SAF SBS 2220 H0, Repair Instructions

Page 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...

Page 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 p...

Page 3: ...s 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 cl...

Page 4: ...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 p...

Page 5: ...d 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...

Page 6: ...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 in...

Page 7: ...lly 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...

Page 8: ...on 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...

Page 9: ...ty 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 expecte...

Page 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 de...

Page 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 t...

Page 12: ...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 D...

Page 13: ...tervals 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 int...

Page 14: ...isc 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...

Page 15: ...ke 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 clear...

Page 16: ...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 di...

Page 17: ...e 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 wh...

Page 18: ...ake 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 bra...

Page 19: ...l 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 proc...

Page 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...

Page 21: ...he 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 a...

Page 22: ...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 sli...

Page 23: ...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 necess...

Page 24: ...alliper 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...

Page 25: ...king 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...

Page 26: ...rake 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...

Page 27: ...n 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 p...

Page 28: ...ponents 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 scr...

Page 29: ...iper 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 ca...

Page 30: ...on 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...

Page 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 I...

Page 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...

Page 33: ...4 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...

Page 34: ...ting 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 shoul...

Page 35: ...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 w...

Page 36: ...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 ca...

Page 37: ...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...

Page 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 par...

Page 39: ...ourney 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 b...

Page 40: ...ist 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...

Page 41: ...4 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 individuall...

Page 42: ...e 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 cha...