Bendix Commercial Vehicle Systems 720CC COMPRESSOR - Manual (Page 11)

11
REAR END COVER
Check for cracks and external damage. Check the
crankshaft rear bearing diameter in the rear end cover for
excessive wear, fl at spots or galling. Check the hydraulic
pump attachment pilot and threaded holes for damage.
Minor thread chasing is permitted, but do not re-cut the
threads. If any of these conditions are found, replace the
compressor.
CRANKCASE
Check the cylinder head gasket surface on the deck (top)
of the crankcase for nicks, gouges, and marring. A metal
gasket is used to seal the cylinder head to the crankcase.
This surface must be smooth and free of all but the most
minor scratching. If excessive marring or gouging is
detected, the compressor must be replaced.
Check the condition of the two countersunk holes on the
deck of the crankcase that retain the o-rings (8) and prevent
coolant leakage between the valve plate assembly and the
crankcase. The surface in contact with the o-ring should be
smooth and free of any scratches and gouges that could
cause leakage around the o-rings.
ASSEMBLY
General Note: All torques specifi ed in this manual are
assembly torques and typically can be expected to fall off
after assembly is accomplished. Do not re-torque after
initial assembly torques fall unless instructed otherwise.
A compiled listing of torque specifi cations is presented on
page 13.
INCH POUNDS TO FOOT POUNDS
To convert inch pounds to foot pounds of torque, divide
inch pounds by 12.
Example: 12 Inch Pounds = 1 Foot Pound
12
FOOT POUNDS TO INCH POUNDS
To convert foot pounds to inch pounds of torque, multiply
foot pounds by 12.
Example: 1 Foot Pound x 12 = 12 Inch Pounds
CRANKCASE FRONT COVER
1. Position the new cover (9) over the hole in the front of
the crankcase. Using a rubber mallet, drive the cover
into the hole in the front of the crankcase until the
outside diameter of the cover is fl ush with cast surface.
CRANKCASE SIDE COVER
1. Position the gasket (11) on the crankcase side cover.
Install the crankcase side cover on the side of the
crankcase using the 6 cap screws previously removed.
“Snug” all 6 cap screws then torque to 101 to 112 inch
pounds (11.4 - 12.6 Nm). When torquing the bolts, it is
best to start with the two mid bolts then use a crossing
pattern with the four remaining bolts.
REAR END COVER
1. Install the o-ring (10) on the rear end cover.
2. Orient the rear end cover to the crankcase using the
reference marks made during disassembly. Carefully
install the rear end cover in the crankcase making
certain not to damage the crankshaft bearing surface.
3. Install the two end cover cap screws. Refer to Figure
9 to ensure that the two cap screws are installed in
the proper crankcase bolt holes. “Snug” the screws,
then tighten to between 195 and 212 inch pounds
(22-24 Nm).
CYLINDER HEAD, COOLING PLATE & VALVE
PLATE ASSEMBLY
1. Install the two crankcase o-rings (8) into the countersunk
holes on the deck of the crankcase.
2. Note the position of the two protruding crankcase
alignment pins on the deck (top) of the crankcase.
Install the metal inlet reed valve gasket (7) over the
alignment pins on the crankcase; being careful not to
disturb the crankcase o-rings (8).
3. Position the valve plate assembly on the crankcase
so that the alignment pins in the crankcase fi t into the
corresponding holes in the valve plate assembly.
4. Position the embossed metal head gasket (5) over
the alignment bushings protruding from the top of
the cooling plate. Position the embossed metal head
gasket (6) over the alignment bushings on the opposite
side of the cooling plate. When properly positioned, the
outline of the two embossed gaskets match the outline
of the cooling plate and the machined sealing surfaces
on the cooling plate will be covered by the embossed
metal gasket material. Important: The two gaskets are
different and must be installed on the proper side of the
cooling plate for the compressor to function properly.
See Figure 8
for proper head gasket positions.
5. Install the cooling plate with the pre-installed head
gaskets (5 and 6) onto the valve plate assembly.
Align the alignment bushings on the cooling plate over
the oversized countersunk holes of the valve plate
assembly. Again, when properly installed, the outline of
the cooling plate matches the outline of the valve plate
assembly.
6. Position and install the cylinder head over the alignment
bushings protruding from the cooling plate. When
properly installed, the outline of the cylinder head
assembly will match the outline of the cooling plate and
valve plate assembly.