SD-23-7541 ® Bendix® ADB22X™, ADB22X-V™ Air Disc Brakes SECTION ONE: AIR DISC BRAKE OVERVIEW 1.
SAFE MAINTENANCE PRACTICES WARNING! PLEASE READ AND FOLLOW THESE INSTRUCTIONS TO AVOID PERSONAL INJURY OR DEATH: When working on or around a vehicle, the following general precautions should be observed at all times: 1. 2. 3. 4. 5. 6. 7. 8. 9. 2 Park the vehicle on a level surface, apply the parking brakes, and always block the wheels.
5RWRU LGHQWL¿FDWLRQ 1.5 Operation 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 %HQGL[ DLU GLVF EUDNHV FRQYHUW DLU SUHVVXUH LQWR EUDNLQJ IRUFH (See Figure 6.
12 Pad 1 Assembly Caliper 9 22 58 Inner Boot 7 Inner Seal 5 Ring Brass Bushing Guide Pin 40 Caliper Bolt Top Sectional View 10 Cap 23 Adjuster Unit 161 Tappet Bushing 32 Chain Wheel 16 Threaded Tube 13 Tappet and Boot Assembly 61 Shear Adapter 45 Washer 26 Spring Clip 37 Adjuster Cap 44 Pad Retainer Pin 27 Spring 30 Chain 11 Pad Retainer 17 Bridge 33 Wear Sensor 22 Inner Seal 16 Threaded Tube 24 Turning Device 161 Tappet Bushing 6 Guide Sleeve 13 Tappet and Boot Assembly 2 Carrier 2 Carr
Type A Type B (Wheel turns toward fixed pin side of ADB) 18/1 Spring Brake Actuator 44 Pad Retainer Pin (Fixed pin) 11 Pad Retainer 18/2 Service Actuator 26 Spring Clip 12/2 Pad Holder Spring :KHHO 5RWDWLRQ W\SLFDOO\ ULJKW KDQG 45 Washer :KHHO 5RWDWLRQ 12/1 Pad W\SLFDOO\ OHIW KDQG (Pad Assembly consists of 12/1 plus 12/2) 10 40 Cap 5 Caliper Guide Bolt 7 Brass Bushing Pin 68 Cap 39 Caliper Bolt 22 Inner Seal Shield Kit (Drive or Steer) 161 Tappet Bushing 13 Tappet and Boot Assembly
SECTION TWO: PREVENTIVE MAINTENANCE SCHEDULE AND WHEEL-ON INSPECTIONS 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 .
2.
H F 1R DFWLRQ LV QHHGHG I R U V P D O O F U D F N V V S U H D G R Y H U W K H VXUIDFH H J $UHD ) Rotor Friction Surface Width “f” Area F )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.
SECTION THREE: TROUBLESHOOTING PROCEDURE FLOWCHART Air Disc Brake Inspection Follow safe maintenance practices, chock wheels. Engage spring brakes and cage spring. Release spring brakes and drain air from system. Raise axle, spin the wheel by hand. Does the wheel turn smoothly? YES NO Is the spring brake fully/ partially applied? Check running clearance (4.1) - OK? NO YES YES NO YES Check running clearance (4.1) - OK? Check adjuster (4.2) - OK? YES YES NO NO Drain air pressure from system.
SECTION FOUR: WHEEL-OFF MAINTENANCE INSPECTIONS 4.
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.
4.3- 4.4 BRAKE PADS AND ROTORS 4.3 INSPECT THE BRAKE PADS CAUTION: Follow all safe maintenance practices. 5HJXODU LQVSHFWLRQ RI WKH EUDNH SDGV HYHQ IRU YHKLFOHV WKDW XVH DQ HOHFWURQLF ZHDU LQGLFDWRU LV DQ LPSRUWDQW SDUW RI YHKLFOH PDLQWHQDQFH ,I HOHFWURQLF ZHDU VHQVRUV DUH SUHVHQW see Section 5.2. ,I GXVW FRYHUV DUH SUHVHQW see Section 5.1. See Figure 23.
%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 a
MACHINING OF BENDIX® SPLINED DISC® ROTORS IS NOT PERMITTED.
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SECTION FIVE: MAINTENANCE KITS AND PROCEDURES Section Five Section Page 0DLQWHQDQFH .LWV 16-17 $LU 'LVF %UDNH 6KLHOG .
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. Kit See Section Piece Number 803129 7UDLOHU $[OH 3DG 5RWRU 6KLHOG .LW Dust Shields 6HFWLRQ 803130 'ULYH $[OH 3DG 5RWRU 6KLHOG .LW 802948 6WHHU $[OH 3DG 6KLHOG .
5.0.1 GENERAL INFORMATION ABOUT BENDIX® AIR DISC BRAKE MAINTENANCE :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.
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.
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.
CAUTION: Never turn the adjuster (23) without the shear adapter (61) installed. The shear adapter is a safety feature and is designed to prevent too much torque being applied. The shear adapter will fail (by breaking) if too much torque is used. Note: For wheel-ends with spring brakes, if a shear adapter fails, always double-check to verify that the spring brake has been released (or caged).
5.3 CALIPER/CARRIER/ACTUATOR ASSEMBLY CAUTION: Follow all safe maintenance practices, including those listed on page two of this document. Park the vehicle (by other means than the foundation brakes) on level ground and chock the wheels.
,I WKH EUDNH DVVHPEO\ GRHV QRW VHSDUDWH IURP WKH DQFKRU SODWH LW PD\ EH KHOSIXO WR LQVWDOO DQ 0 ; VFUHZ ORQJHU WKDQ PP DW WKH EXVKLQJ ORFDWLRQV DQG WDS WKH HQG RI WKH EROW ZLWK D KDPPHU WR IUHH WKH EUDNH DVVHPEO\ 5HPRYH WKH DVVHPEO\ Caliper/Carrier Assembly (Actuator not shown) Axial Mounting Bolt Style Mounting Bolts and Washers (6 sets total) 'LVFRQQHFW WKH DLU KRVH V WR WKH EUDNH FKDPEHU See Figure 42.
5.4 SPRING OR SERVICE BRAKE CAUTION: Follow all safe maintenance practices, including those listed on page two of this document. Park the vehicle (by other means than the foundation brakes) on level ground and chock the wheels. Use the spring brake manufacturer’s recommended safety practices in all cases.
5.5 TAPPET & BOOT ASSEMBLIES, AND TAPPET INNER SEAL REPLACEMENT 22 Inner Seal 11 Pad Retainer CAUTION: Follow all safe maintenance practices, including those listed on page two of this document. Park the vehicle (by other means than the foundation brakes) on level ground and chock the wheels. 13 Tappet and Boot Assy ,Q VRPH FDVHV WKH WHFKQLFLDQ ZLOO QHHG WR UHPRYH WKH FDOLSHU FDUULHU DVVHPEO\ IURP WKH YHKLFOH (See Section 5.3.
)LJXUH LQVHW VKRXOG EH XVHG WR PRYH WKH ERRW DQG DOORZ WKH ZHGJH IRUN ³$´ LQ )LJXUH WR EH LQVHUWHG CAUTION: Do not insert the screw driver more than ¼ inch. Take care not to damage the inner sealing face (see arrow “X” in Figure 48). Gouges or grooves will prevent a good seal and will require that the caliper be replaced.
1RWH ,I WKH VKHDU DGDSWHU IDLOV ZKLOH \RX DUH UHWUDFWLQJ WKH WKUHDGHG WXEHV \RX PD\ WU\ DJDLQ ZLWK DQRWKHU QHZ VKHDU DGDSWHU ,I WKLV DOVR IDLOV WKLV LQGLFDWHV WKDW WKH DGMXVWHU PHFKDQLVP LV GDPDJHG DQG WKH FDOLSHU PXVW EH UHSODFHG To install inner seals where the caliper is on the vehicle: 3RVLWLRQ WKH UHSODFHPHQW LQQHU VHDO RYHU WKH WKUHDGHG WXEH See Figures 52 and 53 for the tools and installation arrangement used.
LV LQVHUWHG LQWR WKH 7 ³FXS´ FRPELQDWLRQ WRRO µ% ¶ +ROGLQJ WKH 7 KDQGOH WXUQ WKH QXW RQ WKH 7 WRRO WR IXOO\ LQVWDOO WKH WDSSHW RQWR WKH WDSSHW EXVKLQJ FIGURE 56 - ON VEHICLE TAPPET AND BOOT INSTALLATION TOOL (B1 - WITH T24 INSTALLED, B2) 13 B1 FIGURE 59 - OFF VEHICLE TAPPET BOOT INSTALLATION TOOL (B3, WITH T24 INSTALLED, B4) B3 13 161 FIGURE 57 - ON VEHICLE TAPPET BOOT INSTALLATION FIGURE 60 - OFF VEHICLE TAPPET BOOT INSTALLATION B2 13 13 B4 FIGURE 58 - ON VEHICLE TAPPET INSTALLA
5.6 GUIDE PIN AND BOOT ASSEMBLIES Vertical Bolt Style (with bushing). Bushing (6) Guide Pin (4) Caliper Bolt (39) Cap (68) Inner Boot (9) Ring (58) Horizontal Mounting Bolt Style Shown: See Inset Above for Vertical Bolt Style (with bushing). Shear Adapter (61) Adjuster Cap (Two alternate caps supplied in kit) (37) Ring (58) Inner Boot (9) Guide Pin (5) KIT CONTENTS Item Guide Bushing (7) Caliper Bolt (40) Cap (10) 4 . 5 . 6 . 7 . 9 . 10. 37. 39. 40. 58. 61. 68. . . . . . . . . . . . .
Bendix Number/ Ken-Tool Number Description 1-3/8 in. diameter disc T14 / KT14 Brass nut T06 / KT06 1-1/2 in. diameter disc T16 / KT16 Dimpling tool T07 / KT07 2 in. diameter sleeve T20 / KT20 8 in. bolt T08 / KT08 2-1/8 in. diameter disc T21 / KT21 Half Sleeve T10 / KT10 8 in. bolt T26 / KT26 Cap installation tool T12 / KT12 3-7/8 in. long sleeve T27 / KT27 Cap installation tool T13 / KT13 10 in.
8VLQJ D PP KH[ ELW VRFNHW UHPRYH DQG GLVFDUG WKH WZR FDOLSHU EROWV DQG See Figure 67.
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3ODFH WKH QHZ EXVKLQJ LQ SRVLWLRQ VR WKDW when drawn into position, the tab will align with the slot in the casting :LWK WKH WDE DOLJQHG SODFH WRRO 7 RYHU WKH EXVKLQJ DQG WDS OLJKWO\ 7R SRVLWLRQ WKH EXVKLQJ see Figure 78.
EHJLQ WR WLJKWHQ WKH EROWV :LWK WKH FDOLSHU FDUULHU LQ D YLFH FRQWLQXH LQVWDOOLQJ WKH EROWV WR D WRUTXH RI IW OEV 1ÂP )LQDOO\ WLJKWHQ HDFK EROW DQ DGGLWLRQDO QLQHW\ GHJUHHV Installation of the Guide Pin Caps See Figure 84.
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5H LQVWDOO WKH DLU GLVF EUDNH (See Section 5.3).
SERVICE DATA INDEX Section One: Air Disc Brake Overview 1 Safe Maintenance Practices 2 Section Two: Preventive Maintenance Schedule and Wheel-On Inspections 6 3UHYHQWLYH 0DLQWHQDQFH 6 %UDNH 3DG $QG 5RWRU ,QVSHFWLRQV
NOTES 39
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