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DX Air Disc Brake DX series of disc brakes

1. Damping However should the screws become disturbed a procedure for resetting should be followed see maintenance Section N Thrust Plate Centering in Saddle ArvinMeritor Air Disc Brake ArvinMeritor Air Disc Brake Maintenance pg 18 Maintenance operations 19 Maintenance intervals 20 A Pad Replacement 21 B Manual Adjustment 21 C Rotor Inspection 24 D Automatic Adjuster Operating Tests 25 E Checking Slide Pin Bush Wear 25 F Brake Slide Pin Checks on vehicle Brake Servicing on bench 26 G Disassembly of Actuating System 28 H Slide Pin amp Bushing Replacement 31 Actuating Piston Seal Boot Replacement 32 Saddle Replacement 34 K Eccentric Shaft amp Cover Plate Replacement 36 L Stabiliser Bar Replacement 38 M Lever Replacement 38 N Thrust Plate Centering in Saddle 39 0 Re assembly of brake unit on vehicle and pad refitting ArvinMeritor DX Air Disc Brake 3 Maintenance operations In order to ensure reliable and efficient brake operation recommended maintenance intervals lubricants and correct procedures should be followed carefully Spare parts Warrantie
2. 43232 LI 031419348 391443 10 530 170 09716 9 WUC SOLS ONS OY 434 ORT 13808311 51414715 _________ 03 Bush Removal DX175 10018 5 04 Bush Insertion 0 225 wo UA 8261 108102 MO GU 103 1 9180 0161 1 1644 fesozossual KE JL 911001 103 03 93134 0161 1 1622 51018139 8 01123 084 SNIA SUUNG TIY 02 66 82 890209593 013 01003 duVHS TW 398 gi 501084 0870 SU3NHOD 301581 TV Dt A SNOISHIMEG IF ot 53 STWHID30 32114 1 09 93 ve H 8230 39114 2 5101 30188110 13980 9 0 9 1 53 8 83101 9419804 2 2 100 2 015 Mid OV 834 S398 v83101 611692 so SUILIMI THM SKOISHINIG TIV JONVEOTIV HSINIG 1031219345 3518013810 603181 WSO SOLS 983 uid 7080 13843311 434 WIS ON 1n01v1 i Kavaj o 7 00706 401134 626 03 08 333 018 231dS O Y au 011 8 01 901 8 234S ON 81 55 0 0706 red ET ILR 0071 30 NOISSIMH3d N3LLISA 20184 LDOHLIA NO 3T10H 035015519 40 0350 032100 438 38 9N1HLON 801133 OL 193805 51578 17119301309 V O3NYOT 1 18144 5101 U3JAV
3. Condition B Adjustment is required as clearance between pads and rotor is excessive Step 3 Condition A 0 At this point when the adjusters begin to turn the pads contact the rotor before the sleeves begin to turn and clamping force F braking begins to build up Step 3A h Clamping force generates friction in the screw threads between the adjuster sleeves B and pistons A and friction under the flanged head of the adjuster sleeves Fig 2 6 ArvinMeritor DX Air Disc Brake 2 Introduction i The friction build up prevents rotation of the adjuster sleeves whilst the torque limiter allows the adjuster shaft to rotate with respect to the bevel gear The adjuster drive train is locked by the friction in the system and no adjustment takes place The main gear turns but does not transmit motion due to the torque limiter blocking Step 3 Condition B During the first stroke stage before the pads come into contact with the rotor the adjuster sleeves are turned by the gear box zx Sleeve rotation due to the threaded coupling with pistons causes pistons to be unscrewed This determines the length L of the extracted part of the pistons to increase and the pads approaching stroke towards the rotor to reduce Fig 2 7 i When the pads come into contact with the rotor the conditions m
4. 101 ONIDHOJ 18 100 2 015 MUG OV Hid 35NY33101 6111555 SH313MVT11K NI SNO SN3NIQ 10V 2031 312395 3518 10 58531801 5015 9N3 OY 13863 18 SLUVd WIS ONIHLON ONY NOLIN3M 49 NOJN Nuni3H Ol 123 8 8 51578 7WIIN3013805 NO 51 1134 011 9 OL 901 9 934 0 MALENI Le 007911 j 00782 0078 dal 0763 00 02 00762 IN 20 20 05200 98 0758 81134 v3uv 51 1 NI 7 00 0 QUYONVIS ONIU33NION3 34 SONINUVN 031212345 AlddV 00 06 Block DX225 21 6 Service tools DXT 16 Metal Parallelism 2 22Xd 73 38 01 wrarnou 194 10N1N02 530 304 WNI9140 891 2 sHto NI 86 vn 62 6 e 295 128004 WEI SE LUN lt NoIssimuaa 00 QUYONVIS 9N1U33N 0N3 3vi23as 3vi831yW ona 0l9 23dS 0 V 831113 50154 LNOHLIM l Vd NO NOil 3roWud 43108449 32084 038012814 0350 5 39 ONTHION NOLIS3M 48 el 0018 881
5. 39414 2 80 09 09 SIOL 36183110 d SLAVE 0 0 9 1 5128 93101 19804 72 100 2 015 ON Hid STOLL DNIISVO 53313011119 NI SNOLSN3MIO TIW 2931319345 381883810 581180 5015 ONT OV ORG 13848311 SLUYd WIS ON ENOAYT 401134 929 01 06 016 739 0 801183M dO NOISSIMU3E NJLLIYA 80184 IHi lnOHLIM 1894 30 31088 035019510 YO 0350 035190438 38 NO3U3H 9NIHION ONY UOLIN3JM AG QNVM3O Mufl38 OL 193 805 51578 TWILN30I JNO V NO Q3RYOT1 5 18184 SINL OUVONVIS ON18338 083 79 34 SONTNUVN BOLIUIM 031319345 2199 011 8 OL 901 8 23dS O V 1155 1161 3 1682 6811 16 FHL OLNI 13 184 NIJHA 311430 01 NOISN3NIG HSINI3 INW3S 00 82 00 02 00 06 00 9 00 81 aM 00728 qu d HL 59 2 X 91 S X 00 en Q0 ve HS 10018 5 Universal Round Head 1003 oN3 0661 16 09 66 ge 98 850605643 03 ve 014 9 gy or Si ve H fi yi 2 eo H SOMVMOTIV HSIMId ON 1004YT SNO1S1A3U 5101133 084 P HSYTA SNIJ SUUNA 3AONH 80103 089 301381 Q3HIHOVN TV 58158310 WO IF S1Y1230 32Y14 1 090 951001230 33 JE 1970 9 1 Sot 9190
6. 0 54 PILXG V3UV 1 N MYYN 6 5 10015 15 Metal Parallelism Block DX175 TIVO WILT 3000 9634 983 69 511 4 40089 108 2 NOIS3Q 31 28 803 151 179 730 WROOT 08 11103734 TYIN31VN fOlld Q3AO0uddV 901114 SZG 03 05 7434 016723dS 0 V WOLIU3N 30 80135134 N31LIUA LnCHLIM Lavd NI 80 370H 438012514 4350 gaondoud3u 5532089 66 at 62 1 316NV 32014 151111198 4 9 00 93 88 eunp 82 98 850208313 53 H 3 24 13 ONT TOOL 304 39 3134 1 2 58011232044 P HSVIJ SNIA SUANA T1Y 53603 d ng 118 08 0 43440 30 58 117 SNOISN3KIG UYTRONY STW4I23G 15714 1 NO 0807 1WMI23d 37719 2 Wort STOL 3S NUSHIO 513 40 870 1 101 ONIDHOJ 18 100 2 015 MUG OV Hid 35NY33101 6111555 SH313MVT11K NI SNO SN3NIQ 10V 2031 312395 3518 10 58531801 5015 9N3 OY 13863 18 SLUVd WIS ONIHLON ONY NOLIN3M 49 NOJN Nuni3H Ol 123 8 8 51578 7WIIN3013805 NO 5
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11. 00 8 08 03 j S X 0071 00 00 81 8 00 06 00 96 E 0s Lv o HL 9 2 X 91H Boot Insertion 0 175 In tools 6 Service DXT 11 Slide P 179 38 9 WW 9180 mz 102 0 7 4 06 021 SL Ce 401134 929 t gt n 031385 7HOLIU3N 3O NOLSSINU3d WALLIGA IDOHLIA 184 Wl 30 v00 Q OORT 9N1333N10N 79 V 834 SONTNUVM S01193H 031312325 11449 a Nid 34175 1008 2661 7 1644 015 9345 0 V 0608 esozossua SRO LUVE V33AVH2 SY X 0011 00 007819 02 66 eunp 82 98 840204481 79417001 104 43543134 2661 7 1622 58015138 8 011937084 1 IECH SUUN TIV 340038 v9 lt 3003 AVIVA v9 84 SHOVE 0870 SAINYO 301581 C3NIHONM TIV 89 41 EVINONY or 4 81081930 29V4 1 000 26 04 81181330 32 14 09 05 5701 3510310 JS SLIVED 38 0 9 14 019803 GE EE GEN Sch 39NVIOT HS1NI 4 3031412346 361 810 EEN 00721 11134 V3uV STHL NI Wav 5015 943 334 OND 13888181 513 47115 ON LNOAYT 10018 5 Tool DX 225 0 195 DX225 21 ion Cover Insert In DXT 12 Slide P pan Lee a e 5 oman morman el Co Q Te
12. 1 1 15 SALONS ATIVANVYA 39 38 LON 1500 1 primm 0 0 E oz p 09 889 V AL 00 798 v 00 vk X uM Es p 00706 Lite axa gt 00 02 g 1 is 8 v3uv SIHL NI 121 4 I a Te H9 Z X 91M 00 9 8 8 1035 6 5 10015 DX175 DXT 22 Piston Boot Insertion Tool ZAXMANLSTACHIIAAI 301 n3 943997 SIHL 40 781 NIO v9 Sg V b 20 1 13385 S9NIMVHO vIN3AHIN3dX3 L W3NDIS30 H9 ALIMOHLNY 1530 lN3ALN3vd3O SNIAJ3NISN3 221 4 D 2161 10 565 Ol STOSMAS TaN 2 829 NIG OL 10 01 151 Ol 5 9 S3903 HSINIA 831414 019313 NXE bbdN 5 MOTTA SZSHLIM 03 06743 OlS O3dS O v 10 88 651 01 MO Tv21NW3HO 313 S Nyda INGALIYdHL JOHINOO 2061 OSI OCH GES SnOQuvzvH ONY 1 11 90 OL LSL OL 553 3993405 v MOL 193 SZ1xa 0 v70 0l 011 8 OL 3018 03 5 0 58 2
13. food arr 0027881 007661 0027091 0007081 0007961 10018 5 Cover Insertion DX175 In DXT 18 Slide P do 66 unr 82 98 850205543 D LOEL V L6c2 41089 1081002 91530 asozoseua ON NND ONE TOOL 403 03599138 1087 1622 No1123r0ud 3 HSYTJ SNIJ SMNDB TIV 93803 duVHS TW Omg 801093 0970 583830 301581 TIW NOISN3HIQ IF S WNI230 3114 1 90 08 035 STVMIDID 39Y1d 2 OF OF SIOL 351883810 ol Fal 1480 9 0 9 44 9328 83101 ONISHOS 2 100 1 01 KUO OY 439 S324Y03101 OWI ISVS SHILANITTIN SNOISIGNIO TV 2031319396 ISIMYZHLO 553180 5015 983 OV Mid ONT 13883111 SLUVd WES ON 100 1 00762 SER 0 00782 401131 SZG 03 06 7418 919234 0 V 011438 30 NOISSINUId LNORLIA 1894 Ni NO 310 NI 035019510 0 0350 0390000038 38 NO3U3H SNIHLON ONY UOlIN3M QNYMIO D NHhI3H OL 1937015 51578 1W11N3014N02 V NO 03NVO1 SI 18134 SINL 00 0 QNVONVLIS 9NI333N1983 79 V 334 SONTNUVM 101043 931219395 ED KR S X 00 1 097091 g gt 0116 2391 811 4 v3uv SIHL NI 10018 6 Service DXT 19 Universal Handle Tool all DX 41089 JI0NYH 20 6811 1622
14. ON LNOAYT 10018 5 225 195 0 225 21 Cover Insert In DXT 12 Slide P S2cXQ Sc2XQ S6 XQ GK wat 62 4 en 091 6 6 2 92 79411001 103 035737134 9081 7 16 5 01123 08 4 1 5 1375813 9 TIV oe 014 153903 5 38 r9 c ed 901014 0870 SU3NHOO 301581 G3NIHOVM TW er od 39015310 SVINONY NO IF Oy Si 51011330 23114 1 09 03 26 11 51 81234 32718 2 oer SIOL 35188810 dE SL 9 0 9 5338183101 0819801 1 23 t 100 2 GLS MYC OV S32NYH3101 DNIISVO 0 li SHILIMETIIK SNOISNSNIQ TW INVIO HSINI4 1031412345 391403810 53701 WHO 5015 9NI OV H3d ON 138483131 134 WIS erer ON 1801Y1 NG Y38 on day ON DLE 2 UCI T 7983 M0113A 829 03 08 134 019 2348 0 seed 211 1 5111 WOLEHIN 30 NOISSINU3d LIN 80189 JHI 1894 NE NO 900 0 QuVONVIS 081H33NI0N3 70 934 SONINUVN WoLIU3N 03131534 41447 133HVH2 X 00 DATK OHL H9 2 X 91H 6 Service tools DXT 13 Metal Parallelism Block DX225 OI 3A EDTA LON Luvd 41049 TOULNOD NbIS3d 3wos 193 034 JIONY GUE 3002
15. 1431915 JSIMYSHLO 853712 N 22 LON 53903 0708 9191 lyd 35007 5 8 H9 Z 91 SONVHO 3055 1831 1 S3lON3d 00 02 00 68 01151 3 2 1 2141 915 5310 34 00766 8 8 NOI123S LON 1504 ONIMYNC 8 9 S 12 g 4 10018 6 Service Boot Insertion DX225 In DXT 09 Slide P HOILIHSIA Aer EEN 522 0 199 ow tava 191830 301 Woliosrowd 319 Qui Snnnnnnnn Nid 34115 1008 Heng 30 66 82 98 950208593 Uu H apos d BM E Um WINSIVR odi ON 401134 25 03 08 438 DIS 2048 ON 30 NOISSIMH3d N31LUUA 40143 LROHLIM luYd NI NO 31088 NE 035015919 Gash 0391009438 8161 1 1642 860706683 KE 79811001 103 35 313 8161 1 1622 SNOISI1A3H 58011917084 P HSVTA SNIA SUURU 11 34034 793803 JN TV 801014 0970 SU3NHO 301581 Q3NIHOYK TIV 58111330 32V 14 1 0908 01v1930 32918 2 MO OF OF 5101 151883810 81380 et 971 933 83101 941903 12 100 2 013 NUQ OV 834 328YU3101 oU SUSISNUTIIM SNOISNINIO TIY 1031319345 39 3810 593110 SQLS 983 OV 934 1384 3101 51844715 wumwe
16. 9N3 697 66 eun 82 960205533 0 8 011 ve 83 9 0 Si ZE H we 53 911 23 80 14 39NYMOTIV MSINI 420 18 NS 1 13TIVuVd 8661 2 1644 ON 4 SAVN 3sv313u 960206633 4 4 l 00751 79011001 104 01573134 9661 2 1622 01 1 33 5 1123 084 Y HSY i 5814 5 71 3AON3H 93003 dans 77 811088 0870 SH3MSOO 30159 119 EROISRZNIO NO A 111230 32v14 NO weert STWHI9AG 32914 2 NO 101 3S1MU3HLO 1 2 SLAVUJ 10 0 971 S39NYUJTOL ONIDHOS 00 2 015 WHC OV N34 S32NVH3701 5NIISYS 79831341 11M NI SHOISN3NIO 2931319395 3SIMUJHIO SS37Mn Mud 5015 5 OY Hid 138dU31NI 304 TVNIBIMO 86 eunt 82166 500 16 00757 20 0 T00 50 Aal 1 45 roud 43 0344 011 9 01 901 8 5345 079 ON ODL HD ON AUIDONI BIR 801111 525 HLIM 03 06 339 01972345 0 HOLIU3M 30 1551 834 NALAIUM 50184 1884 NI 30H 035019810 HO 9390 ONIHLON NOl UJM 18 NOdN 138 OL 102 8 5 51578 7 1443013405 V G3NVOT 1 15184 SIHL 00 4 QUVONVIS 9N U33NISN3 5532004 0 V SONIMNHVW YOLIMIN 031312345 ATdd IERT
17. 61154 vV3uV SIHL NI HM RA 0070 7931 0 98 0791 6 5 10015 14 Metal Parallelism Block DX195 SIMULA BOLINTIN der ON 1874 40089 1031405 530 304 TWNI9INO 31755 TLNOD Y ON DER 401134 929 01 06 438 9N3 God 01973148 0 V 55132084 1403 9530 983 6975 2018 8811311 4 15471666 984 18 4 3NVN 00 93 3573138 850205583 05 66 unr 82 pgj 850205593 nansa 5 3 2 CENTERET 9417001 04 5 139 1661 8 1622 SNOISIA3H 8 1193 984 HSVTIi SNId GHH B TIV 3AOM3H 783943 d n 11 SNIGVE 0870 39154 TIY SNOISHINIG UVINONY NO IF SIOI 32 14 1 NO 09 0T WW1930 32 19 NO 09705 5101 381883 10 QUAE 513880 1870 9719 S3ONVH3TOL IE 2 100 1 915 OY 115 Ni SNOISN3NIO TIY 2031312365 853180 SOLS OV 834 13544311 dx ub S18Vd WIS TON 100 1 00 Er 011 8 01 901 87234S 0 V 2W 131 VN 5 10 JO NOISSIMU3d N31LIU 1HVd NO 310 035012514 0351 38 AYA NOJU3H DNHI
18. NOdN Nuni3s Ol 193 8 5 51578 7W11N3013802 NO 51 INIHd SIHL GX Yad SON INN HOLIMAN 031319345 11444 A SEN 31QNVH AT E EA ON 980713 4 3sva13u 990209503 V i3 vh 8160 1070 05070 S3083H33U31NI 9NIMOTIOJ JHL NIVISO OL ONIATUG 340439 62t1 M 1622 9 0661 1622 N d NO 6261 1624 08 61 NOTSNSNIG 1 5 0681 1622 1181 3 1622 438 NIE 21 30128 66 82 350209813 941 1001 104 418 3133 1161 3 1622 580151 33 5 1358814 88808 TIY 340M38 914 3003 d YHS 77 gg 93 311088 08 0 SHANXOD 31158 TIY 23 SNOISN3MIO NO Jr 1 81 1234 32 14 1 NO op er H S1VAL930 351 MO GP OF 6101 351 10 513980 1870 9716 532 101 6410804 72 100 2 QAS OV S32NYU3 Ol DNIISVO SH313N1T11M NI SKOISN3NIO TIY 1031312345 3S 1883410 31Nn Mug 5015 OV 834 OMG 138483181 S18Vd MIS om 0 0 FONVROTIV HSINTS 10018 ICE Handle Straight Universal 6 Serv ON 1 4 40089 1941405 9 534 A SSY 6811 1 1646 4 ON 304 1 191530 UN 449 ers 0 LIEGE c3 1 0872 ON AMT MONT 1891 SHIO T
19. 9340344 5530094 NEN HOLIMIN JO NOISGINH3d NALLIYM EO Ud FHL 100 118 LuVd NI YO 935079510 dien UOLIUJR NANIA OL LOarens SISYH WIAN3G1dHOD Y SI 18134 STHL 00 0 QuvaNvIS 9 9 NOI19360Uud 319NV 07V Bad SONIMEVA 3002 2834 101 1838 031319345 47647 ELL 3573739 8160 890205631 31151070 05070 STONSUIIMILAL 9NIAOTIO3 381 NIVIGO 01 ONIAIYG 340439 62 1 8 16224 9 08681 16224 N d NO Gei NOISNIWIG 7514 1835 a 6ZEL K 1L622 0861 1622 135 6811 1624 438 07981 WE 0702 66 82 050205533 ONT TOOL 104 04593138 6011 1620 4 SNOI S A3H 5 HSYT4SN J SU4TU VIV 340839 3903 das TTY S010YH 08 0 88345802 161591 GINIHSWM TIY KO15N3H10 HVINSNY 81 1934 39714 1 89 opgoe 1234 3514 2 0 OOF STOL 351845810 214030 8 Q 9719 532 701 9NIDUOI 100 Z 415 OY 32NYU3101 9NIISYO U312M1 TIIN HI SHOISH3NIG TIY 2021219345 2S1AUJHIO 953180 Wi SOLS ONI OY 7084 13848181 SIMVd WIS TEEN Meritor Heavy Vehicle Braking Systems Grange Road Cwmbran Typeset in Italy South Wales NP44 3XU U K Tel 44 0 1633 834238 Copyright 2002
20. Iv L 30 1 13365 TIv LIN3AI33dX3 1 1 aia M3N91S30 H5 ALIYOHLNY N9ISIA INGALNYd3O 9NISS3NISN3 EU am 7 9 9 OL 10 01 VIA IV Ho quse ems EE 30 53903 031914 0312313 NXE STIVA HLNOS MOTTIA 03 00 438 015 0346 0 10 88 51 01 TVOIW3HO MALAY 794 754 S NYNO AMOLVHOBVT INBALYSUL TOYLNOD 2061 051 12 622 622 661 0 HI 01 8 OL gora oads o y Maat Sa 1 7907017151 OSI NIG WOLIS3N wen OL SQv33HL 01 780 01 151 01 SIONS 1009 151 5 oL 13133 6 SNOISN3HIQ WU 0 d c conan ORT JA 150345 0055 6311449 9 1 01104 JHL 031915 351 10 SS3TN 310N MOL 943537 SIHL 30 v 3GNTONI 0579 1508 d ANY 1N3An20Q 9N SIHL 40 31409 ANY AN JHL 30 1 35 N3LLI3M LNOHLIM 036019514 3 1 MO JUNLOVANNVA 303 NI 38 LON Lem LI 30 LHO 1 31va uug o SH3NHNOO 3015 11 uug o 1 8 Tiv 51 NO 8 0 7 S IVWI23 2 NO t O S3ONVHJdIOL 1031915 AS IMYSHLO 5541 11 24 q
21. MERITOR an ArvinMeritor brand Maintenance manual no MM 1147 DX Air Disc Brake DX series of disc brakes Issued 06 2003 2nd Edition service Notes Before You Begin This publication provides installation and maintenance procedures for the DX Air Disc Brake Th CD information contained in this publication was current at the time of printing and is subject to revision without notice or liability You must understand all procedures and instructions before you begin maintenance and service procedures You must follow your company s maintenance and service guidelines You must use special tools when required to avoid serious personal injury and damage to components Meritor uses the following notations to alert the user of possible safety issues and to provide information that will help to prevent damage to equipment and components WARNING A WARNING indicates a procedure that you must follow exactly to avoid serious personal injury AX CAUTION A CAUTION indicates a procedure that you must follow exactly to avoid damaging equipment or components Serious personal injury can also occur NOTE A note indicates an operational procedure or instruction that is important for proper service A NOTE can also supply information that will help to make service quicker and easier o This symbol indicates that you must tighten fasteners to a specific torque 2 ArvinMeritor DX
22. 0 3 lt 0 05 mm Rotor resurfacing Rotors may be resurfaced up to the minimal thickness allowed Remove rotor as described in vehicle s service manual Position 41 mm for DX225 DX225 21 and DX195 30 mm for DX175 rotor on grinder Eliminate all traces of defects found on rotor after resurfacing Resurfacing must be done on both sides of rotor 9 During resurfacing move the grinding wheel gradually until all Wear Limits grinding swarf is removed Wear limits for rotor are visually indicated by the bevel corner 3 x 30 on each outer diameter of both braking surfaces A maximum limit of 3 mm per each side is allowed for machining In order to guarantee total braking efficiency and safety it is recommended when replacing one rotor to replace the other rotor on the same axle Surface finish after machining should be max 5 microns Minimal total thickness allowed for the worn rotor is indicated on rotor outer edge minimum thickness XY mm Minimal total thickness allowed for the worn rotor is 39 mm for DX225 DX225 21 and DX195 28 mm for DX175 min thickness ArvinMeritor DX Air Disc Brake 23 3 Automatic adjuster operating tests Pad wear compensation device check on vehicle This procedure will check function of Automatic adjuster mechanism WARNING The operation must be performed on vehicle Follow all safety pre
23. 2 2 t 913080 9 0 9 1 S328V83101 9419804 2 100 1 015 Mid OV 834 328 V83101 ONIISYO so 13 SUILIMI SNOISN3NIO TIV SJONVEOTIV HSINIG 1031219345 351803810 6637181 5015 983 Oy 334 7080 133413181 5139 IS ON 1n01v1 10018 6 Service DXT 05 Bush Insertion DX195 DX225 21 Ou GU 12 S22X0 S61XQ 1 1 4 911 508 6081 29 16 ER 0 ONT TOOL 404 0353134 6061 2 1624 SNOISIA3H SOLO t SAANA YI 24038 66 UNF 82 850205943 oe 013 93903 4 17 XNV38 ve Si 560144 O8 O SYINYOJ 301531 TIV etr SHOISHIHIC SI NO IF 93 93101234 22114 1 09 0T ze 2 H 31 1234 39V14 2 Of OT 101 3518053810 63 1480 9 0 971 SIQNVYITOL ON10801 2 2 100 2 01 Mud OV Hid 532981101 61155 Sp 13 SUILINETTIN NI SHOISHINIG TW 32 40114 851814 2031412345 181883810 9831811 5015 943 OY 335 OND 13883111 E 14415 00 06 168 0 Ui M Sg WOLINJM E e e e 38 AVH HO3N3H SXIHLON OUR 18 V 334 SSNDISVN 011 8 OL 901 8 034570 Y D E mum ven 80 0 0 NI 401 4 SIHL DEE OR 001 06703 00 58 08701 08 03 0 0709 Y DEER SIHL 003
24. 5 Cover Insertion DX175 In DXT 18 Slide P 3002 12830 ou do 66 unf 92 98 850605543 L0 L V L62 108102 191530 asozoseua KA ND ONT TOOL 403 03599138 10 1 V 1622 500113 084 3 137 5814 SAUNE TIV 93903 duVHS TW Omg 801093 0970 583830 30158 TW NO IF S WNI230 32114 1 40 08 035 1230 39Y 14 2 OF OF SIOL 351883810 ol Fal SLIVUO 9 0 9 44 9328 83101 ONISHOS 2 100 1 01 OY 39 S394Y03101 OWI ISVS 8313NI TN SNOISMGNIO TV 2031319396 ISIMYZHLO SEITAN 5015 9N3 OV Hid ORT 13883131 51939 WES ON LNOAY1 199 38 E 5 1 MU _________ OO 401131 SZG 03 06 7438 919 234 0 V 30 NOISSIMUId 30144 JHA LNORLIA 1894 Ni NO 310 NI 035019510 0 0350 039000038 38 NO3U3H SNIHLON ONY UOlIN3M D NHDI38 OL 1937015 51578 1W11N3014N02 V NO 03NVO1 SI 18184 SIHL 7900 0 GHVONVLS 98IU33N 983 9 V 334 SONINYVN BOLISIM 931219345 188 333 SY X 0071 007 00 81 d 00782 00 2 g gt al H9 2 x IN 811 4 v3uv SIHL NI 10018 6 Service DXT 19 Universal Handle Tool all DX 41089 JI0NYH 20 6811 1622 890208983 02 66
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26. Saddle replacement To replace the saddle it will be necessary to remove the slide pin bolts These are at a very high torque Therefore remove from vehicle and secure it to a bench mounted bracket using the same fixings as on the vehicle Service tool 17 With the help of a hammer and Apply a bead of sealant MBG 1002 to the location diameter of the suitable drift knock out and discard the 2 Slide Pin Covers Fig 3 30 boot metal inserts Apply grease MBG 1003 to each of the piston threads Position the thrust plate together with the actuating pistons within the saddle Using the manual adjuster device engage both pistons within the thread of the adjuster sleeves Turn the manual adjuster device to wind both pistons in to housing do not use excessive force to carry out this operation If a torque in excess of 6 Nm is required disengage threads and start process again Wind in both pistons until the thrust plate is protruding from the caliper body by approximately 60 mm this should give sufficient access to refit the boots into the caliper body Remove and discard the 2 Slide Pin locking screws Due to the high tightening torque use wrench with required adaptor or Using the appropriate service tool gently knock in the boot into the extension Fig 3 31 housing until fully engaged around to whole circumference Ensure that only the metal part of the boot is touched contact with the rubber componen
27. 0 ONT NOVA KA 2818 1 1 9 1644 8 206643 mt 101 0 SIHL NI NN 0 06 vt D U338VH2 8 00 00 49 08703 007081 dd 66 92 79411001 98 850208813 304 43583118 6161 9 1622 58015133 SHOLLOTTOUd 3 WE ONLINE TIV AN ve o 3003 davis TY WOR 801003 0870 301591 C3NIHOVM TY sy H SHOISHIHIG AVINGHY iF oy 93 81081330 22714 1 09 0T ze H 81111234 32118 2 OF OF SIOL 351483010 v2 1970 9 1 8328 83101 9419403 33 HER Sr JONVAOTIV HSIN 2021319385 35103H10 SSIWMN 010 00 oO WHO 5019 GNI OV 34 139413181 SLUVd MIS 10018 5 02 Bush Removal DX195 DX225 21 98 2030 o 66 eunr 82 960205611 2161 1 1644 TET OW 1374 CR A EH KE JL 79411001 104 0353134 2161 1 1622 SROILOIOUd T 85 1475813 SUYUNU TIY JANIE 53903 dE 38 0870 SHINHOD 301581 119 51015831 WWII NO IF 1230 3214 1 08 OF 51641230 32174 2 WO OF E SIOL 35183 10 dE SL 9 0 9 1 819801 2 100 2 OLS OV 834 93943101 911549 SUILINITIIM WE SNOISNSMIO TV 2031319346 39143010 SEIT 5015 93 OV 839 OMG 13848311 SLavd HIS ON 1001Y1 12 444 4 961 0 910 401134 SZG 03 08 334 01973349 ON 5308 3011330 30 Mala N3LLISA 50134
28. 2 100 2 015 ON 834 93983101 1153 rem S1uVd 415 183 40089 1081802 491530 24 950206683 911001 035 1138 0661 1624 53903 ANS TW XV348 2 OF OF SIOL 351413910 SUILINITIIM SNOISN3HIQ 71 1031412345 351883810 5310 5015 OV 834 OMO 133413141 TW Xq 1r9 V3H 03 1WN19140 IT I oad ower 801134 829 03 06 434 1161 3 1622 Y 681L W L622 310NVH OINI 144 NIHA 3NIJ3Q OL NOISN3HIQ HSINIJ 1H3S EI KR SY X 00 6 00702 019 2145 0 8 01 901 8 3385 ON MOLIUIN 30 NOISSIMH3d N31L UA 10134 1898 40 JTOHM 035019910 WO 0351 0391004934 38 AVM SNIHLON UOLIN3M AG XOdN OL i93r nS 51578 WIIN3013NO2 V NO O3NYO S 18188 181 f00 Q QUYQNVIS 0N1833N1983 9 V 934 SONIXUVM 801143A 031212345 1448 00788 2 L u 6 Service tools Handle Shaped Universal 700 0 GUVONVLS 9NI833NI9N OIB LSIA 3402 Loi 98 104616 1200578 30 NOISSIMISd LNOHLIM 1804 NI YO NOILOSPOUd 319NV GYE 43 0844 5532094 015012510 NO 0350 0321908433 AVW NO3U3H ONIHLON JUOLIU3M AG
29. 230 39114 2 wo GE SIOL 381833 10 E 813880 8 0 9 1 S32NV83101 0819803 100 2 GLS W80 834 S39NVH310L DNIISVO SOLS ONI OV 834 DMO 130203181 40089 1081802 91530 960206613 ONT TOOL 3003 dUVHS TIV ERR U313NI TM NE SNOISNSMIQ TIY 2031419395 351803810 55370 184 WIS m C 8961 INA 179 736 708 Ag oud wwu 1 99 06994 X 3914 00 ccu 00 928 3125 801131 526 03 08 7438 01979345 OY eeng 40 015510138 40194 LNOHLIA 1894 NI NO 31018 NI 935019510 NO 0350 0351004434 38 AVN ONIHLON ONY NOLIU3M AH QONYN3O KOJN NHh13 OL 193 8 5 SISYE 10113013 NO SI 18134 SINL 007021 00709 00 82 7900 0 QUVONVIS 1083 70 V Wad SONTIBVN 01183 031312345 194 10018 5 225 195 0 225 21 Cover Insert In DXT 12 Slide P S2cXQ Sc2XQ S6 XQ GK wat 62 4 en 091 6 6 2 92 79411001 103 035737134 9081 7 16 5 01123 08 4 1 5 1375813 9 TIV oe 014 153903 5 38 r9 c ed 901014 0870 SU3NHOO 301581 G3NIHOVM TW er od 39015310 SV
30. 9061 7 1644 860206643 KE JIL 09 66 92 79411001 103 415 3133 9081 2 1624 5 01123 08 4 1 5 1375813 9 TIV 751903 88 9 TY AVENE 901014 0870 Su3NEOD 301581 TV 59015310 SVINONY NO IF 51011230 33114 1 09 03 51 81234 39 1 2 OF OF SIOL 35188310 dE 1480 9 0 9 14 5338183101 0819801 4 100 1 01 WYG OV 814 530093101 DNIISVO SUILIMETIIK SNOISNSNIG TW 1031412345 391403810 53701 WHO 5015 9NI OV H3d 138483131 S IER ON 1801Y1 93 09670 401131 829 03 08 134 01979349 0 011 8 OL 901 8 2345 0 wiv oo veg 08 04 00 70 V 11 4 STHL NI uv 40 NOISSINU3d W3111UM 0199 JHL 100818 1894 NI NO 3108 035012510 0 0350 0351003439 900 0 quVONVIS 081H33NI0N3 70 833 SONINYVN WOLIU3M 031319395 11447 or o amp OHL H9 2 X 9IW 6 Service tools DXT 13 Metal Parallelism Block DX225 OI 3A EDTA LON Luvd 41049 TOULNOD NbIS3d 3wos 193 034 JIONY GUE 3002 9N3 697 66 eun 82 960205533 0 8 011 ve 83 9 0 Si ZE H we 53 911 23 80 14 39NYMOTIV MSINI 420 18 NS 1 13TIVuVd 8661 2 1644 ON 4 SAVN 3sv313u 960206633 4 4
31. Actuation Block and the Adjuster Gear Segment Fig 3 38 NOTE it may be necessary to slightly rotate the eccentric shaft to ensure correct engagement of the eccentric shaft tongues into the adjuster gear segment Fig 3 38 NOTE If the Adjuster Gear Segment has been disturbed and before assembly ensure that the Adjuster Gear Segment is correctly aligned only the cut out segments should be visible the remainder of the segment should be concentric with the large diameter in the Actuation Block Assembly is correct when the Eccentric Shaft is fully engaged in the Adjuster Gear Segment cut outs Figs 3 39 Failure to fully engage may be due to a displaced needle roller in the lower shaft bearing Check that rollers are correctly located or the Adjuster gear segment has become displaced Check for correct location by inserting a hexagonal tool into the manual adjuster port and gently rotate the eccentric shaft the lever may be used for this purpose ArvinMeritor DX Air Disc Brake 3 The hexagonal drive should rotate in one direction only in response to the rotation of the eccentric shaft Failure to do so indicates that the eccentric shaft tongues are not correctly engaged therefore the assembly process should be repeated Thoroughly apply lubricant grease MBG 1003 to needle roller bearing in the new Cover Plate assembly taking care not to allow needle
32. Air Disc Brake Access Information on ArvinMeritor s Web Site Additional maintenance and service information for ArvinMeritor s commercial vehicle systems component lineup is also available at www arvinmeritor com To access information click on Products amp Services Tech Library Icon HVS Publications The screen will display an index of publications by type Information contained in this publication was in effect at the time the publication was approved for printing and is subject to change without notice or liability ArvinMeritor Commercial Vehicle Systems reserves the right to revise the information presented to discontinue the production of parts described at any time Contents 05 Section 1 Description 06 General description 06 Brake pad wear indicator 07 Section 2 Introduction 08 Exploded view Pre March 2001 production 10 Exploded view Post March 2001 production 12 Operating principles 13 Automatic self adjuster mechanism 14 Automatic clearance compensation 15 Thrust plate 17 Section 3 Maintenance 18 Maintenance operations 19 Maintenance intervals 20 A Pad Replacement 21 B Manual Adjustment 21 C Rotor Inspection 24 D Automatic Adjuster Operating Tests 25 E Checking Slide Pin Bush Wear 25 F Brake Slide Pin Checks on vehicle Brake Servicing on bench 26 G Disassembly of Actuating System 28 H Slide Pin amp Bushing Replacement 31 l Actuating Piston Seal Boot Replacement 32 J Saddle
33. Copper washer 1 4 Anti rattle spring 2 32 Adjuster device screw 1 5 Stabiliser bar 1 33 Adjuster gear segment 1 6 Cover plate gasket 1 34 Adjuster sleeve gear 2 7 Eccentric shaft 1 35 Slide pin protective cap 2 8 Cover plate housing 1 36 Adjuster sleeve 2 9 Cover plate screws 2 37 Slide pin locking screw long 1 12 Clamp bolt lever 1 38 Actuating piston 2 13 Lever 1 39 Slide pin to suit long locking screw 1 15 Eccentric shaft bearing unit 2 39b Slide pin to suit short locking screw 1 17 Slide pin bushing 2 40 Identification label 1 18 Eccentric shaft support bearing 1 41 Slide pin seal boot 2 19 Actuation block 1 42 Actuating piston seal boot 2 20 Damping spring 2 43 Roll pin 2 21 Snap ring 2 44 Thrust plate 1 22 Bevel gear torque limiter 1 45 Saddle 1 23 Adjustment box 1 46 Actuating piston screw 2 preinstalled unidirectional bearing 47 Brake pads 2 24 Damping ring 2 48 Brake pad wear indicator if fitted 1 25 Compression spring 1 49 Cover plate eccentric shaft seal 1 26 Air actuator end plate and bracket 1 50 Eccentric shaft seal 1 shape may vary due to brake part number 51 Slide pin locking screw short 1 27 End plate screws 6 style may vary due to brake part number Gear is shown separately since it is an integral part with adjuster screw These components are different according to actuation direction clockwise or counter clockwise Fig 2 2 ArvinMeritor DX Air Disc Brake 2 Int
34. Issued 06 2003 Fax 44 0 1633 834191 A E M 14 www arvinmeritor com ArvinMeritor Inc M graph MM1147 e eri or 10018 DXT 01 Bush Removal DX225 6 Service HO CU ON In 10102 303 9150 NOLIB3N 3O 15510939 4 VOLL BOLE JHL LNOHLIA 1884 NI 80 MAKE W SE ST O V SONIY 0 ONT NOVA KA 2818 1 1 9 1644 8 206643 mt 101 0 SIHL NI NN 0 06 vt D U338VH2 8 00 00 49 08703 007081 dd 66 92 79411001 98 850208813 304 43583118 6161 9 1622 58015133 SHOLLOTTOUd 3 WE ONLINE TIV AN ve o 3003 davis TY WOR 801003 0870 301591 C3NIHOVM TY sy H SHOISHIHIG AVINGHY iF oy 93 81081330 22714 1 09 0T ze H 81111234 32118 2 OF OF SIOL 351483010 v2 1970 9 1 8328 83101 9419403 33 HER Sr JONVAOTIV HSIN 2021319385 35103H10 SSIWMN 010 00 oO WHO 5019 GNI OV 34 139413181 SLUVd MIS 10018 6 Service 4 98 02 Bush Removal DX195 0 225 21 10817 soueen e _ Co OTT TEE dt eege 2161 1 1644 EH KE JL 66 eunr 82 79411001 990205513 404 438 3133 2161 4 1622 SROILOIOUd T 9 14 9 13 SAUNU TIY JANIE 53903 dE MV3N8 50198 0870 SHINHOD 301581 119 51015831 NVTnONV
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38. actuator manufacturer s instructions Remove dirt and debris from caliper Remove the pin clip A and the pin B allowing the stabiliser bar C to rotate and be hinged to the caliper on the lever s side Fig 3 1 Depending on vehicle operating conditions pad lining wear can often be uneven about 1 mm in tangential and radial wear The use of a vacuum cleaner is highly recommended to eliminate build up of dust Otherwise remove dust with water dampened shop towels WARNING Do not use compressed air to clean brakes or rotor Linings are non asbestos but lining dust is an irritant if inhaled and is harmful to health Fig 3 2 Pull out the inner brake pad If pad removal is difficult due to rotor wear a ridge build up on the outer diameter of the rotor then manually de adjust the brake in Section B Manual Adjustment Pull the caliper axially outwards towards the road wheel to free the outboard pad A and pull it out Discard the worn pads and the anti rattle springs Visually inspect the rotor for signs of excessive corrosion physical damage scoring on braking surfaces or signs of cracking in Section C Rotor Inspection Using an emery cloth remove light surface rust from the rim of the rotor If unsure of rotor integrity replace it with a new one Light surface crazing of the rotor is normal and acceptable ArvinMeritor DX Air Disc Brake WARNING This operation requires the caliper to be
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40. caliper body and align the slide pins with the corresponding seats in the saddle Insert the new Slide Pin Locking Screws with the pre applied thread locking compound and hand tighten Refit assembly to the bench mounting device and finally tighten the screws to the specified torque Fig 3 25 see table below 3 175 240 Nm 15 Nm Torx head 200 Nm 10 Nm DX 195 340 Nm 20 Nm DX 225 500 Nm 25 Nm 225 21 340 Nm 20 Nm After torque tightening the locking screws ensure that the caliper Slides freely on the slide pins Install new slide pin caps Before reassemble apply a small bead of sealant MBG 1002 to the edge of the new Slide Pin Cap Push or knock end caps into position using service tool Fig 3 26 Brake type Service Tool DX175 DXT 18 DX195 DXT 12 DX225 DXT 12 0 225 21 DXT 12 Ensure that the caps are fully located Refit brake to the axle NOTE Follow the axle manufacturer s service instructions for fitment of caliper to axle flange Refit brake actuator Refit new clevis pin and pin Clip Follow Section A Pad replacement Follow Section C Manual adjustment I Actuating piston seal boot replacement Remove saddle to axle flange retaining screws Remove brake from vehicle and secure it to a bench mounted bracket using the same fixings as on the vehicle DXT 17 Fig 3 27 Using the manual adjust
41. moved on its slide pins Extreme care must be taken to avoid trapping fingers Fig 3 3 Clean the 8 pad support plates in the saddle with a wire brush removing any build up of debris or rust This allows the new pads to be correctly seated in position 3 Inspect the stabiliser bar for signs of damage distortion wear or corrosion If in doubt of bar integrity replace it Fig 3 4 Completely de adjust the automatic clearance compensation device in Section B Manual Adjustment Install new pads and new anti rattle springs Check that pads are correctly fitted with friction material in contact with rotor Hinge down the stabiliser bar onto the springs anti rattle and retain in position with pin and new pin clip Manually adjust the brakes in Section B Manual Adjustment necessary release the parking brake spring on the air actuators Verify correct operation by actuating brakes about ten times The actual position of brake unit on vehicle can vary from one model to another WARNING Use only approved brake pads complying with original specifications Use of non approved brake pads could adversely affect brake performance and pad life as well as rotor life and efficiency B Manual adjustment It is possible to manually adjust pad to rotor clearance Under the following conditions it will be necessary to manually adjust brake a During inspection of p
42. rollers to become displaced at the same time smear a thin film of grease MBG 1003 to the inside diameter of the cover plate seal Apply a small bead of sealant MBG 1002 on both sides of the paper gasket Position gasket on the cover plate and install the cover plate into the housing securing it with 2 new screws with thread locking compound previously applied and tighten to a 49 torque of 35 Nm Install lever making sure that the marks on the lever and eccentric are aligned Fig 3 44 NOTE Lever is in correct position when it completely engages in the hexagonal section of the eccentric shaft 4D Fit new Lever Clamping Bolt and Nut in its seat on the lever and tighten to a torque of 30 Nm Manually actuate the lever several times in order to check adjustment and actuation device operation to ensure all components are fitted correctly Refit brake to the axle if removed Follow the axle manufacturer s service instructions for fitment of caliper to axle flange Follow Section A Pad replacement Follow Section C Manual adjustment ArvinMeritor DX Air Disc Brake L Stabiliser bar replacement This procedure covers the replacement of the stabilizer bar The operation can be performed on the vehicle although removal will facilitate easier working conditions Preliminary procedures WARNING If the caliper is fitted with a spring parking chamber it is necessary to disarm the parking spring following the air ac
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44. 007 5 8 H9 Z 91 SONVHO 3055 1831 1 S3lON3d 00 02 00 68 01151 3 2 1 2141 915 Y 5310 34 00766 8 8 NOI123S LON 1504 ONIMYNC N310ndWOO 8 9 S 12 g 4 10018 6 Service Boot Insertion DX225 In DXT 09 Slide P HOILIHSIA Aer EEN 522 0 199 ow tava 191830 301 Woliosrowd 319 Qui Snnnnnnnn Nid 34115 1008 Heng 30 66 82 98 950208593 Uu H apos d BM E Um WINSIVR odi ON 401134 25 03 08 438 DIS 2048 ON 30 NOISSIMH3d N31LUUA 40143 LROHLIM luYd NI NO 31088 NE 035015919 Gash 0391009438 8161 1 1642 860706683 KE 79811001 103 35 313 8161 1 1622 SNOISI1A3H 58011917084 P HSVTA SNIA SUURU 11 34034 793803 JN TV 801014 0970 SU3NHO 301581 Q3NIHOYK TIV 58111330 32V 14 1 0908 01v1930 32918 2 MO OF OF 5101 151883810 81380 et 971 933 83101 941903 12 100 2 013 NUQ OV 834 328YU3101 oU SUSISNUTIIM SNOISNINIO TIY 1031319345 39 3810 593110 SQLS 983 OV 934 1384 3101 51844715 wumwe 08701 38 SNTHLON 01 230 48 8041 OL 1
45. 08701 38 SNTHLON 01 230 48 8041 OL 193 015 SISVH 70WtLN301 4809 038 01 SI 18184 SINL 011 9 01 901 8 9345 0 V Y HUN V V 1035 0 ay SAL 02 0 00 0s d 00 01 08703 ONE 00 rt 601 4 STHL 700 0 QUYONVIS 01183331983 Q V 334 SONIXSVN WOLIM3H 031412345 Alda u33HYH2 of X 007 10018 5 0 195 0 225 21 Insert In DXT 10 Slide P 561 0 On GA ON 18 4 ds 109102 TEE 303 19819130 NId 3002 0934 30175 1008 HSNG 1661 16426 lesozoseua 89020983 dQ 66 92 98 950205631 oe re ey oy ec reo LA 870 LEID ONT TOOL 104 41593138 1 1 4 1622 501193 084 P HEH TIV 3003 ANS 328 801018 0870 SUINGOD 301981 GANIHOVA TW S NOISN3NIQ NO IF 31 1530 32914 1 0870 53101330 32914 2 HO OF OF 5701 35141310 13y80 9 0 971 539803701 0410801 2 100 2 015 OY 839 SIONVHITOL 91155 51503010 TIY 1031412348 3918083810 553780 MBO SALS ONI OV 939 ORO 13949311 S180V4 MIS 100 1 mr 66 21 1102 MOLTEN amp Emi 0070 93 24270 401134 92
46. 1 Ep 000 17 01 0 00 67 10018 5 06 Bush Insertion DX175 SI LaN 1038V2 40080 1081802 NOIS3O ROLLI a 3002 2930 eu 2 12 66 UNF 82 960208611 398VIO TW HSENIS 14 9 1 508 8061 84 16424 960206613 ZE ONT 1001 104 35 3139 8061 4 1622 80151438 8801123 084 9 HSVTI SN14 SHUNG 17 3AONIH 93903 IV Wang 501498 0970 838809 301581 119 SHOISHIHIG 57180230 3114 1 08703 WNL230 32Y 14 2 NO OF CF SIOL 351833110 813 80 1870 9 1 328V83101 9819804 72 100 2 01 OV 334 532703701 ONIISYO 8313401114 NI SNOISI3NIC TV 2031319395 3S 883H10 37ft CHUO 5015 983 OY 534 OND 13888301 149 NIS ON LNOAYT 3 33 0071 Ab 011 8 OL 901 8 23dS O V 593 0290 3100318 00 86 00 58 800509 8 ET VOR 00 St MAIS 149130 au 300 530 ag cuvanvis ounen N 935012819 0 0380 0321009438 ET 101183014002 MO Q3NYOT 51 18188 SIKL DUR 931219345 11600 901 4 SIHL NI SIHL TYAN 01 03606 122 010 00 SPD 6 Service tools Tool DX225 DX195 DX225 21 DXT 21 Piston Boot Insertion ZAXMANLSTALHS 4
47. 1 0 mm Radial extension of braking surface less than 75 Tangential scoring Light circular grooves Fig 3 6 C This condition indicates that the rotor has been subjected to extremely high temperatures that have caused a structural change in the rotor material and have caused the rotor to be more susceptible to cracking Residual internal tension could lead to permanent rotor distortion Fig 3 6 D Heat spotted rotor None if tolerance levels are not exceeded Machine if tolerance levels are exceeded Max groove depth 0 5 mm SSG axial run out 0 3 mm None if tolerance levels are not Max radial run out 0 8 mm exceeded Machine if tolerance levels are exceeded see Rotor resurfacing Max rotor thickness variation 0 05 mm Wear and grooves must be approx the same on both surfaces If wear is considerably different brakes will not operate properly and need to be inspected If resurfacing does not remove the spots then the rotor must be replaced Excessive run out may be due to incorrect rotor assembly on the hub excessive tightening torques or incorrectly adjusted wheel bearings Ensure that these conditions are avoided when reassembling Use a dial test indicator DTI to check both axial and radial run out as illustrated in Fig 3 6 22 ArvinMeritor DX Air Disc Brake 3 0 8
48. 1 1134 011 9 OL 901 9 934 0 MALENI Le 007911 j 00782 0078 dal 0763 00 02 00762 IN 20 20 05200 98 0758 81134 v3uv 51 1 NI 7 00 0 QUYONVIS ONIU33NION3 34 SONINUVN 031212345 AlddV 00 06 Block DX225 21 6 Service tools DXT 16 Metal Parallelism IER IA 12 822X0 199 3 ON 593 iuvd 1081405 91534 304 3VNI910 SSL 189138 8 01 1 to e SEE BOLIYAN NOISSINUZd OO Q QUVONVIS ONIU33NION3 3vi23as vi831yW ona 0lS9 23dS 0 V 31113 50154 1599 NO 32084 M 935079519 NO 35 9390004934 AVH NO3H3H ONTHLON YOLIXIN 48 WHNLZH OL 123 805 51578 7WIiN3QiJNOO NO 03NVO1 St 18184 5181 NOI LOarOud Q3AOUddV O Y Yad SONINSVN 3002 Wolld3W 931319395 11449 0530 oN3 011 8 OL 901 87334870 32018 35113118 4 697 11 1 1666 960209513 9Md luVd 00062 0079 00706 CAL DER 00 51 00793 00 91 00 66 82 ONT TOOL 850205943 104 415 3134 1661 1 1624 SNOISIA3H 5 1123 084 P HSVI4 SNLj SHNDG
49. 1311 4 KEE 6975 1881 3 1644 860205513 ON oMd UVd 00 0 2 00 99 00 06 CAL 00 41 00 94 GH EKIA 20 000 C0 66 82 ONT TOOL 950205913 04 44593138 1661 1 1622 SNOISIA38 SHOllOirONd T HSV14 SNIi SHunH TIY 153843 duvHS TV 18014098 0970 583 802 39151 G3NIHOVM TIV 3 5 15 3 14 NO F 3 51 1230 32Y1d MO 0 F 81901330 32 14 2 KO OF OF 9101 3818 10 3 1870 9719 932 83101 19804 23 2 100 2 015 OY 334 532 3101 641155 E 799313 17711 NI NOISN3NIQ TV pe sus d EE sm NI SLAVA NIS 6 Service tools all DX 17 Brake Support universal 2 Ge 1804918 3VEB 281C 1916 8814 1 1644 a sons 96 Ol OFOG 521 810009 027 20 0 00 Ig oem 10751 N 00 seH V V 38 007661 Pl SIHL NI Wish 3015 HCE HE ON ef x gr 7 54108 2 ol oro 126 ooo t ii e yz 2 0700 612
50. 9 03 0 338 01993490 eem 011 8 01 901 9 2345 ON KI 00 51 daa 1335 00 21 d em Gm WOLIU3N 30 NOLSSIMN3d 30134 381 LOOHLIM 1894 NI NO 035012510 30 0350 320003038 900 0 QuVONVIS 9NI333N10N3 KREE V01183N 031319345 4199 T SY X 001 007 00781 g or mit m Boot Insertion 0 175 In tools 6 Service DXT 11 Slide P 179 38 9 WW 9180 mz 102 0 7 4 06 021 SL Ce 401134 929 t gt n 031385 7HOLIU3N 3O NOLSSINU3d WALLIGA IDOHLIA 184 Wl 30 v00 Q OORT 9N1333N10N 79 V 834 SONTNUVM S01193H 031312325 11449 a Nid 34175 1008 2661 7 1644 015 9345 0 V 0608 esozossua SRO LUVE V33AVH2 SY X 0011 00 007819 02 66 eunp 82 98 840204481 79417001 104 43543134 2661 7 1622 58015138 8 011937084 1 IECH SUUN TIV 340038 v9 lt 3003 AVIVA v9 84 SHOVE 0870 SAINYO 301581 C3NIHONM TIV 89 41 EVINONY or 4 81081930 29V4 1 000 26 04 81181330 32 14 09 05 5701 3510310 JS SLIVED 38 0 9 14 019803 GE EE GEN Sch 39NVIOT HS1NI 4 3031412346 361 810 EEN 00721 11134 V3uV STHL NI Wav 5015 943 334 OND 13888181 513 47115
51. 912 NIG LOLL OSI NIG 01 Sei 01 GE 26 02 151 511 07 1 5 v JANTON OSIY LSNW ANY 18 30VA 0 SIHL 40 531400 ANVY ANVdWOO FHL 30 LNASNOD N31113A4 9014 935072519 5 MO 3HnlOv3nNVvW 0350 NI NO 310HM NI 431403 4 oe thai oua o 31111 50345 90559 1531744 9 1 104 AHL 031 15 5 5531 310N SI LIN3AQn2O00 95NIMYuO SIHL s 5 ed L 7 Y Y NOILO3S o Be f 007099 72 5 2 0 oer 33WVH2 02704 X 00 6567 7 p Xs 00709 00 0 00 02 g 4 1 Y 77 xd 2 mes 5 1 84870 SH3NMOO 3015 117 uug o 1dve 119 4 234 ho NO 2 0 7 N OV1d Z v 0 S3ONvH3101 1431915 JSIMYSHLO 853712 N 22 LON 53903 0708 9191 lyd 35
52. 93 015 SISVH 70WtLN301 4809 038 01 SI 18184 SINL 011 9 01 901 8 9345 0 V Y HUN V V 1035 0 ay SAL 02 0 00 0s d 00 01 08703 ONE 00 rt 601 4 STHL 700 0 QUYONVIS 01183331983 Q V 334 SONIXSVN WOLIM3H 031412345 Alda u33HYH2 of X 007 10018 5 0 195 0 225 21 Insert In DXT 10 Slide P 4 1081009 91330 1661 1 16446 960206613 dQ 66 9unf 92 98 990205631 ve re ey oy ve vc LA eo JONVMOTTY 881314 ONT TOOL 104 41543138 1661 1 1622 501133 084 HSVIA SMIA SAUNE TIV 3AON3U 83903 ANS TIY XV388 801018 0870 SYINGOD 301981 GANIHOVA TW 54151310 5YTn5NV NO IF 31001310 12914 1 00 91001934 39V 13 2 WO OF OF 001 38183810 313089 1870 9718 5328 93101 0410804 2 100 2 015 OY Hid SIONVHITOL 8116 NI SNOISN3NIO TIY 2031319395 38188810 553780 MBO SALS ON OV 834 ORO 134493141 SUVA WES ON 100 1 12 SZexd 561 0 401134 929 03 0 338 0162349 0 V eem WOLIU3N 30 NOLSSIMN3d XOlNd IHA lnOHLIA 1UVd NI NO 2008 NI 035019510 30 35 390008938 AVN NO383H ONIHION ONY 5011830 AB VDL OL 193 805 51578 70WI 183013805 V NO Q3NVO1 1 18134 SINL 7900 0 CHVONVES 9N1U33N1083 0 V 039 SONTNUYN BOLISIN 031319345 11448
53. EU am 7 9 9 OL 10 01 VIA IV Ho quse ems EE 30 53903 031914 0312313 NXE STIVA HLNOS MOTTIA 03 00 438 015 0346 0 10 88 51 01 TVOIW3HO MALAY 794 754 S NYNO AMOLVHOBVT INBALYSUL TOYLNOD 2061 051 12 622 622 661 0 HI 01 8 OL gora oads o y Maat Sa 1 7907017151 OSI NIG WOLIS3N wen OL SQv33HL 01 780 01 151 01 SIONS 1009 151 5 oL 13133 6 SNOISN3HIQ WU 0 d c conan ORT JA 150345 0055 6311449 9 1 01104 JHL 031915 351 10 SS3TN 310N MOL 943537 SIHL 30 v 3GNTONI 0579 1508 d ANY 1N3An20Q 9N SIHL 40 31409 ANY AN JHL 30 1 35 N3LLI3M LNOHLIM 036019514 3 1 MO JUNLOVANNVA 303 NI 38 LON Lem LI 30 LHO 1 31va uug o SH3NHNOO 3015 11 uug o 1 8 Tiv 51 NO 8 0 7 S IVWI23 2 NO t O S3ONVHJdIOL 1031915 AS IMYSHLO 5541 11 24 qalliWHddd LON 53944 div 591011 4 35001 SMBn8 L N 3055 1541 1 5310 34 e 115143410
54. HD 0071 SP 01 0F00 09D 700 0 QUVINVIS ON 8318 0N3 79 V 039 SONINUYN 031319345 Lay v01XQ NI MYYN 0008 01 01 000 8 10018 6 Service DXT 05 Bush Insertion DX195 DX225 21 Ou GU 12 S22X0 S61XQ 1 1 4 911 508 6081 29 16 ER 0 ONT TOOL 404 0353134 6061 2 1624 SNOISIA3H SOLO t SAANA YI 24038 66 UNF 82 850205943 oe 013 93903 4 17 XNV38 ve Si 560144 O8 O SYINYOJ 301531 TIV etr SHOISHIHIC SI NO IF 93 93101234 22114 1 09 0T ze 2 H 31 1234 39V14 2 Of OT 101 3518053810 63 1480 9 0 971 SIQNVYITOL ON10801 2 2 100 2 01 Mud OV Hid 532981101 61155 Sp 13 SUILINETTIN NI SHOISHINIG TW 32 40114 851814 2031412345 181883810 9831811 5015 943 OY 335 OND 13883111 E 14415 00 06 168 0 Ui M Sg WOLINJM E e e e 38 AVH HO3N3H SXIHLON OUR 18 V 334 SSNDISVN 011 8 OL 901 8 034570 Y D E mum ven 80 0 0 NI 401 4 SIHL DEE OR 001 06703 00 58 08701 08 03 0 0709 Y DEER SIHL 0031 Ep 000 17 01 0 00 67 10018 5 06 Bush Inse
55. HION 041439 48 QNYN3Q NOdn NBni3H OL 1937905 91598 13 3014802 NO d3NYO St 1 144 SIHL TTTgTTTTTTTTQgTTTTTT 00 0 GUVGNVIS ONIU33NIT5N3 H3d SON INS 3011338 031412348 A1lddV 00 002 1411 0763 00 06 00 52 00 51 20701 200300 66 V3UV 1 VUN 0 54 6 5 10015 15 Metal Parallelism Block DX175 TIVO WILT 3000 9634 983 69 511 4 40089 108 2 NOIS3Q 31 28 803 151 179 730 WROOT 08 11103734 TYIN31VN fOlld Q3AO0uddV 901114 SZG 03 05 7434 016723dS 0 V WOLIU3N 30 80135134 N31LIUA LnCHLIM Lavd NI 80 370H 438012514 4350 gaondoud3u 5532089 66 at 62 1 316NV 32014 151111198 4 9 00 93 88 eunp 82 98 850208313 53 H 3 24 13 ONT TOOL 304 39 3134 1 2 58011232044 P HSVIJ SNIA SUANA T1Y 53603 d ng 118 08 0 43440 30 58 117 SNOISN3KIG UYTRONY STW4I23G 15714 1 NO 0807 1WMI23d 37719 2 Wort STOL 3S NUSHIO 513 40 870 1
56. INONY NO IF Oy Si 51011330 23114 1 09 03 26 11 51 81234 32718 2 oer SIOL 35188810 dE SL 9 0 9 5338183101 0819801 1 23 t 100 2 GLS MYC OV S32NYH3101 DNIISVO 0 li SHILIMETIIK SNOISNSNIQ TW INVIO HSINI4 1031412345 391403810 53701 WHO 5015 9NI OV H3d ON 138483131 134 WIS erer ON 1801Y1 NG Y38 on day ON DLE 2 UCI T 7983 M0113A 829 03 08 134 019 2348 0 seed 211 1 5111 WOLEHIN 30 NOISSINU3d LIN 80189 JHI 1894 NE NO 900 0 QuVONVIS 081H33NI0N3 70 934 SONINUVN WoLIU3N 03131534 41447 133HVH2 X 00 DATK OHL H9 2 X 91H 10018 5 Cover Insertion DX175 In DXT 18 Slide P do 66 unr 82 98 850205543 D LOEL V L6c2 41089 1081002 91530 asozoseua ON NND ONE TOOL 403 03599138 1087 1622 No1123r0ud 3 HSYTJ SNIJ SMNDB TIV 93803 duVHS TW Omg 801093 0970 583830 301581 TIW NOISN3HIQ IF S WNI230 3114 1 90 08 035 STVMIDID 39Y1d 2 OF OF SIOL 351883810 ol Fal 1480 9 0 9 44 9328 83101 ONISHOS 2 100 1 01 KUO OY 439 S324Y03101 OWI ISVS SHILANITTIN SNOISIGNIO TV 2031319396 ISIMYZHLO 553180 5015 983 OV Mid ONT 13883111 SLUVd WES ON 10
57. Replacement 34 Eccentric Shaft amp Cover Plate Replacement 36 L Stabiliser Bar Replacement 38 Lever Replacement 38 N Thrust Plate Centering in Saddle 39 O Re assembly of brake unit on vehicle and pad refitting 41 Section 4 Torque chart 42 Torque Chart Special tools Sealants 43 Section 5 Troubleshooting 44 Troubleshooting 47 Section 6 Service tools ArvinMeritor DX Air Disc Brake Terms used this manual Manufacturer ARVINMERITOR CVS Manual Maintenance manual no MM 1147 Device Air disc brake DX series Technician Qualified personnel working on brake maintenance and servicing Maintenance and servicing Maintenance and servicing refer to periodical checks and or replacement of device parts or components It also refers to the determining of the cause of a malfunction in order to restore the initial operating conditions Operator Any person who will use the device as part of a more complex device 4 ArvinMeritor Air Disc Brake Warranty Warranty 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
58. ad friction material Inspect hub seal Replace with a new one if necessary Clean rotor caliper unit Replace brake pads as described in Section Maintenance A Pad replacement Locking of actuating system ArvinMeritor DX Air Disc Brake Check clearance and rubber seals Replace caliper saddle unit 5 Troubleshooting Condition 5 Poor braking Braking distance too long Negative driver impressions abnormal response unbalanced braking 6 Oscillating or unbalanced braking Possible causes Vehicle air circuit malfunction Checks Check for correct air pressure at chamber inlet Remedies Have air circuit inspected by a qualified technician Brakes de adjustment Check if chamber actuating stroke is longer than value specified by manufacturer Replace caliper saddle unit See Section 1 9 Vehicle overload Check maximum load permitted on the identification label of vehicle Follow vehicle manufacturer s specifications on maximum load permitted Brake pads contamination Grease oil or other substances on pad friction material Inspect hub seal Replace with a new one if necessary Clean rotor caliper unit Replace brake pads Incorrect brake operation See 1 and 5 Check all other brakes and air circuits of vehicle See 1 and 5 Perform registrations or repairs as necessary See 1 and 5 Rotor run out and thickness variation Replace hub rotor unit Arvi
59. ad to rotor clearance b During fitting of new pads To manually adjust the brake first remove the manual adjustment port plug and then rotate the mechanism using a 6 mm Hexagonal wrench The gear train will ensure that the adjuster sleeves will be turned equally The operation which allows pistons to be extended thus reducing pad to rotor clearance is called adjustment The opposite operation is called de adjustment De adjustment direction depends on eccentric rotation direction Wrench should be turned counter clockwise on brakes with clockwise lever actuation de adjustment rotation direction is indicated with an arrow on end plate near the manual adjuster plug hole Fig 3 5 In general de adjustment or back adjustment is achieved when the wrench is turned in the direction which produces clicking feel This indicates that the torque limiter is slipping Turning the wrench in the opposite direction will result in a much smoother and quieter action which will give positive adjustment and reduce pad to rotor clearance During brake de adjustment stop turning the wrench if resistance is felt This indicates that the adjuster pistons are fully retracted Further turning of the wrench could lock the adjuster pistons in ArvinMeritor DX Air Disc Brake 21 3 the sleeves thus preventing auto adjustment operation cause damage to the adjuster mechanism CAUTION Do not use automa
60. aining nuts C attaching the air actuator air chamber to the end plate Fig 3 13 Remove air actuator Fig 3 14 At this stage the caliper is free to slide on the saddle Care should be taken to avoid inadvertently trapping fingers ArvinMeritor DX Air Disc Brake 3 Slide pin amp Slide Pin Bush replacement CAUTION At this stage the caliper is free to slide on the saddle Care should be taken to avoid inadvertently trapping fingers To replace the slide pin mechanism it will be necessary to remove the slide pin bolts As there are at a very high torques used the mounting device should be clamped onto a sturdy workbench Service Tool DXT 17 With the help of a hammer and suitable drift knock out and discard the 2 Slide Pin Covers A Fig 3 15 Remove and discard the 2 Slide Pin Locking Screws Due to the high tightening torque use wrench with required adapter or extension Fig 3 16 NOTE Slide Pin Locking Screws may be different in length Make a note or mark the caliper body in order to identify the correct screw positions ArvinMeritor Air Disc Brake The Slide Pins are also different slight difference on the outside diameter and counter bore different depth to accommodate the different length screws Fig 3 17 Remove the caliper body from the saddle Fig 3 17 Remove the 2 Slide Pin
61. alliWHddd LON 53944 div 591011 4 35001 SMBn8 L N 3055 1541 1 5310 34 e 115143410 1 1 15 SALONS ATIVANVYA 39 38 LON 1500 1 primm 0 0 E oz p 09 889 V AL 00 798 v 00 vk X uM Es p 00706 Lite axa gt 00 02 g 1 is 8 v3uv SIHL NI 121 4 I a Te H9 Z X 91M 00 9 8 8 1035 6 Service tools DX175 DXT 22 Piston Boot Insertion Tool ZAXMANLSTACHIIAAI 301 n3 943997 SIHL 40 781 NIO v9 Sg V b 20 1 13385 S9NIMVHO vIN3AHIN3dX3 L W3NDIS30 H9 ALIMOHLNY 1530 lN3ALN3vd3O SNIAJ3NISN3 221 4 D 2161 10 565 Ol STOSMAS TaN 2 829 NIG OL 10 01 151 Ol 5 9 S3903 HSINIA 831414 019313 NXE bbdN 5 MOTTA SZSHLIM 03 06743 OlS O3dS O v 10 88 651 01 MO Tv21NW3HO 313 S Nyda INGALIYdHL JOHINOO 2061 OSI OCH GES SnOQuvzvH ONY 1 11 90 OL LSL OL 553
62. anual or the vehicle trailer manufacturer s instructions Every 12 months or at the vehicle trailer manufacturer s recommendations Remove brake pads as described in the pad replacement section Inspect the slide pin and actuating piston seal boots and ensure they are undamaged and securely located If any of the boots are detached or damaged the relevant part of the brake should be dismantled and the components examined for corrosion and damage Replace rectify in accordance with the vehicle trailer manufacturer s instructions Check the housing assembly slides easily on the slide pins secured to the saddle If the housing does not slide easily remove from the saddle as described in Section J Slide Pin amp Bushing Replacement If there is any doubt in the suitability for further service replace with new components Check the slide pin bush for wear in line with instructions in Section E Checking Slide Pin Bush Wear WARNING Take care not to trap fingers whilst checking the sliding action of the brake Check the brake disc for signs of heavy grooving cracking or corrosion and the thickness dimension are in accordance with recommendation of the manual of the vehicle trailer manufacturer s recommendations NOTE These service intervals are meant as a guide the frequency should be tailored to suit the environmental conditions of the brake assembly and hence to the vehicle trailer operating conditions s
63. bleshooting pg 44 Troubleshooting ArvinMeritor DX Air Disc Brake 5 Troubleshooting Below there is a chart showing the most common faults occurring to DX family brakes Condition 1 Unbalanced braking 2 Short lifetime of external pad 3 Short lifetime of pads 4 Smoke coming from brakes Possible causes Incorrect clearance between brake pads and rotor Checks Check clearance Remedies Replace caliper saddle unit Incorrect initial clearance Perform new adjustment Vehicle air circuit malfunction Caliper seized or slide pins jammed Check for damaged slide pin boots caps Repair or replace any faulty components Replace caliper saddle unit After removing pads check manually if caliper can freely move back and forth See 1 and 2 See 1 and 2 See 1 and 2 Too much usage of braking system Improper vehicle driving Train driver Rotor surface Check for cracks or signs of In Section Maintenance C Rotor exposure to over temperature Inspection Vehicle overload Check for maximum load permitted on identification label of vehicle Follow vehicle manufacturer s specifications on maximum load permitted Incorrect brake operation Brakes over temperature Check all other brakes and air circuits on vehicle See 1 2 and 3 Perform registrations or repairs as necessary See 1 2 and 3 Brake pads contamination Grease oil or other substances on p
64. cautions and abide by standing regulations concerning vehicle hoisting and workshop conditions The vehicle must be hoisted and the relative wheel of the device to be tested should be removed Clean the area where the operation will be performed WARNING Do not use compressed air Linings are non asbestos but lining dust is an irritant if inhaled and is harmful to health The use of a vacuum cleaner is highly recommended to eliminate build up of dust Otherwise remove dust with water dampened shop towels Reset the manual adjuster in Section B Manual Adjustment in order to have a total clearance of 2 mm between pad and rotor for rotors without wear ridge The clearance should be measured with a feeler gauge once the internal pad touches the rotor pull the gauge outwards Should the rotor have a wear ridge 2 mm clearance could be achieved as follows Fig 3 7 Rotate adjustment device towards the position in which clicking is no longer heard so that both pads are in contact with rotor Rotate the hexagonal wrench 360 in the opposite direction i e 12 torque limiter notches By leaving a hexagonal wrench in the adjuster port device operation can be observed during test ArvinMeritor DX Air Disc Brake 180 270 If a wrench has been left in the device at the end of this operation it should have rotated between 180 amp 270 from starting point in normal conditions If this is so the nex
65. connecting procedures NOTE Parts shown refer to standard configuration and may differ according to brake version and model Use data on identification label 40 to order proper spare parts Identification label 40 See the identification label attached on brake for suitable spare part and note down all spare part data indicated Ref Description Brake Identification Number ArvinMeritor Manufacturing Date Brake Identification Number Customer Brake Serial Number ArvinMeritor Logo Introduction pg 08 Exploded view Pre March 2001 production 09 Parts list 10 Exploded view Post March 2001 production 11 Parts list 12 Operating principles 13 Automatic self adjuster mechanism 14 A Automatic clearance compensation 15 Thrust plate ArvinMeritor DX Air Disc Brake 1 Exploded view Pre March 2001 production E 20 21 95 3 Za 33 24 32 30 29 28 31 ArvinMeritor Air Disc Brake Parts list Pre March 2001 production Ref Description Q ty Ref Description Q ty 1 Stabiliser bar retaining pin 1 24 Damping ring 2 2 Pin clip 1 25 Compression spring 1 3 Caliper 1 26 Airactuator end plate and bracket 1 4 Anti rattle spring 2 27 Flathead screw end plate screw 2 5 Stabiliser bar 1 28 End plate cap 1 6 Cover plate gasket 1 29 Plug of adjuster port 1 7 Eccentric shaft 1 30 Copper washer 1 8 Cover plate 1 31 Hexagona
66. consumables other than those specified Further information on warranty conditions may be obtained directly from the manufacturer or by referring to the ArvinMeritor web site www arvinmeritor com Description pg 06 General description 06 Brake pad wear warning indicator PWWI ArvinMeritor DX Air Disc Brake 8 1 Description General description The ArvinMeritor CVS DX series of air disc brakes is a family of high performance low weight high efficiency brakes designed for trucks coaches buses and other commercial vehicles requiring between 10 000 and 23 000 Nm of braking torque at each wheel EH amping force is produced by a globular cast iron caliper located above the rotor and housing two lining pads The pads are pushed against the rotor by a dual piston actuating block connected to an eccentric shaft which is in turn driven by a lever operated by a standard air actuator air chamber The caliper is carried on a saddle which is a fixed support bolted to the axle flange Equalised clamping action both on the inner and outer pads is generated by allowing the caliper to float on the two slide pins fixed to the saddle Clamping force generated by the primary actuation is applied to the inner pad which forces it into contact with the rotor Reactive force through the caliper body applies equal clamping force to the outer pad applying a balanced clamping force to the rotor The slide pins also allow the caliper t
67. e see Section B Manual Adjustment Refit all air and electrical connections following vehicle manufacturer s recommendations and un cage any parking brake springs on air actuators After reassembly of brakes check for proper operation by actuating them ten times via the air actuators ArvinMeritor DX Air Disc Brake ArvinMeritor Air Disc Brake Torque chart pg 42 Torque Chart Special tools Sealants ArvinMeritor DX Air Disc Brake 4 Torque chart Torque chart Nm Part Ref fig 2 1 Description DX175 DX195 DX225 DX225 21 32 Adjuster device screw 10 10 10 10 27 31 End plate screws 70 100 100 100 46 Piston screws 45 85 85 85 12 14 Lever clamp bolt 30 30 30 30 37 Slide pin locking screws 240 340 500 340 9 Cover plate screws 35 35 35 35 Special tools Description DX175 DX195 DX225 DX225 21 Bush removal tool DXT03 DXT02 DXTO1 DXT02 Bush insertion tool DXT06 DXT05 DXT04 DXTO5 Slide pin cover insertion tool DXT18 DXT12 DXT12 DXT12 Piston boot insertion tool DXT22 DXT21 DXT 1 DXT 1 Slide pin boot insertion tool DXT11 DXT10 DXTO9 DXT10 Metal parallelism block DXT15 DXT14 DXT13 DXT16 Brake support universal DXT1 7 DXT1 7 DXT 7 DXT17 Use straight universal handle tool 19 Use shaped universal handle tool DXT20 Sealants and thread locking compounds Code Description MBG 1002 Sealant for seals ArvinMeritor Air Disc Brake Trou
68. e below Fig 3 33 Fig 3 33 175 240 Nm 15 Nm Torx head 200 Nm 10 Nm DX 195 340 Nm 20 Nm DX 225 500 Nm 25 Nm DX 225 21 340 Nm 20 Nm After torque tightening the locking screws ensure that the caliper slides freely on the slide pins Install new Slide Pin Caps Before reassemble apply a small bead of sealant MBG 1002 to the edge of the new Slide Pin Cap Push or knock end caps into position using service tool Fig 3 34 Brake type Service Tool DX175 DXT 18 DX195 DXT 12 DX225 DXT 12 0 225 21 DXT 12 Ensure that the caps are fully located Refit brake to the axle Follow the axle manufacturer s service instructions for fitment of caliper to axle flange ArvinMeritor DX Air Disc Brake 3 Eccentric shaft amp cover plate replacement The operation can be performed on the vehicle although removal will facilitate easier working conditions Dismantle Procedure Remove Clevis Pin connecting the air actuator rotation chamber pushrod to the brake actuating lever Fig 3 35 Clean the area around Eccentric Cover Plate NOTE if the working area of the brake is not easily accessible remove actuator from the caliper end plate Secure actuator firmly do not allow actuator to be supported on the pneumatic connections and remove the brake from vehicle Remove lever clamp bolt and discard Remove the lever and r
69. ed from the cover plate bearing The bearing assembly is an uncaged needle roller bearing Remove Cover Plate Gasket and discard Remove stabiliser bar from housing Thoroughly clean the contact surface on the caliper housing Ensure no debris is allowed to enter the eccentric bore Clean old thread locking compound from cover plate screw holes Fig 3 41 Fit new stabiliser bar in the location area on the brake Apply grease MBG 1003 to all bearing surfaces of the cover plate assembly and thoroughly lubricate the rollers Fig 3 42 Apply a small bead of sealant MBG 1002 on both sides of the paper gasket Fig 3 42 Position paper gasket on the cover plate and install the cover plate into the housing securing it with 2 new screws with thread locking compound previously applied and tighten to a torque of 4 35 Nm Install Lever making sure that the marks on the lever and eccentric are aligned Fig 3 44 NOTE Lever is in correct position when it completely engages in the hexagonal section of the eccentric shaft 99 Fit new Lever Clamping Bolt and Nut in its seat on the lever and tighten to a torque of 30 Nm Refit brake to the axle if removed Follow the axle manufacturer s service instructions for fitment of brake to axle flange Follow Section C Manual adjustment ArvinMeritor Air Disc Brake 3 Lever replacement Remove
70. emove the pads as described in Section A Pad Replacement Pull the housing towards the wheel flange see Fig 3 9 direction arrow new pad condition Attach a dial gauge 2 whereby the line 3 represents an extension of the centre line of the slide pin The dial gauge should be earthed to either the hub or saddle Hold the housing in such away that point 2 cannot move swivel the housing in direction 1 to a stop Set the gauge to zero Move the housing in the opposite direction to a stop as before ensure the point 2 does not move NOTE it may require several attempts to ensure consistence reading Tangential test Worn pad condition Push the housing in the direction of arrow B see Fig 3 9 Repeat the above Tangential checks Position dial indicator adjacent to the other slide pin and repeat the new and worn pad checks The maximum movement of the caliper in any position depending on the brake size is a listed in the table below Maximum movement DX175 2 0 mm DX195 2 5 mm 0 225 21 2 5 0 225 3 0 Radial Teat Remove the pads as described in the Pad Replacement Section Attach a dial gauge earthed to a position on the vehicle hub or brake saddle as shown in Fig 3 9a Position the caliper in the half worn pad condition mid sliding position Hold the housing in such away that point 7 cannot move swivel the housing in direction 1 to a stop ArvinMer
71. entioned above in step g i are repeated thus halting the movement Step 4 Brakes released When the brake pedal is released pressure is discharged from the air actuator and the brake actuating lever returns to its rest position pulled by the returning action of the internal air actuator spring The eccentric shaft and the adjuster gear segment rotate in reverse direction together with the bevel gear m The unidirectional bearing free wheels without transmitting motion to the gear housing thus avoiding brake adjustment The relative piston sleeve adjustment position does not vary Therefore clearance compensation of pre existing rotor and pads remains unchanged Fig 2 8 Damping Compression springs are mounted in front of and behind the gearbox in order to dampen vibration caused by vehicle movement This prevents induced vibrations from occurring which could modify the clearance setting between rotor and pads Fig 2 9 Thrust plate An important feature of the DX family of brakes is the setting of the thrust plate within the saddle abutments Although this is factory set and provided the 2 locking screws are not removed from the thrust plate no resetting should be necessary Step 2
72. er device carefully wind out both actuating pistons fully until they disengage from the adjuster sleeves within the caliper housing Both actuation pistons must remain attached to the thrust plate Fig 3 28 Remove and discard both piston seal boots from within the caliper body using a suitably size drift Fig 3 29 Clean housing and remove all traces of sealant from around seal boot location within housing Ensure that no debris is allowed to enter the caliper body ArvinMeritor Air Disc Brake 3 Clean the seal boot location groove on the actuating pistons and Brake type Service Tool piston threads with suitable cleaning fluid ensure they are clean DX175 DXT 22 and dry before re assembly DX195 DXT 21 DX225 DXT 21 Re Assembly 0 225 21 DXT 21 Fit new Piston Seal Boots onto Actuating Pistons 0 When the boots correctly fitted fully deadjust brake in reparation for pad fitment NOTE do not use any grease to aid assembly The use of grease PMeP ration for pad fime could cause the boots to prematurely pull off the piston location grove Having fitted the new boot in the appropriate groove gently extend each boot to ensure they are securely located The boot should not pull off when applying a reasonable force It may be appropriate to gently rotate the boot whilst extending it this will promote the boot to correctly locate in the grove J
73. er to gain access with the service tool behind the thrust plate With the brake adjusted it is possible to move the thrust plate to gain access with the tool WARNING do not release thrust plate fixing screws to gain access When inserted ensure that the boot metal ring is fully home and flush with the housing Fit new Slide Pins into the bushes applying lubricant MBG 1004 on to the outside surface on the pins and within the bush in the caliper body NOTE the Slide Pin with the short screw and outer diameter slightly oversized should be installed on the right side looking at the brake from the end plate on brakes with clockwise lever actuation the opposite applies for brakes with counter clockwise lever actuation Position the collar of the rubber seal in the appropriate slot on the slide pin and ensure the boot is correctly located Fig 3 24 Clean all 8 saddle pads mounting surfaces using a metal bush and a suitable vacuum cleaner These should be clean and smooth without any major grooves or ridges If in doubt replace saddle WARNING Clean any traces of thread tightening compound from all inner threads of brake components Use only new screws and bolts during maintenance The use of old screws and bolts is very dangerous and can seriously affect brake performance ArvinMeritor DX Air Disc Brake For ease of assembly remove saddle from the bench mounting device offer the saddle to the
74. etain Should the lever interfere with the eccentric shaft insert an appropriate wedge screwdriver s blade in the groove in order to facilitate disassembly and remove lever Remove the Eccentric Shaft Seal Boot if fitted and discard Remove the manual adjustment port plug and washer and retain Fully de adjust brake assembly do not use excessive force when winding the mechanism Maximum torque applied to the adjuster stem should not exceed 6Nm Remove the 2 Cover Plate Screws and discard Remove the Cover Plate assembly in which the Eccentric Shaft upper bearing unit is positioned Whilst removing the cover plate hold the eccentric shaft in place thus ensuring that the shaft is not pulled out simultaneously with the cover plate and discard Remove Cover Plate Gasket and discard Thoroughly clean the contact surface on the caliper housing and ensure no debris is allowed to enter the eccentric shaft bore Clean old thread locking compound from cover plate screw holes ArvinMeritor DX Air Disc Brake Eccentric shaft removal Rotate the Eccentric shaft in the direction of the brake applied this can be done using the lever until 3 clicks are felt or sufficient rotation has taken place to align the eccentric high point with the elliptical area in the upper caliper opening to allow removal of Eccentric shaft NOTE Rotating the Eccentric Shaft slightly allows the shaft and Eccentric Shaft Support Bearing to pass thr
75. icle manufacturer s workshop instructions for safe jacking of the vehicle and removal of road wheels Before proceeding with brake removal cage any parking brake springs fitted on air actuators and disconnect airlines and all electrical connections ABS and wear sensors Remove pin clip A and pin B allowing the pad stabiliser bar to swing up Remove the inner pad first and then the outer one Fig 3 11 WARNING At this stage the caliper is free to slide on the saddle Care should be taken to avoid inadvertently trapping fingers NOTE For normal servicing ArvinMeritor recommends removal of complete brake unit and that operations be performed on bench 3 In extreme cases of rotor wear it could be difficult to remove pads because of rotor ridges Manual de adjusting of the brakes shall be necessary See Section Manual Adjustment As very high torques is required the mounting device should be clamped onto a sturdy workbench Remove saddle to axle flange retaining screws Remove brake from vehicle and secure it to a bench mounted bracket using the same fixings as on the vehicle Service tool DXT17 Fig 3 12 G Disassembly of actuating system For a correct reassembly note or mark relative rotation chamber position with respect to end flange Remove pin clip A and clevis pin B connecting the air actuator air chamber pushrod to the brake actuating lever Remove the two ret
76. itor DX Air Disc Brake 25 3 Set the gauge to zero Swivel the housing in the opposite direction as far as possible using only light hand pressure ensure the point 7 does not move NOTE it may require several attempts to ensure consistence reading The maximum movement of the caliper in any position depending on the brake size is a listed in the table below Maximum movement DX175 2 0 mm DX195 2 5 0 225 21 2 5 0 225 4 0 If movement of the frame exceeds the above figure then the slide pin and bush mechanism requires attention as detailed in Section H Slide Pin amp Slide pin Bush Replacement F Brake slide pin checks on vehicle Remove the two pads With brake on vehicle check manually the sliding movement of the caliper on the saddle by sliding it on slide pins along the entire allowed stroke Fig 3 10 Whilst carrying out the check ensure that the Thrust plate does not become jammed within the saddle abutments ArvinMeritor DX Air Disc Brake CAUTION At this stage the caliper is free to slide on the saddle Care should be taken to avoid inadvertently trapping fingers If the movement is not smooth with judder or binding or excessive effort is required to slide the housing the brake unit should be disassembled and the caliper slide system inspected and replaced Brake servicing on bench Removal of brake unit from vehicle Refer to veh
77. l 00751 79011001 104 01573134 9661 2 1622 01 1 33 5 1123 084 Y HSY i 5814 5 71 3AON3H 93003 dans 77 811088 0870 SH3MSOO 30159 119 EROISRZNIO NO A 111230 32v14 NO weert STWHI9AG 32914 2 NO 101 3S1MU3HLO 1 2 SLAVUJ 10 0 971 S39NYUJTOL ONIDHOS 00 2 015 WHC OV N34 S32NVH3701 5NIISYS 79831341 11M NI SHOISN3NIO 2931319395 3SIMUJHIO SS37Mn Mud 5015 5 OY Hid 138dU31NI 304 TVNIBIMO 86 eunt 82166 500 16 00757 20 0 T00 50 Aal 1 45 roud 43 0344 011 9 01 901 8 5345 079 ON ODL HD ON AUIDONI BIR 801111 525 HLIM 03 06 339 01972345 0 HOLIU3M 30 1551 834 NALAIUM 50184 1884 NI 30H 035019810 HO 9390 ONIHLON NOl UJM 18 NOdN 138 OL 102 8 5 51578 7 1443013405 V G3NVOT 1 15184 SIHL 00 4 QUVONVIS 9N U33NISN3 5532004 0 V SONIMNHVW YOLIMIN 031312345 ATdd IERT 61154 vV3uV SIHL NI HM RA 0070 7931 0 98 0791 5 10015 14 Metal Parallelism Block DX195 303 TWNI9INO ON 73 17 85 TON 11109273 401134 929 SHL
78. l head screw end plate screw 4 9 Oover plate screws 2 32 Adjuster device screw 1 10 Eccentric shaft seal 1 33 Adjuster gear segment 1 11 Eccentric shaft seal boot 1 34 Adjuster sleeve gear 2 12 Clamp bolt lever 1 35 Slide pin protective cap 2 13 Lever 1 36 Adjuster sleeve 2 14 Clamp bolt nut lever 1 37 Slide pin locking screw 2 15 Eccentric shaft bearing unit 2 38 Actuating piston 2 16 End plate gasket 1 39 Slide pin 2 17 Slide pin bushing 2 40 Identification label 1 18 Eccentric shaft support bearing 1 41 Slide pin seal boot 2 19 Actuation block 1 42 Actuating piston seal boot 2 20 Damping spring 2 43 Roll pin 2 21 Snapring 2 44 Thrust plate 1 22 Bevel gear torque limiter 1 45 Saddle 1 23 Adjustment box 46 Actuating piston screw 2 preinstalled unidirectional bearing 1 47 Brake pads 2 48 Brake pad wear indicator if fitted 1 Gear is shown separately since it is an integral part with adjuster screw These components are different according to actuation direction clockwise or counter clockwise Fig 2 2 ArvinMeritor DX Air Disc Brake ER Exploded view Post March 2001 production ArvinMeritor Air Disc Brake Parts list Post March 2001 production Ref Description Q ty Ref Description Q ty 1 Stabiliser bar retaining pin 1 28 End plate cap 1 2 Pin clip 1 29 Plug of adjuster port 1 3 Caliper 1 30
79. lever clamp bolt Should the lever interfere with the eccentric shaft insert an appropriate wedge screwdriver s blade the groove in order to facilitate disassembly and remove Fig 3 43 Fig 3 43 Reassemble new lever Ensure that the mark on the lever and eccentric shaft are aligned thus ensure correct positioning of the lever on the eccentric shaft Fig 3 44 Fit new clamp bolt and tighten to a torque of 30 Nm Refit actuator and tighten actuator nuts to 200 Nm if removed Follow Section A Pad replacement if required Follow Section C Manual adjustment if required N Thrust plate centering in saddle Due to the eccentric actuating system the thrust plate should be positioned on a longitudinal axis with respect to the two saddle vertical axes that support the inner pad during braking Positioning must be carried out with the lever in rest position and air chamber mounted Install service tool metal block to check parallelism between thrust plate and opposite caliper reaction surface Fig 3 45 Push the thrust plate against metal parallelism block manually rotating adjusting system Use 6 mm hexagonal wrench through adjusting hole on end Service tool Brake type Service Tool DX175 DXT 15 DX195 DXT 14 DX225 DXT 13 0 225 21 DXT 16 0 1 and 0 5 feeler gauge should be placed between each of the saddle s vertical support face and the thrus
80. nMeritor DX Air Disc Brake ArvinMeritor Air Disc Brake Service tools pg 48 DXT 01 Bush Removal DX225 49 DXT 02 Bush Removal Tool DX195 50 DXT 03 Bush Removal Tool DX175 51 DXT 04 Bush Insertion Tool DX225 52 DXT 05 Bush Insertion Tool DX195 53 DXT 06 Bush Insertion Tool DX175 54 DXT21 Piston Boot Insertion Tool DX225 DX195 DX225 21 55 22 Piston Boot Insertion Tool DX175 56 DXT 09 Slide Pin Boot Insertion Tool DX225 57 DXT 10 Slide Pin Insertion Tool DX195 DX225 21 58 DXT 11 Slide Pin Boot Insertion Tool DX175 59 DXT 12 Slide Pin Cover Insertion Tool DX 225 DX195 DX225 21 60 DXT 13 Metal Parallelism Block DX225 61 DXT 14 Metal Parallelism Block DX195 62 DXT 15 Metal Parallelism Block DX175 63 DXT 16 Metal Parallelism Block DX225 21 64 DXT 17 Brake Support universal all DX 65 DXT 18 Slide Pin Cover Insertion Tool DX175 66 DXT 19 Universal Handle Tool all DX 67 DXT 20 Shaped Universal Handle Tool 68 Insert Universal 69 X Round Head Universal Tool 70 Handle Shaped Universal 71 Handle Straight Universal DX225 21 DX225 21 lt ArvinMeritor Air Disc Brake 10018 DXT 01 Bush Removal DX225 6 Service HO CU ON In 10102 303 9150 NOLIB3N 3O 15510939 4 VOLL BOLE JHL LNOHLIA 1884 NI 80 MAKE W SE ST O V SONIY
81. o freely position itself on the saddle to compensate for the reduction in lining pad thickness due to wear An automatic self adjuster mechanism is incorporated in order to maintain constant clearance between pads and rotor The automatic adjuster operates on each clamping action to sense excessive pad rotor clearance and reduces excessive clearance by a fixed proportion with each actuation For brake adjustment and new lining installation the brake incorporates provision for manual adjustment easily performed by using a standard hexagonal wrench Brake actuation can be either clockwise or counter clockwise depending on how the air actuator has been installed on brake unit 6 ArvinMeritor Air Disc Brake Regardless of which side the brake unit is installed on vehicle the brake is referred to as RIGHT when actuation is clockwise Fig 2 2 a and b LEFT when actuation is counter clockwise Fig 2 2 c and d Clockwise actuation Fig 2 2 a and b will always require left hand threaded adjuster sleeves and pistons actuation pistons marked on the bottom with the letter L and its related right housing R H The opposite applies for brakes with counter clockwise actuation Fig 2 2 and d Brake pad wear warning indicator Brakes can have different types of pad wear warning indicators PWWI according to vehicle manufacturer s requirements Follow vehicle manufacturer s instructions for proper installation and
82. o therefore it is up to the operator to determine the most appropriate service intervals with technical support from ArvinMeritor if necessary These service intervals are the maximum recommended times under normal operating conditions Extreme temperatures or adverse conditions e g dusty or severe environments frequent uphill driving very low temperatures will require more frequent servicing It is the responsibility of the vehicle operator to schedule these intervals with technical support from ArvinMeritor if necessary In some cases it is possible to carry out operations with brake unit mounted on vehicle However ARVINMERITOR recommends that all operations with the exception of pad replacement and operating tests be carried out with the brake unit removed from vehicle and installed on bench This promotes safer working conditions and better results ArvinMeritor DX Air Disc Brake 3 Brake pad replacement is necessary when the friction lining is worn down to a thickness of 2 mm total thickness inclusive of support plate is 9 mm With the vehicle on a hard level surface fit anti roll chocks under the road wheels to prevent it from moving either forward or backwards WARNING Carefully follow the manufacturer s instructions when jacking the vehicle and removing the road wheel Preliminary procedures necessary disarm the parking spring following the air
83. ough the upper caliper opening The opening is machined elliptical to allow this operation to take place Pull out Eccentric Shaft together with the Eccentric Shaft Support Bearing and discard Fig 3 36 Fig 3 36 3 NOTE Care should be taken with the eccentric shaft removed that no rollers are dislodged from the Lower Eccentric Shaft Bearing as this is an uncaged needle roller bearing assembly Do not move the manual adjuster stem with the Eccentric shaft removed as this could cause the Adjuster Gear segment to become displaced The consequence of this would be to make re assembly more difficult Reassembly Apply lubricating grease MBG 1003 to the Lower Eccentric Shaft Bearing within the housing taking care not to allow the loose needle rollers to become displaced Apply lubricant grease MBG 1003 to all bearing surfaces of new Eccentric Shaft Open up and position the new Eccentric Shaft Support Bearing in the seat on the eccentric shaft and thoroughly lubricate the rollers Fill gap between new Eccentric Seal and Eccentric Shaft with grease Fig 3 37 Cover plate seal arrangement Fill gap with Eccentric shaft grease MBG 1003 Apply thin film of grease to surface before assembly Insert the new Eccentric Shaft by passing it through the upper caliper housing align the eccentric high point with the machined elliptical section of the housing Pass through the
84. rance caused by continuous wear of the brake pads The action is automatic and occurs during normal brake application Clearance compensation is performed as indicated in the following four steps Step 1 actuation of eccentric shaft a Actuating lever moves and eccentric shaft rotates b Block lifts and begins to move forward carrying the adjuster sleeves and pistons with it Fig 2 4 c Eccentric shaft A begins turning within the gear plate segment eliminating clearance h between the adjuster gear section slot B and the shaft integral tab sides Fig 2 5 Step 2 clearance compensation device d Adjuster gear segment begins to turn causing the rotation of bevel gear adjuster C Fig 2 5 6 Bevel gear rotation causes the adjuster shaft to rotate by means of the ball torque limiter and the rotation is transmitted to the box central gear through the unidirectional bearing f Central gear rotation through the box gear train causes the 2 adjuster sleeves to rotate At this stage depending on the amount of wear of the brake pads one of the following two conditions will occur Condition A No adjustment is required as clearance between pads and rotor is correct
85. roduction Installation configuration TEIL UR Operating principles Actuation Linear force from the air actuator air chamber is converted by lever action to rotary torque on the main eccentric shaft Rotation of the shaft supported by two ro ler bearings causes the block to move towards the inside of the caliper The ratio between the air actuator force and force on rotor is between 12 5 and 16 2 depending on brake model All radia loads in the eccentric shaft are absorbed by two supporting roller bearings maintaining an efficiency of around 95 because of total absence of sliding friction in the system 2 ArvinMeritor Air Disc Brake Clamping The caliper assembly is free to float on the slide pins attached to the saddle This exerts clamping force on the inner pad and determines a reaction through the caliper body ensuring that both pads are loaded onto the rotor by an equal force 2 Introduction Automatic self adjuster mechanism 0 2 Automatic self adjuster mechanism E Description Actuating piston Adjuster sleeve gear Eccentric shaft Actuation block Bevel gear Box adjuster gear train Adjuster gear segment ArvinMeritor Air Disc Brake 13 2 Introduction Automatic self adjuster mechanism clearance compensation This mechanism located inside the caliper allows control of clea
86. rtion DX175 JILIN HO LINGIA a 133 40089 031802 91830 3002 9934 983 66 UNF 82 990209613 ve er or es sl zg 39NVIOT HONMd ONIHSNG 80 1 8 L62c 990206633 980 1814 90811001 104 035 3138 8061 4 1622 80151438 58011231084 HSVTI SN14 SHNG 17 3003 IV Wang 501498 0970 838809 301501 TIW SHOISHIHIG SI 3114 1 08703 SIVMEDIO 32414 2 WO SIOL ISIANIHLO SL 9 0 9718 328V83101 9819801 72 100 2 01 OV 334 SIINVYITO ONIISYO SU313AETTIM NI SNOISN3MIC TIW 2031319395 3S 483H10 8371 MUO 5015 ONI OY 534 ONO l3UGE3IM SLUVd NIS ON LNOAYT 011 8 OL 901 9 Dads 333 0071 Ab 310318 EH MAIS 119138 XOLIN wisst O V wuagiae G3NYOT SI WA SIKL 031415343 27441 901 4 SIHL 00 86 00 68 800509 78 ET VOR 00 SF 51 1 TUfNM 0103508 i 017000 SPD 6 Service tools Tool DX225 DX195 DX225 21 DXT 21 Piston Boot Insertion ZAXMANLSTALHS 4 Iv L 30 1 13365 TIv LIN3AI33dX3 1 1 aia M3N91S30 H5 ALIYOHLNY N9ISIA INGALNYd3O 9NISS3NISN3
87. s from the caliper and discard NOTE Ensure to MARK the respective positions of the 2 slide pins and locking bolts i e Long and short Remove and discard the two Slide Pin Boot seals from the caliper Fig 3 18 3 Push or knock out old bush using special tool Fig 3 19 Brake type Service Tool DX175 DXT 03 DX195 DXT 02 DX225 DXT 01 0 225 21 DXT 02 Re assembly Clean housing remove all traces of old sealant from both ends of the bushing bore Fit new Slide Pin Bushes into the housing Use a press to insert using special tools Service Tools Brake type Service Tool DX175 DXT 06 DX195 DXT 05 DX225 DXT 04 0 225 21 DXT 05 CAUTION Do not hammer in bush as this could damage the edge of the bush and prevent the fitment of the new slide pin fig 3 20 Press in bush until the dimension 1 70mm as shown in sketch is achieved Bush to be proud of bore by the dimension indicated Fig 3 21 Fit new Slide Pin Boots seals Before re assembly apply a sealant MBG 1002 on the outside diameter of the metal ring insert Fig 3 22 ArvinMeritor DX Air Disc Brake 3 Knock into position with service tool Fig 3 23 Service Tools Brake type Service Tool DX175 DXT 11 DX195 DXT 10 DX225 DXT 09 0 225 21 DXT 10 NOTE it may be necessary to wind out adjust brake in ord
88. s shall be null if non original ArvinMeritor spare parts are used Technical specifications Below are the technical specifications of the DX series of disc brakes Recommended lubricants ArvinMeritor recommends the use of two lubricating greases available as spare parts Code Use MBG 1003 grease Use on all actuation and Fuchs Unitemp 2 adjustment system components MBG 1004 lubricating oil Kluber Constant GLY 2100 Use only for slide pin plain bearings bushings WARNING Only original ArvinMeritor spare parts should be used Use of non recommended lubricants shall adversely affect performance and service life Use of non original parts could seriously affect brake performance Disc Brake Model DX175 DX195 DX225 DX225 21 Type Disc brakes Disc brakes Disc brakes Disc brakes Caliper Floating with pad lining compensation device No of pistons per caliper 2 2 2 2 Weight kg 28 38 48 41 Lining thickness mm new 19 20 23 22 min 2 2 2 2 Rotor type Self ventilated Rotor outside diameter mm 336 3 8 436 420 Rotor inside diameter mm 178 218 234 201 Rotor thickness mm new 34 45 45 45 min 28 39 39 39 General Maintenance No Technicians Tools Working position Pad replacement 1 NO On vehicle A Manual clearance adjustment 1 NO On vehicle On bench B Rotor overhaul 1 YES On vehicle On bench C Operating
89. t can seriously damage the boot and will require replacement 82 ArvinMeritor DX Air Disc Brake 3 NOTE Slide Pin Locking Screws may be different in length Make a note or mark the caliper body in order to identify the screw positions Fig 3 32 The Slide Pins are also different slight difference on the outside diameter and counter bore different depth to accommodate the different length screws Remove the caliper body from the saddle NOTE At this time it may be appropriate to inspect the slide pin boots If damaged replace If satisfactory it may be appropriate to re lubricate the slide pins using MBG 1004 NOTE the Slide Pin with the short screw and outer diameter slightly oversized should be installed on the right side looking at the brake from the end plate on brakes with clockwise lever actuation the opposite applies for brakes with counter clockwise lever actuation WARNING Use only new screws during maintenance The use of old screws and bolts is very dangerous and can seriously affect brake performance For ease of assembly offer the new saddle to the caliper body and align the slide pins with the corresponding location seats in the saddle Install the new Slide Pin Locking Screws with the pre applied thread locking compound and hand tighten Refit assembly to the bench mounting device and finally tighten the screws to the specified torque as per tabl
90. t plate in order to manually support it against the shim Fig 3 46 ArvinMeritor Air Disc Brake 3 The 0 1 mm shim should be placed the if actuation is counter clockwise or on the right if actuation is clockwise For further inspection insert a 0 5 mm shim from the opposite end in order to check correct thrust plate positioning Tighten one of two piston screws just enough to keep thrust plate in the calibrated position Fig 3 47 Remove feeler gauges and parallelism block de adjusting the brake slightly Tighten piston screws to a final torque as indicated in table below for the brake model type Model Torque Nm DX225 DX195 DX225 21 85 DX175 45 Fig 3 47 0 Reassembly of brake unit on vehicle and pad refitting Reassemble brake unit on vehicle securing it to the appropriate axle flange Tighten screws to specified torque values refer to standard brake configuration Model Torque Nm Screw DX225 600 Nm M20x1 5 DX195 DX225 21 290 Nm M16x2 0 DX175 200 Nm 14 1 5 For non standard brake configurations apply specified torque for the corresponding type of screw or follow manufacturer s instructions Due to the rotor s presence brake should be de adjusted completely in order to position brake pads see Section B Manual Adjustment Refit pads if required see Section A Pad Replacement Adjust brake as per procedur
91. t step could be skipped Fig 3 8 For this purpose be sure that the wrench does not interfere with brake components all around 360 If the rotation is less than the stated value actuate the brakes 50 times via the brake actuator Measure the pad to rotor clearance using feeler gauge The automatic adjuster device operates correctly if measured clearance with a feeler gauge is between 0 6 and 1 0 mm or if Hexagonal wrench rotation needed to make the pad be in contact with the rotor is between 90 and 180 Should this be the case it should be remembered that the brake should be de adjusted as in the above step The complete brake assembly must be replaced if the clearance is not within these limits 3 checking slide pin bush wear The following is a check that enables the wear on the slide pin mechanism to be checked with the brake assembly in position on the vehicle and to determine if replacement is necessary Periodical checks of the slide pin bush wear should take place The frequency of the periodical checks must be determined by the vehicle trailer user However a frequency of every 12 months or 100000 kilometres must be considered although the frequency will depend on the type of operation or the environmental conditions With the aid of a DTI Dial Test Indicator movement of the brake housing relative to the fixing saddle can be measured Tangential test New pad condition R
92. tests 2 NO On vehicle D Checking slide pin bush wear 1 NO On vehicle E Brake Caliper Servicing Disassembly of Actuating System 1 NO On vehicle On bench G Slide Pin amp Bushing Replacement 1 YES On bench H Actuating Pin Seal Boot Replacement 1 NO On bench Saddle Replacement 1 NO On bench J Eccentric Shaft amp Cover Plate Replacement On bench On vehicle K Stabiliser Bar Replacement 1 NO On bench On vehicle L Lever replacement 1 NO On bench On vehicle M Thrust Plate Centering 1 YES On bench N ArvinMeritor Air Disc Brake 3 Maintenance Intervals Although there is no routine maintenance of the brake assembly required it is important the following inspections are carried out at the periods specified or those detailed in the vehicle or trailer manufacturer s manual Service intervals Every 3 months or 20000 km A visual inspection of pad life should be made Brake pads should be replaced when the lining thickness has worn to 2 0 mm Visually inspect the general condition of the brake assembly for damage or corrosion Inspect the slide pin and actuating piston seal boots and ensure they are undamaged and securely located If any of the boots are detached or damaged the relevant part of the brake should be dismantled and the components examined for corrosion and damage there is any doubt in the suitability for further service replace rectify in accordance with the instructions of this m
93. tic unscrewing devices during manual adjustment If used by mistake breakage of adjuster box gears could occur Do not exceed adjustment torque of 6 Nm Rotate the adjustment mechanism in the direction in which clicking is not heard or felt Continue rotation until both pads come into contact with rotor Then in the opposite direction turn the hexagonal until 7 torque limiter notches are heard or felt this will set the initial pad to disc clearance Remove the hexagonal wrench replace the port plug and washer and tighten to 14 Nm Condition Surface crazing Description Light short random crazing of braking surfaces Fig 3 6 Radial cracks Small slight cracks Fig 3 6 B C Rotor inspection Rotors should be inspected whenever the brakes are serviced or new pads are fitted or immediately if erratic braking performance is perceived The rotor condition should be visually inspected Check braking surface conditions in order to determine if the rotor needs to be replaced Accurate cleaning of the rotor is necessary at 100000 km or 12 months intervals Remove all rust or debris caused by wear from rotor rim from support points of the pads in the saddle and from all caliper actuation surfaces See below a list of conditions often detected on rotors Tolerance Operation None None if tolerance levels are not exceeded If one of the tolerance levels is exceeded replace rotor Max width 0 5 mm Max depth
94. tuator manufacturer s instructions before working on the brake Use care when disarming the parking brake chamber Personal injury can result if correct procedures are not followed Remove Clevis Pin connecting the air actuator rotation chamber pushrod to the brake actuating lever Clean the area where the operation will be performed Eccentric Cover Plate Fig 3 40 NOTE if the working area of the brake is not easily accessible remove actuator from the caliper end plate Secure actuator firmly do not allow actuator to be supported on the pneumatic connections and remove the brake from vehicle Remove lever clamp bolt and discard Remove the lever and retain Should the lever interfere with the eccentric shaft insert an appropriate wedge screwdriver s blade in the groove in order to facilitate disassembly and remove lever 3 Remove the Eccentric Shaft Seal Boot if fitted not used on later level brakes Remove the manual adjustment port plug and washer and retain Remove the 2 Cover Plate Screws and discard Remove the Cover Plate assembly in which the Eccentric Shaft upper bearing unit is positioned Whilst removing the cover plate hold the eccentric shaft in place thus ensuring that the shaft is not pulled out simultaneously with the cover plate and discard NOTE Care should be taken when removing the cover plate assembly that none of the rollers are allowed to become dislodg

DX Air Disc Brake DX series of disc brakes

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