SD-01-3408

Bendix® Inlet Regulating Valve or IRV™ for Compressors

OUTLET FLANGE VENT

(MATES TO
COMPRESSOR INLET) MOUNTING
MOUNTING
HOLE HOLE

OUTLET

SAFETY TURBOCHARGER
VALVE SUPPLY PORT 3/4” NPT
FIGURE 1 - COMPRESSOR INLET REGULATING VALVE

O-RING
BODY
O-RING OR
U-CUP VALVE &
PISTON PISTON
HOUSING ASSEMBLY
O-RING
VALVE
O-RING

VALVE SEAT
OUTLET O-RING
SPRING

SPACER
VALVE

SAFETY SPRING
VALVE O-RING

EXHAUST PLUG CAP NUT

TURBOCHARGER
SUPPLY PORT
FIGURE 2 - INLET REGULATING VALVE

DESCRIPTION air inlet, the IRV™ valve is designed to regulate compressor

inlet pressure to 10 psi or less.
The IRV™ inlet regulating valve is intended for use on
multi-cylinder compressors which receive their induction The cast aluminum body incorporates an outlet flange which
air supply from the pressure side of the engine turbocharger. is capable of mating with all Bendix compressor inlet flanges
The IRV™ valve may not be used in conjunction with single except that of the Tu-Flo® 300 compressor. A 3/4 inch female
cylinder compressors including the Bendix® BX-2150™ pipe thread in the IRV™ valve cap nut facilitates connection
compressor. Generally mounted directly at the compressor to the engine induction system or turbocharger. High

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temperature o-rings, seals, seats, and lubricant are used
PISTON
throughout the IRV™ valve to provide compatibility with
incoming turbocharger air temperatures up to 250°F. The
unitized valve and piston assembly consists of the piston
housing, two o-rings and control piston with its permanently
affixed valve plate. The cavity below the piston is vented to
atmosphere. The ring spacer holds the piston housing in VALVE
PLATE
place and rests on the supply cap nut along with the valve OUTLET
spring. The steel cap nut contains the supply port and retains TO
COMPRESSOR SEAT
an o-ring which serves as the valve seat. A hex socket plug SPRING
with a through drilled vent along with a spring and steel ball
valve comprise the safety valve.

OPERATION
GENERAL TURBOCHARGER
SUPPLY
The IRV™ valve maintains a low pressure at the compressor FIGURE 4 - COMPRESSOR LOADED-
inlet (10 psi or less) regardless of turbocharger supply air HIGH TURBOCHARGER PRESSURE
pressure. The air flow through the IRV™ valve is throttled by
COMPRESSOR LOADED HIGH TURBOCHARGER
PRESSURE (Figure 4)
PISTON
Air at turbocharger supply pressure is continually supplied
to the chamber above the IRV™ valve piston. At pressures
above 5 psi the force on the piston is sufficient to partially
close the valve. With the compressor loaded (compressing
air) the resulting pressure drop across the valve lowers the
VALVE delivery pressure to the compressor. This lower pressure is
OUTLET PLATE
TO effective over the upper surface of the valve plate, tending to
SPRING
COMPRESSOR
SEAT open the valve. The pressure drop across the valve increases
with increased compressor flow (higher compressor RPM).
The position of the valve is thus affected by both turbo
supply pressure and compressor air demand. High turbo
supply pressure coupled with low compressor air demand
will tend to close the valve.
TURBOCHARGER
SUPPLY COMPRESSOR UNLOADED HIGH TURBOCHARGER
PRESSURE (Figure 5)
FIGURE 3 - COMPRESSOR EITHER LOADED OR
UNLOADED WITH LOW TURBOCHARGER PRESSURE

the valve which varies in position from fully open to closed.

Valve position and, therefore, the degree of throttling is
controlled by both turbocharger supply pressure and PISTON
compressor air flow demand. The operation of the IRV™ valve
is described for each of four functional conditions.
VALVE
COMPRESSOR EITHER LOADED OR UNLOADED LOW OUTLET PLATE
TO SEAT
TURBOCHARGER PRESSURE (Figure 3) COMPRESSOR
SPRING
For both loaded and unloaded compressor operation at low
turbocharger pressure (Less than 5 psi) the IRV™ valve
remains fully open. Air is supplied to the compressor at
turbo supply pressure. The position of the piston/valve plate
assembly is determined by the pressure forces acting on
the top of the piston, on the upper and lower valve plate TURBOCHARGER
surfaces, and by the spring force. At low supply pressure SUPPLY
the thrust of the pressure forces is insufficient to overcome FIGURE 5 - COMPRESSOR UNLOADED-
the spring force. HIGH TURBOCHARGER PRESSURE
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 working 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
OUTLET electrically charged components.
TO
COMPRESSOR 3. Do not attempt to install, remove, disassemble or
assemble a component until you have read and
thoroughly understand the recommended
procedures. Use only the proper tools and 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 certain to drain the air pressure from
TURBOCHARGER all reservoirs before beginning ANY work on the
SUPPLY
vehicle. If the vehicle is equipped with an AD-IS™
FIGURE 6 - SAFETY VALVE OPERATION air dryer system or a dryer reservoir module, be
sure to drain the purge reservoir.
With the compressor unloaded air demand ceases and the 5. Following the vehicle manufacturer’s
IRV™ valve closes as turbo supply pressure exceeds 5 psi. recommended procedures, deactivate the electrical
The valve will close at a pressure between 5 and 10 psi and system in a manner that safely removes all
remain closed at higher pressures, allowing only a minute electrical power from the vehicle.
flow to compensate for compressor piston ring blow-by in 6. Never exceed manufacturer’s recommended
the unloaded mode. At the compressor inlet, pressure is pressures.
maintained at less than 10 psi. 7. Never connect or disconnect a hose or line
containing pressure; it may whip. Never remove a
SAFETY VALVE OPERATION (Figure 6) component or plug unless you are certain all
If for any reason pressure at the compressor inlet is system pressure has been depleted.
excessive, the safety valve located in the IRV™ valve outlet 8. Use only genuine Bendix ® replacement parts,
flange will open. Pressure in excess of 18 psi will allow air components and kits. Replacement hardware,
to be exhausted to atmosphere. tubing, hose, fittings, etc. must be of equivalent
size, type and strength as original equipment and
PREVENTIVE MAINTENANCE be designed specifically for such applications and
systems.
Important: Review the Bendix Warranty Policy before
9. Components with stripped threads or damaged
performing any intrusive maintenance procedures. A warranty
parts should be replaced rather than repaired. Do
may be voided if intrusive maintenance is performed during
not attempt repairs requiring machining or welding
the warranty period.
unless specifically stated and approved by the
No two vehicles operate under identical conditions, as a vehicle and component manufacturer.
result, maintenance intervals may vary. Experience is a 10. Prior to returning the vehicle to service, make
valuable guide in determining the best maintenance interval certain all components and systems are restored
for air brake system components. At a minimum, the IRV™ to their proper operating condition.
valve should be inspected every 6 months or 1500 operating
hours, whichever comes first, for proper operation. Should
the IRV™ valve not meet the elements of the operational
tests noted in this document, further investigation and service
of the valve may be required.
WARNING! PLEASE READ AND FOLLOW 1/8” NPT
THESE INSTRUCTIONS TO AVOID CONNECTION

PERSONAL INJURY OR DEATH:

When working on or around a vehicle, the following
general precautions should be observed at all times. COMPRESSOR
INLET
1. Park the vehicle on a level surface, apply the MOUNTING
HOLE(2)
parking brakes, and always block the wheels.
Always wear safety glasses.
2. Stop the engine and remove ignition key when FIGURE 7 - COMPRESSOR INLET ADAPTER PART NO.
working under or around the vehicle. When 236701
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 TEST
COMPRESSOR GAUGE A
INLET CAVITY

AIR LINE
QUICK
COUPLER

ADAPTER
(236701)

IRV
INLET GASKETS
(243430)

TEST
GAUGE B
TYPICAL
MULTI-CYLINDER
COMPRESSOR
PRESSURE
REGULATING
VALVE

TO SHOP AIR

FIGURE 8 - IRV™ VALVE TEST APPARATUS

OPERATION & LEAKAGE TESTS 2. Using a soap solution check for leakage at the IRV™
valve vent in the body, around the two inch cap nut and
(Figures 7 & 8) at the exhaust plug of the safety valve. Leakage in excess
GENERAL of a one inch bubble in one second is unacceptable.

In order to test the operation of the IRV™ valve it will be OPERATIONAL TESTS (FIGURE 8)
necessary to install the equipment and apparatus as
1. Drain the air pressure from the vehicle reservoirs.
illustrated in Figure 8.
2. Apply 25 psi shop air pressure to the turbo supply port
The Bendix compressor inlet adapter in Figures 7 and 8 can of the IRV™ valve, start the engine and allow it to run at
be obtained at the nearest Bendix parts outlet. In most cases an idle (approximately 600-700 RPM). When vehicle air
the inlet adapter will be required, however, if the IRV™ valve system pressure rises above 25 psi, proceed to Step 3.
being tested has a 1/8 inch NPT access port in the area of
3. Using the pressure regulating valve and test gauge B,
its flange, the adapter is not needed.
adjust the shop air pressure being delivered to the IRV™
In addition to the inlet adapter two test gauges of known valve in 5 psi increments between 5 and 25 psi. Pause
accuracy and a pressure regulating valve capable of 15-20 seconds at each pressure setting and note that
graduation in the 5-30 psi range will be required to complete the compressor inlet pressure, as indicated by test gauge
the tests. ‘A’, is 12 psi or less. If the pressure exceeds 12 psi
more than momentarily, the IRV™ valve should be repaired
LEAKAGE TESTS (FIGURE 8) or replaced.
1. With the engine off and vehicle air system pressure above Note: The tests described in this step must be made
15 psi, apply 15 psi shop air pressure at the turbo supply with the compressor loaded.
port of the IRV™ valve. When pressure stabilizes on test
gauge ‘A’, proceed to Step 2.

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4. Adjust shop air to the IRV™ valve to 5 psi and allow the
compressor to build the vehicle air system pressure to
governor cut-out and note that the compressor unloads.
With the compressor unloaded increase the shop air
pressure to the IRV™ valve in 5 psi increments up to 25
psi. Pause 15-20 seconds at each pressure setting and BODY
note that the compressor inlet pressure as indicated by
test gauge ‘A’ is 12 psi or less. If the pressure exceeds
12 psi more than momentarily, the IRV™ valve should be VALVE
repaired or replaced. SPRING
O-RING
Note: The tests described in this step must be made EXHAUST
O-RING PLUG
with the compressor unloaded.
5. Test the function of the IRV™ valve safety. Turn off the
engine and simultaneously apply shop air pressure to VALVE &
PISTON
the IRV™ valve turbo supply port and to the compressor ASSEMBLY
inlet (through the inlet adapter 236701). Beginning at 5
psi, slowly raise the pressure at both locations
simultaneously until an exhaust of air is heard at the
SPRING
IRV™ valve’s safety valve. Note the pressure on gauge
‘A’ when the exhaust is heard. If exhaust occurs below
18 psi or above 25 psi, the IRV™ valve must be repaired
or replaced. SPACER

REMOVAL
1. Park the vehicle on a level surface and block the wheels O-RING
and/or hold the vehicle by means other than the air VALVE SEAT
brakes. (O-RING)
2. Drain the air pressure from all vehicle reservoirs.
3. Disconnect the turbocharged air line at the 3/4 inch
NPT turbo supply port of the IRV™ valve. CAP NUT
4. Remove the two cap screws that secure the IRV valve,
™

then remove the valve itself.

FIGURE 9 - INLET REGULATING VALVE
INSTALLATION
1. Install a new gasket on the mounting flange of the IRV™ 1. Using an adjustable or two inch wrench remove the cap
valve and using two cap screws secure the IRV™ valve. nut from the body.
Note: If 5/16 inch cap screws are used to secure the 2. Remove the spring and spacer.
IRV™ valve to the compressor inlet, torque the cap screws 3. Remove the large diameter o-ring located beneath the
to between 125 and 150 pound inches. hex head of the cap nut.
2. Reconnect the turbocharged air line to the 3/4 inch NPT 4. Taking care not to damage the roll crimp of the cap nut,
turbo supply port of the IRV™ valve. remove the small diameter o-ring which serves as the
3. Before placing the vehicle in service, close all reservoir valve seat.
drain cocks and build air system pressure to governor 5. Gently tap the open end of the valve body on a nonmetallic
cut-out. surface in order to remove the valve and piston assembly.
DISASSEMBLY (FIGURE 9) 6. Remove the large and small diameter o-rings from the
exterior of the valve and piston assembly. NOTE: No
The following disassembly instructions are presented for
further disassembly of the valve and piston assembly
reference purposes. Actual disassembly should not be
should be attempted. The detail parts of this assembly
undertaken without having the necessary maintenance kit
are NON-SERVICEABLE.
and instructions available. Refer to Figure 9 throughout
disassembly. 7. Using a 3/16 inch Allen wrench, remove the exhaust
plug.
8. Remove the valve spring and valve.

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CLEANING & INSPECTION ASSEMBLY
1. Using mineral spirits, clean and thoroughly dry all metal The appropriate lubricant is packaged in Bendix maintenance
parts with the EXCEPTION of the VALVE AND PISTON kits and should be used as directed in the kit instruction
ASSEMBLY. The valve and piston assembly contain sheet. Refer to Figure 9 throughout assembly.
o-rings, therefore, wipe the exterior of the exposed areas
1. Lubricate the interior bore of the body and the o-ring
avoiding the bore in which the piston slides since a
grooves of the valve and piston assembly.
special high temperature lubricant is used on that
surface. 2. Lubricate and install the large and small diameter o-rings
on the valve and piston assembly.
2. Using a thin wire make certain that the vent holes in the
IRV™ valve body and valve and piston assembly are open. 3. Carefully insert the valve and piston assembly into the
body, making certain that it is completely seated and
3. Check all metal parts for severe corrosion, pitting and
the valve plate remains visible.
cracks. Pay particular attention to the valve springs and
valve surfaces. Superficial corrosion and shallow pitting 4. Carefully work the small diameter o-ring, which serves
on the exterior of the cap nut and body is acceptable. as the valve seat, into the cap nut groove. When properly
installed, this o-ring is evenly retained by the rolled over
crimped edges of the cap nut groove. IMPORTANT: Do
not Lubricate this o-ring or the cap nut groove in
which it is installed.
5. Lubricate the cap nut groove for the large diameter
o-ring. Lubricate, then install the large diameter o-ring
on the cap nut.
6. Install the spacer then the spring in the valve body.
7. Install the cap nut in the body and torque it to between
58 and 72 pound feet.
8. Install the safety valve and valve spring in the IRV™ valve
body. Using a 3/16 inch Allen wrench, install the exhaust
plug.
9. Perform the operation and leakage tests before placing
the valve in service.

BW1552 © 2004 Bendix Commercial Vehicle Systems LLC All rights reserved. 3/2004 Printed in U.S.A.
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