Haldex DB22LT, DB22, DB19 User Manual
SERVICE MANUAL
L30039
8/06
ModulX™ Air Disc Brake
DB19/DB22/DB22LT
Contents
• Use appropriate spare parts documentation when obtaining spare parts.
• Use only genuine Haldex spare parts in repairs.
• Haldex reserves the right to make changes in the interest of technical progress.
• The contents of this manual are not legally binding.
• No part of this publication may by reproduced, copied or translated without the prior permission of Haldex
Brake Products Corporation.
• This edition supersedes all previous editions of the same documentation and renders them invalid.
• In case of a dispute between language versions, the English original has priority.
Contents
Page
Introduction
.....................................................................................................................................................2
Product identification ........................................................................................................................2
Description of Product
Disc brake DB19/DB22 Generation 1 - Exploded view....................................................................3
Disc brake DB19/DB22/DB22LT Generation 2 - Exploded view......................................................4
Disc brake component list ................................................................................................................5
Disc brake specifications..................................................................................................................6
Tightening torques............................................................................................................................7
Wear limits........................................................................................................................................7
Operation of Product...................................................................................................................................8
General instructions
Instructions .....................................................................................................................................11
Recycling ........................................................................................................................................11
Cleaning..........................................................................................................................................11
Surface finishing ............................................................................................................................11
Brake force distribution...................................................................................................................12
Inspection/checks/adjustment
Inspection intervals ........................................................................................................................13
Inspection and checks....................................................................................................................14
Function test...................................................................................................................................18
Initial setting. ..................................................................................................................................19
Lubrication. .....................................................................................................................................20
Service
Replacing brake pads ....................................................................................................................21
Removing disc brake unit ..............................................................................................................23
Installing disc brake unit.................................................................................................................23
Replacing protection boots (common thrust plate) .......................................................................24
Replacing protection boots (two separate thrust plates)................................................................27
Replacing slide pins, slide bushings and protection boots ...........................................................30
Replacing caliper housing (mechanism) ........................................................................................35
Replacing brake chamber .............................................................................................................38
Replacing spring brake chamber ..................................................................................................41
Replacing radial seal and adjustment shaft ..................................................................................44
Troubleshooting..........................................................................................................................................45
Tools ........................................................................................................................................................47
1
2
Introduction
The Haldex disc brake is designed to provide high performance coupled with low weight, durability and a
minimum number of wearing parts. Floating, twopiece calipers are used. Brake pad wear is compensated for by an automatic clearance adjustment mechanism. The mechanism, which is activated by the brake
chamber, acts on a thrust plate which presses the inner
brake pad against the rotor, which then causes the
caliper to move (float) laterally, so that the outer
brake pad also comes in contact with the rotor. The
caliper moves on slide pins. Where the rotor also
serves as a parking brake, the mechanism is activated
by a spring brake chamber.
Introduction
Product identification
Type and serial numbers are stamped on an identification plate fixed to the caliper.
1. OEM/Haldex logo 5. Haldex S/N 226123 (example)
2. OEM P/N (if required) 2 = year, 2002
3. Haldex (origin) assembled in the U.S.A. 26 = week number.
4. Haldex P/N xxxxx 123 = sequential number
1
4
5
3
(2)
Assembled in USA
Haldex Disc Brakes
DB19/DB22 Generation 1
3
See Component List on Page 5.
4
Haldex Disc Brakes
DB19/DB22/DB22LT Generation 2
See Component List on Page 5.
Component list
Haldex Disc Brakes
Component list
DB19/DB22/DB22LT
1 Disc brake assembly
2
Caliper assembly
2a Caliper housing
2b Caliper bridge
3 Carrier
4 Adjuster Mechanism
5Pad
6 Pad spring
7 Pad retainer
8 Bolt
9 Protection cap
10 Slide pin attaching bolt
12 Protection boots
13 Slide pin
14 Slide bushing
15 Plug
18 Torx bolt
22 Bolt
25 Brake chamber
26 Spring brake chamber
27 Fixing bolt
28 Thrust plate
29 Thrust plate clip
30 Protection spring
32 Protection boots
33 Adjuster Mechanism Cover
34 Circlip
35 Adjustment screw
37 Bushing
38 Return spring
41 Cross bar
43 Needle bearing (outer)
44 Lever
45 Retainer
46 Rivet
47 Guide pin
48 Needle bearing (inner)
48a Slide bearing (inner)
50 Washer
53 Bearing sleeve
54 Adjuster
55 Adjustment shaft
59 Washer
60 Circlip
61 Clamp
62 Housing (adjuster)
63 Adjustment spring
64 Circlip (small)
64a Circlip (large)
66 Friction spring (one-way)
67 Hub
68 Companion sleeve
69 Radial Seal
71 Protection cup
73 Data plate
74 Adjustment sleeve (driving)
75 Adjustment sleeve (driven)
76 Pin
77 Gear wheel
78 Torx bolt
79 PWI
79a PWI connectors
79b PWI clamp for cable
79c PWI wire connector
79d PWI plate
79e PWI cable
80 PWS
80a PWS connector
81 Bolt
82 O-ring
83 Cable ties/straps
84 Synchronization plate
85 Indicator pin
86 Pin
5
6
Specifications
DB22
DB19
English
Metric
English
Metric
English
Metric
Specifications
DB19 DB22 DB22LT
Wheel size 19.5-22.5 in. 22.5-24.5 in. 22.5-24.5 in.
Max. brake torque with 0.34 COF 159,313 in-lbs. 18 kNm 194,716 in-lbs. 22 kNm 159,313 in-lbs. 18 kNm
Max. brake chamber force 2,698 ft. lbs. 12 kN 3125 ft. lbs. 12.5 kN 2,698 ft. lbs. 12 kN
Number of actuating tappets 2 2 2 2 2 2
Number of slide pins 4 4 4 4 4 4
Threshold Force 11 lbs. 50N 11 lbs. 50N 11 lbs. 50N
Max. brake chamber stroke 2.5 in. 65 mm 2.5 in. 65 mm 2.5 in. 65 mm
Adjustment for excess clearance (see p. 8). 9.8% 9.8% 9.8% 9.8% 9.8% 9.8%
Max. adjustment distance brake lining 1.9 in. 48 mm 2.0 in. 52 mm 2.0 in. 52 mm
Running clearance, brake lining to rotor 0.02-0.04 in. 0.6-1.0 mm 0.02-0.04 in. 0.6-1.0 mm 0.02-0.04 in. 0.6-1.0 mm
Pad lining thickness 0.82 in. 21 mm 0.86 in. 22 mm 0.86 in. 22 mm
Pad backplate thickness 0.35 in. 9 mm 0.31 in. 8 mm 0.31 in. 8 mm
Pad lining area (per pad) 23 in
2
150 cm
2
30.0 in
2
193 cm
2
24.8 in
2
160 cm
2
External diameter of brake rotor 14.8 in. 375 mm 16.9 in 430 mm 16.9 in 430 mm
Brake rotor thickness 1.8 in. 45 mm 1.8 in. 45 mm 1.8 in. 45 mm
Pad weight each 4.2 lbs. 1.9 kg 5.9 lbs. 2.7 kg 4.9 lbs. 2.2 kg
Weight approx. (excl. pads/brake chamber) 73.9 lbs. 33.5 kg 88 lbs. 39.9 kg 73.9 lbs. 33.5 kg
DB22LT
Tightening torques
For number references in parenthesis in the text which do not appear in this section, refer to the
exploded view (p. 3-4)
Follow the vehicle/axle manufacturers recommendations or follow the method described below:
Bolts for carrier mounting (M20, 2.5 pitch) 350+/-25 475+/-34 350+/-25 475+/-34 350+/-25 475+/-34
Torx Bolts (78) for caliper housing/bridge 273-302 390+/-20 391-435 560+/-30 273-302 390+/-20
Torx Bolts for slide pins 148-177 220+/-20 148-177 220+/-20 148-177 220+/-20
attaching bolts (10) Gen 1
Torx Bolts for slide pins 192-221 280+/-20 192-221 280+/-20 192-221 280+/-20
attaching bolts (10) Gen 2
Pad retainer bolt (8) 33-39 45+8/-0 33-39 45+8/-0 33-39 45+8/-0
Fixing bolts (27), brake chamber 133+22/-0 180+30/-0 133+22/-0 180+30/-0 133+22/-0 180+30/-0
* = The bolt must not be re-used
Specifications
DB19 DB22 DB22LT
Wear limits
Pads (5), min. lining thickness 2mm (0.08 in) 2mm (0.08 in) 2mm (0.08 in)
Pads (5), max. uneven wear 1mm (0.04 in) 1mm (0.04 in) 1mm (0.04 in)
Slide pins (13), max. movement 1mm (0.04 in) 1mm (0.04 in) 1mm (0.04 in)
Slide function, max slide resistance 100N (22.5 lbs.) 100N (22.5 lbs.) 100N (22.5 lbs.)
Brake Rotor, min. thickness 37mm (1.45 in ) 37mm (1.45 in) 37mm (1.45 in)
Brake Rotor, max. wear per side 4mm (0.15 in) 4mm (0.15 in) 4mm (0.15 in)
Brake Rotor, max. lateral runout 0.5mm (0.02 in) 0.5mm (0.02 in) 0.5mm (0.02 in)
Brake Rotor, max. thickness variation 0.1mm (0.004 in) 0.1mm (0.004 in) 0.1mm (0.004 in)
DB19 DB22 DB22LT
ft. lbs. ft. lbs. ft. lbs.
Nm
Nm Nm
7
8
Operation of product
For number references in parenthesis in the text which do not appear in this section, refer to the
exploded view (p. 3-4)
Operation of product
Rest position
66
68
63
62
47
54
44
74
2
A
28
35
41
74/75
2
44
25/26
5 (inner)
5 (outer)
Actuation/release of brake
During braking, lever (44) is actuated by brake
chamber (25/26). The inner section of lever (44)
presses the cross bar (41) axially towards the
brake disc (A). The force is transferred from the
cross bar (41) via adjustment sleeves (74/75),
adjustment screws (35) and the thrust plate (28)
to the inner brake pad (5). As the brake pad (5)
comes into contact with the rotor (A), the caliper
(2) moves laterally on the slide pins (13) to allow
the outer pad (5) to contact the rotor (A). When
the brake is released, return spring (38) forces
cross bar (41) back to its rest position, allowing
the design clearance between pad (5)
and rotor (A) to be achieved.
Automatic adjustment
Adjustment is based on the clearance principle.
The braking sequence is split into three phases:
design clearance C, excess clearance Ce (which
must be adjusted out), and the elasticity phase E.
These phases take place when the brakes are
activated and released. The lever (44) activates
the adjuster unit (54) by means of a guide pin
(47). The clearance between the guide pin (47)
and the slot in the adjuster unit housing (62)
determines the clearance between the brake pads
(5) and the rotor (A).The adjuster unit (54) in turn
rotates the adjustement sleeve (74), which is
threaded around the adjustment screw (35). The
thrust plate (28) is held in position on the end
pins of the adjuster screws (35) by clips (29).The
adjustment screws (35) are prevented from
rotating/following the adjuster sleeves (74/75)
by guides on the thrust plate (28). The second
adjustment sleeve (75) is synchronized and
driven by a gear mechanism which consists of
gear wheels (77) attached to each of the two
adjustment sleeves (74/75) plus an intermediate
gear wheel. (Three gear wheels (77) in total).
Application
C - During the forward stroke through C, the design
clearance between pads (5) and rotor (A) is measured.
The clearance between the guide pin (47), which is
attached to the lever (44) and the slot in the adjuster
unit housing (62) determines the magnitude of the
forward stroke before the adjustment process begins.
Ce - If there is any clearance between the rotor (A)
and the brake pad (5) when the thrust plate (29) has
moved axially through the design clearance C, the
adjuster unit (54) rotates the adjuster sleeves (75/75).
The adjustment screws (35) are held in position by the
thrust plate (28) and are therefore prevented from
turning. Rotation of the adjuster sleeves (74/75) in
relation to the adjustment screws (35) removes a percentage of the measured excess clearance Ce.
In adjuster unit (54), turning movement is transferred
from the housing (62) via adjustment spring (63),
companion sleeve (68), one-way spring (66) to the
adjustment sleeves (74/75), which are threaded
around the adjustment screws (35).
E – When pads (5) come into contact with rotor (A),
the braking enters elasticity phase E, the torque rises
and adjuster unit (54) stops adjusting. The continued
rotational movement which now occurs in adjuster
unit (54) is allowed by rotating housing (62) in relation to adjustment spring (63).
Operation of product
54
25/26
44
Clearance phase
62
47
5
A
Adjustment phase
66
68 63 62
74
54
35
74/75
5
A
A
Elasticity phase
62
63
5
9
10
Release
The first part of the return stroke is a combination of
elasticity phase E and design clearance C. Any residual part of the return stroke is excess clearance Ce
which is adjusted out during subsequent braking.
During the return stroke, return spring (38) ensures
that cross bar (41) travels back.
C – During the first part of the return stroke, the force
on the brakes decreases. The guide pin (47) moves to
the opposite side of the slot in the adjuster unit housing (62) = transition of design clearance.
Operation of product
Clearance phase
62
47
41
38
E – Corresponds to forward stroke movement through
E. Adjuster unit housing (62), adjustment spring (63)
and companion flange (68) are rotated in relation to
the adjustment sleeve (74/75), which remains stationary. Movement between the companion flange (68)
and the adjustment sleeve (74) is taken up by the oneway spring (66).
Ce – During the last part of the return stroke (corresponding to the movement of the forward stroke
through Ce), rotational movement in adjuster unit
(54) continues as described under E until adjuster
mechanism (4) reaches its rest position.
The brake is now back in its rest position.
Adjustment phase
66
68 63 62
74
54
Elasticity phase
62
54
74
63
68
66
General Instructions
• Always follow the vehicle manufacturer’s safety instructions when working on the vehicle.
• Follow the vehicle manufacturer’s instructions for recommended practices not described in this manual.
• Comply with local safety regulations.
• Work must be carried out by trained personnel.
• Sudden release of tensioned springs (e.g. the spring brake part of the brake chamber or the disc brake
return spring) may cause injury.
• Use recommended tools only.
• Release pressure from lines and components before disassembly.
• Chock at least one of the vehicle’s axles to prevent involuntary movement of the vehicle.
• Before releasing the vehicle back into service, perform a brake operational check and test the vehicle
to make sure that the brakes are working correctly.
means that special attention is required!
Instructions
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.
To avoid causing damage or displacing hoses, seals and other components
when cleaning/washing/removing snow/ice it is important to take care
when using chemicals, high pressure cleaner or cleaning tools.
Cleaning
For the disc brake’s function it is important to keep it clean so its normal movements are not limited by mud,
ice, snow, objects etc.
!
!
The result of damage may be immediate loss of the brake function or ingress of moisture/dirt and in turn
function irregularities.
This symbol
Surface finishing for disc brake
Surface Coating
Care must be taken to ensure that painting and/or undercoating does not cause damage and/or restrict the natural
movement or operation of the disc brake.
All contact surfaces, brake pads, rubber parts and rotor friction surfaces must therefore be protected or masked.
The mechanism (4) must be protected from the ingress of paint (e.g. if brake chamber (25/26) is not installed).
The following areas must not be painted:
Protection boots (12/32), radial seals (69), brake pads (5) (complete assembly), the swept area of the disc,
mounting surfaces of the assembly and all bolted connections.
11
12
Brake force distribution
It is 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 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, brake
discs, tires and wheel components.
Instructions
!
WARNING: Avoid creating dust. Possible cancer and lung disease hazard.
While Haldex does not offer asbestos brake linings, the long term affects of some non-asbestos
fibers have not been determined. Current OSHA Regulations cover exposure levels to some
components of non-asbestos linings but not all. The following precautions must be used when
handling these materials.
ⓦ Avoid creating dust. Compressed air or dry brushing must never be used for cleaning
brake assemblies or work area.
ⓦ Haldex recommends that workers doing brake work must take steps to minimize
exposure to airborne brake lining particles. Proper procedures to reduce exposure
include working in well ventilated area, segregation of areas where brake work is
done, use of local filtered ventilation systems or use of enclosed cells with filtered
vacuums. Respirators approved by the Mine Safety and Health Administration (MSHA)
or National Institute for Occupational Safety and Health (NIOSH) should be worn at all
times during brake servicing.
ⓦ Workers must wash before eating, drinking or smoking; shower after working and
should not wear work clothes home. Work clothes should be vacuumed and laundered
separately with out shaking.
ⓦ OSHA Regulations regarding testing, disposal of waste and methods of reducing
exposure for asbestos are set forth in 29 Code of Federal Regulations §1910.001.
These Regulations provide valuable information which can be utilized to reduce
exposure to airborne particles.
ⓦ Material Safety Data Sheets (MSDS) on this product, as required by OSHA, are
available from Haldex.
13
Inspection/checks/adjustment
Inspection/checks/adjustment
For number references in parenthesis in the text which do not appear in this section, refer to the exploded
view (p. 3-4).
Clean the disc brakes, removing any dirt and dust. Use dust removal equipment
or a vacuum cleaner but do not use compressed air - inhaling dust particles may
be harmful to your health! See Cleaning for instructions.
Do not disassemble the Torx bolts (78) that hold the caliper housing (2a) and
caliper bridge (2b) together!
IMPORTANT!
Read the safety instructions carefully. See the section entitled Safety.
The vehicle manufacturer’s instructions should also be followed.
If the disc brake is equipped with a parking
brake function, ensure that the spring brake
chamber is fully retracted and mechanically
secured in the released position.
See the vehicle manufacturer’s instructions
Visually Inspect the following items every 3 months.
·
Brake Pads 3 month intervals
· Brake Disc 3 month intervals
Check the following items regularly as indicated. Refer to the instructions
provided in the “Inspection” section.
·
Check brake pads 6 month intervals
· Check brake disc 6 month intervals
· Check slide function 6 month intervals
· Check play inside pins 12 month intervals
· Check protection boots 12 month intervals
!
!
!
!
Inspection and checks
Inspection of pad wear, visual
An indication on the degree of pad wear can be obtained (without removing the wheels) by examining the position of pointer A on the brake caliper assembly (2) in relation to carrier (3). Methods/specifications are the same
for DB19, DB22 and DB22LT. See method descriptions with and without indicator pin below.
W
ith
indicator pin: Examine the position of pointer A in relation to the tip of the indicator pin. See Fig.1.
W
ithout
indicator pin: Use a rigid ruler to measure the distance between carrier assembly (3) and indicator A.
New pads (5) 27 mm (1 1/16 in.) Worn out pads (5) 47 mm (1 7/8 in.) See Fig.2.
NOTE
Inspection procedure only indicates the degree of wear of the outer pad (5)!
To accurately determine the degree of pad wear see Inspection/checks/adjustment,
’Checking pad wear’ [with pads (5) removed] on page 15.
New pads
(5)
27 mm
(1 1/16 in.)
Worn out
pads (5)
47 mm
(1 7/8 in.)
A
A
2
Fig 1
3
A
New Pads
Worn out pads
71
2
A
The checks outlined in subsequent sections should be conducted with brake pads (5) removed. See section entitled ’Replacing brake pads’ for instructions regarding the removal of brake pads.
Inspection of rotors, visual.
Visually inspect the inside and outside faces of the rotors for damage, wear and cracks. (The outside face of the
rotors can be inspected through the holes in the wheel or by using a mirror and looking from the inside of the
wheel outwards). To assess any damage see ’Condition of the brake rotor’ later in this section.
In case of doubt concerning the extent of the damage, remove the wheel to allow closer inspection. Refer also to
the axle/vehicle manufacturer’s instructions.
If there are signs of overheating on the rotor, inspect the protection boots, brake pads and springs for damage (12
and 32). Grease escaping from the wheel hub can also be a sign of overheating. See ’Function test’ and ’Brake
force distribution’ for more information on checking the operation of the disc brake and adjusting the operating
system and brake force if overheating has occurred.
14
Inspection/checks/adjustment
Fig 2
!
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