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BENDIX TU-FLO 600 AIR COMPRESSOR Manual

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®
®
Bendix
TU-FLO
TU-FLO
®
600 AIR COMPRESSOR VERTICAL MOUNT
GENERAL
The function of the air compressor is to build up and maintain
the air pressure required to operate air powered devices in
air brake or air auxiliary systems.
DESCRIPTION
The Tu-Flo
®
600 compressor is a two cylinder reciprocating
single stage compressor with a rated displacement of 14.5
cfm at 1250 rpm.
®
The Tu-Flo
600 compressor is constructed with a crankcase,
block, and head assembly. The crankcase assemblies, in
particular, are essentially the same as corresponding Tu-Flo
500 compressors. The block assembly includes the air inlet
cavity, automatic inlet valves and unloader valves. Vertical
mounting pads for governor mounting are included at each
end of the block. The head assembly includes the discharge
valves with discharge ports either on the side or top of the
block.
®
All Tu-Flo
600 compressors are liquid cooled, both head
and block, by coolant from the engine cooling system.
®
600 Air Compressor
TU-FLO
®
600 AIR COMPRESSOR FLANGE MOUNT
Various mounting and drive configurations are used as
required by different vehicle and engine designs. See Fig. 1.
All Tu-Flo
®
600 compressors receive oil under pressure from
the engine lubricating system for the lubrication of the
internal parts. Fig. 2 shows a cross section of a typical
Tu-Flo
®
600 compressor and the oil flow therein.
Oil is forced through the oil passage in the crankshaft to
each connecting rod journal. Oil is forced out at the journals
and is thrown by centrifugal force against the cylinder walls
and crankshaft main bearings, providing lubrication.
The wrist pins and wrist pin bushings are lubricated in two
®
ways depending on the type connecting rod used. Some
older compressors, and one current design use forged steel
rifle drilled rods, through which oil is forced to the wrist pin
bushings. Standard current design consists of a diecast
aluminum or forged steel rod with an "oil catch-funnel" at
the top of the rod and a short hole connecting to the wrist
pin bushing. See Fig. 3.
1

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Summary of Contents for BENDIX TU-FLO 600 AIR COMPRESSOR

  • Page 1 ® ® ® Bendix TU-FLO 600 Air Compressor TU-FLO ® 600 AIR COMPRESSOR VERTICAL MOUNT TU-FLO ® 600 AIR COMPRESSOR FLANGE MOUNT GENERAL Various mounting and drive configurations are used as required by different vehicle and engine designs. See Fig. 1.
  • Page 2 ® FIGURE 2 - TU-FLO 600 AIR COMPRESSOR SECTIONAL VIEW NEW DESIGN OLD DESIGN “CATCH FUNNEL” WRIST WRIST TEFLON BUSHING BUSHING PLUG PISTON WRIST WRIST PIN LOCK WIRE CAST IRON CAST PISTON PISTON STEEL OIL PASSAGE DIE CAST CONNECTING CONNECTING FIGURE 3 - TU-FLO ®...
  • Page 3 TO RESERVOIR INLET VALVE DISCHARGE UNLOADER VALVE PLUNGER INTAKE PISTON FIGURE 4 STRAINER OPERATION TO GOVERNOR GENERAL STROKE All compressors run continuously while the engine is COMPRESSION running, but actual compression of air is controlled by a governor which stops or starts the compression of air by FIGURE 6 loading or unloading the compressor in conjunction with its unloading mechanism.

  • Page 4: 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 5 For vehicles with accessories that are sensitive to small and reinstall the adapter securely. Check line connections amounts of oil, we recommend installation of a Bendix ® both at the compressor intake adapter and at the engine air PuraGuard ®...
  • Page 6 After installation run compressor and check for air, oil, or leakage is excessive, it is recommended that it be returned water leaks at compressor connections. Also, check for to the nearest Bendix authorized distributor for a factory noisy operation. rebuilt compressor under the repair exchange plan. If this is...
  • Page 7 The discharge valve cap nuts should be inspected for wear If the pistons are removed from the rod, inspect the bronze and replaced if excessive peening has occurred. To wrist pin bushing. Press out and replace the bushing if it is determine if excessive peening has occurred, measure the excessively worn.
  • Page 8 ® FIGURE 13 - TU-FLO 600 AIR COMPRESSOR CYLINDER BLOCK ASSEMBLY ® FIGURE 14 - TU-FLO 600 AIR COMPRESSOR CRANK CASE ASSEMBLY...
  • Page 9 In addition, seats are worn excessively so that there is no longer enough Bendix has developed the "Bendix Air System Inspection metal left to reclaim them by lapping, the seats should be Cup" or BASIC test to help substantiate suspected excessive replaced.
  • Page 10 CYLINDER BLOCK 5 Ring Wrist Ring *Piston Pin Check for cracks or broken lugs on cylinder block. Also Size Piston Maint. Kit check unloader bore bushings to be sure they are not worn, rusted or damaged. If these bushings are to be replaced, Standard 292529 292530...
  • Page 11 REPAIRS ® TU-FLO 500 & 600 AIR COMPRESSOR INCHES M M CORRECT GROOVE DISCHARGE VALVES AND SEATS CLEARANCE NARROW If discharge valve seats merely show signs of slight wear, WIDE RING .0015 .038 RING NARROW they can be dressed by using a lapping stone, grinding WIDE compound and grinding tool.
  • Page 12 Position a rear end cover gasket, when used, over the rear Install the unloader pistons in their bores with caution against end of the crankcase, making sure the oil hole in the gasket cutting the o-rings or distorting the back-up rings. lines up with the oil hole in the crankcase.
  • Page 13 FIGURE 19 - SPONGE TYPE AIR STRAINER EXPLODED VIEW A compressor efficiency or build-up test can be run which is COMPRESSOR TROUBLESHOOTING not too difficult. An engine lubricated compressor must be IMPORTANT: The troubleshooting contained in this section connected to an oil supply line of at least 15 pounds pressure considers the compressor as an integrated component of during the test and an oil return line must be installed to the overall air brake charging system and assumes that an...
  • Page 14 Never remove a component or plug unless you are certain all system pressure has been depleted. ® 8. Use only genuine Bendix replacement parts, components and kits. Replacement hardware, tubing, hose, fittings, etc. must be of equivalent...

  • Page 15: 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 16 (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 ®...

  • Page 17: 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 18: 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 19: 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 20: 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 21 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.

  • Page 22: 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 23: Slow Build (9.0)

    Symptom: What it may indicate: What you should do: ð See engine service manual. 6.0 Excessive oil A problem with engine or other engine 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 24 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.

  • Page 25: 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 26: 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 27: 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. compressor fittings, gaskets, etc. Repair leaks air or replace as necessary. ð Go to Test 6 on page 29. (b) Compressor unloader mechanism malfunction.

  • Page 28: 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 29: 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 30: 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 31 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 32 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 33 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 34 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 35 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 BW 1560 © 2004 Bendix Commercial Vehicle Systems LLC All rights reserved. 9/2004 Printed in U.S.A.

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Tu-flo 600

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