Bendix Commercial Vehicle Systems EVERSURE SPRING BRAKE - Manual (Page 6)

6
WARNING
Do not mechanically release (cage) the spring if there is
any structural damage to the brake. Caging the spring
in such a chamber may cause serious injury or death.
Replace the complete spring brake assembly.
7.0.1 If the service replacement spring brake chamber is not
caged, mechanically release (cage) the replacement spring
brake chamber by following the original manufacturer’s
instructions.
7.0.2 Apply 10 psi (1 bar) of air pressure to the service
port (“11”) of the spring brake chamber.
7.0.3 Since we will be using locking pliers to hold the
service push rod in place, be sure to protect the threads
before clamping down. The locking pliers will prevent the
push rod from retracting when they are used at the push
rod opening of the replacement spring brake chamber.
7.0.4 Release the air pressure from the service port.
7.0.5 Remove the clamp ring and hardware from the spring
brake chamber.
7.0.6 Position the adapter base inlet port by rotating it with
respect to the mounting studs, as needed.
7.0.7 Make sure that the diaphragm is properly aligned and
seated. See Figure 5. Be sure that the service diaphragm
is fully inserted into the clamp.
7.0.8 Reinstall the clamp rings and hardware. Check the
arrangement of the removed actuator and position the
hardware with respect to the mounting studs as required.
Tighten each clamp nut evenly in an alternating pattern.
Torque each clamp nut to a fi nal torque of 20-30 ft-lbs.
(28-40 Nm).
7.0.9 Inspect the clamp ring and hardware for proper
seating.
7.0.10 Apply up to around 10 psi air pressure to the
service port of the spring brake chamber. (Do not exceed
10 psi.) Remove the locking pliers from the brake chamber
push rod.
7.0.11 Perform the Leakage Test (4.2) before returning
the spring brake on the vehicle.
INCORRECT CORRECT
FIGURE 5 - CORRECT DIAPHRAGM POSITION
8.0 MECHANICAL RELEASE (CAGING) AND
REMOVAL OF THE PIGGYBACK SPRING
BRAKE CHAMBER TO BE REPLACED
NOTE: The spring brake chamber can be replaced with
the service brake chamber mounted to the vehicle, or
removed, for ease of access. To remove the assembly
from the vehicle, perform the steps outlined in Step 11.0
Removal and Installation of the Combination Spring Brake.
WARNING
Do not mechanically release (cage) the spring if there is
any structural damage to the brake. Caging the spring
in such a chamber may cause serious injury or death.
Replace the complete assembly.
8.1 Mechanically release the old spring brake by
following the original manufacturer’s instructions.
8.2 Ensure air pressure is removed from all air reservoirs
before removing the air hoses or working on the spring
brake.
8.3 Remove air hoses from the spring brake chamber.
Be sure to mark both hoses to ensure proper reinstallation.
8.4 Clamp a pair of locking pliers around the service
push rod touching the non-pressure housing. This cages
the service return spring.
8.5 Remove the clamp nuts and service clamp assembly
and carefully remove the old piggyback chamber.
8.6 Discard the clamp, clamp hardware and diaphragm.
9.0 INSTALLING THE BENDIX ® EVERSURE ®
PIGGYBACK SPRING BRAKE CHAMBER
FIGURE 6 - PIGGYBACK SPRING BRAKE KIT
9.1 Install new service diaphragm.
9.2 Clock chamber (See Section 7.0) as necessary.
9.3 Line up the new spring brake chamber, the service
diaphragm, and the non-pressure housing, ensuring that
they are centered.