BENDIX BW2066 User's Manual
Contents
1. o tg o a m V Bendix E 8P amp E 10P Dual Brake Valves TREADLE MOUNTING PLATE e T PERA AUXILIARY 27 EXHAUST FIGURE 1 E 8P DUAL BRAKE VALVE DESCRIPTION Refer to Figures 4 5 and 6 for item numbers referenced in parenthesis The Bendix E 8P Figure 1 and E 10P Figure 2 dual brake valves are floor mounted treadle operated type brake valves with two separate supply and delivery circuits for service primary and secondary braking which provides the driver with a graduated control for applying and releasing the vehicle brakes The E 10P dual brake valve Figure 2 is similar to the E 8P dual brake valve except that a metal coil spring 5 housed in an upper body assembly replaces the rubber spring 27 used in the E 8P valve The use of a metal coil spring and the upper body assem bly provides greater treadle travel and therefore provides the driver with a less sensitive feel when making a brake application The E 10P dual brake TREADLE MOUNTING PLATE S DELIVERY EXHAUST FIGURE 2 E 10P DUAL BRAKE VALVE valve is generally used on buses where smooth brake applications contribute to passenger comfort The circuits in the E 8P E 10P dual brake valves are identified as follows The No 1 or primary circuit is that portion of the valve between the spring seat which contacts the plunger and the relay piston the No 2 or secondary circuit is2. 2 OR SECONDARY CIRCUIT When the primary inlet valve 33 is moved off its seat air is permitted to pass through the bleed passage and enters the relay piston cavity The air pressure moves the relay piston 20 which contains the exhaust seat and closes the secondary exhaust valve As the secondary exhaust valve closes the inlet valve 13 is moved off its seat allowing the secondary air to flow out the delivery of the same circuit Because of the small volume of air required to move the relay piston 20 action of the secondary circuit of the valve is almost simultaneous with the primary circuit portion APPLYING LOSS OF AIR IN THE NO 2 OR SECONDARY CIRCUIT Should air be lost in the No 2 or secondary circuit the No 1 or primary circuit will continue to function as described above under Normal Operation No 1 or Primary Circuit Portion APPLYING LOSS OF AIR IN THE NO 1 OR PRIMARY CIRCUIT Should air be lost in the primary circuit the function will be as follows As the brake treadle is depressed and no air pressure is present in the primary circuit supply and delivery ports the primary piston 22 will mechanically move the relay piston 20 allowing the piston to close the second ary exhaust valve and open the secondary inlet valve and allow air to flow out the secondary delivery port BALANCED NO 1 OR PRIMARY CIRCUIT When the primary delivery pressure acting on the primary piston 22 equals the mechanical force
3. for cracks or corrosion OF PN Replace all rubber parts and any part not found to be serviceable during inspection use only genuine Bendix replacement parts ASSEMBLY Prior to reassembling lubricate all o rings o ring grooves piston bores and metal to metal moving surfaces with Dow Corning 55 o ring lubricant Bendix piece number 291126 Note All torques specified in this manual are assembly torques and can be expected to fall off after assembly is accomplished Do not retorque after initial assembly torques fall 1 Install the primary inlet and exhaust assembly 33 in the upper body and replace the retaining ring 32 to secure it Be sure the retaining ring is seated completely in its groove 2 Install the large and small o rings 30 amp 31 on the relay piston 20 3 For E 8P valve only Install o ring 28 in the primary piston 22 o ring groove 4 For E 8P valve only Install the rubber spring do not lubricate 27 concave side down in the primary piston 22 and place the spring seat 26 flat side up over the rubber spring 5 For E 8P valve only Install the primary piston spring seat nut 25 with its hex closest to the spring seat and rotate clockwise until the top surface of the spring seat is even with the top surface of the piston Set aside 10 11 12 13 14 15 16 17 18 19 20 21 Place relay piston spring 21 in concave portion of re
4. of the brake pedal application the primary piston 22 will move and the primary inlet valve 33 will close stopping further flow of air from the primary supply line through the valve The exhaust valve remains closed preventing any escape of air through the exhaust port BALANCED NO 2 OR SECONDARY CIRCUIT When the air pressure on the delivery side of the relay piston 20 approaches that being delivered on the primary side of the relay piston the relay piston moves closing the secondary inlet valve and stopping further flow of air from the supply line through the valve The exhaust remains closed as the secondary delivery pressure balances the primary delivery pressure When applications in the graduating range are made a balanced position in the primary circuit is reached as the air pressure on the delivery side of the primary piston 22 equals the effort exerted by the driver s foot on the treadle A balanced position in the secondary portion is reached when air pressure on the secondary side of the relay piston 20 closely approaches the air pressure on the primary side of the relay piston When the brake treadle is fully depressed both the primary and secondary inlet valves remain open and full reservoir pressure is delivered to the actuators RELEASING NO 1 OR PRIMARY CIRCUIT With the brake treadle released mechanical force is removed from the spring seat 26 graduating spring 23 and primary piston 22 Air pre
5. e 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 electrically charged components 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 10 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 Following the vehicle manufacturer s recommend ed procedures deactivate the electrical system in a manner that safely removes all electrical power from the vehicle Never exceed manufacturer s recommended pressures 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 Use only genuine Bendix replacement parts components and kits Replacement hardware tubin
6. emove adapter 1 and o ring 4 Remove the primary piston 2 from adapter 1 and o ring 34 from the primary piston 2 from the lower BODY _ ATTACHING SCREWS QTY 4 12 EXHAUST COVER ATTACHING SCREWS QTY 4 FIGURE 5 E 8P DUAL BRAKE VALVE EXPLODED FIGURE 6 E 10P DUAL BRAKE VALVE EXPLODED VIEW BODY ATTACHING SCREWS QTY 4 12 EXHAUST COVER ATTACHING SCREWS QTY 4 11 Remove the relay piston 20 relay piston spring 21 primary piston E 8P valve 22 E 10P valve 2 and primary piston return spring E 8P valve 23 E 10P valve 6 from the upper body Use care so as not to nick seats 12 Asmall washer 24 will be found in the cavity of the lower side of the primary piston for E 8P valve 22 for E 10P valve 2 13 For E 8P valve only Disassemble the primary piston by rotating the spring seat nut 25 counterclockwise Separate the spring seat nut spring seat 26 and rubber spring 27 and remove the piston o ring 28 14 Remove the large and small o rings 30 amp 31 from the relay piston 20 15 Remove the retaining ring 32 securing the primary inlet and exhaust valve assembly 33 in the upper body and remove the valve assembly CLEANING AND INSPECTION 1 Wash all metal parts in mineral spirits and dry Inspect all parts for excessive wear or deterioration Inspect the valve seats for nicks or burrs Check the springs
7. g hose fittings etc must be of equivalent size type and strength as original equipment and be designed specifically for such applications and systems Componenis 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 Prior to returning the vehicle to service make certain all components and systems are restored to their proper operating condition For vehicles with Antilock Traction Control ATC the ATC function must be disabled ATC indicator lamp should be ON prior to performing any vehicle maintenance where one or more wheels on a drive axle are lifted off the ground and moving BW2066 2007 Bendix Commercial Vehicle Systems LLC All rights reserved 8 2007 Printed in U S A
8. he piston making certain all three lock tabs have engaged the outer lip of the body For E 10P valve only Install coil spring 5 spring seat 7 and retaining ring 8 Replace the rubber seal ring 14 on the lower body Install the 4 hex head cap screws securing the lower body to the upper body Torque to 30 60 inch pounds Install the secondary inlet and exhaust valve assembly 13 on the lower body Install the screws that secure the exhaust cover 12 to the lower body Torque to 20 40 inch pounds Secure the screw 9 holding the exhaust diaphragm 10 and the diaphragm washer 11 to the exhaust cover 12 Torque to 5 10 inch pounds Install all air line fittings and plugs making certain thread sealant material does not enter valve VALVE INSTALLATION 1 2 Install the assembled brake valve on the vehicle Reconnect all air lines to the valve using the identifica tion made during VALVE REMOVAL step 1 After installing the brake valve assembly perform the OPERATION AND LEAKAGE CHECKS before placing the vehicle in service GENERAL SAFETY GUIDELINES WARNING PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO AVOID PERSONAL INJURY OR 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 Stop the engine and remov
9. lay piston 20 and install relay piston through primary inlet exhaust assembly 33 into under side of upper body For E 10P valve only Install o ring 4 on adapter 1 and install adapter on upper body Install o ring 34 on primary piston 2 Place screwdriver blade up in vise Insert stem 17 through the relay piston upper body sub assembly slide this assembly over the blade of the secured screwdriver engage the screwdriver blade in the slot in the head of the stem Place the washer 24 over the stem 17 and on top of the relay piston 20 Install primary return spring E 8P valve 23 E 10P valve 6 in upper body piston bore For E 8P valve only Install the primary piston rubber spring sub assembly steps 4 amp 5 over the stem into the upper body piston bore For E 10P valve Install primary piston sub assembly reference step 7 Compress piston s For E 8P valve the relay piston 20 for E 10P valve the primary and relay pistons 2 amp 20 and retaining ring into the upper body from either side and hold compressed either manually or mechanically See the cautionary note under step 8 in the Disassembly section of this manual Place the stem spring 19 E 8P valve place over the spring seat nut 25 the spring seat 18 concave side up and lock nut 16 on the stem 17 Torque to 20 30 inch pounds For E 8P valve only Install the primary piston retainer 15 over t
10. m 10 and washer 11 to the exhaust cover 12 3 Remove the four screws that secure the exhaust cover 12 to the lower body 4 Remove the secondary inlet and exhaust valve assembly 13 from the lower body 5 Remove the four hex head cap screws securing the lower body to the upper body and separate the body halves 6 Remove the rubber seal ring 14 body 7 For E 8P valve only While applying thumb pressure to the primary piston 22 lift out and up on the three lock tabs of the primary piston retainer 15 8 For E 10P valve only While depressing spring seat 7 remove retaining ring 8 Remove spring seat 7 and coil spring 5 Caution Before proceeding with the disassembly refer to Figures 3 and 4 and note that the lock nut 16 and stem 17 are used to contain the primary piston return spring for E 8P valve 23 for E 10P valve 6 stem spring 19 and the relay piston spring 21 The com bined force of these springs is approximately 50 pounds and care must be taken when removing the lock nut as the spring forces will be released It is recommended that the primary piston and relay piston be manually or mechanically contained while the nut and stem are being removed 9 Using a 3 8 wrench hold the lock nut 16 on the threaded end of the stem 17 Insert a screwdriver to restrain the stem remove the lock nut 16 spring seat 18 and stem spring 19 10 For E 10P valve only R
11. ssure and spring load moves the primary piston opening the primary exhaust valve allowing air pressure in the primary delivery line to exhaust out the exhaust port RELEASING NO 2 OR SECONDARY CIRCUIT With the brake treadle released air is exhausted from the primary circuit side of the relay piston 20 Air pressure and spring load move the relay piston opening the second ary exhaust valve allowing air pressure in the secondary delivery line to exhaust out the exhaust port PREVENTIVE MAINTENANCE Important Review the Bendix Warranty Policy before performing any intrusive maintenance procedures A warranty may be voided if intrusive maintenance is performed during the warranty period No two vehicles operate under identical conditions as a result maintenance intervals may vary Experience is a valuable guide in determining the best maintenance interval for air brake system components At a minimum the E 8P or E 10P valve should be inspected every 6 months or 1500 operating hours whichever comes first for proper operation Should the E 8P or E 10P valve not meet the elements of the operational tests noted in this document further investigation and service of the valve may be required Visually check for physical damage to the brake valve such as broken air lines and broken or missing parts 3 Every 3 months 25 000 miles or 900 operating hours Clean any accumulated dirt gravel or foreign material awa
12. that portion between the relay piston and the exhaust cavity The primary circuit of the valve is similar in operation to a standard single circuit air brake valve and under normal operating conditions the secondary circuit is similar in operation to a relay valve Both primary and secondary circuits of the brake valve use a common exhaust protected by an exhaust diaphragm TP 5 TRACTOR PROTECTION VALVE n SLACK SPRING USTER BRAKES ADJ USTER AD Pa EAE PT HI sax GF iy AER 6 tT bt Re VALVE Ss 3 A Je f per O SERVICE 2 SERVICE RESERVOIR RESERVOIR FIGURE 3 TYPICAL PIPING SCHEMATIC UPPER BODY 14 LOWER BODY ag iy A Wi pig in oe CHN SUP 2 il i BODY ATTACHING Li SCREWS ai E a m DEL 2 3 EXHAUST COVER ATTACHING SCREWS Pa 9 FIGURE 4 E 8P DUAL BRAKE VALVE SECTIONAL VIEW 2 OPERATION Refer to Figure 3 APPLYING NORMAL OPERATION NO 1 OR PRIMARY CIRCUIT PORTION When the brake treadle is depressed the plunger exerts force on the spring seat 26 graduating spring 23 and primary piston 22 The primary piston which contains the exhaust valve seat closes the primary exhaust valve As the exhaust valve closes the primary inlet valve is moved off its seat allowing primary air to flow out the No 1 or primary delivery port APPLYING NORMAL OPERATION NO
13. uding the pneumatic and mechanical devices are operating normally Always check the vehicle brake system for proper operation after performing brake work and before returning the vehicle to service LEAKAGE CHECK 1 Make and hold a high pressure 80 psi application 2 Coat the exhaust port and body of the brake valve with a soap solution 3 Leakage permitted is a 1 bubble in 3 seconds If the brake valve does not function as described above or leakage is excessive it is recommended that it be replaced with a new or remanufactured unit or repaired with genuine Bendix parts available at authorized Bendix parts outlets Refer to figures 4 5 and 6 for item numbers referenced in parenthesis REMOVAL 1 Chock the vehicle wheels or park the vehicle by mechanical means Block and hold vehicle by means other than air brakes Drain all air system reservoirs 2 Identify and disconnect all supply and delivery lines at the brake valve 3 Remove the brake valve and treadle assembly from the vehicle by removing the three cap screws on the outer bolt circle of the mounting plate The basic brake valve alone can be removed by removing the three cap screws on the inner bolt circle DISASSEMBLY Figures 4 5 and 6 1 If the entire brake valve and treadle assembly was removed from the vehicle remove the three cap screws securing the treadle assembly to the basic brake valve 2 Remove the screw 9 securing the exhaust diaphrag
14. y from the heel of the treadle plunger boot and mount ing plate Lubricate the treadle roller roller pin and hinge pin with Barium grease per BW 204 M Bendix part 246671 Check the rubber plunger boot for cracks holes or dete rioration and replace if necessary Also check mounting plate and treadle for integrity Apply a thin layer of Barium grease per BW 204 M Bendix part 246671 between plunger and mounting plate do not over oil SERVICE CHECKS OPERATING CHECK Check the delivery pressure of both primary and secondary circuits using accurate test gauges Depress the treadle to several positions between the fully released and fully applied positions and check the delivered pressure on the test gauges to see that it varies equally and proportionately with the movement of the brake pedal After a full application is released the reading on the test gauges should fall off to zero promptly It should be noted that the primary circuit delivery pressure will be about 2 PSI greater than the secondary circuit delivery pressure with both supply reservoirs at the same pressure This is normal for this valve Important A change in vehicle braking characteristics or a low pressure warning may indicate a malfunction in one or the other brake circuit and although the vehicle air brake system may continue to function the vehicle should not be operated until the necessary repairs have been made and both braking circuits incl
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