BENDIX AIR COMPRESSOR 1W150R AIR COMPRESSO Caterpillar


Air Compressor Troubleshooting

Usage:

Symptom:

1. Oil in air reservoirs.

Cause:

A. Restricted air inlet or improperly filtered inlet air.

Check engine or air compressor air cleaner and replace if necessary. Check air compressor air inlet for kinks, excessive bends and be certain inlet lines have the minimum specified inside diameter.

B. Restricted oil return (to engine).

Oil 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 (5/8 in) OD tubing or equivalent ID [12.7 mm (1/2 in) minimum]. Return line must CONSTANTLY DESCEND from the air compressor to the engine crankcase. Make certain oil drain passages in the air compressor and mating engine surfaces are unobstructed and aligned. Special care must be taken when sealants are used with, or instead of, gaskets.

C. Poorly filtered inlet air.

Check for damaged, defective or dirty air filter on engine or air compressor. Check for leaking, damaged or defective air compressor air inlet components (ie, induction line, fittings, gaskets, filter bodies, etc). The air compressor inlet should not be connected to any part of the exhaust gas recirculation (EGR) system on the engine.

D. Insufficient air compressor cooling (air compressor runs hot).

For air-cooled portions of the air compressor:

1. Remove accumulated grease, grime or dirt from the cooling fins. Replace components found damaged.

2. Check for damaged cooling fins. Replace components found damaged.

For water-cooled portions of the air compressor:

1. Check for proper coolant line sizes. Minimum recommended size is 12.7 mm (1/2 in) OD tubing.

2. Check the coolant flow through the air compressor. At maximum rpm coolant flow should not be less than 10 L (2.6 US gal) per minute. The minimum rpm coolant flow should not be less than 3 L (.8 US gal) per minute. 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 98°C (208°F).

E. 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 drained to zero (0) psi daily, or optimally to be equipped with a desiccant-type air dryer prior to the reservoir system.

F. Air compressor runs loaded an excessive amount of time.

Vehicle system leakage should not exceed industry standards of 7 kPa (1 psi) pressure drop per minute without brakes applied and 20 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 ventilation components as necessary. (An indication of crankcase pressure is a loose or partially lifted dipstick).

H. Excessive engine oil pressure.

Check the engine oil pressure with a test gauge and compare the reading to the engine specifications. Bendix does not recommend restricting the air compressor oil supply line because of the possibility of plugging the restriction with oil contaminants. Minimum oil supply line size is 4.8 mm (3/16 in) ID tubing.

I. Faulty air compressor.

Replace or repair the air compressor only after making certain none of the preceding installation defects exist.

Symptom:

2. Noisy air compressor operations.

Cause:

A. Loose drive gear or pulley.

Inspect the fit of the drive gear on pulley on the air compressor crankshaft. The pulley on gear must be completely seated and the crankshaft nut must be tight. If the air compressor crankshaft surface or its keyway are damaged, it is an indication of loose drive components. If damage to the air compressor crankshaft is detected, replace the air compressor. When in stalling the drive gear or pulley, tighten the crankshaft nut to a torque of 140 N·m (100 lb ft). Do Not Back Off The Crankshaft Nut To Align The Cotter Pin And Castellated Nut. (Some air compressors do not use castellated nuts). Do Not Use Impact Wrenches.

B. Excessively worn drive couplings or gears.

Inspect drive gear and couplings and engine for excessive wear. Replace as necessary. (Non-metallic gears should be replaced when the air compressor is changed).

C. Air compressor cylinder head or discharge line restrictions.

Inspect the air compressor discharge port and discharge line for carbon build-up. If carbon is detected, check for proper cooling to the air compressor. (See Symptom #1 Cause (D). Inspect the discharge line for kinks and restrictions. Replace discharge line as necessary.

D. Worn or burned out bearings.

Check for proper oil pressure in the air compressor. Minimum required oil pressure; 100 kPa (15 psi) engine idling, 200 kPa (29 psi) maximum governed engine rpm. Oil temperature should not exceed 115°C (240°F).

E. Faulty air compressor.

Replace or repair the air compressor after determining none of the preceding installation defects exist.

Symptom:

3. Air compressor fails to unload.

Cause:

A. Faulty governor or governor installation.

Test the governor for proper operation and inspect air lines to and from the governor for kinks or restrictions. Replace or repair the governor or its connecting air lines.

B. Faulty or worn unloader valve assembly or bore.

Inspect for worn, dirty or corroded unloader valve assembly and its bore. Replace as necessary.

Symptom:

4. Excessive build-up and recover time. With the air compressor operating at 3000 rpm, the time required to raise the reservoir(s) pressure from 0 to 700 kPa (0 to 100 psi) should not exceed 75 seconds. Minimum air compressor performance is certified to meet Federal requirements by the vehicle manufacturer. Do not down-size the original equipment air compressor.

Cause:

A. Dirty induction air filter.

Inspect engine or air compressor air filter and replace if necessary.

B. Restricted induction line.

Inspect the air compressor air induction line for kinks and restrictions and replace as necessary.

C. Restricted discharge line or air compressor discharge cavity.

Inspect the air compressor discharge port and line for restrictions and carbon build-up. If a carbon build-up is found, check for proper air compressor cooling. Replace faulty sections of the discharge line.

D. Slipping drive components.

Check for faulty 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. Vehicle system leakage should not exceed industry standards of 7 kPa (1 psi) pressure drop per minute without brakes applied and 20 kPa (3 psi) pressure drop per minute with brakes applied. If leakage is excessive, check for system leaks and repair.

F. Sticking unloader valve assembly.

Check the operation of the unloading mechanism. Check the proper operation of the air compressor governor. If the air compressor governor is operating properly, replace the unloader mechanism. Inspect for bent, linked or blocked tubing leading to or from the air compressor governor.

G. Faulty air compressor.

Replace or repair the air compressor after determining none of the preceding installation defects exist.

Symptom:

5. Air compressor leaks oil.

Cause:

A. Damaged mounting gasket.

Check the air compressor mounting bolt torque. If the mounting bolt torque is low, replace the compressor mounting gasket before retorquing the mounting bolts.

B. Cracked crankcase, cylinder block or end cover.

Visually inspect the air compressor exterior for cracked or broken components. Cracked or broken crankcases or mounting flanges can be caused by loose mounting bolts. The end cover can be cracked by overtorquing fitting or plugs installed in the end cover. Replace or repair the air compressor as necessary.

C. Loose end cover cap cover.

Check the cap screw torques and tighten as necessary.

D. Loose oil supply or return line fittings.

Check the torque of external oil line fittings and tighten as necessary.

E. Porous air compressor casting.

Replace the air compressor if porosity is found.

F. Mounting flange or end cover, O-ring or gasket is missing, cut or damaged.

Replace as necessary.

Symptom:

6. Air compressor constantly cycles (air compressor remains unloaded for a very short time).

Cause:

A. Leaking air compressor unloader valve assembly.

Remove the air compressor inlet air strainer or fitting. With the air compressor unloaded (not compressing air), check for air leakage. Replace as necessary.

B. Faulty governor.

Test the governor for proper operation and repair or replace as necessary.

C. Excessive system leakage.

Test for excessive system leakage (see Symptom #4 Cause (E). Reduce leakage wherever possible.

D. Excessive reservoir contaminants.

Drain reservoirs.

Symptom:

7. Air compressor leaks coolant.

Cause:

A. Improperly installed plugs and coolant line fittings.

Check torque of fittings and plugs and tighten as necessary. Over-torque fittings and plugs can crack the head or block casting.

B. Freeze cracks due to improper antifreeze strength.

Test antifreeze and strengthen as necessary. Check coolant flow through air compressor to assure the proper antifreeze mixture reaches the air compressor.

C. Faulty air compressor (porous castings).

If casting porosity is detected, replace the air compressor.

Symptom:

8. Air compressor head gasket failure.

Cause:

A. Restricted discharge line.

Clear restriction or replace line.

B. Loose cylinder head bolts.

Tighten evenly to a torque of 25 to 30 N·m (225 to 265 lb in)

C. Faulty air compressor or cylinder head gasket.

Check for rough or poorly machined cylinder head or block surfaces. Replace air compressor as necessary.

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