SAF-HOLLAND SK RB 9022 W INTEGRAL Operating instructions

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

SK RB/RLB 9022WI with WABCO PAN 22-1 11.427GB Edition 11/09 -2-
Trailer Manufacturer..........................................................................................................................................................
Body type..........................................................................................................................................................................
Chassis no........................................................................................................................................................................
Year of manufacturer/Trailer date in 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

SK RB/RLB 9022WI with WABCO PAN 22-1 11.427GB Edition 11/09 -3-
Page
Vehicle and axle identification
General safety instruction
Service instructions
Service schedule / Service 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

SK RB/RLB 9022WI with WABCO PAN 22-1 11.427GB Edition 11/09 -4-
Please observe the following safety instructions in order to maintain the operational
and road safety of your SAF-HOLLAND 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 and/or brake adaption (EBS) 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 synchronisation/brake adaption 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-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.
10. SAF-HOLLAND 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-HOLLAND recommends that at least the inspections and maintenance operations described on page 26
should be carried out.
We recommend the use of original SAF-HOLLAND spare parts.
A close-knit service network of SAF-HOLLAND partner companies is available for the technical support of the
SAF-HOLLAND axles and suspension systems and for the supply of original SAF-HOLLAND spare parts
(see rear cover or on the Internet under www.safholland.com).
Updates will be published as necessary on the Internet under www.safholland.com.
General safety instructions

SK RB/RLB 9022WI with WABCO PAN 22-1 11.427GB Edition 11/09 -5-
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!
During repair work on the brake system, the trailer must be standing on level ground and secured to prevent it from
rolling away. Use only approved equipment for supporting and securing the trailer. During the repair work on the brake
system, measures must be taken to ensure that the brakes are not actuated accidentally. The brakes must not be
actuated as long as the brake pads are removed. Danger of injury!
During repair work on the brake system, do not clean soiled areas with compressed air or other high-pressure cleaners.
Danger of injury!
During work on the brake 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.
High loosening and tightening torques of the bolts. Danger of injury!
The brake calliper with clamping unit must not be opened.
For this reason, the retaining bolts of the cover on the brake calliper must not be loosened.
Carry out repair work only with recommended tools.
Do not use power wrenches or other power tools!
Tighten nuts and bolts only to the recommended tightening torques.
When new brake pads are installed, sharp braking should be avoided for the first 50 kilometres.
Long braking distances and sudden braking should also be avoided.
In the event of severe damage or wear of the castings (e.g. cracks), the complete brake must be replaced.
On completing repair work, a final test should be carried out on a roller dynamometer.
Not!es
For all working steps relating to the disc brake, please refer to the latest edition of the installation and maintenance
instructions for the respective WABCO disc brake.
Service instructions

SK RB/RLB 9022WI with WABCO PAN 22-1 11.427GB Edition 11/09 -6-
Service schedule Periodic check
Whichever occurs first Mileage intervals > After first
5,000 km or every 30,000 km every 75,000 km every 150,000 km
Time intervals > after first
month every 3 months every 6 months every 12 months
Mechanical check
Attention: Torque check wheel nuts after the first 50 km
and 150 km to recommended torque setting, also after any
removal of the wheel.
Visual and safety inspection
Hub Unit maintenance free.
Visual inspection for grease leaks. 
Inspect the brake calliper 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 pas 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/trailer brake compatibility, brake adaption EBS;
LSV etc.) 
Special service conditions
Vehicles with long standing periods: Service at specified time intervals.
Vehicles used under extreme conditions:
e.g. construction site operation, multi-shift operation Shorten the service interval to 6 months / 75,000 km
Warranty claims will only be accepted as long as the operating and maintenance instructions have been
complied with and if SAF-HOLLAND 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-HOLLAND-authorised workshop.
Service schedule

SK RB/RLB 9022WI with WABCO PAN 22-1 11.427GB Edition 11/09 -7-
Hub Unit maintenance free
Check hub unit at each brake disc replacement for wear and grease leackage.
When brake pads replacing check the rubber boot seals of the brake calliper.
Never use high-pressure cleaners or cleaning fluids on the brake disc or hub
unit. Clean stub axle of any contamination and apply fresh SAF-HOLLAND
fitting paste.
Lubricant specifications:
Grease for l
ubrication is contained
in every repair kit.
Stub axle:
Fitting paste
Part No. 5 387 0015 06
Tightening the hub nut
On LH side – LH thread
On RH side – RH thread
Hub nuts with LH thread are marked: Groove on the
outer edge.
1. Pre tightening: 150 Nm, then turn the hub unit
slowly by 5 revolutions
2. Final tightening: Retighten by 1 increment (30°)
Max. permissible axial backlash ob hub unit 0-0.20 mm
A
BC
E
NOTE! Failure to observe these instructions may result in an road accident risk! Worn brake linings or excessively
worn brake discs result in a reduction of the braking efficiency or in a complete failure of the brake.
Wear 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 torque wrench.
NOTE! The assembly bolts item 45, 56, 56.1 must be replaced when carrying out repair works.
The bolts must not be oiled or greased when assembling.
Tighten the assembly bolts with a calibrated torque wrench.
Assembly Item SK RB 9022W INTEGRAL
Axle nut 21 / 22 1. Pre tightening: 150 Nm, then turn the hub unit slowly by 5 revolutions
2. Final tightening: Retighten by 1 increment (30°)
INTEGRAL – Brake disc
Double hex. Bolt, socket 13 M12x1.5 /
45 1. Pre tightening: diagonally with 30 Nm
2. Final tightening: diagonally with torque angle 90°
Brake calliper on axle
Hexagon bolt M16x1.5 56 56.1 290 Nm
Brake chamber hex. nut M16x1.5 1. Pre tightening: 120 Nm
2. Final tightening: 210 Nm
Pad retainer clamp 63 30 ± 15 Nm
Assembly tools Part No. Assembly tools Part No.
Hub nut socket 4 434 3828 00 Tool box WABCO 3 434 6010 00
Puller for Hub Unit 4 434 3822 00
Service chart

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

SK RB/RLB 9022WI with WABCO PAN 22-1 11.427GB Edition 11/09 -9-
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). Here, the distance between the axle
flange and the edge of the housing of each bolt is measured (see illustration).
The amount of wear is determined to have been reached or exceeded by the
following criteria:
PAN 22-1
Long guide pin > 98 mm
Short guide pin > 73 mm
Brake Pad
Note!
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.
E = Wear limits, see diagram
C = New brake pad, see diagram
A
BC
E
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 is permissible.
D1-Cracks going right through the disc are not permissible.
Check the brake disc thickness and turning, if necessary.
For safety reasons, the minimum thickness for turning down the brake
discs is 39 – 40 mm.
Service schedule

SK RB/RLB 9022WI with WABCO PAN 22-1 11.427GB Edition 11/09 -10 -
IPL_17_420_S
61 / 62
56
56.1
01
22 / 22.1
78
78.1
Fahrtrichtung
83 70.6
070
70.1
70.3
80
080
83
80.1
80.2
80.3
65
66
80
059 / 060
63.1 63.2
63
64.2 64.1
64
064
Anziehdrehmomente
Radmuttern:
Mittenzentrierung M22x1,5 600 Nm
Hinweise der Räderhersteller beachten
Die Schraubverbindungen mit Drehmomentschlüssel 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
LH / RG thread
INTEGRAL Brake Disc
INTEGRAL Wheel hub unit
NOTE!
Item 39.1, 45, 56 and 56.1:
The assembly bolts must be replaced
when carrying out repair works.

SK RB/RLB 9022WI with WABCO PAN 22-1 11.427GB Edition 11/09 -11 -
Item Parts designation Item Parts designation
01 Axle beam assembly 059 Brake calliper assembly, RH
including items 62, 64, 65, 66, 070, 080
22 Axle nut, RH, W.A.F. 85
22.1 Axle nut, LH, W.A.F. 85 61/62 Brake calliper carrier, not available
27 INTEGRAL wheel hub 63 Pad retaining clamp
incl. Kerola and exciter ring including items 63.1, 63.2
29 INTEGRAL Brake Disc 64 Brake pads
including items 64.1, 64.2
030 Wheel bolt kit 65 Adjuster 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 items 61, 64, 65, 66, 070, 080
NOTE!
Item 39.1, 45, 56, 56.1
The assembly bolts must be replaced when carrying out repair works.
All repair kits available only as complete sets!
When ordering spare parts quote correct axle identification serial no., refer to the axle type plate.
List of spare parts

SK RB/RLB 9022WI with WABCO PAN 22-1 11.427GB Edition 11/09 -12 -
1.0 Replace Brake Pads
1.1 Fill the air system to cut-off pressure and release the parking brake.
1.2 Disconnect the plug from the wear indicator and pull the ABS sensor
out of the sensor holder, if installed.
1.3 Loosen and remove the retaining screw of the pad retainer bracket.
1.4 Pull the pad retainer bracket out of the brake calliper.
1.5 Lever out the plug of the adjuster using a screwdriver.
Hinweise:
–Use a suitable screwdriver.
–Insert the screwdriver 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.
1.6 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 serving as twist lock for the adjusting pin does not
slip out of the retaining groove. Otherwise there is a risk of the adjusting pin
also turning and destroying the protective cap!
1.7 Push the brake calliper to the rim side and take out the brake pad.
1.8 Push the brake calliper inwards and remove the brake pad together
with the pressure plate (WABCO).
Notes:
Do not apply the brake during dismantled brake pads!
Installation instructions

SK RB/RLB 9022WI with WABCO PAN 22-1 11.427GB Edition 11/09 -13 -
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).
1.9 Move the brake callipers by hand along the guide pins over their full
travel and check for ease of movement.
1.10 If the brake callipers bind, replace the guide 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)
1.12 Clean the contact surface of the brake pads.
1.13 Push the brake calliper inwards and install pressure plate (WABCO)
and new brake pad.
1.14 Push the brake calliper to the rim side and install a new brake pad.
1.15 Install the hold-down springs over brake pads and pressure plate.
1.16 Push brake pad retainer bracket into the brake calliper.
A
B
B
Installation instructions

SK RB/RLB 9022WI with WABCO PAN 22-1 11.427GB Edition 11/09 -14 -
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.
Notes:
–Use a suitable screwdriver.
–Insert the screwdriver 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 is lost, water can enter the system and cause corrosion to the
adjuster.
Caution!
After replacing the brake pads, check the proper function of the brakes
on a roller dynamometer.
Installation instructions

SK RB/RLB 9022WI with WABCO PAN 22-1 11.427GB Edition 11/09 -15 -
2.0 Replace Hub Unit SK RB INTEGRAL
2.1 Loosen and remove the mounting nuts for the brake cylinder.
2.2 Remove the 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

SK RB/RLB 9022WI with WABCO PAN 22-1 11.427GB Edition 11/09 -16 -
Axle nut wrench
W.A.F. 85 (Part No. 4 434 3828 00)
2.7 Pull the complete hub unit SK RB 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

SK RB/RLB 9022WI with WABCO PAN 22-1 11.427GB Edition 11/09 -17 -
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.
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

SK RB/RLB 9022WI with WABCO PAN 22-1 11.427GB Edition 11/09 -18 -
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. 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.
Installation instructions
Pos. 40
Pos. 56
Pos. 56.1

SK RB/RLB 9022WI with WABCO PAN 22-1 11.427GB Edition 11/09 -19 -
2.17 Tighten retaining screws (Pos. 56 and 56.1) to the prescribed torque.
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
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

SK RB/RLB 9022WI with WABCO PAN 22-1 11.427GB Edition 11/09 -20 -
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.
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.
Installation instructions