Service Manual Truck and Trailer Applications
Contents
1. No It will damage the internal mechanism of the adjuster and render it inoperative 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 How much control arm bushing and anchor stud pin wear is acceptable before replacement is required No more than 1 16 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 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 continued on page 13 Frequently Asked Questions continued 15 Are all Haldex automatic brake 18 Does the control arm need to be adjusters pre lubed properly set and secured Yes All Haldex brake adjusters are lubricated at Yes Without proper placement and attachment the factory Please consult the Service and the adjuster will not function properly Make sure Lubrication Section on Page 6 for proper the control arm anchor bracket and wear items lubrication guidelines are2. Shoe return springs Broken weak missing Replace springs Automatic brake adjuster Unknown Check automatic brake adjuster for proper installation Refer to Installation Instructions on pages 4 amp 5 Automatic brake adjuster Unknown Refer to Automatic Brake Adjuster Checking Procedures and Operational Check on pages 9 amp 10 Free Stroke Below the Range If the free stroke is less than 3 8 a dragging brake can occur Check the following Component Cause Action Wheel bearing Out of adjustment Readjust per OEM specs Automatic brake adjuster Unknown Check automatic brake adjuster for proper control arm position Refer to Installation Instructions on pages 4 amp 5 Automatic brake adjuster Unknown Refer to Automatic Brake Adjuster Checking Procedures and Operational Check on pages 9 amp 10 Free Stroke B minus A Applied Stroke C minus A Figure 19 Stroke Measurements taken from face of air chamber to center of clevis pin Drum Contact Using a Lever Brake Application at 90 100 PSI reservoir pressure Automatic Brake Adjuster Checking Procedures If the brake adjuster 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 inspect
3. service Service and Lubrication Intervals 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 None Sealed Unit Each Preventative Adjuster 429 10 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 m Block wheels to prevent vehicle from rolling m Ensure system tank 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 pressure Applied stroke should be at or less than the specified adjustment limits
4. If air is not available spring brake must be manually caged back Install anchor bracket loosely as illustrated fig 13 Some strap brackets have two mounting A holes Proper mounting location is Figure 13 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 Do not tighten anchor bracket fasteners at this time Apply Anti Seize type lubricant to camshaft splines m Install the brake adjuster onto the camshaft with the adjusting hex pointing away from the brake chamber fig 14 m 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 Figure 14 Note Do NOT pull push rod out to meet the brake adjuster Rotate the 7 16 adjusting hex nut CLOCKWISE until the clevis hole lines up with the brake adjuster arm hole Apply anti seize to clevis pin install and secure with cotter pin Installation Procedures Rotate the control arm away from the adjusting hex toward the air chamber until it comes to a definite internal stop fig 15 Most adjusters will be equipped with an Installation Indicator Indicator must fall within the slot for proper installation with brakes fully released fig 16 m
5. spring brake must be manually caged back Manually de adjust brakes turn adjustment hex counterclockwise one full turn to create an excessive drum to lining clearance condition A ratcheting sound should occur Make a full service brake application On release allow sufficient time for brake 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 clearance is achieved If rotation of the adjustment hex is not observed refer to Foundation Brake Operational Check and Troubleshooting Procedures on pages 7 and 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 procedures on pages 4 amp 5 Off Vehicle Inspection Component Cause Adjuster not gt Low clutch x functioning torque properly m gt Control Arm gt slippage gt Unknown gt Worn missing gt control arm wear bushing and anchor stud pin if applicable Action Pl
6. 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 4 1 3 4 16L 2 2als 2 1 2 2 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 19 Use a lever to move the brake adjuster until the brake shoes contact the drum B fig 19 The difference between the fully retracted and drum contact measurement B A fig 19 is the free stroke The free stroke range should fall between 3 8 3 us 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 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 if necessary Brake shoes Uneven lining wear Check spider concentricity Brake shoes Shoe pad missing R
7. in good working order to assure the adjuster will operate as designed 16 Can I use moly lube with the Haldex automatic brake adjuster 19 If automatic adjustment stops can I No A high concentration of moly disulfide can operate as a manual brake adjuster lower the friction capabilities in the adjusting No Completely check out foundation brake and clutch parts and decrease automatic adjustment adjuster to determine cause of problem Repair reliability or replace as needed to restore automatic adjustment 17 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 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 L30033 Installation Tips Automatic Brake Adjuster Pocket Size L20397 Installation Instructions AA1 and S ABA Models L31195 Parts Information Parts and Cross Reference Guide Truck Trailer LOOO90 Supplemental Au
8. 1 Frequently Asked Questions 12 Additional Parts and Service Information csccssesssecseesseeseeesees 13 Important Notice This symbol is used throughout this manual to call attention to procedures where carelessness or failure to follow specific instructions may result in personal injury and or component damage The descriptions 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 The Haldex automatic brake adjuster is a clearance sensing brake adjuster that maintains When the Brake Applies Upon brake application the brake adjuster rotates and moves the shoes into contact with the drum The clearance notch corresponds to the Clutch Assembly normal lining to drum clearance As the brake application continues the rack moves upward and rotates the one way clutch which slips in this direction As O Ring the brake torque increases the coil spring load is overcome and the wormshaft is displaced axially releasing Adjustment the cone clutch Hex Bushing Heat Treated Housing Direction of Applied Stroke Wormshaft When the Brake Releases Enclosed When the brake begins its return stroke Rack the coil spring load returns to normal and the cone clutch is again engaged staat The rack is pul
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10. If the control arm position is wrong a tight brakes will occur fig 17 m Tighten all anchor bracket fasteners make sure the control arm does not move from its position while tightening fasteners q m The adjuster must be manually adjusted at this time m Rotate the adjusting hex clockwise until INCORRECT DE t the lining lightly contacts the drum Brakes released Brakes released m Then back off the adjuster by turning the PERSIE Figure 17 adjusting hex counter clockwise 1 2 of a turn fig 18 m A minimum of 13 ft Ibs is necessary to overcome the internal clutch A ratcheting sound will be present Do NOT use an impact wrench or internal damage will occur FINAL INSPECTION With full system air pressure assure that spring brakes are released and check that the Installation Indicator is within the slotted area IF NOT REPEAT Step 3 Note To ensure proper fit and function always replace both adjuster and mounting bracket Routine Visual Operational Checks Haldex strongly recommends that routine visual operational checks including brackets and control arms be performed at each Preventative Maintenance Service Interval Adjusters or anchor brackets that have visual damage or which fail the operational checks MUST be replaced immediately Automatic adjusters should not be operated as manual adjusters except as may be necessary to get the vehicle off the road for
11. Service Manual Truck and Trailer Applications L30033 1 idii w Mum J Nid g as P A SE EUR eG Table of Contents Warning Haldex strongly recommends routine visual checks be performed at EACH maintenance service interval Foundation brake operational checks utilizing CVSA level 1 applied stroke criteria should always be utilized Manual adjustment of automatic adjusters can disguise hidden problems within the foundation brake Brake components such as S cams bushings return springs actuators drums and adjuster installation MUST be within manufacturer s specifications Adjuster control arms wear bushings or attaching hardware that demonstrate visual damage or which fail the operational checks MUST be replaced immediately Automatic Adjusters should NEVER be operated as manual adjusters except as may be necessary to get the vehicle off the road for service OPTION a ees teres 1 Brake Adjuster Part Number and Build Date 1 Steer Axle Applications 2 Drive Axle Applications 2 Trailer Axle Applications 0 ecsscsee 3 Installation Procedures 4 Routine Visual Operational Checks 6 Service and Lubrication Intervals 6 Foundation Brake Operational Check and Troubleshooting 7 Brake Adjuster Checking Procedures 9 Brake Adjuster Operational Check 9 Typical Parts Identification and Location 10 Torque Specifications 1
12. ace adjuster arm in vise Rotate the 7 16 adjustment hex counterclockwise one full turn to check de adjustment torque After control arm stops rotating a minimum of 13 ft Ibs 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 Place adjuster arm in vise Rotate the control arm counterclockwise until the control arm rotates to an INTERNAL STOP If the installation indicator goes past the indicator notch or does not stop rotating arm slips freely replace the brake adjuster 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 until the installation indicator stops in the indicator notch 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 Remove and replace pin and bushings If adjuster has passed the above checks re install adjuster on vehicle with new hardware Typical Parts Identification and Location Anchor Bracket Adjustment Hex Nut Indicator Notch k Anchor mn Control Arm 3 Stud Pin Single Bend Installation ye Tw Indicator Anchor Wear Bracket Bushing Wear xe Control Arm Bushing Double Bend Torque Specifications Note Tighten all fasteners to m
13. aight 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 applications 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 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 7 amp 8 of this manual Can I use an air ratchet on the adjuster
14. anufacturer s recommendations unless otherwise specified below Round Anchor Stud Pin with Fabricated Ring Clamp Torque to 15 20 ft Ibs when installed 3 8 16 Nut and Bolt Torque to 15 20 ft Ibs when installed U Bolt Style Bracket Torque to 20 30 ft Ibs when installed Flat Anchor Stud Pin Torque to 40 50 ft lbs when installed Round Anchor Stud Pin with Slide Nut Torque to 15 20 ft Ibs when installed Strap Style Bracket Torque to 8 12 ft Ibs when installed Frequently Asked Questions N s A yi 9 N Will the side of the brake adjuster with the installation indicator always face in No Haldex adjusters are normally unhanded Always install with the adjusting hex pointing away from the air chamber My adjuster doesn t have an installation indicator should I be concerned No A few applications aren t manufactured with installation indicators However the set up and function are the same regardless Refer to pages 4 amp 5 for proper installation procedures Why is there resistance when backing off the adjuster It takes approximately 20 25 Ib ft of torque to back off the adjustment hex A ratcheting sound should occur How far do I back off the automatic brake adjuster at a brake reline 1 2 turn NOTE for the first 1 8 turn you may not hear the ratcheting this is normal How do I know if I need an offset angled or str
15. emove 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 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 pre 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 proper shimming and air chamber position for proper adjuster arm length Air system Not exhausting completely Check for cause of air problem and repair
16. ety and warning requirements are met 2010 Haldex AB This material may contain Haldex trademarks and third party trademarks trade names corporate logos graphics and emblems which are the property of their respective companies The contents of this document may not be copied distributed adapted or displayed for commercial purposes or otherwise without prior written consent from Haldex Commercial Vehicle Systems Austria Haldex Wien Ges m b H Vienna Tel 43 1 8 69 27 97 Fax 43 1 8 69 27 97 27 E Mail info AT haldex com Belgium Haldex N V Balegem Tel 32 9 363 90 00 Fax 32 9 363 90 09 E Mail info BE haldex com Brazil Haldex do Brasil Ind e Com Ltda Sao Paulo Tel 55 11 213 55 000 Fax 55 11 503 49 515 E Mail info BR haldex com Canada Haldex Ltd Cambridge Ontario Tel 1 519 621 6722 Fax 1 519 621 3924 E Mail info CA haldex com China Shanghai Tel 86 21 5240 0338 Fax 86 21 5240 0177 E Mail info CN haldex com France Haldex Europe SAS Weyersheim Strasbourg Tel 33 3 88 68 22 00 Fax 33 3 88 68 22 09 E Mail info EUR haldex com Germany aldex Brake Products GmbH eidelberg Tel 49 6 221 7030 Fax 49 6 221 703400 E Mail info DE haldex com Hungary Haldex Hungary Kft Szentl rinckata Tel 36 29 631 300 Fax 36 29 631 301 E Mail info HU haldex com India Haldex India Limited Nasik Tel 91 253 2380094 Fax 91 25
17. ical brackets for automatic brake adjuster applications on drive axle brake assemblies Figures Refer to pages 4 and 5 axle with r i strap bracket for detailed installation 4 Figure 6 procedures 34 drive axle with strap bracket Figure 7 Mack drive axle with clamp bracket and flat anchor stud Figure 8 0 Kenworth drive axle with strap bracket for 8 bag air ride Note Refer to fundamental parts identification and location on page 10 Typical Applications Trailer Axle Figures 9 12 show typical brackets for automatic brake adjuster applications on trailer axle brake assemblies Refer to pages 4 and 5 for detailed installation procedures Figure 10 For 16 1 2 Brake Assemblies For 12 1 4 Brake Assemblies Figure 11 tote ral cam support anchor bracket for 12 1 4 and 16 1 2 brakes Figure 12 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 Installation Procedures Note Configuration of anchor bracket and brake adjuster housing may vary depending upon axle Refer to typical applications on Page 2 and 3 Anchor Bracket ETJE A Note Block wheels to prevent vehicle from rolling Ensure system tank pressure is above 100 PSI m Check that the push rod is fully retracted apply air to release spring brake
18. ion can be performed on or off the vehicle using the following procedures Note Block wheels to prevent vehicle from rolling M Ensure system tank pressure is at 90 100 PSI Check that push rod is fully retracted apply air to release spring brake If air is not available spring brake must be manually caged back Do not use air tools on brake adjuster On Vehicle Inspection Component Cause Action Tight or Control arm Realign control arm and anchor bracket dragging brakes mispositioned Check installation procedures on pages 4 amp 5 Excessive m gt 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 gt Low clutch torque Rotate the 7 16 adjustment hex one full turn counterclockwise Replace brake adjuster if the torque is less than 13 ft Ibs or no racheting sound occurs gt Unknown gt Perform automatic brake adjuster operational check see below Automatic Brake Adjuster Operational Check Functional operation of the brake adjuster can be performed on the vehicle by using the following procedure Block wheels to prevent vehicle from rolling M Ensure tank pressure is at 90 100 psi Check that the push rod is fully retracted apply air to release spring brake If air is not available
19. led back to its original position in the notch and any 0 Ring Worm Wheel additional travel brought about by Clearance lining wear causes the rack to turn the Notch locked one way clutch and rotates the wormshaft through the locked cone Control Arm clutch The wormshaft then rotates the worm wheel and camshaft adjusting Fixed Point the brakes Brake Adjuster Identification Part Number After Prior to 409 prefix Reduced maintenance Sept 1989 Sept 1989 adjuster The Part No The first three numbers P N40910224 would be our adjuster part Serial Number number First 3 digits Day of year built 409 10224 Last 2 digits Year of build stamped on the cover plate is the brake adjuster part number For example 224 would be our adjuster part number 409 10224 429 prefix No Lube adjuster Part Number ee P N40910224 g Serial Number S N33489 Typical Applications Steer Axle Figures 1 4 show typical brackets for automatic brake adjuster applications on steer axle brake assemblies Refer to pages 4 and 5 for detailed installation Figure 1 Figure2 procedures ah cap wai Camp bracket and bracket and flat anchor round anchor stud stud Figure3 Mack 16 000 or higher rated steer axles with spider mounted 7 bracket Figure4 Steer axle with strap bracket Approx 1 16 Drive Axle Figures 5 8 show typ
20. tomatic Brake Adjuster Kits L20447 These materials are readily available on the Haldex website www haldex com or you may order copies by contacting your Customer Service Representative at 1 800 643 2374 Haldex www haldex com headquartered in Stockholm Sweden is a provider of proprietary and innovative solutions to the global vehicle industry with focus on products in vehicles that enhance safety environment and vehicle dynamics Haldex is listed on the Stockholm Stock Exchange Haldex has a yearly turnover of close to 5 6 billion SEK and employs 4 300 people Disclaimer The products described within this literature including without limitation product features specifications designs availability and pricing are subject to change by Haldex and its subsidiaries at any time without notice This document and other information from Haldex its subsidiaries and authorized distributors provide product and or system options for further investigation by users having technical expertise It is important that you analyze all aspects of your application and review the information concerning the product or system in the current literature or catalog Due to the variety of operating conditions and applications for these products or systems the user through their own analysis and testing is solely responsible for making the final selection of the products and systems and assuring that all performance saf
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