Eskridge 49B Caliper Service
Contents
1. Ot ESKRIDGE 49B CALIPER BRAKE TECHNICAL BULLETIN AND SUPPLEMENT TO SERVICE MANUAL CONTENTS 81 600 001 General Guidelines to install Hydraulic Brake Components 2 81 950 016 Burnishing Procedures cccccceeceee cece cess eens eeeeeeeeeeeseeeeeeeseeeeeeeeees 3 81 950 016 Reduce Exposure to Non Asbestos Fiber cccccccscssssssseeees 4 81 515 007 Spring Apply Sliding Caliper Disc Brakes ccccseeeessseeees 5 81 515 008 Hydraulic Apply Sliding Caliper Disc Brakes 00008 9 81 515 009 Mechanical Sliding Caliper Disc Brakes cccccceceeeeeeeeeeees 12 THIS TECHNICAL BULLETIN IS EFFECTIVE FROM S N 57755 SEPT 1998 TOR CURRENT RER TB49B MICO AA www comoso com General Guidelines for installing Hydraulic Brake Components MICO Hydraulic Brake Components are precision built devices and must be treated as such The following guidelines must be followed at the time of installation to ensure optimum performance Where to Mount To properly locate the brake component or brake line you must i Make it convenient for operator 2 Use the shortest and most protected route Protect components from road salts and general debris 3 Avoid exposing components and lines in wheel compartments 4 Avoid mounting near engine exhaust lines muffler or anywhere that heat may be generated NOTE Excessive heat transferred to brake fluid may result in damage to lines or2. 56002 8118 P O Box 9058 Ontario CA U S A 91762 9058 507 625 6426 Facsimile 507 625 3212 909 947 4077 Facsimile 909 947 6054 Form No 81 950 016 Revised 10 14 98 Printed in U S A www comoso com Installation and Service Instructions SPRING APPLY Sliding Caliper Disc Brakes ssns MATEO TABLE 1 Model Number 02 515 001 BF 02 515 002 HO 02 515 003 BF 02 515 004 HO 02 515 005 BF 02 515 006 HO 02 515 007 BF 02 515 008 HO 02 515 012 002 515 018 02 515 020 02 515 024 02 515 028 02 515 038 20 060 082 20 060 082 20 060 082 20 060 082 20 060 082 20 060 082 20 060 082 20 060 082 20 060 082 20 060 036 20 060 082 20 060 082 20 060 082 20 060 082 20 060 082 20 060 082 02 500 037 02 500 036 02 500 037 02 500 036 02 500 037 02 500 036 02 500 037 02 500 036 02 500 036 02 500 036 02 500 036 02 500 077 02 500 077 02 500 077 02 500 036 02 500 036 02 500 192 02 500 187 02 500 193 02 500 186 02 500 194 02 500 188 02 500 195 02 500 190 02 500 189 02 500 188 02 500 190 None 02 500 197 None 02 500 191 02 500 216 Model Number 02 515 152 HO 02 515 154 HO 03 515 003 BF 03 515 004 HO 003 515 005 BF 03 515 006 HO 03 515 008 HO 003 515 013 BF 03 515 014 HO 03 515 016 HO 03 515 018 HO 03 515 023 BF 03 515 028 HO 03 515 034 HO 20 060 082 20 060 082 20 060 082 20 060 082 20 060 082 20 060 082 20 060 082 20 060 082 20
3. Bars 18 Apply hydraulic pressure and check for leaks aaa bags 19 Apply rated hydraulic pressure 20 Thread in brake module housing 7 until a total clearance of approximately 30 mm 012 is obtained between disc and lining assemblies 18 Use a spanner wrench if necessary 21 Insert new nylon plug 15 into set screw 16 hole B D D 099 2 Install nylon plug 15 even if originally not included on your model Items included in Seal Kit 22 Install and tighten set screw 16 and release hy A Items included in Repair Kit draulic pressure E Items included in Lining Kit 23 Tighten hydraulic fitting tube nut Not included in all Lining Kits CHANGE LINING PROCEDURE FIGURE 6 Refer to Figure 6 See Table 1 for Lining Kit required for your brake Lining assemblies 18 can be replaced without removing brake module housing 7 1 Remove cap screw 14 and spring clip 17 allow 3 Install new lining assemblies 18 in housing 19 lining assemblies 18 to drop out of housing 19 4 Install new spring clip 17 and cap screw 14 and NOTE On small diameter discs with large hubs torque 13 6 16 3 N m 10 12 lb ft NOTE If the it may be necessary to remove one mounting lining kit does not include new spring clip 17 bolt and swing housing aside to free lining reinstall compression spring To continue refer assemblies Earlier models used a compression to HYDRAULIC CONNECTION amp ADJUSTMENT spring which is not i
4. Refer to vehicle manufacturer for fluid specification if product is used with 1 Mineral based hydraulic oil 2 Phosphate ester base fluid 3 Water glycol fluid 4 Water in oil emulsion fluid 5 DOT 5 or silicone fluid 2 Be sure fittings and seats are clean before making connections Do not use sealants tapes teflon or cement compounds on any connections or fittings These sealants or compounds can contaminate the hydraulic brake system and interfere with the operation of brake system components 3 Clean top of master cylinder before removing filler cap How to Mount To properly mount components and brake lines to withstand the most severe vibration conditions always 1 Follow the procedures outlined in Vehicle Manufacturer s Service Manual or SAE Standards when making new connections or adding to existing brake system Use only steel brake tubing conforming to SAE specifications 2 Use the proper size bolt for the hole and secure with a steel lock washer whenever possible 3 Secure tubing to frame with proper size tube clamps to avoid possible fractures or fittings loosening and leaking 4 Use good factory flared lengths of steel tubing Hand made flares when used must be double flared Any flash or loose particles must be moved 5 Use flexible brake line between frame and body 6 Use grommets or some other means to protect brake lines that pass through the frame or firewall 7 Make sure fittings and conn
5. Space the stops a mini mum of 2 5 miles 4000 m apart and operate the vehicle at 20 mph 9 m s between stops SERVICE BRAKE Make at least 200 Brake Snubs not less than 50 in a series from 40 to 20 mph 64 to 32 km hr at 10 ft s 3 m s in normal gear range A Brake Snub is the act of retarding a motor vehicle between two positive speed values by the use of a brake system Accelerate to 40 mph at moderate acceleration after each snub and drive 40 mph 64 km hr between snubs At every 25th application minimum make a full stop from 40 mph 46 km hr APPLICATION INTERVALS e For light trucks and buses 6 000 10 000 Ib 2 700 4 500kg GVW 1 0 mile 1 6 km e For truck bus and combination of vehicles over 10 000 Ib 4 500 kg GVW 1 5 miles 2 4 km NOTE Other burnish procedures which produce similar braking conditions and performance charac teristics are permissible After burnishing adjust the parking brake and actuation system in accordance with MICO specifications or the appropriate manufacturer s specifications for compo nents of the actuation system not supplied by MICO Immediately following any dynamic stop resulting from the application of the parking brake the brake and disc must be inspected for any unusual wear or conditions and then adjusted in accordance with MICO specifica tions Recommended Disc Material High quality brake discs should be used in conj
6. torque 13 6 16 3 N m 10 12 lb ft NOTE If the lining kit does not include new spring clip 13 reinstall compression spring 5 To continue refer to ADJUSTMENT PROCEDURE Section www comoso com FIGURE 3 A Items included in Lining Kit Items included in Repair Kit Not included in all Lining Kits K 13 Go LNN N M B Lee HEAVY WATERPROOF GREASE _ 9 3 7 8 6 4 FIGURE 4 MICO could not possibly know of and give advice with respect to all conceivable applications in which this product may be used and the possible hazards and or results of each application MICO has not undertaken any such wide evaluation Therefore anyone who uses an application which is not recommended by the manufacturer first must completely satisfy himself that a danger will not be created by the application selected or by the particular model of our product that is selected for the application MICO has made every attempt to present accurate information in catalogs brochures and other printed material MICO can accept no responsibility for errors from unintentional oversights that may exist Due to a continuous program of product improvement materials specifications and product documentation are subject to change without notice or obligation MICO is a registered trademark of MICO Incorporated MICO is registered in the U S Patent and Trademark Office as well as in Australia C
7. 7 a INSIDE SURFACE p OF HOUSING 7 2 oe WHERE CONTACT IS MADE WITH WASHER 10 GREASE NOTE Brake Fluid Models must use a NOTE The number and order of belleville springs 11 and washers 10 vary from model to model Size and location of spacer 9 also varies from model to model Some models do not use washers and or spacers silicone base grease Hydraulic Oil Models must use a mineral base grease 02 515 152 03 515 013 03 515 023 03 515 003 03 515 014 03 515 028 OPTIONAL SWIVEL ae FITTING BLOCK MODELS t 27 7 4 SAE 1 41 ted 1 09 oS 03 515 004 03 515 016 03 515 005 03 515 018 03 515 006 03 515 008 03 515 104 millimeters lis inch 29 5 TABLE 3 ae 1 186 7 FIGURE 5 www comoso com 16 Install flexible hydraulic line leaving tube nut slightly loose to allow turning adjustment of brake x G7 19 4 8 module NOTE The adjusting procedure may be simplified if a swivel fitting is used See swivel fitting block chart Table 3 XN Hi 17 Remove bleeder screw 8 Adjust module housing 7 so bleeder screw port is at the highest point and bleed system of air Install new screw 8 and torque 12 4 13 6 N m 110 120 Ib in A Z e A GEN A CAUTION IZN a lt During the bleeding process for these MICO 515 RA Sil Series Brakes hydraulic pressure should not exceed BSN VARA 13 8 bar 200 psi
8. bolts and that caliper be centered evenly and squarely over disc This will prevent binding of caliper and ensure even lining to disc contact A CAUTION These MICO 515 Series Brakes are designed to be used with a disc thickness of 12 7 mm 50 For other disc thicknesses contact MICO Inc DISC CENTERLINE TO MOUNTING HOLE DIMENSION 13 1 109 7 52 DIA 4 32 DISC MOUNTING HOLE A DIM 2 PLACES 55 6 DIA m 12 8 152 4 mm 6 85 9 mm 3 38 nae ASSEMBLY 265 SCREW 203 2 mm 8 111 3 mm 4 38 a 254 0 mm 10 136 7 mm 5 38 i 1 368 MOUNTING SURFACE jo 304 8 mm 12 162 1 mm 6 38 n 355 6 mm 14 187 5 mm 7 38 J 406 4 mm 16 212 9 mm 8 38 if look Rook a me 457 2 mm 18 238 3 mm 9 38 LJ CS 508 0 mm 20 263 7 mm 10 38 4 bi TABLE 2 a For disc diameters greater than 508 0 mm add 9 7 mm 20 add 38 to disc radius to obtain A dimension oO millimeters inches DISC FIGURE 1 FIGURE 2 www comoso com MOUNTING PROCEDURE 1 Using Figure 1 and Table 2 determine A dimen sion and locate caliper mounting holes 2 Distance from mounting surface to head of mounting bolt is 82 6 mm 3 25 regardless of disc thickness 3 Mount brake on disc and bolt securely to vehicle or machine using grade
9. ing 6 making sure locking lugs of cam plate 7 align with holes in brake module housing Lightly coat face of piston with heavy waterproof grease 10 Install five belleville springs 5 and retainer 4 on piston 9 NOTE Note stacking sequence of belleville springs 5 11 Depress retainer 4 and install retaining ring 3 in groove on piston 9 12 Thread in brake module housing 6 until lining assemblies 12 contact disc completely Back off brake module until a flat surface lines up with set screw 11 Tighten set screw securely 13 Install lever 2 in desired location on piston 9 14 Install lock nut 1 on piston 9 Torque 12 2 14 9 N m 9 12 lb ft 15 Attach actuating mechanism to lever CHANGE LINING PROCEDURE Refer to Figure 4 See Table 1 for Lining Kit required for your brake Lining assemblies 12 can be replaced without removing brake module housing 6 1 Remove cap screw 10 and spring clip 13 allow lining assemblies 12 to drop out of housing 14 NOTE On small diameter discs with large hubs it may be necessary to remove one mounting bolt and swing housing to free lining assem blies Earlier models used a compression spring which is not included in the lining kit 2 Thread brake module housing 6 out of housing 14 so that piston 9 is flush with housing 3 Install new lining assemblies 12 in housing 14 4 Install new spring clip 13 and cap screw 10 and
10. seals 5 Mount units that have to be bled lower than master cylinder and with bleeder screws on top to facilitate bleeding Internal Heat Cause Effect Solution It is possible for heat to come from within the system itself as in the case of heat generated by the friction of lining to drum when braking This heat can cause the fluid to expand If the fluid is then held captive subsequent cooling and contracting can cause a pressure drop MICO Hydraulic Locking Devices that include a pressure accumulator are designed to dampen these fluctuations of pressure and to absorb the increase in pressure within its operating range Cleanliness It is impossible to overemphasize the importance of cleanliness during installation All lines fittings and adjacent areas must be cleaned of dirt or road residue before any lines or fittings are disconnected Special care must be taken so dirt and road residue are not allowed to enter the hydraulic brake system This can contaminate the system and interfere with the proper operation of the brakes and other hydraulic components Always 1 Use good clean quality fluid Improper or contaminated brake fluid may cause gummy deposits and softening and swelling of other rubber seals in the entire brake system Such a condition must be corrected immediately a Use brake fluid which conforms to SAE Spec No J1703 or DOT 3 or 4 if the product is used with a system utilizing automotive brake fluid b
11. shaking to prevent fiber dust from getting into the remove any remaining dust with a rag soaked in air water and wrung until nearly dry Material safety data sheets on this product as Grinding or machining brake linings If you must required by OSHA are available from MICO MICO could not possibly know of and give advice with respect to all conceivable applications in which this product may be used and the possible hazards and or results of each application MICO has not undertaken any such wide evaluation Therefore anyone who uses an application which is not recommended by the manufacturer first must completely satisfy himself that a danger will not be created by the application selected or by the particular model of our product that is selected for the application MICO has made every attempt to present accurate information in catalogs brochures and other printed material MICO can accept no responsibility for errors from unintentional oversights that may exist Due to a continuous program of product improvement both materials and specifications are subject to change without no tice or obligation MICO is a registered trademark of MICO Incorporated MICO is registered in the U S Patent and Trademark Office as well as in Canada Great Britain South Korea and Australia MICO Incorporated MICO West Division 1911 Lee Boulevard Zip Code 56003 2507 701 East Francis Street Zip Code 91761 5514 P O Box 8118 North Mankato MN U S A
12. 060 082 20 060 082 20 060 082 20 060 082 20 060 082 20 060 082 20 060 082 20 060 082 02 500 095 02 500 036 02 500 137 02 500 095 02 500 137 02 500 095 02 500 095 02 500 139 02 500 095 02 500 095 02 500 095 02 500 137 02 500 095 02 500 036 02 500 036 02 500 095 02 500 199 02 500 186 02 500 205 02 500 200 02 500 204 02 500 201 02 500 202 02 500 205 02 500 200 02 500 201 02 500 202 02 500 205 02 500 202 02 500 200 02 500 186 02 500 203 02 515 022 02 515 044 03 515 038 HO 03 515 036 HO 03 515 104 HO 02 515 119 20 060 082 02 500 037 02 500 208 02 500 209 BF Brake Fluid HO Mineral Base Hydraulic Oil With swivel inlet fitting See swivel fitting block drawing Figure 5 on page three e Belleville Springs are pre greased DO NOT remove grease from springs See GREASE NOTE in Figure 4 READ GENERAL INSTALLATION GUIDELINES SHEET 81 600 001 BEFORE PROCEEDING A WARNING MICO Disc Brake Linings do not contain asbestos Brake lining compounds do however contain elements that may become airborne during the life of the lining To prevent any health problems associated with lining dust we suggest ventilators be installed as needed on enclosed or stationary equipment A Material Safety Data Sheet is available upon request 02 500 196 20 060 082 When installing these MICO 515 Series Brakes it is of utmost importance to maintain parallelism between mounting
13. 5 or better mounting bolts or pins HYDRAULIC CONNECTION amp ADJUSTMENT PROCEDURE Refer to Figure 4 Port Size 4 SAE O ring Boss 1 Install hydraulic line leaving tube nut slightly loose to allow turning adjustment of brake module NOTE The adjusting procedure may be simpli fied if a swivel fitting is used See swivel fitting block chart Table 3 2 Bleed system using bleeder screw 8 at highest point making sure all air is eliminated A CAUTION During the bleeding process for these MICO 515 Series Brakes hydraulic pressure should not exceed 13 8 bar 200 psi Apply hydraulic pressure and check for leaks Apply rated hydraulic pressure Thread in brake module until a total clearance of approximately 30 mm 012 is obtained between disc and linings Use a spanner wrench if neces sary 6 Tighten set screw 16 and release hydraulic pres sure 7 Tighten hydraulic fitting tube nut oR Oo CHANGE SEAL KIT OR REPAIR KIT PROCEDURE Refer to Figures 3 amp 4 See Table 1 for Kit required for your brake 1 Disconnect fluid line from brake and remove caliper from vehicle or machine A CAUTION Cap end of fluid line to prevent entry of dirt into hydrau lic system 2 Remove set screw 16 from housing 19 and remove brake module housing 7 from housing 3 Position brake module housing 7 in a wheel puller Refer to Figure 3 Apply force until piston 12 retracts approximate
14. JUSTMENT PROCEDURE NOTE Do not use lever as a means to turn brake module To do so will cause piston to extend and create false settings 1 Thread in brake module housing until lining assem blies contact disc completely Back off brake module until a flat surface lines up with set screw Tighten set screw securely 2 Remove lock nut and lever from piston Position lever in desired location 3 Install lock nut on piston Torque 12 2 14 9 N m 9 12 lb ft 4 Attach actuating mechanism to lever CHANGE BALL amp CAM PROCEDURE Refer to Figures 3 amp 4 NOTE Do not use the operating lever as a means to turn the brake module 1 Disconnect actuating mechanism from lever 2 and loosen set screw 11 2 Remove brake module housing 6 and lever assembly from housing 14 3 Remove lock nut 1 and lever 2 from piston 9 4 Depress retainer 4 and remove retaining ring 3 from piston 9 5 Remove retainer 4 and five belleville springs 5 from piston 9 NOTE Note stacking sequence of belleville springs 5 for assembly purposes 6 Remove piston 9 two cam plates 7 and three balls 8 from brake module housing 6 7 Lubricate three new balls 8 with heavy waterproof grease and place between ramps of new cam plates 7 8 Install new cam plates 7 on piston 9 making sure locking lugs are aligned with holes on piston 9 Install piston 9 assembly into brake module hous
15. anada Great Britain Japan Peoples Republic of China and South Korea MICO Incorporated MICO West Division 1911 Lee Boulevard Zip Code 56003 2507 701 East Francis Street Zip Code 91761 5514 P O Box 8118 North Mankato MN U S A 56002 8118 P O Box 9058 Ontario CA U S A 91762 9058 S 507 625 6426 Facsimile 507 625 3212 T 909 947 4077 Facsimile 909 947 6054 Form No 81 515 009 Revised 9 19 01 Se Printed in U S A www comoso com
16. aterial MICO can accept no responsibility for errors from unintentional oversights that may exist Due to a continuous program of product improvement both materials and specifications are subject to change without notice or obligation MICO is a registered trademark of MICO Incorporated MICO is registered in the U S Patent and Trademark Office as well as in Canada Great Britain South Korea and Australia MICO Incorporated MICO West Division 1911 Lee Boulevard Zip Code 56003 2507 701 East Francis Street Zip Code 91761 5514 P O Box 8118 North Mankato MN U S A 56002 8118 P O Box 9058 Ontario CA U S A 91762 9058 T 507 625 6426 Facsimile 507 625 3212 T 909 947 4077 Facsimile 909 947 6054 Form No 81 515 008 Revised 5 4 99 Se Printed in U S A www comoso com Installation and Service Instructions MECHANICAL Sliding Caliper Disc Brakes TABLE 1 Model Lining Model Lining Model Lining Number Kit Number Kit Number Kit 02 515 116 20 060 036 02 515 174 20 060 082 t 02 515 180 20 060 082 t 02 515 147 20 060 082 t 02 515 175 20 060 082 02 515 186 20 060 063 02 515 148 20 060 082 02 515 176 20 060 063 t 20 100 297 20 060 082 t 02 515 149 20 060 082 02 515 178 20 060 082 02 515 150 20 060 082 t 02 515 179 20 060 097 Drive line parking brake package t Use spacer s behind lining dead side NOTE Repair Kit 02 500 133 used with all models A WARNING MICO Disc Brake Linings do not contain asbestos Brake lining compounds
17. csimile 909 947 6054 Form No 81 515 007 Revised 2 27 01 Printed in U S A www comoso com Installation and Service Instructions HYDRAULIC APPLY Sliding Caliper Disc Brakes C sss MATICO TABLE 1 02 515 025 BF 20 060 082 02 500 039 02 515 030 HO 20 060 082 02 500 038 02 515 036 HO 20 060 063 02 500 038 BF Brake Fluid HO Mineral Base Hydraulic Oil 02 515 041 BF 02 515 042 HO 20 060 082 02 500 039 20 060 082 02 500 038 READ GENERAL INSTALLATION GUIDELINES SHEET FORM NO 81 600 001 BEFORE PROCEEDING A WARNING MICO Disc Brake Linings do not contain asbestos Brake lining compounds do however contain elements that may become airborne during the life of the lining To prevent any health problems associated with lining dust we suggest ventilators be installed as needed on enclosed or stationary equipment A Material Safety Data Sheet is available upon request When installing these MICO 515 Series Brakes it is of utmost importance to maintain parallelism between mounting bolts and that caliper be centered evenly and MOUNTING PROCEDURE 1 Using Figure 1 and Table 2 determine A squarely over disc This will prevent binding of caliper and ensure even lining to disc contact 2 dimension and locate caliper mounting holes Distance from mounting surface to head of mount ing bolt is 82 6 mm 3 25 regardless of disc thickness Mount brake on disc and bolt securely to vehicle or machin
18. ditional area away from other operations precautions because contact with fiber dust is Always wear a respirator approved by NIOSH or higher during these operations In addition to MSHA during all brake service procedures Wear wearing an approved respirator do such work in the respirator from removal of the wheels through an area with exhaust ventilation assembly Cleaning the work area NEVER use compressed NEVER use compressed air or dry brushing to air or dry sweeping to clean the work area Use an clean brake parts or assemblies OSHA recom industrial vacuum with a HEPA filter and rags mends that you use cylinders that enclose the soaked in water and wrung until nearly dry Dis brake These cylinders have vacuums with high pose of used rags with care to avoid getting dust efficiency HEPA filters and worker s arm sleeves into the air Use an approved respirator when But if such equipment is not available carefully emptying vacuum cleaners and handling used clean parts and assemblies in the open air rags During disassembly carefully place all parts on the Worker clean up Wash your hands before eating floor to avoid getting dust into the air Use an drinking or smoking Do not wear your work industrial vacuum cleaner with a HEPA filter system clothes home Vacuum your work clothes after to clean dust from the brake drums backing plates use and then launder them separately without and other brake parts After using the vacuum
19. do however contain elements that may become airborne during the life of the lining To prevent any health problems associated with lining dust we suggest ventilators be installed as needed on enclosed or stationary equipment A Material Safety Data Sheet is available upon request When installing these MICO 515 Series Brakes it is of MOUNTING PROCEDURE utmost importance to maintain parallelism between aay mounting bolts and that caliper be centered evenly and b Using Figure 1 and Taa do ui fe ED sion and locate caliper mounting holes ee ag A A of caliper 2 Distance from mounting surface to head of mount g i ing bolt is 82 6 mm 3 25 regardless of disc A CAUTION thickness These MICO 515 Series Brakes are designed to be gt Mount praka om dige and bell securely to vehicle OF used with a disc thickness of 12 7 mm 50 For machine using grade 5 or better mounting bolts or other disc thicknesses contact MICO Inc pins DISC CENTERLINE TO MOUNTING HOLE DIMENSION 3 ce Re DIA pram 2 PLACES 85 6 DIA 150 mm 6 85 9 mm 3 38 2 DIA 8 MTG DN 4 PLACES H pH _ D l 263 7 mm 10 38 ASSEMBLY SCREW m zos TABLE 2 millimeters For disc diameters greater than menes ae 510 millimeters add 9 7 mm 20 inches add 38 to disc radius to FIGURE 1 obtain A dimension FIGURE 2 www comoso com AD
20. e using grade 5 or better mounting bolts or A CAUTION Models 02 515 041 amp 02 515 042 are designed to be 3 used with a disc thickness of 6 4 9 5 mm 250 375 All other models listed in Table 1 are designed to be pins used with a disc thickness of 12 7 mm 50 For other disc thicknesses contact MICO Inc DISC CENTERLINE TO MOUNTING HOLE DIMENSION Dose wom MOUNTING SURFACE 13 1 Bp DIA MTG HOLES 2 PLACES ASSEMBLY 66 3 a SCREW 26i i 457 2 mm 18 238 3 mm 9 38 508 0 mm 20 263 7 mm 10 38 gt TABLE 2 50 millimeters 26 9 inches For disc diameters greater than 70 3 i 508 0 mm add 9 7 mm 20 add 38 i FIGURE 1 DISC to disc radius to obtain A dimension FIGURE 2 www comoso com HYDRAULIC CONNECTION amp 6 Carefully install new o ring 3 and new back up ADJUSTMENT PROCEDURE ring 4 on piston 5 Note order of back up ring Refer to Figure 3 and o ring 7 Lubricate piston 5 with clean type system fluid and Port Size 1 8 27 NPTF install in brake module housing 2 Note direction 1 Thread in brake module housing 2 until a total of piston and be sure it is bottomed out in brake clearance of approximately 30 mm 012 is module obtained between disc and linings NOTE Make 8 Thread brake module housing 2 into
21. ear Adequate fluid levels must be maintained In the event of any loss of fluid the brake system must be carefully inspected for leaks MICO is a registered trademark of MICO Incorporated MICO is registered in the U S Patent and Trademark Office as well as in Canada Great Britain South Korea and Australia MICO Incorporated 1911 Lee Boulevard Zip Code 56003 2507 P O Box 8118 North Mankato MN U S A 56002 8118 T 507 625 6426 Form No 81 600 001 Facsimile 507 625 3212 Revised 5 97 A S Conga MICO West Division 701 East Francis Street Zip Code 91761 5514 P O Box 9058 Ontario CA U S A 91762 9058 T 909 947 4077 Facsimile 909 947 6054 Printed in U S A a9 SS www comoso com Burnishing Procedures for MICO Caliper Disc Brakes TECHNICAL NOTICE Maximum torque will be achieved only after the brake has been properly burnished Actual customer testing will be required to determine final acceptance and approval of brake system components MICO recommends the following SAE burnishing pro cedures be performed immediately following the installa tion and adjustment of the brake These SAE recommended practices J360 paragraph 7 3 for parking brakes and J786a paragraph 5 5 for service brakes are intended to be used as guidelines only Contact the vehicle or equipment manufacturer for specific recommendations PARKING BRAKE Make 10 stops from 10 mph 45 m s at 3 ft s 0 9 m s
22. ections are in good condition and tightened to proper torque values as specified in the installation and service instructions Importance of Bleeding The hydraulic brake system must be bled whenever any line has been disconnected Air trapped in the system can cause spongy and inadequate brakes There are two methods of bleeding hydraulic systems pressure bleeding and manual bleeding Both methods are acceptable and adequate but pressure bleeding is recommended if the equipment is available Follow bleeding instructions as specified by vehicle manufacturer To properly bleed the system Be certain all fittings are tight to avoid leaking Depress pedal and open up bleeder screws to allow air to escape Air will always seek the highest level Retighten bleeder screws and allow pedal to return Repeat cycle until pedal is firm Make several static brake applications and then repeat cycle once more ORO No Leak in the System Even the smallest leak in a brake system will adversely affect the system A leak may eventually deplete the reserve supply and reduce braking pressure To help prevent leaking 1 Check connections during bleeding and static brake processes to be sure they are tight 2 Always reinstall new hoses lines and fittings if they look the least bit questionable 3 Brake hoses brake lines MICO locking device brake components cylinders and all fittings must be routinely inspected for leaks damage or w
23. housing 11 sure piston 5 is bottomed out in brake module until a total clearance of approximately 30 mm housing 2 012 is obtained between disc and linings 2 Back off brake module housing 2 as required to 9 Back off brake module housing 2 as required to position ports in vertical alignment position ports in vertical alignment 3 Tighten set screw 8 10 Insert new nylon plug 7 into set screw 8 hole 4 Move bleeder screw 1 to higher of two ports for Install nylon plug 7 even if originally not included ease of bleeding Torque bleeder screw 1 on your model 16 3 19 0 N m 12 14 lb ft 11 Install and tighten set screw 8 5 Install hydraulic line in lower port 12 Move bleeder screw 1 to higher of two ports for 6 Bleed system making sure all air is eliminated ease of bleeding Torque bleeder screw 1 16 3 19 0 N m 12 14 lb ft A CAUTION 13 Install hydraulic line in lower port During the bleeding process for these MICO 515 Se 14 Bleed system making sure all air is eliminated ries Brakes hydraulic pressure should not exceed 13 8 bar 200 psi 7 Apply rated hydraulic pressure and check for leaks CHANGE SEAL PROCEDURE Refer to Figures 3 amp 4 See Table 1 for Repair Kit required for your brake 1 Disconnect necessary fluid line from brake and remove caliper from vehicle or machine A CAUTION Cap end of fluid line to prevent entry of dirt into hy draulic system 2 Rem
24. ly 80 mm 03 Using a spanner wrench remove piston 1 4 Carefully remove o ring 3 and back up ring 2 from piston 1 NOTE Care must be taken so as not to scratch or mar piston Due to the extreme pressure created by the belleville springs 11 the pro cedure shown in Figure 3 is needed to disassemble brake module housing 7 SPANNER WRENCH SPECIAL TOOL MAY BE REQUIRED TO STOP PISTON ASSEMBLY FROM TURNING FIGURE 3 WHEEL PULLER 4 Ne m 12 7 STANDARD 50 DRILL POINT millimeters inches 5 Remove wheel puller from brake module housing 7 Carefully remove piston 12 washers 10 belleville springs 11 spacer 9 back up ring 6 o ring 5 and insert 4 from brake module housing Note Care must be taken so as not to scratch or mar brake module housing bore NOTE Note number and order of belleville springs 11 washers 10 and spacer 9 for assembly purposes 6 Remove cup 13 from piston 12 NOTE In older models item 13 will be an o ring 7 Clean all parts thoroughly and lubricate all rubber components from seal kit or repair kit with clean type system fluid 8 Carefully install new back up ring 6 new o ring 5 and insert 4 in brake module housing 7 Note order of back up ring and o ring 9 Carefully install new o ring 3 and new back up ring 2 on piston 1 Note order of o ring and back up ring 10 Carefully install piston 1 in
25. ncluded in the lining kit PROCEDURE Section 2 Thread brake module housing 7 out of housing 19 so that piston 12 is flush with housing MICO could not possibly know of and give advice with respect to all conceivable applications in which this product may be used and the possible hazards and or results of each application MICO has not undertaken any such wide evaluation Therefore anyone who uses an application which is not recommended by the manufacturer first must completely satisfy himself that a danger will not be created by the application selected or by the particular model of our product that is selected for the application MICO has made every attempt to present accurate information in catalogs brochures and other printed material MICO can accept no responsibility for errors from unintentional oversights that may exist Due to a continuous program of product improvement materials specifications and product documentation are subject to change without notice or obligation MICO is a registered trademark of MICO Incorporated MICO is registered in the U S Patent and Trademark Office as well as in Canada Great Britain South Korea Australia and Japan MICO Incorporated MICO West Division 1911 Lee Boulevard Zip Code 56003 2507 701 East Francis Street Zip Code 91761 5514 P O Box 8118 North Mankato MN U S A 56002 8118 P O Box 9058 Ontario CA U S A 91762 9058 507 625 6426 Facsimile 507 625 3212 909 947 4077 Fa
26. ove set screw 8 from housing 11 and re Apply hydraulic pressure and check for leaks CHANGE LINING PROCEDURE Refer to Figure 3 See Table 1 for Lining Kit required for your brake Lining assemblies 10 can be replaced without removing brake module housing 2 1 Remove cap screw 6 and spring clip 9 allow lining assemblies 10 to drop out of housing 11 NOTE On small diameter discs with large hubs it may be necessary to remove one mounting bolt and swing housing aside to free lining assemblies Earlier models used a com pression spring which is not included in the lining kit 2 Make sure piston 5 is bottomed out in brake mod move brake module housing 2 from housing 11 le housing 2 Loosen set screw 8 and thread 3 Place brake module housing 2 face down on bench support brake module so piston 5 can be slike ian ihe ao 11 so eased aul el ore THIS IS accomplished by pake 3 inet new lining assemblies i 0 in housing 11 fully introducing ow alr pressure AY par 4 Install new spring clip 9 and cap screw 6 and 10715 Pst through the hydraune line port torque 13 6 16 3 N m 10 12 lb ft NOTE If the A CAUTION lining kit does not include new spring clip 9 Do not use high pressure as it is dangerous and un reinstall compression spring 5 To continue refer to HYDRAULIC CONNECTION amp necessary Use just enough air pressure to ease the ADJUSTMENT PROCEDURE Section piston ou
27. rk Office as well as in Canada Great Britain South Korea and Australia MICO Incorporated 1911 Lee Boulevard Zip Code 56003 2507 P O Box 8118 North Mankato MN U S A 56002 8118 507 625 6426 Facsimile 507 625 3212 Form No 81 950 016 Revised 10 14 98 MICO West Division 701 East Francis Street Zip Code 91761 5514 P O Box 9058 Ontario CA U S A 91762 9058 909 947 4077 Facsimile 909 947 6054 Printed in U S A www comoso com Recommended Brake Service Procedures to Reduce Exposure to Non Asbestos Fiber TECHNICAL NOTICE MELE FOR ALL MICO NON ASBESTOS BRAKE LININGS Recently manufactured brake linings no longer contain inhaling non asbestos fibers Some experts asbestos fibers In place of asbestos these linings nonetheless think that long term exposure to some contain a variety of ingredients including glass fibers non asbestos fibers may cause diseases of the lung mineral wool aramid fibers ceramic fibers and including pneumoconiosis fibrosis and cancer There carbon fibers At present OSHA does not specifically fore MICO recommends that workers use caution to regulate these non asbestos fibers except as nui avoid creating and breathing dust when working on sance dust Medical experts do not agree about the brakes that contain non asbestos fibers potential long term risks from working with and A WARNING Whenever possible work on brakes in a separate grind or machine brake linings take ad
28. t of the bore Do not blow piston out of the bore If the piston is seized or cocked or does not come out readily release the air pressure and use a soft brass hammer to rap sharply on and around the end of the piston Reapply air pressure to remove the piston 4 Remove o ring 3 and back up ring 4 from piston 5 NOTE Be careful not to scratch or mar piston 5 Clean all parts thoroughly and lubricate all rubber components from Repair Kit with clean type fluid used in the system www comoso com FIGURE 3 7 y 4 Q SQ RO SANS S gt ELN YX R 6 DBR SS a RSS SY K KX RY KSJ KO 4 4 eS y f 35 A Items included in Lining Kit Items included in Repair Kit Not included in all lining kits FIGURE 4 MICO could not possibly know of and give advice with respect to all conceivable applications in which this product may be used and the possible hazards and or results of each application MICO has not undertaken any such wide evaluation Therefore anyone who uses an application which is not recommended by the manufacturer first must completely satisfy himself that a danger will not be created by the application selected or by the particular model of our product that is selected for the application MICO has made every attempt to present accurate information in catalogs brochures and other printed m
29. to brake module housing 7 11 Lubricate all items as shown in Figure 4 with a light www comoso com coat of heavy waterproof grease See GREASE 12 Install new cup 13 on piston 12 and carefully NOTE Figure 4 Install belleville springs 11 install in brake module housing 7 by threading washers 10 and spacer 9 into brake module onto piston 1 Note direction of cup housing 7 NOTE If seal kit is being installed 13 Reposition brake module housing 7 in wheel use existing belleville springs after completely puller Refer to Figure 3 Apply force until piston lubricating with a light coat of heavy water 12 moves approximately 80 mm 03 Using a proof grease See GREASE NOTE Figure 4 If spanner wrench tighten piston 1 securely repair kit is being installed use new belleville 14 Remove wheel puller springs already greased Be sure to use the 15 Install brake module housing 7 into housing 19 same number of belleville springs and washers in Hand tighten brake module housing the same order as when they were disassembled Items included in Seal Kit A Items included in Repair Kit e FIGURE 4 E Items included in Lining Kit oat uw Not included in all Lining Kits a Lo arn Cog os FULLY GREASE THESE SURFACES FULLY GREASE JHIS SURFACE He eu i me D Se If Sie e Mi FULLY GREASE g ALL SURFACES OF P ITEMS 9 10 AND 11 f p FULLY GREASE
30. unction with MICO Caliper Disc Brakes Depending on strength and performance requirements low to medium carbon steel is generally recommended Fabrication proce dures are as follows Flame cut or machine to required outside diameter with inside diameter machined to size Stress relieve after all machining operations Blanchard ground to a surface finish of 54 Ra to 72 Ra with a visible cross hatch pattern Surfaces to be parallel within 05 mm 002 Surfaces to be flat within 13 mm 005 MICO could not possibly know of and give advice with respect to all conceivable applications in which this product may be used and the possible hazards and or results of each application MICO has not undertaken any such wide evaluation Therefore anyone who uses an application which is not recommended by the manufacturer first must completely satisfy himself that a danger will not be created by the application selected or by the particular model of our product that is selected for the application MICO has made every attempt to present accurate information in catalogs brochures and other printed material MICO can accept no responsibility for errors from unintentional oversights that may exist Due to a continuous program of product improvement both materials and specifications are subject to change without no tice or obligation MICO is a registered trademark of MICO Incorporated MICO is registered in the U S Patent and Tradema
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