BENDIX TC-2 User manual

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Figure 1 – Maintenance Kit Contents
BENDIX®TC-2™TRAILER CONTROL VALVE MAINTENANCE KIT
Handle
KnobSpirol PinHead
O-Ring
Head
Head Seal
O-Ring
Head
1
Body
Graduating Spring
6
7
9
5
Inlet Valve Seat
6
Exhaust Port
Supply Port
Delivery Port
4
Cover
83
Piston
10
Cam
Adjusting Ring
Adjusting Ring Lock Washer
Cam Follower
Kit Contents
Item No. Description Qty.
1 O-Ring 1
2 O-Ring 1
3 O-Ring 1
4 O-Ring 1
5 Stem 1
6 Inlet & Exhaust Valve 2
7 Valve Guide 1
8 Spring 1
9 Spring 1
10 Gasket 1
11 Tube of Lubricant 1
11

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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. Block and hold vehicle by means other than the air brakes.
2. Drain the air brake system.
3. If this is a remote-operated type valve, disconnect the
operating mechanism.
4. Disconnect the air lines from the valve.
5. Remove the mounting clamp bolts, clamp, and then the
valve.
DISASSEMBLY
Handle Operated Valve
1. Drive out the spirol pin and remove the handle, head,
and head seal o-ring.
2. Remove the handle o-ring.
3. Remote Operated Type Valve: Remove set screw,
head, and head seal o-ring.
4. Remove the adjusting ring lock washer.
5. Remove the cap screws that hold the body and the cover
together; separate the cover from the body.
6. Remove the gasket and the graduating spring.
7. Remove the cam and cam follower from the cover.
8. Unscrew and remove the adjusting ring.
9. Remove the piston and piston return spring from the
body.
10. Remove the piston o-ring.
11. Remove the inlet and exhaust insert screws and lock
washers, then insert the o-ring seal.
12. Insert some object – such as a cap screw – in the supply
port to hold the inlet valve on its seat.
13. Depress the exhaust valve guide and spring; remove
the exhaust valve.
14. Remove the stem with the inlet valve from the inlet seat
and remove the inlet valve from the stem.

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ASSEMBLY
Prior to assembly, lubricate the body and cover bores, cam
and cam follower, piston o-ring, and cover top with Dow
Corning®55-M pneumatic grease (Bendix piece number
291126).
1. Press inlet valve on stem. A little water in the boot
valve or some soap on the stem will make it easy to
press on the inlet valve.
2. Place stem with inlet valve installed in the inlet seat.
Insert some object – such as a cap screw – to hold
the inlet valve up against its seat.
3. Position the spring and the exhaust valve guide.
4. Depress the guide and the spring, then press the
exhaust valve on the stem.
5. Place the seal o-ring over the insert seat. Install the
inlet and exhaust insert in the body, securing with cap
screws and lock washers. Recommended torque on
the insert cap screws is 60 to 80 in-lbs.
6. Install the piston return spring.
7. Install the piston o-ring on the piston and install the
piston in the body.
8. Install the adjusting ring in the cover and screw it down
until it is ush with the top of the cover.
9. Place the cam follower and cam in the cover.
10. Position the graduating spring and gasket in the body.
11. Connect the body to the cover; tighten the cap screws
evenly and torque to 75-95 in-lbs.
12. Install the adjusting ring lock washer, head seal o-ring,
and head.
13. Install the set screw in the head of the remote-operated
type valves.
At this stage, before installing the handle and the spirol pin
of the handle-operated type valve, if facilities are available,
the rebuilt valve should be tested and adjusted. If facilities
are not available, the valve can be tested on the vehicle.
ADJUSTABLE
Generally, the Bendix®TC-2™Brake Valve should deliver
full reservoir pressure; however, there are a few exceptions
in special applications.
1. If the delivered pressure is below the specied nal
delivery pressure, it can be adjusted by removing the
head and adjusting the ring lock washer and rotating the
adjusting ring clockwise to raise the delivery pressure.
Care should be taken not to raise the delivery pressure
beyond the design limits; exhaust opening could be
restricted.
2. If the delivery pressure is above the specied nal
delivery pressure, it can be lowered by rotating the
adjusting ring counterclockwise.
A spanner wrench can be used to rotate the adjusting ring,
but if this wrench is not available, the adjusting ring can
be turned with a small screwdriver inserted in one of the
inner notches of the ring. Turning the adjusting ring one
notch will raise the delivered pressure approximately 5 psi.
INSTALLATION
1. Check and clean the air lines to the valve.
2. The operating mechanism for remote type should be
checked for functionally and for proper adjustment.
3. Mount the valve with clamp and mounting bolts.
4. Tighten the mounting bolts evenly to approximately 200
in-lbs torque (3/8-16 Bolt torque 180-220 in-lbs).
5. If remote type valve, connect the operating mechanism.
OPERATING TEST
Connect an accurate test gauge to a delivery port. When
the handle is moved to the fully applied position, the gauge
should register full reservoir pressure.
Note: Some valves may be preset to deliver lower than
reservoir pressure; however, the standard valves
generally used on tractors are set to deliver full
reservoir pressure.
Intermediate positions should deliver proportionate
intermediate pressure. Upon release, the gauge should
immediately register zero.
LEAKAGE TEST
Locate the exhaust port or the exhaust line and apply a
soap solution. (It is common practice to connect a line
from the valve exhaust port to a location remote from the
immediate driver's area.) With the valve in the released
position, exhaust leakage should not exceed a 1 inch bubble
in 5 seconds (100 sccm).
With the valve fully applied, leakage at the exhaust should
not exceed a 1 inch bubble in 3 seconds (175 sccm).

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S-0170 Rev. 002 © 2019 Bendix Commercial Vehicle Systems LLC, a member of the Knorr-Bremse Group • 10/19 • All Rights Reserved
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