Bendix Commercial Vehicle Systems TU-FLO 600 AIR COMPRESSOR 9/04 - Manual (Page 12)

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Position a rear end cover gasket, when used, over the rear
end of the crankcase, making sure the oil hole in the gasket
lines up with the oil hole in the crankcase. Position the end
cover oil seal ring, if used, in the groove in the end cover
boss. The end cover should be positioned correctly in
relation to the oil holes in the gasket and crankcase. As the
end cover is positioned, the oil seal ring must be compressed
as it is positioned in the crankshaft. Secure end cover to
crankcase with cap screws and lock washers.
If the opposite end cover requires an oil seal which was
removed on disassembly, a new seal should be pressed
into end cover. Position new end cover gasket and carefully
install end cover over crankshaft and to crankcase avoiding
damage to the seal. Secure end cover with cap screw and
lock washers (220-250 inch pounds).
INSTALLING PISTONS AND CONNECTING RODS
If new wrist pin bushings are to be used, they should be
pressed into the connecting rods so that the oil hole in the
bushing lines up with the one in the rod. The new bushings
should then be reamed or honed to provide between .0002
in. (.005 mm) and .0007 in. (.018 mm) clearance on the
wrist pin. Position connecting rod in piston and press in
wrist pin so that lockwire hole in the pin aligns with
that of the piston. Install new lockwire through piston and
wrist pin and lock same by snapping short end into lockwire
hole at the bottom of the piston (Fig. 3). Teflon plugs in wrist
pin ends may be used instead of the lockwires (Fig. 3).
Install piston rings in correct location with ring pip marks up
(Fig. 18). Stagger the position of the ring gaps.
Prelubricate piston, piston rings, wrist pin, and connecting
rod bearings with clean engine oil before installing them in
the compressor.
Remove connecting bolts and bearing cap from one
connecting rod. Turn crankshaft so one of its connecting
rod journals is in the downward, center position. Compress
the rings in their respective grooves with a ring compression
tool. Insert the connecting rod with piston through the top of
the cylinder whose journal is down. Position and attach the
bearing cap to the connecting rod making sure the bolt lock
washers are properly positioned on the cap. Tighten
connecting rod bolts (105-120 inch pounds) and bend the
two new lock washer prongs up against the hex head of the
bolt. Install the other connecting rod and piston in the same
manner.
UNLOADING MECHANISM (FIG. 15)
The unloader pistons and their bores must be lubricated
with special lubricant piece number 239379 (dimethyl
polysiloxane) prior to installation. If new unloader kits are
being installed, the pistons in the kit are already lubricated.
Install the unloader pistons in their bores with caution against
cutting the o-rings or distorting the back-up rings.
Position unloader plungers in their guides and slip them in
and over the tops of the pistons.
Install the unloader spring seat in the cylinder block; a small
hole is drilled in the block for this purpose. Position the
saddle between unloader piston guides so its forks are
centered on the guides. Install the unloader spring making
sure it seats over the spring seats both in the block and on
the saddle.
Install inlet valve seats if they have been previously removed.
Position and install inlet valve guides, then drop inlet valves
in their guides. There should be a loose sliding fit between
guides and valves.
CYLINDER HEAD ASSEMBLY
If previously removed, the discharge valve seats should be
installed. Drop discharge valves into their seats. Install
discharge valve spring and cap nuts.
Place the inlet valve springs in the cylinder head. Use a
small quantity of grease to hold them in place, just enough
grease to keep the springs from falling out. Place cylinder
head gasket on cylinder block. Carefully align cylinder head
assembly on block and install cap screws. Torque to
175-225 inch pounds.
AIR STRAINER
If the compressor has its own air strainer, reassemble with
new or cleaned element. Assemble to block with a new
strainer gasket.
GOVERNOR
If compressor is type with pad mounted governor, install a
properly functioning governor using a new governor gasket.
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 or friction tape.
The open bottom of engine lubricated compressors should
be protected against the entrance of dirt during handling or
storage, by installing a temporary cover over base.
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.