BENDIX AIR COMPRESSOR 1W150R AIR COMPRESSO Caterpillar


Air Compressor Components

Usage:

The air compressor flange mounting is also part of the cylinder and crankcase (17). The reed valve plate assembly is (13). The cylinder head (11) is cast aluminum which is partially finned to assist in cooling. Delivery port (9) is the air delivery connection. Water port (7) is one of two cooling water connections.

The delivery valve (air) is (1) and air inlet port is (3). The inlet reed valve is (4). The unloader valve assembly is (5) which is retained in position by circlip (6). The governor signal port connection to the separately mounted D2 Governor. A cylinder head gasket (12) is installed between the cylinder head (11) and the reed valve plate assembly (13). Reed valve plate assembly gaskets (10) are installed between the reed valve plate assembly (13) and the cylinder and crankcase (17).

An aluminum piston is fitted with two compression rings (15) and an oil control ring (16). The wrist pin (18) is held in position by two circlips (19). The forged crankshaft (20) rotates in two crankshaft bearings (22). One of the crankshaft bearing is installed in the end cover (23). End cover (23) is machined to carry the vehicle power steering pump which is driven by drive tang (24) located on the end of crankshaft (20).

A sump plate (26) is installed on the bottom of the crankcase. The connecting rod assembly (25) is made from a forged light alloy which forms an excellent bearing surface. The connecting rod is in direct contact with the crankshaft journal and wrist pin and eliminates the need for connecting rod and wrist pin bearings.

Operation

General

The air compressor is driven by the 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 remote mounted and maintains the brake system air pressure between a preset maximum and minimum pressure level.

Intake And Compression Of Air (Loaded)

Air is drawn from the engine air cleaner through air inlet port (3). The rotation of crankshaft (20) controls the reciprocating action of piston assembly (14) through connecting rod assembly (25). On the downward stroke of the piston, inlet reed valve (4) is drawn away from its seat on the underside of reed valve plate assembly (13). At the same time, this same downward movement of the piston, holds delivery valve (1) against its seat on the upper surface of the reed valve plate assembly (13). As the piston assembly descends air is drawn through the holes in reed valve plate assembly (13) (via the inlet chamber) into the cylinder bore above piston assembly (14).

At the bottom of the piston stroke, both the inlet reed and delivery valves are closed. As the piston assembly (14) starts to rise the inlet reed valve (4) remains closed. But the increase in pressure opens delivery valve (1) to expose the holes through which the air passes into the delivery chamber and then to the vehicle brake system via delivery port (9).

After the piston reaches the top of its stroke and starts to descend, delivery valve (1) closes and inlet reed valve (4) opens to allow the cycle to start again.

Non-Compression Of Air (Unloaded)

When vehicle system pressure is reached, the brake systems governor valve will send a signal pressure to governor signal port (8). This will lift the unloader valve assembly (5) to reveal the holes in the reed valve plate assembly (13) that it normally seals. The effective seal of the inlet chamber is now lost, and the air compressor is now "off-load". This state will remain until system pressure drops sufficiently to allow the governor to respond and the pressure at governor signal port (8) exhausts. The force of the spring above the unloader piston now closes the unloader valve assembly (5), sealing off the holes in the reed valve plate assembly (13). The air compressor is now in the "on-load" condition.

Lubrication

Oil under pressure from the engine lubricating system enter the air compressor through oil inlet port (21). The oil then flows through cross drilled passages in the crankshaft to the crankshaft bearings (22) and the crankshaft end of the connecting rod. The other internal surfaces are lubricated by oil splash and mist. The oil returns to the engine through a drain in the air compressor mounting flange.

Cooling

Air flowing through the engine compartment from the action of the engine's fan and the movement of the vehicle assists in cooling the crankcase. Coolant flowing from the engine's cooling system 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 220°C (428°F) recommended.

Air Induction

There is only one method of providing clean air to the 1W150R Air Compressor which is via the engine air cleaner of the vacuum side (engine air cleaner) of the turbocharger.

Preventive Maintenance

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.

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. If excessive buildup is noted, thoroughly clean or replace the affected parts and closely inspect the compressor cooling system. Check all compressor coolant lines for kinks and restrictions to flow. Minimum coolant line size is 12 mm (1/2 inch) ID Check coolant lines for internal 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 return lines, if applicable, for kinks, bends, or restrictions to flow. Supply lines must be a minimum of 4.8 mm (3/16 inch) ID and return lines must be a minimum of 12.7 mm (1/2 inch) ID 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 air compressor specifications in the back of this manual for oil 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 compression and unloaded cycles generally indicate loose or worn drive components.

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 all compressor mounting brackets, 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, with the minimum required reservoir volume, must have a compressor capable of raising air system pressure from 590 to 700 kPa (85 to 100 psi) in 25 seconds or less. This test is performed with the engine operating at maximum 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.

Check unloader operation by building system pressure to governor cut-out and note that air compression stops. Reduce system pressure to governor cut-in and note that air compression resumes. If the compressor fails to respond as described, make certain the governor is functioning properly before repairing or replacing the compressor.


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 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 containing 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, fittings, etc. 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.

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