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Sd-01-690 Bendix® Ba-921® Compressor: Standard and Closed Room

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Sd-01-690 Bendix® Ba-921® Compressor: Standard and Closed Room SD-01-690 BENDIX® BA-921® COMPRESSOR: STANDARD AND CLOSED ROOM "STANDARD" AND "CLOSED ROOM" VERSIONS Safety Cylinder Valve This service data sheet covers two versions of the Bendix® BA-921® Head compressor. The fi rst version was originally released in 2002 and will be referred to as the “Standard” compressor in this Service Data sheet. The Standard compressor was offered on Caterpillar ACERT Medium Valve Plate Assembly and Heavy duty engines, and the DDC S60 EGR (2002-06) engine. Cooling These installations required an externally-mounted inlet check valve Plate (ICV) on the air inlet side of the compressor. Depending on whether the air induction system was naturally aspirated or turbocharged dictated whether or not additional hardware was required along with the ICV (See Figure 6, page 3 and Section 1 of "Air Induction", on page 6). Crankcase The second version was originally released in 2007 and will be referred to as the “Closed Room” compressor in this service data sheet. This compressor is only permitted to be naturally aspirated – use of engine turbocharger as an air source is not allowed. This compressor eliminates the need for an externally mounted inlet check valve (ICV) on the air inlet side of the compressor (See Figure 6, page 3). Refer to Figure 2 below to see the visual differences between the two BA-921® compressor heads. Other differences between the two versions will be referenced throughout this Service Data sheet. (STANDARD VERSION SHOWN) DESCRIPTION FIGURE 1 - BENDIX® BA-921® COMPRESSOR The function of the air compressor is to provide and maintain air under pressure to operate devices in air brake systems. two sealing gaskets. Depending on the application, the ® ® The Bendix BA-921 compressor is a single-cylinder cylinder head and cooling plate may be aluminum or cast reciprocating compressor with a rated displacement of iron. The cylinder head contains air and water ports as 15.8 cubic feet per minute at 1250 RPM. well as an unloader assembly. A cooling plate is located The compressor consists of a water-cooled cylinder between the cylinder head and valve plate assemblies and head assembly and an integral air-cooled crankcase assists in cooling. assembly. The valve plate assembly consists of brazed steel plates The cylinder head assembly is made up of the cylinder which have valve openings and passages for air and head, cooling plate and valve plate assembly and uses engine coolant to fl ow into and out of the cylinder head. Standard: Standard: Closed Room: Aluminum Cast Iron Aluminum Cylinder Head Cylinder Head Cylinder Head With 4 With 4 With 6 Bolts Bolts Bolts FIGURE 2 - BENDIX® BA-921® COMPRESSOR: STANDARD AND CLOSED ROOM VERSIONS Splash Coolant Ports Unloader Shield (3 total) Coolant Ports Cover Unloader (3 total) Cover Unloader Unloader Air Piston Piston Intake Discharge Cooling Discharge Cooling Reed Plate Reed Plate Valves (2) Valves (2) Crankshaft Piston Piston Piston Piston Rod Rod Crankshaft Crankcase Crankcase Cover Cover Standard Closed Room FIGURE 3 - BENDIX® BA-921® COMPRESSOR (CUT-AWAY) (STANDARD AND CLOSED ROOM) The compressor's discharge valves are part of the valve Compressor Model, plate assembly. The inlet reed valve/gasket is installed Customer Piece Number, Bendix Piece Number and between the valve plate assembly and the top of the Serial Number shown here crankcase. The cast iron crankcase houses the piston assembly, FIGURE 4 - CRANKCASE BASE COVER connecting rod, crankshaft and related bearings. is stamped with information identifying the compressor ® ® All Bendix BA-921 compressors are equipped with a model, customer piece number, Bendix piece number and safety valve to protect the compressor head in the event serial number. See Figures 1 and 4. of, for example, a discharge line blockage downstream of the compressor. Excessive air pressure will cause the OPERATION safety valve to unseat, release air pressure and give an The compressor is driven by the vehicle's engine and audible alert to the operator. The safety valve is installed functions continuously while the engine is in operation. in the cylinder head safety valve port, directly connected Actual compression of air is controlled by the compressor to the cylinder head discharge port. unloading mechanism operating in conjunction with a The crankcase cover located at the bottom of the crankcase governor. Caterpillar Caterpillar Detroit C7, C9 HD Acert Diesel S60 Engines Engines FIGURE 5 - TYPICAL COMPRESSOR DRIVE FLANGES 2 Standard Compressors use an Inlet Check Valve Air Inlet Discharge (ICV), or alternately, an ICV plus a reservoir, Air Port Valve Closed Unloader in the air inlet line depending on the application Discharge Port Port Governor Air Dryer Unloader Port Cooling Plate Governor Valve Reservoir Plate Port Unloader Piston Compressor Down & Seated Supply Reservoir Inlet Valve Closed Room Compressor Typical System Open Governor Air Dryer Unloader Port Piston Moving Down FIGURE 7A - OPERATION - LOADED (INTAKE). (SIMILAR FOR ALL COMPRESSORS - STANDARD COMPRESSOR Governor Reservoir SHOWN) Port Compressor Air Inlet Discharge Port Valve Unloader Supply Reservoir Air Open Port Discharge FIGURE 6 - STANDARD AND CLOSED ROOM BA-921® Port COMPRESSOR CHARGING SYSTEMS AIR INTAKE (LOADED) Cooling Just as the piston begins the down stroke, (a position Plate known as top dead center, or TDC), the vacuum created Valve in the cylinder bore above the piston causes the inlet Plate reed valve to fl ex open. Atmospheric air (in naturally Inlet Unloader Valve Piston aspirated applications) or pressurized air (in turbocharged Closed Down & applications) fl ows through the open inlet valve and fi lls the Seated cylinder bore above the piston. See Figure 7A. AIR COMPRESSION (LOADED) When the piston reaches the bottom of the stroke, (a position known as bottom dead center, or BDC), the inlet reed valve closes. Air above the piston is trapped by the Piston Moving Up closed inlet reed valve and is compressed as the piston moves upwards. When air in the cylinder bore reaches FIGURE 7B - OPERATION - LOADED (COMPRESSION) a pressure greater than that of the system pressure, the (SIMILAR FOR ALL COMPRESSORS - STANDARD discharge reed valves open and allow air to fl ow into the COMPRESSOR SHOWN) discharge line and air brake system. At the same time air fl ows into the hollow center of the unloader piston through an opening in the end of the piston. Compressed air acts on the interior surfaces of the unloader piston and, along with the unloader piston spring, holds the unloader piston in the down position, against its seat on the valve plate. See Figure 7B. 3 Air From Air From Air Inlet Port Governor Governor Unloader Unloader Port Port Cooling Plate Valve Unloader Closed Plate Piston Up & Room Unseated Unloader Piston Up & Unseated Air in Pistons Shuttles Back and Forth from the Piston to the Cylinder Head and Inlet Port During Air in Pistons Shuttles Back and Forth from the Unloaded Mode Piston to the Closed Room FIGURE 8 - OPERATION - UNLOADED (STANDARD) FIGURE 9 - OPERATION - UNLOADED (CLOSED ROOM) NON-COMPRESSION OF AIR (UNLOADED) Section 1: For Standard Compressor. See Figure 8. Section 2: For Closed Room Compressor. See Figure 9. When air pressure in the supply reservoir reaches the When air pressure in the supply reservoir reaches the cutout setting of the governor, the governor delivers cutout setting of the governor, the governor delivers system air to the compressor unloader port. Air entering system air to the compressor unloader port. Air entering the unloader port acts on the unloader piston causing the the unloader port acts on the unloader piston causing piston to move upwards, away from its seat on the valve the piston to move away from its seat on the valve plate plate assembly. When the unloader piston is unseated assembly. When the unloader piston is unseated, an air an air passageway is opened between the cylinder bore passageway is opened between the cylinder bore and a and the air inlet cavity in the cylinder head. secondary compartment or “closed room” in the interior of As the piston moves from bottom dead center (BDC) to the cylinder head. top dead center (TDC) air in the cylinder bore fl ows past As the piston moves from bottom dead center (BDC) to top the unseated unloader piston, into the cylinder head inlet dead center (TDC) air in the cylinder bore fl ows past the cavity and out the inlet port. To prevent the air from fl owing unseated unloader piston, into the “closed room”. The size back into the engine air induction system, an inlet check of the closed room is suffi cient to accept the compressed valve (ICV) is installed upstream of the air compressor inlet air provided by the compressor piston without creating port. The location of the device and the way it is plumbed excessive air pressure in the “closed room”. On the piston into the compressor air induction system is unique to the down stroke (TDC to BDC) air fl ows in the reverse direction, specifi c engine and the type of air induction (naturally from the “closed room” past the unseated unloader piston aspirated or boosted air) the compressor uses. These air and inlet reed valve, and into the cylinder bore. Note: For induction systems will be explained in further detail in the optimum performance, it is recommended that the air dryer “Air Induction” section on page 4. On the piston down is equipped with “turbo cut-off”. stroke (TDC to BDC) air fl ows in the reverse direction, from the inlet cavity past the unseated unloader piston and inlet reed valve, and into the cylinder bore. 4 LUBRICATION Head Discharge Coolant In or Out Bolt (4) The vehicle's engine provides a continuous supply of oil Safety Valve (One or other not used) to the compressor.
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