BENDIX BW2396 User's Manual
Contents
1. DELIVERY PORT JA SUPPLY PORT FILTER SPRING SPRING LOCATOR FIGURE 2 CUT AWAY SHOWING AIR FLOW FIGURE 3 PURAGUARD QC OIL COALESCING FILTER INSTALLATION SYSTEM WITH AIR DRYER The PuraGuard QC oil coalescing 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 QC filter top see Figure 1 Note The PuraGuard QC filter is not recommended to be used in conjunction with an alcohol evaporator or injector The PuraGuard QC oil coalescing filter will remove the liquid or aerosol alcohol introduced defeating the purpose of the evaporator injector and requiring the sump to be drained more often than normal FILTER BYPASS refer to Figure 4 If a situation occurs where the ability of the filter to allow air to pass is impaired and causes a pressure difference of approximately 20 p s i between the air entering the filter element and exiting the filter will move downward 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 Because no two vehicles operate under identical conditions maintenance intervals will vary Experience is a valuable guide in det2. Bendix PuraGuard QC Oil Coalescing Filter DESCRIPTION The PuraGuard QC oil coalescing filter provides purified compressed air on any air braked vehicle It consists of a spin on housing or cartridge mounted to an aluminum body The spin on cartridge contains a drain valve for maintenance For ease of serviceability the spin on cartridge can be removed without disconnecting the supply and delivery lines of the PuraGuard QC oil coalescing filter from its mounting on the vehicle ONE SUPPLY amp ONE DELIVERY PORT SEE ARROW SYMBOL ON THE BODY FOR AIR FLOW MOUNTING BRACKET PURAGUARD BODY CARTRIDGE EXTERIOR VIEW DRAIN VALVE DELIVERY PORT FIGURE 1 PURAGUARD QC OIL COALESCING FILTER Vehicles operate best with clean dry compressed air The PuraGuard QC oil coalescing filter removes approximately 90 of oil aerosols and particulates down to 1 micron in size but it must be used in a system with and follow an air dryer OPERATION GENERAL See Figure 2 Compressed air passes through the supply port of the PuraGuard QC oil coalescing 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 PuraGuard QC filter also collects solid particles 1 micron and larger The cleaned air travels back up from the sump through the delivery port and into the air system
3. working connections reversed 3 Oilin the system Supply and delivery air A Reverse hose connections connections reversed Sump not drained B Drain the sump every 300 operating hours 8 000 regularly miles or one 1 month Draining can be done more frequently if desired Cartridge maintenance C Use a maintenance kit to replace the cartridge interval exceeded stilt ee operating hours 100 000 miles or one 1 year whichever is less Air dryer malfunction D Check the air dryer Compressor malfunction E Check Compressor BW2396 2004 Bendix Commercial Vehicle Systems LLC All rights reserved 1 2004 Printed in U S A
4. aGuard QC filter on the vehicle so that a minimum of 12 inches of clearance is available horizontally 90 minimum arc to allow servicing This will permit a strap wrench to be used when replacing the filter 6 Be sure that there is sufficient room to attach hoses to the PuraGuard QC filter 7 Topermit draining of collected contaminants at least a 6 inch clearance below the filter is recommended Nominal clearance above is required 8 The PuraGuard QC oil coalescing filter must be installed after a properly functioning air dryer Failure to locate the filter after an air dryer can cause the filter to malfunction An air dryer eliminates certain conditions in the discharge line that could compromise the design of the filter 9 Do not mount the unit in the engine compartment MOUNTING THE PURAGUARD QC OIL COALESCING FILTER 1 After positioning the PuraGuard QC oil coalescing 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 Use vehicle manufacturer guidelines for mounting hardware use at least grade 5 hardware Torque to 160 200 in lbs CONNECTING THE AIR HOSES 1 The PuraGuard QC filter supply and delivery ports are 1 2 14 NPT Install minimum 1 2 inch inside diameter air hoses Install fittings prior to mounting the filter 2 Hoses must be installed without tight turns that mig
5. ch do not tighten by turning the drain valve 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 QC filter for leakage and integrity Repair any excessive leaks exceeding a 1 inch bubble in 5 seconds before restoring vehicle to service Mounting Bracket Kit Piece No 5013671 This kit contains the mounting hardware needed for installing the PuraGuard QC oil coalescing filter INCLUDED lt 2 IN KIT FIGURE 5 MAINTENANCE KITS Cartridge Kit Piece No 5013672 This kit contains the PuraGuard QC oil coalescing filter spin on cartridge only 2 Pa CARTRIDGE Pura ra PURAGUARD QC OIL COALESCING FILTER TROUBLESHOOTING CHART 1 More often than normal A PuraGuard QC oil A See figure 3 monthly sump draining coalescing filter installed required in incorrect position in system B Alcohol injector in B The PuraGuard QC filter is not recommended system to be used in conjunction with an alcohol evaporator or injector The PuraGuard QC 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 the air dryer D Compressor malfunction D Check the compressor 2 Bypass feature not A Supply and delivery air A Reverse hose connections
6. ds before restoring vehicle to service 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 procedures Use only the proper tools and observe all precautions pertaining to use of those tools 4 Ifthe 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 5 Following the vehicle manufacturer s recommended procedures deactivate the electrical system in a manner
7. ermining the best maintenance interval for a vehicle Every 300 operating hours 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 Do not open the valve beyond shoulder stop This could loosen the handle 2 Visually check the PuraGuard QC filter for broken or missing parts 3 Check mounting bolts for tightness Re torque to vehicle manufacturers guidelines 4 Perform the Operation amp Leakage Tests listed in this publication Every 3 600 operating hours 100 000 miles or one 1 year 1 With the air system pressure at 0 p s i drain collected contaminants for disposal 2 Visually check for physical damage to the PuraGuard QC filter such as chaffed or broken air hoses and broken or missing parts 3 Replace the cartridge see Maintenance Kits Figure 5 Do not use the drain valve to remove the cartridge 4 Check mounting bolts for tightness Re torque to 160 200 in lbs 5 Perform the Operation amp Leakage Tests listed in this publication FILTER MOVES DOWNWARDS AGAINST SPRING FORCE SHOULDER STOP SPRING FIGURE 4 BYPASS OPERATION amp 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 QC filter for leakage and integrity Repair any excessive leaks exceeding a 1 inch bubble in 5 secon
8. ht cause air flow restrictions Note Check that the hose attachment agrees with the air flow arrow symbol see Figure 1 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 filter for leakage and integrity Repair any excessive leaks exceeding a 1 inch bubble in 5 seconds before restoring vehicle to service MAINTENANCE KIT INSTALLATION KIT DESCRIPTION A kit is available for cartridge replacement VEHICLE PREPARATION 1 Park the vehicle on a level surface and prevent movement by means other than the brakes Drain all reservoirs to 0 p s i 3 Drain the contents of the sump into a suitable container for disposal and then close the drain valve DISASSEMBLY AND CLEANING 1 Using astrap wrench unscrew the cartridge 2 Remove and discard the cartridge INSPECTION 1 Inspect the PuraGuard QC oil coalescing 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 3 Inspect the housing during filter replacement Replace the PuraGuard QC oil coalescing filter if the body is becoming clogged with carbon or dirt clean the supply and delivery ports if necessary ASSEMBLY 1 Tighten the replacement cartridge by turning the cartridge 180 after the cartridge seal touches the aluminum body Tighten with a strap wren
9. t to the vehicle and remove the PuraGuard QC filter from the vehicle REPLACING OR RETROFITTING THE PURAGUARD QC OIL COALESCING FILTER General The following retrofit instructions are presented for reference purposes only since Bendix aftermarket retrofit and replacement PuraGuard QC filter systems are packaged with the most up to date installation instructions The instructions packaged with the filter should be followed in lieu of those presented here ASSEMBLY 1 The top of the system filter has an arrow symbol showing the air flow direction see figure 1 Secure the mounting bracket to the body and spin on cartridge RETROFIT LOCATING THE PURAGUARD QC FILTER ON THE VEHICLE 1 The PuraGuard QC filter must be mounted vertically 5 and must not be exposed to direct wheel splash located behind axle mud flap is acceptable 2 Locate it as close to the first Supply reservoir as possible and upstream of the supply reservoir see figure 3 3 To minimize vibration mount the PuraGuard QC filter on a frame rail If the vehicle requires the 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 4 Do not locate the PuraGuard QC 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 Pur
10. that safely removes all electrical power from the vehicle 6 Never exceed manufacturer s recommended pressures 7 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 8 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 9 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 10 Prior to returning the vehicle to service make certain all components and systems are restored to their proper operating condition PURAGUARD QC OIL COALESCING FILTER REMOVAL This PuraGuard QC filter removal process is presented in the event it becomes necessary to replace the entire coalescing filter Normal service and parts replacement does not require removal of the PuraGuard QC 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 QC filter 4 Remove the two bolts that secure the bracke
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