Bendix Commercial Vehicle Systems TU-FLO 700 COMPRESSOR 10/04 - Manual (Page 11)

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piston and secure same by inserting the new lockwire
through the hole in piston and wrist pin and lock the wire by
snapping the short 90 section into the lockwire hole in the
bottom of the piston.
Compressors built after November, 1976, will have the wrist
pin secured by Teflon buttons in either end of the wrist pin,
allowing the wrist pin to float. The Teflon buttons pc. no.
292392 may be used with either new or old wrist pins. The
later design pistons have two rings above the wrist pin and
one below. Install the piston rings in the correct location
with the ring pipmarks up. Stagger the position of the ring
gaps. Prelubricate the piston, piston rings, wrist pins and
connecting rod.
CYLINDER BLOCK
Align gasket (12), crankcase and cylinder block and secure
with cap screws (23). Torque to 15-19 foot pounds.
UNLOADER
A new unloader kit should used when rebuilding. (Figure
13). (Piece Number 279615). The unloader pistons in the kit
are prelubricated with a special lubricant piece number
239379 and need no additional lubrication. Install the unloader
pistons (28) in their bores being careful not to cut the
o-rings. Position the unloader plungers (37) in their guides
(38) and slip them in and over the tops of the pistons. Install
the unloader spring seat (36) in the cylinder block inlet cavity;
a small hole is drilled in the cylinder block for this purpose.
Position the saddle (35) between the unloader piston guides
(38), so its forks are centered on the guides. Install the
unloader spring (34), making sure it seats over the spring
seats both in the block and on the saddle. Position and
install the inlet valve guides (38), then drop the inlet valves in
their guides. The inlet valves should be a loose sliding fit in
the guides.
36
34
38
35
28
FIGURE 13 - UNLOADER MECHANISM
37
CYLINDER HEAD
Install the inlet valve springs in the cylinder head by applying
a turning motion to the spring after it is in the head. The
turning motion should dig the spring wire into the spring
seat in the bottom of 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 ADAPTER
Position the base plate or base adapter gasket on the
crankcase and install the base plate or base adapter as
marked before disassembly. Tighten the six cap screws
securing the cast iron base adapter evenly to a torque of 38-
45 foot pounds, and 12-16 foot pounds for base plate or
aluminum cover.
TESTING REBUILT COMPRESSOR
In order to properly test a compressor under operating
conditions, a test rack for correct mounting, cooling,
lubricating, and driving the compressor is necessary. Such
tests are not compulsory if the unit has been carefully rebuilt
by an experienced person. A compressor efficiency or build-
up test can be run which is not too difficult. An engine
lubricated compressor must be connected to an oil supply
line of at least 15 P.S.I. pressure during the test and an oil
return line must be installed to keep the crankcase drained.
Connect to the compressor discharge port, a reservoir with
a volume of 1500 cubic inches, including the volume of
connecting line. With the compressor operating at 2100
R.P.M., the time required to raise the reservoir(s) pressure
from 85 P.S.I. to 100 P.S.I. should not exceed 7 seconds.
During this test, the compressor should be checked for
gasket leakage and noisy operation, as well as unloader
operation and leakage.
INSPECTION OF REBUILT UNIT
Check to be sure that covers, plugs, or masking tape are
used to protect all ports if compressor is not to be installed
immediately. Fit the end of all crankshafts with keys, nuts,
and cotter pins as required and then protect the ends against
damage by wrapping with masking tape or friction tape. The
open bottom of a vertical engine lubricated compressors
should be protected against the entrance of dirt during
handling or storage, by installing a temporary cover over the
base.