SAF P89 Service Manual

Service Manual

P89 Disc Brake Axles

XL-SA20018UM-en-US Rev H

Contents

Introduction ......................................................................... 2

Warranty .............................................................................. 2

Notes, Cautions, and Warnings ............................................. 2

Section 1 – General Safety Instructions ................................ 3

Section 2 – General Service and Maintenance Instructions ... 4

Section 3 – Model Identification........................................... 5

Section 4 – Identification Tag ............................................... 5

INTEGRAL

U-Shaped Rotor Brake Exploded View and Parts List ............. 7

Section 5 – Caliper Identification ......................................... 8

Section 6 – Disc Brake Inspection ......................................... 9

Section 7 – Hub, Bearing and Seal Removal ........................ 11

Disc Brake Exploded View and Parts List ............. 6

Contents PageContents Page

Section 8 – Bearing Inspection ........................................... 13

Section 9 – Rotor Replacement .......................................... 13

Section 10 – Hub Wheel Bolt Servicing ............................... 15

Section 11 – Seal, Bearing and Hub Installation.................. 15

Section 12 – Hub Lubrication (Oil) ...................................... 20

Section 13 – Hub Cap Installation ...................................... 20

Section 14 – Caliper Installation......................................... 21

Section 15 – Wheel Installation Procedure .......................... 22

Section 16 – Optional Equipment ....................................... 23

Section 17 – Lubrication and Torque Specifications ............. 24

Section 18 – Troubleshooting Chart .................................... 25

Section 19 – Routine Service Schedule ............................... 27

Introduction

This manual provides the necessary information for the maintenance, inspection and safe operation of the SAF® P89 disc brake. Refer to XL-SA20024UM-en-US for P89 Plus disc brake System.

Knorr® is a registered trademark 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.

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.com.

Notes, Cautions, and Warnings

Before starting any work 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.

Used without the safety alert symbol, indicates a potentially hazardous situation which, if not avoided, could result in property damage.

Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.

Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

XL-SA20018UM-en-US Rev H · 2017-12-14 · 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.

1. General Safety Instructions

General Safety

General and Servicing Safety Instructions



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.

Failure to follow the instructions and safety precautions in this manual could result in improper servicing or operation leading to component failure which, if not avoided, could result in death or serious injury.



All maintenance should be performed by a properly

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.



Properly support and secure the vehicle from unexpected

movement when servicing the unit.

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.



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.



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 should be replaced in sets on both the driver and curb side of an axle.

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.



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.

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.

trained



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.



Make sure that the brakes are not overheated from

continuous operation.

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.



The parking brake MUST NOT be immediately applied

when the brakes are overheated. Refer to the rotor wear inspection information in Section 6.2.

If the parking brake is immediately applied to the brakes when overheated, the brake discs could be damaged by different stress fields during cooling.



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.

IMPORTANT: Off-road operation of axles beyond



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 19.

IMPORTANT: Use only SAF-HOLLAND® Original Parts to

gravel roads, agricultural and forestry tracks, on construction sites and in gravel pits.

the approved application design could result in damage and impair suspension system performance.

Failure to inspect and maintain the SAFHOLLAND® P89 disc brake axle as outlined in Section 19 can result in brake or wheel bearing failure which, if not avoided, could result in death or serious injury.

service the SAF-HOLLAND® P89 disc brake axle.

Failure to maintain the SAF-HOLLAND® P89 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.

XL-SA20018UM-en-US Rev H · 2017-12-14 · 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 Service and Maintenance

2. General Service and Maintenance Instructions

1. Conduct regular visual checks of the brakes, tires and all chassis components. Refer to Section 19 for more information:



Inspect for secure mounting, wear, leaks,corrosion

and damage.



Check for loose, broken or cracked air hoses, air

system leaks, and damaged components.



Check that brake hoses and cables are properly secured.



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 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.

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 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® P89 disc brake axle.

XL-SA20018UM-en-US Rev H · 2017-12-14 · 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.

Model Identification

3. Model Identiﬁcation

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.

Axle Body Part Number: ______________________________

Model Number: _____________________________________

Serial Number: _____________________________________

Figure 1

SERIAL NUMBER TAG LOCATED BETWEEN BEAMS OF EACH AXLE TUBE

Figure 2

P89 INTEGRAL® Disc Brake Exploded View and Parts List

ITEM DESCRIPTION QTY. / AXLE

1 Bolt, Hub Cap 12 2 Hub Cap 2 3 Gasket, Hub Cap 2 4 Nut, Axle Pro-Torq

4A Three Piece Axle Nut 2

5 Hub with Bearing Cups 2 5a* Bearing Cup, Outer 2 5b* Bearing Cup, Inner 2

6 Cone, Bearing, Outer 2

7 Wheel Studs 20

8 INTEGRAL® Rotor with ABS Tone Ring 2

9 Rotor Attachment Bolts 20

* Included in hub, item number 5, but can be serviced.

4A, Three Piece Axle Nut

ITEM DESCRIPTION QTY. / AXLE

10 Cone, Bearing, Inner 2 11 Seal, Hub 2 12 ABS Sensor (WABCO) 2

13 Clamping Bush 2

Brake Caliper Left-Hand

Brake Caliper Right-Hand 1 15 M18 x 1.5" Bolt, Standard 6 16 M18 x 1.5" Bolt, Shoulder 2 17 Brake Chamber 2 18 Brake Chamber nut 4

19 Dust Shield with Clamp (optional) 2

20 Washers 20

XL-SA20018UM-en-US Rev H · 2017-12-14 · 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.

New P89 (U-Shaped Rotor Brake) Exploded View and Parts List

ITEM DESCRIPTION QTY. / AXLE

1 Bolt, Hub Cap 12 2 Hub Cap 2 3 Gasket, Hub Cap 2 4 Nut, Axle Pro-Torq

4A Three Piece Axle Nut 2

5 Hub with Bearing Cups and ABS

Tone Ring 5a* Bearing Cup, Outer 2 5b* Bearing Cup, Inner 2

6 Cone, Bearing, Outer 2 7 Wheel Studs 20 8 U-Shaped Rotor 2

* Included in hub, item number 5, but can be serviced.

4A, Three Piece Axle Nut

ITEM DESCRIPTION QTY. / AXLE

9 Rotor Attachment Bolts 20 10 Cone, Bearing, Inner 2 11 Seal, Hub 2

12 ABS Sensor (WABCO) 2 13 Clamping Bush 2

Brake Caliper Left-Hand

Brake Caliper Right-Hand 1 15 M18 x 1.5" Bolt, Standard 6 16 M18 x 1.5" Bolt, Shoulder 2 17 Brake Chamber 2 18 Brake Chamber nut 4

19 Dust Shield with Clamp (optional) 2

Disc Brake Inspection

5. Caliper Identiﬁcation and inspection

SAF® P89 axles are equipped with one of two disc brake calipers, SAF-HOLLAND® SBS 2220 K0 Calipers, or KnorrBremse® SK7 calipers.

5.1 SAF-HOLLAND® SBS 2220 K0 Caliper

The SAF-HOLLAND® SBS 2220 K0 has a smooth forward face of the caliper and SAF® logo on the rear side (Figure 3).

The inner and outer brake pads for the SBS 2220 K0 are different in shape. The inner brake pad has two "circle X's" on the back side, while the outer brake pad has a relatively smooth back. There is also a notch on the pads to keep them from being installed in the wrong position (Figure 4).

For instructions on SBS 2220 KO brake caliper inspection and repair, refer to XL-AS20032RM-en-US which can be found at www.safholland.com.

5.2 Knorr-Bremse® SK7 Caliper

The Knorr-Bremse® SK7 Caliper has a large indentation on the forward face and no SAF® logo on the rear of the caliper (Figure 5).

The brake pads in the SK7 caliper are the same for the inner and outer side of the caliper. The back of the brake pad has the Knorr-Bremse® logo and six (6) slots on the back of the caliper

(Figure 6).

Figure 3

SAF® LOGO

Figure 4

OUTER BRAKE PAD

SBS 2220 K0

SMOOTH CALIPER FACE

SBS 2220 K0 BRAKE PADS

For instructions on SK7 brake caliper inspection and repair, refer to Knorr-Bremse Pneumatic Disc Brake SN6-SN7-SK7 Service Manual Y006471 which can be found at www.knorr-bremsecvs.com/en/.

SK7

NO SAF® LOGO

LARGE INDENT ON CALIPER FACE

Figure 6 Figure 5

KNORR-BREMSE LOGO

INNER BRAKE PAD

SK7 BRAKE PAD

INBOARD AND OUTBOARD

SLOTS

XL-SA20018UM-en-US Rev H · 2017-12-14 · 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 Inspection

6. Disc Brake Inspection

IMPORTANT: During removal inspect components for

wear and replace worn components.

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).

6.1 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 19.

NOTE: Regular service intervals may be required more

frequently for severe duty applications. Refer to Section 19.

A quick visual inspection of the condition of the brake pads can be performed without removing the wheel:

Figure 7

VIEW A VIEW B

CALIPER MARKING

1. Compare the position of the caliper marking to the carrier marking located on the underside of the caliper unit (Figure 7).

a. Figure 7 - View A shows the positions of the two (2)

markings when the brake pads are in good condition.

b. Figure 7 - 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 Section 5 for caliper and service manual identiﬁcation.

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" (2 mm) at its thinnest area, the brake pad MUST be replaced. (Figure 10).

NOTE: Minor breakouts at the edges are permitted. Major

breakouts on the surface of the brake pad are NOT permitted (Figure 8).

Figure 8

CARRIER MARKING

PERMITTED

CARRIER MARKING

NOT PERMITTED

+ 19 hidden pages

SAF P89 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual