TM

Dry Disc Park Brake

Frein de parc à disque
Maintenance Manual MM4A Issued 04-03
Manuel de maintenance MM4A Edité Avril-03

Models 1270, 1286 and 1287

Modèles 1270, 1286 et 1287
Service Notes

Before
Service Notes
You Begin
This manual provides instructions for AxleTech
International’s 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 company’s 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.
A Caution alerts you to an
CAUTION 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 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.
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.
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 employer’s 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 Copyright 2003
Issued 04-03 AxleTech International
Asbestos and Non-Asbestos Fibers
NON-ASBESTOS FIBERS WARNING
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
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.
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.
Page i
Notes
 Exploded View

Exploded View

2
14
20
19 5
21

22
4

15
18
6 23

3
24 9 7

16
17
12 13

8
11
1 10

25

26

Item Description Item Description

1 Housing 14 Adjusting Screw
2 Large Snap Ring 15 Lock Nut
3 Pressure Ring 16 Nut
4 Piston 17 Cotter Pin
5 Screw Cap 18 O-Ring Seal
6 Slide Pin 19 O-Ring Seal
7 Retainer Ring 20 O-Ring Seal
8 Dust Boot 21 Cup Spring
9 Brake Pad 22 Wear Plate
10 Friction Sleeve 23 Thrust Bolt
11 Magnet 24 Bleeder Screw
12 Cup Seal 25 Washer
13 Cup Seal 26 Inlet Adapter

Maintenance Manual MM-4A Copyright 2003

Issued 04-03 AxleTech International 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.

Copyright 2003 Maintenance Manual MM-4A

Page 2 AxleTech International Issued 04-03

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.
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.
Brake Pads Replacement
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 Copyright 2003
Issued 04-03 AxleTech International
Section 2
Component Replacement
5. Use a screwdriver to push the inner pad away from the
brake disc to create clearance for the new brake pads.
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.
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.
B. Pull both guide bolts out of the brake housing to
remove the housing.
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.
Page 3
Section 2
Component Replacement

Seal Replacement 10. Use a suitable tool with rounded edges to install the
new piston seals. Take care to avoid damage to the
sealing lips.
NOTE: See Section 6 for contents of Seal Kit MPS4646.
11. Use a suitable seal driver and a screw-type clamp to
1. Park the vehicle on a level surface. Block the wheels to press a new dust cap into the housing.
prevent the vehicle from moving.
12. Use silicone grease, Dow Corning DC-4 or equivalent,
2. Apply 1450 psi (100 bar) of hydraulic pressure to to lightly grease the sliding and sealing surfaces of the
release the parking brake. piston.
3. Remove the screw cap. 13. Install the piston and thrust bolt assembly. Install the
dust cap lip into the thrust bolt groove.
4. Loosen the lock nut. Use a male hex wrench, M8 for
model 1270 brake or M10 for models 1286 and 1287 14. Install the cup springs in the original orientation.
brakes, to turn the adjusting screw counterclockwise Figure 2.1.
until the adjusting screw extends 1.1-1.2-inches
15. Install the pressure ring into the housing. Install the
(27-30 mm) outside of the piston.
large snap ring.
5. Release hydraulic pressure. Remove the pressure hose
16. Mount the caliper on the axle adapter using the
and completely remove the brake.
procedure in this section.
6. Remove the large snap ring. Remove the pressure ring
from the housing. Caliper Assembly Installation
7. Remove the cup springs, piston and thrust bolt.
Maintain cup spring orientation. NOTE: Install the caliper assembly when the brake is
cold.
8. Remove the piston seals.
9. Use a suitable tool to pry out the dust cap. 1. Park the vehicle on a level surface. Block the wheels to
prevent the vehicle from moving.
CAUTION 2. Remove the screw cap.
You must mount the piston seals in the direction shown 3. Loosen the lock nut. Use a male hex wrench, M8 for
in Figure 2.1. I ncorrect mounting can result in leakage model 1270 brake or M10 for models 1286 and 1287
and loss of pressure. brakes, to turn the adjusting screw counterclockwise.
4. Push the inner brake pad and pressure bolt assembly
Figure 2.1 toward the caliper head to create a larger opening
between the brake pads.
1
5. Install the caliper assembly onto the brake disc and
fasten it to the axle adapter.
2
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
5 3
brake using the procedure in Section 5.
4 8. Bleed all air from the piston chamber. See Bleed Brake
1 CUP SPRINGS in Section 5.
2 LARGE SNAP RING
3 PRESSURE RING
4 PISTON SEALS
5 DUST CAP

Copyright 2003 Maintenance Manual MM-4A

Page 4 AxleTech International Issued 04-03
 Section 3
Maintenance and Inspection

Section
Maintenance
3 and Inspection
Caliper
WARNING
1. Inspect for fluid leaks. Disassemble the caliper if there
To prevent serious eye injury, always wear safe eye is a leak. Inspect the piston, piston bore and seals.
protection when you perform vehicle maintenance or Replace parts as necessary.
service.
2. Inspect the piston and housing bores for scratches and
Maintenance corrosion. Use a fine emery cloth to remove scratches
or corrosion. Replace worn or damaged components.
The brake pads are maintenance-free. Check for damaged Replace components that are heavily corroded or have
parts and verify that the brake disc operates correctly. 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 lining’s surface, which
are caused by high temperatures, are normal.

Maintenance Manual MM-4A Copyright 2003

Issued 04-03 AxleTech International Page 5
Section 4
Prepare Parts for Assembly

Section
Prepare 4Parts for Assembly
Dry and Inspect Parts
WARNING
1. Use soft, clean paper or cloth rags or compressed air to
To prevent serious eye injury, always wear safe eye completely dry parts immediately after you clean them.
protection when you perform vehicle maintenance or
service. 2. Carefully inspect all parts for wear or damage before
you assemble them.
Clean, Dry and Inspect Parts 3. Repair or replace worn or damaged parts.

Apply Corrosion Protection

WARNING
1. Apply brake system hydraulic fluid to cleaned, dried
Solvent cleaners can be flammable, poisonous and cause parts. Be careful that you do not apply the grease to the
burns. Examples of solvent cleaners are carbon linings or rotor.
tetrachloride, and emulsion-type and petroleum-base
cleaners. Read the manufacturer’s instructions before 2. If you will store the parts, apply a special material,
using a solvent cleaner, then carefully follow the which prevents corrosion and rust, to all surfaces. Store
instructions. Also follow the procedures below. parts inside special paper or other material that
prevents rust and corrosion.

Wear safe eye protection.

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 manufacturer’s 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.

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Page 6 AxleTech International Issued 04-03
 Section 5
Adjustments

Section
Adjustments
5 6. Hold the adjusting screw in position. Tighten the lock
WARNING nut securely.
To prevent serious eye injury, always wear safe eye 7. Install and hand-tighten the screw cap.
protection when you perform vehicle maintenance or
service. 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.
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.
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. 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.
9. Check the parking brake on a slope.
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.
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 N•m) torque on the adjusting screw. T
5. Tighten the lock nut. Install and hand-tighten the screw
cap.

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 clockwise until both
brake pads contact the brake disc.
5. Turn the adjusting screw counterclockwise to set the
TOTAL clearance specified in the following table.
6. Before you return the vehicle to service, adjust the
brake using the procedure in this section.
Bleed Brake
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

Adjusting Screw specified level with the type of hydraulic fluid specified
Total Lining-to-Disc Clearance Revolutions by the equipment manufacturer. Keep the master
Models cylinder filled during bleeding so that you do not pull
Model 1286 and air into the system through the master cylinder. Make
Inch mm 1270 1287 sure the master cylinder is filled when you are done
bleeding the system.
Minimum 0.020 0.5 1/4 1/5
2. Put a clear tube on the bleeder screw. Submerge the
Rated 0.040 1.0 1/2 2/5 other end of the tube in a clear container of the
Maximum 0.060 1.5 3/4 3/5 specified fluid.

Maintenance Manual MM-4A Copyright 2003

Issued 04-03 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 N•m), 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 N•m)
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.

Copyright 2003 Maintenance Manual MM-4A

Page 8 AxleTech International 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

Exploded View Item

Part Name Quantity Number
O-Ring 1 20
O-Ring 1 19
Cup Seal 1 13
Cup Seal 1 12
O-Ring 1 18
Dust Boot 1 8

Maintenance Manual MM-4A Copyright 2003

Issued 04-03 AxleTech International Page 9
Suite 400 AxleTech, International France
3001 West Big Beaver Road 4, Rue Jean Servanton
Troy, Michigan 48084 Boite Postale 656
U.S.A. 42042 Saint Etienne Cedex 1
877-877-9717 France
FAX: 248-435-1990 (33) 477.92.88.00
Website: www.axletech.com FAX: (33) 477.92.88.93

MM-4A © Copyright AxleTech International

Issued 04-03 Printed in the USA