BENDIX BA-922 COMPRESSOR Manual Download Page 30

30

Bulletin No.: TCH-008-021  

  Effective Date: 11/1/92  

 

 

 

 

Page: 2 of 2

High Duty Cycle Vehicles (City Transit Coaches, Refuse Haulers, Etc.)

 

The maximum discharge line length is 16 feet.

 

Length  

I.D. min. 

Other Requirements

 

10-16 ft. 

½ in.   

None

If the discharge line length must be less than 10 feet or greater than 16 feet, contact your local Bendix 

representative.

System Leakage

Check the air brake system for excessive air leakage using the Bendix “Dual System Air Brake Test 

and Check List” (BW1279).  Excessive system leakage causes the compressor to “pump” more air 

and also more moisture into the brake system.

Reservoir Draining (System Without Air Dryer)

Routine reservoir draining is the most basic step (although not completely effective) in reducing the 

possibility of freeze-up.  

All reservoirs

 in a brake system can accumulate water and other contamination 

and must be drained!  The best practice is to drain all reservoirs daily.  When draining reservoirs; turn 

the ENGINE OFF and drain ALL AIR from the reservoir, better still, open the drain cocks on all reservoirs 

and leave them open over night to assure all contamination is drained (reference Service Data Sheet 

SD-04-400 for Bendix Reservoirs).  If automatic drain valves are installed, check their operation 

before

 

the weather turns cold (reference Service Data Sheet SD-03-2501 for Bendix

®

 DV-2

 Automatic Drain 

Valves).  It should be noted that, while the need for daily reservoir draining is eliminated through the 

use of an automatic drain valve, periodic manual draining is still required.

Alcohol Evaporator or Injector Systems

Check  for  proper  operation  of  these  systems  by  monitoring  alcohol  consumption  for  a  few  days 

(Reference Service Data Sheet SD-08-2301 for the Bendix Alcohol Evaporator).  Too little means the 

system is not receiving adequate protection and too much simply wastes alcohol.  As a general guide, 

these systems should consume approximately 1 to 2 ounces of alcohol per hour of compressor loaded 

time (compressing air).  City pick-up and delivery vehicles will operate with the compressors loaded 

(compressing air) more while compressors on highway vehicles will be loaded less.  These figures 

are approximate and assume that air system leakage is within the limits of the Bendix “Dual System 

Air Brake Test and Check List” (BW1279).  Last but not least, begin using alcohol several weeks prior 

to freezing weather to ensure that the system is completely protected.  Use only methanol alcohol, 

such as Bendix “Air Guard”, in evaporators or injectors.

Air Dryers

Make certain air brake system leakage is within the limits stated in BW1279.  Check the operation and 

function of the air dryer using the appropriate Service Data Sheet for the air dryer.
AD-9

 Air Dryer  . . . . . . . . . . . . . . . . . . . . . . . . . . . .Service Data Sheet SD-08-2412

AD-4

 Air Dryer  . . . . . . . . . . . . . . . . . . . . . . . . . . . .Service Data Sheet SD-08-2407

AD-2

 Air Dryer  . . . . . . . . . . . . . . . . . . . . . . . . . . . .Service Data Sheet SD-08-2403

AD-IP

 Air Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . .Service Data Sheet SD-08-2414

AD-SP

 Air Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . .Service Data Sheet SD-08-2415

Trailer System-Guard

 Air Dryer  . . . . . . . . . . . . . . .Service Data Sheet SD-08-2416

Bendix

®

 PuraGuard QC

 Oil Coalescing Filter. . . . .Service Data Sheet SD-08-187B

Appendix B: Continued

Summary of Contents for BA-922 COMPRESSOR

Page 1: ...e part of the valve plate assembly The cylinder head with the cooling and valve plates comprise a complete cylinder head assembly The cast iron crankcase and cylinder block assembly houses the pistons...

Page 2: ...hes 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 it to move away from its seat...

Page 3: ...oolant ow connections See the tabulated technical data in the back of this manual for speci c requirements PREVENTATIVE MAINTENANCE Regularly scheduled maintenance is the single most important factor...

Page 4: ...rticularly oil sensitive systems the Bendix PuraGuard system lter can be used in conjunction with a Bendix air dryer If compressor oil passing is suspected refer to the TROUBLESHOOTING section and TAB...

Page 5: ...he performance degrades signi cantly over time you may use the Advanced Troubleshooting Guide for Air Brake Compressors starting on page 11 of this document to assist your investigation of the cause s...

Page 6: ...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...

Page 7: ...s leading to the compressor 3 Remove as much road dirt and grease from the exterior of the compressor as possible FIGURE 9 BA 922 COMPRESSOR EXPLODED VIEW OF SERVICEABLE PARTS Item Qty Description Ite...

Page 8: ...e balance piston 4 and its spring 5 from the cylinder head 5 Remove the six hex head bolts and washers from the cylinder head 6 Remove the two bolts located in the center of the head Gently tap the he...

Page 9: ...y 12 Example 12 Inch Pounds 1 Foot Pound 12 FOOT POUNDS TO INCH POUNDS To convert foot pounds to inch pounds of torque multiply foot pounds by 12 Example 1 Foot Pound x 12 12 Inch Pounds CRANKCASE COV...

Page 10: ...o all lines reconnected during installation and check for air oil and coolant leaks at compressor connections Also check for noisy operation TESTING REBUILT COMPRESSOR In order to properly test a comp...

Page 11: ...Test Information 26 28 Test Procedures Maintenance Schedule and Usage Guidelines Table A 13 Symptom Page Number Maintenance Usage Guidelines TORQUE SPECIFICATIONS Assembly Torques in inch pounds in I...

Page 12: ...perating 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...

Page 13: ...days Every Month Every 3 Years Every 2 Years Every Year I D Vehicle Used for Column 1 Column 2 Column 3 Column 4 Column 5 Regularly scheduled maintenance is the single most important factor in mainta...

Page 14: ...TION 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 as semble...

Page 15: ...011327 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 3 0 Oil at air dryer purge exhaust or surrounding area c 2 0 Oil...

Page 16: ...ithin the acceptable level If within the normal range return the vehicle to service For vehicles with acces sories that are sensitive to small amounts of oil consider a Bendix PuraGuard QC oil coalesc...

Page 17: ...nlet insulation may be added here or if the inlet tting is a typical 90 degree tting it may be changed to a straight or 45 degree tting For more information on how to help prevent discharge line freez...

Page 18: ...tests all air brake system pneumatic components need to be able to pass including minimum levels of tolerance to contamination 5 0 Oil present at valves e g at exhaust or seen during servicing Air br...

Page 19: ...ay be undersized for the application d Compressor unloader mechanism malfunction e Damaged compressor head gasket Using dash gauges verify that the compressor builds air system pressure from 85 100 ps...

Page 20: ...line see Table A column 2 on page 13 for recommended size and go to Test 3 on page 24 By other restrictions e g kinks Re place the discharge line See Table A col umn 2 on page 13 for recommended size...

Page 21: ...orm and block the ow If instead ice blockages occur at the air dryer inlet insulation may be added here or if the inlet tting is a typical 90 degree tting it may be changed to a straight or 45 degree...

Page 22: ...Test 4 on page 25 Go to Test 2 on page 24 Go to Test 5 on page 25 12 0 Air dryer safety valve releases air a Restriction between air dryer and reservoir b Air dryer safety valve malfunction c Air drye...

Page 23: ...t the head gasket may indicate a downstream restriction such as a freeze up or carbon blockage and or could indicate a defective or missing safety valve Find blockage go to 9 0 f for details and then...

Page 24: ...ry Test 2 Air Brake System and Accessory Leakage 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 d...

Page 25: ...to and from the governor for restrictions e g collapsed or kinked Repair as necessary 2 Using a calibrated external gauge in the supply reservoir service reservoir or reservoir port of the D 2 govern...

Page 26: ...ician inspects items drained and f days Use Test 2 Air Leakage Use Test 2 Air Leakage NO Re test with the BASIC Test after 30 days NO did not know when last drained Was the number of days since last d...

Page 27: ...l loss amount described ______________ Is the engine leaking oil no yes Is the compressor leaking oil no yes Other complaint _____________________________________ No customer complaint Checklist for T...

Page 28: ...h air use or 30 90 days low air use if oil level is at or below acceptance line for number of days if oil level is above acceptance line for number of days System OK Return to service Otherwise if the...

Page 29: ...ome 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 C...

Page 30: ...through the use of an automatic drain valve periodic manual draining is still required Alcohol Evaporator or Injector Systems Check for proper operation of these systems by monitoring alcohol consump...

Page 31: ...c 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 uids into air brake lines or hose couplings glad...

Page 32: ...32 BW2398 2005 Bendix Commercial Vehicle Systems LLC All rights reserved 10 2005 Printed in U S A...

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