BENDIX E-10PR RETARDER CTRL BRAKEVALVE User manual

1
®
SD-03-832
Bendix®E-10PR™Retarder Control Brake Valve
DESCRIPTION
Refer to Figures 3 and 4 for item numbers referenced in
parenthesis.
TheBendix®E-10PR™retarder control brake valve is used
withretardersystemsinstalledon automatictransmissions.
Automatictransmission retardersareusedtoretardforward
motion of the vehicle above 5 mph. Retarders are most
popularin thetransit (buses/coaches)industry andareused
to extend the life of brake system components.
The retarder system is actuated early in the brake
application,beforeair pressureisdelivered.
Retarderscanbeinstalled either internally or externally on
the automatic transmission and are generally electrically
activated by devices such as the E-10PR™valve. Most
retardersredirecttheflowofhydraulicfluidthroughthetorque
converterwhileothersuseasmallinternalbrakeintheoutput
section of the transmission.
The E-10PR™valve is capable of controlling up to a three-
stage retarder (different levels of retardation) through the
sequencingof itsthreeelectrical switches. Thesequencing
oftheseswitches isimportantto the properoperationof the
retarder.
E-10PR™retarder control brake valve is a floor mounted,
treadleoperatedtype brake valvewithtwo separate supply
and delivery circuits for service (primary and secondary)
braking,whichprovidesthe driver with a graduatedcontrol
forapplyingand releasing thevehiclebrakes.
TheE-10PR™valveusesametalcoilspring(6)housedin an
upper body assembly. The use of a metal coil spring (and
the upper body assembly) provides greater treadle travel
and,therefore, providesthe driverwith aless sensitive"feel"
when making a brake application. The E-10PR™retarder
controlbrakevalveisgenerallyusedonbuses,wheresmooth
brakeapplicationscontribute to passenger comfort.
The circuits in the E-10PR™retarder control brake valves
areidentifiedasfollows:TheNo. 1 or primary circuit is that
portionofthe valvebetweenthespring seatwhichcontacts
the plunger and the relay piston; the No. 2 or secondary
circuit is that portion between the relay piston and the
exhaustcavity.
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 arelayvalve.
Bothprimaryand secondary circuits of thebrakevalveuse
a common exhaust protected by an exhaust diaphragm.
OPERATION - Refer to Figure 2
APPLYING: NORMAL OPERATION - NO. 1 OR
PRIMARY CIRCUIT PORTION
When the brake treadle is depressed, the plunger exerts
force on the spring seat (5), graduating spring (12), and
primarypiston(11).Theprimarypiston, which containsthe
exhaust valve seat, closes the primary exhaust valve. As
theexhaustvalvecloses,theprimaryinletvalveismovedoff
itsseatallowingprimaryairtoflowout the No. 1 or primary
deliveryport.
FIGURE 1 - E-10PR™RETARDER CONTROL BRAKE
VALVE
VALVE
MOUNTING
PLATE
TREADLE
SUPPLY
4 PORTS
DELIVERY
4 PORTS
AUXILIARY EXHAUST
RETARDER
CONTROL
SECTION
ELECTRICAL
CONNECTOR

2
FIGURE 2 - TYPICAL PIPING SCHEMATIC
TP-5™TRACTOR
PROTECTION VALVE
MV-3™
MANIFOLD
VALVE
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-10PR™)
RETARDER
CONTROL BRAKE
VALVE
BP-R1™
BOBTAIL
PROPORTIONING
VALVE
QUICK
RELEASE
VALVE
FIGURE 3 - E-10PR™RETARDER CONTROL BRAKE VALVE SECTIONAL VIEW
TREADLE
1
6
13
29
24
19 20
30
12
11
BOOT
SPRING
ROLLER
5

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on the secondary side of the relay piston (24) closely
approachesthe airpressureon theprimaryside oftherelay
piston.
Whenthebrake treadleisfullydepressed, boththeprimary
and secondary inlet valves remain open and full reservoir
pressureisdeliveredto the actuators.
RELEASING: NO. 1 OR PRIMARY CIRCUIT
Withthebraketreadlereleased,mechanicalforceisremoved
fromthespringseat (5), graduating spring(6),andprimary
piston(11).Airpressureand spring loadmovesthe primary
piston, opening the primary exhaust valve, allowing air
pressure in the primary delivery line to exhaust out the
exhaustport.
RELEASING: NO. 2 OR SECONDARY CIRCUIT
With the brake treadle released, air is exhausted from the
primarycircuit side oftherelay piston(24).Airpressure and
spring load move the relay piston, opening the secondary
exhaustvalve,allowingairpressureinthesecondarydelivery
line to exhaust out the exhaust port.
PREVENTIVE MAINTENANCE
Important: Review the Bendix Warranty Policy before
performinganyintrusivemaintenanceprocedures.Awarranty
maybevoided ifintrusivemaintenance isperformedduring
thewarranty period.
No two vehicles operate under identical conditions, as a
result, maintenance intervals may vary. Experience is a
valuableguide indeterminingthebestmaintenance interval
for air brake system components. At a minimum, the
E-10PR™valveshould beinspected every6 monthsor 1500
operatinghours,whichevercomesfirst,forproperoperation.
Should the E-10PR™valve not meet the elements of the
operationaltestsnotedinthisdocument,furtherinvestigation
andservice of thevalvemay berequired.
Visuallycheckfor physical damagetothe brake valvesuch
as broken air lines and broken or missing parts.
Every 3 months, 25,000 miles, or 900 operating hours:
Cleananyaccumulateddirt, gravel,or foreignmaterial away
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 (Bendixpart246671).
Check the rubber plunger boot for cracks, holes or
deteriorationandreplaceifnecessary.Also,checkmounting
plateandtreadle for integrity.
Applya thin layerofBarium grease,perBW-204-M (Bendix
part246671), betweenplunger andmountingplate–do not
over oil!
APPLYING: NORMAL OPERATION - NO. 2 OR
SECONDARY CIRCUIT
Whenthe primaryinletvalve (29) ismovedoff itsseat, airis
permittedto passthroughthebleedpassage andentersthe
relaypistoncavity.Theair pressure moves therelaypiston
(24), which contains the exhaust seat, and closes the
secondary exhaust valve.As the secondary exhaust valve
closes,theinlet valve (19)ismovedoff its seatallowingthe
secondary air to flow out the delivery of the same circuit.
Because of the small volume of air required to move the
relaypiston(24), actionofthe secondarycircuitof the valve
is almost simultaneous with the primary circuit portion.
APPLYING: LOSS OF AIR IN THE NO. 2 OR
SECONDARY CIRCUIT
Should air be lost in the No. 2 or secondary circuit, the No.
1 or primary circuit will continue to function as described
above under Normal Operation: No.1 or Primary Circuit
Portion.
APPLYING: LOSS OF AIR IN THE NO. 1 OR
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
pressureis presentintheprimarycircuit supplyand delivery
ports, the primary piston (11) will mechanically move the
relaypiston (24),allowing thepistonto closethe secondary
exhaustvalve andopenthe secondaryinletvalve andallow
airtoflowout the secondary delivery port.
BALANCED: NO. 1 OR PRIMARY CIRCUIT
When the primary delivery pressure acting on the primary
piston (11) equals the mechanical force of the brake pedal
application,theprimarypiston(11)willmove andtheprimary
inletvalve (29)will close,stoppingfurtherflowof airfrom the
primary supply line through the valve. The exhaust valve
remains closed preventing any escape of air through the
exhaustport.
BALANCED: NO. 2 OR SECONDARY CIRCUIT
Whentheairpressureonthedeliverysideoftherelaypiston
(24)approachesthat beingdeliveredonthe primarysideof
the relay piston, the relay piston moves closing the
secondaryinletvalveandstopping furtherflowofairfromthe
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
balancedpositionin theprimarycircuit is reachedasthe air
pressureonthedeliverysideoftheprimarypiston(11)equals
theeffortexertedbythedriver'sfootonthetreadle.Abalanced
positioninthesecondaryportionisreachedwhenairpressure

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SERVICE CHECKS
OPERATING CHECK
Checkthedelivery pressureofboth primaryandsecondary
circuitsusingaccuratetestgauges.Depressthetreadleto
severalpositionsbetweenthefully releasedandfullyapplied
positions, and check the delivered pressure on the test
gaugestosee thatitvaries equallyandproportionately with
themovementof the brakepedal.
After a full application is released, the reading on the test
gauges should fall off to zero promptly. It should be noted
thattheprimary circuitdeliverypressure will beabout2 PSI
greater than the secondary circuit delivery pressure with
bothsupplyreservoirs atthesame pressure.Thisisnormal
forthisvalve.
Important:Achangein vehicle brakingcharacteristicsor a
low pressure warning may indicate a malfunction in one or
the other brake circuit, and although the vehicle air brake
systemmaycontinueto function, the vehicle shouldnotbe
operated until the necessary repairs have been made and
both braking circuits, including the pneumatic and
mechanicaldevices,areoperating normally.Alwayscheck
thevehiclebrakesystemforproperoperationafterperforming
brakeworkand beforereturningthe vehicle toservice.
LEAKAGE CHECK
1. Makeandholdahigh pressure (80 psi) application.
2. Coattheexhaustportand bodyofthebrakevalve witha
soapsolution.
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
replacedwitha neworremanufactured unit,orrepaired
withgenuineBendixpartsavailableatauthorizedBendix
parts outlets.
REMOVAL - Refer to figures 3 and 4 for item
numbers referenced in parenthesis.
1. Chock the vehicle wheels or park the vehicle by
mechanicalmeans. (Blockandhold vehicle by means
other than air brakes.) Drain all air system reservoirs.
REMOVALOFTHERETARDERCONTROLASSEMBLY
1. Disconnecttheplugoftheelectricalcablefromitsmating
socketof the vehicles power supply.
2. Identifyanddisconnectallairsupplyanddeliverylinesat
thebrakevalveifbrakevalvereplacementisrequired.
3. Removethebrakevalveandtreadleassemblyfromthe
vehiclebyremovingthethreecapscrewsontheouterbolt
circle of the mounting plate.
NOTE: Before removing the treadle assembly, be sure to
mark the position of the treadle mounting plate
relativetotheretardercontrolassembly.
4. Removethetreadlefromthemountingplatebytapping
out the roll pin and then the pin retaining the treadle,
springandmountingplate.
NOTE: Markthepositionoftheretardercontrolassemblyto
theuppervalvehousing.
5. Removethebootfromtheplunger.
6. Remove the three remaining cap screws (2) from the
mounting plate. Separate the mounting plate from the
retarder control section (1) and the retarder control
sectionfromtheuppervalvehousing(13). CAUTION: Do
Not separate the upper valve housing from the
balance of the brake valve. Keep the plunger in the
retardercontrol section in its bore. Switchdamage
will result from attempted removal or permitting it
to slide out of the body/bore by more than 3/8”.
DISASSEMBLY - Refer to figures 3 and 4 for item
numbers referenced in parenthesis.
1. If the entire brake valve and treadle assembly was
removedfrom thevehicle,remove the threecapscrews
securingthetreadle assembly to thebasicbrakevalve.
2. Removethescrew(15)securingtheexhaustdiaphragm
(17)andwasher (16) to theexhaustcover (18).
3. Removethefour screws that secure the exhaust cover
(18)tothelowerbody.
4. Removethesecondaryinletandexhaustvalveassembly
(19)fromthe lower body.
5. Removethefourhexheadcapscrewssecuringthelower
bodytotheupper body and separate the bodyhalves.
6. Removetherubber seal ring(21)from the lowerbody.
7. Whiledepressingspring seat (5), removeretainingring
(4).Removespringseat (5) and coilspring(6).
Caution: Beforeproceeding withthedisassembly, refer
to Figures 3 and 4 and note that the lock nut (7) and
stem (22) are used to contain the primary piston return
spring(12),stemspring (9), and the relay pistonspring
(27). The combined force of these springs is
approximately50pounds andcaremust betakenwhen
removing the lock nut as the spring forces will be
released.It isrecommendedthat theprimarypistonand
relaypistonbemanuallyormechanicallycontainedwhile
thenutand stem are beingremoved.
8. Usinga3/8”wrench,holdthelocknut(7)onthe threaded
endofthe stem (22).Inserta screwdriver torestrainthe
stem,removethe lock nut(7),spring seat, (8)andstem
spring(9).
9. Removeadapter(13)ando-ring(14). Removetheprimary
piston (11) from adapter (13) and o-ring (10) from the
primarypiston(11).
10. Remove the relay piston (24), relay piston spring (27),
primarypiston (11)andprimary pistonreturnspring(12)
from the upper body. Use care so as not to nick seats.

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FIGURE 4 - E-10PR™RETARDER CONTROL BRAKE VALVE - EXPLODED VIEW
12
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30

6
11. A small washer (26) will be found in the cavity of the
lowersideoftheprimary piston (11).
12. Remove the large and small o-rings (23 & 25) from the
relaypiston(24).
13.Remove theretaining ring(28)securingtheprimaryinlet
andexhaustvalve assembly(29)in the upperbodyand
removethe valveassembly.
CLEANING AND INSPECTION
1. Wash all metal parts in mineral spirits and dry.
2. Inspectallparts for excessive wearordeterioration.
3. Inspectthevalve 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
serviceableduringinspection, useonlygenuineBendix
replacementparts.
ASSEMBLY
Prior to reassembling, lubricate all o-rings, o-ring grooves,
pistonbores,and metal tometalmoving surfaces withDow
Corning55o-ring lubricant (Bendixpiecenumber 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 (29) in
the upper body and replace the retaining ring (28) to
secureit. Besurethe retainingringisseatedcompletely
initsgroove.
2. Installthelarge and small o-rings(23&25) on the relay
piston(24).
3. Placerelaypistonspring(27) inconcaveportionofrelay
piston(24)and installrelaypiston through primaryinlet/
exhaust assembly (29) into under side of upper body.
4. Installo-ring(14) on adapter (13)andinstall adapter on
upperbody.Installo-ring(10)on primary piston (11).
5. Place screwdriver, blade up, in vise. Insert stem (22)
throughthe relaypistonupper bodysubassembly,slide
thisassembly overthe bladeofthesecuredscrewdriver,
engage the screwdriver blade in the slot in the head of
the stem.
6. Place thewasher(26)over the stem (22) and ontopof
the relay piston (24).
7. Install primary return spring (12) in upper body piston
bore.
8. Compress the primary and relay pistons (11 & 24) and
retaining ring into the upper body from either side and
holdcompressed,either manuallyormechanically. See
thecautionary note understep 7in theDisassembly
section of this manual.
9. Place the stem spring (9), the spring seat (8) (concave
sideup)and lock nut (7) onthestem(22). Torque to 20
- 30 inch pounds.
10. Install coil spring (6), spring seat (5), and retaining ring
(4) .
11.Replacethe rubber seal ring (21) onthelowerbody.
12. Install the 4 hex head cap screws securing the lower
bodytotheupper body. Torque to 30 - 60 inchpounds.
13.Installthesecondary inlet and exhaust valve assembly
(19) on the lower body.
14.Installthescrewsthat secure the exhaust cover (18) to
the lower body. Torque to 20 - 40 inch pounds.
15. Secure the screw (15) holding the exhaust diaphragm
(17)andthediaphragmwasher(16)totheexhaustcover
(18). Torque to 5 - 10 inch pounds.
INSTALLATION OF THE RETARDER CONTROL
ASSEMBLY
1. Place the retarder control assembly (1) onto the upper
valve housing (13) making sure it is oriented correctly.
(Refer to marks made on unit prior to disassembly).
CAUTION: Switch damage will result if the plunger
is permitted to slide out of the bore by more than
3/8”. Place the mounting bracket onto the top of the
retarder control assembly in its proper location. (Again
referring to marks made prior to disassembly.) Retain
withthethree longcapscrews(2) andtorqueto80-120
in.lbs. Donotusesiliconegreaseintheretardercontrol
section.
2. Replacethebootbyexpandingitslargediameterintothe
recessinthemountingplateandthesmalldiameterinto
the recess of the plunger.
3. Connectallairsupplyanddeliverylinestothebrakevalve
thatwerepreviouslyremoved.
4. Plugtheconnectorofthecableassemblyintoitsmating
component from the vehicles power supply. Switch
adjustmentwillberequiredifthebrakevalveorretarder
controlhasbeenreplaced.
5. Replacethetreadleassemblyontothevalve. Placethe
yellow end of the spring into the hole provided in the
mounting plate. Catch the opposite end of the spring
under the treadle and hold the treadle in place while
installing the pin through the ears of the mounting plate
andtheI.D.ofthespring. Installtherollpinintoitshole
in the bushing on one side of the treadle making sure it
entersitsmatingholdinthepinofthetreadleassembly.

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VALVE INSTALLATION
1. Installtheassembled brake valveonthe vehicle.
2. Reconnectallairlinesto thevalveusingtheidentification
made during VALVE REMOVALstep 1.
3. After installing the brake valve assembly, perform the
“OPERATIONANDLEAKAGECHECKS”beforeplacing
thevehiclein service.
RETARDERBRAKEVALVEADJUSTMENT
PROCEDURE
Equipmentrequiredto performadjustments:
Qty. Description
1 AirGauge
1 PhillipsScrew Driver
1 0.050Allen Wrench
1 Volt-OhmMeter
SWITCHADJUSTMENTS
Adjustments to the closing of the switches can be attained
byinsertinga0.050Allenscrew,turningthescrewclockwise
todecreasetheamount of movement required toclosethe
switch and counterclockwise to increase the amount of
movement required to close the switch.All adjustments of
the switches and readings of the volt-ohm meter are to be
madewiththe treadlebeingdepressed(downward stroke).
Never attempt to adjust the switches on the release of the
treadleapplication(upward stroke).
CALIBRATIONOFMICRO SWITCHESONALLTREADLE
ACTUATED BRAKE VALVES (Except the lever actuated
model)SeeFigure 5.
NOTE: Cannonconnectorpins are identifiedwithnumbers
andPackardconnectorpinsareidentifiedwith letters.
1. RemovethetwoPhillips screws and remove thecover
of the switch plate, exposing the switch plate.
2. Unplugthepowercableat thequick connectconnector.
3. To adjust switch #1, connect the black lead of the volt-
ohm meter to pin #3 or C of the connector and the red
lead to pin #1 or A of the connector. At this time there
should be a maximum reading on the meter (open
circuit). Slowly start to depress the treadle. After
approximately1/4"movement attheend of thetreadle,
switch #1 should close and the volt-ohm meter will
respondwithareadingof near 0 (closed circuit).
4. Tocheck switch #2,leavethe blackleadof the volt-ohm
meterconnectedtopin#3orC oftheconnector;connect
the red lead to pin #4 or D. At this time, the meter will
havea maximumreading(open circuit).Slowlydepress
thetreadleuntilyoucanfeelresistancetothemovement
beingapplied.Atthe point oftheend of thefreetravel of
thetreadle,approximately 1/2" movement attheendof
thetreadle,switch #2shouldclose andthevolt-ohm will
respondwith areadingof near0.If anadjustment tothis
switch is required, follow the instructions under the
heading“SwitchAdjustments.”
FIGURE 5 - RETARDER BRAKE VALVE SWITCH ADJUSTMENT
COURSEVERTICAL
ADJUSTMENT
(SEQUENCE)
LATERALADJUSTER
SCREWS(FINEADJUSTMENT
OFSWITCHARMTRAVEL)
PACKARDSTYLE
CONNECTOR
PACKARD
STYLE
CONNECTOR
(LETTERS)CANNON
STYLE
CONNECTOR
(NUMBERED)
CANNON
STYLE
CONNECTOR

8BW2159 © 2004 Bendix Commercial Vehicle Systems LLC. All rights reserved. 3/2004 Printed in U.S.A.
5. To check switch #3, continue to have the black lead of
the volt-ohm meter connected to pin #3 or C of the
connectorandconnecttheredleadtopin#2orB.Install
an air gauge in the primary delivery circuit. With the
treadlein the retractedposition,the readingonthe volt-
ohm meter will be maximum (open circuit). Slowly
depress the treadle until the air delivery of the primary
circuit(shownontheairgauge)reaches12psi.Atwhich
timeswitch#3 shouldcloseand the volt-ohmmeterwill
respond with a reading of near 0. If an adjustment to
thisswitchis required, followtheinstructionsunder the
heading“SwitchAdjustments.”
6. When all adjustments to the switches are complete,
theAllenscrewsshouldberesealedusinganyavailable
sealant (such as paint or liquid gasket material).
7. Replace the cover and gasket on the switch plate and
retainbyinstallingthetwoPhillipsscrewsandtightening
securely.
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 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
enginebe inoperation, 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. Useonly the propertools andobserve
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 certaintodrain theair pressurefrom
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
recommendedprocedures, deactivatethe 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 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.