User's Manual
14
plunger bore and depress the plunger (21) several
times. The plunger (21) should move freely with only
spring tension resistance noted. If greater resistance
is noted the sliding inlet valve (13) is pinched and the
cylinder head and valve body must be removed and
the sliding inlet valve (13) must be repositioned within
the opening of the meatal gasket (18). Repeat this
procedure for the other unloader plunger and sliding
inlet valve.
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 fi gure eight pattern.
9. Apply a thread sealant to the assembled plug
and sealing washer (19 & 20) and install it in the
cylinder block unloader bore that was marked during
disassembly. Tighten suffi ciently 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 fl ange 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.
4. Install the discharge and inlet fi ttings, if applicable, in
the same position on the compressor noted and marked
during disassembly. Make certain the threads are
clean and the fi ttings are free of corrosion. Replace as
necessary.
5. Inspect all air, oil, and coolant lines and fi ttings 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 briefl y to be sure oil is
fl owing freely through the supply line.
7. Before returning the vehicle to service, perform the
Operation and Leakage Tests specifi ed 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
conditions, 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 effi ciency or
build up test can be run which is not too diffi cult. An engine
lubricated 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.
Connect to the compressor discharge port, a reservoir with
a 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
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.
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 fl ow 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