BENDIX BA-922 COMPRESSOR Manual
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BENDIX BA-922 COMPRESSOR Manual

BENDIX BA-922 COMPRESSOR Manual

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BENDIX
BA-922
COMPRESSOR
®
®
Safety

DESCRIPTION

Cylinder
Valve
Head
The function of the air compressor is to provide and
maintain air under pressure to operate devices in the
air brake systems. The Bendix
BA-922
compressor
®
®
is a two cylinder reciprocating compressor with a rated
displacement of 31.6 cubic feet per minute at 1250 RPM.
Valve Plate
Assembly
The compressor consists of a water cooled cylinder head,
Cooling plate, valve plate assembly and an integral air
cooled crankcase and cylinder block. The cast aluminum
Cylinder Head contains the required air and water ports as
well as two unloader pistons. The cast aluminum cooling
plate provides added cooling to, and is located between,
the cylinder head and valve plate assemblies. The valve
plate assembly consists of laminated brazed steel plates
which incorporate various valve openings and channels
Crankcase and
for conducting air and engine coolant into and out of the
cylinder head.
The discharge valves are part of the valve plate assembly.
FIGURE 1 - BA-922
COMPRESSOR
®
The cylinder head, with the cooling and valve plates
comprise a complete cylinder head assembly.
Unloader (2)
Air
Delivery
The cast iron crankcase and cylinder block assembly,
Intake
Port
houses the pistons, connecting rods, crankshaft and related
bearings.
While not all compressors and charging systems are
Unloader
Discharge
Port
equipped with an optional discharge line safety valve,
Reed
Valves
this component is recommended. The discharge line
safety valve is installed in the cylinder head or close to
Cooling
the compressor discharge port and protects against over
Plate
pressurizing the compressor in the event of a discharge
line freeze up or blockage.
Piston

OPERATION

The compressor is driven by the vehicle 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
Piston Rod
Crankshaft
governor.
FIGURE 2 - BA-922
COMPRESSOR (CUT-AWAY)
®

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  • Page 1 Cylinder Valve Head The function of the air compressor is to provide and maintain air under pressure to operate devices in the air brake systems. The Bendix BA-922 compressor ® ® is a two cylinder reciprocating compressor with a rated displacement of 31.6 cubic feet per minute at 1250 RPM.
  • Page 2 Detroit Detroit Caterpillar John Diesel Diesel Deere FIGURE 3 - TYPICAL COMPRESSOR DRIVE FLANGES cavity and into the other cylinder. A small amount of air moves out the inlet port. On the piston down stroke (TDC AIR INTAKE (LOADED) to BDC) air flows in the reverse direction, from the other During the piston down stroke, a vacuum is created in cylinder through the unloader piston to the inlet cavity, past the cylinder bore above the piston.
  • Page 3 COOLING Discharge Air Inlet Air flowing through the engine compartment from the Unloader Valve Port Port action of the engine fan and the movement of the vehicle Discharge assists in cooling the compressor. Cooling fins are part Port of the crankcase/cylinder block casting. Coolant flowing from the engine cooling system through connecting lines enters the head and passes through internal passages in the cylinder head and valve plate assembly and is returned...
  • Page 4 In addition, 4. Note that the compressor cycles to the loaded and Bendix has developed the “Bendix Air System Inspection unloaded conditions promptly. If prompt action is not Cup” or BASIC kit to help substantiate suspected excessive noted, repair or replace the governor and/or repair the oil passing.
  • Page 5 “cycling” Bendix “Test and Checklist” published in the Air Brake between the load and unloaded modes due to unloader System Handbook (BW5057) and on the back of the Dual plunger leakage.
  • Page 6 If the vehicle is equipped with an AD-IS ® compressor unloader system using a genuine Bendix dryer system or a dryer reservoir module, be sure maintenance kit available from authorized Bendix parts to drain the purge reservoir.
  • Page 7 Cylinder Head Cooling Plate Valve Plate Assy. Crankcase & Cylinder Block End Cover Crankcase Cover Item Qty. Description Item Qty. Description Item Description Unloader Cover Cap Screw O-Ring Head Gasket Unloader Cover O-Ring Inlet Reed Valve/Gasket Unloader Cap Gasket Unloader Piston O-Ring Unloader Balance Piston O-Ring...
  • Page 8 4. Remove the discharge and inlet fittings, if applicable, and 6. Remove the two bolts located in the center of the head. note their position on the compressor to aid in reassembly. Gently tap the head, cooling plate and valve plate assembly with a soft mallet to break the gasket seal.
  • Page 9 INSPECTION OF PARTS FOOT POUNDS TO INCH POUNDS To convert foot pounds to inch pounds of torque, multiply CYLINDER HEAD & VALVE PLATE foot pounds by 12. 1. Carefully inspect the cylinder head gasket surfaces for 1 Foot Pound x 12 = 12 Inch Pounds Example: deep gouges and nicks.
  • Page 10 9. Install the balance piston spring (5) in the unloader piston (7), then install the small diameter of the balance 5, 11 3, 9 piston (4) through the center of the spring. 10. Install the unloader cover gasket (3) on the cylinder 8, 14 head making certain the unloader vent passage and 1, 15...
  • Page 11 TORQUE SPECIFICATIONS Water Port Fittings 3/4"-16 UNF-2B ......319-245 In. Lbs. (36-39 Nm) Assembly Torques in inch pounds (in. Ibs.) M18 x 1.5-6g ......... 230-257 In. Lbs. (26-29 Nm) M8x1.25-6g Cylinder Head ..265-292 In. Lbs. (30-33 Nm) Unloader Port Fittings M5x0.75-6g Unloader Cap ....
  • Page 12 The air with a normal (less than 25%) duty cycle, operating in compressor is typically cooled by the engine coolant system a temperate climate. See Bendix and/or other air dryer and lubricated by the engine oil supply. manufacturer guidelines as needed.
  • Page 13 Discharge line upgrades are not covered under warranty. Note: To help prevent discharge line freeze-ups, shorter discharge line For Bendix Tu-Flo 550 and 750 compressors, unloader service is ® ® lengths or insulation may be required in cold climates. (See Bendix recommended every 250,000 miles.
  • Page 14 Results Do not use this card test to diagnose compressor "oil passing" issues. They are subjective  and error prone. Use only the Bendix Air System Inspection Cup (BASIC) test and the methods described in this guide for advanced troubleshooting.
  • Page 15 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.
  • Page 16 1-800-AIR-BRAKE (1-800-247-2725) and (b) If the vehicle maintenance has speak to a Tech Team been performed as recommended  Drain all air tanks into Bendix BASIC test ® member.) in Table A on page 13, some oil in cup (Bendix Air System Inspection Cup).
  • Page 17 fitting, it may be changed to a straight or 45 degree fitting. For more information Kinked discharge line shown. on how to help prevent discharge line freeze-ups, see Bendix Bulletins TCH-08- 21 and TCH-08-22 (Appendix B). Shorter discharge line lengths or insulation may be required in cold climates.
  • Page 18 Note: After all other operating conditions have been investigated. replacing a compressor, residual oil may Bendix compressors are designed to have a 'dry' take a considerable period of time to be sump and the presence of excess oil in the crankcase flushed from the air brake system.
  • Page 19 Symptom: What it may indicate: What you should do: 6.0 Excessive oil A problem with engine or other engine  See engine service manual. accessory. consumption in engine. The engine service manual has more information. 7.0 Oil present Air brake charging system is functioning ...
  • Page 20 These can increase the rate at which carbon (Appendix B). Shorter discharge line builds up in the discharge line. Bendix recommends oil lengths or insulation may be required in cold soot (solids) be maintained at less than 3%.
  • Page 21 (d) Compressor malfunction.  Replace the compressor only after making certain the preceding conditions do not exist. * Note: For the Bendix DuraFlo 596 air compressor, not only ® ™ the governor, but also the SV-1 synchro valve used would ™...
  • Page 22 Symptom: What it may indicate: What you should do: 12.0 Air dryer (a) Restriction between air dryer and  Inspect delivery lines to reservoir for restric- safety valve reservoir. tions and repair as needed. releases air. (b) Air dryer safety valve ...
  • Page 23 Symptom: What it may indicate: What you should do: (a) Compressor leaks air at connections 16.0 Compressor  Check for leaking, damaged or defective leaks air or ports. compressor fittings, gaskets, etc. Repair or replace as necessary. (b) Compressor unloader mechanism ...
  • Page 24 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. Look Weepage Observe the amount of weepage from the head gasket.
  • Page 25 3. Return the vehicle to service. by the reservoir contents e.g. water or ice.) Test 6: Compressor Unloader Leakage shut off and charge the unloader port by allowing Bendix Compressors: Park vehicle, chock ® wheels, and follow all standard safety procedures.
  • Page 26 Appendix A: Information about the BASIC Test Kit (Bendix P/N 5013711) Service writer records info - including days the number of days since all air tanks Bendix Air System Inspection Cup ® were drained - and f ills out symptom checklist.
  • Page 27 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.
  • Page 28 Appendix A continued: Information about the BASIC Test Kit (Bendix P/N 5013711) ® Filling in the Checklist for the Bendix Air System Inspection Cup (BASIC) Test Note: Follow all standard safety precautions. For vehicles using a desiccant air dryer. STEP C - How to Use the BASIC Test 2.
  • Page 29 Last 3 feet, including fitting at the end of the discharge line, must be insulated with ½ inch thick closed cell polyethylene pipe insulation. If the discharge line length must be less than 6 feet or greater than 16 feet, contact your local Bendix representative.
  • Page 30 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”...
  • Page 31 Appendix B: Continued Technical Bulletin Bulletin No.: TCH-008-022 Effective Date: 1/1/1994 Page: 1 of 1 Additional Cold Weather Operation Tips for the Air Brake System Subject: 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.
  • Page 32 BW2398 © 2005 Bendix Commercial Vehicle Systems LLC. All rights reserved. 10/2005. Printed in U.S.A.

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