Bendix Sd 03 817 Users Manual 817g

2015-04-02

: Bendix Bendix-Sd-03-817-Users-Manual-682523 bendix-sd-03-817-users-manual-682523 bendix pdf

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SD-03-817

Bendix® E-6® & E-10™ Dual Brake Valves

DESCRIPTION

The Bendix® E-6® (Figure 1) and E-10™ (Figure 2) dual

brake valves are ﬂ oor-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

identiﬁ ed 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.

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 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 ﬂ ow out the primary

delivery port.

FIGURE 1 - BENDIX® E-6® DUAL BRAKE VALVE FIGURE 2 - BENDIX® E-10™ DUAL BRAKE VALVE

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

TREADLE

MOUNTING

PLATE

3/8” P.T.

PRIMARY

SUPPLY

3/8” P.T.

SECONDARY

SUPPLY

3/8” P.T.

PRIMARY

DELIVERY

EXHAUST

3/8” P.T.

SECONDARY

DELIVERY

MOUNTING

PLATE

TREADLE

BOOT

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 ﬂ ow out the secondary delivery port.

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 ﬂ ow 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

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 ﬂ ow of air from

the supply line through the valve. The exhaust remains

closed as the secondary delivery pressure balances the

primary delivery pressure.

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

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

SECTIONAL DIAGRAM

9 11 10

18 78

APPLYING: NORMAL OPERATION -

SECONDARY CIRCUIT

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 ﬂ ow 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

Should air be lost in the secondary circuit, the primary

circuit will continue to function as described above under

Normal Operation: Primary Circuit Portion.

APPLYING: LOSS OF AIR IN THE PRIMARY

CIRCUIT

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

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

SECTIONAL DIAGRAM

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

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.

PREVENTIVE MAINTENANCE

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.

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 ﬁ rst,

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.

Lubricate the treadle roller, roller pin, and hinge pin, with

Barium grease per BW-204-M (Bendix part 246671).

Check the rubber plunger boot for cracks, holes or

deterioration and replace if necessary. Also, check

mounting plate and treadle for integrity.

Apply a thin layer of Barium grease, per BW-204-M (Bendix

part 246671), between plunger and mounting plate – do

not over oil!

FIGURE 5 - TYPICAL PIPING SCHEMATIC

BENDIX®

TP-5™ TRACTOR

PROTECTION VALVE

BENDIX®

MV-3™ DASH

CONTROL

MODULE

BRAKE

CHAMBER

SLACK

ADJUSTER

COMPRESSOR

SUPPLY

RESERVOIR

(WET TANK) #1 SERVICE

RESERVOIR #2 SERVICE

RESERVOIR

DOUBLE

CHECK

VALVE

SPRING

BRAKES

SLACK

ADJUSTER

TRAILER

CONTROL

VALVE

AIR DRYER

GOVERNOR

BENDIX®

(E-6® OR E-10™)

DUAL BRAKE

VALVE

BENDIX®

BP-R1™

BOBTAIL

PROPORTIONING

VALVE

QUICK

RELEASE

VALVE

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.

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.

REMOVAL

1. Check the vehicle wheels or park the vehicle by

mechanical means. Drain all air system reservoirs.

2. Identify and disconnect all supply and delivery lines at

the brake valve.

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.

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. While depressing the spring seat (7), remove

retaining ring (8).

B. 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).

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.

BENDIX® E-6® BRAKE VALVE ONLY:

12. Using a screwdriver to restrain the stem, as in step

nine, remove the lock nut (16), spring seat (18) and

stem spring (19).

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).

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

relay piston (20).

17. Remove the retaining ring (32) securing the primary

inlet and exhaust valve assembly (33) in the upper body

and remove the valve assembly.

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.

ASSEMBLY

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).

Note: All torques speciﬁ ed 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.

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), ﬂ at 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.

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.

9. Place the washer (24) over the stem. This washer

should be installed in all valves.

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

bore.

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.

14.Install the lock nut (16) on the stem and torque to

20 - 30 inch pounds.

15. Install the primary piston retainer (15) over the piston,

making certain all three lock tabs have engaged the

outer lip of the body.

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

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 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.

8. Use only genuine Bendix® brand replacement parts,

components and kits. Replacement hardware,

tubing, hose, ﬁ ttings, etc. must be of equivalent

size, type and strength as original equipment and

be designed speciﬁ cally 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 speciﬁ cally 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.

Bendix Sd 03 817 Users Manual 817g

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