Bendix AD-IP User Manual
Bendix® AD-IP™ Integral Purge Air Dryer
SD-08-2414
DESICCANT
CARTRIDGE
MOUNTING
STRAP
SAFETY
VALVE
CONTROL
PORT
HEATER &
THERMOSTAT
CONNECTOR
FIGURE 1 - AD-IP™ INTEGRAL PURGE AIR DRYER
SUPPLY
PORT
SAFETY VALVE
DESCRIPTION
The function of the Bendix® AD-IP™ integral purge air dryer
is to collect and remove air system contaminants in solid,
liquid and vapor form before they enter the brake system. It
provides clean, dry air to the components of the brake system
which increases the life of the system and reduces
maintenance costs. Daily manual draining of the reservoirs
is eliminated.
SADDLE
MOUNTING
BRACKET
CONTROL
PORT
LOWER
MOUNTING
BRACKET
SUPPLY
HEATER & THERMOSTAT
CONNECTOR
PORT
The AD-IP™ air dryer has three female pipe thread air
connections identified as follows:
Air Connection Port ID Function/Connection
CON 4...................... Control Port (purge valve control
& turbo cutoff).
SUP 11 .................... Supply Port (air in).
DEL 2 ...................... Delivery Port (air out).
The AD-IP™ air dryer consists of a desiccant cartridge
secured to a die cast aluminum end cover with a single,
central bolt. The end cover contains a check valve assembly ,
safety valve, heater and thermostat assembly, three pipe
thread air connections and the purge valve assembly . The
removable purge valve assembly incorporates the purge valve
mechanism and a turbo charger cutoff feature that is designed
to prevent loss of engine “turbo” boost pressure during the
purge cycle of the AD-IP™ air dryer. For ease of serviceability ,
all replaceable assemblies can be replaced without removal
of the air dryer from its mounting on the vehicle.
1
FEEDBACK
LINE
SPECIAL DISCHARGE
PORT FTG. W/
FEEDBACK LINE
CONNECTION
DISCHARGE
PORT
LOWER
MTG. BRKT.
(PARTIAL)
SPECIAL DISCHARGE
PORT FTG. W/
FEEDBACK LINE
CONNECTION
FIGURE 2 - AD-IP™ DI DROP IN AIR DRYER FOR HOLSET
COMPRESSORS
END COVER
BOTTOM VIEW
CHECK
VALVE
FEEDBACK
LINE
DISCHARGE LINE
HOLSET COMPRESSOR
HOLSET TYPE E & QE COMPRESSORS - NO AIR DRYER
HOLSET
COMPRESSOR
STANDARD AD-IP
HOLSET TYPE E & QE COMPRESSORS
HOLSET
COMPRESSOR
™
DI DROP IN AIR
AD-IP
DRYER W/FEEDBACK
LINE & CHECK VALVE
AD-IP
HOLSET TYPE E & QE COMPRESSORS
FIGURE 3 - AD-IP™ AIR DRYER AND HOLSET TYPE E & QE
COMPRESSORS
FIGURE A
STANDARD AD-IP
FEEDBACK LINE
FIGURE B
™
AIR DRYER AND
FIGURE C
™
DI DROP IN AIR DRYER AND
W/CHECK VALVE
DRYER
SUPPLY
RES.
™
AIR
SUPPLY
RES.
SUPPLY
RES.
AD-IP™ DI “DROP IN” AIR DRYER MODEL
In addition to the standard AD-IP™ air dryer, the Bendix
AD-IP™ DI (Drop In) air dryer is also offered. It is a specialized
version designed especially for air systems that use either
the Holset (Cummins) T ype E or QE air compressor . These
Holset compressors utilize an unusual unloading system
that requires that air pressure remain in the discharge line
during the entire unloaded cycle of the compressor. To
accomplish this, Holset compressors rely on air “feedback”
from the supply reservoir as shown in Figure 3B. When an
air dryer is installed the direct “feedback” from the supply
reservoir is interrupted and an alternate source for “feedback”
pressure must be provided. A standard AD-IP™ air dryer can
be installed, however a separate “feedback” line with a single
check must be installed as shown in Figure 3C.
The AD-IP™ DI drop in air dryer model incorporates the
feedback line and single check as an integral part of the
dryer and eliminates the need for these components as shown
in Figures 2 & 3C.
2
OPERATION
®
GENERAL
The AD-IP™ air dryer alternates between two operational
modes or “cycles” during operation: the Charge Cycle and
the Purge Cycle. The following description of operation is
separated into these “cycles” of operation.
CHARGE CYCLE (refer to Figure 4)
When the compressor is loaded (compressing air)
compressed air, along with oil, oil vapor, water and water
vapor flows through the compressor discharge line to the
supply port of the air dryer body .
As air travels through the end cover assembly , its direction
of flow changes several times, reducing the temperature,
causing contaminants to condense and drop to the bottom
or sump of the air dryer end cover.
After exiting the end cover , the air flows into the desiccant
cartridge. Once in the desiccant cartridge air first flows
through an oil separator located between the outer and inner
shells of the cartridge. The separator removes water in liquid
form as well as liquid oil and solid contaminants.
PURGE
CONTROL
LINE
PURGE
ORIFICE
CONTROL
PORT
OIL
SEPARATOR
SUPPLY
PORT
DESICCANT
BED
PURGE
VOLUME
GOVERNOR
COMPRESSOR
FIGURE 4 - AD-IP™ INTEGRAL PURGE AIR DRYER CHARGE CYCLE
ENGINE
TURBO
TURBO
CUTOFF
VALVE
EXHAUST
Air, along with the remaining water vapor, is further cooled
as it exits the oil separator and continues to flow upward
between the outer and inner shells. Upon reaching the top
of the cartridge the air reverses its direction of flow and enters
the desiccant drying bed. Air flowing down through the column
of desiccant becomes progressively drier as water vapor
adheres to the desiccant material in a process known as
“ADSORPTION.” The desiccant cartridge using the
adsorption process typically removes most of the water vapor
from the pressurized air.
Dry air exits the bottom of the desiccant cartridge and flows
through the center of the bolt used to secure the cartridge to
the end cover. Air flows down the center of the desiccant
cartridge bolt, through a cross drilled passage and exits the
air dryer delivery port through the delivery check valve. Note:
the early end cover designs incorporated a vertical delivery
check valve while the newer versions have a horizontal check
valve. Both have the same function, but the components
are not interchangeable. See Figure 7.
PURGE
PURGE CYCLE (refer to Figure 5)
As air brake system pressure reaches the cutout setting of
the governor, the governor unloads the compressor (air
compression is stopped) and the purge cycle of the air dryer
begins. When the governor unloads the compressor, it
pressurizes the compressor unloader mechanism and the
line connecting the governor unloader port to the AD-IP™ air
dryer end cover control port. The purge piston moves in
response to air pressure causing the purge valve to open to
the atmosphere and the turbo cutoff valve to close off the
supply of air from the compressor (this will be further
discussed in the T urbo Cutoff Feature section). Water and
contaminants in the end cover sump are expelled
immediately when the purge valve opens. Also, air which
was flowing through the desiccant cartridge changes direction
and begins to flow toward the open purge valve. Liquid oil
and solid contaminants collected by the oil separator are
removed by air flowing from the purge volume through the
desiccant drying bed to the open purge valve.
VALVE
DELIVERY
CHECK VALVE
(OLD STYLE
SHOWN)
DISCHARGE
PORT
Dry air flowing through the center of the desiccant cartridge
bolt also flows out the cross drilled purge orifice and into the
purge volume.
The air dryer will remain in the charge cycle until the air
brake system pressure builds to the governor cutout setting.
The initial purge and desiccant cartridge decompression lasts
only a few seconds and is evidenced by an audible burst of
air at the AD-IP™ air dryer exhaust. No purging of air should
occur after 30 seconds.
3
PURGE
CONTROL
LINE
PURGE
ORIFICE
CONTROL
PORT
OIL
SEPARATOR
SUPPLY
PORT
DESICCANT
BED
PURGE
VOLUME
GOVERNOR
COMPRESSOR
FIGURE 5 - AD-IP™ INTEGRAL PURGE AIR DRYER PURGE CYCLE
ENGINE
TURBO
TURBO
CUTOFF
VALVE
EXHAUST
The actual reactivation of the desiccant drying bed begins
as dry air flows from the purge volume through the purge
PURGE
VOLUME
orifice in the desiccant cartridge bolt, then through the center
of the bolt and into the desiccant bed. Pressurized air from
the purge volume expands after passing through the purge
orifice; its pressure is lowered and its volume increased.
CONTROL
PORT
The flow of dry air through the drying bed reactivates the
desiccant material by removing the water vapor adhering to
it. Generally 30 seconds are required for the entire purge
SUPPLY
PORT
volume of a standard AD-IP™ air dryer to flow through the
desiccant drying bed.
The delivery check valve assembly prevents air pressure in
TURBO
CUTOFF
VALVE
PURGE
VALVE
FIGURE 6 - AD-IP™ INTEGRAL PURGE AIR DRYER TURBO
CUTOFF
the brake system from returning to the air dryer during the
purge cycle. After the 30 second purge cycle is complete
the desiccant has been reactivated or dried. The air dryer is
ready for the next charge cycle to begin. However the purge
valve will remain open and will not close until air brake
system pressure is reduced and the governor signals the
compressor to charge the system.
PURGE
VALVE
DELIVERY
CHECK VALVE
(OLD STYLE
SHOWN)
DISCHARGE
PORT
TURBO CUTOFF FEATURE (Refer to Figure 6)
The primary function of the turbo cutoff valve is to prevent
loss of engine turbocharger air pressure through the AD-IP
air dryer in systems where the compressor intake is
4
™
DESICCANT
BED
OIL
SEPARATOR
PURGE
ORIFICE
CONTROL
PORT
SUPPLY
PORT
TURBO
CUTOFF
VALVE
PURGE
VALVE
CARTRIDGE
BOLT
CHECK
(BLACK)
DELIVERY
PORT
Old Style End Cover -V ertical Delivery Check V alve
PURGE
VOLUME
VALVE
DESICCANT
CARTRIDGE
CARTRIDGE
SPRING
PIPE PLUG
DELIVERY
PORT
O-RING
BOLT
CHECK VALVE
(WHITE)
New Style End Cover - Horizont al Delivery Check V alve
™
FIGURE 7 - AD-IP
AIR DRYER SECTIONAL VIEW
connected to the engine turbocharger. The turbo cutoff valve
also removes the “puffing” of air out the open purge exhaust
when a naturally aspirated, single cylinder compressor,
equipped with an inlet check valve, is in use.
At the onset of the purge cycle, the downward travel of the
purge piston is stopped when the turbo cutoff valve (tapered
portion of purge piston) contacts its mating metal seat in
the purge valve housing. With the turbo cutoff valve seated
(closed position), air in the compressor discharge line and
AD-IP™ air dryer inlet port cannot enter the air dryer. In this
manner the turbo cutoff effectively maintains turbocharger
boost pressure to the engine.
PREVENTIVE MAINTENANCE
Important: Review the warranty policy before performing
any intrusive maintenance procedures. An extended warranty
may be voided if intrusive maintenance is performed during
this period. Note: It is acceptable for the purge valve to be
maintained as necessary, i.e., the installation of a purge
valve maintenance kit, without voiding the warranty .
Because no two vehicles operate under identical conditions,
maintenance and maintenance intervals will vary . Experience
is a valuable guide in determining the best maintenance
interval for any one particular operation.
Every 900 operating hours, or 25,000 miles or three (3)
months:
1. Check for moisture in the air brake system by opening
reservoirs, drain cocks, or drain valves and checking for
presence of water. If moisture is present, the desiccant
cartridge may require replacement; however, the following
conditions can also cause water accumulation and
should be considered before replacing the desiccant:
A. An outside air source has been used to charge the
system. This air does not pass through the drying
bed.
B. Air usage is exceptionally high and not normal for a
highway vehicle.
This may be due to accessory air demands or some
unusual air requirement that does not allow the compressor to load and unload (compressing and
non-compressing cycle) in a normal fashion. Check
for high air system leakage. If the vehicle vocation
has changed it may be necessary to upgrade the
compressor size. Refer to Appendix A, Table A and
the column entitled Vehicle V ocation.
C. The air dryer has been installed in a system that
has been previously used without an air dryer. The
system will be saturated with moisture and several
weeks of operation may be required to dry it out.
5
Note: A small amount of oil in the system is normal and
should not be considered as a reason to replace the
desiccant cartridge; oil stained desiccant can function
adequately.
™
2. Visually check for physical damage to the AD-IP
air
dryer such as chaffed or broken air and electrical lines
and broken or missing parts.
3. Check mounting bolts for tightness. Re-torque to
270- 385 in.lbs.
4. Perform the Operation & Leakage Tests listed in this
publication.
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.
D. Location of the air dryer is too close to the air com-
pressor. Refer to “Locating AD-IP™ Air Dryer On
Vehicle” section and Appendix A, Table A, column 2
for discharge line length.
E. In areas where more than a 30 degree range of tem-
perature occurs in one day , small amounts of water
can temporarily accumulate in the air brake system
due to condensation. Under these conditions, the
presence of small amounts of moisture is normal
and should not be considered as an indication that
the dryer is not preforming properly .
HEATER &
THERMOSTAT
CONNECTOR
LOCKING LATCH
(MUST BE INSERTED UNTIL IT
SNAPS OVER THE MATING
CONNECTOR ON AD-IP
SIDE VIEW
TOP VIEW
A two lead wire harness with attached weather resistant connector is
supplied with all replacement and retrofit AD-IP
two leads is connected to the engine “kill switch” or ignition while the
other must be connected to a good vehicle ground. A fuse is installed
in the lead carrying vehicle power; install a 10 amp fuse for 12 volt
heaters and a 5 amp fuse for the 24 volt heater.
Use 14 AWG wire if it is necessary to lengthen the wire harness leads.
Make certain all splices are weatherproofed. Tie wrap or support all
electrical wires leading to the AD-IP
™
air dryer.
AD-IP™ AIR
DRYER END
COVER
™
AIR DRYER
WEATHERPROOF
ACCORDIAN
SEAL
™
air dryers. One of the
OPERATION & LEAKAGE TESTS
1. Install a pressure gauge in the #1 reservoir . Check all
lines and fittings leading to and from the air dryer for
leakage and integrity . T est the delivery port check valve
assembly by building the air system to governor cutout
and observing a test air gauge installed in the #1 reservoir .
Note the pressure on the air gauge after governor cutout
pressure is reached, a rapid loss of pressure could
indicate a failed delivery port check valve. This can be
confirmed by shutting the engine off, draining system
pressure to a point below governor cutin (usually not
less than 95 psi), draining residual air pressure in the
compressor discharge line. Remove the discharge line
at the supply port of the dryer, and use soapy water to
determine if air is flowing out of the supply port. Make
sure there is no air pressure at the control port, by
removing the line from the control port to the governor
UNL port. The reservoir needs to have a least 50 PSIG
for this test. If a 1” bubble forms within one second, the
delivery check valve should be repaired. Remove the
test gauge before returning the vehicle to service.
FIGURE 8 - AD-IP™ AIR DRYER HEATER AND
THERMOSTAT CONNECTOR
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 exhaust port
and observe that leakage does not exceed a 1” bubble
in 1 second. If the leakage exceeds the maximum
specified, repair the purge valve assembly .
3. Close all reservoir drain cocks. Build up system pressure
to governor cutout and note that AD-IP
™
air 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-IP™ air dryer purge.
4. Check the operation of the end cover heater and
thermostat assembly during cold weather operation as
follows:
6
A. Electric Power to the Dryer
With the ignition or engine kill switch in the ON position, check for voltage to the heater and thermostat
assembly using a voltmeter or test light. Unplug the
electrical connector at the air dryer and place the
test leads on each of the pins of the connector with
the locking latch. If there is no voltage, 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
Note: These tests are not required except in cold weather
operation.
Turn off the ignition switch and cool the thermostat
and heater assembly to below 35 degrees Fahren-
heit. Using an ohmmeter, check the resistance
between the electrical pins in the air dryer connec-
tor half. The resistance should be 1.5 to 3.0 ohms
for the 12 volt heater assembly and 6.0 to 9.0 ohms
for the 24 volt heater assembly .
Warm the thermostat and heater assembly to over
90 degrees Fahrenheit and again check the resis-
tance. The resistance should exceed 1000 ohms. If
the resistance values obtained are within the stated
limits, the thermostat and heater assembly is oper-
ating properly . If the resistance values obtained are
outside the stated limits, replace the heater and ther-
mostat assembly.
REBUILDING THE AD-IP™ AIR DRYER
GENERAL
109498 .............................................. CARTRIDGE BOLT KIT
Contains a replacement desiccant cartridge bolt and related
o-rings.
5003547 ............. PURGE VAL VE HOUSING MAINTENANCE KIT
This kit contains the parts necessary to rebuild the purge
valve housing.
800404 ............................. PURGE VAL VE REPLACEMENT KIT
This kit contains the parts necessary to replace the purge
valve.
5018313 ............................PURGE VAL VE MAINTENANCE KIT
This kit contains the parts necessary to replace and
relubricate the purge valve quad-ring and o-rings.
065626 .... SERVICE NEW PURGE VALVE HOUSING ASSEMBLY
Contains a service new assembly and related components
to accomplish replacement.
109494 .............. DELIVERY CHECK VAL VE MAINTENANCE KIT
This kit contains the parts necessary to replace the delivery
port check valve.
109495 ............................. 12V HEATER & THERMOST A T KIT
109496 ............................. 24V HEATER & THERMOST A T KIT
Each contains a replacement heater and thermostat
assembly and related components required for replacement.
GENERAL SAFETY GUIDELINES
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.
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-IP™ air dryer has been designed so that any of the
following maintenance kits can be installed without removing
the air dryer from the vehicle.
MAINTENANCE KITS A V AILABLE:
065624 ...............SERVICE NEW DESICCANT CARTRIDGE KIT
This kit contains the parts necessary to change the
desiccant cartridge only .
109493 ........REMANUF ACTURED DESICCANT CARTRIDGE KIT
This kit contains the parts necessary to change the
desiccant cartridge only .
5001247 ....................................... MOUNTING BRACKET KIT
This kit contains the upper and lower brackets as well as
the necessary hardware items to mount them.
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.
3. Do not attempt to install, remove, disassemble or
assemble a component until you have read and
thoroughly understand the recommended
procedures. Use only the proper tools and observe
all precautions pertaining to use of those tools.
4. If the work is being performed on the vehicle’s air
brake system, or any auxiliary pressurized air
systems, make certain to drain the air pressure from
7
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-IP™ AIR 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-IP
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-IP™ air 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 (1 1) 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).
™
air dryer is being undertaken.
8
8. Vertical check valve models: Remove the retaining
ring (25) that secures the delivery check valve assembly
in the end cover (6). Remove and separate the perforated
plate (26), spring (27), check valve body (28) and o-ring
(29).
9. Horizontal check valve models: Remove delivery
check valve plug (34) that secures the check valve
assembly in the end cover (6). Remove the spring (35),
check valve (36) and o-ring (2).
10. Remove the retaining ring (30) that secures the heater
and thermostat assembly (31) in the end cover (6). Gently
pull the heater and thermostat (31) out of the end cover
(6) and remove the o-ring (32).
1 1. Using a 9/16” wrench, remove the safety valve assembly
(33) from the end cover (6).
CLEANING & INSPECTION
1. Using mineral spirits or an equivalent solvent, clean and
thoroughly dry all metal parts except the desiccant
cartridge.
2. Inspect the interior and exterior of all metal parts that
will be reused for severe corrosion, pitting and cracks.
Superficial corrosion and or pitting on the exterior portion
of the end cover is acceptable.
3. Inspect the bores of both the end cover and the purge
valve housing for deep scuffing or gouges.
4. Make certain that all purge valve housing and end cover
passages are open and free of obstructions.
5. Inspect the pipe threads in the end cover. Make cert ain
they are clean and free of thread sealant.
6. Inspect the purge valve housing bore and seats for
excessive wear and scuffing.
7. Inspect the purge valve piston seat for excessive wear.
8. Make certain that the purge orifice in the cartridge bolt
is open and free of obstructions.
9. Inspect all air line fittings for corrosion. Clean all old
thread sealant from the pipe threads.
10.All o-rings removed should be discarded and replaced
with new o-rings provided in appropriate kit(s).
ASSEMBLY
Prior to assembly , coat all o-rings, o-ring grooves, and bores
with a generous amount of silicone grease. (Refer to Figures
9 and 10 during assembly unless otherwise advised.)
1. Install the quad ring (21) in its groove on the O.D. of the
purge piston (20). Place the return spring (22) in the
bore of the purge valve housing (19), then insert the purge
piston (20) into the I.D. of the spring (22).
2. Install and center the exhaust diaphragm (17) over the
shoulder bolt (16) making certain that the diaphragm ID
is over the bolt shoulder. Then install the purge valve
(18) on the shoulder bolt making certain its metal support
side is against the diaphragm (17).
3. Push the purge piston (20) into the housing (19) until it
bottoms and insert a large blade screw driver in the
piston’s slotted head. While depressing the purge piston
with the screw driver, install the shoulder bolt (16) with
exhaust diaphragm (17) and purge valve (18) in the piston.
T orque the shoulder bolt (16) to between 60-80 in. lbs.
4. Install the two o-rings (23 & 24) on the purge valve housing
(19) placing each in its appropriate location. DLU models
do not contain o-ring (23). Install the assembled purge
valve housing in the end cover (6) while making certain
the purge valve housing is fully seated against the end
cover. Secure the purge valve housing in the end cover
using the retaining ring (14). Make certain the retaining
ring is fully seated in its groove in the end cover (6).
5. Using a 9/16” wrench, install the safety valve assembly
(33) into the end cover (6).
6. Vertical check valve models: Inst all the o-ring (29) on
the check valve body (28) and push the o-ring down,
over the 3 guide lands until it is in the o-ring groove of
the check valve body (28). Install the check valve spring
(27) on the check valve body so that the small coils of
the spring slip over the check valve body. Install the
assembled check valve body , o-ring, and spring (27, 28
& 29) in the end cover (6) so that the o-ring rests on its
seat in the end cover (6) and the spring is visible. Install
the perforated plate (26), in the end cover (6) and secure
the check valve assembly using the retaining ring (25).
Make certain the retaining ring is fully seated in its groove
in the end cover (6).
7. Horizontal check valve models: Install o-ring (2) onto
check valve (36). Place the check valve in the delivery
check valve port of the end cover (6). Install the spring
(35) over the delivery check valve (36) and secure with
the delivery check valve plug (34).
8. Install the o-ring (32) on the heater and thermostat
assembly (31). Af ter making certain the sponge rubber
cushion is positioned between the connector body and
thermostat, gently push the heater and thermostat
assembly (31) into the end cover (6), making certain
the heating element enters the small diameter bore in
the larger heater and thermostat bore in the end cover
(6). Secure the heater and thermostat assembly in the
body using the retaining ring (30). Make certain the
retaining ring is fully seated in its groove in the end cover
(6).
9. Install both o-rings (12 & 13) on the desiccant cartridge
bolt (10) and using a twisting motion, insert the
assembled desiccant cartridge bolt in the end cover (6).
9
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