SD-08-187 ® Bendix® PuraGuard ® System Filter DESCRIPTION The PuraGuard ® system filter is used to assist the production of purified compressed air on high air use vehicles. The PuraGuard ® system filter consists of a filter element mounted in a die cast aluminum housing. The sump housing contains a drain valve for maintenance. For ease of serviceability, all maintenance kits do not require removal of the PuraGuard ® system filter from its mounting on the vehicle. ONE SUPPLY & ONE DELIVERY PORT (SEE ARROW SYMBOL ON PURAGUARD® SYSTEM FILTER TOP COVER FOR AIR FLOW) MOUNTING BRACKET (2) PURAGUARD® SYSTEM FILTER HEAD High air use vehicles (e.g. transit vehicles) may require the air compressor to exceed its normal duty cycle. The resulting high compressor discharge temperatures can allow oil aerosols to pass through the air dryer, condensing downstream in air system components. The PuraGuard ® system filter follows the air dryer in the system and removes approximately 99% of oil aerosols. On vehicles not using an air dryer, the PuraGuard ® system filter follows the supply (“wet tank”) reservoir (see Figures 3 & 4). OPERATION GENERAL (See Figure 2) Compressed air passes through the supply port of the PuraGuard ® system filter and travels downward through the center of the filter element. As the air passes through the filter material, oil in liquid and aerosol form are removed and collected in the sump. The air travels back up from the sump, through the PuraGuard ® system filter delivery port and into the air system. DELIVERY PORT SUPPLY PORT SUMP HOUSING DRAIN VALVE O-RING FILTER ELEMENT HAS O-RING INCLUDED EXTERIOR VIEW TOP VIEW SUPPLY PORT DELIVERY PORT SPRING LOCATOR FIGURE 1 - PURAGUARD ® SYSTEM FILTER SPRING FILTER ELEMENT DRAIN PORT FIGURE 2 - CUT-AWAY SHOWING AIR FLOW 1 PuraGuard ® System Filter Installation System with Air Dryer Governor Primary Reservoir PuraGuard ® System Filter Air Compressor Supply Reservoir Secondary Reservoir Air Dryer FIGURE 3 PuraGuard® System Filter Installation System without Air Dryer Governor Primary Reservoir PuraGuard ® System Filter Air Compressor Supply Reservoir Secondary Reservoir FIGURE 4 The PuraGuard ® system filter has two female pipe thread air connections: one supply, one delivery — identified by their relationship to the arrow symbol showing air flow on the PuraGuard ® system filter top cover (see Figure 1). Note: The PuraGuard ® system filter is not recommended to be used in conjunction with an alcohol evaporator or injector. The PuraGuard ® system filter will remove the liquid or aerosol alcohol introduced, defeat the purpose of the evaporator/injector and require the sump to be drained more often than normal. 2. Visually check for physical damage to the PuraGuard ® system filter such as chaffed or broken air hoses and broken or missing parts. 3. Check mounting bolts for tightness. Re-torque to vehicle manufacturers guidelines. 4. Perform the Operation & Leakage Tests listed in this publication. FILTER BYPASS (refer to Figure 5) If a situation occurs where the ability of the filter to allow air to pass is impaired and causes a pressure difference of approx. 20 p.s.i. between the air entering the filter element and exiting, the filter will move downwards against the spring. The air entering will then be able to bypass the filter element. PREVENTIVE MAINTENANCE Important: Review the warranty policy before performing any intrusive maintenance procedures. An extended warranty may be voided if intrusive maintenance is performed during this period. FILTER MOVES DOWNWARDS AGAINST SPRING FORCE Because no two vehicles operate under identical conditions, maintenance intervals will vary. Experience is a valuable guide in determining the best maintenance interval for a vehicle. Every 300 operating hours, or 8,000 miles or one (1) month: 1. With the air system pressure at 0 p.s.i., use the drain valve to collect contaminants for disposal. 2 FIGURE 5 - PURAGUARD ® SYSTEM FILTER BYPASS FIGURE 6 - MAINTENANCE KITS AVAILABLE 5006788 MAINTENANCE KIT 5006789 REBUILD KIT 800691 RETROFIT KIT This kit contains the PuraGuard ® system filter assembly, brackets, and drain valve. Some other fittings, etc. are typically required for installation. INCLUDED IN KIT INCLUDED IN KIT ALL PARTS SHOWN ARE INCLUDED IN KIT Every 3,600 operating hours, or 100,000 miles or one (1) year: PuraGuard ® system filter requires replacement or maintenance, refer to Figure 7 to find the appropriate kit. 1. With the air system pressure at 0 p.s.i., drain collected contaminants for disposal. When rebuilding or replacing components of the PuraGuard ® system filter use only genuine Bendix parts. For ease in servicing, the PuraGuard ® system filter has been designed so that the maintenance kits can be installed without removing the PuraGuard ® system filter from the vehicle. 2. Visually check for physical damage to the PuraGuard ® system filter such as chaffed or broken air hoses and broken or missing parts. 3. Replace the filter element (see Maintenance Kits available, Figure 6). 4. Check mounting bolts for tightness. Re-torque to vehicle manufacturers guidelines. 5. Perform the Operation & Leakage Tests listed in this publication. OPERATION & LEAKAGE TESTS Build the air system to governor cutout. Shut off the engine. Using a soap solution, check all lines and fittings leading to and from the PuraGuard ® system filter for leakage and integrity. Repair any excessive leaks — exceeding a 1” bubble in 5 seconds — before restoring vehicle to service. REBUILDING THE PURAGUARD® SYSTEM FILTER GENERAL If, after completing the routine operation and leakage tests, it has been determined that one or more components of the WARNING! PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO AVOID PERSONAL INJURY OR DEATH: When working on or around a vehicle, the following general precautions should be observed at all times. 1. Park the vehicle on a level surface, apply the parking brakes, and always block the wheels. Always wear safety glasses. 2. Stop the engine and remove ignition key when working under or around the vehicle. When working in the engine compartment, the engine should be shut off and the ignition key should be removed. Where circumstances require that the engine be in operation, EXTREME CAUTION should be used to prevent personal injury resulting from contact with moving, rotating, leaking, heated or electrically charged components. 3. Do not attempt to install, remove, disassemble or assemble a component until you have read and thoroughly understand the recommended 3 10. Prior to returning the vehicle to service, make certain all components and systems are restored to their proper operating condition. COVER (SHOWS AIR FLOW DIRECTION) DELIVERY PORT SUPPLY PORT O-RING FILTER INTEGRATED O-RING PURAGUARD® SYSTEM FILTER REMOVAL This PuraGuard ® system filter removal process is presented in the event it becomes necessary to replace the entire system filter. Normal service and parts replacement does not require removal of the PuraGuard® system filter from the vehicle. 1. Park the vehicle on a level surface and prevent movement by means other than the brakes. 2. Drain all reservoirs to 0 p.s.i. 3. Identify and disconnect the two air hoses from the PuraGuard ® system filter. FILTER ELEMENT SPRING LOCATOR SPRING DRAIN PORT FIGURE 7 - CUT-AWAY VIEW 4. 5. 6. 7. 8. 9. procedures. Use only the proper tools and observe all precautions pertaining to use of those tools. If the work is being performed on the vehicle’s air brake system, or any auxiliary pressurized air systems, make certain to drain the air pressure from all reservoirs before beginning ANY work on the vehicle. If the vehicle is equipped with an AD-IS™ air dryer system or a dryer reservoir module, be sure to drain the purge reservoir. Following the vehicle manufacturer’s recommended procedures, deactivate the electrical system in a manner that safely removes all electrical power from the vehicle. Never exceed manufacturer’s recommended pressures. Never connect or disconnect a hose or line containing pressure; it may whip. Never remove a component or plug unless you are certain all system pressure has been depleted. Use only genuine Bendix ® replacement parts, components and kits. Replacement hardware, tubing, hose, fittings, etc. must be of equivalent size, type and strength as original equipment and be designed specifically for such applications and systems. Components with stripped threads or damaged parts should be replaced rather than repaired. Do not attempt repairs requiring machining or welding unless specifically stated and approved by the vehicle and component manufacturer. 4. Remove the two bolts that secure the brackets to the vehicle, and remove the PuraGuard ® system filter from the vehicle. REPLACING OR RETROFITTING THE PURAGUARD® SYSTEM FILTER (using kit shown in figure 8) General The following retrofit instructions are presented for reference purposes only since Bendix aftermarket retrofit and replacement PuraGuard ® system filters are packaged with the most up-to-date installation instructions. The instructions packaged with the PuraGuard ® system filter should be followed in lieu of those presented here. See Figure 8. ALL PARTS SHOWN ARE INCLUDED IN RETROFIT KIT FIGURE 8 - RETROFIT KIT 4 ASSEMBLY 1. Coat the drain valve threads with a liquid pipe thread sealant. Install the drain valve using two wrenches one at the base of the PuraGuard ® system filter and one on the drain valve, using a maximum final torque of 130-170 in. lbs. 2. The threaded top of the sump housing is pre-installed into the head of the PuraGuard ® system filter. Check that this connection is fully hand-tight before proceeding with the installation. 3. The head cover of the PuraGuard ® system filter has an arrow symbol showing the direction that the air must be supplied into the head (see Figure 1). Align the PuraGuard® system filter correctly (the label may not be facing outwards) and then insert the four bolts through the mounting bracket holes into the PuraGuard® system filter head. Tighten to approx. 15 ft. lbs. RETROFIT: LOCATING THE PURAGUARD® SYSTEM FILTER ON THE VEHICLE ELBOW 1/2 NPT HEX NIPPLE FIGURE 9 - ELBOW FITTING IF NEEDED 7. To permit draining of collected contaminants, at least a 6 inch clearance below the PuraGuard ® system filter is recommended. Nominal clearance above is required. MOUNTING THE PURAGUARD® SYSTEM FILTER 1. The PuraGuard ® system filter must be mounted vertically (±5° ) and must not be exposed to direct wheel splash (located behind axle mud flap is acceptable). 1. After positioning the PuraGuard ® system filter according to the installation requirements, mark the position of the mounting holes on the frame rail. Note: Check the vehicle manual before drilling a frame member. 2. Locate the PuraGuard ® system filter as close to the first (Supply) reservoir as possible. 2. Use vehicle manufacturer guidelines for mounting hardware (use at least grade 5 hardware). (a) For vehicles with air dryers, mount the PuraGuard ® system filter upstream of the supply reservoir (see Figure 3). (b) For vehicles without air dryers, install the PuraGuard ® system filter downstream of the supply reservoir (wet tank) (see Figure 4). Both the primary and secondary reservoirs will receive their air supply from the discharge of the PuraGuard ® system filter and depending original vehicle hose arrangement, extra fittings may be required. 3. To minimize vibration, mount the PuraGuard ® system filter on a frame rail. If the vehicle requires the PuraGuard ® system filter to be directly mounted to the reservoir, be sure to only use a high strength nipple fitting. (See further notes under Connecting the Air Hoses.) ITEMS INCLUDED IN MAINTENANCE KIT ITEMS INCLUDED IN REBUILD KIT 4. Do not locate the PuraGuard ® system filter near heat producing components such as the vehicle exhaust and provide adequate clearance from moving components e.g. drive shaft, suspension, pitman arm, etc. 5. Locate the PuraGuard ® system filter on the vehicle so that a minimum of 12 inches clearance horizontally (90° minimum arc) to allow servicing. This will permit, for example, a strap wrench to be used when replacing the filter. 6. Be sure that there is sufficient room to attach hoses to the PuraGuard ® system filter. FIGURE 10 - MAINTENANCE KITS 5 CONNECTING THE AIR HOSES Follow either Figure 4 or 5 for air hose arrangement. 1. The PuraGuard ® system filter supply and delivery ports are 1/2-14 NPT. Install minimum 1/2 inch inside diameter air hoses. When installing an elbow fitting use the fitting arrangement shown in Figure 9, using a high strength nipple and then an elbow fitting. 2. Hoses must be installed without tight turns that might cause air flow restrictions. Note: Check that the hose attachment agrees with the air flow arrow symbol (see Figure 1). The label may not be facing forward when installation is complete. PURAGUARD ® SYSTEM FILTER HEAD LARGE O-RING OPERATIONAL TEST Build the air system to governor cutout. Shut off the engine. Using a soap solution, check all hoses and fittings leading to and from the PuraGuard ® system filter for leakage and integrity. Repair any excessive leaks - exceeding a 1” bubble in 5 seconds - before restoring vehicle to service. MAINTENANCE KIT INSTALLATION FILTER ELEMENT SPRING KIT DESCRIPTION The kits available allow either a filter element replacement or major overhaul of the Bendix® PuraGuard ® system filter. SPRING LOCATOR VEHICLE PREPARATION 1. Park the vehicle on a level surface and prevent movement by means other than the brakes. 2. Drain all reservoirs to 0 p.s.i. 3. Drain the contents of the sump into a suitable container for disposal and then re-close the drain valve. SUMP HOUSING 4. Using detergent and water, clean the exterior of the PuraGuard ® system filter of road grime etc. DISASSEMBLY AND CLEANING (see Figure 11) 1. Unscrew the sump housing of the PuraGuard ® system filter. If necessary, use a strap wrench to assist this process. 2. Remove and discard the filter and o-ring. If only installing the maintenance kit, go to Inspection section below. FIGURE 11 - MAINTENANCE KIT COMPONENTS 3. Using long-nose pliers, carefully remove and discard the spring and spring locator inside the sump housing. If only installing the maintenance kit, go to item 4 below. 4. Using detergent and water or other suitable solvent, clean inside the sump housing. 3. Using long-nose pliers, install the spring locator and spring assembly into the sump (see Figure 11). INSPECTION 4. Insert the replacement filter (guide lands uppermost) into the sump with its base resting on the spring. 1. Inspect the PuraGuard® system filter for broken or missing parts. Replace as necessary. 2. Inspect the drain valve for any build-up that could impair its function. Clean as necessary. ASSEMBLY (see Figure 11) 1. Install the replacement o-ring into the channel in the head of the PuraGuard ® system filter. 6 2. Install the spring onto the spring locator. 5. Coat the threads of the sump housing using barium or lithium grease. Sufficient torque to install the sump will be produced by turning the housing by hand until fully hand-tight. Take care not to damage the large o-ring when installing the sump housing. OPERATIONAL TEST Build the air system to governor cutout. Shut off the engine. Using a soap solution, check all hoses and fittings leading to and from the PuraGuard® system filter for leakage and integrity. Repair any excessive leaks - exceeding a 1” bubble in 5 seconds - before restoring vehicle to service. PuraGuard® System Filter Troubleshooting Chart REMEDY SYMPTOMS CAUSE 1. More often than normal (monthly) sump draining required. A. PuraGuard ® system filter installed in incorrect position in system. A. See Figures 2 and 3 for correct installation. B. Alcohol injector in system. B. The PuraGuard® system filter is not recommended to be used in conjunction with an alcohol evaporator or injector. [The PuraGuard ® system filter will remove the liquid or aerosol alcohol introduced, defeat the purpose of the evaporator/injector and require the sump to be drained more often than usual.] C. Air dryer malfunction. C. Check air dryer. D. Compressor malfunction. D. Check compressor. 2. Bypass feature not working. A. Supply and delivery air connections reversed. A. Reverse hose connections. 3. Oil in system. A. Supply and delivery air connections reversed. A. Reverse hose connections. B. Sump not drained regularly. B. Drain sump every 300 operating hours, or 8,000 miles or one (1) month. C. Filter element maintenance interval exceeded. C. Use a maintenance kit to replace PuraGuard ® system filter element every 3600 operating hours, or 100,000 miles or one (1) year. D. Air dryer malfunction. D. Check air dryer. E. Compressor malfunction. E. Check compressor. 7 8 BW2084 © 2004 Bendix Commercial Vehicle Systems LLC All rights reserved. 7/2004 Printed in U.S.A.