BENDIX BW1624 User's Manual
Contents
1. valve are identified with cast embossed letters for ease of installation The letter identification and air line connections are shown below for reference BP R1 Valve Embossed Air Connection Identification Supply to reservoir SUP Delivery to brake actuator DEL Service brake valve rear axle service delivery SER Control to delivery of trailer supply valve CON TRAILER SUPPLY TRACTOR PROTECTION Br a y SERVICE PORT BP R1 VALVE ELIVERY PORT 4 SERVICE SPRING BRAKE s REAR AXLE SERVICE RESERVOIR FIGURE 2 BP R1 TRACTOR AIR SYSTEM OPERATION INITIAL CHARGING During the initial build up of tractor system air pressure supply air flows through internal body and cover passages in the BP R1 valve to the blend back piston Activating the trailer supply valve dash control with red octagonal button simultaneously charges the trailer and the BP R1 valve control port Air entering the BP R1 valve control port causes the proportioning piston to move toward its stop in the cover The integral inlet and exhaust valve is carried along with the piston until it seats and seals the exhaust passage Continued movement of the proportioning piston opens the inlet valve With the tractor and trailer air system fully charged the vehicle may be operated SERVICE BRAKES APPLYING TRACTOR TRAILER COMBINATION Brake application air enters the BP R1 valve service port and2. cut or pinch the o rings With the bore of the cover facing up install the spring cage 23 in the blend back piston 24 so that its flat side rests against the blend back piston its depressed side out towards spring 22 Install the service piston 20 over the spring 22 in the cage 23 so that its coils are within the I D of the cage Install o ring 18 on exhaust piston 17A Place exhaust piston on service piston with its six ribbed side facing the service piston Then install both pistons while pushing the proportioning and blend back pistons 28 amp 24 all the way into the cover 14 19 16 17 18 19 20 2 h 22 23 24 29 Install the retaining ring 15 making certain it is fully seated in its groove Installthe exhaust cover 37 using screw 36 to retain it Torque the screw to 8 to 15 Ib in Install the valve retainer 8 on the inlet and exhaust valve 9 so that the flange of the retainer 8 Surrounds the rubber portion of the valve Install the inlet and exhaust valve in the body 1 Install the inlet and exhaust valve return spring 7 in the body 1 Install the large and small diameter o rings 5 amp 6 in the exhaust cover 4 then install the exhaust cover in the body 1 taking care not to damage the o rings Hold the exhaust cover in place While depressing the exhaust cover 4 install the retaining ring 3 in the body 1 Make ce
3. differential 7 Make and hold a full 100 psi or greater brake application and note that full pressure is delivered to the chambers 8 Activate the dash mounted trailer supply valve for bobtail tractor operation Then make a slow brake application increasing the pressure at the BP R1 valve service port to 20 psi while watching the reaction atthe delivery port gauge Note that delivery pressure rises to approximately 5 to 10 psi and remains constant while service pressure continues to rise to 20 psi Release the application 9 Make another brake application and slowly increase the pressure at the BP R1 valve service port to be tween 60 and 70 psi while observing the gauge installed at the delivery port Note that when service port pres sure rises to between 20 and 30 psi delivery pressure begins to rise above the initial pressure noted in step 6 The rise of delivery pressure should be at a propor tioned rate of approximately 3 1 At 70 psi service pressure delivered pressure should be 15 to 25 psi 10 Make a full brake application and note that both test gauges register the same pressure 11 Drain air pressure from all vehicle reservoirs and remove the test gauges from the BP R1 valve LEAKAGE TESTS 1 Build the air system pressure to governor cut out With the dash mounted trailer supply valve activated for tractor trailer operation apply a soap solution to both exhaust ports one in the cover and one in the
4. discard the exhaust piston 17 or 17A Remove and discard the exhaust piston o ring 18 and the exhaust diaphragm 19 if fitted Remove and discard the service piston 20 and its o ring 21 from the valve cover 2 Remove the spring 22 and spring cage 23 from the valve cover 2 Discard the spring and retain the spring cage Use shop air at the control port to extract the blend back piston from the valve cover 2 Retain the blend back piston 24 then remove and discard both o rings 25 amp 26 Remove and retain the proportioning piston 28 from the valve cover 2 then remove and discard both o rings 27 amp 29 While holding the inlet valve seat 32 in place remove and discard the retaining ring 30 from the proportion ing piston 28 Remove the inlet valve seat 32 the inlet valve 33 and the valve spring 34 from the proportioning piston 28 then remove and discard the o ring 31 from the valve seat 32 Discard the valve and spring 33 amp 34 also Remove and discard the exhaust cover screw 36 and exhaust cover 37 CLEANING amp INSPECTION 1 Using mineral spirits or an equivalent solvent clean and thoroughly dry all metal parts Do not damage bores with metal tools Wash all non metallic components key nos 4 12 17 20 23 24 28 32 in a soap and water solution making certain to rinse and dry thoroughly Inspect the interior and exterior of all metal parts that
5. 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 Antilock 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 OPERATION amp LEAKAGE TESTS OPERATING TEST To properly test the function of the BP R1 valve a pair of test gauges or gauges of Known accuracy must be used 1 Park the vehicle on a level surface and block the wheels and or hold the vehicle by means other than the air brakes 2 Drain air pressure from all vehicle reservoirs Install a tee at the BP R1 valve service port and at one of the delivery ports then install a gauge in each Note Early models used a Diaphragm 19 Dust Shield 16 Service Piston 17 and o ring 21 SERVICE PISTON ORIGINAL STYLE REQUIRED O RING 21 RETAINING RING SERVICE PISTON NEW STYLE EXHAUST COVER DOES NOT REQUIRE O RING SERVICE PISTON O RING IF FITTED 21 SPRING SPRING CAGE BLEND BACK PISTON VALVE ASSEMBLY CAP SCREWS RELAY PISTON RETURN SPRING RETAINING RING DUST SHIELD IF FITTED EXHAUST PISTON ORIGINAL STYLE 17 INLET VALVE EXHAUST PISTON NEW STYLE 17A VALVE SPRING EXHAUST PISTON O RING SE
6. to the exhaust diaphragm If the release is rapid the diaphragm flexes in response to the returning air and opens the exhaust Air from above the relay piston flows back to the pro portioning piston causing it to move As it moves the proportioning piston unseats the exhaust valve allowing air from above the relay piston to escape to atmosphere Reducing the air pressure above the relay piston causes pressure beneath it to lift the piston away from the exhaust valve Air from the service brake actuators returns to the BP R1 valve and flows out the open exhaust PROP PISTON PISTON Pan INLET EXHAUS PISTON Ni A o FIGURE 9 BP R1 RELEASING BOBTAIL TRACTOR PREVENTIVE MAINTENANCE GENERAL Important Review the Bendix Warranty Policy before performing any intrusive maintenance procedures A war ranty 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 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 Perform the tests and inspections presented at th
7. will be reused for severe corrosion pitting and cracks Superficial corrosion and or pitting on the exterior por tion of the body 1 and cover 2 is acceptable Replace the entire valve if the interior of the body or cover exhibit signs of corrosion or pitting Inspect each non metallic component for cracks wear or distortion Replace the entire valve if these conditions are found Inspect the bores of both the body 1 and cover 2 for deep scuffing or gouges Replace the entire valve if either are found 10 Make certain the air channel running between the top surface of the body 1 and its supply port is clear and free of obstruction Make certain all air channels and exhaust passages in the valve cover 2 are clear and free of obstruction Inspect the pipe threads in the body 1 and valve cover 2 Make certain they are clean and free of thread sealant If the valve was equipped with a relay piston spring 14 inspect it for signs of corrosion pitting and cracks Replace as necessary Inspect all air line fittings for corrosion and replace as necessary Make certain to remove all old thread sealant before reuse ASSEMBLY 1 Prior to assembly lubricate all o rings identify by using Figure 11 seals and pistons as well as body and cover bores using the lubricant provided with the Bendix maintenance kit Use all of the lubricant and spread it evenly on the rubbing surfaces Install the o ring 31 on
8. ALING RING EXHAUST DIAPHRAGM IF FITTED EXHAUST COVER SCREW EXHAUST COVER FIGURE 10 BP R1 BOBTAIL BRAKE PROPORTIONING RELAY VALVE 4 Connect the tractor service and emergency glad 5 With the trailer supply valve dash control w red oc hands hose couplings to hose couplings that have tagonal button and system park control dash control been plugged or alternatively to a trailer Build the trac with yellow diamond button activated for tractor trailer tor system air pressure to governor cut out and make 4 operation apply hold then release the brakes several to 5 full brake applications Check the air fittings at the times varying the application pressures while watch BP R1 valve for leakage Tighten as needed ing the reaction of the gauges installed on the BP R1 valve Check that a prompt application occurs and that it can be held then promptly released 6 Check the BP R1 valve differential pressure by apply ing 10 psi to the service port and noting the pressure registered at the delivery port Subtract delivery port pressure from the 10 psi service pressure to obtain the differential Compare the measured differential with the pressure specified for the BP R1 valve part number Note For BP R1 valves not incorporating a relay piston return spring 14 the measured differential should be approximately 4 psi When a spring is in use the differential will be higher see the I D washer also for the
9. CONTROL EXHAUST DELIVERY SUPPLY DESCRIPTION The BP R1 bobtail proportioning relay valve is a combina tion of two individual valves in a single housing The lower portion or body of the BP R1 valve contains a standard service brake relay valve which functions as a relay station to speed up brake application and release The upper por tion or cover houses a brake proportioning valve which reduces normal service brake application pressure when the tractor is not towing a trailer Used in tractor air brake systems only the BP R1 valve is installed in place of a standard relay valve It functions as a standard service relay during operation of a tractor trailer combination During bobtail tractor operation the BP R1 valve improves controllability and reduces stopping distances by reducing air pressure to the rear actuators chambers whose axle load has been greatly reduced While the BP R1 valve can incorporate various crack pressures to accommodate specific applications the standard is 4 psi CONTROL EXHAUST SUPPLY FIGURE 1 BP R1 BOBTAIL PROPORTIONING RELAY VALVE Designed for frame or cross member mounting the BP R1 valve is furnished with a mounting bracket which is attached to two of the four cover cap screws Replacement valves are furnished with a universal mounting bracket which allows the BP R1 valve to replace most standard relays All air connections on the BP R1
10. assembly procedure Caution The BP R1 valve may be lightly clamped in a bench vise during disassembly however overclamp ing will cause damage to the valve and result in leakage and or malfunction If a vise is to be used position the valve so that the jaws bear on the supply ports on opposing sides of the valve s body 1 Remove all air fittings and plugs from the valve 2 Mark the relationship of the valve cover to the body and if the valve is equipped with a mounting bracket mark the relationship of the bracket to the cover 3 While holding the exhaust cover 4 remove and discard the retaining ring 3 that secures it to the body 1 4 Remove and discard the exhaust cover 4 along with both o rings 5 amp 6 5 Remove and discard the valve spring 7 valve retainer 8 and the valve assembly 9 from the body 1 6 Remove and retain the four cap screws 10 that secure the cover 2 to the body 1 7 Separate the cover 2 from the body 1 then remove and discard the sealing ring 35 and o ring 11 8 Remove and retain the relay piston 13 and relay piston spring 14 from the body 1 Note The relay piston spring item 14 is not used in all valves 7 10 11 12 13 14 19 16 14 18 Remove and discard the o ring 12 from the relay piston 13 Remove and discard dust shield 16 if fitted and the retaining ring 15 from the valve cover 2 then remove and
11. body The leakage noted should not exceed a 1 bubble in less than 3 seconds at any exhaust port 2 Make and hold a full brake application and apply a soap solution to both exhaust ports and around the cover where it joins the body The leakage noted should not exceed a 1 bubble in less than 3 seconds at any exhaust port VALVE REMOVAL 1 Park the vehicle on a level surface and block the wheels and or hold the vehicle by means other than the air brakes 2 Drain the air pressure from all vehicle reservoirs 3 Identify and mark or label all air lines and their respective connections on the valve to facilitate ease of installation 4 Disconnect all air lines 5 Remove the valve from the vehicle VALVE INSTALLATION 1 Install all air line fittings and plugs making certain thread sealing material does not enter the valve Install the assembled valve on the vehicle Reconnect all air lines to the valve using the identifica tion made during VALVE REMOVAL step 3 4 After installing the valve test all air fittings for excessive leakage and tighten as needed DISASSEMBLY GENERAL The following disassembly and assembly procedure is presented for reference purposes only and presupposes that the appropriate maintenance kit is on hand at the time of disassembly The instructions provided with the mainte nance kit should always be used in lieu of those presented here Refer to Figure 10 throughout the disassembly and
12. e pre scribed intervals If the BP R1 valve fails to function as described or leakage is excessive it should be repaired or replaced with a new or genuine Bendix remanufactured unit available at any authorized parts outlet Every 3 months or 25 000 miles or 900 operating hours 1 Remove any accumulated contaminates and visually inspect the exterior for excessive corrosion and physical damage 2 Inspect all air lines connected to the BP R1 valve for signs of wear or physical damage Replace as necessary 3 Test air line fittings for excessive leakage and tighten or replace as necessary 4 Perform the Leakage Test described in this manual Every year 100 000 miles or 3 600 operating hours 1 Perform the Operation and Leakage Tests described in this manual 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
13. essure continues to increase the inlet valve opens as necessary to deliver additional but reduced air pressure to the relay piston thus to the rear axle brakes Proportioning occurs due to the difference in effective area on each end of the proportioning piston TRACTOR TRAILER COMBINATION AL Loco P TRACTOR Ayd ATIII BRAKE VALVE DELIVERY PRESSURE BP R1 VALVE CONTROL PORT oc O JN gt ae I gt ny na LL LU Ez gt cc A ca am m m gt lt E O Lu Xx lt CL m Lu O gt DE m o o a DN FIGURE 8 BP R1 CONTROL VS DELIVERY PRESSURE 4 Service applications of more than 80 psi cause the blend back piston to begin to move Service air pressure acting on the full diameter of the blend back piston overcomes the resistance of reservoir pressure acting on the large diam eter of the other side Above 80 psi the difference between control and delivered air pressure is reduced and blends back from a proportioned delivery to a full 1 1 delivery Complete blend back to a 1 1 delivery is achieved when a full brake application is made and it will occur regardless of reservoir pressure level SERVICE BRAKES RELEASING BOBTAIL TRACTOR When the brake application is released air pressure in the service port of the BP R1 valve returns to the foot brake valve and is exhausted Air between the closed proportion ing piston inlet valve and the service piston returns
14. is conducted through the service piston to the exhaust diaphragm which flexes in response to the incoming air and seals the exhaust passage in the exhaust piston Air flows around the exhaust diaphragm then through the center of both the blend back and proportioning pistons to the inlet and exhaust valve Flowing around the inlet valve applica tion air moves through a passage in the cover to the top of the service relay piston In response to air pressure the relay piston moves into contact with the exhaust portion BLEND CONTROL BACK POR ORT PISTON SERVICE PORT SERVICE PISTON EARLIER MODELS HAVE A DIAPHRAGM HERE SPRING RELAY PISTON PROPORTIONING PISTON INLET EXHAUST _ MODELS DELIVERY SUPPLY PORT PORT INLET EXHAUST VALVE FIGURE 3 BP R1 BOBTAIL PROPORTIONING RELAY VALVE of the inlet and exhaust valve With the exhaust passage sealed continued movement of the piston unseats the inlet portion of the inlet and exhaust valve allowing supply air from the reservoir to flow out the BP R1 valve delivery ports to the brake actuators See Figure 4 PROP PISTON RELAY PISTON a W AS FIGURE 4 BP R1 APPLYING TRACTOR TRAILER COMBINATION INLET EXHAUST PISTON SERVICE BRAKES HOLDING TRACTOR TRAILER COMBINATION The air pressure being delivered to the brake actuators is also present beneath the relay piston When the air pressure above and below
15. relay piston is equal the piston moves slightly allowing the inlet valve to return to its seat The exhaust valve remains closed With both the inlet and exhaust valves closed air pressure in the brake actuators is held stable and neither increases nor decreases See Figure 5 PROP PISTON RELAY PISTON FIGURE 5 BP R1 HOLDING TRACTOR TRAILER COMBINATION SERVICE BRAKES RELEASING TRACTOR TRAILER COMBINATION When the brake application is released air pressure in the service port of the BP R1 valve returns to the foot brake valve and is exhausted Air from above the relay piston flows back through the proportioning blend back and service pistons to the exhaust diaphragm If the service brakes are rapidly released the diaphragm flexes in response to the returning air and opens the exhaust If the brakes are slowly released service air pressure will flow through the slot behind the diaphragm and back to the brake valve As air pressure is reduced above the relay piston pressure beneath it lifts the piston away from the exhaust valve and opens the exhaust passage Air from the service brake actuators returns to the BP R1 valve and flows out the open exhaust See Figure 6 PROP PISTON t INLET EXHAUST PISTON FIGURE 6 BP R1 RELEASING TRACTOR TRAILER COMBINATION SERVICE APPLICATION BOBTAIL TRACTOR When the trailer supply valve dash control with red octago nal button is activated to di
16. 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 an 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 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
17. rtain the retainer 3 is fully seated in its groove in the body If the BP R1 valve was equipped with a relay piston return spring 15 install the spring in the body large diameter first Using lubricant to hold them in place install the large and small sealing rings 11 amp 35 on the cover 2 Install the o ring 12 on the relay piston 13 then install the piston in the body 1 After noting the relationship marks made prior to disas sembly install the mounting bracket not illustrated on the cover 2 then secure the cover 2 and mounting bracket on the body 1 using the four cap screws 10 Torque the cap screws to 120 to 150 Ib in Install all air line fittings and plugs making certain thread sealing material does not enter the valve Install the BP R1 valve on the vehicle and perform the Operation and Leakage Tests before returning the vehicle to service 10 11 12 BW1624 2009 Bendix Commercial Vehicle Systems LLC All rights reserved 6 2009 Printed in U S A
18. sconnect the trailer air in the BP R1 valve control port and trailer supply line is exhaust ed to atmosphere During bobtail tractor operation service application air enters the BP R1 valve service port causing the exhaust diaphragm to seal the exhaust port Service application air passing through the blend back piston exerts a force on the full effective diameter of the piston The blend back piston remains stationary at application pressures below approximately 80 psi because of Opposing reservoir air acting on the large diameter Application air flowing through the blend back piston also exerts a force on the small diameter of the proportioning piston while simultaneously flowing through the center of it on its way to the inlet and exhaust valve Once past the inlet and exhaust valve service air pressure exerts a force on the larger diameter end of the proportioning piston which opposes the air pressure and spring force exerted on the other end The proportioning piston inlet valve remains open until a preset initial application pressure has reached the relay piston assuring that the founda tion brake shoes are brought into contact with the drum As service pressure begins to exceed the preset initial application the proportioning piston will move sufficiently to close its inlet valve without opening the exhaust PROP PISTON io INLET EXHAUST PISTON nA FIGURE 7 BP R1 HOLDING BOBTAIL TRACTOR As service air pr
19. the inlet valve seat 32 O RING IDENTIFICATION KEY NO I D O D 5 8620 6 11 13 18 21 25 26 27 29 31 1 424 3 487 3 234 1 356 1 176 1 112 3 0 4120 IU 4890 1 068 1 630 3 693 3 912 1 496 1 316 1 318 9430 0020 8790 6290 FIGURE 11 O RING IDENTIFICATION 12 13 Install the small end of the inlet exhaust valve spring 34 over the rubber of the valve 33 making sure the spring coils rest on the valve s four tabs Note Both ends of spring 34 are the same diameter on valves manufactured after June 1990 Insert the spring and valve into the valve seat 32 making sure the four tabs are within the seat s bore Insert the valve seat and spring assembly into the proportioning piston 28 While holding the seat 32 in place install the retaining ring 30 to secure it in the piston 28 Make certain the retaining ring is fully seated in its groove Make sure the valve is straight against the exhaust seat and free to move Install both the large and small diameter o rings 27 amp 29 on the proportioning piston 28 Install both the large and small diameter o rings 25 amp 26 on the blend back piston 24 then insert the small diameter of the proportioning piston 28 into the small diameter end of the blend back piston 24 Carefully insert the assembled proportioning and blend back pistons 24 amp 28 to the edge of the bore in the cover 2 Do not
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