SAF-HOLLAND SBS 2220 K0 Setup guide
Repair Instructions
Compressed Air Disc Brake
SAF SBS 2220 K0
XL-SA40001RM-en-DE Rev A • 02.2016
Translation of the original repair instructions
Please note
These repair instructions are intended for the exclusive use of 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
omission 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.
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. Component overview 6
1.1 Components of the disc brake 6
1.2 Brake identication and service kits for the disc brake 7
1.3 Brake discs 7
2. General information 8
2.1 Tightening torques 8
3. Structure and function 9
3.1 Sectional drawing of the disc brake 9
3.2 Functional description 10
4. Inspection points 11
4.1 Safety instructions for service and repair work 12
5. Function and visual inspection 13
5.1 Wear inspection of brake pads and brake discs 13
5.2 Inspecting the adjustment function 16
5.3 Checking the movement of the brake calliper 19
5.4 Checking the clearance in the guide bearing area (6) 20
5.5 Inspecting the sealing elements 21
6. Replacing the brake pads 22
6.1 Removing the brake pads 22
6.2 Installing the brake pads 23
6.3 Mounting the wear contacts 25
7. Replacingthepressurettings 27
7.1 Removing the pressure ttings with bellows (13) 27
7.2 Removing and installing the inner seal (22) 29
7.3 Mounting the pressure ttings with bellows (13) 31
8. Removing and installing the brake calliper 34
8.1 Removing the brake calliper from the carrier 34
8.2 Mounting the brake calliper to the carrier (carrier not removed) 36
9. Repairing the brake calliper bearing 40
9.1 Removing the bellows (9) 40
9.2 Replacing the bushing (7) 40
9.3 Replacing the slide bearing (6) on the short bearing side 42
9.4 Installing the bellows (9) 43
10. Replacing the brake chamber 46
10.1 Removing the diaphragm chamber 46
10.2 Fitting the diaphragm chamber 46
10.3 Removing the combined chamber 47
10.4 Fitting the combined chamber 48
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Safety guidelines
Note: The safety instructions listed below apply to all service and diagnostics operations on brake systems
and must not be directly associated with the activities and products described in this document. In addition,
always observe the information from the axle/vehicle manufacturer with regard to towing, lifting and
securing the vehicle.
ATTENTION: SAF-HOLLAND SHALL NOT BE LIABLE FOR ANY INJURY OR DAMAGE RESULTING
FROM THE IMPROPER USE OF SERVICE KITS OR SERVICE TOOLS: IMPROPER USE OF SERVICE
TOOLS AND IMPROPER ATTACHMENT OR APPLICATION OF SERVICE KITS CAN GIVE RISE TO
DAMAGE OR HAZARDOUS HANDLING. SAF-HOLLAND
ASSUMES NO LIABILITY IN THIS CASE.
The following precautions, in conjunction with the special hazard warnings provided in this document, must
be observed before and during work on and in the vicinity of compressed-air units:
1. Always wear safety goggles when working with compressed air.
2. Never exceed the air pressures specied by the vehicle manufacturer.
3. Never look directly into a compressed-air jet or point a jet at another person.
4. Never loosen a pressurised hose or compressed-air line. The hose may move around uncontrollably
when air is escaping.
5. When removing a device or maintaining a device in the vehicle, always reduce the pressure in the
subsystem in question to 0 bar. In the event that the vehicle is equipped with an air-dryer system,
remember that the system and any installed regeneration-air tanks may still contain compressed air,
even if other storage tanks have already been emptied.
6. In the event that compressed-air tanks are emptied during work on a vehicle's brake system or its
pneumatic auxiliary equipment, maintain a safe distance from piston rods and the brake linkage as these
may be actuated by a drop in pressure in the brake system. When carrying out work on vehicles with
air suspension, always support the frame in order to prevent sudden lowering and trapping between the
frame and axles or the frame and the ground.
7. Place the vehicle on a level surface and engage the parking brake. Secure the vehicle with wheel
chocks to prevent it from rolling away. A loss of pressure in the compressed-air brake unit can impair
braking efciency.
8. When carrying out work underneath or on the vehicle, and especially when working in the engine
compartment, always switch off the engine and disconnect the battery. If circumstances dictate that the
engine be running, UTMOST CAUTION must be exercised as contact with rotating, moving, leaking, hot
or electrically charged components can cause serious injury. In addition, we also recommend afxing
a sign to the steering wheel bearing the words "CAUTION! WORK BEING CARRIED OUT ON THE
VEHICLE!".
9. When carrying out work on vehicles with air suspension, ensure that the vehicle chassis is mechanically
supported by a support opposite the axle or ground. Doing so provides protection against injury caused
by unexpected lowering of the chassis resulting from a sudden loss of pressure in the air-suspension
system.
10. Inspect all compressed-air lines for kinks and pressure points, drying and overheating. Replacement
parts, pipes, hoses, fastening elements, etc. must correspond to the original parts and must have been
designed specically for these applications and systems. Check that all lines are fastened correctly.
Lines should be routed such that they cannot chafe and are not exposed to extreme heat.
11. Components with damaged threads or individual parts must be completely replaced. Avoid machine
repair or welding work if it cannot be inspected and approved by the vehicle or brake manufacturer.
12. Never attempt to remove, install, disassemble and reassemble a device before having read
through and understood the recommended procedures. Some devices contain highly pre-tensioned
compression springs, which can cause serious injury if not properly disassembled and reassembled.
Use only suitable tools and observe all safety precautions regarding use of the tool.
13. Before removing devices, mark their position and connections so that repaired devices and/or
replacement devices can be properly reinstalled. Ensure that proper supports or auxiliary equipment
are available for the removal/installation of heavy parts.
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XL-SA40001RM-en-DE Rev A • 02.2016 • Errors and changes excluded © SAF-HOLLAND
14. Use only original parts and service kits supplied by SAF-HOLLAND or the vehicle manufacturer. Use
only the recommended tools in accordance with the corresponding instructions from SAF-HOLLAND.
15. The maintained or replaced device must be checked to ensure that it is functioning correctly and
effectively.
16. In the event that devices which could inuence braking performance or the behaviour of the brake
system are replaced or repaired, a nal check must be performed on the roller test bench. Please bear
in mind that when brake pads and/or brake discs and/or drums are replaced, full braking performance
will only be available again after the run-in phase.
17. Use of an impact wrench in conjunction with SAF-HOLLAND service tools for pneumatic disc brakes is
not permitted. SAF-HOLLAND service tools have not been designed for use of an impact wrench. Use
of an impact wrench can damage the service tools and vehicle resulting in a risk of injury.
18. Never use compressed air to clean the brake. Avoid swirling brake dust.
19. Before commissioning the vehicle, ensure that all components and the complete brake system are in
an orderly condition.
Welding
To prevent damage to electrical components, the following safety precautions must be observed:
1. Always mark and remove all connections to electronic control units and modules before commencing
electrical welding work. Make a note of the sequence in which the connections were released.
2. When reconnecting the speed sensors (in reverse order), it is essential that they are mounted in the
designated places. The system's function must be checked with a PC diagnostics system.
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Table of contents
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