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BENDIX BW2664 User's Manual

1. Is the point above the HIGH Air Use line on the cup Is the point above the LOW Air Use line on the cup Test for air leakage Vehicle OK Return vehicle to service YES Repair leaks and the vehicle have excessive air leakage return vehicle to END TEST service NO NO did not know when last drained Was the number of days since last draining known YES number of days was known 30 90 days Re test with the BASIC Test after 30 days END TEST 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 C Test Kit Bendix P N 5013711 Bendix Air System Inspection Cup BASIC Test Information Vehicle OK END TEST Return vehicle to service Cloudy emulsion mixture De 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 im Sine the vehicle s air tanks Go to the Advanced Troubleshooting LDF Change air dryer cartridge Guide to find reason s for presence of water Test for air leakage Use Test 2 END TEST Re test with th
2. SD 01 3121 BENDIX 360CC SINGLE CYLINDER COMPRESSOR FOR INTERNATIONAL 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 360cc compressor is a single cylinder compressor with a rated displacement of 15 8 cubic feet per minute at 1250 RPM The compressor consists of an integral water cooled cylinder head assembly and water cooled crankcase The cylinder head assembly is made up of an aluminum cylinder head an aluminum cooling plate and a steel valve plate assembly with two sealing gaskets The cylinder head contains air and water ports The cooling plate situated between the head and valve plate assists in cooling the head assembly The valve plate assembly consisting of brazed steel plates has separate valve openings and passages to allow air and coolant to flow in and out of the compressor See Figure 1 for an external view and Figure 3 for an exploded view The compressor is equipped with a safety valve in the cylinder head safety valve port directly connected to the discharge port The safety valve protects the compressor head in the event of excessively high discharge line pressure for example in the event of blockage downstream of the compressor Excessive air pressure causes the Safety valve to unseat releases air pressure and gives an audible alert to the operator The comp
3. 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 DuraF lo 596 air compressor not only the governor but also the SV 1 synchro valve used would need to be tested See Bulletin TCH 001 048 11 0Compressor 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 Go to Test 4 on page A 15 gt See 9 0 f Replace air dryer heater Replace the compressor only after making certain the preceding conditions do not exist gt If discharge line is restricted By more than 1 16 carbon build
4. A 20 Appendix C Continued Bulletin No TCH 008 021 Effective Date 11 1 92 Page 2 of 2 High Duty Cycle Vehicles City Transit Coaches Refuse Haulers Etc The maximum discharge line length is 16 feet Length LD min Other Requirements 10 16 ft y in None If the discharge line length must be less than 10 feet or greater than 16 feet contact your local Bendix representative 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 more moisture into the brake system Reservoir Draining System Without Air Dryer Routine reservoir draining is the most basic step although not completely effective 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 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
5. 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 Technical Bulletin _ A 21 Appendix E Application Matrix for Bendix 360cc Single Cylinder and 720cc Twin Cylinder Compressors for International Maxxforce Big Bore Engines This useful Compressor Application Guide is a simple point system using vehicle configuration and vocation options to help calculate the Bendix compressor right for your vehicle Review items 1 13 fill in the applicable points on each line then refer to the application grid on the next page for the Bendix compressor selections that can meet your vehicle s intended use When completing the worksheet if a particular entry is not valid for your application enter zero on that line See the examples of how to use this calculator at the end of the next page Vehicle Configuration Points 1 Vehicle is equipped with bulk offloading or central tire inflation See Note 1 2 For every axle tractor amp trailer including lifts Add 1 0 point axle 3 For each non steerable lift axle additional points Add 1 0 point axle 4 For each steerable lift axle additional points Add 0 5
6. 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 on page A 3 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 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 EACH 50 000 MILES WHICHEVER OCCURS FIRST PERFORM THE FOLLOWING INSPECTIONS AND TESTS AIR INDUCTION A supply of clean air is one of the single most important factors in compressor preventive maintenance Since the air Supply for 360cc Single Cylinder 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 Inspectthe 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 Inspectthe intake hose orline forsigns ofdrying cracking chafing and ruptures and replace if necessary 4 Inspect the compressor s cast inlet tube for physical damage COMPRESSOR COOLING Inspect the c
7. or BASIC kitto 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 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 CHARGING SYSTEM UNLOADING amp GOVERNOR Note The 360cc DLU style single cylinder compressor does not contain components to unload the compressor Therefore the compressor pumps continuously In most systems supplied by International a turbo cut off style air dryer governor and discharge line unloader valve are used to unload the system i e air is not being delivered to the brake system reservoirs When system unloading occurs air from the compressor will flow out the exhaust port of the discharge line unloader valve Refer to Figure 6 Test and inspect the unloading system i e air dryer and governor for proper operation and pressure settings 1 Make certain the unloader system lines illustrated in Figure 6 are connected and leak free 2 Cycle the charging system between the loaded and unloaded mode several times This can be achieved by applying the brakes to bleed down the system pressure Make certain that the governor cuts in charging system resumes compressing air at a minimum of 105
8. 3 and discharge safety valve 2 from the cylinder head 15 2 Remove the four hex head bolts 1 from the cylinder head 15 3 Gently tap the cylinder head 15 cooling plate 14 and valve plate assembly 13 with a soft mallet to break the gasket seal between the valve plate assembly 13 and the crankcase Lift the cylinder head 15 with cooling plate 14 and valve plate assembly 13 off the crankcase 4 Remove the metal inlet reed valve gasket 5 5 Remove the crankcase o ring 12 from a countersunk hole on the crankcase 11 deck 6 Gently tap the cylinder head 15 cooling plate 14 and valve plate assembly 13 with a soft mallet to break the gasket seals Then separate the cylinder head 15 from the cooling plate 14 and valve plate assembly 13 and remove and discard the two head gaskets 4 between them 2 ST 4 Safety Valve 3 Washer 1 Head Cap Screws 4 include washers 15 Cylinder Head 4 Head Gasket 2 14 Cooling Plate 13 Valve 5 Inlet Reed Valve Gasket Plate Assembly 6 Crankcase Alignment 12 Crankcase O ring Pins x2 11 Crankcase 7 Cap Screws amma VA ra 10 Cover 8 End Cover T R a Head Cap Screws Kit2 FIGURE 8 360cc SINGLE CYLINDER COMPRESSOR EXPLODED VIEW 8 Kit Notes Kit 1 Discharge Safety Valve Kit K026807 Kit 2 Compressor Seal Kit K026809 CRANKCASE FRONT COVER
9. Operating condition For vehicles with Antilock 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 notuse this card testto 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 A 16 for a flowchart and expanded 7 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 athead gasket b Leak at bottom cover plate c Leak at internal rear flange gasket d Leak through crankcase e If un
10. for daily reservoir draining is eliminated through the use of an automatic drain valve periodic manual draining is still required Alcohol Evaporator or Injector Systems Check for proper operation of these systems by monitoring alcohol consumption for a few days Reference Service Data Sheet S D 08 2301 for the Bendix Alcohol Evaporator Too little means the system is not receiving adequate protection and too much simply wastes alcohol As a general guide these systems should consume approximately 1 to 2 ounces of alcohol per hour of compressor loaded time compressing air City pick up and delivery vehicles will operate with the compressors loaded compressing air more while compressors on highway vehicles will be loaded less These figures are approximate and assume that air system leakage Is within the limits of the Bendix Dual System Air Brake Test and Check List BW1279 Last but notleast begin using alcohol several weeks prior to freezing weather to ensure that the system is completely protected Use only methanol alcohol such as Bendix Air Guard in evaporators or injectors 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 ADeo RIPON les 2 224 6 his dos eked ee oa eee ble ae Service Data Sheet SD 08 2412 ADA Al DIVE casper errs raupa hadd oes oh eee ee 6 Be Service Data Shee
11. sealant material and application procedure Secure the compressor on the engine mounting interface using the 6 mounting bolts NOTE There are 2 Short bolts and 4 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 Operation and Leakage Tests specified in this manual Pay particular attention to all lines and hoses disconnected during the maintenance and check for air oil and coolant leaks at compressor connections and the compressor engine interface Also check for noisy operation 360CC SINGLE CYLINDE
12. air brake system The air compressors typically cooled by the engine coolantsystem and lubricated by the engine oil supply This Bendix 360cc compressor Is a discharge line unloader DLU style compressor meaning that the compressor pumps continuously unlike some compressor designs which use an unloader mechanism in the compressor head to switch from a pumping mode to a non pumping mode Instead the control of air delivery to the vehicle s air system is managed by using a separate discharge line unloader valve mounted in parallel with the compressor a turbo cut off style of air dryer and a governor see Figure below The discharge line unloader valve and governor 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 discharge line unloader valve such that the air from the compressor flows through the exhaust of the discharge line unloader valve and to atmosphere i e preventing air delivery to the reservoirs and also causes the air dryer to purge As the service reservoir air pressure drops to the cut in setting of the governor the governor returns the discharge line unloader valve back to building air mode and the air dryer to air drying mode As the atmospheric air is compressed all the water vapor Origina
13. application Some typical compressor applications Ifthe compressor is too small for the vehicle s role forexample 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 d is not applicable for the OO compressor featured in this SD d Compressor unloader mechanism Go to Test 6 on page A 15 Sheet information is shown malfunction for reference only _ TT e Damaged compressor head gt 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 details and then replace the compressor Do not re use the safety valve without testing See Symptom 12 0 a gasket Symptom What it may indicate 9 0 Air brake f Restricted discharge line charging system seems slow to 2 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 3 g Restricted air inlet not enough air to compressor Check Partly collapsed l l
14. cccceeeeeeeeeeees A 11 Air dryer Doesn t purge 14 0 A 12 Safety valve releases air 12 0 A 12 Compressor Constantly cycles 15 0 2 A 12 Leaks air 16 0 A 13 Safety valve releases air 11 0 A 11 Noisy 18 0 suscuccndnctiaseamansiinncoeed avec A 13 Reservoir Safety valve releases air 13 0 A 12 1 Oil Leakage at Head Gasket 2 System Leakage 3 Compressor Discharge and Air Dryer Inlet Temperature 4 Governor Malfunction 5 Governor Control Line 6 Compressor Unloader BASIC Test Information Symptom Page Number Symptom Page Number Coolant Compressor leaks coolant 17 0 000 A 13 Engine Oil consumption 6 0 sissies sivcvenoorenacansieaciionnceats A 9 Oil Oil Test Card results 1 0 A 4 Oil is present On the outside of the compressor 2 0 A 5 At the air dryer purge exhaust Or Surrounding area 3 0 ccccseeeeee A 5 In the supply reservoir 4 0 00ccceee A 6 8 At the valves 5 0 ccccccccecseseeeeeeeeeeeeeeeeees A 8 At air dryer cartridge 7 0 c cccseeeeeees A 9 In the ping tank or compressor discharge aftercooler 8 0 ccccceeee Maintenance Schedule and Usage Guidelines Table A Advanced Troubleshooting Guide for Air Brake Compressors A 1 Introduction to the Air Brake Charging System Powered by the vehicle engine the air compressor builds the air pressure for the
15. diameter of the cover is flush with cast surface REAR END COVER 1 Install the o ring 9 on the rear end cover 2 Orient the rear end cover 8 to the crankcase 11 using the reference marks made during disassembly Carefully install the rear end cover in the crankcase 11 making certain not to damage the crankshaft bearing Surface 3 Installthe two end cover cap screws 7 Refer to Figure 9 to assure that the two cap screws 7 are installed in 10 the proper crankcase 11 boltholes Snug the screws then tighten to 195 to 212 inch pounds 22 24 Nm CYLINDER HEAD COOLING PLATE amp VALVE PLATE ASSEMBLY 1 Install the crankcase o ring 12 into the slightly countersunk hole on the deck of the crankcase 2 Note the position of the protruding crankcase 11 alignment pins on the deck top of the crankcase Install the metal inlet reed valve gasket 5 over the alignment pins on the crankcase being careful not to disturb the crankcase o ring 12 3 Position the valve plate assembly 13 on the crankcase 11 so that the alignment pins in the crankcase fit into the corresponding holes in the valve plate assembly 13 4 Position one of the embossed metal head gaskets 4 over the alignment bushings protruding from the cooling plate 14 Position the second embossed metal head gasket over the alignment bushings on the opposite side of the cooling plate 14 When properly positioned the outline of the two em
16. i inlet line shown h Poorly filtered inlet air poor air quality to compressor Check i Compressor malfunction Check A 10 What you should do gt If discharge line is restricted 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 instead ice blockages occur atthe 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 TC H 08 21 and TCH 08 22 Appendix B Shorter discharge line lengths or insulation may be required in cold climates Check compressor air inlet line for restric tions brittleness softor sagging hose con ditions etc Repairas 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
17. 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 testthe compressor performance Ifthe 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 S5 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 idle instead of maximum governed Speed and record the time taken to raise the system pressure to a Selected range for example from 90 to 120 psi or from 100 to 120 psi etc and record itin 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 in the investigation of the cause s Note When comparing build up times be sure to make an
18. 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 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 a
19. 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 Step E if the amount of oil STEP E If no air leakage was detected in Step D found orte amoun oime 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 Sendy Bulletin No TCH 008 021 Effective Date 11 1 92 Page 1 of 2 Subject Air Brake System Cold Weather Operation Tips As the cold weather approaches operators and fleets 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
20. 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 21 and TCH 008 22 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 Filling 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 of oil found 3 Action to tanks were last drained take The Technician uses the chart label on the BASIC Y test cup to help decide the action to take based on the amount of oil found Use the lower acceptance yY yY line for low air use vehicles and upper line for high If number of days is Fee ik ee System OK air use vehicles from Step A 30 60 days high air i of days gt Y Return to services use or 30 90 days low air if oil level is above a acceptance line for number Go to Step D gt of days gt if oil l
21. 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 Fitting extensions must be avoided Recommended discharge line lengths and inside diameters are dependent on the vehicle application and are as follows Typical P amp D School Bus and Line Haul The maximum discharge line length is 16 feet Length I D Min Other Requirements 6 0 9 5 ft Yin None 9 5 12 ft in Last 3 feet including fitting at the end of the discharge line must be insulated with inch thick closed cell polyethylene pipe insulation 12 16 ft 5 8 in Last 3 feet including fitting at the end of the discharge line must be insulated with 1 2 inch thick closed cell polyethylene pipe insulation If the discharge line length must be less than 6 feet or greater than 16 feet contact your local Bendix representative A 19
22. 1 Remove the cover 10 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 2 cap screws 7 used to retain the end cover to the crankcase There are 2 longer cap screws not shown in Figure 9 that are used to retain the auxiliary drive unit i e hydraulic pump via the end cover and torqued into the crankcase Ifthe auxiliary drive unit has already been removed these two cap screws are no longer present on the end cover Refer to Figure 10 to see location of the cap screws 7 in the end cover 2 Remove the 2 end cover cap screws 7 that secure the rear end cover to the crankcase 3 Remove the rear end cover 8 from the crankcase Remove and discard the o ring 9 from the end cover 8 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 11 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 inst
23. 807 Discharge Safety Valve Kit K026809 Compressor to Engine Mounting Face Sealant eee ee se ee Supplied by the Engine Manufacturer IMPORTANT PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO AVOID PERSONAL INJ URY 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 2 Stop the engine and remove ignition key when working under or around the vehicle When working in the engine compartment the engine should be shut off and the ignition key should be removed Where circumstances require that the engine be in operation EXTREME CAUTION should be used to prevent personal injury resulting from contact with moving rotating leaking heated or electrically charged components 3 Do not attempt to install remove disassemble or assemble a component until you have read and thoroughly understand the recommended procedures Use only the proper tools and observe all precautions pertaining to use of those tools 4 If the work is being performed on the vehicle s air brake system or any auxiliary pressurized air systems make ce
24. Go to Test5 on page A 15 gt Go to Test 4 on page A 15 gt Verify relief pressure is at vehicle or component manufacturer s specifications typically 150 psi Replace if defective U Go to Test 4 on page A 15 U Go to Test 6 on page A 15 U Verify operation of air dryer Follow vehicle O E maintenance recommendations U Go to Test 4 on page A 15 U Go to Test 2 on page A 14 v Go to Test 5 on page A 15 gt 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 gt Go to Test 6 on page A 15 gt Verify operation of air dryer Follow vehicle O E maintenance recommendations and component Service Data information gt Go to Test 2 on page A 14 Symptom What it may indicate What you should do a Compressor leaks airatconnections 16 0 Compressor leaks air or ports b is not applicable for the compressor featured in this SD Sheet information is shown for reference only malfunction c Damaged compressor head gasket s Head gasket locations s ee Testing for leaks with Soap solution x f i i e bi R 71 Ca A i r 4 L gi 17 0 Compressor leaks coolant line fittings b Damaged compressor head gasket c Porous compressor head casting 18 0 Noisy a Damaged compressor 6 Compressor unloader mechanis
25. R COMPRESSOR SPECIFICATIONS Typical weight Number of cylinders oaoa a ae 1 Bore Diameter 3 622 IN 92 MM Stroke naaa cab eh ee wes 2 126 IN 54 MM Calculated displacement at 1250 RPM 15 8 CFM Flow Capacity 1800 RPM amp 120 PSI 14 5 CFM Flow Capacity 3000 RPM amp 120 PSI 23 1CFM Approximate horsepower required Loaded 1800 RPM at120PSIG 5 2 HP Loaded 1800 RPM atOpsig DLU 2 7 HP Minimum coolant flow at maximum RPM 2 64 GPM 10 LPM Maximum coolanttemperature 203 F 95 C reki 122 F 50 C Maximum inlet air temperature Maximum system pressure 150 PSI Minimum oil pressure required TORQUE SPECIFICATIONS Assembly Torques M8x1 25 6g Cylinder Head Bolts 265 292 In Lbs 30 33 Nm M10x1 5 End Cover Bolts 195 to 213 In Lbs 22 24 Nm M26x1 5 Safety Valve 59 66 ft Ibs 80 90 Nm Maximum M26x1 5 Discharge PortFittings 66 ft Ibs 90 Nm Maximum 33 ft Ibs 45 Nm Maximum M16 x 1 5 6H Water Port Fittings 11 12 Notes Appendix A 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 Air Air brake charging system Slow DUNG 9 0 osonni aaa A 9 10 Doesn t build air 10 0
26. Service Reservoir Rear Service Reservoir Table A Maintenance Schedule and Usage Guidelines Regularly scheduled maintenance is the single most important factor in maintaining the air brake charging system Recom Recom Acceptable Typical Discharge mended mended Reservoir _ of Compressors Line Air Dryer Reservoir Oil Contents Vehicle Used for Axles Spec d Cartridge Drain at Regular Replacement Schedule Drain Intervals Low Air Use acceptable e g Line haul single trailer 5 pe eo E se a w o air suspension air over pone Recom nge hydraulic brakes less sat mended 3 oil units in aa Every 3 Every per month See A di Years Month occ e g Line haul single trailer 5 E for Engine every 90 A with air suspension RV or a a nets days ication school bus less pp upgrades CE le Matrix for 5 8in 12 ft For the BASIC High Air Use Bendix 360cc Single Compressor with up to 25 duty cycle e g Double triple trailer open highway coach most pick up amp delivery yard or terminal jockey off highway construction loggers concrete mixer dump truck fire truck Or less ETS cs s N RE oe Yh Cylinder and 720cc Two Cylinder Compressors Every 2 For oil carry over Years control suggested upgrades Bye is S ii Test Kit Order Bendix P N 5013711 BASIC test acceptable range Every 5 oil units Month per month See ap
27. able 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 If the mounting bolt torques are low replace the gasket gt Replace the fitting gasket Inspect inlet hose and replace as necessary Replace gasket or fitting as necessary to ensure good seal gt Inspect and repair as necessary gt Go to Test 1 on page A 14 gt Reseal bottom cover plate using RTV Silicone sealant gt Replace compressor gt Replace compressor Clean compressor and check periodically Check 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 A 6 Symptom 4 0 Oil in Supply or Service Reservoir air dryer installed Ifa 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 l See Table A on page A 3 for maintenance schedule information What it may indicate Maintenance a I
28. 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 15 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 5 be tested separately Refer to the various maintenance manuals for individual component leakage tests and the Bendix Test and Checklist published in the Air Brake System Handbook BW5057 and on the back of the Dual Circuit Brake System Troubleshooting Card BW1396 CYLINDER HEAD Check the cylinder head gaskets for 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 two gaskets between the cylinder head and the valve plate assembly and the inlet reed valve gasket between the valve plate assembly and crankcase for air leakage 2 No leakage is permitted If leakage is detected replace the compressor or repair the cylinder head using the maintenance kit available from an authorized Bendix parts outlet INLET amp DISCHARGE VALVES In order to test the inlet and discharge valves itis necessary to have shop air pressure and an assortment of fittings A Soap sol
29. amage If detected the compressor mustbe replaced If large amounts of carbon build 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 14 for deep gouges and nicks Also inspect the cooling plate for any cracks or other damage If damage is found the compressor must be replaced 3 Carefully inspect the valve plate assembly 13 gasket Surfaces both sides for deep gouges and nicks Pay particular attention to the gasket surface An inlet reed valve gasket 5 is used between the valve plate assembly 13 and crankcase These gasket surfaces 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 REAR END COVER Visually inspect for cracks and external damage Check the crankshaft rear bearing diameter in the rear end cover 8 for excessive wear flat spots or galling Check the hydraulic pump attachment pilot and threaded holes for 9 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
30. 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 testis run with the engine atnormal operating temperature with engine at max rom If available a dyno may be used 1 Allow the compressor to build the air system pressure to governor cut in 2 Pump the brakes to bring the dash gauge pressure to 90 psi 3 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 Discharge 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 record the surface temperature of the fittings atthe compressor discharge port T1 gt atthe air dryer inlet fitting T2 Usea touch probe thermocouple for measuring the temperature See table below Re test before returning the vehicle to Service Action Fitting Tempera
31. bossed gaskets match the outline of the cooling plate 5 Install the cooling plate with the head gaskets 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 assembly 6 Position and install the cylinder head 15 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 To assist with correct installation the alignment bushings only fit into two of the four cylinder head bolt holes 7 Install the four hex head cylinder head bolts 1 and snug them then tighten evenly to a torque of 265 to 292 inch pounds 30 33 Nm using a crossing pattern 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 8 Install the washer 3 and safety valve 2 in the top port 2 discharge port of the cylinder head 15 then tighten to a torque of 59 to 66 foot pounds 80 90 Nm 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
32. ciated 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 8 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 dirtand grease from the exterior of the compressor with a cleaning solvent Ifthe rear end cover 8 is being removed from the compressor being worked on mark it and the 2 cap screws 7 in relation to the crankcase It is also recommended to mark the relationship of the cylinder head 15 cooling plate 14 valve plate assembly 13 and crankcase A convenient method to indicate the above relationships is to use a metal scribe to mark the parts with numbers orlines Do notuse 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 COOLING PLATE amp VALVE PLATE ASSEMBLY 1 Remove the washer
33. e BASIC Test after 30 days END TEST END TEST If 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 FTO getan accurate reading for the amountof oil collected during a 30 day period ask the customer not to drain the airtanks 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 21 and TCH 008 22 included on pages A 19 21 of this document AN ote 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 Filling 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 Writer fills out these fields with information gained from the customer Number of Days Since Air Tanks Wer
34. e Haul Application Vehicle Configuration 1 NotApplicable 2 Total number of all axles 3 points 3 Total number of non steerable lift axles 0 points 4 Total number of steerable lift axles 0 points 5 Tractor is equipped with air suspension 5 point Vocation Options A typical single axle line haul vehicle 6 7 8 9 10 11 12 Not Applicable 0 points e Air Suspension Total 3 0 5 3 5 points e Three 3 axles total Selection Bendix 360cc Air Compressors Example 2 Line Haul Pulling Single Axle Double Vehicle Configuration 1 NotApplicable 2 Total number of all axles 5 points 3 Total number of non steerable lift axles 0 points 4 Total number of steerable lift axles 0 points 5 Tractor is equipped with air suspension 5 point A 4x2 line haul vehicle pulling Vocation Options e 2 single axle trailers 6 7 8 9 10 11 12 Not Applicable 0 points e 1 single axle dolly e Tractor air Suspension Total 5 0 5 5 5 points e Five 5 axles total Selection Bendix 360cc Air Compressors Example 3 Bulk Gravel Hauler Vehicle Configuration 1 NotApplicable 2 Total number of all axles 7 points 3 Total number of non steerable lift axles 2 points 4 Total number of steerable lift axles 0 points 5 Tractor is equipped with air suspension 5 point Vocation Options A bulk gravel hauling vehicle 6 7 8 9 10 12 13 Not Applicable 0 points 11 Vehicle is used as a dum
35. e 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 Please check all that apply y Relay valve leaks oil O malfunctions Q no U yes 7 The Service Writer Dash valve U leaks oil Q malfunctions Li no Q yes The Technician also checks off any Q Air dryer leaks oil LI no U yes checks boxes it complaints that the 0 Governor malfunction LI no U yes for any of the customer makes to B eae m L no U yes complaints that help the Technician Q Oil on ground or vehicle exterior OnoUyes CaN DG GOMIMEN In investigating amount described Q Short air dryer cartridge life replaces every L miles L kms or LJ months Note A confirmed complaint Q 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 LI Excessive engine oil loss amount described replaced Is the engine leaking oil 0 no 0 yes The full BASIC test below will investigate the facts Is the compressor leaking oil LI no U yes LJ Other complaint LI No customer complaint SPN OM ran STEP A Selectone The Technician selects the air use os category for the vehicle This decides Q This is a low air use vehicle Li
36. e air from the compressor to flow out the exhaust port of the air dryer Note The 360cc compressor Is a discharge line unloader Style unit This means that the compressor functions in a continuous pumping mode regardless whether the brake DLU Valve S Governor Q Compressor system requires air It requires a downstream device e g turbo cut off style air dryer and discharge line unloader valve to unload the system when the air system has Sufficient stored compressed air 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 front sleeve main bearing and 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 COOLING The 360cc Single Cylinder Compressor is cooled by air flowin
37. ee Figure 6 MAXXFORCE _ is a trademark of International Engine Intellectual Property Company LLC Cylinder Head E Cooling Valve Plate Assembly Piston Crankcase Nameplate Crankshaft Plate Connecting Rod Mounting Face FIGURE 3 BENDIX 360cc SINGLE CYLINDER COMPRESSOR CUT AWAY VIEW 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 crankcase houses the piston assembly connecting rod crankshaft and related bearings O rings are located in the countersunk holes one on each side on the crankcase deck to seal the coolant passage between the crankcase and valve plate 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 a downstream component such as a discharge line unloader valve or an air dryer without turbo cut off valve operating in conjunction with a 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 pis
38. ehicle can be returned to ser vice 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 amountof oil found Is within the acceptable level gt If within the normal range return the vehicle to service For vehicles with acces sories that are sensitive to small amounts of oil consider a Bendix PuraGuard QC oil coalescing filter gt If outside the normal range go to Symp tom 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 See Table A column 1 on page A 3 for recommended compressor sizes gt Ifthe compressor is too small for the vehicle s role for example where a vehicle s use has changed or service condi tions 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 If the compressor is correct for the vehicle go to Symptom 4 0 e Symptom 4 0 Oil in Supply or Service Reservoir air dryer i
39. evel is at or below System OK o 30 day acceptance line gt Return to services if the number of daysis Stop inspection unknown or outside the if oil level is above 30 day Test again limits above acceptance line gt satan a 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 Days Since Sa SaS Erang days since the air tanks were drained meets the oil level A Se acephericiaai 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 ie pump excessive amounts of STEP D Air Brake System Leakage Test sian luna spun toother and 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 Observe 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 be gauges ing tested If you
40. f 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 bo If the vehicle maintenance has been performed as recommended in Table A on page A 3 some oil in the reservoirs is normal 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 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 airtanks and check vehicle atnext service interval using the Bendix BASIC test See Table A on page A 3 column 3 and 4 for recommended service sched ule Check Drain all airtanks into Bendix BASIC test cup Bendix Air System Inspection Cup If less than one unit of reservoir contents is found the v
41. g through the engine compartment as it passes the compressor s cast in cooling fins and by the flow of engine coolant through the cylinder head assembly and the water jacket around the cylinder bore of the crankcase Coolant Supplied by the engine cooling system passes through connecting lines into the cylinder head cooling plate valve plate assembly into the crankcase water jacket and returns through the same components out of the coolant outlet port of the cylinder head 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 11 of this manual for specific requirements Air Dryer Front Service Reservoir Rear Service Reservoir FIGURE 6 TYPICAL 360 DLU COMPRESSOR AIR CHARGING SYSTEM Head Bolt 4 Coolant Out Only PortClosed Discharge Port or Safety Inlet Port Discharge Port or Safety Oil Supply UA Coolant In Only CYLINDER HEAD PORT IDENTIFICATION The cylinder head connection ports are identified with castin numerals as follows Compressed AIR OUT CoolantIN Crankcase Port Coolant Out FIGURE 7 360cc SINGLE CYLINDER COMPRESSOR PORT IDENTIFICATION AIR INDUCTION The 360cc Single Cylinder Compressors are only permitted to be naturally aspirated use of engine turbocharger as an air Source is not permitted
42. ir systems make certain to drain the air pressure from all reservoirs before beginning ANY work on the vehicle If the vehicle is equipped with an AD IS air dryer system or a dryer reservoir module be sure to drain the purge reservoir Symptom What it may indicate 1 0 Oil Test Card Nota valid test Look for Y 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 or line containing pressure it may whip Never remove a component or plug unless you are certain all system pressure has been depleted Use only genuine Bendix replacement parts components and kits Replacement hardware tubing hose fittings etc must be of equivalent size type and strength as Original equipment and be designed specifically for such applications and systems Components with stripped threads or damaged parts Should be replaced rather than repaired Do not attempt repairs requiring machining or welding unless specifically Stated and approved by the vehicle and component manufacturer Prior to returning the vehicle to service make certain all components and systems are restored to their proper
43. lly 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 mostof the charging system oil If the temperature of the compressed air is above the normal range oil as oil vapor is able to pass through the air dryer and into the airsystem Larger diameter discharge lines and or longer discharge line lengths can help reduce the temperature The discharge line must maintain a constant slope down f
44. m gt a Improperly installed plugs orcoolant Check for leaking damaged or defective compressor fittings gaskets etc Repair or replace as necessary Go to Test 6 on page A 15 gt An air leak at the head gasket s may indicate 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 Inspect for loose or over torqued fittings Reseal and tighten loose fittings and plugs as necessary If overtorqued fittings and plugs have cracked ports in the head replace the compressor gt Anairleak atthe head gasket may indicate 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 notre use the Safety valve withouttesting See Symptom 12 0 a If casting porosity is detected replace the compressor Replace the compressor compressor Multi cylinder compressors only Other Miscellaneous Areas to Consider This guide attempts to cover most com pressor system problems Here are some rare sources of problems not covered in this guide e Turbocharger leakage oil from leaking turbocharger seals can enter the air compressor intake and give misleading symptoms L
45. ne Haul te SEL Rural or Commercial Refuse Rural or Commercial Refuse Yard or 95 13 Terminal J ockey Residential Refuse with Work Brake 6 5 9 Residential Refuse no Work Brake 95 13 Concrete Mixer Dump Truck 4 Off Highway Construction Logger 360cc Single 720cc Dual any ny ny ny 5 9 a a a 2 526 ee Deg 6 9 5213 6 9 Vv _ em sa fa w pe e m E e Note This compressor application matrix offers directional information when sizing a Bendix compressor for the applicable vehicle vocation Testing should still be performed on the specific application to verify that the compressor remains within the 25 maximum allowable duty cycle This application matrix assumes that all compressor installations use an air induction system that is naturally aspirated The Compressor Installation amp Application Review form explains the methods used to measure the vehicle s duty cycle Compressor Point Totals Selections Bendix 360cc compressor Bendix 720cc comer Ps Points 25 3 4 s 6 lesz e o osi u 2 i r worabove Certification to all applicable vehicle regulations is the sole responsibility of the vehicle manufacturer The application chart is for reference only If your truck tractor does not fall into these guidelines please contact the Bendix Compressor Engineering or Technical Services team at 1 800 AIR BRAKE 35 Appendix E Example 1 Typical Lin
46. ne haul single trailer with 5 or less axles or which of the two acceptance lines on LI 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 Me VENI SnD eee 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 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 Gi CEES yo 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 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
47. nstalled 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 gt Inspectcoolantline Replace as necessary I D is 1 2 gt Inspect the coolant lines for kinks and restrictions and fittings for restrictions Replace as necessary gt Verify coolant lines go from engine block to compressor and back to the water pump Repair as necessary gt 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 preve
48. nt discharge line freeze ups see Bendix Bulletins TCH 08 21 and TCH 08 22 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 conditions etc Repair as necessary Inlet line size is 3 4 ID Maximum restriction requirement for compressors is 25 inches of water 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 Symptom 4 0 Oil in Supply or Service Reservoir air dryer installed continued 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 What it may indicate Other cont i Poorly filtered inlet air poor air quality to compressor Inspect the engine air cleaner j Governor malfunction or setting k Compressor malfunction Bendix compressors are designed to have a dry Sump and the presence of excess oil in the crankcase can lead to oil carryover What you should do Check for leaking damaged or defective compressor air inlet components e g induction line fittings ga
49. ntenance per Maintenance Schedule and Usage Guidelines Table A on page A 3 Return the vehicle to service shut off and charge the unloader port by allowing air pressure to enter the hose and unload the compressor Shut off the air supply and observe the gauge A steady reading indicates no leakage at the unloader port but a falling reading shows thatthe unloader mechanism Is leaking and needs to be serviced Note This Testis not applicable for the compressor featured in this SD sheet information is shown for reference only A 15 Appendix B Information about the BASI 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 g J U Drain contents of ALL air tanks into BASIC cup Is there less than one unit of liquid lt 1 YES NO Is there more than one unit of e water or e cloudy emulsion mixture H20 YES NO only oil Is this a transit vehicle bulk unloader or has more than 5 axles YES this is a high air use vehicle NO this is a low air use vehicle Find the point on the label where the number of oil units meets the number of days msn the vehicle s air tanks were last drained were last drained
50. ompressor discharge port inlet cavity and discharge line for evidence of restrictions and carbon buildup If more than 1 16 of carbon is found thoroughly clean or replace the affected parts In some cases carbon buildup indicates inadequate cooling Closely inspect the compressor cooling system Check all compressor coolant lines for kinks and restrictions to flow Minimum coolantline 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 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 amountof 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 action to be taken In addition Bendix has developed the Bendix Air System Inspection Cup
51. p truck construction 2 points e Two 2 non steerable lift axles Total 7 2 0 5 2 11 5 points e Truck equipped with air suspension e Seven 7 axles total Selection Bendix 720cc Air Compressors Example 4 Fuel Hauler Not Equipped with Bulk Offloading Vehicle Configuration NotApplicable Total number of all axles points oy WwNO l CO Total number of non steerable lift axles point Ol B WN EF Worn Total number of steerable lift axles points Tractor is equipped with air suspension points A fuel delivery vehicle Vocation Options e Air Suspension 6 Vehicle is used as a fuel hauler 1 point e One 1 non steerable lift axle 7 8 9 10 11 12 13 Not Applicable 0 points e Seven 7 axles total Total 7 1 0 5 1 9 5 points Selection choices include Bendix BA 922 Air Compressor Bendix BW 2664 2009 Bendix Commercial Vehicle Systems LLC All Rights Reserved 4 09 Printed in U S A 36
52. pass including minimum levels of tolerance to contamination Symptom What it may indicate What you should do 6 0 Excessive oil A problem with engine or other engine See engine service manual consumption in accessory 5 engine mie enuine Check service manual has more information 7 0 Oil present Airbrake charging system is functioning Air dryers remove water and oil from at air dryer normally the air brake charging system A small cartridge during v Normal amountof oil is normal Check that regular maintenance maintenance is being performed and that the amountof oil in the air tanks reservoirs Oil shown is within the acceptable range shown by the eo BASIC test see also column 5 of Table air dryer A on page A 3 Replace the air dryer cartridge Cartridge as needed and return the vehicle to service 8 0 Oilin ping tank Airbrake charging system is functioning Follow vehicle O E maintenance or compressor dis normally recommendation for these components charge aftercooler Y Normal 9 0 Air brake a Air brake charging system gt Using dash gauges verify that the charging system functioning normally compressor builds air system pressure seems slow to from 85 100 psi in 40 seconds or less with build pressure Y Normal engine at full governed rom Return the vehicle to service b Air brake system leakage Go to Test 2 on page A 14 c Compressor may be undersized for See Table A column 1 on page A 3 for the
53. pendix A Ei Ra International Maxxforce Big Bore e g City transit bus refuse bulk unloaders low boys Engines 3 4 in 12 ft urban region coach central tire inflation 12 Every or year less 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 08 21 and TCH 08 22 included in Appendix B for more information 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 See Appendix E for more an Application Matrix for Bendix 360 and 720 air compressors A 3 Air Brake Charging System Troubleshooting How to use this guide Find the symptom s that you
54. points axle 5 Tractor and or trailer is equipped with air suspension Add 0 5 points gt Vocation Options Select the description that best fits 6 Vehicle is used as a city transit bus See Note 1 add 1 0 point gt e Vehicle without a work brake Add 7 5 points gt 9 Vehicle is used for rural or commercial refuse Add 3 5 points gt 10 Vehicle is used as a yard or terminal jockey Add 7 5 points gt 11 Vehicle is a dump truck a concrete mixer or is used in logging or construction aide oll grannies D 12 Vehicle is a fire truck Fast Fill system See Note 2 Add 6 0 points gt 13 Vehicle is used for line haul Add 0 0 points gt Total Score Add lines 1 13 and use that sum on page two of this guide I Note 1 Vehicles equipped with either bulk offloading central tire inflation or used in City Transit bus applications are required to use a 720cc compressor No points need to be calculated Refer to next page for proper compressor selection Note 2 Itis recommended thata 720cc compressor be used on all Fire Truck and Aircraft Rescue applications to reduce the complexity of the Fast Fill system 34 Appendix E Increasing Performance Point Total Compressor Application School Bus RV Air over Hydraulic senses City Transit Bus Highway Travel Coach Express Route Coach School Bus Rural Route No Auto Brake School Bus City Route No Auto Brake Pick up amp Delivery Li
55. psi Governor cut out charging system stops delivering air to the brake system reservoirs should be approximately 15 20psi greater than cut in pressure Adjust or replace the governor as required 3 Note thatthe charging system cycles to the loaded and unloaded conditions promptly If prompt action is not noted repair or replace the governor the discharge line unloader valve and or the air dryer purge valve assembly IMPORTANT NOTE Replacement air governors must have a minimum cut in pressure of 100psi The cut in pressure is the lowest system pressure registered in the gauges before the compressor resumes compressing air SERVICE TESTS GENERAL The following compressor operating and leakage tests need not be performed on a regular basis These tests Should be performed when it is suspected that leakage is Substantially affecting compressor buildup performance or when it is suspected that the charging system is cycling between the loaded pumping and unloaded charging system stops delivering air to the brake system reservoirs modes due to unloader system leakage INSERVICE 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
56. r hear exhaust from air dryer 15 0 Compressor constantly cycles compressor remains unloaded for a very short time b is not applicable for the compressor featured in this SD sheet information is shown for reference only What it may indicate a Restriction between air dryer and reservolr 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 bo Governor malfunction c Air brake system leakage d Improper governor control line installation to the reservoir a Air brake charging system maintenance not performed Check 6 Compressor unloader mechanism malfunction c Air dryer purge valve or delivery check valve malfunction d Air brake system leakage What you should do gt Inspect delivery lines to reservoir for restrictions and repair as needed gt Verify relief pressure is at vehicle or component manufacturer specifications Replace if defective gt See Maintenance Schedule and Usage Guidelines Table A column 3 on page A 3 gt Verify operation of air dryer Follow vehicle O E maintenance recommendations and component Service Data information gt
57. ressor is cooled by air flow as well as by engine coolant The engine coolant first enters the crankcase water jacket to cool the cylinder bore then passes through passages in the valve plate assembly cooling plate and cylinder head and then out of a port at the top of the compressor back to the engine 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 See Figure 2 Coolant Exits at S afety Top of Head m Valve See Figure 7 gt Ai Cylinder ji Head f aa Valve Plate Cooling Assembly i Plat Wy ate Coolant MN eEnters Here ae Locating Pins FIGURE 1 BENDIX 360cc SINGLE CYLINDER COMPRESSOR Crankcase Bendix O KNORR BREMSE cO O O Bendix Part Number Customer Piece Number Compressor Serial Number FIGURE 2 NAMEPLATES TWO STYLES GENERAL INFORMATION This Bendix 360cc compressor is a discharge line unloader DLU style compressor meaning that the compressor pumps continuously unlike some compressor designs which use an unloader mechanism in the compressor head to switch from a pumping mode to a non pumping mode Instead the control of air delivery to the vehicle s air system is managed by using a separate discharge line unloader valve mounted in parallel with a turbo cut off style of air dryer S
58. rom 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 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 usually consists of an air compressor governor discharge line air dryer and service reservoir DLU Valve Governor OTE n Compressor Air Dryer Front
59. rtain to drain the air pressure from all reservoirs before beginning ANY work on the vehicle If the vehicle is equipped with an AD IS air dryer system or a dryer reservoir module be sure to drain the purge reservoir 5 Following thevehiclemanufacturer s recommended procedures deactivate the electrical system ina manner that safely removes all electrical power from the vehicle 6 Never exceed manufacturer s recommended pressures 7 Never connect or disconnect a hose or line containing pressure itmay whip Never remove a componentor plug unless you are certain all system pressure has been depleted 8 Use only genuine Bendix replacement parts components and kits Replacement hardware tubing hose fittings etc must be of equivalent size type and strength as original equipment and be designed specifically for such applications and systems 9 Components with stripped threads or damaged parts should be replaced rather than repaired Do not attempt repairs requiring machining or welding unless specifically stated and approved by the vehicle and component manufacturer 10 Priorto returning the vehicle to service make certain all components and systems are restored to their proper operating condition 11 For vehicles with Antilock 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 lif
60. ructions and procedures presented in 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 COOLING PLATE amp VALVE PLATE ASSEMBLY 1 Carefully remove all gasket material adhering to the cylinder head 15 cooling plate 14 and valve plate assembly 13 Make certain not to scratch or mar the gasket surfaces Pay particular attention to the gasket Surfaces of the cylinder head and cooling plate 2 Remove carbon deposits from the discharge and inlet cavities of the cylinder head cooling plate and valve plate assembly The cavities must be open and clear Make certain not to damage the parts while cleaning M8x1 25 Cap Screws Smaller M10x1 5 Cap Screws Larger FIGURE 9 REAR END COVER ATTACHMENT BOLTS 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 INSPECTION OF PARTS CYLINDER HEAD COOLING PLATE AND VALVE PLATE ASSEMBLY 1 Carefully inspect the head gasket surfaces on the cylinder head 15 for deep gouges and nicks Also inspect the cylinder head for any cracks or port thread d
61. se damage to the air system or its components 3 Do use dummy hose couplings on the tractor and trailer 4 Do check for sections of air line that could form water traps Look for drooping lines Don ts 1 Do not apply an open flame to air lines and valves Beyond causing damage to the internal nonmetallic parts of valves and melting or burning non metallic 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
62. skets filter bodies etc Repair inlet components as needed Note Dirtingestion 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 BRAKE 1 800 247 2725 and speak to a Tech Team member 5 0 Oil present at valves e g at exhaust or seen during servicing Air brake system valves are required to tolerate a light coating of oil Y Normal Genuine Bendix valves are all SAE J 2024 compliant gt A small amount of oil does not affect SAE J 2024 compliant valves 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 SAE J 2024 outlines tests all air brake system pneumatic components need to be able to
63. t SD 08 2407 AD IDV une nes Cane neat Camtasia eeeb ewes ous Service Data Sheet SD 08 2403 AD IP Air DIV GF sa 4444 00 5 boa e a edad oe oe and ek Service Data Sheet SD 08 2414 AD SP Air Dryer o222066 6425505 Ree tthhdnee3i0nen hes Service Data Sheet SD 08 2415 Trailer System Guard Air Dryer ssaa auaa cee Service Data Sheet SD 08 2416 Bendix PuraGuard QC Oil Coalescing Filter Service Data Sheet SD 08 187B Appendix D 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 Do s 1 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 cau
64. ted 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 compressor and note their positions on the compressor to aid in reassembly 6 Remove the 6 mounting bolts that retain the compressor to the side of the engine block Note the position of the 6 mounting bolts Two of the 6 bolts are shorter and must be installed in their original locations Remove the compressor from the vehicle 7 Inspect drive gear and asso
65. the cylinder head gasket surface on the deck top of the crankcase 11 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 11 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 ll INCH POUNDS TO FOOT POUNDS To convert inch pounds to foot pounds of torque divide inch pounds by 12 Example 12 Inch Pounds 1 Foot Pound 12 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 10 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 11 until the outside
66. ton 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 2 Discharge Valve Closed NANNANMAASSSSSN LZLLLLLL LLL LLL SL LSS NAN NAAN Air Inlet Air Port Discharge Port Cooling Plate LLL LLL LLL LLL SS LLL LLL Lee SAAS S Valve Plate VAAN NAN Piston Moving Down FIGURE 4 OPERATION INTAKE 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 See Figure 5 Air Inlet Discharge Port Valve Discharge P LLL LLL LL LLL Cooling Plate Valve Inlet Valve Piston Moving Up FIGURE 5 OPERATION COMPRESSION NON COMPRESSION OF AIR UNLOADED COMPRESSOR AND AIR DRYER SYSTEM REFER TO FIGURE 6 Air delivery to the vehicle s air system is controlled by the governor and the air dryer or with a separate discharge line unloader valve The governor is plumbed to the component e g air dryer or DLU valve in order to control when the air is delivered to the vehicle s air system When air pressure in the supply reservoir reaches the cutout setting of the governor the governor delivers system air to the discharge line unloader style DLU air dryer s control port This allows the discharg
67. tures 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 1 Inspect control lines to and from the governor for restrictions e g collapsed or kinked Repair as necessary 2 Using a calibrated external gauge in the Test 5 Governor Control Line 1 Ensure that the governor control line from the reservoir is located ator near the top of the res ervoir This line if located near the bottom of the reservoir can become blocked or restricted by the reservoir contents e g water or ice Test 6 Compressor Unloader Leakage Bendix Compressors Park vehicle chock wheels and follow all standard safety procedures Remove the governor and install a fitting to the unloader port Add a section of air hose min 1 ft long for a 1 2 diameter line and a gauge to the fitting followed by a shut off valve and an air source shop air or small air tank Open the Supply reservoir service reservoir or reservoir port of the D 2 governor verify cut in and cut out pressures are within vehicle OEM Specification 3 Ifthe governor is malfunctioning replace it Perform proper reservoir drain intervals and air dryer cartridge mai
68. ubricating e Where a compressor does not have a safety valve installed if a partial or complete discharge line blockage has occurred damage can occur to the con necting rod bearings Damage of this kind may not be detected and could lead to compressor problems ata later date A 13 Tests Test 1 Excessive Oil Leakage at the Head Gasket Exterior leaks at the head gasket are nota 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 Look for Weepage Observe the amount of weepage from the head gasket If the oil is only around the cylinder head area itis 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 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
69. 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 discharge line lengths or insulation may be required in cold climates gt Inspectairlines 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 gt Verify relief pressure is 250 psi Replace if defective gt Go to Test 6 on page A 15 gt Go to Test 4 on page A 15 Symptom 12 0 Air dryer Safety valve releases air Air dryer safety valve Er 3 C 7 T r p i n i 3 2 ih k a i re a ail a i j a ee 4 EA i L Te Technician removes governor 13 0 Reservoir safety valve releases air 14 0 Air dryer doesn t purge Neve
70. ution is also required 1 With the engine shut off drain ALL air pressure from the vehicle 2 Disconnect the inlet and discharge lines 3 Apply 120 130 psi shop air pressure to the discharge portand 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 200 sccm If excessive leakage is noted in Test 3 replace or repair the compressor using genuine Bendix replacements or maintenance kits available from any authorized Bendix parts outlet While it is possible to test for inlet and discharge 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 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 PARTS 360CC SINGLE CYLINDER COMPRESSOR ONLY CompressorSealKit K026

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