Bendix® Dryer Reservoir Module with AD-IS® Air Dryer
SD-98-9808
INTEGRATED
PURGE RESERVOIR
SECONDARY
RESERVOIR
AD-IS® AIR DRYER PART NUMBER STAMPED HERE
GOVERNOR
MOUNTING
DESCRIPTION
The function of the dryer reservoir module (DRM™) is to
provide heavy vehicles with an integrated vehicle air dryer,
secondary reservoir, purge reservoir , governor and a number
of the charging valve components in a module. The DRM
dryer module model covered in this Service Data Sheet is
the first to be released, see updates to this Service Data
Sheet for other models.
DESICCANT
CARTRIDGE
BOLTS (3)
AUXILIARY
DELIVERY PORTS
(5)
SAFETY VALVE
®
AD-IS
Air Dryer
PRESSURE PROTECTION
VALVES (4)
FIGURE 1 - DRYER RESERVOIR MODULE
HEATER/
THERMOSTAT
The air dryer consists of a “spin on” desiccant cartridge
secured to a base assembly.
The base assembly contains a delivery check valve
™
assembly , safety valve, heater and thermostat assembly ,
pressure protection valves, threaded air connections and
the purge valve assembly .
The DRM™ dryer module includes an integrated solution air
dryer (AD-IS®), a reservoir (including a separate purge
reservoir section) a governor and four pressure protection
valves. These have been designed as an integrated air supply
system.
The function of the AD-IS® 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.
The function of the pressure protection valves is to both
control the order in which the components receive air from
the AD-IS® air dryer, and also to protect each reservoir from
a pressure loss in the other reservoir or a pressure loss in
an air accessory.
Air
Connection Function/Connection No.
Port ID
1
IN
21
PRI
22
AUX 1
23
AUX 2
Inlet Port (air in). 1
Delivery Port out (to Primary reservoir) 1
Auxiliary Delivery Port (air out). 4
Auxiliary Delivery Port (air out). 1
UNL Unloader Control Air (D-2A™ Governor) 2
RES Common Reservoir Pressure (D-2A™ Governor) 2
EXH Governor Exhaust 1
TABLE 1 - DRM™ DRYER MODULE AIR CONNECTIONS
1
DESICCANT
BED
OIL
SEPARATOR
GOVERNOR
UNLOADER
PORT
INLET
PORT
(IN)
DELIVERY
CHECK
VALVE
(OPEN)
CONTROL
CHANNEL
TURBO
CUTOFF
VALVE
(OPEN)
PURGE
PURGE
VALVE
(CLOSED)
SEE
NOTE 1
ENGINE
TURBO
COMPRESSOR
SAFETY
VALVE
A
PRIMARY
PORT
(PRI)
PRIMARY
RESERVOIR
PRESSURE PROTECTION
VALVES
CB
AUXILIARY PORTS
(TO ACCESSORIES)
PURGE
ORIFICE
D
PURGE
RESERVOIR
DRAIN VALVE
PURGE
RESERVOIR
SECONDARY
RESERVOIR
Note 1:
The AD-IS® air dryer purge piston has a
purge control channel drain. This allows
any condensation in this area to flow
past a diaphragm in the top of the purge
piston and out through a channel in the
middle of the central bolt of the purge
assembly to be drained. During the
purge cycle this drain is closed.
FIGURE 2 - AD-IS® AIR DRYER CHARGE CYCLE. DIAGRAM SHOWS PRESSURE PROTECTION VALVES A AND B OPEN, C & D CLOSED.
The removable purge valve assembly incorporates the purge
valve mechanism and a turbocharger cutoff feature that is
reservoir, secondary reservoir and accessories, and control
the compressor/dryer charge cycle.
designed to prevent loss of engine “turbo” boost pressure
during the purge cycle of the AD-IS® air dryer. For ease of
serviceability , all replaceable assemblies can be replaced
without removal of the air dryer from its mounting on the
vehicle. Refer to Preventive Maintenance section.
AIR DRYER OPERATION: GENERAL
The AD-IS® air dryer alternates between two operational
modes or “cycles” during operation: the Charge Cycle and
the Purge Cycle. The following descriptions are separated
into these “cycles” of operation.
DRM™ DRYER MODULE OPERATION:
GENERAL
(Refer to Figure 2)
The DRM™ dryer module is designed to receive compressed
air from the vehicle air compressor, clean and dry the air
using the AD-IS® air dryer, deliver air to the vehicle’ s primary
2
CHARGE CYCLE (Refer to Figure 2)
When the compressor is loaded (compressing air)
compressed air, along with oil, oil vapor, water and water
GOVERNOR
UNLOADER
PORT
DELIVERY
CHECK
VALVE
(CLOSED)
DESICCANT
BED
OIL
SEPARATOR
PURGE
ORIFICE
PURGE
RESERVOIR
INLET
PORT
(IN)
CONTROL
CHANNEL
TURBO
CUTOFF
VALVE
(CLOSED)
PURGE
EXHAUST
PURGE
VALVE
(OPEN)
COMPRESSOR
ENGINE
TURBO
SAFETY
VALVE
PRESSURE PROTECTION
VALVES
A
PRIMARY
PORT
(PRI)
D
CB
AUXILIARY PORTS
(TO ACCESSORIES)
PRIMARY
RESERVOIR
SECONDARY
RESERVOIR
PURGE
RESERVOIR
DRAIN VALVE
GOVERNOR SIGNALS AIR
COMPRESSOR TO SUSPEND
COMPRESSED AIR SUPPLY
TO AD-IS
®
AIR DRYER
FIGURE 3 - AD-IS® AIR DRYER PURGE CYCLE.
vapor flows through the compressor discharge line to the
inlet (1 IN) port of the air dryer body .
As air travels through the AD-IS® air dryer, it s temperature
falls, causing some of the contaminants to condense and
drop to the bottom of the air dryer purge valve assembly,
ready to be expelled at the next purge cycle. The air then
flows into the desiccant cartridge, where it flows through an
oil separator which removes liquid oil and solid contaminants.
Air then flows into the desiccant drying bed and becomes
progressively drier as water vapor adheres to the desiccant
material in a process known as “ADSORPTION.”
Dry air exits the desiccant cartridge through the center of
the base assembly . The air then flows to the delivery check
valve and also through an orifice into the purge reservoir.
The delivery check valve opens, supplying air to the pressure
protection valves (A) and (B), the safety valve, and also to
the reservoir port of the attached governor . The purge reservoir
fills, storing air that will be used to reactivate the desiccant
during the purge cycle.
When the air pressure reaches approximately 103 p.s.i.,
the first pressure protection valve (A) will open and air will
be supplied to the primary reservoir. When the air pressure
in the primary reservoir reaches approximately 109 p.s.i.,
3
the second pressure protection valve (B) opens and air will
be supplied to the secondary reservoir and to the accessory
pressure protection valves (C & D). (Note: there is no
external air hose feeding the secondary reservoir, instead
air is supplied by a connector passing through the bulkhead
of the purge reservoir section of the reservoir.) When the air
pressure in the secondary reservoir reaches approximately
55 p.s.i. and 85 p.s.i. respectively, the two remaining
pressure protection valves (C & D) will open and supply air
to the vehicle accessories.
The air dryer will remain in the charge cycle until the air
brake system pressure builds to the governor cutout setting
of approximately 130 p.s.i.
PURGE CYCLE (Refer to Figure 3.)
When air brake system pressure reaches the cutout setting
of the governor, the governor unloads the compressor and
the purge cycle of the air dryer begins.
The governor unloads the compressor by allowing air
pressure to fill the line leading to the compressor unloader
mechanism - causing the delivery of compressed air to
the AD-IS® air dryer to be suspended.
Similarly, the governor also supplies air pressure to the
AD-IS® air dryer purge control channel. The AD-IS® air dryer
purge piston moves down in response to this 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 Turbo
Cutoff Feature section). Water and contaminants which
have collected in the purge valve base 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. Oil and
solid contaminants collected by the oil separator are removed
by air flowing from the purge reservoir through the desiccant
drying bed to the open purge valve.
The initial purge and desiccant cartridge decompression
lasts only a few seconds and is evidenced by an audible
burst of air at the AD-IS® air dryer exhaust.
The actual reactivation of the desiccant drying bed begins
as dry air from the purge reservoir flows through the purge
orifice into the desiccant bed. Pressurized air from the
purge reservoir expands after passing through the purge
orifice; its pressure is lowered and its volume increased.
The flow of dry air through the drying bed reactivates the
desiccant material by removing the water vapor adhering
to it. Approximately 30 seconds are required for the entire
contents of the purge reservoir of a standard AD-IS® air dryer
to flow through the desiccant drying bed.
The delivery check valve assembly prevents air pressure in
the brake system from returning to the air dryer during the
purge cycle. Af ter the purge cycle is complete, the air dryer
is ready for the next charge cycle to begin.
4
TURBO CUTOFF FEATURE (Refer to Figure 3.)
The primary function of the turbo cutoff valve is to prevent
loss of engine turbocharger air pressure through the
®
AD-IS
air dryer in systems where the compressor intake
is connected to the engine turbocharger.
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-IS
®
air dryer inlet port cannot enter the air dryer.
In this manner the turbo cutoff effectively maintains turbo
charger 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.
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
reservoir 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.
This may be due to high air system leakage.
C. In areas where more than a 30 degree range of
temperature 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.
Note: A small amount of oil in the system is normal and
should not be considered as a reason to replace the
desiccant cartridge. Some oil at the dryer exhaust is normal.
2. Visually check for physical damage such as chaffed or
broken air and electrical lines and broken or missing
parts.
3. Check mounting bolts for tightness. See Figure 1.
Re-torque to 360-420 inch pounds.
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.
OPERATION & LEAKAGE TESTS (ALSO SEE
VIDEO BW2327)
1. Check all lines and fittings leading to and from the air
dryer for leakage and integrity. Repair any leaks found.
2. Build up system pressure to governor cutout and note
that the AD-IS® air dryer purges with an audible escape
of air. W atch the system pressure and note the pressure
fall-off for a ten minute period. If pressure drop exceeds,
for a single vehicle - 1 psi/minute from either service
reservoir; or for tractor trailer - 3 psi/minute from either
service reservoir, inspect the vehicle air systems for
sources of leakage and repair them. Refer to section
entitled Troubleshooting, Symptoms 1 and 4.
3. Check for excessive leakage around the purge valve
with the compressor in the 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, refer to section entitled Troubleshooting,
Symptom 4.
4. Build up system pressure to governor cutout and note
that the AD-IS® air dryer purges with an audible burst of
air, followed immediately by approximately 30 seconds
of air flowing out of the purge valve. “Fan” the service
brakes to reduce system air pressure to governor cutin. Note that the system once again builds to full pressure
and is followed by an AD-IS® air dryer purge. If system
does not follow this pattern, refer to section entitled
Troubleshooting, Symptoms 5 and 6.
5. 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 RUN
position, check for voltage to the heater and
thermostat assembly using a voltmeter or testlight.
Unplug the electrical connector at the air dryer and
place the test leads on each of the connections of
the female connector on the vehicle power lead. 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.
HEATER & THERMOSTAT
CONNECTOR
FIGURE 4 - AD-IS® AIR DRYER HEATER AND
THERMOSTAT CONNECTOR
B. Thermostat and Heater Operation
Note: These tests are not possible except in cold
weather operation.
Turn off the ignition switch and cool the thermostat and
heater assembly to below 40 degrees Fahrenheit.
Using an ohmmeter, check the resistance between the
electrical pins in the air dryer connector 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
approximately 90 degrees Fahrenheit and again check
the resistance. The resistance should exceed 1000
ohms. 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, replace the heater and
thermostat assembly.
6. Pressure protection valves. Observe the pressure gauges
of the vehicle as system pressure builds from zero. The
primary gauge should rise until it reaches approximately
109 psi (±5 psi), then level off (or a momentary slight
fall) as the second pressure protection valve opens
supplying the secondary reservoir. When the secondary
pressure gauge passes through approximately 55 (±5
psi) and then 85 psi (±5 psi) there should be an associated
leveling off (or momentary slight fall) of pressure as the
third and fourth pressure protection valves open. Finally
both the primary and secondary gauges should reach
their full pressure of approximately 130 psi (±5 psi).
If the AD-IS® air dryer does not perform within the
pressure ranges as described above recheck using
gauges known to be accurate. If the readings remain
outside of the ranges outlined above, replace the
AD-IS® air dryer. NOTE: There are no kits available for
5
the servicing of the pressure protection valves.
WARNING: Do not attempt to adjust or service the
pressure protection valves - incorrect pressure
protection valve settings can result in automatic
application of the vehicle spring brakes without prior
warning.
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.
REBUILDING THE AD-IS® AIR DRYER
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.
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.
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-IS
AIR DRYER
GOVERNORS
ARE NON-
ADJUST ABLE AND
FEATURE A
BREA THER V AL VE
IN THIS PORT
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
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.
6
PRESSURE
PROTECTION
®
FIGURE 5 - PRESSURE PROTECTION VALVE LOCATIONS
VALVE
LOCATIONS
WARNING:
DO NOT ATTEMPT TO ADJUST OR
SERVICE THE PRESSURE PROTECTION
VALVES. INCORRECT PRESSURE
PROTECTION VALVE SETTINGS CAN
RESULT IN AUTOMATIC APPLICATION OF
VEHICLE SPRING BRAKES WITHOUT
PRIOR WARNING.
LOCK TABS
SPLASH
SHIELD
BRACKET
FIGURE 6 - SPLASH SHIELD BRACKET AND COVER - (EXPLODED VIEW)
SPLASH
SHIELD
COVER
GENERAL
When rebuilding or replacing components of the air dryer
use only genuine Bendix parts. For ease in servicing, the
AD-IS® air dryer has been designed so that any of the
following maintenance kits can be installed without removing
the air dryer from the vehicle.
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).
MAINTENANCE KITS AVAILABLE:
• Service New Desiccant Cartridge Kit: This kit contains
the parts necessary to change the desiccant cartridge
only.
• Delivery Check V alve Maintenance Kit: This kit contains
the parts necessary to replace the delivery check valve.
• Governor/Delivery Check Valve Kit: This kit contains
the parts necessary to replace both the governor and
delivery check valve.
• 12 volt or 24 volt Heater and Thermostat Kits: Contains
a replacement heater and thermostat assembly and
related components required for replacement.
• Purge V alve Housing Maintenance Kit: This kit contains
the parts necessary to rebuild the purge valve subassembly.
• Service New Purge V alve Housing Assembly: Contains
a service new assembly and related components to
change the purge valve sub-assembly.
• Pressure Protection V alve Boot Replacement.
• AD-IS® Air Dryer Replacement: Replaces the complete
air dryer assembly. Includes air dryer assembly and
governor.
• AD-IS® Air Dryer S plash Shield Replacement Kit.
• Purge Reservoir Drain V alve: Replaces the drain valve
on the purge reservoir.
SEE CATALOG PAGE 98-A-1 FOR FULL LIST OF
MAINTENANCE KITS A V AILABLE.
NOTE: There is no kit available for the servicing of the
pressure protection valves (See Figure 5). Do not attempt
to adjust or service the pressure protection valves - these
are not service items.
TESTING THE AD-IS® AIR DRYER
Before placing the vehicle in service, perform the following
tests.
1. Close all reservoir drain valves.
2. Build up system pressure to governor cutout and note
that the AD-IS® air dryer purges with an audible burst of
air, followed immediately by approximately 30 seconds
of air flowing out of the purge valve.
7
3. “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 a purge at the
AD-IS® air dryer exhaust.
4. It is recommended that the total air system be tested for
leakage to assure that the AD-IS® air dryer will not cycle
excessively.
See Bendix publication BW-5057 “Air Brake Handbook.”
BRAKING SYSTEM PROTECTION
The DRM™ dryer module allows the system to maintain
one brake circuit up to about 100 psi even after a pressure
loss in the other brake circuit. This allows a vehicle to be
moved (in an emergency), but with reduced braking capacity .
Compare this to a conventional system where a loss of
pressure in one service tank leaves the vehicle with a limited
number of reduced braking capacity applications before the
parking brakes automatically apply and stay on.
ROADSIDE INSPECTION
In the event of a roadside inspection the system behavior
will be as follows: When the system is charged to governor
cut out, and then one reservoir drain valve is opened,
initially both reservoir gauges will fall, however, the AD-IS
air dryer's primary and secondary pressure protection valves
will close at pressures above 70 psi, protecting the remaining
brake circuit from further loss of pressure.
TEMPORARY AIR DRYER BYPASS
completed. At end of each working day, park vehicle and
slowly drain pressure through the drain valves – leave open
to the atmosphere, for several hours if possible. When
repairs are carried out, be sure to check that all reservoirs
(including the purge reservoir incorporated into the secondary
reservoir) are emptied of all contaminants.
If after bypassing the dryer reservoir module the system
pressure still does not build, use the following procedure to
remove, clean and reinstall the delivery check valve.
DELIVERY CHECK V AL VE CLEANING PROCEDURE
(Note: This is only required if system pressure does not
build after temporary bypass is completed.)
See Figure 7 throughout this procedure. Depressurize
the air brake system following the general safety
precautions outlined elsewhere in this document.
This procedure does not require removal of the AD-IS® air
dryer from the vehicle.
1. Remove line from governor and mark for easy
reinstallation.
2. Remove bolts attaching the governor to the AD-IS® air
dryer and retain for reassembly .
®
3. Remove governor and the adapter’s o-ring.
4. The spring/delivery check valve can now be removed.
(Note: The spring/delivery check valve may be a
previous design. See Figure 7.)
5. Remove o-ring from check valve body.
To temporarily bypass the air dryer, the following procedure
needs to be followed.
Follow the Maintenance Precautions outlined elsewhere in
this document.
Make sure that all residual pressure has been released,
then remove the air supply line from the compressor to
the inlet port (1 IN). Remove the safety valve from the
AD-IS® air dryer body (see Figure 1 for location) and install
a T-fitting into the port. Using any adapters necessary,
re-install the safety valve in one of the branches of the
T-fitting. Using any adapters necessary , install the air supply
line into the remaining T-fitting port. After testing the
T-fitting for any air leakage, using a soap solution after
charging system pressure (a 1” bubble in 10 seconds is
acceptable), the vehicle may be returned to temporary
service.
Note: This is a temporary bypass of the air dryer, and
full repair of the unit must be carried out at the earliest
opportunity. With the air dryer removed from the system,
contaminants will be entering the air system: reservoirs
will need to be manually drained daily until the repairs are
CLEANING & INSPECTION
1. Use a suitable solvent to clean all metal parts, and use
a cotton swab to clean the bore (Note: Do not use
abrasives or tools to clean the bore: any scratches
caused may necessitate replacing the AD-IS® air dryer.)
Superficial external corrosion and/or pitting is
acceptable.
2. Clean the o-rings with a clean dry cloth. Do not use
solvents.
3. Inspect for physical damage to the bore and the check
valve seat. If the bore is damaged (by scratches etc.
that would prevent delivery check valve from seating),
replace the AD-IS® air dryer.
4. Inspect the delivery check valve, o-rings, etc. for wear or
damage. Replace if necessary using the check valve
replacement kit available at authorized Bendix parts
outlets.
5. Inspect all air line fittings for corrosion and replace as
necessary.
8
SMALL
O-RING
CHECK VALVE
BODY
SPRING
FIGURE 7 - AD-IS® AIR DRYER DELIVERY CHECK VALVE
Early models include a different style check
valve and spring
GOVERNOR GASKET
(SPECIAL GASKET,
SEE NOTE 6 ON
PREVIOUS PAGE)
LARGE
O-RING
ORIGINAL STYLE
CHECK VALVE AND
SPRING
GOVERNOR
(NON-ADJUSTABLE,
130 PSI CUT-OUT)
BOLTS
ADAPTER
ASSEMBL Y
1. Lubricate the smaller o-ring and check valve body with
barium or silicon grease.
2. Install this o-ring on the check valve body by sliding the
o-ring over the set of 4 tapered guide lands. The
o-ring groove holds the o-ring in its correct location.
3. At the other end of the check valve body , the spring is
installed over the set of 4 straight guide lands. When
the spring has been pushed to the correct location, the
check valve body is designed to hold the end of the spring
in position - be sure that the spring is not loose before
continuing with this installation.
4. Install the assembled check valve body/o-ring/spring in
the delivery port so that the o-ring rests on its seat and
the free end of the spring is visible.
5. Grease the adapter and the remaining larger o-ring and
install it onto the fitting.
6. Position gasket, insert bolts through the governor and
tighten (to 125 in-lbs). (Note: Do not replace with a
standard compressor/governor gasket.)
7. Reattach line to the governor.
8. Before placing vehicle back into service, check to see
that the system pressure now builds to full operational
pressure.
9
DRM™/AD-IS® AIR DRYER TROUBLESHOOTING CHART
SYMPTOMS
1. Dryer is constantly
“cycling” or purging.
CAUSE
A. Excessive system
leakage.
B. Defective delivery check
valve.
REMEDY
A. Test for excessive system leakage.
Allowable leakage observed at dash gauge:
Single vehicle - 1 psi/minute.
Tractor trailer - 3 psi/minute.
Using soap solution, test vehicle for leakage at
fittings, drain valves and system valves. Repair
or replace as necessary.
B. Build system pressure to governor cut-out. Wait
1 minute for completion of purge cycle. Using
soap solution at exhaust of purge valve, leakage
should not exceed a 1" bubble in less than 5
seconds.
If a rapid loss of pressure is found, the following
procedure will determine if the delivery check
valve is malfunctioning:
Build system pressure to governor cut-out and allow
a full minute for the normal dryer purge cycle to
empty the purge reservoir. Switch off the engine
and “fan” the brakes so that the system pressure
reaches governor cut-in. The purge valve will return
to its closed position. The purge reservoir has a
drain valve which is opened by moving the center
lever away from its closed position. Open the drain
valve and wait 10 seconds to allow any residual
purge pressure to be released. Release the lever,
closing the drain valve. Carefully remove the air
dryer cartridge using a strap wrench and then test
for air leaking through the center of the threaded
boss by applying a soap solution to the boss.
Replace the delivery check valve if there is
excessive leakage (exceeding a 1" bubble in 5
seconds).
Regrease the seal on the air dryer cartridge before
reinstalling. Be sure the drain valve on the purge
reservoir is not leaking before restoring vehicle to
service.
10
C. Defective governor.
D. Compressor unloader
mechanism leaking
excessively.
C. Check governor at both “cut-in” and “cut-out”
position for (i) proper pressures and (ii)
excessive leakage at fittings and exhaust.
D. Remove air strainer or fitting from compressor
inlet cavity . With compressor unloaded, check
for unloader piston leakage. Slight leakage
permissible.
DRM™/AD-IS® AIR DRYER TROUBLESHOOTING CHART (Continued)
SYMPTOMS
2. Water in vehicle
reservoirs.
CAUSE
A. Maximum air dryer inlet
temperature is
exceeded due to
improper discharge line
length.
B. Air system charged from
outside air source
(outside air not passing
through air dryer).
C. Excessive air usage -
Air dryer not compatible
with vehicle air system
requirement (Improper
air dryer/vehicle
application).
REMEDY
A. Check for excessive carbon build up in
compressor discharge line. Replace if
required. Make certain that discharge line
length is at least 6 ft. Increase discharge line
length and/or diameter to reduce air dryer inlet
temperature.
B. If system must have outside air fill provision,
outside air should pass through air dryer .
C. Note: The AD-IS® air dryer is not intended for
use on applications with excessive air usage.
The following applications require more dry air
than the AD-IS® air dryer is designed to supply .
Do not use on:
1) City buses.
2) Vehicle combinations with more than 8 braked
axles.
3) City refuse vehicles except those with work
brakes.
4) Concrete mixers.
5) Dump trucks with more than 3 axles.
6) Off-highway/construction vehicles with more
than 7 braked axles.
7) Vehicles with compressor on times in excess
of 20%.
If the vehicle is equipped with high air usage
accessories such as trailer pump-off systems or
central tire inflation, the air for these accessories
must by-pass the dryer .
D. Desiccant requires
replacement.
E. Air by-passes desiccant
cartridge assembly .
F. Air dryer not purging.
G . Purge (air exhaust) time
insufficient due to
excessive system
leakage.
D. Replace desiccant cartridge assembly .
E. If vehicle uses Holset compressor, inspect
feedback check valve for proper installation and
operation.
F . Refer to Symptom 6.
G . Refer to Symptom 1.
11
DRM™/AD-IS® AIR DRYER TROUBLESHOOTING CHART (Continued)
SYMPTOMS CAUSE
3. Safety valve on air dryer
“popping off” or
exhausting air.
4. Constant exhaust of air
at air dryer purge valve
exhaust or unable to
build system pressure.
(Charge mode.)
A. Defective AD-IS® air
dryer delivery check
valve.
B. System pressure too
high (>135 p.s.i.)
C. Excessive pressure
pulsations from
compressor . (Typical
single cylinder type).
D. Safety valve setting too
low (<150 p.s.i.)
A. Air dryer purge valve
leaking excessively .
REMEDY
A. Test to determine if air is p assing through check
valve. Repair or replace. Refer to Symptom 1,
Remedy B.
B. Test with accurate gauge. Replace governor if
necessary.
C. Increase volume in discharge line. This can be
accomplished by adding a 90 cubic inch (or
larger) reservoir between the compressor and the
AD-IS® air dryer.
D. Replace safety valve.
A. With compressor loaded, apply soap solution
on purge valve exhaust, to test for excessive
leakage. Repair or replace purge valve as
necessary.
B. Purge valve frozen open
- faulty heater and
thermostat, wiring,
blown fuse.
C. Defective AD-IS® air
dryer delivery check
valve.
D. Leaking Turbo Cutoff
valve.
E. Defective governor.
F. Leaking purge valve
control piston quad-ring.
B. Refer to paragraph 5 of Operation and Leakage
Tests for heater and thermostat test.
C. Refer to Symptom 1, Remedy B.
D. Repair or replace purge valve assembly .
E. Check governor at both “cut-in” and “cut-out”
position for (i) proper pressures and (ii)
excessive leakage at fittings and exhaust.
F. Repair or replace purge valve assembly.
12
DRM™/AD-IS® AIR DRYER TROUBLESHOOTING CHART (Continued)
SYMPTOMS CAUSE
5. Can not build system
air pressure.
6. Air dryer does not purge
or exhaust air.
A. Kinked or blocked
(plugged) discharge line.
B. Excessive bends in
discharge line (water
collects and freezes).
C. Pressure protection
valve(s) in air dryer will
not open.
D. Refer to Symptom 4.
E. Refer to Symptom 7.
A. Faulty air dryer purge
valve.
B. See Causes, B, E, and
G for Symptom #4.
REMEDY
A. Check to determine if air passes through
discharge line. Check for kinks, bends,
excessive carbon deposits, or ice blockage.
B. Discharge line should be constantly sloping from
compressor to air dryer with as few bends as
possible.
C. Replace air dryer (pressure protection valves are
not serviceable).
D. Refer to Symptom 4, Remedy A.
E. Refer to Symptom 7, Remedies A through D.
A. After determining air reaches purge valve control
port by installing a T -fitting with a pressure
gauge into the governor unloader port, repair
purge valve if necessary .
B. Refer to Symptom 4, Remedies B, E, and G.
Also refer to Symptom 1, Remedy B.
7. Desiccant material
being expelled from air
dryer purge valve
exhaust (may look like
whitish liquid or paste
or small beads.)
8. Unsatisfactory
desiccant life.
9. “Pinging” noise
excessive during
compressor loaded
cycle.
A. Faulty dryer cartridge.
B. Excessive dryer vibration.
A. Excessive system
leakage.
B. Wrong vehicle application
for AD-IS® air dryer.
C. Compressor passing
excessive oil.
A. Single cylinder
compressor with high
pulse cycles.
A. Replace AD-IS® air dryer cartridge and/or
AD-IS® air dryer.
B. Check reservoir mounting for looseness or
damage. Repair mounting and replace cartridge.
A. Refer to Symptom 1, Remedy A.
B. Refer to Symptom 2, Remedy C.
C. Check for proper compressor installation; if
symptoms persist, replace compressor. Refer to
Bendix Advanced Troubleshooting Guide for Air
Brake Compressors (BW1971).
A. A slight “pinging” sound may be heard during
system build up when a single cylinder
compressor is used. If this sound is deemed
objectionable, it can be reduced substantially by
increasing the discharge line volume.
This can be accomplished by adding a 90 cubic
inch reservoir between the compressor and the
AD-IS® air dryer.
13
DRM™/AD-IS® AIR DRYER TROUBLESHOOTING CHART (Continued)
SYMPTOMS CAUSE
10.The air dryer purge
piston cycles rapidly in
the compressor
unloaded (noncompressing) mode.
A. Compressor fails to
“unload”.
REMEDY
A. Check air hose from governor to compressor for
a missing, kinked or restricted line. Install or
repair air hose.
Repair or replace compressor unloader .
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BW1948 © 2007 Bendix Commercial Vehicle Systems LLC All rights reserved. 3/2007 Printed in U.S.A.
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