BENDIX TW-2 User manual

Figure 1 – Bendix®TW-2™, TH-3™and PE-4™Control Valves Maintenance Kit

BENDIX®TW-2™, TH-3™AND PE-4™CONTROL VALVES MAINTENANCE KIT

Position

Screw

Lever/Cam

Plunger

(x2)

Inlet Plate

Lock Washer

Cap Screws

Body

Spring

Lever Positioner

Figure 1

Figure 2

Figure 3

*NOTE: Some valves (TW-2, TH-3

and PE-4) use a single large inlet

plate o-ring and some models use

two smaller o-rings.

Kit Contents

Item No. Description Qty.

2* Inlet Plate O-Ring 1

2* Inlet Plate O-Ring 2

3 Valve Spring 2

4 Valve 2

5 Plunger Spring 2

6 Plunger O-Ring 2

7 Tube of Lubricant 1

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 guidelines should be observed AT ALL TIMES:

▲Park the vehicle on a level surface, apply the

parking brakes and always block the wheels.

Always wear personal protection equipment.

▲Stop the engine and remove the 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.

▲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.

▲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 a

Bendix®AD-IS®air dryer system, a Bendix®DRM™

dryer reservoir module, or a Bendix® AD-9si®air

dryer, be sure to drain the purge reservoir.

▲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 and/or cause

hazardous airborne dust and dirt particles. Wear

eye protection. Slowly open connections with

care, and verify that no pressure is present. Never

remove a component or plug unless you are

certain all system pressure has been depleted.

▲Use only genuine Bendix®brand replacement

parts, components and kits. Replacement

hardware, tubing, hose, ﬁ ttings, wiring, etc. must

be of equivalent size, type and strength as original

equipment and be designed speciﬁ cally for such

applications and systems.

▲Components with stripped threads or damaged

parts should be replaced rather than repaired.

Do not attempt repairs requiring machining or

welding unless speciﬁ cally stated and approved

by the vehicle and component manufacturer.

▲Prior to returning the vehicle to service, make

certain all components and systems are restored

to their proper operating condition.

▲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.

▲The power MUST be temporarily disconnected

from the radar sensor whenever any tests USING

A DYNAMOMETER are conducted on a vehicle

equipped with a Bendix® Wingman®system.

▲You should consult the vehicle manufacturer's operating and service manuals, and any related literature,

in conjunction with the Guidelines above.

REMOVAL

1. With the vehicle on a level surface, park the vehicle

by means other than the air brakes and drain all air

pressure from all reservoirs.

2. Identify all air lines and their connections to the valve

and disconnect.

3. Remove the two Phillips®head screws securing the dial

plate to the valve and dash panel and remove the valve.

DISASSEMBLY

NOTE: Before beginning disassembly of the valve, mark

the relationship of the lever and cam to the body. The lever

must be placed back in the valve body in the same position

in order to ensure proper operation. DO NOT change the

lever position end for end. Most lever/cams have a locating

slot cut in them.

1. Remove the cap screws and lock washer and remove

the inlet plate. Note whether one or two inlet plate

o-rings (2) are used. *See note on page 1.

2. Remove and discard the o-ring (2), both springs (3) and

both inlet valves (4).

3. Remove the pin and lift the lever out of the body.

4. Remove both plungers and their return springs (5).

5. Remove the lever positioner and its spring, if the valve

is so equipped.

6. Remove the o-ring (6) from both plungers and discard

the o-rings.

ASSEMBLY

Prior to assembly, clean the lever and valve body in

mineral spirits and dry thoroughly. Lubricate o-rings and

o-ring bores with the lubricant (7) supplied with this kit.

1. Install both inlet valves (4) and inlet valve springs (3) in

the valve body.

2. Install the o-ring or o-rings (see NOTE* on page 1) in

the valve body.

3. Install the inlet plate and secure with cap screws and

washer. Torque to 50-180 in-lbs.

4. Install the o-ring (6) on the plungers.

5. Install the plunger return springs (5) and install the

plungers in the valve body.

6. Install the lever positioner spring and lever positioner if

valve is so equipped.

7. Note the markings made on the lever/cam and valve

body during disassembly and position the lever in the

valve body.

8. Install the pin to secure the lever/cam.

OPERATING AND LEAKAGE CHECKS

Connect a 100 psi air source to the supply port(s) and

connect an air gauge to each delivery port. With the lever

in the number 1 position, as noted in Figure 3, apply a soap

solution to the exhaust openings in the valve body. No

leakage is permitted. Note which delivery gauge registers

pressure (if either do). Move the lever to position 2, if the

valve has this position, and wait 20 seconds before applying

a soap solution and checking the delivery port gauges.

Repeat this procedure for position 3.

INSTALLATION

1. Remount the valve in the dash panel using the two

Phillips head screws to secure the dial plate and valve.

2. Notingtheairlineidenticationmadeduringremoval,

reconnect the air lines to the proper ports.

3. Before moving the vehicle, build the air system pressure

and operate the valve to determine if it functions

properly in the system. If operation is incorrect, check

the lever/cam installation and the air line connections.

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