Download BENDIX BW7308 User's Manual

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SD-23-7541
®
Bendix® ADB22X™, ADB22X-V™ Air Disc Brakes
SECTION ONE: AIR DISC BRAKE OVERVIEW
1.1 DESCRIPTION
Bendix ® ADB22X ™ and ADB22X-V ™ Air Disc Brakes
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Sections in this Document
Section
Page
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Full Index - see Page 38
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FIGURE 2 - TYPICAL PART NUMBER LABEL LOCATION
Bendix Part Number
Serial No.
Customer Part Number
FIGURE 3 - PART NUMBER LABEL INFORMATION
Section One
Section
FIGURE 1 - BENDIX® ADB22X ™ AIR DISC BRAKES
Page
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1
SAFE MAINTENANCE PRACTICES
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.
2.
3.
4.
5.
6.
7.
8.
9.
2
Park the vehicle on a level surface, apply the
parking brakes, and always block the wheels.
$OZD\VZHDUVDIHW\JODVVHV:KHUHVSHFL¿FDOO\
directed, the parking brakes may have to be
released, and/or spring brakes caged, and this
will require that the vehicle be prevented from
moving by other means for the duration of these
tests/procedures.
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 prevent personal injury resulting
from contact with moving, rotating, leaking, heated
or electrically charged components.
Do not attempt 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.
If the 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
a Bendix ® AD-IS ® air dryer system or a dryer
reservoir module, be sure to drain the purge
reservoir.
Following the vehicle manufacturer’s recommended
procedures, deactivate the electrical system in a
manner that safely removes all electrical power
from the vehicle.
Never exceed manufacturer’s recommended
pressures.
Never connect or 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.
Use only genuine Bendix® brand replacement
parts, components and kits. Replacement
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of equivalent size, type and strength as original
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applications and systems.
Components with stripped threads or damaged
parts should be replaced rather than repaired.
Do not attempt repairs requiring machining or
ZHOGLQJXQOHVVVSHFL¿FDOO\VWDWHGDQGDSSURYHG
by the vehicle and component manufacturer.
10. Prior to returning the vehicle to service, make
certain all components and systems are restored
to their proper operating condition.
11. For vehicles with Automatic 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.
WARNING: Not all wheels and valve stems are
compatible with Bendix Air Disc Brakes. Use only
wheels and valve stems approved by the vehicle
manufacturer to avoid the risk of valve stem shear
and other compatibility issues.
WARNING: AVOID CREATING DUST.
POSSIBLE CANCER AND LUNG DISEASE
HAZARD.
While Bendix Spicer Foundation Brake LLC does not
offer asbestos brake linings, the long-term affects of
VRPHQRQDVEHVWRV¿EHUVKDYHQRWEHHQGHWHUPLQHG
Current OSHA Regulations cover exposure levels to
some components of non-asbestos linings, but not
all. The following precautions must be used when
handling these materials.
‡ $YRLGFUHDWLQJGXVW&RPSUHVVHGDLURUGU\EUXVKLQJ
must never be used for cleaning brake assemblies
or the work area.
‡ %HQGL[UHFRPPHQGVWKDWZRUNHUVGRLQJEUDNHZRUN
must take steps to minimize exposure to airborne
brake lining particles. Proper procedures to reduce
exposure include working in a well-ventilated
area, segregation of areas where brake work is
done, use of local filtered ventilation systems
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Respirators approved by the Mine Safety and Health
Administration (MSHA) or National Institute for
Occupational Safety and Health (NIOSH) should be
worn at all times during brake servicing.
‡ :RUNHUV PXVW ZDVK EHIRUH HDWLQJ GULQNLQJ RU
smoking; shower after working, and should not
wear work clothes home. Work clothes should
be vacuumed and laundered separately without
shaking.
‡ 26+$ 5HJXODWLRQV UHJDUGLQJ WHVWLQJ GLVSRVDO
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.
‡ 0DWHULDO 6DIHW\ 'DWD 6KHHWV RQ WKLV SURGXFW DV
required by OSHA, are available from Bendix. Call
1-800-247-2725 and speak to the Tech Team or e-mail
[email protected]
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1.5 Operation
See Figure 4 to help you identify which type of rotor is used
on the axle being inspected. 1RWHWKDWWKHPDLQWHQDQFH
LQVSHFWLRQ SURFHGXUH ZLOO GHSHQG RQ WKH W\SH RI URWRU
LQVWDOOHG
%HQGL[ DLU GLVF EUDNHV FRQYHUW DLU SUHVVXUH LQWR EUDNLQJ
IRUFH (See Figure 6.) :KHQ WKH YHKLFOH EUDNHV DUH
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Bendix® Splined
Disc® Rotor
Conventional
Rotor
Service Brake
Chamber
Inner Brake Pad
Outer Brake
Pad
Pressure
Plate
Supply Port
Push rod
Lever
Return Spring
FIGURE 4 - ROTOR IDENTIFICATION
CAUTION: Rotors may not be mixed on a single axle:
axles are only permitted to have all conventional or all
splined disc rotors.
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Diaphragm
See Figure 5 for the electronic wear sensor that may be
present.
104
Cable Protection
Plate
101
Sensor
Rotor
Bridge
Eccentric Bearing
FIGURE 6 - CROSS-SECTION VIEW SHOWING BRAKE
OPERATION
101
Sensor
1.5.1 Brake Release and Adjustment
105
Cable Guide
(2 alternate
designs used)
103
Cable to Electrical
Supply
6HQVRU 101
&DEOHWR(OHFWULFDO6XSSO\ 103
&DEOH3URWHFWLRQ3ODWH 104
&DEOH*XLGHWZRGHVLJQV 105
:KHQ WKH YHKLFOH EUDNHV DUH UHOHDVHG WKH DLU SUHVVXUH
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FIGURE 5 - ELECTRONIC WEAR INDICATOR COMPONENTS
3
12
Pad
1 Assembly
Caliper
9
22
58 Inner Boot
7
Inner Seal
5
Ring
Brass Bushing
Guide Pin
40
Caliper Bolt
Top Sectional View
10
Cap
23
Adjuster Unit
161
Tappet Bushing
32
Chain Wheel
16
Threaded Tube
13
Tappet and Boot
Assembly
61
Shear Adapter
45 Washer
26
Spring Clip
37
Adjuster Cap
44
Pad Retainer Pin
27 Spring
30
Chain
11
Pad Retainer
17
Bridge
33
Wear Sensor
22
Inner
Seal
16
Threaded Tube
24
Turning
Device
161
Tappet
Bushing
6 Guide Sleeve
13
Tappet and
Boot Assembly
2
Carrier
2
Carrier
39
Caliper Bolt
58
Ring
Side Sectional View
Pad Assembly 12
12
Pad
Assembly
18/1 Spring Brake or
18/2
Brake Chamber
46
Rotor
43
Bolt
27
Spring
FIGURE 7 - SECTIONAL VIEWS
4
68
Cap
19
17 Lever
Bridge
20
Eccentric
Bearing
9
Inner
Boot
4
Guide Pin
Short Caliper Bolt
Sectional View
Type A
Type B
(Wheel turns toward
fixed pin side of
ADB)
18/1 Spring Brake
Actuator
44
Pad Retainer Pin
(Fixed pin)
11 Pad Retainer
18/2
Service
Actuator
26 Spring Clip
12/2 Pad Holder Spring
:KHHO5RWDWLRQ
W\SLFDOO\ULJKWKDQG
45
Washer
:KHHO5RWDWLRQ
12/1 Pad
W\SLFDOO\OHIWKDQG
(Pad Assembly
consists of
12/1 plus 12/2)
10
40
Cap
5 Caliper
Guide Bolt
7
Brass
Bushing
Pin
68
Cap
39 Caliper Bolt
22
Inner Seal
Shield
Kit
(Drive or
Steer)
161
Tappet Bushing
13 Tappet
and Boot
Assembly
4 Guide Pin
Actuator
Hardware
61 37*
Shear
Adapter
*37 Adjuster
Caps (2 styles
supplied in kits)
6 Guide Sleeve
Carrier
Mounting
Hardware
1
Caliper
(or Caliper Kit)
U-shaped Rotor
9
58 Inner Boot
Ring
Bendix® ADB22X™
Anchor Plate
2A
Bendix®
ADB 22X™
Carrier
(Rotor Shield for Trailers)
U-shaped
Rotor
Fasteners
2B
Bendix®
ADB 22X-V™
Carrier
SD-1
Drive Hub
SD-2
®
SD-3
Splined Disc® Rotor
(SD)
Splined Disc Rotor
Hardware
SD-1, -2, -3
Bendix®
ADB22X-V™
Anchor Plate
Carrier
Mounting
Hardware
See Section 5.2 for
exploded view of electronic
wear indicator.
Steer Hub
FIGURE 8 - EXPLODED VIEW - BENDIX® ADB22X ™ AND ADB22X-V ™ AIR DISC BRAKES
INDEX TO FIGURES 7 & 8
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$GMXVWHU8QLW 23
%ROW 43
%UDVV%XVKLQJ 7
%ULGJH 17
&DOLSHU 1
&DOLSHU%ROW &DS 68
Carrier $RU%
&KDLQ 30
&KDLQ:KHHO 32
&DS 10
(FFHQWULF%HDULQJ 20
*XLGH3LQV *XLGH6OHHYH 6
,QQHU%RRW 9
,QQHU6HDO 22
/HYHU 19
Pad 12/1
3DG+ROGHU6SULQJ 12/2
3DG$VVHPEO\ 12
3DG5HWDLQHU 11
3DG5HWDLQHU3LQ 44
5LQJ 58
6HUYLFH$FWXDWRU 18/2
6KHDU$GDSWHU 61
6SOLQHG'LVF+DUGZDUH
6'6'DQG6'
6SULQJ 27
6SULQJ%UDNH$FWXDWRU 18/1
6SULQJ&OLS 26
7DSSHWDQG%RRW
$VVHPEO\ 13
7DSSHW%XVKLQJ 161
7KUHDGHG7XEH 16
7XUQLQJ'HYLFH 24
:DVKHU 45
:HDU6HQVRU 33
5
SECTION TWO: PREVENTIVE MAINTENANCE SCHEDULE AND WHEEL-ON INSPECTIONS
2.0 PREVENTIVE MAINTENANCE
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Section Two
Section
Page
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Use the table below for a guide to maintenance interval
planning, KRZHYHUGHSHQGLQJRQWKHSDUWLFXODUYHKLFOH
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Table 1: Inspection Period
(4 to 5 times during the pad lifetime)
* For vehicles with
electronic wear
indicatorsXVHWKH
GDVKLQGLFDWRUV
DQGRUWKHKDQGKHOG
GLDJQRVWLFWRROWR
UHJXODUO\PRQLWRUWKH
SDGZHDU
When
you
check
the tire
pressures
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PRQWKVIRURYHUWKH
URDGDSSOLFDWLRQV
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FRDFKHVHWF
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RIIKLJKZD\FRQVWUXFWLRQ
ORJJHUFRQFUHWHPL[HUGXPS
WUXFNFLW\WUDQVLWEXVUHIXVH
VFKRROEXVHVHWF
See Section 5.2.
At the
very
least,
every
four (4)
months
At least
once
every
year
(and at
every
pad
replacement)
Inspections with the wheel mounted (Sections 2.1 - 2.3)
,QVSHFWWKHSDGWKLFNQHVVE\
FKHFNLQJWKHPHFKDQLFDOZHDU
LQGLFDWRUVSee Section 2.1.
,QVSHFWWKHUXQQLQJFOHDUDQFHV
XVLQJWKHTXLFNLQVSHFWLRQ
WHFKQLTXHSee Section 2.2.
,QVSHFWWKHYLVLEOHSDUWRIWKHURWRUV
IRUFUDFNVHWFSee Section 2.3.
Inspections with wheel removed (Section 4)
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VXUIDFHVIRUFUDFNVHWF%HQGL[®
VSOLQHGGLVF®URWRUV,QVSHFW
UHWDLQLQJKDUGZDUHDQGFKHFN
WRUTXHVSee Section 2.3.
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See Sections 2.2 and 4.2.
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See Section 4.1.
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DVVHPEOLHVSee Section 4.6.
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6
TABLE 1 - PREVENTIVE MAINTENANCE SCHEDULE
2.1 BRAKE PAD AND ROTOR INSPECTIONS
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FDQEHPDGHZLWKRXWUHPRYLQJWKHZKHHOV:KHUHGXVW
JXDUGVDUHQRWXVHGWKHWRSRIWKHSDGVDQGSDUWRIWKH
URWRUDUHYLVLEOHWKURXJKWKHRSHQLQJDWWKHWRSRIWKHEUDNH
2WKHUYLVLEOHSRUWLRQVRIWKHURWRUFDQEHLQVSHFWHGDWWKH
VDPHWLPH
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URWRUVXUIDFHVWKDWFRQWDFWWKHSDGVZLOODOZD\VDSSHDUWR
EHVKLQ\6XUIDFHUXVWRQWKHVHVXUIDFHVZRXOGLQGLFDWHD
PDOIXQFWLRQLQJEUDNHWKDWVKRXOGEHLQVSHFWHGLPPHGLDWHO\
Wear Indicator Style A:
Where both the carrier and caliper have an
indicator notch.
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WKHFDUULHUDQGFDOLSHU:KHQWKHWZRQRWFKHVDOLJQ
LWLVWLPHWRVFKHGXOHDIXOOZKHHOUHPRYHGLQVSHFWLRQ
RIWKHSDGVDQGURWRU
Notch in the
caliper
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UHSODFHGZKHQWKH\UHDFKLQPP5RWRUVDUH
LQ PP WKLFN ZKHQ QHZ DQG PXVW EH UHSODFHG
ZKHQ WKH\ UHDFK LQ PP See Section 4.3 for
further inspection criteria.
Notch in the
carrier
2.1.1 Electronic Wear Indicators
8VHWKHGDVKLQGLFDWRUVDQGRUDKDQGKHOGGLDJQRVWLF
WRROWRUHJXODUO\PRQLWRUWKHSDGZHDU(See Section 5.2.)
2.1.2 Mechanical Wear Indicators
6HH )LJXUH IRU WKH ORFDWLRQ RI WKH PHFKDQLFDO ZHDU
LQGLFDWRUV7KHUHDUHWZRW\SHV(See Figure 10 for Style A
and Figure 11 for Style B)
Quick Visual
Inspection of Pad
Thickness and Rotor
Location of Wear
Indicator Notches
(Both sides of brake)
When the notches
line up, it is time
to schedule an
inspection of the
pads and rotor
FIGURE 10 - STYLE A - WHEN BOTH CARRIER AND CALIPER
HAVE A CAST NOTCH
Wear Indicator Style B:
Where only the caliper has an indicator
notch.
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HGJHRIWKHWRUTXHSODWHLWLVWLPHWRVFKHGXOHDIXOO
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FIGURE 9 - LOCATION OF WEAR INDICATORS
Note: These mechanical wear indicators do
not constitute “out-of-service” criteria. 7KHVH
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WKH ZHDU LQGLFDWRU SRVLWLRQ DW ZKLFK PDLQWHQDQFH LV
DFWXDOO\QHHGHG
Notch in
the caliper
When the
torque plate
edge lines up
with the notch,
it is time to
schedule an
inspection of
the pads and
rotor
No notch
in the
carrier
Torque
plate
FIGURE 11 - CARRIER WEAR INDICATOR NOTCH AND BACKING
PLATE ALIGNMENT
7
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F
1R DFWLRQ LV QHHGHG
I R U V P D O O F U D F N V
V S U H D G R Y H U W K H
VXUIDFHHJ$UHD)
Rotor
Friction
Surface
Width “f”
Area
F
‡ )RU standard Bendix rotors FUDFNV
UXQQLQJ LQ D UDGLDO GLUHFWLRQ ² OLNH
VSRNHVRIDZKHHOVHH$UHD+²OHVV
WKDQ 0.06 in. (1.5 mm) GHHS RU ZLGH
DUH DFFHSWDEOH LI WKH\ GR QRW UHDFK
HLWKHU HGJH (see G) &UDFNV DUH RQO\
DFFHSWDEOHLIWKHOHQJWKRIWKHFUDFNLV
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Area
H
f
Area G
G
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URWRU
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IRUHLWKHU
W\SHRI
URWRU
Area J
J
&LUFXPIHUHQWLDO
JURRYHVDVLQ$UHD
-DUHDFFHSWDEOH
LIOHVVWKDQLQ
PPGHHS
‡ )RUBendix Splined Disc rotorsUDGLDO
FUDFNVDUHRQO\DFFHSWDEOHLIWKH\DUH
OHVV WKDQ 0.04 in. (1.0 mm) GHHS RU
ZLGHDQGLIWKH\GRQRWUHDFKHLWKHUHGJH
(see G). &UDFN OHQJWKV PXVW EH OHVV
WKDQ RI GLPHQVLRQ ³I´ WKH ZLGWK
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,QDGGLWLRQIROORZWKH
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Note: Axles should
have either all Bendix
Splined Disc (or all
conventional) rotors.
FIGURE 12 - EXAMPLES OF ACCEPTABLE AND NON-ACCEPTABLE ROTOR CRACKS AND GROOVES
2.1.3 Rotor Quick Inspection
See Figure 126HHWKHYDULRXVSRWHQWLDOURWRUFRQGLWLRQV
WKDW\RXPD\¿QG6HHWKHFULWHULDEHORZIRUZKHWKHUWKH
URWRU QHHGV WR EH UHSODFHG DQGRU VFKHGXOHG IRU D IXOO
LQVSHFWLRQ
2.2 RUNNING CLEARANCE QUICK
INSPECTION
CAUTION: Follow all safe maintenance practices.
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EUDNHFDOLSHU7KLVVPDOOPRYHPHQWOHVVWKDQPP
DSSUR[LPDWHO\WKHWKLFNQHVVRIDQLFNHOLQWKHLQERDUG
RXWERDUG GLUHFWLRQ LQGLFDWHV WKDW WKH EUDNH LV PRYLQJ
SURSHUO\RQLWVJXLGHSLQV
,IWKHFDOLSHUKDVQRPRYHPHQWRUDSSHDUVWRPRYHJUHDWHU
WKDQ WKH GLVWDQFHV QRWHG DERYH D IXOO ZKHHOUHPRYHG
LQVSHFWLRQZLOOEHQHFHVVDU\(See Section 4.1)
8
Push/Pull
By Hand
to Check
the Caliper
Movement
FIGURE 13 - CALIPER RUNNING CLEARANCE
(FIGURE DOES NOT SHOW WHEEL)
SECTION THREE: TROUBLESHOOTING PROCEDURE FLOWCHART
Air Disc Brake Inspection
Follow safe maintenance practices,
chock wheels. Engage spring brakes
and cage spring. Release spring
brakes and drain air from system.
Raise axle, spin
the wheel by
hand.
Does
the wheel
turn smoothly?
YES
NO
Is
the
spring brake fully/
partially applied?
Check
running
clearance (4.1)
- OK?
NO
YES
YES
NO
YES
Check
running
clearance (4.1)
- OK?
Check
adjuster (4.2)
- OK?
YES
YES
NO
NO
Drain air pressure from
system. Re-start test after
caging spring brakes
Check
Adjuster (4.2)
- OK?
Check
caliper
guidance (4.5)
- OK?
Replace caliper/
carrier assembly
(5.3)
Check
Pad and rotor
wear (4.3-4.4)
- OK?
YES
YES
NO
NO
Replace caliper/
carrier assembly
(5.3)
NO
Tightness not due to
air disc brake. See
vehicle manual.
Replace components
as needed with
genuine Bendix parts.
Disc brake OK
Replace guide pins
(5.6) OR replace
caliper/carrier
assembly (5.3)
FIGURE 14 - TROUBLESHOOTING BENDIX AIR DISC BRAKES
9
SECTION FOUR: WHEEL-OFF MAINTENANCE INSPECTIONS
4.1 CALIPER MOVEMENT TEST
Section Four
Section
Page
:KHHO2II,QVSHFWLRQV 10
&DOLSHU0RYHPHQW7HVW 10
$GMXVWHU0HFKDQLVP,QVSHFWLRQ 11
%UDNH3DGVDQG5RWRUV 12-14
,QVSHFWWKH%UDNH3DGV 12
,QVSHFWWKH5RWRU 13-14
0DFKLQLQJ*ULQGLQJRU7XUQLQJ5RWRUV
14
*XLGH3LQ%HDULQJ,QVSHFWLRQ 14-15
7DSSHW%RRW$VVHPEO\,QVSHFWLRQ 15
CAUTION: Follow all safe maintenance practices.
5HPRYHWKHZKHHO:LWKWKHVSULQJEUDNHVUHOHDVHGRU
FDJHGSXVKWKHFDOLSHUDVVHPEO\LQERDUGRQLWVJXLGHSLQV
Note: To fully release the spring brakes, assure that the
air system pressure is at least 90 PSI. 8VLQJDVXLWDEOH
WRROIRUH[DPSOHDODUJHÀDWEODGHVFUHZGULYHUSUHVVWKH
LQERDUGSDGDZD\IURPWKHWDSSHWV&KHFNWKDWWKHUH
LVQRGLUWHWFLQWKHJDSDQGFOHDQLIQHFHVVDU\7KHQXVH
WZRORQJEODGHIHHOHUJDXJHVWRPHDVXUHRYHUWKHZKROH
WDSSHWVXUIDFHWKHJDSEHWZHHQWKHPDQGWKHLQERDUGSDG
EDFNSODWH(See Figure 16.) 7KHJDSVKRXOGEHEHWZHHQ
LQPPDQGLQPPIf the gap is
within the range given, the test is complete.
4.0 WHEEL-OFF INSPECTIONS
CAUTION: During these inspections, follow all safe
maintenance practices, including those on page
two of this service manual. Also, follow the vehicle
manufacturer’s recommendations. When working on
foundation brakes, be sure that the vehicle is on level
ground, that the vehicle is parked by other means
than the foundation brakes, and that the wheels are
chocked.
4.0.1 Wheel Removal and Re-Installation
Pull
Caliper
Inboard
5HIHUWRWKHYHKLFOHPDQXIDFWXUHU¶VUHFRPPHQGDWLRQVIRU
UHPRYLQJWKHZKHHO
1RWH:KHQUHPRYLQJWKHZKHHOLQVSHFW¿UVWWRVHHWKDW
WKHUHLVQRFRQWDFWEHWZHHQWKHFDOLSHUDQGD[OHYHKLFOH
FKDVVLVVHFWLRQVRUFDUULHUHWFWKDWPD\EHLPSHGLQJWKH
IUHHPRYHPHQWRIWKHFDOLSHU
WARNING: Not all wheels and valve stems are
compatible with Bendix Air Disc Brakes. Use only
wheels and valve stems approved by the vehicle
manufacturer to avoid risk of valve stem shear and
other compatibility issues. $IWHU UHLQVWDOOLQJ D ZKHHO
DFFRUGLQJWRWKHYHKLFOHPDQXIDFWXUHU¶VUHFRPPHQGDWLRQV
SOHDVHHQVXUHWKDWWKHUHLVVXI¿FLHQWFOHDUDQFHEHWZHHQ
WKHWLUHLQÀDWLRQYDOYHVWHPWKHFDOLSHUDQGWKHZKHHOULP
WRDYRLGGDPDJH
FIGURE 15 - PULL CALIPER INBOARD
Check the clearance at
both tappets simultaneously:
0.024 in. to 0.043 in.
(0.6 mm. to 1.1 mm.)
FIGURE 16 - RUNNING CLEARANCE CHECK
CAUTION: If the clearance is too wide, there is a
danger of brake failure. If the clearance is too small,
or if there is no gap at all, there is a danger of the brake
overheating. These conditions must be corrected
before returning the vehicle to service.
)RUIXUWKHULQYHVWLJDWLRQZKHUHWKHUHLVVRPHJDSJRWR
6HFWLRQDQGFKHFNWKHDGMXVWHUPHFKDQLVP:KHUH
WKHUHLVQRPRYHPHQWDWDOODQGVRQRJDSWRPHDVXUH
JRWR6HFWLRQ³*XLGH3LQ,QVSHFWLRQ´
10
4.2 ADJUSTER MECHANISM INSPECTION
CAUTION: Follow all safe maintenance practices.
Aside from the normal maintenance schedule, the
adjuster mechanism inspection that follows is also
FDUULHGRXWZKHQWKH&DOLSHU0RYHPHQW7HVW¿QGV
that the running clearance is too small or too large.
:LWKWKHVSULQJEUDNHUHOHDVHGRUFDJHGUHPRYH
WKHDGMXVWHUFDSXVLQJWKHWDEWDNLQJFDUHQRW
WRPRYHWKHVKHDUDGDSWHU1RWH2QHRIWZR
VW\OHV RI DGMXVWHU FDS VWDPSHG PHWDO RU SODVWLF
DGMXVWHUFDSPD\EHXVHG
FIGURE 20 - BACKING-OFF (INCREASING) THE RUNNING
CLEARANCE
,IWKHVKHDUDGDSWHUIDLOV\RXPD\DWWHPSWDVHFRQGWLPH
ZLWKDQHZXQXVHGVKHDUDGDSWHU
Note: Always double-check that the spring brake is released
(where applicable) if a shear adapter fails; if this step was
missed, the shear adapter will break off, and it may appear
that the caliper is seized.
,Q FDVHV ZKHUH D VHFRQG IDLOXUH RI WKH VKHDU DGDSWHU
FRQ¿UPV WKDW WKH DGMXVWPHQW PHFKDQLVP LV VHL]HG WKH
FDOLSHUPXVWEHUHSODFHG
Adjuster Cap
Location
FIGURE 17 - ADJUSTER CAP LOCATION
37
Cap
23 Adjuster
61 Adapter
Tab
37
Cap
Tab
FIGURE 18 - EXPLODED VIEW FIGURE 19 - CAP INSTALLED:
OF ADJUSTER AND ADAPTER TAB LOCATION
)RU LOOXVWUDWLRQ SXUSRVHV WKH H[SORGHG YLHZ )LJXUH VKRZVWKHDGMXVWHUDQGVKHDUDGDSWHUVHSDUDWHG
:KHQ XVLQJ WKH DGMXVWHU PHFKDQLVP DOZD\V KDYH WKH
VKHDUDGDSWHULQVWDOOHGRQWKHDGMXVWHU
8VLQJDPPVL[SRLQWER[ZUHQFKWXUQWKH6KHDU
$GDSWHU counter-clockwise DQG OLVWHQ IRU
WKHVRXQGRIFOLFNVDVWKHPHFKDQLVPEDFNVRII
LQFUHDVHV WKH UXQQLQJ FOHDUDQFH 1RWH 'R QRW
XVH DQ RSHQHQGHG ZUHQFK DV WKLV PD\ GDPDJH
WKHDGDSWHUSee Figure 20.
CAUTION: Never turn the adjuster (23) without the
shear adapter (61) installed. The shear adapter is a
safety feature and is designed to prevent excessive
torque from being applied to the adjuster. The shear
adapter will fail (by breaking) if too much torque is
applied.
FIGURE 21 - APPLYING MODERATE APPLICATIONS OF THE
BRAKES: THE WRENCH MOVES CLOCKWISE AS THE RUNNING
CLEARANCE IS DIMINISHED
:KHUHWKHDGMXVWHUPHFKDQLVPLVDEOHWREHEDFNHG
RIIQRUPDOO\SRVLWLRQDER[HQGZUHQFKRQWKHVKHDU
DGDSWHUVRWKDWLWFDQWXUQFORFNZLVHIUHHO\ZLWKRXW
FRPLQJLQWRFRQWDFWZLWKSDUWVRIWKHYHKLFOH(See
Figure 21). 0DNH¿YHWRWHQPRGHUDWHDSSOLFDWLRQV
RIWKHEUDNHV>DWDERXWSVL%[email protected]
WKDW WKH ER[HQG ZUHQFK RU VRFNHW VKRXOG WXUQ
FORFNZLVHLQVPDOOLQFUHPHQWV
127($V WKH QXPEHU RI DSSOLFDWLRQV LQFUHDVHV
WKHWXUQLQJPRYHPHQWZLOOGHFUHDVHDVWKHEUDNH
UHDFKHVLWVQRUPDOFDOLEUDWLRQSRLQW
,IWKHER[HQGZUHQFKGRHVQRWDWXUQDWDOOEWXUQVRQO\
ZLWKWKH¿UVWDSSOLFDWLRQRUFWXUQVIRUZDUGDQGEDFNZDUG
ZLWKHYHU\DSSOLFDWLRQWKHDXWRPDWLFDGMXVWHUKDVIDLOHGDQG
WKHFDOLSHUFDUULHUDVVHPEO\PXVWEHUHSODFHG
$IWHUFRPSOHWLQJWKHVHZKHHORIIWHVWV%HQGL[UHFRPPHQGV
LQVWDOOLQJDQHZDGMXVWHUFDSOLJKWO\JUHDVHGXVLQJZKLWH
OLWKLXPEDVHGJUHDVHZKHQUHWXUQLQJWKHEUDNHWRVHUYLFH
(QVXUHWKDWWKHWDELVLQWKHSRVLWLRQVKRZQLQ)LJXUH
11
4.3- 4.4 BRAKE PADS AND ROTORS
4.3 INSPECT THE BRAKE PADS
CAUTION: Follow all safe maintenance practices.
5HJXODU LQVSHFWLRQ RIWKH EUDNH SDGV HYHQ IRUYHKLFOHV
WKDWXVHDQHOHFWURQLFZHDULQGLFDWRULVDQLPSRUWDQWSDUW
RIYHKLFOHPDLQWHQDQFH
,IHOHFWURQLFZHDUVHQVRUVDUHSUHVHQWsee Section 5.2.
,IGXVWFRYHUVDUHSUHVHQWsee Section 5.1.
See Figure 23. :KLOH SUHVVLQJ GRZQ DJDLQVW WKH SDG
UHWDLQLQJ EDU UHPRYH DQG UHWDLQ WKH FOLS ZDVKHUDQGSLQ5HPRYHWKHSDGUHWDLQHUEDU
%HQGL[UHFRPPHQGVWKDWWKHVHLWHPVVKRXOGEHUHSODFHG
ZLWKQHZ(See available kits and parts, Section 5.0)
)ROORZWKHVWHSVLQ6HFWLRQIRUEDFNLQJRIIWKHDGMXVWHU
PHFKDQLVP 6OLGH WKH FDOLSHU LQERDUG WKHQ RXWERDUG WR
SHUPLWHDV\UHPRYDORIWKHEUDNHSDGV
Brake Rotor
4.3.1 See Figure 22. ,I WKH WKLFNQHVV RI WKH IULFWLRQ
PDWHULDO²GLPHQVLRQ³&´²LVOHVVWKDQLQ
PPWKHSDGVPXVWEHUHSODFHG
Bendix® ADB22X™$'%;9™DLUGLVFEUDNHVXVHLQ
PPEDFNLQJSODWHVVRGLPHQVLRQ³'´WKHFRPELQHG
SDGDQGEDFNLQJSODWHWKLFNQHVVPXVWEHDPLQLPXPRI
LQPP
&KHFN IRU XQHYHQ HQGWRHQG SDG ZHDU ,I WKH
GLIIHUHQFHLQZHDULVJUHDWHUWKDQLQPP
UHSODFHWKHEUDNHSDGVDQGDOVRLQVSHFWWKHJXLGH
SLQV(See Section 4.5)
&RPSDUHWKHWKLFNQHVVRIWKHLQERDUGDQGRXWERDUG
SDGV RI HDFK VHW ,I WKH GLIIHUHQFH EHWZHHQ WKH
LQERDUGDQGRXWERDUGSDGWKLFNQHVVLVJUHDWHUWKDQ
LQ PP UHSODFH WKH EUDNH SDGV DQG
LQVSHFWWKHJXLGHSLQV(See Section 4.5)
Outboard
Brake Pad
Inboard
Brake Pad
,IWKHUHVXOWVRIWKHSDGLQVSHFWLRQVDUHZLWKLQWKHDFFHSWDEOH
UDQJHLQVSHFWWKHSDGVXUIDFH(See Figure 24)
Where a
small amount
of brake
material
chipped from
the edge
Minor Damage Is Acceptable
A
7KLFNQHVVRIDQHZSDGLQPP
B
%DFNLQJSODWHWKLFNQHVVLQPP
C 0LQLPXPWKLFNQHVVRIIULFWLRQPDWHULDOLQ
PP
D 0LQLPXP WKLFNQHVV RI D ZRUQ SDG LQ
PPUHSODFHSDGV
(
7KLFNQHVV RI D QHZ URWRU LQ PP
0LQLPXPURWRUWKLFNQHVVLQPP
FIGURE 22 - PAD AND ROTOR DIMENSIONS
Major Damage Is Not Acceptable
Section
damaged or
missing
See Figure 22 for initial brake pad and rotor dimensions,
as well as minimum acceptable dimensions.
FIGURE 24 - BRAKE PAD SURFACE INSPECTION
0LQRUGDPDJHDWWKHHGJHVLVSHUPLWWHGEXWUHSODFHWKH
SDGVLIPDMRUGDPDJHRQWKHVXUIDFHRIWKHSDGLVIRXQG
:KHQUHSODFLQJEUDNHSDGV%HQGL[VWURQJO\UHFRPPHQGV
WKDWDOOWKHEUDNHSDGVRQDQD[OHEHUHSODFHGDWRQHWLPH
See Section 5.1 for the pad replacement procedure$OVR
VHHWKHYHKLFOHPDQXIDFWXUHU¶VUHFRPPHQGDWLRQVIRXQGLQ
WKHRSHUDWRU¶VPDQXDO
44
Pin
11 Pad Retainer Bar
45 Washer
26 Spring Clip
FIGURE 23 - RETAINER BAR REMOVAL
12
%HQGL[DLUGLVFEUDNHVDUHSUHFLVLRQHQJLQHHUHGEUDNLQJ
PHFKDQLVPV7KH³IULFWLRQFRXSOH´EUDNLQJFKDUDFWHULVWLFV
KDYHEHHQFDUHIXOO\RSWLPL]HG²DQGWKHURWRUGHVLJQDQG
PDWHULDOV KDYH EHHQ PDWFKHG ZLWK VSHFLDO IRUPXODWLRQ
EUDNH SDGV IRU RSWLPDO SHUIRUPDQFH ,Q DOO FDVHV XVH
EUDNHSDGVZLWKWKHW\SHRIEDFNLQJSODWHDQGOLQLQJPDWHULDO
RULJLQDOO\VXSSOLHGE\WKHYHKLFOHPDQXIDFWXUHU
CAUTION: When replacing brake pads and rotors,
use only Bendix® brand replacement pads and rotors
and/or those approved by the OEM. Non-approved
replacement disc pads or rotors can cause excess
wear to brake components, and can increase the risk
of rotors cracking, etc.
4.4 INSPECT THE ROTOR
CAUTION: Follow all safe maintenance practices.
,GHQWLI\LIWKHURWRULVD%HQGL[® 6SOLQHG'LVF®RU%HQGL[®
EUDQGFRQYHQWLRQDOURWRU6ee Section 1.035RWRUVVKRXOG
EHLQVSHFWHGUHJXODUO\(See Section 2.0 for recommended
inspection schedule) and DWHDFKSDGFKDQJH
0HDVXUH WKH WKLFNQHVV RI WKH EUDNH URWRU DW WKH
WKLQQHVWSRLQW'LPHQVLRQ³(´LQ)LJXUH$YRLG
PHDVXULQJ QHDU WKH HGJH RI WKH URWRU DV PLQRU
EXUUVPD\UHVXOWLQLQDFFXUDWHPHDVXUHPHQWFor
Bendix® brand rotors, replace the rotor when
the minimum thickness of 1.46 in. (37 mm.) is
reached. )RURWKHUEUDQGVRIURWRUVUHIHUWRWKH
URWRUPDQXIDFWXUHU¶VJXLGHOLQHV
,QVSHFWWKHURWRUVXUIDFHSee Figure 25. 7KHW\SH
RIURWRUDQGDOVRWKHVL]HGHSWKDQGGLUHFWLRQRI
WKHLPSHUIHFWLRQVPXVWDOOEHFRQVLGHUHG
NOTE: If surface wear conditions F through J are
in the permitted range, the rotor is still usable until
it reaches the minimum acceptable thickness for the
rotor manufacturer’s guideline.
4.4.3 Machining (Grinding or Turning) Rotors
Bendix®EUDQGURWRUVDUHQRUPDOO\VHUYLFHIUHH,QWKHFDVH
RIVHYHUHJURRYLQJRIWKHHQWLUHIULFWLRQVXUIDFHKRZHYHU
CONVENTIONAL ROTORSPD\EHWXUQHGZKHQFKDQJLQJ
SDGVWRLQFUHDVHWKHORDGEHDULQJVXUIDFH
H
F
1R DFWLRQ LV QHHGHG
I R U V P D O O F U D F N V
V S U H D G R Y H U W K H
VXUIDFHHJ$UHD)
Rotor
Friction
Surface
Width “f”
Area
F
Area
H
f
Area G
G
&UDFNVUHDFKLQJ
HLWKHUHGJHRIWKH
URWRU
DUHQRW
DFFHSWDEOH
IRUHLWKHU
W\SHRI
URWRU
‡ )RU standard Bendix® brand rotors
FUDFNV UXQQLQJ LQ D UDGLDO GLUHFWLRQ ²
OLNH VSRNHV RI D ZKHHO VHH $UHD +
²OHVVWKDQ0.06 in. (1.5 mm)GHHSRU
ZLGHDUHDFFHSWDEOHLIWKH\GRQRWUHDFK
HLWKHU HGJH (see G) &UDFNV DUH RQO\
DFFHSWDEOHLIWKHOHQJWKRIWKHFUDFNLV
OHVVWKDQRIGLPHQVLRQ³I´WKHZLGWK
RIWKHURWRUFRQWDFWDUHD
Area J
‡ )RU Bendix ® Splined Disc rotors
UDGLDOFUDFNVDUHRQO\DFFHSWDEOHLIWKH\
DUHOHVVWKDQ0.04 in. (1.0 mm)GHHS
RUZLGHDQGLIWKH\GRQRWUHDFKHLWKHU
HGJH(see G). &UDFNOHQJWKVPXVWEH
OHVV WKDQ RI GLPHQVLRQ ³I´ WKH
ZLGWKRIWKHURWRUFRQWDFWDUHD
J
&LUFXPIHUHQWLDO
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-DUHDFFHSWDEOH
LIOHVVWKDQLQ
PPGHHS
,QDGGLWLRQIROORZWKH
UHFRPPHQGDWLRQVRI
WKHYHKLFOHDQGURWRU
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Note: Axles should
have either all Bendix
Splined Disc (or all
conventional) rotors.
FIGURE 25 - EXAMPLES OF ACCEPTABLE AND NON-ACCEPTABLE ROTOR CONDITIONS
13
MACHINING OF BENDIX® SPLINED DISC® ROTORS IS
NOT PERMITTED.
&$87,21$OZD\VPDLQWDLQDLUGLVFEUDNHSDGVDQGURWRUV
ZLWKLQ VSHFL¿FDWLRQV ([FHVVLYH SDG RU URWRU ZHDU ZLOO
GHJUDGHEUDNLQJSHUIRUPDQFH
1
Caliper
5
9
Inner Boot Guide Pin
7
Brass Bushing
10
Cap
3HULRGLFLQVSHFWLRQRIWKH%HQGL[6SOLQHG'LVFDWWDFKPHQW
KDUGZDUH LV UHFRPPHQGHG WR HQVXUH RSWLPXP EUDNLQJ
SHUIRUPDQFH%HQGL[UHFRPPHQGVYHULI\LQJWKHWRUTXHRQ
WKHVSULQJHOHPHQWIDVWHQHUVZKHQHYHUDEUDNHLQVSHFWLRQ
LVSHUIRUPHG
LONG
BEARING SIDE
WARNING! AFTER MACHINING/TURNING,
THE MINIMUM ROTOR THICKNESS FOR BENDIX®
BRAND ROTORS MUST BE AT LEAST 1.535 - 1.575 IN.
(39 - 40 MM.) - FOR OTHER BRANDS, CONSULT THE
MANUFACTURER’S GUIDELINES. ALSO, CHECK THE
VEHICLE MANUFACTURER’S RECOMMENDATIONS.
FAILURE TO COMPLY MAY RESULT IN BRAKE FAILURE
AND IN SERIOUS INJURY OR DEATH. MACHINING OF
BENDIX SPLINED DISC ROTORS IS NOT PERMITTED.
SHORT
BEARING SIDE
4.4.4 Rotor Replacement
An axle is permitted to have only all Bendix Splined
Disc, or all conventional, rotors.
:KHQUHSODFLQJURWRUVEHVXUHWRDGKHUHWRWKHYHKLFOH
PDQXIDFWXUHU¶VUHFRPPHQGDWLRQVLQFOXGLQJEROWWLJKWHQLQJ
WRUTXHV,WLVUHFRPPHQGHGWRLQVWDOORQO\%HQGL[® brand
URWRUVDQGDOVRWKDWWKHSDGVVKRXOGEHUHSODFHGDVDQ
D[OHVHWDWWKHVDPHWLPH
Non-Bendix® brand rotors.,IDQRQ%HQGLx® brand URWRULV
XVHGFRQ¿UPWKDWLWFRPSOLHVWRWKHYHKLFOHPDQXIDFWXUHU¶V
UHFRPPHQGDWLRQV
6 Guide Sleeve
Outboard
Caliper
Movement
Inboard
39
Caliper Bolt
68
Cap
9 Inner Boot
4 Guide Pin
FIGURE 26 - GUIDE PINS
CAUTION: The use of non-approved brake rotors may
reduce levels of safety and invalidate the warranty.
12 Pad Assembly
1
Carrier
See Section 5.7 for re-installation procedures.
4.5 GUIDE PIN BEARING INSPECTION
CAUTION: Follow all safe maintenance practices.
7KLV JXLGH SLQ LQVSHFWLRQ VKRXOG EH FDUULHG RXW LI WKH
WHFKQLFLDQ FDQQRW PRYH WKH FDOLSHU GXULQJ D &DOLSHU
0RYHPHQW7HVW6HFWLRQVDQGRU
Measure the range of travel along the guide pin
bearings:
5HPRYHWKH3DGV(See Section 4.3)8VLQJKDQG
SUHVVXUHRQO\QRWRROVWKHFDOLSHUVKRXOGVOLGH
IUHHO\DORQJWKHZKROHOHQJWKRIWKHJXLGHSLQV7KLV
PRYHPHQW VKRXOG EH DW OHDVW LQFK PP
ZKHQWKHSDGVDUHQRWSUHVHQW,IWKHPRYHPHQW
LVOHVVWKDQWKLVDPRXQWUHSODFHWKHFDOLSHUFDUULHU
DVVHPEO\
14
Magnetic
Dial-Gauge
Measures
Range Here
2
Caliper
FIGURE 27 - MAGNETIC DIAL-GAUGE IN USE
Measure the “play” (range of movement) in the guide
pin bearings:
See Figures 26 and 27.:LWKWKHZKHHOUHPRYHG
UHPRYH WKH SDG UHWDLQHU EDU 7HPSRUDULO\
UHSODFHWKHSDGVZLWKWZRQHZSDGV$WWDFK
DPDJQHWLFGLDOJDXJHKROGHUWRWKHFDUULHURQ
WKHVKRUWEHDULQJVLGHRIWKHFDOLSHU8VHWKH
PHDVXULQJSRLQWRQWKHFDOLSHUVHHWKHFDOORXW
LQ)LJXUH3UHVVWKHFDOLSHULQWKHGLUHFWLRQRI
WKHFDUULHUDQGVHWWKHGLDOJDXJHWR]HUR
3ODFH D VXLWDEOH WRRO HJ D ODUJH IODWEODGH
VFUHZGULYHUEHWZHHQFDUULHUDQGFDOLSHUDQG
XVHOLJKWKDQGIRUFHWRPRYHWKHFDOLSHUDZD\IURP
WKH FDUULHU XQWLO WKH PRYHPHQW VWRSV 5HDG WKH
PD[LPXPYDOXHRQWKHGLDOJDXJHSee Figure 27.
,I WKH YDOXH LV JUHDWHU WKDQ LQ PP UHSODFH
WKHJXLGHSLQEXVKLQJV(See Section 5.6)25UHSODFHWKH
FDOLSHUFDUULHUDVVHPEO\(See Section 5.3)
Inspect the guide pin inner boots:
See Figures 28 and 29. :LWKWKHSDGVUHPRYHG
VOLGHWKHFDUULHUE\KDQGWRWKHLQERDUGSRVLWLRQ(See
Figure 28)%\ORRNLQJWKURXJKWKHRSHQLQJZKHUH
WKHSDGVDUHLQVWDOOHG²DQGDOVRIURPEHORZ²
LQVSHFWWKHLQQHUERRWIRUHDFKRIWKHJXLGHSLQV
INSPECT FOR DAMAGE, CUTS AND CRACKS.
5HSODFH GDPDJHG ERRWV LPPHGLDWHO\ WR SUHYHQW
GLUWDQGRUPRLVWXUHDIIHFWLQJWKHPRYHPHQWRIWKH
JXLGHSLQV(See Section 5.4)'DPDJHGRUFRUURGHG
JXLGHSLQVZLOOLPSDLUWKHRSHUDWLRQRIWKHEUDNH
,Q DGGLWLRQ GXULQJ LQVWDOODWLRQ WKH ERRWV DUH
FRPSUHVVHGWRPLQLPL]HWKHDPRXQWRIDLUWUDSSHG
ZLWKLQWKHP2EVHUYHDV\RXPRYHWKHFDUULHUEDFN
WRZDUGVWKHRXWERDUGSRVLWLRQWKHERRWVVKRXOGRQO\
H[SDQGRXWZDUGVDVPDOODPRXQWGXHWRWUDSSHG
DLU7KHERRWVVKRXOGQRUPDOO\GXHWRWKHLUULEEHG
FRQVWUXFWLRQFRQWUDFWEDFNLQWRSODFHDVWKHFDOLSHU
PRYHVRQWKHJXLGHSLQV7KHERRWVDUHQRWDLU
WLJKWDQGVRVRPHWUDSSHGDLULVQRUPDOH[FHVVDLU
WUDSSHGZLOOGLVVLSDWH
4.6 TAPPET AND BOOT ASSEMBLY
INSPECTION
,QRUGHUWRLQVSHFWWKHWDSSHWDQGERRWDVVHPEO\
UHPRYHWKHSDGV(See Sections 4.3 or 5.2) and
DGYDQFHWKHVKHDUDGDSWHUFORFNZLVH
CAUTION: NEVER EXTEND THE TAPPET MORE THAN
1.75 in. (44.5 mm). See Figure 29. Over-extending the
tappet will result in the tappet losing engagement with
the synchronizing mechanism. Since the mechanism
can only be set at the manufacturing plant, the caliper/
carrier assembly must be replaced if this happens.
INSPECT THE TAPPET AND BOOT ASSEMBLIES
(13) FOR EVIDENCE OF DAMAGE, CUTS,
CRACKS, TEARS AND EVIDENCE OF
CORROSION, ETC. 'DPDJHGERRWVOHDGWRWKH
SHQHWUDWLRQ RI GLUW DQG PRLVWXUH DQG FDQ OHDG WR
FRUURVLRQ DQG LPSDLU WKH RSHUDWLRQ RI WKH EUDNH
5HSODFHDVQHFHVVDU\(See Section 5.5)
13
Extend LESS THAN
1.75 in. (44.5 mm.)
FIGURE 29 - PERMITTED TAPPET EXTENSION
:KHUHWKHWDSSHWVDQGERRWVSDVVWKHLQVSHFWLRQUHWUDFW
WKHWDSSHWVXVLQJWKHVKHDUDGDSWHU
Inspect
Boot
FIGURE 28 - GUIDE PIN BOOT INSPECTION (THIS IMAGE DOES
NOT SHOW THE CARRIER)
,QVSHFWWKHRULJLQDOSDGV(See Section 4.3)DQGWKH\
PD\EHUHXVHGLIWKH\DUHLQJRRGFRQGLWLRQZLWK
VXI¿FLHQWSDGWKLFNQHVV
:KHQLQVWDOOHGWKHERRWVDUHFRPSUHVVHGWRPLQLPL]HWKH
DPRXQWRIDLUWUDSSHGZLWKLQWKHP2EVHUYHDV\RXPRYH
WKHWDSSHWEDFNXVLQJWKHVKHDUDGDSWHUWKHERRWVVKRXOG
RQO\H[SDQGRXWZDUGVDVPDOODPRXQWGXHWRWUDSSHGDLU
7KHERRWVVKRXOGQRUPDOO\GXHWRWKHLUULEEHGFRQVWUXFWLRQ
FRQWUDFWEDFNLQWRSODFHDVWKHWDSSHWVPRYH1RWH,IWKH
EHOORZV KDYH H[FHVV DLU WUDSSHG WKHQ ZLWK WKH WDSSHWV
UHWUDFWHG UHPRYH DQG UHLQVWDOO WKH DFWXDWRU WR YHQW WKH
H[FHVVWUDSSHGDLU(See Section 5.4).
)ROORZ WKH UHLQVWDOODWLRQ VWHSV IRU WKH EUDNH SDGV (See
Section 5.2)
15
SECTION FIVE: MAINTENANCE KITS AND PROCEDURES
Section Five
Section
Page
0DLQWHQDQFH.LWV 16-17
$LU'LVF%UDNH6KLHOG.LW 19
3DG5HSODFHPHQW 20
&DOLSHU&DUULHU$FWXDWRU$VVHPEO\ 22-23
Type A
(Fixed pin)
(Wheel turns toward
fixed pin side of
Type B
ADB)
Section
Page
6SULQJ6HUYLFH%UDNH 24
7DSSHW%RRWDQG7DSSHW,QQHU6HDO 25-28
*XLGH3LQDQG%RRW$VVHPEOLHV 29-34
%HQGL[®6SOLQHG'LVF®+XE5RWRU 35-37
18/1 Spring Brake
Actuator
44
Pad Retainer Pin
11 Pad Retainer
18/2
Service
Actuator
26 Spring Clip
12/2 Pad Holder Spring
:KHHO5RWDWLRQ
W\SLFDOO\ULJKWKDQG
45
Washer
:KHHO5RWDWLRQ
12/1 Pad
W\SLFDOO\OHIWKDQG
(Pad Assembly
consists of
12/1 plus 12/2)
10
40
Cap
5 Caliper
Guide Bolt
7
Brass
Bushing
Pin
68
Cap
39 Caliper Bolt
22
Inner Seal
Shield
Kit
(Drive or
Steer)
161
Tappet Bushing
13 Tappet
and Boot
Assembly
4 Guide Pin
Actuator
Hardware
61 37*
Shear
Adapter
*37 Adjuster
Caps (2 styles
supplied in kits)
6 Guide Sleeve
Carrier
Mounting
Hardware
1
Caliper
(or Caliper Kit)
U-shaped Rotor
9
58 Inner Boot
Ring
Bendix® ADB22X™
Anchor Plate
2A
Bendix®
ADB 22X™
Carrier
(Rotor Shield for Trailers)
U-shaped
Rotor
Fasteners
2B
Bendix®
ADB 22X-V™
Carrier
SD-1
Drive Hub
SD-2
®
SD-3
Splined Disc® Rotor
(SD)
Splined Disc Rotor
Hardware
SD-1, -2, -3
See Section 5.2 for
exploded view of electronic
wear indicator.
Steer Hub
FIGURE 30 - EXPLODED VIEW - BENDIX® ADB22X ™ AND ADB22X-V ™ AIR DISC BRAKES
16
Bendix®
ADB22X-V™
Anchor Plate
Carrier
Mounting
Hardware
5.0 MAINTENANCE KITS
%HORZLVDOLVWRIVRPHRIWKHDYDLODEOHNLWVSee Figure 30 for an exploded view showing the components listed.
Kit
See Section
Piece
Number
803129
7UDLOHU$[OH3DG5RWRU6KLHOG.LW
Dust Shields
6HFWLRQ
803130
'ULYH$[OH3DG5RWRU6KLHOG.LW
802948
6WHHU$[OH3DG6KLHOG.LW
802078
3DGUHWDLQHUEDUVVHWRIIRXUSDGVDQGKROGHUVSULQJVDGMXVWHUFDSVSDGUHWDLQHU
SLQVZDVKHUVVKHDUDGDSWHUV
6HFWLRQ
Pad Kit (axle set)
Components Included in Kit
Spring Clip Kit (box of 25)
NA
803151
6SULQJFOLSV
Shear Adapter (box of 10)
NA
802455
6KHDUDGDSWHUV
Tappet/Boot Kit (wheel end kit)
6HFWLRQ
802119
7DSSHWDQGERRWDVVHPEO\WDSSHWEXVKLQJLQQHUVHDO
Adjuster Cap
(kit has ten each of two styles)
NA
802643
$GMXVWHUFDSV
Guide Pin, Seal and Boot Kit
(wheel end kit)
6HFWLRQ
803114
5LQJLQQHUERRWEUDVVEXVKLQJJXLGHSLQFDOLSHUEROWFDSJXLGHVOHHYH
JXLGHSLQFDOLSHUEROWFDS
Guide Pin Grease
NA
6HFWLRQ
Service Actuator
6HFWLRQ
Spring Brake Actuator
Caliper Kit
(rationalized)
Includes 803114 kit shown above
Carrier Kit
6HFWLRQ
6HFWLRQV
Caliper/Carrier Kit
14525
:KLWHJUDPV
.
Bendix®7\SH8QLYHUVDO>[email protected]
.
Bendix®7\SH8QLYHUVDO>[email protected]
.
Bendix®7\SH8QLYHUVDO>[email protected]
.
Bendix®7\SH8QLYHUVDO>[email protected]
.
Bendix®7\SH3LVWRQ6W\OH7UXFN7UDLOHU8QLYHUVDO>[email protected]
.
Bendix®7\SH3LVWRQ6W\OH7UXFN7UDLOHU8QLYHUVDO>[email protected]
.
Bendix®7\SH3LVWRQ6W\OH7UXFN7UDLOHU8QLYHUVDO>[email protected]
.
Bendix®7\SH'RXEOH'LDSKUDJP6W\OH7UDLOHU8QLYHUVDO>6SULQJEUDNHDFWXDWRUDFWXDWRU
[email protected]
.
6WHHUDQG'ULYH$[OH$>&[email protected]
.
6WHHUDQG'ULYH$[OH%>&[email protected]
.
7UDLOHU$[OH$>&[email protected]
.
7UDLOHU$[OH%>&[email protected]
.
Steer and Drive Axle, Axial5LQJLQQHUERRWFDOLSHUEROWFDSVKHDUDGDSWHU
DGMXVWHUFDSV$'%;FDUULHUFRPSOHWHFDOLSHUEROWFDS
.
Trailer Axle, Axial5LQJLQQHUERRWFDOLSHUEROWFDSVKHDUDGDSWHUDGMXVWHU
FDSV$'%;FDUULHUFRPSOHWHFDOLSHUEROWFDS
.
Steer and Drive Axle, Vertical5LQJLQQHUERRWFDOLSHUEROWFDSVKHDUDGDSWHU
DGMXVWHUFDSV$'%;9FDUULHUFRPSOHWHFDOLSHUEROWFDS
802090
6WHHUDQG'ULYH$[LDO³$´$
809091
6WHHUDQG'ULYH$[LDO³%´$
802984
7UDLOHU$[LDO³$´$
802985
.
6HFWLRQ
Hubs
:KLWHJUDPV
.
7UDLOHU$[LDO³%´$
6WHHUDQG'ULYH9HUWLFDO³$´%
.
6WHHUDQG'ULYH9HUWLFDO³%´%
.
6SOLQHG'LVF®%UDNH$OXPLQXP))6WHHU/06%HDULQJ3DFNDJH+XE
803134
6SOLQHG'LVF®%UDNH$OXPLQXP)/6WHHU/06%HDULQJ3DFNDJH+XE
802847
6SOLQHG'LVF®%UDNH$OXPLQXP5'ULYH/06%HDULQJ3DFNDJH+XE
.
6SOLQHG'LVF®%UDNH$OXPLQXP))6WHHU6WDQGDUG%HDULQJ3DFNDJH+XE
803138
6SOLQHG'LVF®%UDNH$OXPLQXP)/6WHHU6WDQGDUG%HDULQJ3DFNDJH+XE
802859
6SOLQHG'LVF®%UDNH$OXPLQXP5'ULYH6WDQGDUG%HDULQJ3DFNDJH+XE
.
6SOLQHG'LVF®$OXPLQXP717UDLOHU6WDQGDUGEHDULQJSDFNDJH+XE
.
6SOLQHG'LVF®$OXPLQXP737UDLOHU6WDQGDUGEHDULQJSDFNDJH+XE
8VKDSHG,URQ$OXPLQXP/066WDQGDUG%HDULQJ3DFNDJHV
6HHKXE
VXSSOLHUIRU
WKHVHLWHPV )ODW,URQ$OXPLQXP/066WDQGDUG%HDULQJ3DFNDJHV
Splined Disc® Rotor Attaching Kit
6HFWLRQ
6HFWLRQ
Rotor
.
$OO6SOLQHG'LVF®5RWRU$SSOLFDWLRQV6SOLQHG'LVF5RWRUKDUGZDUHNLW6'DQG
802081
PP8VKDSHG5RWRUIDVWHQHUV
802082
PP8VKDSHG5RWRUIDVWHQHUV
802083
6HYHUH'XW\6SOLQHG'LVF.LW6SOLQHG'LVF5RWRU6'DQGKDUGZDUHNLW6'DQG
802569
+HDY\'XW\6SOLQHG'LVF.LW6SOLQHG'LVF5RWRUDQGKDUGZDUHNLW6'DQG
* Universal Replacement with standard bearing configuration and long studs. Contact 1-800-AIR-BRAKE if identification assistance is required.
TABLE 2 - MAINTENANCE KITS
17
5.0.1 GENERAL INFORMATION ABOUT
BENDIX® AIR DISC BRAKE MAINTENANCE
‡
:KHQ UHSODFLQJ EHDULQJV ² RU IRU DQ\ RWKHU
PDLQWHQDQFHSURFHGXUHZKHUHWKHWHFKQLFLDQQHHGV
WRUHPRYHWKHFDOLSHUFDUULHUDVVHPEO\IURPWKHYHKLFOH
WRSHUIRUPWKHPDLQWHQDQFH²replacement caliper/
carrier bolts will be required.3OHDVHQRWHWKDWGXH
WRWKHKLJKWRUTXHUHTXLUHGWKHRULJLQDOEROWVFDQQRW
EHUHXVHG7KHEROWVDUHDYDLODEOHIURPWKHYHKLFOH
PDQXIDFWXUHU
‡
WARNING: Not all wheels and valve stems are
compatible with Bendix Air Disc Brakes. Use only
wheels and valve stems approved by the vehicle
manufacturer to avoid risk of valve stem shear and
other compatibility issues.
:KHQ ZRUNLQJ RQ %HQGL[®$LU 'LVF EUDNHV SOHDVH QRWH
WKHIROORZLQJ
‡
5HDGDQGIROORZWKH6DIH0DLQWHQDQFH3UDFWLFHVRQ
SDJHWZR
‡
'HSHQGLQJRQWKHSDUWLFXODUD[OHWKHWHFKQLFLDQPD\
QHHGWRUHPRYHWKHFDOLSHUFDUULHUWRDOORZVXI¿FLHQW
DFFHVVWRSHUIRUPWKHZRUN
‡
CAUTION: When using a hoist to support the air
disc brake, do not attempt to use the pad retainer
bar as a bracing point as it is not designed to
support the weight of the brake. Use instead a
brace (or chain) wrapped around the entire brake
to attach the hoist.
Kit
See
Section
5.0.2 SERVICE DVD
2UGHU SDUW QXPEHU BW7356 IRU D '9' VKRZLQJ WKH IXOO
VHW RI PDLQWHQDQFH SURFHGXUHV LQFOXGHG LQ WKLV 6HUYLFH
'DWDVKHHW
Remove
Brake Pads?
Section 5.2
Remove Caliper/
Carrier from
Vehicle?
Remove
Actuator from
Caliper?
Section 5.3
Section 5.4
'XVW6KLHOGV
6HFWLRQ
1RW7\SLFDOO\
NA
NA
3DG.LWD[OHVHW
6HFWLRQ
Yes
1R
1R
&DOLSHU.LWUDWLRQDOL]HG
6HFWLRQ
Yes
Yes
Yes
&DUULHU.LW
6HFWLRQ
Yes
Yes
Yes
6HUYLFH$FWXDWRU
6HFWLRQ
1R
1RW7\SLFDOO\
Yes
6SULQJ%UDNH$FWXDWRU
6HFWLRQ
1R
1RW7\SLFDOO\
Yes
7DSSHW%RRW.LWZKHHOHQGNLW
6HFWLRQ
Yes
7\SLFDOO\
7\SLFDOO\
*XLGH3LQ6HDODQG%RRW.LWZKHHOHQGNLW
6HFWLRQ
Yes
7\SLFDOO\
7\SLFDOO\
Hubs
6HFWLRQ
Yes
Yes
Yes
6SOLQHG'LVF®5RWRU$WWDFKLQJ.LW
6HFWLRQ
Yes
Yes
Yes
5RWRU
6HFWLRQ
Yes
Yes
Yes
TABLE 3 - OTHER REQUIRED SECTIONS FOR MAINTENANCE KITS
18
5.1 AIR DISC BRAKE SHIELD KIT
CAUTION: Follow all safe maintenance
practices, including those listed on page two of
this document. Park the vehicle (by other means
than the foundation brakes) on level ground and
chock the wheels.
Note: Most torque plates manufactured after January 1,
2007 have the required torque plate tabs to permit these
shields to be mounted.
5HPRYH DQG GLVFDUG WKH VSULQJ FOLS DQG ZDVKHU
IURPWKHSDGUHWDLQHUSLQ5HPRYHDQGUHWDLQWKH
UHWDLQHUEDUDQGUHWDLQHUSLQ3RVLWLRQWKHSDGVKLHOG
DV VKRZQ DQG UHLQVHUW WKH UHWDLQHU EDU ,QVWDOO
WKHUHWDLQHUSLQ8VHWKHLQFOXGHGVSULQJFOLSDQG
ZDVKHUWRVHFXUHWKHUHWDLQHUSLQ&KHFNWKDWWKH
SDGVKLHOGLVKHOGVHFXUHO\LQSODFHE\WKHUHWDLQHU
EDUSee Figures 31 or 32.
Spring
Clip
Washer
7KLVVKLHOGNLWLQFOXGHVDEUDNHSDGVKLHOGDURWRUVKLHOG
DQG WKH UHTXLUHG DWWDFKLQJ KDUGZDUH IRU XVH LQ %HQGL[®
ADB22X™ and ADB22X-V™ $LU 'LVF %UDNH DSSOLFDWLRQV
ZKHUHH[WHUQDOFRQWDPLQDWLRQDQGH[FHVVLYHURDGGHEULVLV
DFRQFHUQ%UDNHSDGDQGURWRUVKLHOGVFDQJUHDWO\UHGXFH
GDPDJHDQGRUSUHPDWXUHZHDURISDGVDQGURWRUVXQGHU
WKHVHFRQGLWLRQV
Pad Shield
'XULQJ LQVWDOODWLRQ YHULI\ WKDW RQFH WKH VKLHOGV DUH
LQVWDOOHGWKH\ZLOOQRWFRPHLQWRFRQWDFWZLWKDQ\YHKLFOH
FRPSRQHQWVVXVSHQVLRQKRXVLQJVHWFWKURXJKWKHIXOO
UDQJHRIPRWLRQRIWKHZKHHO.HHSLQPLQGWKHSDUWLFXODU
XVHRIWKHYHKLFOHWKHRULHQWDWLRQRIWKHEUDNHRQWKHD[OH
DQGWRUTXHSODWHWKHSUR[LPLW\RIRWKHUD[OHVDQGRUWKH
ZKHHOWLUHEHLQJXVHG
Rotor Shield
Torque
Plate
Fastener
Washer
Spring
Clip
(with Washer)
Fastener
Lock
Washer
Rotor
Shield
Pad Shield
FIGURE 32 - TRAILER AXLE EXPLODED VIEW WITH INSET
SHOWING ROTOR SHIELD INSTALLATION
Drive or Steer Axle Rotor Shields (See Figure
31 3RVLWLRQ WKH URWRU VKLHOG between the torque
plate and the rotor 7KH VXSSOLHG FDS VFUHZV
SDVVWKURXJKWKHPRXQWLQJWDEVLQWKHWRUTXHSODWH
DQGLQVWDOOLQWRWKHVKLHOG7RUTXHFDSVFUHZVWR
)W/EVLQOEV
Rotor Shield
Fastener
Torque
Plate
Fastener
Rotor Shield
FIGURE 31 - DRIVE OR STEER AXLE EXPLODED VIEW WITH
INSET SHOWING ROTOR SHIELD INSTALLATION
Trailer Axle Rotor Shields (See Figure 32
3RVLWLRQ WKH URWRU VKLHOG ZLWK the torque plate
between the shield and the rotor :LWK RQH
VXSSOLHGORFNZDVKHULQSODFHRQHDFKFDSVFUHZ
SDVVWKHVFUHZVWKURXJKWKHVKLHOGEHIRUHPRXQWLQJ
RQWRWKHWKUHDGHGWRUTXHSODWHKROHV7RUTXHWKH
FDSVFUHZVWR)W/EVLQOEV
Note: The installation of air disc brake shields does not
eliminate the need for periodic maintenance and inspection
of the air disc brake and entire wheel end for damage and/
or wear. In addition, the truck and trailer manufacturer’s
VSHFL¿F FULWHULD IRU WKH EUDNH VKLHOG UHTXLUHPHQWV RQ DLU
disc brakes should be consulted before either installing or
removing air disc brake shields from a wheel end(s).
19
5.2 PAD REPLACEMENT
CAUTION: Follow all safe maintenance
practices, including those listed on page two of
this document. Park the vehicle (by other means
than the foundation brakes) on level ground and
chock the wheels.
7KH%HQGL['9'%:VKRZVWKLVSURFHGXUH
Important: If the vehicle is equipped with spring brakes,
cage the spring brakes on all axles to be worked on.
Consult the vehicle manufacturer’s instructions as
necessary. For Bendix piston-style, see Section 5.4.
ELECTRONIC WEAR
104
SENSOR
(if installed) Cable Protection
Plate
101
Sensor
101
Sensor
DQG UHWDLQ WKH PRXQWLQJ KDUGZDUH IRU WKH FDEOH
SURWHFWLRQ SODWH 7KH FDEOH SURWHFWLRQ SODWH FDQ
WKHQEHVHWDVLGHZKLOHVHUYLFLQJWKHSDGV1RWHWKH
SRVLWLRQRIWKHVHQVRUVLQWKHEUDNHSDGFKDQQHOV
DQGFDUHIXOO\UHPRYHWKHP,QPRVWFDVHV\RXGR
QRWQHHGWRUHOHDVHWKHFDEOHFRQQHFWRULQRUGHUWR
PRYHWKHVHQVRUVDZD\IURPWKHSDGLQVWDOODWLRQ
ZRUNDUHD,QVSHFWWKHZHDUVHQVRUVUHSODFHLI
GDPDJHGRUDEUDGHG
See Figure 34. 5HPRYH DQG GLVFDUG WKH SLQ
UHWHQWLRQFOLSDQGZDVKHU
105
Cable Guide
(2 alternate
designs used)
44
Pin
11 Pad Retainer Bar
45 Washer
103
Cable to Electrical
Supply
26 Spring Clip
FIGURE 34 - PAD RETAINER BAR REMOVAL
44
:KLOH SUHVVLQJ DJDLQVW WKH SDG KROG GRZQ EDU
UHPRYHWKHSDGUHWDLQHUEDUSLQ'LVFDUGWKH
KROGGRZQEDU
45
11
26
2
DUG
WER
2X
12
G
RDU
,QE
:LWKWKHVSULQJEUDNHUHOHDVHGRUFDJHGUHPRYH
WKHDGMXVWHUFDSXVLQJWKHWDEWDNLQJFDUHQRW
WRPRYHWKHVKHDUDGDSWHU1RWH7ZRVL]HV
RIDGMXVWHUFDSDUHVXSSOLHGLQNLWVXVHWKHVDPH
VL]HDVEHIRUHLQVWHS
,QVSHFW WKH VKHDU DGDSWHU ,I VLJQLILFDQW
FRUURVLRQ DQGRU GDPDJH LV SUHVHQW UHPRYH WKH
DGMXVWHU DGDSWHU XVLQJ QHHGOHQRVH SOLHUV DQG
UHSODFH ZLWK WKH DGDSWHU VXSSOLHG LQ WKH NLW DQG
FOHDQDVQHFHVVDU\
37
Cap
23 Adjuster
61 Adapter
37
61
FIGURE 33 - PAD REPLACEMENT
5DLVHWKHFRPSOHWHD[OHWREHZRUNHGRQXQWLOWKH
WLUHVFOHDUWKHJURXQG6HHWKHYHKLFOHPDLQWHQDQFH
PDQXDOLQVWUXFWLRQVIRUUHPRYLQJWKHZKHHOV
,IWKHDLUGLVFEUDNHLVHTXLSSHGZLWKDQHOHFWURQLF
ZHDUVHQVRULQGLFDWRU(see top of Figure 33)UHPRYH
20
Tab
37
Cap
Tab
FIGURE 35 - EXPLODED VIEW FIGURE 36 - CAP INSTALLED:
OF ADJUSTER AND ADAPTER TAB LOCATION
)RU LOOXVWUDWLRQ SXUSRVHV WKH H[SORGHG YLHZ )LJXUH VKRZVWKHDGMXVWHUDQGVKHDUDGDSWHUVHSDUDWHG
:KHQ XVLQJ WKH DGMXVWHU PHFKDQLVP DOZD\V KDYH WKH
VKHDUDGDSWHULQVWDOOHGRQWKHDGMXVWHU
CAUTION: Never turn the adjuster (23) without the
shear adapter (61) installed. The shear adapter is a
safety feature and is designed to prevent too much
torque being applied. The shear adapter will fail (by
breaking) if too much torque is used.
Note: For wheel-ends with spring brakes, if a shear adapter
fails, always double-check to verify that the spring brake
has been released (or caged). If the spring brake is applied,
release or cage the brake (assure that the air system
pressure is at least 90 PSI) and start the procedure again.
,IWKHVKHDUDGDSWHUIDLOV\RXPD\DWWHPSWDVHFRQGWLPH
ZLWK D QHZ XQXVHG VKHDU DGDSWHU ,Q FDVHV ZKHUH D
VHFRQG IDLOXUH RI WKH VKHDU DGDSWHU FRQ¿UPV WKDW WKH
DGMXVWPHQW PHFKDQLVP LV VHL]HG WKH FDOLSHU PXVW EH
UHSODFHG
8VHDPPVL[SRLQWER[ZUHQFK(See Figure 37)
WRWXUQWKHDGMXVWHUFRXQWHUFORFNZLVHXQWLOVXI¿FLHQW
VSDFHH[LVWVWRUHPRYHWKHEUDNHSDGV$FOLFNLQJ
QRLVHRFFXUVHDFKWLPHWKHDGMXVWHUWXUQV
CAUTION! Avoid overloading or damaging the adjuster
shaft. Do not use an open-ended wrench since it may
damage the adjuster shaft.
8VHWKHVHWZRLQVSHFWLRQV
$ &KHFN IRU XQHYHQ HQGWRHQG SDG ZHDU ,I
WKHGLIIHUHQFHLQZHDULVJUHDWHUWKDQLQ
PPUHSODFHWKHEUDNHSDGVDQGDOVRLQVSHFW
WKHJXLGHSLQV(See Section 4.5)
% &RPSDUH WKH WKLFNQHVV RI WKH LQERDUG DQG
RXWERDUG SDGV RI HDFK VHW ,I WKH GLIIHUHQFH
EHWZHHQWKHLQERDUGDQGRXWERDUGSDGWKLFNQHVV
LVJUHDWHUWKDQLQPPUHSODFHWKH
EUDNH SDGV DQG LQVSHFW WKH JXLGH SLQV (See
Section 4.5)
,QVSHFWWKH%UDNH5RWRU(See Section 4.4).
,QVSHFWWKHJXLGHSLQV(See Section 4.5)
Important: To maintain optimal braking, Bendix
strongly recommends that whenever brake pads
are replaced, the complete axle set be replaced
together. Use only pads which are permitted by the
vehicle manufacturer, axle manufacturer, and/or disc
brake manufacturer. Failure to comply with this may
invalidate the vehicle manufacturer’s warranty.
Before installing the brake pads, use the adjuster to
fully retract the tappets to provide adequate clearance.
&OHDQWKHVXUIDFHVWKDWZLOOFRPHLQFRQWDFWZLWK
WKHEUDNHSDG
Caution: When installing pads and retaining springs,
where appropriate, use heavy duty gloves and always
NHHS¿QJHUVDZD\IURPSRWHQWLDOSLQFKKD]DUGDUHDV
2
FIGURE 37 - BACKING OFF THE ADJUSTER FOR PAD REMOVAL
G
RDU
,QE
DUG
WER
X
2
12
FIGURE 39 - PAD RETAINING SPRING INSTALLATION
Inboard Pad
FIGURE 38 - PAD REMOVAL
See Figure 38.0RYHWKHFDOLSHUIXOO\LQZDUGDQG
UHPRYHWKHLQERDUGSDGWKHQPRYHWKHFDOLSHUIXOO\
RXWZDUGDQGUHPRYHWKHRXWERDUGSDG
5HSHDW WKH SDG UHPRYDO SURFHGXUH IRU WKH RWKHU
HQGRIWKHD[OH
7R FRQ¿UP WKDW WKH JXLGH SLQV DUH VOLGLQJ IUHHO\
H[DPLQHWKHSDGVMXVWUHPRYHGIRUXQHYHQZHDU
,QVWDOOWKHSDGUHWDLQLQJVSULQJVRQWRWKHEUDNH
SDGV E\ LQVHUWLQJ RQH HQG RI WKH VSULQJ RQWR
WKHOXJDWWKHWRSRIWKHEUDNHSDG (See Figure 39).
&DUHIXOO\DSSO\HQRXJKIRUFHWRSHUPLWWKHVHFRQG
OXJWRIXOO\HQJDJHWDNLQJFDUHWRNHHS¿QJHUVHWF
DZD\IURPWKHVSULQJDVLWVHDWV
3XOOWKHFDOLSHUIXOO\RXWZDUGDQGLQVWDOOWKHRXWERDUG
SDG0RYHWKHFDOLSHUIXOO\LQZDUGDQGLQVWDOOWKH
LQERDUGSDG
7R UHLQVWDOO ZHDU LQGLFDWRUV LI XVHG ,QVHUW WKH
ZHDU VHQVRUV LQWR SRVLWLRQ LQ WKH QHZ EUDNH
SDGV5RXWHWKHVHQVRUFDEOHWKURXJKWKHFDEOH
SURWHFWLRQSODWHFKDQQHODQGVHFXUHWKHSODWHZLWK
WKH PRXQWLQJ KDUGZDUH UHWDLQHG DW GLVDVVHPEO\
(See Section 5.2.)
21
5.3 CALIPER/CARRIER/ACTUATOR
ASSEMBLY
CAUTION: Follow all safe maintenance practices,
including those listed on page two of this document.
Park the vehicle (by other means than the foundation
brakes) on level ground and chock the wheels.
FIGURE 40 - RUNNING CLEARANCE ADJUSTMENT
8VLQJDPPVL[SRLQWER[ZUHQFKWXUQWKH6KHDU
$GDSWHUclockwise XQWLOWKHSDGVFRQWDFWWKH
URWRU1RWH'RQRWXVHDQRSHQHQGHGZUHQFKDV
WKLVPD\GDPDJHWKHDGDSWHU(See Figure 40)
8VLQJWKHVDPHWRROWXUQWKH6KHDU$GDSWHU
counter-clockwise DQG OLVWHQ IRU WKH VRXQG RI FOLFNVDVWKHPHFKDQLVPEDFNVRIILQFUHDVHVWKH
UXQQLQJFOHDUDQFH(See Figure 37).
6HOHFWWKHFRUUHFWUHSODFHPHQWDGMXVWHUFDSIURP
WKRVHVXSSOLHGZLWKWKHNLW/LJKWO\JUHDVHDGMXVWHU
FDSZLWK5HQROLW+/7ZKLWHJUHDVHSDUWQXPEHU
DQGLQVWDOOWKHFDS
3XVKWKHQHZSDGUHWDLQHUEDULQWRWKHJURRYH
RIWKHFDOLSHU3UHVVGRZQRQWKHSDGUHWDLQHUEDU
DQG LQVHUW WKH SDG UHWDLQHU SLQ ZLWK WKH SLQ
SRLQWLQJ GRZQZDUGV ZKHUH SRVVLEOH ,QVWDOO WKH
VXSSOLHGZDVKHUDQGWKHQWKHVSULQJFOLS
(See Figure 34).
$SSO\ DQG UHOHDVH WKH EUDNHV 7KH KXE VKRXOG
WXUQHDVLO\E\KDQGDIWHUDSSO\LQJDQGUHOHDVLQJWKH
EUDNH
CAUTION: When using a hoist to support the air disc
brake, do not attempt to use the pad retainer bar as a
bracing point. It is not designed to support the weight
of the brake. Use instead a brace (or chain) wrapped
around the entire brake to attach the hoist.
,Q DOO FDVHV FKHFN WKDW WKH FXUUHQW KRVH URXWLQJ
DUUDQJHPHQWGRHVQRWUHVWULFWWKHIXOOWUDYHORIWKH
FDOLSHUEHIRUHEHJLQQLQJZRUNRQWKHDVVHPEO\
5HPRYHWKHEUDNHSDGV(See Section 5.2).
(See Section 5.4). ,IWKHDFWXDWRUXVHGLVDVSULQJ
EUDNHIROORZLQJWKHPDQXIDFWXUHU¶VJXLGHOLQHVFDJH
WKHVSULQJ:LWKDOODLUSUHVVXUHGUDLQHGIURPWKH
V\VWHP GLVFRQQHFW WKH DLU KRVHV IURP WKH EUDNH
FKDPEHU
Vertical Mounting Bolt Style
Caliper/Carrier Assembly (Showing
Spring Brake Actuator )
Alignment
Bushing
Anchor Plate/
Torque Plate
5HFKHFN WKH UXQQLQJ FOHDUDQFH 5HDGMXVW LI
QHFHVVDU\
5HLQVWDOO WKHZKHHOIROORZLQJ WKHYHKLFOHPDQXDO
LQVWUXFWLRQV
WARNING!
The brake pads and rotor must be maintained within
the recommended wear limits. Failure to monitor wear
and replace the brake pads and rotor when required
may result in diminished brake performance.
Alignment
Bushing
Mounting Bolts
(6 total - washers
not required)
FIGURE 41 - VERTICAL MOUNT CALIPER/CARRIER
See Figure 41.6XSSRUWLQJWKHDLUGLVFEUDNHE\
QHFHVVDU\ PHDQV UHPRYH WKH VL[ PRXQWLQJ
EROWVZDVKHUVDQGGLVFDUG1RWH%HQGL[VWURQJO\
UHFRPPHQGVWKDWGXULQJUHDVVHPEO\WKHVHEROWV
DUH UHSODFHG VHH \RXU YHKLFOH PDQXIDFWXUHU IRU
UHSODFHPHQWKDUGZDUH/LIWWKHFDOLSHUXSRIIWKH
DQFKRUSODWH
7KHYHUWLFDOEROWDVVHPEO\LQFOXGHVDQDOLJQPHQWEXVKLQJ
This bushing must be saved for re-use during reassembly of the brake.7KHEXVKLQJPRXQWVLQWKHWRUTXH
SODWH DQG PDLQWDLQV WKH FRUUHFW DOLJQPHQW RI WKH EUDNH
DVVHPEO\UHODWLYHWRWKHURWRU
22
,IWKHEUDNHDVVHPEO\GRHVQRWVHSDUDWHIURPWKH
DQFKRUSODWHLWPD\EHKHOSIXOWRLQVWDOODQ0;
VFUHZORQJHUWKDQPPDWWKHEXVKLQJORFDWLRQV
DQGWDSWKHHQGRIWKHEROWZLWKDKDPPHUWRIUHH
WKHEUDNHDVVHPEO\5HPRYHWKHDVVHPEO\
Caliper/Carrier
Assembly
(Actuator not
shown)
Axial Mounting Bolt Style
Mounting Bolts
and Washers
(6 sets total)
'LVFRQQHFWWKHDLUKRVHVWRWKHEUDNHFKDPEHU
See Figure 42.6XSSRUWLQJWKHDLUGLVFEUDNHE\
QHFHVVDU\PHDQVUHPRYHWKHVL[EROWVDWWDFKLQJ
WKH EUDNH WR WKH DQFKRU SODWH DQG UHPRYH WKH
FDOLSHUFDUULHUDVVHPEO\IURPWKHYHKLFOH
Note: Bendix strongly recommends that during re-assembly
these bolts and washers are replaced. See your vehicle
manufacturer for replacement hardware. Remove the
assembly.
Anchor Plate/
Torque Plate
Re-installation (Both Styles)
6XSSRUWLQJWKHDLUGLVFEUDNHE\QHFHVVDU\PHDQV
DWWDFK WKH EUDNH WR WKH DQFKRU SODWH XVLQJ VL[
QHZ EROWV 7RUTXH WR YHKLFOH PDQXIDFWXUHU¶V
VSHFL¿FDWLRQV,IWRUTXHYDOXHVDQGEROWVDUHQRW
VSHFL¿HGE\WKHYHKLFOHPDQXIDFWXUHUWKHQVHOHFW
DUHSODFHPHQWEROWDVVKRZQLQ7DEOH
FIGURE 42 - AXIAL MOUNT CALIPER/CARRIER
5HLQVWDOOWKHDLUKRVHV(See Section 5.4.8-9) and
check for leaks
,QVSHFWDQGUHLQVWDOOWKHSDGV(See Section 5.2)
$LU'LVF%UDNH$WWDFKPHQW+DUGZDUH
7RUTXH3ODWH0DQXIDFWXUHU
%HQGL[$[LDO
&DUULHU7RUTXH3ODWH
)DVWHQHU
)DVWHQHU0[[PP&ODVV
Washer: Requires HARDENED 3 mm
(minimum thickness) for each bolt.1
If the vehicle is using a Bendix
manufactured Axial Anchor Plate, with a
thickness of 1.14 in. (29 mm) where these
bolts are assembled, then a bolt with an
overall length of 2.36 in. (60 mm) will meet
these requirements
7RUTXH
8VHWKHPDQXIDFWXUHU¶VUHFRPPHQGDWLRQV
,IXQDYDLODEOHXVHSKRVSKDWH
DQGRLO¿QLVKIDVWHQHU
3UH7RUTXHIWOEI>1Â[email protected]
)LQDO7RUTXHIWOEI>1Â[email protected]
%HQGL[9HUWLFDO
&DUULHU7RUTXH3ODWH
)DVWHQHU0[[PP&ODVV
Washer: None required.
8VHWKHPDQXIDFWXUHU¶VUHFRPPHQGDWLRQV
,IXQDYDLODEOHXVHSODLQDQGRLO¿QLVKIDVWHQHU
7RUTXHIWOEI>1Â[email protected]
)DVWHQHU0[[/&ODVV
7UDLOHU7RUTXH3ODWH
/HQJWKGHWHUPLQDWLRQ
8VHWKHPDQXIDFWXUHU¶VUHFRPPHQGDWLRQV
/ 7RUTXH3ODWH73WKLFNQHVV&DUULHU
HQJDJHPHQW:DVKHUWKLFNQHVV
,IXQDYDLODEOHXVHSKRVSKDWH
DQGRLO¿QLVKIDVWHQHU
LPLQ 73WKLFNQHVVPPPP
3UH7RUTXHIWOEI>1Â[email protected]
LPD[ 73WKLFNQHVVPPPP
)LQDO7RUTXHIWOEI>1Â[email protected]
Washer: Requires HARDENED 3 mm
(minimum thickness) for each bolt.1
Table Note: 1. The washer outside diameter must be less than 1.1in. (28.5 mm).
TABLE 4 - TORQUE PLATE FASTENERS AND TORQUE RECOMMENDATIONS (SEE MANUFACTURER’S RECOMMENDATIONS)
23
5.4
SPRING OR SERVICE BRAKE
CAUTION: Follow all safe maintenance
practices, including those listed on page two of
this document. Park the vehicle (by other means
than the foundation brakes) on level ground and
chock the wheels.
Use the spring brake manufacturer’s recommended safety practices in all cases.
6RPH VSULQJ EUDNH DQG YHKLFOH PDQXIDFWXUHUV
SHUPLW FDJLQJ WKH VSULQJ EUDNH ZKLOH WKH VSULQJ
EUDNHLVHQJDJHG
THE FOLLOWING INSTRUCTIONS ARE FOR BENDIX®
BRAND PISTON-STYLE ACTUATORS.
:LWKWKHYHKLFOHRQDOHYHOVXUIDFHDQGWKHZKHHOV
SURSHUO\ FKRFNHG DSSO\ DLU WR UHOHDVH WKH VSULQJ
EUDNHVSDUNLQJEUDNHVE\XVLQJWKHGDVKPRXQWHG
DLUFRQWUROYDOYH%DFNRXWWKHUHOHDVHEROW)LJXUH
DUURZ³'´XVLQJDPD[LPXPWRUTXHRIIWOEV
1ÂPWRFDJHWKHDLUUHOHDVHGVSULQJIRUFHRQ
WKHSXVKURG
A
B
A
D
18/1
C
FIGURE 44 - SPRING BRAKE INSTALLATION
CAUTION: Do not use brake chambers with seals that
have a thickness less than 0.12 in. (3 mm). Use only
actuators which are recommended by the vehicle
manufacturer.
,QVWDOO WKH EUDNH FKDPEHU XVLQJ QHZ VHOIORFNLQJ
QXWV(1,62$OWHUQDWHO\WLJKWHQERWKWKH
QXWVVWHSE\VWHSXSWRD¿QDOWRUTXHRI“IWOEV
“1ÂPBendix strongly recommends
that new nuts be used.
5HFRQQHFWWKHDLUKRVHVDQGEHVXUHWKDWHDFK
KRVHLVQRWWZLVWHGRULQFRQWDFWZLWKPRYLQJYHKLFOH
FRPSRQHQWV7KHDLUKRVHURXWLQJPXVWDOORZIRUIXOO
FDOLSHU WUDYHO 1RWH WKDW IRU VSULQJ EUDNH VHUYLFH
FKDPEHUVWKHSRUWVDUHLQGLFDWHGE\³´6HUYLFH
%UDNH3RUWDQG³´6SULQJ%UDNH3RUW
B
FIGURE 43 - ACTUATOR SPRING CAGING AND REMOVAL
FIGURE 45 - PORT DESIGNATIONS
([KDXVWWKHDLUIURPWKHEUDNHFKDPEHUVE\XVLQJ
WKH GDVKPRXQWHG DLU FRQWURO YDOYH :LWK DOO DLU
SUHVVXUHGUDLQHGIURPWKHV\VWHPGLVFRQQHFWWKH
DLUKRVHVIURPWKHEUDNHFKDPEHU:KLOHVXSSRUWLQJ
WKHEUDNHFKDPEHULQSRVLWLRQUHPRYHDQGGLVFDUG
WKH EUDNH FKDPEHU PRXQWLQJ QXWV )LJXUH DUURZVPDUNHG³%´5HPRYHWKHEUDNHFKDPEHU
1RWH :KHUH D QHZ VSULQJ EUDNH FKDPEHU LV EHLQJ
LQVWDOOHGQRWHWKDWLQVRPHFDVHVGUDLQSOXJVDUHLQVWDOOHG
(See Figure 43, arrows marked “A”). :KHUHGUDLQSOXJV
DUH SUHVHQW DIWHU LQVWDOODWLRQ UHPRYH ZKLFKHYHU SOXJ LV
DWWKHORZHVWSRVLWLRQ7KHVHOHFWHGGUDLQKROHPXVWEH
DOLJQHGGRZQZDUGVRUZLWKLQ“ƒZKHQLQVWDOOHGRQWKH
YHKLFOH,QWKHFDVHRIVSULQJEUDNHFKDPEHUVLQVWDOOWKH
SDGVEHIRUHXQFDJLQJWKHVSULQJ
5HLQVWDOODWLRQ%HIRUHLQVWDOOLQJWKHEUDNHFKDPEHU
WKHDFWXDWRUÀDQJH(See Figure 46, arrow “C”)PXVWEH
FOHDQHGDQGLQVSHFWHG&RQVXOWWKHYHKLFOHPDQXDO
7KHVSKHULFDOFXSLQWKHOHYHUPXVWEHJUHDVHG
ZLWKZKLWHJUHDVH3DUW1R RU.
$GGJUHDVHWRWKHUXEEHUJDVNHWRQWKHFKDPEHU
CAUTION: Do not use grease containing molybdenum
disulfate.
24
7KHVHDODVZHOODVWKHSXVKURGDUHDPXVWEH
FOHDQDQGGU\
%HIRUHUHWXUQLQJYHKLFOHWRVHUYLFHZLWKWKHV\VWHP
SUHVVXUL]HG XVLQJ D VRDS VROXWLRQ FKHFN IRU DLU
OHDNDJH 0LQLPDO OHDNDJH LQ WKH DUHD DURXQG WKH
GLDSKUDJPLVSHUPLWWHG6&&0DQGDRQHLQFK
EXEEOHLQRQHPLQXWHDWWKHKRVH¿WWLQJLVDFFHSWDEOH
,IDEQRUPDOOHDNDJHLVGHWHFWHGWKHGLDSKUDJPPXVW
EHUHSODFHGRU¿WWLQJDGMXVWHGUHVSHFWLYHO\
5.5
TAPPET & BOOT ASSEMBLIES, AND
TAPPET INNER SEAL REPLACEMENT
22
Inner Seal
11
Pad Retainer
CAUTION: Follow all safe maintenance
practices, including those listed on page two of
this document. Park the vehicle (by other means
than the foundation brakes) on level ground and
chock the wheels.
13 Tappet
and
Boot Assy
,QVRPHFDVHVWKHWHFKQLFLDQZLOOQHHGWRUHPRYHWKHFDOLSHU
FDUULHUDVVHPEO\IURPWKHYHKLFOH(See Section 5.3.)1RWH
WKDWQHZEROWVDYDLODEOHIURPWKHYHKLFOHPDQXIDFWXUHU
ZLOOEHQHHGHGIRUUHLQVWDOODWLRQ
Important: If the vehicle is equipped with spring brakes,
cage the spring brakes on all axles requiring work.
Consult the vehicle manufacturer’s instructions as
necessary. This procedure may be carried out with
the air disc brake installed on, or removed from, the
vehicle. In cases where the caliper/carrier assembly
is removed from the vehicle, NEW fasteners must be
used and properly torqued during re-installation. Use
only fasteners approved by the vehicle manufacturer.
Note: This maintenance procedure uses specialized
tools. 7KHIXOO%HQGL[DLUGLVFEUDNHWRRONLW.
RU .HQ7RRO NLW LQFOXGHV WKH FRPSOHWH VHW RI
WRROVUHTXLUHGIRUDOOSHUPLWWHGPDLQWHQDQFHSURFHGXUHV
$OWHUQDWHO\IRUORFDWLRQVZKHUHRQO\WKHWDSSHWDQGERRW
UHSODFHPHQW SURFHGXUHV ZLOO EH SHUIRUPHG WKH VPDOOHU
%HQGL[ WRRO NLW . RU .HQ7RRO NLW ZLOO
VXI¿FH7KH'9'%:VKRZVWKLVSURFHGXUH
Bendix
Number/
Ken-Tool
Number
Description
T1 / KT01
Cup
T2 / KT02
Handle for KT01 cup
T3 / KT03
Swivel assembly
(KT03-1 short body
+ KT03-2 brass disc
+ KT03-3 retaining
spring)
Typical Tool View
44 Pad Retainer Pin
26
Spring Clip
45
Washer
12
Pad
Assembly
161
Tappet
Bushing
13
Tappet
and Boot
Assembly
61
Shear
Adapter
161
Tappet
Bushing
22 Inner Seal
6 Adjuster Cap
FIGURE 46 - ADB EXPLODED AND SECTION VIEWS
3DG 5HPRYDO IROORZ 6HFWLRQV IRU
UHPRYDORIWKHEUDNHSDGV
,QVSHFWWKH%UDNH5RWRU(See Section 4.4).
Tappet and Boot Assembly (13) Removal
CAUTION: NEVER EXTEND THE TAPPET MORE THAN
1.75 in. (44.5 mm). See Figure 47. Over-extending the
tappet will result in the tappet losing engagement with
the threads of the synchronizing mechanism. Since
the mechanism can only be set at the manufacturing
plant, the caliper/carrier assembly must be replaced
if this happens.
B
T4 / KT04
Long strut
T9 / KT09
Flange
T15 / KT015 Fork
13
13
Extend
Less Than
1.75 in.
(44.5 mm)
FIGURE 47 - PERMITTED TAPPET EXTENSION
T24 / KT024 Black Nylon Disc
See Figure 47 ([WHQG WKH WDSSHWV ² OHVV WKDQ
LQPP²E\WXUQLQJWKHVKHDUDGDSWHU
FORFNZLVH $ VFUHZGULYHU FDOORXW ³%´ LQ
TABLE 5 - TAPPET AND BOOT REPLACEMENT TOOLS
25
)LJXUHLQVHWVKRXOGEHXVHGWRPRYHWKHERRW
DQGDOORZWKHZHGJHIRUN³$´LQ)LJXUHWREH
LQVHUWHG
CAUTION: Do not insert the screw driver more
than ¼ inch. Take care not to damage the
inner sealing face (see arrow “X” in Figure 48).
Gouges or grooves will prevent a good seal and
will require that the caliper be replaced.
13
T15
,QVSHFW WKH LQQHU VHDOLQJ IDFH IRU GDPDJH ,I
GDPDJHLVIRXQGWKDWZRXOGFDXVHWKHLQQHUVHDOV
QRWWREHDEOHWRVHDOSURSHUO\WKHFDOLSHUFDUULHU
DVVHPEO\PXVWEHUHSODFHG&OHDQWKHDUHDDURXQG
WKHLQQHUVHDO
,QVSHFWWKHWKUHDGHGWXEHVSee Figures 50
and 51([WHQGWKHWXEHVEXWE\OHVVWKDQLQ
PP E\ WXUQLQJ WKH VKHDU DGDSWHU FORFNZLVH,QVSHFWWKHWKUHDGVIRUUXVWFRUURVLRQRU
GDPDJHHWF,IWKHUHLVHYLGHQFHRIGDPDJHWRWKH
WKUHDGVVLJQL¿FDQWUXVWRUFRUURVLRQWKHFDOLSHU
FDUULHUDVVHPEO\PXVWEHUHSODFHG
,IWKHWHFKQLFLDQLVZRUNLQJZLWKWKHFDOLSHURQWKH
YHKLFOHWKHWHFKQLFLDQPD\SODFHDQHZEUDNHSDG
LQWRWKHRXWERDUGJDSWRKHOSDYRLGWKHORVV
RIWKUHDGHQJDJHPHQWRIWKHWKUHDGHGWXEHVSee
Figure 50.
,IWKHZRUNLVEHLQJFDUULHGRXWDWDZRUNEHQFKWKH
WHFKQLFLDQ PD\ LQVHUW D LQ PP VSDFHU
(See callout “E” in Figure 51)LQWRWKHFDOLSHUWR
KHOSDYRLGWKHORVVRIWKUHDGHQJDJHPHQW
A
22
X
13
161
FIGURE 48 - WEDGE TOOL USE
7KHWDSSHWDQGERRWDVVHPEOLHVFDQWKHQEH
UHPRYHGIURPWKHWKUHDGHGWXEHVE\XVLQJWKH
ZHGJHIRUN7 Be sure to orient the wedge tool
with the tapered side towards the tappet.
5HPRYHWKHROGWDSSHWEXVKLQJV
12
16
5HWUDFW WKH WKUHDGHG WXEHV E\ WXUQLQJ WKH VKHDU
DGDSWHUFRXQWHUFORFNZLVH
See Figure 49. &DUHIXOO\ UHPRYH WKH LQQHU VHDO
XVLQJRQHRUWZRÀDWEODGHVFUHZGULYHUVDVVKRZQ
&DXWLRQ'RQRWLQVHUWWKHVFUHZGULYHUVVRIDUWKDW
WKH\ FRPH LQWR FRQWDFW ZLWK WKH WKUHDGHG WXEHV
'DPDJHWRWKHWKUHDGHGWXEHVZRXOGUHTXLUHWKDW
WKHEUDNHEHUHSODFHG
46
FIGURE 50 - USE OF A NEW BRAKE PAD AS A SPACER
2.76 in.
(70 mm)
16
E
1
22
FIGURE 51 - USE OF A SPACER (OFF-VEHICLE INSPECTION)
A
16
FIGURE 49 - INNER SEAL REMOVAL
26
)RUWKUHDGVWKDWDUHLQJRRGFRQGLWLRQJUHDVHWKH
WKUHDGV ZLWK ZKLWH JUHDVH 3DUW 1R RU
.%HIRUHLQVWDOOLQJWKHUHSODFHPHQWLQQHU
VHDOVUHWUDFWWKHWKUHDGHGWXEHVE\WXUQLQJWKH
VKHDUDGDSWHUFRXQWHUFORFNZLVH
1RWH ,I WKH VKHDU DGDSWHU IDLOV ZKLOH \RX DUH UHWUDFWLQJ
WKHWKUHDGHGWXEHV\RXPD\WU\DJDLQZLWKDQRWKHU
QHZVKHDUDGDSWHU,IWKLVDOVRIDLOVWKLVLQGLFDWHV
WKDWWKHDGMXVWHUPHFKDQLVPLVGDPDJHGDQGWKH
FDOLSHUPXVWEHUHSODFHG
To install inner seals where the caliper is on the vehicle:
3RVLWLRQWKHUHSODFHPHQWLQQHUVHDORYHUWKH
WKUHDGHGWXEHSee Figures 52 and 53 for the
tools and installation arrangement used.3RVLWLRQ
WKH / 7 7 ZLWK WKH VKRUW VSDFHU 7 LQ
SRVLWLRQ DV VKRZQ LQ )LJXUH *XLGH WKH WRRO
RYHUWKHHQGRIWKHWKUHDGHGWXEH,QVWDOOWKH
QHZ LQQHU VHDO LQWR SRVLWLRQ E\ URWDWLQJ WKH
DGMXVWHUQXWRQWKH7SRUWLRQRIWKHWRROXVLQJDQ
RSHQHQGHGZUHQFK
T9 / KT09
T4 / KT04
T3 / KT03
FIGURE 54 - ON-VEHICLE INNER SEAL INSTALLATION TOOL
(L2)
L2
16
X
T9 / KT09
L2
T3 / KT03
FIGURE 52 - ON-VEHICLE INNER SEAL TOOL (L1)
22
FIGURE 55 - OFF-VEHICLE INNER SEAL INSTALLATION
L1
22
X
16
T9
FIGURE 53 - ON-VEHICLE INNER SEAL INSTALLATION
To install inner seals where the caliper has been
removed from the vehicle:
3RVLWLRQWKHUHSODFHPHQWLQQHUVHDORYHUWKH
WKUHDGHG WXEH See Figures 54 and 55 for
the tools and installation arrangement used.7KH
WKUHDGHG WXEHV QHHG WR EH UHWUDFWHG WR DOORZ WKH
WRROWREHLQVHUWHG8VHWKHFRPELQDWLRQWRRO/
777ZLWKWKHORQJVSDFHU7DVVKRZQ
LQ)LJXUH6LQFHWKHLQVWDOODWLRQWRROLVJXLGHGE\
WKHFHQWHUSRVWRIWKHWKUHDGHGWXEHDGYDQFHWKH
WXEHDVPDOODPRXQWWRDOLJQWKHWRRODQGWKHFHQWHU
SRVW,QVWDOOWKHQHZLQQHUVHDOLQWRSRVLWLRQ
E\URWDWLQJWKHDGMXVWHUQXWRQWKH7SRUWLRQRIWKH
WRROXVLQJDQRSHQHQGHGZUHQFK
&$87,21 7R FRQ¿UP WKDW WKH LQQHU VHDO KDV EHHQ
correctly installed, begin to extend the threaded tubes
(16) by turning the shear adapter clockwise by 4-5
turns. Watch as the threaded tube extends. Inner seals
that are installed correctly WILL NOT ROTATE as the
threaded tube extends.
1RWH,QVSHFWWKHWDSSHWERRWNLWWRGHWHUPLQHLIWKH
WDSSHWVVXSSOLHGDUHDOUHDG\SUHJUHDVHGDSODVWLF
FRYHUVKRXOGEHSUHVHQW²EHVXUHWRUHPRYHWKH
FRYHUZKHQLQVWDOOLQJWKHWDSSHW2QO\LQWKHFDVH
RI NLWV WKDW DUH QRW SUHJUHDVHG ZLOO WKH LQVWDOOHU
QHHGWRDSSO\JUHDVHWRWKHWDSSHWV,QDOOFDVHV
WKH WKUHDGHG SRUWLRQ RI WKH WXEHV ZLOO QHHG WR EH
JUHDVHG5HWUDFWWKHWKUHDGHGWXEHV
,QVWDOOWKHQHZWDSSHWEXVKLQJRQWRWKHFHQWHU
SRVWRIHDFKWKUHDGHGWXEHE\KDQG%\KDQG
HDVHWKHWDSSHWEXVKLQJVRQWRWKHFHQWHUSRVWRI
WKHWKUHDGHGWXEHVDQGWKH\ZLOOVQDSLQWRSRVLWLRQ
7KHVHDOLQJVHDWLQWKHFDOLSHUIRUWDSSHWDQGERRW
DVVHPEOLHVPXVWEHFOHDQDQGIUHHRIJUHDVH
:LSHWKHRSHQLQJZLWKDFOHDQVKRSUDJ3ODFHD
WDSSHWDQGERRWDVVHPEO\LQSRVLWLRQRYHUWKH
FHQWHUSRVWDQGWDSSHWEXVKLQJ
To install tappet and boot assemblies where the caliper
is on the vehicle:
See Figures 56, 57 and 58. 8VHWRRO%FRPSULVLQJ
WRROV77DQG7WRSUHVVWKHERRWLQWRSRVLWLRQ
7KHWRROLVWKHQUHYHUVHGDQGWKHQ\ORQGLVF7
27
LVLQVHUWHGLQWRWKH7³FXS´FRPELQDWLRQWRROµ%¶
+ROGLQJWKH7KDQGOHWXUQWKHQXWRQWKH7WRROWR
IXOO\LQVWDOOWKHWDSSHWRQWRWKHWDSSHWEXVKLQJ
FIGURE 56 - ON VEHICLE TAPPET AND BOOT INSTALLATION
TOOL (B1 - WITH T24 INSTALLED, B2)
13
B1
FIGURE 59 - OFF VEHICLE TAPPET BOOT INSTALLATION TOOL
(B3, WITH T24 INSTALLED, B4)
B3
13
161
FIGURE 57 - ON VEHICLE TAPPET BOOT INSTALLATION
FIGURE 60 - OFF VEHICLE TAPPET BOOT INSTALLATION
B2
13
13
B4
FIGURE 58 - ON VEHICLE TAPPET INSTALLATION
To install tappet and boot assemblies where the caliper
is removed from the vehicle:
See Figures 59, 60 and 61. 5HWUDFWWKHWDSSHWV
DV QHHGHG LQ RUGHU WR KDYH URRP WR LQVWDOO WKH
WDSSHWV8VHWRRO%FRPSULVLQJWRROV77DQG
7WRSUHVVWKHERRWLQWRSRVLWLRQ7KHWRROLVWKHQ
UHYHUVHGDQGWKHQ\ORQGLVF7LVLQVHUWHGLQWR
WKH7³FXS´FRPELQDWLRQWRROµ%¶+ROGLQJWKH
7KDQGOHWXUQWKHQXWRQWKH7WRROWRIXOO\VHDW
WKHWDSSHWRQWRWKHWDSSHWEXVKLQJ
FIGURE 61 - OFF VEHICLE TAPPET INSTALLATION
&KHFNWKDWWKHWDSSHWVDUH¿UPO\DWWDFKHGWRWKH
EXVKLQJVE\JULSSLQJDQGSXOOLQJOLJKWO\RQWKHPE\
KDQG&RQ¿UPWKDWWKHWDSSHWVDUHDEOHWRURWDWHD
VPDOODPRXQWRQWKHWDSSHWEXVKLQJVE\JUDVSLQJ
DQGWXUQLQJWKHPE\KDQG)LQDOO\XVLQJDER[HQG
ZUHQFKRQWKHVKHDUDGDSWHUH[WHQGWKHWKUHDGHG
WXEHVRXWZDUGDQGFKHFNWKDWWKHERRWVDUHKHOG
LQSODFH5HWUDFWWKHWDSSHWV
5HLQVWDOO WKH FDOLSHUFDUULHU DVVHPEO\ LI LW ZDV
UHPRYHGIURPWKHYHKLFOH(See Section 5.3)
5HLQVWDOOWKHEUDNHSDGV (See Section 5.2).
28
5.6 GUIDE PIN AND BOOT ASSEMBLIES
Vertical
Bolt Style
(with
bushing).
Bushing
(6)
Guide Pin
(4)
Caliper Bolt
(39)
Cap
(68)
Inner
Boot
(9)
Ring
(58)
Horizontal
Mounting Bolt
Style Shown:
See Inset Above
for Vertical
Bolt Style (with
bushing).
Shear
Adapter
(61)
Adjuster Cap
(Two alternate
caps supplied in kit)
(37)
Ring
(58)
Inner
Boot
(9)
Guide Pin
(5)
KIT CONTENTS
Item
Guide Bushing
(7)
Caliper Bolt
(40)
Cap
(10)
4 .
5 .
6 .
7 .
9 .
10.
37.
39.
40.
58.
61.
68.
.
.
.
.
.
.
.
.
.
.
.
.
Description
.
.
.
.
.
.
.
.
.
.
.
.
Quantity
Guide Pin (short) . . . . . . . . . . .
Guide Pin (Long) . . . . . . . . . . .
Bushing . . . . . . . . . . . . . . . .
Guide Bushing (Long) . . . . . . . .
Inner Boot . . . . . . . . . . . . . . .
Cap (small) . . . . . . . . . . . . . .
Adjuster Cap (two versions supplied)
Caliper Bolt (Short) . . . . . . . . . .
Caliper Bolt (Long) . . . . . . . . . .
Ring . . . . . . . . . . . . . . . . . .
Shear Adapter. . . . . . . . . . . . .
Cap (large). . . . . . . . . . . . . . .
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
1
1
1
1
2
1
2
1
1
2
1
1
(White grease is also supplied - not shown)
FIGURE 62 - GUIDE PIN EXPLODED VIEW
7KH%HQGL['9'%:VKRZVWKLVSURFHGXUH
CAUTION: Follow all safe maintenance
practices, including those listed on page two of
this document. Park the vehicle (by other means
than the foundation brakes) on level ground and
chock the wheels.
These procedures are typically carried out with the
caliper/carrier removed from the vehicle (may be
carried out with the air disc brake installed). In cases
where the caliper/carrier assembly is removed from
the vehicle, NEW fasteners must be used and properly
torqued during re-installation. Use only fasteners
approved by the vehicle manufacturer.
Important: If the vehicle is equipped with spring brakes,
cage the spring brakes on all axles to be worked on.
Consult the vehicle manufacturer’s instructions as
necessary. For Bendix® brand piston-style spring
brake chambers, see Section 5.4.
Note: This maintenance procedure uses specialized
tools. 7KHIXOO%HQGL[DLUGLVFEUDNHWRRONLW.
RU.HQ7RRONLWLQFOXGHVWKHWRROVQHHGHGIRUWKH
JXLGHSLQDQGERRWLQVWDOODWLRQ6HH7DEOH
1RWHWKDWDVPDOOHU%HQGL[WRRONLW.RU.HQ7RRO
NLWPD\EHXVHGZKHUHRQO\WKHJXLGHSLQVZLOOEH
VHUYLFHG
29
Bendix
Number/
Ken-Tool
Number
Description
1-3/8 in. diameter disc
T14 / KT14
Brass nut
T06 / KT06
1-1/2 in. diameter disc
T16 / KT16
Dimpling tool
T07 / KT07
2 in. diameter sleeve
T20 / KT20
8 in. bolt
T08 / KT08
2-1/8 in. diameter disc
T21 / KT21
Half Sleeve
T10 / KT10
8 in. bolt
T26 / KT26
Cap installation tool
T12 / KT12
3-7/8 in. long sleeve
T27 / KT27
Cap installation tool
T13 / KT13
10 in. bolt
Bendix
Number/
Ken-Tool
Number
Description
T05 / KT05
Typical Tool View
Typical Tool View
TABLE 6 - BENDIX® ADB22X ™ AIR DISC BRAKE GUIDE PIN
AND SEALS REPLACEMENT TOOLS. (A WASHER IS ALSO
INCLUDED)
5HPRYHWKHZKHHO5HIHUWRWKHYHKLFOHPDQXIDFWXUHU¶VUHFRPPHQGDWLRQV
5HPRYHWKHEUDNHSDGVSee Section 5.2.
,QPRVWFDVHVWKHDFWXDWRUVKRXOGEHUHPRYHGSee
Section 5.4. ,QWKHFDVHRIVSULQJEUDNHDFWXDWRUV
WKH\VKRXOGEHFDJHGEHIRUHUHPRYLQJWKHEUDNH
DVVHPEO\
,QQHDUO\DOOFDVHVWKHDLUGLVFEUDNHFDOLSHUFDUULHU
ZLOOQHHGWREHUHPRYHGIURPWKHYHKLFOHLQRUGHUWR
FRPSOHWHWKLVSURFHGXUH See Section 5.3.
FIGURE 63 - PUNCH GUIDE
PIN CAP (10)
FIGURE 64 - GUIDE PIN CAP
(10) HOLE
FIGURE 65 - PRY TO
REMOVE GUIDE PIN CAP (10)
FIGURE 66 - USING SMALL
CHISEL TO REMOVE GUIDE
PIN CAP (68)
3ODFHWKHEUDNHRQDZRUNEHQFKDQGXVLQJDYLFH
VHFXUHLWE\WKHFDUULHU
8VHDVPDOOFKLVHORUVLPLODUWRROWRSXQFKDKROH
FORVHWRWKHFHQWHURIWKHJXLGHSLQFDSof the
short guide pin,WDNLQJFDUHWRRQO\LQVHUWWKHFKLVHO
DVPDOODPRXQW8VLQJWKHKROHMXVWPDGHSU\WKH
FDSRIIDQGGLVFDUGSee Figures 63-65.
30
5HPRYHWKHRWKHUFDSthat covers the long
guide pinE\XVLQJDVPDOOFKLVHODQGKDPPHUWR
DSSO\OLJKWEORZVWRWKHFDSZLWKWKHFKLVHODLPHG
DZD\ IURP WKH FDVWLQJ See Figure 66. Discard
ERWKFDSV
8VLQJ D PP KH[
ELW VRFNHW UHPRYH
DQG GLVFDUG WKH WZR
FDOLSHUEROWVDQG
See Figure 67.
%\KDQGUHWUDFWERWK
JXLGH SLQV VOLJKWO\
DQG WKHQ UHPRYH
WKH FDOLSHU IURP WKH
FDUULHU
7XUQLQJ WKH EROW DW
WKH WRS GUDZ WKH
EUDVV QXW XS EULQJ
WKH EUDVV EXVKLQJ
XS DQG RXW RI WKH
FKDQQHO'LVFDUGWKH
EXVKLQJ
FIGURE 67 - REMOVE THE
CALIPER BOLTS
7KHJXLGHSLQVDUHQRZRQO\KHOGE\WKHUHWDLQLQJ
ULQJV
5HPRYH WKH ERRW
UHWDLQLQJ ULQJV DQG WKH JXLGH SLQV
DQG 8VH
DVFUHZGULYHUWRSU\
RXW WKH LQQHU ERRWV
See Figure 68.
'LVFDUGWKHUHPRYHG
LWHPV
FIGURE 71 - REMOVE THE
LONG GUIDE PIN
&DXWLRQ.HHSWKHUHPRYDOWRROH[DFWO\DOLJQHGZLWKWKH
JXLGHSLQFKDQQHOWRSHUPLWWKHEXVKLQJWREHUHPRYHG
See Figure 72.
T12 / KT12
Bushing (10)
Removed
T13 /
KT13
FIGURE 68 - REMOVE THE
RETAINING RINGS, GUIDE
PINS, AND BOOTS
&OHDQWKHFDOLSHUXSSHUDQGORZHUVXUIDFHVDURXQG
WKHEXVKLQJV
Bushing
(10)
installed
T14 / KT14
Grease the bolt prior to each use
Above: Incorrect
Alignment
Above: Correct
Alignment
FIGURE 72 - KEEP THE CORRECT ALIGNMENT
Washer
T12 / KT12
T13 / KT13
T14 / KT14
FIGURE 69 - BRASS BUSHING REMOVAL TOOL
3UHSDUHWRUHPRYHWKHEUDVVEXVKLQJXVHGLQWKH
ORQJJXLGHSLQVLGH$VVHPEOHWKHORQJEROW7
ZDVKHUDQGVOHHYH7DVLQ)LJXUHVDQG
$SSO\ JUHDVH WR WKH
EROW DQG ² DIWHU
LQVHUWLQJWKURXJKWKH
JXLGHSLQFKDQQHO²
HQJDJH WKH EUDVV
QXW 7 $OZD\V
GRXEOHFKHFN WKDW
W K H E U D V V Q X W L V
FRUUHFWO\ LQ SODFH LQ
WKH EXVKLQJ EHIRUH
EHJLQQLQJ WR H[WUDFW
WKHEXVKLQJ
3UHSDUH WR UHPRYH
WKH VKRUW JXLGH SLQ
EXVKLQJ E\ ORFDWLQJ
WKH EXVKLQJ WDE
DQG XVLQJ D VPDOO
FKLVHOQDUURZHUWKDQ
WKH WDE RU VLPLODU
WRROUHPRYHWKHWDE
DV VKRZQ LQ )LJXUH
E\VWULNLQJORZRQ
WKHEDVHRIWKHWDE
FIGURE 70 - INSTALL THE
REMOVAL TOOL
FIGURE 73 - REMOVE THE
TAB THAT HOLDS THE
BUSHING IN POSITION
5HPRYH WKH WDE ZLWK D PDJQHW DQG XVH D FOHDQ
VKRS FORWK WR UHPRYH DQ\ H[FHVV GHEULV 1RWH
WKDWLQVRPHFDVHVWKHWDEPD\EHLQWKHRSSRVLWH
RXWHUVORWLQWKHERUH
Grease the bolt prior to each use
Washer
T21 / KT21
T20 / KT20
T14 / KT14
FIGURE 74 - SHORT GUIDE PIN REMOVAL TOOL
31
8VHWKHWRROFRPELQDWLRQVKRZQLQ)LJXUHVDQG
FRPSULVLQJ 7 7 7 DQG D ZDVKHU WR
UHPRYHWKHEXVKLQJ6FUHZQXW7RQWRWKH
DVVHPEO\E\KDQGWKHQWLJKWHQWKHEROW7XVLQJ
DER[HQGZUHQFKWRGUDZRXWWKHEXVKLQJ'LVFDUG
WKH UHPRYHG EXVKLQJ DQG YHULI\ WKDW WKH ERUH LV
FOHDQE\ZLSLQJZLWKDVKRSFORWK
T20
Washer
3ODFHDQHZEUDVVJXLGHEXVKLQJRQWKHGLPSOLQJ
WRRO7DQGLQVHUWLWLQWRWKHFDOLSHUERUH
T14/
KT14
7
T21
7
6
T14
FIGURE 75 - SECTIONAL VIEW: SHORT GUIDE PIN BUSHING
REMOVAL
Installation of the Fixed Guide Pin Brass
Bushing
&OHDQWKHFDOLSHUXSSHUDQGORZHUVXUIDFHVDURXQG
WKHEXVKLQJV
&ODPSWKHFDUULHULQDYLVHVRWKDWWKHJXLGHFKDQQHO
LVYHUWLFDOO\RULHQWHG
T13 / KT13
Grease the bolt prior to each use
Washer
T14 / KT14
T08 / KT08
T16 / KT16
FIGURE 76 - LONG GUIDE PIN BUSHING INSTALLATION AND
DIMPLING TOOL
3ODFHWKHZDVKHUDQGWKUHDGWKHEUDVVQXW7RQ
WRWKHEROW7IROORZHGE\WKHÀDQJH7See
Figure 76.
View
“A”
View
“B”
View
“C”
FIGURE 77 - VIEW “A” AND “B”: DRAW THE BRASS BUSHING
INTO POSITION. VIEW “C”: LOCK THE BUSHING INTO
POSITION
&KHFNWKDWWKHÀDQJH7LVLQDQXSULJKWSRVLWLRQ
DWWKHWRSRIWKHFDOLSHUUHFHVVDV\RXGUDZWKHEUDVV
EXVKLQJXSE\WXUQLQJWKHEUDVVQXW7XQWLO
WKHGLPSOLQJWRROERWWRPVRQWKHFDOLSHU:KHQLW
UHDFKHV WKH FRUUHFW SRVLWLRQ WKH EUDVV EXVKLQJ
H[WHQGV RXW RI WKH JXLGH SLQ FKDQQHO LQ
PP
:LWKWKHGLPSOLQJWRRO7LQSRVLWLRQWLJKWHQWKH
VFUHZLQLWVEDVHXQWLOLWFRQWDFWVWKHGLPSOLQJVFUHZ
KRXVLQJ7KHPRYHPHQWRIWKLVVFUHZIRUFHVWKUHH
SRLQWVRXWZDUGVOHDYLQJLQGHQWDWLRQVLQWKHEUDVV
EXVKLQJSee Figure 77, view “C”.
8QVFUHZWKHGLPSOLQJVFUHZRXWDSSUR[LPDWHO\
LQFKHVPP/RRVHQWKHEUDVVQXW7DQG
URWDWHWKHGLPSOLQJWRRO7GHJUHHV5HSHDW
WKH GLPSOLQJ SURFHVV E\ WLJKWHQLQJ WKH EUDVV QXW
7DQGWKHQWLJKWHQWKHGLPSOLQJVFUHZXQWLOLW
FRQWDFWVWKHGLPSOLQJVFUHZKRXVLQJ%DFNRXWWKH
GLPSOLQJVFUHZDSSUR[LPDWHO\LQFKHVPP
7KHEUDVVEXVKLQJLVQRZKHOGLQSRVLWLRQE\WKH
VL[GLPSOHVPDGHE\WKHWRRO
5HPRYHWKHLQVWDOODWLRQWRROVDQGFKHFNWKHEUDVV
EXVKLQJUHPRYLQJDQ\EXUUVEHLQJFDUHIXOQRW
WROHDYHDQ\PHWDO¿OLQJVLQWKHEXVKLQJ&RDWWKH
LQVLGHRIWKHEXVKLQJZLWKWKHZKLWHJUHDVHLQFOXGHG
LQWKHNLW
Installation of the Floating Guide Pin Bushing
7RLQVWDOOWKHEXVKLQJLQWRWKHVKRUWJXLGHSLQ
VLGH¿UVWLQVSHFWWKHERUHIRUFRUURVLRQGDPDJH
HWF&OHDQDVQHFHVVDU\
32
3ODFHWKHQHZEXVKLQJLQSRVLWLRQVR
WKDW when drawn
into position, the
tab will align with
the slot in the casting :LWK WKH WDE
DOLJQHG SODFH WRRO
7RYHUWKHEXVKLQJDQGWDSOLJKWO\7R
SRVLWLRQWKHEXVKLQJ
see Figure 78.
T20 / KT20
Washer
T06 / KT06
Grease the bolt prior to each use
T10 / KT10
T08 / KT08
FIGURE 78 - POSITION THE
NEW BUSHING
T07 / KT07
FIGURE 81 - SHORT GUIDE PIN BOOT INSTALLATION TOOL
Grease the bolt prior to each use
Washer
T05 / KT05
VXUIDFH RI WKH FDOLSHU LV GDPDJHG UHSODFH WKH
FDOLSHU
T08 / KT08
T14 / KT14
FIGURE 79 - SHORT GUIDE PIN BUSHING INSTALLATION TOOL
8VH WKH WRRO FRPELQDWLRQ VKRZQ LQ )LJXUH WR
GUDZ WKH EXVKLQJ LQWR WKH FDOLSHU See also
Figure 80WRVHHWKHRULHQWDWLRQZLWKWRRO7DW
WKHWRS+DQGWLJKWHQWKHQXW7LQWRSRVLWLRQ
7KHQWLJKWHQWKHEROW7XVLQJDER[HQGZUHQFK
RUVRFNHWWRGUDZWKHEXVKLQJLQWRWKHFDOLSHU
XQWLOWKHEXVKLQJFRQWDFWVWKHPDFKLQHGVWHSLQ
WKHERUH5HPRYHWKHWRRO
See Figure 82. 3ODFH
D ERRW LQWR WKH LQVWDOODWLRQ WRRO 7
PDNLQJ VXUH WKDW
WKH LQQHU EHOORZV
DUH DUUDQJHG FORVH
WR WKH VLGH ZDOOV RI
WKH WRRO DQG ZLOO QRW
EH GDPDJHG GXULQJLQVWDOODWLRQ$OVR
FKHFNWKDWWKHRXWHU
HGJH RI WKH ERRW
UHVWV RQ WKH IURQW
HGJHRIWKHWRRO
FIGURE 82 - POSITION
THE NEW BOOT IN THE
INSTALLATION TOOL (T7)
8VLQJLQOEV1ÂPRIWRUTXHPD[LPXPWLJKWHQ
EROW7WRLQVWDOOWKHLQQHUERRW
5HSHDW WKH LQVWDOODWLRQ SURFHGXUH IRU WKH VHFRQG
LQQHUERRW
&KHFNWKDWWKHERRWVDUHKHOGVHFXUHO\LQSODFHDQG
WKDWQRGDPDJHRFFXUUHGGXULQJLQVWDOODWLRQ
T14
6
Bushing Stop
T08
T06
T05
T20
Washer
FIGURE 80 - GUIDE PIN BUSHING INSTALLATION
8VLQJ D SXQFK EHQG WKH WDE LQWR WKH JURRYH E\
DOLJQLQJ WKH SXQFK ZLWK WKH XSSHU SDUW RI WKH WDE
DQGWDSSLQJWKHSXQFKZLWKDKDPPHU
&RDWWKHLQVLGHRIWKHEXVKLQJZLWKDOLJKWFRDW
RIWKHZKLWHJUHDVHLQFOXGHGLQWKHNLW
,QVWDOO WKH WZR LGHQWLFDO LQQHU ERRWV E\ ¿UVW
FOHDQLQJ WKH DUHD ZKHUH WKH LQQHU ERRWV ZLOO EH
LQVWDOOHGDQGLQVSHFWIRUFRUURVLRQ,IWKHVHDOLQJ
See Figure 83. 7R
L Q V W D O O W K H J X L G H
SLQV ILUVW OXEULFDWH
ERWKJXLGHSLQVZLWK
WKH ZKLWH JUHDVH
VXSSOLHG,QVHUWWKH
JXLGH SLQV LQWR WKHLU
UHVSHFWLYH ERUHV
ZLWKWKHJURRYHGHQG
WRZDUGVWKHEHOORZV
FIGURE 83 - PLACE THE
RETAINING RING ONTO THE
GROOVE IN THE GUIDE PIN
)LWWKHOLSLQWKHHQGRIWKHLQQHUERRWVLQWRWKH
JURRYH RI WKH JXLGH SLQV 3XVK RQ HDFK ULQJ HQVXULQJWKDWWKHERRWLVHQJDJHGRQWRWKHHQG
RIWKHJXLGHSLQVRU
:LWKWKHFDOLSHUUHVWLQJRQDEHQFKVOLGHWKHFDUULHU
LQWRSODFHZLWKDVOLJKWURFNLQJPRWLRQWDNLQJFDUH
WKDWDV\RXGRVRWKHLQQHUERRWVDQGJXLGHSLQV
DUHVHDWHGLQWKHLUSURSHUSODFHRQWKHFDUULHU
,GHQWLI\WKHWZRFDOLSHUEROWVDQG:LWKWKH
VKRUWHUEROWSODFHGLQWKHÀRDWLQJSLQEXVKLQJDQG
WKHORQJHUEROWSODFHGLQWKH¿[HGSLQEXVKLQJ
33
EHJLQWRWLJKWHQWKHEROWV:LWKWKHFDOLSHUFDUULHU
LQDYLFHFRQWLQXHLQVWDOOLQJWKHEROWVWRDWRUTXHRI
IWOEV1ÂP)LQDOO\WLJKWHQHDFKEROWDQ
DGGLWLRQDOžQLQHW\GHJUHHV
Installation of the Guide Pin Caps
See Figure 84. 3ODFH
WKHFDOLSHUFDUULHUDVVHPEO\ RQ D EHQFK
VR WKDW WKH LQQHU
ERRWVDUHIXOO\FRPSUHVVHG FKHFN WKDW
WKH ERUHV DUH FOHDQ
DQG GU\ HJ IUHH
IURPOXEULFDWLRQ
BOOT
COMPRESSED
FIGURE 84 - BOOTS MUST
BE COMPRESSED FULLY
DURING CAP INSTALLATION
1RWH,WLVLPSRUWDQWWKDWWKHLQQHUERRWVDUHIXOO\
FRPSUHVVHGGXULQJWKLVSURFHGXUHWRHQVXUHWKDW
WKHOHDVWDPRXQWRIDLULVUHWDLQHGZLWKLQWKHJXLGH
SLQFKDQQHO,IWRRPXFKDLULVWUDSSHGWKHEHOORZV
FDQSRWHQWLDOO\EHGDPDJHGGXULQJWKHRSHUDWLRQRI
WKHEUDNHIt is also important that the technician
double-check that the retaining rings remain in their
correct position during this procedure.
&OHDQ WKH WZR FDSV DQG FKHFN WKDW WKH FDOLSHU
VXUIDFHVZKHUHWKHFDSVZLOOEHLQVWDOOHGDUHFOHDQ
DQGKDYHQRVLJQVRIGDPDJH
6HOHFW RQH FDS WR
LQVWDOO 8VLQJ WKH
F R U U H F W S U H V V L Q
WRRO ² WKH VPDOOHU
FDSLQVWDOOVLQWKH
ORQJ JXLGH SLQ VLGH
XVLQJWRRO7DQG
WKH ODUJHU FDS LQVWDOOV LQ WKH VKRUW
JXLGHSLQVLGHXVLQJ
WRRO 7 ² SODFH
WKH FDS LQ SRVLWLRQ
XVLQJ WKH PDFKLQHG
FKDQQHOLQWKHFDOLSHU
WRDVVLVWLQFHQWHULQJ
WKHWRRO
FIGURE 85 - BOOTS MUST
BE COMPRESSED FULLY
DURING CAP INSTALLATION
8VHDKDPPHUWRWDSWKHFDSLQWRSRVLWLRQSee
Figure 85. 1RWH WKDW WKH WRRO QHHGV WR UHPDLQ
SHUSHQGLFXODU WR WKH FKDQQHO WR SUHYHQW GDPDJH
GXULQJLQVWDOODWLRQ1RWHWKDWDIWHULQVWDOODWLRQWKH
VPDOOHUFDSH[WHQGVLQPPDQGWKH
ODUJHUFDSH[WHQGVLQPP
5HSHDWIRUWKHVHFRQGFDS
&KHFN WKDW WKH JXLGH SLQV PRYH IUHHO\ ZKHQ WKH
FDUULHULVPRYHGODWHUDOO\DQGWKDWDLULVQRWWUDSSHG
ZLWKLQWKHLQQHUERRWVDQGWKDWWKHERRWVDQG
ULQJDUHLQWKHSURSHUSRVLWLRQEHIRUHFRQWLQXLQJ
ZLWKWKHLQVWDOODWLRQ
,QVWDOOWKHFDOLSHUFDUULHU(See Section 5.3).
,QVWDOOWKHEUDNHFKDPEHU(See Section 5.4).
,QVWDOOWKHEUDNHSDGV(See Section 5.2).
34
5.7 BENDIX® SPLINED DISC® HUB ROTOR
DRIVE HUB
STEER HUB
Wheel Studs
Intermediate Elements
(Spacers)
Spring Elements
(Retention
Brackets)
ABS Tone
Wheel
& Fasteners
Hub
Intermediate Elements
(Spacers)
Spring Elements
ID Label (Retention
Brackets)
Splined Disc Rotor
Above: Splined Disc Rotor on Aluminum Drive Hub
Wheel Studs
Hub
ID Label
ABS Tone Wheel
(press on)
Above: Splined Disc Rotor on Aluminum Steer Hub
FIGURE 86 - SPLINED DISC ROTOR EXAMPLES - EXPLODED VIEWS
Bendix®6SOLQHG'LVF®+XE5RWRUVDUHGHVLJQHGWRDVVLVW
YHKLFOHPDLQWHQDQFHE\W\SLFDOO\DOORZLQJWKHURWRUWREH
VHUYLFHG ZLWKRXW UHTXLULQJ WKH HQWLUH KXEURWRU DVVHPEO\
EHUHSODFHG
3HULRGLF LQVSHFWLRQ RI WKH 6SOLQHG 'LVF DWWDFKPHQW
KDUGZDUH LV UHFRPPHQGHG WR HQVXUH RSWLPXP EUDNLQJ
SHUIRUPDQFH%HQGL[UHFRPPHQGVYHULI\LQJWKHWRUTXHRQ
WKHVSULQJHOHPHQWIDVWHQHUVZKHQHYHUDEUDNHLQVSHFWLRQ
LVSHUIRUPHG
NOTE: Anytime that the entire hub/rotor assembly
is removed, Bendix recommends that the wheel seal
also be replaced at the same time, USING A HIGHTEMPERATURE SEAL. Follow the wheel seal and/or
vehicle manufacturer's guidelines for full installation
LQVWUXFWLRQV$GMXVWWKHEHDULQJVDQGUH¿OOEHDULQJ
RLOWRYHKLFOHPDQXIDFWXUHU
VVSHFL¿FDWLRQV
When replacing a Splined Disc Rotor, Bendix strongly
recommends that the brake pads be replaced (as an
axle set.) Contact 1-800-AIR-BRAKE for appropriate
brake pad kit. Rotor replacement necessitates the
removal of the pads.
CAUTION: Follow all safe maintenance practices,
including those listed on page two of this document.
Park the vehicle (by other means than the foundation
brakes) on level ground and chock the wheels. Also
read the vehicle manufacturer's recommendations.
When installing pads, where appropriate, use heavy
duty gloves and always keep fingers away from
potential pinch hazard areas.
%HQGL[$LU'LVF%UDNHVDUHSUHFLVLRQHQJLQHHUHGEUDNLQJ
PHFKDQLVPV7KH³IULFWLRQFRXSOH´EUDNLQJFKDUDFWHULVWLFV
KDYH EHHQ FDUHIXOO\ RSWLPL]HG DQG WKH URWRU GHVLJQ DQG
PDWHULDOV KDYH EHHQ PDWFKHG ZLWK VSHFLDO IRUPXODWLRQ
EUDNH SDGV IRU RSWLPDO SHUIRUPDQFH WKHUHIRUH XVH RQO\
JHQXLQH%HQGL[®EUDQGSDUWVDQGEUDNHSDGV
Rotor Replacement
%HIRUH UHPRYLQJ WKH EUDNH SDGV LW LV VWURQJO\
UHFRPPHQGHG WKDW WKH DLU GLVF EUDNH DGMXVWHU
PHFKDQLVPEHFKHFNHGIRUFRUUHFWRSHUDWLRQSee
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Note: Follow the vehicle manufacturer's guidelines for
removal of the wheel hub and rotor assembly from the
vehicle in lieu of these instructions, where available.
CAUTION: Be sure to secure both the rotor and hub
before removing the retention clips.
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B
B-B
3
3
4
4
B
2
2
1
1
KEY
1 - Wheel Hub
2 - Splined Disc Rotor
3 - Intermediate Elements (Spacers)
FIGURE 89 - INTERMEDIATE ELEMENT (SPACER)
INSTALLATION
KEY
1 - Wheel Hub
2 - Splined Disc Rotor
3 - Intermediate Element (Spacer)
4 - Spring Element (Fastener), including retention clips
FIGURE 87 - ROTOR WITH CROSS-SECTION VIEW
FIGURE 90 - INTERMEDIATE ELEMENTS (SPACERS) INSTALLED
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FIGURE 88 - ROTOR INSTALLATION
ROTOR INSTALLATION
See Figures 87 through 91. 3ODFH WKH URWRU LQWR
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36
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5HLQVWDOO WKH DLU GLVF EUDNH (See Section 5.3).
6XSSRUWLQJ WKH DLU GLVF EUDNH E\ DOO QHFHVVDU\
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FIGURE 91 - FASTENERS INSTALLED
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Washer: Requires HARDENED 3 mm
(minimum thickness) for each bolt.1
If the vehicle is using a Bendix
manufactured Axial Anchor Plate, with a
thickness of 1.14 in. (29 mm) where these
bolts are assembled, then a bolt with an
overall length of 2.36 in. (60 mm) will meet
these requirements
7RUTXH
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Washer: None required.
8VHWKHPDQXIDFWXUHU¶VUHFRPPHQGDWLRQV
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7RUTXHIWOEI>1Â[email protected]
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7UDLOHU7RUTXH3ODWH
/HQJWKGHWHUPLQDWLRQ
8VHWKHPDQXIDFWXUHU¶VUHFRPPHQGDWLRQV
/ 7RUTXH3ODWH73WKLFNQHVV&DUULHU
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3UH7RUTXHIWOEI>1Â[email protected]
LPD[ 73WKLFNQHVVPPPP
)LQDO7RUTXHIWOEI>1Â[email protected]
Washer: Requires HARDENED 3 mm
(minimum thickness) for each bolt.1
Table Note: 1.
The washer outside diameter must be less than 1.1in. (28.5 mm).
TABLE 7 - TORQUE PLATE FASTENERS AND TORQUE RECOMMENDATIONS (SEE MANUFACTURER’S RECOMMENDATIONS)
37
SERVICE DATA INDEX
Section One: Air Disc Brake Overview 1
Safe Maintenance Practices 2
Section Two: Preventive Maintenance Schedule and Wheel-On Inspections 6
3UHYHQWLYH0DLQWHQDQFH 6
%UDNH3DG$QG5RWRU,QVSHFWLRQV 7
5XQQLQJ&OHDUDQFH4XLFN,QVSHFWLRQ 8
Section Three: Troubleshooting Procedure Flowchart 9
Section Four: Wheel-Off Maintenance Inspections 10
:KHHO2II,QVSHFWLRQV 10
&DOLSHU0RYHPHQW7HVW 10
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,QVSHFW7KH%UDNH3DGV 12
,QVSHFW7KH5RWRU 13
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7DSSHW$QG%RRW$VVHPEO\,QVSHFWLRQ 15
Section Five: Maintenance Kits And Procedures 16
0DLQWHQDQFH.LWV 17
*HQHUDO,QIRUPDWLRQ$ERXW%HQGL[$LU%UDNH0DLQWHQDQFH 18
$LU'LVF%UDNH6KLHOG.LW 19
3DG5HSODFHPHQW 20
&DOLSHU&DUULHU$FWXDWRU$VVHPEO\ 22
6SULQJRU6HUYLFH%UDNH 24
7DSSHW%RRW$VVHPEOLHVDQG7DSSHW,QQHU6HDO5HSODFHPHQW 25
*XLGH3LQDQG%RRW$VVHPEOLHV29
%HQGL[®6SOLQHG'LVF®+XE5RWRU 35
&RQWDFWLQJ%HQGL[ 40
38
NOTES
39
CONTACTING BENDIX
www.foundationbrakes.com
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Bendix Technical Assistance Team
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1-800-AIR-BRAKE
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To better serve you, please collect the following information before you call the
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