Volvo Trucks North America, Inc.

Greensboro, NC USA Date Group No.

TSI
Supp. Page

12.94

561 004

1(4)

Brakemaster Air Dryer Field Test Procedures All with Brakemaster 62, 63, 68, 69, 70, 71, 72, and 73 Air Dryers

Air Dryer Check
(Effective 12/1994) The following test procedures are recommended by CR Services to check the BRAKEMASTER series of air dryers. These procedures are designed to determine specific component operation, analyze individual component functions, and take corrective actions to remedy distinctive problems within the air dryer unit. These procedures are designed to expedite the complete air dryer test process, and in most cases, can be completed in less than 15 minutes. See “CR Brakemaster Air Dryer, Checking” page 2.

V776-561-004SB

USA03950

check valve requires replacement.Page 2 CR Brakemaster Air Dryer. NPT pipe plug Note: All 70 series models do not incorporate an integral check valve. male NPT quick disconnect (1) 1/4 in. Checking WARNING Before performing any test and/or isolating the air dryer. Connect air line to inlet (1/2 in. Block the wheels and make sure the vehicle will not roll before releasing the brakes. Never exceed recommended working air pressure. port) and pressurize. port) and pressurize air dryer assembly. Check air dryer assembly for leakage. Repair kits listed are available through the Volvo GM Heavy Truck Corporation network. 72 and 73 require the following fittings to perform the test procedures: • • • (1) 1 in. male NPT quick disconnect (1) 1 in. Never connect or disconnect a hose or line containing air pressure. Always wear safety glasses when working with air pressure. 2 Connect air line to dryer inlet and pressurize. . the complete air system should be tested for worn compressor. If air does not flow through outlet. Replace check valve following instructions outlined in replacement kit V1113521 (BKM #238). Use only proper tools and observe all precautions pertaining to the use of those tools. male NPT quick disconnect (1) 1/4 in. NPT pipe plugs Models 70. Always support the vehicle with stands. Never look directly into air dryer ports. and 69 require the following fittings to perform the test procedures: Air Dryer Removed from Vehicle Air Dryer Assembly. 71. male NPT quick disconnect (2) 1/2 in. If air leaks out of the inlet (1/2 in. port) of air dryer. or any source contributing to air leaks which will cause false symptoms within the air dryer assembly. the vehicle’s wheels must be chocked. check valve requires replacement. port). Release all air pressure from unit! Replace specific component(s) following instructions outlined in replacement kit. D2 governor. 68. Never remove a component or a pipe plug unless you are certain all system air pressure has been exhausted. 63. Note: Before proceeding with the following test procedures. Check Valve 1 Connect air line to the outlet (1/2 in. Air should flow through outlet. Never work under a unit supported only by a jack. Never attempt to disassemble an air dryer until you have read and understood all recommended procedures. • • • (1) 1/2 in. Pressure Check 1 Install pipe plug in outlet (1/2 in. Stop engine when working under a vehicle. Models 62. Replace check valve following instructions outlined in replacement kit V1113521 (BKM #238).

Ohm meter should read complete circuit. bleed off entire air system. Stop engine. With engine stopped. Do not allow air dryer to exhaust. Release all air pressure from unit! Replace unloader valve following instructions outlined in replacement kit V1113520 (BKM #235). TSI Date 12. Release all air pressure from unit! Replace unloader valve following instructions outlined in replacement kit V1113520 (BKM #235). listen for air leaking from the air dryer’s exhaust port. Air Dryers Installed On Vehicle Note: Read and follow warning instructions before proceeding. With engine off. 3 Remove pressure from air dryer assembly. Cycle dryer to load and unload several times. Note: Thermostat must be cooled to at least 2 C (35 F) to perform the following test procedures. Pressurize unloader valve. Replace check valve following instructions outlined in replacement kit V1113521 (BKM #238). check valve requires replacement.94 Group No.Volvo Trucks North America. Replace heater assembly following instructions outlined in replacement kit V1113524 (BKM #246). 2 Start engine and build air pressure as close to cut-out pressure as possible (approximately 690 kPa [100 psi]). Heater No. 246 1 With thermostat “closed. 2 With air dryer pressurized. If there is continuous air leakage at the exhaust port. heater assembly should be replaced.   . unloader valve requires replacement. NPT unloader port and pressurize. Dryer should unload to atmospheric pressure. Connect air line to inlet (1/2 in. Page 3(4) 561 004 Unloader Valve 1 Install pipe plug in outlet (1/2 in. connect air line to 1/4 in. Release all air pressure from unit! Replace any defective components following specific instructions within appropriate replacement kit. port) and pressurize air dryer assembly. Leakage at exhaust port indicates unloader valve requires replacement. Air Dryer Assembly. Stop engine. check air dryer assembly for leakage.” connect an ohm meter across the heater electrical terminals. Pressure Check 1 With the engine off. If dryer fails to unload or valve sticks. Inc. port) of air dryer. If air leaks at exhaust port. unloader valve requires replacement. If circuit is open. Replace unloader valve following instructions outlined in replacement kit V1113520 (BKM #235). Check Valve 1 Start engine and build air system to cut-out pressure allowing the air dryer to exhaust.

connect an ohm meter across the heater electrical terminals. If air is leaking.   . If air leak stops. Replace heater assembly following instructions outlined in replacement kit V1113524 (BKM #246). start engine and build air pressure as close to cut-out pressure as possible (approximately 690 kPa [100 psi]). Ohm meter should read complete circuit. Cycle dryer to load and unload several times. start engine and build system to cut-out pressure allowing air dryer to exhaust. If dryer fails to unload or valve sticks. replace unloader valve following instructions outlined in replacement kit V1113520 (BKM #235). replacement of the unloader valve is required. With engine off. Note: Thermostat must be cooled to at least 2 C (35 F) to perform the following test procedures. the heater assembly should be replaced. Stop engine. If the circuit is open. replacement of the compressor’s governor is required. 2 To check unloader valve during charge (compressor on) cycle. remove air line from unloader valve nut. If leak continues. Heater Assembly 1 With thermostat ”closed”. Release all air pressure from unit! Replace unloader valve following instructions outlined in replacement kit V1113520 (BKM #235). listen for air leaking from exhaust port.Page 4 Unloader Valve 1 To check unloader valve during unload (compressor off) cycle. Do not allow air dryer to exhaust.