Air Disc Brakes - beamalarm.com

1 Revised 02-99. om Air disc Brakes Maintenance Manual 4M..c m ar al m eaB. w. ww Service Notes This publication provides maintenance and service procedures for Meritor's air disc Brakes . The Service Notes information contained in this publication was current at the time of printing and is subject to revision without notice or liability. 1. You must understand all procedures and instructions before you begin maintenance and service om procedures. 2. You must follow your company's maintenance and service guidelines. 3. You must use special tools, when required, to avoid serious personal injury and damage to components. Meritor uses the following notations to alert the user of possible safety issues and to provide information that will help to prevent damage to equipment and components.

2 C m WARNING NOTE: A NOTE indicates an operation, procedure A WARNING indicates a procedure that or instruction that is important for proper service. you must follow exactly to avoid serious A NOTE can also supply information that will personal injury. help to make service quicker and easier. CAUTION. A CAUTION indicates a procedure that you must follow exactly to avoid damaging arThis symbol indicates that fasteners must be tightened to a specific torque. al equipment or components. Serious personal injury can also occur. m Visit Our Web Site How to Order Visit the Technical Library section of Call Meritor's Customer Service Center at ea for additional product and 800-535-5560.

3 Service information on Meritor's heavy vehicle systems component lineup. Technical Electronic Library on CD. B. The CD includes product and service information on Meritor's heavy vehicle systems component lineup. $20. Order TP-9853. w. Videos Meritor Air disc brake Maintenance T-92108V. $20. ww Table of Contents Asbestos and Non-Asbestos Fibers Warnings ..1. Section 1: Exploded Views Air disc brake Exploded View ..2. Air disc brake Cutaway View ..3. om Section 2: Introduction Model Code .. 4. Description How the brake Functions Section 3: Caliper Remove the Caliper.. 5..c Install the Caliper .. 6. Calipers with Helper Springs ..7.

4 Section 4: Caliper Bushings m Inspect Caliper Bushings .. 8. When the Caliper Is Mounted on the Vehicle When the Caliper Is Removed from the Vehicle Remove Caliper Bushings .. 9. ar Inspect the Caliper Bores Install Caliper Bushings .. 10. Caliper Bushing Kits and Special Tools Prepare to Install the Bushings ..11. al Install the Outer Bushings Install the Inner Bushings ..12. Section 5: Caliper/Piston Boot and O-Ring Remove the Caliper/Piston Boot and O-Ring .. 13. m Replace the Boot and O-Ring .. 16. Install the Caliper/Piston Boot and O-Ring Section 6: Automatic Slack Adjuster ea Removing the Automatic Slack Adjuster .. 20. Pull Pawls Installing the Automatic Slack Adjuster.

5 21. A Slack Adjuster with a Welded Clevis ..23. A Slack Adjuster with a Threaded Clevis B. Section 7: Camshaft Remove the Camshaft .. 24. Install the Camshaft .. 26. w. Install the Caliper ..27. Section 8: disc (Rotor). Inspect the disc (Rotor) .. 28. Cracks ww Heat Checking Grooves or Scores Blue Marks or Bands ..29. Measuring the Thickness of the disc (Rotor). Remove the disc (Rotor). Front Non-Drive Steering Axles and Trailer Axles Drive Axles ..30. Install the disc (Rotor) ..32. Table of Contents Section 9: Torque Plate and Bushings Inspect the Torque Plate .. 34. Inspect Torque Plate Bushings Remove Torque Plate Bushings om Remove the Torque Plate Install the Torque Plate.

6 35. Tighten the Torque Plate Install Torque Plate Bushings Section 10: Reline the Brakes Check Lining Wear .. 36..c Remove the Shoes and Linings (Pads). Install the Shoes and Linings (Pads) .. 40. Section 11: Adjust the brake Check the brake Chamber Push Rod Stroke and Adjust the Clevis Position .. 43. m brake Slack Adjuster Position (BSAP) Method Automatic Slack Adjuster Templates Measure the Slack Adjuster ar Install a Threaded Clevis .. 44. Measuring and Adjusting the Chamber Stroke .. 45. Measuring Initial and In-Service Free Stroke Without a Template .. 46. Measuring In-Service Free Stroke with a Template Adjusting the Stroke.

7 47. al Commercial Vehicle Safety Alliance (CVSA) Guidelines to Measure Push Rod Travel (Adjusted Chamber Stroke). Alternate Method for Determining Push Rod Travel (Adjusted Chamber Stroke) .. 48. Commercial Vehicle Safety Alliance (CVSA) North American Out-of-Service Criteria m Reference Charts Section 12: Prepare Parts for Assembly Clean, Dry and Inspect Parts .. 49. ea Section 13: Lubrication and Maintenance Grease .. 50. Lubricate the Automatic Slack Adjuster Lubricate the Caliper Maintenance .. 51. B. Minor Inspections Major Inspections .. 53. Section 14: Diagnostics w. Air disc brake .. 55. Automatic Slack Adjuster .. 58. Section 15: Torque Chart.

8 59. ww Asbestos and Non-Asbestos Fibers ASBESTOS FIBERS WARNING NON-ASBESTOS FIBERS WARNING. The following procedures for servicing Brakes are recommended to reduce The following procedures for servicing Brakes are recommended to reduce exposure to asbestos fiber dust, a cancer and lung disease hazard. Material Safety exposure to non-asbestos fiber dust, a cancer and lung disease hazard. Material Data Sheets are available from Meritor. Safety Data Sheets are available from Meritor. Hazard Summary Hazard Summary om Because some brake linings contain asbestos, workers who service Brakes must Most recently manufactured brake linings do not contain asbestos fibers.

9 These brake understand the potential hazards of asbestos and precautions for reducing risks. linings may contain one or more of a variety of ingredients, including glass fibers, Exposure to airborne asbestos dust can cause serious and possibly fatal diseases, mineral wool, aramid fibers, ceramic fibers and silica that can present health risks if including asbestosis (a chronic lung disease) and cancer, principally lung cancer and inhaled. Scientists disagree on the extent of the risks from exposure to these mesothelioma (a cancer of the lining of the chest or abdominal cavities). Some studies substances. Nonetheless, exposure to silica dust can cause silicosis, a non-cancerous show that the risk of lung cancer among persons who smoke and who are exposed to lung disease.

10 Silicosis gradually reduces lung capacity and efficiency and can result in asbestos is much greater than the risk for non-smokers. Symptoms of these diseases serious breathing difficulty. Some scientists believe other types of non-asbestos fibers, may not become apparent for 15, 20 or more years after the first exposure to asbestos. when inhaled, can cause similar diseases of the lung. In addition, silica dust and ceramic fiber dust are known to the State of California to cause lung cancer. and Accordingly, workers must use caution to avoid creating and breathing dust when international agencies have also determined that dust from mineral wool, ceramic fibers servicing Brakes .