BENDIX ST-1 ST-3 SAFETY VALVE User manual

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®
DESCRIPTION
The safety valve protects the air brake system against
excessiveairpressurebuild-up.Thevalveconsistsofaspring
loaded ball valve subjected to reservoir pressure which will
permit air to exhaust reservoir pressure to atmosphere if
reservoirpressure risesabove thevalves pressure setting,
which is determined by the force of the spring.
OPERATION
Toillustratetheoperationofthesafetyvalve,weshallassume
that the governor cutout pressure is set at 125 psi.Asafety
valve with a setting of 150 psi could then be used. Should
system pressure rise to approximately 150 psi air pressure
would force the ball valve off its seat, and allow reservoir
pressure to vent to atmosphere through the exhaust port in
the spring cage.
When reservoir pressure decreases sufficiently, the spring
force will seat the ball check valve, sealing off reservoir
pressure.This wouldoccur atapproximately135psiforthe
150psivalve.Itisimportanttonotethatthedesiredpressure
setting of the safety valve is determined by the governor
cutout pressure. The opening and closing pressures of the
safety valve should always be in excess of governor cutout
pressure setting. The pressure setting is stamped on the
lowerwrench flatofthevalve.
Normally, the safety valve remains inoperative and only
functionsiffor anyreasonreservoirpressure risesabovethe
settingof thevalve. Constant“poppingoff”orexhaustingof
thesafetyvalvecanbecausedbyafaultysafetyvalve,faulty
governor, faulty compressor unloading mechanism, or a
combination of any of the preceding.
PREVENTIVE MAINTENANCE
Important: Review the Bendix Warranty Policy before
performinganyintrusivemaintenanceprocedures.Awarranty
maybe voidedif intrusivemaintenance isperformed during
thewarranty period.
No two vehicles operate under identical conditions, as a
result, maintenance intervals may vary. Experience is a
valuableguide indeterminingthe bestmaintenance interval
for air brake system components.At a minimum, the safety
valveshouldbe inspectedevery6monthsor1500operating
hours, whichever comes first, for proper operation. Should
the safety valve not meet the elements of the operational
testsnotedinthisdocument,furtherinvestigationandservice
ofthe valvemay berequired.
OPERATING AND LEAKAGE CHECKS
OPERATING TEST: With air pressure in the system, pull
theexposed endof thevalvestemremovingthe springload
fromtheballcheckvalve.Airshouldexhaustfromthevalve’s
exhaust port. Release the stem, the air flow should stop.
Failure of valve to pass operating test would indicate the
valve should be disassembled, cleaned and rebuilt. (See
“Disassembly and Assembly” section). If adjustment is
necessary, see “Adjustment” section.
LEAKAGE CHECK: Coat the exhaust port with soap
solution.Aleakage ofa 1”bubble in5 secondsis permitted.
Excessiveleakage indicatesdirt invalve,faultyballvalve or
seat. Valve should be disassembled, cleaned and rebuilt.
(See “Disassembly and Assembly” section).
REMOVING AND INSTALLING
REMOVING
1. Block wheels or otherwise secure vehicle and drain
reservoirs.
2. Usingwrenchflatclosesttoreservoir,unscrewvalvefrom
reservoir.
INSTALLING
Safety valve should be installed in same reservoir that
compressor discharge line is connected to. Install in a
convenient location in a top port of the reservoir. If safety
valveisinstalledhorizontally,exhaustportshouldpointdown,
stemof thevalve shouldfacerearofvehicle.
PRESSURE
SETTING
150 PSI
EXHAUST
PORT
ST-3™
VALVE
ST-1™
VALVE
SD-03-1901
Bendix®ST-1™& ST-3™Safety Valve

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DISASSEMBLY: ST-1™ADJUSTABLE VALVE
1. Clamplower wrenchflatinvise (flatnearestpipethread).
2. Usingupper wrenchflat,unscrew locknut.Unscrew and
removespring cagefrombody ofvalve.
3. Remove ball valve, spring and release pin from spring
cage.
DISASSEMBLY: ST-3™NON-ADJUSTABLE VALVE
1. Clamp spring cage in soft jawed vise.
2. Using wrench flat, unscrew body from spring cage.
3. Remove ball valve, spring and release pin from spring
cage.
CLEANING AND INSPECTION
Clean all parts in mineral spirits. Inspect all parts.All parts
notconsideredserviceableshouldbereplaced withgenuine
Bendix replacement parts.
ASSEMBLY: ST-1™ADJUSTABLE VALVE
1. Place the ball valve in body.
2. Installspringandreleasepininspringcagewithadjusting
screw.
3. Positionthe releasepin overballvalve. Screwbody with
ball into the spring cage. Tighten securely.
4. Adjust for proper setting (see “Adjustment” section).
ASSEMBLY: ST-3™NON-ADJUSTABLE VALVE
1. Install spring, release pin in spring cage.
2. Position ball valve in body and screw spring cage onto
body.
3. Hold spring cage in soft jawed vise and tighten body
securely.
TO RAISE PRESSURE SETTING
1. Loosen lock nut.
2. Turn adjusting nut clockwise to obtain correct pressure
setting.
3. Tighten lock nut.
TO LOWER PRESSURE SETTING
1. Loosen lock nut.
2. Turn adjusting nut counter clockwise to obtain correct
pressure setting.
3. Tighten lock nut.
TESTING OF REBUILT SAFETY VALVES:
Performoperating and leakagechecks.
ADJUSTMENT OF SAFETY VALVE
NOTE:The ST-3™safety valveis notadjustable.
The pressure setting of the safety valve is stamped on the
cover wrench flat (closest to the pipe thread). The vehicle
manual may also provide the proper pressure setting. If
setting is not known, determine governor cutout pressure
settingandadjustsafetyvalvesothatthesafetyvalvecloses
at a pressure setting somewhat above governor cutout
pressuresetting(See “Operation” section).
To adjust, the safety valve must be connected to an air
system with air pressure in excess of desired setting. It is
importantthatan accurategaugebe usedtocheckpressure
settings while making adjustments.
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 park-
ing 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 work-
ing 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 electri-
cally charged components.
3. Do not attempt to install, remove, disassemble or
assemble a component until you have read and
thoroughly understand the recommended proce-
dures. Use only the proper tools and observe all
precautions pertaining to use of those tools.
ST-3™SAFETY
VALVE
ADJUSTING
NUT
SPRING
CAGE
LOCK
NUT
SPRING
RELEASE
PIN
BALL
VALVE
PIPE
THREAD
BODY
ST-1™SAFETY
VALVE
BODY
SPRING
CAGE
PIPE
THREAD
BALL
VALVE
SPRING
RELEASE
PIN

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4. If the work is being performed on the vehicle’s air
brake system, or any auxiliary pressurized air sys-
tems, 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 recom-
mended 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 con-
taining 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, com-
ponents 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 weld-
ing unless specifically stated and approved by the
vehicle and component manufacturer.
10. Prior to returning the vehicle to service, make
certainallcomponentsandsystemsarerestoredto
their proper operating condition.

4BW1583 © 2004 Bendix Commercial Vehicle Systems LLC. All rights reserved. 4/2004 Printed in U.S.A.