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 $'%XVHDÀRDWLQJFDOLSHUGHVLJQWRSURYLGHIRXQGDWLRQ EUDNLQJRQDOOD[OHVRIKHDY\FRPPHUFLDOYHKLFOHVEXVHV DQGWUDLOHUV%HQGL[$LU'LVF%UDNHVSURYLGHVDIHW\DQG SHUIRUPDQFHDVZHOODVHDVHRIVHUYLFH 7KH$'%;GLVFEUDNHVPRXQWWRWKHD[OH VDQFKRUSODWH WRUTXH SODWH XVLQJ IDVWHQHUV WKDW DUH LQVWDOOHG SDUDOOHO WRWKHD[OHZKLOHWKHDQFKRUSODWHIDVWHQHUVXVHGIRUWKH Bendix® ADB22X-V™DLUGLVFEUDNHVLQVWDOODWULJKWDQJOHV WRWKHD[OH $YDLODEOHZLWKRUZLWKRXWDFRPELQDWLRQVSULQJEUDNHXQLW WKHVHEUDNHVPD\DOVRLQFOXGHRSWLRQDOZHDUVHQVRUVDQG ZHDUGLDJQRVWLFHTXLSPHQW Sections in this Document Section Page 2YHUYLHZ 1-5 3UHYHQWLYH0DLQWHQDQFHDQG :KHHORQ,QVSHFWLRQV 6-8 7URXEOHVKRRWLQJ)ORZFKDUW 9 :KHHORII0DLQWHQDQFH,QVSHFWLRQV 10-15 0DLQWHQDQFH.LWVDQG3URFHGXUHV 16-37 Full Index - see Page 38 $LU'LVF%UDNH,GHQWL¿FDWLRQ /RFDWHWKHLGHQWL¿FDWLRQODEHOQHDUWKHJXLGHSLQKRXVLQJ 6HHEHORZIRULQIRUPDWLRQDERXWWKHODEHO¿HOGVXVHG 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 'HVFULSWLRQ 1 $LU'LVF%UDNH,GHQWL¿FDWLRQ 1 5RWRU,GHQWL¿FDWLRQ 3 :HDU6HQVRU,GHQWL¿FDWLRQ 3 2SHUDWLRQ 3 %UDNH5HOHDVHDQG$GMXVWPHQW 3 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 KDUGZDUH WXELQJ KRVH ¿WWLQJV HWF PXVW EH of equivalent size, type and strength as original HTXLSPHQWDQGEHGHVLJQHGVSHFL¿FDOO\IRUVXFK 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. $YRLGFUHDWLQJGXVW&RPSUHVVHGDLURUGU\EUXVKLQJ must never be used for cleaning brake assemblies or the work area. %HQGL[UHFRPPHQGVWKDWZRUNHUVGRLQJEUDNHZRUN must take steps to minimize exposure to airborne brake lining particles. Proper procedures to reduce exposure include working in a well-ventilated area, segregation of areas where brake work is done, use of local filtered ventilation systems RU XVH RI HQFORVHG FHOOV ZLWK ¿OWHUHG YDFXXPV Respirators approved by the Mine Safety and Health Administration (MSHA) or National Institute for Occupational Safety and Health (NIOSH) should be worn at all times during brake servicing. :RUNHUV PXVW ZDVK EHIRUH HDWLQJ GULQNLQJ RU smoking; shower after working, and should not wear work clothes home. Work clothes should be vacuumed and laundered separately without shaking. 26+$ 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] 5RWRULGHQWL¿FDWLRQ 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 DSSOLHG DLU HQWHUV WKH VHUYLFH EUDNH FKDPEHU WKURXJK WKHVXSSO\SRUWDSSO\LQJSUHVVXUHZLWKLQWKHGLDSKUDJP 7KH SUHVVXUH H[SDQGV WKH GLDSKUDJP ² DSSO\LQJ IRUFH WRDQGPRYLQJWKHSUHVVXUHSODWHDQGSXVKURGIRUZDUG 7KHSXVKURGDFWVDJDLQVWDFXSLQWKHLQWHUQDOOHYHUZKLFK SLYRWVRQDQHFFHQWULFEHDULQJPRYLQJWKHEULGJH0RYLQJ DJDLQVWDUHWXUQVSULQJWKHEULGJHWUDQVIHUVWKHPRWLRQWR WZR WKUHDGHG WXEHV DQG WDSSHWV ZKLFK PRYH WKH LQQHU EUDNHSDG7KHLQQHUEUDNHSDGIURPLWVQRUPDOSRVLWLRQ RI KDYLQJ D UXQQLQJ FOHDUDQFH EHWZHHQ LW DQG WKH URWRU PRYHVLQWRFRQWDFWZLWKWKHEUDNHURWRU)XUWKHUPRYHPHQW RIWKHEULGJHIRUFHVWKHFDOLSHU²VOLGLQJRQWZRVWDWLRQDU\ JXLGHSLQV²DZD\IURPWKHURWRU7KDWLQWXUQSXOOVWKH RXWHUEUDNHSDGLQWRWKHURWRU7KHFODPSLQJDFWLRQRIWKH EUDNHSDGVRQWKHURWRUDSSOLHVEUDNLQJIRUFHWRWKHZKHHO 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. :HDU6HQVRU,GHQWL¿FDWLRQ 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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¶V LQLWLDO QRQEUDNHG SRVLWLRQ 7KH WRWDO UXQQLQJ FOHDUDQFH WKH VXP RI FOHDUDQFHV RQ ERWK VLGHV RI WKH URWRUVKRXOGEHEHWZHHQWRLQWRPP &RQVXOWWKHLQVWUXFWLRQVKHHWLQFOXGHGZLWKZHDU LQGLFDWRUNLWVIRULQVWDOODWLRQLQIRUPDWLRQ 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 $GMXVWHU&DSV 37 $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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ection Two Section Page 3UHYHQWLYH0DLQWHQDQFH 6 %UDNH3DGDQG5RWRU,QVSHFWLRQV 7-8 5XQQLQJ&OHDUDQFH4XLFN,QVSHFWLRQ 8 Use the table below for a guide to maintenance interval planning, KRZHYHUGHSHQGLQJRQWKHSDUWLFXODUYHKLFOH V XVH PRUH IUHTXHQW FKHFNV RI WKH FRPSRQHQWV PD\ EH QHFHVVDU\ 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 $ERXWHYHUIRXU PRQWKVIRURYHUWKH URDGDSSOLFDWLRQV $ERXWHYHU\WKUHHPRQWKV IRUKLJKHUGXW\DSSOLFDWLRQV HJOLQHKDXO59 RSHQKLJKZD\ FRDFKHVHWF HJSLFNXSGHOLYHU\ 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) ,QVSHFWWKHSDGVDQGHQWLUHURWRU VXUIDFHVIRUFUDFNVHWF%HQGL[® VSOLQHGGLVF®URWRUV,QVSHFW UHWDLQLQJKDUGZDUHDQGFKHFN WRUTXHVSee Section 2.3. ,QVSHFWWKHUXQQLQJFOHDUDQFHVDQG DGMXVWHURSHUDWLRQ See Sections 2.2 and 4.2. ,QVSHFWWKHFDOLSHUWUDYHO See Section 4.1. ,QVSHFWWKHWDSSHWDQGERRW DVVHPEOLHVSee Section 4.6. ,QVSHFWDOOFDSVKRVHVDQGEUDNH H[WHULRUIRUGDPDJHHWF 6 TABLE 1 - PREVENTIVE MAINTENANCE SCHEDULE 2.1 BRAKE PAD AND ROTOR INSPECTIONS 9LVXDOFKHFNVRIWKHFRQGLWLRQRIWKHEUDNHSDGURWRUZHDU FDQEHPDGHZLWKRXWUHPRYLQJWKHZKHHOV:KHUHGXVW JXDUGVDUHQRWXVHGWKHWRSRIWKHSDGVDQGSDUWRIWKH URWRUDUHYLVLEOHWKURXJKWKHRSHQLQJDWWKHWRSRIWKHEUDNH 2WKHUYLVLEOHSRUWLRQVRIWKHURWRUFDQEHLQVSHFWHGDWWKH VDPHWLPH 8QOHVVDYHKLFOHKDVEHHQVWRUHGIRUVRPHWLPHWKHPDLQ URWRUVXUIDFHVWKDWFRQWDFWWKHSDGVZLOODOZD\VDSSHDUWR EHVKLQ\6XUIDFHUXVWRQWKHVHVXUIDFHVZRXOGLQGLFDWHD PDOIXQFWLRQLQJEUDNHWKDWVKRXOGEHLQVSHFWHGLPPHGLDWHO\ Wear Indicator Style A: Where both the carrier and caliper have an indicator notch. &RPSDUHWKHUHODWLYHSRVLWLRQRIWZRQRWFKHVFDVWLQWR WKHFDUULHUDQGFDOLSHU:KHQWKHWZRQRWFKHVDOLJQ LWLVWLPHWRVFKHGXOHDIXOOZKHHOUHPRYHGLQVSHFWLRQ RIWKHSDGVDQGURWRU Notch in the caliper 3DGVDUHLQPPWKLFNZKHQQHZDQGPXVWEH 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. :KHQ WKH QRWFK LQ WKH FDOLSHU DOLJQV ZLWK WKH IURQW HGJHRIWKHWRUTXHSODWHLWLVWLPHWRVFKHGXOHDIXOO ZKHHOUHPRYHGLQVSHFWLRQRIWKHSDGVDQGURWRU FIGURE 9 - LOCATION OF WEAR INDICATORS Note: These mechanical wear indicators do not constitute “out-of-service” criteria. 7KHVH LQVSHFWLRQVRQO\VKRZZKHQWRVFKHGXOHDIXOOZKHHO UHPRYHG LQVSHFWLRQ RI WKH EUDNH SDGV DQG URWRU 7KHWKLFNQHVVHVRIWKHSDGDQGURWRUZLOOERWKDIIHFW 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 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 )RU standard Bendix rotors FUDFNV UXQQLQJ LQ D UDGLDO GLUHFWLRQ ² OLNH VSRNHVRIDZKHHOVHH$UHD+²OHVV WKDQ 0.06 in. (1.5 mm) GHHS RU ZLGH DUH DFFHSWDEOH LI WKH\ GR QRW UHDFK HLWKHU HGJH (see G) &UDFNV DUH RQO\ DFFHSWDEOHLIWKHOHQJWKRIWKHFUDFNLV OHVVWKDQRIGLPHQVLRQ³I´WKHZLGWK RIWKHURWRUFRQWDFWDUHD Area H f Area G G &UDFNVUHDFKLQJ HLWKHUHGJHRIWKH URWRU DUHQRW DFFHSWDEOH IRUHLWKHU W\SHRI URWRU Area J J &LUFXPIHUHQWLDO JURRYHVDVLQ$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 RIWKHURWRUFRQWDFWDUHD ,QDGGLWLRQIROORZWKH UHFRPPHQGDWLRQVRIWKH YHKLFOHPDQXIDFWXUHU 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. 2QOHYHOJURXQGZLWKWKHZKHHOVFKRFNHGDQGWKHSDUNLQJ EUDNH WHPSRUDULO\ UHOHDVHG FKHFN IRU PRYHPHQW RI WKH 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 $GDSWHU counter-clockwise DQG OLVWHQ IRU WKHVRXQGRIFOLFNVDVWKHPHFKDQLVPEDFNVRII LQFUHDVHV WKH UXQQLQJ FOHDUDQFH 1RWH 'R QRW XVH DQ RSHQHQGHG ZUHQFK DV WKLV PD\ GDPDJH WKHDGDSWHUSee Figure 20. CAUTION: Never turn the adjuster (23) without the shear adapter (61) installed. The shear adapter is a safety feature and is designed to prevent excessive torque from being applied to the adjuster. The shear adapter will fail (by breaking) if too much torque is applied. FIGURE 21 - APPLYING MODERATE APPLICATIONS OF THE BRAKES: THE WRENCH MOVES CLOCKWISE AS THE RUNNING CLEARANCE IS DIMINISHED :KHUHWKHDGMXVWHUPHFKDQLVPLVDEOHWREHEDFNHG RIIQRUPDOO\SRVLWLRQDER[HQGZUHQFKRQWKHVKHDU DGDSWHUVRWKDWLWFDQWXUQFORFNZLVHIUHHO\ZLWKRXW FRPLQJLQWRFRQWDFWZLWKSDUWVRIWKHYHKLFOH(See Figure 21). 0DNH¿YHWRWHQPRGHUDWHDSSOLFDWLRQV RIWKHEUDNHV>DWDERXWSVL%DU@DQGREVHUYH WKDW WKH ER[HQG ZUHQFK RU VRFNHW VKRXOG WXUQ FORFNZLVHLQVPDOOLQFUHPHQWV 127($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 $UHD + ²OHVVWKDQ0.06 in. (1.5 mm)GHHSRU ZLGHDUHDFFHSWDEOHLIWKH\GRQRWUHDFK HLWKHU HGJH (see G) &UDFNV DUH RQO\ DFFHSWDEOHLIWKHOHQJWKRIWKHFUDFNLV OHVVWKDQRIGLPHQVLRQ³I´WKHZLGWK RIWKHURWRUFRQWDFWDUHD Area J )RU Bendix ® Splined Disc rotors UDGLDOFUDFNVDUHRQO\DFFHSWDEOHLIWKH\ DUHOHVVWKDQ0.04 in. (1.0 mm)GHHS RUZLGHDQGLIWKH\GRQRWUHDFKHLWKHU HGJH(see G). &UDFNOHQJWKVPXVWEH OHVV WKDQ RI GLPHQVLRQ ³I´ WKH ZLGWKRIWKHURWRUFRQWDFWDUHD J &LUFXPIHUHQWLDO JURRYHVDVLQ$UHD -DUHDFFHSWDEOH LIOHVVWKDQLQ PPGHHS ,QDGGLWLRQIROORZWKH UHFRPPHQGDWLRQVRI WKHYHKLFOHDQGURWRU PDQXIDFWXUHU 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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ee 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 $GMXVWHUFDSV Guide Pin, Seal and Boot Kit (wheel end kit) 6HFWLRQ 803114 5LQJLQQHUERRWEUDVVEXVKLQJJXLGHSLQFDOLSHUEROWFDSJXLGHVOHHYH JXLGHSLQFDOLSHUEROWFDS Guide Pin Grease NA 6HFWLRQ Service Actuator 6HFWLRQ Spring Brake Actuator Caliper Kit (rationalized) Includes 803114 kit shown above Carrier Kit 6HFWLRQ 6HFWLRQV Caliper/Carrier Kit 14525 :KLWHJUDPV . Bendix®7\SH8QLYHUVDO>6HUYLFHEUDNHDFWXDWRUDFWXDWRUKDUGZDUH@ . Bendix®7\SH8QLYHUVDO>6HUYLFHEUDNHDFWXDWRUDFWXDWRUKDUGZDUH@ . Bendix®7\SH8QLYHUVDO>6HUYLFHEUDNHDFWXDWRUDFWXDWRUKDUGZDUH@ . Bendix®7\SH8QLYHUVDO>6HUYLFHEUDNHDFWXDWRUDFWXDWRUKDUGZDUH@ . Bendix®7\SH3LVWRQ6W\OH7UXFN7UDLOHU8QLYHUVDO>6SULQJEUDNHDFWXDWRUDFWXDWRUKDUGZDUH@ . Bendix®7\SH3LVWRQ6W\OH7UXFN7UDLOHU8QLYHUVDO>6SULQJEUDNHDFWXDWRUDFWXDWRUKDUGZDUH@ . Bendix®7\SH3LVWRQ6W\OH7UXFN7UDLOHU8QLYHUVDO>6SULQJEUDNHDFWXDWRUDFWXDWRUKDUGZDUH@ . Bendix®7\SH'RXEOH'LDSKUDJP6W\OH7UDLOHU8QLYHUVDO>6SULQJEUDNHDFWXDWRUDFWXDWRU KDUGZDUH@ . 6WHHUDQG'ULYH$[OH$>&DOLSHUNLW@ . 6WHHUDQG'ULYH$[OH%>&DOLSHUNLW@ . 7UDLOHU$[OH$>&DOLSHUNLW@ . 7UDLOHU$[OH%>&DOLSHUNLW@ . Steer and Drive Axle, Axial5LQJLQQHUERRWFDOLSHUEROWFDSVKHDUDGDSWHU DGMXVWHUFDSV$'%;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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ap 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>1ÂP@ )LQDO7RUTXHIWOEI>1ÂP@ %HQGL[9HUWLFDO &DUULHU7RUTXH3ODWH )DVWHQHU0[[PP&ODVV Washer: None required. 8VHWKHPDQXIDFWXUHU¶VUHFRPPHQGDWLRQV ,IXQDYDLODEOHXVHSODLQDQGRLO¿QLVKIDVWHQHU 7RUTXHIWOEI>1ÂP@ )DVWHQHU0[[/&ODVV 7UDLOHU7RUTXH3ODWH /HQJWKGHWHUPLQDWLRQ 8VHWKHPDQXIDFWXUHU¶VUHFRPPHQGDWLRQV / 7RUTXH3ODWH73WKLFNQHVV&DUULHU HQJDJHPHQW:DVKHUWKLFNQHVV ,IXQDYDLODEOHXVHSKRVSKDWH DQGRLO¿QLVKIDVWHQHU LPLQ 73WKLFNQHVVPPPP 3UH7RUTXHIWOEI>1ÂP@ LPD[ 73WKLFNQHVVPPPP )LQDO7RUTXHIWOEI>1ÂP@ 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¿QDOWRUTXHRIIWOEV 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 DOLJQHGGRZQZDUGVRUZLWKLQZKHQLQVWDOOHGRQWKH 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 FRYHUVKRXOGEHSUHVHQW²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o 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 DGGLWLRQDOQLQHW\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 Section 4.1:KHQUHSODFLQJEUDNHSDGV%HQGL[ VWURQJO\UHFRPPHQGVWKDWWKHSDGVEHUHSODFHGDV DQD[OHVHW 5HIHUWRWKHYHKLFOHPDQXIDFWXUHU¶VUHFRPPHQGDWLRQV DQGUHOHDVHRUFDJHVSULQJEUDNHVDQGUHPRYHWKH ZKHHO 5HPRYHWKHSDGVSee Section 5.2 5HPRYHWKHDLUGLVFEUDNHSee Section 5.3) 5HPRYHWKHKXEURWRUDVVHPEO\ 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. 5HPRYHDQGGLVFDUGWKHWHQVSULQJHOHPHQWV 2Q GULYH D[OHV WKH$%6 WRQH ULQJ PXVW DOVR EH UHPRYHG(See Figure 86.) 5HWDLQIRUUHLQVWDOODWLRQ 8VHVXLWDEOHKDQGWRROVWRUHPRYHWKHLQWHUPHGLDWH HOHPHQWV VSDFHUV 5HPRYH DOO WKH ULJKWKDQG LQWHUPHGLDWH HOHPHQWV VSDFHUV RI HDFK VHW ¿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heel 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 ,QVWDOOWKHWHQQHZVSULQJHOHPHQWVLQFOXGHGLQWKH NLWLQDQHYHQO\GLVWULEXWHGFURVVSDWWHUQVHTXHQFH 7RUTXHWRIWOEV1ÂP FIGURE 88 - ROTOR INSTALLATION ROTOR INSTALLATION See Figures 87 through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ÂP 5HLQVWDOO WKH KXE URWRU DVVHPEO\ XVLQJ D QHZ KLJKWHPSHUDWXUHZKHHOVHDOIROORZLQJWKHYHKLFOH PDQXIDFWXUHU¶VLQVWUXFWLRQV 5HLQVWDOO WKH DLU GLVF EUDNH (See Section 5.3). 6XSSRUWLQJ WKH DLU GLVF EUDNH E\ DOO QHFHVVDU\ PHDQV DWWDFK WKH EUDNH WR WKH DQFKRU SODWH XVLQJ VL[ EROWV DQG ZDVKHUV DV UHTXLUHG %HQGL[ UHFRPPHQGV WKH RULJLQDO EROWV QRW EH UHXVHG 7RUTXH WR YHKLFOH PDQXIDFWXUHU V VSHFL¿FDWLRQV ,IWRUTXHYDOXHVDQGEROWVDUHQRWVSHFL¿HGE\WKH YHKLFOHPDQXIDFWXUHUWKHQWRUTXHDFFRUGLQJWRWKH FKDUWEHORZ%HVXUHWRVHOHFWEROWVZLWKWKHVDPH WKUHDGSLWFKOHQJWKDQGJUDGHDVRULJLQDOO\SURYLGHG IURPYHKLFOHPDQXIDFWXUHU 5HLQVWDOOWKHEUDNHSDGV(See Section 5.2). FIGURE 91 - FASTENERS INSTALLED $LU'LVF%UDNH$WWDFKPHQW+DUGZDUH 7RUTXH3ODWH0DQXIDFWXUHU %HQGL[$[LDO &DUULHU7RUTXH3ODWH )DVWHQHU )DVWHQHU0[[PP&ODVV Washer: Requires HARDENED 3 mm (minimum thickness) for each bolt.1 If the vehicle is using a Bendix manufactured Axial Anchor Plate, with a thickness of 1.14 in. (29 mm) where these bolts are assembled, then a bolt with an overall length of 2.36 in. (60 mm) will meet these requirements 7RUTXH 8VHWKHPDQXIDFWXUHU¶VUHFRPPHQGDWLRQV ,IXQDYDLODEOHXVHSKRVSKDWH DQGRLO¿QLVKIDVWHQHU 3UH7RUTXHIWOEI>1ÂP@ )LQDO7RUTXH IWOEI>1ÂP@ %HQGL[9HUWLFDO &DUULHU7RUTXH3ODWH )DVWHQHU0[[PP&ODVV Washer: None required. 8VHWKHPDQXIDFWXUHU¶VUHFRPPHQGDWLRQV ,IXQDYDLODEOHXVHSODLQDQGRLO¿QLVKIDVWHQHU 7RUTXHIWOEI>1ÂP@ )DVWHQHU0[[/&ODVV 7UDLOHU7RUTXH3ODWH /HQJWKGHWHUPLQDWLRQ 8VHWKHPDQXIDFWXUHU¶VUHFRPPHQGDWLRQV / 7RUTXH3ODWH73WKLFNQHVV&DUULHU HQJDJHPHQW:DVKHUWKLFNQHVV ,IXQDYDLODEOHXVHSKRVSKDWH DQGRLO¿QLVKIDVWHQHU LPLQ 73WKLFNQHVVPPPP 3UH7RUTXHIWOEI>1ÂP@ LPD[ 73WKLFNQHVVPPPP )LQDO7RUTXHIWOEI>1ÂP@ Washer: Requires HARDENED 3 mm (minimum thickness) for each bolt.1 Table Note: 1. The washer outside diameter must be less than 1.1in. (28.5 mm). TABLE 7 - TORQUE PLATE FASTENERS AND TORQUE RECOMMENDATIONS (SEE MANUFACTURER’S RECOMMENDATIONS) 37 SERVICE DATA INDEX Section One: Air Disc Brake Overview 1 Safe Maintenance Practices 2 Section Two: Preventive Maintenance Schedule and Wheel-On Inspections 6 3UHYHQWLYH0DLQWHQDQFH 6 %UDNH3DG$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 $GMXVWHU0HFKDQLVP,QVSHFWLRQ 11 ,QVSHFW7KH%UDNH3DGV 12 ,QVSHFW7KH5RWRU 13 *XLGH3LQ%HDULQJ,QVSHFWLRQ 14 7DSSHW$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$VVHPEOLHV29 %HQGL[®6SOLQHG'LVF®+XE5RWRU 35 &RQWDFWLQJ%HQGL[ 40 38 NOTES 39 CONTACTING BENDIX www.foundationbrakes.com %HQGL[RQOLQHLQIRUPDWLRQLVDYDLODEOH,W¶V\RXUFRPSOHWH%HQGL[UHVRXUFH Bendix Technical Assistance Team )RUGLUHFWSHUVRQDOWHFKQLFDOVXSSRUWFDOOWKH%HQGL[7HFK7HDPDW 1-800-AIR-BRAKE 5HSUHVHQWDWLYHVDUHDYDLODEOHWRDVVLVW\RX0RQGD\WKURXJK)ULGD\$0WR 30(67RUHPDLOWKH%HQGL[7HFK7HDPDW WHFKWHDP#EHQGL[FRP To better serve you, please collect the following information before you call the Bendix Tech Team, or include this information in your e-mail: %HQGL[SURGXFWPRGHOQXPEHUSDUWQXPEHUDQGFRQ¿JXUDWLRQ 9HKLFOHPDNHDQGPRGHO 9HKLFOHFRQ¿JXUDWLRQ1XPEHURID[OHVWLUHVL]HHWF 6\VWHPSHUIRUPDQFHV\PSWRPV:KHQGRWKH\RFFXU" :KDWWURXEOHVKRRWLQJPHDVXUHPHQWVKDYHEHHQSHUIRUPHG" :KDW%HQGL[VHUYLFHGDWDOLWHUDWXUHGR\RXKDYHRUQHHG" 40 %:%HQGL[6SLFHU)RXQGDWLRQ%UDNH//&$OO5LJKWV5HVHUYHG