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SAF-HOLLAND SK RB 9022 W INTEGRAL Repair Manual

With wabco disc brake type pan 22-1
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Maintenance and
Repair Manual
SK RB/RLB 9022 W INTEGRAL
with WABCO Disc Brake type PAN 22-1
Edition 11 /2009

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Summary of Contents for SAF-HOLLAND SK RB 9022 W INTEGRAL

  • Page 1 Maintenance and Repair Manual SK RB/RLB 9022 W INTEGRAL with WABCO Disc Brake type PAN 22-1 Edition 11 /2009...

  • Page 2: Vehicle And Axle Identification

    Vehicle and axle identification Trailer Manufacturer................................Body type..................................Chassis no..................................Year of manufacturer/Trailer date in Service........................For the warranty procedure quote correct Axle Identification- and Serial-No. Type plate for axle identification Identification of axles in case of type plate absence Serial No.

  • Page 3: Table Of Contents

    Contents Page Vehicle and axle identification General safety instruction Service instructions Service schedule / Service chart 6 - 9 Spare parts / List of spare parts 10 - 11 Installation instructions SK RB / RLB W INTEGRAL Replace Brake Pads 12 - 14 Replace Hub Unit SK RB INTEGRAL 15 - 20...

  • Page 4: General Safety Instruction

    The SAF-HOLLAND definition of OFF-ROAD means driving on non-asphalted / non-concreted routes, such as e.g. gravel roads, agricultural and forestry tracks, on construction sites and in gravel pits. Off-road operation of SAF-HOLLAND axles and suspension systems not designed for the purpose may result in damage and hence to an impairment of road safety.

  • Page 5: Service Instructions

    Service instructions Safety instructions for repair work The perfect technical condition of the brake disc is of crucial importance for good driving and safe braking properties. Observe the wear limits of the brake pads and brake disc! Worn brake pads and/or brake discs can lead to a deterioration in the braking efficiency or even a complete brake failure! Danger of accidents! Burnt, glazed or oily brake pads must be replaced immediately! Brake pad replacement must always be performed for all the wheels on an axle!

  • Page 6: Service Schedule / Service Chart

    If the sealmark on the hub nut is broken before the end of the 1,000,000 km this will invalidate all warranty coverage unless the repair works have been carried out in an SAF-HOLLAND-authorised workshop. SK RB/RLB 9022WI with WABCO PAN 22-1 11.427GB Edition 11/09...
  • Page 7 37.0 11.0 Brake pads, always fitt only brake pads material grade approved by SAF-HOLLAND. Under normal wear and replacement conditions always renew the brake pads kit on both sides of the axle. Difference in brake pad wear max. 5.0 mm (inboard / outboard pad) Tightening torques (Nm) Tighten the bolts using a torque wrench.

  • Page 8: Gb Edition 11/09

    Service schedule Error flow chart procedure 1) Difference between wear of inboard and outboard pad, and diagonal wear see diagram. SK RB/RLB 9022WI with WABCO PAN 22-1 11.427GB Edition 11/09 -8 -...
  • Page 9 Service schedule Check brakes for wear Wear limit Wear on the middle of the lining can be measured with a tape measure or a ruler either at the shoulder bolt (long bolt near the disc run in) or at the play bolt (short bolt near the disc run in).

  • Page 10: Spare Parts / List Of Spare Parts

    Spare parts Torque wrench settings Anziehdrehmomente Die Schraubverbindungen mit Drehmomentschlüssel anziehen. Tighten the assembly bolts with a calibrated torque Radmuttern: wrench. Mittenzentrierung M22x1,5 600 Nm Hinweise der Räderhersteller beachten Wheel nuts: 63.1 63.2 64.2 64.1 Hub-spigot centred fixing M22x1.5 / 600 Nm Refer to wheel manufacturers recommendations! 059 / 060 70.3...
  • Page 11 List of spare parts Item Parts designation Item Parts designation Axle beam assembly Brake calliper assembly, RH including items 62, 64, 65, 66, 070, 080 Axle nut, RH, W.A.F. 85 22.1 Axle nut, LH, W.A.F. 85 61/62 Brake calliper carrier, not available INTEGRAL wheel hub Pad retaining clamp incl.

  • Page 12: Replace Brake Pads

    Installation instructions Replace Brake Pads Fill the air system to cut-off pressure and release the parking brake. Disconnect the plug from the wear indicator and pull the ABS sensor out of the sensor holder, if installed. Loosen and remove the retaining screw of the pad retainer bracket. Pull the pad retainer bracket out of the brake calliper.
  • Page 13 Installation instructions Check brake calliper for proper function and serviceability of the parts by – Checking the axial shiftability and sliding function – Checking the admissible wear clearance of the guide pins – Checking the automatic adjustment function – Checking the air bag protection caps and seals If necessary, replace defective parts or brake callipers (see section 4.0).
  • Page 14 Installation instructions 1.17 Insert the retaining screw of the brake pad retainer bracket and tighten to the prescribed torque. Torque wrench settings see page 7 Adjust clearance 1.18 Fill the air system to cut-off pressure and release the parking brake. 1.19 Lever out the plug of the adjuster using a screwdriver.

  • Page 15: Replace Hub Unit Sk Rb Integral

    Installation instructions Replace Hub Unit SK RB INTEGRAL Loosen and remove the mounting nuts for the brake cylinder. Remove the brake cylinder from the brake calliper and place to one side. Loosen and remove the retaining screws for the brake calliper. Remove the brake calliper from the brake carrier and place to one side.
  • Page 16 Installation instructions Axle nut wrench W.A.F. 85 (Part No. 4 434 3828 00) Pull the complete hub unit SK RB INTEGRAL with brake disc off the stub axle and place to one side. If necessary, use a puller to pull the hub unit SK RB INTEGRAL off the stub axle.
  • Page 17 Installation instructions 2.10 Prepare the replacement hub unit SK RB INTEGRAL. 2.11 Insert a new O-ring (39.1) into the O-ring groove of the hub unit. Pos. 39.1 2.12 Push the hub unit SK RB INTEGRAL onto the stub axle. 2.13 Screw on the axle nut.
  • Page 18 Installation instructions 2.14 Tighten the axle nut to the prescribed torque, at the same time turning the hub unit through one revolution. Torque wrench settings see page 7 Notes: On LH side as seen in direction of travel – LH thread Axle nut wrench W.A.F.
  • Page 19 Installation instructions 2.17 Tighten retaining screws (Pos. 56 and 56.1) to the prescribed torque. Pos. 56.1 Caution! Use only new hex. head bolts / fitting pins! (Pos. 56 and 56.1) The bolts must not be oiled or greased! Torque wrench settings see page 7 Pos.
  • Page 20 Installation instructions 2.21 Bolt the brake cylinder to the brake calliper, tightening the lock nuts uniformly and alternately in two steps using the prescribed method. Torque wrench settings see page 7 2.22 Adjust the clearance, see chapter 1 2.23 Install the plug for the adjuster again correctly. Caution! If the plug is lost, water can enter the system and cause corrosion to the adjuster.

  • Page 21: Replace The Brake Disc On The Hub Unit Sk Rb Integral

    Installation instructions Replace the Brake Disc on the Hub Unit SK RB INTEGRAL Remove and install brake pads from brake calliper. See installation instructions, chapter 1 Remove and install brake cylinder from brake calliper. See installation instructions, chapter 2 Remove and install brake calliper from brake carrier. Remove and install wheel cap.
  • Page 22 Installation instructions 3.10 Place the new brake disc on the hub unit SK RB INTEGRAL and align. 3.11 Screw in new DSK bolts to secure the brake disc and tighten using the prescribed tightening method. Anzugsverfahren siehe Tabelle Seite 7 Caution! Use only new DSK bolts!! DSK bolts must not be oiled or greased!

  • Page 23: Installation Instructions Pan

    Installation instructions – PAN 22-1 4. Mechanical Sliding Calliper Disc Brake Type PAN 22-1 Installation and Service Instructions SK RB/RLB 9022WI with WABCO PAN 22-1 11.427GB Edition 11/09 -23 -...

  • Page 24: Mechanical Sliding Calliper Disc Brake, Type Pan 19-1 (Wabco Instructions)

    Installation instructions – PAN 22-1 Dismantling and Assembling WABCO Brake Callipers Installation and Service Instructions PAN 22-1 4. 1 Description of the Mechanical Sliding Calliper Disc Brake 4. 1.1 Introduction The brake “PAN 22-1 ” is a newly developed pneumatic single-cylinder brake designed for use on the front and rear axles of commercial vehicles and trailers with 19.5”...
  • Page 25 Installation instructions – PAN 22-1 Arrow, direction of rotation for forward travel Figure 2 Top view Figure 3 Side view SK RB/RLB 9022WI with WABCO PAN 22-1 11.427GB Edition 11/09 -25 -...
  • Page 26 Installation instructions – PAN 22-1 These instructions together with the following figures describe the steps and work processes necessary for replacement of the available repair kits. The wrench sizes and tightening torques mentioned in the work processes can be found in the corresponding items of Table 1.
  • Page 27 Installation instructions – PAN 22-1 Check the Brake Caution: Do not use power wrenches! When working on the brakes or when shifting the brake calliper, hold with your hands only on the outside in order to avoid crushing of the fingers between brake calliper and brake carrier! 4.2.1 Check Adjuster General Note: The turning directions and torques at the hexagon of...
  • Page 28 Installation instructions – PAN 22-1 Check Brake Pads Note: Check the brake pad thickness at regular intervals and depending on the vehicle operation, during service intervals and in accordance with the statutory provisions. Burned, glazed or oily brake pads must be replaced immediately.
  • Page 29 Installation instructions – PAN 22-1 Brake Pad Replacement Caution: Do not use power wrenches! When working on the brakes or when shifting the brake calliper, hold with your hands only on the outside in order to avoid crushing of the fingers between brake calliper 63.1 and brake carrier! Disconnect the plug from the wear indicator 64.3 (arrow).
  • Page 30 Installation instructions – PAN 22-1 Push the brake calliper 59, 60 to the rim side by hand and remove brake pad 64.1 on the rim side. Fig. 13 Push the brake calliper to the cylinder side by hand (arrow) and remove brake pad 64.1 and pressure plate 64.5 on the cylinder side.
  • Page 31 Installation instructions – PAN 22-1 Move the brake callipers by hand along the guide pins over their full travel and check for ease of movement. If the brake callipers bind, replace the bushings and protective caps as described in section 4.8. Caution: Do not crush the protective caps of the guide pins against the brake carrier.
  • Page 32 Installation instructions – PAN 22-1 Check brake disc wobble: Attach a dial gauge to the brake carrier. With the brake disc installed, check the brake disc wobble by turning the wheel hub as shown in Fig. 21. Limit value 0.15 mm. Note: If higher values are measured, remachine or replace the brake disc.
  • Page 33 Installation instructions – PAN 22-1 64.4 64.4 Install new cable clips 64.4 in the brake calliper. Install a new preassembled wear indicator 64.3 with cable guide plate on the brake calliper and insert the sensor into the brake pads. Caution: The sensor must be inserted correctly into the brake pad! Fig.
  • Page 34 Installation instructions – PAN 22-1 Push new pad retainer bracket 63.1 into the openings (arrows) of the brake calliper and press down so that the bracket engages between 63.1 the radial shoulders of the spring clips. Note: The pad retainer bracket must be installed above the cables of the wear indicator.
  • Page 35 Installation instructions – PAN 22-1 Replace Brake Caution: Do not use power wrenches! When working on the brakes or when shifting the brake calliper, hold with your hands only on the outside in order to avoid crushing of the fingers between brake calliper and brake carrier! Note: The new brake is preassembled and can be fitted complete over the brake carrier onto the vehicle axle.
  • Page 36 Installation instructions – PAN 22-1 Install brake pads and pressure plate as described in section 4.5. Install brake cylinder on brake calliper as described in section 4.10. Caution: Depending on the installation position of the brake, minimum the lower drainage opening on the brake cylinder (facing downwards) must be open! Fig.
  • Page 37 Installation instructions – PAN 22-1 Loosen socket screws 70.6, 80.1 with Allen key (Table 1, position IV) 70.6 80.1 and remove brake calliper 59, 60 from brake carrier 61, 62. Caution: Risk of crushing from loose brake calliper! Clean the contact surfaces (fitting collar) for the guide pins in the brake carrier 61, 62.
  • Page 38 Installation instructions – PAN 22-1 Installation sequence: Press in two new bushes 70.3 for the long guide pin 70.1. = 52.2 ± 0.2 mm) and First (A) press in the inner bush with a drifter (L = 13.2 ± 0.2 mm) until the then (B) the outer bush with a drifter (L drifter bottoms in each bore.
  • Page 39 Installation instructions – PAN 22-1 Grease the sliding surfaces for the guide pins 70.1, 80.2 and edge 59, 60 bead of protective caps 80. 70.1, 80.2 Push new guide pins into the brake calliper 59, 60 from the cylinder side and protective push caps 80 against the seat of the guide pins 70.1, 80.2.
  • Page 40 Installation instructions – PAN 22-1 Grease the bores in the brake calliper (arrows) for the caps 83. Insert new caps 83 into the bores of the brake calliper and press in completely using a suitable driving tool. Note: Avoid damaging the caps. Fig.
  • Page 41 Installation instructions – PAN 22-1 Check the thread of the adjuster. Note: To do this, place the brake pad into the pad seat on the rim side so that the adjuster cannot be turned out of its trailing position. Remember to remove the brake pad again after the check. Fig.
  • Page 42 Installation instructions – PAN 22-1 Install the brake pads and adjust the clearance, following the steps as described in section 4.5. Observe the notes. 4.10 Replace Brake Cylinder Caution: Do not use power wrenches! When working on the brakes or when shifting the brake calliper, hold with your hands only on the outside in order to avoid crushing of the fingers between brake calliper Fig.
  • Page 43 Installation instructions – PAN 22-1 Table 1 Position Width across Hexagon Tightening torque (Nm) flats (WAF) Outer Inner Direction of rotation at the hexagon: Tighten in anti-clockwise direction (left) max. 3, clearance becomes smaller. Loosen in clockwise direction (right) max. 12, clearance becomes larger.
  • Page 44 Installation instructions – PAN 22-1 Exploded View of the Replacement Parts PAN 22-1 SK RB/RLB 9022WI with WABCO PAN 22-1 11.427GB Edition 11/09 -44 -...
  • Page 45 Installation instructions – PAN 22-1 Item Parts designation Item Parts designation Brake calliper assembly, right Plug Brake calliper assembly, left 65.1 Adjuster Brake carrier, right Protective cap for compression piece Brake carrier, left 70.1 Guide pin 63.1 Pad retaining clamp 70.3 Bushing 63.2...
  • Page 46 We are always there for you Assistance +49 6095 301-247 Service +49 6095 301-602 Switchboard +49 6095 301-0 +49 6095 301-259 service@safholland.de www.safholland.com SAF-HOLLAND GmbH Hauptstraße 26 · D-63856 Bessenbach...

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Sk rbl 9022 w integral

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