Bendix Commercial Vehicle Systems EVERSURE SPRING BRAKE User Manual
®
Bendix® EverSure® Spring Brake with No Touch™ Technology
SD-02-4525
NON-PRESSURE
HOUSING
SERVICE RETURN
SPRING
SERVICE
PUSH-ROD
YOKE
(Piggyback spring brake components
are not serviceable, and are shown
here for informational purposes only.)
RELEASE
TOOL
SERVICE
CHAMBER
DUST CAP INSTALLED
DUST CAP
REMOVED
WARNING
SPRING BRAKE CHAMBERS CONTAIN A LOADED
COMPRESSION SPRING. PROPERTY DAMAGE,
SERIOUS INJURY OR DEATH MAY OCCUR IF THESE
INSTRUCTIONS ARE NOT FOLLOWED COMPLETELY.
NEVER attempt to remove a spring chamber crimped
band.
Follow all industry safe maintenance practices, including
those listed on page two of these instructions.
1.0 DESCRIPTION
The Bendix® EverSure® spring brake is made up of a
conventional brake chamber and an emergency, or parking,
spring mechanism for use on vehicles equipped with cam
foundation brakes. The spring brake actuator provides:
(1) service braking, (2) parking and (3) emergency
braking. The actuator can be piped with various system
arrangements to be automatically, or manually, applied
under emergency braking conditions.
The spring brake is a diaphragm-type actuator which
converts the energy of air pressure into mechanical force.
CLAMP
BAND
T-BOLT
STORAGE
POCKET
FIGURE 1 - BENDIX® EVERSURE® SPRING BRAKE
SERVICE
DIAPHRAGM
NON-SERVICEABLE
SECTION SEALED WITH A
CRIMPED BAND
NON-SERVICEABLE
PARKING DIAPHRAGM
RELEASE
TOOL T-BOLT
NON-SERVICEABLE
NO TOUCH™ POWER
SPRING
PARKING/ EMERGENCY
BRAKE HOUSING
Index
Section Page
1.0 Description . . . . . . . . . . . . . . . . .1, 3
2.0 Safe Maintenance Practices . . . . . . . . . 2
3.0 Preventive Maintenance . . . . . . . . . . . 3
4.0 Operation and Leakage Tests. . . . . . . . . 4
5.0 Operation: General . . . . . . . . . . . . . . 4
6.0 Mechanical Release (Caging) of the
Bendix® EverSure® Spring Brake . . . . . . . 4
7.0 Clocking (Rotating) the Bendix Service
Replacement Spring Brake Chamber. . . . . 5
8.0 Mechanical Release (Caging) and Removal
of the Piggyback Spring Brake Chamber to
be Replaced . . . . . . . . . . . . . . . . . 6
9.0 Installing the Bendix® EverSure® Piggyback
Spring Brake Chamber . . . . . . . . . . . . 6
10.0 Un-Caging the Bendix® EverSure® Spring
Brake Chamber (Apply Park Brake) . . . . . 7
11.0 Removal and Installation of the Combination
Spring Brake . . . . . . . . . . . . . . . . . 7
12.0 Replacing the Service Diaphragm . . . . . . 8
1
2.0 SAFE MAINTENANCE PRACTICES
WARNING! PLEASE READ AND
FOLLOW THESE INSTRUCTIONS TO
AVOID PERSONAL INJURY OR DEATH:
When working on or around a vehicle, the following
general precautions should be observed at all times:
1. Park the vehicle on a level surface, apply the
parking brakes, and always block the wheels.
Always wear safety glasses. Where specifi cally
directed, the parking brakes may have to be
released, and/or spring brakes caged, and this
will require that the vehicle be prevented from
moving by other means for the duration of these
tests/procedures.
2. Stop the engine and remove 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 eng ine be in ope rati on, EXTREME
CAUTION should be used to prevent personal
injury resulting from contact wit h moving,
rotating, leaking, heated or electrically charged
components.
3. 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.
4. 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® AD-IS® air dryer system or a dryer
reservoir module, be sure to drain the purge
reservoir.
5. F o l lo wi n g t h e ve hi cl e m a n u fa ct u r e r ’ s
recommended procedures, deactivate th e
electrical system in a manner that safely removes
all electrical power from the vehicle.
6. Never exceed manufacturer’s recommended
pressures.
7. 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.
8. Use only genuine Bendix® brand replacement
parts, components and kits. R epla cement
hardware, tubing, hose, fi ttings, etc. must be
of equivalent size, type and strength as original
equipment and be designed specifi cally for such
applications and systems.
9. Components with stripped threads or damaged
parts should be replaced rather than repaired.
Do not attempt repairs requiring machining or
welding unless specifi cally 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 Automatic Traction Control
(ATC), 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.
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.
WARNING: AVOID CREATING DUST.
POSSIBLE CANCER AND LUNG DISEASE
HAZARD.
While Bendix Spicer Foundation Brake LLC (BSFB)
does not offer asbestos brake linings, the long-term
affects of some non-asbestos fi bers have not been
determined. Current Occupational Safety & Health
Administration (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 filtered 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.
• 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 us at techteam@bendix.com
2
The diaphragm is held between the adapter base and nonpressure plate by a two piece clamp ring.
Different size brake chambers are identifi ed by numbers,
which specify the effective area of a diaphragm. For
example, a Type 30/30 Spring Brake has 30 square inches
of effective area on each diaphragm.
The standard diaphragm material is a compound of natural
rubber with a fabric interior of nylon.
WARNING
• S pr i ng b r ake c ham b er s con t ai n a l oad ed
compression spring. Property damage, serious
injury or death may occur if instructions are not
followed completely.
• When performing any maintenance on the spring
brakes, make sure to block the wheels to prevent
vehicle rollaway.
• DO NOT SERVICE A SPRING BRAKE CHAMBER
IF IT HAS STRUCTURAL DAMAGE OF ANY KIND.
Replace the complete assembly. Dismount a
damaged spring brake by fi rst cutting the service
push rod with an acetylene torch to relieve any
force it might have.
• Do not strike any part of a spring brake chamber
for any reason. This may cause structural damage.
• Be careful not to drop a spring brake chamber at
any time. If dropped, inspect for signs of structural
damage. Replace complete assembly if damaged.
• Spring brake chambers cannot have the emergency
diaphragm replaced. Replace the whole spring
brake chamber.
• Always work from the side of the spring brake
chamber. Never work from the front or back.
3.0 PREVENTIVE MAINTENANCE
Important: Review the warranty policy before performing
any intrusive maintenance procedures. An extended
warranty may be voided if intrusive maintenance is
performed during this period.
3.1.2 Check push-rod-to-slack-adjuster alignment from
release to full stroke position to be sure the push rod
moves out and returns properly without binding at the nonpressure plate hole or with other structures. Also, check
the angle formed by the slack adjuster arm and push rod.
It should be greater than 90 degrees when the chamber
is in the released position and approach 90 degrees at
maximum readjustment stroke.
3.1.3 Check tightness of mounting nuts. Torque on the
non-pressure plate mounting nuts should be 133-155 ft/
lbs.
3.1.4 Check cotter pins to ensure they are in place.
3.1.5 Check all hoses and lines. They should be secure
and in good condition with suffi cient length to allow for axle
movement.
3.2. EVERY 3,600 OPERATING HOURS,
100,000 MILES OR ONE (1) YEAR:
3.2.1 Carefully inspect all metal parts for cracks, distortion
or damage.
3.2.2 Perform the Leakage Test (4.2). As necessary,
install a new diaphragm or any other parts if they are worn
or deteriorated. All diaphragm sealing surfaces should be
smooth and clean. Perform the steps outlined in Section 12
(Replacing the Service Diaphragm). When the service
diaphragm, service return spring, or both, are replaced,
they should also be replaced in the corresponding chamber
on the same axle.
PARKING/
EMERGENCY
PORT
SERVICE
PORT
RELEASE
TOOL
SIDE
POCKET
Because no two vehicles operate under identical conditions,
maintenance intervals will vary. Experience is a valuable
guide in determining the best maintenance interval for a
vehicle.
3.1 EVERY 300 OPERATING HOURS,
8,000 MILES, OR ONE (1) MONTH:
3.1.1 See Figure 2. Check push rod travel and adjust
travel at the slack adjuster if needed (only where manual
slack adjusters are used). Push rod travel should be as
short as possible without the brakes dragging (consult
the manufacturer’s installation instructions for the slack
adjuster. Excessive push rod travel reduces braking
effi ciency, shortens diaphragm life, gives slow braking
response, and wastes air.
MOUNTING NUT
SERVICE
PUSH ROD
COTTER PIN
FIGURE 2 - SPRING BRAKE EXTERNAL VIEW
YOKE
3
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