BENDIX BX-2150 User manual

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BENDIX®BX-2150™COMPRESSOR SPECIAL CATERPILLAR MAINTENANCE KIT
Water Port
3
Discharge Port
1
4
10
Governor
Mounting Pad
9
7
14 5
6
8
11
12
13
2
Water Port
Figure 1 – Bendix®BX-2150™Compressor Special
Caterpillar Maintenance Kit Contents
*Items 3 & 4 are included in the unloader kit. Separate
instructions are included with this kit.
Note 1: These are intended for use in the crankcase
portion of the compressor. They are NOT ILLUSTRATED
in Figure 1. For instruction as to the proper installation
of these components, refer to the latest revision of
"Caterpillar® Service Manual REG 00914".
Kit Contents
Item No. Description Qty.
1 Governor Gasket 1
2 Strainer Gasket 1
3* Unloader Stop 1
4* Unloader Piston 1
5 Inlet Valve Stop 1
6 Inlet Valve Spring 1
7 Inlet Valve 1
8 Inlet Valve Seat 1
9 Unloader Gasket 1
10 Unloader Spring 1
11 Discharge Valve Seat 1
12 Discharge Valve 2
13 Discharge Valve Spring 1
14 Cylinder Head Gakset 1
See Note 1 O-Ring 1
See Note 1 Crankcase Gasket 1
See Note 1 Thrust Washer 2
See Note 1 Lockwasher 2
See Note 1 O-Ring 1
Bendix®BX-2150™
Compressor
1

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GENERAL SAFETY GUIDELINES
WARNING! PLEASE READ AND FOLLOW THESE INSTRUCTIONS
TO AVOID PERSONAL INJURY OR DEATH:
When working on or around a vehicle, the following guidelines should be observed AT ALL TIMES:
▲Park the vehicle on a level surface, apply the
parking brakes and always block the wheels.
Always wear personal protection equipment.
▲Stop the engine and remove the ignition key
when working under or around the vehicle.
When working in the engine compartment,
the engine should be shut off and the ignition
key should be removed. Where circumstances
require that the engine be in operation, EXTREME
CAUTION should be used to prevent personal
injury resulting from contact with moving,
rotating, leaking, heated or electrically-charged
components.
▲Do not attempt to install, remove, disassemble
or assemble a component until you have read,
and thoroughly understand, the recommended
procedures. Use only the proper tools and
observe all precautions pertaining to use of those
tools.
▲If the work is being performed on the vehicle’s
air brake system, or any auxiliary pressurized air
systems, make certain to drain the air pressure
from all reservoirs before beginning ANY work
on the vehicle. If the vehicle is equipped with a
Bendix®AD-IS®air dryer system, a Bendix®DRM™
dryer reservoir module, or a Bendix® AD-9si®air
dryer, be sure to drain the purge reservoir.
▲Following the vehicle manufacturer’s
recommended procedures, deactivate the
electrical system in a manner that safely removes
all electrical power from the vehicle.
▲Never exceed manufacturer’s recommended
pressures.
▲Never connect or disconnect a hose or line
containing pressure; it may whip and/or cause
hazardous airborne dust and dirt particles. Wear
eye protection. Slowly open connections with
care, and verify that no pressure is present. Never
remove a component or plug unless you are
certain all system pressure has been depleted.
▲Use only genuine Bendix®brand replacement
parts, components and kits. Replacement
hardware, tubing, hose, fi ttings, wiring, etc. must
be of equivalent size, type and strength as original
equipment and be designed specifi cally for such
applications and systems.
▲Components with stripped threads or damaged
parts should be replaced rather than repaired.
Do not attempt repairs requiring machining or
welding unless specifi cally stated and approved
by the vehicle and component manufacturer.
▲Prior to returning the vehicle to service, make
certain all components and systems are restored
to their proper operating condition.
▲For vehicles with Automatic Traction Control
(ATC), the ATC function must be disabled (ATC
indicator lamp should be ON) prior to performing
any vehicle maintenance where one or more
wheels on a drive axle are lifted off the ground
and moving.
▲The power MUST be temporarily disconnected
from the radar sensor whenever any tests USING
A DYNAMOMETER are conducted on a vehicle
equipped with a Bendix® Wingman®system.
▲You should consult the vehicle manufacturer's operating and service manuals, and any related literature,
in conjunction with the Guidelines above.
GENERAL
Prior to installation of this kit, park the vehicle on a level
surface and retain by means other than air brakes. Drain
reservoirs to 0 psi. Clean the exterior of the compressor. For
complete compressor removal, refer to the latest revision
of "Caterpillar®Service Manual REG 00914".
DISASSEMBLY (Refer to Figure 1)
1. Remove the discharge line from the discharge port of
the cylinder head and push the discharge line out of
the way.
2. Remove the governor or the air line from the mounting
pad on the head of the compressor. Remove and
discard the governor mounting gasket (1) if the
governor is mounted on the head.

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3. Remove the inlet tting or air strainer and discard
the gasket (2).
4. Remove the inlet and outlet water lines after draining
the radiator.
5. Remove and retain the four hex head cap screws
from the head. Tap the head with a mallet to break
the gasket seal and remove the head. Remove and
discard the head gasket (14).
6. Remove the unloader stop assembly (3) and discard.
7. Remove the unloader piston assembly (4) and discard.
8. Insert a spanner-type wrench into the holes of the inlet
valve stop (5). Remove and discard.
9. Remove and discard the inlet valve spring (6), inlet
valve (7), inlet valve seat (8), unloader gasket (9), and
unloader spring (10).
10. Using a 9/16" Allen®wrench, remove and discard the
discharge valve seat (11).
11. Remove and discard the discharge valve (12) and the
discharge valve spring (13).
12. Remove and discard the cylinder head gasket (14).
CLEANING
Remove all carbon deposits, rust, and scale from all cavities
in the cylinder head. Use shop air to clear any loose
particles from these recesses. Scrape the body surfaces
of the head and the crankcase taking care not to allow
foreign material to fall into the cylinder.
INSPECTION
1. Inspect the inlet bushing and discharge valve stop for
excessive wear, nicks, and scratches. These surfaces
can be "dressed" with a lapping stone to improve their
condition.
2. If it is apparent that these parts are not salvageable,
obtain replacement parts through a local Bendix®outlet.
For instructions on the installation of parts not contained
in maintenance kits, refer to SD-01-331.
ASSEMBLY (Refer to Figure 1)
1. Install the unloader stop assembly (3) into the threaded
port on the top of the head above the air inlet cavity.
Torque to 175-225 in-lbs.
2. Turn the head over and install the unloader piston
assembly (4) into the unloader cavity (short stem rst).
Install unloader spring (10) (small end rst) onto the
long stem of the unloader piston assembly (4). Install
the unloader gasket (9) over the unloader spring and
rest it on the shoulder of the hole in the unloader cavity.
Install the valve seat (8) on top of the unloader gasket
(bevel side of valve seat up). Install the inlet valve (7)
on the valve seat. Install the inlet valve spring (6) on the
inlet valve. Retain with the inlet valve stop (5). Using a
spanner-type wrench, torque to 840-1080 in-lbs.
3. Install the discharge valve spring (13) into the cavity of
the discharge valve stop. Install the discharge valve (12) on
top of the discharge spring and retain with the discharge
valve seat (11). Using a 9/16" Allen wrench, torque to
840-1080 in-lbs.
4. Test the head for air leakage prior to installing the head
onto the compressor. Refer to the Air Leakage Tests
section.
5. Make sure the mating surfaces of the head and the
crankcase have been properly prepared. (Refer
to cleaning instructions.) Install the cylinder head
gasket (14) onto the crankcase. Place the head in the
proper position onto the crankcase and retain with the
four 5/16" cap screws. Snug all four cap screws prior to
torquing in a cross pattern to 175-225 in-lbs.
6. Install the inlet tting or air strainer onto the compressor.
Install the strainer gasket (2) between either component
and the compressor.
7. Replace the governor or air line from the governor onto
the compressor. If the governor is direct mounted onto
the mounting pad of the compressor, install the governor
gasket (1) between the mounting pad and the governor.
8. Connect the discharge air line to the discharge port on
the top of the head.
9. Connect the inlet and outlet water lines to the head and
rell the radiator.
COMPRESSOR TESTING
Vehicles manufactured after the effective date of FMVSS
121, with the minimum required reservoir volume, must
have a compressor capable of raising air system pressure
from 85-100 psi in 25 seconds or less. This test is performed
with the engine operating at maximum recommended
governed speed. The vehicle manufacturer must certify this
performance on new vehicles with appropriate allowances
for air systems with greater than the minimum required
reservoir volume.
AIR LEAKAGE TESTS
Leakage past the discharge valves can be detected as
follows: Remove the discharge line and cylinder head
from the compressor and apply shop air back through
the discharge port. Coat the discharge valve seat with
soapsuds. Bubble leakage is permitted.
The unloader piston can be checked for leakage as follows:
Build up the air system to governor cut-out and shut off
the engine. (If the head is removed from the compressor,
apply shop air to the governor unloader port.) Listen for
escaping air at the compressor inlet cavity. To pinpoint the
leakage, apply a small amount of oil around the unloader
piston. No leakage is permitted.

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S-1121 Rev. 001 © 2017 Bendix Commercial Vehicle Systems LLC, a member of the Knorr-Bremse Group • 10/17 • All Rights Reserved
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