Maintenance manual no.

MM-0153

Stopmaster Wedge Brake

Issue 03/2007

Service Notes

Before You Begin

This publication provides installation and maintenance procedures for the Stopmaster Wedge Brake. The information contained in this publication was current at the time of printing and is subject to revision without notice or liability. You must understand all procedures and instructions before you begin maintenance and service procedures. You must follow your company's maintenance and service guidelines. You must use special tools, when required, to avoid serious personal injury and damage to components. ArvinMeritor uses the following notations to alert the user of possible safety issues and to provide information that will help to prevent damage to equipment and components.

Safety Instructions
Observe the manufacturers safety instructions for jacking up and securing the vehicle Only use original ArvinMeritor parts Use only the tools recommended Observe the following service instructions and notes When working on the brake you must ensure that it cannot be activated inadvertently Never use compressed air to remove brake dust or for the purpose of drying. Any type of dust can be injurious to health if inhaled. Use ArvinMeritor brake cleaner for cleaning the brake. When removing or fitting a complete brake, you should remember it has a dead weight of up to 117lbs (53kg). Use a lifting system, taking care not to damage the brake. When the servicing has been completed, it is essential that you road test the vehicle and try out the brakes.

WARNING
A WARNING indicates a procedure that you must follow exactly to avoid serious personal injury.

CAUTION
A CAUTION indicates a procedure that you must follow exactly to avoid damaging equipment or components. Serious personal injury can also occur.

Access Information on ArvinMeritor's Web Site

Additional maintenance and service information for ArvinMeritor's commercial vehicle systems component lineup is also available at www.meritorhvs.com To access information go to Products & Services Icon; from drop down menu click on Literature on Demand. The screen will display an index of publications by type.

NOTE: A note indicates an operational, procedure or instruction

that is important for proper service. A NOTE can also supply information that will help to make service quicker and easier. This symbol indicates that you must tighten fasteners to a specific torque.

Information contained in this publication was in effect at the time the publication was approved for printing and is subject to change without notice or liability. ArvinMeritor Commercial Vehicle Systems reserves the right to revise the information presented and to discontinue the production of parts described at any time.

ArvinMeritor Stopmaster Wedge Brake

Terms used in this manual

Manufacturer: ARVINMERITOR Manual Maintenance manual no. 0153 Device: Stopmaster Wedge Brake Technician: Qualified personnel working on brake maintenance and servicing. Maintenance and servicing: Maintenance and servicing refer to periodical checks and/or replacement of the Stopmaster brake parts or components. It also refers to the determining of the cause of a malfunction in order to restore the initial operating conditions. Operator: Any person who will use the Stopmaster brake as part of a more complex device. Warranty Warranty applies to the Stopmaster brake installed on vehicles for which it was designed. Warranty is void in the following cases: Improper use of the vehicle on which the Stopmaster brake is installed (usage conditions, overloading etc.) Tampering with vehicle components that may affect brake performance. Use of non-original spare parts. Improper installation, adjustment, repair or modification. Poor or improper maintenance (including consumables other than those specified).

Further information on warranty conditions may be obtained directly from the manufacturer or by referring to the ArvinMeritor web site www.meritorhvs.com

ArvinMeritor Stopmaster Wedge Brake

Contents

pg.

2
2 2 2 3

General information
Introduction Symbols Safety precautions Warranty

5
7 8 9 10 11 12 13 14 15 16 17 18

Section 1 - Description
Field of application Stopmaster II Duplex brake - exploded view Stopmaster II Duplex brake - parts list Stopmaster II Simplex brake - exploded view Stopmaster II Simplex brake - parts list Stopmaster E Simplex brake - exploded view Stopmaster E Simplex brake - parts list Stopmaster E Duplex brake - exploded view Stopmaster E Duplex brake - parts list Stopmaster wedge brake operation Self-Adjustment Mechanism Operation Stopmaster II - Stopmaster E Brakes lubrication instructions

19
20 21 24 27 28

Section 3 - Maintenance
Stopmaster brake preventive maintenance Brake disassembly Checking components Technical assembly data Reassembly

37
38

Section 4 - Troubleshooting
Troubleshooting

Description

pg. 7

8 9 10 11 12 13 14 15 16 17 18

Field of application Stopmaster II Duplex brake - exploded view Stopmaster II Duplex brake - parts list Stopmaster II Simplex brake - exploded view Stopmaster II Simplex brake - parts list Stopmaster E Simplex brake - exploded view Stopmaster E Simplex brake - parts list Stopmaster E Duplex brake - exploded view Stopmaster E Duplex brake - parts list Stopmaster wedge brake operation Self-Adjustment Mechanism Operation Stopmaster II - Stopmaster E Brakes lubrication instructions

ArvinMeritor Stopmaster Wedge Brake

ArvinMeritor Stopmaster Wedge Brake

1 Description

Field of application
The Stopmaster brake is available in two versions: STOPMASTER II STOPMASTER E Both brake types are similar in design except that the actuation parts of the Stopmaster E version are physically bigger than those of the Stopmaster II. Stopmaster brakes are wedge actuated with power provided by air cylinders or in special applications by hydraulic cylinders. They can be equipped with integral spring brake units for parking and emergency braking. The brake power unit forces a wedge between two rollers and two plungers which, being pushed in opposite directions, press the brake shoes against the brake drum. Stopmaster brakes utilise either one power unit (Simplex actuation) or two power units (Duplex actuation). When two power units are used either or both can incorporate an integral spring brake facility.

ArvinMeritor Stopmaster Wedge Brake

Exploded view
Stopmaster II Duplex

29

2 3 30 4 24 5 33 34 9 10

28

27 23 22 21 26 25 12 11

32 6 35 7 1 20 29 30 19 18 17 34 15 16 14

13

25A Alternative one piece dustshield

29A

31

ArvinMeritor Stopmaster Wedge Brake

Stopmaster II Duplex
Brake Components

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 25A 26 27 28 29 29A 30 31 32 33 34 35

Description Brake spider Adjusting bolt Seal - adjuster plunger Actuator (adjusting bolt sleeve) Adjusting plunger Anchor plunger Seal - anchor plunger Gasket Guide pawl assembly Guide screw Wedge assembly Collet nut Cotter pin Washer Wedge spring Rubber boot seal Wedge washer Roller cage Rollers Wedge Nut Washer Hold-down clip Screw Dustshield (half) Dustshield Rubber plug (round) Screw Rubber plug (long) Brake shoe and lining assembly Brake shoe and lining assembly R+R (rolled and relieved) Brake shoe return spring Service grease Identification plate Customer logo plate Rivet Wear sensor

ArvinMeritor Stopmaster Wedge Brake

Exploded view
Stopmaster II Simplex

29 28 2 3 30 24 4 5 33 34 9 9 5 35 4 3 2 10 29 30 8 6 20 7 19 18 16 17 8 23 22 21 11
12

27 26 25

1 6 36 32 34 15 25A Alternative one piece dustshield 14 13

29A 31

10

ArvinMeritor Stopmaster Wedge Brake

Stopmaster II Simplex
Brake Components

Ref 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 25A 26 27 28 29 29A 30 31 32 33 34 35 36

Description Brake spider Adjusting bolt Seal - adjuster plunger Actuator (adjusting bolt sleeve) Adjusting plunger Anchor plunger Seal - anchor plunger Gasket Guide pawl assembly Guide screw Wedge assembly Collet nut Cotter pin Washer Wedge spring Rubber boot seal Wedge washer Roller cage Rollers Wedge Nut Washer Hold-down clip Screw Dustshield (half) Dustshield Rubber plug (round) Screw Rubber plug (long) Brake shoe and lining assembly Brake shoe and lining assembly R+R (rolled and relieved) Brake shoe return spring Service grease Identification plate Customer logo plate Rivet Wear sensor Plug (anchor box)

ArvinMeritor Stopmaster Wedge Brake

11

Exploded view
Stopmaster E Simplex

29

2 3 30 4 5 33 34 9 9 8 11 32 34 1 35 6 19 20 29 30 18 17 16 16A 15 24

28

27 23 21 6 12 25

14

13

31

12

ArvinMeritor Stopmaster Wedge Brake

Stopmaster E Simplex
Brake Components

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16A 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

Description Brake spider Adjusting bolt Seal - adjuster plunger Actuator Adjusting plunger Anchor plunger (Not used) Gasket Guide pawl assembly (Not used) Wedge assembly Collet nut E clip Washer Wedge spring Special washer Boot seal Wedge washer Roller cage Rollers Wedge Nut (Not used) Hold-down clip Screw Dustshield (Not used) Screw Rubber plug (long) Brake shoe and lining assembly Brake shoe return spring Service grease Identification plate Customer logo plate Rivet Wear sensor

ArvinMeritor Stopmaster Wedge Brake

13

Exploded view
Stopmaster E Duplex

29

26A

26 28

2 3 12 30 4 5 33 34 8 9 10 6 7 1 20 35 29 30 19 18 17 16 16A 15 11 32 34 13 14 24 23 21 22 25 12 27A

27

31 36

14

ArvinMeritor Stopmaster Wedge Brake

Stopmaster E Duplex
Brake Components

Ref. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 16A 17 18 19 20 21 22 23 24 25 26 26A 27 27A 28 29 30 31 32 33 34 35 36

Description Brake spider Adjusting bolt Seal - adjuster plunger Actuator Adjusting plunger Anchor plunger Seal - anchor plunger O ring Guide pawl assembly Guide pin Wedge assembly Collet nut E clip Washer Wedge spring Special washer Boot seal Wedge washer Roller cage Rollers Wedge Nut Washer Hold-down clip Screw Dustshield Rubber plug (round) Rubber plug (round) Screw Spring washer Rubber plug (long) Brake shoe and lining assembly Brake shoe return spring Actuator service grease Identification plate Customer logo plate Rivet Wear sensor Brake shoe service grease

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15

1 Description

Stopmaster Wedge Brake Operation

In the brake released position the wedge assembly is held withdrawn by the wedge return spring while plungers are kept closed on rollers and their abutment seats by the brake shoe return spring. Fig. 1.1

When the brake is actuated the air chamber push rod forces the wedge head between the rollers which spread apart and push the plungers outwards causing the brake shoes to open. Plungers are lifted off their abutment seats until shoes contact the brake drum. Fig. 1.2
Fig. 1.1

As shoes contact the drum, the latter under the action of the friction linings drags the shoes in the direction of rotation while brake shoes in turn transfer the friction force to anchor plungers. This causes the shoe plunger to reseat on its abutment and transfer the braking torque to the brake spider, in order to balance the braking torque generated between shoes and drum. Fig. 1.3

Fig. 1.2

When the brake is released the wedge spring returns the wedge and air chamber diaphragm to the off position. The shoe and lining is pulled away from the drum by the shoe return springs and returns the plungers to their abutment seats in the housing. Fig. 1.4

Fig. 1.3

Fig. 1.4

16

ArvinMeritor Stopmaster Wedge Brake

1 Description

Self-Adjustment Mechanism Operation

On the brake application the adjuster bolt and sleeve assembly moves outwards. As the opposing chamfers of teeth on the adjuster sleeve and the teeth on the guide pawl (A) move against each other the pawl is lifted against the spring (B). Fig. 1.5

Fig. 1.5

When the brake lining to drum clearance exceeds its predetermined limit the travel of the adjuster bolt and sleeve is such that it allows the pawl to jump into the next tooth on the adjuster sleeve. Fig. 1.6

Fig. 1.6

As the brake is released and the adjuster bolt and sleeve assembly is returned to the off position, the guide pawl rotates the sleeve anti-clockwise and unscrews it from the fixed adjusting bolt. The lining to drum clearance is reduced, completing one adjustment cycle. This is repeated each time the lining to drum clearance is sufficient to allow further adjustments to take place. Fig. 1.7

Fig. 1.7

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17

1 Description

Stopmaster II - Stopmaster E Brakes Lubrication instructions

General information
Experience shows that some lining specifications produce a type of dust which has a drying (or caking) effect on brake lubricants. To ensure optimum braking performance the following lubrication instructions, regarding lubricant specifications and lubrication frequency should be adhered to. Lubrication intervals should be shortened where lubricant drying or caking is found to occur. The standard lubrication interval for Stopmaster brake units is every 160,000 km or 12 months, whichever comes first.

For STOPMASTER E brake units different types of lubricant are used, according to the following table:

Lubrication points 1. The shoe and rest pads located on the spider. 2. The internal surface of the hold-down clips. 3. The shoe contact surface on the plungers. 4. The wedge assembly cavity. 5. All items of the auto-adjustment mechanism.

This is considered the maximum even under ideal operating conditions. Unusual temperatures or operating conditions will require different lubrication intervals. Therefore comply at all times with lubrication instructions provided by the manufacturer. The lubricant type should meet specifications of the ArvinMeritor 0-616-A standard: High temperature, waterproof grease to NLGI Grade one available under ArvinMeritor RBSK 1022 part number in 1 kg tins or RBSK 0253 in tubes.

4 3 5 2

Fig. 1.8

Lubrication points 1 2 3 4 5

Stopmaster II RBSK1022 - RBSK0253 RBSK1022 - RBSK0253 RBSK1022 - RBSK0253 RBSK1022 - RBSK0253 RBSK1022 - RBSK0253

Stopmaster E Weicon AS450 Weicon AS450 Weicon AS450 Simplex: Duplex: Simplex: Duplex:

RBSK 1022 - RBSK0253 Klber Syntheso GLEP1 RBSK 1022 - RBSK0253 Klber Syntheso GLEP1

18

ArvinMeritor Stopmaster Wedge Brake

Maintenance

pg. 20

21 24 27 28

Stopmaster brake preventive maintenance Brake disassembly Checking components Technical assembly data Reassembly

ArvinMeritor Stopmaster Wedge Brake

19

2 Maintenance

Stopmaster brake preventive maintenance

Check lining wear Every 25,000 Km: 1. Check the lining to drum clearance. 2. If it is 1.5 mm or less, self-adjusters are efficient and there is no need for any further action. 3. Check state of wear through the appropriate inspection plugs located on the dustshield. Fig. 2.1
Fig. 2.1

Check lining to drum clearance (< 1.5 mm)

At every reline: 1. Inspect the seals to see if they are worn, cut or torn. If they are defective they must be replaced, and it also becomes necessary to disassemble the actuating parts and overhaul as required. 1 2. Lubricate the following areas: 1. The shoe rest pads located on the spider. 2. The internal surfaces of the hold-down clips. 3. The shoe contact surface on the plungers. Fig. 2.2
Fig. 2.2

3 2

Every 160,000 Km: 1. Dismantle the actuating parts and check their condition. Overhaul as necessary. 2. Lubricate brake in line with recommended lubrication procedure. Fig. 2.3

Fig. 2.3

20

ArvinMeritor Stopmaster Wedge Brake

2 Maintenance

Brake disassembly
WARNING
Chock and jack up the vehicle. Remove the wheel on which you are going to operate. When working on brakes, the spring brake chamber must be kept in the off position by manually caging the spring (refer to manufacturers instructions). Remove the brake drum. If drums are worn, back off the shoe and lining assemblies manually through the slots in the dustshield, above or below the air chambers, using special tool. Engage tool in the square slot in the head of the adjusting bolts and adjust as required to increase drum to lining clearance. Fig. 2.4

Stopmaster E Tool no. RS410E

Fig. 2.4

STOPMASTER II Tool no. RBSK 0187 STOPMASTER E Tool no. RBSK 1420 Remove the brake shoe return springs using special tool. STOPMASTER II and E Tool no. RBSK 0185 Fig. 2.5
Fig. 2.5

Remove the brake shoe and check the condition of the hold-down clip as illustrated (Fig. 2.6). A = 6.7 mm max, maximum shoe web thickness 8 mm 10 mm max, maximum shoe web thickness 12 mm

A =

Fig. 2.6

ArvinMeritor Stopmaster Wedge Brake

21

2 Maintenance

Remove the dustshield, if necessary. - Fig. 2.7

Unscrew the air chambers and slacken off the collect nut to separate the air chambers from the brake spider or by removing the four capscrews on flange mounted type. - Fig. 2.8

Fig. 2.7

Remove the wedge assembly from its housing.- Fig. 2.9

Unscrew and remove the guide pawl assembly and the anchor plunger guide screw. - Fig. 2.10

Fig. 2.8

Fig. 2.9

Fig. 2.10

22

ArvinMeritor Stopmaster Wedge Brake

2 Maintenance

Drift the seals clear of their bores in the housing, using an appropriate tool.- Fig. 2.11

Remove the adjusting bolt and sleeve assembly and the auto adjust and anchor plungers. - Fig. 2.12

Fig. 2.11

Dismantle the adjusting bolt assembly and carefully clean all parts. Check for wear and damage. - Fig. 2.13

Replace all worn or damaged parts and always renew seals. Fig. 2.14

WARNING
When replacement wedge assemblies or plungers are required, ensure the replacement parts have the same wedge angles as the displaced parts.

Fig. 2.12

LOCATION OF ANGLE MARKING Wedge stem

Plunger end faces

Fig. 2.13

Fig. 2.14

ArvinMeritor Stopmaster Wedge Brake

23

2 Maintenance

Adjusting Pawl

Checking Components
Adjusting Pawl The scored, rounded teeth of the adjusting pawl on the left are unacceptable and the part must be discarded and replaced, while the teeth of the pawl on the right are still undamaged. This part may be re-used. However, if you have any doubts, always replace the pawl.- Fig. 2.15

Scored rounded teeth (replace part)

Fig. 2.15

Straight undamaged teeth (re-use part)

Internally scored Adjusting Plunger

Internally scored Adjusting Plunger If the internal scoring of an adjusting plunger consists of only light markings the plunger may be re-used. However, if the scoring is rough the part must be replaced. Fig. 2.16

light markings (re-use part) rough markings or scores (replace part)

Fig. 2.16

Adjusting Plunger

Adjusting Plunger The light contact marks on the pawl guide slot in the adjusting plunger shown on the left are acceptable and will not hamper performance. The deep scoring shown on the right is unacceptable and this plunger must be replaced. Fig. 2.17

Light contact marks (re-use part)

Fig. 2.17

Scored pawl guide slot (replace part)

24

ArvinMeritor Stopmaster Wedge Brake

2 Maintenance

Adjusting Plunger Adjusting Plunger Shown here on the right is a normal roller contact patch on the ramp of an adjusting plunger and this part may be re-used. On the right we see the rectangular indentation of a brinelled roller ramp. This plunger must be replaced. - Fig. 2.18

Normal roller contact patch (re-use part)

Fig. 2.18

Brinelled roller ramp (replace part)

Actuators Actuators Both of these actuators show normal sign of wear and are reusable. - Fig. 2.19

normal wear (re-use part)

Fig. 2.19

normal wear (re-use part)

Actuators While the abnormal wear or damage on these actuators is unacceptable and these parts must be replaced. - Fig. 2.20

Metal displacement along tooth axis (replace part)

Fig. 2.20

Damaged teeth (replace part)

ArvinMeritor Stopmaster Wedge Brake

25

2 Maintenance

Drum rotation Anchor plunger Adjusting plunger

Duplex Brake
Reassembly In the reassembly of the brake, always ensure that the adjuster bolt and sleeve assembly is positioned at the leading end of the shoe and the anchor plunger is at the trailing end (see illustration). STOPMASTER E shoes are stamped with the word ANCHOR on the anchor end.

Adjusting plunger

Anchor plunger

STOPMASTER II shoes are stamped with the word DRUM rotation and an arrow. When reassembling install both shoes with arrow following drum rotation. Fig. 2.21

Fig. 2.21

Drum rotation Adjusting plunger Anchor plunger

Simplex Brake
Reassembly STOPMASTER E shoes are stamped with the word ANCHOR on the anchor end.

Adjusting plunger
Fig. 2.22

Anchor plunger

NOTE: Any change to the brake system may require type approval. Therefore use only original ArvinMeritor spare parts. Fig. 2.22

26

ArvinMeritor Stopmaster Wedge Brake

2 Maintenance

Technical assembly data

Tightening torques Guide pawl assembly Guide screw Hold-down clip screw Dustshield screw Air chamber collet nut Air chamber flange screw Wear sensor Stopmaster II Box plug Duplex Version 20-30 Nm 20-30 Nm 20-30 Nm 20-30 Nm 300 Nm 10 see vehicle manufacturers manual 10-15 Nm Simplex Version 20-30 Nm 20-30 Nm 20-30 Nm 300 Nm 10 see vehicle manufacturers manual 10-15 Nm 40 5 Nm

SETTING DIMENSIONS Actuator assembly Except where otherwise indicated dimensions are expressed in mm: STOPMASTER II all types 144.5 0.5 STOPMASTER E 360 not applicable 381 144 0.5 410 162 0.5

142.5 0.5 152 0.5 151 0.5 164 0.5 (5/5) 167 0.5 (15/5) 169 0.5 (15/0)

Hold-down clip STOPMASTER II STOPMASTER E STOPMASTER E

- Spacing: A = 6.7 mm max A = 10 mm max A = 6.7 mm max

Shoe web thickness 8 mm 12 mm 8 mm 0.8 - 1.2 mm

Drum to lining clearance:

ArvinMeritor Stopmaster Wedge Brake

27

2 Maintenance

Reassembly of the Brake

NOTE: Only original ArvinMeritor spare parts should be used.

ATTENTION
Use of non-original parts could seriously affect brake performance. Breathing the dust generated by friction of brake linings against drum is hazardous to your health. Always wear the assigned protective equipment when servicing brake units and avoid remaining in the area unless your work requires it. 1 Lubrication points 1. The shoe rest pads located on the brake spider. 2. The internal surface of the hold-down clips. 3. The shoe contact surface on the plungers. 4. The wedge assembly cavity. 5. All items concerned with the self-adjustment mechanism. Fig. 2.23

4 3 5 2
Fig. 2.23

Lubricant At brake reassembly use the following recommended lubricant types: ArvinMeritor Service grease no. RBSK-0253 - RBSK 1022 Weicon Antiseize AS450 grease Klbler Syntheso GLEP1 grease

Lubrication points STOPMASTER II 1, 2, 3, 4, 5

Lubrication points STOPMASTER E 4, 5 Simplex 1, 2, 3 4, 5 Duplex

28

ArvinMeritor Stopmaster Wedge Brake

2 Maintenance

Grease inner bores of brake spider plunger housing. Fig. 2.24

Fig. 2.24

Lightly grease the neck of the seal and carefully assemble onto the anchor plunger. Note the anchor and adjuster seals are different in design. Ensure the right seal is fitted, as follows:

Anchor plunger = short seal Adjuster plunger = long seal

Fig. 2.25

Fig. 2.25

Evenly coat with grease the entire cylindrical surface of the anchor plunger. Locate the anchor plunger into housing, ensuring the slot aligns correctly with the guide screw tapped hole. Fig. 2.26

Fig. 2.26

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2 Maintenance

Fit guide screw and tighten to torque to 20-30 Nm. Fig. 2.27

Fig. 2.27

Evenly coat with grease the entire cylindrical surface of the adjusting plunger.

Locate the adjusting plunger into housing, ensuring the slot aligns correctly with the guide pawl hole. Fig. 2.28

Fig. 2.28

Lightly grease the guide pawl and fit, screwing it in one turn only. Check that the guide pawl moves freely through its bore and with the plunger slot. Note that the guide pawl has a raised ridge which locates into a groove in the brake spider. Remove the guide pawl. Fig. 2.29

Fig. 2.29

30

ArvinMeritor Stopmaster Wedge Brake

2 Maintenance

Lightly grease the adjuster seal neck and carefully assemble onto adjusting bolt; grease bolt threads. Fig. 2.30

Fig. 2.30

Grease actuator threads and screw onto the adjusting bolt (large chamfer towards bolt head). - Fig. 2.31

ATTENTION:
Ensure actuator is screwed in the correct direction. Check chamfers. Threads must not be tight as this would cause adjustment not to function correctly Ensure the adjusting bolt does not protrude through the actuator as this would also inhibit adjustment.

Fig. 2.31

Grease the actuator outer surface. Then fit adjusting bolt and sleeve (with slight rotation) into the adjusting plunger. Fig. 2.32

Fig. 2.32

ArvinMeritor Stopmaster Wedge Brake

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2 Maintenance

Fit guide pawl ensuring correct alignment and torque to 20-30 Nm.- Fig. 2.33

Fig. 2.33

Seat seals using seal driver. Note that the shoe retainer on the bolt head must align with the slot in the seal driver. Fig. 2.34 STOPMASTER II Tool no. RBSK 0186 STOPMASTER E Tool no. RBSK 1427

Fig. 2.34

Through the wedge bore, fill the housing with approx 29 g of grease, coat with grease the wedge assembly and fit into bore aligning the raised ridges on the wedge with the corresponding slots in the wedge bore; press wedge in by hand up to plunger travel starting point. Fig. 2.35

Fig. 2.35

32

ArvinMeritor Stopmaster Wedge Brake

2 Maintenance

Screw collet nut fully onto the air cylinder and then screw in the air chamber till it bottoms in the housing ensuring the collet nut is still free to turn. In order to align air ports unscrew the chamber to a maximum of one full turn, if necessary. Tighten collet nut to a torque of 300 Nm 10. Fit the spring brake chamber in a similar manner but ensure the spring is fully caged. On flange type models locate the chamber to the spider. Fit the retaining capscrew and tighten to the torque recommended in the vehicle Manufacturers Workshop Manual.
Fig. 2.36

If previously removed, refit dustshield halves and tighten screws to a torque of 20-30Nm. One piece dustshields must be fitted prior to reassembling air chambers. Refit brake shoe hold-down clips and tighten to 20-30 Nm torque. Ensure clip condition conforms to specifications (see page 19 for details). Set dimension over brake shoe contact surfaces. Ensure caliper is flat on adjusting bolt at the shoe web contact surface. On Duplex models repeat the same operation on the opposite side.
Fig. 2.37

Fig. 2.38 Except where otherwise indicated, dimensions are expressed in mm STOPMASTER II all sizes STOPMASTER E 360 381 410 DUPLEX 144.5 0.5 DUPLEX 144 0.5 162.5 0.5 SIMPLEX 142.5 0.5 SIMPLEX 152 0.5 151 0.5 164 0.5 (5/5) 167 0.5 (15/5) 169 0.5 (15/0)

Fig. 2.38

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2 Maintenance

Position the shoe return springs in the upper shoe as illustrated and fit the shoes ensuring that the short radius locates against the adjusting bolt assembly. Fit the springs with special tool. Fig. 2.39

ATTENTION
Take care not to touch the seals to prevent seal damage during this operation.

Fig. 2.39

STOPMASTER II and STOPMASTER E: Tool no. RBSK 0185

Fig. 2.40

Measure the brake drum diameter at various points around the drum and record the readings taken. - Fig. 2.41

Fig. 2.41

34

ArvinMeritor Stopmaster Wedge Brake

2 Maintenance

Centralize both brake shoes and measure the brake lining diameter as illustrated. (When setting, it is important to ensure that the spring brake is still totally caged). - Fig. 2.42

Standard brake shoe data Dimensions are expressed in mm Brake type 360 381 394 410 STOPMASTER II 358 0.5 379 0.5 392 0.5 408 0.5 STOPMASTER E 358,5 0.5 379 0.5 408,5 0.5

Fig. 2.42

Adjust the lining diameter by turning the adjusting bolts by an equal amount until the brake lining diameter is 2 mm less the drum diameter previously recorded. Fit the brake drums. With long feeler gauge check clearances at shoe centres. This should be between 0.8 and 1.2 mm. If necessary readjust to obtain these clearances. Fig. 2.43

Fig. 2.43

Uncage the air chamber spring and refit air pipes. Refit wheels and check brakes on a rolling road and test drive.

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35

Troubleshooting

pg. 38

Troubleshooting

ArvinMeritor Stopmaster Wedge Brake

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3 Troubleshooting

The following chart shows the most common faults occurring to Stopmaster brakes.

Fault Self-adjustment not functioning

Possible causes 1 2 3 4 5 6 1 2 3 4 5 1 2 3 4 5 6 7 1 2 3 4 5 1 2 3 4 5 6 7 8 9 Guide pawl spring is broken (9) Worn or damaged pawl and/or actuator teeth (9, 4) Adjusting bolt too tight in actuator (2, 4) Brake shoe web not properly located in shoe retainer (2, 29) Corroded adjustment parts (2, 4, 5, 9, 11) Insufficient lubrication Spring chamber not fully released Air leak from spring chamber Overstretched or broken brake shoe return springs (30) Anchor/adjusting plungers are tight or seized up (5, 6) Broken wedge spring Reverse installation of brake shoe (short radius must be seated on adjusting bolt) (29) Brakes are dragging - see Faults (2) Unequal air chamber output Damaged or broken hold-down clip Brake drum diameter variations (tapering) Dirt and/or grease on lining (29) Variations in surface finish of brake drums Shoe to drum clearances too large Worn linings Unsuitable lining material Grease or oil on linings Input pressure too low Air chamber installation depths incorrect Unequal air chamber output Different shoe drum clearances - see Faults (1) Grease or oil on linings Different brake drum material or surface finish Different lining material Broken wedge spring Heavy dirt ingress See also all Possible Causes described at Fault 3.

Brakes dragging

Uneven lining wear

Insufficient brake performance

Brake pulling

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ArvinMeritor Stopmaster Wedge Brake

ArvinMeritor Heavy Vehicle Braking Systems Grange Road, Cwmbran South Wales NP44 3XU - U.K. Tel.: +44 (0) 1633 834238 Copyright 2002 Fax: +44 (0) 1633 834191 www.arvinmeritor.com ArvinMeritor Inc.

Published in Italy Issued 01/2007 M-graph - MM0153

ArvinMeritor Heavy Vehicle Braking Systems Grange Road, Cwmbran South Wales NP44 3XU - U.K. Tel.: +44 (0) 1633 834238 Copyright 2002 Fax: +44 (0) 1633 834191 www.arvinmeritor.com ArvinMeritor Inc.

Published in Italy Issued 02/2007 M-graph - MM0153