air dryer- ae aug _dec 2010_.pdf

8/18/2019 Air Dryer- AE Aug _DEC 2010_.pdf

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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


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FAIVELEY TRANSPORT INDIA LIMITEDPOST BOX # 39

HARITA, HOSUR – 635 109TAMILNADU, INDIA

Phone : + 91 (4344) 276761 to 276765Fax : + 91 (4344) 276035, 276786, 276033

Email : [email protected]

REGIONAL OFFICES

Faiveley Transport India LimitedB-44/C, Gangotri EnclaveAlaknanda,New Delhi – 110 019

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

Faiveley Transport India LimitedNo. 51, Radhanath Chowdhury RoadSatyajit Tower, 5th FloorKolkata – 700 015

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


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Revision Record

DateNew

VersionNo.

Pages Changed Reason

April, 2001 1 - New Publication

August, 2001 2 1 Correction in Product Configurationtable

November,2001

3 16 (previously20)

Maintenance Schedule of Mufflerchanged

February, 2002 4 16 (previously

20)

Maintenance Schedule of Air Dryer

revised in line with actual practice.February, 2002 5 97 (previously

113)Page 97 (previously 113) revised.

December, 2002 6 Various a) Product Configuration tablerevised.

b) Equivalent FTIL part nos.provided for all the parts andassemblies.

c) Auto Drain Valve kit list added.

d) Maintenance kit list tabulated intheir respective sheets.

e) Fuse kit deleted.

March, 2004 7 Various Manual Reformatted.

August, 2004 8 Sketches for975-123 & 975-124

Operating voltage corrected for bothmodels.

March, 2006 9 Various Manual Reformatted.

May, 2008 10 77O-Ring part no: 029 7220 00 was

029 1008 00

Aug ’ 2008 11 VariousManual updated as per latestpart numbers.

15.10.2010 12 Various Molykote Grease M33 was M55(updated Page 4, 39, 40,44-46,& 55)


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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


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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


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Health and Safety

The following points must be considered and appropriate precautions taken when workingon 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 handledcarefully. DO NOT attempt to service, repair or break any connections without firstassuring 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 areexposed once electrical covers are removed. Maintenance should be carried out onlyby qualified personnel. This device is safe for operation only with the electricalcovers in place.

3. Oils and greases are used which could be a hazard.

4. Chemical cleaning agents may be used for certain operations, the manufacturershandling procedures must be followed.

5. This product contains material which may cause temporary eye and possibly skinirritation. Avoid breathing dust and prolonged contact with skin of the desiccant

material. Wash thoroughly after handling. Use with adequate ventilation. Contactwith moisture (water) can cause rise in temperature which may result in burn.

6. This manual contains information and warning which must be observed by theuser. Failure to adhere to these recommendations could result in mechanicalfailure, property damage and serious injury or death.

7. The weight of the dryer is approximately 65 kg and the Final Filter 7 kgs.


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FAIVELEY TRANSPORT Twin Tower Air Dryer

1. Introduction

The Faiveley Transport 975-120 series twin tower Air Dryers have been developedespecially to suit traction requirements. The dryers remove moisture from thecompressed air supply and ensure that only clean dry air reaches all air operatedequipment. A supply of clean dry air ensures that all air operated equipmentfunctions more efficiently and that the high maintenance costs associated withcontaminated systems are eliminated.

The twin tower Air Dryer system includes a pre-coalescer which removes impuritiesfrom the compressed air supply, and desiccants (activated alumina) located in thedrying towers which remove moisture. After removing moisture, the desiccants‘regenerate’ (restore to their original dryness) during the operating cycle, one cycle ofwhich is described in the section ‘Operation’.

2. Capacity and Applications

Faiveley Transport Air Dryers are made in a range of sizes in twin towerconfiguration. The dryer capacities range from 1000 to 5000 lpm free air deliverycompressor 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. Otherconfigurations can be developed for specific customer needs.

DryerType

FTIL PartNo.

Type VoltageOrifice

sizeMuffler

Pr.Switch

MtgBkt

Pipinginterf-

ace

Applica--tion

975-123with

memory

029002700 Ext. Model 48-110 VDC

0.11” YES 100 PSI YES 1”NPT

Diesel Locos

975-123with

memory

029003200 Ext. Model 48-110 VDC

0.11” YES 100 PSI YES 1¼”NPT

Elec. LocosWAG9, WAP5,GM loco (WDG4& WDP-4)

975-129with

memory

029002800 Std. Model(Shorterversion)

48-110 VDC

0.0625” YES 100 PSI YES 1¼”NPT

Elec. LocosWAG7, WCAM3,WCAG1.

975-124 029003100 Std. Model(Shorterversion)

48-110 VDC

0.052” YES 75 PSI YES 1-1/4”BSPT

EMUs, MG,DEMUs, Others

975-124with

memory

029003300 Std. Model(Shorterversion)

48-110VDC

0.052” YES 100 PSI YES 1” NPT WAP4 Locos

975-124

withmemory

029003500 Std. Model

(Shorterversion)

48-110V

DC

0.0625” YES 75 PSI YES 1¼”

NPT

HHP DEMU


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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 ineach tower are fitted on the dryers. Also, the Final Filter is a standard accessory. Forthe exclusive part numbers which includes Air Dryer, Final Filter, Auto Drain Valveand other accessories refer pages 104 & 105.

3.0 System Description

For the purpose of the following explanation, a Pressure Switch with a 100 psi ratingis considered as an example.

The twin tower Air Filter / Dryer is an air drying system comprising two Air Dryertowers connected by a common inlet manifold with integral pre-coalescer andcommon outlet manifold. The system also includes an electric timer which controlsthe system cycle and allows the unit to ‘regenerate’ only when a predeterminedpressure of approximately 6.9 ksi (100 psi) is reached and the compressor or anycompressor in the consist, is loaded (pumping). Until such time, both Air Dryertowers 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 passesthrough a borosilicate coalescer element comprising four pleated plys which aresupported, externally and internally, by two layers of corrugated / perforatedstainless steel. The coalescer removes microscopic oil aerosols of one micron or lessfrom the compressed air preventing them from entering the drying towers.

Construction of the coalescer filter element is in two layers of pleated borosilicatemedia supported on both sides by pleated polyester media. The first layer of

polyester media serves as a particulate prefilter and helps to evenly distribute theflow of air into the first coalescing layer. The first coalescing layer coalesces the waterand oil aerosols into larger droplets. The second coalescing layer completes thecoalescing operation while the last layer of polyester media enhances drainage.

A desiccant (activated alumina) in the Air Dryer towers then removes water vapourfrom 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


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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 airpressure. The drop in pressure forces the collected impurities from the right AirDryer tower to atmosphere while the moisture absorbed by the desiccant beads isreleased to the surface of the beads.

A small amount of dry air from the left hand side Air Dryer tower then flows throughthe ‘regenerating’ orifice in a reverse direction over and through the right hand sideAir Dryer desiccant beads. Moisture, released to the surface of the desiccant beads, ispicked up by the dry air and exhausted through the open Purge Valve at a levelslightly above atmospheric pressure. In addition, the double seated automatic Drain

Valve located at the sump of the pre-coalescer exhausts any collected impurities toatmosphere.

While the right hand side dryer tower is in the ‘regenerating’ phase, the left hand sidetower is in the ‘dehydrating’ phase and is removing moisture from the compressedair 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 inletand 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 sidedryer ‘dehydrates’ removing moisture as air passes over and through the desiccantbeads 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. Asbefore, the automatic double seated Drain Valve on the pre-coalescer sump exhauststhe collected impurities to atmosphere.

Non-memory type

The drying operation as described above continues as long as the power supply tothe dryer is uninterrupted. The cycling and purging will go on even if theCompressor 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 theparticular Pressure Switch used in the dryer. When the pressure drops down belowthis rating, the power to the dryer control circuit is cut off and the cycling action ofthe dryer will stop. When the Compressor begins to pump, the dryer will begin toregenerate in the right side tower from the beginning of the cycle regardless of whereit previously stopped. The dryer can be changed to memory type by changing thePCB. Refer to the proposed schematic shown in sketch no. FTIL/AD/0363 where theCompressor and Air Dryer needs to be synchronized when the PCBs are changedform Non memory to memory version working under multiple unit operation. Referto 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-energiseboth Solenoid Valves and both dryer towers will return to ‘dehydrating’ mode. Inaddition both the Purge Valves as well as the double seated Purge Valve of the pre-coalescer will remain closed stopping discharge of air from the system. During thisstage, any air drawn from air reservoirs upstream of the Air Dryer will bedehydrated. When the compressor is loaded again, the dryer will commence thecycling 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 iscomplete 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 monitorthe 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 successfuloperation of any form of desiccant.

5.3 Filter/Dryer Body

The desiccant beads, which extract the moisture from the air, are housed in twoaluminum 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 constantpacking density throughout the period of operation in the Dryer. In comparison, thestandard spring loaded compactors provide a decreasing compacting pressure as thespring expands due to attrition of the desiccant beads which is unavoidable. Eachdesiccant canister contains a pneumatic compactor which is charged withcompressed air to maintain a constant mechanical pressure upon a movable disclocated in the bottom of the sump cap. Consequently, the alumina remains compact

and tight preventing attrition of the desiccant beads.


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5.5 Pressure Switch

An integral pressure sensing device is located internally to control the air dryingcycle. 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, cyclingstops immediately and air flows through both Air Dryers to support the immediateair 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 ofthe desiccant is an unavoidable phenomena as explained in para 5.4. If themicroscopic particulates are allowed to pass through the air stream unfiltered, theymay get deposited in critical pneumatic equipment like brake valves causingfunctional problem in such equipment. FTIL Dryer is provided with a separate unitwhich removes any dust generated after air has passed through the main dryersystem.

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 atimer with a cycling frequency of 1 minute to energise the Solenoid Valve of eachtower. The PCBs from Sl. No. M01001 have been redesigned to work satisfactorilyeven 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 installationschanged over to modified design. With the modified design PCB, the fuse provisioncan be deleted.

CAUTION

After removing the fuse and related wiring, the hole in the electrical junction boxis to be suitably kept plugged to prevent entry of dust and foreign matter into theelectrical enclosure.

5.8 Air Dryer Tower Indication

Two LED indicators for one each tower are provided in the terminal box cover toindicate the drying tower during cycling. Refer to electrical schematic C-D3301 sheet1 of 2 for electrical connections.


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5.9 Auto Drain Valve Kit

Auto Drain Valve Kit is recommended to be fitted along with the Air Dryer inservice. 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 Air Strainer (Y type) 1

3 029 8120 00 Male Branch Tee ¼” 1

4 936 0538 00 Spl.Adaptor 7/16” UNF x 3/8”bsp 1

5 002 0200 00 Double Check Valve 3/8” 1


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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 MainReservoirs. Refer sketch in next page.

The under frame location exposes the dryer to cooling air flow produced from Locomotivetravel. Locating the dryer behind Main Reservoir as said above prevents the dryer frombeing exposed to the large amounts of liquid which can precipitate in the compressoraftercooler cooling pipe.

In addition to this location, there should be an Auto Drain Valve fixed immediately beforethe Dryer. Absence of this facility may increase the load on the Dryer and may reduce itsefficiency.

In the EMU’s installation, there should be a Reservoir of at least 50 litres immediately afterthe Dryer to provide the necessary back pressure and volume on the Outlet Check Valve ofthe Dryer. There should not be any device like Check Valve between the Air Dryer and thisReservoir.

It is suggested that the Auto Drain Valve fixed on the MR immediately before the Dryer beactuated by the control pressure from the Dryer itself to ensure a frequent and brief purgingof the moisture from the Reservoir. In such installation, the timing chamber provided in theAuto 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 PCBis 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 away that the other inductive loads in the circuit are not applied to the Dryerelectrical.


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1 - 1/4”

NPT

INLET

: 48 – 130 V DC


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6.0 Maintenance Schedule

SCHEDULEMAINTENANCE Fortnightly Monthly 6 Months Year 3 Years

Inspect Humidity Indicators (ref.trouble shooting guide). 4

Check for proper purging 4 Check for proper cycling 4 Check for Automatic Drainingthrough Double Seated Valve 4

Check for any external leakage. 4 Check for proper functioning forPressure Switch 4

Inspect Regenerating Orificeoperation 4

Check the condition ofPrecoalescing Element (replace ifcontaminated)

4

Check the condition of Final FilterElement (replace if contaminated) 4

Clean Mufflers 4 Replace Mufflers 4

Clean Purge Valves 4 Clean Double Seated Auto DrainValve 4

Check proper functioning of TimerCircuit Board 4

Check the condition of Desiccant(replace if contaminated) 4

Renew all Rubber Parts 4

Renew Precoalescer Kit 4

Renew Final Filter kit 4 Completely overhaul the Air Dryer(ref. Maintenance Manual) 4

Renew the Desiccant Canister Kit 4


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Recommended Spare Parts list for Air Dryer

Parts to be renewed every year (ROH) while overhauling the Air Dryer and Final Filter

entirely (Longer Version).

Sl. No. Description of Spares

FTIL Part No. D&M Part No.

Qty /

Air Dryer

Minimum stock to be

kept in a shed for a fleet of 25 Air Dryers

1 Inlet man coalescer kit (AD) 790 0291 65 RK-AB787-W27B 1 8

2 Kit for Final Filter 790 0291 25 RK-AB787-W40 1 8

3 Regenerating orifice kit (AD) 790 0291 11 RK-AB787-W39 1 5

Parts to be renewed every three years (TOH) while overhauling the Air Dryer and FinalFilter entirely (Longer Version).

Sl. No.

Description of Spares FTIL Part

No. D&M Part No.

Qty / Air

Dryer

Minimum stock to bekept in a shed for a

fleet of 25 Air Dryers1 Inlet man coalescer kit (AD) 790 0291 65 RK-AB787-W27B 1 8



4 Inlet Check Valve kit (AD) 790 0291 35 RK-AB787-W27A 2 10

5 Drain Valve kit (AD) 790 0291 75 RK-AB787-W28 1 5

6 Outlet Check Valve kit (AD) 790 0291 45 RK-AB787-W29 2 10

7 Purge Valve kit (AD) 790 0291 85 RK-AB787-W36 2 10

8 Solenoid assembly kit (AD) 790 0291 55 RK-AB787-W37 2 10

9 Compactor assembly kit (AD) 790 0292 05 RK-AB787-W41 2 10

10 O Ring (ID 1.359 x width - 0.139) 029 7190 00A AB787-121 10 80

11 O Ring (ID 5.234 x width - 0.139) 029 7150 00A AB787-125 4 3212 O Ring (ID 1.734 x width - 0.139) 029 7130 00A AB787-188 2 16

13 Electrical Box Gasket 029 7120 00 AB787-191 1 5

14 Tetra seal for Drain valve 029 7200 00 AB787-224 1 8

15 Gasket for Burndy Connector 029 7075 00 AB787-239 1 8

16 Humidity Indicator kit (AD) 790 0291 05 RK-AB787-187 2 15

17 Desiccant Canister Kit (AD) 790 0291 95 RK-AB787-W44 2 15

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

Renewable Spare Parts for Air Dryer on condition basis (Longer Version)

Sl. No


No. D&M Part No.

Qty / Air

Dryer


fleet of 25 Air Dryers

1 Pressure Switch (100 psi) 029 1065 00 AB787-190 1 3

2 Memory PCB assy 029 2013 00 AB787-250 1 8

3 Coil 74 V DC 029 2070 00 AB787-206 2 6

4 Piping Assy (Extended) 029 1010 00 AB787-W31 1 3



7 Burndy Connectors (Female) 029 8132 00 - 1 5

8 Burndy Connectors (Male) 029 8130 00 - 1 5

* This may be renewed in every four years unless otherwise deemed necessary earlier.


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Recommended Spare Parts list for Air Dryer Parts to be renewed every year (ROH) while overhauling the Air Dryer and Final Filter

entirely (Shorter Version).

Sl.

No. .Description of Spares

FTIL Part

No. D&M Part No.

Qty /

Air Dryer

Minimum stock to be

kept in a shed for a fleet of 25 Air Dryers1 Inlet man coalescer kit (AD) 790 0291 65 RK-AB787-W27B 1 8



Parts to be renewed every three years (TOH) while overhauling the Air Dryer and FinalFilter entirely (Shorter Version).

Sl. No.


No. D&M Part No.

Qty / Air

Dryer



1 Inlet man coalescer kit (AD) 790 0291 65 RK-AB787-W27B 1 8



4 Inlet Check Valve kit (AD) 790 0291 35 RK-AB787-W27A 2 10

5 Drain Valve kit (AD) 790 0291 75 RK-AB787-W28 1 5

6 Outlet Check Valve kit (AD) 790 0291 45 RK-AB787-W29 2 10

7 Purge Valve kit (AD) 790 0292 95 RK-AB787-W36 2 10

8 Solenoid assembly kit (AD) 790 0291 55 RK-AB787-W37 2 10

9 Compactor assembly kit (AD) 790 0292 05 RK-AB787-W41 2 10



12 Electrical Box Gasket 029 7120 00 AB787-191 1 5

13 Tetra seal for Drain valve & PurgeValve

029 7200 00 AB787-224 3 24

14 Gasket for Burndy Connector 029 7075 00 AB787-239 1 8

15 Humidity Indicator kit (AD) 790 0291 05 RK-AB787-187 2 15

16 Desiccant Canister Kit (AD) 790 0292 35 RK-AB787-W44 2 15


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

Renewable Spare Parts for Air Dryer on condition basis (Shorter Version)

Sl. No


No. D&M Part No.

Qty / Air

Dryer



1 Pressure Switch (100 psi) 029 1065 00 AB787-190 1 3

2 Memory PCB assy 029 2013 00 AB787-250 1 8

3 Coil 74 V DC 029 2070 00 AB787-206 2 6

4 Piping Assy (Smaller) 029 1022 00 AB787-W31 1 3



7 Burndy Connectors (Female) 029 8132 00 - 1 5

8 Burndy Connectors (Male) 029 8130 00 - 1 5* This may be renewed in every four years unless otherwise deemed necessary earlier.


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Tooling list for overhauling Air Dryer

Below is a list of basic tools required during the dismantling and assembly process of AirDryer. These may be supplied by FTIL, if requested.

Standard Tools

Tool List – Part No. 790 0293 55

Tool Description Ordering Reference

• 10” Extension 3/8 Drive AA1022001

• 3/8” Open ended wrench AA1022002

• 3/8” Socket – 3/8” drive AA1022003• 7/16” Open ended wrench AA1022004

• 7/16” Socket – 3/8” drive AA1022005

• ½” Open ended wrench AA1022006

• ½” Socket – 3/8” drive AA1022007

• 9/16” Open ended wrench AA1022008

• 9/16” Socket – 3/8” & ½” drive AA1022009

• 5/8” Open ended wrench AA1022010• 5/8” Socket – 3/8” drive AA1022011

• 1” Open ended wrench AA1022012

•1” Socket – ½” drive AA1022013

• 1-3/8” Open ended wrench AA1022014

• 1-3/8” Socket – ½”drive AA1022015• 1-1/2” Open ended wrench AA1022016

• 5/32” Allen wrench AA1022017



• 3/8” Ratchet type Socket wrench AA1022020• ½” Ratchet type Socket wrench AA1022021

• Rubber tipped Hammer AA1022022

•5/16” x 18 Stud driver AA1022023

• Stud Driver 3/8 x 24 AA1022024

• Heli-coil inserting tool – 3/8 x 24 AA1022025• Test kit for PCB RBTR-0113Special Tools

Tool Description Ordering Reference

• Desiccant Compacting tool RPSK-0495

• Guide Installation tool RPSK-0496


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7.0 aintenance Intervals

7.1 Operating Conditions

7.1.1 Air Pressure

The Air Dryer is equipped with a memory feature (type 975-123 & 975-124) whichpermits the unit to regenerate only when the Compressor or any Compressor in theconsist is loading (pumping). The objective is to conserve additional air whilemaintaining an acceptable performance level. For the operational checks theCompressor must be pumping and the air pressure greater than the rated pressurelevel 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 ‘B’ Socket of the Burndy Connector. Any interruption of the signalvoltage ‘B’ (compressors in consist unloaded) causes the dryer to stop cycling. Whenthe signal voltage is re-applied to the ‘B’ Socket, the dryer restarts at the point in thecycle where it stopped previously. In order for the electronics to work with thememory, a constant power source (48 – 110 V DC) must be made available to the ‘A’Socket and a negative (-) source to the ‘C’ Socket within the female connector(Burndy) when power is re-applied to ‘A’, ‘B’ & ‘C’. This sequence providescomplete regeneration to both desiccant canisters.

7.2 Operational Check (30 days)

7.2.1 Examine the Humidity Indicators. A blue colour represents correct operation andwhite indicates unsatisfactory operation and requires further checks to determine thecause.

7.2.2 There should be a slight continuous exhaust of air at the exhaust port of the PurgeValve 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 towerPurge 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 dryercycles.

The change in the exhaust of air from one tower to the other indicates the dryer isoperating properly. In conjunction, the Drain Valve on the sump cap of the pre-coalescer should exhaust each time the Air Dryer cycles. If the change in the exhaustof air is not present or if there is no discharge of air at either Purge Valve or DrainValve, check the following.


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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 fittedwith an internal Pressure Switch, which closes at the rated pressure. If there is noexhaust out of one of the two Purge Valves ‘jump’ the two connecting wires on thePressure Switch. If there is a loud, short exhaust followed by a slight continuousexhaust, 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 ispresent in the piping from the Solenoid Valve to the Inlet Check Valve and PurgeValve. 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 isconfirmed 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 andPurge Valve during the regenerating cycle, the Solenoid Valve should be examined tosee if the electrical power is to the coil. If power is to the coil, but actuating air is notin the tubing to actuate the valve, examine the Solenoid Valve plunger for properseating and renew if defective. If the plunger binds in the coil and does not movefreely, renew the plunger.

7.3.4 Check each Inlet and Outlet Check Valve in the regenerating position to be sure, ofproper 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 orOutlet Check Valve. Clean or renew the seat.

7.3.5 Check each dryer tower while in the dehydrating cycle of proper operation; thereshould be no exhaust of air at the Purge Valve. If exhaust of air is present, the PurgeValve 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 isactuated from one of the two adjacent Purge Valves. If the Drain Valve does notcycle, examine the actuating line from the adjacent Purge Valve and follow steps 7.3.2and 7.3.3.

7.3.7 An operational check of the memory type timer, where fitted, may beaccomplished by unloading the compressor. The Air Dryer should stopregenerating. Load the compressor. The dryer should begin regenerating at thepoint in the cycle where it previously stopped. For example, if one of the towersregenerates for 30 seconds prior to the compressor unloading, when thecompressor loads again the memory feature permits the same tower to restart at

31 seconds and complete the one minute time period prior to cycling.


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7.4 Annual Check Procedures

Check the locomotive system maintenance schedule in case more rigorousrequirements are specified.

7.4.1 Remove and examine the coalescer element, section 15 gives details of theprocedure.

7.4.2 On new locomotives, remove and examine the filter element in the final filter, if itis contaminated, rectify the cause and renew the filter element. Refer to section 20for details.

7.4.3 Check the operation of the regenerating orifice. Push in the orifice plunger, ifplunger will not push in, wait for the dryer to switch cycles, approximately oneminute, then push in plunger. When cycle change occurs, the orifice plungershould automatically return to the extended position. If this does not occur, referto section 9.

7.4.4 Check the condition of each pipe assembly. Renew assemblies, fittings whichshow 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 rigorousrequirements 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 efficientoperation 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 anoverhaul location which has been autorised by Faiveley Transport India Limited.


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Overhaul requires the complete dismantling, overhaul, and renewal ofconsumable parts, of the component assemblies as described in the followingsections.

After completely re-assembling the Air Dryer, it should be tested including the ’30day’ 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 theactuating airlines to the Purge Valves.

7.7.2 Use a 9/16” Socket with 10” extensionto remove 6 Nut and Lock Washers (8)to allow the Bottom Cap (12) to bedropped down.

7.7.3 Remove the Desiccant Canisterassembly (10).

7.7.4 Refer to section 8.8 for DesiccantCompactor maintenance.

Refer to section 8 for Desiccant Canisterrecharge procedure.

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


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8.0 Desiccant Charge Renewal

Use Maintenance Kit RK-AB787-W44)

Sl. No. Kit Part No. Dryer Model

1 790 0291 95 (D&M Ref. RK-AB787-W44) 975-123

2 790 0292 45 (D&M Ref. RK-AB787-W44A) 975-124

8.1 Step 1-A

Using a Screw driver, remove the topRetaining Ring and then extract theCanister Disc Assembly.

8.2 Step 1-B

Discard the old desiccant.

8.3 Step 2

Using a screw driver, remove thebottom Retaining Ring and then extractthe Canister Disc Assembly. Clean boththe Retaining Rings and screens. Wipethe inside of the Canister with a cleandry cloth.


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8.4 Step 3

Install the cleaned Canister DiscAssembly and Retaining Ring in thebottom of the Canister Assembly. Refillthe Canister with new desiccant.

8.5 Step 4

Place the Canister Disc Assembly withthe screen next to the desiccant beadson top of the Desiccant Canister beadsand push down while tightly tappingwith a soft tip hammer and rotating theCanister. Tap and rotate the unit,Canister Disc Assembly drops belowthe Retaining Ring groove.

8.6 Step 5

Remove the Canister Disc Assemblyand add more desiccant. Replace theCanister Disc assembly and continuetapping and rotating procedure untilthe top of the Canister assembly linesup with the bottom edge of theRetaining Ring groove. Carefullyreplace the Retaining Ring into thegroove on the top of the Canister Discassembly.


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Step 6

Renew the Seal on the top of theCanister Disc assembly. Beforereassembly, lubricate the Seal with DowCorning 33 M or equivalent.

8.7 Compactor Removal and Maintenance Procedure

Numbers in ( ) refer to drawing no. 029 1001 00 (D&M Ref. AB787-W41). UseMaintenance kit 790 0292 05 (D&M Ref. RK-AB787-W41).

8.7.1 Using a 9/16” wrench, slacken thefittings on the Inlet Pipes to dischargethe actuating air from the Compactor,see OGA drawing for particular model.

8.7.2 Remove 2 Hexagon Head Screws (4)before removing Compactor Assembly.

8.7.3 Lift the Compactor Assembly upthrough the Sump Cap.

8.7.4 Remove 1 Pan Head Screw (2) from thePiston.

8.7.5 Remove the Spider (3) followed by theCap (5). Renew Seal (6).

8.7.6 Renew the Piston Seal (9) and the SumpCap Seal (7). Examine the Piston andthe Cap for any damage. Renew wherenecessary.

8.7.7 Before reassembly, lubricate all Sealsand sealing surfaces with Siliconegrease, Dow Corning M 33 orequivalent.

8.7.8

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


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8.7.9 Clean all components before re-assembly. Apply Loctite 222 thread locker to theScrew threads than re-assemble Compactor.

8.7.10 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). UseMaintenance Kit RK-AB787-W39).

9.1 Regenerating Orifice

9.1.1 Use a 1” wrench to remove the Regenerating Orifice Assembly (1) from the DryerBody (9).

9.1.2 While holding the Orifice Body (5) in a vice, use a 5/8” wrench to remove theRetainer 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), forany damage which may necessitate renewal.

9.1.5 Before reassembly, lubricate all Seals and sealing surfaces with Silicone grease,Dow Corning M33


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9.1.6 or equivalent.

9.1.6 Refit the orifice plunger with a new Seal (3) into the orifice body and tighten theRetainer 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 andpassivated 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 thecorrect size, refer dryer configuration table in page 1.

Sl. No. Orifice SizeColour of Orifice Body

and Plunger

1 0.11” Colourless (White)

2 0.068” Green3 0.0625” Yellow

4 0.052” Blue

5 0.042” Brown

6 0.078” Red

10. Purge Valve Maintenance

(The figure and the procedure referred below is not applicable for 975-124 modeldryer).


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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 thePurge 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 befollowed 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) andNut (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 whichindicates 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 DowCorning 33 M.

10.3.2 Replace the Piston into the Purge Valve Body followed by the new Cup Washerand 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 withtwo Cap Screws, use 3/8” wrench.


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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 kit790 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” wrench, remove Cap (3) which will be followed from Body (4) bySpring (5).

10a.4 Stem assembly with Stem (6) can now be removed from Body (4). Inspect Seat (7) forusual wear or damage and replace as required by using two 7/16” wrenches to holdStem 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).


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10a.6 Cup Washer (12) and Piston (13) can now be removed. Inspect Cup Washer andSeal (14) for unusual wear or damage and replace as necessary.

10a.7 Upon reassembly of Piston (13) to Body, generously apply Down Corning 33 Mgrease or equivalent to Seal (14) and Cup Washer (12).

10a.8 Reassemble Drain Valve and inspect Seal (15) for damage before reassemblingPurge 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 DrainValve from the Sump Cap.

11.1.3 Use a 1-3/8” wrench to remove the Cap (14) from the Body (12), this will befollowed by the Spring (13).

11.1.4 Use a 3/16” Alley key to remove four Cap Screws (9) with Washers (10) & theCap (8).

11.1.5 The Cup Washer (7) can now be removed. Renew the Cup Washer (7) and Seal (5)on the Piston.


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11.1.6 Use a 3/8” wrench on the Seat Bolt (1) while holding the Piston (6) with a screwdriver 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 whichindicates 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 greaseequivalent to Dow Corning 33 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.


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12.0 Inlet Check Valve

Numbers in ( ) refer to drawing no.AB787-W27. Use Maintenance Kit790 0291 35 (D&M Ref. RK-AB787-W27A).

12.0.1 Using a 3/16” Allen wrench, remove4 Cap Screws (1) and Lock Washers(2) to remove the actuating Cap (3).

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

12.0.3 Remove the Valve Seat (10) from theInlet Check Valve Body (11). Renewthe Valve Seat (10) on reassembly.

Note: Generously lubricate all rubberproducts with silicone grease, DowCorning 33 M or equivalent.

12.0.4 Remove the Piston (5) from theAdaptor (8) and renew internallyassembled O Ring (7). Renew O Ring(9) between the Inlet Check ValveBody and the Adaptor, thenreassemble.

12.0.5 Extract the Cup Washer (4) from theActuating Cap and discard. Lubricateand fit a new Cup Washer in theActuating Cap, making certain thatthe sealing surface above the CupWasher is well lubricated.

12.0.6 Reassemble the Actuating Cap to theAdaptor on the Inlet Valve Body.


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13.0 Outlet Check Valve

Numbers in ( ) refer to drawing no.029 1005 00 (D&M Ref. AB787-W29 orW48). Use Maintenance Kit 790 029145 (D&M Ref. RK-AB787-W29 orW18).

13.1 Dismantling

13.1.1 Using a 3/8” wrench, loosen 4Captive Screws on the SolenoidAssembly (9).

13.1.2 The Valve Seat Assembly (12) willdrop down with the SolenoidAssembly (9) and Spring (11). Aneyebolt has been provided on theSolenoid Assembly to helpdismantling if necessary.

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

13.1.4 Reassemble with a new Valve Seatand Spring.

13.1.5 Refer to section 14 for the Solenoidoverhaul procedure.


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14.0 Solenoid Assembly

Numbers in ( ) refer to drawing no. 029 1008 00(D&M Ref. AB787-W37). Use Maintenance Kit790 0291 55 (D&M Ref. RK-AB787-W37)

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

14.0.2 While holding the Coil Housing (11) carefullyin a vice (hold only the Cap Screw Flange), usea 9/16” wrench on the Solenoid Body (2)wrench flats and remove from the AdaptorAssembly (7).

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

14.0.4 Use a 5/32” Allen wrench to remove 4 CapScrews (6) from the Coil Housing. Lift theAdaptor (7) up.

14.0.5 Remove the Coil (9) from the Coil Housing.Examine the Coil for damage and check forcontinuity and correct resistance – seeelectrical specification on drawing no. 029 100800 (D&M Ref. AB787-W37).

Note: Sparingly lubricate all Seats and sealingsurfaces with silicone grease, Dow Corning33M or equivalent.

14.0.6 Renew two Seals (8) and reassemble the CoilHousing.

14.0.7 Use a 1 ½” wrench to remove the Magnet (12)

from the Coil Housing. Clean and examine thePlunger seating surface. Renew wherenecessary then reassemble.

14.0.8 Place the Spring (5), then a new PlungerAssembly (4) into the Adaptor and CoilHousing. Put a new Seal (3) in position on theAdaptor and re-assemble the Solenoid Body.


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

14.0.10 When required, the complete SolenoidAssembly is replaced in the Dryer, placeSpring and overhauled Valve Seat on topof the Solenoid Assembly and carefullyreassemble the unit to the Outlet CheckValve Body, see figure 16. Refer to section13 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 MaintenanceKit 790 0291 65 (D&M Ref. RK-AB787-W27B).

15.1 Element Renewal Procedure.

15.1.1 Disconnect the actuating airline from theDrain Valve using a 9/16” wrench.

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

15.1.3 Turn Retainer Nut (6) counter-clockwiseand remove Coalescer Retainer (5) andCoalescer Element (4). Renew as required.

15.1.4 Clean any debris from the Sump Cap andCylinder Body.

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

15.1.6 Refer to section 11 of Drain Valve overhaulprocedures.

16.0 Timer Circuit Board Renewal Procedure


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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 powercable 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 anddisconnect.

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

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

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


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17.0 Pressure Switch Renewal Procedure

17.1.1 Disable the air supply line and bleed all trapped pressure from the Air Dryer andsurrounding 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 boxcover 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) onboth 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 allowthe 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 theOutlet 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) fromthe 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” and9/16” wrenches.


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17.1.10 Refit a new Pressure Switch to the Adaptor, then assemble the Adaptor in the Make-up Box. Reconnect two wires to the Pressure Switch in the Make-up Box (non-polarised connection).

17.1.11 Re-attach and reassemble all the parts of the Outlet Manifold and Dryer. Test theDryer 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 visualmonitor showing the operating condition of

the Air Dryer.

A blue colour indicates an Air Dryer operatingsatisfactorily. A totally white colour indicatesthe Dryer operation and desiccant beadsshould be checked. A thorough inspection forthe presence of desiccant dust in the ControlPipe work and the Pressure Switch should bemade. Where dust is found, the PressureSwitch should be replaced. Refer to section 17for Pressure Switch renewal procedure.

Usually only excessive oil aerosols orprolonged saturation by water willpermanently turn the blue paper white. Oilaerosols will coat the paper and turn it a darkgreen or shade of orange or yellow, renderingit ineffective for the sensing of water aerosols.

Warning : Do not alter, modify or use parts not suppliedin Maintenance Kit 790 0291 05 (D&M Ref.

RK-AB787-187) for this component.

The Maintenance Kit is designed to renew thepaper indicator in the Humidity Indicator.

18.1 Procedure


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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 removeoil.

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 beenadded to prolong the life of the blue paper. To be effective, it must beassembled as shown in fig. 20.

When adding the loose desiccant from the ‘sorb-it’ bag, fill the cavity level inonly two Spacers, before inserting the Coalescer media, Rubber Sealing Gasketand Spring Clip into the bushing.

18.1.6 Ensure the Spring Clip is pressed into the bushing firmly against the rubbergasket, convex side first. Use a metal applicator, such a ½” extended socket, totap 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).


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

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

Note: Excess back pressure adversely affects the performance of the Dryer.

19.0.4 Reassemble the Muffler and refit to the Dryer.

20.0 Final Filter 20.1 Function and Operation

The Final Filter is mounted separately fromthe Air Dryer as the next component in the

Outlet Pipe. The Final Filter ensures thatminute dust and dirt particles, which mayhave escaped purging in the main Dryersystem are removed.

Air enters into the Body of the Filter andpasses through the Filter element whichcollects any remaining impurities from theair. A manually operated Drain Cock issituated 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). UseMaintenance Kit No. 790 0291 25 (D&MRef. RK-AB787-W40).

It is possible to renew the Filter elementwithout removing the Body assembly fromthe vehicle, provided sufficient space is

available.

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

20.2.3 Remove six Nuts and Lock Washers (7).The Bottom Cap (6) complete with ManualDrain Valve and Gasket (4) will dropdown.


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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 ofthe element with Dow Corning M33 or equivalent. Carefully align the Filterelement on the Filter Retaining device in the Filter Body Assembly, followed by theFilter 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 reassemblethe Bottom Cap (6) to the Filter Body and secure with the six Nuts with LockWashers (7).

20.3 Trouble Shooting Guide

20.3.1 Oil contamination of the Final Filter indicates that the Compressor is pumping oilor 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 thedesiccant 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 meansthat 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 FinalFilter element.

2. If the Compactor, which exerts pressure on the desiccant bead is notfunctioning properly, the bead could break down and deposit small brokenbeads 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 timeto regenerate before the next cycle.

Check the compressor duty cycle.

After correcting the fault, renew the Desiccant Canister and Final Filter element.


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Page 57

List of Parts

Twin Tower Air Dryer

Drawing no. 029 1001 00 (D&M Ref. AB787-W26). (This is applicable for 975-123 modeldryers).

ItemNo.

FTIL Part No.D&M Part /

Drg No.Description

Qty /Unit

12 **3 **4 **

5 **6 **7 **8

9*101112131415161718

Refer table029 3035 00029 7060 00Refer table

Refer table029 7070 00029 7035 00099 8006 00 &099 8007 00029 1200 00029 1180 00029 7140 00029 1009 00029 7190 00029 1006 00099 5005 00099 6003 00029 3330 00029 7150 00

Refer tableAB787-110AB787-111Refer table

Refer tableAB787-115AB787-116AB787-117

AB787-W34AB787-W44AB787-119AB787-W41AB787-121AB787-W36AB787-122AB787-123AB787-124AB787-125

Orifice AssemblyRetainer NutO Ring (ID 0.237 x width 0.103)Orifice Plunger

Orifice BodyO Ring (ID 0.674 x width 0.103)O Ring (ID 0.549 x width 0.103)Hex nut 3/8 &Multi – tooth lock washerDryer Body assyCanister Assembly – ext versionO Ring (ID 4.234 x width 0.139)Compactor / Sump Cap AssemblyO Ring (ID 1.359 x width 0.139)Al. Purge Valve assySpring Washer 3/8” type ACap Screw 3/8” x 3-1/4 UNC - 16Body SpacerO Ring (ID 5.234 x width 0.139)

1111

111

24

1222224424

* 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.

Orifice SizeOrifice Assy

Part No.Orifice Body Part No. /

Colour codificationOrifice 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)


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Orifice Table with D&M Part Nos.

Sl.No. Orifice Size

Orifice AssyPart No.

Orifice Body Part No. /Colour codification

Orifice Plunger Part No./ Colour codification

1 0.11” AB787-W39 AB787-115 (White) 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)

Maintenance kits

Maintenance kit, part no. 790 0290 11 (D&M Ref. RK-AB787-W39), includes parts fororifice assembly and comprises item 3, 6 and 7. Refer to drawing of the kit foridentification of parts.

Maintenance kit, part no. 790 0291 15 (D&M Ref. RK-AB787-T17), includes all the normalrenewable parts for overhauling a complete Air Dryer. It comprises all the maintenancekits plus individual items. Also, note that this kit is suitable for all extended modeldryers.


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Page 60

List of Parts

Twin Tower Air Dryer

Drawing no. 029 1002 00 (D&M Ref. AB787-W26A). (This is applicable for 975-124 modeldryers).

ItemNo.


Drg No.Description

Qty /Unit

123

45678

9101112

1314151617

Refer table029 3035 00029 7060 00

Refer tableRefer table029 7070 00029 7035 00099 8006 00 &099 8007 00029 1200 00029 1185 00029 7140 00029 1210 00

029 7190 00A029 1007 00099 5001 00099 3001 00029 7150 00A

Refer tableAB787-110AB787-111

Refer tableRefer tableAB787-115AB787-116AB787-117

AB787-W34AB787-W44AAB787-119AB787-W41A

AB787-121AB787-W36AAB787-122AAB787-123AAB787-125

Orifice AssemblyRetainer NutO Ring (ID 0.237 x width 0.103)

Orifice PlungerOrifice BodyO Ring (ID 0.674 x width 0.103)O Ring (ID 0.549 x width 0.103)Hex nut 3/8 &Multi – tooth lock washerDryer Body assyCanister Assembly – std versionO Ring (ID 4.234 x width 0.139)Valve stem assy

O Ring (ID 1.349 x width 0.139)Bronze Purge Valve assySpring Washer 5/16” type BHex nut 5/16 * 18O Ring ( ID 5.234 x width 0.139)

111

1111

24

1222

22444

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 SizeOrifice Assy

Part No.Orifice Body Part No. /

Colour codificationOrifice 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)


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Orifice Table with D&M Part Nos.

Sl.No. Orifice Size

Orifice AssyPart No.

Orifice Body Part No. /Colour codification

Orifice Plunger Part No./ Colour codification

1 0.11” AB787-W39 AB787-115 (White) 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)

Maintenance kits

Maintenance kit, part no. 790 0291 11 (D&M Ref. RK-AB787-W39), includes parts fororifice assembly and comprises item 3, 6 and 7. Refer to drawing of the kit foridentification of parts.

Maintenance kit, part no. 790 0291 16 (D&M Ref. RK-AB787-T17B), includes all thenormal renewable parts for overhauling a complete Air Dryer. It comprises all themaintenance kits plus individual items.


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Page 63

List of Parts

Inlet Check Valve Assembly

Drawing no. 029 1003 00 (D&M Ref. AB787-W27) – Sheet 1

ItemNo.


Drg No.Description

Qty /Unit

12

3456789101112

131415

099 6001 00099 5003 00

029 3280 00029 7240 00029 3050 00099 6501 00029 7030 00029 3340 00029 7105 00029 6070 00029 3330 00029 7190 00

Refer table099 6002 00099 5004 00

AB787-155AB787-156

AB787-157AB787-158AB787-159AB787-160AB787-161AB787-162AB787-99AB787-243AB787-167AB787-121

Refer tableAB787-246AB787-247

Cap Screw socketSpring Washer ¼” type A

Actuating CupCup WasherPistonCap Screw ¼” x ¾” UNC - 20O Ring (ID 0.487 x width 0.103)Actuator headO Ring (ID 1.674 x width 0.103)Plastic wing valveBody spacerO Ring (ID 1.359 x width 0.139)

FlangeCap Screw socketSpring washer 3/8” type B

88

2228222223

122

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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Page 65

List of Parts

Pre-Coalescer Assembly

Drawing no. 029 1003 00 (D&M Ref. AB787-W27) – Sheet 2

ItemNo.


Drg No.Description

Qty /Unit

1

2345678910

099 8006 00 &099 8007 00

029 3350 00029 3080 00029 2040 00029 3090 00099 3005 00029 7180 00029 3270 00029 7200 00029 1004 00

AB787-118

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

Hex nut 3/8 &Multi - tooth lock washer

Pre – coalescer cylinderSeat and GuideCoalescer Element filter (AD)Coalescer RetainerElastic Stop Nut 3/8 UNCO Ring (ID 3.984 x width 0.139)Pre – coalescar sump capTetra Seal for drain valvePre – coalescer Drain valve assy

8

111111111

Maintenance kit

Maintenance kit part no. 790 0291 65 (D&M Ref. RK-AB787-W27B) comprises items 4, 6and 7.

Refer to drawing of the kit for identification of parts.


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Page 67

List of Parts

Drain Valve

Drawing no. 029 1004 00 (D&M Ref. AB787-W28)

ItemNo.


Drg No.Description

Qty /Unit

12

3456789101112

1314

029 8075 00029 4010 00

029 6010 00029 8410 00029 7015 00029 4020 00029 7250 00029 4140 00099 6001 00099 5003 00029 7095 00029 3420 00

029 8055 00029 3060 00

AB787-175AB787-176


AB787-248AB787-185

Shoulder boltSeat Washer

Valve SeatStemO Ring (ID 0.674 x width 0.103)PistonCup sealValve capCap Screw socketSpring washer ¼” type AO Ring (ID 1.364 x width 0.07)Valve body

SpringSpring Cap

11

2111114411

11

Maintenance kit

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


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Page 69

List of Parts

Piping Assembly

Drawing no. 029 1010 00 (Application for 975-123 model Dryers)

ItemNo.


Drg No.Description

Qty /Unit

12345

029 4100 00029 1025 00029 4090 00029 1030 00029 8470 00

AB787-210AB787-211AB787-212AB787-213AB787-214

ElbowTube assyTee 1/8” NPT x ¼”Tube assyElbow 7/16” UNF x ¼” NPT

11111


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Page 70


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Page 71

List of Parts

Piping Assembly

Drawing no. 029 1015 00 (D&M Ref. AB787-W32) – Applicable for 975-123 model Dryers.

ItemNo.


Drg No.Description

Qty /Unit

123456789

029 4080 00029 1045 00029 4090 00029 1055 00029 4070 00029 1060 00029 8120 00029 1050 00029 4100 00

AB787-215AB787-216AB787-217AB787-218AB787-219AB787-220AB787-221AB787-222AB787-210

Straight fitting ¼” x 1/8” NPTTube assyTee 1/8” NPT x ¼”Tube assyFittingCheck Valve assembly ¼” NPTMale branch Tee ¼”Tube AssyElbow

111111122


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Page 72


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Page 73

List of Parts

Piping Assembly

Drawing no. 029 1020 00 (D&M Ref. AB787-W33) – Applicable for 975-123 model Dryers.

ItemNo.


Drg No.Description

Qty /Unit

12345

67

029 4100 00029 1025 00029 4090 00029 1040 00029 8120 00

029 1035 00029 8470 00

AB787-210AB787-211AB787-217AB787-223AB787-221

AB787-223AAB787-214

ElbowTube AssyTee 1/8” NPT x ¼”Tube AssyMale branch Tee ¼”

Tube AssyElbow 7/16” UNF x ¼” NPT

11111

11


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Page 74


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Page 75

List of Parts

Piping Assembly

Drawing no. 029 1022 00 (D&M Ref. AB787-W31B) – Applicable for 975-124 model Dryers.

ItemNo.


Drg No.Description

Qty /Unit

12

345

029 4100 00029 1025 00

029 4090 00029 1140 00029 8470 00

AB787-210AB787-211

AB787-212AB787-213AAB787-214A

ElbowTube Assey

Tee 1/8” NPT x ¼”Tube AssyElbow 7/16” UNF x ¼” NPT

11

111


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Page 76


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Page 77

List of Parts

Piping Assembly


ItemNo.


Drg No.Description

Qty /Unit

123

456789

029 4080 00029 1045 00029 4090 00

029 1057 00029 4070 00029 1060 00029 8120 00029 1051 00029 4100 00

AB787-215AB787-216BAB787-212

AB787-218BAB787-219AB787-220AB787-221AB787-222BAB787-210

Straight Fitting ¼” x 1/8” NPTTube AssyTee 1/8” NPT x ¼”

Tube AssyFittingCheck Valve Assembly ¼” NPTMale Branch Tee ¼”Tube AssyElbow

111

111122


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Page 78


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Page 79

List of Parts

Piping Assembly


ItemNo.


Drg No.Description

Qty /Unit

123

456789

029 8470 00029 1025 00029 4090 00

029 1150 00029 4180 00029 1145 00029 4100 00029 4190 00029 4200 00

AB787-210AB787-211AB787-217

AB787-223AB787-129AAB787-129BAB787-129CAB787-129DAB787-129E

Elbow 7/16” UNF x ¼” NPTTube AssyTee 1/8” NPT x ¼”

Tube AssyTee 7/16” x 7/16” x 1/8” male TeeTubeAssyElbow¼” x 1/8” ReducerElbow 90 deg St.1/4” NPT

111

111111


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Page 80


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Page 81

List of Parts

Purge Valve

Drawing no. 029 1006 00 (D&M Ref. AB787-W36) – Applicable for 975-123 model Dryers

ItemNo.


Drg No.Description

Qty /Unit

123

45678910111213

14

029 7240 00099 3003 00029 7015 00

029 7080 00029 8060 00029 3311 00029 3065 00029 8085 00029 8081 00029 3070 00029 6110 00029 8170 00029 3260 00

099 6001 00

AB787-142AB787-143AB787-144


AB787-155

Cup WasherElastic stop nutO Ring (ID 0.674 x width 0.103)

O Ring (ID 2.112 x width 0.103)SpringValve BodyPistonSeat GuideSeat StemSeat WasherSeatCap NutPurge valve cover

Cap Screw socket

111

1111111111

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 (1no), 3 (1 no.), 4 (1 no.), 5 (1 no.) and 11 (1 no.). Refer to drawing of the kit for identification ofparts.

Two kits are needed if both Valves are to be overhauled.


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Page 83

List of Parts

Purge Valve

Drawing no. 029 1007 00 (D&M Ref. AB787-W36A) – Applicable for 975-124 model Dryers

ItemNo.


Drg No.Description

Qty /Unit

1

234567891011121314

099 3003 00

029 4230 00029 6010 00029 8410 00029 7015 00029 4240 00029 7250 00029 4140 00099 6001 00099 5003 00029 7095 00029 3420 00029 8055 00029 3060 00

AB787-143

AB787-129FAB787-129GAB787-129HAB787-144AB787-129JAB787-129KAB787-129LAB787-155AB787-129MAB787-129NAB787-129OAB787-129PAB787-129Q

Elastic stop nut

Washer, Valve seatValve SeatStemO Ring (ID 0.674 x WIDTH 0.103)PistonCup SealValve capCap Screw socketSpring washer ¼” type AO Ring (ID 1.364 x width 0.07)Drain valve bodySpringSpring Cap

1

1111111441111

Quantities are for a single Purge Valve. Two Valves are fitted to the complete Air Dryer.

Maintenance Kit

Maintenance kit part no. 790 0292 95 (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 foridentification of parts.

Two kits are needed if both Valves are to be overhauled.


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Page 85

List of Parts

Solenoid Valve


ItemNo.


Drg No.Description

Qty /Unit

1

23456789101112

13

029 7220 00

029 8360 00029 7230 00029 2050 00029 8350 00

-029 2080 00029 7210 00029 2070 00029 9040 00029 8420 00029 8430 00

029 8440 00

AB787-198

AB787-199AB787-200AB787-201AB787-202AB787-203AB787-204AB787-205AB787-206/DAB787-194AB787-207AB787-208

AB787-209

O Ring

Solenoid ValveO RingPlunger AssemblySpringCap ScrewBarrier strip assyO RingCoil (74 v dc)Gasket for outlet check valveCoil HousingMagnet

Eye Bolt

2

22228242222

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 foridentification of parts.

Two kits are needed if both Solenoid Valves are to be overhauled.


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Page 87

List of Parts

Final Filter

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

ItemNo.


Drg No.Description Qty / Unit

1234

567

891011

12

029 3380 00099 5001 00099 3001 00029 7150 00

029 1080 00029 3390 00

099 8006 00 &099 8007 00029 3370 00029 4150 00029 7200 00029 8390 00

029 1250 00

AB787-134AB787-39AB787-43AB787-135

AB787-136AB787-137AB787-118

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

AB787-141

Filter BodySpring washer 5/16” type BHex nut 5/16 * 18O Ring (ID 5.234 x width 0.139)Filter ElementSump CapHex nut 3/8 &Multi – tooth lock washerFilter RetainerWing NutTetra SealAdaptorShut off Valve Assy

1221

11

61111

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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Page 89

List of Parts

Compactor / Sump Cap Assembly


ItemNo.


Drg No.Description

Qty /Unit

123

4567891011

029 7150 00099 7002 00029 3210 00

099 2001 00029 3240 00029 7065 00029 7090 00029 3030 00029 7055 00029 3290 00029 3291 00

AB787-135AB787-225AB787-226

AB787-227AB787-228AB787-98AB787-231AB787-230AB787-229AB787-253AB787-253A

O Ring (ID 5.234 x width 0.139)Screw pan head #8 x 0.375Spider

Hex hd cap screw ¼-20UNCx3/4Compactor cylinder capO Ring (ID 0.612 x width 0.103)O Ring (ID 2.114 x width 0.07)PistonO ring (ID 1.799 x width 0.103)Sump Cap longer versionSump Cap shorter version

2224

22222222

Quantities are for complete Air Dryer. Two Compactor / Sump Cap Assemblies arerequired for one complete Air Dryer.

Maintenance Kits

Maintenance kit part no. 790 0292 05 (D&M Ref. RK-AB787-W41) includes parts for theCompactor and comprises items 6 (1 no.), 7 (1 no.) and 9 (1 no.). Refer to drawing of thekit for identification of parts.

Two off each kit are needed if both Canister Assemblies are to be overhauled.


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Page 91

List of Parts

Junction Box Electrical Components (Memory)


ItemNo.


Drg No.Description

Qty /Unit

123

45678910111213

1415

029 3400 00029 8135 00029 1065 00

029 2070 00029 2080 00099 7001 00099 7004 00939 0268 00029 2013 00029 7075 00099 7005 00099 5006 00029 8130 00

029 2090 00029 8132 00

AB787-189AB787-231AB787-190


AB787-237-

Solenoid housingSckt head shoulder screwPressure Switch (100 psi)

Coil – 74V DCBarrier Strip assyScrew pan headScrew pan headWire NutMemory PCB assy (Rerated)GasketN0.4 x 40 UNC Pan head screwSpring washer #4 type BBurndy Connector (Male)

Terminal Block AssyBurndy Connector (Female)

141

2123111441

11


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Page 93

List of Parts

Desiccant Canister

Drawing no. 029 1180 00 (D&M Ref. AB787-W44) – Applicable for 975-123 model Dryers

ItemNo.


Drg No.Description

Qty /Unit

123

4

029 8140 00029 2100 00029 9020 00

029 3020 00

AB787-128AB787-129AB787-130

AB787-131

Retaining RingCanister Disc AssyDesiccant charge Alumina balls

Canister Desiccannt

44

7.3 kgs

2


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 forrecharging 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 foridentification of parts.


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Page 94


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Page 95

List of Parts

Desiccant Canister

Drawing no. 029 1185 00 (D&M Ref. AB787-W44A) – Applicable for 975-124 model Dryers

ItemNo.


Drg No.Description

Qty /Unit

123

4

029 8140 00029 2100 00029 9020 00

029 3022 00

AB787-128AB787-129AB787-130

AB787-131A

Retaining RingCanister Disc AssyDesiccant charge Alumina balls

Canister Desiccant

44

5 kgs

2


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 forrecharging 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 foridentification of parts.


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Page 96


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Page 97

List of Parts

Outlet Check Valve (with memory)

Drawing no. 029 1190 00 (D&M Ref. AB787-W48) – Ap

air dryer- ae aug _dec 2010_.pdf

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