Bendix SB-6-SB-7 AIR DISC BRAKE User Manual
®
AIR DISC BRAKE (SB-6™ and SB-7™)
SD-23-7550
SUPPLY PORT
ACTUATOR ROD
AXIAL
OUTER BRAKE PAD
ROTOR
RETURN SPRINGS
LEVER
ACTUATING
BEAM
INNER BRAKE PAD
ECCENTRIC
BEARING
FIGURE 1 - BENDIX AIR DISC BRAKE
RADIAL
1
2
Index
Page
1 Exploded view of brake
1.1 Axial Disc Brake Components 4
1.2 Axial Disc Brake Repair Kits 5
1.2.1 Axial Disc Brake Wear Indicator Kits 5
1.3 Radial Disc Brake Components 6
1.4 Radial Disc Brake Repair Kits 7
1.4.1 Radial Disc Brake Wear Indicator Kits 7
1.5 Brake Disc Rotor
2 General information
(for “ Axial- and Radial Disc Brake”)
2.1 Service Tools 9
2.2 Diagnostic Equipment 9
2.3 Lubrication 9
2.4 Torque requirements 9
3 Description and Function
3.1 Axial Disc Brake Sectioned View 10
3.2 Description of operation 11
3.2.1 Brake actuation 11
3.2.2 Brake release 11
3.2.3 Brake adjustment (automatic) 11
3.3 Radial Disc Brake Sectioned View 12
3.4 Description of operation 13
3.4.1 Brake actuation 13
3.4.2 Brake release 13
3.4.3 Brake adjustment (automatic) 13
4 Safety instructions for service work 13
(for “ Axial- and Radial Disc Brake”)
5 Brake Testing
(for “ Axial- and Radial Disc Brake”)
5.1 Troubleshooting procedure 14
5.2 Adjuster check 15
5.3 Wear limits of Brake Pads and Rotor 16
5.3.1 Brake wear check using Guide Pin (for Calipers with standard Guide Pins) 18
5.3.2 Brake wear check using Guide Pin (for Calipers with long Guide Pins) 19
5.3.3 Wear Indicators 20
5.4 Diagnostic-Equipment - Hand held device ZB9031 21
5.5 Diagnostic-Equipment - Vehicle mounted device ZB9033 21
6 Pad replacement
(for “ Axial- and Radial Disc Brake”)
6.1 Pad removal 22
6.1.1 Tappet Boot check 22
6.1.2 Caliper floatation check 23
6.2 Pad fitting 23
7 Tappet with Boot replacement
(for “ Axial- and Radial Disc Brake”)
7.1 Tappet with Boot removal 24
7.1.1 Adjuster thread inspection 25
7.2 Tappet with Boot fitting 25
8 Caliper Suspension Sealing 27
(for “ Axial- and Radial Disc Brake”)
8
3
9 Guide Pin Bushing replacement 28
(for “Axial- and Radial Disc Brake”)
9.1 Brass Bushing replacement 28
9.2 Rubber Bushing replacement 28
10 Caliper replacement
(for “Axial- and Radial Disc Brake”)
10.1 Caliper removal 29
10.2 Caliper fitting 30
10.2.1 Caliper with Rubber Boot (10) 30
10.2.2 Caliper with Steel Cap (10a) 31
11 Carrier replacement 32
(for “Axial- and Radial Disc Brake”)
12 Actuation cylinder replacement
(for “Axial- and Radial Disc Brake”)
12.1 Brake Chamber removal 33
12.2 Brake Chamber fitting 33
12.3 Spring Brake removal 34
12.4 Spring Brake fitting 34
13 Additional Information
13.1 Service Video 35
13.2 Service Tool Kit 35
13.3 Diagnostic Equipment 35
Personal Notes
13.4 General Safety Guidelines 36
4
1 Exploded views
VF 00127/12-ÄiO1
26
44
11
39
6*
5
7
4
9
58
40
10
31
37
45
18/1
18/2
1
13
161
Assembly grease (white)
Assembly grease (coloured)
12
2
31a
10a
*
)
*
)
)
1 Caliper
2 Carrier
4 Sleeve
5 Sleeve
6 Rubber Bushing
7 Brass Bushing
9 Inner Boot
10 Outer Boot
10a Steel Cap
11 Pad Retainer
12 Pad
13 Tappet with Boot
18/1 Spring Brake
18/2 Brake Chamber
26 Spring Clip
31 Outer Boot Clip
31a O-Ring
37 Adjuster Cap
39 Caliper Bolt
40 Caliper Bolt
44 Pad Retainer Pin
45 Washer
58 Ring
161 Tappet Bushing
1.1 Axial Disc Brake Components
(for Wear Indicatators Kits see 1.2.1)
*
) possible variants by items 10a & 31a
5
1.2 Axial Disc Brake Repair Kits
CAUTION
Use only Genuine Bendix® parts
The following Repair Kits are available
1.2.1 Axial Disc Brake Wear Indicator Kits
(Typical kits are shown below)
Type 1
Type 2
Type 4
Type 5
101 Sensor
102 Sensor
104 Cable Protection Plate
112 Clip
115 Spring Washer
116 Screw
117 Wear Indicator Cable
119 Bracket
120 Bracket
Type 3
Description Contents Association of Repair Kits to the Disc
Brakes and Repair Kit’s Order no.
Carrier Guide Kit 2, 4, 5, 31, 39, 40
Carrier Guide Kit (Steel Cap) 2, 4, 5, 10a, 31a, 39, 40
Wear Indicator Kit for variants see 1.2.1
(per axle) with or without 104
Guide Pins Kit 4-7, 9, 10, 31, 39, 40, 58
Guide Pins Kit (Steel Cap) 4, 5, 6, 7, 9, 10a, 31a, 39,
40, 58
Seal Kit for Guide Pins 9, 10, 31, 37, 58
Tappet and Boot Kit (2 pcs) 13, 161
Pad Set (per axle) 12, 26, 37, 44, 45 see www.Bendix.com for more
Adjuster Cap (4 pcs) 37 information
Pad Retainer Kit (per axle) 11, 26, 44, 45
Pad Retainer Kit (per axle) wear sensor 11, 26, 44, 45, 104, 115, 116
Kit for Floating Pin 4, 6, 39
http://www.Bendix.com
Outer Guide Seal Kit (10 pcs) 10, 31
Kit for Fixed Pin 5, 7, 9, 10a, 31a, 40, 58
Kit for Steel Cap 10a, 31a
Screw Kit for Steel Cap 10a, 31a, 39, 40
Screw Kit for Outer Boot 10, 31, 39, 40
Exchange Caliper r.h.
see Type plate
only in assembled condition
Exchange Caliper l.h.
on the Caliper
6
1 Caliper
2 Carrier
4 Sleeve
5 Sleeve
6 Rubber Bushing
7 Brass Bushing
9 Inner Boot
10 Outer Boot
10a Steel Cap
11 Pad Retainer
12 Pad
13 Tappet with Boot
18/1 Spring Brake
18/2 Brake Chamber
26 Spring Clip
31 Outer Boot Clip
31a O-Ring
37 Adjuster Cap
39 Caliper Bolt
40 Caliper Bolt
44 Pad Retainer Pin
45 Washer
58 Ring
161 Tappet Bushing
1.3 Radial Disc Brake Components
(for Wear Indicator Kits see 1.4.1)
*
) possible variants by items 10a & 31a
7
1.4 Radial Disc Brake Repair Kits
CAUTION:
Use only Geniune Bendix parts
1.4.1 Radial Disc Brake Wear Indicator Kits
(Typical kits are shown below)
Type 1
Type 2
Type 4
Type 5
101 Sensor
102 Sensor
104 Cable Protection Plate
112 Clip
115 Spring Washer
116 Screw
117 Wear Indicator Cable
119 Bracket
120 Bracket
Type 3
Description Contents Association of Repair Kits to the Disc
Brakes and Repair Kit’s Order no.
Carrier Guide Kit 2, 4, 5, 31, 39, 40
Carrier Guide Kit (Steel Cap) 2, 4, 5, 10a, 31a, 39, 40
Wear Indicator Kit for variants see 1.2.1
(per axle) with or without 104
Guide Pins Kit 4-7, 9, 10, 31, 39, 40, 58
Guide Pins Kit (Steel Cap) 4, 5, 6, 7, 9, 10a, 31a, 39,
40, 58
Seal Kit for Guide Pins 9, 10, 31, 37, 58
Tappet and Boot Kit (2 pcs) 13, 161
Pad Set (per axle) 12, 26, 37, 44, 45 see www.Bendix.com for more
Adjuster Cap (4 pcs) 37 information
Pad Retainer Kit (per axle) 11, 26, 44, 45
Pad Retainer Kit (per axle) wear sensor 11, 26, 44, 45, 104, 115, 116
Kit for Rubber Sleeve 4, 6, 39
http://www.Bendix.com
Outer Guide Seal Kit (10 pcs) 10, 31
Repair Kit 5, 7, 9, 10a, 31a, 40, 58
Kit for Steel Cap 10a, 31a
Screw Kit for Steel Cap 10a, 31a, 39, 40
Screw Kit for Outer Boot 10, 31, 39, 40
Exchange Caliper r.h.
see Type plate
only in assembled condition
Exchange Caliper l.h.
on the Caliper
The following Repair Kits are available
8
1.5 Brake Rotors
(for “Axial- and Radial Disc Brake”)
When replacing the Rotors, please also refer to the instructions provided by the Vehicle Manufacturer.
They should also referred to when spec'ing Bendix Rotors.
When replacing Rotors, please adhere to the recommended bolt tightening torques.
The use of non-approved Brake Rotors will reduce levels of safety and invalidate warranty.
Brake Rotors can be ordered through any authorized Bendix parts outlet.
More information can be found on the internet at www.Bendix.com
This information booklet is also available electronically when you visit www.Bendix.com.
9
2 General Information
(for “Axial- and Radial Disc Brake”)
2.1 Service Tools
Part Number Description
ll 19252 Press-In Tool for Tappet and Boot (13)
ll 19253 Pull-In Tool for Inner Boot (9)
ll 19254 Pull-In/Out Tool for Brass Bushing (7)
II 32202 Wedged Fork for removal of Tappet and Boot (13)
II 36797 Grooving Tool for Brass Bushing (7)
Z001105 Press in Tool for Steel Cap (10a)
Item Number Torque spanner size
Ft. lbs. [Nm] in. (mm)
39 + 40 Caliper Bolts
M16x1.5 - 10.9 210±18 [285
±25
]
0.55 (14)
Actuator Mounting Nuts
M16x1.5 132+22 [180
+30
]
0.94 (24)
2.3 Lubrication
2.4 Torque requirements
2.2 Diagnostic Equipment
Part Number Description
ll 36695 ZB 9031 Hand held device for checking
Potentiometer function. ( Also Pad + Disc wear
when 13 pin chassis plug installed ).
ll 38691F ZB 9033 Chassis mounted device for measuring
Pad + Disc wear
Part Number Description Colour Application
ll 14525 Renolit HLT2 White
2)
Brass Bushing (7)
II 32793 Syntheso GL EP1 Green
2)
Rubber Bushing (6)
2)
Important Note: The correct Grease MUST be used for each Bushing!
Service tool kit ZB 9032 II 37951/004EX contains the
tools listed as well as this Service manual. The
service video is available separately
as Part No. KBP2060/1, in the UK, and elsewhere as
RA-SB0002 EN.
10
1 Caliper
2 Carrier
4 Sleeve
5 Sleeve
6 Rubber Bushing
7 Brass Bushing
9 Inner Boot
10 Outer Boot
10a Steelcap
11 Pad Retainer
12 Pad
13 Tappet with Boot
16 Threaded Tube
17 Bridge
18/1 Spring Brake
18/2 Brake Chamber
19 Lever
20 Eccentric Bearing
22 Inner Seal Cap
23 Adjuster Unit
24 Turning Device
26 Spring Clip
27 Spring
28 Spring
30 Chain
31 Outer Boot Clip
31a O-Ring
32 Chain Wheel
33 Wear Sensor
37 Adjuster Cap
39 Caliper Bolt
40 Caliper Bolt
44 Pad Retainer Pin
45 Washer
46 Rotor
161 Tappet Bush
18/1
18/2
27
28
161
12 46 12 17 19
13 22 4 39 6
31
10
23
37
30
32
33
43
24
12
16
26
45
11
44
1
161 2
20
9
57
40
VF 00127/2-Äi01
31a*)
10a*)
3 Description and function
3.1 Axial Disc Brake Sectioned View
*
) possible variants by items 10a & 31a
11
3.2 Description of operation
(Floating Caliper principle)
3.2.1 Brake actuation
During actuation, the Push Rod of the Actuator (18/1
or 18/2) moves the Lever (19). The input forces are
transferred via the Eccentric Bearing (20) to the
Bridge (17). The force is then distributed by the
Bridge (17) and the two Threaded Tubes (16) to the
Tappets (13) and finally to the inboard Pad (12).
After overcoming the running clearance between the
Pads and the Rotor, the reaction forces are transmitted to the outboard Pad (12). The clamping forces on
the Pads (12) and the Rotor (46) generate the braking
force for the wheel.
3.2.2. Brake release
After releasing the air pressure, the two Return
Springs (27/28) push the Bridge (17) and Lever (19)
back to the start position; this ensures a running
clearance between Pads and Disc is maintained.
3.2.3 Brake adjustment (automatic)
To ensure a constant running clearance between
Disc and Pads, the brake is equipped with a low
wearing, automatic adjuster mechanism.
The Adjuster (23) operates with every cycle of actuation due to the mechanical connection with Lever
(19). As the Pads and Disc wear, the running clearance increases. The Adjuster (23) and Turning
Device (24) turn the Threaded Tubes (16) by an amount necessary to compensate for this wear. The total
running clearance (sum of clearance both sides of
Disc) should be between 0.03 and 0.04 in. (0.6 and
0.9 mm.; smaller clearances may lead to overheating
problems.
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