BENDIX DURAFLO 596 COMPRESSOR User Manual

1
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
™
596 compressor
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
WATER
INLET
PORT (2)
WATER
OUTLET
PORT (1)
CRANKCASE
DISCHARGE
SAFETY VALVE
CRANKCASE
BOTTOM
COVER (2)
CYLINDER
HEAD
VALVE BODY
ASSEMBLY
REAR END
COVER OIL
PORT
CRANKSHAFT
PISTON
CONNECTING
ROD
PISTON RINGS
CYLINDER
HEAD
DISCHARGE
VALVE
VALVE BODY
ASSY.
CRANKCASE
DISCHARGE
VALVE
HOLDER
DISCHARGE
PORTS (2)
DISCHARGE
VALVE
DISCHARGE
VALVE HOLDER
DISCHARGE
CAVITY
PISTON
CYLINDER
BORE
UNLOADER
PORT
FIGURE 1 - DURAFLO
™
596 AIR COMPRESSOR
VIEW OF CYINDER HEAD AND ONE CYLINDER BORE
®
SD-01-670
Bendix
®
DuraFlo
™
596 Air Compressor

BENDIX DURAFLO 596 COMPRESSOR Specifications

General

Brand	BENDIX
Model	DURAFLO 596 COMPRESSOR
Category	Air Compressor
Language	English

Summary

Bendix® DuraFlo™ 596 Air Compressor

OPERATION

COMPRESSOR & THE AIR BRAKE SYSTEM

COMPRESSOR INSTALLATION

Guidelines for installing the compressor.

DISCHARGE LINE TEMPERATURE

LUBRICATION

How the compressor is lubricated by the engine.

COOLING

Methods used to cool the compressor.

AIR INDUCTION

PREVENTATIVE MAINTENANCE

Crucial upkeep procedures for the compressor.

OIL PASSING

Issues related to oil in the air system.

SERVICE TESTS

Compressor Performance

Test for air build-up time.

COMPRESSOR REMOVAL & DISASSEMBLY

UNLOADER & INLET VALVE

DISCHARGE & INLET CHECK VALVES

COMPRESSOR TROUBLESHOOTING

INSPECTION OF PARTS

CYLINDER HEAD & VALVE BODY INSPECTION

END COVER INSPECTION

CYLINDER BLOCK INSPECTION

ASSEMBLY

INSTALLING THE COMPRESSOR

TESTING REBUILT COMPRESSOR

Post-installation performance testing.

DURAFLO™ 596 COMPRESSOR SPECIFICATIONS

TORQUE SPECIFICATIONS

Advanced Troubleshooting Guide for Air Brake Compressors

Table A: Maintenance Schedule and Usage Guidelines

Air Brake Charging System Troubleshooting

WARNING! SAFETY PRECAUTIONS

Critical safety instructions for maintenance.

Tests

Test 1: Excessive Oil Leakage at the Head Gasket

Test for head gasket oil seepage.

Test 2: Air Brake System and Accessory Leakage

Test for air leaks in the system.

Test 3: Air Compressor Discharge Temperature

Measures compressor and dryer inlet temps.

Test 4: Governor Malfunction

Checks governor function and settings.

Test 5: Governor Control Line

Inspects governor control line installation.

Test 6: Compressor Unloader Leakage

Tests for unloader mechanism leaks.

Appendix A: BASIC™ Test Kit Information

Bendix® Air System Inspection Cup (BASIC™) Test