si s® driveline raking system service manual · brake description man-028 sibs service manual -...

MAN-028 SIBS SERVICE MANUAL - DRIVELINE BRAKING SYSTEM (REV 2)

SIBS® Driveline Braking System

Service Manual

Important Information

MAN-028 SIBS SERVICE MANUAL - DRIVELINE BRAKING SYSTEM (REV 2) 2

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Revision History Revision Issue Date Author Comments

0 30 May 13 J. Leighton Initial Release

1 20 Nov. 13 J. Leighton Section 8.1 & 13 updated

2 15 Dec. 16 M. O’Driscoll Electrical Schematic updated with door switch connection

© Advanced Braking Pty Ltd, 2016.

All rights reserved. No part of this manual may be reproduced in any form or by any means without the prior written

consent from the copyright holder. While every attempt is made to ensure that the information in this manual is

correct, no liability can be accepted by the authors for loss, damage or injury caused by any errors in, or omissions

from, the information given.



Table of Contents

1. Important Information .............................................................................................................................................. 6

1.1 About This Manual ............................................................................................................................................ 6

1.2 Web Page .......................................................................................................................................................... 6

1.3 Terminology ...................................................................................................................................................... 6

1.4 Ownership ......................................................................................................................................................... 6

1.5 Contact Information .......................................................................................................................................... 6

2. Brake Description ...................................................................................................................................................... 7

3. Brake Specification .................................................................................................................................................... 8

3.1 HGV15 Brake Specification ............................................................................................................................... 8



4. Brake System – Major Components.......................................................................................................................... 9

5. Brake Schematics .................................................................................................................................................... 11

5.1 HGV15 Brake Assembly: Exploded View ......................................................................................................... 12

5.2 HGV15 Brake Assembly: Parts List .................................................................................................................. 13





5.7 HGV17 Piston Assembly: Parts List ................................................................................................................. 20

5.8 HGV17 Adjustable EMMA™ Piston ................................................................................................................. 20

6. Hydraulic System ..................................................................................................................................................... 21

6.1 To Release the Brake ....................................................................................................................................... 21

6.2 To Apply the Brake .......................................................................................................................................... 21

6.3 EMMA™ Pump Assembly: Exploded View ...................................................................................................... 22

6.4 EMMA™ Pump Assembly: Parts List ............................................................................................................... 23

7. Electrical System ..................................................................................................................................................... 25

7.1 SIBS® Wiring Diagram ...................................................................................................................................... 26

8. SIBS® Maintenance Schedule .................................................................................................................................. 27

8.1 Pre-Start Check ............................................................................................................................................... 28

8.2 Minor Service .................................................................................................................................................. 29

8.3 Major Service .................................................................................................................................................. 30

9. Critical Fastener Torques ........................................................................................................................................ 31

9.1 HGV15 Critical Fastener Torques .................................................................................................................... 31





10. Fluids ................................................................................................................................................................... 32

10.1 Handling and Disposal of SIBS® Cooling Fluid .................................................................................................. 32

10.2 Replacing SIBS® Fluid ....................................................................................................................................... 32

10.3 Topping up ATF ............................................................................................................................................... 33

10.4 Grease the V-seal ............................................................................................................................................ 33

10.5 Check Pad Wear (HGV15 & HGV16 only) ........................................................................................................ 34

10.6 Adjusting for Pad Wear (HGV17 only) ............................................................................................................. 35

10.7 Check for Spline Wear ..................................................................................................................................... 36

10.8 Change the V-seal ........................................................................................................................................... 36

10.9 Change the Differential Seal ........................................................................................................................... 36

10.10 Change the Yoke Seal .................................................................................................................................. 36

11. Major Service ...................................................................................................................................................... 37

11.1 Special Tools .................................................................................................................................................... 37

11.2 Disassembly ..................................................................................................................................................... 37

11.3 Assembly ......................................................................................................................................................... 38

11.4 Brake Housings ................................................................................................................................................ 38

11.5 Housing bolts .................................................................................................................................................. 38

11.6 Brake Pads ....................................................................................................................................................... 38

11.7 Rotor ............................................................................................................................................................... 39

11.8 Yoke ................................................................................................................................................................. 39

11.9 EMMA™ Brake Inspection ............................................................................................................................... 39

11.10 EMMA™ Spring Configurations ................................................................................................................... 40

11.11 Change the EMMA™ Filter .......................................................................................................................... 41

11.12 Bleed Hydraulic System ............................................................................................................................... 41

11.13 Adjustment of Flow Control Valve .............................................................................................................. 42

12. Service Record ..................................................................................................................................................... 43

13. Material Safety Data Sheet ................................................................................................................................. 44



1. Important Information

1.1 About This Manual

This manual applies to the Sealed Integrated Braking System (SIBS®). The manual details how to service the SIBS®

system correctly to ensure optimum safety and performance. While every effort has been made to address all

aspects of servicing, please advise Advanced Braking of any omissions or suggestions on how this manual may be

improved.

SIBS® brakes must be maintained according to the manufacturer’s recommendations as detailed in the manual. We

strongly recommend that SIBS® maintenance is conducted by fitters that have been trained and certified by ABT.

1.2 Web Page

The most up to date version of the manual can be obtained by contacting ABT Customer Service Manager or

download from the web page: www.advancedbraking.com

1.3 Terminology

ATF Automatic transmission fluid

BUW Back-up washer

Driveline Brake Single brake unit acting on the rear axle differential

Emergency Brake Brakes automatically applied in an emergency

EMMA™ Electronically Modulated Mechanically Applied

OE Original equipment

Park Brake Brakes applied independently of the service brake

PWI Pad wear indicator

SIBS® Sealed Integrated Braking System

SIBS® Cooling Fluid Specially formulated cooling fluid for use in SIBS® brakes

1.4 Ownership

The SIBS® and EMMA™ Trademarks are owned by Advanced Braking Pty Ltd.

1.5 Contact Information

Street Address: Advanced Braking Pty Ltd Unit 1, 3 McDonald Street West Osborne Park WA 6017 AUSTRALIA Postal address: PO Box 1177 Osborne Park WA 6916 AUSTRALIA

E-mail: [email protected]

Website: www.advancedbraking.com

Phone: +61 (08) 9273 4800

Fax: +61 (08) 9201 9986

http://www.advancedbraking.com/

mailto:[email protected]

http://www.advancedbraking.com/

Brake Description


2. Brake Description

The Sealed Integrated Braking System (SIBS®) is a Spring Applied Hydraulic Release system operating in isolation from

any other braking system fitted to the vehicle. SIBS® has been configured for mounting to the driveline of heavy

goods vehicles. The brake is bolted to the input side of the rear differential carrier. The torque generated by the

brake is transmitted to the rear wheels via the differential and axle shafts. There are three variants of the brake:

HGV15, HGV16 and HGV17, designed for fitment to the following vehicles with and without diff locks:

• Heavy Goods Vehicle 15 (HGV15):

o 24,500 kg GVM 6x4 trucks with Meritor RT40-145 tandem drive rear axles

o 24,500 kg GVM 6x4 trucks with Meritor RT46-160 tandem drive rear axles

o 26,000 kg GVM Hino FM Series 6x4 trucks


o 10,000 kg GVM Isuzu FSS 550 4x4 trucks

o 13,500 kg GVM Isuzu FTS 800 4x4 trucks

o 13,000 kg GVM Hino Ranger Pro 8Z 4x4 trucks


o 18,000 kg GVM MAN TGM Series 4x4 trucks

o 18,000 kg GVM MAN LE Series 4x4 trucks

The SIBS® brake operates as a spring applied hydraulic release emergency driveline brake only. The hydraulic system

has been designed to modulate the application preventing shock loads damaging the driveline.

SIBS® is an enclosed single rotor high-speed disc brake. It provides greater reliability in a compact enclosed package.

The brake is designed for harsh mining environments and is able to be submerged for short periods without affecting

operation.

Important:

2.1.1 The brake is intended as an emergency brake only for use in the event of a service brake system failure.

The system is not designed as an additional service brake.

2.1.2 Do not perform more than one emergency stop from 40 kmph or more every 20 minutes as the brake

may overheat.

2.1.3 The SIBS® Emergency Driveline brake is not designed as a vehicle retarder and should only be used in

the case of an emergency.

2.1.4 The SIBS® Emergency Driveline Brake System is primarily designed for “off highway” use. Whilst it is

possible to operate the brake at highway speeds without damage, unintended application of the brake

will rapidly and effectively arrest the vehicle. ABT recommends that the brake is disabled for highway

use by installing the supplied retractor bolts. This recommendation applies to delivery of the vehicle to

site and any other extended “on highway” use.

WARNING:

The retractor bolts must be removed to re-commission the brake prior to the vehicle commencing service.

Brake Specification


3. Brake Specification

3.1 HGV15 Brake Specification

Mass of Brake 91 kg

Size Ø445 x 245 mm

Brake Torque 8000 Nm1

Hydraulic Release Pressure 2100 psi

Maximum Hold Gradient 32%

SIBS® Cooling Fluid volume 1.5 litres (brake housing)

ATF Fluid volume 2.0 litres (pump reservoir)


Mass of Brake 54 kg

Size Ø400 x 170 mm







Mass of Brake 64 kg

Size Ø400 x 180 mm






1 Brake torque reduces with pad wear.

2 Brake must be adjusted to compensate for pad wear and maintain brake torque. Adjust brake according to

service schedule.

Brake System – Major Components


4. Brake System – Major Components

The braking system consists of three assemblies:

1. Brake assembly

2. Hydraulic system

3. Electrical system

Figure 1: Driveline brake mounted on rear differential. Figure 2: EMMA™ pump unit mounted to vehicle chassis.

Brake System – Major Components


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Brake Schematics


5. Brake Schematics

Key features:

The brake is bolted to the bearing cage on the input side of the rear differential.

The bearing cage located on the input side of the rear differential is machined to provide a seal surface and

spigot for location of the brake.

The rotor is allowed to ‘float’ on a spline machined into a purpose built yoke.

The spline transmits the torque from the rotor to the input pinion at the differential.

The yoke is designed to incorporate an additional seal surface to contain the SIBS® cooling fluid inside the

brake.

Pad wear indicators are included on the HGV15 and HGV16 brake variants and must be inspected according

to the service schedule.

Adjustable pistons to compensate for pad wear are included in the HGV17 brake variant.

Brake Schematics


5.1 HGV15 Brake Assembly: Exploded View

Brake Schematics


5.2 HGV15 Brake Assembly: Parts List ITEM PART NO. DESCRIPTION COMMENTS QTY/BRAKE

1 07-9006 KIT 2367 (NUT AND WASHER) 1

2 07-9006 KIT 2367 (NUT AND WASHER)

3 07-2003 YOKE DRIVE SHAFT With Diff Lock (07-0001) 1

07-2013 YOKE DRIVE SHAFT Without Diff Lock (07-0002) 1

4 01-5086 GREASE NIPPLE STRAIGHT M6 x 1 With Diff Lock (07-0001) 2

01-5115 GREASE NIPPLE M6 x 45 DEGREE Without Diff Lock (07-0002) 2

5 07-2012 V SEAL COVER HGV15 With Diff Lock (07-0001) 1

07-2020 V SEAL COVER HGV15 Without Diff Lock (07-0002) 1

6 01-4132 SEAL V-LIP 1

7 01-4046 SCOTSEAL PLUS 1

8 15-1380 CAP BLEED NIPPLE 4

9 15-1151 BLEED NIPPLE 4

10 15-1330 FILL / LEVEL PLUG 2

11 07-2000 HOUSING OUTER HGV15 1

12 24-3186 CONNECTOR HOSE EMMA 1

13 15-1890 WASHER COPPER 1

14 07-2007 BRAKE PAD 14 GROOVE - ACW HGV15 1

15 07-2016 BRAKE PAD 14 GROOVE - CW HGV15 1

16 07-2008 SPACER BRAKE PAD 2

17 07-2011 SPRING COMPRESSION HGV15 2

18 01-3248 WASHER FLAT M5 2

19 01-3191 SCREW HEX HD M5 x 20 2

20 07-2002 ROTOR HGV15 1

21 07-2010 LEAF SPRING HGV15 9

22 01-3320 SCREW SKT CAP LOW HD M4 x 14 6

23 07-2017 BRAKE PAD HGV15 OUTER CW 1

24 07-2018 BRAKE PAD HGV15 OUTER ACW 1

25 01-3315 SCREW HEX HD M12 x 60 Brake mounting 8

26 07-9013 WASHER FLAT BEARING CAGE Brake mounting (OEM washers) 8

27 01-2107 O-RING HOUSING 1

28 07-2001 HOUSING INNER HGV15 1

29 07-9000 SEAL DIFF HOUSING 1

30 07-2004 COVER DIFFERENTIAL MODIFIED Modified bearing cage 1

31 15-3021 CONNECTOR BARB HOSE 1

32 15-1341 DRAIN PLUG Plug with magnet 1

33 24-2942 BOLT HOUSING FLANGE HEAD Housing bolts 12

34 01-3214 SCREW HEX HD M8 x 16 Plugs 3

35 01-3334 SCREW HEX HD M8 x 75 For removal of outer housing and yoke in one assembly. Use 3 x holes where item 34 are attached

3

36 15-2530 RETRACTOR BOLT Used to make the brake inoperable 4

37 10-3190 PLUG TAPER 2

38 01-3315 SCREW HEX HD M12 x 60 Spring cover bolts 10

39 15-3070 WASHER FLAT HARDENED M12 Spring cover washers 10

40 10-2120 PLUG PAD WEAR INDICATOR 2

41 10-4110 O-RING PAD WEAR INDICATOR 2

42 10-2130 PLUNGER PAD WEAR INDICATOR 2

43 07-2005 COVER EMMA SPRING HGV15 1

44 10-2030 DISC SPRING 4mm thick 64

45 07-2006 PISTON EMMA HGV15 4

46 15-4060 BACK-UP WASHER LARGE EMMA PISTON 4

47 01-2133 O-RING LARGE EMMA PISTON 4

48 24-4030 O-RING SMALL EMMA PISTON 4

49 01-4051 BACK-UP WASHER SMALL EMMA PISTON 4

Brake Schematics



Brake Schematics


5.4 HGV16 Brake Assembly: Parts List ITEM PART NO. DESCRIPTION QTY/BRAKE

1 01-3306 WASHER SPRING (ISUZU FSS 550& ISUZU FTS 800)

8 01-3005 WASHER SPRING (HINO RANGER PRO)

2 01-3298 BOLT (ISUZU FSS 550& ISUZU FTS 800)

8 01-3038 BOLT (HINO RANGER PRO)

3 01-3375 STUD (ISUZU FSS 550& ISUZU FTS 800)

4 01-3448 STUD (HINO RANGER PRO)

4 01-3245 BOLT 24

5 01-3278 NUT 4

6 01-3323 BOLT 4

7 01-4086 V-SEAL 1

8 01-5120 CONNECTOR 2

9 01-5143 CONNECTOR 1

10 02-6008 ELBOW 1

11 02-6009 TEE 1

12 08-2000 EMMA HOUSING HGV16 1

13

08-2020 HOUSING INNER HGV16 (ISUZU FTS 800)

1 08-2033 HOUSING INNER HGV16 (ISUZU FSS 550)

08-2001 HOUSING INNER HGV16 (HINO RANGER PRO)

14 08-2002 ROTOR HGV16 1

15

08-2022 YOKE (ISUZU FTS 800)

1 08-2035 YOKE (ISUZU FSS 550)

08-2032 YOKE (HINO RANGER PRO)

16

08-2017 COVER DIFF HSG MODIFIED HGV16 (ISUZU FTS 800)

1 08-2036 COVER DIFF HSG MODIFIED HGV16 (ISUZU FSS 550)

08-2004 COVER DIFF HSG MODIFIED HGV16 (HINO RANGER PRO)

17

08-9001 SEAL PINION (ISUZU FTS 800)

1 08-9008 SEAL PINION (ISUZU FSS 550)

08-9000 SEAL PINION (HINO RANGER PRO)

18

08-2021 SEAL CARRIER HGV16 (ISUZU FTS 800)

1 08-2034 SEAL CARRIER HGV16 (ISUZU FSS 550)

08-2006 SEAL CARRIER HGV16 (HINO RANGER PRO)

19 08-2008 V SEAL COVER HGV16 V2 1

20 10-3010 REDUCER 1

21 08-2010 CONNECTOR TUBE 1

22 08-2011 BRAKE PAD 14 GROOVE - ACW 2

23 08-2012 HGV 16 PAD RESTRAINING SPRING 4

24 08-2013 HGV 16 PAD RESTRAINING BRACKET 4

25 01-3019 BOLT 8

26 10-2030 DISC SPRING 24

27 10-2050 GASKET SPRING COVER 2

28 10-2060 PAD BRAKE C/W INNER 1

29 10-2070 PAD BRAKE AC/W INNER 1

30 10-2120 PLUG - PAD WEAR INDICATOR 2

31 10-2130 PLUNGER - PAD WEAR INDICATOR 2

32 10-2150 PISTON EMMA 4

33 10-2210 GASKET-SEAL CARRIER 1

34 10-3110 WASHER 4

35 10-3160 BOLT 2

36 10-3190 PLUG TAPER 4

37 10-3210 PLUG 6

38 10-3230 BOLT 8

39 10-3240 SPRING PIN 4

40 10-4080 O-RING 4

41 10-4081 BACK-UP RING 4

42 10-4090 O-RING 4

Table continues on next page…

Brake Schematics


ITEM PART NO. DESCRIPTION QTY/BRAKE

43 10-4091 BACK-UP RING 4

44 10-4110 O-RING 2

45 10-4711 O-RING CONNECTOR MALE 2

46 10-1070 SPRING COVER 2

47 15-1080 O-RING 1

48 15-1342 MAGNET 1

49 01-4082 OIL SEAL HOUSING (ISUZU FTS 800)

1 15-1470 OIL SEAL HOUSING (HINO RANGER PRO & ISUZU FSS 550)

50 15-1560 GREASE NIPPLE 1

51 15-2530 RETRACTOR BOLT 4

52 01-4122 SPEEDI-SLEEVE 1

Brake Schematics


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Brake Schematics



Brake Schematics


5.6 HGV17 Brake Assembly: Parts List ITEM PART NO. DESCRIPTION QTY/BRAKE




4 10-4080 O-RING # 210 4

5 10-4090 O-RING # 335 4

6 10-2030 DISK SPRING 32

7 10-4091 BACK-UP RING # 335 4

8 10-4081 BACK-UP RING #210 4

9 10-3160 SCREW - FLAT HEAD SOCKET UNATRAC 2

10 10-3190 PLUG TAPER 4

11 10-3210 PLUG 3/4' 16 UNO 6

12 10-2210 GASKETSEAL 1

13 09-2010 SEAL CARRRIER HGV17 1

14 08-2002 ROTOR HGV16 1

15 01-3245 SCREW SKT CAP HD 12

16 15-1080 O-RING #279 ID329.79 x 3.53 SECT 1

17 15-1342 MAGNET 1

18 08-2011 BRAKE PAD 14 GROOVE - ACW 2

19 01-3323 SCREW SKT CAP HD M4 x 0.7 x 25LG 4

20 08-2013 HGV 16 PAD RESTRAINING BRACKET 4

21 01-3019 SCREW SKT CAP HEAD M4 x 0.7 x 10LG 4

22 08-2012 HGV 16 PAD RESTRAINING SPRING 4

23 09-2001 PINION CASE MODIFIED 1

24 09-2003 YOKE ROTOR CARRIER 1

25 09-2018 LINK PIPE HGV17 1

26 01-4082 OIL SEAL SHAFT DIA 121.031 1

27 01-4086 LCV 16 SEAL V-LIP 1

28 01-5120 CONNECTOR 9/16" -18 UNF - 7/16" JIC MALE 2

29 01-5143 CONNECTOR HOSE 1/8" BSPT - 1/4" ID HOSE 1

30 15-1560 GREASE NIPPLE 1/8" BSPT 2

31 02-6008 ELBOW 7/16" JIC MF 1

32 02-6009 TEE 7/16" JIC FMF 1

33 10-3010 REDUCER 3/4"-10 UNC TO 1/8" BSPT 1

34 09-2004 BACK HOUSING MOD 1

35 09-0002 PISTON ASSY 4

36 09-2007 SPACER SPRING COVER 2

37 09-2008 WASHER HARDENED 8

38 09-2012 BELL HOUSING 1

39 09-9002 SEAL REAR DIFF INPUT PINION 1

40 01-4126 SEAL SHAFT ID75 X OD105 X 10 1

41 01-2125 O-RING #157 1

42 09-2014 HOUSING OUTER HGV17 MOD 1

43 01-3396 SCREW SKT CSK HD M4 X 0.7 X 16LG 8

44 01-3397 SCREW SKT CAP HD 12

45 01-3171 PIN SPRING DIA 4 x 28LG 4

46 01-3005 WASHER FLAT DIA 14 11

47 01-3398 SCREW SKT CAP HEAD M14 x 1.5 x 25LG 11

48 09-2015 SPACER YOKE 1mm 1

49 09-2016 SPACER YOKE 0.5mm 1

50 09-2017 RETRACTOR BOLT MOD 4

51 01-3400 SCREW HEX HD M14 x 1.5 x 55LG 12

52 01-3401 STUD M12 x 1.5 x 50LG 4

53 01-3402 NUT NYLOC M12 X 1.5 4

Brake Schematics


5.7 HGV17 Piston Assembly: Parts List ITEM PART NO. DESCRIPTION QTY/BRAKE




4 10-4080 O-RING # 210 4

5.8 HGV17 Adjustable EMMA™ Piston

The HGV17 brake is installed with an adjustable piston that allows compensation for pad wear. Piston adjustment

must be carried out manually during service.

Braking torque is directly related to spring deflection. As the pads wear, the spring deflection increases thereby

reducing the spring force and braking torque. In order to compensate for this, the EMMA™ piston has an adjustable

plunger as shown below.

Arrangement of the piston and springs is shown in Figure 3. The springs act to apply load to the pads, and the

hydraulic pressure on the piston acts against the springs.

The length of the piston can be adjusted by accessing the centre of the piston thru the spring cover plug, removing

the grub screw and rotating the plunger clockwise (to lengthen the piston) or anti-clockwise to shorten; Figure 4.

Figure 3: Cross section view of arrangement of pistons and springs.

Figure 4: Cross section view of adjustable HGV17 EMMA™ piston.

Hydraulic System


6. Hydraulic System

The hydraulic system consists of:

Hydraulic pump

Solenoid valve – normally open

Flow control valve

Pressure switch

Filter

Hydraulic manifold

Heavy duty hydraulic hose, pipes and fittings

6.1 To Release the Brake

6.1.1 The normally open solenoid valve is powered shut, blocking the return path to tank.

6.1.2 The pump runs generating pressure to release the spring applied brake.

6.1.3 The pressure switch – set to 1500 psi for HGV16 and HGV17; 2100 psi for HGV15 – turns the pump off

when the pressure in the line exceeds this value.

6.1.4 Any loss of hydraulic pressure below 1500 psi for HGV16 and HGV17 or 2100 psi for HGV15 will cause the

pump to run and generate more pressure.

6.2 To Apply the Brake

6.2.1 Solenoid valve opens allowing pressure to dump via a flow control valve to zero.

Figure 5: EMMA™ brake hydraulic diagram.

Hydraulic System


6.3 EMMA™ Pump Assembly: Exploded View

Hydraulic System


6.4 EMMA™ Pump Assembly: Parts List ITEM PART NO. DESCRIPTION COMMENTS QTY/KIT

1 01-3418 R-CLIP 4

2 07-0009 COVER ASSEMBLY EMMA PUMP cover including toggle latches 1

3 02-6008 ELBOW 90° SWIVEL 7/16" JIC 1

4 24-3188 CONNECTOR MALE 7/16" UNO - 7/16" JIC 1

5 24-3189 PLUG BLANKING 1

6 01-5032 BOLT BANJO HEX HD 2

7 01-4045 SEAL DOWTY 7/16" 2

8

02-6014 MANIFOLD ASSEMBLY 12V includes solenoid, flow control valve, filter and banjo bolts for 12v

1

02-6022 MANIFOLD ASSEMBLY 24V includes solenoid, flow control valve, filter and banjo bolts for 24v

1

9 01-5071 FILTER ELEMENT 1

10 01-5033 DOWTY WASHER 1/4" BSP 1

11 02-7027 PRESSURE SWITCH 1500psi 1500psi pressure switch 1

02-7062 PRESSURE SWITCH 2100psi 2100psi pressure switch 1

12 02-6020 FLOW CONTROL VALVE 1

13 02-7112 SOLENOID COIL 12V suits 12v vehicles 1

02-7030 SOLENOID COIL 24V suits 24v vehicles 1

14 02-6004 SOLENOID VALVE/COIL ASSEMBLY 12V complete valve, coil & screen assy. Suits 12v vehicles 1

02-6023 SOLENOID VALVE/COIL ASSEMBLY 24V complete valve, coil & screen assy. Suits 24v vehicles 1

15 02-6012 SCREEN screen for solenoid valve 1

16 02-6034 RESERVOIR KIT 'H' 108 SERIES reservoir and cap assembly 1

17 02-6035 CAP 'H' RESERVOIR 108 SERIES cap only for reservoir 1

18 02-7019 MOTOR AM SERIES 12V motor only, suits 12v vehicles 1

02-7020 MOTOR BI SERIES 24V motor only, suits 24v vehicles 1

19 02-1013 MOTOR/PUMP ASSY H-RESERVOIR 12V motor and reservoir assembly only, suits 12v vehicles 1

02-1010 MOTOR/PUMP ASSY H-RESERVOIR 24V motor and reservoir assembly only, suits 24v vehicles 1

20 02-2005 SPACER MOUNTING EMMA PUMP 1

21 01-3158 WASHER SPRING M6 6

22 01-3124 NUT HEX M6 6

23 02-7100 RELAY 12V 100A/400A suits 12v vehicles 1

02-7055 RELAY 24V 100A/400A suits 24v vehicles 1

24 07-2022 BRACKET EMMA HGV15 circuit breaker and relay mounting 2

25 01-3131 SCREW HEX HD M10 8

26 01-3271 WASHER FLAT HARDENED M10 16

27 01-4111 PINCHWELD pinchweld rubber seal 1

28 07-2031 PLATE MOUNTING EMMA PUMP 1

29 01-9042 CABLE GLAND 4

30 01-3007 WASHER FLAT M10 2


32 01-3297 SCREW HEX HD 3/8"-16 UNC 2

33 01-3417 SCREW HEX HD M5 x 30 8

34 01-3410 CRANKED CATCHPLATE 4

35 02-2021 BRACKET PUMP UNIT MOUNT 1

36 02-2022 BRACKET PUMP UNIT MOUNT 1

37 01-3327 SCREW HEX HD M5 x 16 8


39 07-2036 SPACER EMMA BOX CATCHPLATE 4

40 01-3084 SCREW HEX HD M6 x 20 4

41 01-3199 WASHER FLAT M6 12

42 01-5180 BULKHEAD UNION W/LOCKNUT 1

43 01-3248 WASHER FLAT M5 24

44 01-3195 NUT NYLOC M5 10

45 24-3201 HOSE 2 HYDRAULIC EMMA 1

46 01-3191 SCREW HEX HD M5 x 20 2

47 07-2023 BOX MOUNTING CIRCUIT BREAKER box and lid for circuit breaker 1

48 02-7067 CIRCUIT BREAKER 60A suits 12v vehicles 1

02-7065 CIRCUIT BREAKER 30A suits 24v vehicles 1

Hydraulic System


ITEM PART NO. DESCRIPTION COMMENTS QTY/KIT

Table continues on next page…

49 01-3095 NUT NYLOC M4 2

50 02-2015 BRACKET LED LAMP bracket for mounting led lamp 1

51 01-3342 SCREW POZI PAN M4 2

52 02-7063 RED LED LAMP dash mount 1

Electrical System


7. Electrical System

Key features:

These vehicles can operate at either 12 or 24V.

Exposed components are mounted in a sealed box.

All connections are Deutsch® and harnesses are a minimum of IP 65.

The circuit breaker is installed on the main power wire from the battery to the motor, as close to the battery

as possible.

The circuit breaker is mounted in a weather-proof box; Figure 6 and Figure 8.

Figure 6: HGV15 and HGV17 EMMA™ circuit breaker box. Figure 7: HGV15 EMMA™ fuse locations.

Figure 8: HGV16 EMMA™ circuit breaker box. Figure 9: HGV16 and HGV17 EMMA™ fuse locations.

EMMA™ circuit breaker above battery box

10A fuses on vehicle side 10A fuses for EMMA™ unit

10A fuses for EMMA™ unit

EMMA™ circuit breaker

Electrical System


7.1 SIBS® Wiring Diagram

SIBS® Maintenance Schedule


8. SIBS® Maintenance Schedule

The following table shows the recommended service intervals for SIBS® emergency driveline brakes fitted to vehicles

being operated in harsh mining environments. ABT recommends that each site undertake a review of the service

intervals and adjust to suit their specific operating conditions.

Above ground mine Underground mine

Pre-Start Check Daily Daily

Minor Service Every 5,000km Monthly

Major Service Up to 2 years depending on operating conditions

Up to 2 years depending on operating conditions



8.1 Pre-Start Check

The prestart check involves a quick check of the fluid levels and confirms proper brake system operation.

8.1.1 Check EMMA™ reservoir level; if low, top up with automatic transmission fluid and check system for

leaks; Section 10.3.

IMPORTANT:

Use only automatic transmission fluid (ATF Dexron III) for the EMMA™ pump.

8.1.2 With the doors closed, ignition switched to ‘ON’ position, press the E-stop button:

The “red” light on the SIBS® control unit should be on.

The park/emergency brake should be applied.

8.1.3 Twist and reset the E-stop button:

The LED light will change to “green”.

The park/emergency brake should now be released.

8.1.4 Check the park brake applies when:

The E-stop is pressed.

The door is opened (if function installed).

The ignition is switched to the ‘ACC’ position.

NOTE:

The E-Stop must be pressed and then reset between each test.

8.1.5 Check the service brake (foot brake) firmly applies the brake.

8.1.6 Drive the vehicle at 10 kmph. Press the E-stop button. The vehicle must stop within 5 metres or within 3

seconds.

IMPORTANT:

The dynamic brake test should be conducted on a loose surface (gravel or similar).

The dynamic brake test should be used as an indication of correct brake function only. The test does not give an indication of pad wear. Normal service intervals as described in this manual should be followed.



8.2 Minor Service

The minor service involves a general system inspection and replacement of the SIBS® cooling fluid.

8.2.1 General inspections:

Check brake for leaks.

Check EMMA™ pump for leaks.

Check hydraulic lines for leaks or damage.

Check all electrical connectors and wiring for damage.

8.2.2 Check brake pad wear for HGV15 and HGV16 brakes only; section 10.5.

NOTE:

The park brake must be applied to measure brake pad wear.

8.2.3 Adjust EMMA™ pistons to compensate for pad wear, HGV17 brakes only; section 10.6.

8.2.4 Replace the SIBS® cooling fluid:

Drain and discard the SIBS® cooling fluid from each wheel-end brake; section 10.1.

Refit the drain plug using a new sealing washer.

Refill the brake up to the level plug (fill to spill) for HGV15 only; 10.2.

Refill the brake with 1.5 litres of SIBS® cooling fluid for HGV16 & HGV17 only; 10.2.

NOTE:

Approximately 1.5 litres of SIBS® cooling fluid should be found in each wheel end. Check for leaks if this amount is not found.

The SIBS® cooling fluid should drain freely from the brake. If it comes out in a “glug, glug” fashion ensure there is no blockage in the SIBS® breather line.

8.2.5 Conduct a “vehicle prestart check”; Section 8.1.



8.3 Major Service

The Major Service is conducted either to replace worn brake pads or as a preventative maintenance activity to

ensure the continued reliable operation of the SIBS® brake. During the Major Service new seals are fitted throughout

the brake and any worn components replaced.

8.3.1 Strip down SIBS® driveline brake; Section 11.2.

8.3.2 Measure pad wear. Replace pads if below specified limits. Original thickness = 14mm. Replace if thickness

< 12.5mm; Section 10.5 and 12.

8.3.3 Check components and replace the following seals:

Housing O-ring

Yoke seal; section 10.10.

V-seal; section 10.8.

Differential seal; section 10.9.

EMMA™ piston O-rings

EMMA™ piston back-up washers (BUWs)

8.3.4 Replace housing bolts; section 11.5

8.3.5 Inspect yoke and rotor spline; section 10.7. Replace if spline teeth of either component are visibly

stepped or there is excessive play in the fit of the two components.

NOTE:

The splines of the rotor and yoke should engage smoothly and slide under load.

8.3.6 Inspect seal surface on yoke, restore with Speedi-Sleeve® if corroded or pitted.

8.3.7 EMMA™ Pump:

Flush EMMA™ hydraulic system with ATF Dexron III.

Replace the EMMA™ filter element (P/N: 01-5071).

Change EMMA™ electrical relay and inspect wiring harness. Coat all exposed terminals Denso-Tape

to protect against corrosion.

8.3.8 Conduct a “Pre-start Check”; Section 8.1.

Critical Fastener Torques


9. Critical Fastener Torques

9.1 HGV15 Critical Fastener Torques

PART NO DESCRIPTION TORQUE (Nm) REFER TO EXPLODED VIEW

ITEM # (Section 5.1)

01-3315 HOUSING MOUNT BOLTS 167-223 25

01-3315 SPRING HOUSING BOLTS 125 38

24-2942 HOUSING BOLTS 61 33

01-3278 PROP SHAFT NUT 200 1

15-1330 FILL PLUG 15 10

15-1341 DRAIN PLUG 15 32

15-2530 RETRACTOR BOLTS 61 36

Misc. DIFF INPUT PINION NUT 1085–1491 Nm -




01-3298 HOUSING MOUNT BOLTS (ISUZU) 200 2

01-3038 HOUSING MOUNT BOLTS (HINO) 140 2



01-3278 PROP SHAFT NUT (ISUZU) 200 5

- PROP SHAFT NUT (HINO) 130 5

Misc. DIFF INPUT PINION NUT 635 -




01-3400 BELL HOUSING MOUNT BOLTS 200 51

01-3298 HOUSING MOUNT BOLTS 215 47



Misc. DIFF INPUT PINION NUT 589-781 -

Fluids


10. Fluids

10.1 Handling and Disposal of SIBS® Cooling Fluid

10.1.1 Refer to SIBS® Cooling Fluid Material Safety Data Sheet for handling instructions; section 13.

10.1.2 SIBS® Cooling Fluid must be disposed of in accordance with all Regulatory and Environmental regulations.

10.2 Replacing SIBS® Fluid

10.2.1 Remove the drain plug from the brake assembly and drain the SIBS® fluid into a drain pan, ready for

disposal.

10.2.2 Before refilling with new SIBS® cooling fluid, ensure that the drain plug has been cleaned and fitted with

new thread sealant tape. Remove the fill plug and fill the system with fresh SIBS® cooling fluid through

this port.

IMPORTANT:

The HGV15 brake IS fill to spill up to the level plug.

The HGV16 and HGV17 brake IS NOT fill to spill. Max fill is 1.5 litres.

Figure 10: HGV17 driveline brake indicating the SIBS® drain and fill plugs.

WARNING:

Use only SIBS® cooling fluid in the brake. Failure to do so may cause brake failure.

The brakes must be drained and filled with new SIBS® cooling fluid if they remain totally immersed in water for lengthy periods.

SIBS® drain plug

SIBS® fill plug

Fluids


10.3 Topping up ATF

10.3.1 Use only automatic transmission fluid (ATF DEXRON III) in the Pump Reservoir. Only top up with the

brake applied

Figure 11: EMMA™ pump assembly installed on vehicle.

10.4 Grease the V-seal

CAUTION:

Maximum of 5 pumps. Do not over grease.

Over greasing will force grease past the seals and contaminate the brake resulting in reduced brake performance and damage to internal components.

10.4.1 Grease and rotate yoke slowly maximum 5 pumps; Figure 12 and Figure 13.

10.4.2 Check state of the V-seal and replace if necessary.

10.4.3 Replacing the V-seal requires removal of propeller shaft.

NOTE:

This is best performed with the rear wheels off the ground and the front wheels properly chocked. This allows rotation of the yoke to ensure grease is evenly distributed behind the V-seal

ATF Filler cap

V-seal greasing point

Fluids


Figure 12: HGV16 brake greasing point. Figure 13: HGV15 and HGV17 greasing point.

10.5 Check Pad Wear (HGV15 & HGV16 only)

10.5.1 With the SIBS® driveline brake engaged; inspect protrusion of pad wear indicators.

10.5.2 Compare to original depth; Section 12.

10.5.3 Replace pads when 3mm or more of wear has occurred. (plunger measurement 3mm less than when new

pads were last fitted)

10.5.4 Complete service history sheet; Section 12.

Figure 14: Cross section view of pad wear indicator on HGV15 and HGV16 brakes.

Plug (P/N: 10-2120)

Plunger (P/N: 10-2130)

O-ring (P/N: 10-4110)

Pad wear measurement

Fluids


10.6 Adjusting for Pad Wear (HGV17 only)

The HGV17 does not come with a pad wear indicator as standard however the piston length can be adjusted to

account for pad wear thereby maintaining the brake torque. Follow the adjustment procedure below:

10.6.1 Tag the vehicle as per site safety requirements, apply the vehicles park brake and install wheel chocks.

10.6.2 Lift the rear axle from the ground to allow the wheels to rotate, as this will be necessary to check for free

rotation of the brake after adjustment.

10.6.3 Release the driveline brake using the dash mounted control box

10.6.4 Access the 4 x spring cover plugs (10-3190) on the brake housing and remove.

10.6.5 Remove the 4 x grub screws from each piston

10.6.6 Using a flat screw driver, turn the 4 x plungers in each piston clockwise until they stop.

10.6.7 Back off each plunger by ¼ of a turn.

10.6.8 Engage the brake using the control box. This applies load to the pistons and ensures the plungers do not

rotate when re-installing the grub screws.

10.6.9 Reinstall the grub screws and firmly tighten using the Allen key.

10.6.10 Before installing the 4 x spring cover plugs, release the brake and check for free rotation of the brake.

10.6.11 Re-install the 4 x spring cover plugs.

10.6.12 Use Silicone to fill in the heads of the spring cover plugs to reduce corrosion and assist with future

servicing.

Figure 15: HGV16 brake mounted to rear differential. Figure 16: Cross section schematic of HGV17 adjustable piston.

10.6.13 Adjustment of the EMMA™ piston will also be required when installing new pads or stripping the brake.

When new pads are installed, back-off the adjustment of the piston by turning the plunger anti-clockwise.

Spring cover plugs

Fluids


10.7 Check for Spline Wear

10.7.1 Ensure SIBS® driveline brake is engaged.

10.7.2 Check for ‘backlash’ in the SIBS® brake by holding the prop shaft with two hands and attempting to rotate

it. Angular movement of the prop shaft represents the ‘slop’ in the SIBS® brake spline.

10.7.3 Strip and investigate splines when backlash is noticeable – with brake engaged prop-shaft is ‘solid’ when

new.

10.8 Change the V-seal

10.8.1 Remove the prop-shaft from the yoke.

10.8.2 Remove the damaged V-seal and clean the area of grease and dirt.

10.8.3 Inspect the yoke seal for leaks – change if necessary.

10.8.4 Install a new V-seal.

10.8.5 Re-install the prop-shaft.

10.8.6 Grease V-seal.

10.9 Change the Differential Seal

10.9.1 To change the differential seal the brake must be disassembled; Section 11.2.

10.9.2 Remove the outer housing, yoke, rotor carrier and outer pads as one assembly.

10.9.3 Drive new differential seal into differential bearing cage till seal metal part is flush with bearing cage

10.10 Change the Yoke Seal

10.10.1 Engage SIBS® driveline brake with the control box.

10.10.2 Remove differential pinion nut

10.10.3 Remove yoke (mark to ensure splines line up on assembly)

10.10.4 Remove the V-seal cover

10.10.5 Try out old seal

10.10.6 Drive new seal into outer housing till the exposed face is flush with the housing face

10.10.7 Replace the V-seal cover

10.10.8 Replace yoke

10.10.9 Fit new pinion nut (critical torque settings)

10.10.10 Re fit V-seal or replace if necessary

10.10.11 Grease V-seal

Major Service


11. Major Service

11.1 Special Tools

Figure 17: Dowel/ guide pins (M10 x 1.5).

11.2 Disassembly

11.2.1 Apply the vehicles park brakes, install wheel chocks and tag the vehicle as per site safety requirements.

11.2.2 Release the SIBS® driveline brake using the control box.

11.2.3 Remove the spring cover plugs and pad wear indicators and install the 4 x M14 retractor bolts. Tighten to

60Nm.

11.2.4 Engage the brake using the control box.

11.2.5 Remove the hydraulic hose to the inner housing.

11.2.6 Drain the brake of SIBS® cooling fluid.

11.2.7 Remove the prop-shaft from the yoke at the brake.

11.2.8 Loosen and remove the lock nut on the rear differential pinion.

11.2.9 Note the position of the yoke on the pinion – mark if necessary.

11.2.10 Remove 2 housing bolts and install guide pins.

11.2.11 Remove the yoke, rotor and outer housing assembly as one unit. This will require the assistance of

another person and suitable lifting equipment (e.g. a trolley jack).

CAUTION:

On vehicles with Meritor differentials, removing the yoke without the outer housing assembly will damage internal components of the brake.

11.2.12 Remove rotor from yoke.

11.2.13 Remove yoke from outer housing.

11.2.14 Once outer housing assembly has been removed, remove the brake pads from the inner housing.

11.2.15 To remove the inner housing, undo the 8 housing mount bolts.

Major Service


11.3 Assembly

11.3.1 Assembly is the reverse of disassembly.

11.3.2 If inner housing was removed, clean the mounting surfaces of the inner housing and bearings cage and

apply Loctite® 515™ to the mating surfaces.

11.3.3 Place the yoke on a table, supported from the stud’s side. Assemble the components to the yoke:

11.3.4 Place outer housing over the yoke

11.3.5 Place rotor onto yoke

11.3.6 Support rotor in position when offering the outer housing, rotor and yoke combination up to the inner

housing

11.3.7 See torque settings for assembly; Section 9.

11.3.8 Fill the brake with SIBS® cooling fluid.

11.3.9 Grease V-seal

11.4 Brake Housings

11.4.1 Check for signs of damage or leakage.

11.4.2 Use Brake cleaner to clean piston bores. Inspect for signs of corrosion, wear or pitting. Use fine emery

paper (#2400 grit) to remove any corrosion.

11.4.3 Smear piston bores with Silicone grease after cleaning. Do not use brake fluid or SIBS® cooling fluid for

this purpose.

11.5 Housing bolts

11.5.1 Check heads of housing bolts. In corrosive environments it is recommended that all housing bolts be

replaced.

11.6 Brake Pads

11.6.1 Original thickness of brake pads is 14.0 mm

11.6.2 Replace if thickness has dropped below 12.5 mm

11.6.3 Brake pads should be free of damage, distortion and/or blocked grooves.

11.6.4 Before reusing brake pads, it is recommended to lightly ‘buff’ the surface of the pads with #240 grit wet-

and-dry sand paper. This will help ensure consistent brake performance.

11.6.5 Note (HGV17 only): when re-installing brake pads, back off the adjustment of the EMMA™ piston to

ensure the brake does not bind. Follow the procedure set out in Section 10.6.

Major Service


11.7 Rotor

11.7.1 Inspect the spline for damage or wear. Replace rotor if the teeth of the spline are visibly stepped, or

thickness of the friction surface of the rotor is below 13.5mm.

11.7.2 Before installing the new rotor, lightly ‘buff’ both friction surfaces of the rotor using #240 grit wet-and-

dry sand paper. This will help ensure consistent brake performance.

11.8 Yoke

11.8.1 Inspect input pinion and rotor splines for damage and wear. Replace yoke if the teeth of the splines are

visibly stepped.

11.8.2 Inspect prop shaft studs for damage. Replace as required.

11.8.3 Replace seal running surface with a Speedi-Sleeve® if damaged or worn

11.9 EMMA™ Brake Inspection

11.9.1 Ensure that the retractor bolts are installed and tight in the spring covers (compressing the EMMA™

springs).

11.9.2 Remove outer housing assembly as described above

11.9.3 With the outer housing on the bench (this is the housing with the spring cover) remove the spring cover

bolts by undoing slowly, in sequence.

11.9.4 Discard spring cover bolts.

11.9.5 Once all 12 bolts are removed the retractor bolts can be wound out in sequence one turn at a time

(relieving tension on EMMA™ springs).

11.9.6 Lift off the spring covers.

11.9.7 Remove the disc springs. Check for cracking and corrosion; replace as required. On installation ensure the

springs are well greased.

11.9.8 Inspect for signs of ATF in with the disc springs as this will indicate there is a leakage of ATF past the large

EMMA™ piston O-ring.

11.9.9 Push out the EMMA™ pistons and check O-ring seal for damage or wear.

11.9.10 Clean and inspect EMMA™ piston bores for corrosion, pitting or wear.

11.9.11 The O-rings and backup washers (BUWs) must be installed as shown in Figure 18.

11.9.12 Ensure the O-rings and BUW are correctly installed on the EMMA™ pistons. Grease O-rings, BUW’s and

pistons with Silicone grease.

11.9.13 Push pistons into housing. Care should be taken to ensure the BUW’s are not pinched during assembly.

11.9.14 Grease the disc springs with a molybdenum disulphide grease (Castrol LMM or similar).

11.9.15 Stack disc springs (6 per piston) as show in Figure 20. Note: springs must be stacked correctly to ensure

correct brake application.

11.9.16 Place gasket and EMMA™ cover over springs.

11.9.17 Fit retractor bolts to the pistons. Carefully wind down in sequence (one turn at a time).

11.9.18 Install EMMA™ cover bolts.

Major Service


11.9.19 See section 9 for critical torque settings.

Figure 18: EMMA™ piston assembly; P/N: 10-2150.

11.9.20 The O-rings and backup washers (BUWs) must be installed as shown in 0.

Figure 19: EMMA™ piston installation. Figure 20: Disc springs (P/N: 10-2030) – well greased during assembly.

11.10 EMMA™ Spring Configurations

10-2150 – EMMA™ Piston

10-4090 - O-ring EMMA™ Large

10-4081 - Backup Washer EMMA™ Small

10-4091 – Backup Washer EMMA™ Large

10-4080 – O-ring EMMA™ Small

Major Service


Figure 21: HGV15 brake has a stack of 16 x 4.0mm disc springs as shown. Total of 64 per brake assembly.



WARNING:

The EMMA™ covers are under spring tension. Take care when removing EMMA™ covers to avoid bending of the cover or pistons.

If the bolts are tightened individually the EMMA™ piston may retract from the bore.

11.11 Change the EMMA™ Filter

11.11.1 Wipe the filter to remove dirt and prevent contamination of the fluid when the filter is removed.

11.11.2 Use a 25mm spanner and loosen the filter element

11.11.3 Remove used filter and replace.

11.12 Bleed Hydraulic System

11.12.1 Engage the pump using the control box. If it does not work, ensure the door is closed & check the

connections using the wiring diagram.

11.12.2 Bleed the EMMA™ system via the bleed nipple.

11.12.3 Top up the ATF reservoir

Major Service


11.13 Adjustment of Flow Control Valve

11.13.1 Adjustment of the flow control valve is achieved by loosening the locknut on the valve and turning the

adjustment screw with an Allen key:

11.13.2 Turn adjustment screw CLOCKWISE to increase the pressure setting – this will reduce the application rate

of the brake

11.13.3 Turn the adjustment screw COUNTER-CLOCKWISE to reduce the pressure setting – this will increase the

application rate of the brake.

Service Record


12. Service Record

(To remain with the vehicle for completion at future service intervals)

Date Odometer/

Vehicles hours

Fitter SIBS® cooling fluid change

(Y/N)

* Pad wear indicator

measurement (mm)

Spline check (angle)

Comment

*See section 10.5 for measurement procedure

Material Safety Data Sheet


13. Material Safety Data Sheet Issued Date : November 2013 Issued by ABT

Product Name : SIBS COOLING FLUID Classified as hazardous according to criteria of NOHSC

1. IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND COMPANY

Product Name SIBS COOLING FLUID – BLEND 20 Product Use Coolant for Sealed Integrated Braking System Company Name ADVANCED BRAKING PTY LTD (ABT) Address PO Box 1177, Osborne Park WA 6916 AUSTRALIA Emergency Tel. Telephone Tel: +61 8 9273 4800 Number/Fax Fax: +61 8 9201 9986

2. COMPOSITION/INFORMATION ON INGREDIENTS

Ingredients Name CAS Proportion Liquid Hydrocarbons 100% Paraffins & Napthenes Ingredients determined Not required Balance not to be hazardous

3. HAZARDS IDENTIFICATION

Classified as hazardous according to NOHSC criteria. Not classified as dangerous goods according to the ADG code. Risk Phrases R65 Harmful: may cause lung damage if swallowed. Safety Phrases S62 If swallowed, do not induce vomiting; seek medical advice Immediately and show this container or label.

4. FIRST AID MEASURES

Inhalation Remove the source of contamination or move the victim to fresh air. Ensure airways are clear and have qualified person give oxygen through a facemask if breathing is difficult. If irritation develops and persists, seek medical attention.

Ingestion DO NOT induce vomiting. Immediately wash mouth with water. Seek immediate medical attention. Skin Remove contaminated clothing. Wash gently and thoroughly with water and non-abrasive soap.

Ensure contaminated clothing is washed before re-use or discard. If irritation develops, seek medical attention.

Eye If contact with the eye(s) occurs, wash with copious amounts of water, holding eyelid(s) open. Take care not to rinse contaminated water into the non-effected eye. If irritation develops and persists, seek medical attention.

First Aid Facilities Eye wash and normal washroom facilities. Advice to Doctor Treat symptomatically. Other Information For advice, contact a Poisons Information Centre (Phone e.g. Australia 131 126; New Zealand 0800 764

766) or a doctor (at once).

5. FIRST AID MEASURES

Extinguishing Media Water fog, carbon dioxide, foam or dry chemical. Do NOT use water jets. Cool fire exposed containers with water spray. Specific Hazards Combustible C1 liquid. Fire-exposed container may rupture/explode. Hazardous Combustion Products

Under fire conditions this product may emit toxic and/or irritating fumes including oxides of carbon.

Precautions in connection with Fire

Self-contained breathing apparatus (SCBA) and full protective clothing should be worn to minimize exposure.

6. ACCIDENTAL RELEASE MEASURES

Remove all sources of ignition. Increase ventilation. Evacuate all unnecessary personnel. Wear full protective equipment and clothing to minimize exposure. If possible contain the spill. Place inert, non-combustible, absorbent material onto spillage. Use clean non-sparking tools to collect the material and place into a suitable labeled container. If large quantities of this material enter the waterways contact the Environmental Protection Authority, or your local Waste Management Authority.

7. HANDLING AND STORAGE

Handling Repeated or prolonged contact with this material should be avoided in order to lessen the possibility of skin disorders. It is essential that all who come into contact with this material maintain high standards of personal hygiene i.e. washing hands prior to eating, drinking or going to the toilet. Build-up of mists



Issued Date : November 2013 Issued by ABT


in the working atmosphere must be prevented. Storage Combustible C1 liquid for storage and handling purposes. Store in a cool, dry, well-ventilated area, out

of direct sunlight. Avoid sparks, flames, and other ignition sources. Store away from incompatible materials such as materials that support combustion (oxidizing materials). Reference should be made to Australian Standard AS1940- The storage and handling of flammable and combustible liquids.

8. EXPOSURE CONTROLS, PERSONAL PROTECTION

Exposure Limits No exposure standards have been established for this material by the National Occupational Health And Safety Commission (NOHSC).

Respiratory Protection Avoid breathing of vapours or mists. Where ventilation is inadequate and vapours or mists are generated the use of an approved respirator with filter complying with AS/NZS 1715 and AS/NZS 1716 is recommended; however final choice of appropriate breathing protection is dependent upon actual airborne concentrations and the type of breathing protection required will vary according to individual circumstances. Expert advice may be required to make this decision. Reference should be made to Australian Standards AS/NZS 1715- Selection, Use and Maintenance of Respiratory Protective Devices; and AS/NZS 1716- Respiratory Protective Devices.

Eye Protection Safety glasses with side shields, goggles as appropriate recommended. Final choice of appropriate eye/face protection will vary according to individual circumstances i.e. methods of handling or engineering controls and according to risk assessments undertaken. Eye protection should conform to Australian/New Zealand Standard AS/NZS 1337 - Eye Protectors for Industrial Applications.

Hand Protection Wear gloves of impervious material. Final choice of appropriate gloves will vary according to individual circumstances i.e. methods of handling or according to risk assessments undertaken. Reference should be made to AS/NZS 2161.1: Occupational protective gloves - Selection, use and maintenance.

Body Protection Wear appropriate clothing including chemical resistant apron where clothing is likely to be contaminated. It is advisable that a local supplier of personal protective clothing is consulted regarding the choice of material.

Eng. Controls Natural ventilation should be sufficient, however where vapours or mists are generated the use of a local exhaust ventilation system (drawing vapours/mists away from workers breathing zone) is recommended.

Other Information No biological limit allocated

9. PHYSICAL AND CHEMICAL PROPERTIES

Appearance Clear and bright liquid Melting Point Not available Boiling Point 282 – 307oC Solubility in Water Immiscible Specific Gravity (H2O=1)

0.827 @ 15ºC

pH Value Not applicable Vapour Pressure <0.1 mmHg @ 20 oC Viscosity 4 cSt @ 40ºC

1.5 cSt @ 100ºC Flash Point Min 130 oC (ASTM D56) Flammability Classified as a Class C1 (COMBUSTIBLE LIQUID) for the purpose of storage and handling, in accordance

with the requirements of AS1940. Remove all sources of heat and ignition. Ignition Temperature >210ºC (ASTM E-659) Flammable Limits LEL Not available Flammable Limits UEL Not available

10. STABILITY AND REACTIVITY

Stability Stable under normal conditions Hazardous Polymerization Will not occur Materials to Avoid Strong oxidisers such as hydrogen peroxide, nitric acid, sulphuric acid, etc. Hazardous Decomposition Products

Thermal decomposition and combustion produce noxious fumes containing oxides of carbon.

Hazardous Reaction Reacts with oxidising agents. Conditions to Avoid Heat, direct sunlight, open flames or other sources of ignition.

11. TOXICOLOGICAL INFORMATION

Toxicology Information No toxicity data is available for this material. Inhalation May cause irritation to the mucous membrane and upper airways, where material is heated and is

used in poorly ventilated areas. Symptoms may include headache, dizziness, sleepiness, orientation loss and nausea.

Ingestion Harmful-may cause lung damage if swallowed. Subsequent to ingestion or vomiting, small amounts of liquid aspirated into the respiratory system may cause severe pulmonary injury that may lead to death. May also cause irritation to the gastrointestinal system. Symptoms may include nausea, vomiting,



Issued Date : November 2013 Issued by ABT


diarrhea and abdominal pain. Skin May cause irritation in contact with the skin, which may result in redness and itchiness, possibly

leading to dermatitis. Eye May cause eye irritation, resulting in redness, stinging and excessive tearing. Chronic Effects Prolonged or repeated contact with this material may result in skin irritation possibly leading to

dermatitis.

12. ECOLOGICAL INFORMATION

No ecological data is available for this material Environ. Protection Avoid contaminating waterways, drains, sewers, or ground. Mobility No data available for this specific product. Persistence/Degradability No data available for this specific product. Bioaccumulation No data available for this specific product. Ecotoxicity No data available for this specific product.

13. DISPOSAL CONSIDERATIONS

Dispose of waste according to federal, E.P.A. and state regulations. Assure conformity with all applicable regulations

14. TRANSPORT INFORMATION

Not classified as a Dangerous Good according to the Australian Code for the Transport of Dangerous Goods by Road and Rail.

U.N. Number None Allocated Proper Shipping Name None Allocated DG Class None Allocated Hazchem Code None Allocated Packing Group None Allocated

15. REGULATORY INFORMATION

Risk Phrase R65 Harmful: may cause lung damage if swallowed. Safety Phrase S62 If swallowed, do not induce vomiting; seek medical advice immediately and show this container or

label. Poisons Schedule S5 Hazard Category Harmful Packaging & Labelling Labeling requirements of the Standard for Uniform Scheduling of Drugs and Poisons do not apply to a

poison that is packed and sold solely for industrial, laboratory or manufacturing purposes; however is labeled in accordance with the National Occupational Health and Safety Commission's 'National Code of Practice for the Labeling of Workplace Substances'

16. OTHER INFORMATION

SDS History MSDS Creation: January 2005 (Infosfe No. LPU8Z); revised July 2009 (Company details updated) reviewed to NOHSC:2011(2003) & released by ABT; revised Nov 2013 (change of base oil and related information) & released by ABT...End Of MSDS.

si s® driveline raking system service manual · brake description man-028 sibs service manual -...

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