AR42.10-B-0170C | Replacing and installing brake pads | 12.02.16 |
Vehicle 688 with Cumbustion engine 904.918, 904.919, 904.924, 904.957, 374.977, 904.908
B42.10-0317-06
1 Brake caliper
2 Screw
3 Pad retaining bow
4 Retaining spring
5 Separating plate
6 Cap
7 Hex head bolt of the adjusting mechanism
8 Outer brake pad
B42.10-0316-09
3 Pad retaining bow
4 Retaining spring
5 Separating plate
8 Outer brake pad
9 Inner brake pad
10 Protection bellows of the adjusting screw
11 Protection bellows of the guise-pins
12 Adjustment screw
13 Guide pin
14 Wear indicator wire
15 Wear indicator wire clip
| REMOVAL | ||
1 | Remove the wheels. | ||
2 | Release the parking brake | Pressurize the pneumatic system. | |
3 | Remove the bolt (2) of the brake pad retaining bow (3), use a 17 mm box wrench | ||
4 | Move the brake pads retaining bow (3) aside from the brake caliper (1) | ||
5 | Remove the retaining spring (4) from the separating plate (5) | ||
6 | Remove the cover (6) adjusting mechanism (7) of the brake caliper (1) | ||
7 | Move aside the brake pads (8) and (9), turning approximately 1/4 of one turn the hex screw of the adjusting mechanism (7), using a box wrench | The turning direction of the adjusting mechanism hex screw, to move away the brake pads is clockwise. | |
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Push the separating pressure plate (5) with the hand, when moving aside the brake pads, so the plate pin continues fitting in the slot of the adjustment bolt (12); otherwise, the bolt would turn together with the adjusting mechanism, damaging the protector bellows (10). | |||
8 | Slide the brake caliper (1) with the hand, towards the wheel (arrow), and remove the outer brake pad (8) | All brake pads operating on a same axle are to be replaced | |
9 | Slide the brake caliper (1) with the hand, towards the cylinder (arrow), and remove the inner (9) with the wear sensor and the separating pressure plate (5) | Separate the sensor wire connector and memorize the wire's layout, for later reassembly. | |
All brake pads operating on a same axle are to be replaced | |||
| CLEAN | ||
10 | Clean and eliminate the traces of rust, on brake pads (8, 9) thrust surface, and on the guide of the separator pressure plate (5) | Take precautions and do not damage the protector bellows (10, 11). | |
| Check | ||
11 | Slide the brake pad towards the cylinder, to check the protector bellows (10, 11), the adjusting screw (12) and the guide-pins (13), for wear and damage | Replace the protector bellows (10, 11). | |
Assemble the protection bellows. | |||
11 | Slide the brake caliper (1) along its entire stroke on the guide-pins and check for its free motion | If the displacement is somehow difficult, repair the brake caliper guide. | |
12 | Check brake discs for condition and thickness | ||
| Installing | ||
13 | Slide the brake caliper to a side, until there is enough space, between the disc actuation side, to insert the brake pads | ||
14 | Install the separator pressure plate (5) in the brake caliper (1) and fit the adjusting screw (12) in the slot | The separator pressure plate (5) will have to seat between the housing thrust surfaces, with the plate pin fitting in the slot of the adjusting screw (12). Otherwise, the operation of the adjusting mechanism would be jeopardized. It must be possible to turn the adjusting screw (12), to obtain the alignment, ensuring however that the protection bellows does not get twisted. | |
15 | Install the new inner brake pad (9) with the new wear sensor (14) and the new retaining spring (4) | The connector of the wear sensor wire (14) always points to the shortest guide pin, on the brakes, be it on the right side or the left side. | |
The wire (arrow) threads through the separator pressure plate (5), underneath the retaining spring (4) and also the retaining arc (3), and will have run a semicircular routing (arrow). | |||
16 | Slide the brake caliper (1) towards the wheel, until the inner brake pad (9) gets in contact with the brake disc | ||
17 | Install the new outer brake pad (8) and the new retaining spring (4), on the wheel side | ||
18 | Move the two brake pads (8) and (9) against the brake disc, turn the hex screw of the adjusting mechanism (7), and adjust the clearance | The hex screw will have to be turned anticlockwise, to move the brake pads towards the disc. Do not install the brake pads' retaining bow (3), before adjusting the brake clearance. | |
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19 | Install the new retaining spring (4) in the separator pressure plate (5) | ||
20 | Install the brake pads' new retaining bow (3) in the existing orifices in the brake caliper (1), pressing it so the cam of the springs fits in the bow | ||
21 | Install the new bolt (2) in the brake caliper | | |
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22 | Fasten the wear sensor wire (14) in the clip (15) provided on the brake caliper (1) | Make sure the wear sensor cable location and fastening are correct and reconnect the cable. | |
23 | Install a new cover (6) in the brake caliper | Make sure the wheel hub turns freely. |
Compressed air brake system
Número | Denominação | chassis 364, 384.07/08/09, 386, 388, 397, 660, 664, 682, 688 | |||
BE42.60-B-1001-01A | Pressure regulator | Opening pressure - Wabco/Knorr | bar | 7,9 ... 8,3 | |
Closing pressure - Wabco/Knorr | bar | 6,9 ... 7,7 | |||
Service pressure - Wabco/Knorr | bar | 12 | |||
Opening pressure of safety valve - Wabco/Knorr | bar | 12,0 ... 15,0 | |||
Tires filling safety valve opening pressure - Wabco | bar | 9,0 ... 13,0 | |||
Admissible leakage - Wabco/Knorr | bar (smaller or equal cm3) | 10 | |||
Pressure in the test bench feeding circuit - Wabco/Knorr | bar | 10 | |||
Pressure applied to the port 1 for tightness test - Wabco/Knorr | bar | 7 | |||
Pressure applied to the port 21 for tightness test - Wabco/Knorr | bar | 7 | |||
Front axle brake caliper
Número | Denominação | Front axle 733.880/890 | |||
BA42.10-B-1005-10A | Brake pads retaining spring attachment bolts | Nm | - | ||
BA42.10-B-1006-10A | Adjustment device hex bolts | Left rotation direction | Nm | 3 | |
Right rotation direction | Nm | 18 | |||
Rear axle brake caliper