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22

Symptom: 

What it may indicate: 

What you should do:  

15.0  Compressor 

constantly cycles 

(compressor 

remains unloaded 

for a very short 

time.)

(a) Air  brake  charging  system 

maintenance not performed. 

(b) Compressor unloader mechanism 

malfunction. 

(c) Air  dryer  purge  valve  or  delivery 

check valve malfunction.

(d) Air brake system leakage.

 

Available  reservoir  capacity  may  be  re-

duced by build up of water etc.  Drain and 

perform routine maintenance per Table A, 

columns 3 & 4, on page 13.

 

Go to Test 6 on page 25.

 

Verify operation of air dryer.  Follow vehicle 

O.E. maintenance recommendations and 

component Service Data information.

 

Go to Test 2 on page 24.

14.0  Air dryer 

doesn’t purge. 

(Never hear 

exhaust from air 

dryer.)

(a) Air dryer malfunction. 

(b) Governor malfunction. 

(c) Air brake system leakage. 

(d) Improper  governor  control  line 

installation to the reservoir.

 

Verify operation of air dryer.  Follow vehicle 

O.E. maintenance recommendations.

 

Go to 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 dryer maintenance not 

performed. 

(d) Air dryer malfunction. 

(e) Improper  governor  control  line 

installation to the reservoir.

(f) Governor malfunction.

 

Inspect delivery lines to reservoir for restric-

tions and repair as needed. 

 

Verify  relief  pressure  is  at  vehicle  or 

component  manufacturer  specifications. 

Replace if defective. 

 

See  Maintenance  Schedule  and  Usage 

Guidelines  (Table A,  column  3,  on  page 

13). 

 

Verify operation of air dryer. Follow vehicle 

O.E. maintenance recommendations and 

component Service Data information.

 

Go to Test 5 on page 25. 

 

Go to Test 4 on page 25.

13.0  Reservoir 

safety valve 

releases air  

(a) Reservoir safety valve 

malfunction. 

(b) Governor malfunction.

(c) Compressor unloader mechanism 

malfunction. 

 

Verify  relief  pressure  is  at  vehicle  or 

component  manufacturer's  specifications 

(typically 150 psi). Replace if defective. 

 

Go to Test 4 on page 25.

 

Go to Test 6 on page 25.

Technician removes 

governor.

Air dryer 

safety valve

Содержание BA-922 COMPRESSOR

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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