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PAN 22-1 Assembly and Maintenance Instructions

1. Risk of injury due to falling brake parts vice to clamp the brake when per forming repairs on the brake out side the vehicle 1 3 Repair and maintenance instruc tions For good handling and braking characteristics it is essential that the disc brake be in flawless technical condition If cast parts have been heavily damaged or are severely worn cracks for example replace the entire brake following the instructions Do not open the clamping unit on the brake calli per and do not unscrew the fastening screws on the clamping unit cover Do not apply the brake when brake linings have been removed Do not use compressed air or other high pressure devices when cleaning the brake or the vehicle This may result in the risk of personal injury or hazardous dusts Rubber parts of the brake could also be damaged Only use original WABCO parts and approved brake linings An exploded view of replacement parts is found in the annex of this document see chapter 8 2 Exploded view of the replacement parts page 33 Only use grease contained in the repair kits Perform the repair work using only the recom mended tools Do not use motor driven screw tools Tighten screws and nuts only with the speci 6 WABCO Use suitable equipment such as a fied spanners applying only the specified tighten ing torque refer to the table in Annex see chap ter 8 1 Widths A F and tightening torques pag
2. Press in the closing cover right up the end position using the fitting tool for closing covers A B from the WABCO tool box 12 851 021 On assembly ensure that the gaiters 5 are not damaged or twisted during tightening the bolts 6 7 Always tighten the longer guide pin 8 with press fit first and then the shorter guide pin 9 with clearance If the guide pins 8 9 are released from the brake anchor plate 2 during the maintenance work new screws 6 7 must be used for reassembly Manually move the brake calliper on the guide Avoid damaging the covers while pressing them pins 8 9 across the entire displacement path in and check for ease of movement repeat the ac tion a number of times Install the brake brake linings and brake cylinder see chapter 5 2 Installing the brake page 27 6 2 Renewing the protection cap of the adjuster screw If the gaiter is removed individually brake calliper and brake cylinder need not be dismantled Removing the gaiter Remove the brake linings and the pressure plate see chapter 4 1 Removal of the brake linings page 74 Push the calliper towards the cylinder side by hand Do not squeeze the guide pin protection caps against the brake anchor plate while moving the calliper WABCO 25 6 PAN 22 1 Renewing the sealings Pull the protection cap 10 from the sealing seat ring groove of the adjuster screw 21 is i
3. Use the ring spanner to turn hexagon 22 of the adjuster anticlockwise until the adjuster screw reaches the brake disc and check for ease of movement 7 a tg a L 7 F B ii l i oy a z ae a a p oe There must be sufficient space for the engaged ring spanner it must not be obstructed when it is turned during adjustment Do not use an open end spanner for the hexagon 22 of the adjuster and never overstrain the hexagon nut Otherwise the hexagon will be dam aged Use the ring spanner to turn hexagon 22 clock wise back to the stop limit When returning the hexagon 22 clockwise the torque is greater than the torque to turn anti clockwise Gently apply the brake 5 times braking pressure approx 1 bar The adjuster is functioning when the ring spanner turns anti clockwise with every brake actuation With increasing adjustment the angle of rotation of the engaged ring spanner becomes smaller The adjuster is working correctly if the ring spanner rotates anti clockwise as described above Faults that might occur The engaged ring spanner e does not e rotate only with the initial brake action e rotates forward and backward with every brake action In these cases the adjuster is faulty and the brake must be replaced see chapter 5 Renewing the brake page 20 PAN 22 1 4 Check the brake discs see chapter 3 3 Inspec tion of the brake discs pag
4. WABCO 9 3 PAN 22 1 Service Instructions 3 Service Instructions CAUTION Risk of injury Observe all safety instructions as well as all repair and maintenance instructions see chapter 1 Impor tant instructions and safety in structions page 5 These instructions must be ob served to avoid personal injury or material loss 3 1 Checking the brake 3 1 1 Checking the adjuster Directions of rotation and torques of the hexagon nut of the adjuster are listed in the table in the annex see chapter 8 1 Widths A F and tighten ing torques page 37 item Remove the sealing plug 12 of the adjuster aF na When removing the sealing plug apply the respec tive tool such as a screwdriver only to the sealing plugs and do not damage the gaiter 13 of the ad juster or the Brake calliper 10 WABCO Check the gaiter 13 for wear and damage Renew defect gaiter 13 of the adjuster see chapter 6 3 Renewing the gaiter on hexagon nut of the adjuster page 27 Use the ring spanner to turn hexagon 22 of the adjuster 2 turns clockwise see chapter 8 1 Widths A F and tightening torques page 31 item I ir ae me i k k d s s a There must be sufficient space for the engaged ring spanner it must not be obstructed when it is turned during adjustment Do not use an open end spanner for the hexagon 22 of the adjuster and never overstrain
5. Clean the bores in the calliper mounting instructions in the tool box Assembly A B G C Press in two new bushings for the longer guide pin Use pin A and insert mandril F to press the inner bushing 4 into the bores of the brake calli per 1 on the brake disc entry side right to the end stop of the insert mandril F D E A Pin l l B Fitting tool for closing covers Use the pin A and the insert mandril E to press the outer bushing 4 into the same bore right up C Extrusion mandril to end stop D E F G Insert mandril 6 PAN 22 1 Renewing the sealings Grease the space between the bushings and the Position the beaded edge of the protection caps 5 sliding surfaces of the bushings into the sealing seats ring grooves of the guide pins 8 9 Ensure that the metal ring does not Use pin A and insert mandril D to press a new move off gaiter bushing 4 for the short guide pin into the bores of the brake calliper 1 on the brace disc exit side right to the stop position of the insert mandril Ensure that the beaded edge of the protection caps 5 have an even and wrinkle free seat on the brake calliper 1 and the guide pins 8 9 Remove any excess grease The plane surfaces Grease the sliding surfaces of the bushings of the guide pins to the brake anchor plate and the contact areas of the brake anchor plate must be Clean the sealing seats ring groove of
6. Important instructions and safety instructions PAN 22 1 1 Important instructions and safety instructions 1 1 General Information 1 2 Safety instructions WARNING A This publication describes maintenance and repair of the disc brakes PAN 22 1 including the individual operations and work processes required to replace components using available repair kits Reduced braking effect or brake failure Danger of accidents This publication is directed at trained service technicians employed at workshops for commer cial vehicles Before you begin with maintenance repair re placing a part etc carefully read all the safety instructions as well as the repair and maintenance instructions included this publication These in structions must be observed to avoid personal injury or material loss WABCO only guarantees the safety reliability and performance of its products and systems if all instructions notes and safety instructions are observed WARNING Before you perform any work on the vehicle repair maintenance replacing parts etc you must ensure the following Only trained and qualified personnel may perform repairs on the vehicle Always follow specifications and instructions of vehicle manufacturer Always comply with the Company and national accident prevention guidelines and Health and Safety regulations CAUTION Wear any necessary protective clothing The workplace
7. the hexagon nut Otherwise the hexagon will be dam aged Gently apply the brake 5 times braking pressure approx 1 bar The adjuster is functioning when the ring spanner turns anti clockwise with every brake actuation With increasing adjustment the angle of rotation of the engaged ring spanner becomes smaller The adjuster is working correctly if the ring spanner rotates anti clockwise as described above Service Instructions PAN 22 1 3 Faults that might occur Optical pad wear indication The engaged ring spanner The medium brake pad wear can be measured with a does not tape measure or a ruler depending on the access a either at the fitted pin long guide pin at disc leading TORAO At Mie AE AACO side or at the non fitted pin short guide pin at the e rotates forward and backward with every brake disc trailing side action Place ruler on the surface of the brake carrier In these cases the adjuster is faulty and the brake hatched area in picture arrow must be replaced see chapter 5 Renewing the brake page 20 Reset the clearance to 1 mm having completed the adjuster test see chapter 4 3 Fitting the brake linings page 77 Insert the sealing plug 12 into the adjuster and ensure that the plug has a tight seat 3 2 Inspection of the brake linings The brake lining thickness must be checked at regular intervals in relation to vehicle use during maintenance intervals as well a
8. the brake free of grease calliper for the protection caps The sealing seats must be free of grease Manually move the guide pin in the bushings l l backwards and forwards and check for ease of Push the new green protection caps 5 into the movement sealing seats ring groove of the brake calliper 1 Grease the sliding surfaces of the guide pins 8 9 and the inner lip of the gaiters 5 Insert a new long guide pin 8 from the cylinder side into the calliper brake disc leading side Place the calliper 1 on the brake anchor plate 2 and the inserted guide pins 8 9 into the fitting collar Insert a new short guide pin 9 from the cylinder side into the calliper brake disc trailing side Slide the protection caps 5 over both guide pins neere nen screws 6 7 thiowahinecuide pins inserted in the brake calliper 1 Use the long screw 6 for the long guide pin 8 and the short screw 7 for the short guide pin 9 24 WABCO Renewing the sealings PAN 22 1 6 Fasten the screws to the brake anchor plate 2 Grease the bores for the closing cover 11 11 1 see chapter 8 1 Widths A F and tightening in the brake calliper 1 torques page 37 item IV Insert the new closing covers 11 11 1 into the bores of the brake calliper 1 Use the long clos ing cover 11 1 for the long guide pin 8 and the short closing cover 11 for the short guide pin 9
9. 5 mm Fasten the dial indicator to the brake calliper Install the brake linings and adjust the clearance With the brake disc installed check the disc see aad 4 3 Fitting the brake linings runout by rotating the wheel hub Limit value page 17 0 15 mm WABCO 13 4 PAN 22 1 Replacing the brake linings 4 Replacing the brake linings CAUTION Risk of injury Observe all safety instructions as well as all repair and maintenance instructions see chapter 1 Impor tant instructions and safety in structions page 5 These instructions must be ob served to avoid personal injury or material loss 4 1 Removal of the brake linings Disconnect the plug connection 40 of the wear indicator 40 Remove the hexagon head screw 39 from the lining retainer 38 See chapter 8 1 Widths A F and tightening torques page 37 item Il The lining retainer 38 has to be withdrawn from the calliper 1 14 WABCO Remove three hold down springs 37 from the brake linings 35 and 36 and the pressure plate 19 Remove the cable guide 40 with the wear indica tors Remove the spring clips 41 from the calliper Remove the sealing plug 12 of the adjuster from the calliper 1 hen removing the sealing plug apply the respective ool such as a screwdriver only to the sealing plugs and do not damage the gaiter 13 of the adjuster or the Brake calliper Check t
10. PAN 22 1 Assembly and Maintenance Instructions PAN 22 1 Assembly and Maintenance Instructions Edition 3 This publication is not subject to any update service You will find the latest version in INFORM www wabco auto com 2009 WABCO The right of amendment is reserved Version1 06 2009 en 815 010 066 3 PAN 22 1 Table of Contents Important instructions and safety instructions 1 1 General Information 1 2 Safety instructions 1 Repair and maintenance instructions 1 4 Symbols used Description of the mechanical sliding calliper disc brake Service Instructions 3 1 Checking the brake 3 1 1 Checking the adjuster 3 2 Inspection of the brake linings 3 0 Inspection of the brake discs Replacing the brake linings 4 1 Removal of the brake linings 4 2 Checking the protection caps and the ability of the brake calliper to move 4 3 Fitting the brake linings Renewing the brake 5 1 Removing the brake 92 Installing the brake Renewing the sealings 6 1 Renewing the protection caps and the bushings of the guide pins 6 2 Renewing the protection cap of the adjuster screw 6 3 Renewing the gaiter on hexagon nut of the adjuster Replacing the brake cylinder Annex 8 1 Widths A F and tightening torques 8 2 Exploded view of the replacement parts 8 3 Procurement and disposal of spare parts WABCO Ooon on oO 10 10 10 11 12 14 14 16 17 20 20 21 22 22 25 2 29 31 31 33 34
11. e Remove the protection cap 10 from the sealing seat of the brake calliper Check the brake calliper If dirt or moisture has entered the brake or if the sealing seat in the brake calliper or the thread of the adjuster screw is damaged replace the brake see chapter 5 Renewing the brake page 20 Fit the rim side brake lining into the lining slot so that the adjuster screw cannot be screwed out of the adjuster completely Secure the adjuster screw 21 on the pin against twisting 26 WABCO Use a ring spanner to turn the hexagon 22 anti clockwise until the adjuster screw has been screwed outwards approx 30 mm by this action see chapter 8 1 Widths A F and tightening torques page 37 item oul ee N F m r i a m During this process check the thread of the ad juster screw 21 for corrosion and damage If the thread is damaged or corroded renew the brake see chapter 5 Renewing the brake page 20 The gaiter 10 can be renewed if no dirt or water has penetrated into the brake calliper or if the gaiter has been damaged during servicing the brake Clean the sealing seat arrow of the gaiter 10 in the brake calliper Ensure that no dirt or moisture enters the brake when cleaning Grease the thread of the adjuster screw 21 Use a ring spanner to turn the hexagon 22 anti clockwise until the adjuster screw has been pa
12. e 37 for the corresponding positions Perform a concluding roller test stand test having completed the repairs If no roller test stand is available conduct a test drive with brake action tests Do not perform full braking with the exception of emergency braking during the first 50 km after new brake linings have been fitted Also avoid continuous braking over longer periods Ensure that the driver of the vehicle is informed 1 4 Symbols used DANGER WARNING Imminent hazard situation which can cause serious personal injury or death if the safety instruction is not observed CAUTION Potential hazard situation which can cause death or serious per sonal injury if the safety instruction is not observed Potential hazard situations that can cause minor or moderate to severe injury or material loss if the safety instruction is not ob served e List Step Important instructions information or tips that you should always observe Description of the mechanical sliding calliper disc brake PAN 22 1 2 2 Description of the mechanical sliding calliper disc brake The brake PAN 22 1 is a one piston brake The brake is supposed to be used in commercial vehicles and trailers on front and rear axles for 22 5 wheel rims as service auxiliary and parking brake It is actuated mechanically via a diaphragm brake cylinder or a spring brake actuator The latter is f
13. e 72 4 3 Fitting the brake linings To insert the brake linings on the cylinder side push the calliper towards the cylinder side until there is sufficient distance to the brake disc Insert the pressure plate 19 into the brake an chor plate and push the pressure plate against the adjuster screw 21 Ensure that the pressure plate is seated in the guide groove of the brake anchor plate and that it rests with the entire surface on the guide strips of the brake anchor plate Otherwise the pressure plate could slide out of the guiding If required push the calliper a little towards the rim side The pin of the adjuster screw must mesh with the groove small arrow of the pressure plate other wise the adjustment will not function correctly Turn the adjuster screw until the pin meshes with the groove of the pressure plate Ensure that the protection cap is not twisted WABCO 17 4 PAN 22 1 Replacing the brake linings Fit a new brake lining 36 on the cylinder side Fit two new spring clips 41 in the brake calliper Push the calliper towards the rim side until the Place the cable guide 40 with preassembled brake lining 36 of the cylinder side bears against wear indicators onto the brake calliper and insert the brake disc the indicators circle into the brake linings m 1 44 41 Fita new brake lining 35 on the rim side Ensure that each wear side of the indicators Ad
14. ecuted combined 6 1 Renewing the protection caps and the bushings of the guide pins Disassembly Remove brake linings the brake cylinder the wear sensor and the brake calliper with brake an chor plate from the axle see chapter 5 1 Remov ing the brake page 20 Remove the closing cover 11 11 1 of the guide pins 8 9 from the brake calliper 1 spective tool such as a chisel only to the closing cover and do not damage the seat of the closing cover on the brake calliper 22 WABCO When removing the sealing plug apply the re Unscrew the screws 6 7 see chapter 8 1 Widths A F and tightening torques page 37 item IV and remove the brake calliper 1 from the brake anchor plate 2 Danger of bodily injury Risk of injury due to unsecured brake calliper Clean the contact areas fitting collars to the guide pins on the brake anchor plate 2 Remove the guide pins 8 9 from the brake calli per 1 Remove the protection caps 5 from the ring groove of the Brake calliper 1 Renewing the sealings PAN 22 1 6 Place the brake calliper 1 on a firm base for Press the bushings 4 out of the brake calliper 1 pressing out the bushings 4 The cover opening using the pin A and the extrusion mandril C of the brake calliper must face upwards For replacing the bushes use the tools from WABCO tool box 12 851 021 and pay attention to the detailed
15. ess damaged Optionally the disc brake is equipped with an electri cal wear indicator threshold indicator When the indicators in the vehicle light up the mini mum lining thickness has been reached It is neces sary to drive the vehicle to a workshop for the brake linings to be replaced WABCO 2 PAN 22 1 Description of the mechanical sliding calliper disc brake 49 af 39 40 JB 46 19 41 iO Li ii 11 11 1 Ej perg 59 eee 2 Ss a fig 2 2 Top view and sectional view 1 Brake calliper 22 Hexagon nut of the adjuster 2 Brake anchor plate 35 Brake lining rim side 6 Guide pin long 36 Brake lining cylinder side 7 Internal hexagon bolt short 37 Hold down spring 8 Internal hexagon bolt long 38 Lining retainer 9 Guide pin short 39 Hexagon screw 11 Closing cover short 40 Cable guide with wear indicator 11 1Closing cover long 41 Holding clip 13 Gaiter on hexagon nut of the adjuster A Direction of rotation driving forward 19 Pressure plate 8 WABCO Description of the mechanical sliding calliper disc PAN 22 1 2 brake 5 11 1 12 F WP L JL fig 2 3 Page preview and sectional view 1 Brake calliper 35 Brake lining rim side 2 Brake anchor plate 36 Brake lining cylinder side 5 Protection caps for guide pins 37 Hold down spring 11 1 Closing cover long 38 Lining retainer 12 Sealing plug for adjustment 39 Hexagon screw 19 Pressure plate A Direction of rotation driving forward
16. has to be dry as well as suffi ciently lit and ventilated CAUTION CAUTION Regularly check the wear limits of brake linings and brake discs Replace worn scorched glazed or oily brake linings immediately Immediately replace worn or dam aged brake discs Always replace all brake linings and brake discs on an axle Rolling vehicle Danger of accidents Position the vehicle on an even surface and secure it against roll ing away with brake wedges Only use approved devices to jack up and secure the vehicle Ensure that the gearbox is in neu tral and that the hand brake is ap plied Risk of injury due to hazardous dusts Do not clean any soiled areas of the brake with compressed air or other high pressure devices Risk of injury due to heavy load A second technician must assist during removal and installation of the brake Risk of injury due to brake action while working on the brake Attach a clearly marked note on the steering wheel saying that work is being performed on the vehicle and that the brake must not be touched WABCO 5 PAN 22 1 Important instructions and safety instructions CAUTION AN Only grip the brake on the outside with your hands while moving the brake calliper or working on the brake CAUTION Risk of injury Crushing of fingers Do not use motor driven screw tools
17. he gaiter 13 for wear and damage Renew defect gaiter 13 of the adjuster see chapter 6 3 Renewing the gaiter on hexagon nut of the adjuster page 27 Replacing the brake linings PAN 22 1 4 Push the calliper 1 towards the cylinder side Use a ring spanner to turn the hexagon 22 of the arrow by hand adjuster clockwise to the stop position and then turn the hexagon back in anticlockwise direction Remove the brake lining 36 and pressure plate by 90 19 on the cylinder side While turning the hexagon 22 use your hand to push the pressure plate 19 towards the cylinder side to ensure that the pin as an antirotation ele ment for the adjuster screw 21 does not slip out of the retaining groove of the pressure plate Danger of bodily injury Otherwise the adjuster screw could turn and so damage the protection cap 10 Do not apply the brake when brake linings have been removed Push the calliper 1 towards the rim side arrow by hand _ a Use a wire brush to clean pressure plate lining Remove the brake lining 35 on the rim side slot and pressure plate guide and remove any corrosion on these components Take care not to damage the protection caps 5 10 while cleaning The guide surfaces of the brake linings on the brake anchor plate must be free of grease 4 PAN 22 1 Replacing the brake linings 4 2 Checking the protection caps and y i Fotke ahea
18. ined by means of the brake s lining retainer 38 and hexagon screw 39 positions Use the following scheme The retention aperture for the lining retainer 38 and the thread opening for the hexagon screw 39 in the calliper are always offset relative to the brake centre M axle by an axle offset V in the brake disc exit direction brake disc direction of rotation driving forward 5 1 Removing the brake The graphic representation of the brake carrier may differ from the actual design so that the rep resentation does only apply in principle Remove the brake linings see chapter 4 1 Re moval of the brake linings page 74 Remove the brake cylinder from the calliper see page 29 Disconnect the plug connection of the wear indica tor Remove the brake calliper with brake anchor plate from the axle see chapter 8 1 Widths A F and tightening torques page 37 item Ill Check the brake disc see chapter 3 3 Inspection of the brake discs page 72 Check the dismantled brake linings and replace if necessary see chapter 3 2 Inspection of the brake linings page 77 Renewing the brake PAN 22 1 5 5 2 Installing the brake Install pressure plate brake linings and wear indicators and adjust the clearance see chap eater mm tr ge gu pregy ye Citti k li 17 l Observe the mounting instructions of the vehicle ter 4 3 Fitting the brake linings page 17 manufacturer
19. instructions as well as all repair and maintenance instructions see chapter 1 Impor tant instructions and safety in structions page 5 These instructions must be ob served to avoid personal injury or material loss Only use brake cylinders as specified by the vehi cle manufacturer The instruction to replacing the brake cylinder serves as general information Observe the instal lation guidelines as well as instructions for testing and installation of the brake cylinder manufacturer and adhere it strictly Removing the brake cylinder Unscrew the air connection from the brake cylin der Ensure that the air connection of the brake cylin der is pressureless Unscrew the brake cylinder nuts see chapter 8 1 Widths A F and tightening torques page 37 item V Remove the brake cylinder from the brake calliper Ensure that no dirt or moisture enters the brake when removing the brake cylinder Installing the brake cylinder Clean the sealing area on the brake calliper and grease the calotte in the brake lever arrow aes ai EMA Ensure that no dirt or moisture enters the brake when cleaning Attach the brake cylinder to the brake calliper and screw the brake cylinder manually with new fas tening nuts until the brake cylinder rests against the surface of brake calliper Screw the brake cylinder with approx 120 Nm Tighten the fastening nuts with app
20. ion guideline of the axle or vehicle manufacturer and adhere it screwed connec strictly tion IV Guide pin 14 X 310 30 Nm screwed connec l fon Tightening sequence for guide pins e 1 long hexagon socket screw fit pin e 2 short hexagon socket screw clearance fit pin V Brake cylinder 24 X 210 30 Nm tion screwed connec e Screw on the fastening nuts manually till the brake cylinder rests against the surface e Tighten the fastening nuts with approx 120 Nm e Tighten the fastening nuts with 210 30 Nm Use fastening nuts only once The tightening torques apply for original WABCO cylinders WABCO 31 Annex PAN 22 1 Display of positions of widths A F and tightening torques fig 8 1 WABCO 32 Annex PAN 22 1 8 2 Exploded view of the replacement parts fig 8 1 Illustration of a left brake 1 Brake calliper 11 1 Closing cover long 2 Brake anchor plate 12 sealing plug of the adjuster 4 Bushes for guide pins 13 Protection cap for the hexagon of the adjuster 5 Protection caps for guide pins 35 Brake lining rim side 6 Internal hexagon bolt long 36 Brake lining cylinder side 7 Internal hexagon bolt short 37 Hold down springs 8 Guide pin long 38 Lining retainer 9 Guide pin short 39 Hexagon screw 10 Protection cap for adjuster screw 40 Cable guide with wear indicator 11 Closing cover short 41 Clip WABCO 33 8 PAN 22 1 Annex 8 3 P
21. itted directly onto the brake calliper thereby reducing the overall axial length of the brake This enables optimal utilisation of the installation situations The entire disc brake consists of brake cylinder brake calliper 1 and brake anchor plate 2 fig 2 1 Entire disc brake 1 Brake calliper 2 Brake anchor plate Arrow Direction of movement of the brake caliper Functional description More information is provided in the illustrations below Axial movement of the brake calliper 1 occurs on the guide pins 8 9 of the brake carrier 2 In the brake carrier the brake pads 35 36 are guided and supported axially relocatable The brake lining sup port is implemented by means of a retainer 38 and hold down springs 37 The radially open design of the brake calliper allows simple and quick changes of the brake pads Brake pads with a large wear volume are used in order to prolong the pad replacement intervals with this brake For compensating the pad wear the actuating mechanism of the brake is equipped with an auto matic adjuster mechanism This mechanism main tains a preset clearance regardless of load and oper ating conditions This together with a stable and stiff construction of the brake calliper results in a safe control of the pedal travel and increases the distance reserve for emergency braking The internal moving components are lubricated for life and all sealing components are maintenance free unl
22. iust the cl b taimm Teel points towards the brake disc and that the indica 7 Uist et Me dA IM a hcg tors are inserted completely into the brake pad gauge arrow For this purpose insert the feeler gauge between the brake lining of the rim side and the calliper Turn the hexagon 22 of the ad Position the cable guide 40 and the cable outlet juster anticlockwise with a ring spanner until both of the wear indicators onto the brake calliper brake linings bear on the brake disc When laying the cable ensure that the cable does not touch the brake lining Place the new hold down springs 37 over the cable guide onto the brake linings 35 36 and the pressure plate 19 Always insert the feeler gauge into the centre between brake calliper 1 and brake lining sup port plate 35 Do not use an open spanner for the hexagon 22 of the adjuster Otherwise the hexagon will be damaged 18 WABCO Replacing the brake linings PAN 22 1 4 Push the new lining retainers 38 through the Fasten the cable to the spring clip 41 of the openings in the cable guide into the openings ar brake calliper rows of the brake calliper Press down the lining retainer so that the radial lugs of the hold down springs mesh with the re tainer Ensure that the cable has been laid correctly and fix the cable in position using cable ties Push a new sealing plug 12 into the opening of the brake calliper Ens
23. le The brake discs must be cleaned and free of grease Having installed new brake discs it is recom mended that new brake linings be fitted as well T Tss nn aN F SS EMSS WANN SIASIVAQag as D AY Lining thickness with lining support limit value 11 mm minimum lining thickness Overall thickness new lining with lining support 32 mm pad backplate thickness 9 mm minimum pad thickness 2 mm Overall thickness new brake disc 45 mm Wear allowance limit at least 37 mm onmo 0O gt 12 WABCO Remove the brake linings see chapter 4 1 Re moval of the brake linings page 74 Measure the brake disc thickness at the contact area of the brake linings Replace the brake disc if the wear measurement limit of 37 mm has been reached at the thinnest point Checking the condition of the brake disc network type cracks permissible radial cracks up to a max 0 5 mm width permissi ble Uneven disc surface up to max 1 5 mm depth permissible continuous cracks not permissible vo 0O DW PY Width of the braking area Check the brake disc for cracks and the condition of the surface Replace the brake disc if the brake disc has con tinuous cracks or unevenness or cracks reach the maximum dimension Service Instructions PAN 22 1 Replace the brake disc or rework it appropriately if Checking the disc runout the disc runout is greater than 0 1
24. r tially turned inwards through this action Remove the brake lining from the lining slot on the rim side Renewing the sealings PAN 22 1 6 Fitting the gaiter Slide a new protection cap 10 over the adjuster screw Centre the protection cap and push it into the sealing seat of the brake calliper 1 by hand Grease the beaded edge of the protection cap 10 Insert the beaded edge of the protection cap 10 into the sealing seat of the adjuster screw 21 EN E 10 fa Ensure that the cap has a correct sealing seat in the brake calliper 1 and that the beaded edge of the protection cap 10 has an even and wrinkle free seat in the ring groove of the adjuster screw 21 Install the pressure plate and the brake linings and set the clearance see chapter 4 3 Fitting the brake linings page 17 6 3 Renewing the gaiter on hexagon nut of the adjuster If the gaiter is removed individually brake calliper and brake cylinder need not be dismantled Removing the gaiter Remove the sealing plug 12 of the adjuster Push the gaiter 13 using a tool e g screwdriver from the seat of the brake calliper and remove the gaiter 13 of the hexagon 22 of the aduster Clean the sealing seat arrow of the gaiter 13 in the brake calliper Ensure that no dirt or moisture enters the brake when cleaning Check the brake calliper If dirt or moi
25. rocurement and disposal of spare parts Procurement of spare parts Identify the brake by means of the WABCO part number WABCO a B gt t L lt 1 D fig 8 1 WABCO type plate A Vehicle manufacturer part number B Production date C Assembly number D WABCO part number Open INFORM at www wabco auto com Enter the WABCO part number of the brake calliper Click Repair Disposing of the brake components Dispose of used and replaced parts in accordance with the national and regional regulations regarding environmental protection Generally brake components can be scrapped WABCO Vehicle Control Systems NYSE WBC is a leading supplier of safety and control systems for commer cial vehicles For over 140 years WABCO has pioneered breakthrough electronic mechanical and mechatronic technologies for braking stability and transmission automation systems sup plied to the world s leading commercial truck trailer and bus manufacturers WABCO is headquartered in Brussels Belgium For more information visit www wabco auto com 2009 WABCO All rights reserved 815 010 066 3 06 2009
26. rox 210 30 Nm see chapter 8 1 Widths A F and tighten ing torques page 37 item V Always use new fastening nuts for the installation of brake cylinder Depending on the installation position of the brake ensure that the lower drainage aperture of the brake cylinder facing the ground is open All other drainage apertures must be sealed by plugs WABCO 29 J PAN 22 1 Replacing the brake cylinder Screw the air connection to the brake cylinder Ensure that the brake hose does not exert initial _ ee stress on the sliding function of the brake calliper Y Observe the instructions of the manufacturer of and does not obstruct brake calliper movement brake cylinder in this regard Check the air connection for tightness Perform a function and effectiveness test of the Ensure that the brake hose is not twisted and brake routed so that it does not rub against the other parts 30 WABCO 8 8 1 Annex Widths A F and tightening torques Table 1 see also drawing on the next page Annex PAN 22 1 Width Hexagon screw Tightening torque Nm Item Designation AIF Comnen external inside Po a a A 7 Direction of rotation of the hexagon e Adjust anti clockwise left maximum 3 Nm air gap decreases e De adjust clockwise right maximum 12 Nm air gap increases II Screw for lining 17 X 30 15 Nm retainer IH Brake fastening Observe the installat
27. s in the context of applicable local laws and regulations Burned glazed or oil contaminated brake linings must be replaced immediately Always replace all brake linings on an axle To avoid damaging the brake disc replace the brake linings no later than at the point when they reach the wear limit at their weakest spot The measuring point on the brake carrier is the worked on area for screwing of the respective guide pin arrow on hatched area Measure the distance between brake carrier left arrow and the upper edge of the guide pin right arrow on the brake calliper A Lining thickness worn without lining support limit value 2 mm minimum lining thickness B Lining thickness new without lining support 23 mm C Overall thickness new lining with lining support 32 mm D Friction material H Brake pad PAN 22 1 Service Instructions If the measured distance e onthe short guide pin is greater than 94 mm e on the long guide pin is greater than 120 mm the maximum wear is reached Replace the brake linings if the maximum wear is reached see chapter 4 Replacing the brake lin ings page 74 3 3 Inspection of the brake discs Regularly check the wear limits of brake linings and brake discs When brake linings and or brake discs are worn the braking effect is reduced and there is a risk of brake failure Replace brake discs and brake lin ings Always replace all brake discs on an ax
28. spa Manually move the brake calliper on the guide the ability of the brake calliper to pins across the entire displacement path and move check for ease of movement Push the calliper 1 towards the cylinder side by hand arrow Check the protection caps 5 10 for the guide pins 8 9 and the adjuster screw 21 for wear and damage Renew any defective protection caps see chap ter 6 1 Renewing the protection caps and the bushings of the guide pins page 22 and see chapter 6 2 Renewing the protection cap of the adjuster screw page 25 Do not squeeze the guide pin protection caps against the brake anchor plate while moving the calliper Replace the bushings and the protection caps if the calliper moves sluggishly see chapter 6 1 Renewing the protection caps and the bushings of the guide pins page 22 If a protection cap is damaged check whether dirt Check the adjuster or moisture has penetrated into the brake s inte rior parts or have damaged the calliper due to secure the adjuster screw 21 against twisting when corrosion performing the test and when turning the hexagon Renew the brake if you have identified damage or 22 by arresting the pin arrow of the adjuster screw corrosion see chapter 5 Renewing the brake page 20 Renew the protection caps if they are damaged during service work on the brake 16 WABCO Replacing the brake linings
29. sture has entered the brake or if the sealing seat in the brake calliper or the hexagon 22 of the adjuster screw is damaged replace the brake see chap ter 5 Renewing the brake page 20 The gaiter 13 can be renewed if no dirt or water has penetrated into the brake calliper or if the gaiter has been damaged during servicing the brake WABCO 27 6 PAN 22 1 Renewing the sealings Fitting the gaiter Press the mounting sleeve B against the inner Place the mounting cap A onto the hexagon 22 gaiter lip towards that the inner gaiter lip fit cor of the aduster and push the mounting cap right up rect in the annular groove of the adjuster to the stop A 22 Grease the inner lip arrow of a new gaiter 13 Remove mounting sleeve B and mounting cap slightly A Place the gaiter 13 onto the mounting cap A Check and make sure the correct seat of gaiter 13 in the brake calliper and annular groove ar Push the gaiter 13 by hand into the sealing seat l row of the adjuster of the brake calliper 1 right up to the stop B A 13 Place the mounting sleeve B onto the mounting Push a new sealing plug 12 into the gaiter 13 cap A of the adjuster Ensure that the sealing plug 12 has a tight seat 28 WABCO Replacing the brake cylinder PAN 22 1 r 7 Replacing the brake cylinder CAUTION Risk of injury Observe all safety
30. ure that the plug has a tight seat Fasten a new hexagon screw 39 to the brake calliper see chapter 8 1 Widths A F and tighten ing torques page 31 item Il Remove the transport protection cap if in place Connect the wear indicator connector to the socket of the vehicle or the axle Check the wheel hub for ease of movement Having completed the work test the brake on a roller test stand WABCO 19 5 PAN 22 1 Renewing the brake 5 Renewing the brake CAUTION Risk of injury Observe all safety instructions as well as all repair and maintenance instructions see chapter 1 Impor tant instructions and safety in structions page 5 These instructions must be ob served to avoid personal injury or material loss fig 5 1 Left brake with the direction of rotation of the brake disc driving forward fig 5 2 Left brake with the brake disc direction of rotation driving forward 38 Lining retainer 39 Hexagon screw V Axle offset relative to the brake centre in brake disc exit side direction M Brake centre axle centre Arrow Brake disc direction of rotation brake disc exit side top The new brake is supplied as a pre assembled unit and may be mounted to the vehicle s axle via the brake carrier Left and right brake must not be interchanged when they are installed on the axle The correct assignment of the brakes to left and right side of the axle can be determ
31. when installing the brake Connect the wear indicator connector to the socket of the vehicle or the axle and fasten the cable to the hold down clip 41 of the brake calli Remove the transport fastenings from the new per brake calliper Ensure that the cable has been laid correctly and Place the brake with brake anchor plate on top of fix the cable in position using cable ties the brake disc and mount the brake to the axle l l Mount the brake cylinder on the calliper see Tighten the hexagon screw see chapter 8 1 page 29 Widths A F and tightening torques page 37 item III Depending on the installation position of the brake ensure that the lower drainage aperture facing the ground is open All other drainage aper tures must be sealed by plugs Remove the transport protection cap arrow from the brake calliper in the cylinder fastening area WABCO 21 6 PAN 22 1 Renewing the sealings 6 Renewing the sealings CAUTION Risk of injury Observe all safety instructions as well as all repair and maintenance instructions see chapter 1 Impor tant instructions and safety in structions page 5 These instructions must be ob served to avoid personal injury or material loss When replacing all of the gaiters in the calliper the work sequences for renewing the protection caps and the bushings of the guide pins as well as the protection cap of the adjuster screw can be ex

PAN 22-1 Assembly and Maintenance Instructions

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