L31171 Rev. 11/05 - WMFleetParts.com
Contents
1. FIG 24 INCORRECT WHEN BRAKES ARE APPLIED PARKING OR 60 PSI 4 BAR SERVICE FIG 25 MOUNTING SURFACE INCORRECT WHEN BRAKES ARE APPLIED c PARKING OR 60 PSI a 4 BAR SERVICE ROD 15 Piggyback Installation Instructions TO REMOVE PIGGYBACK FROM SERVICE HOUSING 1 Refer to mechanical release instructions Pages 7 9 for Gold Seal Midland brakes Page 10 for Life Seal brakes WARNING Failure to comply with all instructions for mechanical release may result in the forceful release of the spring which COULD CAUSE DEATH SEVERE PERSONAL INJURY AND OR PROPERTY DAMAGE 2 If vehicle air pressure was used to aid in the caging process exhaust the air pressure Co To prevent sudden release of service housing assembly and to facilitate rotation of air ports or mounting studs the service push rod should be prevented from retracting by clamping the service push rod in place with vise grip pliers as shown Figure 28a b 4 Disconnect the airlines from the air ports on the center body on Remove service clamp assembly Figure 28a b IMPORTANT DO NOT bend the clamp assembly when removing TO INSTALL PIGGYBACK ON SERVICE HOUSING 1 If piggyback is not caged follow steps on Pages 7 9 for Gold Seal Midland brakes Page 10 for Life Seal brakes WARNING Failure to comply with all instructions for mechanical release may result in the forceful release o2. required The brake may need adjustment or it may require component replacement IMPORTANT Depending on the location and type of mounting bracket used it may be difficult to observe the stroke indicator s protrusion once the spring brake or service chamber has been mounted to the vehicle IMPORTANT When disassembly of the Haldex Spring Brake is required consult the Haldex Instructions for Mechanical Release and Diaphragm Replacement See Pages 7 9 for Gold Seal Midland brakes Page 10 for Life Seal brakes TABLE 6 RECOMMENDED BRAKE RE ADJUSTMENT STROKE TYPE RATED STROKE RE ADJUST STROKE SIZE INCHES MILLIMETERS INCHES MILLIMETERS 9 1 75 44 1 38 35 12 1 75 44 1 38 35 16 2 25 57 1 75 44 16 2 50 64 2 00 51 20 2 25 57 1 75 44 20 2 50 64 2 00 51 20 3 00 76 2 50 64 24 2 25 57 1 75 44 24 2 50 64 2 00 51 24 3 00 76 2 50 64 30 2 50 64 2 00 51 30 3 00 76 2 50 64 36 3 00 76 2 25 57 FIG 38 NOTE LIFE SEAL VIEWS SHOWN TO REPRESENT SEALED BRAKE MODELS THREADED PORTION OF SERVICE PUSH ROD STROKE INDICATOR ORANGE BAND FIG 39 LEADING EDGE OF STROKE INDICATOR MOUNTING FACE OF SERVICE HOUSING 21 Determining Warranty Status Actuator Date Code Change For standardization and consistency Haldex is modifying the date code format on all brake actuators produced after November 1 2004 The date code will remain in the same location on all actuators The new date cod
3. 3 4 44mm 24 2 14 57mm Without brake 4 3 4 44mm 1 3 8 35mm 24 2 1 2 64mm dragging 2 51mm 1 1 2 38mm 24 3 76mm 2 1 2 54mm 1 34 4mm 30 2 12 64mm 2 54mm 1 1 2 38mm 30 3 76mm 2 1 2 64mm 1 3 4 4mm 36 3 76mm 2 1 4 57mm 1 34 4mm Stroke length measured by applying parking brake or 60 PSIG 4 Bar service brake application Long Stroke t Typical setup stroke values NOTICE For special applications consult vehicle brake or brake adjuster manufacturers IMPORTANT Incorrect push rod brake adjuster setup will result in improper brake operation 2 If the setup results in the condition depicted in Figure 24 or Figure 25 the spring brake is misaligned and must be corrected by one or more of the following Figure 24 a shorten push rod b align spring brake on mounting bracket c mount clevis in proper brake adjuster hole Figure 25 a lengthen push rod b align spring brake on mounting bracket c mount clevis in proper brake adjuster hole If misalignment cannot be corrected consult with foundation brake manufacturer for verification of correct mounting bracket position 3 Once the spring brake and push rod are set properly Figure 23 Page 14 release the brakes and follow vehicle manufacturer s instructions for brake adjustment IMPORTANT After installation check for proper emergency operation service operation and brake adjustment
4. in Table 4 below TABLE 4 INSTALLATION TORQUE VALUES TORQUE Mounting Hardware 130 150 Ib ft 177 203 Nm Jam Nut 15 25 Ib ft 20 34 Nm Port Plug or Reducer 15 20 Ib ft 20 27 Nm Air Fittings 25 30 Ib ft 34 40 Nm LIFE SEAL Release Tool Nut 55 Ib ft 74 Nm GOLD SEAL MIDLAND Release Tool Nut 25 35 lb ft 34 47 Nm GOLD SEAL MIDLAND Release Tool Nut in side pocket 5 8 Ib ft 7 11 Nm Carriage Bolt Nuts for clamps 20 30 Ib ft 27 40 Nm Continued on next page FIG 17 BE CERTAIN THAT MOUNTING BRACKET SURFACE IS FREE OF DEBRIS BURRS CRACKS AND IS FLAT WITHIN 1 64 4mm TORQUE SPECIFICATIONS LISTED IN TABLE 4 BELOW ALWAYS MOUNT THE BRAKE CHAMBER DIRECTLY TO THE BRACKET DO NOT INSERT SPACERS WASHERS OR SHIMS BETWEEN MOUNTING BRACKET AND BRAKE HOUSING CAGED SPRING BRAKE FIG 17A 6 2 159mm 41 4mm BRAKE CHAMBER CROSS HATCHED AREA SHOWS MINIMUM MOUNTING BRACKET CONTACT SUPPORT AREA REQUIRED FOR BRAKE CHAMBER MOUNTING 5 8 M16 BOLTS FIG 18 ipd WASHERS AND NUTS D 9 25 6mm STEEL PLATE 7 X 7 178mm x 178mm CONTACT AXLE BRACKET MANUFACTURER FOR YOUR APPLICATION FIG 18A 45 BRAKE CHAMBER MOUNTING RANGE MUST BE WITHIN 45 OF HORIZONTAL 45 13 Combination Spring Brake Installation Instructions Cont d REINFORCEMENT PLATE WELDMENT LOCATIONS CONTACT AXLE BRACKET MANUF
5. spring brake it is necessary to determine the correct service push rod length to ensure proper alignment for efficient operation of the spring brake NOTE Units are furnished with a universal fully threaded push rod and must be cut to the correct length IMPORTANT Place blocks under wheels to prevent vehicle rollaway before removing spring brake actuators NOTE If spring brake unit being replaced is not available to take measurements from follow the procedures listed under Step 5 Page 12 1 Remove worn or non functional spring brake unit from vehicle Determine manufacturer and model of unit to be replaced Refer to that manufacturer s service manual for caging and removal instructions 2 Make sure the spring chamber of the removed actuator is fully released power spring caged and the service brake push rod is fully retracted to zero stroke position i e brake fully released Co Measure and record the J and K dimensions from unit to be replaced Figure 13 J dimension The dimension from bottom of actuator to end of piston rod K dimension The dimension from bottom of actuator to centerline of clevis pin 4 Take measured J dimension Figure 13 from the removed unit and mark push rod of new unit to be cut Continued on next page FIG 13 J M FIG 14 PUSH ROD BRAKE ADJUSTER 3 16 48mm gt lt MAXIMUM PROTRUSION TO ENSURE NO INTERFERENCE WITH BRAK
6. ACTURER FOR YOUR APPLICATION REMOVE BOLTS AFTER WELDS HAVE COOLED ATTACH CLEVIS AND AIR LINES FIG 19 1 Thread jam nut back onto the push rod a sufficient length to allow assembly of the clevis 2 Thread clevis onto the push rod Clevis from removed unit may be reused provided clevis pin hole is not worn Adjust clevis to the same K dimension as measured from the removed unit Figure 13 Page 11 BE CERTAIN TO KEEP 3 Hold clevis to prevent it from turning and tighten jam nut against WELD AND WELD clevis to torque specifications See Table 4 Page 13 for SPATTER AWAY FROM Installation Torque Values The clevis must be adjusted so that it PLATE FACE SURFACE has full thread engagement on the push rod from flush to 3 16 4 8mm protrusion Figure 14 Page 11 TORQUE SPEC LISTED 4 Connect the service and emergency air line to the proper air IN TABLE 4 Page 13 ports Torque to specifications listed in Table 4 Page 13 5 Connect clevis to the slack adjuster using clevis and cotter pins and uncage the spring brake Refer to uncaging procedures Pages 7 9 for Gold Seal and Midland brakes Page 10 for Life Seal brakes IMPORTANT If push rod is not long enough to reach brake adjuster mounting hole DO NOT physically pull push rod out to reach mounting hole CHAMBER DIRECTLY TO THE BRACKET DO NOT INSERT SPACERS WASHERS OR SHIMS BETWEEN 6 Adjust the brake adjuster to the list
7. E ADJUSTER 11 Combination Spring Brake Installation Instructions Cont d NOTE Step 5 lists the procedures to determine correct push rod length when the spring brake being replaced is not available Move ahead to Step 6 if correct push rod length is already determined 5 To determine the correct push rod length of the brake to be installed measure the B dimension as shown Figure 15 and subtract the setup stroke as listed in Table 5 Page 15 With the spring brake fully caged B minus Setup Stroke Push Rod Length including Clevis Figure 16 NOTE Setup stroke is only to establish push rod length See Step 6 on Page 14 EXAMPLE For a typical Type 30 spring brake if B Figure 15 5 0 inches setup stroke 1 1 2 inches Table 5 Page 15 The push rod length from mounting face to centerline of main clevis pin should measure 5 minus 1 1 2 3 1 2 inches with the spring brake caged Figure 16 6 Before marking push rod to be cut on new unit be sure the spring chamber is caged and the push rod is fully retracted to the zero stroke position Refer to mechanical release instructions Pages 7 9 for Gold Seal brakes Page 10 for Life Seal brakes NOTE When determining the push rod cut off length the length of the threaded rod protruding between the clevis legs must not exceed 3 16 4 8mm to ensure no interference with the operation of the brake adjuster Figure 14 T Thread clevis jam nut past the
8. ENTLY SEALED CHAMBER CAUTION DO NOT ATTEMPT TO DISASSEMBLE General Safety Precautions Continued Haldex manufactures a complete line of 3 0 76mm stroke brake FIG 3 Gold Seal amp Life Seal 3 0 actuators In some cases these are referred to as Long Stroke 76mm Stroke Spring Brake L In other cases they are referred to as Extra Long Stroke XL To avoid confusion please refer to Table 1 below TABLE 1 STROKE MODELS ALUMINUM CENTER BODY 2 5 64MM STROKE MODELS 3 0 76MM STROKE MODELS ET COMBINATION PIGGYBACK COMBINATION PIGGYBACK b GC2424L GP2424L GC2430XL GP2430XL SQUARE SHAPE BOSSES ON AIR GC2430L GP2430L LC2430L LP2430L PORTS IDENTIFY LC2430 LP2430 GC3030L GP3030L duc did GC3030 GP3030 LC3030L LP3030L STROKE GC3036 GP3036 LC3030 LP3030 A WARNING NEVER interchange 3 0 76mm stroke actuator components with 2 25 57mm or 2 5 64mm stroke components Performance and stroke may be seriously affected amp WARNING NEVER interchange spring brake manufacturers components Performance and stroke may be seriously affected Although spring brake manufacturers components look similar they should never be interchanged When servicing 3 0 stroke actuators it is imperative that strict attention is paid to the components These air brake actuators have push rod stroke capabilities in excess of the standard 2 25 57mm or 2 5 64mm design The serviceable compone
9. L31171 Rev 11 05 Sealed Spring Brakes Life Seal amp Gold Seal amp and Midland Installation Instructions Contents GENERAL SAFETY PRECAUTIONS sss 2 5 RECOMMENDED PREVENTATIVE MAINTENANCE 6 GOLD SEAL MIDLAND MECHANICAL RELEASE OF SPRING BRAKE smash 7 9 LIFE SEAL MECHANICAL RELEASE OF SPRING BRAKE niet nde pup ee ER e EH eL H 10 SEALED INSTALLATION INSTRUCTIONS COMBINATION SPRING BRAKES sss 11 15 PIGGYBACK MODEL be 16 17 ROTATING MOUNTING BOLTS CLAMPS AND AIR PORTS actio odi 18 SERVICE DIAPHRAGM REPLACEMENT 19 SPRING BRAKE DISARMING PROCEDURES 20 ORANGE ALERT STROKE INDICATOR OPERATION 21 DETERMINING WARRANTY STATUS sss 22 Throughout this manual you will notice the terms NOTE IMPORTANT WARNING and DANGER followed by important product information So that you may better understand the manual those terms are defined below The amp warns of the possibility of personal injury or death NOTE Is used as a reminder of an instruction where the concern deals with product integrity and has to do with installation operation maintenance or service and care of the product IMPORTANT Used without the safety alert symbol is used as a reminder of an instruction where the concerns deal with product integrity and have to do with installation operation maintenance or service and
10. according to C V S A Appendix A North American Uniform Out of Service Criteria Recommended Preventative Maintenance Preventative maintenance for Haldex Life Seal Gold Seal and Midland combination spring brake models is recommended every three months or every 25 000 miles 40 000 km IMPORTANT ALWAYS BLOCK WHEELS to prevent vehicle rollaway when performing any brake maintenance 1 Check the conditions of the foundation brakes including drums shoes and linings rollers bushings etc Check for structural damage of the Spring Brake Brake Adjuster and S Cam Replace if necessary 3a Gold Seal and Midland Models Apply the parking brake Remove the Dust Plug from the rear of the chamber and physically inspect the condition of the parking spring If the parking spring is broken replace the Spring Brake with either a new piggyback unit or an entire unit Please refer to Pages 16 and 17 for specific piggyback installation instructions or to Pages 11 thru 15 for combination installation instructions IMPORTANT ALWAYS replace dust plug after inspection 3b Life Seal Models Mechanically release the parking brake and follow the procedure listed on Page 10 Apply the Service Brakes Check the air lines and fittings for leaks Check for proper torque according to Table 4 Page 13 After allowing the brake drum to cool to room temperature check for the correct spring brake stroke and verify proper i
11. ase tool nut clockwise with hand wrench DO NOT USE HIGH SPEED OR POWER DRIVEN IMPACT WRENCH This procedure will be made much easier if air pressure 100 120 PSIG 6 6 8 0 BAR is used to collapse the spring 2 Turn release tool nut until contact is made with the chamber Torque to 55 ft Ib 74 Nm Torque value is stamped on chamber Figure 12 FIG 11 SEE TABLE 3 RETRACTING WRENCH PUSH ROD ONLY INTEGRAL CAGING RELEASE TOOL TABLE 3 CHAMBER TYPE STROKE X MINIMUM X MAXIMUM 30 21 2 64mm 2 40 61mm 2 56 65mm 30LS 3 76mm 2 90 74mm 3 06 78mm NOTE If dimension of release tool X dimension length is less than the minimum measurement then spring brake unit must be replaced FIG 12 TORQUE TO 55 FT LBS 74 Nm CLOCK WISE APPLIED OR UNCAGED POSITION RELEASE TOOL NUT TORQUE VALUE STAMPED ON CHAMBER 10 Combination Spring Brake Installation Instructions INSTALLATION PREPARATION IMPORTANT Spring brake must be caged prior to performing installation procedures If brake is not caged follow steps on Pages 7 10 for safety instructions and mechanical release of spring brake NOTE n an effort to maximize the life of Haldex spring brakes Haldex recommends the following brake mounting guidelines when installing spring brakes on your vehicle s CUT PUSH ROD TO CORRECT INSTALLATION LENGTH IMPORTANT Before installing a new combination
12. cage the parking brake power spring 2 Open the lid of the Safety Chamber and place the uncaged Piggyback or Combination Service Spring Brake inside the chamber close lid and lock hinges in place with bolts as shown Figure 36 NOTE Service push rod may need to be cut in order to fit a Combination Service Spring Brake into the Safety Chamber Figure 36 3 While wearing safety glasses use an acetylene cutting torch and cut a 3 76mm diameter hole Figure 37 out of the Spring Brake chamber wall through one of the openings in the Safety Chamber Figure 36 Once the power spring is exposed use the acetylene cutting torch to cut the exposed spring in one or more places until the power spring pieces can be moved around inside the Spring Brake chamber with a long screwdriver or similar tool through the disarming chamber openings A2 c Once the power spring pieces can be moved around inside the Spring Brake chamber the disarming process is complete and the piggyback can be removed from the Safety Chamber after it has cooled down The unit can be submersed in water to cool it quickly WARNING Cutting of the Spring Brake Chamber with an acetylene torch can result in harmful fumes Do not breathe these fumes All cutting should be done outside or in a well ventilated area After cutting the chamber submerse it in water to cool If the disarmed unit is not cooled it will emit additional fumes and it could start a fire i
13. care of the product It is intended to show that vehicle breakdown and or expensive repair could result if the instruction is not followed WARNING Is used with an instruction for the purpose of showing that a safe practice must be adhered to or that an unsafe practice must be avoided and that if proper precautions are not taken personal injury could result DANGER Indicates a potentially hazardous situation which if not avoided may result in serious injury or death General Safety Precautions DANGER A spring brake contains a very powerful compression spring Failure to comply with all of the following instructions may result in forceful release of the piggyback or spring chamber and its contents which could CAUSE DEATH SEVERE PERSONAL INJURY AND OR PROPERTY DAMAGE IMPORTANT ALWAYS BLOCK WHEELS to prevent vehicle rollaway when performing any brake maintenance DANGER Haldex DOES NOT recommend the rebuilding of any of its air brake actuator products Nor does Haldex recommend the use of rebuilt Haldex air brake actuators If spring brake shows structural damage DO NOT cage the spring and DO NOT attempt to service it Replace the complete unit To prevent severe personal injury when removing an uncaged spring brake from a vehicle cut the service push rod making sure to relieve all force on it After cutting the push rod remove the spring brake from the vehi
14. cle then disarm the spring brake using a suitable safety chamber See Page 20 Figure 36 Never strike any part of the spring brake with a hammer or any other heavy object structural damage may result Do not drop spring brake as power spring may forcefully release If air pressure is used to aid in the caging process do not tighten the release tool more than finger tight The air pressure must always be exhausted after the spring has been mechanically caged prior to any disassembly Onall Haldex Life Seal Gold Seal and Midland Spring Brakes the emergency diaphragm cannot be replaced Replace the complete piggyback Follow instructions listed under Mechanical Release on Page 7 9 for Gold Seal Midland brakes Page 10 for Life Seal brakes And Piggyback Installation Instructions on Pages 16 and 17 IMPORTANT It is recommended that a new service brake diaphragm be used when installing a new piggyback DO NOT use a piloted diaphragm on the service side a piloted protrusion diaphragm is designed to be used in the emergency spring chamber only Use of a piloted diaphragm results in a reduction of stroke length Continued on next page FIG 1 Gold Seal Midland Spring Brake eX TETHERED DUST PLUG 4 PERMANENTLY SEALED POCKET CHAMBER FOR RELEASE TOOL CAUTION DO NOT ATTEMPT TO DISASSEMBLE FIG 2 Life Seal Spring Brake INTEGRAL RELEASE TOOL NO SIDE POCKET PERMAN
15. ease of Spring Brake see Pages 7 9 for Gold Seal Midland brakes Page 10 for Life Seal brakes DANGER Failure to comply with all instructions for mechanical release may result in the forceful release of the spring which could CAUSE DEATH SEVERE PERSONAL INJURY AND OR PROPERTY DAMAGE ND Co on D N co If vehicle air pressure was used to aid in the caging process exhaust the air pressure To prevent sudden release of service housing assembly and to facilitate rotation of air ports or mounting studs the service push rod should be prevented from retracting by clamping the service push rod in place with vise grip pliers as shown Figure 32a b Remove service clamp carriage bolt and rotate service housing Figure 32a b or center body Figure 33 to desired position Ensure that diaphragm is properly seated between the center body and housing lip and that the air ports are in the desired positions When reinstalling the one piece service clamp assembly Figure 32a torque the carriage nut to specifications listed in Table 4 Page 13 When reinstalling the two piece service clamp assembly Figure 32b tighten each nut equally alternating every other turn Torque each carriage nut to specifications listed in Table 4 Page 13 DO NOT strike clamp or unit with a hammer Check carriage bolts and clamp assembly for proper seating around the center body and housing lip and remove vise grip pliers pr
16. ed setup stroke See CAGED SPRING BRAKE MOUNTING BRACKET AND BRAKE HOUSING Table 5 Page 15 Figure 22 FIG 21 AIR LINES Pi COTTER PIN CLEVIS PIN Continued on next page G OF BRAKE FIG 23 ADJUSTER PARALLEL 90 BRAKE ADJUSTER TO TO MOUNTING CAGED SPRING BRAKE PUSH ROD ANGLE MUST SURFACE BE MAINTAINED MOUNTING BRACKET SURFACE FIG 22 CORRECT CORRECT WHEN BRAKES ARE WHEN BRAKES ARE APPLIED amp NOT APPLIED PARKING OR o PARKING BRAKE CAGED OF 60 PSIG 4 BAR SERVICE ROD AND 0 PSIG 0 BAR PUSH SERVICE X SET UP CAGED SPRING BRAKE STROKE TABLE 5 14 Combination Spring Brake Installation Instructions Cont d VERIFY PROPER INSTALLATION 1 With the brake applied the following conditions must occur 8 push rod 90 to the centerline of slack adjuster b push rod 90 to the mounting face of the spring brake Figure 23 Page 14 TABLE 5 STROKE VALUES RECOMMENDED CHAMBER CHAMBER AVAILABLE STROKE RANGE SET UP STROKE TYPE STROKE MINIMUM MAXIMUM APPLIED BRAKE 9 1 3 4 44mm 1 3 8 35mm 1 25mm 12 1 3 4 44mm 1 3 8 35mm 1 25mm 16 2 14 57mm 1 3 4 44mm 1 3 8 35mm 16 2 12 64mm 2 54mm 1 1 2 38mm 20 2 14 57mm Should beas 4 3 4 44mm 1 3 8 35mm 20 2 12 64mm Shortastroke 2 51mm 1 1 2 38mm 20 3 76mm AS possible 2 4 2 64mm 1
17. er body and housing lip and remove vise grip pliers previously clamped around the service push rod to prevent it from retracting 10 Apply a maximum of 120 PSIG 8 BAR air pressure to the service port and check diaphragm seal for leakage by applying a water and soap solution to the service clamp area No leakage is allowed Uncage power spring See instructions on Pages 7 9 for Gold Seal Midland brakes Page 10 for Life Seal brakes IMPORTANT After reassembly check for proper emergency and service brake operation If installed on vehicle check brake adjustment by following vehicle manufacturer s instructions FIG 34a ONE PIECE SERVICE CLAMP ASSEMBLY VISE GRIP mm SERVICE PUSH ROD CAGED SPRING BRAKE FIG 34b TWO PIECE FIG 35 CAGED SPRING BRAKE ui s SERVICE CENTER BODY DIAPHRAGM FLAT SURFACE WITH NO PROTRUSIONS 19 Disarming Procedures Piggyback and Combination Service Spring Brakes DANGER A Piggyback or Combination Service Spring Brake must be disarmed before disposal or forceful release of the power spring may occur in the future without warning NOTE A detailed drawing of the Safety Chamber is available free of charge upon request Contact Haldex Engineering Department at 800 643 2374 Drawing 110372 also on the web in Resources Technical Litertaure 1 Remove the caged Piggyback or Combination Service Spring Brake from vehicle after removal un
18. es can be interpreted using the following information Day of Year Shift Year Location DDD S YY L Days running of the year A First Shift Two Digit Year A Apodaca B Second Shift Monterrey Mexico C 7 Third Shift K lola Kansas For example a date code of 307A04A would translate to Tuesday November 2 2004 First Shift Apodaca Monterrey Mexico Date codes on actuators built in Apodaca Monterrey Mexico formerly Anchorlok between June 1 1990 and October 31 2004 can be interpreted using the following information Market Day of Year Year Run No O DDD YY XX O OEM Days running of the year Two Digit Year Production run D Distributor Date codes on actuators built in lola Kansas formerly Midland prior to November 1 2004 can be interpreted using the following information Day of Year Shift Year Location DDD S Y L Days running of the year A First Shift Single Digit Year K lola Kansas B Second Shift C Third Shift If you have questions about this date code change or other Haldex Actuator technical issues please contact your local Haldex Sales Professional 22 Notes 23 Commercial Vehicle Systems North American Sales Division Haldex Brake Products Corporation 10707 N W Airworld Drive Kansas City MO 64153 1215 Phone 816 891 2470 Fax 816 801 4198 North American Sales Division Haldex Limi
19. eviously clamped around the service push rod to prevent it from retracting Apply a maximum of 120 PSIG 8 BAR air pressure to the service port and check seal for leakage by applying a water and soap solution to the service clamp area No leakage is allowed Uncage park brake power spring Refer to uncaging instructions Pages 7 9 for Gold Seal Midland brakes Page 10 for Life Seal brakes WARNING After reassembly check for proper emergency and service brake operation For brake adjustment follow vehicle manufacturer s instructions FIG 32a VISE GRIP PLIERS ONE PIECE SERVICE CLAMP ASSEMBLY mmm SERVICE PUSH ROD CAGED SERVICE SPRING HOUSING CHAMBER FIG 32b TWO PIECE SERVICE CLAMP ASSEMBLY CAGED SPRING CHAMBER SERVICE HOUSING CENTER BODY 18 Service Diaphragm Replacement 1 For Mechanical Release of Spring Brake see Pages 7 9 for Gold Seal Midland brakes Page 10 for Life Seal brakes A DANGER Failure to comply with all instructions for mechanical release may result in the forceful release of the spring which could CAUSE DEATH SEVERE PERSONAL INJURY AND OR PROPERTY DAMAGE 2 If vehicle air pressure was used to aid in the caging process exhaust the air pressure 3 To prevent sudden release of the piggyback or service push rod assembly and to facilitate the installation of the new diaphragm the service push rod should be prevented from retrac
20. f the spring which could CAUSE DEATH SEVERE PERSONAL INJURY AND OR PROPERTY DAMAGE 2 Before installing piggyback on existing non pressure housing inspect the clamp assembly the service return spring the service push rod and non pressure housing If any structural damage is noted replace with new parts 3 Wipe the surface of the service push rod clean of any oil grease or dirt Check to see that the bottom most vent holes in the housing are not plugged FIG 28a VISE GRIP PLIERS SERVICE ONE PIECE SERVICE CLAMP ASSEMBLY IMPORTANT It is recommended that a new service brake diaphragm be used when installing a new piggyback DO NOT use a piloted diaphragm on the service side a piloted protrusion diaphragm is designed to be used in the emergency spring chamber only Use of a piloted diaphragm results in a reduction of stroke length 4 Place the new service diaphragm in center body as shown and center the housing over the diaphragm and adapter lip Figure 29 5 Ensure that diaphragm is properly seated between the center body and housing lip and that the air ports are in the desired positions When reinstalling the one piece service clamp assembly Figure 28a torque the carriage nut to specifications listed in Table 4 Page 13 When reinstalling the two piece service clamp assembly Figure 28b tighten each nut equally alternating every other turn Torque each carriage nut
21. f stored near combustible material FIG 36 SAFETY CHAMBER SAFETY CHAMBER OPENINGS FIG 37 UNIT UNCAGED CUT 3 76mm DIAMETER HOLE HERE 20 Orange Alert Stroke Indicator Operation IMPORTANT All Haldex brake chambers are equipped with a stroke indicator which meets October 1994 FMVSS 121 requirements Please read the following information carefully and familiarize yourself with the operation of this feature WHAT IS A STROKE INDICATOR A Haldex Orange Alert stroke indicator is an orange knurled band located on the service push rod This band is permanently embossed on the push rod and painted Figure 38 The orange band stroke indicator is normally inside the brake chamber Figure 38 and will only start to protrude outside of the mounting face of the service housing when the spring brake or service chamber has only 20 of stroke remaining Figure 39 HOW TO USE A STROKE INDICATOR IMPORTANT A stroke indicator is not intended to be used as the only indicator of when to adjust the brakes on a vehicle For brake adjustment follow vehicle manufacturer s instructions At the point where the leading edge of the stroke indicator is level with the mounting face of the service housing as shown Figure 39 the combination spring brake or service chamber has only 20 of available stroke remaining See Table 6 below When the stroke indicator becomes visible maintenance is
22. ghtly less than the minimum contact area for horizontal mount IMPORTANT Always mount brake chamber directly to bracket if a reinforcement plate is necessary follow the guidelines for plate attachment below DO NOT insert spacers washers or shims between mounting bracket and brake housing Figure 17 Consult the bracket manufacturer for your application to determine if a reinforcement plate is necessary DO NOT mount spring brake in a vertical position The spring brake must be mounted within 45 degrees of horizontal Figure 18A NOTE In some cases it may be necessary to rotate air ports and or clamp bands for proper clearance and installation on vehicle See Page 18 for rotation instructions REINFORCEMENT PLATE ATTACHMENT GUIDELINES When attaching a reinforcement plate to the brake mounting bracket face the following guidelines must be followed 1 Attach 25 6mm steel plate 7 x 7 178mm x 178mm square to brake mounting bracket face Secure with 2 5 8 or M16 bolts washers and nuts and torque to 50 ft Ib 67 5 Nm Figure 18 2 Weld reinforcement plate to brake mounting bracket See Figure 19 for suggested weldment locations For exact location and weld size refer to axle manufacturer s guidelines Allow welds to cool and remove bolts Figure 19 Page 14 3 Attach spring brake directly to new reinforcement plate Fasten with mounting hardware Figure 20 Page 14 Torque to specifications listed
23. he washer to protect the pocket from corrosive elements while allowing the pocket to drain around the T head Figure 6 5 Torque the nut to 5 8 ft Ib 6 8 10 8 Nm 6 Install dust plug in key hole Insert the plug into the keyhole in the housing and push firmly until the plug is securely in place T Lift edge of tether plug to be sure the plug is firmly in place IMPORTANT Always re install tethered dust plug in caging tool key hole Failure to do so will result in corrosion and foreign particle ingestion through the key hole which will void the warranty Do not use excessive force when installing the plug Excessive force may damage the plug and make it unusable Replacement tether plugs can be purchased from your local Haldex Distributor FIG 7 TURN RELEASE TOOL NUT COUNTER CLOCKWISE FIG 8 SEALED TYPE SERVICE il cui CLAMP ASSEMBLY DUST PLUG SERVICE HOUSING SIDE POCKET RELEASE TOOL Life Seal Mechanical Release of Spring Brake DANGER The below listed instructions only apply when spring brake is not pressurized If air pressure is used to compress the spring do not tighten release tool more than finger tight Torquing the release tool nut while the spring brake is pressurized can cause spring piston damage resulting in sud den release of the spring which could CAUSE DEATH SEVERE PERSONAL INJURY AND OR PROPERTY DAMAGE Air pressure must be released after caging pr
24. ing piston Figure 5 Arrow A 4 Turn release tool 1 4 turn clockwise Figure 5 Arrow B Ca mai 5 Pull on release tool to ensure stud crosspin is properly B seated in the spring piston 6 Assemble release tool washer and nut on release stud finger RELEASE tighten only Figure 5 TOOL WASHER KEY HOLE AND NUT Continued on next page Gold Seal Midland Mechanical Release of Spring Brake Continued DANGER The below listed instructions only apply when spring brake is not pressurized If air pressure is used to compress the spring do not tighten release tool more than finger tight Torquing the release tool nut while the spring brake is pressurized can cause spring piston damage resulting in sudden release of the spring which could CAUSE DEATH SEVERE PERSONAL INJURY AND OR PROPERTY DAMAGE Air pressure must be released after caging prior to any disassembly T a Turn release tool nut clockwise with hand wrench DO NOT USE HIGH SPEED AND OR POWER DRIVEN IMPACT WRENCH and make certain push rod is retracting Figure 6 T b This procedure will be made much easier if air pressure 100 120 PSIG 6 6 8 0 BAR is used to collapse the power spring before turning the release tool nut with a hand wrench Proper caging will be complete when a slight resistance is felt after turning the release tool nut Release the air pressure after caging prior to any disassembly IMPORTANT Do not over torque release tool asse
25. ior to any disassembly DANGER DISARM spring chamber before discarding old brake To disarm use a suitable Safety Chamber see Page 20 Failure to disarm assembly prior to disposal may in time result in spontaneous release of the spring chamber and its contents which COULD CAUSE DEATH PERSONAL INJURY AND OR PROPERTY DAMAGE TO CAGE PARK BRAKE COMPRESSION SPRING RELEASE PARK BRAKE IMPORTANT ALWAYS BLOCK WHEELS to prevent vehicle rollaway when performing any brake maintenance IMPORTANT Do not over torque release tool assembly Over torquing release tool can cause spring piston damage Life Seal S Cam type 55 ft Ib 74Nm Maximum Counter Clockwise 1 a Turn release tool nut counter clockwise with hand wrench DO NOT USE HIGH SPEED AND OR POWER DRIVEN IMPACT WRENCH and make certain push rod is retracting Figure 11 1 b This procedure will be made much easier if air pressure 100 120 PSIG 6 6 8 0 BAR is used to collapse the compression spring before turning the release tool nut with a hand wrench Proper caging will be complete when a slight resistance is felt after turning the release tool nut Release the air pressure after caging prior to any disassembly IMPORTANT To ensure the power spring is fully caged the release tool length X dimension Figure 11 should measure as shown in Table 3 TO UNCAGE PARK BRAKE COMPRESSION SPRING APPLY PARK BRAKE 1 Turn rele
26. mark on push rod Align bottom edge of nut with mark to use as a guide for cutting Use a sharp hack saw and cut push rod on the mark After cutting rod thread jam nut off to clean up threads FIG 15 G OF SLACK ADJUSTER MOUNTING SURFACE 7 PARALLEL TO MOUNTING SURFACE CORRECT WHEN BRAKES ARE APPLIED q PARKING OR 60 PSIG OF 4 BAR SERVICE ROD APPLIED BRAKE FIG 16 CORRECT WHEN BRAKES ARE NOT APPLIED M PARKING OR 60 PSIG RET 4 BAR SERVICE ROD X SET UP PUSH ROD SIROKE LENGTH TO B gt TABLES CENTERLINE Page 18 OF CLEVIS PIN 12 Combination Spring Brake Installation Instructions Cont d MOUNTING SPRING BRAKE TO MOUNTING BRACKET When attaching spring brakes to mounting brackets the following checks and instructions should be performed 1 Mounting brackets must be inspected to assure that bracket surface is free from debris burrs cracks weld spatter and is flat within 1 64 4mm Figure 17 2 Attach spring brake directly to mounting bracket on axle Fasten with mounting hardware Figure 17 Torque to specifications listed in Table 4 below IMPORTANT When mounting a spring brake to a horizontal axle bracket as shown in Figure 17 the bracket must meet the minimum contact area Figure 17A When the spring brake mounting bracket requires the studs to be in the vertical position rotated 90 from horizontal the contact area can be sli
27. mbly Over torquing release tool can cause spring piston damage IMPORTANT To insure the power spring is fully caged the release tool length X dimension Figure 6 should measure as shown in Table 2 TABLE 2 MODEL STROKE X MINIMUM 1624 21 4 57mm 2 9 74mm 2024 21 4 57mm 29 74mm 2424 21 4 57mm 29 74mm 2424 21 2 64mm 29 74mm 2430 21 4 57mm 29 74mm 2430 21 2 64mm 29 74mm 2430 3 76mm 34 86mm 3030 21 2 64mm 29 74mm 3030 3 76mm 34 86mm 3636 21 2 64mm 3 6 91mm 3636 3 76mm 2 4 61mm 3636 3 76mm 3 6 91mm NOTE If dimension of release tool X dimension length is less than the minimum measurement then spring brake unit must be replaced Continued on next page FIG 6 SEE TABLE 2 TORQUE TO 35 FT LBS CLOCKWISE HAND WRENCH ONLY RETRACTING PUSH ROD Gold Seal Midland Mechanical Release of Spring Brake Continued TO UNCAGE PARK BRAKE COMPRESSION SPRING APPLY PARK BRAKE 1 Turn release stud nut counter clockwise with hand wrench DO NOT USE HIGH SPEED OR POWER DRIVEN IMPACT WRENCH This procedure will be made much easier if air pressure 100 120 PSIG 6 6 8 0 BAR is used to collapse the spring Figure 7 2 Remove caging tool nut and washer 3 Push caging tool in turn 1 4 turn counter clockwise and remove 4 Place caging tool in pocket with T head down and washer and nut up this allows t
28. nstallation Proper installation can be verified by following the instructions listed on Page 15 Gold Seal Midland Mechanical Release of Spring Brake FIG 4 DANGER Read Pages 2 5 carefully Do not attempt to mechanically release cage the spring on a spring brake if it shows structural damage Caging the spring or disassembly of the chamber may result in the forceful release of the spring chamber and its contents which could CAUSE DEATH SEVERE SERVICE SIDE POCKET PERSONAL INJURY AND OR PROPERTY DAMAGE Remove y complete spring brake and replace with new unit DUST PLUG DANGER DISARM spring chamber before discarding old brake To disarm use a suitable Safety Chamber see Page 20 q un KEY Failure to disarm assembly prior to disposal may in time result 7 HOLE in spontaneous release of the spring chamber and its contents SERVICE d which could CAUSE DEATH SEVERE PERSONAL INJURY AND OR PUSH pop PROPERTY DAMAGE TO CAGE PARK BRAKE COMPRESSION SPRING SERVICE RELEASE PARK BRAKE 4 IMPORTANT ALWAYS BLOCK WHEELS to prevent vehicle rollaway when performing any brake maintenance Remove dust plug from release tool key hole in center of spring chamber Figure 4 FIG 5 I RELEASE TOOL N Remove release tool assembly from side pocket of center body Figure 4 RELEASE TOOL 1 4 TURN CLOCKWISE 3 Insert release tool through key hole in chamber into the spr
29. nts for these actuators are unique They include the following 2 5 stroke T 24 diaphragm may be used in 2 25 stroke T 24 service brake applications 1 Service Diaphragm 2 Service Housing 3 Service Pushrod 4 Complete Piggyback These components are uniquely identified as Long Stroke LS or 3 0 76mm Stroke on each component The unique square bosses on the air inlet ports on the aluminum center body easily identify the spring brake as 3 0 76mm stroke Figure 3 To aid in the identification of Long Stroke brakes being used on vehicles Haldex has decals available Figure 3A These decals can easily be attached to the side of the vehicle Labels can be purchased from your local Haldex Distributor General Safety Precautions Continued FIG 3A Long Stroke Brake Alert Decal L80033 NE 5 50 EE ATTENTION Installed on this vehicle axle are 3 inch LONG STROKE SPRING BRAKES Maximum Readjustment Stroke 2 5 according to C V S A 3 00 Appendix A North American Uniform Out of Service Criteria L80034 5 50 ATTENTION DES FREINS RESSORT COURSE LONGUE DE 3 POUCES sont mont s sur l essieu de ce v hicule Le r glage maximal de course est de 2 5 po selon la C V S A Annexe A Crit res uniformes nord am ricains de mise hors service 3 00 Installed on this vehicle axle are 3 inch LONG STROKE SPRING BRAKES Maximum Readjustment Stroke 2 5
30. ted 525 Southgate Drive Unit 1 Guelph Ontario CANADA N1G 3W6 Phone 519 826 7723 Fax 519 826 9497 www haldex com www hbsna com Rev 11 05 250 ART L31171 Replaces 951 20 001 Rev B June 2002
31. ting by clamping the service push rod in place with vise grip pliers as shown Figure 34a b 4 Remove service clamp assembly and discard old diaphragm 5 Inspect the service clamp assembly the center body wall and lip the housing the service return spring and service push rod If any structural damage is noted replace with new part 6 Wipe the surface push rod plate clean of any oil grease or dirt T Place the new service diaphragm in center body and center the housing over the diaphragm and center body Figure 35 IMPORTANT It is recommended that a new service brake diaphragm be used when installing a new piggyback DO NOT use a piloted diaphragm on the service side a piloted protrusion diaphragm is designed to be used in the emergency spring chamber only Use of a piloted diaphragm results in a reduction of stroke length 8 Ensure that diaphragm is properly seated between the center body and housing lip and that the air ports are in the desired positions When reinstalling the one piece service clamp assembly Figure 34a torque the carriage nut to specifications listed in Table 4 Page 13 When reinstalling the two piece service clamp assembly Figure 34b tighten each nut equally alternating every other turn Torque each carriage nut to specifications listed in Table 4 Page 13 DO NOT strike clamp or unit with a hammer 9 Check carriage bolts and clamp assembly for proper seating around the cent
32. to specifications listed in Table 4 Page 13 DO NOT strike clamp or unit with a hammer Continued on next page PUSH ROD CAGED SPRING CHAMBER FIG 28b TWO PIECE SERVICE CLAMP ASSEMBLY FIG 29 SERVICE CLAMP VISE GRIP ASSEMBLY CAGED SPRING CHAMBER SERVICE HOUSING EMERGENCY AIR PORT SERVICE AIR PORT SERVICE CENTER DIAPHRAGM BODY 16 Piggyback Installation Instructions Continued 6 Check carriage bolts and clamp assembly for proper seating around the center body and housing lip and remove vise grip pliers previously clamped around the service push rod to prevent it from retracting T Reconnect the air lines to the air ports on the center body making sure to connect the proper lines to the service and emergency ports Figure 29 Torque to specifications listed in Table 4 Page 13 8 Apply a maximum of 120 PSIG 8 BAR air to the service port and check diaphragm seal for leakage by applying a water and soap solution to the service clamp area No leakage allowed 9 Uncage park brake power spring Refer to uncaging instructions Pages 7 9 for Gold Seal Midland brakes Page 10 for Life Seal brakes IMPORTANT After reassembly check for proper emergency and service brake operation For brake adjustment follow vehicle manufacturer s instructions 17 Rotating Mounting Bolts Clamps and or Air Inlet Ports TO ROTATE SERVICE HOUSING MOUNTING STUDS 1 For Mechanical Rel
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