BENDIX BW1811 manual AD-IPAIR Dryer Removal, Disassembly

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all reservoirs before beginning ANY work on the vehicle. If the vehicle is equipped with an AD-IS®air dryer system or a dryer reservoir module, be sure to drain the purge reservoir.

5.Following the vehicle manufacturer’s recommended procedures, deactivate the electrical system in a manner that safely removes all electrical power from the vehicle.

6.Never exceed manufacturer’s recommended pressures.

7.Never connect or disconnect a hose or line containing pressure; it may whip. Never remove a component or plug unless you are certain all system pressure has been depleted.

8.Use only genuine Bendix® replacement parts, components and kits. Replacement hardware, tubing, hose, fittings, etc. must be of equivalent size, type and strength as original equipment and be designed specifically for such applications and systems.

9.Components with stripped threads or damaged parts should be replaced rather than repaired. Do not attempt repairs requiring machining or welding unless specifically stated and approved by the vehicle and component manufacturer.

10.Prior to returning the vehicle to service, make certain all components and systems are restored to their proper operating condition.

11.For vehicles with Antilock Traction Control (ATC), the ATC function must be disabled (ATC indicator lamp should be ON) prior to performing any vehicle maintenance where one or more wheels on a drive axle are lifted off the ground and moving.

AD-IPAIR DRYER REMOVAL

This air dryer removal process is presented in the event it becomes necessary to replace the entire air dryer. Normal

service and parts replacement does not require removal of the air dryer from the vehicle.

1.Park the vehicle on a level surface and prevent movement by means other than the brakes.

2.Drain all reservoirs to 0 p.s.i. — Caution: Compressor discharge line may still contain residual pressure.

3.Identify and disconnect the three air lines from the end cover and note the position of end cover ports relative to the vehicle.

4.Unplug the vehicle wiring harness from the heater and thermostat assembly connector on the end cover assembly.

5.Remove the four bolts that secure both the upper and lower mounting brackets to the vehicle, and remove the air dryer from the vehicle.

6.Mark the relationship of the saddle bracket (5) to the end cover assembly (6). Remove the 5/16" cap screw

(1)and sleeve nut (3) securing the upper mounting strap

(4)to the saddle bracket (5). Earlier models used washer and nut in place of the sleeve nut (3). Remove the upper mounting strap (4) from the end cover assembly (6).

7.Mark the relationship of the lower bracket (9) to the end cover assembly (6). Remove the two 3/8" end cover cap screws (7) and two washers (8) that retain the lower mounting bracket (9) to the end cover (6).

DISASSEMBLY

The following disassembly and assembly procedure is presented for reference purposes and presupposes that a major rebuild of the AD-IPair dryer is being undertaken. The replacement parts and maintenance kits available generally do not require full disassembly. The instructions provided with these parts and kits should be followed in lieu of the instructions presented here. Refer to Figure 9 during disassembly.

Caution: While performing service on the AD-IPair dryer, it is not recommended that a clamping device (vise, C-clamp, etc.) be used to hold any die cast aluminum component as damage may result. To hold the end cover, install a pipe nipple in the supply port and clamp the nipple into a vise.

1.Using an adjustable or socket wrench, loosen the desiccant cartridge bolt (10), then separate the desiccant cartridge (11) from the end cover (6). Pull the desiccant cartridge bolt out of the end cover (6).

Caution: Disassembly of the desiccant cartridge assembly should not be attempted! Detail parts for the cartridge are not available and the cartridge contains a 150# spring which can not be mechanically caged.

2.Remove both o-rings (12 & 13) from the desiccant cartridge bolt.

3.Remove the retaining ring (14) that secures the purge valve assembly (15) in the end cover (6).

4.Remove the 1/4" shoulder bolt (16) from the bottom of the purge valve housing assembly (19) using a 3/8" socket wrench and a large blade screw driver, inserted in the slot on top of the purge piston (20). Remove the exhaust diaphragm (17), and the purge valve (18) from the purge valve housing (19).

5.Remove the o-rings (23 & 24) from the purge valve housing (19). Discharge Line Unloader (DLU) models do not have o-ring (23).

6.Remove the purge piston (20) and the return spring (22).

7.Remove the o-ring (21) from the purge piston (20).

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Contents SD-08-2414 Function/ConnectionAD-IPDI Drop in AIR Dryer Model GeneralAD-IPINTEGRAL Purge AIR Dryer Charge Cycle Turbo Cutoff Feature Refer to Figure Preventive Maintenance Operation & Leakage Tests Side View Weatherproof Accordian TOP ViewMaintenance Kits Available Rebuilding the AD-IPAIR DryerDisassembly AD-IPAIR Dryer RemovalCleaning & Inspection Assembly34 35 36 DLU Style Purge Valve Old Style AD-IP End Cover Vertical Delivery Check Valve AD-IPAIR Dryer Installation Total Vehicle Reservoir Volume RequirementRetrofitting the AD-IPAIR Dryer Vehicle Application RequirementsConnecting the AIR Lines Vehicle PreparationLocating AD-IPAIR Dryer on Vehicle Compressor Discharge LineInstalling AD-IPAIR Dryer with Holset Compressor General Purge Exhaust LineStandard AD-IPAir Dryer Refer to B AD-IPDI Drop In Air Dryer Model Refer to CTesting the AD-IPAIR Dryer Wiring Remote Power & Local GroundAD-IPAIR Dryer Troubleshooting Chart Perform tests 1 to 6 in the order presentedAD-IPAIR Dryer Troubleshooting Chart Feedback Line Typical Drop-In Air Dryer End Cover Unloaded for a minimum of 30 seconds. This AD-IPAIR Dryer Troubleshooting Chart Check Valve Preventative Maintenance Section AD-IPAIR Dryer Troubleshooting Chart Low Air Use High Air UseAdditional Troubleshooting Information Conventional Supply System Integral Purge AIR DryerComplaints Common to the Charging & AIR Supply System Complaint Can Not Build System PressureTests Common to More than ONE Complaint Discharge plugged or restricted