BENDIX BW7273 User's Manual
Contents
1. Remove pads clean pads carrier and caliper See vehicle manufacturer s instructions for troubleshooting air system Are pads about to move freely in carrier Are the disc brake and its components attached to the axle as per specifration Non permitted cracks tracks in brake disc s brake disc runout within spec Remove pads clean pads carrier and caliper See section on Replacing slide pins and bushings See vehicle manufacturer s instructions for troubleshooting air system For more information talk to your Bendix or Roadranger representative call 1 866 610 9709 or visit www foundationbrakes com ms Bendix Spicer gt Roadranger Foundation Brake Ere The Roadranger System features ITO ws AL IET f Bendix brand foundation brakes 901 Cleveland Street Elyria Ohio 44035 e 1 866 610 9709 www foundationbrakes com BW7273 2008 Bendix Spicer Foundation Brake LLC e 01 08 All Rights Reserved Printed in U S A2. 2 Reduce the measured dimension by the total thickness of the two 2 spacers 1 Spacers 2 Brake disc 12 Measure the lateral runout of the brake disc as follows 1 Attach a magnetic stand complete with a dial indicator on the frame 2 Place the tip of the dial indicator on the face of the brake disc 3 Rotate the brake disc Max runout 0 5 mm 0 02 in IMPORTANT Do not include the wheel bearing play in the measurement 1 Carrier 2 Brake disc 3 Dial indicator Refer to WESM 0060 for bearing adjustment procedures Endplay not to exceed 005 in Also check the brake disc for cracks and wear tracks Crack length lt 75 Permitted cracking ss Crack length Non permitted cracking Service Instructions Checking Sliding Function Checking Play in the Slide Pins This check is done after the pads have been removed See the Measure the play in the outer slide pins as follows The section on Replacing P ads maximum amount of play is 1 0 mm 0 04 in Check the sliding motion of the caliper on the slide pins If the I rSGa 1 8 TISURENE a DIA HRICGEDI HO the frame caliper does not slide freely on the pins make sure the move ment is not obstructed by external dirt or foreign objects 2 Put the tip of the dial indicator on caliper at point 2 see below 3 Rock the caliper and read the dial 4 Repeat this measurement procedure inside the brake disc for the inner slide p
3. Specifrations Disc Brake ESD225 Fe srt Max brake chamber force Wheels Number of actuating pistons Number of slide pins 4 49 SE Threshold force 28N Brake chamber stroke requirements Mechanical advantage Backplate thickness Thickness brake disc new Thickness brake disc worn Effective radius Swept area brake disc Lining area per pad Grease GGLB NGLI 4350 F 177 C to 35 F 37 C Weight disc brake approximately Exc brake disc pads chamber and sensor Specifrations Tightening Torque Wear Limits Torque fasteners to specifrations in table Mer sTANDARD Torque Torque ze min lining thickness 3mm 012i Fastener N m Ibs ft Frame Mounting Screw 447 to 474 330 to 350 im pins max play Slide Pin Screw 187 to 200 138 to 148 Retaining Bar Screw 42 to 48 31 to 35 Actuator Mounting Screw 24 to 30 18 to 22 Brake disc max wear per 2mm 0 08 in side Brake disc max lateral 0 5 mm 2in runout Brake disc max 0 1 mm DTV 0 004 in thickness variation Bridge Mounting Screw 100 4 10 502 74 4 7 502 22 turn 22 turn ir Chamber Rotor to Iron Hub 339 to 373 250 to 275 use Loctite 266 Rotor to Aluminum Hub 190 19 140 14 Use the Snap on Torque Wrench Heavy Duty Offset 17 16 30mm Box Adapter part number XM 300B with the Snap on 400 lbs ft Torque Wrench part number TQR 400 Snap on Customer Service 877 740 1900
4. Description of Operation Description of Operation Actuation Release of the Brake On braking the lever is actuated by the brake chamber The external and internal radii of the inner part of the lever do not have a common center which means that the crossbar is moved axially in the direction of the brake disc The force is transferred from the crossbar via adjustment screws and thrust plates to the inner pad When the pad comes into contact with the brake disc the caliper is moved on slide pins so that the outer pad also comes into contact with the brake disc When the brake is released the return spring forces the crossbar back into its rest position so that the design clearance between pad and brake disc is achieved 1 Guide pin 4 Friction spring 2 Adjustment spring 5 Hub 3 Companion Sleeve 6 Adjuster housing Self Adjusting Adjustment The brake operates according to the clearance principle The brake sequence is divided into three phases Design Clearance C Excess Clearance Ce which is to be adjusted out and Elasticity E The housing of the adjuster is held in position against the internal radius of the lever by a guide pin The adjuster housing consequently follows the movement of the lever The rotational motion is transferred from housing to adjustment spring which in tum after passing the design clearance transmits the motion of the companion sleeve friction spring and hub 1 Calipe
5. and Boots Removing Slide Pins Slide Bushings and BUOIS Los resets rast esis E es 20 Ins Decl cuit tuttecoteateettheecsande bs 22 Replacing Slide Bushings and Slide Pins 22 Replacing Boots in Caliper 08 23 Replacing Brake Chamber Removing Brake Chamber 05 25 Replacing Brake Chamber 05 25 Replacing Spring Brake Chamber Removing Spring Brake Chamber 26 Replacing Spring Brake Chamber 2 Replacing Rotor Removing ROOF toes sica evens ge xs oed pews 28 Replacing ROUT iii o3 zo ri devise chases 28 Rotor Runout Check eua eo ce c run 28 Cleaning and Inspection isses 29 Rotor Resurfacing s sess zi dps RE Ew eu 29 Troubleshooting 0 000 00 30 General Information Model Identifration Bendix ESD 225 Wheel Size Disc Brake Extended Service General Information Product Identifration Exploded View 1 Torque plate 13 Slider pin bolt 2 Carrier 14 Slider pin cap 4 Caliper Assy 17 Flat washer 5 Retaining bar screw 18 Hex head screw torque plates to frame 6 Retaining bar 20 Air chamber 7 Pad retaining spring 21 Air chamber nut amp air chamber washer 8 Pads 22 Actuator plug 9 Slider boot 23 Actuator assembly extension 10 Boot retaining ring 24 Rotor 11 Slider bushing 25 Rotor mounting cap screw 12 Slide pin 26 Hub Specifrations
6. readjustment shaft is fully retracted IMPORTANT Do not tighten 2 Check that the pad contact surfaces in the disc brake are Chock the wheels on an axle that is not to be raised clean Replace pads Replace pad springs retainer bar and secure with retainer cap screw Torque retainer cap screw to 45 3 Nem 33 2 2 2 lbs ft A WARNING Follow the Safety Instructions The vehicle manufacturer s instructions must also be followed e Liftthe axle support and remove the wheels in accordance with the vehicle manufacturer s instructions A WARNING Clean the disc brake of dirt and dust Use the specifed type of dust removal equipment for cleaning Do not use compressed air Inhaling dust particles may be harmful to your health A WARNING If the disc brake is equipped with a spring brake chamber make sure that the spring is caged in accordance with the manufacturer s instructions 1 Remove the plug of the readjustment shaft 2 Use an 8 mm socket to back off the brake adjuster Turn the readjustment shaft counterclockwise to release the brake Do not tighten IMPORTANT To prevent damage to the adjusting mechanism never use an impact wrench 29 Remove the retainer bar cap screw p Remove the retaining bar Hold the pad springs to prevent them from jumping out uo Check the following refer to section Brake Disc Sliding Function Play in the Slide Pins Boots for Slide P ins Bellows f
7. WARNING Refer to Safety Instructions The vehicle manufacturer s instructions must also be followed Clean the disc brake of dirt and dust Use the specifed type of dust removal equipment to clean not compressed air inhaling dust particles may be harmful to health If the disc brake is equipped with a spring brake chamber ensure thatthe spring is caged in accordance with the manufacturer s instructions 1 Service Instructions Checking Pads Measure the distance from the backplate to the wearing surface of the pad The minimum permitted lining thickness friction material per D O T Department of Transportation standards is currently 3 mm 12 in The lining thickness of a new pad is 22 mm 0 9 in Replace the pads if they are worn out Check thatthe pads are evenly worn by measuring at four different points on the pad A maximum of 1 mm 0 04 in of uneven wear is allowed Also the inner and outer pads must be worn equally In the event of uneven wear check the sliding function of the caliper on the slide pins See Checking Sliding Function IMPORTANT Driving with light braking may result in increased wear on the inner brake lining To replace the pads see the section on Replacing P ads Checking Brake Disc Measure the thickness ofthe brake disc Minimum thickness of the brake disc is 41 mm 1 61 in 1 If the brake disc has a worn edge the measurement can be performed using two 2 spacers
8. boots Socket 1 New protection caps 23 i i SPS SUId 9piis 6Gurerio Replacing Slide Pins Slide Bushings amp Boots 9 Check the following refer to section Installing disc brake Note Always use new bolts e Installing air chamber Installing pads Adjust brakes Perform brake operating test 24 Replacing Brake Chamber Removing Brake Chamber Replacing Brake Chamber 1 Remove the air hose Remove the two 2 nuts holding brake 1 Check that the new brake chamber is of the correct type chamber There must be inner bushings on the push rod 2 Remove brake chamber 3 Check through the aperture in the brake chamber attachment fbnge that no moisture corrosion is present If itis replace caliper 1 Hose 2 New brake chamber 2 Fit the pipe ftting to the new brake chamber 3 Check that the mounting faces of the brake chamber and caliper are clean 4 Lubricate the end of the push rod with grease 4 If action is required see Removing Disc Brake Caliper on 5 Fitthe new brake chamber with nuts and washers and page 19 tighten to 130 Ibs ft 176 Nem 6 Install the air hose to the brake chamber 7 With the service brake applied check brake chamber hose and connections for tightness and damage 8 Install the wheels in accordance with the vehicle manufacturer s instructions 9 IMPORTANT Make sure that the contact surfaces between the wheels and hub
9. 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 1 AVOID CREATING DUST Compressed air or dry brushing must never be used for cleaning brake assemblies or the work area 2 BENDIX SPICER FOUNDATION BRAKE LLC 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 fitered ventilation systems or use of enclosed cells with fitered 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 3 Workers must wash before eating drinking or Smoking shower after working and should not wear work clothes home Work clothes should be vacuumed and laundered separately without Shaking 4 Material safety data sheets on this product as required by OSHA are available from Bendix Spicer Foundation Brake LLC Service Instructions Service Instructions Service Intervals Check the following items regularly every 6 months Refer to the sections as listed below Check brake pads Check brake disc Check caliper sliding function Check operation A
10. resurfaced by mounting in an appropriate then clean rotor in a non toxic greaseless cleaner brake lathe and removing the least amount of material A CAUTION Use of a petroleum based cleaning solvent possible to ensure a smooth face may leave a residue which could damage lining material 2 Depending on the amount of braking surface scoring present every effort should be made to remove equal amounts from 2 Visually inspect rotor for heat checks cracks grooving or M scoring beyond a depth of 030 If the rotor is Note Before installing on the vehicle ensure that the rotor is Clean and re inspected After installing on vehicle verify that the lateral runout is within specifration See Rotor Note Many heat checks are similar in appearance to cracks Runout Check section If in doubt a crack is defned as a surface split radiating into or from an edge of the rotor and or over 75 in length cracked replace rotor heat checked but no cracks reuse rotor Good Rotor grooved or scored More than 43 mm 1 7 in less than 030 reuse rotor as is Replace Rotor Less than 43 mm 1 7 in more than 030 resurface rotor See Crack length 3 Measure thickness of area between rotor faces The rotor must be replaced if thickness is less than 41 mm 1 61 in 29 Troubleshooting Troubleshooting A WARNING Refer to Safety Instructions The vehicle manufacturer s instructions must a
11. are clean and free of distortion follow the vehicle manufacturer s instructions on tightening torques 10 Check that the brake hoses do not pinch during full wheel articulation 11 Remove the axle support and the wheel chocks and lower the axle in accordance with the vehicle manufacturer s instructions 25 Replacing Spring Brake Chamber Removing Spring Brake Chamber A WARNING Follow the Safety Instructions The vehicle manufacturer s instructions must also be followed Activate the spring caging mechanism of the spring brake chamber so that the spring is held in it compressed position See vehicle manufacturer s instructions e Apply the parking brake 1 Remove the air hose connectors of the service and parking brake 2 Remove the two 2 nuts holding the spring brake chamber 3 Remove spring brake chamber 4 Check through the aperture in the brake chamber attachment fbnge that no moisture corrosion is present If so replace caliper 5 Lubricate the end of the push rod with grease 26 Replacing Spring Brake Chamber Replacing Spring Brake Chamber 1 Check that the new spring brake chamber is of the correct 3 4 type Note There must be an inner boot at the push rod 5 6 10 1 New spring brake chamber 11 2 Check that the parking spring is caged in accordance with 12 the manufacturer s instructions 7 8 9 Check that the brake hoses do not pinch during full whe
12. di Premium wheel end brake products Bendix ESD 225 Air Disc Brake Bendix Spicer Foundation Brake LLC Table of Contents General Information Model Identifration 0 0c cee eae Exploded VIBW ics crsa cus Es cua EE Se hsy go Specifrations DISC Brake ESDZ254 2 cock Re PEEPA RA REX Tightening Torque sus cuo xerons cbr rais Wear Limits s vs wx so rvassbodRxe Po dana Description of Operation Actuation Release of the Brake 0 Self Adjusting Adjustment sssssun Applicaton cs super S eun Eos por ET isa rs Do sito Safety Instructions 0005 Service Instructions Service Intervals nannan uaa ede e sews Checking Pausa eco ku b Ex SESS Checking Brake Disc 21 Checking Sliding Function sss Checking Play in the Slide Pins Checking Boots for Slide Pins Checking Bellows for Adjustment Screws Operating TeSt odo 4n3 kii by nRX E ER bas Initial Adjustment ius ek ah cora na Lubrication sesos vue 25 EPI sipa tiise dus Benelli dives sa vets EP YRsrAziM EARS Adjustment Mechanism 08 Slide Pins and Bushings sss Replacing Pads Removing PadS cus ore bbEEAPEEESERP x33 Replacing Pass asss essere ESTE RES Initial Adjustment s susc os secto ikke 9d cos Replacing Disc Brake Removing Disc Brake Caliper LL 19 Replacing Disc Brake Caliper 19 Replacing Slide Pins Slide Bushings
13. ecurely installed A WARNING To prevent damage to the adjusting mechanism never use an impact wrench Do not exceed 150 lbs in or damage to the adjuster extension may occur Note In order to obtain correct clearance between the brake disc and the pads the mechanism itself will perform the fnal fne adjustment during a number of braking applications 7 Lower the axle remove the support and the wheel chocking in accordance with the vehicle manufacturer s instructions 16 Lubrication WARNING Follow the Safety Instructions The vehicle manufacturer s instructions must also be followed General To obtain maximum service life it is important to use only the specifed lubricants for the lubrication points concerned Apply the correct amounts To prevent the lubricant from being dispersed or causing damage during the natural movements of the brake e g on friction surface of pads on brake disc in boots and bellows etc do not apply excessive amounts of lubricant Adjustment Mechanism The adjustment mechanism is lubricated and sealed for life in the factory Slide Pins and Bushings Lubricate the slide pins and bushings sparingly during assembly See the section of Speciftations for selection of the lubricant Use only the specifed lubricant Replacing Pads Removing Pads Replacing Pads Always replace pads on both sides of the axle at the same time 1 Using an 8 mm socket turn counterclockwise until the
14. el Remove the axle support and the wheel chocks and lower Install the pipe fttings to the new spring brake chamber Check that the mounting faces of the spring brake chamber and the caliper are clean Lubricate the end of the push rod with grease Fitthe new spring brake chamber with nuts and washers Torque to specs on page 5 Fit the air hoses to the spring brake chamber IMPORTANT Do not swap the air hoses Apply air pressure min 6 bar 87 psig to the parking brake Uncage the parking spring With the service brake applied and the parking brake released check the air hoses and connectors of the spring brake chamber for tightness and damage Install the wheels in accordance with the vehicle manufacturer s instructions IMPORTANT Make sure that the contact surfaces between the wheels and hub are clean and free of distortion Follow the vehicle manufacturer s instructions on tightening torques articulation the axle in accordance with the vehicle manufacturer s instructions f i 27 Replacing Rotor Removing Rotor 1 Remove the caliper assembly See Removing Disc Brake Caliper on page 19 2 Remove the wheel hub rotor assembly from the vehicle following the recommended procedures in WESM 0060 3 Remove ABS tone ring aluminum hubs only 4 Remove rotor fasteners 5 Remove rotor from wheel hub rr A RO ZN 1 Rotor Replacing Rotor Prior to rotor insta
15. ft 7 Remove caliper Replacing Disc Brake Caliper 1 Place caliper assembly on torque plate 2 Lubricate attachment bolts with anti seize compound 3 Fitbolts through torque plate to caliper and tighten to snug ft 4 Torque bolts to 330 350 Ibs ft 407 448 Nem If torque wrench is not available tighten bolt to snug ft mark fbt of bolt to torque plate then tighten bolt one more fht This will be the approximate torque value 1 Flat 60 deg 5 Verify adjustment shaft is fully retracted IMPORTANT Do not tighten 6 Install Air Chamber See page 25 7 Check that the pad contact surfaces are clean 8 Install new pads 9 Replace retaining bar and secure fastener 10 Perform initial adjustment See Initial Adjustment on page 16 Note Make sure that the sliding function of the air chamber does not pull on the ABS sensor Chamber caliper must be free to slide inboard 20 mm 0 78 in 19 Replacing Slide Pins Slide Bushings amp Boots Removing Slide Pins Slide Bushings and Boots Frame 1 Put the disc brake assembly ina vise 3 Remove the four 4 bolts for the slide pins using Torx E 18 socket 2 Remove protection caps using a hammer and chisel If the inner part of the protection cap remains in the slide pin remove this using an internal bearing puller 1 Slide pins 3 Carrier Note Protection caps must never be reused 2 Caliper 4 Retractthe slide p
16. ide Bushings and Slide Pins 1 Fitfour 4 new slide bushings in caliper 2 Lubricate slide bushings sparingly with grease 3 Lubricate slide pins with grease and press them into position in the slide bushing Use Haldex tool 481921 1 800 643 2374 1 Slide bearings 4 4 Slide pins must slide easily in the slide bushings so that caliper can fbat over carrier 1 Caliper 2 Slide pins Replacing Slide Pins Slide Bushings amp Rotors Replacing Boots in Caliper 1 Install boot in caliper Use Haldex tool 81922 A WARNING To prevent injury only grip from outside 1 800 643 2374 2 Press the outer part of boot into position in the groove in slide pin and secure with boot ring 1 Lift carrier 2 Caliper 7 Apply anti seize compound to the threads of the four 4 bolts and screw them into position Tighten with torque wrench 3 Boot Torx E 18 socket to specs on page 5 1 Caliper 2 Slide pin 4 Boot ring 8 Tap new protection caps into position in the outer ends of the slide pins using a 17 mm socket and extension 3 Clean the contact surfaces between the brake pads frame caliper and on thrust plates Use wire brush Do not grind 4 Apply anti seize compound to the inner surfaces of the slide pins facing the frame f 5 Push slide pins out so that frame can be fited into caliper 6 Life frame into position in caliper and press slide pins into position Take care not to damage
17. ins and measure at point 5 see below 1 Caliper 1 Outer slide pin 4 Carrier 2 Dial indicator tip 5 Measure point 3 Inner slide pin 6 Dial indicator 13 Service Instructions Checking Boots for Slide Pins Check the protection caps and rubber boots of the slide pins two 2 per slide pin If there are signs of cracks or other damage on the rubber bellows and protection caps they must be replaced If action is required see the section on Replacing Slide Pins Slide Bushings and Boots 1 Slide pin protection cap 2 Slide pin rubber boots 14 Checking Bellows for Adjustment Screws 1 Using an 8 mm socket rotate the readjustment shaft until the protection springs are fully visible IMPORTANT Thrust plates should not exceed 50 mm 1 97 in from the cover 2 Inspect the protection springs The protection springs must be replaced if there are signs of cracks or other damage 3 Pull back the protection springs and inspect the rubber bellows The rubber bellows must be replaced if there are Signs of cracks or other damage 4 Turn back the readjustment shaft Do not tighten the shaft If action is required see section Replacing Disc Brake 1 Thrust plates 2 Cover 3 Protection springs Service Instructions Operating Test 1 Lift and support the axle in accordance with the vehicle 6 Leave the wrench in the same position manufacturer s instructions 7 Activate
18. ins sufftiently to remove frame from caliper 2 by alternately pushing frame to and fro If slide pins are yf Seized in the frame cut threads internally in slide pins using 4 WA an M16x2 thread tap ZA Ch XA Od NOE E EET AX 3 A WARNING To prevent injury only grip from outside NY NS ove fe wO Si CD Ex 1 1 Protection cap 3 Caliper 2 Carrier 20 Replacing Slide Pins Slide Bushings amp Boots 8 Remove the four 4 slide bushings which are of a split A CAUTION Do not use gripping tools as the sealing design using a small screwdriver Begin at the split surfaces ofthe slide pins may be damaged IMPORTANT Do not damage the fiting surfaces Ko 1 Carrier 2 Caliper 1 Slide bearings 4 5 Clean parts of dirt and dust p m 4 A WARNING Use the specifed type of dust removal equipment to clean not compressed air Inhaling dust particles may be harmful to health 6 Press the four 4 slide pins out of the caliper 7 Remove the eight 8 boots by carefully prying them out IMPORTANT Do not damage the fiting surfaces Wo 1 Caliper 2 Bellows 8 SPS Suig 9piis Gupnepioy 21 Replacing Slide Pins Slide Bushings amp Boots Inspection 1 Check that the fitting surfaces for slide bushings and boots are damage free O gt Q C VON EZ Q CM Wik Lo J g UM 2 1 Caliper 2 Slide pins 4 22 Replacing Sl
19. llation clean and inspect wheel bearings and replace seals following instructions in WESM 0060 mm N Inspect torque plate for cracks and obvious damage Replace as required Check fasteners and tighten as required to OEM recommended torque specs Position rotor on mounting surface of wheel hub Install fasteners and tighten to torque specifrations Re install ABS tone ring if previously removed Install wheel hub and rotor assembly following the recommended procedures in WES M 0060 8 Install caliper assembly See page 19 9 Perform brake operation check Uo 28 A CAUTION Never release a vehicle from brake service without verifying safe brake operation Rotor Runout Check 1 With rotor installed on vehicle position dial indicator with contact on 90 to rotor face e NS AP d LOK 1 NER een S RA 2 1 Rotor 2 Dial indicator 2 Rotate rotor through at least two full revolutions and check lateral runout 3 Record maximum runout indicated 4 Repeat Steps 1 3 for the opposite rotor face 5 If total indicated runout on either face is less than 5 mm 0 21 in rotor is good more than 5 mm 0 21 in resurface or replace rotor Note Disc Thickness Variation DTV maximum 1 mm 004 in measure around rotor Replacing Rotor Cleaning and Inspection Rotor Resurfacing 1 Wire brush circumference of rotor to remove dirt and rust and 1 The rotor should be
20. lso be followed Symptoms M T No or low braking effect Brake drags does not release completely Vehicle pulls to one side Noise vibrations from the brake 30 Are brake pads worn away Is brake pad to disc clearance OK s brake disc OK s air pressure in brake chamber correct Measure with pressure gauge at brake chamber Change pads Carry out initial adjustment perform function test Change brake disc See vehicle manufacturer s instructions Take action in accordance with vehicle manufacturer s instructions Does air pressure in brake chamber remain after brake has been released 1 psi OK s spring brake if fited completely released when parking brake is off s brake pad to disc clearance OK Are pads able to move freely in carrier e s sliding function of brake caliper OK e Is wheel bearing or wheel bearing clearance OK See vehicle manufacturer s instructions for troubleshooting air system Carry out initial adjustment perform function test Remove pads clean pads carrier and caliper Check slide pins bushings See vehicle manufacturer s instructions Are pads worn out on one side s brake pad to disc clearance OK Are pads able to move freely in carrier e Is the pressure the same in both brake chambers of the axle in braking Measure with pressure gauge atthe brake chambers Replace pads Carry out initial setting and perform function test
21. or Adjustment S crews 17 Replacing Pads Initial Adjustment 1 Check that the brake disc can be turned freely 2 Using an 8 mm wrench turn readjustment shaft until both pads touch brake disc Then loosen 1 2 turn to obtain a basic clearance between pads and brake disc Check that the brake disc can be turned freely Remove the socket or wrench 1 Brake disc 3 Fit plug into access hole readjustment shaft see Item 1 in the illustration below 1 Readjustment shaft 2 Brake disc CAUTION Never use an impact wrench as this could damage the adjusting mechanism 18 Note In order to obtain correct clearance between brake disc and pads the adjusting mechanism itself will perform the fnal fne adjustment during a number of braking operations Replacing Disc Brake Removing Disc Brake Caliper A WARNING Be sure to follow all safety instructions including the blocking of wheels and proper lifting and Support of axle A WARNING Do not use compressed air A WARNING If disc brake is equipped with a spring brake make sure the spring is properly caged 1 Remove air chamber from caliper and secure Do not let the air chamber hang by just the air hose 2 Remove retaining bar 3 Remove brake pads 4 Re install retaining bar and secure with fastener 5 Connect lifting strap and suitable lifting device around retainer bar 6 Remove attachment bolts to torque plate 1 Readjustment sha
22. r 6 Retum spring 2 Outer pad 1 Crossbar 3 Brake disc 8 Lever 4 nner pad 9 Brake chamber 5 Thrust plates Description of Operation Application C During the movement through C the design clearance is measured between the pad and brake disc by the adjuster There is a predetermined clearance between the tongue of the adjustment spring and the slot in the companion sleeve which determines the free stroke before the adjustment E Ce C ni c 3 3 2 3 1 3 weed 1 Adjustment spring 5 Brake disc 2 Companion sleeve 6 Inner pad 3 Adjuster 7 Adjuster 4 Outer pad Ce If excess clearance remains after the mechanism has moved radially in accordance with the design clearance C the adjuster synchronization shaft pinions crown wheels adjusting shaft readjustment shaft and the adjustment screws are turned The rotation of the adjustment screws means that a percentage ofthe measured excess Ce is removed In the adjuster the turning movement is transferred from the housing via the adjustment spring companion sleeve and friction spring to hub which engages with the synchronization shaft o on 2560 nw E Ce C ji C CI 3 3 2 3 4 3 Yee fh 1 Adjuster 5 Friction spring 2 Adjuster spring 6 Hub 3 Housing 7 Synchronization shaft 4 Companion slee
23. s allowed by springs on the adjustment screws prevent the mechanism from the friction spring backing off oh wn C E L d AU 1 Adjuster 1 Adjustment spring 4 Friction spring 2 Rotating housing 5 Hub 3 Companion sleeve 6 Inner pad Brake torque Adjustment phase Ce Free stroke Elasticity Safety Instructions Safety Instructions Always follow the vehicle manufacturer s safety instructions when working on a vehicle Follow the vehicle manufacturer s instructions for jobs which are not described in this manual Follow local safety regulations The work must be carried out by trained personnel Sudden release of tensioned springs such as the spring brake part of the brake chamber and the return spring of the disc brake may cause injury Use recommended tools only Release pressure from lines and components before opening them Chock at least one of the vehicle s wheels to prevent involuntary movement of the vehicle Before releasing the vehicle back in service perform a brake operational check and test drive the vehicle to make sure that the brakes are working correctly 10 A DANGER AVOID CREATING DUST POSSIBLE CANCER AND LUNG DISEASE HAZARD While Bendix Spicer Foundation Brake LLC does not offer asbestos brake linings the long term effects of some non asbestos fbers have
24. the brakes five 5 times The wrench must move on each brake application which shows that the self adjustment A WARNING Follow the Safety Instructions The vehicle is working manufacturer s instructions must also be followed 2 Check that the wheel can be turned freely x5 3 Remove the plug ip 4 Release the brake by turning the readjustment shaft using an 8 mm socket 3 4 turn Note The brake can be released in the counterclockwise direction 5 Position disc brake with the brake chamber at the top and viewed from the side on which the hexagon of the IMPORTANT Movement of the wrench must not be readjustment shaft is accessible turn the readjustment obstructed If the wrench moves to and fro or does not move shaft counterclockwise at all the caliper is defective and must be replaced See the section on Replacing the Disc Brake Release Counterclockwise 15 Service Instructions Initial Adjustment 1 Check that the brake disc can be turned freely 1 Brake disc 2 Using an 8 mm socket turn the readjustment shaft clockwise Do not force until both pads touch the brake disc 3 Loosen the readjustment shaft 1 2 turn counterclockwise to obtain a basic clearance between the pads and the brake disc 4 Check that the brake disc can be turned freely 5 Remove the wrench 6 Fit the plug into the adjustment access hole on the readjustment shaft Make sure itis s
25. ve 8 Adjuster Description of Operation E When the two 2 pads come into contact with the brake Release disc the braking sequence enters elasticity phase E the torque rises and the adjuster stops adjusting The continued rotational The fist part of the return stroke passes through C followed by movement which now occurs in the adjuster is allowed by movement corresponding to E and Ce During the return stroke rotating the housing in relation to the adjustment spring the return spring ensures that the crossbar travels back C During the fist part of the return stroke transmitted force decreases and the tongue of the adjustment spring changes fbnk in the slot of the companion sleeve 6 E Ce C 4 5 JA i c r ls vA 3 3 2 3 1 3 1 Adjustment spring 4 Outer pad 2 Rotating housing 5 Brake disc 3 Adjuster 6 Inner pad 1 Adjustment spring 2 Companion sleeve Description of Operation E The next part of the return stroke corresponds to E The Ce During the last part of the return stroke Ce the rotational housing of the adjuster the adjustment spring and companion movement continues in the adjuster as described under E until Sleeve are rotated in relation to the hub which is stationary the mechanism has reached its resting position The friction Movement between companion sleeve and hub i
Download Pdf Manuals
Related Search