THE MERITOR GUIDE TO ELSA 225/195 BRAKE SERVICING

Meritor Aftermarket Switzerland AG, Neugutstrasse 89, 8600 Dübendorf, Switzerland. Tel: +41 (0) 44 824 8200

Meritor Aftermarket UK Limited, Unit 1 Broad Ground Road,Lakeside Industrial Estate, Redditch, Worcestershire, B98 8YS, U.K. Tel: +44 (0) 1527 50 3950

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©2015 Meritor, Inc. All rights reserved.Issued 02-15 Publication MPN1140EN

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Modern brake designs have to meet exacting legislative and operational demands. To ensure that the efficiency and performance of these brakes is maintained, it is essential that the following procedures and recommendations are carried out.

IMPORTANT: Initial correct setting of the brake is essential after any service work has been conducted. Pay particular attention to the correct setting of the running clearance.

Failure to observe the correct maintenance and servicing procedures may result in un-necessary further work, which otherwise would not have been required. The skilled mechanic will undoubtedly recognise the need for change and amend working practices in line with these recommendations.

A more detailed description of the maintenance procedures maybe obtained from the Meritor maintenance manual MM-0350 which can be found on the following web site. www.meritor.com/customer/northamerica/lod/default

ServicingThere is no routine maintenance of the caliper required, however it is important the following periodic inspections are carried out.

Every 3 months or 12,000 miles (20,000 Km).A visual assessment of pad life remaining should be made.

Brake pads should be replaced when the lining thickness has worn to 2.0 mm (Fig 1). Visually inspect the general condition of the brake assembly including all the excluders for damage or corrosion. If there is any doubt in the suitability for further service replace/rectify.

Every 12 months or Pad ChangeInspect the guide sleeve and piston excluders and ensure they are undamaged and securely located. If damaged replace in accordance with the MM-0350.

Check the housing assembly slides easily on the guide sleeves secured to the carrier (Fig 4). If the housing does not slide easily follow the procedure “for inspection and/ or replacement” detailed in service manual MM-0350.

Pad ChangeBrake pads should be replaced when the lining thickness has worn to 2.0 mm (Fig 1) Always replace brake pads in axle sets.

Remove the pad retaining strap and where applicable, pad wear warning indicators. It may be necessary to de-adjust the brake initially to remove the worn brake pads.

Remove the adjuster stem protecting cap. Locate a suitable 10 mm socket spanner on the adjuster stem and rotate the wrench in an anticlockwise direction as viewed from the air actuator side (Fig 3).

After the pads have been removed, check that the piston excluders and the guide sleeve excluders are intact and fully functional. If in any doubt replace components. Check that guide sleeve system is fully functional by sliding the housing forwards and backwards on the guide sleeves (Fig 4) to ensure that the housing is not seized on the guide sleeves. If there is too much free play between the components there is a check that can be performed to determine if the guide sleeve bushes are worn and need to be replaced, see Meritor maintenance manual MM-0350.

De-adjustment/adjustment of the brake should be done carefully by hand with a suitable wrench (Fig 3).

Never exceed a maximum torque of 40 Nm in either direction and NEVER use power tools.

NOTE: de-adjustment requires a higher torque than adjustment.

De-adjust the brake until, with the housing pulled across, there is a sufficient aperture to fit the outboard pad. Fit the new outboard pad.

Push the housing back towards the rotor until the new pad contacts the rotor face. Continue to de-adjust the brake until the aperture gap between the Piston Heads and the rotor face is large enough to accept the new inboard pad. With the brake fully de-adjusted it may be necessary to lift the tappet excluder (Fig 5) to release any trapped air that may be inflating the excluder. Fit the inboard pad.

Fit new pad wear warning indicator where applicable. Refit both pad springs ensuring that they are correctly located in the pad back plates. Refit the pad retainer and screw, tighten screw to a torque of 33-40Nm.

Manual setting of brakeTo set the correct clearance of the brake, locate a 10mm wrench on the adjuster stem and turn it clockwise viewed from the air chamber side (Fig 3).

Continue to adjust the brake until the pads lightly grip the rotor. De-adjust the brake by 1/2 revolution of the adjuster stem. Ensure the disc is free to turn.

WarrantyWarranty applies to the air disc brake installed on vehicles for which it was designed. Warranty is void in the following cases:

Improper use of the vehicle on which the air disc brake is installed (usage conditions, overloading etc.).

Tampering with vehicle components that may affect brake performance. Use of non-original spare parts.

Improper installation, adjustment, repair or modification.

Poor or improper maintenance (including consumables other than those specified).

Further information on warranty conditions may be obtained directly from the manufacturer or by referring to the Meritor web site www.meritor.com

Component Torque Setting

M18 Guide Sleeve Screw (Long) 430 – 450Nm

M18 Guide Sleeve Screw (Short) 430 – 450Nm

Adjuster Stem 40Nm Maximum

Pad Retaining Strap Screw 33 – 40Nm

Air Chamber Retaining Nut Initial Torque (both nuts) Final Torque

50 – 80Nm180 – 210Nm

Bridge Screw M14 Torx Head M16 Torx Head M16 Internal Hex Cap screw

235 – 275Nm100Nm + 70 degrees

300 – 350Nm

Grease Specification Fuchs Unitemp 2.

Warning: Under no circumstances should another grease be used on this disc brake other than that specified. Always ensure the specified grease is used in the correct area of the disc brake as detailed in the Meritor maintenance manual MM-0350.

Air Disc Brakes

Pads

DO NOT allow friction material to wear down to less than 2mm from backplate (Fig 1).

DO NOT exceed a maximum torque of 40Nm when adjusting or de-adjusting the brake.

DO NOT use air tools to adjust or de-adjust the brake.

DO NOT use friction material other than that recommended by the vehicle manufacturer.

DO NOT use an airline to blow dust from the brake/rotor area. If inhaled any form of dust can at best be an irritant, at worst dangerous.

DO NOT try to accelerate drying time by using an airline.

DO NOT stretch or put undue strain on the pad wear indicator cable when replacing pads.

DO remove dry brake dust with a vacuum brush. Alternatively wipe the areas with a damp cloth.

DO change pads in axle sets.

DO make a visual assessment of pad life remaining every 12,000 miles (20,000 km) or 4 weeks. Use the visual wear indicator where fitted (Fig 2).

Housing

DO NOT use any other grease than that recommended by the vehicle manufacturer.

DO NOT use grease to aid fitment of the piston excluders. Hands should be clean and free from grease.

DO NOT attempt to drive a worn oval bush out of the housing from adjuster side, there is a chamfer preventing removal in this direction.

DO change piston and guide sleeve excluders when found to be damaged. If excluders are damaged always clean and examine the associated components.

DO check that the housing is free to slide on guide sleeves (Fig 4), if the housing does not slide freely or has an excessive amount of free play then check brake guide sleeve bush wear as detailed in the Meritor maintenance manual MM-0350.

DO mark alignment of oval bush on housing before removing (Fig 6).

DO use the correct service tools when changing the guide sleeve bushes (Fig 7). Always remove from the tappet side of the housing (Fig 8).

Fig. 1

Fig. 2

Fig. 4 Fig. 5

Fig. 6

Fig. 8

Fig. 7

Fig. 3

Torque Settings Table2mm Thickness

DO’S AND DON’TS

MAINTENANCE PROCEDURES