BENDIX BW1432 User's Manual
Contents
1. Bendix R 6 Relay Valve SERVICE PORT SUPPLY PORT RESERVOIR MOUNT TYPE DELIVERY PORTS 4 EXHAUST FIGURE 1 DESCRIPTION The relay valve in an air brake system functions as a relay station to speed up the application and release of the brakes The valve is normally mounted at the rear of the vehicle in proximity to the chamber it serves The valve operates as a remote controlled brake valve that delivers or releases air to the chamber in response to the control air delivered to it from the foot brake valve or other source The R 6 relay valve is a piston operated valve For ease of servicing an insert or cartridge type inlet exhaust valve is employed This feature permits service of the inlet exhaust valve without line removal The R 6 relay valve may be mounted directly to or remotely from the reservoir which provides its supply pressure Standard porting consists of one 1 service port and four 4 delivery ports There are two 2 supply ports in the reservoir mounted valve and one 1 supply port in the remote mount valve SD 03 1060 RETURN RELAY PISTON SPRING R 6 RELAY VALVE INSERT FIGURE 2 OPERATION APPLYING Air pressure delivered to the service port enters the small cavity above the piston and moves the piston down The exhaust seat moves down with the piston and seats on the inner or exhaust portion of the inlet exhaust valve sealing off the exhaust passage At the same t2. Bendix parts available at Bendix outlets REMOVING AND INSTALLING REMOVING Block and hold vehicle by means other than air brakes Drain air brake system reservoirs If entire valve is to be removed identify air lines to facilitate installation Disconnect air lines from valve Remove mounting bolts then valve Itis generally not necessary to remove entire valve to service the inlet exhaust valve The inlet exhaust valve insert can be removed by removing the two exhaust cover cap screws and cover Insert then may be pulled out CAUTION DRAIN RESERVOIRS BEFORE REMOVING INSERT Use care so as not to damage inlet exhaust valve or guide o ring COMPRESSOR GOVERNOR SUPPLY RESERVOIR TYPICAL RELAY VALVE PIPING SINGLE CIRCUIT SYSTEM 2 SERVICE RESERVOIR CHAMBERS INSTALLING Clean air lines connecting to valve Inspect all lines and or hoses for damage and replace as necessary Install valve and tighten mounting bolts Connect air lines to valve Plug any unused ports Test valve as outlined in Operating and Leakage Tests DISASSEMBLY NOTE Prior to disassembly mark location of cover to body to facilitate assembly 1 Remove cover cap screws 1 Remove cover 2 with relay piston 4 and spring 6 if so equipped 2 Remove relay piston 4 from cover 3 Remove piston o ring 3 from piston 4 and cover seal o ring from body 4 Remove exhaust cover cap scr
3. RSONAL 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 10 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 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 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 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 p
4. VE ASSEMBLY NOTE If new inlet exhaust valve assembly insert is used disregard Steps 2 to 6 2 Install inlet exhaust valve 9 over valve body 10 smooth surface up 3 Position valve retainer 11 over inlet valve body 10 and valve 4 Install inlet valve spring 12 over inlet body 10 and install o ring 15 in the inner groove in the valve guide 14 5 Depress and hold guide down against inlet spring and install retainer ring 16 A 9 16 twelve point socket can be used to push the retainer ring down until it snaps in the groove in the inlet valve body 6 Install valve insert seat o ring 13 COMPLETE VALVE ASSEMBLY 7 Install insert 8 in valve body 7 install exhaust cover 17 and secure with 10 24 screws 19 torque to approximately 20 30 inch pounds 8 Install exhaust check diaphragm 18 into exhaust cover 17 9 Install cover seal o ring 10 Install relay piston o ring 3 on relay piston 4 then position relay piston in cover 11 If valve utilizes relay piston spring 6 position spring over guide in body 12 Position cover relay piston assembly in correct relative position with body if equipped with piston return spring make sure exhaust seat is centered inside spring 13 Install cover cap screws Torque to approximately 80 120 inch pounds 14 Test valve as outlined in Operating and leakage Tests section WARNING PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO AVOID PE
5. ews 19 exhaust cover and remove inlet exhaust valve insert 8 from body 7 5 Remove exhaust seat 5 from relay piston 4 and exhaust check valve 18 Remove only if new parts are to be installed INLET EXHAUST VALVE INSERT DISASSEMBLY NOTE If complete inlet exhaust valve is replaced disregard steps 6 to 9 6 Depress and hold valve guide down against valve spring tension and remove retainer 16 7 Remove valve insert seal o ring 13 valve guide 14 spring 12 and valve retainer 11 8 Remove the inlet exhaust valve 9 from its body 10 9 Remove inner o ring 15 from valve guide 14 CLEANING AND INSPECTION Wash all metal parts in mineral spirits wipe all rubber parts dry Inspect all parts for signs of wear and or deterioration Inspect springs for cracks distortion or corrosion Inspect inlet seat and exhaust seat for nicks and burrs and replace as necessary It is recommended that all rubber parts be replaced and that any part showing signs of wear or deterioration be replaced ASSEMBLY NOTE All torques specified in this manual are assembly torques and can be expected to fall off after assembly Do not retorque after initial assembly torques fall For assembly hand wrenches are recommended 1 Prior to assembly lightly lubricate the relay piston guide post o rings cover bore and inlet body with Dow Corning Silicone 55 M Pneumatic grease Bendix Pc No 291126 INLET EXHAUST VAL
6. ime the outer or inlet portion of the inlet exhaust valve moves off its seat permitting supply air to flow from the reservoir past the open inlet valve and into the chambers BALANCED The air pressure being delivered by the open inlet valve also is effective on the bottom area of the relay piston When air pressure beneath the piston equals the service air pressure above the piston lifts slightly and the inlet spring returns the inlet valve to its seat The exhaust remains closed as the service line pressure balances the delivery pressure NOTE Some valves are equipped with a piston return spring which will assist the lifting of the piston As delivered air pressure is changed the valve reacts instantly to the change holding the brake application at that level RELEASING When air pressure is released from the service port and air pressure in the cavity above the relay piston is exhausted air pressure beneath piston lifts the relay piston and the exhaust seat moves away from the exhaust valve opening the exhaust passage With the exhaust passage open the air pressure in the chambers is then permitted to exhaust through the exhaust port releasing the brakes PREVENTIVE MAINTENANCE Important Review the Bendix Warranty Policy before performing any intrusive maintenance procedures Awarranty may be voided if intrusive maintenance is performed during the warranty period No two vehicles operate under identical conditions as a
7. ressures 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 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 cer tain all components and systems are restored to their proper operating condition COVER PISTON O RING CAP SCREW 4 RELAY PISTON EXHAUST SEAT RETURN SPRING BODY pina INLET amp EXHAUST VALVE INLET amp EXHAUST VALVE BODY SS RETAINER Se R 6 INSERT VALVE GUIDE O RING CAP SCREW RETAINER RING EXHAUST COVER 7 GUIDE SEAL O RING BW1432 2004 Bendix Commercial Vehicle Systems LLC All rights reserved 3 2004 Printed in U S A
8. 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 OPERATING AND LEAKAGE TEST 1 Fully charge air brake system and adjust brakes 2 Make several brake applications and check for prompt application and release at all appropriate wheels 3 With brake valve in released position coat the exhaust port with soap solution and check for inlet valve and valve guide o ring leakage 1 bubble in 5 seconds leakage permitted 4 Make and hold abrake valve application coat the exhaust port with soap solution and check for leakage 1 bubble in 3 seconds leakage permitted If leakage is detected replacing the inlet exhaust valve may correct the problem If leakage still occurs leakage may be caused by relay piston o ring or exhaust valve seat 5 Make and hold a brake valve application coat outside of valve body in area where cover joins the body for cover o ring leakage No leakage permitted If the valve does not function as described above or if leakage is excessive it is recommended that the valve be replaced with a new or remanufactured unit or repaired with genuine
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