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Product: TRUCK ENGINE

Model: 3126E TRUCK ENGINE 9SZ
Configuration: 3126E Truck Engine 9SZ00001-UP

General Service Information

BENDIX AIR COMPRESSOR
Media Number -SENR6455-00 Publication Date -01/10/1993 Date Updated -03/03/2011

SENR64550016

Compressor Troubleshooting
SMCS - 1317-070

Symptom:

1. Compressor passes excessive oil as evidenced by presence of oil at exhaust ports of

valving or seeping from air strainer.

Cause:

A. Restricted air intake.

Check engine or compressor air cleaner and replace if necessary. Check compressor air inlet
for kinks, excessive bends and be certain inlet lines have the minimum specified inside
diameter. Recommended minimum inlet line is 15.9 mm (5/8inch) ID. Recommended
maximum air inlet restriction is 635 mm (25 inches) of water.

B. Restricted oil return (to engine).

Oil return to the engine should not be in any way restricted. Check for excessive bends,
kinks and restrictions in the oil return line. Minimum recommended oil return line size is
15.9 mm (5/8inch) OD tubing or equivalent ID [12.7 mm (1/2 inch) minimum]. Return line
must CONSTANTLY DESCEND from the compressor to the engine crankcase. Make
certain oil drain passages in the compressor and mating engine surfaces are unobstructed
and aligned. Special care must be taken when sealants are used with, or instead of, gaskets.

C. Poorly filtered inlet air.

Check for damaged, defective or dirty air filter on engine or compressor. Check for leaking,
damaged or defective compressor air intake components (ie, induction line, fittings, gaskets,
filter bodies, etc). The compressor intake should not be connected to any part of the exhaust
gas recirculation (EGR) system on the engine.

D. Insufficient compressor cooling (compressor runs hot).

For air-cooled portions of the compressor:

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1. Remove accumulated grease, grime or dirt from the cooling fins. Replace components
found damaged.

2. Check for damaged cooling fins. Replace components found damaged.

For water-cooled compressor or water-cooled portions of the compressor:

1. Check for proper coolant line sizes. Minimum recommended size is 12.7 mm (1/2 inch)
OD tubing.

2. Check the coolant flow through the compressor. Minimum allowable flow is 9.5 liter/min
(2.5 US gpm) at engine governed speed. If low coolant flow is detected, inspect the coolant
lines and fittings for accumulated rust scale, kinks and restrictions.

3. Water temperature should not exceed 93°C (200°F).

4. Optimum cooling is achieved when engine coolant flow, as shown in Fig 8 of this
manual.

E. Contaminants not being regularly drained from system reservoirs.

Check reservoir drain valves to insure that they are functioning properly. It is recommended
that the vehicle should be equipped with functioning automatic drain valves, or have all
reservoirs drained to zero (0) psi daily, or optimally to be equipped with a desiccant-type air
dryer prior to the reservoir system.

F. Compressor runs loaded an excessive amount of time.

Vehicle system leakage should not exceed industry standards of 7 kPa (1 psi) pressure drop
per minute without brakes applied and 20 kPa (3 psi) pressure drop per minute with brakes
applied. If leakage is excessive, check for system leaks and repair.

G. Excessive engine crankcase pressure.

Test for excessive engine crankcase pressure and replace or repair ventilation components
as necessary. (An indication of crankcase pressure is a loose or partially lifted dipstick).

H. Excessive engine oil pressure.

Check the engine oil pressure with a test gauge and compare the reading to the engine
specifications. Bendix does not recommend restricting the compressor oil supply line
because of the possibility of plugging the restriction with oil contaminants. Minimum oil
supply line size is 3/16inch ID tubing.

I. Faulty compressor.

Replace or repair the compressor only after making certain none of the preceding
installation defects exist.

Symptom:

2. Noisy compressor operations.

Cause:

A. Loose drive gear or pulley.

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Inspect the fit of the drive gear on pulley on the compressor crankshaft. The pulley on gear
must be completely seated and the crankshaft nut must be tight. If the compressor
crankshaft surface or its keyway are damaged, it is an indication of loose drive components.
If damage to the compressor crankshaft is detected, replace the compressor. When in
stalling the drive gear or pulley, torque the crankshaft nut to the appropriate torque
specifications. DO NOT BACK OFF THE CRANKSHAFT NUT TO ALIGN THE
COTTER PIN AND CASTELLATED NUT. (Some compressors do not use castellated
nuts). DO NOT USE IMPACT WRENCHES.

B. Excessively worn drive couplings or gears.

Inspect drive gear and couplings and engine for excessive wear. Replace as necessary. (Non
-metallic gears should be replaced when the compressor is changed).

C. Compressor cylinder head or discharge line restrictions.

Inspect the compressor discharge port and discharge line for carbon build-up. If carbon is
detected, check for proper cooling to the compressor. (See Cause and remedy (D) under
Symptom #1). Inspect the discharge line for kinks and restrictions. Replace discharge line as
necessary.

D. Worn or burned out bearings.

Check for proper oil pressure in the compressor. Minimum required oil pressure; 100 kPa
(15 psi) engine idling, 100 kPa (15 psi) maximum governed engine rpm. Check for
excessive oil temperature. Oil temperature should not exceed 115°C (240°F).

E. Faulty compressor.

Replace or repair the compressor after determining none of the preceding installation
defects exist.

Symptom:

3. Excessive build-up and recover time. Compressor should be capable of building air
system from 590 to 700 kPa (85 to 100 psi) in 40 seconds with engine at full governed rpm.
Minimum compressor performance is certified to meet Federal requirements by the vehicle
manufacturer. Do not down-size the original equipment compressor.

Cause:

A. Dirty inducation air filter.

Inspect engine or compressor air filter and replace if necessary.

B. Restricted induction line.

Inspect the compressor air induction line for kinks and restrictions and replace as necessary.

C. Restricted discharge line or compressor discharge cavity.

Inspect the compressor discharge port and line for restrictions and carbon build-up. If a
carbon build-up is found, check for proper compressor cooling. Replace faulty sections of
the discharge line.

D. Slipping drive components.

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Check for faulty drive gears and couplings and replace as necessary. Check the condition of
drive belts and replace or tighten, whichever is appropriate.

E. Excessive air system leakage.

Test for excessive system leakage and repair as necessary. Use the following as a guide:
Build system pressure to governor cutout and allow the pressure to stabilize for one minute.
Using the dash gauge, note the system pressure and the pressure drop after two minutes.

1. 13.8 kPa (2 psi) in each reservoir for a single vehicle.

2. 41.4 kPa (6 psi) each reservoir for a tractor and trailer.
3. 55 kPa (8 psi) in each reservoir for a tractor and 2 trailers.

F. Sticking unloader pistons.

Check the operation of the unloading mechanism. Check the proper operation of the
compressor air governor. If the governor is operating properly, replace the unloader
mechanism. Inspect for bent, linked or blocked tubing leading to or from the governor.

G. Faulty compressor.

Replace or repair the compressor after determining none of the preceding installation
defects exist.

Symptom:

4. Compressor fails to unload.

Cause:

A. Faulty governor or governor installation.

Test the governor for proper operation and inspect air lines to and from the governor for
kinks or restrictions. Replace or repair the governor or its connecting air lines.

B. Faulty or worn unloader pistons or bores.

Inspect for worn, dirty or corroded unloader pistons and their bores. Replace as necessary.

Symptom:

5. Compressor leaks oil.

Cause:

A. Damaged mounting gasket.

Check the compressor mounting bolt torque. If the mounting bolt torque is low, replace the
compressor mounting gasket before retorquing the mounting bolts.

B. Cracked crankcase or end cover.

Visually inspect the compressor exterior for cracked or broken components. Cracked or
broken crankcases or mounting flanges can be caused by loose mounting bolts. The end
cover can be cracked by overtorquing fitting or plugs installed in the end cover. Replace or
repair the compressor as necessary.

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C. Loose end cover cap cover.

Check the cap screw torques and tighten as necessary.

D. Loose oil supply or return line fittings.

Check the torque of external oil line fittings and tighten as necessary.

E. Porous compressor casting.

Replace the compressor if porosity is found.

F. Mounting flange or end cover, O-ring or gasket is missing, cut or damaged.

Replace as necessary.

Symptom:

6. Compressor constantly cycles (compressor remains unloaded for a very short time).

Cause:

A. Leaking compressor unloader pistons.

Remove the compressor inlet air strainer or fitting. With the compressor unloaded (not
compressing air), check for air leakage. Replace as necessary.

B. Faulty governor.

Test the governor for proper operation and repair or replace as necessary.

C. Excessive system leakage.

Test for excessive system leakage (see Symptom #3 Cause (E)). Reduce leakage wherever
possible.

D. Excessive reservoir contaminants.

Drain reservoirs.

Symptom:

7. Compressor leaks coolant.

Cause:

A. Improperly installed plugs and coolant line fittings.

Check torque of fittings and plugs and tighten as necessary. Over-torque fittings and plugs
can crack the head or block casting.

B. Freeze cracks due to improper antifreeze strength.

Test antifreeze and strengthen as necessary. Check coolant flow through compressor to
assure the proper antifreeze mixture reaches the compressor.

C. Faulty compressor (porous castings).

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If casting porosity is detected, replace the compressor.

Symptom:

8. Compressor head gasket failure.

Cause:

A. Restricted discharge line.

Clear restriction or replace line.

B. Loose head bolts.

Tighten evenly to a torque of 34 to 41 N·m (25 to 30 lb ft).

C. Faulty compressor or head gasket.

Check for rough or poorly machined head or block surfaces. Replace compressor as
necessary.

Copyright 1993 - 2016 Caterpillar Inc. Fri Sep 2 20:27:09 UTC-0430 2016
All Rights Reserved.
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