BENDIX TU-FLO 400-500-1000 AIR COMPRESSOR manual Cooling, Preventive Maintenance

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Discharge

Optional “Ping” Tank

Line

Air Dryer

Compressor

Governor

(Governor plus Synchro valve for the Bendix® DuraFlo™ 596 Compressor)

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

FIGURE 12A - SYSTEM DRAWING

HOLE

THREAD

FIGURE 12B - DISCHARGE LINE SAFETY VALVE

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 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.

PREVENTIVE MAINTENANCE

Regularly scheduled maintenance is the single most important factor in maintaining the air brake charging system. Refer to Table A in 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, its 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.

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Contents SD-01-326 Description GeneralIntake and Compression Loaded OperationCompressor & the AIR Brake System Polyurethane Sponge Strainer Fig Preventive MaintenanceCooling Installation ENGINE-LUBRICATED Types Removing and InstallingDRY Element Pleated Paper AIR Strainer FIG AIR Leakage TestsRemoving and Disassembly DisassemblyConnecting ROD Assemblies Crankcase Base Plate or AdapterTU-FLO400 AIR Compressor Vertical Mount Engine Lubricated Crankcase FigInspection of Parts CleaningInlet Valves and Seats Crankcase and END CoversCylinder Bores PistonsRepairs Installing Cylinder Block AssemblyInstalling Crankshaft Pistons and Connecting RodsBaseplate 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 Or compressor dis Oil in ping tankCharge aftercooler Air brake Charging systemAir 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 InformationStep B Measure the Charging System Contents Checklist for TechnicianStep a Select one Is foundStep D Air Brake System Leakage Test Typical P&D, School Bus and Line Haul Technical BulletinSystem Leakage Thawing Frozen Air Lines Page
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