BENDIX BW7257 User's Manual
Contents
1. Axle Installations Figures 10 through 13 show typical and alternative brackets for self adjusting brake adjuster installations on trailer installations Universal Anchor Bracket Tip The universal anchor bracket mounts to the S cam bushing support bracket Rockwell Dana and Fruehauf brakes mount with two bolts Position plate on adjuster side of the S cam support Added bracket thickness requires the use of longer mounting bolts Eaton trailer axles manufactured after January 1993 have the anchor bracket as an integral part of the S Cam shaft bushing support Referto pages 9 10 and 11 for detailed installation procedures STRAIGHT ARM Figure 10 12 1 4 Brake Application BRACKET SELF ADJUSTING BRAKE ADJUSTER Figure 11 Alternative Bracket Types UNIVERSAL ANCHOR BRACKET EATON MOUNTING HOLE PRE 1993 av A DANA AND FRUEHAUF MOUNTING HOLES Figure 12 Universal Anchor Bracket Anchor Stud Installation STEP ONE STEP TWO STEP THREE 2ND SNAP BUSHING TILT STUD SECURE STUD SECURELY WITH AS SHOWN INTO PLACE TO INSTALL 1ST FLANGE HEAD NUT ALIGN ARROW WITH SLOT Figure 13 Anchor Stud Installation Installation Installation Procedure A Caution The procedures shown in this section are applicable to vehicles originally equipped with Spicer brand self adjusting brake adjusters only and must not be used for aftermarket retrofit Specific retrofit instructions ar2. arm Ifthe self adjusting brake adjuster does not maintain proper applied stroke it must be replaced CONTROL ARM AIR y CHAMBER SELF ADJUSTING gt BRAKE ADJUSTER fm gt STEP 2 APPLIED STEP 1 RETRACTED Figure 20 Measuring Pushrod Length Troubleshooting Tight or Dragging Brakes Check foundation brake components for Control arm anchor bracket not positioned properly See brake adjuster installation procedures Brake chamber notfully releasing Spring brake notfully releasing Pushrod binding on chamber housing Air supply notexhausting completely Out of round brake drums Extreme differences in lining to drum clearances between shoes on same wheel Improper wheel bearing adjustment Broken shoe return spring Loose brake linings Excessive Chamber Pushrod Travel Check foundation brake components for Loose broken or bent control arm anchor bracket Worn camshaft bushings Loose air chamber mounting Binding camshaft Worn clutch assembly See Checking Release Torque 13 Additional Service Information Additional parts and service information on these and related Bendix Spicer Foundation Brake products may be found in the following publications Service Manuals 15 x 4 Steer Axle Brakes Models ES 150 and EB 150 irsessesvsnenvsnevvrnevernevvenevvenevvenevvenevvenesnenesnenesnevesnenesnesesneseeneneenesvenereener BW725
3. assembly by hand Tap drum lightly with a hammer listening for a sharp ringing sound If brake drag is noted back off brake adjuster and recheck free stroke Note A properly working self adjusting brake adjuster does not require manual adjustmentwhile in service NOTE A properly working Automatic Slack Adjuster does not require manual adjustment while in service The manual adjuster hex is intended for use during adjuster installation and brake overhaul WARNING Automatic slack adjusters should not be repeatedly adjusted to correct excessive in service pushrod stroke because this condition indicates that a problem exists with the automatic adjuster with the installation of the adjuster or with related foundation brake components which manual adjustment will not correct Free Stroke B minus A Applied Stroke C minus A Applied Stroke Adjustment 1 Apply and hold an 80 90 psi brake application 2 Measure distance between face of air chamber and clevis pin centerline Record distance as dimension C 3 Subtract dimension A from dimension C The difference is applied stroke Compare applied stroke to maximum value in table below 4 Ifapplied stroke equals or exceeds maximum applied stroke shown adjustbrakes Ifless than the maximum no adjustmentis required 80 90 PSI Air Chamber Maximum Desired Size Applied Free Stroke Stroke Type 30 Long Stroke 2 5 3 8 to 5 8 Type 30 2 Without Drag Type 2
4. clutch and a racheting sound will occur Final Inspection of the Self Adjusting Brake Adjuster je E om 9 With full air pressure release spring and service brake Verify thatthe installation indicatoris within the slot Remove the clevis pin The clevis hole and adjuster hole should remain in alignment Ifthe air chamber clevis pulls into the air chamber repeatthe installation procedure 10 Afterfinalinspection install the cotter pin into the clevis pin Verify that applied stroke is within the legal limits for the air chamber being used 10 ROTATE TO STOP MOUNTING BRACKET Figure 16 Position Brake Adjuster AIR CHAMBER SELF ADJUSTING BRAKE ADJUSTER ET L UD E 7 i CLAMP TYPE f BRACKET ANCHOR BRACKET D se GAP I Figure 17 Proper Anchor Bracket and Control Arm Gap Installation Adjust the Self Adjusting Brake Adjuster Free Stroke Adjustment 1 Withairchamberfullyretracted measure distance from face of air chamber to centerline of clevis pin Record exact measurement as dimension 2 Use a lever to move the brake adjuster until brake shoes contact the drum 3 Measure the distance between face of air chamber and centerline of clevis pin Record distance as dimension B 4 Subtract dimension A from dimension B The difference is free stroke Allowable free stroke is a minimum of 3 8 stroke 5 Remove lever and check that brakes are not dragging Spin wheel end
5. 4 1 3 4 Type 24 w 2 1 2 2 extended stroke Type 24 w 3 extended stroke 2 5 Type 20 and 16 1 3 4 3 8 to 1 2 Type 12 1 3 8 3 8 to 1 2 A Fully Retracted B Drum Contact Using a Lever cC 80 90 PSI Brake Application Figure 18 Stroke Measurements 11 Maintenance Brake Adjuster Maintenance General Service Intervals Visual Inspection Lubrication Interval Type of Lubricant Standard During normal chassis lubrication or 3 months which ever occures first Adjusters manufactured prior to 6 1 96 every 50 000 miles or every 3 months Adjusters manufactured after 6 1 96 once a year Standard Chassis Grease Lube free Spicer brand self adjusting brake adjusters are manufactured without a grease fitting Lubrication Caution Do notuse moly disulfide loaded grease or oil because they may shorten brake adjuster service life Do not use pressure release grease fittings Important In no case should the lubrication interval exceed the published intervals in table above Lube Free Spicer brand self adjusting brake adjusters are lubricated at the factory with a proprietary grease and do not require lubrication at service intervals Note Spicer brand self adjusting brake adjusters manufactured after May 30 1996 have incorporated an improved sealing and grease filling technique This makes it possible to extend service intervals
6. 8 e 16 5 and 18 Axle Brakes Models ES 165 EB 165 and EB 180 e ueuuuuuu II IU IU SILL BW7258 4 Traller A KIOS vices cease HN RD HR HR FR EY HF EU HN RH HN FT FN TN FFY HR FT HF HE AATTEET BW7258 Parts Books Brake Models ES 150 EB 150 ES 165 EB 165 and EB 180 nesesesrsrvnvneresvsvsvnvnesesesvseneresesvsvsesesesesnsvseresernrsssseresesnessvresesernnser BW7253 8 Traller Axl suuusgesdeoddusteebe RUN NON FF WY HT RH FFF AH REY HE HY HWY HD UEN NE HRN Re BW7253 These publications may be ordered through the Bendix Spicer Foundation Brake publications online order system Log on to www bendix com to access our online Literature Center For more information talk to your Bendix or Roadranger representative call 1 866 610 9709 or visit www foundationbrakes com Bendix Spicer Fou nd ation Bra ke LLG Spicer is a registered trademark The Roadranger System features Dana C at 10 of Dana Corporation Bendix brand foundation brakes 901 Cleveland Street Elyria Ohio 44035 1 866 610 9709 www foundationbrakes com BW7257 2006 Bendix Spicer Foundation Brake LLC 09 06 All Rights Reserved e Printed in U S A
7. Premium wheel end brake products Bendix Spicer Spicer Automatic Slack Adjuster Foundation Brake LLC A Bendix Commercial Vehicle Systems and Dana Corporation Joint Venture The description and specifications contained in this service publication Any reference to brand name in this publication is made as an are current at the time of printing example of the types of tools and materials recommended for use and Bendix Spicer Foundation Brake LLC reserves the right to discontinue STOIC Na PO AMENA ENE ET FD or modify its models and or procedures and to change specifications at any time without notice IMPORTANT NOTICE This symbol is used throughout this WARNINGS FAILURE TO FOLLOW manual to call attention to procedures INDICATED PROCEDURES CREATES A HIGH where carelessness or failure to follow RISK OF PERSONAL INJ URY TO THE specific instructions may result in SERVICING TECHNICIAN personal injury and or component damage Caution Failure to follow indicated procedures may cause component damage Departure from the instructions choice oftools aTi materials and recommended parts mentioned in this publication may jeopardize the personal Note Additional service information not safety ofthe service technician orvehicle covered in the service procedures operator Tip Helpful removal and installation procedures to aid in the service of this unit NOTE A properly working Automatic Slack Adjuster does not require manual adj
8. arm hole lines up with the clevis hole See Figure 15 5 Installclevis pin Do notinstall the clevis cotter pin atthis time It will be necessary to remove the clevis pin later to check installation ANCHOR BRACKET CAMSHAFT Figure 14 Install the Anchor Bracket CONTROL ARM 7 16 ADJUSTING HEX ee LOOSELY ADJUST UNTIL HOLES ALIGN Figure 15 Install Adjuster Installation Position the Control Arm 6 Rotate the controlarmcounterclockwise away from adjustment hex towards the air chamber until it comes to a definite internal stop See Figure 16 If necessary use a plastic mallet to tap the control arm into position A Caution Excessive positioning force may damage the control arm Most adjusters will be equipped with an Installation Indicator Indicator must fall within the Slot for proper installation Incorrect control arm position can cause tight or dragging brakes 7 Tighten all control arm anchor bracket fastener s Note Make sure the control arm does not move from its position while tightening the anchor bracket fasteners Note Steer axle applications only a gap of 1 16 should be maintained between the anchor bracket and the control arm See Figure 17 8 Adjust brakes by turning adjusting hex clockwise until the lining contacts the drum Then rotate the adjusting hex ounter clockwise 1 2 of a turn A minimum of 13 ft Ibs is ecessary to overcome the
9. axle brakes Straight brake adjuster using a clamp type bracket See Figure 6 Offset brake adjuster using bolt on bracket See Figure 7 Straight brake adjuster using bolt on type bracket See Figure 8 Disc brake application See Figure 9 Referto pages 9 10 and 11 for detailed installation procedures TORQUE TO 40 50 FT LBS TORQUE TO a 20 30 FT LBS AIR CHAMBER CLAMP TYPE BRACKET STRAIGHT ARM Figure 6 Straight Clamp Type Installation AIR CHAMBER SS he SELF ADJUSTING BRAKE ADJUSTER BOLT ON BRACKET TORQUE TO 15 20 FT LBS Figure 7 Offset Bolt On Type Bracket Installation TORQUE TO 8 12 FT LBS SELF ADJUSTING BRAKE ADJUSTER AIR CHAMBER af fa o 3 5D lt o aE 3 Figure 8 Straight Bolt On Type Bracket Installation TORQUE TO 8 12 FT LBS SELF ADJUSTING BRAKE ADJUSTER BOLT ON JENS BRACKET rd I AIR gt 3 CHAMBER O O an 7 O O STRAIGHT ARM Figure 9 Disc Brake Type Installation Typical Applications Trailer
10. e provided with retrofit kits Attach the Self Adjusting Brake Adjuster A WARNING BLOCK WHEELS TO PREVENT VEHICLE FROM ROLLING CAGE SPRING BRAKES IF INSTALLED NOTE A properly working Automatic Slack Adjuster does not require manual adjustment while in service The manual adjuster hex is intended for use during adjuster installation and brake overhaul WARNING Automatic slack adjusters should not be repeatedly adjusted to correct excessive in service pushrod stroke because this condition indicates that a problem exists with the automatic adjuster with the installation of the adjuster or with related foundation brake components which manual adjustment will not correct 1 Verify thatthe pushrod is fully retracted Apply air to release spring brake If air is not available spring brake mustbe manually caged off 2 Installanchor bracketloosely as shown Do nottighten anchor bracket fasteners See Figure 14 Note Configuration of anchor bracket will vary depending on axle See Axle Installations on pages 5 6 and 7 3 Apply anti seize type lubricantto the shaftsplines Install the brake adjuster onto the camshaft with the adjusting hex pointing away from the brake air chamber Secure the brake adjuster on the camshaft Follow procedures in the applicable Bendix S picer Foundation Brake brake service manual forchecking and adjusting camshaftend play 4 Rotate the 7 16 adjusting hex nut clockwise until the brake adjuster
11. es not require manual adjustment while in service The manual adjuster hex is intended for use during adjuster installation and brake overhaul WARNING Automatic slack adjusters should not be repeatedly adjusted to correct excessive in service pushrod stroke because this condition indicates that a problem exists with the automatic adjuster with the installation of the adjuster or with related foundation brake components which manual adjustment will not correct WORMSHAFT COIL r SPRING CLEARANCE NOTCH CONTROL CONTROL ARM ARM p ANCHOR BRACKET b Sao Figure 1 Components of the Brake Adjuster Introduction Operation Self Adjusting Brake Adjuster Identification The serial and part numbers are stamped on the facing of the self adjusting brake adjuster The serial number is used for control purposes The part number describes the self adjusting brake adjuster specification MANUFACTURER NUMBERS EG00 1 SPICER MFD IN U S A BY HALDEX P N813638 SERIAL PART NUMBER NUMBER Typical Applications Steer Axle Installations Figures 2 3 4 and 5 show typical brackets for self adjusting brake adjusterinstallations on steer axles e Straight brake adjuster using a clamp type bracket See Figure 2 Offset brake adjuster using clamp type bracket See Figure 3 e Offset brake adjuster using bolt on type bracket See Figure 4 e Disc brake type installation See Figure 5 Refe
12. iled inspection procedure on foundation brake components refer to Bendix Spicer Foundation Brake service manual BW 7258 Wheel Bearing Adjustment Accurate wheel bearing preload is necessary to maintain proper alignment between the brake drum and brake shoes Checking Release Torque The following procedure verifies proper operation of the automatic brake adjuster Place a torque wrench on the 7 16 adjusting hex See Figure 19 Turn the torque wrench counterclockwise The clutch should not slip at a torque less than 13 Ib ft 18 Nem A racheting sound occurs when the clutch slips If clutch slips ata lesser torque replace the adjuster RACHETING SOUND OCCURS WHEN CLUTCH SLIPS Figure 19 Checking Release Torque Operational Check Troubleshooting Operational Check 1 Measure the pushrod length distance from the face of airchamber to the centerline ofthe pushrod clevis pin when fully retracted step 1 See Figure 20 2 Have an assistant make an 80 to 90 psi brake application Measure pushrod length again step 2 3 Subtract the step 1 dimension from step 2 The difference is the applied stroke 4 Verify that the applied stroke is less than the maximum Specified below 80 90 PSI Brake Application Air Chamber Type Maximum Applied Stroke Type 36 2 1 4 Type 30 2 Type 24 1 3 4 Type 24 2 with 2 1 2 extended stroke Type 12 1 3 8 Verify the correct installation of the control
13. r to pages 9 10 and 11 for detailed installation procedures AIR CHAMBER STRAIGHT ARM v SELF ADJUSTING BRAKE ADJUSTER Ape J CLAMP TYPE XS U BRACKET TORQUE TO TORQUE TO 20 30 FT LBS 40 50 FT LBS Figure 2 Straight Clamp Type Bracket Installation AIR CHAMBER OFFSET ARM H SELF ADJUSTING BRAKE ADJUSTER CLAMP TYPE VS BRACKET TORQUE TO TORQUE TO 40 50 FT LBS 20 30 FT LBS Figure 3 Offset Clamp Type Bracket Installation AIR CHAMBER OFFSET ARM BOLT ON BRACKET SELF ADJUSTING BRAKE ADJUSTER J yar TORQUE TO 15 20 FT LBS Figure 4 Offset Bolt On Type Bracket Installation TORQUE TO ete ieee SELF ADJUSTING ER e BRAKE ADJUSTER BRACKET i ZAX i X O I o STRAIGHT ARM Q Figure 5 Disc Brake Type Installation Typical Applications Drive Axle Installations Figures 6 7 8 and 9 show typical brackets for self adjusting brake adjuster installations on drive
14. senvesensene 13 Manufactured By Haldex Introduction Operation Introduction Spicer brand self adjusting brake adjusters compensate for wear in brake shoe linings caused by normal braking operation Upon brake application the brake adjuster assembly rotates rotating the brake camshaft The camshaft moves the shoes into contact with the drum During brake application and release the adjuster mechanism rotates the camshaft slightly to maintain the correct shoe to drum clearance Operation The Spicer brand self adjusting brake adjuster is a clearance sensing brake adjuster that maintains a nominal distance or clearance between lining and drum The clearance notch in the rack corresponds to this normal lining to drum clearance See Figure 1 When the brake applies The rack moves upward and rotates the one way clutch The one way clutch allows slippage in this direction e Brake application torque presses the wormshaft against the coil spring Wormshaft movement releases the cone clutch When the brake releases The coil spring presses against the wormshaft engaging the cone clutch e The rack is pulled back to its original position in the clearance notch Any lining wear causes the rack to turn the locked one way clutch while rotating the wormshaft via the locked cone clutch e The wormshaft rotates the wormwheel and camshaft adjusting the brakes NOTE A properly working Automatic Slack Adjuster do
15. thus reducing maintenance Inspection Bendix Spicer Foundation Brake strongly recommends that routine visual operational checks including brackets and control arms be performed at each Preventative Maintenance Service Interval Adjusters or anchor brackets that have visual damage or which fail the operational checks MUST be replaced immediately Inspect brake adjuster and anchor bracket for damage Check that anchor bracket is tight and the control arm is in the full release position Note If self adjusting brake adjuster is equipped with indicator arrow make sure the indicator is within the slow when the brake is in the release position Automatic adjusters should not be operated as manual adjusters except as may be necessary to get the vehicle off the road for service Maintaining proper brake adjustmentand brake balance cannot be accomplished by the brake adjuster alone The condition of founda tion brake components have a directbearing on the effectiveness of brake adjustment Inspect foundation brake components periodically 12 Brake Air Chambers Check thatbrake air chamber mounting bolts are tightand properly aligned to avoid interference between air chamber pushrod and air chamber housing Verify that brake chamber pushrod length is equal on both brake chambers of the same axle Camshaft Bushings Worn S cam bushings will increase push rod travel Replace bushing if worn and at each reline For deta
16. ustment while in service The manual adjuster hex is intended for use during adjuster installation and brake overhaul WARNING Automatic slack adjusters should not be repeatedly adjusted to correct excessive in service pushrod stroke because this condition indicates that a problem exists with the automatic adjuster with the installation of the adjuster or with related foundation brake components which manual adjustment will not correct Always use genuine Spicer replacement parts Self Adjusting Brake Adjuster Contents Important Notice cmeeseserreserrenervenvrvenvevenvanenvenenveneeveneeveneeveneeveneesener 1 Introduetlon misunmeiinundnnntve hewn avers YA YNG ACT Cn seede 3 Operation a ou con L G Y cy nU AAWL YO AY Y CLO An 3 Self Adjusting Brake Adjuster Identification 4 Steer Axle Installations e seseorererrereenevvenevvenerverervererveresseressevensenens 5 Drive Axle Installations csssssessssssesesssseesseeesesseseeeseeeeeeeeseneeeas 6 Trailer Axle Installations rnseceresvovvresvnvrvvrvnenenvnrnneresvrveresnnenvernnener 7 Installation Procedure snsrveresesevrsrenerrsvnresesvsrvvesenennervrenennsrenesennnn 9 Brake Adjuster Maintenance General 12 Operational Check nn nsnesvesvesveserresservervesvesvesersvesersessenrernssveneesersens 13 Troubleshooting mmmsveresvenenvenenvenesvenvevenvevenvevenveseneesenvesenve
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