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INTEGRAL® Disc Brake Axles Service Manual

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Contents

1. 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 MEXICO 52 55 5362 8743 Fax 52 55 5362 8743 www safholland com mx info safholland com SAF HOLLAND USA INC A i 1950 Industrial Blvd Muskegon MI 49442 SA TE www safholland com mm Engineering Your Road to Success XL SA100590M en US Rev E 2014 07 25 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
2. Replace or repair brake assembly Dog tracking Axle not properly aligned Slider assembly racked or NOT aligned properly Align axle 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 Uneven tire wear Improper tire inflation 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 Inspect for and repair any resultant wheel end damage and adjust properly 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 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 High level of side scrub Instruct train driver in proper vehicle speeds Instruct train driver in proper vehicle maneuvering Anti Lock Brake System malfunction Refer to ABS manufacturer s service literature XL SA100590M en US Rev E 2014 07 25 and Amendme
3. Customer Service at 888 396 6501 before performing any work on the SAF HOLLAND INTEGRAL disc brake hub unit IMPORTANT Only qualified mechanics should perform the procedures detailed in this manual NOTE If the seal between the axle spindle and spindle nut is broken before the end of the stated warranty period all warranty coverage will be invalidated unless the repair work has been approved by SAF HOLLAND For approval contact Customer Service at 888 396 6501 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 ACAUTION 2 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 NOTE For certain service and repair work some bolts MUST be replaced DO NOT oil or grease bolts for installation Tighten bolts with a torque wrench following the specified procedure and torque value Refer to Torque Chart in Section 11 9 1 Brake Pad Replacement For instructions on brake replacement refer to the Knorr Bendix SK7 Caliper service data sheet SD 23 7541 Air Disc Brake which can be found at www bendix com IMPORTANT After inspecting the brake pads check that the brake system is functioning properly
4. improper servicing 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 f possible unload the trailer before performing any service procedures m After pre positioning the brake chamber slack adjuster and or ABS system as instructed in this manual always consult the manufacturer s manual for proper operation 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 rotors and drums will normally wear over time m DO NOT paint the wheel contact surfaces between the wheel and hub IMPORTANT The wheel contact surfaces MUST be clean smoo
5. the roadside of the axle and a right hand thread on the curbside of the axle The axle nut with a left handed thread can be identified by a circular groove Figure 13 The left hand threaded axle spindle can be identified by a frontal groove on the end of the axle spindle 4 Clean the surface of the axle nut Attach the magnetic foot of the dial gauge to the surface of the nut and spindle Place the pointer on the rim surface as shown Figure 7 Figure 8 i i ROTATE WHEEL 5 Rock the wheel by first pulling at the top and pressing at FAST AND SLOW the bottom then pulling at the bottom and pressing at the top Push and pull with approximately 50 Ibs 220 N of force While rocking moving the wheel record the end play shown on the dial gauge NOTE Rotate the wheel several times before each N AXLE NUT measurement NOTE If a recorded wheel end play of more than 01 0 25 mm while alternating 50 Ibs 220 N force is measured the hub unit MUST be replaced 7 Wheel Bearing Noise Test 1 For sufficient clearance to perform the test raise the wheel off the ground DO NOT remove the wheel 2 Carefully remove the hub cap 3 Using a size 85 mm socket check the torque of the axle nut to ensure that it is torqued to 663 ft lbs 900 Nem 4 Rotate the wheel in both forward and rearward directions using varying speeds Figure 8 5 If the bearing feels rough and or a grinding noise is heard the h
6. IMPORTANT After replacing the rotor verify that the brake system is functioning properly 9 3 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 at www bendix com SAF HOLLAND Group Figure 19 ROTOR ROTATION Te SHOULDER BOLT IN OUTER MOUNTING HOLE DRIVING DIRECTION a Figure 20 SHORT GUIDE PIN J m la U I GUIDE PIN ROADSIDE CURBSIDE Figure 21 DRIVING DIRECTION 16 XL SA100590M en US Rev E 2014 07 25 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 Servicing the Disc Brake Hub Unit SAF HOLLAND Group 9 4 Hub Unit Servicing The SAF HOLLAND disc brake hub unit with compact bearing system is designed to be maintenance free If there is a malfunction with the hub unit the hub unit including the compact bearing system MUST be replaced The integrated compact bearing system is lifetime sealed and requires no grease or oil application to the bearing IMPORTANT DO NOT remove the integrated compact bearing system If there is a malfunction the bearing system a
7. IMPORTANT When replacing worn brake pads all pads on the axle MUST be replaced SAF HOLLAND Group 12 XL SA100590M en US Rev E 2014 07 25 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 Servicing the Disc Brake Hub Unit SAF HOLLAND Group 9 2 Rotor Replacement AWARNING Failure to observe these instructions could cause component failure which if not avoided could result in death or serious injury 1 Cage the spring brake 2 Remove the ABS sensor by following the instructions detailed in Section 10 1 3 Remove the brake chamber from the brake caliper by loosening and removing the two 2 mounting nuts Figure 11 4 Remove the brake caliper from the brake spider by using a size 24 mm socket to loosen and discard all four 4 brake caliper bolts Figure 12 5 Using a hub cap puller remove the plastic hub cap Figure 13 at the reinforced undercut on the side of the cap IMPORTANT The red dot in the middle of the SAF plastic hub cap is permanent and MUST NOT be removed 6 Using a size 85 mm socket remove the axle spindle nut by rotating the nut in either a left or right handed direction respectively for the road or curbside of the axle NOTE The SAF compact bearing system uses a single piece spindle nut which has a left hand thread on the roadside of the axle a
8. SA100590M en US Rev E 2014 07 25 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 Hub Unit Inspection SAF HOLLAND Group 5 3 Brake Caliper Inspection 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 5 4 Hub Unit Inspection The SAF HOLLAND disc brake hub unit with compact bearing system is designed to be maintenance free If there is a malfunction with the hub unit the hub unit including the compact bearing system MUST be replaced The integrated compact bearing system is sealed and requires no additional grease or oil application to the bearing IMPORTANT DO NOT remove the integrated compact bearing system If there is a malfunction the bearing system and hub unit MUST be replaced 1 When changing brake pads and rotors or in the event of damage e g brake overheating inspect the bearing for signs of wear and grease leakage Perform the Grease Leak Inspection Wheel Rock Test and Wheel Bearing Noise Test as described in Sections 6 through 8 AWARNING Failure to replace bearing system and hub unit when required could cause component failure which if not avoided could result in death or serious injury 2 Visually check the seal system to ensur
9. location for future reference Updates to this manual which are published as necessary are available on the internet at www safholland us Use only SAF HOLLAND Original Parts to service your SAF HOLLAND INTEGRAL disc brake axle 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 Warranty 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 us Knorr Bendix is the manufacturer of the disc brake caliper assembly described in this service manual NOT SAF HOLLAND This manual references service documents which are published by Knorr Bendix The latest versions can be found on their 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 Before starting any work on the unit rea
10. regular visual checks of the brakes tires and 10 Regularly conduct general safety checks in accordance all chassis components Refer to Section 12 for with any applicable laws more information 11 After every wheel change the wheel nuts MUST be a Inspect for secure mounting wear leaks corrosion re tightened to the specified torque level after the initial and damage 100 miles of operation and then at every regular b Check for loose broken or cracked air hoses air service interval system leaks and damaged components CAUTION Failure to re tighten wheel nuts at c Check that brake hoses and cables are properly secured specified intervals could result MY component failure which if not avoided d For proper brake pad wear check that there is enough could result in damage to property clearance to allow the caliper full movement during ii SAs normal operation Use only SAF HOLLAND Original Parts to service your SAF HOLLAND INTEGRAL disc brake axle 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
11. 5 5 Re connect the ABS sensor SAF HOLLAND Group Figure 24 PILOT BOSS Figure 25 SENSOR RETAINING HOLDER ABS SENSOR Tf 7 h CAOLA ad GOs Hall TAAA CO 18 XL SA100590M en US Rev E 2014 07 25 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 Options SAF HOLLAND Group 11 2 Hubodometer The SAF HOLLAND INTEGRAL Disc Brake can be factory equipped or retrofitted with a hubodometer hub cap for installation of a hubodometer 1 Remove the original plastic hub cap Figure 26 at the reinforced undercut on the side of the cap using a hub cap puller 2 Install hubodometer onto hubodometer hub cap 3 Check that the hubodometer hub cap O Ring is installed correctly and is in good condition 4 Install the hubodometer hub cap by pressing it slowly and uniformly against the hub seat until the snap fit is secure Figure 27 Visually inspect the O Ring for a proper seal NOTE A hubodometer hub cap cannot be installed on axles equipped with a Tire Inflation System TIS 11 3 Tire Inflation System If your system is prepped for a Tire Inflation System contact SAF HOLLAND Customer Service for further information and installation instructions 11 4 Dust Shield The SAF HOLLAND INTEGRAL Disc Brake can be factory equipped or retrof
12. ARNING 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 to the latest version of the TMC recommended practice RP 652 Service and Inspection of Air Disc 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 and in accordance with any legal requirements Refer to Routine Service Schedule in Section 12 NOTE Regular service intervals could be required more frequently for severe duty applications Refer to Section 12 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 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 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 b
13. LAND 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 13 Routine Service Schedule AWARNING Failure to inspect and maintain your AWARNING Failure to maintain your SAF HOLLAND SAF HOLLAND INTEGRAL disc brake INTEGRAL disc brake with SAF HOLLAND axle as outlined in Section 12 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 IMPORTANT Use only SAF HOLLAND Original Parts to service your SAF HOLLAND INTEGRAL disc brake axle PERIODIC CHECKS After First Every Every WHICHEVER OCCURS FIRST 3 000 Miles 20 000 Miles 50 000 Miles TIME INTERVALS After First Month Every 3 Months Every 6 Months VISUAL AND SAFETY INSPECTION Inspect for missing or loose hubcap Inspect for grease leakage around hubcap Hub unit maintenance free Check for grease leaks Refer to Section 8 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
14. SAF SAF HOLLAND Group Service Manual XL SA10059OM en US Rev E SAI SAF Contents SAF HOLLAND Group Contents Page Contents Page MNO dUCON esan a 2 Section 6 Wheel Rock Test u seseeressrsererererentnen ener ennne 10 E E E N 2 Section 7 Wheel Bearing Noise Test 10 Notes Cautions and Warnings cccesccssesseessrsrsstereees 2 Section 8 Hub Unit Grease Leak Inspection 11 Section 1 General Safety Instructions sses 3 Section 9 Servicing the Disc Brake Hub Unit seee 12 Section 2 General Service Maintenance Instruction 4 Section 10 Wheel Installation Procedure 18 Section 3 Model Identification 5 Section 11 Disc Brake OptionS cccccsccseseseesseeesseeteens 18 Section 4 Identification Tag eeen 5 Section 12 Torque Chart c ccccccccssescssssssssssssssssssssseeees 20 Exploded View and Parts List cccccsescsessssscssrsssereets 6 Section 13 Routine Service Schedule 1 21 Section 5 Disc Brake Hub Unit Inspection scenes 7 Section 14 Troubleshooting ccccssecssssesesseeesstseeeeeeeees 22 Introduction Notes Cautions and Warnings This manual provides the necessary information for the maintenance inspection and safe operation of the SAF disc brake system For axle end brake replacement components contact SAF HOLLAND Customer Service at 888 396 6501 Read this manual before using or servicing this product and keep it in a safe
15. 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 wheel 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 4 XL SA100590M en US Rev E 2014 07 25 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 rl Serial Number Tag Information 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 SERIAL NUMBER TAG LOCATED BETWEEN BEAMS OF EACH AXLE TUBE 4 Identification Tag The sample tag shown will help you interpret the information Figure 2 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 s Record your tag numbers below for future quick reference SAF HOLLAND USA INC gt al LETT Seley rare Minber ex TTT Model XXXXXXXXXXXX Made in USA Model Number Axle Beam Rating X
16. X XXXIbs US and Foreign Patents Apply Serial Number ea A A XL SA100590M en US Rev E 2014 07 25 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF El and logos are trademarks of SAF HOLLAND S A SAF HOLLAND GmbH and SAF HOLLAND Inc A INTEGRAL Disc Brake Components SAF SAF HOLLAND Group SERIAL TAG NOTE Refer to the model number on the serial tag to identify your specific axle model s wheel end components Contact SAF HOLLAND Customer Service at 888 396 6501 ITEM NO DESCRIPTION QTY AXLE ITEM NO DESCRIPTION QTY AXLE Axle Body Clamping Bush Hub with Compact Bearing Brake Caliper SK7 Right Rotor w Toner Ring Brake Caliper SK7 Left M 14 x 1 5 Bolt Hub Rotor M18 x 1 5 Bolt Standard Wheel Studs M18 x 1 5 Bolt Shoulder O Ring D92 x 4 Brake Chamber Axle Nut Right Hand Chamber Nut Axle Nut Left Hand Dust Shield Optional Hub Cap with Seal Hub Odometer Cap Optional ABS Sensor WABCO 6 XL SA100590M en US Rev E 2014 07 25 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 Hub Unit Inspection SAF HOLLAND Group 5 Disc Brake Hub Unit Inspection IMPORTANT During removal inspect components for wear and replace worn components AW
17. d 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 PE XL SA100590M en US Rev E 2014 07 25 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 General Safety Instructions SAF HOLLAND Group 1 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 AWARNING Failure to follow the instructions and safety precautions in this manual could result in
18. d result in death or serious injury IMPORTANT Use only SAF HOLLAND Original Parts to service your SAF HOLLAND INTEGRAL disc brake axle TAWARNING Failure to maintain your SAF HOLLAND AWARNING 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 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 Follow the recommended routine maintenance and inspections described in this manual These procedures are designed so that optimum performance and operational safety are achieved m Contact a qualified towing and or service company to assist in repairing vehicle or to move it to a qualified repair facility XL SA100590M en US Rev E 2014 07 25 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF a and logos are trademarks of SAF HOLLAND S A SAF HOLLAND GmbH and SAF HOLLAND Inc A F General Service Maintenance Instructions SA SAF HOLLAND Group 2 General Service Maintenance 1 Conduct
19. e found at www bendix com for more information 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 Figure 3 WS N Q g a a Ne SES CALIPER MARKING CALIPER MARKING CARRIER MARKING CARRIER MARKING Figure 4 PERMITTED NOT PERMITTED XL SA100590M en US Rev E 2014 07 25 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 Hub Unit Inspection SAF 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 and their length is less than 75 of the width of the rotor friction surface Area B c Grooves in the rotor surface 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 t
20. e that it is functioning properly and that there is minimal grease leakage Refer to Section 8 for more information For guidance about diagnosing seal system malfunctions refer to Section 13 NOTE Adjustment of the compact bearing system is NOT necessary IMPORTANT DO NOT use high pressure cleaners or liquid cleaners on the hub unit IMPORTANT The red dot in the middle of the SAF plastic hub cap is permanent If you attempt to remove it hub cap failure will result AWARNING Failure to replace plastic hub cap when broken could cause component failure which if not avoided could result in death or serious injury XL SA100590M en US Rev E 2014 07 25 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 Wheel Rock and Bearing Noise Tests SAF SAF HOLLAND Group 6 Wheel Rock Test Figure 7 1 For sufficient clearance to perform the test raise the DIAL GAUGE wheel off the ground DO NOT remove the wheel 2 Carefully remove the hub cap 3 Using a size 85 mm socket check the torque of the axle UV ONO AXLE NUT nut to ensure that it is torqued to 663 ft lbs 900 Nem by rotating the nut in either a left or right handed direction for the roadside or curbside of the axle respectively NOTE The SAF compact bearing system uses a single piece spindle nut which has a left hand thread on
21. g System Left hand thread located on the roadside of the axle M75 x 1 5 Right hand thread located on the curbside of the axle The axle nut with a left handed thread can be identified by a circular groove Figure 13 1 Pre torque with a size 85 mm socket to 110 ft Ibs 150 Nem 2 Rotate the head unit slowly five 5 revolutions 3 For final torque tighten the axle spindle nut by 1 12 turn 30 4 Check that the axle spindle nut has a final torque of at least 663 ft Ibs 900 Nem Maximum permissible end play of the hub unit is shown in Section 6 SAF Specific INTEGRAL Bolt Rotor Hub Torque all ten 10 bolts in a criss cross pattern M14x1 5 1 Pre torque to 37 ft Ibs 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 1 5 1 Pre torque to 88 ft lbs 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 20 XL SA100590M en US Rev E 2014 07 25 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOL
22. general service maintenance inspection Refer to Section 4 Perform disc brake hub unit inspection Refer to Section 5 Perform wheel rock and wheel noise tests Refer to Section 6 and 7 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 your 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 time 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 SA100590M en US Rev E 2014 07 25 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF 21 and logos are trademarks of SAF HOLLAND S A SAF HOLLAND GmbH and SAF HOLLAND Inc Troubleshooting Chart SAF SAF HOLLAND Group 14 Troubleshooting Chart SAF HOLLAND suspensions equipped with disc brake axles PROBLEM Brakes will NOT release No brakes or insufficient brake performance POSSIBLE CAUSE Disc brake caliper bound up POSSIBLE REMEDY Lubricate or replace brake caliper Bra
23. he 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 and brake pads are exceeded Figure 6 the rotor and pads MUST be replaced Refer to brake pad and rotor replacement instructions as detailed in Section 9 1 and 9 2 For both the inner and outer pads the maximum brake pad wear difference is 0 2 5 0 mm BRAKE ROTOR BRAKE PAD L B n n n D n 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 During brake repairs conduct a visual inspection of the seals on the brake caliper Refer to Section 5 3 for more information SAF HOLLAND Group Figure 5 FRICTION __ 0 06 1 5 MM MAX DEPTH Figure 6 cn NEW PAD ER XL
24. he wheel nuts can be started in order to hold wheel in position 4 Tighten the top wheel nut first Apply 50 ft Ibs 68 Nem of torque to draw the wheel up fully against the hub 5 Install remaining wheel nuts Using sequence shown in Figure 24 tighten all wheel nuts to 50 ft Ibs 68 Nem of torque 6 Repeating sequence shown in Figure 24 retighten all wheel nuts to 475 25 ft Ibs 644 34 Nem of torque 7 Check seating of wheel at the pilot bosses Rotate wheel and check for any rotational irregularity AWARNING Retorque all wheel nuts after 5 to 100 miles of service on the initial in service following any installation of wheel to hub assembly 11 Disc Brake Options 11 1 ABS Sensor Replacement NOTE When replacing the ABS sensor only install a sensor manufactured by WABCO DO NOT mix sensors from different manufacturers The SAF HOLLAND INTEGRAL Disc Brake comes with a WABCO ABS mini sensor 011 For further ABS sensor information contact SAF HOLLAND Customer Service at 888 396 6501 1 Disconnect the ABS sensor 2 Remove the ABS sensor from the sensor holder by pulling it straight out from the holder and discard Figure 25 3 If necessary remove the sensor retaining spring clip from the sensor holder and replace with new clip Figure 25 4 Install a new ABS sensor by pushing it directly into the sensor holder spring clip until it contacts the tooth wheel in the hub unit Figure 2
25. itted with a dust shield Refer to Figure 28 for the following instuctions 1 Using a 13mm socket loosen and remove the dust shield clamp band bolt 2 Wrap the clamp band around the axle and loosely install the clamp band bolt 3 Position the clamp band around the axle 4 Route any ABS sensor wires through one of the two rubber grommets on the dust shield 5 Position the clamp band over the clamp band lip portion of the dust shield 6 Slide the dust shield and clamp band together toward the disc brake until the clamp band is about 12mm 0 5 from the brake rotor pulling the ABS sensor wire through the rubber grommet as necessary 7 Torque the clamp band bolt to 20 25 ft Ibs 27 34 Nem 8 Use a pry bar and or rubber mallet to ensure that there is clearance between the dust shield and the rotor 9 Plug the ABS sensor into the abs system wire Figure 26 HUB UNIT HUB CAP Figure 27 HUBODOMETER HUB CAP Figure 28 l i el LAM il SU SA ea I y ty os DUST SHIELD BRAKE ROTOR CLAMP BAND LIP CLAMP CLAMP BAND BOLT XL SA100590M en US Rev E 2014 07 25 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 Torque Chart SAF SAF HOLLAND Group 12 Torque Chart APPLICATION TORQUE SPECIFICATIONS SAF Specific Axle Spindle Nut Compact Bearin
26. ke hoses restricted 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 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 Service air interrupted Warm brakes Open glad hand cut out cock Service air line improperly coupled Properly couple service air line 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 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
27. nd a right hand thread on the curbside of the axle The axle nut with a left handed thread can be identified by a circular groove Figure 13 The left hand threaded axle spindle can be identified by a frontal groove on the end of the axle spindle NOTE DO NOT remove the SAF compact bearing spindle nut with an impact wrench Due to the self tightening design of the SAF compact bearing spindle nuts it may be necessary to apply high torque of up to 1 600 ft Ibs 2 170 Nem to loosen the spindle nuts Use an appropriate length hand wrench and torque multiplier to loosen the SAF compact bearing spindle nut IMPORTANT DO NOT use an impact wrench to remove the SAF compact bearing spindle nut ACAUTION The high speed generated from air impact wrench to loosen the high clamp load of the SAF compact bearing spindle nut could result in damage to the spindle threads Figure 11 BRAKE CHAMBER Figure 12 BRAKE SPIDER BRAKE CALIPER BOLTS FOUR 4 f BRAKE CALIPER Figure 13 FRONTAL AXLE HUB UNIT GROOVE SPINDLE END LEFT ZN HAND THREAD CIRCULAR GROOVE AXLE SPINDLE NUT LEFT HAND THREAD HUB CAP XL SA100590M en US Rev E 2014 07 25 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 Servicing the Disc Brake Hub Unit SAF 7 Remove the head unit b
28. nd hub unit MUST be replaced When replacing the wheel bolts refer to the hub removal instructions described in Section 9 2 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 hub unit and discard Figure 22 2 Install new wheel bolts by pressing them into the hub unit To ensure 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 23 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 22 WHEEL BOLTS TEN HUB UNIT Figure 23 FLAT SIDE WHEEL BOLTS TEN 10 XL SA100590M en US Rev E 2014 07 25 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 Wheel Installation SAF 10 Wheel Installation Procedure The following information is intended to provide basic wheel installation instructions Refer to TMC RP222C for complete installation details 1 Clean all mating surfaces on hub wheels and nuts 2 Rotate the hub so a pilot boss is at the top 12 o clock position 3 Mount wheel s on hub One or more of t
29. ntacting Customer Service at 888 396 6501 IMPORTANT DO NOT use high pressure cleaners or liquid cleaners on the spindle 14 Insert a new bearing O Ring seal into the groove of the hub unit Figure 16 15 Re install the head unit by gently sliding it on the spindle Figure 14 During re installation be sure the O Ring seal is in the proper position SAF HOLLAND Group Figure 14 HEAD UNIT AXLE SPINDLE Figure 15 ROTOR CONTACT SURFACE AND TAPPED HOLES CONNECTION BOLTS TEN 10 BEARING O RING SEAL HUB UNIT Figure 16 HEAD UNIT BEARING O RING SEAL GROOVE 14 XL SA100590M en US Rev E 2014 07 25 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 Servicing the Disc Brake Hub Unit SAF HOLLAND Group 16 Re install the SAF specific axle spindle nut by rotating Figure 17 the nut onto the axle spindle in either a left or right handed direction depending on the direction of the thread AXLE SPINDLE NUT JIAN SS NOTE The SAF compact bearing system uses a single piece spindle nut which has a left hand thread on the roadside of the axle and a right hand thread on the curbside of the axle The axle nut with a left handed thread can be identified by a circular groove The left hand threaded axle spindle can be identified by a frontal groove
30. nts and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF ogos are trademarks of SAF HOLLAND S A SAF HOLLAND GmbH and SAF HOLLAND Inc S4F Troubleshooting Chart 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 literature Excessive heat cracks in rotor Brake out of adjustment Adjust brake repair or replace automatic adjustment device as necessary Overly aggressive braking Unequal brake balance or timing Instruct train driver in proper brake use 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 SA100590M en US Rev E 2014 07 25 Amendments and Errors Reserved SAF HOLLAND Inc SAF HOLLAND HOLLAND SAF 23 and logos are trademarks of SAF HOLLAND S A SAF HOLLAND GmbH and SAF HOLLAND Inc Fal olang
31. on the end of the axle spindle Figure 13 a Pre torque the axle spindle nut with a torque wrench and size 85 mm socket to 110 ft Ibs 150 Nem HUB CAP b Rotate the head unit slowly five 5 revolutions c For final torque tighten the axle spindle nut by 1 12 turn 30 NOTE Each mark on the spindle nut equals 1 12 30 i turn Figure 17 Figure 18 SHOULDER BOLT d Check that the axle spindle nut has a final torque of lcd STD BOLT BOLT 663 ft Ibs 900 Nem Refer to the Torque Chart in BRAKE SPIDER INNER Section 11 s CALIPER NOTE The maximum permissible end play of the hub unit is shown in Section 6 17 Check that the hub cap O Ring seal is in good condition and replace if necessary 18 Re install the hub cap onto the hub unit by pressing it slowly and uniformly against the hub seat until the snap fit is secure Figure 17 Visually inspect for a proper O Ring seal 19 Re install the caliper to the brake spider using four 4 new SAF specific brake caliper bolts Figure 18 XL SA100590M en US Rev E 2014 07 25 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 Servicing the Disc Brake Hub Unit SAF 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 19 The sho
32. th 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 m Only the wheel and tire sizes approved by the trailer builder can be used Operational and Road Safety Instructions 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 CAUTION If the parking brake is immediately applied to the brakes when overheated the brake drums or discs could be damaged by different stress fields during cooling 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 12 AWARNING Failure to inspect and maintain your SAF HOLLAND INTEGRAL disc brake axle as outlined in Section 12 can result in brake or wheel bearing failure which if not avoided coul
33. ub MUST be replaced NOTE Noises can also be caused by the brakes Before removing the hub unit remove the brake pads and repeat the bearing noise test 10 XL SA100590M en US Rev E 2014 07 25 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 Hub Unit Grease Leak Inspection SAF HOLLAND Group 8 Hub Unit Grease Leak Inspection Figure 9 A hub unit grease leak inspection should be performed if more than half of the wheel flange is covered with grease 1 Carefully remove the hub cap 2 Inspect the grease levels inside of the wheel flange including the inside of the hub cap the axle nut axle tube spindle and hub seal a If the hub seal is NOT completely covered with grease Figure 9 the hub units are correct and DO NOT need replacement b If the hub seal is completely covered with tar like grease Figure 10 the hub unit MUST be replaced NOTE There may be a small amount of grease on the lower edge of the hub seal This is normal and DOES NOT indicate grease leakage XL SA100590M en US Rev E 2014 07 25 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 Servicing the Disc Brake Hub Unit SAF 9 Disc Brake Hub Unit Service Contact SAF HOLLAND
34. ulder bolt is located at the outer mounting hole where the brake rotor rotates OUT of the caliper when turning in driving direction Figure 19 A WARNING Failure to install the shoulder bolt in the proper location could cause component failure which if not avoided could result in death or serious injury 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 IMPORTANT Make sure that the brake caliper is mounted on the correct side of the axle The correct location can be identified by the lengths of the guide pins on the caliper unit The longer guide pins should be located on the bottom of the caliper unit when installed on the axle in driving direction The shorter guide pins should be located on the top of the caliper unit Figure 20 and 21 20 Re install the SAF brake chamber by following the instructions in SAF Brake Cylinders for Disc Brakes Installation and Service Guide available online at www safholland us 21 Re install the ABS sensor by following the instructions detailed in Section 10 1 22 To enable the ABS sensor to function properly press the ABS sensor against the toner ring at the hub unit to eliminate any clearance between these parts
35. y gently sliding it off the spindle Figure 14 8 Remove the bearing O Ring seal from the hub unit and discard Figure 15 NOTE The O Ring seal may be stuck to the bearing system or on the axle spindle 9 Clean the hub unit bearing surface 10 Remove the hub unit from the rotor by using a size 15 mm socket to loosen and discard all ten 10 connection bolts Figure 15 11 Clean the rotor contact surface on the hub unit Using compressed air clean the tapped holes in the disc unit Check that the threads are in good working conditions 12 Re install the hub unit to the rotor by using ten 10 new SAF specific connection bolts Use a torque wrench to pre torque the bolts to 37 ft lbs 50 Nem For final torque tighten the bolts with an additional 120 turn using a criss cross pattern Refer to the Torque Chart in Section 11 for more information IMPORTANT When re installing the hub unit and rotor use only new SAF specific connection bolts Bolts MUST be clean and free of oil and grease AWARNING Failure to observe these instructions could cause component failure which if not avoided could result in death or serious injury 13 Clean any grease residues from the axle spindle end and re coat the bearing journal with Renolit Paste AZ 0 1 DO NOT grease or oil the spindle threads NOTE Renolit Paste AZ 0 1 is available in 5 g packets through SAF HOLLAND Original Parts online at www safholland us or by co

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