BENDIX D-2 GOVERNOR MODULE ASSEMBLY KIT

BENDIX D-2 /SV-1 GOVERNOR MODULE ASSEMBLY KITCompressor Mount Governor ModuleRemote Mount Governor ModuleMountingBracketBendix D-2 Governor1/4” Tubing Tee(connectionto the air dryerpurge controlport)ExhaustValveBendix SV-1 SynchroValveBendix SV-1 Delivery Port 1/4” NPT(connectionto compressorunloader port)MountingBracketD-2 GovernorPipe Tee1/8” NPT(Connectionto the air dryerpurge controlport)ExhaustValveBendix SV-1 SynchroValveBendix SV-1 Delivery Port - JIC(connectionto compressorunloader port)14” Metal Braided Hose Assembly (37 fittings)GovernorReservoir Port1/8” NPT(connection tosupply reservoirmust be 3/8Synflex tubing orequivalent)GovernorReservoir Port1/8” NPT(connection to thesupply reservoirmust be 3/8Synflex tubing orequivalent)BracketMountingHoles (2)BracketMountingHoles (2)Kit ContentsKit ContentsDescriptionDescriptionQty.Bendix D-2 /SV-1 RemoteMount Governor Module1 Figure 1 – Bendix D-2 /SV-1 Remote Mount ModuleQty.Bendix D-2/SV-1 CompressorMount Governor Module114” Metal Braided Hose Assembly1Mounting Hardware Kit1Studs2Hex Nuts2Flat Washers2Lock Washers2Figure 2 – Bendix D-2/SV-1 Compressor MountModule1

GENERAL SAFETY GUIDELINESWARNING! PLEASE READ AND FOLLOW THESE INSTRUCTIONSTO 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 theparking brakes and always block the wheels.Always wear personal protection equipment. Stop the engine and remove the ignition keywhen working under or around the vehicle.When working in the engine compartment,the engine should be shut off and the ignitionkey should be removed. Where circumstancesrequire that the engine be in operation, EXTREMECAUTION should be used to prevent personalinjury resulting from contact with moving,rotating, leaking, heated or electrically-chargedcomponents. Do not attempt to install, remove, disassembleor assemble a component until you have read,and thoroughly understand, the recommendedprocedures. Use only the proper tools andobserve all precautions pertaining to use of thosetools. If the work is being performed on the vehicle’sair brake system, or any auxiliary pressurized airsystems, make certain to drain the air pressurefrom all reservoirs before beginning ANY workon the vehicle. If the vehicle is equipped with aBendix AD-IS air dryer system, a Bendix DRM dryer reservoir module, or a Bendix AD-9si airdryer, be sure to drain the purge reservoir. F o l l o w i n g t h e v e h i c l e m a n u f a c t u r e r ’srecommended procedures, deactivate theelectrical system in a manner that safely removesall electrical power from the vehicle. Never exceed manufacturer’s recommendedpressures. Never connect or disconnect a hose or linecontaining pressure; it may whip and/or causehazardous airborne dust and dirt particles. Weareye protection. Slowly open connections withcare, and verify that no pressure is present. Neverremove a component or plug unless you arecertain all system pressure has been depleted. Use only genuine Bendix brand replacementparts, components and kits. Replacementhardware, tubing, hose, fittings, wiring, etc. mustbe of equivalent size, type and strength as originalequipment and be designed specifically for suchapplications and systems. Components with stripped threads or damagedparts should be replaced rather than repaired.Do not attempt repairs requiring machining orwelding unless specifically stated and approvedby the vehicle and component manufacturer. Prior to returning the vehicle to service, makecertain all components and systems are restoredto their proper operating condition. For vehicles with Automatic Traction Control(ATC), the ATC function must be disabled (ATCindicator lamp should be ON) prior to performingany vehicle maintenance where one or morewheels on a drive axle are lifted off the groundand moving. The power MUST be temporarily disconnectedfrom the radar sensor whenever any tests USINGA DYNAMOMETER are conducted on a vehicleequipped 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.2

MountingBracketBendix D-2 GovernorREMOVAL1. Remove as much road dirt and grease from the exteriorof the compressor and module as possible.2. Identify for re-connection, then remove the air dryerpurge tubing or hose at the pipe tee installed in SV-1valve on the module assembly. (See Figure 1 or 2.)3. Identify for re-connection, then remove the 3/8” Synflextubing or (equivalent I.D.) hose at the D-2 governorreservoir port (marked RES) on the module assembly.(See Figure 1 or 2.)Bendix SV-1 Synchro ValveFigure 3 – Obsolete Remote Mount ModuleThe Bendix D-2 /SV-1 governor module is for use withthe Bendix DuraFlo 596 compressor (refer to ServiceData Sheet SD-01-670). The module offers convenientinstallation of the required components in a single, factorypre-assembled component group and provides for eitherdirect mounting to the compressor or remote mounting asrequired by a specific application.The module is primarily intended for use when changingover to (retrofitting) the DuraFlo 596 compressor. It can alsobe used as a replacement assembly, however, individualcomponents (such as the D-2 governor and SV-1 synchrovalve) may also be replaced as required by service.Note: An earlier, and now obsolete, version of the remotemount module was in limited use. (See Figure 3.)The current module can be used to replace theseearlier versions.The module is comprised of a D-2 governor, SV-1 synchrovalve, mounting bracket and various tubing or hose alongwith the appropriate fittings.Two versions of the module are currently available;remote mount and compressor mount. Nylon tubing andtubing fittings are used on the remote mount model whilemetal braided hose and 37 hose fittings are used on thecompressor mount version.Note: The fitting in the governor reservoir port is notsupplied with the D-2/SV-1 governor module and mustbe removed and reused in the replacement unit.If the module is a compressor mount version (with metalbraided hose) proceed to Step 4. For the remote mountmodule, go to Step 7.4. Identify for re-connection, then remove the metalbraided hose from the right angle fitting installed in theSV-1 valve delivery port on the module assembly. (SeeFigure 2.)5. Remove the metal braided hose from the fitting installedin the compressor unloader port. (See Figure 4.)6. Remove the two 13mm nuts and lock washers andflat washers that secure the module mounting bracketon the studs in the rear end cover of the compressor.Remove the module from the compressor. (SeeFigure 4.) Proceed to the Installation section.7. Identify for re-connection, then remove the compressorunloader tubing at the fitting installed in the SV-1 valvedelivery port (marked DEL) on the module assembly.(See Figure 1.)Note: The SV-1 valve delivery port fitting is not suppliedwith the D-2/SV-1 governor module and must beremoved and reused in the replacement unit.8. Remove the two cap screws that secure themodule mounting bracket to the vehicle and removethe module.CompressorUnloader PortConnection andFittingGENERALThese instructions are general and are intended tobe a guide. In some cases additional preparationsand precautions are necessary. In all cases follow theinstructions contained in the vehicle maintenance manualin lieu of the instructions, precautions and procedurespresented here.If the governor module is being installed for the first time ona newly installed DuraFlo 596 compressor, go directly to theInstallation section. If the module is being used to replacean existing module, proceed to the Removal section.13mm ModuleMounting Studs,Nuts & WashersD-2 GovernorReservoir Port(connection to thesupply reservoir)Figure 4 – Compressor Mount Module Installation3

Air DryerBendixDuraFlo 596 Compressor Air Dryer PurgeControl PortSupply Reservoir(first reservoir toreceive air)Bendix D-2 Governor1/4” Synflex Tubing orEquivalent(16’ maximum length)CompressorUnloader PortBendix SV-1 Synchro Valve1/4” Synflex Tubing orEquivalent(10’ maximum length)SV-1 Delivery PortGovernorReservoir Port3/8” Synflex Tubing orEquivalent(16’ maximum length)Figure 5 – Bendix D-2 /SV-1 Governor Module InstallationINSTALLATIONGENERAL INSTALLATION NOTES1. Determine the type of installation and go to theappropriate section. Remote mount modules (partnumber 5007116) have nylon tubing and fittings whilecompressor mount modules (part number 5007404)are equipped with metal braided hose and 37 hose fittings.2. All torques specified are assembly torques andtypically can be expected to fall off after assembly isaccomplished. Do not re-torque after initial assemblytorques fall unless instructed otherwise.3. It will be necessary to install several fittings that are notsupplied in the kit. Read the appropriate instructionsfor the module being installed and obtain the fittingsrequired. When using a thread sealant on the fittings,make certain the sealant material will not enter andcontaminate the system.COMPRESSOR MOUNTED MODULE - KIT 5007404Fittings for the compressor unloader port, governorreservoir port and the pipe tee installed in the Bendix SV-1 valve are not included with the compressor mountmodule or kit.41. Facing the rear of the compressor, remove the 13mmcap screw on the top left and bottom left of thecompressor rear end cover. Install the two 13mm studsprovided in the kit. The chamfered lead threads of thestuds should be installed into the compressor. Torqueto 195-212 in-lbs.2. Install the governor module on the studs and orient itas shown in Figure 4. Secure the module bracket onthe studs installing the flat washers, then lock washersand 13mm nuts. Torque the nuts to 195-212 in-lbs.Note: Hold the stud hex when torquing the nuts.3. Install one end of the 14 inch metal braided, hoseassembly on the compressor unloader port fitting (notsupplied in kit) and the other end on the right anglefitting located in the delivery port of the SV-1. (SeeFigures 2 & 4.)4. Connect the air dryer purge tubing or hose to the fittinginstalled in the pipe tee on SV-1 (this fitting not suppliedwith the module or kit). (See Figure 2.)Note: If an air dryer is not in use on the vehicle, installa plug in the SV-1 pipe tee.5. Connect a length of hose to the D-2 governor reservoirport (marked RES) fitting (this fitting is not suppliedwith the module or kit) on the module assembly. (SeeFigures 2 & 4.)Note: The governor reservoir port air line must be 3/8”Synflex tubing or equivalent I.D. hose or tubing.