BENDIX TU-FLO 501 AIR COMPRESSOR Specifications download pdf (Page 9)

Note: For cast iron flange adapters, torque the four 7/16

in. cap screws to 38-45 foot pounds. For die cast

aluminum end covers, torque the four 7/16 in. cap

screws to 25-30 foot pounds. All end covers using

5/16 in. cap screws or stud and nuts are torqued

to 15-18 foot pounds. For through drive compressors

with a cast iron end cover, torque the four 7/16 in.

cap screws to 25-30 foot pounds.

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 .0001

in. (.00254 mm) and .0006 in. (.01524 mm) clearance on

the wrist pin. Position the connecting rod in the piston and

press in the wrist 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 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. Pre-lubricate the piston, piston rings, wrist pins and

connecting rod.

Unloader

A new unloader kit should used when rebuilding. (Figure

13). (Piece Number 279615). The unloader pistons in the kit

are pre-lubricated with a special lubricant piece number

239379 and need no additional lubrication. Install the unloader

pistons in their bores being careful not to cut the O-Rings.

Position the unloader plungers in their guides and slip them

in and over the tops of the pistons. Install the unloader spring

seat in the crankcase inlet cavity; a small hole is drilled in

the crankcase for this purpose. Position the saddle between

the 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 crankcase and on the saddle.

Position and install the inlet valve guides, then drop the inlet

valves in their guides. The inlet valves should be a loose

sliding fit in the guides.

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 failing 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 25-30 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.

FIGURE 15 - UNLOADER MECHANISM

1 2 3 4 5 6 7 8 9 10 11 12 13

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BENDIX TU-FLO 501 AIR COMPRESSOR Specifications Page 9

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