Hello Caveman,
I'd be happy to help with this. Here's a beginner course on how that unit works, along with some tips & comments:
1. Typically, the timer is a sealed unit in a gray plastic box. This timer actuates a solenoid on the side of the ACD unit. This is an old school geared type unit. I suggest replacing with a solid state unit which can prob be gotten from Grainger.
2. Pilot air is pulled from 2nd or 3rd stage of the compressor and feeds the solenoid.
3. Inside the solenoid is a plunger. This often gets 'clogged' with muck entrained in the pilot air...and prevents the plunger from moving. It will need to be cleaned and polished back up so it slides freely. Be sure to clean the internal bore of the plunger housing too. Also, oftentimes the rubber tip on the end of the plunger rots. I have no good solution to this other than to use "island technology" to repair it.
4. When the solenoid opens, it allows air into the main cavity of the ACD in which there is a large piston. The air pushes the piston upwards which, in turn, lifts 4 small pins. These pins lift 4 small st-steel balls and open the seat so that condensate can drain thru. Several things can go awry in here:
A) Over time the piston and/or the o-ring/sealing ring (around the mid section) wear out....causing the piston to cock and stick.
B) the seats under the balls get soiled or worn. These are a polymer item. Sometimes cleaning will solve the problem but most often they must be replaced. Note that there's an o-ring under each seat.
C) Rarely but on occasion the pins corrode or bend. Try polishing them out.
5. Here is the BIGGEST problem with those ACD units: Each incoming port has a sintered filter behind the connection (captured inside the rectangular aluminum main section of the ACD). These frequently clog and must be replaced as i dont know of anyone ever having success at cleaning them. Note...these are threaded and must be unscrewed using a flat-head driver. I recommend soaking in a solvent first. Be careful that they dont crumble!
6. Lastly, i am not sure Bauer offers parts for these units any longer. We have some items in stock but its pot luck. We also have some usable recycled parts...but again, it's pot luck.
I'd caution that you disassemble slowly, noting the order of everything. Many internals are spring loaded. I may have a blow up diagram somewhere in my archives. Feel free to contact me via phone if you need more in-depth help. 800-338-5493
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