TP-10145
Revised 09-18
Service Procedures for Relay
Revised
1TP-10145
Technical
09-18
Bulletin
Valve (RV)
Technical Bulletin
Hazard Alert Messages Figure 2
CONTROL 41
Read and observe all Warning and Caution hazard alert messages in
this publication. They provide information that can help prevent
serious personal injury, damage to components, or both.
DELIVERY 2
How to Obtain Additional Maintenance SUPPLY 1
(OPPOSITE
and Service Information SIDE ALSO) EXHAUST
PORT FACING
If you have any questions about the material covered in this DOWN
publication, or for more information about the WABCO product line, DELIVERY 2 4008618a
please contact WABCO North America Customer Care at
RELAY VALVE (RV)
855-228-3203 or visit our website, wabco-na.com.
Service Procedures
Description and Function
Before servicing the WABCO relay valve, carefully read and follow all
The WABCO relay valve is designed to, upon service brake outlined procedures.
application and release, speed up the application and release of
delivery air pressure when the control port pressure is applied and
WARNING
released.
To prevent serious eye injury, always wear eye protection
This relay valve receives a control pressure signal (commonly from when you perform vehicle maintenance or service.
the vehicle foot brake valve) which results in pressurized air being
delivered from an air supply reservoir. By controlling the pressure Park the vehicle on a level surface. Block the wheels to
delivered from the vehicle foot brake valve to the relay valve, the air prevent the vehicle from moving. Support the vehicle with
pressure and subsequent braking power can be graduated. When safety stands. Do not work under a vehicle supported only by
the vehicle foot brake valve is released, the control air pressure to jacks. Jacks can slip and fall over. Serious personal injury and
the relay valve is decreased and the air from the brake chambers is damage to components can result.
exhausted at the relay valve exhaust port. A “crack pressure” will
increase the differential between control air pressure and delivery Open drain valves on all reservoirs to remove all pressurized
pressure. air from the air system before you disconnect any component.
Pressurized air can cause serious personal injury.
Removing the Relay Valve
1. Wear safe eye protection.
2. Park the vehicle on a level surface. Block the wheels to prevent
the vehicle from moving.
3. Drain the total air system. Open all of the drain valves on all of
the reservoirs.
4. Follow the vehicle manufacturer’s recommendations for 2. Connect the air lines to the corresponding ports identified
removing all electrical power from the vehicle. during removal.
5. Identify ports and mark corresponding information on all air line 3. Before operating the vehicle, be sure all components and
tubing connected to the valve to ensure that the replacement systems are restored to their correct operation.
valve is connected correctly. Color-coded tubing is
recommended for new installations. Function and Leakage Test
6. Using a tubing removal tool or similar device, disconnect the
NOTE: Install test gauges where pressure readings are required.
push-to-connect air line tubing. Disconnect the remaining air
line tubing by turning the tubing fitting counterclockwise, and
1. With the delivery ports and the control port open, put 15 ±5 psi
cover the ends of the tubing to protect them against
(1.03 ±0.34 bar) in the valve’s supply reservoir. Apply a soap
contamination.
solution to the exhaust port and both delivery ports. Leakage of
7. Remove and save the mounting hardware that mounts the a one-inch bubble in three seconds is permissible at each
valve to the vehicle. Remove the valve assembly. location. Repeat the above test with 125 ±5 psi (8.62 ±
0.34 bar) in the supply reservoir.
Installing the Relay Valve
2. With 125 ±5 psi (8.62 ±0.34 bar) in the valve’s supply
CAUTION reservoir, apply and hold 35 ±5 psi (2.41 ±0.34 bar) at the
Be sure that the replacement valve has the same “crack control port. Apply a soap solution to the exhaust port. Leakage
pressure” as the valve being removed. The crack pressure is of a one-inch bubble in three seconds is permissible. Delivery
located on a tag or plate. A designation of RV040 designates a pressure must be equal to the control pressure minus one half
relay valve with a nominal crack pressure of 4.0 psi. Using a of the nominal “crack pressure.” Repeat the above test with
different crack pressure relay valve may cause a change in 125 ±5 psi (8.62 ±0.34 bar) at the control port. Delivery
braking characteristics. A typical crack pressure is 4.0 psi. pressure must be 125 ±5 psi (8.62 ±0.34 bar).
3. With 125 ±5 psi (8.62 ±0.34 bar) in the valve’s supply
1. Install the new relay valve using the hardware removed in
reservoir, quickly apply and release the control pressure. The
Step 7 of the removal procedure. Tighten the mounting bolts
pressure in the delivery must rise and fall promptly.
from 30 ft-lb (41 N폷m) minimum to 33 ft-lb (45 N폷m) maximum
for 3/8-inch SAE Grade 5 bolts.
Troubleshooting
CAUTION
Tubing for push-to-connect fittings must be cut cleanly and Troubleshooting the Relay Valve
end cuts must be perpendicular within seven degrees. Angles
and sharp edges can damage the seal in the fitting and cause WARNING
air leakage. The relay valve is an important part of the air brake system.
Never ignore any symptom such as leakage or a change in
WARNING operation. Loss of braking may occur resulting in loss of
Ensure the tubing is connected correctly and securely. Insert vehicle control. Serious personal injury can result.
the tubing into the push-to-connect fitting until it hits the stop
1. Conduct the Function and Leakage Test when there is leakage
in the fitting. After inserting the tubing, pull on the tubing to
or a change in operation.
ensure that it is locked in the fitting. Unsecured tubing can
cause excessive leakage which may lead to a loss of braking, 2. Replace the valve if it does not meet the requirements of the
resulting in loss of vehicle control. Serious personal injury can Function and Leakage Test.
result.
Do not kink the tubing. Kinked tubing can block the flow of air
which may cause a loss of braking, resulting in loss of vehicle
control. Serious personal injury can result.
WABCO North America Information contained in this publication was in effect at the time the publication was approved for printing and is subject to
1220 Pacific Drive change without notice or liability. WABCO reserves the right to revise the information presented or to discontinue the
Auburn Hills, MI 48326 USA production of parts described at any time.
855-228-3203
Copyright 2018 TP-10145
wabco-na.com
WABCO, Inc. Revised 09-18
All Rights Reserved Printed in USA (16579)
