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SAF-HOLLAND SK RB 9022 H Maintenance And Repair Manual

With haldex brake calliper
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Maintenance and Repair Manual
for SAF Disc Brakes
SK RB 9022 H
with HALDEX brake calliper
SK 1000 ET 120
Edition 01/2006
Service

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Summary of Contents for SAF-HOLLAND SK RB 9022 H

  • Page 1 Maintenance and Repair Manual for SAF Disc Brakes SK RB 9022 H with HALDEX brake calliper SK 1000 ET 120 Edition 01/2006 Service...
  • Page 2 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, correct type designations are essential. Please enter the vehicle identification data in the type plates shown below so that correct information is available when required.

  • Page 3: Table Of Contents

    4/33-34 A) General safety instructions B) Maintenance instructions Maintenance instructions for SAF axles SK RB 9022 H - SK 1000 ET 120 Maintenance schedule for SAF axles SK RB 9022 H - SK 1000 ET 120 Brake testing (fault-finding procedure)
  • Page 4 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 Instructions

    B) Maintenance instructions SK 1000 Disc / ET 120 SK RB 9022 H - 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 9022 H - Sk 1000 Et 120

    B) Maintenance instructions SK 1000 Disc / ET 120 SK RB 9022 H - SK 1000 ET 120 Hub Unit Lubricant specifications: Hub Unit maintenance free. Copper paste Inspect for signs of wear at each brake disc change SAF Part No. 4 387 0020 00 (e.g.

  • 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 20) Running Check upline Uneven brake clearence OK? brake devices Check adjuster pad wear? (see page 20) and replace,...

  • Page 9: Adjuster Check

    B) Maintenance instructions Functionality test Loosen Loosen anti- clock- clockwise wise Remove the plugs. Loosen the brake. Using an SAF 8 mm ratchet wrench to turn the return shaft by approx. 3/4 revolution. Note that loosening the brake can be carried out in both clockwise and anti-clockwise directions independent of which of both holes the adjusting rods are situated in.

  • 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 9022 H - SK 1000 ET 120 Torque wrench settings Use a torque wrench. Wheel nuts: U-bolts: Shock absorber: The use of impact wrenches Hub-centred fixing: (diagonally in three stages ) M 24 / 400 Nm is strictly forbidden.

  • Page 13: Sk Rb 9022 H - Sk 1000 Et 120

    C) Spare part designation SK 1000 Disc / ET 120 SK RB 9022 H - SK 1000 ET 120 Item Parts designation Item Parts designation Axle beam assembly 59/60 Brake calliper group including items 61 - 70.6 Axle nut, RH, W.A.F. 85 Brake calliper group, RH 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 cap.
  • Page 15 D) Installation instructions Check the brake calliper for free and easy movement. Screw out the pressure pin on the adjuster so far until the folding bellows with the compression spring is visible. Perform a visual inspection of the boots and all seals. Screw in the tappets again completely.
  • 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 (SAF Part No.
  • 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 Check for wear in the guide pins. To measure the outer guide pin fit a magnetic holder with dial indicator onto the brake mounting. Set the tip of the indicator on point A, and raise and lower the brake calliper alternatively as shown in the illustration.
  • Page 20 D) Installation instructions Basic adjustment Check whether the brake disc can be moved easily. Using an SAF 8 mm ratchet wrench, turn the adjuster rod until the brake linings come into contact with the brake disc. Then loosen by approx. 1/4 turn to keep a basic play between the brake linings and the brake disc.

  • Page 21: Replacing The Tappets With Tappet Boots

    D) Installation instructions Removal of the folding bellows Using an 8 mm ring spanner turn the adjuster rod until the pressure pin is approx. 40 mm out of its fully screwed back position. Withdraw the protection screw and cut the bellows in order to gain access to the gap between the pressure pin and the adjusting screw.

  • Page 22: Installing The Tappets With Tappet Boots

    D) Installation instructions Fitting the folding bellows sleeve Remove the securing ring from the pressure plate. Next, lay the pressure plate on a flat surface with the required tools on top. Place the conical part of the special tool on top. Fit the protection springs with their small ends at the bottom onto their position on top of the special tool.
  • Page 23 D) Installation instructions Should the guide pins become seized in the brake mounting, they can be removed by cutting an M16 thread in the guide pin and withdrawing them using an M16 sliding hammer. Remove the brake mounting from the brake calliper. Note! Danger of injury, hold only on the outsides! Clean the parts of dirt and dust.

  • Page 24: Installing The Guide Pin/Slides

    D) Installation instructions Visible check The mounting surfaces of the slides and the bellows must be undamaged. Fitting of the guide pins and the slides. 81921 Fit 4 new slides into the brake calliper. Push the special tool P/N 81921 into the slide and expand the slide by turning the tool in the slide.
  • Page 25 D) Installation instructions Fit the bellows using the special tool P/N 81922 into the brake calliper. 81922 (consists of three parts) Push the outer part of the folding bellows into the slot of the guide pin and secure with the bellows ring. The mounting surfaces - the linings in the brake mounting on the pressure plate;...

  • Page 26: Replacing The Brake Cylinder

    D) Installation instructions Fit new covers to the ends of the guide pins using a 17 mm socket extension with extension. socket Replacing the brake cylinder Caution! Do not repair the brake cylinder due to the “inner sealing”. Use 210 Nm only an original replacement cylinder.

  • Page 27: Replacing The Tensioning Unit

    D) Installation instructions Removing the tensioning unit The brake calliper must be laid onto a workbench with the fixings of the cylinder facing upwards. Secure the bearings of the tensioning unit with a "G" clamp before thescrews are loosened. Remove the sealing collar on the adjusting rod. Remove the two nuts.
  • Page 28 D) Installation instructions Secure the position of the tensioning unit in the brake calliper with "G" clamps. Fit the 4 screws and nuts and carefully tighten until they contact the cover and the brake calliper. Remove the clamps and check that the tensioning unit is located correctly.

  • Page 29: Synchronising The Adjustment Screws Of The Tensioning Unit

    D) Installation instructions Synchronising the adjustment screws of the tensioning unit Synchronisation is carried out with the tensioning unit removed. Check that the pressure plates are fully pushed back against the stops. Lay the tensioning unit on a surface plate with the pressure plates facing downwards.

  • Page 30: 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 31: 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. Tool box SAF Part No. 3 434 6000 00 4. SAF ratchet wrench SAF Part No.

  • Page 32: F) Bolt / Nut Torque Values

    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 33 NOTIZEN / NOTES / NOTE...
  • Page 34 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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