SD-02-4500

Bendix Piggyback Spring Brake

SERVICE PUSH-ROD

SERVICE
CHAMBER

SERVICE
DIAPHRAGM

PIGGYBACK CHAMBER

FIGURE 1 - BENDIX PIGGYBACK SPRING BRAKE

DESCRIPTION PREVENTIVE MAINTENANCE

The Bendix Piggyback Spring Brake is made up of a Important: Review the warranty policy before performing
conventional brake chamber and an emergency or parking any intrusive maintenance procedures. An extended warranty
spring mechanism for use on vehicles equipped with cam may be voided if intrusive maintenance is performed during
foundation brakes. The Spring Brake Actuator provides: (1) this period.
Service Braking, (2) Parking and (3) Emergency Braking. Because no two vehicles operate under identical conditions,
The actuator can be piped with various system arrangements maintenance intervals will vary. Experience is a valuable guide
to be automatically or manually applied under emergency in determining the best maintenance interval for a vehicle.
braking conditions.
The spring brake is a diaphragm type actuator which converts WARNING!
the energy of air pressure into mechanical force. The Piggyback Spring Brake Chambers contain a loaded
diaphragm is held between the pressure plate and non- compression spring. Property damage, serious injury
pressure plate by a two piece clamp ring. or death may occur if instructions are not followed
Different size brake chambers are identified by numbers completely.
which specify the effective area of a diaphragm. For example,
a Type 30/30 Spring Brake has 30 square inches of effective Every 300 operating hours, 8,000 miles, or one (1) month:
area on each diaphragm. 1. Check push rod travel and adjust travel at the slack
The standard diaphragm material is a compound of natural adjuster if needed. Push rod travel should be as short
rubber with a fabric interior of nylon. as possible without the brakes dragging. Excessive push
rod travel reduces braking efficiency, shortens diaphragm
life, gives slow braking response and wastes air.

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2. Check push rod to slack adjuster alignment from release
to full stroke position to be sure the push rod moves out
and returns properly without binding at the non-pressure
plate hole or with other structures. Also check the angle
formed by the slack adjuster arm and push rod. It should
be greater than 90 degrees when the chamber is in the
EMERGENCY
released position and approach 90 degrees at maximum SERVICE PORT
readjustment stroke. PORT

3. Check tightness of mounting nuts. Torque on the non-

pressure plate mounting nuts should be 110 ft/lbs.
4. Check cotter pins to ensure they are in place.
5. Check all hoses and lines. They should be secure and
in good condition with sufficient length to allow for axle
movement. SERVICE
Every 3,600 operating hours, 100,000 miles or one (1) year: PUSH ROD
MOUNTING
1. Disassemble and clean all parts. Clean all metal parts
NUT
in cleaning solvent, removing all rust and scale. Carefully LOCKNUT
inspect all metal parts for cracks, distortion or damage.
YOKE
All diaphragm sealing surfaces should be smooth and
clean.
2. Install new diaphragm or any other parts if they are worn
or deteriorated. Perform steps outlined in "Replacing the COTTER PIN
Service Diaphragm". When the diaphragm, spring, or
both are replaced, they should be replaced in the
corresponding chamber on the same axle.
FIGURE 2 - PIGGYBACK SPRING BRAKE DIAGRAM
WARNING!
A piggyback spring brake chamber cannot have the WARNING! PLEASE READ AND FOLLOW
emergency diaphragm replaced. Replace the whole THESE INSTRUCTIONS TO AVOID
piggyback spring brake chamber. PERSONAL INJURY OR DEATH:
When working on or around a vehicle, the following
OPERATION & LEAKAGE TESTS
general precautions should be observed at all times.
OPERATING TEST 1. Park the vehicle on a level surface, apply the park-
1. Apply brakes and observe that the push rods move out ing brakes, and always block the wheels. Always
promptly and without binding. wear safety glasses.
2. Stop the engine and remove ignition key when
2. Release brakes and observe that the push rods return to working under or around the vehicle. When work-
the released position promptly and without binding. ing in the engine compartment, the engine should
3. Check push rod travel. Push rod travel should be as be shut off and the ignition key should be removed.
short as possible without brakes dragging. Adjust travel Where circumstances require that the engine be
of push rod at slack adjuster if necessary. in operation, EXTREME CAUTION should be used
to prevent personal injury resulting from contact
LEAKAGE TEST with moving, rotating, leaking, heated or electri-
1. Make and hold a full brake application. cally charged components.
3. Do not attempt to install, remove, disassemble or
2. Using soap solution, coat clamping ring(s). If leakage is assemble a component until you have read and
detected, tighten clamping ring only enough to stop thoroughly understand the recommended proce-
leakage. DO NOT OVERTIGHTEN as this can distort dures. Use only the proper tools and observe all
the sealing surface or clamping ring. Coat area around precautions pertaining to use of those tools.
push rod hole (loosen boot if necessary). No leakage is 4. If the work is being performed on the vehicle’s air
permitted. If leakage is detected, the diaphragm must brake system, or any auxiliary pressurized air sys-
be replaced. tems, make certain to drain the air pressure from
all reservoirs before beginning ANY work on the
vehicle. If the vehicle is equipped with an AD-IS™
air dryer system or a dryer reservoir module, be
sure to drain the purge reservoir.
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 OPERATION: GENERAL
MAIN SPRING
The Bendix Piggyback Spring Brake is made up of the service
chamber and the piggyback chamber. The Bendix Piggyback
Spring Brake provides service braking, parking, and
emergency braking.
The spring brake can be mounted with the mounting bolts in
either a vertical or horizontal plane on standard mounting
stud centers. Two air lines are used: the service air line and
EMERGENCY
the emergency air line.
PORT
DIAPHRAGM Controlled air pressure enters the service chamber through
RELEASE the inlet port and acts upon the diaphragm moving the push
TOOL
SIDE
plate and rod assembly forward.
POCKET When the service chamber is used to actuate cam type
brake foundation assemblies, the yoke (which is threaded
on the push rod) is connected to a slack adjuster, which in
turn is connected to the brake cam shaft. This forward motion
of the push rod rotates the slack adjuster, cam shaft and
NON-PRESSURE cam applying the vehicle brakes.
HOUSING PUSH ROD
The greater air pressure admitted to the service chamber,
the greater the force applied by the push rod and, conversely,
the less pressure applied to the service chamber the less
force applied by the push rod. Push rod force is determined
by multiplying the delivered air pressure by the effective
diaphragm area. For example, if 60 p.s.i. is admitted to a
type 30 service chamber, the lineal force on the end of the
FIGURE 3 - PIGGYBACK SPRING BRAKE CUT-AWAY VIEW
push rod is approximately 1,800 lbs.
5. Following the vehicle manufacturer’s recom- When air pressure is released from the brake chamber, the
mended procedures, deactivate the electrical sys- push rod return spring in combination with the brake shoe
tem in a manner that safely removes all electrical return spring returns the diaphragm, push plate and rod
power from the vehicle. assembly, slack adjuster and brake cam to their released
6. Never exceed manufacturer’s recommended positions releasing the brakes.
pressures. When the driver operates the parking brake, air is exhausted
7. Never connect or disconnect a hose or line con- from the piggyback chamber. The main spring is allowed to
taining pressure; it may whip. Never remove a com-
extend, which forces the push rod and the emergency
ponent or plug unless you are certain all system
diaphragm forward. This forces the service diaphragm and
pressure has been depleted.
8. Use only genuine Bendix® replacement parts, com- service push rod forward which applies the brakes.
ponents and kits. Replacement hardware, tubing, When the air pressure in the piggyback chamber drops to
hose, fittings, etc. must be of equivalent size, type below 78 p.s.i., the main spring overcomes chamber
and strength as original equipment and be pressure and forces the push rod and emergency diaphragm
designed specifically for such applications and forward.
systems.
9. Components with stripped threads or damaged WARNING!
parts should be replaced rather than repaired. Do
• Piggyback Spring Brake Chambers contain a
not attempt repairs requiring machining or weld-
loaded compression spring. Property damage,
ing unless specifically stated and approved by the
vehicle and component manufacturer. serious injury or death may occur if instructions
10. Prior to returning the vehicle to service, make are not followed completely.
certain all components and systems are restored • When replacing the piggyback spring brake, make
to their proper operating condition. sure to block the wheels to prevent vehicle
rollaway.

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 ADAPTER
SERVICE RETURN SPRING
RETURN SPRING

MAIN SPRING

LOCKNUT

YOKE
RELEASE TOOL

PRESSURE PLATE
SERVICE
DIAPHRAGM
EMERGENCY
DIAPHRAGM

FIGURE 4 - CAGING THE PIGGYBACK

• DO NOT service a piggyback spring brake 5. Pull on the release tool to seat it in the pressure
chamber if it has structural damage of any kind. plate properly.
Replace the complete assembly. Dismount a 6. Put on the release washer and nut.
damaged piggyback spring brake by first cutting 7. To cage the main spring, tighten the release nut with a
the service push rod with an acetylene torch to hand wrench and ensure the service pushrod
relieve any force it might have. is retracting.
• Do not strike any part of a spring brake chamber 8. Do not over torque the release tool assembly. Maximum
for any reason. This may cause structural torque is 35 ft/lbs.
damage.
WARNING!
• Be careful not to drop a spring brake chamber
Do not use an impact wrench. An impact wrench may
at anytime.
over torque the release tool and cause damage to the
• A piggyback spring brake chamber cannot have pressure plate.
the emergency diaphragm replaced. Replace the 9. The threaded portion of the release tool will extend
whole piggyback spring brake chamber.
approximately 2.9 inches out of the nut when fully
• Always work from the side of the piggyback released.
spring brake chamber(s). Never work from the
front or back. MECHANICAL RELEASE (CAGING) AND
REMOVAL OF THE PIGGYBACK SPRING BRAKE
MECHANICAL RELEASE (CAGING) OF THE CHAMBER TO BE REPLACED
BENDIX PIGGYBACK SPRING BRAKE NOTE: The piggyback spring brake chamber can be
NOTE: The Bendix Piggyback Spring Brake Chamber is replaced with the service brake chamber mounted to the
not shipped caged. It must be caged prior to any work vehicle or removed for ease of access. To remove the
being done. assembly from the vehicle, perform the steps outlined in
1. Remove the dust cap from the keyhole in the center “Removal and Installation of the Combination Spring Brake.”
of the piggyback spring brake chamber.
WARNING!
2. Remove the release tool assembly from the side
pocket of the adaptor base. • Do not mechanically release (cage) the spring if
3. Insert the release tool (T-bolt) through the release tool there is any structural damage to the brake. Caging
keyhole and into the pressure plate. the spring in such a chamber may cause serious
injury or death. Replace the complete assembly.
4. Turn the release tool 1/4 turn clockwise.

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• Do not remove the Piggyback Spring Chamber
Clamps.
1. Mechanically release the old piggyback spring brake by
following the original manufacturer’s instructions.
2. Ensure air pressure is removed from all air reservoirs
before removing the air hoses or working on the
spring brake.
3. Remove air hoses from the Piggyback spring brake
chamber. Be sure to mark both hoses to ensure
proper reinstallation.
4. Clamp a pair of vise grips around the service pushrod
touching the non-pressure housing. This cages the
service return spring.
5. Remove the clamp nuts and service clamp assembly
and carefully remove the old piggyback chamber.

INSTALLING THE BENDIX PIGGYBACK SPRING

BRAKE CHAMBER
1. Visually inspect the service diaphragm for excessive wear,
damage or cracks. Replace if needed. To replace the
service diaphragm, perform the steps outlined in FIGURE 5 - PIGGYBACK CHAMBER
"Replacing the Service Diaphragm".
chamber. Caging the spring in such a chamber may
2. Line up the new piggyback spring brake chamber, the
cause serious injury or death. Replace the complete
service diaphragm, and the non-pressure housing,
assembly.
ensuring that they are centered.
3. Reassemble the service clamp assembly. Ensure all REMOVAL:
parts are seated properly and remain centered. 1. Mechanically release (cage) the old piggyback spring
4. Torque the clamp nuts to 25 ft/lbs. Remove the vise grips brake chamber by following the original manufacturer’s
from the service push rod. instructions.

5. Reconnect the emergency air line to the emergency 2. Ensure air pressure is removed from all air reservoirs
porthole and reconnect the service air line to the before removing the air hoses or working on the spring
service porthole. brake.

6. Pressurize the service half by putting air into the service 3. Remove air hoses from the piggyback spring brake
port. Do not exceed 120 psig. Test for leaks around the chamber. Be sure to mark both hoses to ensure proper
clamps. No leaks are acceptable. reinstallation.

7. Uncage the main spring and return the release tool into 4. Remove the yoke pin, disconnect the yoke from the slack
the release tool side pocket. adjuster, remove the mounting nuts, washer, and lock
washers and remove the combination spring brake. While
8. Replace the dust cap in the keyhole.
removing, use care to prevent the combination spring
WARNING! brake from falling.
Check for proper service and emergency operation INSTALLATION:
after servicing any part of the brake chamber(s). Check 1. Install the combination spring brake using the furnished
the brake adjustment if the combination spring brake hardware. Torque the mounting nuts to 110 ft/lbs.
was removed/installed (Follow vehicle manufacturer’s Connect the yoke to the slack adjuster and install the
instructions to adjust the brakes). yoke pin and the cotter pin.
2. Reconnect the emergency air line to the emergency
REMOVAL AND INSTALLATION OF THE
porthole and reconnect the service air line to the service
COMBINATION SPRING BRAKE
porthole.
WARNING! 3. Pressurize the service chamber by putting air into the
Do not mechanically release (cage) the spring if there service port. Do not exceed 120 psig. Test for leaks
is any structural damage to the piggyback spring brake around the clamps. No leaks are acceptable.

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 RELEASE 2. Ensure that the piggyback spring brake chamber is
TOOL caged. To cage the piggyback spring brake chamber,
perform the steps outlined in either "Mechanical Release
of the Bendix Piggyback Spring Brake" or "Mechanical
Release of the Piggyback Spring Brake to be Replaced".
3. Mark the service clamp ring and non-pressure plate to
ensure proper alignment of parts during reassembly.
4. Remove the service clamp ring assembly and the
PIGGYBACK
CHAMBER piggyback chamber. The service clamp ring is closest
SERVICE
CLAMP RING
to the non-pressure plate and slack adjuster. See
provided illustrations if in doubt.

WARNING!
Do not remove the spring chamber clamps.
5. Visually inspect the service diaphragm for excessive wear,
damage or cracks. Replace if needed.
6. Line up the piggyback spring brake chamber, the service
diaphragm, and the non-pressure housing, ensuring that
SERVICE NON-PRESSURE
HOUSING they are centered.
DIAPHRAGM
7. Reassemble the service clamp assembly. Ensure all
parts are seated properly and remain centered.
FIGURE 6 - SERVICE DIAPHRAGM 8. Torque the clamp nuts to 25 ft/lbs. Remove the vise grips
from the service push rod.
4. Uncage the main spring and return the release tool into
9. Reconnect the emergency air line to the emergency
the release tool side pocket.
porthole and reconnect the service air line to the
5. Replace the dust cap in the keyhole. service porthole.
10. Pressurize the service half by putting air into the service
WARNING! port. Do not exceed 120 psig. Test for leaks around the
clamps. No leaks are acceptable.
Check for proper service and emergency operation
after servicing any part of the brake chamber(s). Check 11. Uncage the main spring and return the release tool into
the release tool side pocket.
the brake adjustment if the combination spring brake
was removed/installed (Follow vehicle manufacturer’s 12. Replace the dust cap in the keyhole.
instructions to adjust the brakes).

REPLACING THE SERVICE DIAPHRAGM WARNING!

To replace the service diaphragm, it is not necessary to Check for proper service and emergency operation
remove the complete combination spring brake from the after servicing any part of the brake chamber(s). Check
vehicle. However, it can be removed for ease of access. To the brake adjustment if the combination spring brake
remove the combination spring brake, perform the steps was removed/installed (Follow vehicle manufacturer’s
outlined in "Removal and Installation of the Combination instructions to adjust the brakes).
Spring Brake".

WARNING!
• A piggyback spring brake chamber cannot have
the emergency diaphragm replaced. Replace the
whole piggyback spring brake chamber.
1. Protect the service push rod with tape, and lock the vise
grips on the push rod close to the non-pressure plate.
(This will hold the rod in the applied position).

BW2106 © 2004 Bendix Commercial Vehicle Systems LLC 8/2004. All rights reserved. Printed in U.S.A.
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