SD-13-4795

Bendix® AR-1™ AntiLock Relay Valve

AR-1™ AR-1™ VALVE

ANTILOCK WITH ANTILOCK
RELAY VALVE CONTROLLER

SERVICE PORT ANTILOCK

CONTROLLER

QUICK/
EXHAUST DIA.

SERVICE
QUICK PORT
EXHAUST

RELAY
PISTON

TYPICAL INLET/
MOUNTING EXHAUST
BRACKET VALVE
SUPPLY PORT
SUPPLY PORT DELIVERY
PORT

DELIVERY PORTS
EXHAUST PORT EXHAUST PORT

FIGURE 1 - AR-1™ ANTILOCK RELAY VALVE ASSEMBLY

DESCRIPTION
The AR-1™ antilock relay valve (Figure 1) is a specialized proximity to the service actuators it serves. A mounting
service brake relay valve. It is essentially an R-14® relay bracket furnished with the valve permits either frame or
valve with a special cover that permits direct attachment cross member mounting. All air connections on the AR-1™
of an antilock controller. When combined with an antilock valve are identified with cast, embossed letters for ease of
controller the resulting assembly is referred to as an installation. The letter identification and air line connections
antilock relay controller. For example, when the AR-1™ are shown below for reference.
antilock relay valve is combined with the EC-30™ tractor
EMBOSSED
antilock controller the resulting assembly is referred to as a AR-1™ VALVE AIR CONNECTION
IDENT.
CR-30™ antilock relay controller. While intended for use on
antilock equipped vehicles, the AR-1™ antilock relay valve Supply (to reservoir) SUP
functions solely as a service brake relay and contains no Delivery (to brake actuator) DEL
electronics of its own. Service (to brake valve rear service
SER
delivery)
In an air brake system, the AR-1™ valve serves as a
relay station to speed the application and release of Like the R-14® relay valve, the AR-1™ valve incorporates
the service brakes. The valve is normally mounted in a quick release valve adjacent to the service port which

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 EC-15™ ANTILOCK
CONTROLLER

AR-1™ ANTILOCK RELAY

VALVE

TYPICAL
MOUNTING
BRACKET

FIGURE 2 - CR-15™ ANTILOCK RELAY CONTROLLER

provides for rapid exhaust of control air pressure from moves into contact with the exhaust portion of the inlet and
above the relay piston. The standard AR-1™ valve is offered exhaust valve. With the exhaust passage sealed, continued
with a 4 psi crack pressure, however, with the addition movement of the relay piston unseats the inlet portion of
of various springs beneath the relay piston, higher crack the inlet and exhaust valve, allowing supply air from the
pressures are possible. reservoir to flow out the AR-1™ valve’s delivery ports to
the antilock modulators and then to the brake actuators.
The AR-1™ valve’s internal components are interchangeable
(See Figure 3)
with the R-12® and R-14® relay valves, therefore, the same
maintenance kit is used to service all three valves. HOLDING-BALANCED
The air pressure being delivered to the antilock modulators
OPERATION and brake actuators is also present beneath the relay
BRAKE APPLICATION piston. When the air pressure above and below the relay
piston is equal, the piston moves slightly allowing the inlet
Brake application air enters the AR-1™ valve’s service port
valve to return to its seat. The exhaust valve remains
and encounters the exhaust diaphragm which flexes in
closed. With both the inlet and exhaust valves closed, air
response to the incoming air, sealing the exhaust passage
pressure in the antilock modulators and brake actuators
in the cover. Air flows around the exhaust diaphragm and
is held stable and neither increases nor decreases. (See
moves through a passage in the cover to the top of the
Figure 4)
relay piston. In response to air pressure, the relay piston

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 ANTILOCK
CONTROLLER

QUICK EXHAUST DIA.

SERVICE PORT

EXHAUST

RELAY PISTON

SUPPLY PORT INLET/EXH.

VALVE DELIVERY PORT

RESERVOIR
ANTILOCK
MODULATOR

EXHAUST BRAKE
ACTUATOR

FIGURE 3 - AR-1™ VALVE BRAKE APPLICATION

ANTILOCK
CONTROLLER QUICK EXHAUST DIA.

SERVICE PORT

EXHAUST

RELAY PISTON

INLET/EXH. VALVE
SUPPLY PORT
DELIVERY PORT

RESERVOIR
ANTILOCK
MODULATOR

BRAKE
EXHAUST ACTUATOR

FIGURE 4 - AR-1™ VALVE HOLDING - BALANCED

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 ANTILOCK
CONTROLLER QUICK EXHAUST DIA.

SERVICE PORT

EXHAUST

RELAY PISTON

INLET/EXH. VALVE
SUPPLY PORT
DELIVERY PORT

RESERVOIR
ANTILOCK
MODULATOR

EXHAUST BRAKE
ACTUATOR

FIGURE 5 - AR-1™ VALVE EXHAUST - BRAKE RELEASE

EXHAUST - BRAKE RELEASE described, or leakage is excessive, it should be repaired

or replaced with a new or genuine Bendix remanufactured
When the brake application is released, air pressure in the
unit, available at any authorized parts outlet.
service port of the AR-1™ valve returns to the foot brake
valve and is exhausted. Air, from above the relay piston,
EVERY 3 MONTHS, 25,000 MILES OR 900
flows back through the cover to the exhaust diaphragm. The
OPERATING HOURS
diaphragm flexes in response to the returning air, sealing
the service port and opening the exhaust in the cover. 1. Remove any accumulated contaminates and visually
With the exhaust diaphragm blocking the service port, inspect the exterior for excessive corrosion and physical
returning air flows out the open exhaust. As air pressure damage.
is reduced above the relay piston, pressure beneath it lifts 2. Inspect all air lines connected to the AR-1™ valve
the piston away from the exhaust valve and opens the for signs of wear or physical damage. Replace as
exhaust passage. Air from the antilock modulators and necessary.
brake actuators returns to the AR-1™ valve and flows out 3. Test air line fittings for excessive leakage and tighten
the open exhaust. (See Figure 5) or replace as necessary.
4. Perform the Leakage Test described in this manual.
PREVENTIVE MAINTENANCE
Important: Review the warranty policy before performing EVERY YEAR, 100,000 MILES, OR 3,600
any intrusive maintenance procedures. An extended OPERATING HOURS
warranty may be voided if intrusive maintenance is 1. Perform the Operation and Leakage Tests described
performed during this period. in this manual.
Because no two vehicles operate under identical conditions,
maintenance intervals will vary. Experience is a valuable OPERATION & LEAKAGE TESTS
guide in determining the best maintenance interval for a OPERATION TEST
vehicle.
1. Apply and release the brakes several times and check
GENERAL for prompt application and release at each wheel. If
prompt reaction is noted at some, but not all wheels, test
Perform the tests and inspections presented at the the AntiLock modulator between the AR-1™ valve and
prescribed intervals. If the AR-1™ valve fails to function as the brake actuator for proper operation. If a “sluggish”

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 response is noted at all wheels, inspect for a kinked or 6. Never exceed manufacturer’s recommended
obstructed air line leading to or from the AR-1™ valve. pressures.
2. If a complete release of the brakes is noted at some, 7. Never connect or disconnect a hose or line
but not all wheels, test the antilock modulator between containing pressure; it may whip. Never remove
the AR-1™ valve and the brake actuator for proper a component or plug unless you are certain all
operation. If an incomplete release is noted at all system pressure has been depleted.
wheels, inspect for a kinked or obstructed air line 8. Use only genuine Bendix® brand replacement parts,
leading to or from the AR-1™ valve. components and kits. Replacement hardware,
tubing, hose, fittings, etc. must be of equivalent
3. During brake release confirm that a slight “puff” of air
size, type and strength as original equipment and
exits at the AR-1™ valve’s quick exhaust port in the be designed specifically for such applications and
cover. Air exiting at this exhaust port indicates the systems.
AR-1™ valve integral quick release is functioning. 9. Components with stripped threads or damaged
LEAKAGE TESTS parts should be replaced rather than repaired. Do
not attempt repairs requiring machining or welding
1. Build the air system pressure to governor cut-out, apply unless specifically stated and approved by the
a soap solution to the exhaust port in body. The leakage vehicle and component manufacturer.
noted should not exceed a one inch bubble in less than 10. Prior to returning the vehicle to service, make
three (3) seconds. certain all components and systems are restored
2. Make and hold a full brake application and apply a soap to their proper operating condition.
solution to the exhaust ports in the body and cover and 11. For vehicles with Automatic Traction Control (ATC),
around the cover where it joins the body. The leakage the ATC function must be disabled (ATC indicator
noted should not exceed a one inch bubble in less than lamp should be ON) prior to performing any vehicle
maintenance where one or more wheels on a drive
three (3) seconds at any exhaust port.
axle are lifted off the ground and moving.
WARNING! PLEASE READ AND FOLLOW
THESE INSTRUCTIONS TO AVOID PERSONAL VALVE REMOVAL
INJURY OR DEATH: 1. Park the vehicle on a level surface and block the wheels
When working on or around a vehicle, the following and/or hold the vehicle by means other than the air
general precautions should be observed at all times. brakes.
1. Park the vehicle on a level surface, apply the parking 2. Drain the air pressure from all vehicle reservoirs.
brakes, and always block the wheels. Always wear 3. Identify, mark or label all air lines and wiring cables and
safety glasses.
their respective connections on the valve or antilock
2. Stop the engine and remove ignition key when
controller to facilitate ease of installation.
working under or around the vehicle. When working
in the engine compartment, the engine should be 4. Disconnect all air lines and wiring.
shut off and the ignition key should be removed. 5. Remove the valve and controller assembly from the
Where circumstances require that the engine be vehicle.
in operation, EXTREME CAUTION should be used
to prevent personal injury resulting from contact VALVE INSTALLATION
with moving, rotating, leaking, heated or electrically
charged components. 1. Install all air line fittings and plugs making certain thread
3. Do not attempt to install, remove, disassemble sealing material does not enter the valve.
or assemble a component until you have read 2. Install the assembled valve on the vehicle.
and thoroughly understand the recommended 3. Reconnect all air lines and wiring cables to the valve
procedures. Use only the proper tools and observe and controller assembly using the identification made
all precautions pertaining to use of those tools. during VALVE REMOVAL step 3.
4. If the work is being performed on the vehicle’s 4. After installing the valve and controller assembly, test all
air brake system, or any auxiliary pressurized air air fittings for excessive leakage and tighten as needed.
systems, make certain to drain the air pressure
from all reservoirs before beginning ANY work
DISASSEMBLY
on the vehicle. If the vehicle is equipped with a
Bendix® AD-IS® air dryer system or a dryer reservoir GENERAL
module, be sure to drain the purge reservoir.
The following disassembly and assembly procedure is
5. Following the vehicle manufacturer’s recommended
procedures, deactivate the electrical system in a presented for reference purposes only and presupposes
manner that safely removes all electrical power that the appropriate maintenance kit is on hand at the
from the vehicle. time of disassembly. The instructions provided with

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 1

ANTILOCK
CONTROLLER

13
13
11 11

12 26

15
MOUNTING
22 21 BRACKET

23 25
24 16 20
14
18

17

19

10

8
7
6
4
3

FIGURE 6 - AR-1™ ANTILOCK RELAY VALVE WITH CONTROLLER

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the maintenance kit should always be used in lieu of CLEANING & INSPECTION
those presented here. Refer to Figure 6 throughout the 1. Using mineral spirits or an equivalent solvent, clean
disassembly and assembly procedure. and thoroughly dry all metal parts.
CAUTION: The AR-1™ valve may be lightly clamped in a 2. Inspect the interior and exterior of all metal parts that
bench vise during disassembly, however, over clamping will be reused for severe corrosion, pitting and cracks.
will cause damage to the valve and result in leakage and/ Superficial corrosion and/or pitting on the exterior
or malfunction. If a vise is to be used, position the valve so portion of the body (5) and cover (15) is acceptable.
that the jaws bear on the supply ports on opposing sides Replace the entire valve if the interior of the body or
of the valve’s body. cover exhibit signs of corrosion or pitting.
1. Remove all air fittings and plugs from the valve. 3. Inspect the bores of both the body (5) and cover (15)
2. Mark the relationship of the antilock electronic controller for deep scuffing or gouges. Replace the entire valve
and valve cover to the body (5). Note the position of if either are found.
the mounting bracket and mark the relationship of the 4. Make certain all air channels and exhaust passages in
bracket to the valve body, cover, and antilock controller. the valve cover (15) are clear and free of obstruction.
Remove and retain the four cap screws and lock 5. Inspect the pipe threads in the body (5). Make certain
washers (1) that secure the controller to the cover (15), they are clean and free of thread sealant.
then carefully remove the electronic controller without
6. Wash all non-metallic components in a soap and water
damaging its gasket (2).
solution making certain to rinse and dry thoroughly.
3. While holding the exhaust cover (4), remove and Inspect each non-metallic component for cracks, wear
discard the retaining ring (3) that secures it to the body or distortion. Replace the entire valve if these conditions
(5). are found.
4. Remove and discard the exhaust cover (4) along with 7. If the valve was equipped with a relay piston spring
both o-rings (6 & 7). (19), inspect it for signs of corrosion, pitting and cracks.
5. Remove and discard the valve spring (8), valve retainer Replace as necessary.
(9), and the valve assembly (10) from the body (5). 8. Inspect all air line fittings for corrosion and replace
6. Remove and retain the two cap screws (11) and lock as necessary. Make certain to remove all old thread
washers (12) that secure the cover (15) to the body (5). sealant before reuse.
Remove and retain the two bolts (13), lock washers
(12), and nuts (14) that secure the cover (15) and ASSEMBLY
mounting bracket to the valve body (5). 1. Prior to assembly, lubricate all o-rings, seals, and
7. Separate the cover (15) and mounting bracket from pistons, as well as body bores, using the lubricant
the body (5), then remove and discard the sealing provided with the Bendix maintenance kit.
ring (16). Remove and retain the two cap screws and 2. Install the valve retainer (9) on the inlet and exhaust
lockwashers (26) that secure the bracket to the cover valve (10) so that the flange of the retainer (9) surrounds
(15). the rubber portion of the valve. Install the inlet and
8. Remove and retain the relay piston (17) and relay piston exhaust valve in the body (5).
spring (19) from the body (5). NOTE: The relay piston 3. Install the inlet and exhaust valve return spring (8) in
spring, item 19 is not used in all valves. the body (5).
9. Remove and discard the o-ring (18) from the relay 4. Install the large and small diameter o-rings (7 & 6) in
piston (17). the exhaust cover (4), then install the exhaust cover
10. Remove and retain the service port cap nut (20) from in the body (5) taking care not to damage the o-rings.
the cover (15), then separate and discard the cap nut Hold the exhaust cover in place.
o-ring (21) from the cap nut. 5. While depressing the exhaust cover (4), install the
11. Remove and discard the quick exhaust diaphragm (22) retaining ring (3) in the body (5). Make certain the
from the cover (15). retainer (3) is fully seated in its groove in the body.
12. Remove the quick exhaust diaphragm retaining screw 6. If the AR-1™ valve was equipped with a relay piston
(23), the diaphragm washer (24) and the diaphragm return spring (19), install the spring in the body, large
(25) from the cover (15). diameter first.
7. Using lubricant to hold them in place, install sealing
ring (16) on the cover (15).

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8. Install the o-ring (18) on the relay piston (17), then install 11. After noting the relationship of marks made prior to
the piston in the body (5). disassembly, attach the gasket (2) to the antilock
9. After noting the relationship marks made prior to controller then secure the antilock controller on the
disassembly, assemble the cover (15) on the body (5) cover (15) using the four cap screws and lock washers
and the mounting bracket on the body (5) and secure (1). Torque the cap screws to 50-80 lb. in.
the components together using the two cap screws 12. Install all air line fittings and plugs making certain thread
(11) and two bolts (13), lock washers (12), and nuts sealing material does not enter the valve.
(14). Torque the cover cap screws (11) and bolts (13) 13. Install the CR-15 (AR-1™ valve with attached antilock
to 120-150 lb. in. controller) on the vehicle and perform the Operation and
10. Install the two cap screws and lock washers (26) that Leakage Tests before returning the vehicle to service.
secure the bracket to the cover (15) and torque them
to 180-220 lb. in.

BW1665 © 2011 Bendix Commercial Vehicle Systems LLC. All Rights Reserved. 01/11 Printed in U.S.A.
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