TM

Dry Disc Park Brake

Frein de parc disque
Maintenance Manual MM4A
Manuel de maintenance MM4A

Models 1270, 1286 and 1287

Modles 1270, 1286 et 1287

Issued 04-03
Edit Avril-03

Service Notes
Service Notes
Before
You Begin

This manual provides instructions for AxleTech

Internationals models 1270, 1286 and 1287 dry disc park
brakes. Before you begin procedures:
1.

Read and understand all instructions and procedures

before you begin to service components.

2.

Read and observe all Caution and Warning safety alerts

that precede instructions or procedures you will
perform. These alerts help to avoid damage to
components, serious personal injury, or both.

3.

Follow your companys maintenance and service,

installation, and diagnostics guidelines.

4.

Use special tools when required to help avoid serious

personal injury and damage to components.

Safety Alerts, Torque Symbol and Notes

A Warning alerts you to an

WARNING instruction or procedure that

you must follow exactly to
avoid serious personal injury.

CAUTION

A Caution alerts you to an

instruction or procedure that
you must follow exactly to
avoid damage to components.
A torque symbol alerts you to
tighten fasteners to a specified
torque value.

NOTE

A Note provides information or

suggestions that help you
correctly service a component.

The instructions contained in this Field Maintenance

Manual are intended for use by skilled and experienced
mechanics knowledgeable in the installation, repair and
replacement of AxleTech dry disc park brakes. Installation,
maintenance and replacement of AxleTech dry disc brakes
require a high degree of skill and experience. The
consequences of improper installation, maintenance or
replacement are grave and can result in brake failure and
resulting loss of control of the vehicle and possible injury
to or death of persons. AxleTech does not authorize anyone
other than highly skilled and experienced individuals to
attempt to utilize the instructions contained in this Manual
for the installation, maintenance or replacement of
AxleTech dry disc brakes and AxleTech shall have no
liability of any kind for damages arising out of (or in
connection with) any other use of the information contained
in this Manual.

Table of Contents
Table of Contents

Asbestos and Non-Asbestos Fibers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . i

Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Section 1: Introduction
Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Section 2: Component Replacement

Brake Pads Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Caliper Assembly Installation

Section 3: Maintenance and Inspection

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspect Parts
Linings
Caliper

Section 4: Prepare Parts for Assembly

Clean, Dry and Inspect Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Clean Parts
Dry and Inspect Parts
Apply Corrosion Protection

Section 5: Adjustments
Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Parking Brake Emergency Release
Bleed Brake

Section 6: Specifications
Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic Pressure
Seal Kit MPS4646

Notes

Asbestos and Non-Asbestos Fibers

ASBESTOS FIBERS WARNING

NON-ASBESTOS FIBERS WARNING

The following procedures for servicing brakes are recommended to reduce

exposure to asbestos fiber dust, a cancer and lung disease hazard. Material
Safety Data Sheets are available from AxleTech.

The following procedures for servicing brakes are recommended to reduce

exposure to non-asbestos fiber dust, a cancer and lung disease hazard. Material
Safety Data Sheets are available from AxleTech.

Hazard Summary

Hazard Summary

Because some brake linings contain asbestos, workers who service brakes must
understand the potential hazards of asbestos and precautions for reducing risks.
Exposure to airborne asbestos dust can cause serious and possibly fatal diseases,
including asbestosis (a chronic lung disease) and cancer, principally lung cancer and
mesothelioma (a cancer of the lining of the chest or abdominal cavities). Some studies
show that the risk of lung cancer among persons who smoke and who are exposed to
asbestos is much greater than the risk for non-smokers. Symptoms of these diseases may
not become apparent for 15, 20 or more years after the first exposure to asbestos.
Accordingly, workers must use caution to avoid creating and breathing dust when
servicing brakes. Specific recommended work practices for reducing exposure to
asbestos dust follow. Consult your employer for more details.

Most recently manufactured brake linings do not contain asbestos fibers. These brake
linings may contain one or more of a variety of ingredients, including glass fibers,
mineral wool, aramid fibers, ceramic fibers and silica that can present health risks if
inhaled. Scientists disagree on the extent of the risks from exposure to these substances.
Nonetheless, exposure to silica dust can cause silicosis, a non-cancerous lung disease.
Silicosis gradually reduces lung capacity and efficiency and can result in serious
breathing difficulty. Some scientists believe other types of non-asbestos fibers, when
inhaled, can cause similar diseases of the lung. In addition, silica dust and ceramic fiber
dust are known to the State of California to cause lung cancer. U.S. and international
agencies have also determined that dust from mineral wool, ceramic fibers and silica are
potential causes of cancer.
Accordingly, workers must use caution to avoid creating and breathing dust when
servicing brakes. Specific recommended work practices for reducing exposure to
non-asbestos dust follow. Consult your employer for more details.

Recommended Work Practices

1. Separate Work Areas. Whenever feasible, service brakes in a separate area away
from other operations to reduce risks to unprotected persons. OSHA has set a maximum
allowable level of exposure for asbestos of 0.1 f/cc as an 8-hour time-weighted average
and 1.0 f/cc averaged over a 30-minute period. Scientists disagree, however, to what
extent adherence to the maximum allowable exposure levels will eliminate the risk of
disease that can result from inhaling asbestos dust. OSHA requires that the following
sign be posted at the entrance to areas where exposures exceed either of the maximum
allowable levels:
DANGER: ASBESTOS
CANCER AND LUNG DISEASE HAZARD
AUTHORIZED PERSONNEL ONLY
RESPIRATORS AND PROTECTIVE CLOTHING
ARE REQUIRED IN THIS AREA.
2. Respiratory Protection. Wear a respirator equipped with a high-efficiency (HEPA)
filter approved by NIOSH or MSHA for use with asbestos at all times when servicing
brakes, beginning with the removal of the wheels.
3. Procedures for Servicing Brakes.
a. Enclose the brake assembly within a negative pressure enclosure. The enclosure
should be equipped with a HEPA vacuum and worker arm sleeves. With the
enclosure in place, use the HEPA vacuum to loosen and vacuum residue from the
brake parts.
b. As an alternative procedure, use a catch basin with water and a biodegradable,
non-phosphate, water-based detergent to wash the brake drum or rotor and other
brake parts. The solution should be applied with low pressure to prevent dust from
becoming airborne. Allow the solution to flow between the brake drum and the
brake support or the brake rotor and caliper. The wheel hub and brake assembly
components should be thoroughly wetted to suppress dust before the brake shoes or
brake pads are removed. Wipe the brake parts clean with a cloth.
c. If an enclosed vacuum system or brake washing equipment is not available,
employers may adopt their own written procedures for servicing brakes, provided
that the exposure levels associated with the employers procedures do not exceed
the levels associated with the enclosed vacuum system or brake washing equipment.
Consult OSHA regulations for more details.
d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA for
use with asbestos when grinding or machining brake linings. In addition, do such
work in an area with a local exhaust ventilation system equipped with a HEPA filter.
e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with
a HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic
solvents, flammable solvents, or solvents that can damage brake components as
wetting agents.
4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter
or by wet wiping. NEVER use compressed air or dry sweeping to clean work areas.
When you empty vacuum cleaners and handle used rags, wear a respirator equipped
with a HEPA filter approved by NIOSH or MSHA for use with asbestos. When you
replace a HEPA filter, wet the filter with a fine mist of water and dispose of the used
filter with care.
5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or
smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped
with a HEPA filter to vacuum work clothes after they are worn. Launder them
separately. Do not shake or use compressed air to remove dust from work clothes.
6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters
with care, such as in sealed plastic bags. Consult applicable EPA, state and local
regulations on waste disposal.

Regulatory Guidance
References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the
United States, are made to provide further guidance to employers and workers employed
within the United States. Employers and workers employed outside of the United States
should consult the regulations that apply to them for further guidance.

Maintenance Manual MM-4A

Issued 04-03

Recommended Work Practices

1. Separate Work Areas. Whenever feasible, service brakes in a separate area away
from other operations to reduce risks to unprotected persons.
2. Respiratory Protection. OSHA has set a maximum allowable level of exposure for
silica of 0.1 mg/m3 as an 8-hour time-weighted average. Some manufacturers of
non-asbestos brake linings recommend that exposures to other ingredients found in
non-asbestos brake linings be kept below 1.0 f/cc as an 8-hour time-weighted
average. Scientists disagree, however, to what extent adherence to these maximum
allowable exposure levels will eliminate the risk of disease that can result from inhaling
non-asbestos dust.
Therefore, wear respiratory protection at all times during brake servicing, beginning
with the removal of the wheels. Wear a respirator equipped with a high-efficiency
(HEPA) filter approved by NIOSH or MSHA, if the exposure levels may exceed OSHA
or manufacturers recommended maximum levels. Even when exposures are expected to
be within the maximum allowable levels, wearing such a respirator at all times during
brake servicing will help minimize exposure.
3. Procedures for Servicing Brakes.
a. Enclose the brake assembly within a negative pressure enclosure. The enclosure
should be equipped with a HEPA vacuum and worker arm sleeves. With the enclosure
in place, use the HEPA vacuum to loosen and vacuum residue from the brake parts.
b. As an alternative procedure, use a catch basin with water and a biodegradable,
non-phosphate, water-based detergent to wash the brake drum or rotor and other
brake parts. The solution should be applied with low pressure to prevent dust from
becoming airborne. Allow the solution to flow between the brake drum and the
brake support or the brake rotor and caliper. The wheel hub and brake assembly
components should be thoroughly wetted to suppress dust before the brake shoes or
brake pads are removed. Wipe the brake parts clean with a cloth.
c. If an enclosed vacuum system or brake washing equipment is not available,
carefully clean the brake parts in the open air. Wet the parts with a solution applied
with a pump-spray bottle that creates a fine mist. Use a solution containing water,
and, if available, a biodegradable, non-phosphate, water-based detergent. The wheel
hub and brake assembly components should be thoroughly wetted to suppress dust
before the brake shoes or brake pads are removed. Wipe the brake parts clean with a
cloth.
d. Wear a respirator equipped with a HEPA filter approved by NIOSH or MSHA when
grinding or machining brake linings. In addition, do such work in an area with a
local exhaust ventilation system equipped with a HEPA filter.
e. NEVER use compressed air by itself, dry brushing, or a vacuum not equipped with
a HEPA filter when cleaning brake parts or assemblies. NEVER use carcinogenic
solvents, flammable solvents, or solvents that can damage brake components as
wetting agents.
4. Cleaning Work Areas. Clean work areas with a vacuum equipped with a HEPA filter
or by wet wiping. NEVER use compressed air or dry sweeping to clean work areas.
When you empty vacuum cleaners and handle used rags, wear a respirator equipped
with a HEPA filter approved by NIOSH or MSHA, to minimize exposure. When you
replace a HEPA filter, wet the filter with a fine mist of water and dispose of the used
filter with care.
5. Worker Clean-Up. After servicing brakes, wash your hands before you eat, drink or
smoke. Shower after work. Do not wear work clothes home. Use a vacuum equipped
with a HEPA filter to vacuum work clothes after they are worn. Launder them
separately. Do not shake or use compressed air to remove dust from work clothes.
6. Waste Disposal. Dispose of discarded linings, used rags, cloths and HEPA filters
with care, such as in sealed plastic bags. Consult applicable EPA, state and local
regulations on waste disposal.

Regulatory Guidance
References to OSHA, NIOSH, MSHA, and EPA, which are regulatory agencies in the
United States, are made to provide further guidance to employers and workers employed
within the United States. Employers and workers employed outside of the United States
should consult the regulations that apply to them for further guidance.

Copyright 2003
AxleTech International

Page i

Notes

Exploded View
Exploded View

2
19

14

20

21

22
15

23

24

17

18

3
9

16
12

13

8
10

11

25

26

Item
1
2
3
4
5
6
7
8
9
10
11
12
13

Description
Housing
Large Snap Ring
Pressure Ring
Piston
Screw Cap
Slide Pin
Retainer Ring
Dust Boot
Brake Pad
Friction Sleeve
Magnet
Cup Seal
Cup Seal

Maintenance Manual MM-4A

Issued 04-03

Item
14
15
16
17
18
19
20
21
22
23
24
25
26

Copyright 2003
AxleTech International

Description
Adjusting Screw
Lock Nut
Nut
Cotter Pin
O-Ring Seal
O-Ring Seal
O-Ring Seal
Cup Spring
Wear Plate
Thrust Bolt
Bleeder Screw
Washer
Inlet Adapter

Page 1

Section 1
Introduction
Brake Operation

Section
Introduction
1

The two brake pads slide on the guide bolts in the housing.
When the brake is actuated, the cup springs move the
piston, adjusting screw, thrust bolt and inner brake pad
toward the brake disc. When the inner brake pad contacts
the brake disc, the housing shifts onto the guide bolts and
the outer brake pad is pressed against the brake disc also.
The brake is released by hydraulic pressure. When the
brake is released, the piston compresses the cup springs,
pulling the inner brake pad away from the brake disc.
Brake lining and brake disc wear reduces braking force.
The brake must be adjusted to maintain braking force.
Refer to Section 5.
When replacing parts, only use factory original parts and
parts sets. Parts must be ordered through the vehicle
manufacturer. Any damage to parts not described in this
manual must be repaired or replaced using original parts.

Page 2

Copyright 2003
AxleTech International

Maintenance Manual MM-4A

Issued 04-03

Section 2
Component Replacement
5.

Section
Component
2 Replacement

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.

NOTE: You only need to remove one of the two guide

bolts to remove the brake pads from the housing.
6.

Remove a guide bolt cotter pin. Unscrew the

castellated nut. Pull the guide bolt out of the brake
housing.

7.

Remove the brake pads from the brake housing in the

direction of the removed guide bolt.

8.

If there is not enough clearance to replace the brake

pads, the brake housing must be completely removed.

When the parking brake is released, the vehicle does not

have any park brake function. You must block the
wheels to prevent the vehicle from moving. Serious
personal injury and damage to components can result.

A. If the hydraulic pressure hose is too short to

remove the brake, you must release the pressure
and disconnect the hose. Perform the parking
brake emergency release procedure before you
remove the brake. Refer to Section 5.

Brake Pads Replacement

B. Pull both guide bolts out of the brake housing to

remove the housing.

CAUTION
Always replace both linings with specified parts. If you
only replace one lining, damage to the disc can occur. If
you use non-AxleTech parts, incorrect brake operation
can occur. Damage to components can result.
Brake lining thickness must be inspected at regular
intervals, depending on vehicle usage. Inspect the lining
thickness every six months minimum. Use the following
procedure to replace the linings if lining thickness reaches:

0.04-inch (1.0 mm) or less for model 1270 brake.

0.08-inch (2.0 mm) or less for models 1286 and 1287
brakes.
1.

Park the vehicle on a level surface. Block the wheels to

prevent the vehicle from moving. If it is necessary to
raise the vehicle to service the parking brake, use a
jack to raise the vehicle. Support the vehicle with
safety stands.

2.

Apply 1450 psi (100 bar) of hydraulic pressure to

release the parking brake.

3.

Remove the screw cap.

4.

Loosen the lock nut. Use a male hex wrench, M8 for

model 1270 brake or M10 for models 1286 and 1287
brakes, to turn the adjusting screw counterclockwise.

Maintenance Manual MM-4A

Issued 04-03

Use a screwdriver to push the inner pad away from the

brake disc to create clearance for the new brake pads.

9.

Install new brake pads. Insert the guide bolts into the
brake housing. Check the permanent magnets to verify
that they have enough magnetic force to hold the brake
pads.

If the permanent magnets do not have enough
magnetic force to hold the brake pads: Replace
the magnets. Use a screwdriver to pry the magnets
from the outer end of the thrust bolt and caliper
boss.

10. Secure the guide bolts with the castellated nut and
cotter pin.
11. If you completely removed the brake, connect the
pressure hose and bleed the brake.
12. Before you return the vehicle to service, adjust the
brake using the procedure in Section 5.

Copyright 2003
AxleTech International

Page 3

Section 2
Component Replacement
Seal Replacement
NOTE: See Section 6 for contents of Seal Kit MPS4646.

10. Use a suitable tool with rounded edges to install the

new piston seals. Take care to avoid damage to the
sealing lips.

1.

Park the vehicle on a level surface. Block the wheels to

prevent the vehicle from moving.

11. Use a suitable seal driver and a screw-type clamp to

press a new dust cap into the housing.

2.

Apply 1450 psi (100 bar) of hydraulic pressure to

release the parking brake.

3.

Remove the screw cap.

4.

Loosen the lock nut. Use a male hex wrench, M8 for

model 1270 brake or M10 for models 1286 and 1287
brakes, to turn the adjusting screw counterclockwise
until the adjusting screw extends 1.1-1.2-inches
(27-30 mm) outside of the piston.

5.

Release hydraulic pressure. Remove the pressure hose

and completely remove the brake.

6.

Remove the large snap ring. Remove the pressure ring

from the housing.

7.

Remove the cup springs, piston and thrust bolt.

Maintain cup spring orientation.

8.

Remove the piston seals.

9.

Use a suitable tool to pry out the dust cap.

12. Use silicone grease, Dow Corning DC-4 or equivalent,

to lightly grease the sliding and sealing surfaces of the
piston.
13. Install the piston and thrust bolt assembly. Install the
dust cap lip into the thrust bolt groove.
14. Install the cup springs in the original orientation.
Figure 2.1.
15. Install the pressure ring into the housing. Install the
large snap ring.
16. Mount the caliper on the axle adapter using the
procedure in this section.

Caliper Assembly Installation

NOTE: Install the caliper assembly when the brake is
cold.

CAUTION
You must mount the piston seals in the direction shown
in Figure 2.1. I ncorrect mounting can result in leakage
and loss of pressure.

1.

Park the vehicle on a level surface. Block the wheels to

prevent the vehicle from moving.

2.

Remove the screw cap.

3.

Loosen the lock nut. Use a male hex wrench, M8 for

model 1270 brake or M10 for models 1286 and 1287
brakes, to turn the adjusting screw counterclockwise.

4.

Push the inner brake pad and pressure bolt assembly

toward the caliper head to create a larger opening
between the brake pads.

5.

Install the caliper assembly onto the brake disc and

fasten it to the axle adapter.

6.

Install a hydraulic pressure line to the caliper inlet

fitting. Apply 1450 psi (100 bar) of pressure. The
piston will retract and the cup springs will be
pre-tensioned.

7.

Before you return the vehicle to service, adjust the

brake using the procedure in Section 5.

8.

Bleed all air from the piston chamber. See Bleed Brake
in Section 5.

Figure 2.1
1

3
4

1
2
3
4
5

CUP SPRINGS
LARGE SNAP RING
PRESSURE RING
PISTON SEALS
DUST CAP

Page 4

Copyright 2003
AxleTech International

Maintenance Manual MM-4A

Issued 04-03

Section 3
Maintenance and Inspection
Caliper

Section
Maintenance
3
and Inspection

WARNING
To prevent serious eye injury, always wear safe eye
protection when you perform vehicle maintenance or
service.

Maintenance
The brake pads are maintenance-free. Check for damaged
parts and verify that the brake disc operates correctly.

1.

Inspect for fluid leaks. Disassemble the caliper if there

is a leak. Inspect the piston, piston bore and seals.
Replace parts as necessary.

2.

Inspect the piston and housing bores for scratches and

corrosion. Use a fine emery cloth to remove scratches
or corrosion. Replace worn or damaged components.
Replace components that are heavily corroded or have
large scratches.

Inspect Parts
Linings
CAUTION
Always replace both linings with specified parts. If you
only replace one lining, damage to the disc can occur. If
you use non-AxleTech parts, incorrect brake operation
can occur. Damage to components can result.
Brake lining thickness must be visually inspected at regular
intervals, depending on vehicle usage. Inspect the lining
thickness every six months minimum.
1.

Remove the linings. Inspect the linings for wear and

damage. Replace damaged linings.

2.

Replace linings if you find the following conditions:

If the lining thickness reaches:
0.04-inch (1.0 mm) or less for model 1270
brake.
0.08-inch (2.0 mm) or less for models 1286 and
1287 brakes.

Each lining has a different thickness.

The linings are contaminated with oil or grease.

The linings have large or deep cracks. Small, tight
cracks or heat checks on the linings surface, which
are caused by high temperatures, are normal.

Maintenance Manual MM-4A

Issued 04-03

Copyright 2003
AxleTech International

Page 5

Section 4
Prepare Parts for Assembly
Dry and Inspect Parts

Section
Prepare 4Parts for Assembly

WARNING
To prevent serious eye injury, always wear safe eye
protection when you perform vehicle maintenance or
service.

Clean, Dry and Inspect Parts

1.

Use soft, clean paper or cloth rags or compressed air to

completely dry parts immediately after you clean them.

2.

Carefully inspect all parts for wear or damage before

you assemble them.

3.

Repair or replace worn or damaged parts.

Apply Corrosion Protection

WARNING
Solvent cleaners can be flammable, poisonous and cause
burns. Examples of solvent cleaners are carbon
tetrachloride, and emulsion-type and petroleum-base
cleaners. Read the manufacturers instructions before
using a solvent cleaner, then carefully follow the
instructions. Also follow the procedures below.

Wear safe eye protection.

1.

Apply brake system hydraulic fluid to cleaned, dried

parts. Be careful that you do not apply the grease to the
linings or rotor.

2.

If you will store the parts, apply a special material,

which prevents corrosion and rust, to all surfaces. Store
parts inside special paper or other material that
prevents rust and corrosion.

Wear clothing that protects your skin.

Work in a well-ventilated area.

Do not use gasoline, or solvents that contain gasoline.
Gasoline can explode.

You must use hot solution tanks or alkaline solutions
correctly. Read the manufacturers instructions
before using hot solution tanks and alkaline
solutions. Then carefully follow the instructions.

Clean Parts
CAUTION
Do not use hot solution tanks or water and alkaline
solutions to clean ground or polished parts. Damage to
parts can result.
1.

Use a cleaning solvent or kerosene or diesel fuel to

clean ground or polished metal parts or surfaces.
Examples of ground or polished parts are the piston
and the piston bore in the caliper.

2.

Use a wire brush to clean fastener and fitting threads.

3.

Remove mud and dirt on the linings. Replace all

linings contaminated with oil or grease.

Page 6

Copyright 2003
AxleTech International

Maintenance Manual MM-4A

Issued 04-03

Section 5
Adjustments
6.

Hold the adjusting screw in position. Tighten the lock

nut securely.

To prevent serious eye injury, always wear safe eye

protection when you perform vehicle maintenance or
service.

7.

Install and hand-tighten the screw cap.

8.

Actuate the brake several times.

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.

9.

Check the parking brake on a slope.

Section
Adjustments
5

WARNING

When the parking brake is released, the vehicle does not

have any park brake function. You must block the
wheels to prevent the vehicle from moving. Serious
personal injury and damage to components can result.

Parking Brake Emergency Release

WARNING
When the parking brake is released, the vehicle does not
have any park brake function. You must block the
wheels to prevent the vehicle from moving. Serious
personal injury and damage to components can result.
If hydraulic pressure is not available, the parking brake can
be manually released using the following procedure.

Brake Adjustment
Brake adjustment is required after installing new brake pads
or brake discs, after all repairs, and to improve braking
performance. Adjust the brakes when the brake is cold. The
park brake must be in the released condition during the
adjustment procedure.

1.

Park the vehicle on a level surface. Block the wheels to

prevent the vehicle from moving.

2.

Remove the screw cap.

3.

Loosen the lock nut.

4.

Use a male hex wrench, M8 for model 1270 brake or

M10 for models 1286 and 1287 brakes, to turn the
adjusting screw counterclockwise until the brake is
released. Emergency release requires approximately
30 lb-ft (40 Nm) torque on the adjusting screw. T

1.

Park the vehicle on a level surface. Block the wheels

to prevent the vehicle from moving. If it is necessary
to raise the vehicle to service the brake, use a jack to
raise the vehicle. Support the vehicle with safety
stands.

2.

Apply 1450 psi (100 bar) of hydraulic pressure to

release the parking brake.

5.

Tighten the lock nut. Install and hand-tighten the screw

cap.

3.

Remove the screw cap.

6.

Before you return the vehicle to service, adjust the

brake using the procedure in this section.

4.

Loosen the lock nut. Use a male hex wrench, M8 for

model 1270 brake or M10 for models 1286 and 1287
brakes, to turn the adjusting screw clockwise until both
brake pads contact the brake disc.

Bleed Brake

5.

Turn the adjusting screw counterclockwise to set the

TOTAL clearance specified in the following table.

Total Lining-to-Disc Clearance

Adjusting Screw
Revolutions
Models
1286 and
1287

Inch

mm

Model
1270

Minimum

0.020

0.5

1/4

1/5

Rated

0.040

1.0

1/2

2/5

Maximum

0.060

1.5

3/4

3/5

Maintenance Manual MM-4A

Issued 04-03

NOTE: When you loosen any brake system hydraulic

connection, you must bleed the brake to remove all air from
the system.
1.

Make sure that the master cylinder is filled to the

specified level with the type of hydraulic fluid specified
by the equipment manufacturer. Keep the master
cylinder filled during bleeding so that you do not pull
air into the system through the master cylinder. Make
sure the master cylinder is filled when you are done
bleeding the system.

2.

Put a clear tube on the bleeder screw. Submerge the

other end of the tube in a clear container of the
specified fluid.

Copyright 2003
AxleTech International

Page 7

Section 5
Adjustments
3.

Bleed brake.
For full hydraulic systems:
Slowly apply low hydraulic pressure to the brake.
Loosen the bleeder screw. Continue to apply pressure
until no air bubbles appear in the container of fluid.
Tighten the bleeder screw 9-12 lb-ft (12-16 Nm), then
release the pressure to the brake. T
For air/hydraulic or mechanical actuator systems:
Apply the brake pedal, then loosen the bleeder screw.
Tighten the bleeder screw 9-12 lb-ft (12-16 Nm)
before you release the brake pedal so that air is not
pulled back into the system. Repeat this procedure
until no air bubbles appear in the container of fluid
when you apply the brake pedal. T

4.

Check for fluid leaks.

Page 8

Copyright 2003
AxleTech International

Maintenance Manual MM-4A

Issued 04-03

Section 6
Specifications
Section
Specifications
6

WARNING
Use only the type of hydraulic fluid specified by the
equipment manufacturer. Do not use or mix different
types of hydraulic fluid. Using incorrect hydraulic fluid
will damage the rubber parts of the caliper. Loss of
braking control, serious personal injury and damage to
components can result.
Do not reuse hydraulic fluid. Used fluid can be
contaminated and can cause incorrect operation.
Serious personal injury and damage to components can
result.

Hydraulic Fluid

Petroleum base hydraulic fluid or mineral oil.
Example: meets MIL-H-5606 specifications.

Hydraulic Pressure

Release pressure is 1450 psi (100 bar).
Never exceed 2,030 psi (140 bar).

Fluid Volume
Volume to release brake: Approximately 1.1 oz (33 cc),
plus allowance for brake line.
NOTE: Always verify brake is fully released when
pressure is applied.

Seal Kit MPS4646

Part Name

Quantity

Exploded View Item

Number

O-Ring

20

O-Ring

19

Cup Seal

13

Cup Seal

12

O-Ring

18

Dust Boot

Maintenance Manual MM-4A

Issued 04-03

Copyright 2003
AxleTech International

Page 9

Suite 400
3001 West Big Beaver Road
Troy, Michigan 48084
U.S.A.
877-877-9717
FAX: 248-435-1990
Website: www.axletech.com

AxleTech, International France

4, Rue Jean Servanton
Boite Postale 656
42042 Saint Etienne Cedex 1
France
(33) 477.92.88.00
FAX: (33) 477.92.88.93

MM-4A
Issued 04-03

Copyright AxleTech International

Printed in the USA