SPIDER + REPAIR PROCEDURE MANUAL THE EFFICIENT AND ECONOMICAL WAY TO REPAIR DAMMAGED, WORN OUT SPIDERS, QUICKLY AND EASILY

Transcription

1 SMSP-TA- 1.2 Advanced Wheelend Technologies SPIDER + REPAIR PROCEDURE MANUAL THE EFFICIENT AND ECONOMICAL WAY TO REPAIR DAMMAGED, WORN OUT SPIDERS, QUICKLY AND EASILY WITH " STATE OF THE ART " TECHNOLOGY FOR MACHINE SHOP QUALITY RESULTS. INDEX

2 Introduction 3 Section A PREPARATION STEP 1 Spider bushing channel inspection 4 STEP 2 Centre bushing alignment 6 STEP 3 Mounting the power driver on the support dolly 8 STEP 4 Mounting the TACP-2000 thrust applicator on the axle 9 Section B RE-BORING PROCEDURE STEP 1 Preparation 11 STEP 2 Building the re-boring tool 12 STEP 3 Making the cut 13 STEP 4 Inspecting the channel after the 1st Re-Bore 15 SECTION C BUSHING INSTALLATION STEP 1 Installing the corrective oversized bushing 16 STEP 2 Seal installation 18 STEP 3 Re- assembly of brake components 22 Tooling and shop supplies checklist 23 Tool maintenance & Service bulletins 24 INTRODUCTION 2

3 The trucking industry is constantly looking for efficient and economical solutions to reduce their maintenance costs, while compliance to road safety regulations is not an option. This manual explains an option that is cost effective and durable. IMPORTANT The SPIDER + re-boring method relies on the integrity of the sealing sections of the cambushing channels of the anchor brackets. These portions of the channels are usually protected by the grease seals of the cam-bushing assembly, and are not damaged by the spun bushings. These seal bearing journal portions of the channel can be used as 0 (zero) point reference. In line with the center of the Hangar Bracket bushing s center, the cam side of the bushing channel s sealing portion can be used to align the 0 (zero) axis of the brake cam assembly. By using this principle, the method and the tooling guides the reamers to the best known center axis of the brake foundation. The SPIDER + re-boring method offers only 2 possible oversized re-bores for each cam size as we do not recommend oversizing the cam-bushing channel further than 1/8 of an inch to reduce risk of breakage. If seal journals of the channel are damaged, usually the damage to the cam-bushing area is to extensive for repair and 2 nd oversize does not correct all damage, and so we don t recommend repairing the said channel. Ultimately, the responsibility of the repairs performed with this repair system is that of the customer who wishes to save the costs of axle replacement. Please follow the recommended procedure as well as safety precautions of your working environment. BEFORE USING SPIDER + SPIDER + is intended to rebuild damaged spider bushing channels of S cam brake anchor brackets as long as they free of cracks and other defects that can compromise the spider's solidity and resistance to impact. Technicians must evaluate the overall condition of the spiders ( cracks, severe bends, wall thickness, etc.) before attempting to recondition them with the method described in this manual. ***Important notice to all users*** AWT and C.F.T.S. Group inc. are not responsible for any consequences, accidents, injuries, or any other mishaps ensuing the use of the SPIDER + method. It is the duty and responsibility of the user to evaluate the reliability of the repairs performed with the method explained in this procedure manual. REBUILDING PROCEDURE Section A: Preperation 3

4 Step 1 : SPIDER BUSHING CHANNEL INSPECTION VERY IMPORTANT At this point we assume that all old brake components have been removed, including cambushings and grease fittings. Center support plates and spiders have been properly cleaned and dried off if needed. It is very important to work in a clean and orderly fashion to ensure the success of this repair. Cleanliness is essential to the success of this method. We now have to check the integrity of the cam-bushing bore of the spiders. If there is no damage, we can proceed. If damage is present we must either repair the spider or replace it. A loose cam bushing in the spider will not be tolerable for this method. The center holding brackets also need to be rust free and properly inspected. Step 1 a: Clean the spider bushing channel. Using a die grinder with a coarse grit flap wheel (80 grit is good) remove all rust and other dirt inside the bushing channel. When bushings spin in their channels, they may leave tracks of wear between the sealing ends of the bushing channel of the anchor brackets. Step 1 b: Inspect the bushing channel for any cracks, severe bends, wall thickness and other defects that could compromise the spider's solidity and resistance to impact. Step 1 c: Measure the width of the spider bushing channel accurately, using a sliding caliper ( "vernier" ), to determine if there is any damage to the sides of the spider (caused by the cam shims). If you detect any width reduction refer to chart 1a on page 5 to select the proper bushing for each spider repair. Step 1 d: Clean center hanger bracket and remove any rust using a hard disc grinder, until both surfaces are ready to receive the new bushing. Paint the bracket before installing the bushing and cups. Spider width inspection 4

5 Some spider brackets may show signs of wear at each side of the Cam-bushing channel due to wear from excessive side pressure from the adjustment shims. When such is the case, use a narrower bushing as specified in chart 1a. Normal spider width Original bushing width Spider width reduction Replacement bushing 2.000" 1.500" 1.750" 1.125" 2.125" 1.500" 1/16" to 3/16" " to 0.188" 1/16" to 1/8" " to 0.125" 1/16" to 1/4" " to 0.250" 1.250" 1.000" 1.250" It is not recommended to repair spiders that exceed the width reduction specified above Chart 1a Standard measurements for cam-bushing channels Size of camshafts used on axles Dimensions of bushing channels 1-1/2'' inch diameter Most trailer axle models 1.875'' +/-.001'' 1-1/2'' inch diameter Intraax first design 2.000'' +/-.001'' 1-5/8'' inch diameter Most trailer axle models 2.000'' +/-.001'' Be sure to take measurements both horizontally and vertically when checking bushing channels integrity. Figure 4.1 Step 2 : Centre bushing alignment Installing the center bracket cam-bushing 5

6 Trailer axles equipped with S cam brakes use spherical bushings at the splined end of the camshafts, near the slack adjusters. These spherical bushings can pivot in their holding plates, and so, need to be properly aligned with the spider bushing before they can be permanently secured in their holding brackets. The holding bracket cam-bushing is mounted in alignment with the center of the cam side sealing journal portion of the bushing channel being repaired. It is then used to guide the PILOT of the Align-boring tool to re-bore a new oversized channel. Step-by-step installation of the center bracket bushing 2a: Make sure all parts are primed and painted. Gather all the necessary bolts and brackets to install all center cam bushings on all wheels. 2b: Align the mounting plates and the brackets as well as the other devices required. Insert the bolts while holding the center cam bushing in place between the mounting plates. 2c: Hand tighten all bolts. 2d: Insert alignment sleeve (tool# BAC-1500) into the center bushing. If using conventional Nylon or Plastic bushings, it may be necessary to insert O-rings to help center the alignment sleeve. 2e: Assemble sliding cone (tool# CO-2000) onto the preselected pilot shaft of the boring tool. The pilot shaft should be selected to be of equal length to the cam or longer. 2f: Insert pilot through the spider bushing and continue forward until insertion through the alignment sleeve is complete. Then drive the sliding cone forward on the pilot until it centers itself out in the spider bushing. Always position the sliding cone from the outside of the spider, pointing to the inside. 2g: Verify the alignment of the center bushing by making sure that both the alignment sleeve and the sliding cone are well positioned in their respective places. 6

7 2h: Tighten all mounting plates bolts to specified torque. Alignment is correct when the sleeve ( tool # BAC-1500) can slide freely in the center bushing, while the cone is well centered in the spider bushing. If the sleeve cannot move freely through the center bushing, some distortion has occurred while tightening the bolts. The next step (2s) explains how to relieve distortion from the mounting plates. 2i: Using a 2-pound plastic hammer, hit the centering sleeve in order to vibrate the assembly to relieve any distortion from the mounting plates. HIT THE BRACKET IF NECESSARY. REMEMBER- Alignment is correct when the sleeve (tool # BAC- 1500) can slide freely in the center bushing, while the cone is well centered in the spider bushing. KEEP TRYING UNTIL YOU FIND THE RIGHT SPOT IN ORDER TO RELIEVE THE DISTORTION. 2k: Remove all alignment tools Center bushing installation is complete. Repeat complete procedure for other wheels if needed. STEP 3 : Mounting the power driver on the support dolly SPIDER+ requires the use of accessories and other gear to perform a spider repair. Here is a list of the accessories and other gear needed. RGD-700 CDR-700 RIDGID-700 Power driver electric tool ½" square drive adaptor for RIDGID-700 power tool 7

8 CHR-700 TACP-2000 HCZ-100 Mobile support dolly for RIDGID-700 power tool Forward thrust application kit Heavy-duty cutting oil Other necessary gear include an electrical cord to supply power to the power tool, safety goggles, compressed air supply hose and blow gun to clean debris from the spiders during the procedure. A tool and shop supplies check list is available on page 23 of this manual. Step 3a : Installing the RGD-700 power tool on the dolly. The RIDGID 700 power tool has a metal ridge between the motor section and the drive section on the opposite side of the handle (underneath the tool). In this case it will serve as a guide to locate the power tool on the support dolly. The support dolly has a slot on the left side of the holding platform. This serves as an insertion groove for the ridge on the power tool (described earlier above). This slot will keep the tool properly centered on the support dolly and allow enough vertical play for the tool to be operated safely. This is the configuration of the power tool and the support dolly once they have been coupled together. Please make sure that the electrical cord of the tool has been passed through the holding platform to prevent interference and also to prevent cord damage. Step 3b : Installing the CDR-700 chuck in the power tool 8

9 The CDR-700 chuck is an adaptor that converts the power tool to a ½" square drive that can be used with all regular sockets and other common tools. It has slotted grooves around the barrel to fit the drive pins of the RIDGID-700 power tool's drive section. Match the drive pins inside the drive section of the power tool to the slotted grooves on the barrel of the chuck by inserting the chuck inside the drive of the power tool and rotating the chuck until the drive pins lock in the grooves. This is a view of the chuck properly inserted in the power tool. STEP 4 : Mounting the TACP-2000 thrust applicator on the axle 9

10 4a: Screw the wheel bearing adjustment nut onto the spindle so that it is completely engaged into the threads. This will protect the threads from possible damage and prevent the thrust coupler to slip off the spindle when torque is applied to the boring tool. 4b: Adjust the height of the thrust applicator coupler by selecting the proper mounting hole of the stopper flange. This is achieved by resting the thrust applicator coupler onto the axle as shown here, making sure the stopper flange is resting on the outer bearing journal of the spindle. Proper position of the stopper is achieved when the coupler is in parallel alignment with the axle. Place retaining bolt in selected hole and secure the holding nut. 4c: Wrap a clean shop rag around the spindle of the wheel being repaired to prevent damage and thrust applicator slipping. Install the TACP-2000 while positioning the RED square swivel bar approximately 1 inch below the spider's bushing channel. Secure holding strap tightly over the inner bearing journal. 4d: Make sure the spindle nut is screwed on the spindle and that the coupler s stopper is resting against it, this will prevent it from slipping outward from the spindle. This picture is only used to show the trust applicator s stopper is leaning against the spindle nut. All of the spindle and the nut should be covered with a cloth. 4e: The ½ square drive extension supplied with the thrust applicator needs to be clean and its thrust bearing must be well lubricated with grease. Make sure the retaining clip is tightly secured onto the extension shaft. 10

11 Section B: Re-boring the spider bushing channel STEP 1: Building the re-boring tool Warning: The flutes of the reamer are very sharp and can cause severe injury. Handle with caution. It is very important to work in a clean environment when building the boring tool. Any dirt wedged between the reamer and its corresponding shank of the Arbor will split open the reamer when you press it on. We provide a guide pin on the Arbor to assess cleanliness of both components. When engaging the cutter by hand onto the shank, the guide pin should be in close proximity with the slots of the cutter (figure 1c below). As a test, take a small piece of about ½ a square inch of the cellophane wrapper of the new cutter and wedge it flat between the shank and the cutter and reinsert it onto the shank. Observe how this thin (less than one thousandth of an inch) shim creates a large gap between the guide pin and the slots of the cutter. Once cleanliness is assessed by the normal engagement of the slots to the pin, the cutter can be secured to the Arbor. Please note that a flat washer is used for the big Arbor only. At first, the torque needed to press on the reamer is very light but as soon as the tapered shank sits into the bore of the cutter, it stops sliding on the shank and the torque value rises quickly. It is necessary to fit the cutter snugly onto the shank as it is the tapered fit that will drive the cutter and not the guide pin. A torque of 10 to 15 foot pounds is required to achieve proper fit. Warning: the reamer (cutter) is made of High Speed Steel and will not bend or expand. Excessive torque will split the cutter in two halves. The same result can happen with dirt or debris wedged between the Arbor and Reamer when pressed on. We recommend that the surfaces both male and female be dry and clean when assembling the cutter onto the Arbor. The Pilot shaft can now be mounted onto the Arbor. The tapered countersink at the threaded end of the pilot needs to clean and dry. Inspect it visually with proper lighting and use compressed air to make sure it is clean. Screw in the shaft by hand until fully seated. Tighten with a proper wrench until snug (approximately 10 to 15 foot pounds). The boring tool is now ready to make the cut. 1a: Secure the Arbor in a vise by holding it by its hexagonal (6 point) drive. The red arrow show the shear pin at the base of the Arbor. 1b: Insert the reamer onto the Arbor after making sure its inner bore is perfectly clean. 1c: The guide pin is there only to confirm cleanliness of both the Arbor and the Cutter. The tapered shank of the Arbor drives the Cutter 11

12 1d: Mount the flat washer and nut onto the Arbor. Screw the nut all the way to the washer by hand. 1e: Tighten the nut until the cutter is fully seated onto the Arbor s shank. Approximately 10 to 15 Ft.Lbs. 1f: Fit the Pilot shaft onto the Arbor and tighten until fully seated. Approximately 10 to 15 Ft. Lbs. 1g: To remove cutter, remove the nut and washer from the Arbor. 1h: Place the Arbor in a vise so that the flat sections of its base are rested loosely against the jaws as shown above and the cutter sits at the top of the vise s jaws. 1i: Using a center punch and a steel hammer, push the Arbor down from the cutter until it falls into the base of the vise. Removing the reamer from the Arbor. The base of the Arbor features two adjacent parallel flat surfaces. These allow removal of the reamer from the tapered shank of the Arbor. It is necessary to place the Arbor as shown in Figure 1 h above, with the flat surfaces of its base resting LOOSELY against the jaws of the vise so that the cutter can sit at the top of the jaws. To release the cutter from the shank, use a center punch and a steel hammer to drive the shank out of the cutter as shown in figure 1i above. Once released from the cutter, the Arbor will fall to the bottom of the vise. Please ensure that it cannot fall out of the vise to prevent damage. Warning: The flutes of the reamer are very sharp and can cause severe injury. Handle with caution. 12

13 STEP 2: Making the cut Insert the alignment sleeve (tool# BAC-1500) into the center bushing to center the pilot shaft of the boring tool. Slide the pilot of the boring tool through the damaged bushing channel and through the alignment sleeve as shown in step 2a. Mount the driving tool s hexagonal socket on the drive of the boring tool and apply cutting oil to the cutting flutes of the reamer and the bushing channel being repaired. Finish assembly of the components of the boring tool assembly. The picture of step 2d shows the normal configuration of the TACP-2000 Thrust applicator. 2a: Insert alignment sleeve (tool# BAC-1500) into the center bushing to center the pilot shaft of the boring tool. 2B: Slide the pilot of the boring tool through the damaged bushing channel and through the alignment sleeve as shown in step 2a. 2c: Mount the socket on the drive of the boring tool and apply cutting oil to the cutting flutes of the reamer. 2d: Finish assembly of the components of the boring tool assembly. This picture shows the normal configuration of the TACP-2000 Thrust applicator. The feeding arm features a rounded thrust application section that delivers a centered contact to the thrust bearing. 13

14 2e: we recommend the use of a 1/2 square drive 12-inch extension, at the end of which a universal joint is most important. The u-joint should be mounted into the female end of the thrust extension. A 1" inch deep socket completes the assembly that will drive the boring tool. The U-joint provides flexibility to prevent forcing the cutter sideways which could cause an oval cut in the channel, as the power driver cannot be aligned perfectly at all times. 2e: Make sure you have applied sufficient amount of Cutting oil and start rotating the boring tool with the power driver. Oil can applied during rotation. Apply a light forward thrust on the thrust lever of the TACP 2000 Trust applicator tool and keep sufficient pressure to feed the reamer into the channel. After 10 to 60 seconds, metal debris will accumulate in the flutes of the reamer and it will tend to jam or seize in the hole. TIME TO RELEASE THE FEED ON THE CUTTER. 2f: Back off the cutter and blow all debris with compressed air. Be sure to clean off the tool and the channel. BE SURE TO WEAR PROPER EYE PROTECTION AND SAFETY GEAR AND PROTECT THE PEOPLE WORKING AROUND YOU. Repeat step 2e using plenty of cutting oil and make another pass. Clean off debris as needed. 2g: After several passes, the reamer will go through the channel completely. The cut is finished. It is normal to take many passes and usually it may take up to 15 minutes per cut to provide excellent surface finish in the channel. Too much debris build up in the cutter will tend to scratch the wall of the channel. CLEAN DEBRIS OFTEN. Clean off the spider bushing channel after the cut is completed and inspect the resulting surface of the re-bore to assess if a second oversize cut is required. The reamers may be damaged by rust and previous welds in the bushing channel. It can re-sharpened several times as long as the finishing section of the cutting flutes are good. Please send us your damaged cutters for inspection and re-sharpening as it is essential to have the correct flute design to prevent tapered cuts and / or oval cuts and / or rough cuts. We have tried many different configurations before we got it right, and we are still learning. As you may have found out by now, this technology is based on extensive expertise and in order to prevent some of the mistakes we have been through over the past 15 years, we do our very best to extend adequate information to our valued customers and offer a tech support (toll free) hot line. 14

15 STEP 3: Inspecting the channel after the 1 st Re-Bore 3a: Inspect bushing channel carefully. Check for cracks and scratches and check if all wear traces are corrected. A smooth surface with little scratches is acceptable as long as all wear damage is corrected to maintain the proper press fit of the corrective oversized bushing. 3b: Once re-bore is complete and successful it is recommended to clean of all the bracket well and prime and paint the components of the brake foundation. Inspection results: If the damage inside the channel has not been corrected by the first oversize, you can go to the second oversize and undertake a second re-bore of the spider bushing channel. Install the second oversize cutter on the boring tool and proceed to the step 2 section above. Warning: We do not recommend going past the 2 nd oversize cut as the thickness of the supporting wall around the bushing channel could become dangerously thin and compromise the integrity and solidity of the anchor bracket. 15

16 SECTION C BUSHING INSTALLATION STEP 1: Pressing the corrective oversized bushing " OPTIMUM-CONTACT " bushings need to be installed in their respective places using the necessary tools supplied with the system. A puller set is used to press the spider bushings in place for certain models. Spider bracket thickness will vary with axle model and make. There are three sizes of puller plungers to accommodate bushing installation for most popular models of 1-1/2" cams and another three for 1-5/8" cams. Here is a brief description of the six models supplied with the BDK-200 puller kit. Bushing installation tool description C B A A: Bushing i.d. size B: Bushing insertion depth shoulder C: Thread size Fig.5 Tool part # Dimension A Dimension B Dimension C In kit RT /2" 1/4" 5/8" X 11 UNC 1 RT /2" 5/16" 5/8" X 11 UNC 1 RT /2" 3/8" 5/8" X 11 UNC 1 RT /2" 9/16" 5/8" X 11 UNC Special order RT /8" 3/16" 5/8" X 11 UNC 1 RT /8" 1/4" 5/8" X 11 UNC 1 RT /8" 5/16" 5/8" X 11 UNC 1 RT /2" 1/4" Acme threads Special order RT /2" 5/16" Acme threads Special order RT /2" 3/8" Acme threads Special order RT /8" 3/16" Acme threads Special order RT /8" 1/4" Acme threads Special order RT /8" 5/16" Acme threads Special order Fig.5a 16

17 A B C D E F Fig.6 A B C D E F Bushing driver Puller threaded rod Centering flange Thrust bearing Tempered steel washer Hexagonal drive Take the following steps to install the spider cam bushings in their respective places. N.B. the pullers used in this procedure require proper maintenance like periodical cleaning and recommended lubrication intervals (see tool maintenance on p.34 ). Step-by-step installation of the spider bushing 2a: Using a 6" precision caliper, measure the thickness of the spider bracket at the bushing channel. Choose the correct bushing driver according to this formula; Spider thickness bushing length / 2 Ex: thickness 2.00" Bushing length " =.500 / 2 =.250" you will need the bushing driver with.250" (1/4") shoulder. Refer to fig. 5 and 5a on page 10, to select proper installation flange. 2b: Using a marker, make a recognition mark on the side of the bushing to indicate grease hole location in the bushing. This will facilitate grease hole alignment when installing the bushing in the spider. 2c: Select the appropriate bushing driver according to formula explained above in step 2a, or start by the bushing driver with the smallest shoulder thickness. Insert bushing onto the driver. 2d: Apply the bushing on CAM SIDE or BRAKE side of the spider-bushing channel with the bushing driver. Look inside the channel to align the grease hole to the lube channel. 17

18 2e: Insert the puller's threaded rod through the centering flange and then through the spider bushing channel and finally into the bushing driver's threaded hole. Apply the centering face of the flange onto the spider's bushing channel and rotate the puller's threaded rod clockwise until it's thrust bearing flattens out on the centering flange. Refer to fig. 6 on page 10, for correct assembled view of installation puller. 2f: Using a ½" square drive impact driver wrench along with a 6 point hexagonal ¾" impact socket, drive the ¾" hexagonal drive of the puller s threaded rod clockwise until the bushing driver flattens out on the spider bracket. 2g: Remove puller from the spider assembly. 2h: Verify the result of the installation for proper grease hole alignment and good centering of the bushing inside the channel. If all is O.K. the installation procedure of the spider bushing is complete. If bushing is not properly centered, go to next step 2i. 2i: Select proper bushing driver in order to drive the bushing toward the center of the spider-bushing channel. 2j: Repeat steps 2d through 2h until proper centering of the bushing is achieved. Installation of the spider bushing is complete. Repeat steps of the above procedure until all spider bushings are in place, and then proceed to install all grease fittings. Check all bushings for proper centering and grease hole alignment. 18

19 STEP 2: Seal installation Seals and O-Rings are installed the same way they are regularly installed in a normal procedure. The one difference being that the "OPTIMUM-CONTACT" system comes with a special seal installing tool that will enable the technician to install these ordinarily "hard to install" seals in a snap, every time. Seal installer tool description A B C A TE-900 9" hexagonal percussion stub B RJ /2" seal installer flange RJ /8" seal installer flange C TE /4" hexagonal percussion stub Fig. 15 Spider dust seal installation Install the spider dust seals in a way that they will allow grease to purge easily from the cambushing assembly. The outer seal must be installed with its sealing lip pointing toward the cam-bushing (positive installation), in order to keep the grease from entering the brake shoes and drum assembly, during lubrication, thus contaminating the brake shoes and drum. The inner seal must be installed with its sealing lip pointing outward from the cam-bushing (negative installation), in order to let the grease escape from the cam-bushing assembly during lubrication. Figure 16 on next page shows proper seal installation. 19

20 Single lip seal design Fig. 16 Double lip seal design Heavy-Duty highway use Fig 16.1 Heavy-Duty Off road use For Heavy-Duty applications see service bulletin # SBOC-104 for complete procedures. 20

21 Step-by step installation of the seals and O-Rings Make sure that the spider is free of metal debris and other dirt. Step 1: Insert the dust seal onto the 2-3/4" stub side of the installer flange making sure that the seal's lip is pointing outward (toward the 2-3/4" stub). Refer to fig.15 for tool description. Step 2: Insert the dust seal onto the other side of the installer flange making sure that the seal's lip is pointing inward on the flange (same direction as the other seal, toward the 2-3/4" stub). Step 3: Insert the seal installer tool's short stub through the outer face of the spider to apply the seal evenly on the bushing channel, and then tap the seal in with a small hammer using the edge of the long extension to hold and drive the tool. Drive the seal in until the wide face the installer flange flattens evenly on the spider. Back out the tool. Step 4: insert the long extension of the tool through the back side of the spider channel and apply the seal evenly on the bushing channel, then hold the tool in position by the long extension, tap the short stub with the hammer to drive the seal in position while holding the tool by the long extension. Remove tool once the seal installation is completed. Step 5: Check for proper installation of inner and outer seals. Make sure that the outer seal is installed with the lip pointing toward the cam-bushing, and that it does not touch the bushing. Make sure that the inner seal lip is pointing away from the cambushing and that the outer shell of the seal is pushed all the way in. Step 6: Check for cleanliness of the whole assembly and apply a thin coating of good quality grease to all parts. Step 7: insert the O-rings in both grooves of the PM-2500-Z bushing and coat inner bore and O-rings with good quality grease. Refer to service bulletin # SBOC at the end of this training manual, for proper procedure. For heavy-duty applications see service bulletins: PM 2500-Z = SBOC-105 PM 2380 = SBOC-109 Installation of the "Optimum-contact" cam-bushing system is complete. 21

22 Step 3: Re- assembly of brake components. Re-assemble the camshaft and all other brake components EXCEPT FOR THE SLACK ADJUSTERS according the normal procedure and specifications of the axle manufacturer. Refer to service bulletin # SBOC-113 for slack adjuster installation procedure. Lubricate the cam-bushing assembly thoroughly and wipe any excess lube. Install a CP cap plug on each grease fitting after lubricating, to protect from damage and dirt. RECOMMENDATIONS We recommend the use of a thread-locking agent to seal the splines of the camshaft and the slack adjuster to prevent the infiltration of contaminants in the splines. This could lead to early wear of the splines and cause the brake stroke to extend. PLEASE REFER TO SERVICE BULLETIN # SBOC-113 FOR PROPER PROCEDURE IN THIS MATTER. It is important to ensure the cleanliness of the grease fittings when lubricating the cam-bushing assemblies (any dirt or contaminants inserted in the assembly will contribute to reduce their durability. The tip of your grease gun coupler also needs to be clean to prevent introduction of contaminants in the cam-bushing assemblies. Lubrication requirements: We recommend that all "Optimum-Contact" cam-bushings be greased at least once per 120 days for normal high way use. For city and heavy high way use; at least once per 90 days. For off-road use and other severe applications; at least once every 2 weeks. 22

23 Tooling and shop supplies checklist " OPTIMUM-CONTACT " CO-1500 / 1625 CK reamer tool kit " OPTIMUM-CONTACT " BDK-100 Bushing installation puller kit 1" 2" Digital Micrometer Magnetic based dial indicator gauge Hard disc 4 ½" Grinder ¼" shank high-speed die grinder ( 20,000 + r.p.m. ) 1 ½" diameter with ¼" shank flap wheel ( grit ) 3/8" square drive impact wrench 3/8" square drive hexagonal 7/16" deep socket 3/8" square drive hexagonal ½" deep socket ½" square drive impact wrench ½" square drive extension ( 12" + long ) ½" square drive universal joint ( impact ) ½" square drive hexagonal 1" deep socket ½" square drive hexagonal ¾" deep socket (BDK-100 / 200 before June 2006) ½" square drive hexagonal 15/16" deep socket (BDK-100 / 200 after June 2006) ½" square drive hand ratchet wrench ( long handle 16" + ) (2) 1" open and closed combined wrenches 7/16" open and closed combined wrench ½" open and closed combined wrench Blow drying air gun Wire brush 6" precision calliper ( digital if possible ) 2lbs plastic hammer Other necessary shop supplies Primer Spray tin Paint Spray tin Small quantity of good quality clean grease Brake cleaner Shop rags Low strength thread locking compound ( yellow or purple "Locktite" ) Ink marker (large) 23

24 Tool maintenance Pullers: Must be kept clean by avoiding the threaded rod and the other components to touch dirty surfaces. If contact with dirt and contaminants is inevitable, clean the tools as soon as possible. Keep bearings and threaded rods well lubricated at all times If you notice that tools run excessively hot, check for proper lubrication. Cool down the tools with water if necessary. Boring tools: All cutters ( reamers ) must never come in contact with any abrasive substance and have to be kept clean at all times (Do not allow the tools to lay on a concrete floor). Special note: Any metal debris on the inner surface of the cutters' tapered mounting journals will render the assembly of the cutter on the arbor very difficult, and if cutter is forced onto the arbor, it will break. Service bulletins Service bulletins supplied with this training manual : SBOC 106 SBOC 107 SBOC 112 SBOC 113 SBOC 114 SBOC SBOC 118 SBOC SBSP BBOC-FRU-1625 bushing installation BBOC-FRU-1932 bushing installation Greasing the bushings before align-boring them Thread locking agent for cam splines and slack adjusters Using the proper seals for Optimum-Contact bushings. Lubrication Lubricant compatibility Intraax tube installation BBSP std and BBSP std bushing installation 24

25 NOTES 25

26 FOR ANY INFORMATION DIAL TOLL FREE The instructor who facilitated this training is: CLAUDE DROUIN This training manual was revised last: September 12, 2011 Revised on Printed in CANADA copyright 2011 all rights reserved 26