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SAF-HOLLAND SK RB 9019 W Maintenance And Repair Manual

Disc brakes with wabco brake calliper
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Maintenance and Repair Manual
for SAF Disc Brakes
SK RB 9019 W
with WABCO brake calliper
SK 1000 ET 120
Edition 01/2006
Service

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Summary of Contents for SAF-HOLLAND SK RB 9019 W

  • Page 1 Maintenance and Repair Manual for SAF Disc Brakes SK RB 9019 W with WABCO brake calliper SK 1000 ET 120 Edition 01/2006 Service...

  • Page 2: Saf Axle Identification

    Vehicle information Manufacturer............................ Address............................. Body type............................Chassis no............................Year of manufacture ........................Registration date..........................Spare parts service for SAF axles and suspension systems When ordering spare parts, quote correct axle identification serial no., refer to the axle type plate.

  • Page 3: Table Of Contents

    Notes A) General safety instructions B) Maintenance instruction Maintenance instructions for SAF axles SK RB 9019 W - SK 1000 ET 120 Maintenance schedule for SAF axles SK RB 9019 W - SK 1000 ET 120 Brake testing (fault-finding procedure)

  • Page 4: Notes

    NOTIZEN / NOTES / NOTE...

  • Page 5: A) General Safety Instructions

    A) General safety instructions Please observe the following safety instructions in order to maintain the operational and road safety of your SAF axles and suspension systems: The wheel contact surfaces between the wheel disc and wheel hub and the wheel nut contact surface at the wheel disc must not be additionally painted.

  • Page 6: B) Maintenance Instruction

    B) Maintenance instructions SK 1000 Disc / ET 120 SK RB 9019 W - SK 1000 ET 120 Periodic checks After first Maintenance intervals 5,000 km every every every Mileage intervals > 150,000 km 30,000 km 75,000 km whichever comes first...

  • Page 7: Sk Rb 9019 W - Sk 1000 Et 120

    B) Maintenance instructions SK 1000 Disc / ET 120 SK RB 9019 W - SK 1000 ET 120 Hub unit Lubricant specifications: Hub unit maintenance-free. Grease for repairs is contained in Inspect for signs of wear at each brake disc change (e.g. escape of every repair kit.

  • Page 8: Brake Testing (Fault-Finding Procedure)

    B) Maintenance instructions Brake testing Fault-finding procedure Disc brake Lift vehicle, turn wheel by hand Does wheel turn freely? Running Residual pressure clearence OK? in brake cylinder? (see page 19) Running Check upline Uneven brake clearence OK? brake devices Check adjuster pad wear? (see page 19) and replace,...

  • Page 9: Adjuster Check

    B) Maintenance instructions Adjuster check Remove cap. Caution! Do not overload or damage the hexagon drive (8 mm) of the adjuster. Do not use an open-ended spanner. Turn the adjuster approx. – spanner turn clockwise using the SAF ratchet wrench. Actuate the brakes 5 times (approx.

  • Page 10: Brake Pad Check

    B) Maintenance instructions Brake pad check Caution! Observe the wear limits of the brake pads. Check the thickness of the brake pads for compliance with the legal requirements at regular intervals, but at least every three months, depending on the operation of the vehicle. A = Minimum residual lining thickness 2 mm B = Total lining thickness of new pads 21 mm When the residual lining thickness is A ≤...

  • Page 11: Special Notes

    B) Maintenance instructions Special notes Storage instructions During storage outdoors, ensure that moisture cannot enter the inside of the brake cal- liper through the brake cylinder connection. Painting instructions During painting work, all rubber parts must be covered as otherwise the rubber will become brittle and thus be damaged.
  • Page 12 C) Spare part illustrations SK 1000 Disc / ET 120 SK RB 9019 W - SK 1000 ET 120 Torque wrench settings Use a torque wrench. Wheel nuts: U-bolts: Shock absorber: The use of impact wrenches Spigot-hub-centred fixing: (diagonally in three stages ) M 24 / 400 Nm is not accepted.

  • Page 13: Sk Rb 9019 W - Sk 1000 Et 120

    C) Spare part designation SK 1000 Disc / ET 120 SK RB 9019 W - SK 1000 ET 120 Item Parts designation Item Parts designation Axle beam assembly 59/60 Brake calliper group including items 61, 65, 66, 70, 80 Axle nut, RH, W.A.F. 85 22.1...

  • Page 14: D) Installation Instructions

    D) Installation instructions Repairing the brakes Remove the brake calliper. Park the vehicle on level, solid ground and chock the wheels to prevent the vehicle from rolling away. Lift the axle using a jack. Loosen the wheel nuts and remove the wheel. Remove the cap.
  • Page 15 D) Installation instructions Check the brake calliper for free and easy movement. Back off the tappets on the adjuster until the boots are visible. Perform a visual inspection of the boots and all seals. Screw in the tappets again completely. Replacing the brake disc Unscrew bolts M 18 x 1.5 from the wheel flange and remove the wheel flange.
  • Page 16 D) Installation instructions Brake disc Brake disc diameter Permissible wear, see table in chapter “Maintenance instructions”. The brake disc may only be cleaned using a dry cleaning agent. Inspecting the brake disc Inspect the braking surface of the brake disc carefully for serviceability. –...
  • Page 17 D) Installation instructions Installing the hub unit Emery the seating surfaces of the hub unit on the stub shaft down to the bare metal and coat with SAF fitting paste (SAF Part No. 4 387 0015 06). Coat the hub unit bearing surfaces with SAF fitting paste and push onto the stub shaft.
  • Page 18 D) Installation instructions Bolting on the brake calliper Position the brake calliper and screw in M 16 x 1.5 x 55 collared bolts (tightening torque 290 Nm). Coat ABS sensor (see arrow) all around with copper paste and install in the sensor holder. Push in the ABS sensor until it contacts the exciter.
  • Page 19 D) Installation instructions Adjustment screw Pressure plate Move the brake calliper so far so that there is enough distance between the brake disc on the actuation side to insert the brake lining. Insert the pressure plate into the brake mounting and push it against the adjustment screw.

  • Page 20: Replacing Pressure Pad And Folding Bellows

    D) Installation instructions Affixing new hex. screw 63.2 with 30±15 using a spanner onto the brake calliper. 63.2 Push the new plug 65 into the opening of the brake calliper! Check the wheel hub for freedom of movement. Note! Check the brakes on a rolling road test station after completion of work.

  • Page 21: Replacing The Folding Bellows Of The Pressure Pad

    D) Installation instructions Replacing the folding bellows of the pressure pad! Dismantle brake linings and pressure plate (see page 14) Move brake calliper by hand towards the cylinder. Pull out the protection cap 66 using a screwdriver from the brake calliper seating.
  • Page 22 D) Installation instructions Clean the seating of the protection cap 66 in the brake calliper (arrow) (illustration without adjustment screw) Push the new protection cap 66 over the adjuster. Centralize the press-in tool over the protection cap 66 and insert the protection cap in its seat in the brake calliper 59.

  • Page 23: Repairing The Brake Calliper Bearing With "Guide And Seal Kit

    D) Installation instructions Repairing the brake calliper bearing with “guide and seal kit” 70.1 80.2 Dismantle the brake calliper 59 from the brake mounting 61 and additionally remove the cap 83 of the guide pin 70.1/80.2 with a screwdriver from the housing 59. Note! Do not damage the holes for the cap in the housing.
  • Page 24 D) Installation instructions Press out the bushes 70.3/80.3 from the brake calliper using a press and mandrel. Clean the holes in the brake calliper. 70.3/ 80.3 70.3/ 80.3 Press in two new bushes 70.3 and for the longer guide pin 70.1: Firstly (A) the inner bush with mandrel (L 1 = 52.2 ±...
  • Page 25 D) Installation instructions Grease the running surfaces for the guide pins 70.1/80.2 and the 70.1/80.2 rim lip of the protection cap 80. Insert the new guide pins from the direction of the cylinder into the brake calliper 59 and push the protection cap 80 against the seating of the guide pins 70.1/80.2.

  • Page 26: Installing The Brake Calliper

    D) Installation instructions Fitting the brake calliper Seat the brakes with brake mounting over the brake disc and fit to the axle. Tightening sequence of the screws: Right hand side clockwise Left hand side anti-clockwise Each time begin the sequence with the shoulder bolt (if applicable). Position of shoulder bolt: In the direction of wheel rotation - the run out side of the outer corner of the flange.

  • Page 27: Overview Of Hub Unit Components

    D) Installation instructions Overview of Hub Unit components Hub Unit Hub Unit Hub cap Axle nut, RH / LH thread Wheel flange Brake disc Brake calliper...

  • Page 28: E) Service Tools

    E) Service tools 1. Axle nut wrench WAF 85 SAF Part No. 2 012 0023 01 2. Wheel hub puller SAF Part No. 4 434 3822 00 3. WABCO tool box SAF Part No. 3 434 6010 00 4. SAF ratchet wrench SAF Part No.

  • Page 29: F) Tightening Torque In Nm

    F) Bolt / Nut torque values The following tightening torques are only valid if no other values are given in the axle maintenance chart. Torque wrenches settings, impact wrench not permissible. Thread Material W.A.F. 10,9 12,9 W.A.F. 13 M 8 x 1 M 10 W.A.F.
  • Page 30 Soforthilfe im Pannenfall NonStopService 24 Support in the case of service · Im Servicefall wählen Sie bitte immer die Rufnummer Ihres Heimatlandes. · In the case of service please always dial the number of your own country. Inland Vom Ausland home country from abroad 03 62 27 23 21...

This manual is also suitable for:

Sk 1000 et 120

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