AR42.10-B-0210B | Remove/install thrust pieces with boots when brake caliper is removed | 12.02.16 |
Vehicle 688.1 with Front axle 732.510, 733.840
Vehicle 979.013 with Front axle 732.561 with Rear axle 743.480
Vehicle 979.016 with Front axle 732.561 with Rear axle 743.480
B42.10-0401-06
1 Main body of the brake caliper
2 Brake shoes holder
3 Guide bearing
4 Brake pads
5 Brake pads damper spring
6 Screws securing the damper spring
7 Sealing rings (piston gaskets)
8 Pistons
9 Fanfold pistons protections
10 Socket head cap screw - hex inside
B42.10-0465-06
| Remove | ||
Warning | Important preliminary information | All recommended requirements should be observed at all times, both relating to personal safety to prevent accidents and to environmental protection. | |
Tips for repairs in the hydro-vacuum or hydraulic brake system. | |||
Tips for the brake fluid. | |||
The work mentioned here is basic, and the brake calipers driven by hydro-vacuum manufactured by VargaTRW are almost similar regarding operation and repair, but may differ in minor details, inclusive the piston dimensions and the outside, depending on the vehicle type. During repair work, we recommend never mixing the tweezer parts and paying attention to the dimensions, on the left-hand and right-hand sides, and especially the front, compared to the rear. Most tweezers indicate the left-hand and right-hand sides embossed. The side of the vehicle is defined as seen by the driver from his seat. | |||
Danger | Risk of injury or property damage while tilting the cab | While tilting the cab forward and back, do not enter the tilting area and take action to prevent the entrance of unauthorized persons. Always tilt the cab to its fully-open position and lock it using the safety device. | |
Danger | Danger to life when incorrectly lifting the cabin. Risk of trapping and crushing parts of the body due to the cabin descent | Use authorized lifting equipment only. Always check that the supports used are safe. Never walk or stay under the cab when raised. | |
1 | Tilt the cab to its fully-open position | Place the vehicle on an appropriate place, preferably a level place, that allows working safely. Fasten the cabin with the safety equipment. | |
2 | Remove the holder with the complete brake caliper | Vehicles with front axles 732.510; 733.840; 732.561 | |
For vehicles with rear axle 743.480. | |||
3 | Support the pistons (8) on an appropriate wooden billet | The wooden billet should be carefully prepared, without sharp edges and with smooth finish, so that it settles on the area of both pistons. Insert the wooden billet between the main body (1) and the guide bearing (3). | |
4 | Carefully move the pistons (8) out | Warning: Do not put your hands between the piston and the wooden billet, since the pistons - depending on the pressure applied - could come out very fast. To avoid damaging the pistons, apply controlled pneumatic pressure to the brake fluid inlet hole until the pistons touch the wooden billet. Then, remove the wooden billet. | |
5 | With the aid of a wooden stylus, remove the fanfold guards (9) from the piston (8) grooves | Use a suitable wooden stylus, which should provide rounded corners to avoid damaging the guards. | |
6 | Loosen the socket head screws with hex inside (10), remove the bearing (3) from the main body of the caliper (1) | Inspect for damage. If necessary, replace it. | |
7 | Remove from the main body of the clamp (1) the brake shoes (2) holder | ||
8 | Move the fanfold guards of the guide sleeves from their seats | ||
9 | Completely remove the pistons (8) from inside the main body of the caliper (1) | ||
10 | Remove from the pistons housing inside the main body of the caliper (1) the fanfold guards (9) and the sealing rings of the pistons (7) | Use the appropriate wooden stylus, previously used in step 5, to prevent damage to the sealing rings. | |
| Cleaning | ||
11 | Thoroughly clean the pistons (8) and the cylinders in the main body (1) | Use isopropyl or methyl alcohol, then dry using clean, dry compressed air at a low pressure. | |
| Check | ||
12 | Replace the sealing rings (7) and fanfold guards (9), inspect the pistons and cylinders for damage by oxidation or scratches | If the parts are damaged, replace them. Machining the pistons or cylinders is not allowed. | |
13 | Slightly lubricate the cylinders and outer surfaces of the pistons with fresh brake fluid, without the sealing rings, check for easy sliding | Brake fluid should be fresh and as specified. | |
| Install | ||
14 | Mount a sealing ring (7) on each cylinder groove | Lubricate the rings using brake fluid and insert them in the main body, pressing with the fingers until they are properly fitted into their housings. | |
15 | Slide (in each piston) the fanfold guard (9) on the lubricated piston (8), so that half of it stands out from the rear face | ||
16 | Approach the piston to the cylinder and, before inserting it, fit the fanfold guard (9) in the cylinder slot in the main body (1). Insert the piston in the cylinder by pressing it evenly so that it enters aligned. Repeat the operation for the other piston | The pistons should be forced until they stop at the bottom of the cylinders. Make sure that the other ends of the fanfold guards fit perfectly into the grooves of the pistons. | |
17 | Insert the brake shoes (2) holder in the main body (1) | Lubricate the fanfold guards and guide sleeves. Make sure the parts are moving easily in the sleeves. | |
18 | install the guide bearing (3) on the main body (1) of the caliper | Apply the specified torque to the socket head screws. | |
| |||
19 | Thoroughly clean the inner parts of the disc housing and the pads | The outside parts of the fanfold guards and the other brake caliper components at the outer parts and the disk and pads housing should be thoroughly cleaned, so that the brake pads and disks are not affected by any kind of lubricant or brake fluid. | |
20 | Install the holder (2) with the rest of the brake caliper at the end of the respective axle | ||
21 | Install the brake pads | ||
22 | Purge the brake system | ||
Danger | Risk of injury or property damage while tilting the cab | While tilting the cab forward and back, do not enter the tilting area and take action to prevent the entrance of unauthorized persons. Always tilt the cab to its fully-open position and lock it using the safety device. | |
Danger | Danger to life when incorrectly lifting the cabin. Risk of trapping and crushing parts of the body due to the cabin descent | Use authorized lifting equipment only. Always check that the supports used are safe. Never walk or stay under the cab when raised. | |
23 | Remove the racks and lower the vehicle | If an appropriate lift or pit is not used. | |
24 | Return the cab to the normal position | ||
25 | Perform a test drive and check the tightness, operation and effectiveness of the service brake system |
Front axle brake caliper
Número | Denominação | Front axle 732.510/561; 733.840/882 | Front axle 732.793 | |||
BA42.10-B-1001-10A | Wearing sensors cables attachment bolts | Nm | 10 | - | ||
BA42.10-B-1002-10A | Caliper support bolts in the axle | M16X1.5 | Nm | - | - | |
BA42.10-B-1003-10A | Brake caliper main body attachment bolt (assembled) in the front axle | Hydro-vacuum brake | M12x1.5 | Nm | 110...140 | - |
Pneumatic brake | M16x1.5 - first stage | Nm | - | 180 | ||
M16x1.5 - second stage | degrees | - | 90 | |||
Pneumatic brake | M18x1.5 | Nm | - | - | ||
BA42.10-B-1004-10A | Brake caliper guiding bearing bolts | Hydro-vacuum brake | M12x1.5 | Nm | 100...115 | - |
Hydro-vacuum brake | M16x1.5 | Nm | - | - | ||
Pneumatic brake | M16x1.5 - first stage | Nm | - | - | ||
M16x1.5 - second stage | degrees | - | - | |||
BA42.10-B-1005-10A | Brake pads retaining spring attachment bolts | Nm | 10 | - | ||
BA42.10-B-1006-10A | Adjustment device hex bolts | Left rotation direction | Nm | - | - | |
Right rotation direction | Nm | - | - | |||
BA42.10-B-1007-10A | Threaded plug | Nm | 30...35 | - | ||
Produtos para reparos
Número | Denominação | Número de pedido |
BR00.45-B-1007-06A | Grease DBL 6812.00 | Klueber Lubrification |
BR00.45-B-1011-06A | Brake fluid as per DBL 7760.30 (DOT 4) | - |