Zacisk Hamulca Instrukcja Konserwacji 8150101533 (48-76) .En
Zacisk Hamulca Instrukcja Konserwacji 8150101533 (48-76) .En
–– Mount the brake cylinder on the calliper (1)Chapter "8.2 Installing the
brake cylinder", page 44.
–– Observe the respective instructions of the brake cylinder manufacturer.
ÖÖ Depending on the installation position of the brake, ensure that the lower
drainage aperture of the brake cylinder facing the ground is open.
ÖÖ Depending on the actuator type, the other drainage openings can either
remain open or they must be sealed with a plug.
48
Replacing the wear sensor
Read all safety instructions before carrying out the work steps to avoid injury
and/or material damage (Chapter "2 Safety information", page 8).
The electrical wear sensor (15) needs to be replaced when it transmits
implausible values or was diagnosed as incorrect by the electronic system of
the vehicle.
–– Use a Torx screw driver to unscrew the Torx screws (19) from the
wear sensor (15).
49
Replacing the wear sensor
50
Replacing the wear sensor
–– Plug the sensor cable connector into the wear sensor (15) socket.
–– Fasten the connector with a Torx screwdriver using three screws on
the wear sensor (15).
51
Renewing the seals
Read all safety instructions before carrying out the work steps to avoid injury
and/or material damage (Chapter "2 Safety information", page 8).
Never use the lining retainer clip (13) as a grab handle or for fastening
the brake to a lifting device, because the lining retainer clip (13) can be
damaged in the process.
General Information
!! If all seals of the calliper (1) are replaced, the work sequences for renewing
the sealing covers and bushings of the guide pins (18) as well as the piston
protection cap (17) can be performed together.
If the seals are replaced separately however, the work steps must be carried
out separately according to the sequences in the chapters "11.1 Renewing the
sealing covers and the bushings of the guide pins" and "11.2 Renewing the
protection cap of the adjuster screw".
11.1 Renewing the sealing covers and the bushings of the guide
pins
11.1.1 Disassembly
For this chapter you require the following tools:
Box spanner with spanner width 24 (outside)
Hexagon screw driver with width 14 (inside)
WABCO Service Case
–– Remove the vehicle wheel in accordance with the instructions of the axle or
vehicle manufacturer.
52
Renewing the seals
–– Use a suitable fastening device (e.g. a vice) to clamp the brake to the brake
anchor plate (2).
53
Renewing the seals
–– Clean the contact areas (fitting collars) to the guide pins (3, 4) on the brake
anchor plate (2).
–– Remove the guide pins (3, 4) from the calliper (1).
–– Pull the protection cap (16) for the guide pins out of the ring groove of the
brake calliper (1).
–– Place the calliper (1) on a firm base for pressing out the guide pin bushings
(18).
ÖÖ The back of the calliper (1) must face upwards.
–– Use WABCO tools E, F, G, K and L (page 16) to press the
bushings of the guide pin (18 A) and the bushing of the short guide
pin (18 B) out of the calliper (1).
!! Do not put down the tool until the bushings (18A or 18B) have been pressed out
of the calliper (1).
G
L
1
18 A
E
18 B F
54
Renewing the seals
11.1.2 Assembly
!! Note the differences in the brake versions. The position of the long guide pin
(fitting bolt) (3) depends on the brake variant and the installation situation and
can be located at the entry as well as the exit side of the brake disc.
18A
1
18A
18A
N
55
Renewing the seals
H
G
18A
J
18B
M
–– Clean the sealing seats (ring groove) of the calliper (1) for the protection
caps (16) for guide pins.
ÖÖ The cleaned sealing seats must be clean and free from grease.
–– Manually push new protection caps (16) for guide pins into the sealing seats
/ ring groove (a) of the brake calliper (1).
–– Grease the bearing surfaces of the guide pins (3, 4) and the beaded edge of
the protection caps (16) for guide pins.
–– Make sure that the protection caps (16) for guide pins have an even and
wrinkle-free seat in the seal seat of the brake calliper (1).
–– Insert the two new guide pins (3, 4) into the calliper (1) from the cylinder
side.
–– Slide the protection caps (16) over the guide pins (3, 4).
–– Position the beaded edge of the protection caps (16) for guide pins into the
sealing seats (ring grooves) of the guide pins (3, 4).
!! Some versions of brakes are equipped with a sheet metal ring (c) and some are
not.
In the case of a design with sheet metal ring make sure that the sheet metal
ring (b) does not come off the protection cap (16) for guide pins.
With both versions, ensure that the beaded edge of the protection caps (16)
have an even and wrinkle-free seat in the sealing seats of the guide pins (3, 4).
56
Renewing the seals
Protection cap with sheet metal ring Protection cap without sheet metal ring
c
–– Place the calliper (1) on the brake anchor plate (2) and the inserted guide
pins (3, 4) into the fitting collar.
57
Renewing the seals
–– Insert two new hexagon socket screws (5) through the guide pins (3, 4)
inserted in the calliper (1).
–– Always tighten the longer guide pin (3) with press-fit first and then the
shorter guide pin (4) with clearance.
–– If the guide pins (3, 4) are released from the brake anchor plate (2) during
the maintenance work, you must use new hexagon socket screws (5) for
reassembly.
–– Screw the hexagon socket screws (5) to the brake anchor plate (2) using a
hexagon screwdriver.
–– Manually move the calliper (1) on the guide pins (3, 4) across the entire
displacement path several times and check for ease of movement; repeat
the action a number of times.
–– Grease the holes for the sealing covers (6) in the calliper (1).
–– Push the calliper (1) against the brake anchor plate (2).
58
Renewing the seals
–– Insert two new sealing covers (6) into the bores of the calliper (1).
–– Check the connecting surface on the fastening flange of the axle and the
brake anchor plate (2) and remove any dirt, rust or oil.
–– Place the brake with brake anchor plate (2) over the brake disc.
–– Install the brake on the axle.
Always note the relevant specifications of the axle or vehicle manufacturer
during this procedure and strictly adhere to them.
–– Use a box spanner to tighten the screws.
59
Renewing the seals
60
Renewing the seals
61
Renewing the seals
–– Turn the adjuster screw (20) counter clockwise about 30 mm out of the
calliper (1) by hand.
–– While threading it out, check the thread of the adjuster screw (20) for
corrosion and damage.
–– If the thread and/or visible internal brake parts are damaged or corroded,
replace the brakeChapter "9 Renewing the brake", page 46.
–– Replace the piston protection cap (17) if dirt or water has penetrated into the
calliper (1) through the seal seat or if the piston protection cap (17) has been
damaged during maintenance work.
–– Make sure that the grey seal (C) is correctly seated in the sealing seat of the
calliper (1). Press the seal (C) back into the seal seat by hand if necessary.
–– Clean the sealing seats (D) of the piston protection cap (17) in the calliper
(1) and the ring groove of the adjuster screw (20).
–– Ensure that no dirt or moisture enters the brake when cleaning.
–– Make sure that the sealing seat for the piston protection cap (17) in the
calliper (1) is clean and free from grease.
62
Renewing the seals
–– Push a new piston protection cap for adjuster screws (17), greased only
on the inner beaded edge, over the adjuster screw (20).
–– Centre the piston protection cap (17) and it onto the sealing seat (A) of the
brake calliper (1) by hand.
63
Renewing the seals
–– Insert the beaded edge (B) of the piston protection cap (17) into the sealing
seat of the adjuster screw (20).
R Q
–– Turn the adjuster screw (20) clockwise toward the calliper (1) so that
WABCO tool Q (page 16) can be placed onto the piston protection
cap (17).
64
Renewing the seals
–– To press in the piston protection cap (17), turn out WABCO tool S with
an open-ended spanner SW24 (page 16) until the piston protection
cap (17) sits flush in the sealing seat of the calliper (1).
!! Ensure that the cap has a correct sealing seat in the brake calliper (1) and that
the beaded edge of the piston protection cap (17) has an even and wrinkle-free
seat in the ring groove of the adjuster screw (20).
–– Install the pressure plate (7) and the brake linings (10, 11), and set the
clearanceChapter "7.4 Fitting the brake linings", page 39.
–– Having completed the work, test the brake on a roller test stand.
65
Replacing the adjuster
Read all safety instructions before carrying out the work steps to avoid injury
and/or material damage (Chapter "2 Safety information", page 8).
General Information
!! Depending on the installation position and the accessibility of the brake on the
vehicle, the brake will have to be removed to replace the return unit (8).
If access to the brake is not hindered, removing the calliper (1) is not necessary.
The brake cylinder still has to be removed.
The return unit (8) is used for adjusting the tensioning unit and thus the
clearance or for resetting to enable disassembly of the brake linings (10, 11).
The reset element (8) is located inside the calliper (1) and consists of three
parts: shaft (8a), gear (8b) and sleeves (8c) with seal.
Depending on the design, the return unit (8) can have a shaft (8a) with different
hexagon head (see figure).
8a 8b 8c
66
Replacing the adjuster
To renew the sleeve (8c) of the return unit (8), only use the WABCO
tools A, B and D(page 16).
A D B
–– Screw the front part of the WABCO tool A into the sleeve (8c).
–– Use the WABCO tool B to beat in the direction of the arrow and beat
or pull the sleeve out of the calliper (1).
WABCO tool B loosely sits on WABCO tool D and is moveable.
–– Remove the shaft (8a) and the gear (8b) from the calliper (1).
–– Clean the opening of the return unit (8) in the calliper (1).
ÖÖ The seat for the return unit (8) in the calliper (1) must be clean and free
from grease.
–– Ensure that no dirt or moisture enters the brake when cleaning.
67
Replacing the adjuster
–– Grease the seat (A) of the shaft (8a) in the calliper (1).
8a 8b 8c
68
Replacing the adjuster
–– Make sure that the shaft (8a) is centred in the opening of the calliper (1).
69
Replacing the adjuster
–– Place the sleeve (8c) in the opening of the calliper (1) so that the seal
(arrow) of the sleeve (8c) is on the opening of the calliper (1).
–– Centre the sleeve (8c) on the opening in the calliper (1) and press the sleeve
(8c) lightly into the opening so that the seal opening of the sleeve (8c)
concentrically encloses the hexagon head of the shaft (8a).
–– Position the small collar (arrow) of WABCO tool B on the sleeve edge
(8c).
–– Centre WABCO tool B on the sleeve.
70
Replacing the adjuster
–– Use WABCO tool B to drive the sleeve (8c) completely into the seat of
the calliper (1).
–– Place the brake with brake anchor plate (2) over the brake disc.
–– Always note the relevant specifications of the axle or vehicle
manufacturer during this procedure and strictly adhere to them.
–– Install the brake on the axle.
–– Tighten the counter-nut with .
71
Replacing the adjuster
–– Push a new sealing plug (9) into the opening of the calliper (1).
–– Ensure that the plug has a tight seat.
–– Connect the plug connector of the sensor cable with the electrical wear
sensor (15)Chapter "10.2 Fitting the wear sensor", page 50.
72
Workshop notes
13 Workshop notes
A
B D
C
LEGEND
A Vehicle manufacturer part number
B Production date
C WABCO part number
D Assembly number
73
Notes
© 2016 WABCO Europe BVBA – All rights reserved – 815 010 153 3 / 12.2016
WABCO (NYSE: WBC) ) is industry as it maps a route towards
a leading global supplier of autonomous driving, WABCO also
technologies and services that uniquely connects trucks, trailers,
improve the safety, efficiency drivers, cargo, and fleet operators
and connectivity of commercial through telematics, as well as
vehicles. Founded nearly 150 advanced fleet management
years ago, WABCO continues and mobile solutions. WABCO
to pioneer breakthrough reported sales of $2.6 billion in
innovations for advanced driver 2015. Headquartered in Brussels,
assistance, braking, stability Belgium, WABCO has 12,000
control, suspension, transmission employees in 39 countries. For
automation and aerodynamics. more information, visit
Partnering with the transportation
www.wabco-auto.com