BENDIX C-5 CUT OUT COCK User manual

1
®
Bendix®C-5™Cut-Out Cock
SD-07-2601
FIGURE 1
CLAMPING
STUD
VALVEO-RING VALVESEATS
DESCRIPTION
TheC-5™cut-outcockisamanuallyoperatedon-offvalve.
Cut-out cocks are used in an air brake system where a
manual shut off air lines is desirable such as in trailer and
trailer dolly systems.
OPERATION
Note that in Figure 1 the C-5™cut-out cock uses a metal
ball valve between two valve seats. Rotating the ball valve
90° will either open or close the air passage through the
cut-out cock.
PREVENTIVE MAINTENANCE
Every six months, 1800 operating hours, or 50,000 miles
thecut-outcockshouldbecheckedforleakagearoundthe
ball valve and past the stem o-ring. Once each year, 3600
hours, or 100,000 miles the C-5™cut-out cock should be
disassembled,cleaned, and inspected for signsof wear or
deterioration.
LEAKAGE CHECK
Withthevalveintheclosedpositionandairpressurepresent
oneitherside,asoap solution is applied to the side open to
atmosphere. A leakage of not more than a 1" bubble in 5
seconds is permitted.
NOTE: Leakageshould becheckedineach directionsince
it is possible for the valve to seal in one direction
but not the other.
Ifthecut-outcockleaksexcessivelyorifwearordeterioration
isnoted duringroutinemaintenance,itisrecommendedthat
itbereplacedwithanewunitorrepairedwithgenuineBendix
parts.
REMOVINGAND INSTALLING
REMOVING
Block and hold vehicle by means other than air brakes.
Completely drain all reservoirs. Disconnect air lines from
both sides of the cut-out cock.
BODY
REDUCER
BUSHING
CAP NUT
OPERATINGHANDLE LOCK NUT STEM
STEM
WASHER
O-RING

2
INSTALLING
Priortoinstalling,check, and if necessary,cleanorreplace
lines leading to the cut-out cock.
Install the valve taking care the operating handle is in a
convenientpositionfor use.
DISASSEMBLY
Unscrewcapnutfrombodyandremovecapnuto-ring.
NOTE: Early models of the C-5™cut-out cock had a cap
nut at both ends of the body. Parts from the earlier
model C-5™cut-out cock are not interchangeable
with the new model and are not available. When
service is required on the older model it should be
replaced with the current style.
Rotate the operating handle of the cut-out cock until the
passage through the valve is closed. Note the position of
thehandleforreassembly.
Lightly tap the open end of the valve body on the work
surface.Theballvalveandbothseatswilldropout.
Remove the lock nut located in the center of the operating
handleandremovethehandle from the stem.
Removehandlestembypushingintovalvebodyandshaking
out.
Removestemwasherand o-ring from stem.
CLEANING AND INSPECTION
Wash all metal parts in mineral spirits.
Ballvalveseatsando-ringsshouldbewipedclean.
Inspectseatsando-rings for nicks, wear or deterioration.
Inspectvalve body,capnut,handleand stemforcracks and
wear. Any part considered unserviceable will necessitate
thattheentirevalvebe rebuilt or replaced.
ASSEMBLY
All o-rings should be lightly lubricated with Bendix silicone
lubricateBW650Mpieceno.291126.
Position stem washer and o-ring on stem.
Pushstem through body(threadedendfirst) fromtheinside
out.
Positionoperatinghandleonstemandreplaceandtighten
stem lock nut. Torque to 30-70 inch pounds.
Position one of the two valve seats in the body with the
contouredsideup.
Placeoperatinghandleinpositionnotedduringdisassembly.
(Drivetang onendofstemshould beparallelwith centerline
ofbody.)
Place ball valve in body with slot coinciding with stem.
Placeremainingvalveseatinbodywithcontouredsidedown
andagainstthe ball valve.
Place o-ring on cap nut and install cap nut in body and
tighten(Torqueto150-400inchpounds).
TESTING
Performleakagetest on reassembled or rebuiltvalve.
WARNING! PLEASE READ AND FOLLOW
THESE INSTRUCTIONS TO AVOID
PERSONAL INJURYOR 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
enginebe 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. Useonly the proper toolsand 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 certainto drainthe airpressure 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
recommendedprocedures, deactivate theelectrical
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.
BW1596 © 2004 Bendix Commercial Vehicle Systems LLC All rights reserved. 4/2004 Printed in U.S.A.