BENDIX BW1660 User's Manual
Contents
1. ORIFICE R 8P VALVE PISTON SERVICE EXHAUST CI 35 RESERVOIR INLET EXHAUST VALVE ASSEMBLY DELIVERY FIGURE 4 OPERATIONAL VIEW OF RELEASE 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 valve should be inspected every 6 months or 1500 operating hours whichever comes first for proper operation Should the valve not meet the elements of the operational tests noted in this document further investigation and service of the valve may be required CONTROL TO SECOND TRAILER CONTROL FROM TOWING TRAILER H e a e EN E Pe a Hf R 8P C 1 SINGLE RELAY VALVE CHECK VALVE SUPPLY TO SECOND TRAILER SUPPLY FROM TOWING TRAILER S SUPPLY C CONTROL D DELIVERY E EXHAUST EM EMERGENCY FIGURE 5 SCHEMATIC OF TYPICAL DOLLY SYSTEM OPERATION AND LEAKAGE TEST 1 Block the wheels and fully charge the air system Adjust the brakes 2 Apply and release the service brakes several times and check for prompt response of the brakes at all appropriate wheels 3 3 With the air system fully charged apply a soap solution to the exhaust of the R 8P valve Leakage of a 1 bubble in 5 seconds is permissible 4 Make and hold a full brake application and again apply a 4 soap solution to the R 8P valve exhaust2. Leakage of a 1 bubble in 3 seconds is permissible 5 With the brakes still applied apply a soap solution around the valve where the cover meets the body No leakage at this point is permitted If the valve is unable to pass these operation and leakage tests repair or replace it with a new or genuine Bendix remanufactured unit 5 available at any authorized parts outlet WARNING PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO AVOID PERSONAL INJURY OR DEATH 7 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 r 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 5 E SYNCHRO VALVE Bs RE 6 RELAY Ho ls EMERGENCY 3 f K VALVE oV 1 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 procedures Use only the proper tools and observe all precautions pertaining to use of those tools If the work i
3. EXHAUST INLET EXHAUST VALVEASSEMBLY SUPPLY PORT FIGURE 1 CUTAWAY AND EXTERNAL VIEW DESCRIPTION The R 8P pressure equalizing pilot relay valve is a device designed to reinforce the control signal on long wheel base towing trailers and converter dollies Unlike a standard relay valve which typically has a 4 p s i crack pressure and similar differential between control and delivery the R 8P valve has a 0 p s i differential On the converter dolly and long wheel base towing trailers the R 8P valve reinforces the service brake application signal without the differential found in standard relay valves The 0 p s i differential of the R 8P valve assures that all trailer and dolly brakes will receive the same strength control signal even during light brake applications By providing a balanced pressure signal to all trailer and dolly brakes the R 8P valve helps achieve overall vehicle brake balance and stability The R 8P valve also helps improve brake lining wear balance on combination vehicles by causing even the most distant brake to contribute its share of braking effort SD 03 1061A PISTON ORIFICE SERVICE CONTROL ee DELIVERY PORT OPERATION APPLICATIONS FIG 2 When a service brake application is made air delivered from the brake valve enters the service port of the R 8P valve As air pressure fills the space above the piston it begins to force the piston down Because of the sp
4. gned and secure with four 10 24 screws Torque screw to 20 30 inch pounds Install sealing ring 3 in valve body 7 Install o rings 1 and 2 on the piston 8 Install spring 9 in valve cover 6 so that the large diameter end of the spring will rest on the piston Install piston 8 with its o rings installed in valve cover 6 Note Make certain spring 9 is centered and not binding Install valve cover 6 on valve body 7 in same position as marked in Step 1 of Disassembly Secure the cover to the body using four 5 16 hex head cap screws Torque to 120 150 inch pounds INSTALLATION 1 2 Mount the R 8P valve to the vehicle using new bolts or other hardware Connect air lines to the R 8P valve using identification made during Step 3 of Removal instructions Perform Operation and Leakage Checks before placing vehicle in service BW1660 2004 Bendix Commercial Vehicle Systems LLC All rights reserved 3 2004 Printed in U S A
5. ring force above the piston the piston exhaust seat is already in contact with the inlet exhaust valve sealing off the exhaust As the piston begins to move downward it forces the inlet exhaust valve off the inlet seat allowing air from the reservoir to be delivered out the delivery ports of the R 8P valve in direct proportion to the pressure received at the service port Any differential between service and delivery pressure caused by friction or resistance to the movement of the piston commonly called crack pressure and normally in the range of 2 to 4 p s i is eliminated due to passage of air through the orifice in the piston BRAKE SS VALVE PISTON ORIFICE R 8P VALVE SPRING PISTON SERVICE il SERVICE BRAKES RELAY VALVE ain INLET EXHAUST VALVE ASSEMBLY VENT CI RESERVOIR DELIVERY FIGURE 2 OPERATIONAL VIEW OF APPLICATION BALANCE FIG 3 The air pressure being delivered by the open inlet valve also is effective on the bottom area of the R 8P valve relay piston When air pressure beneath the piston equals the service air pressure on top of the piston the piston lifts slightly and the inlet exhaust valve is returned to the inlet seat The exhaust remains closed as the delivery pressure balances with the service line pressure Balancing of the pressure above and below the piston through the orifice of the R 8P valve piston assures that the service and delivery pressure
6. s are equal and 0 p s i differential exists As delivered air pressure to the R 8P valve service port is changed the valve reacts holding the desired application pressure EXHAUST OR RELEASE FIG 4 When air pressure is released from the service port and air pressure in the cavity above the piston of the R 8P valve is exhausted air pressure beneath the piston lifts it upward further seating the inlet exhaust valve against the inlet seat Raising the exhaust seat of the piston off the inlet exhaust valve opens the exhaust This allows the delivery air pressure to rapidly exhaust to atmosphere As air pressure under the piston drops the spring force above the piston will push the piston downward once again placing the exhaust seat of the piston in contact with the inlet exhaust valve Any pressure remaining under the piston will pass through the piston orifice and be exhausted at the brake valve 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 BRAKE gt gt VALVE PISTON R 8P VALVE SPRING PISTON ern VENT a oll SERVICE BRAKES RELAY VALVE DELIVERY SUPPLY a EXHAUST a RESERVOIR INLET EXHAUST VALVEASSEMBLY FIGURE 3 OPERATIONAL VIEW OF BALANCED POSITION BRAKE SPRING SSN VALVE PISTON amp
7. s 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 an AD IS air dryer system or a dryer reservoir module be sure to drain the purge reservoir Following the vehicle manufacturer s recommended 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 tubing hose fittings etc must be of equivalent size type and strength as original equipment and be designed specifically for such applications and systems 3 SUPPLY PORT FIGURE 6 CUTAWAY 9 10 Components with stripped threads or damaged parts should be replaced rather than repaired Do not attempt repairs requiring machining or welding 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 REMOVAL 1 2 3 4 Block or hold the vehicle by means other than
8. the brakes Drain all air brake system reservoirs Identify mark and disconnect all air lines from the R 8P pilot relay valve Remove the R 8P valve from its mount on the vehicle DISASSEMBLY OF VALVE REFER TO FIG 6 1 2 Note and mark position of valve cover 6 to body 7 Remove four 5 16 18 hex screws and separate the cover from the body 7 Remove and discard sealing ring 3 from body 7 Remove piston 8 and spring 9 from cover 6 and retain all parts Remove and discard o ring 2 from piston 8 Remove screw 11 washer 12 and diaphragm 5 from exhaust cover 10 Discard diaphragm 5 Remove four 10 24 screws which secure exhaust cover 10 to body 7 Remove and discard inlet exhaust assembly 4 from body 7 Clean all remaining parts in a cleaning solvent equivalent to mineral spirits Make certain all surfaces bores and passages are clean and dry sdi m K i La E E Liz co a Mim p PISTON ORIFICE SERVICE CONTROL PORT DELIVERY PORTS ASSEMBLY REFER TO FIG 6 NOTE Make certain both piston orifices are open and not clogged Grease all o rings o ring grooves and bores with a barium base lubricant Install diaphragm 5 and diaphragm washer 12 and secure with screw 11 Torque screw to 15 25 inch pounds Install inlet and exhaust valve assembly 4 in valve body 7 Position exhaust cover assembly 10 so that all holes are properly ali
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