ZE ZE ZE. Simplex expanding wedge brake Assembly and Maintenance Instructions

Save this PDF as:
 WORD  PNG  TXT  JPG

Size: px
Start display at page:

Download "ZE ZE ZE. Simplex expanding wedge brake Assembly and Maintenance Instructions"

Transcription

1 Simplex expanding wedge brake Assembly and Maintenance Instructions

2

3 Simplex expanding wedge brake Assembly and Maintenance Instructions Edition 1 This publication is not subject to any update service. You will find the latest version in INFORM The right of amendment is reserved. Version 1/ (en)

4 Table of Contents 1 Important instructions and safety instructions General Information Safety instructions Repair and maintenance instructions 6 2 Description and function Simplex expanding wedge brake Simplex expanding device 9 3 Checking the brake pad thickness 10 4 Removing and inspecting the brake Releasing the automatic adjuster Removing and inspecting the brake drum Removing and inspecting the brake shoes Checking other brake parts 13 5 Replacing the expander Removing the expander Checking the expander Dismantling the expander assembly Reassembling the expander assembly Installing the expander assembly 19 6 Installing the brakes Installing the brake shoes Initial brake setting Installing the brake drum Functionality testing and breaking in 23 7 Replacing the brake cylinder Removing the brake cylinder Installing the brake cylinder 24 8 Procurement and disposal of spare parts 26 4

5 Important instructions and safety instructions 1 1 Important instructions and safety instructions 1.1 General Information 1.2 Safety instructions This documentation describes the maintenance and repairs for Simplex expanding wedge brakes of types, and with the required steps and work-procedures for replacing individual parts, utilising the available repair sets. Wheel brake product numbers Brake type Part number This publication is directed at trained service technicians employed at workshops for commercial vehicles. Before you begin with maintenance, repair, replacing a part etc., carefully read all the safety instructions as well as the repair and maintenance instructions included this publication. These instructions must be observed to avoid personal injury or material loss. WABCO only guarantees the safety, reliability and performance of its products and systems if all instructions, notes and safety instructions are observed. Before you perform any work on the vehicle (repair, maintenance, replacing parts, etc.), you must ensure the following: Only trained and qualified personnel may perform repairs on the vehicle. Always follow specifications and instructions of vehicle manufacturer. Always comply with the company and national accident prevention guidelines and Health and Safety regulations. Wear any necessary protective clothing. The workplace has to be dry, as well as sufficiently lit and ventilated. WARNING WARNING WARNING CAUTION CAUTION Reduced braking effect or brake failure Regularly check the wear limits of brake linings and brake drums. Replace worn, scorched, glazed, or oily brake linings immediately. Immediately replace worn or damaged brake drums. Always replace all brake linings and brake drums axle by axle. Rolling vehicle Position the vehicle on an even surface and secure it against rolling away with brake wedges. Only use approved devices to jack up and secure the vehicle. Make sure that the gearbox is in neutral and the hand brake has been pulled. Rolling vehicle Make sure that the release screw of the spring brake cylinder is threaded completely in after completing the maintenance and installation work and check the functionality of the parking brake. Risk of injury due to hazardous dusts Do not clean any soiled areas of the brake with compressed air or other high-pressure devices. Risk of injury due to heavy load A second technician must assist during removal and installation of the brake. 5

6 1 Important instructions and safety instructions CAUTION CAUTION CAUTION Risk of injury due to brake action while working on the brake Attach a clearly marked note on the steering wheel saying that work is being performed on the vehicle and that the brake must not be touched. Danger of injury by the release springs rebounding Use suitable tools or brake spring pliers for installing the release springs. Risk of injury due to falling brake parts Use suitable equipment, such as a vice, to clamp the brake when performing repairs on the brake outside the vehicle. Only use original WABCO parts and brake linings approved by the vehicle manufacturer. Overdimensioned pads are not approved and are not to be used. Renolit LX PEP 2 or an equivalent grease is recommended as a lubricant. Do not use a silicone grease or sprays containing silicone. Make sure that the brake linings, brake hoses, and the friction surfaces of the drum brakes do not contact any grease or oil as this may cause the brake to fail. Perform the repair work using only the recommended tools. Do not use motor-driven screw tools. Only tighten bolts and nuts with the specified wrenches and to the specified torque. Perform a concluding roller test stand test having completed the repairs. Do not perform full braking, with the exception of emergency braking, during the first 500 kilometers after new brake linings have been fitted. Also avoid continuous braking over longer periods. Ensure that the driver of the vehicle is informed. 1.3 Repair and maintenance instructions For good handling and braking characteristics it is essential that the brake and the brake drum be in flawless technical condition. Check the brake at the time intervals specified by the vehicle manufacturer and replace the worn parts. Check the brakes every two years and replace the release springs and all rubber parts. Before opening the brake, release the service brakes and parking brakes and the bus-stop brake on buses. Spring brake cylinders are under tension from the spring. They are loosened by unscrewing the release screw on the spring brake cylinder of the parking brake before performing any maintenance and installation work If cast parts have been heavily damaged or are severely worn, (cracks for example), replace the entire brake following the instructions. Do not apply the brake when brake linings have been removed. Do not use compressed air or other high-pressure devices when cleaning the brake or the vehicle. This may result in the risk of personal injury or hazardous dusts. Rubber parts of the brake could also be damaged. 6

7 Description and function 2 2 Description and function 2.1 Simplex expanding wedge brake Description The Simplex brake consists of a brake calliper (1) in cast with an expander (2) bolted on and the cover plate (3) and the brake shoes (4, 5), which are connected with the brake calliper (1) and the expander (2) by means of the release springs (6). fig. 2-1: View of a drum brake 1 Brake anchor plate 2 Expander 3 Cover plate 4, 5 Brake shoe 6 Release springs 7

8 2 Description and function The braking effect is almost the same when traveling forward or backward. The cover plate protects the brake from the infiltration of splashed water and contamination. The brake lining wear is checked through the opening in the cover plate (3) after removing the sealing plug (8a). Function The actuation of the brake moves the expanding wedge (9) through the brake cylinder (compressed air diaphragm or spring brake cylinder or hydraulic cylinder) in the direction of the arrow (a). The rollers (12) located between the expanding wedge (9) and the piston (10) cause the piston (10) to move in the direction of the arrow (b). The pistons (10) then cause the brake shoes (4, 5) to press on the brake drum. As a result of the varying pad wear of the two brake shoes (4, 5), the expanding wedge (9) will be on a slant. After the braking procedure is ended, the brake shoes (4, 5) are pulled back into the original position by the release springs (6). The expanding wedge is moved back into its original position by the compression spring (11). Based on the Simplex principle, the brake shoe (4) has greater pad wear as a leading braking system than the trailing brake shoe (5). Brake shoes (4, 5) are designed as pivoted shoes. To correct the pad wear, integrated automatic readjustments are used in the expander. fig. 2-2: Cut-out view of the expander device 9 Wedge 10 Piston 11 Pressure spring 12 Rollers a Expander wedge direction of operation b Piston direction of operation 8

9 Description and function Simplex expanding device Description The expander device mainly consists of the housing, an expander wedge, rollers and piston with integrated automatic readjustments. The spreader device is protected against the infiltration of sprayed water and dirt with a protective cap. Function The expander (2) has an automatic readjustment apparatus for each piston (10), which continually readjusts for pad wear, separately for each brake shoe (4, 5) and therefore always guarantees sufficient space between the brake drum and the brake pad. Operation: When actuated, the expander wedge (9) is pressed against the pre-tension of the compression spring (11) between the rollers (12), and the rollers (12) run down the slant of the wedge (9) and the piston (10). This causes both pistons (10) to be pressed outward with the adjuster ring (13) and the adjuster nut (14), which presses the brake shoes against the brake drum and introduces a braking procedure. At the completion of the braking process, the expander wedge (9) is pressed into its original position by the compression spring (11). Release springs (6) for brake shoes (4, 5) press the adjuster nut (14), the adjuster ring (13) and the piston (10) back into their original positions. If there is an increase in the space because of pad wear, the expander wedge (9) presses further down and the piston (10) is pressed further outward. As soon as the adjuster wheel (13) rotation is greater than the tooth distribution of the adjuster wheel teeth (18) - saw-teeth - between the adjuster ring (13) and the adjuster nut (14), the automatic adjustment is put into play. Here the teeth (18) are moved one tooth further by a flexible spring (19). Release: When the brake is released, the adjuster bolt (15), the adjuster nut (14), the adjuster wheel (13) and the piston (10) are pressed back inward by the release springs (6). Because of the lateral shift in the piston (10), the spring-loaded pin (16) is applied on the shoulders of the helical groove (17), so that the adjuster ring (13) can be turned based on the piston (10) stroke. Because the pin (16) is pressed against the shoulder of the helical groove (17), the adjuster nut (14) and the adjuster ring (13) wheel rotate by one tooth. The adjuster bolt (15) is turned outward in the threads of the adjuster nut (14), therefore evening out the pad wear. The adjuster bolt (15) is fastened in place by the flat retainer spring (32) on the brake shoes (4, 5). Because the distribution of the teeth in the wheel (18) is so fine, the adjustment is very small - almost stageless - and equally sized steps of 0.03 mm. 9

10 3 Checking the brake pad thickness 3 Checking the brake pad thickness CAUTION Risk of injury Observe all safety instructions, as well as all repair and maintenance instructions (see chapter 1 "Important instructions and safety instructions", page 5). These instructions must be observed to avoid personal injury or material loss. Always check the brake pad thickness of both brake shoes and especially the brake pad thickness on the brake shoe that is in the direction of travel when moving forward (leading shoe). Remove the seal plugs (8a) from the inspection openings in the cover plate (3). Check the pad thickness of the brake pads. Replace the pads if a pad thickness of 6 mm has been reached on the brake lining. Depending on the type of brake and the available repair kits, either new brake pads can be riveted onto the brake shoes or new brake shoes can be installed with brake pads. Use WABCO replacement parts only and pay attention to the installation instructions provided with the repair kit (see chapter 8 "Procurement and disposal of spare parts", page 26). Make sure to put the seal plugs (8a) back into the inspection openings of the cover plate (3) after checking the brake pads. If braking force is insufficient or noises or vibrations during braking require further inspection, the brake drum will have to be removed. 10

11 Removing and inspecting the brake 4 4 Removing and inspecting the brake CAUTION Risk of injury Observe all safety instructions, as well as all repair and maintenance instructions (see chapter 1 "Important instructions and safety instructions", page 5). These instructions must be observed to avoid personal injury or material loss. Reset the automatic adjuster by turning the gears back to the stop with a flat screwdriver. This is done by inserting the screwdriver through the opening in the cover plate. Be sure not to damage the protective caps with the screwdriver. The brakes must be checked at regular intervals, in relation to vehicle use, during maintenance intervals, as well as in the context of applicable local laws and regulations. Replacing the brake pads, brake shoes and brake drums must always be done per axle and only use the brake pads that are approved for the vehicle by the vehicle manufacturer. 4.1 Releasing the automatic adjuster Release the parking brake by completely unscrewing the release bolt on the spring brake cylinder assembly. Observe the instructions of the brake cylinder manufacturer in this regard. Check for whether the brake is released. Remove the seal plugs (8b) from the cover plate. Turn both gears clockwise to reset the adjuster mechanism. 4.2 Removing and inspecting the brake drum The steps for removing and installing the brake drum depend on the construction of the axle. Refer to the respective documentation from the axle manufacturer! Remove the brake drum from the brake. Remove any course dirt, debris and rust from the brake drum and the clean the brake drum with a non-regreasing solution (brake cleaner). Check the brake drum for wear, grooves, cracks and damage. Degree of wear to the brake drum Diameter Max. drum Wear limit machining dimensions Ø 410 mm Ø 411 mm Ø 412 mm Ø 500 mm Ø 501 mm Ø 502 mm Small cracks and/or grooves can be professionally machined to the maximum drum machining dimensions. Recommended surface finish: Rz = µm 11

12 4 Removing and inspecting the brake Replace the brake drum, if: the wear limit has been reached, cracks and grooves are still evident after machining to the maximum permitted drum machining dimensions, heat markings can be seen on the friction surface of the brake drum. Unhook the release springs (6) from the brake shoes (4, 5) using brake spring pliers or a suitable tool. Make sure that the inner diameters of the brake drums are the same on an axle when reinstalling the brake drums. Always replace both brake drums on an axle. 4.3 Removing and inspecting the brake shoes Burned, glazed or oil contaminated brake linings must be replaced immediately. Check the release springs for damages from corrosion or over-tensioning and replace damaged release springs. Remove both brake shoes (4, 5) from the brake. To avoid damaging the brake drum replace the brake linings no later than at the point when they reach the wear limit at their weakest spot. Only with brakes type : Unhook the springs from the lower release spring and remove the spring hook from the calliper. Check the brake shoes for wear, damage and corrosion. Danger of injury from release springs under tension! Use the respective installation/removal tool (figure) or brake spring pliers for unhooking the release springs. Replace the brake shoes, if: the contact surfaces on the web plate for the expander show signs of wear or are worn out, the contact surfaces of the brake shoe supports to the calliper show signs of wear or are worn out, the brake shoes show signs of corrosion damage, the brake shoes are deformed. Check the brake linings (pads) Replace the brake pads if the remaining pad thickness reaches 6 mm on the brake lining or if 12

13 Removing and inspecting the brake 4 the brake pads are burned, glazed or if they have been contaminated with oil. Depending on the type of brake and the available repair kits, either new brake pads can be riveted onto the brake shoes or new brake shoes can be installed with brake pads. Use WABCO replacement parts only and pay attention to the installation instructions provided with the repair kit (see chapter 8 "Procurement and disposal of spare parts", page 26). 4.4 Checking other brake parts Check all rubber parts of the brake for damages and replace any damaged rubber parts. Avoid damaging the protective caps while servicing or cleaning. Check the brake calliper (1) for damages, cracking, corrosion and wear. Clean the cotter pins and the mounts for the brake shoes on the brake calliper (1) and check them for wear and damage. Replace the brake callipers, if: the brake callipers show signs of cracking, corrosion damage or wear, the cotter pins or the mounts on the brake calliper for the brake shoes show signs of wear or damage. 13

14 5 Replacing the expander 5 Replacing the expander CAUTION Risk of injury Observe all safety instructions, as well as all repair and maintenance instructions (see chapter 1 "Important instructions and safety instructions", page 5). These instructions must be observed to avoid personal injury or material loss. 5.1 Removing the expander Remove the brake cylinder from the brake (see chapter 7.1 "Removing the brake cylinder", page 24). Pull the expander wedge out of the housing of the spreader if necessary. Reset the automatic adjuster mechanism (see chapter 4.1 "Releasing the automatic adjuster", page 11). Remove the brake drum (see chapter 4.2 "Removing and inspecting the brake drum", page 11). Remove the brake shoes (see chapter 4.3 "Removing and inspecting the brake shoes", page 12). Unscrew the four fastening bolts for the expander (2) using a ring spanner (SW 19) and remove the expander (2) from the brake calliper. 5.2 Checking the expander Replace the complete expander assembly if the expanding wedge actuation fails or if the automatic readjustment fails. Indication of a defective expander could also be excessive brake cylinder stroke distance or onesided brake pad wear. Check the protective caps (30) on the expander for damage and replace any damaged protective caps. Check the flat retainer springs (32) on the expander for damage and replace any damaged springs. Check the housing of the expander for damage or cracking. Replace the entire expander assembly if the housing is damaged or if there are signs of cracking. 5.3 Dismantling the expander assembly Pull out the entire expander actuation, consisting of the expander wedge (9), roller (12), roller cage (21), compression spring (11), snap ring (22) and double-sided spring plates from the housing (2) of the expander. 14

15 Replacing the expander 5 Pull the protection cap (30) out of the groove (arrow) of the housing (2). Release the protective cap (30) from the ring groove of the adjuster bolt (15) and remove the protective cap. Pull the complete units out of the pistons (10) of the expander assembly. Check the adjuster bolt (15) for damages to the flat retainer spring (32) or the adjuster bolt (15) with integrated toothed adjuster wheel (31) and replace any damaged parts. Unscrew the adjuster nut (14) from the adjuster bolt (15). 15

16 5 Replacing the expander Unscrew the shoulder bolts (28) with a ring spanner (SW 19) and screw them out of the housing (2). Dismantle the individual parts of the shoulder bolt (28): short and long compression springs (26, 27) with pin (16). Replace damaged or worn parts using WABCO repair kits (see chapter 8 "Procurement and disposal of spare parts", page 26). 5.4 Reassembling the expander assembly Grease a new flexible spring (19) and insert it into the piston (10) so that the ends of the spring (19) face the bottom of the piston and are across from the oblong slot in the piston (10). Grease a new disc (20) and the adjuster wheel (13). Insert the disc (20) and the adjuster wheel (13) into the piston (10) so that the helical groove (17) of the adjuster wheel (13) faces the oblong hole in the piston (10). Pull the piston (10) out of the housing (2). Grease the piston (10) and insert it into the housing (2) so that the oblong hole (arrow) of the piston (10) faces the threaded hole in of the shoulder bolt (28). Remove the adjuster wheel (13), disc (20) and flexible spring (19) from the piston (10). Grease the shoulder bolt (28), the short and long compression springs (26, 27) and the pin (16). Insert the short and long compression springs (26, 27) and the pin (16) into the shoulder bolt (28). Clean all parts and the housing of the expander and check all parts for damage or wear. 16

17 Replacing the expander 5 Insert the complete shoulder bolt (28) into the threaded hole in the housing (2) so that the shoulder bolt (28) reaches into the oblong hole of the piston (10) and the pin (16) in the helical groove (17) of the adjuster wheel (13). Thread on the adjuster nut (14) to the stop on the adjuster bolt (15) and make sure that the adjuster nut (14) does not counter against the stop. Grease the teeth of the adjuster nut (14). Insert the entire unit into the piston (10). Thread the shoulder bolt (28) into the housing (2) and tighten the shoulder bolt (28) with a spanner (SW 19) (tightening torque Nm). Grease the groove and threads of the adjuster bolt (15). Insert a new protective cap (30) onto the adjuster bolt (15) so that it is seated completely in the groove of the adjuster bolt (15). Grease the groove (arrow) of the housing (2). Insert the protective cap (30) on the housing (2) so that it is seated in the groove (arrow) all the way around the housing (2). Grease the inside of the housing (2). This is done by filling the inner space in the base of the housing (2) between the pistons (10) with approximately cm³ grease. 17

18 5 Replacing the expander Grease the parts of the expander actuation: Expander wedge (9), rollers (12), roller cage (21), compression spring (11), snap ring (22) and double-sided spring plate. Put the parts of the expander actuation together. Make sure that when installing the expander wedge actuator, the rollers (12) face toward the piston (10) and the roller cage (21) is not seated on the guide in the side of the housing (2). Make sure that the expander wedge actuation assembly is positioned correctly. This is done by using your hand to put light pressure on the expander wedge (9) and turn it in a circle. Align the expander wedge (9) centred with the housing neck axis (A) and insert the complete expander actuation assembly into the housing (2). If the expander wedge slips back by moving downward, the initial position of the rollers (12) between the pistons (10) is not correct. Realign the expander wedge in this case. Make sure that the expander wedge actuation remains in its initial position when installing the brake cylinder. Avoid putting the expander wedge (9) into the housing (2) at an angle. This could cause the expander wedge actuator to slip out of its original position and the rollers (12) would not go between the pistons (10). 18

19 Replacing the expander 5 Setting the expander assembly Screw in the adjuster bolts (15) under pressure until the wheel teeth (18) of the adjuster wheel (13) and the adjuster nut (14) slide audibly against one another. Screw each of the adjuster bolts (15) out two full turns. Make sure that both adjuster bolts are turned out the same amount. Insert the expander assembly (2) into the locator hole of the brake calliper (1). Screw the expander assembly (2) onto the brake calliper (1) with four new fastening bolts (SW 19). Tighten the fastening bolts, alternating in a crisscross fashion, to a tightening torque of 210 ± 15 Nm. By screwing the two adjuster bolts out, the functionality of the automatic adjuster is guaranteed! 5.5 Installing the expander assembly Clean the locating hole and the mounting surface for the expander assembly on the brake calliper (1). Grease the locator hole (arrow) for the expander assembly (2) on the brake calliper (1) with ANTI- SEIZE or an equivalent grease. The mounting surfaces must be free of grease. With brakes type, the four fastening bolts must also be secured with Loctite 270. Make sure that the threads in the housing and on the fastening bolts are free of grease. Install the brake (see chapter 6 "Installing the brakes", page 20). Install the actuation cylinder (see chapter 7.2 "Installing the brake cylinder", page 24). Perform a function and effectiveness test of the brake (see chapter 6.4 "Functionality testing and breaking in", page 23). 19

20 6 Installing the brakes 6 Installing the brakes CAUTION Risk of injury Observe all safety instructions, as well as all repair and maintenance instructions (see chapter 1 "Important instructions and safety instructions", page 5). These instructions must be observed to avoid personal injury or material loss. Insert the brake shoes into the mounts (b, d) on the brake calliper (1) and into the slots (a, c) of the adjuster bolt (15) for the expander assembly. Set the expander assembly before installing the brake (see page 19). 6.1 Installing the brake shoes Grease the contact surfaces (arrows) of the adjuster bolts (15) in the expander assembly (2). Grease the surfaces (arrows) of the brake shoe mounts on the brake calliper (1). Notes: The brake shoes are symmetric/identical and do not correspond specifically with the main direction of rotation of the brake. Exception In the case of type brakes, the two brake shoes (4, 5) differ in the design of the holes for hooking the release springs (6) in place: The holes with bevels (arrows) must face mounts (b) and (c). 20

21 Installing the brakes 6 The centring pin of the brake calliper (1) must insert into the centring groove on the brake shoe (4, 5). Installing the release springs Danger of injury from release springs under tension! Use the respective installation/removal tool (figure) or brake spring pliers for hooking the release springs in place. Always use new release springs to install brake shoes. The web plate of the brake shoes (4, 5) must be in the gap in the brake calliper (1). Insert the new release springs (6) into the correct mounting position. The brake shoe must be in the groove of the adjuster bolt (15) and the gap of the flat retainer spring. Install a new spring hook (a) as well with type brakes. Insert the angled end of the release spring into the hole in the brake shoe. (This hole is not bevelled on type brakes.) 21

22 6 Installing the brakes Hook the hook-formed end of the release spring into the hole in the brake shoe with brake spring pliers or a suitable tool. (This hole is bevelled on type brakes.) Check the release springs for correct mounting position based on the picture. Make absolutely sure to also hook a new spring hook (a) into the release spring (6) on the shoe support side with type brakes to prevent the release spring from coming into contact with the wheel hub. Insert the angled end of the spring hook (a) into the hole in the brake calliper (1). 6.2 Initial brake setting Every brake must be set up individually to the respective brake drum dimension. Determine the inner diameter of the brake drum in the middle of the contact surface. Determine the outer diameter of the brake shoe with a calliper gauge. Set the brake shoes to the diameter of the brake drum by turning the adjuster bolt (15) evenly out or in. Setting dimensions: Diameter of brake shoe = diameter of brake drum minus 1.5 mm. Hook the release spring into the hook-formed end of the spring hook (a). Check the concentricity of the brake shoes using a gauge. This is done by using magnetic stands to mount the gauge on the wheel hub. Both brake shoes 22

23 Installing the brakes 6 must be measured in the middle (in the pad split groove area) and must show the same value. 6.4 Functionality testing and breaking in WARNING Rolling vehicle Make sure that the release screw of the spring brake cylinder is threaded completely in after completing the maintenance and installation work and check the functionality of the parking brake. Perform a concluding roller test stand test having completed the repairs. An incorrect adjustment will lead to damages to the brake pads and the brake drum. If necessary, correct the concentricity of the brake shoes by screwing the adjuster bolts (15) in or out. Check the setting dimensions with a calliper gauge. After completing the service and adjustment work, insert the seal plugs (8a, 8b) into the openings in the cover plate. 6.3 Installing the brake drum The steps for removing and installing the brake drum depend on the construction of the axle. Refer to the respective documentation from the axle manufacturer! Make sure that the parking brake is released, by completely unscrewing the release bolt on the spring brake cylinder assembly. Observe the instructions of the brake cylinder manufacturer in this regard. Install the brake drum on the axle. Breaking in specifications Every new brake pad must be broken in to achieve optimal braking performance and to prevent later damage to the brake pad, the brake drum and the expander. Breaking in is done with interval braking procedures in the lower to mid-speed range of the vehicle. The break-in distance must be at least 500 kilometers. During the break-in phase, the brake drum temperature must not exceed 200 C. Do not perform full braking, with the exception of emergency braking, after new brake linings have been fitted. Also avoid continuous braking over longer periods. Check braking performance on a rolling test stand after the brakes have cooled. Repeat the break-in process until the specified braking performance has been achieved. While breaking the new brake pads in (at least 500 km), the brake does not achieve full braking performance. With machined brake drums, the break-in time to achieving full braking performance is extended. Ensure that the driver of the vehicle is informed. 23

24 7 Replacing the brake cylinder 7 Replacing the brake cylinder CAUTION Risk of injury Observe all safety instructions, as well as all repair and maintenance instructions (see chapter 1 "Important instructions and safety instructions", page 5). These instructions must be observed to avoid personal injury or material loss. Loosen the counter nut of the actuation cylinder on the expander. Unscrew the brake cylinder out of the expander. Only use brake cylinders as specified by the vehicle manufacturer. These instructions for breaking the brake cylinder in are for general information. Pay attention to the installation specifications and the test and installation instructions of the manufacturer of the brake cylinder and adhere to them. Ensure that no dirt or moisture enters the expander when removing the brake cylinder. 7.1 Removing the brake cylinder Release the parking brake, by completely unscrewing the release bolt on the spring brake cylinder assembly. Observe the instructions of the brake cylinder manufacturer in this regard. 7.2 Installing the brake cylinder Before connecting the air lines to the brake cylinder and screwing the release bolt in again, the brake drum must be mounted. Clean the outer threads of the brake cylinder. Thread the counternut onto the brake cylinder until 27 mm of thread is protruding. Seal the outer thread (arrow) of the brake cylinder against water infiltration by applying sealant on the outer threads. Recommended sealant: Teroson-Atmosit. Mark the compressed air lines so that they cannot be switched when installing again. Unscrew the air lines from the brake cylinder. Ensure that the air connections of the brake cylinder are not pressurised. Thread the brake cylinder into the housing neck of the expander until it is stopped solidly. Release the brake cylinder again until the bleed vent faces upward with the hydraulic cylinder or 24

25 Replacing the brake cylinder 7 the required setting is achieved for the compressed air connection with a pneumatic cylinder. Tighten the counternut on the brake cylinder with the brake actuated. Tightening torque: 160 ± 20 Nm. Check the air connections for tightness. Perform a function and effectiveness test of the brake (see chapter 6.4 "Functionality testing and breaking in", page 23). Make sure that the expander wedge actuation is in the initial position when mounting the actuation cylinder. Make sure that the brake lines are not under the brake cylinder and that one of the drainage openings (e) faces down, vertically. The drainage openings (e) at the bottom must be open. The remaining openings on the brake cylinder must be plugged off. Screw the compressed air lines onto the brake cylinder. Thread the release bolt (arrow) for the spring brake cylinder completely in so that the brake is actuated. Observe the instructions of the brake cylinder manufacturer in this regard. 25

26 8 Procurement and disposal of spare parts 8 Procurement and disposal of spare parts Procurement of spare parts Identify the brake by means of the WABCO part number. Disposing of the brake components Dispose of used and replaced parts in accordance with the national and regional regulations regarding environmental protection. Generally brake components can be scrapped. fig. 8-1: WABCO type plate A Vehicle manufacturer part number B Production date C Assembly number D WABCO part number Open INFORM at Enter the WABCO part number of the brake calliper. Click "Repair". Open the spare part sheet. 26

27

28 WABCO Vehicle Control Systems (NYSE: WBC) is a leading supplier of safety and control systems for commercial vehicles. For over 140 years, WABCO has pioneered breakthrough electronic, mechanical and mechatronic technologies for braking, stability, and transmission automation systems supplied to the world s leading commercial truck, trailer, and bus manufacturers. WABCO is headquartered in Brussels, Belgium. For more information, visit WABCO All rights reserved /

PAN 17 MECHANICAL SLIDING CALLIPER DISC BRAKE ASSEMBLY AND MAINTENANCE INSTRUCTIONS

PAN 17 MECHANICAL SLIDING CALLIPER DISC BRAKE ASSEMBLY AND MAINTENANCE INSTRUCTIONS PAN 17 MECHANICAL SLIDING CALLIPER DISC BRAKE ASSEMBLY AND MAINTENANCE INSTRUCTIONS PAN 17 MECHANICAL SLIDING CALLIPER DISC BRAKE Assembly and Maintenance Instructions 2nd edition This publication is

More information

GENERAL REPAIR AND TEST HINTS SAFE REPAIR AND TEST OF WABCO DEVICES

GENERAL REPAIR AND TEST HINTS SAFE REPAIR AND TEST OF WABCO DEVICES GENERAL REPAIR AND TEST HINTS SAFE REPAIR AND TEST OF WABCO DEVICES General Repair and Test Hints Safe Repair and Test of Edition 2 This publication is not subject to any update service. You will find

More information

Mechanical Sliding Caliper Disc Brake. Type PAN 19-1 Assembly and Maintenance Instructions

Mechanical Sliding Caliper Disc Brake. Type PAN 19-1 Assembly and Maintenance Instructions WABCO Mannheim Mechanical Sliding Caliper Disc Brake Type PAN 19-1 Assembly and Maintenance Instructions WABCO Radbremsen GmbH Postfach 71 02 63 D-68222 Mannheim Bärlochweg 25 D-68229 Mannheim +49 (0)6

More information

Maintenance and Repair Instructions TM 89/03

Maintenance and Repair Instructions TM 89/03 TM 89/0 410 X 180 Simplex 410 X 180 Duplex 500 X 10 Simplex 500 X 160 Simplex 500 X 180 Duplex The brake described in this manual is subject to development and corresponds to the state-of-the-art at the

More information

disc brake axle with WABCO calipers

disc brake axle with WABCO calipers 1 2 disc brake axle with WABCO calipers 3 4 disc brake axle with WABCO calipers 5 6 disc brake axle with WABCO calipers IMT axles are supplied as non-cambered and are within the limits of a 2 minute negative

More information

MAXX TM 22T MECHANICAL SLIDING CALIPER DISC BRAKE INSTALLATION AND MAINTENANCE INSTRUCTIONS

MAXX TM 22T MECHANICAL SLIDING CALIPER DISC BRAKE INSTALLATION AND MAINTENANCE INSTRUCTIONS MAXX TM 22T MECHANICAL SLIDING CALIPER DISC BRAKE INSTALLATION AND MAINTENANCE INSTRUCTIONS MAXX TM 22T Mechanical Sliding Caliper Disc Brake Installation and Maintenance Instructions Edition 1 This publication

More information

MAXXUS 22. Mechanical Sliding Disc Brake Caliper

MAXXUS 22. Mechanical Sliding Disc Brake Caliper MAXXUS 22 Mechanical Sliding Disc Brake Caliper MAXXUS 22 Mechanical Sliding Disc Brake Caliper Assembly Instructions/ Maintenance Guidelines Edition 1 This publication is not subject to any update service.

More information

Brake System H TX, H2.0TXS [B475]; H TX [B466] Safety Precautions Maintenance and Repair

Brake System H TX, H2.0TXS [B475]; H TX [B466] Safety Precautions Maintenance and Repair HMM180001 Brake System H1.5-1.8TX, H2.0TXS [B475]; H2.5-3.5TX [B466] Safety Precautions Maintenance and Repair When lifting parts or assemblies, make sure all slings, chains, or cables are correctly fastened,

More information

CHAPTER 14 PARKING BRAKE

CHAPTER 14 PARKING BRAKE 1 page INDEX1 PARKING BRAKE 14-1 14-143E-05 CHAPTER 14 PARKING BRAKE 1Models FA and FB with LF05S TROUBLESHOOTING...14-2 SPECIAL TOOLS...14-3 INSPECTION AND ADJUSTMENT...14-4 PARKING BRAKE...14-7 14 PARKING

More information

Sisu S-Cam Drum Brakes

Sisu S-Cam Drum Brakes Sisu S-Cam Drum Brakes (For hub reduction rear axles since 1992) Maintenance Manual Sisu Axles, Inc. Autotehtaantie 1 P.O. Box 189 FIN-13101 Hämeenlinna Finland Phone int + 358 204 55 2999 Fax int + 358

More information

1. introduction 3 2. Wheel bearing special features 4 3. Wheel bearing units from an economical point of view 5

1. introduction 3 2. Wheel bearing special features 4 3. Wheel bearing units from an economical point of view 5 Motor chassis Service Technical BROCHuRE Wheel Bearing Repair Solutions for Light Commercial Vehicles CONTENT 1. introduction 3 2. Wheel bearing special features 4 3. Wheel bearing units from an economical

More information

FAG Wheel Bearing Repair Solution for Light Commercial Vehicles

FAG Wheel Bearing Repair Solution for Light Commercial Vehicles FAG Wheel Bearing Repair Solution for Light Commercial Vehicles Mercedes-Benz Sprinter, Viano, Vito and Volkswagen Crafter Front Axle The content of this brochure shall not be legally binding and is for

More information

3 Axles and brakes. 3.1 Function and construction of the axles Construction Function

3 Axles and brakes. 3.1 Function and construction of the axles Construction Function 3 Axles and brakes 3.1 Function and construction of the axles 3.1.1 Function Each wheel has an independent suspension system in the axle body (1), so that individual wheel suspension is provided. The swinging

More information

REMOVAL & INSTALLATION

REMOVAL & INSTALLATION REMOVAL & INSTALLATION REAR DISC BRAKE PADS Removal Raise and support vehicle. Remove wheels. Thoroughly clean outside of caliper to prevent dust and dirt from entering inside. Support caliper with a piece

More information

W BW GW. Workshop manual. Mechanical suspensions BPW, series ECO Cargo W / BW / GW. BPW-WH-W-BW-GW e

W BW GW. Workshop manual. Mechanical suspensions BPW, series ECO Cargo W / BW / GW. BPW-WH-W-BW-GW e W BW GW Workshop manual Mechanical suspensions BPW, series ECO Cargo W / BW / GW BPW-WH-W-BW-GW 35251401e Page 2 BPW-WH-W-BW-GW 35251401e BPW-WH-W-BW-GW 35251401e Page 3 Contents 1. Product identification...

More information

Owners Manual Öhlins road & track front fork FG 43 Including:

Owners Manual Öhlins road & track front fork FG 43 Including: Owners Manual Öhlins road & track front fork FG 43 Including: Safety Adjusters Setting up your fork Changing springs Oil level adjustment Technical information Inspection & maintenance Service Tools 1

More information

This file is available for free download at

This file is available for free download at This file is available for free download at http://www.iluvmyrx7.com This file is fully text-searchable select Edit and Find and type in what you re looking for. This file is intended more for online viewing

More information

Caring for your car. Fig 28.Tyre pressure reading (arrowed).

Caring for your car. Fig 28.Tyre pressure reading (arrowed). Caring for your car Remove the dust cap from the valve in the rim of the wheel. Ensure the extension is fully into the gauge and push the gauge onto the valve, as in Fig 28. Allow the gauge to extend.

More information

DRIVE AXLE Volvo 960 DESCRIPTION & OPERATION AXLE IDENTIFICATION DRIVE AXLES Volvo Differentials & Axle Shafts

DRIVE AXLE Volvo 960 DESCRIPTION & OPERATION AXLE IDENTIFICATION DRIVE AXLES Volvo Differentials & Axle Shafts DRIVE AXLE 1994 Volvo 960 1994 DRIVE AXLES Volvo Differentials & Axle Shafts 960 DESCRIPTION & OPERATION All 960 station wagon models use type 1041 rear axle assembly. All 960 4-door models use type 1045

More information

Sachs 48mm Closed Cartridge fork Service Manual

Sachs 48mm Closed Cartridge fork Service Manual Sachs 48mm Closed Cartridge fork Service Manual 1 Fork seal driver 2 Special soft jaws 3 Fork cap wrench 4 Rebound rod holding tool 5 Compression assembly holding tool 6 Retaining clip tool Special Tools

More information

Maintenance Information

Maintenance Information Form 16575334 Edition 1 April 2005 Electric Screwdrivers EL, EP and ET 34V DC Series Maintenance Information Save These Instructions WARNING Maintenance procedures have the potential for severe shock hazard

More information

Installation Instructions for disc brakes

Installation Instructions for disc brakes Installation Instructions for disc brakes Bedford CF 230-280, built 1974-1986, not suitable for vehicles with rear twin tyres Included 2 pcs. Wheel Hubs with Wheel Bolts, Mounted Brake Discs and Wheel

More information

OVERHAUL. Remove the union bolt and a gasket from the disc brake cylinder, then disconnect the flexible hose from the disc brake cylinder.

OVERHAUL. Remove the union bolt and a gasket from the disc brake cylinder, then disconnect the flexible hose from the disc brake cylinder. OVERHAUL COMPONENTS: See page 3232 Overhaul the RH side by the same procedures with LH side. Two types of brake pad exist; one is with slit and the other without slit. 1. REMOVE REAR WHEEL 2. DRAIN FLUID

More information

Installation Instructions LamboStyleDoors (The instruction are to be used as a reference. Please repeat for both doors)

Installation Instructions LamboStyleDoors (The instruction are to be used as a reference. Please repeat for both doors) Installation Instructions LamboStyleDoors (The instruction are to be used as a reference. Please repeat for both doors) Mercedes C-Class Sport coupé type W203 Part number 500 25 009 Pre installation check

More information

SuperTrac. Axle. Service & Maintenance. Manual

SuperTrac. Axle. Service & Maintenance. Manual SuperTrac Axle Service & Maintenance Manual Table of Contents Page Exploded Views Section 1: General Information General Warnings Description of Axle Models Identifications Section 2: Installation Axle

More information

Fisher 657 Diaphragm Actuator Sizes and 87

Fisher 657 Diaphragm Actuator Sizes and 87 Instruction Manual 657 Actuator (30-70 and 87) Fisher 657 Diaphragm Actuator Sizes 30 70 and 87 Contents Introduction... 1 Scope of Manual... 1 Description... 2 Specifications... 2 Installation... 3 Mounting

More information

Valtek Auxiliary Handwheels and Limit Stops

Valtek Auxiliary Handwheels and Limit Stops Valtek Auxiliary s and Limit Stops Table of Contents Page 1 General information 2 Installation 2 Side-mounted handwheels, size 25 and 50 (linear actuators) 3 Side-mounted handwheels, size 100 and 200 (linear

More information

Operating Instruction

Operating Instruction Operating Instruction Drive element LEWA - ecosmart type LCA with manual stroke adjustment, motor mounted vertically Table of contents 1 General information / safety 1.1 Important preliminary information

More information

Maintenance Information

Maintenance Information 45530136 Edition 1 July 2008 Electric Screwdrivers EL 24V DC Series Maintenance Information Save These Instructions WARNING Always wear eye protection when operating or performing maintenance on this tool.

More information

1. Remove the crankshaft pulley, engine coolant pump pulley and drive belt. 2. Remove the timing belt cover.

1. Remove the crankshaft pulley, engine coolant pump pulley and drive belt. 2. Remove the timing belt cover. DISASSEMBLY 1. Remove the crankshaft pulley, engine coolant pump pulley and drive belt. 2. Remove the timing belt cover. 3. Turn the crankshaft clockwise and align the timing marks so as to bring the No.

More information

Maintenance instructions. BPW Trailer Axles and Suspensions. BPW-W e

Maintenance instructions. BPW Trailer Axles and Suspensions. BPW-W e Maintenance instructions BPW Trailer Axles and Suspensions BPW-W 33111701e Page 2 BPW-W 33111701e BPW-W 33111701e Page 3 Contents Important information 1 1. Important information... Page 3 1.1 General

More information

Sub Section Title Page No.

Sub Section Title Page No. Sub Section Title Page No. 1 Introduction 3 2 Routine Maintenance 3 3 Disassembly 4 3.1 Disassembly of Double Crank Design 4 3.2 Disassembly of Scotch Yoke Design 5 3.3 Disassembly of Actuator Cylinder

More information

Operating Manual for Drum Brake Type: EBN

Operating Manual for Drum Brake Type: EBN Operating Manual for Drum Brake Type: PINTSCH BUBENZER GmbH Postfach 123 57540 Kirchen-Wehbach Tel.: +49-2741 - 9488-0 Fax: +49-2741 - 9488-44 G E R M A N Y www.pintschbubenzer.de e-mail: info@pintschbubenzer.de

More information

HUB & WHEEL INSTALLATION

HUB & WHEEL INSTALLATION HUB & WHEEL INSTALLATION 1.0 SCOPE This specification covers the torque requirements for the attachment of all component parts of Spoke Wheels, Rims, Tyres and Hub assemblies. 1.1 Spoke Wheels CAUTION:

More information

REMOVAL & INSTALLATION

REMOVAL & INSTALLATION REMOVAL & INSTALLATION FRONT DISC BRAKE PADS 1. Raise and support front of vehicle. Remove wheels. Remove caliper bolt and brakeline bracket bolts. Pivot caliper aside. Remove pads and pad shim. Remove

More information

Cam Brakes. Table of Contents

Cam Brakes. Table of Contents Sub-Headings Introduction 3 Q Plus 3 Disassembly 4 Remove the Wheel Components 4 Automatic Slack Adjuster 4 Brake Shoes 5 Remove Camshaft and Auto Slack Adjuster 6 Preparing Parts for Assembly 6 Clean

More information

CHASSIS CONTENTS EXTERIOR PARTS 6-1 FRONT WHEEL 6-2 FRONT BRAKE 6-6 HANDLEBARS 6-12 REAR WHEEL 6-30 REAR BRAKE 6-34 REAR SHOCK ABSORBER 6-36

CHASSIS CONTENTS EXTERIOR PARTS 6-1 FRONT WHEEL 6-2 FRONT BRAKE 6-6 HANDLEBARS 6-12 REAR WHEEL 6-30 REAR BRAKE 6-34 REAR SHOCK ABSORBER 6-36 CHASSIS CONTENTS EXTERIOR PARTS 6-1 FRONT WHEEL 6-2 FRONT BRAKE 6-6 HANDLEBARS 6-12 FRONT FORK ( ) 6-14 FRONT FORK ( ) 6-20 STEERING 6-27 REAR WHEEL 6-30 REAR BRAKE 6-34 REAR SHOCK ABSORBER 6-36 6 SWING

More information

BRAKE E

BRAKE E 8-1 GENERAL...8-2 SPECIFICATIONS...8-6 COMPONENTS...8-7 FRONT BRAKE...8-12 DISASSEMBLY INSPECTION REASSEMBLY (Pn1, Cu2 3 TON SERIES)...8-12 DISASSEMBLY INSPECTION REASSEMBLY (Pn2 3 TON SERIES)...8-17 BRAKE

More information

1992 Clutch. Eclipse, Expo/Expo LRV, Galant, Mirage, Precis, 3000GT

1992 Clutch. Eclipse, Expo/Expo LRV, Galant, Mirage, Precis, 3000GT Article Text ARTICLE BEGINNING 1992 Clutch Eclipse, Expo/Expo LRV, Galant, Mirage, Precis, 3000GT DESCRIPTION All clutches are single disc type. Pressure plate assembly uses a diaphragm spring to engage

More information

HEAVY DUTY TROLLEY JACK. Operation Manual

HEAVY DUTY TROLLEY JACK. Operation Manual HEAVY DUTY TROLLEY JACK 4T Operation Manual Make sure to read and fully understand the instruction manual before using this product and keep the manual properly 1 General Description Product Description

More information

Hook coupling UN 76 Installation,operating and maintenance instructions

Hook coupling UN 76 Installation,operating and maintenance instructions Hook coupling UN 76 Installation,operating and maintenance instructions E S ORL DI I S T E M I D I T R A I N O Registration of the installation and the maintenance operations Vehicle data: Type: Registration

More information

CHASSIS CONTENTS EXTERIOR PARTS 6-1 FRAME COVER 6-2 REAR FRAME COVER 6-4 FRONT WHEEL 6-6 FRONT BRAKE 6-10 HANDLEBARS 6-17 FRONT FORK 6-19

CHASSIS CONTENTS EXTERIOR PARTS 6-1 FRAME COVER 6-2 REAR FRAME COVER 6-4 FRONT WHEEL 6-6 FRONT BRAKE 6-10 HANDLEBARS 6-17 FRONT FORK 6-19 CHASSIS CONTENTS EXTERIOR PARTS 6- FRAME COVER 6- REAR FRAME COVER 6-4 FRONT WHEEL 6-6 FRONT BRAKE 6-0 HANDLEBARS 6-7 FRONT FORK 6-9 STEERING 6-6 REAR WHEEL 6-3 REAR BRAKE 6-39 6 REAR SHOCK ABSORBER 6-43

More information

Operating Manual for Disc Brake Type: SB 8.11

Operating Manual for Disc Brake Type: SB 8.11 for Disc Brake Type: PINTSCH BUBENZER GmbH Postfach 123 57540 Kirchen-Wehbach Tel.: +49-2741 - 9488-0 Fax: +49-2741 - 9488-44 G E R M A N Y www.pintschbubenzer.de e-mail: info@pintschbubenzer.de PB84-0508-01/1

More information

Edition Manual Chapter Page Workshop Manual, Stiga Park 5 Belts 11

Edition Manual Chapter Page Workshop Manual, Stiga Park 5 Belts 11 2008-05-19 Workshop Manual, Stiga Park 5 Belts 11 Pro 20 1. Dismantle the belts A and B as described above. 2. Block up the rear frame and remove the right rear wheel. Clean carefully the insex hole in

More information

Property of American Airlines

Property of American Airlines Date Maintenance Check list The inspection and preventive maintenance schedule of the Power Stow Rollertrack is as follows: Daily (10 hrs), Weekly (50 hrs.), every 6 months ( hrs.), yearly (1 hrs.) and

More information

Repair Manual 11/99 PS-34. Page 1

Repair Manual 11/99 PS-34. Page 1 Repair Manual /99 PS-4 Page Table of contents Index Technical Data page Special tools 4 Repair instructions, general 0 Chain brake 6 0 Centrifugal clutch 8 0 Oil pump 9-04 Ignition system - 0 Starting

More information

Installation Instructions LamboStyleDoors (The instruction are to be used as a reference. Please repeat for both doors)

Installation Instructions LamboStyleDoors (The instruction are to be used as a reference. Please repeat for both doors) Installation Instructions LamboStyleDoors (The instruction are to be used as a reference. Please repeat for both doors) Hyundai enesis Coupé type BK38 Part number 500 66 002 Pre installation check list:

More information

REAR AXLE Click on the applicable bookmark to selected the required model year

REAR AXLE Click on the applicable bookmark to selected the required model year REAR AXLE 27-1 REAR AXLE CONTENTS GENERAL INFORMATION.................. 2 SERVICE SPECIFICATIONS................. 3 LUBRICANTS.............................. 3 SEALANTS AND ADHESIVES.............. 4 SPECIAL

More information

SYSTEM SAVER 318 AIR COMPRESSOR FOR MACK E-TECH AND ASET ENGINES MAINTENANCE MANUAL

SYSTEM SAVER 318 AIR COMPRESSOR FOR MACK E-TECH AND ASET ENGINES MAINTENANCE MANUAL SYSTEM SAVER 318 AIR COMPRESSOR FOR MACK E-TECH AND ASET ENGINES MAINTENANCE MANUAL NON-THROUGH DRIVE THROUGH DRIVE Service Notes About This Manual This manual provides service and repair procedures for

More information

PAH, PAHT, PAHT G pumps PAH , PAHT and PAHT G Disassembling and assembling

PAH, PAHT, PAHT G pumps PAH , PAHT and PAHT G Disassembling and assembling Servie guide PAH, PAHT, PAHT G pumps PAH 10-12.5, PAHT 10-12.5 and PAHT G 10-12.5 Disassembling and assembling hpp.danfoss.com Table of Contents 1. Disassembling the pump...3 2. Inspection...7 2.1. Port

More information

TRAILER AXLE MAINTENANCE

TRAILER AXLE MAINTENANCE Purpose To maintain and extend the product life of the Trailer Axle product line. Safety Failure to follow the instructions provided in this manual may result in death, serious personal injury, severe

More information

Model DFR 070/156/220 Rotary Actuator

Model DFR 070/156/220 Rotary Actuator Figure 1 DFR 156 TABLE OF CONTENTS General 2 Actuator Assembly 18 Scope 2 Bushing / Yoke Assembly 18 Principles of Operation 2 Spring Barrel Assembly 18 Safety Caution 2 Diaphragm Plate Assembly 20 Specifications

More information

MailStar Maintenance and Adjustment March 2002

MailStar Maintenance and Adjustment March 2002 MailStar Maintenance and Adjustment March 2002 The MailStar bicycle incorporates many new features to ease maintenance and improve handling and performance. The majority of components are similar to those

More information

Slack Adjuster. Table of Contents

Slack Adjuster. Table of Contents Slack Adjuster Table of Contents Sub-Headings Automatic Slack Adjuster Service 2 PayMaster Automatic Slack Adjuster 2 How the Automatic Slack Adjuster Works 2 Pressed-In, Sealed Actuator Boot 3 Handed

More information

Öhlins Front Fork Road & Track FG 43. Owner s Manual

Öhlins Front Fork Road & Track FG 43. Owner s Manual Öhlins Front Fork Road & Track FG 43 Owner s Manual Öhlins Headquarters Upplands Väsby, Sweden Öhlins Racing AB - The Story It was the 1970 s, a young man named Kenth Öhlin spent most of his spare time

More information

EAC. Workshop manual. BPW air suspensions, series ECO Air COMPACT. BPW-WH-EAC e

EAC. Workshop manual. BPW air suspensions, series ECO Air COMPACT. BPW-WH-EAC e EAC Workshop manual BPW air suspensions, series ECO Air COMPACT BPW-WH-EAC 35161701e Page 2 BPW-WH-EAC 35161701e Valid: 01.01.2017 Subject to change without notice. Current versions and additional information

More information

Electric motor testing

Electric motor testing Electric motor testing MOTOR (MODELS EJ4-4001 AND EJ8-4001A) 23 GENERAL INFORMATION The vehicle is equipped with a 48-volt DC, shunt-wound, reversible traction motor. The shunt-wound motor is designed

More information

1984 Dodge W250 PICKUP

1984 Dodge W250 PICKUP 1984 Dodge W250 PICKUP Submodel: Engine Type: V8 Liters: 5.2 Fuel Delivery: CARB Fuel: GAS Dana 44 MODELS THROUGH 1984 2. Raise and safely support the vehicle, then remove the wheel hub and bearings as

More information

RO Automatic trailer coupling. Repair instructions. 5KPVM02000 Towing Hitch Automatic Rockinger RO244A

RO Automatic trailer coupling. Repair instructions. 5KPVM02000 Towing Hitch Automatic Rockinger RO244A utomatic trailer coupling Repair instructions 5KPVM02000 Towing Hitch utomatic Rockinger RO244 5KPVM02010 Towing Hitch utomatic Rockinger foot operated RO244L Contents 1 General Validity and application

More information

4. MAINTENANCE MANUAL

4. MAINTENANCE MANUAL 4. MAINTENANCE MANUAL 4.1 INTRODUCTION The maintenance program has been developed by ORIENTAL in accordance to our supplier s own maintenance program for each component. Conforming to this maintenance

More information

Transmission Overhaul Procedures-Bench Service

Transmission Overhaul Procedures-Bench Service How to Assemble the Lower Reverse Idler Gear Assembly Special Instructions In 1996 Eaton changed the reverse idler system design. In the nut design, the reverse idler bearing was lubricated through a hole

More information

DM-SG (English) Dealer s Manual. Nexus. Inter-8 Inter-7 Inter-5

DM-SG (English) Dealer s Manual. Nexus. Inter-8 Inter-7 Inter-5 (English) DM-SG0003-06 Dealer s Manual Nexus Inter-8 Inter-7 Inter-5 CONTENTS MODELS COVERED BY THIS DEALER S MANUAL...4 IMPORTANT NOTICE...5 TO ENSURE SAFETY...6 LIST OF TOOLS TO BE USED...12 INSTALLATION...14

More information

Once properly aligned weld axle saddles to axle using welding practice as below.

Once properly aligned weld axle saddles to axle using welding practice as below. INSTALLATION & MAINTENANCE GUIDE 50 Series Suspensions Shackle bolts and rocker pivot bolts fitted with Nyloc type nuts must be tightened firmly allowing for rotational movement of bushed components. All

More information

2005 Hyundai Tucson LX. On some models, engine is equipped with a timing belt and timing chain. Inspect timing chain when replacing timing belt.

2005 Hyundai Tucson LX. On some models, engine is equipped with a timing belt and timing chain. Inspect timing chain when replacing timing belt. TIMING BELT NOTE: On some models, engine is equipped with a timing belt and timing chain. Inspect timing chain when replacing timing belt. Removal 1. Remove the engine cover. See Fig. 1. 2. Remove right

More information

Standard Valves Series Globe Valves Series Angle Valves Series Way-Valves

Standard Valves Series Globe Valves Series Angle Valves Series Way-Valves Installation, Operation, Maintenance Instructions Standard Valves Series 035 000 Globe Valves Series 031 000 Angle Valves Series 033 000 3-Way-Valves 1 GENERAL INFORMATION These instructions are designed

More information

TECUMSEH/PEERLESS LTH Model Transaxle Supplement

TECUMSEH/PEERLESS LTH Model Transaxle Supplement TECUMSEH/PEERLESS LTH Model Transaxle Supplement This supplemental repair manual has been created to provide service information for the LTH model transaxle. This information will be incorporated into

More information

Husqvarna Hedgetrimmers 325HS/ 325HE/ 325HDA. Workshop manual

Husqvarna Hedgetrimmers 325HS/ 325HE/ 325HDA. Workshop manual Husqvarna Hedgetrimmers 325HS/ 325HE/ 325HDA Workshop manual 101 90 73-26 2 Workshop Manual Hedge trimmers Supplement for models 325HS, 325HE,325HDA Contents 1. Starter 5 2. Ignition system 7 3. Fuel system

More information

Rear axle, servicing (frontwheel-drive

Rear axle, servicing (frontwheel-drive Page 1 of 26 42-1 Rear axle, servicing (frontwheel-drive vehicles) WARNING! Do not attempt to weld and/or straighten the axle beam. Do not re-use fasteners that are worn or deformed in normal use. Some

More information

Operating Manual for Disc Brake Type: SB 28

Operating Manual for Disc Brake Type: SB 28 for Disc Brake Type: PINTSCH BUBENZER GmbH Postfach 123 57540 Kirchen-Wehbach Tel.: +49-2741 - 9488-0 Fax: +49-2741 - 9488-44 G E R M A N Y www.pintschbubenzer.de e-mail: info@pintschbubenzer.de PB28-0508-01/1

More information

REAR AXLE Click on the applicable bookmark to selected the required model year

REAR AXLE Click on the applicable bookmark to selected the required model year REAR AXLE 27-2 REAR AXLE General Information GENERAL INFORMATION 27100010118 The rear axle is a banjo-type semi-floating type. The axle shaft bearings are: *Single taper bearings for vehicles without

More information

Z3 Air (80) GENERAL. BAM: Bomber Aerospace Material. Special alloy developed from aerospace material. Ø TRAVEL 80 L.MAX=461 L.L.=451 L.

Z3 Air (80) GENERAL. BAM: Bomber Aerospace Material. Special alloy developed from aerospace material. Ø TRAVEL 80 L.MAX=461 L.L.=451 L. (80) 175 18 80 Ø30 +0.05 0 55 L.MAX=461 L.L.=451 L.MIN=371 396 ±0,1 TRAVEL 80 ±2 Ø30 15 20 0-0.1 +1 0 248 GENERAL Special air/oil damped cross-country fork: each leg uses pressurized air blown through

More information

Z3 QR20 (110) GENERAL

Z3 QR20 (110) GENERAL (11) 175 18 8 Ø3 +.5 L.MAX=491 L.L.=481 ±2 L.MIN=371 426 55 ±2 TRAVEL 11 Ø3 15 2 -.1 +1 248.5 GENERAL The fork is sprung by a mechanical coil system and uses hydraulic rebound damping. Spring pre-load

More information

Maintenance instructions. BPW Trailer Axles and Suspensions. BPW-W e

Maintenance instructions. BPW Trailer Axles and Suspensions. BPW-W e Maintenance instructions BPW Trailer Axles and Suspensions BPW-W 33111401e Page 2 BPW-W 33111401e BPW-W 33111401e Page 3 Contents Important information 1 1. Important information... Page 3 1.1 General

More information

CHASSIS CONTENTS FRONT WHEEL 6-1 FRONT BRAKE 6-6 FRONT FORK 6-14 STEERING STEM 6-20 REAR WHEEL AND REAR BRAKE 6-25 SUSPENSION 6-31 REAR SWING ARM 6-36

CHASSIS CONTENTS FRONT WHEEL 6-1 FRONT BRAKE 6-6 FRONT FORK 6-14 STEERING STEM 6-20 REAR WHEEL AND REAR BRAKE 6-25 SUSPENSION 6-31 REAR SWING ARM 6-36 CHASSIS CONTENTS FRONT WHEEL 6-1 FRONT BRAKE 6-6 FRONT FORK 6-14 STEERING STEM 6-20 REAR WHEEL AND REAR BRAKE 6-25 SUSPENSION 6-31 REAR SWING ARM 6-36 6 6-1 CHASSIS FRONT WHEEL REMOVAL Support the machine

More information

Timing Belt: Service and Repair

Timing Belt: Service and Repair 2000 Hyundai Sonata L4-2.4L Page 1 Timing Belt: Service and Repair REMOVAL 1. Remove the crankshaft pulley, engine coolant pump pulley and drive belt. 2. Remove the timing belt cover. 2000 Hyundai Sonata

More information

SD Bendix A2LS Hydraulic Drum Brakes w/parking DESCRIPTION

SD Bendix A2LS Hydraulic Drum Brakes w/parking DESCRIPTION SD-20-6608 Bendix A2LS Hydraulic Drum Brakes w/parking DIRT SHIELD CROSS-OVER PIPE RETAINING SPRING WHEEL CYLINDER END SHOE RETURN SPRING CROSS-OVER PIPE CAP SCREWS EXPANDER END SHOE RETURN SPRING WHEEL

More information

Öhlins Front Fork for. Motocross and Enduro. Owner s Manual

Öhlins Front Fork for. Motocross and Enduro. Owner s Manual Öhlins Front Fork for Motocross and Enduro Owner s Manual Safety Precautions The front fork is a very important part of the vehicle and will therefore affect the stability. Read and make sure that you

More information

Z3 Coil (80) GENERAL. BAM: Bomber Aerospace Material. Special alloy developed from aerospace material. Ø TRAVEL 80 55

Z3 Coil (80) GENERAL. BAM: Bomber Aerospace Material. Special alloy developed from aerospace material. Ø TRAVEL 80 55 (8) 175 8 Ø3 +.5 L.MAX=461 L.L.=451 L.MIN=371 ±2 396 TRAVEL 8 55 18 Ø3 15 2 -.1 +1 248.5 GENERAL The fork is sprung by a mechanical coil system and uses hydraulic rebound damping. Spring pre-load adjustment

More information

ORIGA SYSTEM PLUS Guides, Brakes and Valves for Modular Linear Drive Systems OSP Appendix to the Operating Instructions

ORIGA SYSTEM PLUS Guides, Brakes and Valves for Modular Linear Drive Systems OSP Appendix to the Operating Instructions ORIGA SYSTEM PLUS Guides, Brakes and Valves for Modular Linear Drive Systems OSP Appendix to the Operating Instructions TAll personnel who have anything to do with the OSP fitted with guides, brakes or

More information

Technical Description Edition 2007 Mounting, maintenance and repair of propshafts with flanged universal joints

Technical Description Edition 2007 Mounting, maintenance and repair of propshafts with flanged universal joints Technical Description Edition 2007 Mounting, maintenance and repair of propshafts with flanged universal joints 1. Recommendations Assembly, disassembly, maintenance and repair of propshafts should be

More information

Servicing front brakes

Servicing front brakes 46-1 Servicing front brakes C54 brake caliper, servicing Special tools and workshop equipment required VAG 1331 Torque wrench (or equivalent) VAG 1410 Torque wrench (or equivalent) VAG 1869/2 Brake pedal

More information

1 Part Number: M-2300-Y Part Description: S550 Mustang-Shelby Brake Upgrade Kit Installation Instructions

1 Part Number: M-2300-Y Part Description: S550 Mustang-Shelby Brake Upgrade Kit Installation Instructions Please visit www.performanceparts.ford.com for the most current instruction and warranty information. PLEASE READ ALL OF THE FOLLOWING INSTRUCTIONS CAREFULLY PRIOR TO INSTALLATION. AT ANY TIME YOU DO NOT

More information

TROUBLESHOOTING SPECIAL TOOL ASSEMBLY AND ADJUSTMENT

TROUBLESHOOTING SPECIAL TOOL ASSEMBLY AND ADJUSTMENT 1 INDEX Models FD, FE, FF and SG REAR AXLE 10-1 10-108E-07 CHAPTER 10 REAR AXLE Models FD, FE, FF and SG TROUBLESHOOTING...10-2 10 SPECIAL TOOL...10-3 WHEEL HUB AND RELATED PARTS DISASSEMBLY...10-7 INSPECTION...10-9

More information

Maintenance instructions. BPW Trailer Axles and Suspensions. BPW-W e

Maintenance instructions. BPW Trailer Axles and Suspensions. BPW-W e Maintenance instructions BPW Trailer Axles and Suspensions BPW-W 33111501e Page 2 BPW-W 33111501e Contents 1. Important information... Page 3 1.1 General Page 3 1.2. Maintenance, repair and spare parts

More information

Installation Instructions LamboStyleDoors

Installation Instructions LamboStyleDoors Installation Instructions LamboStyleDoors (The instruction refers only to one side of the car, but is valid for both sides) Preparations: (Dismantling according to the regulation of the car manufacturer)

More information

Hydraulic Motors. Radial Piston Motors with fixed displacement Series RM...X Vg = 250 cm³/u cm³/u. Repair manual. Doc.-No.

Hydraulic Motors. Radial Piston Motors with fixed displacement Series RM...X Vg = 250 cm³/u cm³/u. Repair manual. Doc.-No. Hydraulic Motors Radial Piston Motors with fixed displacement Series RM...X Vg = 250 cm³/u - 900 cm³/u Doc.-No. HM3-005 UK Seite 2 Table of contents 1. General... 3 2. Dismantling the distributor unit...

More information

REMOVAL & INSTALLATION

REMOVAL & INSTALLATION REMOVAL & INSTALLATION CAUTION: This application is an interference engine. Do not rotate camshaft or crankshaft when timing belt is removed, or engine damage may occur. TIMING BELT Removal 1. Raise and

More information

1988 Chevrolet Pickup V SUSPENSION - FRONT (4WD)' 'Front Suspension - "V" Series 1988 SUSPENSION - FRONT (4WD) Front Suspension - "V" Series

1988 Chevrolet Pickup V SUSPENSION - FRONT (4WD)' 'Front Suspension - V Series 1988 SUSPENSION - FRONT (4WD) Front Suspension - V Series 1988 SUSPENSION - FRONT (4WD) Front Suspension - "V" Series DESCRIPTION NOTE: Vehicle serial numbers used in this article has been abbreviated for common reference to Chevrolet and GMC models. Chevrolet

More information

SECTION ZF FRONT AXLE

SECTION ZF FRONT AXLE 04-101.01/ 1 2011JA14 SECTION 04-101.01 6 3 5 1 2 9 1. Upper radius rod 2. Lower radius rod 3. Caliper 4. BRAKE Disk 5. Pneumatic connector 6. Hub 7. steering knuckle 8. Grease Fitting 9. Pneumatic connector

More information

Z5 Coil (80) GENERAL. BAM: Bomber Aerospace Material. Special alloy developed from aerospace material. Ø TRAVEL 80 55

Z5 Coil (80) GENERAL. BAM: Bomber Aerospace Material. Special alloy developed from aerospace material. Ø TRAVEL 80 55 (8) 175 8 Ø3 +.5 L.MAX=461 L.L.=451 L.MIN=371 ±2 396 ±2 TRAVEL 8 55 18 Ø3 15 2 -.1 +1 248.5 GENERAL The fork is sprung by a mechanical coil system and uses hydraulic rebound damping. Spring pre-load adjustment

More information

Super T QR20 INSTRUCTIONS GENERAL RULES

Super T QR20 INSTRUCTIONS GENERAL RULES INSTRUCTIONS GENERAL RULES 1. Where specified, assemble and disassemble the shock absorption system using the MARZOCCHI special tools only. 2. On reassembling the suspension system, always use new seals.

More information

BRAKE SYSTEM Return To Main Table of Contents

BRAKE SYSTEM Return To Main Table of Contents BRAKE SYSTEM Return To Main Table of Contents GENERAL... 2 BRAKE PEDAL... 10 MASTER CYLINDER... 13 BRAKE BOOSTER... 16 BRAKE LINE... 18 PROPORTIONING VALVE... 19 FRONT DISC BRAKE... 20 REAR DRUM BRAKE...

More information

A-320 Balanced 1st Stage

A-320 Balanced 1st Stage Technical Manual A-320 Balanced 1st Stage A Manual for Repair and Maintenance Technicians View: Select Full Screen mode to use page arrows. FEATURES Extra durable satin chrome plated brass body. Fully

More information

Maintenance instructions. BPW Trailer Axles and Suspensions. BPW-W e

Maintenance instructions. BPW Trailer Axles and Suspensions. BPW-W e Maintenance instructions BPW Trailer Axles and Suspensions BPW-W 33111401e Page 2 BPW-W 33111401e BPW-W 33111401e Page 3 Contents Important information 1 1. Important information... Page 3 1.1 General

More information

SISU DP-330 DRIVE GEAR. Maintenance Manual

SISU DP-330 DRIVE GEAR. Maintenance Manual SISU DP-330 DRIVE GEAR Maintenance Manual Sisu Axles, Inc. Autotehtaantie 1 PO Box 189 Fin-13101 Hameenlinna Finland Phone +358 204 55 2999 Fax +358 204 55 2900 DP330DG.PDF (3/2007) TABLE OF CONTENTS

More information

BPW Trailer Axles and Suspensions

BPW Trailer Axles and Suspensions BPW BERGISCHE ACHSEN Maintenance instructions BPW Trailer Axles and Suspensions MAINTENANCE INSTRUCTIONS . IMPORTANT INFORMATION CONTENTS: Page. IMPORTANT INFORMATION.. General.. Maintenance, repair and

More information

CAUTION. 2. Remove the wheel cover or nut covers, as required. Remove the wheel and tire assembly.

CAUTION. 2. Remove the wheel cover or nut covers, as required. Remove the wheel and tire assembly. Стр. 1 из 16 REAR DRUM BRAKES CAUTION Brake shoes may contain asbestos, which has been determined to be a cancer causing agent. Never clean the brake surfaces with compressed air! Avoid inhaling any dust

More information

DelTorq Series 21 ACTUATOR

DelTorq Series 21 ACTUATOR Jamieson Equipment Company DelTorq Series 21 ACTUATOR INSTALLATION, OPERATION AND MAINTENANCE MANUAL ENGINEERING DATA SHEET E.D.S. NO EDS055 ISSUE DATE - -- 20/01/2007 (Please read the entire instructions

More information