SD-01-336

Bendix TU-FLO 600 Air Compressor

GENERAL Various mounting and drive configurations are used as

required by different vehicle and engine designs. See Fig. 1.
The function of the air compressor is to build up and maintain
the air pressure required to operate air powered devices in All Tu-Flo 600 compressors receive oil under pressure from
air brake or air auxiliary systems. the engine lubricating system for the lubrication of the
internal parts. Fig. 2 shows a cross section of a typical
DESCRIPTION Tu-Flo 600 compressor and the oil flow therein.
The Tu-Flo 600 compressor is a two cylinder reciprocating
Oil is forced through the oil passage in the crankshaft to
single stage compressor with a rated displacement of 14.5
each connecting rod journal. Oil is forced out at the journals
cfm at 1250 rpm.
and is thrown by centrifugal force against the cylinder walls
The Tu-Flo 600 compressor is constructed with a crankcase, and crankshaft main bearings, providing lubrication.
block, and head assembly. The crankcase assemblies, in
The wrist pins and wrist pin bushings are lubricated in two
particular, are essentially the same as corresponding Tu-Flo
ways depending on the type connecting rod used. Some
500 compressors. The block assembly includes the air inlet
older compressors, and one current design use forged steel
cavity, automatic inlet valves and unloader valves. Vertical
rifle drilled rods, through which oil is forced to the wrist pin
mounting pads for governor mounting are included at each
bushings. Standard current design consists of a diecast
end of the block. The head assembly includes the discharge
valves with discharge ports either on the side or top of the
the top of the rod and a short hole connecting to the wrist
block.
pin bushing. See Fig. 3.
All Tu-Flo 600 compressors are liquid cooled, both head
and block, by coolant from the engine cooling system.
1
 FIGURE 2 - TU-FLO 600 AIR COMPRESSOR SECTIONAL
VIEW

FIGURE 3 - TU-FLO 600 AIR COMPRESSOR PISTON/PIN

DESIGN

NAME PLATE
A name plate is attached to the crankcase of all
compressors. It shows the piece number, type and serial
number (Fig. 4). A name plate with a black background
FIGURE 1 - FLANGE CONFIGURATIONS denotes a new compressor, whereas a name plate with a
red background designates that the compressor is a factory
reconditioned unit. All compressors are identified by the piece
number which is the number to be used when reference is
made to a particular compressor. The type and serial number
is supplementary information.

2
FIGURE 4

OPERATION
GENERAL
All compressors run continuously while the engine is
running, but actual compression of air is controlled by a
governor which stops or starts the compression of air by FIGURE 6
loading or unloading the compressor in conjunction with its
unloading mechanism. This is done when the air pressure
in the system reaches the desired maximum or minimum NON-COMPRESSION (UNLOADED)
pressures. When the air pressure in the reservoir reaches the high
pressure setting of the governor, the governor opens,
allowing air to pass from the reservoir through the governor
and into the cavity beneath the unloader pistons. This lifts
the unloader pistons and plungers. The plungers move up
and hold the inlet valves off their seats (Fig. 7).

FIGURE 5

INTAKE AND COMPRESSION (LOADED)

During the down stroke of the piston, a slight vacuum created
above the piston causes the inlet valve to move off its seat.
Atmospheric air is drawn in through the compressor intake,
by the open inlet valve, and on top of the piston (Fig. 5). As
the piston starts its upward stroke, the air that was drawn in
on the down stroke is being compressed. Now, air pressure FIGURE 7
on top of the inlet valve plus the force of its spring, returns
the inlet valve to its seat. The piston continues the upward
stroke and compresses the air sufficiently to overcome the
With the inlet valves held off their seats by the unloader
discharge valve spring and unseat the discharge valve. The
pistons and plungers, air is merely pumped back and forth
compressed air then flows past the open discharge valve,
between the two cylinders. When air is used from the
into the discharge line and on to the reservoirs (Fig. 6).
reservoir and the pressure drops to low pressure setting of
As the piston reaches the top of its stroke and starts down, the governor, the governor closes and in doing so exhausts
the discharge valve spring returns the discharge valve to its the air from beneath the unloader pistons. The unloader
seat. This prevents the compressed air in the discharge saddle spring forces the saddle, pistons and plungers down
line from returning to the cylinder bore as the intake and and the inlet valves return to their seats. Compression is
compression cycle is repeated. then resumed.
3
 The Air Brake Charging System supplies the
compressed air for the braking system as well as other air
accessories for the vehicle. The system usually consists
Discharge of an air compressor, governor, discharge line, air dryer,
Line Air Dryer and service reservoir.

Optional Bendix PuraGuard QC

Oil Coalescing Filter

Compressor
Governor
(Governor plus Synchro valve Service Reservoir
for the Bendix DuraFlo 596 (Supply Reservoir)
Compressor)
Reservoir Drain

FIGURE 8A - SYSTEM DRAWING

COMPRESSOR & THE AIR BRAKE SYSTEM from fittings, connections, lines, chambers or valves, etc.
Refer to Table A in the Troubleshooting section for a guide to
GENERAL
various duty cycles and the consideration that must be given
The compressor is part of the total air brake system, more to maintenance of other components.
specifically, the charging portion of the air brake system. As
COMPRESSOR INSTALLATION
a component in the overall system its condition, duty cycle,
proper installation and operation will directly affect other While the original compressor installation is usually
components in the system. completed by the vehicle manufacturer, conditions of
operation and maintenance may require additional
Powered by the vehicle engine, the air compressor builds
consideration. The following presents base guidelines.
the air pressure for the air brake system. The air compressor
is typically cooled by the engine coolant system, lubricated DISCHARGE LINE
by the engine oil supply and has its inlet connected to the
The discharge line allows the air, water-vapor and oil-vapor
engine induction system.
mixture to cool between the compressor and air dryer or
As the atmospheric air is compressed, all the water vapor reservoir. The typical size of a vehicle's discharge line, (see
originally in the air is carried along into the air system, as column 2 of Table A in the Troubleshooting section) assumes
well as a small amount of the lubricating oil as vapor. If an a compressor with a normal (less than 25%) duty cycle,
air dryer is not used to remove these contaminants prior to operating in a temperate climate. See Bendix and/or other
entering the air system, the majority, but not all, will condense air dryer manufacturer guidelines as needed.
in the reservoirs. The quantity of contaminants that reach
the air system depends on several factors including The discharge line must maintain a constant slope down
installation, maintenance and contaminant handling devices from the compressor to the air dryer inlet fitting or reservoir
to avoid low points where ice may form and block the flow. If,
in the system. These contaminants must either be eliminated
prior to entering the air system or after they enter. instead, ice blockages occur at the air dryer or reservoir
inlet, insulation may be added here, or if the inlet fitting is a
DUTY CYCLE typical 90 degree fitting, it may be changed to a straight or
45 degree fitting. Shorter discharge line lengths or insulation
The duty cycle is the ratio of time the compressor spends
may be required in cold climates.
building air to the total engine running time. Air compressors
are designed to build air (run "loaded") up to 25% of the While not all compressors and charging systems are
time. Higher duty cycles cause conditions that affect air equipped with a discharge line safety valve this component
brake charging system performance which may require is recommended. The discharge line safety valve is installed
additional maintenance. Factors that add to the duty cycle in the cylinder head or close to the compressor discharge
are: air suspension, additional air accessories, use of an port and protects against over pressurizing the compressor
undersized compressor, frequent stops, excessive leakage in the event of a discharge line freezeup.

4
 HOLE

THREAD

FIGURE 8B - DISCHARGE LINE SAFETY VALVE FIGURE 9 - SPONGE TYPE STRAINER

DISCHARGE LINE TEMPERATURE DRY ELEMENT - PLEATED PAPER AIR STRAINER

(FIG. 10)
When the temperature of the compressed air that enters
the air dryer is within the normal range, the air dryer can Remove the spring clips from either side of mounting baffle
remove most of the charging system oil. If the temperature and remove the cover. Replace the pleated paper filter and
of the compressed air is above the normal range, oil as oil- remount the cleaned cover making sure the filter is in
vapor is able to pass through the air dryer and into the air position. Be sure to replace the air strainer gasket if the
system. Larger diameter discharge lines and/or longer entire air strainer is removed from the compressor intake.
discharge line lengths can help reduce the temperature. NOTE: Some compressors are fitted with compressor intake
adapters (Fig. 11) which allow the compressor intake to be
The air dryer contains a filter that collects oil droplets, and a connected to the engine air cleaner.
desiccant bed that removes almost all of the remaining water
vapor. The compressed air is then passed to the air brake In this case, the compressor receives a supply of clean air
service (supply) reservoir. The oil droplets and the water from the engine air cleaner. When the engine air filter is
collected are automatically purged when the governor changed, the compressor intake adapter should be checked.
reaches its "cut-out" setting. If it is loose, remove the intake adapter, clean the strainer
plate, if applicable, and replace the intake adapter gasket,
For vehicles with accessories that are sensitive to small and reinstall the adapter securely. Check line connections
amounts of oil, we recommend installation of a Bendix both at the compressor intake adapter and at the engine air
PuraGuard QC oil coalescing filter, designed to minimize cleaner. Inspect the connecting line for ruptures and replace
the amount of oil present. it if necessary.
AIR CLEANER MAINTENANCE
POLYURETHANE SPONGE STRAINER (FIG. 9)
Remove and wash all of the parts. The strainer element
should be cleaned or replaced. If the element is cleaned, it
should be washed in a commercial solvent or a detergent
and water solution. The element should be saturated in clean
engine oil then squeezed dry before replacing it in the strainer.
Be sure to replace the air strainer gasket if the entire air
strainer is removed from the compressor intake.

FIGURE 10 - DRY ELEMENT STRAINER

5
 Always use a new mounting gasket and be sure oil hole in
gasket and compressor is properly aligned with oil supply
line.

Inspect pulley or gear and associated parts for wear or

damage. They must be a neat fit on compressor crankshaft.
Replace pulley or gear if worn or damaged.

FIGURE 11 - INLET ADAPTER Install pulley or gear on compressor crankshaft making sure
it properly contacts the shaft and does not ride the key.
AIR LEAKAGE TESTS Tighten crankshaft nut to 65-70 ft. lbs. and install cotter pin.
Leakage past the discharge valves can be detected by Be sure the air cleaner is clean and properly installed. If the
removing the discharge line, applying shop air back through compressor intake is connected to either the engine air
the discharge port and listening for escaping air. Also, the cleaner or supercharger, these connections must be tight
discharge valves and the unloader pistons can be checked with no leakage.
for leakage by building up the air system until the governor
cuts out, then stopping the engine. With the engine stopped, Clean or replace any damaged or dirty air or water lines
carefully listen for escaping air at the intake. To pin-point which may be corroded, before connecting them to the
leakage if noted, squirt oil around the unloader pistons. If compressor. Use a new discharge fitting gasket.
there is no noticeable leakage at the unloader pistons, the Align compressor drive and adjust proper belt tension.
discharge valves may be leaking.
Tighten mounting bolts securely and evenly.
If the compressor does not function as described above, or
leakage is excessive, it is recommended that it be returned After installation run compressor and check for air, oil, or
to the nearest Bendix authorized distributor for a factory water leaks at compressor connections. Also, check for
rebuilt compressor under the repair exchange plan. If this is noisy operation.
not possible, the compressor can be repaired with genuine
Bendix parts in which case the following information should DISASSEMBLY
prove helpful. GENERAL
Clean compressor exterior of road dirt and grease using a
REMOVING AND INSTALLING good cleaning solvent. Before compressor is completely
disassembled the following items should be marked to show
REMOVING
their relationship when the compressor is assembled:
These instructions are general and in some cases additional
precautions must be taken.
Drain air brake system. relation to crankcase, position of crankshaft in relation to
Drain engine cooling system, compressor cylinder head and
block.
A convenient method to indicate the above relationships is
Disconnect all air lines, water and oil lines to and from
to use a metal scribe to mark the parts with numbers or
compressor.
lines. Do not use a marking method that can be wiped off
Remove compressor mounting bolts and compressor from
or obliterated during rebuilding, such as chalk. Remove all
engine.
compressor attachments such as governors, air strainers
Use a gear-puller to remove the gear or pulley from
or inlet fittings, discharge fittings and pipe plugs.
compressor crankshaft.
INSTALLATION CYLINDER HEAD

Clean oil supply line. Before connecting this line to the Remove the cylinder head cap screws and tap the head
compressor run the engine briefly to be sure oil is flowing with a soft mallet to break the gasket seal. Remove the inlet
freely through the supply line. valve springs from the head and inlet valves from their guides
in the block. Remove inlet valve guides from around the
Clean the oil return line or return passages through the inlet valve seats on the block taking care not to damage
brackets; these passages must be unrestricted so oil can seats. Scrape off any gasket material from the cylinder
return to the engine. head and block. Unscrew the discharge cap nuts from the
Prelubricate compressor cylinder walls, piston rings, and head and remove the discharge valves and springs. Inspect
bearings with clean engine oil before assembling compressor. the discharge valve seats for nicks, cracks, and excessive
wear and remove and replace if necessary.

6
The discharge valve cap nuts should be inspected for wear If the pistons are removed from the rod, inspect the bronze
and replaced if excessive peening has occurred. To wrist pin bushing. Press out and replace the bushing if it is
determine if excessive peening has occurred, measure the excessively worn. (See inspection of parts.) Discard the
discharge valve travel. Discharge valve travel must not piston rings and the connecting rod journal bearings. Discard
exceed .046 inches (1.168 mm). the wrist pin bushings if they were removed (Fig. 13).

CRANKCASE BASE PLATE OR ADAPTER CRANKCASE (FIG. 14)

Remove the cap screws securing the base plate or base Remove end cover with oil seal, remove end cover gasket.
adapter. Tap with soft mallet to break the gasket seal. Scrape Replace oil seal after cleaning end cover.
off any gasket material from crankcase and plate or adapter.
Remove cap screws that hold opposite end cover to
CONNECTION ROD ASSEMBLIES crankcase; remove end cover and its gasket. Some
NOTE: Before removing the connecting rods, mark each compressors have crankcases that have a shoulder for
connecting rod and its cap. Each connecting rod is positioning the crankshaft. In these cases, the crankshaft
matched to its own cap for proper bearing fit, and must be removed through one particular end.
these parts must not be interchanged. Press the crankshaft and ball bearings from the crankcase
Straighten the prongs of the connecting rod bolt lock strap then press ball bearings from crankshaft. Many compressors
and remove the bolts and bearing caps. Push the piston will have sleeve type bearings in the crankcase or in the
with the connecting rods attached out the top of the cylinder end cover. If the clearance between crankshaft journal and
block. Replace the bearing caps on their respective bearing exceeds .0065 in. (.165 mm) the sleeve bearing
connecting rods. Remove the piston rings from the pistons. should be replaced with appropriate undersize.
If the pistons are to be removed from the connecting rods,
BLOCK (FIG. 15)
remove the wrist pin lock wires and press the wrist pins
from the pistons and connecting rods. If the wrist pins have If compressor is fitted with an air strainer, inlet elbow or
teflon plugs, remove plugs, then press out the wrist pins. governor, remove same.

Remove cap screws securing cylinder block to crankcase;

separate crankcase and cylinder block and scrape off gasket.

Remove unloader spring, spring saddle and spring seat from

cylinder block (Fig. 15).

Remove unloader guides and plungers and with the use of

shop air blow unloader pistons out of cylinder block unloader
piston bores.

Remove inlet valve guides; inlet valve seats can be removed,

but only if they are worn or damaged and are being
replaced. Unloader bore bushings should be inspected but
not removed unless they are damaged.

PREVENTATIVE MAINTENANCE
Regularly scheduled maintenance is the single most
important factor in maintaining the air brake charging system.
Refer to Table A in the Troubleshooting section for a guide to
various considerations that must be given to the maintenance
of the compressor and other related charging system
components.

CLEANING AND INSPECTION OF PARTS

CLEANING
All parts should be cleaned thoroughly in mineral spirits
before inspection.

FIGURE 12 - TU-FLO 600 AIR COMPRESSOR CYLINDER

HEAD
7
FIGURE 13 - TU-FLO 600 AIR COMPRESSOR CYLINDER BLOCK ASSEMBLY

FIGURE 14 - TU-FLO 600 AIR COMPRESSOR CRANK CASE ASSEMBLY

8
CYLINDER HEAD ASSEMBLY
Remove all carbon deposits from discharge cavities and all
rust and scale from cooling cavities of cylinder head body.
Scrape all foreign matter from body surfaces and use air
pressure to blow dirt particles from all cavities.

Discharge valves can be dressed by lapping them on a

piece of fine crocus cloth on a flat surface, provided they
are not excessively worn.

CYLINDER BLOCK
Clean carbon and dirt from inlet and unloader passages.
Use air pressure to blow carbon and dirt deposits from
unloader passages.

Inlet valves, as in the case of discharge valves, not worn

excessively can be cleaned by lapping them on a piece of
fine crocus cloth on a flat surface.

LUBRICATION
Check the exterior of the compressor for the presence of oil FIGURE 15 - TU-FLO 600 AIR COMPRESSOR BLOCK ASSY
seepage and refer to the TROUBLESHOOTING section for
appropriate tests and corrective action. INSPECTION OF PARTS
OIL PASSING CYLINDER HEAD BODY
All reciprocating compressors currently manufactured will Inspect cylinder head body for cracks or damage.
pass a minimal amount of oil. Air dryers will remove the
WATER-COOLED TYPE
majority of oil prior to entrance into the air brake system.
For particularly oil sensitive systems the Bendix PuraGuard Use air pressure to test water jackets of cylinder head and
QC oil coalescing filter can be used in conjunction with a block for leakage. Replace unit if leakage is found.
Bendix air dryer.
DISCHARGE VALVES AND SEATS
If compressor oil passing is suspected, refer to the If discharge valves are worn and grooved where they contact
TROUBLESHOOTING section and TABLE A for the the seats, they should be replaced. If the discharge valve
symptoms and corrective action to be taken. In addition, seats are worn excessively so that there is no longer enough
Bendix has developed the "Bendix Air System Inspection metal left to reclaim them by lapping, the seats should be
Cup" or BASIC test to help substantiate suspected excessive replaced.
oil passing. The steps to be followed when using the BASIC
test are presented in APPENDIX A at the end of the DISCHARGE VALVE SPRING AND CAP NUTS
TROUBLESHOOTING section. Replace all used discharge valve springs and cap nuts if
OIL PASSAGE cap nuts cannot be reclaimed.

Clean thoroughly all oil passages through crankshaft, CRANKCASE AND END COVERS
connecting rods, crankcase, end covers and base plate. If Check for cracks or broken lugs in crankcase and end
necessary, inspect passages with a wire and blow foreign covers. Also, check oil passages to make sure they are
matter out with air pressure. open and clean.

If an oil seal ring is used in the end cover, check fit of ring in
ring groove. There should be .008 in. (.203 mm) to .015 in.
(.381 mm) clearance at the gap when placed in the end bore
of the crankshaft. If the oil ring is worn thin or is damaged, it
should be replaced. Inspect oil ring groove in end cover; if
groove is worn excessively, replace end cover or machine
groove for next oversize oil seal ring. If the crankshaft main
bearings are installed in the end cover, check for excessive
wear and flat spots; replace if necessary.
9
CYLINDER BLOCK
Check for cracks or broken lugs on cylinder block. Also 5 Ring Wrist Ring *Piston Pin
check unloader bore bushings to be sure they are not worn, Size Piston Pin Set Maint. Kit
rusted or damaged. If these bushings are to be replaced,
Standard 292529 292530 282525 289891
they can be removed by running a 1/8 in. pipe thread tap
inside the bushing, then inserting a 1/8 in. pipe threaded Oversize 292547 292530 282526 289892
rod and pulling the bushing straight up and out. Do not use
an easy-out for removing these bushings. Oversize 292548 292530 282527 289893

INLET VALVES AND SEATS Oversize 292549 292530 282528 289894

If inlet valves are grooved or worn where they contact the
seat, they should be replaced. If the inlet valve seats are * Includes 1 piston, 1 wrist pin, and 2 pin buttons.
worn or damaged so they cannot be reclaimed by facing,
they should be replaced. FIGURE 17

CYLINDER BORES
Cylinder bores which are scored or out of round by more If the compressor has five ring pistons which are to be reused,
than .002 in. (.051 mm) or tapered more than .003 in. (.076 they should be checked for scores, cracks or enlarged ring
mm) should be rebored or honed oversize. Oversize pistons grooves; replace pistons if any of these conditions are found.
are available in .010 in., .020 in., and .030 in. oversizes (Fig. Measure each piston with a micrometer in relation to the
16). cylinder bore diameter to be sure the clearance is between
Cylinder bores must be smooth, straight, and round. .002 in. (.051 mm) minimum and .004 in. (.102 mm)
maximum.
Clearance between cast iron pistons and cylinder bores
should be between .002 in. (.051 mm) minimum and .004 Check fit of wrist pins in pistons. Wrist pin clearance should
in. (.102 mm) maximum (Fig. 16). be from .0000 in. to .0006 in. (.015 mm). Check fit of wrist
pin in connecting rod bushing. This clearance should not
exceed .0007 in. (.018 mm). Replace wrist pin bushings if
excessive clearance is found. Wrist pin bushings should be
reamed after being pressed into connecting rods. Replace
used wrist pin lock wires. Compressors manufactured after
December, 1977, will have Teflon plugs in each end of the
wrist pins instead of the lockwire. The Teflon plugs (piece
number 292392) may be used instead of the lockwires on
all compressors (see Fig. 3).

PISTON RINGS
Check fit of piston rings in piston ring grooves. Check ring
gap with rings installed in cylinder bores. Refer to Fig. 18 for
correct gap and groove clearance.

FIGURE 16 - CHECKING CYLINDER BORE All rings must be located in their proper ring grooves as
shown. The rings can be identified by the width and should
be installed with the bevel or the pip mark (if any) toward the
PISTONS
top of the piston as shown.
Any of three different piston designs may be found in Tu-Flo
600 compressors as follows: three ring cast iron, three ring
aluminum or five ring cast iron. If either of the three ring
designs are found, it is recommended that the unit be updated
to the current five ring design. Piece numbers of five ring
piston, wrist pin maintenance kits and piston ring sets are
shown in Fig. 17.

10
 REPAIRS
DISCHARGE VALVES AND SEATS
If discharge valve seats merely show signs of slight wear,
they can be dressed by using a lapping stone, grinding
compound and grinding tool. Install new valve springs and
re-dressed or new discharge valves.

To test for leakage past the discharge valves, apply about

100 pounds of air pressure through the cylinder head
discharge port and apply soap suds at the discharge valves
and seats. Leakage which will permit the formation of bubbles
is permissible.

If excessive leakage is found, leave the air pressure applied,

and with the use of a fibre or hardwood dowel and hammer,
tap the discharge valves off their seats several times. This
FIGURE 18 - PISTON RING POSITIONS GAPS & GROOVE
CLEARANCE will help the valves to seat and should reduce any leakage.

With the air pressure still applied at the discharge port of

CRANKSHAFT the cylinder head, check for leakage at the discharge valve
Check crankshaft screw threads, keyways, tapered ends cap nuts. No leakage is permissible.
and all machined and ground surfaces for wear, scores, or
INLET VALVES AND SEATS
damage. Crankshaft journals which are out of round more
than .001 in. (.025 mm) must be reground. Bearing inserts If inlet valve seats show sign of slight nicks or scratches,
are available in .010 in. (.254 mm), .020 in. (.508 mm), and they can be redressed with a fine piece of emery cloth or
.030 in. (.762 mm) undersizes for reground crankshafts. by lapping with a lapping stone, grinding compound and
Main bearing journals must be maintained so bearings are grinding tool. If the seats are excessively damaged to the
snug fit. The oil seal ring groove or grooves in crankshafts extent that they cannot be reclaimed, they should be
fitted with oil seal rings must not be worn. The ring groove replaced. The dimension from the top of the cylinder block
walls must have a good finish and they must be square. to the inlet valve seat should not exceed .113 in. (2.870 mm)
Check to be sure the oil passages are open and clean not be less than .101 in. (2.565 mm).
through the crankshaft. Slightly worn or scratched inlet valves can be reclaimed by
CONNECTING ROD BEARINGS lapping them on a piece of fine crocus cloth on a flat surface,
but it is suggested that new inlet valves be installed.
Check connecting rod bearings on crankshaft journals for
proper fit. Used bearing inserts should be replaced. ASSEMBLY
Connecting rod caps are not interchangeable. The locking
slots of the connecting rod and cap should be positioned INSTALLING CYLINDER BLOCK
adjacent to each other. Position cylinder block gasket and block on crankcase
according to markings made prior to disassembly. Using
Clearance between the connecting rod journal and the
cap screws with lockwashers, secure cylinder block to
connecting rod bearing must not be less than .0003 in. (.008
crankcase at 220 to 250 inch pounds.
mm) or more than .0021 in. (.053 mm) after rebuilding.
INSTALLING CRANKSHAFT
MAIN BEARINGS
If the crankshaft is fitted with oil seal rings, install rings.
Check for wear or flat spots; if found, bearings should be
Position ball bearings and crankshaft in crankcase making
replaced. If type with sleeve bearing, this bearing should
sure the drive end of the crankshaft is positioned as marked
be checked for scores and wear and replaced if necessary.
before disassembly.
UNLOADER MECHANISM
If one end of the crankcase is counterbored for holding a
Used unloader mechanism should be replaced by unloader bearing, be sure the crankshaft is installed through the
kits (piece number 279615). correct end of the crankcase.
The new unloader pistons should be a loose sliding fit in the Carefully press crankshaft and bearings into crankcase
unloader piston bores of the cylinder block. using arbor press.

11
Position a rear end cover gasket, when used, over the rear Install the unloader pistons in their bores with caution against
end of the crankcase, making sure the oil hole in the gasket cutting the o-rings or distorting the back-up rings.
lines up with the oil hole in the crankcase. Position the end
Position unloader plungers in their guides and slip them in
cover oil seal ring, if used, in the groove in the end cover
and over the tops of the pistons.
boss. The end cover should be positioned correctly in
relation to the oil holes in the gasket and crankcase. As the Install the unloader spring seat in the cylinder block; a small
end cover is positioned, the oil seal ring must be compressed hole is drilled in the block for this purpose. Position the
as it is positioned in the crankshaft. Secure end cover to saddle between unloader piston guides so its forks are
crankcase with cap screws and lock washers. centered on the guides. Install the unloader spring making
sure it seats over the spring seats both in the block and on
If the opposite end cover requires an oil seal which was
the saddle.
removed on disassembly, a new seal should be pressed
into end cover. Position new end cover gasket and carefully Install inlet valve seats if they have been previously removed.
install end cover over crankshaft and to crankcase avoiding Position and install inlet valve guides, then drop inlet valves
damage to the seal. Secure end cover with cap screw and in their guides. There should be a loose sliding fit between
lock washers (220-250 inch pounds). guides and valves.
INSTALLING PISTONS AND CONNECTING RODS CYLINDER HEAD ASSEMBLY
If new wrist pin bushings are to be used, they should be If previously removed, the discharge valve seats should be
pressed into the connecting rods so that the oil hole in the installed. Drop discharge valves into their seats. Install
bushing lines up with the one in the rod. The new bushings discharge valve spring and cap nuts.
should then be reamed or honed to provide between .0002
in. (.005 mm) and .0007 in. (.018 mm) clearance on the Place the inlet valve springs in the cylinder head. Use a
wrist pin. Position connecting rod in piston and press in small quantity of grease to hold them in place, just enough
wrist pin so that lockwire hole in the pin aligns with grease to keep the springs from falling out. Place cylinder
that of the piston. Install new lockwire through piston and head gasket on cylinder block. Carefully align cylinder head
wrist pin and lock same by snapping short end into lockwire assembly on block and install cap screws. Torque to
hole at the bottom of the piston (Fig. 3). Teflon plugs in wrist 175-225 inch pounds.
pin ends may be used instead of the lockwires (Fig. 3). AIR STRAINER
Install piston rings in correct location with ring pip marks up If the compressor has its own air strainer, reassemble with
(Fig. 18). Stagger the position of the ring gaps. new or cleaned element. Assemble to block with a new
strainer gasket.
Prelubricate piston, piston rings, wrist pin, and connecting
rod bearings with clean engine oil before installing them in GOVERNOR
the compressor.
If compressor is type with pad mounted governor, install a
Remove connecting bolts and bearing cap from one properly functioning governor using a new governor gasket.
connecting rod. Turn crankshaft so one of its connecting
INSPECTION OF REBUILT UNIT
rod journals is in the downward, center position. Compress
the rings in their respective grooves with a ring compression Check to be sure that covers, plugs or masking tape are
tool. Insert the connecting rod with piston through the top of used to protect all ports if compressor is not to be installed
the cylinder whose journal is down. Position and attach the immediately.
bearing cap to the connecting rod making sure the bolt lock Fit the end of all crankshafts with keys, nuts and cotter pins
washers are properly positioned on the cap. Tighten as required and then protect the ends against damage by
connecting rod bolts (105-120 inch pounds) and bend the
wrapping with masking or friction tape.
two new lock washer prongs up against the hex head of the
bolt. Install the other connecting rod and piston in the same The open bottom of engine lubricated compressors should
manner. be protected against the entrance of dirt during handling or
storage, by installing a temporary cover over base.
UNLOADING MECHANISM (FIG. 15)
TESTING REBUILT COMPRESSOR
The unloader pistons and their bores must be lubricated
with special lubricant piece number 239379 (dimethyl In order to properly test a compressor under operating
polysiloxane) prior to installation. If new unloader kits are conditions, a test rack for correct mounting, cooling,
being installed, the pistons in the kit are already lubricated. lubricating and driving the compressor is necessary. Such
tests are not compulsory if the unit has been carefully rebuilt
by an experienced person.
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FIGURE 19 - SPONGE TYPE AIR STRAINER EXPLODED VIEW

A compressor efficiency or build-up test can be run which is COMPRESSOR TROUBLESHOOTING

not too difficult. An engine lubricated compressor must be
connected to an oil supply line of at least 15 pounds pressure IMPORTANT: The troubleshooting contained in this section
during the test and an oil return line must be installed to considers the compressor as an integrated component of
keep the crankcase drained. The compressor (when tested) the overall air brake charging system and assumes that an
should be tested without a strainer. air dryer is in use. The troubleshooting presented will cover
not only the compressor itself, but also other charging system
To the discharge port of the compressor connect a reservoir devices as they relate to the compressor.
or reservoirs whose volume plus the volume of the
connecting line equals 1300 cubic inches. Run the
compressor between 1700 and 1750 RPM. Elapsed time WARNING! PLEASE READ AND FOLLOW
that the compressor takes to build up from 0 to 100 psi THESE INSTRUCTIONS TO AVOID
should be 36 seconds maximum. During the above test, the PERSONAL INJURY OR DEATH:
compressor should be checked for oil leakage and noisy
operation. When working on or around a vehicle, the following
general precautions should be observed at all times.
TABULATED DATA
1. Park the vehicle on a level surface, apply the
Number Cylinders 2
parking brakes, and always block the wheels.
Bore Size 2.75 in. Always wear safety glasses.
6.985 cm 2. Stop the engine and remove ignition key when
Stroke 1-11/16 in. working under or around the vehicle. When
working in the engine compartment, the engine
4.287 cm
should be shut off and the ignition key should be
Piston Displacement at 14.5 cfm removed. Where circumstances require that the
1250 RPM 410.6 liter/min engine be in operation, EXTREME CAUTION should
Piston Displacement per 20.0 cu. in. be used to prevent personal injury resulting from
contact with moving, rotating, leaking, heated or
Revolution at 1250 RPM 327.74 cc
electrically charged components.
Maximum Recommended Speed (RPM) 2400 3. Do not attempt to install, remove, disassemble or
Minimum Cooling Water Flow for 2.5 gal/min assemble a component until you have read and
Water-Cooled compressors at 9.46 liter/min thoroughly understand the recommended
procedures. Use only the proper tools and observe
Maximum Speed
all precautions pertaining to use of those tools.
Horsepower Required at 1250 RPM 3.2
Against 100 psi brake system, or any auxiliary pressurized air
Minimum Oil Pressure Required 5 psi systems, make certain to drain the air pressure
from all reservoirs before beginning ANY work on
at Engine Idling Speed
the vehicle. If the vehicle is equipped with an
Minimum Oil Pressure Required 15 psi AD-IS air dryer system or a dryer reservoir module,
at Maximum Engine Governed Speed be sure to drain the purge reservoir.
13
 recommended procedures, deactivate the electrical
system in a manner that safely removes all electrical
power from the vehicle.

pressures.
7. Never connect or disconnect a hose or line
containing pressure; it may whip. Never remove a
component or plug unless you are certain all
system pressure has been depleted.
8. Use only genuine Bendix replacement parts,
components and kits. Replacement hardware,
tubing, hose, fittings, etc. must be of equivalent
size, type and strength as original equipment and
be designed specifically for such applications and
systems.
9. Components with stripped threads or damaged
parts should be replaced rather than repaired. Do
not attempt repairs requiring machining or welding
unless specifically stated and approved by the
vehicle and component manufacturer.
10. Prior to returning the vehicle to service, make
certain all components and systems are restored to
their proper operating condition.
11. 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.

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