Air Dryer PDF

OPERATION AND MAINTENANCE
INSTRUCTIONS
FOR
FAIVELEY TRANSPORT TWIN TOWER

AIR DRYER AND FINAL FILTER
MODEL NO. 975-120 SERIES
Catalogue No. AD/075
March, 2006
FAIVELEY TRANSPORT INDIA LIMITED
POST BOX # 39
HARITA, HOSUR 635 109
TAMILNADU, INDIA
Phone : + 91 (4344) 276761 to 276765

Fax : + 91 (4344) 276035, 276786, 276033
Email : su.in@faiveleytransport.com
REGIONAL OFFICES
Faiveley Transport India Limited Faiveley Transport India Limited

B-44/C, Gangotri Enclave No. 51, Radhanath Chowdhury Road
Alaknanda, Satyajit Tower, 5th Floor
New Delhi 110 019 Kolkata 700 015
Phone : + 91 (11) 26229325 Phone : + 91 (33) 23295241

Fax : + 91 (11) 26229329 Fax : + 91 (33) 23295240
Revision Record
New
Date Version Pages Changed Reason
No.
April, 2001 1 - New Publication
August, 2001 2 1 Correction in Product Configuration
table
November, 2001 3 16 (previously 20) Maintenance Schedule of Muffler
changed
February, 2002 4 16 (previously 20) Maintenance Schedule of Air Dryer
revised in line with actual practice.
February, 2002 5 97 (previously Page 97 (previously 113) revised.
113)
December, 2002 6 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 7 Various Manual Reformatted.

August, 2004 8 Sketches for Operating voltage corrected for both
975-123 & 975-124 models.
March, 2006 9 Various Manual Reformatted.

Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Capacity and Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
System description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Suggested location of Air Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Installation Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Recommended Spares for Maintenance. . . . . . . . . . . . . . . . . . . . . . . . 23
Tools required for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Desiccant Canister Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Desiccant Charge Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Desiccant Compactor Removal and Maintenance . . . . . . . . . . . . . . . . . . 31
Regenerating Orifice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Purge Valve Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Drain Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Inlet Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Outlet Check Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Solenoid Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Pre-coalescer Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Timer and Circuit Board Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Pressure Switch Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Humidity Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Final Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Troubleshooting guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Exclusive Part numbers for ordering reference . . . . . . . . . . . . . . . . . . . 104

Health and Safety
The following points must be considered and appropriate precautions taken when working on
this equipment. It should not be taken as an exclusive list of hazards.
1. This is compressed air device. Compressed air is extremely dangerous if not handled
carefully. DO NOT attempt to service, repair or break any connections without first
assuring that the entire pressurized device has been vented of all pressure.
2. High electric voltages are used with the risk of electric shock. Dangerous voltages are
exposed once electrical covers are removed. Maintenance should be carried out only by
qualified personnel. This device is safe for operation only with the electrical covers in
place.
3. Oils and greases are used which could be a hazard.
4. Chemical cleaning agents may be used for certain operations, the manufacturers
handling procedures must be followed.
5. This product contains material which may cause temporary eye and possibly skin
irritation. Avoid breathing dust and prolonged contact with skin of the desiccant
material. Wash thoroughly after handling. Use with adequate ventilation. Contact
with moisture (water) can cause rise in temperature which may result in burn.
6. This manual contains information and warning which must be observed by the
user. Failure to adhere to these recommendations could result in mechanical
failure, property damage and serious injury or death.
7. The weight of the dryer is approximately 650 kg and the Final Filter 7 kgs.
FAIVELEY TRANSPORT Twin Tower Air Dryer
1. Introduction
The Faiveley Transport 975-120 series twin tower Air Dryers have been developed
especially to suit traction requirements. The dryers remove moisture from the
compressed air supply and ensure that only clean dry air reaches all air operated
equipment. A supply of clean dry air ensures that all air operated equipment functions
more efficiently and that the high maintenance costs associated with contaminated
systems are eliminated.
The twin tower Air Dryer system includes a pre-coalescer which removes impurities
from the compressed air supply, and desiccants (activated alumina) located in the
drying towers which remove moisture. After removing moisture, the desiccants
regenerate (restore to their original dryness) during the operating cycle, one cycle of
which is described in the section Operation .
2. Capacity and Applications
Faiveley Transport Air Dryers are made in a range of sizes in twin tower configuration.
The dryer capacities range from 1000 to 5000 lpm free air delivery compressor
installations.
The 975-123 and 975-124 Dryers are suitable for use on heavy-duty locomotives &
EMUs operating in moderate / harsh climates.
The table below shows the current 975-120 series product configurations. Other
configurations can be developed for specific customer needs.
Piping
Dryer FTIL Part Orifice Muf Pr. Mtg Applica-
Type Voltage interf-
Type No. size fler Switch Bkt -tion
ace
975-123 029002700 Ext. Model 48-110 V 0.11 YES 100 PSI YES 1 Diesel Locos
with DC NPT
memory
975-123 029003200 Ext. Model 48-110 V 0.11 YES 100 PSI YES 1¼ Elec. Locos
with DC NPT WAG9, WAP5,
memory GM loco (WDG4
& WDP-4)
975-124 029002800 Std. Model 48-110 V 0.0625 YES 100 PSI YES 1¼ Elec. Locos
with (Shorter DC NPT WAG7, WCAM3,
memory version) WCAG1.
975-124 029003100 Std. Model 48-110 V 0.052 YES 75 PSI YES 1 NPT EMUs, MG,
(Shorter DC DEMUs, Others
version)
975-124 029003300 Std. Model 48-110V 0.052 YES 100 PSI YES 1 NPT WAP4 Locos
with (Shorter DC
memory version)
975-124 029003500 Std. Model 48-110V 0.0625 YES 75 PSI YES 1¼ HHP DEMU
with (Shorter DC NPT
memory version)
Page 1
Accessories
The dryers can be supplied with extra equipment such as mounting bracket, mufflers,
end connecting flanges. Two indicators to identify the condition of the desiccant in
each tower are fitted on the dryers. Also, the Final Filter is a standard accessory. For
the exclusive part numbers which includes Air Dryer, Final Filter, Auto Drain Valve
and other accessories refer pages 104 & 105.
3.0 System Description
For the purpose of the following explanation, a Pressure Switch with a 100 psi rating is
considered as an example.
The twin tower Air Filter / Dryer is an air drying system comprising two Air Dryer
towers connected by a common inlet manifold with integral pre-coalescer and common
outlet manifold. The system also includes an electric timer which controls the system
cycle and allows the unit to regenerate only when a predetermined pressure of
approximately 6.9 ksi (100 psi) is reached and the compressor or any compressor in the
consist, is loaded (pumping). Until such time, both Air Dryer towers allow a maximum
flow of air to pass and charge the entire train or system.
4.0 Operation
Refer to diagrams attached.
Compressed air enters the inlet manifold and flows into the pre-coalescer. It passes
through a borosilicate coalescer element comprising four pleated plys which are
supported, externally and internally, by two layers of corrugated / perforated stainless
steel. The coalescer removes microscopic oil aerosols of one micron or less from the
compressed air preventing them from entering the drying towers.
Construction of the coalescer filter element is in two layers of pleated borosilicate

media supported on both sides by pleated polyester media. The first layer of polyester
media serves as a particulate prefilter and helps to evenly distribute the flow of air into
the first coalescing layer. The first coalescing layer coalesces the water and oil aerosols
into larger droplets. The second coalescing layer completes the coalescing operation
while the last layer of polyester media enhances drainage.
A desiccant (activated alumina) in the Air Dryer towers then removes water vapour
from the compressed air.
With the compressor pumping and the predetermined pressure reached

(approximately 6.9 ksi, 100 psi) the right hand side dryer tower begins to regenerate
while the Solenoid Valve is energized allowing air to pass and to close the right Inlet
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Check Valve. Simultaneously, the right spring loaded Outlet Check Valve closes.
When both Inlet and Outlet Check Valves are closed and the right Air Dryer is isolated,
the right sump mounted Purge Valve opens causing a sudden drop in 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 3
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 pre-
coalescer 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.
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5.5 Pressure Switch
An integral pressure sensing device is located internally to control the air drying cycle.
The Air Dryer cycles only when the pre-determined pressure is reached.
If an emergency arises and air pressure drops below the pre-determined level, cycling
stops immediately and air flows through both Air Dryers to support the immediate air
requirements.
5.6 Final Filter
In dryers which use either molecular sieve or bead form of desiccants like activated
alumina used in FTIL Dryer, particulate filtration is a necessity since disintegration of
the desiccant is an unavoidable phenomena as explained in para 5.4. If the microscopic
particulates are allowed to pass through the air stream unfiltered, they may get
deposited in critical pneumatic equipment like brake valves causing functional problem
in such equipment. FTIL Dryer is provided with a separate unit which removes any
dust generated after air has passed through the main dryer system.
5.7 PCB
This is an electronic assembly fully potted to prevent arcing due to moisture and also to
protect the circuit from induced emf (electro magnetic force). This incorporates a timer
with a cycling frequency of 1 minute to energise the Solenoid Valve of each tower. The
PCBs from Sl. No. M01001 have been redesigned to work satisfactorily even during
incidence of more than the rated voltage levels for short periods of time. The modified
PCBs bear FTIL part no. 029201300 only in all the dryer installations changed over to
modified design. With the modified design PCB, the fuse provision can be deleted.
CAUTION
After removing the fuse and related wiring, the hole in the electrical junction box is
to be suitably kept plugged to prevent entry of dust and foreign matter into the
electrical enclosure.
5.8 Air Dryer Tower Indication
Two LED indicators for one each tower are provided in the terminal box cover to
indicate the drying tower during cycling. Refer to electrical schematic C-D3301 sheet 1
of 2 for electrical connections.
Page 5
5.9 Auto Drain Valve Kit
Auto Drain Valve Kit is recommended to be fitted along with the Air Dryer in service.
The kit consists of the following five items:
Sl. No. Part No. Description Qty

1 010 0011 00 Auto Drain Valve 1
2 709 0041 00 3/8 BSP Strainer 1
3 029 8120 00 Male Branch Tee 1
4 936 0538 00 Special Adaptor 1
5 002 0200 00 Double Check Valve 1
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Suggested location of the dryer in the pneumatic system
The dryer shall be connected after the first Main Reservoir in case of two Main Reservoirs.
Refer sketch in next page.
The dryer shall be connected after the second Main Reservoir in case of four Main Reservoirs.
Refer sketch in next page.
The under frame location exposes the dryer to cooling air flow produced from Locomotive
travel. Locating the dryer behind Main Reservoir as said above prevents the dryer from being
exposed to the large amounts of liquid which can precipitate in the compressor aftercooler
cooling pipe.
In addition to this location, there should be an Auto Drain Valve fixed immediately before the
Dryer. Absence of this facility may increase the load on the Dryer and may reduce its
efficiency.
In the EMU s installation, there should be a Reservoir of at least 50 litres immediately after the
Dryer to provide the necessary back pressure and volume on the Outlet Check Valve of the
Dryer. There should not be any device like Check Valve between the Air Dryer and this
Reservoir.
It is suggested that the Auto Drain Valve fixed on the MR immediately before the Dryer be
actuated by the control pressure from the Dryer itself to ensure a frequent and brief purging of
the moisture from the Reservoir. In such installation, the timing chamber provided in the
Auto Drain Valves should be removed to facilitate the blow down time as low as 1 sec max.
“Precautions to be observed for Dryer installation in the Locomotive”
i) While carrying out the periodic megger tests in the locos, ensure that the Dryer PCB is
properly isolated.
ii) Do not take an earthing connection near the Dryer while carrying out any electric
welding on the Locomotive underframe.
iii) Check the inscription printed on the wires for proper identification of the (+ ve) and
(- ve) terminals. The colour code of the wire is not the only identification method.
iv) In all Locos electrical power supply should be taken for Dryer, probably in such a way
that the other inductive loads in the circuit are not applied to the Dryer electrical.
Page 10
v) In case any electrical work is being carried out in the other auxiliary circuits of the
Locomotive with the help of a short supply which might not have a proper voltage
regulation, ensure that the Dryer is isolated from such electrical supply.
vi) Ensure that a Circuit breaker of 1 amp rating is provided in the cab to isolate the Dryer
electrically whenever desired as a standard procedure. Ensure the Circuit breaker is
clearly identified as dryer isolation .
vii) It is advisable that the Air Dryers are not kept in idle storage for longer than 20 24
weeks from the date of manufacture. Adopt a First In First Out (FIFO) system of
fitment. If a longer storage is unavoidable, ensure the Dryers are cycled for at least a
day every fortnight to keep the desiccants in regenerated condition. Close the open
port of the Dryer with protective caps when in storage.
viii) Do not connect 220 / 230 v AC supply to Dryer electrical connections. This will
damage the PCB permanently.
ix) Until installation, do not remove the protection caps from inlet and delivery ports on
both the Dryer and Final Filter.
x) While lifting the Dryer to fix on the mounting bracket in the Locomotive, care must be
taken not to damage the Stainless Steel piping nor the aluminium finned castings of the
Dryer Tower.
Even if the Humidity Indicators are turned white or pinkish during a protracted idle
storage, they will turn blue again once the Air Dryer is electrically connected and
cycled for a few hours. If the blue colour is not regained, change the Humidity
indicators.
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6.0 Maintenance Schedule
SCHEDULE
MAINTENANCE
Fortnightly Monthly 6 Months Year 3 Years
Inspect Humidity Indicators (ref.
trouble shooting guide).
4
Check for proper purging 4
Check for proper cycling 4
Check for Automatic Draining
through Double Seated Valve
4
Check for any external leakage. 4
Check for proper functioning for
Pressure Switch
4
Inspect Regenerating Orifice
operation
4
Check the condition of
Precoalescing Element (replace if 4
contaminated)
Check the condition of Final Filter
Element (replace if contaminated)
4
Clean Mufflers 4
Replace Mufflers 4
Clean Purge Valves 4
Clean Double Seated Auto Drain
Valve
4
Check proper functioning of Timer
Circuit Board
4
Check the condition of Desiccant
(replace if contaminated)
4
Renew all Rubber Parts 4
Renew Precoalescer Kit 4
Renew Final Filter kit 4
Completely overhaul the Air Dryer
(ref. Maintenance Manual)
4
Renew the Desiccant Canister Kit 4
Page 22
Recommended Spare Parts list for Air Dryer
Parts to be renewed in every three years while overhauling the Air Dryer and Final Filter entirely.
Qty / Minimum stock to be

Sl. FTIL Part
Description of Spares D&M Part No. Air kept in a shed for a
No. No.
Dryer fleet of 25 Air Dryers
1 Kit for Precoalescer * 790 0291 65 RK-AB787-W27B 1 8
2 Kit for Final Filter * 790 0291 25 RK-AB787-W40 1 8
3 Kit for regenerating orifice 790 0291 11 RK-AB787-W39 1 5
4 Kit for Inlet Check Valve 790 0291 35 RK-AB787-W27A 2 10
5 Kit for Drain Valve 790 0291 75 RK-AB787-W28 1 5
6 Kit for Outlet Check Valve 790 0291 45 RK-AB787-W29 2 10
7 Kit for Purge Valve 790 0291 85 RK-AB787-W36 2 10
8 Kit for Solenoid Valve 790 0291 55 RK-AB787-W37 2 10
9 Kit for Desiccant Compactor 790 0292 05 RK-AB787-W41 2 10
10 Flange & Purge Valve O Rings 029 7190 00 AB787-121 8 64
11 Dryer Body & Spacer Seats 029 7150 00 AB787-125 4 32
12 Gasket for Inlet Manifold Body 029 7180 00 AB787-173 1 8
13 Seal for Outlet Manifold Body 029 7130 00 AB787-188 2 16
14 Gasket for Electrical Box 029 7120 00 AB787-191 1 5
15 Gasket for Drain Valve 029 7200 00 AB787-224 1 8
16 O Ring for Outlet Check Valve 029 7015 00 AB787-144 1 8
17 Gasket for Burndy Connector 029 7075 00 AB787-239 1 8
* These may be required to be renewed earlier on condition basis and should be examined by
experts atleast once a year.
Renewable Spare Parts for Air Dryer on condition basis

Qty / Minimum stock to be
Sl. FTIL Part
Description of Spares D&M Part No. Air kept in a shed for a
No No.
Dryer fleet of 25 Air Dryers
1 Pressure Switch (100 psi) OR 029 1065 00 AB787-190 1 3
2 Pressure Switch (75 psi) 029 1066 00 - 1 3
3 Timer Circuit Board (Memory) 029 2013 00 AB787-250 1 8
4 Coil 74 V DC 029 2070 00 AB787-206 2 6
5 Piping Assy (Extended) OR 029 1010 00 AB787-W31 1 3
6 Piping Assy (Smaller) 029 1022 00 AB787-W31B 1 3
11 Gasket for Outlet Check Valve 029 9040 00 AB787-194 2 10
12 Burndy Connectors (Female) 029 8132 00 - 1 5
13 Burndy Connectors (Male) 029 8130 00 - 1 5
14 Kit for Humidity Indicator 790 0291 05 RK-AB787-187 2 15
15 Kit for Desiccant Canister 790 0291 95 RK-AB787- 2 15
(Extended) * OR W44
16 Kit for Desiccant Canister (Smaller)* 790 0292 35 - 2 15
* This may be renewed in every four years unless otherwise deemed necessary earlier.
Page 23
Tooling list for overhauling Air Dryer
Below is a list of basic tools required during the dismantling and assembly process of Air
Dryer. These may be supplied by FTIL, if requested.
Standard Tools
Tool Description Ordering Reference
• 10 Extension AA1022001
• 3/8 Open ended wrench AA1022002
• 3/8 Socket 3/8 drive AA1022003
• 7/16 Socket 3/8 drive AA1022005
• Open end wrench AA1022006
• Socket 3/8 drive AA1022007
• 9/16 Open end wrench AA1022008
• 9/16 Socket 3/8 & ½ drive AA1022009
• 5/8 Socket 3/8 drive AA1022011
• Open ended wrench AA1022012
• Socket ½ drive AA1022013
• 1-3/8 Open ended wrench AA1022014
• 1-3/8 Socket ½ drive AA1022015
• 1-1/2 Open ended wrench AA1022016
• 5/32 Allen wrench AA1022017
• 3/8 Ratchet type Socket wrench AA1022020
• Ratchet type Socket wrench AA1022021
• Rubber tipped Hammer AA1022022
• Stud Driver 5/16 x 18 AA1022023
• Stud Driver 3/8 x 24 AA1022024
• Heli-coil inserting tool 3/8 x 24 AA1022005
Special Tools
Tool Description Ordering Reference
• Desiccant Compacting tool RPSK-0495

• Guide Installation tool RPSK-0496
Page 24
7.0 Maintenance Intervals
7.1 Operating Conditions
7.1.1 Air Pressure
The Air Dryer is equipped with a memory feature (type 975-123 & 975-124) which
permits the unit to regenerate only when the Compressor or any Compressor in the
consist is loading (pumping). The objective is to conserve additional air while
maintaining an acceptable performance level. For the operational checks the
Compressor must be pumping and the air pressure greater than the rated pressure
level of the particular Pressure Switch.
Type 975-123 & 975-124
The memory type electronic timer operates only when a signal voltage (48-110 V DC) is
applied to the Socket of the Burndy Connector. Any interruption of the signal
voltage (compressors in consist unloaded) causes the dryer to stop cycling. When
the signal voltage is re-applied to the Socket, the dryer restarts at the point in the
cycle where it stopped previously. In order for the electronics to work with the
memory, a constant power source (48 110 V DC) must be made available to the
Socket and a negative (-) source to the Socket within the female connector (Burndy)
when power is re-applied to , & . This sequence provides complete
regeneration to both desiccant canisters.
7.2 Operational Check (30 days)
7.2.1 Examine the Humidity Indicators. A blue colour represents correct operation and
white indicates unsatisfactory operation and requires further checks to determine the
cause.
7.2.2 There should be a slight continuous exhaust of air at the exhaust port of the Purge
Valve on the tower. After a predetermined time interval of approximately 1 minute,
there should be short loud discharge of air at the exhaust port of the opposite tower
Purge Valve, followed by a slight continuous exhaust of air. Approximately, 1 minute
later, there should be similar discharge of air at the opposite tower. In conjunction, the
Drain Valve on the sump of the pre-coalescer should exhaust every time the dryer
cycles.
The change in the exhaust of air from one tower to the other indicates the dryer is
operating properly. In conjunction, the Drain Valve on the sump cap of the pre-
coalescer should exhaust each time the Air Dryer cycles. If the change in the exhaust of
air is not present or if there is no discharge of air at either Purge Valve or Drain Valve,
check the following.
Page 25
7.3 Operational Check Fault Finding
7.3.1 Confirm that the air system pressure is equal to the minimum of the specified rating of
the Pressure Switch used and that the Compressor is pumping. The Dryer is fitted with
an internal Pressure Switch, which closes at the rated pressure. If there is no exhaust
out of one of the two Purge Valves jump the two connecting wires on the Pressure
Switch. If there is a loud, short exhaust followed by a slight continuous exhaust, the
switch is faulty and must be renewed.
7.3.2 If the Air Dryer does not cycle while the Compressor is pumping, check to see if air is
present in the piping from the Solenoid Valve to the Inlet Check Valve and Purge
Valve. If air is present in the piping on one side, then changes to the opposite side
(while Compressor is pumping), proper timing is occurring. If air is not present in the
tubing, check the power to the Dryer, see electrical note, section 7.1.2. If power is
confirmed and there is no air present in the tubing, renew the circuit board.
7.3.3 If actuating air is not present in the integral tubing to the Inlet Check Valve and Purge
Valve during the regenerating cycle, the Solenoid Valve should be examined to see if
the electrical power is to the coil. If power is to the coil, but actuating air is not in the
tubing to actuate the valve, examine the Solenoid Valve plunger for proper seating and
renew if defective. If the plunger binds in the coil and does not move freely, renew the
plunger.
7.3.4 Check each Inlet and Outlet Check Valve in the regenerating position to be sure, of
proper seating; if the loud discharge of air does not decrease to a slight exhaust of air,
check for foreign matter which may have lodged under the seat of either Inlet or Outlet
Check Valve. Clean or renew the seat.
7.3.5 Check each dryer tower while in the dehydrating cycle of proper operation; there
should be no exhaust of air at the Purge Valve. If exhaust of air is present, the Purge
Valve is not seating properly and must be examined and repaired with new seat, seals
and packing cup.
7.3.6 Examine the Drain Valve (double seated) on the sump of the pre-coalescer. The Drain
Valve is designed to exhaust each time the dryer cycles. The Drain Valve is actuated
from one of the two adjacent Purge Valves. If the Drain Valve does not cycle, examine
the actuating line from the adjacent Purge Valve and follow steps 7.3.2 and 7.3.3.
7.3.7 An operational check of the memory type timer, where fitted, may be accomplished
by unloading the compressor. The Air Dryer should stop regenerating. Load the
compressor. The dryer should begin regenerating at the point in the cycle where it
previously stopped. For example, if one of the towers regenerates for 30 seconds
prior to the compressor unloading, when the compressor loads again the memory
feature permits the same tower to restart at 31 seconds and complete the one
minute time period prior to cycling.
Page 26
7.4 Annual Check Procedures
Check the locomotive system maintenance schedule in case more rigorous

requirements are specified.
7.4.1 Remove and examine the coalescer element, section 15 gives details of the
procedure.
7.4.2 On new locomotives, remove and examine the filter element in the final filter, if it is
contaminated, rectify the cause and renew the filter element. Refer to section 20 for
details.
7.4.3 Check the operation of the regenerating orifice. Push in the orifice plunger, if
plunger will not push in, wait for the dryer to switch cycles, approximately one
minute, then push in plunger. When cycle change occurs, the orifice plunger
should automatically return to the extended position. If this does not occur, refer to
section 9.
7.4.4 Check the condition of each pipe assembly. Renew assemblies, fittings which show
signs of unacceptable corrosion.
7.4.5 Clean the muffler disseminator element where fitted.
7.5 Each 2 Years Check Procedures
Check the locomotive system maintenance schedule in case more rigorous

requirements are specified.
7.5.1 Examine the desiccant, if contaminated with oil or water, renew the desiccant, refer
to section 8. The seals and gaskets should be renewed at the same time.
7.5.2 Remove and examine the coalescer element (see annual check).
7.5.3 Remove and examine the filter element in final filter (see annual check).
7.6 Each 3 years
7.6.1 A complete overhaul is essential to ensure the continued reliable and efficient
operation of unit in providing a clean supply of air throughout the air system. The
Air Dryer should be returned to Faiveley Transport India Limited or an overhaul
location which has been autorised by Faiveley Transport India Limited.
Page 27
Overhaul requires the complete dismantling, overhaul, and renewal of consumable
parts, of the component assemblies as described in the following sections.
After completely re-assembling the Air Dryer, it should be tested including the 30
day operational check to verify timer circuit operation, see section 7.2.
7.7 Desiccant Canister Removal
Numbers in ( ) refer to drawing No. 029 1001 00 (D&M Ref. AB787-W26).
7.7.1 Using a 9/16 wrench, disconnect the

actuating airlines to the Purge Valves.
7.7.2 Use a 9/16 Socket with 10 extension to

remove 6 Nut and Lock Washers (8) to
allow the Bottom Cap (12) to be dropped
down.
7.7.3 Remove the Desiccant Canister assembly

(10).
7.7.4 Refer to section 8.8 for Desiccant

Compactor maintenance.
Refer to section 8 for Desiccant Canister

recharge procedure.
* (Spacer) not assembled in 975-129

model dryers.
Page 28
8.0 Desiccant Charge Renewal
Use Maintenance Kit RK-AB787-W44)
Sl. No. Kit Part No. Dryer Model

1 790 0291 25 (D&M Ref. RK-AB787-W44) 975-123
2 790 0292 45 (D&M Ref. RK-AB787-W44A) 975-124
8.1 Step 1-A
Using a Screw driver, remove the top

Retaining Ring and then extract the
Canister Disc Assembly.
8.2 Step 1-B
Discard the old desiccant.
8.3 Step 2
Using a screw driver, remove the bottom

Retaining Ring and then extract the
Canister Disc Assembly. Clean both the
Retaining Rings and screens. Wipe the
inside of the Canister with a clean dry
cloth.
Page 29
8.4 Step 3
Install the cleaned Canister Disc

Assembly and Retaining Ring in the
bottom of the Canister Assembly. Refill
the Canister with new desiccant.
8.5 Step 4
Place the Canister Disc Assembly with

the screen next to the desiccant beads on
top of the Desiccant Canister beads and
push down while tightly tapping with a
soft tip hammer and rotating the
Canister. Tap and rotate the unit,
Canister Disc Assembly drops below the
Retaining Ring groove.
8.6 Step 5
Remove the Canister Disc Assembly and

add more desiccant. Replace the Canister
Disc assembly and continue tapping and
rotating procedure until the top of the
Canister assembly lines up with the
bottom edge of the Retaining Ring
groove. Carefully replace the Retaining
Ring into the groove on the top of the
Canister Disc assembly.
Page 30
8.7 Step 6
Renew the Seal on the top of the Canister

Disc assembly. Before reassembly,
lubricate the Seal with Dow Corning 55
M or equivalent.
8.8 Compactor Removal and Maintenance Procedure
Numbers in ( ) refer to drawing no. 029 1001 00 (D&M Ref. AB787-W41). Use
Maintenance kit 790 0292 05 (D&M Ref. RK-AB787-W41).
8.8.1 Using a 9/16 wrench, slacken the fittings

on the Inlet Pipes to discharge the
actuating air from the Compactor, see
OGA drawing for particular model.
8.8.2 Remove 2 Hexagon Head Screws (4)

before removing Compactor Assembly.
8.8.3 Lift the Compactor Assembly up through

the Sump Cap.
8.8.4 Remove 1 Pan Head Screw (2) from the

Piston.
8.8.5 Remove the Spider (3) followed by the

Cap (5). Renew Seal (6).
8.8.6 Renew the Piston Seal (9) and the Sump

Cap Seal (7). Examine the Piston and the
Cap for any damage. Renew where
necessary.
8.8.7 Before reassembly, lubricate all Seals and

sealing surfaces with Silicone grease,
Dow Corning M 55 or equivalent.
* - (Spacer) not assembled in 975-124

model dryers.
Page 31
8.8.8 Clean all components before re-assembly. Apply Loctite 222 thread locker to the
Screw threads than re-assemble Compactor.
8.8.9 Reassemble Compactor to the Sump Cap ensuring that new Seals are fitted.
9.0 Regenerating Orifice
Numbers in ( ) refer to drawing no. 029 1001 00 (D&M Ref. AB787-W26). Use
Maintenance Kit RK-AB787-W39).
9.1 Regenerating Orifice
9.1.1 Use a 1 wrench to remove the Regenerating Orifice Assembly (1) from the Dryer
Body (9).
9.1.2 While holding the Orifice Body (5) in a vice, use a 5/8 wrench to remove the
Retainer Nut (2) from the Orifice Body.
9.1.3 Discard the Seals.
9.1.4 Clean and examine the other components, particularly the Orifice Plunger (4), for
any damage which may necessitate renewal.
9.1.5 Before reassembly, lubricate all Seals and sealing surfaces with Silicone grease, Dow
Corning M55 or equivalent.
Page 32
9.1.6 Refit the orifice plunger with a new Seal (3) into the orifice body and tighten the
Retainer Nut. Fit new Seals (6, 7) on the orifice body and refit in the dryer body.
Note:
For an easy identification of the orifice size, the orifice body is anodized and passivated
with different colours and also the orifice size is punched on the body. The following
are the various orifice sizes with its colour code. For selecting the correct size, refer
dryer configuration table in page 1.
Colour of Orifice Body

Sl. No. Orifice Size
and Plunger
1 0.11 Colourless (White)
2 0.068 Green
3 0.0625 Yellow
4 0.052 Blue
5 0.042 Brown
6 0.078 Red
10. Purge Valve Maintenance
(The figure and the procedure referred below is not applicable for 975-124 model dryer).
Page 33
10.1 Dismantling
Refer to drawing no. AB787-W36. Use Maintenance kit RK-AB787-W36.
10.1.1 Using a 9/16 wrench, disconnect the actuating air line from the Purge Valve.
10.1.2 Use a 3/8 wrench to unscrew two Cap Screws and Lock Washers, remove the
Purge Valve from the Dryer bottom Cap.
10.1.3 Use a 1-3/8 wrench to remove the Cap Nut (12) from the Body (6), this will be
followed by the Spring (5).
10.1.4 The Stem Assembly can now be removed from the Body. Use two 7/16 wrenches
to hold the Stem (9) and remove the Nut (2). Renew the Seat (11) and Nut (2).
10.1.5 Use a 3/16 Allen key to remove four Cap Screws (14) and the Cover (13).
10.1.6 The Cup Washer (1) and Piston (7) can now be removed. Renew the Cup Washer
(1) and Seal (3) on the Piston.
10.2 Cleaning and Repairing
10.2.1 Clean and examine the components not being renewed, for any damage which
indicates renewal is necessary.
10.2.2 Use all the components in the Maintenance Kit to renew parts.
10.3 Assembly
10.3.1 Lubricate all O Rings and Cup Washer with a silicone grease equivalent to Dow
Corning 55 M.
10.3.2 Replace the Piston into the Purge Valve Body followed by the new Cup Washer and
secure with the Cap Screws.
10.3.3 Fit the new Spring (5), then assemble the Cap to the Valve Body, using a 1-3/8
wrench.
10.3.4 Fit a new Gasket (15) and secure the Purge Valve to the Dryer bottom Cap with two
Cap Screws, use 3/8 wrench.
Page 34
10a. Purge Valve Maintenance
(The figure and the procedure referred below is for 975-124 model dryer)
Dismantling, Cleaning & Repairing:
Refer to drawing no. AB787-W36A for cross section drawing. Use Maintenance kit
790 0292 95 (RK-AB787-W36A).
10a.1 Using a 9/16 wrench, disconnect actuating air line to Purge Valve.
10a.2 Using a ½ wrench, remove two Nuts (1) and Lock Washers (2), remove Purge Valve
from dryer bottom cap.
10a.3 With a 1-3/8 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 35
10a.6 Cup Washer (12) and Piston (13) can now be removed. Inspect Cup Washer and
Seal (14) for unusual wear or damage and replace as necessary.
10a.7 Upon reassembly of Piston (13) to Body, generously apply Down Corning 55 M
grease or equivalent to Seal (14) and Cup Washer (12).
10a.8 Reassemble Drain Valve and inspect Seal (15) for damage before reassembling
Purge Valve to Dryer bottom Cap.
11.0 Drain Valve Maintenance
11.1 Dismantling
11.1.1 Using a 9/16 wrench, disconnect the actuating airline from the Drain Valve.
11.1.2 Use a ½ wrench to unscrew two Nuts and Lock Washers and remove the Drain
Valve from the Sump Cap.
11.1.3 Use a 1-3/8 wrench to remove the Cap (14) from the Body (12), this will be
followed by the Spring (13).
11.1.4 Use a 3/16 Alley key to remove four Cap Screws (9) with Washers (10) & the
Cap (8).
11.1.5 The Cup Washer (7) can now be removed. Renew the Cup Washer (7) and Seal (5)
on the Piston.
Page 36
11.1.6 Use a 3/8 wrench on the Seat Bolt (1) while holding the Piston (6) with a screw
driver in the slot provided in the Piston, to renew both Seats (3).
11.2 Cleaning and Repairing
11.2.1 Clean and examine the components not being renewed for any damage which
indicates renewal is necessary.
11.2.2 Use all the components in the Maintenance Kit to renew parts.
11.3 Assembly
11.3.1 Lubricate all O Rings, Cup Washer and Piston Body with a silicon grease equivalent
to Dow Corning 55 M.
11.3.2 Reassemble the Drain Valve and secure with both Caps.
11.3.3 Fit a new Gasket (15) and secure the Drain Valve to the Sump Cap with two Nuts,
use ½ wrench.
Page 37
12.0 Inlet Check Valve
Numbers in ( ) refer to drawing no.

AB787-W27. Use Maintenance Kit
790 0291 35 (D&M Ref. RK-AB787-
W27A).
12.0.1 Using a 3/16 Allen wrench, remove 4

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

Cap Screws (6) and remove Adaptor (8)
from the Inlet Check Valve Body (11).
12.0.3 Remove the Valve Seat (10) from the

Inlet Check Valve Body (11). Renew the
Valve Seat (10) on reassembly.
Note: Generously lubricate all rubber

products with silicone grease, Dow
Corning 55 M or equivalent.
12.0.4 Remove the Piston (5) from the Adaptor

(8) and renew internally assembled O
Ring (7). Renew O Ring (9) between the
Inlet Check Valve Body and the
Adaptor, then reassemble.
12.0.5 Extract the Cup Washer (4) from the

Actuating Cap and discard. Lubricate
and fit a new Cup Washer in the
Actuating Cap, making certain that the
sealing surface above the Cup Washer is
well lubricated.
12.0.6 Reassemble the Actuating Cap to the

Adaptor on the Inlet Valve Body.
Page 38
13.0 Outlet Check Valve
Numbers in ( ) refer to drawing no.

029 1005 00 (D&M Ref. AB787-W29 or
W48). Use Maintenance Kit 790 0291 45
(D&M Ref. RK-AB787-W29 or W18).
13.1 Dismantling
13.1.1 Using a 3/8 wrench, loosen 4 Captive

Screws on the Solenoid Assembly (9).
13.1.2 The Valve Seat Assembly (12) will drop

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

(11).
13.1.4 Reassemble with a new Valve Seat and

Spring.
13.1.5 Refer to section 14 for the Solenoid

overhaul procedure.
Page 39
14.0 Solenoid Assembly
Numbers in ( ) refer to drawing no. 029 1008 00

(D&M Ref. AB787-W37). Use Maintenance Kit
790 0291 55 (D&M Ref. RK-AB787-W37)
14.0.1 Remove the Spring and Seal (1) from the

Solenoid Body (2).
14.0.2 While holding the Coil Housing (11) carefully in

a vice (hold only the Cap Screw Flange), use a
9/16 wrench on the Solenoid Body (2) wrench
flats and remove from the Adaptor Assembly
(7).
14.0.3 Clean and examine the seating surface for the

Plunger Assembly inside the Solenoid Body.
14.0.4 Use a 5/32 Allen wrench to remove 4 Cap

Screws (6) from the Coil Housing. Lift the
Adaptor (7) up.
14.0.5 Remove the Coil (9) from the Coil Housing.

Examine the Coil for damage and check for
continuity and correct resistance see electrical
specification on drawing no. 029 1008 00 (D&M
Ref. AB787-W37).
Note: Sparingly lubricate all Seats and sealing surfaces

with silicone grease, Dow Corning 55M or
equivalent.
14.0.6 Renew two Seals (8) and reassemble the Coil

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

from the Coil Housing. Clean and examine the
Plunger seating surface. Renew where necessary
then reassemble.
14.0.8 Place the Spring (5), then a new Plunger

Assembly (4) into the Adaptor and Coil
Housing. Put a new Seal (3) in position on the
Adaptor and re-assemble the Solenoid Body.
Page 40
14.0.9 Fit a new Seal (1) on the Solenoid Body.
14.0.10 When required, the complete Solenoid

Assembly is replaced in the Dryer, place
Spring and overhauled Valve Seat on top of
the Solenoid Assembly and carefully
reassemble the unit to the Outlet Check
Valve Body, see figure 16. Refer to section 13
for overhaul of the Outlet Check Valve.
15.0 Pre-Coalescer
Numbers in ( ) refer to drg no. 029 1003 00

(D&M Ref. AB787-W27). Use Maintenance
Kit 790 0291 65 (D&M Ref. RK-AB787-W27B).
15.1 Element Renewal Procedure.
15.1.1 Disconnect the actuating airline from the

Drain Valve using a 9/16 wrench.
15.1.2 Using a 3/8 Socket with extension, remove

4 Nuts with Lock Washers (1) at the Sump
Cap, permitting the Sump Cap complete
with Drain Valve to drop down.
15.1.3 Turn Retainer Nut (6) counter-clockwise and

remove Coalescer Retainer (5) and Coalescer
Element (4). Renew as required.
15.1.4 Clean any debris from the Sump Cap and

Cylinder Body.
15.1.5 Reverse the procedure to reassemble the 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.
Page 41
16.0 Timer Circuit Board Renewal Procedure
References to items 5 and 7 relate to Dryer with the memory circuit.
16.0.1 Disable the electrical power supply to the Air Dryer, then disconnect the power cable
for the Dryer at the Burndy Connector (1).
16.0.2 Use a 3/8 wrench to loosen 7 Captive Screws (2) and remove the Cover Assembly (3)
and Gasket (10) from the Electrical Box (4).
16.0.3 Remove the Wire Nut (5) from under the Timer / Circuit Board assembly and
disconnect.
16.0.4 Remove the Timer / Circuit Board Assembly Box by grasping Pull Tab (6) and
carefully pulling out. Disconnect the Leads (7) at the Wire Nut (5). Replace the Timer
/ Circuit Board Assembly (6) as required.
16.0.5 Place new / reconditioned Timer / Circuit Board Assembly into the slotted Channels
(8) in the Electrical Box. Push the board firmly inward until locked in place. Join the
Wires (7) with the Wire Nut and safely under the Timer / Circuit Board Assembly.
16.0.6 If the Pressure Switch (9) is satisfactory, refer to section 17, reassemble the Cover and
Gasket to the Electrical Box, renew the Gasket (10), if necessary.
Page 42
17.0 Pressure Switch Renewal Procedure
17.1.1 Disable the air supply line and bleed all trapped pressure from the Air Dryer and
surrounding lines.
17.1.2 Disable the electrical power supply and then disconnect the Burndy Connector (1)
from the Dryer make-up box.
17.1.3 Use a 3/8 wrench to loosen 7 Cap Screws (3) and remove the make-up box cover
and gasket from the Electrical Box (2).
17.1.4 Use a 9/16 wrench to disconnect Tubing Nuts (4) from the Tee Fitting (5) on both
sides of the Dryer Outlet Manifold (2).
17.1.5 Use a 5/16 Allen wrench to remove 2 Socket Head Screws (7) that will allow the
Flange (8) to be separated from the Outlet Manifold (6).
17.1.6 With a 9/16 Socket, remove 4 x 3/8 Nuts and Lock Washers (9) that hold the
Outlet Manifold to the Dryer Body (10).
17.1.7 Remove the Outlet Manifold from the Dryer Body, disconnect Tubing Assembly
(11) from the back of the Oultet Manifold using 9/16 wrench.
17.1.8 Inside the Make-up Box (2), disconnect two electrical Female Fastons (12) from the
Pressure Switch (13).
17.1.9 Use a 1 wrench to remove the Adaptor (14) and Pressure Switch (13) from the
Make-up Box. Separate the Pressure Switch from the Adaptor with 1 and 9/16
wrenches.
Page 43
17.1.10 Refit a new Pressure Switch to the Adaptor, then assemble the Adaptor in the Make-
up Box. Reconnect two wires to the Pressure Switch in the Make-up Box (non-
polarised connection).
17.1.11 Re-attach and reassemble all the parts of the Outlet Manifold and Dryer. Test the
Dryer before returning it to service.
18.0 Humidity Indicator
Use Maintenance Kit, part no. 790 0291 05

(D&M Ref. RK-AB787-187).
The Humidity Indicator is used as a visual

monitor showing the operating condition of the
Air Dryer.
A blue colour indicates an Air Dryer operating

satisfactorily. A totally white colour indicates
the Dryer operation and desiccant beads should
be checked. A thorough inspection for the
presence of desiccant dust in the Control Pipe
work and the Pressure Switch should be made.
Where dust is found, the Pressure Switch should
be replaced. Refer to section 17 for Pressure
Switch renewal procedure.
Usually only excessive oil aerosols or prolonged

saturation by water will permanently turn the
blue paper white. Oil aerosols will coat the
paper and turn it a dark green or shade of
orange or yellow, rendering it ineffective for the
sensing of water aerosols.
Warning : Do not alter, modify or use parts not supplied in

Maintenance Kit 790 0291 05 (D&M Ref.
RK-AB787-187) for this component.
The Maintenance Kit is designed to renew the

paper indicator in the Humidity Indicator.
Page 44
18.1 Procedure
18.1.1 Remove the Spring Clip, all old media and paper.
18.1.2 Clean the inside of the ¾ bushing with and approved solvent that will remove
oil.
18.1.3 Wipe off and dry.
18.1.4 Assemble all the items from the Maintenance Kit in the order shown in Fig. 20.
18.1.5 An oil coalescer medium and humidity / oil absorbing desiccant has been added
to prolong the life of the blue paper. To be effective, it must be assembled as
shown in fig. 20.
When adding the loose desiccant from the sorb-it bag, fill the cavity level in only
two Spacers, before inserting the Coalescer media, Rubber Sealing Gasket and
Spring Clip into the bushing.
18.1.6 Ensure the Spring Clip is pressed into the bushing firmly against the rubber
gasket, convex side first. Use a metal applicator, such a ½ extended socket, to tap
the Spring Clip into place.
19.0 Muffler
(This is an optional unit)
19.0.1 Release two Nuts and remove the Cap from the Muffler assembly.
19.0.2 Remove the disseminator element (silencer).
Page 45
19.0.3 Using a wire bush, brush the inside and the outside of the disseminator element to
remove accumulated dirt from the element.
19.0.4 This procedure is required to return the element to its original condition, thereby
reducing the back pressure through the Muffler to a minimum.
Note: Excess back pressure adversely affects the performance of the Dryer.
19.0.5 Reassemble the Muffler and refit to the Dryer.
20.0 Final Filter
20.1 Function and Operation
The Final Filter is mounted separately from

the Air Dryer as the next component in the
Outlet Pipe. The Final Filter ensures that
minute dust and dirt particles, which may
have escaped purging in the main Dryer
system are removed.
Air enters into the Body of the Filter and

passes through the Filter element which
collects any remaining impurities from the
air. A manually operated Drain Cock is
situated at the foot of the Final Filter.
20.2 Maintenance
20.2.1 Numbers in ( ) refer to drg no. 029 0010 00 &

029 0012 00 (D&M Ref. AB787-W40). Use
Maintenance Kit No. 790 0291 25 (D&M Ref.
RK-AB787-W40).
It is possible to renew the Filter element

without removing the Body assembly from
the vehicle, provided sufficient space is
available.
20.2.2 Ensure that the air system is shut down and

that air pressure has been blow down.
20.2.3 Remove six Nuts and Lock Washers (7). The

Bottom Cap (6) complete with Manual Drain
Valve and Gasket (4) will drop down.
Page 46
20.2.4 Unscrew the Wing Nut (9) to remove the Filter Retainer (8) & the Filter Element (5).
20.2.5 Clean the inside of both the Filter Body assembly and bottom Cap.
20.2.6 Examine the Filter element and renew if necessary. Contamination of the element by
oil, desiccant or water means that a new element must be fitted.
20.2.7 When refitting the Filter Element (5), lubricate the sealing surface at both ends of the
element with Dow Corning M55 or equivalent. Carefully align the Filter element on
the Filter Retaining device in the Filter Body Assembly, followed by the Filter
Retainer (8) and Wing Nut (9). Reassemble the Final Filter.
20.2.8 Renew the Gasket (4), ensure this is fitted the correct way, see fig 22 and reassemble
the Bottom Cap (6) to the Filter Body and secure with the six Nuts with Lock Washers
(7).
20.3 Trouble Shooting Guide
20.3.1 Oil contamination of the Final Filter indicates that the Compressor is pumping oil or
that the Oil Separator and its Drain Valve have failed.
After correcting the fault, renew the Desiccant Canister and Final Filter element.
20.3.2 Desiccant contamination of the Final Filter element is an indication that the desiccant
bead has broken down. This may be caused by
1. If for some reason the compressor duty cycle is continuous or in excess of 75%,
there is insufficient time for the desiccant bead to fully regenerate. This means
that the desiccant will eventually deteriorate and escape from the canister. The
desiccant contamination will be trapped in the Final Filter.
Check the compressor duty cycle, then renew the desiccant canister and Final
Filter element.
2. If the Compactor, which exerts pressure on the desiccant bead is not functioning
properly, the bead could break down and deposit small broken beads of white
dust in the Final Filter.
Repair the Compactor, then renew the desiccant bead and Final Filter element.
20.3.3 Water contamination of the Final Filter element indicates that the duty cycle of the
Compressor is more than 75% and the desiccant bead does not have sufficient time to
regenerate before the next cycle.
Check the compressor duty cycle.
After correcting the fault, renew the Desiccant Canister and Final Filter element.
Page 47
Page 48
List of Parts
Twin Tower Air Dryer
Drawing no. 029 1001 00 (D&M Ref. AB787-W26). (This is applicable for 975-123 model
dryers).
Item D&M Part / Qty /

FTIL Part No. Description
No. Drg No. Unit
1 Refer table Refer table Orifice Assembly 1

2 ** 029 3035 00 AB787-110 Retainer Nut 1
3 ** 029 7060 00 AB787-111 O Ring 1
4 ** Refer table Refer table Orifice Plunger 1
5 ** Refer table Refer table Orifice Body 1
6 ** 029 7070 00 AB787-115 O Ring 1
7 ** 029 7035 00 AB787-116 O Ring 1
8 099 8006 00 & AB787-117 Nut with Lock Washer 24
099 8007 00
9* 029 1200 00 AB787-W34 Dryer Body 1
10 029 1180 00 AB787-W44 Canister Assembly 2
11 029 7140 00 AB787-119 O Ring 2
12 029 1009 00 AB787-W41 Compactor / Sump Cap Assembly 2
13 029 7190 00 AB787-121 O Ring 2
14 029 1006 00 AB787-W36 Purge Valve 2
15 099 5005 00 AB787-122 Lock Washer 4
16 099 6003 00 AB787-123 Cap Screw 4
17 029 3330 00 AB787-124 Body Spacer 2
18 029 7150 00 AB787-125 O Ring 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. Orifice Assy Orifice Body Part No. / Orifice Plunger Part No.
Orifice Size
No. Part No. Colour codification / Colour codification
1 0.11 029 1100 00 029 3170 00 (White) 029 3150 00 (White)
2 0.0625 029 1101 00 029 3173 00 (Yellow) 029 3154 00 (Yellow)
3 0.052 029 1102 00 029 3172 00 (Blue) 029 3152 00 (Blue)
4 0.042 029 1105 00 029 3175 00 (Brown) 029 3156 00 (Brown)
Page 49
Orifice Table with D&M Part Nos.
Orifice Size
1 0.11 AB787-W39 AB787-115 (White) AB787-114 (White)
2 0.0625 AB787-W39B AB787-115B (Yellow) AB787-114B (Yellow)
3 0.052 AB787-W39C AB787-115C (Blue) AB787-114C (Blue)
4 0.042 AB787-W39D AB787-115D (Brown) AB787-114D (Brown)
Maintenance kits
Maintenance kit, part no. 790 0290 11 (D&M Ref. RK-AB787-W39), includes parts 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 50
Page 51
List of Parts
Twin Tower Air Dryer
Drawing no. 029 1002 00 (D&M Ref. AB787-W26A). (This is applicable for 975-124 model
dryers).

No. Drg No. Unit
1 Refer table Refer table Orifice Assembly 1

2 029 3035 00 AB787-110 Retainer Nut 1
3 029 7060 00 AB787-111 O Ring 1
4 Refer table Refer table Orifice Plunger 1
5 Refer table Refer table Orifice Body 1
6 029 7070 00 AB787-115 O Ring 1
7 029 7035 00 AB787-116 O Ring 1
099 8007 00
9 029 1200 00 AB787-W34 Dryer Body 1
10 029 1185 00 AB787-W44A Canister Assembly 2
11 029 7140 00 AB787-119 O Ring 2
12 029 1210 00 AB787-W41A Compactor / Sump Cap Assembly 2
13 029 7190 00 AB787-121 O Ring 2
14 029 1007 00 AB787-W36A Purge Valve 2
15 099 5001 00 AB787-122A Lock Washer 4
16 099 3001 00 AB787-123A Cap Screw 4
17 029 7150 00 AB787-125 O Ring 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.
Orifice Size
1 0.11 029 1100 00 029 3170 00 (White) 029 3150 00 (White)
2 0.0625 029 1101 00 029 3173 00 (Yellow) 029 3154 00 (Yellow)

3 0.052 029 1102 00 029 3172 00 (Blue) 029 3152 00 (Blue)
4 0.042 029 1105 00 029 3175 00 (Brown) 029 3156 00 (Brown)
Page 52
Orifice Table with D&M Part Nos.
Orifice Size
1 0.11 AB787-W39 AB787-115 (White) AB787-114 (White)
2 0.0625 AB787-W39B AB787-115B (Yellow) AB787-114B (Yellow)
3 0.052 AB787-W39C AB787-115C (Blue) AB787-114C (Blue)
4 0.042 AB787-W39D AB787-115D (Brown) AB787-114D (Brown)
Maintenance kits
Maintenance kit, part no. 790 0291 11 (D&M Ref. RK-AB787-W39), includes parts 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 53
Page 54
List of Parts
Inlet Check Valve Assembly
Drawing no. 029 1003 00 (D&M Ref. AB787-W27) Sheet 1

No. Drg No. Unit
1 099 6001 00 AB787-155 Cap Screw 8

2 099 5003 00 AB787-156 Lock Washer 8
3 029 3280 00 AB787-157 Actuating Cup 2
4 029 7240 00 AB787-158 Cup Washer 2
5 029 3050 00 AB787-159 Piston 2
6 099 6501 00 AB787-160 Cap Screw 8
7 029 7030 00 AB787-161 O Ring 2
8 029 3340 00 AB787-162 Adaptor 2
9 029 7105 00 AB787-99 O Ring 2
10 029 6070 00 AB787-243 Valve Seat 2
11 029 3330 00 AB787-167 Valve Body, Inlet 2
12 029 7190 00 AB787-121 O Ring 3
13 Refer table Refer table Flange 1
14 099 6002 00 AB787-246 Cap Screw 2
15 099 5004 00 AB787-247 Lock Washer 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:
Flange Thread Flange Part No. Flange Part No.

Sl. No.
Size FTIL D&M
1 1¼ NPT 029 8163 00 AB787-245
2 1 NPT 029 8160 00 AB787-245A
Page 55
Page 56
List of Parts
Pre-Coalescer Assembly
Drawing no. 029 1003 00 (D&M Ref. AB787-W27) Sheet 2

No. Drg No. Unit

099 8007 00
2 029 3350 00 AB787-168 Cylinder 1
3 029 3080 00 AB787-169 Seat and Guide 1
4 029 2040 00 AB787-170 Coalescer Element 1
5 029 3090 00 AB787-171 Coalescer Retainer 1
6 099 3005 00 AB787-172 Elastic Stop Nut 1
7 029 7180 00 AB787-173 O Ring 1
8 029 3270 00 AB787-174 Sump Cap 1
9 029 7200 00 AB787-224 Tetra Seal 1
10 029 1004 00 AB787-W28 Drain Valve 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 57
Page 58
List of Parts
Drain Valve
Drawing no. 029 1004 00 (D&M Ref. AB787-W28)

No. Drg No. Unit
1 029 8075 00 AB787-175 Seat Bolt 1

2 029 4010 00 AB787-176 Seat Washer 1
3 029 6010 00 AB787-177 Seat 2
4 029 8410 00 AB787-178 Stem 1
5 029 7015 00 AB787-144 O Ring 1
6 029 4020 00 AB787-179 Piston 1
7 029 7250 00 AB787-180 Cup Washer 1
8 029 4140 00 AB787-181 Cap 1
9 099 6001 00 AB787-155 Cap Screw 4
10 099 5003 00 AB787-182 Lock Washer 4
11 029 7095 00 AB787-97 O Ring 1
12 029 3240 00 AB787-183 Body 1
13 029 8055 00 AB787-248 Spring 1
14 029 3060 00 AB787-185 Spring Cap 1
Maintenance kit
Maintenance kit, part no. RK-AB787-W28 comprises 3 (2 nos.) 5, 7, 11 and 13. Refer to drawing
of the kit for identification of parts.
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Page 60
List of Parts
Piping Assembly
Drawing no. 029 1010 00 (Application for 975-123 model Dryers)

No. Drg No. Unit
1 029 4100 00 AB787-210 Elbow 1

2 029 1025 00 AB787-211 Pipe Assembly 1
3 029 4090 00 AB787-212 Tee 1
4 029 1030 00 AB787-213 Pipe Assembly 1
5 029 8470 00 AB787-214 Elbow 1
Page 61
Page 62
List of Parts
Piping Assembly
Drawing no. 029 1015 00 (D&M Ref. AB787-W32) Applicable for 975-123 model Dryers.

No. Drg No. Unit
1 029 4080 00 AB787-215 Fitting 1

2 029 1045 00 AB787-216 Pipe Assembly 1
3 029 4090 00 AB787-217 Tee 1
4 029 1055 00 AB787-218 Pipe Assembly 1
5 029 4070 00 AB787-219 Fitting 1
6 029 1060 00 AB787-220 Check Valve 1
7 029 8120 00 AB787-221 Tee 1
8 029 1050 00 AB787-222 Pipe Assembly 2
9 029 4100 00 AB787-210 Elbow 2
Page 63
Page 64
List of Parts
Piping Assembly
Drawing no. 029 1020 00 (D&M Ref. AB787-W33) Applicable for 975-123 model Dryers.

No. Drg No. Unit
1 029 4100 00 AB787-210 Elbow 1

2 029 1025 00 AB787-211 Pipe Assembly 1
3 029 4090 00 AB787-217 Tee 1
4 029 1040 00 AB787-223 Pipe Assembly 1
5 029 8120 00 AB787-221 Tee 1
6 029 1035 00 AB787-223A Pipe Assembly 1
7 029 8470 00 AB787-214 Elbow 1
Page 65
Page 66
List of Parts
Piping Assembly
Drawing no. 029 1022 00 (D&M Ref. AB787-W31B) Applicable for 975-124 model Dryers.

No. Drg No. Unit
1 029 4100 00 AB787-210 Elbow 1

2 029 1025 00 AB787-211 Pipe Assembly 1
3 029 4090 00 AB787-212 Tee 1
4 029 1140 00 AB787-213A Pipe Assembly 1
5 029 8470 00 AB787-214A Elbow 1
Page 67
Page 68
List of Parts
Piping Assembly

No. Drg No. Unit
1 029 4080 00 AB787-215 Straight Fitting 1

2 029 1045 00 AB787-216B Tube Assembly 1
3 029 4090 00 AB787-212 Tee 1
5 029 4070 00 AB787-219 Fitting 1
6 029 1060 00 AB787-220 Check Valve Assembly 1
7 029 8120 00 AB787-221 Male Branch Tee 1
9 029 4100 00 AB787-210 Elbow 2
Page 69
Page 70
List of Parts
Piping Assembly

No. Drg No. Unit
1 029 8470 00 AB787-210 Elbow 1

2 029 1025 00 AB787-211 Pipe Assembly 1
3 029 4090 00 AB787-217 Tee 1
4 029 1145 00 AB787-223 Pipe Assembly 1
5 029 4180 00 AB787-129A Tee 1
6 029 1150 00 AB787-129B Pipe Assembly 1
7 024 1000 00 AB787-129C Elbow 1
8 029 4190 00 AB787-129D Reducer 1
9 029 4200 00 AB787-129E Reducing Elbow 1
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Page 72
List of Parts
Purge Valve
Drawing no. 029 1006 00 (D&M Ref. AB787-W36) Applicable for 975-123 model Dryers

No. Drg No. Unit
1 029 7240 00 AB787-142 Cup Washer 1

2 099 3003 00 AB787-143 Lock Nut 1
3 029 7015 00 AB787-144 O Ring 1
4 029 7080 00 AB787-145 O Ring 1
5 029 8060 00 AB787-146 Spring 1
6 029 3310 00 AB787-147 Body 1
7 029 3065 00 AB787-148 Piston 1
8 029 8085 00 AB787-149 Seat Guide 1
9 029 8081 00 AB787-150 Seat Stem 1
10 029 3070 00 AB787-151 Seat Washer 1
11 029 6110 00 AB787-152 Seat 1
12 029 8170 00 AB787-153 Cap Nut 1
13 029 3260 00 AB787-154 Cover 1
14 099 6001 00 AB787-155 Cap Screw 4
Quantities are for a single Purge Valve. Two Valves are fitted to the complete Air Dryer.
Maintenance Kit
Maintenance kit part no. 790 0291 85 (D&M Ref. RK-AB787-W36) comprises 1 (1 no.), 2 (1 no),
3 (1 no.), 4 (1 no.), 5 (1 no.) and 11 (1 no.). Refer to drawing of the kit for identification of parts.
Two kits are needed if both Valves are to be overhauled.
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Page 74
List of Parts
Purge Valve
Drawing no. 029 1007 00 (D&M Ref. AB787-W36A) Applicable for 975-124 model Dryers

No. Drg No. Unit
1 099 3003 00 AB787-143 Nut 1

2 029 4230 00 AB787-129F Seat Washer 1
3 029 6010 00 AB787-129G Seat 1
4 029 8410 00 AB787-129H Stem 1
5 029 7015 00 AB787-144 O Ring 1
6 029 4240 00 AB787-129J Piston 1
7 029 7250 00 AB787-129K Cup Seal 1
8 029 4140 00 AB787-129L Cap 1
9 099 6001 00 AB787-155 Cap Screw 4
10 099 5003 00 AB787-129M Lock Washer 4
11 029 7095 00 AB787-129N O Ring 1
12 029 4210 00 AB787-129O Body 1
13 029 8055 00 AB787-129P Spring 1
14 029 3060 00 AB787-129Q Spring Cap 1
Quantities are for a single Purge Valve. Two Valves are fitted to the complete Air Dryer.
Maintenance Kit
Maintenance kit part no. 790 0292 55 (D&M Ref. RK-AB787-W36A) comprises 1 (1 no.), 3
(1 no.), 5 (1 no.), 7 (1 no.), 11 (1 no.) and 17 (1 no.). Refer to drawing of the kit for
Two kits are needed if both Valves are to be overhauled.
Page 75
Page 76
List of Parts
Solenoid Valve

No. Drg No. Unit
1 029 1008 00 AB787-198 O Ring 2

2 029 8360 00 AB787-199 Solenoid Valve Body 2
3 029 7230 00 AB787-200 O Ring 2
4 029 2050 00 AB787-201 Plunger Assembly 2
5 029 8350 00 AB787-202 Spring 2
6 901 0370 00 AB787-203 Cap Screw 8
7 025 2080 00 AB787-204 Adaptor Assembly 2
8 029 7210 00 AB787-205 O Ring 4
9 029 2070 00 AB787-206/D Coil (74 v dc) 2
10 029 9040 00 AB787-194 Gasket 2
11 029 8420 00 AB787-207 Coil Housing 2
12 029 8430 00 AB787-208 Magnet 2
13 029 8440 00 AB787-209 Eye Bolt 2
Quantities are for the complete Air Dryer.
Maintenance Kit
Maintenance kit, part no. 790 0291 55 (D&M Ref. RK-AB787-W37), comprises item 1 (1 no.), 3
(1 no.), 4 (1 no.), 5 (1 no.), 8 (2 nos.) and 10 (1 no.). Refer to drawing of the kit for identification
of parts.
Two kits are needed if both Solenoid Valves are to be overhauled.
Page 77
Page 78
List of Parts
Final Filter
Drawing no. 029 0010 00 & 029 0012 00 (D&M Ref. AB787-W40).
Item D&M Part /

FTIL Part No. Description Qty / Unit
No. Drg No.
1 029 3380 00 AB787-134 Filter Body 1

2 099 5001 00 AB787-39 Lock Washer 2
3 099 3001 00 AB787-43 Nut 2
4 029 7150 00 AB787-135 O Ring 1
5 029 1080 00 AB787-136 Filter Element 1
6 029 3390 00 AB787-137 Bottom Cap 1
099 8007 00
8 029 3370 00 AB787-138 Filter Retainer 1
9 029 4150 00 AB787-139 Wing Nut 1
10 029 7200 00 AB787-140 Tetra Seal 1
11 029 8390 00 AB787-244 Adaptor 1
12 029 1250 00 AB787-141 Shut off Assembly 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 79
Page 80
List of Parts
Compactor / Sump Cap Assembly

No. Drg No. Unit
1 029 7150 00 AB787-135 O Ring 2

2 099 7002 00 AB787-225 Pan Head Screw 2
3 029 3210 00 AB787-226 Spider 2
4 099 2001 00 AB787-227 Screw 4
5 029 3240 00 AB787-228 Cap 2
6 029 7065 00 AB787-98 Seal 2
7 029 7090 00 AB787-231 Seal 2
8 029 3030 00 AB787-230 Piston 2
9 029 7055 00 AB787-229 Seal 2
10 029 3290 00 AB787-253 Sump Cap (975-123) 2
11 029 3291 00 AB787-253A Sump Cap (975-124) 2
Quantities are for complete Air Dryer. Two Compactor / Sump Cap Assemblies are
required for one complete Air Dryer.
Maintenance Kits
Maintenance kit part no. 790 0292 05 (D&M Ref. RK-AB787-W41) includes parts for the
Compactor and comprises items 6 (1 no.), 7 (1 no.) and 9 (1 no.). Refer to drawing of the
kit for identification of parts.
Two off each kit are needed if both Canister Assemblies are to be overhauled.
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Page 82
List of Parts
Junction Box Electrical Components (Memory)

No. Drg No. Unit
1 029 3400 00 AB787-189 Housing 1

2 029 8135 00 AB787-231 Cap Screw with Seal 4
3 029 1065 00 AB787-190 Pressure Switch (100 psi) 1
4 029 2070 00 AB787-233 Receptacle Assembly 2
5 029 2080 00 AB787-234 Barrier Strip 1
6 099 7001 00 AB787-235 Cap Screw 2
7 099 7004 00 AB787-236 Cap Screw 3
8 939 0268 00 AB787-249 Wire Nut 1
9 029 2012 00 AB787-250 Timer / Circuit Board Assy (memory) 1
10 029 7075 00 AB787-239 Gasket 1
11 099 7005 00 AB787-241 Cap Screw 4
12 099 5006 00 AB787-240 Lock Washer 4
13 029 8130 00 AB787-242 Burndy Connector Assembly 1
14 029 2090 00 AB787-237 Terminal Block Assembly 1
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Page 84
List of Parts
Desiccant Canister
Drawing no. 029 1180 00 (D&M Ref. AB787-W44) Applicable for 975-123 model Dryers

No. Drg No. Unit
1 029 8140 00 AB787-128 Retaining Ring 4

2 029 2100 00 AB787-129 Canister Disc Assembly 4
3 029 9020 00 AB787-130 Desiccant charge 7.2 kgs
4 029 3020 00 AB787-131 Desiccant Canister 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 85
Page 86
List of Parts
Desiccant Canister
Drawing no. 029 1185 00 (D&M Ref. AB787-W44A) Applicable for 975-124 model Dryers

No. Drg No. Unit
1 029 8140 00 AB787-128 Retaining Ring 4

2 029 2100 00 AB787-129 Canister Disc Assembly 4
3 029 9020 00 AB787-130 Desiccant charge 4.9 kgs
4 029 3020 00 AB787-131A Desiccant Canister 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 87
Page 88
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

No. Drg No. Unit
1 029 3320 00 AB787-186 Outlet Valve Body 1

2 029 1220 00 AB787-187 Humidity Indicator 2
3 029 7130 00 AB787-188 O Ring 2
4 029 3400 00 AB787-189 Housing 1
5 029 1065 00 AB787-190 Pressure Switch (100 psi) 1
029 1066 00 AB787-190/1 Pressure Switch (75 psi) 1
6 029 7120 00 AB787-191 Gasket 1
7 029 2110 00 AB787-192 Cover Assembly 1
8 029 2012 00 AB787-250 Timer and Circuit Board Assembly 1
9 029 1240 00 AB787-W37 Solenoid Assembly 2
10 029 9040 00 AB787-194 Gasket 2
11 029 8065 00 AB787-195 Spring 2
12 029 6070 00 AB787-243 Plastic Wing Valve 2
13 099 3002 00 AB787-196 Nut 8
14 099 5003 00 AB787-186 Lock Washer 8
15 029 7015 00 AB787-144 O Ring 1
16 029 8180 00 AB787-197 Adaptor 1
Pressure Switch data:
a) 029 1065 00 (D&M Ref. AB787-190) - Closes @ 100 psi ± 5 psi

Opens @ 80 psi ± 5 psi
b) 029 1066 00 (D&M Ref. AB787-190/1) - Closes @ 75 psi ± 5 psi

Opens @ 55 psi ± 5 psi
Maintenance Kit
Maintenance Kit part no. 790 0291 45 (D&M Ref. AB787-W29) comprises item 11 (1 no.) and 12
(1 no.). Refer to drawing of the kit for identification of parts.
Page 89
Complete Air Dryer Maintenance kit
790 0291 15 (D&M Ref. RK-AB787-T17)

790 0291 16 (D&M Ref. RK-AB787-T17B)
The Dryer Maintenance kits comprises the following maintenance kits and individual items.
790 0291 35 (D&M Ref. RK-AB787-W27A) Kit for Inlet Check Valve 2
790 0291 65 (D&M Ref. RK-AB787-W27B) Kit for Pre-Coalescer 1
790 0291 75 (D&M Ref. RK-AB787-W28) Kit for Drain Valve 1
790 0291 45 (D&M Ref. RK-AB787-W29) Kit for Outlet Check Valve 2
A Kit for Purge Valve 2
790 0291 55 (D&M Ref. RK-AB787-W37) Kit for Solenoid Valve 2
790 0291 11 (D&M Ref. RK-AB787-W39) Kit for Regenerating Orifice 1
790 0292 05 (D&M Ref. RK-AB787-W41) Kit for Desiccant Compactor 2
B Kit for Desiccant Canister 2
790 0291 05 (D&M Ref. RK-AB787-187) Kit for Humidity Indicator 2
029 7190 00 (D&M Ref. AB787-121) Flange Purge Valve O Rings 8
029 7150 00 (D&M Ref. AB787-125) Dryer Body and Spacer O Ring 4
029 7180 00 (D&M Ref. AB787-173) O Ring for Inlet Manifold Body 1
029 7130 00 (D&M Ref. AB787-188) O Ring for Outlet Manifold 2
029 7120 00 (D&M Ref. AB787-191) Gasket for Electrical Box 1
029 7200 00 (D&M Ref. AB787-224) Tetra Seal for Drain Valve 1
029 7075 00 (D&M Ref. AB787-239) Gasket for Burndy Connector 1
029 7015 00 (D&M Ref. AB787-144) O Ring for Pr. Switch Adaptor 1
Note that Maintenance Kit 790 0291 45 (D&M Ref. RK-AB787-W29) covers both 029 1005 00
(D&M Ref AB787-W29) and 029 1190 00 (D&M Ref. AB787-W48) assemblies.
Dryer
Piping Assembly
Model Kit Part No. A B
Part No.
No.
975-123 790 0291 15 (D&M 790 0291 85 (D&M Ref. 790 0291 95 (D&M Ref. 029 1500 00 (D&M
Ref. RK-AB787-T17) RK-AB787-W36) RK-AB787-W44) Ref. AB787-W30)
975-124 790 0291 16 (D&M 790 0292 95 (D&M Ref. 790 0292 45 (D&M Ref. 029 1510 00 (D&M
Ref. RK-AB787-T17B) RK-AB787-W36A) RK-AB787-W44A) 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 90
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Page 100
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) 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.
b) If a Drain or Purge Valve has a small continuous leak:
If any of the Valves (two purge on dryer towers and one double seated drain on
Coalescer) are suspected to be leaking, the electrical power should be disconnected
from the dryer and if air leaks from a Valve with no power applied, the Valve should
be replaced. Note that a large blast followed by a small continuous exhaust of air from
the Purge Valves on a timed basis is normal dryer operation.
c) If dryer is blowing excessively out either Purge Valve:
This failure is caused by either a stuck inlet or outlet check valve. Both conditions are
not practical to service on the Locomotive and the Dryer should be removed from
service.
Page 101
d) If the PCB is suspected to be defective:
This can be sorted out by testing the PCB in the test kit which if requested, will be
supplied by FTIL. If the PCB is found to be defective, replace it with a new PCB. Do
not try to tamper any of the components assembled in the PCB.
Ordering reference for PCB test kit : RBTR 0113.
e) The dryer needs to be attended if Humidity Indicator colour is as follows:
BLUE INDICATOR – indicates Dryer has been performing correctly
Verify Dryer is cycling

If Dryer is cycling correctly & # 1 Main Reservoir
Drain Valve is operating correctly Release for
service.
LAVENDER INDICATOR – Dryer is suspect
Check for water in Final Filters

If water is found in Final Filters Remove Dryer
and replace with a new or remanufactured Dryer.
If no water found in Final Filters Verify Dryer is
cycling correctly.
If Dryer is cycling correctly & # 1 Main Reservoir
Drain Valve is operating correctly Release for
service.
WHITE INDICATOR – Possible damaged Dryer. Check for water in Final Filters.
Dryer desiccant has been damaged by excessive

amount of water. Remove Dryer and replace with a
new or remanufactured Dryer. Verify new Dryer is
cycling correctly and # 1 Main Reservoir Drain
Valve is operating correctly.
YELLOW OR BROWN INDICATOR – Damaged Dryer
Dryer has been damaged by oil.

Verify if the Dryer is cycling properly by charging
the Main Reservoir circuit.
Particularly verify if the Double Seated Purge Valve
of the Pre-Coalescer is operating correctly every
time the Dryer is cycling.
Page 102
Switch off the Compressor and drain the Main Reservoir pressure.
Remove Dryer and replace with a new or remanufactured Dryer.
Report compressor problem.
If new Dryer is cycling correctly & # 1 Main Reservoir Drain Valve is operating
correctly Release for service.
Take the Dryer to the workshop and verify the following.
1) Open the Pre-coalescing Filter Body & Sump Cap and remove the Pre-coalescing
Filter.
2) Referring to para 15 of the manual, dismantle the Pre-coalescing Filter as shown in

fig 17 and check if the upper molded cap of Pre-coalescing Element (item 4) is
damaged. If found damaged, replace Pre-coalescing Element (item 4).
Open both the dry towers as given in fig on page 48 under reference drawing no.
029 1001 00 and examine the desiccant beads. If the beads, especially at the bottom side
of the canister appear brown colour, it indicates oil carry over from the Pre-coalescing
Filter. The brown colour desiccant has to be replaced in each of the towers. However,
before replacing the cause of the excess oil throw must be identified and reported. If it
is a problem in the Pre-coalescing Element, it has to be replaced before the Dryer with
the new desiccant is assembled.
Make sure that the Auto Drain Valve fixed in first Main Reservoir is functioning
correctly. Alternately, if the Auto Drain Valve is actuated by a pressure signal tapped
from the Air Dryer itself, make sure that the Auto Drain Valve in the first Reservoir is
actuated briefly whenever one full cycling is completed by the Dryer.
Before fixing the new Dryer, open the Final Filter assembly also and verify if the Filter
element also is damaged by oil throw. If needed, replace the Filter element.
Check the inside of the Final Filter Body for coat of oil. If oil is found, clean the Filter
Body and drain the cock using a suitable solvent and reuse only after cleaning the Filter
Body and the Drain Cock.
Note:
If the oil carry over is not set right before the new Dryer is installed, it is very likely that
the replaced Dryer will suffer the same problem.
Page 103
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 - Consists of Air Dryer assembly 029 0027 00 & Final
Filter 029 0010 00
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 - Special Adaptor
002 0200 00 - Double Check Valve 3/8
Refer the configuration table in page 1 for other details on Air Dryer
assembly.
Filter 029 0012 00
Refer the configuration table in page 1 for other details of Air Dryer
assembly.
Page 104
Filter 029 0012 00
assembly.
Filter 029 0010 00
assembly.
Filter 029 0012 00
assembly.
Filter 029 0010 00
assembly.
Page 105

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OPERATION AND MAINTENANCE

FAIVELEY TRANSPORT TWIN TOWER

MODEL NO. 975-120 SERIES

Catalogue No. AD/075

Phone : + 91 (4344) 276761 to 276765

Faiveley Transport India Limited Faiveley Transport India Limited

Phone : + 91 (11) 26229325 Phone : + 91 (33) 23295241

March, 2004 7 Various Manual Reformatted.

March, 2006 9 Various Manual Reformatted.

Capacity and Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Suggested location of Air Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Recommended Spares for Maintenance. . . . . . . . . . . . . . . . . . . . . . . . 23

Tools required for Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Desiccant Canister Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Desiccant Charge Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Desiccant Compactor Removal and Maintenance . . . . . . . . . . . . . . . . . . 31

Purge Valve Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Drain Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Inlet Check Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Outlet Check Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Solenoid Assembly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Timer and Circuit Board Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Pressure Switch Renewal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Exclusive Part numbers for ordering reference . . . . . . . . . . . . . . . . . . . 104

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

2. Capacity and Applications

3.0 System Description

Refer to diagrams attached.

Construction of the coalescer filter element is in two layers of pleated borosilicate

With the compressor pumping and the predetermined pressure reached

5.0 System Components

5.1 Humidity Indicator

A borosilicate element designed to collect and restrict tiny aerosol contaminants,

5.3 Filter/Dryer Body

5.4 Pneumatic Compactor

5.6 Final Filter

5.8 Air Dryer Tower Indication

Sl. No. Part No. Description Qty

“Precautions to be observed for Dryer installation in the Locomotive”

Qty / Minimum stock to be

Renewable Spare Parts for Air Dryer on condition basis

Tool Description Ordering Reference

Tool Description Ordering Reference

• Desiccant Compacting tool RPSK-0495

7.1 Operating Conditions

7.1.1 Air Pressure

Type 975-123 & 975-124

7.2 Operational Check (30 days)

Check the locomotive system maintenance schedule in case more rigorous

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

7.6 Each 3 years

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

7.7.2 Use a 9/16 Socket with 10 extension to

7.7.3 Remove the Desiccant Canister assembly

7.7.4 Refer to section 8.8 for Desiccant

Refer to section 8 for Desiccant Canister

* (Spacer) not assembled in 975-129

Use Maintenance Kit RK-AB787-W44)