User manual BENDIX AD-2 AIR DRYER

[. . . ] ® Bendix® AD-1TM and AD-2TM Air Dryers AD-1TM AIR DRYER AD-2TM AIR DRYER FIGURE 1 The air dryer collects and removes moisture and contaminants before the air reaches the first reservoir. It is distinctly different than a reservoir drain valve or aftercooler in that it provides "dry air" for the air brake system. The daily draining of the system's reservoirs is no longer necessary, thus reducing maintenance considerably when compared to an air brake system without an air dryer. In a system without an air dryer, the life of air brake components is substantially reduced because of contact with water and oil in the system and since the air dryer removes water and oil in vapor form, life of the component devices is substantially increased when the air dryer is used. The air dryer can be used on most highway vehicles where normal compressor loaded time is 90 seconds or less and unloaded time is 30 seconds or more. [. . . ] Insert one of the perforated plates into the cartridge, cloth side up, and tap it firmly to the bottom. (Cloth always faces desiccant material. ) (See Figure 8) FIGURE 12 FIGURE 11 5. Slide oil separator filter over the cartridge bolt with the gasket surface next to the shell. Install the bolt with the oil separator into the bottom of the shell and through center hole of the perforated plate in the bottom of the shell. Pour the entire package of desiccant material into the shell, making sure none is lost. Level the desiccant material and install second perforated plate cloth side down. (Make sure the shoulder of the bolt is centered, and extends slightly above the top of the perforated plate. ) (See Figure 12) NOTE: If the shoulder of the bolt does not extend above the perforated plate tap the side of the desiccant container. Set the conical spring on top of the perforated plate (large diameter down - small diameter up. ) 10. Install the previously rebuilt desiccant sealing plate on the cartridge bolt so that the ball check retaining clip is in view. Using the lock nut draw the assembly together to approximately half of the spring's free height. While slowly turning the cartridge, tap the side of the shell with a plastic mallet (See Figure 14). Continue to tighten the nut, making sure all items are properly aligned. (See Figures 15-1, 15-2) FIGURE 13 9 DISASSEMBLY REBUILDING THE AD-1TM AIR DRYER END COVER ASSEMBLY To remove the end cover assembly from the air dryer follow steps 1-6 under the section of this manual entitled Removal of Desiccant Cartridge AD-1TM and AD-2TM air dryer. Before rebuilding the end cover, clean the exterior thoroughly using a quality commercial solvent. Place the slot in the plunger (cap nut end) over the blade of the screwdriver, hold it securely and remove the nut from the plunger using a 1/2" socket wrench. NOTE: If during the serviceability checks it was determined that the heater and thermostat were defective, use the following procedure. It is not necessary to replace this assembly each time the purge valve is rebuilt. FIGURE 15-1 FIGURE 15-2 11. Inspect the bore for corrosion and if necessary, clean it. FIGURE 14 ASSEMBLY 13. Install the heater element, securing it in the end cover with the retainer clip and screw. Remove the two screws that secure the shield or thermostat retaining clip to the end cover. Remove the shield or clip and the thermostat and inspect the bore for corrosion. 10 15. Install the thermostat metal side down in the end cover bore and secure it in place using the retaining clip or shield and the two screws. [. . . ] Safety valve on air dryer "popping off" or exhausting air. A. Desiccant cartridge plugged or saturated. Defective check valve between air dryer outlet port and first reservoir. (in standard AD-2TM air dryer, check valve in outlet port. ) Defective fittings, hose or tubing between air dryer and first reservoir. A. B. B. C. C. 15 SYMPTOM 4. Constant exhaust of air at air dryer purge valve exhaust or unable to build system pressure. [. . . ]