SAF-HOLLAND SK 1000 ET 120, Maintenance And Repair Manual

Page 1: ...SK RB 9022 Hwith HALDEX brake calliper SK 1000 ET 120 Maintenance and Repair Manual for SAF Disc Brakes Service Edition 01 2006 ...

Page 2: ...ation of axles without type plate Production No of axle on right of stub axle as seen in direction of forward travel 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: ...ical workshop personnel responsible for maintenan ce and repair A General safety instructions 5 E Service tools 31 F Bolt Nut torque values 32 The item numbers indicated are given only for identification and to distinguish between different versions Use the part numbers from the valid spare parts documents for identification of spare parts SAF axles and suspension units are subject to continuous f...

Page 4: ...NOTIZEN NOTES NOTE 4 ...

Page 5: ...ot overheated 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 brake...

Page 6: ...damages Check adjuster cap for correct seating Inspect the brake pad thickness 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 semi trailer brake compatibility ABS etc Note Be sure to retighten wheel nuts to the prescribed...

Page 7: ...t No Hub nut wrench 2 012 0023 01 Puller for hub unit 4 434 3822 00 Tool box compl 3 434 6000 00 3 4 spanner external torx shape 4 434 3824 00 Thickness of brake disc A Wear limit of brake disc B NOTE Failure to observe these instructions may result in an accident risk Worn brake linings or excessively worn brake discs result in a reduction in the braking efficiency or in a complete failure of the...

Page 8: ...nce OK see page 20 Check adjuster see page 9 END Check brake calliper bearings and repair if necessary see page 19 END END Adjuster OK see page 9 END Replace brake calliper END Binding not due to disc brake Brake calliper guide system OK see page 19 END Check brake calliper bearings and repair if necessary see page 19 Uneven brake pad wear 1 Disc brake Running clearence OK see page 20 NO YES 1 Dif...

Page 9: ...n of the adjuster rod is reached then the adjuster rod is to be turned ant clockwise if it is situated in the right hand hole and clockwise if it is situated in the left hand hole Do not remove the SAF ratchet wrench Actuate the brakes approx 5 times The ring spanner must move after each actuation of the brake the automatic adjustment is working correctly Note The area in which the SAF ratchet wre...

Page 10: ...ckness 2 mm B Total lining thickness of new pads 21 mm When the residual lining thickness is A 2 mm replace the brake pads Wear indicator The amount of life left in the linings can be determined at the point of the inner brake calliper guide when the wheels are still fitted When new the rubber sealing element can be seen with both lips position C When worn the brake calliper is in position D In th...

Page 11: ...sture 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 Only brake cylinders approved by the brake or axle manufacturer may by used ...

Page 12: ... 120 SK RB 9022 H SK 1000 ET 120 Torque wrench settings Use a torque wrench The use of impact wrenches is strictly forbidden Wheel nuts Hub centred fixing M 22 x 1 5 600 Nm U bolts diagonally in three stages M 22 650 Nm Shock absorber M 24 400 Nm ...

Page 13: ...r carrier LH 63 Lining retainer set including items 63 1 63 2 064 Brake pad set including items 63 64 1 64 2 66 Cap for adjuster 67 Tappet with boot 70 Guide set 71 Tensioning 78 ABS sensor Repair kits for SAF disc brake SBH 2243 The following repair kits are available Designation Content Item No AT brake calliper RH incl pads AT brake calliper LH incl pads AT brake calliper RH without pads AT bra...

Page 14: ... jack Loosen the wheel nuts and remove the wheel Remove cap Turn adjuster either clock wise or anti clockwise until the stop so that the linings become free Remove the safety screws from the retainer hoop Remove the lining retainer hoop Remove the brake linings Unbolt the spring pressure or diaphragm cylinder from the brake calliper Then loosen bolts 6 bolts M 16 x 1 5 and remove the brake callipe...

Page 15: ...s and all seals Screw in the tappets again completely Replacing the brake disc Screw out the M 18 x 1 5 Hex screws or the M 18 x 1 5 headed TORX screws and remove the wheel flange Note Bolts must not be oiled Observe tightening torques Press the brake disc off the hub unit with 3 hexagon head bolts M 12 x 30 Clean contact surfaces before assembly Caution Seal on axle nut must not be damaged as thi...

Page 16: ...rn down if necessary For safety reasons the minimum thickness for turning down the brake discs is 39 40 mm Permissible wear see table in chapter Maintenance instructions Note The compact wheel bearing unit and the brake calliper are not remo ved for turning down the brake disc Replacing the Hub Unit Loosen axle nut and unscrew from stub shaft Axle nut wrench SAF Part No 2 012 0023 01 Note Axle nut...

Page 17: ...ue 900 Nm Each hub unit must be rotated smoothly at least twice while tightening the bolts Hub nuts with LH thread are marked Groove on the face Axle nut W A F 85 On left hand side of vehicle as seen in direction of forward travel left hand thread Identification of axle nut with left hand thread Milled groove on outside of hexagonal head Groove on the face Tighten the axle nut Axle nut wrench SAF ...

Page 18: ... be carried out with the brake linings removed see page 14 Turn the adjuster rod using an 8 mm ring spanner until the protec tion spring is completely visible Note The pressure pin may only be screwed out to a max of 50 mm Check the protection spring Finally replace the protection spring and check the folding bellows If the folding bellows or protection spring is torn or show signs of other damage...

Page 19: ...ey show signs of tearing or other damage Should work be required see page 22 24 Fit the brake linings see below Fitting brake linings Note The brake must be completely adjusted in the back position before fitting the linings Clean brake lining cavity Push the brake calliper in the direction of the outside of the vehicle and fit the outer brake lining Push the brake calliper finally in towards the ...

Page 20: ... linings and the brake disc Check whether the brake disc can be moved easily Re fit the plugs and O ring of the adjuster rod greased To achieve the correct play between the brake disc and the brake lining carry out a series of braking movements in order to let the automatic adjusting mechanism set itself to a finer adjustment setting Fit the wheels Tighten the wheel nuts using a torque wrench Caut...

Page 21: ...ote Use issued tools only Clean the pressure pin Remove the protection spring Turn the adjuster rod until the adju ster screws are screwed fully back Note Do not tighten Remove the folding bellows from the cover using an assembly lever Note Do not damage the adjuster screw and or the mounting surface of the bellows Ensure that no dirt enters through the adjuster screw opening Visible check Check t...

Page 22: ...position the special tool P N 81926 onto its place on the cover Press in the bellows unit into the cover using a G clamp Use the special tool P N 81928 in the adjuster rod hole as support Remove the G clamp and special tool P N 81926 and 81928 The folding bellows and the pressure plate must be pressed fully home Removal of the guide pins slides Secure the disc brakes in a vice Remove the 4 cover p...

Page 23: ...y on the outsides Clean the parts of dirt and dust Use the recommended dust remover or vacuum cleaner in no case use compressed air breathing in of the dust particles can be hazardous to health Press out the 4 guide pins from the brake calliper Carefully remove the 8 folding bellows using a removal tool Note The fitting surface must not be damaged Remove the 4 slotted slides with the help of a sma...

Page 24: ...ial tool P N 81921 into the slide and expand the slide by turning the tool in the slide Smear grease SAF Part No 4 387 0018 00 thinly onto the slide Grease the guide pins with grease SAF Part No 4 387 0018 00 and push them into the slides as illustrated Note the direction of the guide pins different hole depths The guide pins should slide easily in the slides so that the brake calli per is easy to...

Page 25: ...urfaces of the guide pins on the brake moun ting with copper paste SAF Part No 4 387 0020 00 Push out the guide pins so that they are free for the brake moun ting to be assembled Set the brake mounting in place on the brake calliper and press in the guide pins so that they slide into the lead in of the brake mounting Note Danger of injury Grip only from the outside Do not damage the bellows Lubric...

Page 26: ...ndary chamber venting see arrows All other venting bores must remain closed Before installing the new diaphragm cylinder grease the ball in the lever with grease SAF Part No 4 387 0018 00 Caution Do not use molybdenum disulphide saponified grease Use only diaphragm cylinders complying with the vehicle manufac turer s specifications Install the diaphragm cylinder Tighten the new hex nuts of the dia...

Page 27: ...pring pressure Clean the brake calliper on the inside as well as the sealing surfaces Fitting a new tensioning unit Note Ensure that the new adjusting rods of the new tensioning unit do not slide out of the adjuster screws as the adjusting mechanism is synchronised from side to side If the adjusting rods do slide out see synchronisation of the adjusting rods at the end of this chapter Lay the brak...

Page 28: ...rake calliper Remove the clamps and check that the tensioning unit is located correctly Note Fit into the brake calliper with the unit untensioned Tightening torque of the screw up to 20 3 Nm Smear the screw pins thinly with sealing compound SAF Part No 4 387 0019 00 and fit the nuts Tightening torque 5 1 Nm D Installation instructions 20 3 Nm 5 1 Nm sealing compound ...

Page 29: ...ote The dial indicator must remain stationary Lift the adjuster rod so that the toothed wheel runs free from the bevel gear Using the adjuster rod turn the adjusting screw until the indicator reads 0 zero Return the adjuster rod to its position If the toothed wheel does not mesh correctly with the bevel gear lift the adjuster rod and locate it inanother position on the adjuster screw Keep trying W...

Page 30: ...D Installation instructions Overview of Hub Unit components Hub cap Axle nut RH LH thread Wheel flange Brake disc Brake calliper Hub Unit Hub Unit 30 ...

Page 31: ...31 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 3 434 3327 00 E Service tools ...

Page 32: ... 640 770 M 22 W A F 32 550 780 930 M 22 x 1 5 610 860 1050 M 24 W A F 36 710 1000 1200 M 24 x 2 780 1100 1300 M 27 W A F 41 1050 1500 1800 M 27 x 2 1150 1600 1950 M 30 W A F 46 1450 2000 2400 M 30 x 2 1600 2250 2700 M 36 x 2 W A F 55 2450 3450 4150 Wheel fixing Wheels see appropriate axle maintenance chart TRILEX wheels M 18 270 300 Nm M 20 320 350 Nm The following tightening torques are only vali...

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