Premium wheel-end brake products Service Manual Bendix® ESD-225™ Air Disc Brake
Table of Contents Replacing Disc Brake Removing Disc Brake Caliper . . . . . . . . . . . . . . 19 Replacing Disc Brake Caliper . . . . . . . . . . . . . . 19 Specifications Disc Brake ESD225 . . . . . . . . . . . . . . . . . . . . . . . 4 Tightening Torque. . . . . . . . . . . . . . . . . . . . . . . . . 5 Wear Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Replacing Slide Pins, Slide Bushings, and Boots Removing Slide Pins, Slide Bushings, and Boots. . . . . . . . . . . . . . . . . .
General Information Model Identification Bendix ESD - 225™ ® Wheel Size Disc Brake Extended Service 2
General Information Product Identification – Exploded View 5 6 7 8 20 General Information 21 22 12 14 19 23 11 13 4 10 9 18 17 Exploded view of conventional hub rotor 1 2 24 25 1 – Torque plate 2 – Carrier 4 – Caliper Assy.
Specifications Specifications Disc Brake ESD225 METRIC 4 STANDARD Max. brake chamber force 13.9 kN 3124.8 lbf. Wheel size 571.5 mm 22.5 in. Number of actuating pistons 2 2 Number of slide pins 4 4 Threshold force 28N 6.3 lbf. Brake chamber stroke requirements min. 57 mm min. 2.2 in. max. 65 mm max. 2.6 in. Mechanical advantage 15:8:1 15:8:1 Max. adjustment distance brake lining 58 mm 2.3 in. Lining thickness (friction material), new 22 mm 0.9 in.
Specifications Tightening Torque Wear Limits Torque fasteners to specifications in table. Fastener Frame Mounting Screw* Slide Pin Screw Retaining Bar Screw Actuator Mounting Screw Bridge Mounting Screw Air Chamber Rotor to Iron Hub (use Loctite 266) Rotor to Aluminum Hub Torque N•m 447 to 474 187 to 200 42 to 48 24 to 30 100 +/-10 +50º +/-2º turn 176 339 to 373 Torque lbs. ft. 330 to 350 138 to 148 31 to 35 18 to 22 74 +/-7 +50º +/-2º turn 130 250 to 275 190 +/- 19 140 +/- 14 Pads, min.
Description of Operation Description of Operation Actuation/Release of the Brake Self-Adjusting Adjustment On braking, the lever is actuated by the brake chamber. The external and internal radii of the inner part of the lever do not have a common center, which means that the crossbar is moved axially in the direction of the brake disc. The force is transferred from the crossbar via adjustment screws and thrust plates to the inner pad.
Description of Operation Application C - During the movement through C, the design clearance is measured between the pad and brake disc by the adjuster. There is a predetermined clearance between the tongue of the adjustment spring and the slot in the companion sleeve, which determines the free stroke before the adjustment.
Description of Operation E - When the two (2) pads come into contact with the brake disc, the braking sequence enters elasticity phase E, the torque rises and the adjuster stops adjusting. The continued rotational movement, which now occurs in the adjuster is allowed by rotating the housing in relation to the adjustment spring. Release The first part of the return stroke passes through C followed by movement corresponding to E and Ce.
Description of Operation E - The next part of the return stroke corresponds to E. The housing of the adjuster, the adjustment spring and companion sleeve are rotated in relation to the hub, which is stationary. Movement between companion sleeve and hub is allowed by the friction spring. Ce - During the last part of the return stroke (Ce), the rotational movement continues in the adjuster as described under E until the mechanism has reached its resting position.
Safety Instructions Safety Instructions • Always follow the vehicle manufacturer's safety instructions when working on a vehicle. • Follow the vehicle manufacturer's instructions for jobs which are not described in this manual. • Follow local safety regulations. ! DANGER AVOID CREATING DUST POSSIBLE CANCER AND LUNG DISEASE HAZARD • The work must be carried out by trained personnel.
Service Instructions Service Instructions Service Instructions Service Intervals Check the following items regularly every 6 months. Refer to the sections as listed below. • Check brake pads • Check brake disc • Check caliper sliding function • Check operation ! WARNING: Refer to Safety Instructions. The vehicle manufacturer's instructions must also be followed. Clean the disc brake of dirt and dust.
Service Instructions Checking Pads Measure the distance from the backplate to the wearing surface of the pad. Measure the lateral runout of the brake disc as follows. The minimum permitted lining thickness (friction material), per D.O.T. (Department of Transportation) standards, is currently 3 mm (.12 in). (The lining thickness of a new pad is 22 mm (0.9 in.).) Replace the pads if they are worn out. 1. Attach a magnetic stand, complete with a dial indicator on the frame.
Service Instructions Checking Play in the Slide Pins This check is done after the pads have been removed. See the section on "Replacing Pads". Measure the play in the outer slide pins as follows. The maximum amount of play is 1.0 mm [0.04 in.]. Check the sliding motion of the caliper on the slide pins. If the caliper does not slide freely on the pins, make sure the movement is not obstructed by external dirt or foreign objects. 1 Service Instructions Checking Sliding Function 1.
Service Instructions Checking Boots for Slide Pins Checking Bellows for Adjustment Screws Check the protection caps and rubber boots of the slide pins [two (2) per slide pin]. If there are signs of cracks or other damage on the rubber bellows and protection caps, they must be replaced. 1. Using an 8 mm socket, rotate the readjustment shaft until the protection springs are fully visible. If action is required, see the section on "Replacing Slide Pins, Slide Bushings and Boots". 2.
Service Instructions 1. Lift and support the axle in accordance with the vehicle manufacturer's instructions. ! WARNING: Follow the Safety Instructions. The vehicle manufacturer's instructions must also be followed. 6. Leave the wrench in the same position. 7. Activate the brakes five (5) times. The wrench must move on each brake application which shows that the self-adjustment is working. 2. Check that the wheel can be turned freely. 3. Remove the plug. 4.
Service Instructions Initial Adjustment 1. Check that the brake disc can be turned freely. Lubrication ! WARNING: Follow the Safety Instructions. The vehicle manufacturer's instructions must also be followed. General To obtain maximum service life, it is important to use only the specified lubricants for the lubrication points concerned. Apply the correct amounts. To prevent the lubricant from being dispersed or causing damage during the natural movements of the brake (e.g.
Replacing Pads Removing Pads Replacing Pads • Always replace pads on both sides of the axle at the same time. 1. Using an 8 mm socket, turn counterclockwise until the readjustment shaft is fully retracted. ! WARNING: Follow the Safety Instructions. The vehicle manufacturer's instructions must also be followed. • Chock the wheels on an axle that is not to be raised. • Lift the axle, support and remove the wheels in accordance with the vehicle manufacturer's instructions.
Replacing Pads Initial Adjustment 1. Check that the brake disc can be turned freely. 2. Using an 8 mm wrench, turn readjustment shaft until both pads touch brake disc. Then loosen 1/2 turn to obtain a basic clearance between pads and brake disc. Check that the brake disc can be turned freely. Remove the socket or wrench. 1 1 – Brake disc 3. Fit plug into access hole readjustment shaft (see Item 1 in the illustration below).
Replacing Disc Brake Removing Disc Brake Caliper ! ! ! Replacing Disc Brake Caliper 1. Place caliper assembly on torque plate. WARNING: Be sure to follow all safety instructions including the blocking of wheels and proper lifting and support of axle. 2. Lubricate attachment bolts with anti-seize compound. 3. Fit bolts through torque plate to caliper and tighten to snug fit. WARNING: Do not use compressed air. 4. Torque bolts to 330-350 lbs. ft. (407-448 N•m).
Replacing Slide Pins, Slide Bushings, & Boots Removing Slide Pins, Slide Bushings, and Boots (Frame) 1. Put the disc brake assembly in a vise. 3. Remove the four (4) bolts for the slide pins using Torx E 18 socket. 3 2 1 2. Remove protection caps using a hammer and chisel. If the inner part of the protection cap remains in the slide pin, remove this using an internal bearing puller. 1 – Slide pins 2 – Caliper Note: Protection caps must never be reused. 4.
Replacing Slide Pins, Slide Bushings, & Boots ! CAUTION: Do not use gripping tools, as the sealing surfaces of the slide pins may be damaged. 8. Remove the four (4) slide bushings (which are of a split design) using a small screwdriver. Begin at the split. IMPORTANT: Do not damage the fitting surfaces. 1 1 2 2 1 – Carrier 2 – Caliper 1 – Slide bearings (4) 2 – Caliper 5. Clean parts of dirt and dust. ! WARNING: Use the specified type of dust removal equipment to clean–not compressed air.
Replacing Slide Pins, Slide Bushings, & Boots Inspection Replacing Slide Bushings and Slide Pins 1. Check that the fitting surfaces for slide bushings and boots are damage free. 1. Fit four (4) new slide bushings in caliper. 2. Lubricate slide bushings sparingly with grease. 3. Lubricate slide pins with grease and press them into position in the slide bushing. Use Haldex tool #81921 (1-800-643-2374). 1 1 2 1 – Caliper 2 – Slide pins (4) 1 – Slide bearings (4) 4.
Replacing Slide Pins, Slide Bushings, & Rotors Replacing Slide Pins, Slide Bushings, & Rotors Replacing Boots in Caliper 1. Install boot in caliper. Use Haldex tool #81922 (1-800-643-2374). ! WARNING: To prevent injury, only grip from outside. 1 2. Press the outer part of boot into position in the groove in slide pin and secure with boot ring. 3 4 2 2 1 1 – Lift carrier 2 – Caliper 1 – Caliper 2 – Slide pin 3 – Boot 4 – Boot ring 7.
Replacing Slide Pins, Slide Bushings, & Boots 9. Check the following (refer to section): • Installing disc brake Note: Always use new bolts.
Replacing Brake Chamber Removing Brake Chamber 1. Remove the air hose. Remove the two (2) nuts holding brake chamber. Replacing Brake Chamber 1. Check that the new brake chamber is of the correct type. (There must be inner bushings on the push rod.) 2. Remove brake chamber. 3. Check through the aperture in the brake chamber attachment flange that no moisture/corrosion is present. If it is, replace caliper. Replacing Brake Chamber 1 – Hose 2 – New brake chamber 2.
Replacing Spring Brake Chamber Removing Spring Brake Chamber ! WARNING: Follow the Safety Instructions. The vehicle manufacturer's instructions must also be followed. • Activate the spring caging mechanism of the spring brake chamber so that the spring is held in it compressed position. See vehicle manufacturer's instructions. • Apply the parking brake. 1. Remove the air hose connectors of the service and parking brake. 2. Remove the two (2) nuts holding the spring brake chamber. 3.
Replacing Spring Brake Chamber Replacing Spring Brake Chamber 1. Check that the new spring brake chamber is of the correct type. Note: There must be an inner boot at the push rod. 3. Install the pipe fittings to the new spring brake chamber. 4. Check that the mounting faces of the spring brake chamber and the caliper are clean. 5. Lubricate the end of the push rod with grease. 6. Fit the new spring brake chamber with nuts and washers. Torque to specs on page 5. 7.
Replacing Rotor Removing Rotor 1. Remove the caliper assembly. See "Removing Disc Brake Caliper" on page 19. 2. Remove the wheel/hub/rotor assembly from the vehicle following the recommended procedures in WESM-0060. 3. Remove ABS tone ring (aluminum hubs only). 4. Remove rotor fasteners. ! CAUTION: Never release a vehicle from brake service without verifying safe brake operation. Rotor Runout Check 1. With rotor installed on vehicle, position dial indicator with contact on 90º to rotor face. 5.
Replacing Rotor Cleaning and Inspection Rotor Resurfacing 1. Wire brush circumference of rotor to remove dirt and rust, and then clean rotor in a non-toxic, greaseless cleaner. 1. The rotor should be resurfaced by mounting in an appropriate brake lathe and removing the least amount of material possible to ensure a smooth face. ! CAUTION: Use of a petroleum-based cleaning solvent may leave a residue which could damage lining material. 2.
Troubleshooting Troubleshooting ! WARNING: Refer to Safety Instructions. The vehicle manufacturer's instructions must also be followed. Symptoms Actions No or low braking effect • Are brake pads worn away? • Is brake pad to disc clearance OK? • Is brake disc OK? • Is air pressure in brake chamber correct? (Measure with pressure gauge at brake chamber.) • Change pads. • Carry out initial adjustment + perform function test. • Change brake disc (See vehicle manufacturer's instructions.
For more information, talk to your Bendix or Roadranger representative, call 1-866-610-9709 or visit www.foundationbrakes.com. The Roadranger® System features Bendix® brand foundation brakes. 901 Cleveland Street • Elyria, Ohio 44035 • 1-866-610-9709 • www.foundationbrakes.com BW7273 ©2008 Bendix Spicer Foundation Brake LLC • 01/08 • All Rights Reserved • Printed in U.S.A.
