General Operating and Service Manual
Contents
1. New Zealand Transport Specialties Limited Cnr Kerrs and Ash Roads Wiri South Auckland Mail Centre NZ Auckland Russia SAF INTCOM Dolgoprydny pos Sheremetevsky Novoe Shosse 1 RUS 141050 Moskovskay Oblast South Africa SAF Axles South Africa Pty Ltd 47 Oxford Road ZA 2196 Forest Town South Korea JB Enterprises Korea Namdong Gu Guwall 1 Dong 201 29 Gumhwa Office Suite 603 ROK 405 827Incheon www saf alko com www saf axles com Jinan SAF ALKO Axle Co Ltd No 9 Xianwen South Road Jinan RC 250101 Shandong Province SAF AL KO Vehicle Technology Yantai Co Ltd Guangchang North Road 1 Laishan RC 264003 Yantai Shandong Mr Craig Wallace Tel 61 3 9369 0856 Fax 61 3 9369 1681 craig wallace hdte com au www hdte com au Mr Johann Strasser Tel 55 19 32954214 Fax 55 19 32953270 johann strasser saf axles com www saf axles com Mr Dian Bo Li Tel 86 1360 640 2297 Fax 86 531 8870352 lidianbo saf alko com www saf alko com Mr Dian Bo Li Tel 86 1360 640 2297 Fax 86 535 672 7797 lidianbo saf alko com www saf alko com Mr Yutaka Nozawa Tel 81 3 34630941 Fax 81 3 34631407 y nozawa nhl shinko co jp www saf axles com Mr Bruce Munro Tel 64 9 9807322 Fax 64 9 9807306 brucemunro transpecs co nz www transpecs co nz Mr Emil Nizamov Tel 7 095 7825082 Fax 7 095 579 94 00 saf intcom yandex ru www saf intcom ru Mr Willem Brits Tel 27 11 646 02922. Fax 27 11 942 1778 whrits saf axlessa co za www saf axles com Mr M S Kim Tel 82 32 4220301 Fax 82 32 4220091 mskim1612 dreamwiz com www saf axles com
3. axle SNF 420 d 420 0 d 422 0 d 424 0 3 057 9912 00 17 5 x 180 3 057 9912 10 19 0 3 057 9912 20 20 0 3 057 9913 00 3 057 9913 10 3 057 9913 20 Assembly tools SAF Part No Axle types 12242 Axle nut wrench 4 434 3828 00 Puller for wheel hub 3 301 0010 00 Universal puller for wheel hub 4 434 3822 00 Fitting mandrel for wheel bearing and seal ring 3 434 3320 00 Fitting mandrel for cassette seal ring 3 434 1036 00 Brake shoe tensioner 3 349 1001 00 Check the brake setting Adjustment of S cam brakes with manual slack adjusters The natural wear of the brake drum and brake lining necessitate frequent adjustment of the wheel brakes in order to maintain the maximum stroke of the brake cylinders In order to achieve good braking it is essential to minimise the clearance between the brake drum and brake lining In order to check the clearance the service brake is applied with full pressure and the stroke of the brake cylinder checked If the stroke at the yoke end is more than 2 3 of the maximum cylinder stroke the brake must be urgently adjusted If the brakes are correctly adjusted it should not be possible to move the piston rod more than 15 mm by hand Turn the adjusting screw to the right until the brake shoes are firmly up against the brake drum No clearance between Turn the adjusting screw to piston and diaphragm the left until permitted in the
4. with the trailer standing on level ground It can be carried out with the trailer either empty or loaded Note For a final check the air suspension system should be lowered to the suspension stop or raised to the limit shock absorbers stop ropes air bag length During this process the specified angle between valve lever and adjustment pipe must not be exceeded in order that the valve lever does not move in the wrong direction V11489GB Edition 01 2006 Last updated 2006 01 31 Amendments and errors reserved SAF SV11489GB Edition 01 2006 Last updated 2006 01 31 Amendments and errors reserved SAF In order to compensate for production tolerances an axle alignment and if necessary a correction should be carried out The maximum permissible deviations tolerances of the alignment values are specified by the tyre manufacturer The maximum possible wheelbase correction per axle is 6 mm Conventional adjustment KONIGSZAPFEN 7 KING PIN Determine the lengths of the diagonals A C and A F for the middle axle reference axle by comparison measurements observing the tolerances Check the wheelbases B C and E F for the front axle and C D and F G for the rear axle and correct if necessary observing the tolerances Optical adjustment Observe the operating and setting instructions of the measuring system manufacturer MeBwert B1 Calculation of the toe in and toe out va
5. 87 0011 05 locking pin Tighten the lock nut to 400 Nm For axle stub end SAF mounting paste Check the running and rock of the wheel bearing SAF Part No 5 387 0021 01 The wheel must turn without resistance and no rock may be felt at the wheel rim Correct the adjustment if necessary For ball in brake carrier Replace the O ring and fit the wheel cap i ie 387 0014 01 art No Replace the brake shoe return springs at every brake pad change Tighten axle nuts Note during brake repairs _ Lubricate the camshafts rotating the camshaft through 360 several times Do not dismantle the wheel bearing unit Use a vacuum cleaner to remove brake dust Use of a high pressure cleaner or liquid cleanser is not permitted on the brake drum and brake hub v i Remove old grease from the stub axle and regrease ka z Max permissible axial backlash of hub unit c S g J 0 0 20 mm Eg lay Tle BRAKE SNF 420 Max admissible brake drum machining diameter 424 0 mm Max admissible brake drum wear diameter 425 0 mm Use only brake lining qualities recommended and approved by SAF Machine new brake linings to diameter 0 3 mm of the brake drum When riveting on observe the lining form see instructions in the pack Brake SAF Part No Brake drum brake lining Brake Rivet Rivet size Brake lining Repair stages in mm lining DIN 7338 Normal dimension 1st repair stage 2nd repair stage Number per
6. General Operating and Service Manual Edition 01 2006 Service SV11489GB Edition 01 2006 Last updated 2006 01 31 Amendments and errors reserved SAF SAF suspension system with J Series axles Axle type designation Type and production number Prod No are required for complaint processing see type plate with J Series axles b ee i a a SAF suspension system PH he S Ni m QE JINAN SAF AXLE CO LTD TYPE R7712242 18C 014712016010 mno 0411121101 cemcap 10 000kg WaxSeeed 105 Km Cul FB32245 HDTE BrakeType SNF420X180 LY Trailer manufacturer Body type Chassis No Date of delivery date of registration Spare parts service for SAF axles and suspension systems Exact type designations are required for spare parts orders Please enter the identification data of the suspension system in the type plate illustrated below so that the correct information is available when necessary _ JINAN SAF AXLE CO LTD TYPE RZT12242H8C 44712016010 pono 041112110 Pemca 10 000 kg Maxsped 105 Krh Ca FB32245 HDTE BrakeType SNF420X180 Py Aoo No Serial No u ae Example 041121101 1121101 RZT RZT 12242118C 8C istae M O andae o M O srdale o M E ahade Lf sha
7. ar the wheel bearings This can result in a significant deterioration in road safety e g failure of wheel bearings 7 The parking brake must not be immediately applied when the brakes are hot as the brake discs and brake drums may be damaged by different stress fields during cooling 8 Use the supports provided when loading and unloading in order to avoid damage to the axle 9 Observe the operating recommendation of the trailer builder for off road operation of the installed axles and Suspension systems The SAF definition of OFF ROAD means driving on non asphalted non concreted routes such as e g gravel roads agricultural and forestry tracks on construction sites and in gravel pits Off road operation of SAF axles and suspension systems not designed for the purpose may result in damage and hence to an impairment of road safety 10 SAF axles and suspension systems require continuous care service and maintenance in order to maintain operational and road safety and to be able to recognise natural wear and defects in good time The daily inspection of the trailer for road safety before starting the journey is one of the driver s obligations SAF recommends that at least the inspections and maintenance operations described on page 26 should be carried out We recommend the use of original SAF spare parts A close knit service network of SAF partner companies is available for the technical support of the SAF axles and suspension
8. ge 7 Carry out a general safety check in accordance with the statutory provisions We recommend the use of original SAF spare parts We recommend that a general safety check is carried out when the minimum wear limit is reached Tightening torques for SAF leaf suspension system and J Series axles M14 105 Nm M24 600 Nm M24x2 SW36 400 Nm M14 105 Nm M14 105 Nm M24 600 Nm M30 350 Nm M48 1100 Nm Strebenstangen Gruppe verstellbar adjustable torque arm kit M30 350 Nm Cut screw K100x40 SW10 20 Nm for plastic plunger piston Attention e Threads not to be oiled or greased e Pivot bolt on steel hanger brackets maintenance free rigid torque arm kit M14 105 Nm M30 350 Nm Strebenstangen Gruppe starr V11489GB Edition 01 2006 Last updated 2006 01 31 Amendments and errors reserved SAF SV11489GB Edition 01 2006 Last updated 2006 01 31 Amendments and errors reserved SAF Axle types RZ 12242 18C RZT 12242 18C RZ 12242 20C RZT 12242 20C Adjust wheel bearing clearance Grease specifications Tighten the WAF 85 axle nut to 150 Nm turning the wheel hub For wheel bearings at the same time SAF Part No 5 387 0011 05 Turn back the axle nut by 2 1 2 holes of the lock washer Poema bal Push on the lock washer and secure the axle nut with the SAF Part No 5 3
9. hou Runhope Automotive Parts Co Ltd 218 From September 2005 QC slack adjusters 12 75 mm hole diameter Manufacturer Wan Xiang Qianchao Co Ltd Tightening instructions for adjustable pivot bolt Attention Tightening always within the specified ride height range No paint residues between eccentric thrust washer and hanger Bolt head always on the eccentric washer side Pretightening 400 Nm Marking for angle tightening Use Torque wrench Angle tightening 120 Visual inspection Use impact wrench or extend lever to 2 5 m SV11489GB Edition 01 2006 Last updated 2006 01 31 Amendments and errors reserved SAF SV11489GB Edition 01 2006 Last updated 2006 01 31 Amendments and errors reserved SAF Semi trailer tilt angle Ride heights Adjust the ride height of the air suspension axles to the permissible range indicated in the corresponding SAF documents With single axles allow for a minimum suspension travel of 60 mm For trailers with multiple axles allow for a minimum suspension travel of 70 mm Exception For multi axle trailers with lift axles the minimum suspension travel at the lift axle should not be less than 100 mm in order to ensure an adequate ground clearance Adjustment of the air suspension system ride height Air suspension valve As standard SAF air suspension axles and system require only one air suspension valve The air suspension valve controls the air bag pressure in
10. le M O Enter the axle data from the SAF type plate SV11489GB Edition 01 2006 Last updated 2006 01 31 Amendments and errors reserved SAF SAF Contents Page Identification of SAF axles sccsczcaccessescansensassassecesavsesaassansensaseansecssasaesanssassessancansessansacseessasaesannsansensansansesnsesacsaasaasaenannexs 2 3 Be Meta satay MNS MUCO lt cccsccesrcrceracurexsesacureevasunexpavacnvensanuseresvasussieavasuses avacureeseesseseavasueet eavachrersasusaresvesusetavesieeeses 5 SAF general service instructions L n nn nn nn 6 Jih y i ee u aaa A A A A A cede 7 RZ 12242 18C RZT 12242 18C RZ 12242 20C RZT 12242 20C L n nu 8 Check the brake setting L nn nn nn nn 9 E A E A AAA ET 10 Tightening instructions for adjustable pivot bolt l nn 11 SU E E AAAA 12 Adjustment of the air suspension system ride height l nn nn 13 Axle alignment EEE EAE 14 SV11489GB Edition 01 2006 Last updated 2006 01 31 Amendments and errors reserved SAF GB Please observe the following safety instructions in order to maintain the operational and road safety of your SAF axles and suspension systems 1 The wheel contact surfaces between the wheel disc and wheel hub and the wheel nut contact surface at the wheel disc must not be additionally painted The contact surfaces must be clean smooth and free from grease Failure to observe this may result in
11. lues A1 B1 mm Me linieal A m FAHRTRICHTUNG S positive value Toe in S negative value Toe out Notes 1 In order to avoid tyre wear we recommend that an axle alignment is performed at regular intervals 2 We recommend the use of an optical measuring system for carrying out the axle alignment 3 For alignment only the centres of the middle of the wheel cap or the middle of the axle stub end are of interest as reference points 4 Possible causes of deviations in the axle alignment are e Loose U bolts e Wear of the spring guide bearing e Deformation of the axle assembly components due to improper use JYS padiasal sioua pue slu uupu uiv LE L0 9007 p lepdn se 900Z 10 uoip3 g5268tLLAS LLJ Q lt N LL Q lt lt L L gt Q lt SV11489GB Edition 01 2006 Last updated 2006 01 31 Amendments and errors reserved SAF Australia HDTE Heavy Duty Transport Equipment Pty Ltd 91 Dohertys Road AUS Altona North Victoria 3025 Brazil SAF Do Brasil Rua Margarida de Campos 77 13076 240 Prq Taquaral BR Campinas China Jinan SAF ALKO Axle Co Ltd No 9 Xianwen South Road Jinan RC 250101 Shandong Province China SAF AL KO Vehicle Technology Yantai Co Ltd Guangchang North Road 1 Laishan RC 264003 Yantai Shandong Japan Shinko Boeki Co Ltd Shibuya Central Building 3 14 Udagawa cho J 150 0042 Shibuya ku Tokyo
12. relation to the trailer load in order to maintain a constant ride height in every load condition The air suspension valve is fastened to the trailer frame with screws and connected to the axle via the pivot joint valve lever and adjustment pipe On triple axle trailers the system is generally connected to the middle axle normally in the middle of the axle and on twin axle trailers to the rear axle In special cases e g large trailer tilt angle the air suspension valve can be installed in the rear axle For trailers with axle lifting system the axle to which the system is connected depends on the axle to be lifted RAHMENBEFESTIGUNG MIN 200 VENTILHEBEL MOUNTING VALVE LEVER GUMMIGELENK FULCRUM ANLENKSTANGE ADJUSTMENT PIPE FAHRHOEHE FH RINF HFIGHT LOWERING Z KONTERMUTTER LOCK NUT AUSFEDERUNG EINFEDERUNG F AHRTRICHTUNG A 8 lt aN te Sw i ee F R 0 N T Z etre Installation The valve lever should be at least 200 mm long and is horizontal when the trailer is in the driving position As a function check move the lever down slightly Air must now escape via the venting cap into the atmosphere If air flows into the air bags when the lever is pushed down the valve lever has to be turned through 180 For this the valve lever has to be disconnected The ride height is set by adjusting the adjustment pipe in the fulcrums and by turning the lock nuts The adjustment must be carried out
13. rest position i the free travel of the slack adjuster at 127 mm is approx 10 15 mm i f f 5 It must be possible to turn the Adjustment is performed at the wheel freely without braking adjustment screw WAF 19 without scraping noises lt gt Special instructions apply for automatic slack adjusters see adjustment procedure on the following pages A Angle must not exceed 90 at 1 2 stroke F B No contact permissible between slack adjuster and axle beam during emergency braking N L Observe piston rod length as per the SAF specifications SV11489GB Edition 01 2006 Last updated 2006 01 31 Amendments and errors reserved SAF Slack adjuster Note when changing over from mechanical slack adjuster to automatic slack adjuster In order to avoid damage to the wheel brake install only the automatic slack adjuster with the prescribed adjustment gate and corresponding mounting point strap approved by SAF for the respective axle type Changes to the effective brake lever lengths are not admissible The field installation of automatic slack adjusters does not require type approval so that no inspection by the technical inspection authorities TUV is necessary Technical information on SAF spare part numbers and correspondence of slack adjusters and axle types can be obtained from the SAF service partners From April 2004 TGL slack adjusters 14 mm hole diameter Manufacturer Guangz
14. systems and for the supply of original SAF spare parts see rear cover or on the Internet under www saf axles com Updates will be published as necessary on the Internet under www saf axles com V11489GB Edition 01 2006 Last updated 2006 01 31 Amendments and errors reserved SAF SV11489GB Edition 01 2006 Last updated 2006 01 31 Amendments and errors reserved SAF Caution After every wheel change always retighten the wheel nuts to the prescribed torque after 50 km and again after 150 km Check the brake lining thickness at regular intervals Carry out general visual inspections of the brakes tyres and all suspension components at regular intervals and check for proper attachment wear leaks corrosion and damage Carry out regular visual inspections of the wheel bearing unit for grease leaks and axial clearance Wheel bearing grease change see page 8 Regularly check the camshaft for smooth return and the slack adjuster for proper function Lubricate the camshaft at regular intervals Inspect the brake drum for wear and cracking at every brake lining change Minimum wear limits see page 8 Replace the brake shoe return springs at every brake lining change Check the air suspension ride height at regular intervals in accordance with the trailer builder s specifications and adjust as described on page 13 On all units check that the bolts of the U brackets are tightened to the prescribed torques as described on pa
15. the wheel coming loose Any additional instructions of the wheel manufacturer must also be observed 2 Only the wheel and tyre sizes approved by the trailer builder may be used The tyres must always have the specified inflation pressure 3 The brake systems of the tractor and the trailer semi trailer must be synchronised by means of a tractor trailer brake synchronisation not later than 5 000 km after the initial start of operation of the trailer semi trailer in order to ensure a safe and uniform braking behaviour and uniform brake pad wear Tractor trailer brake synchronisations should be carried out by appropriately qualified and equipped brake workshops The use of an additional braking system such as a trailer anti jackknife brake is forbidden by law on vehicles with type approval after January 1999 4 Before starting a journey ensure that the maximum permissible axle load is not exceeded and that the load is distributed equally and uniformly 5 On trailers with air suspension ensure that the air bags are completely filled with air before starting the journey Incompletely filled air bags may result in damage to axles suspension frame and superstructure and impair road safety 6 Ensure that the brakes are not overheated by continuous operation With drum brakes overheating can result in a hazardous deterioration in the braking efficiency With disc brakes overheating can result in damage to surrounding components in particul
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