Service Manual
Contents
1. 16 Inspection Procedures 4 Inspection Procedures 4 1 General Information The objective of this chapter is to give guidance on how inspection of the brake components shall be conducted Always start by consulting the Inspection interval table below in chapter 4 2 The Inspection interval table displays how frequent the different brake components shall be inspected and on which pages the check instructions are found The majority of the inspections demand that the wheel is removed from the vehicle Before removing the wheel read chapter 2 Safety Precautions followed by 3 Initial and Final Procedures 4 2 Inspection intervals The check intervals specified in the table below are maximum intervals Depending on the vehicle application type of driving adjustment to the vehicle manufacturer s service inspection intervals etc there may be a need for more frequent inspections C Check E A e a 4 Inspection s is lt lt 23 pe o Lu et Sa 30 e e E 8 5 N o With wheels fitted 5 E 3 E EA With wheels removed oa 3 d S 5 D Ea OD e 5 a 5 S o D me S D S a See oa Page Adjustment of Control System Valves C A Cc C A 7 Braking Force Distribution Tractor Trailer IGE IGO 7 Function Test Uruburu Eee gr Err 12 Plugs and Protective Cups We in BO BENE l 21 Thrust Plate Guide Pins a a ee ee Sur 22 Actuation Interface rE 23 Slide Pin Bellows St oOo RO EO ej E 26 Adjustment Screw Bello2. Tension the lifting strap so taking the full weight of the brake ModulT_060 Figure 68 Disc brake removal 3 Remove the retaining bolts holding the disc brake and lift away from the axle 60 Replacement Procedures 5 7 3 Install Disc Brake 1 Clean the mating faces of the new disc brakes carrier and axle Ensure the faces are free from dirt debris moisture and corrosion 2 Fit the old pad retainer spring then refit the old pad retainer by first locating the housing end in the calliper aperture then locating the pad retainer slot over the calliper latch finally slide the pad retainer under the calliper latch until the pad retainer spring pops into locking position Check that the spring bracket is correctly engaged 3 Attach a lifting strap around the pad retainer and then lift the brake into position 4 Follow the vehicle axle manufacturer s recommendations for fitting tightening the retainingbolts or follow the general method described hereafter 5 Fit and screw home the retaining bolts alternating from side to side of the carrier 6 Tighten all retaining bolts to the torque settings defined by the vehicle axle manufacturers specifications 7 Remove the lifting strap old pad retainer and pad retainer spring Scrap the old pad retainer and pad retainer spring as they are not to be used again 5 7 4 Final Procedure To conclude this procedure read and follow chapters 1 5 2 3 Install Brake
3. in sequence Haldex special tool P N s 95230 De Eessen 95423 95219 95221 and 95220 preloaded SW P ZO with the new parts as shown in figure 59 pee 3 Once fitted correctly turn the threaded tool clockwise which will pull into position the two bearings F and spacer G complete Figure 59 Tool assembly for leading slide bearings Replacement Procedures 53 4 Stop once the bearings are seated in there correct position up to the inside lip of the bearing location surface see figure 60 It is important the bearings are seated correctly but not over tightened as this may cause damage ModulT_083 Figure 60 Leading side bearings installed OK NOK IMPORTANT The trailing side composite bushing must be indexed correctly when being installed into position by hand If not correctly indexed the slide function of the brake will not be correct 5 To install the new composite bushing H on the trailing side by hand push the composite bushing into place until it bottoms out Ensure the index lug locates correctly in the calliper slot see figure 61 No tools or high forces are required for this fitting process nor should they be used If used they may cause damage If the bushing is not indexed correctly the slide pin and protective cup may not fit ModulT_093 Figure 61 Inserting the trailing side composite bushing 54 Replacement Procedures IMPORTANT When inserted the slide pin bel
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5. corrosion upon re assembly 5 4 3 Cleaning IMPORTANT Use a vacuum cleaner to clean surfaces Do not use compressed air IMPORTANT It is important to take care when using chemicals and or cleaning tools e g knife brush etc This to avoid damage or displacement of hoses seals and other components IMPORTANT Make sure that dirt and impurities do not enter the opening for the adjustment screw Clean the thrust plate the adjustment screw and the adjustment screw bellows sealing surfaces in the calliper Ensure the parts are free from dirt dust debris moisture and corrosion Replacement Procedures 43 5 4 4 Install Adjustment Screw Bellows 1 Fasten the thrust plate in a vice fitted with soft jaws see figure 43 for the clamping arrangement Do not over tighten or damage the thrust plate whilst clamping 2 Clean the internal threaded surface of the thrust plate 3 Ensure that the contact surfaces between the thrust plate and the bellows are clean and free from dirt moisture and corrosion ModulT_067 Figure 43 Clamping arrangement for thrust plate IMPORTANT Only use Haldex special tools where specified 4 By hand using Haldex special tool P N 95224 C firmly press the adjustment screw bellows A into position on the thrust plate B see figure 44 Check that the bellows is correctly seated in position on the thrust plate ModulT_037 Figure 44 Fitting the adjustment screw bellow
6. pin bellows sealing surfaces in the calliper 5 By hand push out and remove the leading slide pin C and the trailing slide pin D see figure 52 A Figure 52 Remove the slide pins Replacement Procedures 49 6 By hand carefully remove the two slide pin bellows E see figure 53 If required use a small screwdriver to assist by levering them out Be careful not to damage the slide pin bellows sealing surfaces if using a tool to levering out the bellows Figure 53 Remove the silde pin bellows 7 Carefully follow steps 8 and 9 below to remove the two leading bearings F and the spacer G and trailing composite bushing H see figure 54 ModulT_064 Figure 54 Remove the slide bearings and composite side bushing 50 Replacement Procedures 8 To remove the two bearings F and the spacer G on the leading side assemble in sequence Haldex special tool P N s 95230 95423 95222 95219 and 95220 as shown in figure 55 SLIT SAREA Gre 9 Once fitted correctly turn the threaded tool clockwise which will pull out the two bearings F and the spacer G If required rotate the mandrel P N 95219 half way through the extraction process so the nut P N 95220 can be held Figure 55 Remove the leading slide bearing 10 The composite bushing H on the trailing side should be removable by hand 11 However if this is not possible assemble in sequence Haldex special tool P N
7. 2 7 2 Shot blasting IMPORTANT Failure to follow the instructions below could compromise safety and or reduce the life of the disc brake and its components If the vehicle is shot blasted all rubber parts and pads on the disc brake must be protected The brake chamber must be fitted or any protective parts that have a similar sealing function The shipping seal fitted to the brake chamber opening on a new disc brake does not provide adequate protection during shot blasting NOTE Do not forget to follow the recommendations of the brake chamber manufacturer The disc brake must be thoroughly cleaned after blasting to ensure that its natural movement is not obstructed by remnants of shot blasting material Check seals and rubber parts to make sure they have not been damaged Also refer to the axle manufacturer s instructions 10 Initial and Final Procedures 3 Initial and Final Procedures 3 1 General Information The objective of this chapter is to give guidelines on how Initial and Final Procedures shall be performed in a standardised way Initial Procedure is a recurring procedure that have to be performed prior to the Inspection and or Replacement procedures covered in this Service Manual Final Procedure is a recurring procedure that have to be performed after an Inspection and or Replacement procedure covered in this Service Manual 3 2 Initial Procedure 3 2 1 Lift up and support the vehicle axle At least one of the veh
8. 66 9 1 Component ET EEA 66 9 2 ua uu UE EO 67 2 Disclaimer Please note This Service Manual is intended for the exclusive use by trained persons within the commercial vehicle industry and related workshops The content of this manual is not all inclusive and not legally binding and Haldex Brake Products AB assumes no liability as a result of its use All information contained in the manual does neither represent ensured characteristics of the product nor represent a guarantee Haldex Brake Products AB reserves the right to make changes in the interest of technical progress without prior notice No liability is assumed as a result of incorrect or inappropriate parts being fitted to the product or the omittance of appropriate tests after the servicing of the product Use appropriate spare parts documentation when obtaining spare parts Use only genuine Haldex spare parts in repairs This manual is subject to a copyright of Haldex Brake Products AB that reserves all rights No part of this manual may be reproduced copied or translated in any form or by any means without the prior written permission of Haldex Brake Products AB Brand names mentioned in this manual are not identified as such in all cases but they nevertheless are subject to the provisions of trademark legislation In case of conflicting language versions of this manual the English original prevails The failure of any individual provision of this disclaimer to comply wit
9. AIR DISC BRAKE ModulT www haldex com Table of Contents Disclaimer 2 1 Introduction 3 1 1 ATZO BAZA RUN OA E 3 1 2 The Haldex a I Tce 4 1 3 F n tional DC SCRA casio 5 2 Safety Precautions 6 2 1 BERREGIN aaa 6 2 2 DOGU Oa E 6 2 3 Adjustment of Control System Valves e 7 2 4 GOZ E 8 2 5 E el 8 2 5 Cleaning ee 8 2 6 Surface finishing for Disc Brake nn 9 3 Initial and Final Procedures 10 3 1 General Information ore ee ee 10 3 2 i itial AGA EO 10 3 3 Function OS Ec a ete leet ela al 12 3 4 IER aeeai taoenna meetan e araneta aeee dbanie nai emia maaan narea Hae EH aea omanaan aai dennas 14 4 Inspection Procedures 16 4 1 General Informati t en 16 4 2 Inspection intervals n usnnnnnunnnunnnnnnunnnunnnnnnnnnnnnnnnnnunnnnnnnnnnnnnnnnnnnnnnnn nenn nnnnnn nenn nnnnnnn nenn nmn nnmn nenn nn 16 4 3 HSE Eate atakea eaeko 17 5 Replacement Procedures 30 5 1 General Information E 30 5 2 Replacement of Brake Baden 30 5 3 Replacement of Brake Chambet ss sssssssssssssssnssesnsscsnssssnsnssnsnenesneseenensensnrensnenennenennenes 36 5 4 Replacement of Adjustment Screw Bellows an 41 5 5 Replacement of Slide Function Assembly en 46 5 6 Replacement of Reset Shaft Complete en 57 5 7 Replacement of Disc Brake en 59 6 Specifications 61 6 1 Wear LIMItS issnin eee ee 61 6 2 ARAGUAZO UA 61 7 Tools 62 7 1 Haldex ModulT Tool Kit complete ea 62 7 2 Special tools for Haldex MOUIT e 63 8 Fault Finding 64 9 Component List and Exploded view
10. Pads 5 3 3 Install Brake Chamber 3 3 Function Test to ensure that the disc brake is working correctly WNW N 3 4 Final Procedure Specifications 6 Specifications The Haldex ModulT Air Disc Brake come both left and right handed it is important the correct hand is fitted in relation to the normal wheel disc rotation Figure 69 below shows a general overview of both variants and their relation to the normal wheel disc rotation shown as a red arrow and their leading AL and trailing AT slide functions Each calliper also has a rotation arrow formed on the cast surface where the pad retainer seats on the inboard side see figure 69 ModulT_002 Figure 69 Haldex ModulT orientation 6 1 Wear Limits Brake Pads min lining thickness a 2mm Brake Pads Max uneven wear a 1 5 mm Brake disc min thickness a 37 mm 6 2 Tightening Torques 6 2 1 General Follow the vehicle axle manufacturers recommendations 6 2 2 Haldex ModulT ADB DBT22LT Bolts x2 for slide pins 180 Nm 70 Brake chamber fixation nuts 180 20 Nm Tools 62 7 Tools 7 1 Haldex ModulT Tool Kit complete Part Number P N 95231 Figure 70 Haldex ModulT tool kit Tools 63 7 2 Special tools for Haldex ModulT Contents of tool kit Haldex P N 95231 P N 95219 Mandrel for the removal and assembly of slide function B
11. ads ModulT_070 Figure 29 Inspect the adjustment screw bellows 6 Once the inspection is completed satisfactorily conclude by reading and following chapters 5 2 3 Install Brake Pads and 5 2 4 Final Procedure Inspection Procedures 29 4 3 11 Check Slide Function Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health Brake pad wear produce dust which can cause lung damage IMPORTANT It is important to take care when using chemicals and or cleaning tools e g knife brush etc This to avoid damage or displacement of hoses seals and other components IMPORTANT Use a vacuum cleaner to clean surfaces Do not use compressed air 1 Read and follow chapters 3 2 Initial Procedure and 5 2 2 Remove Brake Pads prior to inspecting the slide function 2 Once the brake pads are removed move the calliper by hand back and forth to check its movement see figure 30 The calliper must be free to slide on the leading and trailing slide pins 3 If the movement is felt to be obstructed in some way then it is necessary to determine the root cause see chapter 8 Fault Finding for assistance in this ModulT_025 Figure 30 Calliper free movement 4 If the root cause investigation concludes that the slide function needs replacing then follow chapter 5 5 Replacement of Slide Function Assembly 5 Once the inspection is completed satisfa
12. amber A and calliper B to ensure that dirt does not get into the mechanism area when removing the brake chamber See figure 22 ModulT_028 Figure 22 The mating surfaces of the brake chamber and calliper the brake system is depressurised that the spring brake chamber is fully disengaged and mechanically secured in the released position f If the disc brake is equipped with a parking brake function ensure that See the vehicle manufacturer s instructions D ited E 3 D Figure 6 Mechanically secure in the released position 24 Inspection Procedures Pressure from lines and components shall be released before opening them 3 If applicable ensure that the spring brake chamber F is fully disengaged and mechanically secured in the released position 4 Ensure that the brake chamber is depressurised 5 Remove the two nuts E holding the brake chamber Remove the brake chamber A F from the calliper B see figure 23 ModulT_091 p d NI 4 TINS ESS E 2 badeza A 4 Figure 23 Removal of brake chamber items 6 With the brake chamber removed and secured the brake chamber actuation rod should protrude 15 mm in its rest position See figure 24 7 Activate the service brake the brake chamber actuation rod should protrude 80 mm 8 Also check that the actuation rod extends perpendicular to the external seal flange ModulT_018 Figure 24 The actuation rod 9 Check th
13. ation IMPORTANT If all the plugs remain fitted the brake chamber and disc brake will not operate correctly 2 5 Recycling When replacing the disc brake or parts thereof the components removed must be recycled destroyed in compliance with applicable environmental legislation regulations and provisions 2 6 Cleaning For the disc brake to function correctly it is important to ensure it is kept clean and that its normal movements are not restricted by mud ice snow objects etc Damage may cause direct brake failure or damp dirt penetration resulting in malfunction shortening of the service life of the disc brake IMPORTANT It is important to take care when using chemicals and or cleaning tools e g knife brush etc This to avoid damage or displacement of hoses seals and other components Safety Precautions 9 2 7 Surface finishing for Disc Brake 2 7 1 Painting The disc brake can be finished with paint that has trade approval for this purpose automotive paint Care must be taken to ensure that the paint layer does not cause damage and or restrict the natural movement or operation of the disc brake All contact surfaces friction and rubber parts must therefore be protected or masked The following areas must not be painted All bellows Reset Shaft and it s protection Plug complete Brake Pads the swept area of the disc the disc brake mounting surfaces to axle brake chamber and all bolted connections
14. ch can cause lung damage TI Wear respiratory protection in order to avoid inhaling particles which can IMPORTANT Use a vacuum cleaner to clean surfaces Do not use compressed air IMPORTANT It is important to take care when using chemicals and or cleaning tools e g knife brush etc This to avoid damage or displacement of hoses seals and other components 1 Carefully clean around the mating surfaces of the brake chamber A and the calliper B to ensure that dirt does not get into the mechanism area when removing the brake chamber See figure 36 ModulT_028 Figure 36 The mating surfaces of the brake chamber and calliper Replacement Procedures 37 the brake system is depressurised that the spring brake chamber is fully disengaged and mechanically secured in the released position See the vehicle manufacturer s instructions f If the disc brake is equipped with a parking brake function ensure that bal Figure 6 Mechanically secure in the released position Pressure from lines and components shall be released before opening them If applicable ensure that the spring brake chamber F is fully disengaged and mechanically secured in the released position See figure 37 Ensure that the brake chamber A is depressurised Mark and remove the hose connections of the service brake C and if applicable the parking brake D Remove the two nuts E holding the brake chamber Remove the bra
15. cking the clearance is only required for an approximation of the clearance between the brake disc and the brake pads The check can be carried out with or without the brake chamber fitted This check is best performed after the wheel is removed and before the brake is de adjusted For this situation the steps 2 and 3 below can be skipped 1 Read and follow chapters 3 2 Initial Procedure and paragraph 4 from 5 2 2 Remove Brake Pads prior to checking the pad clearance 2 Adjust the reset shaft by inserting and manually turning the Haldex special tool P N 95232 Torx 55 clockwise until it comes to a stop and any excessive clearance is removed Then de adjust the reset shaft by turning it anti clockwise by 2 clicks A E E 5 b 3 Activate the brake until the Torx 55 male no longer rotates because any excessive clearance has been removed by the adjustment function Figure 16 Correct location of the feeler gauges 4 Insert two feeler gauges in between the calliper and the outer brake pad to measure the clearance Position the feeler gauges in the upper and lower part of the brake pad back plate so an average clearance is measured see figure 16 5 The normal running clearance is between 0 7mm and 1 1mm If the measurement is outside of the normal running condition then refer to chapter 8 Fault Finding for further investigations 6 Once the inspection is completed satisfactorily conclud
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17. correctly in place The reset shaft complete with x ring already fitted is supplied ready lubricated no additional i grease or other lubrication is required Ge 3 Push the reset shaft into position by hand no impact or high forces are required as they may damage the reset shaft The resent shaft will click into its position in the Z center of the gear wheel when fully engaged See figure 67 Figure 67 Installing the reset shaft 5 6 4 Final Procedure To conclude this procedure read and follow chapters 1 3 3 Function Test to ensure that the disc brake is working correctly 2 3 4 Final Procedure Replacement Procedures 59 5 7 Replacement of Disc Brake 5 7 1 Initial Procedure Read and follow the chapters below prior to removing the disc brake 1 3 2 Initial Procedure 2 5 2 2 Remove Brake Pads instruction 1 through to 5 only 3 5 3 2 Remove Brake Chamber 5 7 2 Remove Disc Brake IMPORTANT Do not remove the disc brakes retaining bolts until the brakes weight is supported by the lifting straps 1 Refit the old pad retainer by first locating the housing end in the calliper aperture then locating the pad retainer slot over the calliper latch finally slide the pad retainer under the calliper latch until the pad retainer spring pops into locking position See figure 68 f Check that the spring bracket is correctly engaged 2 Attach a lifting strap around the pad retainer
18. ctorily conclude by reading and following chapters 5 2 3 Install Brake Pads and 5 2 4 Final Procedure IMPORTANT Obstruction of the slide function can cause operational problems like hot brakes and uneven brake pad wear 30 Replacement Procedures 5 Replacement Procedures 5 1 General Information The objective of this chapter is to give instruction and guidance on how the disc brake and or its components shall be replaced All the replacement procedures in this chapter require that the wheel is taken off to enable the replacement work to be carried out 5 2 Replacement of Brake Pads 5 2 1 Initial Procedure Read and follow chapter 3 2 Initial Procedure prior to removing the brake pads 5 2 2 Remove Brake Pads be hazardous to your health Brake pad wear produce dust which can cause lung damage IMPORTANT Use a vacuum cleaner to clean surfaces Do not use compressed air IMPORTANT It is important to take care when using chemicals and or cleaning tools e g f Wear respiratory protection in order to avoid inhaling particles which can knife brush etc This to avoid damage or displacement of hoses seals and other components 1 If necessary remove dirt dust and other possible obstruction Replacement Procedures 31 NOTE The thrust plate must be fully retracted to be able to fit new pads IMPORTANT Only use Haldex special tools where specified IMPORTANT Never use an impact wre
19. cups are correctly seated and bottomed out see figure 65 5 5 5 Final Procedure To conclude this procedure read and follow chapters 1 5 7 3 Install Disc Brake 2 5 2 3 Install Brake Pads 3 5 3 3 Install Brake Chamber 4 3 3 Function Test to ensure that the disc brake is working correctly 5 3 4 Final Procedure Replacement Procedures 57 5 6 Replacement of Reset Shaft Complete 5 6 1 Initial Procedure Read and follow chapter 3 2 Initial Procedure prior to removing the reset shaft complete IMPORTANT Only use Haldex special tools where specified 5 6 2 Remove Reset Shaft Complete 1 If necessary remove dirt dust and other possible debri from around the reset shaft area Ensure the area is clean prior to removing the reset shaft protection plug 2 Remove the reset shaft protection plug A 3 Insert Haldex special tool P N 95210 and pull out the reset shaft B with x ring complete see figure 66 The x ring is always fitted to the reset shaft and never removed ModulT_094 Figure 66 Removing the reset shaft 58 Replacement Procedures 5 6 3 Install Reset Shaft Complete 1 Clean the reset shaft location surfaces in the calliper housing Ensure the areas are free from dirt dust debris moisture and corrosion 2 Insert Haldex special tool P N 95232 Torx 55 into the new reset shaft and by hand insert it into the calliper Whilst doing so make sure the x ring is
20. d he V O X nH CN Y N Zy ModulT_023 Figure 32 Removal of brake pad components NOTE Always remove the outer brake pad first Replacement Procedures 33 IMPORTANT Always remove the outer brake pad first You cannot directly pull out the inner brake pad with the outer still in place as the inner brake pad is located to the thrust plate on two points 5 Remove the brake pads always remove the outer brake pad A first followed by the inner brake pad B See figure 33 This is because the inner brake pad back plate locates on two holes which mate to the thrust plate therefore you cannot directly pull out the inner brake pad with the outer brake pad still being in place Once the outer brake pad is removed the calliper can be slid across to allow for the inner brake pad to be removed ModulT_024 6 Remove the pad retainer spring bracket C Figure 33 Removal of brake pads 34 Replacement Procedures 5 2 3 Install Brake Pads Make sure that the brake is fully de adjusted before fitting new brake pads N Check that the contact surfaces on the carrier calliper and thrust plate are free from dirt and corrosion Clean if necessary IMPORTANT The inner brake pad must always be installed first IMPORTANT Ensure that the friction material faces the brake disc 3 First install the inner brake pad B in the carrier note that the inner brake pad locates onto the thrust pla
21. distribution between the truck tractor and trailer may require adjustment Brake adjustment must also be carried out during repairs changing spare parts when heating overheating has suspected to damaged the axle brake components e g rubber components hub wheel bearings and brake disc Contact the vehicle supplier for information on the appropriate action Following replacement of any essential components or spare parts in the disc brake operating system e g brake valves or control units the disc brake operating system must also be checked and adjusted in accordance with the relevant braking calculations Failure to follow these instructions may cause damage repeated damage to the disc brake axle and or wheel brake components 8 Safety Precautions 2 4 Brake Chamber Moisture water ingress into the disc brake s mechanism housing will potentially affect the function of the disc brake and as a result shorten its life Therefore to prevent water ingress it is important that the disc brake chamber is of the correct design and that the seal between the brake chamber and disc brake mating surface is undamaged correctly in place It is also important for the disc brake s function that the brake chamber housing is correctly ventilated ModulT_034 As a minimum the drain holes facing downwards must be open see figure 4 Other drain plugs can remain in position in the brake chamber housing Figure 4 Brake chamber ventil
22. e by reading and following chapters paragraph 6 from 5 2 3 Install Brake Pads and all from 5 2 4 Final Procedure 20 Inspection Procedures 4 3 5 Check Brake Disc f Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health Brake pad wear produce dust which can cause lung damage 1 Look for wear damages and cracks see figure 17 Also refer to the axle vehicle manufacturer instructions Cracks that enter the cooling ducts via the outer radius are not permitted Acceptable Unacceptable crack length crack length lt 75 of brake gt 75 of brake disc width disc width ModulT_011 Figure 17 Inspection of the Brake Disc 2 Measure the thickness of the brake disc using a slide calliper If the brake disc has a wear ridge the measurement can be performed using two spacers B e g 5 mm thick flat washers see figure 18 Reduce the measured dimension by the total thickness of the two spacers B Minimum thickness of the brake disc is 37 mm The brake disc must be replaced if the wear limits have been exceeded Figure 18 Measuring the Brake Disc thickness NOTE This brake disc inspection check procedure is only a general guide refer to the vehicle manufacturers documentation for specific brake disc information and instruction Inspection Procedures 21 4 3 6 Check Plugs and Protective Cups be hazardous to your health Brake pad w
23. e to the disc brake axle and or wheel brake components 2 3 1 Before entering the Vehicle into service Prior to first time use a vehicles disc brake operating systems must be checked and adjusted if necessary in accordance with the relevant brake calculations Contact the vehicle manufacturer for relevant information 2 3 2 Replacing Spare Parts Always use spare parts that are approved for the vehicle axle or disc brake Following replacement of any essential components or spare parts in the disc brake operating system such as brake valves or control units the disc brake operating system must also be checked and adjusted if necessary in accordance with the relevant braking calculations 2 3 3 Brake Force Distribution It is very important that the distribution of brake force between axles vehicles in a vehicle combination is adapted so that the brake force for each axle vehicle is proportioned in accordance with the legally applied braking calculations If the brake force is not correctly distributed it can lead to excessive braking of a vehicle and or one or more axles in the combination This can result in overheating accelerated wear and damage to the disc brake pads discs tyres and wheel components Before a vehicle is entered into service it must be set up according to the specified values in the relevant brake calculations After the pads brake discs have been run in for a period of around 3 000 5 000 km the brake force
24. ear produce dust which can cause lung damage IMPORTANT Use a vacuum cleaner to clean surfaces Do not use compressed air IMPORTANT Failure to follow the instructions below could compromise safety and or reduce the life of the Disc Brake and its components f Wear respiratory protection in order to avoid inhaling particles which can 1 Read and follow chapter 3 2 Initial Procedure prior to inspecting the protective plugs and cups 2 Remove dirt from surfaces if necessary 3 Check for signs of excessive heat exposure discolouration debris etc 4 The following plugs and protective cups shall be in place and intact The reset shaft protection plug identified as A and calliper seal B see figure 19 Protection plug B is never removed 5 The three protection cups two for slide pin protection C and one for the mechanism D see figure 20 Proctection cup D is never removed 6 Once the inspection is completed satisfactorily conclude by reading and following chapter 3 4 Final Procedure ModulT_014 Figure 20 The three protection cups IMPORTANT Never remove the protection plug B and protection cup D on figures 20 and 21 If the protection plug B is removed it will void warranty and will compromise the life of the disc brake 22 Inspection Procedures 4 3 7 Check Thrust Plate Guide Pins Wear respiratory protection in order to avoid inhaling particles which can be ha
25. earings and Composite Bushing P N 95220 Nut for the removal and assembly of slide function Bearings and Composite Bushing P N 95221 Clamp washer for the assembly of slide function Bearings and Composite Bushing P N 95222 Cup for the removal of slide function Bearings and Composite Bushing P N 95224 Mounting tool for adjustment screw bellows onto the thrust plate P N 95225 Mounting tool for adjustment screw bellows into the calliper Left P N 95226 Mounting tool for adjustment screw bellows into the calliper Right P N 95233 3 4 drive long reach 14mm Insex for slide pin bolts P N 95232 3 8 drive Torx T55 for the Reset Shaft P N 95210 P N 95230 Special tool for removing Reset Shaft Complete Threaded spindle used with Pull out Pull in tool pieces P N 95423 Axial bearing used with the threaded bar 64 Fault Finding 8 Fault Finding Take all necessary Safety Precautions before wheel removal Read the Safety Precautions carefully The vehicle manufacturer s instructions shall also be followed Symptoms Actions See the relevant chapters for remedial measures No or low braking effort e Are the pads worn out Replace the pads e Is pad disc clearance OK Conduct initial setting function checks e Is the brake disc OK Replace the brake disc See vehicle manufacturer s instructions e Is air pressure in t
26. ellows 5 4 1 Initial Procedure Read and follow the chapters below prior to removing the adjustment screw bellows 1 3 2 Initial Procedure 2 5 2 2 Remove Brake Pads 3 5 3 2 Remove Brake Chamber 4 5 7 2 Remove Disc Brake 5 4 2 Remove Adjustment Screw Bellows 1 Fasten the disc brake securely in a vice with soft jaws see figure 41 for clamping arrangement Ensure that the jaws of the vice do not damage the disc brake ModulT_080 Figure 41 Clamping arrangement for replacing adjustment screw bellows 42 Replacement Procedures 2 Using Haldex special tool P N 95232 Torx 55 manually turn the reset shaft clockwise to extract the thrust plate A Continue extracting until the thrust plate unscrews fully and becomes detached from the adjustment screw see figure 42 The point at which the thrust plate becomes detached is when the gap between the thrust plate inner pad face and the calliper outer pad face becomes smaller than 52 mm Be careful when removing the thrust plate not to damage its internal threads or the external threads on the adjustment screw ModulT_035 Figure 42 Extract the thrust plate 3 Once the thrust plate becomes detached from the adjustment screw by hand pull off the adjustment screw bellows from the thrust plate and calliper Do not use any tools for this removal because damaging the sealing surfaces could cause water penetration leakage or seal
27. er B with nuts E see figure 39 Screw the nuts home first before torque tightening to ensure the brake chamber seats parallel Ze Brake chamber fixation nut tightening torque is 180 20Nm ModulT_033 Figure 39 Installation of brake chamber items IMPORTANT Do not mix up the hoses 6 Fit the brake chamber hose connection of the service brake C and if applicable the parking brake D If fitting both hoses ensure connections C and D are the correct way around See figure 39 40 Replacement Procedures 7 Remove the ventilation drain plug that faces downwards from the brake chamber housing see figure 40 Also from the spring brake chamber if applicable ModulT_034 Figure 40 Remove the ventilation drain plug IMPORTANT Apply air to the parking brake Make sure that there is sufficient air in the system min 6 bar 8 If applicable release the parking brake and disengage the spring brake chamber caging mechanism so that the spring is released Min 6 bar in compressed air system 9 With the service brake engaged and where applicable with the parking brake released check the brake chambers hoses and connections for leaks or damage 5 3 4 Final Procedure To conclude this procedure read and follow chapters 1 3 3 Function Test to ensure that the disc brake is working correctly 2 3 4 Final Procedure Replacement Procedures 41 5 4 Replacement of Adjustment Screw B
28. er lever manually with a suitable tool 6 The Torx 55 must rotate clockwise only on each actuation showing that the automatic adjustment function is working 7 If the Torx 55 rotates back and forth or not at all then the adjustment function is not working correctly 8 To check further manually adjust the reset shaft by turning the Torx 55 clockwise by 360 degrees and then anti clockwise by 180 degrees to ensure the adjuster is not jammed at the full de adjust position o E E E 3 b Figure 9 Brake actuation 9 Also note that once the excessive clearance is taken up by the adjuster the Torx 55 will naturally stop rotating If in doubt turn the Torx 55 anti clockwise by 180 degrees and then press the brake pedal again to check 10 If the Torx 55 still rotates back and forth during actuation then the adjustment function is defective and the calliper must be replaced See chapter 5 7 Replacement of Disc Brake 14 Initial and Final Procedures 3 4 Final Procedure 1 Using Haldex special tool P N95232 Torx 55 manually adjust the brake by turning the reset shaft clockwise until the pads touch the disc and you feel an end stop 2 Then turn the reset shaft anti clockwise by 2 clicks see figure 9 1 This procedure is the initial brake pad setting Figure 9 1 Initial brake pad setting 3 Fit the reset shaft protective plug into the calliper ensure it is correctly orien
29. h current legal provisions does not affect the validity of the remaining provisions Introduction 3 1 Introduction 1 1 General Information This Haldex ModulT Service Manual is divided up into chapters these chapters are sequenced in the same way that a user should read and follow the manual Chapter 1 Introduction provides a general overview of this service manual and the ModulT disc brake It is important to carefully read chapter 2 Safety Precautions before starting any workshop procedures This is to inform the user about the safety measures and the potentially hazardous situations which if not avoided could result in serious injury or death Chapter 3 Initial and Final Procedures describes the start and finish activities necessary to be able to carry out inspection and replacement work It also describes the function test for the ModulT disc brake Consult chapter 4 Inspection Procedures for information and instruction on inspecting the ModulT disc brake Chapter 4 2 Inspection Intervals is useful for the recommended disc brakes inspection intervals Here the Inspection Intervals table displays how frequent the different brake components shall be inspected and on which pages the check instructions are to be found If any inspection shows that a replacement activity needs to be performed continue to the appropriate section in chapter 5 Replacement Procedures Chapter 6 Specifications co
30. he brake chamber OK Measure with a pressure gauge at the brake chamber Implement remedial measures according to vehicle manufacturer s instructions e Has the drain plug been removed from the brake chamber housing Remove the drain plug located at the lowest point of the brake chamber e Does the mechanism and calliper move freely Conduct initial settings and function check The brakes pull to one side e Are the pads worn on one side Replace the pads e Is pad disc clearance OK Conduct initial setting function checks e Can the pads move freely in the carrier Remove the brake pads clean the pads carrier and calliper e Is there the same pressure in both brake chambers of the axle during braking Measure with pressure gauge at the brake chambers See the vehicle manufacturer s instructions for more information e Has one of the drain plugs been removed from the brake chamber housing Remove the drain plug located at the lowest point Fault Finding 65 Symptoms Actions Brakes are binding not releasing have heat damaged components brake pads wear out quickly e Does brake pressure remain in the brake e See the vehicle manufacturer s instructions chamber when the brakes are released for information e Are all of the spring brake chambers released See the vehicle manufacturer s instructions when the parking brake is off for
31. he wheel hub can rotate freely If it does not then first tap to remove any rest tension If the wheel still does not rotate freely then consult chapter 8 Fault Finding to assist further N Remove the reset shaft protection plug A see figure 8 IMPORTANT Use recommended tools only NOTE The Torx 55 and the Thrust plate must be allowed to move unhindered IMPORTANT Never use an impact wrench or similar to turn the reset shaft This may damage internal parts of the mechanism Torque is 20 Nm max 3 Using Haldex special tool P N95232 Torx 55 de adjust the brake by turning the reset shaft anti clockwise by 4 clicks or till the end stop see B figure 8 A distinct clicking sound shall be heard and felt when de adjusting o E E E F 3 b Figure 8 De adjustment via the reset shaft Initial and Final Procedures 13 IMPORTANT When reaching the end stop position of de adjustment never tighten and leave Leaving the reset shaft tightened in the de adjust position could stop the adjustment function from working After reaching the end stop position always then adjust by turning the reset shaft clockwise 90 degrees thus activating the adjustment function 4 Leave the Torx 55 in position in the reset shaft 5 Actuate the brakes 5 times by pressing and releasing the vehicles brake pedal through its full stroke See figure 9 If no brake chamber is fitted then actuate the brake chamb
32. icle s axles shall be chocked to prevent involuntary movement of the vehicle The vehicle manufacturer s safety precautions shall be followed when working on the vehicle Local safety precautions shall be complied 1 On a flat and even surface block the wheels see figure 5 2 Lift the axles and place on stands ModulT_004 Figure 5 Block the wheels Initial and Final Procedures 11 If the disc brake is equipped with a parking brake function ensure that the brake system is depressurised that the spring brake chamber is fully disengaged and mechanically secured in the released position See the vehicle manufacturer s instructions ModulT_055 Figure 6 Mechanically secure in the released position 3 Release the parking brake 3 2 2 Removing the wheel Take all necessary safety precautions before wheel removal The vehicle manufacturer s safety precautions shall also be followed 1 Check the free rolling resistance if the resistance is higher than expected tap the tyre to remove any normal rest tension If the wheel still does not rotate freely then consult chapter 8 Fault Finding to assist further 2 Remove the wheel nuts followed by the wheel see figure 7 ModulT_005 Figure 7 Remove the wheel 12 Initial and Final Procedures 3 3 Function Test 3 3 1 Check of Adjustment Unit The function test can be carried out with the wheel both fitted or removed cl Check that t
33. information e Is pad disc clearance OK e Conduct initial setting function checks e Can the pads move freely in the carrier e Remove the brake pads clean the pads carrier and calliper e Is the calliper slide function OK e Conduct check slide function e b the wheel bearing clearance OK e See the vehicle manufacturer s instructions for information e Has one of the drain plugs been removed Remove the drain plug located at the lowest from the brake chamber housing point e Has valve adjustment brake force distribution Adjust brake valves carry out brake been carried out correctly force adaptation Refer also to vehicle manufacturer s instructions e Uneven pad wear or pads wearing out too e Work through the inspections chapter to quickly ensure the brake is functioning correctly and thus identify any operational problems requiring rectification e Also check that genuine Haldex brake pads are being used only use Haldex original spare parts e Check that the correct brake pad friction material is being used for the specific application e Check the brake harmonisation between the truck and trailer is correctly setup Noise vibrations from the brake e Can the pads move freely in the carrier e Remove the brake pads clean the pads carrier and calliper then refit e Are there non permitted cracks grooves on Probably need to change the brake disc See the brake disc the vehicle manufacturer s ins
34. ings and the mechanism bellows is folded inwards thus protected from external affection stones blister etc Figure 1 The Haldex ModulT Disc Brake High efficiency the use of double roller bearings for the mechanism lever keeps the hysteresis low and thus a high efficiency is achieved Introduction 1 3 Functional Description The ModulT is designed to provide high performance coupled with low weight durability and a minimum number of wearing parts The ModulT enhances a floating monobloc calliper C and an integrated adjustment unit which compensates for brake pad wear The unit which is actuated by the mechanism lever A presses the inner brake pad B against the disc which then causes the calliper C to slide laterally so that the outer brake pad D also comes in contact with the disc see figure 2 The calliper moves on slide pins E see figure 3 Where the disc brake also serves as a parking brake the unit is actuated by a spring brake chamber F ModulT_001 Figure 2 Functional description Figure 3 Slide pins and spring brake chamber 6 Safety Precautions 2 Safety Precautions 2 1 General Information This chapter comprehends the Safety Precautions that shall be read and followed before any Inspection Removal Installation procedure described in this Service Manual is started This Service Manual is intended for the exclusive use of trained persons within the commercial vehicle industry a
35. ke chamber A from the calliper B ModulT_029 Figure 37 Removal of brake chamber items Once the brake chamber is removed it is good practice and highly recommended to read and follow chapter 4 3 8 Check Actuation Interface 38 Replacement Procedures 5 3 3 Install Brake Chamber ek Check that the brake chamber being installed is the correct one for the application and vehicle If a spring brake chamber is being installed ensure that the parking brake spring is caged in accordance with the manufacturer s instructions 2 Prior to fitting the brake chamber it is good practice and highly recommended to read and follow chapter 4 3 8 Check Actuation Interface IMPORTANT It is important to take care when using chemicals and or cleaning tools e g knife brush etc This to avoid damage or displacement of hoses seals and other components 3 Check that the surface of the calliper that mates with the brake chamber is free from dirt moisture and corrosion Do the same check on the brake chambers mating face A and seal See figure 38 Ensure the brake chamber seal is in the correct position and not damaged 4 Put a knob of general purpose grease in the ball cup of the brake chamber lever Do not overfill the cup or let grease fall inside the brake ModulT_032 Figure 38 Pre brake chamber mounting activity Replacement Procedures 39 5 Fit the new brake chamber A to the callip
36. l Procedure and 5 2 2 Remove Brake Pads prior to checking the adjustment screw bellows IMPORTANT Never use an impact wrench or suchlike to turn the reset shaft This may damage the disc brakes mechanism Torque is 20 Nm max Note Do not over adjust extend the thrust plate whilst carrying out the inspection Over adjustment extension will cause the thrust plate to disengage from the adjustment screw and if done unintentionally may cause damage to the thrust plate bellows Max distance between the calliper and thrust plate is 60 mm 2 Using Haldex special tool P N95232 Torx 55 manually turn the reset shaft clockwise to adjust the brake so that the thrust plate A is extended and the bellows can be viewed Stop when the distance between the inner pad face of the thrust plate and outer pad face on the calliper is 60 mm see figure 28 ModulT_089 Figure 28 Max extension to check the thrust plate bellows 28 Inspection Procedures 3 Inspect the adjustment screw bellows see figure 29 Look all around the bellows for damage signs that could have been caused by debris stones or overheating 4 If the bellows are damaged then it needs replacing For instructions on how to replace the bellows read and follow 5 4 Replacement of Adjustment Screw Bellows 5 If OK then manually de adjust the thrust plate by turning the Torx 55 reset shaft anti clockwise until the position required to refit the brake p
37. lows must seat correctly bottoming out against the calliper location shoulder 6 By hand firmly push the two new slide pin bellows into their calliper locations ensuring that the bellows are seated correctly in position see figure 62 It is important to check that the bellows is correctly seated within the calliper do so by looking inside the bellows to see their seating Failure to do so may compromise the sliding function of the brake ModulT_045 Figure 62 Installing slide pin bellows 7 By hand insert the leading slide pin C into the bearings and the trailing slide pin D into the composite bushing see figure 63 The longer slide pin C is fitted into the leading side Note that one end of the slide pins has a machined grove this side is inserted first No grease is required 8 Check that the bellows location ring is fitted correct and in one piece By hand locate the bellows onto the end of the slide pins Ensure the bellows and the bellows location ring seat correctly on the slide pins Failure to do so may compromise the sliding function of the brake ModulT_066 Figure 63 Insert the slide pins Replacement Procedures 55 9 Clean the brake pad contact surfaces on the carrier the calliper and the thrust plate A wire brush can be used but be careful not to damage any of the bellows Do not grind f Never re fit used bolts 10 Lift the carrier into position in the calliper e
38. ls e g knife brush etc This to avoid damage or displacement of hoses seals and other components IMPORTANT Use a vacuum cleaner to clean surfaces Do not use compressed air 1 Read and follow chapters 3 2 Initial Procedure and 5 2 2 Remove Brake Pads prior to inspecting the slide pin bellows 2 Inspect the Leading slide pin bellows A and the Trailing slide pin bellows B see figure 27 Look all around the bellows for damage signs than could have been caused by debris stones or overheating ModulT_020 Figure 27 Inspecting the slide pin bellows 3 If the bellows are damaged then they need replacing For instructions on how to replace the bellows read and follow 5 5 Replacement of Slide Function Assembly 4 Once the inspection is completed satisfactorily conclude by reading and following chapters 5 2 3 Install Brake Pads and 5 2 4 Final Procedure Inspection Procedures 27 4 3 10 Check Adjustment Screw Bellows Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health Brake pad wear produce dust which can cause lung damage IMPORTANT It is important to take care when using chemicals and or cleaning tools e g knife brush etc This to avoid damage or displacement of hoses seals and other components IMPORTANT Use a vacuum cleaner to clean surfaces Do not use compressed air 1 Read and follow chapters 3 2 Initia
39. nch or suchlike to turn the reset shaft This will damage internal parts of the mechanism Torque is 20 Nm max 2 Remove the reset shaft protection plug See figure 31 3 Using Haldex special tool P N 95232 Torx 55 manually turn the reset shaft anti clockwise to de adjust the brake so that the thrust plate fully retracts to its inner position A clicking sound shall be heard and felt when de adjusting The stop at fully retracted inner thrust plate position must be distinct but do not exceed 20 Nm in torque or leave it tightened in this position SAC peg pi N SLNN Vy NST Ic d N SA Figure 31 De adjust the thrust plate via the reset shaft f Sudden release of tensioned springs can cause injury f Do not actuate the brake when changing the brake pads Also ensure the air brake system is pressurised during the replacement procedure minimum 4bar If the pressure drops below 4bar the park brake will be acutated 32 Replacement Procedures IMPORTANT Always ensure the pad retainer spring bracket is fully held down whilst levering out the pad retainer 4 Remove the pad retainer by first pushing and holding down the spring bracket A see figure 32 Whilst the spring bracket A is held down slide out and remove the pad retainer B A tool can be used to help slide out the pad retainer if unable to do so be hand Continue to remove the two pad springs C GN ES
40. nd related work shops Three different alert levels are used through out this Service Manual Warning Important and Note Their differences are explained below A Warning message is always accompanied by a safety alert symbol The safety alert symbol is used to alert about potential personal injury hazards To avoid hazards obey all safety messages that follow this symbol Failure to observe this information can cause serious personal injury or death IMPORTANT An important message is always accompanied by the signal word IMPORTANT The Important sign means risk of damage to the brake Failure to observe this information could result in damage to the whole brake or parts of it NOTE A notification message is always accompanied by the word NOTE The Note sign is used to emphasize important information and is not to be regarded as hazard information 2 2 Installation The disc brake must not be installed or treated in such a way that exposes it to none normal thermal mechanical or chemical influences that can cause reduced braking effect or damage to vital components in the brakes These influences damages may result in a shortened service life for the disc brake and its components reduced brake effect or at worst total brake failure Safety Precautions 7 2 3 Adjustment of Control System Valves Failure to follow the instructions in this chapter may accelerate the wear to the brake pads and may cause damage repeated damag
41. nsuring that the slide pins fitted with bellows do not interfere or obstruct If necessary push out the slide pins slightly by hand whilst lowering in the carrier Hold the carrier in position whilst the two bolts are inserted and screwed home See figure 64 11 Using Haldex special tool P N 95233 3 4 long drive 14mm Insex screw home and then a tighten the slide pin bolts B Their torque setting is defined in chapter 6 2 2 Haldex ModulT ADB ModulT_047 Figure 64 Refit the carrier and its fixing bolts IMPORTANT The protective cups are different sizes and when fitted must be seated correctly The leading cup is smaller than the trailing cup The leading cup must bottom out against the bearing and the trailing cup must bottom out against the calliper shoulder 56 Replacement Procedures 12 Carefully and squarely tap the protective cups AT and AL in place into the calliper using a soft headed mallet G i G i Note that the cups are different sizes the larger cup is fitted to the trailing side AT and the smaller to the leading side AL The leading protective cup AL seats raised from the casting surface whilst the trailing protective cup AT sits nearly flush ModulT_081 13 Do not strike the cups hard or at an angle as this may damage them and therefore Figure 65 Correctly seating the protection cups compromise the sliding function of the brake 14 Ensure the protective
42. ntains technical data for the ModulT disc brake Chapter 7 Tools contains information about the Haldex ModulT Tool Kit which is essential for carrying out much of the replacement procedure work described in this manual Chapter 8 Fault Finding should be used to help with the self diagnosis of any problem being experienced Finally Chapter 9 Components List lists and shows what spare part components are available for the ModulT disc brake 1 1 1 Spare Parts It is vital that only Haldex original spare parts are used during all service replacement activities The use of none Haldex original spare parts can affect the function performance and or lifetime of the parts The use of none Haldex original spare parts will immediately terminate any warranty of the disc brake unit Introduction 1 2 The Haldex ModulT The Haldex ModulT is an air disc brake platform developed for the purpose of meeting increased customer demands on performance robustness service up time and weight The ModulT superior design encompasses the following advantages Low weight Single tappet mechanism with similar clamping force distribution as Haldex twin tappet mechanism Simplified maintenance boltless pad retainer and only two bolts in the complete brake Modular the same mechanism and sliding function design used on multiple brake sizes ModulT_053 Long service life stainless sliding pins PTFE coated steel bush
43. ocedure 46 Replacement Procedures 5 5 Replacement of Slide Function Assembly 5 5 1 Initial Procedure Read and follow the chapters below prior to removing the slide function assembly 1 3 2 Initial Procedure 5 2 2 Remove Brake Pads 5 3 2 Remove Brake Chamber 5 7 2 Remove Disc Brake BW N 5 5 2 Remove Slide Function Assembly IMPORTANT Where specified only use Haldex Special Tools 1 Fasten the calliper securely in a vice with soft jaws see figure 48 for clamping arrangement Ensure that the jaws of the vice do not damage the calliper ModulT_039 Figure 48 Clamping arrangement for replacing the slide function assembly Replacement Procedures 47 2 Use a small hammer and chisel to remove the leading and trailing protective cups A see figure 49 The protective cups are not to be re used ModulT_040 A Figure 49 Remove slide protection cups 3 Using Haldex special tool P N95233 3 4 long drive 14mm Insex remove the two bolts B see figure 50 The bolts are not to be re used ModulT_061 Figure 50 Remove the slide pin bolts 48 Replacement Procedures 4 Remove the carrier from the calliper by gently rocking the carrier to release it from the slide pins and bellows Once released press slide pins back enough to be able to lift out the carrier see figure 51 Figure 51 Remove the carrier IMPORTANT Be careful not to damage the slide
44. rough the aperture in the brake chamber attachment flange for moisture corrosion see figure 25 It s important to look inside the aperture and not just on the surface If corrosion is seen then further inspection is necessary If concluded that water has ingressed causing internal corrosion damages to the mechanism then replace the calliper complete to avoid operating problems ModulT_030 If action is required see chapter 5 8 Replacement of Calliper Figure 25 The brake chamber aperture Check that the bellows are complete and not Check that the external seal flange B Once the inspection is completed Inspection Procedures On the brake chamber there must be an internal bellows A on the push rod see figure 26 damaged by looking around and down the push rod shaft Also look for signs of water or corrosion which may be a sign that the bellows are damaged is correctly seated in place intact and undamaged ModulT_031 Figure 26 Internal view of a brake chamber satisfactorily conclude by reading and following chapters 5 3 3 Install Brake Chamber and 5 3 4 Final Procedure 25 26 Inspection Procedures 4 3 9 Check Slide Pin Bellows Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health Brake pad wear produce dust which can cause lung damage IMPORTANT It is important to take care when using chemicals and or cleaning too
45. s 5 Clean the external threaded surface of the adjustment screw Ensure the parts are free from dirt dust debris moisture and corrosion 6 Apply the grease supplied with the spare parts kit to the internal thread off the thrust plate and the external thread of the adjustment screw 7 Remove the thrust plate from the vice 44 Replacement Procedures IMPORTANT Do not cross thread the thrust plate and the adjustment screw 8 By hand hold the thrust plate in position against the adjustment screw Insert Haldex special tool P N 95232 Torx 55 into the reset shaft and carefully turn anti clockwise as the adjustment screw turns carefully engage the thrust plate threads onto the adjustment screw Be careful not to cross thread the parts if the thread becomes tight or locks turn the reset shaft clockwise to release the thrust plate then try again A clicking sound will be heard and felt when turning the reset shaft anti clockwise See figure 45 EI Ed E E z GO b Figure 45 Loading the thrust plate 9 Shortly after the threads are engaged ensure that the two thrust plate guide pins correctly locate in their calliper holes 10 Continue to retract the thrust plate until the dimension between the thrust plate inner pad face and the calliper outer pad face is 70 mm as per figure 45 Replacement Procedures 45 IMPORTANT Ensure that the bellows is correctly seated and undamaged Failure to do so ma
46. s 95230 95423 95222 95219 and 95220 as shown in figure 56 12 Once fitted correctly turn the threaded tool clockwise which will pull out the composite bushing Figure 56 Remove the trailing side composite bushing Replacement Procedures 51 5 5 3 Cleaning IMPORTANT Use a vacuum cleaner to clean surfaces Do not use compressed air IMPORTANT It is important to take care when using chemicals and or cleaning tools e g knife brush etc This to avoid damage or displacement of hoses seals and other components 1 Clean the bearing bush bellows sealing surfaces of the calliper to ensure they are free from dirt moisture corrosion and damage See figure 57 2 If the sealing surfaces have lost their protective surface coating apply smear a small amount of general purpose grease over the whole area so when parts are refitted the grease will provide corrosion protection ModulT_043 Figure 57 Clean the calliper bearing bushing mating surfaces 52 Replacement Procedures 5 5 4 Install Slide Function Assembly IMPORTANT Only use Haldex special tools where specified 1 Carefully follow steps 8 and 9 below to install the two leading bearings F and the spacer G and trailing composite bushing H see figure 58 ModulT_065 Figure 58 Install the leading slide bearings and trailing side bushing 2 To install the two new bearings F and the new spacer G on the leading side assemble 9
47. tated and pushed fully into its correct sealing position Failure to do so may compromise the life of the brake See Figure 10 Figure 10 Correct fitment of the protective plug 3 4 1 Mounting of the wheel Make sure that the brake hoses are in good condition that they are layed ducted and fastened correctly 1 Check the free rolling resistance The disc brake must not be obstructed in any way 2 Mount the wheel see Figure 11 ModulT_007 Figure 11 Mount the wheel Initial and Final Procedures 15 3 4 2 Lowering of the vehicle axle If the disc brake is equipped with a parking brake function ensure that the brake system is pressurised that the spring brake chamber is fully engaged and mechanically secured in the active position See the vehicle manufacturer s instructions ModulT_003 Figure 12 Mechanically secure in the active position IMPORTANT Apply air to the parking brake Make sure that there is sufficient air in the system min 6 bar 1 Activate the parking brake if fitted with a spring brake chamber 2 Lift the axles so that the stands can be removed 3 Carefully lower the vehicle to the ground 4 Remove the wheel blocks see Figure 13 ModulT_056 Figure 13 Remove the stops IMPORTANT After carrying out any work always finish with a general checking operation followed by test drive to ensure that the brakes are working correctly
48. te on two points see figure 34 Then fit the outer brake pad A 4 Check that the contact surfaces on the pad retainer spring bracket are free from dirt and corrosion Clean if necessary 5 Install a new spring bracket C into the calliper and ensure it is seated in position correctly ModulT_075 Figure 34 Install the brake pads Replacement Procedures 35 locking position Upon assembly ensure the pad retainer spring bracket is in its correct 6 Fit the new pad springs A and the pad retainer B The pad retainer is fitted by first locating the pad retainer in the housing end in the calliper aperture then compressing the pad springs and locating the pad retainer slot over the calliper latch finally slide the pad retainer under the calliper latch until the spring bracket pops into its locking position see figure 35 If necessary use a tool to help push the pad retainer into position ModulT_027 Figure 35 Installation brake pad components 5 2 4 Final Procedure To conclude this procedure read and follow chapters 1 3 3 Function Test to ensure that the disc brake is working correctly 2 3 4 Final Procedure 36 Replacement Procedures 5 3 Replacement of Brake Chamber 5 3 1 Initial Procedure Read and follow chapter 3 2 Initial Procedure prior to removing the spring brake chamber 5 3 2 Remove Brake Chamber be hazardous to your health Brake pad wear produce dust whi
49. the wheel following chapter 3 2 Initial Procedure 3 Remove brake pads according to chapter 5 2 2 Remove Brake Pads ModulT_009 4 Look for unusual conditions like excessive corrosion and high heat cycles i e Figure 14 Inspection of the Visual Wear Indicator delamination discolouration etc If found refer to chapter 8 Fault Finding for actions 5 On both brake pads measure the distance from back plate A to wear surface B of EE Ean the brake pad in four places see figure 15 E Minimum permitted lining thickness friction material is 2 mm 6 Check the condition of the back plate A 7 Replace brake pads if they are worn out or b gt 2mm i if they are expected to be so before the next d inspection For replacement follow the instructions in chapter 5 2 Replacement of Brake Pads 8 If the inspection is completed satisfactorily conclude by following chapters 5 2 3 Install Brake Pads and 5 2 4 Final Procedure Figure 15 Measuring the pad wear condition ModulT_010 NOTE This brake disc inspection check procedure is only a general guide refer to the vehicle manufacturers documentation for specific brake disc information and instruction Inspection Procedures 19 4 3 4 General Brake Pad clearance check Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health Brake pad wear produce dust which can cause lung damage Che
50. tructions for more information e Is the brake disc s run out within specified If not then probably need to change the parameters brake disc See the vehicle manufacturer s instructions for more information 66 9 Component List and Exploded view Component List and Exploded view 9 1 Component List Haldex ModulT Air Disc Brake 010 020 030 040 050 060 070 080 090 100 120 130 140 150 160 170 180 190 210 Air Disc Brake Assemblies Complete Left Hand amp Right Hand Carrier Bearings Leading Slide Function Spacer Leading Slide Pin Slide Pin Bolt Leading Protective Cup Composite Bushing Trailing Slide Function Trailing Slide Pin Trailing Protective Cup Reset Shaft Complete Reset Shaft Protection Plug Bellows Slide Function Brake Pads Pad Springs Spring Bracket Pad Retainer Adjustment Screw Bellow Thrust Plate Component List and Exploded view 67 9 2 Exploded view f A lof 160 ModulT_052 Haldex develops and provides reliable and innovative solutions with focus on brake and air suspension products to the global commercial vehicle industry Listed on the Stockholm Stock Exchange Haldex has annual sales of 3 7 billion SEK and employs 2 200 people 2011 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
51. ws Gk e N N Inspection Procedures 17 4 3 Inspections 4 3 1 Daily Safety Check Contact the Service Workshop immediately if there is any sign of reduced performance or the brakes do not work properly 1 Check that the brakes function properly before driving and that they work effectively and smoothly 2 Check that the service and parking brake function is effective by trying to drive the vehicle with the service and parking brake applied 4 3 2 Check overall condition 1 Make sure you have good lighting conditions 2 Inspect visible parts of the brake and its components Look for Damage Collection of debris Corrosion Overheating signs Cracks in brake discs Unusual wear etc 18 Inspection Procedures 4 3 3 Check Brake Pad wear f Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health Brake pad wear produce dust which can cause lung damage NOTE Step 1 in this procedure only indicate the pad wear of the outer pad For a full examination do all steps 1 Inspect the position of the Visual Wear Indicator VWI as located and shown in figure 14 This check can be done with either the wheel fitted or removed The VWI provides an indication of pad wear condition it does not provide an accurate measurement of pad wear on both pads To obtain and accurate wear measurement of both pads continue with the instructions which follow 2 Remove
52. y compromise the life of the disc brake 11 Assemble Haldex special tool P N 95225 and P N 95226 load the assembled special tools into the calliper end of the adjustment screw bellows See figure 46 12 By hand firmly press on the special tool with equal and parallel force so that the adjustment screw bellows is pressed into position within the calliper 13 The special tool can be removed rotated and gt then reapplied to aid the equal and parallel bellows seating 14 Remove the special tool Check that the bellows is correctly seated all around within the calliper see figure 47 Also re check the bellows is seated correctly on the thrust plate see previous figure 44 Failure to seat the bellows correctly will compromise the life of the brake ModulT_092 Figure 47 Adjustment screw bellows seated OK NOK 15 Retract the thrust plate fully to its inner position by manually turning the reset shaft anti clockwise A clicking sound shall be heard and felt when retracting The stop at fully retracted inner thrust plate position must be distinct but do not exceed 20 Nm in torque or leave it tightened in this position 5 4 5 Final Procedure To conclude this procedure read and follow chapters 1 5 7 3 Install Disc Brake 5 2 3 Install Brake Pads 5 3 3 Install Brake Chamber 3 3 Function Test to ensure that the disc brake is working correctly mn A W N 3 4 Final Pr
53. zardous to your health Brake pad wear produce dust which can cause lung damage IMPORTANT Use a vacuum cleaner to clean surfaces Do not use compressed air 1 Read and follow chapter 3 2 Initial Procedure prior to inspecting the thrust plate guide pins 2 Remove dirt from surfaces as necessary 3 Check that the two thrust plate guide pins E see figure 21 are in their correct position 4 Check that the thrust plate with guide pins are free to move without obstruction 5 Once the inspection is completed satisfactorily conclude by reading and following chapter 3 4 Final Procedure ModulT_015 Figure 21 The two thrust plate guide pins Inspection Procedures 23 4 3 8 Check Actuation Interface be hazardous to your health Brake pad wear produce dust which can cause lung damage Wear respiratory protection in order to avoid inhaling particles which can IMPORTANT It is important to take care when using chemicals and or cleaning tools e g knife brush etc This to avoid damage or displacement of hoses seals and other components IMPORTANT Use a vacuum cleaner to clean surfaces Do not use compressed air This inspection procedure covers both types of brake chamber normal service and spring brake parking chambers 1 Read and follow chapter 3 2 Initial Procedure prior to inspecting the actuation interface 2 Thoroughly clean around the mating surfaces of the brake ch
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