Premium wheel-end brake products Service Manual Bendix® EB™ & ES™ Air Drum Brakes
General Information Section 1: General Information Foreword .................................................................................................................................................................................................. 4 Lining Material Warning ........................................................................................................................................................................... 5 Model Coverage .........................................
General Information List of Illustrations and Tables List of Illustrations Figure 1. How to Use this Manual ............................................................................................................................................................ 4 Figure 2. Bendix Brake Model Identification ............................................................................................................................................. 5 Figure 3. Brake Part Nomenclature, General ..............
General Information List of Illustrations and Tables List of Illustrations Figure 59. Figure 60. Figure 61. Figure 62. Figure 63. Figure 64. Figure 65. Figure 66. Figure 67. Figure 68. Figure 69. Figure 70. Figure 71. Figure 72. Figure 73. Figure 74. Figure 75. Figure 76. Figure 77. Figure 78. Figure 79. Figure 80. Figure 81. Shoe Return Spring and Roller Installation ...........................................................................................................................
General Information Foreword/Lining Material Warning Purpose of this Manual This Bendix Spicer Foundation Brake LLC publication is intended to act as a source of maintenance information to those involved in servicing Bendix brakes. 4 How to Use this Manual 1. Arrangement. This manual is arranged in seven sections: General Information, Periodic Service, Removal/Disassembly, Inspection, Repair/Replacement, Installation/Assembly and Specifications.
General Information Foreword/Lining Material Warning ! DANGER AVOID CREATING DUST POSSIBLE CANCER AND LUNG DISEASE HAZARD While Bendix Spicer Foundation Brake LLC does not offer asbestos area, segregation of areas where brake work is done, use of local brake linings, the long-term effects of some non-asbestos fibers filtered ventilation systems or use of enclosed cells with filtered have not been determined. Current OSHA Regulations cover vacuums.
General Information Model Coverage The service procedures and specifications in this publication cover the Bendix brake models listed in Table 1. The basic instructions cover all 15", 16.5", and 18" brake types and sizes, unless specified otherwise. A breakdown of Bendix brake model identification is provided in Figure 2.
General Information Model Coverage E S - 1 5 0 - 0 8 D Configuration Manufacturer Bendix Spicer Foundation Brake Example: L = Fabricated Shoe Fabricated Spider Single Anchor Pin (SAP) Service B - Standard Service S - Extended Service Shoe Size Example: 8 = 8.63" (219mm) Drum Diameter 122 – 12.25" (311 mm) 150 – 15" (381 mm) 165 – 16.5" (419 mm) 180 – 18" (457 mm) Shoe Size 04 - 4" – (102 mm) 05 - 5" – (127 mm) 06 - 6" – (152 mm) 07 - 7" – (178 mm) 07 - 7.5” – (191 mm) 08 - 8.
General Information Parts Nomenclature General parts nomenclature for Bendix brake models are identified also identified. Specific parts nomenclature for specific Bendix brake in Figure 3. Variations in shoe hold-down springs and guides are models are provided in Figure 4.
ES-150-6D Steer Brake Camshaft Shim Washer Shoe Assembly Parts Nomenclature General Information Camshaft Retainer Snap Ring Brake Adjuster Camshaft Bushing Bracket Assembly Roller Brake Adjuster Inner Washer Retainer Shoe Retainer Springs Color - Orange Grease Seal Shoe Return Spring Color - Red Camshaft Bushing Spider (Stamped Steel) Grease Fitting Grease Seal Cam Head Washer Camshaft Shoe Return Spring Retainer Roller Shoe Assembly ES-150-8D and ES-150-8F Drive & Trailer Brake Camshaf
General Information Parts Nomenclature Brake Model EB-165-5D EB-165-5L EB-165-6D EB-165-6F EB-165-7D EB-165-7F EB-165-7L Cam Roller and Pin for EB-165 and EB-180 Brakes Two-Piece Roller and Pin Brake Adjuster Inspection Hole Plug Shoe Assembly Shoe Retainer Springs Color - Orange Camshaft Shim Washers Dustshield Screw Grease Fitting Brake Adjuster Inner Washer Grease Seal Camshaft Bushing Dustshield Spider (Stamped Steel) Bracket Assembly Nut Lockwasher Grease Seal Camshaft Bushing Bracket Stud
General Information ES-165-7M Heavy-Duty Brake ES-165-7H Severe Duty Brake Camshaft Retainer Snap Ring Snap Ring Washer Brake Adjuster Fabricated Shoe Assembly Camshaft Shim Washer Bracket Assembly Inspection Hole Plug Anchor Pin Brake Adjuster Inner Washer Grease Seal Washer Snap Ring Camshaft Bushing Retainer Grease Fitting Bolt Bracket Lock Washer Camshaft Bushing Roller Cast Spider Cast Shoe Return Spring Color - Orange Grease Seal Nut Dustshield Anchor Pin Bushings Washer Camshaft Cas
General Information Parts Nomenclature Model ES-165 and EB-165 Interchangeability Brake parts for the Extended Service Brake (Model ES-165) are unique and must not be intermixed with Standard Brake parts (Model EB-165) EB™Roller Roller ES ™Cam Cam unless otherwise instructed. These parts consist of the camshaft, camshaft washer, return spring, cam roller and shoe/lining assembly. Any attempt to operate the brake with other than its intended parts may result in unsatisfactory performance.
General Information Parts Nomenclature Bendix brake model parts identification for shoes, return springs, spiders and camshafts are identified in Figure 6.
General Information Brake Spiders Lightweight Stamped Spider Single Anchor Pin Cast Spider Single Anchor Pin Spider Part No. Location Air Chamber Bracket Flange Shape for Cast Spider Air Chamber Bracket Flange Shape for Stamped Spider XX XX X Spider Part No. Location Cast Spider Double Anchor Pin Reduced Envelope Steer Brake Cast Spider Single Anchor Pin Spider Part No. Location Air Chamber Bracket Flange Shape for Cast Spider Spider Part No.
Periodic Service Parts Identification Brake Adjustment - Manual Brake Adjuster Maintenance and Adjustment Due to the importance of a well-maintained brake system, the NOTE: An assistant is required to make a brake adjustment. inspections and maintenance listed below must be accomplished by commercial vehicle operators at the intervals suggested.
Periodic Service Maintenance and Adjustment 3. Apply and hold an 80 psi brake application, and again measure 5. Take “A” dimension exactly as before. Take “B” measurement from face of air chamber to clevis pin centerline. Refer to Figure 9. using a lever to move brake adjuster as shown until the shoes Record distance as dimension “B”. contact drum. Refer to Figure 10. The result of “B” - “A” is brake free stroke. Adjust free stroke to within range specified in Table 3.
Periodic Service Brake Operation Check 4. Drive vehicle at low speeds in a safe area and make several brake check. applications to verify safe operation and absence of pulling, 1. Apply brakes to 80 psi and hold. Check all air line fittings and air grabbing, or noise. If any of these are noted, investigate and repair chambers for leakage. prior to releasing vehicle for service. Maintenance and Adjustment NOTE: An assistant is required to make a thorough brake operation 2.
Periodic Service Periodic Inspections Service Intervals The component inspections discussed below are general in nature. More detailed component inspections are normally done at overhaul. For more specific guidelines, refer to the appropriate inspection instructions in Brake Overhaul. Visual Inspection A thorough visual inspection for brake wear, loose fasteners, broken parts and/or obvious damage should be made each time the brake is being serviced or the wheel and drum have been removed.
Removal / Disassembly Drum Removal • complete disassembly 1. Perform “Brake Maintenance Preliminary Steps”. • cleaning 2. While depressing locking sleeve, back off brake adjuster adjust- • inspection ment nut on manual brake adjusters. Refer to Figure 11. Continue • repair and replacement of components turning until shoes are fully returned to released position and clear of • assembly drum. On self adjusting brake adjusters, follow manufacturer’s • brake operation check instructions.
Removal / Disassembly Shoe Removal Shoe Removal Table 5 provides an index to the location of shoe removal procedures. Locate the brake model under service and identify the page where the appropriate shoe removal procedures are located.
Removal / Disassembly NOTE: The following procedures are divided into sections, identified by brake model numbers. ! WARNING: The long term effects of non-asbestos fibers have not been determined. Therefore, precautions should be used when handling these materials. Shoe Removal See General Information / Lining Material Warning EB models (except EB-150-4L)/ES-165-5D,L / ES-165-6D,L / ES-165-7D, F, L / ES-150-8D, F / ES-150-4D/ES-150-6D/ES-165-8D,F,L 3.
Removal / Disassembly Shoe Removal 6. Push cam end of both shoes toward cam and unhook shoe return 7. Rotate both shoes around anchor pin and remove from vehicle. spring. Remove and discard spring. Refer to Figure 15. NOTE: To remove return spring, position a lever or suitable tool with notch to engage spring rod. Refer to Figure 14. Apply downward 8. Clean and inspect remaining parts as outlined in removal/ force to stretch spring, allowing removal of upper spring hook.
Removal / Disassembly ES-150-4L and EB-150-4L Brakes 1. Perform steps in removal/disassembly : drum removal 2. Using a large screwdriver or lever, lift upper shoe to stretch ! WARNING: The long term effects of non-asbestos fibers, have not been determined. Therefore, precautions should be used return spring. when handling these materials. 3. Remove upper roller. See General Information / Lining Material Warning 4. Report steps 2 through 3 to remove lower roller. 5.
Removal / Disassembly Shoe Removal ES-165-7M Heavy-Duty Brake 4. Using a lever or large screwdriver, lift upper shoe to remove roller and retainer as a unit. Refer to Figure 19. WARNING: The long term effects of non-asbestos fibers, have ! not been determined. Therefore, precautions should be used Lift Upper Shoe to Stretch Spring when handling these materials. See General Information / Lining Material Warning 1. Perform steps necessary for drum removal. See Removal / Disassembly - Drum Removal. 2.
Removal / Disassembly ES-165-7M Heavy-Duty Brake, Continued 9. To remove upper and lower shoes, remove anchor pins with a brass 7. Remove retaining ring and washer from drum side of both drift or a mallet. Refer to Figure 23. anchor pins. Refer to Figure 21. Remove Retaining Rings and Washers Drive Out Anchor Pins Figure 23. Anchor Pin Removal Figure 21. Retaining Ring and Washer Removal is grooved or worn beyond 0.031" (0.79mm), replace pin and bushing.
Removal / Disassembly Shoe Removal ES-165-7H Severe Duty Brake WARNING: The long term effects of non-asbestos fibers have 5. Remove upper anchor pin with a brass drift or a mallet. Refer to Figure 27. not been determined. Therefore, precautions should be used ! when handling these materials. See General Information / Lining Material Warning 1. Perform steps necessary for drum removal, see Removal Disassembly - Drum Removal. Drive Out Anchor Pin 2. Remove cap screws and dustshield, if applicable. 3.
Removal / Disassembly 7. Remove lower anchor pin to remove lower shoe. 9. Do not remove roller from the brake shoe, unless: the roller does NOTE: Inspect anchor pin and bushings. If pin was seized or not roll freely, there are flat spots on the roller, or there is more than bushing is grooved or worn beyond 0.031" (0.79mm), replace pin 0.025" play between the roller and pin. and bushing. Always replace pins and bushings with brake reline.
Removal / Disassembly Brake Adjuster Removal 1. Remove cotter pin and clevis pin from air chamber pushrod clevis. 4. Note orientation of brake adjuster with reference to push rod 2. While depressing locking sleeve, turn adjuster nut until brake before removal to assure assembly is in proper orientation. Remove adjuster is clear of air chamber pushrod clevis. Refer to Figure 31. brake adjuster with a suitable puller. NOTE: Follow manufacturer’s instructions for self adjusting brake adjusters.
Removal / Disassembly Spider Removal Dustshield Removal 1. Perform all steps for drum and shoe removal as outlined in NOTE: On ES-165-7H, M Brakes, the dustshield is removed before Removal / Disassembly section. shoes and anchor pins are removed. 2. Remove spider-to-axle attachment nuts and bolts. Refer to 1. If applicable, remove screws and retaining clip. Remove all Figure 32. screws attaching dustshield to spider (4-6 screws depending on 3. Remove spider. model). Refer to Figure 33. 2.
Removal / Disassembly Cleaning Brake Parts After removing the brake parts to be serviced, the following cleaning procedures should be followed: • Wire brush all parts exposed to mud, road dirt, and salt, ! WARNING: The long term effects of non-asbestos fibers, have not been determined. Therefore, precautions should be used when handling these materials. Do not use including spider, air chamber bracket, dustshields and exterior compressed air to blow from interior of drums. Brake lining of drum.
Inspection Drum Inspection Drum Inspection • Clean all remaining brake parts thoroughly with a suitable shop Bendix does not recommend the turning or reboring of brake drums. The reduction of wall thickness reduces the amount of thermal energy that can be absorbed by the drum during braking. Also, the decrease in wall thickness increases the amount of deflection for the same input load. Both of these are undesirable.
Inspection Inspection Shoe and Lining Inspection 1. Check shoes for bent or cracked webs, or table, broken welds, 4. Check the linings and replace with Bendix OEM grade shoe and loose rivets or elongated rivet holes. Refer to Figure 36. If any are lining assembly if contaminated, cracked, or worn to less than 1/4" found, replace with Bendix OEM grade lining and shoe assemblies. (6.4mm) thickness at any point (see instructions below) or 3/16" (4.5mm) for EB/ES 150-4L brake.
Inspection Shoe and Lining Inspection (cont’d) ! Standard Production EB™ brakes use different shoe and lining WARNING: The long term effects of non-asbestos fibers, have not been determined. Therefore, precautions should be used when handling these materials. assemblies than those used for the ES models. Because of these part See General Information / Lining Material Warning differences, normal wear of either creates a unique lining wear pattern.
Inspection Inspection Camshaft Radial Play Inspection Camshaft Inspection Camshaft radial play should be checked any time the brake shoes 1. Refer to Figure 39. Check spline end for cracks, worn or have been removed from the vehicle. Refer to Figure 38. deformed splines. Replace as necessary. 1. Mount a suitable dial indicator with plunger referencing cam head 2. Check camshaft bushing journals for wear and corrosion. at roller contact area.
Inspection Spider Inspection Air Chamber Bracket Inspection Single Anchor Pin 1. Check for a bent, broken, or cracked arm and cracked welds. Refer to Figure 41. Replace bracket if any are evident. 1. Check visually for cracks around mounting bolt holes, in cam area and around anchor pin. Refer to Figure 40. Replace spider if any are found. 2. Check anchor pin. If loose or grooved more than 0.031" 2. Check mounting studs (or bolts) for looseness, damaged threads, or a bent condition.
Inspection Inspection Air Chamber Inspection ! Brake Adjuster Inspection WARNING: To prevent personal injury, be sure to “cage” NOTE: This information is general in nature. For specific manual spring before removing spring-brake type air chamber. or self adjusting brake adjuster inspection guidelines, refer to the NOTE: This information is general in nature. For specific air chamber inspection guidelines, refer to the manufacturer’s instructions. manufacturer’s instructions. 1.
Repair / Replacement Camshaft Bushing/Lining Replacement Brake Model At Cam Head At Brake Adjuster Non-metallic Non-metallic ES-165M, H and EB-180 Bronze Non-metallic Installation Specs: (All except Trailer Axle) Recessed 9/32" (7.1mm) from tube end. Recessed 22/32" (17.5mm) from tube end. Trailer Axle Spider Bushings Flush with inner recess shoulder at each end of spider (to allow space for the seals).
Repair / Replacement Lining Replacement 3. Clean shoe with solvent if necessary and wire brush shoe ! WARNING: The long-term effects of non-asbestos fibers table. Paint with rust inhibitive paint. have not been determined. Therefore, precautions should be 4. Install lining blocks. used when handling these materials. NOTE: When installing linings or blocks, make sure they are positioned properly to match rivet or bolt patterns. Refer to Figure 46.
Installation / Assembly Spider Installation 3. Reposition dustshield as required to allow a uniform space of SPECIAL NOTE: For ES/EB-150-4L distinct right-hand and lefthand spider assemblies are used on this brake. Although similar in appearance, differences exist in anchor pin and 1/8" (3.2 mm) all along parallel mating edges. Refer to Figure 48. 4. Torque attaching screws to proper torque; see Specifications chart. T retaining nut threads - L.H. brake uses L.H. threads and R.H. brake uses R.H.
Installation / Assembly Dustshield Installation (One Piece) 1. Position dustshield against spider and install screws finger tight. 2. Torque attaching screws to proper torque; see Specifications Chart and Figure 50. T Figure 50.
Installation / Assembly Air Chamber Bracket Installation Air Chamber Bracket Installation EB/ES-150-4L Brake 1. Verify that available air chamber bracket is serviceable, see Inspection - Air Chamber Bracket Inspection. 1. Verify that available air chamber bracket is serviceable. Refer to 2. On stamped steel spider, orient bracket to align mounting studs with holes in bracket. Removal/Disassembly - Air Chamber Bracket Removal. 2. Orient bracket to align stabilizing screw with slot in spider and 3.
Installation / Assembly Camshaft Installation 1. Verify that available camshaft is serviceable and is the correct part for the application, see Inspection - Camshaft Inspection NOTE: Camshaft mounting and related parts vary with Brake Models. Be sure to follow instructions for special parts when installing CAST SPIDER camshafts. STAMPED SPIDER ! CAUTION: Ensure the camshaft being installed is correct for the application. 2. To ensure that camshaft being installed is correct for the Cast Spider.
Installation / Assembly SPECIAL NOTE: For ES-1 655,6,7D,L Steer axle brakes using the 5. Install camshaft shim washers and snap ring. Refer to Figure 54. horse collar spring retention system, position the cam head Check and adjust camshaft axial play (see step 6). washer with the “stamped spider” arrow pointing towards the NOTE: Camshaft axial play must be checked before camshaft center of the spider. The horse collar should be placed over the installation is complete. Follow instructions below.
Installation / Assembly Shoe and Lining Installation Brake Model Page Number 11. Verify that air chamber face-to-clevis centerline dimension is correct, see Inspection - Air Chamber Inspection. Ensure that clevis EB-150-4L 44 EB-165-5D 46 12. While depressing locking sleeve, rotate adjusting nut as required EB-165-5L 46 until appropriate hole in brake adjuster is aligned with hole in air.
Installation / Assembly Shoe and Lining Installation Hook Spring into Shoe Web Hole An index to the location of shoe installation procedures is provided in Table 8. Locate the brake model under service to identify the location of the appropriate shoe installation procedures. EB/ES-150-4L Brake 1. Verify that spider, camshaft, air chamber bracket, and brake adjuster are serviceable and properly installed. Anchor Pin Recess Figure 58. Shoe Retaining Spring Installation 6.
Installation / Assembly Shoe And Lining Installation NOTE: The following procedures are divided into sections, identified by brake model numbers. ES-150-8D, F&6D With Retainer Springs Installed, Position Upper and Lower Shoes Around Anchor Pin 1. See Inspection & Repair / Replacement to verify that spider camshaft, bracket, and brake adjuster are serviceable and properly installed. 2. During shoe installation, lubricate: • Shoe roller recess - one-piece roller.
Installation / Assembly All EB (except EB-150-4L) and ES-165 5/6/7/8D,F,L NOTE: The following procedures are divided into sections, identified by brake model numbers. With Retainer Springs Installed, Position Upper and Lower Shoes Around Anchor Pin 1. See Inspection & Repair / Replacement to verify that spider camshaft, bracket, and brake adjuster are serviceable and properly installed. 2. During shoe installation, lubricate: • Shoe roller recess - one-piece roller. • Roller I.D. - two-piece roller.
Installation / Assembly Shoe And Lining Installation 6. For ES-165 5/6/7/8D, L, F, ES-150-4D, ES-150-8D, F & 6D only: 8. For ES-165 5/6/7/8D, L, F, ES-150-4D, ES-150-8D, F & 6D only: Assemble roller retainer on ends of roller as shown in Figure 64. Position assembly in roller recess as shown. Squeeze loops and swing retainer into position to snap loops into web holes. Refer to Figure 66. Verify that both retainer loops are engaged in web holes before proceeding.
Installation / Assembly ES-165-7M Heavy Duty Brake WARNING: The long term effects of non-asbestos fibers, ! have not been determined. Therefore, precautions should be used when handling these materials. See General Information / Lining Material Warning 1. See Inspection & Repair / Replacement to verify that spider camshaft, bracket, and brake adjuster are serviceable and properly installed. 2. During shoe installation, lubricate: • Shoe roller recess.
Installation / Assembly Shoe Installation 8. Install shoe return spring. Refer to Figure 71. NOTE: A lever may be required to assist in hooking return spring. Stretch Return Spring, Install Roller And Retainer Figure 73. Roller and Retainer Installation Stretch Spring Using Suitable Tool Positioned As Shown Figure 71. Shoe Return Spring Installation 11. Position roller and retainer in shoe recess as shown in Figure 73. Squeeze loops and swing retainer into position to snap loops in shoe web holes.
Installation / Assembly ES-165-7-H Severe Duty Brake WARNING: The long term effects of non-asbestos fibers, ! Secure Roller Pin with Groove Pin have not been determined. Therefore, precautions should be used when handling these materials. See General Information/lining Material Warning 1. See Inspection & Repair / Replacement to verify that spider, camshaft, bracket, and brake adjuster are serviceable and properly installed. 2. During shoe installation, lubricate: • Roller inside diameter. Figure 75.
Installation / Assembly Shoe Installation Complete Installation of Upper Shoe Figure 78. Lower Shoe Positioning Figure 80. Upper Shoe Installation 8. Connect a new return spring to lower shoe. 10. Complete the installation of upper shoe and install anchor pin, 9. Position upper shoe for installation on spider (partially installed washers and retaining rings. Refer to Figure 80. with shoe end disengaged from cam), then connect return spring to 11. Install cap screws in spider to secure anchor pins.
Specifications Specification Chart Fastener Torque Specifications All EB/ES 165, 150-4D, 150-8D, F & 6D Fastener Torque lbs./ft. – lbs./in. N.m Dustshield Retaining Clip Screws Dustshield to Spider Screws 48-60 lbs./in. 150-180 lbs./in. 5-7 N.m 16.9-20.3 N.m Air Chamber Bracket to Steel Stamped Spider Nuts Air Chamber Bracket to Cast Spider Bolts 65-85 lbs.-ft. 65-85 lbs.-ft. 88-115 N.m 88-115 N.m Air Chamber Mounting Nuts (7/16"-20 Nuts) Air Chamber Mounting Nuts (5/8"-18 Nuts) 35-40 lbs.-ft.
Specifications 54
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 BW7258 ©2007 Bendix Spicer Foundation Brake LLC • 03/07 • All Rights Reserved • Printed in U.S.A.
