Air Dryer.pdf

OPERATION AND MAINTENANCE INSTRUCTIONS FOR FAIVELEY TRANSPORT TWIN TOWER AIR DRYER AND FINAL FILTER MODEL NO. 975-120 SERIES

Catalogue No. AD/075 March, 2006

FAIVELEY TRANSPORT INDIA LIMITED POST BOX # 39 HARITA, HOSUR 635 109 TAMILNADU, INDIA Phone Fax Email

: : :

+ 91 (4344) 276761 to 276765 + 91 (4344) 276035, 276786, 276033 [email protected]

REGIONAL OFFICES

Faiveley Transport India Limited B-44/C, Gangotri Enclave Alaknanda, New Delhi 110 019

Faiveley Transport India Limited No. 51, Radhanath Chowdhury Road Satyajit Tower, 5th Floor Kolkata 700 015

Phone : + 91 (11) 26229325 Fax : + 91 (11) 26229329

Phone : + 91 (33) 23295241 Fax : + 91 (33) 23295240

Revision Record

Date

New Version No.

Pages Changed

Reason

April, 2001

1

-

New Publication

August, 2001

2

1

November, 2001

3

16 (previously 20)

February, 2002

4

16 (previously 20)

February, 2002

5

December, 2002

6

97 (previously 113) Various

Correction in Product Configuration table Maintenance Schedule of Muffler changed Maintenance Schedule of Air Dryer revised in line with actual practice. Page 97 (previously 113) revised. a) Product Configuration table revised. b) Equivalent FTIL part nos. provided for all the parts and assemblies. c) Auto Drain Valve kit list added. d) Maintenance kit list tabulated in their respective sheets. e) Fuse kit deleted.

March, 2004

7

Various

Manual Reformatted.

August, 2004

8

Sketches for Operating voltage corrected for both 975-123 & 975-124 models.

March, 2006

9

Various

Manual Reformatted.

Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

Capacity and Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

System description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

Suggested location of Air Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Installation Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

22

Recommended Spares for Maintenance. . . . . . . . . . . . . . . . . . . . . . . .

23

Tools required for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

Desiccant Canister Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

Desiccant Charge Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

Desiccant Compactor Removal and Maintenance . . . . . . . . . . . . . . . . . .

31

Regenerating Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32

Purge Valve Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33

Drain Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

36

Inlet Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

38

Outlet Check Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .

39

Solenoid Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . .

40

Pre-coalescer Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

Timer and Circuit Board Renewal . . . . . . . . . . . . . . . . . . . . . . . . . .

42

Pressure Switch Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43

Humidity Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44

Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45

Final Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46

Troubleshooting guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47

Exclusive Part numbers for ordering reference . . . . . . . . . . . . . . . . . . .

104

Health and Safety

The following points must be considered and appropriate precautions taken when working on this equipment. It should not be taken as an exclusive list of hazards. 1.

This is compressed air device. Compressed air is extremely dangerous if not handled carefully. DO NOT attempt to service, repair or break any connections without first assuring that the entire pressurized device has been vented of all pressure.

2.

High electric voltages are used with the risk of electric shock. Dangerous voltages are exposed once electrical covers are removed. Maintenance should be carried out only by qualified personnel. This device is safe for operation only with the electrical covers in place.

3.

Oils and greases are used which could be a hazard.

4.

Chemical cleaning agents may be used for certain operations, the manufacturers handling procedures must be followed.

5.

This product contains material which may cause temporary eye and possibly skin irritation. Avoid breathing dust and prolonged contact with skin of the desiccant material. Wash thoroughly after handling. Use with adequate ventilation. Contact with moisture (water) can cause rise in temperature which may result in burn.

6.

This manual contains information and warning which must be observed by the user. Failure to adhere to these recommendations could result in mechanical failure, property damage and serious injury or death.

7.

The weight of the dryer is approximately 650 kg and the Final Filter 7 kgs.

FAIVELEY TRANSPORT Twin Tower Air Dryer 1.

Introduction The Faiveley Transport 975-120 series twin tower Air Dryers have been developed especially to suit traction requirements. The dryers remove moisture from the compressed air supply and ensure that only clean dry air reaches all air operated equipment. A supply of clean dry air ensures that all air operated equipment functions more efficiently and that the high maintenance costs associated with contaminated systems are eliminated. The twin tower Air Dryer system includes a pre-coalescer which removes impurities from the compressed air supply, and desiccants (activated alumina) located in the drying towers which remove moisture. After removing moisture, the desiccants regenerate (restore to their original dryness) during the operating cycle, one cycle of which is described in the section Operation .

2.

Capacity and Applications Faiveley Transport Air Dryers are made in a range of sizes in twin tower configuration. The dryer capacities range from 1000 to 5000 lpm free air delivery compressor installations. The 975-123 and 975-124 Dryers are suitable for use on heavy-duty locomotives & EMUs operating in moderate / harsh climates. The table below shows the current 975-120 series product configurations. configurations can be developed for specific customer needs.

Dryer Type

FTIL Part No.

Type

Voltage

975-123 with memory 975-123 with memory

029002700

Ext. Model

029003200

975-124 with memory 975-124

029002800

975-124 with memory 975-124 with memory

029003300

029003100

029003500

Piping interface 1 NPT

Other

Orifice size

Muf fler

Pr. Switch

Mtg Bkt

48-110 V DC

0.11

YES

100 PSI

YES

Ext. Model

48-110 V DC

0.11

YES

100 PSI

YES

1¼ NPT

Std. Model (Shorter version) Std. Model (Shorter version) Std. Model (Shorter version) Std. Model (Shorter version)

48-110 V DC

0.0625

YES

100 PSI

YES

1¼ NPT

48-110 V DC

0.052

YES

75 PSI

YES

1 NPT

48-110V DC

0.052

YES

100 PSI

YES

1 NPT

WAP4 Locos

48-110V DC

0.0625

YES

75 PSI

YES

1¼ NPT

HHP DEMU

Applica-tion Diesel Locos Elec. Locos WAG9, WAP5, GM loco (WDG4 & WDP-4) Elec. Locos WAG7, WCAM3, WCAG1. EMUs, MG, DEMUs, Others

Page 1

Accessories The dryers can be supplied with extra equipment such as mounting bracket, mufflers, end connecting flanges. Two indicators to identify the condition of the desiccant in each tower are fitted on the dryers. Also, the Final Filter is a standard accessory. For the exclusive part numbers which includes Air Dryer, Final Filter, Auto Drain Valve and other accessories refer pages 104 & 105. 3.0

System Description For the purpose of the following explanation, a Pressure Switch with a 100 psi rating is considered as an example. The twin tower Air Filter / Dryer is an air drying system comprising two Air Dryer towers connected by a common inlet manifold with integral pre-coalescer and common outlet manifold. The system also includes an electric timer which controls the system cycle and allows the unit to regenerate only when a predetermined pressure of approximately 6.9 ksi (100 psi) is reached and the compressor or any compressor in the consist, is loaded (pumping). Until such time, both Air Dryer towers allow a maximum flow of air to pass and charge the entire train or system.

4.0

Operation Refer to diagrams attached. Compressed air enters the inlet manifold and flows into the pre-coalescer. It passes through a borosilicate coalescer element comprising four pleated plys which are supported, externally and internally, by two layers of corrugated / perforated stainless steel. The coalescer removes microscopic oil aerosols of one micron or less from the compressed air preventing them from entering the drying towers. Construction of the coalescer filter element is in two layers of pleated borosilicate media supported on both sides by pleated polyester media. The first layer of polyester media serves as a particulate prefilter and helps to evenly distribute the flow of air into the first coalescing layer. The first coalescing layer coalesces the water and oil aerosols into larger droplets. The second coalescing layer completes the coalescing operation while the last layer of polyester media enhances drainage. A desiccant (activated alumina) in the Air Dryer towers then removes water vapour from the compressed air. With the compressor pumping and the predetermined pressure reached (approximately 6.9 ksi, 100 psi) the right hand side dryer tower begins to regenerate while the Solenoid Valve is energized allowing air to pass and to close the right Inlet

Page 2

Check Valve. Simultaneously, the right spring loaded Outlet Check Valve closes. When both Inlet and Outlet Check Valves are closed and the right Air Dryer is isolated, the right sump mounted Purge Valve opens causing a sudden drop in air pressure. The drop in pressure forces the collected impurities from the right Air Dryer tower to atmosphere while the moisture absorbed by the desiccant beads is released to the surface of the beads. A small amount of dry air from the left hand side Air Dryer tower then flows through the regenerating orifice in a reverse direction over and through the right hand side Air Dryer desiccant beads. Moisture, released to the surface of the desiccant beads, is picked up by the dry air and exhausted through the open Purge Valve at a level slightly above atmospheric pressure. In addition, the double seated automatic Drain Valve located at the sump of the pre-coalescer exhausts any collected impurities to atmosphere. While the right hand side dryer tower is in the regenerating phase, the left hand side tower is in the dehydrating phase and is removing moisture from the compressed air passing over and through the desiccant beads on its way to the Main Reservoir. The left Solenoid Valve is de-energised i.e. closed during this operation, the left inlet and Outlet Check Valves are open, and the left sump mounted Purge Valve is closed. Approximately one minute later the operating cycle reverses. The right hand side dryer dehydrates removing moisture as air passes over and through the desiccant beads and on to the Main Reservoir while the left hand side dryer regenerates , purging itself and the desiccant beads of all collected moisture and impurities. As before, the automatic double seated Drain Valve on the pre-coalescer sump exhausts the collected impurities to atmosphere. Non-memory type The drying operation as described above continues as long as the power supply to the dryer is uninterrupted. The cycling and purging will go on even if the Compressor is unloaded and not pumping into the system until the pressure on the inlet side of the first Main Reservoir is depleted to less than the level of rating of the particular Pressure Switch used in the dryer. When the pressure drops down below this rating, the power to the dryer control circuit is cut off and the cycling action of the dryer will stop. When the Compressor begins to pump, the dryer will begin to regenerate in the right side tower from the beginning of the cycle regardless of where it previously stopped. The dryer can be changed to memory type by changing the PCB. Refer to the proposed schematic shown in sketch no. FTIL/AD/0363 where the Compressor and Air Dryer needs to be synchronized when the PCBs are changed form Non memory to memory version working under multiple unit operation. Refer to para 5.7 for more details on the PCB.

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Memory type When the compressor unloads (stops pumping), the electronic timer will de-energise both Solenoid Valves and both dryer towers will return to dehydrating mode. In addition both the Purge Valves as well as the double seated Purge Valve of the precoalescer will remain closed stopping discharge of air from the system. During this stage, any air drawn from air reservoirs upstream of the Air Dryer will be dehydrated. When the compressor is loaded again, the dryer will commence the cycling from the point where it has stopped previously in the same tower. The Faiveley Transport 975-123, 124 series twin tower air filter - dryer system is complete with two individual sump mounted Purge Valves and a double seated sump mounted Drain Valve. 5.0

System Components

5.1

Humidity Indicator A coloured indicator is located at each Outlet Check Valve as a visual aid to monitor the condition of air after passing through each desiccant dryer. Blue indicates dry air. White indicates contaminated air.

5.2

Pre-Coalescer A borosilicate element designed to collect and restrict tiny aerosol contaminants, primarily oil and other contaminants which may prove detrimental to the successful operation of any form of desiccant.

5.3

Filter/Dryer Body The desiccant beads, which extract the moisture from the air, are housed in two aluminum towers with fins on the outside to provide efficient heat transfer. Consequently, internal heat from the compressed air dissipates efficiently.

5.4

Pneumatic Compactor FTIL Air Dryers are provided with pneumatic compactors which provide a constant packing density throughout the period of operation in the Dryer. In comparison, the standard spring loaded compactors provide a decreasing compacting pressure as the spring expands due to attrition of the desiccant beads which is unavoidable. Each desiccant canister contains a pneumatic compactor which is charged with compressed air to maintain a constant mechanical pressure upon a movable disc located in the bottom of the sump cap. Consequently, the alumina remains compact and tight preventing attrition of the desiccant beads. Page 4

5.5

Pressure Switch An integral pressure sensing device is located internally to control the air drying cycle. The Air Dryer cycles only when the pre-determined pressure is reached. If an emergency arises and air pressure drops below the pre-determined level, cycling stops immediately and air flows through both Air Dryers to support the immediate air requirements.

5.6

Final Filter In dryers which use either molecular sieve or bead form of desiccants like activated alumina used in FTIL Dryer, particulate filtration is a necessity since disintegration of the desiccant is an unavoidable phenomena as explained in para 5.4. If the microscopic particulates are allowed to pass through the air stream unfiltered, they may get deposited in critical pneumatic equipment like brake valves causing functional problem in such equipment. FTIL Dryer is provided with a separate unit which removes any dust generated after air has passed through the main dryer system.

5.7

PCB This is an electronic assembly fully potted to prevent arcing due to moisture and also to protect the circuit from induced emf (electro magnetic force). This incorporates a timer with a cycling frequency of 1 minute to energise the Solenoid Valve of each tower. The PCBs from Sl. No. M01001 have been redesigned to work satisfactorily even during incidence of more than the rated voltage levels for short periods of time. The modified PCBs bear FTIL part no. 029201300 only in all the dryer installations changed over to modified design. With the modified design PCB, the fuse provision can be deleted. CAUTION After removing the fuse and related wiring, the hole in the electrical junction box is to be suitably kept plugged to prevent entry of dust and foreign matter into the electrical enclosure.

5.8

Air Dryer Tower Indication Two LED indicators for one each tower are provided in the terminal box cover to indicate the drying tower during cycling. Refer to electrical schematic C-D3301 sheet 1 of 2 for electrical connections.

Page 5

5.9

Auto Drain Valve Kit Auto Drain Valve Kit is recommended to be fitted along with the Air Dryer in service. The kit consists of the following five items: Sl. No.

Part No.

Description

Qty

1

010 0011 00

Auto Drain Valve

1

2

709 0041 00

3/8 BSP Strainer

1

3

029 8120 00

Male Branch Tee

1

4

936 0538 00

Special Adaptor

1

5

002 0200 00

Double Check Valve

1

Page 6

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Page 9

Suggested location of the dryer in the pneumatic system The dryer shall be connected after the first Main Reservoir in case of two Main Reservoirs. Refer sketch in next page. The dryer shall be connected after the second Main Reservoir in case of four Main Reservoirs. Refer sketch in next page. The under frame location exposes the dryer to cooling air flow produced from Locomotive travel. Locating the dryer behind Main Reservoir as said above prevents the dryer from being exposed to the large amounts of liquid which can precipitate in the compressor aftercooler cooling pipe. In addition to this location, there should be an Auto Drain Valve fixed immediately before the Dryer. Absence of this facility may increase the load on the Dryer and may reduce its efficiency. In the EMU s installation, there should be a Reservoir of at least 50 litres immediately after the Dryer to provide the necessary back pressure and volume on the Outlet Check Valve of the Dryer. There should not be any device like Check Valve between the Air Dryer and this Reservoir. It is suggested that the Auto Drain Valve fixed on the MR immediately before the Dryer be actuated by the control pressure from the Dryer itself to ensure a frequent and brief purging of the moisture from the Reservoir. In such installation, the timing chamber provided in the Auto Drain Valves should be removed to facilitate the blow down time as low as 1 sec max. “Precautions to be observed for Dryer installation in the Locomotive” i)

While carrying out the periodic megger tests in the locos, ensure that the Dryer PCB is properly isolated.

ii)

Do not take an earthing connection near the Dryer while carrying out any electric welding on the Locomotive underframe.

iii)

Check the inscription printed on the wires for proper identification of the (+ ve) and (- ve) terminals. The colour code of the wire is not the only identification method.

iv)

In all Locos electrical power supply should be taken for Dryer, probably in such a way that the other inductive loads in the circuit are not applied to the Dryer electrical.

Page 10

v)

In case any electrical work is being carried out in the other auxiliary circuits of the Locomotive with the help of a short supply which might not have a proper voltage regulation, ensure that the Dryer is isolated from such electrical supply.

vi)

Ensure that a Circuit breaker of 1 amp rating is provided in the cab to isolate the Dryer electrically whenever desired as a standard procedure. Ensure the Circuit breaker is clearly identified as dryer isolation .

vii)

It is advisable that the Air Dryers are not kept in idle storage for longer than 20 24 weeks from the date of manufacture. Adopt a First In First Out (FIFO) system of fitment. If a longer storage is unavoidable, ensure the Dryers are cycled for at least a day every fortnight to keep the desiccants in regenerated condition. Close the open port of the Dryer with protective caps when in storage.

viii)

Do not connect 220 / 230 v AC supply to Dryer electrical connections. This will damage the PCB permanently.

ix)

Until installation, do not remove the protection caps from inlet and delivery ports on both the Dryer and Final Filter.

x)

While lifting the Dryer to fix on the mounting bracket in the Locomotive, care must be taken not to damage the Stainless Steel piping nor the aluminium finned castings of the Dryer Tower. Even if the Humidity Indicators are turned white or pinkish during a protracted idle storage, they will turn blue again once the Air Dryer is electrically connected and cycled for a few hours. If the blue colour is not regained, change the Humidity indicators.

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6.0

Maintenance Schedule MAINTENANCE

Inspect Humidity Indicators (ref. trouble shooting guide). Check for proper purging Check for proper cycling

Fortnightly

Check for any external leakage.

4

Replace Mufflers Clean Purge Valves Clean Double Seated Auto Drain Valve Check proper functioning of Timer Circuit Board Check the condition of Desiccant (replace if contaminated)

3 Years

4 4 4

Clean Mufflers

Year

4

Check for Automatic Draining through Double Seated Valve Check for proper functioning for Pressure Switch Inspect Regenerating Orifice operation Check the condition of Precoalescing Element (replace if contaminated) Check the condition of Final Filter Element (replace if contaminated)

SCHEDULE Monthly 6 Months

4 4 4 4 4 4 4 4 4 4

Renew all Rubber Parts

4

Renew Precoalescer Kit

4 4

Renew Final Filter kit Completely overhaul the Air Dryer (ref. Maintenance Manual)

4

Renew the Desiccant Canister Kit

4

Page 22

Recommended Spare Parts list for Air Dryer Parts to be renewed in every three years while overhauling the Air Dryer and Final Filter entirely. Sl. No.

Description of Spares

FTIL Part No.

D&M Part No.

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Kit for Precoalescer * Kit for Final Filter * Kit for regenerating orifice Kit for Inlet Check Valve Kit for Drain Valve Kit for Outlet Check Valve Kit for Purge Valve Kit for Solenoid Valve Kit for Desiccant Compactor Flange & Purge Valve O Rings Dryer Body & Spacer Seats Gasket for Inlet Manifold Body Seal for Outlet Manifold Body Gasket for Electrical Box Gasket for Drain Valve O Ring for Outlet Check Valve Gasket for Burndy Connector

790 0291 65 790 0291 25 790 0291 11 790 0291 35 790 0291 75 790 0291 45 790 0291 85 790 0291 55 790 0292 05 029 7190 00 029 7150 00 029 7180 00 029 7130 00 029 7120 00 029 7200 00 029 7015 00 029 7075 00

RK-AB787-W27B RK-AB787-W40 RK-AB787-W39 RK-AB787-W27A RK-AB787-W28 RK-AB787-W29 RK-AB787-W36 RK-AB787-W37 RK-AB787-W41 AB787-121 AB787-125 AB787-173 AB787-188 AB787-191 AB787-224 AB787-144 AB787-239

Qty / Air Dryer 1 1 1 2 1 2 2 2 2 8 4 1 2 1 1 1 1

Minimum stock to be kept in a shed for a fleet of 25 Air Dryers 8 8 5 10 5 10 10 10 10 64 32 8 16 5 8 8 8

These may be required to be renewed earlier on condition basis and should be examined by experts atleast once a year.

*

Renewable Spare Parts for Air Dryer on condition basis Sl. No 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

*

Description of Spares

FTIL Part No.

D&M Part No.

Qty / Air Dryer 1 1 1 2 1 1 1 1 1 1 2 1 1 2 2

Minimum stock to be kept in a shed for a fleet of 25 Air Dryers 3 3 8 6 3 3 3 3 3 2 10 5 5 15 15

Pressure Switch (100 psi) OR 029 1065 00 AB787-190 Pressure Switch (75 psi) 029 1066 00 Timer Circuit Board (Memory) 029 2013 00 AB787-250 Coil 74 V DC 029 2070 00 AB787-206 Piping Assy (Extended) OR 029 1010 00 AB787-W31 Piping Assy (Smaller) 029 1022 00 AB787-W31B Piping Assy (Extended) OR 029 1015 00 AB787-W32 Piping Assy (Smaller) 029 1018 00 AB787-W32B Piping Assy (Extended) OR 029 1020 00 AB787-W33 Piping Assy (Smaller) 029 1024 00 AB787-W33B Gasket for Outlet Check Valve 029 9040 00 AB787-194 Burndy Connectors (Female) 029 8132 00 Burndy Connectors (Male) 029 8130 00 Kit for Humidity Indicator 790 0291 05 RK-AB787-187 Kit for Desiccant Canister 790 0291 95 RK-AB787(Extended) * OR W44 Kit for Desiccant Canister (Smaller)* 790 0292 35 2 15 This may be renewed in every four years unless otherwise deemed necessary earlier.

Page 23

Tooling list for overhauling Air Dryer Below is a list of basic tools required during the dismantling and assembly process of Air Dryer. These may be supplied by FTIL, if requested. Standard Tools Tool Description • • • • • • • • • • • • • • • • • • • • • • • • •

10 Extension 3/8 Open ended wrench 3/8 Socket 3/8 drive 7/16 Open ended wrench 7/16 Socket 3/8 drive Open end wrench Socket 3/8 drive 9/16 Open end wrench 9/16 Socket 3/8 & ½ drive 5/8 Open ended wrench 5/8 Socket 3/8 drive Open ended wrench Socket ½ drive 1-3/8 Open ended wrench 1-3/8 Socket ½ drive 1-1/2 Open ended wrench 5/32 Allen wrench 3/16 Allen wrench 5/16 Allen wrench 3/8 Ratchet type Socket wrench Ratchet type Socket wrench Rubber tipped Hammer Stud Driver 5/16 x 18 Stud Driver 3/8 x 24 Heli-coil inserting tool 3/8 x 24

Ordering Reference

AA1022001 AA1022002 AA1022003 AA1022004 AA1022005 AA1022006 AA1022007 AA1022008 AA1022009 AA1022010 AA1022011 AA1022012 AA1022013 AA1022014 AA1022015 AA1022016 AA1022017 AA1022018 AA1022019 AA1022020 AA1022021 AA1022022 AA1022023 AA1022024 AA1022005

Special Tools Tool Description • •

Desiccant Compacting tool Guide Installation tool

Ordering Reference RPSK-0495 RPSK-0496 Page 24

7.0

Maintenance Intervals

7.1

Operating Conditions

7.1.1

Air Pressure The Air Dryer is equipped with a memory feature (type 975-123 & 975-124) which permits the unit to regenerate only when the Compressor or any Compressor in the consist is loading (pumping). The objective is to conserve additional air while maintaining an acceptable performance level. For the operational checks the Compressor must be pumping and the air pressure greater than the rated pressure level of the particular Pressure Switch. Type 975-123 & 975-124 The memory type electronic timer operates only when a signal voltage (48-110 V DC) is applied to the Socket of the Burndy Connector. Any interruption of the signal voltage (compressors in consist unloaded) causes the dryer to stop cycling. When the signal voltage is re-applied to the Socket, the dryer restarts at the point in the cycle where it stopped previously. In order for the electronics to work with the memory, a constant power source (48 110 V DC) must be made available to the Socket and a negative (-) source to the Socket within the female connector (Burndy) when power is re-applied to , & . This sequence provides complete regeneration to both desiccant canisters.

7.2

Operational Check (30 days)

7.2.1

Examine the Humidity Indicators. A blue colour represents correct operation and white indicates unsatisfactory operation and requires further checks to determine the cause.

7.2.2 There should be a slight continuous exhaust of air at the exhaust port of the Purge Valve on the tower. After a predetermined time interval of approximately 1 minute, there should be short loud discharge of air at the exhaust port of the opposite tower Purge Valve, followed by a slight continuous exhaust of air. Approximately, 1 minute later, there should be similar discharge of air at the opposite tower. In conjunction, the Drain Valve on the sump of the pre-coalescer should exhaust every time the dryer cycles. The change in the exhaust of air from one tower to the other indicates the dryer is operating properly. In conjunction, the Drain Valve on the sump cap of the precoalescer should exhaust each time the Air Dryer cycles. If the change in the exhaust of air is not present or if there is no discharge of air at either Purge Valve or Drain Valve, check the following.

Page 25

7.3

Operational Check Fault Finding

7.3.1

Confirm that the air system pressure is equal to the minimum of the specified rating of the Pressure Switch used and that the Compressor is pumping. The Dryer is fitted with an internal Pressure Switch, which closes at the rated pressure. If there is no exhaust out of one of the two Purge Valves jump the two connecting wires on the Pressure Switch. If there is a loud, short exhaust followed by a slight continuous exhaust, the switch is faulty and must be renewed.

7.3.2

If the Air Dryer does not cycle while the Compressor is pumping, check to see if air is present in the piping from the Solenoid Valve to the Inlet Check Valve and Purge Valve. If air is present in the piping on one side, then changes to the opposite side (while Compressor is pumping), proper timing is occurring. If air is not present in the tubing, check the power to the Dryer, see electrical note, section 7.1.2. If power is confirmed and there is no air present in the tubing, renew the circuit board.

7.3.3

If actuating air is not present in the integral tubing to the Inlet Check Valve and Purge Valve during the regenerating cycle, the Solenoid Valve should be examined to see if the electrical power is to the coil. If power is to the coil, but actuating air is not in the tubing to actuate the valve, examine the Solenoid Valve plunger for proper seating and renew if defective. If the plunger binds in the coil and does not move freely, renew the plunger.

7.3.4

Check each Inlet and Outlet Check Valve in the regenerating position to be sure, of proper seating; if the loud discharge of air does not decrease to a slight exhaust of air, check for foreign matter which may have lodged under the seat of either Inlet or Outlet Check Valve. Clean or renew the seat.

7.3.5

Check each dryer tower while in the dehydrating cycle of proper operation; there should be no exhaust of air at the Purge Valve. If exhaust of air is present, the Purge Valve is not seating properly and must be examined and repaired with new seat, seals and packing cup.

7.3.6 Examine the Drain Valve (double seated) on the sump of the pre-coalescer. The Drain Valve is designed to exhaust each time the dryer cycles. The Drain Valve is actuated from one of the two adjacent Purge Valves. If the Drain Valve does not cycle, examine the actuating line from the adjacent Purge Valve and follow steps 7.3.2 and 7.3.3. 7.3.7 An operational check of the memory type timer, where fitted, may be accomplished by unloading the compressor. The Air Dryer should stop regenerating. Load the compressor. The dryer should begin regenerating at the point in the cycle where it previously stopped. For example, if one of the towers regenerates for 30 seconds prior to the compressor unloading, when the compressor loads again the memory feature permits the same tower to restart at 31 seconds and complete the one minute time period prior to cycling. Page 26

7.4

Annual Check Procedures Check the locomotive system maintenance schedule in case more rigorous requirements are specified.

7.4.1 Remove and examine the coalescer element, section 15 gives details of the procedure. 7.4.2 On new locomotives, remove and examine the filter element in the final filter, if it is contaminated, rectify the cause and renew the filter element. Refer to section 20 for details. 7.4.3 Check the operation of the regenerating orifice. Push in the orifice plunger, if plunger will not push in, wait for the dryer to switch cycles, approximately one minute, then push in plunger. When cycle change occurs, the orifice plunger should automatically return to the extended position. If this does not occur, refer to section 9. 7.4.4 Check the condition of each pipe assembly. Renew assemblies, fittings which show signs of unacceptable corrosion. 7.4.5 Clean the muffler disseminator element where fitted. 7.5

Each 2 Years Check Procedures Check the locomotive system maintenance schedule in case more rigorous requirements are specified.

7.5.1 Examine the desiccant, if contaminated with oil or water, renew the desiccant, refer to section 8. The seals and gaskets should be renewed at the same time. 7.5.2 Remove and examine the coalescer element (see annual check). 7.5.3 Remove and examine the filter element in final filter (see annual check). 7.6

Each 3 years

7.6.1 A complete overhaul is essential to ensure the continued reliable and efficient operation of unit in providing a clean supply of air throughout the air system. The Air Dryer should be returned to Faiveley Transport India Limited or an overhaul location which has been autorised by Faiveley Transport India Limited.

Page 27

Overhaul requires the complete dismantling, overhaul, and renewal of consumable parts, of the component assemblies as described in the following sections. After completely re-assembling the Air Dryer, it should be tested including the 30 day operational check to verify timer circuit operation, see section 7.2. 7.7

Desiccant Canister Removal Numbers in ( ) refer to drawing No. 029 1001 00 (D&M Ref. AB787-W26).

7.7.1 Using a 9/16 wrench, disconnect the actuating airlines to the Purge Valves. 7.7.2 Use a 9/16 Socket with 10 extension to remove 6 Nut and Lock Washers (8) to allow the Bottom Cap (12) to be dropped down. 7.7.3 Remove the Desiccant Canister assembly (10). 7.7.4 Refer to section 8.8 for Compactor maintenance.

Desiccant

Refer to section 8 for Desiccant Canister recharge procedure.

*

(Spacer) not assembled in 975-129 model dryers.

Page 28

8.0

Desiccant Charge Renewal Use Maintenance Kit RK-AB787-W44) Sl. No.

8.1

Kit Part No.

Dryer Model

1

790 0291 25 (D&M Ref. RK-AB787-W44)

975-123

2

790 0292 45 (D&M Ref. RK-AB787-W44A)

975-124

Step 1-A Using a Screw driver, remove the top Retaining Ring and then extract the Canister Disc Assembly.

8.2

Step 1-B Discard the old desiccant.

8.3

Step 2 Using a screw driver, remove the bottom Retaining Ring and then extract the Canister Disc Assembly. Clean both the Retaining Rings and screens. Wipe the inside of the Canister with a clean dry cloth.

Page 29

8.4

Step 3 Install the cleaned Canister Disc Assembly and Retaining Ring in the bottom of the Canister Assembly. Refill the Canister with new desiccant.

8.5

Step 4 Place the Canister Disc Assembly with the screen next to the desiccant beads on top of the Desiccant Canister beads and push down while tightly tapping with a soft tip hammer and rotating the Canister. Tap and rotate the unit, Canister Disc Assembly drops below the Retaining Ring groove.

8.6

Step 5 Remove the Canister Disc Assembly and add more desiccant. Replace the Canister Disc assembly and continue tapping and rotating procedure until the top of the Canister assembly lines up with the bottom edge of the Retaining Ring groove. Carefully replace the Retaining Ring into the groove on the top of the Canister Disc assembly.

Page 30

8.7

Step 6 Renew the Seal on the top of the Canister Disc assembly. Before reassembly, lubricate the Seal with Dow Corning 55 M or equivalent.

8.8

Compactor Removal and Maintenance Procedure Numbers in ( ) refer to drawing no. 029 1001 00 (D&M Ref. AB787-W41). Use Maintenance kit 790 0292 05 (D&M Ref. RK-AB787-W41).

8.8.1 Using a 9/16 wrench, slacken the fittings on the Inlet Pipes to discharge the actuating air from the Compactor, see OGA drawing for particular model. 8.8.2 Remove 2 Hexagon Head Screws (4) before removing Compactor Assembly. 8.8.3 Lift the Compactor Assembly up through the Sump Cap. 8.8.4 Remove 1 Pan Head Screw (2) from the Piston. 8.8.5 Remove the Spider (3) followed by the Cap (5). Renew Seal (6). 8.8.6 Renew the Piston Seal (9) and the Sump Cap Seal (7). Examine the Piston and the Cap for any damage. Renew where necessary. 8.8.7 Before reassembly, lubricate all Seals and sealing surfaces with Silicone grease, Dow Corning M 55 or equivalent. * -

(Spacer) not assembled in 975-124 model dryers.

Page 31

8.8.8 Clean all components before re-assembly. Apply Loctite 222 thread locker to the Screw threads than re-assemble Compactor. 8.8.9 Reassemble Compactor to the Sump Cap ensuring that new Seals are fitted. 9.0

Regenerating Orifice Numbers in ( ) refer to drawing no. 029 1001 00 (D&M Ref. AB787-W26). Use Maintenance Kit RK-AB787-W39).

9.1

Regenerating Orifice

9.1.1 Use a 1 wrench to remove the Regenerating Orifice Assembly (1) from the Dryer Body (9). 9.1.2 While holding the Orifice Body (5) in a vice, use a 5/8 wrench to remove the Retainer Nut (2) from the Orifice Body. 9.1.3 Discard the Seals. 9.1.4 Clean and examine the other components, particularly the Orifice Plunger (4), for any damage which may necessitate renewal. 9.1.5 Before reassembly, lubricate all Seals and sealing surfaces with Silicone grease, Dow Corning M55 or equivalent.

Page 32

9.1.6

Refit the orifice plunger with a new Seal (3) into the orifice body and tighten the Retainer Nut. Fit new Seals (6, 7) on the orifice body and refit in the dryer body. Note: For an easy identification of the orifice size, the orifice body is anodized and passivated with different colours and also the orifice size is punched on the body. The following are the various orifice sizes with its colour code. For selecting the correct size, refer dryer configuration table in page 1.

10.

Sl. No.

Orifice Size

1 2 3 4 5 6

0.11 0.068 0.0625 0.052 0.042 0.078

Colour of Orifice Body and Plunger Colourless (White) Green Yellow Blue Brown Red

Purge Valve Maintenance (The figure and the procedure referred below is not applicable for 975-124 model dryer).

Page 33

10.1

Dismantling Refer to drawing no. AB787-W36. Use Maintenance kit RK-AB787-W36.

10.1.1 Using a 9/16 wrench, disconnect the actuating air line from the Purge Valve. 10.1.2 Use a 3/8 wrench to unscrew two Cap Screws and Lock Washers, remove the Purge Valve from the Dryer bottom Cap. 10.1.3 Use a 1-3/8 wrench to remove the Cap Nut (12) from the Body (6), this will be followed by the Spring (5). 10.1.4 The Stem Assembly can now be removed from the Body. Use two 7/16 wrenches to hold the Stem (9) and remove the Nut (2). Renew the Seat (11) and Nut (2). 10.1.5 Use a 3/16 Allen key to remove four Cap Screws (14) and the Cover (13). 10.1.6 The Cup Washer (1) and Piston (7) can now be removed. Renew the Cup Washer (1) and Seal (3) on the Piston. 10.2

Cleaning and Repairing

10.2.1 Clean and examine the components not being renewed, for any damage which indicates renewal is necessary. 10.2.2 Use all the components in the Maintenance Kit to renew parts. 10.3

Assembly

10.3.1 Lubricate all O Rings and Cup Washer with a silicone grease equivalent to Dow Corning 55 M. 10.3.2 Replace the Piston into the Purge Valve Body followed by the new Cup Washer and secure with the Cap Screws. 10.3.3 Fit the new Spring (5), then assemble the Cap to the Valve Body, using a 1-3/8 wrench. 10.3.4 Fit a new Gasket (15) and secure the Purge Valve to the Dryer bottom Cap with two Cap Screws, use 3/8 wrench.

Page 34

10a.

Purge Valve Maintenance (The figure and the procedure referred below is for 975-124 model dryer)

Dismantling, Cleaning & Repairing: Refer to drawing no. AB787-W36A for cross section drawing. Use Maintenance kit 790 0292 95 (RK-AB787-W36A). 10a.1 Using a 9/16 wrench, disconnect actuating air line to Purge Valve. 10a.2 Using a ½ wrench, remove two Nuts (1) and Lock Washers (2), remove Purge Valve from dryer bottom cap. 10a.3 With a 1-3/8 Spring (5).

wrench, remove Cap (3) which will be followed from Body (4) by

10a.4 Stem assembly with Stem (6) can now be removed from Body (4). Inspect Seat (7) for usual wear or damage and replace as required by using two 7/16 wrenches to hold Stem while loosening the Nut (8). 10a.5 Remove Cap (9) using a 3/16 allen wrench to remove four Cap Screws (10) and Lock Washers (11).

Page 35

10a.6 Cup Washer (12) and Piston (13) can now be removed. Inspect Cup Washer and Seal (14) for unusual wear or damage and replace as necessary. 10a.7 Upon reassembly of Piston (13) to Body, generously apply Down Corning 55 M grease or equivalent to Seal (14) and Cup Washer (12). 10a.8 Reassemble Drain Valve and inspect Seal (15) for damage before reassembling Purge Valve to Dryer bottom Cap. 11.0

Drain Valve Maintenance

11.1

Dismantling

11.1.1 Using a 9/16 wrench, disconnect the actuating airline from the Drain Valve. 11.1.2 Use a ½ wrench to unscrew two Nuts and Lock Washers and remove the Drain Valve from the Sump Cap. 11.1.3 Use a 1-3/8 wrench to remove the Cap (14) from the Body (12), this will be followed by the Spring (13). 11.1.4 Use a 3/16 Alley key to remove four Cap Screws (9) with Washers (10) & the Cap (8). 11.1.5 The Cup Washer (7) can now be removed. Renew the Cup Washer (7) and Seal (5) on the Piston. Page 36

11.1.6 Use a 3/8 wrench on the Seat Bolt (1) while holding the Piston (6) with a screw driver in the slot provided in the Piston, to renew both Seats (3). 11.2

Cleaning and Repairing

11.2.1 Clean and examine the components not being renewed for any damage which indicates renewal is necessary. 11.2.2 Use all the components in the Maintenance Kit to renew parts. 11.3

Assembly

11.3.1 Lubricate all O Rings, Cup Washer and Piston Body with a silicon grease equivalent to Dow Corning 55 M. 11.3.2 Reassemble the Drain Valve and secure with both Caps. 11.3.3 Fit a new Gasket (15) and secure the Drain Valve to the Sump Cap with two Nuts, use ½ wrench.

Page 37

12.0

Inlet Check Valve Numbers in ( ) refer to drawing no. AB787-W27. Use Maintenance Kit 790 0291 35 (D&M Ref. RK-AB787W27A).

12.0.1

Using a 3/16 Allen wrench, remove 4 Cap Screws (1) and Lock Washers (2) to remove the actuating Cap (3).

12.0.2

Use a 3/16 Allen wrench to remove 4 Cap Screws (6) and remove Adaptor (8) from the Inlet Check Valve Body (11).

12.0.3

Remove the Valve Seat (10) from the Inlet Check Valve Body (11). Renew the Valve Seat (10) on reassembly.

Note:

Generously lubricate all rubber products with silicone grease, Dow Corning 55 M or equivalent.

12.0.4

Remove the Piston (5) from the Adaptor (8) and renew internally assembled O Ring (7). Renew O Ring (9) between the Inlet Check Valve Body and the Adaptor, then reassemble.

12.0.5

Extract the Cup Washer (4) from the Actuating Cap and discard. Lubricate and fit a new Cup Washer in the Actuating Cap, making certain that the sealing surface above the Cup Washer is well lubricated.

12.0.6

Reassemble the Actuating Cap to the Adaptor on the Inlet Valve Body.

Page 38

13.0

Outlet Check Valve Numbers in ( ) refer to drawing no. 029 1005 00 (D&M Ref. AB787-W29 or W48). Use Maintenance Kit 790 0291 45 (D&M Ref. RK-AB787-W29 or W18).

13.1

Dismantling

13.1.1

Using a 3/8 wrench, loosen 4 Captive Screws on the Solenoid Assembly (9).

13.1.2

The Valve Seat Assembly (12) will drop down with the Solenoid Assembly (9) and Spring (11). An eyebolt has been provided on the Solenoid Assembly to help dismantling if necessary.

13.1.3

Discard the Valve Seat (12) and Spring (11).

13.1.4

Reassemble with a new Valve Seat and Spring.

13.1.5

Refer to section 14 for the Solenoid overhaul procedure.

Page 39

14.0

Solenoid Assembly Numbers in ( ) refer to drawing no. 029 1008 00 (D&M Ref. AB787-W37). Use Maintenance Kit 790 0291 55 (D&M Ref. RK-AB787-W37)

14.0.1

Remove the Spring and Seal (1) from the Solenoid Body (2).

14.0.2

While holding the Coil Housing (11) carefully in a vice (hold only the Cap Screw Flange), use a 9/16 wrench on the Solenoid Body (2) wrench flats and remove from the Adaptor Assembly (7).

14.0.3

Clean and examine the seating surface for the Plunger Assembly inside the Solenoid Body.

14.0.4

Use a 5/32 Allen wrench to remove 4 Cap Screws (6) from the Coil Housing. Lift the Adaptor (7) up.

14.0.5

Remove the Coil (9) from the Coil Housing. Examine the Coil for damage and check for continuity and correct resistance see electrical specification on drawing no. 029 1008 00 (D&M Ref. AB787-W37).

Note:

Sparingly lubricate all Seats and sealing surfaces with silicone grease, Dow Corning 55M or equivalent.

14.0.6

Renew two Seals (8) and reassemble the Coil Housing.

14.0.7

Use a 1 ½ wrench to remove the Magnet (12) from the Coil Housing. Clean and examine the Plunger seating surface. Renew where necessary then reassemble.

14.0.8

Place the Spring (5), then a new Plunger Assembly (4) into the Adaptor and Coil Housing. Put a new Seal (3) in position on the Adaptor and re-assemble the Solenoid Body.

Page 40

14.0.9

Fit a new Seal (1) on the Solenoid Body.

14.0.10

When required, the complete Solenoid Assembly is replaced in the Dryer, place Spring and overhauled Valve Seat on top of the Solenoid Assembly and carefully reassemble the unit to the Outlet Check Valve Body, see figure 16. Refer to section 13 for overhaul of the Outlet Check Valve.

15.0

Pre-Coalescer Numbers in ( ) refer to drg no. 029 1003 00 (D&M Ref. AB787-W27). Use Maintenance Kit 790 0291 65 (D&M Ref. RK-AB787-W27B).

15.1

Element Renewal Procedure.

15.1.1

Disconnect the actuating airline from the Drain Valve using a 9/16 wrench.

15.1.2

Using a 3/8 Socket with extension, remove 4 Nuts with Lock Washers (1) at the Sump Cap, permitting the Sump Cap complete with Drain Valve to drop down.

15.1.3

Turn Retainer Nut (6) counter-clockwise and remove Coalescer Retainer (5) and Coalescer Element (4). Renew as required.

15.1.4

Clean any debris from the Sump Cap and Cylinder Body.

15.1.5

Reverse the procedure to reassemble the PreCoalescer, using a new Gasket (7). Tighten the Nuts (1) securely, torque to 34 Nm (24 ft. lb) maximum.

15.1.6

Refer to section 11 of Drain Valve overhaul procedures.

Page 41

16.0

Timer Circuit Board Renewal Procedure References to items 5 and 7 relate to Dryer with the memory circuit.

16.0.1

Disable the electrical power supply to the Air Dryer, then disconnect the power cable for the Dryer at the Burndy Connector (1).

16.0.2

Use a 3/8 wrench to loosen 7 Captive Screws (2) and remove the Cover Assembly (3) and Gasket (10) from the Electrical Box (4).

16.0.3

Remove the Wire Nut (5) from under the Timer / Circuit Board assembly and disconnect.

16.0.4

Remove the Timer / Circuit Board Assembly Box by grasping Pull Tab (6) and carefully pulling out. Disconnect the Leads (7) at the Wire Nut (5). Replace the Timer / Circuit Board Assembly (6) as required.

16.0.5

Place new / reconditioned Timer / Circuit Board Assembly into the slotted Channels (8) in the Electrical Box. Push the board firmly inward until locked in place. Join the Wires (7) with the Wire Nut and safely under the Timer / Circuit Board Assembly.

16.0.6

If the Pressure Switch (9) is satisfactory, refer to section 17, reassemble the Cover and Gasket to the Electrical Box, renew the Gasket (10), if necessary.

Page 42

17.0

Pressure Switch Renewal Procedure

17.1.1

Disable the air supply line and bleed all trapped pressure from the Air Dryer and surrounding lines.

17.1.2

Disable the electrical power supply and then disconnect the Burndy Connector (1) from the Dryer make-up box.

17.1.3

Use a 3/8 wrench to loosen 7 Cap Screws (3) and remove the make-up box cover and gasket from the Electrical Box (2).

17.1.4

Use a 9/16 wrench to disconnect Tubing Nuts (4) from the Tee Fitting (5) on both sides of the Dryer Outlet Manifold (2).

17.1.5

Use a 5/16 Allen wrench to remove 2 Socket Head Screws (7) that will allow the Flange (8) to be separated from the Outlet Manifold (6).

17.1.6

With a 9/16 Socket, remove 4 x 3/8 Nuts and Lock Washers (9) that hold the Outlet Manifold to the Dryer Body (10).

17.1.7

Remove the Outlet Manifold from the Dryer Body, disconnect Tubing Assembly (11) from the back of the Oultet Manifold using 9/16 wrench.

17.1.8

Inside the Make-up Box (2), disconnect two electrical Female Fastons (12) from the Pressure Switch (13).

17.1.9

Use a 1 wrench to remove the Adaptor (14) and Pressure Switch (13) from the Make-up Box. Separate the Pressure Switch from the Adaptor with 1 and 9/16 wrenches. Page 43

17.1.10 Refit a new Pressure Switch to the Adaptor, then assemble the Adaptor in the Makeup Box. Reconnect two wires to the Pressure Switch in the Make-up Box (nonpolarised connection). 17.1.11 Re-attach and reassemble all the parts of the Outlet Manifold and Dryer. Test the Dryer before returning it to service. 18.0

Humidity Indicator Use Maintenance Kit, part no. 790 0291 05 (D&M Ref. RK-AB787-187). The Humidity Indicator is used as a visual monitor showing the operating condition of the Air Dryer. A blue colour indicates an Air Dryer operating satisfactorily. A totally white colour indicates the Dryer operation and desiccant beads should be checked. A thorough inspection for the presence of desiccant dust in the Control Pipe work and the Pressure Switch should be made. Where dust is found, the Pressure Switch should be replaced. Refer to section 17 for Pressure Switch renewal procedure. Usually only excessive oil aerosols or prolonged saturation by water will permanently turn the blue paper white. Oil aerosols will coat the paper and turn it a dark green or shade of orange or yellow, rendering it ineffective for the sensing of water aerosols.

Warning :

Do not alter, modify or use parts not supplied in Maintenance Kit 790 0291 05 (D&M Ref. RK-AB787-187) for this component.

The Maintenance Kit is designed to renew the paper indicator in the Humidity Indicator. Page 44

18.1

Procedure

18.1.1

Remove the Spring Clip, all old media and paper.

18.1.2

Clean the inside of the ¾ bushing with and approved solvent that will remove oil.

18.1.3

Wipe off and dry.

18.1.4

Assemble all the items from the Maintenance Kit in the order shown in Fig. 20.

18.1.5

An oil coalescer medium and humidity / oil absorbing desiccant has been added to prolong the life of the blue paper. To be effective, it must be assembled as shown in fig. 20. When adding the loose desiccant from the sorb-it bag, fill the cavity level in only two Spacers, before inserting the Coalescer media, Rubber Sealing Gasket and Spring Clip into the bushing.

18.1.6

Ensure the Spring Clip is pressed into the bushing firmly against the rubber gasket, convex side first. Use a metal applicator, such a ½ extended socket, to tap the Spring Clip into place.

19.0

Muffler (This is an optional unit)

19.0.1

Release two Nuts and remove the Cap from the Muffler assembly.

19.0.2

Remove the disseminator element (silencer).

Page 45

19.0.3

Using a wire bush, brush the inside and the outside of the disseminator element to remove accumulated dirt from the element.

19.0.4

This procedure is required to return the element to its original condition, thereby reducing the back pressure through the Muffler to a minimum.

Note:

Excess back pressure adversely affects the performance of the Dryer.

19.0.5

Reassemble the Muffler and refit to the Dryer.

20.0

Final Filter

20.1

Function and Operation The Final Filter is mounted separately from the Air Dryer as the next component in the Outlet Pipe. The Final Filter ensures that minute dust and dirt particles, which may have escaped purging in the main Dryer system are removed. Air enters into the Body of the Filter and passes through the Filter element which collects any remaining impurities from the air. A manually operated Drain Cock is situated at the foot of the Final Filter.

20.2

Maintenance

20.2.1

Numbers in ( ) refer to drg no. 029 0010 00 & 029 0012 00 (D&M Ref. AB787-W40). Use Maintenance Kit No. 790 0291 25 (D&M Ref. RK-AB787-W40). It is possible to renew the Filter element without removing the Body assembly from the vehicle, provided sufficient space is available.

20.2.2

Ensure that the air system is shut down and that air pressure has been blow down.

20.2.3

Remove six Nuts and Lock Washers (7). The Bottom Cap (6) complete with Manual Drain Valve and Gasket (4) will drop down.

Page 46

20.2.4

Unscrew the Wing Nut (9) to remove the Filter Retainer (8) & the Filter Element (5).

20.2.5

Clean the inside of both the Filter Body assembly and bottom Cap.

20.2.6

Examine the Filter element and renew if necessary. Contamination of the element by oil, desiccant or water means that a new element must be fitted.

20.2.7

When refitting the Filter Element (5), lubricate the sealing surface at both ends of the element with Dow Corning M55 or equivalent. Carefully align the Filter element on the Filter Retaining device in the Filter Body Assembly, followed by the Filter Retainer (8) and Wing Nut (9). Reassemble the Final Filter.

20.2.8

Renew the Gasket (4), ensure this is fitted the correct way, see fig 22 and reassemble the Bottom Cap (6) to the Filter Body and secure with the six Nuts with Lock Washers (7).

20.3

Trouble Shooting Guide

20.3.1

Oil contamination of the Final Filter indicates that the Compressor is pumping oil or that the Oil Separator and its Drain Valve have failed. After correcting the fault, renew the Desiccant Canister and Final Filter element.

20.3.2

Desiccant contamination of the Final Filter element is an indication that the desiccant bead has broken down. This may be caused by 1.

If for some reason the compressor duty cycle is continuous or in excess of 75%, there is insufficient time for the desiccant bead to fully regenerate. This means that the desiccant will eventually deteriorate and escape from the canister. The desiccant contamination will be trapped in the Final Filter. Check the compressor duty cycle, then renew the desiccant canister and Final Filter element.

2.

If the Compactor, which exerts pressure on the desiccant bead is not functioning properly, the bead could break down and deposit small broken beads of white dust in the Final Filter. Repair the Compactor, then renew the desiccant bead and Final Filter element.

20.3.3

Water contamination of the Final Filter element indicates that the duty cycle of the Compressor is more than 75% and the desiccant bead does not have sufficient time to regenerate before the next cycle. Check the compressor duty cycle. After correcting the fault, renew the Desiccant Canister and Final Filter element. Page 47

Page 48

List of Parts Twin Tower Air Dryer Drawing no. 029 1001 00 (D&M Ref. AB787-W26). (This is applicable for 975-123 model dryers). Item No. 1 2 ** 3 ** 4 ** 5 ** 6 ** 7 ** 8 9* 10 11 12 13 14 15 16 17 18

FTIL Part No. Refer table 029 3035 00 029 7060 00 Refer table Refer table 029 7070 00 029 7035 00 099 8006 00 & 099 8007 00 029 1200 00 029 1180 00 029 7140 00 029 1009 00 029 7190 00 029 1006 00 099 5005 00 099 6003 00 029 3330 00 029 7150 00

D&M Part / Drg No.

Description

Qty / Unit

Refer table AB787-110 AB787-111 Refer table Refer table AB787-115 AB787-116 AB787-117

Orifice Assembly Retainer Nut O Ring Orifice Plunger Orifice Body O Ring O Ring Nut with Lock Washer

1 1 1 1 1 1 1 24

AB787-W34 AB787-W44 AB787-119 AB787-W41 AB787-121 AB787-W36 AB787-122 AB787-123 AB787-124 AB787-125

Dryer Body Canister Assembly O Ring Compactor / Sump Cap Assembly O Ring Purge Valve Lock Washer Cap Screw Body Spacer O Ring

1 2 2 2 2 2 4 4 2 4

*

Note the Dryer Body, reference 9, indicates 16 off Studs, 029 8035 00 (AB787-127)

**

Orifice Assembly comprises items 2, 3, 4, 5, 6 and 7. For selecting the correct orifice assembly, refer dryer configuration details in page 1.

Orifice Table with FTIL Part Nos. Sl. No. 1

0.11

Orifice Assy Part No. 029 1100 00

Orifice Body Part No. / Colour codification 029 3170 00 (White)

Orifice Plunger Part No. / Colour codification 029 3150 00 (White)

2

0.0625

029 1101 00

029 3173 00 (Yellow)

029 3154 00 (Yellow)

3

0.052

029 1102 00

029 3172 00 (Blue)

029 3152 00 (Blue)

4

0.042

029 1105 00

029 3175 00 (Brown)

029 3156 00 (Brown)

Orifice Size

Page 49

Orifice Table with D&M Part Nos.

0.11

Orifice Assy Part No. AB787-W39

Orifice Body Part No. / Colour codification AB787-115 (White)

Orifice Plunger Part No. / Colour codification AB787-114 (White)

2

0.0625

AB787-W39B

AB787-115B (Yellow)

AB787-114B (Yellow)

3

0.052

AB787-W39C

AB787-115C (Blue)

AB787-114C (Blue)

4

0.042

AB787-W39D

AB787-115D (Brown)

AB787-114D (Brown)

Sl. No. 1

Orifice Size

Maintenance kits Maintenance kit, part no. 790 0290 11 (D&M Ref. RK-AB787-W39), includes parts for orifice assembly and comprises item 3, 6 and 7. Refer to drawing of the kit for identification of parts. Maintenance kit, part no. 790 0291 15 (D&M Ref. RK-AB787-T17), includes all the normal renewable parts for overhauling a complete Air Dryer. It comprises all the maintenance kits plus individual items. Also, note that this kit is suitable for all extended model dryers.

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Page 51

List of Parts Twin Tower Air Dryer Drawing no. 029 1002 00 (D&M Ref. AB787-W26A). (This is applicable for 975-124 model dryers). Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

FTIL Part No. Refer table 029 3035 00 029 7060 00 Refer table Refer table 029 7070 00 029 7035 00 099 8006 00 & 099 8007 00 029 1200 00 029 1185 00 029 7140 00 029 1210 00 029 7190 00 029 1007 00 099 5001 00 099 3001 00 029 7150 00

D&M Part / Drg No.

Qty / Unit

Description

Refer table AB787-110 AB787-111 Refer table Refer table AB787-115 AB787-116 AB787-117

Orifice Assembly Retainer Nut O Ring Orifice Plunger Orifice Body O Ring O Ring Nut with Lock Washer

1 1 1 1 1 1 1 24

AB787-W34 AB787-W44A AB787-119 AB787-W41A AB787-121 AB787-W36A AB787-122A AB787-123A AB787-125

Dryer Body Canister Assembly O Ring Compactor / Sump Cap Assembly O Ring Purge Valve Lock Washer Cap Screw O Ring

1 2 2 2 2 2 4 4 4

Note that Dryer Body, reference 9, indicates 16 off Studs 029 8350 00 (AB787-127). Regenerating Orifice Assembly comprises items 2, 3, 4, 5, 6 and 7. For selecting the correct orifice assembly, refer dryer configuration details in page 1. Orifice Table with FTIL Part Nos. Sl. No.

Orifice Size

Orifice Assy Part No.

Orifice Body Part No. / Colour codification

Orifice Plunger Part No. / Colour codification

1

0.11

029 1100 00

029 3170 00 (White)

029 3150 00 (White)

2

0.0625

029 1101 00

029 3173 00 (Yellow)

029 3154 00 (Yellow)

3

0.052

029 1102 00

029 3172 00 (Blue)

029 3152 00 (Blue)

4

0.042

029 1105 00

029 3175 00 (Brown)

029 3156 00 (Brown)

Page 52

Orifice Table with D&M Part Nos.

0.11

Orifice Assy Part No. AB787-W39

Orifice Body Part No. / Colour codification AB787-115 (White)

Orifice Plunger Part No. / Colour codification AB787-114 (White)

2

0.0625

AB787-W39B

AB787-115B (Yellow)

AB787-114B (Yellow)

3

0.052

AB787-W39C

AB787-115C (Blue)

AB787-114C (Blue)

4

0.042

AB787-W39D

AB787-115D (Brown)

AB787-114D (Brown)

Sl. No. 1

Orifice Size

Maintenance kits Maintenance kit, part no. 790 0291 11 (D&M Ref. RK-AB787-W39), includes parts for orifice assembly and comprises item 3, 6 and 7. Refer to drawing of the kit for identification of parts. Maintenance kit, part no. 790 0291 16 (D&M Ref. RK-AB787-T17B), includes all the normal renewable parts for overhauling a complete Air Dryer. It comprises all the maintenance kits plus individual items.

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List of Parts Inlet Check Valve Assembly Drawing no. 029 1003 00 (D&M Ref. AB787-W27)

Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

D&M Part / Drg No.

FTIL Part No. 099 6001 00 099 5003 00 029 3280 00 029 7240 00 029 3050 00 099 6501 00 029 7030 00 029 3340 00 029 7105 00 029 6070 00 029 3330 00 029 7190 00 Refer table 099 6002 00 099 5004 00

AB787-155 AB787-156 AB787-157 AB787-158 AB787-159 AB787-160 AB787-161 AB787-162 AB787-99 AB787-243 AB787-167 AB787-121 Refer table AB787-246 AB787-247

Sheet 1

Description Cap Screw Lock Washer Actuating Cup Cup Washer Piston Cap Screw O Ring Adaptor O Ring Valve Seat Valve Body, Inlet O Ring Flange Cap Screw Lock Washer

Qty / Unit 8 8 2 2 2 8 2 2 2 2 2 3 1 2 2

Quantities are for complete Air Dryer. Maintenance kit Maintenance kit part no. 790 0291 35 (D&M Ref, AB787-W27A) comprises items 4 (1 no.), 7 (1 no.), 9 (1 no.) and 10 (1 no.). Refer to drawing of the kit for identification of parts. Two kits are needed if both Check Valves are to be overhauled. Table: Sl. No.

Flange Thread Size

Flange Part No. FTIL

Flange Part No. D&M

1

1¼ NPT

029 8163 00

AB787-245

2

1 NPT

029 8160 00

AB787-245A

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List of Parts Pre-Coalescer Assembly Drawing no. 029 1003 00 (D&M Ref. AB787-W27)

Item No. 1 2 3 4 5 6 7 8 9 10

FTIL Part No. 099 8006 00 & 099 8007 00 029 3350 00 029 3080 00 029 2040 00 029 3090 00 099 3005 00 029 7180 00 029 3270 00 029 7200 00 029 1004 00

Sheet 2

D&M Part / Drg No.

Description

Qty / Unit

AB787-118

Nut with Lock Washer

8

AB787-168 AB787-169 AB787-170 AB787-171 AB787-172 AB787-173 AB787-174 AB787-224 AB787-W28

Cylinder Seat and Guide Coalescer Element Coalescer Retainer Elastic Stop Nut O Ring Sump Cap Tetra Seal Drain Valve

1 1 1 1 1 1 1 1 1

Maintenance kit Maintenance kit part no. 790 0291 65 (D&M Ref. RK-AB787-W27B) comprises items 4, 6 and 7. Refer to drawing of the kit for identification of parts.

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List of Parts Drain Valve Drawing no. 029 1004 00 (D&M Ref. AB787-W28)

Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

FTIL Part No. 029 8075 00 029 4010 00 029 6010 00 029 8410 00 029 7015 00 029 4020 00 029 7250 00 029 4140 00 099 6001 00 099 5003 00 029 7095 00 029 3240 00 029 8055 00 029 3060 00

D&M Part / Drg No. AB787-175 AB787-176 AB787-177 AB787-178 AB787-144 AB787-179 AB787-180 AB787-181 AB787-155 AB787-182 AB787-97 AB787-183 AB787-248 AB787-185

Description Seat Bolt Seat Washer Seat Stem O Ring Piston Cup Washer Cap Cap Screw Lock Washer O Ring Body Spring Spring Cap

Qty / Unit 1 1 2 1 1 1 1 1 4 4 1 1 1 1

Maintenance kit Maintenance kit, part no. RK-AB787-W28 comprises 3 (2 nos.) 5, 7, 11 and 13. Refer to drawing of the kit for identification of parts.

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List of Parts Piping Assembly Drawing no. 029 1010 00 (Application for 975-123 model Dryers)

Item No. 1 2 3 4 5

FTIL Part No. 029 4100 00 029 1025 00 029 4090 00 029 1030 00 029 8470 00

D&M Part / Drg No. AB787-210 AB787-211 AB787-212 AB787-213 AB787-214

Description Elbow Pipe Assembly Tee Pipe Assembly Elbow

Qty / Unit 1 1 1 1 1

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List of Parts Piping Assembly Drawing no. 029 1015 00 (D&M Ref. AB787-W32) Item No.

FTIL Part No.

1 2 3 4 5 6 7 8 9

029 4080 00 029 1045 00 029 4090 00 029 1055 00 029 4070 00 029 1060 00 029 8120 00 029 1050 00 029 4100 00

D&M Part / Drg No. AB787-215 AB787-216 AB787-217 AB787-218 AB787-219 AB787-220 AB787-221 AB787-222 AB787-210

Applicable for 975-123 model Dryers. Description

Fitting Pipe Assembly Tee Pipe Assembly Fitting Check Valve Tee Pipe Assembly Elbow

Qty / Unit 1 1 1 1 1 1 1 2 2

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List of Parts Piping Assembly Drawing no. 029 1020 00 (D&M Ref. AB787-W33) Item No.

FTIL Part No.

1 2 3 4 5 6 7

029 4100 00 029 1025 00 029 4090 00 029 1040 00 029 8120 00 029 1035 00 029 8470 00

D&M Part / Drg No. AB787-210 AB787-211 AB787-217 AB787-223 AB787-221 AB787-223A AB787-214

Applicable for 975-123 model Dryers. Description

Elbow Pipe Assembly Tee Pipe Assembly Tee Pipe Assembly Elbow

Qty / Unit 1 1 1 1 1 1 1

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List of Parts Piping Assembly Drawing no. 029 1022 00 (D&M Ref. AB787-W31B) Item No.

FTIL Part No.

1 2 3 4 5

029 4100 00 029 1025 00 029 4090 00 029 1140 00 029 8470 00

D&M Part / Drg No. AB787-210 AB787-211 AB787-212 AB787-213A AB787-214A

Applicable for 975-124 model Dryers. Description

Elbow Pipe Assembly Tee Pipe Assembly Elbow

Qty / Unit 1 1 1 1 1

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List of Parts Piping Assembly Drawing no. 029 1018 00 (D&M Ref. AB787-W32B) Item No.

FTIL Part No.

1 2 3 4 5 6 7 8 9

029 4080 00 029 1045 00 029 4090 00 029 1056 00 029 4070 00 029 1060 00 029 8120 00 029 1051 00 029 4100 00

D&M Part / Drg No. AB787-215 AB787-216B AB787-212 AB787-218B AB787-219 AB787-220 AB787-221 AB787-222B AB787-210

Applicable for 975-124 model Dryers. Description

Straight Fitting Tube Assembly Tee Tube Assembly Fitting Check Valve Assembly Male Branch Tee Tube Assembly Elbow

Qty / Unit 1 1 1 1 1 1 1 2 2

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List of Parts Piping Assembly Drawing no. 029 1024 00 (D&M Ref. AB787-W33B) Item No.

FTIL Part No.

1 2 3 4 5 6 7 8 9

029 8470 00 029 1025 00 029 4090 00 029 1145 00 029 4180 00 029 1150 00 024 1000 00 029 4190 00 029 4200 00

D&M Part / Drg No. AB787-210 AB787-211 AB787-217 AB787-223 AB787-129A AB787-129B AB787-129C AB787-129D AB787-129E

Applicable for 975-124 model Dryers. Description

Elbow Pipe Assembly Tee Pipe Assembly Tee Pipe Assembly Elbow Reducer Reducing Elbow

Qty / Unit 1 1 1 1 1 1 1 1 1

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List of Parts Purge Valve Drawing no. 029 1006 00 (D&M Ref. AB787-W36) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

FTIL Part No. 029 7240 00 099 3003 00 029 7015 00 029 7080 00 029 8060 00 029 3310 00 029 3065 00 029 8085 00 029 8081 00 029 3070 00 029 6110 00 029 8170 00 029 3260 00 099 6001 00

Applicable for 975-123 model Dryers

D&M Part / Drg No. AB787-142 AB787-143 AB787-144 AB787-145 AB787-146 AB787-147 AB787-148 AB787-149 AB787-150 AB787-151 AB787-152 AB787-153 AB787-154 AB787-155

Description Cup Washer Lock Nut O Ring O Ring Spring Body Piston Seat Guide Seat Stem Seat Washer Seat Cap Nut Cover Cap Screw

Qty / Unit 1 1 1 1 1 1 1 1 1 1 1 1 1 4

Quantities are for a single Purge Valve. Two Valves are fitted to the complete Air Dryer. Maintenance Kit Maintenance kit part no. 790 0291 85 (D&M Ref. RK-AB787-W36) comprises 1 (1 no.), 2 (1 no), 3 (1 no.), 4 (1 no.), 5 (1 no.) and 11 (1 no.). Refer to drawing of the kit for identification of parts. Two kits are needed if both Valves are to be overhauled.

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List of Parts Purge Valve Drawing no. 029 1007 00 (D&M Ref. AB787-W36A)

Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

FTIL Part No. 099 3003 00 029 4230 00 029 6010 00 029 8410 00 029 7015 00 029 4240 00 029 7250 00 029 4140 00 099 6001 00 099 5003 00 029 7095 00 029 4210 00 029 8055 00 029 3060 00

Applicable for 975-124 model Dryers

D&M Part / Drg No. AB787-143 AB787-129F AB787-129G AB787-129H AB787-144 AB787-129J AB787-129K AB787-129L AB787-155 AB787-129M AB787-129N AB787-129O AB787-129P AB787-129Q

Description Nut Seat Washer Seat Stem O Ring Piston Cup Seal Cap Cap Screw Lock Washer O Ring Body Spring Spring Cap

Qty / Unit 1 1 1 1 1 1 1 1 4 4 1 1 1 1

Quantities are for a single Purge Valve. Two Valves are fitted to the complete Air Dryer. Maintenance Kit Maintenance kit part no. 790 0292 55 (D&M Ref. RK-AB787-W36A) comprises 1 (1 no.), 3 (1 no.), 5 (1 no.), 7 (1 no.), 11 (1 no.) and 17 (1 no.). Refer to drawing of the kit for identification of parts. Two kits are needed if both Valves are to be overhauled.

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List of Parts

Solenoid Valve Drawing no. 029 1008 00 (D&M Ref. AB787-W37) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13

FTIL Part No. 029 1008 00 029 8360 00 029 7230 00 029 2050 00 029 8350 00 901 0370 00 025 2080 00 029 7210 00 029 2070 00 029 9040 00 029 8420 00 029 8430 00 029 8440 00

D&M Part / Drg No. AB787-198 AB787-199 AB787-200 AB787-201 AB787-202 AB787-203 AB787-204 AB787-205 AB787-206/D AB787-194 AB787-207 AB787-208 AB787-209

Description O Ring Solenoid Valve Body O Ring Plunger Assembly Spring Cap Screw Adaptor Assembly O Ring Coil (74 v dc) Gasket Coil Housing Magnet Eye Bolt

Qty / Unit 2 2 2 2 2 8 2 4 2 2 2 2 2

Quantities are for the complete Air Dryer. Maintenance Kit Maintenance kit, part no. 790 0291 55 (D&M Ref. RK-AB787-W37), comprises item 1 (1 no.), 3 (1 no.), 4 (1 no.), 5 (1 no.), 8 (2 nos.) and 10 (1 no.). Refer to drawing of the kit for identification of parts. Two kits are needed if both Solenoid Valves are to be overhauled.

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List of Parts

Final Filter Drawing no. 029 0010 00 & 029 0012 00 (D&M Ref. AB787-W40).

Item No. 1 2 3 4 5 6 7 8 9 10 11 12

FTIL Part No. 029 3380 00 099 5001 00 099 3001 00 029 7150 00 029 1080 00 029 3390 00 099 8006 00 & 099 8007 00 029 3370 00 029 4150 00 029 7200 00 029 8390 00 029 1250 00

D&M Part / Drg No.

Description

Qty / Unit

AB787-134 AB787-39 AB787-43 AB787-135 AB787-136 AB787-137 AB787-118

Filter Body Lock Washer Nut O Ring Filter Element Bottom Cap Nut with Lock Washer

1 2 2 1 1 1 6

AB787-138 AB787-139 AB787-140 AB787-244 AB787-141

Filter Retainer Wing Nut Tetra Seal Adaptor Shut off Assembly

1 1 1 1 1

Maintenance kit Maintenance kit, part no. 790 0291 25 (D&M Ref. RK-AB787-W40) comprises items 4 (1 no), 5 (1 no) & 10 (1 no).

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List of Parts Compactor / Sump Cap Assembly Drawing no. 029 1009 00 (D&M Ref. AB787-W41)

Item No. 1 2 3 4 5 6 7 8 9 10 11

FTIL Part No. 029 7150 00 099 7002 00 029 3210 00 099 2001 00 029 3240 00 029 7065 00 029 7090 00 029 3030 00 029 7055 00 029 3290 00 029 3291 00

D&M Part / Drg No. AB787-135 AB787-225 AB787-226 AB787-227 AB787-228 AB787-98 AB787-231 AB787-230 AB787-229 AB787-253 AB787-253A

Description O Ring Pan Head Screw Spider Screw Cap Seal Seal Piston Seal Sump Cap (975-123) Sump Cap (975-124)

Qty / Unit 2 2 2 4 2 2 2 2 2 2 2

Quantities are for complete Air Dryer. Two Compactor / Sump Cap Assemblies are required for one complete Air Dryer. Maintenance Kits Maintenance kit part no. 790 0292 05 (D&M Ref. RK-AB787-W41) includes parts for the Compactor and comprises items 6 (1 no.), 7 (1 no.) and 9 (1 no.). Refer to drawing of the kit for identification of parts. Two off each kit are needed if both Canister Assemblies are to be overhauled.

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List of Parts Junction Box Electrical Components (Memory) Drawing no. 029 1175 00 (D&M Ref. AB787-W42) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

FTIL Part No.

D&M Part / Drg No.

029 3400 00 029 8135 00 029 1065 00 029 2070 00 029 2080 00 099 7001 00 099 7004 00 939 0268 00 029 2012 00 029 7075 00 099 7005 00 099 5006 00 029 8130 00 029 2090 00

AB787-189 AB787-231 AB787-190 AB787-233 AB787-234 AB787-235 AB787-236 AB787-249 AB787-250 AB787-239 AB787-241 AB787-240 AB787-242 AB787-237

Description Housing Cap Screw with Seal Pressure Switch (100 psi) Receptacle Assembly Barrier Strip Cap Screw Cap Screw Wire Nut Timer / Circuit Board Assy (memory) Gasket Cap Screw Lock Washer Burndy Connector Assembly Terminal Block Assembly

Qty / Unit 1 4 1 2 1 2 3 1 1 1 4 4 1 1

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List of Parts Desiccant Canister Drawing no. 029 1180 00 (D&M Ref. AB787-W44) Item No. 1 2 3 4

FTIL Part No.

D&M Part / Drg No.

029 8140 00 029 2100 00 029 9020 00 029 3020 00

AB787-128 AB787-129 AB787-130 AB787-131

Applicable for 975-123 model Dryers Description

Retaining Ring Canister Disc Assembly Desiccant charge Desiccant Canister

Qty / Unit 4 4 7.2 kgs 2

Quantities are for complete Air Dryer. Two desiccant assemblies are required for one complete Air Dryer. Maintenance kit Maintenance kit part no. 790 0291 95 (D&M Ref. RK-AB78-W44) includes parts for recharging the desiccant canister and comprises items 1 (4 nos.), 3 (7.2 kgs) and O Ring (2 nos.) to part no. 029 7140 00 (D&M Ref. AB787-119). Refer to drawing of the kit for identification of parts.

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List of Parts Desiccant Canister Drawing no. 029 1185 00 (D&M Ref. AB787-W44A) Item No. 1 2 3 4

FTIL Part No. 029 8140 00 029 2100 00 029 9020 00 029 3020 00

D&M Part / Drg No. AB787-128 AB787-129 AB787-130 AB787-131A

Applicable for 975-124 model Dryers Description

Retaining Ring Canister Disc Assembly Desiccant charge Desiccant Canister

Qty / Unit 4 4 4.9 kgs 2

Quantities are for complete Air Dryer. Two Desiccant Canister assemblies are required for one complete Air Dryer. Maintenance kit Maintenance kit part no. 790 0292 45 (D&M Ref. RK-AB787-W44A) includes parts for recharging the Desiccant Canister and comprises items 1 (4 nos.), 3 (4.9 kgs) and O Ring (2 nos.) to part no. 029 7140 00 (D&M Ref. AB787-119). Refer to drawing of the kit for identification of parts.

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List of Parts Outlet Check Valve (with memory) Drawing no. 029 1190 00 (D&M Ref. AB787-W48) Dryers

Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

FTIL Part No. 029 3320 00 029 1220 00 029 7130 00 029 3400 00 029 1065 00 029 1066 00 029 7120 00 029 2110 00 029 2012 00 029 1240 00 029 9040 00 029 8065 00 029 6070 00 099 3002 00 099 5003 00 029 7015 00 029 8180 00

D&M Part / Drg No. AB787-186 AB787-187 AB787-188 AB787-189 AB787-190 AB787-190/1 AB787-191 AB787-192 AB787-250 AB787-W37 AB787-194 AB787-195 AB787-243 AB787-196 AB787-186 AB787-144 AB787-197

Applicable for 975-123 & 124 model

Description Outlet Valve Body Humidity Indicator O Ring Housing Pressure Switch (100 psi) Pressure Switch (75 psi) Gasket Cover Assembly Timer and Circuit Board Assembly Solenoid Assembly Gasket Spring Plastic Wing Valve Nut Lock Washer O Ring Adaptor

Qty / Unit 1 2 2 1 1 1 1 1 1 2 2 2 2 8 8 1 1

Pressure Switch data: a)

029 1065 00 (D&M Ref. AB787-190)

-

Closes @ 100 psi ± 5 psi Opens @ 80 psi ± 5 psi

b)

029 1066 00 (D&M Ref. AB787-190/1)

-

Closes @ 75 psi ± 5 psi Opens @ 55 psi ± 5 psi

Maintenance Kit Maintenance Kit part no. 790 0291 45 (D&M Ref. AB787-W29) comprises item 11 (1 no.) and 12 (1 no.). Refer to drawing of the kit for identification of parts.

Page 89

Complete Air Dryer Maintenance kit

790 0291 15 (D&M Ref. RK-AB787-T17) 790 0291 16 (D&M Ref. RK-AB787-T17B) The Dryer Maintenance kits comprises the following maintenance kits and individual items. 790 0291 35 (D&M Ref. RK-AB787-W27A) Kit for Inlet Check Valve 2 790 0291 65 (D&M Ref. RK-AB787-W27B) Kit for Pre-Coalescer 1 790 0291 75 (D&M Ref. RK-AB787-W28) Kit for Drain Valve 1 790 0291 45 (D&M Ref. RK-AB787-W29) Kit for Outlet Check Valve 2 A Kit for Purge Valve 2 790 0291 55 (D&M Ref. RK-AB787-W37) Kit for Solenoid Valve 2 790 0291 11 (D&M Ref. RK-AB787-W39) Kit for Regenerating Orifice 1 790 0292 05 (D&M Ref. RK-AB787-W41) Kit for Desiccant Compactor 2 B Kit for Desiccant Canister 2 790 0291 05 (D&M Ref. RK-AB787-187) Kit for Humidity Indicator 2 029 7190 00 (D&M Ref. AB787-121) Flange Purge Valve O Rings 8 029 7150 00 (D&M Ref. AB787-125) Dryer Body and Spacer O Ring 4 029 7180 00 (D&M Ref. AB787-173) O Ring for Inlet Manifold Body 1 029 7130 00 (D&M Ref. AB787-188) O Ring for Outlet Manifold 2 029 7120 00 (D&M Ref. AB787-191) Gasket for Electrical Box 1 029 7200 00 (D&M Ref. AB787-224) Tetra Seal for Drain Valve 1 029 7075 00 (D&M Ref. AB787-239) Gasket for Burndy Connector 1 029 7015 00 (D&M Ref. AB787-144) O Ring for Pr. Switch Adaptor 1 Note that Maintenance Kit 790 0291 45 (D&M Ref. RK-AB787-W29) covers both 029 1005 00 (D&M Ref AB787-W29) and 029 1190 00 (D&M Ref. AB787-W48) assemblies. Dryer Model No. 975-123 975-124

Kit Part No.

A

B

790 0291 15 (D&M Ref. RK-AB787-T17) 790 0291 16 (D&M Ref. RK-AB787-T17B)

790 0291 85 (D&M Ref. RK-AB787-W36) 790 0292 95 (D&M Ref. RK-AB787-W36A)

790 0291 95 (D&M Ref. RK-AB787-W44) 790 0292 45 (D&M Ref. RK-AB787-W44A)

Piping Assembly Part No. 029 1500 00 (D&M Ref. AB787-W30) 029 1510 00 (D&M Ref. AB787-W30B)

Note the piping assemblies may be ordered separately or collectively as one kit part number. 029 1500 00 (D&M Ref. AB787-W30) = 029 1010 00 (D&M Ref. AB787-W31) & 029 1015 00 (D&M Ref. AB787-W32) & 029 1020 00 (D&M Ref. AB787-W33). 029 1510 00 (D&M Ref. AB787-W30B) = 029 1022 00 (D&M Ref. AB787-W31B) & 029 1018 00 (D&M Ref. AB787-W32B) & 029 1024 00 (D&M Ref. AB787-W33B).

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TROUBLE SHOOTING GUIDE Safety Warning: The Air Dryer is an electrically controlled compressed air device. Compressed air and electricity can be extremely dangerous if not handled carefully. a)

b)

If dryer is not cycling: 1.

Confirm that the Main Reservoir system pressure is above 105 psi and electrical power is available to Dryer.

2.

Remove electrical make-up box cover and look for burnt connections, overheated or shorted components, broken connections, corrosion or other obvious electrical damage.

3.

If circuit board is burnt or has burnt components, replace the circuit board.

4.

If circuit board does not show obvious damage, verify that power is available to the circuit board connectors by removing the circuit board and checking connectors in electrical box with a voltmeter.

5.

If power is not available at the circuit board connectors, short the terminals of the Pressure Switch. If power becomes available at the connectors when switch is shorted, replace the Pressure Switch.

6.

If power is available at the circuit board connectors, the circuit board should be replaced.

7.

If the above steps do not correct the problem, the Dryer should be removed for service.

If a Drain or Purge Valve has a small continuous leak: If any of the Valves (two purge on dryer towers and one double seated drain on Coalescer) are suspected to be leaking, the electrical power should be disconnected from the dryer and if air leaks from a Valve with no power applied, the Valve should be replaced. Note that a large blast followed by a small continuous exhaust of air from the Purge Valves on a timed basis is normal dryer operation.

c)

If dryer is blowing excessively out either Purge Valve: This failure is caused by either a stuck inlet or outlet check valve. Both conditions are not practical to service on the Locomotive and the Dryer should be removed from service. Page 101

d)

If the PCB is suspected to be defective: This can be sorted out by testing the PCB in the test kit which if requested, will be supplied by FTIL. If the PCB is found to be defective, replace it with a new PCB. Do not try to tamper any of the components assembled in the PCB. Ordering reference for PCB test kit : RBTR 0113.

e)

The dryer needs to be attended if Humidity Indicator colour is as follows: BLUE INDICATOR – indicates Dryer has been performing correctly Verify Dryer is cycling If Dryer is cycling correctly & # 1 Main Reservoir Drain Valve is operating correctly Release for service. LAVENDER INDICATOR – Dryer is suspect Check for water in Final Filters If water is found in Final Filters Remove Dryer and replace with a new or remanufactured Dryer. If no water found in Final Filters Verify Dryer is cycling correctly. If Dryer is cycling correctly & # 1 Main Reservoir Drain Valve is operating correctly Release for service. WHITE INDICATOR – Possible damaged Dryer. Check for water in Final Filters. Dryer desiccant has been damaged by excessive amount of water. Remove Dryer and replace with a new or remanufactured Dryer. Verify new Dryer is cycling correctly and # 1 Main Reservoir Drain Valve is operating correctly.

YELLOW OR BROWN INDICATOR – Damaged Dryer Dryer has been damaged by oil. Verify if the Dryer is cycling properly by charging the Main Reservoir circuit. Particularly verify if the Double Seated Purge Valve of the Pre-Coalescer is operating correctly every time the Dryer is cycling. Page 102

Switch off the Compressor and drain the Main Reservoir pressure. Remove Dryer and replace with a new or remanufactured Dryer. Report compressor problem. If new Dryer is cycling correctly & # 1 Main Reservoir Drain Valve is operating correctly Release for service. Take the Dryer to the workshop and verify the following. 1) Open the Pre-coalescing Filter Body & Sump Cap and remove the Pre-coalescing Filter. 2) Referring to para 15 of the manual, dismantle the Pre-coalescing Filter as shown in fig 17 and check if the upper molded cap of Pre-coalescing Element (item 4) is damaged. If found damaged, replace Pre-coalescing Element (item 4). Open both the dry towers as given in fig on page 48 under reference drawing no. 029 1001 00 and examine the desiccant beads. If the beads, especially at the bottom side of the canister appear brown colour, it indicates oil carry over from the Pre-coalescing Filter. The brown colour desiccant has to be replaced in each of the towers. However, before replacing the cause of the excess oil throw must be identified and reported. If it is a problem in the Pre-coalescing Element, it has to be replaced before the Dryer with the new desiccant is assembled. Make sure that the Auto Drain Valve fixed in first Main Reservoir is functioning correctly. Alternately, if the Auto Drain Valve is actuated by a pressure signal tapped from the Air Dryer itself, make sure that the Auto Drain Valve in the first Reservoir is actuated briefly whenever one full cycling is completed by the Dryer. Before fixing the new Dryer, open the Final Filter assembly also and verify if the Filter element also is damaged by oil throw. If needed, replace the Filter element. Check the inside of the Final Filter Body for coat of oil. If oil is found, clean the Filter Body and drain the cock using a suitable solvent and reuse only after cleaning the Filter Body and the Drain Cock. Note: If the oil carry over is not set right before the new Dryer is installed, it is very likely that the replaced Dryer will suffer the same problem.

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f)

If the outlet pressure is not building up and the Safety Valve on the Inlet side blows of continuously: Check for proper seating of both the Solenoid Valve plungers. If the rubber is found to be defective, replace the plungers. Check and clear any blockage in the eye bolt vent hole of Solenoid Valve. Check for cycling of Solenoids after one minute interval each. If cycling is not noticed further check the PCB for any electrical fault. Check for cycling of Solenoids after one minute interval each. If cycling is not noticed, further check the PCB for any electrical fault. Replace if required.

The following are the exclusive part numbers for ordering reference, which includes Air Dryer, Final Filter, Auto Drain Valve and other accessories. 1.

790 0292 07

029 0115 00

-

010 0011 00 709 0041 00 029 8120 00 936 0538 00 002 0200 00

-

Consists of Air Dryer assembly 029 0027 00 & Final Filter 029 0010 00 Auto Drain Valve 3/8 BSP Air Strainer (Y type) Male Branch Tee Special Adaptor Double Check Valve 3/8

Refer the configuration table in page 1 for other details on Air Dryer assembly. 2.

790 0292 08

029 0120 00

-

010 0011 00 709 0041 00 029 8120 00 936 0538 00 002 0200 00

-

Consists of Air Dryer assembly 029 0032 00 & Final Filter 029 0012 00 Auto Drain Valve 3/8 BSP Air Strainer (Y type) Male Branch Tee Special Adaptor Double Check Valve 3/8

Refer the configuration table in page 1 for other details of Air Dryer assembly.

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3.

790 0293 06

029 0116 00

-

010 0011 00 709 0041 00 029 8120 00 936 0538 00 002 0200 00

-

Consists of Air Dryer assembly 029 0028 00 & Final Filter 029 0012 00 Auto Drain Valve 3/8 BSP Air Strainer (Y type) Male Branch Tee Special Adaptor Double Check Valve 3/8

Refer the configuration table in page 1 for other details of Air Dryer assembly. 4.

790 0292 06

029 0119 00

-

010 0011 00 709 0041 00 029 8120 00 936 0538 00 002 0200 00

-

Consists of Air Dryer assembly 029 0031 00 & Final Filter 029 0010 00 Auto Drain Valve 3/8 BSP Air Strainer (Y type) Male Branch Tee Special Adaptor Double Check Valve 3/8

Refer the configuration table in page 1 for other details of Air Dryer assembly. 5.

790 0292 09

029 0121 00

-

010 0011 00 709 0041 00 029 8120 00 936 0538 00 002 0200 00

-

Consists of Air Dryer assembly 029 0033 00 & Final Filter 029 0012 00 Auto Drain Valve 3/8 BSP Air Strainer (Y type) Male Branch Tee Special Adaptor Double Check Valve 3/8

Refer the configuration table in page 1 for other details of Air Dryer assembly. 6.

790 0292 10

029 0122 00

-

010 0011 00 709 0041 00 029 8120 00 936 0538 00 002 0200 00

-

Consists of Air Dryer assembly 029 0035 00 & Final Filter 029 0010 00 Auto Drain Valve 3/8 BSP Air Strainer (Y type) Male Branch Tee Special Adaptor Double Check Valve 3/8

Refer the configuration table in page 1 for other details of Air Dryer assembly.

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