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BENDIX SD-08-2415A User's Manual

1. Bendix AD RP Remote Purge amp AD RP PuraGuard Oil Coalescing Remote Purge Air Dryers MOUNTING HOLES 3 CONTROL MEDALLION INDICATES BENDIX PURAGUARD OIL COALESCING CARTRIDGE SPIN OFF DESICCANT CARTRIDGE om REMOTE PURGE PORT PT 22 NOT MARKED A HEATER amp lt THERMOSTAT CONNECTOR SUPPLY PORT SUP 1 TURBO CUT OFF VALVE EXHAUST PORT FIGURE 1 BENDIX AD RP REMOTE PURGE AIR DRYER DESCRIPTION The function of the Bendix AD RP remote purge air dryer and the AD RP remote purge air dryer with PuraGuard oil coalescing technology is to collect and remove air system contaminants in solid liquid and vapor form before they enter the brake system The dryer provides clean dry air to the components of the brake system which increases the life of the system and reduces maintenance costs Daily manual draining of the reservoirs is eliminated The Bendix AD RP PuraGuard oil coalescing air dryer has an identical appearance to the standard AD RP 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 RP unit The AD RP PuraGuard oil coalescing air dryer has all of the same functions as the standard AD RP air dryer and is used in applications where lower oil concentration levels are required DELIVERY PORT DEL 2 IMPORTANT When servicing note that stand
2. AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE REMEDY Air dryer is constantly A Excessive system leakage cycling or purging Air dryer purges frequently every 4 minutes or less while vehicle is idling continued IMPORTANT Note whether air pressure loss is shown on dash gauge s Pressure loss shown on gauges is caused by service brake system or component leakage Pressure loss NOT SHOWN on the gauges is caused by supply system or component leakage continued A Test fittings hoses lines and connections Apply soap solution to detect excessive leakage Tighten or replace as needed then repeat the air dryer charge purge cycle and observe the gauge installed in the supply reservoir If the leakage is within limits remove the gauge from the reservoir and replace the drain cock or valve If excessive leakage is detected continue testing Test accessories connected to supply reservoir Drain all air pressure from the system disconnect all air lines leading to accessories fan clutch wipers air seats etc and plug the reservoir at the disconnection point Build air system pressure until the air dryer purges and observe the supply reservoir gauge If the leakage is no longer excessive repair or replace the leaking accessory If excessive leakage is detected continue testing Test governor leakage Build the system pressure to governor cut out turn off the engine and apply a soap solution to
3. B Thermostat and Heater Operation Turn off the ignition switch and cool the body assembly to below 40 F Note this test is performed in warm weather above 30 F it may be necessary to remove the heater and thermostat assembly and cool it in a freezer Using an ohmmeter check the resistance between the electrical pins in the connector The resistance should be 1 5 to 1 7 ohms for the 12 volt heater assembly and 6 0 to 6 9 ohms for the 24 volt heater assembly If the resistance is higher than the maximum stated replace the heater and thermostat assembly Warm the heater and thermostat assembly to over 90 F and once 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 Available through the Bendix Marketing Center on www bendix com DESICCANT CARTRIDGE CONTROL PORT REMOTE PURGE PORT O RINGS AD RP AIR RETAINING RING N O DRYER BODY cy DELIVERY PORT RETAINING RING _ SUPPLY PORT CONNECTOR _ j PURGE VALVE HEATER amp rr o THERMOSTAT ASSEMBLY PURGE PISTON SPRING EXHAUST COVER RETAINING RING FIGURE 6 BENDIX AD RP REMOTE PURGE AIR DRYER EXPLODED VIEW REPAIRING THE BENDIX AD RP AIR DRYER BENDIX AD R
4. Air is not reaching the A Test to determine that air flows through the purge purge or exhaust air AD RP air dryer purge control line to the purge control port on the AD RP Note this symptom control port air dryer when the compressor is unloaded Check often precedes for undrilled fittings Check if the purge control line Symptom 9 if is broken not connected mis connected frozen or desiccant cartridge is damaged Inspect repair or replace as necessary not replaced Replace desiccant cartridge The AD RP air dryer purge B Check the operation of the AD RP air dryer heater valve or piston is frozen and thermostat Repair or replace as necessary closed Replace desiccant cartridge C Extremely high air usage C Refer to the Vehicle Application Requirements requirements on the section of this manual and verify application vehicle continued 23 Bendix AD RP AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE REMEDY 9 Desiccant material A See the related remedies for the causes under is being expelled from the air dryer purge valve exhaust may look like whitish liquid paste or small beads OR Unsatisfactory desiccant life Pinging noise excessive during compressor loaded cycle The air dryer purge piston cycles rapidly in the compressor unloaded non compressing mode A This symptom is almost always accompanied by one or more of Symptoms 1 2 3 4 and 6 See the related ca
5. port and a soap solution to the supply port leakage exceeds a one 1 inch bubble in five 5 seconds repair the turbo cut off piston and valve before proceeding to step 2 B With 120 psi shop air pressure applied to the control port apply a soap solution to the purge exhaust port If leakage exceeds a one 1 inch bubble in five 5 seconds repair the purge piston and valve before proceeding to step 2 C With 120 psi shop air pressure applied to the control and supply port apply a soap solution to the purge exhaust port lf leakage exceeds a one 1 inch bubble in five 5 seconds repair the turbo cut off piston and valve before proceeding to step 2 With a plug installed in the delivery port 0 psi in the control port and 120 psi applied to the supply port apply a soap solution to the purge exhaust port lf leakage exceeds a one 1 inch bubble in five 5 seconds repair the purge piston and valve before proceeding to step 2 2 Perform the Operation amp Leakage Tests shown in this publication Every 10 800 hours or every 350 000 miles or 36 months 1 Replace the air dryer desiccant cartridge Note The desiccant change interval may vary from vehicle to vehicle Although typical desiccant cartridge life is three years many will perform adequately for a longer period of time In order to take maximum advantage of desiccant life and ensure that replacement occurs only when necessary it is important that y
6. The system will be saturated with moisture and several weeks of operation may be required to dry it out D Location of the air dryer is too close to the air compressor Refer to Locating the Bendix AD RP Air Dryer On Vehicle section plus Appendix A Table A column 2 for discharge line length E 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 and should not be considered as an indication that the dryer is not performing properly Note A small amount of oil in the system is normal and Should not be considered as a reason to replace the desiccant cartridge oil stained desiccant can function adequately 2 Visually check for physical damage to the AD RP air dryer such as a dented desiccant cartridge chafed or broken air and electrical lines and broken or missing parts 3 Check mounting bolts for tightness Re torque to 50 Ib ft 4 Perform the Operation amp Leakage Tests listed in this publication Every 3 600 operating hours or every 100 000 miles or twelve 12 months 1 Test the AD RP air dryer turbo cut off and purge valves for leakage Disconnect the supply control and delivery lines from the AD RP dryer Perform the tests below in the order they are presented A Apply 120 psi shop air pressure to the contro
7. air dryer purges with an audible escape of air 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 AD RP air dryer exhaust 14 4 It is recommended that the following items be tested for leakage to ensure that the AD RP air dryer will not cycle excessively A Total air system leakage See Bendix publication BW5057 Air Brake Handbook B Compressor unloader mechanism C Governor D Drain cock and safety valve in the first Supply reservoir E All air connections leading to and from the first supply reservoir and the F Delivery check valve GOVERNOR COMPRESSOR FIGURE 9 AIR SYSTEM WITHOUT BENDIX AD RP REMOTE PURGE AIR DRYER BENDIX AD RP AIR DRYER REMOTE PURGE a a RESERVOIR GOVERNOR COMPRESSOR FIGURE 10 AIR SYSTEM WITH BENDIX AD RP REMOTE PURGE AIR DRYER 15 Bendix AD RP AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE REMEDY Air dryer is constantly A Excessive system leakage cycling or purging IMPORTANT Note whether Air dryer purges air pressure loss is shown frequently every 4 on dash gauge s Pressure minutes or less while loss shown on the gauges vehicle is idling is caused by service brake system or component leakage Pressure loss NOT SHOWN on the gauges is caused by supply system or component leak
8. air lines to the AD RP dryer it will be necessary to remove and discard the Holset ECON and special orifice check valve 4134 INCHES CENTER TO CENTER 1 2 13 UNC THREAD 3 PLACES 2 835 INCHES CENTER TO CENTER FIGURE 7 BENDIX AD RP SYSTEM PURGE AIR DRYER MOUNTING BRACKET DIMENSIONS PURGE CONTROL LINE 1 Install a purge control air line having a minimum inside diameter of 3 16 between the Bendix AD RP air dryer control port and an unused unloader port on the governor The control line must be plumbed direct to the governor and not in series with automatic drain valves lubrication systems etc 2 The control line should slope downward to the AD RP dryer without forming potential water traps DISCHARGE LINE GENERAL Refer to Appendix A Table A for recommended discharge line lengths and sizes for various vehicle applications and vocations PURGE EXHAUST LINE 1 If it is necessary to direct AD RP air dryer discharge contaminates away from vehicle components a 1 25 4 mm I D hose can be clamped on the AD RP dryer exhaust WIRING THE HEATER THERMOSTAT 1 Determine the vehicle s electrical system voltage and make certain that the Bendix AD RP air dryer that is to be installed contains the same voltage heater Confirm the proper voltage by noting the color of the heater and thermostat connector The AD RP air dryer is available with either a 12 or 24 volt heater Each uses 90 w
9. direction and begins to flow back toward the open purge valve Oil and solid contaminants collected by the oil separator are removed by air flowing from the desiccant drying bed to the open purge valve DESICCANT RE ACTIVATION DRYING THE DESICCANT The initial decompression of the air dryer assembly lasts only a few seconds and is evidenced by an audible burst of air at the AD RP air dryer exhaust The actual reactivation of the desiccant drying bed begins as dry air flows from the purge volume through the purge orifice in the body and into the desiccant bed Pressurized air from the purge volume expands after passing through the purge orifice its pressure is lowered and its volume increased The flow of dry air through the drying bed reactivates the desiccant material by removing the water vapor adhering to it Generally 30 seconds minimum are required for the entire purge volume of a standard AD RP air dryer to flow through the desiccant drying bed The delivery check valve assembly prevents air in the brake system from returning to the air dryer during the purge cycle After the purge cycle is complete the desiccant has been reactivated or dried and the air dryer is ready for the next charge cycle to begin However the purge valve will remain open and will not close until air brake system pressure is reduced and the governor signals the compressor to charge the system 5 PREVENTIVE MAINTENANCE Important Review the warranty p
10. from the body Remove the turbo cut off cap o ring 3 Remove the turbo cut off piston from the body 4 Remove the large and small diameter o rings from the piston DISASSEMBLY PURGE RELIEF VALVE 1 If so equipped disconnect remove and save the exhaust line from the exhaust port of the air dryer 2 Remove the retaining ring from the body assembly then remove the non metallic exhaust cover and spring from the body Note The spring exerts a 30 pound force against the exhaust cover 3 Carefully remove the purge piston from the body and remove the o ring from the purge piston 4 The purge valve has two different sides Note which side is visible before removing the valve Remove the valve from the body DISASSEMBLY HEATER AND THERMOSTAT 1 Disconnect the vehicle wiring harness connector that mates with the heater and thermostat connector on the body Pry the lock tabs on the vehicle wiring harness connector out before removal from the air dryer connector Make sure the connector seal is present on the vehicle wiring harness connector 2 Remove the retaining ring that secures the heater and thermostat in the body 3 Carefully pull the heater and thermostat assembly straight out of the body 4 Remove the o ring from the heater connector DISASSEMBLY DESICCANT CARTRIDGE 1 Place a strap wrench or equivalent tool on the desiccant cartridge next to the lip low on the cartridge Rotate counterclockwise to
11. 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 Following the vehicle manufacturer s recommended procedures deactivate the electrical system in a manner that safely removes all electrical power from the vehicle A A 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
12. valve Each is discussed below under a separate subheading OIL COALESCING FILTER PURGE ORIFICE REMOTE PURGE REMOTE PURGE RESERVOIR E PURGE CONTROL LINE GOVERNOR TURBO ENGINE CUT OFF TURBO PORT COMPRESSOR y SAFETY VALVE EXHAUST DESICCANT REAR J DELIVERY RESERVOIR CHECK RESERVOIR DELIVERY PORT PURGE VALVE FIGURE 5 BENDIX AD RP AIR DRYER SYSTEM PURGE CYCLE TURBO CUT OFF VALVE Refer to Figure 5 The primary function of the turbo cut off valve is to prevent loss of engine turbocharger air pressure through the Bendix AD RP air dryer in systems where the compressor intake is connected to the engine turbocharger The turbo cut off valve also eliminates the puffing of air out the open air dryer exhaust when a naturally aspirated single cylinder compressor is equipped with an inlet check valve Governor unloader pressure causes the turbo cut off valve piston to move and close With the turbo cut off valve piston seated closed position air in the discharge line and AD RP air dryer inlet port is prevented from entering the air dryer PURGE PISTON The Bendix AD RP air dryer purge piston also moves in response to governor unloader pressure causing the purge valve to open to atmosphere Contaminants in the body sump are instantly expelled when the purge valve opens Air which was flowing through the desiccant cartridge immediately changes
13. AIR DRYER SYSTEM CHARGE CYCLE The aluminum body of the Bendix AD RP air dryer contains the following serviceable components or assemblies the turbocharger cut off valve the heater and thermostat assembly a delivery check valve assembly and the combined purge and relief valve assembly All service and replacement can be accomplished from the exterior of the dryer without removing it from the vehicle The spin on desiccant cartridge is removed and installed using a strap wrench The AD RP air dryer has four female pipe thread air connections identified as follows Also refer to Figure 1 Air Connection Port ID Function Connection CON 4 Control Port purge valve control amp turbo cut off Supply Port air in DEL 2 Delivery Port air out PT 22 not identified on Remote Purge Port the air dryer OPERATION GENERAL The AD RP air dryer alternates between two operational modes or cycles during operation the Charge Cycle and the Purge Cycle What follows is a description of operation separated into these cycles CHARGE CYCLE Refer to Figure 3 When the compressor is loaded compressing air compressed air along with oil oil vapor water and water vapor flows through the compressor discharge line to the supply port of the air dryer body Air entering the supply port immediately encounters the turbo cut off valve With no air pressure in the control port the turbo cut of
14. P AIR DRYER REMOVAL GENERAL 1 Park the vehicle on a level surface and prevent lf after completing the routine operation and leakage movement by means other than the brakes tests it has been determined that one or more 2 Drain ALL reservoirs to 0 psi 0 kPa Caution The compressor discharge line may still contain components of the air dryer requires replacement or residual pressure maintenance refer to the list below to find the appropriate kit s When repairing or replacing components of the air 3 Identify mark and disconnect the supply delivery dryer use only genuine Bendix parts control and remote purge port air lines Disconnect the wiring harness connector from the heater and Maintenance Kits Available thermostat assembly connector on the body assembly Kit 4 so equipped disconnect remove and save the Part Number exhaust line from the exhaust port of the air dryer i 109495 12 Volt Replacement Heater amp Thermostat Assembly Kit 109496 24 Volt Replacement Heater amp Thermostat Note It is important to retain the three mounting bolts Assembly Kit since their length is specific to mounting the air dryer 109993 Turbo Cut Off Maintenance Kit without damage If these bolts must be replaced the 5008414 Standard Desiccant Cartridge PAME ENO TS li Replacement Kit 6 Remove the Bendix AD RP air dryer from its 5008414PG Bendix PuraGuard Desiccant Cartridge mounting brackets on the vehicl
15. age A If leakage IS SHOWN on the gauges test for excessive service brake system leakage Allowable leakage Single vehicle 1 psi minute per service reservoir Tractor Trailer 3 psi minute per service reservoir Repair and retest as required Dash A Gauge 7 i kere as l Air pressure loss shown Service H on dash gauges test all components fittings and lines in service brake system from this point down stream T Dash Gauge Service leakage is NOT SHOWN on gauges Air pressure loss not shown on dash gauges test all components fittings and lines in supply system from this point up stream Governor Compressor 16 a gt NAS Air Dryer A hq If test for excessive supply system leakage Dash 22 Gauge yi 2 Q d Service i TJ nan nu gt xu T T Oro end Supply oF Dash CA Gauge __ Service Remove the drain cock or valve in the supply reservoir wet tank and install an air gauge Build the system pressure allow the air dryer to purge Observe the air gauge in the supply reservoir The pressure drop should not exceed 1 psi per minute Perform the following tests 1 to 5 in the order presented To Accessories Supply Test Gauge L continued 1 Bendix AD RP
16. ard AD RP air dryers or air dryer cartridges may be serviced with PuraGuard oil coalescing air dryers or cartridges The PuraGuard oil coalescing air dryers or cartridges however must only be serviced with like replacements Note Unless otherwise stated in this manual AD RP air dryer refers to both the standard and PuraGuard oil coalescing remote purge air dryers The remote purge designation is used because the AD RP air dryer uses a small air volume separate from the air brake system to perform the purge or regenerative function The AD RP air dryer consists of two major component groups a spin on desiccant cartridge assembly and a die cast aluminum body assembly The desiccant cartridge is self contained and serviced as a complete assembly 1 FIGURE 2 BENDIX AD RP AIR DRYER SYSTEM DRAWING 2 WARNING PLEASE READ AND FOLLOW THESE INSTRUCTIONS GENERAL SAFETY GUIDELINES 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
17. ation Repair or replace as necessary Replace the desiccant cartridge Excessive pressure E Increase the volume in the discharge line by adjusting pulsations from compressor the length or size of line or add a ping tank Typical single cylinder type 5 Air escaping from air Leaking turbo cut off valve in A Note the dash gauges to verify the purge cycle has dryer exhaust port Bendix AD RP air dryer ended Perform the air dryer Operation amp Leakage during entire purge Tests specified in this manual Repair or replace as cycle Compressor necessary not running Leaking purge piston o ring B Perform the Air Dryer Operation amp Leakage Tests in the AD RP air dryer specified in this manual Repair or replace as necessary Leaking delivery check C Perform the Air Dryer Operation amp Leakage Tests valve specified in this manual Repair or replace as necessary Unable to build air Frozen discharge line A Inspect the discharge line installation for water traps system pressure and that could freeze Refer to Connecting The Air Lines air is not escaping section in manual Repair or replace as necessary from the AD RP air DEVERAN aunng B Compressor unloader B Test the compressor unloader mechanism for proper the charge cycle l l B mechanism malfunction operation Repair or replace as necessary Note This is not the same as symptom C Governor malfunction C Test the govern
18. atts of power 2 A separate wire harness and splice kit is with all AD RP air dryer replacements and retro fit kits Refer to the instructions contained in that kit for the proper wiring procedure Heater amp Thermostat Connector Voltage 12 Volts White No other markings 24 Volts Gray or White w Red Dot WIDTH THICKNESS OF AD RP AIR DRYER MOUNTING BRACKET MOUNTING BOLT 1 8 BELOW SURFACE OF MTG BRACKET VEHICLE FRAME MEMBER MOUNTING BOLT AMAS BOLT 1 4 ABOVE SURFACE OF MOUNTING BRACKET FIGURE 8 BENDIX AD RP SYSTEM PURGE AIR DRYER MOUNTING BRACKET BOLT LENGTHS TESTING THE BENDIX AD RP AIR DRYER GENERAL OPERATIONAL STATEMENT The AD RP remote purge air dryer operates differently than integral purge air dryers such as the Bendix AD 9 air dryer The Remote Purge designation is used because this air dryer uses a small additional volume mounted on the frame rail to purge or dry the desiccant material During the purge cycle the pressure in this purge volume will drop to 0 psi This volume is separate from the air brake system volume no pressure drop in the air brake system should be caused by the purge cycle of the AD RP air dryer 13 TESTING THE BENDIX AD RP AIR DRYER Before placing the vehicle in service perform the following tests 1 Close all reservoir drain cocks 2 Build up system pressure to governor cut out and note that the Bendix AD RP
19. 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 BENDIX AD RP AIR DRYER T a r T ll A _ HH GOVERNOR COMPRESSOR REMOTE PURGE RESERVOIR OIL COALESCING FILTER PURGE REMOTE ORIFICE PURGE RESERVOIR REMOTE PURGE PORT CONTROL PORT PURGE CONTROL LINE SUPPLY PORT Q TURBO J m ENGINE CUT OFF TURBO COMPRESSOR GOVERNOR EXHAUST PORT DESICCANT REAR RESERVOIR DELIVERY CHECK VALVE FRONT RESERVOIR HININ DELIVERY PORT PURGE VALVE SAFETY VALVE FIGURE 3 BENDIX AD RP
20. ded compressor sizes If the compressor is too small for the vehicle vocation for example where a vehicle s vocation has changed or service conditions exceed the original vehicle or engine OE specs then upgrade the compressor Note The costs incurred e g installing a larger capacity compressor etc are not covered under the original compressor warranty Charge Cycle Time The Bendix AD RP air dryer is designed to provide clean dry air for the brake system When a vehicle s air system is used to operate non brake air accessories the compressor should recover from governor cut in to governor cut out usually 100 psi to 120 psi in 90 seconds or less at engine RPMs commensurate with the vehicle vocation If the recovery time consistently exceeds this limit it may be necessary to by pass the air accessory responsible for the high air usage An example of where a by pass system would be required is when the compressor is used to pressurize a tank trailer for purposes of off loading product Consult your local authorized Bendix parts outlet or sales representative for additional information Purge Cycle Time During normal vehicle operation the air compressor must remain unloaded for a minimum of 30 seconds This minimum purge time is required to ensure complete regeneration of the desiccant material If the purge time is consistently less than the minimum an accessory bypass system must be installed Consult you
21. e Replacement Kit 5 Remove the three mounting bolts that secure the air dryer to the vehicle and remove the air dryer 109995 Purge amp Relief Valve Maintenance Kit 5008972 Purge Volume Kit uses 288 cu in reservoir part no 275816 For a more complete listing of service parts refer to the Bendix Quick Reference Catalog BW1114 DISASSEMBLY FOR PART REPLACEMENT AND KIT INSTALLATION 1 The following disassembly and assembly procedures are presented for reference and assumes that the appropriate Bendix AD RP air dryer kits are on hand The instructions provided with these parts and kits should be followed instead of the instructions presented here 2 The replacement parts and maintenance kits that are available do not require full disassembly and in most cases do not require the removal of the AD RP air dryer from the vehicle 3 If removal of the air dryer is necessary adhere to the following caution CAUTION While performing service on the AD RP 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 DISASSEMBLY TURBO CUT OFF VALVE 1 Loosen the supply port line and allow any residual air in the compressor discharge line to drain 2 Remove the retaining ring from the body assembly then remove the turbo cut off cap
22. e and Appendix A Table A columns 1 amp 2 then check reservoir material Maximum air the line size and length dryer inlet temperature is exceeded Air system charged from an If the system must have an outside air fill provision outside air source outside outside air should pass through air dryer This air not passing through air practice should be minimized dryer C Air dryer is not purging C See Symptom 5 D Purge air exhaust time D Check causes and remedies for Symptom 1 insufficient due to excessive system leakage continued 18 Bendix AD RP AIR DRYER TROUBLESHOOTING CHART 2 Water and or oil in supply or service reservoir continued E Excessive air usage duty cycle is too high the air dryer is not compatible with the vehicle air system requirement improper air dryer vehicle application NOTE Duty cycle is the ratio of time the compressor spends building air to total engine running time Air compressors are designed to build air run loaded up to 25 of the time Higher duty cycles cause conditions that affect air brake charging system performance which may require additional maintenance Factors that add to the duty cycle are air Suspension additional air accessories use of an undersized compressor frequent stops excessive leakage from fittings connections lines chambers or valves etc E See Appendix A Table A column 1 for the recommen
23. eets 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 Refer to the Bendix Service Data Sheet of the specific air dryer for additional information 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 Alcohol is removed by the dryer but reduces the effectiveness of the device to dry air Use of other substances can damage the air dryer and may void the warranty OPERATION amp LEAKAGE TESTS ALSO SEE VIDEO 872327 1 Check for excessive leakage around the purge valve With the compressor in the loaded mode compressing air apply a soap solution to the purge valve exhaust port and observe that leakage does not exceed a one 1 inch bubble in five 5 seconds If the leakage exceeds the maximum specified service the purge valve assembly 2 Check for leakage around the desiccant cartridge With the compressor in loaded mode compressing air apply a soap solution around the desiccant cartridge seal and observe that no leakage occurs If leakage is noted tighten the cartridge using a strap wrench and re test for leakage 3 While observing the dash gauge s build up system pressure at approximately 1 800 engine compressor rom to governor cut out N
24. embly in the body Install the o ring on the turbo cut off cap then install the cap in the body Install the retaining ring in the body making certain that it is fully seated in its groove Before placing vehicle back into service perform the Operation amp Leakage Tests detailed in this manual ASSEMBLY PURGE RELIEF VALVE 1 Lubricate the piston o ring with the grease supplied in the Bendix maintenance kit Also lubricate completely around the outside edge of the purge valve Install the purge valve in the body Make certain that it is firmly and squarely seated in the body with the correct side visible Note The three 3 bumps on the purge valve should not be visible If the three 3 bumps are visible after the purge valve is installed the valve must be removed and re installed Install the o ring on the purge piston then install the piston in the body taking care not to cut the piston O ring Install the non metallic exhaust cover and spring in the body Install the retaining ring in the groove in the body Make certain that it is fully seated in its groove If so equipped reconnect the exhaust line from the exhaust port of the air dryer 7 Re tighten the supply port line 8 Before placing vehicle back into service perform the Operation amp Leakage Tests stated elsewhere in this manual ASSEMBLY HEATER AND THERMOSTAT 1 10 Lubricate the connector o ring with the grease supplied in
25. f piston moves the valve away from its seat in the body allowing the supply air to enter the body As air travels through the end cover assembly its direction of flow changes several times reducing the temperature causing contaminants to condense and drop to the bottom or sump of the air dryer body After exiting the end cover the air flows into the desiccant cartridge where an oil separator or coalescing filter if equipped with a Bendix PuraGuard oil coalescing 3 OIL COALESCING FILTER PURGE REMOTE ORIFICE PURGE RESERVOIR REMOTE PURGES PURGE CONTROL LINE NIIN NNN Iji GOVERNOR ENGINE COMPRESSOR CUT OFF EXHAUST PORT DESICCANT REAR DELIVERY RESERVOIR CHECK VALVE FRONT RESERVOIR DELIVERY PORT FIGURE 4 BENDIX AD RP AIR DRYER SYSTEM RELIEF VALVE OPERATION cartridge located between the outer and inner shells of the cartridge removes water in liquid form as well as liquid oil and solid contaminants After exiting the oil separator air enters the space between the desiccant drying bed and the outer cartridge shell and flows down through the column of desiccant Flowing through the desiccant column air becomes progressively more dry as water vapor adheres to the desiccant material in a process known as ADSORPTION Using the adsorption process the desiccant cartridge typically removes 95 of the water vapor from the pressurized air Dry a
26. ge exhaust and purge control port where the control line was removed Leakage should not exceed a one 1 inch bubble in five 5 seconds If leakage is excessive repair or replace purge valve assembly continued 17 Bendix AD RP AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE REMEDY Air dryer is constantly B Incorrect governor setting or B Minimum setting required for Bendix AD RP air cycling or purging malfunctioning governor dryer installation is 100 psi cut in and 120 psi cut out Air dryer purges Test operation of the governor Repair or replace as frequently every 4 necessary minutes or less while vehicle is idling Rapid cycling of the With a gauge installed at the RES port of the governor due to air governor the pressure should not drop below cut in Starvation at the reservoir pressure at the onset of the compressor unloaded RES port of the governor cycle If the pressure drops check for kinks or restrictions in the line connected to the RES port The line connected to the RES port on the governor must be the same diameter or preferably larger than the lines connected to the UNL port s on governor High air usage vehicle Refer to the Vehicle Application Requirements application section of this manual and verify the application 2 Water and or oil in Improper discharge line Refer to the section titled Connecting the Air Lines supply or service length or improper lin
27. h the vehicle vocation Note The Bendix AD RP air dryer must be used in conjunction with governors which have a 120 to 130 psi nominal cut out pressure lf a governor is used that is not within this limitation contact your Bendix parts outlet or sales representative for additional information If the recovery time consistently exceeds this limit it may be necessary to by pass the air accessory responsible for the high air usage 2 Purge Cycle Time During normal vehicle operation the air Compressor must remain unloaded for a minimum of 30 seconds This minimum purge time is required to ensure complete regeneration of the desiccant material If the purge time is occasionally shorter than the times specified no permanent ill effect should be expected If the purge time is consistently less than the minimum however an accessory by pass system must be installed European Air Brake Systems The AD RP air dryer must not be installed in brake systems that incorporate compressors without integral unloading mechanisms and or utilize a compressor discharge line unloader valve When vehicles of this type are encountered other Bendix air dryer models must be used Consult your local authorized Bendix parts outlet or sales representative for additional information Air Compressor Size The AD RP air dryer was designed primarily for use with compressors rated up to 30 CFM Contact and authorized Bendix parts outlet or a Bendix sales
28. he BASIC Note Compressor and or air dryer upgrades are recommended in cases where duiy cycle is greater than the normal range for the examples above For Bendix Tu Flo 550 and 750 compressors unloader service is recommended every 250 000 miles Appendix B For more troubleshooting information refer to Troubleshooting Charging and Air Supply Systems BW1779 This and other literature are available online from the Bendix Literature Center on www bendix com STANDARD SINGLE CHECK VALVE LOW PRESSURE USED W INTEGRAL PURGE AIR INDICATOR CONVENTIONAL SUPPLY SYSTEM amp INTEGRAL PURGE AIR DRYER TWO CYLINDER COMPRESSOR AIR DRYER STANDARD SINGLE CHECK VALVE SAFETY GOVERNOR VALVE Z N z a 1 HOLSET TYPE E ERD Y E amp QE PRESSURE COMPRESSOR H1 n a INDICATOR Eom WITH ECON HOLSET VAENE E OR QE 2 COMPRESSOR FRONT HOLSET o ECON VALVE SPECIAL STANDARD SINGLE SINGLE CHECK DRAIN COCK SAFETY LOW PRESSURE VALVE INDICATOR HOLSET TYPE E amp QE COMPRESSOR W O ECON eSUPPLY SUPPLY VALVE E OR QE SINGLE CHECK SPECIAL PROTECTION VALVE ii USED WISYSTEM E PURGE AIR DRYERS SINGLE CHECK VALVE USED W INTEGRAL PURGE AIR DRYERS 27 28 Log on and Learn from the Best On line training that s available when you are 24 7 365 Visit www brake school com SD 08 2415A 2014 Bendix Commercial Vehicle S
29. ir exits the bottom of the desiccant cartridge through its center opening and returns to the air dryer body assembly The air then flows through the delivery check valve assembly and out the delivery port to the first Supply reservoir of the air system The air dryer will remain in the charge cycle until the air brake system pressure builds to the governor cut out setting To protect against over pressurization of the Bendix AD RP air dryer the purge valve incorporates an integral relief valve feature In the event that the compressor unloader mechanism or governor malfunctions at approximately 200 psi supply air pressure the AD RP air dryer purge valve will open without control pressure and vent excess air pressure to atmosphere Refer to Figure 4 PURGE CYCLE Refer to Figure 5 When air brake system pressure reaches the cut out setting of the governor typically 130 psi the compressor unloads air compression is stopped and the purge cycle of the air dryer begins When the governor unloads the compressor it pressurizes both the compressor unloader mechanism and the line connecting the governor unloader port to the control port of the AD RP air dryer body Air entering the control port is simultaneously directed to the turbo cut off valve and the purge valve control piston The initial purge cycle consists of two simultaneous occurrences a the closing of the turbo cut off valve and b the opening of the purge
30. ndix Tu Flo 750 air compressor Bendix BA 922 or DuraFlo 596 air compressor Footnotes 1 With increased air demand the air dryer cartridge needs to be replaced more often 2 Use the drain valves to slowly drain all reservoirs to zero psi 3 Allow the oil water mixture to fully settle before measuring oil quantity 4 To counter above normal temperatures at the air dryer inlet and resultant oil vapor passing upstream in the air system replace the discharge line with one of a larger diameter and or longer length This helps reduce the air s temperature If sufficient cooling occurs the oil vapor condenses and can be removed by the air dryer Discharge line upgrades are not covered under warranty Note To help prevent discharge line freeze ups shorter discharge line lengths or insulation may be required in cold climates See Bendix Bulletins TCH 008 021 and TCH 008 022 included in Appendix B for more information 5 For certain vehicles applications where turbo charged inlet air is used a smaller size compressor may be permissible 26 Test Kit Order Bendix P N 5013711 BASIC test acceptable range Every 5 oil units Month per month See Appendix A Recom Acceptable mended Reservoir Reservoir Oil Contents Drain at Regular Schedule Drain Interval Bendix BASIC test Recom acceptable mended range Every 3 oil units Month per month max of See every 90 Appendix A days For t
31. olicy before performing any intrusive maintenance procedures An extended warranty may be voided if intrusive maintenance is performed during this period 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 every 25 000 miles or three 3 months 1 Check for moisture in the air brake system by opening reservoirs drain cocks or 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 does not pass through the drying bed 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 Appendix A Table A in this document See the column titled Vehicle Vocation C The air dryer has been installed in a system that has been previously used without an air dryer
32. oolant flow through compressor Inspect the Bendix AD RP air dryer was designed primarily for use with compressors rated up to 30 CFM Contact an authorized Bendix parts outlet or a Bendix sales representative for assistance when using the dryer with a compressor which has a rated displacement exceeding 30 CFM Coolant line Replace as necessary I D is 1 2 min Inspect the coolant lines for kinks and restrictions and the fittings for restrictions Replace as necessary Verify coolant lines go from the engine block to compressor and back to the water pump Repair as necessary Restricted air inlet not enough air to compressor Check the compressor air inlet line for restrictions brittleness soft or sagging hose conditions etc Repair as necessary Inlet line size is 3 4 D the maximum restriction requirement for compressors is 25 inches of water Check the engine air filter and service if necessary if possible check the air filter usage indicator continued 20 Bendix AD RP AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE REMEDY 2 Water and or oil in F Air compressor discharge Poorly filtered inlet air poor air quality to compressor 3 4 supply or service and or air dryer inlet Check for leaking damaged or malfunctioning reservoir continued temperature is too high compressor air inlet components e g induction line continued fittings gaskets filter bodies etc Repair the inle
33. or for proper operation Repair or 4 replace as necessary Air flow to service brake D Check for kinked plugged damaged hose tubing or system is restricted or fittings in the air line between the supply reservoir plugged Air pressure on one and low pressure service reservoir dash gauge normal with no or low pressure on the other gauge continued 22 Bendix AD RP AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE REMEDY 7 Unable to build air A Bendix AD RP air dryer A Check that the purge control of the AD RP air system pressure purge control line incorrectly dryer is connected to the UNL unloader port on connected to governor governor B Air trapped in the purge B Inspect for kinked plugged damaged hose tubing control line between the or fittings Check for undrilled fittings or restricted governor and the AD RP air hose or tubing fittings Repair or replace as dryer necessary C Governor malfunction C Test the governor operation Repair or replace as necessary D Compressor unloader D Test the compressor unloader mechanism for mechanism malfunction proper operation Repair or replace as necessary E The AD RP air dryer purge E Check the operation of the AD RP air dryer heater valve piston is frozen open and thermostat Repair or replace as necessary The AD RP air dryer purge F Check the operation and repair or replace as valve piston is stuck necessary 8 Air dryer does not A
34. ore re installation or replace with a new purge valve NOTES Appendix A Table A Maintenance Schedule and Usage Guidelines Regularly scheduled maintenance is the single most important factor in maintaining the air brake charging system Recom Typical Discharge mended Compressors Line Air Dryer Vehicle Used for No of Spec d Cartridge Axles Replacement Low Air Use Compressor with less than 15 duty cycle e g Line haul single trailer w o air Suspension air over hydraulic brakes Compressor with up to 25 duty cycle e g Line haul single trailer 5 with air suspension school bus High Air Use Compressor with up to 25 duty cycle e g Double triple trailer open highway coach RV most pick up amp delivery yard or terminal jockey off highway construction loggers concrete mixer dump truck fire truck mlalo POr E ot WI 7 Ra Compressor with up to 25 duty cycle e g City transit bus refuse bulk unloaders low boys urban region coach central tire inflation 12 For oil carry over control suggested upgrades Se or Every 3 Years For oil carry over control suggested upgrades 5 8 in 12ft Every 2 For oil carry over Years control suggested upgrades 5 8 in 15 ft Every For oil carry over Year control suggested upgrades 3 4 in 15ft Bendix Tu Flo 550 air compressor Bendix BA 921 air compressor Be
35. ote the pressure on the dash gauge s at the moment governor cut out occurs and that the Bendix AD RP air dryer purges with an audible escape of air Observe the dash gauge s pressure for two minutes after the purge cycle begins The front axle service Secondary and the rear axle primary reservoir pressures should not drop more than 2 psi below the governor cut out pressure noted Perform this test three times to positively confirm the values If the pressure drop in the reservoirs exceeds 2 psi check the air brake system for excessive leakage and repair Build up system pressure to governor cut out wait a minimum of 30 seconds for the purge cycle to complete then 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 an Bendix AD RP air dryer purge 4 Check the operation of the heater and thermostat assembly in the body during cold weather operation if possible as follows A Electric Power to the Heater and Thermostat With the ignition or engine kill switch in the ON 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 place the test leads on each of the pins of the male connector 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
36. ou perform the Operation amp Leakage Tests 2 Perform the Operation amp Leakage Tests shown in this publication For Bendix AD RP PuraGuard oil coalescing air dryers only 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 to help ensure 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 every 100 000 miles For pick up and delivery operations or for double and triple trailer line haul trucks replacement is recommended every two years or 200 000 miles 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 fl
37. r local authorized Bendix parts outlet or sales representative for additional information Air Compressor Size The AD RP air dryer was designed primarily for use with compressors rated up to 30 CFM Contact an authorized Bendix parts outlet or a Bendix sales representative for assistance when using the AD RP dryer with a compressor which has a rated displacement exceeding 30 CFM continued 19 Bendix AD RP AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE REMEDY 2 Water and or oil in F Air compressor discharge F Restricted discharge line See Appendix A Table A supply or service and or air dryer inlet column 1 amp 2 for recommended sizes If discharge reservoir continued temperature is too high line is restricted or more than 1 16 carbon build up is found replace the discharge line Replace as necessary Discharge Line Freeze Up The discharge line must maintain a constant slope down from the compressor to the air dryer inlet fitting to avoid low points where ice may form and block the flow If instead ice blockages occur at the air dryer inlet insulation may be added here Or if the inlet fitting is a typical 90 fitting the fitting may be changed to a Straight or a 45 fitting For more information on how to help prevent discharge line freeze ups see Bendix Bulletins TCH 008 021 and TCH 008 022 Shorter discharge line lengths or insulation may be required in cold climates Insufficient c
38. raGuard oil coalescing style cartridge it must be replaced with another PuraGuard style cartridge Before placing vehicle back into service perform the Operation amp Leakage Tests outlined in this manual INSTALLATION Install the assembled Bendix AD RP air dryer back onto the vehicle using the same three mounting bolts retained during removal Tighten then torque the three cap screws to 50 lb ft Reconnect the four air lines to the proper ports on the body identified during disassembly If the fittings were removed from the body use a thread sealant making certain none enters the body during re installation Apply a dielectric grease on the heater and thermostat connector contacts both the heater and thermostat and vehicle wiring harness connector halves After making certain the accordion seal is in place on the vehicle wire harness connector connect the wire harness to the heater and thermostat assembly on the dryer by plugging it into the air dryer connector until its lock tab snaps clicks into place If so equipped reconnect the exhaust line to the exhaust port of the air dryer Before placing vehicle back into service perform the Operation amp Leakage Tests stated elsewhere in this manual RETROFITTING THE BENDIX AD RP AIR DRYER GENERAL The following retrofit instructions are presented for reference purposes only Bendix replacement air dryers are packaged with the most up to date in
39. remove the desiccant cartridge CLEANING INSPECTION AND ASSEMBLY PREPARATION 1 Clean the exterior of the body 2 Using aclean rag wipe the body bores clean 3 Inspect for physical damage to the body casting broken and or missing parts 4 Inspect the interior and exterior of the body for severe corrosion pitting and cracks Superficial corrosion and or pitting on the exterior portion is acceptable 5 Inspect the bores valve seating and o ring contact areas for deep scuffing or gouges or nicks that would not permit an air tight seal 6 Inspect the pipe threads in the body Make certain they are clean and free of thread sealant 7 Inspect the purge valve piston seat for nicks and excessive wear 8 Inspect all air line fittings for corrosion Clean all old thread sealant from the pipe threads 9 All o rings removed should be discarded and replaced with new o rings provided in the appropriate kit s 10 Lubricate the body bores and o ring grooves in the body and components with the grease supplied in the Bendix maintenance kits 11 Lubricate all o rings with the grease supplied in the Bendix maintenance kits Any component exhibiting a condition described in steps 3 to 8 should be replaced ASSEMBLY TURBO CUT OFF VALVE 1 Lubricate all o rings with the grease supplied in the Bendix maintenance kits Install the large and small diameter o rings on the piston Install the turbo cut off piston ass
40. representative for assistance when using the AD RP dryer with a compressor which has a rated displacement exceeding 30 CFM Holset E or QE Type Air Compressors The AD RP dryer can be installed with the Holset Type E or QE compressor When the AD RP air dryer is used in this installation the Holset ECON valve should be removed and the special orifice check valve in the make up line should be removed and replaced with a conventional single check valve Use the following guidelines to determine the vehicle application suitable for the Bendix AD RP air dryer Total Vehicle Requirement Reservoir Volume Less than Bendix AD RP Air Dryer 12 500 cu in use kit part no 5008972 Greater than Contact Bendix Commercial Vehicle 12 500 cu in Systems LLC 11 VEHICLE PREPARATION 1 Park the vehicle on a level surface and prevent movement by means other than the brakes 2 Drain all reservoirs to 0 psi OkPa LOCATING THE BENDIX AD RP AIR DRYER ON VEHICLE 1 The Bendix AD RP air dryer must be mounted vertically purge exhaust port toward road surface outside the engine compartment in an area of air flow while the vehicle is in motion The AD RP air dryer must not be exposed to direct wheel splash note locating behind an axle mud flap is acceptable 2 Locate the AD RP air dryer as close to the first Supply reservoir as possible 3 Do not locate the AD RP air dryer near heat producing component
41. s such as the vehicle exhaust and make certain adequate clearance from moving components e g drive shaft suspension pitman arm etc is provided 4 Locate the Bendix AD RP air dryer on the vehicle so that a minimum of one 1 inch clearance above the cartridge is available to allow cartridge servicing Additionally provide access to the bracket bolts so the unit may be removed when necessary 5 When choosing the mounting location for the AD RP dryer note the discharge line length requirements stated under the heading Connecting the Air Lines elsewhere in this manual Note Under normal operating conditions the maximum inlet air temperature for the AD RP dryer is 160 F MOUNTING THE BENDIX AD RP AIR DRYER 1 Install the AD RP air dryer by referring to Figure 7 and drilling the triangular mounting hole pattern in a mounting plate and then mounting the plate on the vehicle or by drilling the mounting hole pattern in the area of the vehicle chosen for mounting Note Check the vehicle manual before drilling a frame member 2 Important The length of the three mounting bolts used to attach the AD RP air dryer to the mounting plate is very important Refer to Figure 8 The threaded end of the 1 2 13 UNC bolt must be between 1 8 below to 1 4 above the surface of the AD RP dryer mounting bracket surface when fully installed and tightened to 50 Ib ft Damage to the dryer body will result if the bolt warning is ignored Meas
42. stallation instructions The instructions packaged with the Bendix AD RP air dryer should be followed instead of those presented here The preceding portion of this manual deals with in service repair and or replacement of the AD RP air dryer This portion of the manual is concerned with installing an AD RP air dryer on a vehicle not previously equipped with one VEHICLE APPLICATION REQUIREMENTS The basic application requirements presented here apply to a standard air dryer installation The majority of highway vehicles in use today will meet these basic requirements however some may not Examples of vehicles that may not meet the requirements include refuse trucks city coaches bulk trailer unloading operations and other high air consumption systems While the AD RP air dryer can be used on these vehicles the standard installation procedure presented in this manual may require modification to ensure proper operation and service life Consult your local authorized Bendix parts outlet or sales representative for additional information 1 Charge Cycle Time The AD RP air dryer is designed to provide clean dry air for the brake system When a vehicle s air system is used to operate non brake air accessories it is necessary to determine that during normal daily operation the compressor should recover from governor cut in to governor cut out usually 110 psi to 130 psi in 90 seconds or less at engine RPMs commensurate wit
43. t components as needed Note Dirt ingestion will damage the compressor and is not covered under warranty lf you found excessive oil in the service reservoir and you did not find any issues above the compressor may be passing oil Replace the compressor and if still under warranty follow the normal warranty process G Compressor malfunction G If you found excessive oil present in the service reservoir and you did not find any issues above the compressor may be passing oil Test the compressor using the Bendix BASIC cup method as described in the Bendix compressor service manual and referred to in Appendix A Table A column 5 Replace the compressor and if it is still under warranty follow the normal warranty process H Air by passes the desiccant H When replacing the desiccant cartridge make sure cartridge assembly the desiccant cartridge assembly is properly installed and sealing rings are in place on the mounting surface of the desiccant cartridge Desiccant cartridge requires Replace the desiccant cartridge assembly Refer to replacement Appendix A Table A columns 3 amp 4 for recommended intervals Oil present at air A Air brake charging system is A Air dryers remove water and oil from the air brake dryer purge exhaust functioning normally charging system A small amount of oil is normal or cartridge during Check that regular maintenance is being performed maintenance and that the amoun
44. t of oil in the air tanks reservoirs is within the acceptable range shown on the BASIC cup see also column 5 of Appendix A Table A Replace the air dryer cartridge as needed and return the vehicle to service Air is escaping from A Air dryer purge valve A Repair or replace air dryer purge valve air dryer exhaust leaking during the charge B Compressor unloader B One or both dash air gauges should show higher than cycle but able to build mechanism malfunction normal air pressure Test the compressor unloader system air pressure mechanism for proper operation Repair or replace Compressor unloaders as necessary pumping l C Governor malfunction C One or both dash air gauges may show higher than normal air pressure Test the governor for proper operation Repair or replace as necessary continued 21 Bendix AD RP AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE REMEDY 4 Airis escaping from D Air flow to the supply D Kinked plugged damaged hose tubing or fittings air dryer exhaust reservoir is restricted Check to determine if air is reaching the first reservoir during the charge Inspect for kinked tubing or hose Check for undrilled cycle but is able fittings or restricted hose or tubing fittings Repair or to build system replace as necessary air pressure Desiccant cartridge plugged Check compressor Compressor for excessive oil passing and or correct compressor pumping continued install
45. the Bendix maintenance kits Install the o ring on the connector then slide the heater and thermostat assembly into the body making certain not to cut the o ring Note that the tab on the assembly fits into the corresponding slot in the body Install the retaining ring in the groove in the body making certain that it is fully seated in its groove Apply a dielectric grease on the heater and thermostat connector contacts both the heater and thermostat and vehicle wiring harness connector halves After making certain the accordion seal is in place on the vehicle wire harness connector connect the wire harness to the heater and thermostat assembly on the dryer until its lock tab snaps clicks into place Before placing the vehicle back into service perform the Operation amp Leakage Tests stated elsewhere in this manual ASSEMBLY DESICCANT CARTRIDGE 1 Lubricate the desiccant cartridge sealing ring with the grease supplied in the Bendix maintenance kits and replacement parts Screw the desiccant cartridge onto the body by hand until the seal makes contact with the body Rotate it clockwise approximately one full turn If necessary place a strap wrench or equivalent tool on the desiccant cartridge next to the lip low on the cartridge Note If the replacement cartridge is supplied with an o ring for the dryer threads discard it This o ring is not to be used IMPORTANT If the cartridge removed was a Bendix Pu
46. the governor exhaust port and around the governor cap Leakage should not exceed a one 1 inch bubble in five 5 seconds Reduce the system pressure to 80 psi or less and re apply soap solution Leakage should not exceed a one 1 inch bubble in five 5 seconds If excessive leakage is detected in either test repair or replace the governor Test compressor unloader leakage Drain all air pressure from the system and remove the governor from the compressor Temporarily plug the governor unloader port or the air line that mated with or connected to the compressor Build the air system pressure until the air dryer purges then IMMEDIATELY SHUT OFF THE ENGINE Observe the air gauge in the supply reservoir If the leakage is within limits replace the compressor unloaders Re connect the governor to the compressor after removing the plug installed in governor and retest while observing the supply reservoir gauge If excessive leakage is detected continue testing Test the air dryer purge valve and outlet delivery check valve Drain all air pressure from the system remove the control line connection at the air dryer and plug the end of the air line leading to the governor not the air dryer control port Build the system pressure to governor cut out and observe the air gauge If little or no pressure drop is observed replace the air dryer check valve If the pressure drop continues apply a soap solution to the air dryer pur
47. ure the thickness of all materials that the three mounting bolts must pass through Small adjustments can be made using flat washers under the bolt heads Do not use more than three 3 flat washers 3 Mount the AD RP air dryer on the vehicle using three 1 2 bolts grade 5 min of the proper length and washers Torque to 50 Ib ft 12 CONNECTING THE AIR LINES Important General Instructions These instructions apply to all installations of the AD RP dryer regardless of whether the unit is replacing an existing air dryer or is being installed on a vehicle that never had one installed If the vehicle is currently equipped with an air dryer some additional considerations apply A If the AD RP air dryer is replacing an integral purge air dryer such as the Bendix AD 9 air dryer on a vehicle equipped with any compressor except the Cummins Holset type E amp QE all that is necessary is that the air dryer be removed and the existing air lines be correctly connected to the AD RP dryer An additional purge volume minimum 200 cubic inches must also be installed and connected to the AD RP Remote Purge Port The extended Purge Volume Kit 5008972 can be used B If the AD RP air dryer is replacing an integral purge air dryer such as the Bendix AD 4 or AD 9 air dryer ona vehicle equipped with a Cummins Holset type or QE compressor in addition to removing the existing air dryer and correctly connecting the existing
48. uses for these symptoms Air dryer not securely mounted Excessive vibration Defective desiccant cartridge Compressor passing D excessive oil Air dryer has not purged for an extended period A single cylinder compressor with high pulse cycles A Compressor fails to unload Symptoms 1 2 3 4 and 6 Vibration should be held to minimum Add bracket supports or change the air dryer mounting location if necessary C Replace Check for proper compressor installation if symptoms persist replace compressor Refer to Symptom 7 Causes and Remedies A slight pinging sound may be heard during system build up when a single cylinder compressor is used If this sound is deemed objectionable it can be reduced substantially by increasing the discharge line volume This can be accomplished by adding an additional four feet of discharge line or adding a 90 cubic inch reservoir between the compressor and the Bendix AD RP air dryer Faulty governor installation no air line from the governor to the compressor or the line is kinked or restricted Install or repair the air line If desiccant material is being expelled the cartridge and purge valve must be removed from the air dryer and the desiccant material must be removed from the interior of the dryer Clean the interior surfaces of the dryer and install a new cartridge Clean and inspect the purge valve bef
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BENDIX SD-08-2415A User's Manual

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