BENDIX SD-08-2417 User's Manual
Contents
1. Piece No 5004052 5008414 Kit Description Delivery Check Valve Replacement Kit Desiccant Cartridge Replacement Kit Standard Desiccant Cartridge Replacement Kit Bendix AD IS PuraGuard air dryer can be used to replace the standard cartridge 5008414PG 5004961N 5004049 5007834 109495 109496 Drain Valve Governor and Check Valve Replacement Kit Governor Gasket Heater amp Thermostat Replacement 12 volt Heater amp Thermostat Replacement 24 volt Bendix PuraGuard Oil Coalescing Desiccant Cartridge Service New Kit Mounting Bolt Kit Protective Boots for pressure protection valves K020366 5009233 5005163 800350 5006698 5005266N K021189 109871N Safety Valve Splash Shield Kit includes bracket and cover Splash Shield Cover Silencer Kit Wiring Harness amp Splice Kit Purge Valve Assembly Type Configuration Bendix AD IS Air Dryer K022105 AD IS EverFlow Module AD IS Discharge Line Unloader AD IS Air Dryer AD IS EverFlow Module AD IS Discharge Line Unloader Purge Valve Assembly for climate conditions above 40 C 40 F K031560 K031562 K031559 Arctic Purge Valve Assembly for climate conditions of 40 C to 50 C 40 F to 58 F K031561 K031563 GENERAL When rebuilding or replacing components of the air dryer use only genuine Bendix parts For ease in servicing the AD IS air dryer has been designed so that2. 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 Replace both desiccant cartridges at one time Failure to change both could cause one dryer to pass wet air and the other dryer to pass dry air This would lead to a wet brake system 2 Asmall amount of oil in the system is normal and should not be considered as a reason to replace the desiccant cartridges Oil at the dryer purge exhaust is normal 3 Visually check for physical damage such as chaffed or broken air and electrical lines and broken or missing parts 4 Check the Bendix AD IS EverFlow assembly and purge reservoir bolts for tightness See Figure 1 Torque the three air dryer bolts to 360 420 in Ibs and the four purge reservoir bolts to 300 360 in Ibs 5 Perform the Operation amp Leakage Tests listed in this publication 6 The assembly will not operate without electrical power Ensure electrical power is at the assembly during veh
3. secondary reservoir and accessories Additionally the AD IS EverFlow assembly controls the compressor dryer charge cycle DESICCANT BED OIL COALESCING FILTER BENDIX AD IS PURAGUARD OIL COALESCING AIR DRYER TAE EEY EES DELIVERY CHECK VALVE i ZA al CONTROL OPEN ee aed CHANNEL GOVERNOR y i UNLOADER PORT ie SUPPLY PORT PURGE VALVE En CLOSED TA PRIMARY a e PORT PRI LE Wa VALVE ENGINE OPEN SECONDARY Jen j WE er COMPRESSOR SEE NOTE 1 E ENA EFI N P Mina Note 1 The Bendix AD IS air dryer and reservoir system purge piston has a purge control channel drain This allows any condensation in this area to flow past a diaphragm in the top of the purge piston and out through a channel in the middle of the central bolt of the purge assembly to be drained During the purge cycle this drain is closed PURGE PURGE RESERVOIR ORIFICE PRESSURE PROTECTION VALVES ee gt gt lt gt hb SK m N xe DD E r ll N Hit aA a i C b N EN xn z K iL CIR RE PURGE __ RESERVOIR f 1 DRAIN VALVE PRIMARY T R RESERVOIR SECONDARY RESERVOIR AUXILIARY PORTS TO ACCESSORIES FIGURE 3 BENDIX AD IS AIR DRYER AND RESERVOIR SYSTEM CH
4. BRAKES WITHOUT PRIOR WARNING DELIVERY CHECK VALVE CLEANING PROCEDURE Note This is only required if system pressure does not build after temporary bypass is completed Refer to Figure 6 throughout this procedure Depressurize the air brake system following the General Safety Guidelines outlined on page 2 in this document Also always depressurize the air dryer purge reservoir before servicing the air dryer This procedure does not require removal of the Bendix AD S air dryer from the vehicle 1 Remove the line from governor and mark for easy reinstallation 2 Remove the bolts attaching the governor to the AD IS air dryer and retain for reassembly 3 Remove the governor from the air dryer Be aware that a short puff of trapped air may vent when the governor is removed Retain the governor gasket for reassembly if a new governor gasket is not available Remove and retain the o ring from the adapter 4 The spring delivery check valve can now be removed A second delivery check valve is located in the dryer without a governor This check valve is located behind a hex head plug near the control line from the Bendix EverFlow electronic module to the air dryer Carefully remove the hex plug and follow the instructions that follow 5 Remove and retain the o ring from the check valve body NG CHECK VALVE BODY SPRING GOVERNOR GASKET SPECIAL GASKET CLEANING amp INSPECTION Consult the service
5. T fitting Using any adapters necessary install the air supply line into the remaining T fitting port After testing the T fitting for any air leakage by using a soap solution after charging to system cut out pressure a 1 bubble in 10 seconds is acceptable the vehicle may be returned to temporary service Note This is a temporary bypass of the air dryer and full repair of the unit must be carried out at the earliest opportunity With the EverFlow assembly removed from the system contaminants will be entering the air system reservoirs will need to be manually drained daily until the repairs are completed At the end of each working day park vehicle and slowly drain pressure through the drain valves leave open to the atmosphere for several hours if possible When repairs are carried out be sure to check that all reservoirs including the air dryer purge reservoir are emptied of all contaminants If after bypassing the EverFlow assembly the system pressure still does not build use the following procedure to remove clean and reinstall the delivery check valve BENDIX AD IS AIR DRYER GOVERNORS ARE NON ADJUSTABLE AND FEATURE A BREATHER VALVE IN THIS PORT PRESSURE PROTECTION VALVE LOCATIONS FIGURE 6 PRESSURE PROTECTION VALVE LOCATIONS DO NOT ATTEMPT TO ADJUST OR SERVICE THE PRESSURE PROTECTION VALVES INCORRECT PRESSURE PROTECTION VALVE SETTINGS CAN RESULT IN AUTOMATIC APPLICATION OF VEHICLE SPRING
6. been charging for longer than 30 seconds the dryers will alternatively purge every 30 seconds This is an indication of high volume through the dryer When the governor signal indicates the charge cycle is complete the assembly returns to normal brake cycling PREVENTATIVE MAINTENANCE For Bendix AD IS EverFlow air dryers Preventative Maintenance is as easy as 1 2 3 Adhering to a preventative maintenance schedule is crucial to keeping a vehicle s air system clean and ensuring superior performance of all components that utilize system air such as brakes emissions equipment and automated manual transmissions Depending on vocation Bendix recommends a 1 2 or 3 year air dryer cartridge replacement on vehicles equipped with a Bendix compressor For severe service application such as residential refuse trucks or school buses the air dryer cartridge should be replaced every year or 100 000 miles for pick up and delivery operations or for double and triple trailer line haul trucks every two years or 200 000 miles is the recommendation Line haul operations using a single trailer should swap the filter out every three 3 years or 300 000 miles The recommended intervals for trucks equipped with non Bendix compressors are 6 months 50 000 miles one year 100 000 miles and two years 200 000 miles respectively More frequent intervals may be required depending on a vehicle s age its compressor condition use of a
7. is complete the air dryer is ready for the next charge cycle to begin Air Connection Function Port ID Connection 1 n 22 Delivery Port out to Secondary SEC Reservoir ge Auxiliary Delivery Port air out 4 AUX 1 n Auxiliary Delivery Port air out AUX 2 ry ry Unloader Control Air D 2A Governor Common Reservoir Pressure RES 2 D 2A Governor TABLE 1 BENDIX AD IS AIR DRYER PORT DESIGNATIONS 21 l Delivery Port Out to Primary Reservoir Ea Y 1 1 1 1 6 TURBO CUT OFF FEATURE The primary function of the turbo cut off valve is to prevent loss of engine turbocharger air pressure through the AD IS EverFlow assembly when both dryers are in the unloaded mode 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 with a soft seat 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 AD IS EverFlow assembly inlet port cannot pass through the air dryer In this manner the turbo cut off effectively maintains turbo charger boost pressure to the engine Delivery pressure in excess of 175 PSIG can cause the purge valve to cycle rapidly between load and purge mode All AD IS EverFlow assemblies require a soft seat purge valve HIGH VOLUME MODE If the GOV port of the electronic module indicates that the compressor has
8. ARGE CYCLE AD IS EVERFLOW AIR DRYER OPERATION GENERAL The Bendix AD IS EverFlow assembly alternates between the dryers each time the brake system charges During high air demand the dryers alternate every 30 seconds to allow drying of the added volume of air A pressure protection valve is needed after the dryers to maintain at least 70 PSIG at the dryers during high air demand A Bendix EverFlow electronic module monitors the air brake system and determines the amount of demand The AD IS EverFlow assembly requires a signal from the delivery port of the governor into the GOV port of the EverFlow electronic module The AD IS EverFlow assembly also needs a supply air line from the secondary tank to the electronic module RES port This line must be 3 8 inch or larger tubing The AD IS EverFlow assembly is primarily designed to dry air on systems used for bulk unload and central tire inflation The system operates best when a pressure protection valve is installed between the EverFlow assembly and the source of the high volume air Refer to the system schematics Figure 2 This pressure protection valve should have a minimum pressure of 70 PSIG Delivery pressure in excess of 175 PSIG can cause the purge valve to cycle rapidly between load and purge mode NORMAL BRAKE CYCLE Refer to Figures 3 amp 4 When the compressor is charging compressing air air flows through the compressor discharge line to the inlet 1 IN port of
9. C The air dryer consists of a spin on desiccant cartridge secured to a base assembly The base assembly contains a delivery check valve assembly safety valve heater and thermostat assembly pressure protection valves threaded air connections and the purge valve assembly The removable purge valve assembly incorporates the purge valve mechanism and a turbocharger cut off feature that is designed to prevent loss of engine turbo boost pressure during the purge cycle of the Bendix AD IS air dryer For ease of maintenance all replaceable assemblies can be serviced without removal of the air dryer from its mounting on the vehicle Refer to the Preventative Maintenance section Dryer OUT Pressure E Protection Valve PA Bendix EverFlow Electronic Module Primary Reservoir Secondary A Reservoir Air Dryer Valve e Manual Valve IN Hl a Bulk con CTI CTI System Bulk Tanker These units will not operate properly with a Holset type compressor For discharge line unloaded compressors a three way valve must be installed upstream of the air dryer Contact Bendix Commercial Vehicle Systems for additional information BENDIX AD IS EVERFLOW ASSEMBLY OPERATION GENERAL Refer to Figure 2 The Bendix AD IS EverFlow assembly is designed to receive compressed air from the vehicle air compressor It then cleans and dries the air before delivering it to the vehicle s primary reservoir
10. PURGE RESERVOIR GOVERNOR BENDIX EVERFLOW ELECTRONIC MODULE BENDIX AD IS EVERFLOW ASSEMBLY RES GOVERNOR RESERVOIR 2 PURGE VALVE PRESSURE PROTECTION VALVES 4 PURGE 9 _ RESERVOIR UNL GOVERNOR UNLOADER 2 22 EXH SEC GOVERNOR DELIVERY TO ou EXHAUST SECONDARY AD IS AIR RESERVOIR DELIVERY TO DRYER PART PRIMARY NUMBER RESERVOIR STAMPED HERE DESICCANT CARTRIDGE NS GOVERNOR SAFETY VALVE MOUNTING BOLTS 3 HEATER THERMOSTAT IN SUPPLY FROM COMPRESSOR EVERFLOW MODULE BENDIX AD IS AIR DRYER PURAGUARD MEDALLION MOUNTING HOLES 4 23 AUX2 AUXILIARY DELIVERY PORT 24 AUXILIARY DELIVERY PORTS PRESSURE PROTECTION VALVES 4 FIGURE 1 BENDIX AD IS EVERFLOW ASSEMBLY AD IS AIR DRYER AND EVERFLOW ELECTRONIC MODULE GENERAL SAFETY GUIDELINES 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 E
11. XTREME CAUTION should be used to prevent personal injury resulting from contact with moving rotating leaking heated or electrically charged components Do not attempt to install remove disassemble or assemble a component until you have read and thoroughly understand the recommended procedures Use only the proper tools and observe all precautions pertaining to use of those tools If the work is being performed on the vehicle s air brake system or any auxiliary pressurized air systems make certain to drain the air pressure from all reservoirs before beginning ANY work on the vehicle If the vehicle is equipped with a Bendix AD IS air dryer system a Bendix DRM dryer reservoir module or a Bendix AD 9si air dryer be sure to drain the purge reservoir 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 Component
12. any of the maintenance kits shown in this manual can be installed without removing the air dryer from the vehicle Always depressurize the air dryer purge reservoir and all other reservoirs on the vehicle to 0 psi before servicing the air dryer If after completing the routine operation and leakage tests it has been determined that one or more components of the air dryer requires replacement or maintenance refer to the previous list to find the appropriate kit s TESTING THE BENDIX AD IS EVERFLOW ASSEMBLY Before placing the vehicle in service perform the following tests 1 Close all reservoir drain valves 2 Build up system pressure to governor cut out and note that one Bendix AD IS air dryer purges with an audible burst of air followed immediately by approximately 30 seconds of air flowing out of the purge valve 3 Apply and release the service brakes several times 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 other AD IS air dryer exhaust 4 It is recommended that the total air system be tested for leakage to ensure that the AD IS air dryer will not cycle excessively See Bendix publication BW5057 Air Brake Handbook for additional information BRAKING SYSTEM PROTECTION The Bendix AD IS EverFlow assembly allows the system to maintain one brake circuit up to about 100 psi even after a pressure loss in th
13. data sheet for the dryer used in your AD IS EverFlow assembly The service data sheet contains information useful for maintenance and service of the air dryers CLEANING amp INSPECTION 1 Use a suitable solvent to clean all metal parts and use a cotton swab to clean the bore Note Do not use abrasives or tools to clean the bore any scratches caused may necessitate replacing the AD IS air dryer and reservoir system Superficial external corrosion and or pitting is acceptable 2 Clean the o rings with a clean dry cloth Do not use solvents 3 Inspect for physical damage to the bore and the check valve seat If the bore is damaged by scratches etc that would prevent the delivery check valve from seating replace the AD IS air dryer 4 Inspect the delivery check valve o rings etc for wear or damage Replace if necessary using the check valve replacement kit available at any authorized Bendix parts outlets 5 Inspect all air line fittings for corrosion and replace as necessary GOVERNOR NON ADJUSTABLE 130 PSI CUT OUT SEE NOTE 6 ADAPTER FIGURE 6 BENDIX AD IS AIR DRYER DELIVERY CHECK VALVE 10 ASSEMBLY 1 Lubricate the smaller o ring and check valve body with a heavy duty lithium grease Install this o ring on the check valve body by sliding the o ring over the set of four tapered guide lands The o ring groove holds the o ring in its correct location At the other end of the check va
14. e other brake circuit This allows a vehicle to be moved in an emergency but with reduced braking capacity Compare this to a conventional system where a loss of pressure in one service tank leaves the vehicle with a limited number of reduced braking capacity applications before the parking brakes automatically apply and stay on ROADSIDE INSPECTION In the event of a roadside inspection the system behavior will be as follows When the system is charged to governor cut out and then one reservoir drain valve is opened initially both reservoir gauges will fall however the EverFlow assembly primary and secondary pressure protection valves will close at pressures above 70 psi protecting the remaining brake circuit from further loss of pressure TEMPORARY AIR DRYER BYPASS To temporarily bypass the EverFlow assembly the following procedure needs to be followed Follow the General Safety Guidelines outlined on page 2 in this document Make sure that all residual pressure has been released and the air dryer purge reservoir has been drained to 0 psi then remove the air supply line from the compressor to the inlet port 1 IN Remove the safety valve from the AD IS air dryer body see Figure 1 for location Note that a short puff of trapped air may vent from the safety valve port when the valve is being removed Install a T fitting into the port Using any adapters necessary reinstall the safety valve in one of the branches of the
15. ed by a purge at the other AD IS EverFlow assembly air dryer exhaust It is recommended that the total air system be tested for leakage to ensure that the AD IS EverFlow assembly air dryers will not cycle excessively See Bendix publication BW5057 Air Brake Handbook TROUBLESHOOTING THE AD IS EVERFLOW ASSEMBLY Consult the Bendix AD IS air dryer service data sheet SD 08 2418 for air dryer maintenance and service information 1 Excessive dryer purging in the loaded cycle The purge valves in both dryers must have soft seat turbo cut off valves See Figure 7 Remove the purge valve an examine the upper window replace with soft seat purge valve BLACK RUBBER SOFT SEAT FIGURE 7 IDENTIFICATION OF HARD AND SOFT SEAT PURGE VALVES 11 12 Excessive pressure above 175 PSIG in the compressor discharge line Look for obstruction downstream of the Bendix AD IS EverFlow assembly such as a pinched line or restrictive valve or fitting Air dryers do not purge e Insufficient air pressure in the secondary reservoir The Bendix EverFlow electronic module will not operate until air pressure in the secondary tank reaches 80 PSIG The check valve in the EverFlow assembly supply line from the secondary tank is installed incorrectly Refer to Figure 2 The fuse is blown or the air dryer is not connected to the vehicle electrical system Check the electrical connection If the fuse is bl
16. icle operation 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 and reduces the effectiveness of the device to dry air Use of these or other substances can damage the air dryer and will void the warranty OPERATION amp LEAKAGE TESTS For additional information order Air Leakage Video BW2327 available on www bendix com 1 Check all lines and fittings leading to and from the air dryer for leakage and integrity Repair any leaks found 2 Build up system pressure to governor cut out and note that the Bendix AD IS air dryer purges with an audible escape of air Watch the system pressure for leakage for a ten minute period If pressure drop exceeds for a single vehicle 1 psi minute from either service reservoir or for tractor trailer 3 psi minute from either service reservoir inspect the vehicle air systems for sources of leakage and repair them 3 CAUTION Be sure to wear safety glasses in case of a purge blast Check for excessive leakage around the purge valve of the dryer not in the purge cycle 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 1 bubble in one 1 second If the leakage exceeds the maximum specified
17. les as the air brake system requires This feature prevents wasted air and unnecessary cycles The assembly uses an electronic module that determines air demand and sequences the dryers for maximum efficiency The Bendix AD IS air dryer collects and removes air system contaminants in solid liquid and vapor form before they enter the brake system It 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 but still may be mandated by law The function of the pressure protection valves is to protect each reservoir from a pressure loss in the other reservoir or a pressure loss in an air accessory Each of the pressure protection valves in the AD IS air dryer may have different pressure settings but these are factory set and must not be changed or adjusted Governor GOV Schrader Valve From Engine Bendix AD IS EverFlow Assem Accessories EverFlow Compressor OUT Discharge Line Unloader Valve Note The Bendix AD IS air dryer 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 FIGURE 2 BENDIX AD IS AIR DRYER SYSTEM SCHEMATI
18. lve body the spring is installed over the set of four straight guide lands When the spring has been pushed to the correct location the check valve body is designed to hold the end of the spring in position be sure that the spring is not loose before continuing with this installation Install the assembled check valve body o ring spring in the delivery port so that the o ring rests on its seat and the free end of the spring is visible Grease the adapter and the remaining larger o ring and install it onto the fitting Position the governor gasket then insert the governor mounting bolts through the governor and tighten to 125 in lbs Note Do not replace with a standard compressor governor gasket Re attach the air line to the governor Before placing the vehicle back into service check to see that the system pressure now builds to full operational pressure HARD SEAT TESTING THE EVERFLOW ASSEMBLY AIR DRYERS Before placing the vehicle in service perform the following tests 1 2 Close all reservoir drain valves Build up system pressure to governor cut out and note that one of the AD IS EverFlow Assembly air dryers purges with an audible burst of air followed immediately by approximately 30 seconds of air flowing out of the purge valve Apply and release the service brakes several times to reduce system air pressure to governor cut in Note that the system once again builds to full pressure and is follow
19. nly be conducted during cold weather operation Turn off the ignition switch and cool the thermostat and heater assembly to below 40 F Using an ohmmeter check the resistance between the electrical pins in the air dryer 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 approximately 90 F and again check the resistance The resistance should exceed 1000 ohms If the resistance values obtained are within the stated limits the thermostat and heater assembly is operating properly If the resistance values obtained are outside the stated limits replace the heater and thermostat assembly REBUILDING THE BENDIX AD IS AIR DRYER DO NOT ATTEMPT TO ADJUST OR SERVICE THE PRESSURE PROTECTION VALVES INCORRECT PRESSURE PROTECTION VALVE SETTINGS CAN RESULT IN THE AUTOMATIC APPLICATION OF THE VEHICLE SPRING BRAKES WITHOUT PRIOR WARNING MAINTENANCE KITS See the proper Bendix Service Data Sheet or Quick Reference Catalog BW1114 for a full list of maintenance kits available Note Kits are not available for the servicing of the pressure protection valves See Figure 6 Do not attempt to adjust or service the pressure protection valves these are not service items esa HEATER amp THERMOSTAT CONNECTOR FIGURE 5 AD IS AIR DRYER HEATER AND THERMOSTAT CONNECTOR 8 Maintenance Kits
20. one of the air dryers The compressed air includes contaminates such as oil oil vapor water and water vapor The air then flows into the desiccant cartridge where it flows through a liquid separator which collects liquids and other contaminants DESICCANT BED OIL COALESCING FILTER DE TIN ala IL COALESCING AIR DRYER AIEEE EET APEERE SESE E PURGE PURGE DELIVERY ORIFICE RESERVOIR CLOSED PRESSURE LOSED PROTECTION CHANNEL VALVES GOVERNOR UNLOADER PORT ay r Wy as i ee SUPPLY PORT PURGE VALVE OPEN PRIMARY E UE TURBO SAFETY PORT PRI ize 7 CUT OFF VALVE Ee VAVE SECONDARY me OO Fo COMPRESSOR EXHAUST Q N PURGE RESERVOIR DRAIN VALV C RESERVOIR SECONDARY RESERVOIR AUXILIARY PORTS TO ACCESSORIES DIAGRAM SHOWS ALL PRESSURE PROTECTION VALVES OPEN FIGURE 4 BENDIX AD IS AIR DRYER AND RESERVOIR SYSTEM PURGE CYCLE Air then moves into the desiccant drying bed and becomes progressively drier as water vapor adheres to the desiccant material in a process known as ADSORPTION Dry air exits the desiccant cartridge through the delivery check valve and also through an orifice into the purge reservoir The delivery check valve opens supplying air to pressurize the air brake system The purge reservoir stores air that will be used to reactivate the desiccant during the pu
21. own replace the fuse with a higher amperage fuse The fuse must be 15 amps or higher e Incorrect voltage The air dryer voltage must match the vehicle voltage Air dryers with a white heater connector are 12 volt DC and air dryers with a grey heater connector are 24 volt DC 3 Air brake system will not build air e Compressor is undersized Some small capacity compressors will not develop sufficient air delivery at engine idle to allow proper operation of the EverFlow assembly and charge the air brake system It may be necessary to upgrade to a compressor with a higher delivery Water in downstream reservoirs e Dryers not purging See step 2 Air dryers do not purge e Desiccant cartridges need to be replaced e No pressure protection valve installed downstream of the air dryers Refer to Figure 2 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 2417 2014 Bendix Commercial Vehicle Systems LLC a member of the Knorr Bremse Group 07 14 All Rights Reserved
22. refer to section entitled Troubleshooting Symptom 4 4 Build up system pressure to governor cut out and note that one of the AD IS EverFlow assembly dryers purges with an audible burst of air followed immediately by approximately 30 seconds of air flowing out of the purge valve Apply and release the service brakes several times to reduce system air pressure to governor cut in Note that the system once again builds to full pressure and is followed by the AD IS EverFlow assembly other air dryer purge If system does not follow this pattern refer to section entitled Troubleshooting Symptoms 1 2 and 3 Check the operation of the end cover heater and thermostat assembly during cold weather operation as follows A Electric Power to the Dryer Note The Bendix EverFlow assembly should be wired through the ignition and not the battery With the ignition or engine kill switch in the RUN position check for voltage to the heater and thermostat assembly using a voltmeter or test light Unplug the electrical connector at the air dryer and place the test leads on each of the connections of the female connector on the vehicle power lead If there is no voltage look for a blown fuse broken wires or corrosion in the vehicle wiring harness Check to see if a good ground path exists The EverFlow assembly requires the correct electrical voltage to operate properly B Thermostat and Heater Operation Refer to Figure 5 Note These tests can o
23. rge cycle From a flat system approximately 80 psi the Bendix AD IS EverFlow electronic module is actuated and begins the purge cycle When the air pressure reaches the specified opening pressure typically 106 psi the pressure protection valves will open and air will be supplied to the primary reservoir secondary reservoir or other accessories If the pressure protection valves are preset to different values the valves will open in order of lowest setting to highest setting when charging a flat system The air dryer will remain in the charge cycle until the air brake system pressure builds to the governor cut out setting of approximately 130 psi When air brake system pressure reaches the cut out setting of the governor the governor unloads the compressor and the electronic module sends a signal to one of the air dryers to purge The governor unloads the compressor by allowing air pressure to fill the line leading to the compressor unloader mechanism causing the delivery of compressed air to the Bendix AD IS EverFlow assembly to be suspended Similarly the governor also supplies air pressure to the EverFlow electronic module The electronic module uses this signal to determine the volume of air in the brake system If the volume is normal the electronic module sends a signal to the control port on the proper dryer If the 5 volume is high the electronic module switches the dryers every 30 seconds until the air vol
24. s with stripped threads or damaged parts should be replaced rather than repaired Do not attempt repairs requiring machining or welding unless specifically stated and approved by the vehicle and component manufacturer Prior to returning the vehicle to service make certain all components and systems are restored to their proper operating condition For vehicles with Automatic Traction Control ATC the ATC function must be disabled ATC indicator lamp should be ON prior to performing any vehicle maintenance where one or more wheels on a drive axle are lifted off the ground and moving The power MUST be temporarily disconnected from the radar sensor whenever any tests USING A DYNAMOMETER are conducted on a Bendix Wingman Advanced equipped vehicle You should consult the vehicle manufacturer s operating and service manuals and any related literature in conjunction with the Guidelines above DESCRIPTION The function of the Bendix AD IS EverFlow assembly is to provide heavy vehicles that use large amounts of air with a dryer system that facilitates continuous flow drying This assembly provides in a single package all the components necessary to operate two dryers The assembly determines if high air demand is needed and continuously switches between dryers every 30 seconds until the high air demand ceases When high air demand is not needed the assembly uses the dryers as if in a normal braking system Each dryer cyc
25. ume demand returns to normal The air dryer purge piston moves down in response to a pneumatic signal from the Bendix AD IS EverFlow electronic module 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 which have collected in the dryer 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 Liquids and other contaminants collected by the liquid separator are removed by air flowing from the purge reservoir through the desiccant bed to the open purge valve The initial purge and desiccant cartridge decompression lasts only a few seconds and is evidenced by an audible burst of air at one of the Bendix AD IS EverFlow assembly s purge exhaust The actual reactivation of the desiccant bed begins as dry air from the purge reservoir flows through the purge orifice into the desiccant bed Pressurized air from the purge reservoir expands after passing through the purge orifice The flow of dry air through the drying bed removes water vapor from the desiccant material The purge lasts 30 seconds The delivery check valve assembly prevents air pressure in the brake system from returning to the purging air dryer during the purge cycle After the purge cycle
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