BENDIX BW7308 User manual

Brand: BENDIX

Model: BW7308

Type: User manual

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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 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

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]

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See Figure 4 to help you identify which type of rotor is used

on the axle being inspected. 1RWHWKDWWKHPDLQWHQDQFH

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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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FIGURE 7 - SECTIONAL VIEWS

Lever

Eccentric

Bearing

Bolt

Bridge

Spring

Carrier

Turning

Device

Wear Sensor

Inner

Seal

Threaded Tube

161

Tappet

Tappet and

Boot Assembly

18/1 Spring Brake or

18/2

Brake Chamber

Rotor

Pad Assembly 12

Pad

Assembly

6 Guide Sleeve

Carrier

Guide Pin

Inner

Boot

Ring

Caliper Bolt

Cap

Bushing

Caliper

Guide Pin

Tappet and Boot

Assembly

Adjuster Unit

Spring Clip

27 Spring

Brass Bushing

Inner Boot

Cap

Pad

Assembly

Threaded Tube

Inner Seal

Chain Wheel

161

Tappet Bushing

Shear Adapter

Ring

45 Washer

Caliper Bolt

Top Sectional View

Short Caliper Bolt

Sectional View

Side Sectional View

Bridge

Pad Retainer

Chain

Pad Retainer Pin

Adjuster Cap

FIGURE 8 - EXPLODED VIEW - BENDIX

ADB22X

™

AND ADB22X-V

™

AIR DISC BRAKES

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,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

Hardware

18/1 Spring Brake

Actuator

Cap

39 Caliper Bolt

6 Guide Sleeve

Guide

Shear

Adapter

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

Washer

Pad Retainer Pin

Bendix

ADB 22X

™

Carrier

Bendix

ADB 22X-V

™

Carrier

Brass

Bushing

Cap

161

Tappet Bushing

Caliper

Bolt

Inner Seal

(Rotor Shield for Trailers)

4 Guide Pin

Inner Boot

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)

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)

$ERXWHYHUIRXU

PRQWKVIRURYHUWKH

URDGDSSOLFDWLRQV

$ERXWHYHU\WKUHHPRQWKV

IRUKLJKHUGXW\DSSOLFDWLRQV

HJOLQHKDXO59

RSHQKLJKZD\

FRDFKHVHWF

HJSLFNXSGHOLYHU\

RIIKLJKZD\FRQVWUXFWLRQ

ORJJHUFRQFUHWHPL[HUGXPS

WUXFNFLW\WUDQVLWEXVUHIXVH

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)

,QVSHFWWKHSDGVDQGHQWLUHURWRU

VXUIDFHVIRUFUDFNVHWF%HQGL[

VSOLQHGGLVF

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.

,QVSHFWDOOFDSVKRVHVDQGEUDNH

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SUDFWLFHVRXWOLQHG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

 3UHYHQWLYH0DLQWHQDQFH        6

 %UDNH3DGDQG5RWRU,QVSHFWLRQV   7-8

 5XQQLQJ&OHDUDQFH4XLFN,QVSHFWLRQ    8

2.1 BRAKE PAD AND ROTOR INSPECTIONS

9LVXDOFKHFNVRIWKHFRQGLWLRQRIWKHEUDNHSDGURWRUZHDU

FDQEHPDGHZLWKRXWUHPRYLQJWKHZKHHOV:KHUHGXVW

JXDUGVDUHQRWXVHGWKHWRSRIWKHSDGVDQGSDUWRIWKH

URWRUDUHYLVLEOHWKURXJKWKHRSHQLQJDWWKHWRSRIWKHEUDNH

2WKHUYLVLEOHSRUWLRQVRIWKHURWRUFDQEHLQVSHFWHGDWWKH

VDPHWLPH

8QOHVVDYHKLFOHKDVEHHQVWRUHGIRUVRPHWLPHWKHPDLQ

URWRUVXUIDFHVWKDWFRQWDFWWKHSDGVZLOODOZD\VDSSHDUWR

EHVKLQ\6XUIDFHUXVWRQWKHVHVXUIDFHVZRXOGLQGLFDWHD

PDOIXQFWLRQLQJEUDNHWKDWVKRXOGEHLQVSHFWHGLPPHGLDWHO\

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

6HH )LJXUH  IRU WKH ORFDWLRQ RI WKH PHFKDQLFDO ZHDU

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.

&RPSDUHWKHUHODWLYHSRVLWLRQRIWZRQRWFKHVFDVWLQWR

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.

:KHQWKH QRWFK LQ WKH FDOLSHU DOLJQV ZLWK WKH IURQW

HGJHRIWKHWRUTXHSODWHLWLVWLPHWRVFKHGXOHDIXOO

ZKHHOUHPRYHGLQVSHFWLRQRIWKHSDGVDQGURWRU

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

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

URWRU QHHGV WR EH UHSODFHG DQGRU VFKHGXOHG IRU D IXOO

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

Area G

Area J

&UDFNVUHDFKLQJ

HLWKHUHGJHRIWKH

URWRU

DUHQRW

DFFHSWDEOH

IRUHLWKHU

W\SHRI

URWRU

&LUFXPIHUHQWLDO

JURRYHVDVLQ$UHD

-DUHDFFHSWDEOH

LIOHVVWKDQLQ

PPGHHS

 )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RIGLPHQVLRQ³I´WKHZLGWK

RIWKHURWRUFRQWDFWDUHD

 )RUBendix Splined Disc rotorsUDGLDO

FUDFNVDUHRQO\DFFHSWDEOHLI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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

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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)

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?

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?

Section Four

Section Page

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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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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

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SECTION FOUR: WHEEL-OFF MAINTENANCE INSPECTIONS

4.1 CALIPER MOVEMENT TEST

CAUTION: Follow all safe maintenance practices.

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Note: To fully release the spring brakes, assure that the

air system pressure is at least 90 PSI. 8VLQJDVXLWDEOH

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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.

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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

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that the running clearance is too small or too large.

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Adjuster Cap

Location

FIGURE 17 - ADJUSTER CAP LOCATION

61 Adapter

23 Adjuster

Cap

Tab

Cap

FIGURE 18 - EXPLODED VIEW

OF ADJUSTER AND ADAPTER

FIGURE 19 - CAP INSTALLED:

TAB LOCATION

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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

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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.

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FIGURE 21 - APPLYING MODERATE APPLICATIONS OF THE

BRAKES: THE WRENCH MOVES CLOCKWISE AS THE RUNNING

CLEARANCE IS DIMINISHED

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4.3- 4.4 BRAKE PADS AND ROTORS

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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.

26 Spring Clip

45 Washer

11 Pad Retainer Bar

FIGURE 23 - RETAINER BAR REMOVAL

4.3 INSPECT THE BRAKE PADS

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SDGV RI HDFK VHW  ,I WKH GLIIHUHQFH EHWZHHQ WKH

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LQ PP UHSODFH WKH EUDNH SDGV DQG

LQVSHFWWKHJXLGHSLQV(See Section 4.5)

,IWKHUHVXOWVRIWKHSDGLQVSHFWLRQVDUHZLWKLQWKHDFFHSWDEOH

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

VHHWKHYHKLFOHPDQXIDFWXUHU¶VUHFRPPHQGDWLRQVIRXQGLQ

WKHRSHUDWRU¶VPDQXDO

%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SDGVZLWKWKH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FRQYHQWLRQDOURWRU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URWRUVDUHQRUPDOO\VHUYLFHIUHH,QWKHFDVH

RIVHYHUHJURRYLQJRIWKHHQWLUHIULFWLRQVXUIDFHKRZHYHU

CONVENTIONAL ROTORSPD\EHWXUQHGZKHQFKDQJLQJ

SDGVWRLQFUHDVHWKHORDGEHDULQJVXUIDFH

FIGURE 25 - EXAMPLES OF ACCEPTABLE AND NON-ACCEPTABLE ROTOR CONDITIONS

Area

Area G

Area J

&UDFNVUHDFKLQJ

HLWKHUHGJHRIWKH

URWRU

DUHQRW

DFFHSWDEOH

IRUHLWKHU

W\SHRI

URWRU

&LUFXPIHUHQWLDO

JURRYHVDVLQ$UHD

-DUHDFFHSWDEOH

LIOHVVWKDQLQ

PPGHHS

 )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\GRQRWUHDFK

HLWKHUHGJH(see G) &UDFNVDUH RQO\

DFFHSWDEOHLIWKHOHQJWKRIWKHFUDFNLV

OHVVWKDQRIGLPHQVLRQ³I´WKHZLGWK

RIWKHURWRUFRQWDFWDUHD

 )RU Bendix

Splined Disc rotors

UDGLDOFUDFNVDUHRQO\DFFHSWDEOHLI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)

Caliper

Movement

Caliper

Guide Pin

Inner Boot

9 Inner Boot

Brass Bushing

Cap

6 Guide Sleeve

4 Guide Pin

Caliper Bolt

Outboard Inboard

Cap

SHORT

BEARING SIDE

LONG

BEARING SIDE

FIGURE 26 - GUIDE PINS

12 Pad Assembly

Carrier

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

PDQXIDFWXUHU¶V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YHKLFOHPDQXIDFWXUHU¶V

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WKHZKROHOHQJWKRIWKHJXLGHSLQV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\

LQ)LJXUH3UHVVWKHFDOLSHULQWKHGLUHFWLRQRI

WKHFDUULHUDQGVHWWKHGLDOJDXJHWR]HUR

 3ODFH D VXLWDEOH WRRO HJ D ODUJH IODWEODGH

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WRWKHLQERDUGSRVLWLRQ(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RUFRUURGHG

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

WRZDUGVWKHRXWERDUGSRVLWLRQWKHERRWV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WKHFDOLSHU

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WKHRULJLQDO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)

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

7KHERRWVVKRXOGQRUPDOO\GXHWRWKHLU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)

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

Hardware

FIGURE 30 - EXPLODED VIEW - BENDIX

ADB22X

™

AND ADB22X-V

™

AIR DISC BRAKES

18/1 Spring Brake

Actuator

Cap

39 Caliper Bolt

6 Guide Sleeve

Guide

Shear

Adapter

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

Washer

Pad Retainer Pin

Bendix

ADB 22X

™

Carrier

Bendix

ADB 22X-V

™

Carrier

Brass

Bushing

Cap

161

Tappet Bushing

Caliper

Bolt

Inner Seal

(Rotor Shield for Trailers)

4 Guide Pin

Inner Boot

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)

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

JXLGHSLQFDOLSHUEROWFDS

Guide Pin Grease NA

14525 :KLWHJUDPV

. :KLWHJUDPV

Service Actuator 6HFWLRQ

. Bendix

7\SH8QLYHUVDO>6HUYLFHEUDNHDFWXDWRUDFWXDWRUKDUGZDUH@

. Bendix

7\SH8QLYHUVDO>6HUYLFHEUDNHDFWXDWRUDFWXDWRUKDUGZDUH@

. Bendix

7\SH8QLYHUVDO>6HUYLFHEUDNHDFWXDWRUDFWXDWRUKDUGZDUH@

. Bendix

7\SH8QLYHUVDO>6HUYLFHEUDNHDFWXDWRUDFWXDWRUKDUGZDUH@

Spring Brake Actuator 6HFWLRQ

.

Bendix

7\SH3LVWRQ6W\OH7UXFN7UDLOHU8QLYHUVDO>6SULQJEUDNHDFWXDWRUDFWXDWRUKDUGZDUH@

.

Bendix

7\SH3LVWRQ6W\OH7UXFN7UDLOHU8QLYHUVDO>6SULQJEUDNHDFWXDWRUDFWXDWRUKDUGZDUH@

.

Bendix

7\SH3LVWRQ6W\OH7UXFN7UDLOHU8QLYHUVDO>6SULQJEUDNHDFWXDWRUDFWXDWRUKDUGZDUH@

.

Bendix

7\SH'RXEOH'LDSKUDJP6W\OH7UDLOHU8QLYHUVDO>6SULQJEUDNHDFWXDWRUDFWXDWRU

KDUGZDUH@

Caliper Kit

(rationalized)

Includes 803114 kit shown above

6HFWLRQ

. 6WHHUDQG'ULYH$[OH$>&DOLSHUNLW@

. 6WHHUDQG'ULYH$[OH%>&DOLSHUNLW@

. 7UDLOHU$[OH$>&DOLSHUNLW@

. 7UDLOHU$[OH%>&DOLSHUNLW@

Carrier Kit

6HFWLRQV



.

Steer and Drive Axle, Axial5LQJLQQHUERRWFDOLSHUEROWFDSVKHDUDGDSWHU

DGMXVWHUFDSV$'%;FDUULHUFRPSOHWHFDOLSHUEROWFDS

.

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

. 6SOLQHG'LVF

%UDNH$OXPLQXP))6WHHU/06%HDULQJ3DFNDJH+XE

803134 6SOLQHG'LVF

%UDNH$OXPLQXP)/6WHHU/06%HDULQJ3DFNDJH+XE

802847 6SOLQHG'LVF

%UDNH$OXPLQXP5'ULYH/06%HDULQJ3DFNDJH+XE

. 6SOLQHG'LVF

%UDNH$OXPLQXP))6WHHU6WDQGDUG%HDULQJ3DFNDJH+XE

803138 6SOLQHG'LVF

%UDNH$OXPLQXP)/6WHHU6WDQGDUG%HDULQJ3DFNDJH+XE

802859 6SOLQHG'LVF

%UDNH$OXPLQXP5'ULYH6WDQGDUG%HDULQJ3DFNDJH+XE

. 6SOLQHG'LVF

$OXPLQXP717UDLOHU6WDQGDUGEHDULQJSDFNDJH+XE

. 6SOLQHG'LVF

$OXPLQXP737UDLOHU6WDQGDUGEHDULQJSDFNDJH+XE

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

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

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

ZKHUHH[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 VKLHOGV 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

UHWDLQHUEDUDQGUHWDLQHUSLQ3RVLWLRQWKH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

SDVVWKHVFUHZVWKURXJKWKHVKLHOGEHIRUHPRXQWLQJ

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).

DQG UHWDLQ WKH PRXQWLQJ KDUGZDUH IRU WKH FDEOH

SURWHFWLRQ SODWH  7KH FDEOH SURWHFWLRQ SODWH FDQ

WKHQEH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

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

Cap

Tab

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

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 BW7308 User manual

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