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BENDIX BW7308 User's Manual

1. Air Disc Brake Attachment Hardware Bendix Axial Carrier Torque Plate Fastener M20 x 2 5 x 60 mm Class 10 9 Washer Requires HARDENED 3 mm Use the manufacturer s recommendations minimum thickness for each bolt If the vehicle is using a Bendix If unavailable use phosphate Trailer Torque Plate manufactured Axial Anchor Plate with a thickness of 1 14 in 29 mm where these bolts are assembled then a bolt with an overall length of 2 36 in 60 mm will meet these requirements Fastener M16 x 2 0 x 110 mm Class 10 9 Washer None required Fastener M20 x 2 5xL Class 10 9 Length determination L Torque Plate TP thickness Carrier engagement Washer thickness La TP thickness 24 mm 3mm L a TP thickness 29 mm 3 mm m Washer Requires HARDENED 3 mm minimum thickness for each bolt and oil finish fastener Pre Torque 20 60 ft lbf 27 81 N m Final Torque 350 400 ft lbf 475 542 N m Use the manufacturer s recommendations If unavailable use plain and oil finish fastener Torque 200 220 ft lbf 271 298 N m Use the manufacturer s recommendations If unavailable use phosphate and oil finish fastener Pre Torque 20 60 ft lbf 27 81 N m Final Torque 350 400 ft lbf 475 542 N m Table Note 1 The washer outside diameter must be less than 1 1in 28 5 mm TABLE 4 TORQUE PLATE FASTENERS AND TORQUE RECOMMENDATIONS SEE MANUFACTURER S RECOMMENDATIONS
2. like spokes of a wheel see Area H less than 0 06 in 1 5 mm deep or wide are acceptable if they do not reach either edge see G Cracks are only acceptable if the length of the crack is less than 75 of dimension f the width of the rotor contact area For Bendix Splined Disc rotors radial cracks are only acceptable if they are less than 0 04 in 1 0 mm deep or wide and if they do not reach either edge see G Crack lengths must be less than 75 of dimension f the width of the rotor contact area In addition follow the recommendations of the vehicle manufacturer Note Axles should have either all Bendix Splined Disc or all conventional rotors FIGURE 12 EXAMPLES OF ACCEPTABLE AND NON ACCEPTABLE ROTOR CRACKS AND GROOVES 2 1 3 Rotor Quick Inspection See Figure 12 See the various potential rotor conditions that you may find See the criteria below for whether the rotor needs to be replaced and or scheduled for a full inspection 2 2 RUNNING CLEARANCE QUICK INSPECTION CAUTION Follow all safe maintenance practices On level ground with the wheels chocked and the parking brake temporarily released check for movement of the brake caliper This small movement less than 0 08 2 mm approximately the thickness of a nickel in the inboard outboard direction indicates that the brake is moving properly on its guide pins If the caliper has no movement or appears to move greater tha
3. Bendix ADB22X ADB22X V Air Disc Brakes SECTION ONE AIR DISC BRAKE OVERVIEW 1 1 DESCRIPTION Bendix ADB22X and ADB22X V Air Disc Brakes ADB use a floating caliper design to provide foundation braking on all axles of heavy commercial vehicles buses and trailers Bendix Air Disc Brakes provide safety and performance as well as ease of service The ADB22xX disc brakes mount to the axle s anchor plate torque plate using fasteners that are installed parallel to the axle while the anchor plate fasteners used for the Bendix ADB22X V air disc brakes install at right angles to the axle Available with or without a combination spring brake unit these brakes may also include optional wear sensors and wear diagnostic equipment FIGURE 1 BENDIX ADB22X AIR DISC BRAKES Sections in this Document Section Page Overview aa a aa T5 Preventive Mantenanee And Wheel on Inspections 68 Troubleshooting Flowchart 9 10 15 16 37 Wheel off Maintenance Inspections Maintenance Kits and Procedures Full Index see Page 38 1 2 Air Disc Brake Identification Locate the identification label near the guide pin housing See below for information about the label fields used Bendix Part Number XXXXXXXXKXX q Serial No XXXXXXXXXX Customer Part Number XXXXXXXXXX FIGURE 3 PART NUMBER LABEL INFORMATION Section One Section Description Air Disc Brake AA Rotor Identif
4. and 51 Extend the tubes but by less than 1 75 in 44 5 mm by turning the shear adapter 61 clockwise Inspect the threads for rust corrosion or damage etc If there is evidence of damage to the threads significant rust or corrosion the caliper carrier assembly must be replaced If the technician is working with the caliper on the vehicle the technician may place a new brake pad 12 into the outboard gap to help avoid the loss of thread engagement of the threaded tubes See Figure 50 If the work is being carried out at a workbench the technician may insert a 2 76 in 70 mm spacer See callout E in Figure 51 into the caliper 1 to help avoid the loss of thread engagement FIGURE 50 USE OF A NEW BRAKE PAD AS A SPACER 2 6in _ 0mm mm I 16 ii N U NN a FIGURE 51 USE OF A SPACER OFF VEHICLE INSPECTION 5 5 11 For threads that are in good condition grease the threads with white grease Part No 1114525 or K021964 Before installing the replacement inner seals 22 retract the threaded tubes by turning the shear adapter 61 counter clockwise Note If the shear adapter fails while you are retracting the threaded tubes you may try again with another new shear adapter If this also fails this indicates that the adjuster mechanism is damaged and the caliper must be replaced To install inner seals where the caliper is on the vehicle 5 5 12 Position the replacement in
5. and tap the end of the bolt with a hammer to free the brake assembly Remove the assembly Axial Mounting Bolt Style 5 3 6 Disconnect the air hose s to the brake chamber See Figure 42 Supporting the air disc brake by necessary means remove the six bolts attaching the brake to the anchor plate and remove the caliper carrier assembly from the vehicle Note Bendix strongly recommends that during re assembly these bolts and washers are replaced See your vehicle manufacturer for replacement hardware Remove the assembly Re installation Both Styles 5 3 Supporting the air disc brake by necessary means attach the brake to the anchor plate using six new bolts Torque to vehicle manufacturer s specifications If torque values and bolts are not specified by the vehicle manufacturer then select a replacement bolt as shown in Table 4 Caliper Carrier KA Assembly EE Actuator not eo shown Mounting Bolts and Washers 6 sets total if L Pa i r a ad a i a 7 C s Fie f as i i a li r t i k hy LE I EEP A I feat j Paes a s k Fy l r ti wien a ech i x Tar li F FT sy F i all G ij YA 4 I i A ia ie ui pen F G 5 S AnchorPlate A Torque Plate JI ol T TE p A PL La yA Ya v jz s 3 Fi FIGURE 42 AXIAL MOUNT CALIPER CARRIER 5 3 8 Re install the air hoses See Section 5 4 8 9 and check for leaks 5 3 9 Inspect and re install the pads See Section 5 2
6. 10 4 1 Caliper Movement Test 10 4 2 Adjuster Mechanism Inspection 11 4 3 InspectTheBrakePads 12 AA SE Ihe ROO IIIA oe be ee IIIA NII be ben Se 13 4 5 Guide Pin Bearing Inspection 14 4 6 Tappet And Boot Assembly Inspection 15 Section Five Maintenance Kits And Procedures 16 5 0 Maintenance Kits 17 5 0 1 General Information About Bendix Air Brake Maintenance 18 5 1 Air Disc Brake Shield Kit 19 5 2 PadReplacement 20 5 3 Caliper Carrier ActuatorAssembly 22 5 4 Spring or Service Brake W K 24 5 5 Tappet amp Boot Assemblies and Tappet Inner Seal Replacement 25 5 6 Guide Pin and BootAssemblies 29 5 7 Bendix Splined Disc Hub Rotor 35 Contacting Bendix 40 NOTES 39 40 CONTACTING BENDIX www foundationbrakes com Bendix on line information is available 24 7 365 It s your complete Bendix resource Bendix Technical Assistance Team For direct personal technical support call the Bendix TechTeam at 1 800 AIR BRAKE 1 800 247 2725 Representat
7. 13 Re install the hub rotor assembly using a new high temperature wheel seal following the vehicle manufacturer s instructions 5 7 14 Re install the air disc brake See Section 5 3 Supporting the air disc brake by all necessary means attach the brake to the anchor plate using six bolts and washers as required Bendix recommends the original bolts not be re used Torque to vehicle manufacturer s specifications If torque values and bolts are not specified by the vehicle manufacturer then torque according to the chart below Be sure to select bolts with the same thread pitch length and grade as originally provided from vehicle manufacturer 5 7 15 Reinstall the brake pads See Section 5 2 FIGURE 91 FASTENERS INSTALLED Air Disc Brake Attachment Hardware Bendix Axial Carrier Torque Plate Fastener M20 x 2 5 x 60 mm Class 10 9 Washer Requires HARDENED 3 mm minimum thickness for each bolt If the vehicle is using a Bendix manufactured Axial Anchor Plate with a thickness of 1 14 in 29 mm where these bolts are assembled then a bolt with an overall length of 2 36 in 60 mm will meet these requirements Use the manufacturer s recommendations If unavailable use phosphate and oil finish fastener Pre Torque 20 60 ft lbf 27 81 N m Final Torque 350 400 ft lbf 475 542 N m Bendix Vertical Carrier Torque Plate Fastener M16 x 2 0 x 110 mm Class 10 9 Washer None required Use the manufa
8. 69 and 70 5 6 13 Apply grease to the bolt and after inserting through the guide pin channel engage the brass nut T14 Always double check that the brass nut is correctly in place in the bushing before beginning to extract the bushing FIGURE 70 INSTALL THE REMOVAL TOOL 5 6 14 Turning the bolt at the top draw the brass nut up bring the brass bushing up and out of the channel Discard the bushing Caution Keep the removal tool exactly aligned with the guide pin channel to permit the bushing to be removed See Figure 72 T12 KT12 Bushing 10 Removed aha m a Lecce a t WA Ti a a a i i T a Bushing 10 installed Above Correct Alignment Above Incorrect Alignment FIGURE 72 KEEP THE CORRECT ALIGNMENT 5 6 15 Prepare to remove the short guide pin bushing by locating the bushing 6 tab and using a small chisel narrower than the tab or similar tool remove the tab as shown in Figure 73 by striking low on the base of the tab Remove the tab with a magnet and use a clean shop cloth to remove any excess debris Note that in some cases the tab may be in the opposite outer slot in the bore FIGURE 73 REMOVE THE TAB THAT HOLDS THE BUSHING IN POSITION Grease the bolt prior to each use Washer pn N T20 KT20 T14 KT14 T21 KT21 FIGURE 74 SHORT GUIDE PIN REMOVAL TOOL 31 5 6 16 Use the tool combination shown in Figures 74 and 75
9. 79 SHORT GUIDE PIN BUSHING INSTALLATION TOOL 5 6 27 Use the tool combination shown in Figure 79 to draw the bushing 6 into the caliper See also Figure 80 to see the orientation with tool T14 at the top Hand tighten the nut T14 into position Then tighten the bolt T20 using a box end wrench or socket to draw the bushing 6 into the caliper until the bushing 6 contacts the machined step in the bore Remove the tool MET A A Bushing Stop T08 T06 _ T05 wr Ld Vag TA ee Washer FIGURE 80 GUIDE PIN BUSHING INSTALLATION 5 6 28 Using a punch bend the tab into the groove by aligning the punch with the upper part of the tab and tapping the punch with a hammer 5 6 29 Coat the inside of the bushing 6 with a light coat of the white grease included in the kit 5 6 30 Install the two identical inner boots 9 by first cleaning the area where the inner boots will be installed and inspect for corrosion If the sealing surface of the caliper is damaged replace the caliper Grease the bolt prior to each use Washer Ni T10 KT10 T08 KT08 T07 KT07 FIGURE 81 SHORT GUIDE PIN BOOT INSTALLATION TOOL 5 6 31 See Figure 82 Place a boot into the in stallation tool T7 making sure that the inner bellows are arranged close to the side walls of the tool and will not be damaged dur ing installation Also check th
10. Figure 22 f the thickness of the friction material dimension C is less than 0 080 in 2 mm the pads must be replaced Bendix ADB22X ADB22X V air disc brakes use 0 35 in 9 mm backing plates so dimension D the combined pad and backing plate thickness must be a minimum of 0 43 in 11 mm 4 3 2 Check for uneven end to end pad wear If the difference in wear is greater than 0 080in 2mm replace the brake pads and also inspect the guide pins See Section 4 5 4 3 3 Compare the thickness of the inboard and outboard pads of each set If the difference between the inboard and outboard pad thickness is greater than 0 138in 3 5mm replace the brake pads and inspect the guide pins See Section 4 5 If the results of the pad inspections are within the acceptable range inspect the pad surface See Figure 24 of brake material chipped from the edge Minor Damage Is Acceptable Major Damage Is Not Acceptable Section missing FIGURE 24 BRAKE PAD SURFACE INSPECTION Minor damage at the edges is permitted but replace the pads if major damage on the surface of the pad is found When replacing brake pads Bendix strongly recommends that all the brake pads on an axle be replaced at one time See Section 5 1 for the pad replacement procedure Also see the vehicle manufacturer s recommendations found in the operator s manual Bendix air disc brakes are precision engineere
11. and Drive Axle Axial Ring 58 inner boot 9 caliper bolt 40 cap 10 shear adapter 61 adjuster caps 37 ADB22X carrier complete 1 caliper bolt 39 cap 68 Trailer Axle Axial Ring 58 inner boot 9 caliper bolt 40 cap 10 shear adapter 61 adjuster caps 37 ADB22X carrier complete 1 caliper bolt 39 cap 68 K051853 K043288 Steer and Drive Axle Vertical Ring 58 inner boot 9 caliper bolt 40 cap 10 shear adapter 61 adjuster caps 37 ADB22X V carrier complete 1 caliper bolt 39 cap 68 802090 _ Steer and Drive Axial A 1 2A K056559 809091 Steer and Drive Axial B 1 2A 802984 Trailer Axial A 1 2A 802985 Trailer Axial B 1 2A K021299 Steer and Drive Vertical A 1 2B K021300 Steer and Drive Vertical B 1 2B K020505 Splined Disc Brake Aluminum FF Steer LMS Bearing Package Hub 803134 Splined Disc Brake Aluminum FL Steer LMS Bearing Package Hub 802847 Splined Disc Brake Aluminum R Drive LMS Bearing Package Hub K020514 Splined Disc Brake Aluminum FF Steer Standard Bearing Package Hub 803138 Splined Disc Brake Aluminum FL Steer Standard Bearing Package Hub Section 5 7 re 7 Caliper Carrier Kit Flat Iron Aluminum LMS Standard Bearing Packages See hub supplier for these items Splined Disc Rotor Attaching Kit Section 5 7 K0377
12. bushing Guide Pin 9 5 KIT CONTENTS Item Description Quantity Guide Bushing Guide Pin short 7 Guide Pin Long Caliper Bolt Guide Bushing Long 40 Cap 10 FIGURE 62 GUIDE PIN EXPLODED VIEW The Bendix DVD BW7356 shows this procedure 5 6 1 CAUTION Follow all safe maintenance practices including those listed on page two of this document Park the vehicle by other means than the foundation brakes on level ground and chock the wheels Important If the vehicle is equipped with spring brakes cage the spring brakes on all axles to be worked on Consult the vehicle manufacturer s instructions as necessary For Bendix brand piston style spring brake chambers see Section 5 4 Inner Boot Cap small Adjuster Cap two versions supplied 2 Caliper Bolt Short Caliper Bolt Long Ring Shear Adapter Cap large White grease is also supplied not shown These procedures are typically carried out with the caliper carrier removed from the vehicle may be carried out with the air disc brake installed In cases where the caliper carrier assembly is removed from the vehicle NEW fasteners must be used and properly torqued during re installation Use only fasteners approved by the vehicle manufacturer Note This maintenance procedure uses specialized tools The full Bendix air disc brake tool kit KO29164 or Ken Tool kit 80000 includes the tools nee
13. caliper 1 see the callout in Figure 27 Press the caliper in the direction of the carrier 2 and set the dial gauge to zero 4 5 3 Place a suitable tool e g a large flat blade screwdriver between carrier 2 and caliper 1 and use light hand force to move the caliper away from the carrier until the movement stops Read the maximum value on the dial gauge See Figure 27 If the value is greater than 0 078 in 2 0 mm replace the guide pin bushings See Section 5 6 OR replace the caliper carrier assembly See Section 5 3 Inspect the guide pin inner boots 4 5 4 See Figures 28 and 29 With the pads removed slide the carrier by hand to the inboard position See Figure 28 By looking through the opening where the pads are installed and also from below inspect the inner boot 9 for each of the guide pins INSPECT FOR DAMAGE CUTS AND CRACKS Replace damaged boots immediately to prevent dirt and or moisture affecting the movement of the guide pins See Section 5 4 Damaged or corroded guide pins will impair the operation of the brake In addition during installation the boots are compressed to minimize the amount of air trapped within them Observe as you move the carrier back towards the outboard position the boots should only expand outwards a small amount due to trapped air The boots should normally due to their ribbed construction contract back into place as the caliper moves on the guide pins The boot
14. comprising T14 T20 T21 and a washer to remove the bushing 6 Screw nut T14 onto the assembly by hand then tighten the bolt T20 using a box end wrench to draw out the bushing Discard the removed bushing and verify that the bore is clean by wiping with a shop cloth ___ Washer FIGURE 75 SECTIONAL VIEW SHORT GUIDE PIN BUSHING REMOVAL Installation of the Fixed Guide Pin Brass Bushing 5 6 17 Clean the caliper upper and lower surfaces around the bushings 5 6 18 Clamp the carrier in a vise so that the guide channel is vertically oriented T13 KT13 Washer Grease the bolt prior to each use T14 KT14 T08 KT08 T16 KT16 FIGURE 76 LONG GUIDE PIN BUSHING INSTALLATION AND DIMPLING TOOL 5 6 19 Place the washer and thread the brass nut T14 on to the bolt T13 followed by the flange T08 See Figure 76 32 5 6 20 Place a new brass guide bushing 7 on the dimpling tool T16 and insert it into the caliper bore FIGURE 77 VIEW A AND B DRAW THE BRASS BUSHING INTO POSITION VIEW C LOCK THE BUSHING INTO POSITION 5 6 21 Check that the flange T08 is in an upright position at the top of the caliper recess as you draw the brass bushing 7 up by turning the brass nut T14 until the dimpling tool bottoms on the caliper When it reaches the correct position the brass bushing extends out of the guide pin channel 0 039 in 1 mm 5 6 22 With the dimpling tool T16 in po
15. during installation Note that after installation the smaller cap 10 extends 0 08 in 2 mm and the larger cap 68 extends 0 61 in 15 5 mm Repeat for the second cap Check that the guide pins move freely when the carrier is moved laterally and that air is not trapped within the inner boots and that the boots 9 and ring 58 are in the proper position before continuing with the installation 5 6 42 Install the caliper carrier See Section 5 3 5 6 43 Install the brake chamber See Section 5 4 5 6 44 Install the brake pads See Section 5 2 5 7 BENDIX SPLINED DISC HUB ROTOR DRIVE HUB Wheel Studs Hub Intermediate Elements Spacers Spring Elements Retention Brackets ABS Tone Wheel amp Fasteners ae bo AS 3 Nuni TATAR E zi ioe YA _ 11 k L pE pm a y Splined Disc Rotor Above Splined Disc Rotor on Aluminum Drive Hub FIGURE 86 SPLINED DISC ROTOR EXAMPLES EXPLODED VIEWS Bendix Splined Disc Hub Rotors are designed to assist vehicle maintenance by typically allowing the rotor to be serviced without requiring the entire hub rotor assembly be replaced Periodic inspection of the Splined Disc attachment hardware is recommended to ensure optimum braking performance Bendix recommends verifying the torque on the spring element fasteners whenever a brake inspection is performed NOTE Anytime that the entire hub rotor assembly is removed Bendix recommends that the
16. rotors replace the rotor when the minimum thickness of 1 46 in 37 mm is reached For other brands of rotors refer to the rotor manufacturer s guidelines 4 4 2 Inspect the rotor surface See Figure 25 The type of rotor and also the size depth and direction of the imperfections must all be considered NOTE If surface wear conditions F through J are in the permitted range the rotor is still usable until it reaches the minimum acceptable thickness for the rotor manufacturer s guideline 4 4 3 Machining Grinding or Turning Rotors Bendix brand rotors are normally service free In the case of severe grooving of the entire friction surface however CONVENTIONAL ROTORS may be turned when changing pads to increase the load bearing surface Q e For standard Bendix brand rotors cracks running in a radial direction like spokes of a wheel see Area H less than 0 06 in 1 5 mm deep or wide are acceptable if they do not reach either edge see G Cracks are only acceptable if the length of the crack is less than 75 of dimension f the width of the rotor contact area For Bendix Splined Disc rotors radial cracks are only acceptable if they are less than 0 04 in 1 0 mm deep or wide and if they do not reach either edge see G Crack lengths must be less than 75 of dimension f the width of the rotor contact area In addition follow the recommendations of the vehicle and rotor
17. wheel seal also be replaced at the same time USING A HIGH TEMPERATURE SEAL Follow the wheel seal and or vehicle manufacturer s guidelines for full installation instructions Adjust the bearings and refill bearing oil to vehicle manufacturer s specifications When replacing a Splined Disc Rotor Bendix strongly recommends that the brake pads be replaced as an axle set Contact 1 800 AIR BRAKE for appropriate brake pad kit Rotor replacement necessitates the removal of the pads CAUTION Follow all safe maintenance practices including those listed on page two of this document Park the vehicle by other means than the foundation brakes on level ground and chock the wheels Also read the vehicle manufacturer s recommendations When installing pads where appropriate use heavy duty gloves and always keep fingers away from potential pinch hazard areas ID Label STEER HUB Intermediate Elements Spacers Spring Elements Retention Brackets Wheel Studs ID Label PDA ABS Tone Wheel press on Above Splined Disc Rotor on Aluminum Steer Hub Bendix Air Disc Brakes are precision engineered braking mechanisms The friction couple braking characteristics have been carefully optimized and the rotor design and materials have been matched with special formulation brake pads for optimal performance therefore use only genuine Bendix brand parts and brake pads Rotor Replacement 5 7 1 Before removing the b
18. with a new unused shear adapter Note Always double check that the spring brake is released where applicable if a shear adapter fails if this step was missed the shear adapter will break off and it may appear that the caliper is seized In cases where a second failure of the shear adapter confirms that the adjustment mechanism is seized the caliper must be replaced FIGURE 21 APPLYING MODERATE APPLICATIONS OF THE BRAKES THE WRENCH MOVES CLOCKWISE AS THE RUNNING CLEARANCE IS DIMINISHED 4 2 3 Where the adjuster mechanism is able to be backed off normally position a box end wrench on the shear adapter so that it can turn clockwise freely without coming into contact with parts of the vehicle See Figure 21 Make five to ten moderate applications of the brakes at about 30 psi 2 Bar and observe that the box end wrench or socket should turn clockwise in small increments NOTE As the number of applications increases the turning movement will decrease as the brake reaches its normal calibration point If the box end wrench does not a turn at all b turns only with the first application or c turns forward and backward with every application the automatic adjuster has failed and the caliper carrier assembly must be replaced After completing these wheel off tests Bendix recommends installing a new adjuster cap lightly greased using white lithium based grease when returning the brake to service Ensure th
19. 22X V AIR DISC BRAKES INDEX TO FIGURES 7 amp 8 Adjuster Caps Chain Wheel Pad Assembly Spring Clip Adjuster Unit Pad Retainer Tappet and Boot Eccentric Bearing Pad Retainer Pin Assembly Brass Bushing Guide Pins Tappet Bushing Guide Sleeve Service Actuator Threaded Tube Inner Boot Shear Adapter Turning Device Caliper Bolt Inner Seal Splined Disc Hardware SD 1 SD 2 and SD 3 Wear Sensor Carrier Spring Brake Actuator 18 1 SECTION TWO PREVENTIVE MAINTENANCE SCHEDULE AND WHEEL ON INSPECTIONS 2 0 PREVENTIVE MAINTENANCE Regular inspection and maintenance of air disc brake components is an important part of vehicle maintenance Section Two The maintenance practices outlined here are recommended Section in addition to all standard industry practices including 2 0 Preventive Maintenance daily pre trip inspections Also see the vehicle s manual 2 1 Brake Pad and Rotor Inspections for recommendations Keep track of the results of your 2 2 Running Clearance Quick Inspection maintenance inspections to assist you in determining the ideal maintenance intervals for the vehicle Use the table below for a guide to maintenance interval planning however depending on the particular vehicle s use more frequent checks of the components may be necessary Table 1 Inspection Period 4 to 5 times during the pad lifetime About ever four 4 For vehicles with months for over the electronic wear road applications indi
20. 23 5 4 SPRING OR SERVICE BRAKE 5 4 1 CAUTION Follow all safe maintenance practices including those listed on page two of this document Park the vehicle by other means than the foundation brakes on level ground and chock the wheels 5 4 2 Use the spring brake manufacturer s recom mended safety practices in all cases Some spring brake and vehicle manufacturers permit caging the spring brake while the spring brake is engaged THE FOLLOWING INSTRUCTIONS ARE FOR BENDIX BRAND PISTON STYLE ACTUATORS 5 4 3 With the vehicle on a level surface and the wheels properly chocked apply air to release the spring brakes parking brakes by using the dash mounted air control valve Back out the release bolt Figure 43 arrow D using a maximum torque of 26 ft Ibs 35 N m to cage the air released spring force on the push rod FIGURE 43 ACTUATOR SPRING CAGING AND REMOVAL 5 4 4 Exhaust the air from the brake chambers by using the dash mounted air control valve With all air pressure drained from the system disconnect the air hoses from the brake chamber While supporting the brake chamber in position remove and discard the brake chamber mounting nuts Figure 45 arrows marked B Remove the brake chamber 5 4 5 Re installation Before installing the brake chamber the actuator flange See Figure 46 arrow C must be cleaned and inspected Consult the vehicle manual The spherical cup in the lever 19 mus
21. 66 All Splined Disc Rotor Applications Splined Disc Rotor hardware kit SD 1 2 and 3 802081 138mm U shaped Rotor fasteners Section By 802082 150mm U shaped Rotor fasteners 802083 Severe Duty Splined Disc Kit Splined Disc Rotor SD and hardware kit SD 1 2 and 3 802569 Heavy Duty Splined Disc Kit Splined Disc Rotor and hardware kit SD 1 2 and 3 Universal Replacement with standard bearing configuration and long studs Contact 1 800 AIR BRAKE if identification assistance is required TABLE 2 MAINTENANCE KITS 1 N 5 0 1 GENERAL INFORMATION ABOUT e When replacing bearings or for any other BENDIX AIR DISC BRAKE MAINTENANCE maintenance procedure where the technician needs to remove the caliper carrier assembly from the vehicle When working on Bendix Air Disc brakes please note to perform the maintenance replacement caliper the following carrier bolts will be required Please note that due e Read and follow the Safe Maintenance Practices on to the high torque required the original bolts cannot page two be reused The bolts are available from the vehicle 7 manufacturer e Depending on the particular axle the technician may need to remove the caliper carrier to allow sufficient WARNING Not all wheels and valve stems are access to perform the work compatible with Bendix Air Disc Brakes Use only wheels and valve stems approved by the vehicle manufacturer to avoid risk of valve ste
22. Cable to Electrical X Supply oN 5 ge 3 FIGURE 33 PAD REPLACEMENT 5 2 2 Raise the complete axle to be worked on until the tires clear the ground See the vehicle maintenance manual instructions for removing the wheels 5 2 3 If the air disc brake is equipped with an electronic wear sensor indicator see top of Figure 33 remove 20 and retain the mounting hardware for the cable protection plate The cable protection plate can then be set aside while servicing the pads Note the position of the sensors in the brake pad channels and carefully remove them In most cases you do not need to release the cable connector in order to move the sensors away from the pad installation work area Inspect the wear sensors replace if damaged or abraded 5 2 4 See Figure 34 Remove and discard the pin retention clip 26 and washer 5 p S S A A wi fy SUA Pad Retainer Bar Be 45 Washer 26 Spring Clip FIGURE 34 PAD RETAINER BAR REMOVAL 5 2 5 While pressing against the pad hold down bar remove the pad retainer bar pin 11 Discard the hold down bar 5 2 6 With the spring brake released or caged remove the adjuster cap 37 using the tab taking care not to move the shear adapter 61 Note Two sizes of adjuster cap are supplied in kits use the same size as before in step 5 2 20 5 2 Inspect the shear adapter 61 If significant corrosion and or damage is present remove the adjuster adapter us
23. NSTALLATION TOOL TOOL B1 WITH T24 INSTALLED B2 B3 WITH T24 INSTALLED B4 FIGURE 61 OFF VEHICLE TAPPET INSTALLATION 5 5 19 Check that the tappets are firmly attached to the bushings by gripping and pulling lightly on them by hand Confirm that the tappets are able to rotate a 5 5 18 See Figures 59 60 and 67 Retract the tappets small amount on the tappet bushings by grasping as needed in order to have room to install the and turning them by hand Finally using a box end tappets Use tool B3 comprising tools 11 T2 and wrench on the shear adapter extend the threaded T3 to press the boot into position The tool is then tubes outward and check that the boots are held reversed and the nylon disc T24 is inserted into in place Retract the tappets the T1 cup combination tool B4 Holding the T1 handle turn the nut on the T3 tool to fully seat the tappet onto the tappet bushing 161 To install tappet and boot assemblies where the caliper is removed from the vehicle 5 5 20 Re install the caliper carrier assembly if it was removed from the vehicle See Section 5 3 5 5 21 Re install the brake pads See Section 5 2 28 5 6 GUIDE PIN AND BOOT ASSEMBLIES Bushing 6 Guide Pin 4 Caliper Bolt 39 Q Cap 68 Adjuster Cap Two alternate caps supplied in kit 37 As Vertical Horizontal Mounting Bolt Style Shown See Inset Above for Vertical Bolt Style with
24. Z Bil 37 6 Guide Sleeve Siki and Boot ms EFN Shear lt S Assembly a D eS Ae Adapter Ae Ya eA A DA Carrier er D Mounting EN g7 DY Fe D Caliper or Caliper Kit Bendix ADB22X 2B Anchor Plate Bendix 2A Bendix se ADB 22X U shaped K 2 Rotor e Bx Carrier Fasteners 3 a o E gt SD 1 oY oO ay eS SD 2 ee ADB22X V ey Splined Disc Rotor sant Hardware Anchor Plate Yur Carrier SD 1 2 3 Mounting Hardware Splined Disc Rotor See Section 5 2 for SD exploded view of electronic wear indicator Steer Hub FIGURE 30 EXPLODED VIEW BENDIX ADB22K AND ADB22X V AIR DISC BRAKES 16 5 0 MAINTENANCE KITS Below is a list of some of the available kits See Figure 30 for an exploded view showing the components listed Ts 803129 Trailer Axle Pad amp Rotor Shield Kit 802948 i Drive Axle Pad amp Rotor Shield Kit f Pad retainer bars 5 set of four pads and holder springs 12 adjuster caps 37 pad retainer PEG MEE ec Saon Sac SUA pins 44 washers 45 shear adapters 61 Steer Axle Pad Shield Kit Spring Clip Kit box of 25 803151 Spring clips 26 Shear Adapter box of 10 802455 Shear adapters 61 A Tappet Boot Kit wheel end kit Section 5 5 802119 Tappet and boot assembly 13 tappet bushing 161 inner seal 22 Adjuster Cap kit has ten each of two styles N SUEDE aaa ee CA Guide Pin Seal and Boot Kit wheel e
25. at the outer edge of the boot rests on the front edge of the tool FIGURE 82 POSITION THE NEW BOOT IN THE INSTALLATION TOOL T7 5 6 32 Using 70 in lbs 8 N m of torque maximum tighten bolt T10 to install the inner boot 5 6 33 Repeat the installation procedure for the second inner boot 5 6 34 Check that the boots are held securely in place and that no damage occurred during installation 5 6 35 See Figure 83 To install the guide pins first lubricate both guide pins with the white grease supplied Insert the guide pins into their respective bores with the grooved end FIGURE YA PLACE THE RETAINING RING ONTO THE towards the bellows GROOVE IN THE GUIDE PIN Fit the lip in the end of the inner boots 8 into the groove of the guide pins Push on each ring 7 ensuring that the boot 9 is engaged onto the end of the guide pins 5 or 6 5 6 36 With the caliper resting on a bench slide the carrier into place with a slight rocking motion taking care that as you do so the inner boots and guide pins are seated in their proper place on the carrier 5 6 37 Identify the two caliper bolts 39 and 40 With the shorter bolt placed in the floating pin bushing 4 and the longer bolt placed in the fixed pin bushing 5 33 begin to tighten the bolts With the caliper carrier in a vice continue installing the bolts to a torque of 133 ft Ibs 180 N m Finally tighten each bolt an additional 90 ninety
26. at the tab is in the position shown in Figure 19 11 4 3 4 4 BRAKE PADS AND ROTORS CAUTION Follow all safe maintenance practices If electronic wear sensors are present see Section 5 2 If dust covers are present see Section 5 1 See Figure 23 While pressing down against the pad retaining bar 11 remove and retain the clip 26 washer 45 and pin 44 Remove the pad retainer bar 11 Bendix recommends that these items should be replaced with new See available kits and parts Section 5 0 Follow the steps in Section 4 2 for backing off the adjuster mechanism Slide the caliper inboard then outboard to permit easy removal of the brake pads Brake Rotor Outboard Brake Pad Inboard Brake Pad Thickness of a new pad 1 181 in 30 mm B Backing plate thickness 0 360 in 9mm Minimum thickness of friction material 0 080in 2 mm Minimum thickness of a worn pad 0 433in 11 mm replace pads Thickness of a new rotor 1 77 in 45mm Minimum rotor thickness 1 46in 37 mm FIGURE 22 PAD AND ROTOR DIMENSIONS See Figure 22 for initial brake pad and rotor dimensions as well as minimum acceptable dimensions N MK Pad Retainer Bar p 45 Washer 26 Spring Clip FIGURE 23 RETAINER BAR REMOVAL 12 4 3 INSPECT THE BRAKE PADS Regular inspection of the brake pads even for vehicles that use an electronic wear indicator is an important part of vehicle maintenance 4 3 1 See
27. cators use the e g pick up amp delivery dash indicator s When e g line haul RV off highway construction and or the hand held you open highway logger concrete mixer dump diagnostic tool to check coaches etc truck city transit bus refuse regularly monitor the the tire school buses etc pad wear pressures See Section 5 2 ay eam ja a rE OMO A is z S Inspections with the wheel mounted Sections 2 1 2 3 About every three 3 months for higher duty applications At least once At the every very year least and at every every four 4 pad months replace ment Inspect the pad thickness by checking the mechanical wear indicators See Section 2 1 Inspect the running clearances using the quick inspection technique See Section 2 2 Inspect the visible part of the rotors for cracks etc See Section 2 3 Inspections with wheel removed Section 4 Inspect the pads and entire rotor surfaces for cracks etc Bendix splined disc rotors Inspect retaining hardware and check torques See Section 2 3 Inspect the running clearances and adjuster operation See Sections 2 2 and 4 2 Inspect the caliper travel See Section 4 1 Inspect the tappet and boot assemblies See Section 4 6 Inspect all caps hoses and brake exterior for damage etc 6 TABLE 1 PREVENTIVE MAINTENANCE SCHEDULE 2 1 BRAKE PAD AND ROTOR INSPECTIONS Visual checks of the condition of t
28. cturer s recommendations If unavailable use plain and oil finish fastener Torque 200 220 ft lbf 271 298 N m Trailer Torque Plate Table Note 1 Fastener M20 x 2 5xL Class 10 9 Length determination L Torque Plate TP thickness Carrier engagement Washer thickness Lin TP thickness 24 mm 3 mm L M TP thickness 29 mm 3 mm m Washer Requires HARDENED 3 mm minimum thickness for each bolt The washer outside diameter must be less than 1 1in 28 5 mm Use the manufacturer s recommendations If unavailable use phosphate and oil finish fastener Pre Torgue 20 60 ft lbf 27 81 N m Final Torque 350 400 ft lbf 475 542 N m TABLE 7 TORQUE PLATE FASTENERS AND TORQUE RECOMMENDATIONS SEE MANUFACTURER S RECOMMENDATIONS 37 38 SERVICE DATA INDEX Section One Air Disc Brake OverviewW 1 Safe Maintenance Practices 2 Section Two Preventive Maintenance Schedule and Wheel On Inspections 6 2 0 Preventive Maintenance 6 2 1 Brake Pad And Rotor Inspections 7 2 2 Running Clearance Quick Inspection 8 Section Three Troubleshooting Procedure Flowchart 9 Section Four Wheel Off Maintenance Inspections 10 4 0 Wheel Offinspections
29. d braking mechanisms The friction couple braking characteristics have been carefully optimized and the rotor design and materials have been matched with special formulation brake pads for optimal performance In all cases use brake pads with the type of backing plate and lining material originally supplied by the vehicle manufacturer CAUTION When replacing brake pads and rotors use only Bendix brand replacement pads and rotors and or those approved by the OEM Non approved replacement disc pads or rotors can cause excess wear to brake components and can increase the risk of rotors cracking etc 4 4 INSPECT THE ROTOR CAUTION Follow all safe maintenance practices Identify if the rotor is a Bendix Splined Disc or Bendix brand conventional rotor See Section 1 03 Rotors should be inspected regularly See Section 2 0 for recommended inspection schedule and at each pad change No action is needed for small cracks spread over the surface e g Area F Rotor Friction Surface Width f Cracks reaching either edge of the rotor are not acceptable for either type of rotor Circumferential grooves as in Area J are acceptable if less than 0 06 in 1 5 mm deep N 4 4 1 Measure the thickness of the brake rotor at the thinnest point Dimension E in Figure 22 Avoid measuring near the edge of the rotor as minor burrs may result in inaccurate measurement For Bendix brand
30. d install into the shield Torque cap screws to 44 Ft Lbs 528 in lbs Trailer Axle Rotor Shields See Figure 32 Position the rotor shield with the torque plate between the shield and the rotor With one supplied lock washer in place on each cap screw pass the screws through the shield before mounting onto the threaded torque plate holes Torque the cap screws to 24 Ft Lbs 288 in Ibs 5 1 4 Note The installation of air disc brake shields does not eliminate the need for periodic maintenance and inspection of the air disc brake and entire wheel end for damage and or wear In addition the truck and trailer manufacturer s specific criteria for the brake shield requirements on air disc brakes should be consulted before either installing or removing air disc brake shields from a wheel end s 19 5 2 PAD REPLACEMENT 5 2 1 CAUTION Follow all safe maintenance practices including those listed on page two of this document Park the vehicle by other means than the foundation brakes on level ground and chock the wheels The Bendix DVD BW7356 shows this procedure Important If the vehicle is equipped with spring brakes cage the spring brakes on all axles to be worked on Consult the vehicle manufacturer s instructions as necessary For Bendix piston style see Section 5 4 ELECTRONIC WEAR SENSOR 104 Cable Protection TA Sa 105 if installed i i Cable Guide 7 2alternate designs used
31. d separately without shaking e OSHA Regulations regarding testing disposal of waste and methods of reducing exposure for asbestos are set forth in 29 Code of Federal Regulations 1910 001 These Regulations provide valuable information which can be utilized to reduce exposure to airborne particles Material Safety Data Sheets on this product as required by OSHA are available from Bendix Call 1 800 247 2725 and speak to the Tech Team or e mail techteam bendix com 1 3 Rotor identification See Figure 4 to help you identify which type of rotor is used on the axle being inspected Note that the maintenance inspection procedure will depend on the type of rotor installed FIGURE 4 ROTOR IDENTIFICATION CAUTION Rotors may not be mixed on a single axle axles are only permitted to have all conventional or all splined disc rotors 1 4 Wear Sensor Identification See Figure 5 for the electronic wear sensor that may be present 104 Cable Protection Cable Guide 2 alternate designs used Cable to Electrical Supply Sensor Cable to Electrical Supply Cable Protection Plate Cable Guide two designs Consult the instruction sheet included with wear indicator kits for installation information FIGURE 5 ELECTRONIC WEAR INDICATOR COMPONENTS 1 5 Operation Bendix air disc brakes convert air pressure into braking force See Figure 6 When the vehicle brakes are applied air enters the service brake chamber t
32. ded for the guide pin and boot installation See Table 6 Note that a smaller Bendix tool kit KO29107 or Ken Tool kit 80002 may be used where only the guide pins will be serviced 29 Bendix Bendix Number a A R Number OF Ken Tool Description Typical Tool View Ken Tool Description Typical Tool View Number Number T05 KT05 1 3 8 in diameter disc T14 KT14 T06 KT06 1 1 2 in diameter disc T16 KT16 Dimpling tool T07 KT07 2 in diameter sleeve BB KT20 8 in bolt T08 KT08 2 1 8 in diameter disc EE E KT21 Half Sleeve T10 KT10 8 in bolt T26 KT26 Cap installation tool T12 KT12 3 7 8 in long sleeve T27 KT27 Cap installation tool TABLE 6 BENDIX ADB22X AIR DISC BRAKE GUIDE PIN AND SEALS REPLACEMENT TOOLS A WASHER IS ALSO INCLUDED TIKS 10 in bolt 5 6 2 Remove the wheel Refer to the vehicle manufac turer s recommendations 5 6 3 Remove the brake pads See Section 5 2 5 6 4 In most cases the actuator should be removed See Section 5 4 In the case of spring brake actuators they should be caged before removing the brake assembly FIGURE 63 PUNCH GUIDE FIGURE 64 GUIDE PIN CAP oo PIN CAP 10 10 HOLE 5 6 5 In nearly all cases the air disc brake caliper carrier 7 will need to be removed from the vehicle in order to complete this procedure See Section 5 3 5 6 6 Place the brake on a workbench and using a vice secure it by the carrier 5 6 7 Use a
33. degrees Installation of the Guide Pin Caps 5 6 38 See Figure 84 Place BOOT COMPRESSED a the caliper carrier as sembly on a bench so that the inner boots are fully com pressed check that the bores are clean and dry e g free Pat FIGURE 84 BOOTS MUST from lubrication BE COMPRESSED FULLY DURING CAP INSTALLATION Note It is important that the inner boots are fully compressed during this procedure to ensure that the least amount of air is retained within the guide pin channel If too much air is trapped the bellows can potentially be damaged during the operation of the brake t is also important that the technician double check that the retaining rings remain in their correct position during this procedure 5 6 39 Clean the two caps and check that the caliper 34 surfaces where the caps will be installed are clean and have no signs of damage 5 6 40 Select one cap to 5 6 41 install Using the correct press in tool the smaller cap 10 installs in the long guide pin side using tool T26 and the larger cap 68 installs in the short guide pin side using tool T27 place the cap in position using the machined channel in the caliper to assist in centering the tool FIGURE 85 BOOTS MUST BE COMPRESSED FULLY DURING CAP INSTALLATION Use a hammer to tap the cap into position See Figure 85 Note that the tool needs to remain perpendicular to the channel to prevent damage
34. ds Inner seals that are installed correctly WILL NOT ROTATE as the threaded tube extends 5 5 14 Note Inspect the tappet boot kit to determine if the tappets supplied are already pre greased a plastic cover should be present be sure to remove the cover when installing the tappet Only in the case of kits that are not pre greased will the installer need to apply grease to the tappets In all cases the threaded portion of the tubes will need to be greased Retract the threaded tubes 5 5 15 Install the new tappet bushing 161 onto the center post of each threaded tube 16 by hand By hand ease the tappet bushings onto the center post of the threaded tubes and they will snap into position 5 5 16 The sealing seat in the caliper for tappet and boot assemblies 13 must be clean and free of grease Wipe the opening with a clean shop rag Place a tappet and boot assembly 13 in position over the center post and tappet bushing To install tappet and boot assemblies where the caliper is on the vehicle 5 5 17 See Figures 56 57 and 58 Use tool B1 comprising tools T1 T2 and T3 to press the boot into position The tool is then reversed and the nylon disc T24 27 is inserted into the T1 cup combination tool B2 Holding the T1 handle turn the nut on the T3 tool to fully install the tappet onto the tappet bushing 161 FIGURE 56 ON VEHICLE TAPPET AND BOOT INSTALLATION FIGURE 59 OFF VEHICLE TAPPET BOOT I
35. e adjuster cap with Renolit HLT2 white grease part number I 114525 and install the cap 5 2 21 Push the new pad retainer bar 11 into the groove of the caliper Press down on the pad retainer bar and insert the pad retainer pin 44 with the pin pointing downwards where possible Install the supplied washer 45 and then the spring clip 26 See Figure 34 5 2 22 Apply and release the brakes The hub should turn easily by hand after applying and releasing the brake 5 2 23 Re check the running clearance necessary Readjust if 5 2 24 Reinstall the wheel following the vehicle manual instructions A WARNING The brake pads and rotor must be maintained within the recommended wear limits Failure to monitor wear and replace the brake pads and rotor when required may result in diminished brake performance 22 5 3 CALIPER CARRIER ACTUATOR ASSEMBLY CAUTION Follow all safe maintenance practices including those listed on page two of this document Park the vehicle by other means than the foundation brakes on level ground and chock the wheels CAUTION When using a hoist to support the air disc brake do not attempt to use the pad retainer bar as a bracing point Itis not designed to support the weight of the brake Use instead a brace or chain wrapped around the entire brake to attach the hoist 5 3 1 In all cases check that the current hose routing arrangement does not restrict the full travel of the cal
36. e brake pad Caution When installing pads and retaining springs where appropriate use heavy duty gloves and always keep fingers away from potential pinch hazard areas FIGURE 39 PAD RETAINING SPRING INSTALLATION 5 2 15 Install the pad retaining springs 2 onto the brake pads 12 by inserting one end of the spring onto the lug at the top of the brake pad See Figure 39 Carefully apply enough force to permit the second lug to fully engage taking care to keep fingers etc away from the spring as it seats 5 2 16 Pull the caliper fully outward and install the outboard pad Move the caliper fully inward and install the inboard pad 5 2 17 To reinstall wear indicators if used Insert the wear sensors into position in the new brake pads Route the sensor cable through the cable protection plate channel and secure the plate with the mounting hardware retained at disassembly See Section 5 2 21 FIGURE 40 RUNNING CLEARANCE ADJUSTMENT 5 2 18 Using a 10mm six point box wrench turn the Shear Adapter 61 clockwise until the pads contact the rotor Note Do not use an open ended wrench as this may damage the adapter See Figure 40 5 2 19 Using the same tool turn the Shear Adapter 61 counter clockwise and listen for the sound of 3 clicks as the mechanism backs off increases the running clearance See Figure 37 5 2 20 Select the correct replacement adjuster cap from those supplied with the kit Lightly greas
37. ections 4 1 Caliper Movement Test 4 2 Adjuster Mechanism Inspection 4 3 4 4 Brake Pads and Rotors 4 3 Inspect the Brake Pads 4 4 Inspect the Rotor ar ae 4 4 3 Machining Grinding or Turning Rotors 14 4 5 Guide Pin Bearing Inspection 14 15 4 6 Tappet amp Boot Assembly Inspection 15 4 0 WHEEL OFF INSPECTIONS CAUTION During these inspections follow all safe maintenance practices including those on page two of this service manual Also follow the vehicle manufacturer s recommendations When working on foundation brakes be sure that the vehicle is on level ground that the vehicle is parked by other means than the foundation brakes and that the wheels are chocked 4 0 1 Wheel Removal and Re Installation Refer to the vehicle manufacturer s recommendations for removing the wheel Note When removing the wheel inspect first to see that there is no contact between the caliper and axle vehicle chassis sections or carrier etc that may be impeding the free movement of the caliper WARNING Not all wheels and valve stems are compatible with Bendix Air Disc Brakes Use only wheels and valve stems approved by the vehicle manufacturer to avoid risk of valve stem shear and other compatibility issues After re installing a wheel according to the vehicle manufacturer s recommendations please ensure that there is sufficient clearance between the tire inflation valve stem the caliper and the wheel rim to avo
38. ee wa es ee de ot wn et a4 47 Lever 20 ccentric Pruge Bearing u ot rg Da td FIGURE 7 SECTIONAL VIEWS 4 Wheel turns toward fixed pin side of 18 1 Spring Brake Type A Type B ADB Actuator 44 11 Pad Retainer Pad Retainer a 4 13 2 26 Spring Clip Service gt Actuator 12 2 Pad Holder Spring Ep P AR w Pad Assembly Le ANN consists of TSN 12 1 plus 12 2 40 eh 45 12 1 Pad Caliper A Washer 5 p Wheel Rotation Wheel Rotation Guide Bolt typically right hand typically left hand 7 Pin s Brass ZA YA Bushing AR gt O can Shield 22 A z Kit Ae x Inner Seal ao 39 Caliper Bolt Drive or ISI O YA D N 4 Tappet Bushing Actuator au B 4GuidePin 37 Adjuster 13 Tappet Hardware Mig J De Guide Sleeve Caps 2 styles xy supplied in kits es De Carrier CER Mounting W YA gt lardware ss and Boot Q l Assembly SJ Sa Nl nae we AS WA Bendix ADB22X 2B Anchor Plate Bendix ADB 22X V a Si Carrier 2A Bendix U shaped B B ADB 22X a Carrier Rotor DB Fasteners 2 A NIA LA A A ao SD 1 YA v ay y SD 2 Bendix 8 A N ADB22K V f _ 1 Splined Disc Rotor AnchorPlate 4 SD 3 Hardware Me Carrier SD 1 2 3 Mounting Hardware Splined Disc Rotor See Section 5 2 for SD exploded view of electronic wear indicator Steer Hub FIGURE 8 EXPLODED VIEW BENDIX ADB22X AND ADB
39. es specialized tools The full Bendix air disc brake tool kit KO29164 or Ken Tool kit 80000 includes the complete set of tools required for all permitted maintenance procedures Alternately for locations where only the tappet and boot replacement procedures will be performed the smaller Bendix tool kit KO28829 or Ken Tool kit 80001 will suffice The DVD BW7356 shows this procedure Bendix Number Ken Tool Number T2 KT02 Handle for KT01 cup Swivel assembly KT03 1 short body T3 KT03 KT03 2 brass disc KT03 3 retaining spring T24 KT024 Black Nylon Disc Description Typical Tool View TABLE 5 TAPPET AND BOOT REPLACEMENT TOOLS 22 44 Pad Retainer Pin 11 Pad Retaine SS Inner Seal 26 Spring Clip Assembly 6 Adjuster Cap Bushing 22 Inner Seal FIGURE 46 ADB EXPLODED AND SECTION VIEWS 5 5 2 Pad Removal follow Sections 5 2 1 5 2 11 for removal of the brake pads 5 5 3 Tappet and Boot Assembly 13 Removal CAUTION NEVER EKTEND THE TAPPET MORE THAN 1 75 in 44 5 mm See Figure 47 Over extending the tappet will result in the tappet losing engagement with the threads of the synchronizing mechanism Since the mechanism can only be set at the manufacturing plant the caliper carrier assembly must be replaced if this happens Inspect the Brake Rotor See Section 4 4 Less Than 1 75in 44 5 mm FIGURE 47 PERMITTED TAPPET EXTENSION 5 5 4 See Figure 47 E
40. h since it may damage the adjuster shaft FIGURE 38 PAD REMOVAL 5 2 9 See Figure 38 Move the caliper fully inward and remove the inboard pad then move the caliper fully outward and remove the outboard pad 5 2 10 Repeat the pad removal procedure for the other end of the axle 5 2 11 To confirm that the guide pins are sliding freely examine the pads just removed for uneven wear Use these two inspections A Check for uneven end to end pad wear If the difference in wear is greater than 0 080in 2mm replace the brake pads and also inspect the guide pins See Section 4 5 B Compare the thickness of the inboard and outboard pads of each set If the difference between the inboard and outboard pad thickness is greater than 0 138in 3 5mm replace the brake pads and inspect the guide pins See Section 4 5 5 2 12 Inspect the Brake Rotor See Section 4 4 5 2 13 Inspect the guide pins See Section 4 5 Important To maintain optimal braking Bendix strongly recommends that whenever brake pads are replaced the complete axle set be replaced together Use only pads which are permitted by the vehicle manufacturer axle manufacturer and or disc brake manufacturer Failure to comply with this may invalidate the vehicle manufacturer s warranty Before installing the brake pads use the adjuster to fully retract the tappets to provide adequate clearance 5 2 14 Clean the surfaces that will come in contact with th
41. he vehicle In the case of spring brake chambers install the pads before uncaging the spring 5 4 9 Before returning vehicle to service with the system pressurized using a soap solution check for air leakage Minimal leakage in the area around the diaphragm is permitted 100 SCCM and a one inch bubble in one minute at the hose fitting is acceptable If abnormal leakage is detected the diaphragm must be replaced or fitting adjusted respectively 5 5 TAPPET 8 BOOT ASSEMBLIES AND TAPPET INNER SEAL REPLACEMENT CAUTION Follow all safe maintenance practices including those listed on page two of this document Park the vehicle by other means than the foundation brakes on level ground and chock the wheels 5 5 1 In some cases the technician will need to remove the caliper carrier assembly from the vehicle See Section 5 3 Note that new bolts available from the vehicle manufacturer will be needed for re installation Important If the vehicle is equipped with spring brakes cage the spring brakes on all axles requiring work Consult the vehicle manufacturer s instructions as necessary This procedure may be carried out with the air disc brake installed on or removed from the vehicle In cases where the caliper carrier assembly is removed from the vehicle NEW fasteners must be used and properly torqued during re installation Use only fasteners approved by the vehicle manufacturer Note This maintenance procedure us
42. he brake pad rotor wear can be made without removing the wheels Where dust guards are not used the top of the pads and part of the rotor are visible through the opening at the top of the brake Other visible portions of the rotor can be inspected at the same time Unless a vehicle has been stored for some time the main rotor surfaces that contact the pads will always appear to be shiny Surface rust on these surfaces would indicate a malfunctioning brake that should be inspected immediately Pads are 1 181in 30 mm thick when new and must be replaced when they reach 0 433in 11 mm Rotors are 1 77in 45mm thick when new and must be replaced when they reach 1 46in 37mm See Section 4 3 for further inspection criteria 2 1 1 Electronic Wear Indicators Use the dash indicator s and or a hand held diagnostic tool to regularly monitor the pad wear See Section 5 2 2 1 2 Mechanical Wear Indicators See Figure 9 for the location of the mechanical wear indicators There are two types See Figure 10 for Style A and Figure 11 for Style B Quick Visual Inspection of Pad Thickness and Rotor Location of Wear Indicator Notches Both sides of brake FIGURE 9 LOCATION OF WEAR INDICATORS Note These mechanical wear indicators do not constitute out of service criteria These inspections only show when to schedule a full wheel removed inspection of the brake pads and rotor The thicknesses of the pad and r
43. hrough the supply port applying pressure within the diaphragm The pressure expands the diaphragm applying force to and moving the pressure plate and push rod forward The push rod acts against a cup in the internal lever which pivots on an eccentric bearing moving the bridge Moving against a return spring the bridge transfers the motion to two threaded tubes and tappets which move the inner brake pad The inner brake pad from its normal position of having a running clearance between it and the rotor moves into contact with the brake rotor Further movement of the bridge forces the caliper sliding on two stationary guide pins away from the rotor That in turn pulls the outer brake pad into the rotor The clamping action of the brake pads on the rotor applies braking force to the wheel Pressure Supply Port Service Brake Plate Inner Brake Pad Push rod F Lever Outer Brake Pad Return Spring Diaphragm Eccentric Bearing FIGURE 6 CROSS SECTION VIEW SHOWING BRAKE OPERATION 1 5 1 Brake Release and Adjustment When the vehicle brakes are released the air pressure in the service brake chamber is exhausted and the return springs in the chamber and the bridge return the air disc brake to a neutral non braked position To maintain the running clearance gap between the rotor and the brake pads over time the non braked position is mechanically adjusted by a mechanism in the caliper The adjustment mechanism opera
44. ication Wear Sensor Identification Operation Brake Release and Adjustment SAFE MAINTENANCE PRACTICES A WARNING PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO AVOID PERSONAL INJURY OR DEATH When working on or around a vehicle the following general precautions should be observed at all times 1 Park the vehicle on a level surface apply the parking brakes and always block the wheels Always wear safety glasses Where specifically directed the parking brakes may have to be released and or spring brakes caged and this will require that the vehicle be prevented from moving by other means for the duration of these tests procedures 2 Stop the engine and remove ignition key when working under or around the vehicle When working in the engine compartment the engine should be shut off and the ignition key should be removed Where circumstances require that the engine be in operation EXTREME CAUTION should be used to prevent personal injury resulting from contact with moving rotating leaking heated or electrically charged components 3 Do not attempt to install remove disassemble or assemble a component until you have read and thoroughly understand the recommended procedures Use only the proper tools and observe all precautions pertaining to use of those tools 4 Ifthe work is being performed on the vehicle s air brake system or any auxiliary pressurized air systems make certain to drain the air pressure fro
45. id damage 10 4 1 CALIPER MOVEMENT TEST CAUTION Follow all safe maintenance practices Remove the wheel With the spring brakes released or caged push the caliper assembly inboard on its guide pins Note To fully release the spring brakes assure that the air system pressure is at least 90 PSI Using a suitable tool for example a large flat blade screwdriver press the inboard pad 12 away from the tappets Check that there is no dirt etc in the gap and clean if necessary Then use two long blade feeler gauges to measure over the whole tappet surface the gap between them and the inboard pad backplate See Figure 16 The gap should be between 0 024 in 0 6 mm and 0 043 in 1 1 mm If the gap is within the range given the test is complete Caliper Inboard Check the clearance at both tappets simultaneously 0 024 in to 0 043 in 0 6mm to 1 1mm FIGURE 16 RUNNING CLEARANCE CHECK CAUTION If the clearance is too wide there is a danger of brake failure If the clearance is too small or if there is no gap at all there is a danger of the brake overheating These conditions must be corrected before returning the vehicle to service For further investigation where there is some gap go to Section 4 2 and check the adjuster mechanism Where there is no movement at all and so no gap to measure go to Section 4 5 Guide Pin Inspection 4 2 ADJUSTER MECHANISM INSPECTION CAUTION Follow all safe ma
46. ing needle nose pliers and replace with the adapter supplied in the kit and clean as necessary FIGURE 35 EXPLODED VIEW FIGURE 36 CAP INSTALLED OF ADJUSTER AND ADAPTER TAB LOCATION For illustration purposes the exploded view Figure 35 shows the adjuster 23 and shear adapter 61 separated When using the adjuster mechanism always have the shear adapter installed on the adjuster CAUTION Never turn the adjuster 23 without the shear adapter 61 installed The shear adapter is a safety feature and is designed to prevent too much torque being applied The shear adapter will fail by breaking if too much torque is used Note For wheel ends with spring brakes if a shear adapter fails always double check to verify that the spring brake has been released or caged Ifthe spring brake is applied release or cage the brake assure that the air system pressure is at least 90 PSI and start the procedure again If the shear adapter fails you may attempt a second time with a new unused shear adapter In cases where a second failure of the shear adapter confirms that the adjustment mechanism is seized the caliper must be replaced 5 2 8 Use a 10mm six point box wrench See Figure 37 to turn the adjuster counterclockwise until sufficient space exists to remove the brake pads A clicking noise occurs each time the adjuster turns CAUTION Avoid overloading or damaging the adjuster shaft Do not use an open ended wrenc
47. intenance practices Aside from the normal maintenance schedule the adjuster mechanism inspection that follows is also carried out when the Caliper Movement Test 4 1 finds that the running clearance is too small or too large 4 2 1 With the spring brake released or caged remove the adjuster cap 37 using the tab taking care not to move the shear adapter 61 Note One of two styles of adjuster cap stamped metal or plastic adjuster cap may be used Adjuster Cap Location FIGURE 18 EXPLODED VIEW FIGURE 19 CAP INSTALLED OF ADJUSTER AND ADAPTER TAB LOCATION For illustration purposes the exploded view Figure 18 shows the adjuster 23 and shear adapter 61 separated When using the adjuster mechanism always have the shear adapter installed on the adjuster 4 2 2 Usinga10mm six point box wrench turn the Shear Adapter 61 counter clockwise and listen for the sound of 3 clicks as the mechanism backs off increases the running clearance Note Do not use an open ended wrench as this may damage the adapter See Figure 20 CAUTION Never turn the adjuster 23 without the shear adapter 61 installed The shear adapter is a safety feature and is designed to prevent excessive torque from being applied to the adjuster The shear adapter will fail by breaking if too much torque is applied FIGURE 20 BACKING OFF INCREASING THE RUNNING CLEARANCE If the shear adapter fails you may attempt a second time
48. iper before beginning work on the assembly 5 3 2 3 3 3 Remove the brake pads See Section 5 2 See Section 5 4 If the actuator used is a spring brake following the manufacturer s guidelines cage the spring With all air pressure drained from the system disconnect the air hoses from the brake chamber Vertical Mounting Bolt Style Caliper Carrier Assembly Showing s7 Spring Brake Actuator FA y Alignment Bushing FG li Cane Anchor Plate Torque Plate Pie PLL i i EA TAT ae TR it a FA i yi 1 aN 1 j i E 7E i YA Alignment i N Y SY apsnrs Tha E AN j Mounting Bolts 6 total washers not required at FIGURE 41 VERTICAL MOUNT CALIPER CARRIER 5 3 4 See Figure 41 Supporting the air disc brake by necessary means remove the six 6 mounting bolts washers and discard Note Bendix strongly recommends that during re assembly these bolts are replaced see your vehicle manufacturer for replacement hardware Lift the caliper up off the anchor plate The vertical bolt assembly includes an alignment bushing This bushing must be saved for re use during re assembly of the brake The bushing mounts in the torque plate and maintains the correct alignment of the brake assembly relative to the rotor 5 3 5 If the brake assembly does not separate from the anchor plate it may be helpful to install an M16X2 0 screw longer than 120 mm at the bushing locations
49. ives are available to assist you Monday through Friday 8 00 A M to 6 00 P M EST or e mail the Bendix Tech Team at techteam bendix com To better serve you please collect the following information before you call the Bendix Tech Team or include this information in your e mail Bendix product model number part number and configuration Vehicle make and model Vehicle configuration Number of axles tire size etc System performance symptoms When do they occur What troubleshooting measurements have been performed What Bendix service data literature do you have or need Bendix brand foundation brake products are brought to you by Bendix Spicer Foundation Brake LLC BW7308 2012 Bendix Spicer Foundation Brake LLC All Rights Reserved 5 12
50. m all reservoirs before beginning ANY work on the vehicle If the vehicle is equipped with a Bendix AD IS air dryer system or a dryer reservoir module be sure to drain the purge reservoir 5 Following the vehicle manufacturer s recommended procedures deactivate the electrical system in a manner that safely removes all electrical power from the vehicle 6 Never exceed manufacturer s recommended pressures 7 Never connect or disconnect a hose or line containing pressure it may whip Never remove a component or plug unless you are certain all system pressure has been depleted 8 Use only genuine Bendix brand replacement parts components and kits Replacement hardware tubing hose fittings etc must be of equivalent size type and strength as original equipment and be designed specifically for such applications and systems 9 Components with stripped threads or damaged parts should be replaced rather than repaired Do not attempt repairs requiring machining or welding unless specifically stated and approved by the vehicle and component manufacturer 10 Prior to returning the vehicle to service make certain all components and systems are restored to their proper operating condition 11 For vehicles with Automatic Traction Control ATC the ATC function must be disabled ATC indicator lamp should be ON prior to performing any vehicle maintenance where one or more wheels on a drive axle are lifted off the grou
51. m shear and other compatibility issues e CAUTION When using a hoist to support the air disc brake do not attempt to use the pad retainer bar as a bracing point as it is not designed to support the weight of the brake Use instead a brace or chain wrapped around the entire brake 9 0 2 SERVICE DVD to attach the hoist Order part number BW7356 for a DVD showing the full set of maintenance procedures included in this Service Data sheet Remove Caliper Remove Remove l See Carrier from Actuator from Brake Pads AWA AA Section Vehicle Caliper Sasa Section 5 3 Section 5 4 TABLE 3 OTHER REQUIRED SECTIONS FOR MAINTENANCE KITS 18 5 1 AIR DISC BRAKE SHIELD KIT 5 1 1 CAUTION Follow all safe maintenance practices including those listed on page two of this document Park the vehicle by other means than the foundation brakes on level ground and chock the wheels Note Most torque plates manufactured after January 1 2007 have the required torque plate tabs to permit these Shields to be mounted This shield kit includes a brake pad shield a rotor shield and the required attaching hardware for use in Bendix ADB22X and ADB22X V Air Disc Brake applications where external contamination and excessive road debris is a concern Brake pad and rotor shields can greatly reduce damage and or premature wear of pads and rotors under these conditions During installation verify that once the shield s are installed they will n
52. manufacturer Note Axles should have either all Bendix Splined Disc or all conventional rotors NI SSN GF ne S E FIGURE 25 EXAMPLES OF ACCEPTABLE AND NON ACCEPTABLE ROTOR CONDITIONS 13 MACHINING OF BENDIX SPLINED DISC ROTORS IS NOT PERMITTED CAUTION Always maintain air disc brake pads and rotors within specifications Excessive pad or rotor wear will degrade braking performance Periodic inspection of the Bendix Splined Disc attachment hardware is recommended to ensure optimum braking performance Bendix recommends verifying the torque on the spring element fasteners whenever a brake inspection is performed A WARNING AFTER MACHINING TURNING THE MINIMUM ROTOR THICKNESS FOR BENDIX BRAND ROTORS MUST BE AT LEAST 1 535 1 575IN 39 40 MM FOR OTHER BRANDS CONSULT THE MANUFACTURER S GUIDELINES ALSO CHECK THE VEHICLE MANUFACTURER S RECOMMENDATIONS FAILURE TO COMPLY MAY RESULT IN BRAKE FAILURE AND IN SERIOUS INJURY OR DEATH MACHINING OF BENDIX SPLINED DISC ROTORS IS NOT PERMITTED 4 4 4 Rotor Replacement An axle is permitted to have only all Bendix Splined Disc or all conventional rotors When replacing rotors be sure to adhere to the vehicle manufacturer s recommendations including bolt tightening torques It is recommended to install only Bendix brand rotors and also that the pads should be replaced as an axle set at the same time Non Bendix brand rotor
53. n the distances noted above a full wheel removed inspection will be necessary See Section 4 7 Push Pull By Hand to Check the Caliper Movement FIGURE 13 CALIPER RUNNING CLEARANCE FIGURE DOES NOT SHOW WHEEL SECTION THREE Check running clearance 4 1 OK YES NO Check Adjuster 4 2 OK NO Replace caliper carrier assembly 5 3 the spring brake fully partially applied Check caliper guidance 4 5 OK Replace guide pins 5 6 OR replace caliper carrier assembly 5 3 TROUBLESHOOTING PROCEDURE FLOWCHART Air Disc Brake Inspection Follow safe maintenance practices chock wheels Engage spring brakes and cage spring Release spring brakes and drain air from system Raise axle spin the wheel by hand Does the wheel turn smoothly Check running clearance 4 1 OK Check adjuster 4 2 OK Check Pad and rotor wear 4 3 4 4 OK Replace caliper carrier assembly 5 3 Drain air pressure from system Re start test after caging spring brakes Replace components as needed with genuine Bendix parts Tightness not due to air disc brake See vehicle manual FIGURE 14 TROUBLESHOOTING BENDIX AIR DISC BRAKES YES Disc brake OK SECTION FOUR WHEEL OFF MAINTENANCE INSPECTIONS Section Four Section 4 0 Wheel Off Insp
54. nd and moving A WARNING Notall wheels and valve stems are compatible with Bendix Air Disc Brakes Use only wheels and valve stems approved by the vehicle manufacturer to avoid the risk of valve stem shear and other compatibility issues A WARNING AVOID CREATING DUST POSSIBLE CANCER AND LUNG DISEASE HAZARD While Bendix Spicer Foundation Brake LLC does not offer asbestos brake linings the long term affects of some non asbestos fibers have not been determined Current OSHA Regulations cover exposure levels to some components of non asbestos linings but not all The following precautions must be used when handling these materials e Avoid creating dust Compressed air or dry brushing must never be used for cleaning brake assemblies or the work area e Bendix recommends that workers doing brake work must take steps to minimize exposure to airborne brake lining particles Proper procedures to reduce exposure include working in a well ventilated area segregation of areas where brake work is done use of local filtered ventilation systems or use of enclosed cells with filtered vacuums Respirators approved by the Mine Safety and Health Administration MSHA or National Institute for Occupational Safety and Health NIOSH should be worn at all times during brake servicing e Workers must wash before eating drinking or smoking shower after working and should not wear work clothes home Work clothes should be vacuumed and laundere
55. nd kit Section 5 6 803114 1114525 Guide Pin Grease NA K021964 K028039 Ring 58 inner boot 9 brass bushing 7 guide pin 5 caliper bolt 40 cap 10 guide sleeve 6 guide pin 4 caliper bolt 39 cap 68 White 5 grams White 500 grams Bendix Type 14 Universal Service brake actuator 18 2 actuator hardware K028226 Bendix Type 16 Universal Service brake actuator 18 2 actuator hardware Service Actuator Section 5 4 K028022 K028225 K027557 _ Bendix Type 18 16 Piston Style Truck Trailer Universal Spring brake actuator 18 2 actuator hardware K025670 Bendix Type 18 24 Piston Style Truck Trailer Universal Spring brake actuator 18 2 actuator hardware SPG EVEL Ae MeNe saton S K025669 Bendix Type 20 24 Piston Style Truck Trailer Universal Spring brake actuator 18 2 actuator hardware Bendix Type 18 24 Double Diaphragm Style Trailer Universal Spring brake actuator 18 2 actuator K026451 hardware K019174 Steer and Drive Axle A Caliper kit 1 Caliper Kit K019175 Steer and Drive Axle B Caliper kit 1 rationalized Section 5 3 ae Includes 803114 kit shown above K019180 Trailer Axle A Caliper kit 1 K019181 Trailer Axle B Caliper kit 1 Sections 5 3 Bendix Type 18 Universal Service brake actuator 18 2 actuator hardware Bendix Type 20 Universal Service brake actuator 18 2 actuator hardware Steer
56. ner seal 22 over the threaded tube 16 See Figures 52 and 53 for the tools and installation arrangement used Position the L1 T3 T9 with the short spacer T3 in position as shown in Figure 53 Guide the tool over the end of the threaded tube 16 Install the new inner seal 22 into position by rotating the adjuster nut on the T3 portion of the tool using an open ended wrench T3 KT03 FIGURE 53 ON VEHICLE INNER SEAL INSTALLATION To install inner seals where the caliper has been removed from the vehicle 5 5 13 Position the replacement inner seal 22 over the threaded tube 16 See Figures 54 and 55 for the tools and installation arrangement used The threaded tubes need to be retracted to allow the tool to be inserted Use the combination tool L2 T4 T3 T9 with the long spacer T4 as shown in Figure 55 Since the installation tool is guided by the center post of the threaded tube advance the tube a small amount to align the tool and the center post Install the new inner seal 22 into position by rotating the adjuster nut on the T4 portion of the tool using an open ended wrench T9 KT09 T4 KT04 T3 KT03 FIGURE 54 ON VEHICLE INNER SEAL INSTALLATION TOOL L2 FIGURE 55 OFF VEHICLE INNER SEAL INSTALLATION CAUTION To confirm that the inner seal has been correctly installed begin to extend the threaded tubes 16 by turning the shear adapter clockwise by 4 5 turns Watch as the threaded tube exten
57. ng the shear adapter the boots should only expand outwards a small amount due to trapped air The boots should normally due to their ribbed construction contract back into place as the tappets move Note If the bellows have excess air trapped then with the tappets retracted remove and re install the actuator to vent the excess trapped air See Section 5 4 Follow the reinstallation steps for the brake pads See Section 5 2 15 SECTION FIVE MAINTENANCE KITS AND PROCEDURES Section Five Page Section Page Vieisterarce KE 16 17 5 4 Spring Service Brake 24 Qi Brace Sve Kai WA 55 Tappet amp Boot and Tappet Inner Seal 25 28 20 5 6 Guide Pin and Boot Assemblies 29 34 Pad Replacement j 3 99 93 9r Bendix Splined Disc Hub Rotor 35 37 Caliper Carrier Actuator Assembly Wheel turns toward fixed pin side of 18 1 Spring Brake Type A Type B ADB Actuator 44 11 Pad Retainer Pad Retainer Pin pi 18 2 26 Spring Clip belie ctuator 12 2 Pad Holder Spring Co Wa t Pad Assembly Pas Bs y aN Bee consists of 10 a lt gt 45 aa 12 1 plus 12 2 40 Cap YA sr oh ae 12 1 Pad Caliper at Washer p Wheel Rotation Wheel Rotation iio S Guide Bolt typically right hand typically left hand APS 7 Pin H Ate Y Brass A i I Bushing lt gt Cap Shield 22 a See A z l Driveor Tappet Bushing Actuator ak WA S a 4 Guide Pin 37 Adjuster 13 Tappet kiandware
58. ot come into contact with any vehicle components suspension housings etc through the full range of motion of the wheel Keep in mind the particular use of the vehicle the orientation of the brake on the axle and torque plate the proximity of other axles and or the wheel tire being used Washer Spring N S Pad Shield Syl F Lea A TaN Lf ate Ln x i 1 OA he F Pes ia KA A1 iy yi k A ha eS ented na a at J Fa KI hai E E VA S i 14 ral zi Fastener AOT ECE jee Orue ALI Lee ate g va Fastener Rotor Shield FIGURE 31 DRIVE OR STEER AXLE EXPLODED VIEW WITH INSET SHOWING ROTOR SHIELD INSTALLATION Remove and discard the spring clip and washer from the pad retainer pin Remove and retain the retainer bar and retainer pin Position the pad shield as shown and re insert the retainer bar Install the retainer pin Use the included spring clip and washer to secure the retainer pin Check that the pad shield is held securely in place by the retainer bar See Figures 37 or 32 Sana At Washer YA pad Shield Torque at wh in Plate Fastener with Washer Rotor Shield FIGURE 32 TRAILER AXLE EXPLODED VIEW WITH INSET SHOWING ROTOR SHIELD INSTALLATION 5 1 3 Drive or Steer Axle Rotor Shields See Figure 31 Position the rotor shield between the torque plate and the rotor The supplied cap screws pass through the mounting tabs in the torque plate an
59. otor will both affect the wear indicator position at which maintenance is actually needed Wear Indicator Style A Where both the carrier and caliper have an indicator notch Compare the relative position of two notches cast into the carrier and caliper When the two notches align it is time to schedule a full wheel removed inspection of the pads and rotor Notch in the caliper zA Notchinthe f carrier When the notches line up itis time to schedule an inspection of the pads and rotor FIGURE 10 STYLE A WHEN BOTH CARRIER AND CALIPER HAVE A CAST NOTCH Where only the caliper has an indicator notch When the notch in the caliper aligns with the front edge of the torque plate it is time to schedule a full wheel removed inspection of the pads and rotor Notch in bata the caliper SR EERE I When the torque plate edge lines up with the notch itis time to schedule an inspection of the pads and rotor FIGURE 11 CARRIER WEAR INDICATOR NOTCH AND BACKING PLATE ALIGNMENT 7 No action is needed for small cracks spread over the surface e g Area F Rotor Friction Surface Width f Cracks reaching either edge of the rotor are not acceptable for either type of rotor Circumferential grooves as in Area J are acceptable if less than 0 06 in 1 5 mm deep N GF NI NS Q For standard Bendix rotors cracks running in a radial direction
60. rake pads it is strongly recommended that the air disc brake adjuster mechanism be checked for correct operation See Section 4 1 When replacing brake pads Bendix strongly recommends that the pads be replaced as an axle set 5 7 2 Refer to the vehicle manufacturer s recommendations and release or cage spring brakes and remove the wheel 5 7 3 Remove the pads See Section 5 2 5 7 4 Remove the air disc brake See Section 5 3 5 7 5 Remove the hub rotor assembly Note Follow the vehicle manufacturer s guidelines for removal of the wheel hub and rotor assembly from the vehicle in lieu of these instructions where available CAUTION Be sure to secure both the rotor and hub before removing the retention clips 5 7 6 Remove and discard the ten spring elements 5 7 7 On drive axles the ABS tone ring must also be removed See Figure 86 Retain for re installation 5 7 8 Use suitable hand tools to remove the intermediate elements spacers Remove all the right hand intermediate elements spacers of each set first and then the rotor can be turned slightly to release 35 the remaining intermediate elements Spacers In all cases take care not to damage the hub and its teeth Remove and discard the intermediate elements Spacers and retention clips attaching the rotor Discard the rotor 5 7 9 Following industry standards clean and inspect the hub before installing the rotor Look for corrosion and or damage to the h
61. s If anon Bendix brand rotor is used confirm that it complies to the vehicle manufacturer s recommendations CAUTION The use of non approved brake rotors may reduce levels of safety and invalidate the warranty See Section 5 7 for re installation procedures 4 5 GUIDE PIN BEARING INSPECTION CAUTION Follow all safe maintenance practices This guide pin inspection should be carried out if the technician cannot move the caliper during a Caliper Movement Test Sections 2 2 and or 4 1 Measure the range of travel along the guide pin bearings 4 5 1 Remove the Pads See Section 4 3 Using hand pressure only no tools the caliper 1 should slide freely along the whole length of the guide pins This movement should be at least 0 95 inch 25 mm when the pads are not present If the movement is less than this amount replace the caliper carrier assembly 14 4 5 7 t GuidePin Brass Bushing 9 Caliper Inner Boo BEARING SIDE 4M BEARING SIDE Caliper Outboard gt Inboard 39 Magnetic Dial Gauge Measures Range Here FIGURE 27 MAGNETIC DIAL GAUGE IN USE Measure the play range of movement in the guide pin bearings 4 5 2 See Figures 26 and 27 With the wheel removed remove the pad retainer bar 11 Temporarily replace the pads with two new pads 12 Attach a magnetic dial gauge holder to the carrier 2 on the short bearing side of the caliper 1 Use the measuring point on the
62. s are not air tight and so some trapped air is normal excess air trapped will dissipate yes v Z a N FIGURE 28 GUIDE PIN BOOT INSPECTION THIS IMAGE DOES NOT SHOW THE CARRIER 4 5 5 Inspect Boot Ww Inspect the original pads See Section 4 3 and they may be reused if they are in good condition with sufficient pad thickness 4 6 TAPPET AND BOOT ASSEMBLY INSPECTION 4 6 1 In order to inspect the tappet and boot assembly remove the pads 12 See Sections 4 3 or 5 2 and advance the shear adapter 61 clockwise CAUTION NEVER EXTEND THE TAPPET MORE THAN 1 75 in 44 5 mm See Figure 29 Over extending the tappet will result in the tappet losing engagement with the synchronizing mechanism Since the mechanism can only be set at the manufacturing plant the caliper carrier assembly must be replaced if this happens 4 6 2 INSPECT THE TAPPET AND BOOT ASSEMBLIES 13 FOR EVIDENCE OF DAMAGE CUTS CRACKS TEARS AND EVIDENCE OF CORROSION ETC Damaged boots lead to the penetration of dirt and moisture and can lead to corrosion and impair the operation of the brake Replace as necessary See Section 5 5 Extend LESS THAN 1 75 in 44 5 mm FIGURE 29 PERMITTED TAPPET EXTENSION Where the tappets and boots pass the inspection retract the tappets using the shear adapter When installed the boots are compressed to minimize the amount of air trapped within them Observe as you move the tappet back usi
63. sition tighten the screw in its base until it contacts the dimpling screw housing The movement of this screw forces three points outwards leaving indentations in the brass bushing See Figure 77 view C 5 6 23 Unscrew the dimpling screw out approximately 0 75 inches 20 mm Loosen the brass nut T14 and rotate the dimpling tool T16 60 degrees Repeat the dimpling process by tightening the brass nut T14 and then tighten the dimpling screw until it contacts the dimpling screw housing Back out the dimpling screw approximately 0 75 inches 20 mm The brass bushing 7 is now held in position by the six dimples made by the tool 5 6 24 Remove the installation tools and check the brass bushing 7 removing any burrs being careful not to leave any metal filings in the bushing Coat the inside of the bushing with the white grease included in the kit Installation of the Floating Guide Pin Bushing 5 6 25 To install the bushing 6 into the short guide pin side first inspect the bore for corrosion damage etc Clean as necessary 5 6 26 Place the new bush ing 6 in position so that when drawn into position the tab will align with the slot in the cast ing With the tab aligned place tool T14 over the bush ing and tap lightly To position the bushing see Figure 78 FIGURE 78 POSITION THE NEW BUSHING Washer Grease the bolt prior to each use T20 KT20 T14 KT14 T05 KT05 T06 KT06 T08 KT08 FIGURE
64. small chisel or similar tool to punch a hole close to the center of the guide pin cap 10 of the FIGURE 65 PRY TO FIGURE 66 USING SMALL short guide pin taking care to only insert the chisel REMOVE GUIDE PIN CAP 10 CHISEL TO REMOVE GUIDE a small amount Using the hole just made pry the PIN CAP 68 cap off and discard See Figures 63 65 5 6 8 Remove the other cap 68 that covers the long guide pin by using a small chisel and hammer to apply light blows to the cap with the chisel aimed away from the casting See Figure 66 Discard both caps 30 5 6 9 Using a 14 mm hex bit socket remove and discard the two caliper bolts 39 and 40 See Figure 67 By hand retract both guide pins slightly and then remove the caliper from the FIGURE 67 REMOVE THE carrier CALIPER BOLTS The guide pins are now only held by the retaining rings 58 5 6 10 Remove the boot retaining rings 58 and the guide pins 39 and 40 Use a screwdriver to pry out the inner boots 9 See Figure 68 Discard the removed items FIGURE 68 REMOVE THE RETAINING RINGS GUIDE PINS AND BOOTS 5 6 11 Clean the caliper upper and lower surfaces around the bushings Grease the bolt prior to each use Pa Washer T12 KT12 T13 KT13 T14 KT14 FIGURE 69 BRASS BUSHING REMOVAL TOOL 5 6 12 Prepare to remove the brass bushing used in the long guide pin side Assemble the long bolt T13 washer and sleeve T12 as in Figures
65. t be greased with white grease Part No 1114525 or KO21964 Add grease to the rubber gasket on the chamber CAUTION Do not use grease containing molybdenum disulfate 5 4 6 The seal as well as the push rod area must be clean and dry 24 FIGURE 44 SPRING BRAKE INSTALLATION CAUTION Do not use brake chambers with seals that have a thickness less than 0 12 in 3 mm Use only actuators which are recommended by the vehicle manufacturer 5 4 7 Install the brake chamber using new self locking nuts EN ISO 10513 Alternately tighten both the nuts step by step up to a final torque of 133 7 ft Ibs 180 10 N m Bendix strongly recommends that new nuts be used 5 4 8 Re connect the air hose s and be sure that each hose is not twisted or in contact with moving vehicle components The air hose routing must allow for full caliper travel Note that for spring brake service chambers the ports are indicated by 11 Service Brake Port and 12 Spring Brake Port FIGURE 45 PORT DESIGNATIONS Note installed note that in some cases drain plugs are installed Where a new spring brake chamber is being See Figure 43 arrows marked A Where drain plugs are present after installation remove whichever plug is at the lowest position The selected drain hole must be aligned downwards or within 30 when installed on t
66. tes automatically whenever the brakes are activated to compensate for rotor and brake pad wear and to keep the running clearance constant During pad or rotor maintenance the technician manually sets the system s initial non braked position The total running clearance the sum of clearances on both sides of the rotor should be between 0 024 to 0 043 in 0 6 to 1 1 mm 12 9 Pad 22 4 Assembly oe WEL oct 5 Inner Seal 7 Ring Wa Brass Bushin f Caliper Guide Pin 40 Top Sectional View Caliper Bolt 23 Adjuster Unit 161 Tappet Bushing 32 16 Threaded Tube 13 Tappet and Boot Assembly Cat eligi y Chain Wheel 61 Fa Shear Adapter ki ine mem E EERTE SS rhs x Od a creer Ee Bee Be gral Meee my SNT Wa F ty 4 2 io 45 Washer 26 Spring Clip Adjuster Cap 44 27 Spring Pad Retainer Pin 11 Pad Retainer 33 Sn Turning gt YA Device 5 16 Tappet gE Threaded Tube Bushing 13 Tappetand Boot Assembly Carrier a on a i l AS 58 9 4 Side Sectional View ooed aA aan Ring Inner Guide Pin Boot Pad Assembly 12 A 12 Te ay 18 1 Spring Brake or OTA Oo OY A 7 ty 4 18 2 Assembly 7 a A AYA NA phi Ro Brake Chamber 7 A a7 oe Da S eA A ws eek Sa I ye To yA IF ee os g gt CLA a Short Caliper Bolt Sectional View Apa D A 7 te 7 w or ra ri maa ee JEE P
67. ub and inspect the wheel speed tone ring Where necessary consult the hub manufacturer s guidelines for more details 1 Wheel Hub 2 Splined Disc Rotor 3 Intermediate Element Spacer 4 Spring Element Fastener including retention clips FIGURE 88 ROTOR INSTALLATION ROTOR INSTALLATION 5 7 10 See Figures 87 through 91 Place the rotor into position on the hub Install the new intermediate elements Spacers as shown in Figure 89 With all the intermediate elements Spacers correctly inserted into position verify that the gap between the intermediate elements Spacers and the wheel hub does not exceed 0 004 in 0 1 mm If a gap is found that exceeds this maximum value verify the installation of new intermediate elements Spacers Replace the wheel hub if the excess gap cannot 36 be corrected with proper installation of new rotor retaining hardware 1 Wheel Hub 2 Splined Disc Rotor 3 Intermediate Elements Spacers FIGURE 89 INTERMEDIATE ELEMENT SPACER INSTALLATION FIGURE 90 INTERMEDIATE ELEMENTS SPACERS INSTALLED 5 11 Install the ten new spring elements included in the kit in an evenly distributed cross pattern sequence Torque to 22 1 ft lbs 30 N m 5 7 12 Where the tone ring was removed during step 5 7 7 re install the tone ring Use a professional grade fastener compound such as Loctite blue 242 on the fasteners Torque to 19 22 in lbs 2 1 2 5 N m 5 7
68. xtend the tappets less than 1 75 in 44 5 mm by turning the shear adapter 61 clockwise A screwdriver callout B in 25 Figure 47 inset should be used to move the boot and allow the wedge fork A in Figure 48 to be inserted CAUTION Do not insert the screw driver more than inch Take care not to damage the inner sealing face see arrow X in Figure 48 Gouges or grooves will prevent a good seal and will require that the caliper be replaced FIGURE 48 WEDGE TOOL USE 2 00 5 5 6 5 5 7 5 5 8 The tappet and boot assemblies 13 can then be removed from the threaded tubes 16 by using the wedge fork T15 Be sure to orient the wedge tool with the tapered side towards the tappet Remove the old tappet bushings 161 Retract the threaded tubes by turning the shear adapter 61 counter clockwise See Figure 49 Carefully remove the inner seal using one or two flat blade screwdrivers as shown Caution Do not insert the screwdrivers so far that they come into contact with the threaded tubes Damage to the threaded tubes would require that the brake be replaced FIGURE 49 INNER SEAL REMOVAL 26 2 0 9 5 5 10 Inspect the threaded tubes 16 Inspect the inner sealing face for damage lf damage is found that would cause the inner seals not to be able to seal properly the caliper carrier assembly must be replaced Clean the area around the inner seal See Figures 50

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