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=$0 06 Service Manual EB-32 f March 1984 Single Anchor Pin Brakes 161/*" & 18" Series In re: A ll Asbestos Litigation Filed by The Simmons Firm, Circuit Court, Third Judicial District, Madison Cty., IL ; 8/28/03 EAB00II13 A s b e ^ f Litigation Filed by The Simmons Firm, C itf^ t Court, Third Judicial District, Madison C f f l L ; 8/28/Q3 In re: A ll Asbestos Litigation Filed by The Simmons Firm, Circuit Court, Third Judicial District, Madison Cty., IL ; 8/28/03 Section 1: General Information Parts Identification ................................ 4 Parts Nomenclature .............................. 5 Brake Description Components / Assemblies Brake Operation ............. 6 .2 6o Q) CO Section 2: Periodic Service Inspection Recommendations and Intervals......... 7 Spider Inspection ............................... 8 Shoe & Lining Inspection .................. 8 Camshaft Inspection (General) ......... 9 Camshaft End Play (Axial) ................ 9 Camshaft Fit into Air Chamber Bracket (Radial)............................... 10 Air Chamber Bracket Inspection ..........10 Inspection (Cont'd) Slack Adjuster Inspection .................. 11 Air Chamber Inspection...................... 11 Drum Inspection ................................ 12 Maintenance / Adjustment Brake Maintenance Preliminary Steps ....................... 13 Brake Adjustment ............................... 13 Lubrication ......................................... 15 Brake Operational Check .................. 15 Section 3: Brake Overhaul Removal / Disassembly Drum Removal .................................... 16 Shoe Removal .................................... 17 Slack Adjuster Removal...................... 18 Camshaft Removal ............................. 18 Air Chamber Bracket Removal........... 18 Spider Removal .................................. 19 Cleaning ................................................. 19 Component Repair / Replacement Camshaft Bushing and Grease Seal Replacement .................20 Brake Lining Replacement .................. 21 installation / Assembly Riveting Sequence for Lining Replacement ....................... 22 Spider Installation ............ 22 Air Chamber Bracket Installation....... 23 Camshaft Installation ............... ,............23 Slack Adjuster Installation.................... 24 Shoe Installation ................................ 25 Drum Installation................................. 26 Key Dimensional Specifications............. 26 Key Torque Specifications...................... 26 3 a EAB 001 IT PARTS IDENTIFICATION/NOMENCLATURE General Information 3oa 00 In re: A ll Asbestos Litigation Filed by The Simmons Firm, Circuit Court, Third Judicial D The service procedures and specifications in this publication cover the Eaton Single Anchor Pin Brakes, 16VS>" (419.1 mm) and 18" (457.2 mm) Series. Applications and variations in brake widths are shown below. The basic instructions cover all brake sizes unless specified otherwise. For more detailed information on trailer axle brakes, refer to Service Manual EB-21. Size 16V&" x 5" 1 &A" x 6" 16'/2" x 7" 16'/2" X 85/a" 18" x 7" Eaton Single Anchor Pin Brakes type (419.1 mm x 127.0 mm) (419.1 mm x 152.4 mm) (419.1 mm x 177.8 mm) (419.1 mm x 219.1 mm) (457.2 mm x 177.8 mm) Steer Axle Steer & Drive Axles Drive & Trailer Axle's Drive Axles Heavy-Duty Drive Axles S *3 I g a t 3 ia .b Brake Shoes and Springs 4 $a e On St CO So -o' 5 St 1 .0 R. % ts <*> a 4'i$* On on 'M P 1 EAB001115  00 00 PARTS IDENTIFICATION/NOMENCLATURE a <0 .53 *5 I I ,5*S* 3 s g ta? a a: aa .5 <0 g a* *a s; a .sK* .S) If 5 EAB001116 In re: A ll Asbestos Litigation Filed by The Simmons Firm, Circuit Court, Third Judicial District, Madison Cty., IL ; 8/28/03 BRAKE DESCRIPTION i General Information o In re: A ll Asbestos Litigation Filed by The Simmons Firm, Circuit Court, Third Judicial Brake Components / Assemblies The SPIDER assembly consists of a spider (either stamped steel or cast iron), an ANCHOR PIN and attaching hardware. If an optional DUSTSHIELD is supplied, it is attached by screws to the spider. The SPIDER serves as a mounting platform for the air chamber bracket and shoe and lining assemblies, and transmits the torque generated by the brake into the chassis components through its attachment to the brake mouting flange on the axle. The AIR CHAMBER BRACKET assembly is attached to the stamped steel spider by studs pressed into the bracket mounting flange and secured to the spider by nuts. On cast spiders, the bracket is attached with bolts through tapped holes in the spider. CAMSHAFT BUSHINGS are installed in the bracket tube to support the camshaft journals. The bracket incorporates a grease fitting and spring type GREASE SEALS to retain grease. The seals are installed with the lip and spring of each seal facing toward the slack adjuster so grease can flow out toward the slack adjuster during lubrication but not onto the cam head. The AIR CHAMBER BRACKET serves as a mounting surface for the air chamber and provides support for the camshaft. The SHOE AND LINING assemblies are mounted to pivot at one end on the fixed anchor pin and bear against the CAM ROLLER at the other end. SHOE RETAINER SPRINGS hold the anchor pin ends of the shoes tightly against the anchor pin, and the SHOE RETURN SPRING assists the shoes in pulling away from the drum as brake application is>released. The CAMSHAFT is splined at one end to accept a SLACK ADJUSTER. The cam head bears against the cam rollers and transmits the rotary motion of the shaft into a lift which pushes the rollers and shoes toward the drum. Brake Operation As the brake valve in the vehicle is applied, air pressure is delivered to the brake air chamber. Movement of the air chamber push rod causes the slack adjuster to move and rotate the camshaft. As the camshaft rotates, the rollers "ride-up" on the convex side of the cam head and force the shoes out against the drum. As the brake is released, the return spring pulls the shoes away from the drum, and the air chamber return spring rotates the camshaft to the "at-rest" position. Brake adjustment is accomplished by rotating the adjustment nut of the slack adjuster to regu late the amount of "free-str drum. A "3 I e s Q> I so s -o' i In re: A ll Asbestos Litigation Filed by The Simmons Firm, Circuit Court, Third Judicial District, Madison Cty., IL ; 8/28/03 8/28/03 In re: A ll Asbe^ | Litigation Filed by The Simmons Firm, C iiQ t Court, Third Judicial District, Madison C ^ I L ; Periodic Service INSPECTION Inspection Recommendations and Intervals General Recommendations Due to the importance of a well-maintained braking system, Eaton recommends that the inspections and maintenance listed below be accomplished by Commercial Vehicle Operators at the intervals suggested. Since driver technique and vehicle use can both contribute to rate of brake component wear, it may be appropriate to increase the frequency of the inspections to fit individual needs based upon past experience. Brake Adjustment Brake adjustment should be checked (and adjusted if necessary) WEEKLY or at any time the limits found in Section 2, page 13 are exceeded. Specific Component/Assembly Inspections The specific component/assembly inspec tions found in Section 2, page 8 should be made at each brake overhaul. Lubrication AIR CHAMBER BRACKET -- The lubricant specified in Section 2, page 15 should be applied through the grease fitting at intervals coincident with the Vehicle Manufacturer's recommendations for chassis lubrication. In no case should the lubrication interval exceed 6 months of service. Lining Inspection A visual check of lining thickness and con dition should be made each time the brake drum is removed. Inspection of lining thick ness either from the axle side of the brake spider or through the dustshield inspection holes should be made each time the vehicle is being serviced in the maintenance shop. In no case should the lining thickness/ condition inspection interval exceed 3 months of service. General Inspection A thorough visual inspection for brake wear, broken parts and/or obvious damage should be made each time the brake is being serviced or wheel and drum have been removed. In no case should the general inspection interval exceed 3 months of service. Brake Rellne A brake reline should be accomplished at any time the lining thickness or lining condi tion indicates the need. Refer to Section 2, page 8. Brake Overhaul A complete brake overhaul following the instructions contained in this Service Manual should be accomplished at every third brake reline. In no case should overhaul interval exceed 2 years. A complete brake overhaul consists of: Complete disassembly Cleaning Inspection Camshaft bushing, camshaft seal, cam roller, shoe retainer springs, and shoe return spring replacement o Assembly Brake operational check Brake Operational Check A complete operational check of the braking system should be made following the instruc tions found in Section 2, page 15 at every brake service. In no case should the operational check interval exceed 3 months of service. t it 7 EAB 0011 C^ ' IL ; 8/28/03 INSPECTION %o OP2 , In re.r A ll Asbestos Litigation Filed by The S in W o g m i Spider inspection 1. Check visually for cracks at fastener attachment bolt holes, cam area and around the anchor pin. Replace if defective. 2. Check anchor pin. If pin is loose or grooved more than .031 inches (.79 mm) below original surface, the Spider assembly must be replaced. Shoe and Lining inspection 1. Check linings and replace if contaminated, cracked, or worn to less than 1/4 inch (6.35 mm) or 1/16 inch (1.59 mm) from rivet heads at any point. 2. Check shoes for bent or cracked webs or table, broken welds, loose rivets or elongated rivet holes. Replace if any of these is found. 3. Check Anchor Pin and Camshaft Roller recesses in shoe webs for elongation or visi ble wear. Shoes should be replaced if wear at roller end increases diameter to more than 7/8" (22.2 mm). Use 7/8" bar stock as a "no-Go" gauge. 4. Check shoe span by measuring the dis tance between the centerlines of the Anchor Pin and Camshaft Roller recesses in the shoe web. Replace shoe if this dimension does not fall within the range shown: Steer Axle Brakes... 12-5/16" min. (312.7 mm), 12-1/2" max. (317.5 mm). Drive and Trailer Axle Brakes... 12-5/16" min. (312.7 mm), 12-9/16" max. (319.1 mm). 8 Check for cracks. Check for grooved or loose anchor pin. Check for cracks or contamination. No closer than 1/16" (1.59 mm) minimum thickness. (22.2 mm). Check table and web for cracks Check both ends for wear and $ .on *3 I &fc 2 3 3 S g s 3 oSn .8 g : *8 st 2 Maximum Span See ranges to the left. on Oon EAB001119 a In re: A ll Asbestos Litigation Filed by The Simmons Firm, Circuit Court, Third Judicial District, Madison Cty., IL ; 8/28/03 Camshaft Inspection -- General I .03 2 B .1 g tf aa Camshaft inspection -- End Play (Axial) I to a 1. Mount a suitable dial indicator with plunger referencing cam head at 90 from a cam face. .B 2. Pull inboard on slack adjuster end of cam co to take up end play. so 3. Zero indicator. s 4. Push outboard on slack adjuster end of cam and note maximum reading. a* 5 5. By adding or subtracting washers at the outer position, adjust end play to be within 5 0.005" (.13 mm) to 0.045" (1.14 mm) range. a 2 1. Check spline end for cracks or worn or deformed splines. Replace as necessary. 2. Check camshaft bushing journals for wear and corrosion. Replace camshaft if it shows visible wear or if roughness is felt in journal area. 3. Inspect camshaft head for brinelling, cracking, or flat spots. Replace if ridge can be felt between worn area and cam head surface. i 9 Si EAB001120 lit re: A ll Asbestos Litigation Filed by The Simmons Firm, Circuit Court, Third Judicial District, Madison Cty., IL ; 8/28/03 INSPECTION Camshaft inspection -- Fit into Air Chamber Bracket (Radial Play) m 1. Mount a suitable dial indicator with plunger referencing cam face at 90 to cam bearing journal. 2. Zero indicator. . 3. Move cam head radially back and forth and note maximum reading. 4. Mount dial indicator at slack adjuster end of camshaft and repeat procedure. If play exceeds .020 inches (.51 mm) in either location, rebush camshaft bracket. Refer to Section 3, page 20. After rebushing, recheck. If radial play is still excessive, replace camshaft. Air Chamber Bracket Inspection 1. Check for bent, broken, or cracked arm and cracked welds. Replace if any of these are evident. 2. Check mounting studs for looseness, damaged threads, or a bent condition. 3. Check camshaft bushings for deteriora tion. Inner surface must be smooth. If surface is rough or abrasive, bushings must be replaced. Refer to Section 3, page 20. 4. Inspect seals. Replace if lip is nicked, cut, or distorted. Refer to Section 3, page 20. Check bushings and seals. Check for bending or cracks. 10 EAB00112I In re: A ll Asbestos Litigation Filed by The Simmons Firm, Circuit Court, Third Judicial District, Madison Cty., IL ; 8/28/03 INSPECTION wr Manual Slack Adjuster inspection a .8 'Sts Verify that adjuster nut does not bind (depress locking sleeve). NOTE: This information is general in nature. For specific slack adjuster inspection guide lines, refer to manufacturer's instructions. .tS .1 'N 1. Check clevis for cracks and bushing wear. Replace as necessary. 2. Check splines for chipped teeth and 3 deformation. Replace as necessary. *8 Check for worn 3. Depress locking sleeve and turn adjuster nut with wrench at least one turn in each $ Check for cracked clevis pm bushing. 3 or worn splines. direction. If binding is present or if excessive force is required to rotate, replace slack adjuster. S ilk CAUTION: If any slack adjuster defect taf is found, it should be replaced. Do not a attempt to repair a faulty slack adjuster! Automatic Slack Adjuster Inspection. Refer to manufacturer's instructions. Air Chamber Inspection I a ! ipju)Y^\sui'fe ,fQ ,*QP^,,'spfiJpd;f- a 5 nfrMJL. hofQro removing spring-brake tvpo I NOTE: This information is general in nature. s For specific air chamber inspection guide lines, refer to manufacturer's instructions. a* 1. Check for air leaks, cracked housing, bent 3 pushrod, loose clamp ring, clogged vent s; holes, or loose air fitting. Repair or replace as recommended by manufacturer. a 2 2. If air chamber is repaired or replaced, check distance from clevis pin hole centerline- A to-air chamber face. This distance must measure 2-5/8" 1/16" (66.7 1.59 mm) except Mack 16-1/2" (419.1 mm) brake which is 4-3/8" (111.1 mm). 3. If a new air chamber is installed, insure that cut-off pushrod does not project too far into clevis. Minimum clearance: clevis center line to pushrod end should be 7/8" (22.2 mm). 11 *5 2-5/8" 1/16"* (66.7 7.59 mm) To clevis centerline, Cut-off pushrod clearance. Tighten jam/stag... nutafter adjusting. |Check for bent push rod, (cracked housing, loose iclamp ring or air leaks. l it EAB001122 In re: A ll Asbestos Litigation Filed by The Simmons Firm, Circuit Court, Third Judicial District, Madison Cty., IL ; 8/28/03 06 INSPECTION Drum inspection m NOTE: This information is general in nature. For specific brake drum inspection guide lines, refer to manufacturer's instructions. 1. Check for cracks, heat-checks, glazing, grooving, runout and out-of-round. Cracked drums must be replaced. Drums which are glazed, grooved, etc., may be repaired for return to service. 2. Check drum diameter. Replace if it exceeds maximum diameter stamped in drum. AlCAUTION: Under no circumstances should drum be used if it exceeds manu facturer's recommended maximum diameter or runout specification. In the absence of other specifications, the installed drum T.I.R. (Total Indicated Runout) should not exceed: 0.015" (0.38 mm) for Steer Axle Drums. 0.020" (0.51 mm) for Drive or Trailer Axle Drums. s .<6 'K* .0 1 fs 12 8 EAB 001123 In re: A ll Asbestos Litigation Filed by The Simmons Firm, Circuit Court, Third Judicial District, Madison Cty., IL ; 8/28/03 Court, Third Judicial District, Madison C f ^ I L ; 8/28/03 MAINTENANCE / ADJUSTMENT Brake Maintenance Preliminary Steps Prior to performing any maintenance requiring removal of the tire and wheel, the following preliminary steps should be accomplished. 1. Set parking brake and block wheels to prevent vehicle movement. 2. Raise steering axle with a jack and support on suitable stands. IWARNING: Nevehwork'under a vehicle supported by a jack , , 1 3. Cage spring-type brake/chamber following vehicle manufacturer's instructions. 1 In re: A ll A s b e s ^ Litigation Filed by The Simmons Firm, C i r ^ Brake Adjustment - Manual Slack Adjuster To determine if brake adjustment is required, measure applied stroke and adjust brakes if value exceeds those in table below for appropriate size air chamber. NOTE: Refer to the procedure on page 14 for determining applied stroke. The difference between applied stroke and free stroke is simply the method used to move the slack adjuster from rest. To check applied stroke, move the slack adjuster with an 80 psi air application instead of with a lever. Adjust when Chamber applied stroke at Adjust to Size 80 psi exceeds: Free Stroke 30" (762.0 mm) 24" (609.6 mm) (1) 24" (609.6 mm) 20" (508.0 mm) 16" (406.4 mm) 12" (304.8 mm) 2" (50.8 mm) 1-3/4" (44.5 mm) 2" (50.8 mm) 1-3/4" (44.5 mm) 1-3/4" (44.5 mm) 1-3/8" (34.9 mm) 3/8" to 5/8" (9.5 to 15.9 mm) Without Drag NOTE: (1) 24" (609.6 mm) chamber with 2-1/2" (63.5 mm) extended stroke. If maximum stroke at 80 psi is still exceeded after free stroke adjustment, check the following: A. DRUM: Cracks or excessive runout, see page 12. Maximum diameter being exceeded. B. SHOES: Poor fit...lining to drum. Shoe centers must contact drum first. Verify 0.020 0.060" (0.51-1.52 mm) clearance at both shoe ends. C. CAMSHAFT BUSHING CLEARANCE: 0.020" (0.51 mm) maximum (see page 10). D. SHOE SPAN: See page 8. a ISSFf, mm l: 13 EAB 00112 In re: A ll Asbestos Litigation Filed by The Simmons Firm, Circuit Court, Third Judicial District, Madison Cty., IL ; 8/28/03 District, Madison Cty., IL ; 8/28/03 MAINTENANCE / ADJUSTMENT Period Servict Brake Adjustment -- Manual Slack Adjuster (cont'd) 1. Perform "Brake Maintenance Preliminary Steps." 2. If applied stroke at 80 psi is outside the recommended range shown on page 13, depress locking sleeve on slack adjuster and adjust as required. Ensure that locking sleeve is in "locked" position after adjust ment is completed. 3. With Air Chamber push rod fully retracted, measure distance "A" from face of air chamber to clevis pin hole centerline. Distance should be 2-5/8" 1/16" (66.7 1.6 mm) except Mack I6V2" (419.1mm) brake which is 4%" (111.1mm). If distance is outside this range, disconnect slack adjuster from push rod clevis and reposition clevis. Reconnect slack adjuster and remeasure distance. In re: A ll Asbestos Litigation Filed by The 4. Move slack adjuster by hand or with the aid of the lever in the apply direction. Measure distance "B" from face of air chamber to centerline of clevis pin hole. 5. Subtract measurement in Step 3 from Step 4 measurement. Difference is free stroke. Dim. "B" - "A" = Free Stroke. 6. After brake adjustment, verify that brake is not dragging by rotating wheel or noting sharp ringing sound when drum is tapped with a hammer. iik CAUTION: Brake must be adjusted to recommended free stroke without appreciable drag. If brake cannot be adjusted in this manner, check for an improperly assembled brake, improperly riveted or ground linings, damaged shoes or linings or excessive drum out-of-round. 7. Perform Brake Operational Check. ilk CAUTION: Do not release vehicle with out verifying proper and safe brake operation. 14 I 1 EAB 001125 In re: A ll Asbestos Litigation Filed by The Simmons Firm, Circuit Court, Third Judicial District, Madison Cty., IL ; 8/28/03 =o =o MAINTENANCE / ADJUSTMENT j Brake Adjustment -- Automatic Slack Adjuster For adjustment procedures on automatic slack adjusters, refer to slack adjuster s manufacturer's instructions. .5^ 2 s Brake Operational Check Lubrication aIaf MOTE: An assistant is required to make a thorough brake operational check. Air Chamber Bracket/Slack Adjuster -- Pressure lubricate with the grease specified 1. Apply brakes at 80 psi and hold. Check all air line fittings and air chambers for leakage. by Vehicle Manufacturer for chassis lubrica tion through the appropriate grease fitting. Continue filling until grease flows out of 2. Apply and release brakes While observing Slack Adjuster end of tube or around slack operation of slack adjusters On each axle. As adjuster splines. The same grease may be brakes are applied and released, slack adjust used on assembly of the camshaft, slack ers should move in unison visually. adjuster, and bushings. Cn Sai 3. Investigate source and make corrections for any discrepancies found in Steps 1 and 2. A>CAUTSOM: Grease should not flow out 2 4. Drive vehicle at low speeds in a safe area end of tube toward cam head. If it does, seal I and make several brake applications to verify is defective and must be replaced. Co safe operation and lack of pulling, grabbing or noise. If any of these are noted, investigate iikCAirnQN: Do not replace existing s and repair prior to releasing Vehicle for grease fitting with a pressure relief type. service. Only standard non-vented fittings are to be q4 iflkCAUTIIGN: Never release a vehicle for used with spring-loaded lip seals. s; service if any brake discrepancy -- no matter how minor -- is evident! ,<a 'V* .2 k5 as 15 EAB001126 *5 The Simmons Firm jXIircuit Court, Third Judicial District, Madison Cty., IL ; 8/28/03 In re: A ll Asbestos Litigation Filed by The Simmons Firm, Circuit Court, Third Judicial District, Madison Cty., IL ; 8/28/03 REMOVAL / DISASSEMBLY 1. Perform "Brake Maintenance Preliminary Steps." Refer to Section 2, page 13. 2. While depressing locking sleeve, back off slack adjuster adjustment nut on slack adjuster. Continue turning until shoes are fully returned to the released position and clear of drum. 3. Remove spindle hubcap, cotter key, hex nut, arid spindle washer. 4. While rocking drum, pull outboard enough to allow removal of outer wheel bearing. 5. Remove drum by pulling outboard while rocking from side to side. If shoes are not clear of drum, return to Step 2 above. A CAUTIOM: If difficulty is found on removal -- do not force drum. Excessive pulling force may damage brake parts. 6. Clean and inspect drum. Refer to Section 2, page 12. 16 EAB00I127 In re: A ll Asbestos Litigation Filed by The Simmons Firm, Circuit Court, Third Judicial District, Madison Cty., IL ; 8/28/03 IL ; 8/28/03 :< A ll Asbe^Ql Litigation Filed by The Simmons Firm, C ijQ jt Court, Third Judicial District, Madison REMOVAL / DISASSEMBLY Shoe Removal 1. Perform steps necessary for drum removal. 2. Using a large screwdriver or lever, lift upper shoe to stretch return spring. 3. Remove upper cam roller and pin. 4. Repeat Steps 2 and 3 for lower shoe and roller and pin. ' 5. Push cam end of both shoes toward cam and unhook shoe return spring. 6. Rotate both shoes around anchor pin and remove from vehicle. 7. Discard cam rollers and pins, shoe return spring, and shoe retainer springs. 8. Clean and inspect brake. Refer to Section 2, page 8. 17 s EAB001128 In re: A ll Asbestos Litigation Filed by The Simmons Firm, Circuit Court, Third Judicial District, Madison Cty., IL ; 8/28/03 3o REMOVAL / DISASSEMBLY 5" 'S53 .<3 H .5*9 3 3 2 g aa a _8 $ &9 s ^S%i^ Manual Slack Adjuster Removal 1. Remove cotter pin and clevis pin from air chamber push rod clevis. 2. While depressing locking sleeve, turn adjuster nut until slack adjuster is clear of air chamber push rod clevis. 3. Remove snap ring and outer washer from camshaft. 4. Remove slack adjuster with a suitable puller. jftkCAUTION: Do not hammer on slack adjuster to remove! Damage to slack adjuster and/or camshaft splines may result. 5. Clean and inspect. Refer to Section 2, page 11. Camshaft Removal 1. Perform all steps for drum removal, shoe removal and slack adjuster removal. Refer to Section 3, pages 16, 17, 18. 2. Remove inner washer. 3. Grasp camshaft head and pull camshaft outboard to remove. 4. Clean and inspect. Refer to Section 2, page 9. Air Chamber Bracket Removal (with air chamber installed) 1. Perform all steps for drum removal, shoe removal, slack adjuster removal, and cam shaft removal. Refer to Section 3, pages 16, 17, 18. 2. Disconnect chamber air line. 3. Remove the attaching nuts (bolts on brakes with cast spider) and pull the air chamber bracket away from the spider. IMQTE: On brakes with stamped spiders, the air chamber bracket-to-spider studs are press fit into the bracket. Their removal is not re quired to remove the air chamber bracket. 4. Clean and inspect. Refer to Section 2, pages 10,11. 18 m EAB 00112` IL ; 8/28/03 In je: A ll A s b e jQ Litigation Filed by The Simmons Firm, C i ^ j t Court, Third Judicial District, Madison Spider Removal 1. Perform steps necessary for drum removal shoe removal, slack adjuster removal, cam shaft and camshaft bracket removal. 2. Remove the spider-to-axle attachment nuts and bolts. 3. Remove spider. 4. Clean and inspect. Refer to Section 2, page 8. Cleaning After removing the brake parts being serviced from the vehicle, the following cleaning procedures should be followed: 1. Wire brush all parts exposed to mud, road dirt, and salt, including exterior of drum, spider, air chamber bracket, and dustshields (if so equipped). If shoes are to be relined, thoroughly wire brush shoe table and paint with rust inhibitive coating. iik CAUTION: A layer of oxidation and dirt on the outside of a brake drum acts as an insulator and may hinder normal heat dissi pation. Make sure excessive deposits of oxidation and dirt are removed by wire brushing. 2. Wipe interior of drums with a greaseless solvent to remove lining material dust. Use a vacuum cleaner to pick up excessive dust accumulation. 3. Clean all remaining brake parts thoroughly with a suitable shop solvent. Wipe dry with a clean, lint-free cloth or use low-pressure, filtered, compressed air. 36 $026 & .8 2 3 Tsf <3 13 3u G v I t3Qo .1 V3 EAB 001130 In ile: AU Asbestos Litigation Filed by The Simmons Firm, Circuit Court, Third Judicial District, Madison Cty., IL ; 8/28/03 In re: A ll Asbestos Litigation Filed by The Simmons Firm, Circuit Court, Third Judicial District, Madison Cty., IL ; 8/28/03 COMPONENT REPAIR / REPLACEMENT Camshaft Bushing and Grease Seal Replacement 1. Remove Air Chamber Bracket. Refer to Section 3, page 18. 2. Remove old bushings and grease seals by driving out with a punch. 3. Clean and inspect Air Chamber Bracket. Refer to Section 2, page 10. 4. Install bushings with a suitable piloted driver. NOTE: When installing bushings, be sure they are positioned in the bracket tube to the depths indicated in the illustration below. 5. Install grease seals with a suitable piloted driver. NOTE: Install grease seals so seals are flush with end of air chamber bracket tube. Seal Installation Lip side of both seals must face in same direction -- Toward slack adjuster. Install seals flush with tube ends. Install --' bushing in 21/32" (16.8 mm) from tube end. kj S-*--Slack adjuster end Install bushing in 1/4" (6.4 mm) from tube end. L. il CAUTION: Seals must be installed as indicated so that lip side (with spring) of both seals faces toward slack adjuster end of bracket. Improperly oriented seals may allow grease to exit camshaft head end of air chamber bracket and contaminate lining material. 20 EAB 001131 In re: A ll Asbestos Litigation Filed by The Simmons Firm, Circuit Court, Third Judicial District, Madison Cty., IL ; 8/28/03 * o COMPONENT REPAIR / REPLACEMENT Lining Replacement 1. Remove shoe and lining assemblies. Refer to Section 3, page 17. 2. Using a suitable riveting mandrel, push out old rivets. &4s 3. Clean shoe table. Refer to Section 3, page 19. 2 CAUTION: Drilling out rivets or cutting off upset head with chisel may cause rivet hole elongation. .*2 4. Inspect to determine if shoe is serviceable. Refer to Section 2, page 8. g 5. Verify that replacement lining material iaf conforms to FMSI No. (see chart). a ilk CAUTION: Use of an improper FMSI lin ing specification or friction material type may cause brake dragging, grabbing, or improper brake performance. 1 6. Insert the proper size rivets into all holes and hold heads temporarily in place with masking tape. 2 .8 SPECIAL NOTE: It is important to use 3 rivets of the correct material, shank diameter, length, head size, and shape. S Refer to chart on page 22. a 7. Begin riveting at the center of each edge of shoe and lining and progress uniformly toward each end. aa 8. Check installation by trying to insert a .006" (.152 mm) feeler gage between lining A and shoe table along edges. It should not be s possible to insert the feeler gage in this manner anywhere along the edge with the exception of each end beyond the last row of rivets. A larger clearance may exist in these areas. Replacement Linings FMSI No. vs. Brake Size Brake Size FMSI No. 16-1/2" x 5" (419.1 mm x 127.0 mm) 16-1/2" x 6" (419.1 mm x 152.4 mm) 16-1/2" x 7" (419.1 mm x 177.8 mm) 16-1/2" x 8-5/8" (419.1 mm x 219.1 mm) 18" x 7" (457.2 mm x 177.8 mm) 4223A 4317G 4311J 4674 4527B 21 EAB 001132 1 INSTALLATION / ASSEMBLY t3 Riveting Sequence for Lining Replacement S to Rivets and Bolts I Rivets ....... Brass plated steel (1/4" x 1/2") (Part No. 35861) (6.35 mm x 12.7 mm) Bolts/Nuts ... Flat head, brass plated steel a (Part No. 1000149) (3/8"-16 x 1.25") SAE #10-8 (9.5 mm-16x 31.75 mm) Head Angle - 81 .2 Tightening Torque # $ s g Begin riveting at center of each lining segment then progress uniformly toward Iaf each end. a Bolt/Nut Tightening Sequence Same as riveting: Tighten center bolts first. . 170-200 Lbs-in. (19.21 - 22.6 N-m) & .8 *2 g i2 Iaf 3 a a tao S s S JB 5 Spider installation V3 1. Verify the available spider is serviceable. g Refer to Section 2, page 8. 2. Verify that available spider is correct part number for axle being serviced. ';<fS5t$B ' 3. Position spider on axle flange and install attaching bolts and nuts. * ,"fe 4. Sequentially torque nuts according to . manufacturer's specifications. # S' MOTE: Use hardened washer under 5/8" :s( (15.87 mm) bolt heads. :.<#. .ato > to <t5o 22 EAB 001133 e In re: A ll Asbestos Litigation Filed by The Simmons Firm, Circuit Court, Third Judicial District, Madison Cty., IL ; 8/28/03 IL ; 8/28/0$ 4U A s b e j/) Litigation Filed by The Simmons Firm, C iiiffft Court, Third Judicial District, Madison INSTALLA TION / ASSEMBLY Air Chamber Bracket Installation 1. Verify that available Air Chamber Bracket is serviceable. Refer to Section 2, page 10. 2. Orient bracket to align mounting studs with holes in spider. 3. Position bracket against spider and install lockwashers and nuts on mounting studs. 4. Torque stud nuts to 65-85 Ib-ft. (88-115 N-m). 5. If air chamber was removed, install and tighten nuts to correct torque. 7/16"-20 Nuts .......... 35-40 Ib-ft. (47.5-54.2 N-m) 5/8"-18 Nuts ........ 110-115 Ib-ft. (149-156 N-m) Camshaft installation 1. Verify that available camshaft is serviceable and the correct part for the application. Refer to Section 2, page 9. jEHk CAUTION: To ensure that camshaft being installed is correct for the application, rotate camshaft in the direction of air chamber push rod extension and check that the roller starts to ride up on the convex side of the cam head. 2. Apply a thin film of grease (as specified in Section 2, page 15) on inside of camshaft bushings, seals, and spline area of camshaft. iik CAUTION: Do not grease camshaft head area! 3. Carefully slip camshaft into bracket. : A. fci 'h EAB00I 134 1 j INSTALLATION / ASSEMBLY yr t i s In re: A ll Asbestos Litigation Filed by The Simmons Firm, Circuit Court, Third Judicial District, Madison Cty., IL ; & 0 s .ft a 2 3 3 S g tar a a .8 l to aft 3 .8 03 ft g ft4 *St- ' i" Slack Adjuster Installation 1. Verify that slack adjuster is serviceable. Refer to Section 2, page 11. 2. Install the inner camshaft washer on the camshaft. SPECIAL NOTE: Two different thick ness camshaft washers are used. The thin washer is .030 inches (.76 mm) thick -- the thick washer is .060 inches (1.52 mm) thick. The thick washer should be used as the inner camshaft washer. 3. Apply a thin film of grease, as specified in Section 2, page 15, to slack adjuster splines. 4. Verify that camshaft head is oriented properly. Turn camshaft as required. 5. Install the slack adjuster on the camshaft oriented with the adjuster nut on the side opposite the Air Chamber. tsg&i'i M3 M .'.'to #1 ;,*ft- ' ' 6. Install the outer shim washer and snap ring. . 7. Check camshaft end play. Refer to Section 2, page 9. If necessary, add or delete washers to obtain end play between .005"-.045" (.13 1.14 mm) and slack adjuster centering between air chamber bracket and snap ring groove. 8. Verify that air chamber face-to-clevis centerline dimension is correct. Refer to Section 2, page 11. Ensure that clevis locknut is securely tightened. 9. While depressing the locking sleeve, rotate adjusting nut counterclockwise until appro priate hole in slack adjuster is aligned with hole in air chamber pushrod clevis. 10. Install clevis pin and cotter pin. 11. Pressure lubricate slack adjuster with chassis grease. i3i^-:r>.:'r 24 EAB 001135 In le: A ll A s b e ^ ) Litigation Filed by The Simmons Firm, C flQ ft Court, Third Judicial District, Madison d | P IL : 8/28/03 In re: A ll Asbestos Litigation Filed by The Simmons Firm, Circuit Court, Third Judicial District, Madison Cty., IL ; 8/28/03 Shoe Installation INSTALLATION / ASSEMBLY 1. Verify that spider, camshaft and bracket, and slack adjuster are serviceable. Refer to Section 2, pages 8 through 11. 2. Hook ends of new retainer springs into holes in both shoe webs. NOTE: For correct installation of shoe retainer springs, the spring ends must be positioned as shown in the adjacent photo. 3. Position upper and lower shoes around anchor pin. 4. Install a new shoe return spring. 5. Using a large screwdriver or lever, stretch shoe return spring to allow insertion of new cam roller and pin on the lower shoe web. 6. Repeat process on upper shoe. US 25 EAB001136 In re: A ll Asbestos Litigation Filed by The Simmons Firm, Circuit Court, Third Judicial District, Madison Cty., IL ; 8/28/03 o6 06. INSTALLATION / ASSEMBLY Brake Overhaul s Drum Installation st I The following instructions are general. For your specific application, follow manufactur er's instructions. 5. Adjust and lubricate wheel bearings. Refer to vehicle manufacturer's instructions. 6. Verify proper drum installation and lack 1. Verify that drum is serviceable. Refer to I.tS Section 2, page 12. 2. Prior to drum installation, verify proper of drum-to-dustshield (if so equipped) interference. 7. Adjust brake. Refer to Section 2, page 13. positioning of shoes, cam rollers, and springs. .8 Perform brake operational check. Refer to Section 2, page 15. : 3. Verify that slack adjuster has been backed off to allow drum installation. 4. Verify proper lubrication of wheel A CAUTION: Do not release vehicle with S bearings. Refer to vehicle manufacturer's instructions. out adjusting and verifying proper operation of brakes! tr aa I $ a5 Key Dimensional Specifications .i*8-* Maximum Anchor Pin Groove Depth: 0.031" (.79 mm). <y Minimum Lining Thickness: g 1/4" (6.35 mm) or 1/16" (1.59 mm) from rivet heads. Camshaft End Play (Axial): 0.005"-0.045" (.13-1.14 mm). Camshaft Radial Play-Maximum: 0.020" (.51 mm). Air Chamber Face to Clevis Center: See page 14. Maximum Free Stroke: See page 13. Desired Free Stroke: See page 13. Key Torque Specifications Dustshleld Attachment Screws: 11-16 Ib-ft. (14.9-21.6 N-m). Air Chamber Bracket to Spider Nuts: 65-85 Ib-ft. (88-115 Nm). Air Chamber Mounting Nuts: (7/16-20) Nuts 35-40 Ib-ft. (47.5-54.2 Nm). (5/8-18) Nuts 110-115 Ib-ft. (149-156 N m). Lining Bolts/Nuts: (3/8-16) 170-200 Ibs-in. (19.21-22.6 N-m). 26 EAB001137 i , complete inrorn ns order system! / ; illlliaRSiiSlS EABoome In re: A ll Asbestos Litigation Filed by The Simmons Firm, Circuit Court, Third Judicial District, Madison Cty., IL ; 8/28/03  s 1s tj Eaton0 Axles and Brakes... Backup by Eaton's unique Radrang@rSM Service Support ^|| $ When you spec Eaton, you automatically receive help from the a .05 largest field service network in the industry. You can call on our factory-trained experts for everything from spec'ing advice to parts J3 expediting to on-the-spot troubleshooting, and you get this help whether you're a fleet or just a one truck owner. If you should ever *3 have any question involving any Eaton axle or brake, the answer comes easy. "Ask a Roadranger.SM" Ia Call the nearest Eaton Truck Components Regional Office or write the Eaton Field Service Department (address below). W .CO =1 s Eaton Truck Components Regional Offices: s Western Region: a Oakland, CA a (415)487-8880 Northeast Region: Allentown, PA (215) 395-1212 Canadian Region: Toronto, Ontario (416)678-2751 Calgary, Alberta (403) 250-2942 For further assistance... Ask a Roadranger.TM For emergency parts assistance or toll-free service consultation. Southeast Region: Charlotte, NC (704) 372-5840 s; 0aa5 5 Midwest Region: Dallas, TX (214) 242-8615 .t&*83 Great Lakes Region: Kalamazoo, Ml <u (616) 342-3680 g a* "a !} .3 3 b IaS a a 3 o> aa S to 3 a a For further information, contact Eaton Corporation, Axle & Brake Division, P.O. Box 4008, 33 <5 Kalamazoo, Michigan 49003. 05 1u FJT'N*?to> EB-32 3845 (R88510) Printed in U.S.A. I ^5 to 05 aa EAB 00! 139