BENDIX TU-FLO 400-500-1000 AIR COMPRESSOR manual Cleaning, Inspection of Parts

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Press the crankshaft and ball bearings from the crankcase, then press ball bearings from crankshaft. Many compressors will have sleeve-type bearings in the crankcase or in the end cover. If the clearance between crankshaft journal and bearing exceeds .0065 in. the sleeve bearing should be replaced with appropriate undersize.

FIGURE 19 - CRANKCASE - TU-FLO®400 & 500 AIR COMPRESSORS

FIGURE 19A - CRANKCASE - TU-FLO®1000 AIR COMPRESSOR

BLOCK (Fig. 20)

If compressor is fitted with an air strainer, inlet elbow or governor, remove same.

Remove cap screws securing cylinder block to crankcase; separate crankcase and cylinder block and scrape off gasket.

Remove unloader spring, spring saddle and spring seat from cylinder block.

Remove unloader guides and plungers and, with the use of shop air, blow unloader pistons out of cylinder block unloader piston bores.

Remove inlet valve guides; inlet valve seats can be removed but only if they are worn or damaged and are being replaced. Unloader bore bushings should be inspected but not removed unless they are damaged.

FIGURE 20 - CYLINDER BLOCK - EXPLODED VIEW

CLEANING AND INSPECTION OF PARTS

CLEANING

All parts should be cleaned thoroughly in a good cleaning solvent before inspection.

CYLINDER HEAD ASSEMBLY

Remove all carbon deposits from discharge cavities and all rust and scale from cooling cavities of cylinder head body. Scrape all foreign matter from body surfaces and use air pressure to blow dirt particles from all cavities.

Discharge valves can be dressed by lapping them on a piece of fine crocus cloth on a flat surface, provided they are not excessively worn.

CYLINDER BLOCK

Clean carbon and dirt from inlet and unloader passages. Use air pressure to blow carbon and dirt deposits from unloader passages.

Inlet valves, as in the case of discharge valves, not worn excessively, can be cleaned by lapping them on a piece of fine crocus cloth on a flat surface.

OIL PASSAGE

Clean thoroughly all oil passages through crankshaft, connecting rods, crankcase, end covers and base plate. If necessary, inspect passages with a wire and blow foreign matter out with air pressure.

CRANKCASE - SELF-LUBRICATED TYPE

The breather should be thoroughly washed and cleaned.

The oil pump check valve in the base should be removed and replaced. It is important when the oil pump check valve is replaced that it be installed correctly with the ball stop pin end pressed in first. When installed, the ball and its seat should be visible from the crankcase base.

INSPECTION OF PARTS

CYLINDER HEAD BODY

Inspect cylinder head body for cracks or damage.

WATER-COO LED TYPE

Use air pressure to test water jackets of cylinder head and block for leakage. Replace unit if leakage is found.

DISCHARGE VALVES AND SEATS

If discharge valves are worn and grooved where they contact the seats, they should be replaced. If the discharge valve seats are worn excessively so that there is no longer enough metal left to reclaim them by lapping, the seats should be replaced.

DISCHARGE VALVE SPRING AND CAP NUTS

Replace all used discharge valve springs and cap nuts.

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Contents SD-01-326 Description GeneralIntake and Compression Loaded OperationCompressor & the AIR Brake System Preventive Maintenance CoolingPolyurethane Sponge Strainer Fig 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 Installation Scheduled MaintenanceTabulated Data Test Procedures Maintenance & Usage GuidelinesSymptom Number Introduction to the Air Brake Charging System High Air Use Low Air UseSymptom What it may indicate What you should do Discontinue using this testOil Test Card Not a valid test Results 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 fittingsTest 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 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