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ROR Axle & Brake Service Manual

1. 39 045 8750640 8750513 Meritor HVS Barcelona S A Commercial Vehicle Systems Ctra Granollers Sabadell Km 13 3 Poligono Argelagues 08185 Lli de Vall Spain Telephone 34 9 3 843 95 68 Fax 34 9 3 843 83 59 For further information contact Meritor HVS Limited Commercial Vehicle Systems Rackery Lane Llay Wrexham LL12 OPB U K Telephone 44 0 1978 852141 Fax 44 0 1978 856173 www arvinmeritor com Copyright 2002 Meritor Automotive All rights Reserved Publication 4 98 1 ArvinMeritor Inc World Headquarters 2135 West Maple Road Troy Michigan 48084 U S A Telephone 1 248 435 1000 ArvinMeritor Commercial Vehicle Aftermarket AG Neugutstrasse 89 8600 D bendorf Switzerland Telephone 41 0 1 824 8200 Fax 41 0 1 824 8264 ArvinMeritor Commercial Vehicle Systems Postbus 255 5700AG Helmond Churchilllaan 204A 5705BK Helmond Holland Telephone 31 0 492 535805 Fax 31 0 492 547175 ArvinMeritor South Africa Commercial Vehicle Systems Telephone 27 0 83 602 1603 Descriptions and specifications were in effect at the time of publication and are subject to change without notice or liability Meritor reserve the right to make design improvements change or discontinue parts at any time ArvinMeritor
2. TM Service Use the voltage and amperage recommended by the electrode manufacturers This will provide the best fusion and strongest weld and will minimise the detrimental side effects such as localised hardening and residual stress Deposit the required amount of metal with the least number of passes practicable one pass to be preferred If a second pass is required first thoroughly clean the weld MOST IMPORTANT 1 Do not test the arc on the axle beam or springs 2 Fillet welds up to 12mm 1 2 can be used on round axle beams and the attachment should fit as close as possible to avoid excessive welding minimum recommended fitted weld 8mm 5 16 where practicable It is important to remove all scale in fillet welds prior to painting If this is not adhered to it will precipitate corrosion in these important weld areas NO WELD FIG 3 TM Service TM Axle Maintenance Schedule SERVICE ROUTINE TM Disc amp Drum CHECK BRAKE ADJUSTMENT AND CHECK WHEEL NUT TORQUES ty an ArvinMeritor brand FREQUENCY Before entering service After 150 km After 1500 km Every 3 months After any wheel fixing removal After any brake service TM Drum LUBRICATE CAMSHAFT BEARINGS CHECK BRAKE ADJUSTMENT CHECK OIL LEVEL OIL FILLED HUBS Recommended maximum at 3 monthly intervals Vote If other than ROR Brake Lubricant Total Fina is used or where vehicles are in contact with severe ab
3. 200 000 km Anchor pin assembly xA 197100000 kn A ABS components 2 yr 200 000 km bearing Assister spring 1 yr 100 000 km ABS components 2 yr 200 000 km Camshaft 1 yr 100 000 km Return spring 5 yr 500 000 km Axle beam weld assembly Ex works Including Flexair N 2 yr 200 000 km spring seat ga Cam roller assembly 3 yr 300 000 km TM beam non ArvinMeritor welded 1 yr 100 000 km Brake shoe assemblies Mechanical failure only 3 yr 300 000 km NS 1 yr 100 000 km Brake drum Mechanical A Dust covers amp screws failure only Kd an ArvinMeritor brand TM Service Identifying the Axle Type Anti Lock Type Steer Axle Table D Self S Command Wheel fixing to suit single or twin wheels T Axle series loading Table A Brake size and type denoted by letters Table B Number of wheel bolts either 8 or 10 Type of wheel bolts Table Table A TM Loading Standard and Low Loader TABLE B TM BRAKE CODING CHART Axle Series Nominal Highway Axle Rating kg Maximum Offset mm Axle Letter Gode Brake 310 190 20 000 9 500 460 350 200 22 500 10 170 490 394 180 25 000 11 690 490 The axle ratings shown are for normal highway applications and any special 420mm x 150mm 42
4. and no adjustment takes place The main gear turns but does not transmit motion beyond the over ride clutch into the adjuster train STEP 3B Adjustment is required as clearance is excessive Before the pads contact the rotor the adjuster sleeves are turned by the gear train Rotation of the sleeves has the effect of unscrewing the adjuster piston within the sleeves thus increasing the effective length of the pistons and decreasing the travel required Fig 9 Adjustment Plungers Unscrew Barrels Rotate E Adjustment Barrel Gears NS Turn Bevel Gear Turns One Way Clutch Turns Gears FIG 9 When the pads contact the rotor a clamping force is generated and this is fed back into the adjuster sleeves and pistons generating friction in the adjuster screw threads and friction under the flanged head of the adjuster sleeves Fig 8 an ArvinMeritor brand e The friction build up prevents further rotation of the adjuster sleeves instead the over ride clutch begins to slip 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 beyond the over ride clutch into the adjuster train Fig 8 STEP 4 Brakes Released When the pressure to the air chamber is relieved the actuating lever will be retracted The eccentric shaft and quadrant gear will reverse with the centre gear The
5. assembly The caliper is carried on a saddle which is a fixed support bolted to a torque plate on the axle beam Equalised clamping action 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 created 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 Fixed pad The slide pins also allow the caliper to freely position itself on the saddle to compensate for the reduction in lining pad thickness due to wear Lining wear would result in correspondingly longer actuation lever throw and excessive chamber stroke To eliminate the problem the brake incorporates an inbuilt automatic adjustment mechanism The auto 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 set up and new lining installation the brake incorporates provision for manual adjustment easily made using a standard Hexagon key an ArvinMeritor brand TM Service Axle Installation INTRODUCTION The following notes and recommendations are offered as a guide to the trailer manufacturer and service engineer They are based on experience gained from both the manufacture and the servicing of single and multiple axle installations STR
6. in hot conditions to give long life Should you wish to convert to oil filled 1 Remove hub and drun if original bearings are to be re used ensure they are refitted in the original hubs 2 Clean out the grease from the hub cavity and wash out both bearings with a suitable cleaner If the bearings are dried with the use of an air jet avoid rotating the bearings at high speed 3 Refit inner bearing into hub and fit new unitized oil seal 4 Refit hub and drum assembly refit outer bearing and adjust bearings as per previous instructions and instructions on page 37 5 Fit new oil filled hub cap and gasket Standard Filed 21200624 Hubodometer Oil Filled sess 21204834 Gasket Oil Filled o yt ow ommo tus 21021002 6 Fill to level marked in hub cap window with EP90 oil 7 Readjust brakes TM Service 3 7 BEARINGS All ROR axles come with a built in bearing end float that is pre set There should be no need to adjust this setting However if any hubs are disassembled it is important that the adjustment procedure for hub and drum replacement is followed see page 37 The bearings used in ROR axles are selected to give the user maximum service life To ensure the long life of these bearings the following procedures are recommended 3 7 1 BEARING REMOVAL AND INSPECTION Remove hub and drum this releases the outer bearing cone Remove oil seal this releases the inner bearing co
7. of time and or mileage each component will have to endure until the hubs are again removed proceed as follows 3 2 REMOVING THE HUB amp DRUM If oil filled drain hub and remove hub cap Remove bearing locknut lockwasher and adjusting nut using suitable ROR hub nut box spanner Slacken off brakes by use of the slack adjuster Withdraw hub drum ensuring outer bearing does not fall out of the hub difficulty is experienced in withdrawing the hub it may be necessary to use withdrawal tool No 21200141 as shown in Fig 1 FIG 1 an ArvinMeritor brand FIG 2 NOTE ArvinMeritor recommends the use of a wheel dolly No 21217493 to remove the wheels hub and drum assembly This service aid will speed up the work can be used easily by one man and most important will prevent seal and bearing damage The wheel dolly Fig 2 is available through ArvinMeritor Commercial Vehicle Aftermarket Division The wheel dolly and hub puller have proven to pay for themselves in substantially reduced downtime and unnecessary damage to components such as seals and bearings TM Service 3 3 HUB SEALS GREASE OR OIL 3 3 1 REMOVAL As a rule oil seals should be replaced whenever the hub and drum are removed Special care must be taken not to damage the inner bearing Two types of seal are found on ROR axles 1 Unitised seal NO WEAR SLEEVE FITTED 2 Grease seal with wear sleeve fitted to axle From Jul
8. resurfacing does not remove the spots the rotor must be replaced Max length F X 75 of A Pg FIG 14 an ArvinMeritor brand Rotor Run Out Use a Dial test Indicator DTI to check the run out both axially and radially as in Fig 18b Axial Skimming Run out should not exceed 0 3mm over the rotor braking surface when the rotor is Be EET turned on properly adjusted wheel is d bearings Excessive run out may be due to Rada di incorrect mounting of the hub fastener torque s mal adjusted bearings Surface finish after Radial machining should Run out should not exceed 0 8mm total saa indicator reading um Thickness Rotor thickness must not vary by more than 0 13mm across any two points of the rotor faces w m a j FIG 18b 2 9 CALIPER REMOVAL AND REPLACEMENT GAUTION Note to assist assembly on some axles The two extreme fixings engage slots on the torque plate Never leave the caliper with only these two fixings in place Falling hazard Fig 19a and Fig 19b GAUTION Do not used the stabiliser bar for handling purposes Damage to the bar could result FIG 19a FIG 19b TM Service Removing the caliper assembly Refer to Fig 25 1 Follow steps 1 7 of the lining change procedures Section 2 7 to remove the linings 2 Remove the clip and clevis pin from the lever Fig 20 4 Remove the caliper mounting bolts Take
9. surface and cover the bore with a clean cloth to protect the bearings and grease from contamination Check that the pole wheel mounting spigot on the hub is clean and free from rust using medium emery paper to clean it up if necessary Ensure no emery dust or other debris contaminates the bearings or grease Drift the pole wheel onto the hub spigot using the TM oil seal driver ROR part no 21218568 ensuring it bottoms out against the mounting shoulder Fig 26 Lower the rotor over the fitted pole wheel aligning the M12 tapped holes in the rotor with the corresponding fixing locations in the hub flange NB All rotor fixings must be tightened to the torque value specified in table 2 page 12 WARNING ROTOR WEIGHT IS 32 KGS an ArvinMeritor brand FIG 26 ma Section 3 TM Hub Service for Drum Brakes TM Service SECTION 3 Major Hub Service 3 1 GENERAL Although inspection of brake lining thickness min 8 25mm 0 325 can be determined by the removal of rubber plugs in the dust covers complete internal inspection and overhaul can only be achieved by the removal of the hub and drum assembly The number of re usable parts will not be known until the assembly is stripped Clean containers should be used to keep each set of hub components together and free from dirt When the hub is removed a full inspection of the internal components is advisable Bearing in mind the length
10. the spanner position the nut and washer under the mounting hole in the cross bar of the hub cap Lower the hubodometer through the hole to engage the thread Rotate the hubodometer to screw the nut along the mounting stud until hand tight Finally tighten the nut with the spanner in the normal way Fig 6 The hub cap and gasket can now be fitted to the axle as described in Section 3 FIG 6 TM Service 5 5 GARAGE WORKERS ASBESTOS CODE 1 DON T blow dust out of brake drums or clutch housings with an air line DO use properly designed drum cleaning equipment which prevents dust escaping or use clean wet rags to clean out drums or housings Put used rags in a plastic waste bag while still wet DON T grind or drill linings unless the machine has exhaust ventilation or there is a ventilated booth to do the work in DONT use brushes to sweep up dust DO use a special Type H vacuum cleaner to remove dust DO wet dust thoroughly and scrape it up if you haven t got a vacuum DO wear the protective clothing such as overalls provided by your employer DONT take the protective clothing home It should be cleaned by your employer DON T use equipment if it is not maintained and checked Ask to see the examination reports for ventilation systems an ArvinMeritor brand TM Service APPENDIX Axle and Brake Service Faults Drum POSSIBLE CAUSES HUBS RUNNING H
11. valve linkage at the axle If the pressure reading is not reached then disconnect the trailer s yellow line and with a suitable coupling measure the air pressure at the yellow coupling If there is ample pressure at this point the fault lies in the trailer air system and must be traced and rectified The Foundation Brakes 420mm 350mm 310mm The Brake Actuation 1 1 REMOVING BRAKE SHOES SERIES III Using a screwdriver between brake shoe gussets ease out both retainer springs Fig 1 Take hold of bottom shoe pulling it off the anchor pin tilt forward and lift off camshaft head Fig 2 Remove brake return spring Lift off top shoe 1 2 INSPECTION Inspect brake anchor pins and bushes for wear For Mark Ill anchor pins check and replace 0 rings as required Inspect cam rollers If removed from the brake shoe the roller retainer clip must be replaced by a new unit an ArvinMeritor brand FIG 1 FIG 2 Inspect brake shoes for wear at anchor pin and cam roller at location point Prior to re assembly the following parts should be lightly coated with ROR high perfomance brake lubricant i Bores of Camshaft Bushes ii Cam Rollers and camshaft head profile iii Brake Anchor Pin bearing surfaces and holes in Brake Shoe Gussets Ensure pressure greasing is carried out to the four grease nipples on each axle Use ROR high perfomance brake lubricant Check brake drums for cr
12. 0mm x 180mm 420mm x 200mm application for installation must be approved by ArvinMeritor Design Engineering Track spring centres 420mm x 220mm NB Offset TABLE C TM WHEEL FIXING CODING CHART Axle Letter Gode Wheel Mounting 2 380mm x 180mm Stopmaster TABLE D TYPE OF ANTI LOCK SENSING Axle Letter Gode Exciter Type Suitable For BSF SMMT M22mm x 1 5mm metric DIN A 60 45 Pressed Steel Grau MGX2 8 MGX2E Bendix MDR 8 MDRA Trilex type 100 80T Wabco ISO 4107 type with M22mm x 1 5mm wheel bolts ISO 4107 type with M22mm x 1 5mm wheel bolts for alloy wheels B Japanese M20 x 1 5mm Solid Ring Bosch Grau DGX amp MGX100 Bendix AL 4T Note Please refer to relevant anti lock manufacturers service manual for specific service and replacement instructions Identifying the Serial Number Brake Lining Type Build Month Sequential Number Eel EEEE Build Year Order Number TM Service Introduction to the TM Axles Range AXLE BEAMS The ROR Mark III TM Series Axle is manufactured to a very high standard of beam engineering The beam material is heat treated to provide an excellent yield strength whilst maintaining a good ductility The carbon equivalent of the beam material is controlled to ensure that pre heating is not necessary when welding per the provisions of BS 5135 It is advisable to hav
13. 100 000 km Hub cap amp screws 1 yr 100 000 km 1 yr 100 000 km Oil seal Hub cap gasket 2 w Mechanical failure only Mechanical failure only 300 000 3yr 300 000 km TM Hub assembly 1 yr 100 000 km Axle end fixings Hub cap amp screws D an ArvinMeritor brand TM Service DX 195 Disc Brake for TM Axles Any component not referred to below is covered by a 1 yr 100 000 km warranty for mechanical failure only Labour costs can only be claimed at an agreed rate with ArvinMeritor Service Department prior to work commencing For full warranty terms and conditions see ArvinMeritor Warranty Terms and Conditions Publication No 4 84 1 2 yrs 200 000 km Caliper assembly 1 yr 100 000 km Brake retaining clips 1 yr 100 000 km Brake pad assemblies Mechanical failure only 1 yr 100 000 km ABS components 1 yr 100 000 km ABS components 2 yr 200 000 km Brake rotor Mechanical Failure only TM Service sa TM Axle shown Any component not referred to below is covered by a 1 yr 100 000 km warranty for mechanical failure only Labour costs can only be claimed at an agreed rate with ArvinMeritor Service Department prior to work commencing For full warranty terms and conditions see ArvinMeritor Warranty Terms and Conditions Publication 4 84 1 1 yr 100 000 km 2 Brake shoe assemblies Mechanical failure only 1 yr 100 000 km 1 yr 100 000 km Retaining spring 2 yr
14. ENT The pads must be replaced at or before the amount of pad materials reaches a thickness of 2mm WARNING Caution should be exercised in handling both asbestos and non asbestos materials GAUTION Replace the pads on both brakes of a single axle or all six brakes of a triaxle at the same time If you do not replace all the pads at the same lime poor brake performance may occur 1 Put blocks in front and behind the wheel so that the vehicle cannot roll WARNING Do not work under a vehicle supported only by jacks Jacks can slip or fall over and cause serious personal injury Support the vehicle with safety stands Block the wheels to prevent the vehicle from moving 2 Raise the vehicle enough to get clearance to remove the wheel and tyre Support the axle with safety stands Remove the wheel and tyre 3 Remove the adjuster plug from the air chamber bracket Fig 12 4 Using a Allen key carefully back off the brake Fig 13 and 14a CAUTION Read section 2 5 Manual Adjustment Increase Clearance Decrease Clearance RH BRAKE ASSEMBLY Allen Wrench U Decrease Clearance Increase Clearance FIG 14a 5 Remove the stabiliser bar split pin and stabiliser bar retainer pin Hinge the stabiliser bar up and out of the way Fig 15 and 16 6 Lift the inner pad out of the caliper assembly If these pads are not to be replaced mark the pads as inboard and outboard Fig 17 7 Slide
15. ESSES ON AXLE BEAMS The stresses on the axle beam under the load take two forms The upper portion of the beam is subjected to a COMPRESSION stress equal to the TENSION stress of the lower portion Along the beam centre is a zone of minimum stress often named the neutral stress zone area Fig 1 is a simplified sketch of the transverse section of a tubular axle and spring showing these three zones Fig 2 is a graphic representation of the degree of stress in the wall of the tube when the beam is under load When an air suspension is assembled to the axle beam of a design which uses the beam as a torsional member of the air suspension then an additional allowance must be added to determine overall beam strength In this application beam strength is composed of maximum load air suspension torsional stress and braking stress In general the 22 500 Series axle beam should be applied as a minimum rating ArvinMeritor Engineering should be contacted for written approval of application The length of the arrows represents the amount of stress at a given point From this illustration it is evident that the two opposite stresses diminish as the horizontal centre line is approached The stress imparted by the action of braking is taken into consideration in rating axle capacity The axle beam strength is computed by adding together the maximum load and braking stress to which the beam will be subjected A reasonable allowance of both is then a
16. It runs in bushes that are grease packed The cam bush is bronze whilst the spherical bearing is glass filled nylon encased in a heavy gauge steel housing From June 1991 axles with 420 dia brakes have used a pressed steel anchor bracket with a bolt on spherical bearing at the cam head end of the camshaft SEALS All ROR axles contain unitized seals These seals are suitable for either grease filled or oil filled operation Low Loader axles use special high temperature synthetic seals to prevent leakage even when operating at elevated temperatures HUBS Hubs are normally grease filled but are available oil filled on request HUBODOMETERS Available on request Specify tyre size and Kilometers or Miles SLACK ADJUSTERS ArvinMeritor will supply their own automatic slack adjuster on request RUBBER SEALING From June 1991 all axles with 420mm brakes have camshaft rubber seals fitted as standard For other brake sizes the camshaft sealing kit is available as an option TM Service Introduction to DX195 Disc Brake The ROR DX195 Air Disc Brake is one of a family of modular high performance low weight high efficiency brakes designed for Trailers Trucks Coaches Buses and other Commercial vehicles The brake has a cast caliper which straddles the brake rotor and houses two lining pads Clamping force is produced by a standard industry air chamber amplified via a high efficiency shallow throw eccentric and balance beam
17. Materials are capable of meeting UK EEC braking regulations As a general guide ArvinMeritor recommends TANDEM AXLE TRAILER Normal Use 420x180 brakes TRI AXLE TRAILER Normal Use 420x180 brakes TANDEM AXLE TRAILER Heavy Duty Use 420x220 brakes an ArvinMeritor brand BRAKE SHOES ROR quick change design shoe is accurately produced by manufacturing processes ensuring all shoes are capable of being relined several times When relined with the ROR original part the necessity to machine the linings on the axle is eliminated The anchor pin and roller areas are induction hardened to prevent wear Each shoe is coated with a rust inhibiting finish Every ROR shoe is marked with an ROR logo look for this guarantee to avoid being the recipient of non genuine lower quality shoes For TM Series Axles fitted with the option of Q brake assemblies refer to Axle 8 Brake Service Manual LM Series ANCHOR PINS AND BUSHES The Mark Ill axle has new sealed anchor pins with indented greased bronze bushes This unique feature keeps the pin working providing consistent brake performance The 0 ring seals keep contaminants away from the bush area From June 1991 all axles using 420mm brakes have a fabricated anchor bracket which has a stainless steel anchor pin bush CAMSHAFTS CAMSHAFT BUSHES amp SPHERICAL BEARING ASSEMBLIES The Mark IIl axle camshaft is an induction hardened one piece forging with an SAE 10 spline
18. OT Bearing adjustment too tight Insufficient lubrication Low loader on heavy duty high speed operation an ArvinMeritor brand SUGGESTED CORRECTION Adjust per page 37 Remove and re pack bearings Convert to oil Convert to oil page 35 PREMATURE BEARING FAILURE Bearing adjustment incorrect Condensation water in bearings due to vehicle parked for long periods Dirt foreign material in grease Bearings loose in hub Adjust per page 37 Convert to oil page 35 Clean and re pack bearings see p 36 Change hub and bearings see p 36 LOOSE WHEELS Incorrect torque Worn cones worn bolts Mismatched wheels amp wheel fasteners Damaged wheels mounting face not flat Excessive paint on hub wheel mounting face See Fig 3 page 43 Fit new cones bolts See Fig 3 page 43 Replace wheels Clean all paint grease spigots and re torque per Fig 3 page 43 BROKEN OR BENT AXLE BEAM Welding across high stress zone Air Suspension brackets poor welding practice Excessive shock loading Sleeping Policeman Pot Holes Kerb mounting etc Overloading Notched beam due to poor rework of brackets See page 10 Wrong capacity beam used Follow recommendations page 10 Replace beam with higher capacity Use higher capacity beam Fit new beam Do not attempt to reweld beam GREASE OR OIL LEAKS Incorrect assembly or seal damaged Seal lips low loader distorted D
19. P90 Mobilube GX90 Castrol Hypoy EP90 Multigear EP85W 90 Total EP90 Gear Oil 90EP GX 85 90 Brake Components and Camshaft Bearings ROR Brake Lubricant Total Fina CERAN WRC2 Spindle Bearing Journal Optimol Optimoly White Paste T TABLE 4 HUB amp BEARING GREASE FILL VOLUMES Hub Cavity Inner Bearing Outer Bearing ma Section 1 TM Drum Brake Service TM Th A z e TM Service SECTION 1 Major Brake Service Braking can be divided into sub systems each requiring maintenance to ensure correct performance The Air System The Foundation Brakes The Brake Actuation The Load Sensing Anti Lock System The Air System Since April 1983 it has been a legal requirement to fit air pressure test points at the following points in the air system 1 Each side of the load sensing valve 2 The slowest brake actuator to respond when the brakes are applied In addition to these some trailer manufacturers fit a test point close to the air reservoir With the aid of an air pressure test gauge 21214100 and connecting hose 21214101 the air pressure can be checked at the test points The air pressure measured at the test point close to one of the brake chambers should reach 6 5 to 7 5 bar with maximum application of the tractor brakes If a load sensing valve is fitted it will be necessary to either have the trailer loaded to capacity or disconnect the load sensing
20. RTANT ALL MATING SURFACES SHOULD BE CLEAN DRY AND FREE OF BURRS PRIOR TO REASSEMBLY an ArvinMeritor brand To replace Care should be taken to align the serrations of bolt and hub They must be driven FULLY home with the wheel bolt driving tool ROR Part No 21211274 Fig 2 using the sequence as for wheel nut tightening Ensure no gap exists between hub drum and wheelbolt head When fitted the anti lock Exciter Ring is retained by the wheel bolts When driving the wheel bolts home great care should be taken not to damage the Exciter Ring FIG 1 D TM Service Wheel Fixing Systems Single Wheel an ArvinMeritor brand FIG 3 Twin Wheels B S F 7 8 550 600 Nm 400 450 Ibf ft Nut 21016416 7 Bolt 21020735 6 DIN 950 600 Nm 400 450 Ibf ft Nut 21006511 Bolt 21022167 Cone 21006512 Nut 21016416 7 Bolt 21018490 1 Cone 21201588 Nut 21006511 Bolt 21020997 Outer Cone 21006512 Inner Cone 21019026 ISO 700 750 Nm 500 550 Ibf ft Nut 21226395 Bolt 21022167 Nut 21226395 Bolt 21020997 Alloy Wheels ISO 700 750 Nm 500 550 Ibf ft Nut 21226395 Bolt 21020997 f Nut 21226395 Bolt 21206355 Japanese Twin Metric Bolts R H 21211162 L H 21211163 Optional Clean Thread Closed End Nut M22 x 1 5 For Steel amp Alloy Wh
21. TOR REPLACEMENT If the existing rotor is to be re used refer to Section 2 of this Manual for inspection details prior to re fitting With the hub placed oil seal end upwards on a clean flat surface lower the rotor over the fitted pole wheel aligning the M12 tapped holes in the rotor with the corresponding fixing locations in the hub flange Fit the rotor retaining screws NB All rotor fixings must be tightened to the torque value specified in table 2 page 12 WARNING ROTOR WEIGHT IS 32 KGS an ArvinMeritor brand 4 8 HUB REPLACEMENT Replace the hub and rotor assembly as described in Section 3 of this Manual 4 9 CALIPER AND PAD REPLACEMENT Replace the caliper refit the pads and ensure correct brake adjustment as described in Section 2 of this Manual ma Section 5 Additional Procedures for Disc amp Drum Brakes TM Service SECTION 4 Additional Procedures 5 1 WHEEL FIXINGS Currently there are three different types of wheel mounting in common use e British Standard system using 7 8 BSF thread and 80 conical seatings usually with L H and R H threads e DIN metric system with M22 threads and spherical seatings 50 system again using M22 threads but locates the wheels by the centre bore on a spigot on the hub It is imperative that trailer manufacturers and operators ensure that the wheels and wheel mountings on the axle are compatible before ass
22. acks scoring or other damage Replace all worn parts with genuine ROR parts The use of non Original ROR parts will nullify all warranty and may substantially reduce service life 1 3 RE FITTING BRAKE SHOES 420MM amp 350MM Fit spring pins and rollers lubricate D holes with ROR high perfomance brake lubricant Fig 3 DN LUBRICATE FIG 3 Fit anchor pins applying ROR high perfomance brake lubricant inside the anchor pin bushes Fig 4 FIG 4 FIG 5 fy an ArvinMeritor brand Attach bottom shoe to spring push down and in towards cam head and onto anchor pin Fig 6 FIG 6 Fit both retaining springs to top shoe with screwdriver pull spring down and ease into bottom shoe Fig 7 FIG 7 IMPORTANT If anchor pin bushes require replacement ArvinMeritor recommends fitting the new bronze indented bushes 21016666A sealed anchor pins No 21205193G and 0 rings No 21220668 see page 20 The use of tool 21205456 is recommended as demonstrated in Fig 8 TM Service 1 4 RE FITTING BRAKE SHOES 310MM Fit spring pins and cam rollers lubricate 0 holes with ROR high perfomance brake lubricant Fit top shoe and hang return spring from pin Fig 9 FIG 9 Attach bottom shoe to spring push down and in towards cam head Fig 10 FIG 10 an ArvinMerito
23. ained with a cable tie 3 Outer rubber collar to close the Spherical bearing assembly retained with a cable tie an ArvinMeritor brand DO O FIG 27 4 Inner rubber collar to close the Spherical bearing assembly retained by the Slack Adjuster From June 91 axles fitted with pressed steel anchor brackets 420mm brakes only have dust covers retained by four M10 screws tightened to the torque specified in table 1 page 12 From August 97 TM Series axles with 420 diameter brakes are fitted with the LM style dust cover To refit with the camshaft removed Ensure the filler plate locating tag is engaged around the end of the anchor bracket and secure with two M10 screws Tighten to the torque specified in table 1 page 12 Fit the one piece dust cover ensuring it is correctly located onto the two filler plate studs Tighten the two M10 screws and the two 8 nuts to the torque values specified in table 1 page 12 If the camshaft is to be refitted prior to the dust cover Clean the full length of the camshaft prior to assembly Slide the under head rubber boot onto the camshaft lightly grease the cam head journal and slide the cam head bearing onto the camshaft towards the cam head until the spring clip is ready to engage in the groove light resistance will be felt Slide the inner rubber boots cover plate and spline end spherical bearing onto the camshaft Ensure the faces o
24. amaged worn hub cap gasket Hubodometer stem leaks Refer to page 35 Fit new temperature seal refer to p 34 Replace and torque capscrews as per page 12 Fit O ring to Hubodometer stem and re torque LOW BRAKE PERFORMANCE Low air pressure due to a valve malfunction in trailer system b incorrectly set load sensing valve c insufficient pressure from tractor Check air pressure at coupling and at trailer actuators If actuator pressure is low isolate valve concerned and replace Check load sensing valve input and output pressures compare with data plate and re set valve Check pressure at trailer couplings if low consult tractor manufacturer TM Service 6 an ArvinMeritor brand POSSIBLE CAUSES SUGGESTED CORRECTION UN BRAKE PERFOBMANGE Incorrect brake actuator installation Refer to p 44 for correct installation continued Brake components corroded dirty dry or Brake overhaul and maintenance required Seized See Section 1 on foundation brakes Renew any worn components with latest design Brake linings glazed This condition indicates Clean as per ArvinMeritor Trailer Bearing that the trailer brakes are only being subjected Maintenance booklet or replace linings to light duty usage and may require a detailed check of the trailer design performance and the suitability of the tractor trailer combination Brake linings soaked by oil Replace linings and fit new hub seal Brakes out of adjust
25. an ArvinMeritor brand Axle amp Brake Service Manual TM Series Axles including Disc and Drum Brake variants ArvinMeritor INDEX Section APPENDIX Description QUICK REFERENCE WARRANTY CHART IDENTIFYING THE AXLE Identifying the Axle Type Identifying the Serial Number INTRODUCTION TO THE TM AXLE RANGE AXLE INSTALLATION TM MAINTENANCE SCHEDULE TECHNICAL DATA TABLES Table 1 Fastener Torque Values Table 2 Recommended Lubricants Table 3 Hub Bearing Grease Fill Volumes TM DRUM BRAKE SERVICE TM DISC BRAKE SERVICE TM HUB SERVICE FOR DRUM BRAKES TM HUB SERVICE FOR DISC BRAKES ADDITIONAL PROCEDURES AXLE amp BRAKE SERVICE FAULTS ty an ArvinMeritor brand Page 12 13 13 23 33 39 41 46 an ArvinMeritor brand TM Service TM Hubs Any component not referred to below is covered by a 1 yr 100 000 km warranty for mechanical failure only Labour costs can only be claimed at an agreed rate with ArvinMeritor Service Department prior to work commencing For full warranty terms and conditions see ArvinMeritor Warranty Terms and Conditions Publication 4 84 1 1 yr 100 000 km Hub cap amp screws 1 yr 100 000 km 1 yr 100 000 km 0il seal Hub cap gasket 4 Mechanical failure only Mechanical failure only 3 yr 300 000 km 3 yr 300 000 km TM Hub assembly Axle end fixings 1 yr 100 000 km Hub cap amp screws TM DX195 1 yr
26. ar installation of the brake the handing of the eccentric and the air chamber position In general de adjustment or back adjustment is achieved when the key is turned in the direction which produces load clicks This indicates that the torque limiter is working Turning in the opposite direction will result in a smoother silent action which will give positive adjustment and reduce pad to rotor clearance Fig 13 FIG 13 fy an ArvinMeritor brand NOTE Opening the adjusters from fully worn pad condition to fully retracted position requires approximately 20 turns CAUTION When backing the brake off stop turning the key when resistance is felt This indicates that the adjuster pistons are fully retracted Further turning could lock the adjuster pistons in the sleeves and cause damage to the internal components When this resistance is felt adjust the brake out 1 4 turn to ensure that Auto Adjustment will take place DO NOT USE AN AIR GUN 2 6 BRAKE INSPECTION AND TROUBLE SHOOTING WARNING Do not work under a vehicle supported only by jacks Jacks can slip or fall over and cause serious personal injury Support the vehicle with safety stands block the wheels to prevent the vehicle from moving Inspection Schedules Inspect the brake according to one of the following schedules Use the schedule that gives the most frequent inspection The schedule for chassis lubrication used by your fleet e The sch
27. b and Bearing Removal and Inspection The hub removal service and re fitting procedures are similar to those described in Section 3 However in the case of disc brake installations the following additional procedures are required 4 1 SLACKEN WHEEL NUTS Before lifting the axle it is advisable to slacken the wheel nuts Lift axle enough to get clearance to remove wheel Support axle with safety stands and remove wheel and tyre Warning Do not work under a vehicle supported only by jacks Jacks can slip or fall over and cause serious personal injury Support the vehicle with safety stands and block the wheels ro prevent the vehicle from moving 4 2 DE ADJUST BRAKES Release trailer brakes and de adjust caliper and remove pads See section 2 7 Pad Removal and Replacement 4 3 REMOVE CALIPER Remove the brake caliper as described in Section 2 of this Manual 4 4 HUB REMOVAL PROCEDURE Remove the hub and rotor assembly as described in Section 3 of this Manual 4 5 ROTOR REMOVAL Place the hub and rotor assembly on a clean flat surface Using a wheel bolt removal tool ROR part no 21205455 drift the wheels studs through the hub rotor flange Remove the two retaining screws and separate the hub and rotor Tap the edge of the rotor mounting flange between the knock out grooves if necessary 4 6 HUB SERVICE AND INSPECTION Carry out hub service and inspection procedures as described in Section 3 of this Manual 4 7 RO
28. care not to allow the caliper to fall Fig 22 Remember that the caliper has a weight of 35kgs an ArvinMeritor brand 5 Lift the caliper away from the disc Installing the caliper assembly 1 Lift the caliper over the rotor Read CAUTION Page 30 Fig 19a Fig 19b if assembly slots exist on the torque plate 2 Align the bottom caliper bolt holes and hand start one of the inner fasteners fitted with a hardened washer 3 Hand start the remaining 5 bolts starting on the top half of the torque plate 4 Tighten the six fasteners to the torque value specified in table 2 using a 24mm 1 2 drive square socket Fig 23 FIG 23 Important For 80mm levers chamber fits lower near end of slot For 90mm levers chamber fits upper far end of slot 5 Mount the air chamber to the caliper assembly Fig 24 Tighten the air chamber nuts and washers to to the torque value specified in table 2 Page 12 6 Install the clevis in and R clip Fig 20 7 Follow steps 12 to 16 described in Section 2 7 to fit the pads and adjust the brake TM Service Inboard Pad Pad and Spring Assembly Outboard Pad Pad Backing Plate Pad Backing Plate Stabiliser Bar Load Plate Stabiliser Bar Retainer Pin Split Pin Adjuster Plug Adjuster Plug Washer FIG 25 2 10 FITTING A NEW ROTOR AND ABS RING With the oil seal fitted placed the hub oil seal end upwards on a clean flat
29. ce ASW RO A 25 CR Na 5 FIG 7 NOTE This clearance governs the final pad rotor running clearance and is specific to each brake It is vital that the correct original gear plate segment is retained matched to the eccentric shaft Use of an unmatched gear plate segment will alter the pad rotor running clearances perhaps outside of permissible limits STEP 2 Gear segment begins to turn Main adjuster gear turns in mesh with lower gear segment Main adjuster drives through the one way clutch and the over ride clutch to turn the central gear Complete gear train turns in mesh with the central gear The adjuster barrels begin to turn At this stage one of two conditions will be encountered SEE STEP 3A OR 3B TM Service STEP 3A No Adjustment is required as clearance is correct e At the point when the adjusters begin to turn the pads contact the rotor and clamping force begins to build up The clamping force generates friction in the screw threads between the adjuster sleeves and pistons and friction under the flanged head of the adjuster sleeves Fig 8 5 Clamping Force 5 Friction Build up Barrels Stationary Bevel Gear Turns Over Ride Clutch Slips FIG 8 e The friction build up prevents rotation of the adjuster sleeves instead the over ride clutch begins to slip The adjuster drive train is locked by the friction in the system
30. dded as a safety factor When the axle beam is suddenly relieved of its load and torsional stresses then torsion compression and brake stresses are momentarily relaxed These stresses are re applied and reversed many times during normal axle life For this reason the steel from which the beam is manufactured must have certain qualities of ductility which will permit it to absorb shock and to flex whilst retaining its calculated strength COMPRESSION STRESS gt NEUTRAL STRESS AREA TENSION STRESS FIG 1 an ArvinMeritor brand FIG 2 HOW WELDING AFFECTS BEAM MATERIAL All welds made on the beam create in effect an extreme local heat treatment The heat generated by the weld causes the material immediately adjacent to the weld to become hardened substituting the undesirable characteristic of brittleness for the original and desirable quality of ductility This small hardened area becomes the weakest part of the tube creating a notch effect Since the same characteristics of relative stress apply in both cases it can be seen that the loss of strength at the weld area can cause failure The notch can be at the bottom of the beam as well as at the top Either case is at the maximum stress location Some welding tips to minimise the notch effect 1 Make all tack welds at least one inch long 2 Keep the number of tack welds to a minimum if poss
31. e ArvinMeritor Engineering Department review the application of any welded bracketry if not previously approved The Beam Spindles are forged and heat treated to high strength Quality is built in the whole process is self monitoring with 100 checks of critical dimensions All ROR beams are manufactured to ensure the beam is straight and in line Some slight distortion will occur when spring seats are welded to the beam but in general this is negligible If cambered beams are required these must be ordered specially AIR CHAMBER BRACKETS AND CAM BRACKETS All Mark beams come equipped with air chamber brackets and cam brackets welded in the correct position to ensure brake actuators operate in the optimum way Replacement beams are normally supplied without air chamber brackets or spring seats SPRING SEATS AND AIR SUSPENSION AXLE ADAPTERS ArvinMeritor can supply axles with the above components welded to individual customer requirements ANTI LOCK OPTIONS Axles can be ordered with anti lock sensor equipment already installed and tested BRAKING ArvinMeritor offers S cam brakes in three diameters 420mm diameter as standard available in three widths 350 and 310mm diameter for low loader applications The brake design incorporates ROR patented quick change brake shoes The 380mm diameter Stopmaster is also available ROR s Mark Ill axles are fitted with non asbestos brake linings Effective from 1st January 1992
32. e fitted This will ensure that the correct gap is re set between the sensor and exciter ring Refer to page 36 All anti lock systems incorporate a warning light which should extinguish when the trailer is in motion If it fails to do so then a fault has developed and the system must be thoroughly checked by trained personnel using specialised test equipment Contact the supplier of your anti lock equipment direct It should be possible to achieve between 6 5 and 7 5 bar pressure in the trailer actuators on a full brake application which can be checked with the aid of a test gauge connected to the test point close to one of the brake actuators In addition anti lock systems are automatically switched off at very low vehicle speeds and should not be active during brake roller tests 3 5 mph ma Section 2 TM Disc Brake Service TM Service SECTION 2 Brake and Servicing 2 1 NOMENCLATURE Load Plate Caliper Slide Pin Adjuster Barrel Adjuster Barrel Gear Manual Adjustment Port Adjuster Cassette Block Adjuster Bevel Gear Over Ride Clutch One Way Clutch Actuation Eccentric Spindle Screw FIG 1 2 2 OPERATING PRINCIPLES Actuation Linear force from the Air Chamber is translated by lever action to rotary torque on the main actuation shaft and eccentric The eccentric is located in a balance beam actuation block and rotation of the shaft causes the block t
33. edule for chassis lubrication recommended by the manufacturer of the chassis e Atleast every 3 months e During tyre replacement Inspection should include the following 1 Stroke length Check the adjusted chamber stroke as follows Fig 14 a Measure the distance from the bottom of the air chamber to the centre of the large clevis pin while the brakes are released b Have another person apply the brakes using 80 90 psi of air pressure MEASURE ADJUSTED CHAMBER STROKE this distance FIG 14 NOTE If the vehicle does not have an application pressure gauge build tank pressure to 100 psi shut off the engine then make and hold a full brake application This will give 80 90 psi in the air chamber F an ArvinMeritor brand TM Service c Measure the distance from the air chamber to the centre of the 4 large clevis pin while the brakes are applied Seals Caliper should be replaced if any of the seals are found to be cracked torn or damaged in any way d The difference between the measurement is the adjusted 5 chamber stroke Caliper slides freely on slide pins Clearance between the rotor and the pad should be transferred from the inboard rotor surface to 2 Pad wear The pads must be replaced at or before the amount of the outboard rotor surface by sliding the caliper back and forth pad material reaches a thickness of 2mm 6 Disc Rotor Inspect the rotor for cracks deep sco
34. eels 21226397 TM Service 5 3 THE BRAKE ACTUATION This includes the correct attachment of the brake chamber or spring brake the correct connection of the push rod to the slack adjuster either manual or automatic and the setting and adjustment of the slack adjuster 5 3 1 AIR CHAMBER ATTACHMENT ArvinMeritor welds its air chamber brackets at the angles shown in Fig 4 to give the optimum air chamber installation with the slack adjuster length shown any deviation from this may detract from the optimum brake performance To check the angle use a combination protractor and level gauge Measure the edge of the cam braket and the face of the air chamber bracket as shown in Fig 4 and add the two angles 4 s 1 1 1 AIR CHAMBER d MOUNTING BRACKET ANGLE X ANGLE A SEE TABLE ANGLE Y ANGLE xX CAM BRACKET FIG 4 Slack Adjuster Installed Lengths Length 127 140 amp 152mm 185mm 5 5 6in 127 140 amp 152mm 165mm 5 5 6in 127 to 152mm 195mm 5 to Note Installed length is the distance between the clevis pin centre and the mounting face of the air chamber with the brakes released 5 3 2 AIR CHAMBER TO SLACK ADJUSTER Manual Slack Adjusters Position the air chamber in place on the mounting bracket ensuring the correct hole pairing on the bracket is used corresponding to the slack adjuster lever length bein
35. embling wheels to the axles and tightening to the recommended torque settings The achievable clamp load can vary considerably for a given applied torque depending upon a member of variable factors such as the surface condition of the bolts and nut threads To ensure accurate and positive location of the wheel all mating surfaces should be free from dirt excessive paint rust and damage The only satisfactory method of maintaining the correct torque figures which are based on coated and lightly oiled threads is by using a correctly calibrated torque wrench All ROR axles with DIN and ISO fixings have RIGHT HAND THREADED BOLTS ON BOTH SIDES OF THE AXLES Adhesive labels are available to highlight this If inspection reveals damage to bolts cones or wheels replacement is recommended THIS CONDITION IS USUALLY DIRECTLY RELATED TO IMPROPER TIGHTENING The wheel bolt being a safety critical component should only be replaced with ORIGINAL ROR PARTS 5 2 REMOVAL AND REFITTING OF WHEEL BOLTS REFER TO WHEEL BOLT CHART FIG 3 ROR bolts are pressed into the hub and drum assembly and retained by serrations and the press fit in the hub Damage to wheelbolts is caused by Loose wheel nuts Over tightened wheel nuts Mismatched wheel and fixings Cross threadings Mismatched bolts and nuts To remove They should be carefully pressed or hammered out using the wheel bolt removal tool ROR Part No 21205455 Fig 1 IMPO
36. en to the torque value specified in table 2 page 12 FIG 17 TM Service 2 8 ROTOR INSPECTION Rotors should be examined in situ whenever the brakes are serviced or new pads are fitted or immediately if erratic braking performance is noted The rotor condition should be visually checked for the following surface conditions and replaced with a new rotor if suspect or defective A Surface Crazing Fig 18a Light short random crazing surfaces are normal and acceptable Radial Cracks Fig 18a Short light cracks up to 0 5mm in width and a maximum of 1 0mm in depth are acceptable providing they do not extend radially across more than 75 of the braking surface C Tangential Scoring Fig 18a A series of light circular grooves is normal and permissible if the maximum depth of the grooves is 0 5 Severe grooving indicated that skimming of the rotor is required providing the minimum thickness of the rotor can be maintained see skimming Wear and grooving should be approximately equal on both surfaces If the wear patterns differ significantly the brake is not functioning correctly and should be examined D Heat Spotted Rotor Fig 18a 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 Rotors may be turned to remove hard raised areas See skimming If
37. er in torsion making for improved brake times and reduced air consumption both very important under EEC ECE braking regulations furthermore it is fitted as standard with a thin walled phosphor bronze bush in the anchor bracket having superior wear and temperature characteristics to the P E S bushes used with earlier designs of camshafts On the earlier design of camshaft Fig 18 both the cam and spherical bearing journals were the same diameter with the shaft machined its full length This camshaft was used in conjunction with two nylon cam bushes or single bronze cambush having integral ring seals e an ArvinMeritor brand The cam journal has been increased in diameter on the latest stepped cam design Fig 19 specifically for use with a one piece phosphor bronze cam bush In addition the camshaft now carries the 0 ring seals part number 21016721 This camshaft is not machined along its length with one exception camshafts for use with the 310 x 190 brake when used with Neway air suspension The camshaft number suffixed with an L or R for left and right hand is stamped into the shaft The new design can and should be used in preference to the earlier design when replacement becomes necessary Only the phosphor bronze cam bush part number 21209990 can be used with the new camshaft this bush replacing the two nylon bushes In order to fit stepped camshafts in axles as a replacement for the earlier design of cam
38. er problems with the anti lock system contact the anti lock supplier COIL CASING FIG 7 mma 3 11 HUB AND DRUM REPLACEMENT Correct setting of bearing end float is essential The following procedure has been proven to provide correct end float GAUTION Noticeable end float in the cold standing condition will decrease when hub reaches normal operating temperature Feed hub drum assembly onto spindle until inner bearing reaches shoulder Fit outer bearing and adjusting nut Fig 8 FIG 10 FIG 8 Tighten adjusting nut to lightly pinch bearings AT THE SAME TIME ROTATING THE HUB amp DRUM TO SEAT THE BEARINGS Fig 9 FIG 11 FIG 9 Tighten adjusting nut to 70Nm with special pre set torque wrench Part No 21206783 adaptor 21218567 and box spanner 21218566 Fig 10 Back off adjusting nut 2 3 flats FIG 12 Assemble Lock Washer and Locknut tighten to torque specified in table 8 Pack hub cap with quantity of grease specified in table 4 1 page 12 using torque wrench Fig 11 page 12 Check that hub and rum rotateTeey Fig 1 9 Fit new gasket and attach hub cap Tighten hub cap screws to The above sequence must be strictly observed torque specified in table 1 page 12 TM Service ma Section 4 TM Hub Service for Disc Brakes TM Service SECTION 4 Hu
39. erhaul TM Disc amp Drum MAJOR HUB SERVICE If a problem is found during inspection Prior to 2nd annual test or after 200 000 km whichever occurs first THEN Annually or subsequent 100 000 km intervals whichever is most frequent an ArvinMeritor brand TM Service Technical Data Tables TABLE 1 FASTENER TORQUE VALUES DRUM DISC BRAKE Hub cap grease Hub cap oil Dust covers forged A Bkt Dust covers pressed A Bkt Spherical bearing spline end Spherical bearing cam head end ABS etd ok b aga be EM EPIRI 7 5 11 Nm ABS exciter ring 310 350 brakes 7 5 11 Nm Axle adjustment nut Axle lock nut TABLE 2 Refer to Setting Procedure Section 3 11 350 375 Nm FASTENER TORQUE VALUES DISC BRAKE ONLY Rotor flange bolts Caliper retaining bolts Blanking plug adjuster access Lever clamp bolt nut Air chamber nuts TABLE 3 RECOMMENDED LUBRICANTS Manufacturer Grease Filled Hub 230 270 Nm 280 320 Nm 175 200 Nm Oil Filled Hub ROR Hub Grease Shell Mobil Castrol Texaco Total Esso Silkoline Eurol Axel Christiernsson Fina SKF GB Lubricants Blue Lithium EP2 Shell Calithia EP2T Shell Alvania EP LF 2 Mobilux EP2 Spheerol EPL2 Multifak EP2 Multis EP2 1 5 EP2 Beacon EP2 Silkoline G62 Universalfett EP2 Lithac 162EP Marson EPL2 LGEP2 GB Lithium EP2 Spirax E
40. f the anchor bracket and camshaft bracket are clean Pass the cam head through the key hole slot in the brake anchor bracket and slide the spline end through the cam bracket slot Fasten both camshaft bearings in position using the M10 screws DO NOT FULLY TIGHTEN THE BEARING SECURING SCREWS UNTIL THE BRAKE SHOES ARE RE ASSEMBLED Ensure the filler plate locating tag is engaged around the end of the anchor bracket and secure with two M10 screws Tighten to the torque specified in table 1 page 12 Fit the one piece dust cover ensuring it is correctly located onto the two filler plate studs Tighten the two M10 screws and the two 8 nuts to the torque values specified in table 1 page 12 TM Service 1 12 LOAD SENSING AND ANTI LOCK SYSTEMS 1 12 1 GENERAL All trailers manufactured to EEC Regulations are fitted with either load sensing anti lock or both systems Although the legislation in the UK requires that only one of the above systems is fitted ArvinMeritor recommends the use of load sensing when anti lock is fitted for two reasons 1 to achieve a good brake balance unladen when used with load sensed towing vehicles 2 to minimise the risk of trailer swing should the trailer anti lock system fail and revert to full braking Many towing vehicles are fitted with predominance valves to boost the trailer coupling head pressure compared to the towing vehicle s brake pressure some trailer brake valves also incorporate th
41. g fitted see Fig 5 Secure the air chamber to the air chamber mounting bracket using the mounting provided to ensure the chamber does not move during the setting up procedure and tighten to a torque of 120 130 Nm 85 95 Ibf ft Fit the slack adjuster to the camshaft applying Total Extemp or equivalent grease to the spline Connect pushrod clevis to slack adjuster assembly Optimum braking is achieved when the angle between the pushrod and slack adjuster arm is 90 with the brakes applied an ArvinMeritor brand ArvinMeritor do not recommend the use of a sliding clevis If one is fitted it will be necessary to fit a pull off spring between the slack adjuster and the air chamber bracket Part No 21210215 AIR CHAMBER FITTING HOLES IN BRACKET A B 152mm LEVER U A C 140mm LEVER A D 127mm LEVER 420 350mm 310mm FIG 5 5 4 FITTING OF HUBODOMETER The TM axle may be fitted with an hubodometer by using a special hub cap It is not possible to fit an hubodometer to a standard hub cap and attempting to do so will affect the hub sealing and may damage the spindle For hubodometer types up to 85mm outside diameter use hub cap Meritor Part No 21224904 It is advisable to assemble the hubodometer to the hub cap prior to fitting the hub cap to the axle Place the hub cap on a clean flat surface Fit the nut to a suitable open ended spanner and using a small amount of grease place the washer onto the nut Using
42. h test point will enable you to ascertain what is happening Light crazing of the braking surface indicates that the drum has been overheated but does not render the drum unserviceable However brake drums with any other damage e g rivet grooving must be rectified or replaced immediately Re machining of drums is permissible if surface damage is slight with the exception of the 310mm brake drum which must always be replaced The maximum bore diameters that the drums can be machined to are 420 423mm 350 354mm 310 No re machining Oversize cam rollers 21006610A must be used in conjunction with re machined drums Drums should be clean and dry before refitting Care should be taken with loose dust as stated in The Garage Workers Asbestos Code Page 45 Replacement brake drums from ArvinMeritor are supplied with a protective coating that does not need removing before fitting 1 11 DUST COVERS Dust Covers are provided with inspection apertures to assess lining wear These apertures are closed with rubber plugs which must always be replaced Pre June 91 Dust Covers are fixed with six M8 x 1 25 tightened to the torque specified in table 1 page 12 If additional sealing is required ArvinMeritor offers an optional rubber sealing kit Fig 27 Included 1 U Shaped moulded sealing strip to close the Dust Cover around the Cam end of the Anchor Bracket 2 Rubber Collar to close the end of the Camshaft bush ret
43. herical bearing Cam bush should be renewed at the same time UNEXPECTED WHEEL LOCK Malfunction of anti lock system Anti lock functions correctly but one axle locks Unladen or lightly loaded trailer not fitted with load sensing or anti lock Spring brakes applied automatically Trailer relay emergency valve applied brakes automatically Refer to anti lock manufacturers instructions or have system checked out by authorised agent Check load distribution between axles Refer to trailer manufacturer Fit either load sensing or anti lock system Check for pipe failure in spring brake circuit Check for failure of spring brake diaphragm A broken spring could be the cause if suspected DO NOT disassemble spring chamber split unit at service diaphragm Check for piping failure or valve malfunction Check trailer control valves on tractor unit ma TM Service Meritor HVS Limited Commercial Vehicle Systems Rackery Lane Llay Wrexham LL12 OPB U K Telephone 44 0 1978 852141 Fax 44 0 1978 856173 Meritor HVS Mitry Mory S A Commercial Vehicle Systems 2 1 du Moulin Vent 9 rue des Freres Lumiere 77290 Mitry Mory France Telephone 33 0 1 64 27 44 61 Fax 33 0 1 64 27 30 45 Meritor HVS Verona s r l Commercial Vehicle Systems Via Monte Fiorino 23 37057 San Giovanni Lupatoto Verona Italy Telephone 39 045 8750399 Fax
44. ible clamp the bracket tightly to the beam and eliminate tack welds 3 If more than one bead of weld is required make the second run third etc runs with different start points and BEFORE the first run cools down descaling between runs of course 4 Remove oil and if possible paint from surfaces to be joined RECOMMENDED LOCATION OF WELDS Fig 3 illustrates the recommended location of the weld fillet for round beams All welds should be located in the area of minimum stress The direction of welding should be as near the horizontal as possible Welding around the corners of brackets or spring seats should be avoided It is important that all welds should be excluded from an area of 50 of either side of the bottom vertical centre line of the beam Avoid welds of a circumferential nature on the lower half of the beam Where the brackets fit down the side of the beam they should have a corner radius of approximately 1 25mm The purpose of this radius is to avoid local concentration of stress The illustrations show the recommended weld location for the various parts to be attached to the axle beam None of these parts has been welded to the beam at points of maximum stress The welding rod used should meet BS 639 and BS 1719 British Standard specification They should not be broken at the end of the fillet instead the electrode should be backed up to fill the crater that would otherwise remain an ArvinMeritor brand
45. in and cam roller location points must be inspected for damage Renew shoe if these areas are damaged Part numbers for various components to suit the different camshafts are given in the following table OLD CAMSHAFT Plastic Cam Bushes NEW STEPPED Bronze Bush CAMSHAFT Qty Part No Description Brake Qty Part No Qty Brake Brake Part No Cam Bush 0 Ring 21016720 21016721 Cam Head Washer 21006593 Bevel Washer 21006624 Circlip 99070006 21016721 21016721 21006593 21006624 99070006 21202756 21202757 99070011 TM Service The ROR patented series 111 shoe is capable of many relines Make certain your stockist is giving you genuine ROR shoes when you exchange the original shoes Look for the ROR logo and patent number on every shoe gusset 1 10 BRAKE DRUMS If upon inspection drums are crazed and cracked it is an indication that the brake has been running excessively hot Fitting new drums will not correct the cause of the problem The following list are possible causes a The towing vehicle is fitted with a predominance valve and it is set to make the trailer brakes do most of the check braking b Badly set or malfunctioning automatic slack adjuster c Use of trailer brakes ONLY to check vehicle speed during long descents d The use of a non approved lining e Malfunction in air actuation system see following Section In all cases the use of pressure test gauges at eac
46. is feature Fitting load sensing to the trailer will minimise the adverse effects of too much predominance especially at low brake pressures with an unladen or lightly laden trailer 1 12 2 LOAD SENSING SYSTEMS The basic purpose of load sensing is to reduce the likelihood of wheels locking with different loads being carried The load sensing valve adjusts the air pressure according to how much weight is being carried All new trailers fitted with load sensing are also fitted with a plate showing the setting pressures which correspond to the laden and unladen weights The load sensing valve setting should be checked periodically and corrections made as necessary Air pressure test points are provided in the brake lines each side of the load sensing valve so that both the input and output pressures can be measured the test point on the output side of the load sensing valve may be located close to one of the brake actuators With the aid of test gauges connected to both test points the air pressures can be measured and checked against the values shown on the load sensing data plate for the corresponding axle weights When an annual Government inspection is performed and braking is measured against the axle design weights it is important that the load sensing valve is in the fully laden position during the test Normally in the fully laden position the load sensing valve output pressure will equal the input pressure which on a full bra
47. k Ill Axle has a sealed anchor pin system The anchor pin has two oil and heat resistant 0 rings as shown in Fig 26 and is coated with Dacromet a zinc rich coating with excellent corrosion resistance The pin and 0 rings are fitted into an indented bronze bush The indents are designed to hold additional grease to lubricate the anchor pin over an extended period An additional benefit is the ease of removing anchor pins whenever a major overhaul is carried out FIG 26 The sealed anchor pins and indented bushes are available in kit form from your ArvinMeritor Stockist and are interchangeable with earlier designs of anchor pin bushes used with quick change brake shoes Qty Brake Description Part Number 2 Anchor Pin 21205193G 4 0 Ring 21220668 2 Bush 21016666A From June 91 axles with 420mm brake have a pressed steel anchor bracket which uses a stainless steel bush part number 21221028 1 9 RELINING BRAKE SHOES It is recommended that the correct lining be used to maintain the EEC performance levels designed and approved for your vehicle A change in lining may substantially change the braking performance and could render the vehicle illegal ROR linings are precisely contoured to fit ROR shoes and bed in with the least number of stops The ROR shoe is coated with a rust inhibiting paint When relining the shoe platform should be cleaned and recoated with a rust proof primer The hardened anchor p
48. ke application should be between 6 5 and 7 5 bar To achieve this the trailer must be fully loaded If not the load sensing valve must be disconnected which should only be done at the test station and must be reconnected before leaving the test station Whenever the trailer is tested on the raised rollers it is essential that the load sensing valve is disconnected and set fully open i e laden to ensure that full brake pressure is achieved for all axles Always disconnect the load sensing valve linkage at the axle and not at the valve control arm see Fig 28 When testing an air suspended trailer on raised rollers it is not readily possible to disconnect an air suspension load sensing valve Instead a fitting can be fabricated to accept both the input and output brake lines thus by passing the load sensing valve an ArvinMeritor brand h FIG 28 1 12 3 ANTI LOCK SYSTEMS Unlike load sensing systems that adjust the brake pressure proportional to the load being carried anti lock systems monitor wheel speed and only modulate that brake pressure when the system detects that a sensed wheel is about to lock All anti lock systems have sensors and exciter rings fitted to measure the speed of two or more wheels If the hub and drum are removed from an axle fitted with sensors it is important to remember to push the sensor fully outwards so that the exciter ring will push it back when the hub and drum are r
49. ment Manually adjust brakes Check functions of slack adjuster replace if faulty Check function of locking collar on manual slack adjusters RAPID LINING WEAR Malfunction of automatic slack adjuster Check operation of automatic slack adjuster see also brakes dragging Braking tractor trailer combination by applying trailer brakes only Incorrect function of load sensing valve Incompatible tractor trailer combination due to a Operating load sensed tractors with trailers with anti lock at loads well below the laden rating b Tractor is providing too much trailer lead predominance Check for excessive camshaft play at spherical bearing and replace if necessary Should only be used momentarily to check trailer swing if necessary the trailer should never be dragged with brakes applied Check operating linkage and repair if broken Check setting of load sensing valve Fit load sensing to the trailers Check predominance setting of trailer control valve fitted to tractor unit and adjust if necessary Check that tractor and trailer are not both fitted with valves providing predominance EXCESSIVE BRAKE DRUM WEAR BRAKES BINDING OR DRAGGING Overheating through excessive braking Can result in heat checking and possible eventual failure Contaminated brake linings It is possible for fine abrasive grit to penetrate into brake mechanism for example as a result of shotblasting or nature of load car
50. n vehicle 1 D plate Observe vehicle manufacturers load recommendations Companion brakes not working properly Inspect companion vehicles brakes and air systems Adjust or repair as required Brake smoking High brake temperature Refer to 2 3 and 4 Refer to 2 3 and 4 Contamination of pads Grease oil etc on pads Inspect hub seal Replace as required Clean rotor and caliper assembly Replace pads per Section 2 7 Poor stopping power e Long stopping distances e Poor driver feel e High brake pressures e Lack of normal response e Vehicle pulls to one side Vehicle air systems malfunction Proper air pressure at the chamber inlet Have the air system evaluated by a qualified brake system specialist Brakes out of adjustment Vehicle overload Stroke exceeds 50mm requirement See GAWR limitations on vehicle 1 D plate Replace caliper saddle assembly Refer to Section 2 9 Observe vehicle manufacturer s load recommendations Contamination on pads Grease oil etc on pads Inspect hub seal and replace pads per Section 2 7 Companion brakes not working properly Inspect companion vehicle brakes and air system Adjust or repair as required Shimmey or brake pull Refer to 1 2 and 6 Refer to 1 2 and 6 Refer to 1 2 and 6 Rotor run out and thickness variation Replace hub and rotor assembly TM Service 2 7 PAD REMOVAL AND REPLACEM
51. ne Clean all the old grease from the hub bearing cones and hub cap with clean paraffin or diesel fuel oil DO NOT USE PETROL HOT SOLUTION OR STEAM CLEANING Dry the parts using an air jet or with clean absorbent cloth or paper Care must be taken not to rotate bearings at high speed when using an air jet After thoroughly cleaning hold up the bearing between the light and eyes and turn the cage slowly inspecting each roller and raceway for i Pitting ii Flaking iii Discolouring iv Corrosion If there is any doubt as to the condition of the bearing discard it and fit a replacement At this stage it will be necessary to remove bearing cups from hubs Four cut outs in the casting allow a soft steel drift to be used to remove inner cup using each cut out alternately The bearing will be removed with relative ease and without damage NOTE Hardened steel drifts or brass bars must not be used 3 7 2 BEARING REPLACEMENT Ensure hub is thoroughly cleaned Insert inner bearing cup into hub then using tool No 21205452 drive cup into hub ensuring cup fits squarely to its shoulder Tool No 21205451 is used for outer bearing cup Thoroughly pack the inner bearing cone with grease see table 4 page 12 ensuring grease reaches the inner raceway For oil filled hubs a light coating of oil should be applied to the rollers Fit the seal in accordance with instructions on page 16 This will keep the bearing in position until
52. o lift or travel forward Fig 2 Linear Input Force FIG 2 an ArvinMeritor brand Eccentricity FIG 3 All radial loads in the eccentric shaft and block are taken through precision needle roller assemblies maintaining an efficiency of around 97 due to the complete absence of any sliding friction in the system Clamping The caliper assembly is free to float on the slide pins attached to the fixed saddle Clamping force exerted on the inner pad by the eccentric action on the balance beam creates an equal and opposite reactive force in the caliper body Fig 4 This reaction provides the clamping force for the outer pad ensuring that both pads are loaded onto the rotor with an equal force FIG 4 TM Service 2 3 MAIN AUTO ADJUST PARTS Input shaft amp eccentric Main Block Bevel gear r Adjuster gear and barrel Cassette adjuster gear train Spindle Screw Adjustment gear segment Load Plate 5 2 4 AUTOMATIC ADJUSTMENT MECHANISM Step 1 e Actuating lever moves and eccentric shaft rotates Block lifts begins to move forward carrying the adjuster sleeves and pistons Fig 6 Eccentric shaft turns within the gear plate segment taking up clearance between tongue and shoulders Fig 7 FIG 6 an ArvinMeritor brand Torque takes up clearan
53. one way clutch free wheels preventing reverse transmission into the adjuster gear train and the adjuster sleeves do not move thus holding the adjustment Fig 10 Barrels Stationary Adjustment Barrel Gears Stationary Bevel Gear Reverses One Way Clutch Slips No Gears Turn FIG 10 Damping Compression springs ensure that the adjuster train has the necessary amount of predetermined friction which prevents vibration in service from disturbing the clearance setting Fig 11 Damping Springs FIG 11 TM Service 2 5 MANUAL ADJUSTMENT Under normal operation the automatic adjustment mechanism will maintain correct pad to rotor clearance Provision is made for manual adjustment of the brake which may be required under the following conditions 1 Where the pads cannot be removed due to wear on the rotor in this case the pads will have to be retracted by back adjusting the brake 2 Where new pads are to be fitted it will be necessary to fully retract the adjusters to accommodate full thickness pads The brake is manually adjusted by turning one of the adjuster barrels by means of a 6mm standard hexagon key The gear train will ensure that the other adjuster barrel will be turned by an equal amount Access for the hexagon key is gained by removal of the blanking plug Fig 12 in the back plate FIG 12 The adjustment direction depends on the particul
54. r brand Fit both retaining springs to both shoes Fig 11 FIG 11 Lift top shoe and fit anchor pin Lever down bottom shoe and fit anchor pin do not over stretch springs Fig 12 1 5 REFITTING BRAKE SHOES 420 WITH PRESSED STEEL ANCHOR BRACKET Lubricate as on page 15 Fig 3 amp 4 Brake shoe fitted with rolled roll pin Fig 13 Anchor bracket with anchor pins fitted Fig 14 Offer both brake shoes together to anchor bracket Fig 15 Lift lower shoe into place Fig 16 Fit retainer spring Fig 17 FIG 15 FIG 16 FIG 14 FIG 17 TM Service 1 6 CAMSHAFT AND BUSHINGS 1 6 1 REMOVAL With brake shoes removed as described in previous section Remove slack adjuster Remove circlip adjacent to brake anchor bracket and withdraw camshaft The circlip will not be fully removable until the splined end is clear of the spherical bearing Inspect nylon bushes or bronze bush in the anchor bracket Remove bushes if worn Inspect spherical bearing for serviceability This is a sealed assembly containing no user serviceable components Unscrew the securing bolts and remove the spherical bearing 1 6 2 REPLACEMENT CAMSHAFTS Stepped Camshafts In use on production axles with 350 dia brakes from October 1984 and axles fitted with 420 and 394 dia brakes from January 1985 the stepped camshaft is stiff
55. rable Fig 25 Fit the 0 rings onto the camshaft with old type cam fit O ring into bush Slide the cam head washer onto the camshaft Slide the camshaft through the anchor bracket but not through the spherical bearing at this stage Fit bevel washer concave side facing anchor bracket and circlip onto the shaft Slide the camshaft through the spherical bearing simultaneously pushing the bevel washer and circlip up to the anchor bracket Ensure the circlip is fitted correctly into the groove Rotate the cam to ensure correct alignment and free operation Tighten the spherical bearing bolts or Powerlok screws to 50 60 Nm 30 Ibf ft Rotate camshaft by hand to check that it moves freely If it does not slacken spherical bearing bolts realign camshaft and retighten bolts Check again for free rotation Grease pack the spherical bearings through their grease nipples with Total Extemp or equivalent until grease exudes from body 1 7 SPRINGS The return spring is an essential component for correct brake function It should be examined for any relaxation in the coils or any wear or notching in the hooks The retainer springs keep the shoes in contact with the anchorpins They should also be inspected for any relaxation and hook damage IMPORTANT It is strongly recommended that return and retainer springs are renewed as a matter of course during annual brake servicing an ArvinMeritor brand 1 8 ANCHOR PINS AND BUSHES The Mar
56. rasives a max of 6 week interval necessary TM Drum BRAKE INSPECTION amp SERVICE Linings should be inspected every 6 weeks or 25 000 kms and must be replaced as an axle set if worn down to the wear indicator mm Full stripdown should be prior to 2nd annual test or at 1st reline whichever is soonest THEN Annually or at every subsequent brake reline Whichever is most frequent TM Disc BRAKE INSPECTION amp SERVICE Pads caliper and rotor should be inspected every 50 000 kms or 3 months Pads must be replaced when worn to a minimum lining thickness of 3mm Always replace pads as an axle set At intervals of 100 000 kms or every 6 months preferably when changing pads the opportunity should be taken to remove any accumulations of wear debris and rust from the edge of the rotor and from the pad location points in the caliper Check also condition and location of sealing boots The above service intervals are recommended maximums under normal operating conditions Unusual ambient temperatures or adverse operating conditions e g dusty atmospheres or severe gradients will require more frequent service intervals It is the responsibility of the vehicle operator to establish these intervals TM Disc amp Drum HUB AND BEARING INSPECTION INCLUDING OIL SEAL REPLACEMENT HUB CAP GASKET REPLACEMENT AND HUB OIL RENEWAL WHERE APPLICABLE Whenever hubs are removed from axle Annually after 1st major hub ov
57. res or other 3 Anti rattle springs The pads have anti rattle springs attached damage Replace the rotor when necessary Inspect for bent cracked or broken springs If springs are damaged replace with new Refer to Pad Removal and Replacement Inspection and Troubleshooting CONDITION Air Chamber exceeds 50mm maximum stroke requirement at 80 to 90 psi POSSIBLE CAUSES Improper initial adjustment or inoperative automatic adjuster CHECK FOR Recheck chamber stroke after twenty brake applications CORRECTIONS the air chamber still overstrokes then replace the caliper saddle assembly per Section 2 9 Brake Drag Incorrect pad to rotor clearance Improper initial adjustment Vehicle air system malfunction Minimum stroke at 80 90 psi to be 22mm Replace caliper saddle assembly Readjust per Section 2 7 Repair or replace parts as required Short outboard inboard pad life Caliper seized or sticking on slide pins Damaged slide pin seals Caliper should move back and forth by hand with pads removed Replace caliper saddle assembly Short pad life Refer to 2 and 3 Refer to 2 and 3 Refer to 2 and 3 Abusive use of brake system Driver technique Train drivers Rotor surface Cracks or heavy heat checking Refer to Section 2 8 Refer to Section 2 8 for rotor inspection Non genuine pads Fit ROR pads Vehicle overload See GAWR limitations o
58. ried Failed brake shoe return spring Badly worn spherical bearing and camshaft bush Incorrectly adjusted brakes Review trailer brake duty cycle see comments in previous section Renew linings Fit brake sealing kit Replace spring Replace worn components with latest design Not backed off sufficiently when manually adjusted Check for faulty slack adjuster TM Service POSSIBLE CAUSES BRAKES BINDING OR DRAGGING Brakes not releasing properly continued Faulty valve in trailer brake system Spring brakes beginning to operate an ArvinMeritor brand SUGGESTED CORRECTION If axle concerned is fitted with mechanical hand brake tie bar and the brake actuators have slotted clevis assemblies fit external return spring 21210215 between slack adjuster and brake actuator mounting bracket Camshaft binding re align camshaft refer to page 18 Check for residual pressure in brake actuators Check trailer brake system for trapped residual pressure in brake actuators Check spring brakes for broken spring If found DO NOT disassemble spring chamber split unit at service diaphragm Make sure trailer is not being used before reservoir is fully pressurised Check for excessive build up of fluid in trailer reservoir and drain UNEVEN LINING WEAR Tapered wear across brake shoes Excessive wear on one brake shoe Check for bent anchor bracket and straighten Check for worn out sp
59. s 21209272 1 Jig for 394mm diameter brakes 21206670 3 Jig for 420mm diameter brakes RECOMMENDED NOT RECOMMENDED FIG 21 1 6 3 REFITTING If it is necessary to replace the cam bushings this can be easily done using special tool 21219919 Fig 22 Cam bush must be inserted from camhead side of anchor bracket FIG 22 an ArvinMeritor brand ArvinMeritor recommends replacing the plastic bushes with phosphor bronze These bushes are available in four sizes PHOSPHOR BRONZE BUSHES 21204703 21209990 21209623 old type camshafts new type stepped camshafts oversize bush for old type camshaft bores after reaming 21213259 oversize bush for stepped camshaft IMPORTANT When fitting cam bush the cross holes must be towards the cam head as shown Fig 23 FIG 23 The camhead spherical bearing Fig 24 used on axles after June 91 with the pressed steel anchor bracket applies to 420mm brakes only Refit or replace bearing leaving bolts loose fit the camshaft ensuring the snap ring has locked into the groove in the bearing journal Rotate the camshaft to ensure free operation tighten bearing bolts to the torque specified in table 1 page 12 FIG 24 TM Service FIG 25 Refit or replace spherical bearing leaving bolts loose ArvinMeritor offers a new Mark spherical bearing Part No 15213430 which retains its grease pack and is more du
60. shaft it will be necessary to use the following parts Camshaft bush kits containing these items are available Kit No AXL 131 axle set suitable for T U TH and TM Axles pre May 1974 Kit No AXL 132 axle set suitable for TH and TM Axles after May 1974 Fig 20 shows the rolled spline camshaft used with 420mm brakes on axles produced from 1st January 1992 it has the pressed steel anchor braket with a bolt on cam head spherical bearing This is identified by the snap ring groove in the centre of the cam head bearing journal Similar rolled spline camshafts without the snap ring groove were introduced on axles with 310mm and 350mm brakes TM Service REMOVAL OF THE 420mm CAMSHAFT Having removed the slack adjuster the camshaft is released from the snap ring by tapping the spline end with a suitable soft faced hammer It is necessary for the phosphor bronze bush to be a tight press fit into the anchor bracket Should the anchor bracket be worn see Fig 21 it will be necessary to machine the cam bore to accommodate the oversize phosphor bronze cam bush part number 21213259 If it is necessary to fit oversize cam bushes the anchor bracket reamer tool should be used and is available as follows Part Number Description 21206670 1 Cutter 21206670 2 Shaft 21206670 4 Sleeve 21206670 5 Pins two required 21209271 1 Jig for 310mm diameter brakes 21218572 1 Jig for 350mm diameter brake
61. the caliper outward and remove the outboard pad 8 Verify that the caliper will slide freely on the slide pins The caliper can get jammed if moved past its working range If this occurs use a rubber mallet to get the caliper back to its working range and verify that it will slide freely 9 Remove any dirt or rust from the pad contact surfaces on the saddle fy an ArvinMeritor brand 10 Inspect for damaged boots and replace the caliper if boots are damaged 11 See Section 2 8 for rotor inspection and instructions 12 Slide the caliper outboard then install the pad and spring assembly in the outboard side If pads are to be reused place the pad marked outboard in Step 6 back in the outboard position Take care to prevent the load plate hanging up on the saddle guides 13 Slide the caliper inboard and install the inboard pad and spring assembly If pads are to be reused place the pad marked inboard in Step 6 back in the inboard position 14 Pull down the stabiliser bar compressing the springs and install the stabiliser bar retainer pin and split pin bending its long leg 15 To adjust the initial caliper clearance adjust the caliper by reducing the caliper to rotor clearance to zero See Fig 14a for the adjusting direction Make sure that the load plate is in full contact with the pad backing plate Back off the brake seven clicks to set the initial clearance 16 Reinstall the adjuster plug and washer Fig 12 Tight
62. the hub is fitted to spindle Pack hub cavity with correct quantity of grease specified in table 4 Page 12 of grease As a guide grease should not be above the level of outer bearing cup s smallest diameter see table 4 page 12 for approved grease Thoroughly pack outer bearing cone and place on clean surface ready for re assembly 3 8 SPINDLE END INSPECTION Before replacing the hub and drum assembly it is good practice to inspect the spindle end an ArvinMeritor brand Although bearings are designed to creep on journal in order to distribute the load evenly excessive journal wear may require beam replacement The lower limit of journal sizes are Inner bearing 89 91mm Outer bearing 64 91mm 3 9 ANTI LOCK OPTION If the hub and drum being serviced is fitted with an anti lock sensor make certain the sensor is clean and pushed outwards in its housing before refitting hub and drum assembly Fig 6 FIG 6 3 10 PLASTIC SENSORS If the sensor is excessively worn see Fig 7 it must be replaced Refer to manufacturers instructions Examine the Exciter Ring and renew if any damage is found When fitted to 420mm diameter brakes the pressed steel exciter ring for use with the plastic sensor is held in place by the wheel bolts for removal see page 42 on wheel bolts The action of replacing the hub and drum assembly will correctly position the sensor against the Exciter Ring For any oth
63. y 1980 all ROR axles are fitted with unitized seals and therefore NO wear sleeves are required 3 3 2 FITTING NEW SEALS ArvinMeritor specifies Unitized seals which do not require wear Sleeves Seals must be installed in the hub using service tool No 21218568 as shown in Fig 3 The use of the seal tool will ensure that seals are positioned squarely Avoid problems use the proper tool FIG 3 3 3 3 REMOVAL OF WEAR SLEEVE To remove the wear sleeve carefully tap with a ball hammer taking care not to damage the spindle NOTE 1 Prior to installing any seal in the hub make certain that the seal bore is free of any nicks gouges or other damage This will prevent any leakage around the seal s outer diameter NOTE 2 Unitized seals are directly interchangeable with the older grease seal after removal of the wear sleeve 3 4 GREASE FILLED HUBS Fill hub cavity with correct grease quantity see Fig 4 Specification in table 4 Page 12 Pack hub cap with correct grease quantity see Fig 5 Specification in table 4 Page 12 Pressure pack or carefully hand pack each bearing The two bearings together should contain 80gm an ArvinMeritor brand FIG 4 FIG 5 3 5 OIL FILLED HUBS Fill to a level between the rings found on the hub cap window 380ml approx 3 6 CONVERTING FROM GREASE TO OIL Oil filled bearings are better lubricated and have proven to be necessary when running

ROR Axle & Brake Service Manual

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ROR Axle &amp; Brake Service Manual

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ROR Axle & Brake Service Manual