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®
®
®
Bendix
TU-FLO
501 Air Compressor
DESCRIPTION AND OPERATION
General
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.
Description
®
The Tu-Flo
501 compressor is a two cylinder, single stage,
reciprocating compressor with a rated displacement of 12
cubic feet of air per minute at 1250 R.P.M.
The Tu-Flo
®
501 compressor is constructed from two major
assemblies, the head and the crankcase. The head houses
the discharge valving and is installed on the upper portion of
the crankcase. The crankcase is a one piece casting
combining the cylinder block and the crankcase. The upper
portion of the casting houses the cylinder bores and inlet
valving; and the lower portion, the crankshaft and main
bearings. Various mounting and drive configurations, required
by the numerous vehicle engine designs, are obtained by
bolting different mounting flanges, end covers, and base
adapters to the crankcase. Two horizontal governor mounting
pads are located on either side of the upper portion of the
crankcase to provide convenient governor mounting.
Two methods are employed for cooling the Tu-Flo
®
501
compressor during operation. The cylinder head is connected
to the engine's cooling system, while the cylinder bore portion
of the crankcase has external fins for efficient air cooling.
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Related Manuals for BENDIX TU-FLO 501 AIR COMPRESSOR
Summary of Contents for BENDIX TU-FLO 501 AIR COMPRESSOR
- Page 1 ® ® ® Bendix TU-FLO 501 Air Compressor DESCRIPTION AND OPERATION General 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. Description ®...
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Page 2: Various Compressor Mountings
A nameplate is attached to the crankcase to identify the pressure on top of the inlet valve plus the force of its spring, compressor. The nameplate displays a Bendix piece number returns the inlet valve to its seat. The piston continues the or in some cases an engine or vehicle manufacturer’s piece... -
Page 3: Duty Cycle
(less than 25%) duty cycle, air dryer is not used to remove these contaminants prior to operating in a temperate climate. See Bendix and/or other entering the air system, the majority, but not all, will condense air dryer manufacturer guidelines as needed. - Page 4 "cut-out" setting. TO RESERVOIR For vehicles with accessories that are sensitive to small INLET VALVE ® amounts of oil, we recommend installation of a Bendix DISCHARGE UNLOADER PuraGuard ® ™ oil coalescing filter, designed to minimize...
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Page 5: Preventive Maintenance
POLYURETHANE SPONGE STRAINER EVERY 5000 MILES OR 150 OPERATING HOURS Remove and wash all of the parts. The strainer element should be cleaned or replaced. If the element is cleaned, it should be washed in a commercial solvent or a detergent and water solution. -
Page 6: Service Checks
Check the compressor mountings to be sure they are secure. Check the drive for proper alignment, belt tension, etc. to the nearest authorized Bendix Distributor for a factory remanufactured compressor. If this is not possible, the Inspect the oil supply and return lines. Be sure these lines... - Page 7 A convenient method to indicate the above relationship is to If the pistons are removed from the rod, inspect the bronze use a metal scribe to mark the parts with numbers or lines. wrist pin bushing. Press out and replace the bushing if it is Do not use a marking method that can be wiped off or excessively worn.
- Page 8 In addition, Do not use an easy-out for removing these bushings. If the Bendix has developed the "Bendix Air System Inspection inlet valve seats are worn or damaged, so they cannot be Cup" or BASIC test to help substantiate suspected excessive reclaimed by facing, they should be replaced.
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Page 9: Assembly
Crankshaft Check the crankshaft threads, keyways, tapered ends and all machined and ground surfaces for wear, scores, or damage. Standard crankshaft journals are 1.1250 in. to 1.1242 in. in diameter. If the crankshaft journals are excessively scored or worn or out of round and cannot be reground, the crankshaft must be replaced. - Page 10 If the compressor uses a ball type main bearing, press the Secure the flange adapter, front or rear end cover to the ball bearing onto the correct end of the crankshaft. Position crankcase by tightening the four cap screws. See note below the ball bearing and the crankshaft in the crankcase, making for torque.
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Page 11: Inspection
Position and install the inlet valve guides, then drop the inlet During this test, the compressor should be checked for valves in their guides. The inlet valves should be a loose gasket leakage and noisy operation, as well as unloader sliding fit in the guides. - Page 12 Piston displacement at 1250 RPM 12 cu. ft. system pressure has been depleted. Piston displacement per revolution 16.5 cu. in. ® 8. Use only genuine Bendix replacement parts, Maximum recommended RPM components and kits. Replacement hardware, (naturally aspirated) 3000 tubing, hose, fittings, etc. must be of equivalent Minimum coolant flow at maximum RPM 2.5 gal./min.
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Page 13: Table Of Contents
This troubleshooting guide obsoletes and supersedes all previous published troubleshooting information relative to Bendix air compressors. 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. - Page 14 (less than 25%) duty cycle, system and lubricated by the engine oil supply. operating in a temperate climate. See Bendix and/or other air dryer manufacturer guidelines as needed. The compressor's unloader mechanism and governor (along with a synchro valve for the Bendix ®...
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Page 15: Maintenance Schedule And Usage Guidelines (Table A)
Note: To help prevent discharge line freeze-ups, shorter discharge recommended every 250,000 miles. line lengths or insulation may be required in cold climates. (See Bendix Bulletins TCH-08-21 and TCH-08-22, included in Appendix B, for more information.) 5 For certain vehicles/applications, where turbo-charged inlet air is used, a smaller size... -
Page 16: Oil Test Card Results (1.0)
Do not use this card test to diagnose û compressor "oil passing" issues. They are subjective and error prone. Use only the Bendix Air System Inspection Cup (BASIC) test and the methods described in this guide for advanced troubleshooting. The Bendix ®... -
Page 17: Symptom
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. -
Page 18: In The Supply Reservoir (4.0)
(1-800-247-2725) and been performed as in Column 3. speak to a Tech Team member.) ð Drain all air tanks into Bendix ® (b) If the vehicle maintenance has BASIC test been performed as recom- cup (Bendix Air System Inspection Cup). - Page 19 45 degree fitting. For more Kinked discharge line shown. information on 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.
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Page 20: At The Valves (5.0)
Note: After replacing a compressor, investigated. Bendix compressors are designed to residual oil may take a considerable period have a 'dry' sump and the presence of excess oil in of time to be flushed from the air brake the crankcase can lead to oil carryover. -
Page 21: Slow Build (9.0)
Symptom: What it may indicate: What you should do: ð See engine service manual. A problem with engine or other engine 6.0 Excessive oil consumption in accessory. engine. The engine service manual has more information. ð Air dryers remove water and oil from the air 7.0 Oil present at Air brake charging system is air dryer cartridge... - Page 22 90 degree fitting, it may be changed to a straight or 45 degree fitting. For more information on how to help prevent discharge line freeze-ups, see Bendix Bulletins TCH-08-21 TCH-08-22 (Appendix B). Shorter discharge line lengths or insulation may be required in cold climates.
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Page 23: Doesn't Build Air (10.0)
45 degree fitting. For more information on 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. -
Page 24: Air Dryer
Symptom: What it may indicate: What you should do: ð Inspect delivery lines to reservoir for 12.0 Air dryer (a) Restriction between air dryer and safety valve reservoir. restrictions and repair as needed. releases air. ð Verify relief pressure is at vehicle or (b) Air dryer safety valve malfunction. -
Page 25: Leaks Air (16.0)
Symptom: What it may indicate: What you should do: ð Check for leaking, damaged or defective (a) Compressor leaks 16.0 Compressor connections or ports. leaks air compressor fittings, gaskets, etc. Repair or replace as necessary. ð Go to Test 6 on page 27. (b) Compressor unloader mechanism malfunction. -
Page 26: Oil Leakage At Head Gasket
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 Observe the amount of weepage from the head gasket. -
Page 27: Governor Malfunction
Test 6: Compressor Unloader Leakage off and charge the unloader port by allowing air Bendix ® Compressors: Park vehicle, chock pressure to enter the hose and unload the wheels, and follow all standard safety procedures. - Page 28 NOTES...
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Page 29: Basic Test Information
YES, number of days was known (30 - 90 days) with a Bendix air dryer that are properly maintained.) If, in cold weather conditions, the 30 day air tank drain schedule is longer Replace the Compressor. If under warranty, follow standard procedures. - Page 30 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...
- Page 31 Appendix A 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. STEP C - How to Use the BASIC Test 1.
- Page 32 Last 3 feet, including fitting 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.
- Page 33 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. System Leakage Check the air brake system for excessive air leakage using the Bendix “Dual System Air Brake Test and Check List”...
- Page 34 Appendix B: Continued 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.
- Page 36 BW1421 © 2004 Bendix Commercial Vehicle Systems LLC All rights reserved. 9/2004 Printed in U.S.A.