BENDIX BW1438 User's Manual

BENDIX BW1438 User's Manual
SD-03-3653
Bendix® TP-4™ Tractor Protection Valve (Formerly VM-1)
PRIMARY CIRCUIT
DELIVERY PORT
(PCD)
TRAILER EMERG. STOP
LIGHT SWITCH (TE-SLS)
PORT
TRAILER EMERG.
SUPPLY (TES) PORT
SECONDARY
CIRCUIT
DELIVERY PORT
(SCD)
MOUNTING
SURFACE
VENT
SERVICE STOP
LIGHT SWITCH
(SLS) PORT
TRAILER SERVICE
SUPPLY PORT (TSS)
FIGURE 1 EXTERIOR VIEW
2
10
8
3
VENT
12
6
7
PIPE PLUG
5
9
4
11
13
1
16
15
14
FIGURE 2 SECTIONAL
DESCRIPTION
The Bendix® TP-4™ tractor protection valve is used in the
dual air brake system and houses three valves that serve
the trailer and tractor braking system. The valves are:
1. The trailer service line shut off portion of tractor
protection system which operates in conjunction
with the dash-mounted PP-3™ trailer supply valve to
manually or automatically close and retain sufficient air
pressure in the towing vehicle to stop it with its service
brakes.
2. A double check valve which permits either primary or
secondary circuit air pressure from the dual brake valve
to actuate trailer brakes.
3. A double check valve which permits use of a trailer
control valve to control only the trailer brakes.
In addition to the ports necessary for the function of the
above described valves, the manifold also provides ports
for the installation of the service stop light switch, front
axle limiting control valve, and the TE-1™ trailer emergency
stop light switch.
Four 23/64" holes are provided for mounting.
1
Each double check valve has two separate inlets and one
common outlet, and the passage of air can be traced by
referring to Schematic Figure 3.
OPERATION
TRACTOR PROTECTION VALVE PORTION
Air from the delivery line of the PP-3™ trailer supply valve
located within the cab enters the manifold at the tractor
protection control (delivery) port and passes through the
manifold, acts upon the plunger and moves the inlet valve
off its seat, opening the service line passage through the
manifold.
If the PP-3™ trailer supply valve is manually or automatically
actuated, the trailer emergency line air pressure will exhaust
out the PP-3™ trailer supply valve exhaust port, causing
an application of the trailer brakes. The piston spring will
move the piston allowing the inlet valve spring to close the
inlet valve, closing the service line passage through the
manifold, and protecting tractor air pressure.
DOUBLE CHECK VALVE PORTIONS
There are two double check valves in the TP-4™ tractor
protection valve, and they work in combination with each
other to perform the following functions:
1. To permit the trailer hand control valve to be used for
applying trailer service brakes only.
2. To permit either the primary or secondary circuit from
the dual brake valve to apply trailer brakes if air is lost
in either one of the circuits.
TO FRONT
BRAKE LIMITING
CONTROL VALVE
FROM
TRAILER
DOUBLE CHECK CONTROL
VALVE “A”
VALVE
Double check valve A inlets are connected to the trailer
hand control valve and the secondary delivery circuit of
the dual brake valve. If the hand control valve is applied,
the shuttle of the double check valve will move and seal
off the secondary delivery passage from the brake valve.
Air from the hand control valve will pass out the outlet port
of double check valve A. See Figure 4.
If a foot brake valve application is made, the shuttle of
double check valve A seals off the trailer hand control valve
air passage and application air will pass out the outlet port
of double check valve A.
Double check valve B inlets are connected to the primary
delivery circuit of the dual brake valve and the outlet of
double check valve A. The purpose of double check valve
B is to permit actuation of trailer brakes should a loss of
air occur in either the primary or secondary braking circuits
of the tractor.
When a foot brake application is made, air from the primary
delivery circuit enters one inlet of the double check valve
and air from the secondary circuit passes through double
check valve A and enters the other inlet valve of double
check valve B. Air passes out the outlet port and through
the tractor protection valve to the trailer actuating the trailer
brakes. See Figure 5.
FROM PP-3™ TRAILER
SUPPLY VALVE TO TRAILER
EMERGENCY LINE
DOUBLE CHECK
VALVE “B”
REAR FACE
PRIMARY
CIRCUIT
(DELIVERY)
FROM DUAL
BRAKE VALVE
A
B
C
VENT
TRAILER
SERVICE LINE
SHUT-OFF
VALVE
SECONDARY
CIRCUIT
(DELIVERY)
FRONT FACE
STOP LIGHT
SWITCH
TE-1™ TRAILER EMERGENCY
STOP LIGHT SWITCH
TO TRAILER SERVICE LINE
FIGURE 3 TP-4™ TRACTOR PROTECTION VALVE
2
TRAILER CONTROL VALVE
TRAILER SUPPLY VALVE
TWO WAY VALVE
PRIMARY
RESERVOIR
TO LIMITING AND
Q.R. VALVE
SECONDARY
RESERVOIR
DUAL
BRAKE
VALVE
A
B
TO TRAILER
EMERGENCY
C
VENT
TRAILER
EMERGENCY
STOP-LIGHT SWITCH
STOP LIGHT SWITCH
TO TRAILER SERVICE
FIGURE 4 TP-4™ TRACTOR PROTECTION VALVE (TRAILER APPLICATION)
PREVENTIVE MAINTENANCE
Important: Review the Bendix Warranty Policy before
performing any intrusive maintenance procedures. A
warranty may be voided if intrusive maintenance is
performed during the warranty period.
No two vehicles operate under identical conditions; as
a result, maintenance intervals may vary. Experience is
a valuable guide in determining the best maintenance
interval for air brake system components. At a minimum,
the TP-4™ valve should be inspected every 6 months or
1500 operating hours, whichever comes first, for proper
operation. Should the TP-4™ valve not meet the elements
of the operational tests noted in this document, further
investigation and service of the valve may be required.
SERVICE CHECKS
OPERATING AND LEAKAGE CHECKS
1. With ignition switch on, place tractor protection control
valve in emergency position. If vehicle is equipped with
emergency stop light switch, trailer stop lights should
function.
2. Charge air brake system to governor cut-out and block
wheels.
3. Apply trailer hand control valve and check at open
tractor service hose coupling for leakage. Excessive
leakage would indicate faulty tractor protection valve
inlet valve. (Item 6, Figure 2)
4. Release trailer hand control valve and place tractor
protection control valve in normal position, with trailer
supply hose connected to trailer supply hose coupling.
5. Connect tractor service hose coupling to a test
gauge.
6. Apply trailer hand control valve and note that service
air pressure is present at the service hose coupling. If
service air pressure is not present, this would indicate
either a faulty tractor protection valve or a faulty shuttle
in one of the double check valves. Check foot brake
valve exhaust for leakage. If leakage is detected,
double check valve requires servicing. Release trailer
hand control valve.
7. With ignition switch on, apply and hold a foot brake
valve application and note that stop lights function.
Check foot brake valve exhaust for leakage. If leakage
is detected, double check valve requires servicing.
8. Disconnect line from primary circuit delivery (PCD) port.
Plug end of line. (NOTE: Fitting and crimped copper
tubing can be assembled and used as a plug. Care
should be used so that there is no danger, if plug be
loosened, that it be projected by air when application
of foot brake valve is made.)
9. Make a foot brake valve application and check primary
circuit delivery (PCD) port of manifold for leakage.
Leakage at port indicates double check valve requires
servicing. Remove plug from line and reconnect to
manifold.
3
TRAILER CONTROL VALVE
TRAILER SUPPLY VALVE
TWO WAY VALVE
PRIMARY
RESERVOIR
TO LIMITING AND
Q.R. VALVE
TO TRAILER
EMERGENCY
SECONDARY
RESERVOIR
DUAL
BRAKE
VALVE
A
B
C
VENT
TRAILER
EMERGENCY
STOP LIGHT SWITCH
STOP LIGHT SWITCH
TO TRAILER SERVICE
FIGURE 5 TP-4™ TRACTOR PROTECTION VALVE (SERVICE APPLICATION)
10. Disconnect line from secondary circuit delivery (SCD)
port and plug end of line. Make a foot brake valve
application and check secondary circuit delivery (SCD)
port of valve for leakage. Leakage at port indicates
double check valve requires servicing. Remove plug
from line and reconnect to valve.
11. Make a foot valve application and test for gasket
leakage. Tighten bolts if necessary. (See #4 “Assembly”
for Proper Torque Sequence.)
4. Remove large retaining ring (13) from lower body.
Remove valve retainer (14), spring (7) and inlet valve
(6). Remove o-ring (5) from valve retainer.
(NOTE: Older revision valves may have an o-ring (1),
sealing disc (16) and small retaining ring (15) as
shown in Figure 3. These need not be disturbed
unless leakage was noted, in which case the
retaining ring must be removed and the o-ring
replaced.)
If the TP-4™ tractor protection valve does not function as
described above or leakage is excessive, it is recommended
that it be replaced with a new or remanufactured unit, or
repaired with genuine Bendix parts available at authorized
Bendix parts outlets, in which case the following should
prove helpful.
CLEANING AND INSPECTION
DISASSEMBLY
3. Inspect the bores of the valve housing for deep scuffing
or gouges.
1. Remove six (6) cap screws (11) Figure 2 and
lockwashers. This will permit separation of the body,
intermediate body and lower body and gaskets. (9) &
(10)
2. Remove piston (12) and piston spring (8) from
intermediate body. Remove o-rings (2) and (3) from
piston (12).
3. Remove both double check valve shuttles (4) and
guides from body.
4
1. Clean all metal parts in mineral spirits and dry them
completely.
2. Inspect all parts for excessive wear or deterioration.
Inspect valve seats for nicks or burrs. Check the valve
spring for cracks or corrosion.
Replace all parts that were discarded and any parts not
found to be serviceable during inspection, using only
genuine Bendix replacement parts.
ASSEMBLY
Before assembling the TP-4™ valve, lubricate all o-rings,
o-ring grooves, body bores and rubbing surfaces with
Bendix silicone lubricant (Pc. No. 291126) or equivalent.
NOTE: When using pipe thread sealant during assembly
and installation, take particular care to prevent the
sealant from entering the valve itself. Apply the
sealant beginning with the second thread back
from the end.
3.
1. Install inlet valve (6). Install o-ring (5) on valve retainer
(14). Install spring (7) and valve retainer. Install retainer
ring (13) making certain it is engaged in groove.
2. Install double check valve guides in intermediate body
and install shuttles (4) in guides.
4.
3. Install spring (8) in body. Install o-rings (2) and (3)
on piston (12). Insert stem of piston inside of spring,
making sure vent is open.
4. Install new gaskets (9) and (10) on both sides
of intermediate body (Note: locating pins match
corresponding holes in gasket). Install lower and upper
bodies with assembly in the following manner.
5.
A. Torque center two (2) cap screws to 80" lbs.
6.
B. Torque upper right and lower left cap screws to
80" lbs.
7.
C. Torque lower right and upper left cap screws to
80" lbs.
D. IMPORTANT - Repeat steps A, B, and C.
8.
TESTING REBUILT TP-4™ VALVE
Perform Operating and Leakage Tests, as outlined in
“Service Checks” section.
WARNING! PLEASE READ AND FOLLOW
THESE INSTRUCTIONS TO AVOID PERSONAL
INJURY OR DEATH:
9.
engine be in operation, EXTREME CAUTION should
be used to prevent personal injury resulting from
contact with moving, rotating, leaking, heated or
electrically charged components.
Do not attempt to install, remove, disassemble
or assemble a component until you have read
and thoroughly understand the recommended
procedures. Use only the proper tools and observe
all precautions pertaining to use of those tools.
If the work is being performed on the vehicle’s
air brake system, or any auxiliary pressurized air
systems, make certain to drain the air 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.
Following the vehicle manufacturer’s recommended
procedures, deactivate the electrical system in a
manner that safely removes all electrical power
from the vehicle.
Never exceed manufacturer’s recommended
pressures.
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.
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.
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.
Prior to returning the vehicle to service, make
certain all components and systems are restored
to their proper operating condition.
When working on or around a vehicle, the following
general precautions should be observed at all times.
10.
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
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.
5
6
BW1438 © 2007 Bendix Commercial Vehicle Systems LLC. All rights reserved. 6/2007 Printed in U.S.A.
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