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BENDIX BW2369 User's Manual

1. Technical Bulletin lt 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 g O s Do maintain freeze prevention devices to prevent road calls Don t let evaporators or injectors run out of methanol alcohol or protection will be degraded Check the air dryer for proper operation and change the desiccant when needed 2 Do thaw out frozen air lines and valves by placing the vehicle in a warmed building This is the only method for thawing that will not cause damage to the air system or its components Do use dummy hose couplings on the tractor and trailer Do check for sections of air line that could form water traps Look for drooping lines _h a 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
2. ay i 14 Head Gasket x Alignment 2 Bushings 16 Valve Plate Assembly 30 i Governor 31 PP Olee we Gasket 2 Governor Kit 1 Cylinder Head Gasket 17 Inlet Reed Valve Adapter Kit 5008558 Gaskel Kit 2 Unloader Kit 5008557 l 19 Connecting Kit 3 Governor Adapter Kit 18 Piston Rod 5008561 Kit 4 Cylinder Head Assembly Kit K023600 20 Bearing Crankcase K023601 Sleeve Alignment Other nan N Pins Crankcase Compressor Seal Kit 5008559 Unique Engine Seal Kits are available for Cat C7 C9 Engine Cat C11 C13 C15 C18 Engines and DDC Series 60 Engines ltem Qty Description Head Cap Screws Kit 4 21 Crankcase 27 Bottom Cover Gasket 22 Crankshaft 23 Rear Bearing al 24 O Ring 25 Rear End Cover Unloader Cover Cap Screws Kit 4 Kit 4 Unloader Cover Splash Shield Unloader Cover Kits 2 amp 4 Unloader Cap Gasket Kits 2 amp 4 Y 26 Cap 28 Crankcase ce Screws 4 Cover QE Unloader Balance Piston Kits 2 amp 4 O Ring Kits 2 amp 4 Spring Kits 2 amp 4 O Ring Kits 2 amp 4 Unloader Piston Kits 2 amp 4 O Ring Kits 2 amp 4 ST 4 Safety Valve Kit 4 Item Qty Description Cylinder Head Kit 4 Rear Bearing Head Gaskets Kits 1 amp 4 O Ring Cooling Plate Kit 4 Rear End Cover Cap Screws Valve Plate As
3. 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 _ und or the amount of time Replace the compressor Note If the compressor is within warranty period please follow standard warranty procedures Attach the completed checklist to warranty claim A 18 since the air tanks were last drained exceeds the acceptance level AND the vehicle passes the four minute leakage test no noticeable leakage was detected Appendix C Technical Bulletin PONA 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 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 id
4. A 3 for maintenance schedule information What it may indicate Maintenance a If air brake charging system mainte nance has not been performed That is 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 ob 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 air tanks and check vehicle at next service interval using the Bendix BASIC test See Table A on page A 3 column 3 and 4 for recommended service sched ule Check Drain all air tanks into Bendix BASIC test
5. Closed Room Compressor Assembly Torques in inch pounds in Ibs M8x1 25 6g Cylinder Head M5x0 75 6g Unloader Cap M8x1 25 6g Governor Adapter M8x1 25 6g Rear End Cover M6x1 00 6g Crankcase Cover Inlet Port Fittings M27x2 6g Inlet Port Fittings 991 1089 In Lbs 112 123 Nem Discharge Port Fittings M22x1 5 6H Water Port Fittings M18x1 5 6H Unloader Port Fittings 1 8 27 NPT Safety Valve Port M16x1 5 6H 230 257 In Lbs 26 29 Nem 1 Note TFFT Turns From Finger Tight 270 305 In Lbs 30 5 34 5 Nem 62 71 In Lbs 7 8 Nem 195 213 In Lbs 22 24 Nem 195 213 In Lbs 22 24 Nem 62 71 In Lbs 7 8 Nem 814 912 In Lbs 92 103 Nem 593 637 In Lbs 67 72 Nem 2 3 TFFT 18 TORQUE SPECIFICATIONS Standard Compressor Assembly Torques in inch pounds in Ibs M8x1 25 6g Cylinder Head 265 292 In Lbs 30 33 Nem M5x0 75 6g Unloader Cap 00 62 71 In Lbs 7 8 Nem M8x1 25 6g Governor Adapter 195 213 In Lbs 22 24 Nem M8x1 25 6g Rear End Cover 195 213 In Lbs 22 24 Nem M6x1 00 6g Crankcase Cover 62 71 In Lbs 7 8 Nem Inlet Port Fittings 1 3 16 12 UN 2B Aluminum Cylinder Head Straight fitting 841 925 In Lbs 95 104 Nem adjustable w jam nut 097 655 In Lbs 67 74 Nem M27x2 6g Cast Iron Cylinder Head 885 980 In Lbs 100 111 Nem Discharge Port Fittings 7 8 14 UNF 2B Aluminum Cylinder He
6. Discharge Recom Recom Acceptable mended mended Reservoir Air Dryer Reservoir Oil Contents Cartridge Drain at Regular Replacement Schedule Drain Interval BASIC test e g Line haul single trailer For oil carry over ace ave w o air suspension air over 2 coe o E Recom A hydraulic brakes less eas mended 3 oil units aa 5 8 in 9ft Every 3 Every per month Years Month See e g Line haul single trailer ery 90 days A with air suspension Bendix Tu Flo 550 air compressor For oil carry over control suggested school bus less upgrades m E 5 8in 12 ft For the BASIC High Air Use Compressor with up to 25 duty cycle e g Double triple trailer open highway coach RV most pick up amp delivery yard or terminal jockey off highway construction loggers concrete mixer dump truck fire truck Bendix BA 921 air compressor Bendix Tu Flo 750 air compressor less e 3 8 in 2 m ots We q S Te Te T Compressor with up to 25 duty cycle 9 LO e g City transit bus refuse 3 bulk unloaders low boys m urban region coach central E tire inflation 12 or o less N D lt aa 2 eb aa 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 si 3 Allow the oil water mixture to fully settle before measuring
7. both sides for deep gouges and nicks Pay particular attention to the gasket surface An inlet reed valve gasket 17 is used between the valve plate assembly and crankcase This gasket surface must be smooth and free of all but the most minor scratches If excessive marring or gouging is detected the compressor must be replaced If large amounts of carbon build up are present on the two main surfaces in the two discharge valve holes or between the discharge valve and the discharge seat the compressor should be replaced 4 If the unloader assembly has been removed from the cylinder head the unloader assembly must be serviced using an unloader kit See Maintenance Kits page 12 5 If large amounts of carbon build up are present on the unloader piston 10 seat or orifice or if the return spring exhibits compression set the unloader components must be replaced with an unloader kit REAR END COVER If Present Check for cracks and external damage Check the crankshaft rear bearing diameter in the rear end cover 25 for excessive wear flat spots or galling Check the rear support bracket threaded holes and hydraulic pump attachment threaded holes if present for thread damage Minor thread chasing is permitted but do not re cut the threads If any of these conditions are found replace the compressor CRANKCASE Check the cylinder head gasket surface on the deck top of the crankcase 21 for nicks gouges and marring A
8. cup Bendix Air System Inspection Cup If less than one unit of reservoir contents Is found the vehicle 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 amount of 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 If the 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 gt lf the compressor is correct for the
9. vehicle go to Symptom 4 0 e Symptom 4 0 Oil in Supply or Service Reservoir air dryer installed continued Testing the temperature at the discharge fitting What it may indicate Temperature e Air compressor discharge and or air dryer inlet temperature too high f Insufficient coolant flow Inspecting the coolant hoses g Restricted discharge line Kinked discharge line shown Other h Restricted air inlet not enough air to compressor Partly collapsed inlet line shown What you should do gt Check temperature as outlined in Test 3 on page A 14 If temperatures are normal go to 4 0 h gt Inspect coolant line Replace as necessary I D is 1 2 gt Inspect the coolant lines for kinks and restrictions and fittings for restrictions Replace as necessary 5 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 fit
10. 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 Optional Ping Tank AS Air Dryer Discharge Z EN Line Compressor LN Governor plus Synchro valve for the Bendix DuraFlo 596 Compressor A 2 of an air compressor governor discharge line air dryer and service reservoir Optional Bendix PuraGuard System Filter or PuraGuard QC Oil Coalescing Filter Service Reservoir Supply Reservoir Reservoir Drain Table A Maintenance Schedule and Usage Guidelines Regularly scheduled maintenance is the single most important factor in maintaining the air brake charging Typical Line Vehicle Used for N o Low Air Use Compressor with less than 15 duty cycle
11. Brake Charging System Troubleshooting How to use this guide Find the symptom s that you see then move to the right to find the possible causes What it may indicate and remedies What you should do Review the warranty policy before performing any intrusive compressor maintenance Unloader or cylinder head gasket replacement and resealing of the bottom cover plate are usually permitted under warranty Follow all standard safety procedures when performing any maintenance WARNING Please READ and follow these instructions to avoid personal injury or death When working on or around a vehicle the following general precautions should be observed at all times 1 Park the vehicle on a level surface apply the parking brakes and always block the wheels Always wear safety glasses 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 t
12. Closed Room FIGURE 9 OPERATION UNLOADED CLOSED ROOM Section 2 For Closed Room Compressor See Figure 9 When air pressure in the supply reservoir reaches the cutout setting of the governor the governor delivers system air to the compressor unloader port Air entering the unloader port acts on the unloader piston causing the piston to move away from its seat on the valve plate assembly When the unloader piston is unseated an air passageway is opened between the cylinder bore and a secondary compartment or closed room in the interior of the cylinder head As the piston moves from bottom dead center BDC to top dead center TDC air in the cylinder bore flows past the unseated unloader piston into the closed room The size of the closed room is sufficient to accept the compressed air provided by the compressor piston without creating excessive air pressure in the closed room On the piston down stroke TDC to BDO air flows in the reverse direction from the closed room past the unseated unloader piston and inlet reed valve and into the cylinder bore Note For optimum performance it is recommended that the air dryer is equipped with turbo cut off Head Bolt 4 Discharge Safety Valve Coolant In or Out One or other not used Discharge E Port il 7 V SS k AO Governor Connection Inlet Unloader Port CYLINDER HEAD PORT IDENTIFICATION The cylinder head connection ports are
13. IS UNSAFE AND CAN RESULT IN VEHICLE FIRE 2 Do not introduce pour fluids into air brake lines or hose couplings glad hands Some fluids used can cause immediate and severe damage to rubber components Even methanol alcohol which is used in Alcohol Evaporators and Injectors should not be poured into air lines Fluids poured into the system wash lubricants out of valves collect in brake chambers and valves and can cause malfunction Loss of lubricant can affect valve operating characteristics accelerate wear and cause premature replacement 3 Do not park a vehicle outside after thawing its air system indoors Condensation will form in the system and freeze again Place the vehicle in operation when it is removed to the outdoors Supporting Air and Electrical Lines Make certain tie wraps are replaced and support brackets are re assembled if removed during routine maintenance These items prevent the weight of ice and snow accumulations from breaking or disconnecting air lines and wires Automatic Drain Valves System without Air Dryer As we stated last year routine reservoir draining is the most BASIC step although not completely effective in reducing the possibility of freeze up While automatic drain valves relieve the operator of draining reservoirs on a daily basis these valves MUST be routinely checked for proper operation Don t overlook them until they fail and a road call is required A 21 BW2369 2007 Bendix Com
14. Ports 3 total Unloader Piston Cooling Discharge Plate Reed Valves 2 rm Piston Piston Rod TL Crankshaft ii Crankcase Closed Room Cover FIGURE 3 BENDIX BA 921 COMPRESSOR CUT AWAY STANDARD AND CLOSED ROOM The compressor s discharge valves are part of the valve plate assembly The inlet reed valve gasket is installed between the valve plate assembly and the top of the crankcase The cast iron crankcase houses the piston assembly connecting rod crankshaft and related bearings All Bendix BA 921 compressors are equipped with a safety valve to protect the compressor head in the event of for example a discharge line blockage downstream of the compressor Excessive air pressure will cause the safety valve to unseat release air pressure and give an audible alert to the operator The safety valve is installed in the cylinder head safety valve port directly connected to the cylinder head discharge port The crankcase cover located at the bottom of the crankcase Caterpillar HD Acert Engines Caterpillar C7 C9 Engines FIGURE 5 TYPICAL COMPRESSOR DRIVE FLANGES 2 Compressor Model Customer Piece Number Bendix Piece Number and Serial Number shown here FIGURE 4 CRANKCASE BASE COVER is stamped with information identifying the compressor model customer piece number Bendix piece number and serial number See Figures 1 and 4 OPERATION The compressor is drive
15. STANDARD AND CLOSED ROOM VERSIONS This service data sheet covers two versions of the Bendix BA 921 compressor The first version was originally released in 2002 and will be referred to as the Standard compressor in this Service Data sheet The Standard compressor was offered on Caterpillar ACERT Medium and Heavy duty engines and the DDC S60 EGR 2002 06 engine These installations required an externally mounted inlet check valve ICV on the air inlet side of the compressor Depending on whether the air induction system was naturally aspirated or turbocharged dictated whether or not additional hardware was required along with the ICV See Figure 6 page 3 and Section 1 of Air Induction on page 6 The second version was originally released in 2007 and will be referred to as the Closed Room compressor in this service data sheet This compressor is only permitted to be naturally aspirated use of engine turbocharger as an air source is not allowed This compressor eliminates the need for an externally mounted inlet check valve ICV on the air inlet side of the compressor See Figure 6 page 3 Refer to Figure 2 below to see the visual differences between the two BA 921 compressor heads Other differences between the two versions will be referenced throughout this Service Data sheet DESCRIPTION The function of the air compressor is to provide and maintain air under pressure to operate devices in air brake systems
16. Test Information Introduction to the Air Brake Charging System Powered by the vehicle engine the air compressor builds the air pressure for the air brake system The air compressor is typically cooled by the engine coolant system and lubricated by the engine oil supply The compressor s unloader mechanism and governor along with a synchro valve for the Bendix DuraFlo 596 air compressor control the brake system air pressure between a preset maximum and minimum pressure level by monitoring the pressure in the service or supply reservoir When the air pressure becomes greater than that of the preset cut out the governor controls the unloader mechanism of the compressor to stop the compressor from building air and also 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 compressor back to building air and the air dryer to air drying mode As the atmospheric air is compressed all the water vapor Originally in the air is carried along into the air system as well as a small amount of the lubricating oil as vapor The duty cycle is the ratio of time the compressor spends building air to the total engine running time Air compressors are designed to build air run loaded up to 25 of the time Higher duty cycles cause conditions that affect air brake charging system performance which may require additional maintenance Fac
17. The Bendix BA 921 compressor is a single cylinder reciprocating compressor with a rated displacement of 15 8 cubic feet per minute at 1250 RPM The compressor consists of a water cooled cylinder head assembly and an integral air cooled crankcase assembly The cylinder head assembly is made up of the cylinder head cooling plate and valve plate assembly and uses Standard Aluminum Cylinder Head Standard Cast Iron Cylinder Head With 4 Bolts FIGURE 2 BENDIX BA 921 COMPRESSOR STANDARD AND CLOSED ROOM VERSIONS Cylinder Head Valve Plate Assembly Cooling Plate Crankcase STANDARD VERSION SHOWN FIGURE 1 BENDIX BA 921 COMPRESSOR two sealing gaskets Depending on the application the cylinder head and cooling plate may be aluminum or cast iron The cylinder head contains air and water ports as well as an unloader assembly A cooling plate is located between the cylinder head and valve plate assemblies and assists in cooling The valve plate assembly consists of brazed steel plates which have valve openings and passages for air and engine coolant to flow into and out of the cylinder head Closed Room Aluminum Cylinder Head With 6 Bolts Splash Shield Unloader Cover Coolant Ports 3 total Unloader a Air Piston i Intake Discharge s Cooling Reed j 7 Plate Valves 2 Piston Crankshaft Crankcase Cover Standard Unloader Coolant
18. 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 not least 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 ADO Alr Dryer o tcedece Shou deetoceaueadee penai Service Data Sheet SD 08 2412 AD 4 Air Dryer 0 eee Service Data Sheet SD 08 2407 AD 2 Al Dryer 126 2 oeeee weeds spiere iii ns bw eet es Service Data Sheet SD 08 2403 AD IP Air Dryer 1 ee eee Service Data Sheet SD 08 2414 AD SP Air Dryer mod s eos a eee ene sedan be oo Service Data Sheet SD 08 2415 Trailer System Guard Air Dryer 0 000008 Service Data Sheet SD 08 2416 Bendix PuraGuard QC Oil Coalescing Filter Service Data Sheet SD 08 187B Appendix D
19. cover plate c Leak at internal rear flange gasket d Leak through crankcase e If unable to tell source of leak Head gaskets and rear flange gasket locations Air brake charging system functioning normally Y Normal What you should do Find the source and repair Return the vehicle to service gt Repair or replace as necessary If the mounting bolt torques are low replace the gasket gt Replace the fitting gasket Inspect inlet hose and replace as necessary gt Replace gasket or fitting as necessary to ensure good seal gt Inspect and repair as necessary Go to Test 1 on page A 14 gt Reseal bottom cover plate using RIV silicone sealant gt Replace compressor gt Replace compressor gt 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 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 See Table A on page
20. engine air filter and service if necessary if possible check the air filter usage indicator Check for leaking damaged or defective compressor air inlet components e g induction line fittings gaskets filter bodies etc Repair inlet components as needed Note Dirt ingestion will damage compressor and is not covered under warranty Replace the compressor only after making certain that none of the preceding conditions 9 0 a through 9 0 h exist Symptom What it may indicate 10 0 Air charging a Governor malfunction system doesn t build air b Restricted discharge line c Air dryer heater malfunction exhaust port frozen open d Compressor malfunction Note For the Bendix DuraFlo 596 air compressor not only the governor but also the SV 1 synchro valve used would need to be tested See Bulletin TCH 001 048 11 0 Compressor a Restricted discharge line safety valve releases air 2 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 gt Replace air dryer heater gt Replace the compressor only after making certain the preced
21. for purposes of cooling This oil jet is part of a special crankcase cover that is used only on the BA 921 compressor for CAT C11 and C13 engine installations see Figure 17 This design slightly alters the flow of oil for lubrication The oil supply line from the engine is directly connected to the back side of the special crankcase over The oil flows in parallel through a passageway in the crankcase cover and through the oil jet to spray oil under pressure up onto the underneath of the piston for cooling At the same time oil flows out of the opposite end of the special crankcase cover through a fitting and a metal tube and second fitting into the oil supply port of the compressor At this point oil flows in a similar manner as in the first paragraph of this section COOLING Bendix BA 921 compressors are cooled by air flowing through the engine compartment as it passes the compres sor s cast in cooling fins and by the flow of engine coolant through the cylinder head Coolant supplied by the engine cooling system passes through connecting lines into the cylinder head and passes through internal passages in the cylinder head cooling plate and valve plate assembly and returns to the engine Figures 10 and 11 illustrate the various approved coolant flow connections Proper cooling is important in minimizing discharge air temperatures see the tabulated technical data on page 18 of this manual for specific requirements Air Sup
22. identified with cast in numerals as follows AIR IN Compressed AIR OUT Coolant IN or OUT Governor Control FIGURE 10 STANDARD BENDIX BA 921 COMPRESSOR CYLINDER HEAD Discharge Head Safety Valve Bolt 6 m Coolant In or Out One or other not used LA D O m S Governor Connection Unloader Cover Coolant In or Out Discharge Port CYLINDER HEAD PORT IDENTIFICATION The cylinder head connection ports are identified with cast in numerals as follows AIR IN Compressed AIR OUT Coolant IN or OUT Governor Control FIGURE 11 CLOSED ROOM BENDIX BA 921 COMPRESSOR CYLINDER HEAD 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 An oil passage in the crankshaft routes pressurized oil to the precision sleeve main bearings and to the connecting rod bearings Spray lubrication of the cylinder bores connecting rod wrist pin bushings and ball type main bearings 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 drain holes in the compressor mounting flange Standard Compressor Lubrication for Caterpillar C11 and C13 engine applications Bendix BA 921 compressor for Caterpillar C11 and C13 engine installations only use an oil jet that sprays oil under the piston
23. intake tube through the inlet check valve into the inlet port of the compressor When the compressor is not building air unloaded mode the compressor pushes the air back out the compressor during the cylinder upstroke towards the inlet check valve The ICV prevents the air from traveling beyond this point The air shuttles back and forth between the compressor cylinder bore and the ICV during this phase of the compressor operation AIR INDUCTION Section 2 For Closed Room Compressors Bendix Closed Room BA 921 air compressors are only permitted to be naturally aspirated use of engine turbocharger as an air source is not allowed See Figure 6 on page 3 for an example of a naturally aspirated air induction sysiem NOTE DO NOT install an inlet check valve ICV on air induction systems where a closed room compressor is used PREVENTATIVE MAINTENANCE Regularly scheduled maintenance is the single most important factor in maintaining the air brake charging system Refer to Table Ain the Troubleshooting section on page 21 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
24. oil quantity 6 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 Test Kit Order Bendix P N 5013711 Every 2 For oil carry over Years control suggested upgrades lott BASIC test acceptable range Every 5 oil units Month per month See appendix 3 4 in 12 ft A Every Year Bulletins TCH 08 21 and TCH 08 22 included in Appendix B for more information For certain vehicles applications where turbo charged inlet air is used a smaller size compressor may be permissible Note Compressor and or air dryer upgrades are recommended in cases where duty cycle is greater than the normal range for the examples above For correct compressor upgrades consult Bendix Please note that because a compressor is listed in the same area of the chart does not necessarily mean that it would be a suitable candidate for upgrade purposes lengths or insulation may be required in cold climates See Bendix For Bendix Tu Flo 550 and 750 compressors unloader service is recommended every 250 000 miles A 3 Air
25. setting of the governor the governor delivers system air to the compressor unloader port Air entering the unloader port acts on the unloader piston causing the piston to move upwards away from its seat on the valve plate assembly When the unloader piston is unseated an air passageway is opened between the cylinder bore and the air inlet cavity in the cylinder head As the piston moves from bottom dead center BDC to top dead center TDC air in the cylinder bore flows past the unseated unloader piston into the cylinder head inlet cavity and out the inlet port To prevent the air from flowing back into the engine air induction system an inlet check valve ICV is installed upstream of the air compressor inlet port The location of the device and the way it is plumbed into the compressor air induction system is unique to the specific engine and the type of air induction naturally aspirated or boosted air the compressor uses These air induction systems will be explained in further detail in the Air Induction section on page 4 On the piston down stroke TDC to BDC air flows in the reverse direction from the inlet cavity past the unseated unloader piston and inlet reed valve and into the cylinder bore Air From Governor mM Unloader S Ve INN Sima A R NY SLE n nE jm L7G Z te NAND Port L NLL Unloader Piston Up amp Unseated Air in Pistons Shuttles Back and Forth from the Piston to the
26. the cylinder head cooling plate and valve plate assembly together independent of the crankcase 6 Gently tap the cylinder head cooling plate 15 and valve plate assembly 16 with a soft mallet to break the gasket seal between the valve plate assembly and the crankcase 21 Lift the cylinder head with cooling plate and valve plate assembly off the crankcase Remove the metal inlet reed valve gasket 17 8 Gently tap the cylinder head cooling plate and valve plate assembly with a soft mallet to break the gasket seals Then separate the cylinder head from the cooling plate 15 and valve plate assembly and remove the two gaskets 14 between them CRANKCASE COVER 1 Remove the four crankcase cover cap screws 29 securing the crankcase cover 28 to the crankcase 21 Using a soft mallet gently tap the crankcase cover to break the gasket seal Remove the crankcase cover gasket 27 2 In the case of the Caterpillar C11 and C13 engine application the BA 921 standard compressor utilizes an oil jet that sprays oil under the piston for purposes of cooling This oil jet is part of a special crankcase cover that is used strictly on the BA 921 compressor for the C11 and C13 engine installation Figure 13 Refer to section OPERATION Lubrication for description of the system To disassemble perform the following steps Refer to Figure 17 a Remove the oil supply line from the engine at the inlet to the special
27. 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 lt 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 a selected range for example from 90 to 120 psi or from 100 to 120 psi etc and record it in the vehicle s maintenance files Subsequent build up times throughout the vehicle s service life can then be compared to the first one recorded Note the 40 second guide in the test above does not apply to this build up time If the performance degrades significantly over time you may use the Advanced Troubleshooting Guide for Air Brake Compressors starting on page A 1 of this document to assist investigation of the cause s Note When comparing build up times be sure to make an allowance for any air system modifications which would cause longer times such as adding air components or reservoirs Always check for air system leakage LEAKAGE TESTS See the standard Air Brake System and Accessory Leakage test on Page A 14 Test 2 Note Leakage in the air supply system componen
28. the vehicle to service make certain all components and systems are restored to their proper 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 not use this card test to diagnose compressor oil passing issues They are subjective and error prone Use only the Bendix Air System Inspection Cup BASIC test and the methods described in this guide for advanced troubleshooting The Bendix BASIC test should be the definitive method for judging excessive oil fouling oil passing See Appendix A Bendix on page A 16 for a flowchart and expanded BASIC Test explanation of the checklist used when conducting the BASIC test Symptom 2 0 Oil on the Outside of the Compressor 2 1 Oil leaking at compressor engine connections 2 2 Oil leaking from compressor 3 0 Oil at air dryer purge exhaust or surrounding area What it may indicate Engine and or other accessories leaking onto compressor a Leak at the front or rear fuel pump etc mounting flange b Leak at air inlet fitting c Leak at air discharge fitting d Loose broken oil line fittings a Excessive leak at head gasket b Leak at bottom
29. 3 C15 C18 Engine Seal Kit ceeeeeeneees 5012369 CAT ST 4 Discharge Safety Valve 7 8 14 thrd cceee 801116 Components and kits for DDC Engines DDC Inlet Check Valve cccccssssssssssssssrssessssrssesssersaesesereas 802192 DDC Series 60 Engine Seal Kit c cessessssesersssseersesees 5012371 DDC ST 4 Discharge Safety Valve M16 1 5 thrd 0 800534 Section 2 Closed Room Compressor Cylinder Head Gasket Kit cccsccsssescssssessssssserssssesersesees K022563 CMO QOS K ies EOE 5008557 Governor Adapter Kit ccccccccsecssssseecseseessessessessesseseesaeees 5008561 DDC Series 60 Engine Seal Kit ccesessssssessesseereeeees 5012371 DDC ST 4 Discharge Safety Valve M16 1 5 thrd 800534 All components shown in Figures 15 and 16 with a key number are available in kits and or as individual service parts 12 IMPORTANT PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO AVOID PERSONAL INJURY OR DEATH When working on or around a vehicle the following general precautions should be observed at all times 1 Park the vehicle on a level surface apply the parking brakes and always block the wheels Always wear safety glasses Where specifically directed the parking brakes may have to be released and or spring brakes caged and this will require that the vehicle be prevented from moving by other means for the duration of these tests procedures 2 Stop the engine an
30. FIRST PERFORM THE FOLLOWING INSPECTIONS AND TESTS AIR INDUCTION The Bendix BA 921 compressor is designed for connection to the vacuum side of the engine s air induction system and the pressure side turbocharged of the engine s air induction system A supply of clean air is one of the single most important factors in compressor preventive maintenance Since the air supply for BA 921 compressor and engine is the engine air cleaner periodic maintenance of the engine air filter is necessary Inspect the compressor air induction system each time engine air cleaner maintenance is performed 1 Inspect the intake hose adapters for physical damage Make certain to check the adapters at both ends of the intake hose or tubing 2 Inspect the intake hose clamps and tighten them if needed 3 Inspect the intake hose or line for signs of drying cracking chafing and ruptures and replace if necessary 4 Verify that the compressor inlet fitting is tight check torque 5 Any metal tubes should also be tight torqued properly to the mating fitting Inspect the metal tubes for any cracks or breaks and replace if necessary 6 If an expansion tank is present turbocharged air induction systems only inspect for any cracks and replace if necessary COMPRESSOR COOLING Inspect the compressor discharge port inlet cavity and discharge line for evidence of restrictions and carbon buildup If more than 1 16 of carbon is fo
31. 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 lf automatic drain valves are installed check their operation before the weather turns cold reference Service Data Sheet SD 03 2501 for Bendix DV 2 Automatic Drain Valves It should be noted that while the need for daily reservoir draining is eliminated through the use of an automatic drain valve periodic manual draining is still required Alcohol Evaporator or Injector Systems Check for proper operation of these systems by monitoring alcohol consumption for a few days Reference Service Data Sheet SD 08 2301 for the Bendix Alcohol Evaporator Too little means the system is not receiving adequate protection
32. Press and hold the unloader cover in place on the cylinder head place the spray shield 3 Standard Compressors only over the outboard hole in order to cover the vent slot in the unloader cap Install both unloader cover cap screws 2 Torque the cover cap screws 2 to 62 to 71 inch pounds 7 8 Nem INSTALLING THE COMPRESSOR 1 Install the appropriate gasket or o ring on the front flange of the compressor Make certain oil supply or return holes in the gasket are properly aligned with the compressor and engine On the Detroit Diesel S60 engine installations an additional o ring is required to seal the oil feed passageway between the compressor and engine gear case cover Gasket sealants are not recommended Secure the compressor on the engine and tighten the mounting bolts per Engine Manufacturers recommended torque requirements 2 Install any supporting brackets on the compressor in the same position s noted and marked during removal If a rear Support bracket was on the original installation hand tighten the bolts on both ends before torquing the bolts Note It is important that the rear support bracket is flush to both surfaces before the bolts are torqued 3 Inspect all air oil 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 4 Install the discharge in
33. Technician how much oil did you tnd in investigating L Oil on ground or vehicle exterior amount described Q Short air dryer cartridge life replaces every Q miles O kms or Q months Note A confirmed complaint above does NOT mean that We will measure amount currently found when we get to step B of the test the compressor must be O Excessive engine oil loss amount described replaced The full BASIC test below Is the engine leaking oil LU no yes will investigate the facts Is the compressor leaking oil LI no U yes LI Other complaint LI No customer complaint sys OME Sa lacmicace STEP A Select one The Technician selects the air use category for the vehicle This decides Q This is a low air use vehicle Line haul Single trailer with 5 or less axles or which of the two acceptance lines Q This is a high air use vehicle Garbage truck transit bus bulk unloader or line on the cup will be used for the test haul with more than 5 axles Then go to Step B below 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 the vehicle should be used Completely drain ALL the air tanks into a single BASIC cup 2 3 If there is less than one unit of contents total end the test now and return the vehicle to service Ve
34. ad Straight fitting 909 553 In Lbs 57 62 Nem adjustable w jam nut 354 389 In Lbs 40 44 Nem M22 x 1 5 6g Cast Iron Cylinder Head 531 575 In Lbs 60 65 Nem Water Port Fittings 3 4 16 UNF 2B Aluminum Cylinder Head straight MUNG castes ncsccetenansssnansice 265 292 In Lbs 30 33 Nem adjustable w jam nut 248 274 In Lbs 28 31 Nem M18 x 1 5 6g Cast Iron Cyliner Head 354 395 In Lbs 40 45 Nem Unloader Port Fittings WG 271 INP EE EE E 2 3 TFFT MIO T OO sinnc 120 145 In Lbs 14 16 Nem Safety Valve Port 118 14 UNF 2B sccstncncnsnernioarterstnedyc 230 257 In Lbs 26 29 Nem AGUS IESE 6 isian 230 257 In Lbs 26 29 Nem Oil Port PV TO UNF reseno 150 170 In Lbs 17 19 Nem Special Attachments Cat C11 C13 Engine Crankcase Cover w Oil Jet and Associated Hardware Figure 17 1 Crankcase Cover In Out Oil Fittings EVO VO UNF scerna 150 170 In Lbs 17 19 Nem 2 Compressor Oil Supply Fitting EVO 10 UN ospis 150 170 In Lbs 17 19 Nem 3 Metal Tube Tube Ends CNG UNF sereis 130 150 In Lbs 16 17 5 Nem Option Run fittings down finger tight Tighten 1 4 to turns 1 Note TFFT Turns From Finger Tight Appendix A Advanced Troubleshooting Guide for Air Brake Compressors The guide consists of an introduction to air brake charging system components a table showing recommended vehicle maintenance schedules and a troubleshooting sympto
35. age and noisy operation as well as unloader operation and leakage If the compressor functions as indicated reinstall on the vehicle connecting all lines as marked in the disassembly procedure 17 BA 921 COMPRESSOR SPECIFICATIONS ALL Typical weight Standard Compressor DDC Model cccceseeeeeeeees 66 Ibs Closed Room Compressor DDC Model c cceceeee 55 Ibs Number Of Cylinders cccinciccsindcsecdecsnsoesnincdadedentalseisuscsseatubetoeieieiinientecss 1 BOle Diameldi ssscticnicactiivedasrisinasinbensnionenatenenonsansticat 3 622 in 92 mm RUS E E neice E ATT 2 126 in 54 mm Calculated displacement at 1250 RPM ossee 15 8 CFM Flow Capacity 1800 RPM amp 120 PSI eee 11 6 CFM Flow Capacity 3000 RPM amp 120 PSI eee 16 5 CFM Approximate horsepower required Loaded 1800 REM at 120 PSIG essri inoia 4 6 HP Unloaded 1800 RPM saiisine an 0 8 HP Minimum coolant flow at maximum RPM 008 2 5 Gals Min Maximum inlet air temperature c cc csccceeseseecesteeeeeeeees 250 F Maximum discharge air temperature ccceeseeceeteseeeeenees 400 F Minimum oil pressure required cccccecessseessesesseeteeseeeeees 15 PSI Minimum oil supply line size s ennnnenenennenseenisisresisrrrrsseen 3 16 I D Minimum unloader line size c cccccccccecesseessesseseeeeeees 3 16 I D Minimum Governor Cut out PreSSUre ccccccstesesseeseeeees 120 PSI TORQUE SPECIFICATIONS
36. age at the inlet port should not exceed 50 sccm 4 Apply 120 130 psi shop air pressure to the discharge port and then apply and release air pressure to the inlet port Soap the inlet port and note that leakage at the inlet port does not exceed 20 sccm If excessive leakage is noted in Tests 3 or 4 replace or repair the compressor using genuine Bendix replacements or maintenance kits available from any authorized Bendix parts outlet While it is possible to test for inlet discharge and unloader piston leakage it may not be practical to do so Inlet and discharge valve leakage can generally be detected by longer compressor build up and recovery times Compare current compressor build up times with the last several recorded times Make certain to test for air system leakage as described under In Service Operating Tests before making a determination that performance has been lost Unloader leakage is generally exhibited by excessive compressor cycling between the loaded and unloaded condition 1 With service and supply system leakage below the maximum allowable limits and the vehicle parked bring system pressure to governor cut out and allow the engine to idle 11 2 The compressor should remain unloaded for a minimum of 5 10 minutes If compressor cycling occurs more frequently and service and supply system leakage is within tolerance replace the compressor or repair the compressor unloader system using a genuine Bendix maint
37. ays 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 Note After replacing a compressor residual oil may take a considerable period of time to be flushed from the air brake system Appendix B continued Information about the BASIC Test Kit Bendix P N 5013711 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 fils out these felds with information gained from the customer No ofAxles Checklist for Technician Customer s Have you confrmed complaint Y 1Piease check all that apply The Technician Relay valve Q leaks oil Q malfunctions Q no U yes n hovee The Service Writer Dash valve leaks oil Q malfunctions O no O yes also checks off any 2 Air dryer leaks oil 2 no O yes for any of the complaints that the O Governor malfunction Ono O yes complaints that customer makes to Q Oil in gladhands LI no O yes can be confrmed help the
38. cation for description of the system To re assemble follow the instructions below 15 a Position the gasket 27 on either the crankcase or the special crankcase cover and install the special crankcase cover on the crankcase using the four cap screws Note Make sure that the cover is orientated in its original position Snug all four cap screws then torque to 62 71 inch pounds 7 8 Nem using a crossing pattern b Assuming that the fittings at the outlet of the special crankcase cover and compressor oil supply port had not been removed fittings still torqued in place position both ends of the metal tube over the two fittings and run the fittings down to finger tight then torque to 130 150 inch pounds 16 17 5 Nem If a torque wrench is not available run fittings down to finger tight Then tighten the fittings 1 4 to 1 2 turns REAR END COVER If Present 1 Install the o ring 24 on the rear end cover 2 Orient the rear end cover 25 to the crankcase using the reference marks made during disassembly Carefully install the rear end cover in the crankcase making certain not to damage the crankshaft bearing surface 3 Install the four end cover cap screws 26 or studs Snug the screws then tighten to 195 to 213 inch pounds 22 24 Nem using a crossing pattern CYLINDER HEAD ASSEMBLY PART ONE HEAD INSTALLATION Section 1 Standard Compressors 1 Note the position of the protruding crankcase alig
39. crankcase cover b Remove the metal oil supply tube at the compressor oil supply port and at the outlet fitting of the special crankcase cover 14 Compressor Oil Supply Port Engine Oil Supply Lubricating Oil outlet Lubricating Oil From the Engine Enters Here Crankcase Cover with Oil Jet Assembly FIGURE 17 VIEWS OF SPECIAL CRANKCASE COVER WITH OIL JET ASSEMBLY FOR CAT C11 C13 ENGINE APPLICATIONS NOTE Mark position of the special crankcase cover It must be re installed with the same orientation to assure proper operation of the oil jet c Remove the four crankcase cover cap screws securing the special crankcase cover to the crankcase Using a soft mallet gently tap the crankcase cover to break the gasket seal Remove the crankcase cover gasket 27 REAR END COVER If Present 1 Remove the four end cover cap screws 26 that secure the rear end cover to the crankcase 2 Remove the rear end cover from the crankcase Remove the o ring seal 24 from the end cover CLEANING OF PARTS GENERAL All parts should be cleaned in a good commercial grade of solvent and dried prior to inspection CYLINDER HEAD ASSEMBLY 1 Carefully remove all gasket material adhering to the cylinder head 13 cooling plate 15 valve plate assembly 16 and cast iron crankcase 21 Make certain not to scratch or mar the gasket surfaces Pay particular attention to the gasket surfaces of the head 2 Remove carbon d
40. d an that the unloader mechanism is leaking and needs air source shop air or small air tank Open the to be serviced A 15 Appendix B Information about the BASIC Test Kit Bendix P N 5013711 Service writer records info including the number of days since all air tanks were drained and fills out symptom checklist Technician inspects items START BASIC TEST Park vehicle on LEVEL ground Chock wheels drain air from system Drain contents of ALL air tanks into BASIC cup Bendix Air System Inspection Cup BASIC Test Information Is there YES lt 1 Vehicle OK less than one Return vehicle to END TEST unit of liquid service NO Is there more E a ee H O Y Cloudy emulsion mixture e water or e cloudy emulsion mixture NO only oil Is this a transit vehicle bulk unloader or has more than 5 axles YES this is a high air use vehicle Find the point on the label where the number of oil units meets the number of days were last drained Is the point above the HIGH Air Use line on the cup Is the point above the LOW Air Use line on the cup Test for air leakage Use Test 2 Air Leakage YES the vehicle have Repair leaks and excessive air leakage END TEST return vehicle to service NO NO did not know when last drained Was the number of days since last d
41. d 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 certain to drain the air pressure from all reservoirs before beginning ANY work on the vehicle If the vehicle is equipped with an AD IS air dryer system or a dryer reservoir module be sure to drain the purge reservoir 5 Following the vehicle manufacturer s recommended procedures deactivate the electrical system in a manner that safely removes all electrical power from the vehicle 6 Never exceed manufacturer s recommended pressures 7 Never connect or disconnect a hose or line containing pressure it may whip Never remove a component or plug unless you are certain all system pressure has been depleted 8 Use only genuine Bendix replacement parts components and kits Replacement hardwa
42. d troubleshooting guide 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 The Technician uses the chart label on the BASIC test cup to help decide the action to take based on the amount of oil found Use the lower acceptance line for low air use vehicles and upper line for high air use vehicles from Step A 1 Record days since air tanks were last drained If number of days Is 30 60 days high air use or 2 Record amount of oil found 3 Action to if oil level is at or below acceptance line for number of days gt y System OK Return to service 30 90 days low air if oil level is above use cpa line for number Go to Step D gt of days gt Otherwise gt if the number of days is unknown or outside the limits above BASIC Test Example An oil level of 4 units in a sixty day period is within the acceptance area ator 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 the air tanks were drained meets the oil level Ifitis ator below the low or high use acceptance line the vehicle has passed the test If the point is above
43. e 4 g Tests continued Test 4 Governor Malfunction supply reservoir service reservoir or reservoir 1 Inspect control lines to and from the governor port of the D 2 governor verify cut in and for restrictions e g collapsed or kinked cut out pressures are within vehicle OEM Repair as necessary specification 2 Using a calibrated external gauge in the 3 If the governor is malfunctioning replace it Test 5 Governor Control Line 1 Ensure that the governor control line from the Perform proper reservoir drain intervals and air reservoir is located at or near the top of the res dryer cartridge maintenance per Maintenance ervoir This line if located near the bottom of Schedule and Usage Guidelines Table A on the reservoir can become blocked or restricted page A 3 by the reservoir contents e g water or ice 3 Return the vehicle to service Test 6 Compressor Unloader Leakage Bendix Compressors Park vehicle chock shut off and charge the unloader port by allowing wheels and follow all standard safety procedures air pressure to enter the hose and unload the Remove the governor and install a fitting to the compressor Shut off the air supply and observe unloader port Add a section of air hose min the gauge Asteady reading indicates no leakage 1 ft long for a 1 2 diameter line and a gauge at the unloader port but a falling reading shows to the fitting followed by a shut off valve an
44. e governor as required 4 Note that the compressor cycles to the loaded and unloaded conditions promptly If prompt action is not noted repair or replace the governor and or repair the compressor unloader IMPORTANT NOTE Replacement air governors must have a minimum cut in pressure of 100 psi The cut in pressure is the lowest system pressure registered in the gauges before the compressor resumes compressing air Compressors with no signal line to the unloader port should have avent cap e g Bendix part number 222797 installed in the port Under no circumstances should the port be plugged or left open 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 compressor is cycling between the loaded pumping and unloaded non pumping modes due to unloader leakage 1 Head Cap Screws oO include washers See Figure 10 for Port Details 5 Unloader Cover Gasket 12 ST 4 Safety Valve Oc 13 Cylinder Head 15 Cooling Plate 4 Unloader Cover e r5 1 Pe ii y 2 Unloader Cover Cap Screws 2 3 Unloader Cover Splash Shield M 6 Unloader Balance Piston ee 7 O Ring z 8 Spring 9 O Ring 10 Unloader Piston 11 O Ring
45. enance kit available from authorized Bendix parts outlets COMPRESSOR REMOVAL amp DISASSEMBLY GENERAL The following disassembly and assembly procedure is presented for reference purposes and presupposes 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 Since the compressors have a different head and crankcase design be sure to only use replacement parts specifically applicable Note In particular the heads and head gaskets are not interchangeable between the two compressors covered in this document Section 1 Standard Compressor Cylinder Head Gasket Kit ccccccssssescssssesssssssesssssserssees 9008558 WIIG ACS Ra E E E E AT E iene 5008557 Governor Adapter Kit cxsccnatacneelascnlacestscastasensiaseaadbabieadeiuiaiis 5008561 Compressor Seal Kit CrankCaSe ccccccessesseessetseeeeeees 9008559 Components and kits for Caterpillar Engines CAT C7 C9 Cylinder Head Assembly Kit ccccceceeceees K023601 CAT C11 C13 C15 C18 Cylinder Head Assembly Kit K023600 CAT C7 C9 Inlet Check Valve csessessesssssssssserssrsessesenss 801580 CAT C11 C13 C15 C18 Inlet Check Valve cceceeeeseereeees 801592 CAT C7 C9 Engine Seal Kit c cc ccccscsecessesssscsessessesseeaeees 9012367 CAT C11 C1
46. eposits from the discharge and inlet cavities of the cylinder head cooling plate and valve plate assembly They must be open and clear in both assemblies Make certain not to damage the head 3 Remove rust and scale from the cooling cavities and passages in the cylinder head cooling plate and valve plate assembly and use shop air to clear debris from the passages 4 Check the threads in all cylinder head ports for galling e g abrasion chafing Minor thread chasing damage is permitted 5 Make certain the unloader vent passage under the unloader cover 4 in the head is open and free of debris NOTE This only applies to the unloader cover on the Standard Compressor INSPECTION OF PARTS CYLINDER HEAD COOLING PLATE VALVE PLATE ASSEMBLY AND UNLOADER MECHANISM 1 Carefully inspect the head gasket surfaces on the cylinder head 13 for deep gouges and nicks Also inspect the cylinder head for any cracks or port thread damage If detected the compressor must be replaced If large amounts of carbon build 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 15 for deep gouges and nicks Also inspect the cooling plate for any cracks or other damage If found the compressor must be replaced 3 Carefully inspect the valve plate assembly 16 gasket surfaces
47. h pounds 30 33 Nem using a crossing pattern CYLINDER HEAD ASSEMBLY PART ONE HEAD INSTALLATION Section 2 Closed Room Compressors 1 Note the position of the protruding alignment pins on the deck top of the crankcase 21 Install the metal inlet reed valve gasket 17 over the alignment pins on the crankcase 2 Position the valve plate assembly 16 on the crankcase so that the alignment pins in the crankcase fit into the corresponding holes in the valve plate assembly 3 Position and install one of the embossed metal gaskets 14 over the alignment bushings protruding from the cooling plate Position and install the second embossed metal gasket 14 over the alignment bushings on the opposite side of the cooling plate When properly installed the outline of the two embossed gaskets match the outline of the cooing plate Sequence Torque Sequence Torque Nem FIGURE 18 CLOSED ROOM COMPRESSOR HEAD BOLT TORQUE SEQUENCE 4 Install the cooling plate onto valve plate assembly by lining up the alignment bushings on the cooling plate over the oversized countersunk holes of the valve plate assembly Again when properly installed the outline of the cooling plate matches the outline of the valve plate 5 Position and install the cylinder head over the alignment bushings protruding from the cooling plate When properly installed the outline of the cylinder head assembly will match the outline of the cooling plate a
48. he cylinder head 6 Gently tap the cylinder head cooling plate 15 and valve plate assembly 16 with a soft mallet to break the gasket seal between the valve plate assembly and the crankcase 21 Lift the cylinder head with cooling plate and valve plate assembly off the crankcase 7 Remove the metal inlet reed valve gasket 17 8 Gently tap the cylinder head cooling plate and valve plate assembly with a soft mallet to break the gasket seals Then separate the cylinder head from the cooling plate 15 and valve plate assembly and remove the two gaskets 14 between them 13 Section 2 Closed Room Compressor refer to Figure 16 1 Remove the discharge safety valve 12 from the cylinder head 13 2 To restrain the spring force exerted by balance piston spring 8 of the unloader assembly hold the unloader cover 4 in place while removing the two unloader cover cap screws 2 Carefully release the hold on the unloader cover until the spring force is relaxed then remove the unloader cover 3 Remove the unloader cover gasket 5 4 Remove the balance piston 6 its spring 8 and the unloader piston 10 along with its o rings 7 9 amp 11 from the cylinder head 13 5 Remove the six hex head bolts from the cylinder head Note The five hex bolts located towards the perimeter of the cylinder head retain the cylinder head directly to the crankcase The single hex bolt in the center of the cylinder head holds
49. he work is being performed on the vehicle s air brake system or any auxiliary pressurized air systems make certain to drain the air pressure from all reservoirs before beginning ANY work on the vehicle If the vehicle is equipped with an AD IS air dryer system or a dryer reservoir module be sure to drain the purge reservoir Symptom What it may indicate 1 0 Oil Test Card Not a valid test Look for Normal Normal Charging system is working within normal range Check Check Charging system needs further investigation Following the vehicle manufacturer s recommended procedures deactivate the electrical system in a manner that safely removes all electrical power from the vehicle Never exceed manufacturer s recommended pressures Never connect or disconnect a hose 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
50. hicle O E maintenance recommendation for these components Using dash gauges verify that the compressor builds air system pressure from 85 100 psi in 40 seconds or less with engine at full governed rom Return the vehicle to service Go to Test 2 on page A 14 See Table A column 1 on page A 3 for some typical compressor applications Ifthe compressor is too small for the vehicle s role for example where a vehicle s use has changed then upgrade the compressor Note The costs incurred e g installing a larger capacity compressor etc are not covered under original compressor warranty Go to Test 6 on page A 15 An air leak at the head gasket may indi cate a downstream restriction such as a freeze up or carbon blockage and or could indicate a defective or missing safety valve Find blockage go to 9 0 f for details and then replace the compressor Do not re use the safety valve without testing See Symptom 12 0 a A 9 Symptom What it may indicate What you should do 9 0 Air brake f Restricted discharge line gt If discharge line is restricted charging system seems slow to Check build pressure continued Dash gauges Kinked discharge line shown Engine Oil Quality Inadequate oil change intervals the formulation of the oil and or the quality of oil filter used can all lead to poor oil quality These can increase the rate at which carbon builds up in the discharge line Bendix recomme
51. hicle passes Note for returning vehicles that are being 4 Bmore than one oil unit of water or a cloudy emulsion mixture re tested after a water cloudy emulsion is found mixture was found last time and the air a Change the vehicle s air dryer cartridge dryer cartridge replaced If more than one see Footnote 1 ER TE EE E b Conduct the 4 minute leakage test Step D c STOP the inspection and check the vehicle again after 30 days see Footnote 2 ce tie go to Step C Footnote 1 Note Typical air dryer cartridge replacement schedule is every 3 yrs 300K miles for low air use vehicles and every year 100K miles for high air use vehicles 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 Footnote 2 To get an accurate reading for the amount of oil collected during a 30 day period ask the customer not to drain the air tanks before returning Note that 30 90 days is the recommended air tank drain schedule for vehicles equipped with a Bendix air dryer that are properly maintained If in cold weather conditions the 30 day air tank drain schedule is longer than the customer s usual draining interval the customer must determine based on its experience with the vehicle whether to participate now or wait for warmer weather See the cold weather tips in Bulletins TCH 008 21 and TCH 008 22 included in Appendix B of the advance
52. i e J Technician removes governor 13 0 Reservoir safety valve releases air 14 0 Air dryer doesn t purge Never hear exhaust from air dryer 15 0 Compressor constantly cycles compressor remains unloaded for a very short time A 12 What it may indicate a Restriction between air dryer and reservoir b Air dryer safety valve malfunction c Air dryer maintenance not performed d Air dryer malfunction e lmproper governor control line installation to the reservoir f Governor malfunction a Reservoir safety valve malfunction b Governor malfunction c Compressor unloader mechanism malfunction a Air dryer malfunction b Governor malfunction c Air brake system leakage d Improper governor control line installation to the reservoir a Air brake charging system maintenance not performed Check b 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 Verify relief pressure is at vehicle or component manufacturer specifications Replace if defective See Maintenance Schedule and Usage Guidelines Table A column 3 on page A 3 Verify operation of air dryer Follow vehicle O E maintenance recommendations and component Service Data information Go
53. ing conditions do not exist 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 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 Inspect air lines and verify check valves are operating properly gt 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 A 11 Symptom 12 0 Air dryer safety valve releases air Air dryer safety valve 7 Tj PE Tsi i a iN Ti ES i a a 5 4 Pi q i y ae z z B j a F
54. ing for leaks with soap solution 17 0 Compressor a Improperly installed plugs or coolant Inspect for loose or over torqued fittings leaks coolant line fittings Reseal and tighten loose fittings and plugs as necessary If overtorqued fittings and plugs have cracked ports in the head replace the compressor b Damaged compressor head gt An air leak at the head gasket may indicate gasket a downstream restriction such as a freeze up or carbon blockage and or could indicate a defective or missing safety valve Find blockage go to 9 0 f for details and then replace the compressor Do not re use the safety valve without testing See Symptom 12 0 a c Porous compressor head casting If casting porosity is detected replace the compressor 18 0 Noisy a Damaged compressor gt Replace the compressor compressor 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 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 at a later date this guide e Turbocharger leakage Lubricating oil from leaking turbocharger seals can enter the air compressor intake and give misleading symp
55. l sensitive systems see page 16 SAE J2024 outlines tests all air brake system pneumatic components need to be able to pass including minimum levels of tolerance to contamination Symptom 6 0 Excessive oil consumption in engine 7 0 Oil present at air dryer cartridge during maintenance 8 0 Oil in ping tank or compressor dis charge aftercooler 9 0 Air brake charging system seems slow to build pressure What it may indicate A problem with engine or other engine accessory The engine service manual has more information Air brake charging system is functioning normally 7 NGG Oil shown leaking from an air dryer cartridge Air brake charging system is functioning normally Y Normal a Air brake charging system functioning normally Normal b Air brake system leakage c Compressor may be undersized for the application d Compressor unloader mechanism malfunction e Damaged compressor head gasket What you should do gt See engine service manual Check Air dryers remove water and oil from the air brake charging system A small amount of oil is normal Check that regular maintenance is being performed and that the amount of oil in the air tanks reservoirs is within the acceptable range shown by the BASIC test see also column 5 of Table A on page A 3 Replace the air dryer cartridge as needed and return the vehicle to service Follow ve
56. let coolant and governor adapter 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 5 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 Also check for noisy operation TESTING THE REBUILT COMPRESSOR In order to properly test a compressor under operating conditions a test rack for correct mounting cooling lubricating and driving the compressor is necessary Such tests are not compulsory if the unit has been carefully rebuilt by an experienced person A compressor efficiency or build up test can be run which is not too difficult An engine lubricated compressor must be connected to an oil supply line of at least 15 psi pressure during the test and an oil return line must be installed to keep the crankcase drained Connect to the compressor discharge port a reservoir with a volume of 1500 cubic inches including the volume of the connecting line With the compressor operating at 2100 RPM the time required to raise the reservoir s pressure from 85 psi to 100 psi should not exceed 5 seconds During this test the compressor should be checked for gasket leak
57. ling 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 LD Min Other Requirements 6 0 9 5 ft Yo in None 9 5 12 ft Yin 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 12 16 ft 5 8 in Last 3 feet including fitting at the end of the discharge line must be insulated with 1 inch thick closed cell polyethylene pipe insulation lf the discharge line length must be less than 6 feet or greater than 16 feet contact your local Bendix representative A 19 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 In None If the discharge line length must be less than 10 feet or greater than 16 feet contact your local Bendix representative System
58. m and remedy section with tests to diagnose most charging system problems INDEX Symptom Page Number Symptom Page Number Air Coolant Air brake charging system Compressor leaks coolant 17 0 00 A 13 Slow Duld 90 sinsunecovcerasiniocncredupreinss A 9 10 Doesn t build air 10 0 cccccccccsecsesseesseee A 11 SE Air dryer Oil CONSUMPTION 6 0 cece ee eeeeeeeeeeeeee sees A 9 Doesn t purge 14 0 00 0 eee eeeeeees A 12 Oil Safety valve releases air 12 0 A 12 Compressor Oil Test Card results 1 0 E EE seca veeanns A 4 Constantly cycles 15 0 cccccceeeeee A 12 Oil is present Leaks air 16 0 ccccccscsesecesesseseseseseeeeseees A 13 On the outside of the compressor 2 0 A 5 Safety valve releases air 11 0 A 11 At the air dryer purge exhaust Noisy 18 0 en A 13 or surrounding area 3 0 eee A 5 Reservoir In the supply reservoir 40 siistii A 6 8 f At the valves 5 0 A 8 AN VANE EAEE all Oa ple At air dryer cartridge 7 0 ccccceeeeeeee A 9 In the ping tank or compressor discharge aftercooler 8 0 0008 Maintenance amp Usage Guidelines 1 Maintenance Schedule and A Sytem Keabage Usage Guidelines Table A A 3 3 Compressor Discharge and Oil Leakage at Head Gasket Air Dryer Inlet Temperature 4 Governor Malfunction 5 Governor Control Line 6 Compressor Unloader BASIC
59. mercial Vehicle Systems LLC All Rights Reserved 10 07 Printed in U S A 40
60. 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 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 18 INCH POUNDS TO FOOT POUNDS To convert inch pounds to foot pounds of torque divide inch pounds by 12 12 Inch Pounds 1 Foot Pound 12 Example FOOT POUNDS TO INCH POUNDS To convert foot pounds to inch pounds of torque multiply foot pounds by 12 Example 1 Foot Pound x 12 12 Inch Pounds CRANKCASE COVER 1 Position the crankcase cover gasket 27 on either the crankcase or crankcase cover and install the crankcase cover on the crankcase using the four cap screws Snug all four cap screws then torque to 62 71 inch pounds 7 8 Nem using a crossing pattern 2 In the case of the Caterpillar C11 and C13 engine application the compressor utilizes an oil jet that sprays oil under the piston for purposes of cooling This oil jet is part of a special crankcase cover that is used strictly on the compressor for the C11 and C13 engine installation See Figure 14 Refer to section OPERATION Lubri
61. n by the vehicle s engine and functions continuously while the engine is in operation Actual compression of air is controlled by the compressor unloading mechanism operating in conjunction with a governor Detroit Diesel S60 Standard Compressors use an Inlet Check Valve ICV or alternately an ICV plus a reservoir in the air inlet line depending on the application AS 7 a z a Governor q Unloader Port Compressor Air Dryer Governor Reservoir Supply Reservoir Closed Room Compressor Typical System Governor Unloader Port Air Dryer Governor Reservoir Port Compressor Supply Reservoir FIGURE 6 STANDARD AND CLOSED ROOM BA 921 COMPRESSOR CHARGING SYSTEMS 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 in naturally aspirated applications or pressurized air in turbocharged applications flows through the open inlet valve and fills the cylinder bore above the piston See Figure 7A AIR COMPRESSION LOADED When the piston reaches the bottom of the stroke a position known as bottom dead center or BDC the inlet reed valve closes Air above the piston is trapped by the closed inlet reed valve and is compressed as the piston moves upwards When air in the cylinder bore reaches a pressure greater than that of the system pre
62. nd valve plate assembly Note The alignment bushings will only fit into two of the cylinder head bolt holes 6 Install the 6 hex head cylinder head bolts and washers and snug them finger tight then torque the bolts in the sequence specified in Figure 18 PART TWO UNLOADER INSTALLATION These instructions apply to both the Standard and Closed Room Compressors 7 Apply acoating of the lubricant provided in the unloader kit into the unloader bore both diameters Apply additional lubricant to the three o ring grooves on the unloader piston 10 Note that the o ring 7 installs inside the top of the unloader piston Install the three o rings 7 9 11 into the appropriate o ring grooves on the unloader piston 10 Apply another coating of the lubricant onto the exposed o ring surfaces and onto the large diameter of the balance piston 6 Install the unloader piston with the pre installed o rings into the cylinder head unloader bore making certain not to damage them in the process 8 Install the balance piston spring 8 in the unloader piston 9 Apply a coating of lubricant to the largest diameter of the balance piston Install the small diameter end of the balance piston through the center of the spring 10 Install the unloader cover gasket 5 on the cylinder head making certain both screw holes align 11 Position the unloader cover 4 on top of the balance piston making certain the stamped logo is visible 12
63. nds oil soot solids be maintained at less than 3 g Restricted air inlet not enough air gt to compressor Check Partly collapsed inlet line shown h Poorly filtered inlet air poor air amp quality to compressor Check i Compressor malfunction gt Check A 10 gt By more than 1 16 carbon build up replace the discharge line see Table A column 2 on page A 3 for recommended size and go to Test 3 on page A 14 gt By other restrictions e g kinks Replace the discharge line See Table A column 2 on page A 3 for recommended size Re test for air build Return vehicle to service or if problem persists go to 9 0 a The discharge line must maintain a constant slope down from the compressor to the air dryer inlet fitting to avoid low points where ice may form and block the flow If 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 Check compressor air inlet line for restric tions brittleness soft or sagging hose con ditions etc Repair as necessary Refer to vehicle manufacturer s guidelines for inlet line size Check the
64. nment pins on the deck top of the crankcase 21 Install the metal inlet reed valve gasket 17 over the alignment pins on the crankcase 2 Position the valve plate assembly 16 on the crankcase so that the alignment pins in the crankcase fit into the corresponding holes in the valve plate assembly 3 Position one of the embossed metal head gaskets 14 over the alignment bushings protruding from the cooling plate Position the second embossed metal head gasket over the alignment bushings on the opposite side of the cooling plate 15 When properly positioned the outline of the two embossed gaskets match the outline of the cooling plate 4 Install the cooling plate with the head gaskets onto valve plate assembly by lining up the alignment bushings on the cooling plate over 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 5 Position and install the cylinder head 13 over the alignment bushings protruding from the cooling plate When properly installed the outline of the cylinder head 16 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 6 Install the four hex head cylinder head bolts 1 and snug them then tighten evenly to a torque of 265 to 292 inc
65. nor 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 A 14 pedal in position Observe the dash gauges If you see any noticeable decrease of the dash air gauge readings i e more than 4 psi plus two psi for each additional trailer during either two minute test repair the leaks and repeat this test to confirm that they have been repaired Air leaks can also be found in the charging system parking brakes and or other components inspect and repair as necessary Note that only vehicles that have passed Test 2 would be candidates for this test 4 Then while maintaining max rpm and pressure range measure and record the surface temperature of the fittings gt atthe compressor discharge port T1 gt atthe air dryer inlet fitting T2 Use a touch probe thermocouple for measuring the temperature See table below Re test before returning the vehicle to service T1 T2 Compressor Air Dryer Discharge Inlet Fitting Fitting Temperatures are within normal range for this test check other symptoms Go to 4 0 h This could indicate a discharge line problem e g restriction Call 1 800 AIR BRAKE 1 800 247 2725 and speak with our Tech Team Compressor is running hot Check coolant 4 f and or discharge lin
66. of oil before it can enter the air brake system For particularly oil sensitive systems the Bendix PuraGuard system can be use 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 or BASIC kit to help substantiate suspected excessive oil passing The steps to be followed when using the BASIC kit are presented in APPENDIX B on page A 16 COMPRESSOR DRIVE Check for noisy compressor operation 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 and proper unloader mechanism operation Repair or replace parts as necessary COMPRESSOR UNLOADER amp GOVERNOR Test and inspect the compressor and governor unloader system for proper operation and pressure setting 1 Check for leakage at the unloader port Replace leaking or worn O rings 2 Make certain the unloader system lines are connected as illustrated in Figure 6 3 Cycle the compressor through the loaded and unloaded cycle several times Make certain that the governor cuts in compressor resumes compressing air at a minimum of 105 psi cut out should be approximately 15 20 psi greater than cut in pressure Adjust or replace th
67. ommended but not specifically necessary to mark the relationships of the cylinder head 13 cooling plate 15 valve plate assembly 16 and crankcase 21 A convenient method to indicate the above relationships is to use a metal scribe to mark the parts with numbers or lines Do not use marking methods such as chalk that can be wiped off or obliterated during rebuilding Prior to disassembly make certain that the appropriate kits and or replacement parts are available Refer to Figure 15 for the standard compressor and Figure 16 for the Closed room compressor during the entire disassembly and assembly procedure What follows is a description of a complete disassembly actual maintenance may only need to include portions of these instructions CYLINDER HEAD Section 1 Standard Compressor refer to Figure 15 1 Remove the discharge safety valve 12 from the cylinder head 13 2 To restrain the spring force exerted by balance piston spring 8 of the unloader assembly hold the unloader cover 4 in place while removing the two unloader cover cap screws 2 and spray shield 3 Carefully release the hold on the unloader cover until the spring force is relaxed then remove the unloader cover 3 Remove the unloader cover gasket 5 4 Remove the balance piston 6 its spring 8 and the unloader piston 10 along with its o rings 7 9 amp 11 from the cylinder head 13 5 Remove the four hex head bolts 1 from t
68. ondition unloaded mode the compressor cylinder pushes air back out of the inlet port into the expansion tank The ICV at the end of the expansion tank prevents the air from traveling beyond this point Because the air is boosted under pressure it is important that the compressor inlet line is of sufficient length strength and volume to minimize the build up of air pressure in the inlet system The air shuttles back and forth between the compressor cylinder bore and the expansion tank during this phase of the compressor operation DETROIT DIESEL The Detroit Diesel Series 60 EGR engine is equipped with the Bendix BA 921 compressor and uses naturally aspirated air induction system Detroit Diesel recommends the use of an inlet check valve in the air induction system to prevent the air from the compressor cylinder bore from being forced back into the engine air induction system when the compressor is in the unloaded mode non pumping condition A flexible high pressure hose is installed between the inlet check valve and the compressor inlet fitting This hose can be of various lengths to accommodate the distance between the compressor and inlet check valve See Figure 14 During operation non pressurized air from the engine s air source is routed to the compressor from a point between the engine air filter and the non pressure side of the turbocharger When the compressor is building air loaded mode the air flows from the engine
69. ooling 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 and inlet fittings if applicable and note their position on the compressor to aid in reassembly Note If a cylinder head maintenance kit is being installed stop here and proceed to PREPARATION FOR DISASSEMBLY If replacing the compressor continue 5 Remove any supporting bracketing attached to the compressor and note their positions on the compressor to aid in reassembly 6 Remove the front flange mounting bolts and remove the compressor from the vehicle 7 Inspect drive gear and associated drive parts for visible wear or damage If the compressor drive gear is worn or damaged the compressor must be replaced Refer 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 Remove the balance of road dirt and grease from the exterior of the compressor with a cleaning solvent If a rear end cover or end cover adapter is used on the compressor being worked on mark it in relation to the crankcase It is rec
70. ould do gt Check for leaking damaged or defective compressor air inlet components e g induction line fittings gaskets filter bodies etc Repair inlet components as needed Note Dirt ingestion will damage compressor and is not covered under warranty Check Go to Test 4 on page A 15 If you found excessive oil present in the service reservoir in step 4 0 b above and you did not find any issues in steps 4 0 c through 4 0 j above the compressor may be passing oil Replace compressor If still under warranty follow normal warranty process Note After replacing a compressor residual oil may take a considerable period of time to be flushed from the air brake system If a maintained Bendix PuraGuard system filter or Bendix PuraGuard QC oil coalescing filter is installed call 1 800 AIR 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 J2024 compliant gt A small amount of oil does not affect SAE J2024 compliant valves gt Check that regular maintenance is being performed and that the amount of oil in the air tanks reservoirs is within the accept able range shown on the Bendix BASIC test cup see also column 5 of Table A on page A 3 Return the vehicle to service For oi
71. ply From Engine Inlet Check Valve FIGURE 12 EXAMPLE OF CATERPILLAR ACERT ENGINE C7 C9 COMPRESSOR AIR INDUCTION SYSTEM TURBOCHARGED i T Te Air Supply From Engine FIGURE 13 EXAMPLE CATERPILLAR HD ACERT ENGINE C11 C13 C15 C18 COMPRESSOR AIR INDUCTION SYSTEM TURBOCHARGED AIR INDUCTION Section 1 For Standard Compressors GENERAL The Standard Bendix BA 921 air compressor can be used both with air induction systems that are naturally aspirated atmospheric air and pressurized turbocharged The following section covers Caterpillar and Detroit Diesel engine air induction arrangements See Figure 5 for typical flanges used CATERPILLAR Caterpillar HD ACERT engines C11 C13 C15 and C18 and MD ACERT engines C7 and C9 are typically equipped with Bendix BA 921 compressors These engines provide pressurized turbocharged air to the compressor s inlet port Caterpillar recommends the use of an inlet check valve in the air induction system to prevent the air from the compressor being forced back into the engine air induction system when the compressor is operating in the unloaded condition not building air Because the compressor induction system is turbocharged an additional air volume is required between the compressor inlet port and the inlet check valve to prevent excessive air pressure at the compressor inlet in the unloaded mode Figures 12 and 13 show examples of the different air induc
72. r t h N 29 Cap Screws 4 item Qty Description Rear Bearing see Fig 15 Head Gaskets Kit 1 O Ring see Fig 15 Cooling Plate Rear End Cover see Fig 15 Valve Plate Assembly Cap Screws see Fig 15 Inlet Reed Valve Gasket Kit 1 Bottom Cover Gasket Piston Crankcase Cover Connecting Rod Cap Screws Bearing Governor Gasket Kit 3 Crankcase Governor Adapter Kit 3 4 2 1 1 1 1 1 1 1 1 1 O Ring Kit 2 j 2 1 1 1 1 1 1 1 1 Crankshaft see Fig 15 J i 4 i 4 2 1 2 Bolt with Washer FIGURE 16 BA 921 CLOSED ROOM COMPRESSOR EXPLODED VIEW 10 30 Governor 31 Gasket 2 Governor Ai N 32 Bolt with _ Washer 2 IN SERVICE OPERATING TESTS Compressor Performance Build up Test This test is performed with the vehicle parked and the engine operating at maximum recommended governed speed Fully charge the air system to governor cut out air dryer purges Pump the service brake pedal to lower the system air pressure below 80 psi using the dash gauges As the air pressure builds back up measure the time from when the dash gauge passes 85 psi to the time it passes 100 psi The time should not exceed 40 seconds If the vehicle exceeds 40 seconds test for and fix any air leaks and then re test the compressor performance If the vehicle does not pass the test
73. raining known YES number of days was known 30 90 days Replace the Compressor If under warranty follow standard procedures If after a compressor was already replaced the vehicle fails the BASIC test again do not replace the compressor use the Advanced Troubleshooting Guide to investigate the cause s Re test with the BASIC Test after 30 days END TEST END TEST A 16 NO this is a low air use vehicle Vehicle OK a00 Return vehicle to service C 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 50 the vehicle s air tanks IRC the vehicle s air tanks were last drained Go to the Advanced Troubleshooting Guide to find reason s for presence of water Change air dryer cartridge Test for air leakage END TEST Re test with the 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 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 d
74. re tubing hose fittings etc must be of equivalent size type and strength as original equipment and be designed specifically for such applications and systems 9 Components with stripped threads or damaged parts should be replaced rather than repaired Do not attempt repairs requiring machining or welding unless specifically stated and approved by the vehicle and component manufacturer 10 Prior to returning the vehicle to service make certain all components and systems are restored to their proper operating condition 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 lifted off the ground and moving REMOVAL In many instances it may not be necessary to remove the compressor from the vehicle when installing the various maintenance kits and service parts The maintenance technician must assess the installation and determine the correct course of action These instructions are general and are intended to be a guide In some cases additional preparations and precautions are necessary In all cases follow the instructions contained in the vehicle maintenance manual in lieu of the instructions precautions and procedures presented in this manual 1 Block the wheels of the vehicle and drain the air pressure from all the reservoirs in the system 2 Drainthe engine c
75. sembly Kit 4 Inlet Reed Valve Gasket Kits 1 amp 4 Bottom Cover Gasket Piston Crankcase Cover Connecting Rod Cap Screws Sleeve Bearing Governor Gasket Kits 3 amp 4 Crankcase Governor Adapter Kits 3 amp 4 4 2 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 Crankshaft Bolt with Washer FIGURE 15 BA 921 STANDARD COMPRESSOR EXPLODED VIEW 1 Head Cap Screws 6 include washers 12 ST 4 Safety Valve 2 Unloader Cover Cap Screws 2 4 4 Unloader Cover F so Ba 5 Unloader Cover Gasket e 6 Unloader Balance Piston See Figure 11 for Port Details 13 Cylinder Head lt ne z 8 Spring a a ae Se Unloader Piston 14 Head Gasket 2 s 11 O Ring 15 Cooling Plate Alignment OAN Bushings 16 Valve Plate g Assembly a Crankcase 17 Inlet Reed Valve Alignment Gasket Pins Kit Notes Kit 1 Cylinder Head Gasket Kit KO22563 Kit 2 Unloader Kit 5008557 Kit 3 Governor Adapter Kit 5008561 Head Cap Screws Unloader Cover Cap Screws Unloader Cover Splash Shield Unloader Cover Unloader Cap Gasket Unloader Balance Piston O Ring Kit 2 Spring Kit 2 O Ring Kit 2 Unloader Piston Kit 2 Kit 2 Kit 2 ST 4 Safety Valve Cylinder Head 20 Bearing eS 28 Crankcase Cove
76. ssure the discharge reed valves open and allow air to flow into the discharge line and air brake system At the same time air flows into the hollow center of the unloader piston through an opening in the end of the piston Compressed air acts on the interior surfaces of the unloader piston and along with the unloader piston spring holds the unloader piston in the down position against its seat on the valve plate See Figure 7B Air Inlet a Air Port Panne Unloader Discharge Port Port s 5 S SS IN AS VAIN UTTTUUEEEEA VEEN E ZA SSS EDS OZ INS OS LL LLLLZ ll O M Unloader A Piston Down amp EE Seated PSX Inlet Valve Open Piston Moving Down FIGURE 7A OPERATION LOADED INTAKE SIMILAR FOR ALL COMPRESSORS STANDARD COMPRESSOR SHOWN Air Inlet Discharge Port Valve _ Air Open Discharge Unloader a See Unloader Piston Down amp Seated Piston Moving Up FIGURE 7B OPERATION LOADED COMPRESSION SIMILAR FOR ALL COMPRESSORS STANDARD COMPRESSOR SHOWN Air From Governor Unloader Port Air Inlet Port Unloader Piston Up amp Unseated Air in Pistons Shuttles Back and Forth from the Piston to the Cylinder Head and Inlet Port During Unloaded Mode FIGURE 8 OPERATION UNLOADED STANDARD NON COMPRESSION OF AIR UNLOADED Section 1 For Standard Compressor See Figure 8 When air pressure in the supply reservoir reaches the cutout
77. the line then go to the leakage test if oil level is ator below System OK amp 30 day acceptance line gt Return to service Stop inspection if oil level is above 30 day Test again acceptance line gt after 30 days See Footnote 2 q a Days Since Lask Air Tan Qraining 130 as 40 as So ss 60 65 70 OW Sixty days since last air tank draining Decision point Air leakage is the number one Cause of compressors having to pump excessive amounts of STEP D Air Brake System Leakage Test A run too hot and pass 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 1 Observe the dash gauges for two additional minutes without the service brakes applied 2 Apply service brakes for two minutes allow pressure to stabilize and observe the dash gauges If you see any noticeable decrease of the dash air gauge readings repair leaks Repeat oil vapor along into the system Here the Technician conducts a four minute test to see if leakage is a problem with the vehicle being tested this test to confrm 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
78. ting 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 Check compressor air inlet line for restric tions brittleness soft or sagging hose conditions etc Repair as necessary Inlet line size is 3 4 ID Maximum restriction requirement for compressors is 25 inches of water gt Check the engine air filter and service if necessary if possible check the air filter usage indicator Check If a maintained Bendix PuraGuard system filter or Bendix PuraGuard QC oil coalescing filter is installed call 1 800 AIR BRAKE 1 800 247 2725 and speak to a Tech Team member A 7 A 8 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 sh
79. tion systems used by Caterpillar to perform this function CATERPILLAR C7 C9 ENGINES The Bendix BA 921 compressor in the C7 C9 air induction system see Figure 12 receives its air from the engine s intake manifold turbocharged During the pumping condition loaded mode the air flows from the engine intake manifold through the inlet check valve and inlet line to the compressor inlet port During the non pumping condition unloaded mode the compressor cylinder pushes air back out of the inlet port to the inlet check valve The ICV prevents the air from traveling beyond this point Because the air is boosted under pressure it is important that the compressor inlet line is of sufficient length strength and volume to minimize the build up of air pressure in the inlet system The air shuttles back and forth between the compressor cylinder bore and the ICV during this phase of the compressor operation 7 p DEE FIGURE 14 EXAMPLE OF DETROIT DIESEL EGR S60 COMPRESSOR AIR INDUCTION SYSTEM NATURALLY ASPIRATED CATERPILLAR C11 C13 C15 AND C18 ENGINES The Bendix BA 921 compressor in the C11 C13 C15 and C18 air induction systems see Figure 13 receives its air from the engine s intake manifold turbocharged During the pumping condition loaded mode the air flows from the engine intake manifold through the inlet check valve expansion tank and inlet line to the compressor inlet port During the non pumping c
80. to Test 5 on page A 15 Go to Test 4 on page A 15 Verify relief pressure is at vehicle or component manufacturer s specifications typically 150 psi Replace if defective Go to Test 4 on page A 15 Go to Test 6 on page A 15 Verify operation of air dryer Follow vehicle O E maintenance recommendations Go to Test 4 on page A 15 Go to Test 2 on page A 14 Go to Test 5 on page A 15 Available reservoir capacity may be reduced by build up of water etc Drain and perform routine maintenance per Table A columns 3 amp 4 on page A 3 Go to Test 6 on page A 15 Verify operation of air dryer Follow vehicle O E maintenance recommendations and component Service Data information Go to Test 2 on page A 14 Symptom 16 0 Compressor leaks air What it may indicate a Compressor leaks air at connections or ports b Compressor unloader mechanism malfunction c Damaged compressor head gasket s What you should do Check for leaking damaged or defective compressor fittings gaskets etc Repair or replace as necessary Go to Test 6 on page A 15 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 Head gasket locations Test
81. toms A 13 Tests Test 1 Excessive Oil Leakage at the Head Gasket Exterior leaks at the head gasket are not a sign that oil is being passed into the air charging system Oil weepage at the head gasket does not prevent the compressor from building air Observe the amount of weepage from the head gasket lf the oil is only around the cylinder head area it is acceptable return the vehicle to service but if the oil weepage extends down to the nameplate area of the 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 are not normal vehicle conditions Above normal temperatures can cause oil as vapor to pass through the air dryer into the air brake system This test is run with the engine at normal operating temperature with engine at max rpm If available a dyno may be used 1 Allow the compressor to build the air system pressure to gover
82. tors that add to the duty cycle are air Suspension additional air accessories use of an undersized compressor frequent stops excessive leakage from fittings connections lines chambers or valves etc The discharge line allows the air water vapor and oil vapor mixture to cool between the compressor and air dryer The typical size of a vehicle s discharge line see column 2 of Table A on page A 3 assumes a compressor with a normal less than 25 duty cycle operating in a temperate climate See Bendix and or other air dryer manufacturer guidelines as needed When the temperature of the compressed air that enters the air dryer is within the normal range the air dryer can remove most of the charging system oil If the temperature of the compressed air is above the normal range oil as oil vapor is able to pass through the air dryer and into the air system Larger diameter discharge lines and or longer discharge line lengths can help reduce the temperature The discharge line must maintain a constant slope down from the compressor to the air dryer inlet fitting to avoid low points where ice may form and block the flow If instead ice blockages occur at the air dryer inlet insulation may be added here or if the inlet fitting is a typical 90 degree fitting it may be changed to a straight or 45 degree fitting For more information on how to help prevent discharge line freeze ups see Bendix Bulletins TCH 08 21 and TCH 08 22 see pages
83. ts before the supply reservoir such as the governor air dryer reservoir drain cocks safety valve and check valves will not be registered on the vehicle dash gauges and must be tested separately Refer to the various maintenance manuals for individual component leakage tests and the Bendix Test and Checklist published in the Air Brake System Handbook BW5057 and on the back of the Dual Circuit Brake System Troubleshooting Card BW1396 CYLINDER HEAD Check for cylinder head gasket air leakage 1 With the engine running lower air system pressure to 60 psi and apply a soap solution around the cylinder head Check the gasket between the cylinder head and valve plate assembly 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 a genuine Bendix maintenance kit available from an authorized Bendix parts outlet INLET DISCHARGE amp UNLOADER In order to test the inlet and discharge valves and the unloader piston it is necessary to have shop air pressure and an assortment of fittings A soap solution is also required 1 With the engine shut off drain ALL air pressure from the vehicle 2 Disconnect the inlet and discharge lines and remove the governor or its line or adapter fitting 3 Apply 120 130 psi shop air pressure to the unloader port and soap the inlet port Leak
84. und thoroughly clean or replace the affected parts In some case carbon T buildup indicates inadequate cooling Closely inspect the compressor cooling system Check all compressor coolant lines for kinks and restrictions to flow Minimum coolant line size is 3 8 I D Check coolant lines for internal clogging from rust scale If coolant lines appear suspicious check the coolant flow and compare to the tabulated technical data present in the back of this manual Carefully inspect the air induction system for restrictions LUBRICATION Caterpillar Engine Installations Check the external oil supply line for kinks bends or restrictions to flow Supply lines must be a minimum of 3 16 I D Refer to the tabulated technical data in the back of this manual for oil pressure minimum values Check the exterior of the compressor for the presence of oil seepage and refer to the TROUBLESHOOTING section for appropriate tests and corrective action Detroit Diesel S60 Installations On Detroit Diesel Series 60 engine installations the compressor utilizes an internal oil feed design Check the exterior of the compressor for the presence of oil seepage and refer to the TROUBLESHOOTING section for appropriate tests and corrective action Refer to the tabulated technical data in the back of this manual for oil pressure minimum values OIL PASSING All reciprocating compressors pass a minimal amount of oil Air dyers will remove the majority

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