Disc Brake Service ManualREV G04/091.6mb
Contents
1. 1 Overall view 1 1 Axial Disc Brake Components 18 1 18 2 Montagefett eingef rbt Montagefett wei Assembly grease white 31a 10a 1 Calliper 18 1 Spring Brake 2 Carrier 18 2 Brake Chamber 4 Sleeve 26 Spring Clip 5 Sleeve 31 Outer Boot Clip possible variants by items 10a amp 31a i 6 Rubber Bush 31a O Ring i 7 Brass Bush 37 Adjuster Cap if short rubber bush 6 sleeve ring is 9 Inner Boot 39 Calliper Bolt placed centrally 10 Outer Boot 40 Calliper Bolt oo 10a Steel Cap 44 Pad Retainer Pin Calliper bolts 39 amp 40 are identical 11 Pad Retainer 45 Washer 12 Pad 58 Ring 13 Tappet with Boot 161 Tappet Bush Page 2 of 27 97117 112 1 2 Brake Discs For Axial Disc Brake When replacing the discs please also refer to the instructions of the Vehicle Manufacturer When replacing discs please adhere to the recommended bolt tightening torques The use of non approved brake discs will reduce levels of safety and invalidate warranty Brake discs can be ordered through Hendrickson 2 General Information for Axial Disc Brake 2 1 Service Tools Part Number Description 98596 009 All parts listed below are included in this kit ll 19252 Press in tool for Tappet and Boot 13 ll 19253 Pull in tool for Inner Boot 9 ll 19254 Pull In Out tool for Brass Bush 7 Il 32202 Wedged fork for removal of Tappet and Boot 13 ll 26797 Grooving tool for Brass B2. 100mm DO NOT use an Open Ended Spanner since this may damage the Adjuster shaft The Adjuster should be turned counter clockwise for 2 or 3 clicks increasing running clearance WARNING Make sure that the Ring Spanner or Socket can burn freely during following procedure By applying the brake 5 10 times about 2 Bar the Spanner or Socket should turn clockwise in small increments if the Adjuster is functioning correctly see notes below If Pads are not being changed Cap 37 should be replaced having lightly greased it with Renolit HLT2 Refer to Page 5 for part number NOTE As the number of applications increases incremental adjustment will decrease NOTE If the Spanner or Socket does not turn turns only with the first application or turns forward and backward with every application the automatic Page 7 of 27 97117 112 5 3 Wear Limits of Pads and Discs WARNING For optimum safety stay within the Disc and Pad Wear Limits Pads The thickness of the Pads must be checked regularly dependent on the usage of the vehicle The Pads should be checked corresponding to any legal requirements that may apply If no Wear Indicator has been connected this should be at least every 3 months F SSY w b If friction material is less than 2mm see E the Pads must be replaced NG Wy SSS ww Discs Measure thickness at thinnest point Avoid measuring near the
3. M P KN 016 Wheel mounting refer to Vehicle Manufacturer s recommendations IMPORTANT New Pads need bedding in Heavy or long duration braking should initially be avoided T Tappet with Boot replacement for Axial Disc Brake 7 1 Tappet with Boot removal Note It may be easier to remove the Calliper from the axle to replace the Tappets of the Calliper see Section 10 1 The Adjuster 23 must be screwed clockwise until the Boots can be reached If the Calliper has been removed from the vehicle care must be taken not to overrun the threads see Section 7 1 1 To remove the Tappet Boot from the Calliper bore a Screwdriver should be used to deform the Boot location ring see diagram WARNING Great care must be taken not to damage the Inner Seal since it is not a replacement item Page 14 of 27 97117 112 The Tappets 13 can be removed from the Threaded Tubes by using Wedge Fork A Refer to Page 5 for part number Remove the old Tappet Bush 116 Check Inner Seal arrow and if damaged the Calliper must be replaced 7 1 1 Adjuster thread inspection Place an unworn Pad 12 into the outboard gap to avoid overrunning of the Threaded Tubes IMPORTANT Threaded Tubes should not overrun the inner thread of the Bridge The Calliper must be changed if synchronisation is lost For the inspection of the threads the tubes must be screwed out max 30mm by turnin
4. SS B KRS aay SSS PE RS gt N N N N N N N Na f N ATTAT n aT E Eo LY LLL LLL ne The condition of the Pads can be visually B with rib see also Section 5 3 1 determined without removing the road wheel by C newcondition noting the position of the Fixed Sleeve 4 in the D 18mm or more Pads and Disc must be Floating Calliper 1 checked with road wheel removed If the head of the Fixed Sleeve 4 is inside the Rubber Bush 6 by a dimension D greater than 18mm then a more accurate check of the Pads and Disc must be made If necessary change the Pads see Section 6 Page 11 of 27 97117 112 5 Pad replacement for Axial Disc Brake WARNING Before starting repair work ensure the service brake and parking brake are not applied and that the vehicle cannot roll away 6 1 Pad removal Take the wheel off refer to Vehicle Manufacturer s recommendations Remove Clip 26 and Washer 45 push down the Pad Retainer 11 and remove Pin 44 If the Pad Retainer 11 is corroded it should be replaced Important Before removing Pads it is strongly recommended that the Adjuster mechanism is checked for correct A operation see Section 5 2 MEAN OG WARNING Do not overload or damage the Adjuster 23 Use only 8mm Ring Spanner or 1 4 drive Socket with a lever length no greater than 100mm DO NOT use an Open Ended Spanner since
5. edge of the disc as a burr may be present A Disc thickness new condition 45mm B Disc thickness worn 37mm Disc must be UC N replaced M P KN 002 C Overall thickness of Pad new condition 30mm D Backplate 9mm E Minimum thickness of friction material 3mm F Minimum allowed thickness in worn condition for backplate and friction material 11mm replacement of Pads necessary If wear dimension B lt 37mm Disc should be renewed together with Pads Wear dimension B 37mm must not decrease WARNING If these recommendations are ignored there is a danger of brake failure Page 8 of 27 97117 112 Check Disc at each change of Pads for grooves and cracks The diagram shows possible conditions of the surface A Small cracks spread over the surface are allowed B Cracks less than 1 5mm deep or wide running in a Radial direction are allowed C Grooves circumferential less than 1 5mm wide are allowed D Cracks in the vanes are not allowed and the Disc MUST BE REPLACED a Padcontact area hg YY Note p NY In case of surface conditions A C the Disc can continue to be used until the minimum thickness of 37mm is reached NJ S N IIN Knorr Bremse Discs are normally service free and wona grinding when changing Pads is not necessary ee 2 However grinding could be useful e g to increase the load bearing surface of the Pads after severe grooving on
6. 2 NO YES Caliper guidance ok see section 6 1 2 Tightness not due to disc brake Check and if necessary maintain caliper guide pins see section 9 Check and if necessary change or service preceding braking device Lift vehicle turn wheel by hand es Does wheel turn smoothly Residual pressure within the braking cylinder Page 6 of 27 97117 112 Check adjuster see section 5 2 Running clearance ok see section 5 2 Brake pad wear uneven see note below ENO Check and if necessary maintain caliper guide pins see section 9 5 2 Adjuster check Adjuster has failed and the Calliper must be replaced WARNING Before starting repair work ensure the service brake and parking brake are not applied and that the vehicle cannot roll away Remove wheel The calliper assembly should be pushed inboard on its guide pins Using a suitable tool press the inboard pad 12 away from the Tappets and check Tappet and inboard pad backplate it should be between 0 5mm amp 1 0mm If the running clearance is too small or large the adjuster may not be functioning correctly and should be checked as follows Remove Cap 37 WARNING Do not overload or damage the Adjuster 23 Use only 8mm Ring Spanner or 1 4 drive Socket with a lever length no greater than
7. Refers to Products in the Asia Pacific Region Only HW HENDRICKSON TRAILER AIR SUSPENSIONS H TECHNICAL BULLETIN PNEUMATIC DISC BRAKE No 97117 112 Subject Service Manual Date April 2009 Revision G Axial Disc Brake Index Page 1 Exploded view of Drake eeceeeeeeeeeeeeeereeeeeeeeeeeeeeteeeeeeeenaes 2 2 General information 0 0 eee eeeeeee cece eeeeeeeee sees eeeeeneeeeeeeenees 3 3 Description and function 00 eee eee eeeeeetetetee teat teeeeneeeeeeeenees 4 4 Safety instructions for Service WOrK cccccceeeeteeeereeetteees 6 5 Brake testing o oo eee eee cece eeeeeeneeeeeeseeeeeeeeeaeseeeeeeseaeeeneeeeeeeaees 7 6 Pad replacements NNE 13 7 Tappet with boot replacement eeeeeneseereereereene 15 8 Calliper suspension sealing 18 9 Guide pin bush replacement eeceeeeeeeeeeeeeeeeeteeeneeeees 19 10 Calliper replaceMe nt ee eeeeceeeeeeeeeteeeeeeeeeeeeteeeteeeteeeeeneens 20 11 Carrier replacement eeeeeeeeseceseeeeeeeeeeeeneeeeeeeeneseneteeeees 23 12 Actuation cylinder replacement eeeeeeeeeeeeeeteeeeeeeeeeees 24 TrOUDICSNOOTING 00 cece sete eeteecteeeeee teat eeaeeeeaeteaeeeaeetaaeseaeeeaeeeeaeeeaeesas 27 M COPYRIGHT 2006 j HENDRICKSON ASIA PACIFIC PTY LTD Page 1 of 27 u J ALL RIGHTS RESERVED 97117 112 ABN 21 004 992 769 5 Abbotts Road P O Box 1063 Dandenong Victoria 3175 Australia Phone 61 3 9767 3400 Fax 61 3 9767 3495 www hendrickson com au
8. T Do not use Grease containing molybdenum disulphate Use only Actuators which are recommended by the Vehicle Manufacturer M P KN 034 Ai01 Attach Actuator with new Nuts self locking refer to Page 5 for part number and torque tighten to 180 Nm Connect air hose and check for leakage Make sure that hose is not twisted and that chafing is not possible IMPORTANT Check function and effectiveness of the brake Page 23 of 27 97117 112 12 3 Spring Brake removal CAUTION Chock wheels before releasing Spring Brake Release parking brake move Hand Control Valve to run position Screw out Release Bolt arrow with a maximum torque of 35 Nm Release air from brake move Hand Control Valve to park position Disconnect air hoses from Spring Brake Actuator 18 1 Unscrew Spring Brake Actuator Mounting Nuts do not re use Remove Spring Brake Actuator 12 4 Spring Brake fitting IMPORTANT New Spring Brake Actuators 18 1 have drain plugs installed Remove bottom plug see arrows All other drain holes should be plugged Before fitting the new Brake Actuator the sealing surfaces have to be cleaned and the Spherical Cup S 19 in the Lever must be greased with white Grease ___M4P KN 094 Ai01 Renolit HLT2 refer to Page 5 for part number Surface area of the flange must be plain and clean IMPORTANT Do not use Grease containing Molybdenum disulp
9. board side Pull in new Brass Bush 7 with Tool D NA E NLA SRWRAWE aye Bee anina NZ If Calliper has a groove Pull in new Brass Bush 7 with Tool D To prevent longitudinal displacement use Tool F refer to Page 5 for part number to create new groove Check contact area of Brass Bush 7 for burrs Remove burrs VF 0012717 Grease Bush with white Grease Renolit HLT2 refer to Page 5 for part number Insert new Sleeve 5 Note The Guide Pins Kit contains new Sleeves 4 amp 5 and new Calliper Bolts 39 amp 40 see Sections 1 2 and 1 4 VE 00127 14 9 2 Rubber Bush 6 replacement Remove old Sleeve 4 Pull Rubber Bush 6 out of bore Check bore for corrosion clean if necessary with Corrosion protection paint e g Zinc spray Note Grease new Rubber Bush 6 inside and outside with green Grease Syntheso GL EP 1 refer to Page 5 for part number M P KN 030 Page 18 of 27 97117 112 Deform new Rubber Bush 6 and push from the inner side of the Calliper into the bore Push Rubber Bush 6 so that the outer positioning ring locates in the groove see arrows f Wa KSA RY RX Re N ae iOS Soy SOR Sin beg ge H RIAR ie __ IMPORTANT Under no circumstances must the white Grease containing mineral oil be used for renee 4 lubricating the Bush or Sleeve Use only synthetic bas
10. e Inner Boot 9 on the Sleeve 5 Check that the Calliper slides easily In the shown clamping e g vice press the Calliper against the Carrier as far as possible The Inner Boot 9 must be in compressed condition this is to prevent air being trapped inside of the Cap H Direction _ d of pressure The assembly of the Steel Cap 10a can now be carried out as in Section Assembly at the Vehicle Check Adjuster Section 5 2 FDOOT10EN 11 Carrier replacement for Axial Disc Brake Remove Calliper see Section 10 1 Remove Carrier 2 from axle Clean axle contact area Attach new Carrier with new bolts from Hendrickson Attach Calliper see Section 10 2 M P KN 036 Page 22 of 27 97117 112 12 Actuation cylinder replacement for Axial Disc Brake 12 1 Brake Chamber removal Disconnect air line from Brake Chamber 18 2 Unscrew Brake Chamber Mounting Nuts do not re use them Remove Brake Chamber 12 2 Brake Chamber fitting VF 00127 10 IMPORTANT New Brake Chambers 18 2 have drain plugs installed Remove bottom plug see arrows All other drain holes should be plugged Before fitting the new Brake Actuator the sealing surface see arrow must be cleaned and the Spherical Cup 19 in the Lever must be greased with white Grease Renolit HLT2 refer to Page 5 for part number Surface area of the flange must be plain and clean IMPORTAN
11. ed green Grease refer to Page 5 for part number 3 Note The Guide Pins Kit contains new Sleeves 4 amp 5 and new Calliper Bolts 39 amp 40 Assemble Sleeve 4 Re fit Calliper see Section 10 2 Important Torque Calliper Bolts to 285 Nm and check that the Calliper slides easily 10 Calliper replacement for Axial Disc Brake 10 1 Calliper removal Remove Pads see Section 6 1 Remove Actuator see Section 12 1 and 12 3 Remove Outer Boot Clip 31 and take off Outer Boot 10 Note As well as Callipers with Outer Boot 10 and Outer Boot Clip 31 there are versions with Steel Cap 10a and O Ring 31a available On models with Steel Caps 10a and O Rings 31a place Tool G refer to Page 5 for part number Ped G onto the Steel Cap and tighten the threaded pin by a hexagon socket spanner Then use hammer as shown Remove Cylinder Bolts 39 and 40 FD00109 Page 19 of 27 97117 112 WARNING Hold Calliper only at its outer side Never get your fingers between Calliper and Carrier Remove Calliper from Carrier WARNING The opening or dismantling of the Calliper has not been authorised 10 2 Calliper fitting The correct choice of Calliper must be ensured by checking the Part No on the label arrow picture above Note Service Exchange Callipers have a blue label The Service Exchange Calliper has a plastic cap or an adh
12. esive tape in the are of the Actuator attachment Remove the cap tape after installing the Calliper see arrow Note The service exchange Calliper includes sealing and guiding elements The Pads are not included WARNING Hold Calliper only at its outer side Never get your fingers between Calliper and Carrier 10 2 1 Calliper with Outer Boot 10 Locate the Calliper to the Carrier Screw in Calliper Bolts 39 amp 40 and tighten to 285 Nm use only new parts Check that the Calliper slides easily Check the position of the Inner Boot 9 on the Sleeve 5 Check Adjuster function see Section 5 2 If necessary use new Outer Boot 10 Check grease free seating of the Outer Boot 10 on the Calliper 1 Page 20 of 27 97117 112 Ni pe _ E TT I rac a HHH ha FD00114 M P KN 027 Tighten Outer Boot Clip 31 Fit the Pads see Section 6 2 Attach Brake Chamber or Spring Brake see Sections 12 2 or 12 4 10 2 2 Calliper with Steel Cap 10a IMPORTANT It is only allowed to replace the Outer Boot 10 by the Steel Cap 10a when replacing the Sleeve 5 the O Ring 31a and the Screw 40 at the same time Replace only after permission by Axle or Vehicle Manufacturer On SB 6 19 5 only permissible after manufacturing date A0026 see type plate It may be easier to remove the Calliper and the FD00108 Carrier fro
13. g the Adjuster 23 clockwise If Calliper is not installed on axle put a spacer E length 70mm into the Calliper 1 to avoid overrunning of the Threaded Tubes 16 when screwing them out see illustration opposite During screwing the threads can be checked for corrosion damage In case of water ingress or corrosion the Calliper must be replaced 7 2 Tappet with Boot fitting With Calliper fixed to axle Grease threads with Renolit HLT2 Refer to Page 5 for part number Screw back Threaded Tubes 76 by turning the Adjuster 23 counter clockwise Place new Tappet Bush 167 onto the head of the Tube 76 Sealing seat in the Calliper for Tappet with Boot 73 must be clean and free of grease Place Tappet with Boot 13 onto the head of the Tube Use Push In Tool with the short strut B refer to Page 5 for part number for positioning and pressing in the Boot 13 Page 15 of 27 97117 112 j VF 00127 13 VF 00127 5 Using Tool B in reverse the Tappet can be pressed on With Calliper not installed on axle Grease thread with Renolit HTL2 refer to Page 5 for part number Screw back Threaded Tubes 16 by turning the Adjuster 23 counter clockwise Sealing seat in the Calliper for Tappet with Boot 73 must be clean and free of grease Place new Tappet Bush 167 onto the head of the Tube 76 Place Tappet with Boot 13 onto the head
14. hate Use only Actuators which are recommended by the Vehicle Manufacturer Page 24 of 27 97117 112 Attach Actuator with new Nuts self locking and torque tighten to 180 Nm Connect air hose ensuring that hoses are not mixed up Make sure that hoses are not twisted and that chafing is not possible Release parking brake move Hand Control Valve to run position and check for leakage Screw in Spring Brake Release bolt to maximum 70 Nm IMPORTANT Check function and effectiveness of the brakes For further information please Contact a member of our Repairer Network on 1300 130 960 Page 25 of 27 97117 112 TROUBLESHOOTING Note examples of disc pad wear which may help you identify these problems GAS VENT Cracked Grooved Tapered Worn Beyond Usage PROBLEM Disc Brake Pad Wear Chipped Cracked Grooved Stepped Tapered Worn Beyond Usage CAUSE Excessive heat build up in brake system calliper or calliper piston hanging up creating constant friction rear brakes not functioning effectively causing disproportionate braking energy on the front disc pads Excessive heat build up in brake system calliper or calliper piston hanging up creating constant friction rear brakes not functioning effectively causing disproportionate braking energy on the front disc pads Foreign material or debris embedded in brake pads Pads not in
15. m the axle to replace the Steel Cap Assembly at the Vehicle The fitting must be carried out with Pads still installed e Clean area e Using the Grease supplied refer to Page 5 for part number lightly lubricate the O Ring and place it over the cast spigot see sketch e Remove Threaded Pins from assembly Tool G to avoid damage of the Steel Cap e Hold the new Steel Cap on the end of the Spigot By using a suitable press or special assembly tool refer to Page 5 for part number and a hammer press the Steel Cap fully on the spigot making sure not to deform the Cap After removal the Steel Cap and the O Ring must not be refitted IMPORTANT The Steel Cap 10a and the O Ring must only be used once Page 21 of 27 97117 112 Assembly on the Calliper and Carrier removed from the axle IMPORTANT It is only allowed to replace the Outer Boot 10 by the Steel Cap 10a when replacing the Sleeve 50 the O Ring 31a and the Screw 40 at the same time Replace only after permission by Axle or Vehicle Manufacturer On SB 6 19 5 only permissible after manufacturing date A0026 see type plate Put the Calliper on the Carrier 00011 IMPORTANT Special threaded Screw 40 and Steel Cap 10a as well as the O Ring 31a must be renewed whenever Screw 40 has been removed Screw in Calliper Bolts 39 amp 40 and tighten to 285 Nm Check the position of th
16. of the Tube Use Push In Tool with the long strut B refer to Page 5 for part number for positioning and pressing in the Boot 13 Using the Tool B in reverse the Tappet can be pressed on Page 16 of 27 97117 112 8 Calliper Suspension sealing Replacement of Inner Boot 9 for Axial Disc Brake Remove Calliper see Section 10 1 Remove Ring 58 Pull out Sleeve 5 Push out Boot 9 with screwdriver Inspect and clean contact area of Boot 9 M P KN 025 x LN Put new Boot 9 into the Sleeve arrow of the CELL LR Tool C refer to Page 5 for part number i LLL s ee Position Sleeve with Boot 9 into the Calliper bore and pull in M P KN 026 Fit the Sleeve 5 The Boot end must engage in the groove of the Sleeve 5 arrow Lock with Ring 58 by pushing until it engages Important Before fitting the Calliper the unsealed Sleeve with the Rubber Bush should be checked for its ability to slide Fit Calliper see Section 10 2 VF O0127 15 Page 17 of 27 97117 112 9 Guide Pin Bush replacement for Axial Disc Brake Remove Calliper see Section 10 1 Remove Sleeve 5 and Inner Boot 9 see Section 8 9 1 Brass Bush 7 replacement ae Ns eZ BSN NR ee Remove old Sleeve 5 Pull out Bush 7 with Tool D refer to Page 5 for part number ve oom If Calliper has no groove see arrow Note Groove is always located on the in
17. r 23 must be further de adjusted by rotating it counter clockwise Clean the Pad abutments Push Calliper 1 outboard and fit the outboard Pad 12 For fitting the inboard Pad 12 push Calliper 1 in the opposite direction If fitted replace Wear Indicators and fittings brackets etc See page 5 or 7 WARNING Do not overload or damage the Adjuster 23 Use only 8mm Ring Spanner or 1 4 drive Socket with a lever length no greater than 100mm DO NOT use an Open Ended Spanner since this may damage the Adjuster shaft Rotate the Adjuster clockwise until the Pads come into contact with the Disc Then turn back the Adjuster 2 clicks Page 13 of 27 97117 112 SS LADLE VL a Z 1 mY LN ran PERN y EERE EEE REE EEL Dey ES Mb drrses hm irs SEC Ww Se ee M P KN 013 Ai01 possible variants by items 10a amp 31a M P KN 014 The hub should turn easily by hand after having applied and released the brake The Cap 37 must then be replaced having lightly greased it with Renolit HLT2 refer to Page 5 for part number After setting the Pad Retainer 11 into the groove of the Calliper 1 it must be pushed in to enable the positioning of Pad Retainer Pin 44 Fit washer 45 and Spring Clip 26 to the Pad Retainer Pin 44 use only new parts Our recommendation is fitting Washer 45 and Spring Clip 26 pointing downwards see diagram
18. stalled correctly pads not in full contact with the rotor Worn out calliper bushings and or worn out calliper hardware Disc pads allowed to remain in service beyond normal safe limits of usage Page 26 of 27 97117 112 The disc pads used with the rotor may indicate problems within your braking system Shown below are SOLUTION Check rear brakes replace calliper and calliper piston replace pads and check rotor for damage If damaged replace rotor Check rear brakes replace calliper and calliper piston replace pads and check rotor for damage If damaged replace rotor Rotors need to be turned refaced or replaced and replace pads Replace the guide pins mounting bolts bushing and calliper hardware Replace pads and check rotor for damage If damaged replace rotor Replace calliper bushings and or calliper hardware replace pads check rotor for damage If damaged replace rotor Replace pads and check rotor for damage If damaged replace rotor NOTES Page 27 of 27 97117 112
19. ster 23 and Turning Device 24 turn the Threaded Tubes 16 by an amount necessary to compensate for this wear The total running clearance sum of clearance both sides of Disc should be between 0 6 and 0 9mm smaller clearances may lead to overheating problems 4 Safety Instructions for service work for Axial Disc Brake Please also refer to the relevant safety instructions for repair work on commercial vehicles especially for jacking up and securing the vehicle WARNING Before starting repair work ensure the service brake and parking brake are not applied and that the vehicle cannot roll away Please follow repair manual instructions and adhere to the wear limits of the Pads and the Discs see Section 5 3 Use only recommended tools see Section 2 1 Tighten bolts and nuts to the recommended torque values see Section 2 4 After re fitting the wheel according to the Vehicle Manufacturer s recommendations please ensure that there is sufficient clearance between the Tyre Inflation Valve the Calliper and the wheel rim to avoid damage to the Valve After service work Check the brake performance and the system behaviour on a rolling road or by actual road test Page 5 of 27 97117 112 4 4 1 Brake Testing for Axial Disc Brake Fault finding procedure Adjuster ok YES Change caliper see section 10 Running clearance ok see section 5
20. t Clip A j A 7 i SSSR m DEN I Wear S EAAS NNN SSS ees ZAVAS Calliper Bolt OITA es Calliper Bolt L Pad Retainer Pin Washer B 27 Disc 20 Tappet Bush 28 VF 00127 2 Ai01 m Page 4 of 27 97117 112 possible variants by items 10a amp 31a 3 2 Description of Operation Floating Calliper principle 3 2 1 Brake actuation During actuation the Push Rod of the Actuator 18 1 or 18 2 moves the Lever 19 The input forces are transferred via the Eccentric Bearing 20 to the Bridge 17 The force is then distributed by the Bridge 17 and the two Threaded Tubes 16 to the Tappets 13 and finally to the inboard Pad 12 After overcoming the running clearance between the Pads and the Disc the reaction forces are transmitted to the outboard Pad 12 The clamping forces on the Pads 12 and the Disc 46 generate the braking force for the wheel 3 2 2 Brake release After releasing the air pressure the two Return Springs 27 28 push the Bridge 17 and Lever 19 back to the start position this ensures a running clearance between Pads and Disc is maintained 3 2 3 Brake adjustment automatic To ensure a constant running clearance between Disc and Pads the brake is equipped with a low wearing automatic adjuster mechanism The Adjuster 23 operates with every cycle of actuation due to the mechanical connection with Lever 1 0 As the Pads and Disc wear the running clearance increases The Adju
21. the entire friction surface has occurred To meet safety requirements the minimum thickness after regrinding is gt 37mm In addition the recommendation of the Vehicle Manufacturer MUST be followed WARNING If these recommendations are ignored there is a danger of brake failure If the Pads are worn down to the backplate or if Disc wear is excessive brake performance will be severely affected and may be lost completely Page 9 of 27 97117 112 5 3 1 Brake Wear Check using Guide Pin for all Axial Disc Brakes except those listed in Section 5 3 2 These Callipers do not have the rib in position B see also Section 5 3 2 ae an SOSA SS DR SN ys TIIRI SSY TANAR SOS M P KN 005 The condition of the Pads can be visually B without rib see also Section 5 3 2 determined without removing the road wheel by C pin protrusion shown in new condition noting the position of the Fixed Sleeve 4 in the D minimal pin protrusion Pads and Disc must Floating Calliper 1 a be checked with road wheel removed If dimension C is less than 1mm a more accurate check of the Pads and Disc must be made If necessary change the Pads see Section 6 Page 10 of 27 97117 112 5 3 2 Brake Wear Check using Guide Pin Only for Axial Disc Brakes SB 7541 SB 7551 to SB 7629 SB 7639 These Callipers do have the rib in position B see also Section 5 3 1 WSN aX Oo SS a
22. this may damage the Adjuster shaft Remove Cap 37 Turn the Adjuster counter clockwise until Pads can be removed A clicking noise will be heard during this procedure Push inboard Pad 12 toward Actuator Pull out both Pads 12 6 1 1 Tappet Boot Check The Adjuster 23 should be screwed clockwise until the boots are clearly visible The Boots should not show any damage Check the attachment of the Boots into the Calliper housing Important Any ingress of water or dirt past the Tappet Boot will lead to corrosion and affect the function of the Actuation Mechanism and Adjuster Unit If damaged the Boot and Tappet must be replaced see Section 7 Page 12 of 27 97117 112 6 1 2 Calliper guidance check Following Pad removal Section 6 1 Using hand pressure only no tools the Calliper 1 must slide freely over the whole length of the Guide Pin arrangement gt 30mm During this operation the Sleeve 5 is sealed by the Boot 9 and Cap 10 or Steel Cap 10a and O Ring 31a These must show no signs of damage Check that these are correctly seated 6 2 Pad fitting WARNING Pads must be changed as an axle set and NOT individually Use only Pads which are permitted by the vehicle manufacturer axle manufacturer and brake manufacturer Failure to comply with this may invalidate the vehicle manufacturer s warranty Note Before placing the Pads into the Carrier the Adjuste
23. ush 7 Z001105 Press in tool for Steel Cap 10a Parts not available individually 2 2 Lubrication Hendrickson Part Number Description Colour Application Part Number p PP 98793 004 1114525 Renolit HLT2 White Brass Bush 7 98793 005 II 32793 Syntheso GL EP1 Green Rubber Bush 6 2 Important Note The correct grease MUST be used for each Bush 2 3 Torque Requirements Item Number Description py hese 39 40 Calliper bolts M16 x 1 5 10 9 285 300 210 220 18 Actuator Mounting Nuts M16 x 1 5 180 210 130 150 Toowoomba Steel Hub Rotor to Hub Mounting Bolts 300 340 220 250 Conmet Alloy Hub Rotor to Hub Mounting Bolts 220 250 160 185 Not Shown Calliper to Torque Plate Bolts M20 x 2 5 440 510 325 375 Page 3 of 27 97117 112 3 3 1 Description and Function Axial Disc Brake Sectioned View 31 12 L A E SNG BSS L Eil N ATAZA 26 FEANN HA RESI T gt 37 n s poa pais Ht INS Ta I 32 Calliper KE A 33 Carri A Eta RY Sleeve a4 V azz 43 Sleeve SSSUSSSSGG Sg sears JSS NS 24 Inner Boot 1 Cyt A Outer Boot Steel Cap a Pad Retainer Pad 161 2 13 2 4 39 6 Tappet with Boot Threaded Tube 18 1 Bridge 18 2 j Spring Brake Brake Chamber 12 46 12 17 19 g Lever Eccentric Bearing ys SNY kaau EX ee eee ee I Turning Device C 77 Z CRT PN Sy Spring Clip 3 H N Spring SR f Z SNN ma pring N QO WN epee Boo
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