BENDIX BW1665 User's Manual
Contents
1. CONTROLLER sD 2 ss MOUNTING BRACKET FIGURE 6 1 ANTILOCK RELAY VALVE WITH CONTROLLER 6 the maintenance kit should always be used in lieu of those presented here Refer to Figure 6 throughout the disassembly and assembly procedure CAUTION The AR 1 valve may be lightly clamped in a bench vise during disassembly however over clamping will cause damage to the valve and result in leakage and or malfunction If a vise is to be used position the valve so that the jaws bear on the supply ports on opposing sides of the valve s body 1 2 10 11 12 Remove all air fittings and plugs from the valve Mark the relationship of the antilock electronic controller and valve cover to the body 5 Note the position of the mounting bracket and mark the relationship of the bracket to the valve body cover and antilock controller Remove and retain the four cap screws and lock washers 1 that secure the controller to the cover 15 then carefully remove the electronic controller without damaging its gasket 2 While holding the exhaust cover 4 remove and discard the retaining ring 3 that secures it to the body 5 Remove and discard the exhaust cover 4 along with both o rings 6 amp 7 Remove and discard the valve spring 8 valve retainer 9 and the valve assembly 10 from the body 5 Remove and retain the two cap screws 11 and lock washers 12 that secure the cover 15 to t2. Bendix AR 1 AntiLock Relay Valve AR 1 ANTILOCK RELAY VALVE SERVICE PORT TYPICAL MOUNTING BRACKET SUPPLY PORT SUPPLY PORT DELIVERY PORTS EXHAUST PORT DESCRIPTION The AR 1 antilock relay valve Figure 1 is a specialized service brake relay valve It is essentially an 14 relay valve with a special cover that permits direct attachment of an antilock controller When combined with an antilock controller the resulting assembly is referred to as an antilock relay controller For example when the AR 1 antilock relay valve is combined with the EC 30 tractor antilock controller the resulting assembly is referred to as a CR 30 antilock relay controller While intended for use on antilock equipped vehicles the AR 1 antilock relay valve functions solely as a service brake relay and contains no electronics of its own In an air brake system the AR 1 valve serves as a relay station to speed the application and release of the service brakes The valve is normally mounted in Quick EXHAUST AR 1 VALVE WITH ANTILOCK CONTROLLER ANTILOCK CONTROLLER QUICK EXHAUST DIA SERVICE PORT RELAY PISTON INLET EXHAUST VALVE DELIVERY PORT EXHAUST PORT FIGURE 1 AR 1 ANTILOCK RELAY VALVE ASSEMBLY proximity to the service actuators it serves A mounting bracket furnished with the valve permits either frame or cross member mounting All air connections on the AR 1 va
3. BRAKE RELEASE When the brake application is released air pressure in the service port of the AR 1 valve returns to the foot brake valve and is exhausted Air from above the relay piston flows back through the cover to the exhaust diaphragm The diaphragm flexes in response to the returning air sealing the service port and opening the exhaust in the cover With the exhaust diaphragm blocking the service port returning air flows out the open exhaust As air pressure is reduced above the relay piston pressure beneath it lifts the piston away from the exhaust valve and opens the exhaust passage Air from the antilock modulators and brake actuators returns to the AR 1 valve and flows out the open exhaust See Figure 5 PREVENTIVE MAINTENANCE Important Review the warranty policy before performing any intrusive maintenance procedures An extended warranty may be voided if intrusive maintenance is performed during this period Because no two vehicles operate under identical conditions maintenance intervals will vary Experience is a valuable guide in determining the best maintenance interval for a vehicle GENERAL Perform the tests and inspections presented at the prescribed intervals If the AR 1 valve fails to function as 4 Z i RELAY PISTON INLET EXH VALVE es aa DELIVERY PORT ANTILOCK MODULATOR ACTUATOR described or leakage is excessive it should be repaired or re
4. f of air exits at the AR 1 valve s quick exhaust port in the cover Air exiting at this exhaust port indicates the AR 1 valve integral quick release is functioning LEAKAGE TESTS 1 Build the air system pressure to governor cut out apply a soap solution to the exhaust port in body The leakage noted should not exceed a one inch bubble in less than three 3 seconds 2 Make and hold a full brake application and apply soap solution to the exhaust ports in the body and cover and around the cover where it joins the body The leakage noted should not exceed a one inch bubble in less than three 3 seconds at any exhaust port WARNING PLEASE READ AND FOLLOW THESE INSTRUCTIONS TOAVOID PERSONAL INJURY OR DEATH When working on or around a vehicle the following general precautions should be observed at all times 1 Parkthe vehicle 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 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 3 Do not attempt to install remove disassemble or assemble a component until you
5. f the inlet and exhaust valve With the exhaust passage sealed continued movement of the relay piston unseats the inlet portion of the inlet and exhaust valve allowing supply air from the reservoir to flow out the AR 1 valve s delivery ports to the antilock modulators and then to the brake actuators See Figure 3 HOLDING BALANCED The air pressure being delivered to the antilock modulators and brake actuators is also present beneath the relay piston When the air pressure above and below the relay piston is equal the piston moves slightly allowing the inlet valve to return to its seat The exhaust valve remains closed With both the inlet and exhaust valves closed air pressure in the antilock modulators and brake actuators is held stable and neither increases nor decreases See Figure 4 ANTILOCK CONTROLLER eee QUICK EXHAUST DIA EXHAUST RELAY PISTON INLET EXH DELIVERY PORT ANTILOCK MODULATOR EXHAUST ACTUATOR FIGURE 3 AR 1 VALVE BRAKE APPLICATION ANTILOCK i CONTROLLER Casna J QUICK EXHAUST DIA SERVICE PORT EXHAUST RELAY PISTON INLET EXH VALVE DELIVERY PORT ANTILOCK MODULATOR EXHAUST ACTUATOR FIGURE 4 AR 1 VALVE HOLDING BALANCED ANTILOCK CONTROLLER QUICK EXHAUST DIA SERVICE PORT EXHAUST SUPPLY PORT Ls RESERVOIR EXHAUST FIGURE 5 AR 1 VALVE EXHAUST BRAKE RELEASE EXHAUST
6. 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 all reservoirs before beginning ANY work on the vehicle If the vehicle is equipped with a Bendix AD IS air dryer system ora dryer reservoir module be sure to drain the purge reservoir 5 Following the vehicle manufacturer s recommended 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 containing pressure it may whip Never remove a component or plug unless you are certain all system pressure has been depleted 8 Useonly genuine Bendix brandreplacement 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 attemptrepairs 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 compo
7. he body 5 Remove and retain the two bolts 13 lock washers 12 and nuts 14 that secure the cover 15 and mounting bracket to the valve body 5 Separate the cover 15 and mounting bracket from the body 5 then remove and discard the sealing ring 16 Remove and retain the two cap screws and lockwashers 26 that secure the bracket to the cover 15 Remove and retain the relay piston 17 and relay piston spring 19 from the body 5 NOTE The relay piston spring item 19 is not used in all valves Remove and discard the o ring 18 from the relay piston 17 Remove and retain the service port cap nut 20 from the cover 15 then separate and discard the cap nut o ring 21 from the cap nut Remove and discard the quick exhaust diaphragm 22 from the cover 15 Remove the quick exhaust diaphragm retaining screw 23 the diaphragm washer 24 and the diaphragm 25 from the cover 15 CLEANING amp INSPECTION 1 Using mineral spirits or an equivalent solvent clean and thoroughly dry all metal parts Inspect the interior and exterior of all metal parts that will be reused for severe corrosion pitting and cracks Superficial corrosion and or pitting on the exterior portion of the body 5 and cover 15 is acceptable Replace the entire valve if the interior of the body or cover exhibit signs of corrosion or pitting Inspect the bores of both the body 5 and cover 15 for deep scuffing or gouges Rep
8. ing 3 in the body 5 Make certain the retainer 3 is fully seated in its groove in the body If the AR 1 valve was equipped with a relay piston return spring 19 install the spring in the body large diameter first Using lubricant to hold them in place install sealing ring 16 on the cover 15 8 Install the o ring 18 onthe relay piston 17 then install 11 After noting the relationship of marks made prior to the piston in the body 5 disassembly attach the gasket 2 to the antilock 9 After noting the relationship marks made prior to controller then secure the antilock controller on the disassembly assemble the cover 15 on the body 5 cover 15 using the four cap screws and lock washers and the mounting bracket on the body 5 and secure 1 Torque the cap screws to 50 80 Ib in the components together using the two cap screws 12 Install all air line fittings and plugs making certain thread 11 and two bolts 13 lock washers 12 and nuts sealing material does not enter the valve 14 Torque the cover cap screws 11 and bolts 13 13 Install the CR 15 AR 1 valve with attached antilock to 120 150 Ib in controller on the vehicle and perform the Operation and 10 Install the two cap screws and lock washers 26 that Leakage Tests before returning the vehicle to service secure the bracket to the cover 15 and torque them to 180 220 Ib in BW1665 2011 Bendix Commercial Vehicle Systems LLC Al
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10. lace the entire valve if either are found Make certain all air channels and exhaust passages in the valve cover 15 are clear and free of obstruction Inspect the pipe threads in the body 5 Make certain they are clean and free of thread sealant Wash all non metallic components in a soap and water solution making certain to rinse and dry thoroughly Inspect each non metallic component for cracks wear or distortion Replace the entire valve if these conditions are found If the valve was equipped with a relay piston spring 19 inspect it for signs of corrosion pitting and cracks Replace as necessary Inspect all air line fittings for corrosion and replace as necessary Make certain to remove all old thread sealant before reuse ASSEMBLY 1 Prior to assembly lubricate all o rings seals and pistons as well as body bores using the lubricant provided with the Bendix maintenance kit Install the valve retainer 9 on the inlet and exhaust valve 10 so that the flange of the retainer 9 surrounds the rubber portion of the valve Install the inlet and exhaust valve in the body 5 Install the inlet and exhaust valve return spring 8 in the body 5 Install the large and small diameter o rings 7 amp 6 in the exhaust cover 4 then install the exhaust cover in the body 5 taking care not to damage the o rings Hold the exhaust cover in place While depressing the exhaust cover 4 install the retaining r
11. lve are identified with cast embossed letters for ease of installation The letter identification and air line connections are shown below for reference EMBOSSED AR 1 VALVE AIR CONNECTION IDENT Supply to reservoir SUP Delivery to brake actuator DEL Service to brake valve rear service SER delivery Like the 14 relay valve the AR 1 valve incorporates a quick release valve adjacent to the service port which 1 15 ANTILOCK CONTROLLER TYPICAL MOUNTING BRACKET FIGURE 2 15 ANTILOCK RELAY CONTROLLER provides for rapid exhaust of control air pressure from above the relay piston The standard AR 1 valve is offered with a 4 psi crack pressure however with the addition of various springs beneath the relay piston higher crack pressures are possible The AR 1 valve s internal components are interchangeable with the 12 and 149 relay valves therefore the same maintenance kit is used to service all three valves OPERATION BRAKE APPLICATION Brake application air enters the AR 1 valve s service port and encounters the exhaust diaphragm which flexes in response to the incoming air sealing the exhaust passage in the cover Air flows around the exhaust diaphragm and moves through a passage in the cover to the top of the relay piston In response to air pressure the relay piston AR 1 ANTILOCK RELAY VALVE moves into contact with the exhaust portion o
12. nents and systems are restored to their proper operating condition 11 Forvehicles with Automatic 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 VALVE REMOVAL 1 Park the vehicle on a level surface and block the wheels and or hold the vehicle by means other than the air brakes Drain the air pressure from all vehicle reservoirs Identify mark or label all air lines and wiring cables and their respective connections on the valve or antilock controller to facilitate ease of installation Disconnect all air lines and wiring Remove the valve and controller assembly from the vehicle VALVE INSTALLATION 1 Install all air line fittings and plugs making certain thread sealing material does not enter the valve 2 Install the assembled valve on the vehicle 3 Reconnect all air lines and wiring cables to the valve and controller assembly using the identification made during VALVE REMOVAL step 3 4 After installing the valve and controller assembly test all air fittings for excessive leakage and tighten as needed DISASSEMBLY GENERAL The following disassembly and assembly procedure is presented for reference purposes only and presupposes that the appropriate maintenance kit is on hand at the time of disassembly The instructions provided with 5 ANTILOCK
13. placed with a new or genuine Bendix remanufactured unit available at any authorized parts outlet EVERY 3 MONTHS 25 000 MILES OR 900 OPERATING HOURS 1 Remove any accumulated contaminates and visually inspect the exterior for excessive corrosion and physical damage 2 Inspect all air lines connected to the AR 1 valve for signs of wear or physical damage Replace as necessary 3 Test air line fittings for excessive leakage and tighten or replace as necessary 4 Perform the Leakage Test described in this manual EVERY YEAR 100 000 MILES OR 3 600 OPERATING HOURS 1 Perform the Operation and Leakage Tests described in this manual OPERATION amp LEAKAGE TESTS OPERATION TEST 1 Apply and release the brakes several times and check for prompt application and release at each wheel If prompt reaction is noted at some but not allwheels test the AntiLock modulator between the AR 1 valve and the brake actuator for proper operation If a sluggish response is noted at all wheels inspect for a kinked or obstructed air line leading to or from the AR 1 valve 2 If a complete release of the brakes is noted at some but not all wheels test the antilock modulator between the AR 1 valve and the brake actuator for proper operation If an incomplete release is noted at all wheels inspect for a kinked or obstructed air line leading to or from the AR 1 valve 3 During brake release confirm that a slight puf
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