BENDIX ADB22X Manual Download Page 3

Page: 3 / 28

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

Air Disc Brake Sectional and Exploded Views . . . . .4-5

Air Disc Brake Identiﬁcation . . . . . . . . . . . . . . . . . . . . 6

Rotor Identiﬁcation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Electronic Wear Indicator Exploded Views. . . . . . . . . 6

Preventive Maintenance

Preventive Maintenance Schedule. . . . . . . . . . . . . . . 7

Running Clearance Inspection . . . . . . . . . . . . . . . . . . 7

Mechanical Wear Indicators . . . . . . . . . . . . . . . . . . .8-9

Electronic Wear Indicators, including

Hand Held Diagnostic Equipment . . . . . . . . . . . . . 10

Troubleshooting

Troubleshooting Flowchart . . . . . . . . . . . . . . . . . . . . 11

Inspections

Brake Pads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Rotors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Caliper Running Clearance . . . . . . . . . . . . . . . . . . . 14

Adjuster Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . 15

Guide Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-17

Maintenance Procedures

Pad Replacement. . . . . . . . . . . . . . . . . . . . . . . . .18-19

Electronic Wear Indicator Replacement . . . . . . . .20-21

Tappet and Boot Assemblies

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .22-24

Carrier/Caliper Assembly Replacement . . . . . . . . . . 25

Brake Actuator and Spring

Brake Replacement . . . . . . . . . . . . . . . . . . . . . . .26-27

SERVICE DATA INDEX

Summary of Contents for ADB22X

Page 1: ...tor moves into contact with the brake rotor Further movement of the bridge forces the caliper sliding on two stationary guide pins away from the rotor which pulls the outer brake pad into the rotor The clamping action of the brake pads on the rotor applies braking force to the wheel Brake Release and Adjustment When the vehicle brakes are released the air pressure in the service brake chamber is e...

Page 2: ...s requiring machining or welding unless specifically stated and approved by the vehicle and component manufacturer 10 Prior to returning the vehicle to service make certain all components and systems are restored to their proper operating condition 11 For vehicles with Antilock Traction Control ATC the ATC function must be disabled ATC indicator lamp should be ON prior to performing any vehicle ma...

Page 3: ...l Wear Indicators 8 9 Electronic Wear Indicators including Hand Held Diagnostic Equipment 10 Troubleshooting Troubleshooting Flowchart 11 Inspections Brake Pads 12 Rotors 13 Caliper Running Clearance 14 Adjuster Mechanism 15 Guide Pins 16 17 Maintenance Procedures Pad Replacement 18 19 Electronic Wear Indicator Replacement 20 21 Tappet and Boot Assemblies Replacement 22 24 Carrier Caliper Assembly...

Page 4: ...ube 161 Tappet 13 Tappet andBoot Assembly 4a Guide Pin 18 1SpringBrakeor 18 2 BrakeChamber 19 Lever 20 Eccentric Bearing 46 Rotor 43 Bolt PadAssembly12 17 Bridge 12 Pad Assembly 27 Spring 6c GuideSleeve 2 Carrier 4c GuidePin 9 Inner Boot 58 Ring 39c CaliperBolt 68c Cover 39a CaliperBolt 6a Rubber Bushing 4b GuidePin 6b Rubber Bushing 39b CaliperBolt Top Sectional View Caliper Bolt B Uses Solid Rub...

Page 5: ...in 9 58 Ring Adjuster Cap 37 Adjuster Unit 23 Bolt 43 Brake Chamber 18 2 Brass Bushing 7 Bridge 17 Caliper 1 Caliper Bolt 39a 39b 39c 40 Carrier 2 Chain 30 Chain Wheel 32 Cover 10 Eccentric Bearing 20 Guide Pins 4a 4b 4c 5 Guide Sleeve 6c Inner Boot 9 Inner Seal 22 Lever 19 Pad 12 1 Pad Holder Spring 12 2 Pad Assembly 12 Pad Retainer 11 Pad Retainer Pin 44 Ring 58 Rubber Bushings 6a 6b 6c Shear Ad...

Page 6: ...Certain maintenance inspection procedures depend on the type of rotor installed See Page 13 See below for examples of the different styles of rotor in use ConventionalRotor FIGURE 8 ROTOR IDENTIFICATION FIGURE 9 ELECTRONIC WEAR INDICATOR COMPONENTS Pad Retainer 11 Sensor 101 Cable to Electrical Supply 103 Cable Protection Plate 104 Cable Guide 105 Cable Guide 105a Alternative to Item 105 105a Cabl...

Page 7: ...le See Page 13 for criteria Pad Rotor Wear Running Clearance Inspection with the wheel mounted Basic Inspection Program At Least Once Annually and at Every Pad Replacement Inspection with wheel removed Inspect The rotor for cracks etc see Page 13 for criteria The running clearance and adjuster function see Page 15 The caliper travel see Pages 16 17 The tappet and boot assemblies see Page 14 All co...

Page 8: ...hat the ribbed section of the ﬂexible rubber bushing reaches the point where it folds back in it is time to schedule a full wheel removed inspection of the pads and rotor Note This is only an indication that the pads and rotor are ready for inspection and does not necessarily mean that maintenance is required FIGURE 10 ROLLING BOOT STYLE WEAR INDICATOR INSPECTION Style A Rolling Boot Style Wear In...

Page 9: ...Indicator Notch When the notch in the Carrier aligns with the front edge of the torque plate it is time to schedule a full wheel removed inspection of the pads and rotor Note This is only an indication that the pads and rotor are ready for inspection and does not necessarily mean that maintenance is required Locationof Inspection Grooves Notch in Caliper Notchin Carrier Notches Line Up Torque Plat...

Page 10: ...ert the driver Alternate vehicle arrangements permit a hand held diagnostic tool to be used to test individual wheel connectors or where installed attach to a DIN socket in the dash and allow up to six brakes to be checked from that location The system provides feedback on the pad wear and can also conduct a test of the Wear Indicator Potentiometer Even when using wear indicators always follow the...

Page 11: ...11 FIGURE 18 TROUBLESHOOTING BENDIX AIR DISC BRAKES GENERAL TROUBLESHOOTING PROCEDURE FLOWCHART ...

Page 12: ...ehicle for further information INSPECT BRAKE PADS Regular inspection of the brake pads even for vehicles that use a wear indicator is an important part of vehicle maintenance See Figure 16 If the thickness of the friction material M2 is less than 0 079 in 2 mm the pads must be replaced Bendix ADB 22X ADB 225 SN6 SN7 and some SK7 air disc brakes use 0 35 in 9 mm backing plates so P2 the combined pa...

Page 13: ... grooving of the entire friction surface however turning could be useful and may increase the load bearing surface of the pads To meet Bendix recommendations the minimum rotor thickness after turning must be greater than 1 53 in 39 mm CAUTION Always maintain air disc brake pads and rotors within speciﬁcations Excessive pad or rotor wear will degrade optimum performance When replacing Rotors be sur...

Page 14: ...running clearance is too small or too large the adjuster may not be functioning correctly and should be checked See Inspect Adjuster Mechanism on Page 15 FIGURE 23 MEASURING THE RUNNING CLEARANCE CONTACTING BENDIX www foundationbrakes com Bendix on line information is available 24 7 In the on line contacts directory you can ﬁnd technical support contacts service engineers Bendix account managers i...

Page 15: ...feature and is designed to prevent an excess of torque being applied to the adjuster The shear adapter will fail by breaking loose if too much torque is applied If the shear adapter fails you may attempt a second time with a new unused shear adapter A second failure of the shear adapter conﬁrms that the adjustment mechanism is seized and the caliper must be replaced With a box end wrench or socket...

Page 16: ...e guide pins Remove the Pads see Page 18 One of the three different styles of guide pin A B or C may be present See Figure 28 The bearings for styles A and B use a rubber bushing and style C uses a guide sleeve Clean dirt road grime etc from the guide pin or cover Using hand pressure only no tools the Caliper 1 should slide freely along the whole length of the Guide Pin arrangement With the pads r...

Page 17: ...TEND THE TAPPET MORE THAN 1 18 in 30 mm Over extending the tappet will result in the tappet losing engagement with the threads of the synchronizing mechanism Since the mechanism can only be set at the manufacturing plant the CALIPER CARRIER ASSEMBLY MUST BE REPLACED if this happens Inspect the tappet and boot assemblies 13 for evidence of damage corrosion etc The penetration of dirt and moisture i...

Page 18: ...r 61 in an counter clockwise direction see Page 15 Note Do not use an open ended wrench as this may damage the adapter CAUTION Never turn the adjuster 23 without the shear adapter 61 installed The shear adapter is a safety feature and is designed to prevent an excess of torque being applied to the adjuster The shear adapter will fail by breaking loose if too much torque is applied If the shear ada...

Page 19: ...r design Be sure to install the correct part number for the vehicle After installing the pad retainer 11 supplied with the kit into the groove of the caliper 1 it must be depressed to enable the insertion of the pad retainer pin 44 Install the supplied washer 45 and spring clip 26 to the pad retainer pin 44 It is recommended that the pad retainer pin 44 be installed pointing downwards see Figure 3...

Page 20: ...r indicator cable see arrow must be installed in the outboard pad Insert the Wear Indicator Cables 101 into the pre cut slot in the pads The wear indicators snap into place Outboard Pad 101 12 1 12 1 Long Cable 1 FIGURE 36 WEAR INDICATOR CABLE 5 Install the cable guide 105 onto the pad retainer 11 The cable guide 105 snaps into place when pressing lightly onto the pad retainer 11 5 105 4 Install t...

Page 21: ... not be secured by a wire loop of the cable guide 105a see arrows C 8 Carefully install the cable protection plate 104 with attention to the correct position of the cable protection plate s catch see arrows The cable protection plate 104 will snap into place 7 101 105a 8 6 Press the wear indicator cable 101 into the locating tabs of the cable guide 105 see arrowsA The short cable end of the wear i...

Page 22: ...CALIPER CARRIER ASSEMBLY MUST BE REPLACED if this happens Removal of the tappet and boot assembly 13 requires the use of the wedge fork A See Figure 39 Extend the tappets less than 1 18 in 30 mm by turning the shear adapter 61 clockwise until there is sufﬁcient access to the boots to remove the tappet boot from the caliper bore A screwdriver B should be used to move the boot location ring see Figu...

Page 23: ...iper carrier assembly must be replaced see Page 25 If the threads are in good condition fully wind back the threaded tubes 16 by turning the shear adapter 61 counter clockwise INSTALLING THE TAPPET AND BOOT ASSEMBLIES 13 Grease threads with white grease Part No II14525 or II32868 Screw back the threaded tubes 16 by turning the shear adapter 61 counter clockwise see Cautions earlier in these instru...

Page 24: ...ng into place see Figure 43 Position a tappet 13 onto each tappet bushing Using press in tool B in a reversed orientation with the press in extension T3 T4 towards the threaded tube install each tappet onto its tappet bushing see Figure 45 After assembly check that the tappet 13 is free to turn in both directions Note When installing the tappet for Bendix ADB 22X ADB 225 and SK7 disc brakes use th...

Page 25: ... air disc brake part number on the identiﬁcation label when ordering replacement parts See Page 6 Replacement caliper carrier assemblies may be delivered with a plastic cap adhesive tape or a breakthrough diaphragm in the area of the actuator attachment Remove the cap or tape only after installing the replacement caliper on the vehicle If the replacement caliper has the breakthrough diaphragm it s...

Page 26: ...drain holes remain plugged The drain hole must be aligned downwards or within 30 when installed on the vehicle Before installing the new brake chamber the actuator ﬂange see Figure 51 arrow C must be cleaned and inspected Consult the vehicle manual The spherical cup in the lever 19 must be greased with white grease Part No II14525 or II32868 CAUTION Do not use grease containing molybdenum disulfat...

Page 27: ...position Be sure that all other drain holes remain plugged The drain hole must be aligned downwards or within 30 when installed on the vehicle Before installing the new brake chamber the actuator ﬂange see Figure 51 arrow C must be cleaned and inspected Consult the vehicle manual The spherical cup in the lever 19 must be greased with white grease Part No II14525 or II32868 CAUTION Do not use greas...

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