BENDIX BW1581 User's Manual
Contents
1. or and kits Replacement hardware tubing hose fittings etc must around the vehicle When working in the engine compartment the be of equivalent size type and strength as original equipment engine should be shut off and the ignition key should be removed and be designed specifically for such applications and systems Where circumstances require that the engine be in operation 9 Components with stripped threads or damaged parts should be EXTREME CAUTION should be used to prevent personal injury replaced rather than repaired Do not attempt repairs requiring resulting from contact with moving rotating leaking heated or machining or welding unless specifically stated and approved by electrically charged components _ the vehicle and component manufacturer 3 Do not attempt to install remove disassemble or assemble a 10 Prior to returning the vehicle to service make certain all component until you have read and thoroughly understand the components and systems are restored to their proper operating recommended procedures Use only the proper tools and observe condition all precautions pertaining to use of those tools 11 For vehicles with Automatic Traction Control ATC the ATC 4 Ifthe work is being performed on the vehicle s air brake system function must be disabled ATC indicator lamp should be ON or any auxiliary pressurized air systems make certain to drain the air pressure from all reservoirs before beginning ANY work prior t2. pressure the valve will deliver the remaining supply pressure at the delivery port MOUNTING LOCATION Care should be given to assure proper mounting location of the valve with the exhaust pointed downward toward the road surface It should be mounted high on the frame rail and away from road spray and debris Unprotected or exposed exhaust ports can allow migration of road contaminants into the valve which may cause accelerated wear or unintended operation 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 inversion valves should be inspected every six 6 CONTROL O RING INTERNAL PASSAGE VALVE STOP INLET amp EXHAUST VALVE 1 8 P T PISTON DIAPHRAGM RETAINER PISTON SPRING FIGURE 3 BENDIX TR 3 INVERSION VALVE INTERNAL BLEED CONTROL months or 1500 operating hours whichever comes first for proper operation Should the inversion valves not meet the elements of the operational tests noted in this document further investigation and service of the valve may be required The TR 3 valve is non serviceable while
3. the Bendix TR 2 valve can be serviced with a maintenance kit For the latest service parts and kits refer to the Bendix Quick Reference Catalog BW1114 available for order or download at www bendix com OPERATING AND LEAKAGE TESTS NOTE The following checks should be made with two calibrated gauges or two gauges known to be accurate Depending upon installation it may be easier or necessary to completely remove the valve to test properly Install one test gauge in a common control and supply line install the other gauge in the delivery port Gradually apply pressure to the common supply and control line On ascending pressure note at what pressure exhaust occurs and compare with the vehicle manual With air pressure present in supply and control ports apply a soap solution to the delivery and exhaust ports Leakage should not exceed 100 SCCM ora 1 bubble in 5 seconds Excessive leakage would indicate a faulty o ring or inlet valve Slowly decrease pressure in the control cavity and note at what pressure delivery is made Compare this with the vehicle manual notation NOTE In the Bendix TR 3 valve shown in Figure 3 control pressure is reduced by decreasing supply air pressure because of the internal passage connecting supply and control REMOVAL AND INSTALLATION REMOVAL Block and hold vehicle by means other than the air brakes Drain service and emergency or parking reservoirs If the Bendix TR 3 inversion val
4. SUPPLY PORT INLET amp EXHAUST VALVE SPRING DELIVERY PORT 2 CONTROL PORT 3 CAP NUT Pa SEAL RING MOUNTING NUT Z amp LOCKWASHER a _ NLET amp EXHAUST anh 7 PISTON GROMMET if SMALL J 2 E _ PISTON i PISTON GROMMET LARGE RETAINER RING EXHAUST FIGURE 1 BENDIX TR 2 INVERSION VALVE DESCRIPTION GENERAL The Bendix TR 2 amp TR 3 valves are normally open pilot operated inverting on off two way valves As control pressure is reduced to the point that the piston return spring or springs overcomes the force on the control piston the valve will deliver full supply pressure at the delivery port BENDIX TR 2 INVERSION VALVE Referring to Figure 1 the Bendix TR 2 valve was used primarily in early Bendix DD 3 safety actuator control systems It applied air pressure to the emergency diaphragm of the DD 3 actuators from a protected reservoir as control pressure is released from the lock mechanism The TR 2 valve is available in 1 1 4 bulk head mount only DIAPHRAGM WASHER COVER PLATE EXHAUST DIAPHRAGM CAP SCREW BENDIX TR 3 INVERSION VALVE Referring to Figure 2 the Bendix TR 3 valve is similar in function to the Bendix TR 2 valve but with a die cast body Referring to Figure 3 some TR 3 valves have an internal passage in the body connecting supply pressure to control The external control port is permanently plugged in such
5. o performing any vehicle maintenance where one or more wheels on a drive axle are lifted off the ground and moving BW1581 2011 Bendix Commercial Vehicle Systems Company LLC a member of the Knorr Bremse Group 8 2011 All Rights Reserved
6. valves OPERATION BENDIX TR 2 amp TR 3 INVERSION VALVES When sufficient air pressure is present in the control cavity to overcome the setting of the piston return spring the piston is held away from the inlet valve which is in turn held closed by the inlet valve return spring The delivery lines are vented to atmosphere through the hollow exhaust stem of the piston When air pressure in the control cavity falls to a predetermined pressure or is vented from the control cavity the piston spring forces the piston against the inlet valve closing the exhaust passage in the hollow piston stem Further travel of the piston opens the inlet valve allowing the passage of air past the open inlet valve and out the delivery port 1 4 P T SUPPLY CAP e VALVE SPRING am 1 4 P T DELIVERY O RING re n ee ae o EXHAUST SHIM O RING K ad EXHAUST NUT DIAPHRAGM __ ee ra FIGURE 2 BENDIX TR 3 INVERSION VALVE The Bendix TR 3 valve with the internal control passage functions the same as described in the previous paragraph The only exception is that the control pressure is always the same as the supply pressure Consequently as supply pressure builds up when the pressure is great enough to overcome the piston return spring the delivery pressure will be vented out the exhaust On descending supply control pressure as the piston return spring overcomes the control
7. ve does not function as _ Disconnect air lines from valve Remove the mounting described or leakage is excessive it is recommended that it be replaced with a new valve or remanufactured unit The Bendix TR 2 valve can be serviced with a maintenance kit or replaced with a new or remanufactured valve GENERAL SAFETY GUIDELINES WARNING bolts remove valve INSTALLATION Remount valve securely using holes provided in body Check and clean air lines and reconnect on the vehicle If the vehicle is equipped with a Bendix AD IS air dryer system or a dryer reservoir module be sure to drain the purge reservoir PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO _ 5 Following the vehicle manufacturer s recommended procedures AVOID PERSONAL INJURY OR DEATH deactivate the electrical system in a manner that safely removes all electrical power from the vehicle When working on or around a vehicle the following general 6 Never exceed manufacturer s recommended pressures precautions should be observed at all times 7 Never connect or disconnect a hose or line containing pressure ee it may whip Never remove a component or plug unless you are 1 Park the vehicle on a level surface apply the parking brakes and certain all system pressure has been depleted always block the wheels Always wear safety glasses 8 Use only genuine Bendix brand replacement parts components 2 Stop the engine and remove ignition key when working under
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