Owner's manual

ManualsBrandsBendix Commercial Vehicle Systems ManualsEquipmentEVERSURE SPRING BRAKE

WARNING

SPRING BRAKE CHAMBERS CONTAIN A LOADED

COMPRESSION SPRING. PROPERTY DAMAGE,

SERIOUS INJURY OR DEATH MAY OCCUR IF THESE

INSTRUCTIONS ARE NOT FOLLOWED COMPLETELY.

NEVER attempt to remove a spring chamber crimped

band.

Follow all industry safe maintenance practices, including

those listed on page two of these instructions.

1.0 DESCRIPTION

The Bendix

EverSure

spring brake is made up of a

conventional brake chamber and an emergency, or parking,

spring mechanism for use on vehicles equipped with cam

foundation brakes. The spring brake actuator provides:

(1) service braking, (2) parking and (3) emergency

braking. The actuator can be piped with various system

arrangements to be automatically, or manually, applied

under emergency braking conditions.

The spring brake is a diaphragm-type actuator which

converts the energy of air pressure into mechanical force.

FIGURE 1 - BENDIX

EVERSURE

SPRING BRAKE

Bendix

EverSure

Spring Brake with No Touch

™

Technology

SD-02-4525

PARKING/ EMERGENCY

BRAKE HOUSING

NON-SERVICEABLE

NO TOUCH

™

POWER

SPRING

SERVICE

PUSH-ROD

SERVICE RETURN

SPRING

SERVICE

CHAMBER

RELEASE

TOOL T-BOLT

T-BOLT

STORAGE

POCKET

NON-PRESSURE

HOUSING

YOKE

SERVICE

DIAPHRAGM

CLAMP

BAND

NON-SERVICEABLE

PARKING DIAPHRAGM

NON-SERVICEABLE

SECTION SEALED WITH A

CRIMPED BAND

DUST CAP INSTALLED

DUST CAP

REMOVED

RELEASE

TOOL

T CAP

Index

Section Page

1.0 Description . . . . . . . . . . . . . . . . .1, 3

2.0 Safe Maintenance Practices . . . . . . . . . 2

3.0 Preventive Maintenance . . . . . . . . . . . 3

4.0 Operation and Leakage Tests. . . . . . . . . 4

5.0 Operation: General . . . . . . . . . . . . . . 4

6.0 Mechanical Release (Caging) of the

Bendix

EverSure

Spring Brake . . . . . . . 4

7.0 Clocking (Rotating) the Bendix Service

Replacement Spring Brake Chamber. . . . . 5

8.0 Mechanical Release (Caging) and Removal

of the Piggyback Spring Brake Chamber to

be Replaced . . . . . . . . . . . . . . . . . 6

9.0 Installing the Bendix

EverSure

Piggyback

Spring Brake Chamber . . . . . . . . . . . . 6

10.0 Un-Caging the Bendix

EverSure

Spring

Brake Chamber (Apply Park Brake) . . . . . 7

11.0 Removal and Installation of the Combination

Spring Brake . . . . . . . . . . . . . . . . . 7

12.0 Replacing the Service Diaphragm . . . . . . 8

(Piggyback spring brake components

are not serviceable, and are shown

here for informational purposes only.)

Summary of content (8 pages)

PAGE 1
SD-02-4525 ® Bendix® EverSure® Spring Brake with No Touch™ Technology NON-PRESSURE HOUSING SERVICE RETURN SPRING CLAMP BAND T-BOLT STORAGE POCKET SERVICE DIAPHRAGM NON-SERVICEABLE SECTION SEALED WITH A CRIMPED BAND NON-SERVICEABLE PARKING DIAPHRAGM SERVICE PUSH-ROD RELEASE TOOL T-BOLT YOKE (Piggyback spring brake components are not serviceable, and are shown here for informational purposes only.
PAGE 2
.0 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. Always wear safety glasses.
PAGE 3
The diaphragm is held between the adapter base and nonpressure plate by a two piece clamp ring. Different size brake chambers are identified by numbers, which specify the effective area of a diaphragm. For example, a Type 30/30 Spring Brake has 30 square inches of effective area on each diaphragm. The standard diaphragm material is a compound of natural rubber with a fabric interior of nylon. WARNING • • • Sp r ing b r a ke cha mb er s c ont ain a load ed compression spring.
PAGE 4
MAIN SPRING PARKING/ EMERGENCY PORT (MARKED “12”) DIAPHRAGM DIAPHRAGM NON-PRESSURE HOUSING PUSH ROD FIGURE 3 - SPRING BRAKE CUT-AWAY VIEW 4.0 OPERATION & LEAKAGE TESTS 4.1 OPERATING TEST 4.1.1 Apply the brakes and observe that all the push rods move out promptly and without binding. 4.1.2 Release brakes and observe that all the push rods return to the released position promptly and without binding. 4.1.3 Check the push rod travel.
PAGE 5
SERVICEABLE SECTION SERVICE RETURN SPRING NUT NON-SERVICEABLE PIGGYBACK SECTION PRESSURE PLATE WASHER RELEASE TOOL YOKE YOKE PIN DUST CAP CLAMP BAND SERVICE DIAPHRAGM PARKING/ EMERGENCY BRAKE FIGURE 4 - EXPLODED VIEW SHOWING SERVICEABLE AND NON-SERVICEABLE PORTIONS OF THE BRAKE 6.0.6 Pull on the release tool to ensure the T-section is properly seated in the power spring piston plate. 6.0.7 Assemble the release tool washer and nut onto the release bolt and finger tighten only.
PAGE 6
WARNING Do not mechanically release (cage) the spring if there is any structural damage to the brake. Caging the spring in such a chamber may cause serious injury or death. Replace the complete spring brake assembly. 7.0.1 If the service replacement spring brake chamber is not caged, mechanically release (cage) the replacement spring brake chamber by following the original manufacturer’s instructions. 7.0.2 Apply 10 psi (1 bar) of air pressure to the service port (“11”) of the spring brake chamber. 7.0.
PAGE 7
9.4 Assemble the service clamp assembly. Ensure all parts are seated properly and remain centered (See Figure 5). 9.5 Torque the clamp nuts to 20-30 ft/lbs. Remove the locking pliers from the service push rod. 9.6 Connect the emergency air hose to the emergency/ parking port (“12”) and reconnect the service air line to the service port (“11”). Torque fittings to no more than 30 ft-lbs (40 Nm). 9.7 Pressurize the service half by putting air into the service port. Do not exceed 120 psig.
PAGE 8
11.3.2 If the service replacement is a type that provides an extra-long threaded push rod, thread a nut onto the rod past the point that it will need to be cut. Taking all necessary safety precautions, cut the rod to the required length and remove burrs. Remove the nut installed earlier to ensure that the threads are clear. 11.3.3 Install the combination spring brake using the furnished hardware. Torque the mounting nuts to 133-155 ft/lbs.