SAF-HOLLAND SK RB 9022 K Operating instructions

Service
Edition 01/2006
SK RB 9022 K/SK RB 9019 K with KNORR brake calliper
SK 1000 ET 120
Maintenance and Repair Manual
for SAF Disc Brakes

2
Vehicle information
Manufacturer.................................................................................................................................
Address...........................................................................................................................................
Body type.......................................................................................................................................
Chassis no.......................................................................................................................................
Year of manufacture ....................................................................................................................
Registration date...........................................................................................................................
Type plate (on the inside of the trailing arm or axle beam)
Identification 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, quote correct
axle identification serial no., refer to the
axle type plate.
Please enter the vehicle identification
figures in the type plates shown below
so that correct information is available
when required.

SAF axle identification 2
Notes 4
Repairing the brakes 14-19
Replacing the tappets with tappet boots 20
Inspecting the adjuster thread 20
Installing the tappets with tappet boots 21
Sealing the brake calliper bearing with “seal kit for sliding guide” 22
Repairing the brake calliper bearing with “guide and seal kit” 23
Replacing the rubber guide sleeve 23-24
Replacing the brake calliper 24
Installing the brake calliper 25
Replacing the brake calliper carrier 26
Replacing the brake cylinder 26
Overview of hub unit components 27
D) Installation instructions
Spare part illustration and spare part designation
SK RB 9022 K / 9019 K - SK 1000 ET 120 12-13
C) Spare part illustrations/spare part designation
B) Maintenance instructions
Maintenance instructions for SAF axles
SK RB 9022 K / 9019 K – SK 1000 ET 120 6
Maintenance schedule for SAF axles
SK RB 9022 K / 9019 K – SK 1000 ET 120 7
Brake testing (fault-finding procedure) 8
Adjuster check 9
Brake pad check 10
Special notes 11
3
Contents
Page
This manual is intended for the technical workshop personnel responsible for maintenan-
ce and repair.
A) General safety instructions 5
E) Service tools 28-30
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 further development; the data and drawings
contained in the manual may therefore differ from the details given in the operating permit.
The contents of the manual does not constitute the basis for a legal claim.
Reprinting, reproduction or translation in whole or in part is not permitted.
The issue of this publication invalidates all earlier maintenance and repair manuals.
Note: We wish to thank KNORR-BREMSE for providing various illustrations!
F) Tightening torque in Nm 31

NOTIZEN / NOTES / NOTE
4

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:
1. 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. The contact surfaces must be clean, smooth
and free from grease. Failure to observe this may result in the wheel coming loose. Any additional
instructions of the wheel manufacturer must also be observed.
2. Only the wheel and tyre sizes approved by the trailer builder may be used. The tyres must always have
the specified inflation pressure.
3. The brake systems of the tractor and the trailer/semi-trailer must be synchronised by means of a
tractor/trailer brake synchronisation not later than 5,000 km after the initial start of operation of the
trailer/semi-trailer in order to ensure a safe and uniform braking behaviour and uniform brake pad
wear. Tractor/trailer brake synchronisations should be carried out by appropriately qualified and
equipped brake workshops.
The use of an additional braking system, such as a trailer anti-jackknife brake is forbidden by law on
vehicles with type approval after January 1999.
4. Before starting a journey, ensure that the maximum permissible axle load is not exceeded and that the
load is distributed equally and uniformly.
5. On trailers with air suspension, ensure that the air bags are completely filled with air before starting
the journey. Incompletely filled air bags may result in damage to axles, suspension, frame and
superstructure and impair road safety.
6. Ensure that the brakes are not 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 brakes are hot, as the brake discs and
brake drums may be damaged by different stress fields during cooling.
8. Use the supports provided when loading and unloading in order to avoid damage to the axle.
9. Observe the operating recommendation of the trailer builder for off-road operation of the installed
axles and suspension systems.
The SAF 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 axles and suspension systems not designed for the purpose may result in
damage and hence to an impairment of road safety.
10. SAF axles and suspension systems require continuous care, service and maintenance in order to
maintain operational and road safety and to be able to recognise natural wear and defects in good
time.
The daily inspection of the trailer for road safety before starting the journey is one of the driver’s
obligations.
SAF recommends that at least the inspections and maintenance operations described on page 6 should
be carried out.
We recommend the use of original SAF spare parts.
A close-knit service network of SAF partner companies is available for the technical support of the SAF axle
and suspension systems and for the supply of original SAF spare parts (see rear cover or on the Internet
under www.saf-axles.com).
Updates will be published as necessary on the Internet under www.saf-axles.com.
5

6
B) Maintenance instructions
SK 1000 Disc / ET 120
SK RB 9022 K / 9019 K - SK 1000 ET 120
Vehicles with long standing periods: service at specified time intervals
Vehicles used under extreme conditions: shorten the service interval to 6 months /
e.g. construction site operation, multi-shift operation 75,000 km
Maintenance intervals
whichever comes first
Mileage intervals >
Time intervals >
After first
5,000 km
or every
30,000 km
every
150,000 km
After first
month
every
3 months
every
75,000 km
every
6 months
every
12 months
Periodic checks
Hub unit maintenance-free.
Visual inspection for grease leaks.
Inspect the brake caliper guide system.
Check for free movement and sliding action.
Check rubber dust covers for cracks and 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 torque after the first 50 km and 150 km
(and after every wheel removal).
Mechanical check
Visual and safety inspection
Special service conditions
Warranty claims will only be accepted as long as the operating and maintenance instructions
have been complied with and if SAF approved spare parts have been fitted.
NOTE!
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-authorised workshop.
•
•
•
•
•
•
•

7
B) Maintenance instructions
SK 1000 Disc / ET 120
SK RB 9022 K / 9019 K - SK 1000 ET 120
Hub Unit
Hub Unit maintenance free.
Inspect for signs of wear at each brake disc change
(e.g. excape of grease).
After brake relining, observe the following points:
Inspect the seals on the brake calliper.
Never use high-pressure cleaners or cleaning fluids
on the brake disc or hub unit.
Clean stub axle of any old grease and apply fresh
SAF fitting paste.
Lubricant specifications:
Tappet boots and brass bushes:
SAF Part No. 4 387 0016 00
Rubber guide bush (70.3):
SAF Part No. 4 387 0017 00
Stub axle:
SAF Part No. 4 387 0015 06
SAF fitting paste
Tightening the hub nut
On LH side as seen in direction of travel –
LH thread
On RH side as seen in direction of travel –
RH thread
Tightening torque 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.
Assembly tools SAF Part No.
Hub nut wrench 2 012 0023 01
Wedge fork for tappet with boot 4 434 1065 00
Puller for hub unit 4 434 3822 00
Installation drift for tappet 4 434 1062 00
Puller for inner boot 4 434 1063 00
Puller / pusher for brass bush 4 434 1064 00
Caulking tool for brass bush 4 434 1066 00
3/4” spanner
External torx shape 4 434 3824 00
Assembly pin steel cap (see sketch on page 29)
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
brake system.
Thickness of
brake disc “A”
Wear limit of
brake disc “B”
Thickness of
linings “C”
Lining
wear “E” Disc diameter in mm No. of brake pads
per axle
SB7 22.5“ 45 ≤37 30 11 430 4
SB6 19.5” 45 ≤37 30 11 370 4
Tightening torque
(Nm)
Spanner size
(W.A.F.)
Hexagon
outside inside
Guide bearing on brake calliper
2 hex. socket head screws 290 14 – X
M16 x 1.5 - 10,9
Diaphragm/combination cylinder
2 hex. nuts 210 24 X –
M16 x 1.5
Brake calliper mounting
on axle body 290 24 X –
M16 x 1.5 x 55
Item No.
Caution! Bolts must not be oiled!
Wheel flange mounting
M18 x 1.5 x 75 or 65
44 450 27 X –
TORX screw with head
M18 x 1.5 x 75 or 65
44
Tightening process: pre-
tighten to 50 Nm diagonally,
turning angle of 90º diagonally
tightened (1 1/2 nut corners)
External torx E24 – –
70.1/80.1/
81.1
Brake type

8
B) Maintenance instructions
Brake testing
Fault-finding procedure
Lift vehicle,
turn wheel
by hand
Does wheel
turn freely?
Residual pressure
in brake cylinder?
NO YES
NO YES
NO YES
NO YES
NO YES
Check upline
brake devices
and replace,
if necessary
END
NO YES
Running
clearence OK?
(see page 19)
Check adjuster
(see page 9)
END
Check brake
calliper bearings
and repair,
if necessary
(see page 23)
END
END
Adjuster OK?
END
Replace brake
calliper
(see page 24)
END
Binding not
due to disc brake
Brake calliper
guide system OK?
(see page 18)
END
Check brake
calliper bearings
and repair,
if necessary
(see page 23)
Uneven brake
pad wear?1)
Disc brake
Running
clearence OK?
(see page 19)
NO YES
1) Difference between wear of inboard and outboard pad, and diagonal wear ≤2 mm.

9
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.
With an SAF ratchet wrench on the hexagon drive of the adjuster,
turn the drive in anti-clockwise direction for 2 or 3 clicks.
Apply the brakes 5-10 times (approx. 2 bar).
If the adjuster is functioning correctly, the SAF ratchet wrench
(arrow) should rotate in clockwise direction in small steps.
Caution!
Ensure that there is sufficient room for the SAF ratchet wrench to
rotate freely during adjustment.
Note:
As the number of rotation steps of the ring spanner increases, the
turn angle or movement of the SAF ratchet wrench becomes smaller.
If the SAF ratchet wrench rotates as described above, the adjuster is
functioning correctly.
If the following faults occur:
The adjuster or SAF ratchet wrench
a) does not turn,
b) turns only with the first application of the brakes,
c) turns forward and then back again at each application of the
brakes,
the adjuster is not functioning correctly and the brake calliper has to
be replaced.
Remove the SAF ratchet wrench (arrow).
Coat the cap with white grease (SAF Part No. 4 387 0016 00) in the
snap-fit area, then push on the cap and ensure that it is fitting
tightly.

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 ≤2 mm, replace the brake
pads.
Wear indicators
At the point on the brake calliper (59/60) opposite the fixed sleeve
(70.2), the brake pad thickness can be measured without removing
the wheels.
When the end of the guide sleeve (70.3) is level with the fixed slee-
ve (70.2), the brake pad thickness has to be checked with the wheels
removed.
Replace the brake pads, if necessary.
C = Condition with new brake pads.
D = Brake pad and brake disc inspection necessary with wheels
removed.
A
B
10
C
59/60 70.2
70.3
D
59/60 70.2
70.3

B) Maintenance instructions
Special notes
11
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.
Only brake cylinders approved by the brake
or axle manufacturer may by used

12
C) Spare part illustrations
SK 1000 Disc / ET 120
SK RB 9022 K / 9019 K - SK 1000 ET 120
Torque wrench settings
Use a torque wrench.
The use of impact wrenches
is not accepted.
Wheel nuts:
Spigot-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

13
C) Spare part designation
SK 1000 Disc / ET 120
SK RB 9022 K / 9019 K - SK 1000 ET 120
Item Parts designation Item Parts designation
01 Axle beam assembly
22 Axle nut, RH, W.A.F. 85
22.1 Axle nut, LH, W.A.F. 85
026 Axle end assembly
including items 27-31, 34, 39-40, 44, 77
27 Hub Unit
29 Brake disc
30 Wheel bolt assembly
including items 31, 34
31 Wheel bolt
34 Wheel nut with pressure plate
39 Wheel flange
40 Hub cap with gasket
44 Torx screw
56 Hexagon head bolt
56.1 Shoulder bolt
59/60 Brake calliper assembly
including items 61/62, 65, 66, 70, 81
064 Brake pad set
including items 63, 64.1, 64.2
66 Tappet with boot
including items 66.1-66.2
70 Guide pin group
including items 70.1-70.3
80 Guide pin group
(folding bellows)
including items 80.1-80.3, 82
81 Guide pin group
(steel cap)
including items 80.4-80.5, 81.1-81.2, 83
This guide pin group should, where
possible, be used for repairs.
Repair kits for SAF disc brakes SBK 2243 / SBK 1937
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 brake calliper, LH without pads
Brake calliper carrier with guide kit, RH 61, 70, 81
Brake calliper carrier with guide kit, LH 62, 70, 81
Guide pin group (folding bellows) 80
Guide pin group (steel cap) 81
Guide pin group 70
Tappet with boot 66.1, 66.2
Brake pad retainer kit (per axle) 064
Cap for clearance adjuster (4 caps) 65
All kits available only as complete sets!
When ordering spare parts quote correct axle identification serial no., refer to the axle type plate.

14
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.
Turn the adjuster in anti-
clockwise direction up to the
stop until it clicks 2 - 3 times.
Remove the locking pin and
washer.
Press out the stud.
Remove the bracket.
Remove the brake pads.
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 calliper.

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.
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 this would invalidate all
warranty claims.

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.
A1– Network-like cracks are permissible.
B1– Cracks up to max. 1.5 mm (width and depth) running towards
the middle of the hub are permissible.
C1– Unevenness in the disc surface up to 1.5 mm is permissible.
D1– Cracks going right through the disc are not permissible.
Check the brake disc thickness and turn 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 W.A.F. 85
– on left-hand side as seen in direction of forward travel =
left-hand thread.
The axle nut with left-hand thread has a milled groove on the outer
face for identification.
The complete hub unit can be pulled off the stub shaft using a
puller, SAF Part No. 4 434 3822 00.
(The hub unit cannot be overhauled and has to be replaced complete
with the bolts of the wheel flange).
A1
D1
B1
C1

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. Tighten the axle nut to the prescribed
torque.
On LH side as seen in direction of travel – LH thread
On RH side as seen in direction of travel – RH thread
Tightening torque 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 Part No. 2 012 0023 01
Tightening torque 900 Nm. Each hub unit must
be rotated smoothly at least twice while tightening the bolts.
Special locking of the axle nut is not necessary.
Place the wheel flange onto the hub unit and tighten the new,
unoiled bolts to the prescribed torque.

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.
Measure the output voltage at the ABS sensor cable using a
voltmeter (approx. 100 mV) while turning the brake disc or wheel
flange.
Examining the boots on the tappets
The boots on the tappets (66.1) and caps must have no cracks or
other damage.
Check that the tappets and boots fit correctly and replace the
tappets with boots, if necessary.
Examining the brake calliper guide system
The brake calliper (59/60) must move smoothly and easily over the fill
travel distance > 30 mm on the guide elements (80.2) and (80.3) or
(70.2) and (70.3) when pushed by hand (use no tools).
The guide bush (80.2) is sealed with boot (80.4) and boot cap (82).
Parts (80.4) and (82) must not be cracked or damaged.
Check that these parts are seated correctly.
Boot and boot cap must not be cracked or damaged. If necessary,
reseal or repair.
New type steel cap:
Check for correct seating of the steel cap item 83.1, renew if
necessary.
66.1
80.4 80.2 80.3
82
83.1
83.2
59/60 70.2 70.3

19
D) Installation instructions
Installing the brake pads
Note:
Before installing the brake pads, the brakes must be completely
backed off with the SAF ratchet wrench (SAF Part No. 3 434 3327 00).
Clean the brake pad slots.
Push the brake calliper towards the outside of the vehicle and insert
the outer brake pad.
Then push the brake calliper towards the middle of the vehicle and
insert the inner brake pad
(connect the wear indicator, where applicable).
Inserting the pad retainer
Insert the pad retainer into the groove in the brake calliper and
press down with a screwdriver until the pin can be inserted into the
bore.
Insert locking pin and washer and secure with spring clip.
Note:
After operating the service brake system, it must be possible to turn
the wheel hub by hand (correct running clearance, if necessary).
Checking and adjusting the running clearance
Use a suitable tool to press the brake pad away from the tappets in
the brake calliper slot.
Insert a feeler gauge between tappet and brake pad backplate and
adjust the running clearance to 0.7 mm by turning the hexagon drive
on the adjuster.
Grease and fit the dust cap.
Fit the wheels.
Tighten the wheel nuts using a torque wrench.
Caution!
Tighten the wheel nuts using a torque wrench again after driving
50 km and 150 km!

20
D) Installation instructions
Replacing the tappets with tappet
boots
Note:
Depending on the space available for installation, it may be easier
to remove the brake calliper for replacement of the tappets.
Back off the tappets (66.1) with the adjuster until the boot can be
reached.
Drive in the screwdriver only approx. 4 mm so that the inner sealing
cap is not damaged. Deform the mounting ring of the boot and
lever out of the bore.
Use the wedge fork, SAF Part No. 4 434 1065 00, to push the tappets
(66.1) off the bush at the end of the threaded tubes.
If necessary, remove the old tappet bush (66.2).
Note:
Driving in the wedge fork between the tappet and the end of the
threaded tube has a wedge effect.
Inspect the inner sealing cap (arrow). If the cap is damaged, the
brake calliper must be replaced.
Inspecting the adjuster thread
Install a new brake pad in the outer calliper slot so that the threa-
ded tubes cannot be twisted out of the bridge.
The two threaded tubes are synchronised.
Caution!
Do not unscrew the threaded tubes completely out of the bridge,
otherwise the brake calliper will have to be replaced.
Screw the threaded tubes in towards the brake disc by turning the
hexagonal drive (W.A.F. 8) of the adjuster in clockwise direction
(do not back off by more than 30 mm).
If the brake calliper is not installed on the axle or is lying on the
workbench, insert a spacer (= 70 mm) into brake calliper (59/60)
during unscrewing of the threaded tubes so that the threaded tubes
cannot be completely unscrewed (see illustration).
During screwing, the threads of the threaded tubes can be inspected
for corrosion.
If an ingress of water or corrosion is discovered, the brake calliper
must be replaced.
66.1
66.1
66.2
66.1
66.1
70 mm
59/60