8150101133.pdf

Assembly and

Maintenance Instructions

Mechanical Sliding Calliper

Disc Brake

Type 1000 V-G

1st Edition

8150101133

815 010 113 3

 Copyright WABCO 2006

Vehicle Control Systems

An American Standard Company

The right of amendment is reserved

Version 001/11.05(en)

8150201133

815 010 113 3

Table of Contents

Page

Description the Mechanical Sliding Calliper Disc Brake

1.1

Introduction

1.2

Braking sequence

1.3

Automatic adjuster mechanism

Service Instructions

2.1

Safety tips during repair

2.2

General check

2.3

Checking Brake Function

2.3.1

Checking Adjuster Function

2.4

Checking Brake Pads

2.5

Checking Brake Disc

2.6

Checking that the brake calliper can move on the guide pin

Renewing Brake Pads

Renewing Gaiters

4.1

Renewing Gaiters on Brake Piston and Brake Shaft

4.2

Renewing Guide Pin Gaiters and Bushes

Renewing Brake

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

Note:

The Service Instruction focuses on trained specialists. Operations on the brake can only be

carried out if the appropriate paragraphs have been read through and understood. The safety

instructions according to paragrahph 2.1 are to be considered and to be followed.

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 in

any form or by any means, electronic, photocopying, recording or otherwise without permis-

sion in writing from WABCO Radbremesen GmbH.

Type 1000 V-G

Mechanical Sliding Calliper Disc Brake

Description of the Mechanical Sliding Calliper Disc Brake

1.1 Introduction

The sliding calliper disc brake is supposed to be used in

commercial vehicles and buses on front and rear axle as

service, auxiliary and parking brake. It is actuated me-

chanically via a diaphragm brake cylinder or a spring

brake cylinder.

The brake calliper (1) moves axially on guide pins (3) of

the brake carrier (2), see fig. 1.

2 2

Fig. 1

The radially open brake calliper allows an easy and fast

brake pad change.

1.3 Automatic adjuster mechanism

The actuating mechanism of the brake is equipped with

an automatic adjuster mechanism to compensate the pad

wear, see fig. 2. This maintains a predetermined clear-

ance independend from overall load configuration and

different operating conditions.

During the turn of the brake shaft when applying the

brakes 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 disc

increased through pad wear. If the pads are touching the

brake disc, a clutch inside the adjuster loses friction and

the adjustment is interrupted.

Further advantages result by fitting of the actuator

through a console and a lever - see fig. 1. Via variation of

the lever lenght the actuating force can optimally be

adapted and the position of the brake cylinder can be se-

lected freely concerning the brake. The lever can be

turned 360° in angle steps of 7.5°. Thus a maximum

steering turn for the front axle is possible.

Either when installing new brakes or when changing the

brake pads, the adjustment or reset of the brakes takes

place through the adjuster mechanism. The adjustment

nut can be turned with a hexagon. The opening for the

hexagon is located on the back of the brake and is pro-

tected by a sealing plug.

1.2 Braking sequence

Applying the brakes the linear clamping force of the brake

cylinder activates a rotary motion of the brake lever (44).

The expander turns this rotation into a linear lengthwise

movement of the piston, so that the brake pads are

pressed against the brake disc.

Version 11/2005

Mechanical Sliding Calliper Disc Brake

Type 1000 V-G

Components of the brake

1 Brake calliper

1.1, 1.2 Calliper halfs

Brake Carrier

Guide pin

Piston

Spreader plate

Binding screws

38, 39 Brake pad

Hold-down springs

Pad hold-down pin

Brake lever

Figure 2: Top view and sectional view

Version 11/2005

Type 1000 V-G

Mechanical Sliding Calliper Disc Brake

Service Instructions

This instruction with the following pictures contains the

required 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 (see

page 23).

For lubrication use only the tube of grease supplied

with the brake repair kit.

A second technican must assist during re-

moval and installation of the brake. Heavy

Load - Danger of Bodily Injury!

During repairs outside of the vehicle, the

brake must be secured in a fixture, such as a

heavy vise as high torque is required during

removal and installation of the bolts. Danger

of Bodily Injury!

2.1 Safety tips to be considered during

repair

The flawless technical condition of the disc brake is most

important to ensure good driving and safe braking char-

acteristics.

The brake calliper with clamping unit shall not be

opened. Therefore the bolts holding the cover shall not

be loosened.

Only original and genuine WABCO Service Parts and

approved brake pads are to be used.

Observe brake pad and disc wear limits!

Worn-out pads and discs reduce the brake

effectiveness and cause brake failure! Dan-

ger of accidents! Burned, glazed or oil con-

taminated brake pads must be replaced

immediately.

Always replace brake pads on a per axle

basis!

During repairs use only recommended tools. Do not use

a power-driven socket or tools! Tighten nuts and bolts

only to specified torque limits.

With newly installed brake pads during the first 50 km

emergency stops should be avoided if possible. Also

avoid long braking cycles and forced braking.

When wear of the cast brake parts such as cracks or

heavy abrasion is noticied replace the entire brake as-

sembly according to the instructions.

During repairs on the brake the vehicle must

be parked on a level surface and blocked to

prevent rollaway. Only approved and suitable

fixtures are to be used for the lifting and

blocking of the vehicle. While working on the

brake ensure that the brake cannot be actu-

ated inadvertently.

Do not actuate the brake while the brake

pads are removed. Danger of Bodily Injury!

Upon completion of repairs the vehicle's braking system

must 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 should

be performed as follows:

Do not clean the brake with pressurised air or

other high cleaning pressure apparatus.

Danger of Bodily Injury! Danger of destruc-

tion of rubber parts!

• Check piston gaiter (bellow) for damages. When

damaged, exchange bellow according to Section 4.1.

• Check gaiters (bellows) made of rubber on the guide

pins for damage. In principle the guide pins are main-

tenance-free. Any damaged gaiters must be re-

placed immediately. At the same time maintenance

and grease of the guide pins must take place.

Change of gaiters according to Section 4.2.

Keep hands and fingers out of the inside of

the calliper to avoid injury!

Version 11/2005

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