BENDIX DURAFLO 596 COMPRESSOR Einbauanleitung - Seite 4
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Pivot Arm
Stud
Pivot Arm
Concave Area
Figure 2 – Sliding Inlet Valve Installation
4. Locate one of the sliding inlet valves (1) 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. (See Figure 2).
5. Place the metal gasket (6) on the cylinder block, red
side toward the cylinder block, while aligning the
cylinder head bolt holes.
6. Install the sliding inlet valve (1) 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 (6).
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 cylinder head and valve
body assembly on the cylinder block. The pivot arm
guide pin (5) will locate and guide the installation.
Note: Try not to disturb the location of the metal gasket
(6) during the installation of the valve body because the
sliding inlet valves may be pinched.
2. Insert the six 13mm x 85mm head bolts into the head
and tighten each finger tight.
3. Insert a 1/4" brass dowel into one of the unloader
plunger bore and depress the unloader plunger (9)
several times. The unloader plunger (9) should move
freely with only spring tension resistance noted. If
greater resistance is noted, the sliding inlet valve (1)
is pinched and the cylinder head and valve body must
be removed and the sliding inlet valve (1) must be
repositioned within the opening of the metal gasket (6).
Repeat this procedure for the other unloader plunger
and sliding inlet valve.
4. Beginning with one of the center bolts, torque the six
13mm x 85mm head bolts to 265-292 in-lbs. using a
figure eight pattern.
5. Apply a thread sealant to the assembled plug and
sealing ring (7 & 8) and install it in the cylinder block
unloader bore that was marked during disassembly.
Tighten sufficiently to seal air pressure.
S-1288 Rev. 002 © 2017 Bendix Commercial Vehicle Systems LLC, a member of the Knorr-Bremse Group • 10/17 • All Rights Reserved
4
Valve Body
Inlet Valve
Cyl.
Block
INSTALLING THE COMPRESSOR
1. Install any supporting bracketing on the compressor in
the same position noted and marked during removal.
2. Install a gasket on the drive flange of the compressor.
Make certain oil supply or return holes in the gasket
are properly aligned with the compressor and engine.
Gasket sealants are not recommended. Secure the
compressor on the engine and tighten the mounting
bolts.
3. Install the discharge and inlet fittings, if applicable,
in the same position on the compressor noted and
marked during disassembly. Make certain the threads
are clean and the fittings are free of corrosion. Replace
as necessary.
4. Inspect all air, oil, and coolant lines and fittings before
reconnecting them to the compressor. Make certain
o-ring seals are in good or new condition. Tighten all
hose clamps.
5. Clean the oil supply line. Before connecting this line to
the compressor, run the engine briefly to be sure oil is
flowing freely through the supply line.
6. Before returning the vehicle to service, test all lines
reconnected during installation and check for air, oil,
and coolant leaks at compressor connections. Also
check for noisy operation. Check the compressor for
proper build-up and unloader operation.
TESTING REBUILT COMPRESSOR
With the compressor operating at 2100 RPM, the time
required to raise the reservoir(s) pressure from 85 psi to
100 psi should not exceed 20 seconds (with minimum
required reservoir volume as specified in FMVSS 121).
During this test, the compressor should be checked for
gasket leakage and noisy operation, as well as unloader
operation and leakage. If the compressor functions as
indicated, reinstall on the vehicle connecting all lines as
marked in the disassembly procedure.
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