Bendix Commercial Vehicle Systems BA-921 User Manual

®

BENDIX® BA-921® SMC SINGLE CYLINDER COMPRESSOR FOR NAVISTAR MAXXFORCE™ 11 AND 13 BIG BORE ENGINES

SD-01-1327

DESCRIPTION

The function of the air compressor is to provide, and maintain, air under pressure to operate devices in air brake systems. The Bendix® BA-921® SMC side mount compressor is a single-cylinder reciprocating compressor with a rated displacement of 15.8 cubic feet per minute at 1250 RPM.

The compressor consists of a water-cooled cylinder head assembly and an integral air cooled crankcase assembly .

The cylinder head assembly is made up of the cylinder head, cooling plate, and valve plate assembly and uses two sealing gaskets. Both the cylinder head and cooling plate are aluminum. The cylinder head contains air and water ports, as well as an unloader assembly. A cooling plate is located between the cylinder head and valve plate assemblies and assists in cooling.

The valve plate assembly consists of brazed steel plates which have valve openings and passages for air and engine coolant to ﬂ ow into, and out of, the cylinder head. The compressor's discharge valves are part of the valve plate assembly . The inlet reed valve/gasket is installed between the valve plate assembly and the top of the crankcase.

The crankcase has an open side with a machined face and locating pins. This open face is bolted directly to the side of the engine block, see Figure 3. The compressor gear engages the engine drive gear. In addition, the crankcase houses the piston assembly, connecting rod, crankshaft and related bearings.

The Bendix a safety valve to protect the compressor head in the event of, for example, a discharge line blockage downstream of the compressor. Excessive air pressure will cause the safety valve to unseat, release air pressure and give an audible alert to the operator. The safety valve is installed in the cylinder head safety valve port, directly connected to the cylinder head discharge port.

BA-921® SMC compressor is equipped with

Cylinder

Head

Valve Plate

Assembly

Crankcase

FIGURE 1 - BENDIX® BA-921® SMC COMPRESSOR

Bendix Part Number . . . . . . A

Customer Piece Number . . . . B

Compressor Serial Number . . C

FIGURE 2 - NAMEPLATE

Safety

Valve

Cooling

Plate

A nameplate is attached to a ﬂ at cast face on the side of the crankcase. It is stamped with information identifying the compressor designation, customer piece number, compressor assembly part number and serial number. Refer to Figure 2.

Unloader

Piston

Safety

Valve

Discharge

Port

Coolant

Air Inlet Port

Piston

Compressor to

engine block

mounting face

Discharge

Reed

Valves (2)

Connecting Rod

Crankshaft

FIGURE 3 - BENDIX® BA-921® SMC COMPRESSOR CUT AWAY VIEW

OPERATION

The compressor is driven by the vehicle's engine, and functions continuously while the engine is in operation. Actual compression of air is controlled by the compressor unloading mechanism operating in conjunction with a governor.

AIR INTAKE (LOADED)

Just as the piston begins the down stroke, (a position known as top dead center, or TDC), the vacuum created in the cylinder bore above the piston causes the inlet reed valve to ﬂ ex open. Atmospheric air ﬂ ows through the open inlet valve and ﬁ lls the cylinder bore above the piston. See

Figure 4.

AIR COMPRESSION (LOADED)

When the piston reaches the bottom of the stroke, (a position known as bottom dead center, or BDC), the inlet reed valve closes. Air above the piston is trapped by the closed inlet reed valve and is compressed as the piston moves upwards. When air in the cylinder bore reaches a pressure greater than that of the system pressure, the discharge reed valves open and allow air to ﬂ ow into the discharge line and air brake system.

Discharge

Cooling

Plate

Valve Plate

FIGURE 4 - OPERATION - LOADED (INTAKE)

Air

Port

Oil drain

locations

Mounting Face

Air Inlet

Port

Piston Moving Down

Discharge

Valve

Closed

Unloader

Port

Unloader

Piston

Down &

Seated

Inlet Valve Open

At the same time air ﬂ ows into the hollow center of the unloader piston through an opening in the end of the piston.

Compressed air acts on the interior surfaces of the unloader piston and, along with the unloader piston spring, holds the unloader piston in the down position, against its seat on the valve plate. See Figure 5.

NON-COMPRESSION OF AIR (UNLOADED)

When air pressure in the supply reservoir reaches the cutout setting of the governor, the governor delivers system air to the compressor unloader port. Air entering the unloader port acts on the unloader piston causing the piston to move away from its seat on the valve plate assembly . When the unloader piston is unseated, an air passageway is opened between the cylinder bore and a secondary compartment or “closed room” in the interior of the cylinder head.

As the piston moves from bottom dead center (BDC) to top dead center (TDC) air in the cylinder bore ﬂ ows past the unseated unloader piston, into the “closed room”. The size of the closed room is sufﬁ cient to accept the compressed air provided by the compressor piston without creating excessive air pressure in the “closed room”. On the piston down stroke (TDC to BDC) air ﬂ ows in the reverse direction, from the “closed room” past the unseated unloader piston and inlet reed valve, and into the cylinder bore as shown in Figure 6. Note: For optimum performance, it is recommended that the air dryer is equipped with a “turbo cut-off” feature.

Air Inlet

Air

Discharge

Port

Cooling

Plate

Valve

Plate

Inlet

Valve

Closed

FIGURE 5 - OPERATION - LOADED (COMPRESSION)

Port

Piston Moving Up

Discharge

Valve Open

Unloader

Port

Unloader

Piston

Down &

Seated

LUBRICATION

The vehicle’s engine provides a continuous supply of oil to the compressor. Oil is routed from the engine to the compressor’s oil inlet. Note: There is no external oil supply line; the oil delivery is located at the engine to compressor mounting face. This pressurized oil ﬂ ows to the precision front sleeve main bearing, via an oil passage in the crankshaft, routes pressurized oil to the connecting rod bearings and the rear journal associated with the end cover. Spray lubrication of the cylinder bore and connecting rod wrist pin bushing is obtained as oil is forced out around the crankshaft journals by engine oil pressure. Oil then falls to the bottom of the compressor crankcase and is returned to the engine through the opening at the compressor mounting ﬂ ange.

Air From Governor Unloader

Port

Closed

Room

Unloader

Piston Up &

Unseated

Air in Pistons Shuttles Back and Forth from the

Piston to the Closed Room

FIGURE 6 - OPERATION - UNLOADED

Inlet Port

Head

Bolt (6)

Coolant

In or Out

Discharge

Safety Valve

Discharge

Port

Coolant

In or Out

Governor

Connection

Unloader

Cover

CYLINDER HEAD PORT IDENTIFICATION

The cylinder head connection ports are identiﬁ ed with cast-in numerals as follows:

AIR IN 0 Compressed AIR OUT 2 Coolant IN or OUT 9 Governor Control 4

FIGURE 7 - BENDIX® BA-921® SMC COMPRESSOR CYLINDER HEAD

COOLING

The Bendix® BA-921® SMC compressor is cooled by air ﬂ owing through the engine compartment as it passes the compressor's cast-in cooling ﬁ ns and by the ﬂ ow of engine coolant through the cylinder head. Coolant supplied by the engine cooling system passes through connecting lines into the cylinder head and passes through internal passages in the cylinder head, cooling plate and valve plate assembly and returns to the engine. Figure 7 illustrates the approved coolant ﬂ ow connections. Proper cooling is important in minimizing discharge air temperatures - see the tabulated technical data on page 13 of this manual for speciﬁ c requirements.

AIR INDUCTION

The Bendix® BA-921® SMC compressors is only permitted to be naturally aspirated – use of engine turbocharger as an air source is not allowed. See Figure 8 for an example

of a naturally aspirated air induction system.

PREVENTATIVE MAINTENANCE

Regularly scheduled maintenance is the single most important factor in maintaining the air brake charging system. Refer to Table A in the Troubleshooting section starting on page A-1, for a guide to various considerations that must be given to maintenance of the compressor and other related charging system components.

Important Note: Review the Bendix performing any intrusive maintenance procedures. An extended warranty may be voided if intrusive maintenance is performed during this period.

Governor

Unloader Port

Air Dryer

EVERY 6 MONTHS, 1800 OPERATING HOURS OR AFTER EACH 50,000 MILES, WHICHEVER OCCURS FIRST, PERFORM THE FOLLOWING

Governor Reservoir

Port

Compressor

INSPECTIONS AND TESTS.

Warranty Policy before

FIGURE 8 - COMPRESSOR CHARGING SYSTEM

AIR INDUCTION

The Bendix® BA-921® SMC compressor is designed for connection to the vacuum side of the engine’s air induction system.

A supply of clean air is one of the single most important factors in compressor preventive maintenance. Since

the air supply for Bendix

BA-921® SMC compressor and engine is the engine air cleaner, periodic maintenance of the engine air ﬁ lter is necessary.

Inspect the compressor air induction system each time engine air cleaner maintenance is performed.

1. Inspect the intake hose adapters for physical damage.

Make certain to check the adapters at both ends of the intake hose or tubing.

2. Inspect the intake hose clamps and tighten them if

needed.

3. Inspect the intake hose or line for signs of drying,

cracking, chaﬁ ng and ruptures and replace if necessary.

4. Verify that the compressor inlet ﬁ tting is tight (check

torque).

5. Any metal tubes should also be tight (torqued properly)

to the mating ﬁ tting. Inspect the metal tubes for any cracks or breaks and replace if necessary.

COMPRESSOR COOLING

Inspect the compressor discharge port, inlet cavity and discharge line for evidence of restrictions and carbon build-up. If more than 1/16" of carbon is found, thoroughly clean or replace the affected parts. In some case, carbon build-up indicates inadequate cooling. Closely inspect the compressor cooling system. Check all compressor coolant lines for kinks and restrictions to ﬂ ow. 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 ﬂ ow and compare to the tabulated technical data present in the back of this manual. Carefully inspect the air induction system for restrictions.

LUBRICATION

The compressor utilizes an internal oil feed design. Check the exterior of the compressor (i.e. around the mounting face) for the presence of oil seepage and refer to the Troubleshooting section for appropriate tests and corrective action. Refer to the tabulated technical data in the back of this manual for oil pressure minimum values.

If compressor oil passing is suspected, refer to the Troubleshooting section (starting on page A-1) for the symptoms and corrective actions to be taken. In addition, Bendix has developed the “Bendix Air System Inspection Cup”, or Bendix

BASIC™ kit, to help substantiate

suspected excessive oil passing. The steps to be followed

™

when using the BASIC

kit are presented in APPENDIX

B, on page A-16.

COMPRESSOR DRIVE

Check for noisy compressor operation, which could indicate excessive drive component wear. Adjust and/or replace as necessary. Check all compressor mounting bolts and retighten evenly if necessary . Check for leakage. Repair or replace parts as necessary.

COMPRESSOR UNLOADER & GOVERNOR

Test and inspect the compressor and governor unloader system for proper operation and pressure setting.

1. Check for leakage at the unloader port. Replace leaking or worn o-rings.

2. Make certain the unloader system lines are connected as illustrated in Figure 8.

3. Cycle the compressor through the loaded and unloaded cycle several times. Make certain that the governor cuts-in (compressor resumes compressing air) at a minimum of 105 psi (cut-out should be approximately 15 - 20 psi greater than cut-in pressure). Adjust or replace the governor as required.

4. Note that the compressor cycles to the loaded and unloaded conditions promptly. If prompt action is not noted, repair or replace the governor and/or repair the compressor unloader.

IMPORTANT NOTE

Replacement air governors must have a minimum cut-in pressure of 100 psi. The cut-in pressure is the lowest system pressure registered in the gauges before the compressor resumes compressing air.

Compressors with no signal line to the unloader port should have a vent cap (e.g. Bendix P/N 222797) installed in the port. Under no circumstances should the port be plugged or left open.

OIL PASSING

All reciprocating compressors pass a minimal amount of oil. Air dyers will remove the majority of oil before it can enter the air brake system. For particularly oil sensitive systems, the Bendix® PuraGuard® system can be used in conjunction with a Bendix® air dryer.

SERVICE TESTS

LEAKAGE TESTS

GENERAL

The compressor operating and leakage tests listed below need not be performed on a regular basis. These tests should be performed when it is suspected that leakage is substantially affecting compressor build-up performance, or when it is suspected that the compressor is “cycling” between the loaded (pumping) and unloaded (nonpumping) modes due to unloader leakage.

IN SERVICE OPERATING TESTS

Compressor Performance: Build-up Test

This test is performed with the vehicle parked and the engine operating at maximum recommended governed speed. Fully charge the air system to governor cut-out (air dryer purges). Pump the service brake pedal to lower the system air pressure below 80 psi using the dash gauges. As the air pressure builds back up, measure the time from when the dash gauge passes 85 psi to the time it passes 100 psi. The time should not exceed 40 seconds. If the vehicle exceeds 40 seconds, test for (and ﬁ x) any air leaks, and then re-test the compressor performance. If the vehicle does not pass the test the second time, use the Advanced Troubleshooting Guide for Air Brake Compressors, starting on page A-1 of this document to assist your investigation of the cause(s).

See the standard Air Brake System and Accessory Leakage test on Page A-14 (Test 2).

Note: Leakage in the air supply system (components before the supply reservoir such as the governor, air dryer , reservoir drain cocks, safety valve, and check valves) will not be registered on the vehicle dash gauges and must be tested separately. Refer to the various maintenance manuals for individual component leakage tests and the Bendix “Test and Checklist” published in the Bendix Brake System Handbook (BW5057) and on the back of the Bendix Dual Circuit Brake System Troubleshooting Card (BW1396).

Air

CYLINDER HEAD

Check for cylinder head gasket air leakage.

1. With the engine running, lower air system pressure to 60 psi and apply a soap solution around the cylinder head. Check the gasket between the cylinder head and valve plate assembly, as well as the inlet reed valve/gasket between the valve plate assembly and crankcase for air leakage.

2. No leakage is permitted. If leakage is detected, replace the compressor or repair the cylinder head using a genuine Bendix® maintenance kit available from an authorized Bendix® parts outlet.

Note: All new vehicles are certiﬁ ed using the FMVSS 121 test (paragraph S5.1.1) by the vehicle manufacturer, however the above test is a useful guide for in-service vehicles.

Optional Comparative Performance Check

It may be useful to also conduct the above test with the engine running at high idle (instead of maximum governed speed), and record the time required to raise the system pressure a selected range (for example, from 90 to 120 psi, or from 100 to 120 psi, etc.) in the vehicle’s maintenance ﬁ les. Subsequent build-up times throughout the vehicle’s service life can then be compared to the ﬁ rst one recorded. (Note: the 40 second guide in the test above does not apply to this build-up time.) If the performance degrades significantly over time, you may use the Advanced Troubleshooting Guide for Air Brake Compressors, starting on page A-1 of this document, to assist investigation of the cause(s).

Note: When comparing build-up times, be sure to make an allowance for any air system modiﬁ cations which would cause longer times, such as adding air components or reservoirs. Always check for air system leakage.

INLET, DISCHARGE & UNLOADER

In order to test the inlet and discharge valves and the unloader piston, it is necessary to have shop air pressure and an assortment of ﬁ ttings. A soap solution is also required.

1. With the engine shut off, drain ALL air pressure from the vehicle.

2. Disconnect the inlet and discharge lines and remove the governor or its line or adapter ﬁ tting.

3. Apply 120-130 psi shop air pressure to the unloader port and soap the inlet port. Leakage at the inlet port should not exceed 50 sccm.

4. Apply 120-130 psi shop air pressure to the discharge port and then apply and release air pressure to the inlet port. Soap the inlet port and note that leakage at the inlet port does not exceed 20 sccm.

If excessive leakage is noted in Tests 3 or 4, replace or repair the compressor using genuine Bendix® replacements or maintenance kits available from any authorized Bendix parts outlet.

While it is possible to test for inlet, discharge, and unloader piston leakage, it may not be practical to do so. Inlet and discharge valve leakage can generally be detected by longer compressor build-up and recovery times. Compare current compressor build-up times with the last several recorded times. Make certain to test for air system leakage, as described under In Service Operating Tests, before making a determination that performance has been lost.

Unloader leakage is generally exhibited by excessive compressor cycling between the loaded and unloaded condition.

1. With service and supply system leakage below the maximum allowable limits and the vehicle parked, bring system pressure to governor cut-out and allow the engine to idle.

2. The compressor should remain unloaded for a minimum of 5-10 minutes. If compressor cycling occurs more frequently and service and supply system leakage is within tolerance, replace the compressor or repair the compressor unloader system using a genuine Bendix maintenance kit available from authorized Bendix parts outlets.

COMPRESSOR REMOVAL & DISASSEMBLY

GENERAL

The following disassembly and assembly procedure is presented for reference purposes and pre-supposes that a rebuild or repair of the compressor is being undertaken. Several maintenance kits are available and the instructions provided with these parts and kits should be followed in lieu of the instructions presented here.

MAINTENANCE KITS & SERVICE PARTS FOR

BENDIX

COMPRESSOR ONLY

Cylinder Head Gasket Kit ...................................K023764

Unloader Kit ........................................................K046477

Discharge Safety Valve ......................................800534

Compressor Seal Kit...........................................K051352

Compressor to Engine Mounting Face Sealant (Supplied by the Engine Manufacturer)

All components shown in Figure 9 with a key number are available in kits and/or as individual service parts.

BA-921® SMC SINGLE CYLINDER

GENERAL SAFETY GUIDELINGS IMPORTANT! PLEASE READ AND FOLLOW

THESE INSTRUCTIONS TO AVOID PERSONAL INJURY OR DEATH:

When working on or around a vehicle, the following general precautions should be observed at all times:

1. Park the vehicle on a level surface, apply the parking brakes, and always block the wheels. Always wear safety glasses. Where speciﬁ cally directed, the parking brakes may have to be released, and/or spring brakes caged, and this will require that the vehicle be prevented from moving by other means for the duration of these tests/procedures.

2. Stop the engine and remove ignition key when working under or around the vehicle. When working in the engine compartment, the engine should be shut off and the ignition key should be removed. Where circumstances require that the engine be in operation, EXTREME CAUTION should be used to prevent personal injury resulting from contact with moving, rotating, leaking, heated or electrically charged components.

3. Do not attempt to install, remove, disassemble or assemble a component until you have read and thoroughly understand the recommended procedures. Use only the proper tools and observe all precautions pertaining to use of those tools.

4. If the work is being performed on the vehicle’s air brake system, or any auxiliary pressurized air systems, make certain to drain the air pressure from all reservoirs before beginning ANY work on the vehicle. If the vehicle is equipped with a Bendix® AD-IS® air dryer system or a dryer reservoir module, be sure to drain the purge reservoir.

5. Following the vehicle manufacturer’s recommended procedures, deactivate the electrical system in a manner that safely removes all electrical power from the vehicle.

6. Never exceed manufacturer’s recommended pressures.

7. Never connect or disconnect a hose or line containing pressure; it may whip. Never remove a component or plug unless you are certain all system pressure has been depleted.

8. Use only genuine Bendix® brand replacement parts, components and kits. Replacement hardware, tubing, hose, ﬁ ttings, etc. must be of equivalent size, type and strength as original equipment and be designed speciﬁ cally 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 speciﬁ cally 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 Automatic T raction Control (A TC), the ATC function must be disabled (ATC indicator lamp should be ON) prior to performing any vehicle maintenance where one or more wheels on a drive

axle are lifted off the ground and moving.

REMOVAL

In many instances it may not be necessary to remove the compressor from the vehicle when installing the various maintenance kits and service parts. The maintenance technician must assess the installation and determine the correct course of action. These instructions are general and are intended to be a guide. In some cases additional preparations and precautions are necessary. In all cases follow the instructions contained in the vehicle maintenance manual in lieu of the instructions, precautions and procedures presented in this manual.

1. Block the wheels of the vehicle and drain the air pressure from all the reservoirs in the system.

2. Drain the engine cooling system and the cylinder head of the compressor. Identify and disconnect all air , water and oil lines leading to the compressor.

3. Remove as much road dirt and grease from the exterior of the compressor as possible.

4. Remove the discharge ﬁ tting, if applicable, and note their position on the compressor to aid in reassembly.

5. Remove any supporting bracketing attached to the compressor and note their positions on the compressor to aid in reassembly.

6. Remove the six mounting bolts that retain the compressor to the side of the engine block. Note the position of the six mounting bolts. Two of the six bolts are shorter and must be installed in their original locations. Remove the compressor from the vehicle.

7. Inspect drive gear and associated drive parts for visible wear or damage. If the compressor drive gear is worn or damaged, the compressor must be replaced. Refer to the Engine Manufacturers service manual to address the associated engine drive parts.

8. If the compressor is being replaced stop here and proceed to “Installing the Compressor” at the end of the assembly procedure. (Note: Replacement compressors come with the drive gear pre-assembled on the compressor.)

PREPARATION FOR DISASSEMBLY

Refer to Figure 9 during the entire disassembly and assembly procedure.

Place a clean rag over the openings that expose the gear and crankshaft / connecting rod assembly. No contamination is permitted in these areas.

Remove the balance of the road dirt and grease from the exterior of the compressor with a cleaning solvent. If the rear end cover is being removed from the compressor under repair, mark it, along with the two cap screws, in relation to the crankcase. It is also recommended to mark the relationship of the cylinder head, cooling plate, valve plate assembly, and crankcase.

A convenient method to indicate the above relationships is to use a metal scribe to mark the parts with numbers or lines. Do not use marking methods, such as chalk, that can be wiped off or obliterated during rebuilding.

Prior to disassembly, make certain that the appropriate kits are available.

CYLINDER HEAD

1. Remove the discharge safety valve (9) from the cylinder head.

2. To restrain the spring force exerted by the return spring (3) of the unloader assembly, hold the unloader cover in place while removing the two unloader cover cap screws. Carefully release the hold on the unloader cover until the spring force is relaxed, then remove the unloader cover.

3. Remove the unloader cover gasket (4).

4. Remove the balance piston (5) with its o-ring (6); return spring (3) and the unloader piston assembly (7) which includes the unloader piston, two outer o-rings and two guide bushings from the cylinder head.

5. Remove the six hex head bolts from the cylinder head. Note: The ﬁ ve hex bolts located towards the perimeter of the cylinder head retain the cylinder head directly to the crankcase. The single hex bolt in the center of the cylinder head holds the cylinder head, cooling plate and valve plate assembly together; independent of the crankcase.

6. Gently tap the cylinder head, cooling plate and valve plate assembly with a soft mallet to break the gasket seal between the valve plate assembly and the crankcase. Lift the cylinder head with cooling plate and valve plate assembly off the crankcase.

7. Remove the metal inlet reed valve/gasket (1).

Note: Always

Replace Safety

Valve in Original

Location

Cylinder Head

Gasket

(2)

™

ST-4

Safety

Valve

Cylinder Head

Cooling

Plate

Valve Plate

Assembly

Cylinder Head Cap Screws (6)

(includes washers)

Return Spring

Balance Piston

Unloader Piston

Assembly

Alignment

Bushings

Unloader Cover

Cap Screws Unloader

Cover

Unloader Cover

Gasket

Balance

Piston

O-Ring

Inlet Reed Valve/

Gasket

Cover

Crankcase

CYLINDER HEAD GASKET KIT PIECE NO. K023764 CONSISTS OF THE FOLLOWING:

ITEM QTY DESCRIPTION

1 1 INLET REED VALVE GASKET 2 2 CYLINDER HEAD GASKET

UNLOADER KIT PIECE NO. K046477 CONSISTS OF THE FOLLOWING:

ITEM QTY DESCRIPTION

3 1 RETURN SPRING 4 1 UNLOADER COVER GASKET 5 1 BALANCE PISTON 6 1 BALANCE PISTON O-RING 7 1 UNLOADER PISTON ASSEMBLY 8 1 LUBRICANT (NOT SHOWN)

Crankcase

Alignment Pins

End Cover

Screws

End Cover

O-ring

SAFETY VALVE KIT PIECE NO. 800534 CONSISTS OF THE FOLLOWING:

ITEM QTY DESCRIPTION

™

9 1 ST-4

SAFETY VALVE

CRANKCASE SEAL KIT PIECE NO. K051352 CONSISTS OF THE FOLLOWING:

ITEM QTY DESCRIPTION

10 1 END COVER O-RING 11 1 COVER

FIGURE 9 – BA-921® CLOSED ROOM COMPRESSOR EXPLODED VIEW.

8. Gently tap the cylinder head, cooling plate and valve plate assembly with a soft mallet to break the gasket seals. Then separate the cylinder head from the cooling plate and valve plate assembly and remove the two gaskets (2) between them.

CRANKCASE FRONT COVER

1. Remove the cover (1 1) from the front of the crankcase. Use a sharp ﬂ at head screw driver or a scraper. Place the edge under the lip along the outside diameter of the cover. Pry the cover from the cast surface until the cover can be removed.

REAR END COVER

1. Note: There are two cap screws used to retain the end cover to the crankcase. There are two longer cap screws (not shown in Figure 10) that are used to retain the auxiliary drive unit (i.e. hydraulic pump) via the end cover and torqued into the crankcase. If the auxiliary drive unit has already been removed, these two cap screws are no longer present on the end cover. Refer

to Figure 9 to see location of the cap screws in the end cover.

2. Remove the two end cover cap screws that secure the rear end cover to the crankcase.

3. Remove the rear end cover from the crankcase. Remove and discard the o-ring (10) from the end cover.

CLEANING OF PARTS GENERAL

All parts should be cleaned in a good commercial grade of solvent and dried prior to inspection.

CRANKCASE

1. Carefully remove all sealant gasket material adhering to the machined face of the crankcase. See Figure

3. Make certain not to scratch or mar the mounting surface. Note: Keep the crankcase opening covered to prevent any of the sealant material from entering. Repeat this process on the engine mounting face as well. Follow the instructions contained in the vehicle maintenance manual in lieu of the instructions and procedures presented in this manual.

2. Carefully remove all gasket material adhering to the deck (top) of the crankcase. Remove any carbon deposits from the deck of the crankcase. Make certain not to scratch or mar the gasket surfaces.

CYLINDER HEAD ASSEMBLY

1. Carefully remove all gasket material adhering to the cylinder head, cooling plate, valve plate assembly and cast iron crankcase. Make certain not to scratch or mar the gasket surfaces. Pay particular attention to the gasket surfaces of the head.

2. Remove carbon deposits from the discharge and inlet cavities of the cylinder head, cooling plate and valve plate assembly. They must be open and clear in both assemblies. Make certain not to damage the head.

3. Remove rust and scale from the cooling cavities and passages in the cylinder head, cooling plate and valve plate assembly and use shop air to clear debris from the passages.

4. Check the threads in all cylinder head ports for galling (e.g. abrasion, chaﬁ ng). Minor thread chasing (damage) is permitted.

5. Remove any carbon or old grease from the two bores in the unloader cavity of the cylinder head.

INSPECTION OF PARTS CYLINDER HEAD, COOLING PLATE, VALVE

PLATE A SSEMBLY AND UNLOADER MECHANISM

1. Carefully inspect the head gasket surfaces on the cylinder head for deep gouges and nicks. Also, inspect the cylinder head for any cracks or port thread damage. If detected, the compressor must be replaced. If large amounts of carbon build-up are present in the discharge cavity, such that it restricts the air ﬂ ow through the cylinder head, the compressor should be replaced.

2. Carefully inspect both sides of the head gasket surfaces on the cooling plate for deep gouges and nicks. Also, inspect the cooling plate for any cracks or other damage. If cracks or damage are found, the compressor must be replaced.

3. Carefully inspect the valve plate assembly gasket surfaces (both sides) for deep gouges and nicks. Pay particular attention to the gasket surface. An inlet reed valve/gasket (1) is used between the valve plate assembly and crankcase. This gasket surface must be smooth and free of all but the most minor scratches. If excessive marring or gouging is detected, the compressor must be replaced. If large amounts of carbon build-up are present on the two main surfaces, in the two discharge valve holes or between the discharge valve and the discharge seat, the compressor should be replaced.

M8x1.25

Cap

Screws

(Smaller)

FIGURE 10 - REAR END COVER ATTACHMENT BOLTS

M10x1.5

Cap

Screws

(Larger)

4. If the unloader assembly has been removed from the cylinder head, the unloader assembly must be serviced using an unloader kit. (See Maintenance Kits, page 9.)

5. If large amounts of carbon build-up are present on the unloader piston (7) seat or oriﬁ ce or if the return spring exhibits compression set, the unloader components must be replaced with an unloader kit.

6. Carefully inspect the 2 bores in the unloader cavity of the cylinder head for gouges or material transfer. If this is detected, the compressor should be replaced.

REAR END COVER

Visually inspect for cracks and external damage. Check the crankshaft rear bearing diameter in the rear end cover for excessive wear, ﬂ at spots or galling. Check the hydraulic pump attachment pilot and threaded holes for damage. Minor thread chasing is permitted, but do not re-cut the threads. If any of these conditions are found, replace the compressor.

CRANKCASE

Check the cylinder head gasket surface on the deck (top) of the crankcase for nicks, gouges, and marring. A metal gasket is used to seal the cylinder head to the crankcase. This surface must be smooth and free of all but the most minor scratching. If excessive marring or gouging is detected, the compressor must be replaced.

Check the condition of the countersunk hole on the deck of the crankcase that retains the o-ring and prevents coolant leakage between the valve plate assembly and the crankcase. The surface in contact with the o-ring should be smooth and free of any scratches and gouges that could causes leakage around the o-ring.

ASSEMBLY

General Note: All torques speciﬁ ed in this manual are assembly torques and typically can be expected to fall off after assembly is accomplished. Do not re-torque after initial assembly torques fall unless instructed otherwise. A compiled listing of torque speciﬁ cations is presented on page 13.

INCH POUNDS TO FOOT POUNDS

To convert inch pounds to foot pounds of torque, divide inch pounds by 12.

Example: 12 Inch Pounds = 1 Foot Pound

FOOT POUNDS TO INCH POUNDS

To convert foot pounds to inch pounds of torque, multiply foot pounds by 12.

Example: 1 Foot Pound x 12 = 12 Inch Pounds

CRANKCASE FRONT COVER

1. Position the new cover over the hole in the front of the crankcase. Using a rubber mallet, drive the cover into the hole in the front of the crankcase, until the outside diameter of the cover is ﬂ ush with cast surface.

REAR END COVER

1. Install the o-ring (10) on the rear end cover.

2. Orient the rear end cover to the crankcase using the reference marks made during disassembly. Carefully install the rear end cover in the crankcase making certain not to damage the crankshaft bearing surface.

3. Install the two end cover cap screws. Refer to Figure

10 to assure that the two cap screws are installed in the proper crankcase bolt holes. “Snug” the screws

then tighten to 195 to 212 inch pounds (22-24 N•m).

CYLINDER HEAD ASSEMBLY PART ONE: HEAD INSTALLATION

1. Note the position of the protruding alignment pins on the deck (top) of the crankcase. Install the metal inlet reed valve/gasket (1) over the alignment pins on the crankcase.

2. Position the valve plate assembly on the crankcase so that the alignment pins in the crankcase ﬁ t into the corresponding holes in the valve plate assembly.

3. Position and install one of the embossed metal gaskets (2) over the alignment bushings protruding from the cooling plate. Position and install the second embossed metal gasket (2) over the alignment bushings on the opposite side of the cooling plate. When properly installed, the outline of the two embossed gaskets match the outline of the cooling plate.

4. Install the cooling plate onto the valve plate assembly by lining up the alignment bushings on the cooling plate over the oversized countersunk holes of the valve plate assembly . Again, when properly installed, the outline of the cooling plate matches the outline of the valve plate.

5. Position and install the cylinder head over the alignment bushings protruding from the cooling plate. When properly installed, the outline of the cylinder head assembly will match the outline of the cooling plate and valve plate assembly.

Note: The alignment bushings will only ﬁ t into two of

the cylinder head bolt holes.

6. Install the six hex head cylinder head bolts and washers and snug them (ﬁ nger tight), then torque the bolts in the sequence speciﬁ ed in Figure 11. Note: A light ﬁ lm of oil should be applied to the thread of these bolts prior to installation. Oil should not be applied to any other bolts.

7. Install the safety valve (9) in the discharge safety valve port (see Figure 9) of the cylinder head, then tighten to a

torque between 230 and 257 inch pounds (26 - 29 N•m).

PART TWO: UNLOADER INSTALLATION

1. Using the lubricant provided, lubricate the unloader piston bores. Note: There are two bores that must be lubricated.

2. The service kits contains a pre-lubed and preassembled unloader piston assembly (7) which includes the unloader piston, two o-rings, and guide bushings. Remove the unloader piston assembly (7) from the package, remove the plastic cap that retains the upper bushing on the top of the piston. Using the lubricant (8) provided, apply additional lubricant to the two o-rings on the outside of the unloader piston and the surrounding areas. Note: If an o-ring appears to be twisted, manipulate it to remove any twists.

3. Insert the unloader piston assembly (7) into the prelubed unloader cavity of the cylinder head. Take care to avoid catching or snagging the edge of the two guide bushings as the unit is installed in the unloader cavity bores. If there is signiﬁ cant resistance when installing the unloader piston assembly into the unloader cavity bores; remove it, adjust the position of the bushings and re-install. Make certain the unloader piston assembly is pushed completely into the unloader cavity; this will help prevent possible snagging of the top guide bushing.

4. Using the lubricant (8) provided, thoroughly lubricate the exterior of the balance piston (5), including the o-ring groove. Thoroughly lubricate the balance piston o-ring (6). This o-ring is brown in color. Install the balance piston o-ring onto the balance piston (5) o-ring groove. Note: If an o-ring appears to be twisted, manipulate it to remove any twists.

5. Apply lubricant (8) onto the inside diameter of the unloader piston.

6. Insert the return spring (3) into the unloader piston assembly.

7. Install the balance piston (5) with balance piston o-ring (6) into the unloader piston assembly by installing the stem (small diameter) of the balance piston into the return spring (3).

8. Position the unloader gasket (4) on the top of the unloader cavity of the cylinder head. Make certain the gasket is orientated such that the vent hole is exposed and surrounded on the outside by the gasket material.

9. Position the unloader cover on top of the balance piston making certain the stamped logo is visible.

10. Press and hold the unloader cover in place on the cylinder head. Install both unloader cover cap screws. Torque the cover cap screws (2) between 62 and 71 inch pounds (7-8 N•m).

INSTALLING THE COMPRESSOR

1. Apply a liquid gasket sealant to the compressor / engine mounting interface (Refer to Figure 3 for compressor mounting face). Follow the Engine or Vehicle Manufacturers guidelines for the proper liquid gasket sealant material and application procedure.

2. Position the compressor on the engine mounting face making sure that the alignment pins on the crankcase ﬁ t inside the engine mounting face alignment pin holes.

3. Secure the compressor on the engine mounting interface using the six mounting bolts. NOTE: There are two short bolts and four long bolts. Be sure the use the proper length bolt for the crankcase bolt holes. Run each of the bolts down ﬁ nger tight, making sure not to smear the liquid gasket material on the sealing surface. Once the bolts are all ﬁ nger tight; tighten the mounting bolts per Engine Manufacturers recommended torquing sequence and torque requirements.

4. Install any supporting brackets on the compressor in the same position(s) noted and marked during removal.

5. Inspect all air and coolant lines and ﬁ ttings before reconnecting them to the compressor. Make certain o-ring seals are in good or new condition, the threads are clean and the ﬁ ttings are free of corrosion. Replace as necessary.

6. Install the discharge and coolant ﬁ ttings, if applicable, in the same position on the compressor noted and marked during disassembly . See the Torque Speciﬁ cations for various ﬁ tting sizes and types of thread at the rear of this manual. Tighten all hose clamps.

7. Before returning the vehicle to service, perform the Service Tests speciﬁ ed in this manual. Pay particular attention to all lines and hoses disconnected during maintenance and check for air, oil, and coolant leaks at compressor connections and the compressor engine interface. Also check for noisy operation.

2, 8

4, 10

Sequence Torque (N•m)

1 . . . . . . . . . . . 20

2 . . . . . . . . . . . 20

3 . . . . . . . . . . . 20

4 . . . . . . . . . . . 20

5 . . . . . . . . . . . 20

6 . . . . . . . . . . . 20

FIGURE 11 - CLOSED ROOM COMPRESSOR HEAD BOLT TORQUE SEQUENCE

1, 7

Sequence Torque (N•m)

7 . . . . . . . . . . 31-34

8 . . . . . . . . . . 31-34

9 . . . . . . . . . . 31-34

10 . . . . . . . . . 31-34

11 . . . . . . . . . 31-34

12 . . . . . . . . . 31-34

5, 11

3, 9

6, 12

BA-921® COMPRESSOR SPECIFICATIONS (ALL)

Typical weight ......................................................................... 39 LBS

Number of cylinders ......................................................................... 1

Bore Diameter ....................................................... 3.622 in. (92 mm)

Stroke ................................................................... 2.126 in. (54 mm)

Calculated displacement at 1250 RPM .............................. 15.8 CFM

Flow Capacity @ 1800 RPM & 120 PSI ............................... 11.6 CFM

Flow Capacity @ 3000 RPM & 120 PSI ............................... 16.5 CFM

Approximate horsepower required:

Loaded 1800 RPM at 120 PSIG ............................................... 4.6 HP

Unloaded 1800 RPM ................................................................ 0.8 HP

Minimum coolant ﬂ ow at maximum RPM ..................... 1.5 Gals./Min.

Maximum inlet air temperature ................................................. 170°F

Maximum discharge air temperature ........................................ 400°F

Minimum oil pressure required ................................................. 15 PSI

Minimum unloader-line size ................................................. 3/16" I.D.

Minimum Governor Cut-out Pressure ...................................... 120 PSI

TORQUE SPECIFICATIONS:

Assembly Torques in inch pounds (In. Lbs.)

M8x1.25-6g Cylinder Head ..............265 – 292 In. Lbs. (30 – 33 N•m)

M5x0.75-6g Unloader Cap ..................... 62 – 71 In. Lbs. (7 – 8 N•m)

M8x1.25-6g Governor Adapter ....... 195 – 213 In. Lbs. (22 – 24 N•m)

M10x1.5-6g Rear End Cover ...........195 – 213 In. Lbs. (22 – 24 N•m)

M6x1.00-6g Crankcase Cover ............... 62 – 71 In. Lbs. (7 – 8 N•m)

Inlet Port Fittings

M27x2-6g ..................................991 – 1089 In. Lbs. (112 – 123 N•m)

Discharge Port Fittings

M22x1.5-6H ……….. ......................814 – 912 In. Lbs. (92 – 103 N•m)

Water Port Fittings

M18x1.5-6H ....................................593 – 637 In. Lbs. (67 – 72 N•m)

Unloader Port Fittings

1/8"-27 NPT ...................................................................... 2 – 3 TFFT

Safety Valve Port

M16x1.5-6H .....................................230 – 257 In. Lbs. (26 – 29 N•m)

Oil Port

7/16"-16 UNF ..................................150 – 170 In. Lbs. (17 – 19 N•m)

Note: TFFT = Turns From Finger Tight

Appendix A

Advanced Troubleshooting Guide for Air Brake Compressors

The guide consists of an introduction to air brake charging system components, a table showing recommended vehicle maintenance schedules, and a troubleshooting symptom and remedy section with tests to diagnose most charging system problems.

INDEX

Symptom Page Number

Air

Air brake charging system:

Slow build (9.0) .....................................A-9-10

Doesn’t build air (10.0) ............................. A-11

Air dryer:

Doesn’t purge (14.0) ................................A-12

Safety valve releases air (12.0) ...............A-12

Compressor:

Constantly cycles (15.0) ..........................A-12

Leaks air (16.0) ........................................A-13

Safety valve releases air (11.0) ...............A-11

Noisy (18.0) ............................................A-13

Reservoir:

Safety valve releases air (13.0) ...............A-12

Test Procedures

(1) Oil Leakage at Head Gasket .....A-14

(2) System Leakage .......................A-14

(3) Compressor Discharge and

Air Dryer Inlet Temperature ...........A-15

(4) Governor Malfunction ................A-14

(5) Governor Control Line ...............A-15

(6) Compressor Unloader ...............A-15

BASIC™ Test Information ........A-16-18

Symptom Page Number

Coolant

Compressor leaks coolant (17.0)....................A-13

Engine

Oil consumption (6.0) ......................................A-9

Oil

Oil Test Card results (1.0) .................................A-4

Oil is present:

On the outside of the compressor (2.0) ......A-5

At the air dryer purge/exhaust

or surrounding area (3.0) ........................A-5

In the supply reservoir (4.0) .................... A-6-8

At the valves (5.0) .......................................A-8

At air dryer cartridge (7.0) ...........................A-9

In the ping tank or compressor

discharge aftercooler (8.0) ......................A-9

Maintenance & Usage Guidelines

Maintenance Schedule and

Usage Guidelines (Table A) ..... A-3

A-1

Introduction to the Air Brake Charging System

Powered by the vehicle engine, the air compressor builds the air pressure for the air brake system. The air compressor is typically cooled by the engine coolant system and lubricated by the engine oil supply.

The compressor's unloader mechanism and governor (along with a synchro valve for the Bendix

DuraFlo 596

™

air compressor) control the brake system air pressure between a preset maximum and minimum pressure level by monitoring the pressure in the service (or “supply”) reservoir. When the air pressure becomes greater than that of the preset “cut-out”, the governor controls the unloader mechanism of the compressor to stop the compressor from building air and also causes the air dryer to purge. As the service reservoir air pressure drops to the “cut-in” setting of the governor, the governor returns the compressor back to building air and the air dryer to air drying mode.

As the atmospheric air is compressed, all the water vapor originally in the air is carried along into the air system, as well as a small amount of the lubricating oil as vapor.

The duty cycle is the ratio of time the compressor spends building air to the total engine running time. Air compressors are designed to build air (run “loaded”) up to 25% of the time. Higher duty cycles cause conditions that affect air brake charging system performance which may require additional maintenance. Factors that add to the duty cycle are: air suspension, additional air accessories, use of an undersized compressor, frequent stops, excessive leakage from ﬁ ttings, connections, lines, chambers or valves, etc. The discharge line allows the air, water-vapor and oil-vapor mixture to cool between the compressor and air dryer. The typical size of a vehicle's discharge line, (see column 2 of Table A on page A-3) assumes a compressor

with a normal (less than 25%) duty cycle, operating in a temperate climate. See Bendix and/or other air dryer manufacturer guidelines as needed.

When the temperature of the compressed air that enters the air dryer is within the normal range, the air dryer can remove most of the charging system oil. If the temperature of the compressed air is above the normal range, oil as oil-vapor is able to pass through the air dryer and into the air system. Larger diameter discharge lines and/or longer discharge line lengths can help reduce the temperature.

The discharge line must maintain a constant slope down from the compressor to the air dryer inlet ﬁ tting to avoid low points where ice may form and block the ﬂ ow . If, instead, ice blockages occur at the air dryer inlet, insulation may be added here, or if the inlet ﬁ tting is a typical 90 degree ﬁ tting, it may be changed to a straight or 45 degree ﬁ tting. For more information on how to help prevent discharge line freeze-ups, see Bendix Bulletins TCH-008-021 and TCH-008-022 (see pages A-19-21). Shorter discharge line lengths or insulation may be required in cold climates.

The air dryer contains a ﬁ lter that collects oil droplets, and a desiccant bed that removes almost all of the remaining water vapor. The compressed air is then passed to the air brake service (supply) reservoir. The oil droplets and the water collected are automatically purged when the governor reaches its “cut-out” setting.

For vehicles with accessories that are sensitive to small amounts of oil, we recommended installation of a Bendix PuraGuard® system ﬁ lter , designed to minimize the amount of oil present.

Discharge Line

A-2

Optional “Ping” Tank

Compressor

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

Air Dryer

Governor

(Governor plus Synchro valve for the Bendix

DuraFlo 596™

Compressor)

of an air compressor, governor, discharge line, air dryer, and service reservoir.

Optional Bendix® PuraGuard System Filter or PuraGuard QC™ Oil Coalescing Filter

Service Reservoir

(Supply Reservoir)

Reservoir Drain

Table A: Maintenance Schedule and Usage Guidelines

Regularly scheduled maintenance is the single most important factor in maintaining the air brake charging system.

Recom- Recom- Acceptable Typical Discharge mended mended Reservoir Compressors Line Air Dryer Reservoir Oil Contents No. of Spec'd Cartridge Drain at Regular

Vehicle Used for:

Axles Replacement1 Schedule2 Drain Interval

Low Air Use

Compressor with less than 15% duty cycle

e.g. Line haul single trailer

w/o air suspension, air over

hydraulic brakes.

Compressor with up to 25% duty cycle

less

e.g. Line haul single trailer

with air suspension, RV,

school bus.

less

High Air Use

Compressor with up to 25% duty cycle

e.g. Double/triple trailer,

open highway coach, (most)

pick-up & delivery, yard or

terminal jockey, off-highway,

construction, loggers, concrete

mixer, dump truck, ﬁ re truck.

Compressor with up to 25% duty cycle

less

e.g. City transit bus, refuse,

bulk unloaders, low boys,

urban region coach, central

tire inﬂ ation.

less

12 or

Column 1

(See footnote 7)

1/2 in.

For oil carry-over

control4 suggested

5/8 in. 9 ft.

550 air compressor

For oil carry-over

control4 suggested

Tu-Flo

air compressor

BA-921

Bendix

750 air compressor

5/8 in. 12 ft.

Bendix

1/2 in.

For oil carry-over

control4 suggested

5/8 in. 15 ft.

Tu-Flo

Bendix

air compressor

™

596

3/4 in.

, or DuraFlo

Column 2 Column 3 Column 4 Column 5

I.D.

Length

6 ft.

BASIC™ test

acceptable

upgrades:

9 ft.1/2 in.

Every 3

Years

Recom-

mended

Every

Month -

Max of

range:

3 oil units

per month.

appendix

every 90

days

upgrades:

For the

BASIC™ Test Kit:

Order

Bendix

5013711

12 ft.

Every 2

Years

upgrades:

BASIC™ test

acceptable

range:

Every

Month

5 oil units

per month.

appendix

12 ft.

Every

Year

See

P/N

See

BA-922

Bendix

Footnotes:

1. With increased air demand the air dryer cartridge needs to be replaced more often.

2. Use the drain valves to slowly drain all reservoirs to zero psi.

3. Allow the oil/water mixture to fully settle before measuring oil quantity.

4. To counter above normal temperatures at the air dryer inlet, (and resultant oil-vapor passing upstream in the air system) replace the discharge line with one of a larger diameter and/or longer length. This helps reduce the air's temperature. If sufﬁ cient cooling occurs, the oil-vapor condenses and can be removed by the air dryer. Discharge line upgrades are not covered under warranty. Note: To help prevent discharge line freeze-ups, shorter discharge line lengths or insulation may be required in cold climates. (See Bendix

Bulletins TCH-008-021 and TCH-008-022, 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.

6. Note: Compressor and/or air dryer upgrades are recommended

in cases where duty cycle is greater than the normal range (for the examples above).

7. For correct compressor upgrades consult Bendix - Please note

that because a compressor is listed in the same area of the chart does not necessarily mean that it would be a suitable candidate for upgrade purposes.

For Bendix recommended every 250,000 miles.

Tu-Flo® 550 and 750 compressors, unloader service is

A-3

Air Brake Charging System Troubleshooting

How to use this guide: Find the symptom(s) that you see, then move to the right to ﬁ nd the possible causes (“What it may indicate”) and remedies (“What you should do”). Review the warranty policy before performing any intrusive compressor maintenance. Unloader or cylinder head gasket replacement and resealing of the bottom cover plate are usually permitted under warranty . Follow all standard safety procedures when performing any maintenance.

WARNING! Please READ and follow these instructions to

avoid personal injury or death:

When working on or around a vehicle, the following general precautions should be observed at all times.

1. Park the vehicle on a level surface, apply the parking brakes, and always block the wheels. Always wear safety glasses.

Look for:

Normal - Charging system is working within normal range.

Check - Charging system needs further investigation.

5. Following the vehicle manufacturer’s recommended procedures, deactivate the electrical system in a manner that safely removes all electrical power from the vehicle.

6. Never exceed manufacturer’s recommended pressures.

7. Never connect or disconnect a hose or line containing pressure; it may whip. Never remove a component or plug unless you are certain all system pressure has been depleted.

8. Use only genuine Bendix components and kits. Replacement hardware, tubing, hose, ﬁ ttings, etc. must be of equivalent size, type and strength as original equipment and be designed speciﬁ cally for such applications and systems.

10. Prior to returning the vehicle to service, make certain all components and systems are restored to their proper operating condition.

11. For vehicles with Automatic Traction Control (A TC), the A TC 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.

brand replacement parts,

Symptom: What it may indicate: What you should do:

1.0 Oil Test Card Results

Not a valid test.



Bendix®

BASIC™ Test

Discontinue using this test. Do not use this card test to diagnose compressor "oil passing" issues. They are subjective and error prone. Use only the Bendix® Air System Inspection Cup (BASIC™) test and the methods described in this guide for advanced troubleshooting.

The Bendix® BASIC™ test should be the deﬁ nitive method for judging excessive oil fouling/oil passing. (See Appendix A,

on page A-16 for a ﬂ owchart and expanded explanation of the checklist used when conducting the BASIC™ test.)



A-4

Symptom: What it may indicate: What you should do:

2.0 Oil on the Outside of the Compressor

2.1 Oil leaking at compressor / engine connections:

2.2 Oil leaking from compressor:

Engine and/or other accessories leaking onto compressor.

(a)Leak at the front or rear (fuel

pump, etc.) mounting ﬂ ange.

(b) Leak at air inlet ﬁ tting.

(d) Loose/broken oil line ﬁ ttings.

(a) Excessive leak at head gasket. (b)Leak at bottom cover plate.

(c)Leak at internal rear flange

gasket. (d)Leak through crankcase. (e) (If unable to tell source of leak.)

Find the source and repair. Return the vehicle to service.

Repair or replace as necessary. If the

mounting bolt torques are low, replace the gasket.

Replace the ﬁ tting gasket. Inspect inlet

hose and replace as necessary.

Replace gasket or ﬁ tting as necessary to

ensure good seal.

Inspect and repair as necessary.

Go to Test 1 on page A-14. Reseal bottom cover plate using RTV

silicone sealant.

Replace compressor. Replace compressor. Clean compressor and check periodically.

(a)



3.0 Oil at air dryer purge/exhaust or surrounding area

Head gaskets and rear

(c)

ﬂ ange gasket locations.



Air brake charging system functioning normally.

Air dryers remove water and oil from the air

brake charging system.

Check that regular maintenance is being

performed. Return the vehicle to service. An optional kit (Bendix piece number 5011327 for the Bendix® AD-IS® or AD-IP® air dryers, or 5003838 for the Bendix® AD-9® air dryer) is available to redirect the air dryer exhaust.

A-5

Symptom: What it may indicate: What you should do:

4.0 Oil in Supply or Service Reservoir (air dryer installed)

(If a maintained Bendix® PuraGuard® system ﬁ lter or Bendix® PuraGuard QC coalescing ﬁ lter is installed, call 1-800-AIR-BRAKE (1-800-247-2725) and speak to a Tech Team

member.)

See Table A, on page A-3, for maintenance schedule information.

™

oil

Maintenance

(a) If air brake charging system mainte-

nance has not been performed.

That is, reservoir(s) have not been

drained per the schedule in Table A on page A-3, Column 4 and/or the air dryer maintenance has not been performed as in Column 3.

(b) If the vehicle maintenance has

been performed as recommended in Table A on page

A-3, some oil in

the reservoirs is normal.

(a)

Drain all air tanks (reservoirs) into the Bendix

(Bendix kit P/N 5013711).

cup.

BASIC™ test

Drain all air tanks and check vehicle at next

service interval using the Bendix® BASIC™ test. See Table A on page A-3, column 3 and 4, for recommended service schedule.

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 (T est 2, on page A-14), stop inspection and check again at the next service interval.

See the BASIC™ test kit for full details.

If less than one "oil unit" of water (or water/

cloudy emulsion mixture) is present, use the BASIC™cup chart on the label of the cup to determine if the amount of oil found is within the acceptable level.

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 ﬁ lter.

If outside the normal range go to Symptom

4.0(c).

Also see the Table A on page A-3, column

3 for recommended air dryer cartridge replacement schedule.

Duty cycle too high

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 ﬁ ttings, connections, lines, chambers or valves, etc.

Go to

Test 2 on page A-14.

See Table A, column 1, on page A-3 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).

19A-6

Symptom: What it may indicate: What you should do:

4.0 Oil in Supply or Service Reservoir* (air dryer installed) (continued)

(e)

(g)

Testing the temperature at the discharge ﬁ tting.

(g)

Kinked discharge line shown.

Temperature

(e) Air compressor discharge and/or

air dryer inlet temperature too high.

(f) Insufﬁ cient coolant ﬂ ow.

(f)

Inspecting the coolant hoses.

(g) Restricted discharge line.

Check temperature as outlined in Test 3 on

page A-14. If temperatures are normal go to 4.0(h).

Inspect coolant line. Replace as necessary

(I.D. is 1/2").

Inspect the coolant lines for kinks and

restrictions and ﬁ ttings for restrictions. Replace as necessary.

V erify coolant lines go from engine block to

compressor and back to the water pump. Repair as necessary.

If discharge line is restricted or more than

1/16" carbon build-up is found, replace the discharge line. See Table A, column 2, on page A-3 for recommended size. Replace as necessary.

The discharge line must maintain a

constant slope down from the compressor to the air dryer inlet ﬁ tting to avoid low points where ice may form and block the ﬂ ow. If, instead, ice blockages occur at the air dryer inlet, insulation may be added here, or if the inlet ﬁ tting is a typical 90 degree ﬁ tting, it may be changed to a straight or 45 degree ﬁ tting. For more information on how to help prevent discharge line freezeups, see Bendix Bulletins TCH-008-021 and TCH-008-022 (Appendix B). Shorter discharge line lengths or insulation may be required in cold climates.

(h)

Other

(h) Restricted air inlet (not enough air

to compressor).

Check compressor air inlet line for restric-

tions, brittleness, soft or sagging hose conditions etc. Repair as necessary . Inlet line size is 3/4 ID. Maximum restriction requirement for compressors is 25 inches of water.

Check the engine air ﬁ lter and service if

Partly collapsed inlet line shown.

*If a maintained Bendix ﬁ lter is installed, call 1-800-AIR-BRAKE (1-800-247-2725) and speak to a Tech Team member.

PuraGuard® system ﬁ lter or Bendix® PuraGuard QC™ oil coalescing

necessary (if possible, check the air ﬁ lter usage indicator).

A-7

Symptom: What it may indicate: What you should do:

4.0 Oil in Supply or Service Reservoir* (air dryer installed)

Other (cont.)

(i) Poorly filtered inlet air (poor air

quality to compressor).

(continued)

(j) Governor malfunction or setting.

(k) Compressor malfunction.

Crankcase Flooding Consider installing a compressor bottom drain kit

(where available) in cases of chronic oil passing where all other operating conditions have been investigated. Bendix compressors are designed to have a 'dry' sump and the presence of excess oil in the crankcase can lead to oil carryover.

Check for leaking, damaged or defective

compressor air inlet components (e.g. induction line, ﬁ ttings, gaskets, ﬁ lter bodies, etc.). Repair inlet components as needed. Note: Dirt ingestion will damage compressor and is not covered under warranty.

Inspect the engine air cleaner.

Go to Test 4 on page A-15. If you found excessive oil present in the

service reservoir in step 4.0 (b) above and you did not ﬁ nd any issues in steps 4.0 (c) through 4.0 (j) above, the compressor may be passing oil.

Replace compressor. If still under warranty ,

follow normal warranty process. Note: After replacing a compressor, residual oil may take a considerable period of time to be ﬂ ushed from the air brake system.

*If a maintained Bendix ﬁ lter is installed, call 1-800-AIR-BRAKE (1-800-247-2725) and speak to a Tech Team member.

5.0 Oil present at valves (e.g. at

PuraGuard® system ﬁ lter or Bendix® PuraGuard QC™ oil coalescing

Air brake system valves are required

to tolerate a light coating of oil.

A small amount of oil does not affect SAE

J2024** compliant valves.

exhaust, or seen during servicing).

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 A-3). 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.

Genuine Bendix valves are all SAE J2024 compliant.

A-8

Symptom: What it may indicate: What you should do:

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 discharge aftercooler.

9.0 Air brake charging system seems slow to build pressure.

A problem with engine or other engine accessory.

The engine service manual has more information.

Air brake charging system is functioning normally.

Oil shown leaking from an air dryer cartridge.

Air brake charging system is functioning normally.

(a) Air brake charging system

functioning normally.

(b) Air brake system leakage.

See engine service manual.

Air dryers remove water and oil from

the air brake charging system. A small amount of oil is normal. Check that regular maintenance is being performed and that the amount of oil in the air tanks (reservoirs) is within the acceptable range shown by the BASIC™ test (see also column 5 of Table A on page A-3). Replace the air dryer cartridge as needed and return the vehicle to service.

Follow vehicle O.E. maintenance

recommendation for these components.

Using dash gauges, verify that the

compressor builds air system pressure from 85-100 psi in 40 seconds or less with engine at full governed rpm. Return the vehicle to service.

Go to Test 2 on page A-14.

the application.

(d) Compressor unloader mechanism

malfunction. (e) Damaged compressor head

gasket.

See Table A, column 1, on page A-3 for

some typical compressor applications. If the compressor is "too small" for the vehicle's role, for example, where a vehicle's use has changed, then upgrade the compressor. Note: The costs incurred (e.g. installing a larger capacity compressor, etc.) are not covered under original compressor warranty.

Go to Test 6 on page A-15.

An air leak at the head gasket may indi-

cate a downstream restriction such as a freeze-up or carbon blockage and/or could indicate a defective or missing safety valve. Find blockage (go to 9.0(f) for details) and then replace the compressor. Do not reuse the safety valve without testing. See Symptom 12.0(a).

A-9

Symptom: What it may indicate: What you should do:

9.0 Air brake

(f) Restricted discharge line.

charging system seems slow to build pressure. (continued)

(f)

Dash gauges.

Kinked discharge line shown.

Engine Oil Quality

Inadequate oil change intervals, the formulation of the oil and/or the quality of oil ﬁ lter used can all lead to poor oil quality . These can increase the rate at which carbon builds up in the discharge line. Bendix recommends oil soot (solids) be maintained at less than 3%.

If discharge line is restricted:  By more than 1/16" carbon build-up,

replace the discharge line (see Table A, column 2, on page A-3 for recommended size) and go to Test 3 on page A-14.

 By other restrictions (e.g. kinks).

Replace the discharge line. See Table A, column 2, on page A-3 for recommended size. Re test for air build. Return vehicle to service or, if problem persists, go to

9.0(a).

The discharge line must maintain a

(g)

Partly collapsed inlet line shown.

(g) Restricted air inlet (not enough air

to compressor).

(h) Poorly filtered inlet air (poor air

quality to compressor).

(i) Compressor malfunction.

Check compressor air inlet line for restric-

tions, brittleness, soft or sagging hose conditions, etc. Repair as necessary . Refer to vehicle manufacturer’s guidelines for inlet line size.

Check the engine air ﬁ lter and service if

necessary (if possible, check the air ﬁ lter usage indicator).

Check for leaking, damaged or defective

Replace the compressor only after making

certain that none of the preceding conditions,

9.0 (a) through 9.0 (h), exist.

A-10

Symptom: What it may indicate: What you should do:

10.0 Air charging system doesn’t build air.

* Note: For the Bendix® DuraFlo 596™ air compressor, not only the governor, but also the SV-1™ synchro valve used would need to be tested. See Bulletin TCH-001-048.

11.0 Compressor safety valve releases air (Compressor builds too much air).



(a) Governor malfunction*. (b) Restricted discharge line. (c) Air dryer heater malfunction:

exhaust port frozen open.

(d) Compressor malfunction.

(a) Restricted discharge line.

Damaged discharge line shown.

Go to Test 4 on page A-15. See 9.0(f). Replace air dryer heater.

Replace the compressor only after making

certain the preceding conditions do not exist.

If discharge line is restricted:  By more than 1/16" carbon build-up,

replace the discharge line (see Table A, column 2, on page A-3 for recommended size) and go to Test 3 on page A-14.

 By other restrictions (e.g. kinks).

Replace the discharge line. See Table A, column 2, on page A-3 for recommended size.

The discharge line must maintain a

constant slope down from the compressor to the air dryer inlet ﬁ tting to avoid low points where ice may form and block the ﬂ ow. If, instead, ice blockages occur at the air dryer inlet, insulation may be added here, or if the inlet ﬁ tting is a typical 90 degree ﬁ tting, it may be changed to a straight or 45 degree ﬁ tting. For more information on how to help prevent discharge line freezeups, see Bendix Bulletins TCH-08-21 and TCH-08-22 (Appendix B). Shorter discharge line lengths or insulation may be required in cold climates.

(b) Downstream air brake system check

valves or lines may be blocked or damaged.

(d) Compressor safety valve

malfunction.

(e) Compressor unloader mechanism

malfunction.

(f) Governor malfunction.

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.

V erify relief pressure is 250 psi. Replace if

defective.

Go to Test 6 on page A-15.

Go to Test 4 on page A-15.

A-11

Symptom: What it may indicate: What you should do:

12.0 Air dryer safety valve releases air.

Air dryer safety valve





Technician removes governor.

13.0 Reservoir safety valve releases air.

(a) Restriction between air dryer and

reservoir.

(b) Air dryer safety valve

malfunction.

performed.

(d) Air dryer malfunction.

(e) Improper governor control line

installation to the reservoir.

(f) Governor malfunction.

(a) Reservoir safety valve

malfunction.

(b) Governor malfunction.

Inspect delivery lines to reservoir for

restrictions and repair as needed.

Verify relief pressure is at vehicle or

component manufacturer speciﬁ cations. Replace if defective.

See Maintenance Schedule and Usage

Guidelines (Table A, column 3, on page A-3).

V erify operation of air dryer. Follow vehicle

O.E. maintenance recommendations and component Service Data information.

Go to Test 5 on page A-15.

Go to Test 4 on page A-15.

Verify relief pressure is at vehicle or

component manufacturer's speciﬁ cations (typically 150 psi). Replace if defective.

Go to Test 4 on page A-15.

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.)

malfunction.

(a) Air dryer malfunction.

(b) Governor malfunction. (c) Air brake system leakage. (d) Improper governor control line

installation to the reservoir.

(a) Air brake charging system

maintenance not performed.

(b) Compressor unloader mechanism

malfunction.

check valve malfunction.

Go to Test 6 on page A-15.

V erify operation of air dryer . Follow vehicle

O.E. maintenance recommendations.

Go to Test 4 on page A-15. Go to Test 2 on page A-14. Go to Test 5 on page A-15.

Available reservoir capacity may be

reduced by build-up of water, etc. Drain and perform routine maintenance per T able A, columns 3 & 4, on page A-3.

Go to Test 6 on page A-15.

V erify operation of air dryer. Follow vehicle

O.E. maintenance recommendations and component Service Data information.

A-12

(d) Air brake system leakage.

Go to Test 2 on page A-14.

Symptom: What it may indicate: What you should do:

16.0 Compressor leaks air

Testing for leaks with soap solution.

17.0 Compressor leaks coolant

(a) Compressor leaks air at connections

or ports.

(b) Compressor unloader mechanism

malfunction. (c) Damaged compressor head

gasket(s).



(a) Improperly installed plugs or coolant

line ﬁ ttings.

(b) Damaged compressor head

gasket.

Head

gasket



locations

Check for leaking, damaged or defective

compressor ﬁ ttings, gaskets, etc. Repair or replace as necessary.

Go to Test 6 on page A-15.

An air leak at the head gasket(s) may

indicate a downstream restriction such as a freeze-up or carbon blockage and/or could indicate a defective or missing safety valve. Find blockage (go to 9.0(f) for details) and then replace the compressor. Do not reuse the safety valve without testing. See Symptom 12.0(a).

Inspect for loose or over-torqued ﬁ ttings.

Reseal and tighten loose ﬁ ttings and plugs as necessary. If overtorqued ﬁ ttings 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 freezeup 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).

18.0 Noisy compressor (Multi-cylinder compressors only)

This guide attempts to cover most compressor system problems. Here are some rare sources of problems not covered in this guide:

• Turbocharger leakage. Lubricating oil from leaking turbocharger seals can enter the air compressor intake and give misleading symptoms.

(a) Damaged compressor.

Other Miscellaneous Areas to Consider

• 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.

If casting porosity is detected, replace the

compressor.

Replace the compressor.

A-13

Tests

Test 1: Excessive Oil Leakage at the Head Gasket

Exterior leaks at the head gasket are not a sign that oil is being passed into the air charging system. Oil weepage at the head gasket does not prevent the compressor from building air.

Observe the amount of weepage from the head gasket. If the oil is only around the cylinder head area, it is acceptable (return the vehicle

to service), but, if the oil weepage extends down to the nameplate area of the compressor, the gasket can be replaced.

Test 2: Air Brake System and Accessory Leakage

Look

for

Weepage

Inspect for air leaks when working on a vehicle and repair them promptly. Park the vehicle on level ground and chock wheels. Build system pressure to governor cut-out and allow the pressure to stabilize for one minute. Step 1: Observe the dash gauges for two additional minutes without the service brakes applied. Step 2: Apply the service brakes and allow the pressure to stabilize. Continue holding for two minutes (you may use a block of wood to hold the

Test 3: Air Compressor Discharge Temperature and Air Dryer Inlet Temperature*

Caution: The temperatures used in this test are not normal vehicle conditions. Above normal temperatures can cause oil (as vapor) to pass through the air dryer into the air brake system.

This test is run with the engine at normal operating temperature, with engine at max. rpm. If available, a dyno may be used.

1. Allow the compressor to build the air system pressure to governor cut-in.

2. Pump the brakes to bring the dash gauge pressure to 90 psi.

3. Allow the compressor to build pressure from 95 to 105 psi gauge pressure and maintain this pressure range by cycling the brakes for

ﬁ ve (5) minutes.

Discharge Line

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 conﬁ rm that they have been repaired. Air leaks can also be found in the charging system, parking brakes, and/or other components - inspect and repair as necessary.

(* Note that only vehicles that have passed Test 2 would be candidates for this test.)

4. Then, while maintaining max rpm and pressure range, measure and record the surface temperature of the ﬁ ttings:

at the compressor discharge port. (T1). at the air dryer inlet ﬁ tting. (T2).

Use a touch probe thermocouple for measuring

the temperature.

5. See table below.

6. Re-test before returning the vehicle to service.

T1 T2

Compressor Air Dryer

Discharge Inlet Fitting Fitting

under under Temperatures are within 360°F 200°F normal range for this test, check other symptoms. Go to 4.0 (h).

under over This could indicate a discharge 360°F 200°F line problem (e.g. restriction). Call 1-800-AIR-BRAKE (1-800-247-2725) and speak with our Tech Team.

over __ Compressor is running hot. 360°F Check coolant 4(f) and/or discharge line 4(g).

Action

A-14

Tests (continued)

Test 4: Governor Malfunction

1. Inspect control lines to and from the governor for restrictions (e.g. collapsed or kinked). Repair as necessary.

2. Using a calibrated external gauge in the

Test 5: Governor Control Line

supply reservoir, service reservoir , or reservoir port of the D-2 cut-out pressures are within vehicle OEM speciﬁ cation.

3. If the governor is malfunctioning, replace it.

governor, verify cut-in and

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 ﬁ tting to the unloader port. Add a section of air hose (min 1 ft long for a 1/2" diameter line) and a gauge to the ﬁ tting followed by a shut-off valve and an air source (shop air or small air tank). Open the

2. Perform proper reservoir drain intervals and air dryer cartridge maintenance per Maintenance Schedule and Usage Guidelines (Table A on page A-3).

3. Return the vehicle to service.

shut-off and charge the unloader port by allowing air pressure to enter the hose and unload the compressor. Shut off the air supply and observe the gauge. A steady reading indicates no leakage at the unloader port, but a falling reading shows that the unloader mechanism is leaking and needs to be serviced.

A-15

Appendix B: Information about the BASIC™ Test Kit (Bendix P/N 5013711)

Service writer records info - including the number of days since all air tanks were ills out symptom

drained - and f

checklist. Technician inspects items.

START BASIC TEST

Park vehicle on ground.LEVEL

Chock wheels, drain air from system.

days

Bendix® Air System Inspection Cup

(BASIC™) Test Information

Drain contents of air

tanks into

YES, this is a high air use vehicle.

Find the point on the label

where the number of oil units

High

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?

High

YES

ALL

™

BASIC cup

Is there less than one unit of liquid?

there more

than one unit of:

• water, or

• cloudy emulsion mixture?

NO, only oil.

Is this a

transit vehicle, bulk

unloader, or has more

than 5 axles?

High

Low

YES

NO, this is a low air

use vehicle.

Find the point on the label

where the number of oil units

meets the number of days*

since the vehicle's air tanks

were last drained.

Is the

point above

the LOW Air Use

line on the

cup?

YES

Vehicle OK.

Return vehicle to

service.

Cloudy emulsion mixture

Is this vehicle being re-tested? (after water, etc. was found

last time?)

Low

YES

Go to the

Advanced

Troubleshooting

Guide to find reason(s) for

presence of water

END TEST

Change air dryer

Test for air

leakage

END TEST

cartridge**

Use Test 2: Air Leakage

Re-test with the

™

BASIC Test after

30 days***

Test for air

leakage

Compressor

A-16

Use Test 2: Air Leakage

Does

the vehicle have

excessive air

leakage?

Was

the number of

days since last

draining known?

Replace the Compressor. If under warranty, follow standard procedures.

If, after a compressor was already replaced, the vehicle fails the

™

BASIC Advanced Troubleshooting Guide to investigate the cause(s).

END TEST

YES

Repair leaks and

return vehicle to

service

NO (did not know

when last

drained)

YES, number of days was known (30 - 90 days)

Re-test with the

BASIC Test after

™

30 days***

END TEST

test again, do not replace the compressor**** - use the

Vehicle OK.

Return vehicle to

service.

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.

*** T o get an accurate reading for the amount of oil collected during a 30 day period, ask the customer not to drain the air tanks before returning. (Note that 30-90 days is the recommended air tank drain schedule for vehicles equipped with a Bendix air dryer that is properly maintained.) If, in cold weather conditions, the 30 day air tank drain schedule is longer than the customer's usual draining interval, the customer must determine, based on their experience with the vehicle, whether to participate now, or wait for warmer weather. See the cold weather tips in Bulletins TCH-008-021 and TCH-008-022 (included on pages A-19-21 of this document).

****Note: After replacing a compressor , residual oil may take a considerable period of time to be ﬂ ushed from the air brake system.

Appendix B continued: Information about the BASIC™Test Kit (Bendix P/N 5013711)

Filling in the Checklist for the Bendix

Note: Follow all standard safety precautions. For vehicles using a desiccant air dryer.

The Service Writer ﬁ lls out these ﬁ elds with information gained from the customer

Number of Days Since Air Tanks Were Last Drained: ________ Date: ___________Vehicle #: ____________

Engine SN __________________________ Vehicle Used for: _______________Typical Load:________ (lbs.)

No. of Axles: ____ (tractor) ____ (trailer) No. of Lift Axles: ____ Technician’s Name:

Air System Inspection Cup (BASIC™) Test

____________________

Customer’s Have you conﬁ rmed complaint? (Please check all that apply)

“Relay valve leaks oil /  malfunctions” no yes*

The Service Writer also checks off any complaints that the customer makes to help the Technician in investigating.

BASIC™ test starts here:

“Dash valve leaks oil / malfunctions”no yes* “Air dryer leaks oil” no yes* “Governor malfunction”no yes* “Oil in gladhands” no yes*

how much oil did you ﬁ nd? ________________________________

“Oil on ground or vehicle exterior” no yes*

amount described: ______________________________________ “Short air dryer cartridge life” replaces every: ______________  miles,  kms, or  months  “Oil in air tanks” amount described:_______________________ We will measure amount currently found when we get to step B of the test.

“Excessive engine oil loss”amount described: ______________ Is the engine leaking oil? no yes* Is the compressor leaking oil? no yes*

 Other complaint: _____________________________________ No customer complaint.

STEP A - Select one:

This is a low air use vehicle: Line haul (single trailer) with 5 or less axles, or This is a high air use vehicle: Garbage truck, transit bus, bulk unloader, or line

Checklist for Technician

haul with more than 5 axles.

Then go to Step B.



The Technician checks boxes for any of the complaints that can be conﬁ rmed.

Note: A conﬁ rmed complaint

above does NOT mean that the compressor must be replaced. The full BASIC investigate the facts.

™

test below will

The Technician selects the air use category for the vehicle. This decides which of the two acceptance lines on the cup will be used 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.

If more than one oil unit of water (or a cloudy emulsion mixture)

is found:

(a) Change the vehicle’s air dryer cartridge

- see Footnote 1, (b) Conduct the 4 minute leakage test (Step D),

again after 30 days - see Footnote 2.

STOP + CK.

Oil

Units

Note for returning vehicles that are being re-tested after a water/cloudy emulsion mixture was found last time and the air dryer cartridge replaced: If more than one

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.

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 30 day air tank drain schedule is longer than the customer's usual draining interval, the customer must determine, based on its experience with the vehicle, whether to participate now, or wait for warmer weather. See the cold weather tips in Bulletins TCH-008-021 and TCH-008022 (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.

A-17

Appendix B continued: Information about the BASIC™Test Kit (Bendix P/N 5013711)

Filling in the Checklist for the Bendix

Note: Follow all standard safety precautions. For vehicles using a desiccant air dryer.

Air System Inspection Cup (BASIC™) Test

STEP C - How to Use the BASIC

The Technician uses the chart (label) on the BASIC test cup to help decide the action to take, based on the amount of oil found. Use the lower acceptance line for low air use vehicles, and upper line for high air use vehicles (from Step A).

BASIC™ Test Example

™

Test

1. Record days since air tanks were last drained.

™

_________ days _________ units



If number of days is:

30-60 days (high air

use) or

30-90 days (low air

use)



Otherwise . . .



(if the number of days is

unknown, or outside the

limits above)

2. Record amount

if oil level is at or below

acceptance line for number

of days

if oil level is above

acceptance line for number

of days 

if oil level is at or below

30-day acceptance line 

if oil level is above 30-day

acceptance line 

Acceptance

An oil level of 4 units in a sixty-day period is within the acceptance area (at or below the line) for both low and high air use vehicles. Return the vehicle to service.

The Technician looks for the point where the number of days since the air tanks were drained meets the oil level. If it is at or below the (low or high use) acceptance line, the vehicle has passed the test. If the point is above the line then go to the leakage test.

STEP D - Air Brake System Leakage Test

Park the vehicle on level ground and chock wheels. Build system pressure to governor cut-out and allow the pressure to stabilize for one minute.

1: Observe the dash gauges for two additional minutes without the service brakes applied. 2: Apply service brakes for two minutes (allow pressure to stabilize) and observe the dash

gauges. If you see any noticeable decrease of the dash air gauge readings, repair leaks. Repeat this test to conﬁ rm that air leaks have been repaired and return vehicle to service. Please repeat BASIC system, parking brakes, and/or other components - inspect and repair as necessary.

™

test at next service interval. Note: Air leaks can also be found in the charging

Sixty days since last air

tank draining

of oil found:



Lines

Decision point

Air leakage is the number one cause of compressors having to pump excessive amounts of air, in turn run too hot and pass oil vapor along into the system. Here the Technician conducts a four-minute test to see if leakage is a problem with the vehicle being tested.

3. Action to take



System OK. Return to service.

Go to Step D

System OK. Return to service. Stop inspection.

Test again after 30 days. See Footnote 2.

Oil

Level

STOP

TEST

STOP

TEST

STOP + CK.

If no air leakage was detected, and if you are conducting

this test after completing Step C, go to Step E.

STEP E - If no air leakage was detected in Step D

Replace the compressor.

Note: If the compressor is within warranty period, please follow standard warranty procedures. Attach the completed checklist to warranty claim.

A-18

The Technician only reaches Step E if the amount of oil found, or the amount of time since the air tanks were last drained exceeds the acceptance level, AND the vehicle passes the four-minute leakage test (no noticeable leakage was detected).

Appendix C

Technical Bulletin

Bulletin No: Effective Date: Cancels: Page: 1 of Subject:

As the cold weather approaches, operators and ﬂ eets alike begin to look to their vehicles with an eye toward “winterization”, and particularly what can be done to guard against air system freeze-up. Here are some basic “Tips” for operation in the cold weather.

Engine Idling

Avoid idling the engine for long periods of time! In addition to the fact that most engine manufacturers warn that long idle times are detrimental to engine life, winter idling is a big factor in compressor discharge line freeze-up. Discharge line freeze-ups account for a signiﬁ cant number of compressor failures each year. The discharge line recommendations under “Discharge Lines” are important for all vehicles, but are especially so when some periods of extended engine idling can not be avoided.

Discharge Lines

The discharge line should slope downward from the compressor discharge port without forming water traps, kinks, or restrictions. Cross-overs from one side of the frame rail to the other, if required, should occur as close as possible to the compressor.

Dryer Inlet Temperature

The dryer inlet air temperature should typically be within the range of no more than 160°F and no less than 45°F above low ambient (surrounding) temperature to prevent freeze-ups. (For example, if low ambient is minus 40°F, the dryer inlet must be above 5°F .) Lower dryer inlet temperatures should be avoided to minimize the risk of freeze-up upstream of the air dryer. Higher temperatures should also be avoided to minimize the risk of heat damage to the air dryer seals and to avoid a loss of drying performance.

TCH-008-021

3-5-2010

PRO-08-21 dated 2-6-2008

Air Brake System - Cold Weather Operation Tips

Compressor Line Size

The line size and length is established by the vehicle manufacturer and should not be altered without the vehicle manufacturers approval. As a reference, the line length from the compressor to the air dryer should be less than 16 feet and the minimum line sizes should be as follows:

Minimum

Length

6 ft. 1/2 in. Low Compressor Duty Cycle Applications (0-20%)

10 ft. 5/8 in. High Compressor Duty Cycle Applications (20-40%)

Line Insulation

To guard against freez-ups in Low Duty Cycle applications, the discharge line can be insulated if it is greater than 9 feet in length. The line can only be insulated back to 9 feet and a maximum of 3 feet. For example, if the line is 10 feet, insulate the ﬁ tting and the last one foot of the line. If the line is 15 feet, insulate the ﬁ tting and the last 3 feet of the line.

Minimum

I.D.

Application

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Appendix C: Continued

Bulletin No.: TCH-008-021 Effective Date: 3/5/2010 Page: 2 of 2 System Leakage

Check the air brake system for excessive air leakage using the Bendix “Dual System Air Brake Test and Check List” (BW1279). Excessive system leakage causes the compressor to “pump” more air and also reduce the life of the air dryer desiccant cartridge.

Reservoir Draining (System without an Air Dryer)

Routine reservoir draining is the most basic step in reducing the possibility of freeze-up. All reservoirs in a brake system can accumulate water and other contamination and must be drained! The best practice is to drain all reservoirs daily if the air brake system does not include an air dryer. When draining reservoirs; turn the ENGINE OFF and drain ALL AIR from the reservoir, better still, open the drain cocks on all reservoirs and leave them open over night to assure all contamination is drained (reference Service Data Sheet SD-04-400 for Bendix Reservoirs). If automatic drain valves are installed, check their operation before the weather turns cold (reference Service Data Sheet SD-03-2501 for Bendix while the need for daily reservoir draining is eliminated through the use of an automatic drain valve, periodic manual draining is still required.

Reservoir Draining (System with an Air Dryer)

Daily reservoir draining should not be performed on systems with an air dryer. This practice will cause the dryer to do excessive work (i.e. build pressure from 0 -130 psi instead of the normal 110-130 psi).

Alcohol Evaporator or Injector Systems

Bendix Commercial Vehicle Systems LLC discourages the use of alcohol in the air brake system as a means of preventing system freeze-up in cold temperatures. Studies indicate that using alcohol and alcohol based products sold for this purpose removes the lubrication from the components of the air braking system. In addition, the materials used for the internal seals of the air system components may be adversely impacted by the residue that some anti-freeze additives leave behind. Both are detrimental to air system component life expectancy, causing premature wear. Because of this, Bendix® air system components warranty will be void if analysis shows that alcohol was added to the air brake system.

Alcohol is not an acceptable substitute for having adequate air drying capacity. If the air dryer is maintained in accordance with the manufacturer’s recommended practices and moisture is found to be present in the system reservoirs, more drying capacity is required. Bendix has several viable options including extended purge air dryers, extended purge tandem dryers in parallel with common control, and air dryers arranged to provide continuous ﬂ ow as with the Bendix® EverFlow® continuous ﬂ ow air dryer module. To address concerns with contaminants in trailer air brake systems, the Bendix® Cyclone DuraDrain™ water separator and the Bendix System-Guard® trailer air dryer are available. Refer to Bendix Technical Bulletin TCH-008-042 “Alcohol in the Air Brake System” for additional information.

Air Dryers

Make certain air brake system leakage is within the limits stated in BW1279. Check the operation and function of the air dryer using the appropriate Service Data Sheet for the air dryer.

DV-2™ Automatic Drain Valves). It should be noted that,

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Air Dryer Service Data Sheet

AD-2® air dryer SD-08-2403

air dryer SD-08-2407

AD-4 AD-9® air dryer SD-08-2412

AD-IP

AD-IS

EverFlow® air dryer SD-08-2417

AD-IS

AD-SP® air dryer SD-08-2415

Cyclone DuraDrain

PuraGuard

Trailer System-Guard

QC system ﬁ lter SD-08-187B

air dryer SD-08-24 air dryer SD-08-2418

™

water separator SD-08-2402

air dryer SD-08-2416

Bendix literature is

available to order or

download on Bendix.com

Appendix D

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 apply an open ﬂ ame to air lines and valves. Beyond causing damage to the internal non- metallic 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) ﬂ uids into air brake lines or hose couplings (“glad hands”). Some ﬂ uids 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 effective) in reducing the possibility of freeze-up. While automatic drain valves relieve the operator of draining reservoirs on a daily basis, these valves MUST be routinely checked for proper operation. Don’t overlook them until they fail and a road call is required.

step (although not completely

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