BENDIX BRSM8904 User's Manual
Contents
1. Biow out debris Tlf Copyright Eaton and Dana Corporation 2002 EATON AND DANA CORPORATION National Institute for hereby grants its customers vendors or AUTOMOTIVE distributors permission to freely copy SERVICE reproduce and or distribute this document EXCELLENCE in printed format THIS INFORMATION IS NOT INTENDED FOR SALE OR RE SALE AND THIS NOTICE MUST REMAIN ON ALL COPIES E T N One Great Drivetrain from Two Great Companies Roadranger The Roadranger System is an unbeatable combination of the best products from Eaton and Dana partnering to provide you the most advanced most trouble free drivetrain in the industry And it s backed by the Roadrangers the most experienced most expert most accessible drivetrain consultants in the business Visit our web site at www roadranger com For spec ing or service assistance call 1 800 826 HELP 4357 24 hours a day 7 days a week Mexico 001 800 826 HELP 4357 for more time on the road BRSM 8904 05 04 PDF Printed in USA2. Replace part Replace flat spotted parts Replace lining Deglaze lining or replace Replace linings Replace linings Turn per manufacturer s specifications Replace part Clean and lubricate Replace part Adjust brakes Replace part Inspect and repair per manufacturer s specifications Use same size and materials on all brakes 10 SYMPTOM Poor lining to drum contact Linings tapered across width Unequal wear on in same brake Unequal wear side to side brakes same axle Wear on edge of lining Glazed linings hard and shiny Scored or grooved linings and drum Loose lining Craked lining at rivet holes Elongated rivet holes BRAKE SHOE AND LINING TROUBLESHOOTING CHART A Bell mouth drum B Bent brake spider C Bent or stretched brake shoe D Undersize linings E Loose wheel bearing F Improper lining grind A Bell mouth drum B Bent brake shoe C Bent brake spider D Loose wheel bearings A Mismatched lining friction codes B Stretched shoe C Flat spots on cam or roller D Worn anchor pin E Worn camshaft or bushings A Mismatched lining friction codes B Seized or binding camshaft C Brake drum surface in poor condition D Loose wheel bearing E Relining one brake A Wrong width lining B Holes improperly drilled in lining C Wrong drum o
3. SYMPTOM 1 Degraded brake performance 2 Slow brake application 3 Slow brake release 4 Grabbing or pulling 11 CAUSE Too much push rod free travel Severely glazed or worn out linings Grease or oil on linings Worn seared heat checked cracked drums Push rod length too long Ig mmuocd0ur mmo gt FOUNDATION BRAKE TROUBLESHOOTING CHART Air chamber in wrong position Broken or bent parts Flat spots on cam or rollers Cam shaft bushings binding Binding cam shaft and bushings Weak or broken shoe return spring Flat spotted cam or rollers Grease oil or dirt on lining Glazed linings Brake linings not a balanced set different friction codes or lining brand Loose or broken linings Brake drum out of round Defective brake drum Clevis pin or camshaft binding at one or more wheels Defective slack adjuster Uneven brake adjustment side to side Broken or bent parts Loose spider or drum mounting bolts Different air chamber size or slack adjuster length side to side COMM OOWDY gt Adjust brakes Deglaze linings or replace Replace linings Replace Adjust clevice shorten push rod length Reposition Replace part Replace flat spotted parts Clean and lubricate Check for seal leakage Clean and lubricate
4. stamped on drum has not been exceeded due to wear or machining 4 The two shoe nrelauner springs and 1 insert sturdy lever between the end of the shoe and If only replacing the brake shoes further ihe rebum spring pin Pry shoe away from cam until disassembly is required can be removed Repeat procedure for opposite shoe Reassemble in reverse order Always install new spnngs MANUAL SLACK ADJUSTER REMOVAL 1 Remove the cotter pin from the cleaves pin and ramova piri 2 Depress slack adjuster locking sleeve Turn adjuster nut slack is clear of air chamber pushrod clevis 3 Remove snap ring and shims from splined end of camshaft Remove slack adjusier from camshaft puller rra be ranquired remove Serious damage to the slack adjuster and or the camshaft splines may result 2 Push the ends of bath shoes together until they contact CAMSHAFT REMOVAL the S cam head Unhook the shoe retum spring and discard 1 Grasp camshall al the camshal head and pull in ihe 3 shoes Rotate both shoes off anchor pin and outboard direction to remove ower shoes Io the flock 2 Clean and inspect AIR CHAMBER BRACKET ASSEMBLY 1 Remove the twn nuts and washers secure ihe brake chamber Remove brake chamber and temporarily place it out of the way CAUTION Do not let chamber hang freely supported only by the air line 2 Remove the ar chambe
5. Always use a jack stand 4 Remove wheels and drums using the procedures specified in the vehicle maintenance manual Safety Glasses should be worn at all times when assembling or disassembling brakes Preventative Maintenance BRAKE ADJUSTMENT Weekly or whenever the air chamber push rod stroke exceeds the maximum distance listed on the following chart To determine if brake adjustment is required measure the push rod stroke with the brakes applied as follows 1 Measure the distance between the air chamber mounting face and the center of the clevis pin with brakes released Make an 85 PSI application and hold it Measure the distance between the air chamber mounting face and the center of the clevis pin Subtract measurement A from measurement B If this measurement equals or exceeds the maximum applied stroke shown below the brakes need to be adjusted Co JI If adjustment is required spin the wheel slowly and adjust the slack adjuster until wheel will no longer turn Back off slack adiuster just enough for wheel to spin freely Be sure to adjust brakes equally on each axle Apply and release brakes and observe slack adjusters Both slacks on each axle should respond rapidly and in unison during application and release Drive vehicle at a low speed in a safe area and check for brake effectiveness prior to putting back in service oO ie Adjust when applied stroke at 85 PSI
6. Parts AIR CHAMBER BRACKET ASSEMBLY 1 2 Check assembly for bent chamber bracket and broken or cracked cam tube welds Inspect camshaft bushings for signs of wear Bearing surfaces should be smooth and free of any pitting or fractures Insert camshaft and measure looseness at both ends with a dial indicator If more than 020 movement is note replace bushings and or camshaft NOTE If it is determined that a bushing requires replacement both camshaft bushings and seals should be replaced CAMSHAFT k 2 Inspect camshaft spline for cracks and excessive deformation Replace as necessary Inspect the camshaft bearing journals for wear or corrosion If the shaft shows wear or roughness that is visible or roughness that can be detected by feel it must be replaced Inspect cam head for cracks and its roller surfaces for flat spots brinneling or ridges Note unusual wear patterns which may indicate an out of square condition Replace if any of these conditions exist SPIDER 1 Inspect for cracked or broken surfaces on the spider at the cam anchor pin and mounting bolt holes Replace any spider with visible damage Do not attempt to weld or repair The anchor pin which is not serviced separately s staked into the spider If pin is loose or grooved more than 030 inches the spider assembly must be replaced ROLLERS 1 Inspect rollers for flat spots galling broken or cracked surfaces Replace
7. any elongated holes may result in a loose lining installation If holes are burred they should be filed down flush with the shoe table Rust often develops on the surface of the shoe table under the brake lining or blocks In addition scale may form from salt on the highways or tar and oil may find their way into the brake assembly During every reline job shoe tables should be thoroughly cleaned The best procedure is to steam clean the entire shoe or put it in a degreaser After cleaning the shoe the shoe table should be scraped clean of rust and scale Any burrs or nicks should be filed smooth At the same time the entire shoe should be examined to see whether it is worn or bent The shoe should be either reconditioned or discarded It is also necessary to check for flat spots on the shoe that can be caused by cleaning away the rust from the area that was under the block previously This can cause a mismatch of shoe lining arcs After the shoe is cleaned and inspected it should be given a coating of rust preventative paint Such treatment of a new unpainted shoe is also suggested to prevent the initial rusting problem Never shim the brake linings Brake noise may result because of cracked and or loose lining since a tight installation is not possible with shims The inside surface of the lining is the correct arc to match the shoe table and the rivet holes in the linings will only line up with holes in the shoes when thay are in
8. direct contact Prior to riveting be sure the holes in the lining blocks and the shoes are exactly matched The sequence of riveting should be such that the center of the block is attached first and then the ends The installation should be checked by attempting to insert a 006 feeler gage between the lining and shoe table It should not be possible to insert the feeler gage anywhere along the edge The only exception is at each end and beyond the last row of rivets A slightly larger clearance may exist in these areas some brake failures result from the use of rivets which are too short too long or the wrong diameter Incorrect setting of the riveting machine may induce other types of failures The correct length rivet must be selected for each application A variation in shoe table thickeness may require a different length rivet The solid portion of the rivet should end just at the inner surface of the shoe The hollow portion of the rivet should portrude past the inner surface of the shoe The proper size rivet must be used to completely fill the rivet hole USE ONLY 10 9 RIVETS Brass plated steel rivets are recommended The riveting machine must be adjusted so that the roll of the rivet is complete but the rivet should not split Always use a roll set never a star set when riveting brake linings A star set does not compress the rivet and expand it to fill the hole Consequently the lining may work loose in service 10
9. procedures recommended and described in this service manual are tested effective methods for performing service operation Follow each procedure closely making use of both the text and pictures Some of these service procedures show the use of certain tools designed especially for the operation being performed It is not mandatory that these tools be used they are shown only as preferred means of performing the operation It is not practical to anticipate and advise the service trade of all possible alternate service methods and of all possible hazardous consequences that could result from any particular method Accordingly anyone who uses a service procedure or tool different than shown must first thoroughly satisfy himself that neither his safety nor vehicle safety will be jeopardized by the service method he selects IMPORTANT READ THIS SECTION BEFORE STARTING THE DETAILED ASSEMBLY OR DISASSEMBLY PROCEDURES When working on or around air brake systems and components the following precautions should be observed 1 Always block vehicle wheels Stop engine when working under a vehicle Depleting vehicle air system pressure may cause vehicle to roll Keep hands away from chamber push rods and slack adjusters they may automatically apply as system pressure drops 2 Never connect or disconnect a hose or line containing air pressure It may whip as air escapes Never remove a component or pipe plug unless you are certain all sy
10. Chamber Size Type equals or exceeds 12 T 16 13 4 20 13 4 24 13 4 SLACK ADJUSTER MORE THAN 90 IN RELEASED POSITION APPLIED POSITION BRAKE DRUMS Inspect for heat checks grooves hot spots glazing cracks and out of round Drums which are glazed grooved or have moderate heat checking may be resurfaced and returned to service The drum however should not be used if it exceeds the vehicle manufacturers recommended maximum diameter or runout specification The maximum diameter is generally stamped on the drum CAUTION Drums displaying heat checks with a continuous length of four inches or more or that extend around the open edge of the drum should be discarded BRAKE LUBRICATION Lubricate the camshaft thru the grease fitting on the camshaft bracket with the chassis lube specified by the vehicle manufacturer Lube once every six months or at each chassis lubrication BRAKE RELINE The life of the brake lining is dependent on many factors such as the material of the lining type of operation the vehicle is used for geographic terrain maintenance practice of the shop and the driver of the vehicle If driving conditions require frequent braking lining replacement will be required more often BRAKE OVERHAUL As often as necessary to maintain satisfactory brake performance When overhauling the brakes provide equal service to both the left and right side of an axle Inspection of
11. Roadranger Dana Spicer Brakes A lt Dana gt 15 Series S Cam IM One Great Drivetrain from Two Great Companies Service Manual BRSM 8904 1989 For the most current information visit the Roadranger web site at www roadranger com CONTENTS iion eoe C C A Ree 2 Component Identification 15 inch 2 General Precautions for Assembly and Disassembly 3 Preventative 4 Inspection of Pats 5 Disassembly 6 7 Assembly 7 8 9 Reline Procedure 10 Foundation Brake Troubleshooting Chart 11 Brake Shoe and Lining Troubleshooting Chart 12 Brake Drum Troubleshooting Chart 13 A This symbol warns of possible personal injury SPICER SERVICE PARTS SPICER Spicer Brake Service Parts are manufactured under the same rigid specifications as are original equipment brake components This assures the end user who uses genuine Spicer Service Parts maximum reliability for his Spicer Brake assembly Should a brake assembly require component parts replacement it is recommended that Original Equipment replacement parts be used They may be obtained through your Original equipment manufacturer dealer The use of non original replacement parts may cau
12. as necessary SHOES AND LINING 1 Check shoes for bent shoe ribs cracks in shoe table welds or ribs and elongated rivet holes Replace shoes if any of these conditions exist Measure the shoe span by loosely installing the anchor pin and cam roller in the appropriate ends of the shoe rib If the distance from center of anchor pin to center of cam roller exceeds 11 76 replace shoe Check linings Replace when any of the following conditions exist See reline procedure page A Total Lining thickness at thinnest point is 1 4 or less or 1 16 above the rivets B Linings are cracked or worn in an unusual or odd pattern i e lining wear tapered from side to side across shoe table Unusual wear patterns can indicate damage to foundation brake parts C Hivet holes are elongated in lining or shoes D Lining is oi soaked E Linings can be moved by hand i e loose rivets BRAKE DRUMS 1 Inspect drums for cracks heat checking glazing grooving severe out of round condition or bell mouthing must not exceed 025 T I R Replace any cracked drums It is recommended that drums be turned at reline to prevent hot spotting and achieve quicker more complete burnishing of the new lining CAUTION Drums displaying heat checks with a continuous length of four inches or more or that extend around the open edge of the drum should be discarded 2 Measure the drum to be sure the maximum limit allowed
13. e cam head the camshaft installation is correct NOTE With the wrong hand camshaft It is impossible to apply the brakes SLACK ADJUSTER 1 install the thick camshaft flat washer the slack adjuster SIMs and a new snap ring in that sequence onto the spied end of the camshaft 2 Adjust end play of the camshaft to between 005 and 45 by using the appropnate number of shims Make sure ihe snap ming 5 seated into the groove at the end of Ihe splined carnshalt BRAKE SHOES 2 Apo thin of Lubriplate B30 A grease of its egurvalent to the cam roller journals and me anchor gin Install new brake shoe springs in anchor end 4 Place the top shoe onto ihe spider by engaging ihe open aiota the end with the retaining springs anto the anchor pin Place opposite end of the shoe against the 5 cam Swing the lower shoe with springs attached back until slots tha shoe engage Ihe anchor pin Rotate the shoe toward tha Scam Lower shoe may require support while completing assembly 4 eod Place the short hook of the brake shoe retum spring onto the return soring pin Hold shoes against ihe Scam and push the long hook of the brake shoe return spring over the opposite return spring pin until it snaps in B Insert a sturdy lever between ihe end of ihe shoe and the return spring pin Pry away from the cam until the cam rallar can be installed between the S ca
14. e dry Be carelul not to get any fomign interior of the brake drum Use a wine brush to remove heavy contaraaton from the knuckle the spider brake drum exterior and chamber mounting bracket If shoes 1o be refined thoroughly wire brush shoe table amd paini with a rust inhibilree coating Wipe the inferior of the drums with a greaseless solvent raro lining dust A vacuum cleaner be used pick up heavy concentrations of brake dust SPIDER 1 Use a wire brush 1o remove heavy contamination from knuckle the spider brake drum exterior and chamber mounting bracket 2 Install the spider and chamber bracket assembly onto the axle flange sure spider is properly onented as noted during disassembly Tighten mounting bolts to wihiche manufacturers specications 1 Prior 10 installation verify the camshaft part mumber is correct for the individual brake There are and LH camshatts and they cannot be interchanged See CAUTION and NOTE below 2 Goat bushings seals journals and camshaft spine with light film of chassis lube Do not coat S cam head 3 Carefulby install through ihe large hole in the sower and continue on the chamber bracket tube Be careiul not to damage the grease seals CAUTION assure ihe camshaft is correct for same direction the slack would move during a brake application H the cam rollers begin to ride up on the convex side of th
15. e part Correct as required Correct as required Replace linings Replace or remachine Clean remove dirt and debris Re rivet Re rivet Replace part Replace linings Clean remove rust and paint shoe Replace part Replace lining Clean remove dirt and debris Replace linings Replace shoe and lining 12 SYMPTOM 1 Brake drum heat checked 2 Excessive scoring of drum NOTES 13 CAUSE BRAKE DRUM TROUBLESHOOTING CHART Out of round brake drum Eccentric mounting of drum Loose wheel bearing Glazed linings Improper friction materials for duty cycle of vehicle Overworked brake gt Driver abuse Wrong drum too light Defective brake lining Abrasive material between lining and drum Soft drum Excessive lining wear rivets contacting drum Drum not turned at last reline Build up of abrasives in rivet holes gt gt REMEDY Turn per manufacturer s specifications Inspect wheel and drum and replace defective part Correct as required Replace linings Consult vehicle manufacturer Check for proper brake balance Correct as required Replace part Replace linings Clean remove dirt and debris Check hardness on flange Should be 187 Brinnel minimum Replace lining per manufacturer s specifications
16. hing Rubber Plug Grease Seal Spider Sub Assembly Dust Shield Half drum When brake application is released the return spring pulls the shoes away from the drum KEY DIMENSIONS 1 Minimum lining thickness 1 4 total or 1 16 above rivet heads 2 Camshaft end play axial 005 045 3 Camshaft end play radial 020 max 4 Anchor pin groove depth 030 max 5 Camshaft grease seals installed 000 150 from end of tube TORQUE SPECS 1 Air chamber bracket assembly mounting bolts 70 80 ft Ibs 2 Dust shield screws 90 110 in Ibs 3 Spider to housing mounting bolts vehicle manufacturer specifications Return Spring Pin Shoe Retainer Spring General Precautions for Assembly and Disassembly All Spicer original equipment or service parts for steering and drive axle brakes are manufactured using non asbestos brake lining It is recommended that orginal Spicer service parts be used when brake maintenance is necessary WARNING The long term effects of exposure to non asbestos fibres has not been determined Avoid creating dust when performing ser vice on brake assemblies Excessive ex posure to brake dust may cause respiratory damage or other bodily harm SAFETY PRECAUTIONS Proper service and repair of vehicle components is important to the safe and reliable operation of all motor vehicles This applies particularly to brakes such as the ones described in this manual The
17. m and The slots the end of the brake shoe Make sure the cam rollers are in the lowes position on ihe Repeat the same procedure on the olhe shoe BRAKE ASSEMBLY 1 Lubricate the camshalt bushings filling the camshaft tube with chassis lube through the zerk iting provided Fill until grease is forced out in the area of the slack adjusier Grease should not appear The cam head end If it does the seal has not been properly installed or the old seals should be replaced 2 brake drums and wheels Torque and adjust wheel bearings ta manufacturers specifications NOTE Dua t the many combinations of slack adjusters and brake chambers follow vehicle manufacturer s specifications and procedures for assembly and final adjustment 3 Spin the wheel slowly and adjust the slack adjuster until wheel will no longer turn Back off slack adjuster just enough for wheel to spin freely Be sure to adjust brakes equally each axle 4 Apply and release brakes and observe slack adjusters Both slacks on each axle should respond rapidly and in Unison during application and release 5 Drive vehicle at low speed in a safe area and check for brake effectiveness prior to putting back in service Reline Procedure When removing rivets from the brake shoes be careful to avoid doing any damage to the holes in the shoe Do not use a chisel to shear them off as the force will elongate the rivet holes Neglecting
18. r bracht assembly trom the using a 3 4 socket 1 Remove and discard the two camshalt grease seats The seals are removed by driving out with punch 2 Remove and discard the two camshalt bushings located in aporoximatety the same area as the seals Use a tool of proper diameter and langih drive the bushings out from the backside SPIDER REMOVAL t Note or mark he relationship of the spider to the ada or L A and The orientation the mde flange Assembly CHAMBER BRACKET ASSEMBLY NOTE BOTH LIP SEALS POINT THE SAME DIRECTION LIP TOWARD SLACK ADJUSTER ACTUATOR BRACKET AND CAM TUBE SEAL INSTALLATION CAUTION The of the grease seals must be installed correctly to prevent possible damage The of the seal that ia installed in the spider musi enter the opening first The lip of the seal that is installed in oe ihe cam tube mus enter last See lockwsshers Torque to 70 ft Ibs If removed reinstall the dust sheekts Tighten the six cap screws and iockwashers to 90 110 in 159 terque 2 Remove spider to axle mounting bolts 3 Remove spider DUST SHIELD REMOVAL 1 Mark dust shields upper lett lower right eic la removal 2 Detach dust ahiekds by removing the six cap screws using 778 socket noi remove dusi shied unless there appareni damage Alter disassembly wash the metallic components in sutable Sore and wip
19. r improperly machined D Loose bearing adjustment bearing spacer missing or too thin E Improper wheel bearing or cone Bent brake shoe G Bent brake spider H Worn axle spindle A Overheating due to unbalanced braking system B Wrong type linings for service involved A Scored or worn drum not machined at reline B Abrasive material between lining and drum A Improper size rivets too long too short improper diameter B Improper crimping of rivet C Enlarged rivet holes in shoe D Incorrect lining hole size or counter bore depth E Rust build up on shoe table A Wrong type rivets B Rivets not properly crimped C Dirt or rust on shoe table D Wrong size lining counter bore A Loose rivets mmodo MOODY MOONY 0002 Ur r REMEDY Replace part Replace part Replace Replace linings Correct as required Regrind linings to drum radius minus 015 Replace parts Replace parts Replace part Correct as required Replace linings Replace part Replace flat spotted parts Replace spider assembly Replace part Replace linings Clean and lubricate Replace or turn Correct as required Reline both brakes together Replace linings Heplace linings Replace or turn 1 0 Correct as required Correct as required Replace part Replac
20. se unit failure and or affect vehicle safety and warranty Introduction GENERAL DESCRIPTION The Spicer 15 diameter single anchor pin cam brake is designed for use on heavy duty highway vehicles It is a mechanically actuated leading trailing shoe brake with a fixed position cam and anchor The brake consists of two fabricated steel shoe assemblies anchored to a ductile iron spider and actuated by a single forged camshaft Two retaining springs secure the shoe assemblies to the anchor pin The twin ribs of each shoe assembly engages the anchor pin on one end and the cam roller on the other A single return spring is used to maintain contact between the shoe cam roller and cam OPERATION The Spicer cam brake operates in the following manner during a braking application The force of the push rod of the air camber is converted from a linear force to a rotary torque This is accomplished by use of the slack adjuster On the opposite end of the camshaft is the S cam which when rotated lifts the cam rollers This spreads the brake shoe ends apart and pivots the shoes about the anchor pin so the brake lining comes in contact with the rotating brake Component Identification 15 Inch Camshaft Bushing Grease Fitting Chamber Retaining Ring Camshaft Adjusting Washers Shims Steel Spacer Grease Seal Dust Shield Mounting Bolt Lockwasher Cam Roller Shoe and Lining Assembly Bracket Assembly Camshaft Bus
21. stem pressure has been depleted 3 Never exceed recommended air pressure and always wear safety glasses when working with air pressure Never look into air jets or direct them at anyone 4 Never attempt to disassemble a component until you have read and understand recommended procedures Some components contain powerful springs and injury can result if not properly disassembled Use only proper tools and observe all precautions pertaining to use of those tools 5 Use only genuine Spicer replacement parts and components A Only components devices mounting and attaching hardware specifically designed for use in air brake systems should be used B Replacement hardware tubing hose fittings etc should be of equivalent size type length and strength as the original equipment C Make certain that when replacing tubing or hose all supports clamps or Suspending devices that were originally installed by the vehicle manufacturer are reinstalled 6 Devices with stripped threads or damaged parts should be replaced Repairs requiring machining should not be attempted PREPARATION 1 Park vehicle on a level surface and prevent movement by means other than the brakes 2 If equipped with spring brakes cage the spring on all axles to be worked on 3 Raise the axle to be worked on until the tires clear the ground Support raised axle with heavy duty jack stands WARNING Never work under a vehicle supported only by a jack
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