Bendix Bw5057 Users Manual

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


DRIVING SAFER

DOESN’T

HAPPEN

BY

ACCIDENT.

Our nation’s roadways are increasingly busy, and the need has
never been greater for solutions to help commercial vehicle
drivers respond to the situations they encounter every
day – especially in today’s CSA (Compliance, Safety,
Accountability) environment. Bendix is leading the way
to improved highway safety with an ever-increasing
portfolio of road-tested, advanced commercial
vehicle technologies that are affordable
and effective.
We offer robust active and supportive safety
technologies that help fleets:
» reduce collisions
» increase stopping power
	

» strengthen driver performance
with actionable data

Our solutions are driving
in a new era of safety.

Learn more.
Call 1.800.247.2725 or visit bendix.com today. Follow us on Twitter @Bendix_CVS.

©Bendix Commercial Vehicle Systems LLC, a member of the Knorr-Bremse Group. All Rights Reserved. 06/12

» improve stability

The Air Brake Handbook

For more information, visit www.bendix.com or www.foundationbrakes.com • 1-800-AIR-BRAKE (1-800-247-2725)

1

Device Index
Alphabetic Device Index
AutoVue® by Bendix CVS
Lane Departure Warning (LDW) System . . . . . 50
Bendix® A-18™ Controller Assy . . . . . . . . . . . . . . 44
Bendix® ACom® Diagnostic Software . . . . . . . . . . . 48
Bendix® Brand Actuators. . . . . . . . . . . . . . . . . . 20
Bendix® AD-2®, AD-9®, AD-9si™, AD-IP® Air Dryers . . . . 13
Bendix® AD-IS® Air Dryer Module . . . . . . . . . . . . . 13
Bendix® AD-SP® Air Dryer . . . . . . . . . . . . . . . . . 15
Bendix® AF-3™ In-line Air Filter. . . . . . . . . . . . . . . 15
Bendix® Brand Air Disc Brakes . . . . . . . . . . . . . . 23
Bendix® ASA-5® Automatic Slack Adjuster . . . . . . . . 24
Bendix® BA-921®, BA-922® Air Compressors . . . . . . 10-11
Bendix® BASIC™ Test Kit. . . . . . . . . . . . . . . . . . .11
Bendix® BP-R1® Bobtail Proportioning Relay Valve . . . . 26
Bendix® BVA-85™ Brake Valve Actuator . . . . . . . . . . 30
Bendix® BX-2150™ Air Compressor . . . . . . . . . . . . 10
Bendix® Converter Dolly Brakes . . . . . . . . . . . . . . 36
Bendix® Cyclone DuraDrain® Trailer Water Separator . . . 15
Bendix® D-2® Governor . . . . . . . . . . . . . . . . . . 12
Bendix® DC-4® Double Check Valve. . . . . . . . . . . . 17
Bendix® Dryer Reservoir Module . . . . . . . . . . . . . 14
Bendix® DS-2™ Double Check Valve & Stop Light Switch . 17
Bendix® DuraFlo 596™ Air Compressor . . . . . . . . . 10-11
Bendix® E-10™, E-10P™ Brake Valve . . . . . . . . . . . 19
Bendix® E-10PR™ Retarder Control Brake Valve . . . . . 19
Bendix® E-6® , E-7™, E-8P® Brake Valves . . . . . . . . . 19
Bendix® EC-30™, EC-60™ ABS/ATC Controller . . . . . . 39
Bendix® ESP® Functionality . . . . . . . . . . . . . . . . 41
Bendix® EverFlow® Module . . . . . . . . . . . . . . . . 14
Bendix® Inlet Check Valve . . . . . . . . . . . . . . . . . 12
Bendix® Inlet Regulating Valve. . . . . . . . . . . . . . . 12
Bendix® LP-3™ Low Pressure Indicator . . . . . . . . . . 16
Bendix® LQ-4™ Ratio Valve, LQ-2™, LQ-5™ Limiting Valves 25
Bendix® M-32™ and M-32QR™ Modulators. . . . . . . . . 38
Bendix® MV-3® Dash Control Module . . . . . . . . . . . 32
Bendix® PP-1® and PP-3™ Valves . . . . . . . . . . . . . 27
Bendix® PP-5™ Push-Pull Control Valve . . . . . . . . . . 30
Bendix® PP-7™, PP-8™ Control Valves . . . . . . . . . . . 27
Bendix® PP-DC® Park Control Valve . . . . . . . . . . . 31
Bendix® PR-2™, PR-4™ Pressure Protection Valves . . . . 17
Bendix® PR-3™ Reservoir Control Valve . . . . . . . . . . 37
Bendix® PuraGuard® QC™ Oil Coalescing Filter . . . . . . 15

Bendix® QR-1®, QR-1C® , QR-L™, QRN™
Quick Release Valves . . . . . . . . . . . . . . . 25
Bendix® R-12DC® Relay Valve . . . . . . . . . . . . . . 26
Bendix® R-12P™ Relay Valve . . . . . . . . . . . . . . 26-36
Bendix® R-12®, R-14®, R-6™ Relay Valves . . . . . . . . . 26
Bendix® R-7™ Modulating Valve . . . . . . . . . . . . . . 25
Bendix® R-8P™ Relay Valve . . . . . . . . . . . . . . . . 26
Bendix® RD-3™ Control Valve . . . . . . . . . . . . . . . 30
Bendix® RDU™ (Remote Diagnostic Unit) . . . . . . . . . 47
Bendix® RE-6NC™ Relay Emergency Valve . . . . . . . . 37
Bendix® Reservoirs . . . . . . . . . . . . . . . . . . . . 16
Bendix® RV-1™, RV-3™ Pressure Reducing Valve . . . . . 17
Bendix® Foundation Drum Brakes . . . . . . . . . . . . . 22
Bendix® SC-3™Single Check Valve . . . . . . . . . . . . 16
Bendix® SC-PR™ Valve . . . . . . . . . . . . . . . . . . 15
Bendix® SL-4™ and SL-5™ Stop Lamp Switches . . . . . . 29
Bendix® Spring Brake Actuators . . . . . . . . . . . . . . 20
Bendix® SR-2™, SR-4™, SR-5™ Spring Brake Valve . . . . 34
Bendix® SRC-7000™ Trailer Spring Brake Valve . . . . . 34-35
Bendix® ST-1™, ST-3™ and ST-4™, Safety Valves . . . . . 16
Bendix® SV-1™ Synchro Valve . . . . . . . . . . . . . . . 30
Bendix® SV-4™ Synchro Valve . . . . . . . . . . . . . 30, 36
Bendix® System-Guard® Trailer Air Dryer . . . . . . . 15, 61
Bendix® TABS-6, TABS-6 Advanced Trailer ABS . . . . . 45
Bendix® TABS-6 Advanced MC Trailer ABS . . . . . . . . 46
Bendix® TC-2™, TC-6™, TCS-9000™ Trailer Control Valves 32
Bendix® TE-1™ Trailer Emergency Stop Light . . . . . . . 35
Bendix® TP-3®, TP-3DC™,
TP-5™ Tractor Protection Valves . . . . . . . . . 33
®
Bendix TR-3™ Valve. . . . . . . . . . . . . . . . . . . . 30
Bendix® Trailer Control (TC) Valves . . . . . . . . . . . . 32
Bendix® TRDU™ (Trailer Remote Diagnostic Unit) . . . . . 47
Bendix® Tu-Flo® 400, 500, 501, 550, 700,
and 750 Air Compressors . . . . . . . . . . . . 10-11
Bendix® TW-1™, TW-2™, TW-3™ Control Valves . . . . . . 29
Bendix® TW-11™, TW-12™ Valve . . . . . . . . . . . . . . 29
Bendix® Versajust® . . . . . . . . . . . . . . . . . . . . . 24
Bendix® Wingman® Advanced . . . . . . . . . . . . . . . 49
Bendix® WS-24™ Wheel Speed Sensors . . . . . . . . . 38
Bendix® Yaw Stability . . . . . . . . . . . . . . . . . . . 41
SmarTire® Tire Pressure Monitoring System (TPMS)
by Bendix CVS . . . . . . . . . . . . . . . . . . 50

Bendix Commercial Vehicle Systems LLC and Bendix Spicer Foundation Brake LLC now provide both on-line and
in-person Bendix Brake Training Schools.
• The Bendix On-line Brake School is your complete resource for web-based technical training. Keep your skills
sharp with a comprehensive menu of ever-evolving instructional videos and interactive modules.
• The In-Person Bendix Brake Training School is conducted by the veteran ASE-certified Bendix team, this allinclusive course of classroom lectures is available at locations around the country.
•

To enroll, visit www.bendix.com, click on the "Services & Support" tab, select "Brake School" from the menu on the
left side of the page, and then choose the type of school you wish to participate in.

2

For more information, visit www.bendix.com or www.foundationbrakes.com • 1-800-AIR-BRAKE (1-800-247-2725)

Handbook Section Index

How to use the Air Brake Handbook
This twelve-section handbook provides an introduction to the use and operation of Bendix air brake systems and
devices.
Components are introduced and shown with typical system diagrams to depict where they are used. As new components
are introduced and their function explained, they gradually build up to a complete functioning air brake system reflected
in the schematics at the close of this handbook.
Partial system-drawings, displayed throughout the manual, assist in explaining the use of the components. See section
12 for examples of vehicle system schematics.

Contents
Air Brake Handbook Section

Page No.

Index and Precautions

Air Brake Handbook Section

Page No.

Section 4: Tractor Parking,Trailer Charging/ Parking and
Emergency Systems

Device Index

2

Handbook Section Index

3

Tractor/Trailer Parking and Emergency Systems

31

General Precautions

4

Park Control Valves

31

72-76

Dash Control Valves

32

Tractor Protection Valves

33

Trailer Spring Brake Valves

34-35

Glossary
Section 1: Introduction
An Introduction

6-7

Section 2: The Charging, Air Treatment and Storage System
The Charging, Air Treatment and Storage System
Compressors

8
9-11

Governors, Etc.
Air Dryers

Section 5: Convertor Dolly Brakes
Trailer/Converter Dolly Brakes
Section 6: Antilock Braking System

12

Antilock Braking Systems: Components

38

13-15

Truck and Tractor ABS Operation; ATC

39-40

Reservoirs, Etc.

16

Advanced ABS

Misc. Components

17

Advanced ABS Operation and Features

Section 3: The Control System

41
42-43

Trailer ABS Components and Operation

44
45
46

The Control System: Dual Circuit Brake Valves

19

PLC, Troubleshooting

Actuators

20

Advanced Trailer ABS Operation and Features

Foundation Brakes: Drum Brakes (aka S-Cam)

21

Troubleshooting ABS

Foundation Drum Brakes

22

Air Disc Brakes

23

Slack Adjusters

24

Quick Release, Ratio & Modulating Valves

25

Relay Valves

26

Push-Pull Control Valves

27

Spring Brake Valves

28

Lever-Operated Control Valves

29

Downloading and Ordering Literature

30

Contacting Bendix

Additional Control Valves

36-37

47-48

Section 7: Additional Systems and Components
Additional Systems and Components

49-50

Section 8: The Fundamentals of Air Braking
Air Brake System Fundamentals

51-62

Section 9: Air Brake System Troubleshooting Test
Air Brake System Troubleshooting Tests

63-68

Section 10: Bendix Literature and Contact Information
69-70
69

Section 11: About Bendix
About Bendix Commercial Vehicle Systems LLC

71

Section 12: Typical Air Brake System Schematics
DIN symbols are used in this handbook.

Examples of Air Brake System Schematics

For more information, visit www.bendix.com or www.foundationbrakes.com • 1-800-AIR-BRAKE (1-800-247-2725)

81-89

3

General Precautions

IMPORTANT
The systems presented in this manual are intended for illustrative purposes
only and are not intended to be used for actual vehicle piping.

Air Brake System General Precautions
GENERAL SAFETY GUIDELINES
WARNING! PLEASE READ AND FOLLOW THESE INSTRUCTIONS
TO AVOID PERSONAL INJURY OR DEATH:
When working on or around a vehicle, the following guidelines should be observed AT ALL TIMES:
▲ Park the vehicle on a level surface, apply the
parking brakes and always block the wheels.
Always wear personal protection equipment.
▲ Stop the engine and remove the 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 a
Bendix® AD-IS® air dryer system, a Bendix® DRM™
dryer reservoir module, or a Bendix® AD-9si™ air
dryer, be sure to drain the purge reservoir.
▲ F o l l o w i n g t h e v e h i c l e m a n u f a c t u r e r ’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® brand 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
certain all components and systems are restored
to their proper operating condition.
▲ For vehicles 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.
▲ The power MUST be temporarily disconnected
from the radar sensor whenever any tests USING
A DYNAMOMETER are conducted on a Bendix®
Wingman® Advanced™-equipped vehicle.

▲ You should consult the vehicle manufacturer's operating and service manuals, and any related literature,
in conjunction with the Guidelines above.

4

For more information, visit www.bendix.com or www.foundationbrakes.com • 1-800-AIR-BRAKE (1-800-247-2725)

:KHQ
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