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ManualsBrandsBendix Commercial Vehicle Systems ManualsEquipment360CC SINGLE CYLINDER COMPRESSOR

DESCRIPTION

The function of the air compressor is to provide and maintain

air under pressure to operate devices in air brake systems.

The Bendix

360cc compressor is a single-cylinder

compressor with a rated displacement of 15.8 cubic feet

per minute at 1250 RPM. The compressor consists of an

integral water-cooled cylinder head assembly and water-

cooled crankcase.

The cylinder head assembly is made up of an aluminum

cylinder head, an aluminum cooling plate, and a steel valve

plate assembly with two sealing gaskets. The cylinder head

contains air and water ports. The cooling plate, situated

between the head and valve plate, assists in cooling the

head assembly. The valve plate assembly, consisting of

brazed steel plates, has separate valve openings and

passages to allow air and coolant to ﬂ ow in and out of the

compressor. See Figure 1 for an external view, and Figure

3 for an exploded view.

The compressor is equipped with a safety valve in the

cylinder head safety valve port, directly connected to the

discharge port. The safety valve protects the compressor

head in the event of excessively high discharge line

pressure, for example, in the event of blockage downstream

of the compressor. Excessive air pressure causes the

safety valve to unseat, releases air pressure and gives an

audible alert to the operator.

The compressor is cooled by air ﬂ ow as well as by engine

coolant. The engine coolant ﬁ rst enters the crankcase

water jacket to cool the cylinder bore, then passes through

passages in the valve plate assembly, cooling plate, and

cylinder head and then out of a port at the top of the

compressor, back to the engine.

A nameplate is attached to a ﬂ at cast face on the side of

the crankcase. It is stamped with information identifying

the compressor designation, customer piece number,

compressor assembly part number and serial number.

See Figure 2.

GENERAL INFORMATION

This Bendix® 360cc compressor is a “discharge line

unloader” (DLU) style compressor, meaning that the

compressor pumps continuously, unlike some compressor

designs which use an "unloader" mechanism in the

compressor head to switch from a pumping mode to a

non-pumping mode. Instead, the control of air delivery to

the vehicle’s air system is managed by using a separate

discharge line unloader valve mounted in parallel with a

turbo cut-off style of air dryer (see Figure 6).

SD-01-3121

BENDIX

360CC SINGLE CYLINDER COMPRESSOR FOR

INTERNATIONAL MAXXFORCE

™

11 AND 13 BIG BORE ENGINES

MAXXFORCE

™

is a trademark of International Engine Intellectual Property Company, LLC.

FIGURE 1 - BENDIX

360cc SINGLE CYLINDER

COMPRESSOR

FIGURE 2 - NAMEPLATES (TWO STYLES)

Safety

Valve

Cooling

Plate

Valve Plate

Assembly

Cylinder

Head

Crankcase

Coolant

Enters Here

Locating

Pins

Coolant Exits at

Top of Head

(See Figure 7)

Bendix Part Number . . . . . . A

Customer Piece Number . . . . B

Compressor Serial Number . . C

Summary of content (36 pages)

PAGE 1
SD-01-3121 BENDIX® 360CC SINGLE CYLINDER COMPRESSOR FOR INTERNATIONAL MAXXFORCE™ 11 AND 13 BIG BORE ENGINES DESCRIPTION The function of the air compressor is to provide and maintain air under pressure to operate devices in air brake systems. The Bendix ® 360cc compressor is a single-cylinder compressor with a rated displacement of 15.8 cubic feet per minute at 1250 RPM. The compressor consists of an integral water-cooled cylinder head assembly and watercooled crankcase.
PAGE 2
Safety Valve Cylinder Head Cooling Plate Valve Plate Assembly Connecting Rod Piston Mounting Face Crankcase Nameplate Drive Gear Crankshaft FIGURE 3 - BENDIX® 360cc SINGLE CYLINDER COMPRESSOR (CUT-AWAY VIEW) The crankcase has an open side with a machined face and locating pins. This open face is bolted directly to the side of the engine block, see Figure 3. The compressor gear engages the engine drive gear.
PAGE 3
Air Discharge Port Air Inlet Port system requires air. It requires a downstream device (e.g. turbo cut-off style air dryer and discharge line unloader valve) to unload the system when the air system has sufﬁcient stored compressed air. Discharge Valve Open LUBRICATION The vehicle’s engine provides a continuous supply of oil to the compressor. Oil is routed from the engine to the compressor’s oil inlet.
PAGE 4
Head Bolt (4) Coolant Out Only Port Closed Inlet Port Discharge Port or Safety Valve Port EVERY 6 MONTHS, 1800 OPERATING HOURS OR AFTER EACH 50,000, MILES WHICHEVER OCCURS FIRST, PERFORM THE FOLLOWING INSPECTIONS AND TESTS. AIR INDUCTION A supply of clean air is one of the single most important factors in compressor preventive maintenance. Since the air supply for 360cc Single Cylinder Compressor and engine is the engine air cleaner, periodic maintenance of the engine air ﬁlter is necessary.
PAGE 5
Bendix has developed the “Bendix Air System Inspection Cup” or BASIC kit to help substantiate suspected excessive oil passing. The steps to be followed when using the BASIC kit are presented in APPENDIX B, on page A-16. COMPRESSOR DRIVE Check for noisy compressor operation, which could indicate excessive drive component wear. Adjust and/or replace as necessary. Check all compressor mounting bolts and retighten evenly if necessary. Check for leakage. Repair or replace parts as necessary.
PAGE 6
be tested separately. Refer to the various maintenance manuals for individual component leakage tests and the Bendix “Test and Checklist” published in the Air Brake System Handbook (BW5057) and on the back of the Dual Circuit Brake System Troubleshooting Card (BW1396). MAINTENANCE KITS & SERVICE PARTS CYLINDER HEAD Discharge Safety Valve Kit Check the cylinder head gaskets for air leakage. Compressor to Engine Mounting Face Sealant . . . . . . . . . . Supplied by the Engine Manufacturer 1.
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component or plug unless you are certain all system pressure has been depleted. 8. 9. Use only genuine Bendix ® replacement parts, components and kits. Replacement hardware, tubing, hose, ﬁttings, etc. must be of equivalent size, type and strength as original equipment and be designed speciﬁcally for such applications and systems. Components with stripped threads or damaged parts should be replaced rather than repaired.
PAGE 8
2 ST-4™ Safety Valve 1 Head Cap Screws (4) (include washers) 3 Washer 15 Cylinder Head 4 Head Gasket (2) 14 Cooling Plate 5 Inlet Reed/Valve Gasket 13 Valve Plate Assembly 6 Crankcase Alignment Pins (x2) 12 Crankcase O-ring 11 Crankcase 7 Cap Screws (x2) 10 Cover 8 End Cover Item Qty.
PAGE 9
CRANKCASE FRONT COVER 1. Remove the cover (10) from the front of the crankcase. Use a sharp ﬂat head screw driver or a scraper. Place the edge under the lip along the outside diameter of the cover. Pry the cover from the cast surface until the cover can be removed. M8x1.25 Cap Screws (Smaller) M10x1.5 Cap Screws (Larger) REAR END COVER 1. Note: There are 2 cap screws (7) used to retain the end cover to the crankcase.
PAGE 10
damage. Minor thread chasing is permitted, but do not re-cut the threads. If any of these conditions are found, replace the compressor. CRANKCASE Check the cylinder head gasket surface on the deck (top) of the crankcase (11) for nicks, gouges, and marring. A metal gasket is used to seal the cylinder head to the crankcase. This surface must be smooth and free of all but the most minor scratching. If excessive marring or gouging is detected, the compressor must be replaced.
PAGE 11
2. Secure the compressor on the engine mounting interface using the 6 mounting bolts. NOTE: There are 2 short bolts and 4 long bolts. Be sure the use the proper length bolt for the crankcase bolt holes. Run each of the bolts down ﬁnger tight, making sure not to smear the liquid gasket material on the sealing surface. Once the bolts are all ﬁnger tight; tighten the mounting bolts per Engine Manufacturers recommended torquing sequence and torque requirements. 3.
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Notes 12
PAGE 13
Appendix A Advanced Troubleshooting Guide for Air Brake Compressors The guide consists of an introduction to air brake charging system components, a table showing recommended vehicle maintenance schedules, and a troubleshooting symptom and remedy section with tests to diagnose most charging system problems. INDEX Symptom Page Number Air Symptom Page Number Coolant Air brake charging system: Slow build (9.0) .....................................A-9-10 Doesn’t build air (10.0) .........................
PAGE 14
Introduction to the Air Brake Charging System Powered by the vehicle engine, the air compressor builds the air pressure for the air brake system. The air compressor is typically cooled by the engine coolant system and lubricated by the engine oil supply.
PAGE 15
Table A: Maintenance Schedule and Usage Guidelines Regularly scheduled maintenance is the single most important factor in maintaining the air brake charging system. Vehicle Used for: No. of Axles Column 1 Column 2 Typical Compressors Spec'd Discharge Line I.D. Length 1/2 in. 6 ft.
PAGE 16
Air Brake Charging System Troubleshooting Look for: How to use this guide: Find the symptom(s) that you see, then move to the right to ﬁnd the possible causes (“What it may indicate”) and remedies (“What you should do”). Review the warranty policy before performing any intrusive compressor maintenance. Unloader or cylinder head gasket replacement and resealing of the bottom cover plate are usually permitted under warranty. Follow all standard safety procedures when performing any maintenance.
PAGE 17
Symptom: What it may indicate: What you should do: 2.0 Oil on the Outside of the Compressor Engine and/or other accessories leaking onto compressor. Find the source and repair. Return the vehicle to service. 2.1 Oil leaking at compressor / engine connections: (a) Leak at the front or rear (fuel pump, etc.) mounting ﬂange.  Repair or replace as necessary. If the mounting bolt torques are low, replace the gasket. (b) Leak at air inlet ﬁtting.  Replace the ﬁtting gasket.
PAGE 18
Symptom: 4.0 Oil in Supply or Service Reservoir (air dryer installed) (If a maintained Bendix® PuraGuard® system ﬁlter or Bendix® PuraGuard® QC oil coalescing ﬁlter is installed, call 1-800-AIR-BRAKE (1-800-247-2725) and speak to a Tech Team member.) What it may indicate: What you should do: Maintenance (a) If air brake charging system maintenance has not been performed.
PAGE 19
Symptom: 4.0 Oil in Supply or Service Reservoir* (air dryer installed) (continued) What it may indicate: What you should do: Temperature (e) Air compressor discharge and/or air dryer inlet temperature too high. (f) Insufﬁcient coolant ﬂow.  Inspect coolant line. Replace as necessary (I.D. is 1/2").  Inspect the coolant lines for kinks and restrictions and ﬁttings for restrictions. Replace as necessary. (f) (e)  Check temperature as outlined in Test 3 on page A-14.
PAGE 20
Symptom: 4.0 Oil in Supply or Service Reservoir* (air dryer installed) (continued) What it may indicate: What you should do: Other (cont.) (i) Poorly filtered inlet air (poor air quality to compressor).  Check for leaking, damaged or defective compressor air inlet components (e.g. induction line, ﬁttings, gaskets, ﬁlter bodies, etc.). Repair inlet components as needed. Note: Dirt ingestion will damage compressor and is not covered under warranty. Inspect the engine air cleaner.
PAGE 21
Symptom: What it may indicate: What you should do: 6.0 Excessive oil consumption in engine. A problem with engine or other engine accessory.  See engine service manual. 7.0 Oil present at air dryer cartridge during maintenance. Air brake charging system is functioning normally. The engine service manual has more information. Oil shown leaking from an air dryer cartridge.  Air dryers remove water and oil from the air brake charging system. A small amount of oil is normal.
PAGE 22
Symptom: 9.0 Air brake charging system seems slow to build pressure. (continued) What it may indicate: What you should do: (f) Restricted discharge line.  If discharge line is restricted:  By more than 1/16" carbon build-up, replace the discharge line (see Table A, column 2, on page A-3 for recommended size) and go to Test 3 on page A-14.  By other restrictions (e.g. kinks). Replace the discharge line. See Table A, column 2, on page A-3 for recommended size. Re test for air build.
PAGE 23
Symptom: 10.0 Air charging system doesn’t build air. What it may indicate: What you should do: (a) Governor malfunction*.  Go to Test 4 on page A-15. (b) Restricted discharge line.  See 9.0(f). (c) Air dryer heater malfunction: exhaust port frozen open.  Replace air dryer heater. (d) Compressor malfunction.  Replace the compressor only after making certain the preceding conditions do not exist.
PAGE 24
Symptom: 12.0 Air dryer safety valve releases air. Air dryer safety valve  What it may indicate: What you should do: (a) Restriction between air dryer and reservoir.  Inspect delivery lines to reservoir for restrictions and repair as needed. (b) Air dryer safety valve malfunction.  Verify relief pressure is at vehicle or component manufacturer speciﬁcations. Replace if defective. (c) Air dryer maintenance not performed.
PAGE 25
Symptom: 16.0 Compressor leaks air (b) is not applicable for the compressor featured in this SD sheet —- information is shown for reference only. What it may indicate: What you should do: (a) Compressor leaks air at connections or ports.  Check for leaking, damaged or defective compressor ﬁttings, gaskets, etc. Repair or replace as necessary. (b) Compressor unloader mechanism malfunction.  Go to Test 6 on page A-15. (c) Damaged compressor head gasket(s).
PAGE 26
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 for Weepage Observe the amount of weepage from the head gasket.
PAGE 27
Tests (continued) Test 4: Governor Malfunction 1. Inspect control lines 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® governor, verify cut-in and cut-out pressures are within vehicle OEM speciﬁcation. 3. If the governor is malfunctioning, replace it. Test 5: Governor Control Line 1.
PAGE 28
Appendix B: Information about the BASIC™ Test Kit (Bendix P/N 5013711) Service writer records info - including the number of days since all air tanks were drained - and fills out symptom checklist. Technician inspects items. days Bendix® Air System Inspection Cup (BASIC™) Test Information START BASIC TEST Park vehicle on LEVEL ground. Chock wheels, drain air from system. Drain contents of ALL air tanks into BASIC™ cup Is there less than one unit of liquid? Vehicle OK. Return vehicle to service.
PAGE 29
Appendix B 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.
PAGE 30
Appendix B 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. 2. Record amount of oil found: The Technician uses the chart (label) on the BASIC™ test cup to help decide the action to take, based on the amount of oil found.
PAGE 31
Appendix C Technical Bulletin Bulletin No.: TCH-008-021 Page: 1 of 2 Subject: Air Effective Date: 11/1/92 Brake System - Cold Weather Operation Tips As the cold weather approaches, operators and ﬂeets alike begin to look to their vehicles with an eye toward “winterization”, and particularly what can be done to guard against air system freeze-up. Here are some basic “Tips” for operation in the cold weather.
PAGE 32
Appendix C: Continued Bulletin No.: TCH-008-021 Page: 2 of 2 Effective Date: 11/1/92 High Duty Cycle Vehicles (City Transit Coaches, Refuse Haulers, Etc.) The maximum discharge line length is 16 feet. Length I.D. min. Other Requirements 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.
PAGE 33
Appendix D Technical Bulletin Bulletin No.: TCH-008-022 Page: 1 of 1 Subject: Additional Effective Date: 1/1/1994 Cold Weather Operation Tips for the Air Brake System 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 34
Appendix E Application Matrix for Bendix® 360cc Single Cylinder and 720cc Twin Cylinder Compressors for International Maxxforce™ Big Bore Engines This useful Compressor Application Guide is a simple point system using vehicle conﬁguration and vocation options to help calculate the Bendix® compressor right for your vehicle.
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Appendix E Increasing Performance Compressor Application School Bus / RV / Air over Hydraulic Point Total 360cc Single any  City Transit Bus / Highway Travel Coach / Express Route Coach any School Bus Rural Route (No Auto Brake) any School Bus City Route (No Auto Brake) any Pick-up & Delivery 720cc Dual     2.5 - 9  9.5 - 13 Line Haul   3-6 6.5 - 9  9.5 - 13 Rural or Commercial Refuse 6.5 - 9 Rural or Commercial Refuse / Yard or Terminal Jockey 9.
PAGE 36
Appendix E Example #1: Typical Line Haul Application Vehicle Conﬁguration 1. Not Applicable 2. Total number of all axles 3. Total number of non-steerable lift axles 4. Total number of steerable lift axles 5. Tractor is equipped with air suspension = = = = 3 0 0 .5 points points points point = 0 points Vocation Options 6, 7, 8, 9, 10, 11, 12 (Not Applicable) Total [ 3 + 0.5 = 3.