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13

Compressor with up to 25% duty cycle

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 sufficient cooling occurs, 

the  oil-vapor  condenses  and  can  be  removed  by  the  air  dryer.  

Discharge line upgrades are not covered under warranty.  Note: 

To help prevent discharge line freeze-ups, shorter discharge line 

lengths or insulation may be required in cold climates.  (See Bendix 

 

 

 

 

 

Recom- 

Recom- 

Acceptable

 

 

 

Typical 

Discharge 

mended 

mended 

Reservoir

 

 

 

Compressors 

Line 

Air Dryer 

Reservoir 

Oil Contents

3

 

 

No. of 

Spec'd 

        

Cartridge 

Drain 

at Regular 

 

 

Axles 

 

       

Replacement

1

 

Schedule

2

 

Drain Interval

High Air Use 

Low Air Use

 

e.g. Double/triple trailer, open 

highway coach/RV,  (most) 

pick-up & delivery, yard or 

terminal jockey, off-highway, 

construction, loggers, concrete 

mixer, dump truck, fire truck.

e.g. Line haul single trailer 

w/o air suspension, air over 

hydraulic brakes.

e.g. Line haul single trailer 

with air suspension, 

school bus.

5

or

less

5

or

less

8

or

less

12

or

less

Table A:  Maintenance Schedule and Usage Guidelines

Recom-

mended

Every

Month - 

Max of ev-

ery 90 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  maintaining  the  air  brake  charging 

Length        

6 ft.

1/2 in.

9 ft.

1/2 in.

12 ft.

1/2 in.

3/4 in.

12 ft.

BASIC test

acceptable 

range:

5 oil units

per month.

See 

appendix

A.

For oil carry-over 

control

suggested 

upgrades:

5/8 in.      15 ft.

For oil carry-over 

control

suggested 

upgrades:

5/8 in.      9 ft.

For oil carry-over 

control

suggested 

upgrades:

5/8 in.      12 ft.

Compressor with less than 15% duty 

cycle

Compressor with up to 25% duty cycle

Compressor with up to 25% duty cycle

Bendix

®

 BA-921

®

 air compressor 

Bendix

®

 T

u-Flo

®

 550 air compressor 

Bendix

®

 T

u-Flo

®

 750 air compressor 

Bendix

®

 BA-922

®

or DuraFlo

 596

 

air compressor

BASIC test

acceptable 

range:

3 oil units

per month.

See 

appendix

A.

For the

BASIC 

Test Kit:

Order

Bendix

P/N

 

5013711

e.g. City transit bus, refuse, 

bulk unloaders, low boys, 

urban region coach, central 

tire inflation.

(See footnote 7)

Bulletins TCH-08-21 and TCH-08-22, included in Appendix B, for 

more information.)

5.  For certain vehicles/applications, where turbo-charged inlet air is 

used, a smaller size compressor may be permissible.

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

®

 Tu-Flo

®

 550 and 750 compressors, unloader service is 

recommended every 250,000 miles.

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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