handle the extreme air system demands for such industries as transit and refuse From the light duty maintenance saving Turbo AC to the state of the art 2000 series air dryers now featuring two styles of the Dual Turbo 2000 the standard Dual Turbo 2000 and the High Capacity H C Dual Turbo 2000 these heavy duty air dryers allow fleets to match air dryer performance to specific application requirements This manual provides a detailed technical overview of the SKF Brakemaster line including SKF s Filtration Plus option which can be retrofitted to the Turbo and HD 2000 air dryers already in service for optimal filtration performance And with the addition of the H C Dual Turbo 2000 the SKF Brakemaster line now can meet the requirements of high output compressors on 2010 and la
4. 5 Clean nut and cavity area 6 Install new ball in cavity Next position spindle with spring pocket facing out Install spring 7 Using grease supplied apply a light coating on o ring Install o ring on nut 8 Apply a light coating of grease to threads of nut Install nut and tighten to 60 ft Ib 9 Re connect air line to air dryer outlet port 77 2 Service procedures H C Dual Turbo 2000 Valve spindle r Valve spindle Spring Spring O rings 7 f r O rings Ij MB ii ae i 619938 Inlet check valve kit Inlet Check Valve Service Kit 619938 Note two 2 valves in dryer 1 per kit Warning Before proceeding read and follow safety precautions found on page 17 Symptom 1 Air leak at exhaust port s during the charge mode 2 Pressure slow or no build Operational check Symptom 1 amp 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 2 Remove two 1 4 bolts that fasten the inlet check valve retainer to valve hsg and removed retainer Remove the inlet check valve spindle from the inlet cavity and discard Note If there is
5. 125 126 con t Warning Safety precautions 1 Before performing any test and or isolating the air dryer the vehicle s wheels must be chocked making sure the vehicle will not roll before releasing the brakes 2 Never work under a unit supported only by a jack Always support the vehicle with stands 3 Stop engine when working under a vehicle 4 Never remove a component or a pipe plug unless you are certain all system air pressure has been exhausted Never connect or disconnect a hose or line containing air pressure 6 Never exceed recommended working air pressure 7 Never attempt to disassemble an air dryer until you have read and understood all recommended procedures 8 Use only proper tools and observe all precautions pertaining to the use of those tools 9 Always wear safety glasses when working with air pressure Never look directly into air dryer ports Basic mounting guidelines 1 The air dryer must be mounted with the exhaust ports positioned downward Use grade 5 or better bolts to mount air dryer and purge tank Mount air dryer lower than the air compressor The compressor discharge line should slope continuously downward from the compressor to the air dryer without any dips which cause water traps The compressor discharge line size material and length must be such that the dryer air inlet temperature is typically no more than 160 degrees F or no less than 45 degrees F a
6. Symptom 2 amp 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 1 Remove the two fasteners that attach the purge valve retainer Remove the retainer 2 Remove the purge valve assembly and o ring from the purge cavity and discard Note If there is excessive oil in the cavity compressor may require servicing Clean the cavity thoroughly Remove the three 3 o rings from retainer and discard Using lubricant supplied lightly grease the new o rings 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 Om amp W Warning If the air dryer purge valve port does not align with air dryer exhaust port air dryer will not exhaust 9 Install retainer 10 Apply a light coating of grease on the threads of the two retainer bolts 11 Install two retaine
7. Torque 16 bolts to 25 30 ft lbs Clean top surface of adapter plates and threaded studs Position new filter element around each stud and onto adapter plate Using grease supplied apply a light coating of grease onto o ring Install o ring onto threaded studs Important for easy removal Apply a generous coat of grease on the new desiccant cartridge gasket surface Thread new cartridge onto studs turning clockwise When gasket contacts adapter plate tighten cartridge 1 2 turn Do not overtighten Re connect air line top air dryer inlet port Re connect heater lead wire 81 Service procedures H C Dual Turbo 2000 alee Heater Service Kit 619110 12V amp 619111 24V i en Warning i g Read and follow safety precautions 10 ri found on page 17 before proceeding Er 1 BR 7er lea Ta Symptom Datos rat 1 Dryer won t exhaust p 2 Exhaust port leak Heater Asa Org 3 Cannot build pressure Ld mam Dir As i 619110 120 A 619101 24W heater kts Operational check Note Thermostat must be cooled to at least 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 Heater
8. port and shut off valve in dryer OUTLET port Connect shop air to valve at dryer OUTLET port With air pressure still applied at UNLOADER valve port open valve at OUTLET port to apply air pressure to OUTLET port Check for air leaking at dryer EXHAUST port If air leaks at EXHAUST port dryer check valve is worn and requires service Refer to page 24 Disconnect shop air from dryer OUTLET and UNLOADER ports 113 114 con t Step 9 Differential check poppit valve test This step applies ONLY to Air Dryers compatible with Holset E Type Compressors 1 Remove 1 2 pipe plug from dryer INLET port 2 Connect shop air to shut off valve at UNLOADER port and open valve to pressurize and activate dryer unloader valve Connect shop air to valve at dryer OUTLET port and open valve Check for air flow from dryer INLET port If air does not flow from dryer INLET port the differential check valve requires service Disconnect shop air from dryer OUTLET port Remove shut off valve from dryer OUTLET port and install in dryer INLET port Connect shop air to valve at dryer INLET port and open valve Check for air flow from dryer OUTLET port If air flows from dryer OUTLET port the differential check valve requires service O Oo OND HO rw r Air dryer thermostat heater assembl
9. 249 24V 619110 12V or 619111 24V Line between governor and air Replace the line or remove the blockage compressor is blocked The safety valve is malfunctioning Replace the safety valve 610024 D2 governor malfunctioning Replace D2 governor valve Problem air continually leaks from the exhaust port in compressor standby mode Remedy Clean cavity and replace check valve assembly 238 Clean cavity and replace turbo valve assembly 228 Clean cavities and replace purge valve assembly 235 Problem system air pressure drops rapidly Remedy Fittings are loose or damaged Tighten and or replace as necessary Air reservoir tubing or hoses are Repair or replace as necessary damaged Worn check valve Clean cavity and replace check valve assembly 238 Worn turbo valve Clean cavity and replace turbo valve assembly 228 Worn purge valve seal Clean cavity and replace purge valve assembly 235 101 102 Problem air compressor moves into the standby mode but cycles rapidly Possible cause Remedy Fittings are loose or damaged Tighten and or replace as necessary Air reservoir tubing or hoses are damaged Repair or replace as necessary Worn check valve Clean cavity and replace check valve assembly 238 Worn turbo valve Clean cavity and replace turbo valve assembly 228 D2 governor malfunctioning Replace D2 governor Worn purge valve seal Clean cavity and replace the purge valve assembly 235 Problem air leaks from the exhaust port
10. Cartridge 0 Fing ge 2 EEE Dessicant Cartridge Service Kit T224 amp T224 P Gashet __ Warning Read and follow safety Ti precautions found on page 17 before proceeding Symptom 1 Regular service interval 2 Water or contamination in tanks Filter plate Note If there is excessive oil present compressor may require servicing to T224 P upgrade Operational check Symptom 1 amp 2 Desiccant cartridge requires regular servicing at intervals determined by compressor duty cycle or type of driving conditions Typical service intervals are Line haul 3 years Inner city 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
11. 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 Ib 14 Reconnect the control line to air dryer control port 75 Service procedures H C Dual Turbo 2000 _ kas IE n I oF D ii Aeon abe uf pring Pa i ty En au 4 i dai a i m l a ae Regeneration Valve Service Kit 619913 Warning Read and follow safety precautions found on page 17 before proceeding Regeneration vake Symptom Spring 1 Water in tanks 2 No purge air flow 5 19713 eji va ki Operational check Symptom 1 amp 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 T 2 3 4 Ne 10 11 76 Disconnect air line from outlet port of air dryer Remove eight 8 socket head bolts fastening manifold to adaptor castings Remove manifold from adaptor castings Remove and discard o rings springs
12. L H Turbo 2000 24V heater w tank Standard Non E type L H Turbo 2000 dryer only 24V heater Standard Non E type L H Turbo 3000 12V heater Standard Non E type L H Turbo 3000 24V heater L H Turbo 2000 E type dryer only w 24V heater w Filtration Plus Dual Turbo 2000 air dryer 12V heater Dual Turbo 2000 air dryer 12V heater w o canisters con t Desiccant air dryers cont 620920 Dual Turbo 2000 air dryer 24V heater 620922 Dual Turbo 2000 air dryer 24V w 12V MLT amp special mounting bracket 620924 Dual Turbo 2000 air dryer 24V heater w o canisters 620930 Dual Turbo 2000 air dryer 24V heater w o purge tanks 620950 Dual Turbo 2000 air dryer 110V Non vehicle w o tanks 620960 Dual Turbo 2000 air dryer 110V Non vehicle w tanks 620980 HC Dual Turbo 2000 air dryer 12V heater w purge tanks 620982 HC Dual Turbo 2000 air dryer 12V heater w o purge tanks 620984 HC Dual Turbo 2000 air dryer 24V heater w o purge tanks 620986 HC Dual Turbo 2000 air dryer 24V heater w purge tanks Brakemaster aftercooler air dryers 620570 L H Turbo AC 12V heater 620571 R H Turbo AC 12V heater 620572 L H Turbo AC 24V heater 620578 L H Turbo AC 12V heater Holset QE compatible 620580 L H Turbo AC 24V heater Holset QE compatible Note Bold part numbers represent suggested stock service components NOTES 141 142 NOTES A WARNING Proper selection of the products listed for sale in this catalog is essen
13. Screw will protrude from bottom cap about 1 8 Insert thermostat into position in thermostat cavity Coil lead wires around heater cover posts allowing wires to protrude through slots in cover 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 7 1 6 1 17 7 1 8 Fill heater cover through 1 4 hole with non corrosive RTV Connect blue heater wire to a good chassis ground Connect orange wire to ignition switch Seal and route heater wires carefully 7 2 11 Late Models 619110 or 619111 plug style connection 71 21 71 2 2 71 2 3 71 2 4 71 2 5 7 1 2 6 Slide o ring over heater and thermostat into position around connector flange Slide heater and thermostat into position in cavity Ensure thermostat sits flat in cavity Place foam cube on top of thermostat and bring heater connector into position over heater Secure heater assembly using the 2 8 32 x1 2 screws 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 47 48 Dual Turbo 2000 dryer parts list H C Dual Turbo 2000 dryer parts list may be found on page 68 Component identification A A Note four retainers per dryer two on either side 1 per box F
14. T62 620570 263 Deflector kit 68 69 T68 265 Deflector kit 70 amp 72 610024 Safety valve 175 psi 610029 Top cap nut 62 63 68 69 T62 T68 610030 Unloader valve nut 610069 Seal retainer 610076 10 Filter packing ring Lots of 10 only price per each 610077 Body gasket w o ring 610107 U bolt service kit 610110 Seal retainer for HD2000 and Turbo AC 610179 10 Body gasket E type version w o o ring Lots of 10 only price per each 610236 Desiccant dryer check valve nut 610237 Desiccant dryer bleed valve nut 610271 Filter hold down spring for aftercoolers 610705 Die cast body 62 amp 63 610851 Model 62 bracket 619086 619087 619089 619090 619091 619093 619109 619110 619111 619112 619113 619114 619115 619116 619140 619215 619218 619220 619222 619228 619238 619239 619240 619241 619340 619360 619500 619525 Complete bottom cap assy 12V non E type Complete bottom cap assy 24V non E type Complete bottom cap assy 12V HD 2000 Complete bottom cap assy 24V HD 2000 Turbo 2000 Turbo 3000 amp HD 2000 mid section w valves standard Turbo 2000 Turbo 3000 amp HD 2000 mid section w valves E type Muffler compatible with all SKF dryers 12V75W Thermostat heater w plug in connector 24V75W Thermostat heater w plug in connector Complete bottom cap assy T2000 amp T3000 12V E type Complete bottom cap assy T2000 amp T3000 24V E type C
15. Wn au 3 up VO NF Heater elec connect ir 12or24Vot DC x Exhaust port Reservar wet tank Out to system Purge air tank 300 Cl min Heater elec connect 12 or 24 Volt D C Exhaust port Fig 2 Connection schematic Mount purge tank higher than purge tank port on air dryer Use the purge tank port that is in the lowest position so that moisture can run down into the air dryer for expulsion If it is not possible install a petcock for periodic manual draining Note Eu Dual Turbo 2000 extreme use dryers e Proven effective by the e Integrated filtration system country s largest and most removes compressor severe use municipal blow by before entering fleets desiccant cartridge protects downstream e Keeps air system clean components keeps air capacity high even in the most severe e Easy to install and use situations requiring service reduces 100 compressor duty fleet downtime cycles e Designed to be effective in service use applications such as transit refuse logging etc Dual Turbo 2000 extreme duty cycle SKF now has two styles of the Dual Turbo 2000 the standard Dual Turbo 2000 and the High Capacity H C Dual Turbo 2000 Both the Dual Turbo 2000 and the H C Dual Turbo 2000 can meet the increased demands of tomorrow s vehicles The standard Dual Turbo 2000 has been a successful solutions provider for all types of applications such as articulated buses kne
16. and regeneration valves Clean valve cavities in adaptor castings Position new valve spindles into cavities with spring pockets out Position springs into valves Lubricate new o rings and install onto manifold bosses Position manifold onto adaptor castings ensuring o rings are properly positioned in bores Install eight 8 socket head bolts and tighten to 50 60 in lbs Torque Reconnect air line to outlet port Service procedures H C Dual Turbo 2000 4233 Check vale kA Check Valve Service Kit 238 ie Warning Read and follow safety precautions found on Ex Ball page 17 before proceeding Symptom 1 Dryer frequently exhausts 2 Air continually flows from exhaust port when compressor is in standby mode 3 Wet tank pressure drops rapidly Operational check Symptom 1 2 amp 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 inlet check valve The affected inlet check valve would be located on side of air dryer Check 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
17. from exhaust port of dryer replace turbo valve 228 Note Air discharge could also be due to worn purge valve or check valve Turbo valve replacement 1 2 3 4 o 10 11 12 13 Drain the air system Disconnect the heater wiring Disconnect the inlet and control lines from their respective ports Remove 8 bolts from bottom cap and set aside Discard gasket Remove turbo nut valve stop and valve and discard Clean cavity area thoroughly Lightly coat the 2 small o ring surfaces and install on piston Carefully install valve in cavity with tapered side up Place valve stop on top of valve concave side down Lightly lube large o ring and place on nut Install flat seal into nut Install nut and tighten to 40 45 ft lb 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 Re connect inlet and control lines to their respective ports Re connect heater wiring Service procedures Turbo 2000 Cartridge Dessicant Cartridge Service Kit m Gik T224 amp T224 P m i Fiker Warning Read and follow safety precautions found on page 17 before proceeding Symptom nit 1 Regular service interval __ Fikerpisie 2 Water or contamination in tanks J Operational check Symptom 1 amp 2 Desiccant cartridge requir
18. up to 40 e Safety valve 200 psig 1 e Drying medium 8 Lbs dessicant spin on e Heater options 12V 75 watt 6 6 amps 24V cartridges 2 4Lbs 75 watt 3 2 amps Use 619228 with 690 Cu In or 2 221 with 460 Cu In volume each s o Hener 12 or A E Fig 1 Unit dimensions LA camirol lire i Be Master eier comet Sonat pets TE ar 28 von DLE Fig 2 Connection schematic Note Mount purge tank s higher than purge tank port on air dryer Use the purge tank port that is in the lowest position so that moisture can run down into the air dryer for expulsion If it is not possible install a petcock for periodic manual draining 11 Turbo 3000 over the road The unique Turbo 3000 uses a highly efficient new formula to match compressed air to a compact desiccant package This precise match of desiccant and purge volume reduces both size and weight while effectively cleaning and drying the air system Ease of installation is an added benefit of this compact design It makes retro fitting a one step operation Ports are easily accessible and clearly marked The spin on cartridge holds both desiccant and purge air and can be serviced in minutes For all weather operation the Turbo 3000 is equipped with a sealed 12 Volt or optional 24 Volt 75 watt thermostatically controlled heater e A compact streamlined design for top performance on highway e Self contained purge air doesn t steal from brake syste
19. 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 WiClean dry air Mj Atmospheric pressure MI Dirty wet charged air M 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 Clean cavities and replace purge valve assembly 235 Problem system air pressure drops rapidly Fittings are loose or damaged Tighten and or replace as necessary Air reservoir tubing or hoses are R
20. 24V 75 Wat D a ms TOV 75 Wat eee Includes two 221 purge tanks 460 Cu In volume each A Separate purge tank 690 Cu In available 619228 7 x18 diameter Dual Turbo 2000 Dual Turbo 2000 specifications e Unit dimensions see Fig 1 e Drying medium System purge controlled e Weight 47 Lbs regeneration alternating cycle e Connection ports see Fig 2 e Safety valve 200 psig e Air flow capacity 40 CFM e Heater options 12V 75 Watt 6 6 Amps e Drying medium 8 Lbs desiccant PORA y 1A val 3 2 Amps Spin on cartridges 2 4 Ib e Filtration 6 internal filters per side e Duty cycle Up to 100 2 00 Minimum dearance required for cartridge service 4 i Cartridge 3 00 r Outlet 34 NPT f 8 75 375 MLT HTR connect i 12V or 24V D C Fig 1 Unit dimensions Governor Compressor 3 f Resevoir Out to nd wet tank az system Compressor Ss Outlet port 3 4 NPT NPT MuT Heater elec connect EEE 12 or 24 Volt D C Exhaust port Fig 2 Connection schematic 10 H C Dual Turbo 2000 specifications e Unit dimensions see Fig 1 e Drying medium Dedicated external purge e Weight 47 Lbs regeneration tank minimum volume 600 e Connection ports see Fig 2 Cu In e Air inlet temperature 160 F Max e Filtration 6 internal filters e Air flow capacity 80 CFM e Turbo protection valve Internal e Duty cycle capacity
21. Cornpressor J Outlet port 32 4 NPT Inlet port 3 4 NPT MLI Heater elec conne a 12 or 24 Volt D C Exhaust port Fig 1 Connection schematic 128 con t Basic mounting guidelines 1 The air dryer must be mounted with the exhaust ports positioned downward Use grade 5 or better bolts to mount air dryer and purge tank 2 Mount air dryer lower than the air compressor The compressor discharge line should slope continuously downward from the compressor to the air dryer without any dips which cause water traps 3 3 The compressor discharge line size material and length must be such that the dryer air inlet temperature is typically no more than 160 degrees F or no less than 45 degrees F above low ambient Ref SAE J2383 An example of a typical discharge line Total line length 10 ft to 12 ft which is a combination of rigid copper approx 4 ft length and balance of line length being stainless steel braid sheathed PTFE Avoid using 90 elbow fittings to avoid water traps freeze ups 4 The air dryer should be mounted in a location with sufficient space around it to facilitate service and to provide visual access for periodic inspection Allow at least 2 00 inch clearance above air dryer for desiccant cartridge service 5 The air dryer should be mounted out of direct tire or wheel road splash or protected from splash 6 The air dryer with its mounting bracket lines and fittings should be mounted in a pr
22. G amp 12V heater amp 24V heater 619111 24V 75W 24 Volt heater kit K L per dryer one on either side 1 per box N S Bold part numbers represent suggested stock service components Air dryer part number description 620910 620912 12V w cartridges w o cartridges 620920 620924 24V w cartridges w o cartridges 620922 24V w 12V MLT amp Special Mounting Bracket Use 2 T224 P cartridges 235 Purge valve kit note two valves per dryer one on either side 1 per box 4 A A B k E EA id K M N 0 a R S T T _ Dual Turbo 2000 service schematic 49 50 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 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 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 alter
23. NO continuity replace thermostat heater assembly Refer to pages 31 and 32 Air dryer socket sizes Large strap Wrench to remove Dessicant Cartridge 1 3 4 socket or ChannelLock pliers for Check Valve nut You may need a reducing adapter to connect the discharge line used with a BW AD9 to adapt to ours 3 4 Female NPT to 2 2 Male NPT 7 16 socket for unloader cap 2 bolts Use a 1 1 4 socket for the internal turbo valve nut 1 3 4 socket or ChannelLock Pliers for the Bleed Valve nut our purge tank 1 each 3 4 and 7 s box open end wrenches to remove 1 2 inlet out outlet hose fittings Socket for the pop off valve 1 4 socket for Heater bolts Also can use a slotted screw driver 9 16 socket to remove the 8 bottom plate bolts Note It is very difficult to remove the bottom cap bolts with a wrench Use a socket only with a six 6 inch extension Can substitute open or boxed end wrenches for sockets Carry a long needle nose set of pliers to remove the Turbo valve a small quantity of anti seize to put on bolt threads and a small tube of Teflon pipe sealant for fittings 115 116 Tech Tip 1 Recommended service for Brakemaster family of air dryers The recommended service of SKF Brakemaster air dryers is based on normal operating conditions proper application and installation of air dryer Follow all safety precautions specified in service manual 457938 Individual component op
24. Note that an E Type dryer on a non Holset compressor could leak air out the intake of the compressor There is a yellow sticker on the air dryer that indicates E Type or non E Type A leak less than 4 minutes will likely be the result of a non functioning valve or major leak in air system If soapy water does not reveal the leak replace air dryer unloader valve 235 Turbo valve 228 and check valve 238 Service kit 619340 includes all of these valves plus desiccant cartridge T224 Service kit 619360 includes additional filtration with T224 P Check heater element Remove heater rod from dryer and with ignition off use an ohmmeter to check resistance The resistance for a 12V 75 watt heater is 1 8 watts with 6 6 amp draw and 24V 75 is 7 4 watts with 3 2 amp draw If no ohmmeter is available expose air dryer to temperature below 32 F place hand on bottom portion of air dryer and feel for warmth Service intervals Many factors go into the service interval for an air dryer Conditions where annual service is needed are e Frequent braking transit mountainous driving refuse High air volume use special needs buses cement mixers central tire inflation vehicles Older compressors vehicles with old compressors will experience more oil blow by conditions e Need for clean air supply ABS brakes critical air actuated componentry Vehicles in vocations with low air use should be inspected regularly and serviced every 2 3 years
25. PANES U E NEEE SETVICE SCheMatic sennen arn a R n E Normal operation flow diagram Troublesshootinde a n neene Service PFOCEdUreS naneneneenunsnennnnennnnnnnennnnennnnennnnennnnennnnennennn Original Brakemaster service kit reference chart 110 Section 3 miscellaneous Bench test procedures Socket reference Tech Tips seep a Installation instructions Parts STO sis ah Waray eens rE A AAEN EERE Vocational Matrix issii nesinnes Turbo 2000 high duty cycle The Turbo 2000 is the recommended choice for severe service applications where the compressor output reaches 30 CFM and duty cycles run as high as 40 Its ratio of large purge volume to desiccant produces the ideal filtering system and contamination protection for heavy duty service today A four way filtration system consisting of three filter screens a unique filtering bag plus four pounds of high quality molecular sieve desiccant strips away moisture and traps compressor blow by The spin off cartridge can be serviced in minutes The compact purge tank can be installed anywhere and provides a full 460 cu in of clean purge air Improve the overall performance of your air system by upgrading to the Filtration Plus option Not only does this option reduce overall operating costs of the air dryer by extending the cartridge service life but it also optimizes the air systems efficiency by reducing compressor burden caused by downstream
26. Re install valve housing assembly to adapter plate castings Torque 16 bolts to 25 30 ft lbs Clean top surface of adapter plates and threaded studs Position new filter element around each stud and onto adapter plate Using grease supplied apply a light coating of grease onto o ring Install o ring onto threaded studs 18 Important for easy removal Apply a generous coat of grease on the new desiccant cartridge gasket surface Thread new cartridge onto studs turning clockwise When gasket contacts adapter plate tighten cartridge 1 2 turn Do not overtighten Re connect air line top air dryer inlet port Re connect heater lead wire Service procedures Dual Turbo 2000 Mester Fes anew 619110 1 EI N Heater Service Kit 619110 12V amp 619111 24V Warning Read and follow safety precautions found on page 17 before proceeding Symptom 1 Dryer won t exhaust 2 Exhaust port leak O ring 3 Cannot build pressure hester ee Operational check Note Thermostat must be cooled to at least 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 Heater assembly replacement 1 Disconnect hea
27. 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 43 44 8 9 10 11 12 13 14 15 16 17 18 19 20 No cont Remove filter plate if present and gasket s from bottom cap and discard Clean bottom cap sump cavity gasket surface and inside of adapter plate castings of oil and contaminants Place new gasket on bottom cap bolt flange 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 Re install bottom cap assembly to adapter plate casting Torque 8 bolts to 25 30 ft lbs Clean top surface of adapter plate and threaded stud Position a new filter element around cartridge stud and onto adapter plate Using grease supplied apply a light coating of grease onto o ring Install o ring onto threaded stud Important for easy removal Apply a generous coat of grease on the new desiccant cartridge gasket surface Thread new cartridge onto stud turning clockwise When gasket contacts adapter plate tighten cartridge 1 2 turn Do not overtighten Re connect airlines to air dryer inlet and control ports Re connect heater lead wire te Cartridge Stud Kit 619140 available if stud needs replaci
28. Turbo 2000 MLT 24V Dual Turbo 2000 air control valve 2 air line version from April 2006 Dual Turbo 2000 check valve nut Dual Turbo 2000 manifold Dual Turbo 2000 valve housing includes valves amp 12V heater Dual Turbo 2000HC manifold w o MLT ACV or accessories Dual Turbo 2000 valve housing includes valves amp 24V heater Dual Turbo 2000 heater wire harness Dual Turbo 2000 inlet check valve kit 10 pack of 619938 619932 w bottom cap bolts amp 12V heater HC Dual Turbo 2000 control line service kit 619934 w bottom cap bolts amp 24V heater Dual Turbo 2000HC manifold conversion w o tanks Dual Turbo 2000HC manifold conversion w tanks Dual Turbo 2000HC complete service kit w 24V heater Dual Turbo 2000 mounting bracket Desiccant air dryers 620300 620302 620303 620304 620306 620350 620352 620354 620356 620357 620500 620501 620502 620503 620504 620505 620506 620525 620526 620540 620541 620542 620544 L H Turbo 2000 w Filtration Plus and tank kit 12V heater L H Turbo 2000 w Filtration Plus dryer only 12V heater R H Turbo 2000 dryer only 12V heater w Filtration Plus Opt L H Turbo 2000 w Filtration Plus and tank kit 24V heater L H Turbo 2000 w Filtration Plus dryer only 24V heater L H HD 2000 w Filtration Plus and tank kit 12V heater L H HD 2000 w Filtration Plus dryer only 12V heater L H HD 2000 w Filtration Plus and tank kit 24V
29. WARNING Please read and follow these safety instructions e Before performing any test and or isolating the air dryer the vehicle s wheels must be chocked making sure the vehicle will not roll before releasing brakes Never work under a unit supported only by a jack Always support the vehicle with stands e Stop engine when working under a vehicle e Never remove a component or a pipe plug unless you are certain all system air pressure has been exhausted e Never connect or disconnect a hose or line containing air pressure Never exceed recommended working air pressure Never attempt to disassemble an air dryer until you have read and understood all recommended procedures Use only proper tools and observe all precautions pertaining to the use of those tools con t Fall maintenance recommendations System checks should be done regularly and include e Check for moisture in air system by opening reservoirs drain cocks or valves If moisture is present replace desiccant cartridge T224 If contaminants are present use service kit 619340 or 619360 for additional filtration performance and service compressor as needed 3 Check for air leak by building system to cut out pressure The air dryer should not unload again while at idle If it unloads within 4 to 5 minutes there is a slow leak that needs to be addressed Spray soapy water at fittings around the air dryer wet tank and compressor Repair as needed
30. WNP Install 3 8 x 1 4 bushing into dryer PURGE TANK port Install 1 4 shut off valve to PURGE TANK port of dryer Install quick disconnect connector to shut off valve Connect shop air to valve Open valve Check for air flow from dryer OUTLET port If air flow does not occur the regeneration valve requires service refer to page 23 Step 3 Dryer assembly leak test 5 Install 1 2 pipe plug in OUTLET port of dryer Remove shut off valve and bushing from PURGE TANK port of dryer and install 3 8 pipe plug Open shut off valve at dryer INLET port to pressurize dryer Check for leakage at 4 1 Exhaust port Note if air leaks at dryer exhaust unloader valve requires service Refer to page 21 4 2 Bolts gaskets safety valve cartridge etc Note Repair any leaks detected Close shut off valve at dryer INLET port Step 4 Dryer exhaust test NO Install 1 4 shut off valve to UNLOADER port of dryer Open shut off valve at dryer INLET port to pressurize dryer Connect shop air to shut off valve at UNLOADER port and open valve to pressurize and activate dryer unloader valve Air should exhaust from EXHAUST port of dryer If air exhaust does not occur check for the following 5 1 Unloader valve exhaust port is not aligned and is blocking dryer bottom cap exhaust port 5 2 Exhaust holes trash screen inside bottom cap
31. air governor and the Install or replace the air line or control port is missing leaking or damaged air dryer Tighten the fittings Worn purge valve Clean cavities and replace the purge valve assembly 235 Ice has formed in the purge valve Replace heater assembly 246 12V 247 24V 248 12V 249 24V 619110 12V or 619111 24V Heater is malfunctioning Replace heater assembly 246 12V 247 24V 248 12V 249 24V 619110 12V or 619111 24V Purge valve sleeve is misaligned Align purge valve sleeve Problem safety valve opens Possible cause Air dryer check valve is blocked Clean cavity and replace the check valve assembly 238 Air brake system is blocked down Remove blockage or replace the necessary stream from the air dryer components Air compressor governor is Replace the compressor D2 governor malfunctioning Blocked desiccant cartridge Replace cartridge 1224 and upgrade to filtration plus T224 P The safety valve is malfunctioning Replace the safety valve 610024 Problem water accumulation in air system tanks Desiccant is contaminated Replace desiccant cartridge 1224 Air compressor capacity is too low for Install larger air compressor and replace desiccant cartridge 1224 vehicle Malfunctioning regeneration valve Clean cavity and replace regeneration valve assembly 223 Line between the purge tank and Install or replace the air line or tighten the fittings the air dryer control port is missing leaking or da
32. amp 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 105 and 106 for service procedures on these valves 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 2 104 con t Note If there is excessive oil in the cavity compressor NOMS 00 10 may require servicing Clean the cavity thoroughly Remove the three 3 o rings from retainer and discard Using lubricant supplied lightly grease the new o rings Install on the retainer the two 2 thickest o rings then install the third thinner o ring Install the new filter screen in the purge cavity open end out Apply a light coating of grease around the o ring seat on valve assembly Install the thin o ring on the purge valve seat 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 11 12 13 14 align with air dryer exhaust port air dryer will not exhaust Install retainer Ap
33. 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 amp 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 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 39 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 Note If there is excessive oil in the cavity compressor may require servicing Remove the purge valve assembly from cavity and discard Clean the cavity thoroughly Remove the three 3 o rings from retainer and discard Using lubricant supplied lightly grease the new o rings 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 NOOO Pr W 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 exhau
34. are blocked Disconnect shop air from dryer INLET port con t Step 5 Unloader valve test T 2 3 With air pressure still applied at UNLOADER port check for leaks at EXHAUST port of dryer If air leaks from EXHAUST port unloader valve is worn and requires service Refer to page 21 Disconnect shop air from dryer UNLOADER port 3 Step 6 Turbo O ring and unloader valve retainer O ring test 1 2 3 4 5 Install 1 2 pipe plug in dryer EXHAUST port Connect shop air to valve at UNLOADER port and pressurize unloader valve If air leaks from dryer inlet shut off valve must be open turbo valve O ring seals are worn If leaking turbo valve requires service Refer to page 25 If air leaks at unloader valve retainer flange O ring seals are worn and require service Step 7 Turbo valve flat seal test gt Remove 1 2 pipe plug from dryer EXHAUST port With air pressure still applied at UNLOADER valve port apply air pressure to INLET port of air dryer Check for air leaking from EXHAUST port of air dryer If leaking turbo valve requires service Refer to page 25 Disconnect shop air from dryer INLET port Step 8 Check valve test a Remove 1 2 pipe plug from dryer OUTLET port and shut off valve from dryer INLET port Install 1 2 pipe plug in dryer INLET
35. around it to facilitate service and to provide visual access for periodic inspection Allow at least 2 00 inch clearance above air dryer for desiccant cartridge service The air dryer should be mounted out of direct tire or wheel road splash or protected from splash The air dryer with its mounting bracket lines and fittings should be mounted in a protected location such that minor mechanical damage to the vehicle will not damage the air system integrity Mounting air dryer base assembly 1 After determining proper location for air dryer as instructed in Basic mounting instructions section refer to Fig 2 drawing for mounting reference dimensions Mount air dryer base assembly to vehicle before installing desiccant cartridges to base assembly Make sure there will be at least a 2 00 inch clearance above desiccant cartridges for future installation and removal Refer to Fig 2 drawing to position mounting holes properly on vehicle to match mounting slot locations in air dryer mounting bracket Use at least four 4 3 8 grade 5 bolts to attach air dryer to vehicle Tighten bolts to 25 30 ft lbs torque Installing desiccant cartridges 1 After air dryer base assembly is securely mounted install both desiccant cartridges to base assembly as follows Install o ring into groove of each center thread adaptor in air dryer base assembly a b Lubricate both o rings and threads gi Lubricate
36. assembly replacement 1 Disconnect heater lead wire 2 Remove two screws attaching heater connector to casting 3 Remove heater thermostat assembly and discard 4 Thoroughly clean entire heater thermostat area 5 Slide o ring over heater and thermostat into position around connector flange 6 Apply a light coating of anti seize to the heater element and thermostat cavity 7 Insert heater element into hole and twist slightly to spread anti seize 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 82 H C Dual Turbo 2000 Notes 83 84 Turbo 3000 parts list Component identification Check valve Kit 610236 Check valve nut C 610077 Body gaskets Bottom cap assembly 12V STD Bottom cap assembly 12V E Type Bottom cap assembly 24 STD Bottom cap assembly 24 E Type F 249 24V 75W Orange and blue wires 619111 24V 75W Plug style connection 619115 Mounting bracket 619140 Cartridge stud kit 619091 Mid section with valves STD 619093 Mid section with valves E Type Bold part numbers represent suggested stock service components Dryer part number descript
37. bottom cap so that inlet port is directly below outlet port Install 8 bolts Tighten bolts to 20 25 ft Ib or 25 30 ft lb if equipped with oil separator Re connect inlet and control lines to air dryer Re connect heater wiring 93 Service procedures Turbo 3000 Dessicant Cartridge ee Service Kit T33 3 THO ATER AA aa Warning Read and follow safety precautions found on page 17 before proceeding i Symptom 1 Regular service interval 2 Water in tanks Operational check Symptom 1 amp 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 1334 Desiccant cartridge replacement 1 Drain the air system 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 4 Clean top surface of adapter plate and threaded stud 5 Using grease supplied apply a light coating on o ring 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 tig
38. 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 Charge cycle Purge cycle es EXH UNL RES WiClean dry air Mj Atmospheric pressure MI Dirty wet charged air ll Dirty wet purged air Note Approx 95PSI gov cut in 120PSI gov cut out 100 Trouble shooting Turbo AC dryer Review the Turbo AC normal operation cycles prior to trouble shooting on page 100 Possible cause Worn purge va Dirt foreign material is stuck in purge valve D2 governor malfunctioning Ice has formed in purge valve 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 Fittings are loose or damaged Tighten or replace loose or damaged fittings Air reservoir tubing or hoses are Repair or replace damaged items damaged Air compressor needs to be serviced or Rebuild or replace the air compressor replaced Worn purge valve Clean cavity and replace the purge valve assembly 235 The air compressor capacity is too low for Install larger air compressor and upgrade to Turbo 2000 vehicle Ice has formed in the purge valve Replace heater assembly 246 12V 247 24V 248 12V
39. during compressor charge mode Remedy Clean cavity and replace purge valve assembly 235 Clean cavity and replace purge valve assembly 235 Replace D2 governor Heater assembly malfunctioning Replace heater assembly 246 12V 247 24V 248 12V gt 32 degrees 249 24V 619110 12V Service procedures Turbo AC D rings H H Gp l l m mj Fure kai b Csr w Tiii Screen 235 Purge vaie ki Operational check Symptom 1 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 a Charge mode b Stand by mode 3 Pressure slow or no build 4 Compressor cycles rapidly 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 amp 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
40. excessive oil in cavity compressor may oa om amp W N 10 11 12 require servicing Clean the cavity thoroughly Remove two 2 or one 1 o ring s from seal retainer Install new o rings on seal retainer Three 3 o rings are required Lubricate all o rings on new valve spindle and seal retainer before installing in housing Lubricate bores in valve housing Install valve spindle assembly into housing bore small end first and spring to outside as shown in drawing Make sure spindle is completely engaged in cavity and moves freely Install retainer Apply grease to threads of retainer bolts Install retainer bolts and tighten to 10 15 ft lbs 79 80 Service procedures H C Dual Turbo 2000 224P Deant Miran pis carindge ae Desiccant Cartridge Service Kit T224 P Note two 2 cartridges on dryer 1 per kit Cartridge ihat Gasket Dering D ring Aber Fils Warning Before proceeding read and follow safety precautions found on page 17 Filter late Far plate Casert or ns Peg er Gernket c O ring Art year D ring ic r F x to I Srl Operational check Symptom 1 Regular service interval 2 Water or contamination in tanks Symptom 1 amp 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 Hi
41. from the compressor into the air dryer Air flows past filters and desiccant bed stripping moisture and contaminants from the air and exits 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 an air signal through the governor line to the air dryer opening purge valve and closing turbo 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 Turbo boost from the compressor is checked at inlet of the 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 Charge cycle Purge cycle WiClean dry air E Atmospheric pressure W Dirty wet charged air M Dirty wet purged air Note Approx 95PSI gov cut in 120PSI gov cut out Trouble shooting Turbo 2000 Review Turbo 2000 normal operation cycles prior to trouble shooting Problem system air pressure drops rapidly Remedy Fitti
42. must be such that the dryer air inlet temperature is typically no more than 160 degrees F or no less than 45 degrees F above low ambient Ref SAE J2383 An example of a typical discharge line Total line length 10 ft to 12 ft which is a combination of rigid copper approx 4 ft length and balance of line length being stainless steel braid sheathed PTFE Avoid using 90 degree elbow fittings 4 The air dryer should be mounted in a location with sufficient space around it to facilitate service and to provide visual access for periodic inspection Allow at least 2 00 inch clearance above air dryer for desiccant cartridge service 5 The air dryer should be mounted out of direct tire or wheel road splash or protected from splash 6 The air dryer with its mounting bracket lines and fittings should be mounted in a protected location such that minor mechanical damage to the vehicle will not damage the air system integrity Use mounting bolts that are Grade 5 or higher 17 18 Turbo 2000 parts list Component identification A c E1 F 6 J J z L v 619340 619360 Bold part numbers represent suggested stock service components Dryer part number description STD 620600 620602 620606 bracket to match T2000 hole pattern 221 A For right hand models see parts list on pages 139 amp 140 Turbo 2000 service schematic 19 20 Turbo 2000 normal operation cycles use with Turbo boosted compressors Air flows
43. outlet above inlet port port to air line leading to wet tank 5 Connect air line from governor UNL port to the air dryer 4 NPT unloader directly below inlet port port Note For continuous pumping air system first install a governor if one is not present Connect governor RES port to wet tank with a 3 NPT line 6 For Turbo 2000 and HD 2000 only mount purge tank A drilling template is included Turbo 3000 move onto item 8 7 Connect the 3 8 NPT air dryer purge port opposite side to outlet to purge tank Included with purge tank kit is fittings and 3 8 plastic line Plug the remaining tank ports 8 Connect lead wire coming from harness connector terminal B to a good chassis ground 9 Connect lead wire coming from wire harness connector terminal A to a 12 or 24 volt source 10 Plug in wire harness connector to heater connector on air dryer Note the connector will plug in only one direction a The heater is thermostatically controlled on at 35 F off at 55 F The heater should be connected to 12 or 24 volt source which is hot only when the ignition key is on The 12 volt 75 watt heater will draw 6 6 amps A 24 volt 75 watt heater will draw 3 2 amps Check for proper operation 1 Double check all hoses and fittings for tightness Start vehicle and allow system pressure to build 2 Relieve pressure and cycle several times 3 No air should flow from exhaust port while the syste
44. to air dryer outlet port 92 Service procedures Turbo 3000 ee owner Turbo Valve Service Kit 228 Warning Read and follow safety precautions found on page 17 before proceeding r Symptom 1 Dryer frequently exhausts 2 Air continually flows from exhaust port when compressor is in standby mode 3 System pressure drops very rapidly Note The above symptoms could also lead to Check valve replacement Operational check Symptom 1 2 amp 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 Turbo valve replacement 1 2 3 4 o Neo 10 11 12 13 Drain the air system Disconnect the heater wiring Disconnect the inlet and control lines from their respective ports Remove 8 bolts from bottom cap and set aside Discard gasket Remove turbo nut valve stop and valve and discard Clean cavity area thoroughly Lightly coat the 2 small o ring surfaces and install on piston Carefully install valve in cavity with tapered side up Place valve stop on top of valve concave side down Lightly lube large o ring and place on nut Install flat seal into nut Install nut and tighten to 40 45 ft lb Place gasket on bottom cap aligning all holes Locate
45. tubing connecting air control valve and valve Repair replace air line s tubing copper line or 12 feet of housing and or manifold damaged or missing steel braided Teflon Line between the compressor and air dryer too short Fit new line with a minimum length of 6 feet insufficient pre cool 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 im N DH O ring F 235 Purge vabas ki 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 3 Pressure slow or no build Operational check 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 56 con t
46. visible If that is oily service is needed Trouble shooting information is available in SKF Service Manual 457938 Service Under normal operating conditions the HC Dual Turbo 2000 is designed for at least a 2 year service interval The newer the compressor and the lighter the duty cycle the better service life for the cartridges At service interval be sure to replace o 2 T224 P desiccant cartridges B o 2 619938 inlet check valves ee TEE sone service An ove o 2 235 purge valves o 1 238 outlet check valve Check condition of safety valve 619740 and replace as needed Check continuity of heater 619110 12V or 619111 24V with an ohmmeter Replace if no continuity is present SKF offers service kit 619979 24V heater that includes all of the above along with fresh casting bolts PURGE TANK AIR PRESSURE f PURGE TANK AIR PRESSURE Installation Instruction Brakemaster Turbo 2000 HD 2000 and Turbo 3000 Turbo 2000 Desiccant air dryer with turbo boost protection Available with E Type feed back feature for Holset compressors Requires purge tank with minimum 300 cu in purge volume HD 2000 Desiccant air dryer for DLU Discharge Line Unload or continuous pumping compressors and non turbo boosted compressors Requires purge tank with minimum 300 cu in purge volume Turbo 3000 Desiccant air dryer with turbo boost protection Available with E type feed back feature for Holset compressors
47. with Dual Turbo 2000 amp HC Dual Turbo 2000 Use T334 for Turbo 3000 2 Replace purge valves s 235 3 Replace check valve 238 4 2000 5 6 Replace filter 240 for Brakemaster AC only Replace safety valve every 5 years regardless of model Replace inlet check valves 619915 2 Dual Turbo 2000 619938 HC Dual Turbo Service kit 619340 includes T224 235 228 and 238 Service kit 619360 includes T224 P 235 228 and 238 Preventative maintenance recommended yearly intervals Turbo 2000 3 2 2 1 N R not recommended for application ma N R Turbo 3000 HD 2000 ns zje zZ lt 7 I N R Turbo AC Dual Turbo 2000 HC Dual Turbo 2000 z n inm w es zZ a zZ a A ISIS d d ea ea ISIS d d zZ yu 117 118 Tech Tip 2 Servicing Turbo series desiccant cartridge 1224 The service of the SKF Turbo series desiccant cartridge T224 is quick and easy especially if you follow the instructions The cartridge is spin on spin off similar to an oil filter Application Turbo 2000 HD 2000 HC Dual Turbo 2000 and Dual Turbo 2000 Service intervals Desiccant life is directly impacted by oil blow by from the compressor The compressor will tend to spill more oil when it runs hot from frequent use In general a high duty application such as transit will experience more oil traveling downstream Also as compressors age the air quality d
48. 2 Unit dimensions 130 con t 5 Plug one female connector of the triple connector wire harness into the air dryer heater receptacle and the other female connector of the triple connector wire harness into the receptacle connected to MLT 6 Connect the male connector of the triple connector wire harness to the female connector of the pig tail lead Note The connectors will connect plug in only in one direction 7 The heater is thermostatically controlled ON at 35 deg F and OFF at 55 deg F 8 To prevent damage properly secure harness lead wires and seal any wire splices Start up Operation check 1 Close drain cocks on all reservoirs 2 Start engine and allow pressure in air system to build to required cut out pressure 3 Check air line fittings for leaks and repair any leaks 4 Allow vehicle air compressor to cycle a few times through low cut in and high cut out pressures by applying vehicle brakes to release system air pressure Air dryer operation Cycle 1 The MLT device controls drying and regeneration cycles of 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 air dryer during the compressor charge cycle pumping During the charge cycle one dryer cartri
49. 2 governor malfunctioning Replace governor 51 52 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 Worn purge valve or dirt foreign material is stuck in Clean cavities and replace purge valve assembly 235 the purge valve Worn inlet check valve Clean cavity and replace valve assembly 619915 Ice has formed in purge and or inlet check valves Replace heater assembly 619110 12V or valves heater assembly malfunctioning 619111 24V Possible cause Fittings are loose or damaged Air reservoir tubing or hoses are damaged The air compressor needs to be serviced or replaced Worn purge valve or dirt foreign material is stuck in Clean cavity and replace the purge valve assembly 235 the purge valve The air compressor capacity is too low for vehicle Install larger air compressor Line between governor and air compressor is Replace the line or remove the blockage blocked The safety valve is malfunctioning Replace the safety valve 610024 Worn inlet check valve Clean cavity and replace valve assembly 619915 Ice has formed in purge and or inlet check valves Replace heater assembly 619110 12V or 619111 24V heater assembly malfunctioning D2 governor malfunctioning Replace D2 governor Air line tubing connecting dryer manifold and air Repair replace air line tubing contr
50. 4 NPT Exhaust port Fig 1 Unit dimensions m F CE G Resevoir gt mini Dut to a wet tar k j system U Y Y i an ri I 6 Compressor Sr Fi discharge Governor r A Purge air tank 300 Ci Min f r y Compressor Outlet port 1 2 NPT as 2 Inlet port N Heater elec connect 1 2 NPT 12 or 24 Volt D C Control part Fi sien NP nf gt Fig 2 Connection schematic x Exhaust port Note Mount purge tank higher than purge tank port on air dryer Use the purge tank port that is in the lowest position so that moisture can run down into the air dryer for expulsion If it is not possible install a petcock for periodic manual draining HD 2000 continuous flow The SKF Brakemaster HD 2000 is designed to provide optimum protection for naturally aspirated compressors and systems employing continuous pumping compressors Discharge Line Unload A four way filtration system consisting of three filter screens a unique filtering bag plus four pounds of high quality molecular sieve desiccant strips away moisture and traps contamination The spin off cartridge can be serviced in minutes The compact purge tank can be installed anywhere and provides a full 460 cu in of clean purge air Improve the overall performance of your air system by upgrading to the Filtration Plus option Not only does this reduce the operating costs o
51. Check valve kt z TURBO 2000 ma Check Valve Service Kit 238 ke ea Warning Read and follow safety precautions prag found on page 17 before proceeding wii L l eee Symptom 4 Ss ee a 1 Dryer frequently exhausts Ar Hi 2 Air continually flows from exhaust port i T when compressor is in standby mode Lh 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 style air dryers Operational check Symptoms 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 turbo valve Check 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 7 Using grease supplied apply a light coating on o ring Install o ring on nut 8 Apply a light coating of grease to threads of nut Install nut and tighten to 60 ft Ib 9 Re connect air line
52. Service to the Turbo 2000 should include e Replace Desiccant cartridge T224 upgrade contaminant filtration with T224 P Clean port area and replace purge valve 235 Clean bottom cap and replace turbo valve 228 Clean port area and replace check valve 238 All above are included in 619340 or 619360 for T224 P 123 124 Tech Tip 5 HC Dual Turbo 2000 High output aggressive environments Fall maintenance recommendations Good maintenance practices include the inspection and service of the air system and its components To facilitate this valuable program SKF offers service kit 619979 for the HC Dual Turbo 2000 so that all the parts are accounted for and in one easy to access spot Follow these guidelines for inspection and service Inspection Check the condition of the air dryer and connections Look for damage or loose fittings Examine and compare the outlet of BOTH exhausts If one is excessively dirtier than the other service is needed Perform a cycle check o Deplete air supply allow air to build under high idle to cut out when air dryer exhausts measuring the time This should not take more than a couple of minutes from zero o After cut out measure the time until the next cut out This should take more than 7 minutes if the vehicle is resting at idle o If either of those conditions is not met service is required Remove cartridges and look up into center A filter positioned just inside the air flow exit point will be
53. afety valve 619740 Ice has formed in the purge valve Replace heater assembly 619110 12V or 619111 24V D2 governor malfunctioning Replace D2 governor Problem air dryer does not exhaust during compressor standby mode Remedy The line between the air governor and the air Install or replace the air line or tighten the fittings dryer control port is missing leaking or damaged Clean cavity and replace purge valve assemblies 235 Replace heater assembly 619110 12V or 619111 24V Replace heater assembly 619110 12V or 619111 24V Align purge valve sleeves Problem safety valve opens Remedy Air dryer check valve is blocked Clean cavity and replace check valve assembly 238 Air brake system is blocked down stream of air Remove blockage or replace the necessary components dryer Air compressor governor malfunctioning Replace compressor D2 governor Blocked desiccant cartridge Replace cartridge T224 P The safety valve is malfunctioning Replace the safety valve 619740 Air compressor service may be required to address excessive oil blow by Problem water accumulation in air system tanks Replace both desiccant cartridges T224 P The air compressor capacity is too low for Install larger air compressor and replace desiccant cartridges T224 P vehicle The line between the purge tank and the Install or replace the air line or tighten the fittings air dryer control port is missing leaking or damaged Line bet
54. all nut and tighten to 60 ft Ib 9 Re connect air line to air dryer purge tank port Om amp W PN 41 Service procedures HD 2000 Ade Check valve kE Bal Space ZPiT Li ning h AJ i rah 42 HD200O Check Valve Service Kit 238 Warning Read and follow safety precautions found on page 17 before proceeding Ma Bi ee ea 1 Dryer frequently exhausts 2 Air continually flows from exhaust port j when compressor is in standby mode 3 Wet tank pressure drops rapidly Operational check Symptom 1 2 amp 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 Check 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 7 Using grease supplied apply a light coating on o ring Install o ring on nut 8 Apply a light coating of grease to threads of nut Reinstall nut and tighten to 60 ft Ib Re connect air line to air dryer outlet port Service procedures HD 2000
55. all 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 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 65 Service procedures Dual Turbo 2000 Micro Logic Timer MLT Service Kit 619912 12V 619924 24V a H 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 to allow regeneration air flow at 90 second intervals mit Note A light flow of air from ONE exhaust port during charge cycle is normal regeneration air flow Mico logie timer LT kt 619712 12V amp 619924 24v 2 Water in air tanks Operational che
56. allow air to pass into the compressor causing a rapid cycle UNLOAD PURGE CYCLE SKF E type air dryers use a 50 in the part number 620502 and have a label specifying its use with E type compressors a WARNING This Air Dryer is compatible with Holset QE amp SS E type air compressors Air Dryer exhaust at high pressure Wear eye protection while servicing 628775 01 k 121 122 Tech Tip 4 Turbo 2000 Fall maintenance recommendations As a matter of good practices a fall inspection and preventative maintenance program of the air dryer will prepare your vehicle for the winter ahead Follow the recommendations below to gain the full benefits from an air dryer designed to handle the most severe conditions The function of a Turbo 2000 is to collect and remove solid liquid and vapor contaminants from the air system and deliver clean dry air to the reservoir tanks These tanks provide air to the components of the brake system as well as any other air actuated componentry on the vehicle Turbo 2000 comes in two distinct variations The 500 ie 620500 series is designed for Holset E Type compressors E Type compressors have special plumbing considerations that the E type compatible SKF air dryers contain The Holset E Type compressors are mainly found on Cummins engines and some Mack but have not been an OE option for several years The 600 ie 620600 series should be used on all other compressors
57. amp 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 Disconnect the air line at air dryer purge tank port nom KRUN Drain the air system Remove regeneration valve nut Remove and discard o ring spring and spindle Clean nut and cavity Position new spindle in the cavity with spring pocket side out Install spring Using grease supplied apply a light coating on o ring Install o ring on nut Apply light coating of grease on nut threads Install nut and tighten to 60 ft Ib Re connect air line to air dryer purge tank port Service procedures Turbo 2000 H738 Check wake in D Pro Check Valve Service Kit 238 en Warning Read and follow safety precautions found on page 17 before proceeding Symptom E 1 Dryer frequently exhausts Ch LH 2 Air continually flows from exhaust port when compressor is in standby mode TI 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 Operational check Symptom 1 2 amp 3 Start engine and build to cut out pressure Stop engine Allow one minute for pur
58. anks 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 Charge cycle Purgeunload cycle Len vie Left cece Figa thle Banar wire 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 system air pressure drops rapidly Fittings are loose or damaged Tighten and or replace as necessary Air reservoir tubing Repair or replace as necessary or hoses are damaged Worn check valve Clean cavity and replace ch
59. ater element F and thermostat cavity rik u Screws 7 Insert heater element into hole and twist Lom h a al slightly to spread anti seize k 7 1 Early models orange amp blue lead wires Kit 246 or 247 t ing Poarn cube vertical mount Kit 248 or 249 horizontal mount 7 2 1 Install new set screw until snug 619110 120 8 619111 24 heater bits 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 Note If heater cover is not used use short screws and wire clamps to secure thermostat and wires 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 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
60. bove air dryer for desiccant cartridge service The air dryer should be mounted out of direct tire or wheel road splash or protected from splash The air dryer with its mounting bracket lines and fittings should be mounted in a protected location such that minor mechanical damage to the vehicle will not damage the air system integrity con t Mounting procedure Note Dryers with a steel line that runs from top to bottom on outside of dryer are for use with Holset E Type compressors 1 Drain all air from air reservoirs Note The presence of excessive oil is a sign that compressor requires service Mount air dryer Tighten nuts to 25 30 ft lbs 3 Connect the compressor discharge line to air dryer s 1 2 NPT inlet lower side of dryer port Connect the air dryer s 1 2 NPT outlet top of dryer port to air line leading to wet tank Connect air line from governor UNL port to the air dryer s 1 4 NPT unloader directly below inlet port port Connect lead wire coming from harness connector terminal B to a good chassis ground Connect lead wire coming from wire harness connector terminal A to a 12 or 24 volt source Plug in wire harness connector to heater connector on air dryer Note the connector will plug in only one direction a The heater is thermostatically controlled ON at 35 F OFF at 55 F The heater should be connected to 12 or 24 volt source which is hot only when the ign
61. bove low ambient Ref SAE J2383 An example of a typical discharge line Total line length 10 ft to 12 ft which is a combination of rigid copper approx 4 ft length and balance of line length being stainless steel braid sheathed PTFE Avoid using 90 elbow fittings to avoid water traps freeze ups The air dryer should be mounted in a location with sufficient space around it to facilitate service and to provide visual access for periodic inspection Allow at least 2 00 inch clearance above air dryer for desiccant cartridge service The air dryer should be mounted out of direct tire or wheel road splash or protected from splash The air dryer with its mounting bracket lines and fittings should be mounted in a protected location such that minor mechanical damage to the vehicle will not damage the air system integrity con t Mounting procedure Note Only use E Type Turbo 2000 and Turbo 3000 versions with Holset E Type compressors Use standard dryers for non Holset compressor applications A label on bottom cap identifies the version 1 Drain all air from air reservoirs Note The presence of excessive oil is a sign that compressor requires service 3 2 Mount air dryer Tighten nuts to 25 30 ft Ibs Use the included drilling template to locate and mark the hole locations 3 Connect the compressor discharge line to air dryer 4 NPT inlet between outlet and governor ports port 4 Connect the air dryer NPT
62. ce on nut Install flat seal into nut Install nut and tighten to 40 45 ft lb 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 Re connect inlet and control lines to respective ports Re connect external feed back line if air dryer is so equipped Re connect heater wiring Service procedures Turbo AC Early model Vertical Early model Horizontal 2 248 12V amp 247 24V heater kits 246 12V amp 247 24 heater kits Heater Service Kits 246 247 248 249 619110 619111 Warning Read and follow safety precautions found on page 17 before proceeding Symptom 1 Dryer won t exhaust 2 Exhaust port leak 3 Cannot build pressure Operational check 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 con t L L Late model 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 ass 5 Thoroughly clean entire heater thermostat area 6 Apply a light coating of anti seize to the he
63. ck Symptom 1 amp 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 66 Dual Turbo 2000 Notes 67 68 H C Dual Turbo 2000 parts list Component identification 619933 Manifold mid section assembly with valves 619913 Regeneration valve kit Note Two valves per dryer one on eit
64. cle s compressed air system air quality has become critical A contaminated air system dramatically adds unwanted operating costs that the new Filtration Plus Option can avoid SKF s Turbo 2000 series of air dryers including the HD 2000 and Dual Turbo 2000 have led the field in it s filtration system The new H C Dual Turbo 2000 also comes standard with the Filtration Plus Option Now we have stepped it up a notch with the Filtration Plus cartridge T224 P The Filtration Plus Option provides the same benefits as the current SKF series of air dryers but adds an additional 2 stage high efficiency filter that removes even the finest oil residue The Filtration Plus Option specifically addresses high air volume applications such as transit refuse or cement mixers Compressors with excessive oil blow by will also gain great benefit with the Filtration Plus Option The benefits of the air dryers equipped with the Plus Option are plentiful e Protection of down stream valving that gums up with oil contamination e Improved air capacity Compressor charge times increase as oil and water filled wet tanks reduce air capacity e Improved compressor service life Coked up discharge lines cause the compressor to work harder shortening its service life e Extends air dryer cartridge service life The 2 stage filtration system added to the already extensive cartridge filters extends the service intervals e The 2 stage Fi
65. contact surface of flat gasket d Start cartridge onto thread adaptor being careful not to cross thread Turn cartridge clockwise until flat gasket contacts casting surface After gasket contacts adaptor plate tighten cartridge only 1 2 additional turn Note Do not overtighten cartridge or future removal of cartridge will be extremely difficult 133 134 con t Connecting air lines 1 2 Connect the compressor discharge line to the air dryer s lower 3 4 NPT INLET port Connect the air dryer s 3 4 NPT OUTLET port located at top center to inlet port of 1 air tank wet tank of vehicle Note Use appropriate thread sealant on air line fitting threads to prevent air leaks Connect 1 4 air line from D 2 governor UNL port to 1 4 push connect fitting located on front of dryer Connect purge air tank s 600 cu in minimum to 1 4 port located on air dryer outlet manifold Connecting heater Wire harness 1 The air dryer heater is available in either 12 volt DC or 24 volt DC configuration to match the vehicle electrical system Confirm that voltage of air dryer being installed and vehicle voltage are the same Connect lead wire of the pig tail lead connector coming from connector terminal marked B to a good chassis ground Connect lead wire of the if tail lead connector coming from connector terminal marked A to power source that is powered only when vehicle ignition in ON The powe
66. contaminants For all weather operation the Turbo 2000 is equipped with a sealed 12 Volt or optional 24 Volt 75 watt thermostatically controlled heater e The choice for severe e Turbo boost protected stop and go operations for all engine applications Fully compatible with e Large purge volume for Cummins Holset extended compressor cycles Use HD 2000 for naturally aspirated and discharge line unload DLU applications Turbo 2000 air dryer specifications e Unit dimensions see Fig 1 e Turbo Internal e Weight 19 5 Lbs protection valve e Connection ports see Fig 2 e Safety valve 175 psig e Air flow capacity 30 SCEM e Heater options 12V 75 Watt 6 6 Amps e Drying medium 4 Lbs desiccant 24V 75 Watt 3 2 Amps in trid el oparte Optional 2 stage filtration system e Drying medium External purge tank regeneration 12 X 7 Dia Wat 10 Lbs Volume 460 Cu In 2 00 Minimum clearance required te amp 25 a 116 4 p 547 4 p116 for cartridge service r Ady x 93 t gt Cartridge x a wa 300 6 50 j a Ly m EE v aer my Tumaozoon 3 33 Pi gt re _ Outlet port of P lt fap AI z u n m 1 2 NPT j Purge tanik port T he H Wen HL Tr 38 NPT a f a WALL nwnuuon S anne B wer a ne ee nist aani Paw T pe Heater elec connect J aoe Der y S 12 or 24 Vok D a ri 440 at 1 2 NPT Hr 12 or 24 Vor O GLX T fi t v e410 Control port 1
67. cts are proprietary to SKF Any improper or unauthorized use of these numbering systems including adoption or use of any of their part numbers or part number lists even where the subject of modification or addition is strictly prohibited and will be prosecuted by SKF as a violation of U S and foreign copyright trademark and unfair competition laws In addition use of any SKF trademarks trade names or packaging schemes systems colors or designs is likewise considered a violation of the trademarks trade names and trade identities rights of SKF USA Inc and their affiliates Possible violation of such use should be brought to the attention of SKF SKF USA Inc 890 North State Street Suite 200 Elgin Illinois 60123 Attn Catalog Manager Vocational Matrix ar Dual H C Dual Applications Turbo 2000 Turbo 3000 HD 2000 Turbo AC urbo 2000 Turbo 2000 Linehaul tractor trailer x x Ka x x City pickup delivery emergency rescue On off highway construction mining x x X X x Me Mee Concrete mixer School bus Refuse residential ye yar york york york york Bus travel coach Bus city transit Yard spotter yard jockey Fire truck Small bus RV Air over hydraulic brakes X X X X X X X X X X SS x ea x e x e x e x Central tire inflation Pump off trailer engine mounted compressor Operating parameters Maximum compressor duty cycle 155 au Maximum compressor size 15 CFM 30 CFM
68. d air M Dirty wet purged air Note Approx 95PSI gov cut in 120PSI gov cut out 86 Trouble shooting Turbo 3000 dryer Review Turbo 3000 normal operation cycles prior to trouble shooting on page 86 Air reservoir tubing or hoses are damaged Problem air compressor goes into the standby mode but cycles rapidly Possible cause Worn purge vale Dirt foreign material is stuck in purge valve D2 governor malfunctioning Heater assembly malfunctioning gt 32 F Replace heater assembly 246 12V 247 24V 248 12V 249 24V 619110 12V or 619111 24V 87 88 Problem air compressor runs continuously system pressure will not build Possible cause Fittings are loose or damaged Tighten or replace loose or damaged fittings Air reservoir tubing or hoses are Repair or replace damaged items damaged Air compressor needs to be serviced or Rebuild or replace the air compressor replaced Worn purge valve Clean cavities and replace the purge valve assembly 235 Air compressor capacity is too low for Install larger air compressor and upgrade to Turbo 2000 vehicle Air line between governor and air Replace the line or remove the blockage compressor is blocked The safety valve is malfunctioning Replace the safety valve 610024 D2 governor malfunctioning Replace D2 governor Ice has formed in the purge valve Replace heater assembly 246 12V 247 24V 248 12V 249 24V 619110 12V or 619111 24V Problem air dryer does not
69. d follow safety precautions found on page 17 before proceeding Symptom 1 Dryer won t exhausts 2 Exhaust port leak 3 Cannot build pressure Operational check 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 Thoroughly clean entire heater thermostat area 6 Apply a light coating of anti seize to the heater element and thermostat cavity Oo 31 2 32 con t 7 Insert heater element into hole and twist slightly to spread anti seize 7 1 Early Models 248 or 249 orange and blue wires Install new set screw if required until snug DO NOT OVER TIGHTEN Screw will protrude from bottom cap about 1 8 Insert thermostat into position in thermostat cavity Coil lead wires around heater cover posts allowing wires to protrude through slots in cover 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 7 1 6 lf 1 8 NN 7 2 11 7 1 2 1 71 2 2 71 23 71 2 4 1 1 2 5
70. de of adapter plate castings of oil and contaminants Service of turbo valve is recommended at this time also Refer to service procedures on page 25 Place new gasket on bottom cap bolt flange 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 Re install bottom cap assembly to adapter plate casting Torque 8 bolts to 25 50 ft lbs Clean top surface of adapter plate and threaded stud Position a new filter element around cartridge stud and onto adapter plate Using grease supplied apply a light coating of grease onto o ring Install o ring onto threaded stud Important for easy removal Apply a generous coat of grease on the new desiccant cartridge gasket surface Thread new cartridge onto stud turning clockwise When gasket contacts adapter plate tighten cartridge 1 2 turn Do not overtighten Re connect airlines to air dryer inlet and control ports Re connect heater lead wire Note Cartridge Stud Kit 619140 available if stud needs replacing Fig 1 Kat 7 224 P Service procedures Turbo 2000 ae Early model Late model P 2272802008 Heater Assy a y Hentar Ass lower F i ew Mi Srem BEER ee a IE O 1 LO Ring Foam cube 248 12V amp 249 24W Heater kits 679700 11 amp 619011 4 Heater kts Heater Service Kit 248 249 619110 619111 Warning Read an
71. dge is drying air and other cartridge is being regenerated 3 During the compressor charge cycle there will be a light flow of air from ONE exhaust port located at bottom of air dryer base This is normal regeneration air flow and should be present ONLY when the compressor is in charge cycle pumping This air low will alternate from one exhaust port to the other in conjunction with the MLT cycles ref step 1 If the air dryer cycle alternates during the compressor charge cycle pumping there will be a momentary burst of air from dryer exhaust port This is normal and is beginning of the regeneration air flow Alternately if the compressor is not in charge cycle no air will flow from either exhaust However the indicator light will go on and off every 90 seconds regardless of compressor cycling E 131 132 Installation Instruction Brakemaster HC Dual Turbo 2000 Warning Safety precautions 1 Before performing any test and or isolating the air dryer the vehicle s wheels must be chocked making sure the vehicle will not roll before releasing the brakes 2 Never work under a unit supported only by a jack Always support the vehicle with stands 3 Stop engine when working under vehicle 4 Never remove a component or a pipe plug unless you are certain all system air pressure has been exhausted Never connect or disconnect a hose or line containing air pressure 6 Never exceed recommended maximum working air pre
72. eck valve assembly 238 Worn inlet check valves Clean cavity and replace inlet check valve assembly 619938 Worn purge valve seals Clean cavity and replace purge valve assemblies 235 Problem air compressor moves into the standby mode but cycles rapidly Possible cause Fittings are loose or damaged Tighten and or replace as necessary Air reservoir tubing or hoses are Repair or replace as necessary damaged Problem air leaks from the exhaust port during compressor charge mode Remedy Worn purge valves Clean cavities and replace purge valve assemblies 235 Dirt foreign material Clean cavity and replace valve assemblies 235 is stuck in the purge valves D2 governor malfunctioning Replace D2 governor Heater assembly malfunctioning gt 32 Replace heater assembly 619110 12V or 619111 24V degrees 71 72 Problem air compressor runs continuously system pressure will not build Remedy Fittings are loose or damaged Tighten or replace loose or damaged fittings Air reservoir tubing or hoses are damaged Repair or replace damaged items The air compressor needs to be serviced or Rebuild or replace the air compressor replaced 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 Line between governor and air compressor is Replace the line or remove the blockage blocked The safety valve is malfunctioning Replace the s
73. ed up to 15 cfm Refer to vehicle manufacturer for specific test procedures for non related air dryer components 89 Service procedures Turbo 3000 batt Purge Valve Service Kit 235 Warning Read and follow safety precautions found on page 17 before proceeding Po Dn Symptom hes i i z 1 Dryer won t exhaust Tam ils i 2 Air leak at exhaust port during the Pride Ls a Charge mode b Stand by mode a 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 amp 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 amp 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 A
74. egrades When enough oil has infiltrated the desiccant bed moisture will pass on into the air system Thus below are typical service life expectations Line haul 3 years Refuse 1 year Off highway 1 year Inner City 2 years Transit 1 year Of important note using T224 P with extra filtration will protect the desiccant longer from contaminants and result in lengthening the service intervals Add 1 year to the above for estimated service life s con t Installation tip Be sure to follow all of the instructions located in box There are 2 important steps that will allow the next service to also be quick and easy 1 Lubricate the o ring and rubber gasket with the lubricant provided This step will prevent the rubber from sticking to the base making removal easier Cartridge Tea Gasket E a Lubricate o ring Filter e and gasket gt O ring f Filter plat FI WU Gasket ur 2 Do not over tighten the cartridge while installing When the rubber gasket contacts the base only further tighten turn No more Over tightening even with the gasket and o ring properly lubricated can make removal difficult 119 con t Removal tip Be sure to follow all of the instructions located in box Once pressure is relieved use a strap wrench and turn cartridge counter clockwise If it is difficult to remove or if the can spins without loosening try these tips 1 Using a thin blade such as a putty knife
75. eling buses as well as off road applications that use all types of air actuated valves The Dual Turbo 2000 offers a compressor air flow output of up to 40 CFM and up to 100 percent compressor duty cycle The unit requires no purge tank and has an internal timer to control cycles With the addition of the H C Dual Turbo 2000 the SKF Brakemaster line of dual air dryers now can meet the requirements of the high output compressors required on 2010 and later model transit bus engines The new H C Dual Turbo 2000 is ideal for large compressor output applications and is available in 12V 75W 6 6 amps and 24V 75W 3 2 amps options Additionally it can withstand compressor air flow out put of up to 80 CFM and up to 40 percent compressor duty cycle The H C Dual Turbo 2000 includes the same internal filtration package as the standard Dual Turbo 2000 air dryer with 99 9 percent efficiency H C Dual Turbo 2000 Dual Turbo 2000 specifications Each version of the Dual Turbo 2000 is designed to meet the specific and difficult air quality demands found in high volume applications Large inlet and outlet ports minimize pressure drop easing the burden on the compressor and extending its service life To learn more about which Dual Turbo 2000 unit is more appropriate for your application please reference the chart below Operating parameters H C Dual Turbo 2000 Dual Turbo 2000 Maximum compressor duty cycle 100 80 CFM 20 CFM ee ee Ves
76. epair or replace as necessary damaged Worn check valve Clean cavity and replace check valve assembly 238 Worn purge valve seal Clean cavities and replace purge valve assembly 235 Possible cause Wom pure vale Dirt foreign material is stuck in the Clean cavities and replace the purge valve assembly 235 purge valve D2 governor malfunctioning Replace D2 governor Heater assembly malfunctioning gt 32 Replace heater assembly 246 12V 247 24V degrees 248 12V 249 24V 619110 12V or 619111 24V Problem air compressor runs continuously system pressure will not build Possible cause Fittings are loose or damaged Tighten or replace loose or damaged fittings Air reservoir tubing or hoses are Repair or replace damaged items damaged Air compressor needs to be serviced or Rebuild or replace the air compressor replaced Worn purge valve Clean cavities and replace the purge valve assembly 235 The air compressor capacity is too low Install larger air compressor for vehicle Line between governor and air Replace the line or remove the blockage compressor is blocked The safety valve is malfunctioning Replace the safety valve 610024 Ice has formed in the purge valve Replace heater assembly 246 12V 247 24V 248 12V 249 24V 619110 12V or 619111 24V D2 governor malfunctioning Replace D2 governor 37 38 Problem air dryer does not exhaust during compressor standby mode Possible cause Line between the
77. erational checks may be found in service guide 457938 or on website at www vsm skf com Monthly Drain reservoirs If moisture or oil is present perform functionality checks Replace components as needed Replace cartridge Annually Check air dryer functionality All dryers except Dual Turbo 2000 includes HC Dual Turbo 2000 1 Build up pressure from O to cut out should take less than 3 minutes a If it takes longer than 3 minutes check to see if air is escaping out of exhaust port i Yes check purge valve and governor Check heater if temperatures below 35 F ii No check for leaks at safety valve dryer body and air system by applying soapy water spray 2 Time between dryer unloads should take more than 8 minutes while vehicle is at rest a If time is somewhat less than 8 minutes check for air leaks at safety valve dryer body and air system by applying soapy water b If time is significantly less than 8 minutes check purge valve turbo valve w E type design dryers only and check valve Also check at compressor with E type dryer This style of dryer re directs air pressure back to the compressor during stand by E type dryers should only be used with Holset QE compressors Others may leak and cause a frequent cycle 3 Check functionality of safety valve a Plug outlet of air dryer and install pressure gage at inlet of air dryer Allow pressure to rise to 180 psi i If pressure leaks at 175 psi replace safety valve i
78. es regular servicing at intervals determined by compressor duty cycle or type of driving conditions Typical service intervals are Line haul 3 years Inner city 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 29 30 8 9 10 20 21 11 12 hs ha ja ps pe NDNA he go Ke 2 con t Remove filter plate if present and gasket s from bottom cap and discard Clean bottom cap sump cavity gasket surface and insi
79. ew set screw if required until snug Do not overtighten Screw will protrude from bottom cap about 1 8 Insert thermostat into position in thermostat cavity Coil lead wires around heater cover posts allowing wires to protrude through slots in cover 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 7 1 6 7 1 1 7 1 8 7 2 11 7 1 22 7 1 2 1 7 1 2 2 7 1 2 3 71 2 4 7 1 2 5 7 1 2 6 Fill heater cover through 1 4 hole with non corrosive RTV Connect blue heater wire to a good chassis ground Connect orange wire to ignition switch Seal and route heater wires carefully Late Models 619110 or 619111 plug style connection Slide o ring over heater and thermostat into position around connector flange Slide o ring over heater and thermostat into position around connector flange Slide heater and thermostat into position in cavity Ensure thermostat sits flat in cavity Place foam cube on top of thermostat and bring heater connector into position over heater Secure heater assembly using the 2 8 32 x 1 2 screws 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 97 98 Turbo AC parts list Component identification a eaor Bo
80. exhaust during compressor standby mode Line between the air governor and the Install or replace the air line or tighten the fittings dryer control port is missing leaking or damaged Worn purge valve Clean cavity and replace purge valve assembly 235 Ice has formed in the purge valve Replace heater assembly 246 12V 247 24V 248 12V 249 24V 619110 12V or 619111 24V Heater is malfunctioning Replace heater assembly 246 12V 247 24V 248 12V 249 24V 619110 12V or 619111 24V Purge valve sleeve is misaligned Align purge valve sleeve Problem the safety valve opens The air dryer check valve is blocked Clean cavity and replace the check valve assembly 238 The air system is blocked down stream Remove blockage or replace necessary components from the air dryer Malfunctioning D2 governor Replace the D2 governor Blocked desiccant cartridge Replace cartridge 1334 The safety valve is malfunctioning Replace the safety valve 610024 Problem water accumulation in air system tanks Desiccant is contaminated Replace desiccant cartridge 1334 or upgrade to Turbo 2000 Air compressor capacity is too low for vehicle Install larger air compressor and upgrade to Turbo 2000 Line length between the compressor and air dryer Fit new line with a minimum length of 6 feet insufficient pre cool copper or 12 feet of steel braided Teflon Air dryer capacity is too low for compressor Upgrade to Turbo 2000 Note Turbo 3000 is rat
81. f the air dryer by extending the cartridge service life but also optimizes the air system efficiency by reducing compressor burden caused by downstream contaminants For all weather operation the HD 2000 is equipped with a sealed 12 Volt or optional 24 Volt 75 watt thermostatically controlled heater e Top performance for continuous flow air systems e Large purge volume and desiccant bed keep the air system clean amp dry e Unique internal pump through design means cooler running compressors HD 2000 air dryer specifications e Unit dimensions e Weight e Connection ports e Air flow capacity e Drying medium 1 TE 16 50 i lt 33 te Fig 1 Unit dimensions Governor essor e Drying medium regeneration see Fig 1 19 5 Lbs see Fig 2 30 SCFM 4 Lbs desiccant Spin on cartridge e Safety valve e Heater options External purge tank 12 X 7 Dia Wot 10 Lbs Volume 460 Cu In 175 psig 12V 75 Watt 6 6 Amps 24V 75 Watt 3 2 Amps Optional 2 stage filtration system r200 Minimum clearance required i for cartridge service 44 93 1 n Cartridge 4 dots 3 00 L i tT lt gt a 75 Outlet port 5 1 2 NPT Ha w SS if a pa J Iniet port P a 1 2 NPT Control port 1 4 NPT Compressor discharge Outlet port 1 V2 NPT Inlet port 1 2 NPT Control port 1 4 NPT seid rh Purge tank port
82. g gaskets O O re 610277 flmesmn OOS p 610069 searen o a o Fiter repiacement I pes o S iter sevew et OOOO 619087 24V M e1002 safey vave Ss O OoOo PN 235 Purge valve kit S 0 etyciveow versen matas O o 247 24V 50W Vertical installation ora je OoOO 249 24V 75W Horizontal Installation sim 2iv75m___ tPugstecomecon O 619111 24 V 75W Plug style connection P 619900 0 Wrehames CC Fa 610851 Bracket assembly old syle not show Feed back line Holset E amp QE type compressor S Turbo valve kit Bold part numbers represent suggested stock service components Dryer part number description A For right hand models see parts list on page 140 Turbo AC service schematic En 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
83. ge 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 7 Using grease supplied apply a light coating on o ring Install o ring on nut 8 Apply a light coating of grease to threads of nut Install nut and tighten to 60 ft Ib 9 Re connect air line to air dryer outlet port 27 2 28 Service procedures Turbo 2000 H728 Turbo Wake Ki EL 77902000 u Turbo Valve Service Kit 228 Warning Read and follow safety precautions found on page 17 before proceeding gt tH Lit hy Symptom 1 Dryer frequently exhausts 2 Air continually flows from exhaust port Ep m when compressor is in standby mode 3 System pressure drops very rapidly Note The above symptoms could also lead to Check valve replacement Operational check Symptom 1 2 amp 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
84. ghway 2 years Desiccant Cartridge Filter Element and Internal Filter Plate Replacement Relieve all system air pressure Disconnect heater lead wire from air dryer Disconnect air line from dryer inlet port I wm PR 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 studs and filter elements if present e Pe rR PrP PR NO oO rw j 00 20 21 con t Remove four 4 3 8 allen head bolts located at top of adapter plate castings Remove twelve 12 3 8 hex head bolts attaching bottom valve housing to adapter plate castings Remove bottom valve housing assembly Remove two filter plates gaskets and o rings late model version only and discard Clean valve housing sump gasket surface and inside of two 2 adapter plate castings of oil and contaminates Place new gasket or o ring at each valve housing bolt flange 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 Re install valve housing assembly to adapter plate castings
85. gs Air reservoir tubing or hoses are damaged Repair or replace damaged items The air compressor needs to be serviced or Rebuild or replace the air compressor replaced Worn purge valve Clean cavity and replace the purge valve assembly 235 The air compressor capacity is too low for vehicle Install larger air compressor Line between governor and air compressor is Replace the line or remove the blockage blocked The safety valve is malfunctioning Replace the safety valve 610024 Ice has formed in the purge valve Replace heater assembly 246 12V 247 24V 248 12V 249 24V 619110 12V or 619111 24V D2 governor malfunctioning Replace D2 governor Problem air dryer does not exhaust during compressor standby mode The line between the air governor and the air Install or replace the air line or tighten the fittings dryer control port is missing leaking or damaged Worn purge valve Clean cavity and replace purge valve assembly 235 Ice has formed in the purge valve Replace heater assembly 246 12V 247 24V 248 12V 249 24V 619110 12V or 619111 24V Heater is malfunctioning Replace heater assembly 246 12V 247 24V 248 12V 249 24V 619110 12V or 619111 24V Purge valve sleeve is misaligned Align purge valve sleeve Problem safety valve opens Air dryer check valve is blocked Clean cavity and replace check valve assembly 238 Air brake system is blocked down stream of air Remove blockage or replace the necessary co
86. heater L H Turbo 2000 w Filtration Plus dryer only 24V heater R H HD 2000 w Filtration Plus dryer only 24V heater L H Turbo 2000 E type w tank kit w 12V heater R H Turbo 2000 w tank kit w 12V heater L H Turbo 2000 E type dryer only w 12V heater R H Turbo 2000 E type dryer only w 12V heater L H Turbo 2000 E type w tank kit w 24V heater R H Turbo 2000 w tank kit w 24V heater L H Turbo 2000 E type dryer only w 24V heater R H Turbo 2000 E type dryer only w 12V heater L H Turbo 2000 E type dryer only w 12V heater L H Turbo 3000 E type w 12V heater R H Turbo 3000 w 12V heater SAE design L H Turbo 3000 E type w 24V heater L H Turbo 3000 E type w 12V heater amp Retrofit bracket Note Bold part numbers represent suggested stock service components 139 140 Desiccant air dryers cont 620550 620551 620552 620554 620556 620557 620559 620600 620602 620603 620604 620606 620640 620642 620806 620910 620912 L H HD 2000 w tank kit w 12V heater R H HD 2000 w tank kit w 12V heater L H HD 2000 dryer only w 12V heater L H HD 2000 w tank kit w 24V heater L H HD 2000 dryer only w 24V heater R H HD 2000 dryer only w 24V heater R H Turbo 2000 dryer only 24V w o bracket Standard Non E type L H Turbo 2000 12V heater w tank Standard Non E type L H Turbo 2000 dryer only 12V heater Standard Non E type R H Turbo 2000 dryer only 12V heater Standard Non E type
87. heir essential purpose so long as SKF is willing and able to perform to the extent and in the manner prescribed in this limited warranty SOME STATES OR PROVINCES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR CERTAIN LIMITATIONS REGARDING WARRANTY RIGHTS SO THE ABOVE EXCLUSIONS OR LIMITATIONS MAY NOT APPLY TO YOU This limited warranty gives you specific legal rights and you may also have other rights which vary by state or province INFORMATION AND RETURNS This catalog refers to products as designed prior to its publication and does not cover product changes made after its publication date Inquiries can be directed to SKF Customer Service Department 890 North State Street Suite 200 Elgin IL 60123 or call 1 800 882 0008 Any error in shipment for over shipments in the quantity of product or for product not matching purchaser s description given in its order is returnable for credit or replacement by SKF provided that SKF is advised in writing by purchaser of such non conformance within 30 days after the product s delivery to purchaser and only after written authorization therefore is given by SKF Approved returns must be shipped freight prepaid and arrive in good saleable condition to qualify for credit or replacement SKF shall not otherwise be obligated to accept the return of any products sold or distributed by it NOTICE The SKF part numbering systems for the SKF produ
88. her side 610077 Body gasket 610069 Seal retainer Note Four retainers per dryer two on either side Desiccant cartridge with Filtration Plus Check valve nut Check valve kit Valve TE complete ae 24V heater amp housing bolts 235 Purge valve kit e Note Two valves per dryer one on either side J 1619110 12 Volt heater kit 24 Volt heater kit K Wire harness L Safety valve 200 psi 619938 Inlet check valve kit Note Two valves per dryer one on either side N 619980 Mounting bracket 619140 Cartridge stud 619973 Control line service kit not shown 619979 A kit contains 2 T224 P 2 235 2 619938 1 238 1 619111 1 619740 amp 12 housing bolts Bold part numbers represent suggested stock service components Air dryer part number description 620930 24 V DLU application w o purge tanks min 600 cu in purge volume required 620980 12 V with 2 221 purge tanks 620982 12 V without purge tanks min 600 cu in purge volume required 24 V without purge tanks min 600 cu in purge volume 620986 24 V with 2 221 purge tanks 619228 Purge tank kit w 690 cu in purge volume H C Dual Turbo 2000 service schematic 69 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 t
89. hten cartridge 1 2 turn DO NOT OVER TIGHTEN Note Cartridge Stud Kit 619140 available if stud needs replacing 94 Service procedures Turbo 3000 ae Early model TURBO 2000 Late model I ie E p 2 el f Heater Assy F Heater Bany a Fer fur pe r f ra Screws m 4 a Screws J F a d ri F j er p G i i 777 LO Ring Foam cube 248 12V amp 249 24 Heater kits 519110 120 A 619111 4 Heater kits Heater Service Kits 248 249 619110 619111 Warning Read and follow safety precautions found on page 17 before proceeding Symptom 1 Dryer won t exhaust 2 Exhaust port leak 3 Cannot build pressure Operational check 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 7 Insert heater element into hole and twist slightly to spread anti seize 95 2 96 con t 7 1 Early Models 248 or 249 orange and blue wires 7 11 7 1 2 7 1 3 7 1 4 Install n
90. i If pressure does not flow at 180 psi replace safety valve Check air dryer functionality Dual Turbo 2000 1 Build up pressure from O to cut out should take less than 3 minutes Air should exhaust alternately every 90 seconds while compressor is in charge mode There will always be a light flow of air while compressor is in charge mode a If compressor build time is longer than 3 minutes check to see if steady stream of air is escaping out of exhaust port A light flow of air will be present while compressor is in charge mode i Yes check purge valves and inlet check valve Check heater if temperatures below 35 F ii No check for air leaks at safety valve dryer body and air system by applying soapy water spray 2 Check that exhaust is alternating between ports This will only occur while compressor is charging a If one port is exhausting see if light is flashing when exhaust occurs If not check polarity and or replace Micro logic timer MLT b If one port is exhausting and light is flashing check purge valves air control valve regeneration valves c If no exhaust occurs every 90 seconds while compressor is in charge mode check MLT air control valve regeneration valve and purge valves Check heater if temperature is below 35 F Preventative maintenance Use chart below for interval recommendations 1 Replace cartridge T224 for Turbo 2000 and HD 2000 recommend use T224 P when oil blow by is present and
91. ion Holset SS E Type and QE compressor lt r N A B E E F ET B L MW A For right hand models see parts list on pages 139 amp 140 Turbo 3000 service schematic 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 Charge cycle Purge cycle EH E Clean dry air Mj Atmospheric pressure W Dirty wet charge
92. ir discharge could also be due to worn check valve or turbo valve Refer to pages 92 and 93 for service procedures on these valves 90 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 and or upgrade to Turbo 2000 Clean the cavity thoroughly Remove the three 3 o rings from retainer and discard Using lubricant supplied lightly grease the new o rings Install on the retainer the two 2 thickest o rings then install the third thinner o ring Install the new filter screen in the purge cavity open end out 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 NOOO Mm 00 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 Ib 14 Reconnect air line to control port 91 Service procedures Turbo 3000 W238
93. ist contrary to this limited warranty in a product sold by SKF and purchaser s sole and exclusive remedy for such defect shall be limited to A SKF furnishing without additional charge to purchaser including transportation a replacement for any of the products sold by SKF which are found by SKF to be defective contrary to this limited warranty and B in the case of products which cannot be repaired or replaced by SKF SKF shall credit or refund to purchaser the purchase price paid therefore provided that SKF is advised in writing of such product non conformance within thirty 30 days of the date of discovery thereof and that the non conforming product is returned f o b to SKF s designated warehouse promptly thereafter but in any case not later than twelve 12 months from the date of purchase and only for light duty hub units the first to occur of either i thirty six 36 months from the date of purchase or ii 45 000 miles 72 000 kilometers Valid proof of purchase date mileage required In no event shall SKF be obligated under this limited warranty or otherwise in any way whatsoever for normal wear and tear or for any products sold by SKF which after delivery by SKF and in SKF s sole determination have been subjected to accident abuse misapplication improper or faulty repair or installation improper or faulty maintenance or lubrication any alteration or neglect excessive loading or other excessive operating conditions or fo
94. ition key is on The 12 volt 75 watt heater will draw 6 6 amps A 24 volt 75 watt heater will draw 3 2 amps Check for proper operation 1 Double check all hoses and fittings for tightness Start vehicle and allow system pressure to build Relieve pressure and cycle several times No air should flow from exhaust port while the system is building air If air flow is present check for air pressure in governor line This line should be at atmospheric pressure during charge Dryer should exhaust when compressor reaches cut out There should be no further air flow after burst a Check for leaks if air continues to flow and or compressor goes into charge mode 137 138 Parts listing Service kits and air dryers Note Bold part numbers represent suggested stock service components Service kits T224 Desiccant cartridge T2000 amp HD2000 T224 P Desiccant cartridge w Filtration Plus Dual T2000 Dual T2000HC T2000 amp HD2000 T334 Turbo 3000 desiccant cartridge 221 Purge tank kit 223 Bleed valve kit 228 Turbo valve kit 230 Turbo AC model 62 feedback kit 231 Turbo AC model 68 feedback kit 235 Unloader valve kit 238 Check valve kit 239 Filter service kit for aftercoolers 240 Filter replacement kit for aftercoolers 246 12V50W Thermostat heater short element 247 24V50W Thermostat heater vertical 248 12V75W Thermostat heater long element 249 24V75W Thermostat heater horizontal 261 Deflector kit 62 63
95. ll procedures 2 Always wear eye protection when testing or servicing air dryer Never look directly into air dryer ports during test Never exceed recommended maximum working air pressure 150 psig 3 Never connect or disconnect a hose line containing air pressure or remove a component fitting or pipe plug unless you are certain all system pressure has been exhausted Use only proper tools and observe all precautions pertaining to the use of those tools I W 62 Fittings valves required for test 3 8 shut off valve 1 2 x 3 8 bushing 1 male amp 1 female threads 3 8 x 1 4 bushing 3 8 pipe plug 38 NPT Outlet part Purge tank port ir HF Upaie pori 14 MPT kn 4 177 HPT ahini pri 111 112 con t Note Perform all test steps in sequence shown to insure a properly functioning air dryer Step 1 Dryer air flow test vo rwm HH 6 Install 1 2 x 3 8 bushing in INLET port of dryer Attach shut off valve 3 8 male pipe into 4 2 bushing Install 3 8 x 1 4 bushing into female port of shut off valve Install quick disconnect connector to shut off valve Connect shop air Open valve Check for air flow from dryer OUTLET and PURGE TANK ports If air does not flow from both ports check for internal blockage of ports valves and or desiccant cartridge Close shut off valve Step 2 Regeneration purge tank air flow test me
96. ltration Plus Option is self cleaning with every purge cycle keeping the performance optimized e Easily retrofits and upgrades the filtration system of any existing SKF Turbo series desiccant air dryer with a cartridge Plus kit T224 P For more information visit us on our web site www vsm skf com Safety precautions me Before performing any test and or isolating the air dryer the vehicle s wheels must be chocked making sure the vehicle will not roll before releasing the brakes N Never work under a unit supported only by a jack Always support the vehicle with stands w Stop engine when working under a vehicle 4 Never remove a component or a pipe plug unless you are certain all system air pressure has been exhausted 5 Never connect or disconnect a hose or line containing air Pressure 6 Never exceed recommended working air pressure 7 Never attempt to disassemble an air dryer until you have read and understood all recommended procedures 00 Use only proper tools and observe all precautions pertaining to the use of those tools Basic mounting guidelines 1 The air dryer must be mounted with the exhaust ports positioned downward N Mount air dryer lower than the air compressor The compressor discharge line should slope continuously downward from the compressor to the air dryer without any dips which cause water traps 3 The compressor discharge line size material and length
97. m e Turbo boost protected for all engine applications Fully compatible with Cummins Holset Turbo 3000 air dryer specifications e Unit dimensions see Fig 1 e Drying medium Integral purge volume e Weight 17 5 Lbs regeneration e Connection ports see Fig 2 e Safety valve 175 psig e Air flow capacity 15 SCFM e Heater options 12V 75 Watt 6 6 Amps e Drying medium 2 Lbs desiccant 24V 75 Watt 3 2 Amps Spin on cartridge 2 00 Minimum dearance required 825 for cartridge service R _ Haater elec connect jr 12 of 24 Vor D C LU N Q 4 10 4 Control port Exhaust port Fig 1 Unit dimensions 1 4 NPT pone ane r Resevoir dwet tan pi Otte fm j system 8 Governor N Heater elec connect 12 or 24 Vor DC Fig 2 Connection schematic Control port 7 Exhaust port 13 14 Turbo AC low maintenance This time tested design pays for itself by protecting the brake system from moisture and contamination while reducing maintenance practically to zero With this air dryer you can often install it and forget it A popular choice where there s adequate air flow over the surface of the unit to allow it to cool properly The Turbo AC is designed for compressor output of up to 15 CFM and duty cycles of up to 20 An internal filter traps compressor blow by and contaminants while the large cooling chamber extracts moisture from the air Fo
98. m is building air If air flow is present check for air pressure in governor line This line should be at atmospheric pressure during charge 4 Dryer should exhaust when compressor reaches cut out Air will continue to flow out exhaust port with deminishing intensity as purge air evacuates This could take 45 seconds and should not cause system pressure to drop If the compressor goes into charge mode check for air leaks 127 Installation Instruction Brakemaster Dual Turbo 2000 Warning Safety precautions 1 Before performing any test and or isolating the air dryer the vehicle s wheels must be chocked making sure the vehicle will not roll before releasing the brakes 2 Never work under a unit supported only by a jack Always support the vehicle with stands 3 Stop engine when working under vehicle 4 Never remove a component or a pipe plug unless you are certain all system air pressure has been exhausted 5 Never connect or disconnect a hose or line containing air pressure 6 Never exceed recommended maximum working air pressure 7 Never attempt to disassemble an air dryer until you have read and understood all recommended procedures 8 Use only proper tools and observe all precautions pertaining to the use of those tools 9 Always wear safety glasses when working with air pressure Never look directly into air dryer ports Governor Compressor discharge i Resevoir e Out to wet tank system i _ J
99. maged Line between the compressor and air Fit new line with a minimum length of 6 feet copper dryer too short line 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 l DUPONT Air compressor service may be required to address excessive oil blow by Service procedures HD 2000 p Purge Valve Service Kit 235 Warning Read and follow safety precautions found on page 17 before proceeding 2 Symptom Range ale a i eff er bye a 1 Dryer won t exhaust mow Fl cot tea 2 Air leak at exhaust port during the 17 ea EB i a Charge mode f L b Stand by mode Dm 3 Pressure slow or no build 4 Compressor cycles rapidly fico Pune wake kil 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 amp 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
100. mbly from the purge cavity and discard Note If there is excessive oil in the cavity compressor 4 5 6 7 8 may require servicing Clean the cavity thoroughly Remove the three 3 o rings from retainer and discard Using lubricant supplied lightly grease the new o rings Install on the retainer the two 2 thickest o rings then install the third thinner o ring Install the new filter screen in the purge cavity open end out Note If air dryer is equipped with oil separator 9 10 Aligning the valve exhaust port with the air dryer exhaust port install DO NOT install filter screen Apply a light coating of grease around the o ring seat on valve assembly Install the thin o ring on the purge valve seat 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 11 12 13 14 with air dryer exhaust port air dryer will not exhaust Install retainer Apply a light coating of grease on the threads of the two retainer bolts Install two retainer bolts Tighten to 10 15 ft Ib Reconnect the control line to air dryer control port 25 26 Service procedures Turbo 2000 273 Ropereraiion he i Regeneration Valve Service Kit 223 a Warning Read and follow safety precautions Ring found on page 17 before proceeding Symptom 1 Water in tanks 2 No purge air flow Operational check Symptom 1
101. mponents dryer Air compressor governor malfunctioning Replace compressor D2 governor Blocked desiccant cartridge Replace cartridge T224 and upgrade to filtration plus option T224 P The safety valve is malfunctioning Replace the safety valve 610024 Air compressor service may be required to address excessive oil blow by Problem water accumulation in air system tanks Possible cause Desiccant is contaminated Replace desiccant cartridge 1224 or upgrade to T224 P for optimal filtration performance The air compressor capacity is too low for Install larger air compressor and replace desiccant cartridge T224 vehicle Malfunctioning regeneration valve Clean cavity and replace regeneration valve assembly 223 The line between the purge tank and the Install or replace the air line or tighten the fittings air dryer control port is missing leaking or damaged Line between the compressor and air dryer Fit new line with a minimum length of 6 feet copper line or insufficient too short pre cool 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 l DuPont 23 Service procedures Turbo 2000 Fr Purge Valve Service Kit 235 Warning Read and follow safety precautions found on page 17 before proceeding Let iH Symptom at 1 Dryer won t exhaust Ht ml m 2 Air leak at exhaust por
102. nate 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 Side View Bottom View Wi Clean dry air E Atmospheric pressure EU 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 Remedy Worn check valve Clean cavity and replace check valve assembly 238 Problem system wet tank air pressure drops rapidly Fittings are loose or damaged Tighten and or replace as necessary Air reservoir tubing or hoses are Repair or replace as necessary damaged Worn check valve Clean cavity and replace check valve assembly 238 D2 governor malfunctioning Replace governor Problem air compressor moves into the standby mode but cycles rapidly Possible cause Fittings are loose or damaged Tighten and or replace as necessary Air reservoir tubing or hoses are Repair or replace as necessary damaged Worn check valve Clean cavity and replace check valve assembly 238 D
103. nd intervals Note A light flow of air from ONE exhaust port during charge cycle is normal regeneration air flow 2 Water in air tanks Operational check Drain tanks check for excessive oil and water 64 con t Symptom 1 amp 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 2 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 amp 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 Inst
104. ne containing air pressure 6 Never exceed recommended working air pressure 7 Never attempt to disassemble an air dryer until you have read and understood all recommended procedures 8 Use only proper tools and observe all precautions pertaining to the use of those tools 9 Always wear safety glasses when working with air pressure Never look directly into air dryer ports 135 136 con t Basic mounting guidelines 1 The air dryer must be mounted with the exhaust ports positioned downward Use grade 5 or better bolts to mount air dryer and purge tank Mount air dryer lower than the air compressor The compressor discharge line should slope continuously downward from the compressor to the air dryer without any dips which cause water traps The compressor discharge line size material and length must be such that the dryer air inlet temperature is typically no more than 160 degrees F or no less than 45 degrees F above low ambient Ref SAE J2383 An example of a typical discharge line Total line length 10 ft to 12 ft which is a combination of rigid copper approx 4 ft length and balance of line length being stainless steel braid sheathed PTFE Avoid using 90 elbow fittings to avoid water traps freeze ups The air dryer should be mounted in a location with sufficient space around it to facilitate service and to provide visual access for periodic inspection Allow at least 2 00 inch clearance a
105. ng Fig 1 Kit T224 P Service procedures HD 2000 Early model Late model y Heater Assy hi gt 2 Heater Asay Cover i os 2 f i Screws it IE gt ares eee iL ri F nel T m IE _ a L w UP LO Ring Foam cube 248 12V amp 249 24 Heater kits 419110 17 A 619111 24 Heater bits Heater Service Kits 248 249 619110 619111 Warning Read and follow safety precautions found on page 17 before proceeding Symptom 1 Dryer frequently exhausts 2 Air continually flows from exhaust port when compressor is in standby mode 3 Wet tank pressure drops rapidly Operational check 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 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 7 Insert heater element into hole and twist slightly to spread anti seize 45 46 cont 7 1 Early models 248 or 249 orange and blue wires 7 21 7 1 2 7 1 3 7 14 Install new set screw if required until snug DO NOT OVER TIGHTEN
106. ng on nut Apply a light coating of grease to threads of nut Install nut and tighten to 60 ft lbs Re connect air line to air dryer outlet port 105 106 Service procedures Turbo AC Turbo Valve Service Kit 228 Warning Read and follow safety precautions found on page 17 before proceeding Symptom 1 Dryer frequently exhausts 2 Air continually flows from exhaust port when compressor is in standby mode 3 System pressure drops very rapidly Note The above symptoms could also lead to check valve replacement Operational check Symptom 1 2 amp 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 Turbo valve replacement 1 2 3 4 11 12 13 14 15 Drain the air system Disconnect the heater wiring Disconnect the inlet and control lines from their respective ports If air dryer is equipped with external feed back line disconnect this line at inlet port of dryer Remove 8 bolts from bottom cap and set aside Discard gasket Remove turbo nut valve stop and valve and discard Clean cavity area thoroughly Lightly coat the 2 small o ring surfaces and install on piston Carefully install valve in cavity with tapered side up Place valve stop on top of valve concave side down Lightly lube large o ring and pla
107. ngs are loose or damaged Tighten and or replace as necessary Air reservoir tubing Repair or replace as necessary or hoses are damaged Worn check valve Clean cavity and replace check valve assembly 238 Worn turbo valve Clean cavity and replace turbo valve assembly 228 Worn purge valve seal Clean cavity and replace purge valve assembly 235 Problem air compressor moves into the standby mode but cycles rapidly Possible cause Remedy Fittings are loose or damaged Tighten and or replace as necessary Air reservoir tubing or hoses are Repair or replace as necessary damaged Worn check valve Clean cavity and replace check valve assembly 238 Worn turbo valve Clean cavity and replace turbo valve assembly 228 D2 governor malfunctioning Replace governor Worn purge valve seal Clean cavity and replace purge valve assembly 235 Problem air leaks from the exhaust port during compressor charge mode Possible cause Remedy Worn purge valve Clean cavities and replace purge valve assembly 235 Dirt foreign material Clean cavity and replace valve assembly 235 is stuck in the purge valve D2 governor malfunctioning Replace D2 governor Heater assembly malfunctioning gt 32 Replace heater assembly 246 12V 247 24V degrees 248 12V 249 24V 619110 12V or 619111 24V 21 22 Problem air compressor runs continuously system pressure will not build Possible cause Fittings are loose or damaged Tighten or replace loose or damaged fittin
108. ol valve missing or damaged Problem air dryer does not exhaust during compressor charge mode Micro Logic Timer MLT malfunctioning Replace MLT 619912 12V or 619924 24V Air control valve malfunction Replace air control valve 619910 3 fittings or 619925 2 fittings Worn purge valve Clean cavity and replace the purge valve assembly 235 Exhaust ports in purge valve and valve housing Align exhaust ports in purge valve and valve housing not aligned Air line tubing connecting air control valve Repair replace air line s tubing and valve housing and or manifold damaged or missing Ice has formed in the purge valve Replace heater assembly 619110 12V or 619111 24V Heater is malfunctioning Replace heater assembly 619110 12V or 619111 24V Problem safety valve opens Air dryer outlet check valve is blocked Clean cavity and replace the check valve assembly 238 Air brake system is blocked down stream of air Remove blockage or replace the necessary components dryer 53 54 Problem water accumulation in air system tanks Desiccant is contaminated Replace desiccant cartridge T224 P Replace both cartridge and filters Micro Logic Timer MLT Replace MLT 619912 12V or 619924 24V malfunctioning Air control valve malfunction Replace air control valve 619910 3 fittings or 619925 2 fittings Malfunctioning regeneration valve s Clean cavity and replace regeneration valve s 619911 Air line
109. omplete bottom cap w poppet valve only Mounting bracket w industry standard bolt hole pattern Adaptor plate for T2000 w valves amp bracket Cartridge adaptor stud O ring kit for 619938 10 ea of 3 O ring kit for 223 238 619911 10 ea of 1 O ring kit for 235 10 ea of 3 Hose amp fitting kit for purge tank Dual Turbo 2000HC purge tank kit w 690 Cu ln purge volume O ring kit for T224 10 ea of 1 End cap service kit o rings and bolts Manifold service kit o rings and screws Inlet check valve service kit Service kit includes T224 228 235 238 Service kit includes T224 P 228 235 238 Filter conversion kit to T224 P Filter amp bolts Filter conversion kit to T224 P Filter only Service kits cont 619740 619900 619905 619910 619911 619912 619913 619915 619920 619921 619922 619924 619925 619928 619930 619932 619933 619934 619935 619938 619940 619972 619973 619974 619976 619978 619979 619980 Safety Valve 200 PSI Heater wire harness Universal lead for 12 or 24V applications Dual Turbo 2000 air control valve 3 air line version thru March 2006 Dual Turbo 2000 regeneration valve kit Dual Turbo 2000 MLT 12V Regen valve kit Dual Turbo 2000HC Dual Turbo 2000 inlet check valve kit Superseded to 619938 Dual Turbo 2000 mid section left hand Dual Turbo 2000 mid section right hand Dual Turbo 2000 manifold w valves amp fittings for 2 line version Dual
110. operly 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 Neo 58 Service procedures Dual Turbo 2000 Valve spindle r Valve spindle Spring L O rings ID iio iF a Spring r O rings c j ath a 619938 Inlet check valve kit Inlet Check Valve Service Kit 619938 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 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 2 Pressure slow or no build Operational check Symptom 1 amp 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 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 di
111. otected location such that minor mechanical damage to the vehicle will not damage the air system integrity Mounting air dryer base assembly 1 After determining proper location for air dryer as instructed in Basic mounting instructions section refer to Fig 2 drawing for mounting reference dimensions 2 Mount air dryer base assembly to vehicle before installing desiccant cartridges to base assembly Make sure there will be at least a 2 00 inch clearance above desiccant cartridges for future installation and removal 3 Refer to Fig 2 drawing to position mounting holes properly on vehicle to match mounting slot locations in air dryer mounting bracket Tighten bolts to 25 30 ft lbs torque Installing desiccant cartridges 1 After air dryer base assembly is securely mounted install both desiccant cartridges to base assembly as follows Install o ring into groove of each center thread adaptor in air dryer base assembly a b Using grease supplied lightly lubricate both o rings and threads a Using grease supplied generously lubricate contact surface of flat gasket d Start cartridge onto thread adaptor being careful not to cross thread Turn cartridge clockwise until flat gasket contacts casting surface After gasket contact turn cartridge only 1 2 additional turn Note Do not overtighten cartridge or future removal of cartridge will be extremely difficult 129 con t Connecting air lines 1 Connect the com
112. plug needs to be replaced or is not in vehicle wire harness it is available in Kit 619900 108 Turbo AC Notes 109 Original Brakemaster service kit reference G Safety valve E Top cap nut Body gaskets H Tip cai J Large spring L Filter replacement kit K Filter service kit M Packing ring gasket B Die cast body D Deflector kit Body gaskets IR C Bottom cap N Unloader nut O Unloader valve kit 12V heater 62 63 68 69 70 71 72 73 24V heater 619013 619014 619015 619016 619017 619018 N A 619101 A Bracket assembly 610851 N A B Die cast body 610705 N A C Bottom cap assy 12V 619086 N A 619086 N A 24V 619087 N A 619087 N A D Deflector kit 261 263 265 N A 265 N A E Top cap nut 610029 N A F Check valve kit 238 N A G Safety valve 150 PSI 610024 H Top cap 610229 Body gaskets 610077 J Large spring 610271 K Filter service kit 239 L Filter replacement kit 240 M Packing ring gasket 610076 N Unloader nut 610030 0 Unloader valve kit 235 P Heater Standard 12V 60W 246 Optional 24V 60W 247 A not shown in diagram N A Not available Model 62 superseded to Turbo AC 620570 12V amp 620572 24V All other models are Obsolete 110 Turbo 2000 air dryer Leak valve function test procedure ID Warning M 1 Never attempt to test or service air dryer until you have read and understand a
113. ply a light coating of grease on the threads of the two retainer bolts Install two retainer bolts Tighten to 10 15 ft Ib Reconnect air line to control port Service procedures Turbo AC 24 Check vaba bt Bal O ring Check Valve Service Kit 238 i Spindle Warning Read and follow safety precautions found on page 17 before proceeding 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 style air dryers Operational check Symptom 1 2 amp 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 Check valve replacement 1 2 3 4 Drain air system Disconnect air line from outlet port Remove check valve nut Remove and discard o ring spring spindle and ball Note If there is excessive oil in the check valve cavity COND 01 10 compressor may require servicing Clean nut and cavity area Install new ball in cavity Next position spindle with spring pocket facing out Install spring Using grease supplied apply a light coating on o ring Install o ri
114. pressor discharge line to the air dryer s lower 3 4 NPT INLET port see Fig 2 2 Connect the air dryer s 3 4 NPT OUTLET port see Fig 2 located at top center to inlet port of 1 air tank wet tank of vehicle Note Use appropriate thread sealant on air line fitting threads to prevent air leaks Micro Logic Timer MLT Heater electrical connection 1 The air dryer is available in either 12 Volt DC or 24 Volt DC configuration to match the vehicle electrical system Confirm that voltage of air dryer being installed and vehicle voltage are the same 2 One 1 triple connector 1 male amp 2 female wire harness and one 1 pig tail lead connector are supplied with air dryer 3 Connect lead wire of the pig tail lead connector coming from connector terminal marked B to a good chassis ground 4 Connect lead wire of the pig tail lead connector coming from connector terminal marked A to power source that is powered only when vehicle ignition in ON The power lead source should be protected with a 10 Amp fuse Note The MLT unit is polarity sensitive MLT will not operate if power and ground leads are switched 2 00 Minimum diearance required 1450 for cartridge service 1167 p 543 sur Li Cartridge A AA x 93 Outlet gt i 1 Bots 3 4 NPT fil 333 AE et b 4 50 ALU _ MUT HTR connect ee 12V or 24V 0 0 BEER Exhaust ports Fig
115. r all weather operation the Turbo AC is equipped with a sealed 12 Volt or optional 24 Volt 75 watt thermostatically controlled heater p L e Ideal for light to medium air Turbo boost compressor duty cycles protected for all engine applications e Virtually maintenance free Fully compatible with aftercooler technology Cummins Holset iii ii Hill i Turbo AC air dryer specifications e Unit dimensions see Fig 1 e Safety valve 175 psig e Weight 19 5 Lbs e Heater options 12V 75 Watt 6 6 Amps e Connection ports see Fig 2 24V 75 Watt 3 2 Amps e Air flow capacity 15 SCFM e Drying medium Heat exchange 1 16 543 H 116 r 4 10 r rg f A Li Th 8 75 18 50 ra u r inlet port er j A unse P AO 1 2 NPT lol Heater elec connect 12 or 24 Volt D C ry AA Sn a Fig 1 Unit dimensions pe Fa J JE f amp Resevoir Out to gt Outlet port _ nd _ vo NPT N N fwet tank y da Gavemor Compressor Ba amp Heater elec connect u 12 or 24 Volk O C Fig 2 Connection schematic Control port or 1 4 NPT Exhaust port 15 Es Turbo 2000 Filtration Plus option New from SKF the leader in high performance air dryers with the Filtration Plus Option The best just got better Introducing SKF s new Filtration Plus Option for Turbo 2000 and HD 2000 As more components draw on the vehi
116. r bolts Tighten to 10 15 ft Ib Service procedures Dual Turbo 2000 235 Check waha kit me E Check Valve Service Kit 238 Spindle I Warning Before proceeding read and follow W Ball safety precautions found on page 17 2 te Review description of Normal Dual Turbo 2000 Air Dryer operation cycle on page 50 Symptom 1 Air continually flows from exhaust port when compressor is in standby mode 2 System wet tank air pressure drops rapidly Operational check Symptom 1 amp 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 Check valve replacement 1 Relieve all system air pressure 2 Disconnect air line from dryer outlet port 3 Remove check valve nut 4 Remove and discard o ring spring spindle and ball 5 Clean nut and check valve cavity thoroughly Note If there is excessive oil in the cavity the desiccant cartridges and filters require servicing Install new ball into cavity Install spindle with spring pocket out into cavity Place spring into spring pocket of spindle 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 ou
117. r defects caused by or resulting from purchaser s specifications or designs or otherwise caused by purchaser TO THE FURTHEST EXTENT PERMITTED UNDER APPLICABLE LAW SKF DISCLAIMS LIABILITY IN TORT OR CONTRACT IN NEGLIGENCE STRICT LIABILITY OR OTHERWISE FOR ANY OTHER REMEDY OR DAMAGE WHETHER DIRECT OR INDIRECT INCIDENTAL SPECIAL EXEMPLARY OR CONSEQUENTIAL WITH RESPECT TO ITS PERFORMANCE HEREUNDER INCLUDING WITHOUT LIMITATION THE PRODUCTS SOLD OR PROVIDED HEREUNDER BY SKF AND ITS PROVISION OF ANY RELATED SERVICES THIS LIMITED WARRANTY IS TO THE EXCLUSION OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE COSTS INCURRED FOR ROUTINE MAINTENANCE ARE NOT COVERED BY THIS LIMITED WARRANTY Without limiting the generality of the foregoing SKF specifically disclaims liability to purchaser for any loss cost or damage incurred as a result of equipment downtime or loss of use or availability of worksite lost revenues or lost profits regardless of whether SKF is on notice of the possibility of such damage or loss and did or could have anticipated same No other person has been authorized by SKF to undertake or make on behalf of SKF any further representation warranty or guarantee in addition to or contrary to this limited warranty or contrary to the limitations and disclaimers provided herein The exclusive remedies provided in this limited warranty shall not be deemed to have failed of t
118. r lead source should be protected with a 10 Amp fuse Plug female connector of wire harness into the air dryer heater receptacle Note The connector will connect plug in only in one direction The heater is thermostatically controlled ON at 35 deg F and OFF at 55 deg F To prevent damage properly secure harness lead wires and seal any wire splices ve 1 22 Orat cartridge 2 00 Mrerarn cherarce requred tor dengo carta 100 wt Lertrs ire conrectorn 1 6 90 pawei push connect u Eitward lo droogte 12 24 MPT Fig 2 Unit dimensions Installation Instruction Brakemaster Turbo AC SKF Brakemaster The SKF Brakemaster is a heat exchanger type air dryer To properly dry the compressed air a flow of ambient air across the air dryer is of utmost importance With the air flow the SKF Brakemaster can transfer the heat in the compressed air to the atmosphere thus condensing moisture from the compressed air Warning Safety precautions 1 Before performing any test and or isolating the air dryer the vehicle s wheels must be chocked making sure the vehicle will not roll before releasing the brakes 2 Never work under a unit supported only by a jack Always support the vehicle with stands 3 Stop engine when working under a vehicle 4 Never remove a component or a pipe plug unless you are certain all system air pressure has been exhausted 5 Never connect or disconnect a hose or li
119. resent 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 amp 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 Purge valve replacement 1 Disconnect air line at each 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 Clean the cavity thoroughly Remove the three 3 o rings from retainer and discard Using lubricant supplied lightly grease the new o rings Install on the retainer the two 2 thickest o rings then install the third thinner o ring Install the new filter screen in the purge cavity open end out 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 NOOSE sO 00 Warning
120. scard Note If there is excessive oil in cavity compressor may require servicing 3 Clean the cavity thoroughly 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 10 Install retainer 11 Apply grease to threads of retainer bolts 12 Install retainer bolts and tighten to 10 15 ft lbs Service procedures Dual Turbo 2000 Fr T2u P Denan alon pha antige Larirckze Fiter plte __ e hoot or Irma 1 ell r te Desiccant Cartridge Service nns0 2000 wll Kit T224 P Note two 2 cartridges on dryer 1 per kit af Be Warning Before proceeding read and follow aufn FlR safety precautions found on page 17 Fiker plate Operational check Symptom 1 Regular service interval 2 Water or contamination in tanks Symptom 1 amp 2 Dessicant cartridge requires regular servicing at intervals determined by compressor duty cycle or type of operating conditions Typical service intervals are Inner Ci
121. slide it between the cartridge gasket and the base This could release the tight seal of the rubber on the base Slide the blade as far around as possible and re attempt to remove cartridge 2 f above does not help strike the cartridge with a center punch or a ball nose at the lower end where the diameter is slightly larger This will bind together the internal components of the cartridge Re attempt to remove cartridge Consider these tips when doing the next preventative maintenance PM It could make yours or the next person s job a lot easier 120 Tech Tip 3 E type compatible air dryer SKF offers E type air dryers for specific compressor applications To ensure proper air system functioning only use an SKF E type air dryer with a Holset QE E type air compressor Holset has not manufactured these compressors since 2001 but there are many still in service The Holset QE air dryer is equipped with special valving that is required for the Holset compressor so an SKF E type air dryer should be used as the correct replacement alternative for this application The difference in the E type compatible air dryer is an extra valve check ball located on the flange of the bottom cap There is also an air communication path located between the inlet and the outlet During unload the air is directed back from the wet tank through the air dryer back to the compressor Other compressors are not designed for this back pressure and can
122. ssure Never attempt to disassemble an air dryer until you have read and understood all recommended procedures 8 Use only proper tools and observe all precautions pertaining to the use of those tools 9 Always wear safety glasses when working with air pressure Never look directly into air dryer ports Ostet port A NPT Reger sr ar port VF NPT Dryer aggid ath two 440 Ce in tabs for nem aver ar 1 6 contra lee 7 u gt f Heater eier connect Zu 2 wa De Fig 1 Connection schematic con t Basic mounting guidelines 1 The air dryer must be mounted with the exhaust ports positioned downward Use grade 5 or better bolts to mount air dryer and purge tank Mount air dryer lower than the air compressor The compressor discharge line should slope continuously downward from the compressor to the air dryer without any dips which cause water traps 3 The compressor discharge line size material and length must be such that the dryer air inlet temperature is typically no more than 160 degrees F or no less than 45 degrees F above low ambient Ref SAE J2383 An example of a typical discharge line Total line length 10 ft to 12 ft which is a combination of rigid copper approx 4 ft length and balance of line length being stainless steel braid sheathed PTFE Avoid using 90 elbow fittings to avoid water traps freeze ups The air dryer should be mounted in a location with sufficient space
123. st 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 15ft lb Re connect air line to control port 40 Service procedures HD 2000 nin ed Regeneration Valve Service be Kit 223 prde i Spring Warning Read and follow safety l bmg precautions found on page 17 In 1E al 8 before proceeding I a Te oe Symptom Ti 1 Water in tanks Ur 2 No purge air flow 223 Regeneration waive Operational check Symptom 1 amp 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 Disconnect the air line at air dryer purge tank port Remove regeneration valve nut Remove and discard o ring spring and spindle Clean nut and cavity 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 Inst
124. t during the ae EY pe a Charge mode J Rings RE b Stand by mode Trach Sero 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 amp 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 amp 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 24 con t Purge valve replacement 1 2 3 Disconnect air line at control port Remove the two fasteners that attach the purge valve retainer Remove the retainer Remove the purge valve asse
125. ter lead wire 2 Remove two screws attaching heater connector to casting 3 Remove heater thermostat assembly and discard 4 Thoroughly clean entire heater thermostat area 5 Slide o ring over heater and thermostat into position around connector flange 6 Apply a light coating of anti seize to the heater element and thermostat cavity 7 Insert heater element into hole and twist slightly to spread anti seize 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 Service procedures Dual Turbo 2000 619910 8619925 Ag control wae kit Note en Air wahre for bat ai ins fiting in center port as shown in drawing mm DP C ry i au or A Air valve for kit 619925 has center wl ee port plugged Brass screw ge Fig 1 Air Control Valve Service Kit 619910 amp 619925 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 to allow regeneration air flow at 90 seco
126. ter model transit bus engines See the table on the back cover to determine which air dryer is best suited to your application Table of contents Section 1 dryer highlights and specifications 4 T rb6 2000 2 20 4 en 6 ee 8 ER 12 BER 14 Turbo 2000 Filtration Plus Option 16 Safety precautions mounting guidelines 17 Section 2 recommended service T rbo 2000 nasin 18 Parts E EREET RE ETA EEEE 18 Service schematic Normal operation flow diagram essessssessssesscseseesessseeessees 20 MOUBIE SHOOUG isn 21 Service procedures sessssessssssssessssessseessseessseessesesseseseeceseesesees 24 HD 2008 ue lee Parts list Service schematic Normal operation flow diagram rouble sh66tind 2 eeuneenanain SETVICE procedures 39 Dual Turbo 2000 eenen Partslistuun nsuentkanneraneensnanusgeinsieren Service schematiC unse Normal operation flow diagram Trouble shobting eeeen Service procedures Tati AYE ARER OFEAATEON H C Dual Turbo 2000 eeen Parts listen due iunseiteineksiekennl Service schematic nennen Normal operation flow diagram Troublesshootndgss 2 u 2 nen SETVICE PFOLEUTES engen T rbo 3000 42 21 52 84 Parts list SEIVICE SChematic nuumesenataenienunal 85 Normal operation flow diagram n annenneneeennnn Troubleshooting Service procedures T r DO AC naar
127. tial to minimize the risk of any seal bearing or other product failure Such failures can result in property damage or severe personal injury to operators of machinery vehicles or to others You must carefully evaluate the particular application on or into which you intend to install the products Products in this catalog require installation by an experienced professional mechanic or qualified maintenance professional The product properties and operating parameters described in this catalog are based upon tests conducted by SKF or reported by others SKF does not assume any responsibility for errors in the data published in this catalog The life and performance of the products ultimately depend on a number of factors These include for example selection of product design type selection of materials for their different properties handling and installation operating conditions including shaft surface or bore conditions the quantity quality and chemistry of lubricants and other factors Severe environments can adversely affect product life or performance For help in realizing longer SKF product life and optimal performance for your specific application contact SKF s Customer Services Department at 1 800 882 0008 LIMITED WARRANTY SKF warrants to the first purchaser that the products sold by it when properly installed will be free from defects in material and workmanship SKF s sole obligation and liability for any defect found to ex
128. tlet port sO CON On 57 Service procedures Dual Turbo 2000 cece sas Regeneration Valve Service Kit 619911 Note two 2 valves in Piz dryer 1 per kit cap adel ean od Warning Before proceeding read and follow safety a a sO rare precautions found on page 17 Review er u i l description of Normal Dual Turbo 2000 Spring s r Spring Air Dryer operation cycle on page 50 iM i D ring D ring t F _ Symptom EE y pih 1 No purge air flow ae a a 1 i Note A light flow of air from exhaust port s Or is during charge cycle is normal regeneration air flow 619911 regereralion sah bl 2 Water in air tanks Operational check Symptom 1 amp 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 Position manifold onto adaptor castings ensuring o rings are pr
129. ty Transit 2 years Inner City Refuse 2 years Off Highway 2 years Desiccant Cartridge Filter Element and Internal Filter Plate Replacement 1 Relieve all system air pressure 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 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 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 FRPP PPR NOM amp W H 00 r Xe 20 21 con t Remove two filter plates gaskets and o rings late model version only and discard Clean valve housing sump gasket surface and inside of two 2 adapter plate castings of oil and contaminates Place new gasket or o ring at each valve housing bolt flange 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
130. ween the compressor and air dryer Fit new line with a minimum length of 6 feet copper line or insufficient too short pre cool 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 l DuPont 73 Service procedures H C Dual Turbo 2000 sprees Purge Valve Service Kit 235 e Purge walve i Warning Read and follow safety precautions ml fi found on page 17 before proceeding Symptom 1 a o NE 4 amp l 1 Dryer won t exhaust a 2 Air leak at exhaust ports during the n P Charge mode O ring N i a b Stand by mode D ring pee 3 Slow or no pressure build 235 Purge eve kit 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 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 amp 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 p
131. y test The heater is thermostatically controlled to operate heat between temperature range of 35 degrees F and 55 degrees F which means current flow through heating element is controlled by thermostat internal contacts closing at 35 degrees F and opening at 55 degrees F The thermostat heater assembly may be removed from the dryer to be tested or checked while still installed in dryer Whichever method is used the thermostat must be subjected to a temperature of 35 degrees F or lower and 55 degrees F or higher for proper test If the heater assembly is removed from dryer for test visually check that all wire connections between thermostat and heater element are intact If connections are broken replace thermostat heater assembly Perform continuity test as follows A While thermostat temperature is 55 degrees F or above conduct continuity test by using an Ohm Meter or Test Light Attach one lead of test device to one terminal lead wire of thermostat Connect other lead of test device to other terminal lead wire of thermostat There should be NO continuity If continuity is indicated replace thermostat heater assembly B While thermostat temperature is 35 degrees F or below conduct continuity test by using an Ohm Meter or Test Light Attach one lead of test device to one terminal lead wire of thermostat Connect other lead of test device to other terminal lead wire of thermostat There should be continuity If there is

Brakemaster® air dryers

Contents

Download Pdf Manuals

Related Search

Related Contents

Brakemaster&reg; air dryers

Contents

Download Pdf Manuals

Related Search

Related Contents

Brakemaster® air dryers