SERVICE MANUAL SERVICE MANUAL
Contents
1. Adjuster Manufacture Lubrication Type of Visual Check Type Date Interval Lubricant Interval Standard Prior to 6 1 96 50 000 miles or Standard Chassis Each Preventative Adjuster 409 10 every 3 months Grease Maintenance Service Interval Reduced Maintenance After 6 1 96 Once a year Standard Chassis Each Preventative Adjuster 409 10 Grease Maintenance Service Interval No Lube After 6 1 96 Sealed Unit Each Preventative Adjuster 429 10 Maintenance Service Interval S ABA n a Once a year Standard Chassis Each Preventative Adjuster 409 20 Grease Maintenance Service Interval Notes No Lube automatic brake adjusters are manufactured without a grease fitting and are identified by a 429 prefix Moly disulfide grease should not be used because it may affect the function of the internal friction clutches and reduce the reliability of the automatic adjustment In no case should the lubrication interval exceed the published intervals shown above Foundation Brake Operational Check and Troubleshooting Note H Block wheels to prevent vehicle from rolling H Ensure system reservoir pressure is at 90 100 psi M Check that push rod is fully retracted apply air to release spring brake North American Commercial Vehicle Safety Alliance CVSA Uniform Vehicle Inspection Criteria The applied stroke of the brake should be checked per CVSA guidelines at 90 100 PSI reservoir pressure2. 12 What is the acceptable amount of camshaft bushing wear Automatic adjusters cannot compensate for worn foundation brake parts Please refer to the foundation brake manufacturer s recommendations for maximum bushing and camshaft wear limits 13 Can wheel bearing adjustment affect the brake adjuster Yes Improper wheel bearing adjustment could result in improper brake adjustment It is necessary to refer to the axle manufacturer s wheel bearing adjustment recommendations A loose bearing preload could cause a tight brake 14 Are all Haldex automatic brake adjusters pre lubed Yes All Haldex brake adjusters are lubricated at the factory Please consult the Service and Lubrication Section on Page 6 for proper lubrication guidelines continued on page 13 Frequently Asked Questions continued 15 Can I use moly lube with the Haldex automatic brake adjuster No A high concentration of moly disulfide can lower the friction capabilities in the adjusting clutch parts and decrease automatic adjustment reliability 16 Can I purchase anchor bracket wear items separately i e anchor stud pins wear bushings Yes Normal wear items like anchor stud pins and wear bushings are available Refer to the Haldex Parts and Cross Reference Guide L00090 Otherwise contact Haldex Technical Assistance for the appropriate bracket kit at 17 Does the control arm need to be properly set and secured Yes Without proper p
3. L30037 9 03 SERVICE MANUAL S ABA SELF SETTING AUTOMATIC BRAKE ADJUSTERS innovative Techno Table of Contents S ABA Operation 1 S ABA Brake Adjuster Identification 1 Steer Axle Applications 2 Drive Axle Applications 2 Trailer Axle Applications 3 S ABA Installation Procedures 4 Routine Visual Operational Checks 6 Service and Lubrication Intervals 6 Foundation Brake Operational Check and Troubleshooting T Brake Adjuster Checking Procedures 9 Brake Adjuster Operational Check 9 Typical Parts Identification and Location 160057 805 08 ae 10 Torque Specifications 11 Frequently Asked Ouestions 12 Additional Parts and Service Information 13 Important Notice This symbol is used throughout the manual to call attention to procedures where carelessness or failure to follow specific instructions may result in personal injury and or component damage The description and specifications contained in this service publication are current at the time of printing Haldex Brake Products Corp reserves the right to discontinue or modify its models and or procedures and to change specifications at any time without notice S ABA Operation The Haldex S ABA automatic brake adjuster is a clearance sensing brake adjuster that maintains a nominal distance or clearance between lining and drum
4. Applied stroke should be at or less than the specified re adjustment limits as follows Standard Clamp Type Brake Chamber Long Stroke Type Brake Chamber Type Adjustment Limit Type Adjustment Limit Type Adjustment Limit Type Adjustment Limit 9 1 3 8 24 1 3 4 16L 2 241S 2 1 2 12 1 3 8 30 2 20L 2 30LS 2 1 2 16 1 3 4 36 2 1 4 24L 2 20 1 3 4 NOTE Long stroke chambers are identified with square air ports or port bosses and special trapezoid ID tags Free Stroke Measuring the Free Stroke Free stroke is the amount of movement of the 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 A fig 13 Use a lever to move the brake adjuster until the brake shoes contact the drum B fig 13 The difference between the fully retracted and drum contact measurement B A fig 13 is the free stroke The free stroke range should fall between 3 8 3 4 Free Stroke Within Range If the free stroke is good but the applied stroke is too long there is probably a problem with the foundation brake Check the following and reference CVSA out of service criteria Component Cause Action Brake drums Cracked or out of round Replace or check drum run out Brake shoes Shoe span out of spec Refer to OEM specs and replace
5. typical applications on Pages 2 and 3 Note Block wheels to prevent vehicle from rolling Ensure system tank pressure is above 100 PSI MH Check that the push rod is fully retracted apply air to release spring brake If air is not available spring brake must be manually caged back M Install anchor bracket loosely as illustrated fig 9 H Some strap brackets have two mounting holes Proper mounting location is determined by the length of adjuster arm 5 and 5 1 2 adjuster arm lengths utilize the shorter hole location while 6 and 6 1 2 length adjusters utilize the longer hole locations E Do not tighten anchor bracket fasteners at this time E Apply Anti Seize type lubricant to camshaft splines W Install the brake adjuster onto the camshaft brake chamber fig 10 H Secure the brake adjuster on the camshaft Use at least one inner washer and enough outer washers to allow no more than 060 movement of adjuster on camshaft Per TMC recommended practice RP609 A Note Do NOT pull push rod out to meet the brake adjuster WM Rotate the 7 16 adjusting hex nut CLOCKWISE until the clevis hole lines up with the brake adjuster arm hole H Apply anti seize to clevis pin install and secure with cotter pin Figure9 Figure 10 S ABA Installation Procedures Figure 11a MH The S ABA control arm can be placed anywhere within the range of the bracket slot for automatic adjustment to ta
6. 09 20002 Part Number P N40920002 Serial Number S N26802 Typical Applications Steer Axle Figures 1 and 2 show typical brackets for automatic brake adjuster applications on steer axle brake assemblies Refer to pages 4 and 5 for detailed installation procedures Y Figure 1 Figure 2 Steer axle with clamp bracket Steer axle with strap bracket and flat anchor stud Drive Axle Figures 3 and 4 show typical brackets for automatic brake adjuster applications on drive axle brake assemblies Refer to pages 4 and 5 for detailed installation procedures Figure 3 Figure 4 34 drive axle with Mack drive axle with clamp bracket strap bracket and flat anchor stud Note Refer to fundamental parts identification and location on page 10 Typical Applications Trailer Axle Figures 5 8 show typical brackets for automatic brake adjuster applications on trailer axle brake assemblies Refer to pages 4 and 5 for detailed installation procedures Figure5 Figure 6 For 16 1 2 Brake Assemblies For 12 1 4 Brake Assemblies Figure 7 Integral cam support anchor bracket for 12 1 4 and 16 1 2 brakes Figures Bolt on cam support anchor bracket for 12 1 4 and 16 1 2 brakes Note Refer to fundamental parts identification and location on page 10 S ABA Installation Procedures Note Configuration of anchor bracket and brake adjuster housing may vary depending upon axle Refer to
7. When the Adjuster is Installed With the brake in the released position the control arm is fixed to the anchor bracket The adjustment hex is rotated until the shoes contact the brake drum and then backed off 1 2 turn When the brake is applied on the first application the endless rack rotates to the correct position and sets itself When the Brake Applies When the brake is applied the adjustment regulator rotates through the normal clearance angle and the shoes contact the drum The torque increases and the wormshaft is moved axially causing the coil spring to be compressed and the clutch wheel to disengage The adjustment components are free to rotate as the brake continues to apply Worm Wheel Regulator Gear Control Disc Coil Spring Wormshaft Clutch Treated Clutch Wheel ha Housing Adjustment Hex When the Brake Releases When the brake is released the torque decreases returning the wormshaft to the clutch wheel and re engaging the teeth The adjustment regulator rotates through the normal clearance angle and the brake is released If lining wear has taken place the adjustment regulator advances the clutch wheel reducing the excess clearance during the release stroke S ABA Identification Part Number 409 20_ _ _ S ABA Brake Adjuster Serial Number First 3 digits Day of year built Last 2 digits Year of build The Part No P N40920002 would be our adjuster part number 4
8. ft lbs Round Anchor when installed Stud Pin with Fabricated Ring Clamp Torque to 15 20 ft lbs when installed Round Anchor Stud Pin with Slide Nut Torque to 15 20 ft lbs when installed 3 8 16 Nut and Bolt Torque to 15 20 ft lbs when installed Strap Style Bracket Torque to 8 12 ft lbs when installed U Bolt Style Bracket Torque to 20 30 ft Ibs when installed 11 Frequently Asked Questions 1 N GI D gl N Will the side of the brake adjuster with the face plate always face in No Haldex adjusters are normally unhanded Always install with the adjusting hex pointing away from the air chamber Why is there resistance when backing off the adjuster It takes approximately 20 Ib ft of torque to back off the adjustment hex on a new brake adjuster A ratcheting sound should occur How far do back off the automatic brake adjuster at a brake reline 1 2 turn How do I know if I need an offset angled or straight armed adjuster Haldex manufactures the right adjuster arm for your specific application Haldex adjusters are unhanded no lefts or rights in the majority of applications Please refer to the Haldex Parts and Cross Reference Guide for your specific application L00090 Why does my replacement ABA look different from the original I took off The Haldex ABA replacement adjuster has been designed to fit a number of applicati
9. he push rod is fully retracted apply air to release spring brake If air is not available spring brake must be manually caged back Manually de adjust brakes turn adjustment hex counterclockwise one full turn to create an excessive lining to drum clearance condition A ratcheting sound should occur Make a full service brake application On release allow sufficient time for air chamber to fully retract During the brake release observe rotation of the adjustment hex attaching a wrench on the hex or scribing the hex will make this rotation easier to see This rotation indicates that an excessive clearance condition has been determined by the brake adjuster and it is making an adjustment to compensate On each subsequent brake release the amount of adjustment and push rod travel will be reduced until the desired lining to drum clearance is achieved If rotation of the adjustment hex is not observed refer to Foundation Brake Operational Check and Troubleshooting Procedures on pages 7 amp 8 If foundation brake assembly checks out okay and hex still does not turn check control arm and mounting bracket for possible worn bent or broken components If the control arm and mounting bracket check out okay replace the adjuster and hardware per Installation Instructions on pages 4 amp 5 9 Off Vehicle Inspection Component Cause Action Adjuster not Low clutch gt gt Place adjuster arm in vise Rotate the 7 16 functioning t
10. if necessary Brake shoes Uneven lining wear Check spider concentricity Brake shoes Shoe pad missing Remove amp replace shoes Brake shoes Cracked shoes Remove amp replace shoes Cam bushings Excessive movement Remove amp replace cam bushings per OEM specs Camshaft Flat spots on cam head Replace camshaft Camshaft Cracked broken splines Replace camshaft Camshaft Worn bearing journals Replace camshaft Chamber bracket Broken bent Replace bracket Clevis yoke and pin Worn Remove amp replace Return springs Broken stretched or missing Remove amp replace springs Rollers Flat spots grooved pin worn Remove amp replace roller and pin Rollers Wrong size Remove amp replace with correct parts Spider anchor pins 7 Grooved or scored worn Replace spider or pins as appropriate for OEM Free Stroke Above the Range If the free stroke is above the range and the applied stroke is too long there is a problem with the foundation brake or the adjuster Check the following Component Cause Action Camshaft Binding Remove replace lubricate camshaft Camshaft bushings Excessive movement Remove and replace cam bushings per OEM specs Camshaft bushings Binding shaft Lubricate camshaft bushings or replace Air chamber return springs Broken weak missing Replace chamber Air chamber push rod Binding on chamber housing Check adjuster for pr
11. juster is not maintaining the proper applied stroke before removing the brake adjuster check the condition of the foundation brake see pages 7 amp 8 If after inspecting the foundation brake no apparent problems are found inspect the automatic brake adjuster to determine if it is operating properly The inspection can be performed on or off the vehicle using the following procedures Note H Block wheels to prevent vehicle from rolling H Ensure system reservoir pressure is at 90 100 PSI E Check that push rod is fully retracted apply air to release spring brake M If air is not available spring brake must be manually caged back E Do not use air tools on brake adjuster On Vehicle Inspection Component Cause Action Excessive Improper anchor gt If anchor bracket to control arm connection chamber push bracket connection is worn loose bent or broken it must be rod travel to control arm re secured or replaced Low clutch torque Rotate the 7 16 adjustment hex one full turn counterclockwise Replace brake adjuster if the torque is less than 13 ft lbs or no racheting sound occurs Perform automatic brake adjuster operational check see below Unknown Automatic Brake Adjuster Operational Check Functional operation of the brake adjuster can be performed on the vehicle by using the following procedure m Block wheels to prevent vehicle from rolling H Ensure reservoir pressure is at 90 100 psi MH Check that t
12. ke place Haldex recommends however rotating all control arms towards the axle until they come to a complete stop El PP ing i iti JA NN igure fig 11a b c and securing in that position GB g This will create a common position for all wheels Tighten all anchor bracket fasteners Figure 11c QC coon H The adjuster must be manually adjusted at this time W Rotate the adjusting hex clockwise until the lining lightly contacts the drum MH Then back off the adjuster by turning the adjusting hex counter clockwise 1 2 of a turn fig 12 H A minimum of 13 ft Ibs is necessary to overcome the internal clutch A ratchet ing sound will be present H Do NOT use an impact wrench or permanent internal damage will occur Note To ensure proper fit and function always replace both adjuster and mounting bracket Figure 12 as aset Routine Visual Operational Checks E Haldex strongly recommends that routine visual operational checks including brackets and control arms be performed at each Preventative Maintenance Service Interval E Adjusters or anchor brackets that have visual damage or which fail the operational checks MUST be replaced immediately H Automatic adjusters should not be operated as manual adjusters except as may be necessary to get the vehicle off the road for service Service and Lubrication Intervals for Standard Haldex AA1 and S ABA Brake Adjusters
13. lacement and attachment the adjuster will not function properly Make sure the control arm anchor bracket and wear items are in good working order to assure the adjuster will operate as designed 18 If automatic adjustment stops can operate as a manual brake adjuster No Completely check out foundation brake and adjuster to determine cause of problem Repair or replace as needed to restore automatic adjustment 1 800 643 2374 Additional Information Available Additional parts and service information on Haldex Automatic Brake Adjusters may be found in the following materials Service Information Installation and Maintenance Wall Chart L60047 Service Manual Truck Trailer L30037 Parts Information Parts and Cross Reference Guide Truck Trailer L00090 These materials may be ordered by contacting your Customer Service Representative at 1 800 643 2374 Or you may log in to our website www hbsna com with your customer password to place your order 13 Haldex Commercial Vehicle Systems North American Sales Division North American Sales Division Haldex Brake Products Corporation Haldex Limited 10707 N W Airworld Drive 525 Southgate Drive Unit 1 Kansas City MO 64153 1215 Guelph Ontario CANADA N1G 3W6 Phone 816 891 2470 Phone 519 826 7723 Fax 816 880 9766 Fax 519 826 9497 9 03 2 5M ART L30037 2003 The Haldex Corporation
14. ons It is the same original equipment quality and design of the adjuster you removed however it may look different on the outside If you use all the parts included in the kit the results will be the same as the original equipment adjuster Why is the applied stroke pressure range 90 100 psi at the reservoir This is the pressure recommended by the CVSA Commercial Vehicle Safety Alliance Anything beyond 100 psi measures deflection within the foundation brake and not true push rod stroke Some brake chambers have round port openings and some square what is the difference Standard brake chambers are identified by round ports Long stroke chambers are identified by square ports and trapezoid ID tags 8 Can I vary the amount of lining to drum clearance by moving the control arm No that clearance is set at the factory If long or short stroke continues please refer to the foundation brake checking procedures on pages 9 amp 10 of this manual 9 Can use an air ratchet on the adjuster No It will damage the internal mechanism of the adjuster and render it inoperative 10 Can I access the adjuster through the rear cover No do not tamper with the rear cover it will release the factory set pressure on the spring and destroy the adjuster and its ability to properly function 11 How much control arm bushing and anchor stud pin wear is acceptable before replacement is required No more than 1 16
15. oper shimming and air chamber position for proper adjuster arm length Air system Not exhausting completely Check for cause of air problem and repair Shoe return springs Broken weak missing Replace springs Automatic brake adjuster Unknown Check automatic brake adjuster for proper Automatic brake adjuster Unknown Free Stroke Below the Range If the free stroke is less than 3 8 a dragging brake Component Cause installation Refer to Installation Instructions on pages 4 amp 5 Refer to Automatic Brake Adjuster Checking Procedures and Operational Check on pages 9 amp 10 can occur Check the following Action Wheel bearing Out of adjustment Automatic brake adjuster Unknown Automatic brake adjuster Unknown Free Stroke B minus A Applied Stroke C minus A ALENT Hr iii ih Ban III AN LIE St ki DECIA ii pre MIN UI A Fully Retracted Readjust per OEM specs Check automatic brake adjuster for proper control arm position Refer to Installation Instructions on pages 4 amp 5 Refer to Automatic Brake Adjuster Checking Procedures and Operational Check on pages 9 amp 10 gt r n sirt pr Figure 13 Stroke Measurements B Drum Contact Using a Lever taken from face of air gt chamber to center of reservoir pressure Cc Brake Application at 90 100 PSI clevis pin Automatic Brake Adjuster Checking Procedures If the brake ad
16. orque adjustment hex counterclockwise one full turn to properly check de adjustment torque After control arm stops rotating a minimum of 13 ft lbs will be required and a ratcheting sound will occur Replace brake adjuster If the torque is less than 13 ft Ibs or no de adjustment ratcheting sound is present Control Arm Place adjuster arm in vise Rotate the control arm slippage counterclockwise until the control arm rotates to an INTERNAL STOP If the arm slips freely replace the brake adjuster Unknown gt If torque is above 13 ft Ibs scribe a line on the adjustment hex Manually pull the brake adjuster control arm clockwise then push back counter clockwise The hex will move in a clockwise direction when the control arm of the brake adjuster is pushed back counterclockwise Replace adjuster if hex does not move Worn missing _ W Remove and replace pin and bushings If adjuster control arm wear has passed the above checks re install adjuster bushing and on vehicle with new hardware anchor stud pin if applicable Typical Parts Identification and Location Bracket Bushing Adjustment Hex Nut Anchor Radney Stud Pin Bracket Control Arm m Stud Pin 5 Single Bend EA Tn W Wear Control Arm Bushing 10 Torque Specifications Note Tighten all fasteners to manufacturer s recommendations unless otherwise specified below Flat Anchor Stud Pin Torque to Na 40 50
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