Bendix Commercial Vehicle Systems E-15 BRAKE VALVE 3/04 - Manual (Page 8)

8
ASSEMBLY
1. Using the lubricant provided (Bendix Pc. No. 291126),
lightly coat all o-rings, o-ring bores and grooves. Lightly
lubricate the primary piston (2) bore into which the gradu-
ating spring (8) is installed.
2. Place the primary piston (2) on a flat surface and install
the rubber spring (9) and metal graduating spring (8).
Note: The rubber spring (9) is used in the E-12 ™ brake
valve only. If a rubber spring was not removed in disas-
sembly step 11, discard this component - do not
install it.
3. Install the proper graduating spring retainer (7) on top of
the graduating spring (8) making certain that the side
with the high circular protrusion is away from the spring.
4. Manually depress and hold the spring retainer (7) in the
piston (2), then install the retaining ring (6) making cer-
tain it is completely seated in its groove in the piston
(2).
5. Install the o-rings (15) on both valve assemblies (13).
6. Install the valve spring (14) in the piston (2), then install
the valve assembly (13) in the spring.
7. Install the o-ring (12) into the o-ring groove of piston (2),
then install the valve seat (11) on the valve assembly
(13). Gently depress and hold the valve seat in the pis-
ton (2) while installing the special beveled retaining ring
(10).
Important: The beveled retaining ring (10) must be in-
stalled with its flat side against the valve seat (11) and
its beveled side visible. Make certain the beveled retain-
ing ring (10) is completely seated in its groove in the
piston (2).
8. Install the o-rings (3 & 5) on the primary piston (2), then
install the wear rings (4) in the o-ring grooves next to the
o-rings. Make certain that one flange of the angular wear
ring (4) is in the o-ring groove, while the opposite flange
extends away from the end of the piston (2) and toward
the center. The wear ring flange must not cover or over-
lap either o-ring.
9. Carefully insert the assembled primary piston (2), valve
end first, into the upper valve body until the piston
retaining ring groove in the body is visible. Make certain
the o-rings (3 & 5) and wear rings (4) are not damaged in
the process. Do not force the piston. If substantial
resistance is encountered, check for proper installation
of the wear rings.
10. Install the piston retaining ring (1) in its groove in the
upper body, making certain it is fully seated in the groove.
11. Install the plunger (21) in its return spring (22). Install
the spring and plunger on the secondary piston (18).
While manually depressing and holding the plunger and
spring on the piston, slide the 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 around piston lip and plunger groove.
12. Install the o-rings (19 & 20) on the secondary piston
(18).
13. Install the exhaust diaphragm (25) on the lower body
and secure it using diaphragm retainer (24).
Note: Some E-12 ™ & E-15 ™ brake valves have threaded
exhaust ports in lieu items 24 & 25.
14. Install the valve spring (14) in the lower body, then install
the valve assembly (13) in the spring.
15. Install the o-ring (12) into the o-ring groove of piston (2),
then install the valve seat (11) on the valve assembly
(13). Gently depress and hold the valve seat in the lower
body while installing the special beveled retaining ring
(10).
Important: The beveled retaining ring (10) must be in-
stalled with its flat side against the valve seat (11) and
its beveled side visible.
Make certain the beveled retaining ring (10) is completely
seated in its groove in the lower body.
16. Install the assembled secondary piston (18) in the up-
per body making certain that the o-rings (19 & 20) are
not damaged in the process.
17. Install the o-ring (17) on the upper body. Join the as-
sembled upper and lower body halves noting the
relationship marked in Disassembly step 2. Secure the
body halves together using the four 1/4" cap screws (16)
and torque to 30 to 60 pound inches.
18. If the brake valve is firewall mounted, install the pedal
mounting plate on the basic brake valve noting the rela-
tionship marked during Disassembly step 2. Secure the
mounting plate to the valve using the three 5/16" cap
screws and torque to 80 to 120 pound inches.
19. Install all air line fittings and plugs making certain
thread sealant material does not enter the valve.
VALVE INSTALLATION
1. Install the assembled brake valve on the vehicle.
2. Reconnect all air lines to the valve using the identifica-
tion made during Valve Removal step 1.
3. After installing the brake valve assembly, perform the
Operation & Leakage Checks before placing the vehicle
in service.
BW1622 © 2004 Bendix Commercial Vehicle Systems LLC. All rights reserved. 3/2004 Printed in U.S.A.