BENDIX BW1564 User's Manual
Contents
1. 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 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 3 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 4 Ifthe 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 oO Insert Assembly 6 Position preload spring 21 in exhaust check valve seat 16 7 Install diaphragm 18 diaphragm washer 19 with lips pointing out and install screw 20 Tighten screw securely 8 Install o ring 15 and valve retainer 12 on inlet exhaust valve body 14 9 Install valve spring 13 on exhaust check valve seat 16 and install inlet exhaust valve 14 into exhaust valve seat 16 Press the valve down until the preload spring snaps and holds the2. Every 3 Months 25 000 Miles or 900 Operating Hours Lubricate all mechanical actuation pedal parts with light 10W oil Apply 2 to 4 drops of oil between the plunger and mounting plate DO NOT OVER OIL Lever linkage operated valves should be adjusted so that the roller just contacts plunger Check for integrity of mounting plate and treadle and or pedal SERVICE TESTS Operating Test IMPORTANT Tests should be conducted with an accurate test gauge Install gauge in a delivery port or line depress the treadle or pedal to several positions between fully released and fully applied positions checking the delivery pressure on the gauge to see that it varies proportionately with the movement of the treadle or pedal In the fully applied position the reading on the gauge should be approximately that of full reservoir pressure Upon release of the application the reading of the test gauge should fall to zero psi immediately Leakage Test With 100 psi supply pressure and valve in released position coat exhaust port with soapsuds arid check for leakage NO leakage permitted Fully apply valve and hold application Coat exhaust port with soapsuds NO leakage permitted Coat area around top of valve with soapsuds NO leakage permitted lf the valve does not function as described 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 o
3. Bendix E 2 amp E 3 Brake Valves CAP SCREW 6 PISTON 7 4 RETAINER WASHER 8 3 O RING PISTON 2 RETURN SPRING VALVE 14 O RING 15 EXHAUST CH 16 VALVE SEAT O RING 17 i RETAINING RING WASHER 19 SCREW 20 INSERT ASS Y NPRELOAD 21 SPRING FIGURE 1 E 3 BRAKE VALVE SECTIONAL VIEW DESCRIPTION The Bendix E 2 and E 3 brake valves are single circuit brake valves that provide the driver with single point control of the service braking system The valve can be either treadle operated or fitted with a lever for a linkage connection to a conventional brake pedal Movement of the treadle or pedal controls the graduated application and release of air pressure to the vehicle brake actuators applying or releasing the vehicle brakes The E 2 and E 3 brake valves utilize a rubber spring confined in a retainer resulting in reduced plunger travel as compared to previous design single circuit brake valves The E 3 brake valve differs from the E 2 valve in that it employs a different piston see insert Fig 1 which requires greater plunger travel Because of the greater plunger travel the E 3 valve provides less sensitivity in the 0 40 psi application range as compared to the E 2 valve Other than the different pistons the E 2 and E 3 valves are identical An identification washer located under the retaining ring in the valve s exhaust port provides a means of identifying the
4. equals the mechanical force on the top of the piston the piston lifts and the inlet valve closes cutting off any further flow of air from the supply line through the valve The exhaust remains closed preventing any escape of air through the exhaust port When applications in the above average pressure range are made the valve reaches a balanced position as the air pressure beneath the piston equals the effort exerted by the driver s foot on the pedal or treadle When the piston is pressed down all the way the inlet valve remains open and reservoir pressure is delivered to the actuators Releasing When the treadle or pedal application is released mechanical force is removed from the top of the piston air pressure beneath the piston lifts the piston the inlet valve is closed the exhaust in the valve is open and the air beneath the piston and in the delivery lines is exhausted through the exhaust port PREVENTIVE MAINTENANCE Important Review the warranty policy before performing any intrusive maintenance procedures An extended warranty may be voided if intrusive maintenance is performed during this period Because no two vehicles operate under identical conditions maintenance and maintenance intervals will vary Experience is a valuable guide in determining the best maintenance interval for any one particular operation Visually check for physical damage to the brake valve such as broken air lines and broken or missing parts
5. E 2 and E 3 brake valve SPRING SEAT 9 RUBBER SPRING 10 RETAINER 12 VALVE SPRING 13 INLET EXHAUST DIAPHRAGM 18 SD 03 812 DELIVERY PORTS 4 SUPPLY PORTS 2 EXHAUST AUXILIARY PORTS 2 TREADLE MOUNTING PLATE sg DELIVERY PORTS 4 AUXILIARY PORTS 2 EXHAUST SUPPLY PORTS 2 E 2 E 3 BRAKE VALVE The E 2 and E 3 valves have an insert type inlet exhaust valve assembly which can be removed without disconnecting air lines An exhaust check valve in the bottom of the insert prevents contaminants from entering the valve through the exhaust port An optional exhaust extension is available should an exhaust carry off line be required Porting consists of two 2 1 2 inch P T supply ports four 4 3 8 inch or 1 2 inch P T delivery ports and two 2 1 4 inch P T accessory ports in the supply portion of the valve OPERATION Applying Applying the treadle or pedal exerts a force on the plunger rubber graduating spring and piston The downward movement of the piston causes the piston stem which is the exhaust seat to contact the valve closing the exhaust As the exhaust closes the inlet valve moves away from its seat Air pressure is then allowed to flow by the inlet valve out the delivery ports and to the brake actuators applying the brakes Balanced When the air pressure in the cavity beneath the piston and the air pressure being delivered to the brake actuators
6. assembly together 10 Install o ring 17 on exhaust check valve seat 16 11 Place inlet exhaust insert in valve body position identification washer Press the insert down while installing retaining ring 1 Make certain retaining ring snaps into body groove thus locking in the insert in place Testing A Rebuilt E 2 or E 3 Brake Valve Perform operating and leakage tests as outlined in Service Tests section 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 5 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 8 Use only genuine Bendix brand 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 9 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 compon
7. ent manufacturer 10 Prior to returning the vehicle to service make certain all components and systems are restored to their proper operating condition 11 For vehicles with Automatic 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 BW1564 2011 Bendix Commercial Vehicle Systems LLC a member of the Knorr Bremse Group All Rights Reserved 10 11
8. ert assembly 11 from body Insert Disassembly NOTE Itis recommended that entire inlet exhaust insert be replaced as an assembly Remove o ring 17 from check valve seat 16 Remove screw 20 washer 19 and diaphragm 18 Depress and hold insert and remove preload spring 21 10 Remove inlet exhaust valve 14 valve spring 13 and o ring 15 11 Remove valve retainer 12 Cleaning and Inspection Wash all metal parts in mineral spirits and dry Wipe all rubber parts clean Inspect all parts for excessive wear or deterioration Inspect valve and valve seats for nicks and burrs Check springs for cracks distortion or corrosion Inspect exhaust check diaphragm for flexibility wear and deterioration Replace all parts not considered serviceable during these inspections ASSEMBLY 1 Lightly lubricate the piston valve bores and o rings with Dow Corning 55 M pneumatic grease Bendix piece number 291126 Position rubber spring 10 in piston 7 Install spring seat 9 washer 8 and cap screw 6 Torque cap screw to 50 inch pounds Install piston o ring 3 and place piston return spring 2 in body Install piston retainer 4 Be certain the prongs snap over groove in valve body GENERAL SAFETY GUIDELINES 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
9. ur distributors REMOVING AND INSTALLING Removing Block and hold vehicle by means other than air brakes Drain air brake system If only the insert is to be removed remove retaining ring and pull insert out lf entire valve is to be removed disconnect air lines from valve Remove mounting bolts and remove valve Installing Clean air lines connecting to valve Install valve and tighten mounting bolts Connect air lines to valve plug any unused ports Test valve as outlined under Service Tests NOTE When installing a new or rebuilt insert pre check movement of the inlet and exhaust valve in the exhaust seat by depressing the insert Precaution should be taken to prevent damage to the inlet and exhaust valve and the exhaust check valve grommet when installing the insert in the valve After placing the insert in the valve body depress the exhaust check valve seat and install the retaining ring Make sure the retaining ring snaps into the body groove DISASSEMBLY NOTE Disassembly and assembly instructions are keyed to Fig 1 sectional view 1 Remove treadle or lever assembly boot and plunger 2 Depress piston assembly and remove retainer 4 3 Remove piston assembly 7 and piston return spring 2 from body 4 Remove o ring 3 from piston 7 5 Remove cap screw 6 washer 8 spring seat 9 and rubber spring 10 from piston assembly 7 6 Remove retaining ring 1 and inlet exhaust ins
Download Pdf Manuals
Related Search