BENDIX SD-08-2418 User manual

BENDIX SD-08-2418 User manual
SD-08-2418
®
Bendix® AD-IS® and AD-IS® PuraGuard® (Oil Coalescing) Air Dryer
and Reservoir Systems
RES
GOVERNOR
RESERVOIR (2)
PURGE VALVE
PRESSURE
PROTECTION
VALVES (4)
DESICCANT
CARTRIDGE
(PURAGUARD®
OIL COALESCING
SHOWN)
DESICCANT
CARTRIDGE
(STANDARD SHOWN)
MOUNTING
HOLES (4)
GOVERNOR
SAFETY VALVE
PURGE
RESERVOIR
UNL
GOVERNOR
UNLOADER (2)
MOUNTING
BOLTS (3)
22
SEC
DELIVERY TO
SECONDARY
RESERVOIR
21
PRI
DELIVERY TO PRIMARY
RESERVOIR
23
AUX2
AUXILIARY
DELIVERY
PORT
HEATER /
THERMOSTAT
EXH
GOVERNOR
EXHAUST
AIR DRYER
PART NUMBER
STAMPED HERE
1
IN
SUPPLY FROM
COMPRESSOR
PRESSURE PROTECTION
VALVES (4)
24
AUX1
AUXILIARY
DELIVERY PORTS
(4)
FIGURE 1 - BENDIX® AD-IS® AND AD-IS® PURAGUARD® OIL COALESCING AIR DRYER AND RESERVOIR SYSTEMS
1
GENERAL SAFETY GUIDELINES
WARNING! PLEASE READ AND FOLLOW THESE INSTRUCTIONS
TO AVOID PERSONAL INJURY OR DEATH:
When working on or around a vehicle, the following guidelines should be observed AT ALL TIMES:
▲ Park the vehicle on a level surface, apply the
parking brakes and always block the wheels.
Always wear personal protection equipment.
▲ Stop the engine and remove the 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.
▲ 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.
▲ 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, a Bendix® DRM™
dryer reservoir module, or a Bendix® AD-9si™ air
dryer, be sure to drain the purge reservoir.
▲ F o l l o w i n g t h e v e h i c l e m a n u f a c t u r e r ’s
recommended procedures, deactivate the
electrical system in a manner that safely removes
all electrical power from the vehicle.
▲ Never exceed manufacturer’s recommended
pressures.
▲ 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.
▲ Use only genuine Bendix ® brand replacement
parts, components and kits. Replacement
hardware, tubing, hose, fittings, etc. must be of
equivalent size, type and strength as original
equipment and be designed specifically for such
applications and systems.
▲ Components with stripped threads or damaged
parts should be replaced rather than repaired.
Do not attempt repairs requiring machining or
welding unless specifically stated and approved
by the vehicle and component manufacturer.
▲ Prior to returning the vehicle to service, make
certain all components and systems are restored
to their proper operating condition.
▲ For vehicles with Automatic Traction Control
(ATC), the ATC function must be disabled (ATC
indicator lamp should be ON) prior to performing
any vehicle maintenance where one or more
wheels on a drive axle are lifted off the ground
and moving.
▲ The power MUST be temporarily disconnected
from the radar sensor whenever any tests USING
A DYNAMOMETER are conducted on a Bendix®
Wingman® Advanced™-equipped vehicle.
▲ You should consult the vehicle manufacturer's operating and service manuals, and any related literature,
in conjunction with the Guidelines above.
2
DESCRIPTION
The function of both the Bendix® AD-IS® (Integrated Solution
Air Dryer) air dryer and reservoir system and the Bendix®
AD-IS® PuraGuard® oil coalescing air dryer and reservoir
system is to collect and remove air system contaminants
in solid, liquid and aerosol form before they enter the brake
system and to provide—as a module—heavy vehicles with
an integrated vehicle air dryer, purge reservoir, governor
and a number of the charging valve components in a
module. These components have been designed as an
integrated air supply system.
Both air dryer and reservoir systems provide clean, dry air
to the components of the brake system which increases
the life of the system and reduces maintenance costs.
The necessity for daily manual draining of the reservoirs
is eliminated.
The Bendix AD-IS PuraGuard oil coalescing air dryer has
an identical appearance to the standard Bendix AD-IS air
dryer, but contains a coalescing media at the inlet of the
desiccant bed. The coalescing media provides a higher
level of oil removal over the standard AD-IS air dryer.
The AD-IS PuraGuard oil coalescing air dryer has all of
the same functions as the standard AD-IS air dryer and is
used in applications where lower oil concentration levels
are required.
IMPORTANT: When servicing, note that standard AD-IS
air dryers or air dryer cartridges may be serviced with
PuraGuard oil coalescing air dryers or cartridges, however,
PuraGuard oil coalescing air dryers or cartridges must only
be serviced with like replacements.
Note: Unless otherwise stated in this manual, AD-IS air
dryer and reservoir systems refers to both the standard and
PuraGuard oil coalescing air dryer and reservoir systems.
The function of the pressure protection valves is to protect
each reservoir from a pressure loss in the other reservoir or
a pressure loss in an air accessory. Each of the pressure
protection valves in the AD-IS air dryer and reservoir
systems may have different pressure settings. These are
factory set and must not be changed or adjusted.
Air Connection
Port ID
Function/
Connection
QTY
1
IN
Inlet Port (air in)
1
21
PRI
Delivery Port Out (to Primary Reservoir)
1
22
SEC
Delivery Port out (to Secondary Reservoir)
1
24
AUX 1
Auxiliary Delivery Port (air out)
4
23
AUX 2
Auxiliary Delivery Port (air out)
1
UNL
Unloader Control Air (D-2A™ Governor)
2
RES
Common Reservoir Pressure (D-2A™ Governor)
2
EXH
Governor Exhaust
1
TABLE 1 - PORT DESIGNATIONS
The removable purge valve assembly incorporates the
purge valve mechanism and a turbocharger cut-off feature
that is designed to prevent loss of engine “turbo” boost
pressure during the purge cycle of the Bendix® AD-IS® air
dryer and reservoir system. For ease of maintenance, all
replaceable assemblies can be serviced without removal
of the air dryer and reservoir system from its mounting on
the vehicle. Refer to Preventive Maintenance section.
BENDIX AD-IS AIR DRYER AND RESERVOIR
SYSTEM OPERATION: GENERAL (Refer to Figure 2.)
The Bendix AD-IS air dryer and reservoir systems are
designed to receive compressed air from the vehicle air
compressor, clean and dry the air, deliver air to the vehicle’s
primary reservoir, secondary reservoir and accessories,
and control the compressor/dryer charge cycle.
The AD-IS air dryer and reservoir system alternates
between two modes or “cycles” during operation: the
Charge Cycle and the Purge Cycle. The following describes
these “cycles” of operation.
The air dryer and reservoir system consists of a “spin on”
desiccant cartridge secured to a base assembly. The
base assembly contains a delivery check valve assembly,
safety valve, heater and thermostat assembly, pressure
protection valves, threaded air connections and the purge
valve assembly.
3
Note 1:
The Bendix AD-IS air dryer and reservoir system
purge piston has a purge control channel drain. This
allows any condensation in this area to flow past a
diaphragm in the top of the purge piston and out
through a channel in the middle of the central bolt of
the purge assembly to be drained. During the purge
cycle this drain is closed.
DESICCANT
BED
®
OIL COALESCING FILTER
(BENDIX® AD-IS® PURAGUARD®
OIL COALESCING AIR DRYER)
PURGE
CONTROL
CHANNEL
®
PURGE
ORIFICE
DELIVERY
CHECK VALVE
(OPEN)
PURGE
RESERVOIR
PRESSURE
PROTECTION
VALVES
GOVERNOR
UNLOADER
PORT
SUPPLY
PORT
A
PURGE VALVE
(CLOSED)
TURBO
CUT-OFF
VALVE
ENGINE (OPEN)
TURBO
COMPRESSOR
SAFETY
VALVE
B
C
D
PRIMARY
PORT (PRI)
PURGE
RESERVOIR
DRAIN VALVE
SECONDARY
PORT (SEC)
SEE
NOTE 1
PRIMARY
RESERVOIR
SECONDARY
RESERVOIR
AUXILIARY PORTS
(TO ACCESSORIES)
DIAGRAM SHOWS ALL PRESSURE
PROTECTION VALVES OPEN.
FIGURE 2 - BENDIX® AD-IS® AIR DRYER AND RESERVOIR SYSTEM CHARGE CYCLE
CHARGE CYCLE (Refer to Figure 2.)
When the compressor is running loaded (compressing air),
compressed air flows through the compressor discharge
line to the inlet (1/IN) port of the air dryer body. The
compressed air often includes contaminates such as oil,
oil vapor, water, and water vapor.
Traveling through the discharge line and into the air dryer,
the temperature of the compressed air falls, causing
some of the contaminants to condense and drop to the
bottom of the air dryer and purge valve assembly. These
contaminants are ready to be expelled at the next purge
cycle. The air then flows into the desiccant cartridge,
where it flows through an oil separator—or coalescing
filter if equipped with a Bendix® PuraGuard® oil coalescing
cartridge—which removes water in liquid form as well as
liquid oil and solid contaminants.
4
Air then flows into the desiccant drying bed and becomes
progressively more dry as water vapor adheres to the
desiccant material in a process known as adsorption.
Dry air exits the desiccant cartridge, through the center of
the base assembly, then flows to the delivery check valve
and through an orifice and into the purge reservoir. The
delivery check valve opens, supplying air to the pressure
protection valves (A) through (D) simultaneously, the
safety valve, and also to the reservoir port of the attached
governor. The purge reservoir fills, storing air that will be
used to regenerate the desiccant during the purge cycle.
This air is available to supply downstream components
during the charge mode.
When the air pressure reaches approximately 106 psi, the
four pressure protection valves will open and air will be
supplied to the primary reservoir, secondary reservoir, and
DESICCANT
BED
OIL COALESCING FILTER
(BENDIX® AD-IS® PURAGUARD®
OIL COALESCING AIR DRYER)
PURGE
CONTROL
CHANNEL
PURGE
ORIFICE
DELIVERY
CHECK VALVE
(CLOSED)
PURGE
RESERVOIR
PRESSURE
PROTECTION
VALVES
GOVERNOR
UNLOADER
PORT
SUPPLY
PORT
A
PURGE VALVE
(OPEN)
TURBO
CUT-OFF
VALVE
ENGINE (CLOSED)
TURBO
COMPRESSOR
SAFETY
VALVE
B
C
D
PRIMARY
PORT (PRI)
PURGE
RESERVOIR
DRAIN VALVE
SECONDARY
PORT (SEC)
EXHAUST
PRIMARY
RESERVOIR
SECONDARY
RESERVOIR
AUXILIARY PORTS
(TO ACCESSORIES)
DIAGRAM SHOWS ALL PRESSURE
PROTECTION VALVES OPEN.
FIGURE 3 - BENDIX® AD-IS® AIR DRYER AND RESERVOIR SYSTEM PURGE CYCLE
accessories. If the pressure protection valves are preset
to different values the valves will open—in order of lowest
setting to highest setting—when charging a flat system.
The air dryer and purge reservoir will remain in the charge
cycle until the air brake system pressure builds to the
governor cut-out setting of approximately 130 psi.
PURGE CYCLE (Refer to Figure 3.)
When air brake system pressure reaches the cut-out setting
of the governor, the governor unloads the compressor
activating the purge cycle of the air dryer and reservoir.
The governor unloads the compressor by allowing air
pressure to fill the line leading to the compressor unloader
mechanism. This suspends the delivery of compressed
air to the Bendix® AD-IS® air dryer and reservoir system.
Similarly, the governor also supplies air pressure to the
air dryer. The pressure also moves the air dryer purge
piston down, opening the purge valve to atmosphere and
closing off the compressor air supply to the turbo cut-off
valve (covered in the Turbo Cut-off Feature section of
this document). Water and contaminants captured are
expelled immediately when the purge valve opens. In
addition, air—which was flowing through the desiccant
cartridge—changes direction and begins to flow toward
the open purge valve. Contaminants collected by the air
dryer are removed by air flowing from the purge reservoir
through the desiccant drying bed to the open purge valve.
The initial purge and desiccant cartridge decompression
lasts only a few seconds, evidenced by an audible burst
of air at the air dryer exhaust.
5
The actual regeneration of the desiccant drying bed begins
as dry air from the purge reservoir flows through the purge
orifice into the desiccant bed. Pressurized air from the
purge reservoir expands after passing through the purge
orifice; its pressure lowers and its volume increases. The
flow of dry air through the drying bed regenerates the
desiccant material by removing any water vapor adhering
to it. Approximately 30 seconds are required for the entire
contents of the purge reservoir of a Bendix® AD-IS® air
dryer and reservoir system to flow through the desiccant
drying bed.
The delivery check valve assembly prevents air pressure
in the brake system from returning to the air dryer during
the purge cycle. After the purge cycle is complete, the air
dryer and reservoir system is ready for the next charge
cycle to begin.
TURBO CUT-OFF FEATURE (Refer to Figure 3.)
The primary function of the turbo cut-off valve is to prevent
loss of engine turbocharger air pressure through the
AD-IS air dryer when the dryer is in the purge mode.
At the onset of the purge cycle, the downward travel of the
purge piston is stopped when the turbo cut-off valve (the
tapered portion of purge piston) contacts its mating metal
seat in the purge valve housing. With the turbo cut-off
valve seated (in the closed position), air in the compressor
discharge line—as well as the AD-IS air dryer inlet port—
cannot enter the air dryer. By completing these actions,
the turbo cut-off effectively maintains turbo charger boost
pressure to the engine.
PREVENTIVE MAINTENANCE
Important: Review the warranty policy before performing
any intrusive maintenance procedures. An extended
warranty may be voided if intrusive maintenance is
performed during this period. Purge valve maintenance
is permissible during the warranty period only when using
a genuine Bendix® purge valve kit.
Because no two vehicles operate under identical
conditions, maintenance and maintenance intervals will
vary. Experience is a valuable guide in determining the best
maintenance interval for any one particular operation.
Every 900 operating hours, or 25,000 miles, or three
(3) months:
1. Check for moisture in the air brake system by opening
reservoir drain valves and checking for the presence
of water. If moisture is present, the desiccant cartridge
may require replacement; however, the following
conditions can also cause water accumulation and
should be considered before replacing the desiccant:
A. An outside air source has been used to charge the
system. This air did not pass through the drying
bed.
6
B. Air usage is exceptionally high and not normal for
a highway vehicle.
This may be due to accessory air demands or some
unusual air requirement that does not allow the
compressor to load and unload (compressing and
non-compressing cycle) in a normal fashion. Check
for high air system leakage. If the vehicle vocation
has changed, it may be necessary to upgrade the
compressor size. Refer to Bendix Specification
BW-100-A / Appendix D, to determine if any changes
are necessary. Specification BW-100-A is available
from the Bendix TechTeam at 1-800-247-2725 or
www.bendix.com.
C. The location of the air dryer and reservoir system
is too close to the air compressor. Refer to Bendix
Specification BW-110-A / Appendix B, for discharge
line lengths.
D. In areas where more than a 30 degree range of
temperature occurs in one day, small amounts
of water can temporarily accumulate in the air
brake system due to condensation. Under these
conditions, the presence of small amounts of
moisture is normal.
For Bendix® AD-IS® air dryers: Preventive Maintenance
is as easy as 1-2-3
Adhering to a preventive maintenance schedule is crucial
to keeping a vehicle’s air system clean and ensuring
superior performance of all components that utilize system
air— such as brakes, emissions equipment and automated
manual transmissions. Depending on vocation, Bendix
recommends a 1, 2 or 3-year air dryer cartridge replacement
on vehicles equipped with a Bendix® compressor.
For severe service application—such as residential refuse
trucks or school buses—the air dryer cartridge should
be replaced every year or 100,000 miles; for pick-up
and delivery operations, or for double- and triple-trailer
line haul trucks, every two years or 200,000 miles is the
recommendation. Line-haul operations using a single trailer
should swap the filter out every three (3) years or 300,000
miles. The recommended intervals for trucks equipped with
non-Bendix compressors are 6 months (50,000 miles),
one year (100,000 miles) and two years (200,000 miles),
respectively.
More frequent intervals may be required depending
on a vehicle’s age, its compressor condition, use of a
non-Bendix compressor, the operating environment, the
vehicle’s vocation, and its usage. In conjunction with these
guidelines, fleets can determine the functionality of their
filters by checking for moisture in the air brake system
monthly. If moisture is present, the air dryer cartridge may
require replacement. Reference the Bendix Service Data
Sheet of the specific air dryer for additional information.
(Recommended intervals for trucks equipped with nonBendix compressors are 6 months (50,000 miles), one
year (100,000 miles) and two years (200,000 miles),
respectively.)
2. Visually check for physical damage, such as chafed or
broken air and electrical lines, and broken or missing
parts.
3. Check the AD-IS® air dryer and purge reservoir bolts for
tightness. See Figure 1. Re-torque the three air dryer
bolts to 360–420 in-lbs and the four purge reservoir
bolts to 300–360 in-lbs.
4. Perform the Operation & Leakage Tests listed in this
publication.
! WARNING
This air dryer is intended to remove moisture and other
contaminants normally found in the air brake system.
Do not inject alcohol, anti-freeze, or other de-icing
substances into—or upstream of—the air dryer and
reservoir system. Alcohol is removed by the dryer,
but reduces the effectiveness of the device to dry air.
Use of these or other substances can damage the air
dryer and may void the warranty.
OPERATION & LEAKAGE TESTS (REFER TO THE
TROUBLESHOOTING CHART IN THIS MANUAL)
For additional information see video BW2237 — available
through the Bendix Marketing Center on www.bendix.com.
1. Check all lines and fittings leading to and from the air
dryer and reservoir system for leakage and integrity.
Repair any leaks found.
2. Build up system pressure to governor cut-out and note
that the Bendix® AD-IS® air dryer purges with an audible
escape of air. Watch the system pressure and note the
pressure fall-off for a ten minute period. If pressure
drop exceeds—a) for a single vehicle: 1 psi/minute
from either service reservoir; or b) for tractor trailer: 3
psi/minute from either service reservoir—inspect the
vehicle air systems for leak sources and repair them.
Refer to the Symptoms 1 and 4 in the Troubleshooting
Chart.
3. CAUTION: Be sure to wear safety glasses in case
of a purge blast. Check for excessive leakage around
the purge valve with the compressor in the charge mode
(compressing air). Apply a soap solution to the purge
valve exhaust port and observe that leakage does not
exceed a 1" bubble in one second. If any leakage
exceeds the maximum specified, refer to Symptom 4
in the Troubleshooting Chart.
HEATER & THERMOSTAT
CONNECTOR
FIGURE 4 - HEATER AND THERMOSTAT CONNECTOR
4. Build up system pressure to governor cut-out and note
that the AD-IS air dryer purges with an audible burst of
air, followed immediately by approximately 30 seconds
of air flowing out of the purge valve. "Fan" the service
brakes to reduce system air pressure to governor
cut-in. Note that the system once again builds to full
pressure and is followed by a purge. If the system does
not follow this pattern, refer to Symptoms 5 and 6 in
the Troubleshooting Chart .
5. Check the operation of the end cover heater and
thermostat assembly during cold weather operation as
follows:
A. Electric Power to the Dryer (Refer to Figure 4.)
With the ignition or engine kill switch in the RUN
position, check for voltage to the heater and
thermostat assembly using a voltmeter or test light.
Unplug the electrical connector at the air dryer and
reservoir system and place the test leads on each
of the connections of the female connector on the
vehicle power lead. If there is no voltage, look for a
blown fuse, broken wires, or corrosion in the vehicle
wiring harness. Check to see if a good ground path
exists.
B. Thermostat and Heater Operation
Note: These tests are not possible except in cold
weather operation.
Turn off the ignition switch and cool the thermostat
and heater assembly to below 40° F. Using an
ohmmeter, check the resistance between the
electrical pins in the air dryer and reservoir system
connector half. The resistance should be 1.5 to 3.0
ohms for the 12 volt heater assembly, and 6.0 to 9.0
ohms for the 24 volt heater assembly.
7
Warm the thermostat and heater assembly to
approximately 90° F and again check the resistance.
The resistance should exceed 1000 ohms. If the
resistance values obtained are within the stated
limits, the thermostat and heater assembly is
operating properly. If the resistance values obtained
are outside the stated limits, replace the heater and
thermostat assembly.
6. Pressure Protection Valves. Observe the pressure
gauges of the vehicle as system pressure builds from
zero. The primary or secondary gauge should rise until
it reaches approximately 106 psi (±6 psi), then level
off (or a momentary slight fall) as the next pressure
protection valve opens—supplying its reservoir. When
that pressure gauge passes through approximately 106
psi (±6 psi) there should be an associated leveling off (or
momentary slight fall) of pressure as the third and fourth
pressure protection valves open. Then the primary and
secondary gauges should increase together until they
reach their full pressure of approximately 130 psi (±5
psi).
If the Bendix® AD-IS® air dryer and reservoir system does
not perform within the pressure ranges as described
above, recheck using gauges known to be accurate.
If the readings remain outside of the ranges outlined,
replace the AD-IS air dryer and reservoir system.
NOTE: There are no kits available for the servicing
of the pressure protection valves. Warning: Do not
attempt to adjust or service the pressure protection
valves—incorrect pressure protection valve settings
can result in automatic application of the vehicle spring
brakes without prior warning (in the event one of the
supply circuits experiences rapid pressure loss).
Note: Kits are not available for the servicing of the pressure
protection valves (See Figure 5). Do not attempt to adjust
or service the pressure protection valves - these are not
service items.
TESTING THE BENDIX® AD-IS® AIR DRYER
AND RESERVOIR SYSTEM
Before placing the vehicle into service, perform the
following tests:
1. Close all reservoir drain valves.
2. Build up system pressure to governor cut-out and note
that the Bendix AD-IS air dryer purges (with an audible
burst of air), followed immediately by approximately 30
seconds of air flowing out of the purge valve.
3. Apply and release the service brakes to reduce system
air pressure to governor cut-in. Note that the system
once again builds to full pressure and is followed by a
purge at the air dryer exhaust.
4. It is recommended that the total air system be tested for
leakage to assure that the AD-IS air dryer and reservoir
system will not cycle excessively.
THE BENDIX® AD-IS®
AIR DRYER GOVERNORS ARE
NON-ADJUSTABLE
AND FEATURES A BREATHER
VALVE IN THIS PORT
PRESSURE
PROTECTION
VALVE
LOCATIONS
GENERAL
When rebuilding or replacing components of the air dryer
and reservoir, use only genuine Bendix® brand replacement
parts. For ease in servicing, the AD-IS air dryer and
reservoir have been designed so that maintenance kits can
be installed without removing the air dryer and reservoir
from the vehicle. CAUTION: Always depressurize the air
dryer and purge reservoir—and all other reservoirs on the
vehicle—to 0 psi before servicing the air dryer.
If—after completing the routine operation and leakage
tests—it has been determined that one or more components
of the air dryer requires replacement or maintenance, refer
to the Maintenance Kit listing shown in this manual or the
Bendix® Quick Reference Catalog for the appropriate kit(s).
The Quick Reference catalog (BW1114) can be ordered
and viewed on line at www.bendix.com.
8
FIGURE 5 - PRESSURE PROTECTION VALVE LOCATIONS
WARNING
DO NOT ATTEMPT TO ADJUST OR
SERVICE THE PRESSURE PROTECTION
VALVES. INCORRECT PRESSURE
PROTECTION VALVE SETTINGS CAN
RESULT IN AUTOMATIC APPLICATION
OF VEHICLE SPRING BRAKES WITHOUT
PRIOR WARNING.
BRAKING SYSTEM PROTECTION
Maintenance Kits
The Bendix AD-IS air dryer allows the system to maintain
one brake circuit up to about 100 psi even after a pressure
loss in the other brake circuit. This allows a vehicle to
be moved (in an emergency), but with reduced braking
capacity. Compare this to a conventional system, where a
loss of pressure in one service tank leaves the vehicle with
a limited number of reduced braking capacity applications
before the parking brakes automatically apply and stay on.
Kit Description
Piece No.
Delivery Check Valve Replacement Kit
5004052
Desiccant Cartridge Replacement Kit (Standard)
5008414
Governor and Check Valve Replacement Kit
5004049
See Bendix publication BW5057 "Air Brake Handbook."
Governor Gasket
5007834
Heater & Thermostat Replacement (12 volt)
109495
ROADSIDE INSPECTION
Heater & Thermostat Replacement (24 volt)
109496
In the event of a roadside inspection the system behavior
will be as follows: When the system is charged to governor
cut-out and then one reservoir drain valve is opened,
initially both reservoir gauges will fall; however, the Bendix
AD-IS air dryer primary and secondary pressure protection
valves will close at pressures above 70 psi, protecting the
remaining brake circuit from further loss of pressure.
Bendix PuraGuard Oil Coalescing Desiccant Cartridge
Service New Kit
K020366
Mounting Bolt Kit
5009233
Protective Boots (for pressure protection valves)
5005163
®
®
TEMPORARY AIR DRYER AND RESERVOIR
SYSTEM BYPASS
To temporarily bypass the air dryer, follow these procedures:
Adhere to the General Safety Guidelines outlined
elsewhere in this document.
Make sure that all residual pressure has been released and
the air dryer purge reservoir has been drained to 0 psi,
then remove the air supply line from the compressor to the
inlet port (1/IN). Remove the safety valve from the Bendix
AD-IS air dryer (see Figure 1 for location). Note that a short
puff of trapped air may vent from the safety valve port when
removing the valve. Install a T-fitting into the port. Using
any adapters necessary, reinstall the safety valve in one of
the branches of the T-fitting. Using any adapters necessary,
install the air supply line into the remaining T-fitting port.
After testing the T-fitting for any air leakage—by using a
soap solution after charging to system cut-out pressure (a
1” bubble in 10 seconds is acceptable)—the vehicle may
be returned to temporary service.
Desiccant Cartridge Replacement Kit - Bendix® AD-IS®
PuraGuard® air dryer (can be used to replace the standard
cartridge)
Drain Valve
®
5008414PG
5004961N
®
Safety Valve
800350
Splash Shield Kit (includes bracket and cover)
K052469
Splash Shield Cover
5005266N
Silencer Kit
K021189
Wiring Harness & Splice Kit
109871N
Purge Valve Assembly Type
Purge Valve Assembly for
climate conditions above
-40°C (-40°F)
Arctic Purge Valve Assembly
for climate conditions of
-40°C to -50°C
(-40°F to -58°F)
Configuration
Service Kit
Pc. No.
Bendix® AD-IS® Air Dryer
K022105
AD-IS® EverFlow®
Module
K031560
AD-IS® Discharge Line
Unloader
K031562
AD-IS® Air Dryer
K031559
AD-IS EverFlow
Module
K031561
®
®
AD-IS® Discharge Line
Unloader
K031563
Note: This is a temporary bypass of the air dryer. Full
repair of the unit must be carried out at the earliest
opportunity.
drain pressure through the drain valves—leave open to
the atmosphere—for several hours, if possible. When
repairs are carried out, be sure to check that all reservoirs
(including the air dryer purge reservoir) are emptied of all
contaminants.
With the air dryer removed from the system, contaminants
will be entering the air brake system: reservoirs will need to
be manually drained daily until the repairs are completed.
At the end of each working day, park the vehicle and slowly
If, after bypassing the air dryer and reservoir system, the
system pressure still does not build, use the following
procedure to remove, clean, and reinstall the delivery
check valve.
9
GOVERNOR GASKET
(SPECIAL GASKET,
SEE ASSEMBLY NOTE 6)
SMALL
O-RING
GOVERNOR
(NON-ADJUSTABLE,
130 PSI CUT-OUT)
BOLTS
CHECK VALVE
BODY
SPRING
LARGE
O-RING
ADAPTER
FIGURE 6 - BENDIX® AD-IS® AIR DRYER AND RESERVOIR SYSTEM DELIVERY CHECK VALVE
DELIVERY CHECK VALVE CLEANING PROCEDURE
CLEANING & INSPECTION
(Note: This is only required if system pressure does not
build after temporary bypass is completed.)
1. Use a suitable solvent to clean all metal parts, and
use a cotton swab to clean the bore (Note: Do not use
abrasives or tools to clean the bore: any scratches
caused may necessitate replacing the Bendix®
AD-IS ® air dryer and reservoir system.) Superficial
external corrosion and/or pitting is acceptable.
Refer to Figure 6 throughout the following procedures.
De-pressurize the air brake system following the general
safety precautions outlined elsewhere in this document.
Also, always de-pressurize the air dryer purge reservoir
before servicing the air dryer.
This procedure does not require removal of the Bendix
AD-IS® air dryer and reservoir from the vehicle.
®
1. Remove the line from the governor and mark for easy
re-installation.
2. Remove the bolts attaching the governor to the
AD-IS air dryer and reservoir system and retain for
re-assembly.
3. Remove the governor from the air dryer. Be aware that
a short puff of trapped air may vent when the governor is
removed. Retain the governor gasket for re-assembly if
a new governor gasket is not available. Remove and
retain the o-ring from the adapter.
4. The spring/delivery check valve can now be removed.
5. Remove and retain the o-ring from the check valve
body.
10
2. Clean the o-rings with a clean dry cloth. Do not use
solvents.
3. Inspect for physical damage to the bore and the check
valve seat. If the bore is damaged (by scratches etc.
that would prevent delivery check valve from seating),
replace the AD-IS air dryer.
4. Inspect the delivery check valve, o-rings, etc. for wear or
damage. Replace, if necessary, using the check valve
replacement kit available at any authorized Bendix parts
outlets.
5. Inspect all air line fittings for corrosion and replace as
necessary.
ASSEMBLY
1. Lubricate the smaller o-ring and check valve body with
a heavy duty lithium grease.
2. Install this o-ring on the check valve body by sliding the
o-ring over the set of four tapered guide lands. The
o-ring groove holds the o-ring in its correct location.
3. At the other end of the check valve body, the spring is
installed over the set of four straight guide lands. When
the spring has been pushed to the correct location, the
check valve body is designed to hold the end of the
spring in position: be sure that the spring is not loose
before continuing with this installation.
4. Install the assembled check valve body/o-ring/spring
in the delivery port so that the o-ring rests on its seat
and the free end of the spring is visible.
5. Grease the adapter and the remaining larger o-ring and
install it onto the fitting.
6. Position the governor gasket, then insert the governor
mounting bolts through the governor and tighten (to
125 in-lbs). Note: Do not replace with a standard
compressor/governor gasket.
7. Re-attach line to the governor.
8. Before placing vehicle back into service, check to see
that the system pressure now builds to full operational
pressure.
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11
NOTES
12
BENDIX®AD-IS® AIR DRYER AND RESERVOIR SYSTEM
TROUBLESHOOTING CHART
SYMPTOM
CAUSE
1. Dryer is constantly “cycling” A. Excessive system leakage.
or purging.
B. Defective delivery check valve.
REMEDY
A. Test for excessive system leakage. Allowable leakage
observed at the dash gauge:
- Single vehicle - 1 psi/minute.
- Tractor trailer - 3 psi/minute.
Using a Bensoap solution, test vehicle for leakage at the
fittings, drain valves and system valves and any accessories
(i.e. air suspension) connected to the Bendix® AD-IS® air dryer
auxiliary ports. If an accessory is suspected to be the cause
of leakage, disconnect that accessory from the air dryer, plug
the auxiliary port that it was in, and retest the AD-IS air dryer
for proper purge cycling. Repair or replace as necessary.
B. Build system pressure to governor cut-out. Wait 1 minute for
the completion of the purge cycle. Using a soap solution at
the exhaust of the purge valve, leakage should not exceed
a one inch bubble in less than 5 seconds.
If a rapid loss of pressure is found, the following procedure
will determine if the delivery check valve is malfunctioning:
Build system pressure to governor cut-out and allow a full
minute for the normal dryer purge cycle to empty the purge
reservoir. Switch off the engine and apply and release the
brakes so that the system pressure reaches governor cut-in.
The purge valve will return to its closed position. The purge
reservoir has a drain valve which is opened by moving the
center lever away from its closed position. Open the drain
valve and wait 10 seconds to allow any residual purge
pressure to be released. Release the lever, closing the drain
valve. Carefully remove the air dryer cartridge using a strap
wrench and then test for air leaking through the center of
the threaded boss by applying a soap solution to the area.
Replace the delivery check valve if there is excessive leakage
(exceeding a one inch bubble in five 5 seconds).
Re-grease the seal on the air dryer cartridge before
reinstalling. Be sure the drain valve on the purge reservoir
is not leaking before restoring vehicle to service.
C. Defective governor.
C. Check the governor at both the “cut-in” and “cut-out” position
for (i) proper pressures and (ii) excessive leakage at fittings
and exhaust.
D. Compressor unloader mechanism D. Remove the air strainer, or fitting, from compressor inlet
leaking excessively.
cavity. With the compressor unloaded, check for unloader
piston leakage. Slight leakage is permissible.
13
BENDIX®AD-IS® AIR DRYER AND RESERVOIR SYSTEM
TROUBLESHOOTING CHART
SYMPTOM
CAUSE
REMEDY
2. Wa t e r i n t h e v e h i c l e A. Maximum air dryer inlet temperature is A. Check for excessive carbon build up in the compressor
reservoirs
exceeded due to improper discharge
discharge line. Replace if required. Make certain that the
line length.
discharge line length is at least 6 ft. Increase the discharge
line length and/or diameter to reduce air dryer inlet
temperature.
B. Air system charged from outside B. If system must have outside air fill provision, outside air should
air source (outside air not passing
pass through air dryer.
through air dryer).
C. Excessive air usage - Air dryer not C. Refer to the Bendix Advanced Troubleshooting Guide for Air
Brake Compressors (BW1971) for proper application of the
compatible with the vehicle air system
Bendix® AD-IS® air dryer and reservoir system. An extended
requirement (Improper air dryer/
purge model (Bendix® AD-IS® EP) is available for many higher
vehicle application)
air usage vehicles, such as city buses and construction
vehicles.
If the vehicle is equipped with high air usage accessories,
such as trailer pump-off systems or central tire inflation, the
air for these accessories must by-pass the dryer reservoir
system.
D. Desiccant requires replacement.
D.Replace the desiccant cartridge assembly.
E. Air by-passes desiccant cartridge E.If the vehicle uses a Holset compressor, inspect the feedback
check valve for proper installation and operation.
assembly.
F. Air dryer not purging.
F. Refer to Symptom 6.
G. Purge (air exhaust) time is insufficient G. Refer to Symptom 1.
due to excessive system leakage.
3. Safety valve on the air dryer A. Defective AD-IS air dryer and reservoir A. Test to determine if air is passing through check valve. Repair
is “popping off” or exhausting
system delivery check valve.
or replace. Refer to Symptom 1, Remedy B.
air.
B. Safety valve setting too low (<150 p.s.i.) B. Replace the safety valve.
C. System pressure too high (>135 p.s.i.) C. Test with an accurate gauge. Replace the governor if
necessary.
D. Excessive pressure pulsations from D. Increase volume in discharge line. This can be accomplished
compressor. (Typical single cylinder
by adding a 90 cubic inch (or larger) reservoir between the
type).
compressor and the AD-IS® air dryer and reservoir system.
14
BENDIX®AD-IS® AIR DRYER AND RESERVOIR SYSTEM
TROUBLESHOOTING CHART
SYMPTOM
CAUSE
REMEDY
4. Constant exhaust of air at the A. Air dryer purge valve leaking A.
air dryer purge valve exhaust
excessively.
or unable to build system
pressure. (Charge mode.)
With the compressor loaded, apply a soap solution on the
purge valve exhaust, to test for excessive leakage. Repair
or replace the purge valve as necessary.
Refer to Technical Bulletin TCH-008-040.
B. Purge valve frozen open - faulty heater B. Refer to paragraph 5 of the Operation and Leakage Tests for
and thermostat, wiring, blown fuse.
the heater and thermostat test.
C. Defective AD-IS air dryer delivery C. Refer to Symptom 1, Remedy B.
check valve.
D. Leaking Turbo Cut-Off valve.
D. Repair or replace the purge valve assembly.
E. Defective governor.
E. Check the governor at both “cut-in” and “cut-out” positions
for (i) proper pressures and (ii) excessive leakage at fittings
and exhaust.
F. Leaking purge valve control piston F. Repair or replace the purge valve assembly.
seals.
5. Cannot build system air A. Supply pressure to the air dryer is not A. Ensure the supply pressure to the air dryer is greater than
pressure.
sufficient.
110 psi after the system charges.
B. Kinked or blocked (plugged) discharge B. Check to determine if air passes through discharge line.
line.
Check for kinks, bends, excessive carbon deposits, or ice
blockage.
C. Excessive bends in discharge line C. Discharge line should be constantly sloping from compressor
(water collects and freezes).
to air dryer with as few bends as possible.
D. Pressure protection valve(s) in air D. Replace air dryer (pressure protection valves are not
dryer will not open.
serviceable).
E. Refer to Symptom 4.
E. Refer to Symptom 4, Remedy A.
F. Refer to Symptom 7.
F. Refer to Symptom 7, Remedies A and B.
6. Air dryer does not purge or A. Faulty air dryer purge valve.
exhaust air.
A. After determining air reaches purge valve control port by
installing a T-fitting with a pressure gauge into the governor
unloader port, repair purge valve if necessary.
B. See Causes B, E, and F for Symptom B. Refer to Symptom 4, Remedies B, E, and F.
#4.
Also refer to Symptom 1, Remedy B.
7. Desiccant material being A. Faulty dryer cartridge.
expelled from the air dryer
purge valve exhaust (may B. Excessive dryer vibration.
look like whitish liquid or
paste or small beads.)
A. Replace the Bendix® AD-IS® air dryer cartridge or AD-IS air
dryer.
8. Unsatisfactory desiccant life. A. Excessive system leakage.
A. Refer to Symptom 1, Remedy A.
B. Check the AD-IS air dryer mounting for looseness or damage.
Repair the mounting and replace cartridge.
B. Wrong vehicle application for an B. Refer to Symptom 2, Remedy C.
AD-IS® air dryer.
C. Compressor passing excessive oil.
C. Check for proper compressor installation; if the symptoms
persist, replace the compressor. Refer to Bendix Advanced
Troubleshooting Guide for Air Brake Compressor (BW1971).
15
BENDIX®AD-IS® AIR DRYER AND RESERVOIR SYSTEM
TROUBLESHOOTING CHART
SYMPTOM
CAUSE
REMEDY
9. “Pinging” noise excessive A. Single cylinder compressor with high A. A slight “pinging” sound may be heard during the system build
during compressor loaded
pulse cycles.
up when a single cylinder compressor is used. If this sound
cycle.
is deemed objectionable, it can be reduced substantially by
increasing the discharge line volume.
This can be accomplished by adding a 90 cubic inch (or
larger) reservoir between the compressor and the AD-IS air
dryer and reservoir system.
10.The air dryer purge piston A. Compressor fails to “unload”.
cycles rapidly in the
compressor unloaded (noncompressing) mode.
A. Check air hose from the governor to the compressor for a
missing, kinked or restricted line. Install or repair the air hose.
Repair or replace the compressor unloader.
SD-08-2418 ©2014 Bendix Commercial Vehicle Systems LLC, a member of the Knorr-Bremse Group • 1/14 • All Rights Reserved
16
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