Usage:
1. Release the air pressure in the air tank by loosening the bleed valves on the air tank.
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Do not disconnect any air lines until all the air pressure in the air system is released. Personal injury can be the result if air lines are disconnected before the air pressure is zero. |
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2. Remove spring (2). Remove the cotter pin that holds pin (3) in position. Push accelerator lever (1) down far enough to remove pin (3).
3. Put identification on five air lines (5) for installation purposes. Disconnect the five air lines from the brake control valve.
4. Disconnect two electric lines (4) and two electric lines (6).
5. Remove three bolts (8), bracket (9), brake control valve (7) and spacer and plunger (10).
NOTE: The following steps are for installation of the brake control valve.
6. Put spacer and plunger (10) in position on the machine. Install brake control valve (7) and bracket (9). Install the three bolts (8) that hold the parts in place.
7. Put the brake pedal lever in position in bracket (9). Pull lever (1) down far enough to install pin (3) in bracket (9). Release lever (1). Install spring (2).
8. Connect five air lines (5) to the brake control valve (7).
9. Connect two electric wires (6) and (4) to the brake control valve.
10. Make an adjustment to the brake pedal and to the brake control valve. See the topic, Pedal Adjustments For Service Brakes and Control Valve Adjustment in 12G, 14G, 16G Air System And Brakes Service Manual, Form No. SENR3605.
Disassemble Brake Control Valve
Start By:
a. remove brake control valve
1. Remove switch (1) from the brake control valve.
2. Remove four screws and cover (2).
3. Remove inlet and exhaust valve (3).
4. Put spring (6) under compression so retainer (7) is away from snap ring (8). Use tool (A) to remove snap ring (8). Remove retainer (7), spring (6) and retainer (5) from valve (4).
5. Check the condition of the O-ring seal in the bore of retainer (7) and on the outside diameter. If the O-ring seals are damaged, a replacement of inlet and exhaust valve will be necessary.
6. Remove the four bolts and make a separation of cover (10) and valve body (9).
7. Remove O-ring seal (11) from cover (10). Check O-ring seal (11) for damage and make a replacement if necessary.
8. Use a screwdriver to hold the stem in position. Remove locknut (12).
9. Remove spring guide (13), spring (14), relay piston (16) and spring (15) from the valve body.
10. Remove stem (19) and two O-ring seals (17) and (18) from relay piston (16). Check O-ring seals (17) and (18) for damage and make a replacement if necessary.
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Retainer (21) holds a spring under compression. To prevent personal injury, use the following procedure to remove the retainer. |
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11. Push down and hold primary piston (20). Use a screwdriver to pull retainer (21) away from the edge of the valve body. Slowly release the compression of the spring under primary piston (20).
12. Remove retainer (21), primary piston (20) and spring (22) from the valve body.
13. Remove spring nut (26) from primary piston (22). Remove spring seat (25) rubber spring (24) and O-ring seal (23) from the primary piston.
14. Check the condition of O-ring seal (23) and make a replacement if necessary.
15. Use tool (B) to remove snap ring (27). Remove inlet and exhaust valve assembly (28) from the valve body.
16. Push retainer (33) away from snap ring (35). Use tool (A) to remove snap ring (35). Remove retainer (33), spring (31) and retainer (30) from valve (29).
17. Remove O-ring seals (32) and (34) from retainer (33). Check O-ring seals (32), (34) and the rubber seal on valve (29) for damage. If any of these three components are damaged, it will be necessary to make a replacement of the inlet and exhaust valve assembly.
18. Remove vent filter (36) and make a replacement if necessary.
Assemble Brake Control Valve
1. Put vent filter (36) in position in the valve body.
2. Put Loctite LB 8632 Silicone Lubricant (North America), Loctite LB 8104 Silicone Lubricant (EAME), Loctite LB 8801 Silicone Lubricant (Asia Pacific Division), or Loctite LB Superlube (South America) on O-ring seals (32), (34) and on the rubber end of valve (29). Install retainer (30) on the valve so the counterbore in the retainer is away from spring (31).
3. Install O-ring seals (32) and (34) on retainer (33). Install spring (31) and retainer (33) on valve (29). Compress spring (31) and use tool (A) to install snap ring (35) on the end of valve (29).
4. Put Loctite LB 8632 Silicone Lubricant (North America), Loctite LB 8104 Silicone Lubricant (EAME), Loctite LB 8801 Silicone Lubricant (Asia Pacific Division), or Loctite LB Superlube (South America) on counterbore (37) in the valve body. Put inlet and exhaust valve assembly (28) in position in the valve body as shown.
5. Use tool (B) to install snap ring (27). Snap ring (27) holds inlet and exhaust valve assembly (28) in position in the valve body.
6. Put Loctite LB 8632 Silicone Lubricant (North America), Loctite LB 8104 Silicone Lubricant (EAME), Loctite LB 8801 Silicone Lubricant (Asia Pacific Division), or Loctite LB Superlube (South America) on O-ring seal (23). Do not put any lubricant on rubber spring (24). Install O-ring seal (23) on primary piston (22). Install rubber spring (24) on the primary piston. The flat side of the rubber spring must be toward the primary piston.
7. Install spring seat (25) against rubber spring (14). The flat side of the spring seat must be away from the rubber spring. Install spring nut (26) as shown. Tighten spring nut (26) until the top surface of spring seat (25) is even with the top surface of primary piston (22).
8. Put spring (22) and primary piston (20) in position on the valve body as shown.
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Tabs (38) on retainer (21) hold a spring under compression. To prevent personal injury, make sure tabs (38) are not bent more than 90° away from the bottom inside surface of the retainer as seen in illustration B58200P2. |
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9. Use retainer (21) to push primary piston (22) and spring (22) down into the valve body. Make sure the holes in the retainer are in alignment with the holes in the valve body. Make sure all three tabs (38) are engaged around the valve body.
10. Put Loctite LB 8632 Silicone Lubricant (North America), Loctite LB 8104 Silicone Lubricant (EAME), Loctite LB 8801 Silicone Lubricant (Asia Pacific Division), or Loctite LB Superlube (South America) on O-ring seals (17) and (18). Install the two O-ring seals on relay piston (16).
11. Put stem (19) in position in the relay piston as shown. If the brake control valve is being disassembled and assembled for reconditioning, the rubber washer in the repair kit must be installed on stem (19) at location (X).
12. Put spring (19) and relay piston (16) in position on the valve body.
13. Put stem spring (14) and spring guide (13) in position on stem (19). Use a screwdriver to hold the stem in place. Install locknut (12). Tighten the locknut to a torque of 3 ± 1 N·m (25 ± 5 lb.in.).
14. Put Loctite LB 8632 Silicone Lubricant (North America), Loctite LB 8104 Silicone Lubricant (EAME), Loctite LB 8801 Silicone Lubricant (Asia Pacific Division), or Loctite LB Superlube (South America) on O-ring seal (11). Put the O-ring seal in position in cover (10). Install cover (10) on valve body (9). Tighten the four bolts that hold cover (10) in place to a torque of 5 ± 2 N·m (45 ± 15 lb.in.).
15. Put Loctite LB 8632 Silicone Lubricant (North America), Loctite LB 8104 Silicone Lubricant (EAME), Loctite LB 8801 Silicone Lubricant (Asia Pacific Division), or Loctite LB Superlube (South America) on O-ring seals (39), (40) and on the rubber end of valve (4). Install retainer (5) on the valve so that the counterbore in the retainer is away from spring (6).
16. Install spring (6) on the valve. Install retainer (7) on the valve with the side of the retainer with the small diameter toward the spring as shown. Put spring (6) under compression. Use tool (A) to install snap ring (8) on the end of valve (4).
17. Put Loctite LB 8632 Silicone Lubricant (North America), Loctite LB 8104 Silicone Lubricant (EAME), Loctite LB 8801 Silicone Lubricant (Asia Pacific Division), or Loctite LB Superlube (South America) on counterbore (41). Install inlet and exhaust valve assembly (3) in the cover as shown.
18. Install cover (2). Tighten four machine screws (42) to a torque of 3 ± 1 N·m (25 ± 5 lb.in.).
19. Install switch (1) on the brake control valve.
End By:
a. install brake control valve