SAF SKRS 9042 SK 500 plus System Maintenance And Repair Manual
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SAF SKRS 9042 SK 500 plus System Maintenance And Repair Manual

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Maintenance and
Repair Manual
SK RS 9042 - SK 500 plus
Edition 01/2006
Service

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игорь
April 11, 2025

как собрать ремкомплект на тормозной вал

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1 comments:
Mr. Anderson
May 14, 2025

To assemble the repair kit for the SAF SKRS 9042 SK 500 plus brake shaft, follow these steps:

1. Check Cam Roller:
- Ensure the cam roller is properly mounted on the brake shoes.
- It should turn easily without jamming or having radial clearance.
- Replace the cam roller if the journal is severely worn.

2. Install New Cam Rollers:
- For a secure fit, press the two side faces of the cam roller in a vice.

3. Apply Copper Paste:
- Apply copper paste to:
- The brake shoes
- The ball surface
- The two journals of the cam roller
- The two balls in the brake carrier

4. Install Return Spring:
- Hook the new return spring into the tabs of the brake shoes.

5. Position Brake Shoe:
- Place the upper brake shoe onto the ball pivot point and the cam roller surface.

This completes the brake shaft repair kit assembly.

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Summary of Contents for SAF SKRS 9042 SK 500 plus

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

  • Page 2: Saf Axle Identification

    Body type............................Chassis no............................Year of manufacture ........................Registration, date-in-service......................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...

  • Page 3: Table Of Contents

    Use the part numbers from the valid spare parts documents for identification of spare parts. SAF axles and suspension units are subject to continuous further development; the data and drawings contained in the manual may therefore differ from the details given in the operating permit.

  • Page 4: A) Component Description

    A) Component Description The components of the SAF axle Types SK 500 plus have important technical details which distinguish them from other axle types: – Great ease of installation (e.g. only 1/4 of the working time is now required for brake repairs) –...
  • Page 5 A) Component Description Wheel bearing: Thanks to the protected installation of generously dimensioned wheel bearings, long service lives can be achieved. Grease changing at brake repairs 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.

  • Page 6: A) Component Description

    A) Component Description Wheel bearing clearance The wheel bearing clearance has to be adjusted as in the past. Axle nuts The axle nuts have a right-hand thread on both sides. The wheel hub is secured with a lock nut. Brake shoes The brake shoes are each supported spherically on a ball and are held by a spring clamp.

  • Page 7: B) General Service Instructions For Saf Axles And Suspension Units

    We recommend the use of original SAF spare parts. A close-knit service network of SAF partner companies is available for the technical support of the SAF axles and suspension systems and for the supply of original SAF spare parts (see rear cover or on the Internet under www.saf-axles.com).

  • Page 8: C) Maintenance Instructions

    Vehicles used under extreme conditions: service at suitably reduced intervals Warranty claims will only be accepted as long as the operating and maintenance instructions have been complied with and if SAF approved spare parts have been fitted.

  • Page 9: Maintenance Schedule For Sk Rs 9042 - Sk 500 Plus

    Tighten axle nut W.A.F. 85 (22) to a torque of 150 Nm, Wheel bearings: turning the wheel hub at the same time. SAF Part No. 4 387 0011 05 Back off the axle nut by 2 1/2 holes of the locking collar Camshaft: (23).
  • Page 10 D) Spare part illustrations SK RS 9042 - SK 500 plus Torque wrench settings Use a torque wrench. Wheel nuts: U-bolts: Shock absorber: The use of impact wrenches Spigot-hub-centred fixing: (diagonally in three stages) M 24 / 400 Nm is not accepted. M 22 x 1.5 / 600 Nm M 22 / 650 Nm Bolt-centred fixing:...
  • Page 11 D) Spare part designation SK RS 9042 - SK 500 plus Item Parts designation Item Parts designation Axle beam assembly Brake lining set including items 3 - 25 including items 71 - 73 Spherical mounting plate Brake lining, cam roller side Protective plug for ABS Brake lining, ball side Ball...

  • Page 12: E) Installation Instructions

    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.
  • Page 13 E) Installation instructions Brake drum cleaning: The brake drum may only be cleaned using a dry cleaning material. Liquid cleansers, high-pressure cleaners 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.
  • Page 14 E) Installation instructions Remove the spring clip from the groove in the camshaft and pull the camshaft com- pletely out of the bearing. Arrangement and installation position of the camshaft 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).
  • Page 15 Replace the complete compact bearing assembly on the slack adjuster. Coat the splines on the camshaft and the splines on the slack adjuster with copper paste (SAF Part No. 4 387 0007 00). Suitable greases, see chapter “Maintenance instructions”. Push washer and new sealing sleeve onto the camshaft.
  • Page 16 Corrosion-proofed steel rivets are used for securing the linings. The brake linings have a monitoring shoulder on the face end indi- cating the brake lining type approved by SAF and the wear limit for the minimum brake lining thickness. Only brake linings of the same quality may be installed on the same axle.
  • Page 17 E) Installation instructions The brake lining must contact the brake drum over its full surface. The corners of the brake lining must not be broken and the lining must not be cracked at the rivets. Required riveting force: 25,000 N Read off the required working pressure on the setting plate of the rivetter and set the pressure at the pressure gauge.
  • Page 18 The compact wheel bearing units are not removed when turning down the brake drum. Centre wheel hub on the brake drum lathe using clamping device, SAF Part No. 3 434 1060 00 Further machining of the brake drum can then be carried out as nor- mal in the workshop.
  • Page 19 E) Installation instructions Check the proper mounting of the cam roller on the brake shoes. The cam roller must not jam in the mounting. It must turn easily, but without radial clearance. Replace the cam roller if the journal is severely worn. When installing new cam rollers, a secure mounting in the brake shoe can be achieved by pressing in the two side faces in a vice.
  • Page 20 Completely coat the wheel bearing seats on the stub shaft and in the wheel hub with SAF fitting paste (SAF Part No 4 387 0015 06). See chapter “Maintenance instructions” for recommended media.
  • Page 21 Push the complete wheel hub unit with brake drum onto the stub shaft. Screw on the axle nut. Axle nut wrench: SAF Part No. 2 012 0023 01 Hub end-float setting Tighten hub nut (22) to a torque of 150 Nm at the same time rotating the hub and drum.
  • Page 22 E) Installation instructions Check that the cover plate of the brake shoes is correctly installed and correct the positioning, if necessary, using a clamp. Checking the brake lining thickness The brake lining thickness can be checked at the two sight holes in the rear cover plate.

  • Page 23: Repairing The Wheel Bearings

    E) Installation instructions Repairing the wheel bearings Changing the wheel bearing grease As the operations are identical for both procedures, the descriptions are contained in the same chapter. Arrangement of wheel bearing assembly with seals 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.
  • Page 24 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 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: F) Slack Adjuster

    F) Slack adjuster Braking system – checking and adjustment S-cam brakes with manual slack adjusters Due to normal brake drum and brake lining wear, the wheel brakes must be regularly adjusted in order to maintain the full brake cylinder stroke. To ensure maximum brake efficiency, the clearance between brake lining and drum must be kept to an absolute minimum.

  • Page 27: Adjustment Of Haldex Automatic Slack Adjusters

    • For the anchor bracket mounting (11), ensure that the 2 U-profiles engage firmly together. • Observe the correct push rod length “L” as indicated in the SAF specifications. • Fit slack adjuster retaining clip on camshaft. • Membrane brake cylinder •...

  • Page 28: Adjustment Of S-Aba Automatic Slack Adjusters

    (slack adjuster) up to its end position • Observe the correct push rod length “L” as without applying excessive force. indicated in the SAF specifications. • Membrane brake cylinder Before installing the automatic slack adjuster, ensure that the brake chamber push rod is in released position.

  • Page 29: G) Track Control

    G) Track control Commercially available optical measuring 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.
  • Page 30 Semi-trailers with trailing steering axle Distance A, B, C, max. permissible deviation 1.0 mm. Axle alignment responsablety of vehicle manufacturer. Axle toe in/out + 12’ = + 3.0 mm/m, Axle camber + 12’ (SAF manufacturing tolerance) (values apply to unloaded vehicle) Trailer Distance A, B, C, max.

  • Page 31: H) Service Tools

    H) Service tools 1. Lever for hub 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...
  • Page 32 H) Service tools 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...

  • Page 33: I) Tightening Torque In Nm

    I) Tightening torque in Nm The following tightening torques are only valid if no other values are given in the axle maintenance chart. Torque wrenches settings, impact wrench not permissible. Thread Material W.A.F. 10,9 12,9 W.A.F. 13 M 8 x 1 M 10 W.A.F.
  • Page 34 0 21 22 75 13 21 +386 26 16 58 35 +386 26 16 58 35 www.saf-axles.com Otto Sauer Achsenfabrik GmbH · Hauptstraße 26 · D-63856 Bessenbach Tel +49 (0) 60 95 / 301-0 · Fax +49 (0) 60 95 / 301-259 · www.saf-axles.com...

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