BENDIX BW1450 manual Preventative Maintenance Section

Page 20

AD-4™AIR DRYER TROUBLESHOOTING CHART (Continued)

SYMPTOMS

CAUSE

REMEDY

 

F. Governor malfunction.

F. Test governor operation and/or inspect the

 

Missing or restricted

control line leading from the governor UNL

 

governor control line

(unloader) port to the air dryer control port.

 

installation.

 

 

 

 

5. Constant exhaust of air

A. Air dryer purge valve

A. With compressor loaded, apply soap solution

at air dryer purge valve

leaking excessively.

on purge valve exhaust, to test for excessive

exhaust. (Charge

 

leakage. Repair purge valve as necessary.

mode.)

 

 

B. Compressor fails to

B. Confirm failure to unload by increasing &

 

 

unload (stop

decreasing engine RPM and noting change in

 

compressing air) and air

the rate of leakage and intensity of

 

dryer purge exhaust

accompanying leakage sound. Repair/replace

 

makes “sputtering” or

compressor unloaders.

 

“popping” sound.

 

 

 

 

 

C. Purge control line

C. Purge control line must be connected to

 

connected to reservoir or

unloader port of governor.

 

exhaust port of governor.

 

 

 

 

 

D. Purge valve frozen open -

D. Test heater and thermostat as described in

 

malfunctioning heater

Preventative Maintenance Section.

 

and thermostat, wiring,

 

 

blown fuse.

 

 

 

 

 

E. Excessive system

E. See Symptom #1.

 

leakage.

 

 

 

 

 

F. Purge valve stays open -

F. Repair purge valve and housing.

 

supply air leaks to

 

 

control side.

 

 

 

 

6. Can not build system air

A. Inlet and outlet air

A. Connect compressor discharge to air dryer

pressure.

connections reversed.

supply port. Reconnect lines properly.

 

 

 

 

B. Check valve between air

B. Test check valve for proper operation. Repair or

 

dryer and first reservoir.

replace as necessary.

 

 

 

 

C. Kinked or blocked

C. Check to determine if air passes through

 

(plugged) discharge line.

discharge line. Check for kinks, bends,

 

 

excessive carbon deposits, or ice blockage.

 

 

 

 

D. Excessive bends in

D. Discharge line should be constantly sloping from

 

discharge line (water

compressor to air dryer with as few bends as

 

collects and freezes).

possible.

 

 

 

 

E. Refer to Symptom 4,

E. Refer to Symptom #4, Remedies E & F.

 

causes E & F.

 

 

 

 

7. Air dryer does not purge

A. Missing, broken, kinked,

A. Inspect control line from governor UNL (unloader)

or exhaust air.

frozen, plugged or

port to control port of air dryer. Test to determine

 

disconnected purge

air flows through purge control line when

 

control line.

compressor unloaded. Check for undrilled

 

 

fittings. (See Symptom #4, Remedy C.)

 

 

 

 

B. Faulty air dryer purge

B. After determining air reaches purge valve

 

valve.

(Remedy A above), repair purge valve.

 

C. See Causes, B, E, G for

C. Refer to Remedies B, E, G for Symptom #4.

 

Symptom #4.

 

 

 

 

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Contents Description Port l.D Function/ConnectionPurge Cycle refer to Figure Operation of the AD-4AIR DryerCharge Cycle refer to Figure Preventive Maintenance AD-4AIR Dryer Purge CycleAD-4AIR Dryer Sectional View Rebuild the air dryer including the desiccant cartridge Operation & Leakage TestsEvery 10,800 hours or 300,000 miles or 36 months General Maintenance Kits AvailableRebuilding the AD-4AIR Dryer AD-4AIR Dryer Assembly Disassembly AD-4AIR Dryer RemovalCleaning & Inspection AssemblyThermostat Disassembly Refer to Figures RE-INSTALLATION Total Vehicle Reservoir Volume RequirementRetrofitting the AD-4AIR Dryer Vehicle Application RequirementsConnecting the AIR Lines Testing the AD-4AIR Dryer All electrical connections must be waterproofedAD-4AIR Dryer Troubleshooting Chart PresentedAD-4AIR Dryer Troubleshooting Chart With gauge installed at RES port of governor Pressure should not drop below Cut-In pressureAt the onset of the compressor Unloaded Cycle. If pressure drops, check for kinks orUnloaded for a minimum of 30 seconds. This Points where ice may form and block the flow. If How to help prevent discharge line freeze-ups, seeEngine air filter and service if necessary if Possible, check the air filter usage indicatorAD-4AIR Dryer Troubleshooting Chart Preventative Maintenance Section AD-4AIR Dryer Troubleshooting Chart Low Air Use High Air UseAdditional Troubleshooting Information Conventional Supply System & Integral Purge AIR DryerHolset Type E & QE Compressor with Econ Valve Holset Type E & QE Compressor W/O Econ Valve

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