Bendix Commercial Vehicle Systems BENDIX 720CC COMPRESSOR - Manual (Page 12)

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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 flush with the 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 six (6) cap screws previously
removed. “Snug” all six cap screws then torque to
97–115 in-lbs (11–13 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. Make 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 in-lbs (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 fit 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.
Note: To assist with correct installation, the alignment
bushings in the cooling plate only fit into two of the four
corner head bolt holes on the valve plate assembly and
the cylinder head.
7. Install the eight long hex head cap screws (3) into the
cylinder head. Note: A light film of oil should be
applied to the threads of these cap screws prior to
installing. Oil should not be applied to any of the
other hardware.
8. Install the two short hex head cap screws (4) into the
cylinder head. Important: The two short hex head
cap screws (4) must be installed in hole positions
designated as sequence “3” and “8” in Figure 11.
9. To ensure the cylinder head cap screws are properly
torqued, the following three step procedure must be
adhered to. Each cap screw must be tightened a total
of three times. Referencing Figure 11, tighten each
screw—in numerical order—to the torque identified in
Step 1. Once all have been tightened follow the same
procedure for Steps 2 and 3.
10. Install the washer (1) and safety valve (2) in the side
(discharge) port identified by the number '2' on the
cylinder head (3) as shown in Figure 11, then tighten
to a torque not to exceed 66 foot pounds (90 Nm).
INSTALLING THE COMPRESSOR
1. Apply a liquid gasket sealant to the compressor /
engine mounting interface (Refer to Figure 3 for
compressor mounting face). Follow the “engine or
vehicle manufacturer's guidelines for the proper liquid
gasket sealant material and application procedure.
2. Secure the compressor on the engine mounting
interface using the six mounting bolts. NOTE: There
are two short bolts and four long bolts. Be sure to use
the proper length bolt for the crankcase bolt holes. Run
each of the bolts down finger tight, making sure not to
smear the liquid gasket material on the sealing surface.
Once the bolts are all finger tight, tighten the mounting
bolts per the engine manufacturer's recommended
torquing sequence and torque requirements.