Bendix Commercial Vehicle Systems DURAFLO 596 COMPRESSOR 10/04 - Manual (Page 13)

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4. Locate one of the sliding inlet valves (13) and place it on
a flat surface. Note that there is a concave and convex
side in the surface where the small pivot arm stud hole
is located. Refer to figure 11.
5. Place the metal gasket (18) on the cylinder block, red
side toward the cylinder block, while aligning the
cylinder head bolt holes.
6. Install the sliding inlet valves (13) on the pivot arm
stud, concave side toward the cylinder bock. Make
certain to center the inlet valves within their openings
in the metal gasket (18).
Note: The inlet valves must not be pinched between
the metal gasket and the cylinder block. They must
be free to slide within their openings in the metal
gasket.
VALVE BODY & CYLINDER HEAD
1. Orient and carefully install the valve body assembly
on the cylinder block. The cylinder block guide pins
(17) will locate and guide the installation of the instal-
lation of the valve body.
Note: Try not to disturb the location of the
metal gasket (18) during the installation of the
valve body because the sliding inlet valves
may be pinched.
2. Orient and install the cylinder head gasket (8) on the
valve body.
3. Orient and carefully install the cylinder head on the
valve body assembly. The cylinder block guide pins
(17) will locate and guide the installation of the instal-
lation of the valve body.
4. Insert the six 13mm x 85mm head bolts into the head
and tighten each finger tight.
5. Insert the two 13mm x 60mm head bolts into the head
and tighten each finger tight.
6. Insert a 1/4” brass dowel into one of the unloader
plunger bore and depress the plunger (21) several
times. The plunger (21) should move freely with only
spring tension resistance noted. If greater resistance
is noted the sliding inlet valve (13) is pinched and the
cylinder head and valve body must be removed and
the sliding inlet valve (13) must be repositioned within
the opening of the meatal gasket (18). Repeat this pro-
cedure for the other unloader plunger and sliding inlet
valve.
certain the free tip of the discharge valve (12) is not
pinched between the holder (11) and the valve body as-
sembly. The valve must be free to flex.
4. Torque the 10mm bolts to 101 to 111 inch pounds.
5. Repeat steps one through four for the other discharge
valve assembly.
UNLOADER PLUNGERS
1. Install the metal sealing washer (20) on the plug (19)
and set aside.
2. Install one o-ring (22) and backup ring (23) in the groove
of the unloader plunger (21). The backup ring (23)
should be installed in the groove so that it is closest to
the center of the plunger.
3. Install the unloader plunger return spring (24) in the
bore in the end of the unloader plunger (21).
4. Insert the assembled plunger (21) and spring (24) into
one of the unloader bores in the cylinder block. When
inserting the plunger orient it so that its guide pin hole
will be visible through the slotted opening in the cylin-
der block.
5. Insert a 1/4” brass dowel into the unloader plunger bore
and depress the plunger (21) slightly. While holding
the plunger (21) depressed, insert the plunger guide
pin (16) into the slotted opening in the cylinder block
and into the unloader plunger until it is fully seated and
extends above the top surface of the cylinder block
approximately 1/8”. Slowly extract the dowel rod from
the unloader bore until spring tension is relieved and
the guide pin retains the plunger.
Note: The unloader plunger guide pin (16) is larger
in diameter and longer than the pivot arm guide pin
(17).
6. Repeat steps one through five for the other unloader
plunger assembly.
INLET VALVES & PIVOT ARMS
1. Install both pivot arm guide pins (17) in the cylinder
block.
2. Place the pivot arm studs (15) in their slots in the cylin-
der block. The head (large diameter) of the stud should
be in the slot with the small diameter facing away from
the cylinder block.
3. Install both pivot arms (14) over the cylinder block guide
pin (17) and unloader plunger guide pin (16) as well as
the stud (15). When installed correctly the stud (15)
and unloader plunger guide pin (16) will be in the slot-
ted openings of the pivot arm (14).
Note: It may be necessary to slightly depress each
unloader plunger to allow easy installation of the
pivot arms over the guide pins.
Pivot Arm
Stud
Inlet Valve
Pivot Arm
Valve Body
Cyl.
Block
Concave Area
FIGURE 12 - SLIDING INLET VALVE INSTALLATION