BENDIX SD-08-2414 User's Manual
Contents
1. DS y BENDIX AD IP AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE REMEDY 2 Water and or oil in A Improper discharge line A Refer to Connecting the Air Lines section as well the supply or service length or improper line as Appendix A Table A columns 1 amp 2 then check reservoir material The maximum air line size and length dryer inlet temperature is exceeded B Air system charged from an B Ifthe system has an outside air fill provision outside outside air source outside air should pass through the air dryer This practice air not passing through air should be minimized dryer C Air dryer not purging see C See Symptom 5 Symptom 5 D Purge air exhaust time D Check causes and remedies for Symptom 1 insufficient due to excessive system leakage see causes for Symptom 1 E Excessive air usage duty E See Appendix A Table A column 1 for the cycle too high Air dryer not recommended compressor sizes If the compressor compatible with the vehicle 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 spec s then upgrade the compressor Note Duty Cvcle is th Note The costs incurred e g installing a larger a eee capacity compressor etc are not covered under of time the compressor spends the original compressor warranty building air to total engine running t2. Bendix AD IP Integral Purge and AD IP PuraGuard Oil Coalescing Integral Purge Air Dryers DESICCANT CARTRIDGE MOUNTING BRACKET CONTROL PORT MOUNTING CABLE LOWER MOUNTING BRACKET SAFETY VALVE aa DISCHARGE SUPPLY HEATER amp THERMOSTAT PORT CONNECTOR Bendix AD IP integral purge air dryer with the PuraGuard oil coalescing cartridge and the new cable mounting bracket OLD STYLE SADDLE MOUNTING PURAGUARD OIL ais Tu BRACKET COALESCING AIR j keap DRYER MEDALLION EXTENDED gt i PURGE C s UP PORT PURAGUARD OIL COALESCING AIR DRYER LABEL Standard Bendix AD IP integral purge air dryer shown with the old style saddle mounting bracket FIGURE 1 BENDIX AD IP INTEGRAL PURGE AIR DRYERS GENERAL SAFETY GUIDELINES A WARNING PLEASE READ AND FOLLOW THESE INSTRUCTIONS A 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 result
3. Install the desiccant cartridge 11 on the end cover 6 making certain the cartridge is properly seated and flush on the end cover Note It may be necessary to rotate the cartridge slightly until the anti rotation lugs are properly aligned and allow the cartridge to rest flush against the end cover 13 8 Using an adjustable wrench or a socket tighten the desiccant cartridge bolt 10 to secure the desiccant cartridge 11 to the end cover 6 Torque the desiccant cartridge bolt to 65 75 ft lbs 40 ft lbs minimum Do not over torque BENDIX AD IP AIR DRYER INSTALLATION 1 Using the relationship marks made during step 7 of the Bendix AD IP Air Dryer Removal Procedure install the lower mounting bracket 9 on the end cover 6 and secure it using the two 3 8 cap screws and washers 7 amp 8 Torque the cap screws to 300 360 in lbs 2 Using the relationship marks made during step 6 of the AD IPAir Dryer Removal Procedure install the saddle bracket 5 and mounting strap 4 on the end cover 6 and using the 5 16 cap screw 1 and sleeve nut 3 secure the strap to the saddle bracket Tighten the 5 16 nut on the upper mounting bracket Torque to 60 100 in Ibs 3 Install the air dryer on the vehicle using the four bolts that secure both the upper and lower mounting brackets 4 Reconnect the three airlines to the proper ports on the end cover identified during step 3 of the AD IP Air Dryer Removal
4. mm 4 m D PRESSURE COMPRESSOR WITH ECON PE 5 INDICATOR HOLSET VALVE E OR QE oTo COMPRESSOR HOLSET ECON VALVE SPECIAL SINGLE CHECK CHOKE IN INLET Front J V4 RA STANDARD SINGLE CHECK VALVE DRAIN COCK SAFETY LOW PRESSURE VALVE INDICATOR HOLSET TYPE E amp QE COMPRESSOR W O ECON VALVE EOR QE P SINGLE CHECK A aN PROTECTION VALVE ln CHOKE IN INLET USED W SYSTEM SINGLE CHECK VALVE USED PURGE AIR DRYERS W INTEGRAL PURGE AIR DRYERS 27 COMPLAINTS COMMON TO THE CHARGING amp AIR SUPPLY SYSTEM Complaint Can Not Build System Pressure Discharge line plugged or restricted see Common Test 1 Air pressure trapped between the governor and compressor unloaders see Common Test 2 Blow leakage at air dryer exhaust see Common Test 3 Complaint Air System Builds Too Slow Discharge line restricted see Common Test 1 Discharge line leakage see Common Test 5 Air leaking at the air dryer exhaust see Common Test 3 Compressor head gasket failure apply soap solution around the cylinder head If leakage between the head and the block is noted repair or replace the compressor Air pressure is trapped between the governor and compressor unloaders see Common Test 2 Air system leakage see Common Test 4 Bendix AD IP PuraGuard oil coalescing desiccant cartridge may be contaminated by excess dirt and or carbon Replace the AD IP PuraGuar
5. Assembly Kit for climate Tie wrap or support all electrical wires leading to the AD IP e AD IP EverFlow conditions between air dryer A0 C to 50 C Air Dryer Module K031561 40 F to 58 F AD IP Drop In Air Dryer FIGURE 7 BENDIX AD IP AIR DRYER HEATER AND Urge ae Bendi ADIPTAR Dryer THERMOSTAT CONNECTOR Kit for climate conditions Discharge Line Unloader above 40 C 40 F Arctic Purge Valve Assembly Kit for climate AD IP Air Dryer Discharge 5 K031563 conditions between 40 C Line Unloader to 50 C 40 F to 58 F 2 Drain all reservoirs to 0 psi Compressor discharge 4 Unplug the vehicle wiring harness from the heater line may still contain residual pressure and thermostat assembly connector on the end cover 3 Identify and disconnect the three air lines from the end assembly cover and note the position of end cover ports relative 5 Remove the four bolts that secure both the upper and to the vehicle lower mounting brackets to the vehicle and remove the air dryer from the vehicle 21 Ze P4 J E SLIDE INSTALLATION RING INTO PURGE Il SSS Enne STANDARD STYLE PURGE VALVE APPLY LUBRICANT TO INSIDE SURFACE INSTALLATION RING NOTE THE ORIENTATION OF THE BEVEL OF THE RING BEFORE INSTALLATION DISCHARGE LINE UNLOADED DLU STYLE PURGE VALVE Most OE installed Bendix AD IP air dryers manufactured after January 1 2014
6. E amp F B Faulty air dryer purge valve C See Causes B E G for C Refer to Remedies B E G for Symptom 4 Symptom 4 A With the compressor loaded apply a soap solution on the purge valve exhaust to test for excessive leakage Refer to Technical Bulletin TCH 008 040 Repair the purge valve as necessary Confirm the failure to unload by increasing amp decreasing engine RPM and noting change in the rate of leakage and intensity of accompanying leakage sound Repair replace compressor unloaders Purge control line must be connected to unloader port of governor Test the heater and thermostat as described in Preventative Maintenance Section F Repair the purge valve and housing C Check to determine if air passes through the discharge line Check for kinks bends excessive carbon deposits or ice blockage D Discharge line should be constantly sloping from the compressor to the air dryer with as few bends as possible A Inspect control line from the governor UNL unloader port to control port of air dryer Test to determine if air flows through purge control line when compressor unloaded Check for undrilled fittings See Symptom 4 Remedy C B After determining the air reaches the purge valve Remedy A above repair the purge valve BENDIX AD IP AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE REMEDY 8 Desiccant material A This symptom is almost A See Causes and Remedies for
7. cycling or purging Air dryer purges frequently every four 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 the gauges is caused by service brake system or component leakage Pressure loss NOT SHOWN on gauges is caused by supply system or component leakage continued 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 leakage is within limits remove the gauge from the reservoir and replace drain cock or valve If excessive leakage is detected continue testing 2 Test the accessories connected to the supply reservoir Drain all air pressure from system disconnect all air lines leading to accessories fan clutch wipers air seats etc and plug the reservoir at the disconnection point Build the air system pressure until the air dryer purges and observe the supply reservoir gauge If leakage is no longer excessive repair or replace the leaking accessory If excessive leakage is detected continue testing 3 Test for governor leakage Build the system pressure to the governor cut out turn off the engine and apply a soap solution to governor exhaust port and around the cap Leakage should not exceed a one 1 inch bubble in five 5 seconds Reduce the system pressure to 80 psi or less and
8. a typical 90 fitting it may be changed to a straight or 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 coolant flow through compressor Inspect coolant line Replace as necessary Inside Diameter I D is 1 2 min Inspect the coolant lines for kinks and restrictions and fittings for restrictions Replace as necessary Verify coolant lines go from engine block to compressor and back to the water pump Repair as necessary Restricted air inlet not enough air to compressor Check compressor air inlet line for restrictions brittleness soft or sagging hose conditions etc Repair as necessary Inlet line size is 3 4 ID 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 Poorly filtered inlet air poor air quality to compressor Check for leaking damaged or malfunctioning compressor air inlet components e g induction line fittings gaskets filter bodies etc Repair inlet components as needed Note Dirt ingestion will damage the compressor and is not covered under the warranty If you found excessive oil present in the service reservoir and you did not find any issues above the compressor may be passing oil Repla
9. to install the AD IP air dryer and use those that will best position the unit for ease of installation Utilizing the two cap screws 7 and washers 8 provided with the AD IP air dryer retrofit unit attach the lower mounting bracket and torque to 300 360 in lbs Note The bracket mounting holes in the end cover may not be pre tapped In this case the mounting bolt will self tap the holes on initial installation eaddle Bracket Assemble the mounting strap 4 and saddle bracket 5 as illustrated by utilizing the 5 16 cap screw 1 and sleeve nut 3 provided Place the upper bracket strap in the end cover channel provided for it then install the saddle bracket and secure the strap to the saddle bracket using the cap screw 1 and sleeve nut 3 provided Install but do not tighten the cap screw at this time Orient the strap and saddle bracket 5 so that it is in a flat plane with the lower bracket Torque the 5 16 nut to 60 100 in Ibs to tighten strap onto the shell Cable Bracket Press the isolators 33 onto the upper bracket 31 as shown in Figure 10 Place the air dryer onto the upper bracket 31 Insert the cable assembly 32 through the wing hole of the upper bracket 31 around the air dryer and then again through the bracket 31 on the opposite wing hole Note some applications may require the button end of the cable be placed on the opposite wing When the air dryer is installed make sure that there isn
10. down through the column of desiccant becomes progressively drier as water vapor adheres to the desiccant material in a process known as ADSORPTION The desiccant cartridge using the adsorption process typically removes most of the water vapor from the pressurized air Dry air exits the bottom of the desiccant cartridge and flows through the center of the bolt used to secure the cartridge to the end cover Air flows down the center of the desiccant cartridge bolt through a cross drilled passage and exits the air dryer delivery port through the delivery check valve OIL SEPARATOR ORIFICE CONTROL GOVERNOR ENGINE TURBO TURBO COMPRESSOR CUT OFF VALVE EXHAUST DESICCANT BED PURGE VOLUME DELIVERY CHECK VALVE DISCHARGE PORT PURGE VALVE FIGURE 3 BENDIX AD IP INTEGRAL PURGE AIR DRYER PURGE CYCLE Note the early end cover designs incorporated a vertical delivery check valve while the newer versions have a horizontal check valve Both have the same function but the components are not interchangeable See Figure 4 A small amount of the air flowing through the center of the desiccant cartridge bolt flows out the cross drilled purge orifice and into the purge volume for regenerating the desiccant The air dryer will remain in the charge cycle until the air brake system pressure builds to the governor cut out setting PURGE CYCLE Refer to Figure 3 As air brake system pressure reaches the cut
11. out setting of the governor the governor unloads the compressor air compression is stopped and the purge cycle of the air dryer begins When the governor unloads the compressor it pressurizes the compressor unloader mechanism and the line connecting the governor unloader port to the Bendix AD IP air dryer end cover control port The purge piston moves in response to air pressure causing the purge valve to open to the atmosphere and the turbo cut off valve to close off the supply of air from the compressor this will be further discussed in the Turbo Cut off Feature section Water and contaminants in the end cover sump are expelled immediately when the purge valve opens Also air which was flowing through the desiccant cartridge changes direction and begins to flow toward the open purge valve Liquid oil and solid contaminants collected by the oil separator are removed by air flowing from the purge volume through the desiccant drying bed to the open purge valve The desiccant cartridge decompression lasts only a few seconds and is evidenced by an audible burst of air at the AD IP air dryer exhaust No purging of air should occur after 30 seconds DESICCANT BED OIL SEPARATOR DESICCANT CARTRIDGE PURGE ORIFICE CONTROL PORT N SUPPLY PORT DELIVERY CARTRIDGE PORT BOLT Old Style End Cover Vertical Delivery Check Valve FIGURE 4 BENDIX AD IP AIR DRYER SECTIONAL VIEW The actual reactivation of the d
12. systems where the compressor intake is connected to the engine turbocharger The turbo cut off valve also removes the puffing of air out the open purge exhaust when a naturally aspirated single cylinder compressor equipped with an inlet check valve is in use 3 O RING GROOVES 2 O RING GROOVES PURGE VALVE STANDARD PURGE VALVE HOUSING DLU PURGE VALVE FIGURE 6 BENDIX AD IP AND AD IP DLU AIR DRYER PURGE VALVES At the onset of the purge cycle the downward travel of the purge piston is stopped when the turbo cut off valve tapered portion of purge piston contacts its mating metal seat in the purge valve housing With the turbo cut off valve seated closed position air in the compressor discharge line and Bendix AD IP air dryer inlet port cannot enter the air dryer In this manner the turbo cut off effectively maintains turbocharger boost pressure to the engine DISCHARGE LINE UNLOADER Refer to Figure 6 The Bendix AD IP air dryers are available as a standard air dryer and as a Discharge Line Unloader DLU style The functions of these air dryers Standard vs DLU and their internal components are different The standard air dryer cuts off the supply air from compressor to the air dryer when the compressor is in the unloaded mode while the DLU air dryer utilizes a purge valve to bleed off the excess air instead of unloading the compressor Externally the standard and DLU versions of each air dryer c
13. valve body so that the small coils of the spring slip over the check valve body Install the assembled check valve body o ring and spring 27 28 amp 29 in the end cover 6 so that the o ring rests on its seat in the end cover 6 and the spring is visible Install the perforated plate 26 in the end cover 6 and secure the check valve assembly using the retaining ring 30 Make certain the retaining ring is fully seated in its groove in the end cover 6 Horizontal check valve models Install o ring 2 onto check valve 25 Place the check valve in the delivery check valve port of the end cover 6 Install the spring 24 over the delivery check valve 36 and secure with the delivery check valve plug 23 Install the o ring 19 on the heater and thermostat assembly 21 After making certain the sponge rubber cushion is positioned between the connector body and thermostat gently push the heater and thermostat assembly 21 into the end cover 6 making certain the heating element enters the small diameter bore in the larger heater and thermostat bore in the end cover 6 Secure the heater and thermostat assembly in the body using the retaining ring 20 Make certain the retaining ring is fully seated in its groove in the end cover 6 Lubricate the o rings 12 amp 13 and install them on the desiccant cartridge bolt 10 and using a twisting motion insert the assembled desiccant cartridge bolt in the end cover 6
14. volume in the discharge line by increasing the length or diameter Add a ping tank small reservoir Test the governor operation and or inspect the control line leading from the governor UNL unloader port to the air dryer control port 23 BENDIX AD IP AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE REMEDY 5 Constant exhaust of air at air dryer purge valve exhaust Charge mode A Air dryer purge valve is leaking excessively B Compressor fails to unload stop compressing air and the air dryer purge exhaust makes sputtering or popping sound to reservoir or exhaust port of governor D Purge valve frozen open malfunctioning heater and thermostat wiring blown fuse F Purge valve stays open supply air leaks to control side 6 Can not build system air pressure discharge line D Excessive bends in discharge line water collects and freezes f Air dryer does not purge or exhaust air A Missing broken kinked frozen plugged or disconnected purge control line 24 C Purge control line connected C E Excessive system leakage E See Symptom 1 A Inlet and outlet air A Connect compressor discharge to the air dryer B Check valve between the air B Test the check valve for proper Repair dryer and first reservoir or replace as necessary C Kinked or blocked plugged E Refer to Symptom 4 Causes E Refer to Symptom 4 Remedies E amp F
15. 5 Reconnect the vehicle wiring harness to the Bendix AD IP air dryer heater and thermostat assembly connector by plugging it into the air dryer connector until its lock tab snaps in place 6 Before placing vehicle back into service perform the Operation and Leakage Tests stated elsewhere in this manual RETROFITTING THE AD IP AIR DRYER GENERAL The following retrofit instructions are presented for reference purposes only since Bendix aftermarket retrofit and replacement air dryers are packaged with the most up to date installation instructions The instructions packaged with the Bendix AD IP air dryer should be followed in lieu of those presented here The preceding portion of this manual deals with in service repair and or replacement of the AD IP air dryer The portion of the manual that follows is concerned with installing an AD IP air dryer on a vehicle not previously equipped with one 14 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 Bendix AD IP air dryer can be used on these vehicles the standard installation procedure presented in this manual may require mod
16. NE TO SUP PORT HEATER amp THERMOSTAT LEAD TO IGNITION SWITCH DELIVERY LINE HEATER amp FROM DEL PORT FUSE THERMOSTAT ONAD IP AIR 10 AMP 12 VOLT LEAD TO DRYER 5 AMP 24 VOLT GROUND FIGURE 11 BENDIX AD IP AIR DRYER INSTALLATION FRAME RAIL STAR WASHER 1 4 or 3 8 EYELET SS e My y Wy S hhl s M WEATHERPROOF POWER LEAD SPLICE WIRE HARNESS CONNECTOR TO AIR DRYER 14 GAUGE POWER WIRE FROM VEHICLE FIGURE 12 WIRING REMOTE POWER amp LOCAL GROUND 16 CONNECTING THE AIR LINES PURGE CONTROL LINE 1 Install a purge control air line having a minimum inside diameter of 3 16 inches between the Bendix AD IP air dryer end cover control port and an unused unloader port on the governor The control line must be connected directly to the governor and not in series with automatic drain valves lubrication systems etc 2 he control line should slope downward to the end cover without forming sharp bends or dips COMPRESSOR 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 IP air dryer discharge contaminants away from vehicle components it will be necessary to purchase a special exhaust cover for the AD IP air dryer Pc No 112609 and install on the unit A 1 inch 25 4 mm I D hose can be clamped on th
17. Symptoms 1 2 3 being expelled from always accompanied by 4 and 5 the air dryer purge one or more of Symptoms valve exhaust may 1 2 3 4 and 5 See related causes for these symptoms look like whitish liquid above or paste or small beads ES B Air dryer not securely B Vibration should be held to minimum Add bracket l mounted Excessive supports or change the air dryer mounting location Unsatisfactory vibration if necessary S C Malfunctioning or saturated C Replace the desiccant cartridge assembly desiccant cartridge D Compressor passing D Check for proper compressor installation i excessive oil symptoms persist replace the compressor E Desiccant cartridge not E Check the torque on the desiccant cartridge assembled properly to to end cover attachment Refer to the assembly the end cover Loose section of this data sheet attachment Pinging noise A Single cylinder compressor A A slight pinging sound may be heard during excessive during with high pulse cycles the system build up when a single cylinder compressor loaded compressor is used If this sound is deemed cycle 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 air dryer IMPORTANT Do not exceed the line lengths requirements specified in this m
18. URGE AIR DRYER CHARGE CYCLE OPERATION GENERAL Note Unless otherwise stated in this manual the Bendix AD IP air dryer refers to both the standard and Bendix AD IP PuraGuard oil coalescing air dryer The AD IP air dryer alternates between two operational modes or cycles during operation the Charge Cycle and the Purge Cycle The following description of operation is separated into these cycles of operation CHARGE CYCLE Refer to Figure 2 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 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 end cover After exiting the end cover the air flows into the desiccant 4 cartridge Once in the desiccant cartridge the air first flows through an oil separator located between the outer and inner shells of the cartridge The separator removes water in liquid form as well as liquid oil and solid contaminants Air along with the remaining water vapor is further cooled as it exits the oil separator and continues to flow upward between the outer and inner shells Upon reaching the top of the cartridge the air reverses its direction of flow and enters the desiccant drying bed Air flowing
19. aired 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 DESCRIPTION The function of the Bendix AD IP integral purge air dryer and the Bendix AD IP integral purge air dryer with PuraGuard oil coalescing is to collect and remove air system contaminants in solid liquid and aerosol form before they enter the brake system They provide 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 AD IP and AD IP PuraGuard oil coalescing air dryers consist of a desiccant cartridge secured to a die cast aluminum end cover with a single c
20. anual Constant seepage of A Defective check valve A Refer to Remedy C Symptom 1 air at air dryer purge assembly in Bendix AD IP valve exhaust non air dryer end cover charging mode B Leaking turbo cut off valve B Repair or replace purge valve assembly C Leaking purge valve control C Repair or replace purge valve assembly piston o ring The air dryer purge A Compressor fails to unload A Faulty governor installation no air line from the piston cycles rapidly governor to the compressor or the air line is kinked in the compressor or restricted Install or repair the air line unloaded non compressing mode 25 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 Recom Acceptable mended mended Reservoir Air Dryer Reservoir Oil Contents Cartridge Drain at Regular Replacement Schedule Drain Interval Typical Discharge Vehicle Used for no DI Axles Low Air Use Compressor with less than 15 duty cycle Recom Bendix For oil carry over e g Line haul single trailer r 5 e A A mended BASIC test w o air suspension air over T upgrades E tabi hydraulic brakes less 2 very acceptable 5 8 in 9ft Month range O Every 3 MM O Y max of every 3 oil units Compressor with up to 2596 duty cycle male 90 days per
21. ation When replacing the desiccant cartridge make sure the desiccant cartridge assembly is properly installed and the sealing rings are in place on the mounting surface of the desiccant cartridge Replace the desiccant cartridge assembly Refer to Appendix A Table A columns 3 amp 4 for recommended intervals Air dryers remove water and oil from the air brake charging system A small amount of oil is normal Check that the regular maintenance is being performed and that the amount 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 The Bendix AD IP PuraGuard oil coalescing air dryer removes more oil from the brake system than the standard Bendix AD IP air dryer Check to determine if air is reaching the supply reservoir Inspect for kinked tubing or hose Check for undrilled or restricted hose or tubing fittings and repair or replace as needed Verify the relief pressure is at the vehicle or component manufacturer specifications Replace if malfunctioning Refer to Table A and column 3 Check the compressor for excessive oil passing and or correct compressor installation Repair or replace as necessary Replace the desiccant cartridge valve Repair or replace Test to determine if air is passing through the check Increase the
22. ce the compressor If still under warranty follow the normal warranty process BENDIX AD IP AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE _ t 2 Water and or oil in the supply or service reservoir continued 3 Oil present at the air dryer purge exhaust or cartridge during maintenance Safety valve on the air dryer popping off or exhausting air G Compressor malfunction Air by passes desiccant cartridge assembly Desiccant requires replacement Air brake charging system is functioning normally Restriction between air dryer and supply first reservoir Air dryer safety valve malfunction Desiccant cartridge maintenance required Malfunctioning discharge check valve in the end cover of the AD IP air dryer Excessive pressure pulsations from the compressor Typical single cylinder type Governor malfunction Missing or restricted governor control line installation 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 compressor If still under warranty follow normal warranty process If the vehicle uses a Holset compressor inspect the feedback check valve for proper installation and oper
23. d oil coalescing cartridge Complaint Can Not Build System Pressure Above X psi Blowleakage at the compressor unloaders remove all the hardware from compressor inlet then remove the governor With 120 psi shop air applied to compressor unloader port listen for leakage at the inlet If noted repair the leak or replace the compressor ncorrect setting on the governor verify the safety valve operation Drain the air from the system remove or disconnect the governor from the compressor and install a gauge in governor unloader UNL port Build system pressure and note when pressure on the dash gauge and test gauge are equal Both should be equal at maximum setting of the governor Discharge line leakage see Common Test 5 Air system leakage see Common Test 4 Compressor head gasket failure apply a soap solution around the cylinder head If leakage is found between the head and the block repair or replace the compressor 28 Complaint Air Dryer Cycles ON amp OFF Constantly This complaint caused by leakage either service system or supply system Service system leakage is shown on dash gauges supply system leakage is not Note System purge air dryers will purge more often than those with an integral purge volume Service system leakage see Common Test 4 Supply system component leakage drain the system install a gauge and a shop air hose in place of the drain cock in the supply reservoir Fill t
24. e 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 REBUILDING THE BENDIX AD IP AIR DRYER GENERAL 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 Bendix Quick Reference Catalog BW1114 available on www bendix com for the latest maintenance kits and service parts When rebuilding or replacing components of the air dryer use only genuine Bendix service parts BENDIX AD IP AIR DRYER REMOVAL This air dryer removal process is presented in the event it becomes necessary to replace the entire air dryer Normal service and parts replacement does not require removal of the air dryer from the vehicle 1 Park the vehicle on a level surface and prevent movement by means other than the brakes Maintenance Kits Piece Description Number Cartridge Bolt Kit 109498 Desiccant Cartridge Service New 065624 Desiccant Cartridge Remanufactured 109493X Bendix PuraGuard Coalescing Cartridge Kit Service New PuraGuard Coalescing Cartridge Kit 109493PGX HEATER amp c AD IP AIR 065624PG Reman Exchange THERMOSTAT A DRYER END Delivery Check Valve Kit 109494 3 Xe COVER E
25. e special AD IP air dryer exhaust cover WIRING THE HEATER amp THERMOSTAT Refer to FIGURE 7 1 The air dryer is available with either a 12 or 24 volt heater which uses 90 watts of power Determine the vehicle s electrical system voltage and make certain that the air dryer that is to be installed contains the same voltage heater The air dryer s part number can be used to determine the air dryers heater voltage requirement The heater voltage can also be identified by the color of the heater assembly connector as described in the table below Air Dryer Heater Air Dryer Connector Voltage Identification 12 Volts White No other markings 24 Volts Gray or White w Red Dot 2 Atwolead 24 inch wire harness with attached weather resistant connector is needed for the installation of an AD IP air dryer Connect one of the two leads of the wire harness to the engine kill or ignition switch The remaining lead of the wire harness must be connected to a good vehicle ground not to the air dryer or its mounting bracket Afuse must be installed in the power carrying wire install a 10 amp fuse for 12 volt heaters and a 5 amp fuse for 24 volt heaters 3 he wire harness available in the Wire Harness and 4 Splice Kit from authorized Bendix parts outlets is not included with the service replacement air dryer When using this kit if it becomes necessary to lengthen the harness use only 14 gauge wire When splicing wires ensure al
26. ecommendation 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 non Bendix compressors are 6 months 50 000 miles one year 100 000 miles and two years 200 000 miles respectively Notes 1 Visually check for physical damage to the air dryer such as chaffed or broken air and electrical lines and broken or missing parts 2 Check mounting bolts for tightness Re torque to 270 385 in lbs 3 Perform the Operation amp Leakage Tests listed in this publication A 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 in
27. elow can be used as a guide in determining if additional help is required Total Vehicle Reservoir Volume Requirement Less than 9 000 cu in Standard AD IP Air Dryer 9 000 12 500 CU ITl scii Extended Purge AD IP Air Dryer Greater than 12 500 cu in Contact Bendix Rep or Bendix Engineering Air Compressor Size Although the AD IP air dryer can be used in conjunction with larger compressors it was designed primarily for units rated for up to 30 CFM It is recommended that when using the AD IP air dryer with a compressor which has a rated displacement exceeding 30 CFM that an authorized Bendix parts outlet or Bendix marketing representative be contacted for assistance VEHICLE PREPARATION 1 2 Park the vehicle on a level surface and prevent movement by means other than the brakes Drain all reservoirs to O psi LOCATING BENDIX AD IP AIR DRYER ON THE VEHICLE 1 The Bendix AD IP air dryer must be mounted vertically purge exhaust toward road surface outside the engine compartment in an area of air flow while the vehicle is in motion The AD IP air dryer must not be exposed to direct wheel splash If the air dryer is located directly behind the axle a mud flap is required Maintain a minimum clearance of 12 between the air dryer and any potential heat source e g vehicle exhaust If this is not feasible a heat shield must be used Make certain that ade
28. entral bolt The end cover contains a check valve assembly safety valve heater and thermostat assembly three pipe thread air connections optional extended purge port plugged and the purge valve assembly The removable purge valve assembly incorporates the purge valve mechanism and a turbo charger cut off feature that is designed to prevent loss of engine turbo boost pressure during the purge cycle of the air dryer For ease of serviceability all replaceable assemblies can be replaced without removing the air dryer from its mounting on the vehicle The AD IP PuraGuard oil coalescing air dryer has an identical appearance to the standard AD IP 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 IP air dryer The AD IP PuraGuard oil coalescing air dryer has all the same functions of the standard AD IP air dryer and is used where lower oil concentration levels are required The AD IP PuraGuard oil coalescing air dryer can be identified by the PuraGuard oil coalescing label shown in Figure 1 located on the air dryer cartridge Early Bendix AD IP air dryers included a Drop In configuration for air systems that use either the Holset Cummins Type E or QE air compressor For information pertaining to this configuration see the Bendix AD IP Air Dryer Troubleshooting Chart at the end of the manual A IMPORTANT When servicing note t
29. ept the desiccant cartridge Inspect the interior and exterior of all metal parts that will be reused for severe corrosion pitting and cracks Superficial corrosion and or pitting on the exterior portion of the end cover is acceptable Inspect the bores of both the end cover and the purge valve housing for deep scuffing or gouges Make certain that all purge valve housing and end cover passages are open and free of obstructions Inspect the pipe threads in the end cover Make certain they are clean and free of thread sealant Make certain that the purge orifice in the cartridge bolt is open and free of obstructions Inspect all air line fittings for corrosion Clean all old thread sealant from the pipe threads All o rings removed should be discarded and replaced with new o rings provided in appropriate kit s ASSEMBLY For purge valve assembly instructions refer to the instruction sheet included in the kit A listing of maintenance kits is included in this document 1 9 6 Complete the purge valve installation per the installation instructions provided in the service kit Using a 9 16 wrench install the safety valve assembly 22 into the end cover 6 Vertical check valve models See Figure 9 Install the o ring 29 on the check valve body 28 and push the o ring down over the 3 guide lands until it is in the o ring groove of the check valve body 28 Install the check valve spring 27 on the check
30. esiccant drying bed begins as dry air flows from the purge volume through the purge orifice in the desiccant cartridge bolt then through the center of the bolt 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 CONTROL PORT N n SUPPLY PORT i FIGURE 5 AD IP INTEGRAL PURGE AIR DRYER TURBO CUT OFF 6 SPRING PIPE PLUG DELIVERY PORT CARTRIDGE BOLT CHECK VALVE WHITE New Style End Cover Horizontal Delivery Check Valve reactivates the desiccant material by removing the water vapor adhering to it Generally 30 seconds are required for the entire purge volume of a standard Bendix AD IP air dryer 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 30 second purge cycle is complete the desiccant has been reactivated or dried 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 TURBO CUT OFF FEATURE Refer to Figure 5 The primary function of the turbo cut off valve is to prevent loss of engine turbocharger air pressure through the AD IP air dryer in
31. h 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 For Bendix Tu Flo 550 and removed by the air dryer Discharge line upgrades are not covered under warranty Note To help 750 compressors unloader prevent discharge line freeze ups shorter discharge line lengths or insulation may be required in cold service is recommended every climates See Bendix Bulletins TCH 008 021 and TCH 008 022 available on www bendix com 250 000 miles 5 For certain vehicles applications where turbo charged inlet air is used a smaller size compressor may be permissible 26 Appendix B Additional Troubleshooting Information The troubleshooting procedure presented on the following pages has been excerpted from a laminated card entitled Troubleshooting Charging and Air Supply Systems BW1779 The complete card can be ordered from the Bendix Marketing Center at www bendix com It is presented here because of the air dryers connection to the supply air system and for convenience The procedure is not all inclusive but rather represents the most commonly encountered complaints STANDARD SINGLE CHECK VALVE LOW PRESSURE USED W INTEGRAL PURGE AIR INDICATOR CONVENTIONAL SUPPLY SYSTEM amp INTEGRAL PURGE AIR DRYER TWO CYL COMPRESSOR AIR DRYER STANDARD SINGLE CHECK VALVE SAFETY GOVERNOR VALVE VM HOLSET Ct Q TYPE E amp QE
32. hat standard Bendix AD IP air dryers or air dryer cartridges may be serviced with PuraGuard oil coalescing air dryer or cartridges however PuraGuard PG oil coalescing air dryer or cartridges must only be serviced with like replacements Sensitive downstream components such as automated manual transmissions diesel exhaust emission systems etc can be damaged due to excessive oil levels Therefore always replace a PG cartridge with a Bendix PG cartridge The AD IP air dryer has three female pipe thread air connections identified as follows Air Connection Function Connection CON 4 as saeco cyuseeaeee Control Port purge valve control amp turbo cut off SUP Ti errin Supply Port air in DEI onu E Delivery Port air out Not Identified Extended Purge Port p 7 S20 remm QU e pde iin PURGE ORIFICE SEPARATOR t SUPPLY PORT iin m GOVERNOR ENGINE TURB COMPRESSOR O TURBO CUT OFF VALVE EXHAUST Note 1 The Bendix AD IP 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 PURGE VOLUME DELIVERY CHECK VALVE DISCHARGE PORT PURGE VALVE FIGURE 2 BENDIX AD IP INTEGRAL P
33. he system to 120 psi shut off the shop air and check for leakage on the following components in the order presented Compressor unloader leakage Drain the system remove the governor from compressor and plug the governor UNL port and re test If the leakage is OK repair the compressor unloader mechanism or replace compressor If leakage is NOT OK then continue inspection Holset ECON valve used with Holset type E amp QE compressor is missing malfunctioning leaking Is an ECON valve required but missing If YES install the valve along with special Holset check valve w choke If NO and the ECON valve is present replace the ECON valve and special check valve If NO and the ECON valve is not required then continue inspection Airdryerleakage Remove the line from air dryer inlet and with 120 psi in the supply reservoir and apply a soap solution to the exhaust and inlet port of air dryer If the leakage is greater than a one 1 inch bubble in one 1 second at the exhaust port repair or replace the check valve on dryers with integral purge volume or replace the body assembly on system purge air dryers If the leakage is greater than a one 1 inch bubble in one 1 second at the inlet port repair or replace the purge valve assembly on air dryers with integral purge volume or replace the turbo cut off valve on system purge air dryers COMPLAINTS COMMON TO THE CHARGING amp AIR SUPPLY SYSTEM Complaint S
34. ification to ensure proper operation and service life Consult your local authorized Bendix parts outlet or sales representative for additional information Charge Cycle Time The AD IP 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 100 psi to 120 psi in 90 seconds or less at engine RPMs normal to the vehicle vocation If the recovery time consistently exceeds this limit it may be necessary to bypass the air accessory responsible for the high air usage 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 occasionally shorter than the times specified no permanent ill effect should be expected however if the purge time is consistently less than the minimum an accessory bypass system must be installed Contact the nearest authorized Bendix parts outlet or Bendix representative for additional information Note Reservoir Volume Total vehicle reservoir volume can impact the Charge and Purge Cycle time The chart b
35. ime Air compressors is designed to provide clean dry air for the brake are designed to build air system When a vehicle s air system is used to run loaded up to 25 of operate non brake air accessories it is necessary the time Higher duty cycles to determine that during normal daily operation the cause conditions that affect compressor should recover from governor cut in air brake charging system to governor cut out usually 100 psi to 120 psi in performance which may 90 seconds or less at engine RPM s commensurate with the vehicle vocation If the recovery time consistently exceeds this limit it may be necessary to bypass the air accessory responsible for the high air usage An example of where a by pass system would be required is when the compressor use of an undersized is used to pressurize a tank trailer for purposes of compressor frequent stops off loading product Consult your local authorized excessive leakage from fittings Bendix parts outlet or sales representative for connections lines chambers or additional information valves etc 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 by pass system must be installed Consult your local authorized Bendix parts outlet or sales repre
36. ing 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 damaged parts should be replaced rather than rep
37. ir or replace the purge valve assembly 19 20 BENDIX AD IP AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE REMEDY 1 Air dryer is constantly A Excessive system leakage cycling or purging Air dryer purges frequently every four 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 gauges is caused by supply system or component leakage continued Holset E type compressor 6 With a gauge installed at the RES port of the governor pressure should not drop below the cut in pressure at the onset of the compressor unloaded 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 governor must be the same diameter or preferably larger than the lines connected to UNL port s on governor B Test the Holset E Compressor unloader system with a feedback line and check valve for proper operation Make certain the Holset ECON is not in use with the drop in version of the air dryer if so remove and retest When installing a Bendix Drop In air dryer in a system equipped with a Holset E or QE compressor remove the Holset ECON valve along with its feedback and governor control line Check Valve
38. l wire splices are waterproofed Tie wrap or support all electrical wires leading to the Bendix AD IP air dryer at 6 8 inch intervals Note Wires should have sufficient slack and not be completely taught TESTING THE BENDIX AD IP AIR DRYER Before placing the vehicle in service perform the following tests 1 2 3 Close all reservoir drain cocks Build up system pressure to governor cut out and note that the air dryer purges with an audible escape of air 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 at the AD IP air dryer exhaust It is recommended that the following items be tested for leakage to ensure that the AD IP 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 first supply reservoir E All air connections leading to and from the first supply reservoir F Delivery check valve 17 BENDIX AD IP AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE REMEDY 1 Air dryer is constantly A Excessive system leakage A If leakage IS SHOWN on the gauges test for cycling or purging IMPORTANT Note whether excessive service brake system leakage Air dryer purges air pressure loss is shown Allowable leakage freque
39. lace the plugged discharge line If the build up is NOT OK go to next cause 2 Air pressure trapped between the governor and the compressor Verify the safety valve operation then remove or disconnect the governor from the compressor and check build up If the build up is OK repair or replace the governor or the line between the governor and the compressor If the build up is NOT OK repair or replace the compressor 3 Blow Leakage at the Air Dryer Exhaust Drain all air from the supply reservoir then remove the control air line from the air dryer plug the line and plug the control port in the air dryer Re check build up If the build up is OK repair or replace the governor or the line between the governor and the air dryer If the build up is NOT OK and the temperature is below 32 F turn the ignition ON and allow the heater to warm the air dryer then check the system build up If NOT OK remove the wire connector or terminal from the air dryer Using a test light check the wire end or terminal for battery voltage with the vehicle ignition ON If the voltage is OK repair or replace the air dryer heater and thermostat If the voltage is NOT OK repair or replace the vehicle wire connected to the air dryer Retest build up If build up is still NOT OK or if the temperature is above 32 F replace the air dryer purge valve assembly 4 Air system leakage Build the system pressure to governor cut out wait t
40. month i e e g Line haul single trailer o On with air suspension RV or d EN o E ad i Ta school bus less JE upgrades To EnS Msi 124 For the amp 3 BASIC High Air Use E Test Kit g D 2 Order Compressor with up to 2596 duty cycle T Bendix C P N e g Double triple trailer AE 9013711 open highway coach most a gs pick up amp delivery yard or m terminal jockey off highway E Every 2 construction loggers concrete x For oil carry over Years mixer dump truck fire truck ao as less amp upgrades ESESER m amp XN sn 15t o E wf aL ee acceptable we Re AME e i ks Every SE Compressor with up to 2596 duty cycle a n Month oll units o per month e g City transit bus refuse p bulk unloaders low boys n urban region coach 5 central tire inflation 12 a Every or a For oil carry over Year EMI control suggested less S upgrades 3l4in 15 fit x x e3 m Footnotes Note Compressor and 1 With increased air demand the air dryer cartridge needs to be replaced more often or alr ils aas are recommended in cases where 2 Use the drain valves to slowly drain all reservoirs to zero 0 psi duty cycle is greater than 3 Allow the oil water mixture to fully settle before measuring oil quantity the normal range for the 4 To counter above normal temperatures at the air dryer inlet and resultant oil vapor passing upstream examples above in the air system replace the discharge line wit
41. ntly every four on dash gauge s Pressure l 4 minutes or less loss SHOWN on gauges Single vehicle 1 psi minute either service reservoir while vehicle is idling is caused by service brake Tractor trailer 3 psi minute either service reservoir system or component Repair and retest as required leakage Pressure loss NOT SHOWN on gauges is caused by supply system or component leakage Dash Gauge Air pressure loss shown on sowo J the dash gauges test all apja components fittings and lines in the service brake system from this point downstream Dash Gauge 7 Service m 0 Ll B If leakage is NOT SHOWN on gauges test for excessive supply system leakage Governor amp To a Accessories wiee 4 HAN N a Air Dryer 4 MO I Compressor T H V g Supply Test CA Gauge _ Remove the drain cock or valve in the supply reservoir wet tank and install an air gauge Build the system pressure and 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 tests 1 to 6 in the order presented Governor e To Accessories wee N NO LI Dryer L Compressor h H Cl BENDIX AD IP AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE REMEDY 1 Air dryer is constantly A Excessive system leakage 1 Test fittings hoses lines and connections Apply
42. onfiguration are identical in appearance however the DLU style air dryer often has a silencer on the exhaust port 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 Note lt is acceptable for the purge valve to be maintained as necessary i e the installation of a purge valve maintenance kit without voiding the warranty 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 For Bendix AD IP 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 applications 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 r
43. quate clearance from moving components e g drive shaft suspension pitman arm etc is provided Locate the air dryer on the vehicle so that a minimum of 1 2 clearance above the air dryer is available to allow desiccant cartridge removal A minimum of 8 clearance below the air dryer is required to allow for desiccant cartridge bolt removal When choosing the mounting location for the AD IP air dryer note the discharge line length requirements stated under the heading Connecting the Air Lines elsewhere in this manual Important Note Under normal operating conditions the maximum inlet air temperature for the AD IP air dryer is 160 degrees Fahrenheit If possible locate the AD IP air dryer so that the purge exhaust does not expel contaminants on vehicle components If this is not feasible the purge exhaust may be redirected away from the vehicle by installing an optional special exhaust cover piece no 112609 The exhaust cover is available as a separate item from authorized Bendix parts outlets A 1 ID hose can be clamped on this special exhaust cover to allow the exhaust to be redirected MOUNTING THE AD IP AIR DRYER Refer to Figure 8 1 Install the lower mounting bracket 9 on the AD IP air dryer To accomplish this it will be necessary to choose two of the four available mounting holes To determine which two holes to utilize to attach the lower bracket take into consideration the piping connections required
44. r assembly 6 Remove the 5 16 cap screw 1 and sleeve nut 3 securing the upper mounting strap 4 to the saddle bracket 5 Earlier models used a washer and nut in place of the sleeve nut 3 Remove the upper mounting strap 4 from the end cover assembly 6 Refer to Figure 8 Cable Bracket Mark the relationship of the upper bracket 31 to the air dryer end cover 6 Remove the locknut 34 and washer 35 from the cable assembly Remove the cable assembly 32 from the upper bracket Remove the upper bracket 31 and isolators 99 7 Mark the relationship of the lower bracket 9 to the end cover assembly 6 Remove the two 3 8 end cover cap screws 7 and two washers 8 that retain the lower mounting bracket 9 to the end cover 6 12 DISASSEMBLY The following disassembly and assembly procedure is presented for reference purposes and presupposes that a major rebuild of the Bendix AD IP air dryer is being undertaken The replacement parts and maintenance kits available generally do not require full disassembly The instructions provided with these parts and kits should be followed in lieu of the instructions presented here Refer to Figures 8 and 9 during disassembly While performing service on the AD IP air dryer it is recommended that a clamping device vise C clamp etc not be used to hold any die cast aluminum component as damage may result To hold the end cover install a pipe nipple in the supply po
45. re apply the 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 4 Test the compressor unloader leakage Drain all air pressure from the system and remove the governor from the compressor Temporarily plug the governor unloader port or 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 the 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 a pressure drop continues apply a soap solution to the air dryer purge 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 repa
46. reserved
47. rt and clamp the nipple into a vise 1 Using an adjustable or socket wrench loosen the desiccant cartridge bolt 10 then separate the desiccant cartridge 11 from the end cover 6 Pull the desiccant cartridge bolt out of the end cover 6 Disassembly of the desiccant cartridge assembl should not be attempted Detail parts for the cartridge are not available and the cartridge contains a 150 spring which can not be mechanically caged Remove both o rings 12 amp 13 from the desiccant cartridge bolt Remove the retaining ring 14 that secures the purge valve assembly 15 in the end cover 6 Vertical check valve models Remove the retaining ring 30 that secures the delivery check valve assembly in the end cover 6 Remove and separate the perforated plate 26 spring 27 check valve body 28 and o ring 29 Horizontal check valve models Remove delivery check valve plug 23 that secures the check valve assembly in the end cover 6 Remove the spring 24 check valve 25 and o ring 2 Remove the retaining ring 20 that secures the heater and thermostat assembly 21 in the end cover 6 Gently pull the heater and thermostat 21 out of the end cover 6 and remove the o ring 19 Using a 9 16 wrench remove the safety valve assembly 22 from the end cover 6 CLEANING amp INSPECTION 1 Using mineral spirits or an equivalent solvent clean and thoroughly dry all metal parts exc
48. sentative for additional information air system requirement Improper air dryer vehicle application Charge Cycle Time The Bendix AD IP air dryer require additional maintenance Factors that add to the duty cycle are air suspension additional air accessories 21 22 BENDIX AD IP AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE REMEDY 2 Water and or oil in the supply or service reservoir continued E Continued F Air compressor discharge and or air dryer inlet temperature too high Air Compressor Size Although the Bendix AD IP air dryer can be used in conjunction with larger compressors it was designed primarily for units rated for up to 30 CFM It is recommended that when using the AD IP air dryer with a compressor which has a rated displacement exceeding 30 CFM that an authorized Bendix parts outlet or Bendix marketing representative be contacted for assistance Restricted discharge line See Appendix A Table A column 1 amp 2 for recommended sizes If the discharge 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
49. t any interference between the cable ends and the vehicle mounting bracket The cable assembly 32 should be placed in the end cover channel when routed around the air dryer Install the washer 35 and locknut 34 on the threaded end of the cable assembly 32 adjacent to the upper bracket wing hole Tighten the locknut 34 until the washer 35 makes contact with the upper bracket 31 Do not torque the locknut 34 at this time Orient the cable assembly and upper bracket 31 so that it is in a flat plane with the lower bracket 9 This can be accomplished in one of two ways either off or on the vehicle as follows Off the vehicle Place the air dryer assembly on a flat surface with the mounting brackets 1 amp 9 down Secure the brackets to the surface with C clamps then tighten the cable locknut 34 to 140 in lbs Use a wrench on the hex side of the threaded end to prevent the cable from twisting Onthe vehicle Bolt the brackets 1 amp 9 to the vehicle air dryer bracket then tighten the cable locknut 34 to 140 in Ibs Use a wrench on the hex side of the threaded end to prevent the cable from twisting Components and location used to mount the AD IP air dryer on the vehicle must be rigid enough to minimize air dryer vibration Mountthe air dryer on the vehicle using 3 8 bolts grade 5 min and washers Torque to 25 ft lbs 300 in Ibs 15 GOVERNOR PURGE CONTROL LINE TO CON PORT DISCHARGE LI
50. to 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 1 Install a pressure gauge in the 1 reservoir Check all lines and fittings leading to and from the air dryer for leakage and integrity Test the delivery port check valve assembly by building the air system to governor cut out and observing a test air gauge installed in the 1 reservoir Note the pressure on the air gauge after governor cut out pressure is reached a rapid loss of pressure could indicate a failed delivery port check valve This can be confirmed by shutting the engine off draining the air brake system pressure to a point below governor cut in typically 95 psi Make sure the dryer has completed the purge cycle wait 30 seconds after governor cut out and determine if there is any air flow out of the air dryer purge valve If air flow is detected at the purge valve the air dryer delivery check valve should be serviced Remove the test gauge before returning the vehicle to service 2 Check for excessive leakage around the purge valve With the compressor in 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 one 1 second If the leakage exceeds the maximum specified repair the purge valve assembl
51. will not be equipped with a purge valve installation ring 16 The function of the installation ring has been incorporated into the air dryer lower housing Be sure to replace the installation ring if it was removed during servicing procedures FIGURE 8 BENDIX AD IP AIR DRYER INTERNAL COMPONENTS HORIZONTAL DELIVERY CHECK VALVE 10 we wer ue 5 16 Cap Screw 5 me 6 ae LockWasher 9 LowerMouning Brackett Desiccant Cartridge 16 Installation Ring r Retaining Ring n Retaining Ring Reference Figure 10 Upper Bracket Cable Assembly pm x uk 5 Wester DELIVERY PORT PIPE PLUG TO SUPPLY RESERVOIR CONTROL PORT FROM GOVERNOR AIR DRYER UNLOADER PORT END COVER DELIVERY PORT TO SUPPLY SUPPLY PORT RESERVOIR FROM COMPRESSOR Old Style Bendix AD IP9 End Cover Vertical Delivery Check Valve FIGURE 9 BENDIX AD IP AIR DRYER INTERNAL COMPONENTS VERTICAL DELIVERY CHECK VALVE 11 INSTALL CABLE ASSEMBLY IN THIS AREA DELIVERY PORT LOWER BRACKET MOUNTING HOLES INSERT CABLE ASSEMBLY IN UPPER BRACKET WING HOLE AS SHOWN FIGURE 10 BENDIX AD IP AIR DRYER CABLE BRACKET INSTALLATION There are two types of upper mounting brackets saddle type shown in Figure 8 and cable type shown in Figure 10 Refer to the appropriate figure for the type of air dryer being serviced 6 Saddle Bracket Mark the relationship of the saddle bracket 5 to the end cove
52. wo 2 minutes for the air dryer purge completion Note the pressure on the dash gauges then watch the dash gauges for two 2 minutes The leakage is not to exceed 2 psi in two 2 minutes for truck bus or tractor no trailer If the leakage is NOT OK on the gauges find the leak s in service and park system and repair Retest and if the system purge air dryer is in use and still not OK repair or replace the dryer If the leakage is OK on the gauges drain the air from the supply reservoir remove the drain cock and install an air gauge Build the system air in the supply reservoir and note the leakage If OK continue checking If NOT OK find the leaks and repair 5 Discharge line leakage Apply a soap solution to the cover on the flexible discharge line if leakage is noted replace the line Soap fittings to check for leakage and tighten as needed IMPORTANT The Complaints Causes and Remedies presented here should not be considered as the only situations possible They are only meant to represent the most commonly encountered situations It may be necessary to perform additional troubleshooting using the more detailed information presented in service manuals for the specific components 30 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 2414 O 2014 Bendix Commercial Vehicle Systems LLC a member of Knorr Bremse Group 9 2014 All rights
53. xhaust Cover Kit 5011327 Extended Purge Kit 3 8 U Bolt 90in Reservoir 5012561N Extended Purge Kit 3 8 U Bolt 288in Reservoir 5008972N MUST BE INSERTED UNTIL IT Extended P Kit 1 2 U Bolt 90in R 5005309N SNAPS OVER THE MATING CONNECTOR xtended Purge Ki O in Reservoir ON AD IP AIR DRYER 12 Volt Heater amp Thermostat Kit 109495 24 Volt Heater amp Thermostat Kit 109496 ard Mounting Bracket Kit 5001247 SIBEDVEN MN D WEATHERPROOF i i ACCORDIAN Kit K0211 Slee sails TOP VIEW 5 E SEAL Wiring Harness amp Splicing Kit 109871N Purge Valve Maintenance Kits Purge Valve Configuration Piece A two lead wire harness with attached weather resistant Assembly Type Installation Number connector is available as a service part One of the two Bendix AD IP Air Dryer 022105 leads is connected to the engine kill switch or ignition while iX the other must be connected to a good vehicle ground A Bendix AD IP m i i Purge Valve Assembly EverFlow Air Dryer fuse is installed in the lead carrying vehicle power install Kit for climate conditions K031560 a 10 amp fuse for the 12 volt heater and a 5 amp fuse for Module above 40 C 40 F AD IP Drop In the 24 volt heater Air Dryer Use 14 AWG wire if it is necessary to lengthen the wire Arctic Purge Valve AD IP Air Dryer K031559 harness leads Make certain all splices are weatherproofed
54. y 3 Make sure all reservoir drain cocks are closed Build up system pressure to governor cut out and note that Bendix AD IP air dryer purges with an audible escape of air 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 AD IP air dryer purge 4 Check the operation of the end cover heater and thermostat assembly during cold weather operation as follows A Electric Power to the Dryer 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 connector with the locking latch 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 required except in cold weather operation Turn off the ignition switch and cool the thermostat and heater assembly to below 35 F Using an ohmmeter check the resistance between the electrical pins in the air dryer 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 Warm the thermostat and heater assembly to over 90 F and again check the resistance Th
55. ystem Pressure Goes to 150 psi Drain the air system to zero 0 psi remove disconnect the governor from the compressor Start the engine and note the air pressure rise on the dash gauges Apply 120 psi of shop air to compressor unloader port Ifthe air pressure continues to rise repair compressor unloaders or replace compressor If air ceases to rise repair or replace governor Complaint Low Pressure Warning After Only 1 or 2 Applications Brakes out of adjustment adjust brakes Excessive system leakage on the service application side of system Build the system pressure to 120 psi and turn the engine off With the park brakes released make a full service application and note the dash gauges for two 2 minutes A pressure drop on either gauge should not exceed 4 psi two 2 psi per min If the pressure drop is excessive find the leakage in service system if OK then proceed to next complaint Incorrect low pressure switch in use or setting incorrect Build the system pressure to 120 psi with the engine OFF and the ignition ON slowly drain the air pressure from one service reservoir Low pressure warning on at minimum 60 psi maximum 10 15 psi less than governor cut in pressure 29 TESTS COMMON TO MORE THAN ONE COMPLAINT 1 Discharge plugged or restricted Connect a temporary discharge line from the compressor discharge port to the supply reservoir and re check the build up If the system build up is OK then rep
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