BENDIX E-14 DUAL BRAKE VALVE User manual

1
®
SD-03-828
Bendix®E-14™Dual Brake Valve DESCRIPTION
TheE-14™dualbrakevalveisasuspended-pedalfootvalve
with two separate supply and delivery circuits. The valve
providesthe driverwith graduatedcontrol forapplying and
releasingthe vehicle brakes.
The circuits in the E-14™dual brake valve are identified as
follows: The number one (primary) circuit is the portion of
the valve between the primary piston and the secondary
piston. The number two (secondary) circuit consists of the
areabetween the secondarypistonand the exhaustcavity.
The supply, delivery, and exhaust ports of the E-14™brake
valveareidentified by designations castintothevalve body
next to the port. (See Figure 1). The primary supply and
delivery ports are located in the valve’s primary body, and
the secondary supply and delivery ports are located in the
secondary body.
EXHAUST SECONDARYDELIVERY
SECONDARYSUPPLY
PRIMARY
DELIVERY
PRIMARY
SUPPLY
FIGURE1-E-14™DUAL BRAKE VALVE
FIGURE2-TYPICAL PIPING SCHEMATIC
QUICKRELEASE
VALVE
FRONT SERVICE
BRAKECHAMBER
PRIMARY
CIRCUIT
E-14™DUAL
BRAKE
VALVE
SECONDARY
CIRCUIT
DOUBLECHECK
VALVE
TRAILER
CONTROL
VALVE
DOUBLECHECK
AND
STOP LIGHT SWITCH
TO TRACTOR
PROTECTION
FRONT AXLE
SERVICERESERVOIR
REARAXLE
SERVICERELAY
VALVE
REARSERVICE
BRAKECHAMBER
REARAXLE
SERVICERESERVOIR

2
The primary circuit operates similar to a standard single
circuit air brake valve, and under normal operating
conditions the secondary circuit operates similar to a relay
valve.
Both the primary and secondary circuits use a common
exhaust,protected by anexhaust diaphragm.
OPERATION
APPLYING: NORMALOPERATION-PRIMARYCIRCUIT
When the brake pedal is depressed, the plunger exerts a
force on the spring retainer(7), graduating spring(8), and
primary piston(2). The primary piston, which contains the
exhaustvalveseat,closestheprimarycircuitexhaustvalve.
As the exhaust valve closes, the inlet valve for the primary
circuit moves off its seat, allowing air from the primary
circuit supply port to flow out the delivery port.
APPLYING: NORMAL OPERATION-SECONDARY
CIRCUIT
The secondary piston(18) moves with the primary piston
and closes the secondary circuit exhaust. When the inlet
valve in the primary portion of the valve is moved off its
seat,airpassesthrough the bleed passageinthesecondary
portionoftheprimarybody and enters thesecondarypiston
cavity. The air moves the secondary piston and opens the
secondary inlet valve, allowing the air from the secondary
supply to flow out the delivery port.
APPLYING: LOSS OFAIR IN THE PRIMARY CIRCUIT
If the brake pedal is depressed and no air pressure is
present in the primary circuit, the primary piston will
mechanically move the secondary piston, closing the
secondary exhaust and opening the secondary inlet,
allowing air flow from the secondary supply to its delivery
port.
APPLYING:LOSSOFAIRIN THE SECONDARYCIRCUIT
If the air is lost in the secondary circuit, the primary circuit
will function normally, as described in “Normal Operation:
Primary Circuit.”
BALANCED:PRIMARYCIRCUIT
Whentheprimarydeliverypressureactingupontheprimary
piston equals the mechanical force of the brake pedal
application,the primary pistonwillclose, preventing further
FIGURE3 -E-14™DUALBRAKE VALVE CROSS SECTIONALVIEW
PLUNGER
MOUNTING PLATE
PIVOTPIN
PEDAL
ROLLER
SECONDARYSUPPLY
(#2)
SECONDARYDELIVERY(#2)
EXHAUST
PRIMARY
SUPPLY(#1)
PRIMARY
DELIVERY(#1)
MANIFOLD
SEALING
RING
O-RING
ADAPTERSLEEVE
MOUNTING
PLATE(PEDAL)
MOUNTING
PLATE
(FIREWALL)
B
E-14™DUAL BRAKE
VALVE WITH MANIFOLD
A
E-14™DUAL
BRAKE VALVE

3
airflowfromthesupplyporttothedeliveryport.Theexhaust
valveremains closed, preventingthe escape ofair through
the exhaust port.
BALANCED: SECONDARY CIRCUIT
When air pressure on both sides of the secondary piston
approach each other, the piston moves, closing the
secondary inlet valve and preventing further air flow from
thesupplylinethroughthevalve.Theexhaustremainsclosed
as the secondary delivery pressure balances the primary
deliverypressure.
RELEASING: PRIMARY CIRCUIT
Whenthe force onthebrake pedal isreleased,mechanical
forceisremovedfromthegraduatingspringandtheprimary
piston.Airpressureinthedelivery circuit moves theprimary
piston and opens the primary exhaust valve, allowing air
pressure in the primary circuit to exit through the exhaust
port.
FIGURE4-APPLYING- NORMALOPERATION FIGURE5-APPLYING-FAILURE INTHEPRIMARY CIRCUIT
PLUNGER
FORCE
SUP-1
PEDALFORCE
SUP-2
EXHAUST
DEL-1
DEL-2
AIR FLOW
PEDALFORCE
PLUNGER
FORCE
SUP-1
SUP-2
EXHAUST
DEL-1
DEL-2
DEL-1
RELEASING: SECONDARY CIRCUIT
Whenthebrakepedal is released, airisexhaustedfromthe
primarycircuit sideofthesecondarypistonthroughthebleed
passage.Airpressure inthedelivery sideof the secondary
circuitmoves thepiston andopens thesecondary exhaust
valve,allowingairpressure in thesecondarydeliverylineto
exit through the exhaust port.
PREVENTIVE MAINTENANCE
Important: Review the warranty policy before performing
anyintrusivemaintenanceprocedures.Anextendedwarranty
maybevoided if intrusivemaintenanceisperformedduring
thisperiod.
Becausenotwovehiclesoperateunderidenticalconditions,
maintenanceandmaintenanceintervalswillvary.Experience
is a valuable guide in determining the best maintenance
intervalforanyone particular operation.
Visuallycheckfor physicaldamagetothe brake valvesuch
as broken air lines and broken or missing parts.
á
AIR FLOW
á

4
EVERY3 MONTHS, 25,000 MILES OR 900 OPERATING
HOURS
1. Remove any accumulated contaminants such as dirt
and gravel from the heel of the pedal, plunger, plunger
boot,and mounting plate.
2. Usinga light oil,lubricatethe pedal roller,roller pin, and
hingepin.
3. Inspect the plunger boot for cracks, holes, or
deterioration.Replaceifnecessary.Alsocheckmounting
plateandpedalforwearandcorrosion.Repairorreplace
as necessary.
4. Apply2 to 4drops of oilbetween plunger andmounting
plate- DO NOTOVEROIL!
5. Check for excessive leakage as described in the
“OPERATIONAL & LEAKAGE TEST” section of this
manual.
EVERY YEAR, 100,000 MILES, OR 3,600 OPERATING
HOURS
1. Performsteps1 through 4above.
2. Perform the checks in the “OPERATION & LEAKAGE
TEST”section ofthis manual.
OPERATIONAL & LEAKAGE TESTS
GENERAL
Achangein vehiclebrakingcharacteristicsoralowpressure
warning may indicate a malfunction in one of the brake
circuits. Although the air brake system may continue to
function, the vehicle should not be operated until the
necessaryrepairshavebeenmadeandbothbrakingcircuits,
including the pneumatic and mechanical devices, are
operatingnormally.
Ifthebrake valve doesnotfunctionasdescribed above orif
leakageisexcessive, itisrecommendedthat itbereplaced
withaneworremanufacturedunit,availableatBendixoutlets.
Alwayscheckthevehiclebrakesystemforproper operation
afterperformingbrakeworkandbeforereturningthevehicle
toservice.
OPERATIONALTEST
Check the delivery pressure of both circuits, using test
gaugesknowntobeaccurate.Note:Thepedalwillnotbein
a “normal” released position until the air brake system is
pressurized.Thepedalwillrise toitsnormal release position
asthe brake systemis pressurized from0 psi. Depressthe
pedal to several positions between the fully released and
fullyapplied positions andcheck the deliveredpressure on
thetestgaugestoseethatitvariesequallyandproportionally
withthe movement ofthe brake pedal.
FIGURE6-APPLYING-FAILUREINTHESECONDARYCIRCUIT
PEDAL
FORCE
PLUNGER
FORCE
SUP-1
SUP-2
EXHAUST
DEL-1
DEL-2
DEL-1
FIGURE7 - BALANCEDPOSITION
PLUNGER
FORCE
SUP-1
PEDAL
FORCE
SUP-2
EXHAUST
DEL-1
DEL-2
DEL-1
AIR FLOW
á
AIR FLOW
á

5
After a full application is released, the reading on the test
gauges should fall off to zero promptly. NOTE: the number
one circuit delivery pressure will be about four psi greater
thanthenumbertwocircuitdeliverypressurewithbothsupply
reservoirsatthe samepressure.ThisisnormalfortheE-14™
brakevalve.
LEAKAGETEST
Make and hold a high pressure application (80 psi). Coat
the exhaust port and body of the brake valve with a soap
solution. Leakage permitted is a 1" bubble in 3 seconds in
both the applied and released positions. No leakage is
permittedanywhereelse.
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
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. Useonly 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,makecertain to drain theairpressurefrom
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,deactivatetheelectrical
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.
VALVEREMOVAL
1. Identifyandmarkorlabelallairlinesandtheirrespective
connections on the brake valve to facilitate ease of
installation. Disconnect all air lines.
2. Removethe valve fromitsmounting on thevehicle. For
manifold-typevalves,removethebrakevalveandmanifold,
in tact, from the vehicle.
DISASSEMBLY (SEE FIGURE 9)
The following disassembly and assembly procedure is
presented for reference purposes only. Always have the
appropriatemaintenancekitonhand,anduseitsinstructions
in lieu of those presented here. Refer to Figure nine
throughouttheprocedure.
FIGURE8-RELEASED MODE
PEDALFORCE
PLUNGER
FORCE
SUP-1
SUP-2
EXHAUST
DEL-1
DEL-2
DEL-1

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CAUTION:Thebrakevalvemay belightclampedinabench
vise, but overclamping may damage the valve and
cause leakage and/or malfunction. If a vise is used,
clamp on the supply and delivery ports on opposing
sidesof the valve’sprimarybody.
1. Removeall air linefittings and plugs.
2. On valves that have a manifold on the engine
compartment side, remove the bolts that secure the
manifold to the valve. Separate the valve and manifold
andremovethesealingringsandadaptersleeves.(See
Figure2.)
3. Removethefourcapscrews(16)thatsecuretheprimary
body to the secondary body. Separate the two body
halvesandremoveanddiscardo-ring(17).
4. Pull secondary piston(18) out of the primary body and
remove and discard o-rings(19 & 20).
5. Removeand discard snapring(10) fromthe secondary
body while manually holding and compressing valve
seat(11) in place.
6. Slowly release valve seat(11), allowing it to rise out of
thebody.Removethevalveseat,thenremoveanddiscard
o-ring(12).
7. Removeand discard valveassembly(13) alongwith its
o-ring(15)from thesecondary body. Remove thevalve
assembly return spring(14).
8. Carefully remove and discard exhaust diaphragm
screw(24),diaphragmwasher(25), diaphragm(26), and
diaphragmretainer(27)fromthesecondarybody.NOTE:
SomeE-14™brakevalveshave a threaded exhaust port
insteadof items24-27.
9. Using light force, push piston(2) into the primary body
untilpistonretainingring(1)isfullyvisible.Removepiston
retaining ring(1), taking care not to damage the piston
bore in the body.
10. Gentlytap theprimary bodyon asoft surfacetoremove
piston(2). Remove and discard o-rings(3 & 5) and both
wear rings(4) from piston(2).
11. Place the piston on a flat surface. Using finger force,
depress and hold spring retainer(7), then remove and
discard retaining ring(6) from piston(2).
12. Gently release spring retainer(7), allowing it to rise out
ofthepiston.Remove spring retainer(7)andgraduating
spring(8)frompiston(2).
13. Removeanddiscardrubberspring(9)fromtheinteriorof
piston(2).
14. Remove anddiscard snapring(10) frompiston(2)while
manually holding and compressing valve seat(11) in
place.
15. Slowly release valve seat(11), allowing it to rise out of
piston(2).Removevalveseat(11),thenremoveanddiscard
o-ring(12).
16. Remove and discardvalve assembly(13) alongwith its
o-ring(15)from piston(2).Removevalveassemblyreturn
spring(14).
CLEANING & INSPECTION
1. Usingmineralspiritsoran equivalent solvent, cleanand
thoroughly dry all metal parts.
2. Inspect the interior and exterior of all metal parts that
will be reused for severe corrosion, pitting, or cracks.
Superficialcorrosionand/or pittingontheexteriorportion
of the secondary and primary bodies is acceptable.
3. Inspect the bores of both bodies for deep scuffing or
gouges.
4. If primary piston(2) is reused, make certain that vents
“A & B” are open and free of obstructions. (See Figure
2.)
5. Makecertain vent “C”isopen in theprimarybody ofthe
valve.(SeeFigure2.)
6. Inspect the pipe threads in both bodies. Make certain
they are clean and free of thread sealant.
7. Inspectpedalassemblyandmountingplate.Makecertain
the pedal roller turns freely and is lightly lubricated.
Note:Somepedalassemblies,notfurnishedbyBendix,
do not employ a roller. In this case, make certain the
mechanismin use movesacrossthe plungersmoothly,
withoutbindingorsticking.Inspectplunger for excessive
scuffingorwear. Check the plunger bore inthemounting
plate for excessive wear, shown by “egg shaping” (bell
mouthing).Inspectmountingplate for severecorrosion,
paying particular attention to the area around the pivot
pin bores.
8. Ifthebrakevalveusesarubberbootbetweentheplunger
and mounting plate, inspect the boot for deterioration
or cracking.
9. Inspect all air line fittings and plugs for corrosion Clean
all old thread sealant from the pipe threads.
Anyvalveorpedalassemblycomponentthatdoesnotmeet
theinspectioncriterialisted above shouldbediscardedand
replacedbeforeproceeding.
ASSEMBLY (SEE FIGURE 9)
1. Usingsilicone lubricant (650-M),lightly coat allo-rings,
o-ring bores, and grooves, except for the secondary
piston o-rings(19 and 20). Lightly lubricate primary
piston(2)boreintowhichgraduatingspring(8)isinstalled.
With the 328-M lubricant, lightly coat o-rings (19 and
20)ando-ringgrooves on secondarypiston(18).

7
16
24
25 26
27
14
15
13
12
11
10
19
18
20
22
21
23
17
15
14
5
4
2
4
3
8
9
1
7
6
10
11
12
13
MOUNTING PLATE
PEDALASSEMBLY
PLUNGER
FIGURE9 -EXPLODED VIEW

8
FIGURE 10
2. Placeprimarypiston(2)onaflatsurfaceandinstallrubber
spring(9)andmetalgraduating spring(8).
3. Installgraduatingspringretainer(7)on top of graduating
spring(8), making certain that the side with the high
circular protrusion is away from the spring.
4. Manuallydepressandholdspringretainer(7)inpiston(2),
theninstall snap ring(6),making certain itis completely
seatedin itsgroovein piston(2).
5. Installo-rings(15)onbothvalve assemblies(13).
6. Install valve spring(14) in piston(2), then install valve
assembly(13) in the spring.
7. Installo-ring(12)intothe o-ring groove ofpiston(2),then
install valve seat(11) on valve assembly(13). Gently
depress and hold the valve seat in piston(2) while
installingretainingring(10).
8. Installo-rings(3 and 5)onprimary piston(2), theninstall
wear rings(4) in the o-ring grooves next to the o-rings.
Makecertainthat one flangeofthe wear ring(4)isinthe
o-ring groove, while the opposite flange extends away
from the end of piston(2) and toward the center. The
wear ring flange MUST NOT COVER OR OVERLAP
EITHER O-RING. (SeeFigure 10.)
9. Carefullyinsert the assembledprimary piston(2),valve
end first, into the primary valve body until the piston
retainingringgroove in thebodyisvisible. Make certain
o-rings(3 and 5) and wear rings(4) are not damaged in
the process. Do not force the piston. If substantial
resistanceis encountered, checkfor proper installation
of the wear rings.
10.Install piston retaining ring(1) in its groove in the
secondary body, making certain it is fully seated in the
groove.
11. Installplunger(21)initsreturnspring(22).Installthespring
and plunger on secondary piston(18). While manually
depressing and holding the plunger and spring on the
piston, slide plunger and spring retainer(23) into place
so that it secures both the plunger and spring to the
piston. Make certain the retainer flanges are securely
aroundpistonlipand plunger groove.
12. Installo-rings(19 and20) onsecondarypiston(18).
13. Installdiaphragmretainer(27),diaphragm(26),diaphragm
washer(25). and screw(24) in the exhaust port. Torque
screwto15-25in.lbs.NOTE:Some E-14™brake valves
havethreaded exhaust portsinstead of items24-27.
14. Installvalvespring(14)inthesecondarybody,theninstall
valveassembly(13) in thespring.
15. Installo-ring(12)into theo-ring grooveofpiston(2), then
install valve seat(11) on valve assembly(13). Gently
depress and hold the valve seat in the secondary body
whileinstalling retainingring(10).
16. Installtheassembledsecondarypiston(18)intheprimary
body, making certain that o-rings(19 and 20) are not
damaged.
17. Install o-ring(17) on the secondary body. Join the
assembled secondary and primary bodies. Secure the
bodies using the four cap screws(16), and torque to 30
to 60 in. lbs.
18.Installthepedal mounting plate onthebasicbrakevalve,
notingtherelationship markedduringVALVEREMOVAL
step2.Secure the mountingplatetothe valve usingthe
three cap screws and torque to 80 to 120 in. lbs.
19. If using a manifold-type valve, install the sealing rings
and adapter sleeves that connect the valve to the
manifold. Install the manifold on the valve, and secure
with its bolts. Torque to 80 to 120 in. lbs.
20. Installallairlinefittingsandplugs,makingcertainthread
sealantmaterialdoes not enterthevalve.
VALVE INSTALLATION
1. Install the assembledbrakevalve on thevehicle.
2. Reconnectallairlinesto thevalveusingtheidentification
made during VALVE REMOVAL step 1.
3. After installing the brake valve assembly, perform the
“OPERATIONAL&LEAKAGECHECKS”beforeplacing
thevehiclein service.
PRIMARY PISTON
O-RING
WEAR RINGS
O-RING
DEL-1
21
SUP-1
11
➎
➍
➌
➋
BW1666 © 2004 Bendix Commercial Vehicle Systems LLC. All rights reserved. 3/2004 Printed in U.S.A.