Bendix Commercial Vehicle Systems RV-4 PRESSURE REDUCING VALVE 4/04 - Manual (Page 2)

2
PREVENTIVE MAINTENANCE
Important: Review the Bendix Warranty Policy before
performing any intrusive maintenance procedures. A warranty
may be voided if intrusive maintenance is performed during
the warranty period.
No two vehicles operate under identical conditions, as a
result, maintenance intervals may vary. Experience is a
valuable guide in determining the best maintenance interval
for air brake system components. At a minimum, the RV-4
™
valve should be inspected every 6 months or 1500 operating
hours, whichever comes first, for proper operation. Should
the RV-4
™ valve not meet the elements of the operational
tests noted in this document, further investigation and service
of the valve may be required.
OPERATING & LEAKAGE TESTS
OPERATING
Connect an accurate test gauge in the supply and delivery
lines of the RV-4
™ valve. Make certain that supply air
pressure is at the vehicle manufacturers recommended level.
Delivery pressure should be within plus or minus 5 p.s.i. of
the delivery pressure specified for the RV-4
™ valve. If not,
the valve should be repaired or replaced. If the valve meets
this operating test, proceed to the leakage tests. Do not
remove the gauges at this time.
LEAKAGE
With supply pressure at the level recommended by the vehicle
manufacturer, apply a soap solution to the 1/4" N.P.T. plug
in the control port, around the supply port and to the exhaust.
Leakage should not exceed a 1" diameter bubble in 3
seconds (175 SCCM). If leakage is excessive, the valve
should be repaired or replaced and the operating and leakage
tests performed at the time of repair or replacement. Proceed
to the “Removal and Installation” instructions. This concludes
the operation and leakage tests and the test gauges should
be removed.
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.
REMOVAL & INSTALLATION
REMOVAL
1. Hold the vehicle on a level surface by means other than
the air brakes.
2. Remove all air pressure from all reservoirs.
3. Identify, mark and then disconnect all air lines
attached to the valve.
4. Remove the valve.
INSTALLATION
1. Inspect and clean all air lines that connect to the valve.
2. Clean the vehicle valve mounting area and mount the
valve.
3. Reconnect the air lines according to the identification
marks made during removal.
DISASSEMBLY (Refer to Figure 2)
1. Remove exhaust cover screw (1), exhaust cover (2), and
exhaust diaphragm (3).
2. Remove four cap screws (4) with lockwashers (5) and
cover (6).
3. Remove control piston (7).