This manual describes the installation, operation and maintenance procedures for the FAILSAFE emergency brake.
This workshop manual (document MAN-080, dated 14 September 2020) applies to the fourth generation ABT Failsafe Emergency brake from Advanced Braking Pty Ltd, configured for the driveline of Volvo FE, FM and FMX 6x4 heavy trucks. The brake is a spring applied hydraulic release (SAHR) unit bolted to the input side of the rear differential carrier, and is intended as an emergency brake only, to be used in the event of a service brake system failure; it also acts as an additional parking brake.
The manual covers exploded views and parts lists for the differential brake assembly, wiring diagram, installation of the driveline brake, hydraulic, electrical and pneumatic systems, pre-service inspection, control system setup, service schedules with minor and major service procedures, component replacement procedures such as rotor, pads, springs and EMMA piston, service assembly and bleed, and troubleshooting of control unit fault codes.
| Brake type | Enclosed single rotor high-speed disc brake, spring applied hydraulic release (SAHR) |
|---|---|
| Intended use | Emergency brake only, for off-highway use; also acts as an additional parking brake |
| Highway speed limit | Brake recommended to be disabled above 60 kph using supplied retractor bolts |
| Cooling fluid capacity | Approximately 800 ml of ABT cooling fluid |
| Pump fluid | ATF Dexron III |
| Housing bolts | 20x M14 bolts, torque 158 Nm |
| Drive pinion nut torque | 1350–1670 Nm per Volvo/Meritor specification |
| Low battery fault threshold | Below 22 V |
It is intended as an emergency brake only, for use in the event of a service brake system failure, and it also acts as an additional parking brake. It is not designed as an additional service brake or vehicle retarder.
Yes. ABT recommends disabling the brake for highway use or driving above 60 kph by installing the supplied retractor bolts; before operating on a mine site the retractor bolts must be removed and replaced with plugs and pad wear indicator.
Approximately 800 ml of ABT cooling fluid is required when filling the brake unit, refitted with a new copper washer on the fill plug.
Two flashes then a rest indicates a low battery fault (below 22 V). Charge the vehicle battery; the fault will self-clear when the battery voltage is above 22 V.