SD-03-812

Bendix® E-2™ & E-3™ Brake Valves

CAP SCREW 6
PISTON 7
4 RETAINER WASHER 8
3 O-RING SPRING SEAT 9
RUBBER SPRING 10

PISTON TREADLE
2 RETURN RETAINER 12
SPRING VALVE SPRING 13
INLET/EXHAUST
VALVE 14 MOUNTING
O-RING 15 PLATE
EXHAUST CH. 16
VALVE SEAT DELIVERY
PORTS (4)
O-RING 17
RETAINING DIAPHRAGM 18 AUXILIARY
1 RING WASHER 19 PORTS (2) SUPPLY
PORTS (2)
PRELOAD 21 SCREW 20 EXHAUST
SPRING INSERT ASS’Y 11
FIGURE 1 E-3™ BRAKE VALVE (SECTIONAL VIEW) E-2™ - E-3™ BRAKE VALVE
DESCRIPTION
exhaust port. An optional exhaust extension is available
The Bendix® E-2™ and E-3™ brake valves are single circuit should an exhaust carry-off line be required.
brake valves that provide the driver with single point control
of the service braking system. The valve can be either treadle Porting consists of two (2) 1/2 inch p.t. supply ports, four (4)
operated or fitted with a lever for a linkage connection to a 3/8 inch or 1/2 inch p.t. delivery ports, and two (2) 1/4 inch
conventional brake pedal. Movement of the treadle or pedal p.t. accessory ports (in the supply portion of the valve).
controls the graduated application and release of air pressure
to the vehicle brake actuators, applying or releasing the OPERATION
vehicle brakes. Applying
™ ™
The E-2 and E-3 brake valves utilize a rubber spring Applying the treadle or pedal exerts a force on the plunger,
confined in a retainer, resulting in reduced plunger travel as rubber graduating spring and piston. The downward
compared to previous design single circuit brake valves. movement of the piston causes the piston stem (which is
the exhaust seat) to contact the valve, closing the exhaust.
The E-3™ brake valve differs from the E-2™ valve in that it
As the exhaust closes, the inlet valve moves away from its
employs a different piston (see insert Fig. 1), which requires
seat. Air pressure is then allowed to flow by the inlet valve,
greater plunger travel. Because of the greater plunger travel,
out the delivery ports and to the brake actuators, applying
the E-3™ valve provides less sensitivity in the 0-40 psi
the brakes.
application range as compared to the E-2™ valve. Other than
the different pistons, the E-2™ and E-3™ valves are identical. Balanced
An identification washer, located under the retaining ring in When the air pressure in the cavity beneath the piston and
the valve’s exhaust port, provides a means of identifying the the air pressure being delivered to the brake actuators equals
E-2™ and E-3™ brake valve. the mechanical force on the top of the piston, the piston
The E-2™ and E-3™ valves have an insert type inlet/exhaust lifts and the inlet valve closes, cutting off any further flow of
valve assembly which can be removed without disconnecting air from the supply line through the valve. The exhaust
air lines. An exhaust check valve in the bottom of the insert remains closed, preventing any escape of air through the
prevents contaminants from entering the valve through the exhaust port.
When applications in the above average pressure range are Fully apply valve and hold application. Coat exhaust port
made, the valve reaches a balanced position as the air with soapsuds. NO leakage permitted. Coat area around
pressure beneath the piston equals the effort exerted by the top of valve with soapsuds. NO leakage permitted.
driver’s foot on the pedal or treadle. When the piston is
If the valve does not function as described or leakage is
pressed down all the way, the inlet valve remains open and
excessive, it is recommended that it be replaced with a new
reservoir pressure is delivered to the actuators.
or remanufactured unit, or repaired with genuine Bendix parts
Releasing available at our distributors.
When the treadle or pedal application is released, mechanical
REMOVING AND INSTALLING
force is removed from the top of the piston, air pressure
beneath the piston lifts the piston; (the inlet valve is closed) Removing
the exhaust in the valve is open and the air beneath the Block and hold vehicle by means other than air brakes.
piston and in the delivery lines is exhausted through the
exhaust port. Drain air brake system.

*If only the insert is to be removed, remove retaining ring,

PREVENTIVE MAINTENANCE and pull insert out.
Important: Review the warranty policy before performing
If entire valve is to be removed, disconnect air lines from
any intrusive maintenance procedures. An extended warranty
valve.
may be voided if intrusive maintenance is performed during
this period. Remove mounting bolts and remove valve.

Because no two vehicles operate under identical conditions, Installing

maintenance and maintenance intervals will vary. Experience Clean air lines connecting to valve.
is a valuable guide in determining the best maintenance
interval for any one particular operation. Install valve and tighten mounting bolts.

Visually check for physical damage to the brake valve such Connect air lines to valve (plug any unused ports).
as broken air lines and broken or missing parts.
Test valve as outlined under “Service Tests.”
Every 3 Months, 25,000 Miles or 900 Operating Hours NOTE: When installing a new or rebuilt insert, precheck
Lubricate all mechanical actuation (pedal) parts with light movement of the inlet and exhaust valve in the
(10W) oil. Apply 2 to 4 drops of oil between the plunger and exhaust seat by depressing the insert. Precaution
mounting plate. DO NOT OVER OIL!!! should be taken to prevent damage to the inlet and
exhaust valve and the exhaust check valve grommet,
Lever/linkage operated valves should be adjusted so that when installing the insert in the valve. After placing
the roller just contacts plunger. Check for integrity of mounting the insert in the valve body, depress the exhaust
plate and treadle and/or pedal. check valve seat and install the retaining ring. Make
sure the retaining ring snaps into the body groove.
SERVICE TESTS
Operating Test (IMPORTANT!!! Tests should be DISASSEMBLY
conducted with an accurate test gauge.) NOTE: Disassembly and assembly instructions are keyed
to Fig. 1 sectional view.
Install gauge in a delivery port or line; depress the treadle or
pedal to several positions between fully released and fully 1. Remove treadle or lever assembly, boot and plunger.
applied positions, checking the delivery pressure on the 2. Depress piston assembly and remove retainer (4).
gauge to see that it varies proportionately with the movement 3. Remove piston assembly (7) and piston return spring (2)
of the treadle or pedal. In the fully applied position, the from body.
reading on the gauge should be approximately that of full
4. Remove o-ring (3) from piston (7).
reservoir pressure. Upon release of the application, the
reading of the test gauge should fall to zero psi immediately. 5. Remove cap screw (6), washer (8), spring seat (9),
and rubber spring (10) from piston assembly (7).
Leakage Test
6. Remove retaining ring (1) and inlet/exhaust insert
With 100 psi supply pressure and valve in released position, assembly (11) from body.
coat exhaust port with soapsuds arid check for leakage.
NO leakage permitted.

2
Insert Disassembly Testing A Rebuilt E-2™ or E-3™ Brake Valve
NOTE: It is recommended that entire inlet/exhaust insert Perform operating and leakage tests as outlined in “Service
be replaced as an assembly. Tests” section.
7. Remove o-ring (17) from check valve seat (16).
WARNING! PLEASE READ AND FOLLOW
8. Remove screw (20), washer (19), and diaphragm (18).
THESE INSTRUCTIONS TO AVOID
9. Depress and hold insert, and remove preload spring (21).
PERSONAL INJURY OR DEATH:
10. Remove inlet/exhaust valve (14), valve spring (13), and
o-ring (15). When working on or around a vehicle, the following
11. Remove valve retainer (12). general precautions should be observed at all times.
1. Park the vehicle on a level surface, apply the
Cleaning and Inspection
parking brakes, and always block the wheels.
Wash all metal parts in mineral spirits and dry. Wipe all Always wear safety glasses.
rubber parts clean. 2. Stop the engine and remove ignition key when
working under or around the vehicle. When
Inspect all parts for excessive wear or deterioration.
working in the engine compartment, the engine
Inspect valve and valve seats for nicks and burrs. should be shut off and the ignition key should be
removed. Where circumstances require that the
Check springs for cracks, distortion or corrosion. engine be in operation, EXTREME CAUTION should
Inspect exhaust check diaphragm for flexibility, wear, and be used to prevent personal injury resulting from
deterioration. contact with moving, rotating, leaking, heated or
electrically charged components.
Replace all parts not considered serviceable during these 3. Do not attempt to install, remove, disassemble or
inspections. assemble a component until you have read and
thoroughly understand the recommended
ASSEMBLY
procedures. Use only the proper tools and observe
1. Lightly lubricate the piston, valve bores, and o-rings with all precautions pertaining to use of those tools.
Dow Corning 55-M pneumatic grease (Our piece number 4. If the work is being performed on the vehicle’s air
291126). brake system, or any auxiliary pressurized air
2. Position rubber spring (10) in piston (7). systems, make certain to drain the air pressure from
3. Install spring seat (9), washer (8), and cap screw (6). all reservoirs before beginning ANY work on the
Torque cap screw to 50 inch pounds. vehicle. If the vehicle is equipped with an AD-IS™
air dryer system or a dryer reservoir module, be
4. Install piston o-ring (3) and place piston return spring (2)
sure to drain the purge reservoir.
in body.
5. Following the vehicle manufacturer’s
5. Install piston retainer (4). Be certain the prongs snap recommended procedures, deactivate the electrical
over groove in valve body. system in a manner that safely removes all
Insert Assembly electrical power from the vehicle.
6. Never exceed manufacturer’s recommended
6. Position preload spring (21) in exhaust check valve seat
pressures.
(16).
7. Never connect or disconnect a hose or line
7. Install diaphragm (18), diaphragm washer (19) (with lips containing pressure; it may whip. Never remove a
pointing out), and install screw (20). Tighten screw component or plug unless you are certain all
securely. system pressure has been depleted.
8. Install o-ring (15) and valve retainer (12) on inlet / exhaust 8. Use only genuine Bendix ® replacement parts,
valve body (14). components and kits. Replacement hardware,
9. Install valve spring (13) on exhaust check valve seat (16) tubing, hose, fittings, etc. must be of equivalent
and install inlet/exhaust valve (14) into exhaust valve seat size, type and strength as original equipment and
(16). Press the valve down until the preload spring snaps be designed specifically for such applications and
and holds the assembly together. systems.
9. Components with stripped threads or damaged
10. Install o-ring (17) on exhaust check valve seat (16).
parts should be replaced rather than repaired. Do
11. Place inlet/exhaust insert in valve body; position not attempt repairs requiring machining or welding
identification washer. Press the insert down while unless specifically stated and approved by the
installing retaining ring (1). Make certain retaining ring vehicle and component manufacturer.
snaps into body groove, thus locking in the insert in 10. Prior to returning the vehicle to service, make cer-
place. tain all components and systems are restored to
their proper operating condition.

3
BW1564 © 2004 Bendix Commercial Vehicle Systems LLC. All rights reserved. 3/2004 Printed in U.S.A.