Valx WSM DRUM, Workshop Manual

Page 1: ...Document code WSM_2051 04 Date October 2020 WSM DRUM WORKSHOP MANUAL DRUM BRAKES...

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Page 3: ...y nature The information in this document has been prepared solely for the purpose of providing information about assembly disassembly repair and maintenance on the trailer axle and the suspension sys...

Page 4: ...nable 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 M...

Page 5: ...ument type WSM Workshop Manual TBM Trailer Builder Manual DM Driver Manual Document number The third field contains the document revision number Related documents The following related documents are a...

Page 6: ...m 14 2 Explanation of the axle type code 15 2 1 Location of the identification plate 15 2 2 Information on the identification plate 15 2 3 Ordering of parts 16 3 Maintenance chart 17 4 Tightening torq...

Page 7: ...tion can occur causing personal injury or damage to the product the workshop or the environment If the safety instruction is not observed an imminent hazardous situation will occur causing severe pers...

Page 8: ...he left hand corner is the width across flats 8 Use a ring spanner The value in the left hand corner is the width across flats 290 Nm Use an appropriate torque wrench Tighten the fastener to the torqu...

Page 9: ...Use the special socket tool width across flats 103 The value in the left hand corner is the width across flats Lubricants Optimol White Paste Lubricate with Optimol White Paste Mobilith SHC 220 Lubri...

Page 10: ...se 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 servi...

Page 11: ...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 7 4 2 Remove the dust cover see 7 4 3 Install the dust cover see 7 4 4 Remove the brake drum se...

Page 12: ...EAK ALL SHARP EDGES UNLESS OTHERWISE SPECIFIED DIMENSIONS IN MILLIMETERS SYSTEM THIRD ANGLE PROJECTION DO NOT SCALE DRAWING Solidworks TR 2040 STR 1200 1300 ABS prepared with slack adjusters Axle assy...

Page 13: ...ll 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 conversio...

Page 14: ...e 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 1...

Page 15: ...sk brake rotor R Small 300x200 mm 17 5 rimsize S Medium 370 mm disk 19 5 rimsize M Medium 360x200 mm drum 19 5 rimsize M Large 430 mm disk 22 5 rimsize L Large 420x180 drum 22 5 rimsize L Extra large...

Page 16: ...ABS 2 6 Drum brake axle 19 5 2 7 Drum brake axle 22 5 incl ABS 2 8 Drum brake axle 22 5 2 9 Single mounting OS 0 0 Double mounting 1 Single mounting OS 120 2 Rigid axle X 0 Forced steering axle F 1 Se...

Page 17: ...linder connection damages corrosion leakage 0 X Slack adjuster Check the correct functioning 7 3 4 0 X Lubricate the slack adjuster 2 grease nipples per axle 7 3 5 0 X S cam bearing Lubricate the S ca...

Page 18: ...lt M8 13 20 Nm 22 Nm 4 Nm 2 Brake cylinder nut M16 x 1 5 24 175 Nm 210 Nm 30 Nm 1 3 Set nut yoke M16 x 1 5 24 60 Nm 65 Nm 4 Nm 1 4 Ball bearing nut M8 13 20 Nm 22 Nm 4 Nm Wheel hub unit 8 5 Central nu...

Page 19: ...mplete 5 1 Overview D C B A NOTE The VALX drum brake trailer axle has been designed for 0 offset wheels A Brake system drum brake see chapter 7 B Wheel hub unit see chapter 8 C Air suspension system D...

Page 20: ...WSM_2051 03 20 6 Preparatory actions 6 1 Place the wheel chocks 1 Position the trailer on an even surface and use wheel chocks to secure the trailer against rolling away...

Page 21: ...2 Jack up the trailer Previous steps 6 1 Previous steps vorige Schri e tapes pr c dentes vorige stappen 1 200 mm 200 mm 2 Only use approved devices to jack up the trailer Place the jack only at the in...

Page 22: ...22 WSM_2051 04 6 3 Remove the wheel s Previous steps 6 1 6 2 Previous steps vorige Schri e tapes pr c dentes vorige stappen 1 A 2 25 kg...

Page 23: ...6 3 Previous steps vorige Schri e tapes pr c dentes vorige stappen 1 25 kg 2 A 630Nm No grease oil or paint is allowed on the threaded surface or on the wheel nut Torques Item Size Width across flats...

Page 24: ...24 WSM_2051 04...

Page 25: ...D Yoke E Brake cylinder F1 Circlip F2 Wear indicator G Slack adjuster H Flange bolt I Flange nut J S cam bearing K Slack adjuster bracket L Circlip M Washer N S cam seal O S cam bush P S cam shaft Q D...

Page 26: ...s steps 6 1 6 2 8 4 1 Previous steps vorige Schri e tapes pr c dentes vorige stappen 1 max Check the condition of the brake drum and measure the internal diameter at the top and bottom Replace the bra...

Page 27: ...WSM_2051 04 27 7 3 3 Check the draining plugs 1 E Check if the draining plugs at the bottom side of the brake cylinder have been removed...

Page 28: ...F C 2 3 4 C D A B E F B A 5 6 1 SCALE 1 20 SHEET 12 OF 13 DATE DATE FINISH GENERAL TOLERANCES CHK D proposal MATERIAL TITLE WEIGHT A3 DOC NO DEBURR AND BREAK ALL SHARP EDGES UNLESS OTHERWISE SPECIFIE...

Page 29: ...ly 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 ro...

Page 30: ...SHC 220 7 3 6 Lubricate the S cam bearing 2 1 Mobilith SHC 220 2 1 Mobilith SHC 220 2 2 Mobilith SHC 220 Always lubricate all S cam bearings 4 grease nipples on the same axle and manually move the cam...

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Page 32: ..._2051 04 7 4 Disassembly assembly and adjustments 7 4 1 Remove the brake shoe Previous steps 6 1 6 2 6 3 7 4 9 8 4 1 Previous steps vorige Schri e tapes pr c dentes vorige stappen 1 X2 X2 2 W2 3 X1 4...

Page 33: ...WSM_2051 04 33 6 S U V 7 8 T d max 24 5 mm d 9 10...

Page 34: ...ious steps 6 1 6 2 7 4 1 6 3 7 4 9 8 4 1 Previous steps vorige Schri e tapes pr c dentes vorige stappen 1 Mobilith SHC 220 S U V 2 S 3 X1 W1 4 W2 Mobilith SHC 220 5 W2 Always replace the return spring...

Page 35: ...3 1 4 6 2 8 8 5 6 1 4 2 3 7 10 9 L L R 4 11 1 16 15 9 7 3 8 12 2 10 6 5 13 14 R 7 11 1 15 3 5 8 4 6 L 2 14 10 12 16 9 13 D E F C 2 3 4 C D A B E F B A 5 6 1 SCALE 1 5 SHEET 1 OF 1 DATE DATE FINISH GE...

Page 36: ...36 WSM_2051 04 7 4 3 Remove the dust cover Previous steps 6 1 Previous steps vorige Schri e tapes pr c dentes vorige stappen 2 1 13 Z2 Z1 2 2 Y...

Page 37: ...ll the dust cover Previous steps 6 1 7 4 3 Previous steps vorige Schri e tapes pr c dentes vorige stappen 2 1 Y 2 2 22 Nm Z2 Z1 13 Torques Item Size Width across flats Torque Nm Dust cover bolt Z1 M8...

Page 38: ...051 04 7 4 5 Disassembly brake drum Previous steps 6 1 6 2 6 3 7 4 9 8 4 1 Previous steps vorige Schri e tapes pr c dentes vorige stappen 1 2 W3 25 kg 2 Be careful not to damage the thread of the whee...

Page 39: ...WSM_2051 04 39 7 4 6 Assembly brake drum Previous steps 6 1 6 2 7 4 5 6 3 7 4 9 8 4 1 Previous steps vorige Schri e tapes pr c dentes vorige stappen 1 W3 25 kg 1 2 3...

Page 40: ...rawin Pro REV 1 D E F C 2 3 4 C D A B E F B A 5 6 1 SCALE 1 20 SHEET 1 OF 13 DATE DATE FINISH GENERAL TOLERANCES CHK D proposal MATERIAL TITLE WEIGHT A3 DOC NO DEBURR AND BREAK ALL SHARP EDGES UNLESS...

Page 41: ...ED Mobilith SHC 220 2 D E F C 2 3 4 B A 5 6 1 SCALE 1 20 FINISH GENERAL TOLERANCES CHK D proposal MATERIAL TITLE WEIGHT DOC NO DEBURR AND BREAK ALL SHARP EDGES UNLESS OTHERWISE SPECIFIED DIMENSIONS IN...

Page 42: ...ed 3 0 5 2 mm 6 D E F C 2 3 4 B A 5 6 1 FINISH GE MATERIAL WEIGHT DEBURR AND BR ALL SHARP EDG UNLESS OTHERWISE SPECIFIED DIMENSIONS IN MILLIMETERS SYSTEM DO NOT SCALE DRAWING Dr REV Mobilith SHC 220 7...

Page 43: ...2 Previous steps vorige Schri e tapes pr c dentes vorige stappen 1 12 At least 1 2 STOP 12 3 270 12 Turn the slack adjuster screw approximately 270 counterclockwise When turning counterclockwise one...

Page 44: ...44 WSM_2051 04 7 4 10 Remove the brake cylinder Previous steps 6 1 6 2 7 4 9 Previous steps vorige Schri e tapes pr c dentes vorige stappen 2 1 A P 1 2 2 B 2 3 C1 24 2 4 E 2 5 D C2 24...

Page 45: ...ps vorige Schri e tapes pr c dentes vorige stappen 2 1 D C2 65 Nm 1 2 2 2 3 E Check that the brake cylinder seat is within 0 3 mm flat If not repair Mount the new brake cylinder using the same holes a...

Page 46: ...04 2 4 210 Nm C1 2 5 90 90 E G 5 2 7 Mobilith SHC 220 B A Mobilith SHC 220 6 When the brake is actuated the angle must be 90 Torques Item Size Width across flats Torque Nm Nut C1 M16 24 210 Nm 30 Nm C...

Page 47: ...3 2 3 4 C D A B E F 5 6 SCALE 1 2 SHEET 7 OF 14 DATE DATE FINISH GENERAL TOLERANCES CHK D proposal MATERIAL TITLE WEIGHT A3 DOC NO DEBURR AND BREAK ALL SHARP EDGES UNLESS OTHERWISE SPECIFIED DIMENSION...

Page 48: ...D ANGLE PROJECTION DO NOT SCALE DRAWING Solidworks TR 2040 STR 1200 1300 ABS prepared with slack adjusters Axle assy drum 9t 420x180 OS 0 REVISION Released DATE DATE CHK D proto DRAWN DWG NO Manual_dr...

Page 49: ...the S cam and the S cam bearing continued 4 N N 5 P Q 6 M L M 2 1 Mobilith SHC 220 2 1 Mobilith SHC 220 Mobilith SHC 220 7 2 2 Mobilith SHC 220 Mobilith SHC 220 8 Always lubricate all S cam bearings...

Page 50: ...le assy drum 9t 420x180 OS 0 REVISION Released DATE DATE CHK D proto DRAWN DWG NO ABS sensor 24 08 2020 CH DrawingType Production 20015422 REV DATE APPROVED WABCO ABS sensor grease 2 D E F C 2 3 4 B A...

Page 51: ...5 4 3 2 7 8 9 2 3 4 5 6 7 8 NOTE The VALX drum brake trailer axle has been designed for 0 offset wheels A Hub cap plastic B O ring for plastic hub cap C Circlip D Central nut single use E Nut washer...

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Page 53: ...6 D C B A E F G H A B C D F 5 4 3 2 1 7 8 9 10 11 12 1 2 3 4 5 6 7 8 G SHEET 1 OF 1 SCALE 1 10 DISC 430 MBS VERSION 20015429 02 09 2020 Check bearing play DWG NO MBS V2 DOC NO TITLE 2 1 2 1 2 Check if...

Page 54: ...teps 6 1 6 2 7 4 9 6 3 Previous steps vorige Schri e tapes pr c dentes vorige stappen 1 Plastic hub cap 1 2 A B Plastic hub cap 2 Steel hub cap 1 M N D E F C 2 3 4 C D A B E F B A 5 6 1 SCALE 1 2 SHEE...

Page 55: ...WSM_2051 04 55 8 4 1 Disassembly hub complete 3 C 75 Single use nut 75 3 O P Q Multiple use nut 3 4 G 25 kg 25 kg 4 5 5 6 J 6...

Page 56: ...Optimol White Paste 2 2 G 25 kg 25 kg 3 3 C 75 Single use nut 75 4 Q Multiple use nut 4 Slide the ABS sensor in as far as possible the sensor will adjust automatically Always replace the single use ce...

Page 57: ...0 7 Plastic hub cap 8 8 Plastic hub cap 9 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...

Page 58: ...Steel hub cap 8 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 Wid...

Page 59: ...WSM_2051 04 59 8 4 3 Disassembly outer bearing and inner bearing Previous steps 6 1 6 2 7 4 9 8 4 1 6 3 Previous steps vorige Schri e tapes pr c dentes vorige stappen 1 D 2 E 3 F 4 K 5 J...

Page 60: ...60 WSM_2051 04 6 I 7 H 8 9 Go to step 10 Go to step 12 F H 10 H1 F1 Remove grease from cavity area clean the hub...

Page 61: ...1 H1 200g Mobilith SHC 220 Mobilith SHC 220 1 165g 2 F 80g 120g H Mobilith SHC 220 Mobilith SHC 220 2 65g 90g 3 H If the bearing cups have been removed in the previous step replace the complete beari...

Page 62: ...1 04 4 I 5 Air side up J Mobilith SHC 220 6 K 7 F 8 E 9 D 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...

Page 63: ...SH GENERAL TOLERANCES CHK D proposal MATERIAL TITLE WEIGHT A3 DOC NO DEBURR AND BREAK ALL SHARP EDGES UNLESS OTHERWISE SPECIFIED DIMENSIONS IN MILLIMETERS SYSTEM THIRD ANGLE PROJECTION DO NOT SCALE DR...

Page 64: ...9 Axle beam 9 1 Safety instructions Always observe the general safety instructions and regulations see chapter 1 9 2 Overview A C B D D B C A Axle beam B Brake spider C Air chamber bracket D S cam be...

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Page 68: ...irs SenterNovem Brabant Province SRE and Limburg Province The Netherlands VALX bv De Amert 700 C NL 5462 GH Veghel The Netherlands phone 31 0 88 405 8800 fax 31 0 88 405 8820 email info valx eu web ww...