SAF SBS 2220 H0, SBS 1918 H0 Repair Instructions
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
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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. The information contained in this manual neither represents ensured characteristics
of the product nor 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 components being tted 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 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 identied as such in all cases, but they
are nevertheless subject to the provisions of trademark legislation.
In case of conicting language versions of this manual, the German original prevails.
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 classied 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,
distributed or
in any other way disclosed.
Any breach or infringement will result in liability for damage.
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Table of contents
1 Introduction .................................................. 5
1.1 General information ............................... 5
1.1.1 Type plate ........................................... 5
1.1.2 Spare parts ......................................... 5
1.2 Functional description ........................... 6
2 Safety precautions ....................................... 6
2.1 General information ............................... 6
2.2 Installation ............................................. 7
2.3 Setting the control system/valves .......... 7
2.3.1 Before entering the vehicle into
service ................................................ 7
2.3.2 Replacing spare parts ........................ 7
2.3.3 Brake force distribution ...................... 7
2.4 Brake chamber ...................................... 7
2.5 Recycling ............................................... 8
2.6 Cleaning ................................................ 8
2.7 Surface nishing of the disc brake ........ 8
2.7.1 Painting .............................................. 8
2.7.2 Shot blasting ...................................... 8
3 Initialandnalprocedures .......................... 8
3.1 General information ............................... 8
3.2 Initial procedure ..................................... 8
3.2.1 Lifting and supporting the vehicle
axle ..................................................... 8
3.2.2 Removing the wheel ........................... 9
3.3 Function test .......................................... 9
3.3.1 Checking the adjustment unit ............. 9
3.4 Final procedure ..................................... 11
3.4.1 Mounting the wheel ............................ 11
3.4.2 Lowering the vehicle axle ................... 11
4 Inspection procedures ................................. 13
4.1 General information ............................... 13
4.2 Inspection intervals ............................... 13
4.3 Inspections ............................................ 14
4.3.1 Daily visual inspection ........................ 14
4.3.2 Checking the overall condition ........... 14
4.3.3 Checking brake pad wear .................. 14
4.3.4 General brake pad clearance check .. 15
4.3.5 Checking the brake disc ..................... 16
4.3.6 Plugs and protective caps check ........ 16
4.3.7 Checking the thrust plate guide pins .. 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 Final procedure .................................. 25
5.3 Replacing the brake chamber ............... 25
5.3.1 Initial procedure .................................. 25
5.3.2 Removing the brake chamber ............ 25
5.3.3 Installing the brake chamber .............. 26
5.3.4 Final procedure .................................. 27
5.4 Replacing the adjustment screw
bellows .................................................. 27
5.4.1 Initial procedure .................................. 27
5.4.2 Removing the adjustment screw
bellows ............................................... 27
5.4.3 Cleaning ............................................. 28
5.4.4 Final procedure .................................. 29
5.5 Replacing the slide function assembly .. 30
5.5.1 Initial procedure .................................. 30
5.5.2 Removing the slide function
assembly ............................................ 30
5.5.3 Cleaning ............................................. 32
5.5.4 Installing the slide function assembly . 32
5.5.5 Final procedure .................................. 35
5.6 Fully replacing the reset shaft ............... 35
5.6.1 Initial procedure .................................. 35
5.6.2 Fully removing the reset shaft ............ 35
5.6.3 Fully installing the reset shaft ............. 35
5.6.4 Final procedure .................................. 36
5.7 Replacing the disc brake ....................... 36
5.7.1 Initial procedure .................................. 36
5.7.2 Removing the disc brake .................... 36
5.7.3 Installing the disc brake ...................... 36
5.7.4 Final procedure .................................. 37
6 Specications ............................................... 37
6.1 Wear limits............................................. 38
6.2 Tightening torques ................................. 38
6.2.1 General .............................................. 38
6.2.2 SAF SBS 2220/SBS 1918 H0 ............ 38
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7 Tools .............................................................. 38
7.1 SAF special tool for SBS 2220 H0 ........ 38
8 Faultnding .................................................. 39
8.1 General fault nding instructions ........... 39
8.2 Inspection intervals ............................... 39
9 Spare parts and repair kit list ...................... 40
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1 Introduction
1.1 General information
1 Introduction
The SAF SBS 2220/SBS 1918 H0 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 of the SAF SBS 2220/
SBS 1918 H0 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 precautions
and the potentially hazardous situations which, if not
avoided, could result in serious injury or death!
Chapter "3. Initial and nal procedures" describes the
start and nish activities necessary to be able to carry
out inspection and replacement work. It also describes the function test for the SAF SBS 2220/SBS
1918 H0 compressed-air disc brake.
Consult chapter "4. Inspection procedures" for
information and instructions on inspecting the SAF
SBS 2220/SBS 1918 H0 compressed-air disc brake.
Chapter "4.2. Inspection intervals" details the recommended compressed-air disc brake inspection
intervals. In this chapter, the inspection intervals table
displays how frequently the different brake components 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".
1.1.1 Type plate
Fig. 1 - Type plate
Type Type designation of the brake calliper
P/N Production number of the brake calliper
S/N Serial number of the brake calliper
1.1.2 Spare parts
It is vital that only SAF-HOLLAND original spare parts
are used during all repair work.
The use of non-original spare parts can affect the
function, performance and/or service life of the components.
The use of non-original spare parts will immediately
terminate any warranty of the disc brake unit.
Chapter "6. Specications" contains technical data for
the SAF SBS 2220/SBS 1918 H0 compressed-air disc
brake.
Chapter "7. Tools" contains information about the SAF
SBS 2220/SBS 1918 H0 tool kit, which is essential for
carrying out much of the replacement procedure work
described in this manual.
Chapter "8. Fault nding" should be used to help with
the self diagnosis of any problem being experienced.
Chapter "9. Components list" lists and shows what
spare part components are available for the SAF SBS
2220 / SBS 1918 H0 compressed-air disc brake.
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2 Safety precautions
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1.2 Functional description
The SAF SBS2220 H0 comprises a monobloc
oating calliper (item C) and an integrated adjustment unit, which compensates for the brake pad wear.
C
D
B
D
E
F
E
Fig. 3 - Guide pin and spring brake chamber
D
D
A
D
Fig. 2 - Functional description
The unit, which is actuated by the lever mechanism
(item A), presses the inner brake pad (item B) against
the disc, which then causes the brake calliper (item C)
to slide laterally. In so doing, the outer brake pad
(item D) comes into contact with the disc.
2 Safety precautions
2.1 General information
This chapter details the safety precautions that must
be read and followed before any inspection/repair/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.
The brake calliper moves on the guide pins (item E)
(see If the disc brake also serves as a parking brake,
the unit is actuated with the aid of a spring brake
chamber (item F).
Danger!
This safety instruction with the signal word warns of
a possible safety risk or serious and fatal injury!
Three different alert levels are used throughout these
repair instructions:
● Danger
● Caution
● Note
The following symbols are used to denote particularly
important information and sections of the text. Ensure that they are always read and adhered to before
working with the product.
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Caution!
This safety instruction with the signal word warns of
possible damage to the product!
Note:
Marking for special user tips and other particularly
useful and important information for efcient work
and economical use.
2 Safety precautions
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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 inuences that can cause a
reduced braking effect or damage to vital components
in the brakes.
These inuences/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 Setting the 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.
Before a vehicle is entered into service, it must be
set up in accordance with the specied values in
the relevant brake calculation. After the pads/brake
discs have been run in for a period of around 3,000
to 5,000 km, the brake force distribution between the
truck/tractor and trailer must be checked and adjusted
(if necessary). The same also applies to repair and
replacement of parts if there is any suspicion that
heat/overheating has caused to damage to the axle/
brake components (e.g. seals, hub/wheel bearings
and brake disc).
Contact the vehicle manufacturer for information on
the appropriate action.
Failure to follow these instructions may cause damage/repeated damage to the disc brake, axle and/or
wheel brake components.
2.4 Brake chamber
Dirt/water ingress into the disc brake mechanism
housing could affect the function of the brake and as
a result shorten its service life.
2.3.2 Replacing spare parts
Always use spare parts that are approved for the
vehicle, axle or disc brake. On replacement of any
essential components or spare parts in the disc brake
system (e.g. brake valves or control units), the disc
brake system must also be checked and adjusted
(if necessary) in accordance with the relevant brake
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
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 components.
Fig. 4 - Venting hole
Therefore, to prevent water ingress, it is important
that the brake chamber is of the correct design and
that the seal between the brake chamber and disc
brake mating surfaces is undamaged and correctly in
place.
It is also important for the disc brake's function that
the brake chamber housing is correctly vented.
To this end, the downward-facing drain holes must
be opened as a minimum, see ► Fig. 4. Other drain
plugs can remain in position in the brake chamber
housing.
Caution!
If the venting holes remain closed, the brake chamber and disc brake may not operate correctly.
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3 Initial and nal procedures
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2.5 Recycling
When replacing the disc brake or components
thereof, the components removed must be recycled/
destroyed in accordance with applicable environmental legislation, regulations and provisions.
2.6 Cleaning
For the disc brake to function correctly, it is important
to keep the calliper free from ice and snow and to
ensure that it remains clean so as not to restrict its
movement. Damage may cause direct brake failure or
damp/dirt penetration resulting in malfunction/shortening of the service life of the disc brake.
Caution!
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.
2.7 Surfacenishingofthediscbrake
2.7.1 Painting
● bellows,
● Reset shaft and its protective plug,
● complete brake pads,
● disc surface,
● the disc brake mounting surfaces to axle/brake
chamber, and
● all bolted connections.
2.7.2 Shot blasting
Caution!
Failure to follow the Instructions below could jeopardise 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 tted (or any protective parts that have
a similar sealing function). The shipping seal tted to
the brake chamber aperture on a new disc brake does
not provide adequate protection during shot blasting.
The disc brake can be nished with paint that has
trade approval for this purpose (automotive paint). It
must be ensured that the paint layer does not cause
damage and/or restrict the natural movement/function
of the disc brake. All contact surfaces, pad material and rubber parts must therefore be protected or
masked.
The following areas must not be painted:
3 Initialandnalprocedures
3.1 General information
The objective of this chapter is to give guidelines on
how initial and nal procedures should be performed
in a standardised way.
The initial procedure is a recurring procedure that
must be performed prior to the inspections and/or
repairs covered in this service manual.
The nal procedure is a recurring procedure that must
be performed after the inspections and/or replacements covered in this service manual.
Note:
Follow the recommendations of the brake chamber
manufacturer.
The disc brake must be thoroughly cleaned after
shot blasting to ensure that its natural movement is
not obstructed by remnants of shot-blasting material.
Check the seals/rubber parts to ensure that they have
not been damaged.
3.2 Initial procedure
3.2.1 Lifting and supporting the vehicle axle
Danger!
● At least one of the vehicle's axles must be
chocked in order to prevent involuntary movement of the vehicle!
● The vehicle manufacturer's safety precautions
must be followed when working on the vehicle!
● Local safety precautions must be observed!
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3 Initial and nal procedures
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3.2.2 Removing the wheel
Danger!
● Take all necessary safety precautions before
wheel removal!
● The vehicle manufacturer's safety precautions
must be followed!
Fig. 5 - Securing the wheels
1. Secure the wheels on a at and level surface, see
► Fig. 5
2. Lift the axles and place on stands.
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 this position.
See the vehicle manufacturer's instructions.
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 nding“
on what action to take.
2. Remove the wheel nuts followed by the wheel, see
► Fig. 7.
3.3 Function test
3.3.1 Checking the adjustment unit
Note:
The function test can be carried out with the wheel
either tted or removed.
1. Check that the wheel/hub can rotate freely. If it
does not then rst tap to remove any rest tension.
If the wheel still does not rotate freely then consult
chapter "8. Fault nding" on what action to take.
Fig. 6 - Securing with the extraction tool
3. Release the parking brake
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2. Remove the reset shaft protective plug (item A),
see ► Fig. 8
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3 Initial and nal procedures
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Caution!
● Use recommended tools only!
● Never use an impact wrench or similar to rotate
the reset shaft. Doing so could damage the internal components of the mechanism! The maximum torque is 20 Nm.
● Dirt must not be allowed to enter the aperture of
the reset shaft.
● 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 avoid
damage or displacement of hoses, seals and
other components.
Note:
The Torx 55 and thrust plate must be allowed to
move unhindered!
Caution!
● When reaching the end stop position of de-ad-
justment, never tighten and leave. Leaving the reset 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
A
B
Fig. 8 - De-adjusting with the reset shaft
4
3
2
1
3. Using a Torx 55 socket, de-adjust the brake by
rotating the reset shaft anti-clockwise by 4 clicks,
or until the end stop, see item B , see ► Fig. 8.
A clicking sound must be heard and felt when
de-adjusting.
5
4
Fig. 9 - Brake actuation
1
2
3
5. Actuate the brakes ve times by pressing and
releasing the vehicle brake pedal through its full
stroke, see ► Fig. 9. If no brake chamber is tted
then actuate the brake chamber lever manually
with a suitable tool.
6. The Torx 55 must rotate clockwise on each actuation, showing that the automatic adjustment
function is working.
7. If the Torx 55 rotates back and forth or not at all,
then the adjustment function is not working correctly.
8. To check further, manually adjust the reset shaft.
Rotate the Torx 55 clockwise 360 degrees, and
then anti-clockwise 180 degrees. In so doing,
ensure that the adjuster is not jammed at the full
de-adjust position.
10
9. Observe the following. Once the excessive clearance is taken up by the adjuster, the Torx 55
will suddenly stop rotating. If in doubt, rotate the
Torx 55 anti-clockwise 180 degrees and then press
the brake pedal again to check.
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3 Initial and nal procedures
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10. If the Torx 55 still rotates back and forth during
actuation, then the adjustment function is defective
and the brake calliper must be replaced.
See chapter „5.7 Replacing the disc brake“.
3.4 Final procedure
“CLICK”
1
2
“CLICK”
Fig. 10 - Basic setting
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.
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 are laid/ducted and fastened correctly.
2. Then rotate the reset shaft 2 clicks anti-clockwise, see ► Fig. 10. That is the procedure for the
basic setting after successful repair or brake pad
change.
OKOK
OK
OK
Fig. 12 - Mounting the wheel
1. Check the free rolling resistance. The disc brake
must not be obstructed in any way.
2. Mount the wheel, see ► Fig. 12
3.4.2 Lowering the vehicle axle
Danger!
If the disc brake is equipped with a spring brake
chamber, ensure that the brake system is pressurised, that the spring brake chamber is fully vented
and that the mechanical lock has been removed.
See the vehicle manufacturer's instructions.
Caution!
Actuate the parking brake. Ensure that there is sufcient pressure in the system (min. 6 bar).
Fig. 11 - Correctly tting the protective plug
Note:
The SAF guarantee of competence shall be made
void in the event of improper tting of the reset shaft
protective plug and resulting damage.
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3 Initial and nal procedures
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Fig. 13 - Removing the extraction tool
1. Activate the parking brake if tted with a spring
brake chamber.
2. Lift the axles so that the stands can be removed.
3. Carefully lower the vehicle to the ground.
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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
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4 Inspection procedures
4 Inspection procedures
4.1 General information
The objective of this chapter is to give guidance on
how inspection of the brake components should be
conducted. Always start by consulting the inspection
interval table in chapter
„4.2 Inspection inter-
vals“.
The table indicates how frequently the different brake
components should be inspected and on which pages
the check instructions are found.
Inspection intervals
1 = Function test
2 = Setting
3 = Visual inspection
For the majority of inspections, the wheel should be
removed from the vehicle. Before removing the wheel,
read chapter
tial and nal procedures“
„2 Safety precautions“ and „3 Ini-
.
4.2 Inspection intervals
The inspection intervals specied 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.
Before starting to use vehicle
Setting the control system/valves 1/2 – – – – 1/2 ► chapter 2.3
Braking force distribution tractor/trailer – – 1/2 – – 1/2 ► chapter 2.3.3
Safety check – 1 – – – – ► chapter 4.3.1
Brake pads – – – 3 – – ► chapter 4.3.3
Brake disc – – – 3 – – ► chapter 4.3.5
Function test – – – – 1 – ► chapter 3.3
Plugs and protective caps – – – – 3 – ► chapter 4.3.6
Thrust plate guide pins – – – – 3 – ► chapter 4.3.7
Guide pin bellows – – – – 3 – ► chapter 4.3.9
Thrust plate bellows – – – – 3 – ► chapter 4.3.10
Slide function – – – – 1 – ► chapter 4.3.11
Daily
After 3,000 to 5,000 km
Every 3 months
Every 12 months
If components are replaced in the
system
See page
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