Air Dryer - AE Aug - DEC 2010 - PDF

Page 1
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
Page 2
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
su.in@faiveleytransport.com
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
Page 3
Revision Record
Date
New
Version
No.
Pages Changed
April, 2001
August, 2001
November,
2001
February, 2002
February, 2002
December, 2002
Reason
New Publication
Correction in Product Configuration

table
16
(previously Maintenance Schedule of Muffler
20)
changed
16
(previously Maintenance Schedule of Air Dryer
20)
revised in line with actual practice.
97 (previously
Page 97 (previously 113) revised.
113)
Various
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
Various
Manual Reformatted.
August, 2004
Sketches for
975-123 & 975124
Operating voltage corrected for both

models.
March, 2006
Various
Manual Reformatted.
May, 2008
10
77
O-Ring part no: 029 7220 00 was

029 1008 00
Aug 2008
11
Various
Manual updated as per latest

part numbers.
15.10.2010
12
Various
Molykote Grease M33 was M55

(updated Page 4, 39, 40,44-46,& 55)
Page 4
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacity and Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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
Page 5
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
Page 6
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 65 kg and the Final Filter 7 kgs.
Page 7
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. Other
configurations can be developed for specific customer needs.
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
1
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
1
NPT
48-110 V
DC
0.052
YES
75 PSI
YES
1-1/4
BSPT
Elec. Locos
WAG9, WAP5,
GM loco (WDG4
& WDP-4)
Elec. Locos
WAG7, WCAM3,
WCAG1.
EMUs, MG,
DEMUs, Others
48-110V
DC
0.052
YES
100 PSI
YES
1 NPT
WAP4 Locos
48-110V
DC
0.0625
YES
75 PSI
YES
1
NPT
HHP DEMU
FTIL Part
No.
Type
Voltage
975-123
with
memory
975-123
with
memory
029002700
Ext. Model
029003200
975-129
with
memory
975-124
029002800
975-124
with
memory
975-124
with
memory
029003300
029003100
029003500
Piping
interface
1
NPT
Orifice
size
Dryer
Type
Applica-tion
Diesel Locos
Page 8
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 9
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.
Page 10
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 11
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 12
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
010 0011 00
Auto Drain Valve
709 0041 00
3/8 BSP Air Strainer (Y type)
029 8120 00
Male Branch Tee
936 0538 00
Spl.Adaptor 7/16 UNF x 3/8bsp
002 0200 00
Double Check Valve 3/8
Page 13
Page 14
Page 15
Page 16
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 EMUs 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 17
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.
Page 18
Page 19
Page 20
Page 21
Page 22
Page 23
Page 24
: 48 130 V DC
1 - 1/4
NPT
INLET
Page 25
Page 26
Page 27
Page 28
6.0
Maintenance Schedule
MAINTENANCE
Fortnightly
Inspect Humidity Indicators (ref.

trouble shooting guide).
Check for proper purging

Check for proper cycling
4
4
Check for Automatic Draining

through Double Seated Valve
Check for any external leakage.
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)
Clean Mufflers
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)
SCHEDULE
Monthly 6 Months
Year
3 Years
4
4
4
4
4
4
4
4
4
Renew all Rubber Parts
Renew Precoalescer Kit

Renew Final Filter kit
4
4
Completely overhaul the Air Dryer

(ref. Maintenance Manual)
Renew the Desiccant Canister Kit
Page 29
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).
Qty / Minimum stock to be
FTIL Part
D&M Part No.
Air
kept in a shed for a
Description of Spares
No.
Dryer fleet of 25 Air Dryers
Inlet man coalescer kit (AD)
790 0291 65
RK-AB787-W27B
1
8
Kit for Final Filter
790 0291 25
RK-AB787-W40
1
8
Regenerating orifice kit (AD)
790 0291 11
RK-AB787-W39
1
5
Sl.
No.
1
2
3
Parts to be renewed every three years (TOH) while overhauling the Air Dryer and Final
Filter entirely (Longer Version).
Sl.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17

Inlet Check Valve kit (AD)
Drain Valve kit (AD)
Outlet Check Valve kit (AD)
Purge Valve kit (AD)
Solenoid assembly kit (AD)
Compactor assembly kit (AD)
O Ring (ID 1.359 x width - 0.139)
O Ring (ID 5.234 x width - 0.139)
O Ring (ID 1.734 x width - 0.139)
Electrical Box Gasket
Tetra seal for Drain valve
Gasket for Burndy Connector
Humidity Indicator kit (AD)
Desiccant Canister Kit (AD)
*
FTIL Part
No.
D&M Part No.
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 00A
029 7150 00A
029 7130 00A
029 7120 00
029 7200 00
029 7075 00
790 0291 05
790 0291 95
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
AB787-188
AB787-191
AB787-224
AB787-239
RK-AB787-187
RK-AB787-W44
Qty /
Air
Dryer
1
1
1
2
1
2
2
2
2
10
4
2
1
1
1
2
2
Minimum stock to be
fleet of 25 Air Dryers
8
8
5
10
5
10
10
10
10
80
32
16
5
8
8
15
15
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 (Longer Version)
Sl.
FTIL Part
D&M Part No.
Air
No
No.
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
5
029 1015 00
AB787-W32
1
3
6
029 1020 00
AB787-W33
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.
Page 30
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.
1
2
3
.Description of Spares
FTIL Part
No.
D&M Part No.

790 0291 65
790 0291 25
790 0291 11
RK-AB787-W27B
RK-AB787-W40
RK-AB787-W39
Qty /
Air
Dryer
1
1
1
Minimum stock to be
8
8
5
Parts to be renewed every three years (TOH) while overhauling the Air Dryer and Final
Filter entirely (Shorter Version).
Sl.
No.
1
2
3
4
5
6
7
8
9
10
11
12
13

Purge Valve kit (AD)
Solenoid assembly kit (AD)
Compactor assembly kit (AD)
O Ring (ID 5.234 x width - 0.139)
O Ring (ID 1.734 x width - 0.139)
Tetra seal for Drain valve & Purge
Valve
Desiccant Canister Kit (AD)
O Ring (ID 1.359 x width - 0.139)
14
15
16
17
*
FTIL Part
No.
D&M Part No.
790 0291 65
790 0291 25
790 0291 11
790 0291 35
790 0291 75
790 0291 45
790 0292 95
790 0291 55
790 0292 05
029 7150 00A
029 7130 00A
029 7120 00
029 7200 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
AB787-125
AB787-188
AB787-191
AB787-224
029 7075 00
790 0291 05
790 0292 35
029 7190 00A
AB787-239
RK-AB787-187
RK-AB787-W44
AB787-121
Qty /
Air
Dryer
1
1
1
2
1
2
2
2
2
2
2
1
3
Minimum stock to be
8
8
5
10
5
10
10
10
10
16
16
5
24
1
2
2
8
8
15
15
64
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 (Shorter Version)
Sl.
FTIL Part
D&M Part No.
Air
No
No.
1
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
5
029 1024 00
AB787-W32
1
3
6
029 1018 00
AB787-W33
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.
Page 31
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 List Part No. 790 0293 55
Tool Description
10 Extension 3/8 Drive
3/8 Open ended wrench
3/8 Socket 3/8 drive
Open ended wrench
Socket 3/8 drive
9/16 Socket 3/8 & drive
1 Open ended wrench
1 Socket drive
1-3/8 Open ended wrench
1-3/8 Socket 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
5/16 x 18 Stud driver
Stud Driver 3/8 x 24
Heli-coil inserting tool 3/8 x 24
Test kit for PCB

Special Tools
Tool Description
Desiccant Compacting tool
Guide Installation tool
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
AA1022025
RBTR-0113
Ordering Reference
RPSK-0495
RPSK-0496
Page 32
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) 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 B Socket of the Burndy Connector. Any interruption of the signal
voltage B (compressors in consist unloaded) causes the dryer to stop cycling. When
the signal voltage is re-applied to the B 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 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 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 33
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.
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.
7.3.7
Page 34
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 35
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
assembly (10).
Desiccant
Canister
7.7.4 Refer to section 8.8 for Desiccant

Compactor maintenance.
Refer to section 8 for Desiccant Canister
recharge procedure.
(Spacer) not assembled in 975-129

model dryers.
Page 36
8.0
Desiccant Charge Renewal

Use Maintenance Kit RK-AB787-W44)
Sl. No.
8.1
Kit Part No.
Dryer Model
790 0291 95 (D&M Ref. RK-AB787-W44)
975-123
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 37
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 38
Step 6
Renew the Seal on the top of the
Canister Disc assembly.
Before
reassembly, lubricate the Seal with Dow
Corning 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). Use
Maintenance kit 790 0292 05 (D&M Ref. RK-AB787-W41).
8.7.1 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.
8.7.2
Remove 2 Hexagon Head Screws (4)

before removing Compactor Assembly.
8.7.3
Lift the Compactor Assembly

through the Sump Cap.
up
8.7.4 Remove 1 Pan Head Screw (2) from the

Piston.
8.7.5 Remove the Spider (3) followed by the
Cap (5). Renew Seal (6).
8.7.6 Renew the Piston Seal (9) and the Sump
Cap Seal (7). Examine the Piston and
the Cap for any damage. Renew where
necessary.
8.7.7 Before reassembly, lubricate all Seals
and sealing surfaces with Silicone
grease, Dow Corning M 33 or
equivalent.
8.7.8
* -
(Spacer) not assembled in 975-124

model dryers.
Page 39
8.7.9 Clean all components before re-assembly. Apply Loctite 222 thread locker to the
Screw 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). 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 M33
Page 40
9.1.6
or equivalent.
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 41
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 33 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 42
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 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) by
Spring (5).
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 43
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 33 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 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 44
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 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 wrench.
Page 45
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 33 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 46
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 47
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
33M or equivalent.
14.0.6
Renew two Seals (8) and reassemble the Coil

Housing.
14.0.7
Use a 1 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 48
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-AB787W27B).
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

Pre-Coalescer, 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.
16.0
Timer Circuit Board Renewal Procedure
Page 49
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 50
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 9/16wrench.
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 51
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.
18.1
Procedure
Page 52
18.1.1
Remove the Spring Clip, all old media and paper.
18.1.2
Clean the inside of the 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 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 53
Using a wire bush, brush the inside and the outside of the disseminator element to remove
accumulated dirt from the element.
19.0.3
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.
19.0.4
Reassemble the Muffler and refit to the Dryer.
20.0
20.1
Final Filter
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 54
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 M33 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.
20.3.3
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.
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 55
Page 56
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.
Refer table
AB787-110
AB787-111
Refer table
Refer table
AB787-115
AB787-116
AB787-117
AB787-W34
AB787-W44
AB787-119
AB787-W41
AB787-121
AB787-W36
AB787-122
AB787-123
AB787-124
AB787-125
Qty /
Unit
Description
Orifice Assembly
Retainer Nut
O Ring (ID 0.237 x width 0.103)
Orifice Plunger
Orifice Body
Hex nut 3/8 &
Multi tooth lock washer
Dryer Body assy
Canister Assembly ext version
Compactor / Sump Cap Assembly
Al. Purge Valve assy
Spring Washer 3/8 type A
Cap Screw 3/8 x 3-1/4 UNC - 16
Body Spacer
1
1
1
1
1
1
1
24
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)
0.0625
029 1101 00
029 3173 00 (Yellow)
029 3154 00 (Yellow)
0.052
029 1102 00
029 3172 00 (Blue)
029 3152 00 (Blue)
0.042
029 1105 00
029 3175 00 (Brown)
029 3156 00 (Brown)
Orifice Size
Page 57
Orifice Table with D&M Part Nos.

Sl.
No.
1
0.11
Orifice Assy
Part No.
AB787-W39

Colour codification
AB787-115 (White)

AB787-114 (White)
0.0625
AB787-W39B
AB787-115B (Yellow)
AB787-114B (Yellow)
0.052
AB787-W39C
AB787-115C (Blue)
AB787-114C (Blue)
0.042
AB787-W39D
AB787-115D (Brown)
AB787-114D (Brown)
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.
Page 58
Page 59
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 00A
029 1007 00
099 5001 00
099 3001 00
029 7150 00A
D&M Part /
Drg No.
Refer table
AB787-110
AB787-111
Refer table
Refer table
AB787-115
AB787-116
AB787-117
AB787-W34
AB787-W44A
AB787-119
AB787-W41A
AB787-121
AB787-W36A
AB787-122A
AB787-123A
AB787-125
Description
Qty /
Unit
Orifice Assembly
Retainer Nut
Orifice Plunger
Orifice Body
Hex nut 3/8 &
Dryer Body assy
Canister Assembly std version
Valve stem assy
Bronze Purge Valve assy
Spring Washer 5/16 type B
Hex nut 5/16 * 18
O Ring ( ID 5.234 x width 0.139)
1
1
1
1
1
1
1
24
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.

Colour codification

0.11
029 1100 00
029 3170 00 (White)
029 3150 00 (White)
0.0625
029 1101 00
029 3173 00 (Yellow)
029 3154 00 (Yellow)
0.052
029 1102 00
029 3172 00 (Blue)
029 3152 00 (Blue)
0.042
029 1105 00
029 3175 00 (Brown)
029 3156 00 (Brown)
Page 60
Orifice Table with D&M Part Nos.

Sl.
No.
1
0.11
Orifice Assy
Part No.
AB787-W39

Colour codification
AB787-115 (White)

AB787-114 (White)
0.0625
AB787-W39B
AB787-115B (Yellow)
AB787-114B (Yellow)
0.052
AB787-W39C
AB787-115C (Blue)
AB787-114C (Blue)
0.042
AB787-W39D
AB787-115D (Brown)
AB787-114D (Brown)
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
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.
Page 61
Page 62
List of Parts
Inlet Check Valve Assembly
Drawing no. 029 1003 00 (D&M Ref. AB787-W27) Sheet 1
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
Description
Cap Screw socket
Spring Washer type A
Actuating Cup
Cup Washer
Piston
Cap Screw x UNC - 20
Actuator head
Plastic wing valve
Body spacer
Flange
Cap Screw socket
Spring washer 3/8 type B
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 NPT
029 8163 00
AB787-245
1 NPT
029 8160 00
AB787-245A
Page 63
Page 64
List of Parts
Pre-Coalescer Assembly
Drawing no. 029 1003 00 (D&M Ref. AB787-W27) Sheet 2
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
D&M Part /
Drg No.
AB787-118
AB787-168
AB787-169
AB787-170
AB787-171
AB787-172
AB787-173
AB787-174
AB787-224
AB787-W28
Description
Hex nut 3/8 &
Multi - tooth lock washer
Pre coalescer cylinder
Seat and Guide
Coalescer Element filter (AD)
Coalescer Retainer
Elastic Stop Nut 3/8 UNC
Pre coalescar sump cap
Tetra Seal for drain valve
Pre coalescer Drain valve assy
Qty /
Unit
8
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.
Page 65
Page 66
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 3420 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
Shoulder bolt
Seat Washer
Valve Seat
Stem
Piston
Cup seal
Valve cap
Cap Screw socket
Spring washer type A
Valve 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.
Page 67
Page 68
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
Tube assy
Tee 1/8 NPT x
Tube assy
Elbow 7/16 UNF x NPT
Qty /
Unit
1
1
1
1
1
Page 69
Page 70
List of Parts
Piping Assembly
Drawing no. 029 1015 00 (D&M Ref. AB787-W32) Applicable for 975-123 model Dryers.
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
Description
Straight fitting x 1/8 NPT
Tube assy
Tee 1/8 NPT x
Tube assy
Fitting
Check Valve assembly NPT
Male branch Tee
Tube Assy
Elbow
Qty /
Unit
1
1
1
1
1
1
1
2
2
Page 71
Page 72
List of Parts
Piping Assembly
Drawing no. 029 1020 00 (D&M Ref. AB787-W33) Applicable for 975-123 model Dryers.
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
Description
Elbow
Tube Assy
Tee 1/8 NPT x
Tube Assy
Male branch Tee
Tube Assy
Qty /
Unit
1
1
1
1
1
1
1
Page 73
Page 74
List of Parts
Piping Assembly
Drawing no. 029 1022 00 (D&M Ref. AB787-W31B) Applicable for 975-124 model Dryers.
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
Description
Elbow
Tube Assey
Tee 1/8 NPT x
Tube Assy
Qty /
Unit
1
1
1
1
1
Page 75
Page 76
List of Parts
Piping Assembly
Item
No.
FTIL Part No.
1
2
3
4
5
6
7
8
9
029 4080 00
029 1045 00
029 4090 00
029 1057 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
Description
Straight Fitting x 1/8 NPT
Tube Assy
Tee 1/8 NPT x
Tube Assy
Fitting
Check Valve Assembly NPT
Male Branch Tee
Tube Assy
Elbow
Qty /
Unit
1
1
1
1
1
1
1
2
2
Page 77
Page 78
List of Parts
Piping Assembly
Item
No.
FTIL Part No.
1
2
3
4
5
6
7
8
9
029 8470 00
029 1025 00
029 4090 00
029 1150 00
029 4180 00
029 1145 00
029 4100 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
Description
Tube Assy
Tee 1/8 NPT x
Tube Assy
Tee 7/16 x 7/16 x 1/8 male Tee
TubeAssy
Elbow
x 1/8 Reducer
Elbow 90 deg St.1/4 NPT
Qty /
Unit
1
1
1
1
1
1
1
1
1
Page 79
Page 80
List of Parts
Purge Valve
Drawing no. 029 1006 00 (D&M Ref. AB787-W36) Applicable for 975-123 model Dryers
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 3311 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
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
Elastic stop nut
Spring
Valve Body
Piston
Seat Guide
Seat Stem
Seat Washer
Seat
Cap Nut
Purge valve cover
Cap Screw socket
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.
Page 81
Page 82
List of Parts
Purge Valve
Drawing no. 029 1007 00 (D&M Ref. AB787-W36A) Applicable for 975-124 model Dryers
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 3420 00
029 8055 00
029 3060 00
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
Elastic stop nut
Washer, Valve seat
Valve Seat
Stem
O Ring (ID 0.674 x WIDTH 0.103)
Piston
Cup Seal
Valve cap
Cap Screw socket
Spring washer type A
Drain valve 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 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 for
Two kits are needed if both Valves are to be overhauled.
Page 83
Page 84
List of Parts
Solenoid Valve
Item
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
FTIL Part No.

029 7220 00
029 8360 00
029 7230 00
029 2050 00
029 8350 00
029 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
O Ring
Plunger Assembly
Spring
Cap Screw
Barrier strip assy
O Ring
Coil (74 v dc)
Gasket for outlet check valve
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
Two kits are needed if both Solenoid Valves are to be overhauled.
Page 85
Page 86
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.
AB787-134
AB787-39
AB787-43
AB787-135
AB787-136
AB787-137
AB787-118
AB787-138
AB787-139
AB787-140
AB787-244
AB787-141
Description
Qty / Unit
Filter Body
Spring washer 5/16 type B
Hex nut 5/16 * 18
Filter Element
Sump Cap
Hex nut 3/8 &
Filter Retainer
Wing Nut
Tetra Seal
Adaptor
Shut off Valve Assy
1
2
2
1
1
1
6
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).
Page 87
Page 88
List of Parts
Compactor / Sump Cap Assembly
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
Qty /
Unit
Description
Screw pan head #8 x 0.375
Spider
Hex hd cap screw -20UNCx3/4
Compactor cylinder cap
Piston
O ring (ID 1.799 x width 0.103)
Sump Cap longer version
Sump Cap shorter version
2
2
2
4
2
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.
Page 89
Page 90
List of Parts
Junction Box Electrical Components (Memory)
Item
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
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 2013 00
029 7075 00
099 7005 00
099 5006 00
029 8130 00
029 2090 00
029 8132 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
Solenoid housing
Sckt head shoulder screw
Coil 74V DC
Barrier Strip assy
Screw pan head
Screw pan head
Wire Nut
Memory PCB assy (Rerated)
Gasket
N0.4 x 40 UNC Pan head screw
Spring washer #4 type B
Burndy Connector (Male)
Terminal Block Assy
Burndy Connector (Female)
Qty /
Unit
1
4
1
2
1
2
3
1
1
1
4
4
1
1
1
Page 91
Page 92
List of Parts
Desiccant Canister
Drawing no. 029 1180 00 (D&M Ref. AB787-W44) Applicable for 975-123 model Dryers
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
Description
Retaining Ring
Canister Disc Assy
Desiccant charge Alumina balls
Canister Desiccannt
Qty /
Unit
4
4
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 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
Page 93
Page 94
List of Parts
Desiccant Canister
Drawing no. 029 1185 00 (D&M Ref. AB787-W44A) Applicable for 975-124 model Dryers
Item
No.
1
2
3
4
FTIL Part No.

029 8140 00
029 2100 00
029 9020 00
029 3022 00
D&M Part /
Drg No.
AB787-128
AB787-129
AB787-130
AB787-131A
Description
Retaining Ring
Canister Disc Assy
Desiccant charge Alumina balls
Canister Desiccant
Qty /
Unit
4
4
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 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
Page 95
Page 96
List of Parts
Outlet Check Valve (with memory)
Drawing no. 029 1190 00 (D&M Ref. AB787-W48) Applicable for 975-123 & 124 model
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 00A
029 7130 00A
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
Description
Outlet Manifold
Humidity Indicator assy (import)
Solenoid Housing
Terminal Box Cover Assy
Circuit Board Assy - Memory
Solenoid Assembly in air dryer
Gasket for outlet check valve
Spring
Plastic Wing Valve
Hex nut
Spring Washer type A
Pressure switch 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 97
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)
2
790 0291 65 (D&M Ref. RK-AB787-W27B)
Inlet man.coalescer kit (AD)
1
790 0291 75 (D&M Ref. RK-AB787-W28)
1
790 0291 45 (D&M Ref. RK-AB787-W29)
2
A
Kit for Purge Valve
2
790 0291 55 (D&M Ref. RK-AB787-W37)
Solenoid Assembly kit (AD)
2
790 0291 11 (D&M Ref. RK-AB787-W39)
Regenerating Orifice kit (AD)
1
790 0292 05 (D&M Ref. RK-AB787-W41)
Compactor Assembly kit (AD)
2
B
Kit for Desiccant Canister
2
790 0291 05 (D&M Ref. RK-AB787-187)
2
029 7190 00 (D&M Ref. AB787-121)
O Ring (ID 1.359 x WIDTH 0.139)
8
029 7150 00 (D&M Ref. AB787-125)
4
029 7180 00 (D&M Ref. AB787-173)
1
029 7130 00 (D&M Ref. AB787-188)
O Ring (ID 1.734 x Width 0.139)
2
029 7120 00 (D&M Ref. AB787-191)
1
029 7200 00 (D&M Ref. AB787-224)
Tetra Seal for Drain Valve
1
029 7075 00 (D&M Ref. AB787-239)
1
029 7015 00 (D&M Ref. AB787-144)
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.
790 0291 15 (D&M

Ref. RK-AB787-T17)
790 0291 16 (D&M
Ref. RK-AB787T17B)
790 0291 85 (D&M

Ref. RK-AB787-W36)
790 0292 95 (D&M
Ref. RK-AB787W36A)
790 0291 95 (D&M

Ref. RK-AB787-W44)
790 0292 45 (D&M
Ref.
RK-AB787W44A)
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).
Page 98
Page 99
Page 100
Page 101
Page 102
Page 103
Page 104
Page 105
Page 106
Page 107
Page 108
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 109
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 110
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 Precoalescing 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.
Page 111
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
Male Branch Tee
SPL Adaptor 7/16 UNF x 3/8 BSP
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

Filter 029 0012 00
Auto Drain Valve
Male Branch Tee
Refer the configuration table in page 1 for other details of Air Dryer
assembly.
Page 112
3.
790 0293 06
029 0116 00
010 0011 00
709 0041 00
029 8120 00
936 0538 00
002 0200 00

Filter 029 0012 00
Auto Drain Valve
Male Branch Tee
assembly.
4.
790 0292 06
029 0119 00
010 0011 00
709 0041 00
029 8120 00
936 0538 00
002 0200 00

Filter 029 0010 00
Auto Drain Valve
Male Branch Tee
assembly.
5.
790 0292 09
029 0121 00
010 0011 00
709 0041 00
029 8120 00
936 0538 00
002 0200 00

Filter 029 0012 00
Auto Drain Valve
Male Branch Tee
assembly.
6.
790 0292 10
029 0122 00
010 0011 00
709 0041 00
029 8120 00
936 0538 00
002 0200 00

Filter 029 0010 00
Auto Drain Valve
Male Branch Tee
assembly.
Page 113

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Page 1

OPERATION AND MAINTENANCE

FAIVELEY TRANSPORT INDIA LIMITED

+ 91 (4344) 276761 to 276765

Faiveley Transport India Limited

Faiveley Transport India Limited

Phone : + 91 (11) 26229325

Phone : + 91 (33) 23295241

Correction in Product Configuration

Operating voltage corrected for both

O-Ring part no: 029 7220 00 was

Manual updated as per latest

Molykote Grease M33 was M55

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Health and Safety

Oils and greases are used which could be a hazard.

FAIVELEY TRANSPORT Twin Tower Air Dryer

Capacity and Applications

Air Dryer Tower Indication

Auto Drain Valve Kit

Auto Drain Valve

3/8 BSP Air Strainer (Y type)

Male Branch Tee

Spl.Adaptor 7/16 UNF x 3/8bsp

Double Check Valve 3/8

Suggested location of the dryer in the pneumatic system

Inspect Humidity Indicators (ref.

Check for proper purging

Check for Automatic Draining

Check for any external leakage.

Check for proper functioning for

Renew all Rubber Parts

Renew Precoalescer Kit

Completely overhaul the Air Dryer

Renew the Desiccant Canister Kit

Recommended Spare Parts list for Air Dryer

Inlet man coalescer kit (AD)

D&M Part No.

Recommended Spare Parts list for Air Dryer

D&M Part No.

Inlet man coalescer kit (AD)

Inlet man coalescer kit (AD)

D&M Part No.

Tooling list for overhauling Air Dryer

10 Extension 3/8 Drive

3/8 Open ended wrench

3/8 Socket 3/8 drive

7/16 Open ended wrench