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Meritor Meritor ELSA 195, Maintenance Manual, Page: 31 / 49

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Summary of Contents for Meritor ELSA 195

Page 1: ...an ArvinMeritor brand Maintenance manual no MM 0350 ELSA 195 Reaction Beam Air Disc Brake Issue 02 2003...

Page 2: ...AUTION A CAUTION indicates a procedure that you must follow exactly to avoid damaging equipment or components Serious personal injury can also occur NOTE A note indicates an operational procedure or i...

Page 3: ...new Piston Dust Excluders pg 35 Section 7 Guide Sleeve Dust Excluder Retainer Bushes 36 Checking Slide Pin Bush Wear 36 A Tangential Test 36 B Radial Test 37 Dismantling Round Oval Guide Sleeve Bushes...

Page 4: ...or Any person who will use the air disc brake as part of a more complex device Warranty Warranty applies to the air disc brake installed on vehicles for which it was designed Warranty is void in the f...

Page 5: ...duction 06 Axial brake ELSA 195 exploded view 07 Axial brake ELSA 195 parts list 08 Housing assembly cross section 09 Brake body detail cross section 11 How it works 12 Automatic adjustment 13 Manual...

Page 6: ...6 ArvinMeritor Air Disc Brake ELSA 195 Exploded view Axial brake ELSA 195 1 7 8 9 6 5 19 20 21 22 23 26 27 28 29 30 25 31 29 18 16 13 12 17 14 14 13 12 11 10 4 4 3 3 2...

Page 7: ...used Guide Sleeve Bush Oval Manual adjuster stem Housing Roller Half Bearing Operation Shaft Needle Bearing Saddle Half Bearing 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Ref...

Page 8: ...Fig 2 8 ArvinMeritor Air Disc Brake ELSA 195 Housing assembly cross section 2 Rotor 25 12 14 14 28 45 21 18 28 26 16 12 27 3 3 1...

Page 9: ...Fig 3 9 ArvinMeritor Air Disc Brake ELSA 195 Brake body detail cross section 41 8 34 35 45 36 46 22 23 18 19 44 43 42 21 23 22 19 20 20 7 37 38 39 40 7 8 36 35 34 17...

Page 10: ...46 Ref Description Piston Head Piston Dust Excluder Manual adjuster stem Brake housing Roller Half Bearing Operation Shaft Needle Bearing Saddle Half Bearing Tappet Piston shaft Retainer Clutch plate...

Page 11: ...rrier 2 by means of guide sleeve screws 25 27 The brake carrier is connected to the axle The housing 18 is mounted so that it floats on the guide sleeves and a bridge 1 is fixed to the housing 18 to p...

Page 12: ...ack 37 slips preventing adjustment of the mechanism below the correct running clearance b Operation with adjustment As a result of pad or rotor wear the running clearance is now greater than the inbui...

Page 13: ...locate a 10mm socket on the adjuster stem 17 and turn it clockwise viewed from the air actuator side Continue to adjust the brake until the pads lightly grip the rotor De adjust the brake by 1 2 a tu...

Page 14: ...14 ArvinMeritor Air Disc Brake ELSA 195...

Page 15: ...15 ArvinMeritor Air Disc Brake ELSA 195 pg 2 Pad replacement 16 A Pad replacement 16 B Pad removal with PWWI fitted 17 C Cleaning and inspection 18 D Fitting New Pads...

Page 16: ...ppropriate Jack up the axle and fit suitable axle stands securely Remove the road wheels and exhaust all air from the system Remove any dirt from the Brake assembly Ensure the rubber dust excluders fi...

Page 17: ...uders They should be secure and free from any signs of damage If damaged they should be replaced by following the procedures laid out in Sections 6 and 7 Check that the Brake housing assembly slides f...

Page 18: ...nboard pad Refit both pad springs ensuring that they are correctly located in the pad back plates Refit the pad retaining screw and torque to 33 40Nm Fig 15 Manual adjust brake To adjust the brake loc...

Page 19: ...ct the PWWI to vehicle wiring harness To adjust the brake locate a 10mm socket on the adjuster stem 17 and turn it clockwise viewed from the air actuator side Continue to adjust the brake until the pa...

Page 20: ...20 ArvinMeritor Air Disc Brake ELSA 195...

Page 21: ...21 ArvinMeritor Air Disc Brake ELSA 195 pg 3 Brake replacement 22 A Brake removal 23 B Brake fitment...

Page 22: ...cloth never try to accelerate drying time by using an airline The brake assembly may be fitted with the following wear indicator which needs to be disconnected before removing the Brake PWWI Pad Wear...

Page 23: ...vehicle manufacturers recommendations NOTE if fitting a new brake assembly the transit plug must be removed from the Actuator seal 30 before fitting the Air Actuator NOTE if replacing the original bra...

Page 24: ...24 ArvinMeritor Air Disc Brake ELSA 195...

Page 25: ...25 ArvinMeritor Air Disc Brake ELSA 195 pg 4 Bridge replacement 26 A Removing the Bridge 26 B Fitting the Bridge...

Page 26: ...heck the guide sleeve dust excluder for signs of damage and secure location Fig 21 Replace if in any doubt following procedure laid out in section 7 Guide Sleeve Dust Excluder Retainer Bushes Pay spec...

Page 27: ...27 ArvinMeritor Air Disc Brake ELSA 195 pg 5 Housing assembly replacement 28 A Removing the Housing assembly 28 B Fitting Housing assembly...

Page 28: ...signs of damage or wear paying particular attention to the pad abutment areas and guide sleeves 24 26 Fig 24 5 Housing assembly replacement Fig 24 guide sleeve pad abutment Fig 23 Fig 26 Fig 25 If an...

Page 29: ...carrier 2 Fig 28 Locate the guide sleeve dust excluders 12 onto the housing retainers 13 Fig 29 WARNING Take care not to damage the guide sleeve dust excluder when locating the Housing assembly on to...

Page 30: ...of the housing assembly Check again the free movement of the housing assembly on the guide sleeves Slide the housing assembly backwards and forwards several times to check the smooth movement of the...

Page 31: ...31 ArvinMeritor Air Disc Brake ELSA 195 pg 6 Piston Dust Excluder removal and replacement 32 A Piston Dust Excluder removal 32 B Fitting new Piston Dust Excluders...

Page 32: ...ndition of pistons shafts If excessive corrosion or wear is present the housing assembly or brake assembly should be replaced as described in section 5 Housing Replacement or section 3 Brake replaceme...

Page 33: ...luder stretched pull over and fit into the retainer groove in the Brake housing Fig 40 It is essential that the dust excluder is fitted correctly This is best achieved by rotating the dust excluder an...

Page 34: ...34 ArvinMeritor Air Disc Brake ELSA 195...

Page 35: ...Guide Sleeve Oval Bush 16 Short Guide Sleeve 39 E Fitting Guide Sleeve Oval Bush 16 Short Guide Sleeve 40 F Fitting Guide Sleeve Round Bushes 14 Long Guide Sleeve 41 G Fitting Guide Sleeve Retainer 13...

Page 36: ...at point 5 cannot move Swivel the housing to the stop in one direction arrow 1 Set the gauge to zero Move the housing in the opposite direction to the stop as before NOTE Maximum acceptable reading is...

Page 37: ...acement Transfer the Brake housing to a suitable workbench Remove the guide sleeve end caps Fig 47 Dismantling Round Oval Guide Sleeve Bush Retainer Long Short Guide Sleeves Description There are 2 ty...

Page 38: ...hown in Fig 49 D Dismantling Guide Sleeve Oval Bush 16 Short Guide Sleeve NOTE Alignment of short guide sleeve oval bush in the housing Fig 50 This is important for correct alignment of new bush when...

Page 39: ...he guide sleeve bores with a suitable brake cleaner or clear methylated spirits Examine the condition of the bores for wear corrosion or damage If there is any doubt in the suitability for further ser...

Page 40: ...the guide sleeve F Fitting Guide Sleeve Round Bushes 14 Long Guide Sleeve Place one of the new bushes onto a suitable arbor from the ArvinMeritor service tool MBT 1000 Insert into the housing bore fro...

Page 41: ...the guide sleeve bore Fig 62 WARNING Do not apply excessive force when pulling the retainer into the bore as this may result in damage to the bush or retainer H Fitting Guide Sleeve Retainer 13 Long...

Page 42: ...new Guide Sleeves 24 26 Long and Short NOTE Only use the grease supplied with the replacement components kits Under no circumstances should any other type of grease be used The long guide sleeve and s...

Page 43: ...g 69 Ensure the dust excluders are located correctly on both carrier and housing retainers Fig 70 Slide the housing backwards and forwards several times to check the smooth movement of the guide sleev...

Page 44: ...eeves Slide the housing backwards and forwards several times to check the smooth movement of the housing on the guide sleeves Slide the housing to check the location of the dust excluders Fig 74 Refit...

Page 45: ...45 ArvinMeritor Air Disc Brake ELSA 195 pg 8 Servicing and Specifications 46 Tightening Torque s 46 Grease Specification 46 Servicing 46 Rotor Specification...

Page 46: ...upplied with replacement components kits or that specified by the vehicle manufacturer Under no circumstance should any other type of grease be used Every 12 months Remove the road wheels and brake pa...

Page 47: ...47 ArvinMeritor Air Disc Brake ELSA 195 pg 9 Special Tools 48 MBT 1000 Bush fitting tool...

Page 48: ...9 Special Tools MBT 1000 Bush fitting tool The following tools can be purchased from ArvinMeritor Aftermarket...

Page 49: ...Vehicle Braking Systems Grange Road Cwmbran Published in Italy South Wales NP44 3XU U K Tel 44 0 1633 834238 Copyright 2003 Issued 02 2003 Fax 44 0 1633 834191 www arvinmeritor com ArvinMeritor Inc M...

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