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Repair Instructions

Compressed Air Disc Brake
SAF SBS 2220 H0
SAF SBS 1918 H0

XL-SA30000RM-en-DE Rev A • 02.2016
Translation of the original repair instructions

Содержание SBS 1918 H0

Страница 1: ...Repair Instructions Compressed Air Disc Brake SAF SBS 2220 H0 SAF SBS 1918 H0 XL SA30000RM en DE Rev A 02 2016 Translation of the original repair instructions ...

Страница 2: ... parts in repairs This manual is subject to the copyright of SAF HOLLAND GmbH All rights reserved No part of this manual may be reproduced copied or translated in any form or by any means without the prior written permission of SAF HOLLAND GmbH Brand names mentioned in this manual are not identified as such in all cases but they are nevertheless subject to the provisions of trademark legislation I...

Страница 3: ...ns 17 4 3 8 Checking the actuation interface 18 4 3 9 Checking the guide pin bellows 19 4 3 10 Checking the thrust plate bellows 20 4 3 11 Checking the slide function 21 4 3 12 Measuring the bearing clearance 21 5 Replacement procedure 23 5 1 General information 23 5 2 Replacing the brake pads 23 5 2 1 Initial procedure 23 5 2 2 Removing the brake pads 23 5 2 3 Installing the brake pads 24 5 2 4 F...

Страница 4: ...v A 02 2016 Errors and changes excluded SAF HOLLAND 7 Tools 38 7 1 SAF special tool for SBS 2220 H0 38 8 Fault finding 39 8 1 General fault finding instructions 39 8 2 Inspection intervals 39 9 Spare parts and repair kit list 40 ...

Страница 5: ...ed compressed air disc brake inspection intervals In this chapter the inspection intervals table displays how frequently the different brake compo nents should be inspected and on which pages the check instructions are to be found If any inspection shows that a replacement activity needs to be performed continue to the appropriate section in chapter 5 Replacement procedures Chapter 6 Specification...

Страница 6: ...2 Safety precautions 2 1 General information This chapter details the safety precautions that must be read and followed before any inspection repair in stallation procedure described in these repair instruc tions is started These repair instructions are intended for the exclusive use of trained persons within the commercial vehicle industry and related workshops Three different alert levels are us...

Страница 7: ...ally applied brake calculations If the brake force is not correctly distributed it can lead to excessive braking of a vehicle and or one or more axles in the combination This can result in overheating accelerated wear and damage to the disc brake pads brake discs tyres and wheel com ponents Before a vehicle is entered into service it must be set up in accordance with the specified values in the re...

Страница 8: ...ion Failure to follow the Instructions below could jeop ardise safety and or reduce the service life of the disc brake and its components If the vehicle is shot blasted all rubber parts and pads on the disc brake must be protected as well as all areas in which the pads are seated The brake cham ber must be fitted or any protective parts that have a similar sealing function The shipping seal fitted...

Страница 9: ...ety precautions before wheel removal The vehicle manufacturer s safety precautions must be followed Fig 7 Removing the wheel 1 Check the free rolling resistance If the resistance is higher than expected tap the tyre to remove any normal rest tension If the wheel still does not rotate freely then consult chapter 8 Fault finding on what action to take 2 Remove the wheel nuts followed by the wheel se...

Страница 10: ... the re set shaft tightened in the de adjust position could stop the adjustment function from working After reaching the end stop position always then adjust by rotating the reset shaft clockwise 90 degrees thus activating the adjustment function 4 Leave the Torx 55 in position in the reset shaft x5 1 2 3 4 5 Fig 9 Brake actuation 5 Actuate the brakes five times by pressing and releasing the vehic...

Страница 11: ... the event of improper fitting of the reset shaft protective plug and resulting damage 3 Fit the reset shaft protective plug on the brake calliper and verify that it is correctly aligned and fully in the correct sealing position Failure to do so may compromise the service life of the brake see Fig 11 3 4 1 Mounting the wheel Danger Ensure that the brake hoses are in good condition and that they ar...

Страница 12: ...g brake if fitted with a spring brake chamber 2 Lift the axles so that the stands can be removed 3 Carefully lower the vehicle to the ground Fig 14 Removing the wheel blocks 4 Remove the wheel blocks Danger Work performed must always be completed with a function test chapter 3 3 and a test drive in order to ensure that the brakes are functioning correctly chapter 3 3 ...

Страница 13: ...ntervals The inspection intervals specified in the table below are maximum intervals Depending on the vehicle application type of driving adjustment to the vehicle manufacturer s service inspection intervals etc there may be a need for more frequent inspections Inspection intervals 1 Function test 2 Setting 3 Visual inspection Before starting to use vehicle Daily After 3 000 to 5 000 km Every 3 mo...

Страница 14: ...disc etc 4 3 3 Checking brake pad wear Danger Wear respiratory protection in order to avoid inhaling particles which can be hazardous to health Brake pad wear produces dust which can cause lung dam age Note Step 1 in this procedure only indicates the brake pad wear of the outer brake pad For a full examination complete all steps OK OK Fig 15 Inspection of the visual wear indicator 1 Inspect the po...

Страница 15: ...ake pad clearance check Danger Wear respiratory protection in order to avoid inhaling particles which can be hazardous to health Brake pad wear produces dust which can cause lung dam age Note The clearance can be checked with the brake chamber fitted or removed This check is best performed after the wheel is removed and before the reset shaft is retracted For this situation steps 2 and 3 below can...

Страница 16: ...e the thickness of the brake disc using a calliper If the brake disc has a wear ridge the measurement can be performed using two spac ers B e g 5 mm thick flat washers see Fig 19 Reduce the measured dimension by the total thickness of the two spacers B The minimum thickness of the brake disc is 37 mm Replace the brake disc if it is worn or if it is expected to be so before the next inspection 4 3 ...

Страница 17: ...he warranty and compromise the disc brake The nut D must not be adjusted see Fig 21 4 3 7 Checking the thrust plate guide pins Danger Wear respiratory protection in order to avoid inhaling particles which can be hazardous to health Brake pad wear produces dust which can cause lung dam age Caution Use a vacuum cleaner to clean the surfaces Do not use compressed air E E Fig 22 The two thrust plate g...

Страница 18: ...rake chamber normal service and spring brake parking chamber 1 Read and follow 3 2 Initial procedure prior to inspecting the actuation interface 2 Thoroughly clean around the mating surfaces of the brake chamber A and brake calliper B to ensure that dirt does not get into the mechanism area when removing the brake chamber see Fig 23 3 Release the parking brake see chapter 3 2 1 F A E B Fig 24 Remo...

Страница 19: ...al flange B is correctly seated intact and undamaged 14 Once the inspection is completed satisfactorily conclude by reading and following chapter 5 3 3 Installing the brake chamber and 5 3 4 Final procedure 4 3 9 Checking the guide pin bellows Danger Wear respiratory protection in order to avoid inhaling particles which can be hazardous to health Brake pad wear produces dust which can cause lung d...

Страница 20: ... inspection Over adjustment extension may cause the thrust plate to disengage from the adjustment screw and if done unintentionally may cause damage to the thrust plate bellows The min distance between the brake calliper and thrust plate is 60 mm 60mm A Fig 29 Max unscrewing for inspecting the thrust plate bellows 1 Read and follow 3 2 Initial procedure and 5 2 2 Removing the brake pads prior to i...

Страница 21: ...the brake calliper must be able to slide freely on the guide pin 1 Read and follow 3 2 Initial procedure and 5 2 2 Removing the brake pads prior to inspecting the slide function 2 Once the brake pads are removed move the brake calliper by hand back and forth to check its movement see Fig 31 3 If the movement is restricted in any way the cause must be determined see chapter 8 2 Inspection intervals...

Страница 22: ...n of the red arrows and read the clearance from the dial gauge see Fig 34 Measurement specification The bearing bushing must be replaced if the clear ance exceeds 2 mm See chapter 5 5 Replacing the slide function assembly see Fig 35 and see Fig 36 A B Fig 35 Brake calliper bearing The floating bearing consists of a soft composite If a metallic sound is produced by the floating bearing it must be r...

Страница 23: ...n the surfaces Do not use compressed air Take care when using chemicals and or cleaning tools e g knives brushes etc This to avoid damage or displacement of hoses seals and other components 1 If necessary remove dirt dust and other possible debris Caution Where indicated use SAF HOLLAND tools only Never use an impact wrench or similar to rotate the reset shaft Doing so could damage the inter nal c...

Страница 24: ...calliper can be slid across to allow for the inner brake pad to be removed 6 Remove the pad retainer spring bracket C 5 2 3 Installing the brake pads Caution When replacing the brake pad all components contained in the repair kit must be installed The old components must be properly disposed of 1 Ensure that the brake is fully de adjusted before fitting the new brake pads 2 Check that the contact ...

Страница 25: ...rking correctly 2 3 4 Final procedure 5 3 Replacing the brake chamber 5 3 1 Initial procedure Read and follow chapter prior to removing the spring brake chambers 5 3 2 Removing the brake chamber Danger Wear respiratory protection in order to avoid inhaling particles which can be hazardous to health Brake pad wear produces dust which can cause lung dam age If the disc brake is equipped with a parki...

Страница 26: ...brake chamber installed ensure that the springs of the parking brake have been locked in accordance with the vehicle manufactur er s instructions 2 Before removing the brake chamber it is good practice and highly recommended to read and follow chapter 4 3 8 Checking the actuation inter face Caution Take care when using chemicals and or cleaning tools e g knives brushes etc This to avoid damage or ...

Страница 27: ...in the compressed air system is 6 bar 9 With the service brake engaged and if applicable with the parking brake released check the brake chamber hoses and connections for leaks and damage 5 3 4 Final procedure To conclude this procedure read and follow chapters 1 3 3 Function test to ensure that the disc brake is working correctly 2 3 4 Final procedure 5 4 Replacing the adjustment screw bellows 5 ...

Страница 28: ...mponents Ensure that dirt and impurities do not enter the opening for the adjustment screw Fig 50 Clamping device for the thrust plate Clean the thrust plate the adjustment screw and the adjustment screw bellows mating surfaces in the brake calliper Ensure that the components are free from dirt dust debris moisture and corrosion 1 Fasten the thrust plate securely in a vice with soft jaws see Fig 5...

Страница 29: ...liper end of the adjustment screw bel lows see Fig 53 12 Firmly press on the special tool with equal and parallel force so that the adjustment screw bellows is pressed into position within the brake calliper 13 The special tool can be removed rotated and then reapplied to aid the equal and parallel seating OK OK Fig 54 Thrust plate bellows seated correctly incorrectly 14 Remove the special tool Ch...

Страница 30: ...ion assembly Caution Where indicated use an SAF special tool only Fig 55 Clamping device for inserting the slide function assembly 1 Fasten the brake calliper securely in a vice with soft jaws see Fig 55 Ensure that the jaws of the vice do not damage the brake calliper A A Fig 56 Removing the protective caps 2 Use a small hammer and chisel to remove the protective caps A from the fixed and floatin...

Страница 31: ... D C Fig 59 Removing the guide pins 5 By hand push out the fixed bearing C and float ing bearing D see Fig 59 E Fig 60 Removing the bellows and guide pins 6 Remove both guide pin bellows E see Fig 60 If necessary use a small screwdriver in order to lever them out Be careful not to damage the guide pin bellows sealing surfaces if using a tool to lever out the bellows H F G F Fig 61 Removing the sli...

Страница 32: ... P N 4 434 3884 00 P N 4 434 3837 P N 4 434 3848 00 P N 4 434 3841 00 P N 4 434 3890 00 and P N 4 434 3889 see Fig 63 12 Once fitted correctly rotate the threaded tool clockwise which will pull out the composite bush ing 5 5 3 Cleaning Caution Use a vacuum cleaner to clean the surfaces Do not use compressed air Take care when using chemicals and or cleaning tools e g knives brushes etc This to avo...

Страница 33: ...34 3841 00 P N 4 434 3889 00 and P N 4 434 3890 00 preloaded with the new components see Fig 66 3 Once fitted correctly rotate the threaded tool clockwise which will pull into position the two bearing bushings F and the spacer G OK OK Fig 67 Correct incorrect installation of the fixed bearing bushings 4 Stop once the bearing bushings are seated in the correct position on the inside edge of the bea...

Страница 34: ...ating bearing guide bolt D into the composite bushing see Fig 70 The longer guide pin C is inserted into the fixed bearing side Note that one end of the guide pins has a machined groove This side should be inserted first No grease is required 8 Check that the bellows location ring is fitted correctly and in one piece By hand locate the bel lows onto the end of the guide pin Ensure that the bellows...

Страница 35: ...e this procedure read and follow chapters 1 5 7 3 Installing the disc brake 2 5 2 3 Installing the brake pads 3 5 3 3 Installing the brake chamber 4 3 3 Function test to ensure that the disc brake is working correctly 5 3 4 Final procedure 5 6 Fully replacing the reset shaft 5 6 1 Initial procedure Caution Where indicated use SAF special tools only Read and follow chapter 3 2 Initial procedure pri...

Страница 36: ...e disc brake 1 Refit the old pad retainer by first locating the pad retainer in the housing end in the brake calliper ap erture Then place the rectangular aperture of the pad retainer over the brake calliper seal Finally slide the pad retainer under the brake calliper seal until the spring of the brake pad retainer engages in the locking position see Fig 75 Caution Check that the spring bracket is...

Страница 37: ...d retainer and brake pad retainer spring Dispose of the old brake pad retainer and the old pad retainer spring They must not be re used 5 7 4 Final procedure To conclude this procedure read and follow chapters 1 5 2 3 Installing the brake pads 2 5 3 3 Installing the brake chamber 3 3 3 Function test to ensure that the disc brake is working correctly 4 3 4 Final procedure 6 Specifications The air a...

Страница 38: ... bolts x 2 for guide pins 180 Nm 70 Brake chamber fastening nuts 180 Nm 210 Nm Brake calliper bolted connection 450 Nm 30 120 Nm 60 7 Tools 7 1 SAF special tool for SBS 2220 H0 The listed tools are part of the SAF Universal Toolbox for disc brakes P N 3 434 3328 01 or available as an addi tional set P N 3 434 3335 00 for the existing SAF Universal Toolbox SAF special tool for SBS 2220 H0 SAF no De...

Страница 39: ...journey 8 2 Inspection intervals Caution Risk of serious accidents which may lead to serious or fatal injuries Missing or damaged components must be replaced immediately by an authorised workshop and by appro priately trained personnel In the case of vehicles with extreme operating conditions the inspection intervals must be reduced Inspection intervals Every month or 10 000 km Every 3 months or 5...

Страница 40: ...list 40 en XL SA30000RM en DE Rev A 02 2016 Errors and changes excluded SAF HOLLAND 9 Spare parts and repair kit list Spare parts and repair kits for compressed air disc brake SAF SBS 2220 SBS 1918 H0 Fig 77 Spare part illustration ...

Страница 41: ...64 2 4 Spring clip cannot be ordered individually 065 Reset shaft group item 65 65 1 03434386200 65 1 Adjuster plugs cannot be ordered individually 65 1 1 Adjustment screw cannot be ordered individually 066 Pressure fitting seal kit 03434386300 068 Wear indicator kit 03424203300 68 1 2 Brake pad wear indicator cannot be ordered individually 68 2 2 Mounting plate cannot be ordered individually 70 G...

Страница 42: ...aße 26 D 63856 Bessenbach Emergency hotline 49 6095 301 247 Customer Service 49 6095 301 602 Fax 49 6095 301 259 service safholland de www safholland com XL SA30000RM en DE Rev A 02 2016 Errors and changes excluded SAF HOLLAND ...

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