Bendix Commercial Vehicle Systems RE-4 RELAY EMERGENCY VALVE - Manual (Page 4)

4 BW1433 © 2004 Bendix Commercial Vehicle Systems LLC. All rights reserved. 3/2004 Printed in U.S.A.
13. Remove emergency-supply cap nut (20).
14. Remove filter (21) and o-ring (22) from cap nut.
15. Remove check valve seat (23), check valve (24), and
check valve spring (25). Remove o-ring (26).
CLEANING AND INSPECTION OF PARTS
Wash all metal parts in mineral spirits.
Wipe rubber parts dry.
Inspect all parts for wear, damage or deterioration.
Clean or replace all filters. Replace all rubber parts and any
other parts not considered serviceable by these inspections
with Genuine Bendix parts.
ASSEMBLY
NOTE: All torques specified are assembly torques and can
be expected to fall off after assembly. Do not
retorque after initial assembly torques fall. For
assembly, hand wrenches are recommended.
Prior to assembly, lubricate all o-rings and mating
surfaces with Dow-Corning 55-M pneumatic grease
(Bendix Pc. No. 291126).
1. Install o-ring (13) on top cover (11).
2. Install seal ring (18) and o-ring (19) on piston (14).
3. Install piston return spring (15) in body. Install relay piston
in cover; it should be a neat, sliding fit.
4. Install top cover/piston assembly. Torque cap screws to
100 inch pounds.
5. Install exhaust diaphragm (17), cover (16) and retaining
screw.
Note: If new insert is to be installed omit steps 6-12.
6. Install three o-rings (2) (3) & (4) on the emergency piston
insert and o-ring (12) on the inlet valve body (10).
7. Install valve spring (2) in inlet valve body (10) and slide
inlet valve body into the emergency piston cap nut (6).
Use care to avoid damaging the inlet valve o-ring.
8. Install emergency piston cap nut o-ring (8).
9. Install emergency piston cap nut in emergency piston
and tighten. Torque to 200-250 in. lbs.
10. Install exhaust valve (9) on inlet valve body using
lockwasher and Phillips head screw. (Bead on rubber
and recess in valve surface should face head of screw).
Torque to 80-120 in. lbs.
11. Install insert assembly in valve body.
12. Install emergency piston spring (1).
13. Install cover plate, lockwashers and cap nuts. Torque
cap nuts to approximately 100 in. lbs.
14. Install check valve (24) and check valve spring (25) in
check valve seat (23).
15. Install check valve o-ring (26) in body and install check
valve seat with check valve in body.
16. Install filter (21) and o-ring (22) on cap nut (20) and install
cap nut in body. Torque to 75-175 in. lbs.
17. Install plugs in unused ports.
18. Check valve as outlined in “Operating and Leakage
Check” sections before placing vehicle in service.
WARNING! PLEASE READ AND FOLLOW
THESE INSTRUCTIONS TO AVOID
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. When
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 vehicle manufacturer’s
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 ® replacement parts,
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.