BENDIX BW1231 User's Manual
Contents
1. C The stop lamps should light and go off when the application is released Pop Pressure Vehicle Test Procedure Note Bendix is not aware of any federal legislation that specifies the pressure at which the YELLOW parking brake control valve must automatically trip to apply the vehicle parking brakes This includes the Federal Motor Carrier Safety Regulations FMCSR for in use vehicles the CVSA out of service criteria and the Federal Motor Vehicle Safety Standards FMVSS for newly manufactured vehicles Although the trip pressure for the parking brake control valve is not stipulated for in use or newly manufactured vehicles a parking brake control valve trip pressure of 20 40 psi is currently 02 2009 specified as part of the Commercial Driver License in the CDL Manual The CDL Manual is not consistent with the regulations cited above See Bendix Bulletin TCH 003 051 continued A Charge the air system to governor cut out B Disconnect the service or control blue line to the trailer C Take care to restrain the service coupling and direct flow safely away while making and holding a full service brake application via the foot valve D As the service application is vented through the open gladhand the service system pressure drops until the tractor protection control red valve trips and shuts off the leak through the open coupling This leak must be shut off E Record the pressure in t2. TRACTORS men o Air Dryer J Axle Reservoir l 1 E E E EE U EB 7 Q Front i P i i Axle Reservoir Charging Primary Secondary Park Parking Accessories Supay Rear Supply Control a Reservoir Axle Reservoir Dag K pp y Prr z pee m r L Tu Flo 550 Tu Flo 750 WS 24 Wheel l rmm ES Drum Brake w os BA 921 BA 922 speed Sensor Rear Axle Reservoir Notes The color coding of the brake system schematic follows TMC Recommended Practice 423 ES Drum Brake w l WS 24 Wheel Versajust Automatic Speed Sensor Versajust Automatic Slack Air Compressor Adjuster and SB 4 Spring ES Drum Brake w Tu Flo 550 Tu Flo 750 Versajust Automatic Slack ES Drum Brake w Versajust Automatic BA 9217 BA 922 E Brake Chamber Air disc amp drum brake actuation combined on a single axle are shown for pictorial purposes only Slack Adjuster and Adjuster and SB 4 Spring Slack Adjuster and ir Compressor 1 Equipped with standard Bendix ABS Antilock Brake System Service Chamber Brake Chamber Service Chamber T Equipped with Bendix ABS and Smart ATC Traction Control o Accessories Bendix brand wheel end solutions are brought to you by Bendix brand wheel end solutions are brought to you by Bendix Spicer Foundation Brake LLC a Bendix CVS and Dana joint venture Bendix Spicer Foundation Brake LLC a Bendix CVS and Dana
3. joint venture TEST 1 CHECKLIST 2 TEST 4 TEST 5 TEST 6 Continued si f Governor cut out Low pressure warning Pressure build up If there is excessive leakage in the supply side of the pneumatic system one or more Leakage service air delivery Manual Parking Brake Operation Z Specify genuine Bendix replacement parts every time you VEHICLE PARKED WHEELS CHOCKED of the following devices could be causing the problem FULL PRESSURE ENGINE STOPPED PARKING BRAKES RELEASED FULL PRESSURE ENGINE IDLING 600 900 RPM OK service your air brake system NOTE A leak detector or soap solution will aid in locating the faulty component All k Bendi t t ia dt t i itti enuine bendix replacement parts are manufactured to mee Drain all the reservoirs to 0 psi me lines ara j Make and hold an 80 90 psi brake application This can be accomplished by FOR STRAIGHT TRUCKS BUSES AND BOBTAIL TRACTORS 3 Pop Pressure Vehicle Test Procedure Continued ori T al OE specific ua ons to a arantee quality reliability and Low pressure indicator s m nlai Start the engine and run at fast idle The low pressure warning should be 3 p N using the Bendix BVA 85 brake valve actuator If the vehicle is not equipped Manually operate the park control yellow button valve and note that parking A Install an accurate shop standard pressure gauge in the secondary service roper operating performance on Note on vehicles equipped with ABS the warnin
4. 1 A U N Dented or kinked lines Improperly installed hose fitting A faulty quick release valve or spring brake control valve Damaged or improperly installed Spring Brake Chamber and or Service Chambers 5 Foundation Brake component binding improper installation and or lack of lubrication If the trailer brakes do not actuate and the trailer supply line remains charged check the following 1 2 3 4 Tractor protection control Trailer spring brake valve Damaged spring brake chamber and or service chambers Foundation brake component binding improper installation and or lack of lubrication RETEST TO VERIFY PROPER OPERATION OF ALL ITEMS REPAIRED OR REPLACED TEST 6 Dual circuit system integrity check emergency braking and or automatic application of the parking brake and or Tractor protection valve operation FULL PRESSURE ENGINE STOPPED PARKING BRAKES RELEASED Drain the front axle or secondary reservoir to 0 psi A The rear axle or primary reservoir should retain most of its pressure B On combination vehicles the trailer air system should remain charged C Tractor and trailer brakes should not apply automatically With no air pressure in the front axle reservoir make a brake application A Rear axle brakes should apply and release when application is released B On combination vehicles the trailer brakes should also apply and release when application is released
5. L NECESSARY REPAIRS BEFORE PROCEEDING TO TEST 5 SEE CHECKLIST 4 FOR COMMON CORRECTIONS CHECKLIST 4 If there is excessive leakage in the service side of the pneumatic system one or more of the following devices could be causing the problem NOTE A leak detector or soap solution will aid in locating the faulty component 2 Stoplight switch 4 Dual brake valve Loose service lines and fittings Trailer control valve Tractor protection valve 6 Double check valve N oO wo Service brake relay valves 8 Spring brake chamber service chamber and or brake chamber diaphragms 9 Inverting relay spring brake control valve where applicable usually found on the spring brake relay valve straight trucks and buses If the automatic slack adjuster is not adjusting repair or replace to obtain desired setting CAUTION If the brake chamber push rod travel exceeds the allowable stroke identify and correct the root cause of the excess stroke Do not make manual adjustments of an automatic slack adjuster once it can no longer automatically adjust the brakes Manual adjustment DOES NOT fix the underlying wheel end adjustment As soon as possible have the vehicle inspected by a qualified technician or consult the manufacturer s troubleshooting guidelines to find and fix the problem RETEST TO VERIFY PROPER OPERATION OF ALL ITEMS REPAIRED OR REPLACED CHECKLIST 5 If sluggish performance is noted in either test check for
6. PP 5 Control Typical Tractor System Schematic Typical Truck System Schematic Val 7 Iye 7 Ive 7 with Bendix Components with Bendix Components Mv 3 ms TP 3DC Tractor Hose Couplings Control Control Valve l Protection Valve WS 24 Wheel tl I Speed Sensor Supply maaa g PP DC Park WS 24 Wheel Control Valve Bendix EC 60 ADB 22X Sneed Serisor t ADB 22X Electronic Controller Air Disc Air Di Standard Brake Premium Brake TCS 9000 Bendix EC 60 Air Disc FAAS Brake Valve endix co Brake PON Electronic Controller Standard E M 32 M 32QR Premium r r Modulator M 32 I SR 7 H M 32QR Spring Brake Modulator i I a Modulating _ Tr O u b e S h O O t nN 7 r SS g Service Quick a E 8P E 6 Brake Valve Relay Valve pei an Jj ave E 8P E 6 Brake ein Valve with BVA 85 Service QR 1C Quick x Blake Valemciater a aa a To Accessories aime d CE Indicator i AD 9 AD IP Low Pressure Air Dryer Indicator ADIS TRUCKS AND TRUCK
7. Visit www bendix com or www foundationbrakes com for MAKE ALL THE NECESSARY REPAIRS BEFORE PROCEEDING TO TEST 2 Check brake chamber push rod travel refer to chart below for the CVSA Max 4 For Towing Vehicles Only Test the tractor protection valve feature SEE CHECKLIST 1 FOR COMMON CORRECTIONS CHECKLIST 1 If the low pressure warning lamp or buzzer doesn t come on 1 2 3 Check the warning lamp wiring Check the warning lamp bulb Repair or replace the buzzer bulb or low pressure warning switch es If the governor cut out is higher or lower than specified by the vehicle manual 1 2 Check the dash gauge with test gauge known to be accurate Repair replace or adjust the governor as necessary after ensuring the compressor unloader mechanism is operating correctly If the low pressure warning occurs below 60 psi 1 2 Check the dash gauge with test gauge known to be accurate Repair or replace the faulty low pressure indicator switch If the compressor build up time exceeds 40 second at maximum governed RPM or is considerably greater than the permanent record figure 1 2 3 Examine the compressor air inlet filter and inlet line checking for restrictions damage or wear Clean or replace the filter or inlet line as necessary Check the compressor discharge port and line for excessive carbon Clean or replace the discharge line as necessary If there is carbon find the cause of the excessive heat
8. With the system fully charged and governor in the unloaded mode listen at the compressor inlet for leakage If leakage can be heard remove the unloaders and repair or replace as necessary RETEST TO VERIFY PROPER OPERATION OF ALL ITEMS REPAIRED OR REPLACED FULL PRESSURE TRACTOR PARKING BRAKES APPLIED YELLOW Allow the air pressure to stabilize for at least 1 minute TEST 2 Leakage reservoir air supply For additional information refer to video Assessing Air Brake System Air Leakage BW2327 CD BUTTON OUT amp TRAILER CHARGED RED BUTTON IN 2 Observe the dash gauge pressures for 2 minutes and note any pressure drop A Pressure Drop Single Vehicle A 4 psi drop within 2 minutes is allowable for either service reservoir B Pressure Drop Tractor Trailer A 6 psi drop within 2 minutes is allowable for either service reservoir C Pressure Drop Tractor 2 Trailers An 8 psi drop within 2 minutes is allowable for either service reservoir MAKE ALL NECESSARY REPAIRS BEFORE PROCEEDING TO TEST 3 SEE CHECKLIST 2 FOR COMMON CORRECTIONS BW1231 2013 Bendix Commercial Vehicle Systems LLC a member of the Knorr Bremse Group All Rights Reserved 02 2013 Printed in U S A FULL PRESSURE ENGINE STOPPED PARKING BRAKES RELEASED OK Pressure Modulator Valve and Traction Control Valve Chuff Test Make and hold brake application When ignition power is applied each modulator soleno
9. es apply and release promptly as the the reservoir to drain completely America you re never far from quality genuine Bendix replacement 4 Build up time pressure should build from 85 100 psi within 40 seconds O 9 Governor may be mounted on the air dryer as illustrated on the compressor or remotely aes control button is pulled out and pushed in D Open the secondary reservoir s manual drain valve creating a bleed rate of pans at Commesso disedari B Pressure Drop Tractor Trailer A 6 psi drop within 2 minutes is allowable for Manually operate system park control usually yellow diamond button and note approximately 20 50 psi min Li 5 Governor cut out cuts out at the correct pressure usually 125 135 psi g VOmpreSSor discnarge ne either service reservoir all parking brakes tractor and trailer apply promptly RETEST TO VERIFY PROPER OPERATION OF ALL ITEMS REPAIRED OR REPLACED C Pressure Drop Tractor 2 Trailers An 8 psi drop within 2 minutes is allowable i E Monitor the pressure gauge noting the pressure at which the parking control Governor cut in reduce the service air pressure to governor cut in The Oo ze p bsi crop MAKE ALL NECESSARY REPAIRS BEFORE PROCEEDING TO TEST 6 automatically pops This is not a Federal requirement See Note in previous difference between cut in and cut out pressure must not exceed 30 psi TEST 3 for either service reservoir SEE CHECKLIST 5 FOR COMMON CORRECTIONS column i i
10. g lamp will also come on Sros AKG talay VANO me BVA orae valve actuator an assistant should be used to maintain a brakes apply and release promptly as the control valve button is pulled out and reservoir E ee p aP x momentarily when the ignition is turned on On some systems such as the 4 Spring brake relay valve where applicable constant application during these tests ished T a sT re e Rely on genuine Bendix replacement parts to keep your air brake Bendix AD IS dryer system illustrated reservoirs may not fill simultaneously 5 Dual brake valve Allow pressure to stabilize for 1 minute then begin timing for 2 minutes while FOR TRACTOR TRAILER COMBINATIONS eee PBSerNOUS Unt the Compressor BUFU system operating efficiently and one reservoir may fill to 110 psi before the other starts to fill 8 Trailer hang conttolvalve watching the dash gauges for a pressure drop i e With thousands of authorized Bendix parts outlets across North 3 IL nociach ngi hould do off above 60 psi 7 Parking control valve AP Dron Sinale Vehicle A 4 osi d ithin 2 minutes is allowable f 1 Manually operate the tractor protection control valve trailer supply valve usually C Fully open the manual drain valve on the primary service reservoir allowing E i Low pressure warning dash warning lamp should go off above 60 psi T S E E E E D AREE ehicle A 4 psi drop within 2 minutes is allowable for red octagonal button Note that trailer brak
11. he service reservoirs Disconnect the trailer supply coupling to verify that the supply or emergency red coupling has been vented to atmosphere thereby activating the trailer emergency feature Close the drain cocks recharge the system and drain the rear axle primary reservoir to 0 psi O O O OO A The front axle reservoir should retain most of its pressure B On combination vehicles the trailer air system should remain charged With no air pressure in the rear axle reservoir make and release a brake application A Front axle brakes should apply and release B On combination vehicles the trailer brakes should also apply and release C If the vehicle is equipped with a spring brake modulating valve typically found on trucks towing trucks and buses the rear axle brakes should also apply and release by exhausting spring brake air MAKE ALL NECESSARY REPAIRS BEFORE PROCEEDING SEE CHECKLIST 6 FOR COMMON CORRECTIONS CHECKLIST 6 If the vehicle fails to pass the tests outlined then check the following components for leakage and proper operation 1 Fittings 3 Pressure protection valves 5 7 Parking control valve 9 Trailer spring brake control valve 2 Kinked hose or tubing 4 Double check valves Tractor protection valve 6 Tractor protection control valve 8 Relay valves antilock modulators straight trucks and buses 10 Inverting relay spring brake control val
12. id is briefly energized If the air system is fully charged and the service brake pedal is depressed during ignition the modulator creates a single sharp audible chuff of air pressure The modulators are energized in a certain pattern as follows right front left front right rear left rear This test is performed only when the vehicle is stationary if the vehicle moves the chuff test will not be performed NOTE The Bendix EC 60 controller will perform a PMV chuff test on all installed modulators in the following order 1 Steer Axle Right PMV 2 Steer Axle Left PMV 3 Drive Axle Right PMV 4 Drive Axle Left PMV 5 Additional Axle Right PMV 6 Additional Axle Left PMV 7 Drive Axle TCV The pattern will then repeat itself See appropriate Service Data Sheet for repairs MAKE ALL NECESSARY REPAIRS BEFORE PROCEEDING TO TEST 4 Bendix MV 3 valve allowable Stroke With the parking brakes released and service brakes applied with 80 to 90 psi of air pressure to the service chambers Brake Chamber Type CVSA Max Allowable Stroke 12 1 3 8 12L 1 3 4 16 1 3 4 16L 2 20 1 3 4 20L 2 20L3 2 1 2 24 1 3 4 24L 2 24L3 2 1 2 30 2 30L 2 1 2 36 2 1 4 Check the angle formed between the brake chamber push rod and the slack adjuster arm It should be equal to or slightly less than 90 in the applied position 80 90 psi and the same across the axle MAKE AL
13. ve optional RETEST TO VERIFY PROPER OPERATION OF ALL ITEMS REPAIRED OR REPLACED Service Data Sheets and other literature such as the following BW2780 Troubleshooting Bendix ESP Stability System BW1555 Brake Balance Procedure BW1114 Quick Reference Catalog BW5057 Air Brake Handbook SD 13 4863 Service Data Sheet for Bendix EC 60 ABS ATC Standard amp Premium Controllers Attend Bendix Brake School or visit www brake school com for air brake system and product training endix www bendix com www foundationbrakes com 1 800 AIR BRAKE 1 800 247 2725
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