Compressor Removal And Disassembly; Maintenance Kits And Service Parts; Compressor Troubleshooting - BENDIX DURAFLO 596 COMPRESSOR Manual

1. With the engine running, lower air system pressure to
90 psi and raise engine RPM to 1800. Measure and
record the time required to raise system pressure from
100 psi to 130 psi. Run this test three times and use
the average time.
Note: This test should be run with the engine and
air system at normal operating temperature (i.e. not
cold).
2. Compare the average time recorded in step 2 with previ-
ously recorded build up times to evaluate compressor
performance.
Unloader leakage is exhibited by excessive compressor
cycling between the loaded and unloaded condition.
1. With service and supply system leakage below the
maximum allowable limits and the vehicle parked, bring
system pressure to governor cutout and allow the
engine to idle.
2. The compressor should remain unloaded for a minimum
of 5-10 minutes. If compressor cycling occurs more fre-
quently and service and supply system leakage is within
tolerance replace the compressor or repair the compres-
sor unloader system using a genuine Bendix
maintenance kit available from authorized
Bendix parts outlets.
COMPRESSOR REMOVAL & DISASSEMBLY
GENERAL
The following disassembly and assembly procedure is pre-
sented for reference purposes and presupposes that a rebuild
or repair of the compressor is being undertaken. Several
maintenance kits are available and the instructions provided
with these parts and kits should be followed in lieu of the
instructions presented here.
MAINTENANCE KITS & SERVICE PARTS
Cylinder Head Maintenance Kit.
Unloader Maintenance Kit.
All components shown in Figure 10 with a key number are
available in kits and/or as individual service parts.

COMPRESSOR TROUBLESHOOTING

IMPORTANT: The troubleshooting contained in this section
considers the compressor as an integrated component of
the overall air brake charging system and assumes that an
air dryer is in use. The troubleshooting presented will cover
not only the compressor itself, but also other charging
system devices as they relate to the compressor.
WARNING! PLEASE READ AND FOLLOW
THESE INSTRUCTIONS
PERSONAL INJURY OR DEATH:
When working on or around a vehicle, the following
general precautions should be observed at all times.
1. Park the vehicle on a level surface, apply the
parking brakes, and always block the wheels.
Always wear safety glasses.
2. Stop the engine and remove ignition key when
working under or around the vehicle.
working in the engine compartment, the engine
should be shut off and the ignition key should be
removed. Where circumstances require that the
engine be in operation, EXTREME CAUTION should
be used to prevent personal injury resulting from
contact with moving, rotating, leaking, heated or
electrically charged components.
3. Do not attempt to install, remove, disassemble or
assemble a component until you have read and
thoroughly understand the recommended
procedures. Use only the proper tools and observe
all precautions pertaining to use of those tools.
4. If the work is being performed on the vehicle's air
brake system, or any auxiliary pressurized air
systems, make certain to drain the air pressure
from all reservoirs before beginning ANY work on
the vehicle. If the vehicle is equipped with an
AD-IS air dryer system or a dryer reservoir module,
™
be sure to drain the purge reservoir.
5. Following the
recommended procedures, deactivate the electrical
system in a manner that safely removes all electrical
power from the vehicle.
6. Never exceed manufacturer's recommended
pressures.
7. Never connect or disconnect a hose or line
containing pressure; it may whip. Never remove a
component or plug unless you are certain all
system pressure has been depleted.
8. Use only genuine Bendix
components and kits. Replacement hardware,
tubing, hose, fittings, etc. must be of equivalent
size, type and strength as original equipment and
be designed specifically for such applications and
systems.
9. Components with stripped threads or damaged
parts should be replaced rather than repaired. Do
not attempt repairs requiring machining or welding
unless specifically stated and approved by the
vehicle and component manufacturer.
10. Prior to returning the vehicle to service, make
certain all components and systems are restored to
their proper operating condition.
11. For vehicles with Antilock Traction Control (ATC),
the ATC function must be disabled (ATC indicator
lamp should be ON) prior to performing any vehicle
maintenance where one or more wheels on a
drive axle are lifted off the ground and moving.
TO AVOID
vehicle manufacturer's
replacement parts,
®
When
9