BENDIX RESERVOIRS Leitfaden

RESERVOIRS

SD-04-400

TYPICALSINGLECOMPARTMENTRESERVOIR

DESCRIPTION

The reservoir is a storage tank; its function is to provide a

volumeofcompressedairforbrakingwhichwillbeadequate

in relation to the volume used by the brake chambers and

auxiliary devices. Reservoirs also provide a location in the

systemwheretheair,heatedbycompression,maybecooled

andthe water vaporcondensed.

Bendix®reservoirsarebuiltinaccordancewithSAEStandard

Air Brake Reservoir Test Code and Inspection Procedure

SAEJ-10-a.They aremadefromsteel sheet, withstamped

headsandrolled shells. Theseamsareelectrically welded,

andeachreservoirisinternallycoatedforcorrosionresistance.

Each reservoir is tested at 300 PSI hydrostatic pressure.

Reservoirsaresuppliedinvariouspipeferrule arrangements

and lengths and in diameters from 3-1/2" to 14" having

various volumes from approximately 100 cubic inches to

7600 cubic inches for tractors and trailers. All ferrules are

tapped to SAE dryseal pipe thread standards.

Reservoirsarealsosuppliedindoubleandtriplecompartment

configurationsandin some casesincludeanintegral check

valve between compartments in a double compartment

reservoir.Figure1illustratesatwocompartmentreservoir.

Two styles of check valves are shown in Figures 2 and 3.

Figure 3 is the current design.

OPERATION

Thereservoirsinan airbrake systemprimarilyservetostore

energyin theformofcompressedair.Theyalsoperform the

lessobvious function ofprovidinga meansofcooling theair

asdeliveredfromthecompressor and thereby condensing

water vapor into a liquid as well as collecting oil passed by

thecompressor.Thiswaterand oil collectsasanemulsion;

thegreatestamountinthereservoirnearestthecompressor.

It should be drained off either manually or by means of an

automaticdraindevice.

OPERATION OF INTEGRAL CHECK VALVE

The integral check valve provides a one-way passage of

airfromtheupstreamcompartment to the downstream.

This check valve may serve to meet the legal requirement

for a check valve to protect the service brake system in

case of failure in the compressor, discharge lines or first

reservoircompartment.

PREVENTIVE MAINTENANCE

Allreservoirsshouldbedraineddaily.If an automatic drain

deviceisused,itshouldbe checked periodically for proper

functioning. If an air dryer or aftercooler is used, the

reservoirsshouldbe manually drained periodicallytoverify

theproper function of the drying device. Reservoirs, which

have collected a considerable oily emulsion, should be

drained by opening a drain cock and allow to drain until all

drainagestops.

MAINTENANCE OF THE INTEGRAL CHECK

VALVE

Every six months, 1,800 operating hours or 50,000 miles

the check valve on the two compartment reservoir should

betestedforleakage,asoutlinedbelow,and parts inspected

for damage or deterioration and replaced if considered

unserviceable.

OPERATING AND LEAKAGE TEST FOR TWO

COMPARTMENTRESERVOIRCHECK VALVE

1. Determinethedirectionof the air flow.

2. Build up system air pressure to governor cut-out and

turn off engine.

3. Completely drain compartment #1 (see Figure 1).

NOTE: It may be necessary to remove automatic drain

device if so equipped.

4. To determine pressure retention in #2 compartment,

perform one of the following tests:

a. Check dashgauge (ifconnected to#2 compartment).

b. Apply service brake (if supplied from #2

compartment).

FIGURE1 - TWOCOMPARTMENTRESERVOIRWITHCHECK VALVE

c. Momentarilyopendraindevice on #2compartment.

Do not completely drain #2 Compartment.

5. Apply a soap solution to the drain ferrule #1

compartment.Aslightbubble leakage is permitted.

If #2 compartment fails to hold air pressure or if excessive

leakage is evident at the drain ferrule of #1 compartment,

the check valve should be inspected for serviceability and

its parts replaced if necessary.

DISASSEMBLY

GENERAL

There are two types of two-compartment reservoir check

valvesandtheyare;

1. The old ball style check with a removable seat and a

seat spring (see Figure 2).

2. The new flat style that has a non-removable stainless

steel seat (see Figure 3).

Both types of check valves are located in a housing (large

ferrule)withacapnut cover. Theyaregenerallylocatedon

top of the reservoir shell.

DISASSEMBLY OF THE BALL STYLE CHECK

VALVE (FIGURE 2)

Block and hold vehicle by means other than air brakes.

Completely drain compartments #1 and #2. Remove cap

nutandcapnuto-ring.Removecheck valveandcheckvalve

spring. Remove seat spring. With a hook or similar device,

carefully remove the check valve seat and its

o-ring so as not to mar or scratch it.

DISASSEMBLY OF THE FLAT STYLE CHECK

VALVE (FIGURE 3)

Block and hold vehicle by means other than air brakes.

Completelydraincompartments#1and#2.

Removecapnutand cap nut o-ring.

Removevalvespring.

Removevalve andvalve guide.

CLEANING AND INSPECTION

Wash all metal parts in a good cleaning solvent and dry

them thoroughly. All rubber parts should be wiped clean.

Inspectsprings fordistortion,corrosion, andcracks.Inspect

valvesandvalveseatsfor nicks, cuts and burrs. Inspect all

rubberparts forswelling anddeterioration.Replaceorrepair

as necessary.

CAP NUT CAP NUT

GROOVEIN

CAP NUT

O-RING

VALVE

SPRING

GUIDE

CHECK

VALVE

SPRING

O-RING

SEATSPRING

CHECKVALVE

O-RING

SEAT

SERVICEEACH50,000MILES

OR EVERY 6 MONTHS WITH:

FIELD MAINTENANCE KIT 282350

CONSISTING OF:

1 - CHECK VALVE

1 - GUIDE

1 - SPRING

1 - O-RING COMPARTMENT 1 COMPARTMENT 2

FIGURE 3 FIGURE 2

ASSEMBLY

GENERAL

Beforeassembly,theo-rings shouldbecoated with silicone

lubricant BW-650-M Bendix pc. number 291126.

ASSEMBLYOF THE BALLSTYLECHECK VALVE

Replaceseato-ring and press seatintoshell.Replace seat

spring.Installcheck valve and valve spring.Replaceo-ring

on cap nut and install and tighten cap nut.

ASSEMBLY OF THE FLAT STYLE CHECK VALVE.

Replacevalve guideonvalveand installvalve.

Installvalve spring.

Replace o-ring on cap nut and install and tighten cap nut.

TEST

Perform tests as outlined in “Operation and LeakageTest”

section.

INSTALLATION

Reservoirsshouldbesecurelymountedwheretheywill be

protected against outside damage and so they will not

vibrate or move during normal operation of the vehicle. A

vibrating reservoir usually causes broken tubing lines.

Theyshouldbe the low point intheairbrake system and all

lines connected to them should drain toward the reservoir.

Thepipetapped openings inthereservoirshould not under

any circumstances be reduced in size from original

installation.

A drain cock or draining device must be installed in the

bottom connection of every reservoir and, in the case of

thetwo-compartment reservoir, in each compartment.

The first reservoir or first compartment must be protected

byinstallingasafetyvalve.

MINORREPAIRS

Minor repairs to the reservoir consist of examining the

reservoir mounting and the inspection of the outside for

corrosion or damage. The outside should be kept painted

to prevent the possibility of corrosion causing a failure.

MAJORREPAIRS

Repairs involving welding should never be performed on

reservoirs. If a reservoir has been damaged so as to be

unfit for use, it should be replaced with a new one.

In exceptional cases where the inside of a reservoir has

become excessively coated with sludge which cannot be

drainedoff, itissometimesadvisabletoremoveit andclean

withasolvent,steam,orwater. If a solvent is used to clean

thereservoir,thereservoirshouldbethoroughlyaeratedbefore

reinstalling.

WARNING! PLEASE READ AND FOLLOW

THESE INSTRUCTIONS TO AVOID

PERSONAL INJURY OR 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

enginebeinoperation,EXTREMECAUTIONshould

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. Useonlythepropertoolsandobserve

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 the air pressure

from all reservoirs before beginning ANY work on

the vehicle. If the vehicle is equipped with an

AD-IS™airdryersystemoradryerreservoirmodule,

be sure to drain the purge reservoir.

5. Following the vehicle manufacturer’s

recommendedprocedures,deactivatetheelectrical

systeminamannerthatsafelyremovesallelectrical

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.

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

bedesignedspecificallyforsuchapplicationsand

systems.

9. Components with stripped threads or damaged

parts should be replaced rather than repaired. Do

notattemptrepairsrequiringmachiningorwelding

unless specifically stated and approved by the

vehicle and component manufacturer.

10. Prior to returning the vehicle to service, make

certainallcomponentsandsystemsarerestoredto

their proper operating condition.

11. Forvehicleswith AntilockTraction Control(ATC),

the ATC function must be disabled (ATC indicator

lampshouldbeON)priortoperforminganyvehicle

maintenance where one or more wheels on a

drive axle are lifted off the ground and moving.

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