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Roadranger Dana Spicer Brakes Brake Systems F;T>N One Great Drivetrain from Two Great Companies Troubleshooting Guide BRIP-0300 November 1994 For the most current information, visit the Roadranger web site at www.roadranger.com General Information Table of Contents Foreword .................................................................................................................................................................................... Purpose ...................................................................................................................................................................................... How to Use this Manual................................................................................................................................................................ Lining Material Warning .............................................................................................................................................................. Brake Systems Diagnostic Guide................................................................................................................................................... Noise ......................................................................................................................................................................................... Long Stopping Distances.............................................................................................................................................................. Vehicle Pulls/Cracked Drums......................................................................................................................................................... Parking Brake Will Not Hold/Dragging Brakes ................................................................................................................................. Premature Lining Wear ................................................................................................................................................................ 2 2 2 3 4 7 9 11 13 17 1 General Information Foreword Purpose This Eaton manual is intended as a diagnostics guide for technicians involved in the servicing of Eaton EB and ES Model Brakes. How to Use this Manual This manual outlines the steps necessary to pinpoint the source of problems and concerns related to braking systems. It does not describe service procedures, but instead refers the technician to service manual sections whenever possible. Therefore, this manual should be used as a "checklist" in conjunction with Eaton service manuals and other procedural guides. To isolate the source of a problem or concern, follow the steps below: 1. Identify the symptom(s) exhibited by the braking system. Locate the related section in this manual. (For example, if the brakes are making unusual sounds, turn to the page labeled "Noise".) 2. Use the left-hand column as a checklist. Check each item on the list. If an item is found to be defective, perform the corresponding action prescribed in the right-hand column. (For example, noise may be caused by a bent brake spider. The recommended action is to replace the spider.) 3. Refer to the appropriate service manual section for information on specific procedures. Related service manual sections are shown in parenthesis, whenever possible.(Service Manual BRSM-0033) Note: Included in the General Information section are assembly diagrams to assist in troubleshooting. A Work through all potential conditions or causes related to the symptom encountered before making a final conclusion. It is possible that several problems exist, each with the same symptom. Therefore, checking each item on the list will help to ensure that all problem sources are eliminated or corrected. A Replace only those parts that have been identified as definite problems. Doing so will save unnecessary time and expense. BRAKE SYSTEMS DIAGNOSTIC GUIDE POTENTIAL CONDITION/CAUSE ACTION (SERVICE MANUAL SECTION) Dragging brakes See DRAGGING BRAKES Insufficient lining-to-drum contact: Bell-mouthed drum condition Poor surface condition of drum Bent brake spider " Bent or stretched brake shoe Loose wheel bearing Worn or damaged camshaft Improper lining grind Replace drum (3,6) Rebore or replace drum (3,6) Replace spider (3,6) Replace shoe (3,6) Torgue spindle nuts and check end play (6) Replace camshaft (3,6) Grind linings to fit drum radius Linings tapered across width: Bell-mouthed drum condition Poor surface condition of drum Bent brake spider Loose wheel bearing Replace drum (3,6) Rebore or replace drum (3,6) Replace spider (3,6) Torgue spindle nuts and check end play (6) Unegual shoe wear on same brake: Mismatched lining friction codes Worn camshaft or bushings Correct as reguiredwith proper lining (5) Replace camshaft or bushings (3,6) Glazed linings: Unbalanced brake system Incorrect lining for vehicle type and service Dragging spring brake chamber Inspect brake system (2) Install proper lining (6) Inspect valves and chamber for leaks. Replace air chamber (4,6) Scored or grooved linings and drum: Improperly machined drum Abrasive material between lining and drum Replace or machine drum (3,6) Remove dirt and debris. Clean drum and remachine if reguired (3) Loose lining: Improper rivet size Improper crimping of rivets Enlarged rivet holes in shoe Incorrect lining hole size or counterbore depth Replace rivets (5) Replace rivets (5) Replace shoe (3,6) Replace lining (5) Cracked lining at rivet holes: Dirt or rust on shoe table Incorrect counterbore lining size Loose rivets Remove dirt and debris. Clean and repaint shoe (3) Replace linings (5) Replace linings and check rivet process (5) / 2 General Information A DANGER AVOID CREATING DUST POSSIBLE CANCER AND LUNG DISEASE HAZARD While Eaton does not offer asbestos brake linings, the long-term effects ofsome non-asbestos fibers have not been determined. Current OSHA Regulations cover exposure levels to some components of non asbestos linings but not all. The following precautions must be used when handling these materials. 1. AVOID CREATING DUST. Compressed air or dry brushing must never be used for cleaning brake assemblies or the work area. 2. EATON RECOMMENDS THAT WORKERS DOING BRAKE WORK MUST TAKE STEPS TO MINIMIZE EXPOSURE TO AIRBORNE BRAKE LINING PARTICLES. Proper procedures to reduce exposure include working in a well ventilated area, segregation of areas where brake work is done, use of local filtered ventilation systems or use of enclosed cells with filtered vacuums. Respirators approved by the Mine Safety and Health Administration (MSHA) or National Institute for Occupational Safety and Health (NIOSH) should be worn at all times during brake servicing. 3. Workers must wash before eating, drinking or smoking; shower after working, and should not wear work clothes home. Work clothes should be vacuumed and laundered separately without shaking. 4. OSHA regulations regarding testing, disposal of waste and methods of reducing exposure for asbestos are set forth in 29 Code of Federal Regulations 1910.001. These regulations provide valuable information which can be utilized to reduce exposure to airborne particles. 5. Material safety data sheets on this product, as required by OSHA, are available from Eaton. 3 BRAKE SYSTEMS DIAGNOSTIC GUIDE ES/EB-150-4L 4 BRAKE SYSTEMS DIAGNOSTIC GUIDE 5 BRAKE SYSTEMS DIAGNOSTIC GUIDE 6 NOISE BRAKE SYSTEMS DIAGNOSTIC GUIDE POTENTIAL CONDITION/CAUSE Dragging brakes Insufficient lining-to-drum contact: Bell-mouthed drum condition Poor surface condition of drum Bent brake spider Bent or stretched brake shoe Loose wheel bearing Worn or damaged camshaft Improper lining grind Linings tapered across width: Bell-mouthed drum condition Poor surface condition of drum Bent brake spider Loose wheel bearing Unequal shoe wear on same brake: Mismatched lining friction codes Worn camshaft or bushings Glazed linings: Unbalanced brake system Incorrect lining for vehicle type and service Dragging spring brake chamber Scored or grooved linings and drum: Improperly machined drum Abrasive material between lining and drum Loose lining: Improper rivet size Improper crimping of rivets Enlarged rivet holes in shoe Incorrect lining hole size or counterbore depth Cracked lining at rivet holes: Dirt or rust on shoe table Incorrect counterbore lining size Loose rivets ACTION (SERVICE MANUAL SECTION) See DRAGGING BRAKES Replace drum (3,6) Rebore or replace drum (3,6) Replace spider (3,6) Replace shoe (3,6) Torque spindle nuts and check end play (6) Replace camshaft (3,6) Grind linings to fit drum radius Replace drum (3,6) Rebore or replace drum (3,6) Replace spider (3,6) Torque spindle nuts and check end play (6) Correct as required with proper lining (5) Replace camshaft or bushings (3,6) Inspect brake system (2) Install proper lining (6) Inspect valves and chamber for leaks. Replace air chamber (4,6) Replace or machine drum (3,6) Remove dirt and debris. Clean drum and remachine if required (3) Replace rivets (5) Replace rivets (5) Replace shoe (3,6) Replace lining (5) Remove dirt and debris. Clean and repaint shoe (3) Replace linings (5) Replace linings and check rivet process (5) 7 BRAKE SYSTEMS DIAGNOSTIC GUIDE 8 BRAKE SYSTEMS DIAGNOSTIC GUIDE POTENTIAL CONDITION/CAUSE Inadequate air supply to chamber: Old or broken lines Pinhole leaks in air chamber line Loose or damaged fittings Air line inner lining separation Separation: Plugged lines Contamination Valve problems: Worn valves Internal component failures Seals/O-rings damaged External vents blocked Governor failure: Incorrect set point Contamination Damaged valve Compressor failure: Worn or leaking compressor Slipping/broken belts/drives Contamination: No air dryer Faulty air dryer Dirty/damaged filter Desiccant debris Incompatible oils Leaking air tanks Improperly set air chamber: Too much rod free-travel Slack adjuster improperly set: Incorrect installation of slack adjuster Incorrect in-service adjustment Incorrect setup of external reference control arms (Eaton-Haldex) Worn clevis pin ACTION (SERVICE MANUAL SECTION) Replace chamber air lines (3) Replace chamber air lines (3) Tighten or replace fittings (3) Replace chamber air lines (3) Remove blockage Remove contamination Repair or replace Repair or replace Replace seals/O-rings Remove blockage Correct set point Remove contamination Repair or replace Repair or replace compressor Repair or replace belts or drives Install air dryer Repair or replace air dryer Replace air filter Remove debris Drain and refill oil Repair or replace Adjust brakes (2) Install slack adjuster properly (3,6) Adjust brakes using correct procedure (2,6) Perform correct setup procedure (3,6) Replace clevis pin (3,6) LONG STOPPING DISTANCES 9 BRAKE SYSTEMS DIAGNOSTIC GUIDE LONG STOPPING DISTANCES POTENTIAL CONDITION/CAUSE Slack adjuster not functioning properly: Bushing worn Spline damaged Worn or damaged internal parts Incorrect slack window (auto slacks) Overadjustment/underadjustment: Contamination of internal parts (auto slacks) False feedback to slack adjuster due to degraded foundation brake components (see below) Severely glazed or worn linings )egraded foundation brake components: Grease or oil on linings Flat spots on cam or rollers Camshaft bushings binding: lacks lubricant Stretched shoe Other broken or bent parts Performing downgrade braking using light drag ACTION (SERVICE MANUAL SECTION) Replace bushing (3,6) Replace slack adjuster (3,6) Replace slack adjuster (3,6) Install correct window (3,6) Replace slack adjuster (3,6) Replace bad foundation brake component Replace linings (5) Replace linings (5) Replace cam or roller (3,6) Lubricate bushings Replace shoe (3,6) Replace damaged parts as required (3,6) Use snub method on downgrades 10 BRAKE SYSTEMS DIAGNOSTIC GUIDE VEHICLE PULLS/ CRACKED DRUMS POTENTIAL CONDITION/CAUSE Dragging brakes Grabbing or pulling brakes: Grease, oil or dirt on linings Glazed linings Cam bracket seal failure Brake linings not a balanced set, different codes, or lining brand Loose or broken linings Brake drum out-of-round Defective brake drum Camshaft binding at one or more wheels Defective slack adjuster Uneven brake adjustment (side-to-side) Broken or bent part(s) Loose spider or drum mounting bolts Different air chamber size or slack adjuster length (side-to-side) ACTION (SERVICE MANUAL SECTION) See DRAGGING BRAKES Check brake adjustment Replace linings (5) Deglaze linings or replace (5) Replace seals (5) Replace linings (5) Replace linings (5) Replace drum (3,6) Replace drum (3,6) Clean and lubricate (2,3) Replace slack adjuster (3,6) Adjust brakes (2) Replace part(s)(6) Retorque bolts (6) Use same size air chamber and slack adjuster length on all brakes 11 1.) Scoring BRAKE SYSTEMS DIAGNOSTIC GUIDE 2.) Severe Heat Checking (Drum cannot be turned to eliminate heat cracks) 3.) Cracking Through Hat Section 4.) Cracking Through Side Wall VEHICLE PULLS/ CRACKED DRUMS POTENTIAL CONDITION/CAUSE Dragging brake Brake drum heat checked: Out-of-round brake drum Eccentric mounting of drum Loose wheel bearing Glazed linings Improper friction materials for vehicle type and vocation Overworked brake Driver abuse Wrong drum type Defective brake lining Debris between lining and drum Performing downgrade braking using light drag Excessive scoring of drum: Soft drum Excessive lining wear ACTION (SERVICE MANUAL SECTION) See DRAGGING BRAKES Replace drum (3) Correct as required (3) Correct as required Deglaze or replace linings (5) Consult dealer for proper friction levels Check brake balance (2) Correct as required Replace with correct drum type (3) Replace lining (5) Clean, remove dirt and debris (3) Use snub method on downgrades Replace drum (3) See PREMATURE LINING WEAR 12 BRAKE SYSTEMS DIAGNOSTIC GUIDE PARKING BRAKE WILL NOT HOLD/ DRAGGING BRAKES POTENTIAL CONDITION/CAUSE Blockage in air lines preventing air chamber from exhausting: Air line inner lining separation Plugged lines Contamination Damaged fittings Air valves sticking: Seals/O-rings damaged External vents blocked Contamination Worn valves/internal component failures Spring brake not functioning: Power spring failure Air chamber not set properly: Too much rod free-travel Air chamber in wrong position in bracket slot Pushrod length too long Slack adjuster not set properly: Incorrect installation of slack adjuster Incorrect in-service adjustment Incorrect setup of external reference control arms (Eaton-Haldex) Broken or bent parts No force at shoes: Grease, oil or dirt on linings .ack of friction: Glazed linings Worn/damaged drums New linings, not burnished ACTION (SERVICE MANUAL SECTION) Replace line Remove blockage Remove contamination Replace fittings Replace seals/O-rings Remove blockage Remove contamination Repair or replace as required Replace spring brake chamber Adjust brakes (2) Reposition air chamber or bracket (3 Adjust clevis or shorten pushrod (2) Install slack adjuster properly (3,6) Check and correct adjustment procedure (2) Perform correct setup procedure (2) Replace damaged parts as required (3,6) Replace linings (5) Deglaze or replace linings (5) Replace drums (3) Burnish linings 13 PARKING BRAKE WILL NOT HOLD/ DRAGGING BRAKES BRAKE SYSTEMS DIAGNOSTIC GUIDE POTENTIAL CONDITION/CAUSE Incomplete release of air chamber after service application: Incorrect clevis position Incorrect bracket slot Damaged pushrod Air chamber return spring failure Road debris damage Blockage in other upstream air system parts Incomplete release of parking brake after application of pressure to air chamber: Internal cup/cone hang-up Damaged pushrod Diaphragm leak in parking chamber Cocked power spring Pushrod seal leak Blockage in other upstream air system parts Air leaks in parking system: Old or broken lines Pinhole leaks in air line Loose or damaged fittings Damaged or contaminated valve Blockages in service system air lines: Inner lining separation Plugged lines Contamination Air valves sticking: Seals/O-rings damaged External vents blocked Low air pressure to valve (see below) Low air pressure supplied to system: Governor failure - -- Incorrect set point -- Contamination -- Damaged valve Compressor Failure -- Worn or leaking components -- Damaged components -- Slipping or broken belts or drives ACTION (SERVICE MANUAL SECTION) Reposition clevis (6) Reposition on correct bracket slot (6) Replace air chamber (3,6) Replace air chamber (3,6) Repair damage (5) Remove blockage (5) Repair or replace cup/cone Replace pushrod (3,6) Replace diaphragm or air chamber (3,6) Repair power spring Replace seal (5) Remove blockage Replace lines Replace line Tighten or replace fittings Repair or replace valve Replace chamber air lines Remove blockage Remove contamination Replace seals/O-rings Remove blockage Check for blockage Check compressor Adjust set point Remove contamination Repair or replace valve Repair or replace Repair or replace Repair or replace 14 PARKING BRAKE WILL NOT HOLD/ DRAGGING BRAKES BRAKE SYSTEMS DIAGNOSTIC GUIDE POTENTIAL CONDITION/CAUSE Contamination --No air dryer --Faulty air dryer --Dirty or damaged filter --Desiccant debris --Incompatible oils --Leaking air tanks --Mis-adjusted brakes Insufficient pushrod free travel: Pushrod length too long Incorrect installation of slack adjuster Overadjusted slack adjuster: Incorrect in-service adjustment (manual) Incorrect setup of external reference control arms (Eaton-Haldex) Incorrect slack window (auto slacks) Contamination of internal parts (auto) False feedback to slack adjuster (review all foundation brake and wheel end problems) Auto slack installed and/or adjusted with spring brake partially applied (low reservoir pressure) Performing downgrade braking using light drag Cam flip over: Worn linings/drums Worn shoes/rollers Worn cam Binding of camshaft in bushings: Corrosion Lack of lubricant Damaged bushings/journals Drum out-of-round: Worn-out drum Overloading of vehicle Over-aggressive linings Driver abuse Incorrect turning of drum Performing downgrade braking using light drag ACTION (SERVICE MANUAL SECTION) Install air dryer Repair or replace Replace filter Clean desiccant Drain and refill with proper oil Repair or replace tank Readjust brakes Shorten pushrod to proper length Perform correct installation procedure (6) Readjust using proper procedure Perform correct setup procedure Replace with proper slack window (6) Replace slack adjuster (6) Check lining clearances and hub/drum run-out (4) Readjust with spring brake fully retracted Use snub method on downgrades Replace linings/drums (3,5,6) Replace as necessary (3,6) Replace cam (3,6) Replace bushings and lubricate (5) Lubricate with proper lubricant (2) Replace bushings/journals (5) Replace drum (3,6) Don't exceed legal weight rating of vehicle Change lining friction rating Correct as required Perform correct drum turning operation (2) Use snub method on downgrades 1 1 1 1 15 BRAKE SYSTEMS DIAGNOSTIC GUIDE ES-165-7H, M 16 PREMATURE LINING WEAR BRAKE SYSTEMS DIAGNOSTIC GUIDE POTENTIAL CONDITION/CAUSE Dragging brakes Poor lining-to-drum contact. Linings are tapered across width: Bell-mouthed drum Bent brake spider Bent or stretched brake shoe Loose wheel bearing Worn or damaged cam Shoe-to-shoe variation: Mismatched lining friction codes Stretched shoe Brake components: Flat spots on cam or roller Worn anchor pin Worn camshaft or bushings Unequal wear on side-to-side brakes for same axle: Mismatched lining friction codes Seized or binding camshaft Brake drum surface in poor condition Loose wheel bearing Performing downgrade braking using light drag Slack adjuster not set properly: Incorrect installation of slack adjuster Incorrect in-service adjustment Incorrect setup of external reference control arms (Eaton-Haldex) Broken or bent parts Wear on edge of lining: Wrong lining width Wrong drum Loose bearing adjustment. Bearing spacer missing or too thin ACTION (SERVICE MANUAL SECTION) See DRAGGING BRAKES Replace drum (3) Replace spider (3,6) Replace shoe (3,6) Torque spindle nuts and check end play (6) Replace cam (3,6) Replace lining(s) with proper friction code (5) Replace shoe (3,6) Replace cam or roller (3,6) Replace anchor pin (3,6) Replace camshaft and bushings (5) Replace lining(s) with proper friction code (5) Clean and lubricate camshaft (2) Replace drum (3) Torque spindle nuts and check end play (6) Use snub method on downgrades Install slack adjuster properly (3,6) Check and correct adjustment procedure (2) Perform correct setup procedure (2) Replace damaged parts as required (3,6) Replace lining (5) Replace drum (3) Replace spacer and torque spindle nuts. Check end play (6) 17 NOTES: 18 Copyright Eaton and Dana Corporation, 2002. EATON AND DANA CORPORATION hereby grants its customers, vendors, or distributors permission to freely copy, reproduce and/or distribute this document in printed format. THIS INFORMATION IS NOT INTENDED FOR SALE OR RE SALE, AND THIS NOTICE MUST REMAIN ON ALL COPIES. DANA E iTal One Great Drivetrain from Two Great Companies National Institute lor EXCELLENCE Roacfeanger MORE TIME ON THE ROAD`S The Roadranger System is an unbeatable combination of the best products from Eaton and Dana - partnering to provide you the most advanced, most trouble-free drivetrain in the industry. And it's backed by the Roadrangers - the most experienced, most expert, most accessible drivetrain consultants in the business. For spec'ing or service assistance, call 1-800-826-HELP (4357) 24 hours a day, 7 days a week, (Mexico: 001-800-826-HELP (4357)) for more time on the road. Or visit our web site at www.roadranger.com. BRIP-0300 11/94 PDF Printed in USA