Bendix Sd 03 817 Users Manual 817g

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SD-03-817
Bendix® E-6® & E-10™ Dual Brake Valves

TREADLE

TREADLE

MOUNTING
PLATE
MOUNTING
PLATE

BOOT
3/8” P.T.
PRIMARY
DELIVERY
3/8” P.T.
PRIMARY
SUPPLY

3/8” P.T.
SECONDARY
DELIVERY

EXHAUST

3/8” P.T.
SECONDARY
SUPPLY

3/8” P.T.
PRIMARY
DELIVERY
3/8” P.T.
SECONDARY
DELIVERY

3/8” P.T.
PRIMARY
SUPPLY
EXHAUST

3/8” P.T.
SECONDARY
SUPPLY

FIGURE 1 - BENDIX® E-6® DUAL BRAKE VALVE

FIGURE 2 - BENDIX® E-10™ DUAL BRAKE VALVE

DESCRIPTION

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.

The Bendix® E-6® (Figure 1) and E-10™ (Figure 2) dual
brake valves are floor-mounted, treadle-operated type
brake valves with two separate supply and delivery
circuits for service (primary) and secondary braking. Each
provides the driver with a graduated control for applying
and releasing the vehicle brakes.
The E-10™ dual brake valve (Figure 2) is similar to the E-6®
dual brake valve except that a metal coil spring housed in
an upper body assembly replaces the rubber spring used
in the E-6® valve. The use of a metal coil spring (and the
upper body assembly) provides greater treadle travel and,
therefore, provides the driver with a less sensitive “feel”
when making a brake application. The E-10™ dual brake
valve is generally used on buses, where smooth brake
applications contribute to passenger comfort.
The circuits in the Bendix® E-6/E-10 dual brake valves are
identified as follows: The primary circuit is that portion of the
valve between the spring seat which contacts the plunger
and the relay piston; the secondary circuit is that portion
between the relay piston and the exhaust cavity.

Both primary and secondary circuits of the brake valve use
a common exhaust protected by an exhaust diaphragm.

OPERATION
APPLYING: NORMAL OPERATION - PRIMARY
CIRCUIT PORTION
When the brake treadle is depressed, the plunger exerts
force on the spring seat, graduating spring, and primary
piston. The primary piston, which contains the exhaust
valve seat, closes the primary exhaust valve. As the
exhaust valve closes, the primary inlet valve is moved
off its seat, allowing primary air to flow out the primary
delivery port.

1

18

16
25

7

19
34

17
26

15

8
1
2

27

28

16

22
23

17

24

33
31

21

32

4
5

19
6

20

30

18

14

13
12
9

11

10

FIGURE 3 - BENDIX® E-6® DUAL BRAKE VALVE
SECTIONAL DIAGRAM

FIGURE 4 - BENDIX® E-10™ DUAL BRAKE VALVE
SECTIONAL DIAGRAM

APPLYING: NORMAL OPERATION SECONDARY CIRCUIT

delivery ports – the primary piston will mechanically move
the relay piston, allowing the piston to close the secondary
exhaust valve and open the secondary inlet valve, allowing
air to flow out the secondary delivery port.

When the primary inlet valve is moved off its seat, air is
permitted to pass through the bleed passage and enters the
relay piston cavity. The air pressure moves the relay piston,
which contains the exhaust seat, and closes the secondary
exhaust valve. As the secondary exhaust valve closes, the
secondary inlet valve is moved off its seat allowing the
secondary air to flow out the secondary delivery port.
Because of the small volume of air required to move the
relay piston, action of the secondary circuit of the valve is
almost simultaneous with the primary circuit portion.

APPLYING: LOSS OF AIR IN THE SECONDARY
CIRCUIT

BALANCED: PRIMARY CIRCUIT
When the primary delivery pressure acting on the piston
equals the mechanical force of the brake pedal application,
the primary piston will move and the primary inlet valve will
close, stopping further flow of air from the primary supply
line through the valve. The exhaust valve remains closed,
preventing any escape of air through the exhaust port.

BALANCED: SECONDARY CIRCUIT

APPLYING: LOSS OF AIR IN THE PRIMARY
CIRCUIT

When the air pressure on the secondary side of the relay
piston approaches that being delivered on the primary
side of the relay piston, the relay piston moves, closing the
secondary inlet valve and stopping further flow of air from
the supply line through the valve. The exhaust remains
closed as the secondary delivery pressure balances the
primary delivery pressure.

Should air be lost in the primary circuit, the function will
be as follows: as the brake treadle is depressed – and no
air pressure is present in the primary circuit supply and

When applications in the graduating range are made, a
balanced position in the primary circuit is reached as the air
pressure on the delivery side of the primary piston equals

Should air be lost in the secondary circuit, the primary
circuit will continue to function as described above under
Normal Operation: Primary Circuit Portion.

2

the effort exerted by the driver’s foot on the treadle. A
balanced position in the secondary portion is reached
when air pressure on the secondary side of the relay piston
closely approaches the air pressure on the primary side
of the relay piston.
When the brake treadle is fully depressed, both the primary
and secondary inlet valves remain open and full reservoir
pressure is delivered to the actuators.

RELEASING: PRIMARY CIRCUIT
With the brake treadle released, mechanical force is
removed from the spring seat, graduating spring, and
primary piston. Air pressure and spring load moves the
primary piston, opening the primary exhaust valve, allowing
air pressure in the primary delivery line to exhaust out the
exhaust port.

RELEASING: SECONDARY CIRCUIT

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 Bendix® E-6®/E-10™ valves should be inspected every
6 months or 1500 operating hours, whichever comes first,
for proper operation. Should the E-6®/E-10™ valves not
meet the elements of the operational tests noted in this
document, further investigation and service of the valve
may be required.
Visually check for physical damage to the brake valve such
as broken air lines and broken or missing parts.
Every three (3) months, 25,000 miles, or 900 operating
hours:
Clean any accumulated dirt, gravel, or foreign material
away from the heel of the treadle, plunger boot, and
mounting plate.

With the brake treadle released, air is exhausted from the
primary circuit side of the relay piston. Air pressure and
spring load move the relay piston, opening the secondary
exhaust valve allowing air pressure in the secondary
delivery line to exhaust out the exhaust port.

Lubricate the treadle roller, roller pin, and hinge pin, with
Barium grease per BW-204-M (Bendix part 246671).

PREVENTIVE MAINTENANCE

Apply a thin layer of Barium grease, per BW-204-M (Bendix
part 246671), between plunger and mounting plate – do
not over oil!

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.
BENDIX®
MV-3™ DASH
CONTROL
MODULE

Check the rubber plunger boot for cracks, holes or
deterioration and replace if necessary. Also, check
mounting plate and treadle for integrity.

BENDIX®
TP-5™ TRACTOR
PROTECTION VALVE

TRAILER
CONTROL
VALVE
SLACK
ADJUSTER

GOVERNOR

SLACK
ADJUSTER

BRAKE
CHAMBER
BENDIX®
(E-6® OR E-10™)
DUAL BRAKE
VALVE

DOUBLE
CHECK
VALVE

AIR DRYER

COMPRESSOR

SUPPLY
RESERVOIR
(WET TANK)

#1 SERVICE
RESERVOIR

SPRING
BRAKES

QUICK
RELEASE
VALVE
BENDIX®
BP-R1™
BOBTAIL
PROPORTIONING
VALVE

#2 SERVICE
RESERVOIR

FIGURE 5 - TYPICAL PIPING SCHEMATIC
3

SERVICE CHECKS
OPERATING CHECK
Check the delivery pressure of both primary and secondary
circuits using accurate test gauges. 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 primary and secondary delivery pressures may
vary by up to 5 psi for standard valves or up to 7.5 psi for
high differential valves with both supply reservoirs at the
same pressure. This is normal for this valve.
Important: A change in vehicle braking characteristics or
a low pressure warning may indicate a malfunction in one
or the other brake circuit, and although the vehicle air
brake system may continue to function, the vehicle should
not be operated until the necessary repairs have been
made and both braking circuits, including the pneumatic
and mechanical devices, are operating normally. Always
check the vehicle brake system for proper operation after
performing brake work and before returning the vehicle
to service.

LEAKAGE CHECK
1. Make and hold a high pressure (80 psi) application.
2. Coat the exhaust port and body of the brake valve with
a soap solution.

2. Remove the screw (9) securing the exhaust diaphragm
(10) and washer (11) to the exhaust cover (12).
3. Remove the four screws that secure the exhaust cover
(12) to the lower body.
4. Remove the Secondary inlet and exhaust valve
assembly (13) from the lower body.
5. Remove the four hex head cap screws securing the
lower body to the upper body and separate the body
halves.
6. Remove the rubber seal ring (14) from the lower body.
BENDIX® E-6® BRAKE VALVE ONLY (Figure 3):
7. While applying thumb pressure to the primary piston, lift
out and up on the three lock tabs of the primary piston
retainer (15).
BENDIX® E-10™ BRAKE VALVE ONLY (Figure 4):
8. A.
B.

While depressing the spring seat (7), remove
retaining ring (8).
Remove the spring seat and coil spring (5).

9. Using a 3/8” wrench, hold the lock nut (16) on the
threaded end of the stem (17) in the primary piston (2).
Insert a screwdriver in the exhaust passage through the
center of the valve and engage the slotted head of the
stem.
10. Remove lock nut (16), spring seat (18), stem spring
(19), primary piston (2), and primary piston return spring
(6). Remove o-ring (34).

REMOVAL

11. Remove adapter (1). Remove o-ring (4) from adapter.
Caution: Before proceeding with the disassembly, refer
to Figure 4 and note that the lock nut and stem are used
to contain the primary piston return spring, stem spring
and the relay piston spring. The combined force of these
springs is approximately 50 pounds and care must be
taken when removing the lock nut as the spring forces
will be released. It is recommended that the primary
piston and relay piston be manually or mechanically
contained while the nut and stem are being removed.

1. Check the vehicle wheels or park the vehicle by
mechanical means. Drain all air system reservoirs.

BENDIX® E-6® BRAKE VALVE ONLY:

2. Identify and disconnect all supply and delivery lines at
the brake valve.

12. Using a screwdriver to restrain the stem, as in step
nine, remove the lock nut (16), spring seat (18) and
stem spring (19).

3. Leakage permitted is a 1” bubble in 3 seconds. If the
brake valve does not function as described above or
leakage is excessive, it is recommended that it be
replaced with a new or remanufactured unit, or repaired
with genuine Bendix® parts available at authorized
Bendix® parts outlets.

3. Remove the brake valve and treadle assembly from
the vehicle by removing the three cap screws on the
outer bolt circle of the mounting plate. The basic brake
valve alone can be removed by removing the three cap
screws on the inner bolt circle.

DISASSEMBLY (Figures 3 and 4)
1. If the entire brake valve and treadle assembly was
removed from the vehicle, remove the three cap screws
securing the treadle assembly to the basic brake
valve.
4

13. Remove the relay piston (20), relay piston spring
(21), primary piston and primary piston return spring
(23) from the upper body. Use care so as not to nick
seats.
Note: Certain E-6® brake valves do not have a relay
piston spring (21). If this spring is not found, do not
install a replacement.
14. On valves manufactured after October 7,1976, a small
washer (24) will be found in the cavity in the lower side
of the primary piston (22).

15. Disassemble the primary piston by rotating the spring
seat nut (25) counterclockwise. Separate the spring
seat nut, spring seat (26), rubber spring (27) and
remove the piston o-ring (28).

8. Place screwdriver, blade up, in vise. Place stem (17) in
relay piston upper body sub assembly over the blade
of the screwdriver with blade engaged in the slot in the
head of the stem.

16. Remove the large (30) and small (31) o-rings from the
relay piston (20).

9. Place the washer (24) over the stem. This washer
should be installed in all valves.

17. Remove the retaining ring (32) securing the primary
inlet and exhaust valve assembly (33) in the upper body
and remove the valve assembly.

10. Install primary return spring (23) in upper body piston
bore.

CLEANING AND INSPECTION
1. Wash all metal parts in mineral spirits and dry.
2. Inspect all parts for excessive wear or deterioration.
3. Inspect the valve seats for nicks or burrs.
4. Check the springs for cracks or corrosion.
5. Replace all rubber parts and any part not found to
be serviceable during inspection, using only genuine
Bendix® brand replacement parts.

11. Install the primary piston rubber spring sub assembly
(steps 4 & 5) over the stem, into the upper body piston
bore.
12. Compress the primary and relay pistons into the upper
body from either side and hold them compressed,
either manually or mechanically. See the cautionary
note under step 11 in the Disassembly section of this
manual.
13. Place the stem spring (19) over the spring seat nut (25)
and the spring seat (18) over the stem.

ASSEMBLY

14. Install the lock nut (16) on the stem and torque to
20 - 30 inch pounds.

Prior to reassembling, lubricate all o-rings, o-ring grooves,
piston bores and metal to metal moving surfaces with Dow
Corning 55 M pneumatic grease (Bendix piece number
291126).

15. Install the primary piston retainer (15) over the piston,
making certain all three lock tabs have engaged the
outer lip of the body.

Note: All torques specified in this manual are assembly
torques and can be expected to fall off, after assembly
is accomplished. Do not retorque after initial assembly
torques fall.

GENERAL SAFETY GUIDELINES

1. Install the primary inlet and exhaust assembly (33) in
the upper body and replace the retaining ring (32) to
secure it. Be sure the retaining ring is seated completely
in its groove.
2. Install the large (30) and small (31) o-rings on the relay
piston.
3. Install the primary piston o-ring (28) in the piston o-ring
groove.
BENDIX® E-6® BRAKE VALVE ONLY:
4. Install the rubber spring (do not lubricate) (27), concave
side down in the primary piston (22) and place the
spring seat (26), flat side up, over the rubber spring.
5. Install the primary piston spring seat nut (25), with its
hex closest to the spring seat, and rotate clockwise
until the top surface of the spring seat is even with the
top surface of the piston. Set aside.
6. Install large (30) and small (31) o-rings on relay piston
(20).
7. Place relay piston, spring (21) (if used) in concave
portion of relay piston and install relay piston through
No. 1 inlet/exhaust assembly (33) and into under side
of upper body.

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.

5

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 a
Bendix ® AD-IS ® air dryer system or a dryer
reservoir module, be sure to drain the purge
reservoir.
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.

6

8. 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.
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
certain all components and systems are restored
to their proper operating condition.
11. 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.

BW1427 © 2010 Bendix Commercial Vehicle Systems LLC. All rights reserved. 6/2010



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