MAXX22T_Maintenance Service_R2

Hendrickson MAXX22T™ ADB Maintenance & Service June 2015

CONFIDENTIAL

Contents  Available Service Literature  Disc brake inspection • General inspection • Checking adjuster operation

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• Checking brake pad wear • Inspecting the brake rotor • Checking guide pin bearing play

 Replacing Components • Replacing brake pads • Replacing the caliper • Replacing the chamber

• Replacing the protection boots • Replacing the dust shield

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Service Literature  The following literature is available on the Hendrickson website at www.hendrickson-intl.com

CONFIDENTIAL

• MAXX22T™ INSTALLATION AND MAINTENANCE PROCEDURES (T72009)

• AIR DISC BRAKE PARTS LIST (L1063)

• ADB ROTOR (U-SHAPE STYLE) AND CALIPER MOUNTING (T71004)

 NOTE: This presentation serves as a summary of the above literature. Always refer to the latest revision on the literature found on the Hendrickson website for the most current and accurate information.

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MAXX22T Replacement Parts

CONFIDENTIAL

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MAXX22T Tool Kits

CONFIDENTIAL

These tools will be referred to as the “adjusting wrench” throughout this presentation.

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MAXX22T Torque Specifications

CONFIDENTIAL

Always refer to the latest revision of the maintenance manual for proper torque specifications.

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Disc Brake Inspection

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General Inspection NOTE: The 8 mm adjuster components can be damaged if using open-ended wrenches or power tools. Only use tools listed in the MAXX22T Maintenance Manual (see slide 5: MAXX22T Tool Kits).

CONFIDENTIAL

1. Check the brake for damage and / or missing components.

2. Replace components as needed.

Example of damaged guide pin cap

3. Manually slide the brake caliper across the entire stroke of the guide pins several times and check for ease of movement.

4. If the caliper does not move easily, replace the bushings, guide pins and guide pin boots.

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Checking Adjuster Operation (1 / 2)

CONFIDENTIAL

NOTE: The brake pads and pressure plate MUST be installed in order to check the adjuster.

1. Remove the adjuster plug

NOTE: Damage can occur at the inner seal when the plug removal tool is not positioned properly.

2. Check the adjuster boot and plug for wear and damage.

3. Use the adjusting wrench to turn the adjuster ½ turn clockwise.

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CONFIDENTIAL Checking Adjuster Operation (2 / 2) 4. This step requires two people: Gently apply the brake 5 times. If the adjuster functions correctly, the wrench will turn incrementally. 5. Remove the adjusting wrench. 6. Reinstall the adjuster plug. Ensure a tight fit. 7. Faults that may occur: • The adjuster or the wrench does not turn. • The adjuster or the wrench only turns with the first actuation. • The adjuster or the wrench rotates back and forth in the same position with every actuation. In these cases the adjuster is faulty and the brake must be replaced.

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Checking brake pad wear (1/2)

CONFIDENTIAL

NOTE: • Brake pad thickness must be checked at regular maintenance intervals. • Oil contaminated brake pads must be replaced immediately. • Always replace all brake pads by axle, using a new retaining system for brake pads and pressure plates. • To avoid damaging the brake rotor, replace the brake pads when friction material thickness is at or close to the minimum.

• Pad thickness must not be allowed to be less than 0.08” (2 mm), measured from the backing plate.

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Checking brake pad wear (2/2)

CONFIDENTIAL

Manually measuring brake pad wear 1. Measure the distance between the brake carrier machine fastening surface and the guide pin cap. 2. Caliper movement indicates the amount of wear. Measure the movement at the short caliper pin guide.

3. If wear exceeds 3.94” (100mm) replace pads.

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Inspecting the Rotor

CONFIDENTIAL

Measuring rotor thickness 1. Measure the rotor thickness on the friction surface (3 points, 120 apart).

2. Thickness of new rotor = 1.69” (43 mm)

3. Wear limit = 1.46” (37 mm)

4. Replace brake rotors on both sides of axle if rotor thickness is near or below wear limit.

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Inspecting the Rotor (1/2) Checking the condition of the brake rotors 1. Check the brake rotor for cracks and inspect the condition of the surface.

CONFIDENTIAL

Permissible Web-like crack formation Radial cracks up to max 0.02” (0.5 mm) Unevenness of surface up to max 0.06” (1.5 mm)

2. Replace the brake rotor if a “not permissible” condition exists.

Not Permissible Continuous cracks A crack that passes completely through friction surface to center vent from either side

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Inspecting the Rotor (2/2)

CONFIDENTIAL

Checking the runout of the brake rotors 1. Fasten the dial indicator to the brake caliper.

2. With the rotor installed, check the runout by rotating the wheel hub. Max value = 0.006” (0.15mm).

3. Replace the brake rotor or have it properly resurfaced if the runout is more than 0.006” (0.15 mm). Also replace if, after resurfacing, the thickness is below the allowed minimum.

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CONFIDENTIAL Checking guide pin bearing play (1/2) 1. Remove the wheel.

2. Remove the brake pads and pressure plate.

3. Manually push the brake caliper completely outboard.

4. Fasten the magnetic dial indicator support to the brake carrier or the axle.

5. Clean the measuring point.

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CONFIDENTIAL Checking guide pin bearing play (2/2) 6. Press the dial indicator against the measuring point on the brake caliper.

7. Apply force to tilt the caliper as far as possible toward axle, and set the dial indicator to zero.

8. Apply force to tilt the caliper as far as possible in the opposite direction.

9. Read the dial indicator. The bearing play must not be greater than 0.08” (2 mm).

10. Replace the guide bushings if the measured play is greater than 0.08” (> 2 mm).

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Replacing ADB Components

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REPLACING THE BRAKE PADS • Removing the Brake Pads

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• Checking Guide Pin Bearing Play • Checking Brake Caliper Movement

• Checking the Adjuster Unit • Installing the Brake Pads

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Removing brake pads (1/4)

CONFIDENTIAL

NOTE: It is not necessary to remove the brake to replace the brake pads.

IMPORTANT: Always replace the brake pads by axle and use a new retaining system for brake pads and pressure plates. The 8mm adjuster components can be damaged if using open-ended wrenches or power tools. Only use tools listed in the MAXX22T Maintenance Manual. 1. Remove the wheel.

2. Loosen the pad retainer screw from the brake caliper. Apply slight pressure on the pad retainer bar with your hand at the same time.

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Removing brake pads (2/4)

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3. Completely remove the pad retainer bar from the caliper.

4. Remove the retainer spring from the pressure plate. NOTE: Brake pad retainer springs are pre-attached. DO NOT REMOVE.

5. Carefully remove the adjuster plug form the caliper. Be careful not to damage the inner seal.

6. Check the adjuster boot for wear and damage. Replace if damaged or worn.

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Removing brake pads (3/4)

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7. To prevent rotation, use your hand to push the pressure plate towards the inboard side, with the adjuster piston pin in the pressure plate slot. NOTE: Damage can occur to the boot if the piston is allowed to rotate. 8. Use the adjusting wrench to turn the adjuster counterclockwise as far as it will go. Then turn the adjuster clockwise ~90 degrees.

9. Check adjuster boot for wear and damage. Replace if damaged or worn.

10. Manually push the brake caliper outboard and remove the outboard brake pad.

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Removing brake pads (4/4)

CONFIDENTIAL

11. Manually push the brake caliper inboard and remove the inboard brake pad.

12. Remove the pressure plate from the caliper.

13. Check the pressure plate for excessive corrosion and damage. Replace if necessary. Always replace by axle.

14. Use a wire brush to clean pressure plate, guide groove on caliper and pressure plate and all machined surfaces on the brake caliper. Remove any corrosion. NOTE: Avoid causing any damage to the protection boots.

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Check brake caliper movement (1/2)

CONFIDENTIAL

1. Manually slide the brake caliper across the entire stroke of the guide pins several times and check for ease of movement. NOTE: While moving the caliper, ensure the guide pin boots are not pinched against the brake carrier.

2. If the caliper does not move easily, replace the bushings, guide pins and guide pin boots.

3. Manually push the brake caliper inboard.

4. Carefully wipe clean all protection boots.

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Check brake caliper movement (2/2)

CONFIDENTIAL

5. Check the protection boots for wear and damage.

6. Replace any damaged or worn protection boots.

Improperly seated guide pin boot

Twisted guide pin boot

Adjuster piston boot damage

Wrinkled adjuster piston boot

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Checking the adjuster unit

CONFIDENTIAL

1. While checking the adjuster, restrain the adjuster piston pin to prevent rotation and damage to the adjuster piston. NOTE: This can be accomplished by temporarily installing the pressure plate. 2. Use the adjusting wrench to turn the adjuster clockwise towards the brake rotor. Check for ease of movement.

3. Following the test, rotate the adjuster piston clockwise up to the stop position and back again.

4. If necessary, check the adjuster. (Refer to slide 8)

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Installing the brake pads (1/4)

CONFIDENTIAL

NOTE: The pressure plate must always be placed correctly in the guide groove and is to entirely cover the machined surfaces.

1. Manually move the brake caliper inboard until there is sufficient clearance to insert the pressure plate.

2. Insert the pressure plate into the caliper.

3. Slide the pressure plate up against the adjuster piston with the adjuster piston pin fitting into the pressure plate slot. NOTE: It may be necessary to move the brake caliper and / or rotate the adjuster piston until the pin engages the slot of the pressure plate.

4. Ensure the adjuster piston boot is not twisted.

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Installing the brake pads (2/4)

CONFIDENTIAL

5. Insert the inboard brake pad.

6. Manually push the brake caliper outboard until the inboard pad contacts the rotor.

7. Insert the brake pad on the outboard side.

8. Measure and adjust the clearance using a 0.04” feeler gauge. • Insert the feeler gauge between the outboard pad and caliper. • Turn the adjuster counterclockwise with an adjuster wrench until both brake pads contact the rotor. • Remove the feeler gauge.

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Installing the brake pads (3/4)

CONFIDENTIAL

9. Place a new retainer spring onto the pressure plate. NOTE: Brake pad retainer springs are pre-attached. DO NOT REMOVE.

10. Insert the pad retainer bar into the holes of the brake caliper.

11. Push the pad retainer bar fully into the holes while pushing downward so the retainer springs are engaged into the bar and there is sufficient clearance to install the pad retainer bar screw.

12. Fasten the new pad retainer screw to the brake caliper with the specified torque.

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Installing the brake pads (4/4)

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13. Push a new adjuster plug into the adjuster boot. Ensure the plug has a tight seat.

NOTE: If more repairs are to be performed, proceed to next step.

14. If no more repairs are needed, manually rotate hub to check for ease of movement.

15. Mount wheels per manufacturer instructions.

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REPLACING THE BRAKE • Removing the Brake • Installing the Brake

CONFIDENTIAL

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Removing the brake (1/2)

CONFIDENTIAL

1. Remove the wheel.

2. Remove the brake chamber.

3. Remove the brake pads.

4. Remove the torque plate mounting screws.

5. Remove the brake caliper with the brake carrier from the axle.

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Removing the brake (2/2)

CONFIDENTIAL

6. Check the brake rotor.

7. Check the brake pads and replace if necessary.

8. Check the torque plate on the axle for wear and damage.

9. Clean the torque plate on the axle and remove any dirt, rust and grease.

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Installing the brake (1/2)

CONFIDENTIAL

1. Remove all shipping material from the new brake.

2. Check the connecting surface on the axle torque plate and the brake carrier. Remove any dirt, rust or oil. NOTE: The MAXX22T torque plate is designed to prevent mixing of left and right brakes. An arrow painted on or cast in the brake caliper indicates the brake rotor’s direction of rotation moving forward.

3. Place the brake assembly, with the brake carrier, on top of the brake rotor and mount the brake onto the axle.

4. Tighten the screws.

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Installing the brake (2/2)

CONFIDENTIAL

5. Install brake pads.

6. Mount the brake chamber on the caliper.

NOTE: If more repairs are to be performed, proceed to next step.

7. If no more repairs are needed, manually rotate hub to check for ease of movement.

8. Mount wheels per manufacturer instructions.

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Replacing the brake chamber (1/4)

CONFIDENTIAL

CAUTION: Make sure air connection lines have been removed before removing brake chamber. To avoid injury and damage to brake components, manually cage the brake chamber prior to servicing the brake 1. Unscrew the air connection from the brake chamber.

2. Manually cage the brake chamber.

3. Unscrew the brake chamber nuts. NOTE: Ensure no dirt or moisture enters the brake when removing the brake chamber

4. Remove the brake chamber from the brake caliper.

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Replacing the brake chamber (2/4)

CONFIDENTIAL

NOTICE: Chamber must be installed with breather hole facing the ground when the chamber is mounted.

5. Clean the brake caliper boot surface and flange area.

6. Before attaching the brake chamber, grease the ball cup in the brake lever.

7. Inspect the brake chamber for damage, particularly at the inner area of the push-rod seal. If damaged, replace the brake chamber.

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Replacing the brake chamber (3/4)

CONFIDENTIAL

8. Place the chamber onto the caliper.

9. Use a wrench to screw new fastening nuts onto the brake chamber until the chamber fully rests on the caliper.

10. Torque nuts to specifications.

11. Attach the brake hose to the brake chamber according to chamber manufacturer’s specifications.

12. Ensure enough slack is added to the brake hose to prevent stress. Also secure hoses to avoid obstruction of brake caliper movement over its entire stroke.

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Replacing the brake chamber (4/4)

CONFIDENTIAL

13. Check the air connection for tightness according to the chamber manufacturer’s specifications.

14. Follow the brake chamber manufacturer’s procedures to manually uncage the brake chamber.

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CONFIDENTIAL REPLACING PROTECTION BOOTS

• Removing the brake caliper from carrier • Replacing guide pin boots and bushings • Mounting brake caliper to brake carrier • Replacing adjuster piston boot • Replacing adjuster boot

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Remove Caliper from Carrier (1/2)

CONFIDENTIAL

1. Remove the brake.

2. Use a suitable device to hold brake while servicing the brake assembly.

3. Remove the guide pin caps. NOTE: Damage to the bores may occur if tools are used incorrectly. Do not place tool on caliper face. Only position the tool on the guide pin cap.

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Remove Caliper from Carrier (2/2)

CONFIDENTIAL

4. Remove the guide pin screws. CAUTION: Properly support the caliper while removing the guide pin screws. Once the screws are removed, the caliper is loose and may fall apart if not supported.

5. Separate the brake caliper from the carrier.

6. Clean the guide pin contact surfaces on the brake carrier.

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Replacing boots and bushings (1/5)

CONFIDENTIAL

Guide pin disassembly 1. Remove the guide pins from the caliper.

2. Pull the guide pin boot out of the boot seat on the caliper.

3. Place the brake caliper on a firm base for pressing out bushings. The back of the caliper must face upwards.

4. Assemble tool and use to press the bushings out of the caliper.

5. Thoroughly clean the bores in the caliper.

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CONFIDENTIAL Replacing boots and bushings (2/5) Guide pin Assembly 1. Press in two new bushings for the long guide pin.

• Assemble tool to press the inner bushing into the bore of the caliper until the tool stops.

• Assemble tool to press the outer bushing in the same bore until the tool stops.

2. Assemble tool and use to press a new bushing for the short guide pin into the bore of the caliper until the tool stops.

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Replacing boots and bushings (3/5)

CONFIDENTIAL

3. Grease inside sliding surfaces of all bushings and the space between the long guide pin bushings.

4. Clean the guide pin and boot seats of the caliper.

5. Manually push two new guide pin boots in to the brake caliper boot seats. IMPORTANT: Make sure the guide pin boots are seated and wrinkle-free.

6. Grease the bearing surfaces of the guide pins and the exposed edge of the guide pin boots.

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Replacing boots and bushings (4/5)

CONFIDENTIAL

7. Insert the two new guide pins into the brake caliper from the inboard side.

8. Slide the guide pins boots over the guide pins.

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Replacing boots and bushings (5/5)

CONFIDENTIAL

9. Position the exposed edge of the guide pin boots into the boot seats of the guide pins.

10. Ensure that the exposed edge of the guide pin boots have a wrinkle-free seat in the boot seat of the guide pin and caliper.

11. Remove any excess grease from the pin surfaces.

12. Manually push the guide pins out of caliper towards the carrier until the leading fold of the guide pin boot pulls away from the collar.

13. Manually move the guide pins in the bushing back and forth to ensure the guide pins slide freely within the caliper pin guides.

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Mounting caliper to carrier

CONFIDENTIAL

1. Place the caliper on the carrier with guide pins aligned to contact surfaces.

2. Insert a new long guide pin screw through the long guide pin and thread into carrier. Snug screw with wrench.

3. Repeat step 2 for short guide pin screw.

4. Torque the screws into the brake carrier; long screw first.

5. Manually slide the caliper across the entire stroke several times to check ease of movement. If movement is rough or strained, review installation procedure and correct problem.

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Mounting caliper to carrier

CONFIDENTIAL

6. Grease the bores for the guide pin caps in the caliper.

7. Manually push the caliper against the carrier.

8. Insert two new guide pin caps into the bores of the caliper.

9. Assemble tool to press the guide pin cap down to the piston stop.

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Replacing adjuster piston boot (1/4)

CONFIDENTIAL

1. Manually push the caliper completely inboard.

2. Pull the adjuster piston boot from the boot seat of the adjuster piston.

3. Position the screwdriver between the adjuster piston boot and cover.

4. Remove the adjuster piston boot from the seat of the caliper with a screwdriver.

5. Check the thread of the adjuster piston.

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Replacing adjuster piston boot (2/4)

CONFIDENTIAL

6. Check the brake caliper. If dirt or moisture has entered the brake or if the boot seat in the brake caliper is worn or damaged, replace the brake.

7. Mark the position of the pin on the adjuster piston on the caliper. The pin must be located in the same position after checking the adjuster piston.

8. Manually turn adjuster piston counterclockwise about 1.18” (30 mm) out of the caliper.

9. Check the thread adjuster piston for corrosion, wear and damage.

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Replacing adjuster piston boot (3/4)

CONFIDENTIAL

10. Replace the adjuster piston boot if dirt or water has penetrated into the caliper or if the boot has been worn or damaged.

11. Ensure the seal is correctly seated in the boot seat of the caliper. If necessary, press the seal back into the boot seat by hand.

12. Clean the adjuster piston boot seats.

13. Grease the thread of the adjuster piston.

14. Manually turn the adjuster piston clockwise back into caliper. The pin should be in the same position as it was in step 7.

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CONFIDENTIAL Replacing adjuster piston boot (4/4) 15. Slide a new and grease free adjuster piston boot over the adjuster piston.

16. Center the adjuster piston boot and manually push it into the boot seat of the caliper.

17. Lightly grease the inner exposed edge of the boot.

18. Insert the edge of the boot into the adjuster piston seat.

19. Ensure the adjuster piston boot is correctly seated and is wrinkle-free.

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Replacing adjuster boot (1/3)

CONFIDENTIAL

Removing the adjuster boot 1. Remove the adjuster plug.

2. Use a suitable tool (i.e. screwdriver) to remove the adjuster boot out of the caliper seat.

3. Remove the adjuster boot from the adjuster. IMPORTANT: Ensure no dirt or moisture enters the brake when cleaning.

4. Clean the brake caliper adjuster boot seat.

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Replacing adjuster boot (2/3)

CONFIDENTIAL

Installing the adjuster boot 5. Push the mounting cap onto the adjuster until it stops.

6. Lightly grease the new adjuster boot only at the inner boot bead.

7. Install the adjuster boot onto the mounting cap.

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Replacing adjuster boot (3/3)

CONFIDENTIAL

8. Manually press the adjuster boot fully into the caliper boot seat.

9. Install the mounting bushing onto the mounting bushing and press it against the inner boot bead until the boot bead lies in the boot seat of the adjuster.

10. Remove the mounting bushing and mounting cap.

11. Check correct seat of the adjuster boot in the boot seat.

12. Push a new adjuster plug into the opening and ensure a tight fit.

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Replacing dust shield

CONFIDENTIAL

NOTE: Dust shields have no left / right orientation and can be installed on either side of the axle. It is not necessary to remove the dust shield prior to removing or servicing the brake.

1. Use a 13 mm socket or wrench to remove the four bolts and lock washers.

2. Position new dust shield as shown.

3. Reinstall fasteners and torque.

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Preventative Maintenance

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Inspection Frequency  Refer to L578 for updated information.

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Additional Resources  www.maxx22t.com

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© 2015 Hendrickson USA, L.L.C. All Rights Reserved

CONFIDENTIAL

© 2015 Hendrickson USA, L.L.C. All Rights Reserved

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