Bendix Commercial Vehicle Systems DURAFLO 596 COMPRESSOR 10/04 - Manual (Page 6)

6
AIR INDUCTION
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-
cific requirements.
PREVENTATIVE MAINTENANCE
Regularly scheduled maintenance is the single most impor-
tant factor in maintaining the air brake charging system.
Refer to Table A in the Troubleshooting section for a guide to
various considerations that must be given to the mainte-
nance of the compressor and other related charging system
components.
Important Note: Review the warranty policy before perform-
ing any intrusive maintenance procedures. An extended
warranty may be voided if intrusive maintenance is performed
during this period.
AIR INDUCTION
One of the single most important aspects of compressor
preventive maintenance is the induction of clean air. Since
the DuraFlo
™ 596 is connected to the engine air cleaner,
proper periodic maintenance of the engine air filter eliminates
the need for separate filter maintenance.
Inspect the compressor intake adapter, and the connecting
hoses each time engine air cleaner maintenance is
performed.
1. Inspect the intake hose adapters for physical damage.
Make certain to check the adapters at both ends of the
intake hose or tubing.
2. The intake hose clamps and tighten them if needed.
3. Inspect the intake hose or line for signs of drying, crack-
ing, chafing and ruptures and replace it if necessary.
EVERY 6 MONTHS, 1800 OPERATING HOURS
OR AFTER EACH 50,000 MILES WHICHEVER OC-
CURS FIRST PERFORM THE FOLLOWING
INSPECTIONS AND TESTS.
COMPRESSOR COOLING
Inspect the compressor discharge port, inlet cavity and
discharge line for evidence of restrictions and carboning.
If excessive buildup is noted, thoroughly clean or replace
the affected parts. Since carbon buildup generally indi-
cates inadequate cooling, closely inspect the compressor
cooling system. Check all compressor coolant lines for
kinks and restrictions to flow. Minimum coolant line size
is 3/8" I.D. Check coolant lines for internal clogging from
rust scale. If coolant lines appear suspicious, check the
coolant flow and compare to the tabulated technical data
present in the back of this manual. Carefully inspect the
air induction system for restrictions.
LUBRICATION
Check the external oil supply line for kinks, bends, or re-
strictions to flow. Supply lines must be a minimum of 3/16"
I.D. Refer to the tabulated technical data in the back of this
manual for oil pressure minimum values.
Check the exterior of the compressor for the presence of oil
seepage and refer to the TROUBLESHOOTING section for
appropriate tests and corrective action.
OIL PASSING
All reciprocating compressors currently manufactured will
pass a minimal amount of oil. Air dryers will remove the
majority of oil prior to entrance into the air brake system.
For particularly oil sensitive systems the Bendix
® PuraGuard
QC ™ oil coalescing filter can be used in conjunction with a
Bendix air dryer.
If compressor oil passing is suspected, refer to the
TROUBLESHOOTING section and TABLE A for the symp-
toms and corrective action to be taken. In addition, Bendix
has developed the "Bendix Air System Inspection Cup" or
BASIC test to help substantiate suspected excessive oil
passing. The steps to be followed when using the BASIC
test are presented in APPENDIX A at the end of the
TROUBLESHOOTING section.
FIGURE 9 - TYPICAL DURAFLO ™ 596 AIR COMPRESSOR
CYLINDER HEAD
CYLINDER HEAD PORT IDENTIFICATION
The cylinder head connection ports are identified with cast
in numerals as follows:
Atmospheric AIR IN 0
Compressed AIR OUT 2
Coolant IN 91
Coolant Out 92
COOLANT
IN OR OUT
(
ONE OR THE
OTHER
PLUGGED
)
COOLANT
IN OR
OUT
DISCHARGE
PORT
INLET
PORT
LIFTING
LUG 13 x 85mm
CYL. BOLT
(6)
13 x 60mm
CYL. BOLT (2)
DISCHARGE
SAFETY VALVE