BENDIX TU-FLO 400-500-1000 AIR COMPRESSOR manual Repairs

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TU-FLO®400 AIR COMPRESSOR

CORRECT GROOVE

CLEARANCE

.0015”

.0030”

CORRECT GAP

CLEARANCE WITH RING

IN CYLINDER

.0035”

.014”

FIGURE 23 - TU-FLO®400 AIR COMPRESSOR OLD STYLE

TU-FLO®500 & 1000 AIR COMPRESSOR

CORRECT GROOVE

CLEARANCE

 

 

NARROW

 

 

WIDE

.0035”

.002”

 

.0035”

 

.004”

 

 

 

CORRECT GAP

 

 

CLEARANCE WITH RING

 

IN CYLINDER

 

NARROW

 

 

.0035”

 

WIDE

.014”

 

 

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 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 crankshafts 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-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 leakage 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.

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Contents SD-01-326 Description GeneralIntake and Compression Loaded OperationCompressor & the AIR Brake System Polyurethane Sponge Strainer Fig Preventive MaintenanceCooling AIR Leakage Tests Removing and InstallingInstallation ENGINE-LUBRICATED Types DRY Element Pleated Paper AIR Strainer FIGCrankcase Base Plate or Adapter DisassemblyRemoving and Disassembly Connecting ROD AssembliesTU-FLO400 AIR Compressor Vertical Mount Engine Lubricated Crankcase FigInspection of Parts CleaningPistons Crankcase and END CoversInlet Valves and Seats Cylinder BoresRepairs Pistons and Connecting Rods AssemblyInstalling Cylinder Block Installing CrankshaftBaseplate Page Tabulated Data InstallationScheduled Maintenance Symptom Number Test ProceduresMaintenance & Usage Guidelines Introduction to the Air Brake Charging System High Air Use Low Air UseOil Test Card Not a valid test Results Symptom What it may indicate What you should doDiscontinue using this test Oil at air dryer purge/exhaust or surrounding area Oil on the Outside of the CompressorMaintenance Oil in Supply or Service Reservoir air dryer installedInsufficient coolant flow Oil in SupplyOil in Supply or Service Reservoir Charging system Oil in ping tankOr compressor dis Charge aftercooler Air brakeAir brake charging system seems slow to build pressure Releases air Compressor builds too much air Time Air dryer Safety valve releases airNoisy Leaks coolant Coolant line fittingsAction Test 2 Air Brake System and Accessory LeakageTest 1 Excessive Oil Leakage at Head Gasket Test 6 Compressor Unloader Leakage Test 4 Governor MalfunctionTest 5 Governor Control Line Page Appendix a Information about the Basic Test Kit Bendix P/N Bendix Air System Inspection Cup Basic Test InformationIs found Checklist for TechnicianStep B Measure the Charging System Contents Step a Select oneStep D Air Brake System Leakage Test Typical P&D, School Bus and Line Haul Technical BulletinSystem Leakage Thawing Frozen Air Lines Page