SD-08-2412 ® Bendix® AD-9® and AD-9® IPC (Integrated PuraGuard® Coalescing) Air Dryers EXTENDED PURGE STANDARD IPC AIR DRYER LABEL OUTER SHELL END COVER SUPPLY PORT CONTROL PORT DELIVERY PORT WIRING HARNESS CONNECTION PURGE VALVE CHECK VALVE ASSEMBLY 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
CHECK VALVE ORIFICE DESICCANT CARTRIDGE DESICCANT BED RESERVOIR PURGE VALVE SUPPLY PORT ENGINE TURBO COMPRESSOR GOVERNOR CONTROL PORT OIL SEPARATOR PURGE VOLUME SUMP EXHAUST CHECK VALVE ASSEMBLY DELIVERY PORT HEATER ELEMENT 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® an
CHECK VALVE ORIFICE PURGE VOLUME OIL SEPARATOR CONTROL PORT COMPRESSOR GOVERNOR DESICCANT BED DESICCANT CARTRIDGE SUPPLY PORT RESERVOIR TURBO CUT-OFF PISTON PURGE VALVE ENGINE TURBO EXHAUST HEATER ELEMENT CHECK VALVE ASSEMBLY DELIVERY PORT SUMP FIGURE 3 - BENDIX®AD-9® AND AD-9® IPC AIR DRYER PURGE CYCLE changes several times, reducing the temperature, causing contaminants to condense and dr
UPPER BRACKET STRAP UPPER BRACKET DESICCANT CARTRIDGE DESICCANT BED HOUSING OIL SEPARATOR EXHAUST PURGE VALVE CHECK VALVE DISCHARGE ASSEMBLY 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.
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.
OPERATION & 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.
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.
MAINTENANCE KITS Kit Part Number Service New (S) or Reman Exchange (RX) Purge Valve Type Heater Connector Color 107695 S – – – 5002080 S – – – 5009610 S – – – 107799 S – – – End Cover Check Valve Assembly Replacement 3/4 inch thread size. End Cover Check Valve Assembly Replacement 1/2 inch thread size.
SLEEVE NUT MOUNTING STRAP MOUNTING STRAP ADJUSTING NUT ISOLATOR MOUNTING SADDLE 5/16" HEX HEAD SCREW UPPER BRACKET LOCKNUT SPECIAL WASHER LOCKNUT SPECIAL WASHER LOWER MOUNTING BRACKET O-RING LOWER MOUNTING BRACKET SPECIAL WASHER CHECK VALVE SPECIAL WASHER 3/8" END COVER CAP SCREW 3/8" END COVER CAP SCREW A STANDARD MOUNTING BRACKET KIT B MOUNTING BRACKET KIT SMALL O-RING DELIVERY CHECK VALVE PLUG (NOT INCLUDED IN KIT) CHECK VALVE MAINTENANCE KIT C O-RING MEDIUM O-RING SPRING LARGE
BW GASKET GASKET EXHAUST COVER EXHAUST COVER SCREWS ADAPTER ADAPTER SCREWS EXHAUST COVER KIT F ADAPTER SILENCER BODY FILTER SILENCER SILENCER COVER EXHAUST COVER EXHAUST COVER SCREWS DESICCANT CARTRIDGE DESICCANT CARTRIDGE O-RING OUTER HOUSING O-RING G SILENCER KIT DESICCANT CARTRIDGE KIT SMALL O-RING H MEDIUM O-RING LARGE O-RING STANDARD PURGE VALVE ASSEMBLY CHECK VALVE WASHER SCREWS STANDARD PURGE VALVE SMALL O-RING DISCHARGE LINE UNLOADER PURGE VALVE ASSEMBLY ADAPTER LARGE O-RING
SMALL O-RING MEDIUM O-RING SCREW LARGE O-RING SEALING RING DESICCANT CARTRIDGE O-RING HEATER & THERMOSTAT OUTER HOUSING O-RING HEATER & THERMOSTAT KIT END COVER L WIRE HARNESS ASSEMBLY END COVER REPLACEMENT KIT K UNINSULATED BUTT SPLICE CONNECTOR EYELET W/HEAT SHRINK INSULATOR ADHESIVE LINED HEAT SHRINK TUBING HEATER ELECTRICAL SPLICING KIT UNIVERSAL MOUNTING PLATE M N FIGURE 9 - MAINTENANCE KIT CONTENTS (ILLUSTRATIONS K THROUGH M) DISASSEMBLY Delivery Check Valve Removal The following
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.
SPECIAL ASSEMBLY, MUST BE REPLACED BY AD-9 SOFT SEAT AIR DRYER ASSY. SPECIAL ASSEMBLY, MUST BE REPLACED BY AD-9 SOFT SEAT AIR DRYER ASSY. MAKEUP AIR LINE DELIVERY PORT ADAPTER (WITH 90° FITTING) DELIVERY PORT ADAPTER (WITH 90° FITTING) CHECK VALVE (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.
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. APPLY LUBRICANT DELIVERY CHECK VALVE BODY CHECK VALVE SPRING 6. Inspect the purge valve housing bore and seats for excessive wear and scuffing. 7. Inspect the purge valve piston seat for excessive wear. 8. Inspect all air line fittings for corrosion. Clean all old thread sealant from the pipe threads.
2 6 4 5 3 1&9 8 7 FIGURE 13 - END COVER TO HOUSING TORQUE PATTERN 4. 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. 5. 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.
3. Reconnect the three air lines to the 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.
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.
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 control port and an unused unloader port on the governor. The control line must be plumbed direct to the governor and not in series with automatic drain valves, lubrication systems, etc. 2. The control line should slope downward to the end cover without forming potential water traps.
Bendix® AD-9® AND AD-9® IPC AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE 1. Dryer is constantly “cycling” A. Excessive system leakage. or purging. Dryer purges IMPORTANT: Note whether air frequently (every 4 minutes pressure loss is shown on dash or less while vehicle is idling). 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. REMEDY A.
Bendix® AD-9® AND AD-9® IPC AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE 1. Dryer is constantly “cycling” A. Excessive system leakage. or purging. Dryer purges IMPORTANT: Note whether air frequently (every 4 minutes pressure loss is shown on dash or less while vehicle is idling) gauge(s). Pressure loss shown on (continued). gauges is caused by service brake system or component leakage. Pressure loss NOT SHOWN on gauges is caused by supply system or component leakage. (continued) REMEDY 1.
Bendix® AD-9® AND AD-9® IPC AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE REMEDY 1. Dryer is constantly “cycling” A. Excessive system leakage. or purging. Dryer purges IMPORTANT: Note whether air frequently (every 4 minutes pressure loss is shown on dash or less while vehicle is idling) gauge(s). Pressure loss shown on (continued). gauges is caused by service brake system or component leakage. Pressure loss NOT SHOWN on gauges is caused by supply system or component leakage. (continued) 6.
Bendix® AD-9® AND AD-9® IPC AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE 2. Water and/or Oil in Supply or A. Desiccant requires replacement Service Reservoir. - excessive contaminants in desiccant cartridge assembly. REMEDY A. Replace desiccant cartridge. B. Improper discharge line length or improper line material. Maximum air dryer inlet temperature is exceeded. B. Refer to section entitled Connecting the Air Lines as well as Appendix A, Table A columns 1 & 2 then check line size and length. C.
Bendix® AD-9® AND AD-9® IPC AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE 2. Water and/or Oil in Supply (Continued) or Service Reservoir (continued). REMEDY Purge Cycle Time - During normal vehicle operation, the air compressor must remain unloaded for a minimum of 20 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.
Bendix® AD-9® AND AD-9® IPC AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE 2. Water and/or Oil in Supply (Continued) or Service Reservoir (continued). REMEDY Poorly filtered inlet air (poor air quality to compressor). Check for leaking, damaged or malfunctioning compressor air inlet components (e.g. induction line, fittings, gaskets, filter bodies, etc.). Repair inlet components as needed. Note: Dirt ingestion will damage compressor and is not covered under warranty.
Bendix® AD-9® AND AD-9® IPC AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE REMEDY 4. Safety valve on air dryer A. Restriction between air dryer and “popping off” or exhausting supply (first) reservoir. air. A. Check to determine if air is reaching supply reservoir. Inspect for kinked tubing or hose. Check for undrilled or restricted hose or tubing fittings and repair or replace as needed. B. Air dryer safety valve malfunction. B.
Bendix® AD-9® AND AD-9® IPC AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE 7. Air dryer does not purge or A. Missing, broken, kinked, frozen, exhaust air. plugged or disconnected purge control line. REMEDY A. Inspect control line from governor UNL (unloader) port to control port of air dryer. Test to determine if air flows through purge control line when compressor unloaded. Check for undrilled fittings. (See Symptom #4, Remedy C.) B. Faulty air dryer purge valve. B.
Table A: Maintenance Schedule and Usage Guidelines Regularly scheduled maintenance is the single most important factor in maintaining the air brake charging system. Column 1 Vehicle Used for: Typical Compressors No. of Spec'd Axles Column 2 Discharge Line I.D. Length 1/2 in. 6 ft. Column 3 Recommended Air Dryer Cartridge Replacement1 Column 4 Recommended Reservoir Drain Schedule2 Low Air Use 5 or less e.g. Line haul single trailer with air suspension, RV, school bus. 5 or less High Air Use e.g.
Appendix 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.