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BENDIX BW1420 User's Manual

1. j j j no yes The full BASIC test below will Is the compressor leaking Oil 2 no D yes investigate the facts LI Other complaint LI No customer complaint BASIC test starts here STEP A Select one The Technician selects the air use category for the vehicle This U This is a low air use vehicle Line haul single trailer with 5 or less axles or oo decided which of the two accep LI This is a high air use vehicle Garbage truck transit bus bulk unloader or tance lines on the cup will be ae line haul with 6 or more axles Then go to Step B for the test below STEP B Measure the Charging System Contents Foran accurate test the 1 Park and chock vehicle on level ground Drain the air system by pumping the service brakes 2 Completely drain ALL the air tanks into a single BASIC cup 3 If there is less than one unit of contents total end the test now and return the vehicle to service Vehicle passes 4 Q more than one oil unit of water or a cloudy emulsion mixture is found a Change the vehicle s air dryer cartridge See Footnote 1 b Conduct the 4 minute leakage test Step D c STOP the inspection and check the vehicle again after 30 days see Footnote 2 D Otherwise go to Step C Footnote 1 Note Typical air dryer cartridge replacement schedule is every 3 yrs 300K miles for low air use vehicles and every year 100K miles for high air use v
2. Check What you should do r gt If discharge line is restricted gt By more than 1 16 carbon build up replace the discharge line see Table A column 2 on page 18 for recommended size and go to Test 3 on page 29 gt By other restrictions e g kinks Replace the discharge line See Table A column 2 on page 18 for recommended size Retest for air build Return vehicle to service or if problem persists go to 9 0 a The discharge line must maintain a constant slope down from the compressor to the air dryer inlet fitting to avoid low points where ice may form and block the flow If instead ice blockages occur at the air dryer inlet insulation may be added here or if the inlet fitting is a typical 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 and TCH 08 22 Appendix B Shorter discharge line lengths or insulation may be required in cold climates Check compressor air inlet line for restrictions brittleness soft or sagging hose conditions etc Repair as necessary Refer to vehicle manufacturer s guidelines for inlet line size Check the engine air filter and service if necessary if possible check the air filter usage indicator Check for leaking damaged or defective compressor air inlet components e g induction line fittings gaskets filter bodies etc Repair inlet co
3. CLEANING AND INSPECTION OF PARTS CLEANING All parts should be cleaned thoroughly in a good cleaning solvent before inspection CYLINDER HEAD ASSEMBLY Remove all carbon deposits from discharge cavities and all rust and scale from cooling cavities of cylinder head body Scrape all foreign matter from body surfaces and use air pressure to blow dirt particles from all cavities Discharge valves can be dressed by lapping them on a piece of fine crocus cloth on a flat surface provided they are not excessively worn CYLINDER BLOCK Clean carbon and dirt from inlet and unloader passages Use air pressure to blow carbon and dirt deposits from unloader passages Inlet valves as in the case of discharge valves not worn excessively can be cleaned by lapping them on a piece of fine crocus cloth on a flat surface OIL PASSAGE Clean thoroughly all oil passages through crankshaft connecting rods crankcase end covers and base plate If necessary inspect passages with a wire and blow foreign matter out with air pressure CRANKCASE SELF LUBRICATED TYPE The breather should be thoroughly washed and cleaned The oil pump check valve in the base should be removed and replaced It is important when the oil pump check valve is replaced that it be installed correctly with the ball stop pin end pressed in first When installed the ball and its seat should be visible from the crankcase base INSPECTION OF PARTS CYLINDER HEAD BODY I
4. g r 1 L s N DIE CAST he CONNECTING ROD NEW DESIGN FIGURE 7 PISTONS amp CONNEGTING RODS A nameplate is attached to the crankcase of all compressors It shows the piece number type and serial number Fig 8 A nameplate with a black background denotes a new compressor whereas a nameplate with a red background designates that the compressor is a factory reconditioned unit All compressors are identified by the piece number which is the number to use when reference is made to a particular compressor The type and serial number is supplementary information Bendix i MANUFACTURED BY BENOIX FIGURE 8 COMPRESSOR NAMEPLATE 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 mechanism This is done when the air pressure in the system reaches the desired maximum or minimum pressures INLET VALVE LOADER PLUNGER INTAKE STRAINER STROKE INTAKE FIGURE 9 INTAKE AND COMPRESSION Loaded During the down stroke of the piston a slight vacuum created above the piston causes the inlet valve to move off its seat Atmospheric air is drawn in through the compressor intake by the open inlet valve and on top of the piston Fig 9 As the piston starts its upward stroke the air that was drawn in on the down s
5. lines from engine to compressor inlets 03 qts 5 8 O D tubing or equivalent 1 2 O D tubing or equivalent 1 4 O D tubing or equivalent 5 8 O D tubing or equivalent 5 8 I D Inlet line sizes specified for compressors with inlet connected to engine manifold 15 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 INDEX Symptom Page Number Symptom Page Number Air Coolant Air brake charging system Compressor leaks coolant 17 0 Slow build 9 0 Doesn t build air 10 0 Air dryer Oil consumption 6 0 Doesn t purge 14 0 Oil Safety valve releases air 12 0 l Compressor Oil Test Card results 1 0 Oil is present Constantly cycles 15 0 ve On the outside of the compressor 2 0 20 Leaks air 16 0 Safety valve releases air 11 0 At the air dryer purge exhaust or Surrounding area 3 0 Nol 18 oisy 18 0 In the supply reservoir 4 0 Reservoir Safety valve releases air 13 0 eu heve La 7 0 In the ping tank or compressor discharge aftercooler 8 0 Test Procedures Maintenance amp Usage Gu
6. after they enter DUTY CYCLE The duty cycle is the ratio of time the compressor spends building air to the total engine running time Air compressors are designed to build air run loaded up to 25 of the time Higher duty cycles cause conditions that affect air brake charging system performance which may require additional maintenance Factors that add to the duty cycle are air Suspension additional air accessories use of an undersized compressor frequent stops excessive leakage from fittings connections lines chambers or valves etc Refer to Table Ain the Troubleshooting section for a guide to various duty cycles and the consideration that must be given to maintenance of other components COMPRESSOR INSTALLATION While the original compressor installation is usually completed by the vehicle manufacturer conditions of operation and maintenance may require additional consideration The following presents base guidelines DISCHARGE LINE The discharge line allows the air water vapor and oil vapor mixture to cool between the compressor and air dryer or reservoir The typical size of a vehicle s discharge line See column 2 of Table Ain 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
7. almost all of the remaining water vapor The compressed air is then passed to the air brake service 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 PuraGuard QC oil coalescing filter designed to minimize the amount of oil present COOLING Tu Flo 400 500 or 1000 compressors may be air cooled or water cooled and in some instances will have air cooled blocks and water cooled heads The air cooled versions are easily recognized by the external fins The water cooled versions are cooled by vehicle coolant The Air Brake Charging System supplies the compressed air for the braking system as well as other air accessories for the vehicle The system usually consists of an air compressor governor discharge line air dryer and service reservoir Optional Bendix PuraGuard QC Oil Coalescing Filter Service Reservoir Supply Reservoir Reservoir Drain PREVENTIVE MAINTENANCE Regularly scheduled maintenance is the single most important factor in maintaining the air brake charging system Refer to Table Ain the Troubleshooting section for a guide to various considerations that must be given to the maintenance of the compressor and other related charging system components If the compressor is a self lubricated type i
8. and fleets alike begin to look to their vehicles with an eye toward winterization and particularly what can be done to guard against air system freeze up Here are some basic Tips for operation in the cold weather Engine Idling Avoid idling the engine for long periods of time In addition to the fact that most engine manufacturers warn that long idle times are detrimental to engine life winter idling is a big factor in compressor discharge line freeze up Discharge line freeze ups account for a significant number of compressor failures each year The discharge line recommendations under Discharge Lines are important for all vehicles but are especially so when some periods of extended engine idling can not be avoided Discharge Lines The discharge line should slope downward form the compressor discharge port without forming water traps kinks or restrictions Cross overs from one side of the frame rail to the other if required should occur as close as possible to the compressor Fitting extensions must be avoided Recommended discharge line lengths and inside diameters are dependent on the vehicle application and are as follows Typical P amp D School Bus and Line Haul The maximum discharge line length is 16 feet Length I D Min Other Requirements 6 0 9 5 ft Yo in None 9 5 12 ft Yo in Last 3 feet including fitting at the end of the discharge line must be insulated with 1 2 inch thick closed cell polyethy
9. area it is acceptable return the NSA WEEPAGE vehicle to service but if the oil weepage extends down to the nameplate area JAZA of the compressor the gasket can be replaced Test 2 Air Brake System and Accessory Leakage Inspect for air leaks when working onavehicle and pedal in position Observe the dash gauges repair them promptly lf you see any noticeable decrease of the dash air Park the vehicle on level ground and chock wheels gauge readings i e more than 4 psi plus two psi Build system pressure to governor cut out and allow for each additional trailer during either two minute the pressure to stabilize for one minute test repair the leaks and repeat this test to confirm Step 1 Observe the dash gauges for two additional that they have been repaired minutes without the service brakes applied Air leaks can also be found in the charging system Step 2 Apply the service brakes and allow the parking brakes and or other components inspect pressure to stabilize Continue holding for two and repair as necessary minutes you may use a block of wood to hold the Test 3 Air Compressor Discharge Temperature and Air Dryer Inlet Note that only vehicles that have passed Test 2 Temperature would be candidates for this test Caution The temperatures used in this test Then while maintaining max rpm and are not normal vehicle conditions pressure range measure and record the Above normal temperatur
10. fitting or reservoir to avoid low points where ice may form and block the flow If instead ice blockages occur at the air dryer or reservoir inlet insulation may be added here or if the inlet fitting is a typical 90 degree fitting it may be changed to a straight or 45 degree fitting Shorter discharge line lengths or insulation may be required in cold climates While not all compressors and charging systems are equipped with a discharge line safety valve this component is recommended The discharge line safety valve is installed in the cylinder head or close to the compressor discharge port and protects against over pressurizing the compressor in the event of a discharge line freezeup DISCHARGE LINE TEMPERATURE When the temperature of the compressed air that enters the air dryer is within the normal range the air dryer can remove most of the charging system oil If the temperature of the compressed air is above the normal range oil as oil vapor is able to pass through the air dryer and into the air system Larger diameter discharge lines and or longer discharge line lengths can help reduce the temperature Discharge Optional Ping Tank Line Nes j A E Air Dryer bj Governor Governor plus Synchro valve for the Bendix DuraFlo 596 Compressor FIGURE 12A SYSTEM DRAWING FIGURE 12B DISCHARGE LINE SAFETY VALVE The air dryer contains a filter that collects oil droplets anda desiccant bed that removes
11. gasket may indicate gasket a downstream restriction such as a freeze up or carbon blockage and or could indicate a defective or missing safety valve Find blockage go to 9 0 f for details and then replace the compressor Do not re use the safety valve without testing See Symptom 12 0 a c Porous compressor head casting If casting porosity is detected replace the compressor 18 0 Noisy a Damaged compressor r gt Replace the compressor compressor Multi cylinder compressors only Other Miscellaneous Areas to Consider This guide attempts to cover most e Where a compressor does not have a compressor system problems Here are safety valve installed if a partial or some rare sources of problems not complete discharge line blockage has covered in this guide occurred damage can occur to the e Turbocharger leakage Lubricating oil connecting rod bearings Damage of this from leaking turbocharger seals can enter kind may not be detected and could lead the air compressor intake and give to compressor problems at a later date misleading symptoms Tests Test 1 Excessive Qil 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 2 OO L4 ed OO P LOOK Observe the amount of weepage from the head gasket FOR If the oil is only around the cylinder head
12. not covered under original compressor warranty gt lf the compressor is correct for the vehicle go to Symptom 4 0 e 21 22 Symptom What it may indicate 4 0 Oil in Supply Temperature or Service Reservoir e Air compressor discharge and or air dryer installed air dryer inlet temperature too high continued f Insufficient coolant flow Testing the temperature Inspecting the coolant hoses at the discharge fitting g Restricted discharge line Kinked discharge line shown Other h Restricted air inlet not enough air to compressor Partly collapsed inlet line shown What you should do r gt Check temperature as outlined in Test 3 on page 29 If temperatures are normal go to 4 0 h r gt Inspect coolant line Replace as necessary I D is 1 2 gt Inspect the coolant lines for kinks and restrictions and fittings for restrictions Replace as necessary r gt Verify coolant lines go from engine block to compressor and back to the water pump Repair as necessary r gt If discharge line is restricted or more than 1 16 carbon build up is found replace the discharge line See Table A column 2 on page 18 for recommended size Replace as necessary gt The discharge line must maintain a constant slope down from the compressor to the air dryer inlet fitting to avoid low points where ice may form and block the flow If instead ice blockages occur at the air dryer inle
13. of the lubricating oil as vapor The duty cycle is the ratio of time the compressor spends building air to the total engine running time Air compressors are designed to build air run loaded up to 25 of the time Higher duty cycles cause conditions that affect air brake charging system performance which may require additional maintenance Factors that add to the duty cycle are air Suspension additional air accessories use of an undersized compressor frequent stops excessive leakage from fittings connections lines chambers or valves etc The discharge line allows the air water vapor and oil vapor mixture to cool between the compressor and air dryer The typical size of a vehicle s discharge line see column 2 of Table A on page 18 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 When the temperature of the compressed air that enters the air dryer is within the normal range the air dryer can remove most of the charging system oil If the temperature of the compressed air is above the normal range oil as oil vapor is able to pass through the air dryer and into the air system Larger diameter discharge lines and or longer discharge line lengths can help reduce the temperature The discharge line must maintain a constant slope down from the compressor to the air dryer inlet fitting to avoid low points wh
14. oil hole in the crankcase Position end cover with oil seal ring if used installed over crankcase and end cover gasket The end cover should be positioned correctly in relation to the oil holes in the gasket and crankcase Secure end cover to crankcase with cap screws and lock washers If the opposite end cover requires an oil seal which was removed on disassembly a new seal should be pressed into end cover Position new end cover gasket and carefully install end cover over crankshaft and to crankcase avoiding damage to the seal Secure end cover with cap screw and lock washers PISTONS AND CONNECTING RODS If new wrist pin bushings are to be used they should be pressed into the connecting rods so that the oil hole in the bushing lines up with the one in the rod The new bushings should then be reamed or honed to provide between 0 0002 in and 0 0007 in clearance on the wrist pin Position connecting rod in piston and press in wrist pin so that lockwire hole in the pin aligns with that of the piston Install new lockwire through piston and wrist pin and lock same by Snapping short end into lockwire hole at the bottom of the piston Fig 7 Teflon plugs in wrist pin ends may be used instead of the lockwires Fig 22 Install piston rings in correct location with ring pipmarks up Fig 24 Stagger the position of the ring gaps Prelubricate piston piston rings wrist pin and connecting rod bearings with clean engine oil before insta
15. restrictions e g kinks Replace the discharge line See Table A column 2 on page 18 for recommended size gt The discharge line must maintain a constant slope down from the compressor to the air dryer inlet fitting to avoid low points where ice may form and block the flow If instead ice blockages occur at the air dryer inlet insulation may be added here or if the inlet fitting is a typical 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 and TCH 08 22 Appendix B Shorter discharge line lengths or insulation may be required in cold climates r gt Inspect air lines and verify check valves are operating properly r gt Ensure discharge line is installed into the inlet of the air dryer and delivery is routed to the service reservoir gt Verify relief pressure is 250 psi Replace if defective r gt Go to Test 6 on page 30 r gt Go to Test 4 on page 30 Symptom 12 0 Air dryer safety valve releases air Air dryer safety valve Technician removes governor 13 0 Reservoir safety valve releases air 14 0 Air dryer doesn t purge Never hear exhaust from air dryer 15 0 Compressor constantly cycles compressor remains unloaded for a very short time What it may indicate a Restriction between air dryer and reservoir b Air dryer safety valve malfun
16. see also column 5 of Table A on page 18 Return the vehicle to service For oil sensitive systems see page 17 SAE J2024 outlines tests all air brake system pneumatic components need to be able to pass including minimum levels of tolerance to contamination 24 Symptom 6 0 Excessive oil consumption in engine 7 0 Oil present at air dryer cartridge during maintenance 8 0 Oil in ping tank or compressor dis charge aftercooler 9 0 Air brake charging system seems slow to build pressure What it may indicate A problem with engine or other engine accessory The engine service manual has more information Air brake charging system is functioning normally 7 Normal Oil shown leaking from an air dryer cartridge Air brake charging system is functioning normally Y Normal a Air brake charging system functioning normally Y Normal b Air brake system leakage c Compressor may be undersized for the application d Compressor unloader mechanism malfunction e Damaged compressor head gasket What you should do r gt See engine service manual Check r gt Air dryers remove water and oil from the air brake charging system A small amount of oil is normal Check that regular maintenance is being performed and that the amount of oil in the air tanks reservoirs is within the acceptable range shown by the BASIC Test see also column 5 of Table A on page 1
17. the pressure drops to the low pressure setting of the governor the governor closes and in doing so exhausts the air from beneath the unloader pistons The unloader saddle spring forces the saddle pistons and plungers down and the inlet valves return to their seats Compression is then resumed COMPRESSOR amp THE AIR BRAKE SYSTEM GENERAL The compressor is part of the total air brake system more specifically the charging portion of the air brake system As a component in the overall system its condition duty cycle proper installation and operation will directly affect other components in the system Powered by the vehicle engine the air compressor builds the air pressure for the air brake system The air compressor is typically cooled by the engine coolant system lubricated by the engine oil supply and has its inlet connected to the engine induction system As the atmospheric air is compressed all the water vapor originally in the air is carried along into the air system as well as a small amount of the lubricating oil as vapor If an air dryer is not used to remove these contaminants prior to 4 entering the air system the majority but not all will condense in the reservoirs The quantity of contaminants that reach the air system depends on several factors including installation maintenance and contaminant handling devices in the system These contaminants must either be eliminated prior to entering the air system or
18. wheels drain air from system Drain contents of ALL air tanks into BASIC cup Is there less than one unit of liquid NO Is there more than one unit of water or cloudy emulsion mixture NO only oil Is this a transit vehicle bulk unloader or has more than 5 axles YES this is a high air use vehicle Find the point on the label where the number of oil units meets the number of days were last drained Is the point above the LOW Air Use line on the cup Is the point above the HIGH Air Use line on the Test for air leakage Use Test 2 Air Leakage gt Repair leaks and return vehicle to service the vehicle have excessive air leakage END TEST NO NO did not know when last drained Re test with the BASIC Test after 30 days the number of days since last END TEST YES number of days was known 30 90 days Replace the Compressor If under warranty follow standard procedures If after a compressor was already replaced the vehicle fails the BASIC test again do not replace the compressor use the Advanced Troubleshooting Guide to investigate the cause s END TEST 32 YES lt 1 YES H O1 NO this is a low air use vehicle Vehicle OK e Return vehicle to service Bendix Air System Inspection Cup BASIC Test Information
19. 8 Replace the air dryer cartridge as needed and return the vehicle to service Follow vehicle O E maintenance recommendation for these components Using dash gauges verify that the compressor builds air system pressure from 85 100 psi in 40 seconds or less with engine at full governed rom Return the vehicle to service Go to Test 2 on page 29 See Table A column 1 on page 18 for some typical compressor applications If the compressor is too small for the vehicle s role for example where a vehicle s use has changed then upgrade the compressor Note The costs incurred e g installing a larger capacity compressor etc are not covered under original compressor warranty Go to Test 6 on page 30 An air leak at the head gasket may indicate a downstream restriction such as a freeze up or carbon blockage and or could indicate a defective or missing safety valve Find blockage go to 9 0 f for details and then replace the compressor Do not re use the safety valve without testing See Symptom 12 0 a Symptom What it may indicate 9 0 Air brake f Restricted discharge line charging system seems slow to Check build pressure continued Dash gauges Kinked discharge line shown g Restricted air inlet not enough air to compressor Check Partly collapsed l l l l inlet line shown h Poorly filtered inlet air poor air quality to compressor Check i Compressor malfunction
20. ASIC test nran aza WI m 9 acceptable E 3 range re TE T Every 5 oil units O Compressor with up to 25 duty cycle G Month per month See e g City transit bus refuse appendix bulk unloaders low boys A urban region coach central E tire inflation 12 Every or For oil carry over Year z control suggested less 5 upgrades lt 3 4 in 15 ft xe iS a Footnotes 1 With increased air demand the air dryer cartridge needs to be replaced more often Note Compressor and or air dryer Use the drain valves to slowly drain all reservoirs to zero psi upgrades are recommended in cases 2 l 3 Allow the oil water mixture to fully settle before measuring oil quantity AA a Di 4 To counter above normal temperatures at the air dryer inlet and resultant oil vapor passing above upstream in the air system replace the discharge line with one of a larger diameter and or longer length This helps reduce the air s temperature If sufficient cooling occurs the For Bendix Tu Flo 550 and 750 oil vapor condenses and can be removed by the air dryer Discharge line upgrades are not compressors unloader service is covered under warranty Note To help prevent discharge line freeze ups shorter discharge i line lengths or insulation may be required in cold climates See Bendix Bulletins TCH 08 21 ECOMMENGEG Ev ely EPOCO MIES and TCH 08 22 included in Appendix B for more informat
21. AVOID PERSONAL INJURY OR DEATH When working on or around a vehicle the following general precautions should be observed at all times 1 Park the vehicle on a level surface apply the parking brakes and always block the wheels Always wear safety glasses 2 Stop the engine and remove ignition key when working under or around the vehicle When working in the engine compartment the engine should be shut off and the ignition key should be removed Where circumstances require that the engine be in operation EXTREME CAUTION should be used to prevent personal injury resulting from contact with moving rotating leaking heated or electrically charged components 13 14 Do not attempt to install remove disassemble or assemble a component until you have read and thoroughly understand the recommended procedures Use only the proper tools and observe all precautions pertaining to use of those tools If the work is being performed on the vehicle s air brake system or any auxiliary pressurized air systems make certain to drain the air pressure from all reservoirs before beginning ANY work on the vehicle If the vehicle is equipped with an AD IS air dryer system or a dryer reservoir module be sure to drain the purge reservoir Following the vehicle manufacturer s recommended procedures deactivate the electrical system in a manner that safely removes all electrical power from the vehicle Never exceed manufacturer s recomm
22. LUBRICATED TYPE COMPRESSORS OIL PUMP SCREEN Check oil pump screen to be sure it is clean and not damaged replace if damaged OIL PUMP PISTON AND BUSHING Check fit of oil pump piston in base plate pump bushing It must be a medium sliding fit If excessive clearance is found the oil rod and or bushing must be replaced OIL PUMP RELIEF VALVE If the oil pump relief valve is defective it should be replaced OIL PUMP CHECK VALVE The check valve should be replaced It can be checked by applying air pressure back through the pin stop end and noting that the ball check seals on its seat REPAIRS DISCHARGE VALVES AND SEATS If discharge valve seats merely show signs of slight wear they can be dressed by using a lapping stone grinding compound and grinding tool Install new discharge valves and valve springs To test for leakage by the discharge valves apply about 100 pounds of air pressure through the cylinder head discharge port and apply soap suds at the discharge valves and seats Leakage which will permit the formation of bubbles is permissible If excessive leakage is found leave the air pressure applied and with the use of a fibre or hardwood dowel and hammer tap the discharge valves off their seats several times This will help the valves to seat and should reduce any leakage With the air pressure still applied at the discharge port of the cylinder head check for leakage at the discharge valve cap nuts No leakag
23. TU FLO 500 Air Compressor TU FLO 1000 Air Compressor DESCRIPTION AND OPERATION 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 Tu Flo Type 400 500 and 1000 compressors are single stage reciprocating piston type compressors Tu Flo 400 Fig 1 and 500 Fig 2 compressors have two cylinders 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 400 compressor is 7 1 4 cubic feet per minute The Tu Flo 500 compressor is rated at 12 cubic feet per minute and the Tu Flo 1000 compressor has a rating of 24 cubic feet per minute Tu Flo type compressors have automatic type inlet valves Their unloading mechanisms are located in the cylinder block FIGURE 3 TU FLO 1000 AIR COMPRESSOR 2 and they have no external moving parts Both air and water cooled type compressors are available Various mounting and drive adaptations are used as required by different vehicle engine designs Fig 4 FIGURE 4 VARIOUS COMPRESSOR MOUNTINGS Compressors are either engine or self lubricated The majority used are the engine lubricated types Fig 5 which obtain the oil necessary to lubricate t
24. VING These instructions are general and are intended to be a guide In some cases additional preparations and precautions are necessary Chock the wheels of the vehicle and drain the air pressure from all the reservoirs in the system Drain the engine cooling system and the cylinder head of the compressor Disconnect all air water and oil lines leading to and from the compressor Remove the drive gear s or pulley from the compressor crankshaft using a gear puller Inspect the pulley or gear and associated parts for visible wear or damage Since these parts are precision fitted they must be replaced if they are worn or damaged DISASSEMBLY GENERAL Remove road dirt and grease from the exterior of the compressor with a cleaning solvent Before the compressor is disassembled the following items should be marked to show their relationship when the compressor is assembled Mark both the front and rear end cover in relation to the crankcase Mark the drive end of the crankshaft in relation to the front end cover and the crankcase Mark the cylinder head in relation to the block and block to crankcase Mark the base plate or base adapter in relation to the crankcase A convenient method to indicate the above relationships is to use a metal scribe to mark the parts with numbers or lines Do not use a marking method that can be wiped off or obliterated during rebuilding such as chalk Remove all compressor attachments such as governors air s
25. Vehicle OK END TEST Return vehicle to service Cloudy emulsion mixture ibe Is this vehicle being re tested after water etc was found last time YES NO Find the point on the label where the number of oil units meets the number of days Wn the vehicle s air tanks a the vehicle s air tanks were last drained Go to the Advanced Change air dryer Troubleshooting cartridge Guide to find reason s for presence of water Test for air leakage Use Test 2 END TEST Re test with the BASIC Test after 30 days END TEST END TEST If the number of days since the air tanks were drained is unknown use the 30 day line Note Typical air dryer cartridge replacement schedule is every 3 yrs 300K miles for low air use vehicles and every year 100K miles for high air use vehicles 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 See the cold weather tips in Bulletins TCH 008 21 and TCH 008 22
26. air cooled 2 5 gal min water cooled 250 CFM air flow Displacement at 1 250 RPM Maximum recommended RPM Minimum coolant flow at maximum RPM Approximate horsepower required at 1 250 RPM 1 2H P Maximum inlet air temperature 250 F Maximum discharge air temperature 400 F Minimum pressure required to unload 60 PSI Minimum oil pressure required at engine idling speed 5 PSI Minimum oil pressure required at maximum governed engine speed 15 PSI Approximate average weight 34 Ibs Oil capacity of self lubricated model 53 qts Minimum discharge line size 1 2 O D tubing or equivalent Minimum coolant line size 3 8 O D tubing or equivalent 1 4 O D tubing or equivalent 1 2 O D tubing or equivalent 5 8 I D Minimum oil supply line size Minimum oil return line size Minimum air inlet line size Part Number dictates oil capacity 24 cu ft min 3 000 water cooled 2 400 air cooled 2 5 gal min water cooled 250 CFM air flow 12 cu ft min 3 000 water cooled 2 400 air cooled 2 5 gal min water cooled 250 CFM air flow 2 3H P 4 6H P 250 F 250 F 400 F 400 F 60 PSI 60 PSI 5PSI 5PSI 15PSI 15 PSI 46 Ibs 75 Ibs 95 qts to 5 qts 5 8 O D tubing or equivalent from each head to a common manifold with 1 tubing from manifold 1 2 O D tubing or equivalent 1 4 O D tubing or equivalent 5 8 O D tubing or equivalent 1 I D if equipped with inlet manifold or dual 5 8 I D
27. are out of round more than 0 001 in must be reground Bearing inserts are available in 0 010 in 0 020 in and 0 030 in undersizes for reground crankshafts Main bearing journals must be maintained so bearings are snug fit The oil seal ring groove or grooves in crankshatts fitted with oil seal rings must not be worn The ring groove walls must have a good finish and they must be square Check to be sure the oil passages are open and clean through the crankshaft CONNECTING ROD BEARINGS Check connecting rod bearings on crankshaft journals for proper fit Used bearing inserts should be replaced Connecting rod caps are not interchangeable The locking slots of the connecting rod and cap should be positioned adjacent to each other Clearance between the connecting rod journal and the connecting rod bearing must not be less than 0 0003 in or more than 0 0021 in after rebuilding MAIN BEARINGS Check for wear or flat spots if found bearings should be replaced If type with sleeve bearing this bearing should be checked for scores and wear and replaced if necessary UNLOADER MECHANISM Used unloader mechanism should be replaced by unloader kits 265014 for Type Tu Flo 400 compressors and 265015 for Types Tu Flo 500 and 1000 compressors The Tu Flo 1000 compressor requires two kits per compressor The new unloader pistons should be a loose sliding fit in the unloader piston bores of the cylinder block PARTS SPECIAL TO SELF
28. cing Filter Service Reservoir Supply Reservoir Reservoir Drain 17 Table A Maintenance Schedule and Usage Guidelines Regularly scheduled maintenance is the single most important factor in maintaining the air brake charging system Recom Recom Acceptable Typical Discharge mended mended Reservoir i Air Dryer Reservoir Oil Contents H No of Cartridge Drain at Regular Vehicle Used for Axles Replacement Schedule Drain Interval Low Air Use j fo u W k with less than 15 duty BASIC test e g Line haul single trailer A E ACCERIADIE w o air suspension air over 9 Fere Recom range Nur NEW brakes less 9 mended 3 oil units a EEE 5 8 in 9 ft Ever per month O Every 3 y 2 Month See 5 gt Years Compressor with up to 25 duty cycle with up to 25 duty cycle j Max of appendix e g Line haul ud a trailer AE i every 90 A with air suspension ay E3 For oil carry over days rom jira control suggested school bus a E E upgrades mar EE h E 5 8 in 12ft For the Ss BASIC i i rel Eo Test Kit High Air Use JE ene Compressor with up to 25 duty cycle lt Bendix p p y cy P N e g Double triple trailer open J 5013711 highway coach RV most 2 S pick up amp delivery yard or terminal jockey off highway E SE Every 2 O or oil carry over construction loggers concrete E E E Years mixer dump truck fire truck upgrades ess 5 5 8 in 15 ft a 5 LU B
29. column 3 and 4 for recommended service schedule Check Drain all air tanks into Bendix BASIC test cup Bendix Air System Inspection Cup If less than one unit of reservoir contents is found the vehicle can be returned to service Note If more than one oil unit of water or a cloudy emulsion mixture is present change the vehicle s air dryer check for air system leakage Test 2 on page 29 stop inspection and check again at the next service interval See the BASIC test kit for full details If less than one oil unit of water or water cloudy emulsion mixture is present use the BASIC cup chart on the label of the cup to determine if the amount of oil found is within the acceptable level gt If within the normal range return the vehicle to service For vehicles with accessories that are sensitive to small amounts of oil consider a Bendix PuraGuard QC oil coalescing filter gt If outside the normal range go to Symptom 4 0 c Also see the Table A on page 18 column 3 for recommended air dryer cartridge replacement schedule Go to Test 2 on page 29 See Table A column 1 on page 18 for recommended compressor sizes gt If the compressor is too small for the vehicle s role for example where a vehicle s use has changed or service conditions exceed the original vehicle or engine OE spec s then upgrade the compressor Note The costs incurred e g installing a larger capacity compressor etc are
30. ction c Air dryer maintenance not performed d Air dryer malfunction e Improper governor control line installation to the reservoir f Governor malfunction a Reservoir safety valve malfunction b Governor malfunction c Compressor unloader mechanism malfunction a Air dryer malfunction b Governor malfunction c Air brake system leakage d lmproper governor control line installation to the reservoir a Air brake charging system maintenance not performed Check 6 Compressor unloader mechanism malfunction c Air dryer purge valve or delivery check valve malfunction d Air brake system leakage What you should do cy cy Inspect delivery lines to reservoir for restrictions and repair as needed Verify relief pressure is at vehicle or component manufacturer specifications Replace if defective See Maintenance Schedule and Usage Guidelines Table A column 3 on page 18 Verify operation of air dryer Follow vehicle O E maintenance recommendations and component Service Data information Go to Test 5 on page 30 Go to Test 4 on page 30 Verify relief pressure is at vehicle or component manufacturer s specifications typically 150 psi Replace if defective Go to Test 4 on page 30 Go to Test 6 on page 30 Verify operation of air dryer Follow vehicle O E maintenance recommendations Go to Test 4 on page 30 Go
31. ddle Install inlet valve seats if they have been previously removed Position and install inlet valve guides then drop inlet valves in their guides There should be a loose sliding fit between guides and valves CYLINDER HEAD ASSEMBLY If previously removed the discharge valve seats should be installed Drop discharge valves into their seats Install discharge valve springs and cap nuts Place the inlet valve springs in the cylinder head Use a small quantity of grease to hold them in place just enough grease to keep the springs from falling out Place cylinder head gasket on cylinder block Carefully align cylinder head assembly on block and install cap screws with lock washers Tighten securely and evenly cap screws that hold cylinder head to block BASEPLATE SELF LUBRICATED TYPE COMPRESSORS Install oil pump piston and rod on crankshaft Oil rod bearing fit must be the same as specified for connecting rod bearings Install oil rod cap nuts and cotter pins to lock oil rod nuts Install oil pump relief valve in base plate The relief valve can be tested at this stage by applying air pressure to the relief valve The valve should open when the pressure is between 14 psi minimum and 24 psi maximum When the relief valve is properly installed in the base plate install set screw that locks it in place Place oil pump screen in base and install retaining ring making sure it snaps in place and secures the screw Install oil filte
32. e Technician uses the chart label on the BASIC test cup to help decide the action to take based on the amount of oil found Use the lower J acceptance line for low air use vehicles and upper If number of days is if oil level is at or below System OK e ine for high air use vehicles from Step A 30 60 days hih ai acceptare ae Return to service use or noan yerel CID of days gt if oil level is at or below System OK e if the number of days is Stop inspection unknown or outside the if oil level is above 30 day Test again limits above acceptance line gt after 30 days See Footnote 2 BASIC Test Example An oil level of 4 units in a sixty day period is within the acceptance area at or below the line for both low and high air use vehicles Return the vehicle to service The Technician looks for the point where the number of days since the air tanks were drained meets the oil level If itis at or below the low or high use Sixty days since last air Decision point acceptance line the vehicle has passed the test If tank draining the point is above the line we go to the leakage test Air leakage is the number one Opt of compressors having STEP D Air Brake System Leakage Test So Oe Me ADU air in turn run too hot and Days Since LastAir Tan amp QOraining 30 35 40 45 50 55 65 70 80 85 90 Park the vehicle on level ground and chock wheels Build system pressure to g
33. e adapter should be checked If it is loose remove the intake adapter clean the strainer plate if applicable and replace the intake adapter gasket and reinstall the adapter securely Check line connections both at the compressor intake adapter and at the engine air cleaner Inspect the connecting line for ruptures and replace it if necessary FIGURE 16 COMPRESSOR INTAKE ADAPTER AIR LEAKAGE TESTS Leakage past the discharge valves can be detected by removing the discharge line applying shop air back through the discharge port and listening for escaping air Also the discharge valves and the unloader pistons can be checked for leakage by building up the air system until the governor cuts out then stopping the engine With the engine stopped carefully listen for escaping air at the intake To pinpoint leakage if noted squirt oil around the unloader pistons If there is no noticeable leakage at the unloader pistons the discharge valves may be leaking 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 Bendix parts in which case the following information should prove helpful REMOVING AND INSTALLING REMOVING These instructions are general and in some cases additional precautions mus
34. e is permissible INLET VALVES AND SEATS If inlet valve seats show sign of slight nicks or scratches they can be redressed with a fine piece of emery cloth or by lapping with a lapping stone grinding compound and grinding tool If the seats are excessively damaged to the extent that they cannot be reclaimed they should be replaced The dimension from the top of the cylinder block to the inlet valve seat should not exceed 0 118 in nor be less than 0 101 in 11 Slightly worn or scratched inlet valves can be reclaimed by lapping them on a piece of fine crocus cloth on a flat surface but it is suggested that new inlet valves be installed ASSEMBLY INSTALLING CYLINDER BLOCK Position cylinder block gasket and block on crankcase according to markings made prior to disassembly Using cap screws with lock washers secure cylinder block to crankcase INSTALLING CRANKSHAFT If the crankshaft is fitted with oil seal rings install rings Position ball bearings and crankshaft in crankcase making sure the drive end of the crankshaft is positioned as marked before disassembly If one end of the crankcase is counterbored for holding a bearing be sure the crankshaft is installed through the correct end of the crankcase Carefully press crankshaft and bearings into crankcase using arbor press Position a new rear end cover gasket when used over the rear end of the crankcase making sure the oil hole in the gasket lines up with the
35. ecome blocked or restricted by the reservoir contents e g water or Ice Test 6 Compressor Unloader Leakage Bendix Compressors Park vehicle chock wheels and follow all standard safety procedures Remove the governor and install a fitting to the unloader port Add a section of air hose min 1ft long for a 1 2 diameter line and a gauge to the fitting followed by a shut off valve and an air source shop air or small air tank Open the shut 30 reservoir service reservoir or reservoir port of the D 2 governor verify cut in and cut out pressures are within vehicle OEM specification If the governor is malfunctioning replace it Perform proper reservoir drain intervals and air dryer cartridge maintenance per Maintenance Schedule and Usage Guidelines Table A on page 18 Return the vehicle to service off and charge the unloader port by allowing air pressure to enter the hose and unload the compressor Shut off the air supply and observe the gauge Asteady reading indicates no leakage at the unloader port but a falling reading shows that the unloader mechanism is leaking and needs to be serviced NOTES 31 Appendix A Information about the BASIC Test Kit Bendix P N 5013711 Service writer records info including the number of days since all air tanks were drained and fills out symptom checklist Technician inspects items START BASIC TEST Park vehicle on LEVEL ground Chock
36. ecting air lines and wires Automatic Drain Valves System without Air Dryer As we stated last year routine reservoir draining is the most basic step although not completely effective in reducing the possibility of freeze up While automatic drain valves relieve the operator of draining reservoirs on a daily basis these valves MUST be routinely checked for proper operation Don t overlook them until they fail and a road call is required 37 38 39 40 BW1420 2004 Bendix Commercial Vehicle Systems LLC All rights reserved 10 2004 Printed in U S A
37. ehicles 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 orang nee the customer must determine based on its experience with the vehicle whether to participate now or wait for warmer weather See the cold weather tips in Bulletins TCH 008 21 and TCH 008 22 included in Appendix B of the advanced troubleshooting guide contents of all the air tanks on the vehicle should be used Note for returning vehicles that are being retested after a water cloudy emulsion mixture was found last time and the air dryer cartridge replaced If more than one oil unit of water or a cloudy emulsion mixture is found again stop the BASIC test and consult the air dryer s Service Data sheet troubleshooting section 33 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 Record days since air 2 Record amount 3 Action to tanks were last drained of oil found take Th
38. ended pressures 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 9 10 11 Use only genuine Bendix replacement parts components and kits Replacement hardware tubing hose fittings etc must be of equivalent size type and strength as original equipment and be designed specifically for such applications and systems Components with stripped threads or damaged parts should be replaced rather than repaired Do not attempt repairs requiring machining or welding unless specifically stated and approved by the vehicle and component manufacturer Prior to returning the vehicle to service make certain all components and systems are restored to their proper operating condition For vehicles with Antilock Traction Control ATC the ATC function must be disabled ATC indicator lamp should be ON prior to performing any vehicle maintenance where one or more wheels on a drive axle are lifted off the ground and moving MAINTENANCE INSTRUCTIONS FOR LARGE SUMP TU FLO 1000 AIR COMPRESSOR 288578 SPECIAL APPLICATION This compressor is an air cooled belt driven self lubricated V four cylinder compressor It is driven by an electric motor and cooling air is supplied by a fan on the driven pulley The system air pressure is controlled between 135 psi and 150 psi by a pressure switch starting and stop
39. ere ice may form and block the flow If instead ice blockages occur at the air dryer inlet insulation may be added here or if the inlet fitting is a typical 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 and TCH 08 22 see pages 35 37 Shorter discharge line lengths or insulation may be required in cold climates The air dryer contains a filter that collects oil droplets and a desiccant bed that removes almost all of the remaining water vapor The compressed air is then passed to the air brake service 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 recommended installation of a Bendix PuraGuard system filter designed to minimize the amount of oil present The Air Brake Charging System supplies the compressed air for the braking system as well as other air accessories for the vehicle The system usually Discharge Optional Ping Tank consists of an air compressor governor discharge line Line oN Air Dryer air dryer and service reservoir x Compressor Governor Governor plus Synchro valve for the Bendix DuraFlo 596 Compressor Optional Bendix PuraGuard System Filter or PuraGuarad QC Oil Coales
40. es can cause oil as surface temperature of the fittings vapor to pass through the air dryer into the at the compressor discharge port T1 air brake system at the air dryer inlet fitting T2 If available a dyno may be used l 5 See table below 1 Allow the compressor to build the air system 6 Retest before returning the vehicle to service pressure to governor cut in 2 Pump the brakes to bring the dash gauge T1 T2 pressure to 90 psi i 3 Allow the compressor to build pressure from LD U ev r Au 95 to 105 psi gauge pressure and maintain Fitting Fitting this pressure range by cycling the brakes for i i under under Temperatures are within five 5 minutes 360 F 200 normal range for this test check other symptoms Go to 4 0 h under over This could indicate a discharge 360 F 200 F line problem e g restriction Call 1 800 AIR BRAKE 1 800 247 2725 and speak with our Tech Team over Compressor is running hot 360 F Check coolant 4 f and or Discharge Line discharge line 4 g 29 Tests continued Test 4 Governor Malfunction Inspect control lines to and from the governor for restrictions e g collapsed or kinked Repair as necessary Using a calibrated external gauge in the supply Test 5 Governor Control Line 1 Ensure that the governor control line from the reservoir is located at or near the top of the reservoir This line if located near the bottom of the reservoir can b
41. f excessive clearance is found Wrist pin bushings should be reamed after being pressed into connecting rods Replace used wrist pin lock wires Tu Flo 400 compressors manufactured after September 1977 will have Teflon plugs in each end of the wrist pins instead of the lock wire The Teflon plugs pc no 292392 may be used instead of the lock wires on all compressors See Fig 22 PISTON RINGS Check fit of piston rings in piston ring grooves Check ring gap with rings installed in cylinder bores Refer to Fig 24 for correct gap and groove clearance All rings must be located in their proper ring grooves as shown The rings can be identified by the width and should be installed with the bevel or the pipmark if any toward the top of the piston This applies to cast iron pistons only as shown above Die cast pistons use five 5 narrow rings COMPRESSION RINGS 2 COMPRESSION RINGS 2 FIGURE 22 TU FLO 400 AIR COMPRESSOR NEW STYLE TU FLO 400 AIR COMPRESSOR CORRECT GROOVE CLEARANCE CORRECT GAP CLEARANCE WITH RING IN CYLINDER j 0035 014 TU FLO 500 amp 1000 AIR COMPRESSOR CORRECT GROOVE CLEARANCE CORRECT GAP CLEARANCE WITH RING IN CYLINDER ard FIGURE 24 PISTON RING POSITIONS GAPS AND GROOVE CLEARANCE CRANKSHAFT Check crankshaft screw threads keyways tapered ends and all machined and ground surfaces for wear scores or damage Crankshaft journals which
42. heir moving parts from the engines on which they are mounted To meet the requirements of some manufacturers and for field installations self lubricated types Fig 6 are available They are compressors having a self contained oil supply and pumping system The method of lubricating the moving parts of the compressor is the same in either type Oil is forced through the oil passage in the crankshaft and out around each connecting rod journal The turning motion of the crankshaft throws the oil that is forced out at the journals against the cylinder bores and crankcase walls lubricating the bores and crankshaft bearings The wrist pins and wrist pin bushings are lubricated in two ways depending upon the type connecting rods used Older design compressors had forged steel rifle drilled rods through which oil was forced to the wrist pin bushings Later versions FIGURE 5 ENGINE LUBRICATED TYPE FIGURE 6 SELF LUBRICATED TYPE had either die cast aluminum cast ductile iron or forged steel rods which were not rifle drilled but were drilled at the top of the rod The wrist pins and bushings are lubricated by oil dripping from a drip boss on the piston into a catch funnel at the top of the rod and through the drilled passage to the bushings and pins SEE FIG 7 WRIST PIN BUSHING PISTON WRIST PIN LOCK WIRE CAST IRON WRIST PIN PISTON PASSAGE CONNECTING OLD DESIGN CATCH FUNNEL WRIST PIN BUSHING PISTON
43. hicle in a warmed building This is the only method for thawing that will not cause damage to the air system or its components 3 Do use dummy hose couplings on the tractor and trailer 4 Do check for sections of air line that could form water traps Look for drooping lines Don ts 1 Do not apply an open flame to air lines and valves Beyond causing damage to the internal nonmetallic parts of valves and melting or burning non metallic air lines WARNING THIS PRACTICE IS UNSAFE AND CAN RESULT IN VEHICLE FIRE 2 Do not introduce pour fluids into air brake lines or hose couplings glad hands Some fluids used can cause immediate and severe damage to rubber components Even methanol alcohol which is used in Alcohol Evaporators and Injectors should not be poured into air lines Fluids poured into the system wash lubricants out of valves collect in brake chambers and valves and can cause malfunction Loss of lubricant can affect valve operating characteristics accelerate wear and cause premature replacement 3 Do not park a vehicle outside after thawing its air system indoors Condensation will form in the system and freeze again Place the vehicle in operation when it is removed to the outdoors Supporting Air and Electrical Lines Make certain tie wraps are replaced and support brackets are re assembled if removed during routine maintenance These items prevent the weight of ice and snow accumulations from breaking or disconn
44. idelines 1 Oil Leakage at Head Gasket 29 Maintenance Schedule and Usage Guidelines Table A 18 Engine 2 System Leakage 3 Compressor Discharge and Air Dryer Inlet Temperature 4 Governor Malfunction 5 Governor Control Line 6 Compressor Unloader BASIC Test Information This guide is only for vehicles that use desiccant air dryers 16 Introduction to the Air Brake Charging System Powered by the vehicle engine the air compressor builds the air pressure for the air brake system The air compressor is typically cooled by the engine coolant system and lubricated by the engine oil supply The compressor s unloader mechanism and governor along with a synchro valve for the Bendix DuraFlo 596 air compressor control the brake system air pressure between a preset maximum and minimum pressure level by monitoring the pressure in the service or supply reservoir When the air pressure becomes greater than that of the preset cut out the governor controls the unloader mechanism of the compressor to stop the compressor from building air and also causes the air dryer to purge As the service reservoir air pressure drops to the cut in setting of the governor the governor returns the compressor back to building air and the air dryer to air drying mode As the atmospheric air is compressed all the water vapor originally in the air is carried along into the air system as well as a small amount
45. included on pages 35 37 of this document Note After replacing a compressor residual oil may take a considerable period of time to be flushed from the air brake system 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 The Service Writer fills out these fields with information gained from the customer Vehicle Checklist for Technician Customer s Complaint Have you confirmed complaint Please check all that apply Relay valve leaks oil Q malfunctions The Technician Dash valve L leaks oil OQ malfunctions The Service Writer Q Air dryer leaks oil Ono O yes isn a also checks off any Ll Governor malfunction 2 no yes ease complaints thatthe 0il in gladhands O no yes RAQ k e SU customer makes to how much oil did you find can be confirmed help the Technician LI Oil on ground or vehicle exterior in investigating amount described Short air dryer cartridge life replaces every L miles L kms or Ll months x Note A confirmed com plaintabove does NOT mean We will measure amount currently found when we get to step B of the test that the compressor must be LI Excessive engine oil loss amount described replaced Is the engine leaking oi
46. ion 5 For certain vehicles applications where turbo charged inlet air is used a smaller size compressor may be permissible 18 Air Brake Charging System Troubleshooting How to use this guide Find the symptom s that you see then move to the right to find the possible causes What it may indicate and remedies What you should do Review the warranty policy before performing any intrusive compressor maintenance Unloader or cylinder head gasket replacement and resealing of the bottom cover plate are usually permitted under warranty Follow all standard safety procedures when performing any maintenance WARNING Please READ and follow these instructions to avoid personal injury or death When working on or around a vehicle the following general precautions should be observed at all times 1 Park the vehicle on a level surface apply the parking brakes and always block the wheels Always wear safety glasses Stop the engine and remove ignition key when working under or around the vehicle When working in the engine compartment the engine should be shut off and the ignition key should be removed Where circumstances require that the engine be in operation EXTREME CAUTION should be used to prevent personal injury resulting from contact with moving rotating leaking heated or electrically charged components Do not attempt to install remove disassemble or assemble a component until you have read and tho
47. kage is within the limits stated in BW1279 Check the operation and function of the air dryer using the appropriate Service Data Sheet for the air dryer AD 9 Air Dryer Service Data Sheet SD 08 2412 AD 4 Air Dryer Service Data Sheet SD 08 2407 AD 2 Air Dryer Service Data Sheet SD 08 2403 AD IP Air Dryer Service Data Sheet SD 08 2414 AD SP Air Dryer Service Data Sheet SD 08 2415 Trailer System Guard Air Dryer Service Data Sheet SD 08 2416 36 Appendix B Continued i Be Technical Bulletin Bulletin No TCH 008 022 Effective Date 1 1 1994 Page 1 of 1 nadi Subject Additional Cold Weather Operation Tips for the Air Brake System 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 Thawing Frozen Air Lines The old saying Prevention is the best medicine truly applies here Each year this activity accounts for an untold amount of unnecessary labor and component replacement Here are some Do s and Don ts for prevention and thawing Do s 1 Do maintain freeze prevention devices to prevent road calls Don t let evaporators or injectors run out of methanol alcohol or protection will be degraded Check the air dryer for proper operation and change the desiccant when needed 2 Do thaw out frozen air lines and valves by placing the ve
48. lene pipe insulation 12 16 ft 5 8 in Last 3 feet including fitting at the end of the discharge line must be insulated with 1 2 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 35 Appendix B Continued Bulletin No TCH 008 021 Effective Date 11 1 92 Page 2 of 2 High Duty Cycle Vehicles City Transit Coaches Refuse Haulers Etc The maximum discharge line length is 16 feet Length I D min Other Requirements 10 16 ft Yo 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 BW1279 Excessive system leakage causes the compressor to pump more air and also more moisture into the brake system Reservoir Draining System Without Air Dryer Routine reservoir draining is the most basic step although not completely effective in reducing the possibility of freeze up All reservoirs in a brake system can accumulate water and other contamination and must be drained The best practice is to drain all reservoirs daily When draining reservoirs turn the ENGINE OFF and drain ALL AIR from the reservoir better still open the drain cocks on all reservoirs and leave them open over night to assure a
49. ll contamination is drained reference Service Data Sheet SD 04 400 for Bendix Reservoirs If automatic drain valves are installed check their operation before the weather turns cold reference Service Data Sheet SD 03 2501 for Bendix DV 2 Automatic Drain Valves It should be noted that while the need for daily reservoir draining is eliminated through the use of an automatic drain valve periodic manual draining is still required Alcohol Evaporator or Injector Systems Check for proper operation of these systems by monitoring alcohol consumption for a few days Reference Service Data Sheet SD 08 2301 for the Bendix Alcohol Evaporator Too little means the system is not receiving adequate protection and too much simply wastes alcohol As a general guide these systems should consume approximately 1 to 2 ounces of alcohol per hour of compressor loaded time compressing air City pick up and delivery vehicles will operate with the compressors loaded compressing air more while compressors on highway vehicles will be loaded less These figures are approximate and assume that air system leakage is within the limits of the Bendix Dual System Air Brake Test and Check List BW1279 Last but not least begin using alcohol several weeks prior to freezing weather to ensure that the system is completely protected Use only methanol alcohol such as Bendix Air Guard in evaporators or injectors Air Dryers Make certain air brake system lea
50. lling them in the compressor 12 Remove connecting bolts and bearing cap from one connecting rod Turn crankshaft so one of its connecting rod journals is in the downward center position Compress the rings with a ring compression tool and insert the connecting rod with piston through the top of the cylinder whose journal is down Position and attach the bearing cap to the connecting rod making sure the bolt lock washers are properly positioned on the cap Tighten connecting rod bolts evenly and bend the two new lock washer prongs up against the hex head of the bolt Install the other connecting rod and piston in the same manner FIGURE 25 UNLOADER MECHANISM UNLOADER MECHANISM Fig 25 The unloader pistons and their bores must be lubricated with special lubricant piece number 239379 dimethyl polysiloxane prior to installation If new unloader kits are being installed the pistons in the kit are already lubricated Install the unloader pistons in their bores with caution against cutting the grommets or distorting the back up rings Position unloader plungers in their guides and slip them in and over the tops of the pistons Install the unloader spring seat in the cylinder block a small hole is drilled in the block for this purpose Position the saddle between unloader piston guides so its forks are centered on the guides Install the unloader spring making sure it seats over the spring seats both in the block and on the sa
51. ly rebuilt by an experienced person A compressor efficiency or build up test can be run which is not too difficult Before the test the crankcase of a self lubricated type compressor should be properly filled with lubricating oil An engine lubricated compressor must be connected to an oil supply line of at least 15 pounds pressure during the test and an oil return line must be installed to keep the crankcase drained The compressor when tested should be tested without a strainer To the discharge port of the compressor connect a reservoir or reservoirs whose volume plus the volume of the connecting line equals 1 300 cubic inches Run the compressor between 1 700 and 1 750 RPM Elapsed time that the compressor takes to build up from 0 to 100 psi depends on the type compressor as follows BUILD UP TIME TYPE COMPRESSOR 0 TO 100 PSI TU FLO 400 47 SECONDS MAXIMUM TU FLO 500 30 SECONDS MAXIMUM TU FLO 1000 15 SECONDS MAXIMUM During the above test the compressor should be checked for oil leakage and noisy operation COMPRESSOR TROUBLESHOOTING IMPORTANT The troubleshooting contained in this section considers the compressor as an integrated component of the overall air brake charging system and assumes that an air dryer is in use The troubleshooting presented will cover not only the compressor itself but also other charging system devices as they relate to the compressor WARNING PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO
52. mponents as needed Note Dirt ingestion will damage compressor and is not covered under warranty Replace the compressor only after making certain that none of the preceding conditions 9 0 a through 9 0 h exist 26 Symptom What it may indicate 10 0 Air charging a Governor malfunction system doesn t build air b Restricted discharge line c Air dryer heater malfunction exhaust port frozen open d Compressor malfunction Note For the Bendix DuraFlo 596 air compressor not only the governor but also the SV 1 synchro valve used would need to be tested See Bulletin TCH 001 048 11 0 Compressor a Restricted discharge line safety valve releases air Check Compressor builds too much air Damaged discharge line shown 0 Downstream air brake system check valves or lines may be blocked or damaged c Air dryer lines incorrectly installed d Compressor safety valve malfunction e Compressor unloader mechanism malfunction f Governor malfunction What you should do r gt Go to Test 4 on page 30 r gt See 9 0 f r gt Replace air dryer heater r gt Replace the compressor only after making certain the preceding conditions do not exist r gt If discharge line is restricted gt By more than 1 16 carbon build up replace the discharge line see Table A column 2 on page 18 for recommended size and go to Test 3 on page 29 gt By other
53. ng onto compressor a Leak at the front or rear fuel pump etc mounting flange b Leak at air inlet fitting c Leak at air discharge fitting d Loose broken oil line fittings a Excessive leak at head gasket b Leak at bottom cover plate c Leak at internal rear flange gasket d Leak through crankcase e If unable to tell source of leak Head gasket and rear flange gasket locations Air brake charging system functioning normally mee to service r gt Repair or replace as necessary If the mounting bolt torques are low replace the gasket r gt Replace the fitting gasket Inspect inlet hose and replace as necessary r gt Replace gasket or fitting as necessary to ensure good seal r gt Inspect and repair as necessary r gt Go to Test 1 on page 29 r gt Reseal bottom cover plate using RIV silicone sealant r gt Replace compressor r gt Replace compressor r gt Clean compressor and check periodically Check air brake charging system Check that regular maintenance is being performed 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 Symptom What it may indicate 4 0 Oil in Supply or Maintenance Service Reservoir air dryer installed If a maintained Bendix a If air brake charging sys
54. nspect cylinder head body for cracks or damage WATER COO LED TYPE Use air pressure to test water jackets of cylinder head and block for leakage Replace unit if leakage is found DISCHARGE VALVES AND SEATS lf discharge valves are worn and grooved where they contact the seats they should be replaced If the discharge valve seats are worn excessively so that there is no longer enough metal left to reclaim them by lapping the seats should be replaced DISCHARGE VALVE SPRING AND CAP NUTS Replace all used discharge valve springs and cap nuts CRANKCASE AND END COVERS Check for cracks or broken lugs in crankcase and end covers Also check their oil passages to make sure they are open and clean If an oil seal ring is used in the end cover check fit of ring in ring groove There should be 0 008 in to 0 015 in clearance atthe gap when placed in the end bore of the crankshaft If the oil ring is worn thin or is damaged it should be replaced Inspect oil ring groove in end cover if groove is worn excessively replace end cover or machine groove for next oversize oil seal ring lf the crankshaft main bearings are installed in the end cover check for excessive wear and flat spots and replace if necessary CYLINDER BLOCK Check for cracks or broken lugs on cylinder block Also check unloader bore bushings to be sure they are not worn rusted or damaged If these bushings are to be replaced they can be removed by running a 1 8 in
55. ove end cover gasket Replace oil seal after cleaning end cover Remove cap screws that hold opposite end cover to crankcase remove end cover and its gasket Some compressors have crankcases that have a shoulder for positioning the crankshaft In these cases the crankshaft must be removed through one particular end Press the crankshaft and ball bearings from the crankcase then press ball bearings from crankshaft Many compressors will have sleeve type bearings in the crankcase or in the end cover If the clearance between crankshaft journal and bearing exceeds 0065 in the sleeve bearing should be replaced with appropriate undersize FIGURE 19 CRANKCASE TU FLO 400 amp 500 AIR COMPRESSORS FIGURE 19A CRANKCASE TU FLO 1000 AIR COMPRESSOR BLOCK Fig 20 If compressor is fitted with an air strainer inlet elbow or governor remove same Remove cap screws securing cylinder block to crankcase separate crankcase and cylinder block and scrape off gasket Remove unloader spring spring saddle and spring seat from cylinder block Remove unloader guides and plungers and with the use of shop air blow unloader pistons out of cylinder block unloader piston bores Remove inlet valve guides inlet valve seats can be removed but only if they are worn or damaged and are being replaced Unloader bore bushings should be inspected but not removed unless they are damaged FIGURE 20 CYLINDER BLOCK EXPLODED VIEW
56. overnor cut out pass oil vapor along into the and allow the pressure to stabilize for one minute system Here the Technician 1 Observe the dash gauges for two additional minutes without the service brakes applied conducts a four minute test to 2 Apply service brakes for two minutes allow pressure to stabilize and observe the dash see if leakage is a problem Jagen with the vehicle being tested If you see any noticeable decrease of the dash air gauge readings repair leaks Repeat this test to confirm that air leaks have been repaired and return vehicle to service Please repeat BASIC test at next service interval Note Air leaks can also be found in the charging system parking brakes and or other components inspect and repair as necessary If no air leakage was detected and if you are conducting this test after completing Step C go to Step E 7 The Technician only reaches ee TR since the air tanks were last drained exceeds the accep tance level AND the vehicle passes the four minute leakage test no noticeable leakage was detected Replace the compressor Note If the compressor is within warranty period please follow standard warranty procedures Attach the completed checklist to warranty claim 34 Appendix B Technical Bulletin Bulletin No TCH 008 021 Effective Date 11 1 92 Page 1 of 2 nadi Subject Air Brake System Cold Weather Operation Tips As the cold weather approaches operators
57. ping the electric motor INSTALLATION The base mounted compressor should be securely bolted down with 1 2 grade five or better cap screws torqued to 70 ft pounds making sure that motor and compressor pulleys are aligned and belt tension is correct The crankcase should be filled with five quarts 4 7 liter of SAE 20 W engine oil The compressor must always be installed to rotate clockwise when viewed from the pulley end The oil pump will not function if rotation is not correct SCHEDULED MAINTENANCE NOTE When checking or adding oil or servicing the crankcase breather care should be taken to prevent dirt or foreign material from entering the breather or oil sump Every 7 500 miles or seven weeks whichever occurs first Check oil level replenish to top of filler plug opening Replace both air cleaner filter elements and clean covers Check belts and replace if broken damaged or missing Every 15 000 miles or 14 weeks whichever occurs first Remove crankcase ventilator clean ports and replace with freshly oiled curled hair Every 22 500 miles or 21 weeks whichever occurs first Drain oil and refill with fresh SAE 20 W engine oil Inspect all bolts fittings and plugs to ensure that all are tight TABULATEDDATA TU FLO 400 TU FLO 500 TU FLO 1000 Air Compressor Air Compressor Air Compressor Number Cylinders 2 2 4 Bore Size 2 0625 2 5 2 5 Stroke 1 5 1 6875 1 6875 7 25 cu ft min 3 000 water cooled 2 400
58. pipe thread tap inside the bushing then inserting a 1 8 in pipe threaded rod and pulling the bushing straight up and out Do not use an easy out for removing these bushings INLET VALVES AND SEATS If inlet valves are grooved or worn where they contact the seat they should be replaced If the inlet valve seats are worn or damaged so they cannot be reclaimed by facing they should be replaced CYLINDER BORES Cylinder bores which are scored or out of round by more than 0 002 in or tapered more than 0 003 in should be rebored or honed oversize Oversize pistons are available in 0 010 0 020 and 0 030 oversizes Cylinder bores must be smooth straight and round FIGURE 21 MEASURING CYLINDER BORES 10 Clearance between cast iron pistons and cylinder bores should be between 0 002 in minimum and 0 004 in maximum Fig 21 PISTONS Check pistons for scores cracks or enlarged ring grooves replace pistons if any of these conditions are found Measure each piston with a micrometer in relation to the cylinder bore diameter to be sure the clearance is between 0 002 in minimum and 0 004 in maximum Check fit of wrist pins on pistons and connecting rod bushings Wrist pin should be a light press fit in pistons If wrist pin is loose fit the pin piston or both should be replaced Check fit of wrist pin in connecting rod bushing by rocking the piston This clearance should not exceed 0 0015 in Replace wrist pin bushings i
59. r fitting on base plate in its proper place Install blanking cover on opposite oil filter fitting hole in plate Install a new oil seal gasket around oil pump check valve and position a new base plate gasket on the crankcase Position base plate assembly on crankcase making sure oil pump piston engages the oil pump bushing in the base plate Install and tighten base plate screws FIGURE 26 AIR STRAINER EXPLODED VIEW AIR STRAINER If the compressor is type with air strainer assemble strainer Fig 26 Using a new strainer gasket install strainer on cylinder block GOVERNOR lf compressor is type with pad mounted governor install a new or factory rebuilt governor using a new governor gasket INSPECTION OF REBUILT UNIT Check to be sure that covers plugs or masking tape are used to protect all ports if compressor is not to be installed immediately Fit the end of all crankshafts with keys nuts and cotter pins as required and then protect the ends against damage by wrapping with masking or friction tape The open bottom of engine lubricated compressors should be protected against the entrance of dirt during handling or storage by installing a temporary cover over base TESTING REBUILT COMPRESSOR In order to properly test a compressor under operating conditions a test rack for correct mounting cooling lubricating and driving the compressor is necessary Such tests are not compulsory if the unit has been careful
60. rap and remove the bolts and bearing caps Push the piston with the connecting rods attached out the top of the cylinders of the crankcase Replace the bearing caps on their respective connecting rods Remove the piston rings from the pistons If the pistons are to be removed from the connecting rods remove the wrist pin lock wires or teflon plugs and press the wrist pins from the pistons and connecting rods If the pistons are removed from the rod inspect the bronze wrist pin bushing Press out and replace the bushing if it is excessively worn See Inspection of Parts Discard the piston rings and the connecting rod journal bearings Discard the wrist pin bushings if they were removed New Tu Flo 400 compressors manufactured after approximately September 1977 will have connecting rods without bearing inserts Repair size rods will have inserts REMOVING AND DISASSEMBLING BASE PLATE SELF LUBRICATED TYPE COMPRESSORS Fig 18 Remove screws that hold base plate Remove base plate Remove oil relief valve set screw then oil relief valve Remove oil strainer retaining ring and lift out oil strainer Unless it is necessary the oil pump piston bushing should not be removed If necessary remove the bushing set screw then bushing and shim FIGURE 18 BASE PLATE SELF LUBRICATED TYPE COMPRESSOR Remove cotter pin from oil rod cap nuts remove nuts oil pump piston rod and cap CRANKCASE Fig 19 Remove end cover with oil seal rem
61. resence of excess oil in the crankcase can lead to oil carryover What you should do r gt Check for leaking damaged or defective compressor air inlet components e g induction line fittings gaskets filter bodies etc Repair inlet components as needed Note Dirt ingestion will damage compressor and is not covered under warranty D Check Go to Test 4 on page 30 If you found excessive oil present in the service reservoir in step 4 0 b above and you did not find any issues in steps 4 0 c through 4 0 j above the compressor may be passing oil Replace compressor If still under warranty follow normal warranty process Note After replacing a compressor residual oil may take a considerable period of time to be flushed from the air brake system If a maintained Bendix PuraGuard system filter or Bendix PuraGuard QC oil coalescing filter is installed call 1 800 AIR BRAKE 1 800 247 2725 and speak to a Tech Team member 5 0 Oil present at valves e g at exhaust or seen during servicing Air brake system valves are required to tolerate a light coating of oil v Normal Genuine Bendix valves are all SAE J2024 compliant gt A small amount of oil does not affect SAE J2024 compliant valves r gt Check that regular maintenance is being performed and that the amount of oil in the air tanks reservoirs is within the acceptable range shown on the Bendix BASIC test cup
62. roughly understand the recommended procedures Use only the proper tools and observe all precautions pertaining to use of those tools If the work is being performed on the vehicle s air brake system or any auxiliary pressurized air systems make certain to drain the air pressure from all reservoirs before beginning ANY work on the vehicle If the vehicle is equipped with an AD IS air dryer system or a dryer reservoir module be sure to drain the purge reservoir Symptom What it may indicate 1 0 Oil Test Card Not a valid test Look for Y Normal Normal Charging system is working within normal range Check Check Charging system needs further investigation Following the vehicle manufacturer s recommended procedures deactivate the electrical system in a manner that safely removes all electrical power from the vehicle Never exceed manufacturer s recommended pressures 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 Use only genuine Bendix replacement parts components and kits Replacement hardware tubing hose fittings etc must be of equivalent size type and strength as original equipment and be designed specifically for such applications and systems Components with stripped threads or damaged parts should be replaced rather than repaired Do not attempt repair
63. s requiring machining or welding unless specifically stated and approved by the vehicle and component manufacturer Prior to returning the vehicle to service make certain all components and systems are restored to their proper operating condition For vehicles with Antilock Traction Control ATC the ATC function must be disabled ATC indicator lamp should be ON prior to performing any vehicle maintenance where one or more wheels on a drive axle are lifted off the ground and moving What you should do Discontinue using this test Results Do not use this card test to diagnose 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 BASIC test should be the definitive method for judging excessive oil fouling oil passing See Appendix A on Bendix page 32 for a flowchart and expanded BASIC Test explanation of the checklist used when conducting the BASIC test 19 20 Symptom 2 0 Oil on the What it may indicate Engine and or other accessories What you should do Find the source and repair Return the vehicle Qutside of the Compressor 2 1 Oil leaking at compressor engine connections 2 2 Oil leaking from compressor 3 0 Oil at air dryer r gt Air dryers remove water and oil from the purge exhaust or surrounding area leaki
64. stalled Ifthe compressor intake is connected to either the engine air cleaner or supercharger these connections must be tight with no leakage Clean or replace any damaged or dirty air or water lines which may be corroded before connecting them to the compressor Use a new discharge fitting gasket Align compressor drive and adjust proper belt tension Tighten mounting bolts securely and evenly After installation run compressor and check for air oil or water leaks at compressor connections Also check for noisy operation Check the exterior of the compressor for the presence of oil seepage and refer to the TROUBLESHOOTING section for appropriate tests and corrective action OIL PASSING All reciprocating compressors currently manufactured will pass a minimal amount of oil Air dryers will remove the majority of oil prior to entrance into the air brake system For particularly oil sensitive systems the Bendix PuraGuard QC oil coalescing filter can be used in conjunction with a Bendix air dryer If compressor oil passing is suspected refer to the TROUBLESHOOTING section and TABLE A for the symptoms and corrective action to be taken In addition Bendix has developed the Bendix Air System Inspection Cup or BASIC test to help substantiate suspected excessive oil passing The steps to be followed when using the BASIC test are presented in APPENDIX A at the end of the TROUBLESHOOTING section REMOVING AND DISASSEMBLY REMO
65. t insulation may be added here or if the inlet fitting is a typical 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 and TCH 08 22 Appendix B Shorter discharge line lengths or insulation may be required in cold climates r gt Check compressor air inlet line for restrictions brittleness soft or sagging hose conditions etc Repair as necessary Inlet line size is 3 4 ID Maximum restriction requirement for compressors is 25 inches of water r gt Check the engine air filter and service if necessary if possible check the air filter usage indicator Check If a maintained Bendix PuraGuard system filter or Bendix PuraGuard QC oil coalescing filter is installed call 1 800 AIR BRAKE 1 800 247 2725 and speak to a Tech Team member Symptom 4 0 Oil in Supply or Service Reservoir air dryer installed continued Crankcase Flooding Consider installing a compressor bottom drain kit where available in cases of chronic oil passing What it may indicate Other cont i Poorly filtered inlet air poor air quality to compressor ay me Inspect the engine air cleaner j Governor malfunction or setting k Compressor malfunction where all other operating conditions have been investigated Bendix compressors are designed to have a dry sump and the p
66. t be taken Drain air brake system If water cooled type compressor drain engine cooling system compressor cylinder head and block Disconnect all air lines water and oil lines to and from compressor Remove compressor mounting bolts and compressor from engine Use a gear puller to remove the gear or pulley from compressor crankshaft INSTALLATION ENGINE LUBRICATED TYPES Clean oil supply line Before connecting this line to the compressor run the engine briefly to be sure oil is flowing freely through the supply line Clean the oil return line or return passages through the brackets these passages must be unrestricted so oil can return to the engine Prelubricate compressor cylinder walls and bearings with clean engine oil before assembling compressor Always use a new mounting gasket and be sure oil hole in gasket and compressor is properly aligned with oil supply line SELF LUBRICATED TYPES Fill compressor crankcase with clean engine oil before operating compressor Refer to Tabulated Data section for proper amount ALL TYPES Inspect pulley or gear and associated parts for wear or damage They must be a neat fit on compressor crankshaft Replace pulley or gear if worn or damaged Install pulley or gear on compressor crankshaft making sure it properly contacts the shaft and does not ride the key Tighten crankshaft nut to 65 70 ft lbs and install cotter pin Be sure the air cleaner is clean and properly in
67. tem maintenance has not been PuraGuard system filter performed or Bendix PuraGuard That is reservoir s have not been QC oil coalescing filter drained per the schedule in Table is installed call Aon page 18 Column 4 and or the 1 800 AIR BRAKE air dryer maintenance has not 1 800 247 2725 and been performed as in Column 3 speak to a Tech Team member bo If the vehicle maintenance has been performed as recom mended in Table A on page 18 some oil in the reservoirs is normal if See Table A on page 18 for maintenance schedule information Drain all air tanks reservoirs into the Bendix BASIC test cup Bendix kit P N 5013711 Duty cycle too high c Air brake system leakage d Compressor may be undersized for the application The duty cycle is the ratio of time the compressor spends building air to total engine running time Air compressors are designed to build air to run loaded up to 25 of the time Higher duty cycles cause conditions that affect air brake charging system performance which may require additional maintenance Factors that add to the duty cycle are air Suspension additional air accessories use of an undersized compressor frequent stops excessive leakage from fittings connections lines chambers or valves etc What you should do r gt Drain all air tanks and check vehicle at next service interval using the Bendix BASIC test See Table A on page 18
68. to Test 2 on page 29 Go to Test 5 on page 30 Available reservoir capacity may be reduced by build up of water etc Drain and perform routine maintenance per Table A columns 3 amp 4 on page 18 Go to Test 6 on page 30 Verify operation of air dryer Follow vehicle O E maintenance recommendations and component Service Data information Go to Test 2 on page 29 27 Symptom What it may indicate What you should do 16 0 Compressor a Compressor leaks air at Check for leaking damaged or defective leaks air connections or ports compressor fittings gaskets etc Repair or replace as necessary 6 Compressor unloader mechanism Go to Test 6 on page 30 malfunction c Damaged compressor head gt Anairleak at the head gasket may indicate gasket a downstream restriction such as a freeze up or carbon blockage and or could Testing for leaks Head indicate a defective or missing safety with soap solution uk gasket valve Find blockage go to 9 0 f for location details and then replace the compressor Do not re use the safety valve without testing See Symptom 12 0 a 17 0 Compressor a lmproperly installed plugs or Inspect for loose or over torqued fittings leaks coolant coolant line fittings Reseal and tighten loose fittings and plugs as necessary If overtorqued fittings and plugs have cracked ports in the head replace the compressor b Damaged compressor head Anairleak at the head
69. trainers or inlet fittings discharge fittings and pipe plugs CYLINDER HEAD Remove the cylinder head cap screws and tap the head with a soft mallet to break the gasket seal Remove the inlet valve springs form the head and inlet valves from their guides in the block Remove inlet valve guides from around the inlet valve seats on the block taking care not to damage seats Scrape off any gasket material from the cylinder head and block Unscrew the discharge cap nuts from the head and remove the discharge valves and springs Inspect the discharge valve seats for nicks cracks and excessive wear and remove and replace if necessary The discharge valve cap nuts should be inspected for wear and replaced if excessive peening has occurred To determine if excessive peening has occurred measure the discharge valve travel Discharge valve travel must not exceed 056 in for the Tu Flo 400 compressor and 046 in for the Tu Flo 500 and 1000 compressors CRANKCASE BASE PLATE OR ADAPTER Remove the cap screws securing the base plate or base adapter Tap with soft mallet to break the gasket seal Scrape off any gasket material from crankcase and plate or adapter CONNECTING ROD ASSEMBLIES NOTE Before removing the connecting rods mark each connecting rod and its cap Each connecting rod is matched to its own cap for proper bearing fit and these parts must not be interchanged Straighten the prongs of the connecting rod bolt lock st
70. troke is being compressed Now air pressure on top of the inlet valve plus the force of its spring returns the inlet valve to its seat The piston continues the upward stroke and compresses the air sufficiently to overcome the discharge valve spring and unseat the discharge valve The compressed air then flows by the open discharge valve into the discharge line and on to the reservoirs Fig 10 RESERVOIR anan INLET VALVE a r gt a MOVE G La eT A EE UNLOADER PLUNGER INTAKE morons STRAINER STROKE COMPRESSION FIGURE 10 As the piston reaches the top of its stroke and starts down the discharge valve spring returns the discharge valve to its seat This prevents the compressed air in the discharge line from returning to the cylinder bore as the intake and compression cycle is repeated NON COMPRESSION Unloaded When the air pressure in the reservoir reaches the high pressure setting of the governor the governor opens allowing air to pass from the reservoir through the governor and into the cavity beneath the unloader pistons This lifts the unloader pistons and plungers The plungers move up and hold the inlet valves off their seats Fig 11 L DISCHARGE li z VALVE o PISTON STROKE UNLOADING FIGURE 11 With the inlet valves held off their seats by the unloader pistons and plungers air is merely pumped back and forth between the two cylinders When air is used from the reservoir and
71. ts oil level should be checked daily The oil level should be kept between the bottom of the dipstick threads and the bottom of the dipstick Fig 13 Every 8 000 miles or 300 operating hours the oil should be drained and refilled with SAE 10 20 30 FIGURE 13 OIL LEVEL SELF LUBRICATED COMPRESSOR POLYURETHANE SPONGE STRAINER Fig 14 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 The element should be saturated in clean engine oil then squeezed dry before replacing it in the strainer Be sure to replace the air strainer gasket if the entire air strainer is removed from the compressor intake 5 FIGURE 15 DRY ELEMENT PLEATED PAPER AIR STRAINER DRY ELEMENT PLEATED PAPER AIR STRAINER FIG 15 Remove the spring clips from either side of mounting baffle and remove the cover Replace the pleated paper filter and remount the cleaned cover making sure the filter is in position Be sure to replace the air strainer gasket if the entire air strainer is removed from the compressor intake NOTE Some compressors are fitted with compressor intake adapters Fig 16 which allow the compressor intake to be connected to the engine air cleaner In this case the Compressor receives a supply of clean air from the engine air cleaner When the engine air filter is changed the compressor intak

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