"HS-2A" DISC BRAKE UNIT CALIPER

Transcription

1 "HS-2A" DISC BRAKE UNIT CALIPER Part No February, 2004 This document is comprised of pages i through viii and pages 1 through 27. Copyright 2004 Wabtec Corporation. P.O. BOX 11 SPARTANBURG, SC February, , S.03

2 REVISIONS DATE 2/04 New Document REVISION INFORMATION February, 2004 ii , S.03

3 TABLE OF CONTENTS Section Title Page Revisions... ii Table of Contents... iii List of Figures... iv CHAPTER 1 - HS-2 DISC BRAKE UNIT CALIPER 1.0 GENERAL DESCRIPTION a. Introduction And Features i. General Description ii. Physical Characteristics iii. Product Features iv. Inputs OPERATIONAL DESCRIPTION a. APPLY RELEASE b. ANNUNICATION c. SLACK ADJUSTMENT d. MANUAL RELEASE SAFETY AND WARNINGS MAINTENANCE INFORMATION a. Maintenance Supplies b. Maintenance Schedule i. Daily Inspection and Maintenance ii. Six Months Inspection And Maintenance iii. Brake Lining Replacement TROUBLESHOOTING PARTS CATALOG INFORMATION OVERHAUL INFORMATION a. Overhaul Supplies b. Overhaul Schedule c. Removal From Car d. Disassemble i. Exterior Disassembly ii. Internal Disassembly e. Cleaning f. Inspection g. Assembly i. Bushings and Rings ii. Interior Assembly iii. Exterior Assembly TESTING INFORMATION February, 2004 iii , S.03

4 LIST OF ILLUSTRATIONS Figure Title Page CHAPTER 1 - HS-2 DISC BRAKE UNIT CALIPER Figure HS-2 DISC BRAKE UNIT, Assembled View Figure HS-2 DISC BRAKE UNIT, Apply Release Diagrammatic Figure HS-2 DISC BRAKE UNIT, Annunciation Diagrammatic Figure HS-2 DISC BRAKE UNIT, Slack Adjustment Diagrammatic Figure HS-2 DISC BRAKE UNIT, Manual Release Diagrammatic Figure HS-2 DISC BRAKE UNIT, Exploded View Figure HS-2 DISC BRAKE UNIT CALIPER, Exploded View (Sheet 1 of 2) Figure HS-2 DISC BRAKE UNIT CALIPER Exploded View, (Sheet 2 of 2) February, 2004 iv , S.03

5 Chapter 1 - GENERAL DESCRIPTION Introduction And Features Figure 1 -, Assembled View NOTE: THE FOLLOWING DESCRIPTION AND OPERATION IS BASED ON THIS DEVICE AND ITS COMPONENTS BEING NEW OR THIS DEVICE AND ITS COMPONENTS HAVING BEEN REPAIRED, TESTED, INSTALLED AND MAINTAINED IN ACCORDANCE WITH INSTRUCTIONS ISSUED BY THE APPROPRIATE GOVERNING BODIES AND THIS AND ANY OTHER APPLICABLE WABCO TRANSIT DIVISION PUBLICATION. 1.0 GENERAL DESCRIPTION Figure 1 - page 1 Figure 6 - page 12 Figure 7 - page 16 Figure 7 - page 16 a. Introduction And Features i. General Description The is a spring applied hydraulic release, floating Caliper Disc Brake Unit. It is designed to be installed directly on the February, , S.03

6 Chapter 1 - OPERATIONAL DESCRIPTION Propulsion Motor over a solid brake disc to provide friction braking. The is equipped with a manual release lever, automatic adjustment feature and annunciation switches to indicate applied or released and manual release brake. ii. Physical Characteristics CHARACTERISTIC WEIGHT OUTPUT FORCE MAXIMUM OPERATING PRESSURE iii. Product Features Automatic adjustment capability iv. Inputs Voltage from applicable control unit 2.0 OPERATIONAL DESCRIPTION Figure 2 - page 4 a. APPLY RELEASE SPECIFICATION 65 lbs 1,150 zero pressure 700 psig Under normal running conditions, the Disc Brake Caliper is held in the release mode (OFF) with hydraulic pressure acting on Piston (6) that compresses disc springs (7). The hydraulic pressure is contained be-tween T- Seals (4) and (5). When a brake application is called for, hydraulic pressure acting on Piston (6) is reduced causing the Disc Springs (7) to expand and exert a predetermined amount of force on the Piston (6). The spring force is transferred to the movable Brake Head (61) through Piston (6) acting on Adjusting Screw (13) which in turn acts on Slack Adjuster Nut (30). b. ANNUNICATION Reference: Figure 3 - page 5 Annunciation for the apply and release modes is achieved by the rotation of Switch Lever (72) acting on Micro Switch (73). The pivoted lever rotation is caused by the lateral movement of Piston (6) to the left during a brake application. When the brake is released, Piston (6) moves to the right and the Switch Lever (72) is pushed back to initial position by Spring (76). Manual cut out is annunciated by Switch (52). c. SLACK ADJUSTMENT Reference: Figure 4 - page 6 The is designed to operate at a predetermined constant clearance between the Brake Shoes (101) and the Brake Disc (61). In order to maintain this clearance at all times, brake lining wear is compensated for by the incremental extension of Slack Adjuster Nut (30) during normal operation when the brakes are applied and released. Brake application causes the piston (6) to move right. The piston (6) locks on the cone clutch of the Slack Adjustment Screw (13). Slack adjustment screw (13) moves to the right, along with the slack adjusting nut (30), friction ring (18) and the retaining rings (19) until the friction ring (18) hits the front cover (21). Then slack adjusting nut (30) goes through the cover (21). Friction ring (18) and retaining rings. (19) slide on slack adjusting nut (30), if needed. If design clearance between the Brake Pads (101) and the brake disc (61), [determined by the gap between the flange of the Friction Ring (18) and Cover (21)] is exceeded, Slack Adjuster Nut (30) is forced to slide through the Friction Ring (18) after reaching its stop on Cover (21). The travel of Slack February, , S.03

7 Chapter 1 - SAFETY AND WARNINGS Adjuster Nut (30) past friction ring stop is equivalent to lining wear. When the brake is released. springs (16) and (60) force Brake Head (61), Slack Adjusting Nut (30) and Slack Adjusting Screw (13) to follow Piston (6) to the right until the Friction Ring (18) reaches its stop on Slack Adjuster Housing (17). The frictional force between Slack Adjuster Ring (18) and Slack Adjuster Nut (30) prevents any further movement of Slack Adjuster Nut (30). Spring (60) continues to force Slack Adjusting Screw (13) causing it to rotate (CCW) on Thrust Bearing (14) until it makes contact with Piston (6). d. MANUAL RELEASE Reference: Figure 5 - page 7 If hydraulic power is lost the brake will be applied. Manual release of the brake is accomplished by rotating the Release Arm (40) CW to 90 o from the release area stop on the hanger. Release Arm (40) is directly keyed to release Cam Shaft (37). When rotated, the ramp of Release Cam (37) forces Release Lever (31) to rotate clockwise (CW) around Pivot Pin (33) and force Actuating Piston (6) to the left, caging Disc Springs (7). WARNING: BOTTLED UP AIR UNDER PRESSURE (EVEN THOUGH AIR SUPPLY IS CUT-OFF) MAY CAUSE GASKETS AND/OR PARTICLES OF DIRT TO BECOME AIRBORNE AND AN INCREASE IN SOUND LEVEL WHEN THIS DEVICE AND/OR ANY COMPONENT PART IS REMOVED FROM THE EQUIPMENT ARRANGEMENT. PERSONAL EYE AND EAR PROTECTION MUST BE WORN AND CARE TAKEN TO AVOID POSSIBLE INJURY WHEN PERFORMING ANY WORK ON THIS DEVICE AND/OR COMPONENT PART. WARNING: THE USE OF AN AIR JET, WHICH MUST BE LESS THAN 30 PSIG TO BLOW PARTS CLEAN OR TO BLOW THEM DRY AFTER BEING CLEANED WITH A SOLVENT WILL CAUSE PARTICLES OF DIRT AND/OR DROPLETS OF THE CLEANING SOLVENT TO BE AIRBORNE. THESE CONDITIONS MAY CAUSE SKIN AND/OR EYE IRRITATION. WARNING: WHEN USING AN AIR JET DO NOT DIRECT IT TOWARD ANOTHER PERSON. IMPROPER USE OF AIR JET COULD RESULT IN BODILY INJURY. d 3.0 SAFETY AND WARNINGS WARNING: THE FOLLOWING STATEMENTS OF WARNING APPLY ALL OR IN PART WHEREVER THE W SYMBOL OR D SYMBOL APPEARS IN ANY PROCEDURES CONTAINED WITHIN THIS DOCUMENT. FAILURE TO OBSERVE THESE PRECAUTIONS MAY RESULT IN SERIOUS INJURY TO THOSE PERFORMING THE WORK AND/OR BYSTANDERS. WARNING: PERSONAL EYE PROTECTION MUST BE WORN WHEN PERFORMING ANY WORK ON THIS DEVICE OR ITS COMPONENT PARTS TO AVOID ANY POSSIBLE INJURY TO THE EYES. WARNING: THE USE OF SOLVENTS AS CLEANING AGENTS AND THE USE OF LUBRICANTS CAN INVOLVE HEALTH AND/OR SAFETY HAZARDS. THE MANUFACTURERS OF THE SOLVENTS AND LUBRICANTS SHOULD BE CONTACTED FOR SAFETY DATA (SUCH AS OSHA FORM OSHA-20 OR ITS EQUIVALENT). THE RECOMMENDED PRECAUTIONS AN February, , S.03

8 Chapter 1 - SAFETY AND WARNINGS Figure 2 -, Apply Release Diagrammatic February, , S.03

9 Chapter 1 - SAFETY AND WARNINGS Figure 3 -, Annunciation Diagrammatic February, , S.03

10 Chapter 1 - SAFETY AND WARNINGS CONE CLUTCH Figure 4 -, Slack Adjustment Diagrammatic February, , S.03

11 Chapter 1 - SAFETY AND WARNINGS TRAVEL STOP For Manual Release, Rotate 90 Degrees Away From Stop 40 ACTUATOR HANDLE Figure 5 -, Manual Release Diagrammatic February, , S.03

12 Maintenance Supplies 4.0 MAINTENANCE INFORMATION a. Maintenance Supplies WABCO TD Specification Number Solvent Lithium Grease b. Maintenance Schedule NOTE: Description of Supply *Cleaning Solvent M *The cleaning solvent MUST BE an aliphatic organic solution, such as mineral spirits or kerosene that will dissolve oil or grease and that will permit parts to be cleaned without abrasion. Daily. Period 6 Months Maintenance Task Daily inspection and. Six months inspection and STANDARD OWNER OPERATING PROPERTY PROCEDURES USED FOR A CAR SHUTDOWN, PRIOR TO PERFORMING MAINTENANCE, MUST BE FOLLOWED. i. Daily Inspection and Maintenance 1. During the daily car checkout procedure before the car is put into service the thickness of the brake shoes must be visually checked. 2. Proper steps must be taken to protect inspecting personnel from injury, such as placing a suitable placard indicating that an inspection is in process and applying wheel chocks to prevent vehicle movement. 3. The brake 'shoes are to be replaced when the thickness of the friction material is 1/8 inch or less at any point on either pad. (See Lining Replacement - Section 4.0, Page 4-4) 4. Remove all warning placard and wheel chocks when inspection is completed. WARNING: PERSONAL EYE PROTECTION MUST BE WORN WHEN PERFORMING ANY WORK ON THIS DEVICE OR ITS COMPONENT PARTS TO AVOID ANY POSSIBLE INJURY TO THE EYES. WARNING: THE USE OF SOLVENTS AS CLEANING AGENTS AND THE USE OF LUBRICANTS CAN INVOLVE HEALTH AND/OR SAFETY HAZARDS. THE MANUFACTURERS OF THE SOLVENTS AND LUBRICANTS SHOULD BE CONTACTED FOR SAFETY DATA (SUCH AS OSHA FORM OSHA-20 OR ITS EQUIVALENT). THE RECOMMENDED PRECAUTIONS AND PROCEDURES OF THE MANUFACTURERS SHOULD BE FOLLOWED. WARNING: ASSEMBLY MAY BE UNDER A SPRING LOAD. EXERCISE CAUTION DURING DISASSEMBLY SO THAT NO PARTS FLY OUT AND CAUSE BODILY INJURY WARNING: FAILURE TO ADHERE TO SAFETY PROCEDURES AND WARNINGS COULD RESULT IN INJURY TO PERSONNEL AND/OR DAMAGE Reference: Figure 6 - page 12 ( ii. Six Months Inspection And Maintenance 1. Visually inspect Hanger Bracket (1) for cracks or wear. Replace if necessary , S.03 8 February, 2004

13 Chapter 1 - MAINTENANCE INFORMATION Maintenance Schedule 2. Visually inspect the black and red Mount Isolators (2) and (4). Replace if worn or cut. 3. Apply grease to Rod Guide (3) through provided grease fittings. Use Lithium Molybdenum Disulfide grease (WABCO Spec. M ). 4. After work is completed, remove warning placards and wheel chocks before attempting to move the vehicle. iii. Brake Lining Replacement Reference: Figure 6 - page 12 WARNING: TO PREVENT POSSIBLE INJURY AND/OR PROPERTY DAMAGE, WHEEL CHOCKS MUST BE PLACED UNDER THE VEHICLE WHEELS TO PREVENT MOVEMENT. ALSO, WARNING PLACARDS ARE TO BE PLACED IN THE CAB(S) AREA INDICATING THAT WORK IS BEING PERFORMED ON THE VEHICLE. 5. Install new pads and secure in place with new screws (10) and lockwashers (11) for brake pad mounted on Brake Head (61) and 1/2-28 x l 3/8 (14) for brake pad mounted on Backing Plate (63). Torque to 8 ft-lbs. 6. Rotate Slack Adjuster Screw Counter Clockwise (CCW) 1/4 turn to assure screw moves freely. 7. Install End Cap (68) 8. Apply and release brakes several times, so that proper clearance between brake pads and brake disc is achieved. Remove warning placards and wheel chocks. Return vehicle to service IMPORTANT: TO REPLACE THE BRAKE LININGS THE BRAKES MUST BE RELEASED. 1. Remove Brake Lining (13) by removing three 1/4-28 x 1-3/8 long Screws (14). 2. Remove Brake Lining (12) by removing three 1/4-28 x 5/8 long Screws (10) and Lock Washers (11). Reference: Figure 6 - page Remove Hex End Cap (68). 4. With square end of Slack Adjuster Screw (13) exposed, rotate Slack Adjuster Screw (13) clockwise (CW) to retract Slack Adjuster Nut (11) and Brake Head (61) until Brake Head (61) contacts Caliper Body. February, , S.03

14 Maintenance Schedule 5.0 TROUBLESHOOTING NOTE: FOR ANY GIVEN SYMPTOM, WORK THROUGH THE POSSIBLE CAUSES IN THE SEQUENCE GIVEN (PROCEED TO THE NEXT POSSIBLE CAUSE ONLY IF THE PREVIOUS POSSIBLE CAUSE AND INSPECTION CHECK OUT AS BEING NORMAL. TROUBLESHOOTING SYMPTOM POSSIBLE CAUSE INSPECTION CORRECTIVE ACTION HS-2A DISC BRAKE UNIT Not Applying HS-2A DISC BRAKE UNIT Not Providing Sufficient Braking Effort. Insufficient Brake Cylinder Pressure Damaged HS-2A DISC BRAKE UNIT Brake Shoe(s) Worn Excessively Insufficient Brake Cylinder Pressure Damaged Slack Adjuster Mechanism Brake Cylinder Line not cut-in Inspect for leakage in brake cylinder Inspect for leakage in Brake Cylinder Line Verify other car tread brake unit(s) functioning normally. Inspect Brake Shoe(s) according to criteria in Maintenance Section Inspect for leakage HS-2A DISC BRAKE UNIT cylinder Inspect for leakage in Brake Cylinder Line Back brake shoe off using slack adjuster nut (according to procedure in Maintenance Section) and verify operation by cycling brakes several times. Cut-in Brake Cylinder Line to HS-2A DISC BRAKE UNIT (open associated cutout valve). Isolate leakage by listening for audible signs and/or applying leak detection soap to the tread brake(s) that are not applying. Repair and/or remove and replace Leaking. Isolate leakage and repair. Remove and replace damaged HS-2A DISC BRAKE UNIT. Replace worn brake shoe(s). Isolate leakage by listening for audible signs and/or applying leak detection soap to the tread brake(s) that are not applying. Repair and/or remove and replace Leaking. Isolate leakage and repair. Remove and replace damaged HS-2A DISC BRAKE UNIT. 6.0 PARTS CATALOG INFORMATION Figure 6 - page 12 NOTE: DESCRIPTIVE PARTS NAME IN THE CURRENT ISSUE OF THE WABCO TRANSIT DIVISION PARTS CATALOG , S.03 TO ENSURE THAT THE DESIRED PART IS ORDERED. THE REFERENCE NUMBERS USED IN THIS PUBLICATION AND THOSE USED IN THE PARTS CATALOG MAY DIFFER. REFER TO THE , S February, 2004

15 Chapter 1 - PARTS CATALOG INFORMATION Maintenance Schedule Fig. & Ref. No. Authority Part No. Wabtec Part No. PARTS DESCRIPTION Ref BRACKET, Hanger MOUNT, Isolation (Black) GUIDE, Rod MOUNT, Isolation (Red) SCREW, Hex., 3/8 x1,soc. Hd. Cap STOP, Travel SCREW, Machine, 3/8 x 16 UNC x 5/8 Ig SPACER, Mounting CALIPER ASSEMBLY, HS-2 Disc Brake (Includes 1 items 1-10 thru 1-14) SCREW, Hex Hd. Cap, 1/4-28UNF x 5/8" Ig WASHER, Spring Lock, 1/4", PIt. Steel BRAKE SHOE, Universal BRAKE SHOE, Universal SCREW, Pl Hd Soc Cap, UNC-2A x1-1/2. 3 C WIRE, 052D 2 ft These items are required for installing the HS-2A DISC BRAKE UNIT on car but are not supplied by WABCO PTD as part of the No Number BOLTS, Hex Head, 1/2-13 UNC-2A x 6-1/4 lg LOCKWASHERS, Spring, 1/2 inch WASHERS, Plain, 1/2 inch, stl 4 QTY. February, , S.03

16 Maintenance Schedule Figure 6 -, Exploded View , S February, 2004

17 Chapter 1 - PARTS CATALOG INFORMATION Fig. & Ref. No. WABTEC Part No. PART REFERENCE Parts Description Quantity ACTUATOR ASSEMBLY, HS-2 REF BODY, HS BUSHING, Guide Rod BUSHING, Release Pin SEAL, Hydraulic RG2-3/ SEAL, Hydraulic RG3-3/ PISTON, Stepped DISC SPRING, 2.76 OD x 1.20 ID COVER, Stepped Piston GASKET, Piston Cover SCREW, Cap, Hex. Hd., 3/8-16 x 1" 19., Pit NUT, Spring Adjusting SCREW, Shoulder #10-32UNF-2A x 3/4" Lg SCREW, Slack Adjusting BEARING, Thrust WASHER, Thrust SPRING, OD HOUSING, Slack Adjuster RING, Slack Adjuster RING, External Retaining SCREW, 1/4-28 x 1-3/8 lg, Sems COVER, Cp (includes item 22) BUSHING SCREW, Hex. Soc. Hd., #10-24 x 1-3/4" 19., PIt WASHER, Spring Lock, #10, Zinc PIt. Steel RING, Wiper SCREW, Hex. Soc. Hd. Cap WASHER, Spring Lock, #10, Zinc Pit. Steel BOOT, Molded RING, Retaining NUT, Slack Adjuster LEVER, Release Cp (includes item 32) BUSHING PIN, Release Lever RING, Retaining RESERVED FOR FUTURE USE SPRING CAM, Release GUIDE, Release Arm O-RING, 13/16" 0.D. 1 A bolded item denotes an item that must be replaced on each overhaul interval. The reference numbers used in this publication and those used in the Parts Catalog may differ. Refer to the descriptive parts name in the current issue of The WABCO Transit Division Parts Catalog , S.03 to ensure that the desired part is ordered. February, , S.03

18 Maintenance Schedule Fig. & Ref. No. WABTEC Part No. PART REFERENCE Parts Description Quantity ARM, Release RESERVED FOR FUTURE USE 7-42 RESERVED FOR FUTURE USE PIN, Spring FITTING WIPER, Ring COVER GASKET, Cover SCREW, FI Hd Soc Cap, #10-24UNC x 3/8" Ig BRACKET, Switch SCREW, Rd. Hd. #4-40UNC-2A x 1/4" Lg WASHER, Lock, #4, PIt. Steel MICROSWITCH RESERVED FOR FUTURE USE LOCKWASHER, # SCREW, Rd. Hd. #2-56 UNC-2A x.50 Lg PIN, Locating RESERVED FOR FUTURE USE SPACER, Locating Pin BUSHING SPRING, 1.10 OD PLATE, Moveable Brake Head SCREW, PI Hd Soc Cap, UNC-2A x 1-1/ PLATE, Backing WASHER, 1/4" Flat, PIt SCREW, Hex Cap 1/4-28 x.62 Ig NUT, Elastic Stop, 1/4" WASHER, Lock, 1/4", PIt CAP, End RESERVED FOR FUTURE USE SCREW, Shoulder Switch #4-40 UNC-2A x 3/8" Lg BLOCK, Switch Mounting LEVER, Switch MICROSWITCH SCREW, Rd. Hd. #2-56 UNC-2A x.67"lg WASHER, #2 Lock SPRING,.18 O.D SCREW, Hex Hd. Mach., #6-32 UNC x 1-l/8Ig NUT, Adjusting #6-32UNC-2B NUT, Adjusting #6-32UNC-2B 1 A bolded item denotes an item that must be replaced on each overhaul interval. The reference numbers used in this publication and those used in the Parts Catalog may differ. Refer to the descriptive parts name in the current issue of The WABCO Transit Division Parts Catalog , S.03 to ensure that the desired part is ordered , S February, 2004

19 Chapter 1 - PARTS CATALOG INFORMATION Fig. & Ref. No. WABTEC Part No. PART REFERENCE Parts Description Quantity SCREW, Backing Plate SCREW, Low Hex Soc. Hd. Cap, #10-24 x 3/4" WASHER, Spring Lock, #10, Zinc PIt. Steel SCREW, Hex. Hd. Cap WASHER, Spring Lock, #10, Zinc PIt. Steel WASHER, #10 Flat RING, Internal Retaining RESERVED FOR FUTURE USE WASHER, Flat.92 OD RESERVED FOR FUTURE USE WASHER, Lock, 3/8", PIt SCREW, Rd. #4-40UNC-2A x 7/16" Lg WASHER, Lock, #4, PIt. Steel CONNECTOR, Veam GASKET, Connector WASHER, Spring Lock, 1/4", PIt. Steel O-ring, 1.75 od O-RING,.362 id x.103 thk WASHER, Flat 3/8 inch PIN, Cylindrical Spring ADAPTER, Release Guide BRAKESHOE, Universal SCREW, Bleed (Part of item 1) NUT, 2-56, stl NUT, Elastic Stop, 1/4-20, 3B ASSEMBLY, Connector-Switch- Wire Ref MICROSWITCH MICROSWITCH CONNECTOR, Veam GASKET, Connector 1 REF. WIRE SET 1 A bolded item denotes an item that must be replaced on each overhaul interval. The reference numbers used in this publication and those used in the Parts Catalog may differ. Refer to the descriptive parts name in the current issue of The WABCO Transit Division Parts Catalog , S.03 to ensure that the desired part is ordered. February, , S.03

20 Maintenance Schedule Figure 7 - CALIPER, Exploded View (Sheet 1 of 2) , S February, 2004

21 Chapter 1 - PARTS CATALOG INFORMATION Figure 7 - CALIPER Exploded View, (Sheet 2 of 2) February, , S.03

22 Overhaul Supplies 7.0 OVERHAUL INFORMATION a. Overhaul Supplies Application Period WABCO TD Specification Number Description of Supply Passenger Transit 36 Months 36 Months M n/a Lithium Grease b. Overhaul Schedule NOTE: O-RING LUBRICANT, no 2 Silicone, Dow Corning 55 *Cleaning Solvent M M Hydraulic Fluid *The cleaning solvent MUST BE an aliphatic organic solution, such as mineral spirits or kerosene that will dissolve oil or grease and that will permit parts to be cleaned without abrasion. THE FOLLOWING SCHEDULE AND PROCEDURES MUST BE PROPERLY ACCOMPLISHED FOR EQUIPMENT WARRANTY CONDITIONS TO APPLY. THIS SCHEDULED MAINTENANCE SHOULD ALSO ASSIST IN IMPROVING PRODUCT PERFORMANCE OVER AN EXTENDED PERIOD. WABCO TD RESERVES THE RIGHT TO PERIODICALLY MONITOR THESE MAINTENANCE PRACTICES DURING THE WARRANTY PERIOD AND ASSUMES NO RESPONSIBILITY IN FURNISHING PARTS OR LABOR TO MAINTAIN THE FOLLOWING SCHEDULE. THE FOLLOWING SCHEDULE IS THE MINIMUM RECOMMENDED MAINTENANCE SCHEDULE. MORE FREQUENT MAINTENANCE MAY BE REQUIRED IF CONDITIONS SO DICTATE WARNING: THE USE OF AN AIR JET, WHICH MUST BE LESS THAN 30 PSIG TO BLOW PARTS CLEAN OR TO BLOW THEM DRY AFTER BEING CLEANED WITH A SOLVENT WILL CAUSE PARTICLES OF DIRT AND/OR DROPLETS OF THE CLEANING SOLVENT TO BE AIRBORNE. THESE CONDITIONS MAY CAUSE SKIN AND/OR EYE IRRITATION. DANGER: WHEN USING AN AIR JET DO NOT DIRECT IT TOWARD ANOTHER PERSON. IMPROPER USE OF AIR JET COULD RESULT IN BODILY INJURY. WARNING: PERSONAL EYE PROTECTION MUST BE WORN WHEN PERFORMING ANY WORK ON THIS DEVICE OR ITS COMPONENT PARTS TO AVOID ANY POSSIBLE INJURY TO THE EYES. WARNING: THE USE OF SOLVENTS AS CLEANING AGENTS AND THE USE OF LUBRICANTS CAN INVOLVE HEALTH AND/OR SAFETY HAZARDS. THE MANUFACTURERS OF THE SOLVENTS AND LUBRICANTS SHOULD BE CONTACTED FOR SAFETY DATA (SUCH AS OSHA FORM OSHA-20 OR ITS EQUIVALENT). THE RECOMMENDED PRECAUTIONS AND PROCEDURES OF THE MANUFACTURERS SHOULD BE FOLLOWED. WARNING: WHEN PERFORMING ANY TEST OR WORK ON DEVICES OR EQUIPMENT WHILE THEY ARE ON THE VEHICLE (ON CAR , S February, 2004

23 Chapter 1 - OVERHAUL INFORMATION TEST ETC.) SPECIAL PRECAUTIONS MUST BE TAKEN TO INSURE THAT VEHICLE MOVEMENT WILL NOT OCCUR WHICH COULD RESULT IN INJURY TO PERSONNEL AND/OR DAMAGE TO EQUIPMENT. WARNING: ASSEMBLY MAY BE UNDER A SPRING LOAD. EXERCISE CAUTION DURING DISASSEMBLY SO THAT NO PARTS FLY OUT AND CAUSE BODILY INJURY. DANGER: TO PREVENT RECEIVING ELECTRICAL SHOCK WHEN PERFORMING ELECTRICAL TESTS, HANDS MUST BE CLEAR OF ELECTRICAL COMPONENTS, CONTACTS AND HOUSING AND THERE MUST BE NO BODILY CONTACT WITH THE WORK BENCH. FAILURE TO HEED THIS WARNING COULD RESULT IN SEVERE INJURY OR DEATH. WARNING: AN ADEQUATE SUPPORT OR LIFTING DEVICE MUST BE AVAILABLE TO SUPPORT THE DEVICE AND/OR VALVE PORTIONS DURING REMOVAL, INSTALLATION, AND MAINTENANCE PROCEDURES. c. Removal From Car NOTE: FOLLOW CARBUILDER INSTRUCTIONS FOR REMOVING THE FROM ITS POSITION IN THE EQUIPMENT ARRANGEMENT. 1. With brakes released (hydraulic pressure applied) remove Brake Linings as described in Section 4.0 Maintenance paragraph b subsection iii Brake Lining Replacement. 2. Apply the brakes to relieve hydraulic pressure inside Caliper and Hydraulic Line. 3. Disconnect Hydraulic Line to Caliper. 4. Disconnect Electrical Connector from Veam Receptacle on Caliper. 5. Disconnect Manual Release Linkage from Caliper Manual Release Lever. 6. Remove four Hex Head 6 1/2" long, Caliper mounting bolts (not supplied by WABCO Transit Division) to remove Caliper and Hanger Bracket from vehicle. CAUTION: CALIPER ASSEMBLY COMPLETE WEIGHS APPROXIMATELY 45 LBS., USE LIFTING DEVICE OR ASSISTANCE TO SUPPORT WHILE REMOVING FROM VEHICLE AND TRANSPORTING TO BENCH. 7. Transport Caliper Assembly to a work bench. d. Disassemble Figure 6 - page 12 WARNING: ALL OWNER-OPERATING PROPERTY SAFETY PROCEDURES AND THE SAFETY PROCEDURES AND WARNINGS LISTED OF THIS PUBLICATION MUST BE ADHERED TO. IMPORTANT: TO OBTAIN SATISFACTORY OPERATION AND RELIABILITY OF THIS DEVICE, ONLY REPLACEMENT PARTS SUPPLIED BY WABCO PTD ARE TO BE USED IN THE MAINTENANCE OF THIS DEVICE. IMPORTANT: DURING DISASSEMBLY, CARE MUST BE TAKEN NOT TO DAMAGE PARTS. February, , S.03

24 Disassemble i. Exterior Disassembly Reference: Figure 6 - page Clean residue and dirt on outside of Caliper Assembly with a wire brush and cleaning solvent (Naphtha or Mineral Spirits), then blow dry using a low pressure (30 psig) jet of clean dry air. 2. Remove x 3/4 long Shoulder Screw (12). Reference: Figure 7 - page Remove Adjusting Spring Nut (11). This will relieve any residual force remaining in Disc Springs (7). Reference: Figure 6 - page Remove Socket Head Cap Screw (5) and remove Red Isolation Mount (4) on both sides of Hanger Bracket (1). DISCARD Isolation Mounts. 5. Slide out Rod Guide (3) and Black Isolation Mount (2) on both sides of Hanger Bracket (1). 6. Remove Socket Head Cap Screw from other side on Rod Guide and DISCARD Black Isolation Mounts (2). 7. Remove Cover (8) by removing the four 3/8-16 x 1" long Hex Head Cap Screws (10) and Lock Washer (90). DISCARD Gasket (9). ii. Internal Disassembly 1. Remove Disc Springs (7) and DISCARD. 2. Piston (6) can now be pulled out and set aside. 3. Remove Hydraulic Seal (5) and DISCARD. 4. Using a small hammer and a drift punch, remove pin (99) from Release Arm (40). DISCARD pin (99). Remove Release Arm (40). 5. Punch Spring Pin (43) in so that Release Arm Guide (38) can be unscrewed. Do not unscrew at this time. 6. Remove Cover (46) by removing the four x 3/4" long Flat Head Socket Screws (48). DISCARD Gasket (47). Manual Release Mechanism and Micro Switches are now exposed. 7. Unscrew Manual Release Guide (38) from Adapter (100), remove O-Rings (39, 105) and DISCARD. Set Release Guide aside. 8. Remove Release Cam (37), Flat Washer (88) and Spring (36). DISCARD Spring (36). 9. Remove two screws (50) and lockwashers (51) to remove bracket (49) and switches (52, 53) assembly from body (1). DISCARD lockwashers (51). 10. Remove the two #2-56 x 1/2" Long Screws (74) and Washers (75) to release Micro Switch (73). 11. Unscrew the two #2-56 x 1/2" long Screws (55) and Lock Washer (54) to release Micro Switch (52). DISCARD lock washer (54) 12. Unscrew four #4-40 x 7/16" long Screws (91) and Lock Washers (92) to release Veam Connector (93) and Gasket (94). DISCARD gasket (94). 13. CAREFULLY remove Veam Connector (93) and Micro Switches (73) and (52) through the hole where the Veam Connector (93) was removed. 14. Remove two #10-24 x 3/4" long Low Hex Socket Head Cap Screws (81) and Lock Washer (82). 15. Switch Mounting Block (71) and Switch Lever (72) can now be removed , S February, 2004

25 Chapter 1 - OVERHAUL INFORMATION 16. Remove Spring (76) and DISCARD. 17. Remove #4-40 x 3/8 long Shoulder Screw (70) to remove Lever (72) from Switch Mounting Block (71). 18. Unscrew Release Lever Pin (33) and slide out. Remove Manual Release Lever (31). 19. Unscrew two Locating Pins (56). 20. Remove Locating Pin Spacer (58) and Spring (60). DISCARD Spring. 21. Remove Backing Plate Screw (80). Then remove Backing Plate (61) 22. Remove Retaining Ring (29). DISCARD Retaining Ring (29) 23. Remove Molded Boot (28). 24. Remove four #10-24 x 1 3/4 long Socket Head Screws (23) and Lock Washers (24). Reference: Figure 6 - page 12, Figure 7 - page 16 and Figure 7 - page Slack Adjuster Assembly, Items (13) thru (30) and (83) thru (86) can now be removed from "HS-2A" Body (1). Reference: Figure 7 - page Unscrew Socket Head Cap Screw (83) and remove with Spring Lock Washer (84) and Flat Washer (85). 27. Remove Retaining Ring (86) and unscrew Slack Adjuster Screw (13). DISCARD Retaining Ring (86) Reference:Figure 7 - page Remove Thrust Washers (15) and Thrust Bearing (14) and DISCARD. 29. Remove Spring (16) and DISCARD. 30. Remove four Socket Head Screws (26) and Lock Washers (27). DISCARD lockwashers (27). 31. Remove Slack Adjuster Housing (17). 32. Remove three External Retaining Rings (19) and slide out Slack Adjuster Ring (18). DISCARD Retaining Rings (19) and DISCARD Adjuster Ring (18). 33. Push Slack Adjuster Nut (30) through Cover (21). 34. Remove Wiper Ring (25) and DISCARD. 35. Remove Hydraulic Seal (4) from Caliper Body (1) and DISCARD. e. Cleaning Figure 6 - page 12, Figure 7 - page 16 and Figure 7 - page 17 WARNING: THE USE OF AN AIR JET, WHICH MUST BE LESS THAN 30 PSIG, TO BLOW PARTS CLEAN OR DRY WILL CAUSE PARTICLES OF DIRT AND/OR DROPLETS OF THE CLEANING SOLVENT TO BE AIRBORNE. THESE CONDITIONS MAY CAUSE SKIN AND/ OR EYE IRRITATION. WARNING: WHEN USING AN AIR JET, DO NOT DIRECT IT TOWARD ANOTHER PERSON. IMPROPER USE OF AN AIR JET CAN RESULT IN BODILY INJURY. WARNING: THE USE OF SOLVENTS AS CLEANING AGENTS AND THE USE OF LUBRICANTS CAN INVOLVE HEALTH AND/OR SAFETY HAZARDS. IN THE EVENT OF AN EMERGENCY, CONTACT THE MANUFACTURERS OF THE SOLVENTS AND LUBRICANTS FOR SAFETY DATA (SUCH AS OSHA FORM OSHA-20 OR ITS EQUIVALENT). FOLLOW ALL MANUFACTURER RECOM- MENDED PRECAUTIONS AND PROCEDURES. February, , S.03

26 Inspection WARNING: PERSONAL EYE PROTEC- TION MUST BE WORN WHEN PERFORMING ANY WORK ON THIS DEVICE OR ITS COMPONENT PARTS, IN ORDER TO MINIMIZE THE RISK OF PERSONAL INJURY. 1. Wash all parts in the prescribed cleaning solvent (mineral spirits or Naphtha), then blow them completely dry using a low (30 psig) pressure jet of clean air. Set all components on a clean dry surface. f. Inspection Figure 6 - page Inspect Hanger Bracket (1) for wear in Caliper Support Bores or cracks. Replace if worn or cracked. 2. Replace Travel Stop (6) if Rubber Pad is damaged and/or cut. 3. Check diameter of two Guide Rods (3). Discard if diameter is less than.738 inches. 4. Inspect Caliper Body for cracks or scoring in the Hydraulic Cylinder area. Replace Caliper if cracked or cylinder scored. 5. Remove four Wiper Rings (45) and DISCARD. 6. Check inside diameter of four Guide Rod Bushings (2). Diameter must not exceed.752 inch. If larger, press out and DISCARD. 7. Check inside diameter of Release Lever Pin Bushing (3). Diameter must not exceed.382 inches. If larger, press out and DISCARD. 8. Check inside diameter of Release Cam Bushing (35). If diameter is.450 inches or larger, remove and DISCARD. 9. Check diameter of Release Lever Pin (33). Diameter must not be less than.368 inches. If less, discard. 10. Check Cover (46). Replace if bent or scored on Mating Surface. 11. Check inside diameter of two Release Lever Bushings (32). Diameter must not exceed.387 inches. If larger, press out and DISCARD. 12. Check Release Lever (31) for cracks or wear on Contact Crown. DISCARD if cracked or distance from back face to top of Contact Crown is less than.80 inch. 13. Check Release Cam (37) for wear at Cam and Shank on both ends. Cam must not be less than.48 inches from Flat Face to highest point on Cam face. Check length of Shank with square end The length, not including the square, must not be greater than Check overall length of Release Arm Guide (38) and DISCARD if length is less than 1.11 inches. Reference: Figure 7 - page Check inside diameter of Locating Spacer Pin Bushing (59). Diameter must not exceed.660 inches. If larger, press out and DISCARD. 16. Check diameter of Locating Pin (56). DISCARD if diameter is less than.60 inches. 17. Check diameter of Locating Holes of Moveable Brake Head (61). If diameter of either hole is larger than.676 inches, DISCARD. Rod on Moveable Brake , S February, 2004

27 Chapter 1 - OVERHAUL INFORMATION Head must slide freely through Bushing (59). 18. Check outside diameter of Slack Adjuster Nut (30). DISCARD if diameter is less than inches. Also, check Internal Threads, DISCARD if scored or worn. 19. Check Slack Adjuster Screw (13) for wear on Threads and Cone. If worn, DISCARD. Reference: Figure 7 - page Check inside diameter of Cover Sleeve Bushing (22). Remove and DISCARD if diameter is larger than 1.27 inches. 21. Inspect all threaded fasteners for thread damage, bending, shearing and/or any other damage. Replace as required. 22. Replace any part that is damaged and/or may lead to unsatisfactory performance of the. g. Assembly Figure 6 - page 12 i. Bushings and Rings 1. Install NEW Bushings (2) in Body (1), if removed and discarded. 2. Install four NEW Wiper Rings (45). 3. Install NEW Release Pin Bushings (3), if removed and discarded. 4. Install NEW Release Cam Bushings (35), if removed and discarded. Reference: Figure 7 - page Install NEW Bushing (22) in Cover (21), if removed and discarded. ii. Interior Assembly 1. Install NEW Wiper Ring (25) in Cover (21). 2. Slide Slack Adjuster Nut (30) into Cover (21) from back side of Cover until the groove is exposed on the front side of the Cover. Apply Molybdenum Disulfide Base Grease M to the internal threads of the Adjuster Nut. 3. Slip Slack Adjuster Ring (18) on Slack Adjuster Nut (30). 4. Install three NEW Retaining Rings (19) on Slack Adjuster Ring (18) (Directly behind the Flange). 5. Install Slack Adjuster Housing (17) on Cover (21) and secure with four Socket Head Cap Screws (23) and Spring Lock Washers (24). Torque to 45 in-lbs. and Figure 7 - page Slip Spring (16) into bore of Slack Adjuster Housing (17). 7. Apply light coat of Molybdenum Disulfide Grease M to five Thrust Washers (15) and slip into bore of Slack Adjuster Housing (17) and let them rest on Spring (16). 8. Apply light coat of Molybdenum Disulfide Grease M to Thrust Bearing (14) and slip into bore of Slack Adjuster Housing (17) and let is rest on Thrust Washer (15). 9. Slip one Thrust Washer (15) into bore of Slack Adjuster Housing (17) and let it rest on Thrust Bearing (14). Apply light coat of Molybdenum Disulfide Grease M Apply Molybdenum Disulfide Grease M to threads of Slack Adjuster Screw (13). Then install through bore of Slack Adjuster Housing (17) and into February, , S.03

28 Assembly Slack Adjuster Nut (30) until back side of cone rests on Thrust Washer (15). and Figure 7 - page Install NEW Retaining Ring (86) into bore of Slack Adjuster Housing (17) Slack Adjuster Screw (13) must be screwed in further to compress Spring (16) to enable Retaining Ring (86) to be seated in its groove. 12. Install Flat Washer (85), Lock Washer (84) and Socket Head Cap Screw (83) into front bore of Slack Adjuster Nut (30). Torque to 8 ft-lbs. Reference: Figure 6 - page Install new Hydraulic Seals (4) and (5) in Hydraulic Cylinder portion of Caliper Body (1). Apply Hydraulic Fluid (WABCO Transit Division Spec. M ) to Hydraulic Seals. Reference: Figure 6 - page 12 and Figure 7 - page Install Slack Adjuster Assembly into Caliper Body (1) and secure with four Socket Head Cap Screws (26) and NEW Spring Lock Washers (27). Torque to 45 in-lbs. 15. Turn Slack Adjuster Nut (30) such that notches are on vertical center line of Caliper. 16. Install two new Bushings (32) in Release Lever (31), if removed and discarded. and Figure 6 - page Put Release Lever (31) into Body (1), then insert Release Lever Pin (33) thru hole in Caliper Body (1) and thru Bushed Holes of Release Lever (31) and thru hole on other side of Caliper Body (1). Apply light coat of Molybdenum Disulfide Grease M to Pin and inside of Bushings. 18. Install snap ring (34) to secure Lever Pin (33) 19. Install O-ring (105) on adapter (100) and position assembled items through the inside of body (1). 20. Slip Flat Washer (88) and NEW Spring (36) through round end of Release Cam (37). 21. Apply Molybdenum Disulfide Grease M to Cam and round shank of Release Cam (37) with spring (36) and Washer (88). Then install in Body (1) from top of Caliper opening such that square end of Release Cam extends outside of hole in Adapter (100). 22. Lubricate a NEW o-ring (39) with silicon lubricant M Slide o- ring (39) onto Release Cam Guide (38) 23. Install Release Cam Guide (38) in adapter (100) in Caliper Body (1) with square end shaft of Release Cam (37) going thru Guide (38). Apply light coat of Molybdenum Disulfide Grease M to bore. 24. Turn Release Cam Guide (38) back to align a notch with hole in Caliper Body (1), then insert new Spring Pin (43) to lock Cam Guide (38) in place. 25. Install Release Arm (40) on square end of Release Cam (37). Secure with NEW pin (104). 26. Install Switch Lever (72) on Switch Mounting Block (71) and secure with 3/8 long Shoulder Screw (70). Lever must pivot freely. 27. Install Switch Mounting Block (71) with microswitch (73) inside Caliper Body (1) with two Cap Screws (74) and Lock Washers (75). Apply Thread , S February, 2004

29 Chapter 1 - OVERHAUL INFORMATION Locker M to Screws (74) and Torque to 45 In-lbs. 28. Install a NEW Gasket (94). 29. Install Block/Micro switch assembly (71, 73) and (52) thru hole on side of Caliper Body (1) with Veam Connector (93) and Gasket (94) remaining on outside of Caliper Body (1). 30. Turn Cam Release (37) such that flat on shaft is facing Micro Switch Mounting Block (71). 31. Install Micro Switch (52) on Switch Bracket (49) and secure with two Screws (55), NEW Lock Washer (54) and Nut (Nut not shown). 32. Install Micro Switch and Bracket Assembly in Caliper Body (1) and secure with two Screws (50) and NEW Lock Washers (51). Adjust during test code. 33. Install Veam Connector (93) and Gasket (94) on Caliper Body (1) using four Screws (91) and Washers (92). 34. Install NEW Spring (76) between Switch Mounting Block (71) and Lever (72). 35. Line up small notch on small diameter of Piston (6) with key on Slack Adjuster Housing (17) and large notch with tip of Lever (72). Then install Piston (6) in Caliper Body (1). 36. Install five NEW Disc Springs (7) into Piston as shown below. 37. Install NEW Gasket (9) and Cover (8) on Caliper Body (1) using four Cap Screws (10) and Lock Washers (90). Torque to 25 Ft-lbs. 38. Install Spring Adjusting Nut (11) on Cover (8). Turn Adjusting Nut by hand until it stops, then use Spanner Wrench and turn approximately 3 turns. Final adjustment for proper output force is to be performed during test code. Reference: Figure 7 - page Install Molded Boot (28) in Caliper Body (1) and seat inside diameter of Boot on groove of Slack Adjuster Nut (30). Secure with NEW Retaining Ring (29). and Figure 7 - page Place slotted hole of Moveable Brake Head (61) over notches of Slack Adjuster Nut (11). Reference: Figure 7 - page Secure Moveable Brake Head (61) in place using Backing Plate Screw (80). Torque to 25 Ft-lb. 42. Insert NEW Spring (60) into rod of Brake Head (61). 43. Install NEW Bushing (59) into Locating Pin Spacer (58), if Bushing was removed and discarded. 44. Install Locating Pin Spacer (58) on Caliper Body (1) and secure in place with two Locating Pins (56) and o-rings (57). Torque to 50 Ft-lbs. 45. Align Brake Shoe (101) and Backing Plate (63) on Caliper Body (1) and install assembly with two Flat Head Socket Screws (62),and Flat Washer (64), NEW Lock Washer (67) and NEW Elastic Lock Nut (104). Torque to 8 Ft-lbs. 46. Install Brake Shoe on Moveable Brake Head (61) and secure with three Screws (65) and NEW Lock Washers (95). Torque to 8 Ft-lbs. 47. Install NEW Gasket (47) and Cover (46). Then secure with four Screws February, , S.03

30 Assembly (48). Apply Thread Locker M to Screws and Torque to 30 In-lbs. 48. Adjust Spring Output force with Spring Adjusting Nut (11) when performing the testing on the Caliper Assembly. Lock in place with Shoulder Screw (12). Torque to 10 In-lbs. 49. Install End Cap (68) on Spring Adjusting Nut (11). Torque to 5 Ft-lbs. iii. Exterior Assembly Reference: Figure 6 - page Place Hanger Bracket (1) over Caliper Assembly (9). 2. Fasten two Red Isolation Mounts (4) with Socket Head Cap Screws (5) on Guide Rods (3). Torque to 40 Ft-lbs. Use Thread Locker M-7499-S. 3. Insert the two Guide Rods (3) and Red Isolation Mounts (4) into Hanger Bracket holes and thru Caliper Assembly Bushings. 4. Fasten two Black Isolation Mounts (2) to Guide Rods (3) with two Screws (5). Torque to 40 Ft-lbs. Use Thread Locker. 8.0 TESTING INFORMATION IMPORTANT: AFTER THE IS ASSEMBLED BUT BEFORE IT IS RETURNED TO SERVICE IT MUST PASS A SERIES OF TESTS FOLLOWING THE PROCEDURES OF THE CURRENT ISSUE OF THE APPROPRIATE WABCO PTD TEST SPECIFICATION. IMPORTANT: AFTER ASSEMBLY HAS BEEN COMPLETED LITHIUM-MOLYBDENUM DISULFIDE BASE GREASE, WABCO PTD SPECIFICATION M , MUST BE APPLIED UNDER PRESSURE TO THE ALEMITE FITTINGS LOCATED OVER THE GUIDE ROD BUSHING ON THE CALIPER HOUSING. INSTALL ASSEMBLY AND HANGER BRACKET ON VEHICLE.WITH FOUR HEX HEAD 6 1/2 LONG, MOUNTING BOLTS (NOT SUPPLIED BY WABCO TRANSIT DIVISION) AND TORQUE TO OPERATING AUTHORITY SPECIFICATION. AFTER A IS INSTALLED ON THE VEHICLE, MANUAL ADJUSTMENTS TO THE BRAKE UNIT ARE TO BE MADE SOTHAT PROPER CLEARANCE IS OBTAINED BETWEEN THE BRAKE SHOE AND DISC. BRAKES MUST BE APPLIED AND RELEASED SEVERAL TIMES AFTER MANUAL ADJUSTMENT TO OBTAIN ACCURATE BRAKE DISC TO BRAKE SHOE CLEARANCE. WHENEVER IS REMOVED FROM THE VEHICLE FOR ANY REASON AND IT IS RE-INSTALLED OR REPLACED WITH A NEW OR REPAIRED AND TESTED UNIT, A STATIONARY VEHICLE BRAKE TEST MUST BE MADE TO BE SURE THAT THE UNIT FUNCTIONS PROPERLY. IMPORTANT: REMOVE ALL WHEEL CHOCKS BEFORE ATTEMPTING TO MOVE VEHICLE , S February, 2004

31 Please consult your WABCO TD service representative if you require any additional , S February, 2004