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BENDIX BW1424 User's Manual

1. if oil level is at or below System OK Otherwise 30 day acceptance line gt Return to service if the number of days is Stop inspection unknown or outside the if oil level is above 30 day Test again Stg limits above acceptance line gt after 30 days See Footnote 2 BASIC Test Example An oil level of 4 units in a sixty day period is within the acceptance area at or below the line for both low and high airuse vehicles Return the vehicle to service DaysSince Ua The Technician looks for the point where the number a aay raat aa Om Ne of days since the air tanks were drained meets the lt 0 ss zo oil level If itis at or below the low or high use Sixty days since last air Decision point acceptance line the vehicle has passed the test If tank draining the point is above the line we go to the leakage test Air leakage is the number one cause of compressors having STEP D Air Brake System Leakage Test ies pump excessive amounts of air in turn run too hot and Park the vehicle on level ground and chock wheels Build system pressure to governor cut out pass oil vapor along into the and allow the pressure to stabilize for one minute system Here the Technician 1 Observe the dash gauges for two additional minutes without the service brakes applied conducts a four minute test to 2 Apply service brakes for two minutes allow pressure to stabilize and observe the dash see if leakage is a probl
2. 002 0015 004 0035 CORRECT GAP CLEARANCE WITH RINGS IN CYLINDER WNW 012 FIGURE 11 CORRECT GROOVE CLEARANCE CRANKSHAFT Check the crankshaft threads keyways tapered ends and all machined and ground surfaces for wear scores or damage Standard crankshaft connecting rod journals are between 1 2500 inches and 1 249 inches in diameter If the crankshaft journals are excessively scored or worn or out of round the crankshaft must be replaced Main bearing journals must be maintained so the ball bearings are a snug fit or so that no more than 004 inch clearance exists between the precision sleeve main bearing and the main bearing journals on the crankshaft In crankshafts fitted with oil seal rings the oil seal ring groove or grooves must not be worn The ring groove walls must have a good finish and they must be square Using a wire or similar device check to be sure the oil passages are open through the crankshaft 11 CONNECTING RODS The BX 2150 compressor connecting rod does not incorporate replaceable crankshaft journal bearing inserts and must be replaced if excessively worn Clearance between the crankshaft journal and the connecting rod bearing must not be less than 001 inch or more than 0025 inches REPAIRS It is generally recommended that genuine Bendix service parts and maintenance kits be used whenever the compressor is disassembled A listing of the most common kits and their contents can be found in
3. Bendix BX 2150 Air Compressor AIR OUTLET 2 1 NOT SHOWN UNLOADER WATER STOP OUTLET OUTLET UNLOADER PORTS WATER INLET NOT SHOWN UNLOADER PISTON AIR OUTLET DISCHARGE VALVE PISTON REAR END OIL INLET SLEEVE BEARING ROLLER BEARING BX 2150 AIR COMPRESSOR BELT DRIVE MODEL DESCRIPTION GENERAL The function of the air compressor is to provide and maintain air under pressure to operate devices in the air brake and or auxiliary air systems DESCRIPTION The BX 2150 compressor is a single cylinder single stage reciprocating compressor with a rated displacement of 9 5 CRANKSHAFT OIL PASSAGE cubic feet per minute at 1250 R P M The BX 2150 compressor is constructed from two major assemblies the cylinder head and the crankcase The cylinder head is an iron casting containing the inlet discharge and unloader valving Itis installed on the crankcase and is secured using four cap screws symmetrically placed The cylinder head can be therefore installed in any one of four different positions which are 90 apart Two governor mounting surfaces adjacent to the single rectangular inlet cavity provide a convenient means of mounting the governor to the cylinder head One eighth inch 1 1 2 PT 1 2 P T AIR WATER DISCHARGE PORT 3 2 OUTLET WATER ONLY 1 2 P T WATER PORT 1 8 P T GOVERNOR PORT 2 PLACES BX 2150 COMPRESSOR CYLINDER HEAD pipe
4. Shorter discharge line lengths or insulation may be required in cold climates Inspect air lines and verify check valves are operating properly Ensure discharge line is installed into the inlet of the air dryer and delivery is routed to the service reservoir gt Verify relief pressure is 250 psi Replace if defective Go to Test 6 on page 29 gt Go to Test 4 on page 29 25 26 Symptom 12 0 Air dryer safety valve releases air Air dryer safety valve 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 What it may indicate a Restriction between air dryer and reservoir b Air dryer safety valve malfunction not c Air dryer maintenance 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 lmproper 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 delive
5. Air Dryer Service Data Sheet SD 08 2414 AD SP Air Dryer Service Data Sheet SD 08 2415 Trailer System Guard Air Dryer Service Data Sheet SD 08 2416 34 Appendix B Continued Bendix Technical Bulletin Bulletin No TCH 008 022 Effective Date 1 1 1994 Page 1 of 1 Subject Additional Cold Weather Operation Tips for the Air Brake System Last year we published Bulletin PRO 08 21 which provided some guidelines for winterizing a vehicle air brake system Here are some additional suggestions for making cold weather vehicle operation just a little more bearable Thawing Frozen Air Lines The old saying Prevention is the best medicine truly applies here Each year this activity accounts for an untold amount of unnecessary labor and component replacement Here are some Do s and Don ts for prevention and thawing Do s 1 Do maintain freeze prevention devices to prevent road calls Don t let evaporators or injectors run out of methanol alcohol or protection will be degraded Check the air dryer for proper operation and change the desiccant when needed 2 Do thaw out frozen air lines and valves by placing the vehicle in a warmed building This is the only method for thawing that will not cause damage to the air system or its components 3 Do use dummy hose couplings on the tractor and trailer 4 Do check for sections of air line that could form water traps Look for drooping lines Don ts 1 Do not a
6. Connect the compressor discharge port to a reservoir with a volume of 650 cubic inches including the volume of connecting line With the compressor operating at 1800 R P M the time required to raise the reservoir s pressure from 0 P S I to 100 P S I should not exceed 20 seconds During this test the compressor should be checked for gasket leakage and noisy operation as well as unloader operation and leakage NOTE With no inlet check valve or air strainer attached to the compressor inlet TABULATED TECHNICAL DATA Average weight 33 Ibs Number of cylinders 1 Bore size 3 375 Stroke 1 468 Displacement at 1250 R P M 9 5 C F M Maximum recommended R P M 3000 R P M Minimum coolant flow water cooled at Maximum R P M 2 5 G P M Minimum R P M 5 G P M Minimum coolant flow air cooled N A Approximate horsepower required at 1250 R P M at 120 PSIG naturally aspirated 1 7 Turbocharge limits Maximum R P M 2200 R P M Maximum pressure gauge 15PSIG Maximum inlet air temperature 250 F Maximum discharge air temperature 400 F Minimum pressure required to unload naturally aspirated 60PSIG with inlet check valve 85 PSIG turbocharged 85 PSIG Minimum oil pressure required at engine idling speed 5 PSIG Minimum oil pressure required at any engine speed 15PSIG Oil capacity of self lubricated model N A Minimum discharge line size 1 2 I D Minimum coolant line size 3 8 I D Minimum oil supply line size 3 16 I
7. mended Air Dryer Cartridge Drain Replacement mended Reservoir Reservoir Oil Contents at Regular Schedule Drain Interval BASIC test acceptable Recom range mended 3 oil units Every per month Month See Max of appendix every 90 A with air Suspension control suggested days school bus upgrades a Fe 5 8in 12 ft For the BASIC High Air Use TOSE I 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 Ca with up to 25 duty cycle e g City transit bus refuse bulk unloaders low boys Bendix Tu Flo 750 air compressor Bendix BA 921 air compressor For oil carry over control suggested upgrades 5 8 in 15 ft Order Bendix P N 5013711 BASIC test acceptable range 5 oil units per month See appendix A urban region coach central tire inflation For oil carry over control suggested upgrades 3 4 in 15 ft Bendix BA 922 or DuraFlo 596 air compressor Footnotes 1 With increased air demand the air dryer cartridge needs to be replaced more often 2 Use the drain valves to slowly drain all reservoirs to zero psi 3 Allow the oil water mixture to fully settle before measuring oil quantity 4 Tocounter above normal temperatures at the air dryer inl
8. Air Strainer Compressor utilizes its own attached air strainer polyurethane sponge or pleated paper dry element 2 Naturally aspirated Engine Air Cleaner Compressor inlet is connected to the engine air cleaner or the vacuum side engine air cleaner of the supercharger or turbocharger 3 Pressurized induction Compressor inlet is connected to the pressure side of the supercharger or turbocharger See the tabulated technical data in the back of this manual for specific requirements for numbers 2 and 3 above OLD STYLE HEAD ADAPTER REQUIRED INLET CHECK VALVE KIT 104670 FAILURE TO INSTALL ADAPTER 297871 WHEN USING AN INLET CHECK VALVE WITH THIS STYLE HEAD WILL RESULT IN COMPRESSOR DAMAGE IDENTIFY NEW HEAD BY NOTING NEW STYLE HEAD PRESENCE OF PLUGGED BOSS ADAPTER NOT REQUIRED INLET CHECK VALVE KIT 104670 FIGURE 6 INLET CHECK VALVE An inlet check valve is used on some naturally aspirated BX 2150 compressors never with pressurized induction see 3 above to prevent inlet oil misting during the unloaded cycle The new style BX 2150 compressor head See Figure 6 can be identified by the plugged boss on the upper right hand side This head only requires kit 104670 to install an inlet check valve All other old style BX 2150 compressor heads See Figure 6 require the use of the inlet adapter 297871 and inlet gasket 243430 in addition to the kit 104670 WARNING FAILURE TO
9. D Minimum oil return line size 1 2 I D Minimum air inlet line size 5 8 I D Minimum unloader line size 3 16 I D Installed weight determined by final mounting configuration 14 WATER PORT DISCHARGE FIGURE 12 UNLOADER KIT The unloader kit is designed for use when unloader piston leakage is detected as described under the Compressor Air Leakage Tests section of this manual The kit contains the following components which are keyed to Figure 12 Qty Description Key 1 Unloader stop assembly 3 1 Unloader piston assembly 4 MAJOR MAINTENANCE KIT The major maintenance kit is designed to rebuild the BX 2150 compressor head assembly and contains the following parts which are keyed to Figure 12 Qty Description Key 1 Unloader Kit 3 amp 4 1 Discharge Valve 12 1 Governor Gasket 1 1 Strainer Gasket 2 1 Discharge Valve Spring 13 1 Cylinder Head Gasket 14 1 Unloader Spring 10 1 Inlet Valve Gasket 9 1 Discharge Valve Seat 11 1 Inlet Valve Stop 5 1 Inlet Valve 7 1 Inlet Valve Seat 8 1 Inlet Valve Spring 6 This troubleshooting guide obsoletes and supersedes all previous published troubleshooting information relative to Bendix air compressors Advanced Troubleshooting Guide for Air Brake Compressors The guide consists of an introduction to air brake charging system components a table showing recommended vehicle maintenance schedules and a troubleshooting symptom and remedy section with tests to diagnose most
10. 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 35 36 BW1424 2004 Bendix Commercial Vehicle Systems LLC All rights reserved 9 2004 Printed in U S A
11. a discharge line safety valve this component is recommended The discharge line safety valve is installed in the cylinder head or close to the compressor discharge port and protects against over pressurizing the compressor in the event of a discharge line freezeup FIGURE 4B DISCHARGE LINE SAFETY VALVE Optional Bendix PuraGuara QC Oil Coalescing Filter Service Reservoir Supply Reservoir Reservoir Drain DISCHARGE LINE TEMPERATURE 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 air dryer contains a filter that collects oil droplets anda 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 recommend installation of a Bendix PuraGuard QC oil coalescing filter designed to minimize the amount of oil present LUBRICATION All BX 2150 compressors are connected to the
12. air brake system For particularly oil sensitive systems the Bendix PuraGuard QC oil coalescing filter can be used in conjunction with a Bendix air dryer If compressor oil passing is suspected refer to the TROUBLESHOOTING section and TABLE A for the symptoms and corrective action to be taken In addition Bendix has developed the Bendix Air System Inspection Cup or BASIC test to help substantiate suspected excessive oil passing The steps to be followed when using the BASIC test are presented in APPENDIX A at the end of the TROUBLESHOOTING section COMPRESSOR DRIVE Every six months 1800 operating hours or 50 000 miles whichever occurs first check for noisy compressor operation Variations in noise level in conjunction with the compression and unloaded cycles generally indicate loose or worn drive components On belt drive compressors check for pulley and belt alignment and tension Adjust as necessary paying particular attention not to overtighten belt tension Check for loose and out of aligned pulleys Adjust or replace as necessary Compressor crankshaft keyway damage indicates a loose pulley and often requires compressor replacement Main bearing failures on belt driven compressors often indicate excessive belt tension A thorough inspection and possible replacement of drive components should be made at each compressor change Special attention should be given to drive gears and couplings on compressors which have b
13. 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 Ne 7 20 What you should do Drain all air tanks and check vehicle at next service interval using the Bendix BASIC test See Table A on page 17 column 3 and 4 for recommended service schedule Check gt Drain all air tanks into Bendix BASIC test cup Bendix Air System Inspection Cup If less than one unit of reservoir contents is found the vehicle can be returned to service Note If more than one oil unit of water or a cloudy emulsion mixture is present change the vehicle s air dryer check for air system leakage Test 2 on page 28 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 f
14. engine s pressurized oil system and a continuous flow of oil is provided to the compressor which is eventually returned to the engine Oil is fed into the compressor in various ways for example through the rear end cover or the drive end of the crankshaft An oil passage in the crankshaft conducts pressurized oil to the precision sleeve main bearings and to the connecting rod bearing The cylinder bore connecting rod wrist pin bushing and ball type main bearing where used are splash lubricated Splash lubrication is obtained as oil is forced out around the crankshaft journals by engine oil pressure See the tabulated technical data in the back of this manual for specific requirements COOLING Air flowing through the engine compartment from the action of the engine s fan and the movement of the vehicle assists in cooling the crankcase Coolant flowing from the engine s cooling system through connecting lines enters the head and passes through the head s water jacket and back to the engine Proper cooling is important in maintaining discharge air temperatures below the maximum 400 F recommended Figure 5 illustrates the various approved coolant flow directions See the tabulated technical data in the back of this manual for specific requirements FIGURE 5 WATER CONNECTIONS FLOW AIR INDUCTION GENERAL There are three methods of providing clean air to the BX 2150 compressor 1 Naturally aspirated Local
15. further investigation Following the vehicle manufacturer s recommended procedures deactivate the electrical system in a manner that safely removes all electrical power from the vehicle Never exceed manufacturer s recommended pressures Never connect or disconnect a hose or line containing pressure it may whip Never remove a component or plug unless you are certain all system pressure has been depleted Use only genuine Bendix replacement parts components and kits Replacement hardware tubing hose fittings etc must be of equivalent size type and strength as original equipment and be designed specifically for such applications and systems Components with stripped threads or damaged parts should be replaced rather than repaired Do not attempt repairs requiring machining or welding unless specifically stated and approved by the vehicle and component manufacturer Prior to returning the vehicle to service make certain all components and systems are restored to their proper 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 e
16. is noted thoroughly clean or replace the affected parts and 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 Inspect and clean the external air cooling fins on the cylinder portion of the crankcase If fins are cracked or broken replace the compressor Inspect the air induction system for restrictions LUBRICATION Every six months 1800 operating hours or 50 000 miles whichever occurs first check external oil supply and return lines if applicable for kinks bends or restrictions to flow Supply lines must be a minimum of 3 16 I D and return lines must be a minimum of 1 2 I D Oil return lines should slope as sharply as possible back to the engine crankcase and should have as few fittings and bends as possible Refer to the tabulated technical data in the back of this manual for oil pressure minimum valves Check the exterior of the compressor for the presence of oil seepage and refer to the TROUBLESHOOTING section for appropriate tests and corrective action OIL PASSING All reciprocating compressors currently manufactured will pass a minimal amount of oil Air dryers will remove the majority of oil prior to entrance into the
17. may require additional consideration The following presents base guidelines DISCHARGE LINE The discharge line allows the air water vapor and oil vapor mixture to cool between the compressor and air dryer or reservoir The typical size of a vehicle s discharge line see column 2 of Table Ain the Troubleshooting section 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 The discharge line must maintain a constant slope down from the compressor to the air dryer inlet fitting or reservoir to avoid low points where ice may form and block the flow If 3 The Air Brake Charging System supplies the compressed air for the braking system as well as other air accessories for the vehicle The system usually consists of an air compressor governor discharge line air dryer and service reservoir Optional Ping Tank Air Dryer Discharge ompressor FIGURE 4A SYSTEM DRAWING Governor Governor plus Synchro valve for the Bendix DuraFlo 596 Compressor instead ice blockages occur at the air dryer or reservoir 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 Shorter discharge line lengths or insulation may be required in cold climates While not all compressors and charging systems are equipped with
18. threads in each of the two governor mounting pads allow plugging of the unused port or the installation of a tubing fitting for remote governor mounting Three 1 2 N P T ports provide the means for the connection of coolant lines and are labeled WATER Two 1 2 N P T discharge ports are located on the top and side of the cylinder head and are labeled AIR OUT The various mounting and drive configurations required by the numerous vehicle engine designs are accommodated by different crankcase castings and crankshafts Two methods for cooling the BX 2150 compressor are employed The cylinder head is water cooled using the engine s cooling system while external fins on the crankcase provide a means for efficient air cooling in that area All BX 2150 compressors utilize the engine s pressurized oil system to lubricate internal moving parts Anameplate attached to the compressor crankcase identifies the compressor model and is stamped to indicate the Bendix part number and serial number OPERATION GENERAL The compressor is driven by the vehicle engine and is operating continuously while the engine is running Actual COMPRESSOR MOUNTING DRIVE CONFIGURATIONS 2 PART NUMBER BX 2150 104041 a H0585L MANUFACTURED BY BENDIX Bendix i SERIAL NUMBER TYPICAL NAMEPLATE compression of air is controlled by the compressor unloading mechanism and the governor The governor is generally mounted on the compr
19. 0 pay ar tank drain schedule is longer than the customer s usual draining interval the customer must determine based on its experience with the vehicle whether to participate now or wait for warmer weather See the cold weather tips in Bulletins TCH 008 21 and TCH 008 22 included in Appendix B of the advanced troubleshooting guide For an accurate test the contents of all the air tanks on the vehicle should be used 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 31 Appendix A continued Information about the BASIC Test Kit Bendix P N 5013711 Filling in the Checklist for the Bendix Air System Inspection Cup BASIC Test Note Follow all standard safety precautions For vehicles using a desiccant air dryer STEP C How to Use the BASIC Test 1 Record days since air 2 Record amount 3 Action to tanks were last drained of oil found take 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 If number of days is Lahey ator berow System OK line for high air use vehicles from Step A 30 60 days high air accep d N Numos Return to service use or F if oil level is above 30 90 aii air use lacceptance line for number Go to Step D of days gt
20. AIR UNLOADED When air pressure in the reservoir reaches the cut out setting of the governor the governor allows air to flow from the reservoir into the unloader piston cavity The unloader piston moves in response to air pressure and drives the inlet valve away from its seat and holds it against its stop With the inlet valve held away from its seat air compression is stopped and air is free to move back and forth past the inlet valve in response to piston travel System pressure will eventually drop to the cut in pressure setting of the governor due to air usage When the cut in pressure is reached the governor responds by exhausting air from the unloader piston cavity Spring force moves the unloader piston away from the inlet valve and compression is resumed as the inlet valve returns to its seat UNLOADER DISCHARGE VALVE PISTON FIGURE 3 UNLOADED CYCLE COMPRESSOR amp THE AIR BRAKE SYSTEM GENERAL The compressor is part of the total air brake system more specifically the charging portion of the air brake system As a component in the overall system its condition duty cycle proper installation and operation will directly affect other components in the 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 lubricated by the engine oil supply and has its inlet connected to the engi
21. Check temperature as outlined in Test 3 on page 28 If temperatures are normal go to 4 0 h Inspect coolant line Replace as necessary I D is 1 2 gt Inspect the coolant lines for kinks and restrictions and fittings for restrictions Replace as necessary 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 17 for recommended size Replace as necessary gt The discharge line must maintain a constant slope down from the compressor to the air dryer inlet fitting to avoid low points where ice may form and block the flow If instead ice blockages occur at the air dryer inlet insulation may be added here or if the inlet fitting is a typical 90 degree fitting it may be changed to a straight or 45 degree fitting For more information on how to help prevent discharge line freeze ups see Bendix Bulletins TCH 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 restrictions brittleness soft or sagging hose conditions etc Repair as necessary Inlet line size is 3 4 ID Maximum restriction requirement for compressors is 25 inches of water Check the engine air filter and service if necessary if possible check the air filt
22. INSTALL ADAPTER 297871 WHEN REQUIRED WILL RESULT INCOMPRESSOR DAMAGE The inlet check valve consists of three parts the inlet gasket the inlet check valve reed and the inlet check valve seat See Figure 6 during the compression cycle the inlet check valve reed is drawn away from its seat uncovering three inlet holes which allows air to flow into the compressor inlet cavity A machined stop in the cylinder head inlet cavity or in the inlet adapter 297871 limits the travel of the inlet check valve reed In the unloaded cycle the inlet check valve reed rests on its seat covering the three inlet holes Air from within the compressor is prevented from exiting the inlet cavity Inlet gasket 243430 is required between the inlet check valve reed and the inlet cavity of new style heads or between the inlet check valve reed and the inlet adapter 297871 for old style heads as its thickness contributes to the minimum reed travel required The pin in the check valve seat must align with the holes in the check valve the inlet gasket and enter the mating hole in the head or the inlet adapter Refer to Figure 6 CAUTION If ICV is used with air dryer aftercooler which vents the discharge line during its purge cycle a PR 4 valve P N 103976 is recommended to be installed in the discharge line to minimize oil passing which can occur in the combined use of an ICV and a vented discharge line See Bulletin No PRO 08 13 for proper installation of the
23. ISASSEMBLY Remove the four cylinder head cap screws and tap the head with a soft mallet to break the gasket seal Scrape off any gasket material from the cylinder head and crankcase Before disassembling the discharge valve mechanism measure and record the discharge valve travel from closed to completely open 1 If the measured discharge valve travel DOES NOT EXCEED 032 inches the discharge valve stop need not be removed It is recommended that the cylinder head body be replaced if the discharge valve stop requires replacement In the event this is not possible the following procedure can be followed Using a 9 16 Allen wrench remove the discharge valve seat valve and valve spring To remove the discharge valve stop support the machined surface of the cylinder head on an arbor press bed and gently press the stop from the top of the head and out the bottom Be sure to allow sufficient clearance for the stop between the press bed and the bottom of the cylinder head The valve stop bore in the cylinder head must be inspected for excessive scoring Anew cylinder head body must be used if scoring is excessive 2 Remove the unloader stop and o ring 3 Remove the unloader piston and o ring Insert the lugs of a spanner wrench into the holes of the inlet valve stop and remove the inlet valve stop along with the inlet valve valve seat unloader gasket and spring NOTE Reference Williams adjustable face spanner 483 5 Insp
24. PR 4 valve 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 for a guide to various considerations that must be given to the maintenance of the compressor and other related charging system components AIR INDUCTION One of the single most important aspects of compressor preventive maintenance is the induction of clean air The type and interval of maintenance required will vary depending upon the air induction system used The intervals listed under the headings below pertain to typical highway and street operation More frequent maintenance will be required for operation in dusty or dirty environments POLYURETHANE SPONGE STRAINER Every month 150 operating hours or 5 000 miles whichever occurs first remove and wash all of the parts RD HD MACHINE SCREW r S CREW OVER FILTER BAFFLE ELEMENT STRAINER VER SSEMBLY BODY A Sy BAFFLE GASKET lt Sa BASE PLATE a FIGURE 7 MOUNTING BAFFLE FILTE R ELEMENT COVER FIGURE 8 The strainer element should be cleaned or replaced If the element is cleaned it should be washed in a commercial solvent or a detergent and water solution The element should be saturated in clean engine oil then squeezed dry before replacing it in the strainer Be sure to replace the air strainer gasket if the entire air stra
25. alve seat Using a 9 16 Allen wrench torque the discharge valve seat to 70 90 pound feet 12 3 Test for leakage by the discharge valve Apply 100 psi of air pressure through the cylinder head discharge port and apply a soap solution to the discharge valve and seat A slight leakage in the form of soap bubbles is permissible If excessive leakage is found leave the air pressure applied and with the use of a fiber or hardwood dowel and a hammer tap the discharge valve off its seat several times This will help the valve to seat and should reduce the leakage With the air pressure still applied at the discharge port of the cylinder head check for leakage around the discharge valve stop exposed on the top of the cylinder head casting No leakage is permitted 4 Ifthe unloader piston bushing was removed press ina new bushing following the same pressing procedures given in Step 1 The inside diameter of the unloader piston bushing must be between 7497 inches and 7460 inches after pressing 5 Using a 3 8 Allen wrench install the unloader piston stop and o ring in the head Torque to 175 225 pound inches 6 Install the unloader piston and o ring in the head so that the short stem of the piston rests on the unloader stop 7 Install the unloader piston spring small end first on the stem of the unloader piston Install the metal copper inlet valve gasket so that it rests on the shoulder of the inlet valve cavity Install the inl
26. an arbor press Make certain not to damage the oil seal if the compressor is so equipped 3 Place the o ring seal in the groove around the rear end cover or in the crankcase proper in the event a rear main ball bearing is in use If the rear end cover contains a precision sleeve bearing that serves as the crankshaft main bearing make certain to install the thrust bearing Install the end cover in the position as marked before disassembly taking care not to damage the sleeve bearing if so equipped 4 Install the four cap screws or nuts that secure the rear end cover to the crankcase and torque to 175 225 pound inches PISTON amp CONNECTING ROD ASSEMBLY 1 Prelubricate the piston piston rings wrist pin and connecting rod 2 Install the piston rings in the correct location with the ring pipmarks up Refer to Figure 11 Stagger the position of the ring gaps 3 Align the wrist pin bore of the connecting rod with the piston bores and install the wrist pin to secure the rod to the piston Make certain the TEFLON buttons are installed in each end of the wrist pin 4 Using an automotive type ring compressor or similar tool compress the piston rings and gently install the connecting rod and piston in the cylinder bore Install the connecting rod cap on the connecting rod in the same position as marked during disassembly 5 Secure the rod cap to the rod using the two cap screws and special lockwashers Torque the cap scr
27. ank Open the shut reservoir service reservoir or reservoir port of the D 2 governor verify cut in and cut out pressures are within vehicle OEM specification If the governor is malfunctioning replace it Perform proper reservoir drain intervals and air dryer cartridge maintenance per Maintenance Schedule and Usage Guidelines Table A on page 17 Return the vehicle to service off and charge the unloader port by allowing air pressure to enter the hose and unload the compressor Shut off the air supply and observe the gauge Asteady reading indicates no leakage at the unloader port but a falling reading shows that the unloader mechanism is leaking and needs to be serviced 29 Appendix A 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 g 2a O 919 Drain contents of ALL air tanks into BASIC cup Is there less than one unit of liquid NO Is there more than one unit of e water or 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 w
28. aring must be replaced The cylinder bore should be checked with inside micrometers or calipers Cylinder bores which are scored or out of round by more than 0005 inch or tapered more than 0005 inch should be rebored or honed oversize Oversized pistons and piston rings are available in 010 inch 020 inch and 030 inch oversizes The cylinder bore must be smooth straight and round PISTONS Check the piston for scores cracks or enlarged ring grooves replace the piston if any of these conditions are found Measure the diameter of the top of the piston and the top two ring lands Compare to cylinder bore and piston diameters to be sure the diametrical clearance is between 0128 inch minimum and 0177 inch maximum Check the fit of the wrist pin to the piston The wrist pin should be a light press fit in the piston This clearance should not exceed 0006 inch If the wrist pin is a loose fit the piston and pin assembly should be replaced Check the fit of the wrist pin in the connecting rod by rocking the piston Conn rod wrist pin 0009 max Replace the connecting rod if excessive clearance is found NOTE Wrist pin bushing replacement is not recommended for those connecting rods which incorporate them Check the fit of the piston rings in the piston ring grooves Check the ring gap with the rings installed in the cylinder bores Refer to Figure 11 for correct gap and groove clearances PISTON RING F OIL RING an
29. assages through the crankshaft crankcase end covers and base plate or base adapter Inspect the passages with a wire to be sure they are clear Blow the loosened foreign matter out with shop air INSPECTION OF PARTS CYLINDER HEAD BODY Inspect the cylinder head for cracks and obvious physical damage Pay particular attention to the area around coolant ports for cracks Check for stripped or damaged threads Apply shop air pressure to one of the coolant ports with all others plugged and check for leakage by applying a soap solution to the exterior of the body If leakage is detected replace the head END COVERS Check for cracks stripped oil port threads and external damage and if noted replace the end cover If the crankshaft main bearings are installed in the end cover check for excessive wear and flat spots and replace the end cover if necessary CRANK CASE Check all crankcase surfaces for cracks and damage Pay particular attention to cooling fins On compressors where ball bearing main bearings are used the difference between the O D of the outer race and the I D of the crankcase hole should be 0000 inch to 0015 inch loose This is to maintain the correct press fit The crankcase must be replaced if the fit is too loose On compressors fitted with precision sleeve main bearings the difference between the O D of the crankshaft journal and the main bearing I D must not exceed 004 inch or the end cover and main be
30. be tested See Bulletin TCH 001 048 11 0 Compressor safety valve a Restricted discharge line 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 Go to Test 4 on page 29 gt See 9 0 f Replace air dryer heater Replace the compressor only after making certain the preceding conditions do not exist gt If discharge line is restricted By more than 1 16 carbon build up replace the discharge line see Table A column 2 on page 17 for recommended size and go to Test 3 on page 28 gt By other restrictions e g kinks Replace the discharge line See Table A column 2 on page 17 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
31. charging system problems INDEX Symptom Page Number Symptom Page Number Air Coolant Air brake charging system Compressor leaks coolant 17 0 Slow build 9 0 z Doesn t build air 10 0 Engine Air dryer Oil consumption 6 0 Doesn t purge 14 0 Oil Safety valve releases air 12 0 Compressor Oil Test Card results 1 0 Constantly cycles 15 0 Oil is present Leaks air 16 0 On the outside of the compressor 2 0 19 Safety valve releases air 11 0 At the air dryer purge exhaust or surrounding area 3 0 Noisy 18 0 Reservoir In the supply reservoir 4 0 At the valves 5 0 Safety valve releases air 13 0 At air dryer cartridge 7 0 In the ping tank or compressor discharge aftercooler 8 0 Maintenance amp Usage Guidelines Test Procedures 1 Oil Leakage at Head Gasket 28 2 System Leakage 3 Compressor Discharge and Air Dryer Inlet Temperature Maintenance Schedule and Usage Guidelines Table A 17 4 Governor Malfunction 5 Governor Control Line 6 Compressor Unloader Bend X BASIC Test Information mag This guide is only for vehicles that use desiccant air dryers 15 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 gov
32. commended that a genuine Bendix unloader kit be installed and the cylinder head retested DISCHARGE VALVE LEAKAGE Unloader piston leakage must be repaired before this test is performed Leakage past the discharge valve can be detected by removing the discharge line applying shop air to the unloader mechanism and the discharge port and listening for the escape of air at the compressor inlet cavity A barely audible escape of air is generally acceptable however if there is any question as to the leakage rate it is recommended that the cylinder head or compressor be removed and repaired or replaced With shop air still applied at the discharge port apply a soap solution to the valve stop recess on the top of the head If leakage is detected the cylinder head must be repaired or replaced Only genuine Bendix remanufactured compressors or service parts and kits should be used COMPRESSOR TROUBLESHOOTING IMPORTANT The troubleshooting contained in this section considers the compressor as an integrated component of the overall air brake charging system and assumes that an air dryer is in use The troubleshooting presented will cover not only the compressor itself but also other charging system devices as they relate to the compressor 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 t
33. e instructions to avoid personal injury or death When working on or around a vehicle the following general precautions should be observed at all times 1 Park the vehicle on a level surface apply the parking brakes and always block the wheels Always wear safety glasses Stop the engine and remove ignition key when working under or around the vehicle When working in the engine compartment the engine should be shut off and the ignition key should be removed Where circumstances require that the engine be in operation EXTREME CAUTION should be used to prevent personal injury resulting from contact with moving rotating leaking heated or electrically charged components Do not attempt to install remove disassemble or assemble a component until you have read and thoroughly understand the recommended procedures Use only the proper tools and observe all precautions pertaining to use of those tools If the work is being performed on the vehicle s air brake system or any auxiliary pressurized 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 Y Normal Normal Charging system is working within normal range 2 Check Check Charging system needs
34. ect the unloader piston bushing for nicks wear corrosion and scoring It is recommended that the 10 cylinder head body be replaced if it is determined that the unloader piston bushing requires replacement If this is not possible the bushing can be pressed out of the head using the same procedure presented in Step 2 of this disassembly section NOTE if the bushing is pressed out and the cylinder head casting is damaged in the process cylinder head repair is not recommended Pressing in the replacement bushing will result in air or water leakage CRANKCASE BASE PLATE OR ADAPTER DISASSEMBLY 1 Remove the cap screws securing the base plate or base adapter Tap with soft mallet to break the gasket seal Scrape off any gasket material from crankcase and plate adapter CONNECTING ROD DISASSEMBLY Before removing the connecting rod mark the connecting rod and its cap The connecting rod is matched to its own cap for proper fit and the cap must be reinstalled in the same position on the rod 1 Straighten the prongs of the connecting rod bolt locks and remove the bolts and bearing cap 2 Push the piston with the connecting rod attached out the top of the cylinder of the crankcase Replace the bearing cap on the connecting rod 3 Remove the piston rings from the piston If the piston is to be removed from the connecting rod remove the wrist pin teflon plugs and press the wrist pin from the piston and connecting rod 4 Ifthe
35. een operated at high discharge pressures due to a blocked or frozen discharge line Check all compressor mounting bolts and retighten evenly as necessary Check the condition of all compressor mounting bracketry tighten hardware as necessary and replace if damaged OPERATIONAL TESTS Every three months 900 operating hours or 25 000 miles whichever occurs first Vehicles manufactured after the effective date of FMVSS 121 with the minimum required reservoir volume must have a compressor capable of raising air system pressure from 85 100 p s i in 25 seconds or less This test is performed with the engine operating at maximum governed speed The vehicle manufacturer must certify this performance on new vehicles with appropriate allowances for air systems with greater than the minimum required reservoir volume Check unloader operation by building system pressure to governor cut out and note that air compression stops Reduce system pressure to governor cut in and note that air compression resumes If the compressor fails to respond as described make certain the governor is functioning properly before repairing or replacing the compressor COMPRESSOR AIR LEAKAGE TESTS Compressor leakage tests need not be performed on a regular basis These tests should be performed when itis suspected that discharge valve leakage is substantially affecting compressor build up performance or when it is suspected that the compressor is cycling be
36. ehicle Garbage truck transit bus bulk unloader or tance lines on the cup will be a line haul with 6 or more axles Then go to Step B for the test below STEP B Measure the Charging System Contents 1 Park and chock vehicle on level ground Drain the air system by pumping the service brakes 2 Completely drain ALL the air tanks into a single BASIC cup 3 If there is less than one unit of contents total end the test now and return the vehicle to service Vehicle passes ae Note for returning vehicles that are being 4 Q rore than one oil unit of water or a cloudy emulsion mixture retested after a water cloudy emulsion is found mixture was found last time and the air a Change the vehicle s air dryer cartridge dryer cartridge replaced If more than one see Footnote 1 b Conduct the 4 minute leakage test Step D c STOP the inspection and check the vehicle again after 30 days see Footnote 2 D Otherwise 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 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 3
37. em gauges If you see any noticeable decrease of the dash air gauge readings repair leaks Repeat with the vehicle being tested this test to confirm that air leaks have been repaired and return vehicle to service Please repeat BASIC test at next service interval Note Air leaks can also be found in the charging system parking brakes and or other components inspect and repair as necessary If no air leakage was detected and if you are conducting this test after completing Step C go to Step E The Technician only reaches STEP E wno ar leakage wo sected np ike ten since the air tanks were last drained exceeds the accep tance level AND the vehicle passes the four minute leakage test no noticeable leakage was detected Replace the compressor Note If the compressor is within warranty period please follow standard warranty procedures Attach the completed checklist to warranty claim 32 Appendix B Technical Bulletin Pens 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 e
38. er 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 22 Symptom What it may indicate 4 0 Oil in Supply Other cont or Service l l Reservoir i Poorly filtered inlet air poor air air dryer installed quality to compressor continued Inspect the engine air cleaner j Governor malfunction or setting k Compressor malfunction f Grenka Flooding Consider installing a compressor bottom drain kit where available in cases of chronic oil passing where all other operating conditions have been investigated Bendix compressors are designed to have a dry sump and the presence of excess oil in ne crankcase can lead to oil carryover S What you should do 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 2 Check Go to Test 4 on page 29 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 Afte
39. ernor 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 Factors that add to the duty cycle are air suspension additional air accessories use of an undersized compressor frequent stops excessive leakage from fittings connections lines chambers or valves etc The discharge line allows the air water vapor and oil vapor mixture to cool between the compressor and air drye
40. essor and maintains the brake system air pressure between a preset maximum and minimum pressure level INTAKE AND COMPRESSION OF AIR LOADED During the down stroke of the piston a slight vacuum is created between the top of the piston and the head causing the flat circular inlet valve to move off its seat Note the flat square discharge valve remains on its seat Atmospheric air is drawn into the intake cavity and flows past the open inlet valve and into the cylinder See Figure 1 As the piston begins its upward stroke the air that was drawn into the cylinder on the down strike is compressed Air pressure on the inlet valve plus the force of its spring returns the inlet valve to its seat As the piston continues its upward stroke air is compressed and forces the discharge valve away from its seat Air flows past the open discharge valve into the discharge line and on to the reservoirs See Figure 2 As the piston reaches the top of its stroke and starts down the discharge valve spring and air pressure in the discharge line returns the discharge valve to its seat This prevents the compressed air in the discharge line from returning to the UNLOADER PISTON DISCHARGE VALVE PISTON INTAKE CYCLE FIGURE 1 UNLOADER PISTON INLET RESERVOIR INLET VALVE DISCHARGE VALVE PISTON FIGURE 2 COMPRESSION DISCHARGE CYCLE cylinder bore as the intake and compression cycle is repeated NON COMPRESSION OF
41. et and resultant oil vapor passing upstream in the air system replace the discharge line with one of a larger diameter and or longer length This helps reduce the air s temperature If sufficient cooling occurs the oil vapor condenses and can be removed by the air dryer Discharge line upgrades are not covered under warranty Note To help prevent discharge line freeze ups shorter discharge line lengths or insulation may be required in cold climates See Bendix Bulletins TCH 08 21 and TCH 08 22 included in Appendix B for more information 5 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 Bendix Tu Flo 550 and 750 compressors unloader service is recommended every 250 000 miles 17 Air Brake Charging System Troubleshooting How to use this guide Find the symptoms 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 thes
42. et valve seat on top of the inlet valve gasket with its beveled side visible Make certain the large coils of the piston spring rest within the recess of the inlet valve seat on the side opposite the bevel Install the inlet valve so that it rests on the beveled side of the valve seat 8 Install the inlet valve spring on the inlet valve stop and install the stop in the head Using a spanner wrench torque the inlet valve stop to between 70 90 pound feet 9 Apply 100 psi air pressure to the unloader port of the governor mounting pad and note the inlet valve is driven away from its seat Using a soap solution test for air leakage at the unloader piston stop No leakage is permitted CRANKCASE amp CRANKSHAFT ASSEMBLY 1 Ifthe compressor requires a drive end crankshaft oil seal press it into the crankcase until it is flush with the crankcase casting Using clean oil lubricate the sealing lips of the seal 2 Ifthe compressor uses a ball type main bearing press the ball bearing onto the correct end of the crankshaft Position the ball bearing and the crankshaft in the crankcase making sure the drive end of the crankshaft is positioned in the crankcase as marked before disassembly NOTE n the case of compressors with a rear main ball bearing make certain to install the thrust bearing in the crankcase before pressing the crankshaft and ball bearing into place Carefully press the crankshaft and ball bearing into the crankcase using
43. ew to between 120 140 pound inches and bend the tabs of the lockwashers until they are firmly against the flats of the hex head of the cap screws BASE PLATE OR BASE ADAPTER ASSEMBLY 1 Position the base plate or base adapter gasket on the crankcase and install the base plate or base adapter as marked before disassembly 2 Install the cap screws that secure either the crankcase base plate or crankcase mounting base adapter Torque the cap screws evenly to the appropriate valve Base plate 85 115 pound inch mounting base adapter 175 225 pound inches FINAL COMPRESSOR ASSEMBLY 1 Place the cylinder head gasket on the crankcase and position the head on the crankcase as marked during disassembly A gasket sealer is neither required or recommended 2 Secure the cylinder head to the crankcase using the four cylinder head cap screws Torque the cap screws in a X pattern to between 175 225 pound inches Using a thread sealant install all necessary pipe plugs and torque as follows 1 8 P T plugs 85 105 pound inches 1 2 P T plugs 200 270 pound inches Install all crankshaft keys making certain to support the crankshaft to avoid bearing damage Install the crankshaft nut where applicable When installing drive couplings gears or pulleys DO NOT EXCEED 120 foot pounds torque on the crankshaft nut The self locking crankshaft nut used on the BX 2150 compressor requires that it be installed so that the narrow castel
44. 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 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 AD 9 Air Dryer Service Data Sheet SD 08 2412 AD 4 Air Dryer Service Data Sheet SD 08 2407 AD 2 Air Dryer Service Data Sheet SD 08 2403 AD IP
45. harging system is functioning normally Y Normal Oil shown leaking from an air dryer cartridge Air brake charging system is functioning normally y Normal a Air brake charging system functioning normally Y Normal b Air brake system leakage c Compressor may be undersized for the application d Compressor unloader mechanism malfunction e Damaged compressor head gasket What you should do See engine service manual 2 Check gt 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 17 Replace the air dryer cartridge as needed and return the vehicle to service Follow vehicle O E maintenance recommendation for these components Using dash gauges verify that the compressor builds air system pressure from 85 100 psi in 40 seconds or less with engine at full governed rpm Return the vehicle to service Go to Test 2 on page 28 See Table A column 1 on page 17 for some typical compressor applications If the compressor is too small for the vehicle s role for example where a vehicle s use has changed then upgrade the compressor Note The costs incurred e g installing a larger capacity compressor etc are not c
46. he vehicle on a level surface apply the parking brakes and always block the wheels Always wear safety glasses 2 Stop the engine and remove ignition key when working under or around the vehicle When working in the engine compartment the engine should be shut off and the ignition key should be removed Where circumstances require that the engine bein 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 lf 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 ora 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 manufacturers 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 certa
47. he 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 Optional Ping Tank Air Dryer Discharge Line NS air accessories for the vehicle The system usually consists of an air compressor governor discharge line air dryer and service reservoir Compressor Governor Governor plus Synchro valve for the Bendix DuraFlo 596 Compressor 16 Optional Bendix PuraGuard System Filter or PuraGuard QC Oil Coalescing Filter Service Reservoir Supply Reservoir Reservoir Drain Table A Maintenance Schedule and Usage Guidelines Regularly scheduled maintenance is the single most important factor in maintaining the air brake charging system Recom Recom Acceptable Vehicle Used for Low Air Use Compressor with less than 15 duty cycle e g Line haul single trailer w o air suspension air over hydraulic brakes r FR top Compressor with up to 25 duty cycle e g Line haul single trailer Bendix Tu Flo 550 air compressor For oil carry over control suggested upgrades 5 8 in 9 ft For oil carry over
48. here the number of oil units meets the number of days since the vehicle s air tanks were last drained Is the point above the HIGH Air Use line on the cup point above the LOW Air Use line on the cup Use Test 2 Air Leakage SOU Repair leaks and return vehicle to service the vehicle have excessive air leakage END TEST NO did not know when last drained Re test with the BASIC Test after 30 days END TEST YES number of days was known 30 90 days Replace the Compressor If under warranty follow standard procedures If after a compressor was already replaced the vehicle fails the BASIC test again do not replace the compressor use the Advanced Troubleshooting Guide to investigate the cause s 30 END TEST Bendix Air System Inspection Cup BASIC Test Information YES lt 1 Vehicle OK Return vehicle to END TEST service Cloudy emulsion mixture NO this is a low air use vehicle Vehicle OK Return vehicle to service ry 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 K i the vehicle s air tanks E were last drained Go to the i Advanced P Troubleshooting g Guide to find reason s for prese
49. ields with information gained from the customer Vehicle No of Axles ___ Checklist for Technician Customer s Complaint Have you confirmed complaint Please check all that apply Vv Relay valve O leaks oil 10 malfunctions 0 yes The Technician The Service Writer Dane C1 leaks oil CQ malfunctions O yes checks boxes for ryer leaks oil U yes any of the also checks off any Q Governor malfunction T yes laints th complaints that the Q Oil in gladhands complaints that customer makes to how much oil did you find can be confirmed help the Technician 0 Oil on ground or vehicle exterior in investigating amount described O Short air dryer cartridge life replaces every 1 miles Q kms or Q months Note A confirmed com z plaint above does NOT mean We will measure amount currently found when we get to step B of the test that the compressor must be Q Excessive engine oil loss amount described replaced Is the engine leaking oil 00 cece eee Ono The full BASIC test below will Is the compressor leaking oil 0000 Ono investigate the facts O Other complaint O No customer complaint BASIC test starts here STEP A Select one The Technician selects the air use category for the vehicle This Q This is a low air use vehicle Line haul single trailer with 5 or less axles or ie decided which of the two accep 0 This is a high air use v
50. in all system pressure has been depleted 8 Use only genuine Bendix replacement parts components and kits Replacement hardware tubing hose fittings etc must be of equivalent size type and strength as original equipment and be designed specifically for such applications and systems 9 Components with stripped threads or damaged parts should be replaced rather than repaired Do not attempt repairs requiring machining or welding unless specifically stated and approved by the vehicle and component manufacturer 10 Prior to returning the vehicle to service make certain all components and systems are restored to their proper operating condition 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 COMPRESSOR REMOVAL amp DISASSEMBLY GENERAL The following instructions are presented here for reference Removal and disassembly of the compressor is not recommended unless the appropriate service parts and or kits are on hand REMOVAL These instructions are general and are intended to be a guide in some cases additional preparations and precautions are necessary 1 Block the wheels of the vehicle and drain the air pressure from all the reservoirs in the system 2 Drain the engine cooling system and the cylinder head of the compre
51. iner is removed from the compressor intake DRY ELEMENT PLEATED PAPER AIR STRAINER Every two months 800 operating hours or 20 000 miles whichever occurs first remove the spring clips from either side of mounting baffle and remove the cover Replace the pleated paper filter and remount the cleaned cover making sure the filter is in position Make certain to replace the air strainer gasket if the entire air strainer is removed from the compressor intake INTAKE ADAPTER When the engine air cleaner is replaced Some compressors are fitted with intake adapters which allow the compressor intake to be connected to the engine air cleaner turbo or super charger In this case the compressor receives a supply of clean air from the engine air cleaner When the engine air filter is changed the compressor intake adapter should be checked If it is loose remove the intake adapter clean the strainer plate if applicable and replace the intake adapter gasket and reinstall the adapter securely Check line connections both at the compressor intake adapter and at the engine or engine air cleaner Inspect the connecting line for kinks and ruptures and replace it if necessary FIGURE 9 COMPRESSOR INTAKE ADAPTER COMPRESSOR COOLING Every six months 1800 operating hours or 50 000 miles whichever occurs first inspect the compressor discharge port inlet cavity and discharge line for evidence of restrictions and carboning If excessive buildup
52. lation slots are toward the end of the crankshaft and not against the pulley coupling or gear that the nut retains Some BX 2150 through drive compressors require the installation of a spline coupling on the rear of the crankshaft The cap screw securing the coupling should be torqued to 175 225 inch pounds Using covers plugs or masking tape to protect all ports if compressor is not to be installed immediately Protect the ends of the crankshaft against damage by wrapping with masking tape or friction tape The open bottom of a vertical engine lubricated compressors should be protected against the entrance of dirt during handling or storage by installing a temporary cover over the base COMPRESSOR BUILD UP TIME CHART COMPRESSOR BUILD UP TIME 0 120 PSI 6900 CUBIC INCH RESERVOIR O mi u w 2 E a 2 2 va 0 1200 1500 1800 2100 2400 2700 3000 COMPRESSOR SPEED RPM 13 TESTING REBUILT COMPRESSOR In order to properly bench testa 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 The compressor must be connected to an oil supply line of at least 15 P S I pressure during the test and an oil return line must be installed to keep the crankcase drained
53. may use a block of wood to hold the Test 3 Air Compressor Discharge Temperature and Air Dryer Inlet Temperature Caution The temperatures used in this test are not normal vehicle conditions Above normal temperatures can cause oil as vapor to pass through the air dryer into the air brake system This test is run with the engine at normal operating temperature with engine at max rpm If available a dyno may be used Allow the compressor to build the air system pressure to governor cut in Pump the brakes to bring the dash gauge pressure to 90 psi Allow the compressor to build pressure from 95 to 105 psi gauge pressure and maintain this pressure range by cycling the brakes for five 5 minutes Discharge Line 28 Test 2 Air Brake System and Accessory Leakage Compressor Air Dryer LOOK FOR WEEPAGE 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
54. nce of water Test for air Use Test 2 Air Leakage END TEST o UOU 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 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 on pages 33 35 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 A continued Information about the BASIC Test Kit Bendix P N 5013711 Filling in the Checklist for the Bendix Air System Inspection Cup BASIC Test Note Follow all standard safety precautions For vehicles using a desiccant air dryer The Service Writer fills out these f
55. ne induction system 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 If an air dryer is not used to remove these contaminants prior to entering the air system the majority but not all will condense in the reservoirs The quantity of contaminants that reach the air system depends on several factors including installation maintenance and contaminant handling devices inthe system These contaminants must either be eliminated prior to entering the air system or after they enter DUTY CYCLE The duty cycle is the ratio of time the compressor spends building air to the total engine running time Air compressors are designed to build air run loaded up to 25 of the time Higher duty cycles cause conditions that affect air brake charging system performance which may require additional maintenance Factors that add to the duty cycle are air suspension additional air accessories use of an undersized compressor frequent stops excessive leakage from fittings connections lines chambers or valves etc Refer to Table Ain the Troubleshooting section for a guide to various duty cycles and the consideration that must be given to maintenance of other components COMPRESSOR INSTALLATION While the original compressor installation is usually completed by the vehicle manufacturer conditions of operation and maintenance
56. nections or ports b Compressor unloader mechanism malfunction c Damaged compressor head gasket Head gasket location a lmproperly installed plugs or coolant line fittings b Damaged compressor head gasket c Porous compressor head casting a Damaged compressor 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 29 An air leak at the head gasket may indicate a downstream restriction such as a freeze up or carbon blockage and or could indicate a defective or missing safety valve Find blockage go to 9 0 f for details and then replace the compressor Do not re use the safety valve without testing See Symptom 12 0 a Inspect for loose or over torqued fittings Reseal and tighten loose fittings and plugs as necessary If overtorqued fittings and plugs have cracked ports in the head replace the compressor An air leak at the head gasket may indicate a downstream restriction such as a freeze up or carbon blockage and or could indicate a defective or missing safety valve Find blockage go to 9 0 f for details and then replace the compressor Do not re use the safety valve without testing See Symptom 12 0 a If casting porosity is detected replace the compressor Replace the compressor Other Miscellaneous Areas to Consider This guide attempts to cover most c
57. ngine manufacturers warn that long idle times are detrimental to engine life winter idling is a big factor in compressor discharge line freeze up Discharge line freeze ups account for a significant number of compressor failures each year The discharge line recommendations under Discharge Lines are important for all vehicles but are especially so when some periods of extended engine idling can not be avoided Discharge Lines The discharge line should slope downward form the compressor discharge port without forming water traps kinks or restrictions Cross overs from one side of the frame rail to the other if required should occur as close as possible to the compressor Fitting extensions must be avoided Recommended discharge line lengths and inside diameters are dependent on the vehicle application and are as follows Typical P amp D School Bus and Line Haul The maximum discharge line length is 16 feet Length I D Min Other Requirements 6 0 9 5 ft Ya in None 9 5 12 ft Va in Last 3 feet including fitting at the end of the discharge line must be insulated with 1 2 inch thick closed cell polyethylene pipe insulation 12 16 ft 5 8 in Last 3 feet including fitting at the end of the discharge line must be insulated with 1 2 inch thick closed cell polyethylene pipe insulation If the discharge line length must be less than 6 feet or greater than 16 feet contact your local Bendix representative 33 Ap
58. ock 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 restrictions brittleness soft or sagging hose conditions etc Repair as necessary Refer to vehicle manufacturer s guidelines for inlet line size Check the engine air filter and service if necessary if possible check the air filter usage indicator Check for leaking damaged or defective compressor air inlet components e g induction line fittings gaskets filter bodies etc Repair inlet components as needed Note 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 the governor but also the SV 1 synchro valve used would Note For the Bendix DuraFlo 596 air compressor not only need to
59. of the fittings at the compressor discharge port T1 atthe air dryer inlet fitting T2 Use a touch probe thermocouple for measuring the temperature 5 See table below 6 Retest before returning the vehicle to service T1 T2 Inlet Action Fitting Discharge Fitting Temperatures are within normal range for this test check other symptoms Go to 4 0 h This could indicate a discharge line problem e g restriction Call 1 800 AIR BRAKE 1 800 247 2725 and speak with our Tech Team Compressor is running hot Check coolant 4 f and or discharge line 4 g Tests continued Test 4 Governor Malfunction Inspect control lines to and from the governor for restrictions e g collapsed or kinked Repair as necessary Using a calibrated external gauge in the supply Test 5 Governor Control Line 1 Ensure that the governor control line from the reservoir is located at or near the top of the reservoir This line if located near the bottom of the reservoir can become blocked or restricted by the reservoir contents e g water or ice Test 6 Compressor Unloader Leakage Bendix Compressors Park vehicle chock wheels and follow all standard safety procedures Remove the governor and install a fitting to the unloader port Add a section of air hose min 1ft long for a 1 2 diameter line and a gauge to the fitting followed by a shut off valve and an air source shop air or small air t
60. ompressor system problems Here are some rare sources of problems not covered in this guide e Turbocharger leakage Lubricating oil from leaking turbocharger seals can enter the air compressor intake and give misleading symptoms 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 connecting rod bearings Damage of this kind may not be detected and could lead to compressor problems at a later date 4 27 Tests Test 1 Excessive Oil Leakage at the Head Gasket Exterior leaks at the head gasket are not a sign that oil is being passed into the air charging system Oil weepage at the head gasket does not prevent the compressor from building air Observe the amount of weepage from the head gasket If the oil is only around the cylinder head area it is acceptable return the vehicle to service but if the oil weepage extends down to the nameplate area of the compressor the gasket can be replaced 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
61. ood seal Inspect and repair as necessary Go to Test 1 on page 28 Reseal bottom cover plate using RTV silicone sealant gt Replace compressor gt Replace compressor Clean compressor and check periodically 2 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 Symptom What it may indicate 4 0 Oil in Supply or Service Reservoir air dryer installed If a maintained Bendix PuraGuard system filter or Bendix PuraGuard QC oil coalescing filter is installed call 1 800 AIR BRAKE 1 800 247 2725 and speak to a Tech Team member Maintenance a lf air brake charging system maintenance has not been performed That is reservoir s have not been drained per the schedule in Table Aon page 17 Column 4 and or the air dryer maintenance has not been performed as in Column 3 b If the vehicle maintenance has been performed as recom mended in Table A on page 17 some oil in the reservoirs is normal H See Table A on page 17 for maintenance schedule information Drain all air tanks reservoirs into the Bendix BASIC test cup Bendix kit P N 5013711 Duty cycle too high
62. ound is within the acceptable level gt If within the normal range return the vehicle to service For vehicles with accessories that are sensitive to small amounts of oil consider a Bendix PuraGuard QC oil coalescing filter gt If outside the normal range go to Symptom 4 0 c Also see the Table A on page 17 column 3 for recommended air dryer cartridge replacement schedule Go to Test 2 on page 28 See Table A column 1 on page 17 for recommended compressor sizes If the compressor is too small for the vehicle s role for example where a vehicle s use has changed or service conditions exceed the original vehicle or engine OE spec s then upgrade the compressor Note The costs incurred e g installing a larger capacity compressor etc are not covered under original compressor warranty If the compressor is correct for the vehicle go to Symptom 4 0 e Symptom 4 0 Oil in Supply or Service Reservoir air dryer 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
63. overed under original compressor warranty Go to Test 6 on page 29 An air leak at the head gasket may indicate a downstream restriction such as a freeze up or carbon blockage and or could indicate a defective or missing safety valve Find blockage go to 9 0 f for details and then replace the compressor Do not re use the safety valve without testing See Symptom 12 0 a 23 24 Symptom What it may indicate 9 0 Air brake f Restricted discharge line charging system seems slow to 2 Check build pressure continued Dash gauges Kinked discharge line shown g Restricted air inlet not enough air to compressor 9 Check Partly collapsed inlet line shown h Poorly filtered inlet air poor air quality to compressor 2 Check i Compressor malfunction Check What you should do gt gt gt gt 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 17 for recommended size and go to Test 3 on page 28 gt By other restrictions e g kinks Replace the discharge line See Table A column 2 on page 17 for recommended size Retest 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 bl
64. pendix B 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 I D min Other Requirements 10 16 ft V2 in None If the discharge line length must be less than 10 feet or greater than 16 feet contact your local Bendix representative System Leakage Check the air brake system for excessive air leakage using the Bendix Dual System Air Brake Test and Check List BW1279 Excessive system leakage causes the compressor to pump more air and also more moisture into the brake system Reservoir Draining System Without Air Dryer Routine reservoir draining is the most basic step although not completely effective in reducing the possibility of freeze up All reservoirs in a brake system can accumulate water and other contamination and must be drained The best practice is to drain all reservoirs daily When draining reservoirs turn the ENGINE OFF and drain ALL AIR from the reservoir better still open the drain cocks on all reservoirs and leave them open over night to assure all contamination is drained reference Service Data Sheet SD 04 400 for Bendix Reservoirs If automatic drain valves are installed check their operation before the weather turns cold reference Service Data Sheet SD 03 2501 for Bendix DV 2 Automatic Drain Valves It should be noted that while the need
65. piston is removed from the rod inspect the wrist pin bore or the bronze wrist pin bushing in the connecting rod If excessive wear is noted or suspected replace the connecting rod COMPRESSOR CRANKCASE DISASSEMBLY 1 Remove the key or keys from the crankshaft and any burrs from the crankshaft where the key or keys were removed NOTE Through drive compressors may have a crankshaft key at both ends 2 Remove the four cap screws and lockwashers or nuts and lockwashers that secure the rear end cover to the crankcase 3 Remove the rear end cover thrust bearing and end cover o ring taking care not to damage the bearing if present in the end cover 4 Ifthe compressor has ball type main bearings press the crankshaft and ball bearings from the crankcase then press the ball bearings from the crankshaft 5 Press the oil seal out of the compressor crankcase if so equipped CLEANING OF PARTS GENERAL All parts should be cleaned in a good commercial grade solvent and dried prior to inspection CYLINDER HEAD Remove carbon deposits from the discharge cavity and rust and scale from the cooling cavities of the cylinder head body Scrape all foreign matter from the body surfaces and use shop air pressure to blow the dirt particles from the cavities Clean carbon and dirt from the inlet and unloader passages Use shop air to blow the carbon and dirt deposits from the unloader passages OIL PASSAGES Thoroughly clean all oil p
66. pply an open flame to air lines and valves Beyond causing damage to the internal nonmetallic parts of valves and melting or burning non metallic air lines WARNING THIS PRACTICE IS UNSAFE AND CAN RESULT IN VEHICLE FIRE 2 Do not introduce pour fluids into air brake lines or hose couplings glad hands Some fluids used can cause immediate and severe damage to rubber components Even methanol alcohol which is used in Alcohol Evaporators and Injectors should not be poured into air lines Fluids poured into the system wash lubricants out of valves collect in brake chambers and valves and can cause malfunction Loss of lubricant can affect valve operating characteristics accelerate wear and cause premature replacement 3 Do not park a vehicle outside after thawing its air system indoors Condensation will form in the system and freeze again Place the vehicle in operation when it is removed to the outdoors Supporting Air and Electrical Lines Make certain tie wraps are replaced and support brackets are re assembled if removed during routine maintenance These items prevent the weight of ice and snow accumulations from breaking or disconnecting air lines and wires Automatic Drain Valves System without Air Dryer 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
67. r The typical size of a vehicle s discharge line see column 2 of Table A on page 17 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 33 35 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 t
68. r 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 Air brake system valves are required valves e g at to tolerate a light coating of oil exhaust or seen during servicing Y Normal Genuine Bendix valves are all SAE J2024 compliant gt A small amount of oil does not affect SAE J2024 compliant valves Check that regular maintenance is being performed and that the amount of oil in the air tanks reservoirs is within the acceptable range shown on the Bendix BASIC test cup see also column 5 of Table A on page 17 Return the vehicle to service For oil 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 c
69. rror 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 on Bendix page 30 for a flowchart and expanded BASIC Test explanation of the checklist used when es conducting the BASIC test 18 Symptom What it may indicate 2 0 Oil on the Engine and or other accessories Outside of the leaking onto compressor Compressor 2 1 Oil leaking at a Leak at the front or rear fuel compressor engine pump etc mounting flange connections b Leak at air inlet fitting c Leak at air discharge fitting d Loose broken oil line fittings 2 2 Oil leaking a Excessive leak at head gasket from compressor b Leak at bottom cover plate c Leak at internal rear flange gasket d Leak through crankcase e If unable to tell source of leak Head gasket and rear flange gasket locations 3 0 Oil at air dryer Air brake charging system functioning purge exhaust or normally surrounding area 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 Replace the fitting gasket Inspect inlet hose and replace as necessary Replace gasket or fitting as necessary to ensure g
70. ry check valve malfunction d Air brake system leakage What you should do D D D D D D D 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 17 Verify operation of air dryer Follow vehicle O E maintenance recommendations and component Service Data information Go to Test 5 on page 29 Go to Test 4 on page 29 Verify relief pressure is at vehicle or component manufacturer s specifications typically 150 psi Replace if defective Go to Test 4 on page 29 Go to Test 6 on page 29 Verify operation of air dryer Follow vehicle O E maintenance recommendations Go to Test 4 on page 29 Go to Test 2 on page 28 Go to Test 5 on page 29 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 17 Go to Test 6 on page 29 Verify operation of air dryer Follow vehicle O E maintenance recommendations and component Service Data information Go to Test 2 on page 28 Symptom 16 0 Compressor leaks air Testing for leaks with soap solution 17 0 Compressor leaks coolant 18 0 Noisy compressor Multi cylinder compressors only What it may indicate a Compressor leaks air at con
71. ssor Identify and disconnect all air water and oil lines leading to and from the compressor 3 Remove the governor and any supporting bracketry attached to the compressor and note their positions on the compressor to aid in reassembly 4 Remove the discharge port and inlet cavity fittings if applicable and note their position on the compressor to aid in reassembly 5 Remove the flange or base mounting bolts and remove the compressor from the vehicle 6 Remove the drive gear s or pulley from the compressor crankshaft using a gear puller Inspect the pulley or gear and associated parts for visible wear or damage Since these parts are precision fitted they must be replaced if they are worn or damaged PREPARATION FOR DISASSEMBLY Remove road dirt and grease from the exterior of the compressor with a cleaning solvent Before the compressor is disassembled the following items should be marked to show their relationship when the compressor is assembled Mark the rear end cover in relation to the crankcase Mark the cylinder head in relation to the crankcase Mark the base plate or base adapter in relation to the crankcase Aconvenient method to indicate the above relationship is to use a metal scribe to mark the parts with numbers or lines Do not use a marking method that can be wiped off or obliterated during rebuilding such as chalk Remove all compressor attachments which have not been previously specified CYLINDER HEAD D
72. the back of this manual ASSEMBLY TORQUES All torques specified in this manual are assembly torques and can be expected to fall off after assembly is accomplished Do not retorque after initial assembly torques fall To convert pound inches of torque to pound feet of torque divide inch pounds by 12 pound inches pound feet 12 To convert pound feet of torque to pound inch of torque multiply pound feet by 12 pound feet x 12 pound inches CYLINDER HEAD ASSEMBLY 1 If the discharge valve stop was removed and must be replaced a sealant such as LOCKTITE RETAINING COMPOUND 75 must be applied to the stop and its corresponding bore in the cylinder head Before applying the sealant make certain that the press fit between the discharge valve stop outside diameter and the valve stop bore in the cylinder head is a minimum of 0013 inches and a maximum of 0028 inches If this fit cannot be maintained a new cylinder head body must be used Be sure to completely support the outside top of the cylinder head casting while pressing in the replacement stops IMPORTANT The cylinder head must be supported in a fashion that allows the machined head surface to be parallel to the arbor press bed and perpendicular to the press ram This is necessary to permit the discharge valve stop to be installed squarely in its bore and to minimize the possibility of cocking 2 Install the discharge valve spring discharge valve and v
73. tween the load and unloaded modes due to unloader piston leakage These tests must be performed with vehicle parked on a level surface the engine not running the entire air system completely drained to 0 P S I and the inlet check valve detail parts removed if applicable UNLOADER PISTON LEAKAGE Remove the governor and apply shop air pressure to the 1 8 pipe thread unloader port on the governor mounting pad Listen for the escape of air at the inlet cavity An audible escape of air should not be detected If any question exists 7 DESCRIPTION Cylinder Head Assembly Governor Gasket Unloader Bushing O Ring Unloader Piston Unloader Spring Inlet Valve Gasket Inlet Valve Seat Inlet Valve Inlet Valve Spring Inlet Valve Stop Unloader Piston Stop Hex Head Screws O Ring Inlet Strainer Gasket Discharge Valve Stop Discharge Valve Spring Discharge Valve Discharge Valve Seat Cylinder Head Gasket Piston Ring Set STD 1 Piston Ring 2 Piston Ring Piston Ring Oil Expander Ring Piston Wrist Pin Plug Wrist Pin Connecting Rod Connecting Rod Cap Lockwasher Connecting Rod Bolt 23 O Ring 24 Thrust Washer 25 End Cover Assembly z O A E a 23 5 16 MACH SCREW WITH LOCKWASHER CRANKCASE FRONT BALL BEARING CRANKSHAFT CRANKSHAFT KEY OIL SEAL b O0 Ol j DRIVE SCREWS CRANKSHAFT NUT NAME PLATE SOME APPLICATIONS USE FRONT AND REAR REF SOME FLANGE MOUNTS WITHOUT BALL BEARINGS as to leakage it is re

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