BENDIX BW1450 manual Operation & Leakage Tests, Every 10,800 hours or 300,000 miles or 36 months

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2.Check mounting bolts for tightness. Retorque to 270- 385 inch pounds.

3.Perform the Operation & Leakage Tests listed in this publication.

Every 10,800 hours or 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 & 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.

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 supply reservoir. A rapid loss of pressure could indicate a failed outlet port check valve. (Note: Purge valve will be open when governor cut-out pressure is reached. Allow 45 seconds after governor cut-out occurs to complete the purge cycle before testing the check valve.) Coat the exhaust with a soap solution. Leakage should not exceed a 1" bubble in 1 second.

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.

3.Close all reservoir drain cocks. Build up system pressure to governor cut-out and note that AD-4air dryer purges with an audible escape of air. “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 an AD-4air 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 reseat 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 power at the dryer’s electrical terminal using a voltmeter or test light. On a single terminal AD-4air dryer’s disconnect the lead wire at the end cover terminal post. Place the test leads on the lead wire and a GOOD vehicle ground. On dual terminal AD-4air dryer’s disconnect both lead wires at the end cover terminal posts. If there is no voltage indicated, 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 terminal and the metal end cover (see Figure 5). (Note: On the dual terminal end cover, check the resistance between the two terminals.) The

HEATER POST

9

 

1

 

 

 

 

8

 

9

A

 

 

 

 

 

 

10

B

 

 

7

 

THERMOSTAT

11

 

6

 

COVER

4

 

1

 

 

3

2

 

5

1

 

SINGLE WIRE SYSTEM

 

BOLD NUMBERS ARE ITEMS IN MAINTENANCE KITS

 

 

 

1

 

 

 

9

11

 

 

10

 

 

 

8

 

 

7

6

 

 

 

 

 

5

 

 

BOOT

4

 

 

 

 

 

3

 

 

 

2

CONNECTIONS FOR POWER

1

BOOT

AND INSULATED RETURN

 

 

DUAL WIRE SYSTEM

 

FIGURE 5 - AD-4AIR DRYER SINGLE AND DUAL

TERMINAL THERMOSTAT ASSEMBLIES

5

Image 5
Contents Port l.D Function/Connection DescriptionPurge Cycle refer to Figure Operation of the AD-4AIR DryerCharge Cycle refer to Figure AD-4AIR Dryer Purge Cycle Preventive MaintenanceAD-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 AD-4AIR Dryer Removal DisassemblyAssembly Cleaning & InspectionThermostat Disassembly Refer to Figures Total Vehicle Reservoir Volume Requirement RE-INSTALLATIONRetrofitting the AD-4AIR Dryer Vehicle Application RequirementsConnecting the AIR Lines All electrical connections must be waterproofed Testing the AD-4AIR DryerPresented AD-4AIR Dryer Troubleshooting ChartAD-4AIR Dryer Troubleshooting Chart Pressure should not drop below Cut-In pressure With gauge installed at RES port of governorAt the onset of the compressor Unloaded Cycle. If pressure drops, check for kinks orUnloaded for a minimum of 30 seconds. This How to help prevent discharge line freeze-ups, see Points where ice may form and block the flow. IfEngine 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 High Air Use Low Air UseConventional Supply System & Integral Purge AIR Dryer Additional Troubleshooting InformationHolset Type E & QE Compressor with Econ Valve Holset Type E & QE Compressor W/O 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.

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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.