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Meritor ELSA 195 Maintenance Manual

Reaction beam air disc brake
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an ArvinMeritor brand
Maintenance manual no. MM-0350
ELSA 195 Reaction Beam Air Disc Brake
Issue 02/2003

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Summary of Contents for Meritor Meritor ELSA 195

  • Page 1 an ArvinMeritor brand Maintenance manual no. MM-0350 ELSA 195 Reaction Beam Air Disc Brake Issue 02/2003...
  • Page 2 Service Notes Before You Begin Access Information on ArvinMeritor's Web Site This publication provides installation and maintenance procedures for the ELSA 195 Reaction Beam Air Disc Brake. Additional maintenance and service information for ArvinMeritor's commercial vehicle systems component lineup is also available at The information contained in this publication was current at the www.arvinmeritor.com.
  • Page 3 Contents Section 1: Introduction 35 Section 7: Guide Sleeve, Dust Excluder, Retainer & Bushes Axial brake ELSA 195 - exploded view Axial brake ELSA 195 - parts list Checking Slide Pin Bush Wear Housing assembly - cross section A - Tangential Test Brake body detail - cross section B - Radial Test How it works...
  • Page 4 Terms used in this manual Manufacturer: Warranty ARVINMERITOR Warranty applies to the air disc brake installed on vehicles for which it was designed. Warranty is void in the following cases: Manual: Maintenance manual no. MM-0350 • Improper use of the vehicle on which the air disc brake is installed (usage conditions, overloading etc.) Device: ELSA 195 Reaction Beam Air Disc Brake...

  • Page 5: Table Of Contents

    Introduction Axial brake ELSA 195 - exploded view Axial brake ELSA 195 - parts list Housing assembly - cross section Brake body detail - cross section How it works Automatic adjustment Manual adjustment and de-adjustment during a pad change ArvinMeritor Air Disc Brake ELSA 195...
  • Page 6 Exploded view Axial brake ELSA 195 ArvinMeritor Air Disc Brake ELSA 195...
  • Page 7 ELSA 195 Axial brake parts list Description Description Bridge Guide Sleeve (Long) Carrier Guide Sleeve Screw (Long) Guide Sleeve (Short) Pad spring Guide Sleeve Screw (Short) Screw (Pad Retaining Plate) End Cap Pad Retaining Plate Bridge Screw x 4 Piston Head Seal (Actuator) Piston Dust Excluder Seal Manual Adjuster Stem...

  • Page 8: Housing Assembly - Cross Section

    Housing assembly - cross section Rotor Fig. 2 ArvinMeritor Air Disc Brake ELSA 195...

  • Page 9: Brake Body Detail - Cross Section

    Brake body detail - cross section Fig. 3 ArvinMeritor Air Disc Brake ELSA 195...
  • Page 10 Brake body detail - cross section Parts list Description Piston Head Piston Dust Excluder Manual adjuster stem Brake housing Roller Half Bearing Operation Shaft Needle Bearing Saddle (Half Bearing) Tappet Piston shaft Retainer Clutch plate Drive sleeve Clutch drive sleeve Wrap spring Piston housing Intermediate gear...

  • Page 11: How It Works

    1 Introduction The air actuated disc brake has been designed to incorporate a direct mounted air actuator which is mounted axially as shown in Fig. 4. The Brake, detailed in the exploded view (Fig. 1), can be fitted to any axle and can be used for vehicle parking when a service / spring brake actuator is fitted.

  • Page 12: Automatic Adjustment

    1 Introduction Automatic adjustment b) Operation with adjustment As a result of pad or rotor wear, the running clearance is now The automatic adjuster makes an adjustment to the operation of greater than the inbuilt tolerance and adjustment of the the brake pad to compensate for pad wear.

  • Page 13: Manual Adjustment And De-Adjustment During A Pad

    1 Introduction c) Manual adjustment and de-adjustment during a pad Actuator change The ELSA 195 disc brake uses a 65 mm stroke actuator. - See Manual adjustment of the brake must only be made at a pad Fig. 5. - This actuator is supplied with a pushrod setting length of change.
  • Page 14 ArvinMeritor Air Disc Brake ELSA 195...
  • Page 15 Pad replacement A – Pad replacement B – Pad removal with PWWI fitted C – Cleaning and inspection D – Fitting New Pads ArvinMeritor Air Disc Brake ELSA 195...
  • Page 16 2 Pad replacement The ELSA 195 Air Disc Brake uses a device to monitor pad wear (optional). The Device if fitted, is known as a PWWI (Pad Wear Warning Indicator) and is fitted to the pad/s - Fig 6. If fitted, this device will illuminate a warning lamp to indicate that a pad change is required.
  • Page 17 2 Pad replacement It is now possible to remove the pad strap and PWWI assembly as C - Cleaning and inspection far as the connecting cable will allow. Ensure that this cable is not With the brake pads removed check the integrity of the guide stretched.
  • Page 18 2 Pad replacement D - Fitting New Pads De-adjust the brake until, with the housing pulled across, there is a sufficient aperture to fit the outboard pad. Fit the new outboard pad. - Fig. 10 Push the housing back towards the rotor until the new pad contacts the rotor face.
  • Page 19 2 Pad replacement Do not use excessive force but ensure they are pushed to the bottom of the slot. Fig. 13 Refit both pad springs ensuring that they are correctly located in the pad back plates. Fig. 14 Ensure that the wires exit to the back of the pad. Insert the pad retaining plate together with the PWWI assembly into the slot in the brake housing.
  • Page 20 ArvinMeritor Air Disc Brake ELSA 195...
  • Page 21 Brake replacement A - Brake removal B - Brake fitment ArvinMeritor Air Disc Brake ELSA 195...
  • Page 22 3 Brake replacement A – Brake Removal Park the vehicle on hard ground and chock the road wheels. Apply air pressure to release the park brake and wind off the spring actuator retraction screw (where appropriate). Jack up the axle and fit suitable axle stands securely. Remove the road wheels and exhaust all air from the system.
  • Page 23 3 Brake replacement CAUTION When lifting the Brake assembly avoid trapping fingers between the Brake housing and carrier which are free to slide relative to each other. Also prevent any sudden movement, which may result in rapid sliding of the components, which may cause damage to rubber dust excluder areas.
  • Page 24 ArvinMeritor Air Disc Brake ELSA 195...
  • Page 25 Bridge replacement A - Removing the Bridge B - Fitting the Bridge ArvinMeritor Air Disc Brake ELSA 195...
  • Page 26 4 Bridge replacement A - Removing the Bridge Ensure that the mating surface of the housing is clean. Check the guide sleeve dust excluder for signs of damage and secure Remove the pads and PWWI where fitted as described in section location - Fig.
  • Page 27 Housing assembly replacement A - Removing the Housing assembly B - Fitting Housing assembly ArvinMeritor Air Disc Brake ELSA 195...
  • Page 28 5 Housing assembly replacement A - Removing the Housing assembly If any doubt exists as to the suitability for further service replace with new guide sleeves (24, 26) and if necessary a new carrier (2) Support the vehicle and remove the air actuator as described in the section 3 “Brake replacement”.
  • Page 29 5 Housing assembly replacement Apply grease to the guide sleeve and housing guide sleeve bores. Fig. 27 NOTE : Only use the grease supplied with the replacement components/kits. Under no circumstance should any other type of grease be used. Carefully slide the housing assembly (18) into position on the guide sleeves (24, 26) secured to the carrier (2) Fig.
  • Page 30 5 Housing assembly replacement Using a suitable sized tool (socket) fig 31, tap the end cap in until forwards several times to check the smooth movement of the it meets the dimensions shown in the diagram Fig. 32 & 33 guide sleeves.
  • Page 31 Piston Dust Excluder removal and replacement A - Piston Dust Excluder removal B - Fitting new Piston Dust Excluders ArvinMeritor Air Disc Brake ELSA 195...
  • Page 32 6 Piston Dust Excluder removal and replacement A - Piston Dust Excluder removal Remove the brake pads as described in section 2 “Pad replacement”. Using the manual override stem adjust out the piston assemblies approximately 50 mm. - Figs.35 & 36 Adjusting out the brake aids removal of the Piston Dust Excluders.
  • Page 33 6 Piston Dust Excluder removal and replacement Carefully fit dust excluder into groove on Piston Head (7) - ensure the excluder is correctly seated in bead groove. Fig. 38 The next stage is to stretch the dust excluder using 2 fingers. Fig.
  • Page 34 ArvinMeritor Air Disc Brake ELSA 195...
  • Page 35 Guide Sleeve, Dust Excluder, Retainer and Bushes Checking Slide Pin Bush Wear A - Tangential Test B - Radial Test Dismantling Round & Oval Guide Sleeve Bushes & Retainers (Long & Short Guide Sleeve) C - Dismantling Guide Sleeve Round Bushes (14) Long Guide Sleeve D - Dismantling Guide Sleeve “Oval”...
  • Page 36 7 Guide Sleeve, Dust Excluder, Retainer and Bush NOTE : The following are checks that enable the wear on the slide system to be established with the brake assembly in position on the vehicle. Checking Slide Pin Bush Wear A - Tangential Test Remove the pads as described in section 2 “Pad replacement”...
  • Page 37 7 Guide Sleeve, Dust Excluder, Retainer and Bush Set the gauge to zero. Swivel the housing as far as possible in the opposite direction without allowing the Brake to slide. NOTE : Maximum acceptable reading is 2.0 mm If this figure is exceeded then the guide sleeve and bushes require attention as described in the following pages.
  • Page 38 7 Guide Sleeve, Dust Excluder, Retainer and Bush C - Dismantling Guide Sleeve Round Bushes (14) – Long Guide Sleeve To remove the long guide sleeve round bushes. Using a suitable arbor, press or drift out the bushes from the housing together with the dust excluder retainer as shown in Fig 49 D - Dismantling Guide Sleeve “Oval”...
  • Page 39 7 Guide Sleeve, Dust Excluder, Retainer and Bush NOTE : If the short guide sleeve excluder retainer is undamaged bronze bush it is not necessary for it to be removed, as the oval bush must be pushed out in the direction of the end cap (Fig 53). If replacement is required, the retainer can be knocked out after the bush has been removed - Fig 54.
  • Page 40 7 Guide Sleeve, Dust Excluder, Retainer and Bush Pull the oval bush into the guide sleeve bore to a depth between 9.2 to 9.6 mm from the end of the guide sleeve excluder retainer side of the bore - Figs 57 & 58. The bush must be fitted from the actuator side of the housing.
  • Page 41 7 Guide Sleeve, Dust Excluder, Retainer and Bush Fitting New Dust Excluder Retainers (13) Using ArvinMeritor Service tool MBT1000, place Retainer (13) onto suitable arbor Fig. 61 G - Fitting Guide Sleeve Retainer (13) Oval Bush - Short Guide Sleeve Place retainer onto the housing and with remaining applicable parts of the service tool, draw the retainer into the guide sleeve bore until the flat face of the retainer is between 4.65 to 5.15mm...
  • Page 42 7 Guide Sleeve, Dust Excluder, Retainer and Bush NOTE : It is possible that the guide sleeve dust excluder remained attached to the Brake housing retainers and is therefore removed with the housing. Remove the guide sleeve screws retaining the guide sleeves to the carrier Fig.
  • Page 43 7 Guide Sleeve, Dust Excluder, Retainer and Bush Carefully slide the housing assembly into position on the guide sleeves secured to the carrier Fig. 68 NOTE : Take care not to damage the guide sleeve dust excluder when locating the housing on to the carrier. Locate the guide sleeve dust excluder beads in to the grooves on the housing retainers Fig 69 Ensure the dust excluders are located correctly on both carrier...
  • Page 44 7 Guide Sleeve, Dust Excluder, Retainer and Bush Repeat for the second end cap. The end caps for long and short pins will be fitted to a different dimension as shown in Fig 72 for short pin & Fig 73 for long pin. The dimensions must be checked to ensure that they do no exceed the stated maximum figures.
  • Page 45 Servicing and Specifications Tightening Torque’s Grease Specification Servicing Rotor Specification ArvinMeritor Air Disc Brake ELSA 195...
  • Page 46 8 Servicing and Specifications Tightening Torque’s Component Torque M18 Guide Sleeve Screw (long) 430 - 450 Nm M18 Guide Sleeve Screw (short) 430 - 450 Nm Adjuster Stem 40 Nm Maximum Pad Retaining Plate Screw 33 - 40 Nm Air Actuator Retaining Nut : Pre Torque 80 - 100 Nm Final Torque 180 - 210 Nm Bridge Screws...
  • Page 47 Special Tools MBT 1000 Bush fitting tool ArvinMeritor Air Disc Brake ELSA 195...
  • Page 48 9 Special Tools The following tools can be purchased from ArvinMeritor Aftermarket MBT 1000 Bush fitting tool...
  • Page 49 Meritor Heavy Vehicle Braking Systems Grange Road, Cwmbran Published in Italy South Wales NP44 3XU - U.K. Tel.: +44 (0) 1633 834238 © Copyright 2003 Issued 02/2003 Fax: +44 (0) 1633 834191 www.arvinmeritor.com ArvinMeritor Inc. M-graph - MM0350...