Repair Instructions Compressed Air Disc Brake SAF SBS 2220 H0
Contents
1. Chapter 4 3 1 Brake Pads Sae gt Chapter 4 3 3 Brake Disc gs Chapter 4 3 5 Function Test I Chapter 3 3 Plugs and Protective Cups 1 Chapter 4 3 6 Thrust Plate Guide Pins TES Chapter 4 3 7 Actuation Interface ius gt Chapter 4 3 8 Slide Pin Bellows Le Chapter 4 3 9 Adjustment Screw Bellows qx Chapter 4 3 10 Slide Function Les Chapter 4 3 11 4 3 Inspections 4 3 1 Daily Visual Inspection Danger Contact the Service Workshop immediately if there is any sign of reduced performance or the brakes do not work properly 1 Check that the brakes function properly before driving and that they work effectively and smoothly 2 Check that the service and parking brake function is effective by trying to drive the vehicle with the service and parking brake applied 4 3 2 Check overall condition 1 Make sure you have good lighting conditions 2 Inspect visible parts of the brake and its components Look for damage collection of debris corrosion overheating signs cracks in brake discs unusual wear etc XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND 4 Inspection Procedures SAF P SAF HOLLAND Group 4 3 3 Check Brake Pad wear N Danger Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health Brake pad wear produces dust which can cause lung damage2. The failure of any individual provision of this disclaimer to comply with current legal provisions does not affect the validity of the remaining provisions Copyright These repair instructions are classified as in accordance with the law on unfair competition All rights reserved by SAF HOLLAND GmbH Hauptstrasse 26 63856 Bessenbach Germany These repair instructions contain text and drawings that without the express permission of the manufacturer cannot be either fully or partly duplicated e distributed or e in any other way disclosed Any breach or infringement will result in liability for damages XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND S a F Table of Contents P SAF HOLLAND Group Table of Contents ul iffe M 4 TeV General Informations an Mes mn nel tin 4 1 2 Functional D SCripti n rss EUER 4 PAS Mudis eT 5 2 1 General INFOMATION err rette t Ee Fg peste dente d dened Tia i egasini E aii dana 5 PAPA liene 5 2 3 Adjustment of Control System Valves iii 5 2 4 Brake Chamber M 6 25 R CVEIITI Rd A M EINE ILES UE IEEE 6 PAESI Io 6 2 7 Surface finishing for DISC Brake re iecit teer ti e iii teret ev irr Re p eee eee 6 3 Initial and Final Procedures isinsin e e tif Drei EErEE rE EAA S a Ce
3. a Note Step 1 in this procedure only indicate the pad wear of the outer pad For a full examination do all steps 1 Inspect the position of the Visual Wear Indicator VWI see Fig 14 This check can be done with either the wheel fitted or removed The VWI provides an indication of pad wear condition but it does not provide an accurate measurement of pad wear on both pads To obtain an accurate wear measurement of both pads continue with the following instructions 2 Remove the wheel according to gt Chapter 3 2 3 Remove brake pads according to gt Chapter 5 2 2 4 Look for unusual conditions like excessive corrosion and high heat cycles i e delamination discolouration etc If found carry out the relevant measures see chapter 2 Chapter 8 2 for fault finding Fig 14 Inspection of the Visual Wear Indica 5 On both brake pads measure the distance from back plate A to wear surface B of the brake pad in four places see Fig 15 Minimum permitted lining thickness friction material is 2 mm 6 Check the condition of the back plate A 7 Replace brake pads if they are worn out or if they are expected to be so before dy Tom the next inspection For replacement follow the instructions in chapter Chapter 5 2 8 If the inspection is completed satisfactorily conclude by following chapters Chapter 5 2 3 and 2Chapter 5 2 4 Fig 15 Measuring the pad wear condition Note This brak
4. The shipping seal fitted to the brake chamber opening on a new disc brake does not provide adequate protection during shot blasting a Note Do not forget to follow the recommendations of the brake chamber manufacturer The disc brake must be thoroughly cleaned after blasting to ensure that its natural movement is not obstructed by remnants of shot blasting material Check the seals rubber parts to make sure they have not been damaged Also refer to the axle manufacturer s instructions XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND 3 Initial and Final Procedures SAF SAF HOLLAND Group 3 Initial and Final Procedures 3 1 General Information The objective of this chapter is to give guidelines on how Initial and Final Procedures shall be performed in a standardised way Initial Procedure is a recurring procedure that have to be performed prior to the Inspection and or Replacement procedures covered in this Service Manual Final Procedure is a recurring procedure that have to be performed after an Inspection and or Replacement procedure covered in this Service Manual 3 2 Initial Procedure 3 2 1 Lift up and support the vehicle axle N Danger e At least one of the vehicle s axles shall be chocked to prevent involuntary movement of the vehicle e The vehicle manufacturer s safety precautions shall be followed when working on the vehicle e Local safety precautions must be observed 1 On a f
5. 8 Fault Finding to assist further 2 Remove the reset shaft protection plug item A see Fig 7 Careful Use recommended tools only e Never use an impact wrench or similar to turn the reset shaft This may damage internal parts of the mechanism Torque is 20 Nm max a Note The Torx 55 and the Thrust plate must be allowed to move unhindered 3 Using a Torx 55 socket de adjust the brake by turning the reset shaft anti clockwise by 4 clicks or till the end stop see item B see Fig 7 A clicking sound shall be heard and felt when retracting Careful e When reaching the end stop position of de adjustment never tighten and leave Leaving the reset shaft tightened in the de adjust position could stop the adjustment function from working i TN e After reaching the end stop position always then adjust by Fig 7 De adjustment via the reset turning the reset shaft clockwise 90 degrees thus activating shaft the adjustment function 4 Leave the Torx 55 in position in the reset shaft XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND 3 Initial and Final Procedures SAF Actuate the brakes 5 times by pressing and releasing the vehicles brake pedal The Torx 55 must rotate clockwise only on each actuation showing that the If the Torx 55 rotates back and forth or not at all then the adjustment function To check further manually adjust the reset shaf
6. HO P N 4 434 3886 00 Sleeve SBS 2220 HO 8 Fault Finding 8 1 General fault finding instructions Danger Risk of serious traffic accidents which may lead to serious or fatal injuries e Repair work must only be carried out by authorised workshops and by staff with the appropriate training e All components which are not in a serviceable condition must be replaced e The general safety inspection must be performed as per legal regulations e Itis the duty of the driver to perform a daily inspection of the vehicle for traffic safety before starting the journey 8 2 Fault finding rectification Danger Risk of serious accidents which may lead to serious or fatal injuries e Missing or damaged parts should be replaced immediately by an authorised workshop and by appropriately trained personnel e n the case of vehicles with extreme operating conditions the inspection intervals must be reduced Inspection intervals E E E E o 8 x E o S E e S o A e S e 6 E i dram ss B S S A o E E gt E m wo N E E E o v o v gt gt gt gt LL LL LL LL General safety inspection as per legal regulations Visual inspection Connecting hoses X Electrical cables X Functional test Check the control unit for outlet pressure x Prior to initial use Check the warning light F 7 X E Prior to initial use Check pressure pipes through alignment of the system pressure 7 E x
7. SAF HOLLAND SAF 5 Replacement Procedures FA SAF HOLLAND Group Careful Be careful not to damage the slide pin bellows sealing surfaces in the calliper 5 By hand push out and remove the leading slide pin C and the trailing slide pin D see Fig 52 6 Remove both guide pin bellows E see Fig 53 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 levering out the bellows Fig 53 Remove bellows and slide pins 7 Carefully follow the steps below Step 8 and Step 9 to remove the two leading bearings F and the spacer G and trailing composite bushing H see Fig 54 ModulT_064 Fig 54 Remove the slide bearings and composite side bushing 8 To remove both bearings F and the spacer G on the leading side assemble in pS sequence SAF special tools 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 as FR shown in Fig 55 9 Once fitted correctly turn the threaded tool clockwise which will pull out the two bearings F and the spacer G If necessary rotate the mandrel P N 4 434 3889 00 half way through the extraction process so the nut P N 4 434 3841 00 can be held 10 The c
8. VEDI 33 7 1 SAF special tool for SBS 2220 HO iii 33 Az dshpp bec 34 8 1 General fault finding instructions sis 34 8 amp 2 Fault findlig FectitiCatiOn u ocior e pesich sOedeantednes armes endet dle gen orar aene tub Ripe Rn icd enge Rcs 34 9 Component and Repair Kit List eeeeeeeeeeseeseeeeeeeeee seen nnn enne aAA n ninh nennt nain nnns tnn Rasi Srina TEFA 35 9 d1 Componentand RepaltKIB EISE ucc Nosti nn tie nn nd 35 XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND 1 Introduction SAF SAF HOLLAND Group 1 Introduction 1 1 General Information The SAF SBS 2220 HO repair instructions are divided up into chapters The sequence of the chapters is structured in such a way as to make the instructions easy for the user to read and simple to follow Chapter 1 Introduction provides a general overview of these repair instructions and the SAF SBS 2220 HO compressed air disc brake It is important to carefully read chapter 2 Safety Precautions before starting any workshop procedures This is to inform the user about the safety measures and the potentially hazardous situations which if not avoided could result in serious injury or death Chapter 3 Initial and Final Procedures describes the start and finish activities necessary to be able to carry out inspection and rep
9. approx 15 mm in its rest position see Fig 24 8 Activate the service brake the brake chamber actuation rod should protrude approx 65 mm 9 Also check that the actuation rod extends perpendicular to the external seal flange 10 Check through the aperture in the brake chamber attachment flange for moisture corrosion see Fig 25 It s important to look inside the aperture and not just on the surface If corrosion is seen then further inspection is necessary If concluded that water has ingressed causing internal corrosion damages to the mechanism then replace the calliper complete to avoid operating problems If action is required see Replacement of Calliper 11 0n the brake chamber there must be an internal bellows A on the push rod see Fig 26 12 Check that the bellows are complete and not damaged by looking around and down the push rod shaft Also look for signs of water or corrosion which may be a sign that the bellows are damaged 13 Check that the external seal flange B is correctly seated in place intact and undamaged 3 D 14 Once the inspection is completed satisfactorily conclude by reading and Fig 26 Internal view of a brake following chapters 2 Chapter 5 3 3 and 2Chapter 5 3 4 chamber 4 3 9 Check Slide Pin Bellows Danger Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health Brake pad wear produces dust which can cause lung damage Car
10. avoid damage or displacement of hoses seals and other components XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND 5 Replacement Procedures SAF SAF HOLLAND Group 1 If necessary remove dirt dust and other possible obstruction Careful e Use SAF HOLLAND tools only where this is specified Never use an impact wrench or suchlike to turn the reset shaft This will damage internal parts of the mechanism Torque is 20 Nm max g Note The thrust plate must be fully retracted to be able to fit new pads N Remove the reset shaft protection plug See Fig 31 UJ Use the Torx 55 socket to manually turn the reset shaft anti clockwise to de adjust the brake so that the thrust plate fully retracts to its inner position A clicking sound shall be heard and felt when retracting The stop at fully retracted inner thrust plate position must be distinct but do not exceed 20 Nm in torque or leave it tightened in this position In the de adjust position the adjustment function is overridden Fig 31 De adjust the thrust plate via the reset shaft Careful Always ensure the pad retainer spring bracket is fully held down whilst levering out the pad retainer 4 Remove the pad retainer by first pushing and holding down the spring bracket A see Fig 32 Whilst the spring bracket A is held down slide out and remove the pad retainer B A tool can be used to help slide
11. calliper B with nuts E see Fig 39 Screw the nuts home first before torque tightening to ensure the brake chamber sits parallel Brake chamber fixation nut tightening torque is 180 20 Nm Careful Do not mix up the hoses Fig 39 Install Brake Chamber components 6 Fit the brake chamber hose connection of the service brake C and if applicable the parking brake D If fitting both hoses ensure connections C and D are the correct way around See Fig 39 7 Remove the ventilation drain plug that faces downwards from the brake chamber housing see Fig 40 Also from the spring brake chamber if applicable Careful Apply air to the parking brake Make sure that there is sufficient air in the system min 6 bar Mout 034 amp SX SUR M Fig 40 Remove the ventilation drain pl 8 If applicable release the parking brake and disengage the spring brake ES chamber s caging mechanism so that the spring is released Min 6 bar in compressed air system 9 With the service brake engaged and where applicable with the parking brake released check the brake chambers hoses and connections for leaks or damage 5 3 4 Final Procedure To conclude this procedure read and follow chapters 1 Function Test Chapter 3 3 to ensure that the disc brake is working correctly 2 Final Procedure Chapter 3 4 5 4 Replacement of Adjustment Screw Bellows 5 4 1 Initial Procedure Read and follow the c
12. disc brake 1 Initial Procedure Chapter 3 2 2 Remove the brake pads 2 Chapter 5 2 2 3 Remove the brake chamber 2 Chapter 5 3 2 XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND 6 Specifications SAF SAF HOLLAND Group 5 7 2 Remove the Disc Brake N Careful Do not remove the disc brakes retaining bolts until the brakes weight is supported by the lifting straps 1 Refit the old pad retainer by first locating the pad retainer in the housing end in the calliper aperture then locating the pad retainer slot over the calliper latch finally slide the pad retainer under the calliper latch until the pad retainer spring pops into locking position See Fig 68 Careful Check that the spring bracket is correctly engaged 2 Attach a lifting strap around the pad retainer Tension the lifting strap so taking the full weight of the brake Fig 68 Remove the Disc Brake 3 Remove the retaining bolts holding the disc brake and lift away from the axle 5 7 3 Install Disc Brake 1 Clean the mating faces of the new disc brakes carrier and axle Ensure the faces are free from dirt debris moisture and corrosion 2 Fit the old pad retainer spring then refit the old pad retainer by first locating the pad retainer in the housing end in the calliper aperture then locating the pad retainer slot over the calliper latch finally slide the pad retainer under the calliper latch until the pad retainer
13. excluded SAF HOLLAND Srp olang OFFICIAL SERVICE SAF D GF TRILEX ew Emergency hotline 49 6095 301 247 Emergency hotline Num ro d urgence Customer Service 49 6095 301 602 Customer Service Service apr s vente Fax 49 6095 301 259 service safholland de www safholland com SAF HOLLAND GmbH Hauptstrasse 26 SA au 63856 Bessenbach Germany 1 Engineering Your Road to Success XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND
14. is completed satisfactorily conclude by reading and Fig 30 Free movement of the following chapters 2 Chapter 5 3 3 and 2 Chapter 5 3 4 calliper it must be free to slide on the leading and trailing slide pins a Note Obstruction of the slide function can cause operational problems like hot brakes and uneven brake pad wear 5 Replacement Procedures 5 1 General Information The objective of this chapter is to give instruction and guidance on how the disc brake and or its components shall be replaced All the replacement procedures in this chapter require that the wheel is taken off to enable the replacement work to be carried out 5 2 Replacement of Brake Pads 5 2 1 Initial Procedure Read and follow chapter Chapter 3 2 Initial Procedure prior to removing the brake pads 5 2 2 Remove Brake Pads Danger Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health Brake pad wear produces dust which can cause lung damage e Sudden release of tensioned springs can cause injury e Do not actuate the brake when changing the brake pads e Also ensure the air brake system is pressurised during the replacement procedure min 6 bar If the pressure drops below 6 bar the park brake will be actuated N Careful Use a vacuum cleaner to clean surfaces Do not use compressed air e Itis important to take care when using chemicals and or cleaning tools e g knife brush etc This to
15. is to give guidance on how inspection of the brake components shall be conducted Always start by consulting the Inspection interval table below in chapter 4 2 The Inspection interval table displays how frequent the different brake components shall be inspected and on which pages the check instructions are found The majority of the inspections demand that the wheel is removed from the vehicle Before removing the wheel read chapter 2 Safety Precautions followed by 3 Initial and Final Procedures XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND 4 Inspection Procedures SAF SAF HOLLAND Group 4 2 Inspection intervals The check 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 Functional test 2 Adjustment a 3 Visual inspection si z With wheels fitted z With wheels removed v 5 E 9 o 9 E n as E o e PE a LE IS g o E t 9 B P o S 8 2 E 9 eo N o o em e 2A 2 o gt 5 D E a s P P S s ea a lt x mw wi ua Adjustment of Control System Valves Wes Ts Chapter 2 3 Braking Force Distribution Tractor 7 _ 1 2 ES 1 2 Chapter 2 3 3 Trailer Safety Check A
16. out the pad retainer if unable to do so by hand Continue to remove the two pad springs C Fig 32 Remove Brake Pad components N Careful Always remove the outer brake pad first You cannot directly pull out the inner brake pad with the outer still in place as the inner brake pad is located to the thrust plate on two points 5 Remove the brake pads Always remove the outer brake pad A first followed by the inner brake pad B See Fig 33 This is because the inner brake pad back plate locates on two holes which mate to the thrust plate therefore you cannot directly pull out the inner brake pad with the outer brake pad still being in place Once the outer brake pad is removed the calliper can be slid across to allow for the inner brake pad to be removed 6 Remove the pad retainer spring bracket C E Fig 33 Remove Brake Pads XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND SAF 5 Replacement Procedures FA SAF HOLLAND Group 5 2 3 Install Brake Pads 1 Make sure that the brake is fully de adjusted before fitting new brake pads 2 Check that the contact surfaces on the carrier calliper and thrust plate are free from dirt and corrosion Clean the thrust plate as required Careful Theinner brake pad must always be installed first e Ensure that the friction material faces the brake disc 3 First install the inner brake pad B in the carrier not
17. particles which can be hazardous to your health Brake pad wear produces dust which can cause lung damage e If the disc brake is equipped with a parking brake function ensure that the brake system is depressurised that the spring brake chamber is fully disengaged and mechanically secured in the released position See the vehicle manufacturer s instructions e Pressure from lines and components shall be released before opening them N Careful e Use a vacuum cleaner to clean surfaces Do not use compressed air XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND 5 Replacement Procedures N Careful e Itis important to take care when using chemicals and or cleaning tools e g knife brush etc This to avoid damage or displacement of hoses seals and other components Thoroughly clean around the mating surfaces of the brake chamber A and calliper B to ensure that dirt does not get into the mechanism area when removing the brake chamber See Fig 36 If applicable ensure that the spring brake chamber F is fully disengaged and mechanically secured in the released position See Fig 37 Ensure that the brake chamber A is depressurised Mark and remove the hose connections of the service brake C and if applicable the parking brake D Remove the two nuts E holding the brake chamber Remove the brake chamber A from the calliper B Once the brake chamber is removed it i
18. parts in the disc brake operating system such as brake valves or control units the disc brake operating system must also be checked and adjusted if necessary in accordance with the relevant braking calculations 2 3 3 Brake Force Distribution It is very important that the distribution of brake force between axles vehicles in a vehicle combination is adapted so that the brake force for each axle vehicle is proportioned in accordance with the legally applied braking 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 discs tyres and wheel components XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND 2 Safety Precautions S A E SAF HOLLAND Group Before a vehicle is entered into service it must be set up according to the specified values in the relevant brake calculations After the pads brake discs have been run in for a period of around 3 000 5 000 km the brake force distribution between the truck tractor and trailer may require adjustment Brake adjustment must also be carried out during repairs changing spare parts when heating overheating has suspected to damaged the axle brake components e g seals hub wheel bearings and brake disc Contact the vehicle supplier for information on the appropriate action Following repla
19. squarely tap the protective cups AT and AL in place into the calliper using a soft headed mallet Note that the cups are different sizes the larger cup is fitted to the trailing side AT and the smaller to the leading side AL The leading protective cup AL seats raised from the casting surface whilst the trailing protective cup AT sits nearly flush See Fig 65 13 Do not strike the cups hard or at an angle as this may damage them and therefore compromise the sliding function of the brake 3 A 14 Ensure the protective cups are correctly seated and bottomed out see Fig 65 Fig 65 Correctly s protection cups eating the 5 5 5 Final Procedure To conclude this procedure read and follow chapters 1 Install the disc brake 2 Chapter 5 7 3 Install the brake pads 2 Chapter 5 2 3 Install the brake chamber 2 Chapter 5 3 3 Function Test 2 Chapter 3 3 to ensure that the disc brake is working correctly Ui BU N Final Procedure 2 Chapter 3 4 XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND SAF 5 Replacement Procedures FA SAF HOLLAND Group 5 6 Replacement of Reset Shaft Complete 5 6 1 Initial Procedure Careful Only use SAF special tools where specified Read and follow chapter Chapter 3 2 Initial Procedure prior to removing the reset shaft complete 5 6 2 Remove Reset Shaft Complete 1 If necessary remove dirt dust and other possible d
20. to remove the two leading bearings F and the spacer G and trailing composite bushing H see Fig 58 NON 9 SO pos Fig 58 Install the leading slide bearings and trailing side bushing XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND SAF 5 Replacement Procedures SAF HOLLAND Group assemble in sequence SAF special tools P N 4 434 3837 00 P N 4 434 3848 00 P N 4 434 3841 00 P N 4 434 3889 00 and P N 4 434 3890 00 preloaded with the new parts as shown in Fig 59 LO 2 To install the two new bearings F and the new spacer G on the leading side e e i 3 Once fitted correctly turn the threaded tool clockwise which will pull into position the two bearings F and spacer G complete Fig 59 Tool assembly for leading slide bearings 4 Stop once the bearings are seated in there correct position up to the inside lip of the bearing location surface see Fig 60 It is important the bearings are seated correctly but not over tightened as this may cause damage ModulT 083 Fig 60 Leading side bearings installed correctly incorrectly Careful The trailing side composite bushing must be indexed correctly when being installed into position by hand If not corr
21. E Prior to initial use XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND cn 9 Component and Repair Kit List 9 1 Component and Repair Kit List Spare parts and repair kits for the compressed air disc brake SAF SBS 2220 HO Spare parts and repair kits Fig 70 item no Quantity Designation Order no 060 1 Right brake calliper group SBS 2220 HO 3080008200 63 1 64 1 2 Pad retainer spring bracket SBS 2220 4 Brake pad 22 5 cannot be ordered individually cannot be ordered individually 065 Reset shaft group Items 65 65 1 03434386200 65 1 e Adjustment screw cannot be ordered individually 068 68 2 Wear indicator kit 2 Mounting plate 03424203300 cannot be ordered individually 70 1 2 Torx screw cannot be ordered individually 70 3 2 Bearing cannot be ordered individually 70 5 1 Slide bearing cannot be ordered individually 80 4 2 Bellows cannot be ordered individually 83 1 1 Protective cup cannot be ordered individually XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND 9 Component and Repair Kit List SA SAF HOLLAND Group Spare parts overview ModulT 052 Fig 70 Spare parts illustration XL SA11745RM en DE 02 2012 Errors and changes
22. Fig 10 S E Fig 10 Attach the protection plug correctly 3 4 1 Mounting of the wheel Danger Make sure that the brake hoses are in good condition that they are laid ducted and fastened correctly XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND 4 Inspection Procedures SAF SAF HOLLAND Group 1 Check the free rolling resistance The disc brake must not be obstructed in any way 2 Mount the wheel see Fig 11 8 h 5 E E Fig 11 Mounting of the wheel 3 4 2 Lowering of the vehicle axle Danger If the disc brake is equipped with a parking brake function ensure that the brake system is pressurised that the spring brake chamber is fully engaged and mechanically secured in the active position See the vehicle manufacturer s instructions See the vehicle manufacturer s instructions Careful Actuate the parking brake Make sure that there is sufficient air in the system min 6 bar wo oO E 3 o Fig 12 Mechanically secure in released position 1 Activate the parking 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 4 Remove the wheel blocks see Fig 13 5 i Fig 13 Removing the safeguards 4 Inspection Procedures 4 1 General Information The objective of this chapter
23. SAF HOLLAND Group Compressed Air Disc Brake SAF SBS 2220 HO XL SA11745RM en DE ayy Holland Engineering Your Road to Success SAF SAF HOLLAND Group Please note These repair instructions are intended for the exclusive use by trained persons within the commercial vehicle industry and related workshops The content of this manual is not all inclusive and not legally binding SAF HOLLAND GmbH assumes no liability as a result of its use All information contained in the manual does neither represent ensured characteristics of the product nor represent a guarantee SAF HOLLAND GmbH reserves the right to make changes in the interest of technical progress without prior notice No liability is assumed as a result of incorrect or inappropriate parts being fitted to the product or the omittance of appropriate tests after the servicing of the product Use appropriate spare parts documentation when obtaining spare parts Use only genuine SAF HOLLAND GmbH spare parts in repairs This manual is subject to a 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 In case of conflicting language versions of this manual the English original prevails
24. brake disc is 37 mm The brake disc must be replaced if the wear limits have been exceeded XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND 4 Inspection Procedures SAF i SAF HOLLAND Group a Note This brake disc inspection check procedure is only a general guide Refer to the vehicle manufacturers documentation for specific brake disc information and instruction 4 3 6 Check Plugs and Protective Cups Danger Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health Brake pad wear produces dust which can cause lung damage N Careful Use a vacuum cleaner to clean surfaces Do not use compressed air Failure to follow the instructions below could compromise safety and or reduce the life of the Disc Brake and its components Read and follow chapter 2Chapter 3 2 Initial Procedure prior to inspecting the protective plugs and cups Remove dirt from surfaces if necessary Check for signs of excessive heat exposure discolouration debris etc The following plugs and protective cups shall be in place and intact The reset shaft protection plug identified as A and calliper seal B see Fig 19 e Protection plug B is never removed T5 Vh s 5 The three protective cups two for slide pin protection C and one for the mechanism D see Fig 20 6 Once the inspection is completed satisfactorily conclude by reading and follow
25. cement of any essential components or spare parts in the disc brake operating system e g brake valves or control units the disc brake operating system must also be checked and adjusted in accordance with the relevant braking calculations Failure to follow these instructions may cause damage repeated damage to the disc brake axle and or wheel brake components 2 4 Brake Chamber Moisture water ingress into the disc brake s mechanism housing will potentially affect the function of the disc brake and as a result shorten its life Therefore to prevent water ingress it is important that the disc brake chamber is of the correct design and that the seal between the brake chamber and disc brake mating surface is undamaged correctly in place It is also important for the disc brake s function that the brake chamber housing is correctly ventilated As a minimum the drain holes facing downwards must be open see Fig 3 Other drain plugs can remain in position in the brake chamber housing K Fig 3 Brake chamber ventilation Careful If all the plugs remain fitted the brake chamber and disc brake will not operate correctly 2 5 Recycling When replacing the disc brake or parts thereof the components removed must be recycled destroyed in compliance with applicable environmental legislation regulations and provisions 2 6 Cleaning For the disc brake to function correctly it is important to ensure it is kept clean and that its nor
26. e Note that one end of the slide pins has a machined groove this side is inserted first No grease is required 8 Check that the bellows location ring is fitted correctly and in one piece By hand locate the bellows onto the end of the slide pins Ensure the bellows and the bellows location ring seat correctly on the slide pins Failure to do so may compromise the sliding function of the brake 9 Clean the brake pad contact surfaces on the carrier the calliper and the thrust plate A wire brush can be used but be careful not to damage any of the bellows Do not grind Fig 63 Insert the slide pins ModulT 056 Careful Never re fit used bolts 10 Lift the carrier into position in the calliper ensuring that the slide pins fitted with bellows do not interfere or obstruct If necessary push out the slide pins slightly by hand whilst lowering in the carrier Hold the carrier in position whilst the two bolts are inserted and screwed home See Fig 64 11 Use a 3 4 long drive 14mm Insex to screw in and tighten the screws B The tightening torque is defined in chapter 2 Chapter 6 2 2 Fig 64 Refit the carrier and its fixing bolts N Careful The protective cups are different sizes and when fitted must be seated correctly The leading cup is smaller than the trailing cup The leading cup must bottom out against the bearing and the trailing cup must bottom out against the calliper shoulder 12 Carefully and
27. e disc inspection check procedure is only a general guide Refer to the vehicle manufacturers documentation for specific brake disc information and instruction 4 3 4 General Brake Pad clearance check Danger Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health Brake pad wear produces dust which can cause lung damage Note e Checking the clearance is only required for an approximation of the clearance between the brake disc and the brake pads e The check can be carried out with or without the brake chamber fitted XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND sr 4 Inspection Procedures SAF a Note e This check is best performed after the wheel is removed and before the brake is de adjusted For this situation the steps 2 and 3 below can be skipped SAF HOLLAND Group 1 Read and follow chapters gt Chapter 3 2 and paragraph 5 2 Chapter 5 2 2 Remove Brake Pads prior to checking the pad clearance 2 Adjust the reset shaft by inserting and manually turning the Torx 55 socket clockwise until it comes to a stop and any excessive clearance is removed Then de adjust the reset shaft by turning it anti clockwise by 2 clicks 3 Activate the brake until the Torx 55 male no longer rotates because any excessive clearance has been removed by the adjustment function 4 Insert two feeler gauges in between the calliper and the outer brake pad to measure the c
28. e that the inner brake pad locates onto the thrust plate on two points see Fig 34 Then fit the outer brake pad A 4 Check that the contact surfaces on the pad retainer spring bracket are free from dirt and corrosion Clean the pad retainer as required 5 Install a new spring bracket C into the calliper and ensure it is seated in position correctly Fig 34 Install Brake Pads Danger Upon assembly ensure the pad retainer spring bracket is in its correct locking position 6 Fit the new pad springs A and the pad retainer B The pad retainer is fitted by first locating the pad retainer in the housing end in the calliper aperture then compressing the pad springs and locating the pad retainer slot over the calliper latch finally slide the pad retainer under the calliper latch until the spring bracket pops into its locking position see Fig 35 If necessary use a tool to help push the pad retainer into position Fig 35 Install Brake Pads 5 2 4 Final Procedure To conclude this procedure read and follow chapters 1 Function Test Chapter 3 3 to ensure that the disc brake is working correctly 2 Final Procedure Chapter 3 4 5 3 Replacement of Brake Chamber 5 3 1 Initial Procedure Read and follow chapter gt Chapter 3 2 Initial Procedure prior to removing the spring brake chamber 5 3 2 Remove Brake Chamber N Danger Wear respiratory protection in order to avoid inhaling
29. ebris from around the reset shaft area Ensure the area is clean prior to removing the reset shaft protection plug 2 Remove the reset shaft protection plug A 3 Insert SAF special tool P N 4 434 3885 00 and pull out the reset shaft B with x ring complete see Fig 66 The x ring is always fitted to the reset shaft and never removed Fig 66 Remove the reset shaft 5 6 3 Install Reset Shaft Complete 1 Clean the reset shaft location surfaces in the calliper housing Ensure the areas are free from dirt dust debris moisture and corrosion 2 Insert the Torx 55 socket into the new reset shaft and put this into the brake calliper Whilst doing so make sure the x ring is correctly in place The reset shaft complete with x ring already fitted is supplied ready lubricated no additional grease or other lubrication is required 3 Push the reset shaft into position by hand no impact or high forces are required as they may damage the reset shaft The resent shaft will click into its position in the centre of the gear wheel when fully engaged See Fig 67 Fig 67 Install the reset shaft 5 6 4 Final Procedure To conclude this procedure read and follow chapters 1 Function Test Chapter 3 3 to ensure that the disc brake is working correctly 2 Final Procedure 2 Chapter 3 4 5 7 Replacement of Disc Brake 5 7 1 Initial Procedure Read and follow the chapters below prior to removing the
30. ectly indexed the slide function of the brake will not be correct 5 To install the new composite bushing H on the trailing side by hand push the composite bushing into place until it bottoms out Ensure the index lug locates correctly in the calliper slot see Fig 61 No tools or high forces are required for this fitting process nor should they be used If used they may cause damage If the bushing is not indexed correctly the slide pin and protective cup may not fit 8 E 5 E Fig 61 Inserting the trailing side composite bushing Careful When inserted the slide pin bellows must seat correctly bottoming out against the calliper location shoulder 6 By hand firmly push the two new slide pin bellows into their calliper locations TN CAEN ensuring that the bellows are seated correctly in position see Fig 62 It is M MA 69 important to check that the bellows is correctly seated within the calliper do so by looking inside the bellows to see their seating Failure to do so may compromise the sliding function of the brake ModutT_045 Fig 62 Install Slide Pin Bellows XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND 5 Replacement Procedures SAF SAF HOLLAND Group 7 By hand insert the leading slide pin C into the bearings and the trailing slide pin D into the composite bushing see Fig 63 The longer slide pin C is fitted into the leading sid
31. eful e Itis important to take care when using chemicals and or cleaning tools e g knife brush etc This to avoid damage or displacement of hoses seals and other components Use a vacuum cleaner to clean surfaces Do not use compressed air 1 Read and follow Chapter 3 2 Initial Procedure prior to inspecting the slide pin bellows 2 nspect the Leading slide pin bellows A and the Trailing slide pin bellows B see Fig 27 Look all around the bellows for damage signs than could have been x caused by debris stones or overheating 3 If the bellows are damaged then they must be replaced For instructions on SS how to replace the bellows read and follow chapter 2 Chapter 4 3 11 4 Once the inspection is completed satisfactorily conclude by reading and S following chapters gt Chapter 5 3 3 and gt Chapter 5 3 4 Fig 27 Inspecting the slide pin bellows XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND 4 Inspection Procedures SAF SAF HOLLAND Group 4 3 10 Check Adjustment Screw Bellows Danger Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health Brake pad wear produces dust which can cause lung damage Careful gt e Itis important to take care when using chemicals and or cleaning tools e g knife brush etc This to avoid damage or displacement of hoses seals and other components e Use a vacuum cleaner to clean surfac
32. er end of the adjustment screw bellows See Fig 46 12 By hand firmly press on the special tool with equal and parallel force so that the adjustment screw bellows is pressed into position within the calliper 13 The special tool can be removed rotated and then reapplied to aid the equal and parallel bellows seating Fig 46 Pressing in the Adjustment Screw Bellows 14 Remove the special tool Check that the bellows is correctly seated all around within the calliper see Fig 47 Also re check the bellows is seated correctly on the thrust plate see Fig 44 Failure to seat the bellows correctly will compromise the life of the brake 15 Retract the thrust plate fully to its inner position by manually turning the reset shaft anti clockwise A clicking sound shall be heard and felt when retracting The stop at fully retracted inner thrust plate position must be distinct but do not exceed 20 Nm in torque or leave it tightened in this position In the de adjust position the adjustment function is overridden ModulT 092 Fig 47 Adjustment screw bellows seated correctly incorrectly 5 4 4 Final Procedure To conclude this procedure read and follow chapters 1 Install the disc brake 2 Chapter 5 7 3 Install the brake pads 2 Chapter 5 2 3 Install the brake chamber 2 Chapter 5 3 3 Function Test Chapter 3 3 to ensure that the disc brake is working correctly Fi
33. es Do not use compressed air e Never use an impact wrench or suchlike to turn the reset shaft This may damage the disc brakes mechanism Torque is 20 Nm max a Note Do not over adjust extend the thrust plate whilst carrying out the inspection Over adjustment extension will cause the thrust plate to disengage from the adjustment screw and if done unintentionally may cause damage to the thrust plate bellows Min distance between the calliper and thrust plate is 60 mm 1 Read and follow gt Chapter 3 2 Initial Procedure and Chapter 5 2 2 Remove Brake Pads prior to inspecting the adjustment screw bellows 2 Use the Torx 55 socket to manually turn the reset shaft clockwise to adjust the brake so that the thrust plate A is extended and the bellows can be viewed Stop when the distance between the inner pad face of the thrust plate and outer pad face on the calliper is 60 mm see Fig 28 M 5 s E Fig 28 Max extension to check the thrust plate bellows 3 Inspect the adjustment screw bellows see Fig 29 Look all around the bellows for damage signs than could have been caused by debris stones or overheating 4 If the bellows are damaged then they must be replaced For instructions on how to replace the bellows read and follow chapter 2 Chapter 5 4 Replacement of Adjustment Screw Bellows 5 If OK then manually de adjust the thrust plate by turning the Torx 55 reset sha
34. ft anti clockwise until the position required to refit the brake pads Fig 29 Inspecting the Adjustment 6 Once the inspection is completed satisfactorily conclude by reading and Screw Bellows following chapters 2 Chapter 5 3 3 and 2Chapter 5 3 4 4 3 11 Check Slide Function N Danger Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health Brake pad wear produces dust which can cause lung damage XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND SAF 5 Replacement Procedures FA SAF HOLLAND Group Careful e Itis important to take care when using chemicals and or cleaning tools e g knife brush etc This to avoid damage or displacement of hoses seals and other components e Use a vacuum cleaner to clean surfaces Do not use compressed air 1 Read and follow 2 Chapter 3 2 Initial Procedure and 2 Chapter 5 2 2 Remove Brake Pads prior to inspecting the slide function 2 Once the brake pads are removed move the calliper by hand back and forth to check its movement see Fig 30 The calliper 3 If the movement is felt to be obstructed in some way then it is necessary to determine the root cause see chapter Chapter 8 2 Fault Finding for assistance in this 4 If the root cause investigation concludes that the slide function needs replacing then follow chapter 2 Chapter 5 5 Replacement of Slide Function Assembly 5 Once the inspection
35. hapters below prior to removing the adjustment screw bellows 1 Initial Procedure Chapter 3 2 2 Remove the brake pads Chapter 5 2 2 3 Remove the brake chamber 2 Chapter 5 3 2 4 Remove the disc brake 2 Chapter 5 7 2 5 4 2 Remove Adjustment Screw Bellows 1 Fasten the disc brake securely in a vice with soft jaws see Fig 41 for clamping arrangement Ensure that the jaws of the vice do not damage the disc brake f 1 ModuiT 080 Fig 41 Clamping arrangement for replacing adjustment screw bellows XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND 5 Replacement Procedures Using the Torx 55 socket manually turn the reset shaft clockwise to extract the thrust plate A Continue extracting until the thrust plate unscrews fully and becomes detached from the adjustment screw see Fig 42 The point at which the thrust plate becomes detached is when the gap between the thrust plate inner pad face and the calliper outer pad face becomes smaller than 52 mm Be careful when removing the thrust plate not to damage its internal threads or the external threads on the adjustment screw Once the thrust plate becomes detached from the adjustment screw by hand pull off the adjustment screw bellows from the thrust plate and calliper Do not use any tools for this removal because damaging the sealing surfaces could cause water penetratio
36. hich can cause lung damage e Pressure from lines and components shall be released before opening them Careful e Itis important to take care when using chemicals and or cleaning tools e g knife brush etc This to avoid damage or displacement of hoses seals and other components Use a vacuum cleaner to clean surfaces Do not use compressed air This inspection procedure covers both types of brake chamber normal service and spring brake parking chambers 1 Read and follow Chapter 3 2 Initial Procedure prior to inspecting the actuation interface 2 Thoroughly clean around the mating surfaces of the brake chamber A and calliper B to ensure that dirt does not get into the mechanism area when removing the brake chamber See Fig 22 3 Release the parking brake see 2Chapter 3 2 1 Fig 22 Mating surfaces of the brake chamber and calliper 4 If applicable ensure that the spring brake chamber Fig 23 F is fully disengaged and mechanically secured in the released position 5 Ensure that the brake chamber is depressurised 6 Remove the two nuts E holding the brake chamber Remove the brake chamber A F from the calliper B see Fig 23 Fig 23 Remove Brake Chamber components XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND 4 Inspection Procedures SAF p SAF HOLLAND Group 7 With the brake chamber removed and secured the brake chamber actuation rod should protrude
37. ing chapter 2Chapter 3 4 Final Procedure Fig 20 Three protective cups N Careful Never remove the protection plug B or the protective cup D see Fig 20 and Fig 19 If the protection plug B is removed it will void warranty and will compromise the life of the disc brake 4 3 7 Check Thrust Plate Guide Pins Danger Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health Brake pad wear produces dust which can cause lung damage XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND a 4 Inspection Procedures SAF N Careful Use a vacuum cleaner to clean surfaces Do not use compressed air SAF HOLLAND Group 1 Read and follow chapter gt Chapter 3 2 Initial Procedure prior to inspecting the thrust plate guide pins 2 Remove dirt from surfaces as necessary 3 Check that the two thrust plate guide pins E are in their correct position see Fig 21 Ze A 4 Check that the thrust plate with guide pins are free to move without SG M obstruction SA f K 5 Once the inspection is completed satisfactorily conclude by reading and AU Cor ILS ad A NO E following chapter Chapter 3 4 Final Procedure N m O A O 7 Fig 21 The two thrust plate guide pins 4 3 8 Check Actuation Interface Danger Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health Brake pad wear produces dust w
38. lacement work It also describes the function test for the SAF SBS 2220 HO compressed air disc brake Consult chapter 4 Inspection Procedures for information and instructions on inspecting the SAF SBS 2220 HO compressed air disc brake Chapter 4 2 Inspection Intervals is useful for the recommended compressed air disc brake inspection intervals Here the Inspection Intervals table displays how frequently the different brake components shall 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 Specifications contains technical data for the SAF SBS 2220 HO compressed air disc brake Chapter 7 Tools contains information about the SAF SBS 2220 HO Tool Kit which is essential for carrying out much of the replacement procedure work described in this manual Chapter 8 Fault Finding should be used to help with the self diagnosis of any problem being experienced Finally Chapter 9 Components List lists and shows what spare part components are available for SAF SBS 2220 HO compressed air disc brake 1 1 1 Spare Parts It is vital that only SAF HOLLAND original spare parts are used during all service replacement activities The use of non original spare parts can affect the function performance and or service life of the parts The use of non original spare part
39. lat and even surface block the wheels see Fig 4 2 Lift the axles and place on stands N Danger If the disc brake is equipped with a parking brake function ensure that the brake system is depressurised that the spring brake chamber is fully disengaged and mechanically secured in the released position See the vehicle manufacturer s instructions 1 Fig 4 Block the wheels 3 Release the parking brake s i5 e E 3 3 e z Fig 5 Mechanically secure in released position 3 2 2 Removing the wheel Danger e Take all necessary safety precautions before wheel removal e The vehicle manufacturer s safety precautions must be followed XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND SAF 3 Initial and Final Procedures P SAF HOLLAND Group 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 to assist further 2 Remove the wheel nuts followed by the wheel see Fig 6 8 hi 5 E E Fig 6 Removing the wheel 3 3 Function Test 3 3 1 Check of Adjustment Unit a Note The function test can be carried out with the wheel both fitted or removed 1 Check that the wheel hub can rotate freely If it does not then first tap to remove any rest tension If the wheel still does not rotate freely then consult chapter
40. learance Position the feeler gauges in the upper and lower part of the brake pad back plate so an average clearance is measured see Fig 16 5 The normal running clearance is between 0 7 mm and 1 1mm If the measurement is outside of the normal running condition then refer to chapter Chapter 8 2 for further investigations 6 Once the inspection is completed satisfactorily conclude by reading paragraph 5 from chapter 2 Chapter 5 2 3 Install Brake Pads and the entire chapter Chapter 5 2 4 Final Procedure Fig 16 Correct location of the feeler gauges 4 3 5 Check Brake Disc Danger Wear respiratory protection in order to avoid inhaling particles which can be hazardous to your health Brake pad wear produces dust which can cause lung damage 1 Look for wear damages and cracks see Fig 17 Also refer to the axle vehicle manufacturer instructions Cracks that enter the cooling ducts via the outer radius are not permitted Acceptable Unacceptable crack length crack length lt 75 of brake disc width gt 75 of brake disc width 2 Measure the thickness of the brake disc using a slide calliper If the brake disc has a wear ridge the measurement can be performed using two spacers B e g 5 mm thick flat washers see Fig 18 Reduce the measured dimension by the total thickness of the two spacers B Fig 18 Measuring the brake disc thickness Minimum thickness of the
41. mal movements are not restricted by mud ice snow objects etc Damage may cause direct brake failure or damp dirt penetration resulting in malfunction shortening of the service life of the disc brake Careful It is important to take care when using chemicals and or cleaning tools e g knife brush etc This to avoid damage or displacement of hoses seals and other components 2 7 Surface finishing for Disc Brake 2 7 1 Painting The disc brake can be finished with paint that has trade approval for this purpose automotive paint Care must be taken to ensure that the paint layer does not cause damage and or restrict the natural movement or operation of the disc brake All contact surfaces friction and rubber parts must therefore be protected or masked The following areas must not be painted bellows reset shaft and its protection plug complete brake pads disc surface the disc brake mounting surfaces to axle brake chamber and all bolted connections XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND S A F 2 Safety Precautions FA SAF HOLLAND Group 2 7 2 Shot blasting Careful Failure to follow the instructions below could compromise safety and or reduce the 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 The brake chamber must be fitted or any protective parts that have a similar sealing function
42. n leakage or seal corrosion upon re assembly 5 4 3 Cleaning N Careful e Use a vacuum cleaner to clean surfaces Do not use compressed air SAF SAF HOLLAND Group Fig 42 Extract the thrust plate e Itis important to take care when using chemicals and or cleaning tools e g knife brush etc This to avoid damage or displacement of hoses seals and other components e Make sure that dirt and impurities do not enter the opening for the adjustment screw Clean the thrust plate the adjustment screw and the adjustment screw bellows sealing surfaces in the calliper Ensure the parts are free from dirt dust debris moisture and corrosion 1 Fasten the thrust plate securely in a vice with soft jaws see Fig 43 Clamping Arrangement Do not over tighten or damage the thrust plate whilst clamping 2 Clean the internal threaded surface of the thrust plate 3 Ensure that the contact surfaces between the thrust plate and the bellows are clean and free from dirt moisture and corrosion Careful Only use SAF special tools where specified Using SAF special tool P N 4 434 3886 00 C press the adjustment screw bellows A into position on the thrust plate B see Fig 44 Check that the bellows is correctly seated in position on the thrust plate Clean the external threaded surface of the adjustment screw Ensure the parts are free from dirt dust debris moisture and corrosion Appl
43. nal Procedure 2 Chapter 3 4 UM PROB IN 5 5 Replacement of Slide Function Assembly 5 5 1 Initial Procedure Read and follow the chapters below prior to removing the slide function assembly 1 Initial Procedure Chapter 3 2 2 Remove the brake pads Chapter 5 2 2 3 Remove the brake chamber 2 Chapter 5 3 2 4 Remove the disc brake 2 Chapter 5 7 2 XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND 5 Replacement Procedures SAF SAF HOLLAND Group 5 5 2 Remove Slide Function Assembly Careful Only use SAF special tools where specified 1 Fasten the disc brake securely in a vice with soft jaws see Fig 48 Clamping Arrangement Ensure that the jaws of the vice do not damage the calliper ModuT 039 Fig 48 Clamping arrangement for inserting the slide function assembly 2 Use a small hammer and chisel to remove the leading and trailing protective cups A see Fig 49 The protective cups are not to be re used ModuiT 040 3 Using a long drive 14 mm Insex remove both screws B see Fig 50 The screws are not to be re used ModulT 061 4 Remove the carrier from the calliper by gently rocking the carrier to release it from the slide pins and bellows Once released press slide pins back enough to be able to lift out the carrier see Fig 51 ModuiT 041 Fig 51 Remove the carrier XL SA11745RM en DE 02 2012 Errors and changes excluded
44. omposite bushing H on the trailing side should be removable by hand Fig 55 Remove the trailing slide bearing XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND 5 Replacement Procedures SAF SAF HOLLAND Group 11 If this is not possible assemble in sequence SAF special tools 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 as shown in Fig 56 12 Once fitted correctly turn the threaded tool clockwise which will pull out the composite bushing Fig 56 Remove the composite side bushing 5 5 3 Cleaning N Careful e Use a vacuum cleaner to clean surfaces Do not use compressed air e Itis important to take care when using chemicals and or cleaning tools e g knife brush etc This to avoid damage or displacement of hoses seals and other components 1 Clean the bearing bush bellows sealing surfaces of the calliper to ensure they are free from dirt moisture corrosion and damage see Fig 57 2 If the sealing surfaces have lost their protective surface coating apply smear a small amount of general purpose grease over the whole area so when parts are refitted the grease will provide corrosion protection Fig 57 Clean the calliper bearing bushing mating surfaces 5 5 4 Install Slide Function Assembly Careful Only use SAF special tools where specified 1 Carefully follow the steps below 2Step 8 and Step 9
45. r Vi irt EESE drea au Rees 8 3 1 General Information iii 8 3 2 Initial Procedure SR a D Re tad 8 3 3 FUNCHON TEST p 9 3 4 Final FOCUS 10 A Inspection PFOCGQUFGs iret tti ras sans ses ttai iiie eae ssans etai danses amine sen aasia eA AAE PaE EATERS 11 4 1 Kerr eleme m 11 4 2 Inspection iitervals ues tette tee EIN eee Pe nere deg SEU M deca RRRENM S RENT SER URBE AENEID PATERE E 12 acaso c M 12 5 Replacement ProOCedUles 5 coii tere certe eia ceuieta Lea Ek ss sereine HARE rennes AASS I Pier anu le ecrans tnt lise tas 19 5 1 General InfOttriatiORi cstis testo aoaia Bose tee anna nee den ie entiere ete 19 5 2 Replacement of Brake Pads iii 19 5 3 Replacement of Brake Chamber n i Ibero eic eligenda edes ixi duced TEENE 21 5 4 Replacement of Adjustment Screw Bellows ssssssssssssssseeeeeeeeneeeneeeeeeneeene enne eene 23 5 5 Replacement of Slide Function Assembly sssssssssssssssseeeee eene nnns 25 5 6 Replacement of Reset Shaft Complete sisi 31 5 7 Replacement ot Disc Brake tede Cogito tiges tn Meu mae stc deua aden dea M dat 31 6 Specificatiorns rti Dco i eri che od Doe tace i Ee EE Sten ein Seni dk dra cea ELS D goa 32 eu Wear Ee c 33 6 2 TIGHTENING IOFQUGS rr een seen trame ere fen i irme en ever dete tad Bader eee 33
46. rd side see Fig 69 XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND 7 Tool SAF i SAF HOLLAND Group D TT ModulT 002 Fig 69 SAF SBS 2220 HO orientation 6 1 Wear Limits Wear Limits Brakelkads mm ined iii REGIS SR EO 2mm Brake Pads max uneven wear 1 5 mm Bea CKE min CR SS T 37 mm 6 2 Tightening Torques 6 2 1 General Follow the vehicle axle manufacturers recommendations 6 2 2 SAF SBS 2220 HO Screw connection Tightening torque Nm Bolts x2 for slide pins 180 Nm 70 Brake chamber fixation nuts 180 20 Nm 7 Tools 7 1 SAF special tool for SBS 2220 HO The listed tools are part of the SAF Universal Toolbox for disc brakes P N 3 434 3328 01 or available as an additional set P N 3 434 3335 00 for the existing SAF Universal Toolbox SAF special tool for SBS 2220 HO SAF no Designation P N 4 434 3837 00 Threaded spindle TR20 x 2 P N 4 434 3848 00 Thrust bearing P N 4 434 3841 00 Nut TR20 x 2 P N 4 434 3890 00 Pressure piece SBS 2220 HO XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND 8 Fault Finding SAF SAF HOLLAND Group SAF no Designation P N 4 434 3889 00 Sleeve SBS 2220 HO P N 4 434 3884 00 Sleeve SBS 2220 HO P N 4 434 3888 00 Right puller SBS 2220 HO P N 4 434 3887 00 Left puller SBS 2220 HO P N 4 434 3885 00 Mounting clip SBS 2220
47. s good practice and highly recommended to read and follow chapter 2 Chapter 4 3 8 Check Actuation Interface 5 3 3 Install Brake Chamber ls SAF SAF HOLLAND Group Fig 36 Mating surfaces of the brake chamber and calliper Fig 37 Remove Brake Chamber components Check that the brake chamber being installed is the correct one for the application and vehicle If a spring brake chamber is being installed ensure that the parking brake spring is caged in accordance with the manufacturer s instructions Chapter 4 3 8 Check Actuation Interface N Careful It is important to take care when using chemicals and or cleaning tools e g knife brush etc This to avoid damage or displacement of hoses seals and other components Check that the surface of the calliper that mates with the brake chamber is free from dirt moisture and corrosion See Fig 38 Ensure the brake chamber seal is in the correct position and not damaged Put a knob of general purpose grease in the ball cup of the brake chamber lever Do not overfill the cup or let grease fall inside the brake Once the brake chamber is removed it is good practice and highly recommended to read and follow chapter Fig 38 Pre brake chamber mounting activity XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND SAF 5 Replacement Procedures FA SAF HOLLAND Group 5 Fit the new brake chamber A to the
48. s will immediately terminate any warranty of the disc brake unit 1 2 Functional Description The SAF SBS2220 HO contains a floating monobloc calliper item C and an integrated adjustment unit which compensates for brake pad wear The unit which is actuated by the mechanism lever item A presses the inner brake pad item B against the disc which then causes the calliper tem C to slide laterally As such the outer brake pad item D also comes into contact with the disc The calliper moves on slide pins item E see Where the disc brake also serves as a parking brake the unit is actuated by a spring brake chamber item F Fig 2 Slide pins and spring brake chamber XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND S A F 2 Safety Precautions FA SAF HOLLAND Group 2 Safety Precautions 2 1 General Information This chapter comprehends the Safety Precautions that shall be read and followed before any Inspection Removal Installation procedure described in these repair instructions 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 used throughout these repair instructions e Danger Careful and e Note The following symbols are used to denote particularly important information and sections of the text Make sure that they are always read and adhered
49. spring pops into locking position Careful Check that the spring bracket is correctly engaged 3 Attach a lifting strap around the pad retainer and then lift the brake into position 4 Follow the vehicle axle manufacturer s recommendations for fitting tightening the retaining bolts or follow the general method described hereafter 5 Fit and screw home the retaining bolts alternating from side to side of the carrier 6 Tighten all retaining bolts to the torque settings defined by the vehicle axle manufacturers specifications 7 Remove the lifting strap old pad retainer and pad retainer spring Scrap the old pad retainer and pad retainer spring as they are not to be used again 5 7 4 Final Procedure To conclude this procedure read and follow chapters 1 Install the brake pads 2 Chapter 5 2 3 2 Install the brake chamber 2Chapter 5 3 3 3 Function Test 2 Chapter 3 3 to ensure that the disc brake is working correctly 4 Final Procedure 2 Chapter 3 4 6 Specifications The SAF SBS 2220 HO Air Disc Brake comes both left and right handed it is important the correct hand is fitted in relation to the normal wheel disc rotation Fig 69 see below shows a general overview of both variants and their relation to the normal wheel disc rotation see red arrow and their leading AL and trailing AT slide functions Each calliper also has a rotation arrow formed on the cast surface where the pad retainer seats on the inboa
50. t Turn the Torx 55 clockwise by In doing so observe the following Note that once the excessive clearance is SAF HOLLAND Group x5 through its full stroke See Fig 8 If no brake chamber is fitted then actuate the brake chamber lever manually with a suitable tool K O automatic adjustment function is working is not working correctly 360 degrees and then anti clockwise by 180 degrees Thus ensuring the adjuster is not jammed at the full de adjust position Fig 8 Brake actuation taken up by the adjuster the Torx 55 will naturally stop rotating If in doubt turn the Torx 55 anti clockwise by 180 degrees and then press the brake pedal again to check 10 If the Torx 55 still rotates back and forth during actuation then the adjustment function is defective and the calliper must be replaced See chapter 5 7 Replacement of Disc Brake 3 4 Final Procedure 1 Use the Torx 55 socket to manually rotate the reset shaft clockwise until it stops so that the brake pads lie on the brake disc Then turn the reset shaft 2 clicks anti clockwise see Fig 9 That is the procedure for the basic setting after successful repair or brake pad change Fig 9 Basic setting Fit the reset shaft protection 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
51. to before working with the product Danger This safety instruction with the exclamation mark warns of a possible safety risk or serious and fatal injuries Careful This safety instruction with the exclamation mark warns of possible damage to the product Note Marking for special user tips and other particularly useful and important information for efficient work and economical use 2 2 Installation The disc brake must not be installed or treated in such a way that exposes it to excessive thermal mechanical or chemical influences that can cause a reduced braking effect or damage to vital components in the brakes These influences damages may result in a shortened service life for the disc brake and its components reduced brake effect or at worst total brake failure 2 3 Adjustment of Control System Valves Failure to follow the instructions in this chapter may accelerate the wear to the brake pads and may cause damage repeated damage to the disc brake axle and or wheel brake components 2 3 1 Before entering the Vehicle into service Prior to initial use a vehicle s disc brake compressed air brake unit must be checked and adjusted if necessary in accordance with the relevant brake calculations Contact the vehicle manufacturer for relevant information 2 3 2 Replacing Spare Parts Always use spare parts that are approved for the vehicle axle or disc brake Following replacement of any essential components or spare
52. y the grease supplied with the spare parts kit to the internal thread off the thrust plate and the external thread of the adjustment screw Remove the thrust plate from the vice Fig 43 Clamping arrangement for thrust plate 2 G Fig 44 Attach the Adjustment Screw Bellows ModulT 037 XL SA11745RM en DE 02 2012 Errors and changes excluded SAF HOLLAND SAF 5 Replacement Procedures FA SAF HOLLAND Group Careful Do not cross thread the thrust plate and the adjustment screw 8 By hand hold the thrust plate in position against the adjustment screw Insert the Torx 55 socket into the reset shaft and turn carefully anti clockwise as the adjustment screw turns carefully engage the thrust plate threads onto the adjustment screw Be careful not to cross thread the parts if the thread becomes tight or locks turn the reset shaft clockwise to release the thrust plate then try again A clicking sound will be heard and felt when turning the reset shaft anti clockwise see Fig 45 9 Shortly after the threads are engaged ensure that the two thrust plate guide pins correctly locate in their calliper holes 10 Continue to retract the thrust plate until the dimension between the thrust plate inner pad face and the calliper outer pad face is less than 70 mm see Fig 45 11 Assemble SAF special tools P N 4 434 3887 00 and P N 4 434 3888 00 and insert them into the callip
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