BENDIX TU-FLO 700 COMPRESSOR Manual Download | Manualshive

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1

®

SD-01-335

Bendix

®

TU-FLO

®

700 Air Compressor

COMPRESSOR NAMEPLATE

SER

NO.

B W
NO.

MANUFACTURED BY

BENDIX

TU-FLO 700

Two methods are employed for cooling the Tu-Flo

®

700

compressor during operation. The cylinder head is
connected to the engine’s cooling system, while the cylinder
has external fins for efficient air cooling.

All Tu-Flo

®

700 compressors utilize the engine’s pressurized

oil system to lubricate the internal moving parts. A nameplate
is attached to the crankcase to identify the compressor.
The nameplate displays a Bendix piece number or in some
cases an engine or vehicle manufacturer’s piece number,
along with a serial number.

DESCRIPTION

The function of the air compressor is to provide and main-
tain air under pressure to operate devices in the air brake
and/or auxiliary air systems

The Tu-Flo

®

700 compressor is a two cylinder, single stage,

reciprocating compressor with a rated displacement of 15.5
cubic feet of air per minute at 1250 R.P.M. The Tu-Flo

®

700

compressor is constructed from three major assemblies,
the head, the cylinder block and the crankcase.

The head houses the discharge valving and is installed on
the upper portion of the cylinder block. The cylinder block
contains the cylinder bores and inlet valves and is mounted
to the crankcase. The crankcase houses the crankshaft
and main bearings.

Various mounting and drive configurations, required by the
numerous vehicle engine designs, are available. Two
governor mounting pads are located on either side of the
cylinder block to provide convenient governor mounting.

EXTERIOR

BENDIX

®

TU-FLO

®

700 AIR COMPRESSOR

(CROSS SECTION)

CRANKCASE

D I S C H A R G E

CAP NUT

P I S T O N

P I S T O N

R I N G S

CRANKSHAFT

CONNECTING

R O D

D I S C H A R G E

V A L V E

S P R I N G

I N L E T

V A L V E

S P R I N G

I N L E T

V A L V E

D I S C H A R G E

V A L V E

D I S C H A R G E

VALVE SEAT

U N L O A D E R

M E C H A N I S M

1
2
3
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Summary of Contents for TU-FLO 700 COMPRESSOR

Page 1: ...0 compressor is a two cylinder single stage reciprocating compressor with a rated displacement of 15 5 cubic feet of air per minute at 1250 R P M The Tu Flo 700 compressor is constructed from three major assemblies the head the cylinder block and the crankcase The head houses the discharge valving and is installed on the upper portion of the cylinder block The cylinder block contains the cylinder ...

Page 2: ...ernor the governor allows air to pass from the reservoir into the cavity beneath the unloader pistons This lifts the unloader pistons and plungers The plungers move up and hold the inlet valves off their seats see Figure 4 With the inlet valves held off their seats by the unloader pistons and plungers air is pumped back and forth between the two cylinders When air is used from the reservoir and th...

Page 3: ...section assumes a compressor with a normal less than 25 duty cycle operating in a temperate climate See Bendix and or other air dryer manufacturer guidelines as needed The discharge line must maintain a constant slope down from the compressor to the air dryer inlet fitting or reservoir to avoid low points where ice may form and block the flow If instead ice blockages occur at the air dryer or rese...

Page 4: ...ucts pressurized oil to the precision sleeve main bearings and to the connecting rod bearings Splash lubrication of the cylinder bores connecting rod wrist pin bushings and the ball type main bearings on some models is obtained as oil is forced out around the crankshaft journals by engine oil pressure Check the exterior of the compressor for the presence of oil seepage and refer to the TROUBLESHOO...

Page 5: ...ws through the internal passages in the cylinder block and head and back to the engine Proper cooling is important in maintaining discharge air temperatures below the 400 F recommended maximum PREVENTIVE MAINTENANCE Regularly scheduled maintenance is the single most important factor in maintaining the air brake charging system Refer to TableAin the Troubleshooting section for a guide to various co...

Page 6: ...S 121 with the minimum required reservoir volume must have a compressor capable of raising air system pressure from 85 100 P S I in 25 seconds or less This test is performed with the engine operating at maximum governed speed The vehicle manufacturer must certify this performance on new vehicles with appropriate allowances for air systems with greater than the minimum required reservoir volume AIR...

Page 7: ...st not exceed 046 inches If discharge valve travel is excessive replace the cap nut stop assembly discharge valve and spring Discard the inlet valves 3 and springs 2 the discharge valves 7 springs 8 and the discharge valve seats 6 if defective CRANKCASE BASE PLATE OR ADAPTER Remove the cap screws securing the base plate or base adapter Tap with soft mallet to break the gasket seal 11 Scrape off an...

Page 8: ... of the cylinder head body Scrape all the foreign matter from the body surfaces and use shop air pressure to blow the dirt particles from all the cavities CYLINDER BLOCK Clean the carbon and dirt from the inlet and unloader passages Use shop air pressure to blow the carbon and dirt deposits from the unloader passages OIL PASSAGES Thoroughly clean all oil passages through the crankshaft crankcase e...

Page 9: ...bored or honed oversize Oversized pistons and piston rings are available in 010 in 020 in and 030 in oversizes Cylinder bores must be smooth straight and round Clearance between the cast iron pistons and cylinder bores should be between 002 in minimum and 004 in maximum FIGURE 9 MEASURING CYLINDER BORES FIGURE 10 CORRECT GROOVE CLEARANCE 002 010 END GAP 000 006 OIL RING 002 004 OIL RING STANDARD P...

Page 10: ...2 inch pounds INSTALLING THE CRANKSHAFT Press new sleeve bearings in the end cover and crankcase Ensure that the slot in the bearings line up with the oil passages in the end cover or crankcase If you have a model with no oil passage present in the crankcase press the sleeve bearing into the crankcase with the slot located 90 degrees from vertical Install the front thrust washer with the tang inse...

Page 11: ... the spring bore in the head Should this procedure fail after repeated attempts use a very small quantity of grease to hold them in place just enough to keep the springs from falling out Place the cylinder head gasket on the cylinder block Carefully align the cylinder head assembly on the block and install the cap screws tightening them evenly to a torque of 15 19 foot pounds BASE PLATE OR BASE AD...

Page 12: ... the vehicle manufacturer s recommendedprocedures deactivatetheelectrical systeminamannerthatsafelyremovesallelectrical power from the vehicle 6 Never exceed manufacturer s recommended pressures 7 Never connect or disconnect a hose or line containing pressure it may whip Never remove a component or plug unless you are certain all system pressure has been depleted 8 Use only genuine Bendix replacem...

Page 13: ...y cycles 15 0 24 Leaks air 16 0 25 Safety valve releases air 11 0 23 Noisy 18 0 25 Reservoir Safety valve releases air 13 0 24 INDEX Air Coolant Engine Oil Compressor leaks coolant 17 0 25 Oil consumption 6 0 21 Oil Test Card results 1 0 16 Oil is present On the outside of the compressor 2 0 17 At the air dryer purge exhaust or surrounding area 3 0 17 In the supply reservoir 4 0 18 20 At the valve...

Page 14: ...ing 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 dryer can remove most of the charging system oil If the temperature of the compressed air is above the normal range oil as oil vapor is able to pass through the air dryer and into the air system Larger...

Page 15: ...ck 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 Y...

Page 16: ...REME 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 assemble a component until you have read and thoroughly understand the recommended procedures Use only the proper tools and observe all precautions pertaining to use of those tools 4 If the work is bei...

Page 17: ...for 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 Outside of the Compressor Find the source and repair Return the vehicle to service ð Repair or replace as necessary If the mounting bolt torques are low replace the gasket ð Replace the fitting gaske...

Page 18: ...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 ð If outside the normal range go to Symptom 4 0 c Also see the Table A on page 15 column 3 for recommended air dryer cartridge replacement schedule Maintenance a ð Go to Test 2 on page 26 ð See Table A column 1 on page 15 for recommended ...

Page 19: ... 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 Temperature Other ð Check compressor air inlet line ...

Page 20: ...ines 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 brake system valves are required to tolerate a light coating of oil ð A small amount of oil does not affect SAE J2024 compliant valves ð Check that regular maintenance is being performed and that th...

Page 21: ...y be undersized for the application d Compressor unloader mechanism malfunction e Damaged compressor head gasket ð Using dash gauges verify that the compressor builds air system pressure from 85 100 psi in 40 seconds or less with engine at full governed rpm Return the vehicle to service ð Go to Test 2 on page 26 ð See Table A column 1 on page 15 for some typical compressor applications If the comp...

Page 22: ...to build pressure continued f Restricted discharge line ð If discharge line is restricted ð By more than 1 16 carbon build up replace the discharge line see Table A column 2 on page 15 for recommended size and go to Test 3 on page 26 ð By other restrictions e g kinks Replace the discharge line See Table A column 2 on page 15 for recommended size Retest for air build Return vehicle to service or if...

Page 23: ...Replace the discharge line See Table A column 2 on page 15 for recommended size ð The 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 change...

Page 24: ...n page 27 ð Go to Test 2 on page 26 ð Go to Test 5 on page 27 12 0 Air dryer safety valve releases air a Restriction between air dryer and reservoir b Air dryer safety valve malfunction c Air dryer maintenance not performed d Air dryer malfunction e Improper governor control line installation to the reservoir f Governor malfunction ð Inspect delivery lines to reservoir for restrictions and repair ...

Page 25: ...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 then replace the compressor Do not re use the safety valve without testing See Symptom 12 0 a ð If casting porosity is detected replace the compressor 18 0 Noisy compressor Multi cylinder compressors only...

Page 26: ...t 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 into the air brake system This test is run with the engine at normal operating temperature with engine at max rpm If available a dyno may be used 1 Allow the compressor to build the air system pressure...

Page 27: ...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 governor verify cut in and cut out pressures are within vehicle OEM specification 3 If the governor is malfunctioning replace it Tests continued Test 4 Governor Malfunction 2 Perform proper reservoir dr...

Page 28: ...an 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 draining known YES number of days was known 30 90 days END TEST Bendix Air System Inspection Cup BASIC Test Information Appendix A Information about the BASIC Test Kit Bendix P N 5013711 If the number of ...

Page 29: ...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 customer complaint Checklist for Technician è The Service Writer fills out these fields with information gained from the customer The Service Writer also checks off any complaints that the customer ma...

Page 30: ...days is 30 60 days high air use or 30 90 days low air use è if oil level is at or below acceptance line for number of daysè if oil level is above acceptance line for number of days è System OK Return to service Otherwise è if the number of days is unknown or outside the limits above if oil level is at or below 30 day acceptance line è if oil level is above 30 day acceptance line è STOP TEST Stop i...

Page 31: ...some 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 Cross overs from one side of the frame rail to the other if required should occur as close as possible to the compressor Fitting extensions must be avoided Recommended discharge line lengths and insid...

Page 32: ...aily 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 ...

Page 33: ...arts 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 hands Some fluids used can cause immediate and severe damage to rubber components Even methanol alcohol which is used in Alcohol Evaporators and Injectors should not be poured into air lines Fluids pou...

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Page 36: ...BW1422 2004 Bendix Commercial Vehicle Systems LLC All rights reserved 10 2004 Printed in U S A 36 ...

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