BENDIX 360CC User manual

DESCRIPTION
The function of the air compressor is to provide and
maintainairunderpressuretooperatedevicesinairbrake
systems. The Bendix®360cc compressor is a single-
cylindercompressorwitharated displacementof15.8 cubic
feet per minute at 1250 RPM. The compressor consists
of an integral water-cooled cylinder head assembly and
water-cooled crankcase.
The cylinder head assembly is made up of an aluminum
cylinderhead,analuminum cooling plate,andasteelvalve
plateassemblywith twosealinggaskets. The cylinderhead
contains air and water ports. The cooling plate, situated
between the head and valve plate, assists in cooling the
head assembly. The valve plate assembly, consisting of
brazed steel plates, has separate valve openings and
passages to allow air and coolant to flow in and out of the
compressor. See Figure 1 for an external view,andFigure
3 for an exploded view.
The compressor is equipped with a safety valve in the
cylinder head safety valve port, directly connected to the
discharge port. The safety valve protects the compressor
head in the event of excessively high discharge line
pressure,for example,inthe eventofblockage downstream
of the compressor. Excessive air pressure causes the
safety valve to unseat, releases air pressure and gives an
audible alert to the operator.
The compressor is cooled by air flow, as well as by engine
coolant. The engine coolant first enters the crankcase
waterjackettocoolthecylinderbore,thenpassesthrough
passages in the valve plate assembly, cooling plate, and
cylinder head and then out of a port at the top of the
compressor, back to the engine.
A nameplate is attached to a flat cast face on the side of
the crankcase. It is stamped with information identifying
the compressor designation, customer piece number,
compressor assembly part number and serial number.
See Figure 2.
GENERAL INFORMATION
This Bendix®360cc compressor is a “discharge line
unloader” (DLU)-style compressor, meaning that the
compressorpumpscontinuously,unlikesomecompressor
designs which use an "unloader" mechanism in the
compressor head to switch from a pumping mode to a
non-pumping mode. Instead, the control of air delivery to
the vehicle’s air system is managed by using a separate
discharge line unloader valve mounted in parallel with a
turbo cut-off style of air dryer (see Figure 6).
SD-01-3121
BENDIX®360CC SINGLE CYLINDER COMPRESSOR FOR
INTERNATIONAL MAXXFORCE™11 AND 13 BIG BORE ENGINES
MAXXFORCE™is a trademark of International Engine Intellectual Property Company, LLC.
FIGURE 1 - BENDIX®360cc SINGLE CYLINDER
COMPRESSOR
FIGURE 2 - NAMEPLATES (TWO STYLES)
Safety
Valve
Cooling
Plate
Valve Plate
Assembly
Cylinder
Head
Crankcase
Coolant
Enters Here
Locating
Pins
Coolant Exits at
Top of Head
(See Figure 7)
Bendix Part Number . . . . . . A
Customer Piece Number . . . . B
Compressor Serial Number . . C
A
B
C
A
B
C

2
The crankcase has an open side with a machined face
and locating pins. This open face is bolted directly to the
side of the engine block, see Figure 3. The compressor
gear engages the engine drive gear. In addition, the
crankcase houses the piston assembly, connecting rod,
crankshaft and related bearings. An o-ring is located in
the countersunk hole on the crankcase deck to seal the
coolant passage between the crankcase and valve plate.
OPERATION
The compressor is driven by the vehicle’s engine and
functions continuously while the engine is in operation.
Actual compression of air is controlled by a downstream
component, such as a discharge line unloader valve or an
airdryerwithout turbocut-offvalve,operatingin conjunction
with a governor.
AIR INTAKE (LOADED)
Just as the piston begins the down stroke, (a position
known as top dead center, or TDC), the vacuum created
in the cylinder bore above the piston causes the inlet reed
valvetoflexopen. Atmosphericairflowsthroughtheopen
inletvalveandfillsthecylinderboreabovethepiston. See
Figure 4.
AIR COMPRESSION (LOADED)
When the piston reaches the bottom of the stroke, (a
position known as bottom dead center, or BDC), the inlet
reed valve closes. Air above the piston is trapped by the
closed inlet reed valve and is compressed as the piston
moves upwards. When air in the cylinder bore reaches
a pressure greater than that of the system pressure, the
discharge reed valves open and allow air to flow into the
discharge line and air brake system. See Figure 5.
FIGURE 3 - BENDIX®360cc SINGLE CYLINDER COMPRESSOR (CUT-AWAY VIEW)
Safety
Valve
Cooling
Plate
Valve Plate
Assembly
Cylinder
Head
Crankcase
Drive Gear
Nameplate
Piston
Crankshaft
Mounting
Face
Connecting
Rod
FIGURE 4 - OPERATION - INTAKE
Piston Moving Down
Air Inlet
Port
Inlet
Valve
Open
Air
Discharge
Port
Discharge
Valve
Closed
Valve
Plate
Cooling
Plate

3
NON-COMPRESSION OF AIR (UNLOADED)
COMPRESSOR AND AIR DRYER SYSTEM
(REFER TO FIGURE 6)
Air delivery to the vehicle’s air system is controlled by the
governorandthe air dryer, or withaseparatedischarge line
unloadervalve. Thegovernor isplumbedtothe component
(e.g. air dryer or DLU valve) in order to control when the
air is delivered to the vehicle’s air system.
When air pressure in the supply reservoir reaches the
cutout setting of the governor, the governor delivers
system air to the discharge line unloader-style (DLU) air
dryer’s control port. This allows the discharge air from the
compressor to flow out the exhaust port of the air dryer.
Note: The Bendix® 360cc compressor is a discharge line
unloader-style unit. This means that the compressor
functions in a continuous pumping mode regardless
whether the brake system requires air. It requires a
downstream device (e.g. turbo cut-off style air dryer and
discharge line unloader valve) to unload the system when
the air system has sufficient stored compressed air.
LUBRICATION
The vehicle’s engine provides a continuous supply of oil
to the compressor. Oil is routed from the engine to the
compressor’soilinlet. Note:There is no externaloilsupply
line; the oil delivery is located at the engine to compressor
mounting face. This pressurized oil flows to the precision
front sleeve main bearing, and via an oil passage in the
crankshaft routes pressurized oil to the connecting rod
bearingsandthe rearjournalassociated withtheendcover.
Spray lubrication of the cylinder bore and connecting rod
wristpinbushingisobtained as oil is forced out around the
crankshaftjournalsbyengineoilpressure. Oilthenfallsto
the bottom of the compressor crankcase and is returned
to the engine through the opening at the compressor
mounting flange.
COOLING
The Bendix®360cc Single Cylinder Compressor is cooled
byairflowingthrough the enginecompartmentasitpasses
the compressor’s cast-in cooling fins and by the flow of
engine coolant through the cylinder head assembly and
thewaterjacketaroundthecylinderboreof the crankcase.
Coolant supplied by the engine cooling system passes
through connecting lines into the cylinder head, cooling
plate, valve plate assembly, into the crankcase water
jacket and returns through the same components, out of
the coolant outlet port of the cylinder head and returns to
the engine. Figure 7 illustrates the approved coolant flow
connections. Proper cooling is important in minimizing
discharge air temperatures – see the tabulated technical
data on page 11 of this manual for specific requirements.
21 22
S
D
S
C
UNL
Compressor
Governor
Air Dryer
FIGURE 6 - TYPICAL BENDIX®360 (DLU) COMPRESSOR AIR CHARGING SYSTEM
Front Service
Reservoir
Rear Service
Reservoir
DLU Valve
FIGURE 5 - OPERATION - COMPRESSION
Piston Moving Up
Air Inlet
Port
Inlet
Valve
Closed
Air
Discharge
Port
Discharge
Valve
Open
Valve
Plate
Cooling
Plate

4
AIR INDUCTION
The Bendix® 360cc Single Cylinder Compressors is
only permitted to be naturally aspirated – use of engine
turbocharger as an air source is not permitted.
PREVENTATIVE MAINTENANCE
Regularly scheduled maintenance is the single most
important factor in maintaining the air brake charging
system. Refer to Table A: Maintenance Schedule and
Usage Guidelines in the troubleshooting section (page
A-3) for a guide to various considerations that must be
given to maintenance of the compressor and other related
charging system components.
Important Note: Review the Bendix®Warranty Policy
before performing any intrusive maintenance procedures.
An extended warranty may be voided if intrusive
maintenance is performed during this period.
EVERY 6 MONTHS, 1800 OPERATING HOURS
OR AFTER EACH 50,000 MILES WHICHEVER
OCCURS FIRST, PERFORM THE FOLLOWING
INSPECTIONS AND TESTS.
AIR INDUCTION
A supply of clean air is one of the single most important
factors in compressor preventive maintenance. Since the
air supply for Bendix®360cc Single Cylinder Compressor
andengineistheengineaircleaner, periodic maintenance
of the engine air filter is necessary.
Inspect the compressor air induction system each time
engine air cleaner maintenance is performed.
1. Inspect the intake hose adapters for physical damage.
Make certain to check the adapters at both ends of the
intake hose or tubing.
2. Inspect the intake hose clamps and tighten them if
needed.
3. Inspecttheintakehoseorlineforsignsofdrying,cracking,
chafing and ruptures and replace if necessary.
4. Inspect the compressor’s cast inlet tube for physical
damage.
COMPRESSOR COOLING
Inspect the compressor discharge port, inlet cavity and
discharge line for evidence of restrictions and carbon
buildup. If more than 1/16" of carbon is found, thoroughly
cleanorreplacetheaffectedparts. In some cases, carbon
buildup indicates inadequate cooling. Closely inspect the
compressorcoolingsystem. Check all compressor coolant
linesforkinks andrestrictionstoflow. Minimumcoolantline
size is 3/8" I.D. Check coolant lines for internal clogging
from rust scale. If coolant lines appear suspicious, check
the coolant flow and compare to the tabulated technical
data present in the back of this manual.
LUBRICATION
Thecompressorutilizesaninternaloilfeeddesign. Check
the exterior of the compressor (i.e. around the mounting
face) for the presence of oil seepage and refer to the
troubleshootingsectionfor appropriate tests andcorrective
action. Refer to the tabulated technical data in the back of
this manual for oil pressure minimum values.
OIL PASSING
All reciprocating compressors pass a minimal amount of
oil. Air dyers will remove the majority of oil before it can
enter the air brake system. For particularly oil sensitive
systems, the Bendix®PuraGuard®system can be used in
conjunction with a Bendix®air dryer.
If compressor oil passing is suspected, refer to the
Troubleshooting section (starting on page A-1) for the
FIGURE 7 - BENDIX®360cc SINGLE CYLINDER
COMPRESSOR PORT IDENTIFICATION
Discharge
Port or
Safety
Valve
Port
Inlet
Port
Oil Supply
Head
Bolt (4)
CYLINDER HEAD PORT IDENTIFICATION
The cylinder head connection ports are identified
with “cast in” numerals as follows:
AIR IN . . . . . . . . . . . . . 0
Compressed AIR OUT. . . . . 2
Coolant IN . . . .Crankcase Port
Coolant Out . . . . . . . . . .92
Coolant Out Only
Discharge
Port or Safety
Valve
Port
Port Closed
Coolant In Only

5
SERVICE TESTS
GENERAL
The compressor operating and leakage tests listed below
need not be performed on a regular basis. These tests
should be performed when it is suspected that leakage is
substantiallyaffectingcompressorbuildupperformance,or
when it is suspected that the charging system is “cycling”
between the loaded (pumping) and unloaded (charging
systemstopsdeliveringairtothebrakesystemreservoirs)
modes due to unloader system leakage.
IN-SERVICE OPERATING TESTS
Compressor Performance: Build-up Test
This test is performed with the vehicle parked and the
engine operating at maximum recommended governed
speed. Fullychargetheairsystemtogovernorcut-out(air
dryer purges). Pump the service brake pedal to lower the
system air pressure below 80 psi using the dash gauges.
As the air pressure builds back up, measure the time
from when the dash gauge passes 85 psi to the time it
passes 100 psi. The time should not exceed 40 seconds.
If the vehicle exceeds 40 seconds, test for (and fix) any
air leaks and then re- test the compressor performance.
If the vehicle does not pass the test the second time,
use the Advanced Troubleshooting Guide for Air Brake
Compressors, starting on page A-1 of this document to
assist your investigation of the cause(s).
Note: All new vehicles are certified using the FMVSS
121 test (paragraph S5.1.1) by the vehicle manufacturer,
however the above test is a useful guide for in-service
vehicles.
Optional Comparative Performance Check
It may be useful to also conduct the above test with the
enginerunning at high idle (instead of maximum governed
speed), and record the time taken to raise the system
pressure to a selected range (for example, from 90 to
120 psi, or from 100 to 120 psi, etc.) and record it in the
vehicle’s maintenance files. Subsequent build-up times
throughoutthevehicle’sservice life can then be compared
to the first one recorded. (Note: the 40 second guide in
the test above does not apply to this build-up time.) If the
performance degrades significantly over time, you may
use the Advanced Troubleshooting Guide for Air Brake
Compressors, starting on page A-1 of this document, to
assist in the investigation of the cause(s).
Note: When comparing build-up times, be sure to make
anallowanceforanyairsystemmodificationswhichwould
cause longer times, such as adding air components or
reservoirs. Always check for air system leakage.
symptoms and corrective action to be taken. In addition,
Bendix has developed the “Bendix Air System Inspection
Cup”orBASIC kittohelpsubstantiate suspectedexcessive
oilpassing. Thestepstobefollowed whenusingthe BASIC
kit are presented in APPENDIX B, on page A-16.
COMPRESSOR DRIVE
Checkfornoisy compressoroperation,which couldindicate
excessive drive component wear. Adjust and/or replace
as necessary. Check all compressor mounting bolts and
retighten evenly if necessary. Check for leakage. Repair
or replace parts as necessary.
CHARGING SYSTEM UNLOADING &
GOVERNOR
Note: The Bendix®360cc (DLU)-style single cylinder
compressor does not contain components to unload
the compressor. Therefore, the compressor pumps
continuously. In most systems supplied by International,
a turbo cut-off style air dryer, governor and discharge line
unloader valve are used to unload the system (i.e. air is
notbeingdeliveredtothebrakesystemreservoirs). When
systemunloadingoccurs,airfromthecompressorwillflow
out the exhaust port of the discharge line unloader valve.
Refer to Figure 6.
Test and inspect the unloading system (i.e. air dryer and
governor) for proper operation and pressure settings.
1. Make certain the unloader system lines (illustrated in
Figure 6) are connected and leak free.
2. Cycle the charging system between the loaded and
unloadedmodeseveral times. This canbeachievedby
applyingthebrakes tobleeddown the systempressure.
Make certain that the governor cuts-in (charging
system resumes compressing air) at a minimum of
105 psi. Governor cut-out (charging system stops
deliveringairtothebrakesystemreservoirs)should be
approximately 15 - 20 psi greater than cut-in pressure.
Adjust or replace the governor as required.
3. Notethatthechargingsystemcyclestotheloadedand
unloaded conditions promptly. If prompt action is not
noted, repair or replace: the governor; the discharge
line unloader valve; and/or the air dryer purge valve
assembly.
IMPORTANT NOTE
Replacement air governors must have a minimum
cut-in pressure of 100 psi. The cut-in pressure is the
lowest system pressure registered in the gauges before
the compressor resumes compressing air.

6
LEAKAGE TESTS
Seethe standardAirBrake SystemandAccessoryLeakage
test on Page A-15 (Test 2).
Note: Leakage in the air supply system (components
beforethesupply reservoir-suchas the governor, air dryer,
reservoir drain cocks, safety valve, and check valves) will
not be registered on the vehicle dash gauges and must
be tested separately. Refer to the various maintenance
manuals for individual component leakage tests and the
Bendix “Test and Checklist” published in the Bendix® Air
Brake System Handbook (BW5057) and on the back of
the Bendix® Dual Circuit Brake System Troubleshooting
Card (BW1396).
CYLINDER HEAD
Check the cylinder head gaskets for air leakage.
1. With the engine running, lower air system pressure to
60 psi and apply a soap solution around the cylinder
head. Check the two gaskets between the cylinder
head and the valve plate assembly, as well as the inlet
reed valve/gasket between the valve plate assembly
and crankcase for air leakage.
2. No leakageispermitted. Ifleakage is detected, replace
the compressor or repair the cylinder head using the
maintenance kit available from an authorized Bendix
parts outlet.
INLET & DISCHARGE VALVES
Inorder totestthe inletanddischarge valves,itis necessary
to have shop air pressure and an assortment of fittings. A
soap solution is also required.
1. With the engine shut off, drain ALL air pressure from
the vehicle.
2. Disconnect the inlet and discharge lines.
3. Apply 120-130 psi shop air pressure to the discharge
portandthenapplyand release air pressure to the inlet
port. Soap the inlet port and note that leakage at the
inlet port does not exceed 200 sccm.
If excessive leakage is noted in Test 3, replace or repair
the compressor using genuine Bendix replacements or
maintenance kits available from any authorized Bendix
parts outlet.
While it is possible to test for inlet and discharge leakage,
it may not be practical to do so. Inlet and discharge valve
leakage can generally be detected by longer compressor
build-upandrecovery times. Compare currentcompressor
build-up times with the last several recorded times. Make
certain to test for air system leakage, as described under
“In-ServiceOperatingTests”,beforemakingadetermination
that performance has been lost.
COMPRESSOR REMOVAL & DISASSEMBLY
GENERAL
The following disassembly and assembly procedure is
presented for reference purposes and pre-supposes that
a rebuild or repair of the compressor is being undertaken.
Severalmaintenancekits are available andtheinstructions
provided with these parts and kits should be followed in
lieu of the instructions presented here.
MAINTENANCE KITS & SERVICE PARTS
BENDIX®360CC SINGLE CYLINDER
COMPRESSOR ONLY
Compressor Seal Kit (Major) . . . . . . . . . K026807
Compressor Seal Kit (Minor) . . . . . . . . . K051352
Discharge Safety Valve Kit . . . . . . . . . . K026809
Compressor to Engine Mounting Face Sealant
. . . . . . . . . . Supplied by the Engine Manufacturer
GENERAL SAFETY GUIDELINES
WARNING! PLEASE READ AND FOLLOW
THESEINSTRUCTIONSTOAVOIDPERSONAL
INJURY OR DEATH:
When working on or around a vehicle, the following
general precautions should be observed at all times.
1. Park the vehicle on a level surface, apply the parking
brakes, and always block the wheels. Always wear
safety glasses.
2. Stoptheengineandremoveignitionkeywhenworking
underoraroundthevehicle. Whenworkingintheengine
compartment, the engine should be shut off and the
ignition key should be removed. Where circumstances
require that the engine be in operation, EXTREME
CAUTION should be used to prevent personal injury
resulting from contact with moving, rotating, leaking,
heated or electrically charged components.
3. Do not attempt to install, remove, disassemble or
assemble a component until you have read and
thoroughly understand the recommended procedures.
Use only the proper tools and observe all precautions
pertaining to use of those tools.
4. Iftheworkisbeingperformed on the vehicle’sairbrake
system,oranyauxiliarypressurizedairsystems, make
certain to drain the air pressure from all reservoirs
beforebeginningANYworkonthe vehicle. Ifthevehicle
is equipped with a Bendix®AD-IS®air dryer system or
a dryer reservoir module, be sure to drain the purge
reservoir.

7
5. Following the vehicle manufacturer’s recommended
procedures, deactivate the electrical system in a manner
that safely removes all electrical power from the vehicle.
6. Never exceed manufacturer’s recommended 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®brand 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
repairsrequiringmachiningorweldingunlessspecifically
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 Automatic Traction Control (ATC), the
ATCfunctionmust bedisabled(ATC indicator lampshould
beON)priortoperformingany vehiclemaintenancewhere
oneormore wheelsonadrive axle areliftedofftheground
and moving.
REMOVAL
In many instances it may not be necessary to remove the
compressor from the vehicle when installing the various
maintenance kits and service parts. The maintenance
technician must assess the installation and determine the
correct course of action. These instructions are general
and are intended to be a guide. In some cases additional
preparations and precautions are necessary. In all cases
follow the instructions contained in the vehicle maintenance
manualinlieuof the instructions, precautionsandprocedures
presented in this manual.
1. Block the wheels of the vehicle and drain the air pressure
from all the reservoirs in the system.
2. Drain the engine cooling system and the cylinder head
of the compressor. Identify and disconnect all air, water
and oil lines leading to the compressor.
3. Remove as much road dirt and grease from the exterior
of the compressor as possible.
4. Remove the discharge fitting, if applicable, and note their
position on the compressor to aid in reassembly.
5. Remove any supporting bracketing attached to the
compressor and note their positions on the compressor
to aid in reassembly.
6. Remove the 6 mounting bolts that retain the
compressor to the side of the engine block. Note
the position of the 6 mounting bolts. Two of the 6
boltsareshorter andmustbe installedintheiroriginal
locations. Remove thecompressorfromthevehicle.
7. Inspect drive gear and associated drive parts for
visible wear or damage. If the compressor drive
gear is worn or damaged, the compressor must be
replaced. Refertothe Engine Manufacturersservice
manualtoaddress theassociatedenginedrive parts.
8. If the compressor is being replaced stop here and
proceed to “Installing the Compressor” at the end
of the assembly procedure. (Note: Replacement
compressors come with the drive gear pre-
assembled on the compressor.)
PREPARATION FOR DISASSEMBLY
Refer to Figure 8 during the entire disassembly and
assembly procedure.
Place a clean rag over the openings that expose the
gear and crankshaft / connecting rod assembly. No
contamination is permitted in these areas.
Removethebalance of the roaddirtandgreasefrom the
exteriorofthecompressorwith a cleaning solvent. If the
rearendcover (8)isbeing removedfromthecompressor
under repair, mark it along with the two cap screws (7)
in relation to the crankcase. It is also recommended to
mark the relationship of the cylinder head (15), cooling
plate (14), valve plate assembly (13), and crankcase.
Aconvenient method to indicate the above relationships
is to use a metal scribe to mark the parts with numbers
or lines. Do not use marking methods, such as chalk,
that can be wiped off or obliterated during rebuilding.
Prior to disassembly, make certain that the appropriate
kits are available.
CYLINDER HEAD, COOLING PLATE & VALVE
PLATE ASSEMBLY
1. Remove the washer (3) and discharge safety valve
(2) from the cylinder head (15).
2. Removethefourhexhead bolts (1) from thecylinder
head (15).
3. Gently tap the cylinder head (15), cooling plate (14)
and valve plate assembly (13) with a soft mallet
to break the gasket seal between the valve plate
assembly (13) and the crankcase. Lift the cylinder
head (15) with cooling plate (14) and valve plate
assembly (13) off the crankcase.
4. Remove the metal inlet reed valve/gasket (5).
5. Removethecrankcaseo-ring(12)fromacountersunk
hole on the crankcase (11) deck.

8
End Cover
Cooling Plate
Cap
Screws
(x2)
Crankcase
Alignment
Pins (x2)
Valve Plate
Assembly
ST-4™Safety Valve
Cylinder Head
Crankcase
Washer
3
4
7
8
10
11
12
5
14
15
13
12 6
9
FIGURE 8 – BENDIX®60cc SINGLE CYLINDER COMPRESSOR EXPLODED VIEW
Head Gasket
(2)
Head Cap Screws (4)
(include washers)
Kit Notes:
Kit 1: Discharge Safety Valve Kit (K026809)
Kit 2: Compressor Seal Kit (Major) (K026807)
Kit 3: Compressor Seal Kit (Minor) (K051352)
End Cover O-ring
Inlet Reed/Valve Gasket
Crankcase O-ring
Cover
Item Qty. Description
1 4 Head Cap Screws - (Kit 2)
2 1 ST-4™Safety Valve - (Kit 1)
3 1 Washer - (Kit 1)
4 2 Head Gaskets - (Kit 2)
5 1 Inlet Reed Valve/Gasket - (Kit 2)
6 2 Crankcase Alignment Pins
7 2 Cap Screws
8 1 End Cover
9 1 End Cover O-Ring (Kit 2 & 3)
10 1 Cover (Kit 2 & 3)
11 1 Crankcase
12 1 Crankcase O-ring (Kit 2)
13 1 Valve Plate Assembly
14 1 Cooling Plate
15 1 Cylinder Head

9
6. Gentlytapthecylinder head (15),coolingplate(14) and
valve plate assembly (13) with a soft mallet to break
thegasketseals. Thenseparatethe cylinder head (15)
from the cooling plate (14) and valve plate assembly
(13),andremoveanddiscardthetwoheadgaskets(4)
between them.
CRANKCASE FRONT COVER
1. Removethecover(10)fromthefrontofthecrankcase.
Use a sharp flat head screw driver or a scraper. Place
the edge under the lip along the outside diameter of
the cover. Pry the cover from the cast surface until the
cover can be removed.
REAR END COVER
1. Note: There are two cap screws (7) used to retain the
end cover to the crankcase. There are two longer cap
screws (not shown in Figure 9) that are used to retain
theauxiliarydriveunit(i.e. hydraulicpump)via the end
cover and torqued into the crankcase. If the auxiliary
drive unit has already been removed, these two cap
screws are no longer present on the end cover. Refer
to Figure 9 to see location of the cap screws (7) in the
end cover.
2. Remove the two end cover cap screws (7) that secure
the rear end cover to the crankcase.
3. Remove the rear end cover (8) from the crankcase.
Remove and discard the o-ring (9) from the end cover
(8).
CLEANING OF PARTS
GENERAL
All parts should be cleaned in a good commercial grade of
solvent and dried prior to inspection.
CRANKCASE
1. Carefully remove all sealant gasket material adhering
to the machined face of the crankcase. See Figure
3. Make certain not to scratch or mar the mounting
surface. Note: Keep the crankcase (11) opening
covered to prevent any of the sealant material from
entering. Repeat this process on the engine mounting
face as well. Follow the instructions contained in the
vehicle maintenance manual in lieu of the instructions
and procedures presented in this manual.
2. Carefully remove all gasket material adhering to the
deck (top) of the crankcase. Remove any carbon
depositsfromthedeck of the crankcase. Make certain
not to scratch or mar the gasket surfaces.
CYLINDER HEAD, COOLING PLATE & VALVE
PLATE ASSEMBLY
1. Carefully remove all gasket material adhering to the
cylinder head (15), cooling plate (14) and valve plate
assembly (13). Make certain not to scratch or mar the
gasket surfaces. Pay particular attention to the gasket
surfaces of the cylinder head and cooling plate.
2. Remove carbon deposits from the discharge and inlet
cavities of the cylinder head, cooling plate and valve
plate assembly. The cavities must be open and clear.
Make certain not to damage the parts,while cleaning.
3. Remove rust and scale from the cooling cavities and
passages in the cylinder head, cooling plate and valve
plate assembly and use shop air to clear debris from
the passages.
4. Check the threads in all cylinder head ports for
galling (e.g. abrasion, chafing). Minor thread chasing
(damage) is permitted.
INSPECTION OF PARTS
CYLINDER HEAD, COOLING PLATE AND VALVE
PLATE ASSEMBLY
1. Carefully inspect the head gasket surfaces on the
cylinder head (15) for deep gouges and nicks. Also,
inspect the cylinder head for any cracks or port thread
damage. Ifdetected,the compressormustbe replaced.
If large amounts of carbon build-up are present in the
dischargecavitysuch thatitrestricts the airflowthrough
the cylinder head, the compressor should be replaced.
2. Carefullyinspectbothsides ofthehead gasketsurfaces
on the cooling plate (14) for deep gouges and nicks.
Also, inspect the cooling plate for any cracks or other
damage. If damage is found, the compressor must be
replaced.
3. Carefully inspect the valve plate assembly (13) gasket
surfaces (both sides) for deep gouges and nicks. Pay
particular attention to the gasket surface. An inlet
reed valve/gasket (5) is used between the valve plate
assembly (13) and crankcase. These gasket surfaces
must be smooth and free of all but the most minor
scratches. Ifexcessivemarringorgouging is detected,
FIGURE 9 - REAR END COVER ATTACHMENT BOLTS
M10x1.5
Cap
Screws
(Larger)
M8x1.25
Cap
Screws
(Smaller)

10
the compressor must be replaced. If large amounts of
carbonbuild-up arepresenton thetwomain surfaces,in
thetwodischarge valve holesorbetweenthe discharge
valve and the discharge seat, the compressor should
be replaced.
REAR END COVER
Visually inspect for cracks and external damage. Check
the crankshaft rear bearing diameter in the rear end cover
(8) for excessive wear, flat 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
Checkthecylinder head gasketsurfaceonthe deck(top)of
thecrankcase(11) for nicks, gouges, and marring. Ametal
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 countersunk hole on the deck
of the crankcase (11) that retains the o-ring and prevents
coolantleakagebetweenthevalveplateassembly and the
crankcase. The surface in contact with the o-ring should
besmoothand free of anyscratchesandgouges that could
causes leakage around the o-ring.
ASSEMBLY
General Note: All torques specified 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.
Acompiled listing of torque specifications is presented on
page 11.
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 (10) 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 (11), until the
outsidediameterofthecoverisflushwithcastsurface.
REAR END COVER
1. Install the o-ring (9) on the rear end cover.
2. Orient the rear end cover (8) to the crankcase (11)
using the reference marks made during disassembly.
Carefullyinstallthe rear endcoverinthe crankcase (11)
making certain not to damage the crankshaft bearing
surface.
3. Install thetwoend covercapscrews(7). Refer toFigure
9 to ensure that the two cap screws (7) are installed
in the proper crankcase (11) bolt holes. “Snug” the
screws,thentighten tobetween195to 212inchpounds
(22-24 Nm).
CYLINDER HEAD, COOLING PLATE & VALVE PLATE
ASSEMBLY
1. Install the crankcase o-ring (12) into the slightly
countersunk hole on the deck of the crankcase.
2. Note the position of the protruding crankcase (11)
alignment pins on the deck (top) of the crankcase.
Install the metal inlet reed valve/gasket (5) over the
alignment pins on the crankcase; being careful not to
disturb the crankcase o-ring (12).
3. Positionthevalveplate assembly(13)onthe crankcase
(11) so that the alignment pins in the crankcase fit into
the corresponding holes in the valve plate assembly
(13).
4. Position one of the embossed metal head gaskets
(4) over the alignment bushings protruding from the
cooling plate (14). Position the second embossed
metal head gasket over the alignment bushings on the
opposite side of the cooling plate (14). When properly
positioned, the outline of the two embossed gaskets
match the outline of the cooling plate.
5. Install the cooling plate with the head gaskets onto the
valve plate assembly.Align the alignment bushings on
thecoolingplateovertheoversizedcountersunkholes
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 (15) over the
alignment bushings protruding from the cooling plate.
Whenproperlyinstalled, the outlineofthecylinder head
assemblywillmatchtheoutlineof the cooling plate and
valve plate assembly.
Note: To assist with correct installation, the alignment
bushings only fit into two, of the four, cylinder head cap
screws.
7. "Snug" the four hex head cylinder head cap screws
(1) and snug them, then tighten evenly to a torque of
265 to 292 inch pounds (30-33 Nm) using a crossing
pattern. Note: A light film of oil should be applied
to the thread of these bolts prior to installation. Oil
should not be applied to any other bolts.