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Dry Disc Brake Calipers

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Dry Disc Brake Calipers MAINTENANCE MANUAL DRY DISC BRAKE CALIPERS MANUFACTURED BY 2300 OREGON ST., SHERWOOD 97140, OR U.S.A. PHONE: 503.625.2560 • FAX: 503.625.7980 E-MAIL: [email protected] WEBSITE: http://www.alliedsystems.com 80-767 3/2/2021 Contents pg. i Asbestos and Non-Asbestos Fibers 1 Section 1: Exploded View 2 Section 2: Introduction Description Hydraulic Fluid Identification 3 Section 3: Disassembly Manually Release the Brakes Releasing a Brake with Caging Studs and Nuts Releasing a Brake without Caging Studs and Nuts Remove the Caliper Disassemble the Caliper 5 Section 4: Prepare Parts for Assembly Cleaning Corrosion Protection 6 Section 5: Assembly Assemble the Caliper Prepare to Install the Linings Install the Linings 7 Install the Pistons, Linings and Springs Install the Caliper Bleeding the Brakes 8 Full Hydraulic Systems Air/Hydraulic or Mechanical Actuator Systems 9 Section 6: Adjust the Brakes Adjust the Brakes Adjusting a Brake with Caging Studs and Nuts Adjusting a Brake without Caging Studs and Nuts 10 Test the Caliper Adjusting the Caliper Off the Vehicle Adjusting the Caliper on the Vehicle 12 Section 7: Inspection Inspection Periodic On-Vehicle Inspections Inspect the Linings Inspect the Caliper for Leaks Inspect the Disc 13 Inspect Caliper Parts 14 Section 8: Diagnostics Troubleshooting 15 Section 9: Specifications Torque Specifications Wear Dimensions Total Lining-to-Disc Clearance Hydraulic Fluid Asbestos and Non-Asbestos Fibers Figure 0.1 ASBESTOS FIBERS WARNING NON-ASBESTOS FIBERS WARNING The following procedures for servicing brakes are recommended to reduce exposure to The following procedures for servicing brakes are recommended to reduce exposure to asbestos fiber dust, a cancer and lung disease hazard. Material Safety Data Sheets are non-asbestos fiber dust, a cancer and lung disease hazard. Material Safety Data available from ArvinMeritor. Sheets are available from ArvinMeritor. Hazard Summary Hazard Summary Because some brake linings contain asbestos, workers who service brakes must understand the Most recently manufactured brake linings do not contain asbestos fibers. These brake linings may potential hazards of asbestos and precautions for reducing risks. Exposure to airborne asbestos contain one or more of a variety of ingredients, including glass fibers, mineral wool, aramid fibers, dust can cause serious and possibly fatal diseases, including asbestosis (a chronic lung disease) ceramic fibers and silica that can present health risks if inhaled. Scientists disagree on the extent and cancer, principally lung cancer and mesothelioma (a cancer of the lining of the chest or of the risks from exposure to these substances. Nonetheless, exposure to silica dust can cause abdominal cavities). Some studies show that the risk of lung cancer among persons who smoke silicosis, a non-cancerous lung disease. Silicosis gradually reduces lung capacity and efficiency and who are exposed to asbestos is much greater than the risk for non-smokers. Symptoms of and can result in serious breathing difficulty. Some scientists believe other types of non-asbestos these diseases may not become apparent for 15, 20 or more years after the first exposure to fibers, when inhaled, can cause similar diseases of the lung. In addition, silica dust and ceramic asbestos. fiber dust are known to the State of California to cause lung cancer. U.S. and international Accordingly, workers must use caution to avoid creating and breathing dust when servicing agencies have also determined that dust from mineral wool, ceramic fibers and silica are potential brakes. Specific recommended work practices for reducing exposure to asbestos dust follow. causes of cancer. Consult your employer for more details. Accordingly, workers must use caution to avoid creating and breathing dust when servicing brakes. Specific recommended work practices for reducing exposure to Recommended Work Practices non-asbestos dust follow. Consult your employer for more details. 1. Separate Work Areas. Whenever feasible, service brakes in a separate area away from other Recommended Work Practices operations to reduce risks to unprotected persons. OSHA has set a maximum allowable level of exposure for asbestos of 0.1 f/cc as an 8-hour time-weighted average and 1.0 f/cc averaged over 1. Separate Work Areas. Whenever feasible, service brakes in a separate area away from other a 30-minute period. Scientists disagree, however, to what extent adherence to the maximum operations to reduce risks to unprotected persons. allowable exposure levels will eliminate the risk of disease that can result from inhaling asbestos 2. Respiratory Protection. OSHA has set a maximum allowable level of exposure for silica of 0.1 dust. OSHA requires that the following sign be posted at the entrance to areas where exposures mg/m3 as an 8-hour time-weighted average. Some manufacturers of non-asbestos brake linings exceed either of the maximum allowable levels: recommend that exposures to other ingredients found in non-asbestos brake linings be kept DANGER: ASBESTOS below 1.0 f/cc as an 8-hour time-weighted average. Scientists disagree, however, to what extent CANCER AND LUNG DISEASE HAZARD adherence to these maximum allowable exposure levels will eliminate the risk of disease that can AUTHORIZED PERSONNEL ONLY result from inhaling non-asbestos dust. RESPIRATORS AND PROTECTIVE CLOTHING Therefore, wear respiratory protection at all times during brake servicing, beginning with the ARE REQUIRED IN THIS AREA. removal of the wheels. Wear a respirator equipped with a high-efficiency (HEPA) filter 2. Respiratory Protection. Wear a respirator equipped with a high-efficiency (HEPA) filter approved by NIOSH or MSHA, if the exposure levels may exceed OSHA or manufacturers’ approved by NIOSH or MSHA for use with asbestos at all times when servicing brakes, beginning recommended maximum levels. Even when exposures are expected to be within the maximum with the removal of the wheels. allowable levels, wearing such a respirator at all times during brake servicing will help minimize 3. Procedures for Servicing Brakes. exposure. a. Enclose the brake assembly within a negative pressure enclosure. The enclosure should be 3. Procedures for Servicing Brakes. equipped with a HEPA vacuum and worker arm sleeves. With the enclosure in place, use the a. Enclose the brake assembly within a negative pressure enclosure. The enclosure should be HEPA vacuum to loosen and vacuum residue from the brake parts. equipped with a HEPA vacuum and worker arm sleeves. With the enclosure in place, use the b. As an alternative procedure, use a catch basin with water and a biodegradable, non- HEPA vacuum to loosen and vacuum residue from the brake parts. phosphate, water-based detergent to wash the brake drum or rotor and other brake parts. b. As an alternative procedure, use a catch basin with water and a biodegradable, non- The solution should be applied with low pressure to prevent dust from becoming airborne. phosphate, water-based detergent to wash the brake drum or rotor and other brake parts. Allow the solution to flow between the brake drum and the brake support or the brake rotor The solution should be applied with low pressure to prevent dust from becoming airborne. and caliper. The wheel hub and brake assembly components should be thoroughly wetted to Allow the solution to flow between the brake drum and the brake support or the brake rotor suppress dust before the brake shoes or brake pads are removed. Wipe the brake parts and caliper. The wheel hub and brake assembly components should be thoroughly wetted to clean with a cloth. suppress dust before the brake shoes or brake pads are removed. Wipe the brake parts c. If an enclosed vacuum system or brake washing equipment is not available, employers may clean with a cloth. adopt their own written procedures for servicing brakes, provided that the exposure levels c. If an enclosed vacuum system or brake washing equipment is not available, carefully clean associated with the employer’s procedures do not exceed the levels associated with the the brake parts in the open air. Wet the parts with a solution applied with a pump-spray enclosed vacuum system or brake washing equipment. Consult OSHA regulations for more bottle that creates a fine mist. Use a solution containing water, and, if available, a details. biodegradable, non-phosphate, water-based detergent. The wheel hub and brake assembly d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA for use with components should be thoroughly wetted to suppress dust before the brake shoes or brake asbestos when grinding or machining brake linings. In addition, do such work in an area with pads are removed. Wipe the brake parts clean with a cloth. a local exhaust ventilation system equipped with a HEPA filter. d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA when grinding or e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a HEPA machining brake linings. In addition, do such work in an area with a local exhaust ventilation filter when cleaning brake parts or assemblies. NEVER use carcinogenic solvents, system equipped with a HEPA filter. flammable solvents, or solvents that can damage brake components as wetting agents. e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with a HEPA 4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or by wet filter when cleaning brake parts or assemblies. NEVER use carcinogenic solvents, wiping. NEVER use compressed air or dry sweeping to clean work areas. When you empty flammable solvents, or solvents that can damage brake components as wetting agents. vacuum cleaners and handle used rags, wear a respirator equipped with a HEPA filter approved 4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter or by wet by NIOSH or MSHA for use with asbestos.
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