SAF SKRS 9042 SK 500 plus System Maintenance And Repair Manual
SK RS 9042 - SK 500 plus
Maintenance and
Repair Manual
Service
Edition 01/2006
2
Vehicle information
Manufacturer.................................................................................................................................
Address...........................................................................................................................................
Body type.......................................................................................................................................
Chassis no.......................................................................................................................................
Year of manufacture ....................................................................................................................
Registration, date-in-service................................................................................................
.........
Identification of axles without type plate
Production No. of axle on right of stub axle as seen in
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.
96
195
047
Spare part illustration and spare part designation
SK RS 9042 - SK 500 plus 10-11
SAF axle identification 2
Repairing the brakes 12-22
Repairing the wheel bearings
Replacing the wheel bearing grease 23-25
E) Installation instructions
D) Spare part illustrations/spare part designation
C) Maintenance instructions
Maintenance instructions for SK RS 9042 - SK 500 plus 8
Maintenance schedule for SK RS 9042 - SK 500 plus 9
3
Contents
Page
This manual is intended for the technical workshop personnel responsible for
maintenance and repair.
A) Component description 4-6
B) General service instructions for SAF axles and suspension units 7
Adjustment of S-cam brakes 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 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.
The contents of the manual does not constitute the basis for a legal claim.
Reprinting, reproduction or translation in whole or in part is not permitted.
The issue of this publication invalidates all earlier maintenance and repair manuals.
4
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)
– Long wheel bearing grease change intervals of 500,000 km or 60 months’ operation
– Favourable 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 typePresent type
New typePresent type
Wheel hub:
A compact unit of hub with two different sized wheel bearings and seal rings.
The wheel bearings are filled with a longlife grease and sealed.
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.
2) Replacement of the complete wheel bearing assembly with seals and long-term grease packing.
The wheel hub can continue to be used.
New typePresent type
6
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. Only one return spring is required for the
return of the brake shoes. The brake shoe cam rollers are guided
exactly in the specially machined S-cam profile.
Brake linings
Two different asymmetrically formed lining segments are riveted
onto the brake shoes. The thicker end of the lining is installed on
the S-cam side (cam roller).
As a result of this scythe-shaped brake lining contour, uniform maximum wear of the brake lining over the 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 lubrication and are protected by seal
rings and rubber sleeves against the ingress of dirt and splash water.
On the slack adjuster end the camshaft has a milled groove and a
slip-on indicator for visual checking of the brake lining wear.
When the wear indicators have reached a horizontal position, an
inspection of the brake lining thickness must be carried out.
Max. permitted radial play: 2 mm
Inspection of the brake lining thickness
During maintenance work, the thickness of the brake linings can be
inspected at two sight holes in the rear cover plate.
7
B) General service instructions
Please observe the following safety instructions in order to maintain the operational and road safety
of your SAF axles and suspension systems:
1. The wheel contact surfaces between the wheel disc and wheel hub and the wheel nut contact surface at
the wheel disc must not be additionally painted. The contact surfaces must be clean, smooth and free
from grease. Failure to observe this may result in the wheel coming loose. Any additional instructions of
the wheel manufacturer must also be observed.
2. Only the wheel and tyre sizes approved by the trailer builder may be used. The tyres must always have
the specified inflation pressure.
3. The brake systems of the tractor and the trailer/semi-trailer must be synchronised by means of a
tractor/trailer brake synchronisation not later than 5,000 km after the initial start of operation of the
trailer/semi-trailer in order to ensure a safe and uniform braking behaviour and uniform brake pad wear.
Tractor/trailer brake synchronisations should be carried out by appropriately qualified and equipped
brake workshops.
The use of an additional braking system, such as a trailer anti-jackknife brake is forbidden by law on
vehicles with type approval after January 1999.
4. Before starting a journey, ensure that the maximum permissible axle load is not exceeded and that the
load is distributed equally and uniformly.
5. On trailers with air suspension, ensure that the air bags are completely filled with air before starting the
journey. Incompletely filled air bags may result in damage to axles, suspension, frame and superstructure
and impair road safety.
6. Ensure that the brakes are 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 brakes are hot, as the brake discs and
brake drums may be damaged by different stress fields during cooling.
8. Use the supports provided when loading and unloading in order to avoid damage to the axle.
9. Observe the operating recommendation of the trailer builder for off-road operation of the installed
axles and suspension systems.
The SAF definition of OFF-ROAD means driving on non-asphalted / non-concreted routes, such as e.g.
gravel roads, agricultural and forestry tracks, on construction sites and in gravel pits.
Off-road operation of SAF axles and suspension systems not designed for the purpose may result in
damage and hence to an impairment of road safety.
10. SAF axles and suspension systems require continuous care, service and maintenance in order to maintain
operational and road safety and to be able to recognise natural wear and defects in good time.
The daily inspection of the trailer for road safety before starting the journey is one of the driver’s
obligations.
SAF recommends that at least the inspections and maintenance operations described on page 8 should
be carried out.
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).
Updates will be published as necessary on the Internet under www.saf-axles.com.
8
C) Maintenance instructions
SK RS 9042 - SK 500 plus
Vehicles with long standing periods: service at specified time intervals
Vehicles used under extreme conditions: service at suitably reduced intervals
Maintenance intervals
whichever comes first
Mileage intervals >
Time intervals >
After first
5,000 km
or
every
30,000 km
every
150,000 km
After first
month
every
3 months
every
75,000 km
every
6 months
every
12 months
Periodic checks
Check and adjust hub end-float (if required) after every brake
lining replacement.
Pack wheel bearings with fresh grease after 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 sure to retighten wheel nuts to the prescribed torque
after the first 50 km and 150 km (and after every wheel removal).
Mechanical check
Visual and safety inspection
Special service conditions
•
•
•
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.
9
C) Maintenance instructions
SK RS 9042 - SK 500 plus
Adjusting the wheel bearing clearance:
Tighten axle nut W.A.F. 85 (22) to a torque of 150 Nm,
turning the wheel hub at the same time.
Back off the axle nut by 2 1/2 holes of the locking collar
(23).
Push on the locking collar and secure the hub nut with
dowel.
Tighten the lock nut (24) to a torque of 400 Nm.
Check that the wheel bearing rotates freely and without
excessive end float. The wheel must rotate freely and without resistance and no end float should be felt at the wheel
rim. Repeat the adjustment, if necessary.
Lubricant specification:
Wheel bearings:
SAF Part No. 4 387 0011 05
Camshaft:
SAF Part No. 4 387 0011 05
Stub axle:
SAF Part No. 4 387 0015 06
SAF fitting paste
Brake anchor bracket ball:
SAF Part No. 4 387 0007 00
Copper paste
Hub nut tightening
Assembly tools SAF parts no.
Hub nut spanner 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 mm
SAF approved brake linings: BERAL 1541, BREMSKERL 6386
Turn new brake linings to brake drum bore dimension + 0.3 mm.
When renewing rivets, observe the manufacturer’s instructions regarding the brake lining form
(see leaflet enclosed in pack).
Normalmaß
1. Rep.-Stufe
2. Rep.-Stufe
d
0
d
1
d
2
Brake linings Rivets
420.0
422.0
424.0
DIN 7338
rivet
number per axle
SNK 420 d0-420.0 d1-422.0 d2-424.0
x 180 1 057 0060 00 20.6 21.6 22.6
1 057 0061 00 20.0 21.0 22.0
x 200 1 057 0066 00 20.6 21.6 22.6
1 057 0067 00 20.0 21.0 22.0
64 B 8 x 15
Nominal size 1st oversize 2nd oversize
Brake SAF parts no.
size brake lining
4
nominal size
1st oversize
2nd oversize
10
D) Spare part illustrations
SK RS 9042 - SK 500 plus
Torque 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
11
D) Spare part designation
SK RS 9042 - SK 500 plus
Item Parts designation Item Parts designation
01 Axle beam assembly
including items 3 - 25
3 Spherical mounting plate
4 Protective plug for ABS
5 Ball
6 Compact bearing,
brake carrier side
6.1 Riffle bolt
6.2 Lock nut
010 Camshaft bearing assembly
linkage adjustment side
including items 11, 15, 18
11 Compact bearing,
linkage adjuster side
15 Pinch bolt
18 Bellows
18.3 Brake lining wear gauge
22 Hub nut with dowel
23 Locking collar
24 Lock nut
25 Mounting plate for MB cylinder
27 Wheel hub (present type)
27.1 Wheel hub (new type)
29 Brake drum
30 Wheel bolt assembly
including items 31 - 34
31 Riffle bolt
34 Wheel nut with pressure plate
35 Taper roller bearing
36 Taper roller bearing
37 Unitised seal
38 Inner seal ring
38.1 Protective plug
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 hose
80.2 Clamp
80.3 Circlip
89 Mechanical slack adjuster
081 Camshaft assembly (LH)
including items 18.3, 85.1 - 88.1
082 Camshaft assembly (RH)
including items 18.3, 85.1 - 88.1
85 Disc spring
86 Clamp
87 Washer
88 Washer
88.1 Clamp
with automatic adjustment
89.1 Automatic slack adjuster
89.2 Anchor plate, RH
89.3 Anchor plate, LH
90 Return spring
091 Dust cover assembly
including items 92 - 99
92 Dust cover, RH
93 Dust cover, LH
94 Plug
95 Cable clamp
96 Hex bolt
97 Clamp
98 Plug
99 Rubber grommet, ABS
When ordering spare parts quote correct axle identification serial no., refer to the axle type plate.
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