BENDIX | AD-1 AIR DRYER | AD9 Universal Check Valve Kit with Install Info for Bendix Air Dryer

Installation
Instructions
BENDIX® AD-9® AIR DRYER UNIVERSAL CHECK VALVE KIT
A
End Cover
with Horizontal Delivery Check Valve
Delivery Check
Valve Plug
7
8
6
Delivery Check Valve
Purge Valve Housing
B
End Cover
with Vertical Delivery Check Valve
(Hex Body)
Delivery Check Valve
2
Delivery
Check Valve
Body
1
Delivery Check Valve
Purge Valve Housing
3
4
Figure 1 - Bendix® AD-9® Air Dryer Universal Check Valve Kit
1
2
3
1
Bendix® AD-9® Air Dryer Universal
Check Valve Kit (K041395) Contents
Item
Description
AD-9® Air Dryer
End Cover Type
Qty
1
Check Valve
1
2
O-ring
1
3
Spring
1
4
Retainer
1
5
Lubricant
1
-
Delivery Check Valve
Kit (109494)
1
4
Delivery Check
Valve Kit
End Cover "B"
5
Universal
Check Valve Kit
Pc. No. K041395
End Cover A
See Kit Contents
The Bendix® AD-9® Air Dryer Universal Check Valve
Kit contains the necessary components to service
both Bendix® AD-9® end cover styles as well as the
Bendix® AD-IP® air dryer. The components not used
in this installation can be saved and used for the
other installations.
Delivery Check Valve Kit (109494) Contents
Item
Description
Qty
Items Needed for
End Cover Type "A"
6
Check valve Body (Long)
1
Retain
7
O-ring
1
Retain
8
Spring
1
Retain
9
Lubricant
1
Retain
10
Check valve Body (Short)
1
Not Needed
11
Conical Spring
1
Not Needed
12
Perforated Plate
1
Not Needed
13
Retaining Ring
1
Not Needed
Delivery
Check Valve Kit
Pc. No. 109494
7
8
10
Components
Needed
12
6
Components Not
Needed
11
13
9
Figure 2 - AD-9® Air Dryer Universal Check Valve Kit Check Valve Kit Contents
2
This kit contains all the necessary components to service the
and strength as original equipment and be designed
Bendix® AD-9® air dryer delivery check valve. There are two
specifically for such applications and systems.
different types of end covers as shown in Figure 1. Type "A" 9. Components with stripped threads or damaged parts
is the current production version and has a horizontal check
should be replaced rather than repaired. Do not
valve. Type "B" is an earlier design and has a vertical check
attempt repairs requiring machining or welding unless
valve that can be identified by its large brass hex body in the
specifically stated and approved by the vehicle and
bottom of the air dryer end cover.
component manufacturer.
10.
Prior
to returning the vehicle to service, make certain
This kit services both end cover styles. Once the installation
all
components
and systems are restored to their
is complete, the remaining components can be saved for
proper
operating
condition.
installation in the other style of end cover. Note that the
11.
For
vehicles
with
Automatic Traction Control (ATC),
delivery check valve kit, contained within this kit, is the same
the
ATC
function
must be disabled (ATC indicator
delivery check valve kit used to service the Bendix® AD-IP®
lamp
should
be
ON)
prior to performing any vehicle
air dryer.
maintenance where one or more wheels on a drive
axle are lifted off the ground and moving.
GENERAL SAFETY GUIDELINES
WARNING! PLEASE READ AND FOLLOW THESE
INSTRUCTIONS TO AVOID PERSONAL INJURY CLEANING AND INSPECTION
OR DEATH:
1. Using mineral spirits or an equivalent solvent, clean and
When working on or around a vehicle, the following
general precautions should be observed at all times.
1. Park the vehicle on a level surface, apply the parking
brakes, and always block the wheels. Always wear
safety glasses.
2. Stop the engine and remove ignition key when
working under or around the vehicle. When working
in the engine compartment, the engine should be
shut off and the ignition key should be removed.
Where circumstances require that the engine be
in operation, EXTREME CAUTION should be used
to prevent personal injury resulting from contact
with moving, rotating, leaking, heated or electrically
charged components.
3. Do not attempt to install, remove, disassemble or
assemble a component until you have read and
thoroughly understand the recommended procedures.
Use only the proper tools and observe all precautions
pertaining to use of those tools.
4. If the work is being performed on the vehicle’s
air brake system, or any auxiliary pressurized air
systems, make certain to drain the air pressure from
all reservoirs before beginning ANY work on the
vehicle. If the vehicle is equipped with a Bendix®
AD-IS® air dryer system or a dryer reservoir module,
be sure to drain the purge reservoir.
5. Following the vehicle manufacturer’s recommended
procedures, deactivate the electrical system in a
manner that safely removes all electrical power from
the vehicle.
6. Never exceed manufacturer ’s recommended
pressures.
7. Never connect or disconnect a hose or line containing
pressure; it may whip. Never remove a component or
plug unless you are certain all system pressure has
been depleted.
8. Use only genuine Bendix® brand replacement parts,
components and kits. Replacement hardware, tubing,
hose, fittings, etc. must be of equivalent size, type
dry the outside of the air dryer.
2. When servicing, inspect the interior and exterior of all
metal parts for severe corrosion, pitting and cracks. If this
condition exists, replace the air dryer. Superficial corrosion
and/or pitting on the exterior portion of the upper and lower
body halves is acceptable.
3. Inspect all air line fittings for corrosion. Repair or replace
any leaking or damaged lines or fittings. Clean all old
thread sealant from the pipe threads.
4. Identify the end cover type ("A" or "B") as shown in
Figure 1.
5. Identify the components needed for the correct installation
and set the others aside. See Figures 1 and 2 for
components needed.
6. Be sure to replace all the components in the check valve
with those provided in the kit.
CHECK VALVE KIT INSTALLATION
BENDIX® AD-9® AIR DRYER WITH A TYPE "A" END COVER
This maintenance kit does not require removal of the AD-9®
air dryer from the vehicle or disconnection of the hoses,
however if removal of the air dryer is necessary, adhere to
the following caution.
Caution: While performing service on the AD-9® air dryer, it
is not recommended that a clamping device (vise, C-clamp,
etc.) be used to hold any die cast aluminum component as
damage may result. To hold the body, install a pipe nipple in
the supply port and clamp the nipple into a vise.
Disregard the instructions that are contained in the Delivery
Check Valve Kit box. These instructions pertain to the Bendix®
AD-IP® air dryer only.
3
DISASSEMBLY
1. Remove and retain the delivery check valve plug from
the air dryer end cover. See Figure 1.
2. Remove and discard the spring (8), check valve body (6)
and o-ring (7).
3. Using a clean rag, wipe the delivery check valve port
clean. Clean any thread sealant from the pipe threads
in the delivery check valve port.
2
Delivery Check
Valve Body
4. Inspect for physical damage to the end cover delivery
check valve port and the check valve seat in the port.
5. Inspect all air line fittings for corrosion and replace as
necessary.
ASSEMBLY
1. Lubricate the o-ring (7) and the long check valve body (6)
with the lubricant provided. Note: Use only the lubricant
contained in this kit.
Figure 3 - Check Valve Removal - Type "B" End Cover
Punch
Delivery Check
Valve Body
3
2. Install the o-ring (7) on the long check valve body (6).
Push the o-ring (7) down, over the 3 guide lands until it
is in the o-ring groove. Ensure the o-ring (7) is seated
properly and not twisted.
3. Install the spring (8) on the white check valve body (6) so
that the small coils of the spring slip over the check valve
body.
4. Install the assembled long check valve body (6), o-ring
(7), and spring (8) in the end cover delivery check valve
port so that the o-ring (7) rests on its seat in the end cover
and the spring (8) is visible.
5. Install the delivery check valve plug that was removed in
step 1 of the disassembly, into the air dryer end cover.
See Figure 5. Torque the plug to 130-170 inch pounds.
6. Before placing the vehicle back in service, perform THE
OPERATION AND LEAKAGE TEST FOR A BENDIX®
AD-9® AIR DRYER WITH A TYPE "A" END COVER.
OPERATION AND LEAKAGE TEST FOR A BENDIX® AD-9®
AIR DRYER WITH A TYPE "A" END COVER
Check for proper operation. If the air dryer cycles rapidly
review the installation procedures to ensure proper kit
installation.
CHECK VALVE KIT INSTALLATION
BENDIX® AD-9® AIR DRYER WITH TYPE "B" END COVER
DISASSEMBLY
1. With the delivery line removed, use an adjustable wrench
or 1-5/8” socket and remove the delivery check valve
assembly.
2. Remove the outer o-ring (2) from the delivery check valve
body.
3. Place the check valve on a bench with the hex end
down. Use a hammer and punch to remove the retainer
(4), spring (3) and check valve (1) from the check valve
housing as shown in Figure 4. Discard items 1 through
4.
1
4
Figure 4 - Check Valve Disassembly - Type "B" End Cover
4. Inspect the delivery check valve body, and the delivery
check valve port in the end cover where it was removed,
for corrosion, pitting and cracks. If this condition exists,
replace the delivery check valve body or end cover as
needed.
ASSEMBLY
1. Assemble the spring (3) to the retainer (4) and check
valve (1) as shown in Figure 4. Ensure the spring (3) is
fully seated on the retainer (4) and the check valve (1).
2. Lubricate the entire spherical surface of the check valve
(1) and bore chamfer of the check valve housing with the
lubricant contained in this kit as shown in Figure 5. Note:
Use only the lubricant contained in this kit.
3. Place the retainer (4), spring (3) and check valve (1)
sub-assembly into the check valve housing. Press
the retainer (4) using a 7/16" deep socket with a 3/8"
drive, and a vise as shown in Figure 5.
4. Inspect the bore of the end cover. Make certain that the
end cover passage is open and free of obstructions.
5. Inspect the threads in the end cover. Make certain they
are clean.
6. Install the o-ring (1) on the outer body of the delivery
check valve assembly. Ensure the o-ring (1) is seated
properly and not twisted. Lubricate the o-ring (1) with the
lubricant provided in this kit. Note: Use only the lubricant
contained in this kit.
4
Apply Lubricant
Delivery Check
Valve Body
1
3
4
7/16" Deep Socket
With a 3/8" Drive
Bench Vise
Figure 5 - Check Valve Assembly
OPERATION AND LEAKAGE TEST FOR A BENDIX® AD-9®
AIR DRYER WITH A TYPE "B" END COVER
Test the delivery check valve by building the air system to
governor cut-out and observing a test air gauge installed in
the #1 reservoir. Check all lines and fittings leading to and
from the air dryer for leakage and integrity. A rapid loss
of pressure could indicate a malfunctioning delivery check
valve. This can be confirmed by bench testing the delivery
check valve.
To test the delivery check valve, bleed the brake system down
and remove the check valve assembly from the end cover.
Bench test the check valve by applying air pressure to the
check valve and soaping the other end. Leakage should not
exceed a 1" bubble in 1 second. Replace the check valve if
excessive leakage is found.
7. Install the delivery check valve assembly into the end
cover. Torque to 200-250 in. lbs.
8. Re-install the delivery line to the air dryer delivery port.
9. Before placing the vehicle back in service, perform the
OPERATION AND LEAKAGE TEST FOR A BENDIX®
AD-9® AIR DRYER WITH A TYPE "B" END COVER.
10. Set aside the remaining components for use in an AD-9®
air dryer with a Type "A" end cover or a Bendix® AD-IP®
air dryer.
S-1519 © 2010 Bendix Commercial Vehicle Systems LLC, a member of the Knorr-Bremse group 10/2010 All rights reserved.
5
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