BENDIX BW7308 User manual

BENDIX
Brand
BENDIX
Model
BW7308
Type
User manual
1
®
Bendix
®
ADB22X
™
, ADB22X-V
™
Air Disc Brakes
SD-23-7541
SECTION ONE: AIR DISC BRAKE OVERVIEW
1.1 DESCRIPTION
Bendix
®
ADB22X
™
and ADB22X-V
™
Air Disc Brakes
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Bendix
®
ADB22X-V
™
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FIGURE 1 - BENDIX
®
ADB22X
™
AIR DISC BRAKES
Sections in this Document
Section Page
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 :KHHORII0DLQWHQDQFH,QVSHFWLRQV  10-15
 0DLQWHQDQFH.LWVDQG3URFHGXUHV  16-37
Full Index - see Page 38
Section One
Section Page
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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
2
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. Park the vehicle on a level surface, apply the
parking brakes, and always block the wheels.
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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.
2. Stop the engine and remove ignition key when
working under or around the vehicle. When
working in the engine compartment, the engine
should be shut off and the ignition key should
be removed. Where circumstances require that
the engine be in operation, EXTREME CAUTION
should be used to prevent personal injury resulting
from contact with moving, rotating, leaking, heated
or electrically charged components.
3. 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.
4. 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.
5. Following the vehicle manufacturer’s recommended
procedures, deactivate the electrical system in a
manner that safely removes all electrical power
from the vehicle.
6. Never exceed manufacturer’s recommended
pressures.
7. 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.
8. 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.
9. Components with stripped threads or damaged
parts should be replaced rather than repaired.
Do not attempt repairs requiring machining or
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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
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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.
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must never be used for cleaning brake assemblies
or the work area.
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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.
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smoking; shower after working, and should not
wear work clothes home. Work clothes should
be vacuumed and laundered separately without
shaking.
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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.
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required by OSHA, are available from Bendix. Call
1-800-247-2725 and speak to the Tech Team or e-mail
[email protected]
3
5RWRULGHQWL¿FDWLRQ
See Figure 4 to help you identify which type of rotor is used
on the axle being inspected. 1RWHWKDWWKHPDLQWHQDQFH
LQVSHFWLRQ SURFHGXUH ZLOO GHSHQG RQ WKH W\SH RI URWRU
LQVWDOOHG
Conventional
Rotor
Bendix
®
Splined
Disc
®
Rotor
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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See Figure 5 for the electronic wear sensor that may be
present.
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103
Cable to Electrical
Supply
104
Cable Protection
Plate
101
Sensor
101
Sensor
105
Cable Guide
(2 alternate
designs used)
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FIGURE 5 - ELECTRONIC WEAR INDICATOR COMPONENTS
1.5 Operation
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Supply Port
Return Spring
Push rod
Lever
Outer Brake
Pad
Inner Brake Pad
Rotor
Eccentric Bearing
Service Brake
Chamber
Bridge
Pressure
Plate
Diaphragm
FIGURE 6 - CROSS-SECTION VIEW SHOWING BRAKE
OPERATION
1.5.1 Brake Release and Adjustment
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4
FIGURE 7 - SECTIONAL VIEWS
19
Lever
20
Eccentric
Bearing
43
Bolt
17
Bridge
27
Spring
2
Carrier
24
Turning
Device
33
Wear Sensor
22
Inner
Seal
16
Threaded Tube
161
Tappet
13
Tappet and
Boot Assembly
18/1 Spring Brake or
18/2
Brake Chamber
46
Rotor
Pad Assembly 12
12
Pad
Assembly
6 Guide Sleeve
2
Carrier
4
Guide Pin
9
Inner
Boot
58
Ring
39
Caliper Bolt
68
Cap
Bushing
1
Caliper
5
Guide Pin
13
Tappet and Boot
Assembly
23
Adjuster Unit
26
Spring Clip
27 Spring
7
Brass Bushing
9
Inner Boot
10
Cap
12
Pad
Assembly
16
Threaded Tube
22
Inner Seal
32
Chain Wheel
161
Tappet Bushing
61
Shear Adapter
58
Ring
45 Washer
40
Caliper Bolt
Top Sectional View
Short Caliper Bolt
Sectional View
Side Sectional View
17
Bridge
11
Pad Retainer
30
Chain
44
Pad Retainer Pin
37
Adjuster Cap
5
FIGURE 8 - EXPLODED VIEW - BENDIX
®
ADB22X
™
AND ADB22X-V
™
AIR DISC BRAKES
$GMXVWHU&DSV 37
$GMXVWHU8QLW 23
%ROW 43
%UDVV%XVKLQJ 7
%ULGJH 17
&DOLSHU 1
&DOLSHU%ROW 
&DS 68
Carrier $RU%
&KDLQ 30
&KDLQ:KHHO 32
&DS 10
(FFHQWULF%HDULQJ 20
*XLGH3LQV 
*XLGH6OHHYH 6
,QQHU%RRW 9
,QQHU6HDO 22
/HYHU 19
Pad 12/1
3DG+ROGHU6SULQJ 12/2
3DG$VVHPEO\ 12
3DG5HWDLQHU 11
3DG5HWDLQHU3LQ 44
5LQJ 58
6HUYLFH$FWXDWRU 18/2
6KHDU$GDSWHU 61
6SOLQHG'LVF+DUGZDUH
6'6'DQG6'
6SULQJ 27
6SULQJ%UDNH$FWXDWRU 18/1
6SULQJ&OLS 26
7DSSHWDQG%RRW
$VVHPEO\ 13
7DSSHW%XVKLQJ 161
7KUHDGHG7XEH 16
7XUQLQJ'HYLFH 24
:DVKHU 45
:HDU6HQVRU 33
INDEX TO FIGURES 7 & 8
18/2
Service
Actuator
Actuator
Hardware
18/1 Spring Brake
Actuator
68
Cap
39 Caliper Bolt
6 Guide Sleeve
5
Guide
Pin
61
Shear
Adapter
1
Caliper
13 Tappet
and Boot
Assembly
26 Spring Clip
11 Pad Retainer
(Pad Assembly
consists of
12/1 plus 12/2)
12/1 Pad
12/2 Pad Holder Spring
45
Washer
44
Pad Retainer Pin
2A
Bendix
®
ADB 22X
™
Carrier
2B
Bendix
®
ADB 22X-V
™
Carrier
7
Brass
Bushing
10
Cap
161
Tappet Bushing
40
Caliper
Bolt
22
Inner Seal
(Rotor Shield for Trailers)
4 Guide Pin
9
Inner Boot
58
Ring
See Section 5.2 for
exploded view of electronic
wear indicator.
*37 Adjuster
Caps (2 styles
supplied in kits)
SD-1
SD-2
SD-3
Splined Disc
®
Rotor
Hardware
SD-1, -2, -3
Splined Disc
®
Rotor
(SD)
U-shaped Rotor
Steer Hub
Drive Hub
U-shaped
Rotor
Fasteners
(or Caliper Kit)
Bendix
®
ADB22X
™
Anchor Plate
Carrier
Mounting
Hardware
Bendix
®
ADB22X-V
™
Anchor Plate
37*
Carrier
Mounting
Hardware
(Wheel turns toward
fixed pin side of
ADB)
(Fixed pin)
Type A
:KHHO5RWDWLRQ
W\SLFDOO\ULJKWKDQG
Type B
:KHHO5RWDWLRQ
W\SLFDOO\OHIWKDQG
Shield
Kit
(Drive or
Steer)
6
Table 1: Inspection Period
When
you
check
the tire
pressures
(4 to 5 times during the pad lifetime)
At the
very
least,
every
four (4)
months
At least
once
every
year
(and at
every
pad
replace-
ment)
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VFKRROEXVHVHWF
Inspections with the wheel mounted (Sections 2.1 - 2.3)
,QVSHFWWKHSDGWKLFNQHVVE\
FKHFNLQJWKHPHFKDQLFDOZHDU
LQGLFDWRUVSee Section 2.1.
,QVSHFWWKHUXQQLQJFOHDUDQFHV
XVLQJWKHTXLFNLQVSHFWLRQ
WHFKQLTXHSee Section 2.2.
,QVSHFWWKHYLVLEOHSDUWRIWKHURWRUV
IRUFUDFNVHWFSee Section 2.3.
Inspections with wheel removed (Section 4)
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®
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URWRUV,QVSHFW
UHWDLQLQJKDUGZDUHDQGFKHFN
WRUTXHVSee Section 2.3.
,QVSHFWWKHUXQQLQJFOHDUDQFHVDQG
DGMXVWHURSHUDWLRQ
See Sections 2.2 and 4.2.
,QVSHFWWKHFDOLSHUWUDYHO
See Section 4.1.
,QVSHFWWKHWDSSHWDQGERRW
DVVHPEOLHVSee Section 4.6.
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H[WHULRUIRUGDPDJHHWF
TABLE 1 - PREVENTIVE MAINTENANCE SCHEDULE
2.0 PREVENTIVE MAINTENANCE
5HJXODU LQVSHFWLRQ DQG PDLQWHQDQFH RI DLU GLVF EUDNH
FRPSRQHQWVLVDQLPSRUWDQWSDUWRIYHKLFOHPDLQWHQDQFH
7KHPDLQWHQDQFHSUDFWLFHVRXWOLQHGKHUHDUHUHFRPPHQGHG
LQ DGGLWLRQ WR DOO VWDQGDUG LQGXVWU\ SUDFWLFHV LQFOXGLQJ
GDLO\SUHWULSLQVSHFWLRQV$OVRVHHWKHYHKLFOHVPDQXDO
IRU UHFRPPHQGDWLRQV .HHS WUDFN RI WKH UHVXOWV RI \RXU
PDLQWHQDQFHLQVSHFWLRQVWRDVVLVW\RXLQGHWHUPLQLQJWKH
LGHDOPDLQWHQDQFHLQWHUYDOVIRUWKHYHKLFOH
Use the table below for a guide to maintenance interval
planning, KRZHYHUGHSHQGLQJRQWKHSDUWLFXODUYHKLFOHV
XVH PRUH IUHTXHQW FKHFNV RI WKH FRPSRQHQWV PD\ EH
QHFHVVDU\
SECTION TWO: PREVENTIVE MAINTENANCE SCHEDULE AND WHEEL-ON INSPECTIONS
* For vehicles with
electronic wear
indicatorsXVHWKH
GDVKLQGLFDWRUV
DQGRUWKHKDQGKHOG
GLDJQRVWLFWRROWR
UHJXODUO\PRQLWRUWKH
SDGZHDU
See Section 5.2.
Section Two
Section Page
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 %UDNH3DGDQG5RWRU,QVSHFWLRQV   7-8
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7
2.1 BRAKE PAD AND ROTOR INSPECTIONS
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VDPHWLPH
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3DGVDUHLQPPWKLFNZKHQQHZDQGPXVWEH
UHSODFHGZKHQWKH\UHDFKLQPP5RWRUVDUH
LQPPWKLFN ZKHQ QHZ DQG PXVW EH UHSODFHG
ZKHQWKH\ UHDFKLQPP See Section 4.3 for
further inspection criteria.
2.1.1 Electronic Wear Indicators
8VHWKHGDVKLQGLFDWRUVDQGRUDKDQGKHOGGLDJQRVWLF
WRROWRUHJXODUO\PRQLWRUWKHSDGZHDU(See Section 5.2.)
2.1.2 Mechanical Wear Indicators
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LQGLFDWRUV7KHUHDUHWZRW\SHV(See Figure 10 for Style A
and Figure 11 for Style B)
Location of Wear
Indicator Notches
(Both sides of brake)
Quick Visual
Inspection of Pad
Thickness and Rotor
FIGURE 9 - LOCATION OF WEAR INDICATORS
Note: These mechanical wear indicators do
not constitute “out-of-service” criteria. 7KHVH
LQVSHFWLRQVRQO\VKRZZKHQWRVFKHGXOHDIXOOZKHHO
UHPRYHG LQVSHFWLRQ RI WKH EUDNH SDGV DQG URWRU
7KHWKLFNQHVVHVRIWKHSDGDQGURWRUZLOOERWKDIIHFW
WKHZHDU LQGLFDWRU SRVLWLRQDW ZKLFK PDLQWHQDQFH LV
DFWXDOO\QHHGHG
Wear Indicator Style A:
Where both the carrier and caliper have an
indicator notch.
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WKHFDUULHUDQGFDOLSHU:KHQWKHWZRQRWFKHVDOLJQ
LWLVWLPHWRVFKHGXOHDIXOOZKHHOUHPRYHGLQVSHFWLRQ
RIWKHSDGVDQGURWRU
Notch in the
caliper
Notch in the
carrier
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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HGJHRIWKHWRUTXHSODWHLWLVWLPHWRVFKHGXOHDIXOO
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Torque
plate
No notch
in the
carrier
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
FIGURE 11 - CARRIER WEAR INDICATOR NOTCH AND BACKING
PLATE ALIGNMENT
8
2.1.3 Rotor Quick Inspection
See Figure 126HHWKHYDULRXVSRWHQWLDOURWRUFRQGLWLRQV
WKDW\RXPD\¿QG6HHWKHFULWHULDEHORZIRUZKHWKHUWKH
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LQVSHFWLRQ
2.2 RUNNING CLEARANCE QUICK
INSPECTION
CAUTION: Follow all safe maintenance practices.
2QOHYHOJURXQGZLWKWKHZKHHOVFKRFNHGDQGWKHSDUNLQJ
EUDNH WHPSRUDULO\ UHOHDVHG FKHFN IRU PRYHPHQW RI WKH
EUDNHFDOLSHU7KLVVPDOOPRYHPHQWOHVVWKDQPP
DSSUR[LPDWHO\WKHWKLFNQHVVRIDQLFNHOLQWKHLQERDUG
RXWERDUG GLUHFWLRQ LQGLFDWHV WKDW WKH EUDNH LV PRYLQJ
SURSHUO\RQLWVJXLGHSLQV
,IWKHFDOLSHUKDVQRPRYHPHQWRUDSSHDUVWRPRYHJUHDWHU
WKDQ WKH GLVWDQFHV QRWHG DERYH D IXOO ZKHHOUHPRYHG
LQVSHFWLRQZLOOEHQHFHVVDU\(See Section 4.1)
FIGURE 13 - CALIPER RUNNING CLEARANCE
(FIGURE DOES NOT SHOW WHEEL)
FIGURE 12 - EXAMPLES OF ACCEPTABLE AND NON-ACCEPTABLE ROTOR CRACKS AND GROOVES
Push/Pull
By Hand
to Check
the Caliper
Movement
Area
F
Area
H
Area G
f
Area J
&UDFNVUHDFKLQJ
HLWKHUHGJHRIWKH
G
H
URWRU
DUHQRW
DFFHSWDEOH
IRUHLWKHU
W\SHRI
URWRU
&LUFXPIHUHQWLDO
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-DUHDFFHSWDEOH
LIOHVVWKDQLQ
PPGHHS
J
 )RU standard Bendix rotors FUDFNV
UXQQLQJ LQ D UDGLDO GLUHFWLRQ ² OLNH
VSRNHVRIDZKHHOVHH$UHD+²OHVV
WKDQ0.06 in. (1.5 mm) GHHSRU ZLGH
DUH DFFHSWDEOH LI WKH\ GR QRW UHDFK
HLWKHUHGJH(see G) &UDFNVDUH RQO\
DFFHSWDEOHLIWKHOHQJWKRIWKHFUDFNLV
OHVVWKDQRIGLPHQVLRQ³I´WKHZLGWK
RIWKHURWRUFRQWDFWDUHD
 )RUBendix Splined Disc rotorsUDGLDO
FUDFNVDUHRQO\DFFHSWDEOHLIWKH\DUH
OHVV WKDQ 0.04 in. (1.0 mm) GHHS RU
ZLGHDQGLIWKH\GRQRWUHDFKHLWKHUHGJH
(see G). &UDFNOHQJWKVPXVW EHOHVV
WKDQ  RI GLPHQVLRQ ³I´ WKH ZLGWK
RIWKHURWRUFRQWDFWDUHD
,QDGGLWLRQIROORZWKH
UHFRPPHQGDWLRQVRIWKH
YHKLFOHPDQXIDFWXUHU
Note: Axles should
have either all Bendix
Splined Disc (or all
conventional) rotors.
Rotor
Friction
Surface
Width “f”
1R DFWLRQ LV QHHGHG
I R U V P D O O F U D F N V
V S U H D G R Y H U W K H
VXUIDFHHJ$UHD)
F
9
FIGURE 14 - TROUBLESHOOTING BENDIX AIR DISC BRAKES
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.
Tightness not due to
air disc brake. See
vehicle manual.
Replace caliper/
carrier assembly
(5.3)
Drain air pressure from
system. Re-start test after
caging spring brakes
Replace caliper/
carrier assembly
(5.3)
NO
NO
NO
NO
NO
NO
NO
NO
YES
YES
YES
YES
YES
YES
YES
YES
Replace guide pins
(5.6) OR replace
caliper/carrier
assembly (5.3)
Replace components
as needed with
genuine Bendix parts.
Disc brake OK
Does
the wheel
turn smoothly?
Is
the
spring brake fully/
partially applied?
Check
running
clearance (4.1)
- OK?
Check
caliper
guidance (4.5)
- OK?
Check
running
clearance (4.1)
- OK?
Check
adjuster (4.2)
- OK?
Check
Pad and rotor
wear (4.3-4.4)
- OK?
Check
Adjuster (4.2)
- OK?
10
Section Four
Section Page
 :KHHO2II,QVSHFWLRQV        10
 &DOLSHU0RYHPHQW7HVW       10
 $GMXVWHU0HFKDQLVP,QVSHFWLRQ    11
 %UDNH3DGVDQG5RWRUV      12-14
 ,QVSHFWWKH%UDNH3DGV       12
 ,QVSHFWWKH5RWRU        13-14
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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
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UHPRYLQJWKHZKHHO
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WKHUHLVQRFRQWDFWEHWZHHQWKHFDOLSHUDQGD[OHYHKLFOH
FKDVVLVVHFWLRQVRUFDUULHUHWFWKDWPD\EHLPSHGLQJWKH
IUHHPRYHPHQWRIWKHFDOLSHU
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UHLQVWDOOLQJ D ZKHHO
DFFRUGLQJWRWKHYHKLFOHPDQXIDFWXUHUVUHFRPPHQGDWLRQV
SOHDVHHQVXUHWKDWWKHUHLVVXI¿FLHQWFOHDUDQFHEHWZHHQ
WKHWLUHLQÀDWLRQYDOYHVWHPWKHFDOLSHUDQGWKHZKHHOULP
WRDYRLGGDPDJH
SECTION FOUR: WHEEL-OFF MAINTENANCE INSPECTIONS
4.1 CALIPER MOVEMENT TEST
CAUTION: Follow all safe maintenance practices.
5HPRYHWKHZKHHO:LWKWKHVSULQJEUDNHVUHOHDVHGRU
FDJHGSXVKWKHFDOLSHUDVVHPEO\LQERDUGRQLWVJXLGHSLQV
Note: To fully release the spring brakes, assure that the
air system pressure is at least 90 PSI. 8VLQJDVXLWDEOH
WRROIRUH[DPSOHDODUJHÀDWEODGHVFUHZGULYHUSUHVVWKH
LQERDUGSDGDZD\IURPWKHWDSSHWV&KHFNWKDWWKHUH
LVQRGLUWHWFLQWKHJDSDQGFOHDQLIQHFHVVDU\7KHQXVH
WZRORQJEODGHIHHOHUJDXJHVWRPHDVXUHRYHUWKHZKROH
WDSSHWVXUIDFHWKHJDSEHWZHHQWKHPDQGWKHLQERDUGSDG
EDFNSODWH(See Figure 16.) 7KHJDSVKRXOGEHEHWZHHQ
LQPPDQGLQPPIf the gap is
within the range given, the test is complete.
Pull
Caliper
Inboard
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.
)RUIXUWKHULQYHVWLJDWLRQZKHUHWKHUHLVVRPHJDSJRWR
6HFWLRQDQGFKHFNWKHDGMXVWHUPHFKDQLVP:KHUH
WKHUHLVQRPRYHPHQWDWDOODQGVRQRJDSWRPHDVXUH
JRWR6HFWLRQ³*XLGH3LQ,QVSHFWLRQ´
11
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
FDUULHGRXWZKHQWKH&DOLSHU0RYHPHQW7HVW¿QGV
that the running clearance is too small or too large.
 :LWKWKHVSULQJEUDNHUHOHDVHGRUFDJHGUHPRYH
WKHDGMXVWHUFDSXVLQJWKHWDEWDNLQJFDUHQRW
WRPRYHWKHVKHDUDGDSWHU1RWH2QHRIWZR
VW\OHV RI DGMXVWHU FDS VWDPSHG PHWDO RU SODVWLF
DGMXVWHUFDSPD\EHXVHG
Adjuster Cap
Location
FIGURE 17 - ADJUSTER CAP LOCATION
61 Adapter
23 Adjuster
37
Cap
Tab
Tab
37
Cap
FIGURE 18 - EXPLODED VIEW
OF ADJUSTER AND ADAPTER
FIGURE 19 - CAP INSTALLED:
TAB LOCATION
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VKRZVWKHDGMXVWHUDQGVKHDUDGDSWHUVHSDUDWHG
:KHQ XVLQJ WKH DGMXVWHU PHFKDQLVP DOZD\V KDYH WKH
VKHDUDGDSWHULQVWDOOHGRQWKHDGMXVWHU
 8VLQJDPPVL[SRLQWER[ZUHQFKWXUQWKH6KHDU
$GDSWHU  counter-clockwise DQG OLVWHQ IRU
WKHVRXQGRIFOLFNVDVWKHPHFKDQLVPEDFNVRII
LQFUHDVHVWKH UXQQLQJ FOHDUDQFH 1RWH 'R QRW
XVHDQRSHQHQGHG ZUHQFKDV WKLVPD\ GDPDJH
WKHDGDSWHUSee Figure 20.
CAUTION: Never turn the adjuster (23) without the
shear adapter (61) installed. The shear adapter is a
safety feature and is designed to prevent excessive
torque from being applied to the adjuster. The shear
adapter will fail (by breaking) if too much torque is
applied.
FIGURE 20 - BACKING-OFF (INCREASING) THE RUNNING
CLEARANCE
,IWKHVKHDUDGDSWHUIDLOV\RXPD\DWWHPSWDVHFRQGWLPH
ZLWKDQHZXQXVHGVKHDUDGDSWHU
Note: Always double-check that the spring brake is released
(where applicable) if a shear adapter fails; if this step was
missed, the shear adapter will break off, and it may appear
that the caliper is seized.
,Q FDVHV ZKHUH D VHFRQG IDLOXUH RI WKH VKHDU DGDSWHU
FRQ¿UPV WKDW WKH DGMXVWPHQW PHFKDQLVP LV VHL]HG WKH
FDOLSHUPXVWEHUHSODFHG
FIGURE 21 - APPLYING MODERATE APPLICATIONS OF THE
BRAKES: THE WRENCH MOVES CLOCKWISE AS THE RUNNING
CLEARANCE IS DIMINISHED
 :KHUHWKHDGMXVWHUPHFKDQLVPLVDEOHWREHEDFNHG
RIIQRUPDOO\SRVLWLRQDER[HQGZUHQFKRQWKHVKHDU
DGDSWHUVRWKDWLWFDQWXUQFORFNZLVHIUHHO\ZLWKRXW
FRPLQJLQWRFRQWDFWZLWKSDUWVRIWKHYHKLFOH(See
Figure 21). 0DNH¿YHWRWHQPRGHUDWHDSSOLFDWLRQV
RIWKHEUDNHV>DWDERXWSVL%DU@DQGREVHUYH
WKDW WKH ER[HQG ZUHQFK RU VRFNHW VKRXOG WXUQ
FORFNZLVHLQVPDOOLQFUHPHQWV
127($V WKH QXPEHU RI DSSOLFDWLRQV LQFUHDVHV
WKHWXUQLQJPRYHPHQWZLOOGHFUHDVHDVWKHEUDNH
UHDFKHVLWVQRUPDOFDOLEUDWLRQSRLQW
,IWKHER[HQGZUHQFKGRHVQRWDWXUQDWDOOEWXUQVRQO\
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OLWKLXPEDVHGJUHDVHZKHQUHWXUQLQJWKHEUDNHWRVHUYLFH
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12
4.3- 4.4 BRAKE PADS AND ROTORS
CAUTION: Follow all safe maintenance practices.
,IHOHFWURQLFZHDUVHQVRUVDUHSUHVHQWsee Section 5.2.
,IGXVWFRYHUVDUHSUHVHQWsee Section 5.1.
See Figure 23. :KLOH SUHVVLQJ GRZQ DJDLQVW WKH SDG
UHWDLQLQJ EDU  UHPRYH DQG UHWDLQ WKH FOLS 
ZDVKHUDQGSLQ5HPRYHWKHSDGUHWDLQHUEDU
%HQGL[UHFRPPHQGVWKDWWKHVHLWHPVVKRXOGEHUHSODFHG
ZLWKQHZ(See available kits and parts, Section 5.0)
)ROORZWKHVWHSVLQ6HFWLRQIRUEDFNLQJRIIWKHDGMXVWHU
PHFKDQLVP 6OLGH WKH FDOLSHU LQERDUG WKHQ RXWERDUG WR
SHUPLWHDV\UHPRYDORIWKHEUDNHSDGV
A 7KLFNQHVVRIDQHZSDGLQPP
B %DFNLQJSODWHWKLFNQHVVLQPP
C 0LQLPXPWKLFNQHVVRIIULFWLRQPDWHULDOLQ
PP
D 0LQLPXPWKLFNQHVVRI DZRUQ SDGLQ
PPUHSODFHSDGV
( 7KLFNQHVV RI D QHZ URWRU LQ PP
0LQLPXPURWRUWKLFNQHVVLQPP
Outboard
Brake Pad
Inboard
Brake Pad
Brake Rotor
FIGURE 22 - PAD AND ROTOR DIMENSIONS
See Figure 22 for initial brake pad and rotor dimensions,
as well as minimum acceptable dimensions.
44
Pin
26 Spring Clip
45 Washer
11 Pad Retainer Bar
FIGURE 23 - RETAINER BAR REMOVAL
4.3 INSPECT THE BRAKE PADS
5HJXODULQVSHFWLRQRIWKHEUDNH SDGV HYHQIRUYHKLFOHV
WKDWXVHDQHOHFWURQLFZHDULQGLFDWRULVDQLPSRUWDQWSDUW
RIYHKLFOHPDLQWHQDQFH
4.3.1 See Figure 22. ,I WKH WKLFNQHVV RI WKH IULFWLRQ
PDWHULDO²GLPHQVLRQ³&´²LVOHVVWKDQLQ
PPWKHSDGVPXVWEHUHSODFHG
Bendix
®
ADB22X
™
$'%;9
™
DLUGLVFEUDNHVXVHLQ
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SDGDQGEDFNLQJSODWHWKLFNQHVVPXVWEHDPLQLPXPRI
LQPP
 &KHFN IRU XQHYHQ HQGWRHQG SDG ZHDU ,I WKH
GLIIHUHQFHLQZHDULVJUHDWHUWKDQLQPP
UHSODFHWKHEUDNHSDGVDQGDOVRLQVSHFWWKHJXLGH
SLQV(See Section 4.5)
 &RPSDUHWKHWKLFNQHVVRIWKHLQERDUGDQGRXWERDUG
SDGV RI HDFK VHW ,I WKH GLIIHUHQFH EHWZHHQ WKH
LQERDUGDQGRXWERDUGSDGWKLFNQHVVLVJUHDWHUWKDQ
LQ PP UHSODFH WKH EUDNH SDGV DQG
LQVSHFWWKHJXLGHSLQV(See Section 4.5)
,IWKHUHVXOWVRIWKHSDGLQVSHFWLRQVDUHZLWKLQWKHDFFHSWDEOH
UDQJHLQVSHFWWKHSDGVXUIDFH(See Figure 24)
Minor Damage -
Is Acceptable
Where a
small amount
of brake
material
chipped from
the edge
Major Damage -
Is Not Acceptable
Section
damaged or
missing
FIGURE 24 - BRAKE PAD SURFACE INSPECTION
0LQRUGDPDJHDWWKHHGJHVLVSHUPLWWHGEXWUHSODFHWKH
SDGVLIPDMRUGDPDJHRQWKHVXUIDFHRIWKHSDGLVIRXQG
:KHQUHSODFLQJEUDNHSDGV%HQGL[VWURQJO\UHFRPPHQGV
WKDWDOOWKHEUDNHSDGVRQDQD[OHEHUHSODFHGDWRQHWLPH
See Section 5.1 for the pad replacement procedure$OVR
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WKHRSHUDWRU¶VPDQXDO
13
%HQGL[DLUGLVFEUDNHVDUHSUHFLVLRQHQJLQHHUHGEUDNLQJ
PHFKDQLVPV7KH³IULFWLRQFRXSOH´EUDNLQJFKDUDFWHULVWLFV
KDYHEHHQFDUHIXOO\RSWLPL]HG²DQGWKHURWRUGHVLJQDQG
PDWHULDOV KDYH EHHQ PDWFKHG ZLWK VSHFLDO IRUPXODWLRQ
EUDNH SDGV IRU RSWLPDO SHUIRUPDQFH ,Q DOO FDVHV XVH
EUDNHSDGVZLWKWKHW\SHRIEDFNLQJSODWHDQGOLQLQJPDWHULDO
RULJLQDOO\VXSSOLHGE\WKHYHKLFOHPDQXIDFWXUHU
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\LIWKHURWRULVD%HQGL[
®
6SOLQHG'LVF
®
RU%HQGL[
®
EUDQGFRQYHQWLRQDOURWRU6ee Section 1.035RWRUVVKRXOG
EHLQVSHFWHGUHJXODUO\(See Section 2.0 for recommended
inspection schedule) and DWHDFKSDGFKDQJH
 0HDVXUH WKH WKLFNQHVV RI WKH EUDNH URWRU DW WKH
WKLQQHVWSRLQW'LPHQVLRQ³(´LQ)LJXUH$YRLG
PHDVXULQJ QHDU WKH HGJH RI WKH URWRU DV PLQRU
EXUUVPD\UHVXOWLQLQDFFXUDWHPHDVXUHPHQWFor
Bendix
®
brand rotors, replace the rotor when
the minimum thickness of 1.46 in. (37 mm.) is
reached. )RURWKHUEUDQGVRIURWRUVUHIHUWRWKH
URWRUPDQXIDFWXUHU¶VJXLGHOLQHV
 ,QVSHFWWKHURWRUVXUIDFHSee Figure 25. 7KHW\SH
RIURWRUDQGDOVRWKHVL]HGHSWKDQGGLUHFWLRQRI
WKHLPSHUIHFWLRQVPXVWDOOEHFRQVLGHUHG
NOTE: If surface wear conditions F through J are
in the permitted range, the rotor is still usable until
it reaches the minimum acceptable thickness for the
rotor manufacturer’s guideline.
4.4.3 Machining (Grinding or Turning) Rotors
Bendix
®
EUDQGURWRUVDUHQRUPDOO\VHUYLFHIUHH,QWKHFDVH
RIVHYHUHJURRYLQJRIWKHHQWLUHIULFWLRQVXUIDFHKRZHYHU
CONVENTIONAL ROTORSPD\EHWXUQHGZKHQFKDQJLQJ
SDGVWRLQFUHDVHWKHORDGEHDULQJVXUIDFH
FIGURE 25 - EXAMPLES OF ACCEPTABLE AND NON-ACCEPTABLE ROTOR CONDITIONS
Area
F
Area
H
Area G
f
Area J
&UDFNVUHDFKLQJ
HLWKHUHGJHRIWKH
G
H
URWRU
DUHQRW
DFFHSWDEOH
IRUHLWKHU
W\SHRI
URWRU
&LUFXPIHUHQWLDO
JURRYHVDVLQ$UHD
-DUHDFFHSWDEOH
LIOHVVWKDQLQ
PPGHHS
J
 )RU standard Bendix
®
brand rotors
FUDFNVUXQQLQJLQDUDGLDOGLUHFWLRQ²
OLNH VSRNHV RI D ZKHHO VHH $UHD +
²OHVVWKDQ0.06 in. (1.5 mm)GHHSRU
ZLGHDUHDFFHSWDEOHLIWKH\GRQRWUHDFK
HLWKHUHGJH(see G) &UDFNVDUH RQO\
DFFHSWDEOHLIWKHOHQJWKRIWKHFUDFNLV
OHVVWKDQRIGLPHQVLRQ³I´WKHZLGWK
RIWKHURWRUFRQWDFWDUHD
 )RU Bendix
®
Splined Disc rotors
UDGLDOFUDFNVDUHRQO\DFFHSWDEOHLIWKH\
DUHOHVVWKDQ0.04 in. (1.0 mm)GHHS
RUZLGHDQGLIWKH\GRQRWUHDFKHLWKHU
HGJH(see G). &UDFNOHQJWKVPXVWEH
OHVV WKDQ  RI GLPHQVLRQ ³I´ WKH
ZLGWKRIWKHURWRUFRQWDFWDUHD
,QDGGLWLRQIROORZWKH
UHFRPPHQGDWLRQVRI
WKHYHKLFOHDQGURWRU
PDQXIDFWXUHU
Note: Axles should
have either all Bendix
Splined Disc (or all
conventional) rotors.
Rotor
Friction
Surface
Width “f”
1R DFWLRQ LV QHHGHG
I R U V P D O O F U D F N V
V S U H D G R Y H U W K H
VXUIDFHHJ$UHD)
F
14
Caliper
Movement
1
Caliper
5
Guide Pin
9
Inner Boot
9 Inner Boot
7
Brass Bushing
10
Cap
6 Guide Sleeve
4 Guide Pin
39
Caliper Bolt
Outboard Inboard
68
Cap
SHORT
BEARING SIDE
LONG
BEARING SIDE
FIGURE 26 - GUIDE PINS
12 Pad Assembly
1
Carrier
2
Caliper
Magnetic
Dial-Gauge
Measures
Range Here
FIGURE 27 - MAGNETIC DIAL-GAUGE IN USE
Measure the “play” (range of movement) in the guide
pin bearings:
 See Figures 26 and 27.:LWKWKHZKHHOUHPRYHG
UHPRYH WKH SDG UHWDLQHU EDU  7HPSRUDULO\
UHSODFHWKHSDGVZLWKWZRQHZSDGV$WWDFK
DPDJQHWLFGLDOJDXJHKROGHUWRWKHFDUULHURQ
WKHVKRUWEHDULQJVLGHRIWKHFDOLSHU8VHWKH
PHDVXULQJSRLQWRQWKHFDOLSHUVHHWKHFDOORXW
MACHINING OF BENDIX
®
SPLINED DISC
®
ROTORS IS
NOT PERMITTED.
&$87,21$OZD\VPDLQWDLQDLUGLVFEUDNHSDGVDQGURWRUV
ZLWKLQ VSHFL¿FDWLRQV ([FHVVLYH SDG RU URWRU ZHDU ZLOO
GHJUDGHEUDNLQJSHUIRUPDQFH
3HULRGLFLQVSHFWLRQRIWKH%HQGL[6SOLQHG'LVFDWWDFKPHQW
KDUGZDUH LV UHFRPPHQGHG WR HQVXUH RSWLPXP EUDNLQJ
SHUIRUPDQFH%HQGL[UHFRPPHQGVYHULI\LQJWKHWRUTXHRQ
WKHVSULQJHOHPHQWIDVWHQHUVZKHQHYHUDEUDNHLQVSHFWLRQ
LVSHUIRUPHG
WARNING! AFTER MACHINING/TURNING,
THE MINIMUM ROTOR THICKNESS FOR BENDIX
®
BRAND ROTORS MUST BE AT LEAST 1.535 - 1.575IN.
(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.
4.4.4 Rotor Replacement
An axle is permitted to have only all Bendix Splined
Disc, or all conventional, rotors.
:KHQUHSODFLQJURWRUVEHVXUHWRDGKHUHWRWKHYHKLFOH
PDQXIDFWXUHUVUHFRPPHQGDWLRQVLQFOXGLQJEROWWLJKWHQLQJ
WRUTXHV,WLVUHFRPPHQGHGWRLQVWDOORQO\%HQGL[
®
brand
URWRUVDQGDOVRWKDWWKHSDGVVKRXOGEHUHSODFHGDVDQ
D[OHVHWDWWKHVDPHWLPH
Non-Bendix
®
brand rotors.,IDQRQ%HQGLx
®
brand URWRULV
XVHGFRQ¿UPWKDWLWFRPSOLHVWRWKHYHKLFOHPDQXIDFWXUHUV
UHFRPPHQGDWLRQV
CAUTION: The use of non-approved brake rotors may
reduce levels of safety and invalidate the warranty.
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
0RYHPHQW7HVW6HFWLRQVDQGRU
Measure the range of travel along the guide pin
bearings:
 5HPRYHWKH3DGV(See Section 4.3)8VLQJKDQG
SUHVVXUHRQO\QRWRROVWKHFDOLSHUVKRXOGVOLGH
IUHHO\DORQJWKHZKROHOHQJWKRIWKHJXLGHSLQV7KLV
PRYHPHQWVKRXOG EH DW OHDVW  LQFK  PP
ZKHQWKHSDGVDUHQRWSUHVHQW,IWKHPRYHPHQW
LVOHVVWKDQWKLVDPRXQWUHSODFHWKHFDOLSHUFDUULHU
DVVHPEO\
15
LQ)LJXUH3UHVVWKHFDOLSHULQWKHGLUHFWLRQRI
WKHFDUULHUDQGVHWWKHGLDOJDXJHWR]HUR
 3ODFH D VXLWDEOH WRRO HJ D ODUJH IODWEODGH
VFUHZGULYHUEHWZHHQFDUULHUDQGFDOLSHUDQG
XVHOLJKWKDQGIRUFHWRPRYHWKHFDOLSHUDZD\IURP
WKH FDUULHU XQWLO WKH PRYHPHQW VWRSV 5HDG WKH
PD[LPXPYDOXHRQWKHGLDOJDXJHSee Figure 27.
,I WKH YDOXH LV JUHDWHU WKDQ LQ  PP UHSODFH
WKHJXLGHSLQEXVKLQJV(See Section 5.6)25UHSODFHWKH
FDOLSHUFDUULHUDVVHPEO\(See Section 5.3)
Inspect the guide pin inner boots:
 See Figures 28 and 29. :LWKWKHSDGVUHPRYHG
VOLGHWKHFDUULHUE\KDQGWRWKHLQERDUGSRVLWLRQ(See
Figure 28)%\ORRNLQJWKURXJKWKHRSHQLQJZKHUH
WKHSDGVDUHLQVWDOOHG²DQGDOVRIURPEHORZ²
LQVSHFWWKHLQQHUERRWIRUHDFKRIWKHJXLGHSLQV
INSPECT FOR DAMAGE, CUTS AND CRACKS.
5HSODFH GDPDJHG ERRWV LPPHGLDWHO\ WR SUHYHQW
GLUWDQGRUPRLVWXUHDIIHFWLQJWKHPRYHPHQWRIWKH
JXLGHSLQV(See Section 5.4)'DPDJHGRUFRUURGHG
JXLGHSLQVZLOOLPSDLUWKHRSHUDWLRQRIWKHEUDNH
,Q DGGLWLRQ GXULQJ LQVWDOODWLRQ WKH ERRWV DUH
FRPSUHVVHGWRPLQLPL]HWKHDPRXQWRIDLUWUDSSHG
ZLWKLQWKHP2EVHUYHDV\RXPRYHWKHFDUULHUEDFN
WRZDUGVWKHRXWERDUGSRVLWLRQWKHERRWVVKRXOGRQO\
H[SDQGRXWZDUGVDVPDOODPRXQWGXHWRWUDSSHG
DLU7KHERRWVVKRXOGQRUPDOO\GXHWRWKHLUULEEHG
FRQVWUXFWLRQFRQWUDFWEDFNLQWRSODFHDVWKHFDOLSHU
PRYHVRQWKHJXLGHSLQV7KHERRWVDUHQRWDLU
WLJKWDQGVRVRPHWUDSSHGDLULVQRUPDOH[FHVVDLU
WUDSSHGZLOOGLVVLSDWH
Inspect
Boot
FIGURE 28 - GUIDE PIN BOOT INSPECTION (THIS IMAGE DOES
NOT SHOW THE CARRIER)
 ,QVSHFWWKHRULJLQDOSDGV(See Section 4.3)DQGWKH\
PD\EHUHXVHGLIWKH\DUHLQJRRGFRQGLWLRQZLWK
VXI¿FLHQWSDGWKLFNQHVV
4.6 TAPPET AND BOOT ASSEMBLY
INSPECTION
 ,QRUGHUWRLQVSHFWWKHWDSSHWDQGERRWDVVHPEO\
UHPRYHWKHSDGV(See Sections 4.3 or 5.2) and
DGYDQFHWKHVKHDUDGDSWHUFORFNZLVH
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,
C R A C K S , T E A R S A N D E V I D E N C E O F
CORROSION, ETC. 'DPDJHGERRWVOHDGWRWKH
SHQHWUDWLRQRIGLUWDQG PRLVWXUHDQGFDQ OHDG WR
FRUURVLRQ DQG LPSDLU WKH RSHUDWLRQ RI WKH EUDNH
5HSODFHDVQHFHVVDU\(See Section 5.5)
13
Extend LESS THAN
1.75 in. (44.5 mm.)
FIGURE 29 - PERMITTED TAPPET EXTENSION
:KHUHWKHWDSSHWVDQGERRWVSDVVWKHLQVSHFWLRQUHWUDFW
WKHWDSSHWVXVLQJWKHVKHDUDGDSWHU
:KHQLQVWDOOHGWKHERRWVDUHFRPSUHVVHGWRPLQLPL]HWKH
DPRXQWRIDLUWUDSSHGZLWKLQWKHP2EVHUYHDV\RXPRYH
WKHWDSSHWEDFNXVLQJWKHVKHDUDGDSWHUWKHERRWVVKRXOG
RQO\H[SDQGRXWZDUGVDVPDOODPRXQWGXHWRWUDSSHGDLU
7KHERRWVVKRXOGQRUPDOO\GXHWRWKHLUULEEHGFRQVWUXFWLRQ
FRQWUDFWEDFNLQWRSODFHDVWKHWDSSHWVPRYH1RWH,IWKH
EHOORZV KDYH H[FHVV DLU WUDSSHG WKHQ ZLWK WKH WDSSHWV
UHWUDFWHGUHPRYH DQG UHLQVWDOOWKH DFWXDWRUWR YHQWWKH
H[FHVVWUDSSHGDLU(See Section 5.4).
)ROORZ WKH UHLQVWDOODWLRQ VWHSV IRU WKH EUDNH SDGV (See
Section 5.2)
16
SECTION FIVE: MAINTENANCE KITS AND PROCEDURES
Section Five
Section Page
 0DLQWHQDQFH.LWV        16-17
 $LU'LVF%UDNH6KLHOG.LW      19
 3DG5HSODFHPHQW         20
 &DOLSHU&DUULHU$FWXDWRU$VVHPEO\   22-23
Section Page
 6SULQJ6HUYLFH%UDNH       24
 7DSSHW%RRWDQG7DSSHW,QQHU6HDO 25-28
 *XLGH3LQDQG%RRW$VVHPEOLHV   29-34
 %HQGL[
®
6SOLQHG'LVF
®
+XE5RWRU   35-37
18/2
Service
Actuator
Actuator
Hardware
FIGURE 30 - EXPLODED VIEW - BENDIX
®
ADB22X
™
AND ADB22X-V
™
AIR DISC BRAKES
18/1 Spring Brake
Actuator
68
Cap
39 Caliper Bolt
6 Guide Sleeve
5
Guide
Pin
61
Shear
Adapter
1
Caliper
13 Tappet
and Boot
Assembly
26 Spring Clip
11 Pad Retainer
(Pad Assembly
consists of
12/1 plus 12/2)
12/1 Pad
12/2 Pad Holder Spring
45
Washer
44
Pad Retainer Pin
2A
Bendix
®
ADB 22X
™
Carrier
2B
Bendix
®
ADB 22X-V
™
Carrier
7
Brass
Bushing
10
Cap
161
Tappet Bushing
40
Caliper
Bolt
22
Inner Seal
(Rotor Shield for Trailers)
4 Guide Pin
9
Inner Boot
58
Ring
See Section 5.2 for
exploded view of electronic
wear indicator.
*37 Adjuster
Caps (2 styles
supplied in kits)
SD-1
SD-2
SD-3
Splined Disc
®
Rotor
Hardware
SD-1, -2, -3
Splined Disc
®
Rotor
(SD)
U-shaped Rotor
Steer Hub
Drive Hub
U-shaped
Rotor
Fasteners
(or Caliper Kit)
Bendix
®
ADB22X
™
Anchor Plate
Carrier
Mounting
Hardware
Bendix
®
ADB22X-V
™
Anchor Plate
37*
Carrier
Mounting
Hardware
(Wheel turns toward
fixed pin side of
ADB)
(Fixed pin)
Type A
:KHHO5RWDWLRQ
W\SLFDOO\ULJKWKDQG
Type B
:KHHO5RWDWLRQ
W\SLFDOO\OHIWKDQG
Shield
Kit
(Drive or
Steer)
17
Kit
See Section
Piece
Number
Components Included in Kit
Dust Shields 6HFWLRQ
803129 7UDLOHU$[OH3DG5RWRU6KLHOG.LW
803130 'ULYH$[OH3DG5RWRU6KLHOG.LW
802948 6WHHU$[OH3DG6KLHOG.LW
Pad Kit (axle set)
6HFWLRQ 802078
3DGUHWDLQHUEDUVVHWRIIRXUSDGVDQGKROGHUVSULQJVDGMXVWHUFDSVSDGUHWDLQHU
SLQVZDVKHUVVKHDUDGDSWHUV
Spring Clip Kit (box of 25) NA 803151 6SULQJFOLSV
Shear Adapter (box of 10) NA 802455 6KHDUDGDSWHUV
Tappet/Boot Kit (wheel end kit) 6HFWLRQ 802119 7DSSHWDQGERRWDVVHPEO\WDSSHWEXVKLQJLQQHUVHDO
Adjuster Cap
(kit has ten each of two styles)
NA 802643 $GMXVWHUFDSV
Guide Pin, Seal and Boot Kit
(wheel end kit)
6HFWLRQ 803114
5LQJLQQHUERRWEUDVVEXVKLQJJXLGHSLQFDOLSHUEROWFDSJXLGHVOHHYH
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Guide Pin Grease NA
14525 :KLWHJUDPV
. :KLWHJUDPV
Service Actuator 6HFWLRQ
. Bendix
®
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. Bendix
®
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. Bendix
®
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. Bendix
®
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Spring Brake Actuator 6HFWLRQ
.
Bendix
®
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.
Bendix
®
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.
Bendix
®
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.
Bendix
®
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KDUGZDUH@
Caliper Kit
(rationalized)
Includes 803114 kit shown above
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. 7UDLOHU$[OH$>&DOLSHUNLW@
. 7UDLOHU$[OH%>&DOLSHUNLW@
Carrier Kit
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
.
Steer and Drive Axle, Axial5LQJLQQHUERRWFDOLSHUEROWFDSVKHDUDGDSWHU
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.
Trailer Axle, Axial5LQJLQQHUERRWFDOLSHUEROWFDSVKHDUDGDSWHUDGMXVWHU
FDSV$'%;FDUULHUFRPSOHWHFDOLSHUEROWFDS
.
Steer and Drive Axle, Vertical5LQJLQQHUERRWFDOLSHUEROWFDSVKHDUDGDSWHU
DGMXVWHUFDSV$'%;9FDUULHUFRPSOHWHFDOLSHUEROWFDS
Caliper/Carrier Kit
802090 6WHHUDQG'ULYH$[LDO³$´$
809091 6WHHUDQG'ULYH$[LDO³%´$
802984 7UDLOHU$[LDO³$´$
802985 7UDLOHU$[LDO³%´$
. 6WHHUDQG'ULYH9HUWLFDO³$´%
. 6WHHUDQG'ULYH9HUWLFDO³%´%
Hubs 6HFWLRQ
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803134 6SOLQHG'LVF
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802847 6SOLQHG'LVF
®
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. 6SOLQHG'LVF
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803138 6SOLQHG'LVF
®
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802859 6SOLQHG'LVF
®
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. 6SOLQHG'LVF
®
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. 6SOLQHG'LVF
®
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6HHKXE
VXSSOLHUIRU
WKHVHLWHPV
8VKDSHG,URQ$OXPLQXP/066WDQGDUG%HDULQJ3DFNDJHV
)ODW,URQ$OXPLQXP/066WDQGDUG%HDULQJ3DFNDJHV
Splined Disc
®
Rotor Attaching Kit 6HFWLRQ . $OO6SOLQHG'LVF
®
5RWRU$SSOLFDWLRQV6SOLQHG'LVF5RWRUKDUGZDUHNLW6'DQG
Rotor 6HFWLRQ
802081 PP8VKDSHG5RWRUIDVWHQHUV
802082 PP8VKDSHG5RWRUIDVWHQHUV
802083 6HYHUH'XW\6SOLQHG'LVF.LW6SOLQHG'LVF5RWRU6'DQGKDUGZDUHNLW6'DQG
802569 +HDY\'XW\6SOLQHG'LVF.LW6SOLQHG'LVF5RWRUDQGKDUGZDUHNLW6'DQG
* Universal Replacement with standard bearing configuration and long studs. Contact 1-800-AIR-BRAKE if identification assistance is required.
5.0 MAINTENANCE KITS
%HORZLVDOLVWRIVRPHRIWKHDYDLODEOHNLWVSee Figure 30 for an exploded view showing the components listed.
TABLE 2 - MAINTENANCE KITS
18
5.0.1 GENERAL INFORMATION ABOUT
BENDIX
®
AIR DISC BRAKE MAINTENANCE
:KHQ ZRUNLQJ RQ %HQGL[
®
$LU 'LVF EUDNHV SOHDVH QRWH
WKHIROORZLQJ
 5HDGDQGIROORZWKH6DIH0DLQWHQDQFH3UDFWLFHVRQ
SDJHWZR
 'HSHQGLQJRQWKHSDUWLFXODUD[OHWKHWHFKQLFLDQPD\
QHHGWRUHPRYHWKHFDOLSHUFDUULHUWRDOORZVXI¿FLHQW
DFFHVVWRSHUIRUPWKHZRUN
 CAUTION: When using a hoist to support the air
disc brake, do not attempt to use the pad retainer
bar as a bracing point as it is not designed to
support the weight of the brake. Use instead a
brace (or chain) wrapped around the entire brake
to attach the hoist.
Kit
See
Section
Remove
Brake Pads?
Section 5.2
Remove Caliper/
Carrier from
Vehicle?
Section 5.3
Remove
Actuator from
Caliper?
Section 5.4
'XVW6KLHOGV 6HFWLRQ 1RW7\SLFDOO\ NA NA
3DG.LWD[OHVHW 6HFWLRQ Yes 1R 1R
&DOLSHU.LWUDWLRQDOL]HG 6HFWLRQ Yes Yes Yes
&DUULHU.LW 6HFWLRQ Yes Yes Yes
6HUYLFH$FWXDWRU 6HFWLRQ 1R 1RW7\SLFDOO\ Yes
6SULQJ%UDNH$FWXDWRU 6HFWLRQ 1R 1RW7\SLFDOO\ Yes
7DSSHW%RRW.LWZKHHOHQGNLW 6HFWLRQ Yes 7\SLFDOO\ 7\SLFDOO\
*XLGH3LQ6HDODQG%RRW.LWZKHHOHQGNLW 6HFWLRQ Yes 7\SLFDOO\ 7\SLFDOO\
Hubs 6HFWLRQ Yes Yes Yes
6SOLQHG'LVF
®
5RWRU$WWDFKLQJ.LW 6HFWLRQ Yes Yes Yes
5RWRU 6HFWLRQ Yes Yes Yes
TABLE 3 - OTHER REQUIRED SECTIONS FOR MAINTENANCE KITS
 :KHQ UHSODFLQJ EHDULQJV ² RU IRU DQ\ RWKHU
PDLQWHQDQFHSURFHGXUHZKHUHWKHWHFKQLFLDQQHHGV
WRUHPRYHWKHFDOLSHUFDUULHUDVVHPEO\IURPWKHYHKLFOH
WRSHUIRUPWKHPDLQWHQDQFH²replacement caliper/
carrier bolts will be required.3OHDVHQRWHWKDWGXH
WRWKHKLJKWRUTXHUHTXLUHGWKHRULJLQDOEROWVFDQQRW
EHUHXVHG7KHEROWVDUHDYDLODEOHIURPWKHYHKLFOH
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.
5.0.2 SERVICE DVD
2UGHUSDUW QXPEHU BW7356 IRUD '9'VKRZLQJ WKH IXOO
VHW RI PDLQWHQDQFH SURFHGXUHV LQFOXGHG LQ WKLV 6HUYLFH
'DWDVKHHW
19
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.
7KLVVKLHOGNLWLQFOXGHVDEUDNHSDGVKLHOGDURWRUVKLHOG
DQG WKH UHTXLUHG DWWDFKLQJ KDUGZDUH IRU XVH LQ %HQGL[
®
ADB22X
™
and ADB22X-V
™
$LU 'LVF %UDNH DSSOLFDWLRQV
ZKHUHH[WHUQDOFRQWDPLQDWLRQDQGH[FHVVLYHURDGGHEULVLV
DFRQFHUQ%UDNHSDGDQGURWRUVKLHOGVFDQJUHDWO\UHGXFH
GDPDJHDQGRUSUHPDWXUHZHDURISDGVDQGURWRUVXQGHU
WKHVHFRQGLWLRQV
'XULQJ LQVWDOODWLRQ YHULI\ WKDW RQFH WKH VKLHOGV DUH
LQVWDOOHGWKH\ZLOOQRWFRPHLQWRFRQWDFWZLWKDQ\YHKLFOH
FRPSRQHQWVVXVSHQVLRQKRXVLQJVHWFWKURXJKWKHIXOO
UDQJHRIPRWLRQRIWKHZKHHO.HHSLQPLQGWKHSDUWLFXODU
XVHRIWKHYHKLFOHWKHRULHQWDWLRQRIWKHEUDNHRQWKHD[OH
DQGWRUTXHSODWHWKHSUR[LPLW\RIRWKHUD[OHVDQGRUWKH
ZKHHOWLUHEHLQJXVHG
Washer
Spring
Clip
Pad Shield
Rotor Shield
Fastener
Torque
Plate
Fastener
Rotor Shield
FIGURE 31 - DRIVE OR STEER AXLE EXPLODED VIEW WITH
INSET SHOWING ROTOR SHIELD INSTALLATION
 5HPRYH DQG GLVFDUG WKH VSULQJ FOLS DQG ZDVKHU
IURPWKHSDGUHWDLQHUSLQ5HPRYHDQGUHWDLQWKH
UHWDLQHUEDUDQGUHWDLQHUSLQ3RVLWLRQWKHSDGVKLHOG
DV VKRZQ DQG UHLQVHUW WKH UHWDLQHU EDU ,QVWDOO
WKHUHWDLQHUSLQ8VHWKHLQFOXGHGVSULQJFOLSDQG
ZDVKHUWRVHFXUHWKHUHWDLQHUSLQ&KHFNWKDWWKH
SDGVKLHOGLVKHOGVHFXUHO\LQSODFHE\WKHUHWDLQHU
EDUSee Figures 31 or 32.
Washer
Spring
Clip
Pad Shield
Rotor Shield
Fastener
Lock
Washer
Torque
Plate
Fastener
(with Washer)
Rotor
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
SDVVWKURXJKWKHPRXQWLQJWDEVLQWKHWRUTXHSODWH
DQGLQVWDOOLQWRWKHVKLHOG7RUTXHFDSVFUHZVWR
)W/EVLQOEV
 Trailer Axle Rotor Shields (See Figure 32
3RVLWLRQ WKH URWRU VKLHOG ZLWK the torque plate
between the shield and the rotor :LWK RQH
VXSSOLHGORFNZDVKHULQSODFHRQHDFKFDSVFUHZ
SDVVWKHVFUHZVWKURXJKWKHVKLHOGEHIRUHPRXQWLQJ
RQWRWKHWKUHDGHGWRUTXHSODWHKROHV7RUTXHWKH
FDSVFUHZVWR)W/EVLQOEV
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).
20
DQG UHWDLQ WKH PRXQWLQJ KDUGZDUH IRU WKH FDEOH
SURWHFWLRQ SODWH 7KH FDEOH SURWHFWLRQ SODWH FDQ
WKHQEHVHWDVLGHZKLOHVHUYLFLQJWKHSDGV1RWHWKH
SRVLWLRQRIWKHVHQVRUVLQWKHEUDNHSDGFKDQQHOV
DQGFDUHIXOO\UHPRYHWKHP,QPRVWFDVHV\RXGR
QRWQHHGWRUHOHDVHWKHFDEOHFRQQHFWRULQRUGHUWR
PRYHWKHVHQVRUVDZD\IURPWKHSDGLQVWDOODWLRQ
ZRUNDUHD,QVSHFWWKHZHDUVHQVRUVUHSODFHLI
GDPDJHGRUDEUDGHG
 See Figure 34. 5HPRYH DQG GLVFDUG WKH SLQ
UHWHQWLRQFOLSDQGZDVKHU
44
Pin
26 Spring Clip
45 Washer
11 Pad Retainer Bar
FIGURE 34 - PAD RETAINER BAR REMOVAL
 :KLOH SUHVVLQJ DJDLQVW WKH SDG KROG GRZQ EDU
UHPRYHWKHSDGUHWDLQHUEDUSLQ'LVFDUGWKH
KROGGRZQEDU
 :LWKWKHVSULQJEUDNHUHOHDVHGRUFDJHGUHPRYH
WKHDGMXVWHUFDSXVLQJWKHWDEWDNLQJFDUHQRW
WRPRYHWKHVKHDUDGDSWHU1RWH7ZRVL]HV
RIDGMXVWHUFDSDUHVXSSOLHGLQNLWVXVHWKHVDPH
VL]HDVEHIRUHLQVWHS
 ,QVSHFW WKH VKHDU DGDSWHU ,I VLJQLILFDQW
FRUURVLRQ DQGRU GDPDJH LV SUHVHQW UHPRYH WKH
DGMXVWHU DGDSWHU XVLQJ QHHGOHQRVH SOLHUV DQG
UHSODFH ZLWK WKH DGDSWHU VXSSOLHG LQ WKH NLW DQG
FOHDQDVQHFHVVDU\
61 Adapter
23 Adjuster
37
Cap
Tab
Tab
37
Cap
FIGURE 35 - EXPLODED VIEW
OF ADJUSTER AND ADAPTER
FIGURE 36 - CAP INSTALLED:
TAB LOCATION
)RULOOXVWUDWLRQ SXUSRVHV WKH H[SORGHGYLHZ )LJXUH 
VKRZVWKHDGMXVWHUDQGVKHDUDGDSWHUVHSDUDWHG
:KHQ XVLQJ WKH DGMXVWHU PHFKDQLVP DOZD\V KDYH WKH
VKHDUDGDSWHULQVWDOOHGRQWKHDGMXVWHU
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'%:VKRZVWKLVSURFHGXUH
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.
2XWERDUG
,QERDUG
12
2
11
44
45
26
61
37
ELECTRONIC WEAR
SENSOR
(if installed)
103
Cable to Electrical
Supply
104
Cable Protection
Plate
101
Sensor
101
Sensor
105
Cable Guide
(2 alternate
designs used)
FIGURE 33 - PAD REPLACEMENT
 5DLVHWKHFRPSOHWHD[OHWREHZRUNHGRQXQWLOWKH
WLUHVFOHDUWKHJURXQG6HHWKHYHKLFOHPDLQWHQDQFH
PDQXDOLQVWUXFWLRQVIRUUHPRYLQJWKHZKHHOV
 ,IWKHDLUGLVFEUDNHLVHTXLSSHGZLWKDQHOHFWURQLF
ZHDUVHQVRULQGLFDWRU(see top of Figure 33)UHPRYH
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BENDIX BW7308 User manual

BENDIX
Brand
BENDIX
Model
BW7308
Type
User manual
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