BENDIX TU-FLO 501 Скачать руководство пользователя страница 28 | Manualshive

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Содержание TU-FLO 501

Страница 1: ... The crankcase is a one piece casting combining the cylinder block and the crankcase The upper portion of the casting houses the cylinder bores and inlet valving and the lower portion the crankshaft and main bearings Various mounting and drive configurations required by the numerous vehicle engine designs are obtained by bolting different mounting flanges end covers and base adapters to the crankc...

Страница 2: ...into the cylinder on the down stroke is being compressed Air pressure on top of the inlet valve plus the force of its spring returns the inlet valve to its seat The piston continues the upward stroke and compressed air then flows by the open discharge valve into the discharge line and on to the reservoirs see Fig 5 As the piston reaches the top of its stroke and starts down the discharge valve spr...

Страница 3: ...mpressor Discharge Line Optional Ping Tank Optional Bendix PuraGuard QC Oil Coalescing Filter 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 from fittings connections lines chambers or valves etc Refer to TableAi...

Страница 4: ... Flo 501 compressors are connected to the engine s pressurized oil system a continuous flow of oil is provided to the compressor which is eventually returned to the engine Oil is fed into the compressor in various ways for example through the rear end cover the drive end of the crankshaft or through the front flange adapter An oil passage in the crankshaft conducts pressurized oil to the precision...

Страница 5: ...ers which allow the compressor intake to be connected to the engine air cleaner In this case the compressor receives a supply of clean air from the engine air cleaner When the engine air filter is changed the compressor intake adapter should be checked If it is loose remove the intake adapter clean the strainer plate if applicable and replace the intake adapter gasket and reinstall the adapter sec...

Страница 6: ... by removing the discharge line applying shop air back through the discharge port and listening for escaping air Also the discharge valves and the unloader pistons can be checked for leakage by building up the air system until the governor cuts out then stopping the engine With the engine stopped listen for escaping air at the compressor intake To pinpoint leakage if noted apply a small quantity o...

Страница 7: ...g caps on their respective connecting rods Remove the piston rings from the pistons If the pistons are to be removed from the connecting rods remove the wrist pin lock wires or teflon plugs and press the wrist pins from the pistons and connecting rods If the pistons are removed from the rod inspect the bronze wrist pin bushing Press out and replace the bushing if it is excessively worn See inspect...

Страница 8: ...replaced Check the unloader bore bushings to be sure they are not worn rusted or damaged If these bushings are to be replaced they can be removed by running a 1 8 in pipe thread tap into the bushing and inserting a 1 8 in pipe threaded rod and pulling the bushing straight up and out Do not use an easy out for removing these bushings If the inlet valve seats are worn or damaged so they cannot be re...

Страница 9: ...rings and valves Screw in the discharge valve seats Discharge valve travel should be between 041 in to 057 in To test for leakage by the discharge valves apply 100 pounds of air pressure through the cylinder head discharge port and apply a soap solution to the discharge valves and seats A slight leakage in the form of soap bubbles is permissible If excessive leakage is found leave the air pressure...

Страница 10: ...st pin Pistons installed in compressors manufactured prior to November 1976 will have the wrist pin secured in the piston by a lock wire extending through matching holes in wrist pin and piston boss anchored in a hole in the side wall of the piston If the original pistons are used the wrist pin must be pressed in so the hole in the wrist pin aligns with that of the piston and secure same by insert...

Страница 11: ...hose tools 4 If the work is being performed on the vehicle s air brake system or any auxiliary pressurized air systems make certain to drain the air pressure from all reservoirs before beginning ANY work on the vehicle If the vehicle is equipped with an AD IS airdryersystemoradryerreservoirmodule be sure to drain the purge reservoir 5 Following the vehicle manufacturer s recommendedprocedures deac...

Страница 12: ...trol ATC the ATC function must be disabled ATC indicator lampshouldbeON priortoperforminganyvehicle maintenance where one or more wheels on a drive axle are lifted off the ground and moving TABULATED DATA Number of cylinders 2 Bore size 2 625 in Stroke 1 50 in Piston displacement at 1250 RPM 12 cu ft Piston displacement per revolution 16 5 cu in Maximum recommended RPM naturally aspirated 3000 Min...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 28: ...28 NOTES ...

Страница 29: ...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 ...

Страница 30: ...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...

Страница 31: ...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...

Страница 32: ...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...

Страница 33: ...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 ...

Страница 34: ...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...

Страница 35: ...35 ...

Страница 36: ...BW1421 2004 Bendix Commercial Vehicle Systems LLC All rights reserved 9 2004 Printed in U S A 36 ...

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