BENDIX DURAFLO 596 COMPRESSOR Manual
Hide thumbs Also See for DURAFLO 596 COMPRESSOR:
Table of Contents

Advertisement

®
Bendix
DuraFlo
®
DISCHARGE
DISCHARGE
VALVE
HOLDER
VALVE BODY
ASSY.
PISTON
PISTON RINGS
CRANKSHAFT

DESCRIPTION

The function of the air compressor is to provide and main-
tain air under pressure to operate devices in the air brake
and/or auxiliary air systems. The DuraFlo
is a two cylinder reciprocating compressor with a rated dis-
placement of 27 cubic feet per minute at 1250 RPM.
The compressor consists of a water cooled cylinder head
and valve body assembly and an air cooled integral
crankcase and cylinder block. The cylinder head is an
aluminum casting which contains the required air and water
ports as well as inlet check valves for each cylinder. The
valve body assembly consists of steel upper and lower
halves, each of which incorporate various valve openings
and channels for conducting air and engine coolant into
and out of the cylinder head. The discharge valves for
each cylinder are part of the valve body assembly. The
valve body assembly is secured to the cylinder head
596 Air Compressor
CYLINDER
VALVE
CONNECTING
ROD
596 compressor
HEAD
CYLINDER
HEAD
VALVE BODY
UNLOADER
PORT
CRANKCASE
CRANKCASE
DISCHARGE
VALVE
DISCHARGE
PORTS (2)
CYLINDER
BORE
PISTON
VIEW OF CYINDER HEAD AND ONE CYLINDER BORE
FIGURE 1 - DURAFLO
DISCHARGE
SAFETY VALVE
WATER
INLET
PORT (2)
DISCHARGE
CAVITY
596 AIR COMPRESSOR
WATER
OUTLET
PORT (1)
REAR END
COVER OIL
PORT
CRANKCASE
BOTTOM
COVER (2)
DISCHARGE
VALVE HOLDER
1

Advertisement

Table of Contents
loading

Summary of Contents for BENDIX DURAFLO 596 COMPRESSOR

  • Page 1 ® Bendix DuraFlo 596 Air Compressor ® ™ WATER DISCHARGE OUTLET SAFETY VALVE WATER DISCHARGE DISCHARGE CYLINDER PORT (1) INLET VALVE VALVE HEAD PORT (2) HOLDER CYLINDER HEAD VALVE BODY VALVE BODY ASSY. ASSEMBLY UNLOADER PISTON PORT REAR END COVER OIL...
  • Page 2 DETROIT DIESEL CATERPILLAR reduces compressor power consumption by approximately FIGURE 2 - TYPICAL COMPRESSOR DRIVE FLANGES 80% in the unloaded mode. The ESS also reduces assembly using two cap screws and the cylinder head is compressor oil consumption (oil passing) when the secured to the cylinder block with six cap screws.
  • Page 3 pressure the discharge valves open and air flows into the INLET CHECK discharge line and air brake system. DISCHARGE VALVE OPEN INLET PORT PORT NON-COMPRESSION OF AIR (UNLOADED) CHAMBER When air pressure in the supply reservoir reaches the cut- out setting of the governor, the governor delivers system INLET VALVE air to the control port of the synchro valve.
  • Page 4 SLIDING a compressor with a normal (less than 25%) duty cycle, INLET VALVE operating in a temperate climate. See Bendix and/or other air dryer manufacturer guidelines as needed. FIGURE 7 - UNLOADER MECHANISM The discharge line must maintain a constant slope down COMPRESSOR &...
  • Page 5 (Supply Reservoir) ® Compressor) Reservoir Drain FIGURE 8A - SYSTEM DRAWING For vehicles with accessories that are sensitive to small amounts of oil, we recommend installation of a Bendix ® PuraGuard oil coalescing filter, designed to minimize ® ™ the amount of oil present.
  • Page 6 TROUBLESHOOTING section and TABLE A for the symp- The cylinder head connection ports are identified with cast toms and corrective action to be taken. In addition, Bendix in numerals as follows: has developed the "Bendix Air System Inspection Cup" or...
  • Page 7 This can be definitely component leakage tests and the Bendix “Test confirmed by installing a test gauge in the unused and Checklist” published in the Air Brake Sys-...
  • Page 8 VALVE BODY ASSY. CYLINDER HEAD CRANKCASE & CYLINDER BLOCK FLANGE MOUNT END COVER Item Qty. Description Item Qty. Description Item Description 13mm x 85mm Bolt Discharge Valve Backup Ring 13mm x 60mm Bolt Sliding Inlet Vlv Spring 10mm x 25mm Bolt Pivot Arm 13mm Washer Spacer Sleeve...
  • Page 9: Compressor Troubleshooting

    4. If the work is being performed on the vehicle’s air tolerance replace the compressor or repair the compres- brake system, or any auxiliary pressurized air sor unloader system using a genuine Bendix systems, make certain to drain the air pressure maintenance kit available from authorized from all reservoirs before beginning ANY work on Bendix parts outlets.
  • Page 10 REMOVAL UNLOADER & INLET VALVE 1. Remove the discharge safety valve (26) from the cylin- These instructions are general and are intended to be a guide. der head. In some cases additional preparations and precautions are necessary. In all cases follow the instructions contained in 2.
  • Page 11 5. Remove the two 10mm x 25mm discharge valve bolts OIL PASSAGES (9) that secure the discharge check valve components. Thoroughly clean all oil passages through the end cover or Remove the spacer sleeve (10), holder (11) and dis- end cover adapter. Inspect the passages with a wire to be charge valve (12).
  • Page 12 ASSEMBLY 2. Locate one of the two inlet check valve holders (5). Place the holder (5) on the inlet check valve (6) making cer- General Note: All torques specified in this manual are as- tain that the three indentations around the bolt hole, on sembly torques and typically can be expected to fall off the holder, interlock with the tabs on the inlet check after assembly is accomplished.
  • Page 13 certain the free tip of the discharge valve (12) is not 4. Locate one of the sliding inlet valves (13) and place it on pinched between the holder (11) and the valve body as- a flat surface. Note that there is a concave and convex sembly.
  • Page 14 7. Torque the two 13mm x 60mm head bolts to 265 - 292 volume of 1500 cubic inches, including the volume of the inch pounds. connecting line. With the compressor operating at 2100 RPM., the time required to raise the reservoir(s) pressure 8.
  • Page 15 DIMENSIONAL DATA Port Sizes Metric (Detroit Diesel) Water inlet ............M16 x 1.5 Water outlet ............M16 x 1.5 Discharge Safety Valve ........M16 x 1.5 Air discharge ............M27 x 2 Unloader Port ............. M22 x 1.5 Oil inlet (end cover or adapter) ......M12 x 1.5 U.S.
  • Page 16 This troubleshooting guide obsoletes and supersedes all previous published troubleshooting information relative to Bendix air compressors. Advanced Troubleshooting Guide for Air Brake Compressors The guide consists of an introduction to air brake charging system components, a table showing recommended vehicle maintenance schedules, and a troubleshooting symptom and remedy section with tests to diagnose most charging system problems.
  • Page 17 (less than 25%) duty cycle, system and lubricated by the engine oil supply. operating in a temperate climate. See Bendix and/or other air dryer manufacturer guidelines as needed. The compressor's unloader mechanism and governor...
  • Page 18 Note: To help prevent discharge line freeze-ups, shorter discharge recommended every 250,000 miles. line lengths or insulation may be required in cold climates. (See Bendix Bulletins TCH-08-21 and TCH-08-22, included in Appendix B, for more information.) 5 For certain vehicles/applications, where turbo-charged inlet air is used, a smaller size...
  • Page 19 Do not use this card test to diagnose û compressor "oil passing" issues. They are subjective and error prone. Use only the Bendix Air System Inspection Cup (BASIC) test and the methods described in this guide for advanced troubleshooting. The Bendix...
  • Page 20 Return the vehicle to service. An optional kit (Bendix piece number 5011327 for the Bendix AD-IS or AD-IP ™ ™ ® air dryers, or 5003838 for the Bendix ® AD-9 air dryer) is available to redirect the ™ air dryer exhaust.
  • Page 21 1-800-AIR-BRAKE air dryer maintenance has not (1-800-247-2725) and been performed as in Column 3. speak to a Tech Team member.) ð Drain all air tanks into Bendix BASIC test (b) If the vehicle maintenance has ® ™ cup (Bendix Air System Inspection Cup).
  • Page 22 45 degree fitting. For more Kinked discharge line shown. information on how to help prevent discharge line freeze-ups, see Bendix Bulletins TCH-08-21 and TCH-08-22 (Appendix B). Shorter discharge line lengths or insulation may be required in cold climates.
  • Page 23 Note: After replacing a compressor, investigated. Bendix compressors are designed to residual oil may take a considerable period have a 'dry' sump and the presence of excess oil in of time to be flushed from the air brake the crankcase can lead to oil carryover.
  • Page 24 Symptom: What it may indicate: What you should do: A problem with engine or other engine ð See engine service manual. 6.0 Excessive oil consumption in accessory. engine. The engine service manual has more information. 7.0 Oil present at ð Air dryers remove water and oil from the air Air brake charging system is air dryer cartridge brake charging system.
  • Page 25 90 degree fitting, it may be changed to a straight or 45 degree fitting. For more information on how to help prevent discharge line freeze-ups, see Bendix Bulletins TCH-08-21 TCH-08-22 (Appendix B). Shorter discharge line lengths or insulation may be required in cold climates.
  • Page 26 45 degree fitting. For more information on how to help prevent discharge line freeze-ups, see Bendix Bulletins TCH- 08-21 and TCH-08-22 (Appendix B). Shorter discharge line lengths or insulation may be required in cold climates.
  • Page 27 Symptom: What it may indicate: What you should do: ð Inspect delivery lines to reservoir for 12.0 Air dryer (a) Restriction between air dryer and safety valve reservoir. restrictions and repair as needed. releases air. ð Verify relief pressure is at vehicle or (b) Air dryer safety valve malfunction.
  • Page 28 Symptom: What it may indicate: What you should do: (a) Compressor leaks ð Check for leaking, damaged or defective 16.0 Compressor connections or ports. compressor fittings, gaskets, etc. Repair leaks air or replace as necessary. (b) Compressor unloader mechanism ð Go to Test 6 on page 30. malfunction.
  • Page 29 Tests Test 1: Excessive Oil Leakage at the Head Gasket Exterior leaks at the head gasket are not a sign that oil is being passed into the air charging system. Oil weepage at the head gasket does not prevent the compressor from building air. LOOK Observe the amount of weepage from the head gasket.
  • Page 30 Test 6: Compressor Unloader Leakage off and charge the unloader port by allowing air Bendix Compressors: Park vehicle, chock ® pressure to enter the hose and unload the wheels, and follow all standard safety procedures.
  • Page 31 NOTES...
  • Page 32 YES, number of days with a Bendix air dryer that are properly maintained.) If, in cold was known (30 - 90 days) weather conditions, the 30 day air tank drain schedule is longer Replace the Compressor.
  • Page 33 Footnote 2: To get an accurate reading for the amount of oil collected during a 30 day period, ask the customer not to drain the air tanks before returning. (Note that 30-90 days is the recommended air tank drain schedule for vehicles equipped with a Bendix air dryer that are properly maintained.) If, in cold weather conditions, the 30 day air tank drain schedule is longer than the customer's usual draining interval, the customer...
  • Page 34 Appendix A continued: Information about the BASIC Test Kit (Bendix P/N 5013711) ™ ® Filling in the Checklist for the Bendix Air System Inspection Cup (BASIC ) Test ™ Note: Follow all standard safety precautions. For vehicles using a desiccant air dryer.
  • Page 35 Last 3 feet, including fitting at the end of the discharge line, must be insulated with ½ inch thick closed cell polyethylene pipe insulation. If the discharge line length must be less than 6 feet or greater than 16 feet, contact your local Bendix representative.
  • Page 36 10-16 ft. ½ in. None If the discharge line length must be less than 10 feet or greater than 16 feet, contact your local Bendix representative. System Leakage Check the air brake system for excessive air leakage using the Bendix “Dual System Air Brake Test and Check List”...
  • Page 37 Appendix B: Continued Technical Bulletin Bulletin No.: TCH-008-022 Effective Date: 1/1/1994 Page: 1 of 1 Additional Cold Weather Operation Tips for the Air Brake System Subject: Last year we published Bulletin PRO-08-21 which provided some guidelines for “winterizing” a vehicle air brake system.
  • Page 40 BW1845 © 2004 Bendix Commercial Vehicle Systems LLC. All rights reserved. 10/2004 Printed in U.S.A.

Table of Contents