assembly and maintenance instructions -...

Assembly and Maintenance InstructionsMechanical Sliding CalliperDisc Brake Type 1000 V-G

1st Edition

8150101133815 010 113 3

Copyright WABCO 2006

Vehicle Control SystemsAn American Standard Company

The right of amendment is reservedVersion 001/11.05(en)

8150201133 815 010 113 3

31

Table of Contents

Page

1. Description the Mechanical Sliding Calliper Disc Brake 4

1.1 Introduction 4

1.2 Braking sequence 4

1.3 Automatic adjuster mechanism 4

2. Service Instructions 6

2.1 Safety tips during repair 6

2.2 General check 6

2.3 Checking Brake Function 7

2.3.1 Checking Adjuster Function 7

2.4 Checking Brake Pads 8

2.5 Checking Brake Disc 9

2.6 Checking that the brake calliper can move on the guide pin 10

3. Renewing Brake Pads 10

4. Renewing Gaiters 13

4.1 Renewing Gaiters on Brake Piston and Brake Shaft 13

4.2 Renewing Guide Pin Gaiters and Bushes 19

5. Renewing Brake 22

Table 1: Spanner Widths [AF] and Tightening Torques [Nm] 23

Note:The Service Instruction focuses on trained specialists. Operations on the brake can only becarried out if the appropriate paragraphs have been read through and understood. The safetyinstructions according to paragrahph 2.1 are to be considered and to be followed.

These Service Instructions are copyright. All rights reserved.

This publication is not subject to any update service. You will find the latest versions in IN-FORM under www.wabco-auto.com when quoting the publications number 815 020 113 3.

No part of this publication maybe reproduced, stored in a retrieval system, or transmitted inany form or by any means, electronic, photocopying, recording or otherwise without permis-sion in writing from WABCO Radbremesen GmbH.

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1. Description of the Mechanical Sliding Calliper Disc Brake1.1 Introduction

The sliding calliper disc brake is supposed to be used incommercial vehicles and buses on front and rear axle asservice, auxiliary and parking brake. It is actuated me-chanically via a diaphragm brake cylinder or a springbrake cylinder.

The brake calliper (1) moves axially on guide pins (3) ofthe brake carrier (2), see fig. 1.

Mechanical Sliding Calliper Disc BrakeType 1000 V-G

Fig. 1

1

2 23

1

3

The radially open brake calliper allows an easy and fastbrake pad change.

The actuating mechanism of the brake is equipped withan automatic adjuster mechanism to compensate the padwear, see fig. 2. This maintains a predetermined clear-ance independend from overall load configuration anddifferent operating conditions.

Further advantages result by fitting of the actuatorthrough a console and a lever - see fig. 1. Via variation ofthe lever lenght the actuating force can optimally beadapted and the position of the brake cylinder can be se-lected freely concerning the brake. The lever can beturned 360° in angle steps of 7.5°. Thus a maximumsteering turn for the front axle is possible.

1.2 Braking sequence

Applying the brakes the linear clamping force of the brakecylinder activates a rotary motion of the brake lever (44).The expander turns this rotation into a linear lengthwisemovement of the piston, so that the brake pads arepressed against the brake disc.

1.3 Automatic adjuster mechanism

During the turn of the brake shaft when applying thebrakes an adjuster mechanism screws out the brake pis-ton towards the brake disc, if the required clearance be-tween the brake pads (38, 39) and the brake discincreased through pad wear. If the pads are touching thebrake disc, a clutch inside the adjuster loses friction andthe adjustment is interrupted.

Either when installing new brakes or when changing thebrake pads, the adjustment or reset of the brakes takesplace through the adjuster mechanism. The adjustmentnut can be turned with a hexagon. The opening for thehexagon is located on the back of the brake and is pro-tected by a sealing plug.

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Components of the brake

1 Brake calliper1.1, 1.2 Calliper halfs2 Brake Carrier3 Guide pin

21 Piston

31 Spreader plate

36 Binding screws

38, 39 Brake pad

40 Hold-down springs

41 Pad hold-down pin

44 Brake lever

Mechanical Sliding Calliper Disc Brake Type 1000 V-G

1

Figure 2: Top view and sectional view

21

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1

2. Service Instructions

This instruction with the following pictures contains therequired steps and work sequences to replace the avail-able repair kits. The spanner size and the tightening tor-ques in the sequences are listed in table 1 (seepage 23). For lubrication use only the tube of grease suppliedwith the brake repair kit.

2.1 Safety tips to be considered duringrepair

The flawless technical condition of the disc brake is mostimportant to ensure good driving and safe braking char-acteristics.

Observe brake pad and disc wear limits!Worn-out pads and discs reduce the brakeeffectiveness and cause brake failure! Dan-ger of accidents! Burned, glazed or oil con-taminated brake pads must be replacedimmediately. Always replace brake pads on a per axlebasis!

During repairs on the brake the vehicle mustbe parked on a level surface and blocked toprevent rollaway. Only approved and suitablefixtures are to be used for the lifting andblocking of the vehicle. While working on thebrake ensure that the brake cannot be actu-ated inadvertently. Do not actuate the brake while the brakepads are removed. Danger of Bodily Injury!

Do not clean the brake with pressurised air orother high cleaning pressure apparatus.Danger of Bodily Injury! Danger of destruc-tion of rubber parts!

Keep hands and fingers out of the inside ofthe calliper to avoid injury!

A second technican must assist during re-moval and installation of the brake. HeavyLoad - Danger of Bodily Injury!

During repairs outside of the vehicle, thebrake must be secured in a fixture, such as aheavy vise as high torque is required duringremoval and installation of the bolts. Dangerof Bodily Injury!

The brake calliper with clamping unit shall not beopened. Therefore the bolts holding the cover shall notbe loosened.

Only original and genuine WABCO Service Parts andapproved brake pads are to be used.

During repairs use only recommended tools. Do not usea power-driven socket or tools! Tighten nuts and boltsonly to specified torque limits.

With newly installed brake pads during the first 50 kmemergency stops should be avoided if possible. Alsoavoid long braking cycles and forced braking.

When wear of the cast brake parts such as cracks orheavy abrasion is noticied replace the entire brake as-sembly according to the instructions.

Upon completion of repairs the vehicle's braking systemmust be tested on a roller dynamometer. If no roller dy-namometer is available a driving test with brake applica-tions must be perfomed.

2.2 General checks

When changing the brake pads, a brake check shouldbe performed as follows:

• Check piston gaiter (bellow) for damages. Whendamaged, exchange bellow according to Section 4.1.

• Check gaiters (bellows) made of rubber on the guidepins for damage. In principle the guide pins are main-tenance-free. Any damaged gaiters must be re-placed immediately. At the same time maintenanceand grease of the guide pins must take place.Change of gaiters according to Section 4.2.

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2.3 Checking Brake Function

2.3.1 Checking Adjuster FunctionGeneral Note: The turning directions and the torques for the hexagonon the adjustment nut are given in table 1, position I.

Work sequences:• Remove the sealing plug (16) for the adjustment.

• Use the ring spanner AF 10 (table 1, position I) on thehexagon of the adjustment nut to place back the ad-justment by 1 turn.

Caution: Do not overload the adjuster hexagon! Do not use anopen-ended spanner. With the ring spanner mount-ed on the adjuster nut ensure that there is sufficientsuch that it will not be prevented from turning duringthe adjuster check.

Failures that might occur:No click-sound of the skipping adjuster clutch audi-ble! Adjuster defective ⇒ Exchange brake

Adjustment nut cannot be turned! Adjuster defective ⇒ Exchange brake

• Apply the brake approx. 5 to 10 times (approx. 1 bar)or move the brake lever in the operating directionmanually.

• Observe, that the hexagon rotates with the ring span-ner in the operating pulse step by step.

An axial back and forth movement of the hexagon for2 mm towards the brake disc takes place on every brakeoperation.


• Check proper placing of the sealing plug in the brakeshaft. If not, check whether the inner parts of the ad-justment device are corroded. If yes, exchange thebrake according to the work sequences in section 5.

• Make sure that the sealing caps of the guide pins areproperly seated in the brake calliper and check themfor damage.

Fig. 3

16

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Note: The angular deflection of the brake lever decreas-es during the operating pulse. Therefore also the axialmovement of the hexagon decreases.

The adjuster is in order when the ring spanner rotates asdescribed above.

• Remove ring spanner (arrow).

• Refit plug (16) and ensure that the plug is placedproperly.

Failures that might occur:Ring spanner does not turn!Adjuster defective ⇒ Exchange brake.

Ring spanner turns only with the first actuation!Adjuster defective ⇒ Exchange brake

Ring spanner turns forward and backward with every actuation!Adjuster defective ⇒ Exchange brake

Hexagon moves not towards the brake disc!Brake piston blocked ⇒ Exchange brake

Hexagon does not return from the brake disc!Brake piston blocked ⇒ Exchange brake

2.4 Checking Brake Pads

Note: the brake pad thickness is to be checked regularlydepending on operating conditions during maintenanceintervals and under applicable local laws and regula-tions. Burned, glazed or oil contaminated brake padsmust be replaced immediately. The thickness of the re-sidual friction material should not be less than 2 mm.

Always replace brake pads on a per axle basis!

Work sequences:Caution: To avoid damage to the brake disc, the brake padsshould be replaced at the latest when the thinnestsection of the friction material is 2 mm.

A = residual friction material thickness 2 mmB = total friction material thickness 16 mm

At residual friction material thickness A < 2 mm renewbrake pads according to section 3.


Brake padFriction material

Fig. 4

Fig. 5

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2.5 Checking brake disc

Note: If all checks have been carried out, removal andinstallation of the brake pads are no longer required.

Important: Observe wear limits of the brake disc!Worn-out discs reduce the brake effec-tiveness and cause brake failure! Dangerof accidents!Always replace brake discs on a per axlebasis! Install only cleaned brake discs.The brake discs must be free of grease.

Work sequences:• Remove brake pads according to section 3 and

measure thickness disc over the rubbing faces.

C = total disc thickness - new 30 mm

D = wear allowance limit 26 mmthe brake disc must be renewed

E = total pad thickness - new 22 mm

F = pad backplate thickness 6 mm

G = minimum residual friction material thickness2 mm

H = absolute minimum pad and pad backplatethickness 8 mm, the brake pads must be re-newed.

If the wear measurement is D ≤ 26 mm, the brake discmust be exchanged. The renewal is recommended ona per axle basis.

Brake Disc Condition Inspection:Check brake disc for cracks, condition of the rubbingfaces and maximum wear dimension.

A = crazing = permissible

B = radial cracks to max: 0.5 mm (width and depth)= permissible

C = uneveness under 1.5 mm of the plate surface = permisssible

D = continuous cracks = not permissible

a = braking surface

Fig. 6

Fig. 7

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Checking brake disc runout:• Mount a dial indicator on the brake carrier.

• With the disc installed measure the runout by rotatingthe hub as shown in fig. 8. Limit 0.15 mm. At highervalues rework or renew the disc.

• Install the brake pads according to section 3 and ad-just the clearance.

2.6 Check that the brake calliper canmove on the guide pin

Work sequences• Remove pads according to section 3.

• Slide the calliper on the guide pins several times byhand over its total displacement and check for free-dom of movement.

Important: While moving the brake handlethe calliper only from outside to avoid in-jury! Do not squeeze guide pins dust capsagainst brake calliper! The movement must be running smooth.Change the sliding bushing according tosection 4.2 if the movement is not runningsmooth.

• Install the brake pads according to section 3 and ad-just the clearance.

3. Renewing Brake PadsNote:Always replace brake pads on a per axle basis!

When changing the brake pads check the brake disc forits condition and its wear according to section 2.5. Incase of visible deep disc cracks change also the brakedisc. Install only cleaned and free of grease brake discs.


Fig. 8

Fig. 9

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Work Sequences for Brake Pad Removal:• Remove sealing plugs (16).

• Readjust the brake with the hexagon.(table 1, position I).

Caution: Do not use a power-driven socket!

• Hit the pad hold down pin (41) with a pin punch-ing tool towards the wheel side out of the brake.

Important: When hitting the pad holddown pin (41) watch for hold-downsprings (40) jumping out!

• Remove worn brake pads.

• Before installing the new brake pads, use a wirebrush to remove any corrosion from the guide surfac-es in the brake anchor plate (2) and the spreaderplate (31).

Important: Take care not to damage the dust caps(7, 8). The guide surfaces must be free of grease!

• Move the brake calliper towards the cylinder side andcheck the gaiters (7, 8) of the brake piston and theguide pins for wear and damage. Renew all defectgaiters according to Section 4.1 and 4.2!

• Check adjustment according to section 2.3.1.

• Check brake disc according to Section 2.5.

• Check guide pins according to Section 2.6.

Fig. 10

Fig. 12

Fig. 11

7

40

F

312

8

41

16

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Work Sequences for Brake Pad Installation:

• Insert the brake pad (39) on the wheel side and thebrake pad (38) on the actuation side.

• Insert the feeler gauge (1 mm) in the middle of thebrake between brake calliper and brake pad plate onthe wheel side (arrow) and push the brake calliperagainst the brake disc.

• Adjust the brake by screwing the hexagon of the ad-justment nut until both brake pads touch the brakedisc (table 1, position I). Remove feeler gauge.

Caution: Do not overload the adjuster hexagon!

Note: Do not fit hold-down springs and pad hold down pin be-fore adjusting air gap!

• Place new leaf springs (40) onto the brake pad.

• Push the springs against the brake pad plate.

• Drive the new pad hold down pin (41) into the calliperfrom the wheel side.

Note: The clamping sleeve of the pad hold-down pin(41) sits in the calliper half on the wheel side (1.2).

• Fit new plug (16) to the opening in the brakeshaft (20)! Check and make sure the correct seat!

• Move the belt of the sealing plug behind the brake lever.


Fig. 13

Fig. 14

38

39

F

39

411.2

40

38

12

Fig. 15

16

20

Fig. 14

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• Place the upper end of the belt on the brake lever.

• Press the clip into the hole and fix the belt.

• Fit the plug (16) to the opening in the brakeshaft (20).

• Adjust the clearance of the brake by actuating it sev-eral times.

• Ensure that the wheel hub turns freely.

Caution: Upon completion test the brakes onthe roller dynamometer!

4. Renewing GaitersNote: When replacing all of the gaiters in the caliper, thework sequences 4.1 and 4.2 are to be combined. In thiscase work sequences will not be repeated.

When replacing individual gaiters, follow the corre-sponding work sequences of the seccions 4.1 and 4.2.

4.1 Renewing Gaiters on Brake Pistonand Brake Shaft

Work Sequences for Seal Removal:• Remove the brake pads according to section 3 and

unscrew the spreader plate (31) from the brake pis-ton (21) (table 1, position IV).

• Clean the spreader plate and the area of contact be-tween brake piston and spreader plate.

Fig. 16

Fig. 18

Fig. 17

1620

3121

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• Remove brake cylinder (table 1, position II).

• Hit the spring pin (43) out of the brake lever.

• Disassemble the brake lever from the brake shaft us-ing two screwdrivers or a pull-off tool.

• Cleaning the brake lever and the brake shaft.

• For further working sequences, removing the con-sole (45) from the brake calliper is recommended.Therefore remove the screws (46) (table 1,position VI).

If necessary, remove the whole brake from the axle andclamp it in a vice in an appropriate position. Thereforeremove the hexagonal screws (47) from the brake fas-tening (table 1, position III).

• Removing the O-ring (10) from the brake shaft (20).


Fig. 20

Fig. 1943

F

46

45

Fig. 2147

10

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• Push the compund sealing washer (9) out of thebrake calliper using a small screwdriver. Do notdamage the seat for the sealing washer in thebrake calliper.

• Clean the sealing seats and the brake shaft (20).

• Remove the gaiter (8) of the brake piston (not shown)from the seat of the brake calliper using a screwdriv-er. For this purpose push the screwdriver behind theback of the sealing washer and support it using thefront side of the brake piston.

• Clean the sealing seats.

Checking the condition of the brake piston:• Unscrew the brake piston (21) on the hexagon of the

adjustment nut (back of the brake) (table 1,position I).

• Check the brake piston visually for traces of corro-sion and moisture. If yes, renew the brake accordingto section 5. If no, rescrew the brake piston.

Fig. 23

Fig. 24

Fig. 22

8

21

20

20

9

9

10

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Work Sequences for Sealing Installation:

• Grease the inner lip seal of the combined sealingwasher (9).

Caution: Do not grease the outer area of thesealing washer!• Push the new compund sealing washer (9) over the

serration of the brake shaft (20) using an appropriatefitting tool.

• Push the sealing washer in the seat of the calliper(1.1) with a fitting dimension X of 1 ± 0.3 mm. See installation position and specification of parallel-ism in Fig. 25.

Note: The compound sealing washer is used for the ra-dial and axial sealing. Push in the sealing washer thatway, that dirt from outside is prevented from coming in,this says the lip seal points outwards.

• Push the spring pin a little inside the opening of thebrake lever (44).

Note: The spring pin (43) should be inserted towards theactuation of the brake lever (44).

• Wet the serration of the brake shaft (20) and thebrake lever (44) with anti-seize assembly paste.

• Put the brake lever (44) on the serration of the brakeshaft (20).

Caution: For the correct position of the brake lever(44), the line markings between the brake lever andthe brake shaft have to match. The brake lever hasto point towards the console.

• Hit the spring pin (43) into the brake lever (44).

Note: The spring pin has to engage into the ring grooveof the brake shaft and is used for the axial saving of thebrake lever.


Fig. 25

Fig. 26

9

F

201.1

Rangegreasing!

9

0,3

X

F 20 4443

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• Grease the annular chamber (arrow) between thebrake lever and the brake shaft.

• Pushing the new O-ring (10) over the brake lever(44).

• Push a tool, e.g. screwdriver, between O-ring andbrake lever.

• Pull the O-ring into the greased annular chamber.

• Push the O-ring into the annular chamber all side byhand.

• Push the new gaiter (8) in its greased seat of thebrake calliper (1) using a fitting tool.

• Slightly grease the sealing bead of the gaiter (8) andfit it into the ring groove of the piston (21).

Note: Do not damage the rubber caps and gaiters dur-ing the installation.

Fig. 29

Fig. 27

Fig. 28

F

10

44

1

218

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• Fix the spreader plate (31) with the new pressurespring (17) and the new screw (18) to the brake pis-ton (21) (table 1, position IV).

Installation instruction for attaching the con-sole with actuation cylinder on the assembledbrake.Note: The position and contour of the console on the fig-ure does not always match the particular installation ofthe brake, but the following installation instructions applyalways.

• Set the console with the assembled actuation cylin-der against the brake calliper.

• Screw the screw pin (46) with spanner AF 19 and atightening torque of 135 ± 9 Nm (use AF 10 for hex-agon socket screw) / (table 1, position VI).

• Align the piston rod towards the brake lever (44) - see arrow.

Caution: The length of the piston rod needs to bematched to the position of the brake lever. Do nottwist the brake lever out of its starting position!

• Fix the piston rod to the brake lever (44) and secure it.

• Fixing the lock nut to the piston rod.

• Fix the brake on the axle (table 1, position III).

• Install brake pads according to Section 3. and pay at-tention to Notes.

• Finally insert the new sealing plug (16) paying atten-tion to the installation notes in section 3.


Fig. 30

Fig. 32

Fig. 31

16

46

44

31 21

1817

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4.2 Renewal of the gaiters and bushes ofthe guide pins

Working sequence for demounting the gaitersand bushes:• Remove brake pads according to Section 3.

• Remove the brake cylinder, the brake lever and theconsole according to section 4.1.

• Remove cover (6) from brake calliper with hammerand flat chisel.

Note: Do not damage the seats in the brake calliperwhen removing the cover!

• Loosen both cylinder screws (5) from the brake car-rier (2) (table 1, position V).

Important: Prevent the brake calliper from fallingdown when loosening the cylinderscrews! Danger of Bodily Injury!

• Detach the brake calliper from the brake carrier andremove the guide pins (3).

• Remove both gaiters (7).

• Clean the area of contact on the brake carrier and theguide pins (3).

Fig. 33

6

F

5

2

Fig. 34

Fig. 35

37

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• Press the sliding bushes (4) out of the brake callipertowards the wheel side using a pressing tool.

Working sequence for installing the gaiters andbushes:• Clean the borehole for the guide pins and the annular

groove for the gaiters in the brake calliper (1).

Note: For inserting the sliding bushes (4) put the brakecalliper (1) onto a straight and rigid board, the wheel sidefacing downward.

Position of the guide pins with sliding bushes in thebrake calliper driving forward:

Install two sliding bushes for every guide pin in the order A, B.

• For the guide pin (3) first push in bush A using an in-sert mandrel (L1 = 44 mm), and afterwards push inbush B using an insert mandrel (L2 = 15 mm), bothtimes as far as the mandrel will go.

• Grease the bushes and the space between them.


Fig. 36

Fig. 37

4 4

41

F F

BA

L1

L2

Fig. 38

F F

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• Insert the new gaiters (7) into the seats of the brakecalliper (1).

Note: Clean seats before fitment. For easy insertion ofthe gaiters, slightly grease the gaiter lips.

Ensure that the gaiter sits free of folds in the ringgroove, according to the cross-section forfigure 40).

• Grease the sliding surface of the guide pins (3).

• Insert the guide pins (3) from the outside into thebrake calliper.

Note: To make sure the gaiter lip does not slide out ofthe annular groove when inserting, first move the guidepin in direction A and then move it back in direction B,see cross-section for figure 40.

• Grease gaiter lips, slip them over the guide pins (3),and insert them into the into the annular grooves -see arrow - of the guide pins.

Caution: The guide pin on the brake disc leading side is theclose fit. The guide pin on the brake disc trailingside is the clearance fit. Remove all exess grease. The brake carrier end ofthe guide pins (arrow) must be free of grease!

• Place the brake calliper (1) with guide pins on thecarrier (2) and insert the guide pins (3) into the collar.

• Insert the new cylinder screws (5) in the guide pinsand screw them on the brake carrier (table 1,position V).

Caution: The areas of contact between the guidepins and the brake carrier need to be free of greasewhen assembling!Do not damage the gaiters during the assembly.First screw the guide pin with a close fit tightly onthe brake disc leading side.If the guide pins get detached from the brake carrierduring maintenance work, new cylinder screwsmust be used when reassembling!

Fig. 39

Fig. 41

Fig. 40

17

3 4

A B

317

52

1

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• Move the brake calliper on the guide pins back andforth several times and check for freedom of move-ment.

• Grease the boreholes for the covers (6) in the brakecallipers (1).

• Place new covers (6) in the boreholes of the brakecalliper and press them in via suitable tool up to thecollar.

• For air pressure balance raise the gaiters carefully inthe area of the ring groove and insert them back intothe ring groove.

• Assemble brake pads according to Section 3.

• Mount the console, the brake lever and the brake cyl-inder according to section 4.1.

5. Renewing BrakeNote:The new brake is supplied as a pre-assembledunit and may be mounted to the vehicle's axle via thebrake carrier. Observe the direction of installation ofthe brake in the vehicle directed forward (left brake/left vehicle side; right brake/right vehicle side).

Work Sequences for Brake Removal:• Remove and check brake pads according to

Section 3.

• Remove the brake cylinder, the brake lever and theconsole according to section 4.1.

• Loosen the hexagon scews (47) (table 1, position III)and remove the brake from the axle.

• Check brake disc according to section 2.5.

Working sequence for Installation:• Remove the transport protection from the brake

calliper.

• Put the brake over the brake disc and fasten it on theaxle. Thighten the hexagon screws (47) with the re-quired tightening torque (table 1, posttion III).

• After check according to section 3 install the brake pads.

• Check the seat of the brake pads, adjust the clear-ance of the brake according to section 3. and pay at-tention to notes.

• Mount the console, the brake lever and the brake cyl-inder according to section 4.1.


Fig. 42

Fig. 44

1

6

F

47 47

47 47

Fig. 43

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Table 1: Tightening torques

Position Spanner Width[AF]

hexagonTightening Torque:

[Nm]Exter-nal Internal

I 10 X –

Turning direction of the hexagon:• Adjustment in the direction of operation of the

brake lever.

• De-adjustment in the opposite direction of operation of the brake lever.

Caution: Do not use a power-driven socket! Do not overload the adjuster hexagon!

II 24 X – 210 - 30Fastening nut actuation cylinder

III 22 X – 180 ± 20 Brake fastening hexagon screw greased

IV 5 X 9 ± 1 Fastening spreader plate / piston

V 10 X

135 ± 9 Tightening order for guide pins:

1. Close fit (disc entry side)2. Clearance fit (disc delivery side)

VI 1910

XX

135 ± 9 Fastening screw console

VII 21 X – According to the cylinder manufacturer's instruction

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assembly and maintenance instructions -...

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