BENDIX BW1450 manual Rebuilding the AD-4AIR Dryer, General, Maintenance Kits Available

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resistance should be 2.0 to 4.0 ohms for the 12 volt, 60 watt end cover and 4.0 - 7.0 ohms for the 24 volt, 120 watt end cover. These resistance values apply to either single or dual terminal air dryer end covers.

Warm the end cover assembly to over 90 degrees Fahrenheit and again check the resistance as above. The resistance should exceed 1000 ohms for both single and dual terminal air dryers. 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, proceed to Step C to determine the cause.

C.Heater Element Inspection

With the ignition or engine control switch “off”, remove the thermostat cover (see Figure 5). Using an ohmmeter, check the resistance between the metal end cover and the heater post (see Figure 5). (Note: On the dual terminal end cover, check the resistance between the two terminals.) For a 12 volt, 60 watt end cover, the resistance should be 2.0 - 2.8 ohms and for a 24 volt, 120 watt end cover, 4.0 - 5.6 ohms. These resistance values apply to either single or dual terminal air dryer end covers. If the heater resistance value obtained is outside the stated limits, a new or remanufactured end cover should be installed, since the heater element cannot be serviced. Check that a good ground path exists between the air dryer end cover casting and the vehicle chassis. Correct if needed. If the heater resistance value obtained is within the stated limits the thermostat should be replaced (Kit Number 102657) or a new or remanufactured end cover installed. Note: The dual terminal air dryer cover requires kit number 103982.

D.Reassembly

Reinstall the thermostat cover as illustrated in Figure 5. Take special care to assure the rubber spacer and the gasket are correctly installed, to assure proper operation.

REBUILDING THE AD-4™AIR DRYER

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 following list to find the appropriate kit(s).

When rebuilding or replacing components of the air dryer use only genuine Bendix parts. For ease in servicing the AD-4™air dryer desiccant cartridge assembly, it is recommended that the air dryer be removed from the vehicle.

MAINTENANCE KITS AVAILABLE:

103817 Major Maintenance Kit

This kit contains the parts necessary to completely rebuild the AD-4™air dryer (desiccant cartridge included) and includes kit 103980.

103818 AD-4™Air Dryer Purge Valve Maintenance Kit

This kit contains the parts necessary to rebuild the AD-4™air dryer end cover purge valve only.

103879 AD-4™Air Dryer Seal Kit

This kit contains the outlet port check valve and the o-rings and seals required when removing the end cover assembly. This kit is included with kits 103980 and 103981.

103980 End Cover Maintenance Kit

This kit contains the parts necessary to rebuild the end cover of the AD-4™air dryer and includes kit 103818.

103981 Desiccant Cartridge Replacement Kit

This kit contains the parts necessary to change the desiccant cartridge only.

102657 Thermostat Maintenance Kit (single terminal models)

This kit contains the parts necessary to rebuild a single terminal thermostat assembly in the AD-4™air dryer.

103982 Thermostat Maintenance Kit (dual terminal models)

This kit contains the parts necessary to rebuild a two terminal thermostat assembly (insulated ground).

288918 Thermostat Cover Replacement Kit (single

terminal models)

This kit contains the necessary components for replacing the non-metallic thermostat cover.

104964 Thermostat Cover Replacement Kit (dual terminal models)

This kit contains the necessary components for replacing the non-metallic thermostat cover.

WARNING! PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO AVOID PERSONAL INJURY OR DEATH:

When working on or around a vehicle, the following general precautions should be observed at all times.

1.Park the vehicle on a level surface, apply the parking brakes, and always block the wheels. Always wear safety glasses.

2.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 charged components.

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Contents Description Port l.D Function/ConnectionOperation of the AD-4AIR Dryer Charge Cycle refer to FigurePurge Cycle refer to Figure Preventive Maintenance AD-4AIR Dryer Purge CycleAD-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 Disassembly AD-4AIR Dryer RemovalCleaning & Inspection AssemblyThermostat Disassembly Refer to Figures Retrofitting the AD-4AIR Dryer RE-INSTALLATIONTotal Vehicle Reservoir Volume Requirement 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 At the onset of the compressor Unloaded With gauge installed at RES port of governorPressure should not drop below Cut-In pressure Cycle. If pressure drops, check for kinks orUnloaded for a minimum of 30 seconds. This Engine air filter and service if necessary if Points where ice may form and block the flow. IfHow to help prevent discharge line freeze-ups, see Possible, check the air filter usage indicatorAD-4AIR Dryer Troubleshooting Chart Preventative Maintenance Section AD-4AIR Dryer Troubleshooting Chart Low Air Use High Air UseHolset Type E & QE Compressor with Econ Valve Additional Troubleshooting InformationConventional Supply System & Integral Purge AIR Dryer 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.

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.
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