BENDIX DURAFLO 596 COMPRESSOR Einbauanleitung - Seite 3
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UNLOADER & INLET VALVE
1. Remove and discard the unloader port plug and sealing
ring (7 & 8).
Note the thread type (DDC
CAT
compressors-US) to facilitate reassembly.
®
2. Remove and discard both sliding inlet valves (1).
Note: The sliding inlet valves may have "stuck" to the
cylinder head.
3. Remove and discard both the pivot arms (2) and pivot
arm studs (3).
4. To remove spring tension from the unloader plunger
guide pin (4), insert a 1/4" brass dowel into one of
the unloader plunger bore and depress the plunger
(9) slightly. While holding the plunger (9) depressed,
remove and discard the plunger guide pin (4). Slowly
extract the dowel rod from the unloader bore until spring
tension is relieved.
Note: As an alternative to this procedure an appropriately
sized nut or dowel rod can be placed in the unloader
bore and the plug (7) installed then removed after the
guide pin is removed.
5. Remove and discard the unloader plunger (9), with its
o-ring (10) and back-up ring (11) from the bore. Remove
the unloader spring (12).
6. Repeat steps 4 and 5 for the other unloader plunger.
CLEANING AND INSPECTION OF PARTS
GENERAL
All parts should be cleaned in a good commercial grade of
solvent and dried prior to inspection.
CYLINDER HEAD
1. Carefully remove all gasket material adhering to the
cylinder head and valve body assembly. Make certain
not to deeply scratch or mar the gasket surfaces.
2. Remove carbon deposits from the cylinder head
and valve body assembly. Make certain the inlet and
discharge ports of the valve body assembly are open
and clear.
3. Remove rust and scale from the cooling cavities and
passages in the head and valve body assembly and
use shop air to clear debris from the passages.
4. Check the threads in all cylinder head ports for galling.
Minor chasing is permitted.
5. Carefully inspect the cylinder head gasket (6) surfaces
on the cylinder block and valve body assembly for deep
gouges and nicks. If detected, the compressor must be
replaced.
compressors-Metric or
®
ASSEMBLY
General Note: All torques specified 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. Using the lubricant
(13) provided in this kit, coat items (7) through (11) prior
to installation.
UNLOADER PLUNGERS
1. Choose the appropriate unloader plug (7) either Metric
(for DDC compressors) or US (for CAT compressors).
Both are provided in the kit. Discard the unused plug.
Install the sealing ring (8) on the plug (7) and set it
aside.
2. Install one o-ring (10) and back-up ring (11) in the
groove of the unloader plunger (9). The back-up ring
(11) should be installed in the groove so that it is closest
to the center of the plunger.
3. Install the unloader plunger return spring (12) in the
bore in the end of the unloader plunger (9).
4. Insert the assembled plunger (9) and spring (12) 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 cylinder
block.
5. Insert a 1/4" brass dowel into the unloader plunger bore
and depress the plunger (9) slightly. While holding the
plunger (9) depressed, insert the plunger guide pin
(4) 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 (4) is larger in
diameter and longer than the pivot arm guide pin (5).
6. Repeat steps one through five for the other unloader
plunger assembly.
INLET VALVES & PIVOT ARMS
1. Install both pivot arm guide pins (5) in the cylinder block.
2. Place the pivot arm studs (3) in their slots in the cylinder
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 (2) over the pivot arm guide pin
(5) and unloader plunger guide pin (4) as well as the
stud (3). When installed correctly, the pivot stud (3)
and unloader plunger guide pin (4) will be in the slotted
openings of the pivot arm (2).
Note: It may be necessary to slightly depress each
unloader plunger to allow easy installation of the pivot
arms over the guide pins.
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