Assembly and maintenance instructions for mechanical
Contents
1. Fig 13 N WABCO Mechanical Sliding Calliper Disc Brake PAN 19 1 plus Checking the dust caps gaiters and the brake calliper movability e Slide the calliper towards the side to allow examination of the gaiters 5 10 the guide pins 8 9 and the adjuster screw 21 for wear and damage Renew all defective gaiters according to section 5 1 and 5 2 Caution In case of a defective gaiter 10 check whether dirt or water has already entered or damaged the inner parts of the brake or the gaiter seat in the calliper by corrosion In case of doubt the brake must be renewed according to section 4 If the gaiter 10 is damaged while the brake is serviced the gaiter must be renewed according to section 5 2 Fig 15 Slide the calliper on the guide pins by hand over its total displacement and check for freedom of movement If the movement is restricted renew the guide pin bushes and gaiters according to section 5 1 Caution Do not squeeze the dust caps of the guide pins against the brake carrier Fig 16 Checking the adjuster unit clamping unit e Prevent the adjuster screw from turning during the test and while rotating on the adjuster hexagon by e g holding the pin fig 17 WABCO n PAN 19 1 0 e Extend the adjuster 22 towards the brake disc by turning the adjuster hexagon anti clockwise with a ring spanner and check for ease of movement After checking the adjuster unit ret2. e Clean the mating surfaces collars of the carrier 2 Fig 37 e Withdraw the guide pins 8 9 and remove the gaiters 5 from the calliper 1 Place the calliper 1 on a firm base to push out the bushes 4 so that the calliper opening is facing upwards e Press the bushes 4 out of the calliper 1 using a mandrel Clean the bores in the calliper WABCO gt PAN 19 1 plus Mechanical Sliding Calliper Disc Brake Work sequence for installation Note Clean gaiter seats before fitment The sealing seats must be free of grease It is possible to fit the gaiters by hand Ensure that the gaiters are fitted evenly into the seats in the brake calliper Press in two new bushes 4 for the longer guide pin 8 Firstly A fit the inner bush with the special fitting tool L and secondly B the outer bush with the special fitting tool L by pressingin as far as the mandrel will go Use special fitting tools from WABCO case no 12 851 021 Grease the bushes and the space between them Press in new bush 4 for the shorter guide pin 9 Fit the bush C with special fitting tool L by pressing in as far as the mandrel will go Use special fitting tools from WABCO case no 12 851 021 Grease the bush c Fig 42 Fit new green gaiters 5 in the gaiter seats ring groove arrow in the brake calliper 1 Fig 43 20 WABCO Mechanical Sliding Calliper Disc Brake PAN
3. maximum wear X Y gt 122 mm Change lining WABCO d PAN 19 1 Mechanical Sliding Calliper Disc Brake 2 4 Checking brake disc Work sequences Remove brake pads according to section 3 and measure the thickness of the disc in the contact area of the brake pads C total disc thickness new 45 mm D wear allowance limit 37 mm the brake disc must be renewed The renewal is recommended on a per axle basis E total pad thickness new 30 mm F pad backplate thickness 9 mm minimum residual friction material thickness 2 mm H absolute minimum pad thickness 11 mm the brake pads must be renewed Caution Observe brake pad and disc wear limits Worn out pads and discs reduce the brake effectiveness and cause brake failure Danger of accidents 3 Renewing brake pads Caution Do not use a power driven socket While working at the brake or moving of the brake calliper handle the calliper only from outside to avoid injury Work sequences for removal of pads e Disconnect cable of the wear indicator 40 at the plug arrow e Remove hexagon bolt 39 with spanner AF 17 table 1 position II from pad hold down hoop 38 S Y SU SN IER KA Y 9 g Y SI SNS A Y SS SESS N Fig 7 Fig 8 8 WABCO Mechanical Sliding Calliper Disc Brake PAN 19 1 plus e Pad hold down hoop 38 has to be withdrawn from the calliper 1 Fig 9 e Remove three ho
4. Mechanical Sliding Calliper Disc Brake PAN 19 1 2 Service Instructions This instruction with the following pictures contains the required steps and work sequences to replace the available repair kits The spanner size and the tightening torques in the sequneces are listed in table 1 see page 26 For lubrication use only the tube of grease supplied with the brake repair kit 2 1 Safety tips to be considered during repair The flawless technical condition of the disc brake is most important to ensure good driving and safe braking characteristics A Observe brake pad and disc wear limits Worn out pads and discs reduce the brake effectiveness and cause brake failure Danger of accidents Burned glazed or oil contaminated brake pads must be replaced immediately Always replace brake pads on a per axle basis A During repairs on the brake the vehicle must be parked on a level surface and be blocked to prevent rollaway Only approved and suitable fixtures are to be used for the lifting and blocking of the vehicle While working on the brake it must be ensured that the brake cannot be actuated inadvertently Do not actuate the brake while the brake pads are removed Danger of bodily injury A Do not clean the brake with pressurised air or other high cleaning pressure apparatus Danger of bodily injury Keep hands and fingers out of the inside of the calliper to avoid injury A second technican must assist duri
5. 19 1 plus e Grease the sliding surfaces of the guide pins 8 9 and the inner lip of the gaiters 5 Insert the new guide pins from the cylinder side into the calliper 1 and e push gaiter 5 against its guide pin seat 8 9 e Move guide pins backwards and forwards as shown in figure 44 several times Check for ease of movement Caution The longer guide pin 8 is a close fit and is located at the brake disc leading side The shorter guide pin 9 is a clearence fit and is located at the brake disc trailing side Remove all excess grease The brake carrier end of the guide pins arrow and the mating surfaces of the carrier must be free of grease Do not lose the metal ring on gaiter 5 and check for proper seat right side in fig 44 e Place the calliper 1 on the carrier 2 and insert the guide pins 8 9 into the collars in the carrier e Insert new bolts 6 long for close fit pin 8 7 short for clearence fit pin 9 into the guide pins in the brake calliper 1 e Screw bolts to the brake carrier 2 with spanner table 1 position IV Caution On assembly ensure that the gaiters 5 are not damaged or twisted during tightening the bolts Firstly tighten the bolt for the close fit longer pin 8 followed by the bolt for the clearance fit shorter pin 9 If during the maintenance work the guide pin 8 9 fastening to the carrier 2 is loosened then new bolts 6 7 must be used
6. drainage hole facing the ground is open All other holes must be plugged Fig 34 WABCO we PAN 19 1 plus Mechanical Sliding Calliper Disc Brake 5 Renewing gaiters Caution Do not use a power driven socket While working at the brake or moving of the brake calliper handle the calliper only from outside to avoid injury Note When replacing all of the gaiters in the calliper the work sequences 5 1 and 5 2 are to be combined In this case work sequences need not to be repeated sev eral times When replacing individual gaiters follow the corre sponding work sequences of the seccions 5 1 and 5 2 5 1 Renewing guide pin gaiters and bushes Work sequences for removal Remove brake pads according to section 3 Remove brake cylinder from brake calliper according to section 6 e Dismantle the calliper with the carrier from the axle according to section 4 Fig 35 e Dismantle brake calliper 1 from brake carrier 2 by removing short and long caps 11 11 1 from the guide pins 8 9 in the calliper housing with a suitable tool e g chisel Caution Take care not to damage cover bores in housing The proper tool position is against the cover 1 WABCO Mechanical Sliding Calliper Disc Brake PAN 19 1 plus e Release the bolts 6 7 with a male socket table 1 position IV and separate the calliper 1 from the carrier 2 Caution Moving brake calliper Danger of bodily injury
7. when reasssembling Fig 45 WABCO ee PAN 19 1 plus Mechanical Sliding Calliper Disc Brake Move brake calliper backwards and forwards on guide pins 8 9 several times Check for ease of movement Caution Do not squeeze guide pins dust caps against brake calliper e Lubricate the bores for the caps 11 11 1 in the brake calliper 1 e Place new caps 11 11 1 in the bores of the brake calliper and press in with a suitable tool Note Fit the long cap 11 1 on the longer guide pin 8 Take care to avoid damaging the covers e Mount brake over the brake disc on the axle according to section 4 Note Special assembly instructions of the vehicle manufacturer have to be noted e Install brake pads and set clearence Carry out according to section 3 and pay attention to notes Before refitting the brake cylinder clean the sealing surface on the calliper and grease the concave seat arrow in the brake lever e Refit the brake cylinder on the calliper according to section 6 Caution With the brake cylinder in its installed position ensure that the lower drainage hole facing the ground is open All other holes must be plugged Fig 46 Fig 48 ae WABCO Mechanical Sliding Calliper Disc Brake PAN 19 1 plus 5 2 Renewing adjuster screw gaiter Note If the gaiter only is to be renewed it is not necessary to dismantle the brake calliper and cylinder Work sequences for remo
8. 63 3 No part of this publication maybe reproduced stored in a retrieval system or transmitted in any form or by any means electronic photocopying recording or otherwise without permission in writing from WABCO WABCO 3 PAN 19 1 0 Mechanical Sliding Calliper Disc Brake 1 Description of the mechanical sliding calliper disc brake 1 1 Introduction The brake PAN 19 1 plus is a new developed one piston brake which is intended for use in commercial vehicles and trailers on front and rear axles for 19 5 or 22 5 wheel rims as service auxiliary and parking brake It is actuated mechanically via a diaphragm brake cylinder or a spring brake cylinder This cylinder is mounted to the end cover of the brake calliper A very compact unit is achieved by the direct mounting of the brake cylinder onto the calliper This enables optimal utilisation of the installation situations The complete disc brake including brake cylinder consists of two assemblies Brake calliper 1 Brake Carrier 2 The radially open design of the brake calliper allows a simple and quick change of the brake pads Brake pads with a large wear volume are used in order to prolong the pad replacement intervals with this brake The internal moving components are lubricated for life and all sealing components are maintenance free unless damaged The disc brake is equipped with an electrical wear indicator 40 Fig 1 a WABCO
9. ake calliper handle the calliper only from outside to avoid injury Note The new brake is supplied as a pre assembled unit and may be mounted to the vehicle s axle via brake carrier Pay attention to the correct mounting side in the vehicle directed forward left brake left vehicle side right brake ricght vehicle side The removed brake pads must be tested for wear according to section 2 3 If the use of new brake pads is necessary the renewal is recommended on a per axle basis Work sequences for brake removal Remove brake pads according to section 3 Remove brake cylinder from brake calliper according to section 6 e Dismantle the calliper with the carrier from the axle table 1 position III e Check brake disc according to section 2 4 Fig 31 1 WABCO Mechanical Sliding Calliper Disc Brake PAN 19 1 plus Work sequences for installing brake e Place the new brake with the brake carrier over the brake disc and mount on the axle Thighten hexagon bolts with spanner table 1 position III Note Special assembly instructions of the vehicle manufacturer have to be noted Fig 32 e Remove the transport protection cap from the cylinder flange on the brake calliper Fig 33 e Refit brake pads and spreader plate according to section 3 e Refit the brake cylinder on the calliper according to section 6 Caution With the brake cylinder in its installed position ensure that the lower
10. ection 4 Fig 4 WABCO Mechanical Sliding Calliper Disc Brake PAN 19 1 Fig 5 Pi Fi Ge Friction material 2 3 Checking brake pads Note The brake pad thickness needs to be checked regularly depending on operating conditions during maintenance intervals and under applicable local laws and regulations Burned glazed or oil contaminated brake pads must be replaced immediately Always replace brake pads on a per axle basis Work sequences Caution To avoid damage to the brake disc the brake pads should be replaced at the latest when the thinnest section of the friction material is 2 mm The thickness of the residual friction material should not be less than 2 mm A residual friction material thickness 2 mm B total friction material thickness 21 mm At residual friction material thickness A lt 2 mm renew brake pads according to section 3 Measuring of wear The average brake pad wear can be measured depending on the access at the close fit longer guide pin at the brake disc entry or at the clearence fit shorter guide pin at the brake disc exit Therefore measure the thickness X of the flange of the axle and the distance Y between the flange and the edge of the brake calliper of the particular close fit arrows The maximum wear is reached or exceeded wtih the following values Shorter guide pin maximum wear X Y gt 95 mm Change lining Longer guide pin
11. ere is sufficient space between the actuation side and the disc to insert the brake pad e Insert spreader plate 19 in the brake carrier and engage with the adjuster screw 21 Caution The spreader plate must be located within the brake carrier guidance and the pin of the adjuster screw must be located in the slot of the spreader plate Otherwise the function of the adjuster mechanism is not ensured The adjuster screw can be turned to obtain alignment The gaiter may not be twisted e New brake pad 36 has to be inserted on the actuating side Slide the calliper toward the wheel until the brake pad 36 contacts the disc New brake pad 35 has to be inserted on the wheel side e Using a 1 mm thick feeler gauge arrow inserted between the backing plate of the brake pad on the wheel side and the brake calliper turn the hex nut 22 of the adjuster screw with a closed end wrench until both brake pads contact the brake disc Caution Do not overload the adjuster hexagon 22 Note The turning direction to adjust the break is to the left that means anti clockwise Do not fit pad hold down hoop before adjusting clearance WABCO i PAN 19 1 plus Mechanical Sliding Calliper Disc Brake e Fit new cable clips 41 to the brake calliper e Install new pre assembled wear indicator and the cable guide 40 and insert sensor contact into the brake pads Caution The sensor contacts must be pointed in the di
12. he concave seat arrow in the brake lever e Fit brake cylinder and tighten nuts with spanner table 1 positionV e Reconnect brake hose to brake cylinder according to cylinder manufacturer s data Note The brake hose must not be twisted or located such that it will rub against anything The brake hose of the air supply is not allowed to have an influence on the movability of the brake calliper Test air connection for leaks according to cylinder manufacturer s data Carry out function and effectiveness tests according to cylinder manufacturer s data WABCO PAN 19 1 Mechanical Sliding Calliper Disc Brake Table 1 Tightening torques id Spanner width Hexagon Tightening Torque Position AF N AF External Internal Nm Turning direction of the hexagon Adjust anti clockwise left maximum 3 clearance decreases I 8 x De adjust clockwise right maximum 12 clearance increases Caution Do not use a power driven socket ll 17 X 30 15 290 20 recommended 111 24 x Please note the special assembly instructions of the vehicle manufacturer 310 30 Tightening order for guide pins IV 14 1 Close fit pin long internal hexagon bolt 2 Clearence fit pin short internal hexagon bolt V 24 210 30 ae WABCO Notes WABCO 4 Notes ae WABCO
13. ld down springs 37 from the brake pads 35 and 36 and the spreader plate 19 e Remove cable guide 40 and contacts from the brake pads e Both cable clips 41 have to be removed from the brake calliper Fig 10 Remove plug 12 for the adjuster 22 of the calliper 1 carefully Caution While disassemblying plug 12 please note the instructions for fig 2 e De adjust the brake by rotating the hexagon on the adjuster nut 22 with a ring spanner then release by approx 1 4 turn Note The turning direction to de adjust is to the right that means clockwise Fig 11 WABCO 3 PAN 19 1 plus Mechanical Sliding Calliper Disc Brake Caution When re adjusting push back the spreader plate 19 by hand to ensure that the pin as torsion lock fig 17 for the adjusting screw does not slip out of its groove Otherwise the adjuster screw might turn thereby damaging its gaiter e Slide the calliper 1 by hand towards the wheel side and remove the brake pad 35 e Slide the calliper 1 by hand towards the wheel side and remove the brake pad 36 and the spreader plate 19 Caution Do not actuate the brake while the brake pads are removed Danger of bodily injury e Using a wire brush remove any corrosion from the spreader plate brake pad slot and brake pads guide surfaces Caution Take care not to damage the dust caps 5 10 The guide surfaces must be free of grease Fig 12
14. m Assembly and Maintenance Instructions Mechanical Sliding Calliper Disc Brake Type PAN 19 1 m 1 Edition This publication is not subject to any update service New versions are available in INFORM at www wabco auto com p Copyright WABCO 2006 WABCO Vehicle Control Systems An American Standard Company The right of amendment is reserved Version 001 10 03 en 815 010 063 3 Table of contents 6 Description of the mechanical sliding calliper disc brake 1 1 Introduction Service instructions 2 1 Safety tips during repair 2 2 Checking brake function 2 2 1 Checking adjuster function 2 3 Checking brake pads 2 4 Checking brake disc Renewing brake pads Renewing brake Renewing gaiters 5 1 Renewing guide pin gaiters and bushes 5 2 Renewing adjuster screw gaiter Renewing brake cylinder Table 1 Spanner widths AF and tightening torques Nm Note The Service Instruction focuses on trained specialists Operations on the brake can only be carried out if the appropriate paragraphs have been read through and understood The safety instructions according to paragrahph 2 1 are to be considered and to be followed These Service Instructions are copyright All rights reserved This publication is not subject to any update service You will find the latest versions in Page gt 0 NO 01 A WO 16 18 18 23 25 26 INFORM under www wabco auto com when quoting the publications number 815 010 0
15. nd the torques for the hexagon on the adjuster nut are given in table 1 position I Work sequences e Remove plug 12 for the adjuster from the calliper 22 carefully Caution On disassembly the proper tool position is against the plug 12 left side in fig 2 Do not place the tool between calliper and outer side of the sealing ring otherwise the inner sealing might be damaged right side in fig 2 e Using a AF 8 ring spanner table 1 position I turn the adjuster 22 hexagon approx 1 2 turn clockwise Caution Do not overload the adjuster hexagon Do not use an open ended spanner With the ring spanner mounted on the adjuster nut ensure that there is sufficient space soit will not be prevented from turning during the adjuster check e Actuate the brake about approx 5 times apprx 1 bar The adjuster is functioning when the ring spanner arrow turns anti clockwise with every brake actuation Note With increasing adjustment increments the angular movement of the ring spanner becomes smaller The adjuster is in order when the ring spanner rotates as described above e Remove ring spanner e Refit plug 12 and ensure that the plug is placed properly Failures that might occur If the adjuster 22 respectively ring spanner arrow a does not turn b turns only with the first actuation c turns forward and backward with every actuation the adjuster is not ok Change the brake according to s
16. ng removal and installation of the brake Heavy load Danger of bodily injury During repairs outside of the vehicle the brake must be secured in a fixture such as a heavy vise as high torque is required during removal and installation of the bolts Danger of bodily injury A A The brake calliper with clamping unit shall not be opened Therefore the bolts holding the cover shall not be loosened Only original and genuine WABCO service parts and approved brake pads are to be used During repairs use only recommended tools Do not use a power driven socket or tools Tighten nuts and bolts only to specified torque limits With newly installed brake pads on the first 50 km no emergency stops should be made Also avoid long braking cycles and forced brakings When wear of the cast brake parts such as cracks or heavy abrasion is noticied replace the entire brake assembly according to the instructions Upon completion of repairs the vehicle s braking system must be tested on a roller dynamometer If no roller dynamometer is available a driving test with brake applications must be perfomed 2 2 Checking Brake Function Caution Do not use a power driven socket While working at the brake or moving of the brake calliper handle the callipercalliper only from outside to avoid injury WABCO PAN 19 1 plus Mechanical Sliding Calliper Disc Brake 2 2 1 Checking adjuster function General note The turning directions a
17. rection of the break disc and the contacts must be properly seated e Raise cable guide 40 e place three new hold down springs 37 under the cable guide and on top of the spreader plate and the brake pads Caution Lay cables on the actuation side so that they are not located on the brake pad see cable position in fig 25 e Then push cable guide against the hold down springs and position on brake calliper WABCO Mechanical Sliding Calliper Disc Brake PAN 19 1 plus e Insert new pad hold down hoop 38 in the holes arrows of the brake calliper and then push downward so that the radial corners of the hold down springs snap into the hold down hoop Note The hoop has to be installed above the cables of the wear indicator Fig 27 e Fit new hexagon bold 39 to the brake calliper table 1 position II with required tightening torque e Connect wear indicator cable plug to mating end on vehicle side e Secure exit cable on new cable clip 41 Fig 28 e Check the correct cable position Fig 29 WABCO X PAN 19 1 plus Mechanical Sliding Calliper Disc Brake e Fit new plug 12 to the opening in the brake calliper Check and make sure the correct seat e Check that the hub rotates freely Caution Upon completion test the brakes on the roller dynamometer 4 Renewing brake Caution Do not use a power driven socket While working at the brake or moving of the br
18. t in the calliper 1 Fit gaiter 10 into ist seat of the adjuster screw 21 Lubricate gaiter lip to ease insertion Note Ensure that the gaiter lip in the annular groove in the adjuster screw sits free of folds 21 Fig 54 e Install brake pads and set clearence Carry out according to section 3 and pay attention to notes WABCO Mechanical Sliding Calliper Disc Brake PAN 19 1 plus 6 Renewing brake cylinder Caution Do not use a power driven socket While working at the brake or moving the brake calliper handle the calliper only from outside to avoid injury Note Only use cylinders as specified by vehicle manufacturer The following work sequences only inform in principle about the assembly and disassembly of the brake cylinder Detailed assembly and check instructions have to be used according to the cylinder type and the instructions of the cylinder manufacturer Work sequences for removal Make sure that the brake hoses are pressureless e Disconnect air line to cylinder according to cylinder manufacturer s data e Remove brake cylinder from calliper by releasing cylinder nuts table 1 position V Work sequence for installation Caution With the brake cylinder in its installed position ensure that the lower drainage hole facing the ground is open All other holes must be plugged Before refitting the brake cylinder clean the sealing surface on the calliper and grease t
19. urn the adjuster screw completely by turning clockwise Note The torque to return the adjuster screw is greater than the torque to turn it towards the disc Caution Do not overload the adjuster hexagon Do not use an open ended spanner With the ring spanner mounted on the adjuster nut ensure that there is sufficient space so it will not be prevented from turning during the adjuster check e Actuate the brake lightly several times and check that the adjuster unit automatically adjusts The ring spanner will turn with every brake actuation Brake disc condition inspection Check brake disc for cracks condition of the rubbing faces and maximum wear dimension A crazing permissible B Radial cracks to max 0 5 mm width permissible C unevenness under 1 5 mm of the plate surface permissible D continuous cracks not permissible a braking surface Checking brake disc runout Mount a dial indicator on the brake carrier e With the disc installed measure the runout by rotating the hub as shown in fig 20 Limit 0 15 mm Note At higher values rework or renew the disc Installation of cleaned brake discs only The brake discs must be free of grease Mechanical Sliding Calliper Disc Brake Fig 19 Fig 20 2 WABCO Mechanical Sliding Calliper Disc Brake PAN 19 1 plus Fig 21 Fig 22 Fig 23 Work sequence for pad installation e Slide the calliper until th
20. val Remove brake pads and spreader plate according to section 3 Fig 49 e Pull brake calliper to actuation cylinder side by hand e Pull the gaiter 10 out of the annular groove in the adjuster screw 21 e Remove the gaiter from the seat in the brake calliper by means of a screwdriver e Check the adjuster screw thread Note For this purpose refit the wheel side brake pad so that the adjuster screw cannnot be screwed completely out of the adjuster After the thread check remove the brake pad Fig 51 WABCO PAN 19 1 plus Mechanical Sliding Calliper Disc Brake e Secure adjuster screw 21 against turning arrow fig 51 and screw out the adjuster screw approx 30 mm by turning the adjuster hexagon anti clockwise with a ring spanner Examine the thread for corrosion and damage whilst screwing out Caution The gaiter 10 can be renewed if definitely no dirt or water has penetrated into the brake calliper or if the gaiter has been directly damaged during servicing the brake In case of doubt the brake must be replaced according to section 4 if internal parts are corroded After examination grease the thread and partly screw back the adjuster screw clockwise Work sequence for installation Clean the gaiter 10 seat arrow in the calliper e Push the new gaiter 10 over the adjuster screw Centralise the fitting tool on the gaiter 10 and press the gaiter into the sea
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