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1、Maintaining Guide Manual of the Air Disc BrakeContentCATALOGUE1. Summarize2. Maintaining description2.1 Safety briefing during maintaining2.2 Breaking function check2.2.1 Clearance check2.2.2 Adjuster check2.3 Brake pads check2.4 Rotor check3. Brake pads replacement4. Brake replacement5. Dust cap re
2、placement5.1 Dust cap & bushing replacement5.2 Screw dust cap replacement6. Rotor check/replacement6.1 Rotor check6.2 Rotor replacement7. Brake chamber replacement7.1 Brake chamber removal7.2 Brake chamber installation8. Adjuster replacement9. Troubleshooting10. Exploded view11. List of mounting & m
3、aintaining toolsBrief introduction of YOUFINYOUFIN was established on May 20th, 1998. It is a Sino-Foreign joint-venture enterprise registered in Wuhan Economic and Technological Development Zone with multi-investors among which private investors dominate. It is a professional company engaged in man
4、ufacturing disc brakes and serving the principal automobile manufacturers by providing modularized supply. The main products cover hydraulic disc brakes and air disk brakes in close to thirty sizes.YOUFIN developed the air disc brake autonomously and patented the product. So far we are the only manu
5、facturer in China that can mass produce air discs to be used in long distance coaches and inner city buses. It is evaluated that the quality of our products is close to the advanced international level in field use. The product development is part of the National Torch Plan and is also sponsored by
6、the Small and Medium-sized Enterprise Technical Innovation Foundation of Chinese Ministry of S&T.Our Air Disc Brake products are on an absolute leading position in China and the same international level as far as the key technology is concerned.1. SummarizeYOUFIN Air Disc Brake has four sizes (16, 1
7、7.5 19.5, 22.5). It can satisfy different vehicles. The brakes have compact structure; automatically wear compensation and can easily changing the brake pad.2. Maintaining description2.1 Safety briefing during maintainingIts most important to ensure safety driving and breaking by good characteristic
8、s of the brake.Observe brake pad and rotor wear limits. When they warned already to assigned smallest thickness, it need replace immediately, otherwise, it may cause the accident. The pads scorches, grinds or greases must replace immediately. Every pad on each bridge must replace at the same time.Wh
9、en services the brake, the vehicle must park in smooth gound and the wheel withstand with the block/ stone prevent rolls.Note: Must guarantee it does not occur with careless brake. When replace brake pad dont make the brake, otherwise, it will hurts the body! Do not use the compressed air or other c
10、leaning up equipment clean the brake, in order to avoid injures the body. Be sure your hands and fingers place outside the caliper, in order to avoid injures the body. When moves and installs the brake should have some assistance, avoids it too heavy to hurts the body. When take off the brake to mak
11、e maintenance, it must fix on the clamp with high strength bolt, in order to avoid hurts the body. Only allowed genuine YOUFIN kits and pads permitted by YOUFIN. During the first 50 miles driving after new pad replacement, should avoid promptly brake and brake at a long distance, Prevent overhigh te
12、mperature. Allowed genuine YOUFIN kits and brake pads permitted by YOUFIN. Only can use the recommendation kits in service. Screws the bolt/nut according to the request moment of force.2.2 Brake Function check2.2.1 Clearance checkProcess: Take off the hexagon bolt (39), loosen the pad retainer (38).
13、 Remove pad retainer (38) from caliper. Remove 3pcs of pad clip (37). Move the cable (40) to the side. Push the caliper towards the wheel and check the clearance with tune-up gauge.0.5mm clearance 1.2mmNote: Insert tune-up gauge between the caliper (1) and the brake pad (35). Should check the adjust
14、er while the clearance is out of standard.2.2.2 Adjuster checkProcess: Remove the rubber cap (12). Turn hexagon head (22) clockwise by wrench to ensure clearance larger than 3mm. (Or remove the brake pad and the push board)Note: a. Need enough room (3mmclearance) for turn adjuster preventing un-fit.
15、b. Never force to adjust the hexagon head (22) and/or the adjuster!Push the pressure arm 5 times in small increments and observe the hexagon head (22). While the adjuster is in good condition, hexagon head (22) must rotate clockwise.c. As the regulated quantity increase, rotation angle decreases. If
16、 the adjuster hexagon head (22):a) Not running at allb) Only running at first pushc) Running, but stopped in the middleWhile considers adjuster failed. You should replace the brake on the basis of section 4 or change the adjuster in accordance with section 8. Keep the clearances at 1mm (section 3) after adjuster check is finished. Reinstall the rubber cap (12).2.3 Brake pads wearing checkAllowed wear limits as follow:Brake No. New Pads Thickness
