BENDIX TU-FLO 400-500-1000 AIR COMPRESSOR manual Releases air Compressor builds too much air

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Symptom:

What it may indicate:

What you should do:

 

 

 

10.0Air 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.

ðGo to Test 4 on page 30.

ðSee 9.0(f).

ðReplace air dryer heater.

ðReplace the compressor only after making certain the preceding conditions do not exist.

11.0Compressor (a)Restricted discharge line. safety valve

releases air (Compressor builds too much air).

Damaged discharge line shown.

ðIf discharge line is restricted:

ðBy 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.

ðBy other restrictions (e.g. kinks). Replace the discharge line. See Table A, column 2, on page 18 for recommended size.

ðThe 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.

(b)Downstream air brake system check valves or lines may be blocked or damaged.

(c) Air dryer lines incorrectly installed.

ðInspect air lines and verify check valves are operating properly.

ðEnsure discharge line is installed into the inlet of the air dryer and delivery is routed to the service reservoir.

(d)Compressor safety valve malfunction.

(e)Compressor unloader mechanism malfunction.

(f) Governor malfunction.

ðVerify relief pressure is 250 psi. Replace if defective.

ðGo to Test 6 on page 30.

ðGo to Test 4 on page 30.

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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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