CSI Midland/Gunite Automatic Brake Adjuster Service Manual
Contents
1. Adjust the brakes as follows 1 Rotate the hex extension clockwise until the brake linings contact the brake drum Back off the automatic brake adjuster by rotating the hex counterclockwise 1 2 tum 2 Backing off the brake adjuster will require more than 25 30 5 of torque When backing off the brake adjuster a ratcheting sound will be heard 3 Using a ruler measure the distance fram the face of the air chamber to the center of the large pin in the clevis A See Figure 5 Make an 85 psi brake application and allow the chamber push rod to travel its maximum stroke Measure to the center of the large pin The difference between A and is the push rod stroke Check the following chart for proper maximum stroke after adjustment of the brakes STANDARD CLAMP TYPE BRAKE CHAMBER DATA Outside Rated Maximum stroke at which Diameter Stroke brakes must be readjusted 9 514 175 1 3 8 12 nne 175 1 38 16 638 225 1 34 20 62532 225 1 34 24 7782 225 1 34 30 8382 250 2 36 9 3 00 214 Note 36 chambers used brake adjuster length should be less than 6 LONG STROKE CLAMP TYPE BRAKE CHAMBER DATA Outside Rated Maximum stroke at which Diameter Stroke brakes must be readjusted 16 638 250 2 20 62582 250 2 24 7782 250 2 24 7782 3 00 2 1 2 30 8382 3 00 2 1 2 Note Identified by square air2. 8 2 25 1 3 4 20 6 25 32 225 1 3 4 24 7 182 225 1 3 4 30 8 3 32 2 50 36 9 3 00 2 14 36 chamber is used brake aduster length should be less hang LONG STROKE CLAMP TYPE BRAKE CHAMBER DATA Outside Rated Maximum stroke at which Type Diameter Stroke brakes must be readjusted 16 6 3 8 2 50 2 20 6 25 32 2 50 24 7 7132 2 50 x 24 7 782 3 00 2 12 30 8 3 32 3 00 2 1 2 Note Identified by square air port bosses Figure 15 Measuring Maximum Stroke HALDEX PRODUCTS DISTRIBUTED LOCALLY BY Brake Systems Division World Headquarters 10930 N Pomona Avenue Kansas City Missouri 64153 1297 Phone 816 891 2470 Fax 816 891 9447 www haldexbrakes com Brake Systems Division Brake Systems Division North American Sales amp Service Organization Haldex Limited 10707 N W Airworld Drive 525 Southgate Drive Unit 1 Kansas City Missouri 64153 1215 Guelph Ontario Canada N1G 3W6 Phone 816 891 2470 Phone 519 826 7723 Fax 816 880 9766 Fax 519 826 9497 www hbsna com www hbsna com REV 3 02 1M ART 130006
3. Greasing the Automatic Brake Adjuster 1 A grease fitting is provided to allow lubrication during normal chassis servicing See Figure 7 With a conventional grease gun lubricate until grease appears the camshaft or grease flows from the grease relief Grease Re ee Figure 8 Grease Relief The newest CSI Midland Gunite automatic brake adjusters are produced without a grease relief forcing lubricant through the drilled worm wheel onto the camshaft Previous designs incorporated a grease relief See Figure 8 Lubriplate Aero is the grease used in the manufacture of CSI Midland Gunite automatic brake adjusters It is recommended for use in temperatures as low as 40 F TROUBLESHOOTING AND BOOT REPLACEMENT Brake Adjuster Function Test Ifthe maximum stroke with an 85 psi brake application is less than the distance shown in the chart on page 6 the CSI Midland Gunite automatic brake adjuster is functioning properly Troubleshooting 1 The CSI Midland Gunite automatic brake adjuster should not require manual readjustment If the maximum chamber stroke is within the range for the size chamber used See Figure 5 the brake adjuster should not be manually readjusted If the chamber stroke exceeds the limit measure the free stroke If the free stroke is good but the applied stroke is too long there is a problem with the foundation brake Check the foundation brake for missing or wom components cracke
4. on your CSI Midland Gunite automatic brake adjusters Installation of the CSI land Gunite Threaded Clevis and Extended Threaded Clevis 1 Apply anti seize compound to the air chamber push od Install the new clevis on the air chamber push rod inthe same location as the clevis which was removed Do not tighten the jam nut at this time 2 Using the gage supplied insert the large pin through the large hole at the top of the gage and into the clevis Center the proper 1 4 hole at the bottom of the gage over the center hole of the camshaft Figure 3 Adjust the clevis until all of the 1 4 pin hole is visible in the notch area of the gage Double check the installation by making sure the 1 4 hole at the bottom of the gage is stil centered on the camshaft when the 1 4 pin hole is visible If the push rod threads protrude through the clevis boss more than 1 16 remove the clevis and cut the push rod to length The push rod must not be more than 1 8 short of being flush with the clevis boss NOTE On axles equipped with spring brake chambers be sure the chambers are fully caged before cutting the push rod Ifthe spring brakes are not fully caged the push rod can be cut too short 4 Ifthe push rod fails to come within 1 8 of full engagement with the clevis boss threads install a long push rod and cut to length Extended Clevis On trailer applications an extended clevis can be used instead of r
5. L30006 Rev 3 02 CSI Midland Gunite Automatic Brake Adjuster Service Manual TABLE OF CONTENTS hin 3 Installation Procedures ai 4 Brake Adjustment wiza 6 Preventative Maintenance T Testing Adjuster Function and Boot Replacement 8 Cutting the Brake Chamber Push Rods 9 Service Practices Points and Precautions 10 Lining Drum Replacement 10 WARNING AS WITH ALL PRODUCTS CLOSE ATTENTION SHOULD BE GIVEN TO ALL INSTRUCTIONS INCORPORATED IN THIS MANUAL IN PARTICULAR THE NOTES AND WARNINGS WHICH ARE HIGHLIGHTED FAILURE TO STRICTLY FOLLOW THESE INSTRUCTIONS MAY RESULT IN THE UNIT PERFORMING IN AN UNSATISFACTORY MANNER AND RESULT IN INADEQUATE BRAKING ABILITY OR DRAGGING BRAKES THESE CONDITIONS COULD MAKE OPERATION OF THE VEHICLE EXTREMELY HAZARDOUS When installing or replacing an Automatic Brake Adjuster a new clevis must be installed Refer to the Haldex Master Catalog for clevis selection OVERVIEW Haldex offers a complete line of unhanded automatic brake adjusters for installation on steering drive and trailer axles The space required for the CSI Midland Gunite automatic brake adjuster is similar to that which is required for manual brake adjusters CSI Midland Gunite automatic brake adjusters do n
6. anual adjustment procedure was followed correctly Manually readjust the brake following the Brake Adjustment After Installation procedure on this page Figure 6 Free Stroke RECOMMENDED PREVENTATIVE MAINTENANCE Every Three Months or 25 000 Miles 1 Check the condition of the foundation brakes including drums shoes and linings cams rollers bushings etc 2 Check for structural damage of the housing worn clevis worn clevis bushings and condition of the boot for cuts or tears Replace if necessary After allowing the brake drum to cool to room temperature check for correct chamber stroke following the procedure on page 6 Due to different operating conditions chamber stroke tests may be necessary at earlier intervals See Charts on page 6 for the recommended stroke measurements NOTE automatic brake adjuster should not have to be manually adjusted except for initial installation and at the time of brake reline Every Six Months or 50 000 Miles CSI Midland Gunite automatic brake adjusters are factory lubricated and extensively sealed to protect against dirt water salt and other corrosive elements Nevertheless periodic lubrication is recommended NOTE Brake Adjusters with a grooved and drilled worm wheel will not have a grease relief on the end cap opposite the adjusting hex Hex Extension _ 26 Figure 7 Lubrication Points
7. d brake drums or improper lining to drum contact Ifthe free stroke is greater than the recommended distance 3 8 5 87 a function test of the automatic brake adjuster should be performed To test the function of the automatic brake adjuster place a 7 16 box wrench the hex extension and rotate it 3 4 of a turn count er clockwise A ratcheting sound will be heard Mark the 7 16 hex extension with chalk and apply the brakes several times and watch for the hex to rotate clockwise See Figure 9 The hex extension must rotate clockwise The adjustment is intentionally made in small increments so it wili take several cycles to bring the adjuster within the stroke limit shown in the chart Ifthe free stroke is less than 3 8 a dragging brake can occur Check to see that the manual adjustment procedure was followed correctly Manually readjust the brake following the Brake Adjustment After Installation procedure on page 6 Figure 9 Brake Adjuster Function 2 Check the torque by attaching a torque wrench to the hex extension and turning it in a counterclockwise direction and record the measurement 3 hex extension did not rotate clockwise or there is less than 15 ft lbs of torque required to rotate the hex extension in the counterclockwise direction the automatic brake must be replaced If immediate replacement is not possible proper brake adjustment must be maintained by manual adjustment 4 Ifthe hex ext
8. djust the Adjuster Length Dimension brake adjuster to the shortest possible stroke 5 5 1 2 2 174 without the brakes dragging Proper set up 6 7 21 2 stroke should now be established rake must be disarmed before disposal or the future without warning DANGER spring brake or combination servicelsprin forceful release of the compression spring may occur SERVICE PRACTICES POINTS AND PRECAUTIONS 1 Replace the automatic brake adjuster if it is not functioning properly as described under Brake Adjuster Function Test on page 8 2 Replace the entire unit if damage is evident the automatic brake adjuster housing or assembly 3 The unit must be replaced if less than 15 ftlbs of torque exists when turning the hex extension counterclockwise 4 Never operate the vehicle with small 1 4 pin missing from the clevis The automatic brake adjuster will not maintain proper brake adjustment with either pin missing 5 Never attempt to disassemble the automatic brake adjuster Factory setting cannot be duplicated in the field Instead replace the entire unit LINING DRUM REPLACEMENT PROCEDURES Special attention must be given to proper maintenance procedures of the automatic brake adjuster when you change brake linings and or brake drums 1 Ifthe axle is equipped with spring brake chambers manually cage the spring brakes following the manufacturer s recommended procedures 2 Us
9. ension rotates clockwise and has a torque of greater than 15 ft lbs when rotated counterclockwise the brake adjuster is functioning properly Check the foundation brake for proper function worn quick connect clevis worn clevis bushings and clevis pins Repair as necessary and repeat the function test 5 Readjust the brake adjuster after the function test Boot Replacement 1 Remove the 1 4 and the large clevis pins 2 Rotate the hex extension counterclockwise to clear the link from the clevis This will require up to 45 ft lbs of torque and produce a ratcheting sound 3 Remove the damaged boot from the link Link Clevis Large Pin Grease Fitting Figure 10 Location of Clevis Pins Hex Extensions amp Boot 4 Install the replacement boot over the link with the heavy section down Care should be taken not to damage the boot with a sharp tool fi ja Link Figure 11 Boot j Figure 12 Boot Position 5 Position the boot on the link so that the bottom is retained by the boot insert and the top is positioned by the groove in the link 6 Install the clevis pins as described in Aligning the Automatic Brake Adjuster with the Clevis on page 5 CUTTING THE BRAKE CHAMBER PUSH RO Service Brake Chamber or Double Diaphragm Spring Brake Chamber WARNING Always chock wheels to prevent vehicle from le system air pressure to zero psi When preparing to install a spring brake chamb
10. eplacing the push rod However you must have at least 1 2 of thread engagement inside the clevis If you have less than 1 2 thread engagement a new push rod must be installed 5 Apply anti seize compound to camshaft 6 Install the automatic brake adjuster on the camshaft using the original mounting hardware Aligning the Automatic Brake Adjuster with the Clevis 8 Apply anti seize compound to clevis pins Rotate the hex extension clockwise until the 1 4 hole in the brake link aligns with the 1 4 hole in the clevis Install the clevis pin and the cotter pin 9 Tap the clevis upward or downward until the large hole in the brake arm aligns with the large hole in the clevis Install the clevis pin and the cotter pin NOTE Tapping the clevis downward moves the link into the brake housing If alignment is not achieved when the link bottoms out it indicates improper clevis installation Downward movement of the link requires only light tapping 10 Tighten the nut against the clevis NOTE Failure to tighten the jam nut will allow th chamber push rod to rotate in the clevis and change the installed position of the brake preventing proper automatic adjuster function 11 Refer to installation check on page 6 Installation of the CSI Midland Gunite Collar Lock Clevis and Extended Collar Lock Cle Apply anti seize compound to the end of the air chamber push r
11. er ensure that the unit is fully released power spring caged and the service brake push rod is fully retracted to zero stroke position Thread the clevis jam nut onto the push rod B Place the brake chamber into the appropriate brake assembly bracket Tighten the holding nuts to the bracket studs 100 140 Ib ft Measure the distance from the centerline of the 5 to the centerline of the push rod See Figure 13 Dimension A This measurement should be equal to the length of the brake adjuster being used See Figure 14 Dimension A NOTE If Dimension A Figure 13 and Figure 13 Dimension A Figure 14 are not identical the chamber mounting bracket is either bent and must be straightened or replaced the chamber has been mounted improperly in the bracket or the length of the adjuster installed is incorrect Make any necessary corrections before going to Step D L J D Using a square mark the push rod at the Figure 14 90 setting See Figure 13 Mark 1 E From Mark 1 measure back toward the brake 4 chamber mounting surface in accordance with A Chart A X Dimension make a second mark and cut the push rod at Mark 2 See Figure 13 Install the clevis onto the push rod and secure BRAKE ADJUSTER the jam nut Connect the clevis to the brake adjuster Uncage the spring brake Chart A Brake G Release parking spring brakes and a
12. ing a 7 16 socket rotate the hex extension counterclockwise You should have at least 15 ft lbs resistance and a ratcheting sound will be heard as the hex extension is rotated 3 Only back off the adjusting hex enough to allow the drum to clear the lining Remove the brake drum After the brake drum has been removed rotate the extension clockwise until the cam turns over This will allow the brake rollers to be in the release position 4 Proceed with the lining change and or brake drum replacement 5 Rotate the hex extension clockwise until the brake linings contact the brake drum 6 Back off the automatic brake adjuster by rotating the hex extension 1 2 tum counterclockwise A ratcheting sound will be heard This provides running clearance between the lining and the drum 7 Using a ruler measure the distance from the face of the air chamber to the center of the large pin in the clevis A See Figure 15 Make an 85 psi brake application and allow the air chamber to travel its maximum stroke Measure to the center of the large pin B The difference between and is the push rod stroke Check the following charts for proper maximum stroke after adjustment of the brakes 8 Manually uncage the spring brakes STANDARD CLAMP TYPE BRAKE CHAMBER DATA Outside Rated Maximum stroke at which Type Diameter Stroke _ brakes must be readjusted 9 5 1 4 1 75 1 3 8 12 5 1116 1 75 1 3 8 16 6 3
13. ipped with spring brake chambers be sure the chambers are fully caged before cutting the push rod If the spring brakes are not fully caged the push rod can be cut too short 5 Apply anti seize compound to camshaft 6 Install the automatic brake adjuster on the camshaft using the original mounting hardware Aligning the Automatic Brake Adjuster with the Clevis 7 Apply anti seize compound to the clevis pins 8 Rotate the hex extension clockwise until the 1 4 hole in the brake link aligns with the 1 4 hole in the clevis Install the link pin and the cotter 9 Tap the clevis upward or downward until the large hole in the brake arm aligns with the large hole in the clevis Install the clevis pin and the cotter pin 10 Tighten 1 1 4 nut to 40 50 ft lbs of torque NOTE Tapping the clevis downward moves the link into the brake housing If alignment is not achieved when the link bottoms out it indicates improper clevis installation Downward movement of the link requires only light tapping 11 Tighten the 15 16 jam nut against the 1 1 4 nut Tighten to 40 50 ft lbs of torque NOTE Failure to tighten the jam nut will allow th chamber push rod to rotate in the clevis and change the installed position of the brake adjuster preventing proper automatic adjuster function 12 Refer to installation check on page 6 Installation Check 1 Manually uncage the spring brakes
14. od Install the 1 1 4 nut on the air chamber push rod Thread the 3 4 collar onto the push rod Connect the clevis to the 1 1 4 nut Using the gage supplied insert the large pin through the large hole at the top of the gage and into the clevis Center the proper 1 4 hole at the bottom of the gage over the center hole of the camshaft Figure 3 Adjust the clevis by rotating the 3 4 collar until all of the 1 4 pin hole is visible in the notch area of the gage Double check the installation by making sure the 1 4 hole at the bottom of the gage is still centered on the camshaft when the 1 4 hole is visible If the push rod threads protrude through the clevis boss than 1 8 mark the push rod remove the clevis and cut the push rod to length The push rod must have at least full thread engagement inside the 3 4 collar nut If you do not have full thread engagement the push rod must be replaced If you replace the push rod you must cut the new push rod to the proper length Refer to cutting push rod section on page 9 trailer applications an extended clevis can be used instead of replacing the push rod However you must still have full thread engagement inside the collar nut If you have less than full thread engagement a new push rod must be installed If you replace the push rod you must cut the new push rod to the proper length Refer to cutting push rod section on page 9 NOTE On axles equ
15. ot require any external brackets adapters or special mounting holes for installation Link Clevis 1 2 5 8 1 4 Pin Grease Fitting Hex Extension Drilled amp Grooved Worm Wheel Figure 1 Automatic Brake Adjuster 3 INSTALLATION PROCEDURE Standard Standard Collar Nut Thi i 1 10 nut Collar Lock Nut and Clevis Standard length clevises be used for either truck or trailer applications should be used for trailer applications only Figure 2 Clevis Types Figure 3 Gage Location Preparation for Installation 1 Ifthe axle is equipped with spring brake chambers manually cage the spring brakes following the manufacturer s recommended procedures NOTE When caging the spring brakes always be sure to block the vehicle wheels to prevent unwanted movement Check the operating condition of the foundation brakes including drums shoe and linings cams bushings rollers etc Replace or repair as necessary 3 Remove the existing clevis and brake adjuster Do not discard the existing mounting hardware Do not move the clevis jam nut 4 Refer to Figure 2 and determine if your CSI Midland Gunite automatic brake adjusters are equipped with the threaded clevis or the collar lock clevis extended or standard length Refer to the correct installation procedure for the style of clevis used
16. port bosses 2 Build up vehicle air pressure If the axle in question has parking brakes be sure they re released Using template recheck for proper clevis setting If incorrect readjust per instructions under installation procedures 3 Fully apply the brakes and allow the air chamber to travel its maximum stroke Clearance must exist between the brake adjuster and all adjacent chassis components such as axle housing suspension brackets etc Release the brakes Figure 5 Measuring Maximum Stroke Measuring the Free Stroke 4 Free stroke is the amount of movement of the brake adjuster arm required to move the brake shoes against the drum With brakes released measure from the face of the chamber to the center of the clevis pin Use a lever measure the movement of the brake adjuster until the brake shoes contact the drum Figure 6 The difference between the released and applied measurements is the free stroke The free stroke should be 3 8 5 8 Ifthe free stroke is good but the applied stroke is too long there is problem with the foundation brake Check the foundation brake for missing worn compo nents cracked brake drums or improper lining to drum contact Ifthe free stroke is greater than the recommended distance 3 8 5 87 a function test of the automatic brake adjuster should be performed see page 8 Ifthe free stroke is less than 3 8 a dragging brake can occur Check to see that the m
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