Service Manual: Disc Brake Modulx Db22, Db22Lt, Db19

Service
manual
D I S C B R A K E M o d u l X D B 2 2 , D B 2 2 LT, D B 1 9
www.haldex.com
Contents 1
Contents
Page
Introduction.......................................................................................................... 2
Product identification .............................................................................................2
Specifications ...................................................................................................... 3
Disc brake DB19, DB22, DB22LT . .........................................................................3
Tightening torques. ................................................................................................4
Wear limits ..............................................................................................................4
Description of operation. ....................................................................................... 5
Tools ............................................................................................................. 8
General instructions. ........................................................................................... 10
Instructions ...........................................................................................................10
Safety ...................................................................................................................10
Adjustment of control system/valves ...................................................................10
Brake Chamber ....................................................................................................11
Recycling ..............................................................................................................11
Cleaning ...............................................................................................................11
Surface finishing ...................................................................................................12
Brake force distribution ........................................................................................12
Inspection/checks/adjustment . ........................................................................... 13
Inspection intervals. .............................................................................................13
Instructions ...........................................................................................................14
Function test.........................................................................................................19
Initial setting. ........................................................................................................20
Lubrication............................................................................................................21
Service ........................................................................................................... 22
Replacing brake pads ........................................................................................22
Replacing disc brake ...........................................................................................31
Replacing adjustment screw bellows ...................................................................42
Replacing slide bearings and bellows ................................................................54
Replacing calliper housing .................................................................................. 71
Replacing brake chamber ...................................................................................89
Replacing spring brake chamber ........................................................................93
Additional work....................................................................................................................95
Replacing the lip seal and adjustment shaft ........................................................95
Pad Wear Indicator (PWI) .....................................................................................96
Pad Wear Sensor (PWS) .......................................................................................99
Fault-finding. .................................................................................................... 102
Component list. ................................................................................................ 103
Exploded view............................................................................................. 104-105
• 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 without prior notice.
• 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 AB.
• 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.
2 Introduction
Introduction

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1
(2)
3
4
5
Product identification
Type and serial numbers are stamped on an identification plate fixed to the calliper.
1. OEM/Haldex logo 5. Haldex S/N 5150234 (example)
2. OEM P/N (if required) 5 = year, 2005
3. Haldex EC (origin) 15 = week number.
4. Haldex P/N xxxxx 0234 = sequential number
Specifications 3
Specifications
DB19 DB22 DB22LT
Max. brake chamber force ................................................. 13,9 kN 13,9 kN 12,0 kN

Wheel size............................................................................. 19,5”-22,5” 22,5” 22,5”
Number of actuating pistons ............................................ 2 2 2
Number of thrust plates .................................................... 2* 2* 2
Number of slide pins ......................................................... 4 4 4
Hysteresis (of complete brake) ........................................ <10% <10% <10%
Threshold force (for brake assembly) .............................. 50 N 50 N 50 N
Brake chamber stroke ......................................................... >57 mm >57 mm >57 mm
Adjustment for excess clearance (see p. 5). ..................... 14,0% 14,0% 14,0%
Mechanical ratio .................................................................. 15,8:1 15,8:1 15,8:1
Max. adjustment capacity .................................................. 52 mm 52 mm 52 mm
Pad thickness (friction material), new .............................. 22 mm 22 mm 22 mm
Pad backplate thickness ...................................................... 8 mm 8 mm 8 mm
Running clearance, brake pad to brake disc .................... 0,6-1,2 mm 0,6–1,2 mm 0,6–1,2 mm
External diameter of brake disc max ............................... 377mm 430 mm 430 mm
Brake disc thickness, new................................................... 45 mm 45 mm 45 mm
Effective radius .................................................................... 150 mm 173 mm 173 mm
2 2
Swept area, brake disc......................................................... 1420 cm 1860 cm 1860 cm2
Lining area (per pad)........................................................... 155 cm2 192 cm2 160 cm2
Grease ................................................................................... Haldex P/N89652
Sealant ................................................................................... Haldex P/N89653
Anti-seize compound ......................................................... Haldex P/N81934
Weight, disc brake, approx. ................................................ 31,2 kg 39,8 kg 31,5 kg
(Without brake disc/pads/chamber and wear

sensor)
Wear sensor (PWS) Optional
Wear indicator (PWI) Optional
* Previous design 1 thrust plate
DB19 DB22
DB22 LT
4 Specifications
Tightening torques
For number references in ( ) in the text which do not appear in this section, refer to the exploded view
(p. 101-102)
Bolts (22) for attaching disc brake (1) to the axle. DB 19, DB 22 and DB 22LT.
Follow the vehicle/axle manufacturers recommendations or follow the method described below:
Step 1: Tighten to 100±5Nm (for all bolt sizes in the table below)
+;= ? @=
Angle tightening table M16* M18 M20

Pitch
1,0 mm +70° +70° +80°
1,5 mm +50° +50° +55°
2,0 mm +35° +35° +40°
2,5 mm – +30° +35°
Example: Bolt M 16 x 1.5 * = The bolt must not be

Tighten to 100±5 Nm + 50° re-used
DB 19 DB 22 DB22LT
Bolts (78) for calliper housing/bridge (Torx) ................. 390± 20 Nm 560± 30 Nm 390± 20 Nm
Bolts (10) for slide pins (Torx cylindrical) ....................... 220±20 Nm 220±20 Nm 220±20 Nm
Bolts (10) for slide pins (Torx conical) ............................ 280±20 Nm 280±20 Nm 280±20 Nm
Pad retainer bolt (8) ............................................................ 45±5 Nm 45±5 Nm 45±5 Nm
Bolt (81) for PWS ............................................................... 5±1 Nm 5±1 Nm 5±1 Nm
Fixation nuts (27), brake chamber .................................... 180 ±20 Nm 180 ±20 Nm 180 ±20 Nm
Wear limits
Pads (5), min. lining thickness ......................................... 2 mm 2 mm 2 mm
Pads (5), max. uneven wear ............................................... 1 mm 1 mm 1 mm
Brake disc, min. thickness ................................................ 37 mm 37 mm 37 mm
Brake disc, max. wear per side .......................................... 4 mm 4 mm 4 mm
Brake disc, max. lateral runout .......................................... 0,5 mm 0,5 mm 0,5 mm
Brake disc, max. thickness variation ................................. 0,1 mm (DTV) 0,1 mm (DTV) 0,1 mm (DTV)
Carrier (3): max clearance to brake-
pad (5) back plate short side (with new pad) .................. 3,0 mm 3,0 mm 3,0 mm
Carrier (3): max clearance to brake
pad (5) back plate ”bump” (with new pad) ..................... 2,0 mm 2,0 mm 2,0 mm
Description of operation 5
Description of operation

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8 Tools
Tools
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Tools 9
Tool kit P/N 81918
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P/N 81918
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10 Instructions
Instructions
General instructions
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12 Instructions
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Read the safety instructions carefully. See the section entitled ”Safety”. The
vehicle manufacturer’s instructions should also be followed.
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.
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brake function, ensure that the spring brake
chamber is fully disengaged and
mechanically secured in the released position.
See the vehicle manufacturer’s instructions.
14 Inspection/checks/adjustment
Inspection
Instructions
Daily safety check
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function, ensure that the spring brake chamber
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the released position.
See the vehicle manufacturer’s instructions for more information.

Replacing brake pads 23
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Replacing disc brake 31
Replacing disc brake

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";]$ ! "\Q$
Z "K$ 35
! "\Q$
}
"K$
+ {
Fitting bellows
_ ! "QQ$

";]$
! "\Q$"
$Z ! ZYU;;
! {"QQ$
@<&;8A!$
"\;$ "\\$

@<&;8%%; }
"Z$
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7
K*
";]$ !

"\Q$
"\;$ !
"\Q$ @<&;8%%8 "
P/N 89778
$
P/N 89779
_ "\$
32
"\\$
";]$";]$
! "\Q$ 35
35
";]$
! "\Q$
32
" $
/
A
U]||\X# P/N 89936

";|$
P/N 89936
";|$ 29
";|$ ! 29
"\Q$} "Z$
28
";|$
32
! "\Q$+/
P/N 89936

7
K* 29
35
? ";|$
32
P7

/ :
A

3

3
/
*

Replacing bellows on disc brakes

with two separate thrust plate
(later design of ModulX)
Removing the bellows

"\$
? " $
!;

"QQ$ ";]$\QK

"\$ "\;$
";]$
";]$
! ! "\Q$Z
! "\Q$U"\Q$
Do not pry off the thrust plates

(28) using a chisel or suchlike on
the cover (33). This could lead to
damage of the mechanism (4). 33
"\$

35 28 35 28
";|$ 32 32
!"QQ$

!

"\;$ "\\$

Z

IMPORTANT! Avoid damaging the

adjustment screws and/or the
29
seals’ mounting surfaces!
" $

Cleaning
_ "\\$";]$ !
"\Q$
Make sure that dirt and other

contamination does not enter
through the openings at the
adjustment screws!
Inspection
_ {"\;$
"\\$ ";]$

_ { ";]$

! "\Q$
Z "K$

! "\Q$
} U
";$
32
+
35
33
P/N89778
Installing the bellows

! {"\Q$
@<&;8A!$"\;$
"\\$
A
@<&;8%%;
"Z$
@<&;8%%;Z "Z$
";|$ ! "\Q$
"\$

"\\$
";]$
29
29
"\;$ ";]$

? ";]$
! "\Q$ @<
&;8%%; 35
"\;$ ! "\Q$ 32

";]$
28
If protection springs (30) are used:

make sure they are correctly
positioned in their seats and do
not damage the bellows (32)! 28
" $
Fitting brake pads

6
!"QQ$ 7
5 5
;`
"\$ " "\$ $
! U

";]$_
"Q$
6
3
"Q$

Q
}
Q
?
^ Q
#

7

*
} %}" %} $? %} "%}$

Z %
} %+" %+$? %+"%+$

Z %
8
45±5Nm
"X$ "[$

"]$^!G!&
Initial setting
_ "Z$
; !

"QQ$ "Q$ "Z$
<
"Q$ "Z$_

IMPORTANT!

55
A
_ "X|$ _U

^
+ Z 55

P/N 89652

"YQ$ " $= 15
"YQ$
!@<&;8A!$
?"YQ$ !"QQ$_

"YQ$ !"QQ$
"+ $ P/N 89652 15

"Z$ "Q$ ?
!


(min. 6 bar).
%

{

&'*
"
7

H E/ /

/I
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7

3
7/
7

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7

H
54 Replacing slide bearings and bellows
Replacing slide bearings and bellows

!
IMPORTANT!
{

{
(2b) together!


Replacing slide bearings and bellows 55
Removing pads
; ! Release
!"QQ$
";]$
IMPORTANT!

28
IMPORTANT!
33
% ! 30
"\$

"\\$";]$
28

33
30
!
";]$
? "Q$
7
";]$

8
J
"]$ "[$ "X$
%}" %} $
6
6
} %}" %} $? %} "%}$

Z %
} %+" %+$? %+"%+$

Z %
"X$ "Q$ 5
} @<&;8$ "Q$
_ "Q$ ";]$

P/N81920
";$ "\$+
/*
5
3
"Q$
} @<&;8$

P/N81920
"Q$
5
} ? ";X$

▼ A
+ {

";[$

";QU;X$
";Q$ U

";X$ "Z$ 25/26

_ ";QU;X$

#U }
";$

P/N
819
} ^ 27

2
@<&;8$%
";$
Removing disc brake

22 22
{";;$
"[$ "]$_

";;$
"]$ "[$
8
Removing slide pins, slide bearings

and bellows
!
"|$ 9

"[Y$ 9
>

8
%

3
2
71
71
?

"Y$
@<&;8::"
`Y] $ 3
"Y\$ " "\$
";$$ "\$

2
NB!
Do not use gripping tools or simi-

lar - this will damage the slide pin
sealing surfaces!
"\$ ";$
NB! Only grip on external surfa- 2

ces!
Clean the components, removing

any dirt and dust. Use dust remo-
val equipment or a vacuum clea-
ner, but do not use compressed
air - inhaling dust particles may
be harmful to your health!
12
K "Y\$ ";$

"Y;$

6P@QJ>K&>* K //

H $
/

$*
"YK$"

$ 14
6P@QJ>K&>*K//

/ H
/

$* 2

Cleaning/Inspection
_ ";$
"YK$ "Y;$

13
Fitting slide pins, slide bearings 14 14

and bellows
##
_

ZJ ?
P/N81921

^
P/N81921
/
R>
R S 14
+ "YK$ # +

"YK$"
$ ?
";$
`
"YK$U
U]Y|;Y
14
/

"

S
+ "YK$

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!
}
";$

^
=}

+
"Y\$ 2 13

"YK$
+ "Y\$

"Y$
=
= "Y\$ ?

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"Y$

= "Y\$

? "\$

"Y$

? "Y\$

+ "Y\$

"YK$ ";$# "\$
10 Cylindrical
"Y\$" $U

Previous design
"Y$" $
symmetrical 13
"Y\$U
"Y$" $
}^

10 Conical
Later design
assymmetrical
"Y;$ ";$ @< 2

&;8$$
&'*
"[Y$ ?

"Y$^ ^
12
P/N81922
(Consists of three parts)
2
"Y;$
"Y\$
13 12
_ {"Q$ "\$
";$ ";]$Z "Q$"
$J
"Y\$

"\$ ?
"\$ ";$
3
"Y\$? "\$J
"Y;$ 2
NB! Only grip on external surfa-

ces! Do not damage the bellows
(12)!
?

"Y$
@ @<&;8: P/N81933
^ @< (Torx E18 socket)
&;8::"
`Y] $=
10
=
_ ^$$G$& Skyddslock
P/N81927
=
_ ^$;G$&
Cylindrical 220 ±20 Nm
Conical 280 ±20 Nm
_ "\$ ";$

"Y$ ?

=&"+ } U U
10 Cylindrical
!$ 220 ±20 Nm
Previous design

"|$ symmetrical 13
"Y\$%

&'*>

8 /
3 10 Conical

280 ±20 Nm

Later design
assymmetrical

9
Extension
Socket
_ "[Y$
"Y\$ ";$
6P@QJ>K&>*@
%

$*
71
Installing disc brake

_ ?

";QU;X$ "Q$
"[$ "]$_ 22 100 ±5Nm +

angle tightening

U

?U";;$
=
";;$

K3

$$ M
7
O

";;$

";$
";;$
"]$ "[$
G!& /

/

Angle tightening table M16* M18 M20 Standard

protractor for
Pitch angle tightening
1.0 mm +70° +70° +80°
1.5 mm +50° +50° +55°
2.0 mm +35° +35° +40°
2.5 mm - +30° +35°


}

}

+
Fitting brake chamber A
_ "Z$ ";QU;X$ 25/26

#
" $ Z B ▼
";QU;X$" C
{"_$
{
$
}

";QU;X$
" $@<&;8$%
_ ";QU;X$ #

P/N89652
@<& ;8A!$

"KK$
";QU;X$";[$

^;G$&
180 ±20 Nm
27
Fitting brake pads

!"QQ$ 6
;` 7
"\$ " "\$ $
! U

";]$_
"Q$
"Q$

Q
}
Q
?
^ Q
#

7

*
} %}" %} $? %} "%}$

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} %+" %+$? %+"%+$

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8
45±5Nm
"X$ "[$

"]$^!G!&
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_ "Z$
; !

"QQ$ "Q$ "Z$
<
"Q$ "Z$_

IMPORTANT!

55
A
_ "X|$ _U

^
+ Z 55

P/N 89652
Installing the plug (15).

"YQ$ " $= 15
"YQ$
!@<&;8A!$
?"YQ$ !"QQ$_

"YQ$ !"QQ$
"+ $ P/N 89652 15

"Z$ "Q$ ?
!


(min. 6 bar).
%

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7

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7

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7/
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Replacing calliper housing 71
Replacing calliper housing/mechanism

!
VERY IMPORTANT!
{

{


72 Replacing calliper housing
Removing pads
; ! Release
!"QQ$
";]$
IMPORTANT!

28
IMPORTANT!
33
% ! 30
"\$

"\\$";]$
28

33
30
!
";]$
? "Q$
7
";]$

8
J
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%}" %} $
6
6
} %}" %} $? %} "%}$

Z %
} %+" %+$? %+"%+$

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} @<&;8$ "Q$
_ "Q$ ";]$

P/N81920
";$ "\$+
/*
5
3
} ? ";X$

▼ A
+ {

";[$

";QU;X$
";Q$ U

";X$ "Z$ 25/26

Removing disc brake

22 22
{";;$
"[$ "]$_

";;$
"]$ "[$
8
Removing carrier

!
"|$

"[Y$
>

8
%

9 9
3
?
"Y$
@<&;8::"
`Y] $
"Y\$ " "\$

";$$ "\$
2
71
71
NB!
Do not use gripping tools or simi-

lar - this will damage the slide pin
sealing surfaces!
"\$ ";$ 3

2
NB! Only grip on external sur-

faces!
Clean the components, remo-

ving 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!
2b
Removing calliper housing 2a

"[]$
";$ ";$
@<&8%8%"
`; $+'8@<&8%8;
"
`;K $+'$$
78
";$
P/N90797 for DB19/DB22LT

P/N90798 for DB22
Removing slide bearings from cal- 2b

liper bridge.
"Y;$

&'*+/

/
*
"Y\$

";$
12
"YK$"
$
&'*+/

/
* 14
2b
Cleaning/Inspection
_ ";$
"YK$ "Y;$

2b
Z
"[]$
";$
";$
"Y$

13 2b
_ "Y\$

14
Fitting slide pins, slide bearings 14
and bellows
##
_
P/N81921

ZJ ?
P/N81921
14
^
/

R>
R S
+ "YK$ # +

"YK$"
$ ? 14
";$
`
"YK$U
U]Y|;Y
/

"

S
+ "YK$

_ ?

!
}
";$

^
=}

+
Fitting calliper housing
It is important that all the surfaces in the

joint between the calliper housing (2a) and
the calliper bridge (2b) are dry and free
from contaminants (oil, grease, etc.).

"[]$

}Z !

";$ ";X$
Z ";$

";$
"[]$ 390±20Nm DB19/DB22LT
560±30Nm DB22
&'*6
>
3

/
$ *

"[]$
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`;$+'8<+'$$U>
@<&8%8;"
`;K$+'$$
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>I
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+'8 :8G$& PA @<&8%8% P/N90798 for DB22
+'$$ !AG:& P; @<&8%8;
+'$$U> :8G$& PA @<&8%8%

2 13
Fitting slide pins and bearings
"Y\$
"YK$
+ "Y\$

"Y$
=
= "Y\$ ?

"\$
"Y$

= "Y\$?

"\$

"Y$

? "Y\$
10 Cylindrical
"Y\$ Previous design

"YK$ ";$# symmetrical 13
"\$
"Y;$ ";$ 10 Conical

@<&;8$$" "[Y$
? $
Later design
assymmetrical
2
&'*
"[Y$ ? 12

"Y$ ^
"Y;$

P/N81922
"Y\$
(Consists of three parts)
2
13 12
Fitting the carrier 2

_ "Y\$
"Q$ "\$+
/*
"\$ ";$

"Y\$? "\$J
"Y;$
NB! Only grip on external surfa-

ces! Do not damage the bellows
(12)!
?

"Y$ @ @<&;8: P/N81933
^ (Torx E18 socket)
@<&;8::"
`Y] $
=
_ ^
10
$$G$&
=
_ ^$;G$&
_ {"\$

";$
Cylindrical 220 ±20 Nm

"Y$ ? Conical 280 ±20 Nm

=Y"+ } U U
!$
10 Cylindrical
220 ±20 Nm
13
10 Conical
280 ±20 Nm
"|$ 9
"Y\$%

&'* >

8 /
3 9

Extension
Socket
_ "[Y$

"Y\$ ";$
}Z "[Y$

";$
71
71
Fitting disc brake

_ ?

";QU;X$ "Q$
7
"[$ "]$_
8

U

?U";;$
=
";;$

K3

$$ M
7
O

";;$

";$
";;$
"]$ "[$

22 100 ±5Nm +
G!& /
/
angle tightening


Pitch
1.0 mm +70° +70° +80°
1.5 mm +50° +50° +55°
2.0 mm +35° +35° +40°
2.5 mm - +30° +35°

Standard
protractor for
angle tightening

}

}

+
A
Fitting brake chamber
_ "Z$ ";QU;X$ 25/26
#
" $ Z B ▼
";QU;X$ "
C
"_$
{
$
} ^
{
";$

#
P/N89652
180±20 Nm
_ "KK$

@<&;8A!$ ^
_ ";QU;X$#

";QU;X$";[$

^;G$&
Fitting brake pads

!"QQ$ 6
;` 7
"\$ " "\$ $
! U

";]$_
"Q$
"Q$

Q
}
Q
?
^ Q
#

7

*
} %}" %} $? %} "%}$

Z %
} %+" %+$? %+"%+$

Z %
8
45±5Nm
"X$ "[$

"]$^!G!&
Initial setting
_ "Z$
] !

"QQ$ "Q$
"Z$<
"Q$ "Z$_

IMPORTANT!


"YQ$ " $= 55 A
"YQ$
!@<&;8A!$
?"YQ$ !"QQ$_

"YQ$ !"QQ$
55
"+ $
P/N 89652
15

"Z$ "Q$
? !

P/N 89652 15

(min. 6 bar).
%

{

&'*
"
7

H E/ /

/I
*
"
7

3
7/
7

J

7

H
Replacing brake chamber 89
Replacing brake Chamber

!
IMPORTANT!
{

{
together!
27
Removing brake chamber
▼

";Q$ ";$ A
▼

";Q$

"Z$";[$ 25
";Q$ ";Q$
_
#U }

";$ "K$
2
} ^

90 Replacing brake chamber
Fitting brake chamber A
_ ";Q$ 25/26

B ▼
"Z$
_
#" $

? ";Q$
_ ";Q$

"Z$
" $
P/N89652
@<&;8A!$

"KK$
";Q$";[$ 180 ±20 Nm

^;G$& 27
Replacing brake chamber 91
_ ";Q$ "Z$

";Q$
A➞
25
It is important to remove the

lowest drain plug in the chamber
housing.
Other drain plugs can remain in

position in the chamber housing.
If all the plugs remain fitted the

mechanism will not operate cor-
rectly!
%

{

&'*
"
7

H E/ /

/I
*
"
7

3
7/
7

J

7

H
92 Replacing spring brake chamber
Replacing spring brake chamber

$
IMPORTANT!
{

{
together!
26
Removing spring brake chamber
_
";X$ ";$
"$X

Z

+ {
Z" $

Replacing spring brake chamber 93

"Z$ " $ 27
";[$
26
";X$
";X$
B
A
_

#U }
";$ "K$ 2

} ^

Fitting spring brake chamber A
_

25/26
{
";X$
B ▼
"Z$

_
#" $

?

";X$
_ ";Q$

"Z$
" $
P/N89652
@<&;8A!$

"KK$
94 Replacing spring brake chamber
";X$";[$

^;G$&
180±20 Nm
";X$
&'*+

* 27

";Q$ 26

{
X
It is important to remove the

lowest drain plug in the chamber
housing.
Other drain plugs can remain in

position in the chamber housing.
NB! If all the plugs remain fitted

the mechanism will not operate
A➞
correctly! 25
%

{

&'*
"
7

H E/ /

/I
*
Check that the brake hoses do not foul during full wheel and suspension articulation.
"
7

3
7/
7

J

7

H
Additional work 95
Additional work
K7 /

3
=

6 7

3

WJ
/
7
X
3

/
= /

$
Replacing the lip seal (69) and

adjustment shaft (55) 55 69

! "QQ$ 69
!
55
"X|$
}
!
_ "YQ$

"X|$ "X|$
";$ @<&;8A!$
"X|$ !
@<&;8A!$
NB! Directon of fitting!
&'*+
E/Y
E/

"X|$ !"QQ$

P/N81928
@<&;8%;
_

U}
55
69
IMPORTANT!

96 Additional work
Pad Wear Indicator PWI 79c

Removing the Pad Wear Indicator
(PWI)
% %} "[|$
"Q$
"]\$ %}"[|$

} %} "[|$

%}"[|$ J 79a (inner)
%} "[| $
%}"[|$= 79a

"[$ "[$ (outer)
+ Z

%}

"[$%}"[|$
5 5
(outer) (inner)
Fitting the Pad Wear Indicator (PWI)
%} "[|$
"Q$%} "[|$
? "Q$
%} "[|$ "Q$

%}{"[| $ "Z$+?
%} "[|$ "Q$

{";$
+?
%? "[$U%}"[|$

";$%} "[|$
%}"[| $
{

}Z {";$

"[$

";$ +?
+ %} "]\$

Additional work 97
} %}"[|$ =
_ %}
"[| $ "]\$

Transfer of pad retainer in the PWI

plate
+ /
%}{"[| $K"Z$

"[$ "[$
K
3 A A
_ %} "[|$

" $%}"[| $+? 79a
7 79e
"[$ %}"[| $ A
79e A
"Z$
79c
79a
IMPORTANT!
Do not pry/bend the lugs (B) their position ensures that the PWI cable (79e) is
held in place without getting jammed, at the same time as they serve as spacers
to the pad retainer (7)!
%? "[$U%}"[|$

";$%} "[|$
%}"[| $
{

98 Additional work
}Z { 79a

";$ "[$

A 79e
%} "[|$
";$ %} "[|$ B
B
+? A
A
B
79a 79d
79e
79d
Additional work 99
Pad Wear Sensor (PWS)
J
/@ZV 81
_ %+ "]$

"]$

80
2a
{ %+
"]$ "]\$ 80a
"]Y$Y

%+"]$ ";$

";$
_ ";$

%+"]$
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2a
6P@QJ>K&>* 6
/

/$

82 (x2)

3
Q/ ;$

36 O-ring 80

7
3

/$
*
100 Additional work
6P@QJ>K&>*
>

3
@ZV3
?6UU
K'#6

@ZV

3

/

?6UU
K'#

+

7/3
K'#3
@ZV[

3
?6UU
K 7
E
?6UU@ZV

K'#3
@ZV'

K'#7
=
K'#@ZV
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K'#3

=
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37/

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7

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7 3
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3
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7
>

7

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7
3

3

K
7
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37/
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@7 E

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@7

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@ZV

3 /$
K?6UU3
@ZV 7
K'#
@ZV

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K'#@ZV7 E

Additional work 101
/
@ZV3
K'#7 3
?6UU

7

/
@ZV3
?6UU
K'#

Z ? Z `%+

? Y;

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"^ $
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?
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";$
/
@ZV3
?6UUK'#
"];$%+"]$

"];$U]|XQ;
%+"]$ ";$

%+"]$ U 2a

82 (x2)
O-ring 80
#

@ZV; 3

<

/$

E/
;*
+ "]Y$^G&
{ %+

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U
6P@QJ>K&>*" <

7 3

*
_ %+"]$

? {
%+"]$?
%+"]$
J

5±1Nm
+ { +
{

2a 80
102 Fault-finding
Fault-finding
NB Follow safety instructions! See the section entitled ’Safety’.
The vehicle manufacturer’s instructions should also be followed!
V3 Z
+
& 7/

Z
} U _
} "+ { $
}
} {
" $

'7

/<

/<

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< 7

I73 + {
J
+ {
Z
_
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_ U
} + {
}

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7

Z _
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_ + {
}

"
$

&
<
7

_ + { {
Z ?

? + {
Z U + {

} { ?

Component list 103
Haldex Disc brakes

Component list
DB 19
DB 22
DB 22 LT
Y J QK Z !

; _ QQ Z !
; _ Q| %
; _ X _
\ _ XY _
K X; " !$
Q X\ Z !
X XK _ "$
[ XK _ "$
] XX "$
| X[
Y
X] _
Y; X|
Y\ + [Y
YK + [\ J
YQ [K Z !"J$
Y]
[Q Z !"J$
;; [X
;Q [[
;X + []

;[ [| %}
;] [| %}
;| _ [| %}
\ "$ [| %}
\; [| %}
\\ _ [| %}
\Q Z ! [| %}
\[ ] %+
\] ] %+
KY _ ] %+
K\ ]Y
KK ];
KK ]\ _U+
K] ]K + @
K] + "$ ]Q }
Q % ]X
Q\

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Haldex (www.haldex.com), headquartered in Austria Korea
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©2011, Haldex AB. This material may contain
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Commercial Vehicle Systems www.haldex.com

90138-4_GB/03.2011/Landskrona

Service Manual: Disc Brake Modulx Db22, Db22Lt, Db19

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Service Manual: Disc Brake Modulx Db22, Db22Lt, Db19

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Service

Max. brake chamber force ................................................. 13,9 kN 13,9 kN 12,0 kN

(Without brake disc/pads/chamber and wear

* Previous design 1 thrust plate

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Angle tightening table M16* M18 M20

Example: Bolt M 16 x 1.5 * = The bolt must not be

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Application Clearance phase 62 44a

Release Clearance phase

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Contents of tool kit Haldex P/N 81918.

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Tool kit P/N 81918

81922 87833 81933

81927 81928 89778 89779

89781 89780 89936 81919

Means that special attention is required!

Adjustment of control system/valves

Replacing spare parts

             U  

Brake force distribution

Surface ﬁnishing for disc brake

     =

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Brake force distribution

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If the disc brake is equipped with a parking

Inspection of pad wear, visual

Inspection of brake discs, visual.

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Replace the pads!

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Checking brake disc B B

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Cracks in the brake disc Crack length

Checking slide function

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Checking slide pins bellows

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Checking adjustment screws

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