Cat Air Compressor Service Manual

  1. CATERPILLAR TIER 3. All parts must meet the same specifications as new. To the precise technical specifications expected of a Sullair air compressor.
  2. AIR CONDITIONER & HEAT PUMP SERVICE MANUAL This Service Manual is the result of the dedication of The Dometic Cor.

If you need to find the specs for your air compressor, you'll need to consult your owner's manual. Finding the manual from a few years back is no easy task so Air Compressors Direct has created a quick and easy air compressor manual lookup.

. ® 550 AIR COMPRESSOR (EXTERIOR) The function of the air compressor is to provide and maintain air under pressure to operate devices in the air brake and/or auxiliary air systems.

The Bendix ® Tu-Flo ® UNLOADER compressor is a two cylinder single stage, reciprocating CYLINDER compressor with a rated displacement of 13.2 cubic feet. The down stroke is being compressed.

Cat Air Compressor Service Manual

Air pressure on the MANUFACTURED BY BENDIX inlet valve plus the force of the inlet spring, returns the inlet valve to its seat and closes. The piston continues the FIGURE 3 - NAMEPLATE upward stroke and compressed air pushes the discharge valve off its seat and air fl.

UNLOADER DISCHARGE PISTON GOVERNOR GOVERNOR DISCHARGE PORT PORT PORT PORT INLET PORT INLET PORT INLET VALVE INLET HELD OPEN VALVE DISCHARGE DISCHARGE BY UNLOADER OPEN VALVE VALVE PISTON CLOSED CLOSED PISTON MOVING DOWN FIGURE 4 - OPERATIONAL-LOADED (INTAKE) FIGURE 6 - OPERATIONAL-UNLOADED force the pistons upward and the inlet valves return to their GOVERNOR DISCHARGE. (see column 2 of Table A in the Troubleshooting section) assumes a compressor with a normal (less than 25%) duty cycle, operating in a temperate climate. See Bendix and/or other air dryer manufacturer guidelines as needed. The discharge line must maintain a constant slope down from the compressor to the air dryer inlet fi. (238948) be installed with an inlet gasket (291909) on both sides of the screen. FIGURE 7 - LUBRICATION For vehicles with accessories that are sensitive to small WATER amounts of oil, we recommend installation of a Bendix ® ® ™ PuraGuard oil coalescing fi. COMPRESSOR TURBOCHARGING POLYURETHANE SPONGE STRAINER PARAMETERS Every month, 150 operating hours or 5,000 miles, whichever occurs fi rst, remove and wash all of the parts.

Air entering the compressor inlet during the loaded cycle The strainer element should be cleaned or replaced. If the must not exceed 250 degrees Fahrenheit (121 degrees element is cleaned, it should be washed in a commercial Celsius). INTAKE ADAPTER Bendix has developed the 'Bendix Air System Inspection Cup' or BASIC test to help substantiate suspected When the engine air cleaner is replaced: Some excessive oil passing. The steps to be followed when using compressors are fi tted with compressor intake adapters.

Do not use marking methods such as chalk that can returned to the nearest authorized Bendix distributor for a be wiped off or obliterated during rebuilding. Factory remanufactured compressor. If it is not possible. COMPRESSOR CRANKCASE DISASSEMBLY material (5) from the cover plate, cylinder head and crankcase. Remove the key or keys (30) from the crankshaft (29) and any burrs from the crankshaft where the key or keys 1.

Remove the unloader pistons (7), o-rings (6) and were removed. CYLINDER HEAD CRANKCASE BASE MOUNT NAMEPLATE CRANKCASE BALL BEARING (MACK EXTENDED FLANGE) FLANGE MOUNT ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION Cylinder Head Cap Screws Discharge Valve Spring Thrust Washer Unloader Plate Cap Screws Discharge Valve Sleeve (or Ball) Bearing Unloader Plate Lock Washers Discharge Valve Stop End Cover Seal. END COVERS PISTON RINGS Check for cracks and external damage.

If the crankshaft Check the pistons for scores, cracks or enlarged ring main bearing (32) is installed in the end cover (34), grooves; replace the pistons if any of these conditions are check for excessive wear and fl. Discharge valve travel should be between.030 in.

To test for leakage by the discharge valves, apply 100 psi to the cylinder head discharge port and apply a soap solution to the discharge valve and seats. Leakage TU-FLO OTHER BENDIX ® ® AIR COMPRESSOR TU-FLO AIR COMPRESSORS ®.

Install the other connecting rod and piston in the same Tu-Flo ® 550 compressor are similar to those of other Bendix manner. It is recommended that new connecting rod cap compressor models but may be identifi ed by the piston screws be used. Connect to the compressor discharge port, a reservoir with TORQUE SPECIFICATIONS a volume of 1500 cubic inches, including the volume of the Bolt, Nut or Screw.Assembly Torque connecting line. With the compressor operating at 2100 (in.

Lbs.) R.P.M., the time required to raise the reservoir(s) pressure Cylinder Head. Never connect or disconnect a hose or line containing pressure; it may whip.

Never remove a component or plug unless you are certain all system pressure has been depleted. Use only genuine Bendix ® replacement parts, components and kits.


Replacement hardware, tubing, hose, fi. 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. (less than 25%) duty cycle, operating in builds the air pressure for the air brake system. The air a temperate climate. See Bendix and/or other air dryer compressor is typically cooled by the engine coolant system manufacturer guidelines as needed. Discharge line upgrades are not covered under warranty.

Note: To help prevent discharge line freeze-ups, shorter discharge line For Bendix ® Tu-Flo ® 550 and 750 compressors, unloader service is lengths or insulation may be required in cold climates. (See Bendix recommended every 250,000 miles. Discontinue using this test.

Not a valid test. Results Do not use this card test to diagnose compressor 'oil passing' issues. They are subjective and error prone. Use only the Bendix ® System Inspection Cup (BASIC ™ ) test and the methods described in this guide for advanced troubleshooting. Return the vehicle to service.

An optional kit (Bendix piece number 5011327 for the Bendix AD-IS or AD-IP ™ ® ® ™ air dryers, or 5003838 for the Bendix AD-9 ® air dryer) is available to redirect the air dryer exhaust. BASIC test member.) in Table A on page A-3, some oil in cup (Bendix Air System Inspection Cup). If the reservoirs is normal. Less than one unit of reservoir contents is found, the vehicle can be returned to ser- vice. Note: If more than one oil unit of. 45 degree fi tting.

For more information on Kinked discharge line shown. How to help prevent discharge line freeze- ups, see Bendix Bulletins TCH-08-21 and TCH-08-22 (Appendix B). Shorter discharge line lengths or insulation may be required in cold climates. Note: After all other operating conditions have been investigated. Replacing a compressor, residual oil may Bendix compressors are designed to have a 'dry' take a considerable period of time to be sump and the presence of excess oil in the crankcase fl. Symptom: What it may indicate: What you should do: 6.0 Excessive oil A problem with engine or other engine See engine service manual.

Consumption in engine. The engine service manual has more information. 7.0 Oil present Air brake charging system is functioning Air dryers remove water and oil from at air dryer normally. These can increase the rate at which carbon Bendix Bulletins TCH-08-21 and TCH-08-22 builds up in the discharge line.

Bendix recommends oil (Appendix B). Shorter discharge line soot (solids) be maintained at less than 3%. Replace air dryer heater.

Exhaust port frozen open. (d) Compressor malfunction. Replace the compressor only after making certain the preceding conditions do not exist.

Note: For the Bendix ® DuraFlo ™ 596 air compressor, not only the governor, but also the SV-1 ™. Symptom: What it may indicate: What you should do: 12.0 Air dryer (a) Restriction between air dryer and Inspect delivery lines to reservoir for reservoir. Safety valve restrictions and repair as needed. Releases air. (b) Air dryer safety valve Verify relief pressure is at vehicle or malfunction. Symptom: What it may indicate: What you should do: (a) Compressor leaks air at connections 16.0 Compressor Check for leaking, damaged or defective leaks air or ports.

Compressor fi ttings, gaskets, etc. Repair or replace as necessary. (b) Compressor unloader mechanism Go to Test 6 on page A-15. 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.

Ingersoll Rand Air Compressor Service Manual

Observe the amount of weepage from the head gasket. Test 6: Compressor Unloader Leakage ® shut-off and charge the unloader port by allowing Bendix Compressors: Park vehicle, chock wheels, and follow all standard safety procedures. Air pressure to enter the hose and unload the compressor. 30 days. returning. (Note that 30-90 days is the recommended air tank known?

Drain schedule for vehicles equipped with a Bendix air dryer that YES, number of days is properly maintained.) If, in cold weather conditions, the 30 day was known (30 - 90 days) Replace the Compressor. Footnote 2: To get an accurate reading for the amount of oil collected during a 30 day period, ask the customer not to drain the air tanks before returning. (Note that 30-90 days is the recommended air tank drain schedule for vehicles equipped with a Bendix air dryer that are properly maintained.) If, in cold weather conditions, the 30 day air tank drain schedule is longer than the customer's usual draining interval, the customer must determine, based on its experience with the vehicle, whether to participate now, or wait for warmer weather.

™ 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. Last 3 feet, including fi tting at the end of the discharge line, must be insulated with ½ inch thick closed cell polyethylene pipe insulation. If the discharge line length must be less than 6 feet or greater than 16 feet, contact your local Bendix representative. Other Requirements 10-16 ft.

Bendix Air Compressor

None If the discharge line length must be less than 10 feet or greater than 16 feet, contact your local Bendix representative. System Leakage Check the air brake system for excessive air leakage using the Bendix “Dual System Air Brake Test and Check List”.

Sullair 185 Air Compressor Service Manual

Appendix D Technical Bulletin Bulletin No.: TCH-008-022 Effective Date: 1/1/1994 Page: 1 of 1 Additional Cold Weather Operation Tips for the Air Brake System Subject: 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. BW1639 © 2007 Bendix Commercial Vehicle Systems LLC. All rights reserved. 3/07 Printed in U.S.A.

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