Troubleshooting Guide - BENDIX DURAFLO 596 COMPRESSOR Manual

This troubleshooting guide obsoletes and supersedes all previous published
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.
Symptom
Air
Air brake charging system:
Slow build (9.0) . . . . . . . . . . . . . . . . . 24 - 25
Doesn't build air (10.0) . . . . . . . . . . . . . . . 26
Air dryer:
Doesn't purge (14.0) . . . . . . . . . . . . . . . . . 27
Safety valve releases air (12.0) . . . . . . . . . 27
Compressor:
Constantly cycles (15.0) . . . . . . . . . . . . . . 27
Leaks air (16.0) . . . . . . . . . . . . . . . . . . . . . 28
Safety valve releases air (11.0) . . . . . . . . . 26
Noisy (18.0) . . . . . . . . . . . . . . . . . . . . . . . . 28
Reservoir:
Safety valve releases air (13.0) . . . . . . . . . 27
Test Procedures
(1) Oil Leakage at Head Gasket . . . 29
(2) System Leakage . . . . . . . . . . . . 29
(3) Compressor Discharge and
Air Dryer Inlet Temperature . . . . 29
(4) Governor Malfunction . . . . . . . . 30
(5) Governor Control Line . . . . . . . . 30
(6) Compressor Unloader . . . . . . . . 30
BASIC Test Information . . . . . . 32-34
16
troubleshooting information relative to Bendix air compressors.
INDEX
Page Number
Symptom
Coolant
Compressor leaks coolant (17.0) . . . . . . . . . . 28
Engine
Oil consumption (6.0) . . . . . . . . . . . . . . . . . . . 24
Oil
Oil Test Card results (1.0) . . . . . . . . . . . . . . . . 19
Oil is present:
On the outside of the compressor (2.0) . . . 20
At the air dryer purge/exhaust
or surrounding area (3.0) . . . . . . . . . . . 20
In the supply reservoir (4.0) . . . . . . . . 21 - 23
At the valves (5.0) . . . . . . . . . . . . . . . . . . . 23
At air dryer cartridge (7.0) . . . . . . . . . . . . . 24
In the ping tank or compressor
discharge aftercooler (8.0) . . . . . . . . . . 24
Maintenance & Usage Guidelines
Maintenance Schedule and
Usage Guidelines (Table A) . . 18
*This guide is only for vehicles that use desiccant air dryers.
*
Page Number