Stopmaster Wedge Brake: Maintenance Manual No. MM 0153

TM
an ArvinMeritor brand
STOPMASTER®
WEDGE BRAKE
Maintenance manual no. MM 0153
Revised 10/2001
STOPMASTER® - MM 0153 TM
TABLE OF CONTENTS
GENERAL INFORMATION PAG.

Introduction 4
Symbols 5
Warranty 6
Safety precautions 7
DESCRIPTION
Field of application 8
Stopmaster® II Duplex brake components 9
Stopmaster® II Simplex brake components 10
Stopmaster® E Simplex brake components 11
Stopmaster® E Duplex brake components 12
Stopmaster® wedge brake operation 13
MAINTENANCE
Stopmaster® II/Stopmaster® E brakes - Lubrication instructions 16
Preventive maintenance 17
Checking components 22
Reassembly 24
TROUBLESHOOTING 33
CONVERSION TABLES 34
2
All rights reserved.

No part of this publication may be reproduced in any
form or by any means or granted to any third parties
without the written permission of ARVINMERITOR.
ARVINMERITOR reserves the right to publish revisions
at any time for technical or commercial purposes.
Therefore all material contained in this manual is based
on the latest information available at time of
publication approval.
Copyright 2001 - ARVINMERITOR

Document No. MM 0153
1st Edition, February 2001
STM001
APPLICABLE PAGES
The following table lists the applicable pages of this manual and the date of relative revisions.
CHAPTER PAGES 1st EDITION REVISION
from to 02/2001
maintenance 16 16 10/2001
3
General information
INTRODUCTION This manual must be considered as an

integral part of the device and must
This manual covers ARVINMERITOR Stopmaster® be carefully read by all qualified
Wedge brake. personnel working on brake
maintenance.
LIABILITY
In no event shall ARVINMERITOR be liable for any
damages arising from incorrect service, use of non-
original spare parts and tampering of components.
The workshop manager is responsible for the
enforcement of all safety precautions outlined in this
manual. The manager must be qualified to carry out
all operations, must be aware of and must
meticulously observe all general and applicable safety
rules and regulations described in this manual. Failure
to observe safety precautions can result in personal
injury or damage to components.
PURPOSE OF THIS MANUAL

This manual has been compiled essentially for
workshop personnel.
It gives all necessary technical information regarding
the drum brake with the purpose of assuring safe
working conditions for maintenance personnel and to
guarantee perfect, long-life efficiency of drum brake.
However, personnel involved should be adequately
trained. To guarantee correct maintenance
procedures, the workshop must comply with all
regulations in force regarding safety and hygiene.
The manual covers all information necessary for
technicians to be able to correctly carry out brake
modifications and adjustments, service and repair
work. Please read this manual carefully before
proceeding to work on the device.
By following the enclosed instructions and by using
the appropriate special tools, guarantee of correct
repair work is given. At the same time, personnel are
safeguarded from possible accidents.
Read and observe all caution and warning

safety alerts in this manual - and comply
with all standard service, installation and
diagnostics guidelines issued by the
service operatives’ employing company.
Access information on ArvinMeritor’s web site

Additional maintenance and service information for
ArvinMeritor’s Commercial Vehicle System
components is also available at
www.arvinmeritor.com
(see “Technical manuals” section)
4
General information
SYMBOLS: MEANING AND USE

Various symbols are used to underline certain important
aspects of an instruction or procedure. They also
indicate the type of operation to be carried out.
The following table lists and describes the meaning of
these symbols.
SYMBOL MEANING DESCRIPTION
Indicates a procedure that must be followed exactly to

Warning:
avoid damage to components and to avoid risk of personal
risk of personal injury
injury.
Indicates danger with risk of environmental pollution.

Warning:
Very careful attention should be paid to the text where
environmental risk
this symbol is used.
Points out or gives useful information on key functions.

Indicates that text has been inserted to give supplementary
information. This information does not directly relate to the
Note
description of a function or to the development of a
procedure. It can refer the reader to other complementary
publications or to other sections in this manual.
Special tool The use of a special tool is necessary for this operation.
Tightening Symbol associated with one value: use of a torque wrench

torque setting is required, suitable for the specific value.
Symbol associated with two values: use of a torque

Tightening torque
wrench is required, suitable for the
and angle setting
specification value and for measuring tightening angle.
Setting / Operation carried out to obtain accurate specification values

adjustment (pressure, preloading, relative distance, etc.).
Measurement / Operation carried out to obtain a value needed to restore

observation optimum operating conditions.
MERITOR Indicates that only original MERITOR spare parts should

spare parts be used.
Positioning Mating operation with relative position markings.
5
General information
TERMS USED IN THIS MANUAL
Manufacturer: ARVINMERITOR
Manual: Maintenance manual no. MM 0153
Device: Stopmaster® Wedge Brake
Technician: Qualified personnel working on brake maintenance and servicing.
Maintenance and servicing: Maintenance and servicing refer to periodical checks and/or replacement of
device parts or components. It also refers to identification of the cause of a
malfunction in order to restore the initial operating conditions.
Operator: Any person using the device as part of a more complex unit.
WARRANTY
Meritor guarantees that all Stopmaster® brake components are not subject to wear.
Friction linings are guaranteed with regard to their structural reliability. Warranty applies exclusively to brakes
installed on vehicles approved by Meritor.
Warranty is void in the following conditions:
• Improper use of the vehicle on which the brake is installed (usage conditions, overloading etc.).
• Tampering with vehicle components that may affect axle performance.
• Use of non-original spare parts.
• Improper installation, adjustment, repair or modification.
• Poor or improper maintenance.
Further information on warranty conditions may be obtained directly from the manufacturer or by
referring to the ArvinMeritor web site at www.meritorauto.com and www.arvinmeritor.com
6
General information
SAFETY PRECAUTIONS Technicians must read this entire

The purpose of these safety precautions is to define a manual.
line of conduct and obligations to follow during
operations listed herein with the aim of guaranteeing
safe working conditions with regard to personnel, the Tampering or unauthorized replacement
environment and equipment. of one or more parts of the device,
The workshop manager is responsible for warning all installation of accessories which modify
personnel against accident risks, informing them about its use, and the use of non-
safety devices to be adopted and general rules referring recommended products can cause
to accident prevention in accordance with EEC personal injury.
directives and standing legislation.
Operations on brake installed on vehicle
Maintenance operations must be carried out by should be performed in accordance with
qualified technicians. vehicle manufacturer’s safety
precautions and standing legislation.
The brake should be moved using

appropriate hoisting and transportation
devices.
OTHER RISKS
Risk during handling of components.
INDIVIDUAL PROTECTION SYSTEMS
All qualified maintenance personnel involved must During assembly / disassembly of
adhere to individual protection systems. Safety components, technicians should wear
glasses, suitable shoes and gloves must be worn in suitable gloves.
order to eliminate all possible risks during operation
performance.
Clothing worn by maintenance personnel

must be in accordance with fundamental
safety requirements outlined in EEC
Directives 89/656 and 89/868 and standing
legislation.
To prevent accidents, technicians must

wear suitable overalls during maintenance
operations.
7
Description
INTRODUCTION
PURPOSE OF THIS CHAPTER
This chapter covers the field of application and composition of the wedge brake. It also lists components and
their terminology.
FIELD OF APPLICATION
The Stopmaster ® brake is available in two versions, STOPMASTER ® II and STOPMASTER ® E.
Both brake types are similar in design except that the actuation parts of the Stopmaster ® E version are
physically bigger than those of the Stopmaster ® II.
Stopmaster ® brakes are wedge actuated with power provided by air cylinders or in special applications by
hydraulic cylinders. They can be equipped with integral spring brake units for parking and emergency
braking. The brake power unit forces a wedge between two rollers and two plungers which, being
pushed in opposite directions, press the brake shoes against the brake drum. Stopmaster ® brakes utilise
either one power unit (Simplex actuation) or two power units (Duplex actuation). When two power units
are used either or both can incorporate an integral spring brake facility.
8
Description
STOPMASTER® II DUPLEX BRAKE COMPONENTS
RIF. DESCRIPTION 19 Rollers

1 Brake spider 20. Wedge
2. Adjusting bolt 21. Nut
3. Seal - adjuster plunger 22. Washer
4. Actuator (adjusting bolt sleeve) 23. Hold-down clip
5. Adjusting plunger 24. Screw
6. Anchor plunger 25. Dustshield (half)
7. Seal - anchor plunger 25A. Dustshield
8. Gasket 26. Rubber plug (round)
9. Guide pawl assembly 27. Screw
10. Guide screw 28. Rubber plug (long)
11. Wedge assembly 29. Brake shoe and lining assembly
12. Collet nut 29A. Brake shoe and lining assembly R+R (rolled and relieved)
13. Cotter pin 30. Brake shoe return spring
14. Washer 31. Service grease
15. Wedge spring 32. Identification plate
16. Rubber boot seal 33. Customer logo plate
17. Wedge washer 34. Rivet
18. Roller cage 35. Wear sensor
29
2 28
3
27
30 4
24 23
21 26
5 22
25
33
34 12
8
9 11
10
32 13
6 34 14
15
35 7
16
1 17
18 25A
19
20
Alternative
one piece
29 dustshield
30
29A 31
Figure 1. Main brake components
9
Description
STOPMASTER® II SIMPLEX BRAKE COMPONENTS
RIF. DESCRIPTION 19. Rollers

4. Actuator (adjusting bolt sleeve) 23. Hold-down clip
6. Anchor plunger 25. Dustshield (half)
7. Seal - anchor plunger 25A. Dustshield
8. Gasket 26. Rubber plug (round)
10. Guide screw 28. Rubber plug (long)
12. Collet nut 29A. Brake shoe and lining assembly R+R (rolled and relieved)
13. Cotter pin 30. Brake shoe return spring
14. Washer 31. Service grease
15. Wedge spring 32. Identification plate
16. Rubber boot seal 33. Customer logo plate
17. Wedge washer 34. Rivet
18. Roller cage 35. Wear sensor
36. Plug (anchor box)
29
28
2
3 12 27
30 24 23 22 21
4 11
26
5
25
33
34 1
8
9
6
9
36
32
5 34 13
14
35 4 15
3 16
17 25A
2 6 18
8 19
10 20 Alternative
7 one piece
29 dustshield
30
29A
31
STM 003
10
Description
STOPMASTER® E SIMPLEX BRAKE COMPONENTS
RIF. DESCRIZIONE 18. Roller cage

1. Brake spider 19. Rollers
2. Adjusting bolt 20. Wedge
3. Seal - adjuster plunger 21. Nut
4. Actuator 22. (Not used)
5. Adjusting plunger 23. Hold-down clip
6. Anchor plunger 24. Screw
7. (Not used) 25. Dustshield
8. Gasket 26. (Not used)
10. (Not used) 28. Rubber plug (long)
12. Collet nut 30. Brake shoe return spring
13. E clip 31. Service grease
14. Washer 32. Identification plate
15. Wedge spring 33. Customer logo plate
16. Special washer 34. Rivet
16A. Boot seal 35. Wear sensor
17. Wedge washer
29
2
28
3
4 27
24 23
30
5 21
6 25
33
34
12
9 8
9 11
32
13
34 14
1
15
16
35 6 16A
17
18
19
20
29
30
31
STM 004
11
Description
STOPMASTER® E DUPLEX BRAKE COMPONENTS
RIF. DESCRIPTION 19. Rollers

4. Actuator 23. Hold-down clip
6. Anchor plunger 25. Dustshield
7. Seal - anchor plunger 26+26A. Rubber plug (round)
8. O ring 27. Screw
9. Guide pawl assembly 27A. Spring washer
10. Guide pin 28. Rubber plug (long)
12. Collet nut 30. Brake shoe return spring
13. E clip 31. Actuator service grease
14. Washer 32. Identification plate
15. Wedge spring 33. Customer logo plate
16. Special washer 34. Rivet
16A. Boot seal 35. Wear sensor
17. Wedge washer 36. Brake shoe service grease
18. Roller cage
26
29 26A
28
2 27
3 27A
12
30 4
24 23
21
5 22
33 25
34 12
8
9
11
10 32
34
6 13
14
15
7 16
16A
1 17
18
19
20
35
29
30
31
36
STM 005
12
Description
STOPMASTER® WEDGE BRAKE

OPERATION
In the brake released position the wedge assembly is

held withdrawn by the wedge return spring while
plungers are kept closed on rollers and their abutment
seats by the brake shoe return spring.
STM 006
When the brake is actuated the air chamber push rod

forces the wedge head between the rollers which
spread apart and push the plungers outwards causing
the brake shoes to open. Plungers are lifted off their
abutment seats until shoes contact the brake drum.
STM 007
As shoes contact the drum, the latter under the action

of the friction linings drags the shoes in the direction of
rotation while brake shoes in turn transfer the friction
force to anchor plungers. This causes the shoe plunger
to reseat on its abutment and transfer the braking
torque to the brake spider, in order to balance the
braking torque generated between shoes and drum.
STM 008
13
Description
When the brake is released the wedge spring returns the

wedge and air chamber diaphragm to the off position.
The shoe and lining is pulled away from the drum by the
shoe return springs and returns the plungers to their
abutment seats in the housing.
STM 009
SELF-ADJUSTMENT MECHANISM
OPERATION
On the brake application the adjuster bolt and sleeve

assembly moves outwards.
As the opposing chamfers of teeth on the adjuster sleeve
and the teeth on the guide pawl (A) move against each
other the pawl is lifted against the spring (B).
STM 010
When the brake lining to drum clearance exceeds its

predetermined limit the travel of the adjuster bolt and
sleeve is such that it allows the pawl to jump into the next
tooth on the adjuster sleeve.
STM 011
14
Description
As the brake is released and the adjuster bolt and

sleeve assembly is returned to the off position, the
guide pawl rotates the sleeve anti-clockwise and
unscrews it from the fixed adjusting bolt. The lining to
drum clearance is reduced, completing one adjustment
cycle. This is repeated each time the lining to drum
clearance is sufficient to allow further adjustments to
take place.
STM 012
15
Maintenance
STOPMASTER® II / STOPMASTER® E BRAKES

LUBRICATION INSTRUCTIONS
GENERAL INFORMATION
Today an ever-increasing number of alternative brake linings, both asbestos and non-asbestos, is available to the
commercial vehicle operator. Experience shows that some lining specifications produce a type of ‘dust’ which
has a drying (or caking) effect on brake lubricants.
To ensure optimum braking performance the following lubrication instructions, regarding lubricant specifications
and lubrication frequency should be adhered to. Lubrication intervals should be shortened where lubricant
drying or caking is found to occur.
The standard lubrication interval for Stopmaster® brake units is every 160,000 km or 12 months, whichever comes
first.
This is considered the maximum even under ideal operating conditions.
Unusual temperatures or operating conditions will require different lubrication intervals. Therefore comply at all
times with lubrication instructions provided by the manufacturer.
The lubricant type should meet specifications of the Meritor 0-616-A standard: High temperature, waterproof
grease to NLGI Grade one available under Meritor RBSK 1022 part number in 1 kg tins or RBSK 0253 in tubes.
For STOPMASTER® E brake units different types of lubricant are used, according to the following table:
1
Lubrication Points
1. The shoe and rest pads located on the spider.
2. The internal surface of the hold-down clips.
3. The shoe contact surface on the plungers.
4. The wedge assembly cavity. 4
5. All items of the auto-adjustment mechanism.
STMFR
Lubrication point Stopmaster® II Stopmaster® E
1 RBSK1022 - RBSK0253 Weicon AS450

Simplex: RBSK 1022 - RBSK0253
4 RBSK1022 - RBSK0253
Duplex: Syntheso GLEP1
Simplex: RBSK 1022 - RBSK0253
5 RBSK1022 - RBSK0253
Duplex: Syntheso GLEP1
16
Maintenance
STOPMASTER® BRAKE
PREVENTIVE MAINTENANCE
CHECK
LINING WEAR
EVERY 25,000 KM:
1. Check the lining to drum clearance.

2. If it is 1.5 mm or less, self-adjusters are efficient
and there is no need for any further action.
3. Check state of wear through the appropriate CHECK LINING TO
inspection plugs located on the dustshield. DRUM
CLEARANCE 1.5
MM OR LESS
STMOMT
AT EVERY RELINE:
1. Inspect the seals to see if they are worn, cut or

torn.
If they are defective they must be replaced, and it 1
also becomes necessary to disassemble the
actuating parts and overhaul as required.
3
2. Lubricate the following areas: 2
1. The shoe rest pads located on the spider.
2. The internal surfaces of the hold-down clips.
STMFR
EVERY 160,000 KM:
1. Dismantle the actuating parts and check their

condition. Overhaul as necessary.
2. Lubricate brake in line with recommended

lubrication procedure.
STMGLOB
17
Maintenance
BRAKE DISASSEMBLY
Chock and jack up the vehicle. Remove the

wheel on which you are going to operate.
When working on brakes, the spring brake

chamber must be kept in the off position by
manually caging the spring (refer to
manufacturer’s instructions).
Remove the brake drum. If drums are worn, back off

the shoe and lining assemblies manually through the Stopmaster® E
slots in the dustshield, above or below the air chambers, (RS410E) Tool
using special tool. Engage tool in the square slot in the STM013
head of the adjusting bolts and adjust as required to
increase drum to lining clearance.
STOPMASTER® II
Tool no. RBSK 0187
STOPMASTER® E
Tool no. RBSK 1420
Remove the brake shoe return springs using

special tool.
STOPMASTER® II and E
Tool no. RBSK 0185
STM014
18
Maintenance
Remove the brake shoe and check the condition of the

hold-down clip as illustrated:
A = 6.7 mm max,
maximum shoe web
thickness 8 mm
A = 10 mm max,
maximum shoe web
thickness 12 mm
STM015
Remove the dustshield, if necessary.
STM016
Unscrew the air chambers and slacken off the collect nut
to separate the air chambers from the brake spider or by
removing the four capscrews on flange mounted type.
STM017
19
Maintenance
Remove the wedge assembly from its housing.
STM018
Unscrew and remove the guide pawl assembly and the

anchor plunger guide screw.
STM019
Drift the seals clear of their bores in the housing, using

an appropriate tool.
STM020
20
Maintenance
Remove the adjusting bolt and sleeve assembly and the

auto adjust and anchor plungers.
STM021
Dismantle the adjusting bolt assembly and carefully clean

all parts. Check for wear and damage.
STM022
LOCATION OF ANGLE MARKING
Replace all worn or damaged parts and always renew

seals. WEDGE STEM
When replacement wedge assemblies or

plungers are required, ensure the
replacement parts have the same wedge
angles as the displaced parts.
PLUNGER END FACES
21
Maintenance
CHECKING COMPONENTS
ADJUSTING PAWL
ADJUSTING PAWL
The scored, rounded teeth of the adjusting pawl on the

left are unacceptable and the part must be discarded
and replaced, while the teeth of the pawl on the right are
still undamaged.
This part may be re-used. However, if you have any
doubts, always replace the pawl.
SCORED ROUNDED STRAIGHT UNDAMAGED

TEETH TEETH
(REPLACE PART) (RE-USE PART)
ADJ1
INTERNALLY SCORED ADJUSTING

PLUNGER
INTERNALLY SCORED ADJUSTING PLUNGER
If the internal scoring of an adjusting plunger consists of

only light markings the plunger may be re-used.
However, if the scoring is rough the part must be
replaced.
• LIGHT MARKINGS (RE-USE PART)
• ROUGH MARKINGS OR SCORES (REPLACE PART)
STMINT
ADJUSTING PLUNGER
ADJUSTING PLUNGER
The light contact marks on the pawl guide slot in the

adjusting plunger shown on the left are acceptable and
LIGHT CONTACT SCORED PAWL GUIDE
will not hamper performance. The deep scoring MARKS (RE-USE PART) SLOT (REPLACE PART)
shown on the right is unacceptable and this plunger
must be replaced.
ADJ2
22
Maintenance
ADJUSTING PLUNGER
ADJUSTING PLUNGER
Shown here on the right is a normal roller contact patch

on the ramp of an adjusting plunger and this part may
be re-used. On the right we see the rectangular
indentation of a brinelled roller ramp.
This plunger must be replaced. NORMAL ROLLER BRINELLED
CONTACT PATCH ROLLER RAMP
(RE-USE PART) (REPLACE PART)
PLU2
ACTUATORS
ACTUATORS
Both of these actuators show normal sign of wear and

are re-usable.
NORMAL WEAR NORMAL WEAR

(RE-USE PART) (RE-USE PART)
ACTUATORS1
ACTUATORS
While the abnormal wear or damage on these actuators

is unacceptable and these parts must be replaced.
METAL DISPLACEMENT DAMAGED TEETH

ALONG TOOTH AXIS (REPLACE PART)
(REPLACE PART)
ACTUATORS2
23
Maintenance
DUPLEX BRAKE
Drum rotation
REASSEMBLY
In the reassembly of the brake, always ensure that the Anchor Adjusting
plunger plunger
adjuster bolt and sleeve assembly is positioned at the
leading end of the shoe and the anchor plunger is at the
trailing end (see illustration).
STOPMASTER® E shoes are stamped with the word
anchor on the anchor end.
STOPMASTER® II shoes are stamped with the word drum
rotation and an arrow.
When reassembling install both shoes with arrow following
drum rotation. Adjusting Anchor
plunger plunger
SIMPLEX BRAKE Drum rotation
REASSEMBLY Adjusting Anchor

STOPMASTER ® E shoes are stamped with the word plunger plunger
anchor on the anchor end.
Any change to the brake system may require

type approval.
Therefore use only original Meritor spare
parts.
Adjusting Anchor
plunger plunger
TECHNICAL ASSEMBLY DATA

TIGHTENING TORQUES DUPLEX VERSION SIMPLEX VERSION
Guide pawl assembly 20-30 Nm 20-30 Nm
Guide screw 20-30 Nm
Hold-down clip screw 20-30 Nm 20-30 Nm
Dustshield screw 20-30 Nm 20-30 Nm
Air chamber collet nut 300 Nm ± 10 300 Nm ± 10
Air chamber flange screw see vehicle manufacturers workshop manual
Wear sensor 10-15 Nm 10-15 Nm
STOPMASTER® II box plug 40 ± 5 Nm
SETTING DIMENSIONS
Actuator assembly - Except where otherwise indicated dimensions are expressed in mm:
STOPMASTER® II all types 144.5 ± 0.5 142.5 ± 0.5
STOPMASTER® E 360 not applicable 152 ± 0.5
381 144 ± 0.5 151
410 162 ± 0.5 164 ± 0.5 (5°/5°)
167 ± 0.5 (15°/5°)
169 ± 0.5 (15°/0°)
Hold-down clip - Spacing: shoe web thickness
STOPMASTER® II A = 6.7 mm max 8 mm
STOPMASTER® E A = 10 mm max 12 mm
STOPMASTER® E A = 6.7 mm max 8 mm
Drum to lining clearance: 0.8 - 1.2 mm
24
Maintenance
REASSEMBLY OF THE BRAKE Only original Meritor spare parts

should be used.
Use of non-original parts could

seriously affect brake performance.
Breathing the dust generated by

friction of brake linings against
drum is hazardous to your health.
Always wear the assigned protective
equipment when servicing brake
units and avoid remaining in the
area unless your work requires it.
Lubrication points
1. The shoe rest pads located on the brake spider. 1
2. The internal surface of the hold-down clips.
4. The wedge assembly cavity.
5. All items concerned with the self-adjustment
mechanism. 4
LUBRICANT L U B R I C AT I O N P O I N T S
At brake reassembly use the following

recommended lubricant types: STOPMASTER® II STOPMASTER® E
Meritor Service grease no. RBSK-0253 - RBSK 1022 1, 2, 3, 4, 5 4, 5 Simplex
Weicon Antisize AS450 grease 1, 2, 3
Klübler Syntheso GLEP1 grease 4, 5 Duplex
25
Maintenance
Grease inner bores of brake spider plunger housing.
STM032
Lightly grease the neck of the seal and carefully

assemble onto the anchor plunger.
Note the anchor and adjuster seals are different in
design.
Ensure the right seal is fitted, as follows:
Anchor plunger = short seal

Adjuster plunger = long seal
STM033
Evenly coat with grease the entire cylindrical surface of

the anchor plunger.
Locate the anchor plunger into housing,

ensuring the slot aligns correctly with the guide
screw tapped hole.
STM034
26
Maintenance
Fit guide screw and tighten to torque to 20-30

Nm.
STM035
Evenly coat with grease the entire cylindrical

surface of the adjusting plunger.
Locate the adjusting plunger into housing,

ensuring the slot aligns correctly with the guide
pawl hole.
STM036
Lightly grease the guide pawl and fit, screwing it

in one turn only.
Check that the guide pawl moves freely through
its bore and with the plunger slot. Note that the
guide pawl has a raised ridge which locates into
a groove in the brake spider.
Remove the guide pawl.
STM037
27
Maintenance
Lightly grease the adjuster seal neck and carefully

assemble onto adjusting bolt; grease bolt threads.
STM038
Grease actuator threads and screw onto the adjusting bolt

(large chamfer towards bolt head).
Warning! Ensure actuator is screwed in the

correct direction. Check chamfers.
Threads must not be tight as this would cause

adjustment not to function correctly
Warning! Ensure the adjusting bolt does not

protrude through the actuator as this would
also inhibit adjustment.
STM039
Grease the actuator outer surface.
Then fit adjusting bolt and sleeve (with slight rotation) into
the adjusting plunger.
STM040
28
Maintenance
Fit guide pawl ensuring correct alignment and

torque to 20-30 Nm.
STM041
Seat seals using seal driver. Note that the shoe retainer on
the bolt head must align with the slot in the seal driver.
STOPMASTER® II Tool No. RBSK 0186

STOPMASTER® E Tool No. RBSK 1427
STM042
Through the wedge bore, fill the housing with

approx 20 g of grease, coat with grease the
wedge assembly and fit into bore aligning the
raised ridges on the wedge with the
corresponding slots in the wedge bore; press
wedge in by hand up to plunger travel starting
point.
STM043
29
Maintenance
Screw collet nut fully onto the air cylinder and then
screw in the air chamber till it bottoms in the housing
ensuring the collet nut is still free to turn. In order to
align air ports unscrew the chamber to a maximum of
one full turn, if necessary.
Tighten collet nut to a torque of 300 Nm ± 10.

Fit the spring brake chamber in a similar
manner but ensure the spring is fully caged.
On flange type models locate the chamber to
the spider.
Fit the retaining capscrew and tighten to
the torque recommended in the vehicle
Manufacturers Workshop Manual.
STM044
If previously removed, refit dustshield halves

and tighten screws to a torque of 20-30Nm.
One piece dustshields must be fitted prior to

reassembling air chambers.
Refit brake shoe hold-down clips and tighten
to 20-30 Nm torque. Ensure clip condition
conforms to specifications (see page 19 for
details).
STM045
Set dimension over brake shoe contact
surfaces. Ensure caliper is flat on adjusting
bolt at the shoe web contact surface. On
Duplex models repeat the same operation on
the opposite side.
Except where otherwise indicated, dimensions are

expressed in mm
STOPMASTER® E DUPLEX SIMPLEX

All sizes 144.5 ± 0.5 142.5 ± 0.5
STOPMASTER® E DUPLEX SIMPLEX
360 152 ± 0.5

381 144 ± 0.5 151 ± 0.5
410 162 ± 0.5 164 ± 0.5 (5°/5°)
167 ± 0.5 (15°/5°)
169 ± 0.5 (15°/0°)
STM046
30
Maintenance
Position the shoe return springs in the upper

shoe as illustrated and fit the shoes ensuring that
the short radius locates against the adjusting bolt
assembly. Fit the springs with special tool.
Take care not to touch the seals to prevent

seal damage during this operation.
STM047
STOPMASTER® II and STOPMASTER® E :

Tool No. RBSK 0185
STM048
Measure the brake drum diameter at various

points around the drum and record the readings
taken.
STM049
31
Maintenance
Centralize both brake shoes and measure the

brake lining diameter as illustrated.
(When setting, it is important to ensure that the
spring brake is still totally caged).
Standard brake shoe data

Dimensions are expressed in mm
Brake type Stopmaster® II Stopmaster® E
360 358 ± 0.5 358.5 ± 0.5

381 379 ± 0.5 379 ± 0.5
394 392 ± 0.5
410 408 ± 0.5 408.5 ± 0.5 STM050
Adjust the lining diameter by turning the adjusting

bolts by an equal amount until the brake lining
diameter is 2 mm less the drum diameter
previously recorded.
Fit the brake drums.
With long feeler gauge check clearances at shoe

centres.
This should be between 0.8 and 1.2 mm.
If necessary readjust to obtain these clearances.
STM051
Uncage the air chamber spring and refit air pipes.

Refit wheels and check brakes on a ‘rolling road’ and test
drive.
32
Troubleshooting
The following chart shows the most common faults occurring to Stopmaster® brakes.
FAULT POSSIBLE CAUSES
Self-adjustment 1 Guide pawl spring is broken (9)

not functioning 2 Worn or damaged pawl and/or actuator teeth (9, 4)
3 Adjusting bolt too tight in actuator (2, 4)
4 Brake shoe web not properly located in shoe retainer (2, 29)
5 Corroded adjustment parts (2, 4, 5, 9, 11)
6 Insufficient lubrication
Brakes dragging 1 Spring chamber not fully released

2 Air leak from spring chamber
3 Overstretched or broken brake shoe return springs (30)
4 Anchor/adjusting plungers are tight or seized up (5, 6)
5 Broken wedge spring
Uneven lining wear 1 Reverse installation of brake shoe

(short radius must be seated on adjusting bolt) (29)
2 Brakes are dragging - see Faults (2)
3 Unequal air chamber output
4 Damaged or broken hold-down clip
5 Brake drum diameter variations (tapering)
6 Dirt and/or grease on lining (29)
7 Variations in surface finish of brake drums
Insufficient brake 1 Shoe to drum clearances too large

performance 2 Worn linings
3 Unsuitable lining material
4 Grease or oil on linings
5 Input pressure too low
Brake pulling 1 Air chamber installation depths incorrect

2 Unequal air chamber output
3 Different shoe drum clearances - see Faults (1)
4 Grease or oil on linings
5 Different brake drum material or surface finish
6 Different lining material
7 Broken wedge spring
8 Heavy dirt ingress
9 See also all Possible Causes described at Fault 3.
33
Conversion tables
MEASUREMENT VALUES
MEASUREMENT VALUES (INTERNATIONAL SYSTEM)
Force in N (Newton): Conversion: 1N = 0.1019 kg

1 kg = 9.81 N
Power in kW (kilowatt) Conversion: 1 kW = 1.36 CV Other measurement values used:
1 kW = 1.34 HP CV (Metric horsepower)
1 CV = 0.736 kW HP (Horsepower)
1 CV = 0.986 HP
1 HP = 0.746 kW
1 HP = 1.014 CV
Torque in Nm (Newton metre) Conversion: 1 Nm = 0.1019 kgm
1 kgm = 9.81 Nm
1 kgm = 10 Nm *
Specific consumption in Conversion: 1 g/kWh = 0.736 g/CVh Other measurement values used: g/CVh
g/kWh (grams per kilowatt 1 g/CVh = 1.36 g/kWh (Grams per metric horsepower hour)
hour)
Conversion: 1 kg/cm2 = 1 Atm Other measurement values used:
Pressure in kPa 1 kg/cm2 = 98.1 kPa kg/cm2 (Kilogram/square centimeter)
(kilopascal) 1 kg/cm2 = 0.981 bar Atm (Metric atmosphere)
1 kg/cm2 = 1 bar * psi (Pounds per square inch)
1 kg/cm2 = 14.22 psi
1 bar = 100 kPa
1 bar = 1.02 kg/cm2
1 bar = 14.51 psi
1 psi = 6.9 kPa
1 psi = 0.069 bar
1 psi = 0.0703 kg/cm2
1 kPa = 0.145 psi
1 kPa = 0.0102 kg/cm2
1 kPa = 0.01 bar
* * For practical reasons Nm and bar units are converted according to 10:1 and 1:1 ratios.
34
Commercial Vehicle Systems Information contained in this publication was in effect as the time the publication was approved
for printing and is subject to change without notice or liability. ArvinMeritor Commercial Vehicle
Meritor HVS Cameri S.p.A. Systems reserves the right to revise the information presented or discontinue the production of
Str. Prov. Cameri/Bellinzago km 5 parts described at any time.
28060 Cameri NO Italy
Copyright 2001
www.arvinmeritor.com ArvinMeritor, Inc.
All rights reserved Printed in Italy Maintenance Manual MM 0153

Stopmaster Wedge Brake: Maintenance Manual No. MM 0153

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Maintenance manual no. MM 0153

GENERAL INFORMATION PAG.

All rights reserved.

Copyright 2001 - ARVINMERITOR

CHAPTER PAGES 1st EDITION REVISION

INTRODUCTION This manual must be considered as an

PURPOSE OF THIS MANUAL

Read and observe all caution and warning

Access information on ArvinMeritor’s web site

SYMBOLS: MEANING AND USE

SYMBOL MEANING DESCRIPTION

Indicates a procedure that must be followed exactly to

Indicates danger with risk of environmental pollution.

Points out or gives useful information on key functions.

Tightening Symbol associated with one value: use of a torque wrench

Symbol associated with two values: use of a torque

Setting / Operation carried out to obtain accurate specification values

Measurement / Operation carried out to obtain a value needed to restore

MERITOR Indicates that only original MERITOR spare parts should

Positioning Mating operation with relative position markings.

TERMS USED IN THIS MANUAL

Manual: Maintenance manual no. MM 0153

Device: Stopmaster® Wedge Brake

Technician: Qualified personnel working on brake maintenance and servicing.

SAFETY PRECAUTIONS Technicians must read this entire

The brake should be moved using

Clothing worn by maintenance personnel

To prevent accidents, technicians must

STOPMASTER® II DUPLEX BRAKE COMPONENTS

RIF. DESCRIPTION 19 Rollers

Figure 1. Main brake components

STOPMASTER® II SIMPLEX BRAKE COMPONENTS

RIF. DESCRIPTION 19. Rollers

STOPMASTER® E SIMPLEX BRAKE COMPONENTS

RIF. DESCRIZIONE 18. Roller cage

STOPMASTER® E DUPLEX BRAKE COMPONENTS

RIF. DESCRIPTION 19. Rollers

STOPMASTER® WEDGE BRAKE

In the brake released position the wedge assembly is

When the brake is actuated the air chamber push rod

As shoes contact the drum, the latter under the action

When the brake is released the wedge spring returns the

On the brake application the adjuster bolt and sleeve

When the brake lining to drum clearance exceeds its

As the brake is released and the adjuster bolt and

STOPMASTER® II / STOPMASTER® E BRAKES

Lubrication point Stopmaster® II Stopmaster® E

1 RBSK1022 - RBSK0253 Weicon AS450

1. Check the lining to drum clearance.

1. Inspect the seals to see if they are worn, cut or

EVERY 160,000 KM:

1. Dismantle the actuating parts and check their

2. Lubricate brake in line with recommended

Chock and jack up the vehicle. Remove the

When working on brakes, the spring brake

Remove the brake drum. If drums are worn, back off

Remove the brake shoe return springs using

Remove the brake shoe and check the condition of the

Remove the dustshield, if necessary.

Remove the wedge assembly from its housing.

Unscrew and remove the guide pawl assembly and the

Drift the seals clear of their bores in the housing, using