Table of Contents
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®
®
Bendix
Tu-Flo
DISCHARGE
VALVE STOP
DISCHARGE
VALVE
DISCHARGE
VALVE SEAT
CONNECTING
ROD
CRANKSHAFT
®
BENDIX
TU-FLO
(CROSS SECTION)
DESCRIPTION
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. The Bendix
compressor is a two cylinder single stage, reciprocating
compressor with a rated displacement of 13.2 cubic feet
per minute at 1250 RPM.
The compressor assembly consists of two major
subassemblies, the cylinder head and the crankcase. The
Cylinder Head is an iron casting which houses the inlet,
discharge, and unloader valving. (See Figure 1.) The
Cylinder Head contains the air inlet port and is designed
with both top and side air discharge ports. Three water
coolant ports provide a choice of coolant line connections.
Governor mounting surfaces are provided at both the front
and the rear of the cylinder head. The head is mounted
on the crankcase and is secured by six cap screws. The
Tu-Flo
®
550 compressor is designed such that the cylinder
head can be installed in one of two positions which are 180
degrees apart. The crankcase houses the cylinder bores,
pistons, crankshaft and main bearings, and provides the
fl ange or base mounting surface.
550 Air Compressor
UNLOADER
COVER
DISCHARGE
VALVE SPRING
®
550 AIR COMPRESSOR
®
Tu-Flo
AIR DISCHARGE
WATER
INLET
GOVERNOR
MOUNTING
PAD
PISTON
BENDIX
®
550
CYLINDER
HEAD
END VIEW OF CYLINDER HEAD
®
TU-FLO
®
550 AIR COMPRESSOR
(EXTERIOR)
UNLOADER
WATER OUTLET
AIR INLET
CRANKCASE
PIECE NO.
TAG
INLET VALVE
INLET VALVE
SEAT
INLET
INLET VALVE
SPRING
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Table of Contents
Troubleshooting
Related Manuals for BENDIX TU-FLO 550 COMPRESSOR
Summary of Contents for BENDIX TU-FLO 550 COMPRESSOR
- Page 1 ® 550 AIR COMPRESSOR (EXTERIOR) 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. The Bendix ® Tu-Flo ® UNLOADER compressor is a two cylinder single stage, reciprocating CYLINDER compressor with a rated displacement of 13.2 cubic feet...
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Page 2: Intake And Compression Of Air (Loaded)
BENDIX NO. SERIAL NO. the down stroke is being compressed. Air pressure on the MANUFACTURED BY BENDIX inlet valve plus the force of the inlet spring, returns the inlet valve to its seat and closes. The piston continues the FIGURE 3 - NAMEPLATE upward stroke and compressed air pushes the discharge valve off its seat and air fl... -
Page 3: Non-Compression Of Air (Unloaded)
UNLOADER DISCHARGE PISTON GOVERNOR GOVERNOR DISCHARGE PORT PORT PORT PORT INLET PORT INLET PORT INLET VALVE INLET HELD OPEN VALVE DISCHARGE DISCHARGE BY UNLOADER OPEN VALVE VALVE PISTON CLOSED CLOSED PISTON MOVING DOWN FIGURE 4 - OPERATIONAL-LOADED (INTAKE) FIGURE 6 - OPERATIONAL-UNLOADED force the pistons upward and the inlet valves return to their GOVERNOR DISCHARGE... -
Page 4: Discharge Line
(see column 2 of Table A in the Troubleshooting section) assumes a compressor with a normal (less than 25%) duty cycle, operating in a temperate climate. See Bendix and/or other air dryer manufacturer guidelines as needed. The discharge line must maintain a constant slope down from the compressor to the air dryer inlet fi... -
Page 5: Lubrication
(238948) be installed with an inlet gasket (291909) on both sides of the screen. FIGURE 7 - LUBRICATION For vehicles with accessories that are sensitive to small WATER amounts of oil, we recommend installation of a Bendix ® ® ™ PuraGuard oil coalescing fi... -
Page 6: Compressor Turbocharging Parameters
COMPRESSOR TURBOCHARGING POLYURETHANE SPONGE STRAINER PARAMETERS Every month, 150 operating hours or 5,000 miles, whichever occurs fi rst, remove and wash all of the parts. Air entering the compressor inlet during the loaded cycle The strainer element should be cleaned or replaced. If the must not exceed 250 degrees Fahrenheit (121 degrees element is cleaned, it should be washed in a commercial Celsius). -
Page 7: Operating Tests
INTAKE ADAPTER Bendix has developed the "Bendix Air System Inspection Cup" or BASIC test to help substantiate suspected When the engine air cleaner is replaced: Some excessive oil passing. The steps to be followed when using compressors are fi tted with compressor intake adapters,... -
Page 8: Removal And Disassembly
Do not use marking methods such as chalk that can returned to the nearest authorized Bendix distributor for a be wiped off or obliterated during rebuilding. factory remanufactured compressor. If it is not possible,... - Page 9 COMPRESSOR CRANKCASE DISASSEMBLY material (5) from the cover plate, cylinder head and crankcase. 1. Remove the key or keys (30) from the crankshaft (29) and any burrs from the crankshaft where the key or keys 1. Remove the unloader pistons (7), o-rings (6) and were removed.
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Page 10: Parts List
CYLINDER HEAD CRANKCASE BASE MOUNT NAMEPLATE CRANKCASE BALL BEARING (MACK EXTENDED FLANGE) FLANGE MOUNT ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION Cylinder Head Cap Screws Discharge Valve Spring Thrust Washer Unloader Plate Cap Screws Discharge Valve Sleeve (or Ball) Bearing Unloader Plate Lock Washers Discharge Valve Stop End Cover Seal... - Page 11 END COVERS PISTON RINGS Check for cracks and external damage. If the crankshaft Check the pistons for scores, cracks or enlarged ring main bearing (32) is installed in the end cover (34), grooves; replace the pistons if any of these conditions are check for excessive wear and fl...
- Page 12 Discharge valve travel should be between .030 in. to .046 in. To test for leakage by the discharge valves, apply 100 psi to the cylinder head discharge port and apply a soap solution to the discharge valve and seats. Leakage TU-FLO OTHER BENDIX ® ® AIR COMPRESSOR TU-FLO AIR COMPRESSORS ®...
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Page 13: Pistons/Connecting Rods
Install the other connecting rod and piston in the same Tu-Flo ® 550 compressor are similar to those of other Bendix manner. It is recommended that new connecting rod cap compressor models but may be identifi ed by the piston screws be used. -
Page 14: Specifications
Connect to the compressor discharge port, a reservoir with TORQUE SPECIFICATIONS a volume of 1500 cubic inches, including the volume of the Bolt, Nut or Screw ......Assembly Torque connecting line. With the compressor operating at 2100 (in. lbs.) R.P.M., the time required to raise the reservoir(s) pressure Cylinder Head .......... - Page 15 7. Never connect or disconnect a hose or line containing pressure; it may whip. 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, fi...
- Page 17 Appendix A 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. INDEX Symptom Page Number...
- Page 18 (less than 25%) duty cycle, operating in builds the air pressure for the air brake system. The air a temperate climate. See Bendix and/or other air dryer compressor is typically cooled by the engine coolant system manufacturer guidelines as needed.
- Page 19 Discharge line upgrades are not covered under warranty. Note: To help prevent discharge line freeze-ups, shorter discharge line For Bendix ® Tu-Flo ® 550 and 750 compressors, unloader service is lengths or insulation may be required in cold climates. (See Bendix recommended every 250,000 miles.
- Page 20 Discontinue using this test. Not a valid test. Results Do not use this card test to diagnose compressor "oil passing" issues. They are subjective and error prone. Use only the Bendix ® System Inspection Cup (BASIC ™ ) test and the methods described in this guide for advanced troubleshooting.
- Page 21 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 22 BASIC test member.) in Table A on page A-3, some oil in cup (Bendix Air System Inspection Cup). If the reservoirs is normal. less than one unit of reservoir contents is found, the vehicle can be returned to ser- vice. Note: If more than one oil unit of...
- Page 23 45 degree fi tting. For more information on Kinked discharge line shown. 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 Note: After all other operating conditions have been investigated. replacing a compressor, residual oil may Bendix compressors are designed to have a 'dry' take a considerable period of time to be sump and the presence of excess oil in the crankcase fl...
- Page 25 Symptom: What it may indicate: What you should do: 6.0 Excessive oil A problem with engine or other engine See engine service manual. accessory. consumption in engine. The engine service manual has more information. 7.0 Oil present Air brake charging system is functioning Air dryers remove water and oil from at air dryer normally.
- Page 26 These can increase the rate at which carbon Bendix Bulletins TCH-08-21 and TCH-08-22 builds up in the discharge line. Bendix recommends oil (Appendix B). Shorter discharge line soot (solids) be maintained at less than 3%.
- Page 27 Replace air dryer heater. exhaust port frozen open. (d) Compressor malfunction. Replace the compressor only after making certain the preceding conditions do not exist. * Note: For the Bendix ® DuraFlo ™ 596 air compressor, not only the governor, but also the SV-1 ™...
- Page 28 Symptom: What it may indicate: What you should do: 12.0 Air dryer (a) Restriction between air dryer and Inspect delivery lines to reservoir for reservoir. safety valve restrictions and repair as needed. releases air. (b) Air dryer safety valve Verify relief pressure is at vehicle or malfunction.
- Page 29 Symptom: What it may indicate: What you should do: (a) Compressor leaks air at connections 16.0 Compressor Check for leaking, damaged or defective leaks air or ports. compressor fi ttings, gaskets, etc. Repair or replace as necessary. (b) Compressor unloader mechanism Go to Test 6 on page A-15.
- Page 30 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. Observe the amount of weepage from the head gasket.
- Page 31 Test 6: Compressor Unloader Leakage ® shut-off and charge the unloader port by allowing Bendix Compressors: Park vehicle, chock wheels, and follow all standard safety procedures. air pressure to enter the hose and unload the compressor.
- Page 32 30 days*** returning. (Note that 30-90 days is the recommended air tank known? drain schedule for vehicles equipped with a Bendix air dryer that YES, number of days is properly maintained.) If, in cold weather conditions, the 30 day was known (30 - 90 days) Replace the Compressor.
- 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 must determine, based on its experience with the vehicle, whether to participate now, or wait for warmer weather.
- Page 34 ™ Appendix B 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.
- Page 35 Last 3 feet, including fi tting 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. A-19...
- Page 36 Other Requirements 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 D 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. Here are some additional suggestions for making cold weather vehicle operation just a little more bearable.
- Page 40 BW1639 © 2007 Bendix Commercial Vehicle Systems LLC. All rights reserved. 3/07 Printed in U.S.A.
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Questions and answers
can a problem exist on the air compressor and force air in to the water system on a 12.7 detroit engine 550 or 750 unit
The Bendix® Tu-Flo® 550 and 750 air compressors have water inlet and outlet connections for cooling, but their primary function is to compress air for brake and auxiliary systems. If there is an internal failure, such as a cracked head or damaged seals, it is possible for compressed air to leak into the cooling system. This could cause air to enter the water system on a 12.7 Detroit engine if the compressor is mounted and integrated into the engine's cooling circuit. Proper inspection of the compressor for internal leaks is recommended.
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