Bendix Commercial Vehicle Systems E-5 BRAKE VALVE 3/04 - Manual (Page 3)

Replace all parts not considered serviceable. It is
recommended that all rubber parts be replaced.
Maintenance Kits containing all necessary detail parts are
available from Bendix outlets. Consult the Bendix catalog
for piece numbers.
ASSEMBLY
Basic E-5 ™ Brake Valve
1. Lightly lubricate body bores, inlet/exhaust valve stem,
o-rings, inlet seat, and piston with Dow Corning 55-M
pneumatic grease (Bendix piece number 291126).
2. Install rubber spring in piston (as shown in illustration);
install seat (with convolution towards rubber spring) on
rubber spring. Install washer and cap screw. Torque
cap screw to 50 inch pounds.
3. Install piston o-ring (11) on piston assembly.
4. Install valve retainer and stem o-ring on inlet/exhaust
valve assembly.
5. Install inlet valve spring (10) in body; install inlet/exhaust
valve assembly (9) in bore of body.
6. Instal o-rings on inlet valve seat (8) and install in body so
tab in seat lines up with its slot in the body.
7. Install piston return spring (7) in inlet seat.
8. Install piston assembly (6); while exerting pressure on
piston, install retainer (5); make certain retainer tabs
snap into place in grooves of body.
Pedal and Mounting Plate
9. Lightly lubricate plunger, plunger bore, fulcrum, roller
pins, and all pedal actuation contact points with
Molybdenum Disulfide grease (Bendix piece number
239378).
10. Install stop button and lock nut in mounting plate.
11. Install rollers on pedal with roller pin, secure pin with
cotter pin.
12. Connect pedal to mounting plate with fulcrum pin (1);
secure fulcrum pin with cotter pin.
13. Install plunger in mounting plate; install pedal cover (3).
14. Attach pedal/mounting plate assembly to valve body with
cap screws (4). Torque cap screws to 80-120 inch pounds.
15. Adjust free pedal travel so that the rollers just contact
the plunger by adjusting the stop button. Tighten lock
nut when adjustment is complete.
Testing Rebuilt E-5 ™ Brake Valve
Perform Operating and Leakage Tests as outlined in “Service
Test” section.
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
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 cer-
tain all components and systems are restored to
their proper operating condition.
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