XL-SA20018UM - SAF-HOLLAND USA, Inc.
Contents
1. If necessary remove the sensor retaining spring clip from the sensor holder and replace with a new clip Figure 29 Install a new ABS sensor by pushing it directly into the sensor holder spring clip until it contacts the ABS toner ring in the hub assembly Figure 29 Re connect the ABS sensor 15 2 Hubodometer The SAF HOLLAND INTEGRAL P Spindle Disc Brake axle can be factory equipped or retrofitted with any hubodometer currently compatible with a North American standard P Spindle six bolt hub cap For information on specific hubodometer availability contact SAF HOLLAND Customer Service at 888 396 6501 15 3 Tire Inflation System SAF HOLLAND does not supply tire inflation systems However the SAF HOLLAND INTEGRAL P Spindle Disc Brake axle can be factory equipped to be compatible with many tire inflation systems currently compatible with a North American standard P Spindle six bolt hub cap This includes providing tire inflation system hubcaps that are compatible with hubodometers For information on specific Tire Inflation fitting availability contact SAF HOLLAND Customer Service at 888 396 6501 15 4 Dust Shield The SAF HOLLAND INTEGRAL Disc Brake can be factory equipped or retrofitted with a disc dust shield 1 2 3 Install the dust shield as illustrated Figure 30 Remove clamp band bolt and wrap clamp band around axle Insert clamp band bolt and tighten to 20 25 ft lbs 27 34 Nem using2. 1 5 1 Pre torque to 88 ft Ibs 120 Nem 2 Verify the pre torque of the bolts a second time and if necessary re tighten all bolts to 88 ft Ibs 120 Nem 3 Final torque from inner bolts to outer bolts to 331 22 ft lbs 450 30 Nem SAF Specific Brake Chamber Nut Brake Chamber Pre torque both chamber nuts to 60 75 ft lbs 80 100 Nem 5 8 11 UNC Nylock or M16 x 1 5 For final torque tighten both chamber nuts to 130 155 ft lbs 180 210 Nem 5 16 18 Bolt Hub Cap 12 16 ft lbs 16 22 Nem M8 x 1 25 Bolt Dust Shield Clamp 20 25 ft lbs 27 34 Nem 20 XL SA20018UM en US Rev B 2014 09 24 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF and logos are trademarks of SAF HOLLAND S A SAF HOLLAND GmbH and SAF HOLLAND Inc A SAF Routine Service Schedule SAF HOLLAND Group 17 Routine Service Schedule AWARNING Failure to inspect and maintain the AWARNING Failure to maintain the SAF HOLLAND SAF HOLLAND INTEGRAL disc brake INTEGRAL disc brake with SAF HOLLAND axle as outlined in Section 17 can result Original Parts can result in brake or wheel in brake or wheel bearing failure which bearing failure which if not avoided if not avoided could result in death or could result in death or serious injury serious injury ae NOTE Service intervals are based upon normal operations IMPORTANT Use only SAF HOLLAND Original Parts to Reduce
3. NUMBER TAG LOCATED Axle Body Part Number BETWEEN BEAMS OF EACH AXLE TUBE Model Number Serial Number Figure 2 SAF HOLLAND USA INC YATZY pesos AMMAN TIANA AAT Model XXXXXXXXXXXX Made in USA Axle Beam Rating Xx xxxIbs US and Foreign Patents Apply aa AIT TA ea XL SA20018UM en US Rev B 2014 09 24 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF and logos are trademarks of SAF HOLLAND S A SAF HOLLAND GmbH and SAF HOLLAND Inc SAF INTEGRAL Disc Brake Exploded View and Parts List SAF HOLLAND Group DESCRIPTION Bolt Hub Cap QTY AXLE 19 DESCRIPTION Cone Bearing Inner QTY AXLE Hub Cap Seal Hub Gasket Hub Cap ABS Sensor WABCO Nut Axle Pro Torg Hub with Bearing Cups Clamping Bush Bearing Cup Outer Brake Caliper Left Hand Brake Caliper Right Hand Bearing Cup Inner M18 x 1 5 Bolt Standard Cone Bearing Outer Wheel Studs M18 x 1 5 Bolt Shoulder Brake Chamber Rotor with ABS Tone Ring Brake Chamber nut Rotor Attachment Bolts Included in hub item number 5 but can be serviced Dust Shield with Clamp optional XL SA20018UM en US Rev B 2014 09 24 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF and logos are trademarks of SAF HOLLAND S A SAF HOLLAND GmbH and SAF HOLLAND
4. a 13 mm socket Figure 29 SENSOR RETAINING HOLDER SPRING CLIP i at ASA D K K fo 2 i qs H SAN Disc Brake Servicing ABS SENSOR CLAMP BAND BOLT XL SA20018UM en US Rev B 2014 09 24 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF and logos are trademarks of SAF HOLLAND S A SAF HOLLAND GmbH and SAF HOLLAND Inc A Torque Specifications SAF SAF HOLLAND Group 16 Lubrication and Torque Specifications LUBRICATION SPECIFICATION COMPONENT SURFACE TO BE LUBRICATED TORQUE VALUE Bearings and Hubs NLGI 00 Semi Fluid Grease Oil lubed bearings and hubs should remain lubricated with oil grease lubed bearings and hubs should remain lubricated with grease NOTE Intervals are based upon normal operations Reduce intervals to compensate for abnormal operations or severe conditions During inactive periods sufficient lubrication MUST be performed for equipment preservation APPLICATION TORQUE SPECIFICATIONS Pro Torg Axle Spindle Nut P Spindle Bearing System While rotating the hub torque to 500 ft Ibs 680 Nem 3 48 12 UNS 2A SAF Specific INTEGRAL Bolt Rotor Hub Torque all ten 10 bolts in a criss cross pattern M14 x 1 5 1 Pre torque to 37 ft lbs 50 Nem 2 For final torque tighten by an additional 120 turn SAF Specific Caliper Bolt Caliper Spider Torque bolts from inner bolts to outer bolts M18 x
5. bearings and level off 3 Insert the plug into the hole in the hub cap Figure 25 IMPORTANT Axles equipped with a centralized tire inflation system MUST use a vented hub cap 4 Re install wheel on hub using support device such as a wheel dolly jack Failure to support weight during installation A CAUTION or removal of brake drum could create a crush hazard which if not avoided could result in minor to moderate injury CAUTION Failure to uncage spring brakes in accordance with manufacturer s instructions after servicing is complete will prohibit proper brake function which could result in uneven brake system component wear 12 Hub Cap Installation 1 Install the hub cap assembly making sure the hub cap gasket is in place Figure 26 IMPORTANT When installing hub cap make sure the hub cap gasket is not bent or damaged IMPORTANT DO NOT over torque This can crush the hub cap gasket CAUTION Failure to avoid damaging the hub cap gasket could allow lubricant to lead which if not avoided could result in bearing failure 2 Install the six 6 bolts to secure the hub cap assembly Figure 26 Tighten bolts to 12 16 ft Ibs 16 21 Nem Figure 25 O f SU O S OIL FILL LEVEL Figure 26 HUB CAP HUB CAP BOLTS 6 XL SA20018UM en US Rev B 2014 09 24 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF and logos are trademarks of SAF HOLLAND S A SAF HOLL
6. directions while pulling outward until dial indicator does not change Figure 24 SAF HOLLAND Group Figure 22 OUTER BEARING PRO TORQ WHEEL NUT KEYWAY NO CONTACT Figure 24 DIAL INDICATOR XL SA20018UM en US Rev B 2014 09 24 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF and logos are trademarks of SAF HOLLAND S A SAF HOLLAND GmbH and SAF HOLLAND Inc SAF Disc Brake Servicing SAF HOLLAND Group d End play is the difference between reading number one and reading number two NOTE Final adjustment should allow the wheel to rotate freely with 0 001 0 003 0 03 mm 0 08 mm end play If end play is not within specification re adjustment of bearing is required IMPORTANT If end play is not within specification re adjustment is required AWARNING Failure to maintain proper hub bearing adjustment could allow bearing failure and wheel end separation which if not avoided could result in death or serious injury 11 Hub Lubrication Oil IMPORTANT DO NOT mix oil with grease If the bearing assembly has been lubricated with grease DO NOT add oil AWARNING Failure to correctly lubricate bearings could damage bearings which if not avoided could result in death or serious injury 1 Remove plug and fill the hub to the FULL mark with specified lubricant oil through the hole in the hub cap Figure 25 2 Allow the oil to flow through the
7. intervals to compensate for abnormal service the SAF HOLLAND INTEGRAL operations or severe conditions During inactive disc brake axle periods sufficient lubrication MUST be performed for equipment preservation PERIODIC CHECKS After First Every Every MILEAGE INTERVALS 3 000 Miles 20 000 Miles 50 000 Miles DLO AIS URS FA TIME INTERVALS After First Month Every 3 Months Every 6 Months VISUAL AND SAFETY INSPECTION Head Unit Check for grease leaks Inspect the brake caliper guide system Check for free movement and sliding action Refer to Section 5 3 Check rubber dust covers for cracks and damage Check adjuster cap for correct seating Refer to Section 5 3 Inspect brake pad thickness regularly Refer to Section 5 Inspect brake rotors for cracks Refer to Section 5 Perform general service maintenance inspection Refer to Section 2 Perform disc brake head unit inspection Refer to Section 5 MECHANICAL CHECK Attention Check torque of wheel nuts after the first 5 100 miles 8 160 km from date vehicle was placed into service and after every wheel removal Continually check wheel torque every 10 000 miles 16 000 km or at the intervals indicated in the vehicle owner s manual whichever occurs first SPECIAL SERVICE CONDITIONS Vehicles with long standing periods Service at specified time intervals e g Trailer used for storage or frequently left standing for several days at a ti
8. positions of the two 2 markings when the wheel MUST be removed for further inspection of wear to the brake pads and brake rotor For further inspection of the brake pads the wheel and brake pads MUST be removed Refer to the Knorr Bendix SK7 brake pad change service data sheet SD 23 7541 Air Disc Brake which can Figure 4 be found at www bendix com for more information s PERMITTED NOT PERMITTED IMPORTANT After inspecting the brake pads check that the brake system is functioning properly IMPORTANT When replacing worn brake pads ALL pads on the axle MUST be replaced If the friction material of the brake pad is less than 0 43 11 mm at its thinnest area the brake pad MUST be replaced Figure 6 NOTE Minor breakouts at the edges are permitted Major breakouts on the surface of the brake pad are NOT permitted Figure 4 El XL SA20018UM en US Rev B 2014 09 24 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF and logos are trademarks of SAF HOLLAND S A SAF HOLLAND GmbH and SAF HOLLAND Inc SAF Disc Brake Inspection SAF HOLLAND Group 5 2 Rotor Wear Inspection 1 Carefully inspect both sides of the brake rotor friction surface Figure 5 a Spider web cracking is acceptable Area A b Radial cracks less than 0 06 1 5 mm deep or wide with lengths less than 75 of the width of the rotor friction surface Area B are acceptable c Grooves in the rotor su
9. trademarks of SAF HOLLAND S A SAF HOLLAND GmbH and SAF HOLLAND Inc SAF Disc Brake Servicing SAF HOLLAND Group 3 Remove the rotor from the head unit using a size 15 mm socket to loosen and discard all ten 10 connection bolts Figure 13 4 Clean the rotor contact surface on the head unit Using compressed air clean the tapped holes in the disc unit Check to make sure the threads are undamaged 5 Attach the new rotor to the hub using ten 10 new SAF specific INTEGRAL bolts Figure 13 Using a torque wrench pre torque the bolts to 37 ft lbs 50 Nem For final torque tighten the bolts an additional 120 1 3 turn using a crisscross pattern Refer to the Torque Chart in Section 18 for more information IMPORTANT When attaching a new rotor to the head unit use only new SAF specified connection bolts Bolts MUST be clean and free from oil and grease AWARNING Failure to use only SAF specified connection bolts could cause component failure which if not avoided could result in death or serious injury 9 Hub Wheel Bolt Servicing When replacing the wheel bolts refer to the rotor removal instructions described in Section 8 NOTE NOT all bolts may need to be replaced ONLY replace bolts that are damaged or in need of replacement 1 Remove the wheel bolts by pressing them out of the head unit and discard Figure 14 2 Install new wheel bolts by pressing them into the head unit To ens
10. AND GmbH and SAF HOLLAND Inc A Disc Brake Servicing SAF SAF HOLLAND Group 13 Caliper Installation Figure 27 1 Re install the caliper onto the brake spider using four 4 SHOULDER BOLT SHOULDER STD new SAF specific brake caliper bolts Figure 27 BRAKE SPIDER BOLT INNER CALIPER a Pre torque the bolts to 88 ft Ibs 120 Nem from inner bolts to outer bolts using a size 24 mm socket b Verify the pre torque of the bolts a second time and if necessary re tighten all bolts to 88 ft lbs 120 Nem c Final torque from inner bolts to outer bolts to 331 22 ft lbs 450 30 Nem NOTE The caliper is connected to the disc brake spider using four 4 SAF specific bolts three 3 standard bolts and one 1 shoulder bolt Figure 27 The shoulder bolt is located at the top mounting hole whether the caliper is installed forward or rearward of the axle IMPORTANT Make sure that the brake caliper is mounted on the correct side of the axle The correct position can be identified by the lengths of the guide pins on the caliper unit The longer guide pins should be positioned ROTOR ROTATIO on the bottom of the caliper unit when installed rear of the axle and on top when forward of the axle Figure 28 Figure 28 2 Re install the SAF brake chamber by following the sc SHORT GUIDE RIN instructions in SAF Brake Chambers Installation and Service Guide XL SA10062IM en US available on the a internet at www s
11. EXICO 52 55 5362 8743 Fax 52 55 5362 8743 www safholland com mx info safholland com SAF HOLLAND USA INC A li 1950 Industrial Blvd Muskegon MI 49442 SA lolland www safholland com m Engineering Your Road to Success XL SA20018UM en US Rev B 2014 09 24 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF and logos are trademarks of SAF HOLLAND S A SAF HOLLAND GmbH and SAF HOLLAND Inc
12. Inc A Disc Brake Inspection SAF SAF HOLLAND Group 5 Disc Brake Inspection Figure 3 IMPORTANT During removal inspect components for wear and replace worn components AWARNING Failure to properly support axle during maintenance could allow axle to fall which if not avoided could result in death or serious injury NOTE For further disc brake inspection information refer Q to the latest version of the TMC recommended a A Jy practice RP 652 Service and Inspection of Air Disc eZ NOS N dA YES Brakes TMC DVD supplement 5 1 Pad Wear Inspection Check the brake pads for proper thickness at regular service intervals based on vehicle usage Brake pad inspections should be carried out at least every three 3 months or 20 000 miles whichever comes first and in accordance with any legal requirements Refer to Routine Service Schedule in Section 17 NOTE Regular service intervals may be required more frequently for severe duty applications Refer to Section 17 CALIPER CALIPER MARKING MARKING A quick visual inspection of the condition of the brake pads can be performed without removing the wheel 1 Compare the position of the caliper marking to the carrier marking located on the underside of the caliper unit Figure 3 CARRIER CARRIER i ve MARKING MARKING a Figure 3 View A shows the positions of the two 2 markings when the brake pads are in good condition b Figure 3 View B shows the
13. SAF SAF HOLLAND Group Service Manual XL SA20018UM en US Rev B SAI SAF Contents SAF HOLLAND Group Contents Page Contents Page MEOCUCUONis shan crores stata aini 3 Section 8 Rotor Replacement ses 12 Wara e estan mee 3 Section 9 Hub Wheel Bolt Servicing n se 13 Notes Cautions and Warnings seeen 3 Section 10 Seal Bearing and Hub Installation 14 Section 1 General Safety Instructions scenen 4 Section 11 Hub Lubrication Oil 17 Section 2 General Service and Maintenance Instructions 5 Section 12 Hub Cap Installation secs 17 Section 3 Model Identification 6 Section 13 Caliper Installation 18 Section 4 Identification Tag senere 6 Section 14 Brake Caliper Servicing sees 19 INTEGRAL Disc Brake Exploded View and Parts List 7 Section 15 Disc Brake Options ener 19 Section 5 Disc Brake Inspection sees 8 Section 16 Lubrication and Torque Specifications 20 Section 6 Bearing Hub Bearing and Seal Removal 10 Section 17 Routine Service Schedule screen 21 Section 7 Bearing INSPeCtiONn 0 ee rener 12 Section 18 Troubleshooting Chart 22 Introduction Warranty This manual provides the necessary information for the maintenance inspection and safe operation of the SAF INTEGRAL disc brake system with P89 spindle Knorr Bendix is the manufacturer of the disc brake caliper assembly described in this service manua
14. afholland us Q eM DRIVING DIRECTION 3 Re install the ABS sensor by following the instructions detailed in Section 15 1 LONG GUIDE PIN 4 To enable the ABS sensor to function properly press the ABS sensor against the ABS toner ring at the hub unit to eliminate any clearance between these parts IMPORTANT After replacing the rotor verify that the brake system is functioning properly AWARNING Failure to verify brake system function after rotor replacement could result in brake malfunction which if not avoided could result in death or serious injury 18 XL SA20018UM en US Rev B 2014 09 24 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF and logos are trademarks of SAF HOLLAND S A SAF HOLLAND GmbH and SAF HOLLAND Inc SAF SAF HOLLAND Group 14 Brake Caliper Servicing For instructions on brake caliper and repair replacement refer to the Knorr Bendix SK7 Caliper service data sheet SD 23 7541 Air Disc Brake which can be found on the internet at www bendix com 15 Disc Brake Options 15 1 ABS Sensor 5 NOTE When replacing the ABS sensor DO NOT mix sensors from different manufacturers Only install a sensor manufactured by WABCO For further ABS sensor information contact SAF HOLLAND Customer Service at 888 396 6501 Disconnect the ABS sensor Remove the ABS sensor from the sensor holder by pulling it straight out from the holder and discard Figure 29
15. als 10 1 Spindle mounted wheel seal Installation instructions Refer to 10 2 for hub mounted wheel seal instructions Figure 17 Before installing the wheel seal on the axle spindle inspect the machined spindle seal surface for nicks scratches burrs or marks If needed use crocus cloth or emery cloth to repair any damaged areas 2 Clean the threads and keyway thoroughly with a wire brush to avoid false bearing adjustments and to avoid introduction of contaminants into the lubricant cavity 3 Thoroughly clean the spindle and spindle threads of rust dirt grease or any other contaminants that could damage the hub seal and cause it to leak CAUTION NEVER install a spindle mounted wheel seal in the hub and then force it onto the axle spindle by tightening the axle nut Damage to seal will result CAUTION To avoid damaging the seal support the hub against the spindle inner shoulder until the outer bearing and adjusting nut are installed Apply a thin layer of sealant to the O D of the spindle Figure 18 shoulder Place the wheel seal on the spindle with the side labeled oil bearing side facing out towards the end of the spindle Figure 16 S Seat wheel seal into place using a hub seal installation tool and DISC HEAD UNIT INNER BEARING Le hammer Rotate the wheel seal installation tool 1 4 turn with NY every hammer tap until the seal is properly seated with the metal face of the seal flush with the inner s
16. ction or obstruction or replace hoses Brake control valve restricted inoperable Brake out of adjustment Repair replace control valve Adjust brake repair or replace automatic adjustment device as necessary Damaged brake chamber Replace brake chamber Damaged brake assembly Replace or repair brake assembly Dragging Brakes Slow brake application or release timing Brake hoses restricted Relieve restriction or obstruction or replace hoses Brake control valve restricted inoperable Repair replace control valve Brake out of adjustment Adjust brake repair or replace automatic adjustment device as necessary Damaged brake chamber Replace brake chamber Damaged brake assembly Replace or repair brake assembly Dog Tracking Uneven tire wear Axle not properly aligned Align axle Slider assembly racked or not aligned properly Repair or replace slider assembly Frame bent or not aligned properly Repair or align frame Damaged suspension component Repair or replace suspension component Bent axle Improper tire inflation Replace axle Inflate tire to proper pressure Loose wheel stud nuts Inspect for and repair any resultant wheel end damage and tighten properly Improper wheel bearing adjustment Axle not properly aligned Inspect for and repair any resultant wheel end damage and adjust properly Align axle Slider assembly racked or not a
17. demarks of SAF HOLLAND S A SAF HOLLAND GmbH and SAF HOLLAND Inc SAF General Service and Maintenance SAF HOLLAND Group 2 General Service and Maintenance Instructions 1 Conduct regular visual checks of the brakes tires and all chassis components Refer to Section 17 for more information m Inspect for secure mounting wear leaks corrosion and damage m Check for loose broken or cracked air hoses air system leaks and damaged components m Check that brake hoses and cables are properly secured m For proper brake pad wear check that there is enough clearance to allow the caliper full movement during normal operation 2 Check the brake pads at regular service intervals to ensure that the brake pad hold down springs are in the correct position and that brake pads are not worn beyond the minimum wear limits described in this manual 3 When replacing brake pads inspect the rotors for signs of wear cracks grooves scoring or hot spots 4 Visually check the brake caliper at regular service intervals as defined by the brake caliper manufacturer s basic inspection program Refer to Section 5 3 of this manual for further information 5 Check the spring brake chambers to make sure the parking springs are NOT caged in the released position Be sure the dust plugs are properly installed 6 Make sure that the vent holes in the air brake chamber are not covered with snow ice mud etc 7 Inspect the wh
18. eel bearing unit for grease leaks at every brake pad change 8 Visually check the brake assembly e g pads rotor etc for oil or grease contamination 9 Check that all dust caps and boots are present and in good condition 10 Regularly conduct general safety checks in accordance with any applicable laws 11 After every wheel change the wheel nuts MUST be re tightened to the specified torque level after the initial 100 miles of operation and then at every regular service interval Failure to re tighten wheel nuts at CAUTION oe i specified intervals could result in component failure which if not avoided could result in damage to property IMPORTANT Use only SAF HOLLAND Original Parts to service the SAF HOLLAND INTEGRAL disc brake axle XL SA20018UM en US Rev B 2014 09 24 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF and logos are trademarks of SAF HOLLAND S A SAF HOLLAND GmbH and SAF HOLLAND Inc A Model Identification SAF SAF HOLLAND Group 3 Model Identification Figure 1 The disc brake axle serial tag is located near the center of the axle tube Figure 1 4 Identification Tag The sample tag shown will help interpret the information on the SAF HOLLAND USA Inc serial number tag The model number axle body part number and serial number are listed on the tag Figure 2 Record the tag numbers below for future quick reference SERIAL
19. ervicing or operation leading to component failure which if not avoided could result in death or serious injury m All maintenance should be performed by a properly trained technician using proper special tools and safe procedures NOTE In the United States workshop safety requirements are defined by federal and or state Occupational Safety and Health Act OSHA Equivalent laws may exist in other countries This manual is written based on the assumption that OSHA or other applicable employee safety regulations are followed by the location where work is performed m Properly support and secure the vehicle from unexpected movement when servicing the unit AWARNING Failure to properly support and secure the vehicle and axles prior to commencing work could create a crush hazard which if not avoided could result in death or serious injury m Several maintenance procedures in this manual require re positioning of the brake chamber brake calipers and or ABS system Consult the manufacturer s manual for procedures on the proper operation of brake chamber brake calipers and or ABS system m Service both roadside and curbside of an axle Worn parts should be replaced in sets Key components on each axle s braking system such as friction material and rotors will normally wear over time IMPORTANT Key components on each axle s braking system including brake pads and brake rotors are intended to wear over time Worn parts sh
20. ged by different stress fields during cooling m Observe the operating recommendation of the trailer manufacturer for off road operation of the installed axles IMPORTANT The definition of OFF ROAD means driving on non asphalt non concrete routes e g gravel roads agricultural and forestry tracks on construction sites and in gravel pits IMPORTANT Off road operation of axles beyond the approved application design could result in damage and impair suspension system performance m SAF axles require routine service inspection and maintenance in order to maintain optimum performance and operational safety as well as an opportunity to recognize natural wear and defects before they become serious Refer to the Routine Service Schedule in Section 17 AWARNING Failure to inspect and maintain the SAF HOLLAND INTEGRAL disc brake axle as outlined in Section 17 can result in brake or wheel bearing failure which if not avoided could result in death or serious injury IMPORTANT Use only SAF HOLLAND Original Parts to service the SAF HOLLAND INTEGRAL disc brake axle AWARNING Failure to maintain the SAF HOLLAND INTEGRAL disc brake with SAF HOLLAND Original Parts can result in brake or wheel bearing failure which if not avoided could result in death or serious injury eal XL SA20018UM en US Rev B 2014 09 24 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF and logos are tra
21. houlder of the axle spindle Figure 17 Clean and remove any excess sealant OUTER P Fig y BEARING CUP L HUB SEAL INSTALLATION TOOL BP DISC SPIDER al 6 Prepare the hub Remove the old lube and thoroughly clean the hub cavity and hub bore If needed use emery cloth to remove any burrs or old bore sealant Inspect the hub bore for damage Replace if necessary INNER BEARING CUP 7 Install new inner and outer bearing cups into the hub as necessary Figure 18 14 XL SA20018UM en US Rev B 2014 09 24 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF and logos are trademarks of SAF HOLLAND S A SAF HOLLAND GmbH and SAF HOLLAND Inc SAF Disc Brake Servicing SAF HOLLAND Group 8 Install inner bearing on spindle Figure 18 NOTE If using oil for lubrication coat bearings with oil before installation Refer to Section 11 for proper wheel end oil lubrication instructions Figure 18 CAUTION Failure to lubricate bearing correctly and maintain proper lubrication could result in bearing damage NOTE If using grease and NOT oil for hub lubrication the inner and outer bearing and the hub cavity MUST be pre packed with grease before installation Lubricate wheel end components with grease specified in Section 16 9 Lubricate inside of hub cavity and install on spindle Figure 18 NOTE Be sure wheel seals are properly installed before performing the
22. hub bearing adjustment procedure 10 2 Hub Mounted Wheel Seal Installation Instructions 1 Remove all burrs from the hub bore and spindle Thoroughly clean hub cavity and spindle NOTE DO NOT apply any sealant to the spindle shoulder 2 Place the hub on a smooth hard surface in a horizontal position Pre lube the inner bearing and place it into the hub bearing cup Figure 19 NOTE When using grease pre pack the inner bearing before placement into the hub 3 Place the wheel seal on the installation tool make sure that the words oil bearing side faces the inner bearing Position the tool with the seal correctly mounted in the tool head into the hub bore Use a three to five pound hammer to drive against the end of the tool Drive seal into bore until complete bottoming is assured Figure 20 Remove the installation tool and apply a thin layer of lubricant on the I D surface of the seal NOTE DO NOT apply lubricant to the O D of the seal 4 Gently push the head unit onto the spindle to the proper position Fill the hub cavity with lubricant until it runs over the outer bearing cup Coat the outer bearing with lubricant and place the outer bearing on the spindle and into the bearing cup Figure 21 NOTE When using grease pre pack the hub cavity The grease fill amount should be to a 3 o clock and 9 o clock level This is to ensure a 50 hub cavity fill Use a template to hold grease in place while filling the h
23. l not SAF HOLLAND This manual references service documents which are published by Knorr Bendix The latest versions can be found on the website at www bendix com These document references are intended to provide additional information when performing service work on the caliper assembly SAF HOLLAND assumes no liability for the use of incorrect or unsuitable parts in the servicing or repair of the Knorr Bendix disc brake caliper assembly SAF HOLLAND assumes no liability for damages or claims arising out of incorrectly following procedures outlined in the Knorr Bendix service manuals Knorr and Bendix are registered trademarks of the Knorr Bremse Group Read this manual before using or servicing this product and keep it in a safe location for future reference Updates to this manual which are published as necessary are available on the internet at www safholland us When replacement parts are required SAF HOLLAND highly recommends the use of only SAF HOLLAND Original Parts A list of technical support locations that supply SAF HOLLAND Original Parts and an Aftermarket Parts Catalog are available on the internet at www safholland us or contact Customer Service at 888 396 6501 Refer to the complete warranty for the country in which the product will be used A copy of the written warranty is included with the product or available on the internet at www safholland com Notes Cautions and Warnings Before starting any work
24. ligned properly Repair or replace slider assembly Frame bent or not aligned properly Repair or align frame Damaged suspension component Repair or replace suspension component Bent axle Replace axle Mismatched tire sizes Properly match tire sizes Unequal brake balance or timing Repair brakes as necessary Overly aggressive braking Instruct train driver in proper brake use High speed turns Instruct train driver in proper vehicle speeds High level of side scrub Instruct train driver in proper vehicle maneuvering Anti Lock Brake System malfunction Refer to ABS manufacturer s service literature XL SA20018UM en US Rev B 2014 09 24 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF and logos are trademarks of SAF HOLLAND S A SAF HOLLAND GmbH and SAF HOLLAND Inc SAF Troubleshooting SAF HOLLAND Group PROBLEM POSSIBLE CAUSE Grabbing brakes Contaminants on brake lining POSSIBLE REMEDY Replace brake pads Brake out of adjustment Adjust brake repair or replace automatic adjustment device as necessary Warped brake rotor Machine or replace brake rotor Damaged brake chamber Replace brake chamber Damaged brake assembly Replace or repair brake assembly Unequal brake balance or timing Repair brakes as necessary Anti Lock Brake System malfunction Refer to ABS manufacturer s service
25. literature Excessive heat cracks in rotor Brake out of adjustment Adjust brake repair or replace automatic adjustment device as necessary Overly aggressive braking Instruct train driver in proper brake use Unequal brake balance or timing Repair brakes as necessary Anti Lock Brake System malfunction Refer to ABS manufacturer s service literature Damaged brake chamber Replace brake chamber Damaged brake assembly Replace or repair brake assembly XL SA20018UM en US Rev B 2014 09 24 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF and logos are trademarks of SAF HOLLAND S A SAF HOLLAND GmbH and SAF HOLLAND Inc Fal olang ORIGINAL PARTS From fifth wheel rebuild kits to suspension bushing repair kits SAF HOLLAND Original Parts are the same quality components used in the original component assembly SAF HOLLAND Original Parts are tested and designed to provide maximum performance and durability Will fits look alikes or worse yet counterfeit parts will only limit the performance potential and could possibly void SAF HOLLAND s warranty Always be sure to spec SAF HOLLAND Original Parts when servicing your SAF HOLLAND product SAF HOLLAND USA 888 396 6501 Fax 800 356 3929 www safholland us SAF HOLLAND CANADA 519 537 3494 Fax 800 565 7753 WESTERN CANADA 604 574 7491 Fax 604 574 0244 www safholland ca SAF HOLLAND M
26. me Vehicles used under severe duty and Service at suitably reduced intervals e g Trailer operating in continuous multi shifts or in extreme conditions off road construction sites XL SA20018UM en US Rev B 2014 09 24 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF and logos are trademarks of B SAF HOLLAND S A SAF HOLLAND GmbH and SAF HOLLAND Inc Troubleshooting SAF SAF HOLLAND Group 18 Troubleshooting Chart SAF HOLLAND suspensions equipped with disc brake axles PROBLEM Brakes will not release POSSIBLE CAUSE Disc brake caliper bound up POSSIBLE REMEDY Lubricate or replace brake caliper Brake hoses restricted Brake control valve restricted inoperable Replace hoses Repair replace control valve Brake out of adjustment Adjust brake repair or replace automatic adjustment device as necessary Damaged brake chamber Replace brake chamber Damaged brake assembly Replace or repair brake assembly Supply air interrupted Open glad hand cut out cock or push brake control valve in Supply line improperly coupled Properly couple supply air line Brake pads frozen to rotor in cold weather Warm brakes No brakes or insufficient brake performance Service air interrupted Open glad hand cut out cock Service air line improperly coupled Properly couple service air line Brake hoses restricted Relieve restri
27. on the unit read and understand all the safety procedures presented in this manual This manual contains the terms NOTE IMPORTANT CAUTION and WARNING followed by important product information These terms are defined as follows NOTE Includes additional information to enable accurate and easy performance of procedures IMPORTANT Includes additional information that if not followed could lead to hindered product performance CAUTION Used without the safety alert symbol indicates a potentially hazardous situation which if not avoided could result in property damage ACAUTION Indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury XL SA20018UM en US Rev B 2014 09 24 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF and logos are trademarks of SAF HOLLAND S A SAF HOLLAND GmbH and SAF HOLLAND Inc General Safety SAF 1 General Safety Instructions General and Servicing Safety Instructions m Read and observe all Warning and Caution hazard alert messages The alerts provide information that can help prevent serious personal injury damage to components or both AVWARNING Failure to follow the instructions and safety precautions in this manual could result in improper s
28. otor BRAKE CALIPER BOLTS 4 2 Remove wheels from hub using support device such as a wheel dolly ACAUTION Failure to support weight during installation or removal of wheels could create a crush hazard which if not avoided could result in minor to moderate injury 3 Remove the ABS sensor by following the instructions BRAKE CALIPER detailed in Section 15 1 4 Detach the brake chamber from the brake caliper by loosening and removing the two 2 mounting nuts Figure 7 5 Remove the brake caliper from the brake spider by using a size 24 mm socket to loosen Discard all four 4 brake caliper bolts Figure 8 10 XL SA20018UM en US Rev B 2014 09 24 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF and logos are trademarks of SAF HOLLAND S A SAF HOLLAND GmbH and SAF HOLLAND Inc SAF Disc Brake Servicing SAF HOLLAND Group 6 With a 1 2 socket remove the six 6 hub cap bolts and Figure 9 the hub cap Figure 9 IMPORTANT The red dot in the middle of the SAF plastic hub cap is permanent and MUST NOT be removed HUB CAP NOTE Be prepared to collect lubrication fluid when HUB CAP removing hub cap BOLTS 6 7 Utilizing a screwdriver carefully pry the orange keeper arm from the undercut groove on each side of the Pro Torq wheel nut until the keeper is released from it Figure 10 8 Using a standard 4 13 16 P Spindle wheel nut socket remove the axle s
29. ould be replaced in sets on both the driver and curb side of an axle AWARNING Failure to follow manufacturer s instructions regarding spring pressure or air pressure control could allow uncontrolled release of energy which if not avoided could result in death or serious injury m The wheel contact surfaces between the wheel and hub MUST NOT receive additional paint IMPORTANT The wheel contact surfaces MUST be clean smooth and free from grease AWARNING Failure to keep wheel and hub contact surfaces clean and clear of foreign material could allow wheel hub separations which if not avoided could result in death or serious injury SAF HOLLAND Group m Only the wheel and tire sizes approved by the trailer builder can be used Operational and Road Safety Instructions m Before operating vehicle ensure that the maximum permissible axle load is not exceeded and that the load is distributed equally and uniformly m Make sure that the brakes are not overheated from continuous operation AWARNING Failure to minimize the use of brakes during overheating conditions could result in deterioration of brake efficiency which could result in death or serious injury m The parking brake MUST NOT be immediately applied when the brakes are overheated Refer to the rotor wear inspection information in Section 5 2 CAUTION If the parking brake is immediately applied to the brakes when overheated the brake discs could be dama
30. pindle nut Pro Torq by rotating the nut in a counter clockwise direction Figure 10 NOTE All axle nuts on SAF HOLLAND INTEGRAL P89 Disc Brake Axles are right hand threaded 9 Remove the outer hub bearing from the spindle Figure 10 Figure 10 NOTE With the Pro Torg nut removed it is possible to access the outer bearing ACAUTION DO NOT hit steel parts with a steel hammer as parts could break sending flying steel fragments in any direction creating a hazard which if not avoided could result in minor to moderate injury 10 Grasp the head unit with both hands and pull the head unit off the axle spindle Figure 11 NOTE Depending on type of hub seal the hub seal and inner bearing may remain on spindle or come off with the head unit Figure 11 XL SA20018UM en US Rev B 2014 09 24 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF and logos are trademarks of SAF HOLLAND S A SAF HOLLAND GmbH and SAF HOLLAND Inc Disc Brake Servicing SAF 11 Remove the inner hub bearing from the spindle or from the inside of the hub Figure 12 12 The spindle mount hub seal can be driven off the spindle by striking the ring from the back side or prying off with a crow s foot bar Be careful not to gouge the spindle shoulder Discard the used seal A new seal is required when re assembled Figure 12 CAUTION DO NOT use a chisel to cut the seal The shoulde
31. r can be damaged resulting in a leak which if not avoided could lead to wheel end and or brake failure 7 Bearing Inspection CAUTION Thoroughly clean bearings DO NOT mix a synthetic base grease or oil with an organic mineral base lubricant CAUTION DO NOT dry hub bearings with compressed air Bearing damage could result 1 After removing the head unit clean excess grease from the bearings IMPORTANT A bearing which has been removed from a vehicle should be cleaned with solvent NEVER use steam or water which will rust bearings IMPORTANT Bearings that are rusted flaked pitted or have damaged cages should be replaced It is recommended to replace all questionable bearings and ALWAYS replace the cup and cone as a matched set IMPORTANT NEVER re assemble a tapered roller bearing in a damaged or worn bearing cup or spindle Bearing cup or spindle should be replaced and NOT re machined if damaged or worn 8 Rotor Replacement AWARNING Failure to follow these instructions could cause component failure which if not avoided could result in death or serious injury 1 Remove the ABS sensor by following the instructions detailed in Section 15 1 2 Remove the head unit refer to Section 6 instructions SAF HOLLAND Group Figure 12 HUB SEAL INNER HUB BEARING 112 XL SA20018UM en US Rev B 2014 09 24 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF and logos are
32. rface are acceptable only if they are less than 0 06 1 5 mm deep Area C d Cracks that run completely to either edge of the hub are NOT acceptable regardless of depth Area D 2 Measure the brake rotor thickness and re surface if necessary For proper brake function the minimum thickness for re surfacing the brake rotor is defined as 1 54 1 57 39 40 mm AVWARNING Re surfacing the brake rotor beyond the minimum thickness could cause component failure which if not avoided could result in death or serious injury IMPORTANT DO NOT use high pressure cleaners or liquid cleaners on the brake rotor If the overall wear limits for the brake rotor or brake pads are exceeded Figure 6 the rotor and pads MUST be replaced Refer to rotor replacement instructions as detailed in Section 8 For brake pad replacement refer to instructions available on the Knorr Bendix website For both the inner and outer pads the maximum brake pad wear difference is 0 2 5 0 mm BRAKE ROTOR BRAKE PAD ug u p DIAMETER WEAR LIMIT WEAR LIMIT AWARNING Failure to replace brake rotor and pads when minimum wear limits are reached could cause component failure which if not avoided could result in death or serious injury NOTE When replacing the brake pads or brake rotor use only Original SAF HOLLAND rotors and approved brake pads IMPORTANT When replacing worn brake pads ALL pads on the axle MUST be replaced NOTE D
33. ub cavity Figure 21 CAUTION DO NOT ram the hub into the spindle bearing shoulder This could damage the wheel seal Figure 19 INNER BEARING HUB BEARING CUP DISC HEAD UNIT DISC HEAD UNIT Figure 21 PRE PACK HUB CAVITY WITH GREASE PRE PACK OUTER GREASE LEVEL TEMPLATE XL SA20018UM en US Rev B 2014 09 24 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF and logos are trademarks of SAF HOLLAND S A SAF HOLLAND GmbH and SAF HOLLAND Inc Disc Brake Servicing SAF 5 Install outer bearing on spindle 6 Install the Pro Torg wheel nut onto the spindle threads Figure 22 7 Adjust the bearing using the Pro Torg axle nut a an m o Q p Use a screwdriver to carefully pry the keeper arm from the undercut groove on each side until the keeper is released Seat the bearing Using a torque wrench tighten the nut to 200 ft Ibs 271 Nem and spin the wheel at least one 1 full rotation PERFORM THIS STEP THREE 3 TIMES Back the nut off until it is loose Adjust the bearing Using a torque wrench tighten the nut to 100 ft Ibs 137 Nem Spin the wheel at least one 1 full rotation PERFORM THIS STEP THREE 3 TIMES Back the nut off one raised face mark 1 8 of a turn Install the keeper with orange side facing out by inserting the keeper tab into the undercut groove of the nut and engage the keyway tang in the axle ke
34. ure correct alignment of the bolts during installation position the flat side of each wheel bolt head so that it is facing the center of the hub Figure 15 ACAUTION DO NOT hit steel parts with a steel hammer as parts could break sending flying steel fragments in any direction creating a hazard which if not avoided could result in minor to moderate injury Figure 13 oi I L SS Ze HEAD UNIT Figure 14 WHEEL BOLTS 10 HEAD UNIT FLAT SIDE OF BOLT HEAD WHEEL BOLTS TEN 10 Sp LTE ASE XL SA20018UM en US Rev B 2014 09 24 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF and logos are trademarks of SAF HOLLAND S A SAF HOLLAND GmbH and SAF HOLLAND Inc A Disc Brake Servicing SAF SAF HOLLAND Group 10 Seal Bearing and Hub Installation Figure 16 and Adjustment AXLE SPINDLE INNER SHOULDER IMPORTANT DO NOT mix oil and grease wheel end lubricants Although all SAF HOLLAND P89 INTEGRAL Disc Brake wheel ends are factory lubricated with NLGI 00 semi fluid grease HUB SEAL wheel end can be serviced with oil or grease Before servicing the SAF HOLLAND P89 wheel end with oil all grease MUST be cleaned with appropriate solvent from the bearings and hub KEYWAY NOTE Athough all SAF HOLLAND P89 INTEGRAL Disc Brake wheel ends are manufactured with spindle mounted wheel seals they can be serviced with either spindle or hub mounted se
35. uring brake repairs conduct a visual inspection of the seals on the brake caliper Refer to Section 5 3 for more information Figure 5 FRICTION Figure 6 0 06 1 5 MM MAX DEPTH XL SA20018UM en US Rev B 2014 09 24 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF and logos are trademarks of SAF HOLLAND S A SAF HOLLAND GmbH and SAF HOLLAND Inc A Disc Brake Servicing SAF SAF HOLLAND Group 5 3 Brake Caliper Inspection Figure7 For instructions on brake caliper inspection and repair refer to the Knorr Bendix SK7 Caliper service data sheet SD 23 7541 Air Disc Brake which can be found at www bendix com BRAKE CHAMBER 6 Standard Bearing Hub Bearing and Seal Removal NOTE Before beginning any axle brake service procedures park the vehicle on a level surface Block the wheels to prevent the vehicle from moving Support the vehicle and axles s with safety stands DO NOT work under a vehicle supported only by jacks Jacks can slip or fall over Serious personal injury and damage to components can result AWARNING Failure to properly support the vehicle and axles prior to commencing work could create a crush hazard which if not avoided could result in death or serious injury 1 Release the trailer brakes and cage the spring brakes according to the spring brake manufacturer s instructions Remove the tire and wheel assembly to access hub and r
36. yway Insert keeper tab with bent legs facing out Engage the mating teeth of the keeper with the teeth of the wheel nut Compress and insert the keeper arms one at a time into the undercut groove with a screwdriver i If the keeper teeth DO NOT line up with teeth in nut loosen the nut slightly until they engage IMPORTANT DO NOT tighten nut to align teeth CAUTION Failure to properly tighten nut could j result in bearing damage which if not avoided could result in bearing failure Using a dial indicator verify that end play reading is 001 0 03 mm to 003 0 08 mm Re adjust bearing if necessary 8 Make sure that the keeper tab and keeper arms are fully seated into the undercut groove Inspect the keyway tang to ensure it does not contact the bottom of the keyway Figure 23 If contact exists immediately notify a Pro Torq representative AWARNING Failure to ensure that the keeper is properly installed could cause wheel separation which if not avoided could result in death or serious injury 9 Check the wheel bearing end play as follows a Attach the magnetic base of a dial indicator to the spindle Touch dial indicator stem to hub cap gasket face Figure 24 Reading Number One Slightly rotate wheel end in both directions while pushing inward until dial indicator does not change Set the dial indicator to zero Figure 24 Reading Number Two Slightly rotate hub in both
Download Pdf Manuals
Related Search