SAF SKRS 9042 SK 500 plus System Maintenance And Repair Manual Download Page 12

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E) Installation instructions

Repairing the brakes

Removing and installing the wheel hub

Park the vehicle on level, solid ground and chock the wheels to
prevent the vehicle from rolling away

Lift the axle using a jack. Do not position the jack in the middle of
the axle.

Completely release the wheel brake by turning the adjusting screw
on the slack adjuster until cam and brake shoes are in the end
position.

Lever the hub cap (SAF Part No. 1 434 1041 00) off the wheel hub
using one of the recesses around the circumference of the hub cap.

Loosen the lock nut and unscrew from the stub axle.
Axle nut wrench: SAF Part No. 2 012 0023 01.
Remove the locking collar.

Unscrew the axle nut.

Pull off the wheel hub.

The complete wheel hub unit can be easily pulled off the stub axle.

If the bearing races tilt on the stub shaft, the hub unit can be pulled
off using a normal workshop puller or SAF Part No. 4 434 3822 00.

Summary of Contents for SKRS 9042 SK 500 plus

Page 1: ...SK RS 9042 SK 500 plus Maintenance and Repair Manual Service Edition 01 2006 ...

Page 2: ...direction of forward travel Type plate for axle identification on the inside of the trailing arm or axle beam Spare parts service for SAF axles and suspension systems When ordering spare parts quote correct axle identification serial no refer to the axle type plate Please enter the vehicle identification figures in the type plates shown below so that correct information is available when required ...

Page 3: ...kes with manual slack adjusters 26 Adjustment of HALDEX automatic slack adjusters 27 Adjustment of S ABA automatic slack adjusters 28 F Slack adjuster G Track control 29 30 H Service tools 31 32 I Tightening torque in Nm 33 The item numbers indicated are given only for identification and to distinguish between different versions Use the part numbers from the valid spare parts documents for identif...

Page 4: ...le lubrication intervals for the camshaft bearing at each brake lining change but not later than every 12 months Approx 40 less individual components in the brakes Wheel bearing clearance adjustment is required as in the past Overview of the Components Hub cap with snap fit Removal and fitting is quick and easy simply lever off and push on New type Present type New type Present type Wheel hub A co...

Page 5: ...pairs is no longer necessary After 500 000 km or after 60 months operation the following 2 procedures are possible 1 Inspection of the wheel bearing for further serviceability with grease change and replacement of the seal rings 2 Replacement of the complete wheel bearing assembly with seals and long term grease packing The wheel hub can continue to be used New type Present type ...

Page 6: ...whole surface is achieved during normal operation The brake linings have an embossed groove on the end surfaces which indicates the maximum permissible lining wear Camshaft The camshafts are mounted in the brake carrier and in the slack adjuster in a compact bearing which allows quick replacement Both bearings have grease nipples and must be regresed every 12 months Both bearings have a long life ...

Page 7: ... not overheated by continuous operation With drum brakes overheating can result in a hazardous deterioration in the braking efficiency With disc brakes overheating can result in damage to surrounding components in particular the wheel bearings This can result in a significant deterioration in road safety e g failure of wheel bearings 7 The parking brake must not be immediately applied when the bra...

Page 8: ...er 500 000 km or 60 months whichever comes first Lubricate camshaft bearings after every brake lining replacement however at least every 12 months The U bolt must be tightened once only within the first 5 000 km after the first loaded test drive Perform general annual inspection brakes air bags tyres etc Perform general annual safety check tractor semi trailer brake compatibility ABS etc Note Be s...

Page 9: ...er W A F 85 2 012 0023 01 Puller for wheel hub 4 434 3822 00 Brake shoe clamping device 3 349 1001 00 Brake drum fixing flanges 3 434 1060 00 Wheel bearing installation drift 3 434 3308 00 Mounting drifter for cassette seal 3 434 1036 00 Brake drum brake lining refacing stages in mm BRAKE type SNK 420 Max permissible turned brake drum bore 424 0 mm Brake drum bore with max permissible wear 425 0 m...

Page 10: ...ue wrench settings Use a torque wrench The use of impact wrenches is not accepted Wheel nuts Spigot hub centred fixing M 22 x 1 5 600 Nm Bolt centred fixing M 22 x 1 5 430 Nm U bolts diagonally in three stages M 22 650 Nm Shock absorber M 24 400 Nm Type plate ...

Page 11: ... 38 2 Outer seal ring 39 O ring 40 Wheel cap complete including items 39 41 41 Plug 059 Brake assembly including items 64 74 75 64 Brake shoe assembly including items 65 71 73 65 Brake shoe with item 66 66 Cam roller 70 Brake lining set including items 71 73 71 Brake lining cam roller side 72 Brake lining ball side 73 Rivet 74 Clamp 75 Return spring 77 Exciter 78 ABS rod sensor 80 1 Protective hos...

Page 12: ...djuster until cam and brake shoes are in the end position Lever the hub cap SAF Part No 1 434 1041 00 off the wheel hub using one of the recesses around the circumference of the hub cap Loosen the lock nut and unscrew from the stub axle Axle nut wrench SAF Part No 2 012 0023 01 Remove the locking collar Unscrew the axle nut Pull off the wheel hub The complete wheel hub unit can be easily pulled of...

Page 13: ... the retainer in the brake shoe using a screwdriver Remove the spring clip Pull the upper brake shoe sideways over the cam and ball pivot point and then remove both brake shoes from the brake carrier Inspecting the camshaft Push the camshaft backwards and forwards firmly in the compact bearing and measure the radial clearance Max permitted radial play 2 mm If the maximum permissible radial clearan...

Page 14: ...bearings see drawing on page 13 Remove the bolts from the compact bearing and replace with a new bearings see page 10 item 81 with parts 85 1 88 1 and item 10 with parts 11 15 and 18 After installation of th e new compact bearing the cams haft must rotate freely Insert the bolts and fit the nuts Tightening torque for the bolts on the compact bearing Brake side 40 Nm Slack adjuster side 35 Nm ...

Page 15: ...camshaft for free rotation If necessary correct the position of the compact bearing relative to the slack adjuster again Push on both seal sleeves until they contact the compact bearing on the slack adjuster side Install the slack adjusters and wear indicators place both cover plates and secure on the axle tube with clamps Pack the compact bearing in the brake carrier and on the slack adjuster wit...

Page 16: ...axle Observe the approved rivet quality see table in chapter Maintenance Replacement of the brake lining Clean all parts and inspect for wear Inspect the brake drum for wear and turn down to the next repair stage if necessary see table in chapter Maintenance instructions Remove the brake lining from the brake shoe Thoroughly clean the mounting surface for the brake lining on the brake shoe grind s...

Page 17: ...s or machine cleaning are not permitted With this type of cleaning there is a danger of cleansing fluid entering the wheel bearing with a consequent failure of the wheel bearing lubrication Inspecting the brake drum Removing and installing the brake drum Inspect the brake surface of the brake drum closely for further serviceability Brake drums with fine hairline cracks in the contact surface can c...

Page 18: ... from the contact surfaces Drive the wheel studs into the brake drum flange until they are flush with the inner surface using a normal workshop drift Ensure that the twist lock engages correctly The circlips 33 are no longer required If necessary the wheel studs can also be correctly positioned by pulling in using a wheel nut Ensure that the ABS exciter ring is in the correct operating position In...

Page 19: ...or recommended media Hook a new return spring into the tabs of the brake shoes Position the upper brake shoe on the ball pivot point and the cam roller surface Suspend the spring clip on the upper brake shoe Tilt the lower brake shoe towards the cover plate until the correct seating on the cam and on the ball pivot point is achieved if necessary turn the camshaft into the required position Insert ...

Page 20: ...the tool can take off material over the whole circumference of the brake linings Now tighten the clamping device Turn down the brake linings Inspect the brake lining surface all over for complete machining If necessary loosen the clamping device and spread the brake shoes slightly further and repeat the machining process Remove the clamping device Remove all chips of the brake lining from the brak...

Page 21: ...3 onto the dowel on the hub nut noting the position of the dowel in relation to the collar Remove the collar and turn the hub nut 2 1 2 holes anti clockwise Reverse the collar and re locate it onto the repositioned hub nut dowel Fit the lock nut 24 and tighten using a torque of 400 Nm Check whether the hub rotates freely and without excessive end float adjust if necessary On the wheel hub replace ...

Page 22: ...r Slack adjuster Carry out a normal test run and check the function and adjustment of the wheel brakes Check the freewheeling of the brake drum and check the clearance repeat the adjustment at the slack adjuster if necessary Brake lining wear indicator On the slack adjuster end the camshaft has a milled groove and a slip on indicator for visual checking of the brake lining wear Wear indicator in v...

Page 23: ...be disassembled for the inspections replace any parts which are worn or damaged The wheel bearings must be in a good and serviceable condition The outer races must still have a correct secure seating in the wheel hub The wheel bearing must turn freely without noises During assembly of the wheel bearing set ensure absolute cleanliness of all the parts as even the slightest dirt can significantly re...

Page 24: ...eel hub together with the seal rings Drive the bearing outer races out of the hub housing using a normal workshop drift Thoroughly clean the hub housing Installing the wheel bearing assembly Install seal ring 38 and protective ring 38 1 in the hub housing Press both bearing outer races into the hub housing until they bottom using installation drift SAF Part No 3 434 3308 00 ...

Page 25: ...e ring gap on the face side of the bearing with long life grease Press in unitised seal 37 and outer sealing washer 38 2 using installation drift SAF Part No 3 434 1036 00 Install the exciter ring Installation drift SAF Part No 3 434 3308 00 If the hubs are subsequently painted ensure that the contact surface for the wheel and brake drum are not painted ...

Page 26: ...usted without delay With a correctly adjusted brake it should be impossible to move the piston rod by hand more than 15 mm Turn adjusting screw to the right until the brake shoes fit closely to the brake drum Turn adjusting screw to the left until the no load stroke at the slack adjuster at 127 mm is approx 10 15 mm long The wheel must rotate freely with no grating noise No load absolu tely no pla...

Page 27: ... see drawing Grease split pin 8 and secure Install return spring 10 Move the control arm 2 in the direction of the arrow operating direction of slack adjuster up to its end position A without applying excessive force When control arm 2 is in its end position A tighten the fixing bolts 4 For the anchor bracket mounting 11 ensure that the 2 U profiles engage firmly together Fit slack adjuster retain...

Page 28: ... coincides with the bore in the clevis end 9 see drawing For the fixed point mounting ensure that the 2 U profiles engage firmly inside one another Grease split pin 8 and secure Install return spring 10 Mount slack adjuster on camshaft Axial clearance Adjust 0 5 2 mm using shims Adjust control arm Possible adjustment range for control lever position slack adjuster up to its end position without ap...

Page 29: ...instruments must be used for performance of the track control on SAF SK Series axles 1 For the original installation in the vehicle manufacturer s works using universal centering on the wheel studs 2 For the service inspection using universal rim centering 29 ...

Page 30: ...ecked at regular intervals The relevant reference point for alignment check is the hub cap centre or stub axle centre Alignment deviations may be caused by loose U bolts spring seat wear deformation of axle assembly components due to excessive vehicle operation For track control the air suspension ride height must be adjusted to the values specified by SAF Semi trailers with trailing steering axle...

Page 31: ...ub cap SAF Part No 1 434 1041 00 2 Axle nut wrench W A F 85 SAF Part No 2 012 0023 01 3 Wheel hub puller SAF Part No 4 434 3822 00 4 Installation drift for unitised seal SAF Part No 3 434 1036 00 H Service tools 31 ...

Page 32: ...5 Wheel bearing installation drift SAF Part No 3 434 3308 00 6 Brake shoe clamping device SAF Part No 3 349 1001 00 7 Clamping rings for brake drum lathe SAF Part No 3 434 1060 00 H Service tools 32 ...

Page 33: ...0 640 770 M 22 W A F 32 550 780 930 M 22 x 1 5 610 860 1050 M 24 W A F 36 710 1000 1200 M 24 x 2 780 1100 1300 M 27 W A F 41 1050 1500 1800 M 27 x 2 1150 1600 1950 M 30 W A F 46 1450 2000 2400 M 30 x 2 1600 2250 2700 M 36 x 2 W A F 55 2450 3450 4150 Wheel fixing Wheels see appropriate axle maintenance chart TRILEX wheels M 18 270 300 Nm M 20 320 350 Nm The following tightening torques are only val...

Page 34: ...4 32 59 33 07 07 34 9 13 82 68 41 48 6 18 31 98 70 40 2 12 50 02 60 39 02 66 16 55 74 45 75 72 74 74 42 02 61 10 45 06 386 26 16 58 35 90 21 22 75 13 21 386 26 16 58 35 Inland home country 03 62 27 23 21 0 59 33 07 07 30 21 09 40 19 80 386 26 16 58 35 0 19 08 64 90 2 61 10 45 06 0800 72 37 37 84 0 73 33 80 81 58 75 72 74 74 9 02 18 19 92 697 91 96 03 88 72 06 43 0 93 51 31 33 41 19 08 64 90 0 87 0...

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