BENDIX E-10 DUAL BRAKE VALVES User manual

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®
SD-03-817
Bendix®E-6™& E-10™Dual Brake Valves
DESCRIPTION
TheE-6™(Figure1)andE-10™(Figure2)dual brake valves
are floor mounted, treadle operated type brake valves with
two separate supply and delivery circuits for service (pri-
mary)andsecondarybraking, whichprovidesthedriverwith
a graduated control for applying and releasing the vehicle
brakes.
TheE-10™dual brakevalve(Figure2)issimilartotheE-6™
dual brake valve except that a metal coil spring housed in
anupper body assembly replacestherubberspring used in
theE-6™valve. Theuseof ametalcoil spring(andthe upper
body assembly) provides greater treadle travel and, there-
fore, provides the driver with a less sensitive "feel" when
making a brake application. The E-10™dual brake valve is
generallyused on buses, where smooth brake applications
contribute to passenger comfort.
ThecircuitsintheE-6™/E-10™dualbrakevalvesareidentified
as follows: The primary circuit is that portion of the valve
betweenthe spring seatwhichcontactsthe plunger andthe
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
operationto 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.Theprimarypiston,whichcontains theexhaust valve
seat,closestheprimary exhaustvalve.Astheexhaustvalve
closes,the primary inlet valve is moved offits seat allowing
primary air to flow out the primary delivery port.
FIGURE 1 - E-6™DUAL BRAKE VALVE FIGURE 2 - 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

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delivery ports, the primary piston will mechanically move
the relay piston, allowing the piston to close the secondary
exhaustvalve and openthesecondaryinlet valve andallow
air to flow out the secondary delivery port.
BALANCED: PRIMARY CIRCUIT
When the primary delivery pressure acting on the piston
equalsthe 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
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
secondaryinletvalve andstopping furtherflow ofair fromthe
supply line through the valve. The exhaust remains closed
as the secondary delivery pressure balances the primary
deliverypressure.
When applications in the graduating range are made, a
balancedposition in the primary circuit is reached as theair
FIGURE 3 - E-6™DUAL BRAKE VALVE SECTIONAL
DIAGRAM
14
30
32
31
33
28
15
911
10
25
16
12
13
20
21
24
23
22
27
26
17
19
18 78
18
4
5
19
1
2
6
16
17
APPLYING: NORMAL OPERATION -
SECONDARY CIRCUIT
When the primary inlet valve is moved off its seat, air is
permittedto passthroughthe bleed passageandenters the
relaypiston cavity.Theair pressure moves the relaypiston,
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
Should air be lost in the secondary circuit, the primary
circuit will continue to function as described above under
NormalOperation: 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 - E-10™DUAL BRAKE VALVE SECTIONAL
DIAGRAM
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pressure on the delivery side of the primary piston equals
the effort exerted by the driver's foot on the treadle. A
balancedposition in thesecondaryportionis reached when
airpressureonthe secondaryside oftherelaypistonclosely
approachesthe air pressureontheprimary side oftherelay
piston.
Whenthe 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
primarypiston, opening theprimaryexhaustvalve, 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: ReviewtheBendixWarranty Policy before per-
forming any intrusive maintenance procedures.Awarranty
maybe voided if intrusive maintenance isperformedduring
thewarranty period.
No two vehicles operate under identical conditions, as a
result,maintenanceintervalsmayvary.Experience isa valu-
ableguideindeterminingthebestmaintenanceintervalforair
brake system components. At a minimum, the E-6™/E-10™
valvesshould be inspected every 6monthsor1500operat-
inghours,whichevercomesfirst,forproperoperation.Should
the E-6™/E-10™valves not meet the elements of the opera-
tionaltests noted inthisdocument, further investigation and
serviceof the valve mayberequired.
Visuallycheck for physical damage to the brake valve such
as broken air lines and broken or missing parts.
Every 3 months, 25,000 miles, or 900 operating hours:
Cleananyaccumulateddirt, gravel,orforeignmaterialaway
from the heel of the treadle, plunger boot, and mounting
plate.
Lubricate the treadle roller, roller pin, and hinge pin, with
Bariumgreaseper BW-204-M (Bendix part 246671).
Check the rubber plunger boot for cracks, holes or deterio-
rationandreplace if necessary.Also, check mountingplate
andtreadle for integrity.
Applya thin layer ofBariumgrease,per BW-204-M (Bendix
part246671), betweenplungerandmountingplate – do not
over oil!
FIGURE 5 - TYPICAL PIPING SCHEMATIC
TP-5™TRACTOR
PROTECTION VALVE
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
(E-6™OR E-10™)
DUAL BRAKE
VALVE
BP-R1™
BOBTAIL
PROPORTIONING
VALVE
QUICK
RELEASE
VALVE

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SERVICE CHECKS
OPERATING CHECK
Checkthe delivery pressure of bothprimaryandsecondary
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
testgaugesto 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
thatthe primary circuit delivery pressure will be about 2PSI
greater than the secondary circuit delivery pressure with
bothsupply reservoirs at the same pressure.Thisisnormal
forthis valve.
Important:Achange invehicle 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
bothbraking circuits, includingthepneumatic and mechani-
caldevices,areoperatingnormally.Alwayscheckthevehicle
brake system for proper operation after performing brake
workand before returning the vehicle to service.
LEAKAGE CHECK
1. Make and hold a high pressure (80 psi) application.
2. Coatthe exhaust portandbody of thebrakevalve witha
soap solution.
3. Leakage permitted is a 1” bubble in 3 seconds. If the
brakevalvedoesnotfunctionasdescribedaboveorleak-
age is excessive, it is recommended that it be replaced
withaneworremanufacturedunit,orrepairedwithgenu-
ine 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
thebrakevalve.
3. Removethe 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
alonecanberemovedbyremovingthethreecapscrews
on the inner bolt circle.
DISASSEMBLY (Figures 3 and 4)
1. If the entire brake valve and treadle assembly was re-
moved 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. Removethe Secondary inlet and exhaust valve assem-
bly (13) from the lower body.
5. Removethefourhexheadcapscrewssecuringthelower
body to the upper body and separate the body halves.
6. Removethe rubber seal ring (14) from the lower body.
E-6™VALVE ONLY (Figure 3):
7. Whileapplying thumb pressure to theprimarypiston,lift
out and up on the three lock tabs of the primary piston
retainer(15).
E-10™VALVE ONLY (Figure 4):
8. A. Whiledepressing spring seat (7), remove retaining
ring(8).
B. Remove 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).
Inserta screwdriver in theexhaustpassagethrough the
center of the valve and engage the slotted head of the
stem.
10. Removelocknut(16),spring seat(18), stemspring (19),
primary piston (2), and primary piston return spring (6).
Removeo-ring(34).
11. Remove adapter (1). Remove o-ring (4) from adapter.
Caution:Before proceeding withthedisassembly, refer
toFigure 4 and note that thelocknutand stem are used
to contain the primary piston return spring, stem spring
andthe relaypistonspring. Thecombined forceofthese
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.
E-6™VALVE ONLY:
12. Usinga screwdrivertorestrainthe stem,asin stepnine,
remove the lock nut (16), spring seat (18) and stem
spring(19).
13. Remove the relay piston (20), relay piston spring (21),
primarypistonandprimary pistonreturn spring(23)from
the upper body. Use care so as not to nick seats.
Note: CertainE-6™valvesdonot have a relay pistonspring
(21). If none is found, none should be replaced.
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
seatnut(25)counterclockwise. Separatethe springseat

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nut,spring seat (26), rubber spring (27)andremovethe
pistono-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
inletand exhaust valveassembly(33)in the upperbody
andremove thevalveassembly.
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 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 specified in this manual are assembly
torques and can be expected to fall off, after assembly is
accomplished. Do not retorque after initial assembly
torquesfall.
1. Install the primary inlet and exhaust assembly (33) in
the upper body and replace the retaining ring (32) to
secureit. Besuretheretaining ringisseatedcompletely
initsgroove.
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.
E-6™VALVE ONLY:
4. Installthe rubber spring (do not lubricate)(27),concave
sidedowninthe primarypiston(22) andplace thespring
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)andinto under side of
upperbody.
8. Place screwdriver, blade up, in vise. Place stem (17) in
relaypistonupper body sub assembly over the blade of
the screwdriver with blade engaged in the slot in the
head of the stem.
9. Placethe washer(24) overthestem.Thiswashershould
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
bodyfrom either sideandhold 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,
makingcertainallthreelocktabshaveengagedtheouter
lip of the body.
GENERAL SAFETY GUIDELINES
WARNING! PLEASE READ AND FOLLOW
THESE INSTRUCTIONS TO AVOID
PERSONAL INJURYOR 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
underoraround thevehicle. When workingintheengine
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.

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4. Ifthe work is being performed on the vehicle’s air brake
system, or any auxiliary pressurized air systems, make
certaintodraintheairpressure fromall reservoirsbefore
beginning ANY work on the vehicle. If the vehicle is
equipped with an AD-IS®air dryer system or a dryer
reservoirmodule, be sure to drainthepurgereservoir.
5. Following the vehicle manufacturer’s recommended
procedures,deactivatetheelectricalsysteminamanner
thatsafely removes allelectricalpower from thevehicle.
6. Neverexceed manufacturer’srecommendedpressures.
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
beendepleted.
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
shouldbe replacedratherthan repaired. Donotattempt
repairsrequiringmachiningorweldingunlessspecifically
stated and approved by the vehicle and component
manufacturer.
10. Priorto returningthe vehicletoservice,makecertain all
components and systems are restored to their proper
operatingcondition.
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
maintenancewhere one or more wheels on a drive axle
arelifted off the ground andmoving.5. Following the
vehicle manufacturer’s recommended procedures,
deactivate the electrical system in a manner that safely
removesall electrical power from the vehicle.

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8BW1427 © 2007 Bendix Commercial Vehicle Systems LLC. All rights reserved. 3/2007 Printed in U.S.A.