SAC Brake Training Presentation

February 2012

Simplex Air Cam Drum

Brake

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 SAC Brake Training Presentation
February 2012

Simplex Air Cam Drum Brake: EXPLODED VIEW & LIST

1 Lining inspection grommet
2 Dirt shield
3 Tappet Screw Cover
4 “O” Ring
5 Tappet Head Assembly
6 Tappet Dust Excluder
7 Strut
8 Torque Plate
9 Housing Bearing
10 Camshaft Seal (Bracket)
11 Camshaft Seal (Housing)
12 Thrust Washer
13 Cross Shaft
14 Cover Plate
15 Gasket
16 Camshaft
17 Bolt
18 Washer
19 Spring Clip
20 “C” Spring
21 Spring Pin
22 Seal
23 “O” Ring
24 Plug
25 Circlip
26 Auto-adjuster Pinion
27 Cup Assembly
28 Spring
29 Manual Override Stem
30 Circlip
31 Stem Seal
32 Plug
33 “O” Ring
34 Adjuster Pinion
35 Spring
36 Manual Adjuster Stem
37 Ref. Early version
38 Spacer
39 Spring Clip
40 Washer
41 Nut
42 Circlip

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 SAC Brake Training Presentation
February 2012

Simplex Air Cam Drum Brake: How it Works

• How it Works
• The leading / trailing shoe brake operation utilises the tried and
proven principle of the FCSS cam unit.
• The camshaft, when turned, pushes out the struts located in the
cam pockets at one end and tappet pockets at the other. This
movement is transmitted to the brake shoes via the tappet heads.
• The ends of the shoe webs are free to slide on the tappet heads
and torque plate abutment faces, thus optimizing shoe efficiency
and lining wear.
• Adjustment, whether automatic or manual, functions within the
cam unit. The "C" type shoe return spring is located at the torque
plate abutment block loading the shoes towards the centre of the
brake by pressing against the shoe spring pins.
• Lining inspection holes, covered by rubber grommets, are included
in the dirt shield.
• Actuation is by air diaphragms with spring brake chambers for
parking.
• The push rod of the actuating unit operates directly on the
camshaft lever and turns the camshaft, thus applying the brake.
• As the shoe to drum clearance is maintained by the automatic
adjusters, diaphragm travel and thus air consumption is minimized
and brake response times are improved. 3
 SAC Brake Training Presentation
February 2012

Simplex Air Cam Drum Brake : How it Works

• Automatic Adjustment
• The exponential auto-adjust mechanism is
contained completely within the cam housing.
• When the lining wear creates a lining to drum
clearance greater than a predetermined
amount adjustment takes place on both the
leading and trailing shoes.
• The shoe to drum clearance is determined
primarily by the clearance, or backlash,
existing between the tappet screw helix teeth
and the adjuster pinion helix teeth.
• During normal brake application, if lining to
drum clearance is within limits, the tappet
screw movement will be insufficient to take up
the backlash and no adjustment will occur.
• As lining wear takes place and auto
adjustment is required the tappet screw will
move further out to apply the shoes to the
drum.

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 SAC Brake Training Presentation
February 2012

Simplex Air Cam Drum Brake : How it Works

• In moving out, the backlash between the tappet
screw helix and the adjuster pinion helix teeth is
taken up, the adjuster pinion is lifted off its cone
seating and rotated as the tappet screw
continues to move out.
• On the return of the tappet screw, when the
brake is released, the other face of the tappet
screw helix contacts the adjuster pinion helix
teeth and forces the pinion down onto its cone
seating.
• The pinion cannot now move, thus causing the
tappet screw to rotate (Fig.), as it is pushed back
by the load created by the "C“ spring.
• The tappet head itself cannot turn as it is held by
the brake shoe webs, so a simple "screw-jack"
effect is obtained maintaining the designed lining
to drum clearance.
•The cup assembly prevents the auto-adjuster from de-adjusting under adverse conditions.
•From Fig.on slide 4 it will be seen that wear is sensed directly at the leading shoe.
•Trailing shoe adjustment is achieved via the adjuster cross shaft connecting the helix on
the leading shoe tappet screw to the helix on the trailing shoe tappet screw.

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 SAC Brake Training Presentation
February 2012

Simplex Air Cam Drum Brake : How it Works

•A tappet stop ring (Fig.) is incorporated on early

tappet screws to prevent the adjuster operating when
the lining is fully worn. On later level brakes the
tappet head assemblies all have a stop pin fitted into
the tappet head (Fig) and may have a tappet stop on
one of the tappet screws.

•On a left hand brake the tappet stop is on the

leading shoe tappet screw whilst on the right hand
brake it is on the trailing shoe tappet.

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 SAC Brake Training Presentation
February 2012

Simplex Air Cam Drum Brake : How it Works

• Manual Override Mechanism:
A • Auto-Adjust Brake (Fig.A)
• A manual override stem is incorporated:
• - to enable initial shoe to drum clearance to be set after
new shoes are fitted
• - to de-adjust the brake, if necessary, to enable the drum to
be removed
• - to fully de-adjust the brake.
• There is no need to use this stem for any other purpose.
• To operate the manual override depress the stem into the
torque plate and turn it until it engages with the adjuster
pinion head (Fig.A).
• With pressure being maintained it is then possible, by
B turning the adjuster in the same direction as forward drum
rotation, to increase the shoe to drum clearance, i.e. to de-
adjust the brake (Fig.B).
• Do not use excessive force.
• Note: there are a number of variations of the adjuster
design: it is important to establish the brake part number to
identify the correct service kit.

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 SAC Brake Training Presentation
February 2012

Simplex Air Cam Drum Brake : How it Works

A • Manual Adjustment:
• Non-Automatic Brake adjuster (Fig.A)
• Regular inspection and adjustment, where
necessary, of the lined shoes is important.
• The manual adjuster stem is situated in the same
position as the manual override stem on the auto-
adjust brake, and external identification is shown in
Fig.B
• As with the auto-adjust version a tappet head stop
B is incorporated in some brake variants.
• This adjuster stem is permanently engaged
therefore it is not necessary to press the stem into
the brake before turning the adjuster.
• Turn the adjuster stem in the same direction as
forward drum rotation to increase the shoe to drum
clearance (i.e. to de-adjust the brake)
• Do not use excessive force.

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 SAC Brake Training Presentation
February 2012

Simplex Air Cam Drum Brake: Servicing

• Observance of suitable servicing and inspection schedules will help
to ensure that the vehicle's braking system is kept at optimum
safety and efficiency throughout its life.
• Should conditions exist whereby it is not possible to renew the
mechanical components, the existing components should be
overhauled using the appropriate ArvinMeritor service kit.
• Whether the unit is overhauled or renewed, care must be taken to
prevent contamination and emphasis must be placed on
cleanliness.
• The work area, bench, tools, containers, overalls and hands must
be scrupulously clean.
• CAUTION:
• Any inspection or work carried out in line with the schedules must
be done by an experienced fitter/mechanic suitably trained to a high
degree of competence relating to the vehicles in question.

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 SAC Brake Training Presentation
February 2012

Simplex Air Cam Drum Brake: Servicing

A • Every 20,000 km (12,500 miles) check the linings for
wear via the lining inspection holes (Fig.A). Always
replace the grommets after checking to avoid dirt and
water ingress.
• The linings must not be allowed to wear below a
minimum thickness of 5 mm (0.20 in.) (Fig.B).
• Prior to fitting now shoes always check the "C" spring
(Fig.B). If the distance between the two inner ends of
the spring exceeds 250 mm (9.85 ins.) the spring must
be replaced.
• If re-lined shoes are to be fitted and they are pop-riveted
B refer to Fig.C

C
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 SAC Brake Training Presentation
February 2012

Simplex Air Cam Drum Brake: Servicing

• Checking brake function in service SETTING LEVER TRAVEL AFTER SERVICE:
• Lever travel is used to assess brake and adjuster AT 6 TO 7 BAR AIR PRESSURE
function. BRAKE BRAKE LEVER
• Ensure the lever operates freely. CYLINDER SIZE: LEVER TRAVEL AT
SQUARE INCHES LENGTH: mm CLEVIS PIN:
• The lever travels in the table of ‘Setting Lever Travels
after Servicing’ are at the higher end of the values to be mm Tolerance: 0
expected in service. to + 5
16 125 30
• There will usually be a difference in the lever travels
between left and right brakes on the same axle. The 16 140 30
balance of braking response is not usually affected until
the difference exceeds 20% of the longest travel. 20 125 30
20 140 35
• CAUTION: Do not be tempted to use the
override mechanism to "standardise" the
24 110 30
clearances. 24 125 30
24 140 35
LEVER TRAVEL 24 155 40
24 170 45
24 180 50

30 110 30
30 125 35
30 140 40
30 155 45
30 170 50
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 SAC Brake Training Presentation
February 2012

Simplex Air Cam Drum Brake: Servicing

• Fitting New Shoes and "C" Spring
• Brake shoes should be replaced with double crown
ground lined shoes when the lining material is worn to
a minimum thickness of 5mm (0.20 in.)
• Inspect shoe tips, if the flat length (Fig) exceeds 28mm
the shoes must be replaced.
• Failure to replace the shoes at the correct time may
result in damage to the shoes and drums and impair
brake efficiency.
• Always fit new shoes in pairs to both sides of the
vehicle.
• If new or re-lined box sectioned shoes are to be fitted
always replace the "C" spring.
• Park vehicle on hard level ground.
• Chock road wheels.
CAUTION
• Jack up axle and securely fit axle stands.
Do not apply brakes after brake
• Wind off spring brake retraction bolt from appropriate drums have been removed
units. otherwise damage may be caused
to brake components.
• Remove wheels and drums.

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 SAC Brake Training Presentation
February 2012

Simplex Air Cam Drum Brake: Servicing

• NOTE: If difficulty is experienced in removing drums, A
possibly due to a lipped drum condition, it will be
necessary to wind off the brake adjustment sufficiently
to allow the lip to clear the shoe.
• Use the manual adjuster or override to de-adjust the
brake.
• Before fully de-adjusting the brake inspect the dust
covers for splits or damage. Fig.A Dust Cover

• Then fully wind back the adjustment with the

manual stem or manual adjuster stem. Fig.B
•WARNING: Always de-adjust/adjust the brake
carefully by hand with a suitable spanner. NEVER use
power tools, air or electric, to de-adjust or adjust the
brake.
•Rotate the stem one turns in the opposite direction
from this position to ensure that the tappet head
assemblies are not locked onto the tappet screw. Fig.B
•Remove the shoes.

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 SAC Brake Training Presentation
February 2012

Simplex Air Cam Drum Brake: Servicing

Dust Cover Replacement on Both Tappets Dust Cover Service Tool
•Release the dust cover from the tappet head groove.

•Lever the dust cover free from the housing and pull the
dust cover off over the tappet head.

•Extreme care must be taken to avoid overstretching the

dust cover when carrying out the following.
•Fit the new dust cover by sliding it over the tappet head
until it locates in the groove.

•Always ensure that the tappet heads in question are not

wound back to a locked condition.
•Without using excessive force wind the tappet heads
fully back by hand. Wind out the leading tappet head
one full turn and the trailing tappet one and a half turns.

•Push the dust cover outer edge into the housing and using the tool (See Fig.) gently tap squarely into
place.
•Refit shoes, spring pins and drums. Re-set the brake shoes, referring to Shoe Setting Procedure.

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 SAC Brake Training Presentation
February 2012

Simplex Air Cam Drum Brake: Servicing

• Remove the brake shoes, spring pins and "C" spring (only
remove the "C" spring if replacing it) as follows: A
• Using the ArvinMeritor spring tool YCB244 (Fig.A) relieve
the load on the spring.
• Support the shoes, extract the pins and remove the shoes.
• Remove the tool. Unscrew the bolt/nut and remove the clip.
• CAUTION: Do not turn the tappet heads (Fig.B) otherwise it
will be necessary to carry out the re-setting procedure.
• Remove the "C" spring. The operation of the auto-adjust is
dependant on the effectiveness of the spring and prior to B
fitting new shoes check the "C" spring.
• Using a suitable solvent wash down the brake assembly.
• WARNING: Do not use an air line to blow dust from the
backplate. If inhaled any form of dust can be at best an
irritant, at worst dangerous.
• Check the points indicated (Fig.B) for signs of damage or
corrosion. Clean up any slight markings and apply "P.B.C.“
copper based grease.
• Check the tappet head assemblies for damage to the metal
tappet screw covers.
• Replace with new covers if in doubt.
• Replace the rubber dust covers if damaged (Refer to "Dust
Cover Replacement").
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 SAC Brake Training Presentation
February 2012

Simplex Air Cam Drum Brake: Servicing

• Apply copper based grease to the shoe tips.
• Ensure shoe linings are free from oil and grease.
• On truck units (Fig) fit the "C" spring into the torque
plate, position the spring clip and lightly retain with a
new bolt/nut.
• On some bus units, position the "C" spring and retain
with the spring clip and new bolt.
• If re-using the bolt a thread retaining compound must
be applied.
• NOTE: Bolts with a captive washer and later flange
bolts are interchangeable.
• Check the "C" spring is located correctly I the plate and
clip.
• Tighten the spring clip bolt to a torque of 48 to 58 Nm BUS!?
(36to 41 lbf.ft.) or the nut to 22 to 27 Nm (16 to
201bf.ft.).

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 SAC Brake Training Presentation
February 2012

Simplex Air Cam Drum Brake: Servicing

• CAUTION
• The leading and trailing shoes must not be
confused.
• Position shoes as shown in Fig.
• Using the ArvinMeritor spring tool YCB244 (Slide 13
Fig.A), position the shoes and fit the spring pins.
Remove the tool.
• If fitted, reposition sensor wire. Ensure that the
sensor is reset according to the manufacturers
instructions.
• Inspect the drum for brake lining dust and signs of
grooving.
• WARNING: Do not use an air line to blow
dust from the drum. If inhaled any form of
dust can be at best an irritant, at worst
dangerous.
• Heavily grooved drums may be machined to
manufacturers recommendations. If in doubt
replace.
• Complete by following Lever Setting After Service
section. Slide 10 17
 SAC Brake Training Presentation
February 2012

Simplex Air Cam Drum Brake: Servicing

•Shoe Setting Procedure - if necessary
•Whenever maintenance work is carried out the following check should be made to
facilitate the correct bedding in of the linings when renewed.
•If this is not carried out differential braking across the axle may occur during the
bedding-in period.
•The object is to ensure that the trailing shoe contacts the drum before the leading
shoe and is achieved by manual adjustment.
•Time spent in setting up the brake initially will pay dividends in brake performance and
driver satisfaction.

• The trailing shoe lead may need to be reset after

servicing expanders, adjusters or after refitting
shoes.
• The use of the ArvinMeritor Brake Shoe Setting
Gauge - Part No.YCB 229 (Fig) - ensures that the
correct relationship between the leading and trailing
shoes and the drum is achieved.

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 SAC Brake Training Presentation
February 2012

Simplex Air Cam Drum Brake: Servicing

• Centralizing and Checking the Shoes A
• Both shoes should be centralized visually.
• Mount the Shoe Setting Gauge as in Fig.A
• Measuring positions 1, 2, 3, & 4 are at the second row of
rivets from each end of the shoes.
• SLIDE SHOE ‘S’ SO THAT 1 AND 2 READ THE
SAME
• ZERO THE DIAL TEST INDICATOR ( DTI)
• SLIDE SHOE ‘P’ SO THAT THE DTI READS ZERO
AT 3
• MOVE DTI TO 4: READ MEASUREMENT
• THE READING IS REQUIRED TO BE BETWEEN:
+0.00 and - 0.25mm
• IF SETTING IS REQUIRED:
• REMOVE COVERPLATE ‘a’ AND THE CROSS
SHAFT
• OPERATE THE MANUAL ADJUSTER TO GIVE THE
CORRECT DTI READING AT 4 – KEEP CHECKING
AND RE-SETTING THE READING AT 3 TO ZERO
BY SLIDING THE SHOE ‘P’
• REFIT THE CROSS SHAFT AND COVER PLATE ‘a’ –
MAKE SURE THE GEARS ENGAGE – IF
NECESSARY MOVE THE MANUAL ADJUSTER A
SMALL AMOUNT SO THAT THE COVER PLATE IS
FULLY DOWN BY HAND PRESSURE

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