BENDIX TU-FLO 400-500-1000 AIR COMPRESSOR manual System Leakage

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Appendix B: Continued

Bulletin No.: TCH-008-021Effective Date: 11/1/92Page: 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.

½ in.

None

If the discharge line length must be less than 10 feet or greater than 16 feet, contact your local Bendix representative.

System Leakage

Check the air brake system for excessive air leakage using the Bendix “Dual System Air Brake Test and Check List” (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 all 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-2Automatic 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 leakage 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-SPAir Dryer

Service Data Sheet SD-08-2415

Trailer System-GuardAir Dryer

Service Data Sheet SD-08-2416

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Contents SD-01-326 General DescriptionOperation Intake and Compression LoadedCompressor & the AIR Brake System Preventive Maintenance CoolingPolyurethane Sponge Strainer Fig Removing and Installing Installation ENGINE-LUBRICATED TypesDRY Element Pleated Paper AIR Strainer FIG AIR Leakage TestsDisassembly Removing and DisassemblyConnecting ROD Assemblies Crankcase Base Plate or AdapterCrankcase Fig TU-FLO400 AIR Compressor Vertical Mount Engine LubricatedCleaning Inspection of PartsCrankcase and END Covers Inlet Valves and SeatsCylinder Bores PistonsRepairs Assembly Installing Cylinder BlockInstalling Crankshaft Pistons and Connecting RodsBaseplate Page Installation Scheduled MaintenanceTabulated Data Test Procedures Maintenance & Usage GuidelinesSymptom Number Introduction to the Air Brake Charging System Low Air Use High Air UseSymptom What it may indicate What you should do Discontinue using this testOil Test Card Not a valid test Results 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 Oil in ping tank Or compressor disCharge aftercooler Air brake 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 NoisyTest 2 Air Brake System and Accessory Leakage Test 1 Excessive Oil Leakage at Head GasketAction Test 4 Governor Malfunction Test 5 Governor Control LineTest 6 Compressor Unloader Leakage Page Bendix Air System Inspection Cup Basic Test Information Appendix a Information about the Basic Test Kit Bendix P/NChecklist for Technician Step B Measure the Charging System ContentsStep a Select one Is foundStep D Air Brake System Leakage Test Technical Bulletin Typical P&D, School Bus and Line HaulSystem Leakage Thawing Frozen Air Lines Page