BENDIX BW7514 User Manual

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All foundation brakes are designed to convert kinetic energy (energy of motion) into heat and work (to stop the vehicle).

Air disc brakes work the same way and in everyday operation — compared to drum brakes — will produce higher braking temperatures and cool off faster. Also, air disc brakes will often have differences in temperatures at wheel ends on the same axle. The actual

temperatures reached will depend on the vehicle conguration, vocation and brake usage.

This document is intended to help technicians identify instances where an individual wheel end has evidence of thermal overload, and check for potential causes.

SECTION ONE: Inspect the Vehicle

Question One:

Do any of the rotors have bright orange or red color edges? Check the box(es) on the vehicle diagram to the right for any found.

Normal Evidence of thermal overload

Question Two:

Are any of the calipers coated with a bright orange or red colored dust? Check the box(es) on the vehicle diagram to the right for any found.

Normal Evidence of thermal overload

Bendix® Air Disc Brake

Checklist for

Identifying Single Wheel

End Thermal Overload

Follow all General Safety

Guidelines (see nal page.)

c L. Steer

c L. Drive c R. Drive

c L. Add’l.

Steer Axle

Drive

Axle

Additional

Axle

c R. Steer

c R. Add’l.

Check box(es) where Thermal Overload is suspected.

Question Three:

Are any tappets and/or guide pin boots heat damaged? Check the box(es) on the vehicle diagram to the right for any found.

Typical Evidence of thermal

overload

Are

any boxes

checked?

YES

Are

both boxes

on a single axle

checked?

Only

one box has a

check mark?

Evidence of thermal

overload

YES

Trailer Front

c L. Trlr. Front

c L. Trlr. Rear

Axle

Trailer Rear

Axle

c R. Trlr. Front

c R. Trlr. Rear

STOP!

Exit this

owchart.

This is not a single wheel end

Thermal Overload event.

When both ends of an axle are

affected, a thorough brake system

diagnosis is needed, as other

factors — such as brake balance,

overloaded vehicles, or extreme

use — are more likely the source.

Go to Section Two (over)

In cases where more than one wheel end is affected — but on different axles — complete a separate checklist for each brake being examined.

SECTION TWO: Investigate Other Potential External Causes

• Follow all Safe Maintenance Practices (see nal page.)

Inspect the brake pads.

(New pads have 21 mm of brake pad, plus a 9 mm backing plate.)

there

2 mm, or less, of

YES

brake pad friction

material?*

Replace the pads (axle set recommended)

after performing all Section Two inspections.

(Not a Thermal Overload warranty condition.)

*2 mm of friction material, plus a 9 mm backing plate, for a total of 11 mm.

Inspect the caliper

Inspect the air hoses (“jounce lines”).

Push/pull

by hand to check the

caliper movement [at least 0.75 Inch

(20 mm) with the

pads removed]

Does

the brake

caliper have

restricted movement in

YES

the inboard/outboard

direction?

• Is air trapped in the hose?**

• Do the hose(s) pull or push on the caliper? (It is

important that the hoses permit the lateral motion of the caliper, the vertical motion of the suspension, and — for steering axles — the full turn of the wheels.)

• Are there any kinks, restrictions?

• Are the hoses in good condition?

Complete this

step on level ground, with the wheels chocked

and the parking

brake temporarily

released!

Service the guide pins.

Perform all Section Two inspections.

(Not a Thermal Overload warranty condition.)

**Take full safety precautions during the inspection for trapped air, to avoid the air hose whipping if air pressure is found to be trapped. Conditions that might cause trapped air include kinked lines, or when an ABS modulator is malfunctioning and not exhausting service air.

Are

any of

these conditions

found?

Go to the next page . . .

YES

Service as needed.

Perform all Section Two inspections.

(Not a Thermal Overload warranty condition.)

SECTION TWO Continued

Inspect the actuator.

On level ground, with the wheels chocked, cage the spring brake actuator (if equipped) per the manufacturer’s guidelines, remove and inspect the actuator.

• Is there visible damage?

• In the installed position, was the lowest drain plug sealed?

• Is the seal in poor condition/damaged?

• Does the push‑rod extend further than 15 mm from the mounting face?

Are

any of

YES

these conditions

found?

With the actuator removed, inspect the internal caliper surfaces through the actuator push rod opening.

Are

any of

YES

these conditions

found?

Service the actuator.

(Not a Thermal Overload warranty condition.)

• Is there visible damage, rust, water?

• With th e pads removed, use a s c rew drive r to depres s the lev e r.

Does the lever have a restricted range of motion? (The lever must touch the caliper body when fully retracted.)

Replace the caliper. Inspect the rotor.

(Not a Thermal Overload warranty condition.)

No Section Two external causes found? Replace the caliper.

Where applicable, process a thermal overload warranty claim.

Actions When Replacing a Caliper

Replacement:

Replace the caliper on the affected wheel end and all the pads at both ends of

the axle.

Inspect the rotor according to the guidelines in Service Data sheet SD‑23‑7541.

If the brake assembly is still under warranty coverage:

File a claim. Clearly state the claim is for a single axle thermally overloaded brake.

The claim must include photographs of the rotor from both ends of the affected axle.

Return the caliper from the affected wheel end, and label the caliper with the claim

number.

Return the pads from both sides of the affected axle (LH and RH set of pads).

Please clearly label the parts with the wheel position and claim number.

Please include this completed checklist, the photographs of the rotors, and a copy

of the warranty claim with the returned parts.

VIN #: _________________________________ Claim #: _______________________

Vehicle Make: ___________________________ Vehicle Model: __________________

Mileage: ____________________

Where other external causes

were found, perform service

and exit this owchart.

Bendix® ADB22X® Air Disc Brake

Replacement Part Numbers

Caliper/Carrier

Axial Bolt 12 degree

Vertical Bolt 12 degree

Left Fixed Pin Right Fixed Pin

Please note that replacement caliper/carrier bolts (available from the vehicle manufacturer) are rec ommended.

12 degree

Right Fixed Pin K0 81142

Left Fixed Pin K0 81143

Right Fixed Pin K081256

Left Fixed Pin K081257

Caliper Only

Right Fixed Pin K081258

Left Fixed Pin K081259

(Air Disc Brake Label)

Caliper Part Number: _________________

Caliper Serial Number: _________________

Bendix TechTeam Help Line: 1‑800‑AIR‑BRAKE,

(1‑800‑247‑2725), option 2‑1. Mon. ‑ Fri., 8 a.m. ‑ 6 p.m.

Reference Document:

Service Data: SD‑23‑7541 Bendix® ADB 22X™, ADB 22X‑V™ Air Disc Brakes. Go to the document library at www.bendix.com for

free downloads of Service Data Sheets and warranty policies.

GENERAL SAFETY GUIDELINES

TO AVOID PERSONAL INJURY OR DEATH:

Following the vehicle manufacturer’s recommended

brand replacement parts,

and strength as original equipment and be designed

should be replaced rather than repaired. Do not

operating and service manuals, and any related literature, in conjunction with the Guidelines above.

WARNING! PLEASE READ AND

FOLLOW THESE INSTRUCTIONS

WARNING: Not all wheels and valve stems are

compatible with Bendix Air Disc Brakes. Use only wheels and valve stems approved by the vehicle manufacturer to avoid the risk of valve stem shear and other compatibility issues.

When working on or around a vehicle, the following guidelines should be observed AT ALL TIMES:

Park the vehicle on a level surface, apply the parking brakes and always block the wheels. Always wear personal protection equipment.

Stop the engine and remove the ignition key when working under or around the vehicle. When working in the engine compartment, the engine should be shut off and the ignition key should be removed. Where circumstances require that the engine be in operation, EXTREME CAUTION should be used to prevent personal injury resulting from contact with moving, rotating, leaking, heated or electrically-charged components.

Do not attempt to install, remove, disassemble or assemble a component until you have read, and thoroughly understand, the recommended procedures. Use only the proper tools and observe all precautions pertaining to use of those tools.

If the work is being performed on the vehicle’s air brake system, or any auxiliary pressurized air systems, make certain to drain the air pressure from all reservoirs before beginning ANY work on the vehicle. If the vehicle is equipped with a Bendix Bendix

DRM™ dryer reservoir module, or a Bendix

AD-IS® air dryer system, a

AD-9si™ air dryer, be sure to drain the purge reservoir.

procedures, deactivate the electrical system in a manner that safely removes all electrical power from the vehicle

Never connect or disconnect a hose or line containing pressure; it may whip. Never remove a component or plug unless you are certain all system pressure has been depleted.

Use only genuine Bendix

components and kits. Replacement hardware, tubing,

hose,  ttings, etc. must be of equivalent size, type

speci cally for such applications and systems.

Components with stripped threads or damaged parts

WARNING: AVOID CREATING DUST.

POSSIBLE CANCER AND LUNG DISEASE HAZARD.

While Bendix Spicer Foundation Brake LLC does not offer asbestos brake linings, the long-term affects of some non-

asbestos bers have not been determined. Current OSHA

Regulations cover exposure levels to some components of non-asbestos linings, but not all. The following precautions must be used when handling these materials.

• Avoid creating dust. Compressed air or dry brushing must never be used for cleaning brake assemblies or the work area.

• Bendix recommends that workers doing brake work must take steps to minimize exposure to airborne brake lining particles. Proper procedures to reduce exposure include working in a well-ventilated area, segregation of areas where

brake work is done, use of local ltered ventilation systems or use of enclosed cells with ltered vacuums. Respirators

approved by the Mine Safety and Health Administration (MSHA) or National Institute for Occupational Safety and

Health (NIOSH) should be worn at all times during brake servicing.

• Workers must wash before eating, drinking or smoking; shower after working, and should not wear work clothes home. Work clothes should be vacuumed and laundered separately without shaking.

• OSHA Regulations regarding testing, disposal of waste and methods of reducing exposure for asbestos are set forth in 29 Code of Federal Regulations §1910.001. These Regulations provide valuable information which can be utilized to reduce exposure to airborne particles.

• Material Safety Data Sheets on this product, as required by OSHA, are available from Bendix. Call 1-800-247-2725 and speak to the Tech Team or e-mail techteam@bendix.com

attempt repairs requiring machining or welding unless

speci cally stated and approved by the vehicle and

component manufacturer. Prior to returning the vehicle to service, make certain all

components and systems are restored to their proper operating condition.

the ATC function must be disabled (ATC indicator lamp should be ON) prior to performing any vehicle maintenance where one or more wheels on a drive axle are lifted off the ground and moving.

The power MUST be temporarily disconnected from the radar sensor whenever any tests USING A DYNAMOMETER are conducted on a Bendix Advanced

You should consult the vehicle manufacturer's

™

-equipped vehicle.

Wingman®

BENDIX BW7514 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual