BENDIX TU-FLO 600 Manual Download Page 17

17

Compressor with up to 25% duty cycle

Footnotes:
1 With increased air demand the air dryer cartridge needs to be replaced more often.
2 Use the drain valves to slowly drain all reservoirs to zero psi.
3 Allow the oil/water mixture to fully settle before measuring oil quantity.
4 To counter above normal temperatures at the air dryer inlet, (and resultant oil-vapor passing

upstream in the air system) replace the discharge line with one of a larger diameter and/
or longer length.  This helps reduce the air's temperature.  If sufficient cooling occurs, the
oil-vapor condenses and can be removed by the air dryer.  Discharge line upgrades are not
covered under warranty.  Note: To help prevent discharge line freeze-ups, shorter discharge
line lengths or insulation may be required in cold climates.  (See Bendix Bulletins TCH-08-21
and TCH-08-22, included in Appendix B, for more information.)

5 For certain vehicles/applications, where turbo-charged inlet air is used, a smaller size

compressor may be permissible.

Recom-

Recom-

Acceptable

Typical

Discharge

mended

mended

Reservoir

Compressors

Line

Air Dryer

Reservoir

Oil  Contents

3

No. of

Spec'd

Cartridge

Drain

at Regular

Axles

Replacement

1

Schedule

2

Drain Interval

High Air Use

Low Air Use

e.g. Double/triple trailer, open

highway coach/RV,  (most)

pick-up & delivery, yard or

terminal jockey, off-highway,

construction, loggers, concrete

mixer, dump truck, fire truck.

e.g. Line haul single trailer

w/o air suspension, air over

hydraulic brakes.

e.g. Line haul single trailer

with air suspension,

school bus.

e.g. City transit bus, refuse,

bulk unloaders, low boys,

urban region coach, central

tire inflation.

5

or

less

5

or

less

8

or

less

12

or

less

Table A:  Maintenance Schedule and Usage Guidelines

Recom-

mended

Every

Month -

Max of

every 90

days

Every

Month

Every 3

Years

Every 2

Years

Every

Year

I.D.

Vehicle Used for:

Column 1

Column 2

Column 3

Column 4

Column 5

Regularly scheduled maintenance is the single most important factor in maintaining the air brake charging system.

Note: Compressor and/or air dryer
upgrades are recommended in cases
where duty cycle is greater than the
normal range (for the examples
above).

For Bendix

®

 Tu-Flo

®

 550 and 750

compressors, unloader service is
recommended every 250,000 miles.

Length

6 ft.

1/2 in.

9 ft.

1/2 in.

12 ft.

1/2 in.

5/8 in.

12 ft.

BASIC test
acceptable

range:

5 oil units

per month.

See

appendix

A.

For oil carry-over

control

suggested

upgrades:

3/4 in.      15 ft.

For oil carry-over

control

suggested

upgrades:

5/8 in.      15 ft.

For oil carry-over

control

suggested

upgrades:

5/8 in.      9 ft.

For oil carry-over

control

suggested

upgrades:

5/8 in.      12 ft.

Compressor with less than 15% duty
cycle

Compressor with up to 25% duty cycle

Compressor with up to 25% duty cycle

Bendix

®

 BA-921

 air compressor

Bendix

®

 T

u-Flo

®

 550 air compressor

Bendix

®

 T

u

-Flo

®

 750 air compressor

Bendix

®

 BA-922

or DuraFlo

 596

 

air compressor

BASIC test
acceptable

range:

3 oil units

per month.

See

appendix

A.

For the

BASIC

Test Kit:

Order

Bendix

P/N

5013711

Summary of Contents for TU-FLO 600

Page 1: ...om the engine cooling system Various mounting and drive configurations are used as required by different vehicle and engine designs See Fig 1 All Tu Flo 600 compressors receive oil under pressure from...

Page 2: ...CTING ROD NAME PLATE A name plate is attached to the crankcase of all compressors It shows the piece number type and serial number Fig 4 A name plate with a black background denotes a new compressor w...

Page 3: ...inlet valve to its seat The piston continues the upward stroke and compresses the air sufficiently to overcome the discharge valve spring and unseat the discharge valve The compressed air then flows...

Page 4: ...that must be given to maintenance of other components COMPRESSOR INSTALLATION While the original compressor installation is usually completed by the vehicle manufacturer conditions of operation and m...

Page 5: ...cial 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 t...

Page 6: ...neat fit on compressor crankshaft Replace pulley or gear if worn or damaged Install pulley or gear on compressor crankshaft making sure it properly contacts the shaft and does not ride the key Tighten...

Page 7: ...emove end cover with oil seal remove end cover gasket Replace oil seal after cleaning end cover Remove cap screws that hold opposite end cover to crankcase remove end cover and its gasket Some compres...

Page 8: ...8 FIGURE 13 TU FLO 600 AIR COMPRESSOR CYLINDER BLOCK ASSEMBLY FIGURE 14 TU FLO 600 AIR COMPRESSOR CRANK CASE ASSEMBLY...

Page 9: ...he steps to be followed when using the BASIC test are presented in APPENDIX A at the end of the TROUBLESHOOTING section OIL PASSAGE Clean thoroughly all oil passages through crankshaft connecting rods...

Page 10: ...the compressor has five ring pistons which are to be reused they should be checked for scores cracks or enlarged ring grooves replace pistons if any of these conditions are found Measure each piston w...

Page 11: ...alves and seats Leakage which will permit the formation of bubbles is permissible If excessive leakage is found leave the air pressure applied and with the use of a fibre or hardwood dowel and hammer...

Page 12: ...onnecting rod and piston in the same manner UNLOADING MECHANISM FIG 15 The unloader pistons and their bores must be lubricated with special lubricant piece number 239379 dimethyl polysiloxane prior to...

Page 13: ...n integrated component of the overall air brake charging system and assumes that an air dryer is in use The troubleshooting presented will cover not only the compressor itself but also other charging...

Page 14: ...equivalent size type and strength as original equipment and be designed specifically for such applications and systems 9 Components with stripped threads or damaged parts should be replaced rather th...

Page 15: ...cycles 15 0 26 Leaks air 16 0 27 Safety valve releases air 11 0 25 Noisy 18 0 27 Reservoir Safety valve releases air 13 0 26 INDEX Air Coolant Engine Oil Compressor leaks coolant 17 0 27 Oil consumpt...

Page 16: ...ng in a temperate climate See Bendix and or other air dryer manufacturer guidelines as needed When the temperature of the compressed air that enters the air dryer is within the normal range the air dr...

Page 17: ...k fire truck e g Line haul single trailer w o air suspension air over hydraulic brakes e g Line haul single trailer with air suspension school bus e g City transit bus refuse bulk unloaders low boys u...

Page 18: ...E CAUTION should be used to prevent personal injury resulting from contact with moving rotating leaking heated or electrically charged components 3 Do not attempt to install remove disassemble or asse...

Page 19: ...or the Bendix AD IS or AD IP air dryers or 5003838 for the Bendix AD 9 air dryer is available to redirect the air dryer exhaust 3 0 Oil at air dryer purge exhaust or surrounding area c 2 0 Oil on the...

Page 20: ...l range return the vehicle to service For vehicles with accessories that are sensitive to small amounts of oil consider a Bendix PuraGuard QC oil coalescing filter If outside the normal range go to Sy...

Page 21: ...t 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 fr...

Page 22: ...es tests all air brake system pneumatic components need to be able to pass including minimum levels of tolerance to contamination 5 0 Oil present at valves e g at exhaust or seen during servicing Air...

Page 23: ...ay be undersized for the application d Compressor unloader mechanism malfunction e Damaged compressor head gasket Using dash gauges verify that the compressor builds air system pressure from 85 100 ps...

Page 24: ...o build pressure continued f Restricted discharge line If discharge line is restricted By more than 1 16 carbon build up replace the discharge line see Table A column 2 on page 17 for recommended size...

Page 25: ...eplace the discharge line See Table A column 2 on page 17 for recommended size The discharge line must maintain a constant slope down from the compressor to the air dryer inlet fitting to avoid low po...

Page 26: ...est 4 on page 29 Go to Test 2 on page 28 Go to Test 5 on page 29 12 0 Air dryer safety valve releases air a Restriction between air dryer and reservoir b Air dryer safety valve malfunction c Air dryer...

Page 27: ...ak at the head gasket may indicate a downstream restriction such as a freeze up or carbon blockage and or could indicate a defective or missing safety valve Find blockage go to 9 0 f for details and t...

Page 28: ...st 2 Air Brake System and Accessory Leakage Caution The temperatures used in this test are not normal vehicle conditions Above normal temperatures can cause oil as vapor to pass through the air dryer...

Page 29: ...ines to and from the governor for restrictions e g collapsed or kinked Repair as necessary 2 Using a calibrated external gauge in the supply reservoir service reservoir or reservoir port of the D 2 go...

Page 30: ...n inspects items drained and f days Use Test 2 Air Leakage Use Test 2 Air Leakage NO Re test with the BASIC Test after 30 days NO did not know when last drained Was the number of days since last drain...

Page 31: ...q Excessive engine oil loss amount described ______________ Is the engine leaking oil q no q yes Is the compressor leaking oil q no q yes q Other complaint ______________________________________ q No...

Page 32: ...days is 30 60 days high air use or 30 90 days low air use if oil level is at or below acceptance line for number of days if oil level is above acceptance line for number of days System OK Return to s...

Page 33: ...ome periods of extended engine idling can not be avoided Discharge Lines The discharge line should slope downward form the compressor discharge port without forming water traps kinks or restrictions C...

Page 34: ...ily 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 s...

Page 35: ...rts of valves and melting or burning non metallic air lines WARNING THIS PRACTICE IS UNSAFE AND CAN RESULT IN VEHICLE FIRE 2 Do not introduce pour fluids into air brake lines or hose couplings glad ha...

Page 36: ...BW 1560 2004 Bendix Commercial Vehicle Systems LLC All rights reserved 9 2004 Printed in U S A 36...

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