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EB/ES
User Manual
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Bendix Commercial Vehicle Systems EB/ES User Manual

Premium wheel-end brake products
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General Information
Section 1: General Information
Foreword .......................................................................................................................................................................................................................4
Lining Material Warning .................................................................................................................................................................................................5
Model Coverage ............................................................................................................................................................................................................ 6
Parts Nomenclature .......................................................................................................................................................................................................8
Model ES-165-7 and EB-165-7 Interchangeability ..........................................................................................................................................12
EB
Section 2: Periodic Service
Brake Maintenance Preliminary Steps ........................................................................................................................................................................15
Brake Adjustment ........................................................................................................................................................................................................15
Brake Operation Check ............................................................................................................................................................................................... 17
Lubrication ...................................................................................................................................................................................................................17
Periodic Inspections ....................................................................................................................................................................................................18
Service Intervals ..........................................................................................................................................................................................................18
Section 3: Removal/Disassembly
Drum Removal .............................................................................................................................................................................................................19
Shoe Removal .............................................................................................................................................................................................................20
EB models (except EB-150-4L)/ES-165-5, 6, 7D, F, L/ES-150-8D, F/ES-150-6D ...........................................................................................21
ES-150-4L and EB-150-4L ...............................................................................................................................................................................23
ES-165-7M .......................................................................................................................................................................................................24
ES-165-7H ....................................................................................................................................................................................................... 26
Brake Adjuster Removal ..............................................................................................................................................................................................28
Camshaft Removal ......................................................................................................................................................................................................28
Air Chamber Bracket Removal ....................................................................................................................................................................................28
Spider Removal ...........................................................................................................................................................................................................29
Dustshield Removal .....................................................................................................................................................................................................29
Cleaning Brake Parts ...................................................................................................................................................................................................30
™
Roller and ES™ Cam Interchangeability ...................................................................................................................................................12
Section 4: Inspection
Drum Inspection ..........................................................................................................................................................................................................31
Shoe and Lining Inspection ......................................................................................................................................................................................... 32
Camshaft Radial Play Inspection .................................................................................................................................................................................34
Camshaft Inspection .................................................................................................................................................................................................... 34
Camshaft Bushing and Seal Inspection .......................................................................................................................................................................34
Spider Inspection ......................................................................................................................................................................................................... 35
Air Chamber Bracket Inspection .................................................................................................................................................................................. 35
Air Chamber Inspection ...............................................................................................................................................................................................36
Brake Adjuster Inspection ............................................................................................................................................................................................36
Section 5: Repair/Replacement
Camshaft Bushing/Grease Seal Replacement ............................................................................................................................................................37
Lining Replacement ..................................................................................................................................................................................................... 38
Section 6: Installation/Assembly
Spider Installation ........................................................................................................................................................................................................39
Dustshield Installation (Two Piece) ..............................................................................................................................................................................39
Dustshield Installation (One Piece) .............................................................................................................................................................................40
Air Chamber Bracket Installation .................................................................................................................................................................................41
Camshaft Installation ...................................................................................................................................................................................................42
Cam Head Washer Installation .................................................................................................................................................................................... 42
Brake Adjuster Installation ...........................................................................................................................................................................................43
Shoe and Lining Installation ........................................................................................................................................................................................44
Shoe Installation ..........................................................................................................................................................................................................46
ES-150-8D, F & 6D .......................................................................................................................................................................................... 46
All EB (except EB-150-4L) and ES-165-5, 6, 7D, F, L .....................................................................................................................................47
ES-165-7M .......................................................................................................................................................................................................49
ES-165-7H ....................................................................................................................................................................................................... 51
Specifi cation Chart ..................................................................................................................................................................................................57
General Information
List of Illustrations and Tables
List of Illustrations
Figure 1. How to Use this Manual ................................................................................................................................................................................4
Figure 2. Bendix Brake Model Identifi cation .................................................................................................................................................................5
Figure 3. Brake Part Nomenclature, General ............................................................................................................................................................... 6
Figure 4. Brake Model Part Nomenclature ................................................................................................................................................................... 7
Figure 4. Brake Model Part Nomenclature, Continued ................................................................................................................................................. 8
Figure 5. EB™ Roller and ES™ Cam Contact Pattern .................................................................................................................................................. 12
Figure 6. Parts Identifi cation .......................................................................................................................................................................................13
Figure 6. Parts Identifi cation, Continued .................................................................................................................................................................... 14
Figure 7. Vehicle Maintenance Support ......................................................................................................................................................................15
Figure 8. Measurement, At Rest .................................................................................................................................................................................15
Figure 9. Measurement, 80 psi Applied ...................................................................................................................................................................... 16
Figure 10. Measurement, Brake Applied ....................................................................................................................................................................16
Figure 11. Brake Adjuster Adjustment ........................................................................................................................................................................16
Figure 12. Roller Retainer Removal ........................................................................................................................................................................... 21
Figure 13. Upper Cam Roller and Pin Removal ......................................................................................................................................................... 21
Figure 14. ES-165-7D, L, F Shoe Removal ................................................................................................................................................................ 22
Figure 15. Shoe Removal ........................................................................................................................................................................................... 22
Figure 16. Shoe Return Spring Removal ....................................................................................................................................................................23
Figure 17. Lower Shoe Removal ................................................................................................................................................................................23
Figure 18. Retainer Loop Removal .............................................................................................................................................................................24
Figure 19. Roller and Retainer Removal .................................................................................................................................................................... 24
Figure 20. Return Spring Removal .............................................................................................................................................................................24
Figure 21. Retaining Ring and Washer Removal ....................................................................................................................................................... 25
Figure 22. Cap Screw Removal ..................................................................................................................................................................................25
Figure 23. Anchor Pin Removal ..................................................................................................................................................................................25
Figure 24. Anchor Pin Bushing Removal ....................................................................................................................................................................25
Figure 25. Retaining Ring and Washer Removal ....................................................................................................................................................... 26
Figure 26. Cap Screw Removal ..................................................................................................................................................................................26
Figure 27. Anchor Pin Removal ..................................................................................................................................................................................26
Figure 28. Shoe Removal ........................................................................................................................................................................................... 26
Figure 29. Anchor Pin Bushing Removal ....................................................................................................................................................................27
Figure 30. Groove Pin Removal ................................................................................................................................................................................. 27
Figure 31. Brake Adjuster Removal ............................................................................................................................................................................28
Figure 32. Spider Mounting Hardware Removal ........................................................................................................................................................29
Figure 33. Dustshield Mounting Hardware Removal ..................................................................................................................................................29
Figure 34. Drum Inspection ........................................................................................................................................................................................ 31
Figure 35. Cam Roller Identifi cation ...........................................................................................................................................................................31
Figure 36. Shoe and Lining Inspection .......................................................................................................................................................................32
Figure 37. Brake and Lining Blocks ............................................................................................................................................................................ 33
Figure 38. Camshaft Radial Play Inspection ..............................................................................................................................................................34
Figure 39. Camshaft Inspection ..................................................................................................................................................................................34
Figure 40. Spider Inspection .......................................................................................................................................................................................35
Figure 41. Air Chamber Bracket Inspection ................................................................................................................................................................35
Figure 42. Air Chamber Inspection ............................................................................................................................................................................. 36
Figure 43. Brake Adjuster Inspection ..........................................................................................................................................................................36
Figure 44. Air Chamber Bracket Bushing Installation ................................................................................................................................................. 37
Figure 45. Camshaft Bushing Installation ................................................................................................................................................................... 37
Figure 46. Lining Rivet (or Bolt) Tightening Sequence ............................................................................................................................................... 38
Figure 47. Installing Spider Mounting Hardware ........................................................................................................................................................39
Figure 48. Dustshield Spacing ....................................................................................................................................................................................39
Figure 49. Designed Interference Fit ..........................................................................................................................................................................39
Figure 50. Attaching Screw Location .......................................................................................................................................................................... 40
Figure 51. Air Chamber Bracket Mounting Hardware ............................................................................................................................................... 41
Figure 52. Camshaft Installation ................................................................................................................................................................................. 42
Figure 53. Cam Head Washer Installation ..................................................................................................................................................................42
Figure 54. Shim Washer and Snap Ring Installation .................................................................................................................................................. 43
Figure 55. Brake Adjuster End Play Check ................................................................................................................................................................ 43
Figure 56. Brake Adjuster Lubrication and Adjustment ............................................................................................................................................... 43
Figure 57. Shoe Web Lubrication ...............................................................................................................................................................................45
Figure 58. Shoe Retaining Spring Installation ............................................................................................................................................................ 45
General Information
List of Illustrations
Figure 59. Shoe Return Spring and Roller Installation ............................................................................................................................................... 45
Figure 60. Upper and Lower Shoe Positioning ........................................................................................................................................................... 46
Figure 61. Shoe Return Spring Installation .................................................................................................................................................................46
Figure 62. Upper and Lower Shoe Positioning ........................................................................................................................................................... 47
Figure 63. Shoe Return Spring Installation .................................................................................................................................................................47
Figure 64. Roller Retainer Installation ........................................................................................................................................................................ 48
Figure 65. Shoe Return Spring Installation .................................................................................................................................................................48
Figure 66. Retainer Installation ...................................................................................................................................................................................48
Figure 67. Anchor Pin Bushing Installation .................................................................................................................................................................49
Figure 68. Lower Shoe and Anchor Pin Installation ....................................................................................................................................................49
Figure 69. Upper Shoe and Anchor Pin Installation ....................................................................................................................................................49
Figure 70. Cap Screw Installation ...............................................................................................................................................................................49
Figure 71. Shoe Return Spring Installation .................................................................................................................................................................50
Figure 72. Roller Retainer Installation ........................................................................................................................................................................ 50
Figure 73. Roller and Retainer Installation ................................................................................................................................................................. 50
Figure 74. Retainer Installation ...................................................................................................................................................................................50
Figure 75. Groove Pin Installation .............................................................................................................................................................................. 51
Figure 76. Spider Anchor Pin Bushing Installation ..................................................................................................................................................... 51
Figure 77. Shoe Anchor Pin Bushing Installation ....................................................................................................................................................... 51
Figure 78. Lower Shoe Positioning .............................................................................................................................................................................52
Figure 79. Upper Shoe Positioning .............................................................................................................................................................................52
Figure 80. Upper Shoe Installation .............................................................................................................................................................................52
Figure 81. Lower Shoe and Anchor Pin Installation ....................................................................................................................................................52
List of Illustrations
and Tables
List of Tables
Table 1. Bendix Brake Models and Specifi cations .........................................................................................................................................................4
Table 2. Distance Range .............................................................................................................................................................................................15
Table 3. Stroke Values ................................................................................................................................................................................................. 16
Table 4. Lubrication Intervals ....................................................................................................................................................................................... 17
Table 5. Shoe Removal Procedure Index ....................................................................................................................................................................20
Table 6. Distance: Clevis Pin Hole Centerline to Air Chamber Face ...........................................................................................................................36
Table 7. Camshaft Bushing Installation Specifi cations ................................................................................................................................................37
Table 8. Shoe Installation Procedure Index .................................................................................................................................................................44
General Information
Foreword/Lining Material Warning
Purpose of this Manual
This Bendix Spicer Foundation Brake LLC publication is intended to act as a source of maintenance information to those involved in servicing Bendix brakes.
How to Use this Manual
1. Arrangement. This manual is arranged in seven sections: General Information, Periodic Service, Removal/Disassembly, Inspection, Repair/Replacement, Installation/Assembly and Specifi cations. General page layout, including section and paragraph headings, indention levels, and Figure and Table designator information, is shown in Figure 1.
2. Table of Contents. The Table of Contents lists all section headings and primary paragraph headings in this publication.
3. Illustrations and Tables. Illustrations and tables are included to help make the text of this publication clear. See the List of Illustrations and List of Tables following the Table of Contents.
4. Specifi cation Chart. A tabulation of all measurement specifi cations is provided at the back of this publication.
General Information
!
DANGER
AVOID CREATING DUST
POSSIBLE CANCER AND LUNG DISEASE HAZARD
Material Warning
Foreword/Lining
While Bendix Spicer Foundation Brake LLC does not offer asbestos brake linings, the long-term effects of some non-asbestos fi 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.
1. AVOID CREATING DUST. Compressed air or dry brushing must never be used for cleaning brake assemblies or the work area.
2. BENDIX SPICER FOUNDATION BRAKE LLC 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 fi ltered ventilation systems or use of enclosed cells with fi 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.
3. 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.
4. Material safety data sheets on this product, as required by OSHA, are available from Bendix Spicer Foundation Brake LLC.
General Information
Model Coverage
The service procedures and specifi cations in this publication cover the Bendix brake models listed in Table 1. The basic instructions cover all 15", 16.5", and 18" brake types and sizes, unless specifi ed otherwise. A breakdown of Bendix brake model identifi cation is provided in Figure 2.
Brake Model
Size
mmin.
Shoe Spider Anchor
Confi guration
Applications
EB-150-4L 15.0 x 4 381 x 102 Fabricated Fabricated SAP Steer Axles
EB-165-5D 16.5 x 5 419 x 127 Fabricated Cast SAP Steer or Drive Axles
EB-165-5L 16.5 x 5 419 x 127 Fabricated Fabricated SAP Steer or Drive Axles EB-165-6D 16.5 x 6 419 x 152 Fabricated Cast SAP Steer or Drive Axles EB-165-6L 16.5 x 6 419 x 152 Fabricated Fabricated SAP Steer or Drive Axles EB-165-7D 16.5 x 7 419 x 178 Fabricated Cast SAP Steer or Drive Axles EB-165-7F 16.5 x 7 419 x 178 Fabricated Forged SAP Trailer Axles EB-165-7L 16.5 x 7 419 x 178 Fabricated Fabricated SAP Steer or Drive Axles EB-165-8D 16.5 x 8.63 419 x 219 Fabricated Cast SAP Drive Axles EB-165-8L 16.5 x 8.63 419 x 219 Fabricated Fabricated SAP Drive Axles EB-180-7R 18.0 x 7 457 x 178 Cast Heavy Cast SAP On/Off Hwy. Drive Axles ES-150-4L 15.0 x 4 381 x 102 Fabricated Fabricated SAP Steer Axles ES-150-4D 15.0 x 4 381 x 102 Fabricated Cast SAP Steer Axles ES-150-6D 15.0 x 6 381 x 152 Fabricated Cast SAP Steer or Drive Axles ES-150-8D 15.0 x 8.63 381 x 219 Fabricated Cast SAP Drive Axles ES-150-8F 15.0 x 8.63 381 x 219 Fabricated Forged SAP Trailer Axles ES-165-5D 16.5 x 5 419 x 127 Fabricated Cast SAP Steer or Drive Axles ES-165-5L 16.5 x 5 419 x 127 Fabricated Fabricated SAP Steer or Drive Axles ES-165-6D 16.5 x 6 419 x 152 Fabricated Cast SAP Steer or Drive Axles ES-165-6L 16.5 x 6 419 x 152 Fabricated Fabricated SAP Steer or Drive Axles 165 XL Cast 16.5 x 6 419 x 152 Cast Cast DAP Steer Axle Transit ES-165-7D 16.5 x 7 419 x 178 Fabricated Cast SAP Steer or Drive Axles ES-165-7F 16.5 x 7 419 x 178 Fabricated Forged SAP Trailer Axles ES-165-7H 16.5 x 7 419 x 178 Cast Heavy Cast DAP On/Off Hwy. Drive Axles ES-165-7L 16.5 x 7 419 x 178 Fabricated Fabricated SAP Steer or Drive Axles ES-165-7M 16.5 x 7 419 x 178 Fabricated Heavy Cast DAP On/Off Hwy. Drive Axles ES-165-8L 16.5 x 8.63 419 x 219 Fabricated Fabricated SAP Drive Axles ES-165-8D 16.5 x 8.63 419 x 219 Fabricated Cast SAP Drive Axles ES-165-8F 16.5 x 8.63 419 x 219 Fabricated Forged SAP Trailer Axles ES-165-8L 16.5 x 8.63 419 x 219 Fabricated Forged SAP Trailer Axles 165 XL Cast 16.5 x 10 419 x 254 Cast Cast DAP Drive Transit
Table 1. Bendix Brake Models and Specifi cations
Manufacturer
Bendix Spicer Foundation Brake
Service
B - Standard Service S - Extended Service
Drum Diameter
122 – 12.25" (311 mm) 150 – 15" (381 mm) 165 – 16.5" (419 mm) 180 – 18" (457 mm)
Shoe Size
04 - 4" – (102 mm) 05 - 5" – (127 mm) 06 - 6" – (152 mm) 07 - 7" – (178 mm) 07 - 7.5” – (191 mm) 08 - 8.63" – (219 mm) 10 - 10" – (254 mm)
General Information
E S - 1 5 0 - 0 8 D
Configurations
A - Fab Shoe Weld On Spider Self Contained Cam Bracket SAP B - Fab Shoe Weld On Spider Self Contained Cam Bracket DAP D - Fabricated Shoe/Cast Spider SAP F - Fabricated Shoe Weld On Spider SAP (Non Self Contained) H - Cast Shoe/Heavy Cast Spider DAP L - Fabricated Shoe/Fabricated Spider SAP M - Fabricated Shoe/Cast Spider (DAP Closed A/P) P - Fabricated Shoe/Weld On Spider (DAP Closed A/P) R - Cast Shoe/Heavy Cast Spider SAP S - Reinforced Fabricated Shoe/Heavy Cast Spider (SAP) T - Fabricated Shoe/Weld On Spider DAP (Non Self Contained)
Configuration
Example: L = Fabricated Shoe
Fabricated Spider Single Anchor Pin (SAP)
Shoe Size
Example: (219mm)
8 = 8.63"
Model Coverage
Figure 2. Bendix Brake Model Identifi cation
SAP - Single Anchor Pin
DAP - Double Anchor Pin
Parts Nomenclature
General Information
General parts nomenclature for Bendix brake models are identifi ed in Figure 3. Variations in shoe hold-down springs and guides are
ES-150-4L Brake
Camshaft
Retainer
Snap Ring
Brake Adjuster
Inner Washer
Camshaft
Shim
Camshaft
Bushing
Washer
Brake
Adjuster
Grease
Seal
Dustshield Screw
Shoe Assembly
*Shoe Hold-Down Spring and Guide Variation
Stabilizer Nut
Bracket
Assembly
Camshaft
Bushing
Bolt
Cam Roller
Shoe Retainer
Spring
Color - Blue
also identifi ed. Specifi c parts nomenclature for specifi c Bendix brake models are provided in Figure 4.
Shoe Hold-Down Spring and Guide Variation
New Style
Shoe Spacer Not Required
Shoe Assembly
Camshaft
Grease
Seal
Barrel Nut
Dustshield
Assembly*
Spider
Old Style
Shoe Hold-Down Spring
Shoe Return
Spring
Color - Blue
Nut
Washer
Shoe*
Hold-Down
Spring
Shoe Spacer
Cam Roller
Bolt*
Standard Nut
(Must be Removed for New Style Hold-Down)
Shoe Guide and Shoe
Hold-Down Spring
ES-150-4D Brake
Shoe
Return Spring
Color - Red
Cast
Spider
Cam Head
Washer
Camshaft
Figure 3. Brake Part Nomenclature, General
Shoe Return
Color - Grey
Shoe Assembly
Retainer
Spring
Shoe Assembly
Inspection
Hole Plug
Roller
Bracket
Stud
Roller
Lock Washer
Dustshield
Retainer
Bracket
Assembly
Nut
Camshaft
Bushing
Grease
Seal
Grease
Camshaft
Bushing
Grease
Fitting
Seal
Camshaft
Shim
Washer
Brake Adjuster
Brake Adjuster
Inner Washer
Camshaft
Retainer
Snap Ring
General Information
Parts Nomenclature
ES-150-6D Steer Brake
Shoe
Retainer Springs
Color - Orange
(Stamped Steel)
Camshaft
Shoe Assembly
Retainer
Shoe Return
Spring
Color - Red
Spider
Cam Head Washer
Roller
Shoe Return
Camshaft
Bushing
Spring
Roller
Grease
Seal
Retainer
Bracket
Assembly
Brake
Adjuster
Camshaft
Bushing
Camshaft
Shim
Washer
Brake Adjuster
Inner Washer
Grease
Seal
Grease Fitting
Camshaft
Retainer
Snap Ring
ES-150-8D and ES-150-8F Drive & Trailer Brake
Shoe
Retainer Springs
Color - Orange
Spider
(Stamped Steel)
Cam Head Washer
Camshaft
Shoe Assembly
Shoe Assembly
Roller
Retainer
Shoe Return
Spring
Color - White
Retainer
Roller
Bracket
Assembly
Camshaft
Bushing
Grease
Seal
Camshaft
Bushing
Grease
Grease Fitting
Brake Adjuster
Seal
Camshaft
Shim
Washer
Brake Adjuster
Inner Washer
Forged Spider
Camshaft
Retainer
Snap Ring
Figure 4. Brake Model Part Nomenclature
Shoe Assembly
Parts Nomenclature
General Information
Brake Model EB-165-5D EB-165-5L EB-165-6D EB-165-6F EB-165-7D EB-165-7F EB-165-7L
Cam Roller and Pin for
EB-165 and EB-180 Brakes
Two-Piece Roller and Pin
Shoe Assembly
Shoe Retainer
Springs
Color - Orange
(Stamped Steel)
Camshaft
Spider
Shoe Return Spring
Dustshield
Grease Seal
Bracket Stud
Cam Roller
and pin
Shoe Assembly
Inspection Hole Plug
Dustshield Screw
Grease Fitting
Camshaft Bushing
Brake Adjuster
Camshaft
Shim Washers
Nut
Lockwasher
Note: Cast spiders are tapped
and require 4 bolts and lock-
chamber bracket assembly.
Camshaft Retainer Snap Ring
Brake Adjuster Inner Washer
Grease Seal
Camshaft Bushing
Bracket Assembly
Cast Spider
washers to attach air
Brake Model ES-165-5D ES-165-5L ES-165-6D ES-165-6F ES-165-7D ES-165-7F ES-165-7L
Shoe
Retainer Springs
Color - Orange
Cam Head Washer
Cast Spider
With Horse
Shoe
Return Spring
Color - Red
Spider
(Stamped Steel)
Camshaft
Collar
Cam Head
Washer
Shoe Return
Color - Grey
Shoe Assembly
Retainer
Spring
Shoe Assembly
Inspection
Hole Plug
Roller
Bracket
Stud
Roller
Lock Washer
Dustshield
Retainer
Bracket
Assembly
Nut
Camshaft
Bushing
Grease
Seal
Forged
Spider
Grease
Camshaft
Bushing
Grease
Fitting
Seal
Camshaft
Shim
Wash er
Brake Adjuster
Brake Adjuster
Inner Washer
Cast
Spider
Camshaft
Retainer
Snap Ring
Figure 4. Brake Model Part Nomenclature, Continued
10
y
General Information
ES-165-7M Heavy-Duty Brake
ES-165-7H Severe Duty Brake
Cast Shoe Return Spring
Color - Orange
Fabricated Shoe Assembly
Anchor Pin
Washer
Snap Ring
Anchor Pin Bushings
Camshaft
Snap Ring
Nut
Washer
Snap Ring
Washer
Retainer
Roller
Cast
Spider
Washer
Washer
Anchor Pin
Fabricated Shoe Assembly
Inspection
Hole Plug
Snap Ring
Dustshield
Shoe Return
Spring
Color - llow
Retainer
Roller
Brake Adjuster
Bracket
Assembly
Bracket Lock Washer
Camshaft Bushing
Grease Seal
Camshaft
Retainer
Snap Ring
Camshaft
Shim Washer
Brake Adjuster Inner Washer
Grease Seal
Camshaft Bushing
Grease Fitting
Bolt
Cast Spider H version
Roller Dowel Pin
Camshaft Roller
and Pin
Bushing
Anchor Pin
Washer
Snap Ring
NO s are tapped
and require four bolts and lockwashers
to attach air chamber bracket assembl
Bushing
.
ES-180-7R Brake
Shoe
Retainer Springs
Color - Orange
Spider
(Stamped Steel)
Shoe Assembly
Camshaft Roller and pin
Camshaft
Camshaft Roller
and Pin
Inspection
Hole Plug
Assembly
Lock Washer
Shoe Return
Spring
Color - Green
Bracket
Bolt
Grease
Seal
Dustshield
Camshaft
Bushing
Camshaft
Bushing
Grease
Seal
Grease
Fitting
Camshaft
Washer
Brake Adjuster
Inner Washer
Bracket Bolt
Lock Washer
Shim
Camshaft
Retainer
Snap Ring
Brake Adjuster
Shoe Assembly
11
Parts Nomenclature
Model ES-165 and EB-165 Interchangeability
General Information
Brake parts for the Extended Service Brake (Model ES-165) are unique and must not be intermixed with Standard Brake parts (Model EB-165) unless otherwise instructed. These parts consist of the camshaft, camshaft washer, return spring, cam roller and shoe/lining assembly. Any attempt to operate the brake with other than its intended parts may result in unsatisfactory performance. “On-Road” Repair: If a vehicle should need “On-Road” repair and
™
ES
Brake hardware is not available, it is possible to retrofi t the brake with Standard Brake parts in order to return the vehicle to service. These parts consist of the Standard shoe/lining assembly, cam roller, pin and return spring. The retaining springs and camshaft with cam washer will work in this situation and do not need to be replaced.
EB™ Roller and ES™ Cam Interchangeability
The EB™ Roller and the ES™ Cam are compatible and can be used together. Figure 5 illustrates the proper fi t of an EB
™
ES
Cam. As shown, the contact pattern is at two points and the
two parts will function satisfactorily with this fi t.
NOTE: The ES
™
Roller and EB™ Cam are not compatible and should
not be used together.
™
Roller to an
EB™ Roller
Figure 5. EB
™
Roller and ES™ Cam Contact Pattern
ES
™
Cam
12
General Information
Bendix brake model parts identifi cation for shoes, return springs, spiders and camshafts are identifi ed in Figure 6.
Parts Nomenclature
ES-150-D,F
ES/EB 150-4L
Old
ES-165-D,L,F
New
Shoe without Spring Attaching Lugs
High and Low mount shoes
Figure 6. Parts Identifi cation
Shoe Return Spring
13
Brake Spiders
General Information
Camshafts
Stamped Spider ES/EB-150-4L
Air Chamber Brake Flange shape for ES/EB-150-4L
Figure 6. Parts Identifi cation, Continued
14
Periodic Service
Parts Identifi cation
Maintenance and Adjustment
Due to the importance of a well-maintained brake system, the inspections and maintenance listed below must be accomplished by commercial vehicle operators at the intervals suggested. Since driver technique and vehicle use affect the rate of brake component wear, it may be appropriate to increase the frequency of the following inspections to fi t individual needs based upon past experience.
Brake Maintenance Preliminary Steps
Prior to performing any maintenance requiring removal of the tire and wheel, the following preliminary steps must be taken to ensure your safety. Refer to Figure 7.
Brake Adjustment - Manual Brake Adjuster
NOTE: An assistant is required to make a brake adjustment.
WARNING: Block all wheels before beginning this adjustment
!
procedure.
To determine whether Bendix Brakes require adjustment, applied stroke is measured and compared to the maximum value for the air chamber size in use on the vehicle.
1. Perform “Brake Maintenance Preliminary Steps” described earlier.
2. With air chamber pushrod fully retracted, measure distance from
face of air chamber to centerline of clevis pin hole. Refer to Figure 8. If the measurement is not within ranges shown in Table 2, reposition clevis. Remeasure the distance and repeat until within range. Record exact measured distance as dimension “A”.
Distance: Clevis Pin Hole Centerline to Air Chamber Face
All brakes (except 2-5/8" ± 1/16" Mack and Trailer Axle) (66.7 ± 1.59 mm)
Figure 7. Vehicle Maintenance Support
1. Set parking brake and block wheels to prevent vehicle
movement.
2. Raise drive axle with a jack and support on suitable stands.
WARNING: Never work under a vehicle supported by a jack.
!
3. Cage spring-type brake chamber following vehicle manufacturer’s instructions.
4-3/8" ± 1/16"
Mack brakes
(111.1 ± 1.59 mm) Trailer Axle 6-1/2" ± 1/8"
brakes (165.1 ± 3.175 mm)
Table 2. Distance Range
Figure 8. Measurement, At Rest
15
Maintenance and Adjustment
Periodic Service
3. Apply and hold an 80 psi brake application, and again measure
from face of air chamber to clevis pin centerline. Refer to Figure 9. Record distance as dimension “B”.
Figure 9. Measurement, 80 psi Applied
4. Subtract dimension “A” from “B”. The difference is applied stroke.
Compare applied stroke to maximum value in Table 3. If applied stroke equals or exceeds maximum applied stroke shown, adjust brakes. If less than the maximum, no adjustment is required and you may perform Brake Operation Check.
80 - 90 PSI
Air Chamber Maximum Desired Size Applied Free
Stroke Stroke
Type 30" Long Stroke 2.5" 3/8" to 5/8" Type 30" 2" (Without Drag) Type 24" 1-3/4" Type 24" (w/ 2-1/2" 2" extended stroke) Type 24 (w/3" extended stroke) 2.5" Type 20" and 16" 1-3/4" 3/8" to 1/2" Type 12" 1-3/8" 3/8" to 1/2"
Table 3. Stroke Values NOTE: If adjustment is necessary, Bendix Brakes are adjusted to
achieve proper free stroke. The difference between free stroke and applied stroke is merely the method used to move the brake adjuster from rest. Applied stroke uses an 80 psi brake application; free stroke is measured using a lever to move the brake adjuster until the brake shoes contact the drum. If applied stroke exceeded the maximum and adjustment is necessary, adjust the brakes as described in steps 5 through 8 below.
16
5. Take “A” dimension exactly as before. Take “B” measurement using a lever to move brake adjuster as shown until the shoes contact drum. Refer to Figure 10. The result of “B” - “A” is brake free stroke. Adjust free stroke to within range specifi ed in Table 3.
Figure 10. Measurement, Brake Applied
6. To adjust free stroke, depress locking sleeve on brake adjuster
adjustment nut and turn in direction required. Recheck free stroke to verify it is within range. Make sure sleeve is “locked” when adjustment is completed.
7. Verify that brakes are not dragging by spinning wheels by hand or tapping drum lightly with a hammer and listening for a sharp ringing sound.
8. Perform Brake Operation Check, to verify proper operation of brakes before releasing vehicle for service.
Brake Adjustment - Automatic Slack Adjuster
NOTE: A properly working Automatic Slack Adjuster does not require manual adjustment while in service. The manual adjuster hex is intended for use during adjuster installation and brake overhaul. WARNING: Automatic slack adjusters must never be repeatedly adjusted to correct excessive in service pushrod stroke, because this condition indicates that a problem exists with the automatic adjuster, with the installation of the adjuster or with related foundation brake components which manual adjustment will not correct.
1. Brake adjustment for automatic slack adjusters is the same as for manual brake adjusters.
2. Refer to the Automatic Slack Adjuster Manufacturer's Instructions for proper installation.
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