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Edition 11 /2009

Maintenance and
Repair Manual

SK RB/RLB 9022 W

INTEGRAL

with WABCO Disc Brake type PAN 22-1

Содержание SK RB 9022 W INTEGRAL

Страница 1: ...Edition 11 2009 Maintenance and Repair Manual SK RB RLB 9022 W INTEGRAL with WABCO Disc Brake type PAN 22 1 ...

Страница 2: ...n Service Identification of axles in case of type plate absence Serial No on spindle end RH side Ident No Prod No Serial No Example 1 Axle 2 Axle 3 Axle 4 Axle 5 Axle Enter axle data from type plate Vehicle and axle identification For the warranty procedure quote correct Axle Identification and Serial No Type plate for axle identification ...

Страница 3: ...vice chart Spare parts List of spare parts 2 4 5 6 9 10 11 Installation instructions SK RB RLB W INTEGRAL 1 0 Replace Brake Pads 2 0 Replace Hub Unit SK RB INTEGRAL 3 0 Replace the Brake Disc on the Hub Unit SK RB INTEGRAL 12 14 15 20 21 22 Installation instructions PAN 22 1 23 4 0 Mechanical Sliding Calliper Disc Brake Type PAN 19 1 WABCO Instructions 24 45 Contents ...

Страница 4: ...heated by continuous operation With drum brakes overheating can result in a hazardous deterioration in the braking efficiency With disc brakes overheating can result in damage to surrounding components in particular the wheel bearings This can result in a significant deterioration in road safety e g failure of wheel bearings 7 The parking brake must not be immediately applied when the brakes are h...

Страница 5: ...system or when moving the brake calliper hold the parts only at the outer edges to prevent fingers being trapped between brake calliper and brake bracket During removal and installation of the brakes on the trailer obtain assistance from a second fitter Heavy load Danger of injury During repair work on the brakes away from the trailer the brake must be gripped firmly in a suitable device e g vice ...

Страница 6: ...ness at regular intervals e g when ever tyre pressure is checked but at least every 3 months Inspect the brake disc for cracks Perform general annual inspection brakes air bags tyres etc Perform general annual safety check Tractor trailer brake compatibility brake adaption EBS LSV etc Special service conditions Vehicles with long standing periods Service at specified time intervals Vehicles used u...

Страница 7: ...limits Brake Disc Brake Pads Diameter mm A new mm B Wear limit mm C new mm E Wear limit mm 430 45 37 0 32 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...

Страница 8: ...SK RB RLB 9022WI with WABCO PAN 22 1 11 427GB Edition 11 09 8 1 Difference between wear of inboard and outboard pad and diagonal wear see diagram Service schedule Error flow chart procedure ...

Страница 9: ...ve 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 E Wear limits see diagram C New brake pad see diagram A B C E Brake Disc Inspect the braking surface of the brake disc carefully for serviceability A1 Network like cracks are permissible ...

Страница 10: ...entschlüssel anziehen INTEGRAL Bremsscheibe 34 31 29 40 39 1 27 45 030 INTEGRAL Radnabeneinheit Achtung Pos 39 1 45 56 u 56 1 müssen bei Reparaturarbeiten erneuert werden Links Rechtsgewinde Spare parts Torque wrench settings Tighten the assembly bolts with a calibrated torque wrench Wheel nuts Hub spigot centred fixing M22x1 5 600 Nm Refer to wheel manufacturers recommendations Driving direction ...

Страница 11: ...ster plug including items 31 34 66 Air bag protective cap 31 Wheel bolt 34 Wheel nut 070 Repair kit Guide pin 39 1 O ring including items 70 1 70 6 80 83 40 Hub cap with O ring 78 ABS rod sensor 45 Double hex bolt M12x1 5 SW 13 78 1 Rod sensor clamping bush 56 Hexagon head bolt 080 Repair kit 56 1 Shoulder bolt Guide pin including items 80 80 1 80 3 83 059 Brake calliper assembly LH including item...

Страница 12: ...move the plug The seal ring must not be deformed or damaged 1 6 Back off the brake at the hexagon of the adjuster with a ring spanner then loosen again by approx 1 4 spanner rotation Notes The direction of rotation for backing off the adjuster is to the right i e in clockwise direction Caution During backing off the pressure plate must be pushed back by hand at the same time so that the pin servin...

Страница 13: ...ide pins 1 11 Check air bag protection cap A Caution If air bag protection cap A is defective check whether any dirt or water has entered the brake and damaged the internal parts of the brake or the seal seat in the brake calliper due to corrosion If in doubt replace the brake calliper Check air bag protection cap B If damage is discovered replace the corresponding protection caps see section 4 0 ...

Страница 14: ...crewdriver between plug and seal ring Do not rest the screwdriver on the housing seal ring and apply pressure here to remove the plug The seal ring must not be deformed or damaged 1 20 Adjust the clearance by Filling the air system to cut off pressure and releasing the parking brake Adjust the clearance using the adjuster 1 21 Install the plug for the adjuster again correctly Caution If the plug i...

Страница 15: ... brake cylinder from the brake calliper and place to one side 2 3 Loosen and remove the retaining screws for the brake calliper 2 4 Remove the brake calliper from the brake carrier and place to one side 2 5 Pull the wheel cap off the hub unit 2 6 Loosen the axle nut and pull off the stub axle Notes On LH side as seen in direction of travel LH thread Installation instructions ...

Страница 16: ...INTEGRAL with brake disc off the stub axle and place to one side 2 8 If necessary use a puller to pull the hub unit SK RB INTEGRAL off the stub axle 2 9 Clean the seating surfaces for the hub unit SK RB INTEGRAL on the stub axle and coat all over with a minimum amount of mounting paste Fitting paste Part No 5 387 0015 06 Installation instructions ...

Страница 17: ...replacement hub unit SK RB INTEGRAL 2 11 Insert a new O ring 39 1 into the O ring groove of the hub unit 2 12 Push the hub unit SK RB INTEGRAL onto the stub axle 2 13 Screw on the axle nut Notes On LH side as seen in direction of travel LH thread Installation instructions Pos 39 1 ...

Страница 18: ...irection of travel LH thread Axle nut wrench W A F 85 Part No 4 434 3828 00 2 15 Install new wheel cap with O ring in the hub unit SK RB INTEGRAL 2 16 Position the brake calliper on the brake carrier and secure in this position using new retaining screws for the brake calliper Caution The fitting pin Pos 56 1 must only be inserted into the tapped bore with the recess in the brake calliper Installa...

Страница 19: ... 56 1 The bolts must not be oiled or greased Torque wrench settings see page 7 2 18 Check brake calliper for proper function and serviceability of the parts see section 1 2 19 Check the condition of the gasket A at the brake cylinder flange and replace the gasket if necessary Use new lock nuts B 2 20 Clean sealing surface A on the brake calliper A B Installation instructions Pos 56 Pos 56 1 A ...

Страница 20: ...ngs 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 2 24 Install the ABS sensor in the sensor holder and press against the exciter ring Caution After replacing the hub unit SK RB INTEGRAL check the proper function of the brakes on a roller dynamometer...

Страница 21: ...axle nut 3 6 Pull hub unit SK RB INTEGRAL complete with brake disc from the stub axle and place to one side See installation instructions chapter 1 See installation instructions chapter 2 3 7 Loosen and remove the DSK bolts holding the brake disc Torque wrench settings see page 7 3 8 Remove the brake disc from hub unit SK RB INTEGRAL 3 9 Clean the contact surfaces for the brake disc on the hub uni...

Страница 22: ...ren siehe Tabelle Seite 7 Caution Use only new DSK bolts DSK bolts must not be oiled or greased 3 12 Insert a new O ring 39 1 into the O ring groove of the hub unit 3 13 Install hub unit SK RB INTEGRAL complete with brake disc on the stub axle See installation instructions chapter 2 Caution After replacing the brake disc on the hub unit SK RB INTEGRAL check the proper function of the brakes on a r...

Страница 23: ...SK RB RLB 9022WI with WABCO PAN 22 1 11 427GB Edition 11 09 23 4 Mechanical Sliding Calliper Disc Brake Type PAN 22 1 Installation and Service Instructions Installation instructions PAN 22 1 ...

Страница 24: ... on guide pins 70 1 80 2 of the brake carrier 61 62 The brakes pads 64 1 are guided and supported in the brake carrier and can slide axially The brake pads are held by a pad retaining bracket 63 1 and spring clips 64 2 see Figures 1 to 3 The radially open design of the brake calliper permits a quick and easy pad change In order to prolong the pad changing intervals with this brake system brake pad...

Страница 25: ...SK RB RLB 9022WI with WABCO PAN 22 1 11 427GB Edition 11 09 25 Installation instructions PAN 22 1 Arrow direction of rotation for forward travel Figure 2 Top view Figure 3 Side view ...

Страница 26: ...brakes do not clean soiled areas with compressed air or other high pressure cleaners Risk of injury 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 During removal and installation on the brake on the vehicle always have a second fitter to help Heavy load Risk o...

Страница 27: ...n jaw wrench for the adjuster The space for the ring spanner on the hexagon must be large enough to allow it to turn without being hindered during rotation Apply the brakes approx 5 times approx 1 bar If the adjuster is functioning correctly the ring spanner arrow should turn back slowly in anti clockwise direction Note With increasing adjustment the turn angle or movement of the ring spanner will...

Страница 28: ... at the leading end of the pad or at the clearance pin short pin at the trailing end of the pad Measure the distance between the axle flange and the edge of the brake calliper of the respective guide pin arrows The wear limit is reached or exceeded at the following values Short guide pin Wear limit 73 mm Replace brake pads Long guide pin Wear limit 98 mm Replace brake pads 4 4 Check Brake Disc Rem...

Страница 29: ...e 64 5 Remove wear indicator 64 3 with sensors from the brake pads Remove both cable clips 64 4 from the brake calliper Remove plug 65 for adjuster 65 1 from brake calliper Turn back the brake at the hexagon of the adjuster 65 1 using a ring spanner then loosen again by approx 1 4 rotation Note The adjuster is turned back by turning the spanner to the right i e in clockwise direction Caution Durin...

Страница 30: ...e caps and ease of movement of brake calliper Push the brake calliper to the cylinder side and inspect protective caps 80 of guide pins 70 1 80 2 and protective cap 66 of the pressure pad for wear or damage Replace damaged protective caps as described in sections 4 8 and 4 9 Caution In the event of protective cap 80 being damaged check whether any dirt or water has entered the brake and damaged th...

Страница 31: ...o the stop in clockwise direction Note The torque is higher when turning back than when turning forward Caution Do not overload the hexagon of the adjuster 65 1 Do not use an open jaw wrench for the adjuster The space for the ring spanner on the hexagon must be large enough to allow it to turn without being hindered during rotation Apply the brakes lightly several times and check whether the adjus...

Страница 32: ...endangered In order to achieve this the pressure pad can be turned until the pin engages in the groove of the pressure plate The protective cap must not be turned Install a new brake pad 64 1 on the actuating side Push the brake calliper towards the rim side until the actuating side brake pad 64 1 is in contact with the brake disc Install a new brake pad 64 1 on the rim side Insert a 1 mm thick fe...

Страница 33: ...into the brake pad Raise the cable guide plate of the wear indicator 64 3 slightly push three new spring clips 64 2 under the cable guide plate and onto the pressure plate and brake pads Caution On the actuating side lay the cables see arrow so that there are no cables lying on the brake pad see cable position in figure Finally press the cable guide plate against the spring clips and position on t...

Страница 34: ...new bracket screw 63 2 to the brake calliper with the prescribed torque Table 1 position II Attach the connector of the wear indicator Fasten the cable outlet to the new cable clip 64 4 Check that the cables are laid correctly Press new plug 65 into the opening of the brake calliper Ensure that it seals tightly Check that the wheel hub can turn without binding Caution After completion of the insta...

Страница 35: ...d brake pads as described in section 4 3 If new brake pads have to be installed replace the pads on both sides of the axle at the same time Brake removal procedure Remove the brake pads as described in section 4 5 Remove the brake cylinder from the brake calliper as described in section 4 10 Remove the brake calliper with brake carrier from the axle Table 1 position III Inspect the brake disc as d...

Страница 36: ...ions 4 8 and 4 9 should be performed together In this case the steps in the individual sections do not have to be carried out several times If seals are replaced individually the steps from the corresponding sections 4 8 and 4 9 have to be performed 4 8 Replace Protective Caps and Bushes of the Guide Pins Removal procedure Remove the brake pads as described in section 4 5 Remove the brake cylinder...

Страница 37: ... the brake carrier 61 62 Remove guide pins 70 1 80 2 and caps 83 from brake calliper 59 60 Place brake calliper 59 60 on a solid surface for pressing out the bushes 70 3 80 3 so that the cover opening of the brake calliper 59 60 is facing upwards Press bushes 70 3 80 3 out of brake calliper 59 60 using a press and drifter Clean the bores in the brake calliper 59 60 61 62 80 59 60 Fig 38 Fig 39 Fig...

Страница 38: ...one new bush 80 3 for the short guide pin 80 2 Press in bush C with a drifter L3 25 7 0 2 mm until the drifter bottoms in the bore Grease the sliding surface of the bush Press new green protective caps 80 into the seal seat ring groove arrow of the brake calliper 59 60 Note Clean the seal seats before pressing in the caps The seal seats must be grease free The protective caps 80 can be pressed int...

Страница 39: ... Fig 45 Place brake calliper 59 60 onto the brake carrier 61 62 and thread the inserted guide pin 70 1 80 2 into the fitting collar Insert new socket screws 70 6 long for fitting pin 70 1 80 1 short for clearance pin 80 2 through the guide pin installed in the brake calliper 59 60 and fasten to the brake carrier 61 62 with a wrench Table 1 position IV Caution During installation ensure that the pr...

Страница 40: ...he brake calliper and grease the spherical seat arrow in the brake lever 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 4 9 Replace Protective Cap on Pressure Pad Note If the protective cap is removed individually removal of the b...

Страница 41: ...brake calliper via the seal seat or if the protective cap has only just been damaged during the service work If in doubt or if parts are corroded replace the brake as described in section 4 6 After checking grease the thread and turn the adjuster back in clockwise direction Installation sequence Clean the seat for the protective cap 66 in the brake calliper arrow Push a new protective cap 66 over ...

Страница 42: ...inder manufacturer Remove the brake cylinder from the brake calliper by loosening the nuts of the brake cylinder and removed from the brake calliper Table 1 position V Installation sequence Caution Depending on the installation position of the brake minimum the lower drainage opening on the brake cylinder facing downwards must be open Before installing the brake cylinder clean the sealing surface ...

Страница 43: ...tion left max 3 clearance becomes smaller Loosen in clockwise direction right max 12 clearance becomes larger Do not use power wrenches II 17 X 30 15 III 24 X 290 20 recommended Please observe the trailer manufacturer s special installation instructions IV 14 X 310 30 Tightening sequence for guide pins 1 Fitting pin long socket screw 2 Clearance pin short socket screw V 24 X 210 30 Installation in...

Страница 44: ...SK RB RLB 9022WI with WABCO PAN 22 1 11 427GB Edition 11 09 44 Exploded View of the Replacement Parts PAN 22 1 Installation instructions PAN 22 1 ...

Страница 45: ...carrier right 66 Protective cap for compression piece 62 Brake carrier left 70 1 Guide pin 63 1 Pad retaining clamp 70 3 Bushing 63 2 Bracket screw 70 6 Socket screw 64 1 Brake pads disc brake 19 5 80 Protective cap for guide pins 64 2 Spring clip 64 3 Wear indicator preassembled 80 1 Carriage bolt 64 4 Cable clips 80 2 Guide pin 64 5 Pressure plate 80 3 Bushing 83 Cap Installation instructions PA...

Страница 46: ...1427GB Edition 11 2009 Last updated 2009 11 02 Amendments and errors reserved SAF HOLLAND We are always there for you Assistance 49 6095 301 247 Service 49 6095 301 602 Switchboard 49 6095 301 0 Fax 49 6095 301 259 service safholland de www safholland com ...

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