CARLISLE INDUSTRIAL BRAKE, Carlisle Companies, Inc 1031 East Hillside Drive Bloomington, Indiana 47401-6597 (812) 336-3811 (800) 873-6361 fax (812) 334-8775 | CARLISLE 440-1052 CARLISLE SERVICE MANUAL FOR THE SERIES SA7000 LP 419-9154 SPRING APPLY/AIR RELEASE PARK BRAKE ASSEMBLY REV _ | ECN DESCRIPTION DATE_| DFT | CHK =| 11004 PRODUCTION RELEASE. ovo7/ii | PAP Page | of 9Manual 440-1052 TABLE OF CONTENTS| 5.0 OPERATION 6.0 TOOLS REQUIRED 11.0 DISASSEMBLY 12.0 PRE-ASSEMBLY 13,0 TORQUE PLATE ASSEMBLY 15.0 TORQUE SPECIFICATIONS 1.0 DESCRIPTION This manual covers installation and service procedures for the Spring Apply/Air Release Park Brake (SA7000). The $A7000 is generally mounted on the driveline and is designed to serve as a park brake and emergency brake as well Page 2 of 11Manual 440-1052 Illustration 2.0 Page 3 of IfManual 440-1052 30 PARTS LIST ITEM NO. |_PARTNO. [DESCRIPTION [ary] 1 NEEDLE BEARING 1 2 IBALL BEARING 3 3 THRUST CAM 1 4 CAM 1 5 TORQUE PLATE 1 6 [DOWEL PIN 3 7 LINING & CARRIER ASSEMBLY 2 3 16” SERVICE CHAMBER 1 eA CLEVIS 1 8B CLEVIS PIN 1 Bc COTTER PIN 1 8D 716-20 HEX NUT 2 ee LOCK WASHER 2 @F 12-20 HEX NUT i @ DISC SPRING 5 10 URETHANE SPRING 2 11 314-10 X 6 HEX BOLT 2 2 318-16 X 4-1/2 SOCKET HEAD CAP SCREW 1 13 318-16 X 7/8 FLAT HD SOCKET CAP SCREW | _2 14 MAGNET 1 15 5/8-18 COUPLING NUT 1 16 (8-16 SOCKET SET SCREW 1 17 [SHIM 4 18 PLUG 1 19 378-16 HEX NUT 2 20 374-10 JAM NUT/SLEEVE 2 2 [O-RING SEAL i 22 (O-RING SEAL 2 23 (O-RING SEAL 1 24 PISTON ASSEMBLY 1 25 [SPRING HOUSING 1 26 FLAT WASHER 2 27 FLAT WASHER-HARDENED 2 28 FLAT WASHER 2 29 RETAINING RING 1 30 LEVER 1 3t MOUNTING BRACKET 1 304-7170 [DISC SPRING KIT 1 304-7179 _ OVERHAUL KIT-BRAKE 1 304-7221 OVERHAUL KIT-CAM 1 304-7201 OVERHAUL KIT-SEALS. LININGS, SPRINGS | _1 305-7061 [URETHANE SPRING KIT 1 306-7165 [SEAL KIT 1 328-7843 [LINING & CARRIER ASSEMBLY KIT 1 Page 4 of IfManual 440-1052 4.0 PARTS KITS 304-7170 [DISC SPRING KIT 2 40-7688 __ [DISC SPRING. 5 TEM NO_| PART NO. [DESCRIPTION TY. 304-7179 OVERHAUL KIT-BRAKE T 2 80-7643 FLAT WASHER 2 10 40-7692 _ | URETHANE SPRING 2 29 85-7724 [RETAINING RING 1 23 68-8699 JO-RING SEAL t 21 66-282 [O-RING SEAL 1 1 711-7002 [NEEDLE BEARING T 27 80-7641 FLAT WASHER-HARDENED 2 ° 40-7888 [DISC SPRING 5 16 43-9250 | 5/8-18 SOCKET SET SCREW. 1 24 74-8013 [PISTON ASSEMBLY t 15 43-9247 __ [578-18 COUPLING NUT 1 2 68-8568 __ [O-RING SEAL 2 MNO [PART NO [DESCRIPTION Jay] 304.7221 OVERHAUL KIT-CAM 1 a 112-7027, 1 3 112-7026 1 2 411-7030, 3 6 20-712 3 [TEMNO._[ PART NO [DESCRIPTION ary. 304.7291 OVERHAUL KIT-SEALS. LININGS, SPRINGS [1 306-7165 [SEAL KIT 1 328-7849 [LINING & CARRIER ASSEMBLY KIT 1 304-7170 [DISC SPRING KIT 1 305-7061_ URETHANE SPRING KIT 1 TEM Ni PART NO___JDESCRIPTION T_ary_] 305-7061 [URETHANE SPRING KIT 1 7 40-7692 _ [URETHANE SPRING 2 N oid 306-7165 SEAL KIT 1 2 68.202 [O-RING SEAL 1 23 68-8699 O-RING SEAL 1 2 68-8568 _ [O-RING SEAL 2 TEM Ni PART NO. JDESCRIPTION T_ary_] 328-7849 [LINING & CARRIER ASSEMBLY KIT 1 7 244-7852 | LINING & CARRIER ASSEMBLY 2 2 43-8910 | 3/8-16 X 4-1/2 SOCKET HEAD CAP SCREW 1 19 63-7641 [3/6-16 HEX NUT 2 Page Sof IfManual 440-1052 ITEM NO. [PART NOT DESCRIPTION [ory] 3 394-165 [SERVICE CHAMBER - TYPE 16 1 8A = CLEVIS 1 38 u LEVIS PIN i aC = PIN = COTTER, 1 a0 = NUT = HEX 7/16:20 2 3E a LOCK WASHER 2 3F y NUT — HEX 1420, 4 31 95-8375 __ | MOUNTING BRACKET 1 3 43-9016 [578-16 X 7/6 FLAT HD SOCKET CAP SCREW | 2 30 93-6062 LEVER 4 29 85-7724 [RETAINING RING 7 Ea 80.601 [FLAT WASHER, 2 NOTE: PARTS NUMBERS MARKED * ABOVE ARE INCLUDED WITH THE 394-165 5.0 OPERATION Five dise springs (9) are used to hold the SA 7000 park brake in the actuated state. The springs push the cam (4) and piston assembly (24) into the lining & carrier assembly (7) which squeezes a driveline mounted disc, The brake is released by air entering a 3/8-18 NPT threaded inlet inthe top of the service chamber (8) ‘which extends the push rod, there-by rotating the lever (30) and thrust cam (3) which compresses the disc springs (9). 6.0 TOOLS REQUIRED Spanner Wrench (Two 5/16 inch dia, pins on a 3.25 inch dia, hole circle) ‘Small. Screwdriver 5/16 inch Allen Wrench 15/16 inch Socket 1-1/8 inch Crows Foot Torque Wrench (capable of 200 LB-FT) 7/16 inch Combination Wrench 13/16 inch Spark Plug Socket or 13/16 inch Drop Neck Box End Wrench 7.0 INSTALLATION 7.1 Slide brake over disc and into the mounting position (per vehicle specification). NOTE: Mount Brake so that the linings are parallel with the disc within 0.015 inch. Dise to be located the proper distance from mounting surface per assembly drawing. 7.2 Start hex (mounting) bolts (11) into mounting surface far enough fo just support the brake. 73 Remove plug (18), loosen the coupling nut (15) and then tighten socket set serew (16) until Finings (7) are clamped on to the disc. This locates and holds the brake in the proper position to set the hex (mounting) bolts. 74 Tighten hex (mounting) bolts (11) until they make contact with the urethane springs (10), then tighten 4 flats (approx. 0.07 inch) more. This puts the proper amount of pre-load on the urethane springs. 7.5 Tighten jam nuvsleeves (20) against mounting surface and torque per Section 15.0 Torque Specifications CAUTION: Brake linings are susceptible fo contamination. When installing or servicing brakes, ‘keep all oil and fluids away from the linings. Poor brake performance may result if the linings are contaminated. Page 6 of 11Manual 440-1052 7.6 Attach air line to one of the 3/8-18 NPT inlet ports located on the service chamber (8). Plug the other port. 8.0 ADJUSTMENT CAUTION: Do not exceed 70 psi air pressure to avoid damage to the brake, 45 psi is required to fully release the brake, 8.1 Apply ar pressure to the brake. 82 Setrunning clearance between the dise and lining surface by removing the plug (18), and doing the following: Loosen coupling nut (15). Rotate the socket set screw (16) until the brake is clamped onto the dise. Loosen the outer hex nut (19) and rotate socket head cap serew (12) until it makes contact with the bump stop on the ‘mounting bracket, then back it off 4 turn (,016"), Hold the socket head cap screw (12) in place while tightening the outer hex nut (19) against the inner hex nut (19) to 30-35 ft-lbs. Finally, back off socket set screw (16) % turn (.028"). Hold socket set screw (16) in place and torque coupling nut (15) per Section 15.0 ‘Torque Specification, Replace plug (18) and torque plug per Section 15.0 Torque Specifications. 8.3 Re-adjust the brake when running clearance reaches a total oF 0.100 inch, 9.0 REBUILD CRITERIA 9.1 Any signs of air leakage. 92 Thickness of ether lining is less than 0,031 inch, 9.3 Cracked or chipped linings. 10.0 REMOVAL FROM VEHICLE 10.1 Block vehicle in position to prevent movement. 10.2 Apply air pressure to the brake, remove plug (18), back off both nuts (19), loosen socket head cap serew (12) and socket set serew (16). cAUTIO Do not exceed 70 psi air pressure to avoid damage to the brake. 45 psi is required to fully release the brake. 10.3 Release air pressure from the brake and loosen the air line and cap inlet port 10.4 Loosen jam nuvsleeves (20), remove hex (mounting) bolt (11) from bracket and remove brake. 11.0 DISASSEMBLY CAUTION: Itis recommended that the brake be removed according to seetion 10.0 prior to disassembly. It is important to follow the following directions regarding the removal of the spring housing (25) and the lining & carrier assemblies (7) very closely. 1.1 Apply air pressure to the brake, Remove plug (18) and loosen socket set serew (16). CAUTION: Do not exceed 70 psi air pressure to avoid damage to the brake, 45 psi is required to fully release the brake. 11.2 Release air pressure from the brake and remove socket head cap screw (12), hex nuts (19), and lining & cartier assemblies (7). 11.3 Using a press and special mandrel tools as shown in illustration 3.0, compress dise springs (9) to reduce force on spring housing (25). Use a spanner wrench to remove the spring housing (25) (counter-clockwise irection). The dise springs (9) will be accessible when the spring housing is removed, Page 7 of IfManual 440-1052 NOTE: The spring housing (25) may be removed without compressing the dise springs (9), however it is not recommended due to the high torque required. | 6000-8000 Les, waNDREL (rewae Bg 00 NOT COMPRESS sssione; — . SPR PSE SERN nr; COMPRESSION ANCE pene Q uanogey ‘ ;—— (real Exo} 1 1408.020 Sin Eoureession a nose. (MALE END) mance a 1.595.010 750 wax. Bin’ Puce: a FKTURE Illustration 3.0 114 Remove cotter pin (8C), clevis pin (8B), and washers (26) from clevis (8A). ILS Remove service chamber (8) from mounting bracket (31) by removing hex nuts (8D) and lock washers (SE. 11.6 Remove retaining ring (29) and lever (30) from the spline on the thrust cam (3), 11.7 ‘The opposing cams (3 & 4), piston assembly (24), and dowel pins (6) can be removed by pressing them out of the torque plate (5) from the ining & cartier assembly (7) side. 11.8 Remove ball bearings (2) and piston assembly (24) from cams (3 & 4). 11.9 ‘The o-ring seal (21) can be removed from the piston assembly (24) if necessary. 11.10 Remove needle bearing (1), hardened washers (27), and o-ring seal (23) from the torque plate (5) once the ‘cams (3 & 4) are removed. Page 8 of 11Manual 440-1052 12.0 PRE-ASSEMBLY I 122 123 124 125 126 27 121 1212 Clean all metal parts prior to assembly Blow excess cleaning solution off ofall parts and out of all fluid passages. All seals should be lubricated with mineral oil based fluid, (suggested product; UCON LB285 fluid), prior to assembly. Apply a thin coat of *high grade lithium based grease around the inside diameter of the thrust cam (3). “Suggested produ Chemtool Inc. Alpha 2000 Apply a liberal coating of *high grade lithium based grease to the three ball bearings (2) and the ramps of both the thrust eam (3) and the eam (4). Apply a liberal coating of *high grade lithium based grease to both sides of the needle bearing (1) and the sides ofthe hardened washers (27) facing the needle bearing Apply a liberal coating of *high grade lithium based grease to the three dowel pins (6) and the three partial holes of the cam (4). Apply a liberal coating of *high grade lithium based grease to all surfaces of the ive dise springs (9). Place the five dise springs (9) in the spring housing (25) with the springs placed in an alternating, cupped face to cupped face orientation, The top spring should be oriented cupped face out Seg illustration 4.0 Illustration 4.0 Apply a liberal coating of *high grade lithium based grease to the inside diameter of the spring housing (25), Apply a liberal coating of *high grade lithium based grease in the mounting bolt counterbores on the back side ofthe torque plate (5) where the jam nutsleeves (20) mate to it Apply a liberal coating of *high grade lithium based grease to the small outside diameter of the thrust cam (3) and to the bore in the torque plate (5). Page 9 of IfManual 440-1052 13.0 TORQUE PLATE ASSEMBLY 1B 132 133 134 138 136 137 138 13.10 13.1 13.12 13.13, 13.14 14.1 142 Install seal o-ring (21) in seal groove on piston assembly (24), Slide the piston assembly (24) into the bore located in the thrust eam (3) until the seal o-ring (21) is inside the pi y 8 bore. Install seal o-ring (23) inthe groove located in the small bores in the torque plate (5). Refer to erass section fn the brake assembly drawing. Install the pre-greased needle bearing (1) between the two hardened washers (27) as shown in Detail A on the brake assembly drawing. With needle bearing and hardened washers (1 & 27) in place, install pre-greased thrust cam (3) into torque plate (3). Install the pre-greased cam (4), and dowel pins (6) in torque plate (5). Thread socket set serew (16) through the cam (4) until it contacts the piston assembly (24), Place dise springs (9) into spring housing (25). Springs should be placed in an alternating cupped face to cupped face orientation. The top spring should be oriented cupped face out. See Illustration 4.0 Apply a thin coating ofa thread sealant (suggested product; Loctite #577), to the mating threads of the spring, housing (25) and the torque plate (5). Install spring housing (25) containing springs into torque plate (5), using an appropriate fixture (as shown in illustration 3.0), to compress the spring pack, until the spring housing face contacts the torque plate (5) face. A spanner wrench is required to tighten the spring housing ‘Torque spring housing per Section 15.0 Torque Specifications. Caution: A fixture must be used so that springs are not over compressed. (See Illustration 3.0) Assemble flat washers (28) and urethane springs (10) on the hex (mounting) bolts (11) then slide hex. (mounting) bolts through bolt holes in the torque plate (5). Thread jam nuvsleeve (20) onto hex (mounting) bolt. The cylindrical part ofthe jam nut/sleeve should extend into the torque plate, Refer to cross section on brake assembly drawing. Install lever (30) on the spline of thrust cam (3). ‘The centerline of the lever should be oriented parallel tothe top of the torque plate (5) as shown on brake assembly drawing, Install retaining ring (29) in groove on the thrust cam (3) Install lining & cartier assemblies (7), ‘Thread socket head cap screw (12) into hex nuts (19) located in the slot inthe back side ofthe torque plate (5). Torque the two hex nuts (19) against each other per Section 15.0 ‘Torque Specifications. Lubricate seal on plug (18) and serew plug onto spring housing (25). Note: Plug must be torqued per Section 15.0 Torque Specifications. ERVICE CHAMBER ASSEMBLY CAUTION: Do not disassemble service chamber (8). Position service chamber (8) onto mounting bracket (31). Check the position of clevis (8A) onthe service ‘chamber push rod. The hole in te clevis (8A) must line up with the hoe in the lever (30). Adjust i necessary and tighten the hex nut (SF) securely. Install the lock washers (SE) and hex nuts (8D) onto the service chamber mounting studs. Torque nuts per Section 15.0 Torque Specifications. Page 10 of 11Manual 440-1052 14.3 Pin clevis (8A) and washers (26; one om each side of the lever) tothe lever (30) with clevis pin (8B) and. cotter pin (8C). 0 TORQUE SPECIFICATIONS DESCRIPTION (TEM Nt THREAD SIZE _LUB/DRY TORQUE. INLET FITTING ON SERVICE CHAMBER (8) 318-18 NPT 37-44 (IbiA) SERVICE CHAMBER MOUNTING HEX NUTS (8D) 716-20 (63-73 (bit) ‘MOUNTING BRACKET SCREWS (13) 318-16 25-30 (Ibi) HEX NUT (SF) 112-20 (60-73 (Ib) TAM NUTSLEEVE 314-10 200 bt) HEX NUT (19) (torque against each other) 318-16 30-35 (Ibi) ‘SPRING HOUSING 25) 35816 60-80 (Ibi) PLUG (18) 2-115 NPS 45-50 (Ib) COUPLING NUFGS) 518-18 50-55 (Ibi) Page 11 of If