NHTSA ID Number: 10126590
Manufacturer Communication Number: FSB 512-001
TSB/Document Date: 2017-12-22
Summary
Thermal Overload
Field Service Bulletin
Trucks
Volvo Trucks
North America
Greensboro, NC USA
Date
11.13
Group
No.
Release
512 001 01
Page
1(24)
Thermal Overload
VAH, VHD, VN
FSB 512-001, Thermal Overload
(November 2013)
It has been reported in the field that the Bendix air disc brake may exhibit a thermal overload
condition. Thermal overload is simply an over adjustment of the normal pad wear
compensation that maintains the running clearance between the brake pad and rotor.
Thermal overload reduces the running clearance between the pad and rotor below a desired
level. This over adjustment does not come on suddenly, but rather slowly over time, until the
running clearance goes to zero and the pads are in contact with the rotor. Under this condition
the pads swell and may drag until the high temperature (accelerated) wear removes enough
pad material to reestablish running clearance. The main causal issue is high frequency or
magnitude of axle vibration and why it is typically only seen at one wheel end.
There have been very limited occurrences of thermal overload across varying applications
and vehicle configurations. However, in the event that any of the above issues are found, or
any thermal overload is suspected, immediately go to the on-line document library at www.
bendix.com for free downloads of Service Data Sheets (SD-23-7541). BW7514b will provide
specific instructions regarding how to diagnose a potential thermal overload occurrence. You
can also contact the Bendix Technical Help Line: 1-800-AIR-BRAKE, (1-800-247-2725) and
select option 2, then option 1, Mon.- Fri., 8 a.m. - 6 p.m. EST. for information on how to
remedy these issues.
Part Numbers
•
•
•
•
85136663 — Disc Brake Caliper Assembly LHS
85136662 — Disc Brake Caliper Assembly RHS
85136940 — Brake Shoes
21538404 — Brake Rotor
Service personnel: Please circulate, read and initial
Service
Manager
Warranty
Administrator
PV729-FSB512-001
Workshop
Foreman
Service Technicians
USA61809
Volvo Trucks North America
Field Service Bulletin
Date
11.13
Group
No.
Release
512
001
01
Inspection Procedure
Section A: Inspect Vehicle (Thermal Overload Event)
1 Secure the vehicle for service by parking it on a level surface, applying the parking brake,
blocking the wheels, and placing the transmission in neutral or park.
2 Disconnect all cables from the negative (ground) battery terminals to prevent personal
injury from electrical shock and prevent damage to electrical components.
3 Follow safe lifting guidelines, lift and support both the frame and the axle housing.
DANGER
Failure to properly support the front of the axle housing may result in the axle rolling
forward, causing serious injury or death.
4 Remove the wheels and tires.
5 Release the parking brake.
6 Retrieve instructions for inspection.
7 Perform a search for the words “thermal overload”.
8 Click “more” on the Bendix Commercial Vehicle Systems, BW7514 THERMAL
OVERLOAD CHECKLIST Download.
9 Download the latest BW7514 THERMAL OVERLOAD CHECKLIST.
10 Perform steps in the checklist.
11 Replace as needed.
Page
2(24)
Volvo Trucks North America
Field Service Bulletin
Date
11.13
Group
No.
Release
512
001
01
Brake Pad Replacement
1 Chock the wheels.
2 Lift and support the axle on jack stands.
3 Release the parking brakes.
4 Remove the wheel(s) from the wheel end in question.
5 Back off the brake adjuster.
6 Remove the brake pad retainer, pin and clip. Remove the brake pads.
Note: Ensure the rest of the brake assembly is operational and within serviceable limits.
W5084508
1 Retainer
2 Pin
3 Clip
4 Washer
Page
3(24)
Volvo Trucks North America
Field Service Bulletin
Date
11.13
Group
No.
Release
512
001
01
W5084510
1 Pad removal
7 Install new brake pads and secure with retainer, pin, washer and clip.
Note: If wear sensors are used, ensure they are serviceable or replace as needed.
Note: The adjuster may need to be turned counter-clockwise to open up enough room
between the caliper and rotor to install the pads.
Note: Clean the brake pad contact area on caliper.
Page
4(24)
Volvo Trucks North America
Field Service Bulletin
Date
11.13
W5084526
1 Pads installed
Group
No.
Release
512
001
01
Page
5(24)
Volvo Trucks North America
Field Service Bulletin
Date
11.13
Group
No.
Release
512
001
01
W5084527
1 Retainer
2 Pin
3 Clip
4 Washer
8 Adjust the brake pad clearance by turning the adjuster screw until the clearance between
the tappets and pads is between 0.5 mm (0.020 in.) and 1.0 mm (0.040 in.).
Note: The caliper should be pushed inboard on its guide pins during this check.
9 Repeat the above steps for the other wheel end of the same axle.
10 Install wheel(s). Torque to 610 NM (450 ft-lb).
Page
6(24)
Volvo Trucks North America
Field Service Bulletin
Date
11.13
Group
No.
Release
512
001
01
W5084816
11 Apply the parking brake.
12 Lift the axle, remove the jack stands and chocks. Lower vehicle.
Page
7(24)
Volvo Trucks North America
Field Service Bulletin
Date
11.13
Group
No.
Release
512
001
01
Caliper Replacement
1 Chock the wheels.
2 Lift and support the axle on jack stands.
3 Release the parking brakes.
4 Remove the wheel(s) from the wheel end in question.
W5084810
5 Back off the brake adjuster.
6 Remove the brake pad retainer, pin and clip. Remove the brake pads.
Note: Ensure the rest of the brake assembly is operational and within serviceable limits.
Page
8(24)
Volvo Trucks North America
Field Service Bulletin
Date
11.13
W5084508
1 Retainer
2 Pin
3 Clip
4 Washer
Group
No.
Release
512
001
01
Page
9(24)
Volvo Trucks North America
Field Service Bulletin
Date
11.13
Group
No.
Release
512
001
01
W5084510
1 Pad removal
7 Release parking brakes and cage brake chamber (if applicable).
8 Remove the brake hose.
9 Remove the actuator assembly - service brake chamber or park brake chamber.
Page
10(24)
Volvo Trucks North America
Field Service Bulletin
Date
11.13
Group
No.
Release
512
001
01
W5084511
1 Actuator Assembly (Park Brake Chamber)
2 Fasteners
10 Remove the outer boot clips or cap.
Note: Brake chamber mounting hardware can be reused.
11 Remove the caliper bolts and discard.
WARNING
Never insert fingers between caliper and carrier. Hold the exterior of caliper only, or
serious personal injury may result.
Page
11(24)
Volvo Trucks North America
Field Service Bulletin
Date
11.13
Group
No.
Release
512
001
01
W4084963
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TSB/Document ID: FSB 512-001
Replacement Service Bulletin Number:
MFR Communication Date: 2013-11-07
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING:COOLING SYSTEM
MFR Component System:
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