BENDIX AR-1 ANTILOCK RELAY VALVE User manual

1
®
SD-13-4795
DESCRIPTION
The AR-1™antilock relay valve (Figure 1) is a specialized
service brake relay valve. It is essentially an R-14™relay
valvewithaspecialcoverthatpermitsdirectattachmentof
an antilock controller. When combined with an antilock
controllertheresultingassemblyisreferredtoasaantilock
relaycontroller.ForexamplewhentheAR-1™antilockrelay
valveis combinedwith theEC-30™tractorantilock controller
the resulting assembly is referred to as a CR-30™antilock
relaycontroller.Whileintended foruseon antilockequipped
vehicles,theAR-1™antilockrelayvalvefunctionssolelyas
aservice brake relayandcontains no electronicsofits own.
In an air brake system, theAR-1™valve serves as a relay
station to speed the application and release of the service
brakes. The valve is normally mounted in proximity to the
service actuators it serves. A mounting bracket furnished
withthevalvepermitseitherframeorcrossmembermounting.
All air connections on the AR-1™valve are identified with
cast, embossed letters for ease of installation. The letter
identification and air line connections are shown below for
reference.
AR-1™VALVE
AIR CONNECTION EMBOSSED IDENT.
Supply(to reservoir) SUP
Delivery (to brake actuator) DEL
Service (to brake valve rear service delivery) SER
LiketheR-14™relayvalve, theAR-1™valveincorporates a
quickreleasevalveadjacenttotheserviceportwhichprovides
for rapid exhaust of control air pressure from above the
Bendix®AR-1™AntiLock Relay Valve
FIGURE1-AR-1™ANTILOCKRELAYVALVEASSEMBLY
EXHAUST PORT
SERVICEPORT
QUICKEXHAUST
DELIVERYPORTS
SUPPLY PORT
TYPICAL
MOUNTING
BRACKET
SUPPLY PORT
EXHAUST PORT
DELIVERY
PORT
QUICK
EXHAUST
INLET/
EXHAUST
VALVE
RELAY
PISTON
SERVICE
PORT
QUICK/
EXHAUST DIA.
ANTILOCK
CONTROLLER
AR-1™
ANTILOCK
RELAY VALVE
AR-1™VALVE
WITH ANTILOCK
CONTROLLER

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FIGURE 2 - CR-15™ANTILOCK RELAY CONTROLLER
relaypiston.ThestandardAR-1™valve isofferedwitha4psi
crackpressurehoweverwiththeadditionofavarioussprings
beneath the relay piston higher crack pressures are
possible.
TheAR-1™valve’sinternalcomponentsareinterchangeable
with the R-12™and R-14™relay valves therefore the same
maintenancekitisusedtoservice all three valves.
OPERATION
BRAKEAPPLICATION
BrakeapplicationairenterstheAR-1™valve’sserviceportand
encounterstheexhaustdiaphragmwhichflexesinresponse
totheincomingair,sealingtheexhaustpassageinthecover.
Airflowsaroundtheexhaustdiaphragmandmovesthrougha
passageinthecovertothetopoftherelaypiston.Inresponse
to air pressure, the relay piston moves into contact with the
exhaustportionoftheinletandexhaustvalve.Withtheexhaust
passage sealed, continued movement of the relay piston
unseatstheinletportionoftheinletandexhaustvalve,allowing
supplyairfromthereservoirtoflowouttheAR-1™valve’sdelivery
ports to the antilock modulators and then to the brake
actuators.(Figure3)
HOLDING-BALANCED
Theairpressure being delivered to the antilockmodulators
andbrakeactuatorsisalsopresentbeneaththerelaypiston.
When the air pressure above and below relay piston is
equal, the piston moves slightly allowing the inlet valve to
return to its seat. The exhaust valve remains closed. With
boththe inlet and exhaustvalvesclosed,air pressure in the
antilockmodulatorsandbrakeactuatorsisheldstable and
neither increases nor decreases. (Figure 4)
EXHAUST - BRAKE RELEASE
When the brake application is released, air pressure in the
serviceportof theAR-1™valvereturnstothefootbrakevalve
andisexhausted.Air,fromabovetherelaypiston,flowsback
throughthecovertotheexhaustdiaphragm.Thediaphragm
flexesinresponsetothereturningair,sealingtheserviceport
and opening the exhaust in the cover. With the exhaust
diaphragmblockingtheserviceport,returningairflowsoutthe
openexhaust.Asairpressureisreducedabovetherelaypiston,
pressure beneath it lifts the piston away from the exhaust
valve and opens the exhaust passage.Air from the antilock
modulators and brake actuators returns to the AR-1™valve
andflowsouttheopenexhaust. (Figure5)
EC-15™ANTILOCK
CONTROLLER
TYPICAL
MOUNTING
BRACKET
AR-1™ANTILOCK RELAY

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FIGURE3-AR-1™VALVEBRAKEAPPLICATION
RESERVOIR
BRAKE
ACTUATOR
PREVENTIVE MAINTENANCE
Important: Review the warranty policy before performing
anyintrusivemaintenanceprocedures.Anextendedwarranty
maybe voided if intrusivemaintenanceis performed during
thisperiod.
Becausenotwovehicles operateunder identicalconditions,
maintenanceintervalswillvary.Experienceisavaluableguide
indeterminingthe best maintenance interval for avehicle.
GENERAL
Perform the tests and inspections presented at the
prescribed intervals. If theAR-1™valve fails to function as
described,orleakageis excessive, it should be repaired or
replaced with a new or genuine Bendix remanufactured
unit,availableatanyauthorizedpartsoutlet.
EVERY 3 MONTHS, 25,000 MILES OR 900
OPERATING HOURS
1. Remove any accumulated contaminates and visually
inspectthe exteriorforexcessivecorrosionand physical
damage.
2. Inspect all air lines connected to the AR-1™valve for
signsofwearorphysicaldamage.Replaceasnecessary.
3. Testairlinefittingsfor excessive leakage and tighten or
replace as necessary.
4. Performthe LeakageTestdescribed in this manual.
EVERY YEAR, 100,000 MILES, OR 3,600
OPERATING HOURS
1. Perform the Operation and LeakageTests described in
thismanual.
OPERATION & LEAKAGE TESTS
OPERATINGTEST
1. Apply and release the brakes several times and check
for prompt application and release at each wheel. If
prompt reaction is noted at some, but not all wheels,
test the AntiLock modulator between the AR-1™valve
andthebrakeactuatorforproperoperation.Ifa“sluggish”
response is noted at all wheels, inspect for a kinked or
obstructedairlineleading to or from theAR-1™valve.
2. Ifa complete releaseofthe brakesisnotedat some,but
not all wheels, test the antilock modulator between the
AR-1™valveand thebrakeactuatorforproperoperation.
If an incomplete release is noted at all wheels, inspect
for a kinked or obstructed air line leading to or from the
AR-1™valve.
SUPPLY PORT
EXHAUST
ANTILOCK
CONTROLLER
QUICKEXHAUSTDIA.
SERVICEPORT
RELAYPISTON
DELIVERYPORT
INLET/EXH.
VALVE
ANTILOCK
MODULATOR
EXHAUST

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3. During brake release confirm that a slight “puff” of air
exitsattheAR-1™valve’squickexhaustportinthe cover.
Airexiting at thisexhaustportindicates theAR-1™valve
integralquickreleaseisfunctioning.
LEAKAGETESTS
1. Buildthe air system pressure togovernorcut-out,apply
asoap solution totheexhaust port inbody.Theleakage
notedshouldnotexceedaoneinchbubbleinless than
three(3)seconds.
2. Makeand hold a fullbrakeapplicationand apply a soap
solutionto the exhaust ports in the bodyand cover and
around the cover where it joins the body. The leakage
notedshouldnotexceedaoneinchbubbleinlessthan
three (3) seconds at any exhaust port.
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
enginebeinoperation,EXTREMECAUTIONshould
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. Useonlythepropertoolsandobserve
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™airdryersystemoradryerreservoirmodule,
be sure to drain the purge reservoir.
5. Following the vehicle manufacturer’s
recommendedprocedures,deactivatetheelectrical
systeminamannerthatsafelyremovesallelectrical
power from the vehicle.
FIGURE4 - AR-1™VALVE HOLDING- BALANCED
RESERVOIR
BRAKE
ACTUATOR
SUPPLY PORT
EXHAUST
ANTILOCK
CONTROLLER QUICKEXHAUSTDIA.
SERVICEPORT
RELAYPISTON
DELIVERYPORT
INLET/EXH.VALVE
ANTILOCK
MODULATOR
EXHAUST

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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
bedesignedspecificallyforsuchapplicationsand
systems.
9. Components with stripped threads or damaged
parts should be replaced rather than repaired. Do
notattemptrepairsrequiringmachiningorwelding
unless specifically stated and approved by the
vehicle and component manufacturer.
10. Prior to returning the vehicle to service, make
certainallcomponentsandsystemsarerestoredto
their proper operating condition.
VALVE REMOVAL
1. Parkthe vehicleonalevel surfaceandblock the wheels
and/or hold the vehicle by means other than the air
brakes.
2. Drainthe air pressure fromallvehiclereservoirs.
3. Identify,markorlabel all air lines and wiring cables and
their respective connections on the valve or antilock
controllertofacilitateeaseofinstallation.
4. Disconnect all air lines and wiring.
5. Remove the valve and controller assembly from the
vehicle.
VALVE INSTALLATION
1. Installall air linefittingsand plugs makingcertainthread
sealingmaterialdoes not enter the valve.
2. Install theassembledvalve on the vehicle.
3. Reconnectall airlinesandwiringcables tothe valveand
controllerassembly usingtheidentification madeduring
VALVE REMOVAL step 3.
4. Afterinstallingthe valveandcontroller assembly, testall
airfittings for excessiveleakageandtighten asneeded.
FIGURE5 - AR-1™VALVE EXHAUST- BRAKE RELEASE
RESERVOIR
BRAKE
ACTUATOR
SUPPLY PORT
EXHAUST
ANTILOCK
CONTROLLER QUICKEXHAUSTDIA.
SERVICEPORT
RELAYPISTON
DELIVERYPORT
INLET/EXH.VALVE
ANTILOCK
MODULATOR
EXHAUST

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FIGURE6 - AR-1™ANTILOCKRELAYVALVE WITH CONTROLLER
ANTILOCK
CONTROLLER
1
MOUNTING
BRACKET
2
13
12
11
13
11
15
23 24 25 16
18
17
19
5
26
14
20
21
22
10
9
7
4
8
6
3

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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
maintenance kit should always be used in lieu of those
presentedhere.Refertofigure6throughoutthedisassembly
andassembly procedure.
CAUTION: The AR-1™valve may be lightly clamped in a
benchvise duringdisassembly,however,over clampingwill
cause damage to the valve and result in leakage and/or
malfunction. If a vise is to be used, position the valve so
thatthejawsbearonthesupplyportsonopposingsides of
thevalve’sbody.
1. Removeallair fittings and plugsfromthevalve.
2. Markthe relationshipoftheantilock electroniccontroller
andvalvecoverto the body (5). Note the position of the
mountingbracketandmarktherelationshipofthebracket
tothevalvebody,cover,andantilockcontroller.Remove
andretain thefourcapscrews andlockwashers (1)that
secure the controller to the cover (15), then carefully
remove the electronic controller without damaging its
gasket(2).
3. Whileholding theexhaustcover(4),removeanddiscard
the retaining ring (3) that secures it to the body (5).
4. Remove and discard the exhaust cover (4) along with
both o-rings (6 & 7).
5. Removeand discard the valve spring(8),valveretainer
(9),andthevalve assembly (10) from the body (5).
6. Remove and retain the two cap screws (11) and lock
washers(12)thatsecurethe cover (15) to the body (5).
Removeandretainthetwobolts (13),lock washers(12),
and nuts (14) that secure the cover (15) and mounting
brackettothevalve body (5).
7. Separatethecover(15) and mounting bracket from the
body(5), then remove anddiscardthesealing ring (16).
Removeandretainthetwocapscrewsand lockwashers
(26) that secure the bracket to the cover (15).
8. Removeand retaintherelay piston(17)and relaypiston
spring (19) from the body (5). NOTE: The relay piston
spring, item 19 is not used in all valves.
9. Removeand discardtheo-ring(18)fromtherelay piston
(17).
10. Removeandretaintheservice portcap nut(20)fromthe
cover(15), then separateanddiscardthe cap nuto-ring
(21)from the cap nut.
11. Remove and discardthequickexhaustdiaphragm(22)
fromthe cover(15).
12. Remove the quick exhaust diaphragm retaining screw
(23),thediaphragmwasher (24)and thediaphragm (25)
fromthe cover(15).
CLEANING & INSPECTION
1. Usingmineral spiritsoranequivalent solvent,cleanand
thoroughlydryallmetal parts.
2. Inspect the interior and exterior of all metal parts that
will be reused for severe corrosion, pitting and cracks.
Superficial corrosion and/or pitting on the exterior
portion of the body (5) and cover (15) is acceptable.
Replacetheentirevalveiftheinteriorofthebodyorcover
exhibit signs of corrosion or pitting.
3. Inspectthe bores of boththebody (5) and cover(15)for
deep scuffing or gouges. Replace the entire valve if
either are found.
4. Make certain all air channels and exhaust passages in
thevalve cover (15) areclearand free ofobstruction.
5. Inspect the pipe threads in the body (5). Make certain
they are clean and free of thread sealant.
6. Washall non-metalliccomponentsin asoap and water
solution making certain to rinse and dry thoroughly.
Inspect each non-metallic component for cracks, wear
ordistortion. Replacetheentire valveifthese conditions
are found.
7. Ifthe valvewasequipped with arelaypiston spring(19),
inspect it for signs of corrosion, pitting and cracks.
Replace as necessary.
8. Inspect all air line fittings for corrosion and replace as
necessary.Makecertaintoremove alloldthreadsealant
before reuse.
ASSEMBLY
1. Priortoassembly,lubricateallo-rings,seals,andpistons,
aswellas body bores, using the lubricant provided with
the Bendix maintenance kit.
2. Installthe valveretainer(9)ontheinletandexhaustvalve
(10) so that the flange of the retainer (9) surrounds the
rubberportionofthevalve.Installtheinletandexhaust
valvein the body(5).
3. Installthe inlet andexhaustvalve return spring(8)in the
body(5).
4. Installthe large andsmalldiametero-rings (7 &6)in the
exhaust cover (4), then install the exhaust cover in the
body(5) taking carenotto damage theo-rings.Hold the
exhaustcoverinplace.
5. While depressing the exhaust cover (4), install the
retainingring(3)inthebody(5).Makecertaintheretainer
(3) is fully seated in its groove in the body.
6. IftheAR-1™valvewasequippedwitharelaypistonreturn
spring(19), installthespring in the body, large diameter
first.

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7. Usinglubricant to hold theminplace,install sealing ring
(16)on the cover(15).
8. Installthe o-ring(18)on therelaypiston (17),theninstall
the piston in the body (5).
9. After noting the relationship marks made prior to
disassembly, assemble the cover (15) on the body (5)
and the mounting bracket on the body (5) and secure
thecomponentstogetherusingthe two cap screws(11)
and two bolts (13), lock washers (12), and nuts (14).
Torque the cover cap screws (11) and bolts (13) to
120-150lb.in.
10. Install the two cap screws and lock washers (26) that
securethebrackettothe cover (15) and torque them to
180-220lb.in.
11. After noting the relationship of marks made prior to
disassembly, attach the gasket (2) to the antilock
controllerthensecuretheantilockcontrolleronthecover
(15) using the four cap screws and lock washers (1).
Torque the cap screws to 50-80 lb. in.
12. Install allairlinefittings andplugsmakingcertain thread
sealingmaterialdoes not enter the valve.
13. Install the CR-15 (AR-1™valve with attached antilock
controller)on thevehicleandperformthe Operationand
LeakageTestsbefore returning the vehicle toservice.
BW1665 © 2004 Bendix Commercial Vehicle Systems LLC. All rights reserved. 6/2004 Printed in U.S.A.