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Meritor Heavy-Duty P Series Maintenance Manual

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Maintenance Manual MM-0440
Heavy-Duty P Series Cam Brakes
Issued 09-04

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  • Page 1 Maintenance Manual MM-0440 Heavy-Duty P Series Cam Brakes Issued 09-04...
  • Page 2 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. Meritor Heavy Vehicle Systems, LLC, reserves the right to revise the information presented or to discontinue the production of parts described at any time.

  • Page 3: Table Of Contents

    Contents Asbestos and Non-Asbestos Fibers Section 1: Exploded View Section 2: Introduction Description Cam Brake Tips Section 3: Removal and Disassembly Removal Wheel Components Brake Shoes Camshaft and Slack Adjuster Section 4: Prepare Parts for Assembly Clean, Dry and Inspect Parts Clean and Dry Parts Corrosion Protection Inspect Parts...
  • Page 4 Employers and workers employed outside of the United States should consult the regulations that Employers and workers employed outside of the United States should consult the regulations that apply to them for further guidance. apply to them for further guidance. Meritor Maintenance Manual MM-0440 (Issued 09-04)
  • Page 5 Cam Head Washer Small Spacing Washer Cam Needle Bearing Shoe and Lining Assembly Anchor Pin Lock Screw Brake Spider Brake Shoe Anchor Pin Anchor Pin Lock Anchor Pin Felt Retainer Anchor Pin Felt Shoe Return Spring Meritor Maintenance Manual MM-0440 (Issued 09-04)

  • Page 6: Section 2: Introduction

    2 Introduction To avoid flat spots, lubricate a cam roller directly in the web roller Meritor P Series cam brakes are air actuated and cam operated with pocket and not at the cam-to-roller contact area. Flat spots can two brake shoes – each mounted on a separate anchor. The brakes...

  • Page 7: Section 3: Removal And Disassembly

    WARNING If the slack adjuster is not a Meritor automatic slack adjuster, refer To prevent serious eye injury, always wear safe eye protection to the manufacturer’s literature for the correct service procedures.

  • Page 8: Brake Shoes

    Cut the lock wire and remove the anchor pin lock screws from the brake spider. Figure 3.3. 0.030" (0.76 MM) 4000342a Figure 3.4 Remove the washers, retainers and spacers from the camshaft. Pull the camshaft from the spider and bracket. Meritor Maintenance Manual MM-0440 (Issued 09-04)

  • Page 9: Section 4: Prepare Parts For Assembly

    NOTE: If you remove cotter pins from a slack adjuster during correctly. Read the manufacturer’s instructions before maintenance and service procedures, Meritor recommends that you using hot solution tanks and alkaline solutions. Then install clevis pin retainer clips at assembly.
  • Page 10 Replace the slack adjuster if the worm drive does not operate If the gap exceeds 0.060-inch (1.52 mm): Replace the correctly. Do NOT repair a manual slack adjuster. clevis with a one-piece threaded clevis. Meritor Maintenance Manual MM-0440 (Issued 09-04)
  • Page 11 NOTE: If necessary, install a camshaft into the slack adjuster gear to minimize grease flow through the gear holes. Use a grease gun to apply Meritor specification O-616-A, O-692 or O-645 lubricant to the slack adjuster grease fitting, until grease flows from around the camshaft splines and pawl assembly.

  • Page 12: Section 5: Assembly And Installation

    Tighten the capscrews to the correct torque as specified in Section 9. Install the cam head thrust washer onto the camshaft. Apply BOLT Meritor specification O-617-A or O-617-B grease to the TORQUE SIZE camshaft needle bearings and journals.

  • Page 13: Brake Shoes

    Do not allow grease to contact the area of the camshaft roller that touches the camshaft head. Lubricate the camshaft roller pin and anchor pin with Meritor specification O-617-A or O-617-B grease. Install the brake shoes onto the spider with the anchor pins.
  • Page 14 If you are installing a new slack adjuster: Verify it is the same length as the one you are replacing. Install the clevis on the push rod. Check the position of the clevis with the Installation template. Figure 5.7. PAWL ASSEMBLY 4004500a Figure 5.8 Meritor Maintenance Manual MM-0440 (Issued 09-04)
  • Page 15 NOTE: Refer to Maintenance Manual 4, Cam Brakes and Automatic Slack Adjuster, for complete installation instructions. Release the brakes and verify that the manual adjusting nut rotates to the left as the push rods fully retract. Meritor Maintenance Manual MM-0440 (Issued 09-04)

  • Page 16: Section 6: Adjustment

    Replace linings against the drum, brakes applied. Measure the same damaged pawls before putting the vehicle in service. distance again while the brakes are applied. The measurement you obtain is Y in Figure 6.2. Meritor Maintenance Manual MM-0440 (Issued 09-04)

  • Page 17: Commercial Vehicle Safety Alliance (Cvsa) Guidelines

    Test the vehicle before you return it to service. Step 3 STROKE 90-100 psi (620-690 kPa) in air tank — engine OFF • Spring brakes released • Service brakes applied 4000374b Figure 6.4 Meritor Maintenance Manual MM-0440 (Issued 09-04)
  • Page 18 6-25/32 1-3/4 7-7/32 1-3/4 8-3/32 2-1/4 Table B: Long Stroke Clamp-Type Brake Chamber Data Brake Outside Diameter Adjustment Limit Type (inches) (inches) 6-3/8 6-25/32 7-7/32 7-7/32 8-3/32 *For 3" maximum stroke type 24 chambers. Meritor Maintenance Manual MM-0440 (Issued 09-04)

  • Page 19: Section 7: Reline The Brakes

    If the cam Install the rivets into the rivet holes following the correct is in front of the axle, the bottom shoe is the primary shoe. sequence. Figure 7.2. Meritor Maintenance Manual MM-0440 (Issued 09-04)

  • Page 20: Reline The Brakes

    Check to ensure that the lining and shoe contact faces are clean. Align the bolt holes in the lining with the holes in the shoe. NOTE: Verify that the bolts are the correct body diameter, head size and shape, length and material. Meritor Maintenance Manual MM-0440 (Issued 09-04)

  • Page 21: Section 8: Maintenance

    1-1/2 Calcium Base Refer to the grease manufacturer’s O-641 — Anti-Seize specifications for the temperature service limits. *Do not mix Meritor specification O-637 grease, part number 2297-U-4571, a calcium-base, rust-preventive grease, with other greases. Meritor Maintenance Manual MM-0440 (Issued 09-04)
  • Page 22 8 Maintenance Camshaft Bushings Meritor recommends that you install new camshaft bushings whenever you install a new camshaft. Lubricate through the fitting on the bracket or spider until new grease flows from the inboard seal. Rollers and Anchor Pins When you disassemble the brake, or when necessary, lubricate the anchor pins and rollers where these parts touch the brake shoes.

  • Page 23: Slack Adjuster

    O-641 — Anti-Seize the temperature service limits. *Do not mix Meritor specification O-637 grease, part number 2297-U-4571, a calcium-base, rust-preventive grease, with other greases. Anti-Seize Compound Off-Highway Use anti-seize compound on the clevis pins of all automatic slack At least every four months when you replace the seals and reline the adjusters.

  • Page 24: Reline The Brakes

    Damage to components will result. Primary Shoe Locations Meritor recommends that you replace the springs, rollers, camshaft bushings and anchor pins at each reline. The first shoe past the camshaft in the direction of wheel rotation is the primary shoe.

  • Page 25: Major Overhaul

    FRONT AXLE Perform a major overhaul at every second reline, or as necessary. Replace the shoe return springs. Replace the damaged or worn parts with genuine Meritor parts. Check the components for the following conditions. Spiders for distortion and loose bolts...

  • Page 26: Section 9: Specifications

    4004505a Figure 9.1 Table E: Brake Mounting Bolts Bolt Size, Grade 8 Torque, lb-ft (N m) 7/16″-20 60-75 (81-102) 1/2″-20 85-115 (115-156) 9/16″-18 130-165 (176-224) 5/8″-18 180-230 (244-312) Meritor Maintenance Manual MM-0440 (Issued 09-04)
  • Page 27 65-85 lb-ft (88-115 N m) Haldex 35-50 lb-ft (48-68 N m) 70-100 lb-ft (95-136 N m) 35-40 lb-ft (48-54 N m) 133-155 lb-ft (180-210 N m) Anchorlok/ — 130-150 lb-ft (177-203 N m) Haldex Meritor Maintenance Manual MM-0440 (Issued 09-04)
  • Page 28 Meritor Heavy Vehicle Systems, LLC 2135 West Maple Road Printed in USA Troy, MI 48084 USA 866-OnTrac1 (668-7221) Copyright 2004 Issued 09-04 meritor.com Meritor, Inc. Maintenance Manual MM-0440 (16579)

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