DISC PLUS EX225 INSPECTION PROCEDURE

Service Bulletin No. 3019 MODEL

TYPE

D / E / J Series Coaches

SECTION/GROUP

Service Information

4-- Brakes

DATE

July 06, 2009

DISC PLUS EX225 INSPECTION PROCEDURE

SUBJECT

CONDITIONS

Service Information Only

Description: MCI is informing our customers that Meritor WABCO has released Product Information Letter #507 which details an inspection of the disc brake pad contact surfaces. The inspection applies to all MCI coaches fitted with DiscPlus EX225 brakes. The attached Product Information Letter #507 identifies damaged or corroded brake components which could restrict free movement of the brake pads and result in premature pad wear.

Parts Qty. 1

New P/N

Description

04-01-1117 Service Kit, Disc Pad Retaining Kit

Service Information:

1. New part will be available for service replacement.

PREVENTATIVE MAINTENANCE NOTICE Meritor WABCO recommends that the attached inspection be conducted at the following intervals; brake pad change, when significant corrosion build ---up occurs and when brake drag is felt or experienced.

To avoid personal injury, follow all safety warnings in the attached Meritor WABCO Product Information Letter #507.

REFER TO MANUAL Refer to Section 3 / Lifting, in the MCI Maintenance Manual, for the basic procedures and safety precautions that must be followed before a coach is lifted. Refer to Section 4 / Brakes and Air Systems, in the MCI Maintenance Manual, in conjunction with this procedure. Refer to Meritor WABCO DiscPlus EX225 Air Disc Brake Maintenance Manual (MM ---0467) available at www.meritorwabco.com

Printed in Canada

PRODUCT INFORMATION LETTER Meritor WABCO Vehicle Control Systems 2135 West Maple Road Troy, MI 48084-7121

PRODUCT INFORMATION LETTER #507 DATE:

May 15, 2009

SUBJECT: Service recommendation supplement for air disc brake maintenance All vehicles fitted with DiscPlus EX225 air disc brakes

This document applies to all vehicles fitted with DiscPlus™ EX225 Brakes. Vehicles operating in areas where road salts or de-icing materials are used are particularly subject to the conditions described in this document. The following reinforces procedures available in MM-0467, DiscPlus™ EX225 Air Disc Brake Maintenance Manual. In normal operating conditions the brake assembly will slide freely with even pad wear. It is possible that damaged or corroded brake components could restrict free movement of the brake pads. Meritor WABCO recommends that an inspection of the disc brake pad contact surfaces is conducted at the following intervals: • Pad change • When significant corrosion build up occurs • When concern of residual brake drag is present Procedure: 1. Park the vehicle on hard ground and chock the road wheels. Where necessary, to gain access, jack up the axle and fit suitable axle stands securely. WARNING To prevent serious eye injury, always wear safe eye protection when you perform vehicle maintenance or service. Park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. Support the vehicle with safety stands. Do not work under a vehicle supported only by jacks. Jacks can slip and fall over. Serious personal injury and damage to components can result.

2. Remove the brake pads as detailed in MM-0467 DiscPlus™ EX225 Air Disc Brake Maintenance Manual available at www.meritorwabco.com. 3. Use a vacuum brush or damp cloth to remove the dirt and dust from the carrier brake pad contact surfaces.

PRODUCT INFORMATION LETTER



MODELS:


PRODUCT INFORMATION LETTER #507

4. Inspect the carrier for signs of damage, wear or surface corrosion. Pay particular attention to the pad abutment surfaces. Figure 1 If there is excessive wear or damage to the abutments, it may be necessary to replace the caliper assembly. 5.While wearing suitable eye protection remove all traces of scale, dirt, etc from the pad apertures / abutment faces and around the edge of the rotor, particularly any that encroach onto the braking area. These may restrict free movement of the pads. A scraper or old screwdriver supported on the brake body while the rotor is rotated will remove most of the corrosion. Figure 3. Finish off if necessary with emery cloth.

Figure 1 Pad abutment surface corrosion build up

Figure 2 Abutments after clean up (1)




WARNING Never use an air line to blow dust from the brake/disc area. If inhaled any form of dust can irritate the throat and lungs or result in injury. When ever possible remove dry brake dust with a vacuum brush. Alternatively wipe the areas with a damp cloth; never try to accelerate drying time by using an air line.


Figure 3 Clean surfaces with scraper

Figure 4 Abutments after clean up (2)

6. A. Inspect the pad retainer for deformation by resting a straight edge against it. A deformed pad retainer (more than 0.5mm gap) could result in incorrect pad spring loading. Replace a deformed pad retainer with service kit KIT225210 (see parts book PB8857B). B. Inspect the pad retainer for corrosion buildup where the pad spring contacts it. An excessively corroded retainer could restrict free pad movement. Scrape clean or replace a severely corroded pad retainer with service kit KIT225210 (see parts book PB8857B).









Figure 5

7. Refit brake pads following instructions in MM-0467.
