BENDIX EVERFLOW User manual

1
Installation
Instructions
BENDIX®EVERFLOW®AIR DRYER ASSEMBLY INSTALLATION
FIGURE 1 - BENDIX®EVERFLOW®AIR DRYER ASSEMBLIES
BENDIX®EVERFLOW®CONTROL MODULE
Electrical
Connector
1/8” NPT
Control
Dryer #1
1/8” NPT
Control Dryer
#2
1/8” NPT
RES 1
1/8” NPT
GOV
CON
4
3/8”-16 UNC x 0.7” Deep
Mounting Holes (2)
Packard
Connector
Mounting
Slots
Delivery Ports (5)
Supply Port
Mounting
Bracket
BENDIX®AD-IS®EVERFLOW®
AIR DRYER ASSEMBLY
BENDIX®AD-IP®EVERFLOW®
AIR DRYER ASSEMBLY
EverFlow
Control Module
EverFlow
Control
Module
Bendix®AD-IS®
Air Dryer
Bendix®AD-IP®
Air Dryer
Bendix®
PuraGuard®
Medallion
Bendix
PuraGuard
Medallion

2
The Bendix®EverFlow®air dryer assembly removes
moisture and other contaminants normally found in the
air brake system. Using alcohol, anti-freeze, oil or other
de-icing substances in the brake system can damage the
air dryers and the control module and will therefore void
the warranty.
KIT DESCRIPTION
This kit is intended for installing the Bendix EverFlow air
dryer assembly.
OPERATION OF THE BENDIX®EVERFLOW®
AIR DRYER ASSEMBLY
The Bendix EverFlow air dryer assembly consists of two
integral soft seat purge dryers, Bendix EverFlow module,
mounting bracket and interconnecting hoses. By properly
connecting the inlet, outlet, and electrical service, the unit
provides dry air for bulk unloading, central tire ination or
high air usage.
The assembly monitors compressor charge time and when
the charge time exceeds 30 seconds, the EverFlow control
module switches the drying load to the other air dryer in
the system. The module continues to alternate between
the dryers at 30 second intervals, allowing the unloaded
air dryer to purge while the other dries the incoming air.
MOUNTING THE EVERFLOW AIR DRYER
ASSEMBLY
If an air dryer is installed on the vehicle, disconnect all air
lines and electrical connectors and remove the air dryer
from the vehicle.
If the air dryer has a Bendix®PuraGuard®medallion
mounted on top of the cartridge and/or a PuraGuard
identier on the side of the cartridge, then the EverFlow air
dryer assembly is equipped with a Bendix PuraGuard®oil
coalescing cartridge. When servicing a PuraGuard
air dryer, a PuraGuard cartridge must be used. Note:
Replacing a PuraGuard cartridge with a standard cartridge
may damage downstream components that are sensitive
to oil.
LOCATING THE EVERFLOW AIR DRYER ASSEMBLY
ON THE VEHICLE
1. The EverFlow assembly must be mounted vertically
(purge exhaust toward the road surface) towards the
outside the engine compartment in an area of air ow
while the vehicle is in motion. The assembly must not
be exposed to direct wheel splash. If the air dryer is
located directly behind the axle, a mud ap is required.
2. Maintain a minimum clearance of 12” between the
assembly and any potential heat source (e.g., vehicle
exhaust). If this is not feasible, a heat shield must be
used.
GENERAL SAFETY GUIDELINES
WARNING! PLEASE READ AND
FOLLOW THESE INSTRUCTIONS
TO AVOID PERSONAL INJURY OR DEATH:
When working on or around a vehicle, the following
guidelines should be observed AT ALL TIMES:
▲Park the vehicle on a level surface, apply the parking
brakes and always block the wheels. Always wear
personal protection equipment.
▲Stop the engine and remove the ignition key when
working under or around the vehicle. When working
in the engine compartment, the engine should be shut
off and the ignition key should be removed. Where
circumstances require that the engine be in operation,
EXTREME CAUTION should be used to prevent personal
injury resulting from contact with moving, rotating,
leaking, heated or electrically-charged components.
▲Do not attempt to install, remove, disassemble or
assemble a component until you have read, and
thoroughly understand, the recommended procedures.
Use only the proper tools and observe all precautions
pertaining to use of those tools.
▲If the work is being performed on the vehicle’s air brake
system, or any auxiliary pressurized air systems, make
certain to drain the air pressure from all reservoirs
before beginning ANY work on the vehicle. If the vehicle
is equipped with a Bendix®AD-IS®air dryer system, a
Bendix®DRM™dryer reservoir module, or a Bendix®
AD-9si™air dryer, be sure to drain the purge reservoir.
▲
Following the vehicle manufacturer’s recommended
procedures, deactivate the electrical system in a manner
that safely removes all electrical power from the vehicle
.
▲Never exceed manufacturer’s recommended pressures.
▲Never connect or disconnect a hose or line containing
pressure; it may whip. Never remove a component or
plug unless you are certain all system pressure has
been depleted.
▲Use only genuine Bendix®brand replacement parts,
components and kits. Replacement hardware, tubing,
hose, fi ttings, etc. must be of equivalent size, type
and strength as original equipment and be designed
specifi cally for such applications and systems.
▲Components with stripped threads or damaged parts
should be replaced rather than repaired. Do not
attempt repairs requiring machining or welding unless
specifi cally stated and approved by the vehicle and
component manufacturer.
▲Prior to returning the vehicle to service, make certain all
components and systems are restored to their proper
operating condition.
▲For vehicles with Automatic Traction Control (ATC),
the ATC function must be disabled (ATC indicator
lamp should be ON) prior to performing any vehicle
maintenance where one or more wheels on a drive axle
are lifted off the ground and moving.
▲The power MUST be temporarily disconnected
from the radar sensor whenever any tests USING A
DYNAMOMETER are conducted on a Bendix®Wingman®
Advanced™-equipped vehicle.
▲You should consult the vehicle manufacturer's
operating and service manuals, and any related
literature, in conjunction with the Guidelines above.

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FIGURE 2 - BENDIX®EVERFLOW®AIR DRYER ASSEMBLY INSTALLATION
Bendix®
EverFlow®
Control Module
Compressor
Governor 1/4”
1/4”
RES
1
GOV
CON
4
Control
Dryer
#1
Control
Dryer #2
Supply
Reservoir Primary
Reservoir
Secondary
Reservoir
Pressure
Protection
Valve
TO HIGH
AIR USE
ACCESSORIES
FIGURE 3 - BENDIX®EVERFLOW®AIR DRYER ASSEMBLY INSTALLATION WITH A BENDIX®DURAFLO 596™COMPRESSOR
Bendix
EverFlow
Control Module
Bendix® Durao 596™
Compressor
Governor
1/4”
1/4”
RES
1
Control
Dryer #2
Control
Dryer #1
E
D
S
D
S
C
D
S
C
D
S
C
GOV
CON
4
D
S
C
D
S
C
E
D
S
Bendix®SV-1™
Synchro Valve
Bendix®
EverFlow®
Air Dryer
Assembly
Bendix
EverFlow
Air Dryer Assembly
3/8”
Bendix AD-IP, AD-IS or
AD-9 Air Dryer
Supply
Reservoir
Primary
Reservoir
Secondary
Reservoir
Bendix®AD-IP®, AD-IS®
or AD-9®Air Dryer
This schematic is a general guideline. For specic applications or questions
contact the Bendix TechTeam at 1-800-AIR-BRAKE (1-800-247-2725).
This schematic is a general guideline. For specic applications or questions
contact the Bendix TechTeam at 1-800-AIR-BRAKE (1-800-247-2725).

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3. Make certain that adequate clearance from moving
components (e.g., drive shaft, suspension, pitman arm,
etc.) is provided.
4. Locate the Bendix®EverFlow®air dryer assembly
on the vehicle so that a minimum clearance of 1/2”
for the Bendix®AD-IP®air dryer, 2” for the Bendix®
AD-IS®air dryer, or 11” for the Bendix® AD-9®air
dryer is above the air dryer and is available to allow
desiccant cartridge removal. An 8” minimum clearance
below the air dryer is required to allow for cartridge bolt
removal. The air dryers can be removed for servicing
the desiccant if clearance is an issue.
5. When choosing the mounting location for the assembly,
note the discharge line length requirements stated
under the heading “CONNECTING THE AIR LINES”,
elsewhere in this manual.
IMPORTANT
Under normal operating conditions, the maximum inlet
air temperature for the air dryer is 160° F.
6. If possible, locate the EverFlow air dryer assembly
so that the air dryer purge exhaust does not expel
contaminants on vehicle components. If this is not
feasible, the purge exhaust may be redirected away
from the vehicle. The exhaust cover is available as a
separate item from authorized Bendix parts outlets. A
one (1) inch inside diameter (ID) hose can be clamped
on this special exhaust cover to allow the exhaust to
be redirected.
MOUNTING THE EVERFLOW ASSEMBLY
1. After positioning the assembly according to the location
requirements, mark the position of the pre-drilled
mounting holes on the selected location. Mark the hole
location using the bracket as a template. Note: Check
the vehicle manual before drilling the selected location.
2. Mount the EverFlow air dryer assembly on the vehicle
using 5/8” bolts (grade 5 min.) and washers. Torque to
25 ft-lbs (300 in-lbs).
3. Components and location used to mount the assembly
on the vehicle must be rigid enough to minimize air dryer
vibration.
CONNECTING THE AIR LINES
(Follow Figures 1, 2 & 3 for air line arrangement.)
1. For new installations, the discharge line from the
compressor to the supply reservoir can be cut and
ttings can be installed to facilitate the installation
provided that the discharge line recommendations in
the air dryer installation guidelines are adhered to.
2. Connect the compressor discharge line to the supply
port of the assembly. Connect the delivery line to the
delivery port of the assembly.
3. The Bendix EverFlow control module supply and control
line ports are 1/8” NPT.
Bendix®Tu-Flo®Compressor Installations
(See Figure 2.)
1. If the vehicle was previously equipped with an air dryer,
connect the control line that was disconnected to the
“GOV CON” port of the Bendix EverFlow module.
2. For new installations, install 1/4” tubing from the “UNL”
port of the governor to the “GOV CON” port of the
EverFlow module.
Bendix®DuraFlo 596™Compressor Installations
(See Figure 3.)
1. Connect the control line that was disconnected from
the air dryer control port to the Bendix®SV-1™synchro
valve (delivery) to the “GOV CON” governor control port
of the EverFlow module.
Wiring
Note: The voltage of the Bendix EverFlow assembly must
be equivalent to the vehicle voltage. Since two dryers
are used in the system, fusing of the electrical line must
accommodate both heaters in the dryers and the EverFlow
module. Damage could result if not adhered to.
1. Use Bendix cable assembly kit — piece number
5008484 — to make electrical connection to dryer and
EverFlow module. Use tie wraps to secure the dryer to
the bracket.
TESTING THE AIR DRYERS
Before placing the vehicle in service, perform the following
tests.
1. Close all reservoir drain cocks.
2. Build up the system pressure to governor cut-out and
note that the air dryer purges with an audible escape
of air.
3. If the charge time exceeds 30 seconds, the EverFlow
module will activate the second air dryer. The two will
cycle in 30 second intervals.
4. Rapidly apply the service brakes several times to reduce
system air pressure to governor cut-in. Note that the
system once again builds to full pressure and is followed
by a purge at the air dryer exhaust.
5. It is recommended that the following items be tested
for leakage to ensure that the air dryer will not cycle
excessively.
(A) Total air system leakage (See Bendix publication
BW5057 “Air Brake Handbook” or visit our internet site:
www.bendix.com)
(B) Compressor unloader mechanism.
(C) Governor.
(D) Drain cock and safety valve in rst (supply) reservoir.
(E) All air connections leading to and from the rst
(supply) reservoir.
S-1294 ©2014 Bendix Commercial Vehicle Systems LLC, a member of the Knorr-Bremse Group • 06/14 • All Rights Reserved