BENDIX BW1627 User's Manual
Contents
1. Mounting Kit End Cover Check Valve Assembly Replacement 3 4 inch thread size End Cover Check Valve Assembly Replacement 1 2 inch thread size Purge Valve Housing Maintenance Kit Contains the parts necessary to rebuild the air portion of the purge valve housing and does not include the heater and thermostat Universal Check Valve Kit E Exhaust Cover Kit F Silencer Kit G Desiccant Cartridge Replacement Kit Contains the parts necessary to change the desiccant cartridge only Non IPC Air Dryer 107695 5002080 5009610 107799 107800N l EN a sf MEA 5005037 5005893 K041395 5003838 5004224N 107796 107794X Desiccant Cartridge Replacement Kit Contains the parts necessary to change the desiccant cartridge only IPC Air Dryer Makeup Line Kit Adaptor Kit K028830 109960 5000457 109961 800405 5004338 5004341 X 5004342X 5004479 5004480 Bee MM x O MN LA EN we Sa a Sa 12 750 12V 75W 5004381 Yellow 5004339 White 5004340 Gray soso sou toon vo See Catalog Pose s row e sass ss EIA Poor s ee ong mos s meralcamingprte TON White Purge Valve Housing Assembly w heater and thermostat N MN MN MN nN N MN N MN MN O O M N MN W PTE a 0p OJO OIOI O 00 SLEEVE MOUNTING ADJUSTING NUT NUTN o STRAP MOUNTING mon OLAS ISOLATOR a ey R Sy 5 16 HEX MOUNTING HEAD SCREW SADDLE je2. PORT D E E BESS ii STR RRA o ERE RECAE EOS SH VALVE ASSEMBLY Y ai sump PORT HEATER ELEMENT VALVE EXHAUST FIGURE 2 BENDIX AD 9 AND AD 9 IPC AIR DRYER CHARGE CYCLE of engine turbo boost pressure during the purge cycle of the Bendix AD 9 and AD 9 IPC air dryers For ease of serviceability the desiccant cartridge and discharge check valve assembly are screw in type The purge valve housing assembly which includes the heater and thermostat assembly and the discharge check valve assembly are serviceable from the exterior of the air dryer while servicing the screw in desiccant cartridge requires removal of the air dryer assembly from the vehicle The AD 9 IPC air dryer appears identical to the standard AD 9 air dryer but contains a coalescing media at the inlet of the desiccant bed This coalescing media provides a higher level of oil removal over the standard AD 9 air dryer The AD 9 IPC air dryer has all the same functions of the standard AD 9 air dryer and is used where oil is contaminating downstream components The Bendix AD 9 IPC air dryer can be identified by the IPC label shown in Figure 1 located on the air dryer housing The Bendix AD 9 and AD 9 IPC air dryers have three female pipe thread air connections and each is identified as follows Port I D Function Connection GON 4s cacocerenuests Control Port purge valve control and turbo cut off SUP 11 cose Supply
3. SD 08 2412 EXTENDED PURGE STANDARD IPC AIR DRYER LABEL OUTER END COVER SUPPLY CONTROL PORT WIRING HARNESS DELIVERY PORT CONNECTION r CHECK VALVE A ASSEMBLY Wee PORT gt AN IO gt SR a WS amp gt ar e K E r Po i PURGE VALVE a SAFETY VALVE END COVER FIGURE 1 BENDIX AD 9 AND AD 9 IPC AIR DRYER MODELS DESCRIPTION The function of the Bendix AD 9 and AD 9 IPC Integrated PuraGuard Coalescing air dryers is to collect and remove air system contaminants in solid liquid and vapor 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 Bendix AD 9 and AD 9 IPC Integrated PuraGuard Coalescing air dryers consists of a desiccant cartridge and adie cast aluminum end cover secured to a cylindrical steel outer shell with eight cap screws and nuts The end cover contains a check valve assembly a safety valve three threaded air connections and the purge valve housing assembly The removable purge valve housing assembly incorporates a purge valve mechanism and a turbocharger cut off feature that is designed to prevent loss 1 ORIFICE DESICCANT CARTRIDGE T AS es DESICCANT BED PURGE VOLUME OIL SEPARATOR CONTROL PORT GOVERNOR COMPRESSOR ENGINE e
4. turn off engine and apply soap solution to governor exhaust port and around cap Leakage should not exceed a 1 in bubble in 5 seconds Reduce system pressure to 80 psi or less and re apply soap solution Leakage should not exceed a 1 in bubble in 5 seconds lf excessive leakage is detected in either test repair or replace governor 4 Test compressor unloader leakage Drain all air pressure from 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 air system pressure until air dryer purges then IMMEDIATELY SHUT OFF THE ENGINE Observe the air gauge in the supply reservoir If leakage is within limits replace the compressor unloaders Re connect the governor to the compressor after removing plug installed in governor and retest while observing supply reservoir gauge If excessive leakage is detected continue testing Testair dryer purge valve and outlet delivery check valve Drain all air pressure from 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 system pressure to governor cut out and observe air gauge If little or no pressure drop is observed replace the air dryer check valve If pressure drop continues apply soap solution to air dryer purge exhaust and purge control port where the control line was removed
5. AD 9 IPC air dryer desiccant cartridge may need to be replaced Every 10 800 hours 300 000 miles or 36 months 1 Rebuild the air dryer including the desiccant cartridge Note The desiccant change interval may vary from vehicle to vehicle Although typical desiccant cartridge life is three years many will perform adequately for a longer period of time In order to take maximum advantage of desiccant life and assure that replacement occurs only when necessary it is important that Operation amp Leakage Tests be performed WARNING This air dryer is intended to remove moisture and other contaminants normally found in the air brake system Do not inject alcohol anti freeze or other de icing substances into or upstream of the air dryer 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 GENERAL SAFETY GUIDELINES Park the vehicle on a level surface apply the parking brakes and always block the wheels Always wear safety glasses Stop the engine and remove ignition key when working under or around the vehicle When working in the engine compartment the engine should be shut off and the ignition key should be removed Where circumstances require that the engine be in operation EXTREME CAUTION should be used to prevent personal injury resulting from contact with moving rotating leaking heated or electrically char
6. Leakage should not exceed a 1 in bubble in 5 seconds If leakage is excessive repair or replace purge valve assembly 20 Bendix AD 9 AND AD 9 IPC AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE REMEDY 1 Dryer is constantly cycling A Excessive system leakage 6 With gauge installed at RES port of governor pressure should or purging Dryer purges IMPORTANT Note whether air not drop below Cut In pressure at the onset of the compressor frequently every 4 minutes pressure loss is shown on dash Unloaded cycle If pressure drops check for kinks or or less while vehicle is idling gauge s Pressure loss shown on restrictions in line connected to RES port Line connected to continued gauges is caused by service brake RES port on governor must be same diameter or preferably system or component leakage larger than lines connected to UNL port s on governor Pressure loss NOT SHOWN on gauges is caused by supply system or component leakage continued Leaking purge valve housing With the supply port open to atmosphere apply 120 psi at the assembly and or o rings in air control port Apply a soap solution to the supply port and exhaust dryer end cover port purge valve seat area Permissible leakage 1 bubble in 5 seconds Holset E type compressor Test the Holset E Compressor unloader system with feedback line and check valve for proper operation Make certain Holset ECON is not i
7. Port air in DELE aen Delivery Port air out OPERATION OF THE BENDIX AD 9 AIR DRYER The AD 9 and AD 9 IPC air dryers alternate 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 end cover As air travels through the end cover assembly its direction of flow DESICCANT CARTRIDGE DESICCANT SEPARATOR CONTROL PORT GOVERNOR COMPRESSOR PISTON PURGE VOLUME AE a VALVE ASSEMBLY DELIVERY SUMP PORT VALVE EXHAUST HEA ELEMENT FIGURE 3 BENDIX AD 9 AND AD 9 IPC AIR DRYER PURGE CYCLE 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 cartridge Once in the desiccant cartridge air first flows through an oil separator which removes water in liquid form as well as oil and solid contaminants Air exits the oil separator and enters the desiccant drying bed Air flowing through the column of desiccant becomes progressively drier as water vapor adheres to the desiccant material
8. attached fitting is in the same approximate position as the original See Figure 11 LOWER BRACKET SPECIAL WASHER 2 1 8 BRACKET CAP SCREW FIGURE 14 LOWER BRACKET INSTALLATION Install the check valve and fitting taking care that the replacement is in the same approximate position as the original Install the makeup line and tighten the tubing nuts at both ends while preventing the 90 degree fittings from turning Tighten the nuts sufficiently to prevent air leakage but do not over tighten Air Dryer Assembly 1 Install the desiccant cartridge o ring in its groove in the end cover Using a light coat of lubricant included in kit lubricate the bottom of the desiccant cartridge in the area that will contact the o ring and end cover Screw the desiccant cartridge into the end cover until contact is made between it and the o ring Using a strap or chain wrench positioned 2 3 inches from the bottom of the cartridge turn the desiccant cartridge clockwise 180 225 degrees beyond the position where initial contact was made between the cartridge and end cover o ring Torque should not exceed 50 ft lbs Install the end cover outer housing o ring on the shoulder in the end cover Place the housing over the desiccant cartridge and align the holes Install the six 3 8 cap screws locknuts and twelve special washers making certain they are in the proper position as marked during disassembly The two longer 3 8 cap screws
9. complete the air dryer is ready for the next charge cycle to begin The purge valve will remain open after the purge cycle is complete and will not close until air brake system pressure is reduced and the governor signals the compressor to charge TURBO CUT OFF FEATURE Refer to Figure 4 The primary function of the turbo cut off valve is to prevent loss of engine turbocharger air pressure through the Bendix AD 9 and AD 9 IPC air dryers in systems where the compressor intake is connected to the engine turbocharger The turbo cut off valve also reduces the puffing of air out 4 UPPER BRACKET DESICCANT CARTRIDGE DESICCANT BED HOUSING OIL SEPARATOR LOWER BRACKET CONTROL PORT 020 OO ees Ll SO OOOO eeeeeee PRESS IA Ar A N CHECK VALVE TURBO ASSEMBLY CUT OFF PISTON PURGE VALVE HOUSING ASSEMBLY PURGE DISCHARGE VALVE PORT FIGURE 5 BENDIX AD 9 AND AD 9 IPC AIR DRYER CROSS SECTION the open exhaust when a naturally aspirated single cylinder compressor equipped with an inlet check valve is in use 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 discharge line and air dryer inlet port is restricted from entering the air dryer While the turbo cut off
10. pressure to governor cut in Note that the system once again builds to full pressure and is followed by an air dryer purge 4 Check the operation of the safety valve by pulling the exposed stem while the compressor is loaded compressing air There must be an exhaust of air while the stem is held and the valve should re seat when the stem is released 5 Check all lines and fittings leading to and from the air dryer for leakage and integrity 6 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 male connector If there is no voltage look for a blown fuse broken wires or corrosion in the vehicle wiring harness Check to see if a good ground path exists B Thermostat and Heater Operation Turn off the ignition switch and cool the end cover assembly to below 40 degrees Fahrenheit Using an ohmmeter check the resistance between the electrical pins in the female connector The resistance should be 1 5 to 3 0 ohms for the 12 volt heater assembly and 6 8 to 9 0 ohms for the 24 volt heater assembly Some early models of the Bendix AD 9 air dryer will have resistance readings of 1 0 to 2 5 ohms
11. procedure is not all inclusive but rather represents the most commonly encountered complaints CONVENTIONAL SUPPLY SYSTEM 8 INTEGRAL PURGE AIR DRYER STANDARD SINGLE CHECK VALVE LOW PRESSURE USED W INTEGRAL PURGE AIR INDICATOR GOVERNOR TWO CYLINDER COMPRESSOR HOLSET TYPE E amp QE COMPRESSOR WITH ECON VALVE HOLSET E OR QE COMPRESSOR HOLSET ECON VALVE HOLSET TYPE E 8 QE COMPRESSOR W O ECON VALVE HOLSET E OR QE 28 NL AIR DRYER STANDARD SINGLE CHECK VALVE SAFETY GOVERNOR VALVE i Jr LOW PRESSURE INDICATOR 7 SUPPLY Y Fo ra an STANDARD SINGLE CHECK VALVE OO SPECIAL SINGLE CHECK CHOKE IN INLET DRAIN COCK SAFETY VALVE LOW PRESSURE INDICATOR re SINGLE CHECK PROTECTION VALVE NID USED W SYSTEM PURGE AIR DRYERS SPECIAL SINGLE CHECK CHOKE IN INLET SINGLE CHECK VALVE USED W INTEGRAL PURGE AIR DRYERS BW1627 O 2011 Bendix Commercial Vehicle Systems LLC All Rights Reserved 4 2011
12. 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 Bendix AD 9 AND AD 9 IPC AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE REMEDY 2 Water and or Oil in Supply Continued Poorly filtered inlet air poor air quality to compressor Check or Service Reservoir for leaking damaged or malfunctioning compressor air inlet continued components e g induction line fittings gaskets filter bodies etc Repair inlet components as needed Note Dirt ingestion will damage compressor and is not covered under 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 Replace compressor If still under warranty follow normal warranty process H Compressor malfunction If excessive oil is present in the service reservoir and no other issues from above were found 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 und
13. unless you are certain all system pressure has been depleted Use only genuine Bendix brand replacement parts components and kits Replacement hardware tubing hose fittings etc must be of equivalent size type and strength as original equipment and be designed specifically for such applications and systems Components with stripped threads or damaged parts should be replaced rather than repaired Do not attempt repairs requiring machining or welding unless specifically stated and approved by the vehicle and component manufacturer Prior to returning the vehicle to service make certain all components and systems are restored to their proper operating condition For vehicles with Automatic Traction Control ATC the ATC function must be disabled ATC indicator lamp should be ON prior to performing any vehicle maintenance where one or more wheels on a drive axle are lifted off the ground and moving 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 housing assembly exhaust port and observe that leakage does not exceed a 1 bubble in 1 second If the leakage exceeds the maximum specified service the purge valve housing assembly 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
14. which end cover bolts to utilize to attach the lower bracket take into consideration the piping connections required to install the air dryer and use those that will best position the unit for ease of installation Locate the bracket such that it cradles the end cover as shown in Figure 9 Utilizing the two 2 3 8 long cap screws locknuts and special washers provided with the AD 9 or AD 9 IPC air dryer retrofit unit attach the lower mounting bracket and torque to 270 385 in lbs 2 Assemble the mounting strap and upper mounting bracket as illustrated in Figure 10 by utilizing the 5 16 cap screw and sleeve nut 3 Place the upper bracket assembly onto the shell of the AD 9 or AD 9 IPC air dryer and orient it so that it bears entirely on the cylindrical surface and does not extend onto the domed top The slot spacing between the upper and lower bracket should be a minimum of 5 5 inches apart Do not tighten strap onto the shell at this time 4 Mount the air dryer on the vehicle using 3 8 bolts grade 5 min and washers Torque to 25 ft lbs 300 inch pounds After positioning and mounting the upper bracket assembly according to the installation requirements torque the 5 16 nut to 80 120 in lbs to tighten strap onto the shell 17 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 9 or AD 9 IPC air dryer end cover co
15. HICLE 1 The AD 9 or AD 9 IPC 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 air dryer must not be exposed to direct wheel splash located behind axle mud flap is acceptable 2 Locate the AD 9 or AD 9 IPC air dryer as close to the first Supply reservoir as possible 3 Do not locate the AD 9 or AD 9 IPC air dryer near heat producing components such as the vehicle exhaust and make certain adequate clearance from moving components e g drive shaft suspension pitman arm etc is provided 4 Locate the AD 9 or AD 9 IPC air dryer on the vehicle so that a minimum of 11 inches 28 cm clearance below the end cover is available to allow servicing Alternatively provide access to the bracket bolts so the unit may be removed for servicing 5 When choosing the mounting location for the AD 9 or AD 9 IPC air dryer note the discharge line length requirements stated under the heading Connecting the Air Lines elsewhere in this instruction sheet Important Note Under normal operating conditions the maximum inlet air temperature for the AD 9 and AD 9 IPC air dryers is 160 degrees Fahrenheit MOUNTING THE BENDIX AD 9 AND AD 9 IPC AIR DRYER 1 To install the lower mounting bracket on the AD 9 or AD 9 IPC air dryer it will be necessary to remove and discard two of the end cover bolts and locknuts To determine
16. ING lt gt LARGE DISCHARGE MAKEUP AIR LINE LINE UNLOADER PURGE VALVE KON ASSEMBLY 1 E of ADAPTER LETTER U STAMPED HERE TO IDENTIFY DLU ASSEMBLY DISCHARGE LINE UNLOADER PURGE VALVE J MAKEUP LINE KIT FIGURE 8 MAINTENANCE KIT CONTENTS ILLUSTRATIONS F THROUGH J 10 DESICCANT CARTRIDGE O RING OUTER HOUSING O RING C O END COVER END COVER REPLACEMENT KIT UNIVERSAL MOUNTING PLATE N SMALL O RING gt MEDIUM C gt O RING LARGE O RING THERMOSTAT EALING RING Ema UNINSULATED BUTT SPLICE EYELET CONNECTOR W HEAT SHRINK INSULATOR HEATER ELECTRICAL SPLICING KIT FIGURE 9 MAINTENANCE KIT CONTENTS ILLUSTRATIONS K THROUGH M DISASSEMBLY The following disassembly procedure is presented for reference purposes and presupposes that a major rebuild of the Bendix AD 9 or AD 9 IPC air dryer is being undertaken Several replacement parts and maintenance kits are available which 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 7 8 and 9 during disassembly Caution While performing service on the AD 9 and AD 9 IPC air dryers it is not recommended that a clamping device vise C clamp etc be used to hold any die cast aluminum component as damage may result To hold the end cover install a pipe nipple in the supply po
17. TROUBLESHOOTING CHART SYMPTOMS CAUSE REMEDY Dryer is constantly cycling or purging Dryer purges frequently every 4 minutes or less while vehicle is idling A Excessive system leakage 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 ACA Alr pressure loss not shown on dash gauges test all components fittings and lines In suppi system irom Tus pont up steam A If leakage IS SHOWN on gauges test for excessive service brake system leakage Allowable leakage Pre 121 vehicles single vehicles 2 psi minute Tractor trailer 3 psi minute 121 vehicles single vehicle 1 psi minute per service reservoir Tractor trailer 3 psi minute per service reservoir Repair and retest as required Dash gauge y Air pressure lass shown on Gosh gouges test al components fittings and lines in service broke stem fran Mis point down stream Dash Gouge lf leakage is NOT SHOWN on gauges test for excessive supply system leakage Dash Gouge Dash Sauge Remove drain cock or valve in supply reservoir wet tank and install air gauge Build system pressure allow air dryer to purge and observe air gauge in supply reservoir Pressure drop should not exceed 1 psi per minute Perform tests 1 to 6 in th
18. UPPER BRACKET LOCKNUT SPECIAL ar i VAR SPECIAL LOWER MOUNTING ZAR WASHER BRACKET ES LOWER SPECIAL lt A MOUNTING WASHER BRACKET Sa SPECIAL a I 3 8 END i WASHER n eA COVER CAP 3 8 ENDCOVER____H e SCREW CAP SCREW CHECK VALVE STANDARD MOUNTING BRACKET KIT A MOUNTING BRACKET KIT MAINTENANCE KIT DELIVERY CHECK VALVE PLUG NOT INCLUDED SMALLO RING Cc gt IN KIT LD MEDIUM O RING LARGE O RING QUAD RING 2 PISTON ASSEMBLY PURGE VALVE ASSEMBLY R BW SPRING NOT a INCLUDED IN KIT WASHER 7735 a ENG ae VALVE screw 9 VERTICAL EXHAUST Ey GUIDE ___ SHOULDER BOLT DELIVERY CHECK VALVE HOUSING o gt NOT INCLUDED 7 RETAINER IN KIT CHECK VALVE PURGE VALVE HOUSING MAINTENANCE KIT NS SPRING DELIVERY CHECK VALVE KIT FIGURE 7 MAINTENANCE KIT CONTENTS ILLUSTRATIONS A THROUGH E C ea GASKET GASKET Gs EXHAUST COVER EXHAUST f coveR 1 SCREWS L _ EXHAUST COVER ADAPTER ADAPTER 8 KIT F lid gt SILENCER BODY DESICCANT SILENCER FILTER CARTRIDGE SILENCER COVER FP EXHAUST COVER N EXHAUST COVER SCREWS DESICCANT CARTRIDGE O RING OUTER HOUSING O RING G SILENCER KIT PURGE VALVE ASSEMBLY CHECK VALVE ___ WASHER screws STANDARD PURGE VALVE N OJ ie WW SMALL lt O R
19. accessories use of an undersized compressor frequent stops excessive leakage from fittings connections lines chambers or valves etc 22 A Replace desiccant cartridge B Refer to section entitled Connecting the Air Lines as well as Appendix A Table A columns 1 amp 2 then check line size and length C If system must have outside air fill provision outside air should pass through the air dryer This practice should be minimized D See Symptom 5 E Check causes and remedies for Symptom 1 F See Appendix A Table A column 1 for recommended compressor sizes If the compressor is too small for the vehicle vocation for example where a vehicle s vocation has changed or service conditions exceed the original vehicle or engine OE spec s then upgrade the compressor Note The costs incurred e g installing a larger capacity compressor etc are not covered under original compressor warranty Charge Cycle Time Bendix AD 9 and AD 9 IPC air dryers are 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 RPM s commensurate with the vehicle vocation If the recovery time consistently exceeds this limit it may be neces
20. ake quality vary by vehicle manufacturer Because vehicle vocation and maintenance can influence when the AD 9 IPC air dryer cartridge requires replacement each fleet should modify their replacement schedule based on experience The change out interval will be extended if the compressor passes a low level of particles and the interval will be reduced if excessive carbon particles are delivered to the dryer inlet Higher compressor build up times at idle and AD 9 AD 9 IPC AIR DRYER LOWER MOUNTING BRACKET A FEMALE CONNECTOR MALE ar CONNECTOR LATCH MUST BE INSERTED UNTIL IT SNAPS OVER TAB ON MATING END COVER CONNECTOR p SN SIDE VIEW END VIEW A two lead 12 inch wire harness with attached weather resistant connector is supplied with all retrofit and replacement Bendix AD 9 and AD 9 IPC air dryers 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 A fuse should be installed in the power carrying wire install a 10 amp fuse for 12 volt heaters and a 5 amp fuse for a 24 volt heater Use 14 AWG wire if it is necessary to lengthen the wire harness provided Make certain all wire splices are waterproofed Tie wrap or support all electrical wire leading to the AD 9 or AD 9 IPC air dryer FIGURE 6 HEATER AND THERMOSTAT CONNECTOR water or oil in downstream reservoirs indicate an
21. ck for undrilled or restricted hose air or tubing fittings and repair or replace as needed B Air dryer safety valve malfunction B Verify relief pressure is at vehicle or component manufacturer specifications Replace if malfunctioning C Desiccant cartridge maintenance C Refer to Appendix A Table A and column 3 Check compressor required for excessive oil passing and or correct compressor installation Repair or replace as necessary Replace desiccant cartridge Malfunctioning discharge check Test to determine if air is passing through check valve Repair valve in end cover of the Benidix or replace AD IP air dryer Excessive pressure pulsations Increase volume in discharge line by increasing length or from compressor Typical single diameter Add a ping tank small reservoir cylinder type Governor malfunction Missing Test governor operation and or inspect the control line leading or restricted governor control line from the governor UNL unloader port to the air dryer control installation port 5 Constant exhaust of air at air A Air dryer purge valve leaking With compressor loaded apply soap solution dryer purge valve exhaust excessively on purge valve exhaust to test for excessive leakage Refer Charge mode to Technical Bulletin TCH 008 040 Repair purge valve as necessary Compressor fails to unload stop Confirm failure to unload by increasing amp decreasing engine compressing air and a
22. dryer does not purge or A Missing broken kinked frozen A Inspect control line from governor UNL unloader port to control exhaust air plugged or disconnected purge port of air dryer Test to determine if air flows through purge control line control line when compressor unloaded Check for undrilled fittings See Symptom 4 Remedy C B Faulty air dryer purge valve B After determining air reaches purge valve Remedy A above repair purge valve C See Causes B E G for Symptom C Refer to Remedies B E G for Symptom 4 4 Desiccant material being A This symptom is almost always A See Causes and Remedies for Symptoms 1 2 3 4 and 5 expelled from air dryer purge accompanied by one or more of valve exhaust may look like Symptoms 1 2 3 4 and 5 See whitish liquid or paste or related causes for these symptoms small beads above OR B Air dryer not securely mounted B Vibration should be held to minimum Add bracket supports or Unsatisfactory desiccant life Excessive vibration change air dryer mounting location if necessary C Malfunctioning or saturated C Replace desiccant cartridge assembly desiccant cartridge D Compressor passing excessive oil D Check for proper compressor installation if symptoms persist replace compressor E Desiccant cartridge not assembled E Check the torque on the desiccant cartridge properly to end cover Loose to end cover attachment Refer to assembly section of
23. ds or some unusual air requirement that does not allow the compressor to load and unload compressing and non compressing cycle in a normal fashion Check for high air system leakage If the vehicle vocation has changed it may be necessary to upgrade the compressor size Refer to Appendix A Table A and the column titled Vehicle Vocation C The air dryer has been installed in a system that has been previously used without an air dryer This type of system will be saturated with moisture and several weeks of operation may be required to dry it out D Location of the air dryer is too close to the air compressor Refer to the Locating Bendix AD 98 and AD 9 IPC Air Dryer On Vehicle section and Appendix A Table A column 2 for discharge line length or E In areas where more than a 30 degree range of temperature occurs in one day small amounts of water can accumulate in the air brake system due to condensation Under these conditions the presence of small amounts of moisture is normal and should not be considered as an indication that the dryer is not performing properly Note A small amount of oil in the system may be normal and should not in itself be considered a reason to replace the desiccant oil stained desiccant can function adequately 2 Check mounting bolts for tightness Re torque to 270 385 inch pounds 3 Perform the Operation amp Leakage Tests listed in this publication Oil removal requirements for air br
24. e bulk trailer unloading operations and other high air consumption continuous flow systems While the AD 9 or AD 9 IPC air dryer can be used on these vehicles the standard installation procedure presented in this manual may require modification to assure proper operation and service life Consult your local authorized Bendix parts outlet or sales representative for additional information 1 Charge Cycle Time The Bendix AD 9 and AD 9 IPC air dryers are 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 commensurate with the vehicle vocation If the recovery time consistently exceeds this limit tt 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 CONTROL HIDDEN Q PC Q DELIVERY GOVERNOR 2 Purge Cycle Time During normal vehicle operation the air compressor must remain unloaded for a minimum of 20 seconds for the standard air dryer or 30 seconds for the extended purge model These minimum purge times are required to ensure complete regeneration of the desiccant material If the pu
25. e following assembly procedure is presented for reference purposes and presupposes that a major rebuild of the Bendix AD 9 or AD 9 IPC air dryer is being undertaken Several replacement parts and maintenance kits are available which 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 7 8 and 9 during assembly Purge Valve Housing Assembly 1 Prior to assembly coat all o rings o ring grooves and bores with a generous amount of the lubricant included in the maintenance kit See Figure 7 illustration D A Install the quad ring in its groove on the O D of the purge piston Place the return spring in the bore of the purge valve housing Insert the purge piston into the 1 D of the return spring Place the purge valve guide onto the shoulder bolt followed by the purge valve Using a ratchet or wrench screw the purge valve purge valve guide and shoulder bolt into the purge housing until it bottoms This will require a tool to hold the top of the purge piston from rotating as the shoulder bolt is screwed into the bottom of the purge piston to complete the purge valve assembly Torque the shoulder bolt to 60 90 in lbs B Install the o rings on the purge valve housing placing each in its appropriate location Note the medium O ring is not used on Discharge Line Unloaded DLU models If the exhaust cover was removed duri
26. e order presented SOVENTE Ey O ACCOSSones hay Alt Dryer 2 i Compressor o Supo last Gouge 19 Bendix AD 9 AND AD 9 IPC AIR DRYER TROUBLESHOOTING CHART 1 Dryer is constantly cycling A Excessive system leakage 1 Test fittings hoses lines and connections Apply soap solution or purging Dryer purges IMPORTANT Note whether air to detect excessive leakage Tighten or replace as needed frequently every 4 minutes pressure loss is shown on dash then repeat the air dryer charge purge cycle and observe the or less while vehicle is idling gauge s Pressure loss shown on gauge installed in the supply reservoir If leakage is within limits continued gauges is caused by service brake remove gauge from reservoir and replace drain cock or valve If system or component leakage excessive leakage is detected continue testing Pressure loss NOT SHOWN 2 Test accessories connected to supply reservoir Drain all on gauges is caused by supply air pressure from system disconnect all air lines leading to system or component leakage accessories fan clutch wipers air seats etc and plug the continued reservoir at disconnection point Build air system pressure until air dryer purges and observe supply reservoir gauge If leakage is no longer excessive repair or replace leaking accessory If excessive leakage is detected continue testing 3 Test governor leakage Build system pressure to governor cut out
27. effectively prevents loss of turbocharger boost pressure to the engine some seepage of air may be detected under certain conditions of compressor engine and turbocharger operation Even so there will always be low pressure trapped in the discharge line 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 It 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 Every 900 operating hours or 25 000 miles or every three 3 months 1 Check for moisture in the air brake system by opening reservoirs drain cocks or valves and checking for presence of water If moisture is present the desiccant may require replacement however the following conditions can also cause water accumulation and should be considered before replacing the desiccant A An outside air source has been used to charge the system This air did not pass through the drying bed B Air usage is exceptionally high and not normal for a highway vehicle This may be due to accessory air deman
28. er warranty follow normal warranty process Air by passes desiccant cartridge If the vehicle uses a Holset compressor inspect the assembly feedback check valve for proper installation and operation When replacing the desiccant cartridge make sure desiccant cartridge assembly is properly installed and sealing rings are in place on mounting surface of desiccant cartridge Check Valve Feed Back Line Typical Drop In Air Dryer End Cover Replace desiccant cartridge assembly Refer to Appendix A Table A columns 3 amp 4 for recommended intervals J Desiccant requires replacement J 3 Oilpresent at air dryer purge A Air brake charging system is A Air dryers remove water and oil from the air brake charging exhaust or cartridge during functioning normally system A small amount of oil is normal Check that regular maintenance 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 24 Bendix AD 9 AND AD 9 IPC AIR DRYER TROUBLESHOOTING CHART CAUSE 4 Safety valve on air dryer A Restriction between air dryerand A Check to determine if air is reaching supply reservoir Inspect popping off or exhausting supply first reservoir for kinked tubing or hose Che
29. for the 12 volt heater assembly and 4 8 to 7 2 ohms for the 24 volt heater assembly If the resistance is higher than the maximum stated replace the purge valve housing assembly which includes the heater and thermostat assembly Warm the end cover assembly to over 90 degrees Fahrenheit 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 purge valve housing assembly which includes the heater and thermostat assembly REBUILDING THE BENDIX AD 9 AND AD 9 IPC AIR DRYERS 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 maintenance kit listing in this manual or the Bendix Quick Reference Catalog BW1114 for complete kit information When rebuilding or replacing components of the air dryer use only genuine Bendix parts For ease in servicing the Bendix AD 9 and AD 9 IPC air dryer desiccant cartridge assemblies it is recommended that the air dryer be removed from the vehicle The kit illustrations on the following pages show the kit contents and will be referenced throughout the rebuilding procedures BENDIX AD 9 AND AD 9 IPC AIR DRYER REMOVAL 1 Park the veh
30. ged 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 ADAS air dryer system ora dryer reservoir module 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 OPERATION amp LEAKAGE TESTS 1 Test the outlet port check valve assembly by building the air system to governor cut out and observing a test air gauge installed in the 1 reservoir A rapid loss of pressure could indicate a failed outlet port check valve This can be confirmed by bleeding the system down and removing the check valve assembly from the end cover Once this has been done subject air pressure to the unit and apply a soap solution to the check valve side Leakage should not exceed a 1 bubble in 1 second 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
31. good vehicle ground not to the air dryer or its mounting bracket A fuse should be installed in the power carrying wire install a 10 amp fuse for 12 volt heaters and a 5 amp fuse for a 24 volt heater 18 3 Use 14 GA wire if it is necessary to lengthen the wire harness provided with the AD 9 or AD 9 IPC air dryer Make certain all wire splices are waterproofed 4 Tie wrap or support all electrical wire leading to the AD 9 or AD 9 IPC air dryer at 6 8 inch intervals Note Wires should have sufficient slack and not be completely taught TESTING THE BENDIX AD 9 AND AD 9 IPC AIR DRYER Before placing the vehicle in service perform the following tests 1 Close all reservoir drain cocks 2 Build up system pressure to governor cut out and note that the air dryer purges with an audible escape of air 3 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 air dryer exhaust 4 ltis recommended that the following items be tested for leakage to assure that the AD 9 or AD 9 IPC air dryer will not cycle excessively A Total air system leakage See Bendix Air Brake Handbook BW5057 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 Bendix AD 9 AND AD 9 IPC AIR DRYER
32. he head of the purge valve shoulder bolt See Figure 7 illustration D A Secure the top of the purge piston assembly using the two opposing cast indentations and a removal tool Remove the purge valve shoulder bolt from the bottom of the purge valve housing assembly Remove the exhaust guide and purge valve from the purge valve housing B Remove the purge piston assembly and return spring from the opposite end of the purge valve housing assembly Remove the quad ring from the purge piston assembly HEATER amp THERMOSTAT Step B SEALING RING RUBBER CUSHION HEATER ELEMENT THERMOSTAT SEALING RING PURGE VALVE HOUSING W HEATER amp THERMOSTAT SECTIONAL VIEW FROM BOTTOM W HEATER amp THERMOSTAT INSTALLED SECTIONAL VIEW FROM BOTTOM FIGURE 10 HEATER amp THERMOSTAT REMOVAL amp INSTALLATION 12 ATTY 3 CeT 177 DELIVERY PORT ADAPTER WITH 90 FITTING DELIVERY PORT ADAPTER WITH 90 FITTING MAKEUP AIR LINE FIGURE 11 BENDIX AD 9 DROP IN AIR DRYER Heater and Thermostat Assembly Removal 1 Remove the two screws that secure the heater and thermostat assembly to the purge valve assembly See Figure 9 illustration L for kit contents CAUTION DO NOT PULL THE HEATER amp THERMOSTAT ASSEMBLY STRAIGHT OUT OF THE PURGE VALVE BODY READ STEP 2 COMPLETELY BEFORE ATTEMPTING REMOVAL 2 Study Figure 10 closely and note the Y shape of the Heater amp Thermostat assembly in its insta
33. he adapter off of the exhaust cover 3 Remove the three screws that secure the exhaust cover to the purge valve housing assembly of the end cover Remove the exhaust cover and gasket Purge Valve Removal 1 Remove the three 1 4 screws that secure the purge valve housing assembly to the end cover assembly Pull the purge valve housing assembly out of the end cover assembly Remove the three o rings from the exterior of the purge valve housing assembly The medium SMALL O RING C DD MEDIUM___ O RING LARGE O RING SEALING THERMOSTAT RING PURGE VALVE ASSEMBLY HEATER amp THERMOSTAT HEATER ELEMENT PURGE VALVE o ring is not included in DLU models The o rings may be lodged in the end cover bores if so they must be removed Refer to Figure 8 illustration J Purge Valve Disassembly Note In some cases a flat non extended exhaust cover is used If an extended type exhaust cover is in use to accommodate the attachment of an exhaust hose the exhaust cover must be carefully peeled off of the purge valve housing Use a thin flat blade to pry the exhaust cover off taking care not to damage the potting material RTV sealant under the cover Removal of the piston from the purge valve housing assembly requires a tool to hold the head of the purge piston while unscrewing the purge valve shoulder bolt Remove the piston from the purge valve housing assembly using a twelve point 1 4 socket to hold t
34. he desiccant cartridge changes direction and begins to flow toward the open purge valve Oil and solid contaminants collected by the oil separator are removed by air flowing from the desiccant drying bed to the open purge valve E TA 50 50 5 57 yO 3 Pene eee PATO a af LLILIT T N FAENAS BE Na e esesese ese seeeetasecscacscscececes EA estate ER 20 Setas CUT OFF PISTON CHECK VALVE ASSEMBLY DISCHARGE EXHAUST LINE FIGURE 4 BENDIX AD 9 AND AD 9 IPC AIR DRYER TURBO CUT OFF The initial purge and desiccant cartridge decompression lasts only a few seconds and Is evidenced by an audible burst of air at the Bendix AD 9 or AD 9 IPC air dryer exhaust The actual reactivation of the desiccant drying bed begins as dry air flows from the purge volume through the desiccant cartridge purge orifice and into the desiccant drying bed Pressurized air from the purge volume expands after passing through the purge orifice its pressure is lowered and its volume increased The flow of dry air through the drying bed reactivates the desiccant material by removing the water vapor adhering to it Generally 15 30 seconds are required for the entire purge volume of a standard Bendix AD 9 or AD 9 IPC air dryer to flow through the desiccant drying bed The end cover single 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
35. he proper ports on the end cover identified during disassembly 4 Reconnect the vehicle wiring harness to the air dryer heater and thermostat assembly connector by plugging it into the air dryer connector until its lock tab snaps in place 5 Before placing vehicle back into service perform the Operation and Leakage Tests stated earlier in this manual RETROFITTING THE BENDIX AD 9 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 9 and AD 9 IPC air dryers 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 9 and AD 9 IPC air dryers The portion of the manual that follows is concerned with installing an AD 9 or AD 9 IPC air dryer on a vehicle not previously equipped with one UNLOADER PORT 10 AMP 12V 5 AMP 24V 14 GA WIRE TO IGNITION amp GROUND FIGURE 11 AD 9 AIR DRYER CHARGE CYCLE 16 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 includ
36. icle on a level surface and prevent movement by means other than the brakes 2 Drain all reservoirs to O psi 0 kPa Caution compressor discharge line may still contain residual pressure 3 Identify and disconnect the three air lines from the end cover and note the position of end cover ports relative to the vehicle See Figure 1 4 Unplug the vehicle wiring harness from the heater and thermostat assembly connector on the purge valve housing assembly See Figure 6 5 Loosen the 5 16 hex cap screw and sleeve nut securing the upper mounting strap to the upper mounting bracket See Figure 7 illustration A Some air dryers may contain a one piece upper mounting strap as shown in Figure 7 illustration B If this is type of strap is present loosen the adjustment locknut and remove the strap and isolator from the upper bracket 6 Mark and remove the two 3 8 end cover cap screws locknuts and four special washers that secure the lower mounting bracket to the end cover Also be sure to mark these two holes of the end cover These bolts are longer than the other 6 bolts Retain the mounting hardware See Figure 7 illustrations A and B 7 Remove the air dryer from the vehicle MAINTENANCE KITS Service New S Connector Color Kit Part or Reman Purge Number Exchange RX Valve Type Kit Description Complete Mounting Bracket Kit Contains the upper and lower brackets as well as the necessary mounting hardware
37. in a process known as adsorption The desiccant cartridge using the adsorption process typically removes 95 of the water vapor from the pressurized air The majority of dry air exits the desiccant cartridge through its integral single check valve to fill the purge volume between the desiccant cartridge and outer shell Some air will also exit the desiccant cartridge through the purge orifice adjacent to the check valve Dry air flows out of the purge volume through the single check valve assembly and out the delivery port to the first Supply reservoir of the air system The air dryer will remain in the charge cycle until air brake system pressure builds to the governor cut out setting PURGE CYCLE Refer to Figure 3 When air brake system pressure reaches the cut out setting of the governor the compressor unloads air compression stopped and the purge cycle of the air dryer begins When the governor unloads the compressor it pressurizes the compressor unloader mechanism and line connecting the governor unloader port to the air dryer end cover control port The purge piston moves in response to air pressure causing the purge valve to open to atmosphere and partially closing off the supply of air from the compressor This will be further discussed in the section covering the turbo cut off feature Contaminants in the end cover sump are expelled immediately when the purge valve opens Also air which was flowing through t
38. ir dryer RPM and noting change in the rate of leakage and intensity purge exhaust makes sputtering of accompanying leakage sound Repair replace compressor or popping sound unloaders Purge control line connected Purge control line must be connected to unloader port of to reservoir or exhaust port of governor governor Purge valve frozen open Test heater and thermostat as described in Preventive malfunctioning heater and Maintenance Section thermostat wiring blown fuse E Excessive system leakage E See Symptom 1 F Purge valve stays open supply air F Repair purge valve and housing leaks to control side 6 Can not build system air A Inlet and outlet air connections A Connect compressor discharge to air dryer supply port pressure reversed Reconnect lines properly B Check valve between air dryer and B Test check valve for proper operation Repair or replace as first reservoir necessary C Kinked or blocked plugged C Check to determine if air passes through discharge line Check discharge line for kinks bends excessive carbon deposits or ice blockage D Excessive bends in discharge line D Discharge line should be constantly sloping from compressor water collects and freezes to air dryer with as few bends as possible E Refer to Symptom 4 CausesE amp E Refer to Symptom 4 Remedies E amp F F 25 Bendix AD 9 AND AD 9 IPC AIR DRYER TROUBLESHOOTING CHART 7 Air
39. is important that the same approximate routing be duplicated during re installation See Figure 11 2 Disconnect the makeup line from the 90 degree fitting on the check valve 3 Disconnect the makeup line from the 90 degree fitting on the port adapter itself or the check valve Remove the adapter along with the attached 90 degree fitting CLEANING amp INSPECTION 1 Using mineral spirits or an equivalent solvent clean and thoroughly dry all metal parts 2 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 upper and lower body halves is acceptable 3 Inspect the bores of both the end cover and the purge valve housing for deep scuffing or gouges 13 4 Make certain that all purge valve housing and end cover passages are open and free of obstructions 5 Inspect the pipe threads in the end cover Make certain they are clean and free of thread sealant 6 Inspect the purge valve housing bore and seats for excessive wear and scuffing 7 Inspect the purge valve piston seat for excessive wear Inspect all air line fittings for corrosion Clean all old thread sealant from the pipe threads 9 All o rings removed should be discarded and replaced with new o rings provided in appropriate kit s Any component exhibiting a condition described in step 1 to 8 should be replaced ASSEMBLY Th
40. lled position in the purge valve housing As illustrated remove the heater amp thermostat assembly by gently rotating the connector to the left Step A until the thermostat clears the purge valve housing then slide the heater element out to the right and up Step B End Cover Removal 1 Remove the remaining six 3 8 cap screws locknuts and twelve special washers that secure the end cover to the housing air dryer housing Separate the end cover and desiccant cartridge from the housing See Figure 9 illustration K Remove the end cover to outer housing o ring 3 Do not remove the safety valve from the end cover unless it has been proven defective If replacement is required apply thread sealant or Teflon tape on the threads of the replacement valve and torque to 120 400 in lbs See Figure 1 for safety valve location N ilig ee CHECK VALVE WITH 90 FITTING 4 Place a strap or chain wrench around the desiccant cartridge so that it is approximately 2 3 inches away from the end cover Rotate the cartridge counterclockwise until it completely separates from the end cover Note A substantial torque up to 50 lb ft may be required to perform this disassembly 5 Remove the desiccant cartridge o ring from the end cover Drop In Air Dryer Makeup Line Removal 1 Before beginning note the approximate angle of the fittings check valve and the general routing of the makeup line on the air dryer It
41. n 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 Feedback Line Typical Drop In Air Dryer End Cover 21 Bendix AD 9 AND AD 9 IPC AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE REMEDY 2 Water and or Oil in Supply or A Desiccant requires replacement Service Reservoir excessive contaminants in desiccant cartridge assembly B Improper discharge line length or improper line material Maximum air dryer inlet temperature is exceeded C Air system charged from outside air source outside air not passing through air dryer D Air dryer not purging see Symptom 5 E Purge air exhaust time insufficient due to excessive system leakage see causes for Symptom 1 F Excessive air usage duty cycle too high Air dryer not compatible with vehicle air system requirement Improper air dryer vehicle application NOTE Duty Cycle is the ratio of time the compressor spends building air to total engine running time Air compressors are designed to build air run loaded up to 25 of the time Higher duty cycles cause conditions that affect air brake charging system performance which may require additional maintenance Factors that add to the duty cycle are air suspension additional air
42. ng disassembly install it on the purge valve assembly making certain the bubble portion is positioned over the thermostat Install the assembled purge valve housing in the end cover Make certain to orient both parts such that the connector is approximately 10 degrees clockwise from the supply port while making certain the purge valve housing is fully seated against the end cover Secure the purge valve housing to the end cover using the three 1 4 14 APPLY LUBRICANT DELIVERY CHECK VALVE BODY SPRING RETAINER 7116 DEEP SOCKET WITH A 3 8 DRIVE BENCH VISE FIGURE 12 VERTICAL DELIVERY CHECK VALVE self tapping screws Start all three screws by hand then torque to 50 80 in lbs Delivery Check Valve Assembly The current style AD 9 air dryer end cover has a horizontal delivery check valve while earlier styles contained a vertical design Identify the style of AD 9 air dryer end cover and proceed to the appropriate step for installation See Figure 7 illustration E Vertical Delivery Check Valve 1 Assemble the spring to the retainer and check valve Ensure the spring is fully seated on the retainer and the check valve 2 Lubricate the entire spherical surface of the check valve and bore chamfer of the check valve housing with the lubricant provided in the kit 3 Place the retainer spring and check valve sub assembly into the check valve housing Press the retainer using a 7 16 deep socket
43. ntrol port and an unused unloader port on the governor The control line must be plumbed direct to the governor and not in series with automatic drain valves lubrication systems etc 2 The control line should slope downward to the end cover without forming potential water traps DISCHARGE LINE General Refer to Appendix A Table A for recommended discharge line lengths and sizes for various vehicle applications and vocations PURGE EXHAUST LINE 1 If it is necessary to direct AD 9 or AD 9 IPC air dryer discharge contaminants away from vehicle components it may be necessary to purchase a special exhaust cover for the AD 9 or AD 9 IPC air dryer Pc No 5003838 A one inch 25 4 mm I D hose can be clamped on the special air dryer exhaust cover WIRING THE HEATER THERMOSTAT 1 Determine the vehicle s electrical system voltage and make certain that the AD 9 or AD 9 IPC air dryer that is to be installed contains the same voltage heater Use the AD 9 or AD 9 IPC air dryer part number to confirm the proper voltage The AD 9 and AD 9 IPC air dryers are available with either a 12 or 24 volt heater which uses 75 watts of power 2 Atwo lead 12 inch wire harness with attached weather resistant connector is supplied with all retrofit and replacement AD 9 and or AD 9 IPC air dryers 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
44. rge 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 by pass system must be installed 3 European Air Brake Systems Brake systems that incorporate compressors without integral unloading mechanisms and or utilize a compressor discharge line unloader valve have special Bendix AD 9 and AD 9 IPC air dryer installation requirements Consult your local authorized Bendix parts outlet or sales representative for additional information 4 Holset E or QE Type Air Compressors In order for the AD 9 or AD 9 IPC air dryer to function properly when installed with the Holset Type E or QE compressor several specialized Holset components are required Consult your local authorized Holset parts outlet or sales representative for additional information 5 Use of Standard or Extended Purge AD 9 or AD 9 IPC Air Dryer Use the following guidelines Total Vehicle Reservoir Volume Bendix AD 9 or AD 9 IPC Air Dryer Requirement Less than 9 000 cu in Standard Air Dryer 9 000 12 500 cu in Extended Purge Air Dryer Greater than 12 500 cu in Contact Bendix Rep or Bendix Engineering VEHICLE PREPARATION 1 Park the vehicle on a level surface and prevent movement by means other than the brakes 2 Drain all reservoirs to O psi 0 kPa LOCATING THE BENDIX AD 9 AIR DRYER ON VE
45. rt and clamp the nipple into a vise Delivery Check Valve Removal The current style AD 9 air dryer end cover has a horizontal delivery check valve while earlier styles contained a vertical design Identify the style of AD 9 air dryer end cover and proceed to the appropriate step for removal See Figure 7 illustration E 1 Vertical Delivery Check Valve Removal Using an adjustable wrench or a 1 3 4 socket remove the delivery check valve assembly and o ring Remove the o ring from the check valve assembly Horizontal Delivery Check Valve Removal Remove the delivery check valve plug from the air dryer end cover 2 Remove the spring check valve body and o ring 11 Silencer Removal If the air dryer purge valve has a silencer attached to it identify the style of silencer before attempting to remove it There are two different styles of silencers that have been used with the Bendix AD 9 air dryer One design is secured to the air dryer purge valve adapter with four cap screws that are visible from the bottom The other is a snap on design See Figure 8 illustration G Screw Mounted Silencer 1 Remove the four screws that secure the exhaust cover silencer cover filter and silencer body to the adapter 2 Remove the three screws that secure the adapter to the purge valve Remove the adapter and gasket Snap on Silencer 1 Firmly grip the silencer and pull it away from the air dryer end cover 2 Slide t
46. sary 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 is used to pressurize a tank trailer for purposes of off loading product Consult your local authorized Bendix parts outlet or sales representative for additional information Bendix AD 9 AND AD 9 IPC AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE REMEDY 2 Water and or Oil in Supply Continued Purge Cycle Time During normal vehicle operation the or Service Reservoir air compressor must remain unloaded for a minimum of 20 continued seconds for the standard Bendix AD 9 and AD 9 IPC air dryer or 30 seconds for the extended purge model These minimum purge times are 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 representative for additional information European Air Brake Systems Brake systems that incorporate compressors without integral unloading mechanisms and or utilize a compressor discharge line unloader valve have special air dryer installation requirements Consult your local authorized Bendix parts outlet or sales representative for additional information Air Compressor Size Although the AD 9 and AD 9 IPC air dryers can be used in conjunction with larger compressors it was de
47. signed primarily for units rated for up to 17 CFM It is recommended that when using the AD 9 or AD 9 IPC air dryer with a compressor which has a rated displacement exceeding 17 CFM that an authorized Bendix parts outlet or Bendix marketing representative be contacted for assistance G Air compressor discharge and or G Restricted discharge line See Appendix A Table A column 1 air dryer inlet temperature too high amp 2 for recommended sizes If 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 lf instead ice blockages occur at the air dryer inlet insulation may be added here or if the inlet fitting is a typical 90 degree fitting it may be changed to a straight or 45 degree 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 1 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
48. this attachment data sheet Pinging noise excessive A Defective check valve assembly in A Refer to Remedy C Symptom 1 during compressor loaded air dryer end cover cycle B Leaking Turbo Cut off valve B Repair or replace purge valve assembly C Leaking purge valve control piston C Repair or replace purge valve assembly o ring Constant seepage of air at A Defective check valve assembly in A Refer to Remedy C Symptom 1 air dryer purge valve exhaust air dryer end cover non charging mode B Leaking Turbo Cut off valve B Repair or replace purge valve assembly C Leaking purge valve control piston C Repair or replace purge valve assembly o ring 11 The air dryer purge piston A Compressor fails to unload A Faulty governor installation no air line from governor to cycles rapidly in the compressor or line is kinked or restricted Install or repair air compressor unloaded non line compressing mode 26 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 Typical Discharge mended mended Reservoir Air Dryer Reservoir Oil Contents H No of Cartridge Drain at Regular Vehicle Used for Axles Replacement Schedule Drain Interval Low Air Use C ith less than 15 dut
49. tle before measuring oil quantity To counter above normal temperatures at the air dryer inlet and resultant oil vapor passing upstream in the air system replace the discharge line with one of a larger diameter and or longer length This helps reduce the air s temperature If sufficient cooling occurs the oil vapor condenses and can be removed by the air dryer Discharge line upgrades are not covered under warranty Note To help prevent discharge line freeze ups shorter discharge line lengths or insulation may be required in cold climates See Bendix Bulletins TCH 008 021 and TCH 008 022 included in Appendix B for more information For certain vehicles applications where turbo charged inlet air is used a smaller size compressor may be permissible 2 3 4 Note Compressor and or air dryer upgrades are recommended in cases where duty cycle is greater than the normal range for the examples above For Bendix Tu Flo 550 and 750 compressors unloader service is recommended every 250 000 miles 27 Appenalx B Additional Troubleshooting Information The troubleshooting procedure presented on the following pages has been excerpted from a troubleshooting card entitled Troubleshooting Charging and Air Supply Systems The complete card can be obtained from authorized Bendix parts outlets under literature number BW1779 It is presented here because of the air dryers connection to the supply air system and for convenience The
50. will be used to secure the air dryer to its mounting bracket Tighten the six cap screws and nuts in a star pattern in a fashion similar to Figure 13 depending on lower bracket location Torque to 270 385 in lbs Note The two remaining bolt holes in the end cover and two 3 8 cap screws must be the ones marked during disassembly to assure proper orientation of the ports and adequate length of the cap screws INSTALLATION 1 Install the assembled Bendix AD 9 or AD 9 IPC air dryer back onto the vehicle by slipping it into the upper mounting bracket Align the two unused holes in the end cover with the bottom mounting bracket such that the bottom bracket supports the air dryer The air dryer end cover should rest on the bracket Using the remaining two 3 8 cap screws four special washers and two locknuts secure the air dryer to the lower bracket Tighten then torque the two remaining cap screws to 270 385 in los See Figure 14 See Figure 7 illustrations A and B to determine the mounting bracket type Illustration A Style Attach the mounting strap to the air dryer and secure it to the mounting saddle with the 5 16 X 4 1 2 hex cap screw and nut Torque to 80 120 in lbs Illustration B Style Place the isolator between the upper bracket and air dryer Secure the air dryer to the upper bracket with the mounting strap Tighten the adjusting nut to 50 60 in lbs 15 3 Reconnect the three air lines to t
51. with a 3 8 drive and a vise as shown in Figure 12 4 Inspect the bore of the end cover Make certain that the end cover passage is open and free of obstructions 5 Install the o ring on the outer body of the delivery check valve assembly Ensure the o ring is seated properly and not twisted Lubricate the o ring 6 Install the delivery check valve assembly into the end cover Torque to 200 250 in lbs Horizontal Delivery Check Valve 1 Lubricate the o ring and the long check valve body with the lubricant provided Use only the lubricant contained in the kit 2 Install the o ring on the long check valve body Push the o ring down over the 3 guide lands until it is in the o ring groove Ensure the o ring is seated properly and not twisted 3 Install the spring on the white check valve body so that the small coils of the spring slip over the check valve body FIGURE 13 END COVER TO HOUSING TORQUE PATTERN Install the assembled long check valve body o ring and spring in the end cover delivery check valve port so that the o ring rests on its seat in the end cover and the spring is visible Install the delivery check valve plug that was removed during the disassembly into the air dryer end cover See Figure 5 Torque the plug to 130 170 inch pounds Drop In Air Dryer Makeup Line Assembly 1 Install the adapter and the attached 90 degree fitting in the air dryer Take care that the replacement adapter and
52. y cycl packed 5 acceptable e g Line haul single trailer gt E eth ee ins w o air suspension air over 9 Moss Recom range hydraulic brakes less p9 mended 3 oil units 5 8 in 9ft E Every 3 Every per month Years Month See Compressor with up to 25 duty cycle T Max of appendix P E a pe e g Line haul single trailer 5 op i every 90 A with air suspension RV or fo E days Q f LL school bus less JE upgrades TE Mo AH sin 12 ft For the 3 E BASIC High Air Use Io Test Kit 9 gt Order Compressor with up to 25 duty cycle a ga O e g Double triple trailer x Z 5013711 open highway coach most D g pick up amp delivery yard or q terminal jockey off highway 3 Every 2 construction loggers concrete gt For oil carry over Years ixer dump truck fire truck TE camren sun Joss mixer QUMp less B upgrades ca a LEE S H een st BASIC test Q i e me HEI corer p S E Every ol NN Compressor with up to 25 duty cycle oO i Month pn A see e g City transit bus refuse 3 appendix bulk unloaders low boys rs A urban region coach central tire 5 inflation 12 a Every sau For oil carry over Year 8 control suggested gt upgrades me 13 4 in 15 ft E y c 9 faa Footnotes 1 With increased air demand the air dryer cartridge needs to be replaced more often Use the drain valves to slowly drain all reservoirs to zero psi Allow the oil water mixture to fully set
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