ap hydraulics ltd catalogue web.pdf · ap hydraulics ltd po box 1683 tachbrook road leamington spa...

AP Hydraulics Ltd PO Box 1683

Tachbrook Road Leamington Spa

Warwickshire CV31 3ZU

United Kingdom Tel : 01926 473737 Fax : 01926 473836

Sales Enquiries : 01926 473643

[email protected]

AP Braking is a division of AP Hydraulics Ltd

www.apbraking.com

Table of Contents

Section Contents

1.0 Engineering Excellence

2.0 Opposed Piston Calipers

2 Piston Calipers

4 Piston Centre Split Calipers

Landrover Discovery Up-rated Brakes Package

3.0 Drum Brakes

Leading Trailing Brakes

Duo Servo Brakes

Twin Leading Shoe Brakes

Transmission Brakes

4.0 Brake Actuation

Single Master Cylinders

Tandem Master Cylinders

Direct Acting Vacuum Servos

Remote Vacuum Servos

5.0 Brake Valves

Pressure Reducing Valves

Pressure Failure Conscious Valves

Load Sensing Valves

6.0 Brake Rotors

7.0 Brake Hoses

8.0 Clutch Actuation

Master Cylinders

Slave Cylinders

Dampers

Clutch Hoses 9.0 Misc. Parts 10.0 System Questionnaires 11.0 Heritage Product

Engineering Excellence A.P. Braking is committed to utilise the latest design and test technology to achieve the optimum product performance whilst conforming to our customers ever reducing time constraints. Design and Development The AP Braking Engineering Group have a wealth of experience in all aspects of automotive hydraulics and braking systems. At all stages of the design and development process the latest technology and proven systems are utilised to ensure that our solutions meet all our customers requirements. AP Braking fully utilises the latest generation of CAD technology. Extensive FEA (finite Element Analysis) and exhausting physical test programs verify our product designs. Our engineers are fully conversant with the use of FMEAs and, in addition to performing them on our own products, are competent in helping with our customers larger assembly design FMEAs. By investing in technology compatible with our customers and partners we are able to share our considerable experience to create the best systems for specific vehicle applications Our Engineers are fully trained to use the latest Parametric 3D design CAD technology including Pro/ENGINEER, CADDS5, CATIA, Medusa and SolidWorks. Our CAD technology bridges the gap between our design, manufacturing and materials. Design Verification Finite Element Analysis (FEA) is fully utilised in the design of our products. Extensive stress analysis is carried out at all stages of the design process to achieve the optimum design for strength whilst maintaining an overall compact size. All our products are subject to intensive on and off car test programs, which typically exceed minimum international specification requirements. AP Braking have extensive in-house test facilities that enable performance and durability of product to be rigorously examined. Intensive testing, which simulates the most extreme environmental conditions, ensures that AP Braking deliver the best quality products. Laboratory Services AP Braking on-site laboratory service ensures that the correct materials, used in the design of our products, suit their specific OE applications. Laboratory staff also uses their expertise to make sure that material process-treatments are appropriate for potentially harsh vehicle-operating environments. Their skills are key to manufacturing decisions, ensuring that our manufacturing facility is optimised for machining and that raw materials are supplied to the correct specification. The AP Braking Laboratory is available as a sub-contract service. Please contact AP Braking Sales Dept for details or visit our website.

Installation Expertise Our long experience in vehicle Brakes systems design is commonly utilised by our customers to help them with installation solutions. Our design engineers will help, at all stages of the design process, with installation design. Development technicians will help with prototype installations to ensure components are fitted correctly and interface with steering and suspension components safely. Vehicle Support In-house garage and skilled technicians support all our design, test, prototype and installation requirements. Prototyping Service Due to AP Brakings flexible machining cells, machine shop and advanced computer aided engineering technology prototype components may be produced within relatively short lead times. New Generation Products

A range of New Generation braking components have been developed reflecting advances in technologies and materials alongside the latest trends driven by vehicle manufactures and their customers. New Generation calipers, for example, are lighter, stronger and mechanically more efficient than older products. They also reflect market trends in performance styling.

Sheet 1.1

SECTION 2.0

Opposed Piston Calipers AP Braking opposed piston calipers may be seen on a wide variety of vehicle applications. They are essential where a high braking performance is required. Current applications include 4 x 4, light commercial, high performance and taxicabs. Opposed piston calipers are more efficient than sliding calipers. They are of a very rigid design that evenly loads both pads. They also give a greater level of positive piston retraction. As the caliper does not slide there is not a requirement for direct hoses making rear caliper installation more flexible. AP Braking provides a total design solution to meet individual customer requirements. Body materials vary from aluminium alloy, for lightweight applications, to SG cast iron, for extra strength. Where extra protection is required on, for example 4 x 4 applications, fluid transfer is by cross-drilled holes within the body. Where heat is a real problem, for example on performance vehicles, an external bridge pipe is used.

ABS compatible Simple, robust construction Fast & easy pad replacement Low maintenance High performance High durability Low drag

Sheet 2.0

P

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mm cm2 mm mm mm mm mm mm mm mm mm mm HC112/3 41.3 30.6 M10x1 183 43.2 82.6 79.5 182 73.2 62.8 57 12.7 25.2 HC114/5 44.5 3/8UNFx24 154.4 26 88.9 72.1 127.8 59.7 55.1 53.9 9.5 20.6 HC116/7 46 38.7 M10x1 189.5 43.5 82.6 79.5 187 83 73 70 14.2 28 HC118/9 46 38.7 M10x1 189.5 43.5 82.6 79.5 182 80 75 70 14.2 28 HC120/1 50.8 26.8 3/8UNFx24 157 40.4 88.9 45.2 142.7 63 59.9 65.5 9.6 28 HC122/3 54 31.5 3/8UNFx24 182 34.4 82.6 58.4 156 77.9 60.6 70.5 8.9 29.4 HC124/5 54 31.5 3/8INFx24 182 34.4 82.6 58.4 156 78.5 65 70.5 18 30.8 HC126/7 57.2 38.7 M10x1 189.5 39.7 88.9 69.6 173 83 73 73 14.5 28

CAST IRON OPPOSED PISTON CALIPERS

SHEET 2.1

2 PISTON SIDE SPLIT CALIPERS Piston diameters from 41.3mm to 57.2mm. Standard lug mounting. Hanging or standard pads.

* Dimensions may be modified to suit installation. For more technical and dimensional information, please contact A.P. Brakings Engineering Dept.

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mm cm2 mm mm mm mm mm mm mm mm mm mm HC128/9 41.3 22 M10x1 148 23.8 88.9 77.2 145.5 50.1 48.4 50 7.1 19.4


SHEET 2.2

2 PISTON CENTRE SPLIT CALIPERS Piston diameters from 41.3mm to 57.2mm. Standard lug mounting. Hanging pads.


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mm cm2 mm mm mm mm mm mm mm mm mm mm 2S46M 46 M10x1


SHEET 2.3

2 PISTON CENTRE SPLIT CALIPERS Piston diameters from 41.3mm to 57.2mm. Reverse lug mounting. Hanging or standard pads. External bridge pipe option.


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mm cm2 mm mm mm mm mm mm mm mm mm mm HC130/1 36 24.4 M10x1 173.8 36.1 88.9 45.3 131 83.4 56.2 58 20.6 34 HC132/3 38 43 M10x1 198 45 82.6 63.6 165.6 95.4 63.1 53.5 12.8 27.9 HC134/5 41.3 48.8 M10x1 215.4 39.9 88.9 69 168.4 96.4 68 67.5 14.4 34 HC136/7 41.3 48.8 M10x1 215.4 39.9 88.9 69 168.4 97 76 67.5 24 35.5 HC138/9 46 57.8 M10x1 237 42.8 88.9 67.5-81 164-178 77 70.8 68 14.2 28 HC140/1 46 57.8 M10x1 237 42.8 88.9 67.5-81 167-178 81.8 76.2 68 24 32.8 HC142/3 48 57.8 M10x1 237 42.8 88.9 67.5-81 164-178 77 70.8 68 14.2 28


SHEET 2.4

4 PISTON CENTRE SPLIT CALIPERS Piston diameters from 36mm to 46mm. Standard lug mounting. Hanging or standard pads.


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mm cm2 mm mm mm mm mm mm mm mm mm mm 4S32I 32 4V32IE 32 4V38IE 38 4V48I 48 4V48I 48


SHEET 2.5

4 PISTON CENTRE SPLIT CALIPERS Piston diameters from 32mm to 46mm. Reverse lug mounting. External bridge pipe option. Gold, grey,black or red finish.

For more technical and dimensional information, please contact A.P. Brakings Engineering Dept.

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mm cm2 mm mm mm mm mm mm mm mm mm mm 4V38AE 38 4V41AE 41.3

ALUMINIUM OPPOSED PISTON CALIPERS

SHEET 2.6

4 PISTON CENTRE SPLIT CALIPERS Piston diameters from 38mm to 41.3mm. Reverse lug mounting. External bridge pipe. Grey, black or red finish


This package has been developed in response to customer demand for up-rated braking performance: pedal feel, increased system integrity. Features:- Developed by an original equipment supplier of brakes systems to Land Rover. Powerful opposed piston calipers. 4 x 48mm front & 2 x 46mm rear. No change to ABS functionality. Full installation without minimal modification (trim front dust shield-only) No special tools; standard workshop equipment. Full 12 months warranty. Retro fit Discovery Series 2 complete and Range Rover (P38) front brakes. Benefits:- Better, overall braking performance. Improved pedal feel. Enhanced fade resistance. Simple installation. Meets all current legislation. Also available in blue PTFE paint with external bridge pipe. Please contact AP Braking Sales Dept. for distributor details


SHEET 2.7


Rear installation Front installation

LANDROVER DISCOVERY UP-RATED BRAKES PACKAGE

SECTION 3.0

Drum Brakes Leading Trailing Brake With Parking Facility

The leading trailing brake is suitable for all applications where high degrees of stability and consistent brake performance are required. It includes an effective parking brake facility and is ABS compatible.

A double-ended wheel cylinder attached to the back plate reacting through a fixed abutment actuates the brake shoes. Automatic adjustment for wear is a built in feature, but manual adjustment can also be provided.

The mechanical parking facility offers a choice of forward or cross axle pull actuated by the handbrake lever.

Ease of installation and service Low maintenance High stability Non asbestos linings Efficient park brake Vacuum bleed compatible ABS compatible

Duo Servo Brake With Parking Facility These brakes offer greater braking performance within a limited installation envelope, whilst maintaining an effective parking brake facility. This type of brake is particularly suitable for rear axle applications where vacuum servo assist availability is restricted.

The brake shoes are actuated by a double-ended wheel cylinder attached to the back plate reacting through a fully floating abutment, which generates a self-servo effect. Adjustment is achieved either manually or automatically.

The mechanical parking facility offers a choice of forward or cross axle pull actuated by the handbrake lever.

High brake factor Ease of installation and service Compact installation Low maintenance Non asbestos linings Integral park brake Vacuum bleed compatible

Transmission Mechanical Brake

The transmission-mounted brake gives a mechanical parking brake facility within the vehicles drive train. Used in conjunction with disc/disc foundation brake systems if provides an effective parking brake for multi terrain 4x4 vehicles where the adhesion of all 4 wheels can be utilised to park the vehicle. Actuation is by means of a simple cable system, which enables it to be used in complex installations.

Careful attention to detailed design of this brake enables it to cope with the high speed dynamic application required for residual braking.

Durable/robust construction Allows the operation of four wheel parking Optimum installation

Sheet 3.0

Part Number Drum Diameter Shoe width Wheel cylinder size* mm mm mm

HB104/5 178 38.1 23.8 HB106/7 228.6 44.45 20.32 HB108/9 228.6 44.45 23.8 HB110/1 223.6 44.45 15.9 HB112/3 254 69.9 20.32 HB114/5 254 69.6 23.8

Leading / Trailing Drum Brakes To fit drum diameters 178 to 254. Shoe widths of 38.1 to 69.9. Various wheel cylinder sizes.

DRUM BRAKES SHEET 3.1


Part Number Drum Diameter Shoe width Wheel cylinder size* mm mm mm

HB116/7 254 57.2 15.9 HB118/9 254 69.9 15.9 HB120/1 254 69.9 17.46 HB122/3 254 69.9 19

Duo Servo Drum Brakes To fit drum diameter 254 (10). Shoe widths of 57.2 & 69.9. Various wheel cylinder sizes.



Part Number Drum Diameter Shoe width mm mm

HB124 254 44.45

Transmission Brakes To fit drum diameter 254 (10). Shoe width of 44.45.

DRUM BRAKE SHEET 3.3


Part Number Drum Diameter Shoe width mm mm

HB125/6 178 38.1

Twin Leading Shoe Brakes To fit drum diameter 178. Shoe width of 38.1.



SECTION 4.0

Brake Actuation

Single Brake Master Cylinders

AP Braking supplies a wide range of single master cylinders. They can be fitted either horizontally or vertically with either fluid reservoir attached or fitted remotely. These units are ideal for specialist and heavy-duty applications and can be used for clutch actuation.

Ease of installation and service Low maintenance Vacuum bleed compatible

Tandem Brake Master Cylinders

A comprehensive range of tandem master cylinders is available for passenger cars and light commercial vehicles. They can be supplied as a complete unit or directly mounted onto a vacuum servo, where the interface is rigidly controlled to give minimum lost master cylinder travel, ensuring optimum system efficiency. The master cylinder range covers bore diameters of 17.8mm to 27mm to suit all variations of foundation brake configuration

Double centre valve master cylinders, which are compatible with ABS and traction control systems, are available.

Vertical master cylinders are also available for installations where under bonnet space restrictions prevent the use of the standard horizontally mounted unit

Low maintenance Controlled differential pressure Short cut off ABS and traction control compatible Vacuum bleed compatible

Direct Acting Vacuum Servos

A comprehensive range of vacuum servos is available for passenger cars and light commercial vehicles AP Braking supply units complete with tandem master cylinders. Computer simulation is utilised to ensure that optimum braking performance can be predicted for any given installation.

AP Brakings servos give smooth take up and progressive performance up to the knee point.

Low maintenance Fixed or variable boost ratio Low travel loss Application flexibility No maintenance, sealed unit Light weight, compact design Low friction losses / high efficiency

Sheet 4.0

Remote Vacuum Servos

Three basic sizes of remote servo are available, and each size is available with various bore sizes to suit a large range of vehicle applications. The units fit within the hydraulic circuit to give boost. There are no outside levers, rods or links to clog with rust or dirt or to require adjustment

No maintenance, sealed unit Light weight, compact design Low friction losses / high efficiency

For more information on currently available actuation product please contact AP Brakings Sales Department

Sheet 4.1

BRAKE ACTUATION SHEET 4.2

Barrel and Flange Master Cylinders These single master cylinders are designed to give the greatest manufacturing flexibility, ensuring a wide range of performance and installation solutions are possible.

Piston Diameters & Strokes Piston diameters available are 15.9mm (5/8), 17.8mm (0.7), 19.0mm (3/4), 20.6mm (13/16) and 22.2mm (7/8). Piston strokes are available up to 34mm.

Flange mounting Flange mounting can be vertical, horizontal or at any angle in-between. Fixing dimensions as shown. Through hole or studded fixings are available.

Cylinder orientation Cylinder can be mounted either horizontally or vertically



Fluid reservoir A variety of reservoirs are available for horizontal and vertical mounting in both plastic and tin.

BRAKE ACTUATION SHEET 4.3

Barrel and Flange Master Cylinders (Cont.)

Fluid spouts A variety of spouts are available for feed from remote reservoirs.

SECTION 5.0

Pressure Reducing Valves Pressure Conscious Valve The pressure conscious valve modulates hydraulic pressure to the vehicle rear brakes. The valve operates in a bypass mode until a pre-determined cut-in pressure is attained. The valve is suitable for passenger vehicles where change between laden and unladen weight is small.

Failure-Conscious Valve Failure-conscious pressure reducing valves operate in a similar way to conventional pressure conscious valves but incorporate a feature which monitors the pressure in the front brake circuit. Should a failure occure in the front brake circuit, the cut in pressure of the valve is increased providing a higher pressure to the rear brakes. Load Sensing Single Valve Axle control valves are designed to modulate the rear brake pressure on vehicles, which have a wide variation between laden and unladen height. Single valves operate on a similar principle to conventional pressure conscious valves: a by-pass is maintained until a cut-in point is attained, above which a reduced rate of increase in pressure is supplied to the rear brakes. A Sensing spring is attached between the valve and the rear axle of the vehicle and, a the rear ride height alters due to an increase loading, the cut-in point of the valve is steadily increased to allow the rear brakes of the vehicle to do more work. Should the sensing spring fail, it will revert to fully laden mode to give full brake power to the rear brakes.

Suitable for V split systems Dynamic sensing of load variation Simple hydraulic installation Optimum laden/unladen cut-in pressure Can cope with wide variation in ride height ABS compatible

Load Sensing Twin Valve The twin valve is essentially of similar construction to the single lever type load-sensing valve. This valve has two separate hydraulic circuits for connecting to each rear brake; the twin valve is particularly suitable for light commercial vehicle applications.

Suitable for diagonal split systems Dynamic sensing of load variation Simple hydraulic installation Optimum laden/unladen cut-in pressure Can cope with wide variation in ride height ABS compatible

Sheet 5.0

SECTION 6.0

Brake Rotors AP Brakings experience in brake system technology allows them to design and supply high quality brake discs and drums as original equipment. Toleranced to eliminate brake judder they are also designed to reduce pad and disc wear due to material specification and designed in heat absorption. FEA is used to ensure minimal distortion during utilisation. It is also used, along with the calliper design, to predict and reduce brake noise early in the development program.

Sheet 6.0

SECTION 7.0

Automotive Brake Hose Hose Construction AP Braking use 3.2mm (0.125) double braded automotive hose in their brake hose assemblies. Our brake hose assemblies meet all the applicable International Specification requirements: -

FMVSS 106 SAE J1401 ISO 3996 JIS D2601 ADR 7

A wide range of end fittings, brackets, armouring, clips and sheathing are available. Installation Service Experienced installation engineers ensure that the best hose run is found, thus giving the safest and most economical solution. This service is backed up by a rapid prototype Clutch hoses These hoses are designed to fit the specific installation. A Wide range of fittings and brackets are available and our installation engineers will ensure that the hose route is the safest and least expensive. AP Braking use Goodyear 4.75mm (0.187) double braded hose.

Assembled using OE brake hose equipment.

Sheet 7.0

AUTOMOTIVE BRAKE HOSE

SHEET 7.1

Brake Hose Assemblies AP Braking manufacture a high variety of brake hose assemblies which fit a number of vehicle applications. As all hose installations are different, complete hose assemblies are not shown in this catalogue. AP Braking will make hose assemblies to either the customers specification or will conduct an installation appraisal to ensure that a safe and economical design is achieved. Shown below are examples of some of the fittings in use.


Male Hose End Fittings

Metric or imperial Gasket or cone seal

Female Hose End Fittings

Metric or imperial Standard or inverted cone seal Hex, Star, Cruciform or D location

AUTOMOTIVE BRAKE HOSE

SHEET 7.2


Banjo End Fittings

Flat, neck, pin or nose location Neck cranked to suit installation Supplied with or without banjo

bolt and gaskets

Fixing Brackets

Centre or end Crimped to hose, pressed around

grommet or nut fixing Standard brackets available Bespoke bracket design facility Rubber grommets available for

push in fixing

Hose Clip

Single or twin eye Suitable for ABS and Pad Wear cables Non twist or slip design

Hose protection

Rubber sheaths of various lengths Buffers of various length and diameter Coiled armour in various lengths

Hose to bundy crimped sleeve

Eliminates tube nut fixing Allows hard pipe to be used in non-

articulating areas of hose, simplifying hose run and reducing system expansion

SECTION 8.0

Clutch Actuation Clutch Master Cylinders AP Braking supplies a wide range of clutch master cylinders. They can be fitted either horizontally or vertically with either fluid reservoir attached or fitted remotely. Cast Iron and aluminium are available, although it is the fabricated steel bodies units that give the greatest flexibility of design and installation. These units are ideal for specialist and heavy-duty applications.


Clutch Slave Cylinders AP Braking supplies a range of clutch slave cylinders in cast iron. These units are ideal for specialist and heavy-duty applications.


Clutch Dampers Clutch dampers eliminate clutch pedal vibration and unacceptable noise during clutch actuation. They do this by absorbing vibrations seen as cyclic displacement at the clutch release lever. This is opposed by the drivers pedal effort plus losses in the actuation system. The damper absorbs the cyclic displacement amplitude over a wide frequency range.

May be fixed to the master cylinder or in the hydraulic line. Simple robust construction Service free life.

Clutch hoses These hoses are designed to fit the specific installation. A Wide range of fittings and brackets are available and our installation engineers will ensure that the hose route is the safest and least expensive. AP Braking use Goodyear 4.75mm double braded hose.

Assembled using OE brake hose equipment.

Sheet 8.0

CLUTCH ACTUATION SHEET 8.1

Clutch Actuation Scheme


Barrel and Flange Master Cylinders These single master cylinders are designed to give the greatest manufacturing flexibility, ensuring a wide range of performance and installation solutions are possible.

Piston Diameters & Strokes Piston diameters available are 15.9mm (5/8), 17.8mm (0.7), 19.0mm (3/4), 20.6mm (13/16) and 22.2mm (7/8). Piston strokes are available up to 34mm.

Flange mounting Flange mounting can be vertical, horizontal or at any angle in-between. Fixing dimensions as shown. Through hole or studded fixings are available.

Cylinder orientation Cylinder can be mounted either horizontally or vertically




Fluid reservoir A variety of reservoirs are available for horizontal and vertical mounting in both plastic and tin.


Barrel and Flange Master Cylinders (Cont.)

Fluid spouts A variety of spouts are available for feed from remote reservoirs.

Integral damper This range of cylinders can be supplied with a clutch damper fitted.

SECTION 9.0

SECTION 10.0

SECTION 11.0

AP Braking Heritage Product Heritage Vehicles AP Braking continue to service classic vehicles by manufacturing a variety of product to its original specification off, in many cases, original tooling or tooling used for current original equipment. Product is still available for marks such as Triumph, Mini, MG, Morris, Austin, Rover, Wolseley, Standard Triumph, Austin Healey, BMC, Jaguar, Bedford, Aston Martin, Ford and LandRover to name but a few. For distributor details please contact AP Brakings Sales Department. Classic parts for ex Rover Group companies (Triumph, Mini, Austin, etc) are available from British Motor Heritage Ltd. Visit www.bmh-ltd.com for details.

ap hydraulics ltd catalogue web.pdf · ap hydraulics ltd po box 1683 tachbrook road leamington spa...

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