Fitting guidelines Product Air Brake Caliper
EBS Brand Quality
EBS brake calipers are rigorously tested and assembled in a strictly controlled environment, ensuring durability, long service life and exceptional performance.
At EBS, we are proud to say that our aftermarket remanufactured caliper range meets the OEM equivalent standard and is the ideal solution for your vehicle maintenance needs every time.
General fitting instructions
This procedure is a universal guide. Precise instructions from the vehicles maintenance manual is advised.
1. Disconnect all electrical connections. Blank off, or cover, any exposed connectors placing them away from the working area.
2. Remove the air brake chamber. In the event of spring brake chambers, ensure the wind off mechanism is fully wound off. Refrain from using Pneumatic Air Tools!
3. Isolate the air supply and remove the air piping from the brake chamber. Proceed to cover and safeguard the supply air pipe.
4. Position the lifting equipment below the caliper, ensuring there is a firm and secure contact between the caliper and lifting dolly.
5. Wind back the adjusting mechanism present on the caliper in order to reduce pressure on the brake disc creating a spacious aperture for the brake pads.
6. Release the brake pads retention clips or bars (if present) and take out the brake pads.
7. Examine the brake pads for uneven wear. This may be an indication of other underlying issues within the brake system.
8. (Where required) unscrew the bolts attaching the brake caliper body to the brake carrier assembly and secure the caliper to the lifting dolly (generally applicable to Knorr Bremse style calipers).
9. Carefully lower the old caliper away from the vehicle and store securely.
10. For applications where the carrier is required to be removed from the vehicle frame, please unscrew the bolts connecting the carrier to the vehicle frame and remove the carrier.
11. Examine the carrier, paying particular attention to the casting, checking for indications of warpage, cracking and/or damage to the threaded holes. Replace the carrier if required and can be purchased from EBS.
12. Inspect the brake disc for any wear patterns and ensure it is within the specified vehicle manufacturer’s tolerance. If there is uneven wear, crazing, cracking or discolouration the disc must be replaced and can be purchased from EBS.
13. If replacing the disc, this must be performed in accordance with the vehicle manufacturer’s maintenance guidelines.
14. Clean the entire area using an approved solvent, removing all dirt, debris, grease, and brake dust from the brake assembly area.
15. (When installing a caliper WITHOUT a ‘pre-mounted carrier assembly) - reinstall the brake carrier and tighten the attachment bolts and torque in accordance with the vehicle manufacturer specifications.
16. Visually compare the newly supplied caliper to the removed caliper for any obvious differences. If in the unlikely event that there is any doubt, please contact the EBS technical department.
17. Ensure adequate lubrication of new slider pins using the grease sachet supplied. Using lifting equipment, reposition the new caliper over the brake disc and secure using new bolts and slider pins.
18. Torque all fixing bolts in accordance with the vehicle manufacturer’s specifications.
19. Check up/down movement of the caliper and carrier assembly. Any movement in excess of 2mm would indicate wear to the carrier, which in turn should be replaced.
20. Install new brake pads and retaining clips/bars. These can be purchased from EBS.
21. Ensure the brake disc is rotating freely by spinning it by hand and the caliper has sufficient clearance from the brake disc.
22. Mount the brake chamber assembly with utmost care. Ensure an adequate seal is present between the brake chamber and caliper to avoid any water penetration into the brake caliper internals. Apply white grease generously on the caliper lever arm cup and the sealing area between the caliper body and the brake chamber. Refrain from using grease that contains molybdenum disulphide.
Ensure correct operation of the brake chamber in accordance with the vehicle manufacturers specification. Please also ensure brake chamber mounting is at the correct orientation in relation to the chamber drain hole to prevent water build up inside the chamber which can leak into the caliper actuation box mechanism and cause premature caliper failure.
23. If the sealing on the brake chamber appears distorted, impaired or extends less than 3mm, a replacement brake chamber is necessary.
The liability to ensure an entirely watertight seal between the caliper and brake chamber lies with the assembler/installer. In the likelihood of any caliper, covered under the warranty, being subjected to water penetration either in the proximity of the chamber placement or within the caliper lever panel, it will be rebuffed. EBS recommend the use of waterproof sealing materials wherever appropriate.
24. Torque the brake chamber in accordance with vehicle manufacturer guidelines.
25. Re-install the pneumatic connections to the brake chamber, removing all air isolations. For spring brake chambers, ensure that the disengaging mechanism is completely rotated and positioned in a state of readiness. Refrain from using Pneumatic Air Tools!
26. Re-install all the electronic connectors onto the caliper such as pad wear leads etc. Ensure they are free of any chaffing against the body parts and do not interfere with the brake caliper assembly.
27. Pressurise the vehicles air brake system and cycle the brakes several times, ensuring a correct operation of the caliper assembly. It is to be noted that in some instances, vehicle manufacturers insist on a predefined clearance between the brake pad and disc.
This information can be obtained from the vehicle manufacturer.
Brake caliper aftercare
Regular checks on the condition of the associated items such as electrical looms, caliper assembly components, brake discs & pads.
Ensure brake pads are inspected and replaced promptly when required. Brake pads that display uneven wear, scoring, cracking or crazing will indicate a problem within that brake position and should be investigated immediately.
When cleaning the vehicle, never directly aim any high-pressure water/air cleaning apparatus at the caliper and brake chamber assembly. This can cause damage to electrical connections, rubber gaiters/ seals and strip lubrication from moving surfaces/ components. It can also result in promoting water ingress between the brake chamber and the caliper lever box.
Ensure during regular inspection routines, particular attention is focused on the adequate lubrication of any exposed elements of the caliper guide pins. Failure to have an adequate grease film on exposed guide pin surfaces can result in a shorter service life of brake calipers in general.
If in any doubt please contact the EBS technical department.
Caliper health & safety
Whilst installing this product, kindly take into account the following health and safety considerations:
Assistance may be required when fitting this unit.
To remove the previous caliper and fit this new one, lifting equipment may be required, as some calipers can weigh in excess of 35kgs.
Please wear a dust mask as residual brake dust present around the caliper section can pose a risk to your respiratory system if inhaled.
Please wear protective gloves due to residual brake dust, trace oils, and greases that can lead to skin irritation and complex disorders including dermatitis.
*We recommend that the rotor is pressed into place using a hydraulic press with suitable tooling to spread the load around the diameter of the rotor.
Associated products
Caliper repair kits
Caliper carriers
Caliper potentiometer test device
Brake chambers
Brake pads
Brake discs
European Braking Systems Ltd. Unit 3-4 Westpoint Enterprise Park, Clarence Avenue, Trafford Park, Manchester, M17 1QS
