CATERPILLAR® september 1896 Service Manual Bendix Air Compressor BX-2150 Air CompressorImportant Safety Information Most accidents involving product operation, maintenance and repair are caused by fallure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skils and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and wamings are provided in this manuel and on the product. If hese hazard warnings are not heeded, bodily injury or death could occur to you or other persons. The hazards are identitied by the “Safely Alert Symbol’ and followed by a “Signal Word" such as "WARNING’ as shown below. The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. ‘The message that appears under the warning, explaining the hazard, can be either written or pictorially presented. Operations that may cause product damage are identified by NOTICE labels on the product and in this publication, Caterpillar cannot anticipate every possible circumstance that might invalve a potential hazard, The |warings in this publication and on the product are therefore not all inclusive. Ifa tool, procedure, work method or operating technique not specifically recommended by Caterpilar is used, you must satisfy yourselt that itis safe for you and others, You should also ensure that the product will nat be damaged ‘or made unsafe by the operation, lubrication, maintenance or repair procedures you choose. The information, specifications, and ilustrations in this publication are on the basis of inforrnation avaliable at the time it was written. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and most current information before starting any job. Caterpillar dealers have the most current information available, For alist of the most current publication form numbers avaliable, see the Service Manual Contents Microfiche, REG1139F.Index BX-2150 Air Compressor Ar Induction Compressor Removal And Disassembly ‘Assembly Cleaning Of Parts Inspection Of Parts Preparation For Disassembly Repairs Compressor Troubleshooting Description Maintenance Kit information Operation Cooling Lubrication Intake And Compression Of Air (Loaded) Non-Compression Of Air (UnLoaded) Preventive Maintenance Testing Rebuilt Compressor Tabulated Technical Data 10 14 13 13 12 14 7 NOTICE When working on or around air brake systems and components, the following precautions should be observed: Always block vehicle wheels. Stop engine when ‘working under a vehicle, Depleting vehicle air system pressure may cause vehicle to roll. Keep. hands away from chamber push rods and slack adjusters; they may automatically apply as system. pressure drops. 2. Never connect or disconnect a hose or line Ccontaining air pressure. It may whip as air escapes. Never remove @ component or pipe plug unless you are certain all system pressure has been depleted, 3. Never exceed recommended air pressure and always wear safety glasses when working with air pressure. Never look into air jets or dect them at anyone. 4. Never attempt to disassemble a component unt you have read and understand recommended Procedures. Some components contain powerful springs and injury can result if not properly disassembled. Use only proper tools and observe all precautions pertaining to use of those tools. Bendix Air Compressors IndexDescription ‘The function of the air compressor is to provide and maintain air under pressure to operate devices in the air brake andjor auxiliary air systems, ‘The BX-2150 is a single cylinder, single stage reciprocating compressor with a rated displacement of 915 cubic feet per minute at 1250 rpm. The BX-2150 is, constructed from two major assembles, the cylinder hhead and the crankcase. The cylinder head is an iron casting containing the inlet, discharge and unioader valving. Its installed on the crankcase and is secured Using four cap screws symmetrically placed. The cylinder head can be, therefore installed in any one of four different positions which are 90 degrees apart. Outlet / 2px covernas Fort Water Bort yBaces Air niet Fig. 1 Oyiinder Head ‘Two governor mounting surfaces, adjacent to the single rectangular inlet cavity, provide a convenient means of mounting the governor to the cylinder head. (One eighth inch pipe threads in each of the two governor mounting pads allow plugging of the unused Port or the installation of a tubing fitting for remote governor mounting, Three ¥ inch NPT. ports provide the means for the connection of coolant lines and are labeled WATER, Two 12 inch N.P.T. discharge ports are located on the top and side of the cylinder head and are labeled AIR OUT. ‘The various mounting and drive configurations required by the numerous vehicle engine designs are ‘accommodated by different crankcase castings and crankshatts. ‘Two methods for cooling the BX-2180 are employed. The cylinder head is water cooled using the engine's cooling system, while external fins on the crankcase provide a means for efficient air cooling in that area, Bendix Air Compressors BX-2150Compressor Mounting/Drive Configurations Fig, 2 Flange Configurations All BX-2180 Air Compressors utilize the engine's pressurized oll system to lubricate internal moving parts, Fig. 3 Nameplate A nameplate attached to the compressor crankcase identifies the compressor model and is stamped to indicate the part number and serial number. Operation General ‘The air compressor is driven by the vehicle engine and is operating continuously while the engine is running, Actual compression of air is controlled by the compressor unloading mechanism and the governor, The governor is generally mounted on the compressor land maintains the brake system air pressure between a preset maximum and minimum pressure level Intake And Compression Of Air (Loaded) unroapen vawe isto ioe wnrae, Ey tir neseSvorn wer VALVE 3 view ‘DISCHARGE ct ston ’ INTAKE CYCLE Fig, 4 Operational-Loaded (Intake) During the down stroke of the piston, a slight vacuum | created between the top of the piston and the head, causing the flat circular inlet valve to move off its seat, (Note the flat square discharge valve remains on its seal). almospheric air is drawn into the intake cavity and flows past the open inlet valve and into the cylinder (see Fig. 4). As the piston begins its upward stroke, the air that was drawn into the cylinder on the down stroke is compressed. Ar pressure on the inlet valve plus the force of its spring, returns the inlet valve to its Seat. As the piston continues its upward stroke, air is compressed and forces the discharge valve away {rom its seat, Air flows past the open discharge valve into the discharge line and on to the reservoirs, (See Fig. 5) Bendix Air Compressors BX-2150,vatve ‘STOP R nse Q INLET VALVE ISCHARGE VALVE PISTON COMPRESSION/DISCHARGE CYCLE Fig, 5 Operational oaded (Compression) ‘As the piston reaches the top of its stroke and starts down, the discharge valve spring and air pressure in the discharge line returns the discharge valve to its seat. This prevents the compressed air in the discharge line from returning to the cylinder bore as the intake ‘and compression cycle is repeated. GAs PRESSURE UNLOADER. PISTON. vatve ‘STOP 10 MET: RESERVOIR, DISCHARGE INLET. VALVE VALVE ISTON UNLOADED CYCLE Fig, 6 Operational Unioaded Non-Compression Of Air (Unloaded) When air pressure in the reservoir reaches the cut-out setting of the governor, the governor allows air to flow from the reservoir into the unloader piston cavity The unioader piston moves, in response to air pressure, and drives the inlet valve away from its seat and holds it against its stop, With the inlet valve held away from its seat, air compression is stopped and air is free to move back and forth past the inlet valve in response to piston travel. System pressure will eventually drop to the cutin pressure setting of the governor due to air usage. ‘When the cut-in pressure is reached, the governor responds by exhausting air from the unloader piston cavity. Spring force moves the unloader piston away from the inlet valve and compression is resumed as the inlet vaive returns to its seat Lubrication All BX.2180 Air Compressors are connected to the engine's pressurized ail system and a continuous low of cil is provided to the compressor, which is eventually returned to the engine. lis fed into the compressor in various ways, for ‘example; through the rear end cover or the drive end of the crankshaft. An oil passage in the crankshaft conducts pressurized oil to the precision sleeve main bearings and to the connecting rod bearing, The cylinder bore, connecting rod wrist pin bushing and ball type main bearing, where used, are splash lubricated. Splash lubrication is obtained as ol is forced ‘out around the crankshalt journals by engine oil pressure, See the Tabuiated Technical Data section of this manual for specitic requirements, Bendix Air Compressors BX-2150Cooling Air lowing through the engine compartment from the action of the engine's fan and the movernent of the vehicle assists in cooling the crankcase. Coolant flowing from the engine’s cooling systern through connecting lines enters the head and passes through the head's water jacket and back to the engine. Proper Cooling is important in maintaining discharge air temperatures below the maximum 204°C (40°F) recommended, Figure 7 ilustrates the various approved coolant flow directions. See the Tabulated Technical Data section of this manual for specific requirements. WATER CONNECTIONS/FLOW Fig. 7 Cooling Air Induction General ‘There are three methods of providing clean air to the BX.2150, 41. Naturally aspirated - Compressor utilizes its own attached air strainer (polyurethane sponge or pleated paper dry element) 2. Naturally aspirated - Compressor inlet is connected to the engine air cleaner or the vacuum side (engine air cleaner) of the supercharger or turbocharger. Pressurized induction - Compressor inlet is connected to the pressure side of the supercharger or turbocharger. See the Tabulated Technical Data section of this manual for specific requirements for numbers 2 and 3 above. check CYLINDER HEAD VALVE asker INLET CHECK VALVE Fig. 8 Inlet Check Valve Inlet Check Valve ‘An inlet check valve is used on some naturally aspirated BX-2150 Air Compressors (never with pressurized induction, see number 3 above) to prevent inlet oil misting during the unloaded cycle. The inlet check valve is mounted directly at the inlet cavity of the Compressor. It consists of three parts, the inlet gasket, the inlet check valve reed, and the inlet check valve seat (s2e Fig. 8). During the compression cycle, the inlet check valve reed is drawn away from its seat uncovering three inlet holes which allows air to flow into the compressor inlet cavity. A machined stop in the ‘finder head inlet cavity limits the travel of the inlet check valve reed. In the unloaded cycle the inlet check valve reed rests on its seat covering the three inlet holes. Ar from within the compressor is prevented from exiting the inlet cavity ‘The inlet check valve may only be used in conjunction with cylinder heads incorporating the machined inlet ccheck valve stop in the inlet cavity. An inlet gasket is, required since its thickness contributes to the minimum reed travel required, Either side of the inlet check valve reed may be installed next to the gasket; however, the ‘ree end (tip) ofthe inlet check vaive reed must coincide with the machined inlet cavity stop in the cylinder head. The inlet check valve seat must be installed, so that the two half moon indentations are on the side facing the inlet check valve as illustrated in Figure 8 Bendix Air Compressors BX-2150Air induction One of the single most important aspects of compressor preventive maintenance is the induction of clean air. The type and interval of maintenance required will vary depending upon the air induction system used, The intervals listed under the headings below pertain to typical highway and street operation, More frequent maintenance will be required for operation in dusty or dirty environments. oe Fig. 8 Polyurethane Sponge Strainer Polyurethane Sponge Strainer Every month, 150 operating hours or 5,000 miles, whichever occurs first, remove and wash all of the parts. The strainer element should be cleaned or replaced. If the element is cleaned, it should be washed ina commercial solvent or a detergent and water solution. The element should be saturated in clean ‘engine oil, then squeezed dry before replacing it in the strainer. Be sure to replace the air strainer gasket if the entire air strainer is removed from the compressor intake. MOUNTING BAFFLE FILTER ELEMENT COVER. Fig, 10 Dry Element - Pleated Paper Ai Strainer Dry Element - Pleated Paper Air Strainer Every two months, 800 operating hours or 20,000 miles whichever occurs first, comove the spring clips from either side of mounting bale and remove the cover. Replace the pleated paper filter and remount the cleaned cover making sure the filter isin position. Make certain to replace the air strainer gasket if the entice air strainer is removed from the compressor intake. Fig, 1 Intake Adapter Intake Adapter When the engine air cleaner is replaced; Some compressors are fitted with intake adapters which allow the compressor intake to be connected to the engine air cleaner, turbo or supercharger. In this case, the Compressor receives a supply of clean air from the engine air cleaner. When the engine a filter is changed, the compressor intake adapter should be checked, fit is loose, remove the intake adapter, clean the strainer plate, it applicable, and replace the intake adapter gasket, and reinstall the adapter securely, Check line connections both at the compressor intake adapter and at the engine or engine air cleaner. Inspect the connecting line for kinks and ruptures and replace it if necessary, Bendix Air Compressors BX-2150,Compressor Cooling Every six months, 1800 operating hours or 50,000 miles, whichever occurs first, inspect the compressor discharge port, inlet cavity and discharge line for evidence of restrictions and carboning, it excessive buildup is noted, thoroughly clean or replace the affected parts and closely inspect the compressor cooling system. Check all compressor cooiant lines for kinks and restrictions to flow. Minimum coolant line size is 9.5 mm (4 inch) LD. Check coolant lines for intemal clogging from rust scale. if coolant lines appear suspicious, check the coolant flow and compare to the tabulated technical data present in the back of this manual Inspect and clean the external air cooling fins on the ‘cylinder portion of the crankcase. If fins are cracked or broken, replace the compressor. Inspect the air induction system for restrictions. Lubrication Every six months, 1800 operating hours or 50,000 miles, whichever occurs first; check external oil supply and retum lines, if applicable, for kinks, bends, or restrictions to flow. Supply lines must be a minimum of 4.8 mm (3s inch) LD. and return lines must be a minimum of 12.7 mm (14 inch) LD. Oil return lines should slope as sharply as possible back to the engine crankcase and should have as few fittings and bends as possible. Refer to the tabulated technical data in the back of this manual for oll pressure ‘minimum valves. ‘Compressor Drive Every six months, 1800 operating hours or 50,000 miles, whichever occurs first, check for noisy compressor operation. Variations in noise level in Conjunction with the comoression and unloaded cycles generally indicate loose or worn dewve components (On belt drive compressors check for pulley and belt, alignment and tension. Adjust as necessary, paying particular attention not to overtighten belt tension. Check for loose and out of aligned pulleys. Adjust or replace as necessary. Compressor crankshaft keyway ‘damage indicates a loose pulley and often requires, ‘compressor replacement. Main bearing failures on belt riven compressors often indicate excessive belt tension. ‘A thorough inspection, and possible replacement, of drive components should be made at each compressor change. Special attention should be given to drive ‘gears and couplings on compressors which have been operated at high discharge pressures due to a blocked or frozen discharge line Check all compressor mounting bolts and retighten evenly as necessary. Check the condition of al Compressor mounting brackels, tighten hardware as necessary, and replace if damaged. Operational Tests Every three months, 900 operating hours or 25,000 miles whichever occurs first. Vehicles manufactured after the effective date of FMVSS 121, withthe minimum requited reservoir volume, must have @ compressor capable of raising ar system pressure from 890 to 700 kPa (85 to 100 psi) in 25 seconds or less. This testis performed with the engine operating at maximum governed speed. The vehicle manufacturer must ceriy this performance on new vehictes with appropriate allowances for air systems with greater than the minimum required reservoir volume. ‘Check unioader operation by building system pressure to governor cut-out and note that air compression stops. Reduce system pressure to governor cutin and note that air compression resumes. If the compressor falls to respond as described, make certain the ‘governor is functioning properly betore repairing or replacing the compressor. ‘Compressor Air Leakage Tests Compressor leakage tests need not be performed on @ reguiar basis. These tests should be performed when; it is suspected that discharge valve leakage is substantially affecting compressor build up performance, or when itis suspected that the ‘compressor is cycling between the load and unloaded modes due to unioader piston leakage These tests must be performed with vehicle parked on level surface, the engine not running, the entire air system completely drained to O KPa (0 psi) and the inet check valve detail parts removed, it apalicable. Unloader Piston Leakage Remove the governor and apply shop air pressure to the ¥ inch pipe thread unloader port on the governor ‘mounting pad. Listen for the escape of air at the inlet cavity. An audible escape of air should not be detected, f any question exists as to leakage, itis recommended that a genuine unloader kit be installed and the cylinder head retested, Bendix Air Compressors BX-2150Discharge Valve Leakage Unioader piston leakage must be repaired before this testis performed, Leakage past the discharge valve can be detected by removing the discharge line, applying shop air to the tnloader mechanism and the discharge port and listening for the escape of air at the compressor inlet cavity. A barely audible escape of air is generally acceptable; however, i there is any question as to the leakage rate, itis recommended that the cylinder head or compressor be removed and repaired or replaced. With shop air still applied at the discharge port, apply a soap solution to the valve stop recess on the top of the head. If leakage is detected, the cylinder head must be repaired or replaced. Only genuine remanufactured compressors or service paris and kits should be used. NOTICE When working on or around air brake systems and components, the following precautions should be observed: 1 Always block vehicle wheels. Stop engine when ‘working under a vehicle. Depleting vehicle air system pressure may cause vehicle to rol. Keep hands away from chamber push rods and slack agjusters; they may automatically apply as system pressure drops, 2. Never connect or disconnect a hase or ine ccontaining air pressure. it may whip as air escapes. ‘Never remove a component or pipe plug unless you are certain all system pressure has been depleted. 3. Never exceed recommended air pressure and always wear safety glasses when working with air pressure, Never look into air jets or direct them at anyone. 4. Never attempt to disassemble a component until ‘you have read and understand recommended procedures. Some components contain powerful springs and injury can result if not properly disassembled, Use only proper tools and observe all precautions pertaining to use of those tools. 5. Use only genuine replacement parts and ‘components. ‘A. Only components, devices, mounting and attaching hardware specifically designed for use in air brake systems should be used. B. Replacement hardware, tubing, hose, fitings, ete. should be of equivalent size, type length, and strength as the original equipment, C. Make certain that when replacing tubing or hose, all supports, clamps or suspending devices that were Originally installed are reinstalled. 6. Devices with stripped threads or damaged parts should be replaced. Repairs requiring machining should not be attempted. Compressor Removal And Disassembly General The following instructions are presented here for reference, Removal and disassembly of the ‘compressor is not recommended unless the appropriate service parts andjor kits are on hand. Removal ‘These instructions are general and are intended to be a uide, in some cases additional preparations and precautions are necessary. 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 cisconnect all air, water and oll lines leading to and from the compressor. 3. Remove the governor and any supporting brackets atached to the compressor and note their positions fon the compressor to aid in reassembly, 4, Remove the discharge port and inlet cavity ftings, if applicable, and note their position on the compressor to aid in reassembly. 5. Remove the flange or base mounting bolts and remove the compressor from the vehicle. 6. Remove the drive gear(s) or pulley trom the ‘compressor crankshaft using a gear puller. Inspect the pulley or gear and associated parts for visible wear or damage. Since these parts are precision fitted, they must be replaced if they are worn or damaged, Bendix Air Compressors 10 BX-21501 j}—- {ees oe & : (ut Seat Drive Screws Name Plate NO. DESCRIPTION. Grinder Head Assembly 1 | Governor Gasket 2 | Unioader Bushing 3 | oFing 4 | Unioader Piston 5 | Unioader Spring & | Inlet Valve Gasket 7 | inlet vaive Seat 8 | Inlet Valve 2 | init Valve Spring 10. | Inlet Valve Stop 11 | Unioader Piston Stop 32 | Hex Head Screns 13 | O-Ring 14 | Inlet Strainer Gasket 45. | Discharge Valve Stop 46 | Discharge Valve Spring 17 | Discharge Valve 18. | Discharge Valve Seat 19 | Cylinder Head Gasket 20 | Piston Ring Set (STD) 1 Piston Ring #2 Piston Ring Piston Ring Oi! Expander Fing a1 | Piston Wiist Pin Plug Wiist Pin 22 | Connecting Roe ‘Connecting Rod Cap Leckwasher Connecting Rod Bolt 23 | Oning 24 | Thrust Washer 25 | End Cover Assembly 2 Note: Some sppieatons ue ont Mounts without Bal Bearings, Fig, 12 Exploded View BX2150 Bendix Air Compressors 4 BX.2150,Preparation For Disassembly Remove road dirt and grease from the exterior of the compressor with a cleaning solvent. Before the compressor is disassembled, the following items should be marked to show their relationship when the compressor is assembled. Mark the rear end cover in relation to the crankcase. Mark the cylinder head in relation to the crankcase. Mark the base plate or base adapler in relation to the crankcase. ‘A-convenient method to indicate the above relationship is to use a metal scribe to mark the parts with numbers ‘7 lines, Do nat use a marking method that can be ‘wiped off or obliterated during rebuilding, such as chalk. Remove all compressor attachments which have not been previously specified. Cylinder Head Disassembly Remove the four cylinder head cap screws and tap the head with a soft mallet to break the gasket seal Scrape off any gasket material from the cylinder head and crankcase. Before disassembling the discharge valve mechanism, measure and record the discharge valve travel (rom closed to completely open). 1. Ifthe measured discharge valve travel DOES NOT EXCEED 0.8128 mm (.032 in), the discharge valve ‘stop need not be removed. Its recommended that the cylinder head body be replaced if the discharge valve stop requires replacement. In the event this is not possible the following procedure can be followed: Using a %ie hex wrench, remove the discharge valve seat, valve, and valve spring, To remove the discharge valve stop, support the machined surface of the cylinder head on an arbor press bed and gently press the stop from the top ‘of the head and out the bottom. Be sure to allow sufficient clearance for the stop between the press bed and the bottom of the cylinder head. The valve stop bore in the cylinder head must be inspected for excessive scoring. A new cylinder head body must be sed if scoring is excessive. 2. Remove the unloader stop and O-ring 3. Remove the unioader piston and O-ring 4. Insert the lugs of a spanner wrench into the holes of the inlet valve stop and remove the inet vale stop along with the inet valve, valve seat, unloadar ‘gasket and spring, (NOTE: Reference Wiliams adjustable face spanner #483), 5. Inspect the unioader piston bushing for nicks, wear, corrosion and scoring. Itis recommended that the cylinder head body be replaced iit is determined that the unioader piston bushing requires replacement. If this is not possible, the bushing can be pressed out of the head using the same procedure presented in Step 2 of this disassembly section. NOTE: If the bushing is pressed out and the cylinder head casting is damaged in the process, cylinder head repair is not recommended. Pressing in the replacement bushing will esult in air or water leakage. Crankcase Base Plate Or Adapter Disassembly 1. Remove the cap screws securing the base plate or ‘base adapter. Tap with soft mallat to break the {gasket seal. Scrape off any gasket material from crankcase and plate or adapter. Connecting Rod Disassembly Before removing the connecting rod, mark the connecting rod and its cap, The connecting rod is matched to its own cap for proper fit, and the cap ‘must be reinstalled in the same position on the rod, 4. Straighten the prongs of the connecting rod bolt locks and remove the bolts and bearing cap. 2, Push the piston with the connecting rod attached ‘ut the top of the oyinder of the crankcase. Replace the bearing cap on the connecting rod. 3. Remove the piston rings from the piston. Ifthe piston is to be removed from the connecting rod, remove the wrist pin teflon plugs and press the wrist pin from the piston and connecting rod. 4, If the piston is removed from the rod, inspect the wrist pin bore or the bronze wrist pin bushing in the connecting rod. f excessive wear is noted or suspected, replace the connecting rod. Compressor Crankcase Disassembly 1, Remove the key or keys from the crankshaft and any bur's from the crankshaft where the key or keys were removed, NOTE: Through drive compressors may have @ crankshatt key at both ends. 2. Remove the four cap sorews and lockwashers or ruts and lockwashers that secure the rear end cover to the crankcase. 3. Remove the rear end cover, thrust bearing and end ‘cover Oring taking care not to damage the bearing if present in the end cover. 4, I the compressor has bell type main bearings, press the crankshaft and ball bearings from the crankcase, then press the ball bearings from the crankshaft. Bendix Air Compressors BX-21505. Press the oil seal out of the compressor orankoase i's0 equipped Cleaning Of Parts General All parts should be cleaned in a good commercial grade solvent and dried prior to inspection. Cylinder Head Remove carbon deposits from the discharge cavity and rust and scale from the cooling cavities of the cylinder head body. Scrape all foreign matter trom the body surfaces and use shop air pressure to blow the dirt, particles from the cavities, Clean carbon and dit from the inlet and unloader passages. Use shop air to blow the carbon and dirt deposits from the unioader passages, Oil Passages Thoroughly clean all oil passages through the crankshafl, crankcase, end covers, and base plate or base adapter. Inspect the passages with a wire to be sure they are clear. Blow the loosened foreign matter ‘out with shop air. Inspection Of Parts Cylinder Head Body Inspect the cylinder head for cracks and obvious physical damage, Pay particular attention to the area ‘around coolant ports for cracks. Check for stripped or damaged threads. Apply shop air pressure to one of the coolant ports with al others plugged, and check for leakage by applying a soap solution to the exterior of the body. If leakage is detected, replace the head, the correct press ft. The crankcase must be replaced if the fits too loose. ‘On compressors fitted with precision, sleeve main bearings the difference between the O.D. of the ‘crankshaft journal and the main bearing LD. must not ‘excged 0,102 mm (,0040 in), or the end cover and ‘main bearing must be replaced. ‘The oylnder bore should be checked with inside micrometers or calipers. Cynder bores which are scored or out of round by more than 0.0123 mm (0008 in) or tapered more than 0.0123 rm (0008 in) should be rebored or honed oversize. Oversized pistons and piston rings are availabe in 0.25 mm {010 in), 0.50 mm 020 in) and 0:75 mm (030 in) Oversizes. The cylinder bore must be smooth, straight and round Pistons Check the piston for scores, cracks, or enlarged ring ‘grooves; replace the piston if any of these conditions are found. Measure the diameter of the top of the piston and the top two ring lands. [Compare to cylinder bore and piston diameters to be sure the diametrical Clearance is between 0.925 mm (0128 in) minimum and 0.500 mm (.0177 in) maximum} Check the fit of the wrist pin to the piston. The wrist pin should be a light press fitn the piston, This clearance should not exceed 0.015 mm (0006 in). Ifthe wrist pin is @ loose fit, the piston and pin assembly should be replaced. Check the fit of the wrist pin in the connecting rod by rocking the piston. Clearance for ‘connecting rod wrist pin is 0.023 mm (,0009 in) max. Replace the connecting rod if excessive clearance is found. NOTE: Wrist pin bushing replacement is not recommended for those connecting rods which incorporate them. Check the fit ofthe piston rings in the piston ring (grooves. Check the ring gap with the rings installed in the cylinder bores. Refer to Figure 13 for correct gap and groove clearances. End Covers ‘Check for cracks, stripped oil port threads and external PISTON RING Ot. RING damage; and if noted, replace the end cover. if the Piston. ‘ crankshaft main bearings are installed inthe end ane + = ‘cover, check for excessive wear and flat spots and a ons replace the end cover if necessary. 0098 Sonics in Grunoe Crankcase on. rN i Check all crankcase surfaces for cracks and damage. ot Pay particular attention to cooling fin. (On compressors where ball bearing main bearings are Fig 18 Gap and Groove Okara Used the difference between the O.D. of the outer race and the ID. of the crankcase hole should be 0.000 to 0.038 mm (,0000 to .0015 in) loose. This is to maintain Bendix Air Compressors 13 BX-2150Crankshaft Check the crankshaft threads, keyways, tapered ends and all machined and ground surfaces for wear, scores, or damage. Standard crankshaft connecting rod journals are between 31.750 mm (1.2500 in) and 31.725 mm (1.2490 in) in diameter. Ifthe crankshaft journals are excessively scored or worn or out of round, the crankshaft must be replace. Main bearing Journals must be maintained so the ball bearings are a snug fit or 60 that no more than 0.102 mm (.004 in) clearance exists between the precision sleeve main bearing and the main bearing journals on the crankshaft. In crankshafts fitted with ol seal rings, the cil seal ring groove or grooves must not be worn. The ring groove walls must have a good finish and they ‘must be square. Using a wire or similar device, check to be sure the oll passages are open through the crankshaft Connecting Rods The BX-2150 connecting rod does not incorporate replaceable crankshaft journal bearing inserts and must be replaced if excessively worn. Clearance between the crankshaft journal and the connecting rod bearing must not be less than 0,025 mm (,0010 in) or more than 0.064 mm (,0026 in) Repairs Its generally recommended that genuine service parts and maintenance kits be used whenever the compressor is disassembled. The Unloader Kit and Major Maintenance Kit and their contents are isted in this manual Assembly Torques Al torques specified in this manual are assembly torques and can be expected to falloff after assembly is accomplished. Do not retorque after initial assembly torques fal, To convert pound inches of torque to pound feet of torque, divide inch pounds by 12 pound inches + 12 = pound feet To convert pound feet of torque to pound inch of torque, multiply pound feet by 12, pound feet x 12 = pound inches Cylinder Head Assembly 1. Ifthe discharge valve stop was removed and must be replaced, a sealant such as "LOCKTITE RETAINING COMPOUND #75", must be applied to the stop and its corresponding bore in the cylinder head. Before applying the sealant, make certain that the press fit between the discharge valve stop outside diameter and the valve stop bore in the cylinder head is a minimum of 0.033 rm (.0013 in) {and a maximum of 0.071 mm (.0028 in). I this fit cannot be maintained, a new cylinder head body must be used. Be sure to completely support the outside top of the cylinder head casting, while pressing in the replacement stops. IMPORTANT: The cylinder head must be supported in a fashion that allows the machined head surface to be parallel to the arbor press bed and perpendicular to the press ram. This is necessary to permit the discharge valve stop to be installed squarely in its bore and to minimize the possibilty of ‘cocking’ 2. Install the discharge valve spring, discharge valve and valve seat. Using @ %e inch hex wrench, torque the discharge valve Seat to 62 to 66 Nem (70 to 90 tt. 3. Tost for leakage by the discharge valve. Apply 700 KPa (100 psi) of air pressure through the oylinder head discharge port and apply a soap solution to the discharge valve and seat. A slight leakage in the form of soap bubbles is permissible. If excessive leakage is found, leave the air pressure applied and with the use of a fiber or hardwood dowel and a hammer, tap the discharge valve off its seat several times. This will help the valve to seat land should reduce the leakage. With the air pressure still applied at the discharge port of the cylinder head, check for leskage around the discharge valve stop exposed on the top of the cylinder head casting. No leakage is permitted, 4. If the unioader piston bushing was removed, press in a new bushing following the same pressing procedures given in Step 1. The inside diameter of the unloader piston bushing must be between 49.042 mm (.7497 in) and 18.948 mm (.7460 in) alter pressing. 5. Using a % hex wrench, install the unloader piston stop and O-ring in the head. Torque to 20 to 25 Nem (175 to 225 Io in). 6. Install the unioader piston and O-ring in the head so that the short stem of the piston rests on the tnloader stop. Bendix Air Compressors 4 BX-21507, Install the unloader piston spring, small end first, on the stem of the unloader piston. install the metal (copper) inlet valve gasket so that it rests on the shoulder of the inlet valve cavity. Install the inlet valve seat on top of the inlet valve gasket with its beveled side visible. Make certain the large coils of the piston spring rest within the recess of the inlet valve seat on the side opposite the bevel. Install the inlet valve so that It rests on the beveled side of the valve seat, 8. Install the inlet valve spring on the inlet valve stop and install the stop in the head. Using a spanner ‘wrench, torque the inlet valve stop to between 52 to {66 Nem (70 to 90 Io tt), 9. Apply 700 kPa (100 psi) air pressure to the unloader pport of the governor mounting pad and note the inlet valve is driven away from its seat. Using a soap ‘solution, test for ar leakage at the unioader piston ‘stop, No leakage is permitted, Crankcase & Crankshaft Assembly 1. If the compressor requires a drive end crankshaft ol! seal, press it into the crankcase until itis flush with the crankcase casting, Using clean ol lubricate the sealing lips of the seal 2. If the compressor uses a ball type main bearing, press the ball bearing onto the correct end of the ‘crankshaft. Position the ball bearing and the crankshaft in the crankcase, making sure the drive end of the cankshatt is positioned in the crankcase as marked before disassembly, NOTE: In the case of compressors with a rear main ball bearing, make certain to instal the thrust bearing in the crankcase before pressing the crankshaft and. bball bearing into place. Carefully press the crankshaft and ball bearing into the crankcase using an arbor press. Make certain not to damage the oll seal, if the ‘compressor is so equipped. 3. Place the O-ring seal in the groove around the rear ‘end caver or in the crankcase proper in the event a rear main ball bearing is in use. If the rear end cover contains a precision sleeve bearing that serves as the crankshaft main bearing, make certain to instal the thrust bearing, Install the end cover in the position as marked before disassembly, taking care not to damage the sleeve bearing, if so equipped. 4. Install the four cap sorews or nuts that secure the rear end cover to the crankcase and torque to 20 to 25 Nem (175 to 225 ib in), Piston & Connecting Rod Assembly 1 Prelubricate the piston, piston rings, wrist pin ‘connecting rod, 2. Install the piston rings in the correct location the ring pipmarks up (Refer to Figure 13). Stagger the position of the ring gaps. 3. Align the wrist pin bore of the connecting rod with the piston bores and install the wrist pin to secure the rod to the piston. Make certain the TEFLON “buttons’ are installed in each end of the wrist pin 4. Using an automotive type ring compressor or similar tool, compress the piston rings and gently install the ‘connecting rod and piston in the cylinder bore. Insta the connecting rod cap an the connecting rod in the same position as marked during disassembly. 5. Secure the rod cap to the rod using the two cap ‘screws and special lockwashers. Torque the cap ‘screw to between 14 to 16 Nem (120 to 140 Ib in) land bend the tabs of the lockwashers until they are firmly against the flats of the hex head of the cap serews. Base Plate Or Base Adapter Assembly 1. Position the base plate or base adapter gasket on. the crankcase and install the base plate or base adapter as marked before disassembly. 2. Install the cap screws that secure either the ‘crankcase base plate or crankcase mounting base adapter. Torque the cap screws evenly to the appropriate valve: base plate 10 to 13 Nem (85 to 115 lb in), mounting base adapter 20 to 25 Nem (175 to 225 I in, Final Compressor Assembly 1. Place the oylinder head gasket on the crankcase and position the head on the crankcase as marked during disassembly, A gasket sealer is neither required or recommended. 2. Secure the cylinder head to the crankcase using the {our cylinder head cap screws. Torque the cap serews in an "X" pattern to between 20 to 25 Nem (175 to 225 i in). 3. Using a thread sealant install all necessary pipe plugs and torque as follows: Ye inch PLT. plugs 10 to 12Nem (BS to 105 Io in). Ye inch PLT. plugs 23 to 31 Nem (200 to 270 Ib in), Bendix Air Compressors 18 BX-2150,4. Install all crankshaft keys making certain to support the crankshaft to avoid bearing damage. Install the ‘crankshaft nut where applicable. When instaling drive couplings, gears or pulleys, OO NOT EXCEED 165 Nem (120 tb ft) torque on the crankshaft nut. ‘The self locking crankshaft nut used on the BX-2180 requires that it be installed so that the narrow ceastellation slots are toward the end of the ‘crankshaft and not against the pulley, coupling or gear that the nut retains, ‘Some BX-2150 through drive compressors require the instalation of a spline coupling on the rear of the crankshaft. The cap screw securing the coupling should be torqued to 20 to 25 Nem (175 to 225 lb in) 5. Use covers, plugs, or masking tape to protect all ports if compressor is not to be installed immediately. Protect the ends of the crankshaft against damage by wrapping with masking tape or friction tape. The open bottom of a vertical engine lubricated compressors should be protected against the entrance of dirt during handling or storage, by installing a temporary cover over the base. Testing Rebuilt Compressor Compressor Build-Up Time Chart COMPRESSOR BUILD-UP TIME 0-120 Ps (6900 CUBIC INCH RESERVOIR 3 8 8 BUILD UP TIME (SECONDS) 8 ° 2001500 180021002400 2700 3000 (COMPRESSOR SPEED (RPM) Compressor Bulé-Up Time Chart In order to properly bench test a compressor under ‘operating conditions, a test rack for correct mounting, ‘cooling, lubricating, and driving the compressor is necessary. Such tests are not compulsory if the unit has been carefully rebuilt by an experienced person. A, ‘compressor efficiency or build-up test can be run which is not too dificult. The compressor must be connected to an oil supply line of at least 100 kPa (15 psi) pressure during the test and an oll return line must be installed to keep the crankcase drained, Connect the compressor discharge port to @ reservoir with a volume of 650 cubic inches, including the volume of connecting Ine. With the compressor operating at 1800 rpm, the time required to raise the reservoirs) pressure from 0 kPa (0 psi to 700 KPa (100 ps) should not exceed 20 seconds. NOTE: During this test (with no inlet check valve or air strainer attached to the compressor inlet), the ‘compressor should be checked for gasket leakage and Noisy operation, as well as unloader operation and. leakage, Tabulated Technical Data Average weight 38ibs Number of eyinders 1 Bore size 85.725 mm (3.3750 in) Stroke 37.287 mm (1.4679 in) Displacement at 1250 rpm O5CFM Maximum recommended rpm 3000 rpm Minimum coolant flow (water cooled) at: Maximum pm 5 iter min (25US. gpm) Minimum rpm 1.9lter/min (5 U.S. gpm) Minimum coolant flow (air-cooled) NA Approximate horsepower required at 1250 rpm at 820 kPa (120 psinaturally aspirated) 1.7 hp Turbocharge limits: Maximum pm 2200 1pm Maximum pressure (gauge) 100 KPa (15 psi) Maximum inlet air temperature 121°C (250°F) Maximum discharge air temperature 205°C (400°F) Minimum pressure required to unioad Bendix Air Compressors 16 naturally aspirated 420 kPa (60 psi) with inlet check valve $580 kPa (85 psi) turbocharged! 1580 KPa (85 psi) BX-2150Minimum oil pressure required: at engine idling speed ‘35 kPa (5 psi) ‘at maximum governed engine speed ..... 100 KPa (15psi) il capacity of selFtubricated model NIA Minimum dischargesine size 12.7 (Yeinch)|D. Minimum coolanttine size 9.5mm (% inch) LD. Minimum oil supply line size ....... 4.8mm (¥s inch) LD. Minimum oilxetum line size 12.7 mm ("einch) LD. Minimum air-inlet line size 15.9 mm (%inch) LD. Minimum unloaderine size 4.8mm (Meinch) LD. Unloader Kit The unloader kit is designed for use when unloader piston leakage is detected as desoribed under the Compressor Air Leakage Tests section of this manual, The kit contains the following components which are keyed to Figure 14, WATER PORT 3 4 e DISCHARGE PORT GOVERNOR MOUNTING PAD —s Fig 14 Exploded View Head Assembly ‘ary. Description Key 1 Unioader Stop Assembly 3 1 ‘Unioager Piston 4 Major Maintenance Kit The major maintenance Kit is designed to rebuild the BX-2150 head assembly and contains the following parls which are keyed to Figure 14. ay. Descrintion Koy 1 Unioader Kit Bae 1 Discharge Valve 2 1 (Governor Gasket 1 1 ‘Strainer Gasket 2 1 Discharge Valve Spring 3 1 (Gylinder Head Gasket 4 1 ‘Unioader Spring 70 1 Inet Valve Gasket 2 1 Discharge Valve Séat 7 [4 Trt Valve Stop 5 1 | Inet Valve 7 o Trt Vaive Seat @ 1 Inet Valve Spring @ Compressor Troubleshooting Symptom: 1. Compressor passes excessive oll as evidenced by presence of al at exhaust ports of valving or seeping inlet from air starter, Cause: A. Restricted air intake, ‘Check engine or compressor air cleaner and replace if necessary. Check compressor air inlet line for kinks, excessive bends and be certain inlet lines have the minimum specitied inside diameter. Recommended minimum inlet line is 15.9 mm (56 inch) LD. Recommended maximum air inlet restriction is 635 mm (25 inches of water). B. Restricted oil return (to engine}. il return to the engine should not be in any way restricted. Check for excessive bends, kinks, and restrictions in the oil return line. Minimum recommended oil return line size is 15.9 mm (9% inch) 0.D. tubing or equivalent LD. [12.7 mm (¥ inch) minimum]. Return line must CONSTANTLY DESCEND from the compressor to the engine ‘crankcase, Make certain oll drain passages in the compressor and mating engine surfaces are unobstructed and aligned. Special care must be taken when sealants are used with or instead of gaskets, Bendix Air Compressors 7 BX-2150C. Poorly filtered inlet air, Check for damaged, defective or dirty air iter on engine or compressor. Check for leaking, damaged or defective compressor air intake ‘components (i... induction ine, fitings, gaskets, filter bodies, etc.}. The compressor intake should ‘not be connected to any part of the exhaust gas recirculation (E.G.R,) system on the engine, D. Insufficient compressor cooling, For air-cooled portions of the compressor: 4. Remove accumulated grease, grime, or dit ‘rom the cooling fins. Replace components found damaged. 2. Check for damaged cooling fins. Replace ‘components found damaged. For water-cooled portions of the compressor: 1. Check for proper coolant line sizes. Minimum recommended size is 9.5 mm (¥s inch) LD. tubing 2. Check the coolant flow through the compressor. Minimum allowable flow is 9.5 literzmin (2.5 U.S. gor) at engine governed speed. If low coolant flow is detected, inspect the coolant lines and fittings for accumulated rust scale. kinks and restrictions. ‘3, Water temperature should not exceed 83°C (20°F), 4, Optimum cooling is achieved when engine Coolant flows as shown in Figure 7 ofthis manual Contaminants not being regularly drained from system reservoirs. Check reservoir drain valves to insure that they are functioning properly. it is recommended that the vehicle should be equipped with functioning automatic drain valves, or have all reservoirs rained to 0 kPa (0 psi) dally optimally to be equipped with a desiccant-type air dryer prior to the reservoir system, ‘Compressor runs loaded an excessive amount of time. Vehicle system leakage should not exceed industry standards of 6.9 kPa ( psi) pressure drop per ‘minute without brakes applied, and 20.7 kPa (3 psi) pressure drop per minute with brakes applied. if leakage is excessive, check for system leaks and repair. G. Excessive engine crankcase pressure Test for excessive engine crankcase pressure and replace or repair crankcase ventilation components, ‘as necessary. (An indication of crankcase pressure is a loose or partially ited dipstick) H. Excessive engine ol pressure Check the engine oll pressure with a test gauge and compare the reading to the engine specications. Bendix does not recornmend restricting the compressor oil supply line because of the possibilty of plugging the restriction with oil Contartinants. Minimum oil Supply line size is 4.8 mm (9s inch LD.) tubing. |. Faulty compressor. Replace or repair the compressor only after aking certain none of the preceding installation defects exist Symptom: 2. Noisy compressor Cause: ‘A. Loose drive gear or pulley Ingpect the fit of the drive gear or pulley on the ‘compressor crankshatt. The pulley or gear must be completely seated and the crankshaft nut must be tight. Ifthe compressor crankshaft surface or its keyway are damaged, itis an indication of loose drive components. If damage to the compressor crankshaft is detected, replace the compressor or the crankshaft. When installing the drive gear or pulley, torque the crankshaft nut to 113 Nem (100 ib ft). 00 NOT BACK OFF THE CRANKSHAFT NUT TO ALIGN THE COTTER PIN AND CASTELLATED NUT. (Some compressors do Not use castellated nuts). DO NOT USE IMPACT WRENCHES. B. Excessively worn drive couplings or gears Inspect rive gear and couplings and engine for excessive wear. Replace as necessary. (Non: metalic gears should be replaced when the compressor is changed.) ©. Compressor cylinder head or discharge line restrictions. Inspect the compressor discharge port and discharge line for carbon build-up. If carbon is detected, check for proper cooling to the ‘compressor. (See Cause and remedy (0) under ‘Symptom #1,} Inspect the discharge line for kinks and restrictions. Replace discharge line as necessary, Bendix Air Compressors 18 BX-2150D. Worn or burned out bearings. Check for proper oil pressure in the compressor. Minimum required oil pressure; 34.5 kPa (5 psi) engine idling, 103 kPa (15 psi) maximum governed ‘engine rpm. Check for excessive oil temperature. il temperature should not exceed 115°C (240°F), E. Faulty compressor. Replace or repair the compressor after determining none of the preceding instalation defects exist. ‘Symptom: 3. Excessive build-up and recovery time. Compressor should be capable of building air system from 586 to 690 kPa (85 to 100 psi) in 40 seconds with engine at ful governed rps. Minimum compressor performance is certitied to meet Federal requirements by the vehicle manufacturer. Do not downsize the original equipment compressor. Cause: ‘A, Dirty induction air filter. Inspect engine or compressor air fter and replace if necessary. B. Restricted induction line. Inspect the compressor air induction line for kinks and restrictions and replace as necessary. C. Restricted discharge line or compressor discharge cavity. Inspect the compressor discharge port and line for restrictions and carbon build-up. Ifa carbon build Up is found, check for proper compressor cooling, Replace faulty sections of the discharge line D. Slipping drive components Chaok for fauity drive gears and couplings and replace as necessary. Check the condition of drive belts and replace or tighten, whichever is appropriate. E. Excessive air system leakage. Test for excessive system leakage and repair as necessary. Use the following as a guide: Build system pressure to governor cutout and allow the pressure to stabilize for one minute. Using the dash gauge, note the system pressure and the pressure drop after two minutes, The pressure drop for Post-1975 vehicles should not exceed 41. 19.8kPa (2 ps) in each reservoir fora single vehicte 2. 41.4 kPa (6 ps) each reservoir for a tractor and taller 3, 55 KPa (8.03) in each reservoir for a tractor and 2 taller. F. Sticking unloader pistons Check the operation of the unloading mechanism, Check the proper operation of the compressor air governor. If the governor is operating properly, replace the unloader mechanism. Inspect for bent, linked or blocked tubing leading to or from the governor. G. Faulty compressor. Replace or repair the compressor after determining none of the preceding installation defects exist. ‘Symptom: 4, Compressor fails to unload. Cause: ‘A. Faulty governor or governor operation, Test the governor for proper operation and inspect, air ines to and from the governor for kinks or restrictions. replace or repair the governor or its ‘connecting air lines. B, Faulty or worn unloader pistons or bores Inspect for worn, dirty or corroded unioader piston and bore. Replace as necessary. Bendix Air Compressors 19 BX-2150‘Symptom: 5. Compressor leaks ol Cause: ‘A. Damaged mounting gasket. ‘Check the compressor mounting bolt torque. If the ‘mounting bolt torque is low, replace the ‘compressor mounting gasket before retorquing the ‘mounting bolts, B. Cracked crankcase or end cover. Visually inspect the compressor exterior for ‘racked or broken components. Cracked or broken crankcases or mounting flanges can be caused by loose mounting bolts. The end cover can be cracked by avertorquing fitting or plugs installed in the end cover. Replace or repair the compressor as necessary, C. Loose end cover. Check the cap screw torques and tighten as necessary, D. Loose olf supply or return line fitings. Check the torque of external oil ine fittings and tighten as necessary. E. Porous compressor casting, Replace the compressor if porosity is found. F. Mounting flange or end cover, Oxing or gasket. missing, cut, or damaged. F. Replace as necessary, Symptom: 6. Compressor constantly cycles (compressor remains unloaded for a very short time). Cause: ‘A, Leaking compressor unloader piston. Remove the compressor inlet air strainer or fing, With the compressor unloaded (nat compressing ait), check for air leakage, Replace as necessary. B. Faulty governor. Test the governor for proper operation and repair or replace as necessary, CC. Excessive system leakage, Test for excessive system leakage (see Symptom #3 Cause (E)). Reduoe leakage wherever possible. D. Excessive reservoir contaminants, Drain reservoirs, Symptom: 7. Compressor leaks coolant Cause: ‘A. Improperly installed plugs and coolant line fitings. Check torque of fitings and plugs and tighten as necessary. Over torque fittings and plugs can crack the head casting B. Freeze cracks due to improper antifreeze strength. Test anti-reeze and strengthen as necessary, Check coolant flow through compressor to assure the proper antifreeze mixture reaches the compressor C. Faulty compressor (porous castings) I casting porosity is detected, replace the compressor Symptom: 8. Compressor head failure. Cause: A, Restricted discharge line Clear restriction or replace line. B. Loose head bolts. Tighten evenly to a torque of 20 to 25 Nem (175 to 2225 Io in), CC. Faulty compressor or head gasket ‘Check for rough or poorly machined head or block surfaces Replace necessary components Bendix Air Compressors BX-2150(©1996 Caterpilar ented n USA Al Fights Reserved