Bendix TR-2-TR-3-TR-4 INVERSION VALVE User Manual

®
Bendix® TR-2™, TR-3™ & TR-4™ Inversion Valves
SD-03-4650
CAP NUT
SUPPLY PORT
INLET & EXHAUST
DELIVERY PORT (2)
CONTROL PORT (3)
PISTON SPRINGS
RETAINER RING
EXHAUST
DIAPHRAGM WASHER
FIGURE 1 - TR-2™ INVERSION VAL VE
DESCRIPTION
GENERAL
The TR-2™ & TR-3™ valves are normally open pilot-operated, inverting, on-off, two-way valves. The TR-4™ valve is lever operated. With normal operating pressure at both supply and control ports, the delivery port will be exhausted to atmosphere. 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.
TR-2™ INVERSION V AL VE
SEAL RING
VALVE SPRING
BODY
CAP SCREW
MOUNTING NUT
& LOCKWASHER
INLET & EXHAUST
VALVE
PISTON GROMMET
(SMALL)
PISTON
PISTON GROMMET
(LARGE)
COVER PLATE
EXHAUST
DIAPHRAGM
TR-3™ INVERSION V AL VE
Referring to Figure 2, the TR-3™ valve is similar in function to the TR-2™ valve, but with a die cast body . Referring to Figure 3, some TR-3™ valve’s have an internal passage in the body connecting supply pressure to control. The external control port is permanently plugged in such valves.
TR-4™ INVERSION V AL VE
Referring to Figure 4, the TR-4™ valve is a TR-3™ valve with the internal passage connecting supply and control plus a manual lever control which permits the valve to be locked in the open position.
Referring to Figure 1, the TR-2™ valve was used primarily in early DD-3™ Safety Actuator control systems to apply air pressure to the emergency diaphragm of the DD-3 actuator’s from a protected reservoir as control pressure is released from the lock mechanism. The TR-2™ valve is available in 11/4" bulk head mount only .
OPERATION
TR-2™ & TR-3™ INVERSION V AL VES
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 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
1
EXHAUST
DIAPHRAGM
PISTON SPRING
DIAPHRAGM
RETAINER
PISTON
SHIM
1/8” P.T.
CONTROL
INLET &
EXHAUST
VALVE
VALVE STOP
O-RING
1/4” P.T. SUPPLY
FIGURE 2 - TR-3™ INVERSION VAL VE FIGURE 3 - TR-3™ INVERSION VAL VE
predetermined pressure or is vented from the control cavity ,
EXHAUST
NUT
O-RING
O-RING
1/4” P.T.
DELIVERY
VALVE
SPRING
CAP
PIPE
PLUG
INTERNAL
PASSAGE
INTERNAL BLEED CONTROL
PREVENTIVE MAINTENANCE
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.
The TR-3™ valve with the internal control passage functions the same as above except 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 pressure the valve will deliver the remaining supply pressure at the delivery port.
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 6 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.
TR-4™ INVERSION V AL VE
The TR-4™ valve provides the same functions as the internal passaged TR-3™ valve except the lever override gives the operator the option of locking the valve in the open or delivery position.
MOUNTING LOCATION
Care should be given to assure proper mounting location of the valve with the exhaust pointed downward, 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.
2
OPERA TING 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 vehicle manual. With air pressure present in supply and control port, apply a soap solution around the supply port cap nut. No leakage is permitted. Apply soap solution to the delivery and exhaust ports. Leakage should not exceed 100 SCCM or a 1" bubble in not less than 5 seconds. Excessive leakage would indicate a faulty o-ring or inlet valve. Operate the manual control of the TR-4™ valve and note that delivery and exhaust occur promptly .
PLUNGER
LEVER
PLUNGER SPRING
PISTON SPRING
VALVE STOP
FIGURE 4 - TR-4™ INVERSION VAL VE
Slowly decrease pressure in the control cavity and note at what pressure delivery is made and compare with vehicle manual.
NOTE: In the TR-3™ valve shown in Figure 3 and the TR-4
valve in Figure 4, control pressure is reduced by decreasing supply air pressure because of the internal passage connecting supply and control.
If the TR-2™, TR-3™ or TR-4™ inversion valve does not function as described or leakage is excessive, it is recommended that it be replaced with a new valve or remanufactured unit, or repaired with genuine Bendix parts available at Bendix outlets.
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 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
COVER PIN
SHIM
PISTON O-RING
PLUGGED
INLET/EXHAUST
VALVE
O-RING
1/4” P.T. SUPPLY
LOCK NUT COVER NUT
O-RING
1/4” P.T.
DELIVERY
VALVE
SPRING CAP
thoroughly understand the recommended procedures. Use only the proper tools and observe 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 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.
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 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 component manufacturer.
10. Prior to returning the vehicle to service, make certain all components and systems are restored to their proper operating condition.
3
REMOV AL AND INST ALLA TION
REMOV AL
Block and hold vehicle by means other than air brakes. Drain service and emergency or parking reservoirs. Disconnect air lines from valve. Remove the mounting bolts, remove valve.
INST ALLATION
Remount valve securely using holes provided in body . Check and clean air lines and reconnect.
DISASSEMBL Y
NOTE: Care should be taken if body is clamped in vise.
Excessive tightening can cause distortion of valve body.
TR-2™ INVERSION V AL VE
1. Remove the cap nut with sealing ring, remove sealing ring from cap nut.
2. Remove the inlet/exhaust valve spring and inlet/exhaust valve.
3. Turn the valve over and remove the exhaust diaphragm cap screw with lockwasher, then the diaphragm washer and diaphragm.
4. With a pair of #1 Truarc pliers, remove the retainer ring. Remove the cover plate and two (2) piston springs.
5. Remove the piston with grommets.
6. Remove the piston grommets.
TR-3™ INVERSION V AL VE
1. Remove the exhaust port cap nut and o-ring.
2. Remove the diaphragm retainer and piston spring.
3. Remove the shim washer or washers (if present).
4. Remove the piston from the valve body .
5. Remove the piston o-ring and exhaust stem o-ring.
6. Remove the supply cap nut and o-ring.
7. Remove the valve stop and spring.
8. Remove the inlet and exhaust valve.
TR-4™ INVERSION V AL VE
1. Press lever pin out of the lever and remove lever.
2. Remove the plunger and plunger return spring from cover.
3. Remove the cover nut lock nut.
4. Remove the cover nut and o-ring.
5. Remove the cover and shim washer or washers.
6. Remove the piston spring and piston from body .
7. Remove the piston and exhaust stem o-rings.
8. Remove the supply port cap nut and o-ring.
9. Remove the valve stop and valve return spring.
10. Remove the inlet and exhaust valve.
CLEANING AND INSPECTION
Wash all metal parts in a good cleaning solvent. Rubber parts should be wiped clean.
Inspect all parts for signs of wear or deterioration. Check the springs for cracks, corrosion, or distortion. Inspect the piston and its exhaust seat, body bores, and inlet valve for nicks, scratches, or burrs.
Replace all parts not considered serviceable during inspection.
ASSEMBL Y
Before assembling the valve, lubricate the piston o-rings and body bores with Bendix silicone lubricant such as BW650M Bendix Pc. No. 291 126.
TR-2
INVERSION V AL VE
1. Install the piston grommets on piston.
2. Install the piston with grommets in valve body .
3. Position the piston springs, cover plate and retainer ring in the piston in that order. Press the cover and ret ainer down and with a pair of Truarc #1 pliers, snap the ring into the body groove.
4. Install the diaphragm and diaphragm washer and secure with cap screw.
5. Turn the inversion valve over and position the inlet and exhaust valve in its bore.
6. Place the spring over inlet valve.
7. Install the sealing ring on cap nut. Install the cap nut with sealing ring and tighten securely . T orque to approx. 125 in. lbs.
8. Using the mounting nut and lockwasher, install the valve on vehicle.
TR-3™ INVERSION V AL VE
1. Install the inlet and exhaust valve in the body (supply port).
2. Install the inlet valve spring and valve stop (center stop on spring).
3. Install the o-ring on the supply cap nut and install and tighten the cap nut. Torque to approx. 100 in. lbs.
4. Install the piston and exhaust stem o-ring on piston. Install the piston in body .
5. Install the shim washer or washers (if present). Install the piston spring.
6. Install the diaphragm retainer and exhaust diaphragm.
7. Install the o-ring on exhaust cap nut and install and tighten the cap nut. Torque to approx. 275 in. lbs.
TR-4™ INVERSION V AL VE
1. Replace the inlet and exhaust valve.
2. Install the valve return spring and valve stop.
3. Install the o-ring on supply cap nut and install and tighten
the cap nut. Torque to approx. 100 in. lbs.
4. Install the piston and exhaust stem o-ring on the piston.
Install the piston in the body.
5. Install the piston spring.
6. Install the cover and washer or washers.
7. Replace the cover nut o-ring on the cover nut and install
and tighten the cover nut. Torque to approx. 275 in. lbs.
8. Install the plunger return spring and plunger.
9. Install the cover nut lock nut. T orque to approx. 100 in.
lbs.
10. Install lever and press the lever pin in to secure.
TESTING REBUIL T VAL VES
Perform operating and leakage tests as outlined in “Operating and Leakage Tests” section.
4
BW1581 © 2004 Bendix Commercial Vehicle Systems LLC. All rights reserved. 4/2004 Printed in U.S.A.
Loading...