pan 17 product manual 11-2011

8/11/2019 PAN 17 Product Manual 11-2011

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Disc Brake PAN 17PAN 17PAN 17PAN 17

PAN 17_General, Edition 11/2011

List of Contents Page

1. Description of the Mechanical Sliding Caliper Disc Brake 1

1.1 Introduction with Sectioned Drawings 1

2. Service Instructions 3

2.1 Safety Tips during Repair 3

2.2 WABCO Tools overview 4

Table 1: Tools, Spanner Widths [AF]and Tightening Torques [Nm] 6

2.3 Checking Brake Function 7

2.3.1 Checking Adjuster Function 7

2.4 Checking Brake Pads 9

2.5 Checking Brake Disc 9

2.6 Checking Guide Pin Clearance 11

3. Renewing Brake Pads 12

4. Renewing Brake 20

5. Renewing Gaiters 23

5.1 Renewing Guide Pin Gaiters and Bushes 23

5.2 Renewing Adjuster Screw Gaiter 30

5.3 Renewing Adjuster Nut Gaiter 33

6. Renewing Brake Cylinder 37

Explosive Diagram of the PAN 17PAN 17PAN 17PAN 17Replacement Parts 40

Note:

These Service Instructions are copyright. All rights reserved.No part of this publication maybe reproduced, stored in a retrieval system, or transmitted in anyform or by any means, electronic, photocopying, recording or otherwise, without permission inwriting from WABCO Radbremsen GmbH.

PANis a registered Trademark of the WABCO Radbremsen GmbH.


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1. Description of the Mechanical Sliding Caliper Disc Brake

The Brake "PAN 17" is a pneumatic one-piston-brake, which is intended for use in commercialvehicles on front and rear axles as service, auxiliary and parking brake. It is actuated mechanicallyvia a diaphragm brake cylinder or a spring brake cylinder, which is mounted to the end cover of

the brake caliper.

A very compact unit is achieved by the direct mounting of the brake cylinder onto the caliper. Thisenables optimal utilisation of the installation situations.

The complete disc brake including brake cylinder consists of two assemblies, the brake caliper (1)and the brake carrier (2).

Fig. 1

The brake caliper (1) moves axially on guide pins (8, 9) of the brake carrier (2). In the brake carrierthe brake pads (35, 36) are guided and supported axially relocatable. The fastener of the brake

pads works with a hold-down hoop (38) and hold-down springs (37) - see figures 1 to 3.

The radially open design of the brake caliper allows simple and quick changes of the brake pads.

For compensating the pad wear the actuating mechanism of the brake is equipped with anautomatic adjuster mechanism. This maintains a predetermined clearance independent fromoverall load configuration and different operating conditions. This, together with a stable and stiffconstruction of the brake caliper, results in a safe control of the pedal travel and increases thedistance reserve for emergency braking.

The internal moving components are lubricated for life and all sealing components aremaintenance free unless damaged.

The disc brake is equipped optionally with an electrical wear indicator (40).

1

2


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2

Fig. 2 Plan View and Section (left brake)

Fig. 3 Side View and Section (left brake)

393835 3637

19

21

12

40

1

2

9

8 7

6

21

19

22

4

5

10

13

Arrow,Forward-Rotation


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2. Service Instructions

The instructions with the following pictures encompass the necessary steps and work sequencesto replace the available repair kits. The spanner size and the tightening torques in the sequencesare listed in Table 1. For lubrication use only the tube of grease supplied with the brakerepair kit.

2.1 Safety Tips to be considered during Repair

The flawless technical condition of the Disc Brake is of utmost importance to ensure good drivingand safe braking characteristics.

All service and repair works, which can be implemented at the brake, are to be accomplishedexclusive by trained technical personnel. Inappropriate works on the brake system can lead to theloss of the brakes and to traffic accidents.

Observe the wear limits of the brake pads and brake disc. When brake pads or brake disc aredamaged, or worn beyond their specified minimum thickness, brake effectiveness will diminish andpossibly result in an accident. Burned, glazed or oil contaminated brake pads must be replacedimmediately. Always replace brake pads with a new brake pad hold down system for padsand spreader plates on a per axle basis!

During repairs on the brake the vehicle must be parked on a level surface and be blocked toprevent rollaway. Only approved and suitable fixtures are to be used for the lifting and blocking ofthe vehicle. While working on the brake it must be ensured that the brake can not be actuatedinadvertently.Do not actuate the brake when brake pads are removed. Danger of destruction of brakeparts! Danger of Bodily Injury!

Do not clean the brake when repair or whilst cleaning at the vehicle with pressurised air orother high pressure cleaning apparatus. Danger of destruction of the rubber parts! Danger ofBodily Injury!

While working at the brake or moving of the brake caliper handle the caliper only from outsideto avoid injury! Keep hands and fingers out of the inside of the caliper! Danger of Bodily Injury!

A second technician must assist during removal and installation of the brake. Heavy Load -Danger of Bodily Injury!

Never attach a lifting device to the pad hold down hoop as the hoop could be damaged.

During repairs outside of the vehicle, the brake must be secured in a fixture, such as a heavyvise, as high torque is required during removal and installation of the bolts. Danger of Bodily Injury!

The Brake Caliper with Clamping Unit shall not be opened, therefore the bolts holding thecover shall not be loosened. No serviceable parts are inside the clamping unit.

Only original and genuine WABCO Service Parts and approved brake pads with a newbrake pad hold down system for pads and spreader plates are to be used.


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During repairs use only recommended tools. Do not use power-driven sockets or unsuitabletools!Tighten Nuts and Bolts only to specified torque limits.

With newly installed brake pads avoid emergency stops and long braking cycles during the first 50km to prevent excessive temperatures.

When wear of the cast brake parts, such as cracks or heavy abrasion, is observed, replacethe entire brake assembly according to instructions.

Dispose the used up and exchanged parts considering environmental protection according to thenational and / or the regional defaults. Usually brake parts can be scrapped.

Upon completion of repairs the vehicles braking system must be tested on a rollerdynamometer. If no roller dynamometer is available a driving test with brake applications must beperformed.

2.2 Overview of the tools and tightening torques

For service works on the disc brake the following tools are needed:

- Ring spanner / tool for hexagonal at the brake adjuster *)

- Tools for pressing the bushings - guiding pins - out from the brake caliper *)

- Tools for pressing the bushings - guiding pins - into the brake caliper *)

*)WABCO Tools can be ordered under the following part / set numbers see page 5.


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I. WABCO basis tool set 640195 522 2.The basis tool set is necessary for all WABCO Air Disc Brakes.

Nr. Term Tool Illustration Tool Set

10 Grip / Pin

11 Adapter part

12 Ring Spanner / Ratchet

13 Extension

640 195 522 2

II. WABCO tool set 640 175 521 2 for PAN 17.Additionally the WABCO basis tool set 640195 522 2 is necessary.

Nr. Term Tool Illustration Tool Set

14 Extrusion mandril

15 Insert mandril long-1

16 Insert mandril long -2

17 Insert mandril short

18Insert mandril for closing

covers

19*)

Toolbrake adjuster

20*)

Toolbrake adjuster

640 175 521 2

*)These tools as a component of the tool set are not needed for this brake type PAN 17.


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Table 1:Overview of the necessary tools and tightening torques

Position Term SpannerWidth

Hexagon Tightening Torque

[[[[SW]]]] External Internal [[[[Nm]]]]

I Hexagon head /adjuster

8 X --

Turning direction of hexagon:

Adjust, anti-clockwise (left),maximum 3, air gap decrease.

De-adjust, clockwise (right),maximum 12, air gapincrease.

Do not use power-drivensockets!

II Hexagon bolt / Padhold down hoop

17 X -- 20 2

III Brake mounting -- X -- Please note the special assemblyinstructions of the vehiclemanufacturer.

IV Guide pin mounting 14 -- X340 20

Tightening order for guide pins:1. Close fit pin

(with long internal hexagon bolt)2. Clearance fit pin

(with short internal hexagon bolt)V Brake cylinder

mounting24 X -- 210 30

(only apply for original WABCOcylinders)

The attachment of the brakecylinder at the disc brake isrecommended as follows:

Screw on the fastening nutsmanually till the brake cylinderis snug on the surface.

Tighten the fastening nuts withapproximately 120 Nm.

Tighten the fastening nuts with210 30 Nm using a torquewrench.

Note: Use fastening nuts onlyonce.


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2.3 Checking Brake Function

Note: It is not necessary to dismantle the brake cylinder. The brake is shown only for betterrepresentation without brake cylinder.

Caution: Do not use power-driven sockets!

While working at the brake or moving of the brake caliper handle the caliper only fromoutside to avoid injury!

2.3.1 Checking Adjuster Function:

Generally Note:The turning directions and the torques for the hexagon on the adjuster nut aregiven in Table 1, Position I.

Work Sequences Figures

Note: Brake pads and spreader plate areinserted.

Remove plug 12 for the adjuster 22 from the

caliper carefully.

Caution: On disassembly the proper toolposition is against the plug 12 (left side inFig. 4)!Do not place the tool between caliper andouter side of the sealing ring; otherwisethere is a danger of the damage the innersealing 13 (right side in Fig. 4)!

Check the adjuster nut gaiter 13 for wear and

damage. Renew defect gaiter according toSection 5.3!

Using a ring spanner / tools 12and 13(page5) / (Table 1, Position I), turn the adjusterhexagon. c. 1/2 turn in the clockwisedirection.

Caution: Testing of the adjuster is possibleonly with a higher air gap. Do not overloadthe adjuster hexagon 22.Do not use an open-ended spanner.With the ring spanner mounted on theadjuster nut ensure that there is sufficientspace such that it will not be prevented fromturning during the adjuster check!

Fig. 4

Fig. 5

12

13

1222

13


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Actuate the brake lightly about 5 times (c. 1bar). The adjuster is functioning when thering spanner (arrow) turns in the anti-clockwise direction with every brake

actuation.

Note: With increasing adjustment incrementsthe angular movement of the ring spannerbecomes smaller.The adjuster is in order when the ring spannerrotates as described above.

Remove ring spanner / tools 12and 13(page5).

Refit plug 12, ensure that the plug sits

properly.

Possible faults:

The adjuster 22 respectively ring spanner(arrow)a) does not turnb) turns only with the first actuationc) turns backwards and forwards with every

actuation, then the adjuster is not in order.

Exchange the brake according to Section 4.!

Fig. 612

22


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2.4 Checking Brake Pads

Notice:The brake pad thickness is to be checked regularly dependent on operating conditionsduring maintenance intervals and under applicable local laws and regulations. Burned, glazed oroil contaminated brake pads must be replaced immediately.Always replace brake pads with a new brake pad hold down system for pads and spreader

plates on a per axle basis!


Caution: To avoid damage to the brake disc,the brake pads should be replaced at thelatest when the thinnest section of thefriction material is 2 mm over the padbackplate.

The remaining brake pad thickness must not be

less than 2 mm.A= Remaining brake pad thickness 2 mm.B= Total friction material thickness new

19 mm.C= Total pad thickness new with pad backplate

26 mmAt remaining brake pad thickness A < 2 mm,renew brake pads according to Section 3.

Fig. 7

2.5 Checking Brake Disc


Remove brake pads according to Section 3.,and measure thickness of disc over therubbing faces.

D= Total disc thickness - new 34 mmE= Wear allowance limit 28 mm,

the brake disc must be renewed. Therenewal is recommend on a per axlebasis.

F= Total pad thickness - new 26 mmG= Pad backplate thickness 7 mmH= Minimum remaining brake pad thickness

2 mmI = Absolute minimum pad thickness with

pad backplate 9 mm, the brake padsmust be renewed.

Caution: Observe brake pad and discwear limits. Worn-out pads and discs reducethe brake effectiveness and can cause brakefailure! Discs must be free of oil.

Accident danger!

Fig. 8

Pad Backplate Friction Material


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Brake Disc Condition Inspection:

Check brake disc for cracks, condition ofrubbing surfaces and maximum wear

dimension.

A = Crazing = permissibleB = Radial cracks max. 0.5 mm

(width) = permissibleC = Unevenness under 1.5 mm = permissibleD= Cracks across rubbing

surface = not permissible

a= Rubbing surfaceFig. 9

Checking Brake Disc Runout:


Mount a dial indicator on the brake carrier.

With the disc installed measure the runout byrotating the hub as shown in Fig. 10. Runoutlimit 0.15 mm.

At higher values rework or renew the disc / s.Note: Only cleaned brake discs have to beinstalled. Brake discs must be free of oil.

Install brake pads and set clearance. Carryout according to Section 3. and pay attentionto Notes.

Fig. 10


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2.6 Checking Guide Pin Clearance


Remove the wheel according the axlerespectively vehicle manufacturerinstructions.

Remove brake pads and spreader plateaccording to Section 3.

Note: Use always the measuring point on thecaliper at the wheel side see arrow in figure10. Clean the measuring point before themeasurement.

Slide the caliper by hand fully towards thewheel side.

Fasten a magnetic dial-gauge holder to thebrake carrier or to the axle.

Press the dial-gauge in the direction ofmeasuring point - see arrow in figure.

Press brake caliper maximally in radialdirection with easily hand strength and setthe dial-gauge to zero.

Press brake caliper maximally in oppositeradial direction with easily hand strength.

Read the maximum value on the dial-gauge.Themeasured guide pin clearance may notbe larger than 2.0 mm. If the value isgreater than 2.0 mm, the parts must be

replaced according to Section 5.1. Remove the measuring instrument.

Install spreader plate and brake pads and setclearance. Carry out according to Section 3.and pay attention to Notes.

Install the wheel according the axlerespectively vehicle manufacturerinstructions.

Fig. 11

Fig. 12

Fig. 13


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3. Renewing Brake Pads

Note: It is not necessary to dismantle the brake cylinder. The brake is shown only for betterrepresentation without brake cylinder.

Caution: Do not use power-driven sockets!

While working at the brake or moving of the brake caliper handle the caliper only fromoutside to avoid injury!

Working Sequences for Removal of Pads:


Note:The cable position and their fastening onthe brake might vary depending on the brakemodel. A use-case is described here. Thereforeit is necessary to pay attention to the originalposition of the fastening for the followingreinstallation!

Loosen the connection (arrow) and unplug.

Remove hexagon bolt 39 from pad hold-downhoop 38 with spanner (Table 1, Position II).

Withdraw pad hold-down hoop 38 fromcaliper 1.

Remove three hold-down springs 37 from thebrake pads 35, 36 and the spreader plate 19.

Fig. 14

Fig. 15

Fig. 16

40

35,37 19,36,37


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Remove cable guide 40 and contacts from

the brake pads. Remove cable clip 41 from brake caliper.

Remove plug 12 for the adjuster 22 from thecaliper 1 carefully.

Caution: During disassembly of the plug 12

see the notes to Fig. 4! De-adjust the brake by rotating the hexagon

on the adjuster nut 22 with a ring spanner /tools 12and 13(page 5) / (Table 1, PositionI), then release by c. 1/4 turn.

Note:The turning direction to de-adjust is to theright, i.e. clockwise.Caution: When de-adjusting, push back thespreader plate 19 (arrow Fig. 19) by hand atthe same time to ensure the pin in theadjuster screw remains engaged in the slotin the spreader plate; otherwise there is adanger that the adjuster screw will turn,thereby damaging its gaiter!

Check the gaiter 13 for wear and damage.Renew defect gaiter according to Section5.3!

Slide the caliper 1 by hand towards the wheelside and remove the brake pad 35.

Fig. 17

Fig. 18

Fig. 19

1

12

22 13

40

41


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Slide the caliper 1 by hand towards thecylinder side (arrow) and remove the brakepad 36 and the spreader plate 19.

Examine the spreader plate 19 for damageand strong corrosion.

Caution: If the spreader plate is not anymore correct, a new spreader plate must beinserted. Always replace spreader plates ona per axle basis in the left and the rightbrake!

Caution: Do not actuate the brake whenbrake pads are removed! Danger ofdestruction of brake parts! Danger of BodilyInjury!

Using a wire brush remove any corrosionfrom the spreader plate, brake pad slot, andspreader plate and brake pads guidesurfaces.

Caution: Take care not to damage the dustcaps (gaiters) 5, 10. The guide surfaces mustbe clean and free of grease!

Inspecting the Dust Caps (Gaiters) andChecking Brake Caliper Movement:

Slide the caliper towards the cylinder side toallow examination of the gaiters 5, 10, theguide pins 8, 9, and the adjuster screw 21 forwear and damage. Renew all defect gaitersaccording to Section 5.1 and 5.2!

Caution: In case of a damaged gaiter 10must be checked, if dirt or water has alreadyentered and damaged the inner parts of thebrake or the gaiter seat in the caliper bycorrosion. In case of doubt the brake mustbe renewed according to Section 4. If thegaiter 10 is damaged during servicing thebrake, the gaiter must be renewed accordingto Section 5.2.

Fig. 20

Fig. 21

Fig. 22

36 191

5105

10,21

5,8 5,9


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Slide the caliper on the guide pins by hand

over its total displacement and check forfreedom of movement. If the movement isrestricted, renew the guide pins, the guidepin bushes and gaiters according toSection 5.1.

Caution: Do not squeeze the dust caps of theguide pins against the torque plate!

Checking the Adjuster Unit (Clamping Unit):

Prevent the adjuster screw turning by e.g.holding the pin (arrow) during the test andwhilst rotating the adjuster hexagon.

Extend the adjuster 22 towards the brakedisc by turning the adjuster hexagon in theanti-clockwise direction with a ring spanner /tools 12and 13(page 5) / (Table 1, Position

I) and check for ease of movement. After checking the adjuster unit return the

adjuster screw completely by turning in theclockwise direction.

Note:The torque to return the adjuster screw isgreater than when turning the screw towards thedisc.Caution: Do not overload the adjuster 22hexagon. Do not use an open endedspanner.

If necessary, check adjuster functionaccording to Section 2.3.1.

Fig. 23

Fig. 24

Fig. 25

22


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Install newpre-assembled wear indicator andcable guide 40 and insert sensor contactsinto brake pads.

Caution: The sensor contacts must bepointed in the direction of the brake disc andthe contacts must be properly seated!

Position cable guide and cable exit of thewear indicators on the brake caliper.

Caution: Twist and position the cablewrappings on the actuation side, so that no

cable touches the brake pad.

Position three new hold down springs 37over the cable guide and on top of thespreader plate 19 and the brake pads 35, 36.

Fig. 29

Fig. 30

Fig. 31

40

37,35

37,19,36


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Slide new hold down hoop 38 throughopening in cable guide and openings in thebrake caliper, then push downward so thatthe radial corners of the hold down springssnap into the hold down hoop.

Fit newhexagon bolt 39 to the brake caliper(Table 1, Position II).

If available, remove the transport protectioncap (arrow) from the plug connection of thewear indicator.

Insert the new clip 41 in the brake caliperand inlay the cable inside.

Secure exit cable on newcable clip 41.

Plug in the plug of the wear indicator in theconnector coupling (arrow).

Fig. 32

Fig. 33

Fig. 34

39

38

41


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Fit newplug 12 to the opening in the brakecaliper! Check and make sure the correctseat!

Check that the hub rotates freely. Install the wheel according the axle

respectively vehicle manufacturerinstructions.

Caution: Upon completion test thebrakes on the roller dynamometer!

Fig. 35 12


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4. Renewing Brake

Caution: Do not use a power-driven socket! While working at the brake or moving of thebrake caliper handle the caliper only from outside to avoid injury!

Never attach a lifting device to the pad hold down hoop 38 as the hoop could be damaged.

Note:The graphic representation of the brake carrier may differ from the actual design, so that therepresentation does only apply in principle.

New brakes without brake pads are assembled and together with the brake carrier can be fitted inthe assembled state to the axle.

Should new pads be required, then all pads on the axle must be renewed! Do not exchangeleft brake (fig. A) and right brake (fig. B) on the axle! Identify the correct placement of thebrakes on the left or the right side of the axle through the position of the hold-down hoop38 and the hexagon bolt 39 in the brake.

Use the following scheme: The retaining opening in the caliper for the hold-down hoop 38and the thread opening in the caliper for the hexagon bolt 39 are always relocated for anoffset V compared with the axle M in the middle of the brake in the rotating direction of thebrake disc driving forward towards brake disc trailing side.

Fig. A Fig. B

Rotating direction of the brake discdriving forward

Brake disc trailing side

38

39

V

38

39

V

M M


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Work Sequences for Brake Removal:



Remove brake pads according to Section 3. Remove brake cylinder from the brake caliper

according to Section 6.

Dismantle the caliper with the carrier from theaxle (Table 1, Position III).

Check brake disc according to Section 2.5.

The removed brake pads must be tested forwear according to section 2.4.

Prior to brake assembly, inspect and cleanthe axle contact respectively mountingsurfaces. Remove any loose debris, rust or

oil which may be present. Fig. 36

Work Sequences for Installing Brake:


Mount the new brake with the brake carrierover the brake disc on the axle. Tightenhexagon bolts with spanner (Table 1, PositionIII).

Caution: If necessary note the correct fixingorder of the hexagon bolts according theaxle respectively vehicle manufacturerspecial instructions (Table 1, Position III).

Remove all the transport protection parts onthe newbrake.

Caution: The transport protection / adhesivecover (arrow) at the brake caliper in the areaof the brake cylinder attachment must becompletely removed before the mounting ofcylinder.

Fig. 37

Fig. 38

38


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Caution: Check the brake cylinder ondamages before mounting. Particularly theinternal piston rod sealing must be checkedfor damages. A defective brake cylinder maynot be attached again.

Clean the sealing surface and surface areaof the brake cylinder flange.

Refit the brake cylinder on the caliperaccording to Section 6.

Note:The special assembly instructions of theaxle respectively vehicle manufacturer must benoted.

Caution: With the brake cylinder in itsinstalled position, ensure that the lowerdrainage hole facing the ground is open!Depending upon cylinder type and accordingthe cylinder manufacturer instructions, theother holes can be either openly, or must beplugged!

Check that the hub rotates freely.

Install the wheel according the axle

respectively vehicle manufacturerinstructions.

Caution: Upon completion test thebrakes on the roller dynamometer!

Fig. 39


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5.1 Renewing Gaiters

Caution: Do not use a power-driven socket! While working at the brake or moving of thebrake caliper handle the caliper only from outside to avoid injury!

Never attach a lifting device to the pad hold down hoop 38 as the hoop could be damaged.

Note:When replacing all of the gaiters in the caliper, the work sequences 5.1 and 5.2 should becombined so as not to repeat some operations.When replacing individual gaiters, follow the corresponding work sequences of the sections 5.1and 5.2.

5.1 Renewing guide pin gaiters and bushes

Caution: The position of the guide pins in the brake may vary depending on the case ofoperation. An example of installation with a long guide pin 8 (close fit) driving forward on

the brake disc leading side is shown here. The renewal can also be carried out with ashorter guide pin 9 (clearance fit) on the brake disc trailing side.


Work Sequences for Removal:



Remove brake pads according to Section 3.

Remove brake cylinder from the brake caliperaccording to Section 6.

Dismantle the caliper with the carrier from theaxle according to Section 4.

Caution: During repairs on the guidanceparts of the brake, the brake carrier mustfirmly in a mounting plate e.g. vice to be

fastened!Fig. 40

38


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Dismantle brake caliper 1 from brake carrier2 by removing caps / covers 11 from theguide pins 8, 9 in the caliper housing 1 with asuitable tool, e.g. chisel.

Caution: Take care not to damage coverbores in housing.The proper tool position is against thecovers.

Release the bolts 6, 7 with a male socket(Table 1, Position IV) and separate thecaliper 1 from the carrier 2.

Caution: Moving Brake Caliper. Dangerof Bodily Injury!

Clean the mating surfaces (collars) of thecarrier 2.

Withdraw the guide pins 8, 9 and remove thegaiters 5 from the caliper 1.

Fig. 41

Fig. 42

Fig. 43

76

21

1

8, 9

11

F

2

8,59,5


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Place the caliper 1 on a firm base to push out

the bushes 4, so that the caliper opening isfacing upwards.

For the change of the bushes 4 use theWABCO tools (page 5).

Press the bushes 4 out of the caliper 1 usingtools 10, 11and 14.

Clean the bores in the caliper.

Fig. 44

Fig. 45

Work Sequences for Installation:


Press in two newbushes for the longer guidepin.

Firstly fit the inner bush with tools 10, 11and16by pressing in as far as the tool abutment.

Fig. 46

4 4

1

4

41

10

14

11

16

1011


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Secondly fit the outer bush with tools 10, 11

and 15 by pressing in as far as the toolabutment.

Grease the bushes and the space betweenthem.

Press in one newbush for the shorter guidepin with tools 10, 11and 17by pressing in asfar as the tool abutment.

Grease the bush.

Fit new green gaiters 5 in the gaiter seats(ring groove / arrow) in the brake caliper 1.

Note: Clean gaiter seats before fitment. Theseats must be clean and free of grease. It ispossible to fit the gaiters by hand. Ensure thatthe gaiters are fitted evenly into the seats inthe brake caliper!

Fig. 47

Fig. 48

Fig. 49

15

10

11

10

17

11

1

5


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Move brake caliper backwards and forwardson guide pins 8, 9 several times. Check forease of movement.

Caution: Do not squeeze guide pin dust capsagainst brake caliper!

Lubricate the bores for the caps / covers 11in the brake caliper 1.

Slide brake caliper against the brake carrier.

Place newcaps 11 in the bores in the brakecaliper 1 and press home with tools 10, 11and 18.

Note:Take care to avoid damaging the covers.

For air pressure equalisation lift the gaiters 5in the range of the ring groove and reinsertthem.

Fig. 52

Fig. 53

Fig. 54

8

9

5

11

11

1

10

1811


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5.2 Renewing Adjuster Screw Gaiter

Note: If the gaiter only is to be renewed it is not necessary to dismantle the brake caliper andcylinder.



Remove brake pads and spreader plateaccording to Section 3.

Push brake caliper to the actuation / cylinderside by hand.

Pull the gaiter 10 out the annular groove inthe adjuster screw 21.

Remove the gaiter from the seat in the brakecaliper by means of a screwdriver.

Check the adjuster screw thread.

Note:For this purpose refit the wheel side brakepad so that the adjuster screw cannot bescrewed completely out of the adjuster.After the thread check remove the brake pad.

Fig. 57

Fig. 58

Fig. 59

10

21

21


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Secure adjuster screw 21 against turning(arrow Fig. 60) and screw out the adjusterscrew c. 30 mm by turning the adjusterhexagon in the anti-clockwise direction with a

ring spanner / tools 12 and 13 (page 5) /(Table 1, Position I).

Examine the thread for corrosion anddamage whilst screwing out.

Caution: The gaiter 10 can be renewed, ifdefinitely no dirt or no water has penetratedinto the brake caliper, or if the gaiter hasbeen directly damaged during servicing thebrake. In case of doubt the brake has to bereplaced according to Section 4., if internal

parts are corroded.

Clean the gaiter 10 seats in the caliper andthe annular groove in the adjuster screw 21(arrows).

Caution: The seat in caliper for gaiter 10must be clean and free of oil or grease.When cleaning be careful to ensure, that dirt orwater does not enter in the brake.

After examination grease the thread andpartly screw back the adjuster screw inclockwise sense by hand. The pin positionmust be in the same direction like beforescrew out.

Fig. 60

Fig. 61



Push the newand greaselessgaiter 10 overthe adjuster screw, centre and press by handinto the seat in the caliper 1.

Lubricate gaiter 10 lip (arrow) lightly to easefitment.

Fit gaiter 10 into its seat in the adjuster screw21.

Note: Ensure that the gaiter lip in the annulargroove in the adjuster screw sits proper and freeof folds!

Fig. 62

10

21

10

1

21


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32



Fig. 63


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5.3 Renewing Adjuster Nut Gaiter

Note: If the gaiter only is to be renewed it is not necessary to dismantle the brake caliper andcylinder.



Remove plug 12 for the adjuster 22 from thecaliper

Remove the gaiter 13 from the seat in thebrake caliper by means of a screwdriver, andpull gaiter out the adjuster nut.

Clean the gaiter seats in the caliper.Note:When cleaning be careful to ensure, thatdirt or water does not enter in the brake.Caution: The gaiter 13 can be renewed, ifdefinitely no dirt or no water has penetratedinto the brake caliper, or if the gaiter hasbeen directly damaged during servicing thebrake. In case of doubt the brake has to bereplaced according to Section 4., if internalparts are corroded.

Fig. 64

Fig. 65

Fig. 66

2212

13


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Place the mounting cap A on the hexagon ofadjuster 22 and push it towards the stop.

Lubricate only the inner gaiter lip (arrow) ofthe newgaiter 13 lightly to ease fitment.

Push the gaiter 13 over the mounting cap A,and

press by hand into the seat stop in thecaliper.

Place the mounting sleeve B on the mountingcap A

Fig. 67

Fig. 68

Fig. 69

22A

13

A

AB


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35


Press mounting sleeve B against the innergaiter lip towards, that the inner gaiter lip fitcorrect in the annular groove of the adjuster.

Remove mounting sleeve and mounting cap.

Check and make sure the correct seat ofgaiter 13 in the brake caliper and annulargroove (arrow).

Fit newplug 12 to the opening in the brakecaliper!

Fig. 70

Fig. 71

Fig. 72

Fig. 73

B

13

12


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Check and make sure the correct seat!

Fig. 74


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37

6. Renewing Brake Cylinder

Caution: Do not use power-driven sockets!While working at the brake or moving of the brake caliper handle the caliper only fromoutside to avoid injury!

Note:Only use cylinders as specified by axle respectively vehicle manufacturer. The followingwork sequences only inform in principle about the assembly and disassembly of the brakecylinder. Detailed assembly and check instructions have to be used according to the cylinder typeand the instructions of the cylinder manufacturer.


Work Sequences for Diaphragm Chamber Removal:


Make sure that the brake hoses arepressureless.

Disconnect airline to cylinder (according tocylinder manufacturer's data).

Remove brake cylinder from caliper byreleasing cylinder nuts (table 1, position V).

Note: When disassembling be careful toensure, that dirt or water does not enter in thebrake.

Fig. 75

Work Sequences for Diaphragm Chamber Installation:


Caution: With the brake cylinder in itsinstalled position, ensure that the lowerdrainage hole facing the ground is open!

Depending upon cylinder type and accordingthe cylinder manufacturer instructions, theother holes can be either openly, or must beplugged!

Before refitting the brake cylinder clean thesealing surface and the mounting flange onthe caliper and grease the concave seat(arrow) in the brake lever.

Note:When cleaning be careful to ensure, thatdirt or water does not enter in the brake. Fig. 76

Sealing surface

greaseconcave seat

Flange area


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Fit brake cylinder and tighten nuts withspanner (Table 1, Position V). For theattachment observe the references in thetable.

Reconnect brake hose to brake cylinder(according to cylinder manufacturer's data).

Note: The brake hose must not be twisted orlocated such that it will rub against anything!The brake hose of the air supply is not allowedto have an influence on the moveability of thebrake caliper over its full range of movement. Test air connection for leaks (according to

cylinder manufacturer's data).

Carry out function and effectiveness tests(according to cylinder manufacturer's data).

Fig. 77

Work Sequences for Spring Storage Cylinder Removal:


Secure vehicle against rolling. Loosen hand brake. Screw out release mechanism. Apply hand brake.Caution: Brake hose connection 12 =

pressureless. Mark both brake hoses for proper assembly.

Screw brake hoses out of the connection.

Caution: Do not remove brake cylinder withscrewed on brake hoses. Brake hoses might

be damaged!

Remove brake cylinder from caliper byreleasing cylinder nuts (Table 1, Position V).

Note: When disassembling be careful toensure, that dirt or water does not enter in thebrake.

Fig. 78

Fig. 79


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Work Sequences for Spring Storage Cylinder Installation:


Caution: With the brake cylinder in its

installed position, ensure that the lowerdrainage hole facing the ground is open!Depending upon cylinder type and accordingthe cylinder manufacturer instructions, theother holes can be either openly, or must beplugged!

Before refitting the brake cylinder clean thesealing surface and the mounting flange onthe caliper and grease the concave seat(arrow) in the brake lever.

Note:When cleaning be careful to ensure, that

dirt or water does not enter in the brake.

Fit brake cylinder and tighten nuts withspanner (Table 1, Position V). For theattachment observe the references in thetable!

Reconnect both brake hoses to brakecylinder (according to cylinder manufacturer'sdata).

Important: Pay attention to the correctconnections!Connection 11 = foot brake.Connection 12 = hand brake. Loosen hand brake. Screw in release mechanism.

Note: The brake hose must not be twisted orlocated such that it will rub against anything!The brake hose of the air supply is not allowedto have an influence on the moveability of the

brake caliper over its full range of movement.

Test air connection for leaks (according tocylinder manufacturer's data).

Carry out function and effectiveness tests(according to cylinder manufacturer's data).

Fig. 80

Fig. 81

Sealing surface

greaseconcave seat

Flange area


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Disc Brake PAN 17PAN 17PAN 17PAN 17 40

Explosive Diagram of the PAN 17PAN 17PAN 17PAN 17Replacement Parts

(a left hand brake is shown)Observe left and right brake configurations. Do not interchange!

Legend:

1 Preassembled Brake Caliper 1 withclamping unit inside, Brake Carrier 2and Spreader Plate 19

13 Adjuster Nut Gaiter

4 Guide Pin Bushes 19 Spreader Plate

5 Guide Pin Gaiters 35 Brake Pad, Wheel Side with wearsensor

6 Internal Hexagon Bolt (long) 36 Brake Pad, Actuation Side with wearsensor

7 Internal Hexagon Bolt (short) 37 Hold Down Springs

8 Guide Pin (long) 38 Pad Hold Down Hoop9 Guide Pin (short) 39 Screw

10 Adjuster Screw Gaiter 40 Wear Indicator (pre-mounted)

11 Cap / Cover 41 Cable Clip

12 Plug

35

36

37

1

10

4

7

6 11

5

39

12

38

40

41

9

8

13

19

2 11

4

pan 17 product manual 11-2011

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