BENDIX BRIP-0300 User's Manual
Contents
1. External vents blocked e Low air pressure to valve see below Replace seals O rings Remove blockage Check for blockage Check compressor v SO Low air pressure supplied to system e Governor failure Incorrect set point Adjust set point Contamination Remove contamination Damaged valve Repair or replace valve e Compressor Failure Worn or leaking components Repair or replace Damaged components Repair or replace Slipping or broken belts or drives Repair or replace 14 BRAKE SYSTEMS DIAGNOSTIC GUIDE POTENTIAL CONDITION CAUSE ACTION SERVICE MANUAL SECTION Contamination No air dryer Faulty air dryer Dirty or damaged filter Desiccant debris Incompatible oils Leaking air tanks Mis adjusted brakes Install air dryer Repair or replace Replace filter Clean desiccant Drain and refill with proper oil Repair or replace tank Readjust brakes Insufficient pushrod free travel Pushrod length too long e Incorrect installation of slack adjuster Shorten pushrod to proper length Perform correct installation procedure 6 Overadjusted slack adjuster e Incorrect in service adjustment manual Incorrect setup of external reference control arms Eaton Haldex Incorrect slack window auto slacks Contamination of internal parts auto False feedback to slack adjuster review all foundation brake and wheel end problems Auto slack installed and or a2. Retaining S Bolt eN Ring 2 Wa 3A RON Anchor Pin NI IA Inner Washer PS Camshaft Shim Washers Lockwire q Als Grease Seal NN Camshaft Bushing Pin Bushings oe 5 y Grease Bracket 9 o Fitting Assembly Camshaft S Flat Washer Shoe Return Retaining Ring Anchor Pin Cam Roller Roller Ds Retainer gt Shoe and Lining Shoe and Lining ES 165 7H ES 165 7M Cast Shoe Fabricated Shoe 16 BRAKE SYSTEMS DIAGNOSTIC GUIDE POTENTIAL CONDITION CAUSE ACTION SERVICE MANUAL SECTION Dragging brakes See DRAGGING BRAKES Poor lining to drum contact Linings are tapered across width e Bell mouthed drum Bent brake spider Bent or stretched brake shoe Loose wheel bearing Worn or damaged cam e e e e Replace drum 3 Replace spider 3 6 Replace shoe 3 6 Torque spindle nuts and check end play 6 Replace cam 3 6 Shoe to shoe variation e Mismatched lining friction codes Stretched shoe Replace lining s with proper friction code 5 Replace shoe 3 6 Brake components e Flat spots on cam or roller Worn anchor pin e Worn camshaft or bushings Replace cam or roller 3 6 Replace anchor pin 3 6 Replace camshaft and bushings 5 Unequal wear on side to side brakes for same axle Mismatched lining friction codes e Seized or binding camshaft Brake drum surface in poor condition e Loose wheel bearing e Performing downgrade braking using light drag Replace
3. gt Y p 11 o J gt o 5 m oO oO er Mm ST1Nd J1JIH3A oO gt a Lu l T Lu 22 gt cc n Lu x o lt cc o BRAKE SYSTEMS DIAGNOSTIC GUIDE 1 Scoring 2 Severe Heat Checking Drum cannot be turned to eliminate heat cracks 3 Cracking Through Hat Section SU 4 Cracking Through Side Wall POTENTIAL CONDITION CAUSE ACTION SERVICE MANUAL SECTION Dragging brake See DRAGGING BRAKES Brake drum heat checked e e e e e e Out of round brake drum Eccentric mounting of drum Loose wheel bearing Glazed linings Improper friction materials for vehicle type and vocation Overworked brake Driver abuse Wrong drum type Defective brake lining Debris between lining and drum Performing downgrade braking using light drag y Y u u Y FS Replace drum 3 Correct as required 3 Correct as required Deglaze or replace linings 5 Consult dealer for proper friction levels Check brake balance 2 Correct as required Replace with correct drum type 3 Replace lining 5 Clean remove dirt and debris 3 Use snub method on downgrades Excessive scoring of drum Soft drum Replace drum 3 Excessive lining wear 12 See PREMATURE LINING WEAR BRAKE SYSTEMS DIAGNOSTIC GUIDE BRAKE CHAMBER BRAKE CHAMBER all RELAY VALVE POTENTIAL CONDITION CAUSE ACTION SERV
4. lining s with proper friction code 5 Clean and lubricate camshaft 2 Replace drum 3 Torque spindle nuts and check end play 6 Use snub method on downgrades Slack adjuster not set properly e Incorrect installation of slack adjuster e Incorrect in service adjustment e Incorrect setup of external reference control arms Eaton Haldex e Broken or bent parts Install slack adjuster properly 3 6 Check and correct adjustment procedure 2 Perform correct setup procedure 2 Replace damaged parts as required 3 6 Wear on edge of lining Wrong lining width e Wrong drum Loose bearing adjustment Bearing spacer missing or too thin 17 Replace lining 5 Replace drum 3 Replace spacer and torque spindle nuts Check end play 6 5 JJ m m E ep m gt J NOTES 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 O SALE AND THIS NOTICE MUST REMAIN ON ALL COPIES FTN 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 dr
5. servicing 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 OSHA regulations regarding testing disposal of waste and methods of reducing exposure for asbestos are set forth in 29 Code of Federal Regulations 1910 001 These regulations provide valuable information which can be utilized to reduce exposure to airborne particles Material safety data sheets on this product as required by OSHA are available from Eaton ONINYWM E ep m gt ES BRAKE SYSTEMS DIAGNOSTIC GUIDE ES EB 150 4L Camshaft Shim Camshaft Washer el Sjack nap Rin ee Adjuster Grease Spacer Seal Zz Stabilizing Screw Air Chamber Bracket Camshaft Bushing P Grease Slack Adjuster IA go Inner Washer VO A gt Camshaft gt Bushing Sd Bolt Grease Fitting Lining Inspection Plug Cam Roller Assembly Shoe and Lining Assembly Lockwasher Barrel Nut Shoe Retainer Spring Shoe Return Hold Down Spring Camshaft BRAKE SYSTEMS DIAGNOSTIC GUIDE ES 150 8D F Camshaft hi Shoe Assembly BA lee Camshaft Retainer Snap Ring Bracket Assembly Retainer Shoe NT Bracket Retainer Springs MS Stud Color Orange 7 0 Oe Slack Adjuster Inner Washer N Camshaft Bushing A Grease Seal Spider SS e Stamped Steel aX Al y Grease Fitting Cam Head Washer
6. E IN Camshaft Bushing Grease Seal Camshaft Shoe Return Spring Retainer Roller Shoe Assembly BRAKE SYSTEMS DIAGNOSTIC GUIDE Cam Roller and Pin for EB 165 and EB 180 Brakes Two Piece Roller and Pin Shoe Assembly net Shoe Retainer Springs Color Grange Spider Stamped Steel m Cam Head Washer for ES 165 7D L Extended a Service Brake Only Camshaft Shoe Return Spring EB ES 165 7L D Retainer Cam Roller and Retainer for ES 165 7D L F Extended Service Brake Only Roller One Piece Roller and Pin Inspection Camshaft Shim Washers Dustshield Screw Grease z Tear Camshaft Fitting Retainer Slack Adjuster Inner Washer Camshaft Bushing Grease Seal e WA Snap Ring 5 u Bracket Assembly Lockwasher Camshaft Bracket Stud Bushing Grease Seal See Cam Roller Notes Above Cast Spider Note Cast spiders are tapped and require 4 bolts and lock washers to attach air Shoe Assembly chamber bracket assembly BRAKE SYSTEMS DIAGNOSTIC GUIDE POTENTIAL CONDITION CAUSE ACTION SERVICE MANUAL SECTION Dragging brakes See DRAGGING BRAKES Insufficient lining to drum contact e Bell mouthed drum condition Poor surface condition of drum Bent brake spider e Bent or stretched brake shoe e Loose wheel bearing e Worn or damaged camshaft e Improper lining grind Replace drum 3 6 Rebore or replace drum 3 6 Replace spider 3 6 Repl
7. ICE MANUAL SECTION Blockage in air lines preventing air chamber from exhausting e Air line inner lining separation Plugged lines e Contamination Damaged fittings Replace line Remove blockage Remove contamination Replace fittings Air valves sticking e Seals O rings damaged e External vents blocked Contamination e Worn valves internal component failures Replace seals O rings Remove blockage Remove contamination Repair or replace as required Spring brake not functioning e Power spring failure Replace spring brake chamber Air chamber not set properly e Too much rod free travel Air chamber in wrong position in bracket slot Pushrod length too long Adjust brakes 2 Reposition air chamber or bracket 3 Adjust clevis or shorten pushrod 2 Slack adjuster not set properly e Incorrect installation of slack adjuster e Incorrect in service adjustment e Incorrect setup of external reference control arms Eaton Haldex e Broken or bent parts Install slack adjuster properly 3 6 Check and correct adjustment procedure 2 Perform correct setup procedure 2 Replace damaged parts as required 3 6 No force at shoes e Grease oil or dirt on linings Replace linings 5 Lack of friction e Glazed linings e Worn damaged drums e New linings not burnished 13 Deglaze or replace linings 5 Replace drums 3 Burnish linings S3MY44 INIYIYHA Q10H LON TIM 3444 I
8. ICE MANUAL SECTION Dragging brakes See DRAGGING BRAKES Insufficient lining to drum contact Bell mouthed drum condition Poor surface condition of drum Bent brake spider Bent or stretched brake shoe Loose wheel bearing Worn or damaged camshaft Improper lining grind Replace drum 3 6 Rebore or replace drum 3 6 Replace spider 3 6 Replace shoe 3 6 Torque spindle nuts and check end play 6 Replace camshaft 3 6 Grind linings to fit drum radius Linings tapered across width Bell mouthed drum condition Poor surface condition of drum Bent brake spider e Loose wheel bearing Replace drum 3 6 Rebore or replace drum 3 6 Replace spider 3 6 Torque spindle nuts and check end play 6 Unequal shoe wear on same brake e Mismatched lining friction codes e Worn camshaft or bushings Correct as required with proper lining 5 Replace camshaft or bushings 3 6 Glazed linings Unbalanced brake system e Incorrect lining for vehicle type and service Dragging spring brake chamber Inspect brake system 2 Install proper lining 6 Inspect valves and chamber for leaks Replace air chamber 4 6 Scored or grooved linings and drum e Improperly machined drum Abrasive material between lining and drum Replace or machine drum 3 6 Remove dirt and debris Clean drum and remachine if required 3 Loose lining Improper rivet size Improper crimping of rivets e En
9. NIMHYd BRAKE SYSTEMS DIAGNOSTIC GUIDE POTENTIAL CONDITION CAUSE ACTION SERVICE MANUAL SECTION Incomplete release of air chamber after service application e Incorrect clevis position e Incorrect bracket slot Damaged pushrod Air chamber return spring failure Road debris damage Blockage in other upstream air system parts Reposition clevis 6 Reposition on correct bracket slot 6 Replace air chamber 3 6 Replace air chamber 3 6 Repair damage 5 Remove blockage 5 y 3 Y 3 Incomplete release of parking brake after application of pressure to air chamber Internal cup cone hang up Damaged pushrod Diaphragm leak in parking chamber Cocked power spring Pushrod seal leak Blockage in other upstream air system parts DRAGGING BRAKES Repair or replace cup cone Replace pushrod 3 6 Replace diaphragm or air chamber 3 6 Repair power spring Replace seal 5 Remove blockage PARKING BRAKE WILL NOT HOLD SY 3 y y 3 Y Air leaks in parking system e Old or broken lines e Pinhole leaks in air line e Loose or damaged fittings e Damaged or contaminated valve Replace lines Replace line Tighten or replace fittings Repair or replace valve Y Blockages in service system air lines Inner lining separation Replace chamber air lines Plugged lines Remove blockage e Contamination Remove contamination Air valves sticking e Seals O rings damaged e
10. Roadranger Dana Spicer Brakes lt Dana gt E T N Brake Systems One Great Drivetrain from Two Great Companies Troubleshooting Guide BRTS 0300 November 1994 For the most current information visit the Roadranger web site at www roadranger com General Information Table of Contents Foreword ns ee e ets de ee ales 2 AN 2 How to Use this Manual A id 2 Lining Material Warning 2 2 AA A oh kes Beech ae Ves Vie nee ee 3 Brake Systems Diagnostic Guide eee eee a E bebe eee e bees et eben bette eenrernres 4 NI ee ee ende Str ER idu ale try hae aa ia an Gehl ee ren ale Matias E ANE Web 7 LOng Stopping DISTANCES cita ee Sondre id nen teren be enced ons Sen ai bd bai 9 Vehicle Pulls Gracked Drums 22 da wie eee ee ho een we Viv a hee ee a eae nina 11 Parking Brake Will Not Hold Dragging Brakes amaannaaaanaawanannan 13 Premature Liming Wear use ee ek oeanalAt th cg Lean eagle tls in tects ahah 17 General Information Foreword Purpose This Eaton manual is intended as a diagnostics guide for technicians involved in the servicing of Eaton EB and ES Model Brakes How to Use this Manual This manual outlines the steps necessary to pinpoint the source of problems and concerns related to braking systems lt does not describe service procedures but instead refers the technician to service manual sections whenever possible Therefore this manual should b
11. ace shoe 3 6 Torque spindle nuts and check end play 6 Replace camshaft 3 6 Grind linings to fit drum radius Linings tapered across width Bell mouthed drum condition e Poor surface condition of drum Bent brake spider e Loose wheel bearing ln Replace drum 3 6 Rebore or replace drum 3 6 Replace spider 3 6 Torque spindle nuts and check end play 6 Unequal shoe wear on same brake e Mismatched lining friction codes e Worn camshaft or bushings Correct as required with proper lining 5 Replace camshaft or bushings 3 6 Glazed linings e Unbalanced brake system e Incorrect lining for vehicle type and service e Dragging spring brake chamber Inspect brake system 2 Install proper lining 6 Inspect valves and chamber for leaks Replace air chamber 4 6 Scored or grooved linings and drum e Improperly machined drum e Abrasive material between lining and drum Replace or machine drum 3 6 Remove dirt and debris Clean drum and remachine if required 3 Loose lining e Improper rivet size e Improper crimping of rivets e Enlarged rivet holes in shoe e Incorrect lining hole size or counterbore depth v Replace rivets Replace rivets 5 5 Replace shoe 3 6 Replace lining 5 Cracked lining at rivet holes e Dirt or rust on shoe table e Incorrect counterbore lining size Loose rivets Remove dirt and debris Clean and repaint shoe 3 Replac
12. djusted with spring brake partially applied low reservoir pressure Performing downgrade braking using light drag Readjust using proper procedure Perform correct setup procedure Replace with proper slack window 6 Replace slack adjuster 6 Check lining clearances and hub drum run out 4 Readjust with spring brake fully retracted Use snub method on downgrades Cam flip over e Worn linings drums e Worn shoes rollers e Worn cam Replace linings drums 3 5 6 Replace as necessary 3 6 Replace cam 3 6 Binding of camshaft in bushings e Corrosion e Lack of lubricant e Damaged bushings journals Replace bushings and lubricate 5 Lubricate with proper lubricant 2 Replace bushings journals 5 Drum out of round e Worn out drum Overloading of vehicle e Over aggressive linings e Driver abuse Incorrect turning of drum Performing downgrade braking using light drag 15 Replace drum 3 6 Don t exceed legal weight rating of vehicle Change lining friction rating Correct as required Perform correct drum turning operation 2 Use snub method on downgrades Sava INIYYYYA Q10H LON TIM 3444 INUA BRAKE SYSTEMS DIAGNOSTIC GUIDE ES 165 7H M Shoe and Lining Anchor Pin Bushing ES 165 7H Retaining Ring Cast Shoe pi y Anchor Pin Flat Washer Camshaft Bushin i Groove Pin Slack Adjuster Shan King Inspection oo E Flat Washer aa Hole Plug ockwasher Y
13. e linings 5 Replace linings and check rivet process 5 BRAKE SYSTEMS DIAGNOSTIC GUIDE dd mmm PRIMARY rm rar SECONDARY am PARKING I u e a e pu a o a e YA CL gt T A A 3 en OT AT OT A PAE A A SA ete I ri a pl EIN pl o 1 22 BRAKE SYSTEMS DIAGNOSTIC GUIDE POTENTIAL CONDITION CAUSE ACTION SERVICE MANUAL SECTION Inadequate air supply to chamber e Old or broken lines e Pinhole leaks in air chamber line e Loose or damaged fittings e Air line inner lining separation Replace chamber air lines 3 Replace chamber air lines 3 Tighten or replace fittings 3 Replace chamber air lines 3 vv gt in Separation e Plugged lines Contamination Remove blockage Remove contamination Valve problems e Worn valves e Internal component failures e Seals O rings damaged e External vents blocked Repair or replace Repair or replace Replace seals O rings Remove blockage vv Wu Governor failure e Incorrect set point Contamination e Damaged valve Correct set point Remove contamination Repair or replace Compressor failure e Worn or leaking compressor e Slipping broken belts drives Repair or replace compressor Repair or replace belts or drives Contamination e No air dryer Faulty air dryer Dirty damaged filter Desiccant debris Incompatible oils Install air dryer Repair or replace air dryer Replace a
14. e used as a checklist in conjunction with Eaton service manuals and other procedural guides To isolate the source of a problem or concern follow the steps below 1 Identify the symptom s exhibited by the braking system Locate the related section in this manual For example if the brakes are making unusual sounds turn to the page labeled Noise 2 Use the left hand column as a checklist Check each item on the list If an item is found to be defective perform the corresponding action prescribed in the right hand column For example noise may be caused by a bent brake spider The recommended action is to replace the spider 3 Refer to the appropriate service manual section for information on specific procedures Related service manual sections are shown in parenthesis whenever possible Service Manual BRSM 0033 Note Included in the General Information section are assembly diagrams to assist in troubleshooting A Work through all potential conditions or causes related to the symptom encountered before making a final conclusion It is possible that several problems exist each with the same symptom Therefore checking each item on the list will help to ensure that all problem sources are eliminated or corrected A Replace only those parts that have been identified as definite problems Doing so will save unnecessary time and expense BRAKE SYSTEMS DIAGNOSTIC GUIDE POTENTIAL CONDITION CAUSE ACTION SERV
15. ir filter Remove debris Drain and refill oil Leaking air tanks SS v sete SF Repair or replace Improperly set air chamber e Too much rod free travel Adjust brakes 2 Slack adjuster improperly set e Incorrect installation of slack adjuster e Incorrect in service adjustment e Incorrect setup of external reference control arms Eaton Haldex e Worn clevis pin Install slack adjuster properly 3 6 Adjust brakes using correct procedure 2 6 Perform correct setup procedure 3 6 Replace clevis pin 3 6 r oo ep AA i ep k gt or m 7 N Lu E Ca do a a Fr e do Z BRAKE SYSTEMS DIAGNOSTIC GUIDE POTENTIAL CONDITION CAUSE ACTION SERVICE MANUAL SECTION Slack adjuster not functioning properly e Bushing worn e Spline damaged e Worn or damaged internal parts e Incorrect slack window auto slacks v Replace bushing 3 6 Replace slack adjuster 3 6 Replace slack adjuster 3 6 Install correct window 3 6 Overadjustment underadjustment e Contamination of internal parts auto slacks e False feedback to slack adjuster due to degraded foundation brake components see below e Severely glazed or worn linings Replace slack adjuster 3 6 Replace bad foundation brake component Replace linings 5 Degraded foundation brake components e Grease or oil on linings e Flat s
16. ivetrain 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 BRTS 0300 04 04 PDF Printed in USA
17. larged rivet holes in shoe e Incorrect lining hole size or counterbore depth Replace rivets Replace rivets 5 5 Replace shoe 3 6 Replace lining 5 Cracked lining at rivet holes e Dirt or rust on shoe table e Incorrect counterbore lining size Loose rivets Remove dirt and debris Clean and repaint shoe 3 Replace linings 5 Replace linings and check rivet process 5 General Information A DANGER AVOID CREATING DUST POSSIBLE CANCER AND LUNG DISEASE HAZARD While Eaton does not offer asbestos brake linings the long term effects 3 of some non asbestos fibers have not been determined Current OSHA Regulations cover exposure levels to some components of non asbestos linings but not all The following precautions must be used 4 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 EATON RECOMMENDS THAT WORKERS DOING BRAKE WORK MUST TAKE STEPS TO MINIMIZE EXPOSURE TO AIRBORNE BRAKE 5 LINING PARTICLES Proper procedures to reduce exposure include working in a well ventilated area segregation of areas where brake work is done use of local filtered ventilation systems or use of enclosed cells with filtered vacuums Respirators approved by the Mine Safety and Health Administration MSHA or National Institute for Occupational Safety and Health NIOSH should be worn at all times during brake
18. pots on cam or rollers Replace linings 5 Replace cam or roller 3 6 Camshaft bushings binding e lacks lubricant e Stretched shoe e Other broken or bent parts e Performing downgrade braking using light drag 10 v Lubricate bushings Replace shoe 3 6 Replace damaged parts as required 3 6 Use snub method on downgrades BRAKE SYSTEMS LINING RETURN SPRING LINING DIAGNOSTIC GUIDE RETURN SPRING POTENTIAL CONDITION CAUSE ACTION SERVICE MANUAL SECTION Dragging brakes See DRAGGING BRAKES Check brake adjustment gt Grabbing or pulling brakes e e e e e e e e e e e e e Grease oil or dirt on linings Glazed linings Cam bracket seal failure Brake linings not a balanced set different codes or lining brand Loose or broken linings Brake drum out of round Defective brake drum Camshaft binding at one or more wheels Defective slack adjuster Uneven brake adjustment side to side Broken or bent part s Loose spider or drum mounting bolts Different air chamber size or slack adjuster length side to side Replace linings 5 Deglaze linings or replace 5 Replace seals 5 Replace linings 5 Replace linings 5 Replace drum 3 6 Replace drum 3 6 Clean and lubricate 2 3 Replace slack adjuster 3 6 Adjust brakes 2 Replace part s 6 Retorque bolts 6 Use same size air chamber and slack adjuster length on all brakes SY JW y y rm Y 8 Y 3
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