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BENDIX BW2000 User's Manual

1. Remove wheel The caliper assemply should be pushed inboard on its guide pins Using a suitable tool press the inbo ard pad 12 away from the Tappets and check Tappet and inboard pad backplate it should be bet ween 0 02in 0 5mm amp 0 04in 1 0mm If the running clearance is too small or large the adjuster may not be functioning correctly and should be checked as follows Remove Cap 37 E CAUTION T Do not overload or damage the Adjuster 23 Use only 8mm Box End Wrench or 4 drive Socket with a lever length no greater than 4in 100mm DO NOT use an Open Ended Wench this may damage the Adjuster i The Adjuster should be turned counter clockwise for 2 or 3 clicks increasing running clearance CAUTION UN Make sure that the Box End Wrench or Socket can turn freely while C completing the following d By applying the brake 5 10 times about 30psi or 2 Bar the Box End Wrench or Socket should turn clockwise in small increments if the Adjuster is functioning correctly see notes below If Pads are not being changed Cap 37 should be replaced having lightly greased it with Renolit HLT2 available as part number 114525 NOTE As the number of applications increases incremental adjustment will decrease NOTE If the Box End Wrench or Socket does not turn turns only with the first application or turns forward and backward with every app
2. Servit AIR DISC BRAKE SB 6 and SB 7 SD 23 7550 SUPPLY PORT ACTUATOR ROD X Tr RETURN SPRINGS ACTUATING ECCENTRIC BEAM OUTER BRAKE PAD BEARING INNER BRAKE PAD ROTOR FIGURE 1 BENDIX AIR DISC BRAKE D gt m I NJ NA NO DO BR WN mM UJ N I W WwW CO CO CO UJ e SP NO DOPO H UJ PA UJ N N e UI eo oooo NA e NNN NJ HH Exploded view of brake Axial Disc Brake Components Axial Disc Brake Repair Kits Axial Disc Brake Wear Indicator Kits Radial Disc Brake Components Radial Disc Brake Repair Kits Radial Disc Brake Wear Indicator Kits Brake Disc Rotor General information for Axial and Radial Disc Brake Service Tools Diagnostic Equipment Lubrication Torque requirements Description and Function Axial Disc Brake Sectioned View Description of operation Brake actuation Brake release Brake adjustment automatic Radial Disc Brake Sectioned View Description of operation Brake actuation Brake release Brake adjustment automatic Safety instructions for service work for Axial and Radial Disc Brake Brake Testing for Axial and Radial Disc Brake Troubleshooting procedure Adjuster check Wear limits of Brake Pads and Rotor Brake wear check using Guide Pin for Calipers with standard Guide P ins Bra
3. Exchange Caliper r h only in assembled condition Exchange Caliper l h see Type plate on the Caliper 1 2 1 Axial Disc Brake Wear Indicator Kits Typical kits are shown below Type 4 Mounting Bracket 119 varies Suit 5 101 Sensor 115 Spring Washer 102 Sensor 116 Screw 104 Cable Protection Plate 117 Wear Indicator Cable NEN 112 Clip 119 Bracket 120 Bracket Mounting Bracket 119 varies to suit specific applications 1 3 Radial Disc Brake Components for Wear Indicator Kits see 1 4 1 Caliper 26 Carrier 31 Sleeve 3la Sleeve Rubber Bushing 39 Brass Bushing 40 Inner Boot 44 Outer Boot 45 Steel Cap 58 Pad Retainer 151 Pad Tappet with Boot Spring Brake Brake Chamber Spring Clip VF00113 2 i01 Outer Boot Clip O Ring Adjuster Cap Caliper B olt Caliper B olt Pad Retainer Pin Washer Ring Tappet Bushing x possible variants by items 10a amp 31a 1 4 Radial Disc Brake Repair Kits CAUTION Use only Geniune Bendix parts The following Repair Kits are available Description Contents Association of Repair Kits to the Disc Brakes and Repair Kit s Order no Carrier Guide Kit 2 4 5 31 39 40 Carrier Guide Kit Steel Cap 2 4 5 10a 31a 39 40 Wear Indicator Kit for variants see 1 2 1 per axle with or without 104 Guide Pins Kit 4 7 9 10 31 39
4. LN rrr SS 7 2 E 55 SS fay AN WLM ITI n a We NES S 4 A LE HHHHHHHHHHHHHHI EN 4 9 28402 2 AM pt I TUW AN 2228 iA 5 oo 1 x possible variants by items 10a amp 31a M P KN 014 23 The hub should turn easily by hand after having applied and released the brake The Cap 37 must then be replaced after it has been lightly greased it with Renolit HLT2 available as part number 114525 After setting the Pad Retainer 11 into the groove of the Caliper 1 it must be pushed in to allow the insertion of the Pad Retainer Pin 44 Fit washer 45 and Spring Clip 26 to the Pad Retainer Pin 44 use only new parts Our recommendation is to fit the Washer 45 and Spring Clip 26 pointing downwards see diagram M P KN 016 Wheel mounting refer to Vehicle Manufacturer s recommentations 4 IM PORTANT UN As with all brake pad replacements new Pads require a break in period Heavy or or prolonged braking should be NC avoided during this break in period 2 Follow Industry recommendations to determine the optimum break in period for the vehicle 7 Tappet with Boot replacement for Axial and Radial Disc Brake 7 1 Tappet with Boot removal No
5. must slide freely over the whole length of the Guide Pin arrangement 1 2in 30mm During this operation the Sleeve 5 is sealed by the Boot 9 and Cap 10 or Steel Cap 10a and O Ring 31a These must show no signs of damage Check that these are correctly seated The Caliper may have to be re sealed by using a suitable Kit see page 5 or page 7 6 2 Pad installation IMPORTANT N Pads must be changed as an axle set and NOT individually Use only Pads which are permitted by the vehicle axle or brake manufacturer Failure to comply with this policy may invalidate C the vehicle manufacturer s Note Before placing the Pads into the Carrier the Adjuster 23 must be further de adjusted by rotating it counter clockwise M P KN 013 Ai01 Clean the Pad abutments Push Caliper 1 outboard and fit the outboard Pad 12 For fitting the inboard Pad 12 push Caliper 1 in the opposite direction If fitted replace Wear Indicators and fittings brackets etc See page 5 or 7 CAUTION UN Do not overload or damage the Adjuster 23 Use only 8mm Box End Wrench or 14 drive Socket with a lever length no greater than 4 in 100mm DO NOT use an Open Ended Wrench since this may damage the Adjuster shaft 2 Rotate the Adjuster clockwise until the Pads come into contact with the Rotor Then turn back the Adjuster 2 clicks SA 2 222
6. 1 2 26 Spring Clip 4 Sleeve 31 Outer Boot Clip 5 Sleeve 3la O Ring 6 Rubber Bushing 37 Adjuster Cap 7 Brass Bushing 39 Caliper Bolt 9 Inner Boot 40 Caliper Bolt 4 2 15 Pin x possible variants by items 10a amp 31a 11 Retainer 58 Ring 12 Pad 161 Tappet Bushing 13 Tappet with Boot 18 1 Spring Brake 1 2 Axial Disc Brake Repair Kits CAUTION Use only Genuine Bendix arts The following Repair Kits are available Description Contents Association of Repair Kits to the Disc Brakes and Repair Kit s Order no Carrier Guide Kit 2 4 5 31 39 40 Carrier Guide Kit Steel Cap 2 4 5 10a 31a 39 40 Wear Indicator Kit for variants see 1 2 1 per axle with or without 104 Guide Pins Kit 4 7 9 10 31 39 40 58 Guide Pins Kit Steel Cap 4 5 6 7 9 10a 31a 39 40 58 Seal Kit for Guide Pins 9 10 31 37 58 Tappet and Boot Kit 2 pcs 13 161 Pad Set per axle 12 26 37 44 45 Adjuster Cap 4 pcs 37 Pad Retainer Kit per axle 11 26 44 45 Pad Retainer Kit per axle wear sensor 11 26 44 45 104 115 116 Kit for Floating Pin 4 6 39 Outer Guide Seal Kit 10 pcs 10 31 Kit for Fixed P in 5 7 9 10a 31a 40 58 Kit for Steel Cap 10a 31a Screw Kit for Steel Cap 10a 31a 39 40 Screw Kit for Outer Boot 10 31 39 40 see www Bendix com for more information http www Bendix com
7. B Special threaded Screw 40 and Steel Cap 10a as well as the O Ring 31a must be renewed whenever Screw 40 has been removed M P Screw in Caliper Bolts 39 and 40 and tighten to 210 ft Ibs 285 Nm Check the position of the Inner Boot 9 on the Sleeve 5 Check that the Caliper slides easily In the exposed clamping e g vice press the Caliper against the Carrier as far as possible The Inner Boot 9 must be in compressed condition to prevent air being trapped inside of the Cap Assembly of the Steel Cap 10a can now be carried out as in Section Assembly at the Vehicle Check Adjuster Section 5 2 11 Carrier replacement for Axia and Radial Disc Brake Remove Caliper see Section 10 1 Remove Carrier 2 from axle Clean axle contact area Bolts are not supplied by Bendix Attach the new Carrier with new bolts from the truck manufacturer Attach the Caliper see Section 10 2 32 FD00112 fd Direction of pressure FDOO110EN M P KN 036 12 Actuation cylinder replacement for Axial and Radial Disc Brake 12 1 Brake Chamber removal Disconnect the air line from the Brake Chamber 18 2 Unscrew the Brake Chamber Mounting Nuts do not re use them Remove the Brake Chamber VF 00127 10 12 2 Brake Chamber fitting IMPORTANT New Brake Chambers 18 2 have drain plugs instal led Remove the bottom plug see arrows All other drain hole
8. attempt repairs requiring machining or welding unless specifically stated and approved by the vehicle and component manufacturer 10 Priorto returning the vehicle to service make certain all components and systems are restored to their proper operating condition 11 Forvehicles with Antilock 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 ground and moving For more information visit www Bendix com 36 BW2000 2002 Bendix Commercial Vehicle Systems LLC All rights reserved Printed in USA
9. tion due to the mechanical connection with Lever 19 As the Pads and Disc wear the running clea rance increases The Adjuster 23 and Turning Device 24 turn the Threaded Tubes 16 by an amo unt necessary to compensate for this wear The total running clearance sum of clearance both sides of Disc should be between 0 03 and 0 04 in 0 6 and 0 9 mm smaller clearances may lead to overheating problems 11 3 3 Radial Disc Brake Sectioned View Brass Bushing A J 13 39 4 6 VF 00113 3 Aio1 Inner Boot 10 Outer Boot 10a Steelcap 11 Pad Retainer 12 12 Pad 13 Tappet with Boot 16 Threaded Tube 17 Bridge 18 1 Spring Brake 18 2 Brake Chamber 19 Lever 20 Eccentric Bearing 22 Inner Seal Cap 23 Adjuster Unit 24 Turning Device 26 Spring Clip 27 Spring 28 Spring j 30 Chain 31 Outer Boot Clip 3la O Ring 32 Chain Wheel 33 Wear Sensor 37 Adjuster Cap 39 Caliper Bolt 40 Caliper Bolt 44 Pad Retainer Pin 45 Washer 46 Rotor VF 00113 4 161 Tappet Bushing x possible variants by items 10a amp 31a 2 161 LIS 16 Boc 22 E B 33 44 L Ji 9 32 26 de 45 Pa 11 1 na A i 30 17 am SNE j NN 37 1 Caliper 05 2 C
10. wearing automatic adjuster mechanism The Adjuster 23 operates with every cycle of actuation due to the mechanical connection with Lever 19 As the Pads and Rotor wear the running clearance increases The Adjuster 23 and Turning Device 24 turn the Threaded Tubes 16 by an amount neces sary to compensate for this wear The total running clearance sum of clearance both sides of Rotor should be between 0 03 and 0 04 in 0 6 and 0 9 mm smaller clearances may lead to overheating problems 4 Safety Instructions for service work for Axial and Radial Disc Brake Please refer to the relevant safety instructions for repair work on commercial vehicles especially for jacking up and securing the vehicle Use only Genuine Bendix parts WARNING Before starting repair work block the wheels to ensure that the vehicle cannot roll away before releasing the park brake a See Page 36 for full Safety oo Please follow repair manual instructions and adhere to the wear limits of the Pads and the Rotors see Section 5 3 Use only recommended tools see Section 2 1 Tighten bolts and nuts to the recommended torque values see Section 2 4 After re fitting the wheel according to the Vehicle Manufacturer s recommendations please ensure that there is sufficient clearance between the Tire Valve Stem the Caliper and the wheel rim to avoid dama ge to the Valve After service work Check the
11. 26 M P KN 021 M P KN 023 8 Caliper Suspension sealing Replacement of inner Boot 9 for the Axial and Radial Disc Brake Remove Caliper see Section 10 1 Remove Ring 58 Pull out Sleeve 5 Push out Boot 9 with screw driver Inspect and clean contact area of Boot 9 M P KN 025 NNNANSANANNANAN 244 lt Put new Boot 9 into the Cup arrow of the Tool C Order No 1119253 Position Sleeve with Boot 9 into the Caliper bore and pull in M P KN 026 Fit the Sleeve 5 The Boot end must engage in the groove of the Sleeve 5 arrow Lock with Ring 58 by pushing on until it engages Important Before fitting the Caliper the unsealed Sleeve with the Rubber Bushing should be checked for its ability to slide Fit Caliper see Section 10 2 27 9 Guide Pin Bushing replacement for Axial and Radial Disc Brake Remove Caliper see Section 10 1 Remove Sleeve 5 and inner Boot 9 see Section 8 9 1 Brass Bushing 7 replacement Remove old Sleeve 5 Pull out Bushing 7 with Tool D Order No 119254 If Caliper has no groove see arrow Note Groove is always located on the inboard side Pull in new Brass Bush 7 with Tool D If Caliper has a groove Pull in new Brass Bush 7 with Tool D To prevent longitudinal displacement use Tool F Order No 1136797 to create dents in bushing Check contact area of Brass Bushing 7 for burrs Remove bur
12. 40 58 Guide Pins Kit Steel Cap 4 5 6 7 9 10a 31a 39 40 58 Seal Kit for Guide Pins 9 10 31 37 58 Tappet and Boot Kit 2 pcs 13 161 Pad Set per axle 12 26 37 44 45 Adjuster Cap 4 pcs 37 Pad Retainer Kit per axle 11 26 44 45 Pad Retainer Kit per axle wear sensor 11 26 44 45 104 115 116 Kit for Rubber Sleeve 4 6 39 Outer Guide Seal Kit 10 pcs 10 31 Repair Kit 5 7 9 10a 31a 40 58 Kit for Steel Cap 10a 31a Screw Kit for Steel Cap 10a 31a 39 40 Screw Kit for Outer Boot 10 31 39 40 see www Bendix com for more information http www Bendix com Exchange Caliper r h Exchange Caliper I h only in assembled condition see Type plate on the Caliper 1 4 1 Radial Disc Brake Wear Indicator Kits Typical kits are shown below Type 1 NEZA S 116 115 EN 112 VF 00127 6 4 116 115 A M eu gt 116 i 4 104 VF 00127 8EN Mounting Bracket 119 varies to suit specific applications Type 4 bng Mounting Bracket 119 varies suit Se opcris Type 5 101 Sensor 115 Spring Washer 102 Sensor 116 Screw 104 Cable Protection Plate 117 Wear Indicator Cable 112 Clip 119 Bracket 120 Bracket 1 5 Brake Rotors for Axial and Radial Disc Brake When replacing the Rotors please also refer to the instructions provided by the Vehicle Manufacturer They should also referred to when spec ing Be
13. EX 592 E 50 S ww Bs pale zx N Lh x A o ppp AN Es M P KN 005 without rib see also Section 5 3 2 pin protrusion shown in new condition minimal pin protrusion Pads and Rotor must be checked with road wheel removed Pad conditions can be visually inspected without removing the road wheel by noting the positon of the Floating Pin 4 in the Caliper 1 UO UJ If dimension C is less than 0 04in 1mm a more accurate check of the Pads and Disc must be completed If necessary change the Pads see Section 6 18 5 3 2 Brake Wear Check using Guide Pin Only for Axial Disc Brakes SB 7541 SB 7551 to SB 7629 SB 7639 and Radial Disc Brakes SB 7102 SB 7112 SB 7103 SB 7113 SB 7104 SB 7114 SB 7105 SB 7115 SB 7108 SB7118 SB 7109 SB 7119 SB 7120 SB 7130 These Callipers do have the rib in position B see also Section 5 3 1 MX gt WS SES a NEP 2 p Pl NZ 25 SS KON ZEN ZX mA YZ Ax v do eh XEON SI 222222022 z SAS 2 y np LN H UA UR M P KN 006 Pad conditions can be visually inspected without B with rib see also Section 5 3 1 removing the
14. _ 58 E 37 NP Ils NE E Ah 30 an 1 0 SY 33 M a 43 SBI W I Ms 24 l 2 PR N 277777 RWW SRY p X DX X DX DX X X X o X CK KKK KKK KKK KKK KK KKK XO SLL L SLA 20 28 x possible variants by items 10 amp 31a 3 2 Description of operation Floating Caliper principle 3 2 1 Brake actuation During actuation the Push Rod of the Actuator 18 1 or 18 2 moves the Lever 19 The input forces are transferred via the Eccentric Bearing 20 to the Bridge 17 The force is then distributed by the Bridge 17 and the two Threaded Tubes 16 to the Tappets 13 and finally to the inboard Pad 12 After overcoming the running clearance between the Pads and the Rotor the reaction forces are transmit ted to the outboard Pad 12 The clamping forces on the Pads 12 and the Rotor 46 generate the braking force for the wheel 3 2 2 Brake release After releasing the air pressure the two Return Springs 27 28 push the Bridge 17 and Lever 19 back to the start position this ensures a running clearance between Pads and Disc is maintained 3 2 3 Brake adjustment automatic To ensure a constant running clearance between Disc and Pads the brake is equipped with a low wearing automatic adjuster mechanism The Adjuster 23 operates with every cycle of actua
15. brake performance and the system beha vior by actual road test 13 5 Brake Testing for Axial and Radial Disc Brake 5 1 Fault finding procedure Air Disc Brake Lift vehicle turn wheel by hand Does wheel turn smoothly NO YES Residual Running pressure clearance ok within the see section 5 2 braking cylinder NO Yes NO mE Y Y Running Check and if Check adjuster Brake pad wear clearance ok necessary see section 5 2 uneven see section 5 2 change or see note below service NO YES preceding END NO YES braking device END END Adjuster ok Check and if necessary maintain caliper NO YES guide pins see section 9 END Caliper guidance ok see section 6 1 2 Change caliper see section 10 END NO YES Tightness not due to disc brake END Check and if necessary maintain caliper guide pins see section 9 END mM Note Difference between inboard and outboard pad less than 0 2in 5mm and diagonal wear lt 0 08in 2 mm FD00102EN Ai01 14 5 2 Adjuster check WARNING N Before starting repair work block the wheels to ensure that the vehicle cannot roll away before releasing the park brake S Page 36 for full Safety 0
16. road wheel by noting the positon C new condition of the Floating Pin 4 in the Caliper 1 D 0 64in 18mm or more Pads and Rotor must be checked with road wheel removed If the head of the Floating Pin 4 is inside the Rubber Bush 6 by a dimension D greater than 0 64in 18mm then a more accurate check of the Pads and Rotor must be made If necessary change the Pads see Section 6 19 5 3 3 Wear Indicators There are two types of Pad Wear Indicators available to accommodate the differences in vehicle types and manufacturers including a In Pad Normally Closed Indicator Circuit is broken when Pad Wear reaches the limit b In Normally Open Indicator Circuit is made when Pad Wear reaches the limit See Figure to the right C Wear Indicator using built in Potentiometer This is avallable either as an on off version or as a continuous signal version which can be linked to the vehicle s electronic monitoring systems An optical or acoustic device may be linked to any of the above Important Please refer to the specifications provided by the Vehicle Manufacturer 20 SS SISSSSSSS N SN 222222272272 22222 ZZ M P KN 008 5 4 Bendix Diagnostic Equipment The Bendix Diagnostic Unit ZB 9031 is a hand held device suitable for vehicles that are fitted with Bendix Air Disc Brakes using a continuous signal type of Wear Potentiometer The wear condition
17. time Replace only on the recommendation of the Axle or Vehicle manufacturer On SB 6 19 5 only permissible after manufacturing date C A0026 see type plate 31 FD00108 It may be easier to remove the Caliper and the Carrier from the axle to replace the Steel Cap Assembly at the Vehicle The fitting must be carried out with the Pads installed Clean the area Using the Grease supplied 1114525 lightly lubricate the O Ring and place it over the cast spigot see Sketch Remove the Threated Pins from the assembly tool G FD00106 to avoid damaging the Steel Cap Hold the new Steel Cap on the end of the Spigot By using a Suitable press or special assembly tool Part Number Z001105 and a hammer press the Steel Cap fully on the spigot making sure not to deform the Cap After removal the Steel Cap and the O Ring must not be refitted IMPORTANT The Steel Cap 10a and the O Ring FD00103 Aio1 are single use items do not re use 31 Assemply on the Caliper and Carrier removed from the axle 2 IMPORTANT UN Replace the Rubber Boot 10 by the Steel Cap 10a when replacing the Sleeve 5 the O Ring 31a and the Screw 40 at the same time Replace only on the recommendation of the Axle or Vehicle manufacturer On SB 6 19 5 only permissible after manufacturing date C A0026 see type plate J Put the Caliper on the Carrier IMPORTANT
18. Part No on the label arrow Figure above right to ensure that you have selected the proper replacement Caliper Note Service Exchange Calipers have a blue label The Service Exchange Caliper has a plastic cap or an adhesive tape in the area of the Actuator attachment Remove the cap or tape after installing the Caliper see arrow Note The service exchange Caliper includes sealing and guiding elements The Pads are not included WARNING N Hold the Caliper only on the exterior Never insert your fingers between C the Caliper and Carrier P 10 2 1 Caliper with Rubber Boot 10 Locate the Caliper to the Carrier Screw in Caliper Bolts 39 and 40 and tighten to 18 210 ft Ibs 285 Nm use only new parts Check that the Caliper slides easily Check the position of the Inner Boot 9 on the Sleeve 5 Check Adjuster function see Section 5 2 If necessary use a new Rubber Boot 10 Ensure grease free seating of the Rubber Boot 10 on the Caliper 1 30 FD00114 FD00116 M P KN 027 Tighten Rubber Boot Clip 31 Fit the Pads see Section 6 2 Attach the Brake Chamber or Spring Brake see Section 12 2 or 12 4 M P KN 042 10 2 2 Caliper with Steelcap 10a BLU Y mie 6 155 d CZ IMPORTANT N PO Replace the Rubber Boot 10 by the Steel Cap 10a when replacing the Sleeve 5 the 31 S ON 40 10a O Ring 31a and the Screw 40 at the same
19. Sleeves 4 amp 5 and new Caliper Bolts 39 amp 40 Assemble Sleeve 4 Re fit Caliper See Section 10 2 Important Torque Caliper Bolts to 210 ft Ibs 285 Nm and check that the Caliper slides easily 10 Caliper replacement for Axial and Radial Disc Brake 10 1 Caliper removal Remove Pads see Section 6 1 Remove Actuator see Section 12 1 and 12 3 Remove Outer Boot Clip 31 and take off Outer Boot 10 M P KN 024 Ai01 Note In addition to Calipers with an Outer Boot 10 and Outer Boot Clip 31 there are also versions available with a Steel Cap 10a and O Ring 31a On models with Steel Caps 10a and O Rings 31 place tool G Part Number Z001105 onto the Steel Cap and tighten the threated pin by a hexagon socket spanner Then use hammer as shown Remove Caliper Bolts 39 and 40 FD00109 29 WARNING B Hold the Caliper only on the exterior Never insert your fingers between ee A C the Caliper and Carrier F Remove Caliper from Carrier e 12 eL E T 4 IMPORTANT N Se SES g 5 Opening or dismantling the Caliper is not i shat Lr Lem LEE permitted Use only Genuine Bendix cts service Exchange Calipers Disassembly of the Caliper will void any Warranty Claim A 10 2 Caliper fitting Check the
20. age 36 for full Safety 6 1 Pad removal Take the wheel off refer to Vehicle Manufacturer s recommendations Remove Clip 26 and Washer 45 push down the Pad Retainer 11 and remove Pin 44 If the Pad Retainer 11 is corroded it should be replaced Important Before removing the Pads it is strongly recommended that the Adjuster mechanism should be checked for correct operation See Section 5 2 ideis CAUTION UN Do not overload or damage the Adjuster 23 Use only 8mm Box End Wrench or 1 4 drive Socket with a lever length no greater than 4in 100mm DO NOT use an Open Ended Wrench om this may damage the Adjuster snare Remove Cap 37 Turn the Adjuster counter clockwise until the Pads can be removed A clicking noise will be heard during this procedure Push inboard Pad 12 toward Actuator Pull out both Pads 12 TRE 6 1 1 Tappet Boot Check The Adjuster 23 should be screwed clockwise until the boots are clearly visible The Boots should not show any damage Check the attachment of the Boots into the Caliper housing Important Any ingress of water or dirt past the Tappet Boot will lead to corrosion and affect the function of the Actuation Mechanism and Adjuster Unit If damaged the Boot and Tappet must be replaced see Section 7 22 6 1 2 Caliper guidance check Following Pad removal Section 6 1 Using hand pressure only no tools the Caliper 1
21. arrier LA ta a E 43 4 Sleeve Ly 5 Sleeve 6 Rubber Bushing 1S AN 7 9 2 SS 7 IR QW ANN y 2 VIN N 77 A 2 I I NY NZU SS SS RM 27 28 20 19 18 1 18 2 URGE NE J RB lo Hm HEFE d 12 3 4 Description of operation Floating Caliper principle 3 4 1 Brake Actuation During actuation the Push Rod of the Actuator 18 1 or 18 2 moves the Lever 19 The input forces are transferred via the Eccentric Bearing 20 to the Bridge 17 The force is then distributed by the Bridge 17 and the two Threaded Tubes 16 to the Tappets 13 and finally to the inboard Pad 12 After overcoming the running clearance between the Pads and Rotor the reaction forces are transmitted to the outboard Pad 12 The clamping forces on the Pads 12 and the Rotor 46 generate the braking force for the wheel 3 4 2 Brake release After releasing the air pressure the two Return Springs 27 28 push the Bridge 17 and Lever 19 back to the start position this ensures a running clearance between Pads and Rotor is maintained 3 4 3 Brake adjustment automatic To ensure a constant running clearance between Rotor and Pads the brake is equipped with a low
22. for grooves and cracks The diagram at the right shows possible conditions of the surface A4 Small cracks spread over the surface are allowed B4 Cracks less than 0 06in 1 5mm deep or wide running in a Radial direction are allowed C Grooves circumferencial less than 0 06in 1 5mm wide are allowed Cracks in the vanes are not allowed and the Rotor MUST BE REPLACED a Pad contact area Note In case of surface conditions A C the Rotor can remain in service until it has reached the minimum thickness of 1 46in 37 mm is reached Knorr Bremse Rotor are normally service free and refinishing when changing Rotors is not necessary However refinishing could be useful e g to increase the load bearing surface of the Pads after severe grooving on the entire friction surface has occurred To meet safety requirements the minimum thickness after refinishing is gt 1 53in 39 mm In addition follow the recommendations provided by the Vehicle Manufacturer 0 75 x a 1 Ne NS GF SSS REE S VF 00127 3 CAUTION Folow these recommendations Excessive Pad or Disc wear will degrade optimum performance M 17 5 3 1 Brake Wear Check using Guide Pin For all Axial and Radial Disc Brakes except those listed in Section 5 3 2 These Callipers do not have the rib in position B see also Section 5 3 2 TAX q 2522 ZS I i I ROY
23. ke wear check using Guide Pin for Calipers with long Guide Pins Wear Indicators Diagnostic Equipment Hand held device ZB9031 Diagnostic Equipment Vehicle mounted device ZB 9033 Pad replacement for Axial and Radial Disc Brake Pad removal Tappet Boot check Caliper floatation check P ad fitting Tappet with Boot replacement for Axial and Radial Disc Brake Tappet with Boot removal Adjuster thread inspection Tappet with Boot fitting Caliper Suspension Sealing for Axial and Radial Disc Brake CO WO WO NA ke 10 10 1 10 2 1 10 2 2 11 Guide Pin Bushing replacement for Axial and Radial Disc Brake Brass Bushing replacement Rubber Bushing replacement Caliper replacement for Axial and Radial Disc Brake Caliper removal Caliper fitting Caliper with Rubber Boot 10 Caliper with Steel Cap 10a Carrier replacement for Axial and Radial Disc Brake Actuation cylinder replacement for Axial and Radial Disc Brake Brake Chamber removal Brake Chamber fitting Spring Brake removal Spring Brake fitting Additional Information Service Video Service Tool Kit Diagnostic Equipment General Safety Guidelines Personal Notes 28 28 28 33 33 34 35 35 36 1 Exploded views 1 1 Axial Disc Brake Components for Wear Indicatators Kits see 1 2 1 18 1 18 2 Assembly grease coloured 1 Caliper 18 2 Brake Chamber VF 00127 12
24. lication the automatic Adjuster has failed and the Caliper must be replaced 15 5 3 Wear Limits of Pads and Rotors CAUTION Stay within the Rotor and Pad Wear Limits Pads The thickness of the Pads must be checked regularly dependent on the usage of the vehicle The Pads should be checked to adhere to any applicable legal requirements that may apply If no Wear Indicator has been connected check for wear at least every 3 months If friction material is less than 0 08in 2mm see E the Pads must be replaced 5 n SEN oy SSSSSSSSSSSSNNNS Rotors 7 2 Measure thickness at the thinnest point Avoid measu ring near the edge of the disc as a burr may be pre MOY Rotor thickness new condition 1 77in 45mm Rotor thickness worn 1 46in 37 mm Disc must be replaced Overall thickness of Pad new 1 18in 30mm Backplate 0 35in 9mm 5 Minimum thickness of friction material 0 08in 2mm n7 Minimum allowed thickness in worn condition 1222222 for backplate and friction material 0 43in 11mm replacement of Pads necessary y 7 j rr M P KN 002 If wear dimension B x 1 53in 39 mm Rotor should be replaced together with Pads Wear dimension 1 46in 37 mm must not decrease Minimum allowable thickness B 1 46in 37 mm CAUTION These recommendations must be followed for proper brake performance 16 At each change of Pads check the Rotors
25. ndix Rotors When replacing Rotors please adhere to the recommended bolt tightening torques The use of non approved Brake Rotors will reduce levels of safety and invalidate warranty Brake Rotors can be ordered through any authorized Bendix parts outlet More information can be found on the internet at www Bendix com This information booklet is also available electronically when you visit www Bendix com 2 General Information for Axial and Radial Disc Brake 2 1 Service Tools Part Number Description I 19252 Press In Tool for Tappet and Boot 13 1 19253 Pull In Tool for Inner Boot 9 19254 Pull In Out Tool for Brass Bushing 7 32202 Wedged Fork for removal of Tappet and Boot 13 36797 Grooving Tool for Brass Bushing 7 2001105 Press in Tool for Steel Cap 10a a Service tool kit ZB 9032 Il 37951 004EX contains the tools listed as well as this Service manual service video is available separately as Part No KBP2060 1 in the UK and elsewhere as RA SBOOO2 2 2 Diagnostic Equipment Part Number Description ll 36695 ZB 9031 Hand held device for checking Potentiometer function Also Pad Disc wear when 13 pin chassis plug installed ll 38691F ZB 9033 Chassis mounted device for measuring Pad Disc wear 2 3 Lubrication Part Number Description Colour Application I 14525 Renolit HLT2 White Brass Bushi
26. ng 7 32793 Syntheso GL EP1 Green Rubber Bushing 6 Important Note The correct Grease MUST be used for each Bushing 2 4 Torque requirements Item Number Torque spanner size Ft los Nm in mm 39 40 Caliper Bolts M16x1 5 10 9 210218 285 4 0 55 14 Actuator Mounting Nuts M16x1 5 132422 180 73 0 94 24 3 Description and function 3 1 Axial Disc Brake Sectioned View 10 UO BN EF m e 10a WN HR 18 1 18 2 19 20 22 23 24 26 21 28 30 al 3la 32 83 37 39 40 44 45 46 161 Caliper Carrier Sleeve Sleeve Rubber Bushing Brass Bushing Inner Boot Outer Boot Steelcap Pad Retainer Pad Tappet with Boot Threaded Tube Bridge Spring Brake Brake Chamber Lever Eccentric Bearing Inner Seal Cap Adjuster Unit Turning Device Spring Clip Spring Spring Chain Outer Boot Clip O Ring Chain Wheel Wear Sensor Adjuster Cap Caliper Bolt Caliper Bolt Pad Retainer Pin Washer Rotor Tappet Bush Y 3 161 2 12 46 12 17 19 d ADAE I Y SRM EU Ree UE 1 S 5555 m 20 VF 00127 2 Ai01 25 LZ VA a DAYI 10 SS 10 as H nem 777 SSN Rossen lt N2 C2 BREMEN LEN E Wea IN b 1
27. nt personal injury resulting from contact with moving rotating leaking heated or electrically charged components 3 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 from all reservoirs before beginning ANY work on the vehicle If the vehicle is equipped with an AD IS air dryer system or a dryer reservoir module be sure to drain the purge reservoir Bendix 5 Following the vehicle manufacturer s recommended procedures deactivate the electrical system in manner that safely removes all electrical power from the vehicle 6 Neverexceed manufacturer s recommended pressures 7 Neverconnector 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 eplacement 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 ratherthan repaired Do not
28. of each brake can be measured by connecting the device to a suitable 13 pin socket DIN 72570 where fitted This socket must have been connected to each sensor by the vehicle manufacturer The Diagnostic unit permits Quick and simple wear check A check of the potentiometer function A detailed instruction manual is included with each unit 5 5 Bendix Diagnostic Equipment The Bendix Wear Check Module ZB 9033 is a chassis mounted device suitable for vehicles that are fitted with Bendix Air Disc Brakes using a continuous signal type of Wear Potentiometer The module continuously monitors and displays the wear at each brake For vehicles without an automatic brake control system particularly Trailer applications the module enables a quick and simple wear check The Wear Check Module permits Up to six 6 Brakes to be checked together LED monitoring of each Brake condition A detailed instruction manual is included with each unit 13 Pin Plug DIN 72570 to Vehicle Plug to Potentiometer Disc Brake FDOO100EN Plugs to Potentiometer Disc Brake fixed at Vehicle Trailer FDOO101 electric supply from Vehicle Trailer DC 24Volt EN 21 6 Pad replacement for Axial and Radial Disc Brake WARNING N Before starting repair work block the wheels to ensure that the vehicle cannot roll away before releasing the park brake C See P
29. rs Grease Bushing with white Grease RENOLIT HLT2 Order No 1114525 Insert new Sleeve 5 Note The Guide Pins Kit contains new Sleeves 4 amp 5 and new Caliper Bolts 39 amp 40 see Section 1 2 and 1 4 9 2 Rubber Bushing 6 replacement Remove old Sleeve 4 Pull Rubber Bushing 6 out of bore Check bore for corrosion clean if necessary coat bore with Corrosion protection paint e g Zinc spray Note Grease new Rubber Bushing 6 inside and outside with green Grease SYNTHESO GL EP 1 Order No 132793 28 T LE ME A EL 247 h JH EN VF 00127 16 ease SS LG T NE riu ed SM RN sR IN VF 00127 17 re E AWW M P KN 030 Deform new Rubber Bushing 6 and push from the inner side of the Caliper into the bore NSN Push Rubber Bushing 6 so that the outer positioning NS n NAN ring locates in the groove see arrows 2227 B IMPORTANT UN Never use the white Grease containing mineral oil for lubricating the Bushing or Sleeve Use only synthetic based green INN Grease Part Number 1132793 Improper Grease may cause the rubber Bushing to C swell and prevent proper floatation p 25 Vara xx ae SSS 5052604 Note The Guide Pins Kit contains new
30. s or fittings reinstalled during maintenance work using a soap solution to check for leakage A 1inch bubble in 1 minute is acceptable otherwise repair replace components as necessary 13 Additional information 13 1 Service Video A Video is available for additional information Order number RA SB0002 EN Video English RA SB0002 FR Video French RA SB0002 PO Video Portugese RA SB0002 SP Video Spanish 13 2 Service Tool Kit ZB 9032 For service and repair work we recommend our BendixTool Kit ZB 9032 11 37951 004EX which contains all the necessary special tools 13 3 Diagnostic Equipment For vehicles fitted with continuous potentiometer type wear sensors Bendix Diagnostic Equipment may be used to ensure quick and simple measurement of wear at each caliper See sections 5 4 and 5 5 35 13 4 General Safety Guidelines 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 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 preve
31. s should be plugged Before fitting the new Brake Actuator the sealing surface of the Caliper see arrow must be cleaned and the Spherical Cup 19 in the Lever must be greased with white Grease RENOLIT HLT2 Order no 114525 The surface area of the flange must be clean F IMPORTANT UN Do not use Grease containing molyb denum disulphate Use only Bendix Actuators recommended 5 174 by the Vehicle Manufacturer 2 M4P KN 034 i01 Attach Actuator with new Nuts self locking EN ISO 7042 and torque tighten to 133 ft Ibs 180 Nm Connect the air hose and check for leakage Make sure that the hose is not twisted and that chafing IS not possible IMPORTANT Road test vehicle before returning to service Test any air hoses or fittings removed during maintenance work using a soap solution to check for leakage A Linch bubble in 1minute is acceptable otherwise repair replace components as necessary 29 12 3 Spring Brake removal WARNING Before starting repair work block the wheels to ensure that the vehicle cannot roll away before releasing the park brake See Page 36 for full Safety Guidelines Release the parking brake move the Hand Control Valve to the run position Screw out Release Bolt arrow with a maximum tor que of 26 ft los 325Nm Release air from brake move Hand Control Valve to park position Mark the hoses to assist with re connection then disconnec
32. see illustration opposite During adjusting m the threads can be checked for corrision damage In case of water ingress or corrosion the Caliper must be replaced E 7 2 Tappet with Boot installation With Caliper fixed to axle hy Grease threads with RENOLIT HLT2 Order No 1 114525 VF 00127 13 Screw back Threaded Tubes 16 by turning the Adjuster 23 counter clockwise Place new Tappet Bushing 161 onto the head of the Tube 16 awk Sealing seat in the Caliper for with Boot 13 i must be clean and free of grease Place Tappet with Boot 13 onto the head of the Tube Use Push In Tool with the short strut B Z Order No 119252 for positioning and pressing in the Boot 13 VF 00127 5 25 Using Tool B in reverse direction the Tappet can be pressed on With Caliper not installed on axle Grease threads with RENOLIT HLT2 Order No 114525 Screw back Threaded Tubes 16 by turning Adjuster 23 counter clockwise Sealing seat in the caliper for Tappet with Boot 13 must be clean and free of grease Place new Tappet Bushing 161 onto the head of the Tube 16 Place Tappet with Boot 13 onto the head of the Tube Use Push In Tool with the long strut B Order No 119252 for positioning and pressing in the Boot 13 Using the Tool B in reverse direction the Tappet can be pressed on
33. t them from the Spring Brake Actuator 18 1 Unscrew the Spring Brake Actuator Mounting Nuts do not re use Remove the Spring Brake Actuator 12 4 Spring Brake Installation IMPORTANT New Spring Brake Actuators 18 1 have drain plugs installed Remove the bottom plug see arrows All other drain holes should be plugged Before fitting the new Brake Actuator the sealing surfaces of the Caliper have to be cleaned and the Spherical Cup 19 in the Lever must be greased with white Grease RENOLIT HLT2 Order no 1114525 The surface area of the flange must be clean M P KN 034 Ai01 A IMPORTANT B Do not use grease containing molybdenum disulphate Use only Bendix Actuators 5 recommended by the rE C Vehicle Manufacturer iM 240 2 5 N P BER 22 i S rw 5 yj IMPORTANT On Radial Disc Brakes the Drain Plugs in the bottom of the Cylinder Flange must V be open J 34 Attach the Actuator with new Nuts self locking EN ISO 7042 and torque tighten to 133 ft lbs 180 Nm Connect air hose ensuring that hoses are correctly connected Make sure that hoses are not twisted and that cha fing is not possible Push park control valve in to release parking brake and check for leakage Screw in Spring Brake Release bolt to maximum 52 ft lbs 70 Nm IMPORTANT Road test vehicle before returning to service Test any air hose
34. te It may be easier to remove the Caliper from the axle for replacement of the Tappets see Section 10 1 The Adjuster 23 must be screwed clockwise until the Boots can be reached Exercise caution to avoid thread overrun if the Caliper has been removed from the vehicle see setion 7 1 1 To remove the Tappet Boot from the Caliper bore a Screwdriver should be used to deform the Boot loca tion ring see diagram a CAUTION N Because it is not a replacement item use caution to avoid damage to the Inner Seal 2 24 The Tappets 13 can be removed from the Threaded Tubes by using Wedge Fork A Order No 1132202 Remove the old Tappet Bush 116 Check Inner Seal arrow and if damaged replace the Caliper 7 1 1 Adjuster thread inspection Place an new thickness Pad 12 into the outboard gap to avoid overrunning of the Threaded Tubes VF 00127 4 a IMPORTANT UN IL Threaded Tubes should not be extended beyond thread engagement of the Bridge If thread engagement synchronization is 16 C lost the Caliper must be replaced A For the inspection of the threads the tubes must be I screwed out max 1 2in 30mm by turning the Adjuste B 23 clockwise 12 M P KN 019 If Caliper is not installed on axle put a spacer E length 2 76in 70mm into the Caliper 1 to avoid overrunning of the Threaded Tubes 16 when adjusting them out

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