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SD-01-670
DURAFLO™ 596 COMPRESSOR

DISCHARGE WATER
SAFETY VALVE OUTLET
DISCHARGE DISCHARGE CYLINDER WATER PORT (1)
VALVE VALVE HEAD INLET
HOLDER PORT (2)
CYLINDER
HEAD

VALVE BODY
ASSY. VALVE BODY
ASSEMBLY

PISTON
REAR END
PISTON RINGS COVER OIL
CRANKCASE PORT
CRANKCASE

CRANKCASE
BOTTOM
COVER (2)
CONNECTING
CRANKSHAFT ROD

DISCHARGE DISCHARGE
CAVITY VALVE HOLDER
DESCRIPTION
The function of the air compressor is to provide and DISCHARGE
VALVE
maintain air under pressure to operate devices in the air
brake and/or auxiliary air systems. The DuraFlo™ 596
compressor is a two cylinder reciprocating compressor
with a rated displacement of 27 cubic feet per minute at
1250 RPM.

The compressor consists of a water cooled cylinder head DISCHARGE

PORTS (2)
and valve body assembly and an air cooled integral
crankcase and cylinder block. The cylinder head is an CYLINDER
BORE
aluminum casting which contains the required air and water
ports as well as inlet check valves for each cylinder. The PISTON
valve body assembly consists of steel upper and lower
halves, each of which incorporate various valve openings
and channels for conducting air and engine coolant into
VIEW OF CYLINDER HEAD AND ONE CYLINDER BORE
and out of the cylinder head. The discharge valves for
each cylinder are part of the valve body assembly. The FIGURE 1 - DURAFLO™ 596 COMPRESOR
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DETROIT DIESEL DETROIT DIESEL MACK CATERPILLAR

ADAPTERLESS

FIGURE 2 - TYPICAL COMPRESOR DRIVE FLANGES reduces compressor power consumption by approximately
80% in the unloaded mode. The ESS also reduces
valve body assembly is secured to the cylinder head
assembly using two cap screws and the cylinder head is compressor oil consumption (oil passing) when the
compressor is in the unloaded mode.
secured to the cylinder block with six cap screws. The
cylinder head, with the valve body halves comprise a A nameplate identifying the compressor piece number and
complete cylinder head assembly. serial number is attached to the end of the cylinder block
opposite the drive end.

OPERATION
The compressor is driven by the vehicle engine and func-
tions continuously while the engine is in operation. Actual
compression of air is controlled by the compressor un-
loading mechanism operating in conjunction with a remote
mounted governor and synchro valve. Unlike the TuFlo
The cast iron crankcase and cylinder block assembly, houses series compressors, the DuraFlo requires the addition of a
the pistons, connecting rods, crankshaft and related synchro valve to assure proper operation and service life.
bearings. Unloader plungers and related seals and springs The governor and synchro valve combination maintains
are contained in bores in the cylinder block. Sliding inlet brake system air pressure between a preset maximum and
valves and their pivot arms are sandwiched between the minimum pressure level. Refer to figure 3.
cylinder block and valve body assembly.
The compressor has a built in unloading and ESS or En-
The DuraFlo™ 596 compressor incorporates an unloader ergy Saving System.
system that features an energy saving system or ESS which

AIR SYNCHRO FROM

DRYER VALVE SUPPLY
SYNCHRO VALVE
SUPPLY RESERVOIR
GOVERNOR
DELIVERY
GOVERNOR
(110 CUTIN 130
TO CUTOUT)
COMPRESSOR
UNLOADERS

TO AIR
DRYER
FROM
DURAFLO 596 SUPPLY CONTROL SUPPLY
COMPRESSOR RESERVOIR RESERVOIR

FIGURE 3 - DURAFLO 596 UNLOADER SYSTEM

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AIR
pressure the discharge valves open and air flows into the
INLETCHECK
AIR VALVE OPEN DISCHARGE discharge line and air brake system.
INLET PORT
PORT
NON-COMPRESSION OF AIR (UNLOADED)
ESS
CHAMBER When air pressure in the supply reservoir reaches the cut-
INLET out setting of the governor, the governor delivers system
VALVE air to the control port of the synchro valve. The synchro
OPEN DISCHARGE
VALVE valve opens in response to control pressure from the gov-
CLOSED
ernor and delivers system pressure to either of the two
compressor unloader ports. Air entering the unloader port
acts on one unloader plunger directly and is simultaneously
UNLOADER conducted through a passage in the valve body assembly
PISTON to the other unloader plunger.
PISTON The unloader plungers move horizontally in their bores in
MOVING
DOWN response to control pressure from the governor and syn-
chro valve. A guide pin in the unloader plunger rotates the
FIGURE 4 - OPERATIONAL-LOADED (INTAKE)
pivot arm which causes the inlet valve to slide. As the
AIR INTAKE (LOADED) inlet valve slides from the loaded to the unloaded position
The piston strokes are 180 degrees opposed. As one piston it blocks the two discharge ports and opens the six inlet
is on an up stroke the opposing piston is on a down stroke. ports connecting the cylinder bore to the ESS chamber.
During the piston down stroke, a vacuum is created in the When the piston travels upward, air in the cylinder is
cylinder and ESS chamber within the cylinder head. The trapped between the top of the piston and the closed inlet
vacuum causes the inlet check valve and sliding inlet valve check valve and is compressed. The intake check valves
to flex open. Atmospheric air flows through the open inlet prevent the intake air from escaping through the air intake
check valve into and through the ESS chamber to the slid- port when the compressor is in the unloaded ESS mode.
ing inlet valve. Air flowing past the sliding inlet valve fills the See figure 5 & 7.
cylinder above the piston. See Figure 4 & 7.
INLETCHECK AIR
AIR VALVE CLOSED DISCHARGE
INLET PORT
INLETCHECK AIR PORT
AIR VALVE CLOSED DISCHARGE
INLET PORT ESS
PORT CHAMBER
ESS INLET
CHAMBER VALVE
OPEN DISCHARGE
INLET VALVE
VALVE CLOSED
CLOSED DISCHARGE
VALVE
OPEN

UNLOADER
PISTON & PIVOT
UNLOADER PISTON MOVING ARM SLIDES INLET
PISTON UP & DOWN VALVE OVER

PISTON
MOVING
UP FIGURE 6 - OPERATIONAL-UNLOADED
The added volume of the ESS chamber lowers the amount
FIGURE 5 - OPERATIONAL-LOADED (COMPRESSION)
of compression. Air that is compressed during the upward
AIR COMPRESSION (LOADED) movement of the piston provides a driving force for the
piston during its downward movement. As one piston is
When the piston reaches approximately bottom dead cen- moving downward the opposing piston is moving up. With
ter (BDC) the inlet check valve and sliding inlet valve close. the exception of losses in the form of heat, which is formed
Air above the piston is trapped by the closed inlet valve during compression, the energy used to compress the air
and is compressed as the piston begins to move toward will be reused as the driving force for the downward stroke
top dead center (TDC). When air in the cylinder bore of the piston. This results in the compressor using very
reaches a pressure greater than that of the system little power in its unloading position. See figure 6 & 7.
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DISCHARGE INLET PORTS

assists in cooling the compressor. Cooling fins are part of
VALVE the crankcase/cylinder block casting. Coolant flowing from
the engine cooling system through connecting lines en-
ters the head and passes through internal passages in the
cylinder head and is returned to the engine. Proper cool-
ing is important in maintaining discharge air temperatures
below the maximum recommended 400 degrees Fahren-
DISCHARGE PORTS heit. Figure 8 illustrates the various approved coolant flow
connections. See the tabulated technical data in the back
CYLINDER HEAD SIDE OF VALVE BODY ASSY. of this manual for specific requirements.

AIR INDUCTION
DISCHARGE SLIDING INLET INLET
PORTS VALVES PORTS The DuraFlo™ 596 compressor is approved for natural aspi-
ration only. The compressor inlet is connected to the
vacuum side of the engine air induction system. See the
tabulated technical data in the back of this manual for spe-
PIVOT cific requirements.
ARMS
PREVENTATIVE MAINTENANCE
COMPRESSOR LOADED COMPRESSOR UNLOADED
Important Note: Review the warranty policy before per-
CYLINDER BLOCK SIDE OF VALVE BODY ASSY. forming any intrusive maintenance procedures. An extended
warranty may be voided if intrusive maintenance is performed
UNLOADER
during this period.
UNLOADER PLUNGER GUIDE PIN
PORT AIR INDUCTION
One of the single most important aspects of compressor
preventive maintenance is the induction of clean air. Since
UNLOADER AIR the DuraFlo 596 is connected to the engine air cleaner,
PASSAGE
proper periodic maintenance of the engine air filter
PIVOT eliminates the need for separate filter maintenance.
ARM
Inspect the compressor intake adapter, and the connect-
ing hoses each time engine air cleaner maintenance is
SLIDING
INLET VALVE performed.
13 x 60mm
CYL. BOLT (2) LIFTING
13 x 85mm LUG
FIGURE 7 - UNLOADER MECHANISM CYL. BOLT
(6) DISCHARGE
LUBRICATION PORT

The vehicle's engine provides a continuous supply of oil

to the compressor. Oil is routed from the engine to the
compressor oil inlet. An oil passage in the crankshaft con- COOLANT
IN OR OUT
ducts pressurized oil to precision sleeve main bearings (ONE OR THE
and to the connecting rod bearings. Spray lubrication of OTHER
PLUGGED) COOLANT
the cylinder bores, connecting rod wrist pin bushings, and DISCHARGE INLET IN OR
ball type main bearings is obtained as oil is forced out SAFETY VALVE PORT OUT
around the crankshaft journals by engine oil pressure. Oil
CYLINDER HEAD PORT IDENTIFICATION
then falls to the bottom of the compressor crankcase and
The cylinder head connection ports are identified with cast
is returned to the engine through drain holes in the com- in numerals as follows:
pressor mounting flange. Atmospheric AIR IN 0
Compressed AIR OUT 2
COOLING
Coolant IN 91
Air flowing through the engine compartment from the ac- Coolant Out 92
tion of the engine fan and the movement of the vehicle
FIGURE 8- TYPICAL DURAFLO 596 CYLINDER HEAD
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1. Inspect the intake hose adapters for physical damage. loader port on the compressor and observing the reac-
Make certain to check the adapters at both ends of the tion during transition from the loaded and unloaded
intake hose or tubing. condition. Air pressure should be applied and exhausted
2. The intake hose clamps and tighten them if needed. with a distinct “snap action” with no appreciable lag for
buildup or release of pressure. If prompt action is not
3. Inspect the intake hose or line for signs of drying, crack-
noted, repair or replace the synchro valve.
ing, chafing and ruptures and replace it if necessary.
EVERY 6 MONTHS, 1800 OPERATING HOURS OR SERVICE TESTS
AFTER EACH 50,000 MILES WHICHEVER OC-
CURS FIRST PERFORM THE FOLLOWING GENERAL
INSPECTIONS AND TESTS. The following compressor operating and leakage tests need
not be performed on a regular basis. These tests should
COMPRESSOR COOLING
be performed when; it is suspected that leakage is sub-
Inspect the compressor discharge port, inlet cavity and stantially affecting compressor buildup performance, or
discharge line for evidence of restrictions and carboning. when it is suspected that the compressor is “cycling” be-
If excessive buildup is noted, thoroughly clean or replace tween the load and unloaded modes due to unloader
the affected parts. Since carbon buildup generally indi- plunger leakage.
cates inadequate cooling, closely inspect the compressor
cooling system. Check all compressor coolant lines for OPERATING TESTS
kinks and restrictions to flow. Minimum coolant line size Compressor Performance
is 3/8" I.D. Check coolant lines for internal clogging from
Vehicles manufactured after the effective date of FMVSS
rust scale. If coolant lines appear suspicious, check the
121 must have a compressor capable of raising air sys-
coolant flow and compare to the tabulated technical data
tem pressure from 85-100 psi in 25 seconds or less, with
present in the back of this manual. Carefully inspect the
the minimum required reservoir volume for the vehicle.
air induction system for restrictions.
This test is performed with the engine operating at maxi-
LUBRICATION mum recommended governed speed. The vehicle
manufacturer must certify this performance on new ve-
Check the external oil supply line for kinks, bends, or re- hicles with appropriate allowances for air systems with
strictions to flow. Supply lines must be a minimum of 3/16" greater than the minimum required reservoir volume. As
I.D. Refer to the tabulated technical data in the back of a less severe alternative to running a high RPM test, a
this manual for oil pressure minimum values. new compressor's buildup time can be measured and re-
corded at high idle. Subsequent testing throughout the
COMPRESSOR DRIVE
compressor’s service life can be compared to the base line
Check for noisy compressor operation, which could indi- new compressor performance. Compressor buildup times
cate excessive drive component wear. Adjust and/or replace should be recorded and kept with the vehicle maintenance
as necessary. Check all compressor mounting bolts and files for reference. When testing compressor buildup times
retighten evenly if necessary. Check for leakage and proper it is essential that air system leakage be kept below the
unloader mechanism operation. Repair or replace parts as allowed maximum for the vehicle type being tested. Before
necessary. running buildup tests check the service and supply sys-
tems for excessive leakage and repair as necessary.
COMPRESSOR & GOVERNOR UNLOADER
SYSTEM Note: Supply system leakage is not displayed
on the vehicle dash gauges and must be tested
Test and inspect the compressor and governor unloader separately. Supply system components such
system for proper operation and pressure setting. as the governor, synchro valve, air dyer, reser-
1. Make certain the unloader system contains both the voir drain cocks, safety valve and check
governor and synchro valve as illustrated in figure 3. valves can leak without indication on the dash
gauges. These components must be checked
2. Cycle the compressor through the loaded and unloaded
for leakage separately and individually. Refer
cycle several times. Make certain that the governor
to the various maintenance manuals for indi-
cuts out at 130 psi (cut in should be approximately 110
vidual component leakage tests and the Bendix
psi). Adjust or replace the governor as required.
“Test and Checklist” published in the Air Brake
3. Note that the DuraFlo cycles to the loaded and un- System Handbook (BW5057) for air system
loaded conditions promptly. This can be definitely leakage testing.
confirmed by installing a test gauge in the unused un-

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LEAKAGE TESTS COMPRESSOR REMOVAL & DISASSEMBLY

Cylinder Head
GENERAL
Check for cylinder head gasket air leakage.
The following disassembly and assembly procedure is pre-
1. With the engine running, lower air system pressure to sented for reference purposes and presupposes that a rebuild
60 psi and apply a soap solution around the cylinder or repair of the compressor is being undertaken. Several
head. Check the gasket between the cylinder head and maintenance kits are available and the instructions provided
valve body assembly and the gasket between the valve with these parts and kits should be followed in lieu of the
body assembly and cylinder block for air leakage. instructions presented here.
2. No leakage is permitted. If leakage is detected replace
the compressor or repair the cylinder head using a
MAINTENANCE KITS & SERVICE PARTS
genuine Bendix maintenance kit available from autho- Cylinder Head Maintenance Kit.
rized Bendix parts outlets.
Unloader Maintenance Kit.
Inlet, Discharge & Unloader
All components shown in figure 9 with a key number are
While it is possible to test for inlet, discharge, and unloader available in kits and/or as individual service parts.
plunger leakage it requires disassembly of the cylinder head
to accomplish. For this reason it is not recommended. IMPORTANT! PLEASE READ:

Inlet and discharge valve leakage can generally be detected When working on or around a vehicle, the following
by longer compressor buildup and recovery times. Compare general precautions should be observed:
current compressor buildup times with the last several re- 1. Park the vehicle on a level surface, apply the park-
corded times. Make certain to test for Air system leakage, ing brakes, and always block the wheels.
as described under Operating Tests, before making a deter- 2. Stop the engine when working around the vehicle.
mination that performance has been lost.
3. If the vehicle is equipped with air brakes, make
1. With the engine running, lower air system pressure to certain to drain the air pressure from all reservoirs
90 psi and raise engine RPM to 1800. Measure and before beginning any work on the vehicle.
record the time required to raise system pressure from
4. Following the vehicle manufacturer’s recom-
100 psi to 130 psi Run this test three times and use the
mended procedures, deactivate the electrical
average time.
system in a manner that removes all electrical
Note: This test should be run with the engine and power from the vehicle.
air system at normal operating temperature (i.e. not 5. When working in the engine compartment the en-
cold). gine should be shut off. Where circumstances
2. Compare the average time recorded in step 2 with previ- require that the engine be in operation, extreme
ously recorded build up times to evaluate compressor caution should be used to prevent personal injury
performance. resulting from contact with moving, rotating, leak-
ing, heated, or electrically charged components.
Unloader leakage is exhibited by excessive compressor
cycling between the loaded and unloaded condition. 6. Never connect or disconnect a hose or line con-
taining pressure; it may whip. Never remove a
1. With service and supply system leakage below the component or plug unless you are certain all sys-
maximum allowable limits and the vehicle parked, bring tem pressure has been depleted.
system pressure to governor cutout and allow the en-
7. Never exceed recommended pressures and always
gine to idle.
wear safety glasses.
2. The compressor should remain unloaded for a mini-
8. Do not attempt to install, remove, disassemble or
mum of 5-10 minutes. If compressor cycling occurs
assemble a component until you have read and
more frequently and service and supply system leak-
thoroughly understand the recommended proce-
age is within tolerance replace the compressor or repair
dures. Use only the proper tools and observe all
the compressor unloader system using a genuine
precautions pertaining to use of those tools.
Bendix maintenance kit available from authorized Ben-
dix parts outlets. 9. Use only genuine Bendix replacement parts, com-
ponents, and kits. Replacement hardware, tubing,
hose, fittings, etc. should be of equivalent size,
type, and strength as original equipment and be

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9
2 9
1 26 10
10 11
12
11
25
12 VALVE BODY
CYLINDER ASSY.
HEAD 7
6
7 5
13
6 4
5 14
3
4 15
17
16
3 8

18

41

CRANKCASE
&
CYLINDER
23 BLOCK
21 24
19
22
20
31
FLANGE
MOUNT
27

END COVER
30
29

28

Item Qty. Description Item Qty. Description Item Qty Description

1 6 13mm x 85mm Bolt 12 2 Discharge Valve 23 2 Backup Ring
2 2 13mm x 60mm Bolt 13 2 Sliding Inlet Vlv 24 2 Spring
3 2 10mm x 25mm Bolt 14 2 Pivot Arm 25 6 13mm Washer
4 2 Spacer Sleeve 15 2 Stud 26 1 Discharge Safety Valve
5 2 Holder 16 2 Guide Pin 27 2 Base Plate Gskt.
6 2 Inlet Check Valve 17 2 Guide Pin 28 8 Base Plate Cap Screw
7 2 Seat 18 1 Vlv. Assy. to Block Gskt. 29 2 Base Plate
8 1 Head to Vlv. Assy. Gskt. 19 1 Plug 30 1 End Cover O-Ring
9 4 10mm x 25mm Bolt 20 1 Sealing Washer 31 4 13mm x 20mm Bolt
10 4 Spacer Sleeve 21 2 Unloader Plunger
11 2 Holder 22 2 O-Ring
FIGURE 9- DURAFLO™ 596 EXPLODED VIEW OF SERVICEABLE PARTS
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designed specifically for such applications and sys- adapter in relation to the crankcase. Mark the relationship
tems. of the cylinder head to the valve body assembly and crank-
10. Components with stripped threads or damaged case and cylinder block assembly.
parts should be replaced rather than repaired. Re- A convenient method to indicate the above relationships
pairs requiring machining or welding should not is to use a metal scribe to mark the parts with numbers or
be attempted unless specifically approved and lines. Do not use marking methods such as chalk that can
stated by the vehicle or component manufacturer. be wiped off or obliterated during rebuilding.
11. Prior to returning the vehicle to service, make cer-
Prior to disassembly make certain that the appropriate kits
tain all components and systems are restored to
and or replacement parts are available. Refer to figure 9
their proper operating condition.
during the entire disassembly and assembly procedure.
REMOVAL
UNLOADER & INLET VALVE
These instructions are general and are intended to be a guide.
1. Remove the discharge safety valve (26) from the cyl-
In some cases additional preparations and precautions are
inder head.
necessary. In all cases follow the instructions contained in
the vehicle maintenance manual in lieu of the instructions, 2. Remove the unloader port plug and sealing washer
precautions and procedures presented in this manual. (19 & 20).

1. Block the wheels of the vehicle and drain the air pres- 3. Loosen but do not remove the two 13mm x 60mm bolts (2).
sure from all the reservoirs in the system. 4. Remove the six 13mm x 85mm cylinder head bolts
2. Drain the engine cooling system and the cylinder head and washers (1 & 25) and tap the head with a soft
of the compressor. Identify and disconnect all air, wa- mallet to break the gasket seal. Lift off the cylinder
ter and oil lines leading to the compressor. head and valve body assembly off the cylinder block.

3. Remove as much road dirt and grease from the exte- IMPORTANT NOTE: Do not attempt to sepa-
rior of the compressor as possible. rate the two halves of the valve body assembly.
Service replacements and gaskets are not
4. Remove the discharge and inlet fittings, if applicable, and
available
note their position on the compressor to aid in reassembly.
5. Remove the metal gasket (18).
Note: If a cylinder head or unloader mainte-
nance kit is being installed, stop here and 6. Remove both sliding inlet valves (13).
proceed to PREPARATION FOR DISASSEM- 7. Remove both pivot arms (14) and pivot arm studs (15).
BLY. If replacing the compressor continue. 8. To remove spring tension from the unloader plunger guide
3. Remove any supporting bracketing attached to the pin (16), insert a 1/4” brass dowel into one of the un-
compressor and note their positions on the loader plunger bore and depress the plunger (21) slightly.
compressor to aid in reassembly. While holding the plunger (21) depressed, remove the
5. Remove the flange mounting bolts and remove the plunger guide pin (16). Slowly extract the dowel rod from
compressor from the vehicle. the unloader bore until spring tension is relieved.

6. Inspect gear and associated drive parts for visible wear Note: As an alternative, to this procedure an appro-
or damage. Since these parts are precision fitted, priately sized nut or dowel rod can be placed in the
they must be replaced if they are worn or damaged. If unloader bore and the plug (19) installed then re-
replacing the compressor or replacing the drive gear, moved after the guide pin is removed.
remove the drive gear from the compressor crank- 9. Remove the unloader plunger (21), with its O-ring (22)
shaft using a gear puller. and backup ring (23) from the bore. Remove the unloader
7. If the compressor is being replaced stop here and spring (24).
proceed to "Installing The Compressor" at the end of 10. Repeat steps 7 and 8 for the other unloader plunger.
the assembly procedure. 11. Remove both pivot arm guide pins (17) from the cylin-
der block.
PREPARATION FOR DISASSEMBLY
Remove the balance of road dirt and grease from the ex- DISCHARGE & INLET CHECK VALVES
terior of the compressor with a cleaning solvent. Before 1. Remove the two 13mm x 60mm cylinder head bolts
the compressor is disassembled, the following items should (2) and gently tap the head and valve body assembly
be marked to show their relationship when the compres- with a soft mallet to break the gasket seal. Separate
sor is assembled. Mark the rear end cover or end cover the cylinder head and valve body assembly.

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IMPORTANT NOTE: Do not attempt to separate the 3. Remove rust and scale from the cooling cavities and
two halves of the valve body assembly. Service re- passages in the head and valve body assembly and
placements and gaskets are not available use shop air to clear debris from the passages.
2. Remove the gasket (8). 4. Make certain the unloader air passages and coolant pas-
3. Turn the cylinder head over to expose the inlet check sages through the valve body are open and clear of
valves and remove the 10mm x 25mm inlet check contamination.
valve bolt (3) that secures the inlet check valve com- 5. Check the threads in all cylinder head ports for galling.
ponents. Remove the spacer sleeve (4), holder (5), Minor chasing is permitted.
check valve (6) and check valve seat (7).
OIL PASSAGES
4. Repeat step 3 for the second inlet check valve assem-
bly. Thoroughly clean all oil passages through the end cover
or end cover adapter. Inspect the passages with a wire to
5. Remove the two 10mm x 25mm discharge valve bolts
be sure. Blow the loosened foreign matter out with air pres-
(9) that secure the discharge check valve components.
sure.
Remove the spacer sleeve (10), holder (11) and dis-
charge valve (12).
CYLINDER BLOCK UNLOADER BORES
6. Repeat step 5 for the second discharge valve assembly.
Thoroughly clean the unloader bore on both sides of the
CRANKCASE COVER compressor cylinder block. Make certain not to scratch or
1. Remove the four cap screws (28) securing the crank- gouge the air pressure sealing surfaces of the bores dur-
case cover (29). Using a soft mallet, gently tap the ing the cleaning process.
crankcase cover (29) to break the gasket seal. Scrape
off any gasket material (27) from the crankcase and
INSPECTION OF PARTS
bottom cover or adapter. CYLINDER HEAD & VALVE BODY
2. Repeat step 1 for the second crankcase cover. 1. Carefully inspect the cylinder head gasket surfaces for
END COVER OR END COVER ADAPTER deep gouges and nicks. If detected, the compressor
must be replaced.
1. Remove the cap screws (31) that secure the rear end
cover or end cover adapter to the crankcase. 2. Carefully inspect the valve body gasket surfaces for
deep gouges and nicks. Pay particular attention to the
Note: Some compressor models use four cap
metal gasket surface. A metal gasket (18) is used be-
screws while others use a combination of cap
tween the valve body assembly and cylinder block.
screws and studs.
This surface must be smooth and free of all but the
3. Remove the rear end cover or end cover adapter from the most minor scratching. If excessive marring or goug-
crankcase. Remove the O-ring seal (30) from the end ing is detected, the compressor must be replaced.
cover if so equipped.
3. Inspect the cylinder head for cracks or damage. With
the cylinder head and head gasket secured to the valve
CLEANING OF PARTS
body, apply shop air pressure to one of the coolant ports
GENERAL with all others plugged, and check for leakage by apply-
ing a soap solution to the exterior of the head. If leakage
All parts should be cleaned in a good commercial grade of
is detected in the cylinder head casting, replace the
solvent and dried prior to inspection.
compressor.
CYLINDER HEAD END COVER OR END COVER ADAPTER
1. Carefully remove all gasket material adhering to the
Check for cracks and external damage. Check the crankshaft
cylinder head, valve body assembly and cylinder block.
main bearing surface in the end cover or end cover adapter,
Make certain not to deeply scratch or mar the gasket
check for excessive wear and flat spots and replace the end
surfaces. Pay particular attention to the gasket sur-
cover if necessary. Check for galling of the oil port threads
faces of the aluminum head.
and replace the end cover or end cover adapter if necessary.
2. Remove carbon deposits from the discharge and inlet Minor thread chasing is permitted but do not “recut” the
cavities of the cylinder head and valve body assem- threads if they are badly damaged.
bly. Make certain the inlet and discharge ports of the
valve body assembly are open and clear. CYLINDER BLOCK
1. Check the cylinder head gasket surface on the cylinder
block for nicks, gouges, and marring. A metal gasket is
used to seal the cylinder head to the cylinder block. 9
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This surface must be smooth and free of all but the most 2. Locate one of the two inlet check valve holders (5). Place
minor scratching. If excessive marring or gouging is de- the holder (5) on the inlet check valve (6) making cer-
tected, the compressor must be replaced. tain that the three indentations around the bolt hole, on
the holder, interlock with the tabs on the inlet check
ASSEMBLY valve (5). When properly assembled the seat (7), valve
General Note: All torques specified in this manual are (6) and holder (5) should be parallel and interlocked.
assembly torques and typically can be expected to fall off 3. Place the three components over one of the two slot-
after assembly is accomplished. Do not re-torque after ted inlet openings in the cylinder head making certain
initial assembly torques fall unless instructed otherwise. A that the bolt holes in the components and head corre-
compiled listing of torque specifications is presented at spond.
the end of this manual.
4. Insert one of the two 10mm x 25mm bolts (3) through
INCH POUNDS TO FOOT POUNDS
a spacer sleeve (4). Using the bolt and sleeve, secure
To convert inch pounds to foot pounds of torque, divide
the assembled seat (7), valve (6) and holder (5) in the
inch pounds by 12.
cylinder head. Tighten the bolt finger tight and check
Example: 12 Inch Pounds = 1 Foot Pound
that the seat (7), valve (6) and holder (5) are still inter-
12
locked. This can be done by attempting to rotate the
FOOT POUNDS TO INCH POUNDS
holder (5) and noting that the valve and seat follow
To convert foot pounds to inch pounds of torque, multiply
and are locked together.
foot pounds by 12.
Example: 1 Foot Pound x 12 = 12 Inch Pounds 5. Torque the 10mm bolt to 101 to 111 inch pounds.
6. Repeat steps one through five for the other inlet check
CRANKCASE COVER valve assembly.
1. Position one of the two crankcase cover gaskets (27)
on either the crankcase or crankcase cover and install DISCHARGE VALVES
the crankcase cover (29) using the position marks made 1. Locate and place one of the two discharge valves (12)
prior to disassembly. Tighten the four cap screws (28), on the valve body assembly with its bolt hole corre-
securing the crankcase cover to a torque of 101-111 sponding with the threaded hole on the outside edge
inch pounds for crankcase cover or cover in a crossing of the valve body assembly. When correctly placed,
pattern after first snugging all 4 screws. the discharge valve (12) will cover the two discharge
2. Repeat this assembly for the second crankcase cover holes in the valve body assembly. Refer to figure 10.
(29).

CRANKCASE END COVER OR END COVER Discharge Valve

ADAPTER
Guide Lug
1. Install the end cover O-ring (30) on the crankcase end
cover.
Discharge
2. Orient the crankcase end cover or end cover adapter
to the crankcase using the reference marks made dur- Valve
ing disassembly. Carefully install the end cover or end
cover adapter in the crankcase making certain not to
damage the crankshaft bearing surface in it.
FIGURE 10 - DISCHARGE VALVE INSTALLATION
3. Install the four 13mm x 20mm end cover or end cover
2. Locate one of the two discharge valve holders (11) and
adapter bolts or studs (31) and tighten to 195 to 212
install it over the discharge valve (12) so that the free
inch pounds.
end of the discharge valve (12) is contained between
CYLINDER HEAD INLET CHECK VALVES the two guide lugs on the sides of the holder. Refer to
1. Locate one of the two inlet check valve seats (7) and figure 10.
note that one side is flat while the other has three pro- 3. Insert one of the four 10mm x 25mm bolts (9) through
truding tabs around the bolt hole. Position one of the a spacer sleeve (10). Using the bolt and sleeve, loosely
two the inlet check valves (6) on the inlet check valve secure one end of the discharge valve (12) and holder
seat (7) so that the three positioning and locating tabs (11) to the valve body assembly. Insert a second 10mm
interlock with the corresponding tabs on the seat. When x 25mm bolts (9) through a spacer sleeve (10) and
properly fitted together, the valve (6) should lay flat loosely secure the other end of the discharge valve
against the seat (7) and cover the slotted opening of (12) and holder (11) to the valve body assembly. Be-
the seat.
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fore attempting to tighten the two 10mm bolts make 4. Locate one of the sliding inlet valves (13) and place it on
certain the free tip of the discharge valve (12) is not a flat surface. Note that there is a concave and convex
pinched between the holder (11) and the valve body side in the surface where the small pivot arm stud hole
assembly. The valve must be free to flex. is located. Refer to figure 11.
4. Torque the 10mm bolts to 101 to 111 inch pounds. Pivot Arm Valve Body Inlet Valve
5. Repeat steps one through four for the other discharge Stud
valve assembly. Pivot Arm Cyl.
Block
UNLOADER PLUNGERS Concave Area
1. Install the metal sealing washer (20) on the plug (19)
and set aside. FIGURE 11 - SLIDING INLET VALVE INSTALLATION

2. Install one O-ring (22) and backup ring (23) in the groove 5. Place the metal gasket (18) on the cylinder block, red
of the unloader plunger (21). The backup ring (23) side toward the cylinder block, while aligning the
should be installed in the groove so that it is closest to cylinder head bolt holes.
the center of the plunger. 6. Install the sliding inlet valves (13) on the pivot arm
3. Install the unloader plunger return spring (24) in the stud, concave side toward the cylinder bock. Make
bore in the end of the unloader plunger (21). certain to center the inlet valves within their openings
4. Insert the assembled plunger (21) and spring (24) into in the metal gasket (18).
one of the unloader bores in the cylinder block. When Note: The inlet valves must not be pinched be-
inserting the plunger orient it so that its guide pin hole tween the metal gasket and the cylinder block.
will be visible through the slotted opening in the cylin- They must be free to slide within their openings in
der block. the metal gasket.
5. Insert a 1/4” brass dowel into the unloader plunger bore VALVE BODY & CYLINDER HEAD
and depress the plunger (21) slightly. While holding
1. Orient and carefully install the valve body assembly
the plunger (21) depressed, insert the plunger guide
on the cylinder block. The cylinder block guide pins
pin (16) into the slotted opening in the cylinder block
(17) will locate and guide the installation of the instal-
and into the unloader plunger until it is fully seated and
lation of the valve body.
extends above the top surface of the cylinder block
approximately 1/8”. Slowly extract the dowel rod from Note: Try not to disturb the location of the
the unloader bore until spring tension is relieved and metal gasket (18) during the installation of the
the guide pin retains the plunger. valve body because the sliding inlet valves
may be pinched.
Note: The unloader plunger guide pin (16) is larger
in diameter and longer than the pivot arm guide pin 2. Orient and install the cylinder head gasket (8) on the
(17). valve body.
6. Repeat steps one through five for the other unloader 3. Orient and carefully install the cylinder head on the
plunger assembly. valve body assembly. The cylinder block guide pins
(17) will locate and guide the installation of the instal-
INLET VALVES & PIVOT ARMS lation of the valve body.
1. Install both pivot arm guide pins (17) in the cylinder 4. Insert the six 13mm x 85mm head bolts into the head
block. and tighten each finger tight.
2. Place the pivot arm studs (15) in their slots in the cyl- 5. Insert the two 13mm x 60mm head bolts into the head
inder block. The head (large diameter) of the stud and tighten each finger tight.
should be in the slot with the small diameter facing
6. Insert a 1/4” brass dowel into one of the unloader
away from the cylinder block.
plunger bore and depress the plunger (21) several
3. Install both pivot arms (14) over the cylinder block guide times. The plunger (21) should move freely with only
pin (17) and unloader plunger guide pin (16) as well as spring tension resistance noted. If greater resistance
the stud (15). When installed correctly the stud (15) is noted the sliding inlet valve (13) is pinched and the
and unloader plunger guide pin (16) will be in the slot- cylinder head and valve body must be removed and
ted openings of the pivot arm (14). the sliding inlet valve (13) must be repositioned within
Note: It may be necessary to slightly depress each the opening of the meatal gasket (18). Repeat this pro-
unloader plunger to allow easy installation of the cedure for the other unloader plunger and sliding inlet
pivot arms over the guide pins. valve.

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7. Torque the two 13mm x 60mm head bolts to 265 - 292 connecting line. With the compressor operating at 2100
inch pounds. RPM., the time required to raise the reservoir(s) pressure
8. Beginning with one of the center bolts, torque the six from 85 psi to 100 psi should not exceed 5 seconds. During
13mm x 85mm head bolts to 265 - 292 inch pounds this test, the compressor should be checked for gasket leak-
using a figure eight pattern. age and noisy operation, as well as unloader operation and
leakage. If the compressor functions as indicated reinstall
9. Apply a thread sealant to the assembled plug and seal-
on the vehicle connecting all lines as marked in the disas-
ing washer (19 & 20) and install it in the cylinder block
sembly procedure.
unloader bore that was marked during disassembly.
Tighten sufficiently to seal air pressure. DURAFLO™ 596 SPECIFICATIONS
INSTALLING THE COMPRESSOR Typical weight ........................................................ 50 lbs.
1. If the compressor was removed for replacement, in- Number of cylinders ........................................................ 2
stall the drive components. Torque the crankshaft nut Bore size .............................................. 3.465 in. (88 mm)
to 125 foot pounds. Stroke ................................................... 1.968 in. (50 mm)
2. Install any supporting bracketing on the compressor in Calculated displacement at 1250 RPM ................ 27 CFM
the same position noted and marked during removal. Flow Capacity @ 2100 RPM & 120 PSI ............... 23 CFM
Maximum recommended RPM ........................ 3000 RPM
3. Install the gasket on the drive flange of the compressor.
Make certain oil supply or return holes in the gasket are Minimum coolant flow maximum RPM ...... 2.5 Gals./Min.
properly aligned with the compressor and engine. Gas- Approximate horsepower required:
ket sealants are not recommended. Secure the Loaded 1800 RPM at 120 PSIG ............................ 7.5 HP
compressor on the engine and tighten the mounting Unloaded 1800 RPM .............................................. 0.9 HP
bolts. Maximum inlet air temperature .............................. 250 F°
4. Install the discharge and inlet fittings, if applicable, in Maximum discharge air temperature ..................... 400 F°
the same position on the compressor noted and marked Minimum oil pressure required at
during disassembly. Make certain the threads are clean engine idling speed ............................................. 15 PSI
and the fittings are free of corrosion. Replace as nec- Minimum oil pressure required at
essary. maximum governed engine speed ...................... 15 PSI
5. Inspect all air, oil, and coolant lines and fittings before Minimum oil-supply line size ............................. 3/16" I.D.
reconnecting them to the compressor. Make certain O- Minimum unloader-line size ............................... 3/16" I.D.
ring seals are in good or new condition. Tighten all Minimum Governor Cutout Pressure ..................... 130 PSI
hose clamps.
TORQUE SPECIFICATIONS
6. Clean oil supply line. Before connecting this line to the
Assembly Torques in inch pounds (in. Ibs.)
compressor. Run the engine briefly to be sure oil is
13mm Cylinder Head Bolts ................................. 265 - 292
flowing freely through the supply line.
10mm Valve Bolts ............................................... 101 -111
7. Before returning the vehicle to service, perform the
Rear End cover or adapter Bolts/Studs .............. 195 - 212
Operation and Leakage Tests specified in this manual.
Bottom Cover ...................................................... 97 - 115
Pay particular attention to all lines reconnected during
Crankshaft Nut .............................................. 1770 - 2212
installation and check for air, oil, and coolant leaks at
compressor connections. Also check for noisy opera-
Metric (Detroit Diesel)
tion.
M12 x1.5 ..................................................................... 222
TESTING REBUILT COMPRESSOR M16 x1.5 ..................................................................... 386
M22 x1.5 ..................................................................... 531
In order to properly test a compressor under operating con-
ditions, a test rack for correct mounting, cooling, lubricating, M27 x2 ........................................................................ 792
and driving the compressor is necessary. Such tests are
not compulsory if the unit has been carefully rebuilt by an U.S. (Caterpillar)
experienced person. A compressor efficiency or build up 1/2"-20 UNF ................................................................ 222
test can be run which is not too difficult. An engine lubri- 3/4"-16 UNF ................................................................ 398
cated compressor must be connected to an oil supply line 7/8"-14 UNF ................................................................ 531
of at least 15 psi. pressure during the test and an oil return 1 1/16"-12 UNF ........................................................... 792
line must be installed to keep the crankcase drained. Con-
nect to the compressor discharge port, a reservoir with a
volume of 1500 cubic inches, including the volume of the
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DIMENSIONAL DATA
Port Sizes
Metric (Detroit Diesel)
Water inlet ......................................................... M16 x1.5
Water outlet ....................................................... M16 x1.5
Discharge Safety Valve ....................................... M16 x1.5
Air discharge ......................................................... M27 x2
Unloader Port ..................................................... M22 x1.5
Oil inlet (end cover or adapter) ............................ M12 x1.5

U.S. (Caterpillar)
Water inlet .................................................... 3/4"-16 UNF
Water outlet .................................................. 3/4"-16 UNF
Discharge Safety Valve .................................. 3/4"-16 UNF
Air discharge ............................................ 1 1/16"-12 UNF
Unloader Port ................................................ 7/8"-14 UNF
Oil inlet (end cover or adapter) ....................... 1/2"-20 UNF

See Page 14 for Troubleshooting Section

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COMPRESSOR TROUBLESHOOTING CHART

SYMPTOMS CAUSE REMEDY
1. Compressor passes A. Restricted air intake. A. Check engine or compressor air cleaner and
excessive oil as replace if necessary. Check compressor air
evidenced by presence inlet for kinks, excessive bends and be certain
of oil at exhaust ports inlet lines have the minimum specified inside
of valving. diameter. Recommended maximum air inlet
restriction is 25" of water.

B. Restricted oil return B. Oil return to the engine should not be in any
to engine. way restricted. Make certain oil drain passages
in the compressor and mating engine surfaces
are unobstructed and aligned. Correct gaskets
must be used. Special care must be taken
when sealants are used with, or instead of,
gaskets.

C. Poorly filtered inlet air. C. Check for damaged, defective or dirty air filter
on engine or compressor. Check for leaking,
damaged or defective compressor air intake
components (e.g. induction line, fittings,
gaskets, filter bodies, etc.). The compressor
intake should not be connected to any part of
the exhaust gas recirculation (E.G.R.) system
on the engine.
D. Insufficient compressor D. For air-cooled portions of the compressor:
cooling (compressor runs
1. Remove accumulated grease, grime or dirt
hot).
from the cooling fins. Replace components
found damaged.
2. Check for damaged cooling fins. Replace
compressor if found damaged.

For water-cooled portions of the compressor:

1. Check for proper coolant line sizes. Minimum
recommended size is 3/8" I.D. tubing.
2. Check the coolant flow through the compressor.
Minimum allowable flow is 2.5 gallons per
minute at engine governed speed. If low
coolant flow is detected, inspect the coolant
lines and fittings for accumulated rust scale,
kinks and restrictions.
3. Water temperature should not exceed 200
degrees Fahrenheit.
4. Optimum cooling is achieved when engine
coolant flows, as shown in Figure 8 of this
manual.

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COMPRESSOR TROUBLESHOOTING CHART (Continued)

SYMPTOMS CAUSE REMEDY
1. (Continued.) E. Contaminants not being E. Check reservoir drain valves to insure that they
regularly drained from are functioning properly. It is recommended
system reservoirs. that the vehicle should be equipped with
functioning automatic drain valves, or have all
reservoirs drained to zero (0) psi daily, or
optimally to be equipped with a desiccant-type
air dryer prior to the reservoir system.
F. Compressor runs loaded F. Vehicle system leakage should not exceed
an excessive amount of industry standards of 1 psi pressure drop per
time. minute without brakes applied and 3 psi
pressure drop per minute with brakes applied.
If leakage is excessive, check for system leaks
and repair.
G. Excessive engine G. Test for excessive engine crankcase pressure
crankcase pressure. & replace or repair ventilation components as
necessary. (An indication of crankcase
pressure is a loose or partially lifted dipstick.)
H. Excessive engine oil H. Check the engine oil pressure with a test gauge
pressure. and compare the reading to the engine
specifications. Bendix does not recommend
restricting the compressor oil supply line
because of the possibility of plugging the
restriction with oil contaminants. Minimum oil
supply line size is 3/16" I.D. tubing.
I. Faulty compressor. I. Replace or repair the compressor only after
making certain none of the preceding
installation defects exist.

2. Noisy compressor A. Loose drive gear or A. Inspect the fit of the drive gear on the
operations. components. compressor crankshaft. The gear or coupling
must be completely seated and the crankshaft
nut must be tight. If the compressor crankshaft
surface is damaged, it is an indication of loose
drive components. If damage to the
compressor crankshaft is detected, replace the
compressor. When installing the drive gear or
pulley, torque the crankshaft nut to the
appropriate torque specifications and use care
when pressing drive components onto the
crankshaft.
Do not back off the crankshaft nut once it is
tightened to the proper torque.
Do not use impact wrenches to install the
crankshaft nut.

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COMPRESSOR TROUBLESHOOTING CHART (Continued)

SYMPTOMS CAUSE REMEDY
2. (Continued.) B. Excessively worn drive B. Inspect drive gear and couplings and engine
couplings or gears. for excessive wear. Replace as necessary.
(Nonmetallic gears should be replaced when
the compressor is changed.)
C. Compressor cylinder C. Inspect the compressor discharge port and
head or discharge line discharge line for carbon build-up. If carbon is
restrictions. detected, check for proper cooling to the
compressor. (See Cause and Remedy (D)
under Symptom #1.) Inspect the discharge line
for kinks and restrictions. Replace discharge
line as necessary.
D. Worn or burned out D. Check for proper oil pressure in the
bearings. compressor. Minimum required oil pressure; 15
psi engine idling, 15 psi maximum governed
engine rpm. Check for excessive oil
temperature—should not exceed 240 degrees
Fahrenheit.
E. Faulty compressor. E. Replace or repair the compressor after
determining none of the preceding installation
defects exist.

3. Excessive build-up and A. Dirty induction air filter. A. Inspect engine or compressor air filter and
recover time. replace if necessary.
Compressor should be B. Restricted induction line. B. Inspect the compressor air induction line for
capable of building air kinks and restrictions and replace as
system from 85-100 psi necessary.
in 40 seconds with
C. Restricted discharge line C. Inspect the compressor discharge port and line
engine at full governed
or compressor discharge for restrictions and carbon build-up. If a carbon
rpm. Minimum com-
cavity. build-up is found, check for proper compressor
pressor performance is
cooling. Replace faulty sections of the
certified to meet
discharge line.
Federal requirements
by the vehicle manu- D. Slipping drive D. Check for faulty drive gears and couplings and
facturer. Do not components. replace as necessary. Check the condition of
downsize the original drive belts and replace or tighten, whichever is
equipment compressor. appropriate.
E. Excessive air system E. Test for excessive system leakage and repair
leakage. as necessary. Use the following as a guide:
Build system pressure to governor cutout and
allow the pressure to stabilize for one minute.
Using the dash gauge, note the system
pressure and the pressure drop after two
minutes.
The pressure drops should not exceed:
1. 2 psi in each reservoir for a single vehicle.
2. 6 psi in each reservoir for a tractor and trailer.
3. 8 psi in each reservoir for a tractor and 2
trailers.

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COMPRESSOR TROUBLESHOOTING CHART (Continued)

SYMPTOMS CAUSE REMEDY
3. (Continued.) F. Sticking unloader F. Check the operation of the unloading
pistons. mechanism. Check for proper operation of the
compressor air governor and synchro valve.
Make certain the air connections between the
governor and synchro valve are correct. Refer
to figure 3. If the governor and synchro valve
are operating properly, replace the unloader
mechanism. Inspect for bent, linked or blocked
tubing leading to or from the governor and
synchro valve.
G. Faulty compressor. G. Replace or repair the compressor after
determining none of the preceding installation
defects exist.

4. Compressor fails to A. Faulty governor and A. Test the governor and synchro valve for proper
unload. synchro valve or operation and inspect air lines to and from both
installation. for kinks or restrictions. Replace or repair the
governor or synchro valve or connecting air
lines
B. Faulty or worn unloader B. Inspect for worn, dirty or corroded unloader
pistons or bores. pistons and their bores. Replace as necessary.

5. Compressor leaks oil. A. Damaged mounting A. Check the compressor mounting bolt torque. If
gasket. the mounting bolt torque is low, replace the
compressor mounting gasket before retorquing
the mounting bolts.
B. Cracked crankcase or B. Visually inspect the compressor exterior for
end cover. cracked or broken components. Cracked or
broken crankcases or mounting flanges can be
caused by loose mounting bolts. The end cover
can be cracked by overtorquing fitting or plugs
installed in the end cover. Replace or repair the
compressor as necessary.
C. Loose crankcase end C. Check the cap screw torques and tighten as
cover or bottom cover. necessary. Replace gaskets or o-ring.
D. Loose oil supply or return D. Check the torque of external oil line fittings and
line fittings. tighten as necessary.
E. Porous compressor E. Replace the compressor if porosity is found.
casting.
F. Mounting flange or end F. Replace as necessary.
cover, O-ring or gasket -
missing, cut or damaged

6. Compressor constantly A. Leaking compressor A. Repair or replace as necessary. Remove the

cycles (compressor unloader pistons. compressor inlet air strainer or fitting. With the
remains unloaded for a compressor unloaded (not compressing air),
very short time).

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COMPRESSOR TROUBLESHOOTING CHART (Continued)

SYMPTOMS CAUSE REMEDY

6. (Continued.) B. Faulty Governor or B. Test the governor and synchro valve for proper
synchro valve or operation and inspect air lines to and from both
installation. for kinks or restrictions. Replace or repair the
governor or synchro valve or connecting air
lines lines
C. Excessive system C. Test for excessive system leakage as instructed
leakage. in Symptom #3 Remedy E. Reduce leakage
wherever possible.
D. Excessive reservoir D. Drain reservoirs.
contaminants.

7. Compressor leaks A. Improperly installed A. Check torque of fittings and plugs and tighten
coolant. plugs and coolant line as necessary. Overtorqued fittings and plugs
fittings. can crack the head or block casting.
B. Freeze cracks due to B. Test antifreeze and strengthen as necessary.
improper antifreeze Check coolant flow through compressor to
strength. assure the proper antifreeze mixture reaches
the compressor.
C. Faulty compressor C. If casting porosity is detected, replace the
(porous castings). compressor.

8. Compressor head A. Restricted discharge line. A. Clear restriction or replace line.

gasket failure.

B. Loose head bolts. B. Tighten evenly to a torque of 265-292 inch

pounds.
C. Faulty compressor or C. Check for rough or poorly machined head or
head gasket. block surfaces. Replace compressor as
necessary.

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Notes

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20 BW1845 ©Honeywell Commercial Vehicle Systems Company 9/1999 Printed in U.S.A.