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Valx WSM DRUM Workshop Manual

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WSM DRUM
WORKSHOP MANUAL DRUM BRAKES
Document code: WSM_2051-04
Date: October 2020

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Summary of Contents for Valx WSM DRUM

  • Page 1 WSM DRUM WORKSHOP MANUAL DRUM BRAKES Document code: WSM_2051-04 Date: October 2020...
  • Page 3 General update This document and all information herein is and remains at all times the exclusive property of VALX B.V. and shall not - in whole nor in part - without the prior written permission of VALX B.V. be disclosed to any other person, published in any form of publicity or news story, copied, photographed, reproduced or stored in any retrieval system of any nature.
  • Page 4 This Workshop Manual is intended for trained and qualified service technicians to enable them to perform all required maintenance and repair tasks on VALX products in an efficient, safe and environmentally sound way. TAKE THE TIME TO READ THIS MANUAL THOROUGHLY BEFORE PERFORMING ANY MAINTENANCE OR REPAIR TASK.
  • Page 5 “VALX” is used as a substitute for “VALX B.V.” NOTE The VALX drum brake trailer axle has been designed for 0-offset wheels. 0-offset Document code The document code of this manual can be found in the footer of each page. The document code consists of two fields:...

  • Page 6: Table Of Contents

    General safety instructions and regulations General This manual Decals and instructions on the product Warranty and original VALX parts Maintenance and repair A contribution to the protection of our environment Safety instructions when working on the brake system Safety instructions when working on the wheel hub unit...

  • Page 7: Pictograms In This Manual

    Pictograms in this manual Pictograms for general alerts In this manual the following pictograms and symbols may be used for general alerts: NOTE Important instruction, recommendation or tip that you must always observe. If the safety instruction is not observed, a potential hazardous situation can occur, causing personal injury or damage to the product, the workshop or the environment.

  • Page 8: Symbols

    Symbols Sometimes, a picture or a pictogram tells more than text can. For that reason, the maintenance, assembly and disassembly procedures in the chapters 5 through 9 mainly consist of graphical instructions. In these graphical instructions the following pictograms may be used: Tools Use a spanner The value in the left-hand corner is the width across flats.
  • Page 9 Special tools Use the central nut locking tool Use the socket wrench (width across flats 75) The value in the left-hand corner is the width across flats. Use the special socket tool (width across flats 103) The value in the left-hand corner is the width across flats. Lubricants Lubricate with Optimol White Paste Optimol White Paste Lubricate with Mobilith SHC 220 Mobilith SHC 220 Lubricate with Renolit HLT1...
  • Page 10 Miscellaneous Release the brake Release the brake prior to this step. Actuate the brake Actuate the brake prior to this step. Visual check Check for damage, wear, corrosion, correct fastening. This step requires two trained and qualified service technicians Clean with a lint free cloth Measure WSM_2051-04...

  • Page 11: Symbols For Quick Reference

    Symbols for quick reference Place the wheel chocks (see § 6.1 ) Jack up the trailer (see § 6.2 ) Remove the wheel(s) (see § 6.3 ) Install the wheel(s) (see § 6.4 ) Remove the brake shoes (see § 7.4.1 ) Install the brake shoes (see §...
  • Page 12 Adjust the slack adjuster (see § 7.4.9 ) Remove the brake cylinder (see § 7.4.10 ) Install the brake cylinder (see § 7.4.11 ) Remove the S-cam and the S-cam bearing (see § 7.4.12 ) Install the S-cam and the S-cam bearing (see § 7.4.13 ) Install the ABS sensor (see §...

  • Page 13: General Safety Instructions And Regulations

    - All products of VALX are covered by warranty as stipulated in the “VALX Warranty Conditions”. The “VALX Warranty Conditions” can also be downloaded from our website www.valx.eu. - Modification and / or conversion of the product without the written consent of VALX is not allowed at the risk of forfeiting all warranty rights.

  • Page 14: A Contribution To The Protection Of Our Environment

    - Never use worn tools and do not leave tools behind on the trailer axle or on the trailer. - Never weld on any part of the trailer axle or suspension without the prior written permission of VALX. - Never re-use self-locking fixing materials. Always replace them.

  • Page 15: Explanation Of The Axle Type Code

    Explanation of the axle type code 2.1 Location of the identification plate Type: Axle nr.: Brake appr.: Prod. nr.: Perm. axle cap. stat.: V Max.: km/h 2.2 Information on the identification plate The identification plate consists of the following fields: Axle type code The axle type code is built up as shown in the table below. Brake Brake Wheel...

  • Page 16: Ordering Of Parts

    Hub with 6 wheel bolts Hub with 8 wheel bolts Hub with 10 wheel bolts Unique ID number axles Ordering of parts See the parts ordering procedure on www.valx.eu or contact VALX at tel: +31 (0)88 405 88 00. WSM_2051-04...

  • Page 17: Maintenance Chart

    Maintenance chart NOTE As road conditions may vary from one country to another, and specific use of the trailer axle may differ per user, the maintenance intervals given below are only indicative. The maintenance tables differentiate between on-road use (X) and off-road use (0). Inspection item Maintenance task See section...

  • Page 18: Tightening Torques

    Tightening torques NOTE Always tighten or check the fasteners with a calibrated torque wrench. Torques Subassembly Chapter Item Size Width across flats Inspection When replacing Brake system 1 Dust cover bolt 20 Nm 22 Nm ± 4 Nm 2 Brake cylinder nut M16 x 1.5 175 Nm 210 Nm –...

  • Page 19: Axle Complete

    Axle complete Overview NOTE The VALX drum brake trailer axle has been designed for 0-offset wheels. Brake system (drum brake) (see chapter 7 ) Wheel hub unit (see chapter 8 ) Air suspension system Axle beam (see chapter 9 )

  • Page 20: Preparatory Actions

    Preparatory actions Place the wheel chocks Position the trailer on an even surface and use wheel chocks to secure the trailer against rolling away. WSM_2051-03...

  • Page 21: Jack Up The Trailer

    Jack up the trailer Previous steps / vorige Schri e Previous steps étapes précédentes / vorige stappen 200 mm 200 mm §6.1 Only use approved devices to jack up the trailer. Place the jack only at the indicated positions. WSM_2051-04...

  • Page 22: Remove The Wheel(S)

    Remove the wheel(s) Previous steps / vorige Schri e Previous steps étapes précédentes / vorige stappen § 6.1 § 6.2 >25 kg WSM_2051-04...

  • Page 23: Install The Wheel(S)

    Install the wheel(s) Previous steps / vorige Schri e Previous steps étapes précédentes / vorige stappen >25 kg § 6.1 § 6.2 § 6.3 630Nm No grease, oil or paint is allowed on the threaded surface or on the wheel nut. Torques Item Size...
  • Page 24 WSM_2051-04...

  • Page 25: Brake System

    Brake system Safety instructions Always observe the general safety instructions and regulations (see chapter 1). Overview A Cotter pin S-cam shaft Yoke pin D-washer C1 Nut Shoe anchor pin C2 Set nut Roller Yoke Bush Brake cylinder Roller shaft F1 Circlip Roller retainer F2 Wear indicator W1 Brake shoe...

  • Page 26: Periodic Maintenance And Inspection

    Periodic maintenance and inspection 7.3.1 Check the thickness of the friction material of the brake lining min. 5 mm 7.3.2 Check the internal diameter of the brake drum Previous steps / vorige Schri e Previous steps étapes précédentes / vorige stappen §...
  • Page 27 7.3.3 Check the draining plugs Check if the draining plugs at the bottom side of the brake cylinder have been removed. WSM_2051-04...
  • Page 28 7.3.4 Check the functioning of the slack adjuster Previous steps / vorige Schri e Previous steps étapes précédentes / vorige stappen § 6.1 § 6.2 Go to step 2 REV. Released FINISH: GENERAL TOLERANCES: CHK'D pro CHK'D pro DRAWN Go to §7.3.5 MATERIAL: DrawingType: TITLE:...
  • Page 29 Gently apply the brake 5 times (braking pressure approx. 1 bar). With increasing adjustment the angle of rotation of the ring spanner becomes smaller. The adjuster is working correctly when the ring spanner rotates with every actuation of the brake. WSM_2051-04...
  • Page 30 7.3.5 Lubricate the slack adjuster Mobilith SHC 220 7.3.6 Lubricate the S-cam bearing Mobilith SHC 220 Mobilith SHC 220 Mobilith SHC 220 Always lubricate all S-cam bearings (4 grease nipples) on the same axle and manually move the cam shaft whilst greasing till the grease comes out of the bearing.
  • Page 31 WSM_2051-04...

  • Page 32: Disassembly, Assembly And Adjustments

    Disassembly, assembly and adjustments 7.4.1 Remove the brake shoe Previous steps / vorige Schri e Previous steps étapes précédentes / vorige stappen § 6.1 § 6.2 § 6.3 § 7.4.9 § 8.4.1 WSM_2051-04...
  • Page 33 WSM_2051-04...
  • Page 34 7.4.2 Install the brake shoe Previous steps / vorige Schri e Previous steps étapes précédentes / vorige stappen Mobilith SHC 220 § 6.1 § 6.2 § 6.3 § 7.4.9 § 8.4.1 § 7.4.1 Mobilith SHC 220 Always replace the return spring (X1) whenever the return spring has been removed. WSM_2051-04...
  • Page 35 420 x 180 420 x 220 360 x 220 REV. REV. APPROVED DATE APPROVED DATE Released DATE Released DATE FINISH: GENERAL TOLERANCES: FINISH: GENERAL TOLERANCES: CHK'D proto DATE CHK'D proto DATE CHK'D proposal DATE CHK'D proposal DATE DRAWN DATE 06-08-2020 DRAWN DATE 06-08-2020...
  • Page 36 7.4.3 Remove the dust cover Previous steps / vorige Schri e Previous steps étapes précédentes / vorige stappen § 6.1 WSM_2051-04...
  • Page 37 7.4.4 Install the dust cover Previous steps / vorige Schri e Previous steps étapes précédentes / vorige stappen § 6.1 § 7.4.3 22 Nm Torques Item Size Width across flats Torque (Nm) Dust cover bolt (Z1) 22 Nm ± 4 Nm Check 20 Nm WSM_2051-04...
  • Page 38 7.4.5 Disassembly – brake drum Previous steps / vorige Schri e Previous steps étapes précédentes / vorige stappen § 6.1 § 6.2 § 6.3 § 7.4.9 § 8.4.1 >25 kg Be careful not to damage the thread of the wheel bolts. WSM_2051-04...
  • Page 39 7.4.6 Assembly – brake drum Previous steps / vorige Schri e Previous steps étapes précédentes / vorige stappen >25 kg § 6.1 § 6.2 § 6.3 § 7.4.9 § 8.4.1 § 7.4.5 WSM_2051-04...
  • Page 40 7.4.7 Remove the slack adjuster Previous steps / vorige Schri e Previous steps étapes précédentes / vorige stappen § 6.1 § 6.2 § 6.3 § 7.4.9 § 8.4.1 § 7.4.10 REV. FINISH: GENERA MATERIAL: Drawin UNLESS OTHERWISE SPECIFIED: DEBURR AND BREAK DIMENSIONS IN MILLIMETERS ALL SHARP EDGES DO NOT SCALE DRAWING...
  • Page 41 7.4.8 Install the slack adjuster Previous steps / vorige Schri e Previous steps étapes précédentes / vorige stappen § 6.1 § 6.2 § 6.3 § 7.4.9 § 8.4.1 § 7.4.10 § 7.4.7 REV. FINISH: GENERAL TOLERANCE Mobilith SHC 220 MATERIAL: DrawingType: Production UNLESS OTHERWISE SPECIFIED:...
  • Page 42 7.4.8 Install the slack adjuster (continued) 0.5 - 2 mm Mobilith SHC 220 REV. FINISH: MATERIAL: UNLESS OTHERWISE SPECIFIED: DEBURR AND BR DIMENSIONS IN MILLIMETERS ALL SHARP EDG DO NOT SCALE DRAWING WEIGHT: SYSTEM: If necessary, use shims to obtain the proper clearance. WSM_2051-04...
  • Page 43 7.4.9 Adjust the slack adjuster Previous steps / vorige Schri e Previous steps étapes précédentes / vorige stappen § 6.1 § 6.2 At least 1 Turn the slack adjuster screw approximately 270° counterclockwise. When turning counterclockwise, one or more clicks are heard. When turning clockwise, no clicks are heard. WSM_2051-04...
  • Page 44 7.4.10 Remove the brake cylinder Previous steps / vorige Schri e Previous steps étapes précédentes / vorige stappen § 6.1 § 6.2 § 7.4.9 WSM_2051-04...
  • Page 45 7.4.11 Install the brake cylinder Previous steps / vorige Schri e Previous steps étapes précédentes / vorige stappen 65 Nm § 6.1 § 6.2 § 7.4.9 § 7.4.10 Check that the brake cylinder seat is within 0.3 mm flat. If not, repair. Mount the new brake cylinder using the same holes as before.
  • Page 46 210 Nm >90° 90° Mobilith SHC 220 Mobilith SHC 220 When the brake is actuated, the angle must be 90°. Torques Item Size Width across flats Torque (Nm) Nut (C1) 210 Nm - 30 Nm Check 175 Nm WSM_2051-04...
  • Page 47 7.4.12 Remove the S-cam and the S-cam bearing Previous steps / vorige Schri e Previous steps étapes précédentes / vorige stappen § 6.1 § 6.2 § 6.3 § 7.4.9 § 8.4.1 § 7.4.1 § 7.4.7 REV. Released FINISH: GENERAL TOLERANCES: CHK'D proto CHK'D proposal DRAWN...
  • Page 48 7.4.13 Install the S-cam and the S-cam bearing Previous steps / vorige Schri e Previous steps étapes précédentes / vorige stappen § 6.1 § 6.2 § 6.3 § 7.4.9 § 8.4.1 § 7.4.1 § 7.4.7 § 7.4.12 REV. FINISH: GENERAL TOLERANCES: MATERIAL: DrawingType: Production...
  • Page 49 7.4.13 Install the S-cam and the S-cam bearing (continued) Mobilith SHC 220 Mobilith SHC 220 Mobilith SHC 220 Mobilith SHC 220 Mobilith SHC 220 Always lubricate all S-cam bearings (4 grease nipples) on each axle. WSM_2051-04...
  • Page 50 7.4.14 Assembly - ABS sensor Previous steps / vorige Schri e Previous steps étapes précédentes / vorige stappen § 6.1 § 6.2 § 6.3 § 7.4.9 § 8.4.1 WABCO ABS sensor grease Axle a TITLE: TR=2040 VERSION 24-08-2020 REV. APPROVED DATE Released DATE...

  • Page 51: Wheel Hub Unit

    Always observe the general safety instructions and regulations (see chapter 1). Overview 360x200 420x180 420x220 NOTE The VALX drum brake trailer axle has been designed for 0-offset wheels. Hub cap (plastic) Wear ring Central nut (multiple use) O-ring (for plastic hub cap) Seal...
  • Page 52 WSM_2051-04...

  • Page 53: Periodic Maintenance And Inspection

    Periodic maintenance and inspection 8.3.1 Check the bearing play Previous steps / vorige Schri e Previous steps étapes précédentes / vorige stappen § 6.1 § 6.2 2 1 2 1 DISC 430 MBS TITLE: MBS-V2 VERSION DWG NO. Check bearing play 02-09-2020 DOC NO.

  • Page 54: Disassembly, Assembly And Adjustments

    Disassembly, assembly and adjustments 8.4.1 Disassembly – hub complete Previous steps / vorige Schri e Previous steps étapes précédentes / vorige stappen § 6.1 § 6.2 § 6.3 § 7.4.9 Plastic Plastic hub cap hub cap Steel Steel hub cap hub cap TITLE: DXDX1880 980...
  • Page 55 8.4.1 Disassembly – hub complete Single- Multiple- use nut use nut >25 kg >25 kg WSM_2051-04...
  • Page 56 8.4.2 Assembly – hub complete Previous steps / vorige Schri e Previous steps étapes précédentes / vorige stappen Optimol White Paste § 6.1 § 6.2 § 6.3 § 7.4.9 § 8.4.1 >25 kg >25 kg Single- Multiple- use nut use nut Slide the ABS sensor in as far as possible, the sensor will adjust automatically.
  • Page 57 8.4.2 Assembly – hub complete Single- use nut 630 Nm 630 Nm Multiple- Plastic use nut hub cap Mobilith SHC 220 Mobilith SHC 220 Plastic Plastic hub cap hub cap Plastic hub cap instructions (7) Always replace the O-ring whenever the hub cap has been removed. (7) Always check whether the O-ring (B) is properly seated and not damaged! (8) Make sure the plastic hub cap (A) can rotate freely to ensure the O-ring is seated properly.
  • Page 58 Steel Steel hub cap hub cap Mobilith SHC 220 Steel hub cap instructions (7) Always replace the O-ring whenever the hub cap has been removed. (8) Always check whether the O-ring is properly seated and not damaged! Torques Item Size Width across flats Torque (Nm) Steel hub cap...
  • Page 59 8.4.3 Disassembly – outer bearing and inner bearing Previous steps / vorige Schri e Previous steps étapes précédentes / vorige stappen § 6.1 § 6.2 § 6.3 § 7.4.9 § 8.4.1 WSM_2051-04...
  • Page 60 Go to step 10 Go to step 12 Remove grease from cavity area (clean the hub). WSM_2051-04...
  • Page 61 8.4.4 Assembly – outer bearing and inner bearing Previous steps / vorige Schri e Previous steps étapes précédentes / vorige stappen 165g § 6.1 § 6.2 § 6.3 § 7.4.9 Mobilith SHC 220 Mobilith SHC 220 § 8.4.1 § 8.4.3 Mobilith SHC 220 Mobilith SHC 220 If the bearing cups have been removed in the previous step,replace the complete bearings.
  • Page 62 Mobilith SHC 220 Always replace the seal (J) whenever the seal has been removed. Press the new seal with great care into the hub, making sure that the seal is flat and even. WSM_2051-04...
  • Page 63 8.4.5 Assembly – ABS ring Previous steps / vorige Schri e Previous steps étapes précédentes / vorige stappen § 6.1 § 6.2 § 6.3 § 7.4.9 § 8.4.1 REV. APPROVED DATE Released DATE FINISH: GENERAL TOLERANCES: CHK'D proto DATE CHK'D proposal DATE DRAWN DATE...

  • Page 64: Axle Beam

    Axle beam Safety instructions Always observe the general safety instructions and regulations (see chapter 1). Overview Axle beam Brake spider Air chamber bracket S-cam bearing bracket WSM_2051-04...
  • Page 65 WSM_2051-04...
  • Page 66 WSM_2051-04...
  • Page 68 +31 (0)88 405 8820 email info@valx.eu web www.valx.eu technical support email support@valx.eu sales support email sales@valx.eu VALX is subsidized by the Ministry of Economic Affairs / SenterNovem, Brabant Province, SRE and Limburg Province, The Netherlands Valx axles. The smart alternative.

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