Professional Documents
Culture Documents
PRIMARY
SERVICE SECONDARY
SERVICE
EXTERIOR
R-12DC™ VALVE
(MODEL WITH
4 VERTICAL
DELIVERY PORTS)
EXTERIOR
R-12DC™ VALVE
SUPPLY (2) (MODEL WITH 2
DELIVERY HORIZONTAL AND 2
EXTERIOR R-12DC VALVE™ VERTICAL DELIVERY
(MODEL WITH 2 HORIZONTAL PORTS) PORTS)
PRIMARY
SERVICE
CAP SCREW PORT
COVER
SEALING SECONDARY
RING SERVICE PORT
RELAY
PISTON
O-RING
EXHAUST
SEAT
RELAY
SPRING PISTON DOUBLE CHECK
DIAPHRAGM
VALVE
O-RINGS RETAINER
INLET
EXHAUST
RETAINING EXHAUST VALVE SPRING GUIDE
RING PORT
FIGURE 2 - R-12DC™ RELAY VALVE WITH BIASED DOUBLE CHECK SECTIONAL VIEW
1
OPERATION
APPLICATION
R-12DC™
Under normal conditions, the internal biased double check VALVE
valve assures that the primary service signal controls the
valve. Air pressure delivered to the primary service port RELAY PISTON
enters the small cavity above the piston and moves the
piston down. The exhaust seat moves down with the piston
BRAKE VALVE
and seats on the inner or exhaust portion of the inlet/exhaust INLET (DELIVERY
valve, sealing off the exhaust passage. At the same time, EXHAUST LINES ARE
VALVE SHOWN)
the outer or inlet portion of the inlet/exhaust valve moves
off its seat, permitting supply air to flow from the reservoir,
past the open inlet valve and into the service brake
chambers. In the event of a loss of the primary service ANTILOCK
line, (see Figure 4) the double check valve mechanism in MODULATOR
the cover of the R-12DC™ valve will move, shutting off the
EXHAUST
primary service line, and instead allow the secondary service PORT
line to apply the air pressure needed to operate the valve.
RESERVOIR
Note: Secondary service line may leak out of the primary
service at control pressures up to 20 psi when the primary
signal is not present. BRAKE
ANTILOCK SENSOR CHAMBERS
BALANCE TONE RING
The air pressure being delivered by the open inlet valve FIGURE 3 - R-12DC™ SECTIONAL VIEW WITH TYPICAL
also is effective on the bottom area of the relay piston. SYSTEM COMPONENTS
NORMAL: BIASED
DOUBLE-CHECK VALVE
ALLOWS PRIMARY
CONTROL LINE SUPPLIES
RELAY PISTON
CONTROL LINE
FAILURE
BRAKE PEDAL
APPLIED
SECONDARY
BRAKES CONTROL LINE
APPLIED SUPPLIES RELAY
PISTON
FIGURE 4 - R-12DC™ APPLIED POSITION (SHOWING BIASED DOUBLE CHECK OPERATIONAL VIEWS)
2
BRAKE PEDAL BRAKE
POSITION PEDAL
HELD RELEASED
AIR PRESSURE
ABOVE RELAY
VALVE IS
EXHAUSTED
HERE
AIR PRESSURE
FROM BRAKE BRAKE
BRAKE CHAMBERS IS CHAMBERS
CHAMBERS EXHAUSTED RELEASED
MAINTAIN HERE
APPLICATION
When air pressure beneath the piston equals the service air valuable guide in determining the best maintenance interval
pressure above, the piston lifts slightly and the inlet spring for air brake system components. At a minimum, the valve
returns the inlet valve to its seat. The exhaust remains should be inspected every 6 months or 1500 operating hours,
closed as the service line pressure balances the delivery whichever comes first, for proper operation. Should the valve
pressure. As delivered air pressure is changed, the valve not meet the elements of the operational tests noted in this
reacts instantly to the change, holding the brake application document, further investigation and service of the valve may
at that level. be required.
3
Key No. DESCRIPTION
1 VALVE COVER
2 VALVE SPRING CAP SCREW
3 CHECK VALVE GUIDE
4 CHECK VALVE PRIMARY CONTROL
5 O-RING PORT 1/4 NPT
6 DOUBLE CHECK COVER
1
7 O-RING 2 3
8 O-RING 4 5
9 RELAY PISTON
10 VALVE BODY
11 INLET & EXHAUST VALVE 6
12 VALVE RETAINER
13 SPRING
14 O-RING
15 O-RING 7
16 EXHAUST COVER
17 RETAINING RING SECONDARY
18 DIFFERENTIAL SPRING (IF USED) 8 CONTROL PORT CAP
1/4 NPT SCREW
9
18
DIFFERENTIAL SPRING
(CONTROLS CRACK PRESSURE*)
(NOT REQUIRED FOR MOST
MODELS.
SEE BELOW.)
10
HORIZONTAL
DELIVERY
PORTS SUPPLY
PORT
DIFFERENTIAL SPRINGS 11
VERTICAL
DELIVERY
*Crack Pressure is the amount of control PORTS 12
pressure required by the valve to initiate
air delivery. For Crack pressures other 13
than 4 psi, a differential spring is used in
the assembly to produce the required 14
valve response.
(Models designed to have a 4 psi crack 15
pressure do not require a differential spring.)
16
17
Caution: Drain all reservoirs before attempting to remove 1. Remove the four cap screws securing the mounting
the inlet exhaust valve. bracket and cover to the body. Retain the cap screws
for reuse.
DISASSEMBLY
2. Discard the mounting bracket.
Note: Prior to disassembly, mark the location of the 3. Remove and discard sealing ring (7) from the cover (1).
mounting bracket to the cover and the cover to the body.
a. Remove the 2 torx screws securing the double check
CAUTION: The valve body may be lightly clamped in a bench cover (6) to the cover (1).
vise during disassembly, however, over-clamping will result b. Remove the double check cover (6) from cover (1)
in damage to the valve and result in leakage and/or and remove and discard spring (2), guide (3), double
malfunction. If a vise is to be used, position the valve so check diaphragm (4), and o-ring (5).
that the jaws bear on the supply ports on opposing sides of
4. Remove and discard sealing ring (7) from the cover (1),
the valve’s body.
and mounting bracket.
4
5. Remove piston (9) from the body (10) and retain for reuse. 4. Install retainer (12) on inlet exhaust valve (11) and insert
6. Remove and discard o-ring (8) from piston (9). both in the body (10).
7. Depress and hold the exhaust cover assembly (16) and 5. Install spring (13) in the body (10).
remove and discard retaining ring (17) from the valve 6. Install exhaust cover assembly (16) in the body (10).
body (10). Depress and hold the exhaust cover assembly in the
8. Slowly release the holding force on the exhaust cover body.
assembly (16) to relax the spring. 7. Install retaining ring (17) in the body (10). Make certain
9. Remove and discard the following parts: the retaining ring is completely seated in the groove in
the body.
a. Exhaust cover assembly (16)
8. Install piston (9) in body (10).
b. O-rings (14 & 15)
9. Install o-ring (5) on double check cover (6), install spring
c. Spring (13)
(2), guide (3) and double check diaphragm (4) in cover
d. Inlet exhaust valve (11) (1). Install cover (1) and torque torx head screws to
e. Retainer (12) 80-100 in. lbs.
10. Referring to the marks made during disassembly, install
CLEANING AND INSPECTION
cover (1).
1. Wash all metal parts in mineral spirits and dry them
11. Install the mounting bracket (not shown) on the cover
thoroughly.
(1).
(Note: When servicing the R-12DC™ valve, all springs
12. Install the four cap screws in the cover (1) and torque to
and all rubber parts should be replaced.)
80-100 inch pounds.
2. Inspect all metal parts for deterioration and wear, as
13. Test the valve as outlined in the Operational and Leakage
evidenced by scratches, scoring and corrosion.
Test section before returning the valve to service.
3. Inspect the exhaust valve seat on the relay piston for
nicks and scratches which could cause excessive INSTALLATION
leakage. 1. Clean air lines.
4. Inspect the inlet valve seat in the body for scratches 2. Inspect all lines and/or hoses for damage and replace
and nicks, which could cause excessive leakage. as necessary.
5. Inspect the check valve seat in the R-12DC™ valve cover 3. Install valve and tighten mounting bolts.
and make sure all internal air passages in this area are
4. Connect air lines to valve (plug any unused ports).
open and clean and free of nicks and scratches.
5. Test valve as outlined in Operational and Leakage Tests.
6. Replace all parts not considered serviceable during these
inspections and all springs and rubber parts. Use only OPERATIONAL AND LEAKAGE TEST
genuine Bendix replacement parts, available from any
1. Chock the wheels, fully charge air brake system and
authorized Bendix parts outlet.
adjust the brakes.
ASSEMBLY 2. Make several brake applications and check for prompt
application and release at each wheel.
Note: All torque specified in this manual are assembly torque
and can be expected to fall off slightly after assembly. Do 3. Check for inlet valve and o-ring leakage. Make this check
not re-torque after initial assembly torque fall. For assembly, with the service brakes released. Coat the exhaust port
hand wrenches are recommended. and the area around the retaining ring with a soap solution;
a 1” bubble in 3 seconds leakage is permitted.
Prior to assembly, lubricate all o-rings, o-ring bores and any
4. Check for exhaust valve leakage. Make this check with
sliding surface with a silicone lubricant equivalent to Dow
the service brakes fully applied. Coat the outside of
Corning #10.
the valve where the cover joins the body to check for
Wash all remaining parts in mineral spirits and dry thoroughly. seal ring leakage; no leakage is permitted.
Using the lubricant provided in this kit, lightly lubricate all
If the valves do not function as described above, or if
o-rings, o-ring grooves, body bores any sliding surfaces.
leakage is excessive, it is recommended that the valves
1. Install o-rings (14 & 15) in the exhaust cover assembly be replaced with new or remanufactured units or repaired
(16). with genuine Bendix parts, available at any authorized Bendix
2. Install o-ring (8) on piston (9). parts outlet.
3. Install sealing ring (7) on cover (1).
5
6
DIAGNOSTIC ABS/TRACTION
CONNECTION WARNING PARKING SR-1™ SPRING
INDICATORS WHEEL SPEED
TONE RING VALVE BRAKE VALVE SENSOR SPRING
TONE RING BRAKES
WHEEL SPEED
SENSOR
ABS
SERVICE ECU
MODULATOR BRAKE
VALVE
MODULATOR
ANTI-COMPOUND
LINE
QUICK
RELEASE ENGINE ECU
VALVE
ANTI-COMPOUNDING
SPRING BRAKE
RELAY VALVE
MODULATOR R-12DC™
RELAY
MODULATOR BRAKE DC-4™ VALVE
CHAMBER DOUBLE
CHECK
WHEEL SPEED VALVE
SENSOR
AIR DRYER
FRONT AXLE
TONE RING SERVICE
RESERVOIR GAUGE
SUPPLY SPRING
RESERVOIR BRAKES
SINGLE
CHECK
VALVE
REAR AXLE
SERVICE
LOW PRESSURE RESERVOIR
COMPRESSOR WARNING
INDICATOR
2. Stop the engine and remove ignition key when 8. Use only genuine Bendix ® replacement parts,
working under or around the vehicle. When components and kits. Replacement hardware,
working in the engine compartment, the engine tubing, hose, fittings, etc. must be of equivalent
should be shut off and the ignition key should be size, type and strength as original equipment and
removed. Where circumstances require that the be designed specifically for such applications and
engine be in operation, EXTREME CAUTION should systems.
be used to prevent personal injury resulting from 9. Components with stripped threads or damaged
contact with moving, rotating, leaking, heated or parts should be replaced rather than repaired. Do
electrically charged components. not attempt repairs requiring machining or welding
3. Do not attempt to install, remove, disassemble or unless specifically stated and approved by the
assemble a component until you have read and vehicle and component manufacturer.
thoroughly understand the recommended 10. Prior to returning the vehicle to service, make
procedures. Use only the proper tools and observe certain all components and systems are restored
all precautions pertaining to use of those tools. to their proper operating condition.
4. If the work is being performed on the vehicle’s air 11. For vehicles with Antilock Traction Control (ATC),
brake system, or any auxiliary pressurized air the ATC function must be disabled (ATC indicator
systems, make certain to drain the air pressure lamp should be ON) prior to performing any vehicle
from all reservoirs before beginning ANY work on maintenance where one or more wheels on a
the vehicle. If the vehicle is equipped with an drive axle are lifted off the ground and moving.
AD-IS ® air dryer system or a dryer reservoir
module, be sure to drain the purge reservoir.
7
8 BW1933 © 2007 Bendix Commercial Vehicle Systems LLC. All rights reserved. 3/2007 Printed in U.S.A.