BENDIX AR-1 ANTILOCK RELAY VALVE Manuel - Page 7

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DISASSEMBLY

GENERAL

The following disassembly and assembly procedure is

presented for reference purposes only and presupposes

that the appropriate maintenance kit is on hand at the time

of disassembly. The instructions provided with the

maintenance kit should always be used in lieu of those

presented here. Refer to figure 6 throughout the disassembly

and assembly procedure.

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CAUTION: The AR-1

valve may be lightly clamped in a

bench vise during disassembly, however, over clamping will

cause damage to the valve and result in leakage and/or

malfunction. If a vise is to be used, position the valve so

that the jaws bear on the supply ports on opposing sides of

the valve's body.

1. Remove all air fittings and plugs from the valve.

2. Mark the relationship of the antilock electronic controller

and valve cover to the body (5). Note the position of the

mounting bracket and mark the relationship of the bracket

to the valve body, cover, and antilock controller. Remove

and retain the four cap screws and lock washers (1) that

secure the controller to the cover (15), then carefully

remove the electronic controller without damaging its

gasket (2).

3. While holding the exhaust cover (4), remove and discard

the retaining ring (3) that secures it to the body (5).

4. Remove and discard the exhaust cover (4) along with

both o-rings (6 & 7).

5. Remove and discard the valve spring (8), valve retainer

(9), and the valve assembly (10) from the body (5).

6. Remove and retain the two cap screws (11) and lock

washers (12) that secure the cover (15) to the body (5).

Remove and retain the two bolts (13), lock washers (12),

and nuts (14) that secure the cover (15) and mounting

bracket to the valve body (5).

7. Separate the cover (15) and mounting bracket from the

body (5), then remove and discard the sealing ring (16).

Remove and retain the two cap screws and lockwashers

(26) that secure the bracket to the cover (15).

8. Remove and retain the relay piston (17) and relay piston

spring (19) from the body (5). NOTE: The relay piston

spring, item 19 is not used in all valves.

9. Remove and discard the o-ring (18) from the relay piston

(17).

10. Remove and retain the service port cap nut (20) from the

cover (15), then separate and discard the cap nut o-ring

(21) from the cap nut.

11. Remove and discard the quick exhaust diaphragm (22)

from the cover (15).

12. Remove the quick exhaust diaphragm retaining screw

(23), the diaphragm washer (24) and the diaphragm (25)

from the cover (15).

CLEANING & INSPECTION

1. Using mineral spirits or an equivalent solvent, clean and

thoroughly dry all metal parts.

2. Inspect the interior and exterior of all metal parts that

will be reused for severe corrosion, pitting and cracks.

Superficial corrosion and/or pitting on the exterior

portion of the body (5) and cover (15) is acceptable.

Replace the entire valve if the interior of the body or cover

exhibit signs of corrosion or pitting.

3. Inspect the bores of both the body (5) and cover (15) for

deep scuffing or gouges. Replace the entire valve if

either are found.

4. Make certain all air channels and exhaust passages in

the valve cover (15) are clear and free of obstruction.

5. Inspect the pipe threads in the body (5). Make certain

they are clean and free of thread sealant.

6. Wash all non-metallic components in a soap and water

solution making certain to rinse and dry thoroughly.

Inspect each non-metallic component for cracks, wear

or distortion. Replace the entire valve if these conditions

are found.

7. If the valve was equipped with a relay piston spring (19),

inspect it for signs of corrosion, pitting and cracks.

Replace as necessary.

8. Inspect all air line fittings for corrosion and replace as

necessary. Make certain to remove all old thread sealant

before reuse.

ASSEMBLY

1. Prior to assembly, lubricate all o-rings, seals, and pistons,

as well as body bores, using the lubricant provided with

the Bendix maintenance kit.

2. Install the valve retainer (9) on the inlet and exhaust valve

(10) so that the flange of the retainer (9) surrounds the

rubber portion of the valve. Install the inlet and exhaust

valve in the body (5).

3. Install the inlet and exhaust valve return spring (8) in the

body (5).

4. Install the large and small diameter o-rings (7 & 6) in the

exhaust cover (4), then install the exhaust cover in the

body (5) taking care not to damage the o-rings. Hold the

exhaust cover in place.

5. While depressing the exhaust cover (4), install the

retaining ring (3) in the body (5). Make certain the retainer

(3) is fully seated in its groove in the body.

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6. If the AR-1

valve was equipped with a relay piston return

spring (19), install the spring in the body, large diameter

first.