Installing The Compressor; Testing Rebuilt Compressor; Compressor Specifications; Torque Specifications - BENDIX DURAFLO 596 COMPRESSOR Manual

7. Torque the two 13mm x 60mm head bolts to 265 - 292
inch pounds.
8. Beginning with one of the center bolts, torque the six
13mm x 85mm head bolts to 265 - 292 inch pounds
using a figure eight pattern.
9. Apply a thread sealant to the assembled plug and seal-
ing washer (19 & 20) and install it in the cylinder block
unloader bore that was marked during disassembly.
Tighten sufficiently to seal air pressure.

INSTALLING THE COMPRESSOR

1. If the compressor was removed for replacement, install
the drive components. Torque the crankshaft nut to 120
foot pounds.
2. Install any supporting bracketing on the compressor in
the same position noted and marked during removal.
3. Install the 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. Gas-
ket sealants are not recommended. Secure the
compressor on the engine and tighten the mounting
bolts.
4. 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.
5. 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.
6. Clean 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.
7. Before returning the vehicle to service, perform the
Operation and Leakage Tests specified in this manual.
Pay particular attention to all lines reconnected during
installation and check for air, oil, and coolant leaks
at compressor connections. Also check for noisy
operation.

TESTING REBUILT COMPRESSOR

In order to properly test a compressor under operating con-
ditions, a test rack for correct mounting, cooling, lubricating,
and driving the compressor is necessary. Such tests are
not compulsory if the unit has been carefully rebuilt by an
experienced person. A compressor efficiency or build up
test can be run which is not too difficult. An engine lubri-
cated compressor must be connected to an oil supply line
of at least 15 psi. pressure during the test and an oil return
line must be installed to keep the crankcase drained. Con-
nect to the compressor discharge port, a reservoir with a
14
volume of 1500 cubic inches, including the volume of the
connecting line. 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 5 seconds. During
this test, the compressor should be checked for gasket leak-
age 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 disas-
sembly procedure.
DURAFLO

596 COMPRESSOR SPECIFICATIONS

™
Typical weight ........................................................ 50 lbs.
Number of cylinders ........................................................ 2
Bore size .............................................. 3.465 in. (88 mm)
Stroke ................................................... 1.968 in. (50 mm)
Calculated displacement at 1250 RPM ................ 27 CFM
Flow Capacity @ 2100 RPM & 120 PSI ............... 23 CFM
Maximum recommended RPM ........................ 3000 RPM
Minimum coolant flow maximum RPM ...... 2.5 Gals./Min.
Approximate horsepower required:
Loaded 1800 RPM at 120 PSIG ............................ 7.5 HP
Unloaded 1800 RPM .............................................. 0.9 HP
Maximum inlet air temperature ............................... 250°F
Maximum discharge air temperature ...................... 400°F
Minimum oil pressure required at
engine idling speed ............................................. 15 PSI
Minimum oil pressure required at
maximum governed engine speed ...................... 15 PSI
Minimum oil-supply line size ............................. 3/16" I.D.
Minimum unloader-line size ............................... 3/16" I.D.
Minimum Governor Cutout Pressure ..................... 130 PSI

TORQUE SPECIFICATIONS

Assembly Torques in inch pounds (in. Ibs.)
13mm Cylinder Head Bolts ................................. 265 - 292
10mm Valve Bolts ............................................... 101 -111
Rear End cover or adapter Bolts/Studs .............. 195 - 212
Bottom Cover ...................................................... 97 - 115
Crankshaft Nut .............................................. 1200 - 1440
Metric (Detroit Diesel)
M12 x 1.5 ..................................................................... 222
M16 x 1.5 ..................................................................... 386
M22 x 1.5 ..................................................................... 531
M27 x 2 ........................................................................ 792
U.S. (Caterpillar)
1/2"-20 UNF ................................................................ 222
3/4"-16 UNF ................................................................ 398
7/8"-14 UNF ................................................................ 531
1 1/16"-12 UNF ........................................................... 792