SD-23-7541 Bendix ADB22X , ADB22X-V Air Disc Brakes
SD-23-7541 Bendix ADB22X , ADB22X-V Air Disc BrakesSECTION ONE: AIR DISC BRAKE OVERVIEW1.1 DESCRIPTIONBendix ADB22X and ADB22X-V Air Disc Brakes(ADB) use a floating caliper design to provide foundationbraking on all axles of heavy commercial vehicles, busesand trailers. Bendix Air Disc Brakes provide safety andperformance as well as ease of service.The ADB22X disc brakes mount to the axle's anchor plate(torque plate) using fasteners that are installed parallelto the axle, while the anchor-plate fasteners used for theBendix ADB22X-V air disc brakes install at right anglesto the axle.Available with or without a combination spring brake unit,these brakes may also include optional wear sensors andwear diagnostic equipment.Sections in this DocumentSection12345PageOverview . . . . . . . .Preventive Maintenance andWheel-on Inspections . . . .Troubleshooting Flowchart . . .Wheel-off Maintenance InspectionsMaintenance Kits and Procedures. 1-5. . 6-8. . 9. 10-15. 16-37Full Index - see Page 381.2 Air Disc Brake IdentificationLocate the identification label near the guide pin housing.See below for information about the label fields used.FIGURE 2 - TYPICAL PART NUMBER LABEL LOCATIONBendix Part NumberSerial No.Customer Part NumberFIGURE 3 - PART NUMBER LABEL INFORMATIONSection OneSectionFIGURE 1 - BENDIX ADB22X AIR DISC BRAKES1.11.21.31.41.51.5.1PageDescription . . . . . . .Air Disc Brake Identification. .Rotor Identification . . . .Wear Sensor Identification . .Operation . . . . . . .Brake Release and Adjustment.1133331
GENERAL SAFETY GUIDELINESWARNING! PLEASE READ ANDFOLLOW THESE INSTRUCTIONSTO AVOID PERSONAL INJURY OR DEATH:When working on or around a vehicle, the followingguidelines should be observed AT ALL TIMES: Park the vehicle on a level surface, apply the parkingbrakes and always block the wheels. Always wearpersonal protection equipment. Stop the engine and remove the ignition key whenworking under or around the vehicle. When workingin the engine compartment, the engine should be shutoff and the ignition key should be removed. Wherecircumstances require that the engine be in operation,EXTREME CAUTION should be used to prevent personalinjury resulting from contact with moving, rotating,leaking, heated or electrically-charged components. Do not attempt to install, remove, disassemble orassemble a component until you have read, andthoroughly understand, the recommended procedures.Use only the proper tools and observe all precautionspertaining to use of those tools. If the work is being performed on the vehicle’s air brakesystem, or any auxiliary pressurized air systems, makecertain to drain the air pressure from all reservoirsbefore beginning ANY work on the vehicle. If the vehicleis equipped with a Bendix AD-IS air dryer system, aBendix DRM dryer reservoir module, or a Bendix AD-9si air dryer, be sure to drain the purge reservoir. Following the vehicle manufacturer’s recommendedprocedures, deactivate the electrical system in a mannerthat safely removes all electrical power from the vehicle. Never exceed manufacturer’s recommended pressures. Never connect or disconnect a hose or line containingpressure; it may whip. Never remove a component orplug unless you are certain all system pressure hasbeen depleted. Use only genuine Bendix brand replacement parts,components and kits. Replacement hardware, tubing,hose, fittings, etc. must be of equivalent size, typeand strength as original equipment and be designedspecifically for such applications and systems. Components with stripped threads or damaged partsshould be replaced rather than repaired. Do notattempt repairs requiring machining or welding unlessspecifically stated and approved by the vehicle andcomponent manufacturer. Prior to returning the vehicle to service, make certain allcomponents and systems are restored to their properoperating condition. For vehicles with Automatic Traction Control (ATC),the ATC function must be disabled (ATC indicatorlamp should be ON) prior to performing any vehiclemaintenance where one or more wheels on a drive axleare lifted off the ground and moving. The power MUST be temporarily disconnectedfrom the radar sensor whenever any tests USING ADYNAMOMETER are conducted on a Bendix Wingman Advanced -equipped vehicle. You should consult the vehicle manufacturer'soperating and service manuals, and any relatedliterature, in conjunction with the Guidelines above.2WARNING: Not all wheels and valve stemsare compatible with Bendix Air Disc Brakes. Useonly wheels and valve stems approved by thevehicle manufacturer to avoid the risk of valvestem shear and other compatibility issues.WARNING: AVOID CREATINGDUST. POSSIBLE CANCER AND LUNGDISEASE HAZARD.While Bendix Spicer Foundation Brake LLC does notoffer asbestos brake linings, the long-term affects ofsome non-asbestos fibers have not been determined.Current OSHA Regulations cover exposure levels tosome components of non-asbestos linings, but notall. The following precautions must be used whenhandling these materials. Avoid creating dust. Compressed air or drybrushing must never be used for cleaning brakeassemblies or the work area. Bendix recommends that workers doing brakework must take steps to minimize exposureto airborne brake lining particles. Properprocedures to reduce exposure include workingin a well-ventilated area, segregation of areaswhere brake work is done, use of local filteredventilation systems or use of enclosed cells withfiltered vacuums. Respirators approved by theMine Safety and Health Administration (MSHA)or National Institute for Occupational Safety andHealth (NIOSH) should be worn at all times duringbrake servicing. Workers must wash before eating, drinking orsmoking; shower after working, and should notwear work clothes home. Work clothes shouldbe vacuumed and laundered separately withoutshaking. OSHA Regulations regarding testing, disposalof waste and methods of reducing exposurefor asbestos are set forth in 29 Code of FederalRegulations §1910.001. These Regulationsprovide valuable information which can be utilizedto reduce exposure to airborne particles. Material Safety Data Sheets on this product, asrequired by OSHA, are available from Bendix.Call 1-800-247-2725 and speak to the Tech Teamor e-mail techteam@bendix.com
1.3 Rotor Identification1.5 OperationSee Figure 4 to help you identify which type of rotor is usedon the axle being inspected. Note that the maintenanceinspection procedure will depend on the type of rotorinstalled.Bendix air disc brakes convert air pressure into brakingforce. (See Figure 6.) When the vehicle brakes areapplied, air enters the service brake chamber throughthe supply port, applying pressure within the diaphragm.The pressure expands the diaphragm — applying forceto, and moving, the pressure plate and push rod forward.The push rod acts against a cup in the internal lever whichpivots on an eccentric bearing moving the bridge. Movingagainst a return spring, the bridge transfers the motion totwo threaded tubes and tappets, which move the innerbrake pad. The inner brake pad (from its normal positionof having a running clearance between it and the rotor)moves into contact with the brake rotor. Further movementof the bridge forces the caliper — sliding on two stationaryguide pins — away from the rotor. That, in turn, pulls theouter brake pad into the rotor. The clamping action of thebrake pads on the rotor applies braking force to the wheel.Bendix SplinedDisc RotorConventionalRotorService BrakeChamberInner Brake PadOuter BrakePadPressurePlateSupply PortPush RodLeverReturn SpringFIGURE 4 - ROTOR IDENTIFICATIONCAUTION: Rotors may not be mixed on a single axle:axles are only permitted to have all conventional or allsplined disc rotors.1.4 Wear Sensor IdentificationDiaphragmSee Figure 5 for the electronic wear sensor that may bepresent.104Cable ric BearingFIGURE 6 - CROSS-SECTION VIEW SHOWING BRAKEOPERATION105Cable Guide(2 alternatedesigns used)103Cable to ElectricalSupplySensor . . . . . . . . . . . . . . . . . . . . . 101Cable to Electrical Supply. . . . . . . 103Cable Protection Plate . . . . . . . . . 104Cable Guide (two designs) . . . . . . 105Consult the instruction sheet included with wearindicator kits for installation information.1.5.1 Brake Release and AdjustmentWhen the vehicle brakes are released, the air pressurein the service brake chamber is exhausted and the returnsprings in the chamber and the bridge return the air discbrake to a neutral, non-braked position. To maintain therunning clearance gap between the rotor and the brakepads over time, the non-braked position is mechanicallyadjusted by a mechanism in the caliper. The adjustmentmechanism operates automatically whenever the brakesare activated, to compensate for rotor and brake pad wearand to keep the running clearance constant. During pador rotor maintenance, the technician manually sets thesystem’s initial non-braked position. The total runningclearance (the sum of clearances on both sides of therotor) should be between 0.024 to 0.043 in. (0.6 to 1.1 mm).FIGURE 5 - ELECTRONIC WEAR INDICATOR COMPONENTS3
12Pad1 AssemblyCaliper92258 Inner Boot7Inner Seal5RingBrass BushingGuide Pin40Caliper BoltTop Sectional View10Cap23Adjuster Unit161Tappet Bushing32Chain Wheel16Threaded Tube13Tappet and BootAssembly61Shear Adapter45 Washer26Spring Clip37Adjuster Cap44Pad Retainer Pin27 Spring30Chain11Pad Retainer17Bridge33Wear Sensor22InnerSeal16Threaded Tube24TurningDevice161TappetBushing6 Guide Sleeve13Tappet andBoot Assembly2Carrier2Carrier39Caliper Bolt58RingSide Sectional ViewPad Assembly 1212PadAssembly18/1 Spring Brake or18/2Brake Chamber46Rotor43Bolt27SpringFIGURE 7 - SECTIONAL VIEWS468Cap1917 LeverBridge20EccentricBearing9InnerBoot4Guide PinShort Caliper BoltSectional View
Type AType B35 Double-Diaphragm StyleSpring Brake Chamber(Wheel turns towardfixed pin side ofADB)44Pad Retainer Pin(Fixed pin)18/1 Spring BrakeActuator11 Pad Retainer18/2ServiceActuator26 Spring Clip12/2 Pad Holder Spring(Pad Assemblyconsists of12/1 plus 12/2)45WasherWheel RotationWheel Rotation(typically right hand)(typically left hand)1040CapCaliper5Guide Bolt12/1 Pad7BrassBushingPin68Cap39 Caliper Bolt22Inner SealShieldKit(Drive orSteer)161Tappet Bushing13 Tappetand BootAssembly4 Guide PinActuatorHardware61 37*ShearAdapter*37 AdjusterCaps (2 stylessupplied in kits)6 Guide SleeveCarrierMountingHardware1Caliper(or Caliper Kit)U-shaped Rotor958 Inner BootRingBendix ADB22X Anchor Plate2ABendix ADB22X Carrier(Rotor Shield for Trailers)U-shapedRotorFasteners2BBendix ADB22X-V CarrierSD-1Drive HubSD-2 SD-3Splined Disc Rotor(SD)Splined Disc RotorHardwareSD-1, -2, -3Bendix ADB22X-V Anchor PlateCarrierMountingHardwareSee Section 5.2 forexploded view of electronicwear indicator.Steer HubFIGURE 8 - EXPLODED VIEW - BENDIX ADB22X AND ADB22X-V AIR DISC BRAKESINDEX TO FIGURES 7 & 8Adjuster Caps . . . . . . . . . . 37Adjuster Unit . . . . . . . . . . . 23Bolt . . . . . . . . . . . . . . . . . . 43Brass Bushing . . . . . . . . . . 7Bridge . . . . . . . . . . . . . . . . 17Caliper . . . . . . . . . . . . . . . . 1Caliper Bolt . . . . . . . . . 39, 40Cap . . . . . . . . . . . . . . . . . . 68Carrier. . . . . . . . . . 2 (A or B)Chain . . . . . . . . . . . . . . . . 30Chain Wheel . . . . . . . . . . . 32Cap . . . . . . . . . . . . . . . . . . 10Eccentric Bearing . . . . . . . 20Guide Pins . . . . . . . . . . . 4, 5Guide Sleeve . . . . . . . . . . . 6Inner Boot . . . . . . . . . . . . . . 9Inner Seal . . . . . . . . . . . . . 22Lever. . . . . . . . . . . . . . . . . 19Pad . . . . . . . . . . . . . . . . 12/1Pad Holder Spring . . . . 12/2Pad Assembly. . . . . . . . . . 12Pad Retainer. . . . . . . . . . . 11Pad Retainer Pin . . . . . . . 44Ring . . . . . . . . . . . . . . . . . 58Service Actuator . . . . . . 18/2Shear Adapter. . . . . . . . . . 61Splined Disc Hardware. . . . . .SD-1, SD-2 and SD-3Spring . . . . . . . . . . . . . . . . 27Spring Brake Actuator. . 18/1Spring Brake Actuator (DoubleDiaphragm style) . . . . . . . 35Spring Clip . . . . . . . . . . . . 26Tappet and BootAssembly . . . . . . . . . . . 13Tappet Bushing. . . . . . . . 161Threaded Tube . . . . . . . . . 16Turning Device . . . . . . . . . 24Washer . . . . . . . . . . . . . . . 45Wear Sensor. . . . . . . . . . . 335
SECTION TWO: PREVENTIVE MAINTENANCE SCHEDULE AND WHEEL-ON INSPECTIONS2.0 PREVENTIVE MAINTENANCERegular inspection and maintenance of air disc brakecomponents is an important part of vehicle maintenance.The maintenance practices outlined here are recommendedin addition to all standard industry practices (includingdaily pre-trip inspections.) Also, see the vehicle's manualfor recommendations. Keep track of the results of yourmaintenance inspections to assist you in determining theideal maintenance intervals for the vehicle.Section TwoSection2.02.12.2PagePreventive Maintenance . . . . .Brake Pad and Rotor Inspections . .Running Clearance Quick Inspection . 6. 7-8. 8Use the table below for a guide to maintenance intervalplanning, however, depending on the particular vehicle'suse, more frequent checks of the components may benecessary.Table 1: Inspection Period(4 to 5 times during the pad lifetime)* For vehicles withelectronic wearindicators, use thedash indicator(s)and/or the hand-helddiagnostic tool toregularly monitor thepad wear.Whenyoucheckthe tirepressuresAbout every four (4)months for over-theroad applications:About every three (3) monthsfor higher-duty applications:e.g. line haul, RV,open-highwaycoaches, etc.e.g. pick-up & delivery,off-highway, construction,logger, concrete mixer, dumptruck, city transit bus, refuse,school buses, etc.See Section 5.2.At theveryleast,everyfour (4)monthsAt leastonceeveryyear(and ateverypadreplacement)Inspections with the wheel mounted (Sections 2.1 - 2.3)Inspect the pad thickness bychecking the mechanical wearindicators*. See Section 2.1.Inspect the running clearancesusing the quick inspectiontechnique. See Section 2.2.Inspect the visible part of the rotorsfor cracks, etc. See Section 2.3.Inspections with wheel removed (Section 4)Inspect the pads and entire rotorsurfaces for cracks, etc. (Bendix splined disc rotors: Inspectretaining hardware and checktorques) See Section 2.3.Inspect the running clearances andadjuster operation.See Sections 2.2 and 4.2.Inspect the caliper travel.See Section 4.1.Inspect the tappet and bootassemblies. See Section 4.6.Inspect all caps, hoses, and brakeexterior for damage etc.6TABLE 1 - PREVENTIVE MAINTENANCE SCHEDULE
2.1 BRAKE PAD AND ROTOR INSPECTIONSVisual checks of the condition of the brake pad/rotor wearcan be made without removing the wheels. Where dustguards are not used, the top of the pads and part of therotor are visible through the opening at the top of the brake.Other visible portions of the rotor can be inspected at thesame time.Wear Indicator Style A:Where both the carrier and caliper have anindicator notch.Compare the relative position of two notches cast intothe carrier and caliper. When the two notches align,it is time to schedule a full wheel-removed inspectionof the pads and rotor.Unless a vehicle has been stored for some time, the mainrotor surfaces that contact the pads will always appear tobe shiny. Surface rust on these surfaces would indicate amalfunctioning brake that should be inspected immediately.Notch in thecaliperPads are 1.181 in. (30 mm.) thick when new and must bereplaced when they reach 0.433 in. (11 mm.). Rotors are1.77 in. (45 mm.) thick when new and must be replacedwhen they reach 1.46 in. (37 mm.). See Section 4.3 forfurther inspection criteria.Notch in thecarrier2.1.1 Electronic Wear IndicatorsUse the dash indicator(s) and/or a hand-held diagnostictool to regularly monitor the pad wear. (See Section 5.2.)2.1.2 Mechanical Wear IndicatorsSee Figure 9 for the location of the mechanical wearindicators. There are two types (See Figure 10 for Style Aand Figure 11 for Style B).Quick VisualInspection of PadThickness and RotorLocation of WearIndicator Notches(Both sides of brake)When the notchesline up, it is timeto schedule aninspection of thepads and rotorFIGURE 10 - STYLE A - WHEN BOTH CARRIER AND CALIPERHAVE A CAST NOTCHWear Indicator Style B:Where only the caliper has an indicatornotch.When the notch in the caliper aligns with the frontedge of the torque plate, it is time to schedule a fullwheel-removed inspection of the pads and rotor.FIGURE 9 - LOCATION OF WEAR INDICATORSNote: These mechanical wear indicators donot constitute “out-of-service” criteria. Theseinspections only show when to schedule a full wheelremoved inspection of the brake pads and rotor.The thicknesses of the pad and rotor will both affectthe wear indicator position at which maintenance isactually needed.Notch inthe caliperWhen thetorque plateedge lines upwith the notch,it is time toschedule aninspection ofthe pads androtorNo notchin thecarrierTorqueplateFIGURE 11 - CARRIER WEAR INDICATOR NOTCH AND BACKINGPLATE ALIGNMENT7
HFNo action is neededfor small cracksspread over thesurface (e.g. Area F)RotorFrictionSurfaceWidth “f”AreaF For standard Bendix rotors, cracksrunning in a radial direction — likespokes of a wheel (see Area H) — lessthan 0.06 in. (1.5 mm) deep or wideare acceptable if they do not reacheither edge (see G). Cracks are onlyacceptable if the length of the crack isless than 75% of dimension “f” (the widthof the rotor contact area).AreaHfArea GGCracks reachingeither edge of therotorare notacceptablefor eithertype ofrotorArea JJCircumferentialgrooves, as in AreaJ, are acceptableif less than 0.06 in.(1.5 mm) deep. For Bendix Splined Disc rotors, radialcracks are only acceptable if they areless than 0.04 in. (1.0 mm) deep orwide and if they do not reach either edge(see G). Crack lengths must be lessthan 75% of dimension “f” (the widthof the rotor contact area).In addition, follow therecommendations of thevehicle manufacturer.Note: Axles shouldhave either all BendixSplined Disc (or allconventional) rotors.FIGURE 12 - EXAMPLES OF ACCEPTABLE AND NON-ACCEPTABLE ROTOR CRACKS AND GROOVES2.1.3 Rotor Quick InspectionSee Figure 12. See the various potential rotor conditionsthat you may find. See the criteria below for whether therotor needs to be replaced and/or scheduled for a fullinspection.2.2 RUNNING CLEARANCE QUICKINSPECTIONCAUTION: Follow all safe maintenance practices.On level ground, with the wheels chocked and the parkingbrake temporarily released, check for movement of thebrake caliper. This small movement, less than 0.08" (2 mm)- approximately the thickness of a nickel - in the inboard/outboard direction indicates that the brake is movingproperly on its guide pins.If the caliper has no movement or appears to move greaterthan the distances noted above, a full wheel-removedinspection will be necessary (See Section 4.1).8Push/PullBy Handto Checkthe CaliperMovementFIGURE 13 - CALIPER RUNNING CLEARANCE(FIGURE DOES NOT SHOW WHEEL)
SECTION THREE: TROUBLESHOOTING PROCEDURE FLOWCHARTAir Disc Brake InspectionFollow safe maintenance practices,chock wheels. Engage spring brakesand cage spring. Release springbrakes and drain air from system.Raise axle, spinthe wheel byhand.Doesthe wheelturn smoothly?YESNOIsthespring brake fully/partially applied?Checkrunningclearance (4.1)- OK?NOYESYESNOYESCheckrunningclearance (4.1)- OK?Checkadjuster (4.2)- OK?YESYESNONODrain air pressure fromsystem. Re-start test aftercaging spring brakesCheckAdjuster (4.2)- OK?Checkcaliperguidance (4.5)- OK?Replace caliper/carrier assembly(5.3)CheckPad and rotorwear (4.3-4.4)- OK?YESYESNONOReplace caliper/carrier assembly(5.3)NOTightness not due toair disc brake. Seevehicle manual.Replace componentsas needed withgenuine Bendix parts.Disc brake OKReplace guide pins(5.6) OR replacecaliper/carrierassembly (5.3)FIGURE 14 - TROUBLESHOOTING BENDIX AIR DISC BRAKES9
SECTION FOUR: WH
1 Bendix ADB22X , ADB22X-V Air Disc Brakes SD-23-7541 SECTION ONE: AIR DISC BRAKE OVERVIEW 1.1 DESCRIPTION Bendix ADB22X and ADB22X-V Air Disc Brakes (ADB) use a fl oating caliper design to provide foundation
1 Bendix TABS‑6 Advanced Multi‑Channel Trailer ABS Module FIGURE 1 - bendix tAbS-6 AdvAnced multi-ch Annel module (bendix tAbS-6 AdvAnced mc) 1. InTRodUCTIon The Bendix TABS‑6 Advanced MC module is an integrated multi‑channel (4S/2M) trailer service brake module controller for
ACom diagnostic software 5.12, open the Bendix ACom diagnostic software 5.12 User Guide PDF available on the Bendix web site (www.bendix.com). Bendix ACom Diagnostic Windows 6.9 ECU Status Screen Refer to the Service Data sheet for the system being diagnosed for all cautions and warnings; certainFile Size: 2MB
START C CONTENTS PREVIOUS PAGE NEXT PAGE END Dana Australia ADB22X Disc Brake / Hub Parts Information Book 6 Spicer Hubs & Rotors Item No. Item Description 10082993 Hub & Rotor – FF Front Prese
5 6 AIR BRAKES AIR BRAKE VALVES FC102626 FC065104 FC065437 FC229635 Part No. Description Replaces FC065066 QR Valve, 1 PSI Max, ½” - ⅜” NPTF BENDIX 802745 FC065067 QR Valve, 1 PSI Max, ⅜” - ⅜” NPTF BENDIX 802743 FC065104 R-12 Relay Valve BENDIX 065104 FC065145 BP-R1 Type Bobtail Proportioning Valve BENDIX 65145N FC065146 BP-R1 Type Bobtail Proportioning Valve .
QUICK RELEASE VALVES 04 4. RELAY VALVES 05 - 07 5. SPRING BRAKE VALVES 08 - 09 6. PRESSURE PROTECTION VALVES 10 7. FOOT VALVES 11 9. DASH VALVES 12 - 13 10. . Bendix Air Dryer Reference Bendix AC1001 107796 AD-SP / AD-IS Bendix AC2001 5008414 AD-9 Bendix AC3001 065624 AD-IP SKF
systems, make certain to drain the air pressure from all reservoirs before beginning ANY work on the vehicle. If the vehicle is equipped with a Bendix AD-IS air dryer system, a Bendix DRM dryer reservoir module, or a Bendix AD-9si air dryer, be sure to drain
6 Brake Size Unlined Application Shoe Number BW7248 BRAKE SHOE QUICK REFERENCE LISTED BY DRUM DIAMETER NOTE: Unlined shoes are listed numerically by FMSI number in the Brake Shoe Application section of this catalog. 161/2 X 7 4701HA BENDIX (SPICER ) HEAVY AXLE 161/2 X 7 4707R ROCKWELL / MERITOR Q PLUS 161/2 X 7 4708H BENDIX (SPICER ) CAST 161/2 X 7 4708M BENDIX (SPICER ) SEVERE DUTY
Andhra Pradesh State Council of Higher Education w.e.f. 2015-16 (Revised in April, 2016) B.A./B.Sc. FIRST YEAR MATHEMATICS SYLLABUS SEMESTER –I, PAPER - 1 DIFFERENTIAL EQUATIONS 60 Hrs UNIT – I (12 Hours), Differential Equations of first order and first degree : Linear Differential Equations; Differential Equations Reducible to Linear Form; Exact Differential Equations; Integrating Factors .
