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Issued 10-99
$2.50
DXP 195 Air Release and
Hydraulic Release Parking
Disc Brakes
Maintenance Manual No. MM-9902
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Service Notes This publication provides maintenance and service procedures for Meritor's DXP 195 air release and hydraulic release parking disc brakes. The information contained in this publication was current at the time of printing and is subject to revision without notice or liability. 1. You must understand all procedures and instructions before you begin maintenance and service procedures. 2. You must follow your company's maintenance and service guidelines. 3. You must use special tools, w
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Table of Contents Asbestos and Non-Asbestos Fibers Warnings ................................................................1 Section 1: Exploded View........................................................................................................2 Section 2: Introduction Description..............................................................................................................................4 Identification ................................................................
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Notes
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Asbestos and Non-Asbestos Fibers 1
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Section 1 Exploded View Spring-Applied Air Release Brake (Left-Hand Brake) 6 5 8 4 7 9 10 3 1 2 Item Description Sequence Number * Item Description Sequence Number * 1 Chamber 00100 6 Spring 00150 2 Pin 00110 7 Retaining Pin 00160 3 Cotter Pin 00120 8 Cotter Pin 00170 4 Spacer 00130 9 Washer 00180 5 Lining Assembly 00140 10 Adjuster Plug 00190 * Sequence numbers appear in the bill of material available from the equipment manufacturer. 2
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Section 1 Exploded View Spring-Applied Hydraulic Release Brake (Left-Hand Brake) 7 6 9 5 8 3 2 4 1 10 11 Item Description Sequence Number * Item Description Sequence Number * 1 Chamber 00100 7 Spring 00150 2 Spacer 00105 8 Retaining Pin 00160 3 Pin 00110 9 Cotter Pin 00170 4 Cotter Pin 00120 10 Washer 00180 5 Spacer 00130 11 Adjuster Plug 00190 6 Lining Assembly 00140 * Sequence numbers appear in the bill of material available from the equipment manufacturer. 3
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Section 2 Introduction Description Figure 2.1 The DXP 195 dry disc parking brake fits a 14.88-16.54-inch (378-420 mm) disc range and can be packaged as a driveline, wheel end or axle-mounted park brake. It is designed for use in off-highway haulers, mining vehicles, front-end loaders and various stationary machinery. • The brake features a lightweight single-piece cast caliper, supported on twin slide pins, which is fixed to a "universal" mounting saddle. • Brake pads are located in the sadd
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Section 2 Introduction Identification To identify the DXP 195 assembly, refer to the tag located on the chamber bracket. Figure 2.3. Figure 2.3 5
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Section 3 Disassembly Remove the Linings CAUTION Use an Allen wrench to manually adjust and WARNING de-adjust the brakes. Do not use an air gun to To prevent serious eye injury, always wear safe adjust or de-adjust the brakes. Damage to eye protection when you perform vehicle components can result. maintenance or service. Stop turning the Allen wrench when you feel Do not work under a vehicle supported only by resistance. Do not continue to turn the Allen jacks. Jacks can slip or fall over an
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Section 3 Disassembly 5. Remove the stabilizer bar cotter pin and Remove the Caliper Assembly retainer pin. Hinge the stabilizer bar so it is out of the way. Figure 3.3. CAUTION Do not use the stabilizer bar to lift the caliper on or off of the vehicle. Damage to the stabilizer bar Figure 3.3 can result. 1. Remove the brake linings. Refer to "Remove the Linings" in this section. 2. Remove the clevis pin from the lever. Figure 3.4. 3. Remove the chamber. Figure 3.4. 4. Remove the four saddle bol
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Section 4 Assembly Install the Caliper Assembly Install the Linings WARNING CAUTION To prevent serious eye injury, always wear safe Use only the specified components when you eye protection when you perform vehicle service the caliper. Do not mix components from maintenance or service. other calipers. If you install the wrong components, the caliper will not operate Use Meritor parts only. Do not use parts correctly and can cause damage to the manufactured by other suppliers. Use of equipment.
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Section 4 Assembly 4. Install the adjuster plug and washer. Tighten Adjust the Initial Caliper the adjuster plug to 8-12 lb-ft (11-17N•m). Clearance Figure 4.2. 1. Adjust the caliper by reducing the caliper-to-disc clearance to ZERO. Refer to Table A for the adjusting direction. Figure 4.2 2. Check that the load plate fully contacts the lining backing plate. WASHER-ADJUSTER PLUG 3. Use a 6 mm Allen wrench to increase the disc clearance SEVEN CLICKS, which sets the initial clearance. Figure 4.1
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Section 5 Maintenance Hydraulic Fluid Check the Adjusted Chamber Stroke Length WARNING Use only the type of hydraulic fluid specified by WARNING the equipment manufacturer. Do not use To prevent serious eye injury, always wear safe different types of hydraulic fluid. Using incorrect eye protection when you perform vehicle hydraulic fluid will damage the rubber parts of maintenance or service. the caliper. Component damage, loss of braking and serious personal injury can result. Do not work un
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Section 5 Maintenance 5. Measure the distance from the bottom of the Inspect the Brake Components chamber to the center of the clevis pin while the brakes are applied. Figure 5.1. WARNING Use Meritor parts only. Do not use parts Figure 5.1 manufactured by other suppliers. Use of MEASURE ADJUSTED non-Meritor parts can cause damage, loss of CHAMBER STROKE braking and serious personal injury. Lining Thickness Lining material thickness must not be less than 0.200-inch (5.1 mm). Replace the lining
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Section 5 Maintenance Heavy Heat Checking Disc Heavy heat checking is surface cracks with width and depth. Figure 5.3. If you find heavy CAUTION heat checking, always replace the disc. You must always replace a damaged disc. 1. When you inspect the brakes, inspect both sides and the outer diameter of the disc for Figure 5.3 the following conditions: • Cracks • Heat checking • Grooves or scoring • Blue marks or bands 2. When you reline the brakes, you must measure the thickness of the disc. Crac
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Section 5 Maintenance Blue Marks or Bands Cleaning Blue marks or bands indicate that the disc was very hot. If blue marks or bands are present, WARNING refer to Section 6 to find and correct the cause of the problem. Figure 5.5. To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. Figure 5.5 Solvent cleaners can be flammable, poisonous and cause burns. Examples of solvent cleaners are carbon tetrachloride, emulsion-type cleaners and pet
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Section 5 Maintenance Cleaning Non-Metal Parts • Use soap and water to clean non-metal parts. • Scrape away build-ups of mud and dirt on the linings. Replace all linings contaminated with oil or grease. Drying Cleaned Parts • Dry the parts immediately after cleaning and washing. • Dry the parts with soft clean paper or rags. Corrosion Protection Apply rust inhibiting fluid to the cleaned and dried parts that are not damaged and are to be immediately assembled. Do NOT apply fluid to the brake lin
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Section 6 Diagnostics DXP 195 Air Release and Hydraulic Release Parking Disc Brakes Conditions: Possible Cause(s): What to Check: Corrections: ➀ Chamber exceeds Incorrect initial Check the chamber stroke If the air chamber still two-inch maximum adjustment or after 20 brake overstrokes, replace the stroke requirement inoperative automatic applications. caliper/saddle assembly. adjuster Refer to Sections 3 and 4. ➁ Brake drag Incorrect lining-to- Minimum stroke Replace the caliper/saddle rotor c
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Section 7 Specifications Torque Specifications Component Torque Mounting Bolts 400-500 lb-ft (544-680 N•m) Chamber Nuts • Air Release Brakes 135-155 lb-ft (180-210 N•m) • Hydraulic Release Brakes 30-40 lb-ft (41-54 N•m) Adjustment Plug 8-12 lb-ft (11-17 N•m) 16
