BENDIX DURAFLO 596 COMPRESSOR Installation Instructions - Page 2

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BENDIX DURAFLO 596 COMPRESSOR Installation Instructions

GENERAL SAFETY GUIDELINES

WARNING! PLEASE READ AND

FOLLOW THESE INSTRUCTIONS

TO AVOID PERSONAL INJURY OR DEATH:

When working on or around a vehicle, the following

guidelines should be observed AT ALL TIMES:

▲Park the vehicle on a level surface, apply the parking

brakes and always block the wheels. Always wear personal

protection equipment.

▲Stop the engine and remove the ignition key when working

under or around the vehicle. When working in the engine

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.

▲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.

▲If the work is being performed on the vehicle's air brake

system, or any auxiliary pressurized air systems, make

certain to drain the air pressure from all reservoirs before

beginning ANY work on the vehicle. If the vehicle is

equipped with a Bendix

DRM

dryer reservoir module, or a Bendix

™

dryer, be sure to drain the purge reservoir.

▲ Following the vehicle manufacturer's recommended

procedures, deactivate the electrical system in a manner

that safely removes all electrical power from the vehicle.

▲Never exceed manufacturer's recommended pressures.

▲Never connect or disconnect a hose or line containing

pressure; it may whip and/or cause hazardous airborne

dust and dirt particles. Wear eye protection. Slowly open

connections with care, and verify that no pressure is

present. Never remove a component or plug unless you are

certain all system pressure has been depleted.

▲ Use only genuine Bendix

components and kits. Replacement hardware, tubing, hose,

ﬁ ttings, wiring, etc. must be of equivalent size, type and

strength as original equipment and be designed speciﬁ cally

for such applications and systems.

▲Components with stripped threads or damaged parts should

be replaced rather than repaired. Do not attempt repairs

requiring machining or welding unless speciﬁ cally stated

and approved by the vehicle and component manufacturer.

▲Prior to returning the vehicle to service, make certain all

components and systems are restored to their proper

operating condition.

▲ For vehicles with Automatic Traction Control (ATC), the ATC

function must be disabled (ATC indicator lamp should be

ON) prior to performing any vehicle maintenance where

one or more wheels on a drive axle are lifted off the ground

and moving.

▲The power MUST be temporarily disconnected from the

radar sensor whenever any tests USING A DYNAMOMETER

are conducted on a vehicle equipped with a Bendix

Wingman

system.

▲You should consult the vehicle manufacturer's operating

and service manuals, and any related literature, in

conjunction with the Guidelines above.

AD-IS

air dryer system, a Bendix

AD-9si

brand replacement parts,

COMPRESSOR REMOVAL

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 manual in lieu of the instructions,

precautions, and procedures presented here.

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.

Note: If the compressor is not being removed, stop here

and proceed to PREPARATION FOR DISASSEMBLY,

if not, continue.

4. Remove any supporting bracketing attached to the

compressor and note their positions on the compressor

to aid in reassembly.

5. Remove the flange mounting bolts and remove the

compressor from the vehicle.

PREPARATION FOR DISASSEMBLY

Remove the balance of road dirt and grease from the

air

exterior of the compressor with a cleaning solvent. Before

the compressor is disassembled, mark the items that are

to be removed or disconnected to show their relationship

when the compressor is assembled. Mark the relationship

of the cylinder head to the valve body assembly.

A convenient 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.

HEAD REMOVAL

1. Loosen, but do not remove, the six 13mm x 85mm head

bolts around the circumference of the head.

2. DO NOT REMOVE the two 13mm x 60mm bolts at the

center of the cylinder head.

3. Using a soft mallet, tap the head – under the water outlet

port (See Figure 1) or the discharge fitting – to break the

metal gasket seal between the cylinder head and valve

body assembly and the cylinder block (metal gasket

item 6).

4. Remove the six 13mm x 85mm bolts and washers and

lift the cylinder head and valve body assembly off the

cylinder block.

5. Remove and discard the metal gasket (6).