User manual BENDIX RE-4 RELAY EMERGENCY VALVE

[. . . ] For ease of service the valve features an "insert" cartridge consisting of the inlet/exhaust valve and emergency piston. Removal of the insert can usually be accomplished without line removal. The valve may be flange or reservoir mounted, and identified, convenient porting locations of delivery, service, emergency (supply) and reservoir ports are provided. (Note: Reference Figures 1 and 2, two configurations of the RE-4TM valve are shown). [. . . ] A two minute check should result in no more than an eight (8) psi pressure drop for the combination vehicle system. If this check indicates possible excessive leakage of valve, soap suds should be applied to cover plate, cover plate vent, and exhaust port to detect exhaust valve, valve guide o-ring, emergency piston o-ring and relay piston o-ring leakage. A combined leakage as indicated by a 1" soap bubble in not less than 2 seconds is permissible. With tractor and trailer air brake system fully charged, place the tractor protection control valve to "Emergency" position or close the supply line cut-out cock on the tractor and uncouple the trailer emergency line coupling. Note that trailer brakes apply promptly. Check leakage at valve, and at the emergency line coupling. Reconnect and recharge tractor and trailer air brake system, noting that trailer brakes release at a maximum of 65 psi trailer emergency line pressure as the trailer air brake system is recharged to full normal operating pressure. With tractor and trailer air brake system fully charged, stop engine. Reduce pressure by making a series of applications and note that trailer brakes apply automatically at approximately 40 psi tractor reservoir pressure or at the automatic emergency setting of the tractor protection equipment, if installed. REMOVING AND INSTALLING If the valve does not function as described, or leakage is excessive, it is recommended that it be replaced with a new or remanufactured unit or repaired with genuine Bendix parts available at Bendix outlets. Identify and disconnect air lines from valve. (Note: the emergency piston and valve assembly, generally referred to as the "insert" can be removed without line removal. To remove the insert, remove cover plate and pull insert out. ) 4. INSTALLING If valve will be flange mounted directly to steel, it is recommended that a flange gasket be utilized to prevent electrolytic action between the unlike metals. If the valve is adapter or nipple mounted directly to a reservoir, it is recommended that "Never Seez" lubricant be applied to the threads before installation. This will prevent galling of the threads and make removal easier. Clean and inspect all connecting lines and hoses for cracks, deterioration or damage. Remove capscrews, lockwasher, then cover plate and emergency spring (1) from bottom of valve. Remove insert (5) through bottom of valve (keep insert centered during removal to avoid damage to exhaust valve. (Note: If new insert is to be installed omit steps 3-8). Remove three o-rings (2) (3) & (4) from insert. Using wrench flats provided, remove emergency piston cap nut (6) from emergency piston (5). Use care to avoid damaging finished diameters. [. . . ] Never exceed manufacturer's recommended pressures. 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. Install cover plate, lockwashers and cap nuts. [. . . ]