SAF XL-TA10006OM User Manual

Service Manual for Drum Brake Axles

Tapered and Parallel Spindle Axles

XL-TA10006OM-en-US Rev B

Contents

Contents Page

Introduction ......................................................................... 3

Warranty .............................................................................. 3

Notes, Cautions, and Warnings ............................................. 3

Section 1 – General Safety Instructions ................................ 4

Section 2 – Model Identification........................................... 5

Section 3 – Identification Tag ............................................... 5

Brake Components Parts List Prior to November 30, 2012 ..... 6

Brake Components Parts List After November 30, 2012 ......... 7

Section 4 – Hubs, Bearings and Seal Removal ....................... 8

Section 5 – Bearing Inspection ........................................... 10

Section 6 – Hubs, Bearings and Seal Installation ................. 11

Section 7 – Hub Bearing Adjustment .................................. 13

Section 8 – Hub Cap Installation ........................................ 15

Section 9 – Filling Hub with Lubricant (Oil Based) .............. 15

Introduction

This manual provides the necessary information for the maintenance, inspection, and safe operation of the SAF® axle/brake system.

Read this manual before using or servicing this product and keep it in a safe location for future reference. Updates to this manual, which are published as necessary, are available on the internet at www.safholland.us.

Use only SAF-HOLLAND SAF-HOLLAND INTEGRAL™ disc brake axle. A list of technical support locations that supply SAF-HOLLAND® Original Parts and an Aftermarket Parts Catalog are available on the internet at www.safholland.us or contact Customer Service at 888-396-6501.

Warranty

Refer to the complete warranty for the country in which the product will be used. A copy of the written warranty is included with the product or available on the internet at www.safholland.us.

®

Original Parts to service your

Contents Page

Section 10 – Retracting the Brake Shoes or Slack

Adjuster Control Arm(s).................................. 16

Section 11 – Brake Shoe Removal ...................................... 17

Section 12 – Brake Shoe Installation .................................. 19

Section 13 – Brake Adjuster Removal ................................. 22

Section 14 – Brake Adjuster Installation ............................. 22

Section 15 – S-Camshaft and Bearing Removal Procedure ... 23

Section 16 – S-Camshaft and Bearing Installation .............. 24

Section 17 – Brake Adjustment Procedure .......................... 26

Section 18 – ABS Sensor Replacement Procedure ............... 27

Section 19 – Axle Alignment Inspection .............................. 27

Section 20 – Routine Service Schedule ............................... 28

Section 21 – Torque and Lubrication Specifications ............. 29

Section 22 – Troubleshooting Chart .................................... 30

Notes, Cautions, and Warnings

Before starting any work on the unit, read and understand all the safety procedures presented in this manual. This manual contains the terms “NOTE”, “IMPORTANT”, “CAUTION”, and “WARNING” followed by important product information. These terms are defined as follows:

NOTE: Includes additional information to enable accurate

and easy performance of procedures.

IMPORTANT: Includes additional information that

if not followed could lead to hindered product performance.

Used without the safety alert symbol, indicates a potentially hazardous situation which, if not avoided, could result in property damage.

Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.

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Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

3

General Safety, Maintenance and Inspection Instructions

1. Safety Instructions

General and Servicing Safety Instructions



Read and observe all Warning and Caution hazard alert

messages. The alerts provide information that can help prevent serious personal injury, damage to components, or both.

Failure to follow the instructions and safety precautions in this manual could result in improper servicing or operation leading to component failure which if not avoided could result in death or serious injury.



All installation should be performed by a properly

technician using proper/special tools, and safe procedures.

NOTE: In the United States, workshop safety requirements

are defined by federal and/or state Occupational Safety and Health Act (OSHA). Equivalent laws could exist in other countries. This manual is written based on the assumption that OSHA or other applicable employee safety regulations are followed by the location where work is performed.

IMPORTANT: Use only SAF-HOLLAND

®

Original Parts to

service your SAF-HOLLAND disc brake axle.

Failure to maintain your SAF-HOLLAND® INTEGRAL™ disc brake with SAF-HOLLAND Original Parts can result in brake or wheel bearing failure which, if not avoided, could result in death or serious injury.



Properly support and secure the vehicle and axles from

unexpected movement when servicing the unit.

Failure to properly support the vehicle and axles prior to could create a crush hazard which, if not avoided, could result in death or serious injury.



If possible, unload the trailer before performing any

service procedures.



After re-positioning the brake chamber, brake adjuster

and/or ABS system as instructed in this manual, ALWAYS consult the manufacturer’s manual for proper operation.

IMPORTANT: Key components on each axle system

including but not limited to suspension, brake adjuster, brake chambers, bearings, hubs, and drums require information supplied by the original manufacturer of the components to ensure proper and safe operation of the axle system.

Failure to follow the original manufacturer’s instructions regarding spring brake or air pressure control could allow an uncontrolled release of energy which could result in death or serious injury.



Service both roadside and curbside of an axle. Worn parts

should be replaced in sets. Key components on each axle’s braking system, such as friction material, rotors and drums will normally wear over time.

trained

®

INTEGRAL™

Operational and Road Safety Instructions



The wheel contact surfaces between the wheel and hub

MUST NOT receive additional paint.

IMPORTANT: The wheel contact surfaces MUST be clean,

smooth and free from grease.

Failure to keep wheel and hub contact surfaces clean and clear of foreign material could allow wheel/hub separations which, if not avoided, could result in death or serious injury.



Only the wheel and tire sizes approved by the trailer builder

can be used.



Before operating the vehicle, ensure that the maximum

permissible axle load is not exceeded and that the load is distributed equally and uniformly.



Make sure that the brakes are not overheated from

continuous operation.

Failure to minimize the use of brakes during overheating conditions could result in deterioration of brake efficiency which, if not avoided, could result in death or serious injury.

®



The parking brake MUST NOT be immediately applied when

the brakes are overheated.

If the parking brake is immediately applied to the brakes when overheated, the brake drums or discs could be damaged by different stress fields during cooling.



Observe the operating recommendation of the trailer

manufacturer for off-road operation of the installed axles.

IMPORTANT: The deﬁnition of OFF-ROAD means driving

on non-asphalt/non-concrete routes,

such

as gravel roads, agricultural and forestry tracks, on construction sites and in gravel pits.

IMPORTANT: Off-road operation of axles beyond

the approved application design could result in damage and impair suspension system performance.



SAF® axles require routine service, inspection and maintenance

to maintain optimum performance, operational and road safety, and to recognize natural wear and defects before they become serious. Please refer to the Service Manual for Drum Brake Axles XL-TA1000060M-en-US which can be found at www.safholland.us or contact our customer service group at 888-396-6501.

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and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.

Model and Serial Number

2. Model Identiﬁcation

The Drum Brake Axle Serial Tag is located near the center of the axle tube (Figure 1).

3. Identiﬁcation Tag

The sample tag shown will help you interpret the information on the SAF-HOLLAND USA Inc number, axle body part number, axle beam rating, and serial number are listed on the tag (Figure 2).

Record your tag numbers below for future quick reference.

®

. serial number tag. The model

Figure 1

SERIAL NUMBER TAG LOCATED NEAR CENTER OF AXLE TUBE

Figure 2

Axle Body Part Number _________________________________

Model Number _______________________________________

Axle Beam Rating _____________________________________

Serial Number _______________________________________

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5

Brake Components Parts List – Prior to November 30, 2012

5

16

8

1

9

4

3

2

12

6

13

25

23

24

22

20 21

19

20

17 LH AND 18 RH (NOT SHOWN) AXLE BRACKET

10 LH AND 11 RH (NOT SHOWN)

12

BRAKE COMPONENTS

ITEM DESCRIPTION QTY

1 Axle Body Assembly 1

2 Fitting, Lubrication 2

3 Bushing, Anchor Pin 4

4 Pin, Anchor 4

5 Brake Shoe Assembly 4

6 Bearing Assembly, S-Cam-Spider inboard 2

7 Bearing Assembly, S-Cam-Spider Outboard 2

8 Retainer, Roller 4

9 Roller, Brake Shoe 4

10 S-Camshaft, Left-Hand 1

11 S-Camshaft, Right-Hand (not shown) 1

12 Washer, S-Cam Bearing-Outboard 4

13 Retainer Ring 2

7

14

15

14

9

8

5

TAPERED SPINDLE AXLE SHOWN

BRAKE COMPONENTS

ITEM DESCRIPTION QTY

14 Return Spring Pin 4

15 Spring, Return-Hub/Drum 2

16 Spring, Anchor Pin 4

17 Housing, S-Cam Bearing, Left-Hand Slotted 1

18 Housing, S-Cam Bearing, Right-Hand Slotted 1

19 Bearing Assembly S-Camshaft 2

20 O-Ring, S-Camshaft Bearing Seal-Inboard 4

21 Housing, S-Cam Bearing 2

22 Screw, Thread Rolling Tapping 8

23 Washer, Shaft End 2

24 Washer, Shaft End 2

25 Retaining Ring 2

NOTE: Refer to Drum Brake Axle Parts Manual XL-TA10058PM-en-US for

axle component and service kit part numbers.

6

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and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.

Brake Components Parts List – After November 30, 2012

10 LH AND 11 RH (NOT SHOWN)

16

4

3

7

24

14

5

8

9

2

12

7

6

15

9

8

5

13

1

19

21

22

20

17 LH & 18 RH (NOT SHOWN) AXLE BRACKET

TAPERED SPINDLE AXLE SHOWN

23

BRAKE COMPONENTS

ITEM DESCRIPTION QTY

1 Axle Body Assembly 1

2 Fitting, Lubrication 2

3 Bushing, Anchor Pin 4

4 Pin, Anchor 4

5 Brake Shoe Assembly 4

6 Bushing, Cam Bearing 2

7 Cam Seal, Spider 4

8 Retainer, Cam Roller 4

9 Roller, Brake Shoe 4

10 S-Camshaft, Left-Hand 1

11 S-Camshaft, Right-Hand (not shown) 1

12 Washer, S-Cam Bearing-Outboard 2

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BRAKE COMPONENTS

ITEM DESCRIPTION QTY

13 Retainer Ring 2

14 Return Spring Pin 4

15 Spring, Return-Hub/Drum 2

16 Spring, Anchor Pin 4

17 Cam Bearing Kit - Left-Hand 1

18 Cam Bearing Kit - Right-Hand (not shown) 1

19 Nut, Lock 8

20 Bolt, Hex Head Cap 8

21 Washer, Shaft End 2

22 Washer, Shaft End 4

23 Retaining Ring 2

24 Guide PLate, Brake Roller Shoe 2

NOTE: Refer to Drum Brake Axle Parts Manual XL-TA10058PM-en-US for

axle component and service kit part numbers.

7

Hubs, Bearings, and Seal Components

4. Hubs, Bearings and Seal Removal

NOTE: Before you begin any axle/brake service procedures,

park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. Support the vehicle and axle(s) with safety stands. DO NOT work under a vehicle supported only by jacks. Jacks can slip or fall over. Serious personal injury and damage to components can result.

Failure to properly support the vehicle and axles prior to commencing work could create a crush hazard which, if not avoided, could result in death or serious injury.

1. Release trailer brakes and cage spring brakes according to spring brake manufacturer’s instructions. Remove tire and wheel assembly to access hub and drum.

2. Remove drum from hub using support device such as a drum dolly (Figure 3).

Failure to support weight during installation or removal of brake drum could create a crush hazard which, if not avoided, could result in minor to moderate injury.

NOTE: It is necessary to retract brake shoes in accordance

with brake adjuster’s manufacturer manual to allow brake drum to clear brake shoes during brake drum removal.

Figure 3

Figure 4

HUB CAP GASKET

HUB CAP

BOLTS (6)

3. Remove the hub cap and gasket by removing six (6) bolts (Figure 4).

NOTE: Be prepared to collect lubrication fluid when

removing the hub cap.

8

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and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.

Hubs, Bearings, and Seal Components

4. Remove set screws (Figure 5).

5. Remove the axle nut from the spindle using a wrench

with the axle nut socket. If the unit is equipped with

®

a Pro-Torq

(Figure

spindle nut, remove nut and skip Step 5.

6).

6. Release the axle washer and inner axle nut from the

spindle (Figure 6).

7. Remove the outer hub bearing from the spindle (Figure 6).

NOTE: With axle nut, washer, and inner nut removed, it is

possible to access the outer bearing.

DO NOT hit steel parts with a steel hammer as parts could break, sending flying steel fragments in any direction creating a hazard which, if not avoided, could result in minor to moderate injury.

8. Grasp the hub assembly with both hands and pull the

hub assembly off the axle spindle (Figure 7).

NOTE: Depending on the type of hub seal, the hub seal

and inner bearing could remain on spindle or come off with hub assembly.

Figure 5

OUTER HUB BEARING

INNER AXLE NUT

AXLE WASHER

SET SCREWS

AXLE NUT

3-PIECE SPINDLE NUT SHOWN

Figure 6

PRO-TORQ® SPINDLE NUT

AXLE NUT SOCKET

Figure 7

HUB ASSEMBLY

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9

Hubs, Bearings, and Seal Components

the inside of the hub (Figure 8).

10. Remove the hub seal from the hub bore using a pry bar. A spindle mount hub seal can be driven off the spindle by striking the ring from the back side or prying off with a crow’s foot bar. Discard the used hub seal and use a new hub seal during re-assembly being careful not to gouge the spindle shoulder (Figure 8).

DO NOT use a chisel to cut the seal. The shoulder can be damaged, resulting in a leak which could lead to wheel end and/or brake failure.

5. Bearing Inspection

Thoroughly clean bearings. DO NOT mix a synthetic base grease or oil with an organic/mineral base lubricant.

DO NOT spin dry hub bearings with compressed air. Bearing damage could result.

Figure 8 9. Remove the inner hub bearing from the spindle or from

HUB SEAL

INNER HUB BEARING

1. After removing the hub assembly, clean excess grease from the bearings.

IMPORTANT: A bearing which has been removed from

a vehicle should be cleaned with solvent. When cleaning DO NOT use steam or water which will cause bearings to rust.

IMPORTANT: Bearings that are rusted, flaked, pitted, or

have damaged cages should be replaced. It is recommended to replace all questionable bearings and ALWAYS replace the cup and cone as a matched set. NEVER re-assemble a tapered roller bearing in a damaged or worn housing or on damaged or worn spindles. Housings or spindles should be replaced and NOT re-machined if the bearing journal is worn.

10

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and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.

Hubs, Bearings, and Seal Components

6. Hubs, Bearings and Seal Installation

6.1. Spindle mounted Hub Seal Installation

instructions. (Refer to 8.2. for hub mounted Hub Seal instructions).

1. Before installing the hub seal on the axle spindle, inspect

the machined spindle seal surface for nicks, scratches, burrs or marks. If needed, use crocus cloth or emery cloth to repair any damaged areas.

2. Clean the threads and keyway thoroughly with a wire

brush to avoid false bearing adjustments and to avoid introduction of contaminants into the lubricant cavity.

3. Thoroughly clean the spindle and spindle threads of rust,

dirt, grease or any other contaminants that could damage the hub seal and cause it to leak.

NEVER install a spindle mounted hub seal in the hub and then force it onto the axle spindle by tightening the axle nut. Damage to seal will result.

4. The seal assembly should be placed on the spindle so the

words “Oil Bearing Side” are exposed to the oil (Figure 9).

5. Drive the hub seal into place using the seal installation

tool and hammer. Rotate the hub seal installation tool in 1/4-turn intervals with every hammer tap until the seal is properly seated with the metal face of the seal ﬂush with the inner shoulder of the axle spindle (Figure 10).

6. Apply a thin coat of oil to the O.D. of the seal.

7. Prepare the hub. Remove the old lube and thoroughly

clean the hub cavity and hub bore. Inspect the inner hub bore for roughness. If needed, use emery cloth to remove any burrs or old bore sealant.

Figure 9

AXLE SPINDLE INNER SHOULDER

KEYWAY

HUB SEAL

Figure 10

HUB SEAL INSTALLATION TOOL

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11

Hubs, Bearings, and Seal Components

8. Install the inner and outer bearing cups into hub (Figure 11).

9. Pre-lube the inner bearing with the lubricant that is being retained and place it into the hub.

Failure to lubricate bearing correctly and maintain proper lubrication could result in bearing damage.

NOTE:

If using grease and not oil for hub lubrication, the inner and outer bearing, and the hub cavity MUST be pre-packed with grease before installation. Lubricate wheel end components with grease specified in lubrication table in Section 21.

10. Push the hub onto the spindle until it contacts the seal. Pre-lube the outer bearing with the lubricant that is being retained and place it into the hub.

Support the hub against the spindle inner shoulder until the outer bearing and adjusting nut are installed. DO NOT ram the hub into the bearing shoulder, which, if not avoided could damage the hub seal.

6.2. Hub Mounted Hub Seal

Installation Instructions

1. Remove all burrs from the hub bore and spindle. Thoroughly clean hub cavity and spindle.

2. Place the hub on a smooth, hard surface in a horizontal position. Pre-lube the inner bearing with the lubricant that is being retained and place it into the hub bearing cup (Figure 12).

Figure 11

INNER BEARING

HUB

OUTER BEARING CUP

INNER BEARING CUP

Figure 12

INNER BEARING

HUB BEARING CUP

HUB

NOTE: When using grease, pre-pack the inner bearing

before placement into the hub.

3. With the correct head on the hub seal installation tool, place the hub seal on the installation tool, so that the words “Lube Side” face the inner bearing. Place the tool (with the seal correctly mounted in the tool head) into the hub bore. Use a three to five pound hammer to drive against the end of the tool. Drive seal into bore until complete bottoming is assured (Figure 13). Remove Installation Tool and apply a thin layer of lubricant on the I.D. surface of the seal. Ensure the inner bearing rotates freely. Install a new seal if the seal is crooked or damaged or after installation.

NOTE: DO NOT apply lubricant to the O.D. of the seal.

12

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Figure 13

HUB SEAL INSTALLATION TOOL

and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.

Hubs, Bearings, and Seal Components

4. Align the hub bore to the center of spindle with mechanical

supports. Gently push the hub assembly onto the spindle until the seal is seated against the bearing shoulder. Rotate the hub and lightly strike to ensure that the seal is properly seated against bearing shoulder.

5. Pre-lube the outer bearing with the lubricant that is being

retained and place into the hub.

NOTE: When using grease, pre-pack the hub cavity. The

grease fill amount should be to a three o’clock and nine o’clock level. This is to ensure a 50% hub cavity fill. Use a template to hold grease in place while filling the hub cavity (Figure 14).

7. Hub Bearing Adjustment

7.1. Hub Bearing Adjustment

Using 3-Piece Axle Nut

1. Install the bearing inner-axle adjustment nut finger tight

against the outer bearing (Figure 15).

2. While rotating the hub assembly, tighten the inner axle

adjustment nut to 200 ft.-lbs. (271 N•m).

3. Back off the inner axle adjustment nut one full turn and

then re-torque nut to 50 ft.-lbs. (68 N•m) while rotating the hub assembly.

4. Back off inner axle nut approximately 1/4 turn and install

the axle lock washer (Figure 16). DO NOT include socket backlash in the 1/4 turn.

5. Install the lock washer. If the hole in the washer is not

aligned with the pin on the inner nut, turn the washer around and re-install. If the pin and hole are still not aligned, slightly adjust parts as needed.

6. Install the outer axle nut finger tight against the axle

lock washer (Figure 16).

7. Tighten the outer axle nut to 300-400 ft.-lbs. (406-541 N•m).

Figure 14

PRE-PACK HUB CAVITY WITH GREASE

PRE-PACK OUTER BEARING WITH GREASE

GREASE LEVEL TEMPLATE

Figure 15

OUTER BEARING

INNER AXLE NUT

Figure 16

AXLE LOCK WASHER

OUTER AXLE NUT

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13

Hubs, Bearings, and Seal Components

8. Check the wheel bearing end play as follows:

a. Attach the magnetic base of a dial indicator to

spindle. Touch dial indicator stem to hubcap gasket face (Figure 17).

b. Reading Number One – Slightly rotate wheel-end

in both directions while pushing inward until dial indicator does not change. Set the dial indicator to zero (Figure 17).

c. Reading Number Two − Slightly rotate hub in both

directions while pulling outward until dial indicator does not change (Figure 17).

d. End play is the difference between reading number

one and reading number two.

IMPORTANT: Final adjustment should allow the wheel to

rotate freely with 0.001" to 0.005" (0.025 mm to 0.0127 mm) end play. If end play is not within speciﬁcation, re-adjustment is required.

Failure to maintain proper hub bearing adjustment could allow bearing failure and wheel-end separation which, if not avoided, could result in death or serious injury.

Figure 17

HUB ASSEMBLY

DIAL INDICATOR

Figure 18

NOTE: If wheel bearing end play needs adjustment,

remove outer nut and lock washer. Tighten or loosen inner nut as needed. Return to Step 6.

9. Install

set screw into an accessible threaded hole in the

lock washer. Set screw MUST contact the inner adjusting nut. Tighten to 16-20 in.-lbs. (1.8-2.2 N•m) (Figure 19).

7.2. Hub Bearing Adjustment Using Pro-Torq

The unit could be equipped with a Pro-Torq® spindle nut (Figure 18). Refer to Stemco® “Pro-Torq® Installation Instructions” (Part No. 09-571-006) which can be found at www.stemco.com for more information.

®

Axle Nut

PRO-TORQ® SPINDLE NUT

Figure 19

OUTER HUB BEARING

INNER AXLE NUT

AXLE WASHER

SET SCREWS

AXLE NUT

14

3-PIECE SPINDLE NUT SHOWN

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and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.

Hubs Cap Installation

O

I

L

E

V

E

L

O

I

L

E

V

E

L

F

U

L

A

D

F

U

L

A

D

8. Hub Cap Installation

1. Install the hub cap assembly, making sure the hub cap gasket is in place (Figure 20).

When installing hub cap, make sure the hub cap gasket is not bent or damaged.

DO NOT over torque. This can crush the hub cap gasket and cause a leak.

2. Install the six (6) bolts to secure the hub cap assembly (Figure 18). Tighten bolts to 12-16 ft.-lbs. (16-21 N•m).

9. Filling Hub With Lubricant (Oil Based)

IMPORTANT: DO NOT mix oil lubricant with grease

lubricant. If your bearing assembly has been lubricated with grease DO NOT add oil.

Failure to correctly lubricate bearings could damage bearings which, if not avoided, could result in death or serious injury.

1. Remove plug and fill the hub to the FULL mark with the specified lubricant (oil), through the hole in the hub cap (Figure 21).

2. Allow the oil to flow through the bearings and level off.

3. Insert the plug into the hole in the hub cap (Figure 22).

Figure 20

HUB CAP GASKET

HUB CAP

BOLTS (6)

Figure 21

IMPORTANT: Axles equipped with a centralized tire inﬂation

system MUST use a vented hub cap.

OIL FILL LEVEL

Figure 22

HUB CAP

PLUG

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15

Retracting Brake Shoes or Brake adjuster Arm

drum dolly jack (Figure 23).

Failure to support weight during installation or removal of brake drum could create a crush hazard which, if not avoided, could result in minor to moderate injury.

Failure to uncage spring brakes in accordance with manufacturer’s instructions after servicing is complete will prohibit proper brake function which could result in uneven brake system component wear.

10. Retracting the Brake Shoes or Brake Adjuster Control Arm(s)

IMPORTANT: Refer to brake adjuster’s manufacturer’s

procedures for proper adjustment of the brake adjusters.

Figure 234. Re-install drum on hub using support device such as a

Failure to operate with proper brake adjuster position could render brakes inoperable which, if not avoided, could result in death or serious injury.

NOTE: When servicing the brakes, in some instances it

could be necessary to fully retract the brake shoes in order to remove the brake drum.

NOTE: When removing the S-Camshaft, it is necessary to

retract the brake adjuster control arm(s) from the clevis so the brake adjuster can be removed from the S-Cam shaft.

In both of the notes above, the brake shoes or the brake adjuster control arm(s) are retracted by turning the adjusting nut manually on the automatic brake adjuster.

16

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and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.

Brake Shoe Replacement

11. Brake Shoe Removal

NOTE: Before you begin any axle/brake service procedures,

park the vehicle on a level surface. Block the wheels to prevent the vehicle from moving. Support the vehicle and axle(s) with safety stands. DO NOT work under a vehicle supported only by jacks. Jacks can slip or fall over. Serious personal injury and damage to components can result.

Failure to properly support the vehicle and axles prior to commencing work could create a crush hazard which, if not avoided, could result in death or serious injury.

1. Release trailer brakes and cage spring brakes according to spring brake manufacturer’s instructions. Remove tire and wheel assembly to access hub and drum.

2. Remove drum from hub using support device such as a drum dolly (Figure 24).

Failure to support weight during installation or removal of brake drum could create a crush hazard which, if not avoided, could result in minor to moderate injury.

Figure 24

Figure 25

NOTE: It is necessary to retract brake shoes in accordance

with brake adjuster’s manufacturer’s manual to allow brake drum to clear brake shoes during brake drum removal.

3. Using the brake spring pliers, unhook both brake retaining springs from the brake shoes (Figure 25).

4. Press down on the lower brake shoe to disengage it from the anchor pin. Move the lower shoe to the side of the anchor bracket and lift the upper and lower shoes (still connected by brake return spring) from the anchor pins (Figure 26).

IMPORTANT: The brake return spring, brake shoe rollers

and roller retaining clips will remain on the brake shoes during this procedure.

RETAINING SPRING

BRAKE SPRING PLIERS

Figure 26

UPPER BRAKE SHOE

ANCHOR PINS

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LOWER BRAKE SHOE

17

Brake Shoe Replacement

5. Discard the used brake hardware.

IMPORTANT: Brake hardware such as brake rollers,

roller retaining clips and brake return springs experience fatigue during their normal lifespan and could not have the same performance characteristics as new components. Since most of these brake components are supplied new with the brake overhaul kit, the existing components should not be re-used.

6. With the brake shoes off, inspect the S-Camshaft and S-Camshaft bushings for wear. Verify that S-Cam-to-bushing radial free play is within specification by using a dial indicator and moving S-Camshaft back and forth. (Figure 27) Rotate the S-Camshaft in all directions when checking for radial free play.

NOTE: Use a dial indicator to verify that S-Cam-to-bushing

free play is 0.030" (0.76 mm) or less.



If radial free play is less than 0.030" (0.76 mm):

DO NOT replace the bushings and seals.



If radial free play is more than 0.030" (0.76 mm):

Replace the bushings and seals.

7. Inspect brake shoes and components for wear:

a. Inspect the spider for expanded anchor pin holes and

for cracks. Brake spiders cannot be repaired and must be replaced with new axle assembly.

b. Inspect the S-Camshaft bracket for broken welds, cracks

and correct alignment. Replace damaged brackets.

c. Inspect the anchor pins for corrosion and wear.

Replace worn or damaged anchor pins.

Figure 27

Figure 28

WEAR LIMIT

mm)

1/4" (6 MINIMUM

S-CAMSHAFT

DIAL INDICATOR

S-CAM ENDANCHOR PIN END

NOTE: Follow brake shoe manufacturer specifications

for minimum brake shoe thickness and maximum brake drum inner diameter. A general guideline for replacing brake shoes is when the lining thickness is 1/4" (6 mm) or less, or when the lining rivets have begun to contact the drum (Figure 28).

Failure to replace brake shoes that are excessively worn could result in damage to brake drum or other components

d. Inspect the brake shoes for wear, expanded rivet holes,

broken welds and correct alignment. Replace shoes as a set with any of the above conditions.

18

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and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.

Brake Shoe Replacement

8. Inspect brake drums for wear.

DO NOT operate the vehicle with the brake drum worn or machined beyond the discard dimension indicated by the drum manufacturer. The brake system could not operate correctly. Damage to components, death or serious injury, could result.

Replace the brake drum if it is out-of-round. DO NOT turn or re-bore a brake drum beyond manufacturers recommendations. Doing so could decrease the strength and capacity of the drum which, if not avoided, could result in brake component damage.

a. Inspect the brake drums for cracks, severe heat checking,

heat spotting, scoring, pitting and distortion. Replace drums as required.

b. Measure the inside diameter of the drum in several

locations with a drum caliper or internal micrometer

(Figure 29).

c. If brake drum is excessively worn or out of round

replace brake drum.

Failure to replace an out of round brake drum could result in damage to brake drum or other components.

Figure 29

MEASURE INNER DRUM DIAMETER TO DETERMINE WEAR AND OUT OF ROUND IN ACCORDANCE WITH BRAKE DRUM MANUFACTER’S MANUAL.

Figure 30

BRAKE SHOE ROLLER

RIBS

12. Brake Shoe Installation

1. Install the brake shoe roller into the roller retainer

(Figure 30).

2. Install the roller and roller retainer into the brake shoe

ribs (Figure 30).

3. Coat anchor pins (ends only) completely with lubricant

(Never-Seez spider (Figure 31).

®

) and install (if removed) in the brake

ROLLER RETAINER

Figure 31

ANCHOR PINS

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19

Brake Shoe Replacement

4. Install return spring pin into brake shoe ribs (Figure 32).

5. Connect the hub/drum return spring to the upper and lower brake shoes (Figure 33).

6. Position the roller of the upper brake shoe up against the S-Cam, then place the other end of the shoe against the anchor pin (Figure 34).

Failure to control spring pressure during brake shoe installation could create a pinch hazard which, if not avoided, could result in minor to moderate injury.

Figure 32

RETURN SPRING PIN

Figure 33

HUB/DRUM RETURN SPRING

20

Figure 34

UPPER BRAKE SHOE

S-CAM

ANCHOR PINS

LOWER BRAKE SHOE

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and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.

Brake Shoe Replacement

7. Position the roller of the lower brake shoe up against the

S-Cam, then place the other end of the shoe against the anchor pin (Figure 35).

8. Install the two (2) brake anchor pin springs using the

anchor pin pliers (Figure 36).

9. Make sure the brake linings are clean.

10. Re-install drum using support device such as a drum dolly

jack (Figure 37).

Failure to support weight during installation or removal of brake drum could create a crush hazard which, if not avoided, could result in minor to moderate injury.

11. Adjust the brakes as described in Section 17.

Figure 35

UPPER BRAKE SHOE

S-CAM

ANCHOR PINS

LOWER BRAKE SHOE

Figure 36

Figure 37

SPRING PLIERS

BRAKE ANCHOR PIN SPRING

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21

Brake Adjuster Replacement

13. Brake Adjuster Removal

NOTE: Maintenance procedures in this section require

re-positioning of the brake adjuster. Consult the manufacturer’s manual for procedures to properly operate brake adjusters.

1. Remove the cotter pins that secure the brake adjuster/brake chamber clevis pins (Figure 38). Remove the clevis pins.

2. Remove the retaining ring and washer that secure the brake adjuster to the S-Camshaft (Figure 39).

3. Remove the self-adjusting brake adjuster from the spline end of the brake S-Camshaft.

4. Rotate adjusting mechanism to back the brake adjuster out of the clevis in accordance with brake adjusters manual.

14. Brake Adjuster Installation

1. Apply an even coat of anti-seize compound to splined surface of S-Camshaft.

2. Position the spacing washers on both sides of the brake adjuster, then install the brake adjuster onto the S-Camshaft spline and secure the brake adjuster on the S-Camshaft by assembling the retaining ring (Figure 40).

3. Align the brake adjuster to the clevis and pin together using the clevis pins and cotter pins (Figure 38).

4. Apply service and spring brake several times. Final brake adjustment is required to ensure proper initial brake operation. The brake adjuster will then seek the proper working stroke during normal operating conditions. Refer to brake adjuster and brake chamber manufacturers' procedures for proper adjustment.

Figure 38

CLEVIS PINS

Figure 39

S-CAM SPLINE

CLEVIS PINS

SPACING WASHERS

CLEVIS

BRAKE ADJUSTER

COTTER PINS

RETAINING RING

COTTER PINS

22

Figure 40

BRAKE ADJUSTMENT NUTBRAKE CHAMBER

CLEVIS

PUSH ROD JAM NUT

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and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.

S-camshaft Replacement

15. S-Camshaft and Bearing

Removal Procedure

1. Remove the brake shoes and brake adjuster as described

in Section 11 and 13, respectively.

2. Remove the retaining ring from the spider end of the

S-Camshaft (Figures 41).

3. Remove the S-Camshaft by sliding it out of the S-Camshaft

bearing housing and bearings. It could be necessary to tap the end of the shaft with a soft mallet to release it from the bearings (Figure 41).

4. Remove existing bolts securing the S-Camshaft bearing

housing to the axle bracket (Figure 42).

5. Inspect bearings assembly for wear and deterioration.

Replace as necessary.

Figure 41

BRAKE SPIDER

RETAINING RING

Figure 42

S-CAMSHAFT BEARING HOUSING

AXLE BRACKET

S-CAMSHAFT

AXLE BRACKET

BOLTS (4)

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23

S-camshaft Replacement

16. S-Camshaft and Bearing Installation

1. Attach the S-Cam bearing housing bracket to (Figure 43) the axle bracket, securing it with the four (4) nuts and bolts (Figure 44). Tighten the nuts to 15-22 ft.-lbs. (20-30 N•m).

2. Install the S-Camshaft bearing into the brake spider, ensuring that the bearing is centered (Figure 45).

Failure to center S-Camshaft bearing into the brake spider could not allow grease flow to bearing which, if not avoided, could result in premature bearing failure.

3. Install the guide plate, brake roller shoe and cam seal on the S-Camshaft and slide S-Camshaft and washer assembly through the S-Camshaft bearing in the brake spider (Figure 45).

Figure 43

S-CAMSHAFT BEARING HOUSING

Figure 44

S-CAMSHAFT BEARING HOUSING

AXLE BRACKET

Figure 45

BOLTS (4)

SPIDER GREASE FITTING

NUTS (4)

S-CAM BEARING

CAM SEAL

GUIDE PLATE, BRAKE ROLLER SHOE

S-CAMSHAFT

24

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S-camshaft Replacement

5. Install the cam seal washer and retaining ring onto

S-Camshaft and slide S-Camshaft into the S-Camshaft bearing housing bracket (Figure 46).

6. Install the brake shoes and brake adjusters as described

in Section 12 and 14, respectively.

7. Inspect S-Camshaft installation to ensure that the correct

S-Camshaft has been installed on the required side of the axle for proper operation (Figure 47).

Figure 46

HOUSING BRACKET S-CAM BEARING

RETAINING RING

WASHER

CAM SEAL

BRAKE SPIDER

GUIDE PLATE, BRAKE ROLLER SHOE

S-CAMSHAFT

Figure 47

CORRECT S-CAMSHAFT INSTALLED

WHEEL ROTATION

INCORRECT S-CAMSHAFT INSTALLED

WHEEL ROTATION

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S-CAM ROTATION

25

Brake Adjustment

8. Lubricate the S-Camshaft bearings with grease specified in the Lubrication Table in Section 21 (Figure 48).

17. Brake Adjustment Procedure

1. Verify that the spring brakes are caged prior to beginning adjustment procedure.

2. Adjust the brake adjuster until the brake lining contacts the brake drum, then back off 1/2 turn.

3. Apply the service brakes using normal operating pressure (average line pressure should be 90 psi, but not less than 80 psi). Check the following while brake pressure is applied.

• The optimum distance of push rod travel should be

approximately 1.5"-1.75" (38-44 mm) (Figure 49).

• Angle between the push rod and the brake adjuster

with brake applied, should be

• Brake lining to drum contact. A 0.010" feeler gauge

should not fit between the lining and the drum contact area.

4. Release the air pressure from the service brake system and check to see that all brakes release to the normal relaxed position. If all brakes do not properly release, Refer to Troubleshooting Chart in Section 22.

Failure to adjust brakes in accordance with manufacturer’s instructions prior to placing trailer back in service will prohibit proper brake function which, if not avoided, could result in uneven brake system component wear.

95°-100° (Figure 50).

Figure 48

S-CAMSHAFT LUBRICATION FITTING LOCATIONS

BRAKE ADJUSTER

S-CAMSHAFT

S-CAM BEARING HOUSING

Figure 49

5. Uncage spring brakes

Failure to uncage spring brakes in accordance with manufacturers's instructions after servicing is complete will prohibit proper brake function which, if not avoided, could result in death or serious injury.

26

.

OPTIMUM PUSH ROD TRAVEL APPROX. 1.75"-2.0" (38-44

mm)

Figure 50

95-100O

O

95-100

(WITH BRAKES APPLIED)

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ABS Sensor Replacement

18. ABS Sensor Replacement Procedure

18.1 Sensor Removal

NOTE: ABS sensors MUST match the system. DO NOT mix

sensors from different manufacturers.

1. Manually release the brakes.

2. Remove brake drum assembly as described in Section 4.

3. Disconnect the ABS sensor connector and remove the

sensor from the sensor holder by pulling straight out

(Figure 51).

4. Remove the sensor retaining spring clip, if necessary.

18.2 Sensor Installation

NOTE: Be sure to use the correct spring clip for the sensor

being installed.

1. Install the sensor retaining spring clip, if removed, into

the sensor holder.

2. Install the ABS sensor into the spring clip and sensor

holder. Push the sensor in until it contacts the tone ring

(Figure 52).

3. Connect the ABS sensor connector.

4. Re-install drum using support device such as a drum dolly

jack (Figure 37).

5. Adjust brakes as described in Section 17.

Figure 51

Figure 52

ABS SENSOR CONNECTOR

SPRING CLIP

ABS SENSOR HOLDER

19. Axle Alignment Inspection

NOTE: Alignment can be achieved using an optical device

designed specifically for this purpose. Follow the instructions in the optical device operating instructions to align the axles.

1. To manually align the axles attached to your trailer, first

pull the trailer in a straight line for a sufficient distance to release/clear any binds in the suspension.

NOTE: A straight, unbound suspension is the position of

a suspension during normal operations.

Using the alignment procedures per the suspension

manufactuer’s recommendations, align the axles to the following specifications.

2. Measure the distance from the king pin to the centerline

of the spindles on each side of the front axle. Dimensions A and B MUST be equal to within 1/8" (4 mm) (Figure

53, A and B).

3. Measure the distance from the centerline of the spindles

of the front axle to the centerline of the spindles of each additional axle. Dimension C and D must be equal to within 1/16" (1 mm) (Figure 53, C and D).

Figure 53

KING PIN

A=B

C=D

A

B

D

C

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27

Routine Service Schedule

20. Routine Service Schedule

WHICHEVER OCCURS FIRST PERIODIC CHECKS

AFTER FIRST

MILEAGE INTERVALS

TIME INTERVALS

VISUAL INSPECTION FOR WEAR/DAMAGE

Check brake linings for wear. • •

Check S-Camshaft for proper operation. • •

Check brake adjusters for correct function. • •

Check air brake system for leaks (brake applied). • •

Check axle structural components for cracks or damage. • •

Check hub lubrication level for excessive leakage. • •

MECHANICAL

Attention: Torque check wheel nuts after the ﬁrst thirty (30) miles (50 km) and 100 miles (150 km) (repeat also after every wheel removal). •

Torque check all nuts and bolts to recommended setting. • •

Check and adjust wheel bearing end play. • •

Pack hub bearings with fresh lubricant (also after every brake lining replacement, check hub bearing wear). •

Lubricate S-Camshaft bearing bushings. • •

SAFETY INSPECTION

Check brake lining to drum clearance for correct adjustment – re-adjust clearance if necessary. Check service brake and parking brake for performance. • •

CHECK

3,000 MILES

AFTER FIRST

MONTH EVERY MONTH EVERY 6 MONTHS EVERY 12 MONTHS

EVERY 10,000

MILES

EVERY 50,000

MILES

EVERY 100,000

MILES

SPECIAL SERVICE CONDITIONS

Service at speciﬁed time intervals, e.g. trailer used for storage or frequently left standing for

Vehicles with long standing periods.

Vehicles used under extreme conditions.

Warranty claims will only be accepted as long as the operation and maintenance instructions have been complied with and if SAF-HOLLAND approved spare parts have been ﬁtted.

several days at a time.

Service at suitably reduced intervals, e.g. trailer operating in continuous multi-shifts or in off-road construction sites.

28

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21. Torque and Lubrication Speciﬁcations

Torque and Lubrication

TORQUE SPECIFICATIONS

COMPONENT TORQUE VALUE

Grease Fitting, Spider 20-50 in-lbs (2-6 N•m)

Axle, Inner Nut Refer to Section 7

Axle, Outer Nut 300-400 ft.-lbs. (406-542 N•m)

Air Chamber Nuts 80-125 ft.-lbs. (108-169 N•m)

Hubcap Bolts 12-16 ft.-lbs. (16-21 N•m)

Self-Threading Screw 15-22 ft.-lbs. (20-30 N•m)

LUBRICATION SPECIFICATION

COMPONENT SURFACE TO BE LUBRICATED TORQUE VALUE

S-Camshafts

S-Camshaft Bearings (Four (4) Grease Fittings per Axle)

Lithium Complex Grease

S-Camshafts S-Camshaft Spline NeverSeez

Brakes

Brakes − Brake Adjuster

Brake Shoe Rollers anchor Pins

Brake Adjuster Grease Fitting

NeverSeez

Lithium Complex Grease

80/90 Gear Oil or Lithium Complex

Axle Bearings and Hubs

* Oil lubed bearings and hubs should remain lubricated with oil, grease lubed

bearings and hubs should remain lubricated with grease.

NOTE: Intervals are based upon normal operations. Reduce intervals to

compensate for abnormal operations or severe conditions. During inactive periods, sufficient lubrication must be performed for equipment preservation.

Grease*

XL-TA10006OM-en-US Rev B · 2014-03-13 · Amendments and Errors Reserved · © SAF-HOLLAND, Inc., SAF-HOLLAND, HOLLAND, SAF, and logos are trademarks of SAF-HOLLAND S.A., SAF-HOLLAND GmbH, and SAF-HOLLAND, Inc.

29

Troubleshooting

22. Troubleshooting Chart

PROBLEM POSSIBLE CAUSE RESOLUTION

Brake shoes bound up at anchor pins Lubricate brake operating parts

Brake hoses Restricted Replace hoses

Brakes out of adjustment Adjust brakes

Brakes will not release

No brakes or insufﬁcient brakes (NOTE: All of the possible causes would result in brake lockup.)

Dog tracking

Uneven tire wear

Grabbing brakes

Excessive heat cracks on drum

ABS inoperable Refer to ABS manufacturer’s service literature

Slow brake application or release

Damaged brake assembly Replace or repair as required

Open cutout cocks at rear of tractor cab or push

Source of air supply shut off at tractor

Low brake line pressure Check air pressure gauge on tractor - inoperative

Brake lines between tractor and trailer not properly coupled Properly couple brake lines

Reservoir drain cock open Close drain cock

Leaf spring broken Replace complete spring

Bent Axle Replace or straighten axle

Frame or suspension out of alignment Straighten frame or align axles

Over or under inﬂation Inﬂate to proper pressure

Loose wheel stud nuts or clamps Tighten wheel stud nuts or clamps

Loose or tight wheel bearing adjustment Adjust bearings

Axle bent or out of alignment Straighten, align or replace axle

Tires not properly matched Match tires

Improper acting brakes Correct brakes as required

Rapid Stopping Apply brakes slowly when approaching stop

High-speed driving on turns Reduce speed

Oil, grease or foreign material on brake lining Reline brakes

Brakes out of alignment Adjust brakes

Brake drum out-of-round Replace brake drum

Damaged brake chamber or internal assembly Replace brake chamber/internal assembly

Leaky or broken hose between relay valve and brake chamber Replace or Repair as required

Rapid stopping or poor air ﬂow to brakes Replace drum

Out of adjustment Adjust brakes

Binding S-Cam, anchor pins or chamber rod end pin Lubricate and free up

Damaged brake assembly/brake drum out-of-round Replace or repair as required

Lack of lubrication Lubricate brake operating parts

Excessive travel in brake chamber push rod Adjust brakes

Restiction in hose or lines Replace hoses

Defective brake valve Replace brake valve

control valve “IN”

30

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Notes

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31

From fifth wheel rebuild kits to suspension bushing repair kits,

SAF-HOLLAND Original Parts are the same quality components used

in the original component assembly.

SAF-HOLLAND Original Parts are tested and designed to provide

maximum performance and durability. Will-fits, look-alikes or, worse

yet, counterfeit parts will only limit the performance potential and

could possibly void SAF-HOLLAND’s warranty. Always be sure to spec

SAF-HOLLAND Original Parts when servicing your

SAF-HOLLAND product.

SAF-HOLLAND USA

www.safholland.us

SAF-HOLLAND CANADA

WESTERN CANADA

www.safholland.ca

SAF-HOLLAND MEXICO

www.safholland.com.mx

info@safholland.com

SAF-HOLLAND USA, INC. 1950 Industrial Blvd., Muskegon, MI 49442 www.safholland.com

888.396.6501

·

519.537.3494

·

604.574.7491

·

52.55.5362.8743

·

Fax 800.356.3929

·

Fax 800.565.7753

·

Fax 604.574.0244

·

Fax 52.55.5362.8743

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SAF XL-TA10006OM User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual