HEAVY DUTY SPECIALISTS, INC. Service...HEAVY DUTY SPECIALISTS, INC. 9341 “G” Court • Omaha, NE 68127-1230 Phone (402) 592-5400 • Toll Free (800) 642-2514 • Fax (402) 592-9659

HEAVY DUTYSPECIALISTS, INC.

9341 “G” Court • Omaha, NE 68127-1230Phone (402) 592-5400 • Toll Free (800) 642-2514 • Fax (402) 592-9659

Turbo - 2000 Series

Service Manual Operations, Trouble Shooting

and Parts Listing

9/06

� • Turbo-2000 www.HvyDuty.com



Sure-Change air Dryer Monitor Kit #314a

The only sure way to save money on air dryer rebuilds and down time.

Desiccant type air dryers are the most efficient way to remove moisture from an air system - Until the Desiccant Becomes Saturated. When oil and moisture saturate the desiccant beads, the efficiency goes down hill quick.

• Oil resistant material to keep oil off the sight glass.• Burst pressure 900 psi.• no electrical or moving parts.• Mounts in minutes on your air system.

Blue indicates that the desiccant is good and the air dry.

Pink indicates that the desiccant is saturated and the air damp.

Sure-Change pin points the exact time the desiccant needs to be changed, saving down time and money. Changing the desiccant too often is costly, changing it too late could be even more expensive!!

Sure-Change mounts after the air dryer. When the desiccant is good and the air dry the sight glass is blue. When the desiccant becomes saturated and moisture gets through the dryer, the sight glass turns pink.

Mounting Instructions1. Remove air line from outlet side of the air dryer.2. Install 1/2 inch Street Tee in outlet side of dryer.3. Install air line in opposite end of the tee.4. Install SURE-CHANGE in side port of the tee.

One time purchase. no need to replace.after the desiccant is changed, Sure-Change turns back to blue.

1.31

2 H

EX

1.25




DESICCANT AIR DRYERS ......................................... 4 AirSystemsGeneralDescription...................................... 4 DesiccantAirDryerGeneralDescription......................... 4 TheoryofDesiccantOperation......................................... 5 MountingRecommendations.......................................... 12

TURBO PRODUCT LINE ............................................ 6 Turbo-2000HighDutyCycle.......................................... 6 HD-2000ContinuousFlow............................................... 6 Turbo-2000&HD-2000Specifications............................ 7 DualTurbo-2000ExtremeDutyCycle............................. 8 DualTurbo-2000Specifications........................................ 9 Turbo-2000OilSeparator&Specifications...............10-11

SAFETY PRECAUTIONS ......................................... 12

Turbo-2000 & HD-2000 AIR SYSTEM & AIR DRYER TROUBLE-SHOOTING ........................ 18 Problem:Aircontinuallyleaksfrom.............................. 18 theexhaustportduringcompressorstandbymode Problem:Systemairpressuredropsrapidly.................... 18 Problem:Aircompressormovesintothe....................... 18 standbymodebutcyclesrapidly Problem:Airleaksfromtheexhaustportduring........... 18 aircompressorchargecycle Problem:Aircompressorrunscontinuously.................. 19 systempressurewillnotbuild) Problem:Airdryerdoesnotpurge.................................. 19 Problem:Safetyvalveopens........................................... 19 Problem:Wateraccumulationinairsystem(tanks)........ 20

Turbo-2000 & HD-2000 SERVICE PROCEDURES ......................................... 21 PurgeValveServiceKit#235......................................... 21 CheckValveServiceKit#238........................................ 22 RegenerationValveServiceKit#223............................. 23 DesiccantCartridgeServiceKit#T224.......................... 24 HeaterAssembliesServiceKits#248,.......................25-26 #249,#619110,#619111

TURBO-2000 ‘ONLY’ SERVICE PROCEDURES ...... 27 TurboValveServiceKit#228......................................... 27 OilSeparatorServiceKit#619650................................. 28 OilSeparatorServiceKit#619600................................. 29

SPECIFICATIONS & PARTS LIST............................ 17 Turbo-2000&HD-2000PartsSchematic....................... 13 Turbo-2000&HD-2000ChargeCycleSchematic......... 14 Turbo-2000&HD-2000Unload/Purge......................... 15 CycleSchematic Turbo-2000&HD-2000ServiceSchematic................... 16

DUAL Turbo-2000 COMPONENT ID ....................... 33 DualTurbo-2000AirFlowSchematic............................ 30 DualTurbo-2000BottomSchematic.............................. 31 DualTurbo-2000ServiceSchematic.............................. 32

DUAL Turbo-2000 TROUBLE SHOOTING ............... 34 Problem:Aircontinuallyflowsfromtheexhaust.......... 34 portduringcompressorstandbymode Problem:System/wettankairpressuredropsrapidly..... 34 Problem:Aircompressormovesintothestandby........... 34 modebutcyclesrapidly Problem:Heavyairflowfromoneorboth..................... 35 exhaustportsduringcompressor Problem:Aircompressorrunscontinuously................... 35 Problem:Airdryerdoesnotexhaustduring................... 36 compressorchargemode Problem:Safetyvalveopens........................................... 36 Problem:Wateraccumulationin(airsystem)tanks........ 37

SERVICE PROCEDURES ......................................... 38 DualTurbo-2000 PurgeValveServiceKit#235......................................... 38 CheckValveServiceKit#238........................................ 39 RegenerationValveServiceKit#619911....................... 40 InletCheckValve#619915............................................. 41 DesiccantCartridgeServiceKit#T224.......................... 42 HeaterServiceKit#619910&#619111......................... 43 OilSeparatorServiceKit#619600............................45-46 MicroLogicTimerServiceKit#619912&#619924..... 47

AIR DRYER SOCKET SIZES .................................... 48

Turbo-2000 AIR DRYER TEST PROCEDURES .. 49-52

QUICK REFERENCE & ORDER FORM ................... 53

TaBLe OF COnTenTS




aIr SYSTeMS generaL DeSCrIPTIOnCompressedairisusedinavarietyofvehiclevocations(bothtraditionalandnon-traditional)primarilyfor

brakeapplication.Compressedairalsooperatesforairseats,airridesuspensions,airshift,horns,etc.Mounteddirectlytotheengine,thecompressoriscontrolledthroughapneumaticdeviceknownasaD2governor.Thegovernorcontrolsthecompressor’spumpingandnon-pumpingcycles.

Dieselenginedesigns,inordertoachieveoptimumhorsepowerandfuelefficiency,incorporatetheuseofturbochargers.Aturbochargerforcesgreateramountsofairintoanengine’scombustionchamberforacleanerengineburn.Onvocationswhereanaircompressor’sintakeisconnectedtothepressuresideofaturbocharger,thecompressorproducesagreaterCFM(cubicfeetperminute)flowrate.

Compressor DesignsFlowrate,compressordutycycleandvehiclevocationarethreevariablesthataffectanaircompressor,

airdryer,andtheentireairsystem.Sizeofthecompressor(cfm)ispredicatedbytheairrequirementsofthevehiclevocation.CompressorCFManddutycycledeterminesairdryermodeltyperequired.Somevocationsmayrequiretheinstallationofdualairdryerstomeetthedemandsofhighairflow(CFM)anddutycycles.

Duringthenon-pumpingcycle,turboboostpressureislostthroughtheaircompressor’sexhaustvalve(s)andexitsthroughtheairdryer’sopenpurgeport.Topreventthis,ChicagoRawhide’sturboseriesofairdryersincorporateaturboboostprotectionvalve.

DischargeLineUnload(DLU)airsystemsdonotrequireturboboostprotectionasthecompressorsarenaturallyaspiratedanddesignedtopumpcontinuously.TheChicagoRawhideHDairdryeriscontrolledbyatraditionalD2governorallowsthecompressortopumpcontinuouslythroughthepurgeportoftheairdryer.Thisallowstheaircompressortoruncooler.

DeSICCanT aIr DrYerSDesiccant Air Dryer General Description

ChicagoRawhide’sdesiccantseriesofairdryers,Turbo-2000andHD-2000,aremodelsdesignedtomountverticallybetweentheaircompressorandtheairsystem’ssupplyreservoirs.Thedesiccantairdryerreceiveshotcompressedairthatitcools,dries,andfiltersbeforedeliverytothesupplyreservoirs

TheTURBO-2000andHD-2000incorporatefourpoundsofdesiccantandaseparatepurgetank(460cubicinches)thatisisolatedfromthevehicleairsystem.Thepurgetankstoresclean,dryairforregenerationofthedesiccantbed.Thedesignoftheseairdryersservevehiclevocationswithcompressordutycyclesofupto40%.

Airdryersareconstructedofalightweightaluminumandsteelhousingwithauniquespin-offcartridge.Belowthecartridgearefiveports:1)inlet,2)outlet,3)regeneration,4)control,and5)purgeport.Eachporthasaspecificfunction.Theinletportreceivescontaminatedairfromtheaircompressor.Outletportdirectscleandryairtotheairsystem.Connectedtotheisolatedpurgetankistheregenerationport.Thecontrolportreceivesanairsignalfromagovernordeviceandthepurgeportexpelswaterandcontaminatesfromtheairdryer.




Theory of Desiccant OperationHot,compressedairenterstheairdryerthroughtheinletport.Astheairentersthedryer,theairexpands;

oilandwatervaporcondense,andaccumulateinthesump.Theairpassesthroughaseriesoffiltersandaclothbagremovingcarbonandothercontaminates.Removaloftheremainingwatervaporoccursasairpassesthroughthedesiccantbedwithinthecartridge.Thecleandryairisthendirectedtothevehicleairsystemthroughtheoutletport.The2000seriesofdryerssimultaneouslyrefillsaregenerationtankthroughtheregenerationport.

Whentheairsystemreachesthegovernor-regulatedcutoutpressure(typically120psi),theairdryerpurgevalveopensviaanairsignalreceivedfromtheairsystemgovernor.Thegovernorwillalsosimultaneouslysignalthecompressortostopcompressingairinvehicleapplicationsnot utilizing a DLU (Discharge Line Unloaded).InvehiclesutilizingaDLU,anaturallyaspiratedaircompressorornon-computerizedengines,theHD-2000airdryerisrequired,asthecompressorswillcontinuetopumpairthroughtheairdryerspurgeport.

Theairdryer’scheckvalveclosesduringthenon-pumpingcycleofthecompressor.Withthecheckvalveclosed,airsystemreservoirsmaintainairpressure.Thefiltered,driedpurgeair,whichhasaccumulatedineithertheexternalisolatedpurgetankbeginsacontrolledregenerationcycleflowingcleandryairthroughtheairdryerdesiccantbed.Thisregenerationcycle,removesaccumulatedmoisturefromthedesiccantbed;backflushesandcleansthefiltersexpellingcontaminantsoutthedryer’spurgeport.Thiscompletestheregenerationcycle.

Whentheairsystempressuredropstothegovernorregulatedcut-inpressure(typically95psi),theairdryer’spurgevalveclosesasthevalvereactstotheevacuatingofairpressurethroughtheexhaust(EXH)portofthegovernor.Thecompressorthenbeginsthepumpingcycle.

Additionally,theTURBO-2000designincludesanadditionalvalvewithinthedryer:(Turbo cut off valve).Thisvalveensuresengineboostpressurewillnotescapeouttheairdryer’spurgeportduringthenon-pumpingcycles.

Chicago Rawhide offers additional air dryers to meet the unique requirements for the Holset SS or QE designed air compressors. These air compressors require a differential check valve which maintain’s system air pressure within the air compressor’s discharge line.

For Specific Application Information Contact:

BoB Thomas

operaTions manager & producT Technical supporT

[email protected]

roBerT horner

Vp sales & markeTing cell: 402-203-0115

[email protected]




TheTurbo-2000istherecommendedchoiceforsevereserviceapplications,wherethecompressoroutputreaches30CFManddutycyclesrunashighas40%!Itsratiooflargepurgevolumetodesiccantproducestheidealfilteringsystemandcontaminationprotectionforheavydutyservicetoday.Afour-wayfiltrationsystem,consistingofthreefilterscreens,auniquefilteringbag,plusfourpoundsofhighqualitymolecularsievedesiccant,stripsawaymoistureandtrapscompressorblow-by.Thespin-offcartridgecanbeservicedinminutes.Thecompactpurgetankcanbeinstalledanywhereandprovidesafull460cu.in.ofcleanpurgeair.TheTurbo-2000modelsareavailableinstandardandHolsetQEcompressorcompatibleversions.TheHolsetQEcompatiblemodelsincludeaninternalvalvesystemthatprovidesfullturboboostprotectionandaninternalfeedbackfeaturerequiredfortheCummins/HolsetQEandE-Typecompressors.Noadditionalexternalvalvesarenecessary,reducingriskoffreeze-ups.ThestandardmodelTurbo-2000providesturboboostprotectionandiscompatiblewithallnonHolsetQE,HDandE-Typecompressors.Forall-weatheroperationtheTurbo-2000isequippedwithasealed12volt(oroptional24volt)75wattthermostaticallycontrolledheater. Thechoiceforseverestop-and-gooperations Largepurgevolumeforextendedcompressorcycles Turboboostprotectedforallengineapplications (FullycompatiblewithCummins/Holset)

TURBO-2000 HIGH DUTY CYCLE

TheCRBrakemasterHD-2000isdesignedtoprovideoptimumprotectionfornaturallyaspiratedcompressorsandsystemsemployingcontinuouspumpingcompressors(DischargeLineUnload).TheHD-2000istherecommendedchoiceforsevereserviceapplications,wherethecompressoroutputreaches30CFManddutycyclesrunashighas40%!Itsratiooflargepurgevolumetodesiccantproducestheidealfilteringsystemandcontaminationprotectionforheavydutyservicetoday.ExtendedcompressorlifemaybetheprimarybenefitoftheHD-2000.Atmaximumperformanceithasaninternalpressuredropofonly3psi!Asaresult,thecompressorrunssmoothlyunderacontinuousload.Forall-weatheroperationtheHD-2000isequippedwithasealed12volt(oroptional24volt)75wattthermostaticallycontrolledheater. 4-wayfiltrationsystem Topperformanceforcontinuousflowairsystems Largepurgevolumeanddesiccantbedkeeptheairsystemclean&dry Uniqueinternalpump-throughdesignmeanscoolerrunning compressors

HD-2000 CONTINUOUS FLOW




TURBO-2000 & HD-2000aIr DrYer SPeCIFICaTIOnS

• Unit Dimensions: See Figure 1• Weight: 19.5 Lbs.• Connection Ports: See Figure 2• Air Flow Capacity: 30 SCFM• Drying Medium: 4 Lbs. Desiccant (Spin-on Cartridge)• Dry Medium Regeneration: External Purge Tank (12” x 7” Diameter Wgt. = 10 Lbs., Volume = 460 Cu. In.)• Turbo Protection Valve: Internal on Turbo-2000 Only• Safety Valve: 175 psig• Heater Options: 12v 75 Watt (6.6 Amps) 24v 75 Watt (3.2 Amps)




Proveneffectivebythecountry’s largestandmostsevere-use municipalfleets.

Keepsairsystemclean,keepsair capacityhigh—eveninthemost severeusesituationsrequiring100% compressordutycycles.

Electronictoggledevicechannelsair flowthroughonecartridgewhilethe otherregenerates.

InternalOilSeparatorremoves compressorblow-bybeforeentering desiccantcartridge-protects downstreamcomponents.

Easytoinstallandservice;reduces fleetdowntime.

TheCRBrakemasterDualTurbo-2000isdesignedforvehiclesthatuselargeamountsofair,suchastransitandrefuse,whichcanrequirenearly100%compressorchargetimeat40SCFM.Thisingenious,drop-inreplacementdryerconsistsoftwodesiccantcartridgesandonebasewithelectronictoggledevicetochannelairflowthroughonecartridgewhiletheotherregenerates.LikeallCRBrakemasterdryers,itisequippedwitha12or24voltheater.However,unlikeothermodels,theDualTurbo-2000doesnotrequireapurgetank:instead,purgeairisprovidedbytheopposingcartridge.

Largeinletandoutletportsminimizeapressuredropwithinthedryers,easingtheburdenonthecompressorandextendingitsservicelife.Theinternalregenerationprocessprovideshighlyefficientdryingandcontaminationremovaltooptimizeairpurityandavailability.

DUAL TURBO-2000 EXTREME DUTY CYCLE




DUAL TURBO-2000SPeCIFICaTIOnS

• Unit Dimensions: (see Fig. 1)• Weight: 47 Lbs.• Connection Ports: (see Fig. 2)• Air Flow Capacity: 40 SCFM• Drying Medium: 8 Lbs. Desiccant (Spin-on Cartridges, 2 @ 4 lb.)• Drying Medium Regeneration: System Purge (controlled alternating cycle)• Safety Valve: 175 psig• Heater Options: 12v 75 Watt (6.6 Amps) 24v 75 Watt (3.2 Amps)

10 • Turbo-2000 www.HvyDuty.com



TURBO-2000 INTEGRATED OIL SEPARATOR

SKFThenewTURBO-2000IntegratedOilSeparatorisaninternalaccessoryforChicagoRawhide’sBrakemasterseriesofairdryersremovingoilcontaminantsintroducedintotheairsystemviathevehicle’saircompressor.Thehighcompressordutycycleinherenttoheavybrakingapplicationssuchastransientbuseseventuallycreatesmanyproblems: Oilinfiltratingthedesiccantand shorteningthecartridgeservicelife. Damageddryeranddownstreamvalving. Cokedupdischargelinecausingreduced airflow. Reducedaircapacityastanksfillwithoil.

WithTURBO-2000OilSeparator,theairsystemisprotectedfromthedamagingeffectsofcompressorblow-by.Thefeaturesofthenewseparatorinclude: Positioningoftheseparatorinsidethe dryerbeforedesiccantbed. -Extendedlifeofairdryercartridge. -Protectingairsystemcomponents. -RetrofitseasilytoexistingCRair dryers. Selfcleaningdesign. -Assurescontinuousremovalofoil withoutblockage. -Longservicelife. Stainlesssteelunitizedconstruction. -Durablelonglife. -Corrosionresistance.

11 • Turbo-2000 www.HvyDuty.com



Diameter 6 3/4”Height 1 1/2”Weight .05 lb.Construction Stainless SteelMounting Internal Air Dryer

620750 Dryer/Tank 12v620754 Dryer/Tank 24v

A 610077 Flange GasketsB 610600 Oil Separator

620700 Dryer/Tank 12v620704 Dryer/Tank 24v

A 610077 Flange GasketB 610600 Oil SeparatorC 228 Turbo Valve Kit

OIL SeParaTOr unIT

hD-2000

Kit 619600 Contents

Turbo-2000

Kit 619650

AB

AB

C

1� • Turbo-2000 www.HvyDuty.com



Mounting recommendations

Airdryersaremountedbetweentheaircompressorandthefirstreservoirtank.TheaircompressordischargelineshouldbeeithercopperorsteelbraidedTeflon®.Whenusingcopper,itisrecommendedthatasmallamountofflexibleTeflon‚steelbraidedhosebeusedtoabsorbvibration.

Thecompressordischargelinesize,length,andmaterialmustbesuchthatthedryerinletairtemperatureistypicallynomorethan160oFornolessthan45oFabovelowambienttemperature(referenceSAEJ2383).Forexample:ifambienttemperatureis-40oF,thedryerinlettemperaturemustbeabove+5oF.

Lowerdryerinletairtemperaturesshouldbeavoidedtominimizetheriskoffreeze-upinthedischargelineordryerinletfitting.Higherdryerinletairtemperaturesshouldbeavoidedtominimizetheriskofheatdamagetothedryer’ssealsand/ortoavoidalossofdryingperformance.Itisrecognizedthatbothlimitsmaynotbeachievableatallextremesofambienttemperatureandcompressordutycycle.Therefore,toprotectfromdischargelinefreeze-up,itisrecommendedthatapressurereliefvalvebeinstallednearthecompressoroutlet,particularlyonthosevehicleswhichwillnotmeetthelowtemperaturelimitatthedryerinlet.

Theairdryermountinglocationmustbeawayfromaheatsourceanddownhillfromaircompressor.Itisrequiredthatambientaircirculationoccursaroundairdryer.Detailedinstallationinstructionscomewitheachairdryerfromthefactory.

SaFeTY PreCauTIOnS1. Beforeperforminganytestand/orisolatingtheairdryer,thevehicle’swheelsmustbechockedmakingsurethe vehiclewillnotrollbeforereleasingthebrakes.

2. Neverworkunderaunitsupportedonlybyajack.Alwayssupportthevehiclewithstands.

3. Stopenginewhenworkingunderavehicle.

4. Neverremoveacomponentorapipeplugunlessyouarecertainallsystemairpressurehasbeenexhausted.

5. Neverconnectordisconnectahoseorlinecontainingairpressure.

6. Neverexceedrecommendedworkingairpressure.

7. Neverattempttodisassembleanairdryeruntilyouhavereadandunderstoodallrecommendedprocedures.

8. Useonlypropertoolsandobserveallprecautionspertainingtotheuseofthosetools.







Turbo-2000 Charge Schematic

•••

**CLOSED

T224

*228OPEN

238OPEN

223OPEN

610024COMP

WETTANK

PURGETANK

EXHUNLRES

619110 & 619111(Metri-Pak Connector)

248 & 249(Plastic Cover)

235CLOSED

-




Turbo-2000 regeneration Schematic

**OPEN

T224

238CLOSED

610024

EXH

UNL•••

COMP

WETTANK

PURGETANK

223PURGE

235OPEN

*228CLOSED

619110 & 619111(Metri-Pak Connector)

248 & 249(Plastic Cover)

EXH

UNL

RES

unload/Purge Cycle




Turbo-2000 & hD-2000 Service Schematic

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

Turbo-2000 hD-2000




TurBO-2000 & hD-2000 COMPOnenT IDenTIFICaTIOnA 610237 REGENERATIONVALVENUTB 223 REGENERATIONVALVEKITC 610077 BODYGASKETD 610069 SEALRETAINERE T224 DESICCANTCARTRIDGEF 610236 CHECKVALVENUTG 238 CHECKVALVEKITH 619086 BOTTOMCAPASSY12vSTD 619112 BOTTOMCAPASSY12vE-TYPEH 619087 BOTTOMCAPASSY12vSTD 619113 BOTTOMCAPASSY24vE-TYPEH 619089 BOTTOMCAPASSY12v (HD-2000) 619090 BOTTOMCAPASSY24v (HD-2000)I 235 PURGEVALVEKITJ 248 12v75WHEATERKITEARLYMODEL 249 24v75W(ORANGEANDBLUEWIRES)J 619110 12v75WHEATERKITLATEMODEL 619111 24v75WPLUGSTYLECONNECTIONK 619900 WIREHARNESSL 610024 SAFETYVALVE175PSIM 228 TURBOVALVEKIT(TURBO-2000 ONLY)N 619115 MOUNTINGBRACKETO 619140 CARTRIDGESTUDP 619650 OILSEPARATOR 221 PURGETANK 619091 ADAPT.CSTG.,STD&HDTYPES

TurBO-2000 aIr DrYer ParT nuMBer DeSCrIPTIOnSTD E-TYPE* STD-W/OIL SEPARATOR DESCRIPTION 620600 620500 620700 12vDRYER&PURGETANK620604 620504 620704 24vDRYER&PURGETANK620602 620502 620702 12vAIRDRYERONLY620606 620506 620706 24vAIRDRYERONLY*HOLSET SS E-TYPE OR QE COMPRESSOR COMPATIBLE (STANDARD ON CUMMINS ENGINES)

hD-2000 aIr DrYer ParT nuMBer DeSCrIPTIOnSTD STD-W/OIL SEPARATOR DESCRIPTION620550 620750 12vDRYER&PURGETANK620554 620754 24vDRYER&PURGETANK620552 620756 12vDRYER620556 620756 24vDRYER




Trouble-Shooting TurBO-2000 & hD-2000PROBLEM: AIR CONTINUALLY LEAKS FROM THE EXHAUST PORT DURING COMPRESSOR STANDBY MODEPOSSIBLE CAUSE REMEDYWORNCHECKVALVE Cleancavityreplacecheckvalveassembly#238WORNTURBOVALVE(TURBO-2000 ONLY) Cleancavityandreplaceturbovalveassembly#228WORNPURGEVALVESEAL Cleancavityandreplacepurgevalveassembly#235

PROBLEM: SYSTEM AIR PRESSURE DROPS RAPIDLYPOSSIBLE CAUSE REMEDYFITTINGSARELOOSEORDAMAGED Tightenand/orreplaceasnecessaryAIRRESERVOIR,TUBING, RepairorreplaceasnecessaryORHOSESAREDAMAGEDWORNCHECKVALVE Cleancavityandreplacecheckvalveassembly#238WORNTURBOVALVE Cavityreplaceturbovalveassembly#228WORNPURGEVALVESEAL Cleancavityandreplacepurgevalveassembly#235

PROBLEM: AIR COMPRESSOR MOVES INTO THE STANDBY MODE BUT CYCLES RAPIDLYPOSSIBLE CAUSE REMEDYFITTINGSARELOOSEORDAMAGED Tightenand/orreplaceasnecessaryAIRRESERVOIR,TUBING, RepairorreplaceasnecessaryORHOSESAREDAMAGEDWORNCHECKVALVE Cleancavityandreplacecheckvalveassembly#238WORNTURBOVALVE Cleancavityandreplaceturbovalveassembly#228D2GOVERNORMALFUNCTIONING ReplacegovernorWORNPURGEVALVESEAL Cleancavityandreplacepurgevalveassembly#235

PROBLEM: AIR LEAKS FROM THE EXHAUST PORT DURING COMPRESSOR CHARGE MODEPOSSIBLE CAUSE REMEDYWORNPURGEVALVE Cleancavitiesreplacepurgevalveassembly#235DIRT/FOREIGNMATERIAL Cleancavityreplacevalveassembly#235ISSTUCKINTHEPURGEVALVED2GOVERNORMALFUNCTIONING Replaced2governorHEATERASSEMBLYMALFUNCTIONING Replaceheaterassembly#246(12v),247(24v),(>32DEGREES) 248(12v),249(24v),619110(12v)or619111(24v)




PROBLEM: AIR COMPRESSOR RUNS CONTINUOUSLY (SYSTEM PRESSURE WILL NOT BUILD)POSSIBLE CAUSE REMEDYFITTINGSARELOOSEORDAMAGED TightenorreplacelooseordamagedfittingsAIRRESERVOIR,TUBING, RepairorreplacedamageditemsORHOSESAREDAMAGEDTHEAIRCOMPRESSORNEEDS RebuildorreplacetheaircompressorTOBESERVICEDORREPLACEDWORNPURGEVALVE Cleancavityreplacethepurgevalveassembly#235THEAIRCOMPRESSOR InstalllargeraircompressorCAPACITYISTOOLOWFORVEHICLELINEBETWEENGOVERNOR ReplacethelineorremovetheblockageANDAIRCOMPRESSORISBLOCKEDTHESAFETYVALVE Replacethesafetyvalve#610024ISMALFUNCTIONINGICEHASFORMEDINTHE Replaceheaterassembly#246(12v),247(24v),PURGEVALVE 248(12v),249(24v),619110(12v)or619111(24v)D2GOVERNORMALFUNCTIONING ReplaceD2governor

PROBLEM: AIR DRYER DOES NOT EXHAUST DURING COMPRESSOR STANDBY MODE

POSSIBLE CAUSE REMEDYTHELINEBETWEENTHEAIRGOVERNOR Installorreplacetheairline,ortightenthefittingsANDTHEAIRDRYERCONTROLPORTISMISSING,LEAKING,ORDAMAGEDWORNPURGEVALVE Cleancavityandreplacepurgevalveassembly#235ICEHASFORMEDINTHEPURGEVALVE Replaceheaterassembly#246(12v),247(24v),248(12v),249(24v), 619110(12v)or619111(24v)HEATERISMALFUNCTIONING Replaceheaterassembly#246(12v),247(24v),248(12v),249(24v), 619110(12v)or619111(24v)PURGEVALVESLEEVEISMISALIGNED Alignpurgevalvesleeve

PROBLEM: SAFETY VALVE OPENSPOSSIBLE CAUSE REMEDYAIRDRYER Checkvalveisblockedcleancavityandreplacecheckvalve assembly#238AIRBRAKESYSTEMISBLOCKED Removeblockageorreplacethenecessarydownstreamofairdryer componentsAIRCOMPRESSORGOVERNOR ReplacecompressorD2governorMALFUNCTIONINGBLOCKEDDESICCANTCARTRIDGE Replacecartridge#T224andoilseparator#619650ifpresentor installoilseparatorTHESAFETYVALVEISMALFUNCTIONING Replacethesafetyvalve#610024OILSEPARATORISBLOCKED Replaceoilseparator#619650

�0 • Turbo-2000 www.HvyDuty.com



PROBLEM: WATER ACCUMULATION IN AIR SYSTEM (TANKS)POSSIBLE CAUSE REMEDYDESICCANTISCONTAMINATED Replacedesiccantcartridge#T224andoilseparator#619650 ifpresentTHEAIRCOMPRESSORCAPACITY Installlargeraircompressorandreplacedesiccantistoolowfor vehiclecartridge#T224MALFUNCTIONING Cleancavityandreplaceregenerationvalveregenerationvalve assembly#223THELINEBETWEENTHEPURGETANK Installorreplacetheairline,ortightenthefittingsANDTHEAIRDRYERCONTROLPORTISMISSING,LEAKING,ORDAMAGEDLINEBETWEENTHECOMPRESSOR Fitnewlinewithaminimumlengthof6feetcopperANDAIRDRYERTOOSHORT lineor(insufficientpre-cool)12feetofsteelbraidedTeflon®*

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 TurBO-2000 & hD-2000 Purge Valve Service Kit #235

WARNING: READ AND FOLLOW SAFETY PRECAUTIONS FOUND ON PAGE 13 BEFORE PROCEEDINGSymptom:

1. Dryerwon’texhaust.2. Airleakatexhaustportduringthe: a.chargemode b.Stand-bymode3. Pressureslowornobuild.4. Compressorcyclesrapidly.

Operational Check: Startengineandbuildtocutoutpressure. Cycleseveraltimes.Ifdryerdoesnot exhaust,replacepurgevalve#235.

Symptom #2A & 3: Startengineandbuildpressuretojustbeforecutout(approx.

100psi).Stopengine.Applysoapsolutionatexhaustportor listenforairleakatexhaustport.Ifaleakispresent,replace purgevalve#235.Symptom #2B & 4:

RemovegovernorlinefromUNLportonairdryer.Start engineandbuildtocutoutpressure.Stopengine.Ifnoair| leaksarepresent,replacepurgevalve#235.Purge Valve Replacement:

1. Disconnectthepurgeairline.2. Removethetwofastenersthatattachthepurgevalveretainer.

Removetheretainer.3. Removethepurgevalveassemblyfromthepurgeportand

discard.NOTE: If there is excessive oil in the purge port, compressor may require servicing.

4. Cleanthepurgeportthoroughly.5. Removethethree(3)o-ringsfromretaineranddiscard.6. Usinglubricantsupplied,lightlygreasethenewo-rings.7. Installontheretainerthetwo-(2)thickesto-ringstheninstallthethird(thinner)o-ring.8. Installthenewfilterscreeninthepurgecavityopenendout.9. Applyalightcoatingofgreasearoundtheo-ringseatonvalveassembly. Installthethino-ringonthepurgevalveseat.10.Aligningthevalveexhaustportwiththeairdryerexhaustport,installthepurgevalve assembly.Usecarenottodislodgetheo-ringfromitsseat.

WARNING: If the air dryer purge valve port does not align air dryer will not exhaust.

11. Installretainer.12. Applyalightcoatingofgreaseonthethreadsofthetworetainerbolts.13. Installtworetainerbolts.Tightentol0-l5ft.lb.14. Reconnectthepurgeairlinetoairdryerpurgeport.

�� • Turbo-2000 www.HvyDuty.com



SerVICe PrOCeDureS TurBO-2000 & hD-2000 Check Valve Service Kit #238

WARNING: READ AND FOLLOW SAFETY PRECAUTIONS FOUND ON PAGE 13 BEFORE PROCEEDING

Symptom:1. Dryerfrequentlyexhausts.2. Aircontinuallyflowsfromexhaustportwhen compressorisinstandbymode.3. Wettankpressuredropsrapidly.

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, & #3:Disconnectlineatcontrolportandplug.Startengineandbuildtocutoutpressure.Stopengine.Applysoapysolutionaroundexhaustport.Ifsoapbubblesexist,replacecheckvalve#238.

Check Valve Replacement:1. Drainairsystem.2. Disconnectairlinefromoutletport.3. Removecheckvalvenut.4. Removeanddiscardo-ring,spring,spindle,andball.NOTE: If there is excessive oil in the check valve cavity, compressor may require servicing.5. Cleannutandcavityarea.6. Installnewballincavity.Next,positionspindlewithspringpocketfacingout.Installspring.7. Usinggreasesupplied,applyalightcoatingono-ring.Installo-ringonnut.8. Applyalightcoatingofgreasetothreadsofnut.Installnutandtightento60ft.lb.9. Re-connectairlinetoairdryeroutletport.

OR




SerVICe PrOCeDureS TurBO-2000 & hD-2000regeneration Valve Service Kit #223


Symptom:1. Waterintanks.2. Nopurgeairflow.

Operational Check:Symptom #1 & #2:Startengineandbuildtocut-outpressure.Stopengine.Afterinitialexhaust,airshouldflowwithdecreasingintensityouttheexhaustportforapproximately45seconds.Ifairfailstoflow,replaceregenerationvalvekit#223.

Regeneration Valve Replacement:1. Draintheairsystem.2. Disconnecttheairlineatairdryerpurge tankport.3. Removeregenerationvalvenut.4. Removeanddiscardo-ring,springandspindle.5. Cleannutandcavity.6. Positionnewspindleinthecavitywithspringpocketsideout.Installspring.7. Usinggreasesupplied,applyalightcoatingono-ring.Installo-ringonnut.8. Applylightcoatingofgreaseonnutthreads.Installnutandtightento60ft.lb.9. Re-connectairlinetoairdryerpurgetankport.

OR




SerVICe PrOCeDureS TurBO-2000 & hD-2000Desiccant Cartridge Service Kit #T224


Symptom:1.Regularserviceinterval.2.Waterintanks.NOTE: If there is excessive oil present, compressor may require servicing or an oil separator, kit #619650, may be required.

Operational Check:Symptom #1 & #2:Desiccantcartridgerequiresregularservicingatintervalsdeterminedbycompressordutycycleortypeofdrivingconditions.Typicalserviceintervalsare:

LineHaul 3yearsInnerCity 2yearsRefuse/Transit 1yearOffHighway 1year

Theaboveisaguidelineonly.Draintanksonregularbasis.Ifmoistureexists,replacecartridge#T224.(Seepage2onSureChangeMonitorKit)

Desiccant Cartridge Replacement:1.Draintheairsystem.2.Usingastrapwrench,turnthedesiccantcartridgecounterclockwiseandremoveit.Discard.3.Removeanddiscardo-ringfromadapterplatestud.4.Cleantopsurfaceofadapterplateandthreadedstud.5.Usinggreasesupplied,applyalightcoatingono-ring.Installo-ringonstud.6.Applyagenerouscoatofgreaseonthenewdesiccantcartridgegasketsurface.7.Threadnewcartridgeontostudturningclockwise.Whengasketcontactsadapterplate,tightencartridge1/2turn.DO NOT OVER-TIGHTEN!

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

CARTRIDGE

GASKET

O'RING

Original Design New Rimless DesignOR




SerVICe PrOCeDureS TurBO-2000 & hD-2000heater Service Kit #248, #249, #619110, #619111


Symptom:1.Dryerwon’texhausts.2.Exhaustportleak.3.Cannotbuildpressure.

Operational Check:

NOTE: Thermostat must be cooled to at least 35 degrees F to check.1.Closedohmmetercircuitindicatesheaterisfunctioning.2.Openohmmetercircuitindicatesfaultyheaterassembly.

Heater Assembly Replacement:1.Disconnectheaterleads.2.Removesetscrew(ifpresent)holdingheaterelementincasting.3.Removetwoscrewsattachingheatercoverand/orthermostattocasting.4.Removeheater/thermostatassemblyanddiscard.5.Thoroughlycleanentireheater/thermostatarea.6.Applyalightcoatingofanti-seizetotheheaterelementandthermostatcavity.7.Insertheaterelementintoholeandtwistslightlytospreadanti-seize.

7.1 early Models (#248 or #249; orange and blue wires)7..1.1Installnewsetscrew(ifrequired)untilsnug(DONOTOVERTIGHTEN)Screwwillprotrudefrombottomcapabout1/8”.7..1.2Insertthermostatintopositioninthermostatcavity.7..1.3Coilleadwiresaroundheatercoverpostsallowingwirestoprotrudethroughslotsincover.7..1.4Placetwo(2)6-32x1-1/8screwsinheatercoverandattachthethermostat.NOTE: If heater cover is not used, use short screws and wire clamps to secure thermostat and wires.

OR




SerVICe PrOCeDureS TurBO-2000 & hD-2000 heater Service Kit #248, #249, #619110, #619111 (Cont.)

7..1.5Fillheatercoverthrough1/4”holewithnon-corrosiveRTV.

7..1.6Connectblueheaterwiretoagoodchassisground.

7..1.7Connectorangewiretoignitionswitch.

7..1.8Sealandrouteheaterwirescarefully.

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

7.1.2.1Slideo-ringoverheaterandthermostatintopositionaroundconnectorflange.

7.1.2.2.Slideheaterandthermostatintopositionincavity.

7.1.2.3.Ensurethermostatsitsflatincavity.

7.1.2.4.Placefoamcubeontopofthermostatandbringheaterconnectorintopositionoverheater.

7.1.2.5.Secureheaterassemblyusingthe(2)8-32x1/2”screws.

7.1.2.6.ReconnectMetri-Pakconnectortomaleplug.

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 ONLY SerVICe PrOCeDure Turbo Valve Service Kit #228


Symptom:1. Dryerfrequentlyexhausts.2. Aircontinuallyflowsfromexhaustport

whencompressorisinstandbymode.3. Systempressuredropsveryrapidly.

NOTE: The above symptoms could also lead to check valve replacement. A malfunctioning Turbo valve will tend to allow pressure to drop to cut-in

pressure within seconds.

Operational Check: Symptom #1, 2, & 3:Disconnectlineatpurgeportandplug.Startengine

andbuildpressuretocut-outpressure.Stopengine.Applysoapysolutionaroundexhaustport.Ifsoapbubblesexist,replaceTurbovalve#228.

Turbo Valve Replacement:1. Draintheairsystem.2. Disconnecttheheaterwiring.Disconnectthe

inletandpurgelinesfromtheirrespective ports.Marklinesforlaterassembly.

3. Remove8boltsfrombottomcapandsetaside. Discardgasket.

4. Removeturbonut,valvestopandvalveanddiscard.5. Cleancavityareathoroughly.6. Lightlycoatthe2(small)o-ringsurfacesandinstallonpiston.Carefullyinstallvalveincavity

withtaperedsideup.7. Placevalvestopontopofvalveconcavesidedown.8. Lightlylube(large)o-ringandplaceonnut.Installflatsealintonut.9. Installnutandtightento50ft.lb.10.Placegasketonbottomcapaligningsmallholewithsmallcheckvalve.Locatebottomcapso

thatinletportisdirectlybelowoutletport.Installthe8boltsset-asideduringdisassembly. Tightenboltsto15-20ft.lb.

11.Re-connectinletandpurgelinesaspreviouslymarkedtoairdryer.12.Re-connectheaterwiring.




SerVICe PrOCeDureS TurBO-2000 ONLY Oil Separator Service Kit #619650


Symptom:1. Excessivewetoilaccumulationatexhaust portofdryer.2. Water/oilinairsystem.

NOTE: If oil present in system air tanks, replace desiccant cartridge, T224

Operational Check:Draintanks,checkforexcessiveoilandwater.

Oil Separator Replacement:1. Drainairsystem.2. Disconnectheaterwiresfromairdryer.3. Disconnectinletandcontrollinesfromtheir respectiveports.4. Remove(8)boltsfrombottomcapandset aside.5. Removebottomcapassembly.6. Removeoilseparatorand(2)gasketsfrom bottomcapanddiscard.7. Cleanbottomcapsumpandinsideofair dryeradapterplateofalloiland contaminates.8. Replaceturbovalveperserviceproceduresonpage25.9. Placeonenewgasketonbottomcapflange.10.Placenewoilseparatorontopoffirstgasketonbottomcap(usetwoboltstoaligncomponents).11.Placesecondnewgasketontopofoilseparator.12.Reinstallbottomcap/oilseparatorontoadapterplate.13.Torque8bolts25-30ft.lbs.14.Re-connectinletandcontrollinestotheirrespectiveports.15.Re-connectheaterwires.

This service kit applies to Holset QE Air Compressors




SerVICe PrOCeDureS hD-2000 ONLYOil Separator Service Kit #619600


Symptom:1. Excessivewetoilaccumulation atexhaustportofdryer.2. Water/oilinairsystem.NOTE: If oil is present in system air tanks,replace desiccant cartridge, T224.


Oil Separator Replacement:1. Drainairsystem.2. Disconnectheaterwiresfromairdryer.3. Disconnectinletandcontrollinesfromtheir respectiveports.4. Remove(8)boltsfrombottomcapandset aside.5. Removebottomcapassembly.6. Removeoilseparatorand(2)gasketsfrom bottomcapanddiscard.7. Cleanbottomcapsumpandinsideofairdryeradapterplateofalloilandcontaminates.8. Placeonenewgasketonbottomcapflange.9. Placenewoilseparatorontopoffirstgasketonbottomcap(usetwoboltstoaligncomponents).10.Placesecondnewgasketontopofoilseparator.11.Reinstallbottomcap/oilseparatorontoadapterplate.12.Torque8bolts25-30ft.lbs.13.Re-connectinletandcontrollinestotheirrespectiveports.14.Re-connectheaterwires.




D2

619915 OPEN

619110 HEATER 12v 619111 HEATER 24v

235 OPEN

LeFT SIDe rIghT SIDe

▲

CLEAN / DRY AIR

ATMOSPHERIC PRESSURE

DIRTY / WET CHARGED AIR

DIRTY / WET PURGED AIR

▲

▲

▲

▲

▲

▲

▲

▲

WETTANK

TOSYSTEM

AIR COMPRESSOR

EXH

UNL

RES ▲

238 OPEN

DURING CHARGE

619911 OPEN

▲

619911 CLOSED

LeFT SIDeSIDe VIeW

rIghT SIDeSIDe VIeW







DuaL TurBO-2000 Service Schematic

Bottom ViewSide View




DuaL TurBO-2000 DrYer COMPOnenT IDenTIFICaTIOnA 619930 MANIFOLD

B 619911 REGENERATIONVALVEKIT

C 610077 BODYGASKET

D 610069 SEALRETAINERNOTE: FOUR RETAINERS PER DRYER, TWO ON EITHER SIDE/1 PER BOX.

E T224 DESICCANTCARTRIDGE

F 619928 CHECKVALVENUT

G 238 CHECKVALVEKIT

H 619932 VALVEHOUSING,COMPLETEWITHVALVES&12vHEATER

H 619934 VALVEHOUSING,COMPLETEWITHVALVES&24vHEATER

I 235 PURGEVALVEKITNOTE: TWO VALVES PER DRYER, ONE ON EITHER SIDE/1 PER BOX.

J 619110 12v75WHEATERKIT

J 619111 24v75WHEATERKIT

K 619935 WIREHARNESS

L 610024 SAFETYVALVE(175PSI)

M 619915 INLETCHECKVALVEKITNOTE: TWO VALVES PER DRYER, ONE ON EITHER SIDE/1 PER BOX.

N 619980 MOUNTINGBRACKET

O 619140 CARTRIDGESTUD

P 619600 OILSEPARATORKIT

Q 619920 MID-SECTIONL.H.

R 619921 MID-SECTIONR.H.

S 619910 AIRCONTROLVALVE

T 619912 MLT12v

T 619924 MLT24vBOLD PART NUMBERS REPRESENT SUGGESTED STOCK SERVICE COMPONENTS




TrOuBLe-ShOOTIng DuaL TurBO-2000NORMAL DUAL TURBO-2000 AIR DRYER OPERATION/CYCLE

1. TheMicroLogicTimer(MLT)controlsdryingandregenerationcyclesofthedualTurbo-2000air byenergizingandde-energizingtheAirControlValveofairdryerat90-secondintervals.Anindicator lightonMLTwillbe“on”duringenergizedcycleand“off”duringthede-energizedcycle.2. Theairdryer’sAirControlValvecontrolsairflowdirectionthroughthedryerduringthecompressor’s chargemode(pumping).Duringthischargemodeonedryercartridgeisdryingairandothercartridge isbeingregenerated.3. DuringthecompressorchargemodetherewillbealightflowofairfromONEexhaustportofairdryer. Thisisnormal,regenerationairflowandshouldbepresentONLYwhenthecompressorisincharge mode(pumping).Theairflowwillalternate(every90-seconds)fromoneexhaustporttotheotherin conjunctionwiththeMLTcycles.Whentheairdryercyclealternatesduringthecompressorcharge mode(pumping),therewillbeamomentaryburstofairfromoneoftheairdryerexhaustports. Thisisnormal.

PROBLEM: AIR CONTINUALLY FLOWS FROM THE EXHAUST PORT DURING COMPRESSOR STANDBY MODEPOSSIBLE CAUSE REMEDYWORNCHECKVALVE Cleancavityandreplacecheckvalveassembly#238

PROBLEM: SYSTEM/WET TANK AIR PRESSURE DROPS RAPIDLYPOSSIBLE CAUSE REMEDYFITTINGSARELOOSEORDAMAGED Tightenand/orreplaceasnecessaryAIRRESERVOIR,TUBING, RepairorreplaceasnecessaryORHOSESAREDAMAGEDWORNCHECKVALVE Cleancavityandreplacecheckvalveassembly#238D2GOVERNORMALFUNCTIONING Replacegovernor

PROBLEM: AIR COMPRESSOR MOVES INTO THE STANDBY MODE BUT CYCLES RAPIDLYPOSSIBLE CAUSE REMEDYFITTINGSARELOOSEORDAMAGED Tightenand/orreplaceasnecessaryAIRRESERVOIR,TUBING,REPAIROR ReplaceasnecessaryORHOSESAREDAMAGEDWORNCHECKVALVE Cleancavityandreplacecheckvalveassembly#238D2GOVERNORMALFUNCTIONING Replacegovernor




PROBLEM: HEAVY AIR FLOW FROM ONE OR BOTH EXHAUST PORTS DURING COMPRESSOR CHARGE MODE.

NOTE: ALTERNATING “LIGHT” AIR FLOW FROM EXHAUST PORTS DURING COMPRESSORCHARGE MODE IS NORMAL, REGENERATION AIR FLOW

POSSIBLE CAUSE REMEDYWORNPURGEVALVEOR Cleancavitiesandreplacepurgevalveassembly#235DIRT/FOREIGNMATERIALISSTUCKINTHEPURGEVALVEWORNINLETCHECKVALVE Cleancavityandreplacevalveassembly#619915ICEHASFORMEDINPURGE Replaceheaterassembly#619110(12v)orvalvesAND/ORINLETCHECK619111(24V)HEATERASSEMBLYMALFUNCTIONING

PROBLEM: AIR COMPRESSOR RUNS CONTINUOUSLY (SYSTEM PRESSURE WILL NOT BUILD)POSSIBLE CAUSE REMEDYFITTINGSARELOOSEORDAMAGED TightenorreplacelooseordamagedfittingsAIRRESERVOIR,TUBING, RepairorreplacedamageditemsORHOSESAREDAMAGEDTHEAIRCOMPRESSORNEEDS RebuildorreplacetheaircompressorTOBESERVICEDORREPLACEDWORNPURGEVALVEOR Cleancavityandreplacethepurgevalveassembly#235DIRT/FOREIGNMATERIALISSTUCKINTHEPURGEVALVETHEAIRCOMPRESSORCAPACITY InstalllargeraircompressorISTOOLOWFORVEHICLELINEBETWEENGOVERNOR ReplacethelineorremovetheblockageANDAIRCOMPRESSORISBLOCKEDTHESAFETYVALVEIS Replacethesafetyvalve#610024MALFUNCTIONINGWORNINLETCHECKVALVE Cleancavityandreplacevalveassembly#619915ICEHASFORMEDINPURGE Replaceheaterassembly#619110(12v)AND/ORINLETCHECKVALVES, or619111(24v)HEATERASSEMBLYMALFUNCTIONINGD2GOVERNORMALFUNCTIONING ReplaceD2governorAIRLINE(TUBING)CONNECTING Repair/replaceairline(tubing)DRYERMANIFOLDANDAIRCONTROLVALVEMISSINGORDAMAGED




TrOuBLe-ShOOTIng DuaL TurBO-2000PROBLEM: AIR DRYER DOES NOT EXHAUST DURING COMPRESSOR CHARGE MODEPOSSIBLE CAUSE REMEDYMICROLOGICTIMER(MLT) Replacemlt#619912(12v)or619924(24v)MALFUNCTIONINGAIRCONTROLVALVEMALFUNCTION Replaceaircontrolvalve#619910WORNPURGEVALVE Cleancavityandreplacethepurgevalveassembly#235EXHAUSTPORTSINPURGE AlignexhaustportsinpurgevalveandvalvehousingVALVEANDVALVEHOUSINGNOTALIGNEDAIRLINE(TUBING)CONNECTING Repair/replaceairline(s)(tubing)AIRCONTROLVALVEANDVALVEHOUSINGAND/ORMANIFOLDDAMAGEDORMISSINGICEHASFORMEDINTHEPURGE Replaceheaterassembly#619110(12v)orVALVE 619111(24v)HEATERISMALFUNCTIONING Replaceheaterassembly#619110(12v)or619111(24v)

PROBLEM: SAFETY VALVE OPENSPOSSIBLE CAUSE REMEDYAIRDRYEROUTLET CheckcleancavityandreplacetheVALVEISBLOCKED Checkvalveassembly#238.AIRBRAKESYSTEMISBLOCKED RemoveblockageorreplacethenecessaryDOWNSTREAMOFAIRDRYER componentsAIRCOMPRESSORGOVERNOR ReplacecompressorD2governorMALFUNCTIONINGAIRCOMPRESSORUNLOADER ReplacecompressorunloadervalveVALVEMALFUNCTIONINGBLOCKEDDESICCANTCARTRIDGE Replacecartridge#T224andoilseparator#619600THESAFETYVALVE Replacethesafetyvalve#610024ISMALFUNCTIONINGOILSEPARATORISBLOCKED Replaceoilseparator#619600AIRDRYERINLET CheckcleancavityandreplacetheinletcheckvalveVALVE(S)ISBLOCKED assembly#619915




PROBLEM: WATER ACCUMULATION IN AIR SYSTEM (TANKS)POSSIBLE CAUSE REMEDYDESICCANTISCONTAMINATED Replacedesiccantcartridge#T224andoilseparator#619600MICROLOGICTIMER(MLT) ReplaceMLT#619912(12v)or619924(24v)MALFUNCTIONINGAIRCONTROLVALVEMALFUNCTION Replaceaircontrolvalve#619910MALFUNCTIONING Cleancavityandreplaceregenerationvalve(s)#619911REGENERATIONVALVE(S)AIRLINE(TUBING)CONNECTING Repair/replaceairline(s)(tubing)AIRCONTROLVALVEANDVALVE copperlineor12feetofsteelbraidedTeflon®HOUSINGAND/ORMANIFOLDDAMAGEDORMISSINGLINEBETWEENTHECOMPRESSOR Fitnewlinewithaminimumlengthof6feetANDAIRDRYERTOOSHORT(INSUFFICIENTPRE-COOL)

REFER TO VEHICLE MANUFACTURER FOR SPECIFIC TEST PROCEDURES FOR NON RELATED AIR DRYER COMPONENTS.

*TeFLOn(r) IS a regISTereD TraDeMarK OF e.I. DuPOnT.




SerVICe PrOCeDureS DuaL TurBO-2000 Purge Valve Service Kit #235,

Note: Two (2) valves in dryer/1 per kit WARNING: BEFORE PROCEEDING READ AND FOLLOW SAFETY PRECAUTIONS FOUND ON PAGE 13.

REVIEW DESCRIPTION OF “NORMAL” DUAL TURBO-2000 AIR DRYER OPERATION/CYCLE, LOCATED AT BEGINNING OF DUAL TURBO-2000 AIR DRYER TROUBLE SHOOTING SECTION. (Page 30)

Symptom:1.Dryerwon’texhaustduringchargecycle.2.Largeairleakatexhaustport(s)duringthechargemode.Note: A light flow of air from ONE exhaust port during charge cycle is normal, regeneration air flow.3.Pressureslowornobuild.

Symptom #1:Startengineandbuildsystempressure.Ifdryerdoesnotexhaust,duringthechargecycle,proceedasfollows:1.Checkforblockageatexhaustport(s)ofairdryer2.Ifitem1OK,checkandreplace,ifnecessary,purgevalve#235NOTE: Failure of dryer to exhaust could also be due to malfunctioning MLT Valve. Refer to page 43 for service procedure on this item.

Symptom #2 & #3:Startengineandbuildairpressure.Duringthechargecycle,checkforlargeairleakatexhaustport(s)ofdryer.Iflargeamountofairisleakingfromexhaustportproceedasfollows:1.Checkandreplace,ifnecessary,purgevalve#235NOTE: Large air leak could also be due to worn inlet check valve. Refer to page 37 for service on this valve.

Purge Valve Replacement (Two places):1.Removethetwofastenersthatattachthepurgevalve

retainer.Removetheretainer.2.Removethepurgevalveassemblyando-ringfromthepurgecavityanddiscard.NOTE: If there is excessive oil in the cavity, compressor may require servicing.3.Cleanthecavitythoroughly.4.Removethethree(3)o-ringsfromretaineranddiscard.5.Usinglubricantsupplied,lightlygreasethenewo-rings.6.Installontheretainerthetwo(2)largero-ringstheninstallthethird(smaller)o-ring.7.Applyalightcoatingofgreasearoundtheo-ringseatonvalveassembly.Installthethino-ringonthepurgevalveseat.8.Insertvalveassemblyintocavity.Insurethatvalveexhaustportisalignedwithairdryerexhaustport.Usecarenottodislodgetheo-ringfromitsseat.WARNING: If the air dryer purge valve port does not align with air dryer exhaust port, air dryer will not exhaust!9.Installretainer.10.Applyalightcoatingofgreaseonthethreadsofthetworetainerbolts.11.Installtworetainerbolts.Tightentol0-l5ft.lb.

Operational Check:




SerVICe PrOCeDureS DuaL TurBO-2000 Check Valve Service Kit #238

WARNING: BEFORE PROCEEDING READ AND FOLLOW SAFETY PRECAUTIONS FOUND ON PAGE 13. REVIEW DESCRIPTION OF “NORMAL” DUAL TURBO-2000 AIR DRYER OPERATION/CYCLE,

LOCATED AT BEGINNING OF DUAL TURBO-2000 AIR DRYER TROUBLE SHOOTING SECTION. (Page 30)

Symptom:1. Aircontinuallyflowsfromexhaustportwhen compressorisinstandbymode.2. System/wettankairpressuredropsrapidly.

Operational Check:Symptoms #1 & #2:Startengineandbuildsystemairpressuretocutoutpressurethenshutoffengine.Allowatleast90secondsfordryertocyclethroughregenerationcycle.Checkforairleakatexhaustportswithsoap/watersolution.Ifairleakisdetectedreplacecheckvalve#238.

Check Valve Replacement:1. Relieveallsystemairpressure.2. Disconnectairlinefromdryeroutletport.3. Removecheckvalvenut.4. Removeanddiscardo-ring,spring,spindle,andball.5. Cleannutandcheckvalvecavitythoroughly.NOTE: If there is excessive oil in the cavity, oil separator and desiccant cartridges require servicing.6. Installnewballintocavity.7. Installspindle,withspringpocketout,intocavity.8. Placespringintospringpocketofspindle.9. Applyalightcoatingofgreaseontoo-ringandplaceontocheckvalvenut.10.Applylightcoatingofgreasetonutthreads.Installnutandtightento60ft.lbs.torque.11.Re-connectairlinetooutletport.




SerVICe PrOCeDureS DuaL TurBO-2000 regeneration Valve Service Kit #619911

Note: Two (2) valves in dryer/1 per kitWARNING: BEFORE PROCEEDING READ AND FOLLOW SAFETY PRECAUTIONS FOUND ON PAGE 13.


Symptom:1.Nopurgeairflow.Note: A light flow of air from exhaust port(s) during charge cycle is normal, regeneration air flow.2.Waterinairtanks.

Operational Check:Symptom #1 & #2:Startengineandbuildairpressure.Duringthechargecycle(compressorpumping),checkforairflowatexhaustport(s)ofdryer.Ifnoairflowispresentreplaceregenerationvalves#619911.

Regeneration Valve Replacement (two valves):1.Disconnectairlinefromoutletportofairdryer.2.Removeeight(8)socketheadboltsfasteningmanifoldtoadaptorcastings.3.Removemanifoldfromadaptorcastings.4.Removeanddiscardo-rings,springsandregenerationvalves.5.Cleanvalvecavitiesinadaptorcastings.6.Positionnewvalvespindlesintocavitieswithspringpocketsout.7.Positionspringsintovalves.8.Lubricatenewo-ringsandinstallontomanifoldbosses.9.Positionmanifoldontoadaptorcastingsensuringo-ringsareproperlypositionedinbores.10.Installeight(8)socketheadboltsandtightento50-60in.lbs.torque.11.Reconnectairlinetooutletport.




Operational Check:Symptom #1 & #2:Startengineandbuildairpressure.Duringthechargecycle,checkforlargeairleakatexhaustport(s)ofdryer.Iflargeamountofairisleakingfromexhaustport,proceedasfollows:1. Checkandreplace,ifnecessary,inletcheckvalve#619915.NOTE: Large air leak could also be due to worn #235 Purge Valve. Refer to page 34 for service on this valve.

Inlet Check Valve Replacement (Two places):1. Removethetwofastenersthatattachtheinletcheckvalveretainer.Removetheretainer.2. Removetheinletcheckvalvespindlefromtheinletcavityanddiscard.NOTE: If there is excessive oil in the cavity, compressor may require servicing.3. Cleanthecavitythoroughly.4. Removethetwo(2)o-ringsfromretaineranddiscard.5. Usinglubricantsupplied,lightlygreasethenewo-rings.6. Installtwo(2)largeo-ringsontheretainer.7. Lubricateo-ringsoncheckvalvespindleandinstallthespindle(smallendfirst)intotheinletcavity.Make surespindleiscompletelyengagedincavityandslidesfreely.8. Installretainer.9. Applyalightcoatingofgreaseonthethreadsofthetworetainerbolts.10.Installtworetainerbolts.Tightentol0-l5ft.lb.

SerVICe PrOCeDureS DuaL TurBO-2000 Inlet Check Valve Service Kit #619915

Note: Two (2) valves in dryer/1 per kit WARNING: BEFORE PROCEEDING READ AND FOLLOW SAFETY PRECAUTIONS FOUND ON PAGE 13.


Symptom:1. Largeairleakatexhaustport(s)duringthechargemode.Note: A light flow of air from ONE exhaust port during charge cycle is normal, regeneration air flow.2. Pressureslowornobuild.




SerVICe PrOCeDureS DuaL TurBO-2000 Desiccant Cartridge Service Kit #T224

Note: Two (2) cartridges on dryer/1 per kitWARNING: BEFORE PROCEEDING READ AND FOLLOW SAFETY PRECAUTIONS FOUND ON PAGE 13.

Symptom:1.Regularserviceinterval.2.Waterintanks.

Operational Check:Symptom #1 & #2:Desiccantcartridgerequiresregularservicingatintervalsdeterminedbycompressordutycycleortypeofoperatingconditions.Typicalserviceintervalsare: InnerCityTransit2years InnerCityRefuse2years OffHighway2yearsTheaboveisaguidelineonly.Draintanksonregularbasis.Ifmoistureexists,replacecartridgeT224.

Desiccant Cartridge Replacement:1.Relieveallsystemairpressure.2.Usingastrapwrench,turnthedesiccantcartridgecounterclockwiseandremoveit.Discard.3.Removeanddiscardo-ringfromadapterplatestud.4.Cleantopsurfaceofadapterplateandthreadedstud.NOTE: If there is excessive oil present, compressor and/or oil separator (Kit #619600) require servicing.5.Usinggreasesupplied,applyalightcoatingono-ring.Installo-ringonstud.6.Applyagenerouscoatofgreaseonthenewdesiccantcartridgegasketsurface.7.Threadnewcartridgeontostudturningclockwise.Whengasketcontactsadapterplate,tightencartridge1/2turn.DO NOT OVER-TIGHTEN!

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

OriginalDesign

NewRimlessDesign

OR




SerVICe PrOCeDureS DuaL TurBO-2000 heater Service Kit #619110 (12v) & #619111 (24v)

WARNING: READ AND FOLLOW SAFETY PRECAUTIONS FOUND ON PAGE 13 BEFORE PROCEEDING.

Symptom:1.Dryerwon’texhaust.2.Exhaustportleak.3.Cannotbuildpressure.

Operational Check:NOTE: Thermostat must be cooled to at least 35 degrees F to perform test. ConductcontinuitytestbyusinganOhmmeterorTestLight.Attachoneleadoftestdevicetooneterminalofheaterconnectorandotherleadoftestdevicetootherterminalofheaterconnector.ThetestlightshouldlightorOhmmeterindicatescontinuity.IfthereisNOcontinuity,replaceheater/thermostatassembly.

Heater Assembly Replacement:1.Disconnectheaterleadwire.2.Removetwoscrewsattachingheaterconnectortocasting.3.Removeheater/thermostatassemblyanddiscard.4.Thoroughlycleanentireheater/thermostatarea.5.Slideo-ringoverheaterandthermostatintopositionaroundconnectorflange.6.Applyalightcoatingofanti-seizetotheheaterelementandthermostatcavity.7.Insertheaterelementintoholeandtwistslightlytospreadanti-seize.8.Placethermostatintopositionincavityandensurethermostatsitsflatincavity.9.Placefoamcubeontopofthermostatandbringheaterconnectorintopositionovercavity.10.Secureheaterconnectorusingthe(2)8-32x1/2”screws.11.ReconnectMetri-Pakconnectortomaleplug.NOTE: If heater lead wire with male plug needs replaced or is not in vehicle wire harness it is available in Kit #619935.




SerVICe PrOCeDureS DuaL TurBO-2000 Oil Separator Service Kit #619600

Note: two (2) separators in dryer/1 per kitWARNING: READ AND FOLLOW SAFETY PRECAUTIONS FOUND ON PAGE 13 BEFORE PROCEEDING.

Symptom:1.Excessivewetoilaccumulationatexhaustportofdryer.2.Water/oilinairsystem.


Oil Separator Replacement:1.Drainairsystem.2.Disconnectheaterleadwirefromairdryer.3.Disconnectairlinefromdryerinletport.4.Removetwo(2)desiccantcar-tridges.5.Remove(4)3/8”allenheadbolts,locatedattopofadaptorcasting,attachingadaptorcastingstobottomvalvehousing.6.Remove(12)3/8”hexheadboltsattachingbottomvalvehousingtoadaptorcastings.7.Removebottomvalvehousingassembly.8.Removetwo(2)oilseparatorsand(4)gasketsfromvalvehousinganddiscard.9.Cleanvalvehousingsumpandinsideoftwo(2)adaptorcastingsofalloilandcontaminates.10.Placeonenewgasketoneachvalvehousingboltflange.11.Placenewoilseparatorsontopoffirstgasketsonvalvehousing(usetwoboltstoaligncomponents).12.Placesecondnewgasketontopofoilseparators.13.Reinstallvalvehousing/oilseparatortoadaptorcastings.14.Torque(16)boltsto25-30ft.lbs.15.Re-installtwo(2)desiccantcartridges.NOTE: If oil present in system air tanks, replace desiccant cartridge, T22416.Re-connectairlinetoairdryerinletport.17.Re-connectheaterwire.




SerVICe PrOCeDureS DuaL TurBO-2000 air Control Valve Service Kit #619910

WARNING: BEFORE PROCEEDING READ AND FOLLOW SAFETY PRECAUTIONS FOUND ON PAGE 13. REVIEW DESCRIPTION OF “NORMAL” DUAL TURBO-2000 AIR DRYER OPERATION/CYCLE,

LOCATED AT BEGINNING OF DUAL TURBO-2000 AIR DRYER TROUBLE SHOOTING SECTION. (Page 30)

Symptom:

1. Dryerwon’texhaustduringcharge cycletoallowregenerationairflowat 90secondintervals.Note: A light flow of air from ONE exhaust port during charge cycle is normal regeneration air flow.

2. Waterinairtanks.

Operational Check: Symptom #1 & #2:Startengineandbeginbuildingsystemairpressure.Afterapproximately90secondsintochargecycle,anexhaustairburstshouldoccurfromoneexhaustport.Ifexhaustairburstdoesnotoccurproceedasfollows:

1. Duringthechargecycle,turnthebrassscrew locatedonairvalve(seeFig.1),turntotheright (screwslotwillbeinhorizontalposition). Ifexhaustairburstdoesnotoccur,replace valve. Ifexhaustdoesoccur,turnscrewbackto originalposition(screwslotmustbeinvertical positionfornormaloperation)andproceedtostep2.

VALVE

Dual Dual

BRASS SCREWFigure1




air Control Valve Service Kit #619910 (cont.)

2. Failureofdryertoexhaustcouldalsobedueto malfunctioningMLTorpurgevalve.Refertopages34and43forserviceoftheseitems.

Air Control Valve Replacement:1. Un-plugelectricalconnectorfromMLT/Valve.

2. Removethree(3)airlinesconnectedtofittingsinairvalve.

3. RemoveretainingnutholdingMLTassemblytovalvestemandremoveMLTassemblyfromvalve. SetasidenutandMLTforlaterre-assembly.

4. Removethree(3)screwsholdingvalvetomanifold. Removevalveanddiscard.

5. Installthree(3)pushconnectairlinefittingstoopenportsofnewvalve.

6. Attachvalvetomanifoldwiththree(3)screws. Tightenscrewstol5-20in.lb.

7. Re-connectairlinefrommanifoldtofrontportofairvalve.

8. Re-connecttworemainingairlinestobackportsofvalve.

9. Re-assembleMLTassemblytovalvestemandsecurewithretainingnut.

10.Re-connectelectricalplugtoMLT.




Symptom:1. Dryerwon’texhaustduringchargecycleto allowregenerationairflowat90second intervals.Note: A light flow of air from ONE exhaust port during charge cycle is normal regeneration air flow.2. Waterinairtanks.

Operational Check: Symptom #1 & #2:Startengineandbeginbuildingsystemairpressure.Afterapproximately90secondsintochargecycle,anexhaustairburstshouldoccurfromoneexhaustport.

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. InsurethatpowerispresentatMLTconnectorandthatallelectricalconnectionsareproperlyconnected.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. Failureofdryertoexhaustcouldalsobeduetomalfunctioningaircontrolvalveorpurgevalve. Refertopages45and54forserviceoftheseitems.

MLT Replacement:1. Un-plugelectricalleadwirefromMLTconnector.2. RemoveretainingnutholdingMLTtovalvestemandremoveMLTfromvalve.Setasidenutforlater re-assembly.3. Re-assemblenewMLTtovalvestemandsecurewithretainingnut.4. Re-connectelectricalplugtoMLT.

SerVICe PrOCeDureS DuaL TurBO-2000 Micro Logic Timer (MLT)

Service Kits #619912 (12v) & #619924 (24v) WARNING: BEFORE PROCEEDING READ AND FOLLOW SAFETY PRECAUTIONS FOUND ON PAGE 13.


MLT

Dual Dual




air Dryer Socket SizesUse a 1 1/4” socket for the

internal turbo valve nut

Large strap wrench to remove Desiccant Cartridge

1 3/4” socket (or channel lock 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 1/2” male NPT)

7/16” socket for unloader cap (2) bolts

9/16” socket to remove the 8 bottom plate bolts

1/4” socket for Heater bolts. Also can use a slotted screw driver

Socket for the pop off valve

1 each 3/4” and 7/8” box/open end wrenches to remove 1/2” inlet out

outlet hose fittings

1 3/4” socket (for channel lock pliers) for the Bleed Valve nut

(our purge tank)




Air Dryer Leak/Valve Function Test Procedure

WarnIng

1. Neverattempttotestorserviceairdryeruntilyouhavereadandunderstandallprocedures.2. Alwaysweareyeprotectionwhentestingorservicingairdryer.Neverlookdirectlyintoairdryerports duringtest.3. Neverexceedrecommendedmaximumworkingairpressure(150psig.)4. Neverconnectordisconnectahose/linecontainingairpressureorremoveacomponent,fitting,orpipe plugunlessyouarecertainallsystemairpressurehasbeenexhausted.5. Useonlypropertoolsandobserveallprecautionspertainingtotheuseofthosetools.

3/8" NPT

1/2" NPT EXHAUST PORT

PURGE TANK PORTOUTLET PORT1/2" NPT

1/2" NPTINLET PORT

1/4" NPTUNLOADER PORT

FITTIngS/VaLVeS reQuIreD FOr TeSTQty Description Note1 3/8”shutoffvalve 1male&1femalethreads1 1/2”x3/8”bushing2 3/8”x1/4”bushing1 1/4”shutoffvalve 1male&1femalethreads1 3/8”pipeplug2 1/2”pipeplugs2 Quickdisconnect Connectorsvaryatshops




NOTE: Perform all test steps, in sequence shown, to insure a properly functioning air dryer.

Step 1 - Dryer air Flow Test1. Install1/2”x3/8”bushingin“INLET”portofdryer.2. Attachshutoffvalve(3/8”malepipeinto1/2”bushing)3. Install3/8”x1/4”bushingintofemaleportofshutoffvalve.4. Installquick-disconnectconnectortoshutoffvalve.5. Connectshopair.Openvalve.Checkforairflowfromdryer“OUTLET”and“PURGETANK”ports.Ifair doesnotflowfrombothportscheckforinternalblockageofports,valves,and/ordesiccantcartridge.6. Closeshutoffvalve.

Step 2 - regeneration (Purge Tank) air Flow Test1. Install3/8”x1/4”bushingintodryer“PURGETANK”port.2. Install1/4”shutoffvalveto“PURGETANK”portofdryer.3. Installquick-disconnectconnectortoshutoffvalve.4. Connectshopairtovalve.Openvalve.Checkforairflowfromdryer“OUTLET”port.5. Ifairflowdoesnotoccur,theregenerationvalverequiresservice.(Refertopage23)

Step 3 - Dryer assembly Leak Test1. Install1/2”pipeplugin“OUTLET”portofdryer.2. Removeshutoffvalveandbushingfrom“PURGETANK”portofdryerandinstall3/8”pipeplug.3. Openshutoffvalveatdryer“INLET”porttopressurizedryer.4. Checkforleakageat:4.1.Exhaustport-Note:ifairleaksatdryerexhaust,unloadervalverequiresservice.(Refertopage21)4.2.Bolts,gaskets,safetyvalve,cartridge,etc.Note:Repairanyleaksdetected.5. Closeshutoffvalveatdryer“INLET”port.

Step 4 - Dryer exhaust Test1. Install1/4”shutoffvalveto“UNLOADER”portofdryer.2. Openshutoffvalveatdryer“INLET”porttopressurizedryer.3. Connectshopairtoshutoffvalveat“UNLOADER”portandopenvalvetopressurizeandactivatedryer unloadervalve.4. Airshouldexhaustfrom“EXHAUST”portofdryer.5. Ifairexhaustdoesnotoccur,checkforthefollowing:5.1Unloadervalveexhaustportisnotalignedandisblockingdryerbottomcapexhaustport.5.2Exhaustholes/trashscreeninsidebottomcapareblocked.6. Disconnectshopairfromdryer“INLET”port.




Step 5 - unloader Valve Test1. Withairpressurestillappliedat“UNLOADER”port,checkforleaksat“EXHAUST”portofdryer.2. Ifairleaksfrom“EXHAUST”port,unloadervalveiswornandrequiresservice.(Refertopage21)3. Disconnectshopairfromdryer“UNLOADER”port.

Step 6 - Turbo “O” ring and unloader Valve retainer “O” ring Test1. Install1/2”pipeplugindryer“EXHAUST”port.2. Connectshopairtovalveat“UNLOADER”portandpressurizeunloadervalve.3. Ifairleaksfromdryerinlet,(shutoffvalvemustbeopen)turbovalve”O”ringsealsareworn.4. Ifleaking,turbovalverequiresservice.(Refertopage27)5. Ifairleaksatunloadervalveretainerflange,“O”ringsealsarewornandrequireservice.

Step 7 - Turbo Valve Flat Seal Test1. Remove1/2”pipeplugfromdryer“EXHAUST”port.2. Withairpressurestillappliedat“UNLOADER”valveport,applyairpressureto“INLET”portofairdryer.3. Checkforairleakingfrom“EXHAUST”portofairdryer.4. Ifleaking,turbovalverequiresservice.(Refertopage27)5. Disconnectshopairfromdryer“INLET”port.

Step 8 - Check Valve Test1. Remove1/2”pipeplugfromdryer“OUTLET”portandshutoffvalvefromdryer“INLET”port.2. Install1/2”pipeplugindryer“INLET”portandshutoffvalveindryer“OUTLET”port.3. Connectshopairtovalveatdryer“OUTLET”port.4. Withairpressurestillappliedat“UNLOADER”valveport,openvalveat“OUTLET”porttoapplyair pressureto“OUTLET”port.5. Checkforairleakingatdryer“EXHAUST”port.6. Ifairleaksat“EXHAUST”port,dryercheckvalveiswornandrequiresservice.(Refertopage22)7. Disconnectshopairfromdryer“OUTLET”and“UNLOADER”ports.




Step 9 - Differential Check (poppit) Valve Test.This step applies ONLY to Air Dryers compatible with Holset E-Type Compressors.1. Remove1/2”pipeplugfromdryer“INLET”port.2. Connectshopairtoshutoffvalveat“UNLOADER”portandopenvalvetopressurizeandactivatedryer unloadervalve.3. Connectshopairtovalveatdryer“OUTLET”portandopenvalve.4. Checkforairflowfromdryer“INLET”port.5. Ifairdoesnotflowfromdryer“INLET”port,thedifferentialcheckvalverequiresservice.6. Disconnectshopairfromdryer“OUTLET”port.7. Removeshutoffvalvefromdryer“OUTLET”portandinstallindryer“INLET”port.8. Connectshopairtovalveatdryer“INLET”portandopenvalve.9. Checkforairflowfromdryer“OUTLET”port.10.Ifairflowsfromdryer“OUTLET”portthedifferentialcheckvalverequiresservice.

air Dryer Thermostat/heater assembly TestTheheateristhermostaticallycontrolledtooperate(heat)betweentemperaturerangeof35deg.Fand55deg.F,whichmeanscurrentflowthroughheatingelementiscontrolledbythermostatinternalcontacts“closing”at35deg.Fand“opening”at55deg.F.Thethermostat/heaterassemblymayberemovedfromthedryertobetestedorcheckedwhilestillinstalledindryer.Whichevermethodisused,thethermostatmustbesubjectedtoatemperatureof35deg.Forlowerand55deg.Forhigherforpropertest.Iftheheaterassemblyisremovedfromdryerfortest,visuallycheckthatallwireconnectionsbetweenthermostatandheaterelementareintact.Ifconnectionsarebroken,*replacethermostat/heaterassembly.Performcontinuitytestasfollows:

A:Whilethermostattemperatureis55deg.Forabove,conductcontinuitytestbyusinganOhmmeterorTestLight.Attachoneleadoftestdevicetooneterminal/leadwireofthermostat.Connectotherleadoftestdevicetootherterminal/leadwireofthermostat.ThereshouldbeNOcontinuity.Ifcontinuityisindicated,*replacethermostat/heaterassembly.

B:Whilethermostattemperatureis35deg.Forbelow,conductcontinuitytestbyusinganOhmmeterorTestLight.Attachoneleadoftestdevicetooneterminal/leadwireofthermostat.Connectotherleadoftestdevicetootherterminal/leadwireofthermostat.Thereshouldbecontinuity.IfthereisNOcontinuity,*replacethermo-stat/heaterassembly.(*Refertopages24and25)




Quick Order Form Print out and fax or call your order in today. FAX: 402-592-9659 Call: 1-800-642-2514

Turbo-2000hDS number Description Order Qty.620600 12v Dryer with Tank Kit 620604 24v Dryer with Tank Kit620602 12v Air Dryer Only620606 24v Air Dryer Only

holset SS or Qe Compressor CompatiblehDS number Description Order Qty.620500 12v Dryer with Tank Kit620504 24v Dryer with Tank Kit620502 12v Air Dryer Only620506 24v Air Dryer Only620700 12v Dryer with Tank Kit & Oil Separator620704 24v Dryer with Tank Kit & Oil Separator620702 12v Air Dryer Only & Oil Separator620706 24v Air Dryer Only & Oil Separator

Dual Turbo-2000hDS number Description620910 12v Dual Air Dryer620920 24v Dual Air Dryer

Service ComponentshDS number Description Order Qty.314A Sure-Change Service Kit619340 Complete Service Kit (T224, 228, 235, 238)T224 (E) Desiccant Cartridge228 (M) Turbo Valve Kit235 (I) Purge Valve Kit238 (G) Check Valve Kit248 (12v) (J) Heater Kit (Early Model - Plastic Cover) 249 (24v) 619110 (12v) (J) Heater Kit (Late Model - Metri-Pak) 619111 (24v) 610077 (C) Body Gasket619900 Wire Harness610024 (L) Safety Valve 175 psi619086 (H) Bottom Cap Assembly (12v)619112 (H) Bottom Cap Assembly (12v) - Holset Compatible619087 (H) Bottom Cap Assembly (24v)619113 (H) Bottom Cap Assembly (24v) - Holset Compatible223 (B) Bleed Valve Kit221 Purge Tank610237 (A) Bleed Valve Nut610069 (D) Seal Retainer610236 (F) Check Valve Nut619650 (P) Oil Separator (pages 10-11)

Documents

HEAVY DUTY SPECIALISTS, INC. Service...HEAVY DUTY SPECIALISTS, INC. 9341 “G” Court • Omaha, NE 68127-1230 Phone (402) 592-5400 • Toll Free (800) 642-2514 • Fax (402) 592-9659