User's Manual

6
PREVENTATIVE MAINTENANCE
Regularly scheduled maintenance is the single most
important 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 maintenance of the compressor and other related
charging system components.
Important Note: Review the warranty policy before
performing 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
fi lter eliminates the need for separate fi lter 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. Inspect the intake hose clamps and tighten them if
needed.
3. Inspect the intake hose or line for signs of drying,
cracking, chafing and ruptures and replace it if
necessary.
EVERY 6 MONTHS, 1800 OPERATING HOURS
OR AFTER EACH 50,000 MILES WHICHEVER
OCCURS 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 indicates
inadequate cooling, closely inspect the compressor cooling
system. Check all compressor coolant lines for kinks and
restrictions to fl ow. 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 fl ow
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
restrictions to fl ow. 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
symptoms and corrective actions 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.
COMPRESSOR DRIVE
Check for noisy compressor operation, which could indicate
excessive drive component wear. Adjust and/or replace
as necessary. Check all compressor mounting bolts and
retighten evenly if necessary. Check for leakage and proper
unloader mechanism operation. Repair or replace parts
as necessary.
FIGURE 9 - TYPICAL DURAFLO 596
™
AIR COMPRESSOR
CYLINDER HEAD
CYLINDER HEAD PORT IDENTIFICATION
The cylinder head connection ports are identifi ed 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