Post on 03-Jul-2020
trailer axles
gigant – Trenkamp & Gehle GmbHMärschendorfer Str. 4249413 Dinklage | GermanyTel: +49 (0) 44 43 | 96 20-0E-Mail: contact@gigant-group.comwww.gigant-group.com
trailer axles
Ausg
abe
1.1
| 02
.201
7 |
Art-
Nr. 7
0301
2816
| T
echn
isch
e Än
deru
ngen
vor
beha
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| Su
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tech
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l cha
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Service booklet| Stub axle
GEOKH2 10010 4218
EN
Serv
iceh
eft |
Ach
sstu
mm
el
Ser
vice
boo
klet
| S
tub
axle
S
ervi
ceha
ndbo
ek |
Ass
tom
ptr
aile
r ax
les
CONTENTS
a. GENERAL INFORMATION 6
b. AXLE DATA PLATE 7
1. MAINTENANCE 9
1.1 MAINTENANCE INTERVAL: AFTER 1,000 KM 10
1.1.1 CHECKING THE RUNNING CLEARANCE OF THE AUTOMATIC SLACK ADJUSTER 10
1.2 MAINTENANCE INTERVAL: EVERY 50,000 KM 11
1.2.1 CHECKING THE BRAKE DRUM 11
1.2.2 CHECKING THE BRAKE LININGS 12
1.2.3 LUBRICATING THE BRAKE CAMSHAFT 12
1.3 MAINTENANCE INTERVAL: EVERY 100,000 KM 13
1.3.1 CHECKING THE ANCHOR BRACKET 13
1.3.2 CHECKING THE AUTOMATIC SLACK ADJUSTER ATTACHMENT 13
1.4 MAINTENANCE INTERVAL: ANNUALLY 14
1.4.1 LUBRICATING THE AUTOMATIC SLACK ADJUSTER 14
1.5 MAINTENANCE INTERVAL: EVERY 200,000 KM 14
1.5.1 CHECKING THE BRAKE SHOE BEARINGS 14
1.6 RECOMMENDATIONS FOR INSPECTING THE COMPACT BEARING 15
1.6.1 NOISE TEST 15
1.6.2 INCREASED GREASE LEAKAGE 15
1.6.3 BEARING CLEARANCE 16
1.7 DOCUMENTATION 18
2. REPAIR 20
2.1 BRAKE DRUM 20
2.1.1 REMOVING THE BRAKE DRUM 20
2.1.2 FITTING THE BRAKE DRUM 21
2.1.3 ADJUSTING THE BRAKE 22
2.2 HUB UNIT 24
2.2.1 REMOVING THE HUB UNIT 24
2.2.2 FITTING THE HUB UNIT 26
2.2.3 ABS SENSOR RING 29
2.4 BRAKE SHOE 30
2.4.1 REMOVING THE BRAKE SHOES 30
2.4.2 FITTING THE BRAKE SHOES 32
2.5 BRAKE CAMSHAFT 33
2.5.1 REMOVING THE BRAKE CAMSHAFT 33
2.5.2 FITTING THE BRAKE CAMSHAFT 34
2.5.3 REPLACING THE BRAKE CAMSHAFT BUSHING 36
2.6 ABS-SENSOR 37
z. WARRANTY 40
GEOKH2 10010 4218 | CONTENTS
gigant - Trenkamp & Gehle GmbH
CONTENTS | GEOKH2 10010 4218
gigant - Trenkamp & Gehle GmbH
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The maintenance rules apply to axles from gigant. They are an integral part of the warranty conditions.
To preserve full operational readiness as well as ensure operational safety and road safety, the following
maintenance work must be performed at the intervals prescribed. To maintain the validity of the operating permit
for gigant axles, only original spare parts may be used.
After painting work and before commissioning, all grease nipples must be checked for continuity and must be
lubricated with grease until fresh grease emerges from the bearing point. Only gigant grease in accordance with
the specification may be used.
The connection to a central lubrication system, which is able to deliver special long-life grease with consistency
class 2-3, is permitted.
The use of fluid greases is not permitted!
The correction of any faults detected and the replacement of worn parts must be carried out by a specialist
workshop.
Before starting every journey, the driver must ensure that the braking system and air suspension system are ready
for operation to his/her satisfaction. An air suspension system may only be driven in the driving position.
a. GENERAL INFORMATION
The information contained in this manual has been created with the greatest possible care. No liability can be
accepted for any errors. Technical changes reserved. Illustrations are not binding (errors excepted).
Changes will be notified by the publication of a new manual. Please ensure that you have the current version.
New versions will be announced on the website. Invalid manuals should be destroyed.
b. RATING PLATE
Ident No: 711110018 / YA15450305 GEOKH2 10010 4218 250 000 242 ABS AGS RE
ID1- 20-225-24 stat.axle loadID2- 4218P 10.000 kgID3- 10006,2 v maxID4- 36101507 105 km/h
gigant - Trenkamp & Gehle GmbHD-49413 Dinklage
Ident no. Serial no.Axle type description
Test report
Brake identifier
Test axle load
Axle identifier
Max. speed
Max. permitted static axle load
Note
Test wheel nuts for tightness after initial delivery and 50 km after every tyre change.
DE DE
1 1
GEOKH2 10010 4218 | GENERAL INFORMATION
gigant - Trenkamp & Gehle GmbH
GENERAL INFORMATION | GEOKH2 10010 4218
gigant - Trenkamp & Gehle GmbH
2 2
EN
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2
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EN | 7
EN | 7
6 | EN
6 | EN
NL
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5
4
1
2
3
6
8
9
10
7
SYMBOL MAINTENANCE INTERVALS
After first 1,000 km After first loaded drive
Every 50,000 km Quarterly
Every 100,000 km Every six months
On every brake lining change Annually
Every 200,000 km and on every brake lining change Every 2 years
1. MAINTENANCE
1.1.1, page 10 1.2.1, page 11
1.2.3, page 121.2.2, page 12
1.3.1, page 13
1.3.2, page 13
1.4.1, page 14
1.5.1, page 14
GEOKH2 10010 4218 | MAINTENANCE
gigant - Trenkamp & Gehle GmbH
DE
1
2
EN
1
2
a
a
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z
EN | 9
EN | 9
NL
1
2
a
z
NOTES | GEOKH2 10010 4218
gigant - Trenkamp & Gehle GmbH
DE
1
2
EN
1
2
a
a
z
z
8 | EN
8 | EN
NL
1
2
a
z
1.1 MAINTENANCE INTERVAL: AFTER 1,000 KM
1.1.1 CHECKING THE RUNNING CLEARANCE OF THE AUTOMATIC SLACK ADJUSTER
After the first loaded trip, or
after the first 1,000 km
Note
With free travel (A) of the cylinder push rod of max. 35 mm, the
wheel brake must be readjusted.
Note
Check lubrication of the brake camshaft and the automatic slack
adjuster
1.2.1 CHECKING THE BRAKE DRUM
Brake drum dimensions
Dimensions
of the brake 420x180
1 Original dimension
Ø Brake drum 420
Item no. brake linings, set 709317090
Brake linings thickness 16.8 mm
2First repair
dimension
Ø Brake drum 422
Item no. brake linings, set 709317091
Brake lining thickness 17.8 mm
3
Max. wear Ø Brake drum 425
Brake linings Number per axle 8
Steel rivetNumber per axle 80
Order no. steel rivet 702950003 Ø 8x15
3
2
1
1
2
3
1.2 MAINTENANCE INTERVAL: EVERY 50,000 KM
Quarterly or every 50,000 km
» Check for cracks and wear
» Check the brake drum wear using a vernier calliper
GEOKH2 10010 4218 | MAINTENANCE
gigant - Trenkamp & Gehle GmbH
MAINTENANCE | GEOKH2 10010 4218
gigant - Trenkamp & Gehle GmbH
DE DE
1 1
2 2
EN
1
2
EN
1
2
a a
aa
zz
zz
EN | 11
EN | 11
10 | EN
10 | EN
NL
1
2
a
z
NL
1
2
a
z
1.2.2 CHECKING THE BRAKE LININGS
Quarterly or every 50,000 km
» Remove the brake drum ( 2.1.1, page 20)
» Remaining brake lining thickness ≤ 5 mm (visible on the
brake lining wear edge, smallest lining thickness counts)
» replace brake lining ( 2.4, page 30)
1.2.3 LUBRICATING THE BRAKE CAMSHAFT
Quarterly or every 50,000 km, and
on every brake lining change, and
before commissioning after not being used for a long period of time
» Grease the grease nipple (Item no. 704290061) until fresh
grease emerges from the rear bearing point
! Attention
No grease may emerge from the camshaft head.
» perform a visual inspection
Note
» Check that the cover plate is tightly fitted
1.3 MAINTENANCE INTERVAL: EVERY 100,000 KM
1.3.1 CHECKING THE ANCHOR BRACKET
Every six months or every 100,000 km
» Check for tight fit, if necessary, replace the bolts ( 2.6.h, page 39)
1.3.2 CHECKING FIXING OF THE AUTOMATIC SLACK ADJUSTER
Every six months or every 100,000 km
» Test torque with M12: 100 Nm
» Tightening torque with M12: 130 Nm
GEOKH2 10010 4218 | MAINTENANCE
gigant - Trenkamp & Gehle GmbH
MAINTENANCE | GEOKH2 10010 4218
gigant - Trenkamp & Gehle GmbH
DE DE
1 1
2 2
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1
2
EN
1
2
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EN | 13
EN | 13
12 | EN
12 | EN
NL
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NL
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1.4 MAINTENANCE INTERVAL: ANNUALLY
1.4.1 LUBRICATING THE AUTOMATIC SLACK ADJUSTER
Annually or on every brake lining change and
before commissioning after not being used for a long period of
time
» Grease the grease nipple (Item no. 704290061) until fresh
grease emerges from the bearing point
1.5 MAINTENANCE INTERVAL: EVERY 200,000 KM
1.5.1 CHECKING THE BRAKE SHOE BEARINGS
Every 2 years, or every 200,000 km, or
on every brake lining change
» Clean the components of the brake shoe bearing, check for
wear and replace if necessary
» Apply all bearing points with copper paste
1.6 RECOMMENDATIONS FOR INSPECTING THE COMPACT BEARING
Attention
If the brake system is defective, e.g overheated brakes,
» check the compact bearing, replace if necessary
After expiry of the extended warranty on the compact bearing, the
bearing clearance and a noise test should be performed as part of the
annual inspection.
1.6.1 NOISE TEST
!
» Lift the wheel and turn in both directions
» If it runs roughly and there is a "grinding" noise
» replace the compact bearing
Note
A ticking or clicking noise is normal, as the bearing is not loaded
with the wheel lifted and therefore the rollers are not aligned.
1.6.2 INCREASED GREASE LEAKAGE
» Remove the hub cap ( 2.2.1, page 24)
» If the inside of the hub cap, the axle nuts, axle tube and seal
are wet with grease » replace the compact bearing
Note
A small amount of grease may be present on the edge of the seal.
GEOKH2 10010 4218 | MAINTENANCE
gigant - Trenkamp & Gehle GmbH
MAINTENANCE | GEOKH2 10010 4218
gigant - Trenkamp & Gehle GmbH
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2 2
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14 | EN
14 | EN
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1.6.3 CHECK BEARING CLEARANCE
» Remove the hub cap and lift the wheel
» Fasten a magnetic foot to the rim between the wheel bolts
» The measuring probe touches the spindle
» Press the wheel while swivelling it until there is no deviation of
the measuring pointer
» Set the dial gauge to zero
» Then pull the wheel and swivel it
» Difference between the two measurements » axial play
» Result: > 0.2 mm (200 µm) » replace the compact bearing
GEOKH2 10010 4218 | NOTES
gigant - Trenkamp & Gehle GmbH
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1
2
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1
2
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EN | 17
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MAINTENANCE | GEOKH2 10010 4218
gigant - Trenkamp & Gehle GmbH
DE
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1. AFTER THE FIRST 1,000 KM OR AFTER THE FIRST LOADED DRIVE
CHECK THE CLEARANCE OF THE AUTOMATIC SLACK ADJUSTER KILOMETER REPAIR ORDER NO NAME SIGNATURE/STAMP DATE
CHEC
K BR
AKE
DRUM
S
CHEC
K TH
E BR
AKE
LINI
NGS
LUBR
ICAT
E TH
E
BRAK
E CA
MSH
AFT
CHEC
KING
THE
ANCH
OR B
RACK
ET
CHEC
KING
THE
AUTO
MAT
IC S
LACK
AD
JUST
E ATT
ACHM
ENT
LUBR
ICAT
ING
THE
AUTO
MAT
IC S
LACK
AD
JUST
ER
CHEC
KING
THE
BR
AKE
SHOE
BE
ARIN
GS
KILOMETER REPAIR ORDER NO NAME SIGNATURE/STAMP DATE
1st Y
EAR
2. 50,000 KM OR QUARTERLY
3. 100,000 KM OR EVERY SIX MONTHS
4. 150,000 KM OR QUARTERLY
5. ANNUALLY OR ON EVERY BRAKE LININGS CHANGE
6. 200,000 KM OR EVERY TWO YEARS, ORON EVERY BRAKE LINING CHANGE
2nd
YEAR
7. 250,000 KM OR QUARTERLY
8. 300,000 KM OR EVERY SIX MONTHS
9. 350,000 KM OR QUARTERLY
10. ANNUALLY OR ON EVERY BRAKE LININGS CHANGE
11. 400,000 KM OR EVERY TWO YEARS, ORON EVERY BRAKE LINING CHANGE
3rd
YEAR
12. 450,000 KM OR QUARTERLY
13. 500,000 KM OR EVERY SIX MONTHS
14. 550,000 KM OR QUARTERLY
15. ANNUALLY OR ON EVERY BRAKE LININGS CHANGE
16. 600,000 KM OR EVERY TWO YEARS, ORON EVERY BRAKE LINING CHANGE
4th
YEAR
17. 650,000 KM OR QUARTERLY
18. 700,000 KM OR EVERY SIX MONTHS
19. 750,000 KM OR QUARTERLY
20. ANNUALLY OR ON EVERY BRAKE LININGS CHANGE
21. 800,000 KM OR EVERY TWO YEARS, ORON EVERY BRAKE LINING CHANGE
5th
YEAR
22. 850,000 KM OR QUARTERLY
23. 900,000 KM OR EVERY SIX MONTHS
24. 950,000 KM OR QUARTERLY
25. ANNUALLY OR ON EVERY BRAKE LININGS CHANGE
26. 1.000,000 KM OR EVERY TWO YEARS, ORON EVERY BRAKE LINING CHANGE
6th
YEAR
27. 1.050,000 KM OR QUARTERLY
28. 1.100,000 KM OR EVERY SIX MONTHS
29. 1.150,000 KM OR QUARTERLY
30. ANNUALLY OR ON EVERY BRAKE LININGS CHANGE
31. 1.200,000 KM OR EVERY TWO YEARS, ORON EVERY BRAKE LINING CHANGE
GEOKH2 10010 4218 | MAINTENANCE
gigant - Trenkamp & Gehle GmbH
MAINTENANCE | GEOKH2 10010 4218
gigant - Trenkamp & Gehle GmbH
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1 1
2 2
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1
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2.1 BRAKE DRUM
2.1.1 REMOVING THE BRAKE DRUM
a l Loosen the wheel nuts
IMPORTANT
Raise the axle according to the vehicle manufacturer's specifications and secure with
catch hooks!
The wheel must rotate freely to perform the subsequent work steps!
b l Removing the wheel
c l Automatic slack adjuster
» Remove the bolt
Note
» Mark the position of the bolt on the automatic automatic
slack adjuster!
d l Release the wheel brake
» Release the wheel brake on the automatic automatic slack
adjuster to release the brake
C Box nut: SW 12 mm
2. REPAIR e l Brake drum
2.1.2 FITTING THE BRAKE DRUM
a l Brake drum
» Push on the brake drum to the stop
» Mount the wheel
» Secure with wheel nuts
IMPORTANT
Let down the axle in accordance with the vehicle manufacturer's operating instructions!
b l Wheel
» Tighten up the wheel nuts to the specification: 600 Nm
C Socket wrench: SW 32 mm
» Pull off the brake drum and check it ( 1.2.1, page 11),
replace if necessary
GEOKH2 10010 4218 | REPAIR
gigant - Trenkamp & Gehle GmbH
REPAIR | GEOKH2 10010 4218
gigant - Trenkamp & Gehle GmbH
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2 2
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1
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EN
1
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aa
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EN | 21
EN | 21
20 | EN
20 | EN
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8
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10
7
10 x
2.1.3 ADJUSTING THE BRAKE
IMPORTANT
Check the brake linkage position in accordance with the vehicle manufacturer's operating
instructions!
a l Automatic slack adjuster
» Move by turning the setting screw backwards until the hole
on the lever arm fits to the clevis
C Socket wrench: SW 17 mm
Attention
Observe the markings for the bolts on the AGS!
b l Clevis
» Grease the bolt (Item no. 704290061)
» Connect the clevis and the lever arm
» Secure the bolt with a cotter pin
IMPORTANT
Attach the return spring in accordance with the vehicle manufacturer's operating
instructions!
c l Return spring
Note
» Ensure that the anchor bracket and the control arm are
correctly positioned! ( 2.5.2c, page 35)
d l Air gap
» Turn the setting screw on the Automatic slack adjuster
clockwise until the brake lining lies on the brake drum
» Turn the setting screw on the Automatic slack adjuster
about ¾ turn back
C Socket wrench: SW 12 mm
Note
» With proper functioning of the adjustment coupling, a torque of
at least 18 Nm should be felt when turning back
» A creaking sound is audible
e l Brake
» Check the brake
GEOKH2 10010 4218 | REPAIR
gigant - Trenkamp & Gehle GmbH
REPAIR | GEOKH2 10010 4218
gigant - Trenkamp & Gehle GmbH
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2 2
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EN | 23
22 | EN
22 | EN
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2.2 HUB UNIT
a l Hub cap
» Remove the hub cap
» Dispose of the O-ring
C Socket wrench: SW 170 mm (Item no. 710500963)
2.2.1 REMOVING THE HUB UNIT
REMOVE THE BRAKE DRUM S. 2.1.1, PAGE 20
Attention
» Pay attention to right-hand and left-hand thread!
» The axle nut with a left-hand thread is marked with a
circumferential groove!
!
b l Axle nut
» Loosen the securing screw
C Socket wrench: SW 10 mm
» Bend the clamping open
» Loosen the axle nut
C Socket wrench: SW 95 mm (Item no. 710500968)
c l Mandrel
» Screw on the mandrel (Item no. 709297006)
!
d l Hub unit
» Pull off the hub unit using the mandrel,
if necessary use a hub puller
Attention
Do not tilt the hub unit! !
Attention
Pay attention to right-hand and left-hand thread!
GEOKH2 10010 4218 | REPAIR
gigant - Trenkamp & Gehle GmbH
REPAIR | GEOKH2 10010 4218
gigant - Trenkamp & Gehle GmbH
DE DE
1 1
2 2
EN
1
2
EN
1
2
a a
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EN | 25
EN | 25
24 | EN
24 | EN
NL
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2.2.2 FITTING THE HUB UNIT
a l Thread
» Remove the mandrel
» Check the axle nut and the stub axle
b l Stub axle
» Clean the stub axle back to bare metal
» Lightly and evenly grease the bearing seat with Molykote TP42
(Item no. 704290082)
Note
Do not lubricate at the axle stub the thread, area between the
bearing seats and the axial contact surface of the bearing.
c l Mandrel
» Fit the mandrel (Item no. 709297006)
Attention
Pay attention to right-hand and left-hand thread! !
Attention
Pay attention to right-hand and left-hand thread! !
d l ABS sensor
» Push the ABS sensor forwards to the stop
» Clean the front side of the ABS sensor
e l Hub unit
» Push the hub unit up to the stop
» Remove the mandrel
Attention
Do not tilt the hub unit! !
f l Mandrel
Attention
Pay attention to right-hand and left-hand thread! !
GEOKH2 10010 4218 | REPAIR
gigant - Trenkamp & Gehle GmbH
REPAIR | GEOKH2 10010 4218
gigant - Trenkamp & Gehle GmbH
DE DE
1 1
2 2
EN
1
2
EN
1
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EN | 27
26 | EN
26 | EN
NL
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NL
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g l Axle nut
» Lightly grease the bearing contact surface of the axle nut
» Tighten while turning the wheel hub to 870 Nm
C Socket wrench: SW 95 mm (Item no. 710500968)
Attention
» Pay attention to right-hand and left-hand thread!
» The axle nut with a left-hand thread is marked with a
circumferential groove!
!
» Screw in the securing bolt: 15 Nm
h l Hub cap
Attention
Check correct position of O-Ring!! i l ABS sensor
» Check the contact between the ABS sensor and the ABS
sensor ring!
FIT THE BRAKE DRUM 2.1.2, PAGE 21
» Lightly grease the O-ring (Item no. 702500179) and
place on the hub unit
» Put on the hub cap and tighen it up: 750 Nm
C Socket wrench: SW 170 mm (Item no. 710500963)
2.2.3 ABS SENSOR RING
REMOVE THE BRAKE DRUM 2.1.1, PAGE 20
REMOVE THE HUB UNIT 2.2.1, PAGE 24
a l Removing the ABS sensor ring
» Remove the ABS sensor ring from the hub and dispose of it!
b l Fitting the ABS sensor ring
» Push the ABS sensor ring evenly and
parallel up to the stop
C Tools: Washer: Ø 220 mm and 15 mm thick
Note
Max. permitted deviation from parallel: ≤0.2 mm
FIT THE HUB UNIT 2.2.2, PAGE 26
FIT THE BRAKE DRUM 2.1.2, PAGE 21
GEOKH2 10010 4218 | REPAIR
gigant - Trenkamp & Gehle GmbH
REPAIR | GEOKH2 10010 4218
gigant - Trenkamp & Gehle GmbH
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1 1
2 2
EN
1
2
EN
1
2
a a
aa
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EN | 29
EN | 29
28 | EN
28 | EN
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2.4 BRAKE SHOE
REMOVE THE BRAKE DRUM 2.1.1, PAGE 20
REMOVE THE HUB UNIT 2.2.1, PAGE 24
2.4.1 REMOVING THE BRAKE SHOES
a l Fixed point spring
» Remove the fixed point spring
b l Brake shoe
» Lift up the brake shoe assembly and remove over the brake
camshaft
Attention
Mark the top and bottom brake shoe! !
Caution: Danger of crushing!
c l Return spring
» Remove the return spring and dispose of it
d l Fixed point springs
» Clean the fixed point springs and check for wear
if necessary, remove and replace (Item no. 709215011)
» Grease with copper paste
e l Brake linings
» Check the brake linings, replace if necessary
» Check the brake shoes, replace if necessary
When using the old brake shoes
» De-rivet the old brake linings and dispose of them
» Clean the brake shoes, remove rust and uneven surfaces
from the contact surface, if necessary, apply rust protection
» Rivet on the brake lining, riveting force = 1800-2300 DaN
Note!
» If the brake drums have distorted, use brake linings
of an appropriate oversize
» Gap between lining and the brake shoe < 0.15 mm
» For an optimal load pattern, over tighten the brake linings
(see table page 11)
GEOKH2 10010 4218 | REPAIR
gigant - Trenkamp & Gehle GmbH
REPAIR | GEOKH2 10010 4218
gigant - Trenkamp & Gehle GmbH
DE DE
1 1
2 2
EN
1
2
EN
1
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EN | 31
EN | 31
30 | EN
30 | EN
NL
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13 9
57
84
2 6 10
2.4.2 FITTING THE BRAKE SHOES
a l Return spring
» Attach a new return spring (Item no. 703011144)
b l Brake shoe group
» Put on the brake shoe group
Attention
Observe the top and bottom marking! !
c l Fixed point spring
» Fit the fixed point spring (Item no. 709361008)
FIT THE HUB UNIT 2.2.2, PAGE 26
FIT THE BRAKE DRUM 2.1.2, PAGE 21
Caution: Danger of crushing!
Note
Do not damage the sensor ring!
2.5 BRAKE CAMSHAFT
REMOVE THE BRAKE DRUM 2.1.1, PAGE 20
REMOVE THE HUB UNIT 2.2.1, PAGE 24
REMOVE THE BRAKE SHOES 2.4.1, PAGE 30
2.5.1 REMOVING THE BRAKE CAMSHAFT
a l Hexagon socket screw
b l Camshaft bushing
» Check the bushing for wear, < 0.8 mm bearing play/
bushing wear on the lubricating groove depth » replace if
necessary ( 2.5.3, page 36)
» Loosen the hexagon socket screw by three turns
» Loosen the eccentric nut by hitting the head of hexagon
socket screw with a hammer
» Completely loosen the hexagon socket screw
C Allen key: S 10 mm
» Pull out the brake camshaft
» Secure automatic slack adjuster against removal!
GEOKH2 10010 4218 | REPAIR
gigant - Trenkamp & Gehle GmbH
REPAIR | GEOKH2 10010 4218
gigant - Trenkamp & Gehle GmbH
DE DE
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2 2
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1
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EN
1
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EN | 33
32 | EN
32 | EN
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2.5.2 FITTING THE BRAKE CAMSHAFT
a l Brake camshaft kit
» Spare parts kit
» Left-hand side (Item no. 703011303)
» Right-hand side (Item no. 703011304)
» Slide on the washer (outer diameter 51 mm), plastic
bushing and O-ring seal
» Slide the securing washer with the smaller opening at the
front over the eccentric nut until it locks into the groove
» Insert the hexagon socket screw and the eccentric nut and
pre-tighten » the pre-assembled unit should have about
1 mm of play
» Grease (Item no. 704290061) the plastic plugs and
press on
» Grease (Item no. 704290061) the brake camshaft
» Grease (Item no. 704290061) the bushing
b l Brake camshaft
» Secure the washer (outer diameter 65 mm) with a little
grease at the rear on the bearing seat
» Insert the brake camshaft until the shaft profile is visible
c l AGS
» Place AGS on the shaft profile and attach AGS to the anchor
bracket
» Push brake camshaft till plastic bushing and O-ring seal
are just to see
» Swivel and pull AGS (in correct position: anchor bracket) to
the brake shield and push brake camshaft all the way
Note
By swivelling the plastic bushing is centring. Maybe insert
complete with light hits of a plastic hammer.
Attention
If the AGS could not pull all the way to the brake shield, check
if the with grease locked outer diameter 65 mm washer is
jumped over all steps of the shaft profile.
!
GEOKH2 10010 4218 | REPAIR
gigant - Trenkamp & Gehle GmbH
REPAIR | GEOKH2 10010 4218
gigant - Trenkamp & Gehle GmbH
DE DE
1 1
2 2
EN
1
2
EN
1
2
a a
aa
zz
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EN | 35
EN | 35
34 | EN
34 | EN
NL
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2.5.3 REPLACING THE BRAKE CAMSHAFT BUSHING
» Using a assembly/disassembly tool (driving pin), push the
bushing forwards from its seat and dispose of it
C Driving pin and socket: S 24 mm
» Push a new bushing onto the driving pin
Note
Observe the position of the ring groove!
» Using a mounting tool and a plastic hammer, drive on the
bushing to the stop
Inspection
The bushing must be flush at the rear!
2.6 ABS SENSOR
REMOVE THE BRAKE DRUM 2.1.1, PAGE 20
REMOVE THE HUB UNIT 2.2.1, PAGE 24
REMOVE THE BRAKE SHOES 2.4.1, PAGE 30
REMOVE THE BRAKE CAMSHAFT 2.4.1, PAGE 33
a l Anchor bracket
Attention
Mark the fixed point position on the cover plate!
» Loosen the bolt and dispose of it
» Dispose of the anchor bracket
C Socket wrench: SW 17 mm
b l ABS sensor cable
» Remove the sensor cable at two positions
» Pull away the cable with the contact plug towards the rear
c l ABS sensor
Note
Push the cover plate rearwards to remove the ABS sensor!
» Using a drift punch, remove the ABS sensor and the
bushing and dispose of them
!
d l Brake camshaft and automatic slack adjuster
» Grease (Item no. 704290061) the brake camshaft and the
automatic slack adjuster until fresh grease emerges
» Tightening up the hexagon socket screw: 130 Nm
C Allen key: S 10 mm
FIT THE BRAKE SHOES 2.4.2, PAGE 32
FIT THE HUB UNIT 2.2.2, PAGE 26
FIT THE BRAKE DRUM 2.1.2, PAGE 21
Note
A little axial play is necessary
GEOKH2 10010 4218 | REPAIR
gigant - Trenkamp & Gehle GmbH
REPAIR | GEOKH2 10010 4218
gigant - Trenkamp & Gehle GmbH
DE DE
1 1
2 2
EN
1
2
EN
1
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aa
zz
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EN | 37
EN | 37
36 | EN
36 | EN
NL
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NL
1
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0.5 - 2 mm
e l ABS sensor
» Lift up the dust cover and thread in the ABS sensor cable
Attention
Do not damage the sensor cable throughout the entire process!
f l ABS sensor
» Push the dust cover towards the rear
» Grease the ABS sensor (Item no. 704290061) and comple-
tely insert it into the sensor bracket
» Clean the front side of the ABS sensor thoroughly
g l Grommet
» Pull the grommet over the sensor cable
» Position it in the cover plate
!
d l Socket
» Completely pusch on a new bushing (Item no. 708505035)
and grease (Item no. 704290061)
h l Anchor bracket
» Put on the anchor bracket
Attention
Observe the marking on the cover plate!
» Tighten up the micro-encapsulated screw (Item no.
701310021): 25 Nm
C Socket wrench: SW 17 mm
FIT THE BRAKE CAMSHAFT 2.5.2, PAGE 34
FIT THE BRAKE SHOES 2.4.2, PAGE 32
FIT THE HUB UNIT 2.2.2, PAGE 26
FIT THE BRAKE DRUM 2.1.2, PAGE 21
!
GEOKH2 10010 4218 | REPAIR
gigant - Trenkamp & Gehle GmbH
REPAIR | GEOKH2 10010 4218
gigant - Trenkamp & Gehle GmbH
DE DE
1 1
2 2
EN
1
2
EN
1
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EN | 39
EN | 39
38 | EN
38 | EN
NL
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The warranty is only valid if the first final user has had the hand-over of his vehicle in proper condition confirmed on the warranty card in the owner
protection plan booklet by his seller within one month of the hand-over of the vehicle! The copy of the warranty card must be enclosed with any
warranty application!
The manufacturer (hereinafter called gigant) grants the users of gigant axle systems and compact bearing axles in the GK series manufactured and
deliv-ery by them since 01.01.2007 a warranty according to the following conditions:
1. Scope of warranty
As warranty, we grant a warranty on parts from product deficiencies which are demonstrable as within the warranty period and are due to a material
or production defect. The warranty exists in addition to the seller’s legal warranty obligation aris-ing from the contract of sale with the first final user
and does not affect this.
The warranty is restricted to vehicles regis-tered and operated in Europe or in Turkey. The warranty lapses on sale of a vehicle to a country outside
this area.
The warranty covers the costs for the replacement of defective components. This warranty does not include the labour and workshop costs for the
disassembly and assembly and testing of components. This warranty only applies to damage to the gigant products themselves. Con-sequential
damage caused by a defect, in particular towing costs, rental costs for substitute vehicles, claims for loss of profits or claims for damages are
excluded from this warranty. Any more extensive liability based on compulsory legal provi-sions remains unaffected by this.
2. Exclusions from liability
The warranty excludes damage to wearing parts (e.g. brake linings, brake drums, brake disks) and damage caused by:
» incorrect installation of gigant axle systems,
» no brake compatibility check,
» mechanical damage due to accidents, dropping, impacts,
» negligent or wilful destruction as well as fire,
» misuse of the vehicle (for example: overloading, overheating, use under abnormal conditions),
» lack of maintenance, in particular failure to have regular maintenance work performed as described in the gigant maintenance manual (See
current information on www.gigant-group.com),
» conversion of parts or modifications to the gigant axle systems or,
» the use of parts of other origin instead of original gigant parts and the use of unsuitable lubricants and liquids.
The warranty also excludes phenomenon such as noises, odours, vibration or oil leaks which do not impact the perfor-mance capability of the gigant
axle sys-tems. If the deficiency is revealed within 6 months of first delivery of the vehicle to the final user, then it is assumed refutably that this is a
material or production defect.
3. Warranty duration
The warranty commences with the hand-over of the vehicle to the first final user as certified on the warranty card. The war-ranty duration is shown in
the Table below for the respective gigant axle system; whereby the duration is restricted to the mileage limit stated if the vehicle reaches this prior to
the duration stated.
The warranty duration depends on whetherthe vehicle is used on-road or off-road.
The classification of a gigant axle system in the On-Road operation or Off-Road operation categories is decisive for the use of the vehicle. If the
vehicle is only operated on roads that have a fixed surface, this is On-Road operation. If the vehicle is also occasionally operated beyond this on
construction sites, in quarries, for agricultural purposes, for military purposes or on roads with gravel surfaces, then this is Off-Road operation.
Z WARRANTYOn-Road
6 years, max. 1,000,000 km Components: Axle body generation K2
5 years, max. 1,000,000 km Components: Axle body
24 months, without km limitation Components: Camshaft, automatic slack adjuster, ABS sensor and sensor ring, brake shoes
24 months, with exclusion of
wear as a cause for complaint Components: Brake drum, brake linings, bearing and seals, springs
Differing from this:
6 years, max. 600,000 km Components: Wheel hub units
Off-Road
1 year, max. 100,000 km
The displays from ABS, EBS and similar measurement systems are decisive for the determination of the exact mileage if complete registration of the
entire mileage is possible using these displays. Stating incorrect mileages or manipulating the measuring units causes this warranty to lapse.
The warranty is not extended by any claims on it. The warranty period for any parts replaced during warranty service is 6 months; however the current
warranty period as a minimum.
4. Enforcement of warranty claims
Warranty claims are enforced by sending a gigant warranty service application to gigant. The gigant warranty application must include the informa-
tion required. The gigant warranty application must include:
» The complete filled warranty card* as copy
» The maintenance documents* as copy
» In complaints of the wheel hub unit the digital EBS/ODR data records
» In complaints of brake components the report of the brake compatibility check and the digital EBS/ODR data records
Any warranty claim must be enforced immediately to gigant, at the latest two weeks after discovery of the defect. The defective components disas-
sembled are to be kept and may only be disposed of with the express consent of gigant .
Any costs arising due to unjustified war-ranty claims may be charged by gigant.
* gigant reserves the right to demand the original documents!
GEOKH2 10010 4218 | WARRANTY
gigant - Trenkamp & Gehle GmbH
WARRANTY | GEOKH2 10010 4218
gigant - Trenkamp & Gehle GmbH
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WARRANTY CARD
Ident No: 711110018 / YA15450305 GEOKH2 10010 4218 250 000 242 ABS AGS RE
ID1- 20-225-24 stat.axle loadID2- 4218P 10.000 kgID3- 10006,2 v maxID4- 36101507 105 km/h
gigant - Trenkamp & Gehle GmbHD-49413 Dinklage
DATE OF INITIAL REGISTRATION
CHASSIS NUMBER
SIGNATURE OF THE VEHICLE MANUFACTURERDATE STAMP OF THE VEHICLE MANUFACTURER
AXLE 1, LHS
AXLE 2, LHS
AXLE 3, LHS
ENTER ITEM NUMBER
AXLE 1, LHS
AXLE 2, LHS
AXLE 3, LHS
ENTER SERIAL NUMBER
The work and designs were carried out in accordance with the valid gigant regulations.
(See current information at www.gigant-group.com.)
Operating instructions and maintenance instructions for the work/changes performed or the installed
unit have been left in the vehicle.
AXLE 1, RHS
AXLE 2, RHS
AXLE 3, RHS
AXLE 1, RHS
AXLE 2, RHS
AXLE 3, RHS
The seller hereby certifies that the vehicle was handed over to the
first end user .
With their signatures, the seller and the first end user confirm that the vehicle has been procured for use
ON-ROAD (only on a road with a solid road surface)
or,
OFF-ROAD (operation on construction sites, in quarries, in agriculture, for military purposes, or
on gravel roads) and will be used there.
With their signatures, the seller and the first end user confirm that the vehicle is in a fault-free condition on
handover.
The first end user also confirms with his/her signature that they have taken note of the gigant warranty conditions.
COMPANY NAME
COMPANY NAME
SIGNATURE OF THE VEHICLE MANUFACTURERDATE STAMP OF THE VEHICLE MANUFACTURER
SIGNATURE OF THE FIRST END USERDATE STAMP OF THE FIRST END USER
ENTER ALL THE INFORMATION AND TICK AS APPROPRIATE!
GEOKH2 10010 4218 | WARRANTY
gigant - Trenkamp & Gehle GmbH
WARRANTY | GEOKH2 10010 4218
gigant - Trenkamp & Gehle GmbH
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2 2
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EN | 43
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42 | EN
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trailer axles
gigant – Trenkamp & Gehle GmbHMärschendorfer Str. 4249413 Dinklage | GermanyTel: +49 (0) 44 43 | 96 20-0E-Mail: contact@gigant-group.comwww.gigant-group.com
trailer axlesAu
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Service booklet| Stub axle
GEOKH2 10010 4218
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