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ASSEMBLY
1. Install the heater element, securing it in the end cover
with the retainer clip and screw.
2. Install the square-cut seal ring in the thermostat bore.
3. Install the thermostat metal side down in the end cover
bore and secure it in place using the retaining clip or
shield and the two screws.
4. Lubricate and install the o-rings on the plunger and cap
nut.
5. Lubricate the plunger bore and install the spring and
plunger (through the cap nut end).
6. Install the valve on the plunger, making certain the
chamfered end of the valve is in contact with the metal
seat of the body.
7. Using the screwdriver held in the vise, as described in
Steps 4 & 5, compress the plunger into the bore while
installing and tightening the nut.
8. Install the cap nut and tighten it.
9. Lubricate and install the large diameter o-ring around
the end cover assembly.
REBUILDING THE BENDIX
END COVER
ASSEMBLY
To remove the end cover assembly from the air dryer,
follow steps 1-6 under the section of this manual entitled
Removal of Desiccant Cartridge. Before rebuilding the
end cover, clean the exterior thoroughly using a quality
commercial solvent.
DISASSEMBLY
1. Remove and discard the large o-ring around the end
cover assembly.
2. Remove the single #6-32 screw securing the exhaust
diaphragm and separate the diaphragm, washer, and
screw. Discard the diaphragm.
3. Remove the three #6-32 screws securing the exhaust
cover and remove the exhaust cover.
4. Remove the purge valve assembly and the large hex
cap nut from the end cover and discard both o-rings
around the cap nut.
5. Using a 7/16" socket wrench and a large screwdriver,
remove the 1/4"-20 hex head cap screw which holds
the assembly together.
6. Separate cap screw, purge valve, purge valve piston
and the piston return spring.
7. Discard the piston o-ring, the purge valve, and the
piston return spring.
8. Wash all remaining parts in a commercial solvent,
making sure all surfaces, bores, ports, and passages
are clean and dry before assembly.
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AD-2
AIR DRYER
NOTE: If during the serviceability checks it was determined
that the thermostat was defective, use the following
procedure. It is not necessary to replace this unit each time
the end cover is rebuilt. To service, install the thermostat
kit as shown in Figure 17.
9. Remove nut (2), then lock washer (3), plain washer (4)
and o-ring (5). Discard o-ring and retain other parts.
10. Remove and retain the four Phillips head screws (7)
and cover (6).
11. Remove and discard gasket (10).
12. Remove and retain spacer (11).
13. Cut uninsulated thermostat wire at Point B. (Figure
17), remove and discard the thermostat and terminal
assembly (1).
14. Clean the remaining wire attached to the heater
terminal.
15. Clean the thermostat "pocket" in the end cover (9).
ASSEMBLY
1. Cut the uninsulated lead of new thermostat (1) at Point
A (Figure 17).
2. Install thermostat in end cover "pocket" and position
uninsulated leads next to each other.
3. Using a soldering heat sink, clamp uninsulated leads at
Point B and solder leads with straight rosin core solder.
DO NOT USE ACID CORE SOLDER. Clean excess
solder off of the end cover.
4. Install thermostat terminal (1) in cover (6).
5. Install o-ring (5), washer (4), lock washer (3) and nut
(2). Torque nut to 20-30 in-lbs.
6. Install spacer (11) over thermostat (1).
7. Install gasket (7) and cover (6) and secure cover to end
cover (9) using screws (7) and lock washers (8).
8. Torque to 30-40 in-lbs.
9. Test thermostat as follows:
A. At a temperature above 85°F, check resistance
between thermostat terminal (1) and end cover (9).
Resistance should be 200,000 ohms or greater; if
not, check for solder "path" short.
B. Chill the entire end cover assembly to 35°F or below
and check resistance again. Resistance should be
2-15 ohms.
10. Lubricate the piston o-ring and install it on the piston.
11. Lubricate the piston bore.
12. Install the purge piston return spring and piston.
13. Install the purge valve in the large cap nut so that the
rubber portion rests on the metal seat of the cap nut.
14. Secure the valve to the piston using the 1/4"-20 cap
screw and lock washer and torque to 50 in-lbs.
11
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