BENDIX BW1450 manual AD-4AIR Dryer Troubleshooting Chart

Page 15

AD-4™AIR DRYER TROUBLESHOOTING CHART (Continued)

SYMPTOMS

CAUSE

REMEDY

1. Test fittings, hoses, lines and connections. Apply soap solution to detect excessive leakage. Tighten or replace as needed then repeat the air dryer charge-purge cycle and observe the gauge installed in the supply reservoir. If leakage is within limits remove gauge from reservoir and replace drain cock or valve. If excessive leakage is detected, continue testing.

2. Test accessories connected to supply reservoir. Drain all air pressure from system, disconnect all air lines leading to accessories (fan clutch, wipers, air seats, etc.) and plug the reservoir at 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, turn off engine and apply soap solution to governor exhaust port and around cap. Leakage should not exceed a 1" bubble in 5 seconds. Reduce system pressure to 80 psi or less, and re-apply soap solution. Leakage should not exceed a 1" bubble in 5 seconds. If 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.

5. Test air 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). Leakage should not exceed a 1" bubble in 5 seconds. If leakage is excessive repair or replace purge valve assembly.

15

Page 14 Page 16
Image 15
Page 14 Page 16
Contents Port l.D Function/Connection DescriptionOperation of the AD-4AIR Dryer Charge Cycle refer to FigurePurge Cycle refer to Figure AD-4AIR Dryer Purge Cycle Preventive MaintenanceAD-4AIR Dryer Sectional View Operation & Leakage Tests Every 10,800 hours or 300,000 miles or 36 monthsRebuild the air dryer including the desiccant cartridge Maintenance Kits Available Rebuilding the AD-4AIR DryerGeneral AD-4AIR Dryer Assembly AD-4AIR Dryer Removal DisassemblyAssembly Cleaning & InspectionThermostat Disassembly Refer to Figures Vehicle Application Requirements RE-INSTALLATIONTotal Vehicle Reservoir Volume Requirement Retrofitting the AD-4AIR DryerConnecting the AIR Lines All electrical connections must be waterproofed Testing the AD-4AIR DryerPresented AD-4AIR Dryer Troubleshooting ChartAD-4AIR Dryer Troubleshooting Chart Cycle. If pressure drops, check for kinks or With gauge installed at RES port of governorPressure should not drop below Cut-In pressure At the onset of the compressor UnloadedUnloaded for a minimum of 30 seconds. This Possible, check the air filter usage indicator Points where ice may form and block the flow. IfHow to help prevent discharge line freeze-ups, see Engine air filter and service if necessary ifAD-4AIR Dryer Troubleshooting Chart Preventative Maintenance Section AD-4AIR Dryer Troubleshooting Chart High Air Use Low Air UseHolset Type E & QE Compressor W/O Econ Valve Additional Troubleshooting InformationConventional Supply System & Integral Purge AIR Dryer Holset Type E & QE Compressor with Econ Valve

BW1450 specifications

The BENDIX BW1450 is a highly regarded air brake system that delivers exceptional performance and reliability in the heavy-duty truck and automotive sectors. The BW1450 is designed with advanced technologies and engineering breakthroughs that ensure enhanced safety and efficiency in braking operations.

One of the standout features of the BENDIX BW1450 is its robust and compact design. Constructed to withstand the rigors of heavy use, the system is both lightweight and durable, allowing for easy installation and maintenance. It incorporates a corrosion-resistant finish that helps protect against environmental factors, ensuring longevity and dependability.

The BW1450 leverages advanced modulation technology, which provides superior control during braking. This technology allows for gradual engagement and disengagement of the brakes, significantly reducing the risk of skidding or jackknifing during emergency stops. The system's sophistication extends to its ability to maintain consistent brake performance under various load conditions, making it a versatile choice for different vehicle types.

Another significant characteristic of the BENDIX BW1450 is its integrated Air Disc Brake technology. This feature not only improves the overall stopping power but also results in shorter stopping distances. In addition to enhanced performance, the air disc brakes are easier to maintain compared to traditional drum brakes, reducing downtime and service costs.

The BENDIX BW1450 also incorporates smart sensor technologies that monitor brake performance, providing real-time data to drivers and fleet operators. This capability enhances fleet management as it allows for timely maintenance interventions and ensures that the braking system operates optimally at all times.

Safety is a paramount concern in any braking system, and the BENDIX BW1450 is equipped with an anti-lock braking system (ABS). This feature prevents wheel lock-up during hard braking, thus providing additional control in slippery conditions and enhancing the vehicle's stability. Moreover, the system meets or exceeds various industry safety standards, reinforcing its position as a reliable choice for heavy-duty applications.

In conclusion, the BENDIX BW1450 air brake system represents a combination of innovative design, cutting-edge technology, and reliable performance. Its lightweight construction, advanced modulation control, air disc braking capabilities, and integrated safety features make it an exemplary choice for the demanding requirements of heavy-duty vehicles.
Top Page Image Contents