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BENDIX BW2827 User's Manual

1. Is this a transit vehicle bulk unloader or has more than 5 axles YES this is a high air use vehicle Find the point on the label where the number of oil units meets the number of days were last drained Is the point above the HIGH Air Use line on the Is the point above the LOW Air Use line on the cup Test for air leakage Vehicle OK Return vehicle to service YES the vehicle have Repair leaks and excessive air leakage return vehicle to END TEST service NO NO did not know when last drained Re test with the BASIC Test after 30 days Was the number of days since last draining known END TEST YES number of days was known 30 90 days Replace the Compressor If under warranty follow standard procedures If after a compressor was already replaced the vehicle fails the BASIC test again do not replace the compressor use the Advanced Troubleshooting Guide to investigate the cause s END TEST A 16 NO this is a low air use vehicle al Is this vehicle being re tested after water etc was found last time YES NO Find the point on the label where the number of oil units meets the number of days Me once the vehicle s air tanks ke since the vehicle s air tanks were last drained Go to the Advanced Troubleshooting Guide to find reason s for presence of
2. SD 01 1327 BENDIX BA 921 SMC SINGLE CYLINDER COMPRESSOR FOR NAVISTAR MAXXFORCE 11 AND 13 BIG BORE ENGINES DESCRIPTION The function of the air compressor is to provide and maintain air under pressure to operate devices in air brake systems The Bendix BA 9219 SMC side mount compressor is a single cylinder reciprocating compressor with a rated displacement of 15 8 cubic feet per minute at 1250 RPM The compressor consists of a water cooled cylinder head assembly and an integral air cooled crankcase assembly The cylinder head assembly is made up of the cylinder head cooling plate and valve plate assembly and uses two sealing gaskets Both the cylinder head and cooling plate are aluminum The cylinder head contains air and water ports as well as an unloader assembly A cooling plate is located between the cylinder head and valve plate assemblies and assists in cooling The valve plate assembly consists of brazed steel plates which have valve openings and passages for air and engine coolant to flow into and out of the cylinder head The compressor s discharge valves are part of the valve plate assembly The inlet reed valve gasket is installed between the valve plate assembly and the top of the crankcase The crankcase has an open side with a machined face and locating pins This open face is bolted directly to the side of the engine block see Figure 3 The compressor gear engages the engine drive gear In addition the
3. A 21 BW2827 2010 Bendix Commercial Vehicle Systems LLC All Rights Reserved 08 2010 Printed in U S A CB Printed on recycled paper
4. gt Air dryers remove water and oil from the air brake charging system Check that regular maintenance is being performed Return the vehicle to service An optional kit Bendix piece number 5011327 for the Bendix AD IS or AD IP air dryers or 5003838 for the Bendix AD 9 air dryer is available to redirect the air dryer exhaust Symptom A 6 What it may indicate 4 0 Oil in Supply or Service Reservoir air dryer installed If a maintained Bendix PuraGuard system filter or Bendix PuraGuard QC oil coalescing filter is installed call 1 800 AIR BRAKE 1 800 247 2725 and speak to a Tech Team member Maintenance a If air brake charging system mainte nance has not been performed Thatis reservoir s have not been drained per the schedule in Table A on page A 3 Column 4 and or the air dryer maintenance has not been performed as in Column 3 b If the vehicle maintenance has been performed as recommended in Table A on page A 3 some oil in the reservoirs is normal li See Table A on page A 3 for maintenance schedule information Drain all air tanks reservoirs into the Bendix BASIC test cup Bendix kit P N 5013711 Duty cycle too high c Air brake system leakage d Compressor may be undersized for the application The duty cycle is the ratio of time the compressor spends building air to total engine running time Air compressors are designed to build air to
5. NON COMPRESSION OF AIR UNLOADED When air pressure in the supply reservoir reaches the cut out setting of the governor the governor delivers system air to the compressor unloader port Air entering the unloader port acts on the unloader piston causing the piston to move away from its seat on the valve plate assembly When the unloader piston is unseated an air passageway is opened between the cylinder bore and a secondary compartment or closed room in the interior of the cylinder head As the piston moves from bottom dead center BDC to top dead center TDC air in the cylinder bore flows past the unseated unloader piston into the closed room The size of the closed room is sufficient to accept the compressed air provided by the compressor piston without creating excessive air pressure in the closed room On the piston down stroke TDC to BDC air flows in the reverse direction from the closed room past the unseated unloader piston and inlet reed valve and into the cylinder bore as shown in Figure 6 Note For optimum performance it is recommended that the air dryer is equipped with a turbo cut off feature LUBRICATION The vehicle s engine provides a continuous supply of oil to the compressor Oil is routed from the engine to the compressor s oil inlet Note There is no external oil supply line the oil delivery is located at the engine to compressor mounting face This pressurized oil flows to the precision fron
6. 30 60 days high air a cePtante Ine tor number Return to services use or of days3 30 90 davs low air if oil level is above m acceptance line for number Go to Step D gt of days gt if oil level is at or below System OK e cle 30 day acceptance line gt Return to services if the number of daysis l Stop inspection unknown or outside the if oil level is above 30 day Test again limits above acceptance line gt r o 3 Action to take The Technician uses the chart label on the BASIC BASIC Test Example An oil level of 4 units in a sixty day period is within the acceptance area at or below the line for both low and high air use vehicles Return the vehicle to service The Technician looks for the point where the number of T DaysSince cj tanny days since the air tanks were drained meets the oil level a If itis at or below the low or high use acceptance line Sixty days since last air Decision point the vehicle has passed the test If the point is above tank draining the line then go to the leakage test Air leakage is the number one cause of compressors having te pump excessive amounts of STEP D Air Brake System Leakage Test ai te etun ioe kotana pass Park the vehicle on level ground and chock wheels Build system pressure to governor cut out oil vapor along into the system and allow the pressure to stabilize for one minute Here the Technician conducts a 1 Ob
7. Check all compressor coolant lines for kinks and restrictions to flow Minimum coolant line size is 3 8 I D Check coolant lines for internal clogging from rust scale If coolant lines appear suspicious check the coolant flow and compare to the tabulated technical data present in the back of this manual Carefully inspect the air induction system for restrictions LUBRICATION The compressor utilizes an internal oil feed design Check the exterior of the compressor i e around the mounting face for the presence of oil seepage and refer to the Troubleshooting section for appropriate tests and corrective action Refer to the tabulated technical data in the back of this manual for oil pressure minimum values OIL PASSING All reciprocating compressors pass a minimal amount of oil Air dyers will remove the majority of oil before it can enter the air brake system For particularly oil sensitive systems the Bendix PuraGuard system can be used in conjunction with a Bendix air dryer If compressor oil passing is suspected refer to the Troubleshooting section starting on page A 1 for the symptoms and corrective actions to be taken In addition Bendix has developed the Bendix Air System Inspection Cup or Bendix BASIC kit to help substantiate suspected excessive oil passing The steps to be followed when using the BASIC kit are presented in APPENDIX B on page A 16 COMPRESSOR DRIVE Check for noisy compressor operation
8. Footnote 2 To get an accurate reading for the amount of oil collected during a 30 day period ask the customer not to drain the air tanks before returning Note that 30 90 days is the recommended air tank drain schedule for vehicles equipped with a Bendix air dryer that are properly maintained If in cold weather conditions the 30 day air tank drain schedule is longer than the customer s usual draining interval the customer must determine based on its experience with the vehicle whether to participate now or wait for warmer weather See the cold weather tips in Bulletins TCH 008 021 and TCH 008 022 included in Appendix B of the advanced troubleshooting guide oil unit of water or a cloudy emulsion mixture is found again stop the BASIC test and consult the air dryer s Service Data sheet troubleshooting section A 17 Appendix B continued Information about the BASIC Test Kit Bendix P N 5013711 Filing in the Checklist for the Bendix Air System Inspection Cup BASIC Test Note Follow all standard safety precautions For vehicles using a desiccant air dryer STEP C How to Use the BASIC Test 1 Record days since air 2 Record amount tanks were last drained of oil found a test cup to help decide the action to take based on the amount of oil found Use the lower acceptance line for low air use vehicles and upper line for high If number of days is if sere at ins System OK air use vehicles from Step A
9. Multi cylinder compressors only Other Miscellaneous Areas to Consider This guide attempts to cover most com Where a compressor does not have pressor system problems Here are some a safety valve installed if a partial or rare sources of problems not covered in complete discharge line blockage has this guide occurred damage can occur to the con Turbocharger leakage Lubricating necting rod bearings Damage of this kind oil from leaking turbocharger seals can may not be detected and could lead to enter the air compressor intake and give compressor problems at a later date misleading symptoms A 13 Tests Test 1 Excessive Oil Leakage at the Head Gasket Exterior leaks at the head gasket are not a sign that oil is being passed into the air charging system Oil weepage at the head gasket does not prevent the compressor from building air Observe the amount of weepage from the head gasket If the oil is only around the cylinder head area it is acceptable return the vehicle to service but if the oil weepage extends down to the nameplate area of the compressor the gasket can be replaced Test 2 Air Brake System and Accessory Leakage Inspect for air leaks when working on a vehicle and repair them promptly Park the vehicle on level ground and chock wheels Build system pressure to governor cut out and allow the pressure to stabilize for one minute Step 1 Observe the dash gauges for two additional minutes
10. 10 12 Using the lubricant provided lubricate the unloader piston bores Note There are two bores that must be lubricated The service kits contains a pre lubed and pre assembled unloader piston assembly 7 which includes the unloader piston two o rings and guide bushings Remove the unloader piston assembly 7 from the package remove the plastic cap that retains the upper bushing on the top of the piston Using the lubricant 8 provided apply additional lubricant to the two o rings on the outside of the unloader piston and the surrounding areas Note If an o ring appears to be twisted manipulate it to remove any twists Insert the unloader piston assembly 7 into the pre lubed unloader cavity of the cylinder head Take care to avoid catching or snagging the edge of the two guide bushings as the unit is installed in the unloader cavity bores If there is significant resistance when installing the unloader piston assembly into the unloader cavity bores remove it adjust the position of the bushings and re install Make certain the unloader piston assembly is pushed completely into the unloader cavity this will help prevent possible snagging of the top guide bushing Using the lubricant 8 provided thoroughly lubricate the exterior of the balance piston 5 including the o ring groove Thoroughly lubricate the balance piston o ring 6 This o ring is brown in color Install the balance piston o ring onto the balanc
11. A 16 for a flowchart and expanded explanation of the checklist used when BASIC Test conducting the BASIC test Symptom 2 0 Oil on the Outside of the Compressor 2 1 Oil leaking at compressor engine connections 2 2 Oil leaking from compressor 3 0 Oil at air dryer purge exhaust or surrounding area What it may indicate Engine and or other accessories leaking onto compressor a Leak at the front or rear fuel pump etc mounting flange b Leak at air inlet fitting c Leak at air discharge fitting d Loose broken oil line fittings a Excessive leak at head gasket b Leak at bottom cover plate c Leak at internal rear flange gasket d Leak through crankcase e If unable to tell source of leak Head gaskets and rear flange gasket locations Air brake charging system functioning normally Y Normal What you should do Find the source and repair Return the vehicle to service gt Repair or replace as necessary f the mounting bolt torques are low replace the gasket gt Replace the fitting gasket Inspect inlet hose and replace as necessary gt Replace gasket or fitting as necessary to ensure good seal gt Inspect and repair as necessary gt Qo to Test 1 on page A 14 gt Reseal bottom cover plate using RIV silicone sealant Replace compressor gt Replace compressor gt Clean compressor and check periodically Check
12. basic step in reducing the possibility of freeze up All reservoirs in a brake system can accumulate water and other contamination and must be drained The best practice is to drain all reservoirs daily if the air brake system does not include an air dryer When draining reservoirs turn the ENGINE OFF and drain ALL AIR from the reservoir better still open the drain cocks on all reservoirs and leave them open over night to assure all contamination is drained reference Service Data Sheet SD 04 400 for Bendix Reservoirs If automatic drain valves are installed check their operation before the weather turns cold reference Service Data Sheet SD 03 2501 for Bendix DV 2 Automatic Drain Valves It should be noted that while the need for daily reservoir draining is eliminated through the use of an automatic drain valve periodic manual draining is still required Reservoir Draining System with an Air Dryer Daily reservoir draining should not be performed on systems with an air dryer This practice will cause the dryer to do excessive work i e build pressure from 0 130 psi instead of the normal 110 130 psi Alcohol Evaporator or Injector Systems Bendix Commercial Vehicle Systems LLC discourages the use of alcohol in the air brake system as a means of preventing system freeze up in cold temperatures Studies indicate that using alcohol and alcohol based products sold for this purpose removes the lubrication from the components of the air brakin
13. compressor and note their positions on the compressor to aid in reassembly 6 Remove the six mounting bolts that retain the compressor to the side of the engine block Note the position of the six mounting bolts Two of the six bolts are shorter and must be installed in their original locations Remove the compressor from the vehicle 7 Inspect drive gear and associated drive parts for visible wear or damage If the compressor drive gear is worn or damaged the compressor must be replaced Refer to the Engine Manufacturers service manual to address the associated engine drive parts 8 If the compressor is being replaced stop here and proceed to Installing the Compressor at the end of the assembly procedure Note Replacement compressors come with the drive gear pre assembled on the compressor PREPARATION FOR DISASSEMBLY Refer to Figure 9 during the entire disassembly and assembly procedure Place a clean rag over the openings that expose the gear and crankshaft connecting rod assembly No contamination is permitted in these areas Remove the balance of the road dirt and grease from the exterior of the compressor with a cleaning solvent If the rear end cover is being removed from the compressor under repair mark it along with the two cap screws in relation to the crankcase Itis also recommended to mark the relationship of the cylinder head cooling plate valve plate assembly and crankcase A convenient method to i
14. crankcase houses the piston assembly connecting rod crankshaft and related bearings The Bendix BA 921 SMC compressor is equipped with a safety valve to protect the compressor head in the event of for example a discharge line blockage downstream of the compressor Excessive air pressure will cause the safety valve to unseat release air pressure and give an audible alert to the operator The safety valve is installed in the cylinder head safety valve port directly connected to the cylinder head discharge port Cylinder Head Valve Plate Assembly NE Crankcase Bendix Part Number Customer Piece Number Compressor Serial Number FIGURE 2 NAMEPLATE A nameplate is attached to a flat cast face on the side of the crankcase It is stamped with information identifying the compressor designation customer piece number compressor assembly part number and serial number Refer to Figure 2 Safety Discharge Coolant Valve Port E Jm Tw ar Unloader J Piston i Compressor to engine block mounting face Piston Discharge Reed Valves 2 Connecting Rod Crankshaft Oil drain locations y Mounting Face FIGURE 3 BENDIX BA 921 SMC COMPRESSOR CUT AWAY VIEW OPERATION The compressor is driven by the vehicle s engine and functions continuously while the engine is in operation Actual compression of air is controlled by the compressor unloading mechanism operating in conjunction with a
15. discharge line lengths or insulation may be required in cold climates gt Inspect air lines and verify check valves are operating properly Ensure discharge line is installed into the inlet of the air dryer and delivery is routed to the service reservoir Verify relief pressure is 250 psi Replace if defective gt Go to Test 6 on page A 15 Qo to Test 4 on page A 15 A 11 Symptom 12 0 Air dryer safety valve releases air Air dryer safety valve SW 1 NU jJ Jui P A m 3 f NEU a k F P i p 3 2 4 EY z 3 j am Technician removes governor 13 0 Reservoir safety valve releases air 14 0 Air dryer doesn t purge Never hear exhaust from air dryer 15 0 Compressor constantly cycles compressor remains unloaded for a very short time A 12 What it may indicate a Restriction between air dryer and reservoir b Air dryer safety valve malfunction c Air dryer maintenance not performed d Air dryer malfunction e Improper governor control line installation to the reservoir f Governor malfunction a Reservoir safety valve malfunction b Governor malfunction c Compressor unloader mechanism malfunction a Air dryer malfunction b Governor malfunction c Air brake system leakage d lmproper governor control line installation to the reservoir a Air brake charging system maintenance not perf
16. embossed metal gaskets 2 over the alignment bushings protruding from the cooling plate Position and install the second embossed metal gasket 2 over the alignment bushings on the opposite side of the cooling plate When properly installed the outline of the two embossed gaskets match the outline of the cooling plate 4 Install the cooling plate onto the valve plate assembly by lining up the alignment bushings on the cooling plate over the oversized countersunk holes of the valve plate assembly Again when properly installed the outline of the cooling plate matches the outline of the valve plate 5 Position and install the cylinder head over the alignment bushings protruding from the cooling plate When properly installed the outline of the cylinder head assembly will match the outline of the cooling plate and valve plate assembly Note The alignment bushings will only fit into two of the cylinder head bolt holes 6 Install the six hex head cylinder head bolts and washers and snug them finger tight then torque the bolts in the sequence specified in Figure 11 Note A light film of oil should be applied to the thread of these bolts prior to installation Oil should not be applied to any other bolts 11 9 Install the safety valve 9 in the discharge safety valve port see Figure 9 of the cylinder head then tighten to a torque between 230 and 257 inch pounds 26 29 N m PART TWO UNLOADER INSTALLATION 1
17. for cylinder head gasket air leakage 1 With the engine running lower air system pressure to 60 psi and apply a soap solution around the cylinder head Check the gasket between the cylinder head and valve plate assembly as well as the inlet reed valve gasket between the valve plate assembly and crankcase for air leakage 2 Noleakage is permitted If leakage is detected replace the compressor or repair the cylinder head using a genuine Bendix maintenance kit available from an authorized Bendix parts outlet INLET DISCHARGE amp UNLOADER In order to test the inlet and discharge valves and the unloader piston it is necessary to have shop air pressure and an assortment of fittings A soap solution is also required 1 With the engine shut off drain ALL air pressure from the vehicle 2 Disconnect the inlet and discharge lines and remove the governor or its line or adapter fitting 3 Apply 120 130 psi shop air pressure to the unloader port and soap the inlet port Leakage at the inlet port should not exceed 50 sccm 4 Apply 120 130 psi shop air pressure to the discharge port and then apply and release air pressure to the inlet port Soap the inlet port and note that leakage at the inlet port does not exceed 20 sccm If excessive leakage is noted in Tests 3 or 4 replace or repair the compressor using genuine Bendix replacements or maintenance kits available from any authorized Bendix parts outlet While it is possib
18. governor AIR INTAKE LOADED Just as the piston begins the down stroke a position known as top dead center or TDC the vacuum created in the cylinder bore above the piston causes the inlet reed valve to flex open Atmospheric air flows through the open inlet valve and fills the cylinder bore above the piston See Figure 4 AIR COMPRESSION LOADED When the piston reaches the bottom of the stroke a position known as bottom dead center or BDC the inlet reed valve closes Air above the piston is trapped by the closed inlet reed valve and is compressed as the piston moves upwards When air in the cylinder bore reaches a pressure greater than that of the system pressure the discharge reed valves open and allow air to flow into the discharge line and air brake system At the same time air flows into the hollow center of the unloader piston through an opening in the end of the piston 2 Air Inlet Discharge Air Port Valve Discharge Closed Port i 5 1 N _ 1 INS VZ LN ISSSSAN Pa eer AA nien umm Wc 0 ME f ZLLL LLL LLL LN eee pg Piston Moving Down FIGURE 4 OPERATION LOADED INTAKE Unloader Unloader Piston Down amp Seated Inlet Valve Open Compressed air acts on the interior surfaces of the unloader piston and along with the unloader piston spring holds the unloader piston in the down position against its seat on the valve plate See Figure 5
19. highway coach most pick up amp delivery yard or terminal jockey off highway construction loggers concrete mixer dump truck fire truck Bendix BA 921 air compressor Bendix Tu Flo 750 air compressor For oil carry over control suggested upgrades Order Bendix P N 2013711 Every 2 Years less o te i Tee dit BASIC test aT p p d acceptable z range TP ue 8 Every 5 oil units 7 5 Month per month Soe e g City transit bus refuse 5 appendix bulk unloaders low boys m 3 4in 12 ft A urban region coach central E tire inflation 12 Every Or n Year less N xdi lt to i E xe d Footnotes 1 With increased air demand the air dryer cartridge needs to be replaced more often 2 Use the drain valves to slowly drain all reservoirs to zero psi 3 Allow the oil water mixture to fully settle before measuring oil quantity 4 To counter above normal temperatures at the air dryer inlet and resultant oil vapor passing upstream in the air system replace the discharge line with one of a larger diameter and or longer length This helps reduce the air s temperature If sufficient cooling occurs the oil vapor condenses and can be removed by the air dryer Discharge line upgrades are not covered under warranty Note To help prevent discharge line freeze ups shorter discharge line lengths or insulation may be required in cold climates See Bendix Bulletins TCH 008 021 and TCH 0
20. leakage tests listed below need not be performed on a regular basis These tests should be performed when it is suspected that leakage is substantially affecting compressor build up performance or when it is suspected that the compressor is cycling between the loaded pumping and unloaded non pumping modes due to unloader leakage IN SERVICE OPERATING TESTS Compressor Performance Build up Test This test is performed with the vehicle parked and the engine operating at maximum recommended governed speed Fully charge the air system to governor cut out air dryer purges Pump the service brake pedal to lower the system air pressure below 80 psi using the dash gauges As the air pressure builds back up measure the time from when the dash gauge passes 85 psi to the time it passes 100 psi The time should not exceed 40 seconds If the vehicle exceeds 40 seconds test for and fix any air leaks and then re test the compressor performance If the vehicle does not pass the test the second time use the Advanced Troubleshooting Guide for Air Brake Compressors starting on page A 1 of this document to assist your investigation of the cause s Note All new vehicles are certified using the FMVSS 121 test paragraph 85 1 1 by the vehicle manufacturer however the above test is a useful guide for in service vehicles Optional Comparative Performance Check It may be useful to also conduct the above test with the engine running at high id
21. run loaded up to 25 of the time Higher duty cycles cause conditions that affect air brake charging system performance which may require additional maintenance Factors that add to the duty cycle are air suspension additional air accessories use of an undersized compressor frequent stops excessive leakage from fittings connections lines chambers or valves etc What you should do gt Drain all air tanks and check vehicle at next service interval using the Bendix BASIC test See Table A on page A 3 column 3 and 4 for recommended service schedule Check gt Drain all air tanks into Bendix BASIC test cup Bendix Air System Inspection Cup If less than one unit of reservoir contents is found the vehicle can be returned to service Note If more than one oil unit of water or a cloudy emulsion mixture Is present change the vehicle s air dryer check for air system leakage Test 2 on page A 14 stop inspection and check again at the next service interval See the BASIC test kit for full details If less than one oil unit of water or water cloudy emulsion mixture is present use the BASIC cup chart on the label of the cup to determine if the amount of oil found is within the acceptable level f within the normal range return the vehicle to service For vehicles with accessories that are sensitive to small amounts of oil consider a Bendix PuraGuard QC oil coalescing filter gt If outside
22. up are present in the discharge cavity such that it restricts the air flow through the cylinder head the compressor should be replaced 2 Carefully inspect both sides of the head gasket surfaces on the cooling plate for deep gouges and nicks Also inspect the cooling plate for any cracks or other damage If cracks or damage are found the compressor must be replaced 3 Carefully inspect the valve plate assembly gasket surfaces both sides for deep gouges and nicks Pay particular attention to the gasket surface An inlet reed valve gasket 1 is used between the valve plate assembly and crankcase This gasket surface must be smooth and free of all but the most minor scratches If excessive marring or gouging is detected the compressor must be replaced If large amounts of carbon build up are present on the two main surfaces in the two discharge valve holes or between the discharge valve and the discharge seat the compressor should be replaced M10x1 5 FIGURE 10 REAR END COVER ATTACHMENT BOLTS 4 If the unloader assembly has been removed from the cylinder head the unloader assembly must be serviced using an unloader kit See Maintenance Kits page 9 5 If large amounts of carbon build up are present on the unloader piston 7 seat or orifice or if the return spring exhibits compression set the unloader components must be replaced with an unloader kit 6 Carefully inspect the 2 bores in the unloader cavity of the cyl
23. 08 022 included in Appendix B for more information For certain vehicles applications where turbo charged inlet air is used a smaller size compressor may be permissible Note Compressor and or air dryer upgrades are recommended in cases where duty cycle is greater than the normal range for the examples above For correct compressor upgrades consult Bendix Please note that because a compressor is listed in the same area of the chart does not necessarily mean that it would be a suitable candidate for upgrade purposes For Bendix Tu Flo 550 and 750 compressors unloader service is recommended every 250 000 miles A 3 Air Brake Charging System Troubleshooting How to use this guide Find the symptom s that you see then move to the right to find the possible causes What it may indicate and remedies What you should do Review the warranty policy before performing any intrusive compressor maintenance Unloader or cylinder head gasket replacement and resealing of the bottom cover plate are usually permitted under warranty Follow all standard safety procedures when performing any maintenance 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
24. 2 71 In Lbs 7 8 Nem Inlet Port Fittings M27X2 69 seen 991 1089 In Lbs 112 123 Nem Discharge Port Fittings WIZZ 1 9 814 912 In Lbs 92 103 Nem Water Port Fittings M18X1 5 BH oscssatenietleki eerta roues 593 637 In Lbs 67 72 Nem Unloader Port Fittings TOA NRT aa E E OR 2 3 TFFT Safety Valve Port M16x1 5 6H ae etnies md ze tgo 230 257 In Lbs 26 29 Nem Cil Port 215 19 DNE ttd dori 150 170 In Lbs 17 19 Nem 1 Note TFFT Turns From Finger Tight 13 Appendix A Advanced Troubleshooting Guide for Air Brake Compressors The guide consists of an introduction to air brake charging system components a table showing recommended vehicle maintenance schedules and a troubleshooting symptom and remedy section with tests to diagnose most charging system problems INDEX Symptom Page Number Symptom Page Number Air Coolant Air brake charging system Compressor leaks coolant 17 0 A 13 Slow DUNG 90 espren A 9 10 Doesn t build air 10 0 A 11 EISE Air dryer Oil consumption 6 0 A 9 Doesn t purge 14 0 A 12 Oil Safety valve releases air 12 0 A 12 l Compressor Oil Test Card results 1 0 T A 4 Constantly cycles 15 0 A 12 Oil is present Leaks air 16 0 A 13 On the outside of the comp
25. BRAKE 1 800 247 2725 and speak to a Tech Team member 5 0 Oil present Air brake system valves are required gt A small amount of oil does not affect SAE at valves e g at to tolerate a light coating of oil J2024 compliant valves exhaust or seen during servicing Normal gt Check that regular maintenance is being performed and that the amount of oil in the air tanks reservoirs is within the accept able range shown on the Bendix BASIC test cup see also column 5 of Table A on page A 3 Return the vehicle to service For oil sensitive systems see page 16 kk Genuine Bendix valves are all SAE J2024 compliant SAE J2024 outlines tests all air brake system pneumatic components need to be able to pass including minimum levels of tolerance to contamination Symptom 6 0 Excessive oil consumption in engine 7 0 Oil present at air dryer cartridge during maintenance 8 0 Oil in ping tank or compressor dis charge aftercooler 9 0 Air brake charging system seems slow to build pressure What it may indicate A problem with engine or other engine accessory The engine service manual has more information Air brake charging system is functioning normally ZINSENSI Oil shown leaking from an air dryer cartridge Air brake charging system is functioning normally Y Normal a Air brake charging system functioning normally Y Normal b Air brake system lea
26. EACH 50 000 MILES WHICHEVER OCCURS FIRST PERFORM THE FOLLOWING INSPECTIONS AND TESTS AIR INDUCTION The Bendix BA 9219 SMC compressor is designed for connection to the vacuum side of the engine s air induction system A supply of clean air is one of the single most important factors in compressor preventive maintenance Since the air supply for Bendix BA 9219 SMC compressor and engine is the engine air cleaner periodic maintenance of the engine air filter is necessary Inspect the compressor air induction system each time engine air cleaner maintenance is performed 1 Inspect the intake hose adapters for physical damage Make certain to check the adapters at both ends of the intake hose or tubing 2 Inspect the intake hose clamps and tighten them if needed 3 Inspect the intake hose or line for signs of drying cracking chafing and ruptures and replace if necessary 4 Verify that the compressor inlet fitting is tight check torque 5 Any metal tubes should also be tight torqued properly to the mating fitting Inspect the metal tubes for any cracks or breaks and replace if necessary COMPRESSOR COOLING Inspect the compressor discharge port inlet cavity and discharge line for evidence of restrictions and carbon build up If more than 1 16 of carbon is found thoroughly clean or replace the affected parts In some case carbon build up indicates inadequate cooling Closely inspect the compressor cooling system
27. H 001 048 11 0 Compressor a Restricted discharge line safety valve releases air Check Compressor builds too much air Damaged discharge line shown b Downstream air brake system check valves or lines may be blocked or damaged c Air dryer lines incorrectly installed d Compressor safety valve malfunction e Compressor unloader mechanism malfunction f Governor malfunction What you should do gt Qo to Test 4 on page A 15 gt See 9 0 f gt Replace air dryer heater gt Replace the compressor only after making certain the preceding conditions do not exist f discharge line is restricted gt By more than 1 16 carbon build up replace the discharge line see Table A column 2 on page A 3 for recommended size and go to Test 3 on page A 14 gt By other restrictions e g kinks Replace the discharge line See Table A column 2 on page A 3 for recommended size gt The discharge line must maintain a constant slope down from the compressor to the air dryer inlet fitting to avoid low points where ice may form and block the flow If instead ice blockages occur at the air dryer inlet insulation may be added here or if the inlet fitting is a typical 90 degree fitting it may be changed to a straight or 45 degree fitting For more information on how to help prevent discharge line freeze ups see Bendix Bulletins TCH 08 21 and TCH 08 22 Appendix B Shorter
28. NDS To convert inch pounds to foot pounds of torque divide inch pounds by 12 12 Inch Pounds 1 Foot Pound 12 Example FOOT POUNDS TO INCH POUNDS To convert foot pounds to inch pounds of torque multiply foot pounds by 12 Example 1 Foot Pound x 12 12 Inch Pounds CRANKCASE FRONT COVER 1 Position the new cover over the hole in the front of the crankcase Using a rubber mallet drive the cover into the hole in the front of the crankcase until the outside diameter of the cover is flush with cast surface REAR END COVER 1 Install the o ring 10 on the rear end cover 2 Orient the rear end cover to the crankcase using the reference marks made during disassembly Carefully install the rear end cover in the crankcase making certain not to damage the crankshaft bearing surface 3 Install the two end cover cap screws Refer to Figure 10 to assure that the two cap screws are installed in the proper crankcase bolt holes Snug the screws then tighten to 195 to 212 inch pounds 22 24 Nem CYLINDER HEAD ASSEMBLY PART ONE HEAD INSTALLATION 1 Note the position of the protruding alignment pins on the deck top of the crankcase Install the metal inlet reed valve gasket 1 over the alignment pins on the crankcase 2 Position the valve plate assembly on the crankcase so that the alignment pins in the crankcase fit into the corresponding holes in the valve plate assembly 3 Position and install one of the
29. RTS FOR BENDIX BA 921 SMC SINGLE CYLINDER COMPRESSOR ONLY Cylinder Head Gasket Kit 023764 Unloader VU PN T K046477 Discharge Safety Valve sssssse 800534 Compressor Seal Kit sssssuus 051352 Compressor to Engine Mounting Face Sealant Supplied by the Engine Manufacturer All components shown in Figure 9 with a key number are available in kits and or as individual service parts GENERAL SAFETY GUIDELINGS IMPORTANT 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 Where specifically directed the parking brakes may have to be released and or spring brakes caged and this will require that the vehicle be prevented from moving by other means for the duration of these tests procedures 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 co
30. STEP A Select one The Technician selects the air use category for the vehicle This decides Q This is a low air use vehicle Line haul single trailer with 5 or less axles or which of the two acceptance lines on L1 This is a high air use vehicle Garbage truck transit bus bulk unloader or line the cup will be used for the test below haul with more than 5 axles Then go to Step B STEP B Measure the Charging System Contents Foran accurate test the 1 Park and chock vehicle on level ground Drain the air system by contents of all the air tanks on pumping the service brakes 2 Completely drain ALL the air tanks into a single BASIC cup the vehicle should be used 3 If there is less than one unit of contents total end the test now and return the vehicle to service Vehicle passes Note for returning vehicles that are being 4 admore than one oil unit of water ora cloudy emulsion mixture re tested after a water cloudy emulsion IS found mixture was found last time and the air a Change the vehicle s air dryer cartridge dryer cartridge replaced If more than one see Footnote 1 b Conduct the 4 minute leakage test Step D c STOP the inspection and check the vehicle again after 30 days see Footnote 2 GU go to Step C Footnote 1 Note Typical air dryer cartridge replacement schedule is every 3 yrs 300K miles for low air use vehicles and every year 100K miles for high air use vehicles
31. 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 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 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 a Bendix AD IS air dryer system or a dryer reservoir module be sure to drain the purge reservoir Symptom What it may indicate 1 0 Oil Test Card Not a valid test Look for Normal Normal Charging system is working within normal range Check Check Charging system needs further investigation 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
32. U ep peer 39 LBS Number Of Cy NG SES srecitecadonc lt pscanect asicaeat epsontioteuadaencacauesatecatie tru nica 1 Bore Diameter cscccessssseessssserssssessesesseeeees 3 622 in 92 mm vllo WR E E A E m 2 126 in 54 mm Calculated displacement at 1250 RPM 15 8 CFM Flow Capacity 1800 RPM amp 120 PSI 11 6 CFM Flow Capacity 3000 RPM amp 120 PSI 16 5 CFM Approximate horsepower required Loaded 1800 RPM at 120 PIG tert ii 4 6 HP Unloaded 1800 TPM NER RR PURA 0 8 HP Minimum coolant flow at maximum RPM 1 5 Gals Min Maximum inlet air temperature eeeeeee TOF Maximum discharge air temperature 400 F Minimum oil pressure required eeeeeee 15 PSI Minimum unloader line size sesessss 3 16 I D Minimum Governor Cut out Pressure 120 PSI TORQUE SPECIFICATIONS Assembly Torques in inch pounds In Lbs M8x1 25 6g Cylinder Head 265 292 In Lbs 30 33 Nem M5x0 75 6g Unloader Cap 62 71 In Lbs 7 8 Nem M8x1 25 6g Governor Adapter 195 213 In Lbs 22 24 Nem M10x1 5 6g Rear End Cover 195 213 In Lbs 22 24 Nem M6x1 00 6g Crankcase Cover 6
33. ails and then replace the compressor Do not re use the safety valve without testing See Symptom 12 0 a A 9 Symptom What it may indicate What you should do 9 0 Air brake f Restricted discharge line charging system seems slow to Check build pressure continued Dash gauges Kinked discharge line shown Engine Oil Quality Inadequate oil change intervals the formulation of the oil and or the quality of oil filter used can all lead to poor oil quality These can increase the rate at which carbon builds up in the discharge line Bendix recommends oil soot solids be maintained at less than 396 g Restricted air inlet not enough air to compressor Check Partly collapsed l inlet line shown h Poorly filtered inlet air poor air quality to compressor Check i Compressor malfunction Check A 10 f discharge line is restricted gt By more than 1 16 carbon build up replace the discharge line see Table A column 2 on page A 3 for recommended size and go to Test 3 on page A 14 gt By other restrictions e g kinks Replace the discharge line See Table A column 2 on page A 3 for recommended size Re test for air build Return vehicle to service or if problem persists go to 9 0 a The discharge line must maintain a constant slope down from the compressor to the air dryer inlet fitting to avoid low points where ice may form and block the flow If instea
34. ally consists Optional Ping Tank A Air Dryer Discharge Line B Governor Governor plus Synchro valve for the Bendix DuraFlo 596 Compressor A 2 of an air compressor governor discharge line air dryer and service reservoir Optional Bendix PuraGuard System Filter or PuraGuard QC Oil Coalescing Filter Service Reservoir Supply Reservoir Reservoir Drain Table A Maintenance Schedule and Usage Guidelines Regularly scheduled maintenance is the single most important factor in maintaining the air brake charging system Typical Vehicle Used for Low Air Use Compressor with less than 15 duty cycle Discharge Recom Recom Acceptable mended mended Reservoir Air Dryer Reservoir Cil Contents Cartridge Drain at Regular Replacement Schedule Drain Interval BASIC test l l acceptable e g Line haul single trailer i For oil carry over dn w o air suspension air over 9 N eee Recom oe hydraulic brakes less r Xd A mended 3 oil units SN r month a E Every 3 Every per mont o AUR Month See Compressor with up to 25 duty cycle E Max of appendix e g Line haul single trailer 5 D l every 90 A with air suspension RV or roy For oil carry over days haol bus T control suggested SC ess 5 upgrades gr MEN Ri 5in 12ft For the I BASIC High Air Use Z Test Kit Compressor with up to 25 duty cycle e g Double triple trailer open
35. amage to the air dryer seals and to avoid a loss of drying performance Compressor Line Size The line size and length is established by the vehicle manufacturer and should not be altered without the vehicle manufacturers approval As a reference the line length from the compressor to the air dryer should be less than 16 feet and the minimum line sizes should be as follows apna Application Length PP 6 ft Low Compressor Duty Cycle Applications 0 20 10 ft High Compressor Duty Cycle Applications 20 40 Line Insulation To guard against freez ups in Low Duty Cycle applications the discharge line can be insulated if it is greater than 9 feet in length The line can only be insulated back to 9 feet and a maximum of 3 feet For example if the line is 10 feet insulate the fitting and the last one foot of the line If the line is 15 feet insulate the fitting and the last 3 feet of the line 2010 Bendix Commercial Vehicle Systems LLC All rights reserved 3 2010 Printed in U S A A 19 Appendix C Continued Bulletin No TCH 008 021 Effective Date 3 5 2010 Page 2 of 2 System Leakage Check the air brake system for excessive air leakage using the Bendix Dual System Air Brake Test and Check List BW1279 Excessive system leakage causes the compressor to pump more air and also reduce the life of the air dryer desiccant cartridge Reservoir Draining System without an Air Dryer Routine reservoir draining is the most
36. auses the air dryer to purge As the service reservoir air pressure drops to the cut in setting of the governor the governor returns the compressor back to building air and the air dryer to air drying mode As the atmospheric air is compressed all the water vapor originally in the air is carried along into the air system as well as a small amount of the lubricating oil as vapor The duty cycle is the ratio of time the compressor spends building air to the total engine running time Air compressors are designed to build air run loaded up to 25 of the time Higher duty cycles cause conditions that affect air brake charging system performance which may require additional maintenance Factors that add to the duty cycle are air suspension additional air accessories use of an undersized compressor frequent stops excessive leakage from fittings connections lines chambers or valves etc The discharge line allows the air water vapor and oil vapor mixture to cool between the compressor and air dryer The typical size of a vehicle s discharge line see column 2 of Table A on page A 3 assumes a compressor with a normal less than 25 duty cycle operating in a temperate climate See Bendix and or other air dryer manufacturer guidelines as needed When the temperature of the compressed air that enters the air dryer is within the normal range the air dryer can remove most of the charging system oil If the temperature of the com
37. d ice blockages occur at the air dryer inlet insulation may be added here or if the inlet fitting is a typical 90 degree fitting it may be changed to a straight or 45 degree fitting For more information on how to help prevent discharge line freeze ups see Bendix Bulletins TCH 008 021 and TCH 008 022 Appendix B Shorter discharge line lengths or insulation may be required in cold climates Check compressor air inlet line for restric tions brittleness soft or sagging hose con ditions etc Repair as necessary Refer to vehicle manufacturer s guidelines for inlet line size Check the engine air filter and service if necessary if possible check the air filter usage indicator Check for leaking damaged or defective compressor air inlet components e g induction line fittings gaskets filter bodies etc Repair inlet components as needed Note Dirtingestion will damage compressor and is not covered under warranty Replace the compressor only after making certain that none of the preceding conditions 9 0 a through 9 0 h exist Symptom What it may indicate 10 0 Air charging a Governor malfunction system doesn t build air b Restricted discharge line c Air dryer heater malfunction exhaust port frozen open d Compressor malfunction Note For the Bendix DuraFlo 596 air compressor not only the governor but also the SV 1 synchro valve used would need to be tested See Bulletin TC
38. d the surface temperature of the fittings gt atthe compressor discharge port T1 gt atthe air dryer inlet fitting T2 Use atouch probe thermocouple for measuring the temperature 5 See table below 6 Re test before returning the vehicle to service T1 T2 Compressor Air Dryer Discharge Inlet Fitting Fitting Temperatures are within normal range for this test check other symptoms Go to 4 0 h This could indicate a discharge line problem e g restriction Call 1 800 AIR BRAKE 1 800 247 2725 and speak with our Tech Team Compressor is running hot Check coolant 4 f and or discharge line 4 g Tests continued Test 4 Governor Malfunction supply reservoir service reservoir or reservoir 1 Inspect control lines to and from the governor port of the D 29 governor verify cut in and for restrictions e g collapsed or kinked cut out pressures are within vehicle OEM Repair as necessary specification 2 Using a calibrated external gauge in the 3 If the governor is malfunctioning replace it Test 5 Governor Control Line 1 Ensure that the governor control line from the reservoir is located at or near the top of the res ervoir This line if located near the bottom of Schedule and Usage Guidelines Table A on the reservoir can become blocked or restricted page A 3 by the reservoir contents e g water or ice 3 Return the vehicle to service Perform proper reservo
39. e piston 5 o ring groove Note If an o ring appears to be twisted manipulate it to remove any twists Apply lubricant 8 onto the inside diameter of the unloader piston Insert the return spring 3 into the unloader piston assembly Install the balance piston 5 with balance piston o ring 6 into the unloader piston assembly by installing the stem small diameter of the balance piston into the return spring 3 Position the unloader gasket 4 on the top of the unloader cavity of the cylinder head Make certain the gasket is orientated such that the vent hole is exposed and surrounded on the outside by the gasket material Position the unloader cover on top of the balance piston making certain the stamped logo is visible Press and hold the unloader cover in place on the cylinder head Install both unloader cover cap screws Torque the cover cap screws 2 between 62 and 71 inch pounds 7 8 Nem INSTALLING THE COMPRESSOR 1 Apply a liquid gasket sealant to the compressor engine mounting interface Refer to Figure 3 for compressor mounting face Follow the Engine or Vehicle Manufacturers guidelines for the proper liquid gasket sealant material and application procedure Position the compressor on the engine mounting face making sure that the alignment pins on the crankcase fit inside the engine mounting face alignment pin holes Secure the compressor on the engine mounting interface using the six mounting bolt
40. ections gt Check for leaking damaged or defective leaks air or ports compressor fittings gaskets etc Repair or replace as necessary b Compressor unloader mechanism Go to Test 6 on page A 15 malfunction c Damaged compressor head gt An air leak at the head gasket s may gasket s indicate a downstream restriction such as a freeze up or carbon blockage and or could Testing for leaks with Head indicate a defective or missing safety valve soap solution gasket Find blockage go to 9 0 f for details and locations then replace the compressor Do not re use the safety valve without testing See Symptom 12 0 a 17 0 Compressor a Improperly installed plugs or coolant Inspect for loose or over torqued fittings leaks coolant line fittings Reseal and tighten loose fittings and plugs as necessary If overtorqued fittings and plugs have cracked ports in the head replace the compressor b Damaged compressor head gt Anairleak at the head gasket may indicate gasket a downstream restriction such as a freeze up or carbon blockage and or could indicate a defective or missing safety valve Find blockage go to 9 0 f for details and then replace the compressor Do not re use the safety valve without testing See Symptom 12 0 a c Porous compressor head casting If casting porosity is detected replace the compressor 18 0 Noisy a Damaged compressor gt Replace the compressor compressor
41. eets alike begin to look to their vehicles with an eye toward winterization and particularly what can be done to guard against air system freeze up Here are some basic Tips for operation in the cold weather Engine Idling Avoid idling the engine for long periods of time In addition to the fact that most engine manufacturers warn that long idle times are detrimental to engine life winter idling is a big factor in compressor discharge line freeze up Discharge line freeze ups account for a significant number of compressor failures each year The discharge line recommendations under Discharge Lines are important for all vehicles but are especially so when some periods of extended engine idling can not be avoided Discharge Lines The discharge line should slope downward from the compressor discharge port without forming water traps kinks or restrictions Cross overs from one side of the frame rail to the other if required should occur as close as possible to the compressor Dryer Inlet Temperature The dryer inlet air temperature should typically be within the range of no more than 160 F and no less than 45 F above low ambient surrounding temperature to prevent freeze ups For example if low ambient is minus 40 F the dryer inlet must be above 5 F Lower dryer inlet temperatures should be avoided to minimize the risk of freeze up upstream of the air dryer Higher temperatures should also be avoided to minimize the risk of heat d
42. er fills out these fields with information gained from the customer Number of Days Since Air Tanks Were Last Drained Date Vehicle Engine SN Vehicle Used for Typical Load No of Axles tractor trailer No of Lift Axles Technician s Name Checklist for Technician Customer s Have you confirmed complaint V Please check all that apply Oe The Technician Relay valve LI leaks oil CJ malfunctions LI no LI yes hene The Service Writer Dash valve O leaks oil C malfunctions O no O yes MIU PONES also checks off any L1 Air dryer leaks oil L no D yes for any of the complaints that the L Governor malfunction L no yes complaints that O Oil in gladhands O no LI yes can be confirmed how much oil did you find L1 Oil on ground or vehicle exterior LI no U yes amount described L1 Short air dryer cartridge life replaces every LJ miles L kms or C months Note A confirmed complaint L1 Oil in air tanks amount described above does NOT mean that We will measure amount currently found when we get to step B of the test the compressor must be L1 Excessive engine oil loss amount described replaced Is the engine leaking oil LJ no L1 yes qe full BASIC fest below wil mE investigate the facts Is the compressor leaking oil LJ no L1 yes L Other complaint LJ No customer complaint customer makes to help the Technician in investigating cy Ne Cae
43. fins and by the flow of engine coolant through the cylinder head Coolant supplied by the engine cooling system passes through connecting lines into the cylinder head and passes through internal passages in the cylinder head cooling plate and valve plate assembly and returns to the engine Figure 7 illustrates the approved coolant flow connections Proper cooling is important in minimizing discharge air temperatures see the tabulated technical data on page 13 of this manual for specific requirements Governor Unloader Port Air Dryer Governor Reservoir Port Compressor FIGURE 8 COMPRESSOR CHARGING SYSTEM AIR INDUCTION The Bendix BA 9219 SMC compressors is only permitted to be naturally aspirated use of engine turbocharger as an air source is not allowed See Figure 8 for an example of a naturally aspirated air induction system PREVENTATIVE MAINTENANCE Regularly scheduled maintenance is the single most important factor in maintaining the air brake charging system Refer to Table A in the Troubleshooting section starting on page A 1 for a guide to various considerations that must be given to maintenance of the compressor and other related charging system components Important Note Review the Bendix Warranty Policy before performing any intrusive maintenance procedures An extended warranty may be voided if intrusive maintenance is performed during this period EVERY 6 MONTHS 1800 OPERATING HOURS OR AFTER
44. g system In addition the materials used for the internal seals of the air system components may be adversely impacted by the residue that some anti freeze additives leave behind Both are detrimental to air system component life expectancy causing premature wear Because of this Bendix air system components warranty will be void if analysis shows that alcohol was added to the air brake system Alcohol is not an acceptable substitute for having adequate air drying capacity If the air dryer is maintained in accordance with the manufacturer s recommended practices and moisture is found to be present in the system reservoirs more drying capacity is required Bendix has several viable options including extended purge air dryers extended purge tandem dryers in parallel with common control and air dryers arranged to provide continuous flow as with the Bendix EverFlow continuous flow air dryer module To address concerns with contaminants in trailer air brake systems the Bendix Cyclone DuraDrain water separator and the Bendix System Guard trailer air dryer are available Refer to Bendix Technical Bulletin TCH 008 042 Alcohol in the Air Brake System for additional information Air Dryers Make certain air brake system leakage is within the limits stated in BW1279 Check the operation and function of the air dryer using the appropriate Service Data Sheet for the air dryer Bendix literature is available to order or download on Bendix co
45. hat it may indicate What you should do A 8 4 0 Oil in Supply Other cont siii i Poorly filtered inlet air poor air air dryer installed quality to compressor continued pee Va Inspect the engine air cleaner j Governor malfunction or setting gt k Compressor malfunction gt Crankcase Flooding Consider installing a compressor bottom drain kit where available in cases of chronic oil passing where all other operating conditions have been investigated Bendix compressors are designed to have a dry sump and the presence of excess oil in the crankcase can lead to oil carryover Check for leaking damaged or defective compressor air inlet components e g induction line fittings gaskets filter bodies etc Repair inlet components as needed Note Dirt ingestion will damage compressor and is not covered under warranty Check Go to Test 4 on page A 15 If you found excessive oil present in the service reservoir in step 4 0 b above and you did not find any issues in steps 4 0 c through 4 0 j above the compressor may be passing oil Replace compressor If still under warranty follow normal warranty process Note After replacing a compressor residual oil may take a considerable period of time to be flushed from the air brake system If a maintained Bendix PuraGuard system filter or Bendix PuraGuard QC oil coalescing filter is installed call 1 800 AIR
46. inder head for gouges or material transfer If this is detected the compressor should be replaced REAR END COVER Visually inspect for cracks and external damage Check the crankshaft rear bearing diameter in the rear end cover for excessive wear flat spots or galling Check the hydraulic pump attachment pilot and threaded holes for damage Minor thread chasing is permitted but do not re cut the threads If any of these conditions are found replace the compressor CRANKCASE Check the cylinder head gasket surface on the deck top of the crankcase for nicks gouges and marring A metal gasket is used to seal the cylinder head to the crankcase This surface must be smooth and free of all but the most minor scratching If excessive marring or gouging is detected the compressor must be replaced Check the condition of the countersunk hole on the deck of the crankcase that retains the o ring and prevents coolant leakage between the valve plate assembly and the crankcase The surface in contact with the o ring should be smooth and free of any scratches and gouges that could causes leakage around the o ring ASSEMBLY General Note All torques specified in this manual are assembly torques and typically can be expected to fall off after assembly is accomplished Do not re torque after initial assembly torques fall unless instructed otherwise A compiled listing of torque specifications is presented on page 13 INCH POUNDS TO FOOT POU
47. ir drain intervals and air dryer cartridge maintenance per Maintenance Test 6 Compressor Unloader Leakage Bendix Compressors Park vehicle chock shut off and charge the unloader port by allowing wheels and follow all standard safety procedures air pressure to enter the hose and unload the Remove the governor and install a fitting to the compressor Shut off the air supply and observe unloader port Add a section of air hose min the gauge Asteady reading indicates no leakage 1 ft long for a 1 2 diameter line and a gauge at the unloader port but a falling reading shows to the fitting followed by a shut off valve and an that the unloader mechanism is leaking and needs air source shop air or small air tank Open the to be serviced A 15 Appendix B Information about the BASIC Test Kit Bendix P N 5013711 Service writer records info including the number of days since all air tanks were drained and fills out symptom checklist Technician inspects items START BASIC TEST Park vehicle on LEVEL ground Chock wheels drain air from system Drain contents of ALL air tanks into BASIC cup Bendix Air System Inspection Cup BASIC Test Information ls there YES lt 1 Vehicle OK less than one Return vehicle to END TEST unit of liquid service NO Is there more E ves MOJ Cloudy emulsion mixture water or cloudy emulsion mixture NO only oil
48. kage c Compressor may be undersized for the application d Compressor unloader mechanism malfunction e Damaged compressor head gasket What you should do gt See engine service manual Check Air dryers remove water and oil from the air brake charging system A small amount of oil is normal Check that regular maintenance is being performed and that the amount of oil in the air tanks reservoirs is within the acceptable range shown by the BASIC test see also column 5 of Table A on page A 3 Replace the air dryer cartridge as needed and return the vehicle to service Follow vehicle O E maintenance recommendation for these components Using dash gauges verify that the compressor builds air system pressure from 85 100 psi in 40 seconds or less with engine at full governed rpm Return the vehicle to service Go to Test 2 on page A 14 See Table A column 1 on page A 3 for some typical compressor applications If the compressor is too small for the vehicle s role for example where a vehicle s use has changed then upgrade the compressor Note The costs incurred e g installing a larger capacity compressor etc are not covered under original compressor warranty Go to Test 6 on page A 15 An air leak at the head gasket may indi cate a downstream restriction such as a freeze up or carbon blockage and or could indicate a defective or missing safety valve Find blockage go to 9 0 f for det
49. le instead of maximum governed speed and record the time required to raise the system pressure a selected range for example from 90 to 120 psi or from 100 to 120 psi etc in the vehicle s maintenance files Subsequent build up times throughout the vehicle s service life can then be compared to the first one recorded Note the 40 second guide in the test above does not apply to this build up time If the performance degrades significantly over time you may use the Advanced Troubleshooting Guide for Air Brake Compressors starting on page A 1 of this document to assist investigation of the cause s Note When comparing build up times be sure to make an allowance for any air system modifications which would cause longer times such as adding air components or reservoirs Always check for air system leakage LEAKAGE TESTS See the standard Air Brake System and Accessory Leakage test on Page A 14 Test 2 Note Leakage in the air supply system components before the supply reservoir such as the governor air dryer reservoir drain cocks safety valve and check valves will not be registered on the vehicle dash gauges and must be tested separately Refer to the various maintenance manuals for individual component leakage tests and the Bendix Test and Checklist published in the Bendix Air Brake System Handbook BW5057 and on the back of the Bendix Dual Circuit Brake System Troubleshooting Card BW1396 CYLINDER HEAD Check
50. le to test for inlet discharge and unloader piston leakage it may not be practical to do so Inlet and discharge valve leakage can generally be detected by longer compressor build up and recovery times Compare current compressor build up times with the last several recorded times Make certain to test for air system leakage as described under In Service Operating Tests before making a determination that performance has been lost Unloader leakage is generally exhibited by excessive compressor cycling between the loaded and unloaded condition 1 With service and supply system leakage below the maximum allowable limits and the vehicle parked bring system pressure to governor cut out and allow the engine to idle 2 The compressor should remain unloaded for a minimum of 5 10 minutes lf compressor cycling occurs more frequently and service and supply system leakage is within tolerance replace the compressor or repair the compressor unloader system using a genuine Bendix maintenance kit available from authorized Bendix parts outlets COMPRESSOR REMOVAL amp DISASSEMBLY GENERAL The following disassembly and assembly procedure is presented for reference purposes and pre supposes that a rebuild or repair of the compressor is being undertaken Several maintenance kits are available and the instructions provided with these parts and kits should be followed in lieu of the instructions presented here MAINTENANCE KITS amp SERVICE PA
51. llic air lines WARNING THIS PRACTICE IS UNSAFE AND CAN RESULT IN VEHICLE FIRE 2 Do not introduce pour fluids into air brake lines or hose couplings glad hands Some fluids used can cause immediate and severe damage to rubber components Even methanol alcohol which is used in Alcohol Evaporators and Injectors should not be poured into air lines Fluids poured into the system wash lubricants out of valves collect in brake chambers and valves and can cause malfunction Loss of lubricant can affect valve operating characteristics accelerate wear and cause premature replacement 3 Do not park a vehicle outside after thawing its air system indoors Condensation will form in the system and freeze again Place the vehicle in operation when it is removed to the outdoors Supporting Air and Electrical Lines Make certain tie wraps are replaced and support brackets are re assembled if removed during routine maintenance These items prevent the weight of ice and snow accumulations from breaking or disconnecting air lines and wires Automatic Drain Valves System without Air Dryer As we stated last year routine reservoir draining is the most BASIC step although not completely effective in reducing the possibility of freeze up While automatic drain valves relieve the operator of draining reservoirs on a daily basis these valves MUST be routinely checked for proper operation Don t overlook them until they fail and a road call is required
52. lve plate assembly off the crankcase 7 Remove the metal inlet reed valve gasket 1 Note Always Replace Safety ST 4 Safety Valve in Original Valve Location Cylinder Head 2 Cooling Cylinder Head Plate 7 pa Gasket Valve Plate Assembly Inlet Reed Valve uu i n s Gasket Crankcase CYLINDER HEAD GASKET KIT PIECE NO K023764 CONSISTS OF THE FOLLOWING ITEM DESCRIPTION INLET REED VALVE GASKET CYLINDER HEAD GASKET Cylinder Head Cap Screws 6 includes washers Unloader Cover t Cap Screws gt Unloader Return enl Cover Spring gt Unloader Cover s 2 Gasket dice 8 Balance Piston Balance Piston O Ring S i Unloader Piston Assembly Alignment Bushings Crankcase Alignment Pins End Cover E d Screws os X ee End Cover 10 End Cover O ring SAFETY VALVE KIT PIECE NO 800534 CONSISTS OF THE FOLLOWING s sra sarev CRANKCASE SEAL KIT PIECE NO K051352 CONSISTS OF THE FOLLOWING DESCRIPTION END COVER O RING COVER ITE O FIGURE 9 BA 921 CLOSED ROOM COMPRESSOR EXPLODED VIEW 8 Gently tap the cylinder head cooling plate and valve plate assembly with a soft mallet to break the gasket seals Then separate the cylinder head from the cooling plate and valve plate assembly and remove the two gaskets 2 between them CRANKCASE FRONT COVER 1 Remove the cove
53. m A 20 Appendix D Technical Bulletin a Bulletin No TCH 008 022 Effective Date 1 1 1994 Page 1 of 1 Subject Additional Cold Weather Operation Tips for the Air Brake System Last year we published Bulletin PRO 08 21 which provided some guidelines for winterizing a vehicle air brake system Here are some additional suggestions for making cold weather vehicle operation just a little more bearable Thawing Frozen Air Lines The old saying Prevention is the best medicine truly applies here Each year this activity accounts for an untold amount of unnecessary labor and component replacement Here are some Do s and Don ts for prevention and thawing a o s Do maintain freeze prevention devices to prevent road calls Don t let evaporators or injectors run out of methanol alcohol or protection will be degraded Check the air dryer for proper operation and change the desiccant when needed 2 Do thaw out frozen air lines and valves by placing the vehicle in a warmed building This is the only method for thawing that will not cause damage to the air system or its components Do use dummy hose couplings on the tractor and trailer Do check for sections of air line that could form water traps Look for drooping lines DOM Don ts 1 Do not apply an open flame to air lines and valves Beyond causing damage to the internal non metallic parts of valves and melting or burning non meta
54. mponents 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 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 a Bendix 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 brand 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 7 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 man
55. n this manual 2 Carefully remove all gasket material adhering to the deck top of the crankcase Remove any carbon deposits from the deck of the crankcase Make certain not to scratch or mar the gasket surfaces CYLINDER HEAD ASSEMBLY 1 Carefully remove all gasket material adhering to the cylinder head cooling plate valve plate assembly and cast iron crankcase Make certain not to scratch or mar the gasket surfaces Pay particular attention to the gasket surfaces of the head 10 2 Remove carbon deposits from the discharge and inlet cavities of the cylinder head cooling plate and valve plate assembly They must be open and clear in both assemblies Make certain not to damage the head 3 Remove rust and scale from the cooling cavities and passages in the cylinder head cooling plate and valve plate assembly and use shop air to clear debris from the passages 4 Check the threads in all cylinder head ports for galling e g abrasion chafing Minor thread chasing damage is permitted 5 Remove any carbon or old grease from the two bores in the unloader cavity of the cylinder head INSPECTION OF PARTS CYLINDER HEAD COOLING PLATE VALVE PLATE ASSEMBLY AND UNLOADER MECHANISM 1 Carefully inspect the head gasket surfaces on the cylinder head for deep gouges and nicks Also inspect the cylinder head for any cracks or port thread damage If detected the compressor must be replaced If large amounts of carbon build
56. ndicate the above relationships is to use a metal scribe to mark the parts with numbers or lines Do not use marking methods such as chalk that can be wiped off or obliterated during rebuilding Prior to disassembly make certain that the appropriate kits are available CYLINDER HEAD 1 Remove the discharge safety valve 9 from the cylinder head 2 To restrain the spring force exerted by the return spring 3 of the unloader assembly hold the unloader cover in place while removing the two unloader cover cap screws Carefully release the hold on the unloader cover until the spring force is relaxed then remove the unloader cover 3 Remove the unloader cover gasket 4 4 Remove the balance piston 5 with its o ring 6 return spring 3 and the unloader piston assembly 7 which includes the unloader piston two outer o rings and two guide bushings from the cylinder head 5 Remove the six hex head bolts from the cylinder head Note The five hex bolts located towards the perimeter of the cylinder head retain the cylinder head directly to the crankcase The single hex bolt in the center of the cylinder head holds the cylinder head cooling plate and valve plate assembly together independent of the crankcase 6 Gently tap the cylinder head cooling plate and valve plate assembly with a soft mallet to break the gasket seal between the valve plate assembly and the crankcase Lift the cylinder head with cooling plate and va
57. 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 brand 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 Prior to returning the vehicle to service make certain all components and systems are restored to their proper operating condition For vehicles with Automatic Traction Control ATC the ATC function must be disabled ATC indicator lamp should be ON prior to performing any vehicle maintenance where one or more wheels on a drive axle are lifted off the ground and moving What you should do Discontinue using this test Results Do not use this card test to diagnose compressor oil passing issues They are subjective and error prone Use only the Bendix Air System Inspection Cup BASIC test and the methods described in this guide for advanced troubleshooting The Bendix BASIC test should be the definitive method for judging excessive oil fouling oil passing See Appendix A Bendix on page
58. ormed Check b Compressor unloader mechanism malfunction c Air dryer purge valve or delivery check valve malfunction d Air brake system leakage c c c What you should do Inspect delivery lines to reservoir for restrictions and repair as needed Verify relief pressure is at vehicle or component manufacturer specifications Replace if defective See Maintenance Schedule and Usage Guidelines Table A column 3 on page A 3 Verify operation of air dryer Follow vehicle O E maintenance recommendations and component Service Data information Go to Test 5 on page A 15 Go to Test 4 on page A 15 Verify relief pressure is at vehicle or component manufacturer s specifications typically 150 psi Replace if defective Go to Test 4 on page A 15 Go to Test 6 on page A 15 Verify operation of air dryer Follow vehicle O E maintenance recommendations Go to Test 4 on page A 15 Go to Test 2 on page A 14 Go to Test 5 on page A 15 Available reservoir capacity may be reduced by build up of water etc Drain and perform routine maintenance per Table A columns 3 amp 4 on page A 3 Go to Test 6 on page A 15 Verify operation of air dryer Follow vehicle O E maintenance recommendations and component Service Data information Go to Test 2 on page A 14 Symptom What it may indicate What you should do 16 0 Compressor a Compressor leaks air at conn
59. place as necessary gt Verify coolant lines go from engine block to compressor and back to the water pump Repair as necessary If discharge line is restricted or more than 1 16 carbon build up is found replace the discharge line See Table A column 2 on page A 3 for recommended size Replace as necessary gt The discharge line must maintain a constant slope down from the compressor to the air dryer inlet fitting to avoid low points where ice may form and block the flow If instead ice blockages occur at the air dryer inlet insulation may be added here or if the inlet fitting is a typical 90 degree fitting it may be changed to a straight or 45 degree fitting For more information on how to help prevent discharge line freeze ups see Bendix Bulletins TCH 008 021 and TCH 008 022 Appendix B Shorter discharge line lengths or insulation may be required in cold climates gt Check compressor air inlet line for restric tions brittleness soft or sagging hose conditions etc Repair as necessary Inlet line size is 3 4 ID Maximum restriction requirement for compressors is 25 inches of water gt Check the engine air filter and service if necessary if possible check the air filter usage indicator Check If a maintained Bendix PuraGuard system filter or Bendix PuraGuard QC oil coalescing filter is installed call 1 800 AIR BRAKE 1 800 247 2725 and speak to a Tech Team member A 7 Symptom W
60. pressed air is above the normal range oil as oil vapor is able to pass through the air dryer and into the air system Larger diameter discharge lines and or longer discharge line lengths can help reduce the temperature The discharge line must maintain a constant slope down from the compressor to the air dryer inlet fitting to avoid low points where ice may form and block the flow If instead ice blockages occur at the air dryer inlet insulation may be added here or if the inlet fitting is a typical 90 degree fitting it may be changed to a straight or 45 degree fitting For more information on how to help prevent discharge line freeze ups see Bendix Bulletins TCH 008 021 and TCH 008 022 see pages A 19 21 Shorter discharge line lengths or insulation may be required in cold climates The air dryer contains a filter that collects oil droplets and a desiccant bed that removes almost all of the remaining water vapor The compressed air is then passed to the air brake service supply reservoir The oil droplets and the water collected are automatically purged when the governor reaches its cut out setting For vehicles with accessories that are sensitive to small amounts of oil we recommended installation of a Bendix PuraGuard system filter designed to minimize the amount of oil present The Air Brake Charging System supplies the compressed air for the braking system as well as other air accessories for the vehicle The system usu
61. r 11 from the front of the crankcase Use a sharp flat head screw driver or a scraper Place the edge under the lip along the outside diameter of the cover Pry the cover from the cast surface until the cover can be removed REAR END COVER 1 Note There are two cap screws used to retain the end cover to the crankcase There are two longer cap screws not shown in Figure 10 that are used to retain the auxiliary drive unit i e hydraulic pump via the end cover and torqued into the crankcase If the auxiliary drive unit has already been removed these two cap screws are no longer present on the end cover Refer to Figure 9 to see location of the cap screws in the end cover 2 Remove the two end cover cap screws that secure the rear end cover to the crankcase 3 Remove the rear end cover from the crankcase Remove and discard the o ring 10 from the end cover CLEANING OF PARTS GENERAL All parts should be cleaned in a good commercial grade of solvent and dried prior to inspection CRANKCASE 1 Carefully remove all sealant gasket material adhering to the machined face of the crankcase See Figure 3 Make certain not to scratch or mar the mounting surface Note Keep the crankcase opening covered to prevent any of the sealant material from entering Repeat this process on the engine mounting face as well Follow the instructions contained in the vehicle maintenance manual in lieu of the instructions and procedures presented i
62. ressor 2 0 A 5 Safety valve releases air 11 0 A 11 At the air dryer purge exhaust Noisy 18 0 s A 13 FSO CUNO MER A Paraan is Reservoir In the supply reservoir 4 0 A 6 8 i At the valves 5 0 A 8 volg Neel a ID erase As At air dryer cartridge 7 0 A 9 In the ping tank or compressor discharge aftercooler 8 0 Maintenance amp Usage Guidelines 1 Maintenance Schedule and ie are Bodo Usage Guidelines Table A A 3 3 Compressor Discharge and Oil Leakage at Head Gasket Air Dryer Inlet Temperature 4 Governor Malfunction 5 Governor Control Line 6 Compressor Unloader BASIC Test Information Introduction to the Air Brake Charging System Powered by the vehicle engine the air compressor builds the air pressure for the air brake system The air compressor is typically cooled by the engine coolant system and lubricated by the engine oil supply The compressor s unloader mechanism and governor along with a synchro valve for the Bendix DuraFlo 596 air compressor control the brake system air pressure between a preset maximum and minimum pressure level by monitoring the pressure in the service or supply reservoir When the air pressure becomes greater than that of the preset cut out the governor controls the unloader mechanism of the compressor to stop the compressor from building air and also c
63. s NOTE There are two short bolts and four long bolts Be sure the use the proper length bolt for the crankcase bolt holes Run each of the bolts down finger tight making sure not to smear the liquid gasket material on the sealing surface Once the bolts are all finger tight tighten the mounting bolts per Engine Manufacturers recommended torquing sequence and torque requirements Install any supporting brackets on the compressor in the same position s noted and marked during removal Inspect all air and coolant lines and fittings before reconnecting them to the compressor Make certain o ring seals are in good or new condition the threads are clean and the fittings are free of corrosion Replace as necessary Install the discharge and coolant fittings if applicable in the same position on the compressor noted and marked during disassembly See the Torque Specifications for various fitting sizes and types of thread at the rear of this manual Tighten all hose clamps Before returning the vehicle to service perform the Service Tests specified in this manual Pay particular attention to all lines and hoses disconnected during maintenance and check for air oil and coolant leaks at compressor connections and the compressor engine interface Also check for noisy operation Sequence Torque Sequence Torque Nem FIGURE 11 CLOSED ROOM COMPRESSOR HEAD BOLT TORQUE SEQUENCE BA 921 COMPRESSOR SPECIFICATIONS ALL TYPICAL W
64. serve the dash gauges for two additional minutes without the service brakes applied four minute test to see if leakage 2 Apply service brakes for two minutes allow pressure to stabilize and observe the dash is a problem with the vehicle gauges being tested If you see any noticeable decrease of the dash air gauge readings repair leaks Repeat this test to confirm that air leaks have been repaired and return vehicle to service Please repeat BASIC test at next service interval Note Air leaks can also be found in the charging system parking brakes and or other components inspect and repair as necessary If no air leakage was detected and if you are conducting this test after completing Step C go to Step E The Technician only reaches Me S L d Step E if the amount of oil STEP E If no air leakage was detected in Step D found orine anouneol ine since the air tanks were last drained exceeds the acceptance Note If the compressor is within warranty period level AND the vehicle passes the four minute leakage test please follow standard warranty procedures Attach no noticeable leakage was the completed checklist to warranty claim detected 3 Replace the compressor A 18 Appendix C Technical Bulletin Pene Bulletin No TCH 008 021 Effective Date 3 5 2010 Cancels PRO 08 21 dated 2 6 2008 Page 1 of 2 Subject Air Brake System Cold Weather Operation Tips As the cold weather approaches operators and fl
65. t sleeve main bearing via an oil passage in the crankshaft routes pressurized oil to the connecting rod bearings and the rear journal associated with the end cover Spray lubrication of the cylinder bore and connecting rod wrist pin bushing is obtained as oil is forced out around the crankshaft journals by engine oil pressure Oil then falls to the bottom of the compressor crankcase and is returned to the engine through the opening at the compressor mounting flange Air Inlet Discharge Valve Unloader PS SN NO AS Unloader Piston Down amp Seated Piston Moving Up FIGURE 5 OPERATION LOADED COMPRESSION Air From Governor Ky Pen Port SS TTT TLL IN B Voas EID s nn 3 ASAA NN NN NN S M M 7 Closed Unloader Piston Up amp Unseated Air in Pistons Shuttles Back and Forth from the Piston to the Closed Room FIGURE 6 OPERATION UNLOADED Discharge Safety Valve Coolant In or Out Discharge Port Coolant ea In or Out 3 f Governor A Lon Connection Unloader Cover CYLINDER HEAD PORT IDENTIFICATION The cylinder head connection ports are identified with cast in numerals as follows AIR IN Compressed AIR OUT Coolant IN or OUT Governor Control FIGURE 7 BENDIX BA 921 SMC COMPRESSOR CYLINDER HEAD COOLING The Bendix BA 9219 SMC compressor is cooled by air flowing through the engine compartment as it passes the compressor s cast in cooling
66. the normal range go to Symptom 4 0 c Also see the Table A on page A 3 column 3 for recommended air dryer cartridge replacement schedule Go to Test 2 on page A 14 gt See Table A column 1 on page A 3 for recommended compressor sizes gt If the compressor is too small for the vehicle s role for example where a vehicle s use has changed or service conditions exceed the original vehicle or engine OE spec s then upgrade the compressor Note The costs incurred e g installing a larger capacity compressor etc are not covered under original compressor warranty gt If the compressor is correct for the vehicle go to Symptom 4 0 e 19 Symptom 4 0 Oil in Supply or Service Reservoir air dryer installed continued Testing the temperature at the discharge fitting What it may indicate Temperature e Air compressor discharge and or air dryer inlet temperature too high f Insufficient coolant flow Inspecting the coolant hoses g Restricted discharge line Kinked discharge line shown Other h Restricted air inlet not enough air to compressor Partly collapsed inlet line shown What you should do gt Check temperature as outlined in Test 3 on page A 14 If temperatures are normal go to 4 0 h Inspect coolant line Replace as necessary I D is 1 2 gt Inspect the coolant lines for kinks and restrictions and fittings for restrictions Re
67. ufacturer 10 Prior to returning the vehicle to service make certain all components and systems are restored to their proper operating condition 11 For vehicles with Automatic Traction Control ATC the ATC function must be disabled ATC indicator lamp should be ON prior to performing any vehicle maintenance where one or more wheels on a drive axle are lifted off the ground and moving REMOVAL In many instances it may not be necessary to remove the compressor from the vehicle when installing the various maintenance kits and service parts The maintenance technician must assess the installation and determine the correct course of action These instructions are general and are intended to be a guide In some cases additional preparations and precautions are necessary In all cases follow the instructions contained in the vehicle maintenance manual in lieu of the instructions precautions and procedures presented in this manual 1 Block the wheels of the vehicle and drain the air pressure from all the reservoirs in the system 2 Drain the engine cooling system and the cylinder head of the compressor Identify and disconnect all air water and oil lines leading to the compressor 3 Remove as much road dirt and grease from the exterior of the compressor as possible 4 Remove the discharge fitting if applicable and note their position on the compressor to aid in reassembly 5 Remove any supporting bracketing attached to the
68. water Change air dryer cartridge Test for air leakage END TEST Re test with the BASIC Test after 30 days END TEST END TEST f the number of days since the air tanks were drained is unknown use the 30 day line Note Typical air dryer cartridge replacement schedule is every 3 yrs 300K miles for low air use vehicles and every year 100K miles for high air use vehicles To get an accurate reading for the amount of oil collected during a 30 day period ask the customer not to drain the air tanks before returning Note that 30 90 days is the recommended air tank drain schedule for vehicles equipped with a Bendix air dryer that is properly maintained If in cold weather conditions the 30 day air tank drain schedule is longer than the customer s usual draining interval the customer must determine based on their experience with the vehicle whether to participate now or wait for warmer weather See the cold weather tips in Bulletins TCH 008 021 and TCH 008 022 included on pages A 19 21 of this document Note After replacing a compressor residual oil may take a considerable period of time to be flushed from the air brake system Appendix B continued Information about the BASIC Test Kit Bendix P N 5013711 Filing in the Checklist for the Bendix Air System Inspection Cup BASIC Test Note Follow all standard safety precautions For vehicles using a desiccant air dryer The Service Writ
69. which could indicate excessive drive component wear Adjust and or replace as necessary Check all compressor mounting bolts and retighten evenly if necessary Check for leakage Repair or replace parts as necessary COMPRESSOR UNLOADER amp GOVERNOR Test and inspect the compressor and governor unloader system for proper operation and pressure setting 1 Check for leakage at the unloader port Replace leaking Or worn o rings 2 Makecertain the unloader system lines are connected as illustrated in Figure 8 3 Cycle the compressor through the loaded and unloaded cycle several times Make certain that the governor cuts in compressor resumes compressing air at a minimum of 105 psi cut out should be approximately 15 20 psi greater than cut in pressure Adjust or replace the governor as required 4 Note that the compressor cycles to the loaded and unloaded conditions promptly If prompt action is not noted repair or replace the governor and or repair the compressor unloader IMPORTANT NOTE Replacement air governors must have a minimum cut in pressure of 100 psi The cut in pressure is the lowest system pressure registered in the gauges before the compressor resumes compressing air Compressors with no signal line to the unloader port should have a vent cap e g Bendix P N 222797 installed in the port Under no circumstances should the port be plugged or left open SERVICE TESTS GENERAL The compressor operating and
70. without the service brakes applied Step 2 Apply the service brakes and allow the pressure to stabilize Continue holding for two minutes you may use a block of wood to hold the Test 3 Air Compressor Discharge Temperature and Air Dryer Inlet Temperature Caution The temperatures used in this test are not normal vehicle conditions Above normal temperatures can cause oil as vapor to pass through the air dryer into the air brake system This test is run with the engine at normal operating temperature with engine at max rpm If available a dyno may be used Allow the compressor to build the air system pressure to governor cut in Pump the brakes to bring the dash gauge pressure to 90 psi Allow the compressor to build pressure from 95 to 105 psi gauge pressure and maintain this pressure range by cycling the brakes for five 5 minutes Discharge Line A 14 pedal in position Observe the dash gauges If you see any noticeable decrease of the dash air gauge readings i e more than 4 psi plus two psi for each additional trailer during either two minute test repair the leaks and repeat this test to confirm that they have been repaired Air leaks can also be found in the charging system parking brakes and or other components inspect and repair as necessary Note that only vehicles that have passed Test 2 would be candidates for this test 4 Then while maintaining max rpm and pressure range measure and recor

BENDIX BW2827 User's Manual

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