Retrofitting The Bendix Dura-Flo 596 Air Compressor to Existing Industrial Engines and Truck Engines{1803} Caterpillar

On-Highway Engines:

3406E (S/N: 1MM1-UP; 2WS1-UP)

C-10 (S/N: 3CS1-UP; 2PN1-UP; 8YS1-UP)

C-12 (S/N: 1YN1-UP; 9NS1-UP; 8YF1-UP; 2KS1-UP)

C-15 (S/N: 6NZ1-UP)

C-16 (S/N: 7CZ1-UP)

Industrial Engines:

3176C (S/N: 2AW1-UP)

3196 (S/N: 1DW1-UP)

3406E (S/N: 3LW1-UP; 6BR1-UP)

C-15 (S/N: BEM1-UP)

C-16 (S/N: BFM1-UP)

Introduction

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Before you disconnect any line from the air compressor, purge the system of pressurized air. Failure to purge the pressurized air before you service the air compressor can result in personal injury.

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Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.

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Personal injury can result from rotating and moving parts. Stay clear of all rotating and moving parts. Never attempt adjustments while the machine is moving or the engine is running unless otherwise specified. The machine must be parked on a level surface and the engine stopped.

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NOTICE
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

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NOTICE
Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Do not perform any procedure in this Special Instruction until you read this information and you understand this information.

This Special Instruction details the procedure that is used to replace the existing air compressor with a new Bendix DuraFlo 596 air compressor. There are many engine configurations that are available and some modification may be required to this instruction. The following tables list the part numbers that may be required for the installation of the new air compressor. Additional components such as fittings, lines, and wire ties may be required to complete the installation. The system must have an extended purge air dryer.

Note: Refer to the Service Manual, RENR2312 for additional information on the Bendix Dura-Flo 596 air compressor.

Procedure and Components for the Installation of Bendix DuraFlo 596 Air Compressor on 3176C,3196,C-10, and C-12 Engines

Illustration 1	g00800465

Table 1

Required Components for3176C,3196, C-10 and C-12 Engines
Callout	Part Number	Description	Qty
1A	163-6367	New Bendix DF-596 Compressor	1
OR
1B	0R-9901	Remanufactured Bendix DF-596 Compressor	1
2	117-0221	Pilot Ring	1
3	160-8137	Drive Gear	1
4	6V-7742	Nut	1
5	8T-3282	Washer	1
6	030-7948	Fitting	1
7	6V-6609	O-ring	2
8	3N-1294	Elbow	1
9	5P-7814	O-ring	1
10	030-8195	Connector	1
11	129-2181	Seal	1
12	162-8781	Rear Support Bracket	1
13	101-6596	Oil Supply Line	1
14	166-6359	Coolant Inlet Line	1
15	166-6339	Air Pipe Assembly	1
16	105-1175	Hose	2
17	3E-7424	Hose Clamp	4
18	7X-7958	Hose Clamp	2
19	5N-7444	Hose	As Required
20	069-4269	Hose Barb Coupler	2
OR
21	3E-4041	Elbow	2
22	189-2288	Air Compressor Governor	1
23	138-7573	Link Bracket	1
24	4C-9506	Retaining Compound	1
25	2M-9780	O-ring	1
26	5P-7970	Nut	2
27	9N-0869	Washer	2
28	6V-4248	Bolt	1
29	3E-4353	Washer	1
30	6V-3668	Bolt	1
31	7D-1649	Washer	1
32	6V-5048	O-ring	1
33	030-7946	Elbow	1
34	5P-9615	Connector	1

Procedure for Removing the Existing Air Compressor and the Installation of the Bendix DuraFlo 596 Air Compressor

1. Park the vehicle on a level surface. Engage the vehicle parking brake and block the vehicle wheels.

2. Stop the engine before working on the engine.

3. Verify that no interference with chassis components or engine components will prevent the installation of the new Bendix DuraFlo 596 air compressor.

4. Drain the air reservoir and drain the engine coolant.

5. Disconnect all air lines, all coolant lines, and all oil lines from the existing air compressor. Remove the existing air compressor from the engine. Retain the fasteners from the existing air compressor. Reuse the fasteners on the new air compressor.

6. The new Bendix DuraFlo 596 air compressor utilizes a non-boosted air inlet. Determine if the prior air compressor used turbocharged air. Remove the air intake hose from the engine intake manifold if the prior air compressor used turbocharged air. Plug the open port on the air intake manifold with a plug of the appropriate type and the appropriate thread. If the prior air compressor used turbocharged air, see the procedure that follows on the installation of the air inlet line.

7. Remove the coolant outlet line for the air compressor. Insert a plug of the appropriate type and appropriate thread in the open coolant port of the engine.

8. The Bendix DuraFlo 596 air compressor drains the oil used for lubrication back into the engine through the mounting flange of the air compressor. On conversions of Bendix TuFlo 1400 air compressors, the open oil return port must be plugged. Insert a pipe plug of the appropriate type and of the appropriate thread in the open oil return port that was used by the Bendix TuFlo 1400 air compressor.

9. Apply retaining compound (24) to the mating surface of the pilot ring (2). Assemble the pilot ring to the air compressor.

10. Assemble the air compressor drive gear (3) to the air compressor with the nut (4) and washer (5). Refer to Disassembly and Assembly, SENR1002, "Air Compressor Drive Gear - Install" for the proper procedure. Torque the nut (4) to 160 ± 15 N·m (118 ± 11 lb ft). Strike the gear with a soft faced hammer in order to seat the gear on the tapered shaft. Tighten the gear again to 160 ± 15 N·m (118 ± 11 lb ft).

11. Assemble O-rings (7) to the inlet fitting (6) for the coolant and to the outlet fitting (34) for the coolant. Install inlet fitting (6) and outlet fitting (34) into the air compressor.

12. Assemble the O-ring (25) to the connector (10). Install the connector (10) in the unloader port of the air compressor.

13. Install the seal (11) between the front housing and the air compressor. Install the link bracket (23) and a proper lifting device to the air compressor. The weight of the Bendix DuraFlo 596 air compressor is approximately 23 kg (50 lb).

14. Position the air compressor in the front housing. Ensure that the drive gear engages correctly with the gear in the front housing. Use the nuts, washers or bolts from the prior air compressor to mount the new air compressor. Torque the fasteners to standard torque.

15. Install the rear support bracket (12) onto the studs on the rear of the air compressor. Assemble the nuts (26) and washers (27) onto the rear of the air compressor. Install bolt (28) and washer (29) in the upper hole of the cylinder block. Install bolt (30) and washer (31) in the lower hole of the cylinder block. Tighten all nuts and bolts finger tight in order to position the bracket correctly. Tighten all nuts and bolts to standard torque.

16. Install O-ring (9) onto the elbow (8). Install the elbow (8) for the oil supply into the air compressor. Install the oil supply line (13) onto the elbow. Install the O-ring (32) onto the elbow (33). Install the elbow (33) into the engine cylinder block. Install the oil supply line to the elbow.
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    Table 2

    Port Size and Fitting Torque
    Port	Thread Size	Torque (In. Lb)
    Air Inlet	1-1/16-12UNF	531-575
    Air Discharge	1-1/16-12UNF	531-575
    Coolant Inlet and Outlet	3/4-16UNF	221-248
    Unloader	7/8-14UNF	221-248
    Oil Supply	1/2-20UNF	177-204
    Safety Valve	3/4-16UNF	221-248

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    Table 3

    Recommended Sizes of Lines
    Line	Minimum Size
    Air Inlet	1 inch Id.
    Air Discharge	0.5 inch Id.
    Coolant Inlet and Outlet	0.40 inch Id.
    Oil Supply	0.18 inch Id.

Procedure for the Installation of the Coolant Inlet Line and the Coolant Outlet Line

1. Install the coolant inlet line (14) to the air compressor cylinder head.

2. Locate a plugged port on the intake side of the water pump housing. If no port is available find a port that will allow the installation of a tee. Install the appropriate tee fittings for the coolant outlet hose.

3. Measure an appropriate length of hose and cut an appropriate length of hose for the water outlet line. Install the proper hose clamps on the outlet line. Install the outlet line to the outlet fitting (34) of the air compressor. Route the coolant outlet line to the water pump. Install the coolant outlet line to the inlet fitting on the water pump. The coolant outlet line must not come into contact with other engine components. Contact with other engine components may cause wear to the coolant outlet line. Use tie straps to secure the coolant outlet line.

Procedure for Installation of the Air Inlet Line

Illustration 2	g00800635

1. The new Bendix Dura-Flo 596 utilizes a non-boosted air inlet. The location for the air supply line must be between the air cleaner and the engine turbocharger. If the prior air compressor used a non-boosted air inlet the prior air inlet line may be reused. If the prior air compressor used turbocharged air for the supply, see the following steps.

2. Determine if the vehicle has a 152 mm (6 inch) air intake pipe. Cut the air intake pipe and remove all the metal burrs. Use the air pipe assembly (15) with a 25 mm (1 inch) hose barb coupler. Install the air pipe assembly (15) with hose (16) and clamps (17) .

3. Determine the length of the air inlet hose (19) that is required. Cut the air inlet hose (19) to the required length. Install the air inlet hose to the pipe assembly (15) and to the hose barb coupler (20) or elbow (21) with the hose clamps (18).

4. Refer to Testing and Adjusting, SENR6593, "Air Inlet and Exhaust System" for the proper procedure to measure the pressure in the air intake. The engine intake vacuum must not be more than 635 mm (25 inches) of water. Check the condition of the air cleaner element or reduce the length of the inlet hose (19) if the engine vacuum is more than 635 mm (25 inches) of water.

Procedure for Installation of the Discharge Line for the Air Compressor

1. Determine if the existing air line to the extended purge air dryer may be reused. When a new discharge line is required, replace the compressor discharge line with a discharge line of the proper dimension. Install the hose for the air dryer to the hose barb coupler (20) or the elbow (21) with the appropriate hose clamp.

Procedure and Components for the Installation of Bendix DuraFlo 596 Air Compressor on 3406E,C-15, and C-16 Engines

Table 4

Required Components for 3406E,C-15, and C-16 Engines
Callout	Part Number	Description	Qty
1A	175-6779	New Bendix DF-596 Compressor	1
OR
1B	0R-9900	Remanufactured Bendix DF-596 Compressor	1
2	178-8095	Pilot Ring	1
3	155-6635	Drive Gear	1
4	6V-7742	Nut	1
5	8T-3282	Washer	1
6	030-7948	Fitting	1
7	6V-6609	O-ring	2
8	3N-1294	Elbow	1
9	5P-7814	O-ring	1
10	030-8195	Connector	1
11	144-6142	Seal	1
12	103-6037	Adapter	1
13	170-8738	Oil Supply Line	1
14	185-0799	Coolant Inlet Line	1
15	166-6339	Air Pipe Assembly	1
16	105-1175	Hose	2
17	3E-7424	Hose Clamp	4
18	7X-7958	Hose Clamp	2
19	5N-7444	Hose	As Required
20	069-4269	Hose Barb Coupler	2
OR
21	3E-4041	Elbow	2
20	189-2288	Air Compressor Governor	1
21	138-7573	Link Bracket	1
22	4C-9506	Retaining Compound	1
23	5P-9615	Connector	1
25	2M-9780	O-ring	1
32	6V-5048	O-ring	1
33	03-7946	Elbow	1
34	0S-1588	Bolt	2
35	5M-2894	Washer	2

Procedure for Removing the Existing Air Compressor and the Installation of the Bendix DuraFlo 596 Air Compressor

1. Park the vehicle on a level surface. Engage the vehicle parking brake and block the vehicle wheels.

2. Stop the engine before working on the engine.

3. Verify that no interference with chassis components or engine components will prevent the installation of the new Bendix DuraFlo 596 air compressor.

4. Drain the air reservoir and drain the engine coolant.

5. Disconnect all air lines, all coolant lines, and all oil lines from the existing air compressor. Remove the existing air compressor from the engine. Retain the fasteners from the existing air compressor. Reuse the fasteners on the new air compressor.

6. The new Bendix DuraFlo 596 air compressor utilizes a non-boosted air inlet. Determine if the prior air compressor used turbocharged air. Remove the air intake hose from the engine intake manifold if the prior air compressor used turbocharged air. Plug the open port on the air intake manifold with a plug of the appropriate type and the appropriate thread. If the prior air compressor used turbocharged air, see the procedure that follows on the installation of the air inlet.

7. Remove the coolant outlet line for the air compressor. Insert a plug of the appropriate type and appropriate thread in the open coolant port of the engine.

8. Apply retaining compound (22) to the mating surface of the pilot ring (2). Assemble the pilot ring to the air compressor.

9. Assemble the air compressor drive gear (3) to the air compressor with the nut (4) and washer (5). Refer to Disassembly and Assembly, RENR1277, "Air Compressor Drive Gear - Install" for the proper procedure. Torque the nut (4) to 160 ± 15 N·m (118 ± 11 lb ft). Strike the gear with a soft faced hammer in order to seat the gear on the tapered shaft. Tighten the gear again to 160 ± 15 N·m (118 ± 11 lb ft).

10. Assemble O-ring (7) to the inlet fitting (6) for the coolant. Assemble O-ring (7) to the outlet fitting (23) for the coolant. Install inlet fitting (6) and outlet fitting (23) into the air compressor.

11. Assemble the O-ring (25) to the connector (10). Install the connector (10) into the unloader port of the air compressor.

12. Install the seal (11) between the front housing and the air compressor. Install the link bracket (21) and a proper lifting device to the air compressor. The weight of the Bendix DuraFlo 596 air compressor is approximately 23 kg (50 lb).

13. Position the air compressor in the front housing. Ensure that the drive gear engages correctly with the gear in the front housing. Use the nuts, washers or bolts from the prior air compressor to mount the new air compressor. Torque the fasteners to standard torque.

14. The Bendix DuraFlo 596 air compressor drains the oil used for lubrication back into the engine through the mounting flange of the air compressor. Install adapter (12) on the engine cylinder block in order to convert the C-15, C-16, and 3406E engines that used a Bendix TuFlo 1400 air compressor. Install adapter (12) to the engine cylinder block with bolts (34) and washers (35). Install O-ring (9) onto the elbow (8). Install the elbow into the air compressor. Install the oil supply line (13) onto the elbow of the air compressor. Install the O-ring (32) onto the elbow (33). Install the elbow (33) into the top of the adapter (12). Install the oil supply line to the elbow.
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    Table 5

    Port Size and Fitting Torque
    Port	Thread Size	Torque (In. Lb)
    Air Inlet	1-1/16-12UNF	531-575
    Air Discharge	1-1/16-12UNF	531-575
    Coolant Inlet and Outlet	3/4-16UNF	221-248
    Unloader	7/8-14UNF	221-248
    Oil Supply	1/2-20UNF	177-204
    Safety Valve	3/4-16UNF	221-248

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    Table 6

    Recommended Sizes of Lines
    Line	Minimum Size
    Air Inlet	1 inch Id.
    Air Discharge	0.5 inch Id.
    Coolant Inlet and Outlet	0.40 inch Id.
    Oil Supply	0.18 inch Id.

Procedure for the Installation of the Coolant Inlet Line and the Coolant Outlet Line

Illustration 3	g00797427

1. Install the coolant inlet line (14) to the air compressor cylinder head.

2. Locate a plugged port on the intake side of the thermostat housing. If no port is available find a port that will allow the installation of a tee. Install the appropriate tee fittings.

3. Measure an appropriate length of hose and cut an appropriate length of hose for the water outlet line. Install the proper hose clamps on the outlet line. Install the outlet line to the outlet fitting (34) of the air compressor. Route the coolant outlet line to the thermostat housing. Install the coolant outlet line to the thermostat housing with the appropriate hose clamp. The coolant outlet line must not come into contact with other engine components. Contact with other engine components may cause wear to the coolant outlet line. Use tie straps to secure the coolant outlet line.

Procedure for Installation of the Air Inlet Line

1. The new Bendix Dura-Flo 596 utilizes a non-boosted air inlet. The location for the air supply line must be between the air cleaner and the engine turbocharger. If the prior air compressor used a non-boosted air inlet the prior air inlet line may be reused. If the prior air compressor used turbocharged air for the supply, see the following steps.

2. Determine if the vehicle has a 152 mm (6 inch) air intake pipe. Use the air pipe assembly (15) with a 25 mm (1 inch) hose barb coupler. Cut the air intake pipe and remove all the metal burrs. Install the air pipe assembly (15) with hose (16) and clamps (17) .

3. Determine the length of the air inlet hose (19) that is required. Cut the air inlet hose (19) to the required length. Install the air inlet hose to the pipe assembly (15) and to the intake fitting (20) or (21) with the hose clamps (18).

4. Refer to Testing and Adjusting, SENR6593, "Air Inlet and Exhaust System" for the proper procedure to measure the pressure in the air intake. The engine intake vacuum must not be more than 635 mm (25 inches) of water. Check the condition of the air cleaner element or reduce the length of the inlet hose (19) if the engine vacuum is more than 635 mm (25 inches) of water.

Procedure for Installation of the Discharge Line for the Air Compressor

1. Determine if the existing air line to the extended purge air dryer may be reused. When a new discharge line is required, replace the compressor discharge line with a discharge line of the proper dimension. Install the hose to the hose barb coupler (20) or the elbow (21) with the appropriate hose clamp.

Procedure for Installation of the Air Compressor Governor

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Illustration 4	g00797430

1. Determine a location in order to mount the air compressor governor. The module may be mounted on the air compressor if there is no interference with other engine components. The module may be mounted in a remote location on the vehicle. Determine that the lengths of the air lines are not longer than the specified limits.

Table 7

Required Components for Air Compressor Governor
Callout	Part Number	Description	Qty
1	7D-9949	Valve Assembly	1
2	175-3170	Stud	2
3	183-6689	Flared Tee	1
4	189-1918	Bracket	1
5	189-1919	Air Valve	1
6	189-1920	Air Compressor Governor	1
7	189-1922	Hose	1
8	1891923	Hose	1
9	1891924	Hose	1
10	1D-4541	Bolt	1
11	2N-1287	Flared Elbow	1
12	3B-6768	Reducing Bushing	1
13	5J-7303	Flared Elbow	1
14	5P-0537	Washer	4
15	5P-7970	Nut	2
16	5S-0003	Nut	1
17	6K-1972	Flared Elbow	1
18	8B-2377	Bolt	1
19	8S-4711	Bolt	1
20	8T-6757	Pipe Plug	3
21	9L-5125	Elbow	1
22	9M-1974	Washer	5
23	9S-8750	Nut	2
24	030-8195	Flared Connector	1

Illustration 5	g00796956
Brake System Air Supply

Illustration 6	g00800140
Air Compressor Governor

Procedure for Installing the Air Compressor Governor on the Air Compressor

1. Remove the upper left end cover bolt and the lower left end cover bolt from the rear of the compressor. Install the two studs (2). Install the chamfered threads into the compressor. Torque the studs to 23 ±1 N·m (204 ± 8 lb in).

2. Position the air compressor governor onto the studs. Position the compressor governor with the cap end on top. Install the washers (22) and nuts (15). Tighten the nuts to 23 ± 1 N·m (204 ± 8 lb in).

3. Install the flared connector (24) into the compressor unloader port. Torque the flared connector to 27 ± 1 N·m (236 ± 12 lb in). Install one end of the hose (9) to flared elbow (17). Attach the opposite hose end to the flared connector (24). Tighten the fittings to standard torque.

4. The existing air line for the air compressor governor may be used if the length is adequate. Connect the air line to the port of the governor control air reservoir with the appropriate fitting. These fittings are not supplied with the kit. Connect the other end of the air line to the tee on the governor.

   Replace the lines if the lines are not long enough. Replace the lines if the lines are not of the appropriate diameter. Determine that all lines do not contact engine components or contact chassis components that may cause wear. Use tie straps to secure the air lines.

Remote Mounted Governor

1. Determine that the location for the remote mount is protected from dirt and water. Mount the bracket for the governor to the vehicle. Mount the governor with the exhaust valves in a downward position.

2. Connect an appropriate length of 6.35 mm (0.25 inch) tubing to the unloader port of the air compressor with the proper fittings. Connect the other end to the flared elbow (17) with the proper fittings.

3. The existing air line for the air compressor governor may be used if the length is adequate. Connect the air line to the port of the governor control air reservoir with the appropriate fitting. Connect the other end of the air line to the tee on the governor.

   These fittings are not supplied with the kit. Replace the lines if the lines are not long enough. Replace the lines if the lines are not of the appropriate diameter. Determine that all lines do not contact other engine components that may cause wear. Use tie straps to secure the air lines.

Operating Tests

1. Refill engine coolant to proper levels.

2. Refer to Service Manual, RENR2312, "BendixDuraFlo 596 Air Compressor " in order to perform a test on the compressor. Start the vehicle engine. Monitor the dash mounted air pressure gauge. Determine that the air compressor is building up air pressure in the air supply tank.

3. Allow the air compressor to fully cycle. Check that the air pressure in the system has built up to system specifications. Use a soap solution in order to check all fittings for air leakage. If air leakage is detected tighten fittings.

4. Operate the compressor through the loaded state and operate the compressor through the unloaded state. Operate the brakes of the vehicle in order to reduce the air pressure in the system. Verify that the air compressor governor activates at approximately 760 kPa (110 psi). Verify that the air compressor governor deactivates at approximately 900 kPa (130 psi).

5. The air compressor should cycle between the loaded position and the unloaded position quickly. This may be checked by installing a test gauge in the unloader port that is not used on the air compressor. Observe the gauge during the change from the loaded position and the unloaded position. The air pressure should be applied and the air pressure should be exhausted quickly. There should not be any lag between the buildup of the air pressure and the release of the air pressure. If prompt action is not noted check the installation for a restriction in the tubing or in the hoses.