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ManualsBrandsBendix Commercial Vehicle Systems ManualsEquipmentAD-RP PuraGuard Oil Coalescing Remote Purge Air Dryers

SD-08-2415A

Bendix

AD-RP

™

Remote Purge

& AD-RP

™

PuraGuard

Oil Coalescing

Remote Purge Air Dryers

“SPIN OFF”

DESICCANT

CARTRIDGE

EXHAUST PORT

MOUNTING

HOLES (3)

IMPORTANT! When servicing, note that standard

AD-RP air dryers or air dryer cartridges may be

serviced with PuraGuard oil coalescing air dryers or

cartridges. The PuraGuard oil coalescing air dryers or

cartridges, however, must only be serviced with like

replacements.

Note: Unless otherwise stated in this manual, AD-RP

air dryer refers to both the standard and PuraGuard oil

coalescing remote purge air dryers.

The remote purge designation is used because the

AD-RP air dryer uses a small air volume, separate

from the air brake system, to perform the purge or

regenerative function.

The AD-RP air dryer consists of two major component

groups—a spin on desiccant cartridge assembly, and a

die cast aluminum body assembly. The desiccant cartridge

is self-contained and serviced as a complete assembly.

DESCRIPTION

The function of the Bendix

AD-RP

™

remote purge air dryer

— and the AD-RP

™

remote purge air dryer with PuraGuard

oil coalescing technology — is to collect and remove air

system contaminants in solid, liquid and vapor form before

they enter the brake system. The dryer provides clean, dry

air to the components of the brake system which increases

the life of the system and reduces maintenance costs. Daily

manual draining of the reservoirs is eliminated.

The Bendix AD-RP PuraGuard oil coalescing air dryer

has an identical appearance to the standard AD-RP air

dryer but contains a coalescing media at the inlet of the

desiccant bed. The coalescing media provides a higher

level of oil removal over the standard AD-RP unit. The

AD-RP PuraGuard oil coalescing air dryer has all of the

same functions as the standard AD-RP air dryer and is

used in applications where lower oil concentration levels

are required.

FIGURE 1 - BENDIX

AD-RP

™

REMOTE PURGE AIR DRYER

DELIVERY PORT

DEL 2

SUPPLY

PORT

SUP 1

TURBO

CUT-OFF VALVE

HEATER &

THERMOSTAT

CONNECTOR

CONTROL

PORT

CON 4

REMOTE

PURGE

PORT

PT 22

(NOT

MARKED)

MEDALLION

(INDICATES BENDIX

PURAGUARD

OIL

COALESCING CARTRIDGE)

Summary of content (28 pages)

PAGE 1
SD-08-2415A ® Bendix® AD-RP™ Remote Purge & AD-RP™ PuraGuard® Oil Coalescing Remote Purge Air Dryers MEDALLION (INDICATES BENDIX® PURAGUARD® OIL COALESCING CARTRIDGE) “SPIN OFF” DESICCANT CARTRIDGE MOUNTING HOLES (3) REMOTE PURGE PORT PT 22 (NOT MARKED) CONTROL PORT CON 4 HEATER & THERMOSTAT CONNECTOR SUPPLY PORT SUP 1 TURBO CUT-OFF VALVE DELIVERY PORT DEL 2 EXHAUST PORT FIGURE 1 - BENDIX® AD-RP™ REMOTE PURGE AIR DRYER DESCRIPTION The function of the Bendix® AD-RP™ remote purge air dryer — and t
PAGE 2
GENERAL SAFETY GUIDELINES WARNING! PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO AVOID PERSONAL INJURY OR DEATH: When working on or around a vehicle, the following guidelines should be observed AT ALL TIMES: ▲ Park the vehicle on a level surface, apply the parking brakes and always block the wheels. Always wear personal protection equipment. ▲ Stop the engine and remove the ignition key when working under or around the vehicle.
PAGE 3
DESICCANT OIL COALESCING FILTER PURGE ORIFICE REMOTE PURGE RESERVOIR DELIVERY CHECK VALVE REMOTE PURGE PORT REAR RESERVOIR CONTROL PORT PURGE CONTROL LINE FRONT RESERVOIR SUPPLY PORT GOVERNOR ENGINE TURBO TURBO CUT-OFF DELIVERY PORT SAFETY VALVE PURGE VALVE EXHAUST PORT COMPRESSOR FIGURE 3 - BENDIX® AD-RP™ AIR DRYER SYSTEM - CHARGE CYCLE The aluminum body of the Bendix® AD-RP™ air dryer contains the following serviceable components or assemblies: the turbocharger cut-off valve; the heater a
PAGE 4
DESICCANT OIL COALESCING FILTER REMOTE PURGE RESERVOIR PURGE ORIFICE DELIVERY CHECK VALVE REMOTE PURGE PORT REAR RESERVOIR CONTROL PORT PURGE CONTROL LINE FRONT RESERVOIR SUPPLY PORT GOVERNOR ENGINE TURBO TURBO CUT-OFF EXHAUST PORT SAFETY VALVE DELIVERY PORT PURGE VALVE COMPRESSOR FIGURE 4 - BENDIX® AD-RP™ AIR DRYER SYSTEM - RELIEF VALVE OPERATION cartridge, located between the outer and inner shells of the cartridge — removes water in liquid form, as well as liquid oil and solid contaminant
PAGE 5
DESICCANT OIL COALESCING FILTER REMOTE PURGE RESERVOIR PURGE ORIFICE DELIVERY CHECK VALVE REMOTE PURGE PORT REAR RESERVOIR CONTROL PORT PURGE CONTROL LINE FRONT RESERVOIR SUPPLY PORT GOVERNOR ENGINE TURBO TURBO CUT-OFF SAFETY VALVE EXHAUST PORT DELIVERY PORT PURGE VALVE COMPRESSOR FIGURE 5 - BENDIX® AD-RP™ AIR DRYER SYSTEM - PURGE CYCLE TURBO CUT-OFF VALVE (Refer to Figure 5) The primary function of the turbo cut-off valve is to prevent loss of engine turbocharger air pressure through the B
PAGE 6
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 and maintenance intervals will vary. Experience is a valuable guide in determining the best maintenance interval for any one particular operation. Every 900 operating hours; or every 25,000 miles or three (3) months: 1.
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For Bendix® AD-RP™ PuraGuard® oil coalescing air dryers only: Preventive Maintenance is as easy as 1-2-3 Adhering to a preventive maintenance schedule is crucial to keeping a vehicle’s air system clean and to help ensure superior performance of all components that utilize system air — such as brakes, emissions equipment and automated manual transmissions. Depending on vocation, Bendix recommends a 1, 2 or 3-year air dryer cartridge replacement on vehicles equipped with a Bendix® compressor.
PAGE 8
DESICCANT CARTRIDGE CONTROL PORT CAP REMOTE PURGE PORT AD-RP™ AIR DRYER BODY O-RINGS RETAINING RING DELIVERY PORT RETAINING RING SUPPLY PORT HEATER & THERMOSTAT ASSEMBLY PURGE VALVE O-RING CONNECTOR O-RING PISTON PURGE PISTON SPRING EXHAUST COVER RETAINING RING FIGURE 6 - BENDIX® AD-RP™ REMOTE PURGE AIR DRYER EXPLODED VIEW REPAIRING THE BENDIX® AD-RP™ AIR DRYER BENDIX AD-RP AIR DRYER REMOVAL GENERAL 1. Park the vehicle on a level surface and prevent movement by means other than the brakes.
PAGE 9
DISASSEMBLY FOR PART REPLACEMENT AND KIT INSTALLATION 1. The following disassembly and assembly procedures are presented for reference and assumes that the appropriate Bendix® AD-RP™ air dryer kits are on hand. The instructions provided with these parts and kits should be followed instead of the instructions presented here. 2. The replacement parts and maintenance kits that are available do not require full disassembly and in most cases do not require the removal of the AD-RP air dryer from the vehicle. 3.
PAGE 10
ASSEMBLY - TURBO CUT-OFF VALVE 1. Lubricate all o-rings with the grease supplied in the Bendix® maintenance kits. 2. Install the large and small diameter o-rings on the piston. 3. Install the turbo cut-off piston assembly in the body. 4. Install the o-ring on the turbo cut-off cap then install the cap in the body. 5. Install the retaining ring in the body, making certain that it is fully seated in its groove. 6.
PAGE 11
RETROFITTING THE BENDIX® AD-RP™ AIR DRYER GENERAL The following retrofit instructions are presented for reference purposes only. Bendix® replacement air dryers are packaged with the most up-to-date installation instructions. The instructions packaged with the Bendix® AD-RP™ air dryer should be followed instead of those presented here. The preceding portion of this manual deals with "in-service" repair and/or replacement of the AD-RP air dryer.
PAGE 12
VEHICLE PREPARATION CONNECTING THE AIR LINES 1. Park the vehicle on a level surface and prevent movement by means other than the brakes. Important General Instructions 2. Drain all reservoirs to 0 psi (0kPa). These instructions apply to all installations of the AD-RP dryer regardless of whether the unit is replacing an existing air dryer, or is being installed on a vehicle that never had one installed. If the vehicle is currently equipped with an air dryer some additional considerations apply.
PAGE 13
PURGE CONTROL LINE 1. Install a purge control air line having a minimum inside diameter of 3/16" between the Bendix® AD-RP™ air dryer control port and an unused unloader port on the governor. The control line must be plumbed direct to the governor and not in series with automatic drain valves, lubrication systems, etc. WIDTH (THICKNESS) OF AD-RP™ AIR DRYER MOUNTING BRACKET 2. The control line should slope downward to the AD-RP dryer without forming potential water traps.
PAGE 14
TESTING THE BENDIX® AD-RP™ AIR DRYER Before placing the vehicle in service, perform the following tests: 1. Close all reservoir drain cocks. 2. Build up system pressure to governor cut-out and note that the Bendix® AD-RP™ air dryer purges with an audible escape of air. 3. Apply and release the service brakes to reduce system air pressure to governor cut-in. Note that the system once again builds to full pressure and is followed by a purge at the AD-RP air dryer exhaust. 4.
PAGE 15
GOVERNOR COMPRESSOR FIGURE 9 - AIR SYSTEM WITHOUT BENDIX® AD-RP™ REMOTE PURGE AIR DRYER BENDIX® AD-RP™ AIR DRYER REMOTE PURGE RESERVOIR GOVERNOR COMPRESSOR FIGURE 10 - AIR SYSTEM WITH BENDIX® AD-RP REMOTE PURGE AIR DRYER 15
PAGE 16
Bendix® AD-RP™ AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE 1. Air dryer is constantly A. Excessive system leakage. “cycling” or purging. IMPORTANT: Note whether Air dryer purges air pressure loss is shown frequently (every 4 on dash gauge(s). Pressure minutes or less) while loss shown on the gauges vehicle is idling. is caused by service brake system or component leakage. Pressure loss NOT SHOWN on the gauges is caused by supply system or component leakage. REMEDY A.
PAGE 17
Bendix® AD-RP™ AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE 1. Air dryer is constantly A. Excessive system leakage. “cycling” or purging. IMPORTANT: Note whether Air dryer purges air pressure loss is shown frequently (every on dash gauge(s). Pressure 4 minutes or less) loss shown on gauges is while vehicle is idling. caused by service brake (continued) system or component leakage. Pressure loss NOT SHOWN on the gauges is caused by supply system or component leakage. (continued) REMEDY A.
PAGE 18
Bendix® AD-RP™ AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE 1. Air dryer is constantly B. Incorrect governor setting or “cycling” or purging. malfunctioning governor. Air dryer purges frequently (every 4 minutes or less) while vehicle is idling. C. Rapid cycling of the governor due to air starvation at the reservoir (RES) port of the governor. 2. Water and/or oil in supply or service reservoir. REMEDY B.
PAGE 19
Bendix® AD-RP™ AIR DRYER TROUBLESHOOTING CHART SYMPTOMS 2. Water and/or oil in supply or service reservoir. (continued) CAUSE E. Excessive air usage, duty cycle is too high; the air dryer is not compatible with the vehicle air system requirement (improper air dryer/vehicle application). NOTE: Duty cycle is the ratio of time the compressor spends building air to total engine running time. Air compressors are designed to build air (run “loaded”) up to 25% of the time.
PAGE 20
Bendix® AD-RP™ AIR DRYER TROUBLESHOOTING CHART SYMPTOMS 2. Water and/or oil in supply or service reservoir. (continued) CAUSE F. Air compressor discharge and/or air dryer inlet temperature is too high. REMEDY F. Restricted discharge line - See Appendix A/ Table A/ column 1 & 2 for recommended sizes. If discharge line is restricted — or more than 1/16" carbon build up is found — replace the discharge line. Replace as necessary.
PAGE 21
Bendix® AD-RP™ AIR DRYER TROUBLESHOOTING CHART SYMPTOMS 2. Water and/or oil in supply or service reservoir. (continued) 3. Oil present at air dryer purge exhaust or cartridge during maintenance. CAUSE REMEDY F. Air compressor discharge and/or air dryer inlet temperature is too high. (continued) Poorly ﬁltered inlet air (poor air quality to compressor). Check for leaking, damaged or malfunctioning compressor air inlet components (e.g. induction line, ﬁttings, gaskets, ﬁlter bodies, etc.).
PAGE 22
Bendix® AD-RP™ AIR DRYER TROUBLESHOOTING CHART SYMPTOMS CAUSE 4. Air is escaping from D. Air ﬂow to the supply air dryer exhaust reservoir is restricted. during the charge cycle, but is able to build system air pressure. (Compressor pumping.) (continued) REMEDY D. Kinked, plugged, damaged hose tubing or ﬁttings: Check to determine if air is reaching the ﬁrst reservoir. Inspect for kinked tubing or hose. Check for undrilled ﬁttings or restricted hose or tubing ﬁttings. Repair or replace as necessary.
PAGE 23
Bendix® AD-RP™ AIR DRYER TROUBLESHOOTING CHART SYMPTOMS 7. Unable to build air system pressure. 8. Air dryer does not purge or exhaust air. Note: this symptom often precedes Symptom #9 if desiccant cartridge is not replaced. CAUSE ® ™ REMEDY A. Bendix AD-RP air dryer purge control line incorrectly connected to governor. A. Check that the purge control of the AD-RP air dryer is connected to the UNL (unloader) port on governor. B.
PAGE 24
Bendix® AD-RP™ AIR DRYER TROUBLESHOOTING CHART SYMPTOMS 9. Desiccant material is being expelled from the air dryer purge valve exhaust (may look like whitish liquid, paste, or small beads). – OR Unsatisfactory desiccant life. CAUSE REMEDY A. This symptom is almost always accompanied by one or more of Symptoms 1, 2, 3, 4 and 6. See the related causes for these symptoms. A. See the related remedies for the causes under Symptoms 1, 2, 3, 4 and 6*. B. Air dryer not securely mounted. (Excessive vibration.
PAGE 25
NOTES 25
PAGE 26
Appendix A Table A: Maintenance Schedule and Usage Guidelines Regularly scheduled maintenance is the single most important factor in maintaining the air brake charging system. Vehicle Used for: No. of Axles Column 1 Column 2 Typical Compressors Spec'd Discharge Line I.D. Length 1/2 in. 6 ft. Column 3 Recommended Air Dryer Cartridge Replacement1 Column 4 Recommended Reservoir Drain Schedule2 Column 5 Acceptable Reservoir Oil Contents3 at Regular Drain Interval Low Air Use 5 or less e.g.
PAGE 27
Appendix B For more troubleshooting information refer to Troubleshooting Charging and Air Supply Systems (BW1779). This and other literature are available, online, from the Bendix Literature Center on www.bendix.com. STANDARD SINGLE CHECK VALVE (USED W/INTEGRAL PURGE AIR DRYERS) GOVERNOR LOW PRESSURE INDICATOR DASH GAUGE CONVENTIONAL SUPPLY SYSTEM & INTEGRAL PURGE AIR DRYER REAR SAFETY VALVE SUPPLY TWO CYLINDER.
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