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Transit Bus Air Disc Brake Wheels-Off Inspection and Reline

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Transit Bus Air Disc Brake Wheels-Off Inspection and Reline APTA STANDARDS DEVEL OPMENT PROGRAM APTA BTS-BC-RP-007-17 RECOMMENDED PRACTICE Published: January 26, 2017 American Public Transportation Association APTA Bus Brake Working Group 1300 I Street, NW, Suite 1200 East, Washington, DC 20006 Transit Bus Air Disc Brake Wheels-Off Inspection and Reline Abstract: This Recommended Practice provides guidelines for performing complete brake maintenance on a bus with disc brakes. It includes disassembly, cleaning, inspection and assembly. This document is to be used in conjunction with the manufacturer’s service manual. It is recommended that all components be replaced equally on both wheel ends of the axle. Failure to do so may affect braking performance. Keywords: ABS tone ring, boot, bridge, bushing, caliper, carrier, disc, disc brake maintenance, hub, pads, pin, potentiometers, retaining strap, rotor, seal, slide pins, spring clips, torque plate, wear indicator, wear sensors, wheel seals Summary: This document establishes a recommended practice for transit bus front/rear axle disc brake inspection and reline. Individual operating agencies should modify these guidelines to accommodate their specific equipment and mode of operation. The recommended practices and guidelines in this document assume that the end users have sufficient skills and knowledge to repair and maintain the related systems at a journeyman level. This must include a fluent understanding of safe shop working practices, not only for the agency but also OSHA/CCOHS/provincial/federal/state and local safety standards. A familiarity with applicable industries, component/system suppliers and vehicle manufacturers is also assumed. Scope and purpose: This Recommended Practice provides guidelines for disassembly, preparation, inspection and reassembly of the typical heavy-duty transit bus disc brake. The components may be different than pictured, and some procedures will vary. Frequency of off-wheel inspections will vary depending on operating environment but should not be limited to pad change intervals. The purpose of this document is to provide a uniform standard for heavy-duty transit bus disc brake troubleshooting and reline. This document represents a common viewpoint of those parties concerned with its provisions, namely operating/ planning agencies, manufacturers, consultants, engineers and general interest groups. The application of any standards, recommended practices or guidelines contained herein is voluntary. In some cases, federal and/or state regulations govern portions of a transit system’s operations. In those cases, the government regulations take precedence over this standard. The North American Transit Service Association and its parent organization APTA recognize that for certain applications, the standards or practices, as implemented by individual agencies, may be either more or less restrictive than those given in this document. © 2017 NATSA and its parent organization. No part of this publication may be reproduced in any form, in an electronic retrieval system or otherwise, without the prior written permission of NATSA. Table of Contents 1. Hazardous material warning...................................................................................................... 1 2. Operation .................................................................................................................................... 1 2.1 Automatic adjustment ................................................................................................................................... 3 3. Inspection with wheels removed .............................................................................................. 4 3.1 Brake chamber identification ........................................................................................................................ 5 3.2 Brake chamber initial inspection ................................................................................................................... 6 3.3 Caliper inspection ......................................................................................................................................... 6 3.4 Torque plate inspection ................................................................................................................................. 7 3.5 Fasteners and mounting hardware ................................................................................................................. 7 3.6 Visual inspection ........................................................................................................................................... 7 3.7 Knorr-Bremse caliper movement test ........................................................................................................... 9 3.8 Knorr-Bremse guide pin inspection with pads installed ............................................................................. 10 3.9 Knorr-Bremse caliper adjuster test ............................................................................................................. 11 3.10 Meritor EX225 caliper movement test ...................................................................................................... 14 3.11 Meritor EX225 caliper adjuster test .......................................................................................................... 15 3.12 Meritor EX225 slide pin bushing tangential test....................................................................................... 16 3.13 Meritor EX225 slide pin bushing radial test ............................................................................................. 16 3.14 Caliper guide pin inspection with pads removed ...................................................................................... 17 3.16 Brake pad inspection ................................................................................................................................. 18 3.17 Rotor inspection ........................................................................................................................................ 20 3.18 Carrier and pad abutment inspection ........................................................................................................ 25 3.19 Guide and slide pin boot inspection .......................................................................................................... 26 3.20 Tappet boot and seal inspection ................................................................................................................ 27 3.21 Tappet seal and guide/slide pin seal replacement ..................................................................................... 28 3.22 Tappet inspection ...................................................................................................................................... 29 3.23 Brake chamber inspection ......................................................................................................................... 29 3.24 Brake chamber non-pressure housing plugs ............................................................................................. 32 Related APTA standards ................................................................................................................................... 36 References ......................................................................................................................................................... 36 Definitions......................................................................................................................................................... 36 Abbreviations and acronyms ............................................................................................................................. 36 Summary of document changes ........................................................................................................................ 36 Document history .............................................................................................................................................. 36 © 2017 American Public Transportation Association | ii List of Figures and Tables Figure 1 Axial and Radial Mounting Designs .................................................................. 2 Figure 2 Cross-Section of Knorr-Bremse Caliper Assembly ........................................... 2 Figure 3 Meritor EX225 Caliper Gear-Driven Adjustment Mechanism (Not Serviceable)3 Figure 4 Knorr-Bremse Timing Chain Mechanism (Not Serviceable) ............................. 4 Figure 5 Wheels-Off Inspection ....................................................................................... 5 Figure 6 Axial and Radial Positions ................................................................................. 5 Figure 7 Brake Chamber Types ........................................................................................ 6 Figure 8 Caliper Types ..................................................................................................... 6 Figure 9 Brake Assemblies With and Without Thermal Overload ................................... 8 Figure 10 Other Types of Brake Assembly Damage ........................................................ 9 Figure 11 Knorr-Bremse Caliper Movement Test ............................................................ 9 Figure 12 Knorr-Bremse Tappets-to-Pad Clearance....................................................... 10 Figure 13 Measuring Knorr-Bremse Caliper Guide Pin Wear ......................................
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