BENDIX E-10 Mounting instructions

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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 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.
TheE-10™dualbrakevalve(Figure2)issimilartotheE-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
identifiedasfollows:Theprimarycircuitis that portionofthe
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.
Bothprimaryandsecondarycircuitsofthebrakevalveuse
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.
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

2
delivery ports – the primary piston will mechanically move
therelay piston, allowing thepiston to close the secondary
exhaustvalveandopenthesecondaryinletvalve,allowing
air to flow out the secondary delivery port.
BALANCED: PRIMARY CIRCUIT
When the primary delivery pressure acting on the piston
equalsthemechanicalforceofthebrake pedal application,
theprimarypistonwillmove 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
sideoftherelaypiston, 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.
When applications in the graduating range are made, a
balancedpositionintheprimarycircuit is reached astheair
pressure on the delivery side of the primary piston equals
FIGURE 3 - BENDIX®E-6®DUAL BRAKE VALVE
SECTIONAL DIAGRAM
14
30
32
31
33
28
15
9 11 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
permittedtopassthrough thebleedpassageand entersthe
relaypistoncavity.Theairpressuremovesthe relay piston,
whichcontainstheexhaustseat,andcloses the secondary
exhaustvalve.Asthesecondaryexhaustvalvecloses,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
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
34

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the effort exerted by the driver’s foot on the treadle. A
balanced position in the secondary portion is reached
whenairpressureonthesecondarysideof the relay piston
closely approaches the air pressure on the primary side
of the relay piston.
Whenthebraketreadleisfully depressed, both theprimary
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,openingthe primary exhaustvalve,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 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.
Visuallycheckfor physical damage to the brakevalvesuch
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.
Applyathinlayerof Barium grease,perBW-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
(WETTANK) #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™)
DUALBRAKE
VALVE
BENDIX®
BP-R1™
BOBTAIL
PROPORTIONING
VALVE
QUICK
RELEASE
VALVE

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SERVICE CHECKS
OPERATING CHECK
Checkthedeliverypressureof both primaryandsecondary
circuits using accurate test gauges. Depress the treadle
to several positions between the fully released and fully
appliedpositions,andcheckthe delivered pressure on the
testgaugestoseethatitvaries 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
replacedwithaneworremanufacturedunit,orrepaired
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
valvealonecanberemovedbyremovingthethreecap
screws on the inner bolt circle.
DISASSEMBLY (Figures 3 and 4)
1. If the entire brake valve and treadle assembly was
removedfromthevehicle, remove thethreecapscrews
securing the treadle assembly to the basic brake
valve.
2. Removethescrew(9)securingtheexhaustdiaphragm
(10) and washer (11) to the exhaust cover (12).
3. Removethefour 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. Whileapplyingthumbpressuretothe 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).
Insertascrewdriverintheexhaustpassagethroughthe
center of the valve and engage the slotted head of the
stem.
10.Remove lock nut (16), spring seat (18), stem spring
(19),primarypiston(2), andprimarypistonreturnspring
(6). Remove o-ring (34).
11. Remove adapter (1). Remove o-ring (4) from adapter.
Caution:Beforeproceedingwiththedisassembly, refer
toFigure4andnote that thelocknutandstemareused
tocontaintheprimarypiston return spring, stem spring
andtherelay pistonspring.The combinedforceofthese
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).

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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
inletandexhaustvalve assembly (33)intheupperbody
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 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.
1. Install the primary inlet and exhaust assembly (33) in
the upper body and replace the retaining ring (32) to
secureit.Besure theretainingringisseated completely
in its groove.
2. Install the large (30) and small (31) o-rings on the relay
piston.
3. Installthe primary piston o-ring (28) in the piston o-ring
groove.
BENDIX®E-6®BRAKE VALVE ONLY:
4. Installtherubberspring(donotlubricate) (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.
8. Placescrewdriver, bladeup,invise. 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.Placethestemspring(19)overthespringseatnut(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
THESEINSTRUCTIONSTOAVOIDPERSONAL
INJURY OR DEATH:
Whenworkingonoraroundavehicle,thefollowing
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 bein operation, EXTREMECAUTION 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 theproper tools and observe
all precautions pertaining to use of those tools.

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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. Followingthevehiclemanufacturer’srecommended
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. Useonlygenuine Bendix®brand replacementparts,
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 withAutomatic Traction Control (ATC),
the ATC function must be disabled (ATC indicator
lamp should beON) prior to performingany 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