BENDIX PP-1-2-5-8-RD-3 PUSH-PULL VALVES User manual

1
®
PP-1™
VALVE PP-5™ VALVE RD-3™
VALVE
SD-03-3611
Bendix®PP-1™, PP-2™, PP-5™, PP-8™, & RD-3™Push-Pull Type
Control Valves
FIGURE 1 - PUSH-PULL TYPE CONTROL VALVES
PP-2™
VALVE
DESCRIPTION
The PP valves are push-pull manually operable on-off air
control valves with an exhaust function. Most are pressure
sensitive, so that they will automatically move from the
applied to the exhaust position as supply pressure is
reduced to a certain minimum, depending on the spring in-
stalled. The exception to this is the PP-8™valve and some
PP-1™valves which have no spring. The PP-8™valve also
hasalargerdiametershaftforbuttonmountingsothatwhen
installed on the same panel with other PP valves the
buttons cannot be inadvertently mixed. The PP-8™valve is
normallyusedtooperatetractorspringbrakesindependently
fromthe trailer.
The PP-5™valve is unique in having an auxiliary piston in
thelowercoverwhich,upon receiving a pneumaticsignalof
18psiormore,willcausethevalvetomovefromtheapplied
to the exhaust position from a 100 psi application.
TheRD-3™valvediffersslightlyinthat it normally remains in
the exhaust position and requires a constant manual force
to hold it in the applied position.
ThePP-2™valvehasanauxiliaryportwhichmaybeplumbed
into a service brake line to release the spring brakes if a
service application is made, preventing compounding of
forceson thefoundation brakes.
PREVENTIVE MAINTENANCE
Important: Reviewthe Bendix WarrantyPolicy before per-
forming any intrusive maintenance procedures.Awarranty
maybevoided if intrusivemaintenanceis performed during
thewarrantyperiod.
No two vehicles operate under identical conditions, as a
result,maintenance intervalsmayvary.Experienceisavalu-
able guide in determining the best maintenance interval for
airbrakesystemcomponents.Ata minimum,thePPvalves
shouldbeinspectedevery6monthsor1500operatinghours,
whichever comes first, for proper operation. Should the PP
valvesnotmeet the elementsof the operationaltestsnoted
in this document, further investigation and service of the
valvemayberequired.
PP-8™
VALVE

2
PP-1 20,30,40
or 60 psi
PP-2 40 psi
PP-5 40 psi 18 psi
RD-3 Must be held
manually
PP-8 Will remain in
either position
4. Removetheinlet-exhaust valve (4),andpiston (5).
5. Removeo-rings (6 & 7) from piston.
OPERATING AND LEAKAGE TESTS
PP-1™, PP-8™, RD-3™VALVE
1. An accurate test gauge should be tee’d into the supply
lineanda means ofcontrollingthe supply pressurepro-
vided. Apply a 120 psi air source to the supply port. A
small volume reservoir (e.g. 90 cu. in.) with a gauge
should be connected to the delivery port.
2. With 120 psi supply pressure, and the button pulled out
(exhaust position), leakage at the exhaust port should
not exceed a 1" bubble in 5 seconds; at the plunger
stema1"bubblein5 seconds. There should benoleak-
agebetweenupper and lower body.
3. Push the button in (applied position). Leakage at the ex-
haustport should not exceed a 1" bubble in 3seconds;at
the plunger a 1" bubble in 3 seconds. (The RD-3™valve
will have to be manually held in this position.)
4. Reduce the supply pressure. At a pressure from 60 to
20psidependingonthespringinstalledthebuttonshould
pop out automatically, exhausting the delivery volume.
(This does not apply to the RD-3™, PP-8™or some
PP-1™valve’s).
PP-5™VALVE
1. Proceedas for PP-1™valvethrough Step3.
2. Connect a modulated source of air pressure to the pilot
air inlet. With the button pushed in (applied position)
with125psi supply pressureanda gradually increasing
pressure applied at the pilot air port the valve should
move to the release position with a pilot pressure of not
more than 18 psi. Leakage in this mode should not
exceed a 1" bubble in 3 seconds at the exhaust port
and a 1" bubble in 5 seconds at the plunger stem.
PP-2™VALVE
1. Proceedas for PP-1™valvethrough Step1.
2. With the button pulled out (exhaust position), leakage
atthebrake valve portorat the plungerstemshould not
exceed a 1" bubble in 5 seconds.
3. Push the button in. Supply pressure should be present
in the delivery volume. Leakage at the exhaust port or
aroundtheplunger stem shouldnot exceed a1" bubble
in 5 seconds.
4. Pull the button out and apply supply pressure at the
brake valve port. Supply pressure should be present in
the delivery volume and leakage at the exhaust port
should not exceed a 1" bubble in 5 seconds.
Note: Ifanyoftheabovepush-pullvalvesdo not function as
described or if leakage is excessive, it is recommended
they be returned to our nearest authorized distributor for a
factoryrebuiltornew valve.
REMOVAL
Block and/or hold the vehicle by a means other than air
brakesanddrain all reservoirs.
1. Drivethebuttonroll-pinoutwithapunchandremovethe
button.
2. Markeachair supply lineandits port foreasyreinstalla-
tion,then disconnectthem. Remove the valve from the
panelby removing the panel mountingnut.
INSTALLING
1. Install valve in panel, securing with the panel mounting
nut.
2. Reconnecttheairlinesusingmarksmadeduringremoval
as a guide.
3. Installtheoperatingbutton.Secure the operating button
by installing the button roll pin.
DISASSEMBLY: PP-1™, PP-8™AND RD-3™
VALVES
1. Remove the two cap screws (3) which retain the lower
coverandremovecover. Remove the sealingring(4).
2. Insertasmall punch through therollpin hole inthestem
and remove the lock nut (5).
3. Removeinlet-exhaustvalve(6)andplunger(7)andspring
(8)(if any).
4. Removeo-ring(9)fromplunger.
DISASSEMBLY: PP-5™VALVE
1. Performsameoperations as forPP-1™valve.
2. Remove inlet seal (10) in Figure 4 from lower cover.
Removethe ringdiaphragm (4)from theinlet seat.
3. Removepiston(11)Figure 4 ando-ring (2).
DISASSEMBLY: PP-2™VALVE
1. Insertasmallpunchthroughtherollpinholeintheplunger
and remove the lock nut (1) from the plunger.
2. Withdraw the plunger and remove the spring (9) and
o-ring(8).
3. Remove the two machine screws (2) and remove the
lowercover(3).
AUTOMATIC MOMENTARY PILOT TRIP NON-
EXHAUST APPLY FEATURE AUTOMATIC

3
PP-1™
VALVE
4
3
5
6
8
2
3
6
7
1
5
4
BRAKE
VALVE
PORT
8
BUTTON ROLL
PIN
BUTTON ROLL
PIN
PANEL
MOUNTING
NUT
PANEL
MOUNTING
NUT
7
PANEL
MOUNTING
NUT
7
4
3
5
6
9
6
3
4
5
78
9
9
10
FIGURE 5FIGURE 4
FIGURE 2 FIGURE 3 PP-2™
VALVE
PP-5™
VALVE PP-8™
VALVE
9
11 2

4
BUTTON ROLL
PIN
PANEL
MOUNTING
NUT
7
4
5
6
3
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 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. 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,make certain to drain theair pressure from
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, 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.
RD-3™
VALVE
FIGURE 6
8
9
BW1578 © 2006 Bendix Commercial Vehicle Systems LLC. All rights reserved. 7/2006 Printed in U.S.A.
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.
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
maintenance where one or more wheels on a drive
axle are lifted off the ground and moving.on a drive
axle are lifted off the ground and moving.