User manual BENDIX TU-FLO 550 COMPRESSOR

[. . . ] Bendix® Tu-Flo® 550 Air Compressor DISCHARGE VALVE STOP DISCHARGE VALVE UNLOADER COVER AIR DISCHARGE WATER OUTLET WATER INLET AIR INLET DISCHARGE VALVE SPRING PISTON DISCHARGE VALVE SEAT CRANKCASE PISTON RINGS CONNECTING ROD GOVERNOR MOUNTING PAD CRANKCASE CRANKSHAFT BENDIX TU-FLO 550 AIR COMPRESSOR (CROSS SECTION) ® ® PIECE NO. TAG 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® 550 compressor is a two cylinder single stage, reciprocating compressor with a rated displacement of 13. 2 cubic feet per minute at 1250 RPM. The compressor assembly consists of two major subassemblies, the cylinder head and the crankcase. [. . . ] Prior to returning the vehicle to service, make certain all components and systems are restored to their proper operating condition. For vehicles with Antilock Traction Control (ATC), the ATC function must be disabled (ATC indicator lamp should be ON) prior to performing any vehicle maintenance where one or more wheels on a drive axle are lifted off the ground and moving. 16 Appendix A Advanced Troubleshooting Guide for Air Brake Compressors The guide consists of an introduction to air brake charging system components, a table showing recommended vehicle maintenance schedules, and a troubleshooting symptom and remedy section with tests to diagnose most charging system problems. INDEX Symptom Air Air brake charging system: Slow build (9. 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9-10 Doesn't build air (10. 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11 Air dryer: Doesn't purge (14. 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12 Safety valve releases air (12. 0) . . . . . . . . . . . . . . . A-12 Compressor: Constantly cycles (15. 0) . . . . . . . . . . . . . . . . . . . . . . . . . . A-12 Leaks air (16. 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13 Safety valve releases air (11. 0) . . . . . . . . . . . . . . . A-11 Noisy (18. 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13 Reservoir: Safety valve releases air (13. 0) . . . . . . . . . . . . . . . A-12 Page Number Symptom Coolant Compressor leaks coolant (17. 0). . . . . . . . . . . . . . . . . . . . A-13 Engine Oil consumption (6. 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9 Oil Oil Test Card results (1. 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Oil is present: On the outside of the compressor (2. 0) . . . . . . A-5 At the air dryer purge/exhaust or surrounding area (3. 0) . . . . . . . . . . . . . . . . . . . . . . . . A-5 In the supply reservoir (4. 0) . . . . . . . . . . . . . . . . . . . . A-6-8 At the valves (5. 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8 At air dryer cartridge (7. 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9 In the ping tank or compressor discharge aftercooler (8. 0). . . . . . . . . . . . . . . . . . . . . . A-9 Page Number Test Procedures (1) Oil Leakage at Head Gasket . . . . . A-14 (2) System Leakage . . . . . . . . . . . . . . . . . . . . . . . A-14 (3) Compressor Discharge and Air Dryer Inlet Temperature. . . . . . . . . . . A-15 (4) Governor Malfunction . . . . . . . . . . . . . . . . A-14 (5) Governor Control Line . . . . . . . . . . . . . . . A-15 (6) Compressor Unloader . . . . . . . . . . . . . . . A-15 BASICTM Test Information . . . . . . . . A-16-18 Maintenance & Usage Guidelines Maintenance Schedule and Usage Guidelines (Table A) . . . . . A-3 A-1 Introduction to the Air Brake Charging 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 and lubricated by the engine oil supply. The compressor's unloader mechanism and governor (along with a synchro valve for the Bendix® DuraFloTM 596 air compressor) control the brake system air pressure between a preset maximum and minimum pressure level by monitoring the pressure in the service (or "supply") reservoir. When the air pressure becomes greater than that of the preset "cut-out", the governor controls the unloader mechanism of the compressor to stop the compressor from building air and also causes the air dryer to purge. As the service reservoir air pressure drops to the "cut-in" setting of the governor, the governor returns the compressor back to building air and the air dryer to air drying mode. As the atmospheric air is compressed, all the water vapor originally in the air is carried along into the air system, as well as a small amount of the lubricating oil as vapor. The duty cycle is the ratio of time the compressor spends building air to the total engine running time. Air compressors are designed to build air (run "loaded") up to 25% of the time. Higher duty cycles cause conditions that affect air 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 fittings, connections, lines, chambers or valves, etc. [. . . ] Here are some Do's and Don'ts for prevention and thawing. Do maintain freeze prevention devices to prevent road calls. Don't let evaporators or injectors run out of methanol alcohol or protection will be degraded. Check the air dryer for proper operation and change the desiccant when needed. [. . . ]