SD-22-70147

SD-22-70147
Formerly BW7258
Bendix® ES™ Foundation Drum Brake
Actuator
Brake Spider
Slack Adjuster
Retainer Spring
Cam Shaft
Cam Roller
Shoe Assembly
Return Spring
Bendix® ES™ Foundation Drum Brake
Figure 1 – Bendix® ES™ Foundation Drum Brake
DESCRIPTION
PURPOSE OF THIS MANUAL
The Bendix® ES™ foundation drum brake is used in
various applications on axles of commercial vehicles,
providing the service and parking brake function.
This document is intended to act as a source of
maintenance information to those involved in servicing
Bendix® brakes.
With all types of drum brakes, friction forces are
generated by the internal brake shoes being pressed
against the inner surfaces of the brake drum by the force
generated by a cam. Due to their almost completely
sealed housing, the brake shoes are well protected
against corrosive influences (water, salt, and dust) and
dirt (sand, stones, and mud), even when driving on rough
terrain.
With the S-Cam brake, the cam and camshaft are rotated
as a result of the force of the brake actuator acting on
the slack adjuster. The brake shoes with brake linings
are thereby pressed against the brake drums.
ADDITIONAL SUPPORT
For additional service information contact the Bendix
Tech Team online at [email protected], or by
calling 1-800-AIR-BRAKE (1-800-247-2725), option 2.
Tech Team members are available Monday through
Thursday, 8:00 a.m. to 6:00 p.m. and Friday, 8:00 a.m.
to 5:00 p.m. ET.
GENERAL SAFETY GUIDELINES
WARNING! PLEASE READ AND
FOLLOW THESE INSTRUCTIONS
TO AVOID PERSONAL INJURY OR DEATH:
When working on or around a vehicle, the following
guidelines should be observed AT ALL TIMES:
▲Park the vehicle on a level surface, apply the parking
brakes and always block the wheels. Always wear personal
protection equipment.
▲Stop the engine and remove the ignition key when working
under or around the vehicle. When working in the engine
compartment, the engine should be shut off and the ignition
key should be removed. Where circumstances require that
the engine be in operation, EXTREME CAUTION should be
used to prevent personal injury resulting from contact with
moving, rotating, leaking, heated or electrically-charged
components.
▲Do not attempt to install, remove, disassemble or
assemble a component until you have read, and thoroughly
understand, the recommended procedures. Use only the
proper tools and observe all precautions pertaining to use
of those tools.
▲If the work is being performed on the vehicle’s air brake
system, or any auxiliary pressurized air systems, make
certain to drain the air pressure from all reservoirs before
beginning ANY work on the vehicle. If the vehicle is
equipped with a Bendix® AD-IS® air dryer system, a Bendix®
DRM™ dryer reservoir module, a Bendix ® AD-9si ®, AD-HF®,
or AD-HFi™ air dryer, be sure to drain the purge reservoir.
▲Following the vehicle manufacturer’s recommended
procedures, deactivate the electrical system in a manner
that safely removes all electrical power from the vehicle.
▲Never exceed manufacturer’s recommended pressures.
▲Never connect or disconnect a hose or line containing
pressure; it may whip and/or cause hazardous airborne
dust and dirt particles. Wear eye protection. Slowly open
connections with care, and verify that no pressure is
present. Never remove a component or plug unless you are
certain all system pressure has been depleted.
▲Use only genuine Bendix ® brand replacement parts,
components and kits. Replacement hardware, tubing, hose,
fittings, wiring, etc. must be of equivalent size, type and
strength as original equipment and be designed specifically
for such applications and systems.
▲Components with stripped threads or damaged parts should
be replaced rather than repaired. Do not attempt repairs
requiring machining or welding unless specifically stated
and approved by the vehicle and component manufacturer.
▲Prior to returning the vehicle to service, make certain all
components and systems are restored to their proper
operating condition.
▲For vehicles with Automatic Traction Control (ATC), the ATC
function must be disabled (ATC indicator lamp should be
ON) prior to performing any vehicle maintenance where
one or more wheels on a drive axle are lifted off the ground
and moving.
▲The power MUST be temporarily disconnected from the
radar sensor whenever any tests USING A DYNAMOMETER
are conducted on a vehicle equipped with a Bendix ®
Wingman ® system.
▲You should consult the vehicle manufacturer's operating
and service manuals, and any related literature, in
conjunction with the Guidelines above.
2
General Information
TABLE OF CONTENTS
Section 1: General Information
Description.............................................................................................................1
Safety Guidelines/Warnings...................................................................................2
Model Coverage..................................................................................................4-5
Parts Nomenclature...........................................................................................5-12
Model Bendix® ES™-165 and EB™-165 Interchangeability..........................10
EB™ Brake Roller and ES™ Brake Cam Interchangeability.........................10
Section 2: Periodic Service
Brake Maintenance Preliminary Steps.................................................................13
Brake Adjustment.................................................................................................13
Brake Operation Check........................................................................................15
Lubrication............................................................................................................15
Periodic Inspections.............................................................................................16
Service Intervals...................................................................................................16
Section 3: Removal/Disassembly
Brake Assembly Removal....................................................................................17
Shoe Removal.................................................................................................17-20
Roller Removal................................................................................................21-23
Slack Adjuster Removal.......................................................................................24
Camshaft Removal...............................................................................................24
Air Chamber Bracket Removal.............................................................................24
Spider Removal....................................................................................................25
Dust Shield Removal............................................................................................25
Cleaning Brake Parts...........................................................................................26
Section 4: Inspection
Drum Inspection...................................................................................................27
Shoe and Lining Inspection.............................................................................28-29
Camshaft Radial Play Inspection.........................................................................30
Camshaft Inspection.............................................................................................30
Camshaft Bushing and Seal Inspection...............................................................30
Spider Inspection..................................................................................................31
Air Chamber Bracket Inspection...........................................................................31
Air Chamber Inspection........................................................................................32
Slack Adjuster Inspection.....................................................................................32
Section 5: Repair/Replacement
Camshaft Bushing/Grease Seal Replacement.....................................................33
Lining Replacement..............................................................................................34
Section 6: Installation/Assembly
Spider Installation.................................................................................................35
Dust Shield Installation (Two Piece).....................................................................35
Dust Shield Installation (One Piece).....................................................................36
Air Chamber Bracket Installation..........................................................................37
Camshaft Installation............................................................................................38
Cam Head Washer Installation.............................................................................39
Slack Adjuster Installation....................................................................................39
Shoe and Lining Installation.................................................................................41
Shoe Installation..............................................................................................42-47
Specification Chart ...........................................................................................48
3
General Information
MODEL COVERAGE
The service procedures and specifications in this
publication cover the Bendix® brake models listed in Table
1. The basic instructions cover all 15-in., 16.5-in., and
18-in. brake types and sizes, unless specified otherwise.
A breakdown of Bendix brake model identification is
provided in Figure 2.
Size
Bendix® ES™
Brake Model
in.
Configuration
mm
Shoe
Spider
Anchor
Applications
ES-150-04D
15.0 x 4
381 x 102
Fabricated
Cast
SAP
Steer Axles
ES-150-04L
15.0 x 4
381 x 102
Fabricated
Fabricated
SAP
Steer Axles
ES-150-08D
15.0 x 8.63
381 x 219
Fabricated
Cast
SAP
Drive Axles
ES-165-05D
16.5 x 5
419 x 127
Fabricated
Cast
SAP
Steer
ES-165-05L
16.5 x 5
419 x 127
Fabricated
Fabricated
SAP
Steer
ES-165-05X
16.5 x 5
419 x 127
Fabricated
Fabricated
SAP
Steer
ES-165-06D
16.5 x 6
419 x 152
Fabricated
Cast
SAP
Steer
ES-165-06L
16.5 x 6
419 x 152
Fabricated
Fabricated
SAP
Steer
ES-165-06X
16.5 x 6
419 x 127
Fabricated
Fabricated
SAP
Steer
ES-165-07D
16.5 x 7
419 x 178
Fabricated
Cast
SAP
Steer or Drive Axles
ES-165-07H
16.5 x 7
419 x 178
Cast
Heavy Cast
DAP
On/Off Hwy. Drive Axles
ES-165-07L
16.5 x 7
419 x 178
Fabricated
Fabricated
SAP
Steer or Drive Axles
ES-165-07M
16.5 x 7
419 x 178
Fabricated
Heavy Cast
DAP
On/Off Hwy. Drive Axles
ES-165-07X
16.5 x 7
419 x 178
Fabricated
Fabricated
DAP
Steer or Drive Axles
ES-165-07Z
16.5 x 7
419 x 178
Fabricated
Fabricated
DAP
Steer or Drive Axles
ES-165-08L
16.5 x 8.63
419 x 219
Fabricated
Fabricated
SAP
Drive Axles
ES-165-08D
16.5 x 8.63
419 x 219
Fabricated
Cast
SAP
Drive Axles
ES-165-08X
16.5 x 8.63
419 x 219
Fabricated
Fabricated
SAP
Drive Axles
ES-165-08Z
16.5 x 8.63
419 x 219
Fabricated
Fabricated
SAP
Drive Axles
Table 1 – Bendix® Brake Models and Specifications
Bendix® Brake Model Identification
Configurations
D - Fabricated Shoe/Cast Spider SAP
H - Cast Shoe/Heavy Cast Spider DAP
L - Fabricated Shoe/Fabricated Spider SAP
M - Fabricated Shoe/Cast Spider (DAP Closed A/P)
R - Cast Shoe/Heavy Cast Spider SAP
S - Reinforced Fabricated Shoe/Heavy Cast Spider SAP
X - Fabricated Shoe/Heavy Fabricated Spider SAP
Z - Reinforced Fabricated Shoe/Heavy Fabricated Spider SAP
ES-165-07X
Service
ES Extended Service
Drum Diameter
150 - 381 mm (15 in.)
165 - 419 mm (16.5 in.)
180 - 457 mm (18 in.)
  
Figure 2 – Bendix® Brake Model Identification
4
Shoe Size
04 - 102 mm (4 in.)
05 – 127 mm (5 in.)
06 – 152 mm (6 in.)
07 – 178 mm (7 in.)
08 – 219 mm (8.63 in.)
SAP - Single Anchor Pin
DAP - Double Anchor Pin
General Information
PARTS NOMENCLATURE
General parts nomenclature for Bendix® brake models are
identified in Figure 3. Exploded views of various brake
models are shown for part identification.
Large Clevis Pin Retaining Clip
Large Clevis Pin
Small Clevis Pin Retaining Clip
Small Clevis Pin
Bendix® ES™ Brake
ES-150-04D
Camshaft Retainer
Snap Ring
Camshaft Shim
Washer
Slack Adjuster
Slack Adjuster
Inner Washer
Grease Seal
Camshaft Bushing
Bracket Mounting Bolt
Lockwasher
Bracket Assembly
Grease Fitting
Camshaft Bushing
Grease Seal
Cam
Roller
Retainer
Shoe Return
Spring
Dust Shield Mounting Bolt
Dust Shield Inspection Plug
Retainer
Shoe Assembly
Dust Shield
Retainer Spring
Camshaft
Cam Head
Washer
Brake
Spider
Cam Roller
Shoe Assembly
Retainer Spring
Figure 3 – Brake Part Nomenclature
5
General Information
Bendix® ES™ Brake
ES-150-04L Brake
Large Clevis Pin
Retaining Clip
Camshaft Retainer
Snap Ring
Small Clevis Pin
Retaining Clip
Camshaft Shim
Washer
Large Clevis Pin
Small Clevis Pin
Grease
Fitting
Slack
Adjuster
Slack Adjuster
Inner Washer
Grease
Seal
Camshaft
Bushing
Bracket
Assembly
Stabilizer
Bolt
Stabilizer
Flat Washer,
Lockwasher &
Nut
Washer
Bolt
Bracket Bolt
Cam Roller
Return
Spring
Dust Shield Bolt
Dust Shield
Inspection Plug
Shoe Guide
Shoe Assembly
Shoe Assembly
Dust Shield
Cam Roller
Brake Spider
Camshaft
Retainer Spring
Shoe Hold
Down Spring
Bracket Bolt Nut
Bracket Bolt Washer
Figure 3 – Brake Part Nomenclature, Continued
6
Bendix® ES™ Brake
ES-150-08D
Shoe Assembly
Camshaft
Shim
Washer
Camshaft
Bushing
Bracket
Assembly
Slack
Adjuster
Slack Adjuster
Inner Washer
Cam Roller
Shoe Retainer
Spring
(Orange)
Grease
Seal
Retainer
Camshaft Retainer
Snap Ring
Grease Fitting
Camshaft
Bushing
Spider
(Stamped Steel)
Grease Seal
Shoe Return Spring
(White)
Cam Head Washer
Roller Retainer
Camshaft
Cam Roller
Shoe Assembly
Bendix ES Brakes
ES-165-05D
ES-165-05L
ES-165-05X
ES-165-06D
ES-165-06L
ES-165-06X
ES-165-07D
ES-165-07L
ES-165-07X
Cam Roller
ES-165-07Z
Roller
Retainer
ES-165-08D
ES-165-08X
ES-165-08Z
Large Clevis Pin Retaining Clip
Small Clevis Pin Retaining Clip
Large Clevis Pin
Small Clevis Pin
Camshaft Retainer
Snap Ring
Camshaft Shim Washer
Grease Fitting
Slack Adjuster
Slack Adjuster
Inner Washer
Grease Seal
Camshaft Bushing
Bracket Assembly
Camshaft Bushing
Grease Seal
Shoe Return
Springs
Bracket
Studs
Bracket Mounting Bolt
Lockwasher
Dust Shield Mounting Bolt
Dust Shield Inspection Plug
Dust Shield
Shoe Assembly
Cam Head Washer
Camshaft
Cam Roller
Retainer Spring
Spider
Shoe Assembly
Retainer Spring
Figure 3 – Brake Part Nomenclature, Continued
7
Bendix® ES™ Brake with Horse Collar
ES-165-06D
ES-165-06X
ES-165-07D
ES-165-07X
ES-165-07Z
Horse Collar
Small Clevis Pin
Slack Adjuster
Small Clevis Pin Retaining Clip
Large Clevis Pin
Retaining Clip
Large Clevis Pin
Camshaft Retainer
Snap Ring
Camshaft Bushing
Camshaft Shim Washer
Grease Fitting
Lockwasher
Shoe Return
Springs
Slack Adjuster Inner Washer
Grease Seal
Grease Seal
Bracket Assembly
Cam Roller
Roller Retainer
Camshaft Bushing
Dust Shield Mounting Bolt
Dust Shield Inspection Plug
Shoe Assembly
Dust Shield
Cam Roller
Cam Head Washer
Camshaft
Shoe Assembly
Retainer Spring Spider
Bendix ES Brakes
ES-165-07H
Severe-Duty
Brake
ES-165-07M
Heavy-Duty
Brake
Retainer Spring
Clevis Pin
Retaining Clip
Clevis Pin
Camshaft Retainer
Snap Ring
Bracket Assembly
Camshaft
Shim Washer
Grease Fitting
Camshaft Bushing
Nut
Slack Adjuster
Grounding Strap
Grease Seal
Slack Adjuster
Dust Shield
Camshaft Bracket
Support
Grease Seal
Camshaft
Roller & Pin
Spider
(M-version Cast)
Camshaft Bushing
Shoe Assembly
Dust Shield Mounting Bolt
Rubber Inspection Plug
Shoe Retainer
Springs
(Orange)
Camshaft
Roller & Pin
Shoe Assembly
Snap Ring
Washer
Anchor Pin Bushing
Lock Bolt
Safety Wire
Figure 3 – Brake Part Nomenclature, Continued
8
Washer
Washer
Washer
Anchor Pin Bushing
Snap Ring
Camshaft
Bendix® EB™ Brakes
EB-180-07R
Clevis Pin Retaining Clip
Slack Adjuster
Grounding Strap
Camshaft Retainer
Snap Ring
Clevis Pin
Nut
Bracket
Assembly
Grease
Fitting
Camshaft
Shim Washer
Slack Adjuster
Nut
Camshaft Bushing
Grease Seal
Slack Adjuster Inner Washer
Grease Seal
Camshaft Bushing
Dust Shield
Camshaft
Roller & Pin
Bolt & Washer
Dust Shield
Mounting Bolt
Camshaft
Rubber Inspection Plug
Camshaft
Roller & Pin
Shoe Assembly
Shoe Assembly
Nut
Washer
Friction Bolt
Shoe Retainer
Springs
(Orange)
Shoe Return Spring
(Green)
Spider
(Stamped Steel)
Figure 3 – Brake Part Nomenclature, Continued
9
Bendix® ES™-165 and EB™-165 Brake
Interchangeability
Brake parts for the Bendix® ES™ (Extended Service) brake
(Model ES-165) are unique and must not be intermixed
with the Bendix® EB™ Standard Brake parts (Model EB165) unless otherwise instructed. These parts consist
of the camshaft, camshaft washer, return spring, cam
roller, and shoe/lining assembly. Any attempt to operate
the brake with other than its intended parts may result in
unsatisfactory performance.
“On-Road” Repair: If a vehicle should need “On-Road”
repair and ES brake hardware is not available, it is
possible to retrofit the brake with Standard Brake parts in
order to return the vehicle to service. These parts consist
of the standard shoe/lining assembly, cam roller, pin, and
return spring. The retaining springs and camshaft with
cam washer will work in this situation and do not need
to be replaced.
(CW Rotation)
ES Brake Cam
EB Brake Roller
Normal
Contact
Pattern
Figure 4 – EB Brake Roller and ES Brake Cam Contact Pattern
and Camshafts
ES Brake Camshaft
28-Tooth Spline
EB Brake Roller and ES Brake Cam
Interchangeability
The EB Roller and the ES Cam are compatible and can
be used together. Figure 5 illustrates the proper fit of an
EB Roller to an ES Cam. As shown, the contact pattern is
at two points and the two parts will function satisfactorily
with this fit.
EB-180-07R Brake
The EB-180-07R brake uses the ES Brake cam and
standard service lining.
NOTE: The ES Brake roller and EB Brake cam are not
compatible and should not be used together.
10
10-Tooth Spline
Left-Hand Cam
(CW Rotation)
Figure 5 – ES Brake Camshafts
Right-Hand Cam
(CCW Rotation)
Bendix® brake model parts identification for shoes,
return springs, spiders, and camshafts are identified in
Figure 6.
Bendix® ES™-150-XXD, -XXF
Bendix® ES™-165-XXD, -XXL, -XXF
ES-150-04L
Old
ES-165-7D,L,F
Shoew/Spring
with Spring
Shoes
Attaching
Lugs
Attaching Lugs
New
Shoe without
Spring Attaching Lugs
8-3
Bendix® ES™ -165-07M
Bendix® ES™-165-07H
Bendix® EB™-180-07R
ES-165-07M
Double Anchor Pin
Double Anchor Pin
Double Anchor Pin w/Cam Roller
& Anchor Pin Bushings
Single Anchor Pin
8-4
Shoe Return Spring
Color Coded by Application
Blue
ES-150-04L
White
ES-150-08D, 08F
Grey
ES-165-05D, 05L, 06D, 06L,07D, 07L, 07F, 08D, 08L, 08F
Yellow
ES-165-07M
Orange
ES-165-07H
Red
ES-150-06D, ES-165-05D, 05L, 06D, 06L, 07D, 07L
Figure 6 – Parts Identification
11
Brake Spiders
Stamped Spider
Single Anchor Pin
NGHD
Stamped Spider
Single Anchor Pin
NGLW
NGHD
Thickness = 3/8 in.
Legacy Stamped Spider
Single Anchor Pin
NGLW
Thickness = 1/4 in.
Cast Spider
Single Anchor Pin
Spider Part No.
Location
Air Chamber
Bracket Flange
Shape for
Stamped Spider
Air Chamber
Bracket Flange
Shape for
Cast Spider
Spider Part No.
Location
Cast Spider Double
9-1
Anchor Pin
Spider Part No.
Location
Reduced Envelope Steer Brake
9-2 Spider
Cast
Single Anchor Pin
Spider Part No.
Location
Air Chamber
Bracket Flange
Shape for
Cast Spider
Air Chamber
Bracket Flange
Shape for
Cast Spider
Stamped Spider Bendix® ES™-150-04L
Reduced Envelope Drive Brake
Cast Spider
Single Anchor Pin
XX
XX
XX
XX
X
XX
Spider Part No.
Location
Air Chamber
Brake Flange Shape
for ES-150-04L
Air Chamber
Bracket Flange
Shape for
Cast Spider
Spider Part No.
Location
Figure 6 – Parts Identification, Continued
12
MAINTENANCE AND ADJUSTMENT
Due to the importance of a well-maintained brake system,
the inspections and maintenance shown here must be
completed by commercial vehicle operators at the intervals
suggested. Since driver technique and vehicle use affect
the rate of brake component wear, it may be appropriate
to increase the frequency of the following inspections to
fit individual needs based upon past experience.
Brake Maintenance Preliminary Steps
Prior to performing any maintenance requiring removal of
the tire and wheel, the following preliminary steps must
be taken to ensure your safety. See Figure 7.
1. Set the parking brake and block the wheels to prevent
vehicle movement.
Brake Adjustment - Automatic / Manual
Slack Adjuster
NOTE: An assistant is required to make a brake adjustment.
Block all wheels before beginning this adjustment
procedure.
To determine whether the Bendix® ES™ brakes require
adjustment, the applied stroke is measured and compared
to the maximum value for the air chamber size in use on
the vehicle.
1. Perform “Brake Maintenance Preliminary Steps”
described earlier.
2. With the air chamber pushrod fully retracted, measure
the distance from the face of the air chamber to the
centerline of the clevis pin hole. See Figure 8. If the
measurement is not within the ranges shown in Table
2, reposition the clevis. Remeasure the distance and
repeat until the measurement is within range. Record
the exact measured distance as dimension “A”.
A
Block Wheels
Measure this
Distance with
Chamber "At Rest",
Dimension "A"
Support on
Jack Stands
of Adequate
Capacity
Figure 7 – Vehicle Maintenance Support
2. Raise the drive axle with a jack and support it on
suitable stands.
Never work under a vehicle supported by a jack.
Figure 8 – Measurement, At Rest
3. Cage the spring-type brake chamber following vehicle
manufacturer’s instructions.
13
Periodic Service
3. Measure the applied free stroke using a lever, and
again measure from the face of the air chamber to
the clevis pin centerline. See Figure 9. Record the
distance as dimension “B”.
Measure Applied
Free Stroke using
a Lever
Dimension "B"
B
NOTE: If adjustment is necessary, Bendix® brakes are
adjusted to achieve proper free stroke. The difference
between free stroke and applied stroke is merely the
method used to move the slack adjuster from rest. Applied
stroke uses a 90-100 psi brake application; free stroke is
measured using a lever to move the slack adjuster until
the brake shoes contact the drum. If the applied stroke
exceeded the maximum and adjustment is necessary,
adjust the brakes as described in steps 5 through 7.
5. Apply 90-100 psi pressure and measure from the
face of the chamber to the center of the large clevis
pin. See Figure 10. Subtract dimension "C" from "A"
for the applied stroke at 90-100 psi. Refer to Table
2 for the maximum legal stroke for the chamber you
have.
Figure 9 – Measure Applied Free Stroke Using A Lever
4. Subtract dimension “A” from “B”. The difference is the
applied free stroke. Compare the applied free stroke
to the maximum value in Table 2. If the applied free
stroke equals or exceeds the maximum applied stroke
shown, adjust the brakes. If the applied free stroke
is less than the maximum value, no adjustment is
required and you may perform the Brake Operation
Check (page 15).
6. Verify that brakes are not dragging by spinning the
wheels by hand or tapping the drum lightly with a
hammer and listening for a sharp ringing sound.
7. Perform the Brake Operation Check (page 15), to
verify the proper operation of brakes before releasing
the vehicle for service.
C
Measure the
Applied Stroke
at 90-100 psi
Dimension "C"
90-100 PSI
Maximum
Applied
Stroke
Desired
Free
Stroke
Type 12
1-3/8 in.
3/8 in. to 1/2 in.
Type 16
1-3/4 in.
3/8 in. to 1/2 in.
Type 20
1-3/4 in.
3/8 in. to 1/2 in.
Type 24
1-3/4 in.
Air Chamber Size
Type 24 (w/ 2-1/2 in.
Extended Stroke)
Type 24 (w/ 3 in. Extended Stroke)
Type 30
Type 30 Long Stroke
Table 2 – Stroke Values
14
Figure 10 – Measure Applied Stroke at 90-100 PSI
2 in.
2.5 in.
2 in.
2.5 in.
3/8 in. to 5/8 in.
(Without Drag)
Periodic Service
PERIODIC INSPECTIONS
Brake Adjustment - Automatic Slack Adjuster
NOTE: A properly working Automatic Slack Adjuster
(ASA) does not require manual adjustment while in
service. The manual adjuster hex is intended for use
during adjuster installation and brake overhaul.
Automatic slack adjusters must never be repeatedly
adjusted to correct excessive in service pushrod stroke,
because this condition indicates that a problem exists
with the automatic adjuster, with the installation of the
adjuster, or with related foundation brake components
which manual adjustment will not correct.
1. Brake adjustment for automatic slack adjusters is the
same as for manual slack adjusters.
2. Refer to the automatic slack adjuster manufacturer's
instructions for proper installation.
Brake Operation Check
NOTE: An assistant is required to make a thorough brake
operation check.
1. Apply the brakes to 80 psi and hold. Check all air line
fittings and air chambers for leakage.
2. Apply and release the brakes while observing
operation of the slack adjusters on each axle. As the
brakes are applied and released, the slack adjusters
should move in unison visually.
3. Investigate the source and make corrections for any
discrepancies found in Steps 1 and 2.
4. Drive the vehicle at low speeds in a safe area and
make several brake applications to verify safe
operation and absence of pulling, grabbing, or noise.
If any of these are noted, investigate and repair prior
to releasing the vehicle for service.
Never release a vehicle for service if any brake
discrepancy – no matter how minor – is evident.
Lubrication
When servicing brakes or replacing components, lubricate
per the guidelines listed in Table 3 below. Lubricate the
following components with grease specified in the table
below:
• One-piece roller - lubricate the shoe roller recess
• Two-piece roller - lubricate the shoe roller I.D.
• Roller and anchor pin recesses of each shoe on
the Bendix® ES™-150-04L brake model.
Note: When lubricating the camshaft bracket, lubricate
until the grease comes out at the slack adjuster
end. The seal is installed at this end – with the air
side in – so that grease purges out.
Do not use moly-disulfide loaded grease or oil because
this may shorten the service life.
IMPORTANT
Do Not Lubricate The Following:
• The cam head surface or related parts that contact
the cam head surface. For efficient operation, the
cam head surface must remain free of oil, grease,
or other contaminants.
In no case should the lubrication interval exceed the
published intervals in the table below.
Slack Adjuster Lubrication: Pressure lubricate according
to the manufacturer’s instructions.
Component
Lubrication Interval
Type of Lubricant
Standard
Every 50,000 miles or every three (3) months
Standard Chassis Grease
Table 3 – Lubrication Intervals
15
Periodic Inspections
SERVICE INTERVALS
The component inspections discussed below are general
in nature. More detailed component inspections are
normally done at an overhaul. For more specific guidelines,
refer to the appropriate inspection instructions in Brake
Overhaul Service Interval on this page.
Brake Reline
Visual Inspection
Camshaft radial play should be checked with a dial
indicator any time the brake shoes have been removed
from the vehicle to assess the condition of the camshaft
bushings. Refer to Camshaft Inspection.
A thorough visual inspection for brake wear, loose
fasteners, broken parts, and/or obvious damage should
be made each time the brake is being serviced or the
wheel and drum have been removed. In no case should
the visual inspection interval exceed three (3) months
of service.
Lining Inspection
A visual check of lining thickness and condition 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 three
(3) months of service.
Brake Adjustment
Brake adjustment should be checked, (if the
adjustment is out of specification, inspection of all
brake components for damage or out of specification)
WEEKLY or any time the applied stroke exceeds the
maximums shown in Periodic Maintenance: Brake
Adjustment - Manual Slack Adjuster on page 13.
Brake Operation Check
A complete operation check of the braking system should
be made following the instructions in the Brake Operation
Check (page 15), after any brake service. In no case
should the operation check interval exceed three (3)
months of service.
16
A brake reline should be done any time the lining thickness
or condition indicates the need.
Camshaft Radial Play
Camshaft Axial Play
Camshaft axial play should be checked any time the
camshaft or slack adjuster has been removed from the
vehicle. Refer to the axial play instructions in Slack
Adjuster Installation, (page 39) starting with Step 6.
Brake Overhaul
A complete brake overhaul following the instructions in
the service manual should be accomplished at every
third brake reline.
Lubrication
See Periodic Service/Lubrication for detailed lube
instructions and intervals.
SHOE REMOVAL
A complete brake overhaul consists of:
• complete disassembly
• cleaning
• inspection
• repair and replacement of components
• assembly
• brake operation check
Detailed instructions for each of these steps are listed
on the following pages in the order in which they would
normally be encountered during a typical brake overhaul.
The long-term effects of non-asbestos fibers have
not been determined. Therefore, precautions should
be used when handling these materials. See General
Information / Lining Material Warning.
Turn the Adjuster Nut
counterclockwise to
"Back-Off" Adjustment
Figure 11 – Slack Adjuster Adjustment
Brake Assembly Removal
1. Perform “Brake Maintenance Preliminary Steps”.
2. Back off the slack adjuster per the manufacturer's
recommendations. See Figure 11. Continue turning
until the shoes are fully returned to the released
position and clear of the drum.
NOTE: Remove the wheels and brake drums per
manufacturer's recommendations.
3. Back the slack adjuster off (counterclockwise) until
the brake shoes are clear of the brake drum or the
slack adjuster comes to a stop.
17
SHOE REMOVAL
3. Using a large screwdriver or lever, lift the upper shoe
to stretch the return spring as shown in Figure 13.
Bendix® ES™-150-04D
ES-150-04L
ES-150-08D
ES-165-05D, L, X
ES-165-06D, L, X
ES-165-07D, L, X, Z
ES-165-08D, L, X
4. Remove the upper cam roller.
NOTE: For Bendix models ES-150-04D, L/ES-150-08D,
ES-165-05D, L,X/ES-165-06D, L, X/ES-165-07D, L, X, Z/
ES-165-08D,L,X. Remove the roller and roller retainer
as a unit.
1. Perform steps in Removal/Disassembly: Drum
Removal.
Lift Upper Shoe
to Stretch Spring
2. For Bendix models ES-150-04D/ES-150-08D/
ES-165-05,-06,-07,-08,D,L ONLY: Pry the roller
retainer coiled loops out of both shoe web holes as
shown in Figure 12. Pivot the roller retainer to swing
the loops clear of the shoe webs.
Remove Roller, Then
Repeat for Lower Shoe.
For ES Brakes, See Note Below
Shoe Web
Figure 13 – Upper Cam Roller & Pin Removal
Roller Retainer
5. Repeat Steps 2 through 4 to remove the lower shoe
roller and retainer.
Disengage
Retainer Coiled
Loops From
Shoe Webs
Pivot Retainer to
Swing Loops Clear
of Shoe Web
Figure 12 – Roller Retainer Removal
The long term effects of non-asbestos fibers have
not been determined. Therefore, precautions should
be used when handling these materials. Refer to the
General Information / Lining Material Warning.
18
NOTE: Bendix recommends the use of a suitable brake
tool when removing the rollers and the return springs.
6. Push the cam end of both shoes toward the cam and
unhook the shoe return spring. Remove and discard
the spring.
Stretch Using Suitable
Tool Positioned as Shown
Brake Assembly Inspection
1. Clean the brake spider, anchor pin, and cam head.
2. Inspect all fasteners, spider mounting, cam bracket,
and chamber mounting bolts.
3. Inspect all welds for cracks.
4. Measure the cam-bushing radial play and cam endplay.
5. Replace out-of-spec parts as needed.
Figure 14 – Bendix® ES™-165-07D, L Shoe Removal
NOTE: To remove the return spring, position a lever or
suitable tool – with a notch – to engage the spring rod.
Refer to Figure 14. Apply a downward force to stretch
the spring, allowing removal of the upper spring hook.
Remove and discard the spring.
7. Rotate both shoes around the anchor pin and
remove them from the vehicle. Refer to Figure 15.
Rotate Both Shoes
Around Anchor
Pin and Lift Off
Brake Shoes
Figure 15 – Shoe Removal
8. Clean and inspect the remaining parts as outlined in
the removal/disassembly section of this manual.
NOTE:  Bendix ®   ES ™ -150-06D / ES-165-05D,L,X /
ES-165-06D,L,X/ES-165-07D,L,X,Z / ES-165-08Z: steer
axle brakes may use two return springs with a horse
collar or dual spring post. To remove the return springs,
position a lever or suitable tool – with a notch –to engage
the spring. Refer to Figure 14. Apply a downward force
to stretch the upper spring, allowing removal of the
upper spring hook. Remove and discard. Repeat the
procedure for the lower spring.
Cast Spider w/
Horse Collar
Figure 16 – Cast Spider With Horse Collar
19
Bendix® ES™-150-04L Brake
1. Perform the steps in Removal/Disassembly: Drum
Removal.
2. Using a large screwdriver or lever, lift the upper shoe
to stretch the return spring.
3. Remove the upper roller.
The long term effects of non-asbestos fibers, have
not been determined. Therefore, precautions should
be used when handling these materials. Refer to the
General Information / Lining Material Warning.
4. Repeat steps 2 through 3 to remove the lower roller.
Unhook the
Retaining Spring
5. Stretch the shoe return spring and unhook it from the
upper shoe web. Refer to Figure 18.
6. Rotate the shoe downward and turn it to allow
disengagement of the shoe retaining spring from the
lower shoe web. Refer to Figure 17.
Stretch Spring to
Unhook from the
Shoe Web
Rotate Down
Figure 18 – Lower Shoe Removal
Shoe Return
Spring
Figure 17 – Shoe Return Spring Removal
7. Rotate the upper shoe upward and remove the shoe
and shoe retaining spring.
8. Clean and inspect the remaining brake parts as
outlined in the Removal/Disassembly section of this
manual.
20
ROLLER REMOVAL
Bendix® ES™-165-07M Heavy-Duty Brake
3. To remove the upper and lower shoes, remove the
anchor pins with a brass drift or a mallet. Refer to
Figure 21.
1. Remove the retaining ring and washer from the drum
side of both anchor pins. Refer to Figure 19.
Remove
Retaining Rings
and Washers
Figure 21 – Anchor Pin Removal
Figure 19 – Retaining Ring and Washer Removal
2. To allow removal of the anchor pins, cut the lockwire
and remove the cap screws from the spider. Refer to
Figure 20.
NOTE: Inspect the anchor pin and bushings. If the pin
was seized, or if the bushing is grooved or worn beyond
0.031-in. (0.79mm), replace the pin and bushing. Always
replace the pins and bushings with each brake reline.
Cut the Lockwire
and Remove
the Cap Screws
Drive Out Bushings
with a Suitable
Driver
Figure 20 – Cap Screw Removal
Figure 22 – Anchor Pin Bushing Removal
4. If any noted conditions are found, drive out the
old anchor pin bushings from the spider. Refer to
Figure 22.
5. Clean and inspect the remaining brake parts as
outlined in the Removal/Disassembly section of this
manual.
21
Bendix® ES™ -165-07H Severe-Duty Brake
5. Remove the upper anchor pin with a brass drift or a
mallet. Refer to Figure 25.
The long term effects of non-asbestos fibers, have
not been determined. Therefore, precautions should
be used when handling these materials.
Refer to the General Information / Lining Material
Warning
Drive Out
Anchor Pin
1. Perform the steps necessary for drum removal, see
Removal/Disassembly: Drum Removal.
2. Remove the cap screws and dust shield, if applicable.
3. Remove the retaining ring and washer from the drum
side of each anchor pin. Refer to Figure 23.
Remove Retaining
Rings & Washers
Figure 23 – Retaining Ring and Washer Removal
4. To allow removal of the anchor pin, cut the lockwire
and remove the cap screws from the spider. Refer
to Figure 24.
Cut the Lockwire
and Remove the
Cap Screws
Figure 25 – Anchor Pin Removal
6. Rotate the upper shoe around the cam end,
disengage the roller end from the cam, then unhook
the return spring from the shoe and remove the upper
shoe. Refer to Figure 26. Discard the return spring.
Rotate Upper
Shoe Around
Cam End
Disengage Shoe
End from Cam then
Unhook the Return
Spring and Remove
the Shoe
Figure 24 – Cap Screw Removal
Figure 26 – Shoe Removal
22
7. Remove the lower anchor pin to remove the lower
shoe.
NOTE: Inspect the anchor pin and bushings. If the pin
was seized, or if the bushing is grooved or worn beyond
0.031-in. (0.79mm), replace the pin and bushing. Always
replace the pins and bushings with each brake reline.
9. Do not remove the roller from the brake shoe, unless:
the roller does not roll freely; there are flat spots on
the roller; or there is more than 0.025-in. play between
the roller and pin. If removal of the roller is necessary,
use a steel punch to drive out the groove pin, then
push the pin out of the shoe. Discard the roller and
pin. Refer to Figure 28.
8. Drive out the old anchor pin bushings from the
brake shoe and spider with a suitable driver. Refer
to Figure 27.
Drive Out
Groove Pin
Drive Out
Bushings with
Suitable Driver
Figure 28 – Groove Pin Removal
10. Clean and inspect remaining brake parts as outlined
in the Removal/Disassembly section of this manual.
Drive Out
Bushings with
Suitable Driver
Figure 27 – Anchor Pin Bushing Removal
23
SLACK ADJUSTER REMOVAL
1. Remove the cotter pin/retaining clip and clevis pin
from the air chamber pushrod clevis.
2. Turn the adjuster nut counterclockwise until the slack
adjuster is clear of the air chamber pushrod clevis.
Refer to Figure 29.
Remove
Snap Ring
Use Puller
to Remove
3. Remove the snap ring and outer shim washer(s) from
the camshaft.
4. Note the orientation of the slack adjuster with
reference to the pushrod before removal to ensure
assembly is in the proper orientation. Remove the
slack adjuster with a suitable puller.
Do not hammer on the slack adjuster to remove!
Damage to the slack adjuster and/or camshaft splines
may result.
Camshaft Removal
1. Under certain situations the hub will need to be
removed before the camshaft removal. NOTE: follow
the hub manufacture guidelines for removal.
2. Grasp the camshaft head and pull the camshaft
outboard to remove.
Rotate the Slack Adjuster
Until it is Clear of the Clevis
Figure 29 – Slack Adjuster Removal
NOTE: Follow the manufacturer’s instructions for selfadjusting slack adjusters.
Air Chamber Bracket (S-Cam Bracket)
Removal
1. Perform all steps for drum, shoe, slack adjuster,
and camshaft removal as outlined in the Removal /
Disassembly section.
2. Disconnect the chamber air line.
Bendix® Versajust® LS
Automatic Slack Adjuster
Bendix® Versajust® GS
Automatic Slack Adjuster
Figure 30 – Bendix® Versajust® Automatic Slack Adjusters
3. Remove the attaching fasteners and pull the air
chamber bracket away from the spider. NOTE: On
16.5-in. diameter brakes with stamped spiders, the
air chamber bracket-to-spider "ribbed" studs are
pressed into the spider. Their removal is not required
to remove the air chamber bracket (do not attempt
to remove these studs from the spider). See Figure
31. If a stud is damaged or broken, the spider should
be replaced.
Stamped Steel Spider
and Pin Assembly
Washer
Stud
Figure 31 – S-Cam Bracket Removal
24
Nut
Bracket Assembly
Removal / Disassembly
NOTE: On the Bendix® ES™-150-04L brake, a stabilizing
nut has to be removed. The bracket-to-spider studs are
welded into the air chamber bracket flange. Their removal
is not required to remove the air chamber bracket.
To prevent personal injury, be sure to “cage” the spring
before removing the spring brake type air-chambers.
NOTE: For information on slack adjuster removal, refer to
the slack adjuster manufacturer's service manual.
Dust Shield Removal
NOTE: On Bendix® ES™-165-07H, M Brakes, the dust
shield must be removed before the shoes and anchor
pins are removed.
1. If applicable, remove the screws and the retaining
clip. Remove all screws attaching the dust shield to
the spider (4-6 screws depending on model). Refer
to Figure 33.
2. Remove the dust shield.
Spider Removal
1. Perform all steps for drum and shoe removal as
outlined in the Removal / Disassembly section.
2. Remove the spider-to-axle attachment nuts and bolts.
Refer to Figure 32.
T
3. Remove the spider.
Figure 33 – For All 165-XX Models
Remove All
Four Screws
Dust Shield
Figure 32 – Dust Shield Mounting Hardware Removal
25
CLEANING BRAKE PARTS
After removing the brake parts to be serviced, the following
cleaning procedures should be followed:
1. With a wire brush, clean all parts exposed to mud,
road dirt, and salt, including the spider, air chamber
bracket, dust shields, and the exterior of the drum.
A layer of oxidation and dirt on the outside of a brake
drum acts as an insulator and may hinder normal heat
dissipation.
2. Remove excessive deposits by wire brushing.
3. Use a vacuum cleaner to remove the brake dust
from the drums. Wipe the interior of the drums with
a greaseless solvent to remove any spilled oil.
26
The long term effects of non-asbestos fibers have
not been determined. Therefore, precautions should
be used when handling these materials. Refer to the
General Information / Lining Material Warning.
INSPECTION
Drum Inspection
Clean all remaining brake parts thoroughly with a suitable
shop solvent. Wipe dry with a clean, lint-free cloth.
NOTE: This information is general in nature. For specific
brake drum inspection guidelines, refer to the drum
manufacturer’s instructions.
1. Check for cracks, heat-checks, glazing, grooving, runout, and out-of-round. Refer to Figure 34. Cracked
drums must be replaced. Drums which are glazed,
grooved, out-of-round, etc., may be returned to
service if they can be repaired without exceeding
manufacturer’s maximum diameter or run-out
specifications.
Bendix does not recommend the turning or reboring of
brake drums. The reduction of wall thickness reduces
the amount of thermal energy that can be absorbed
by the drum during braking. Also, the decrease in wall
thickness increases the amount of deflection for the same
input load. Both of these are undesirable. If the drums
are refaced or oversized, the new diameter MUST NOT
exceed the maximum diameter marked on the drum
during its service life.
Check for Cracks,
Heat Checks, Glazing
and Grooving
Check Diameter
and
Out-of-Round
Figure 34 – Drum Inspection
2. Check the drum diameter. Replace the drum if it
exceeds the maximum diameter stamped in the drum.
Under no circumstances should the drum be used if it
exceeds the manufacturer’s recommended maximum
diameter or run-out specification.
27
Shoe and Lining Inspection
1. Check the shoes for bent or cracked webs or table,
broken welds, loose rivets, or elongated rivet holes.
Refer to Figure 35. If any issues are found, replace
the shoes with Bendix® OEM-grade lining and shoe
assemblies.
Check Table and Web for Cracks and Bends
Check Both Ends
for Wear and
Elongation
Anchor
Pin End
See Chart for
Specifications
Roller End
Figure 35 – Shoe & Lining Inspection
2. Check the anchor pin and cam roller contact areas
in the shoe webs for elongation or wear. Replace
the shoe if the diameter exceeds the following
specifications.
Bendix® ES™ Brake Model
All ES-165, ES-150-04D,
Roller End
Anchor Pin
End
0.836 in.
1.400 in.
0.774 in.
1.280 in.
ES-150-06D, ES-150-08D, F
ES-165-07M
3. For Bendix® ES™-165-07H severe-duty brake only:
Anchor pin bushings are mounted in these brake
shoes. Refer to Inspection-Spider Inspection (Double
Anchor Pin) for instructions.
NOTE: The two-piece roller and pin are mounted in the
brake shoes for the -07H model brake. Do not remove
the roller and roller pin unless: the roller does not roll
freely;there are flat spots on the rollers; or there is more
than 0.025 in. play between the roller and the pin. Replace
the roller and the pin if these conditions are found.
4. Check the linings and replace with Bendix OEM-grade
shoe and lining assembly if contaminated, cracked,
or worn to less than 1/4-in. (6.4mm) thickness at any
point (see instructions that follow) or 3/16 in. (4.5mm)
for the Bendix® ES™-150-04L brake.
28
NOTE: To eliminate premature lining replacement, Bendix
recommends the use of the Bendix® ES™ Brake Lining
Wear Gauge to accurately measure lining thickness. This
tool is available through Bendix as BW7261.
Important: The wear gauge is for use with air actuated
cam brakes where minimum allowable lining thickness
is 1/4-in. (NOTE: Do not use for strip linings on 15 x 4
brakes or similar brakes.)
5. With the brake
not applied,
place the tip
of the gauge
between the two
lining blocks,
between the
top of the shoe
table and the
drum. Use the
gauge to scrape
away any mud, rust, or other contaminants that could
interfere with proper lining measurement.
6. Remove the gauge from the brake.
7. With the vehicle’s brakes applied, try to put the gauge
between the two lining blocks and the top of the shoe
table. Note the “hook” of the gauge allows insertion
around a worn drum lip. If the tip of the gauge will not
fit between the brake drum and the top of the shoe
table, the lining is worn below 5/16-in. and will need
to be replaced.
8. I f t h e t i p o f
the gauge fits
between the
brake drum and
the shoe table,
the lining is not
worn below 1/4in. at this time.
9. Because brake
shoes can wear
at different rates,
check both shoes on each brake and all brakes on
the vehicle.
The long term effects of non-asbestos fibers, have not
been determined. Therefore, precautions should be used
when handling these materials. Refer to the General
Information / Lining Material Warning.
New- ES-150-08D & 06D
ES-165-07D & L
(Extended Service)
• When the Bendix® ES™ Extended Service linings
require replacement due to normal wear, the lining
thickness will be uniform all along its length.
Wearable
Lining
Remaining
Lining
Minimum
Thickness
At Any Point
1/4 in. (6.4mm)
Worn ES-150-04D, ES-150-08D, F &
ES-150-06D, ES-165-07D, L & F
(Extended Service)
Wearable
Lining
Remaining
Lining
Minimum
Thickness
At Any Point
3/16 in. (4.5 mm)
Worn ES-150-04L
(Extended Service)
Figure 36 – Brake and Lining Blocks
29
Camshaft Radial Play Inspection
Camshaft Inspection
The camshaft radial play should be checked any time
the brake shoes have been removed from the vehicle.
Refer to Figure 37.
1. Refer to Figure 38. Check the spline end for cracks,
worn, or deformed splines. Replace as necessary.
1. Mount a suitable dial indicator (with a plunger),
referencing the cam head at the roller contact area.
2. Set the dial indicator to zero.
3. Move the cam head up and down and note the
maximum reading.
4. If the play exceeds 0.035-in. (0.91 mm), rebush the
air chamber bracket. See Repair/Replacement Camshaft Bushing and Grease Seal Replacement.
2. Check the camshaft bushing journals for wear and
corrosion. Replace the camshaft if it shows visible
wear or if roughness is felt in the journal areas.
3. Inspect the camshaft head for brinelling, cracking, or
flat spots. Replace the camshaft if a ridge can be felt
between the worn areas and the cam head surface.
Check for Cracks, Wear, or
Deformed Splines
If More Than .035 in.
(.91mm), Replace
Bushings and
Recheck
Check for Wear,
Roughness, and
Corrosion
Check for Wear,
Cracks, and
Flat Spots
Figure 38 – Camshaft Inspection
Move Camshaft,
Note Maximum
Deflection
Camshaft Bushing and Seal Inspection
Figure 37 – Camshaft Radial Play Inspection
27-1
30
NOTE: Steer and drive axle camshaft bushings and seals
are mounted in the air chamber bracket assembly.
1. Check the bushing for deterioration or wear. The
inner surface must be smooth. If the surface is
rough or abrasive, replace the bushing, see Repair/
Replacement - Camshaft Bushing and Grease Seal
Replacement.
2. Inspect the grease seals. Replace the seal if the lip
is nicked, cut, or distorted. See Repair/Replacement
- Camshaft Bushing and Grease Seal Replacement.
Spider Inspection (Single Anchor Pin)
Spider Inspection (Double Anchor Pin)
1. Visually inspect for cracks around the mounting bolt
holes, in the cam area, and around the anchor pin.
Refer to Figure 39. Replace the spider if any are
found.
1. Visually check for cracks around the mounting bolt
holes and cam and anchor pin areas. Replace the
spider if any are found.
2. Check the anchor pin. If it is loose or grooved more
than 0.031-in. (0.79mm) below the original surface,
replace the spider assembly.
NOTE: Anchor pins are not replaceable on single anchor
pin brake spiders.
3. On the Bendix® ES™-150-04L brake, check the anchor
pin retaining nut torque. Refer to the last page of this
manual for current torque values.
Check for Cracks
2. Check the anchor pin and bushings for wear, grooves,
and free movement of the pin. If the pin is seized,
worn, or grooved beyond 0.031-in. (0.79mm), replace
the pin and bushing. Refer to the Shoe Removal and
Installation Sections for the procedure.
NOTE: Replace the pins and the bushings at each brake
reline.
Air Chamber Bracket Inspection
1. Check for a bent, broken, or cracked arm and cracked
welds. Refer to Figure 40. Replace the bracket if any
are evident.
2. Check the mounting studs (or bolts) for looseness,
damaged threads, or a bent condition. Replace the
mounting stud if any of these conditions are evident.
NextGen Flange
NGHD
Legacy Flange
Check Busings
and Seals
NGLW
Check for Grooved or
Loose Anchor Pin
Figure 39 – Spider Inspection
SPECIAL NOTE: ES-150-04L R.H. brakes use a
right-hand thread anchor pin retaining nut and L.H.
brakes use a left-hand thread nut. Ensure that the nut
is being turned in the proper direction when checking
the nut torque.
Check Welds
Check for Bending
or Cracks
Figure 40 – Air Chamber Bracket Inspection
If the anchor pin turns while checking the retaining
nut torque, the spider assembly must be replaced.
31
Air Chamber Inspection
Slack Adjuster Inspection
To prevent personal injury, be sure to “cage” the spring
before removing the spring-brake type air chamber.
NOTE: This information is general in nature. For specific
manual or self-adjusting slack adjuster inspection
guidelines, refer to the manufacturer’s instructions.
1. Check the clevis pin bushing for cracks and wear.
Refer to Figure 42. Replace as necessary.
NOTE: This information is general in nature. For
specific air chamber inspection guidelines, refer to the
manufacturer’s instructions.
1. Check for air leaks, cracked housing, a bent pushrod,
a loose clamp ring, clogged vent holes, or a loose
air fitting. Repair or replace as recommended by the
manufacturer.
2. If the air chamber is repaired or replaced, check the
distance from the clevis pin hole centerline to the
air chamber face. Refer to Figure 41 and Table 4
for manual slack adjusters. For self-adjusting slack
adjusters, refer to the manufacturer's guidelines.
Tighten Jam Nut
After Adjusting
Threaded Pushrod
See
Table 4
Welded Clevis
Figure 41 – Air Chamber Inspection
Distance: Clevis Pin Hole Centerline
to Air Chamber Face
All brakes (for threaded clevis)
2-5/8 in. ± 1/16 in.
(66.7 ± 1.59 mm)
2-1/4 in. ± 1/16 in.
(57 mm ± 1.59 mm)
Table 4 – Air Chamber Clevis Dimensions
3. If a new air chamber is installed, ensure that the cutoff pushrod does not project too far into the clevis.
Minimum clearance: clevis-centerline-to-pushrod-end
should be 7/8-in. (22.2 mm).
4. Check the clevis pin for cracks and wear.
32
Check Overall
for Cracks
Check for
Cracks or
Worn Splines
Check for Worn
Clevis Pin
Bushing
Figure 42 – Automatic Slack Adjuster Inspection
See
Table 4
Welded Clevis
2. Check the splines for chipped teeth and deformation.
Replace the slack adjuster if necessary.
3. Turn the slack adjuster adjustment nut with a
wrench – at least one turn in each direction. If binding
is present, or if excessive force is required to rotate,
replace the slack adjuster. If binding is present,
consult with the manufacturer's literature to determine
if the slack adjuster needs serviced or replaced.
If any of those conditions are found, consult with the
manufacturer's literature to determine if the slack
adjuster needs serviced or replaced.
Repair / Replacement
Camshaft Bushing/Lining Replacement
Routinely replace lower-cost items – such as springs,
seals, bushings, and heavily-worn, but unbroken parts.
If these components aren't replaced routinely, more
extensive damage may result.
Camshaft Bushing/Grease Seal
Replacement
1. Remove the air chamber bracket, see Removal/
Disassembly - Air Chamber Bracket Removal.
2. Drive out the old bushings and grease seals with a
suitable driver.
5. Install new grease seals with a suitable piloted driver
so that the seals are flush with the end of the air
chamber bracket tube. Refer to Figure 44.
Seals must be installed as indicated so that the lip
side (with spring) of both seals faces toward the slack
adjuster end of the bracket. Improperly oriented seals
may allow grease to exit camshaft head end of the air
chamber bracket and contaminate the lining material.
Install Seals Flush
with End of Tube
3. Clean and inspect the air chamber bracket, see
Inspection - Air Chamber Bracket Inspection.
4. Install new bushings in the air chamber bracket (Drive
and Steer Axles) with a suitable piloted driver. For
identification and installation specifications, refer to
Figure 43.
At Cam Head End,
Recess Bushing
9/32 in. (7.1 mm)
Lip Side of Both Seals
Must Face Toward the
Brake Adjuster End of
the Bracket
Figure 44 – Camshaft Bushing Installation
30-2
All Bendix Brakes
At Slack Adjuster
End, Recess Bushing
22/32 in. (17.5 mm)
Figure 43 – Air Chamber Bracket Bushing Installation
30-1
33
Repair / Replacement
Lining Replacement
The long-term effects of non-asbestos fibers have
not been determined. Therefore, precautions should
be used when handling these materials. Refer to the
General Information / Lining Material Warning.
NOTE: Reline the brakes when the inspection indicates
replacement is necessary, see Inspection - Shoe, and
Lining Inspection. When replacing the lining only, make
sure the shoes are in good condition. For replacement,
use only Bendix® OEM-grade linings or shoe and lining
assemblies.
1. Remove the shoe and lining assemblies.
2. Remove the lining blocks.
• If the blocks are bolted, use suitable tools to remove
the bolts and discard.
• Inspect the shoe to be sure it can be reused.
ES-180 Brakes
(Lining Bolted To Shoe)
Figure 45 – Bolt on Lining Tightening Sequence
34
3. Clean the shoe with solvent if necessary. Using a wire
brush, clean the shoe table. Paint with rust inhibitive
paint.
4. Install the lining blocks.
NOTE: When installing linings or blocks, make sure they
are positioned properly to match the rivet or bolt patterns.
Refer to Figure 45.
For Bolted Linings: Using the machine screws provided
in the lining kit, assemble the blocks to the shoes in the
sequence shown in the illustration for Bendix® EB™-180
brakes. Torque the nuts as specified on the instructions
provided within the lining kit.
5. Check the lining installation by trying to insert a
.006-in. (.15 mm) feeler gauge between the lining
and the shoe table along the edges. It should not
be possible to insert a feeler gauge in this manner
anywhere along the edge with the exception of the
outside ends beyond the last row of rivets. A larger
clearance may exist in these areas.
Spider Installation
SPECIAL NOTE: For the Bendix® ES™-150-04L
brake, distinct right-hand (R.H.) and left-hand (L.H.)
spider assemblies must be used. Although similar in
appearance, differences exist in the anchor pin and
retaining nut threads - L.H. brake uses L.H. threads
and R.H. brake uses R.H. threads.
3. Reposition the dust shield, as required, to allow a
uniform space of 1/8-in. (3.2 mm) all along the parallel
mating edges. Refer to Figure 47.
4. Torque the attaching screws to the proper
torque; see the Specifications chart.
T
Ensure Uniform
1/8 in. (3mm) Gap
1. Verify the spider is serviceable, see Spider
Inspection.
2. Verify that the spider is the correct part number for
the axle being serviced.
3. Position the spider on the axle flange and install
attaching the bolts and nuts.
NOTE: Use hardened washers under the bolt heads.
4. Sequentially torque the nuts according to the
manufacturer’s specifications, Refer to Figure
46.
T
T
Figure 47 – Dust Shield Spacing
32-3
SPECIAL NOTE: For the ES-150-04L brake, a designed
interference fit at the upper dust shield to the air chamber
bracket area may cause the need to deform the upper
dust shield by hand, slightly, to allow the upper dust
shield half to align properly with the lower half. Refer
to Figure 48.
Tighten All Bolts
According to
Manufacturer's
Instructions
Figure 46 – Installing Spider Mounting Hardware
Dust Shield Installation
(Two Piece)
32-1
NOTE: On Bendix® ES™-165-07H, M Brakes, the dust
shield is installed after the shoes and anchor pins are
installed, see Installation/Assembly - Shoe Installation.
Designed
In
Interference
Figure
48 – Designed
Interference Fit
These Areas
1. Place both dust shield halves into position against
the spider. Install all attaching screws finger tight.
2. Install the retaining clip and screws, if applicable.
32
35
Installation / Assembly
Dust Shield Installation
1. Position the dust shield against the spider and install
the screws finger tight.
2. Torque the attaching screws to the proper
torque; see the Specifications Chart and
Figures 49 and 50.
T
Figure 49 – Attaching Screw Location
T
Figure 50 – Attaching Screw Location
36
T
Air Chamber Bracket (S-Cam Bracket)
Installation
Bendix® ES™-150-04L Brake
1. Verify that the air chamber bracket is serviceable,
see Air Chamber Bracket Inspection, page 31.
For Stamped Steel Spider
2. Orient the bracket to align the mounting studs with
the holes in the bracket.
•
 osition the bracket against the spider and
P
install the hardened washers and nuts. Use only
approved washers. See Figure 51.
•
 orque the stud nuts to the proper torque.
T
Refer to the Specifications Chart.
T
2. Orient the bracket to align the stabilizing screw with
the slot in the spider and the mounting studs with the
holes in the spider.
3. Position the bracket against the spider and install the
lock washers and barrel (or standard) nuts on the
mounting bolts. Refer to Figure 52.
NOTE: Two brake shoe hold-down spring designs are
used on the Bendix® ES™-150 brakes, see General
Information - Parts Nomenclature.
4. Torque the standard nut to the proper torque.
Refer to the Specifications Chart.
For Cast Spider
3. Orient the bracket to align the bracket holes with the
tapped holes in the spider.
•
 osition the bracket against the spider and install
P
the bolts and lock washers.
•
 orque the bolts to the proper torque.
T
Refer to the Specifications Chart.
T
4. If the air chamber was removed, install the
chamber and tighten the nuts to the correct
torque. Refer to the Specifications Chart.
T
Stamped Steel Spider
and Pin Assembly
1. Verify that the air chamber bracket is serviceable.
Refer to Removal/Disassembly - Air Chamber Bracket
Removal.
Washer
Stud
Bracket Assembly
T
5. Install the plain washer, lock washer, and nut on the
stabilizing screw.
6. Torque the nut to the proper torque, see the
Specifications chart.
T
T
T
Nut
Figure 52 – Air Chamber Bracket Mounting Hardware
33-1
Figure 51 – S-Cam Bracket Installation
37
Camshaft Installation
NOTE: The camshaft mounting and related parts vary
with brake models. Be sure to follow the instructions for
special parts when installing the camshafts.
CAST
SPIDER
STAMPED
SPIDER
1. Verify that the camshaft is serviceable and is the
correct part for the application, see Inspection Camshaft Inspection.
Ensure the camshaft being installed is correct for
the application.
3. Apply a thin film of chassis grease on the inside of
the camshaft bushing and seals, and on the spline
area of the camshaft.
STAMPED
SPIDER
Note: For ES-150-08D & 06D
brakes: position the cam head
washer under the cam head
with the "CAST SPIDER" arrow
pointing away from the center of
the spider.
Stamped Spider: Position the
Cam Head Washer Under the
Cam Head with the “STAMPED
SPIDER” Arrow Pointing Towards
the Center of the Spider.
CAST
SPIDER
2. To ensure that camshaft being installed is correct for
the application, rotate the camshaft in the direction
of air chamber pushrod extension and check that the
roller starts to ride up on the convex side of the cam
head. Refer to Figure 53.
Cast Spider: Position the cam
head washer under the cam head
with the “CAST SPIDER” Arrow
Pointing Toward the Center of
the Spider.
Figure 54 – Cam Head Washer Installation
Do not grease the cam head surface. For efficient
operation, this surface must remain free of oil, grease,
or other contaminants.
4. Carefully slip the camshaft into the mounting position.
SPECIAL NOTE: For the Bendix® ES™-165-07M, H install
the flat washer adjacent to the cam head before installing
the camshaft.
SPECIAL NOTE: For ES-165-05,06,07 DL steer axle
brakes using the horse collar spring retention system,
position the cam head washer with the “stamped spider”
34
arrow pointing towards the center of the spider. The horse
collar should be placed over the cam tube first, then the
ES washer, and finally the cam. Refer to Figure 55.
ES-165-05,06,D,L / ES-165-07,08,X,Z
On ES-165-05/06/07,08D, L, brakes the camshafts use a
special washer between the cam head and the spider. It
is important that this washer be installed correctly. Refer
to Figure 54.
Figure 55 – Horse Collar Retention System
Rotate Camshaft
Toward the Pushrod
Extension . . .
Figure 53 – Camshaft Installation
33-2
38
. . . Roller Should
Ride Up on the Convex
Side of the Cam Head
CAMSHAFT BUSHING/LINING
REPLACEMENT
Cam Head Washer Installation
Slack Adjuster Installation
1. Verify that the slack adjuster is serviceable, see
Inspection - Slack Adjuster Inspection.
2. Install the slack adjuster inner washer on the
camshaft. The inner washer is identified by its 0.060Camshaft
Shim Washers
5. Install the camshaft shim washers and snap ring.
Refer to Figure 56. Check and adjust the camshaft
axial play. See Step 6.
NOTE: The camshaft axial play must be checked before the
camshaft installation is complete. Follow the instructions
below.
6. Mount a suitable dial indicator with the plunger
referencing the end of the cam head. Refer to
Figure 57.
7. Pull inboard on the slack adjuster end of the cam to
take up the end play.
8. Set the dial indicator to zero.
9. Push outboard on the slack adjuster end of the cam
and note the maximum reading. If necessary, add
or delete camshaft shim washers to obtain end play
between 0.005 in. - 0.045 in. (0.13 mm - 1.14 mm) with
the slack adjuster centered between the air chamber
bracket and the snap ring groove.
Install
Snap Ring
10. Pressure lubricate the slack adjuster according to
the manufacturer’s instructions. Pressure lubricate
the air chamber bracket until grease flows out of the
slack adjuster end of the tube. Refer to Figure 58.
Thick Washer with
Large Hole Here
(Behind the Slack
Adjuster)
Figure 56 – Shim Washer and Snap Ring Installation
in. thickness and larger hole. Refer to Figure 56.
3. Apply a thin film of chassis grease to the slack
adjuster splines.
4. Install the slack adjuster on the camshaft in the same
position as noted before removal.
Grease should not flow out the end of tube toward the
cam head. If it does, the seal is defective and must
be replaced.
Do not replace the existing grease fitting with a
pressure relief type. Only standard non-vented fittings
are to be used with spring loaded lip seals.
Lubricate the Slack
Adjuster with
Chassis Grease
Move Camshaft and Note
the Maximum Deflection
No Less Than 0.005 in. (0.13 mm)
No More Than 0.045 in. (1.143 mm)
Figure 57 – Slack Adjuster End Play Check
35-2
Rotate the Adjuster Nut Until
the Slack Adjuster is Aligned
with the Clevis Hole
Figure 58 – Slack Adjuster Lubrication and Adjustment
35-3
39
Installation / Assembly
CAMSHAFT BUSHING/LINING REPLACEMENT
11. Verify that the air chamber face-to-clevis centerline
dimension is correct, see Air Chamber Inspection.
Ensure that the clevis lock nut is securely tightened.
12. All chambers equipped by the OE on new trucks
come with a welded clevis. Rotate the adjusting nut
as required until the appropriate hole in the slack
adjuster is aligned with the hole in the clevis. Refer
to Figure 58.
13. Lubricate the clevis pin before inspection and install
the washer and cotter pin or spring clip. If using a
spring clip, lock the clip after installation. Refer to
Figure 59.
Unlocked
Figure 59 – Spring Clips
40
Locked
Installation / Assembly
SHOE AND LINING INSTALLATION
Shoe and Lining Installation
Hook the
Spring into the
Shoe Web Hole
Locate the brake model being serviced to identify the
location of the appropriate shoe installation procedures.
Bendix® ES™-150-04L Brake
1. Verify that the spider, camshaft, air chamber bracket,
and slack adjuster are serviceable and properly
installed.
NOTE: See General Information - Parts Nomenclature
for shoe hold-down spring variations.
Anchor Pin
Recess
Figure 61 – Shoe Retaining Spring Installation
7. Rotate the lower shoe into position
on the spider.
36-2
Use Only a Light
Film of Specified
Grease
Roller Recess
Figure 60 – Shoe Web Lubrication
8. Hook one end of a new shoe return spring in the lower
shoe web hole. Using a screwdriver for assistance,
stretch the shoe return spring to hook it in the upper
shoe web hole. Refer to Figure 62.
9. Using a large screwdriver or lever with tip, stretch the
shoe return spring to allow insertion of a new cam
roller on the upper shoe web.
10. Install a new cam roller on the lower shoe web in the
same manner.
2. Apply a thin film of grease to the cam roller and the
36-1shoe web. Refer to
anchor pin recesses of each
Figure 60.
Install New
Return Spring
Use only grease conforming to NLGI grade #1, high
temperature and waterproof.
3. Position the upper shoe and lining web on the anchor
pin and rotate down. Continue the rotation until the
shoe is held in place by the shoe hold-down spring.
4. Hook one end of a new shoe retaining spring into the
hole in the upper shoe web so the coil lays across
the anchor pin. Refer to Figure 61.
5. Hook the opposite end of the spring into the hole on
the lower shoe web.
6. Stretch the spring to allow positioning of the lower
shoe web against the anchor pin.
Install
Rollers
Figure 62 – Shoe Return Spring and Roller Installation
36-3
41
Installation / Assembly
SHOE INSTALLATION
All Bendix® ES™-165-05/06/07/08D,X /
ES-165-08Z Brakes
With the Retainer Springs
Installed, Position the Upper
and Lower Shoes Around the
Anchor Pin
NOTE: The following procedures are divided into sections,
identified by the brake model numbers.
1. S
 ee Inspection & Repair / Replacement to verify that
the spider camshaft, bracket, and slack adjuster are
serviceable and properly installed.
2. During the shoe installation, lubricate as follows:
•
Shoe roller recess - one-piece roller.
•
Roller I.D. - two-piece roller.
Use only grease conforming to NLGI grade #1, hightemperature, waterproof.
Do Not Lubricate:
•
Cam head surface. For efficient operation, this
surface must remain free of oil, grease or other
contaminants.
3. Hook the ends of the new retainer springs into the
holes in both shoe tables, and the web.
Figure 63 – Upper and Lower Shoe Positioning
38-1
ES-165-D,L Only: Stretch
the Spring Using a Suitable
Tool Positioned as Shown
4. Position the upper and lower shoes around the
anchor pin. Refer to Figure 63.
The long-term effects of non-asbestos fibers, have not
been determined. Therefore, precautions should be used
when handling these materials.
See General Information / Lining Material Warning.
5. Install a new shoe return spring. Refer to Figure 64.
NOTE: For ES-165-D, L, X, Z brakes, a lever may be
required to assist in hooking the shoe return spring.
42
NOTE: For ES-165-D, L, X, Z a lever may be required to
assist in hooking the shoe return spring
Figure 64 – Shoe Return Spring Installation
Installation / Assembly
SHOE INSTALLATION
6. Install the shoe return spring. Ensure the return spring
hooks face the rollers. Refer to Figure 65.
Stretch the
Return Spring,
Install the Roller
and Retainer
NOTE: A lever may be required to assist in hooking the
return spring.
Figure 67 – Roller and Retainer Installation
Stretch the
Spring Using
Suitable Tool
Positioned As
Shown
Figure 65 – Shoe Return Spring Installation
9. Position the roller and retainer in the shoe recess as
shown in Figure 67. Squeeze the loops and swing
the retainer into position to snap the loops in the
shoe web holes. Refer to Figure 68. Verify that both
retainer loops are engaged in the web holes before
proceeding.
NOTE: If drums are oversized, see Inspection - Drum
Inspection.
7. Assemble the roller retainer on the ends of the roller
as shown below. NOTE: Be sure to lubricate the
roller pockets on the shoe before installing the roller.
Refer to Figure 66.
Install Retainer
on the Roller
Web
Hole
Install Retainer
Loops in Shoe
Web Holes
Figure 68 – Retainer Installation
41-4
10. Repeat the process on the upper shoe.
Figure 66 – Roller Retainer Installation
8. Using a lever or large screwdriver, stretch the shoe
return spring to allow installation
of the new roller and
41-2
retainer assembly on the lower shoe web. Refer to
Figure 67.
11. Install the dust shield. Secure the dust shield
with cap screws, and tighten to correct torque,
see Specifications chart.
T
43
Installation / Assembly
SHOE INSTALLATION
Bendix® ES™-165-07M Heavy-Duty Brake
The long-term effects of non-asbestos fibers, have not
been determined. Therefore, precautions should be used
when handling these materials.
See General Information / Lining Material Warning.
1. See Inspection & Repair / Replacement to verify that
spider camshaft, bracket, and slack adjuster are
serviceable and properly installed.
2. During the shoe installation, lubricate as follows:
•
Shoe roller recess.
•
Anchor pin - light film of grease.
Position Lower Shoe on Spider and Install
Anchor Pin, Washers, and Retaining Rings
Figure 70 – Lower Shoe and Anchor Pin Installation
Use only grease conforming to NLGI grade #1, hightemperature, waterproof.
5. Place the lower shoe in the mounting
position on the
40-2
spider, and install the lower anchor pin, washers, and
retaining rings. Refer to Figure 70.
Do Not Lubricate:
•
Cam head surface. For efficient operation, this
surface must remain free of oil, grease, or other
contaminants.
3. After driving out the old anchor pin bushings from the
spider, see Removal/Disassembly - Shoe Removal.
Press new anchor pin bushings in the spider, aligning
the slot in the bushing with the tapped holes in the
spider. Refer to Figure 69.
Screw Holes
in Spider
Place Upper Shoe on Spider and Install
Anchor Pin, Washers, and Retaining Rings
Figure 71 – Upper Shoe and Anchor Pin Installation
40-3
Slot in
Bushing
Position the Bushing
to Align Spider Screw
Hole With Bushing Slot
Figure 69 – Anchor Pin Bushing Installation
40-1
4. Lubricate the anchor pins during the installation. See
Step 2.
44
6. Place the upper shoe in the mounting position on the
spider, and install the upper anchor pin, washers, and
retaining rings. Refer to Figure 71.
Installation / Assembly
SHOE INSTALLATION
7. Install the shoe return spring. Ensure the return spring
hooks face the rollers. Refer to Figure 72.
Stretch the
Return Spring,
Install the Roller
and Retainer
NOTE: A lever may be required to assist in hooking the
return spring.
Figure 74 – Roller and Retainer Installation
Stretch the
Spring Using
Suitable Tool
Positioned As
Shown
Figure 72 – Shoe Return Spring Installation
10. Position the roller and retainer in the shoe recess as
shown in Figure 74. Squeeze the loops and swing
the retainer into position to snap the loops in the
shoe web holes. Refer to Figure 75. Verify that both
retainer loops are engaged in the web holes before
proceeding.
NOTE: If drums are oversized, see Inspection - Drum Inspection.
8. Assemble the roller retainer on the ends of the roller
as shown below. NOTE: Be sure to lubricate the roller
pockets on the shoe before installing the roller. Refer to
Figure 73.
Install Retainer
on the Roller
Web
Hole
Install Retainer
Loops in the Shoe
Web Holes
Figure 75 – Retainer Installation
41-4
11. Repeat the process on the upper shoe.
Figure 73 – Roller Retainer Installation
9. Using a lever or large screwdriver, stretch the shoe
return spring to allow installation
of the new roller and
41-2
retainer assembly on the lower shoe web. Refer to
Figure 67.
12. Install the dust shield. Secure the dust shield
with cap screws, and tighten to correct torque,
see Specifications chart.
T
45
Installation / Assembly
SHOE INSTALLATION
Bendix® ES™-165-07-H Severe-Duty Brake
The long-term effects of non-asbestos fibers have not
been determined. Therefore, precautions should be used
when handling these materials.
See General Information/Lining Material Warning.
1. See Inspection & Repair / Replacement to verify that
the spider, camshaft, bracket, and slack adjuster are
serviceable and properly installed.
2. During the shoe installation, lubricate as follows:
•
Roller inside diameter.
•
Anchor pin - light film of grease.
Figure 76 – Groove Pin Installation
42-1
Screw Holes
in Spider
Use only grease conforming to NLGI grade #1, hightemperature, waterproof.
Do Not Lubricate:
•
 am head surface. For efficient operation, this
C
surface must remain free of oil, grease, or other
contaminants.
NOTE: If the rollers were removed, replace with new
Bendix® OEM rollers and pins.
3. Lubricate the roller inside diameter (see Step 2),
prior to installation. Assemble the roller and pin to
the shoe and secure with the groove pin. Stake
the casting area around the groove pin. Refer to
Figure 76.
Slot in
Bushing
Position the
Bushing to Align
Spider Screw Hole
With Bushing Slot
Figure 77 – Spider Anchor Pin Bushing Installation
4. After driving out the old anchor pin bushings from the
spider, see Removal/Disassembly - Shoe Removal,
press the new anchor pin bushings in the spider,
aligning the slots in the bushing with the tapered
holes in the spider. Refer to Figure 77.
5. Press the anchor pin bushings in the brake shoes.
Refer to Figure 78.
40-1
Press Bushings
in the Shoe
6. Lubricate the anchor pin prior to installation. See
Step 2.
7. Place the lower shoe in position on the spider, and
install the lower anchor pin, washers, and retaining
rings. Refer to Figure 79.
Figure 78 – Shoe Anchor Pin Bushing Installation
46
Shoe Installation
42-3
Installation / Assembly
SHOE INSTALLATION
Complete Installation of Upper Shoe
Figure 79 – Lower Shoe Positioning
Figure 81 – Upper Shoe Installation
43-3
8. Connect a new return spring to the lower shoe.
10. Complete the installation of the upper shoe and install
the anchor pin, washers, and retaining rings. Refer
to Figure 81.
9. Position the upper shoe for installation on the spider
(partially installed with the shoe end disengaged from
the cam), then connect the return spring to the upper
shoe. Refer to Figure 80.
11. Install the cap screws in the spider to secure
the anchor pins. Tighten the screws to the
proper torque, see the Specifications chart,
then secure the lockwire. Refer to Figure 82.
T
Install Cap
Screws in the
Spider and
Affix Lockwire
Return
Spring
Figure 82 – Lower Shoe and Anchor Pin Installation
Position the Upper Shoe on the Spider,
Connect the Return Spring
(with the Shoe End Disengaged from the Cam)
12. Install the dust shield. Secure with the cap
screws. Tighten the screws to the correct
torque, see the Specifications chart.
T
Figure 80 – Upper Shoe Positioning
43-2
47
Specifications
SPECIFICATION CHART
Fastener Torque Specifications
Torque
Fastener
English
Metric
150-180 lb-in
16.9-20.3 N.m
Air Chamber Bracket to Steel Stamped Spider Nuts
65-85 lb-ft
88-115 N.m
Air Chamber Bracket to Cast Spider Bolts
65-85 lb-ft
88-115 N.m
Air Chamber Mounting Nuts (7/16 in.-20 Nuts)
35-40 lb-ft
48-54 N.m
135-155 lb-ft
180-210 N.m
Bendix ES -165
®
™
Dust Shield to Spider Screws
Air Chamber Mounting Nuts (5/8 in.-18 Nuts)
Lining Bolts/Nuts
For torque specs refer to the installation note in the lining kit
Anchor Pin Cap Screw (ES-165-07H, 07M)
120-150 lb-in
13.6-16.9 N.m
Dust Shield Attaching Screws
11-16 lb-ft
15-22 N.m
Air Chamber Bracket Nuts
55-65 lb-ft
75-88 N.m
Stabilizing Screw Nut
23-27 lb-ft
31-37 N.m
Anchor Pin Reinforcement Nuts
35-40 lb-ft
47-54 N.m
475-525 lb-ft
644-712 N.m
6-9 lb-ft
8-12 N.m
ES-150-04L
Anchor Pin Retaining Nut
Shoe Hold-Down Spring Screws
Key Dimensional Specifications
Minimum Lining Thickness (See Shoe and Lining Inspection)
ES-150-4L
3/16 in. (4.76 mm) or 1/16 in. (1.59 mm) from rivet heads
ES-165
1/4 in. (6.4 mm) or 1/16 in. (4.76 mm) from rivet heads
Camshaft End Play (Axial)
.005 in. - .045 in. (0.127-1.143 mm)
Camshaft Radial Play
.035 in. (.91 mm) maximum
Air Chamber Face to Clevis Pin Centerline
(clevis pin center line on all threaded clevis)
2-5/8 in. ± 1/16 in. (66.7 mm ± 1.59 mm)
Welded Clevis
2-1/4 in. ± 1/16 in. (57 mm ± 1.59 mm)
Air Chamber / Applied & Free Stroke
Max. Air Chamber Size
30 in. (762.0 mm)
30 in. (762.0 mm) Long Stroke

24/7/365 ACCESS
FULL SERVICE AT YOUR FINGERTIPS
Max Desired Applied Stroke
2 in. (50.8 mm)
2.5 in. (63.5 mm)
  
1-800-AIR-BRAKE (1-800-247-2725)
[email protected]
Free Stroke
3/8 in. to 5/8 in.
   
WEB-BASED TRAINING
LOG ON AND LEARN FROM THE BEST
ES™ Brakes is a trademark of Dana.
48
SD-22-70147 Rev 001 © 2023 Bendix Commercial Vehicle Systems LLC, a member of Knorr-Bremse • 12/23 • All Rights Reserved