Designer’s Manual · Haldex is an innovator in vehicle technology and supplies proprietary...

Innovative Vehicle Technology

Haldex is an innovator invehicle technology andsupplies proprietary products

for trucks, cars and industrial vehicles on aglobal basis.

Haldex is listed on the Stockholm StockExchange and has annual sales exceeding 6billion SEK with 4,250 employees worldwide.

Designer’s Manual– How to apply and install Automatic Brake Adjusters

84

40

3 E

dt

2/05

.04

Land

skro

na

AUSTRIAHaldex Wien Ges.m.b.H.ViennaTel +43-1 865 16 40Fax +43-1 865 16 40 27e-mail: [email protected]

BELGIUMHaldex N.V.Balegem (Oosterzele)Tel +32 9 363 90 00Fax +32 9 363 90 09e-mail: [email protected]

BRAZILHaldex do BrasilSão PauloTel +55-11 5034 4999Fax +55-11 5034 9515e-mail: [email protected]

CHINAHaldex International Trading Co. Ltd.ShanghaiTel +86-21 6289 44 69Fax +86-21 6279 05 54e-mail: [email protected]

FRANCEHaldex Europe S.A.S.Weyersheim (Strasbourg)Tel +33-3 88 68 22 00Fax +33-3 88 68 22 09e-mail: [email protected]

GERMANYHaldex Brake Products GmbHDenkendorf (Stuttgart)Tel +49-711 934 9170Fax +49-711 934 91740e-mail:[email protected]

Haldex Brake Products GmbHHeidelbergTel +49-622170 30Fax +49-622 170 3400e-mail: [email protected]

INDIAHaldex India LimitedNasikTel +91-253 38 00 91/2/3Fax +91-253 38 07 29e-mail: [email protected]

ITALYHaldex Italia SrlMuggio (Mi)Tel +39-039 278 2350Fax +39-039 796 525e-mail: [email protected]

POLANDHaldex Sp.z.o.o.PraszkaTel +48-34 350 11 00Fax +48-34 350 11 11e-mail: [email protected]

SOUTH KOREAHaldex Korea Ltd.SeoulTel +82-2 2636 7545-7Fax +82-2 2636 75 48e-mail:[email protected]

SPAINHaldex Espãna S. A.Parets del Valles (Barcelona)Tel +34-93 573 10 30Fax +34-93 573 07 28e-mail: [email protected]

SWEDENHaldex Brake Products ABLandskronaTel +46-418 47 60 00Fax +46-418 47 60 01e-mail: [email protected]

UNITED KINGDOMHaldex Ltd.Newton AycliffeTel +44-1325 310 110Fax +44-1325 311 834e-mail: [email protected] Brake Products Ltd.RedditchTel +44-1527 499 499Fax +44-1527 499 500e-mail: [email protected]

USAHaldex Brake Products Corp.Kansas City MOTel +1-816 891 2470Fax +1-816 891 9447e-mail: [email protected].

Designer’s manualDesigner’s manual 1

ContentsIntroduction ____________________________________ 2

Requirements for Haldex Automatic Brake Adjusters _ 3

Input load ______________________________________ 3 – 4

Release Torque _________________________________ 5

Brake lining to drum clearance __________________ 5

Adjustment portion _____________________________ 5

Brake Chamber ________________________________ 6 – 7

• Anti compound device _____________________________________ 6

• Door-/bus stop brake ______________________________________ 7

• Positioning of Brake Chamber ______________________________ 7

Control arm ____________________________________ 8 – 10

• Installation adjustments ___________________________________ 8 – 9

• Three categories of control arm ____________________________ 9 – 10

Fixed attachment __________________________________________ 9

Flexible attachment ________________________________________ 10

Floating attachment ________________________________________ 10

Anchor Bracket ________________________________ 11

• Fixed and floating attachment ______________________________ 11

• Flexible attachment ________________________________________ 11

Lubrication_____________________________________ 11 – 12

• Grease ____________________________________________________ 11

• Long term greased ABA’s __________________________________ 11

• Greaseable ABA’s __________________________________________ 12

External return springs _________________________ 12

Quality control _________________________________ 13

Check list after initial installation ________________ 14

Release torque measurement instructions __________ 15

Technical Data _________________________________ 15 – 16

DESIGNER’S MANUALAutomatic Brake Adjusters

Docs No. 9811912Issue 02

16

● ABA axial clearance on S-cam splines: 0,5-2,0mm.

● Haldexol Grease: Calcium base (water repellent), EPadditive, NLGI 2.Temperature range -40+100°C.Separation (dropping) point 140°C.Haldexol is fully compatible with Lithium basedgrease (chassis grease).

● ABA operating temperature range: -40 +80°C. Peaktemperature 110°C.

● Automatic lubrication: Std. auto-lube liquid-grease,max. input 0,1-0,2cm3 / 3-6hrs dep. on installation.

● Coating: All types of paint are suitable for coating ofHaldex ABA’s. The ABA must be clean beforecoating. (According to demand, follow actual paintmanufacturer’s instructions.)

● Max. flexing (= bushing to S-cam clearance (A+B)

+ flexing) exposed to control arm fixed style: 0,5mm.

50 %50 %}0,5 – 2mm

A

B

Control arm fixed style.


max0,5mmflexing

0,5 – 2mm

Control arm flexing/floating style.

Designer’s manualDesigner’s manual2

Introduction

Haldex Designer’s Manual for Automatic Brake Adjusters (ABA) is adocument including requirements and tips for design of applicationsand installation of Haldex Automatic Brake Adjuster in axle/vehicleapplications. To ensure safe operation and to achieve optimum life-time for the product it is of outmost importance that the installationof the ABA should follow the requirements and advice given.

15

Technical Data● Input load: Acc. to SAE J1462, rated torque 2600Nm.

● Max. input torque: 3000Nm.

● Release torque at 90° rotation of the S-cam shaft:Max. 20Nm. (Measured during the return stroke –not on the apply stroke).

● Adjustment portion: AA1 8% of excess. S-ABA 3% ofexcess per application.

● Deadjustment torque, new ABA: Min 32Nm.Replacement / overhaul limit: 18Nm.Deadjustment torque is measured by checking torqueneeded to turn the worm shaft hexagon head anticlockwise. Read off the torque wrench at the first”click over”.

Release torque measurementinstructions

Turn ~110° in direction of apply, read off when passing90° on the return stroke. (Measure 3 times and average).Max. release torque at 90° rotation = 20Nm.

~110°

90°

0° (= rest position)


Remove brake adjuster and drum. Fit special tool 76977 to the S-cam.Attach a torque spanner (~0–70Nm)

76977

Deadjustment torque measurement.


Requirements for HALDEX Automatic Brake AdjustersThe following is intended to ensure safe operation and to achive optimum life time.

● Braking distribution: Each wheel / axle on the vehicle,and each vehicle in the vehicle combination mustperform braking in relation to the weight it iscarrying.

To ignore this will result in incorrect brake distribu-tion between axles in a combination, which normallyis noticed as overheating on some axle(s) and lowtemperature on other axles during/after retardation.Also, there will not be maximum retardation on thevehicle / vehicle combination (truck / trailer) as someaxle(s) is (are) not performing as intended. Installa-tion of ABA’s (Change from Manual’s or nonfunctional ABA’s) will put focus on (not create-)incorrect balance between axles / vehicles.

Input load● Maximum input load must follow SAE J1462,

@ rated torque 2600Nm.

Extract from SAE J1462:

NOTE! This is just an excerpt - important to followthe complete instruction for test performance !

7.2 Gear set and Automatic Adjustment Integrity Test

7.2.1 To simulate lining wear, the worm wheel shall be rotated in the samedirection that the load is applied at a rate of 0,5 degrees per 160 cycles of testoperation.

7.2.2 The slack adjuster test cycle shall be run in the following sequence:

TABLE 1-SLACK ADJUSTER TEST CYCLE SEQUENCENumber of cycles Percent of Rated Torque

155 000 4035 000 608 000 801 500 100

9. Brake distribution between wheels/axles in balance?An overheated wheel/axle/vehicle in a combinationmight be an indication on ”over braking” on theoverheated axle, but it could also be ”under braking”on other axles/wheels not working properly. Thisis normally not caused by the ABA.Consult the vehicle manufacturers instructions.

10. ABA function check after installation: Turn the wormshaft 180° anticlockwise. Let the spanner stay on thehexagon. Apply/release the brake ex. 5 times – thespanner moves clockwise on every return stroke = OK.

8. Control arm, floating style: The peg bolt is correctlyfitted = exposed ~2mm through the plastic insert.

Check list after initial installation1. Max. flexing exposed to fixed style control arm

within specification?

2. The ABA freely returns to its definitive rest posi-tion on the return stroke?

3. The control arm is correctly installed/adjusted andnot exposed to excessive loads in any direction? Tocheck this, remove the clevis pin. (If spring brakeactuator is present, this must be fully released = min.6 bar) If the clevis pin hole and the ABA bushingholes stay aligned, the installation is correct. If thebrake chamber push rod or the ABA moves in eitherdirection – the installation needs to be corrected.(Follow Haldex installation instructions.)

4. The anchor bracket is correctly installed?

5. ABA axial clearance on the S-cam splines is withinspecification?

6. Recommended anti compound function installedwhen spring brake is used?

7. Max. effective brake chamber stroke (specified bythe brake chamber manufacturer) not exceeded withthe brake fully applied? (See specification for actualbrake chamber.)

peg bolt

anchor bracket

control arm~ 2mm


28,5

56

0,24

0,19

0,16

0,38

Offset

L-dimension (mm)L-145

Relation offset/L-dimension

L-150

L-120

L-180

13

● Relationship between offset and L-dimension affectsthe ABA life time. Higher value = increased stress.

Relation: 0-0,20 = OK.0,20-0,35 = Worm gear exposedto excessive wear.0,35-0,50 = Lifetime affected.>0,50 = Not approved.

Example: Offset 56mm. L-dimension 145mm.56 =0,38145

Quality controlAfter the assembly 100% of the ABAs goes through amultiple high level quality / function test program. Afterapproval a ”G” is automatically stamped in the rear cover.

WARNING!

Do not use impact wrench on the worm shafthexagon – internal components may bedamaged! = Warranty invalid.

WARNING!

Coil spring force specified is for initialadjustment of a new spring and will normallydecrease during transportation and operationbut should not, even if it is below specificationfor initial adjustment, be readjusted. The ABAis ”sealed” at the factory by a rivet locking therear cover.Adjustment with new spring only!


External return springsExternal return spring (as in the picture) attached tothe ABA arm does not affect the automatic adjustmentfunction, but is neighter required nor recommendedby Haldex.

Release TorqueMax. release torque at 90° S-camshaft rotation 20Nm(see page 15).

Brake lining to drumclearanceLining to drum clearance is designed with the inten-tion of achieveing the shortest possible brake chamberstroke (= low air consumption) without running therisk of dragging brakes. The requested clearance isachieved by selecting a suitable position/notch size inrelation to actual S-cam lift, type of service and brakedesign. (Position/notch size is determined accordingto a calculation performed by Haldex). In case arequested clearance is not specified by the axlemanufacturer, Haldex’s recommendation is 0,8-1,0mm.

Adjustment portionHaldex AA1 compensates for ~8% of measuredexcessive clearance per application. Haldex S-ABA isslower, ~3%, which is an advantage in case of a temporarywheel brake temperature peak - the adjustment functiondoes not compensate as quickly for increased clearance.(For brakes with continuously high temperature bothAA1 and S-ABA will adjust to nominal clearance.)

NOTE!Max. push rod travel allowed by the brake chamber manufacturer should not be exceeded at any level ofbrake application! Refer to actual brake chamber force-chart!

Clearance between lining and brake drum is determined in relation to brake installation design. Clearance,angular S-cam free travel and brake chamber push rod free travel are in straight relationship to each other.Depending on difficulties to measure clearance (sometimes brake drum ovality exceeds actual clearance), freetravel is always used as a reference regarding on-vehicle/axle checks.

S-ABA: Plug or grease nipple threads, M10x1, areavailable on top of the front cover (28°). Grease nippleis available in straight version.

AA1: Plug or grease nipple threads, M10x1 (or M8x1),are available in the following locations: below the rearcover (0°), below the front cover (180°) or on top (atthe left side) of the front cover (20°). Grease nipple isavailable in straight version.

Greaseable ABAs

Greasable ABAs are equipped with M10x1 (or M8x1)threads for fitting a plug or a grease nipple in variousstandard positions. ABAs with a plug: The endcustomer has the advantage to choose whether he wantsto keep the ABA long term greased or, depending onsevere driving conditions etc, retrofit with a greasenipple and perform periodical greasing.

Plug Grease nipple

20°

180° 0°

28° 28°

Note! Once the ABA has been equipped with agrease nipple and been greased, the greasing hasto continue throughout the adjusters lifetime,on a regular basis.


Example. TrailerExample. Truck/Bus

Brake ChamberTo approach max. retardation the ABA installation mustbe designed to have fully applied brakes with the brakechamber push rod travel safely within the full power bandspecified by the brake chamber manufacturer. The brakechamber push rod should be adjusted to have 90° betweenthe ABA inclination line and the brake chamber pushrod at 50% of the total brake chamber stroke.

90°

50% 50%em

erg

ency

line

(sup

ply

)

serv

ice

line

servicebrakeline

servicebrakeline

parking brake line

park brake line

servicebrake line

anticompoundvalve

11

➞➞➞➞

Anti compound device

To avoid excessive forces in axle components when aspring brake chamber is used, an anti compound functionis necessary. This to avoid simultaneous application ofservice and parking brake.

NOTE! Sketches below are just examples – consultactual authority for approval!

Lubrication

Grease

The ABA is greased with genuine water repellentHaldexol grease from the factory. Regardless of whetherthe ABA is long term greased, equipped with a plug or agrease nipple the assembly greasing process is the same.

Haldexol is Calcium based and is fully compatible withLithium based grease (= chassis grease).

Long term greased ABA’s

Long term greased ABA’s are ”sealed for life” anddelivered without a fitting hole for plug or grease nipple.

Flexible attachmentThe anchor strap must be designed to protect thecontrol arm from loads caused by radial S-cam shaftmovement.

Anchor Bracket

Fixed and floating attachmentThe anchor bracket must be designed to minimize thetransfer of any flexibility to the control arm. No flexingis allowed when performing deadjustment torque checkon a new ABA (=max. readjustment torque possible).


Example. Flexible attachment

flexible strap(anchor bracket)

A

nut

peg bolt

washeranchor bracket

peg boltnut

washer

A

(flat) peg bolt

anchorbracket

peg bolt

Example. Floating attachment

B

clearance inanchor bracket tocontrol arm joint

anchor bracket

➞➞➞ ➞

Positioning of brake chamber

The brake chamber bracket must be positioned to havethe brake chamber:

A) level with actual L-dimension, i.e. to allow the pushrod clevis-hole to be in line with the ABA bushing hole.

B) in line with the ABA on actual L-dim. level to avoidside thrust on the ABA and the brake chamber pushrod. Neither the bottom of the clevis-U nor the end ofthe push rod are allowed to touch the ABA-arm at anybrake chamber stroke.

L-dimension

C C

A

A

CC CCB B

Door- / bus stop brake

In case door- / bus stop activation (partial apply) of anaxle is used, application pressure is recommended tobe max. 2,5bar. Consult actual authority for legislation.

Floating attachmentA) Control arm including plastic insert used in acombination with anchor bracket / peg bolt. Theplastic insert is a wearing part exposed to wear in allinstallations. The level of wear depends on the relativemovement and/or force transferred through the pegbolt/plastic insert joint.

The portion of clearance in the floating control armto anchor bracket joint will be an addition not onlyto the free stroke, but also to the total stroke withfully applied brakes. Max. effective brake chamberstroke allowed by the brake chamber manufacturermust not be exceeded. It is recommended to selectone position lower for a floating attachment incomparison with fixed/flexible attachment. Anincorrect installation will/might increase the wear andforces exposed to the control arm = risk of break-down.See Haldex installation instructions for actual ABA.

B) Control arm of U/saddle type used together withcorresponding fabricated anchor bracket. In case ofexcessive flexing, this saddle design is preferred byHaldex to be used as a preference before all otherattachment versions, as it relieves the anchor bracketof both lateral and radial loads. This solution ispatented by Haldex.

Flexible attachmentControl arm with threaded stud used together withstrap (anchor bracket) with longitudinal slot for in-stallation adjustments.

Designer’s manualDesigner’s manual8 9

Example. Fixed attachment

axle attachment

anchor bracket

Control armThe control arm (A) is designed to be a reference-linkbetween the actual brake chamber push rod positionand the automatic adjustment device and also to trans-fer forces needed to perform automatic adjustment. Thecontrol arm is not designed to carry any load betweenthe S-cam and the axle beam/brake carrier.

To achieve a correct adjustment cycle, it is importantthat the S-cam/ABA/brake chamber push rod assemblyfreely returns fully to the rest position.

Installation adjustments

Haldex AA1: The control arm must be fixed in its restposition, i.e. fully pushed in the direction of applicationwhen the brake chamber push rod is (fully) in its restposition. No remaining forces are allowed on thecontrol arm neither from the brake chamber returnspring nor from external springs. (See Haldex Installa-tion Instructions.)

A

A

NOTE! In case an axle is delivered with AA1’s fitted to the S-cam, but without brake chambers,installation adjustments must be performed after the brake chambers have been fitted!

Haldex S-ABA: Control arm installation adjustmentis not needed. To avoid damage to the control arm atmaximum brake chamber push rod travel, it isimportant to fix the control arm at a safe angulardistance from the front cover area. (See Haldex In-stallation Instructions.)

Three categories of control arm

Fixed attachmentControl arm with a linear or radial slot. The controlarm is attached directly to the corresponding anchorpoint. Max. flexing of the fixed style control arm:0,5mm. If >0,5mm a flexible or floating attachmentshould be used! For details, see Technical data page15.


Example. Flexible attachment

flexible strap(anchor bracket)

A

nut

peg bolt

washeranchor bracket

peg boltnut

washer

A

(flat) peg bolt

anchorbracket

peg bolt

Example. Floating attachment

B

clearance inanchor bracket tocontrol arm joint

anchor bracket

➞➞➞ ➞

Positioning of brake chamber

The brake chamber bracket must be positioned to havethe brake chamber:

A) level with actual L-dimension, i.e. to allow the pushrod clevis-hole to be in line with the ABA bushing hole.

B) in line with the ABA on actual L-dim. level to avoidside thrust on the ABA and the brake chamber pushrod. Neither the bottom of the clevis-U nor the end ofthe push rod are allowed to touch the ABA-arm at anybrake chamber stroke.

L-dimension

C C

A

A

CC CCB B

Door- / bus stop brake

In case door- / bus stop activation (partial apply) of anaxle is used, application pressure is recommended tobe max. 2,5bar. Consult actual authority for legislation.

Floating attachmentA) Control arm including plastic insert used in acombination with anchor bracket / peg bolt. Theplastic insert is a wearing part exposed to wear in allinstallations. The level of wear depends on the relativemovement and/or force transferred through the pegbolt/plastic insert joint.

The portion of clearance in the floating control armto anchor bracket joint will be an addition not onlyto the free stroke, but also to the total stroke withfully applied brakes. Max. effective brake chamberstroke allowed by the brake chamber manufacturermust not be exceeded. It is recommended to selectone position lower for a floating attachment incomparison with fixed/flexible attachment. Anincorrect installation will/might increase the wear andforces exposed to the control arm = risk of break-down.See Haldex installation instructions for actual ABA.

B) Control arm of U/saddle type used together withcorresponding fabricated anchor bracket. In case ofexcessive flexing, this saddle design is preferred byHaldex to be used as a preference before all otherattachment versions, as it relieves the anchor bracketof both lateral and radial loads. This solution ispatented by Haldex.

Flexible attachmentControl arm with threaded stud used together withstrap (anchor bracket) with longitudinal slot for in-stallation adjustments.


Example. TrailerExample. Truck/Bus

Brake ChamberTo approach max. retardation the ABA installation mustbe designed to have fully applied brakes with the brakechamber push rod travel safely within the full power bandspecified by the brake chamber manufacturer. The brakechamber push rod should be adjusted to have 90° betweenthe ABA inclination line and the brake chamber pushrod at 50% of the total brake chamber stroke.

90°

50% 50%

emer

gen

cy li

ne(s

upp

ly)

serv

ice

line

servicebrakeline

servicebrakeline

parking brake line

park brake line

servicebrake line

anticompoundvalve

11

➞➞➞➞

Anti compound device

To avoid excessive forces in axle components when aspring brake chamber is used, an anti compound functionis necessary. This to avoid simultaneous application ofservice and parking brake.

NOTE! Sketches below are just examples – consultactual authority for approval!

Lubrication

Grease

The ABA is greased with genuine water repellentHaldexol grease from the factory. Regardless of whetherthe ABA is long term greased, equipped with a plug or agrease nipple the assembly greasing process is the same.

Haldexol is Calcium based and is fully compatible withLithium based grease (= chassis grease).

Long term greased ABA’s

Long term greased ABA’s are ”sealed for life” anddelivered without a fitting hole for plug or grease nipple.

Flexible attachmentThe anchor strap must be designed to protect thecontrol arm from loads caused by radial S-cam shaftmovement.

Anchor Bracket

Fixed and floating attachmentThe anchor bracket must be designed to minimize thetransfer of any flexibility to the control arm. No flexingis allowed when performing deadjustment torque checkon a new ABA (=max. readjustment torque possible).


External return springsExternal return spring (as in the picture) attached tothe ABA arm does not affect the automatic adjustmentfunction, but is neighter required nor recommendedby Haldex.

Release TorqueMax. release torque at 90° S-camshaft rotation 20Nm(see page 15).

Brake lining to drumclearanceLining to drum clearance is designed with the inten-tion of achieveing the shortest possible brake chamberstroke (= low air consumption) without running therisk of dragging brakes. The requested clearance isachieved by selecting a suitable position/notch size inrelation to actual S-cam lift, type of service and brakedesign. (Position/notch size is determined accordingto a calculation performed by Haldex). In case arequested clearance is not specified by the axlemanufacturer, Haldex’s recommendation is 0,8-1,0mm.

Adjustment portionHaldex AA1 compensates for ~8% of measuredexcessive clearance per application. Haldex S-ABA isslower, ~3%, which is an advantage in case of a temporarywheel brake temperature peak - the adjustment functiondoes not compensate as quickly for increased clearance.(For brakes with continuously high temperature bothAA1 and S-ABA will adjust to nominal clearance.)

NOTE!Max. push rod travel allowed by the brake chamber manufacturer should not be exceeded at any level ofbrake application! Refer to actual brake chamber force-chart!

Clearance between lining and brake drum is determined in relation to brake installation design. Clearance,angular S-cam free travel and brake chamber push rod free travel are in straight relationship to each other.Depending on difficulties to measure clearance (sometimes brake drum ovality exceeds actual clearance), freetravel is always used as a reference regarding on-vehicle/axle checks.

S-ABA: Plug or grease nipple threads, M10x1, areavailable on top of the front cover (28°). Grease nippleis available in straight version.

AA1: Plug or grease nipple threads, M10x1 (or M8x1),are available in the following locations: below the rearcover (0°), below the front cover (180°) or on top (atthe left side) of the front cover (20°). Grease nipple isavailable in straight version.

Greaseable ABAs

Greasable ABAs are equipped with M10x1 (or M8x1)threads for fitting a plug or a grease nipple in variousstandard positions. ABAs with a plug: The endcustomer has the advantage to choose whether he wantsto keep the ABA long term greased or, depending onsevere driving conditions etc, retrofit with a greasenipple and perform periodical greasing.

Plug Grease nipple

20°

180° 0°

28° 28°

Note! Once the ABA has been equipped with agrease nipple and been greased, the greasing hasto continue throughout the adjusters lifetime,on a regular basis.


28,5

56

0,24

0,19

0,16

0,38

Offset

L-dimension (mm)L-145

Relation offset/L-dimension

L-150

L-120

L-180

13

● Relationship between offset and L-dimension affectsthe ABA life time. Higher value = increased stress.

Relation: 0-0,20 = OK.0,20-0,35 = Worm gear exposedto excessive wear.0,35-0,50 = Lifetime affected.>0,50 = Not approved.

Example: Offset 56mm. L-dimension 145mm.56 =0,38145

Quality controlAfter the assembly 100% of the ABAs goes through amultiple high level quality / function test program. Afterapproval a ”G” is automatically stamped in the rear cover.

WARNING!

Do not use impact wrench on the worm shafthexagon – internal components may bedamaged! = Warranty invalid.

WARNING!

Coil spring force specified is for initialadjustment of a new spring and will normallydecrease during transportation and operationbut should not, even if it is below specificationfor initial adjustment, be readjusted. The ABAis ”sealed” at the factory by a rivet locking therear cover.Adjustment with new spring only!


Requirements for HALDEX Automatic Brake AdjustersThe following is intended to ensure safe operation and to achive optimum life time.

● Braking distribution: Each wheel / axle on the vehicle,and each vehicle in the vehicle combination mustperform braking in relation to the weight it iscarrying.

To ignore this will result in incorrect brake distribu-tion between axles in a combination, which normallyis noticed as overheating on some axle(s) and lowtemperature on other axles during/after retardation.Also, there will not be maximum retardation on thevehicle / vehicle combination (truck / trailer) as someaxle(s) is (are) not performing as intended. Installa-tion of ABA’s (Change from Manual’s or nonfunctional ABA’s) will put focus on (not create-)incorrect balance between axles / vehicles.

Input load● Maximum input load must follow SAE J1462,

@ rated torque 2600Nm.

Extract from SAE J1462:

NOTE! This is just an excerpt - important to followthe complete instruction for test performance !

7.2 Gear set and Automatic Adjustment Integrity Test

7.2.1 To simulate lining wear, the worm wheel shall be rotated in the samedirection that the load is applied at a rate of 0,5 degrees per 160 cycles of testoperation.

7.2.2 The slack adjuster test cycle shall be run in the following sequence:

TABLE 1-SLACK ADJUSTER TEST CYCLE SEQUENCENumber of cycles Percent of Rated Torque

155 000 4035 000 608 000 801 500 100

9. Brake distribution between wheels/axles in balance?An overheated wheel/axle/vehicle in a combinationmight be an indication on ”over braking” on theoverheated axle, but it could also be ”under braking”on other axles/wheels not working properly. Thisis normally not caused by the ABA.Consult the vehicle manufacturers instructions.

10. ABA function check after installation: Turn the wormshaft 180° anticlockwise. Let the spanner stay on thehexagon. Apply/release the brake ex. 5 times – thespanner moves clockwise on every return stroke = OK.

8. Control arm, floating style: The peg bolt is correctlyfitted = exposed ~2mm through the plastic insert.

Check list after initial installation1. Max. flexing exposed to fixed style control arm

within specification?

2. The ABA freely returns to its definitive rest posi-tion on the return stroke?

3. The control arm is correctly installed/adjusted andnot exposed to excessive loads in any direction? Tocheck this, remove the clevis pin. (If spring brakeactuator is present, this must be fully released = min.6 bar) If the clevis pin hole and the ABA bushingholes stay aligned, the installation is correct. If thebrake chamber push rod or the ABA moves in eitherdirection – the installation needs to be corrected.(Follow Haldex installation instructions.)

4. The anchor bracket is correctly installed?

5. ABA axial clearance on the S-cam splines is withinspecification?

6. Recommended anti compound function installedwhen spring brake is used?

7. Max. effective brake chamber stroke (specified bythe brake chamber manufacturer) not exceeded withthe brake fully applied? (See specification for actualbrake chamber.)

peg bolt

anchor bracket

control arm~ 2mm


Introduction

Haldex Designer’s Manual for Automatic Brake Adjusters (ABA) is adocument including requirements and tips for design of applicationsand installation of Haldex Automatic Brake Adjuster in axle/vehicleapplications. To ensure safe operation and to achieve optimum life-time for the product it is of outmost importance that the installationof the ABA should follow the requirements and advice given.

15

Technical Data● Input load: Acc. to SAE J1462, rated torque 2600Nm.

● Max. input torque: 3000Nm.

● Release torque at 90° rotation of the S-cam shaft:Max. 20Nm. (Measured during the return stroke –not on the apply stroke).

● Adjustment portion: AA1 8% of excess. S-ABA 3% ofexcess per application.

● Deadjustment torque, new ABA: Min 32Nm.Replacement / overhaul limit: 18Nm.Deadjustment torque is measured by checking torqueneeded to turn the worm shaft hexagon head anticlockwise. Read off the torque wrench at the first”click over”.

Release torque measurementinstructions

Turn ~110° in direction of apply, read off when passing90° on the return stroke. (Measure 3 times and average).Max. release torque at 90° rotation = 20Nm.

~110°

90°



Remove brake adjuster and drum. Fit special tool 76977 to the S-cam.Attach a torque spanner (~0–70Nm)

76977

Deadjustment torque measurement.


ContentsIntroduction ____________________________________ 2

Requirements for Haldex Automatic Brake Adjusters _ 3

Input load ______________________________________ 3 – 4

Release Torque _________________________________ 5

Brake lining to drum clearance __________________ 5

Adjustment portion _____________________________ 5

Brake Chamber ________________________________ 6 – 7

J Anti compound device _____________________________________ 6

J Door-/bus stop brake ______________________________________ 7

J Positioning of Brake Chamber______________________________ 7

Control arm ____________________________________ 8 – 10

J Installation adjustments ___________________________________ 8 – 9

J Three categories of control arm ___________________________ 9 – 10

Fixed attachment __________________________________________ 9

Flexible attachment ________________________________________ 10

Floating attachment ________________________________________ 10

Anchor Bracket ________________________________ 11

J Fixed and floating attachment _____________________________ 11

J Flexible attachment _______________________________________ 11

Lubrication_____________________________________ 11 – 12

J Grease ___________________________________________________ 11

J Long term greased ABA’s __________________________________ 11

J Greaseable ABA’s _________________________________________ 12

External return springs _________________________ 12

Quality control _________________________________ 13

Check list after initial installation ________________ 14

Release torque measurement instructions __________ 15

Technical Data _________________________________ 15 – 16

DESIGNER’S MANUALAutomatic Brake Adjusters

Docs No. 9811912Issue 02

16

● ABA axial clearance on S-cam splines: 0,5-2,0mm.

● Haldexol Grease: Calcium base (water repellent), EPadditive, NLGI 2.Temperature range -40+100°C.Separation (dropping) point 140°C.Haldexol is fully compatible with Lithium basedgrease (chassis grease).

● ABA operating temperature range: -40 +80°C. Peaktemperature 110°C.

● Automatic lubrication: Std. auto-lube liquid-grease,max. input 0,1-0,2cm3 / 3-6hrs dep. on installation.

● Coating: All types of paint are suitable for coating ofHaldex ABA’s. The ABA must be clean beforecoating. (According to demand, follow actual paintmanufacturer’s instructions.)

● Max. flexing (= bushing to S-cam clearance (A+B)

+ flexing) exposed to control arm fixed style: 0,5mm.

50 %50 %}0,5 – 2mm

A

B



max0,5mmflexing

0,5 – 2mm

Control arm flexing/floating style.

Designer’s Manual · Haldex is an innovator in vehicle technology and supplies proprietary...

Documents

Transcript of Designer’s Manual · Haldex is an innovator in vehicle technology and supplies proprietary...