SAF SBS 2220 H0 Setup guide

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 lia-
bility 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 identied as such in all cases, but they
are nevertheless subject to the provisions of trademark legislation.
In case of conicting 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 classied 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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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 Initialandnalprocedures.......................... 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 Specications ............................................... 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
Table of contents

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7 Tools .............................................................. 38
7.1 SAF special tool for SBS 2220 H0 ........ 38
8 Faultnding.................................................. 39
8.1 General fault nding instructions........... 39
8.2 Inspection intervals ............................... 39
9 Spare parts and repair kit list...................... 40

1 Introduction
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1 Introduction
1.1 General information
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 pre-
cautions" 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 de-
scribes 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 rec-
ommended compressed-air disc brake inspection
intervals. In this chapter, the inspection intervals table
displays how frequently the different brake compo-
nents should be inspected and on which pages the
check instructions are to be found.
If any inspection shows that a replacement activity
needs to be performed, continue to the appropriate
section in chapter "5. Replacement procedures".
Chapter "6. Specications" 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.
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 com-
ponents.
The use of non-original spare parts will immediately
terminate any warranty of the disc brake unit.

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 adjust-
ment unit, which compensates for the brake pad wear.
D
D
D
B
D
C
D
A
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.
E
F
E
Fig. 3 - Guide pin and spring brake chamber
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).
2 Safety precautions
2.1 General information
This chapter details the safety precautions that must
be read and followed before any inspection/repair/in-
stallation procedure described in these repair instruc-
tions is started. These repair instructions are intended
for the exclusive use of trained persons within the
commercial vehicle industry and related workshops.
Three different alert levels are used throughout these
repair instructions:
●Danger
●Caution
●Note
The following symbols are used to denote particularly
important information and sections of the text. En-
sure that they are always read and adhered to before
working with the product.
Danger!
This safety instruction with the signal word warns of
a possible safety risk or serious and fatal injury!
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 efcient 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 inuences that can cause a
reduced braking effect or damage to vital components
in the brakes.
These inuences/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 com-
pressed-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. 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 com-
ponents.
Before a vehicle is entered into service, it must be
set up in accordance with the specied 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 dam-
age/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.
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 cham-
ber and disc brake may not operate correctly.

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 environmen-
tal 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/shorten-
ing 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 Surfacenishingofthediscbrake
2.7.1 Painting
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 mate-
rial and rubber parts must therefore be protected or
masked.
The following areas must not be painted:
●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 jeop-
ardise safety and/or reduce the service life of the
disc brake and its components.
If the vehicle is shot blasted, all rubber parts and pads
on the disc brake must be protected, as well as all
areas in which the pads are seated. The brake cham-
ber must be 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.
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 Initialandnalprocedures
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 replace-
ments covered in this service manual.
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 move-
ment of the vehicle!
●The vehicle manufacturer's safety precautions
must be followed when working on the vehicle!
●Local safety precautions must be observed!

3 Initial and nal procedures
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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 depressur-
ised, that the spring brake chamber is fully disen-
gaged and mechanically secured in this position.
See the vehicle manufacturer's instructions.
Fig. 6 - Securing with the extraction tool
3. Release the parking brake
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. 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.
2. Remove the reset shaft protective plug (item A),
see ► Fig. 8

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 inter-
nal components of the mechanism! The maxi-
mum 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!
1
2
3
4
B
A
Fig. 8 - De-adjusting with the reset shaft
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.
Caution!
●When reaching the end stop position of de-ad-
justment, never tighten and leave. Leaving the re-
set shaft tightened in the de-adjust position could
stop the adjustment function from working!
●After reaching the end stop position, always then
adjust by rotating the reset shaft clockwise 90
degrees, thus activating the adjustment function.
4. Leave the Torx 55 in position in the reset shaft.
x5
1
2
3
4
5
Fig. 9 - Brake actuation
5. Actuate the brakes 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 ac-
tuation, 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 cor-
rectly.
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.
9. Observe the following. Once the excessive clear-
ance 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.

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
1
2“CLICK”
“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.
2. Then rotate the reset shaft 2 clicks anti-clock-
wise, see ► Fig. 10. That is the procedure for the
basic setting after successful repair or brake pad
change.
OK
OKOK
OK
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.
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.
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 pressur-
ised, 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 suf-
cient pressure in the system (min. 6 bar).

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.
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

4 Inspection procedures
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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.
For the majority of inspections, the wheel should be
removed from the vehicle. Before removing the wheel,
read chapter „2 Safety precautions“ and „3 Ini-
tial and nal procedures“.
4.2 Inspection intervals
The inspection intervals specied in the table below
are maximum intervals. Depending on the vehicle
application, type of driving, adjustment to the vehicle
manufacturer's service/inspection intervals etc., there
may be a need for more frequent inspections.
Inspection intervals
1 = Function test
2 = Setting
3 = Visual inspection
Before starting to use vehicle Daily After 3,000 to 5,000 km Every 3 months Every 12 months If components are replaced in the system See page
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

4 Inspection procedures
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4.3 Inspections
4.3.1 Daily visual inspection
Danger!
Contact the Service Workshop immediately if there
is any sign of reduced performance or if 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 Checking the overall condition
1. Ensure that you have good lighting conditions.
2. Inspect the visible parts of the brake and its com-
ponents. Pay particular attention to:
●damage,
●collection of debris,
●corrosion,
●signs of overheating,
●cracks in the brake discs,
●unusual wear etc.,
●corrosion on the friction surface of the brake
disc, etc.
4.3.3 Checking brake pad wear
Danger!
Wear respiratory protection in order to avoid inhaling
particles which can be hazardous to health! Brake
pad wear produces dust which can cause lung dam-
age!
Note:
Step 1 in this procedure only indicates the brake pad
wear of the outer brake pad! For a full examination,
complete all steps.
OK OK
Fig. 15 - Inspection of the visual wear indicator
1. Inspect the position of the visual wear indicator
(VWI), see ► Fig. 15. This check can be com-
pleted with either the wheel tted or removed.
The VWI provides an indication of the 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, con-
tinue with the following instructions.
2. Remove the wheel in accordance with ► chapter
3.2.
3. Remove the brake pads in accordance with ►
chapter 5.2.2.
4. Look for unusual conditions such as excessive
corrosion and high heat cycles, i.e. delamination,
discolouration, etc. If found, carry out the relevant
measures, see chapter „8.2 Inspection intervals“.

4 Inspection procedures
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>2mm
B
A
A
B
Fig. 16 - Measuring brake pad wear
5. On both brake pads, measure the distance from
the back plate (A) to the wear surface (B) of the
brake pad in four places, see ► Fig. 16. The min-
imum permitted pad thickness (friction material) is
2 mm.
Danger!
Failure to comply poses a risk of the pad back plate
becoming lost, which could endanger individuals.
The SAF guarantee of competence shall be made
void in the event of the minimum pad thickness not
being met and if damage results.
6. Check the condition of the back plate (A).
7. Replace the brake pads if they are worn out or if
they are expected to be so before the next inspec-
tion. For replacement follow the instructions in
chapter „5.2 Replacing the brake pads“.
8. Once the inspection is completed satisfactorily,
conclude by following chapters „5.2.3 Installing the
brake pads“ and „5.2.4 Final procedure“.
Note:
This brake disc inspection check procedure is only
a general guide. Refer to the vehicle manufacturer's
documentation for specic brake disc information
and instructions.
4.3.4 General brake pad clearance check
Danger!
Wear respiratory protection in order to avoid inhaling
particles which can be hazardous to health! Brake
pad wear produces dust which can cause lung dam-
age!
Note:
●The clearance can be checked with the brake
chamber tted or removed.
●This check is best performed after the wheel is
removed and before the reset shaft is retracted.
For this situation, steps 2 and 3 below can be
skipped.
1. Read and follow chapter „3.2 Initial procedure“ and
„5.2.2 Removing the brake pads“ prior to checking
the clearance.
2. Reduce the clearance by inserting and manually
rotating the Torx 55 socket clockwise until it comes
to a stop. The excessive clearance is hereby
rectied. Now set the correct clearance by rotating
270° anti-clockwise.
3. Activate the brake until the Torx 55 bolt no longer
rotates because any excessive clearance has
been removed by the adjustment function.
Fig. 17 - Correct location of the feeler gauges
4. Insert two feeler gauges in between the brake
calliper and the outer brake pad to measure the
clearance. Position the feeler gauges in the upper
and lower part of the brake pad back plate so that
the axial clearance can be measured, see ► Fig.
17.
5. The normal clearance is between 0.7 mm and
1.1 mm. If the measurement is outside of the nor-
mal running condition then continue with chapter
„8.2 Inspection intervals“.

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6. Once the inspection is completed satisfactorily,
conclude by reading and following „5.2.3 Install-
ing the brake pads“ and all of chapter „5.2.4 Final
procedure“.
4.3.5 Checking the brake disc
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!
OK OK
Fig. 18 - Inspection of the brake disc
1. Look for wear, damage and cracks, see ► Fig. 18.
Cracks that enter the cooling ducts via the outer
circumference or on the inner diameter of the fric-
tion ring are not permitted!
Acceptable crack length Unacceptable crack
length
<75% of brake disc
width
>75% of brake disc width
B B
Fig. 19 - Measuring the brake disc thickness
2. Measure 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 at washers), see ► Fig.
19. Reduce the measured dimension by the total
thickness of the two spacers (B).
The minimum thickness of the brake disc is 37 mm.
Replace the brake disc if it is worn or if it is expected
to be so before the next inspection.
4.3.6 Plugs and protective caps 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!
Caution!
●Use a vacuum cleaner to clean the surfaces. Do
not use compressed-air.
●Failure to follow the instructions below could
compromise safety and/or reduce the service life
of the disc brake and its components.
1. Read and follow „3.2 Initial procedure“ prior to in-
specting the protective plugs and protective caps.
2. Remove dirt from surfaces if necessary.
3. Check for signs of excessive heat exposure, dis-
colouration, debris, etc.

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B
A
Fig. 20 - Two protective plugs
4. The following plugs and protective caps must be in
place and intact:
● The reset shaft protective plug (A) and brake
calliper seal (B), see ► Fig. 20,
● The housing seal (b) must not be removed.
C
C
D
Fig. 21 - Two protective caps
5. Two protective caps to protect the guide pins (C),
see ► Fig. 21.
6. Once the inspection is completed satisfactorily,
conclude by reading and following chapter „3.4
Final procedure“.
Caution!
Never remove the housing seal (B), see ► Fig. 20.
If the housing seal (B) is removed, it will void the
warranty and compromise the disc brake!
The nut (D) must not be adjusted, see ► Fig. 21.
4.3.7 Checking the thrust plate guide pins
Danger!
Wear respiratory protection in order to avoid inhaling
particles which can be hazardous to health! Brake
pad wear produces dust which can cause lung dam-
age!
Caution!
Use a vacuum cleaner to clean the surfaces. Do not
use compressed-air.
E
E
Fig. 22 - The two thrust plate guide pins
1. Read and follow „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. 22.
4. Check that the thrust plate with guide pins are free
to move without obstruction.
5. Once the inspection is completed satisfactorily,
conclude by reading and following chapter „3.4
Final procedure“.

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4.3.8 Checking the actuation interface
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 damage!
●Pressure from lines and components must be
released before they are opened!
●If a brake chamber is installed with a spring
mechanism, it must be ensured that the spring is
mechanically safeguarded during removal, see
chapter „3.2.1 Lifting and supporting the vehicle
axle“.
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.
●Use a vacuum cleaner to clean the surfaces. Do
not use compressed-air.
B
A
Fig. 23 - Mating surfaces of the brake chamber and brake calliper
This inspection procedure covers both types of brake
chamber; normal (service) and spring brake (parking)
chamber.
1. Read and follow „3.2 Initial procedure“ prior to
inspecting the actuation interface.
2. Thoroughly clean around the mating surfaces of
the brake chamber (A) and brake calliper (B) to
ensure that dirt does not get into the mechanism
area when removing the brake chamber, see ►
Fig. 23.
3. Release the parking brake, see ► chapter 3.2.1.
F
A
E
B
Fig. 24 - Removing the brake chamber components
4. If applicable, ensure that the spring brake chamber
see ► Fig. 24 (F) is fully disengaged and mechan-
ically secured in this position.
5. Ensure that the brake chamber is depressurised.
6. Remove the two nuts (E) holding the brake cham-
ber. Remove the brake chamber (A/F) from the
brake calliper (B), see ► Fig. 24.
Fig. 25 - Piston rod
7. With the brake chamber removed and secured, the
brake chamber piston rod should protrude approx.
15 mm in its rest position, see ► Fig. 25.
8. With the service brake activated, the brake cham-
ber actuation rod should protrude approx. 72 mm
- 80 mm (depending on the brake chamber type).
9. In addition, check that the actuation rod extends
perpendicular to the external seal ange.

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Fig. 26 - Brake chamber aperture
10.Check through the aperture in the brake chamber
attachment ange for moisture/corrosion, see
► Fig. 26. It is essential to look inside the aper-
ture and not just on the surface. In the event of
corrosion, further inspection is necessary. In the
event that water has ingressed causing internal
corrosion/damages to the mechanism, replace the
brake calliper to avoid malfunction. For requisite
measures, see "Replacing the brake calliper".
B
A
Fig. 27 - Internal view of the brake chamber
11.On the brake chamber, there must be an internal
bellows (A) on the piston rod, see ► Fig. 27.
12.Check that the bellows are complete and not dam-
aged by inspecting around and down the piston
rod shaft. Check for signs of water or corrosion.
These may be a sign that the bellows are dam-
aged.
13.Check that the external seal ange (B) is correctly
seated, intact and undamaged.
14.Once the inspection is completed satisfactorily,
conclude by reading and following chapter „5.3.3
Installing the brake chamber“ and „5.3.4 Final
procedure“.
4.3.9 Checking the guide pin bellows
Danger!
Wear respiratory protection in order to avoid inhaling
particles which can be hazardous to health! Brake
pad wear produces dust which can cause lung dam-
age!
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.
●Use a vacuum cleaner to clean the surfaces. Do
not use compressed-air.
B
A
Fig. 28 - Inspecting the guide pin bellows
Read and follow „3.2 Initial procedure“ prior to in-
specting the guide pin bellows.
15.Inspect the xed bearing guide pin bellows (A) and
the oating bearing guide bolt bellows (B), see ►
Fig. 28. Inspect all around the bellows for signs of
damage as a result of debris, stones or overheat-
ing.
16.If the bellows are damaged then they must be
replaced. For instructions on how to replace the
bellows, read and follow chapter „4.3.11 Checking
the slide function“.

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17.Once the inspection is completed satisfactorily,
conclude by reading and following chapter „5.3.3
Installing the brake chamber“ and „5.3.4 Final
procedure“.
4.3.10 Checking the thrust plate bellows
Danger!
Wear respiratory protection in order to avoid inhaling
particles which can be hazardous to health! Brake
pad wear produces dust which can cause lung dam-
age!
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.
●Use a vacuum cleaner to clean the surfaces. Do
not use compressed-air.
●Never use an impact wrench or similar to rotate
the reset shaft. This may damage the disc brake
mechanism! The maximum torque is 20 Nm.
Note:
Do not over adjust/extend the thrust plate whilst car-
rying out the inspection. Over adjustment/extension
may cause the thrust plate to disengage from the
adjustment screw and if done unintentionally may
cause damage to the thrust plate bellows! The min.
distance between the brake calliper and thrust plate
is 60 mm.
60mm
A
Fig. 29 - Max. unscrewing for inspecting the thrust plate bellows
1. Read and follow „3.2 Initial procedure“ and „5.2.2
Removing the brake pads“ prior to inspecting the
thrust plate bellows.
2. Use the Torx 55 socket to manually rotate the reset
shaft clockwise. This unscrews the thrust plate (A)
from the adjustment screw so that the bellows can
be inspected. Stop when the distance between the
inner pad face of the thrust plate and outer pad
face of the brake calliper is 60 mm, see ► Fig. 29.
Fig. 30 - Inspect the adjustment screw bellows
3. Inspecting the adjustment screw bellows, see ►
Fig. 30. Inspect all around the bellows for signs of
damage as a result of debris, stones or overheat-
ing.
4. If the bellows are damaged then they must be
replaced. For instructions on how to replace the
bellows, read and follow chapter „5.4 Replacing
the adjustment screw bellows“.