Bendix Air Disc Brake Manual
Contents
1. Pad nner 22 58 Boot 9 7 Assembly Ring Guide Inner Seal Stass Bushing Caliper Pin 40 Top Secti I Vi F Caliper Bolt Top Sectional View L 10 Cover 23 Adjuster Unit 161 Tappet Bushing J ARRAS SSN JA mi aaa i 32 16 8 Nib Chain 61 Threaded Tube a a mee Shear Adapter 13 Tappet and Boot Assembly Jad aaa i k Ja C LOT a 4 45 Washer mao j I 26 Ea Li La 37 Spring Cli ko ago aaa Hg Adjuster Cap 44 AE La Al aag 8 27 Sprin Pad Retainer Pin a 1 Jp a g NG Ba 30 11 DL LI Chain PadRetainer pe ok es i pal nu 17 a 1 EEE Bridge Po Wear Sensor Ji Nga 22 Caliper Bolt B AY Inner j Uses Solid Rubber Bushing Tj Ak Nga E pr il N I Z i Device 4 J KA I tag Ji ete 68a C rss IS N 68a Cap a T cii A A 39b 161 E ge 6a 39a Ly Guide Pi Caliper Bolt 46 Tappet AN Dia Caliper Bolt 7 Ha a pi Bushin J 4a Bushing Threaded Tube g Guide One of Three NW Rubber 13 2 Pin Alternate Bushing Tappet Carrier Caliper Bolt and Boot HIN Styles Used Assembly ee KAEN 2 6c Guide SI p Main Diagram shows Caliper Bolt A Aa e gt jii i Uses Flexible Rubber Wear Uf Caliper Bolt C Indicator Sleeve AA Has2. Bendix Spicer Foundation Brake LLC Bendix ADB 22X ADB 225 SN6 SN7 SK7 Air Disc Brakes DESCRIPTION Bendix Air Disc Brakes use a floating caliper design to provide foundation braking on all axles of heavy commercial vehicles buses and trailers Bendix Air Disc Brakes provide safety and performance as well as ease of service Available in models with or without a combination spring brake unit these brakes may also include optional wear sensors and or wear diagnostic equipment OPERATION Bendix Air Disc Brakes convert air pressure into braking force See Figure 2 When the vehicle brakes are applied air enters the service brake chamber through the supply port applying pressure within the diaphragm The pressure expands the diaphragm applying force to and moving the pressure plate and pushrod forward The pushrod acts against a cup in the internal lever which pivots on an eccentric bearing moving the bridge Moving against a return spring the bridge transfers the motion to two threaded tubes and tappets which move the inner brake pad The inner brake pad from its normal position of having a running clearance between it and the rotor moves into contact with the brake rotor Further movement of the bridge forces the caliper sliding on two stationary guide pins away from the rotor which pulls the outer brake pad into the rotor The clamping action of the brake pads on the rotor applies braking forc
3. Brake Pad Assembly FIGURE 32 BRAKE PAD REMOVAL 1 fully to the outboard position first Similarly to remove the inboard pad first move the caliper fully to the inboard position and then remove the pad See Figure 32 Inspect the rotor See Page 13 for full information PAD INSTALLATION CAUTION When replacing brake pads take care to always use the correct replacement pads For example note that two thicknesses of backing plate are generally available to maintain vehicle within spec s only use brake pads with the type of backing plate and lining material originally supplied by the vehicle manufacturer See the manual supplied with the vehicle for further information As noted above Bendix strongly recommends that when replacing brake pads pads are replaced as an axle set Use only pads which are permitted by the vehicle manufacturer axle manufacturer and or disc brake manufacturer Failure to comply with this may invalidate the vehicle manufacturer s warranty Check that the tappet and boot assemblies have been fully retracted as outlined above Clean the brake as needed see the vehicle manufacturer s recommendations To install the outboard brake pad 12 slide the caliper 1 fully to the outboard position before inserting the pad with the brake lining material facing the rotor Similarly to install the inboard pad move the caliper fully to the inboard position and then install the brake pad with the
4. Guide Pins Guide Sleeve Adjuster Cap Adjuster Unit Pad Holder Spring Caliper Bolt 39a 39b 39c 40 Carrier Pad Assembly Pad Retainer Caliper Bolt B Caliper Bolt Guide Pin Rubber Bushing Caliper Bolt C Caliper Bolt Guide Pin AIR DISC BRAKE IDENTIFICATION ROTOR IDENTIFICATION To determine which version of the Bendix air disc brake is Certain maintenance inspection procedures depend on installed locate the identification label near the guide pin the type of rotor installed See Page 13 See below for housing See below for examples of the different styles of examples of the different styles of rotor in use label you may find nventional Rotor FIGURE 6 PART NUMBER LABEL LOCATION Bendix Bendix Part No ug Serial No XXXXXXXXXX Oe JA XXXXXXXXXX number Some air disc brakes carry the Knorr Bremse label shown below OI KNORR BREMSE FIGURE 8 ROTOR IDENTIFICATION XXXXX XXXXXXXX Axle or Vehicle Type of XXXXXXXXXX Manufacturer s No Caliper X XXXX XXXX Date of Manufacture FIGURE 7 PART NUMBER LABEL FIELDS 104 104 Cable Protection TB Cable Protection Plate Pi 2 101 101 og V Sensor Sensor A 105 lt a Cable Guide 105a Cable Guide Cable to Electrical Cable Protection Alternative to male REA Item 105 101 s3 ian Pad Retainer Type 2 Sensor 7 Sensor w K Cable Guide Dn Sensor N S N 11 Pad Retainer a oo Set Cable to Electrical Supp
5. lining material facing the rotor See Figure 30 Install new in pad wear indicator kit if appropriate see Pages 20 21 Using a box end wrench or socket turn the shear adapter 61 clockwise until the pads come into contact with the rotor Then turn back the shear adapter counter clockwise two clicks to set the initial running clearance Note Use only pads with the same backing plate thickness as originally specified for the vehicle s brakes Note The Bendix air disc brakes covered by this service manual use more than one pad retainer design Be sure to install the correct part number for the vehicle After installing the pad retainer 11 supplied with the kit into the groove of the caliper 1 it must be depressed to enable the insertion of the pad retainer pin 44 Install the supplied washer 45 and spring clip 26 to the pad retainer pin 44 It is recommended that the pad retainer pin 44 be installed pointing downwards see Figure 35 Apply and release the brake and then check that the hub turns easily by hand Lightly grease and install a new adjuster cap 37 using white lithium based grease Note The tab of the adjuster cap should be positioned as shown by the arrow in Figure 34 for ease of access Re install the wheel according to the vehicle manufacturer s recommendations Note Not all wheels and or valve stems are compatible with Bendix Air Disc Brakes Use only wheels and valve stems approved by
6. radial cracks are only acceptable if they are less than 0 04 in 1 0 mm deep or wide and if they are less than 75 of the width of the rotor contact area i e 75 of dimension a Circumferential Grooves as in Area C are acceptable if less than 0 06 in 1 5 mm deep are not acceptable for either type of rotor In addition follow the recommendations of the vehicle manufacturer An axle should only have either spline or standard rotors NS TIS N FIGURE 22 EXAMPLES OF ACCEPTABLE AND NON ACCEPTABLE ROTOR CRACKS AND GROOVES 13 2 CALIPER RUNNING CLEARANCE CAUTION Follow all standard safety procedures including but not limited to those on page 2 of this service manual See the vehicle manufacturer s recommendations When working on foundation brakes be sure that the vehicle is on level ground that the vehicle is parked by other means than the foundation brakes and that the wheels are chocked CALIPER MOVEMENT TEST Remove the wheel With the spring brakes caged push the caliper assembly inboard on its guide pins Using a suitable tool press the inboard pad 12 away from the tappets and check the gap between the tappet and the inboard pad backplate it should be between 0 024 in 0 6 mm amp 0 043 in 1 1 mm If the movement is within the range there is no need to inspect further CAUTION If the clearance is too wide there is a danger of brake failure If the clearance is too
7. Less Than 1 18 in 30 mm FIGURE 30 TAPPET EXTENSION LIMIT After re installing a wheel according to the vehicle manufacturer s recommendations please ensure that there is sufficient clearance between the tire inflation valve stem the caliper and the wheel rim to avoid damage WARNING Not all wheels and valve stems are compatible with Bendix Air Disc Brakes Use only wheels and valve stems approved by the vehicle manufacturer to avoid risk of valve stem shear and other compatibility issues 17 MAINTENANCE PROCEDURES PAD REPLACEMENT CAUTION Follow all standard safety procedures including but not limited to those on page 2 of this service manual See the vehicle manufacturer s recommendations When working on foundation brakes be sure that the vehicle is on level ground that the vehicle is parked by other means than the foundation brakes and that the wheels are chocked When installing pads where appropriate use heavy duty gloves and always keep fingers away from potential pinch hazard areas As noted earlier Bendix Air Disc Brakes are precision engineered braking mechanisms The friction couple braking characteristics have been carefully optimized and the rotor design and materials have been matched with special formulation brake pads for optimal performance PAD REMOVAL Bendix strongly recommends that when replacing brake pads pads are replaced as an axle set Release or cage spring brakes and
8. approved replacement disc pads can cause excess wear to brake components and can increase the risks of rotor cracking etc Note that two thicknesses of backing plate are generally available so to maintain the vehicle within spec s only use brake pads with the type of backing plate and lining material originally supplied by the vehicle manufacturer See the manual supplied with the vehicle for further information INSPECT BRAKE PADS Regular inspection of the brake pads even for vehicles that use a wear indicator is an important part of vehicle maintenance See Figure 16 If the thickness of the friction material M2 is less than 0 079 in 2 mm the pads must be replaced Bendix ADB 22X ADB 225 SN6 SN7 and some SK7 air disc brakes use 0 35 in 9 mm backing plates so P2 the combined pad and backing plate thickness must be a minimum of 0 43 in 11 mm Note that for some Bendix SK7 air disc brakes a 0 28 in 7 mm backing plate is used so P2 the combined pad and backing plate thickness must be a minimum of 0 35 in 9 mm If the pad thickness is within the acceptable range inspect the pad surface Minor damage at the edges is permitted see Figure 20 but replace the pads if major damage on the surface of the pad is found see Figure 21 When replacing brake pads Bendix strongly recommends that all the brake pads on an axle be replaced at one time See pages 18 19 for the pad replacement p
9. plug refer to the vehicle manufacturer s recommendations CAUTION See the cautions in this document with regard to possible pinch hazard and the restriction against using the pad retainer 11 as a place to secure lifting devices With the replacement carrier caliper assembly held in position install with new bolts Note Replacement bolts are not supplied by Bendix use only those of a grade and type specified by the vehicle manufacturer Consult the vehicle manual for required torques 25 BRAKE ACTUATOR AND SPRING BRAKE REPLACEMENT CAUTION Replace actuator and spring brakes only with the same as originally installed on the vehicle Replacement with alternate equipment without written authorization from Bendix and the vehicle manufacturer could compromise brake performance CAUTION Follow all standard safety procedures including but not limited to those on page 2 of this service manual See the vehicle manufacturer s recommendations When working on foundation brakes be sure that the vehicle is on level ground that the vehicle is parked by other means than the foundation brakes and that the wheels are chocked Brake Chamber Removal With all air pressure drained from the air brake system disconnect the air hose from the brake chamber 18 2 Remove and discard brake chamber mounting nuts see Figure 50 arrows B Brake Chamber Installation Note New brake chambers 18 2 have drain plugs installed se
10. remove the wheel refer to the vehicle manufacturer s recommendations Note Before removing the brake pads it is strongly recommended that the adjuster mechanism be checked for correct operation see Page 15 Remove the clip 26 and washer 45 depress the pad retainer 11 and remove the pad retainer pin 44 Discard these four items replacements are included in the service kits AS necessary remove any in pad wear sensor components and discard Pull off the adjuster cap 37 using the tab taking care to keep the shear adapter 61 in position on the adjuster 23 Using a box end wrench or socket fully wind back the tappet and boot assemblies 13 by rotating the shear adapter 61 in an counter clockwise direction see Page 15 Note Do not use an open ended wrench as this may damage the adapter CAUTION Never turn the adjuster 23 without the shear adapter 61 installed The shear adapter is a safety feature and is designed to prevent an excess of torque being applied to the adjuster The shear adapter will fail by breaking loose if too much torque is applied If the shear adapter fails you may attempt a second time with a new unused shear adapter A second failure of the shear adapter confirms that the adjustment mechanism is seized and the caliper carrier assembly must be replaced To remove the outboard brake pad 12 slide the caliper 18 O IB IF SUS 11 Pad Retainer oe 45 Washer 26 Clip
11. small there is a danger of overheating That may lead to consequential damage CONTACTING BENDIX www foundationbrakes com FIGURE 23 MEASURING THE RUNNING CLEARANCE If there is no movement at all go to pages 16 17 for the Guide Pin Inspection Procedure If instead there is movement but the running clearance is too small or too large the adjuster may not be functioning correctly and should be checked See Inspect Adjuster Mechanism on Page 15 14 Bendix on line information is available 24 7 In the on line contacts directory you can find technical support contacts service engineers Bendix account managers international contacts and more www foundationbrakes com is your complete Bendix resource Bendix Technical Assistance Team For direct personal technical support call the Bendix technical assistance team at 1 800 AIR BRAKE 1 800 247 2725 Monday through Friday 8 00 A M to 6 00 P M EST and follow the instructions in the recorded message Alternatively you may e mail the Bendix technical assistance team at techteam bendix com To better serve you please record the following information before you call the Bendix Tech Team or include this information in your e mail Bendix product model number part number and configuration Vehicle make and model Vehicle configuration Number of axles tire size etc System performance symptoms When do they occur What troubleshooting measureme
12. term effects of certain non asbestos fibers have not been determined Current OSHA Regulations cover exposure levels to some but not all components of non asbestos linings and pads The following precautions should be used when handling these materials e Avoid creating dust Compressed air or dry brushing must never be used to clean brake assemblies or the work area e Brake workers must take steps to minimize their exposure to airborne brake lining particles Procedures to reduce exposure include working in a well ventilated area segregating areas where brake work is performed using local filtered ventilation systems or enclosed cells with filtered vacuums for all brake work Respirators approved by the Mine Safety and Health Administration MSHA or National Institute for Occupational Safety and Health NIOSH should be worn at all times during brake servicing e Workers must wash before eating or drinking should not use tobacco products in any form shower after working and not wear work clothes home Work clothes should be vacuumed using a high efficiency particulate filter HEPA vacuum and laundered separately without shaking e OSHA Regulations regarding testing disposal of waste and methods of reducing exposure for asbestos are set forth in 29 Code of Federal Regulations 1910 001 These Regulations provide valuable information which can be utilized to reduce exposure to airborne particles e Material Safety Data Sh
13. the vehicle manufacturer CAUTION Bendix recommends that after every air brake service if available the technician checks the brake performance and the system behavior on a dynamometer Backplate of Pad 12 Brake Pad FIGURE 33 PAD Assembly INSTALLATION FIGURE 34 TAB POSITION Pk er 45 Washer 26 Clip mer Ws Ea 11 Pad Retainer 19 ELECTRONIC WEAR INDICATOR REPLACEMENT Normally Closed or Normally Open Type See page 10 New wear indicators are normally installed whenever brake pads are replaced Please see Brake Pad Installation on Page 18 for cautions and procedures The wear indicator is installed after the new brake pads are installed into the Outboard Pad brake but before the retainer hardware Remove and retain the pad holder springs 42 1 See page 6 for typical contents of wear indicator kits Installation The longer branch of the wear indicator cable see arrow must be installed in the outboard pad Insert the Wear Indicator Cables 101 into the pre cut slot in the pads The wear indicators snap into place 2 Insert wear indicator sensors into 3 Install the pad holder springs 12 2 the pads onto the pads 12 1 with the wear indicator cable 101 as shown i NT AR k i 5 Install the cable guide 105 onto 20 4 Install the pad retainer 11 pad retainer pin 44 washer 45 and spring clip 26 with the wear indicator cable 101 as shown t
14. the Spring Running Brake Fully Partially Clearance Check OK Applied see page 14 YES NO YES NO YES Running Adjuster Clearance Check OK Check OK see page 14 see page 15 YES YES NO Y r Pad and Adjuster Drain Air Pressure from Replace Caliper Disc Wear Check OK gee oo NA Carrier Assembly OK see page 15 ging spring see page 25 r Dp Caliper Guidance OK YES see pages 16 17 YES NO NO y y Replace Components Disc Brake N y x as Needed with oK J Replace Caliper NO Tightness Not Genuine Bendix Parts Carrier Assembly Due to Air Disc from Bendix Spicer see page 25 Brake See Foundation Brake LLC Owner s Manual y Replace Caliper Carrier Assembly see page 25 FIGURE 18 TROUBLESHOOTING BENDIX AIR DISC BRAKES 11 INSPECTIONS Follow all standard safety procedures including but not limited to those on page 2 of this service manual BRAKE PADS AND ROTORS Bendix Air Disc Brakes are precision engineered braking mechanisms The friction couple braking characteristics have been carefully optimized and the rotor design and materials have been matched with special formulation brake pads for optimal performance CAUTION When replacing brake pads Bendix strongly recommends using only replacement pads and replacement rotors approved by the OEM Use of non approved rotors or non
15. the tappet boot from the caliper bore A screwdriver B should be used to move the boot location ring see Figure 40 and allow the wedge fork A to be inserted CAUTION Take care not to damage the inner sealing face See arrow X in Figure 40 Gouges or grooves that would prevent a good seal necessitate caliper replacement The tappet and boot assemblies 13 can then be removed from the threaded tubes 16 by using the wedge fork A Remove the old tappet bushing s 161 Inspect the inner sealing face see arrow X for damage If damage is found to the inner seal the caliper carrier assembly must be replaced 22 Less Than 1 18 in 30 mm T3 N 115 Ta Press in Tool arrangement for Tappet and Boot Assembly 13 when Caliper is fitted on the vehicle Press in Tool arrangement for Tappet and Boot Assembly 13 when Caliperis removed from the vehicle Ring T24 for SK7 and 225 and 22X Air Disc Brakes Installation device for Tappet and Boot Assembly 13 when Caliper is removed from axle Press in Tool Z004190 for Tappet and Boot Assembly 13 Wedged Fork 1132202 for removal of Tappet and Boot Assembly 13 Ring K004082 for Tappet and Boot Assembly 13 FIGURE 39 TAPPET REMOVAL TOOL il SN 1 ha Nh th NG NG ks NG a AN ny hul n Na P s y ba oo NN bait H Puta maa Se pn k nee SSS N7 a FIGURE 471 USE OF A NEW BRAKE PAD AS A SPACER INSPEC
16. this movement should be at least 0 8 inch 20mm If the movement is less than this amount replace the caliper carrier assembly To measure the clearance from the rubber bushing 6a 6b or guide sleeve 6c to the guide pin See Figures 29 and 30 Remove the wheel Remove the pad retainer 11 but leave the pads 12 in position Attach a magnetic dial gauge holder to the carrier 2 on the short bearing side of the caliper 1 Use the measuring point on the caliper 1 see the arrow in Figure 28 Press the caliper in the direction of carrier 2 and set the dial gauge to zero Place a suitable tool e g screwdriver between Carrier 2 and Caliper 1 forcing them in opposite directions and read the maximum value on the dial gauge For styles A and B guide pins if the value is greater than 0 079 in 2 0 mm or for style C guide pins if the value is greater than 0 039 in 1 0 mm the caliper carrier assembly must be replaced 16 13 1 Tappet and Boot 5 Caliper Assembly Guide Pin Brass Bushing 10 Cover LONG BEARING SIDE 23 Adjuster Unit 61 Shear Adapter ae NATAN ANG a PP PAY a EL KO HA oO N 77 7A Af iri Ss aaa aa aa a md a Aa a a F SHORT 3 BEARING SIDE J nig N BAN i en ko as ie a pm pai Na N pa 57 a LP 6a Rubber Bushing 39a Caliper Bolt 4a Guide Pin 6b Rubber Bushing 39b Caliper Bolt 39b 4b Guide P
17. those on page 2 of this service manual See the vehicle manufacturer s recommendations When working on foundation brakes be sure that the vehicle is on level ground that the vehicle is parked by other means than the foundation brakes and that the wheels are chocked With the caliper carrier assembly securely supported remove and discard the six bolts attaching the carrier to the axle CAUTION Do not attempt to use the pad retainer 11 to attach any lifting device to the brake The pad retainer is not suitable for this purpose and damage to the brake and or unsafe conditions may result Clean and inspect the axle contact area See axle or vehicle manual for instructions if damage is found CALIPER CARRIER ASSEMBLY INSTALLATION The correct choice of caliper carrier must be ensured by using the air disc brake part number on the identification label when ordering replacement parts See Page 6 Replacement caliper carrier assemblies may be delivered with a plastic cap adhesive tape or a breakthrough diaphragm in the area of the actuator attachment Remove the cap or tape only after installing the replacement caliper on the vehicle If the replacement caliper has the breakthrough diaphragm it should be left in place FIGURE 49 CALIPER CARRIER ASSEMBLY REPLACEMENT If the replacement caliper carrier assembly is equipped with a potentiometer for wear indication then the connection must be made using the appropriate mating
18. time to schedule a full wheel removed inspection of the pads and rotor Note This is only an indication that the pads and rotor are ready for inspection Time to Schedule and does not necessarily mean that Inspection of maintenance is required Pads and Rotor FIGURE 10 ROLLING BOOT STYLE WEAR INDICATOR INSPECTION Style B Solid Rubber Bushing Bio Wear IHGICALOE Inspect the position of the guide pin compared to the solid rubber bushing See Figure 11 When the guide pin is aligned with the bushing it is time to schedule a full wheel removed inspection of the pads and rotor Note This is only an indication that the pads and rotor are ready for inspection and does not necessarily mean that maintenance is required Time to Schedule Inspection of Pads and Rotor FIGURE 12 PIN COVER Where the Guide Pin is enclosed bya cover see next page for inspection criteria MECHANICAL BRAKE PAD AND ROTOR WEAR INDICATORS continued Style C Where Both the Carrier and Caliper Have an Indicator Notch Compare the relative position of two notches cast into the Carrier and Caliper See Figure 13 When the two notches align it is time to schedule a full wheel removed inspection of the pads and rotor Note This is only an indication that the pads and rotor are ready for inspection and does not necessarily mean that maintenance is required Style D Where Only the Caliper has an Indicator Notch When the notch in the C
19. which are recommended by the vehicle manufacturer Install the brake chamber using new self locking nuts EN ISO 10513 Tighten alternately both the nuts step by step up to a final torque of 133 7 ft Ibs 180 10 Nm Re connect the air hose and be sure that the hose is not twisted or in contact with moving vehicle components The air hose routing must allow for full caliper travel Test for leakage and check the brake operation and effectiveness before returning vehicle to service FIGURE 54 CAP INSTALLATION 27 28 Bendix Spicer Foundation Brake LLC BW7308 2005 Bendix Spicer Foundation Brake LLC All rights reserved 12 05 Printed in U S A
20. External Metal Cover 68c Cover Pad Assembly 12 Mm 22 58 9 4c N if 7 18M Spring Brak Ring Inner GuidePin py DN a i Boot Assembly LA PANT 7 Brake Chamber 46 Yj oe Rotor Ld Hm KW NZ ASIA Z Sie e re APA Side Sectional ii 1 Wed Li A View Lil Te Bolt T T 27 Di i 19 eee Cie by Spring Lever FIGURE 4 SECTIONAL VIEW MG 17 20 Bridge Eccentric Bearing a 44 Pad Retainer Pin 1 Pad Retainer 26 Spring Clip 45 Washer 18 1 Spring Brake 18 2 P Y Brake 9 Chamber Pd Inner O tg 12 2 Ac Boot Guide Pin 12 Uses White Assembly Grease oy Ba oe 12 1 Pad Assembly One of Three Different ae Caliper Bolt Styles are K Used Designated by p NG a i A B orC O ND aliper ak S vA Rubber SON Ng N IN BAM Boot SK Bushing a f SE O L gt Assembly 6c Guide NG lt IM N NSIS N ae iN 39 Sleeve gt N LI X Caliper Bolt S gt E p 68c 39b l Cover 6a Brass Biao Rubber Bushing O Bushing 37 e Adjuster Cap A ia y i 39a CaliperBolt 3 Guid At 68a Cap al j 40 A 7 Caliper Bolt Uses L White Assembly Pre Applied Grease Thread Adhesive FIGURE 5 EXPLODED VIEW 2 Carrier FOR REFERENCE ONLY MANY OF THE PARTS SHOWN ARE ONLY FACTORY SERVICEABLE AT THIS TIME See Figure 9 on Page 6 for exploded views of electronic wear indicators Caliper Bolt A Caliper Bolt Guide Pin Rubber Bushing Eccentric Bearing
21. T THE THREADED TUBES 16 For the inspection of the threads the tubes must be extended but by less than 1 18 in 30mm by turning the shear adapter 61 clockwise If working with the caliper on the vehicle the technician may place a new brake pad 12 into the outboard gap to help avoid the loss of thread engagement of the threaded tubes If the work is being carried out at a workbench the technician may insert a 2 76 in 70 mm spacer E into the caliper 1 to help avoid the loss of thread engagement See CAUTION on Page 22 Check the threads for rust corrosion or damage etc If there is evidence of damage to the threads rust or corrosion the caliper carrier assembly must be replaced see Page 25 If the threads are in good condition fully wind back the threaded tubes 16 by turning the shear adapter 61 counter clockwise INSTALLING THE TAPPET AND BOOT ASSEMBLIES 13 Grease threads with white grease Part No 1114525 or 1132863 YYZ co f MA ma bell GBA FIGURE 44 INNER SEAL INSTALLATION Screw back the threaded tubes 16 by turning the shear adapter 61 counter clockwise see Cautions earlier in these instructions The sealing seat in the caliper for tappet and boot assemblies 13 must be clean and free of grease See Figure 44 Fit a new tappet bushing 161 onto the center post of each threaded tube 16 23 FIGURE 45 ON VEHICLE TAPPET INSTALLATION Technicians working with t
22. air brake to service Ensure that the tab is in the position shown in Figure 26 15 GUIDE PINS CAUTION Follow all standard safety procedures including but not limited to those on page 2 of this service manual See the vehicle manufacturer s recommendations When working on foundation brakes be sure that the vehicle is on level ground that the vehicle is parked by other means than the foundation brakes and that the wheels are chocked Note If the steps below lead the technician to a step where the wheel needs to be removed inspect first to see that there is no contact between the caliper and axle vehicle chassis sections or carrier etc that may be impeding the caliper movement When removing wheels refer to the vehicle manufacturer s recommendations This guide pin inspection should be carried out if the result of the Caliper Movement Test see Page 13 is that the technician cannot move the caliper GUIDE PIN BEARING INSPECTION Use the following procedure to check caliper movement along the guide pins Remove the Pads see Page 18 One of the three different styles of guide pin A B or C may be present See Figure 28 The bearings for styles A and B use a rubber bushing and style C uses a guide sleeve Clean dirt road grime etc from the guide pin or cover Using hand pressure only no tools the Caliper 1 should slide freely along the whole length of the Guide Pin arrangement With the pads removed
23. arrier aligns with the front edge of the torque plate it is time to schedule a full wheel removed inspection of the pads and rotor Note This is only an indication that the pads and rotor are ready for inspection and does not necessarily mean that maintenance is required FIGURE 14 CARRIER WEAR INDICATOR NOTCH AND BACKING PLATE ALIGNMENT Location of Inspection Grooves Notch in Caliper SS GA ns po 1 Notchin lt Carrier Notches _ le ae AS Time to Schedule Inspection of Pads and Rotor FIGURE 13 STYLE C NOTCHED CARRIER AND CALIPER Notch in Caliper Time to Schedule Inspection of Pads and Rotor 101 11 Wear Sensor Pad Retainer Cable Example of a Wear Sensor 101 Installed into Slot in Brake Pad ia 12 iG Brake Pad Assembly NIKA A7 7 b gt 46R WAS 6 Rotor FIGURE 15 EXAMPLE OF NORMALLY OPEN OR CLOSED WEAR SENSOR ELECTRONIC BRAKE PAD WEAR INDICATORS The electronic monitoring system uses sensors installed in a pre formed slot in the brake pad to allow the status of the pad wear to be monitored When the pad wears away through use the point is reached when the indicator itself comes into contact with the rotor For in pad Normally Closed Indicators when the point is reached when the indicator itself is worn through the circuit flowing through it is broken and the vehicle operator is alerted For in pad Normally Open Indicators when the point is reached when the indicator itse
24. cked and the parking brake temporarily released check for movement of the brake caliper This small movement less than 0 80 2 mm approximately the thickness of a nickel in the inboard outboard direction indicates that the brake is moving properly on its guide pins If the caliper has no movement or appears to move greater than the distances above a full wheel removed inspection will be necessary See Page 16 MECHANICAL BRAKE PAD AND ROTOR WEAR INDICATORS A preliminary visual check of the condition of the brake pad rotor wear can be made without removing the wheels See below Style Aand B for the inspection to make for each of the three guide pin styles Inspect position in use for Bendix air disc brakes W Note These inspections provide an indication of when to schedule a full wheel removed inspection of the brake pads and rotor The thicknesses of both the pad and rotor will affect the wear indicator position at Style C and D Where the indicator pin is covered see Figure 12 inspect notches in carrier and caliper or backing plate see Page 9 which maintenance is actually needed These inspections do not constitute out of service criteria Style A Rolling Boot Style Wear Indicator Inspect the position of the guide pin flexible rubber bushing See Figure 10 When the guide pin has moved in so that the ribbed section of the flexible rubber bushing reaches the point where it folds back in it is
25. e Figure 50 arrows A After installation remove whichever plug is at the lowest position Be sure that all other drain holes remain plugged The drain hole must be aligned downwards or within 30 when installed on the vehicle Before installing the new brake chamber the actuator flange see Figure 51 arrow C must be cleaned and inspected Consult the vehicle manual The spherical cup in the lever 19 must be greased with white grease Part No 1114525 or 1132868 CAUTION Do not use grease containing molybdenum disulfate See Figure 52 The seal as well as the pushrod area must be clean and dry CAUTION Do not use brake chambers with seals with a thickness less than 0 12 in 8 mm Use only actuators which are recommended by the vehicle manufacturer Install the brake chamber using new self locking nuts EN ISO 10513 Tighten alternately both the nuts step by step up to a final torque of 133 7 ft Ibs 180 10 Nm Re connect the air hose and be sure that the hose is not twisted or in contact with moving vehicle components The air hose routing must allow for full caliper travel Test for leakage and check the brake operation and effectiveness before returning vehicle to service 26 Pa ag NN Pang it K pm f j FIGURE 52 CAP INSTALLATION 18 2 Brake Chamber or 18 1 Spring Brake Spring Brake Removal CAUTION Follow all standard safety procedures see note above Be familiar wi
26. e to the wheel Brake Release and Adjustment When the vehicle brakes are released the air pressure in the service brake chamber is exhausted and the return springs in the chamber and the bridge return the air disc brake to a neutral non braked position To maintain the running clearance gap between the rotor and the brake pads over time the non braked position is mechanically adjusted by a mechanism in the caliper The adjustment mechanism operates automatically whenever the brakes are activated to compensate for rotor and brake pad wear and to keep the running clearance constant During pad or rotor maintenance the technician manually sets the system s initial non braked position The total running clearance sum of clearances on both sides of the rotor should be between 0 024 to 0 043 in 0 6 and 1 1 mm FIGURE 1 BENDIX ADB 22X AIR DISC BRAKE Service Brake Pressure Supply Port Chamber Plate Pushrod Lever Return Spring Diaphragm Outer Brake Eccentric Bearing Pad InnerBrakePad Bridge FIGURE 2 CROSS SECTION VIEW SHOWING BRAKE OPERATION SAFE MAINTENANCE PRACTICES 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 Where specifically direct
27. ed the parking brakes may have to be released and or spring brakes caged and this will require that the vehicle be prevented from moving by other means for the duration of these tests procedures 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 li
28. ed to prevent an excess of torque being applied to the adjuster The shear adapter will fail by breaking loose if too much torque is applied If the shear adapter fails you may attempt a second time with a new unused shear adapter Asecond failure of the shear adapter confirms that the adjustment mechanism is seized and the caliper must be replaced With a box end wrench or socket positioned so that it can turn freely without coming into contact with parts of the vehicle See Figure 27 on the shear adapter make five to ten moderate applications of the brakes at about 30 psi 2 Bar For a normally functioning Bendix air disc brake the box end wrench or socket should turn clockwise in small increments NOTE As the number of applications increases the turning movement will decrease as the brake reaches its normal calibration point If the box end wrench or socket does not a turn at all or b turns only with the first application or c turns forward and backward with every application the automatic adjuster has failed and the caliper carrier assembly must be replaced SO LP p ET ath me iff PZ gt 4 Outboard Brake Pad 23 Adjuster 61 Adapter Ca Tab P FIGURE 25 EXPLODED VIEW OF ADJUSTER AND ADAPTER FIGURE 26 TAB POSITION FIGURE 27 ADJUSTMENT MECHANISM TEST Bendix recommends installing a new adjuster cap lightly greased using white lithium based grease when returning the
29. eets on Bendix air disc brake pads as required by OSHA are available from Bendix Spicer Foundation Brake LLC SERVICE DATA INDEX Overview 0 02 1 Safe Maintenance Practices 2 Air Disc Brake Sectional and Exploded Views 4 5 Air Disc Brake ldentification 6 Rotor Identification Kada KAG neues eens NG KA 6 Electronic Wear Indicator Exploded Views 6 Preventive Maintenance Preventive Maintenance Schedule T Running Clearance Inspection T Mechanical Wear Indicators 8 9 Electronic Wear Indicators including Hand Held Diagnostic Equipment 10 Troubleshooting Troubleshooting Flowchart 11 Inspections Brake Pads Aye toon tase se deae eee ds 12 MOOS oc eSeevepedeterceteeieee deca EEEE 13 Caliper Running Clearance 14 Adjuster Mechanism a 15 Guide PINS 2 a AMEN oe ee Sele 16 17 Maintenance Procedures Pad Replacement 000000 ees 18 19 Electronic Wear Indicator Replacement 20 21 Tappet and Boot Assemblies Replacement 2 0000 e eee ees 22 24 Carrier Caliper Assembly Replacement 25 Brake Actuator and Spring Brake Replacement 26 27 12
30. foundation brakes be sure that the vehicle is on level ground that the vehicle is parked by other means than the foundation brakes and that the wheels are chocked When installing pads where appropriate use heavy duty gloves and always keep fingers away from potential pinch hazard areas Cage spring brakes before beginning procedure Note In some cases the technician may find it easier to remove the caliper from the vehicle before making the replacement see Page 25 for instructions on caliper carrier removal REMOVAL OF TAPPET AND BOOT ASSEMBLIES 13 Follow the procedure for removing brake pads 12 on Page 18 CAUTION Never turn the adjuster 23 without the shear adapter 61 installed The shear adapter is a safety feature and is designed to prevent an excess of torque being applied to the adjuster The shear adapter will fail by breaking loose if too much torque is applied CAUTION NEVER EXTEND THE TAPPET MORE THAN 1 18 in 30 mm Over extending the tappet will result in the tappet losing engagement with the threads of the synchronizing mechanism Since the mechanism can only be set at the manufacturing plant THE CALIPER CARRIER ASSEMBLY MUST BE REPLACED if this happens Removal of the tappet and boot assembly 13 requires the use of the wedge fork A See Figure 39 Extend the tappets less than 1 18 in 30 mm by turning the shear adapter 61 clockwise until there is sufficient access to the boots to remove
31. he caliper installed on vehicle e Install the boots using the press in tool B with the short press in extension T3 for positioning and pressing into place see Figure 43 e Position a tappet assembly 13 onto each tappet bushing Using press in tool B in a reversed orientation with the press in extension T3 towards the threaded tube install each tappet onto its tappet bushing see Figure 45 Technicians working with the caliper not installed on vehicle e Install the boots using the press in tool B with the long press in extension T3 T4 for positioning and pressing into place see Figure 43 Position a tappet 13 onto each tappet bushing Using press in tool B in a reversed orientation with the press in extension T3 T4 towards the threaded tube install each tappet onto its tappet bushing see Figure 45 After assembly check that the tappet 13 is free to turn in both directions Note When installing the tappet for Bendix ADB 22X ADB 225 and SK7 disc brakes use the supplemental ring T24 inserted into the tool T2 see Figure 48 to assist the installation since the caliper s back plate is too thin using only Tool B to achieve the correct position 24 FIGURE 46 OFF VEHICLE BOOT INSTALLATION FIGURE 48 OFF VEHICLE USE OF EXTRA TOOL FOR SOME STYLES CALIPER CARRIER ASSEMBLY REPLACEMENT CAUTION Follow all standard safety procedures including but not limited to
32. he pad retainer 11 The cable guide 105 snaps into place when pressing lightly onto the pad retainer 11 6 Press the wear indicator cable 101 into the locating tabs of the cable guide 105 see arrows A The short cable end of the wear indicator cable 101 must not be secured by locating tabs of the cable guide 105 According to vehicle type install the cable that leads to the electrical supply of the vehicle in one of the two locating tabs see arrows B 7 Install the indicator cable 101 in the middle of the pad retainer 11 Insert the cable guide 105a at one side of the pad retainer 11 see arrow B Slightly press in on the other side of the pad retainer 11 see arrows A The cable guide 105a snaps into place According to vehicle type install the cable that leads to the electric supply of the vehicle in one of the wire loop see arrows C The short end of the wear indicator cable 101 must not be secured by a wire loop of the cable guide 105a see arrows C 8 Carefully install the cable protection plate 104 with attention to the correct position of the cable protection plate s catch see arrows The cable protection plate 104 will snap into place 21 TAPPET AND BOOT ASSEMBLIES REPLACEMENT CAUTION Follow all standard safety procedures including but not limited to those on page 2 of this service manual See the vehicle manufacturer s recommendations When working on
33. in 6c Guide Sleeve FIGURE 29 MAGNETIC DIAL GAUGE GUIDE PIN SEAL INSPECTION Caliper Guide Pin Seals The long bearing side guide pin 5 is sealed with the cover 10 and with the inner boot 9 See Figure 28 Note It may be necessary to remove the pads to inspect the inner boots 9 if pad wear is minimal The guide pin 4a 4b or 4c depending on the style is also sealed with an inner boot 9 and a cover style C or a flexible rubber wear indicator in the case of style A guide pins Inspect the above components and if damage is found replace the caliper carrier assembly No kits are available at this time for Guide Pin Seals TAPPET AND BOOT ASSEMBLY INSPECTION In order to inspect the tappet and boot assembly it may be necessary to remove the pads 12 see Page 18 and advance the shear adapter 61 clockwise see Page 15 until the boots are clearly visible CAUTION NEVER EXTEND THE TAPPET MORE THAN 1 18 in 30 mm Over extending the tappet will result in the tappet losing engagement with the threads of the synchronizing mechanism Since the mechanism can only be set at the manufacturing plant the CALIPER CARRIER ASSEMBLY MUST BE REPLACED if this happens Inspect the tappet and boot assemblies 13 for evidence of damage corrosion etc The penetration of dirt and moisture into the brake can lead to corrosion and impair the function of the air disc brake Replace as necessary see Pages 22 24 Extend
34. lf is worn through the circuit is completed by the rotor touching the contacts and the vehicle operator is again alerted On some vehicles the electronic system is fully integrated into the vehicle monitoring system and uses a buzzer or indicator lamp to alert the driver Alternate vehicle arrangements permit a hand held diagnostic tool to be used to test individual wheel connectors or where installed attach to a DIN socket in the dash and allow up to six brakes to be checked from that location The system provides feedback on the pad wear and can also conduct a test of the Wear Indicator Potentiometer Even when using wear indicators always follow the standard preventive maintenance schedule outlined on page Refer to the vehicle manual and or the diagnostic tool manual for specific device operating instructions 10 LIN To Vehicle Electronic Monitoring System or for use with Diagnostic Tool FIGURE 16 EXAMPLE OF POTENTIOMETER WEAR SENSOR 13 Pin Plug DIN 72570 to vehicle Plug for Individual Wheel Inspection FIGURE 17 HAND HELD DIAGNOSTIC TOOL GENERAL TROUBLESHOOTING PROCEDURE FLOWCHART Air Disc Brake Inspection Follow Cautions on Page 2 Chock Wheels Engage Spring Brakes and Cage Spring Release Spring Brakes and Drain Air from System y Raise Axle Spin the Wheel by Hand Does Wheel Turn Smoothly YES NO Is
35. lifetime At the same time conduct the Running Clearance Inspection see below e Avisual check of the mechanical wear indicator every time the tire pressures are checked is recommended Be alert for any rotor cracks etc visible See Page 13 for criteria e For vehicles with electronic wear indicators e g Pick Up amp Delivery use the dash indicator s and or the hand held Off Highway Construction diagnostic tool to regularly monitor the pad In all cases visually inspect the wear indicator City Transit Bus Refuse see Pages 8 9 every three months or keep Urban Region Coach track of the results of maintenance inspections School Bus to schedule checks 4 to 5 times during the pad lifetime At the same time conduct the Running Clearance Inspection see below A visual check of the mechanical wear indicator every time the tire pressures are checked is recommended Be alert for any rotor cracks etc visible See Page 13 for criteria Inspect e The rotor for cracks etc see Page 13 for criteria e The running clearance and adjuster function see Page 15 e The caliper travel see Pages 16 17 e The tappet and boot assemblies see Page 14 e All covers caps hoses and brake exterior for damage etc Air Disc Brake Running Clearance Inspection Follow all industry safety guidelines including those listed on Page 2 On level ground with the wheels cho
36. ly Cable Protection Plate 9 Cable Guide Cable Guide FIGURE 9 ELECTRONIC WEAR INDICATOR COMPONENTS 6 PREVENTIVE MAINTENANCE Regular inspection and maintenance of air disc brake components is an important part of vehicle maintenance The maintenance practices outlined here are recommended in addition to all standard industry practices including e g daily pre trip inspections etc Also see the vehicle s manual for recommendations Use the table below for a guide to maintenance interval planning however depending on the vehicle use more frequent checks of the components may be necessary Keep track of the results of your maintenance inspec tions to assist you determine the ideal maintenance interval for the vehicle Basic Inspection Program Pad amp Rotor Wear At Least Once Annually and at 2 Running Clearance Every Pad Replacement Vehicle Used for Inspection with the wheel mounted Inspection with wheel removed Over the Road For vehicles with electronic wear indicators use the dash indicator s and or the hand held diagnostic tool to regularly monitor the pad e g Line haul RV Open Highway Coach WEEE Higher Duty Use Loggers Concrete Mixer wear Dump Truck In all cases visually inspect the wear indicator FE ER see Pages 8 9 every four months or keep Ed track of the results of maintenance inspections to schedule checks 4 to 5 times during the pad
37. ne 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 11 For vehicles with Antilock 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 WARNING Not all wheels and valve stems are compatible with Bendix Air Disc Brakes Use only wheels and valve stems approved by the vehicle manufacturer to avoid the risk of valve stem shear and other compatibility issues BRAKE DUST WARNING AVOID CREATING DUST WHEN WORKING WITH BRAKE PADS DUE TO POSSIBLE CANCER AND LUNG DISEASE HAZARD While Bendix Spicer Foundation Brake LLC does not offer asbestos containing brake linings or disc pads the long
38. nts have been performed What Bendix service data literature do you have or need 3 INSPECT ADJUSTER MECHANISM CAUTION Follow all standard safety procedures including but not limited to those on page 2 of this service manual See the vehicle manufacturer s recommendations When working on foundation brakes be sure that the vehicle is on level ground that the vehicle is parked by other means than the foundation brakes and that the wheels are chocked Aside from the normal maintenance schedule this Adjuster Check is also carried out when the Caliper Movement Test see Page 14 finds that the running clearance is too small or too large The adjuster should then be checked as follows With the spring brake released or caged remove the adjuster cap 37 using the tab taking care not to move the shear adapter 61 Note One of two styles of adjuster cover stamped metal or plastic may be used Although exploded view Figure 25 shows the adjuster 23 and shear adapter 61 separated only turn the adjuster with the shear adapter installed on the adjuster Using a box end wrench or socket turn the Shear Adapter 61 counter clockwise and listen for the sound of 2 or 3 clicks as the mechanism increases the running clearance Note Do not use an open ended wrench as this may damage the adapter CAUTION Never turn the adjuster 23 without the shear adapter 61 installed The shear adapter is a safety feature and is design
39. rocedure Also see the vehicle manual recommendations 12 NEW PAD P1 1 18 in 30 mm USED PAD ROTOR R new 1 77 in 45 mm P2 R minimum 1 46 in 37 mm B Backing plate thickness P2 Pad min thickness Bendix ADB 22X ADB 225 SN6 and some SK7 Air Disc Brake Pads SK7 Air Disc Brake Pads with 0 28 in 7 mm backing plate FIGURE 19 PAD AND ROTOR DIMENSIONS Small Amountof ss Brake Material Chipped from Edge FIGURE 20 MINOR PAD DAMAGE IS ACCEPTABLE FIGURE 21 MAJOR PAD DAMAGE IS NOT ACCEPTABLE Section ie Damaged or alee Missing INSPECT ROTORS Identify if the rotor is a conventional or a splined assembly see Page 6 Examine the rotor and measure the thickness at thinnest point Avoid measuring near the edge of the rotor as minor burrs may be present Replace Bendix rotors when the minimum thickness of 1 46 in 37 mm is reached or as instructed by vehicle manufacturer When replacing Rotors please refer to the instructions of the Vehicle Manufacturer It is recommended to install Bendix Brake Rotors available from your local Bendix Spicer Foundation Brake parts outlet and it is also recommended that the pads should be replaced at the same time Non Bendix rotors If a non Bendix rotor is used refer to the vehicle manual and rotor manufacturer s recommendations CAUTION The use of non approved brake rotors may reduce levels of safety and in
40. th the spring brake manufacturer s recommended safety practices With all air pressure drained from the air brake system disconnect the air hose from the brake chamber 18 1 Back out the release bolt Figure 53 arrow D using a maximum torque of 26 ft Ibs 35 Nm to release spring force on the pushrod Refer to the spring brake and vehicle manufacturer s recommendations in some cases it may be permissible to cage the spring brake while the spring brake is engaged While supporting the spring brake in position remove and discard brake chamber mounting nuts see Figure 53 arrows B Remove the spring brake Spring Brake Chamber Installation Note New spring brake chambers 18 1 have drain plugs installed see Figure 53 arrows A After installation remove whichever plug is at the lowest position Be sure that all other drain holes remain plugged The drain hole must be aligned downwards or within 30 when installed on the vehicle Before installing the new brake chamber the actuator flange see Figure 51 arrow C must be cleaned and inspected Consult the vehicle manual The spherical cup in the lever 19 must be greased with white grease Part No 1114525 or 1132868 CAUTION Do not use grease containing molybdenum disulfate See Figure 54 The seal as well as the pushrod area must be clean and dry CAUTION Do not use brake chambers with seals with a thickness less than 0 12 in 8 mm Use only actuators
41. validate warranty No action is needed for small cracks spread over the surface e g Area A Rotor Friction Surface Width ma Cracks reaching either edge of the rotor Rotor Surface Inspection Inspect the rotor at each change of pads for grooves and cracks The action to take depends on the type of rotor and also the size depth and direction of the imperfections see Figure 22 Rotor Turning Grinding Bendix rotors are normally service free Turning of Bendix spline rotors is not permitted Conventional rotors may be turned when changing pads but is not normally necessary In the case of severe grooving of the entire friction surface however turning could be useful and may increase the load bearing surface of the pads To meet Bendix recommendations the minimum rotor thickness after turning must be greater than 1 53 in 39 mm CAUTION Always maintain air disc brake pads and rotors within specifications Excessive pad or rotor wear will degrade optimum performance When replacing Rotors be sure to adhere to the vehicle manufacturer s recommended bolt tightening torques e For standard Bendix rotors cracks running in a radial direction that is from the inside to the outside see Area B less than 0 06 in 1 5 mm deep or wide are acceptable Cracks are only acceptable if they are less than 75 of the width of the rotor contact area i e 75 of dimension a For spline Bendix rotors
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