BENDIX TU-FLO 550 COMPRESSOR Manual 

Text of BENDIX TU-FLO 550 COMPRESSOR User Guide:

• BENDIX TU-FLO 550 COMPRESSOR, A-13 Symptom: What it may indicate: What you should do: This guide attempts to cover most com- pressor system problems. Here are some rare sources of problems not covered in this guide: • Turbocharger leakage. Lubricating oil from leaking turbocharger seals can enter the air compressor intake and give misleading symptoms. • Where a compressor does not have a safety valve installed, if a partial or complete discharge line blockage has occurred, damage can occur to the con- necting rod bearings. Damage of this kind may not be detected and could le

• Connect to the compressor discharge port, a reservoir with a volume of 1500 cubic inches, including the volume of the connecting line. With the compressor operating at 2100 R.P.M., the time required to raise the reservoir(s) pressure from 85 psi to 100 psi should not exceed 7 seconds. During this test, the compressor should be checked for gasket leakage and n

• BENDIX TU-FLO 550 COMPRESSOR, A-11 Symptom: What it may indicate: What you should do: 10.0 Air charging system doesn’t build air. (a) Governor malfunction*. (b) Restricted discharge line. (c) Air dryer heater malfunction: exhaust port frozen open. (d) Compressor malfunction.  Go to Test 4 on page A-15.  See 9.0(f).  Replace air dryer heater.  Replace the compressor only after making certain the preceding conditions do not exist. 11.0 Compressor safety valve releases air (Compressor builds too much air). (a) Restricted discharge line.  If discharge line is restricted:  By more than 1/16" carbon build-up,

• BENDIX TU-FLO 550 COMPRESSOR, A-5 (a)  Symptom: What it may indicate: What you should do: 2.2 Oil leaking from compressor: (a) Excessive leak at head gasket. (b) Leak at bottom cover plate. (c) Leak at internal rear flange gasket. (d) Leak through crankcase. (e) (If unable to tell source of leak.)  Go to Test 1 on page A-14.  Reseal bottom cover plate using RTV silicone sealant.  Replace compressor.  Replace compressor.  Clean compressor and check periodically. Air brake charging system functioning normally.  Air dryers remove water and oil from the air brake charg

• BENDIX TU-FLO 550 COMPRESSOR, SD-01-333 Bendix ® Tu-Flo ® 550 Air Compressor BENDIX ® TU-FLO ® 550 AIR COMPRESSOR (CROSS SECTION) BENDIX ® TU-FLO ® 550 AIR COMPRESSOR (EXTERIOR) AIR DISCHARGE WATER OUTLET PIECE NO. TAG GOVERNOR MOUNTING PAD CRANKCASE PISTON RINGS PISTON CRANKSHAFT CONNECTING ROD INLET VALVE SEAT UNLOADER INLET VALVE CYLINDER HEAD END VIEW OF CYLINDER HEAD DISCHARGE VALVE SPRING DISCHARGE VALVE DISCHARGE VALVE STOP AIR INLET CRANKCASE INLET INLET VALVE SPRING DESCRIPTION The function of the air compressor is to provide and maintain air under pressure to operate devices in the air brake and/or auxiliary air systems. The Bendix ® Tu-Flo ® 55

• journal bearing segments (38) on the connecting rod (37) and connecting rod cap (39). Tighten the connecting rod bolts (40) evenly and torque to 150 - 170 inch pounds. Install the other connecting rod and piston in the same manner. It is recommended that new connecting rod cap screws be used. Before replacing the cylinder head on the crankcase ensure the correct pist

• BENDIX TU-FLO 550 COMPRESSOR, material (5) from the cover plate, cylinder head and crankcase. 1. Remove the unloader pistons (7), o-rings (6) and springs (8). 2. Inspect the unloader piston bushings (9) for nicks, wear, corrosion and scoring. It is recommended that the compressor be replaced if it is determined that the unloader bushing is damaged or worn excessively. Before disassembling the discharge valve mechanism, measure and record the discharge valve travel (from closed to completely open). 3. If the measured discharge valve travel exceeds .046 inches, the compressor should be replaced. If the discharge valve travel does not exceed .046, using a 9/16" Allen wrenc

• BENDIX TU-FLO 550 COMPRESSOR, A-7 Symptom: What it may indicate: What you should do: (e) Air compressor discharge and/or air dryer inlet temperature too high. (f) Insuffi cient coolant fl ow. (g) Restricted discharge line.  Check temperature as outlined in Test 3 on page A-14. If temperatures are normal go to 4.0(h).  Inspect coolant line. Replace as necessary (I.D. is 1/2").  Inspect the coolant lines for kinks and restrictions and fi ttings for restrictions. Replace as necessary.  Verify coolant lines go from engine block to compressor and back to the water pump. Repair as necessary.  If discharge

• BENDIX TU-FLO 550 COMPRESSOR, ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION ITEM QTY DESCRIPTION 1 6 Cylinder Head Cap Screws 16 2 Discharge Valve Spring 31 2 Thrust Washer 2 4 Unloader Plate Cap Screws 17 2 Discharge Valve 32 2 Sleeve (or Ball) Bearing 3 4 Unloader Plate Lock Washers 18 2 Discharge Valve Stop 33 1 End Cover Seal 4 1 Unloader Plate 19 1 Cylinder Head Gasket 34 1 End Cover 5 1 Unloader Plate Gasket 20 1 Base Gasket 35 4 End Cover Cap Screws 6 2 O-ring 21 1 Base Plate 36 2 Wrist Pin Bushing 7 2 Unloader 22 6 Base Plate Cap Screws 37 2 Connecting

• A-10 Symptom: What it may indicate: What you should do: (g) Restricted air inlet (not enough air to compressor).  Check compressor air inlet line for restric- tions, brittleness, soft or sagging hose con- ditions etc. Repair as necessary. Refer to vehicle manufacturer’s guidelines for inlet line size.  Check the engine air fi lter and service if ne

• BENDIX TU-FLO 550 COMPRESSOR, A-17 Footnote 1: Note: Typical air dryer cartridge replacement schedule is every 3 yrs/ 300K miles for low air use vehicles and every year/100K miles for high air use vehicles. Footnote 2: To get an accurate reading for the amount of oil collected during a 30 day period, ask the customer not to drain the air tanks before returning. (Note that 30-90 days is the recommended air tank drain schedule for vehicles equipped with a Bendix air dryer that are properly maintained.) If, in cold weather conditions, the 30 day air tank drain schedule is longer than the customer's usual draining interval, the customer must determine, based on its experience with the vehicle, whether to

• BENDIX TU-FLO 550 COMPRESSOR, A-16 High START BASIC TEST Is this a transit vehicle, bulk unloader, or has more than 5 axles? YES, this is a high air use vehicle. NO, this is a low air use vehicle. Park vehicle on ground.LEVEL Chock wheels, drain air from system. Drain contents of air tanks into ALL BASIC cup ™ • water, or • cloudy emulsion mixture? Is this vehicle being re-tested? (after water, etc. was found last time?) NO YES Is the point above the HIGH Air Use line on the cup? YES NO Does the vehicle have excessive air leakage? Repair leaks and return vehicle to service Is there less than one unit of liquid? END TEST Vehicle OK. Return vehicle to service. YES NO YES YES NO, only oil. Ve

• A-15 1. Ensure that the governor control line from the reservoir is located at or near the top of the res- ervoir. (This line, if located near the bottom of the reservoir, can become blocked or restricted by the reservoir contents e.g. water or ice.) Bendix ® Compressors: Park vehicle, chock wheels, and follow all standard safety procedures. Remove th

• BENDIX TU-FLO 550 COMPRESSOR, A-21 Technical Bulletin Bulletin No.: TCH-008-022 Effective Date: 1/1/1994 Page: 1 of 1 Subject: Additional Cold Weather Operation Tips for the Air Brake System Last year we published Bulletin PRO-08-21 which provided some guidelines for “winterizing” a vehicle air brake system. Here are some additional suggestions for making cold weather vehicle operation just a little more bearable. Thawing Frozen Air Lines The old saying; “Prevention is the best medicine” truly applies here! Each year this activity accounts for an untold amount of unnecessary labor and component replacement.

• BENDIX TU-FLO 550 COMPRESSOR, the slot toward the fl ange. Insert the crankshaft and the rear thrust washer with the tang toward the rear of the compressor. Place the oil seal ring on the boss of the rear end cover and install the end cover making sure not to pinch the seal ring. Ensure the tang of the thrust washer is inserted in the slot of the end cover. Fasten the end cover to the crankcase with the four cover cap screws. Torque the cap screws to 175-225 inch pounds in a cross pattern. with a special lubricant piece number 239379 and need no additional lubrication. Install the springs and unloader pistons in their bores being careful not to cut the o-rings. Install the unloader cover gasket and u

• BENDIX TU-FLO 550 COMPRESSOR, brake charging system performance which may require additional maintenance. Factors that add to the duty cycle are: air suspension, additional air accessories, use of an undersized compressor, frequent stops, excessive leakage from fi ttings, connections, lines, chambers or valves, etc. Refer to Table A in the Troubleshooting section for a guide to various duty cycles and the consideration 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

• BENDIX TU-FLO 550 COMPRESSOR, COMPRESSOR TURBOCHARGING PARAMETERS Air entering the compressor inlet during the loaded cycle must not exceed 250 degrees Fahrenheit (121 degrees Celsius). A metal inlet line is suggested to help meet this parameter. The following compressor crankshaft rotative speed and inlet pressure relationships may not be exceeded. Crankshaft Maximum Compressor R.P.M. Inlet Pressure 2200 RPM 30.0 psi (207 kPa) 2600 RPM 25.0 psi (172.5 kPa) POLYURETHANE SPONGE STRAINER Every month, 150 operating hours or 5,000 miles, whichever occurs fi rst, remove and wash all of the parts. The strainer element

• BENDIX TU-FLO 550 COMPRESSOR, A-4 Air Brake Charging System Troubleshooting 1.0 Oil Test Card Results Not a valid test. Discontinue using this test. Do not use this card test to diagnose compressor "oil passing" issues. They are subjective and error prone. Use only the Bendix ® Air System Inspection Cup (BASIC ™ ) test and the methods described in this guide for advanced troubleshooting. The Bendix ® BASIC ™ test should be the defi nitive method for judging excessive oil fouling/oil passing. (See Appendix A, on page A-16 for a

• A-8 Symptom: What it may indicate: What you should do: (i) Poorly filtered inlet air (poor air quality to compressor). (j) Governor malfunction or setting. (k) Compressor malfunction. 4.0 Oil in Supply or Service Reservoir* (air dryer installed) (continued)  Check for leaking, damaged or defective compressor air inlet components (e.g. induction line, fi ttings, gaskets,

• BENDIX TU-FLO 550 COMPRESSOR, force the pistons upward and the inlet valves return to their seats. Compression is then resumed. COMPRESSOR & THE AIR BRAKE SYSTEM GENERAL The compressor is part of the total air brake system, more specifi cally, the charging portion of the air brake system. As a component in the overall system its condition, duty cycle, proper installation and operation will directly affect other components in the system. Powered by the vehicle engine, the air compressor builds the air pressure for the air brake system. The air compressor is typically cooled by the engine coolant system, lubricated by the engine oil supply and has its in

• BENDIX TU-FLO 550 COMPRESSOR, A-3 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 suffi cient cooling occurs, the oil-vapor condenses and can be removed

• BENDIX TU-FLO 550 COMPRESSOR, A-14 Tests Exterior leaks at the head gasket are not a sign that oil is being passed into the air charging system. Oil weepage at the head gasket does not prevent the compressor from building air. Observe the amount of weepage from the head gasket. If the oil is only around the cylinder head area, it is acceptable (return the vehicle to service), but, if the oil weepage extends down to the nameplate area of the compressor, the gasket can be replaced. Test 1: Excessive Oil Leakage at the Head Gasket Inspect for air leaks when working on a vehicle an

• BENDIX TU-FLO 550 COMPRESSOR, A-20 Bulletin No.: TCH-008-021 Effective Date: 11/1/92 Page: 2 of 2 High Duty Cycle Vehicles (City Transit Coaches, Refuse Haulers, Etc.) The maximum discharge line length is 16 feet. Length I.D. min. Other Requirements 10-16 ft. ½ in. None If the discharge line length must be less than 10 feet or greater than 16 feet, contact your local Bendix representative. System Leakage Check the air brake system for excessive air leakage using the Bendix “Dual System Air Brake Test and Check List�

• BENDIX TU-FLO 550 COMPRESSOR, FIGURE 7 - LUBRICATION OIL INLET 2. Naturally aspirated Engine Air Cleaner - Compressor inlet is connected to the engine air cleaner or the vacuum side (engine air cleaner) of the supercharger or turbocharger. 3. Pressurized induction - Compressor inlet is connected to the pressure side of the supercharger or turbocharger. See the tabulated technical data on page 14 of this manual for specifi c requirements for numbers 2 and 3 above. If a previously unturbocharged compressor is being turbocharged, it is recommended that the inlet cavity screen (238948) be installed with an inlet gasket (291909) on both sides of the screen. WATER IN OR (1 PORT ONLY) WATER

• BENDIX TU-FLO 550 COMPRESSOR, A-19 Technical Bulletin Bulletin No.: TCH-008-021 Effective Date: 11/1/92 Page: 1 of 2 Subject: Air Brake System - Cold Weather Operation Tips As the cold weather approaches, operators and fl eets alike begin to look to their vehicles with an eye toward “winterization”, and particularly what can be done to guard against air system freeze-up. Here are some BASIC ™ “Tips” for operation in the cold weather. Engine Idling Avoid idling the engine for long periods of time! In addition to the fact that most engine manufacturers warn that long idle times are detrimental to engine life, winter idling is a big factor in compressor discharge

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