BENDIX BW1622 User's Manual
Contents
1. UPPER BODY ASSEMBLY PRIMARY DELIVERY DEL 1 21 SECONDARY DELIVERY TREADLE MOUNTING PLATE PRIMARY SUPPLY 2UP 1 11 PRIMARY SUPPLY SUP 2 SD 03 826 PRIMARY DELIVERY DEL 1 21 SECONDARY DELIVERY LOWER BODY EXHAUST ASSEMBLY FIGURE 1 E 12 AND E 15 DUAL BRAKE VALVES DESCRIPTION The E 12 and E 15 dual brake valves are floor mounted treadle operated type brake valves with two separate supply and delivery circuits for service and secondary braking The separation of circuits provides the driver with a graduated control for applying and releasing the vehicle brakes The E 12 and E 15 brake valves are similar in design with the exception of the rubber spring 9 and spring retainer 7 located in the upper body The rubber spring which is used in the E 12 brake valve alters the performance of the valve such that the primary circuit delivers full reservoir pressure to the spring brakes with less treadle travel than that of the E 15 brake valve See Figure 2 for delivery pressure versus treadle travel diagram The greater treadle travel of the E 15 brake valve yields a more gradual delivery of air to the spring brakes resulting in a less sensitive feel to the driver when a brake application is made This characteristic makes the E 15 brake valve more adaptable to transit vehicle applica tions where smooth brake applications contribute to passenger comfo2. per body making certain that the o rings 19 amp 20 are not damaged in the process Install the o ring 17 on the upper body Join the as sembled upper and lower body halves noting the relationship marked in Disassembly step 2 Secure the body halves together using the four 1 4 cap screws 16 and torque to 30 to 60 pound inches If the brake valve is firewall mounted install the pedal mounting plate on the basic brake valve noting the rela tionship marked during Disassembly step 2 Secure the mounting plate to the valve using the three 5 16 cap screws and torque to 80 to 120 pound inches Install all air line fittings and plugs making certain thread sealant material does not enter the valve VALVE INSTALLATION LE 2 Install the assembled brake valve on the vehicle Reconnect all air lines to the valve using the identifica tion made during Valve Removalstep 1 After installing the brake valve assembly periorm the Operation amp Leakage Checks before placing the vehicle in service w BW1622 2004 Bendix Commercial Vehicle Systems LLC All rights reserved 3 2004 Printed in U S A
3. no two vehicles operate under identical conditions maintenance and maintenance intervals will vary Experi ence is a valuable guide in determining the best maintenance interval for any one particular operation Visually check for physical damage to the brake valve such as broken air lines and broken or missing parts EVERY 3 MONTHS 25 000 MILES OR 900 OPERATING HOURS 1 Remove any accumulated contaminates such as dirt and gravel from the heel of the treadle 26 plunger 27 plunger boot 28 and mounting plate 29 2 Use alight oil lubricate the treadle roller 30 roller pin 31 and hinge pin 32 3 Inspect the plunger boot 28 for cracks holes or dete rioration and replace if necessary Also check mounting plate and treadle for integrity wear and corrosion and replace or repair as necessary 4 Apply 2 to 4 drops of oil between plunger and mounting plate do not over oil 5 Check for excessive leakage as described in the Operation amp Leakage Checks section of this manual EVERY YEAR 100 000 MILES OR 3 600 OPERATING HOURS 1 Perform steps 1 through 4 above 2 Perform the operation and leakage checks described in the Operation amp Leakage Checks section of this manual OPERATION amp LEAKAGE CHECKS GENERAL A change in vehicle braking characteristics or a low pres sure warning may indicate a malfunction in one or the other brake circuit and although the vehicle air brake system may continue to fun
4. ring 6 making cer tain it is completely seated in its groove in the piston 2 Install the o rings 15 on both valve assemblies 13 Install the valve spring 14 in the piston 2 then install the valve assembly 13 in the spring Install the o ring 12 into the o ring groove of piston 2 then install the valve seat 11 on the valve assembly 13 Gently depress and hold the valve seat in the pis ton 2 while installing the special beveled retaining ring 10 Important The beveled retaining ring 10 must be in Stalled with its flat side against the valve seat 11 and its beveled side visible Make certain the beveled retain ing ring 10 is completely seated in its groove in the piston 2 Install the o rings 8 amp 5 on the primary piston 2 then install the wear rings 4 in the o ring grooves next to the o rings Make certain that one flange of the angular wear ring 4 is in the o ring groove while the opposite flange extends away from the end of the piston 2 and toward the center The wear ring flange must not cover or over lap either o ring Carefully insert the assembled primary piston 2 valve end first into the upper valve body until the piston retaining ring groove in the body is visible Make certain the o rings 3 amp 5 and wear rings 4 are not damaged in the process Do not force the piston If substantial resistance is encountered check for proper installation of the wear rings Ins
5. seat air passes through the bleed passage in the lower portion of the upper body and enters the relay piston cavity The air moves the relay piston 18 downward and opens the sec ondary inlet valve allowing the air from the secondary supply to flow out the delivery port ofthe same circuit APPLYING LOSS OF AIR IN THE PRIMARY CIRCUIT If air is lost in the primary circuit the valve will function as follows As the brake pedal is depressed and no air pres sure is present in the primary circuit the primary piston 2 willmechanically move the relay piston closing the second ary exhaust and opening the inlet valve ofthe same circuit allowing air flow from the secondary supply to its associ ated delivery port APPLYING LOSS OF AIR IN THE SECONDARY CIRCUIT If the air is lost in the secondary circuit the primary circuit will function as described above under Normal Operation Primary circuit portion PLUNGER FIGURE 6 APPLYING FAILURE IN THE PRIMARY CIRCUIT BALANCED PRIMARY CIRCUIT PORTION When the primary delivery pressure acting upon the primary piston 2 equals the resultant mechanical force of the brake treadle application the primary piston will close preventing further air flow from the supply to the delivery port of the brake valve The exhaust valve remains closed preventing the escape of air through the exhaust port PLUNGER E wr u 7755 EXHAUST FIGURE 7 APPLYING FAILURE IN THE SECONDARY
6. CIRCUIT PLUNGER FIGURE 8 BALANCED POSITION BALANCED SECONDARY CIRCUIT PORTION When the air pressure on the secondary side of the relay piston approaches the pressure being delivered on the pri mary side of the relay piston the relay piston moves closing the secondary inlet valve preventing further air flow from the supply line through the valve The exhaust remains closed as the secondary delivery pressure balances the primary delivery pressure PLUNGER FIGURE 9 RELEASED MODE 4 RELEASING PRIMARY CIRCUIT PORTION When the force on the brake treadle is released the me chanical force is removed from the graduation spring 8 and the primary piston 2 Air pressure in the delivery circuit moves the primary piston exhaustive valve allowing air pres sure in the primary piston to exhaust through the exhaust port RELEASING SECONDARY CIRCUIT PORTION When the brake treadle is released air is exhausted from the primary circuit side of the relay piston through the bleed passage Air pressure in the delivery side of the secondary circuit moves the relay piston upward 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 warranty policy before performing any intrusive maintenance procedures An extended war ranty may be voided if intrusive maintenance is performed during this period Because
7. at 11 in place 14 Slowly release the valve seat 11 allowing it to rise out of the piston 2 Remove the valve seat 11 then remove and discard the o ring 12 15 Remove and discard the valve assembly 13 along with its o ring 15 from the piston 2 Remove the valve assembly return spring 14 CLEANING amp INSPECTION 1 Using mineral spirits or an equivalent solvent clean and thoroughly dry all metal parts 2 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 por tion of the upper and lower body halves is acceptable 3 Inspect the bores of both body halves for deep scuffing or gouges 4 lf the primary piston 2 is to be reused make certain that vents A amp B are open and free of obstructions 5 Make certain vent C is open in the upper body of the valve 6 Inspect the pipe threads in both body halves Make certain they are clean and free of thread sealant 7 Inspect the treadle or pedal assembly and mounting plate which attaches to the basic valve Make certain that the treadle or pedal roller turns freely and is lightly lubricated Note Some treadle pedal assemblies not furnished by Bendix do not employ a roller in which case make cer tain the mechanism in use moves across the plunger smoothly without binding or sticking Inspect the plunger for excessive scuffing a
8. ction the vehicle should not be oper ated until the necessary repairs have been made and both braking circuits including the pneumatic and mechanical devices are operating normally If the brake valve does not function as described above or leakage is excessive it isrecommended that it be replaced with a new or remanu factured unit available at Bendix outlets Always check the vehicle brake system for proper operation alter performing brake work and before returning the vehicle to service OPERATING CHECK Check the delivery pressure of both No 1 and No 2 circuits using test gauges known to be accurate Note The treadle or pedal will not be in a normal released position until the air brake system is pressurized The pedal or treadle will rise to its normal release position as the brake system is pressurized from O psi 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 No 1 circuit delivery pressure will be about 4 psi greater than the No 2 circuit delivery pressure with both supply reservoirs at the same pressure This in normal for this valve LEAKAGE CHECK Make and hold a pressure application of 20 psi Coa
9. ing plate then remove the valve from its mounting on the vehicle 5 21 22 20 18 EEE U Z I 13 FIGURE 10 EXPLODED VIEW 6 DISASSEMBLY The following disassembly and assembly procedure is pre sented for reference purposes and presupposes that a major rebuild of the brake valve is being undertaken Several re placement parts and maintenance kits are available which do not require full disassembly The instructions provided with these parts and kits should be followed in lieu of the instructions presented here Caution The brake valve may be lightly clamped in a bench vise during disassembly however over clamping will result in 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 delivery and supply ports on opposing sides of the valve s upper body 1 Remove all air line fittings and plugs 2 Mark the relationship of the upper and lower body a scribed line can be used then remove the four cap screws 16 that secure the lower body to the upper body Separate the two body halves and remove and discard the o ring 17 3 Pullthe secondary piston 18 out ofthe upper body and remove and discard the o rings 19 amp 20 from it 4 Remove and discard the special beveled retaining ring 10 from the lower body while manually holding and compressing the valve seat 11 in place 5 Slowly release the valve sea
10. nd wear Check the plunger bore inthe mounting plate for excessive wear as exhibited by egg shaping Inspect the mounting plate for severe corrosion paying particular attention to the area around the pedal or treadle fulcrum pin bores 8 When applicable in use check the rubber boot installed between the plunger and mounting plate for deteriora tion or cracking Replace if necessary 9 Inspect all air line fittings and plugs for corrosion Clean all old thread sealant from the pipe threads Any valve or treadle assembly component exhibiting a con dition described in inspection steps 1 to 9 should be discarded and replaced before proceeding ASSEMBLY 1 10 11 Using the lubricant provided Bendix Pc No 291126 lightly coat all o rings o ring bores and grooves Lightly lubricate the primary piston 2 bore into which the gradu ating spring 8 is installed Place the primary piston 2 on a flat surface and install the rubber spring 9 and metal graduating spring 8 Note The rubber spring 9 is used in the E 12 brake valve only If a rubber spring was not removed in disas sembly step 11 discard this component do not install it Install the proper graduating spring retainer 7 on top of the graduating spring 8 making certain that the side with the high circular protrusion is away from the spring Manually depress and hold the spring retainer 7 in the piston 2 then install the retaining
11. rt 12 DEL 2 7 The E 12 and E 15 valves are designed such that the treadle does not sit in an upright position until the air sys tem is built up to full reservoir pressure The supply pressure moves the primary piston upward transmitting a mechanical force to the spring retainer and plunger of the treadle assembly causing the treadle to move upright E 12 DUAL E 15 DUAL BRAKE VALVE BRAKE VALVE Z 5 J AG 7 or Q PRIMARY DELIVERY PSI TREADLE TRAVEL TREADLE TRAVEL FIGURE 2 TREADLE TRAVEL VERSUS DELIVERY PRESSURE m re BODY in mi Al DK N FIGURE 3 E 12 DUAL BRAKE VALVE CROSS SECTIONAL VIEW b E HE m 11 MV 3 MODULE _ TRAILER Le CONTROL VALVE al DUAL BRAKE VALVE S Z Lt SLACK ADJ USTER ge 7 AIR DRYER IN 1 SUPPLY RESERVOIR COMPRESSOR 1 SERVICE RESERVOIR FIGURE 4 TYPICAL PIPING SCHEMATIC 2 Ks 3 The circuits in the E 12 E 15 valves are identified as follows The no 1 or primary circuit is that portion of the valve between the primary piston 2 and the secondary piston 18 the no 2 or secondary circuit portion consists of the area between the secondary piston and the exhaust Cavity The supply delivery and exhaust ports of the E 12 E 15 brake valves are identified by designations cast into the valve body adjacent to their associated port See Figure 1 The primary supply and delivery ports are located in
12. t 11 allowing itto rise out of the body Remove the valve seat 11 then remove and discard the o ring 12 6 Remove and discard the valve assembly 13 along with its o ring 15 from the lower body Remove the valve assembly return spring 14 7 Carefully remove and discard the exhaust diaphragm retainer 24 and exhaust diaphragm 25 from the lower body Note Some E 12 amp E 15 brake valves have threaded exhaust ports in lieu items 24 amp 25 8 Using finger force push the piston 2 into the body until the piston retaining ring 1 is fully visible Remove the piston retaining ring 1 taking care not to damage the piston bore in the body 9 Gently tap the body on a soft surface to remove the piston 2 Remove and discard the o rings 3 amp 5 and both wear rings 4 from the piston 2 10 Place the piston on a flat surface and using finger force depress and hold the spring retainer 7 then remove and discard the retaining ring 6 from the piston 2 11 Gently release the spring retainer 7 allowing it to rise out of the piston Remove the spring retainer 7 and graduating spring 8 from the piston 2 12 Remove and discard the rubber spring 9 from the interior ofthe piston 2 Note The rubber spring 9 is installed in the E 12 brake valve only 13 Remove and discard the special beveled retaining ring 10 from the piston 2 while manually holding and compressing the valve se
13. t the exhaust port and body of the brake valve with a soap solution Leakage permitted is a 1 bubble in 3 seconds in both the applied and released positions 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 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 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 an AD IS air dryer system or a dryer reservoir module be sure to drain the purge reser
14. tall the piston retaining ring 1 in its groove in the upper body making certain it is fully seated in the groove Install the plunger 21 in its return spring 22 Install the spring and plunger on the secondary piston 18 12 13 14 15 16 17 18 19 While manually depressing and holding the plunger and spring on the piston slide the plunger and spring retainer 23 into place so that it secures both the plunger and spring to the piston Make certain the retainer flanges are securely around piston lip and plunger groove Install the o rings 19 amp 20 on the secondary piston 18 Install the exhaust diaphragm 25 on the lower body and secure it using diaphragm retainer 24 Note Some E 12 amp E 15 brake valves have threaded exhaust ports in lieu items 24 amp 25 Install the valve spring 14 in the lower body then install the valve assembly 13 in the spring Install the o ring 12 into the o ring groove of piston 2 then install the valve seat 11 on the valve assembly 13 Gently depress and hold the valve seat in the lower body while installing the special beveled retaining ring 10 Important The beveled retaining ring 10 must be in stalled with its flat side against the valve seat 11 and its beveled side visible Make certain the beveled retaining ring 10 is completely seated in its groove in the lower body Install the assembled secondary piston 18 in the up
15. the upper body portion while the secondary supply and delivery ports are located in the lower body portion of the valve 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 the primary and secondary circuits of the brake valve use acommon exhaust protected by an exhaust diaphragm OPERATION APPLYING NORMAL OPERATION PRIMARY CIRCUIT PORTION When the brake treadle 26 is depressed the plunger 27 exerts a force on the spring retainer 7 graduation spring 8 and primary piston 2 The primary piston which con tains the exhaust valve seat closes the primary circuit exhaust valve As the exhaust valve closes the inlet valve for the primary circuit moves off of its seat allowing the air from the supply port of the primary circuit to flow out the delivery port of the same circuit TP 5 TRACTOR PROTECTION SPRING BRAKES SLACK ADJ USTER GR AE QUICK vouele UA AL RELEAGE CHECK UO HARZ 5 1 ANN BP R1 BOBTAIL PROPORTIONING VALVE Le lz ul amp 6 2 SERVICE RESERVOIR PLUNGER FIGURE 5 APPLYING NORMAL OPERATION APPLYING NORMAL OPERATION SECONDARY CIRCUIT PORTION The relay piston moves down with the primary piston and closes the secondary circuit exhaust When the inlet valve in the primary portion of the valve is moved off its
16. voir 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 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 9 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 10 Prior to returning the vehicle to service make cer tain all components and systems are restored to their proper operating condition VEHICLE PREPARATION 1 Parkthe vehicle on a level surface and block the wheels and or hold the vehicle by means other than the air brakes 2 Drain the air pressure from all vehicle reservoirs VALVE REMOVAL 1 Identify and mark or label all air lines and their respec tive connections on the brake valve to facilitate ease of installation Disconnect all air lines 2 Mark the relationship of the valve body to the mount
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