BENDIX TU-FLO 400-500-1000 AIR COMPRESSOR manual General, Description

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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

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 1 - TU-FLO®400 AIR COMPRESSOR

FIGURE 2 - TU-FLO®500 AIR COMPRESSOR

FIGURE 3 - TU-FLO®1000 AIR COMPRESSOR

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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 their 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

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Contents SD-01-326 General DescriptionOperation Intake and Compression LoadedCompressor & the AIR Brake System Polyurethane Sponge Strainer Fig Preventive MaintenanceCooling DRY Element Pleated Paper AIR Strainer FIG Removing and InstallingInstallation ENGINE-LUBRICATED Types AIR Leakage TestsConnecting ROD Assemblies DisassemblyRemoving and Disassembly Crankcase Base Plate or AdapterCrankcase Fig TU-FLO400 AIR Compressor Vertical Mount Engine LubricatedCleaning Inspection of PartsCylinder Bores Crankcase and END CoversInlet Valves and Seats PistonsRepairs Installing Crankshaft AssemblyInstalling Cylinder Block Pistons and Connecting RodsBaseplate Page Tabulated Data InstallationScheduled Maintenance Symptom Number Test ProceduresMaintenance & Usage Guidelines Introduction to the Air Brake Charging System Low Air Use High Air UseOil Test Card Not a valid test Results Symptom What it may indicate What you should doDiscontinue using this test Oil on the Outside of the Compressor Oil at air dryer purge/exhaust or surrounding areaOil in Supply or Service Reservoir air dryer installed MaintenanceOil in Supply Insufficient coolant flowOil in Supply or Service Reservoir Charge aftercooler Air brake Oil in ping tankOr compressor dis Charging systemAir brake charging system seems slow to build pressure Releases air Compressor builds too much air Air dryer Safety valve releases air TimeLeaks coolant Coolant line fittings NoisyAction 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 Bendix Air System Inspection Cup Basic Test Information Appendix a Information about the Basic Test Kit Bendix P/NStep a Select one Checklist for TechnicianStep B Measure the Charging System Contents Is foundStep D Air Brake System Leakage Test Technical Bulletin Typical P&D, School Bus and Line HaulSystem Leakage Thawing Frozen Air Lines Page
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