Related Manuals for BENDIX TU-FLO 400-500-1000 AIR COMPRESSOR
Summary of Contents for BENDIX TU-FLO 400-500-1000 AIR COMPRESSOR
- Page 1 ® ® ® Bendix TU-FLO 400, 500, 1000 Air Compressors TU-FLO ® 400 Air Compressor TU-FLO ® 500 Air Compressor ® TU-FLO 1000 Air Compressor...
- Page 2 ® while the Tu-Flo 1000 compressor (Fig. 3) is a V-type design having four cylinders. The rated capacity of all Bendix compressors is their piston displacement in cubic feet per minute when operating at 1,250 RPM. The rated capacity of the Tu-Flo ®...
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Page 3: Intake And Compression (Loaded)
OPERATION GENERAL All compressors run continuously while the engine is running, but actual compression of air is controlled by a governor, which stops or starts the compression of air by loading or unloading the compressor in conjunction with its unloading FIGURE 5 FIGURE 6 mechanism. -
Page 4: Non-Compression (Unloaded)
(less than 25%) duty cycle, between the two cylinders. When air is used from the operating in a temperate climate. See Bendix and/or other reservoir and the pressure drops to the low pressure setting air dryer manufacturer guidelines as needed. - Page 5 (supply) reservoir. The oil droplets and the water collected are automatically purged when the governor reaches its "cut-out" setting. For vehicles with accessories that are sensitive to small amounts of oil, we recommend installation of a Bendix ® ® ™...
- Page 6 If the compressor does not function as described above, or leakage is excessive, it is recommended that it be returned to the nearest Bendix authorized distributor for a factory rebuilt compressor under the repair exchange plan. If this is not possible, the compressor can be repaired with genuine...
- Page 7 Tu-Flo 500 and 1000 compressors. symptoms and corrective action to be taken. In addition, Bendix has developed the "Bendix Air System Inspection CRANKCASE BASE PLATE OR ADAPTER Cup" or BASIC test to help substantiate suspected excessive Remove the cap screws securing the base plate or base oil passing.
- Page 8 ® FIGURE 17 - TU-FLO 400 AIR COMPRESSOR VERTICAL MOUNT - ENGINE LUBRICATED Straighten the prongs of the connecting rod bolt lock strap and remove the bolts and bearing caps. Push the piston with the connecting rods attached out the top of the cylinders of the crankcase.
- Page 9 Press the crankshaft and ball bearings from the crankcase, CLEANING AND INSPECTION OF PARTS then press ball bearings from crankshaft. Many compressors CLEANING will have sleeve-type bearings in the crankcase or in the end cover. If the clearance between crankshaft journal and All parts should be cleaned thoroughly in a good cleaning bearing exceeds .0065 in.
- Page 10 Clearance between cast iron pistons and cylinder bores CRANKCASE AND END COVERS should be between 0.002 in. minimum and 0.004 in. Check for cracks or broken lugs in crankcase and end covers. maximum (Fig. 21). Also check their oil passages to make sure they are open and clean.
- Page 11 UNLOADER MECHANISM TU-FLO ® 400 AIR COMPRESSOR CORRECT GROOVE Used unloader mechanism should be replaced by unloader CLEARANCE ® kits 265014 for Type Tu-Flo 400 compressors and 265015 for Types Tu-Flo ® 500 and 1000 compressors. The Tu-Flo ® .0015” 1000 compressor requires two kits per compressor.
- Page 12 Remove connecting bolts and bearing cap from one Slightly worn or scratched inlet valves can be reclaimed by connecting rod. Turn crankshaft so one of its connecting lapping them on a piece of fine crocus cloth on a flat surface, rod journals is in the downward, center position.
- Page 13 BASEPLATE TESTING REBUILT COMPRESSOR SELF-LUBRICATED TYPE COMPRESSORS In order to properly test a compressor under operating conditions, a test rack for correct mounting, cooling, Install oil pump piston and rod on crankshaft. lubricating and driving the compressor is necessary. Such Oil rod bearing fit must be the same as specified for tests are not compulsory if the unit has been carefully rebuilt connecting rod bearings.
- Page 14 ® 3. Do not attempt to install, remove, disassemble or 8. Use only genuine Bendix replacement parts, assemble a component until you have read and components and kits. Replacement hardware, thoroughly understand the recommended tubing, hose, fittings, etc. must be of equivalent procedures.
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Page 15: Scheduled Maintenance
MAINTENANCE INSTRUCTIONS FOR SCHEDULED MAINTENANCE ® LARGE SUMP TU-FLO 1000 AIR NOTE: When checking or adding oil or servicing the crankcase breather, care should be taken to prevent COMPRESSOR 288578 (SPECIAL dirt or foreign material from entering the breather or APPLICATION) oil sump. -
Page 16: 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 17 (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 18: 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 19: 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 20: 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 21: 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 cup (Bendix Air System Inspection Cup). - Page 22 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 23: 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 24: 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 25 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 26: 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 27: 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 28: 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 30. (b) Compressor unloader mechanism malfunction. -
Page 29: 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 30: 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. Remove the governor and install a fitting to the compressor. - Page 31 NOTES...
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Page 32: 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 33 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 34 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 35 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 36 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 37 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 40 BW1420 © 2004 Bendix Commercial Vehicle Systems LLC All rights reserved. 10/2004 Printed in U.S.A.