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SD-01-3408
INLET REGULATING VALVE 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 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 designed to regulate compressor inlet pressure to 10 psi or

less.
The Inlet Regulating Valve or IRV 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 may not be used in conjunction with single cylinder except that of the TuFlo 300 Compressor. A 3/4 inch female
compressors including the Bendix BX-2150. Generally pipe thread in the IRV cap nut facilitates connection to the
mounted directly at the compressor air inlet, the IRV is engine induction system or turbocharger. High temperature

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O-rings, seals, seats, and lubricant are used throughout the

PISTON
IRV 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 place and rests on the VALVE
PLATE
supply cap nut along with the valve spring. The steel cap nut OUTLET
contains the supply port and retains an 0-ring which serves TO
COMPRESSOR SEAT
as the valve seat. A hex socket plug with a through drilled SPRING
vent along with a spring and steel ball valve comprise the
safety valve.

OPERATION
GENERAL TURBOCHARGER
SUPPLY
The IRV maintains a low pressure at the compressor inlet FIGURE 4 - COMPRESSOR LOADED-
(10 psi or less) regardless of turbocharger supply air HIGH TURBOCHARGER PRESSURE
pressure. The air flow through the IRV is throttled by the
COMPRESSOR LOADED HIGH TURBOCHARGER
PRESSURE (Figure 4)
PISTON Air at turbocharger supply pressure is continually supplied
to the chamber above the IRV 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 delivery
pressure to the compressor. This lower pressure is effective
VALVE over the upper surface of the valve plate, tending to open
OUTLET PLATE
TO SPRING the valve. The pressure drop across the valve increases
COMPRESSOR
SEAT 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 COMPRESSOR UNLOADED HIGH TURBOCHARGER

SUPPLY PRESSURE (Figure 5)
FIGURE 3 - COMPRESSOR EITHER LOADED OR
UNLOADED WITH LOW TURBOCHARGER PRESSURE

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

position and, therefore, the degree of throttling is controlled PISTON
by both turbocharger supply pressure and compressor air
flow demand. The operation of the IRV is described for each
of four functional conditions. VALVE
OUTLET PLATE
TO SEAT
COMPRESSOR EITHER LOADED OR UNLOADED LOW COMPRESSOR
TURBOCHARGER PRESSURE (Figure 3) SPRING

For both loaded and unloaded compressor operation at low

turbocharger pressure (Less than 5 psi) the IRV remains
fully open. Air is supplied to the compressor at turbo supply
pressure. The position of the piston/valve plate assembly is
TURBOCHARGER
determined by the pressure forces acting on the top of the SUPPLY
piston, on the upper and lower valve plate surfaces, and by
FIGURE 5 - COMPRESSOR UNLOADED-
the spring force. At low supply pressure the thrust of the HIGH TURBOCHARGER PRESSURE
pressure forces is insufficient to overcome the spring force.
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3. If the vehicle is equipped with air brakes, make certain

to drain the air pressure from all reservoirs before
beginning ANY work on the vehicle.
4. Following the vehicle manufacturer’s recommended
procedures, deactivate the electrical system in a manner
that removes all electrical power from the vehicle.
OUTLET
TO 5. When working in the engine compartment the engine
COMPRESSOR
should be shut off. 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 electrically
charged components.
6. Never connect or disconnect a hose or line containing
TURBOCHARGER
pressure; it may whip. Never remove a component or
SUPPLY plug unless you are certain all system pressure has
been depleted.
FIGURE 6 - SAFETY VALVE OPERATION
7. Never exceed recommended pressures and always wear
With the compressor unloaded air demand ceases and the safety glasses.
IRV closes as turbo supply pressure exceeds 5 psi. The 8. Do not attempt to install, remove, disassemble or
valve will close at a pressure between 5 and 10 psi and assemble a component until you have read and
remain closed at higher pressures, allowing only a minute thoroughly understand the recommended procedures.
flow to compensate for compressor piston ring blow-by in Use only the proper tools and observe all precautions
the unloaded mode. At the compressor inlet, pressure is pertaining to use of those tools.
maintained at less than 10 psi. 9. Use only genuine Bendix replacement parts,
components, and kits. Replacement hardware, tubing,
SAFETY VALVE OPERATION (Figure 6)
hose, fittings, etc. should be of equivalent size, type,
If for any reason pressure at the compressor inlet is and strength as original equipment and be designed
excessive, the safety valve located in the IRV outlet flange specifically for such applications and systems.
will open. Pressure in excess of 18 psi will allow air to be
10. Components with stripped threads or damaged parts
exhausted to atmosphere.
should be replaced rather than repaired. Repairs requiring
machining or welding should not be attempted unless
PREVENTIVE MAINTENANCE
specifically approved and stated by the vehicle or
Every three months, 30,000 miles or 900 operating hours, component manufacturer.
whichever occurs first: 11. Prior to returning the vehicle to service, make certain all
1. Make certain the vent hole in the IRV (inlet Regulating components and systems are restored to their proper
Valve) body is open and clear of debris. operating condition.
2. Check the turbocharger air Iine for cracking, tears,
kinking or wear and tighten hose clamps as needed.
Every 12 months, 120,000 miles or 3600 operating hours,
whichever occurs first:
1. Perform the operation and leakage tests.

IMPORTANT! PLEASE READ 1/8” NPT

CONNECTION
When working on or around a vehicle, the following general
precautions should be observed:
1. Park the vehicle on a level surface, apply the parking COMPRESSOR
brakes, and always block the wheels. INLET
MOUNTING
2. Stop the engine when working around the vehicle. HOLE(2)

FIGURE 7 - COMPRESSOR INLET ADAPTER PART NO.

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 TEST APPARATUS

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

In order to test the operation of the IRV it will be necessary OPERATIONAL TESTS (FIGURE 8)
to install the equipment and apparatus as illustrated in Figure
1. Drain the air pressure from the vehicle reservoirs.
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, start the engine and allow it to run at an idle
be obtained at the nearest Bendix parts outlet. In most cases (approximately 600-700 RPM). When vehicle air system
the inlet adapter will be required, however, if the IRV being pressure rises above 25 psi, proceed to Step 3.
tested has a 1/8 inch NPT access port in the area of its
3. Using the pressure regulating valve and test gauge B,
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 in 5 psi increments between 5 and 25 psi. Pause 15- 20
accuracy and a pressure regulating valve capable of seconds at each pressure setting and note that the
graduation in the 5-30 psi range will be required to complete 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 should be repaired or
LEAKAGE TESTS (FIGURE 8) replaced.
1. With the engine off and vehicle air system pressure Note: The tests described in this step must be made
above 15 psi, apply 15 psi shop air pressure at the with the compressor loaded.
turbo supply port of the IRV When pressure stabilizes
on test gauge ‘A’, proceed to Step 2.

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4. Adjust shop air to the IRV 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 in 5 psi increments up to 25 psi.
Pause 15-20 seconds at each pressure setting and note BODY
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 should be repaired VALVE
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 safety. Turn off the engine
and simultaneously apply shop air pressure to the IRV VALVE &
PISTON
turbo supply port and to the compressor inlet (through ASSEMBLY
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 IRV safety valve. Note
SPRING
the pressure on gauge ‘A’ when the exhaust is heard. If
exhaust occurs below 18 psi or above 25 psi, the IRV
must be repaired or replaced.
SPACER
REMOVAL
1. Park the vehicle on a level surface and block the wheels
and/or hold the vehicle by means other than the air O-RING
brakes. VALVE SEAT
2. Drain the air pressure from all vehicle reservoirs. (O-RING)

3. Disconnect the turbocharged air line at the 3/4 inch

NPT turbo supply port of the IRV.
4. Remove the two cap screws that secure the IRV, then CAP NUT
remove the valve itself.

INSTALLATION FIGURE 9 - INLET REGULATING VALVE

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

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CLEANING & INSPECTION ASSEMBLY

1. Using mineral spirits, clean and thoroughly dry all metal The appropriate lubricant is packaged in Bendix
parts with the EXCEPTION of the VALVE AND PISTON maintenance kits and should be used as directed in the kit
ASSEMBLY. The valve and piston assembly contain instruction sheet. Refer to Figure 9 throughout assembly.
O-rings, therefore, wipe the exterior of the exposed
1. Lubricate the interior bore of the body and the O-ring
areas avoiding the bore in which the piston slides since
grooves of the valve and piston assembly.
a 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 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 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 © Honeywell Commercial Vehicle Systems Company 1/1999 Printed in U.S.A.

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