General Operating and Service Manual
Contents
1. For axle stub end SAF mounting paste Use a vacuum cleaner to remove brake dust SAF Part No 5 387 0021 05 Use of a high pressure cleaner or liquid cleanser is not permitted on the brake drum and brake hub Remove old grease from the stub axle and regrease Replace the O ring Replace the brake shoe return springs at every brake pad change For ball in brake carrier Copper paste SAF Part No 5 387 0014 01 Tighten axle nuts On left hand side in direction of travel Left hand thread On right hand side in direction of travel Right hand thread Pretightening 150 Nm then turn the hub unit slowly by 5 revolutions Final tightening Retighten by 1 increment 30 Marking of the nuts with left hand thread Milled groove on outside of hexagon Max permissible axial backlash of hub unit 0 0 20 mm 367 0 d nominal size 1st oversize 369 0 2 2nd oversize BRAKE SNK 367 Max admissible brake drum machining diameter Max admissible brake drum wear diameter 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 371 0 mm 372 0 mm SAF 396 BREMSKERL 6386 Brake SAF Part No size Brake lining Rivet DIN 7338 Brake drum brake lining Repair stages in mm Rivet Normal dimension 1st repair stage 2nd repair stage d 367 0 d 369 0 d 371 0 per axl2. 58 35 0 19 08 64 90 2 61 10 45 06 0800 72 37 37 84 0 73 33 80 81 58 75 72 7474 9 02 18 19 92 697 91 96 03 88 72 06 43 0 93 51 31 33 41 19 08 64 90 0 87 02 42 02 37 21 09 40 19 80 06 13 45 17 27 386 26 16 58 35 02 66 16 55 74 44 87 02 42 02 37 32 59 33 07 07 372 697 91 96 372 697 91 96 33 3 88 72 06 43 386 26 16 58 35 45 75 72 74 74 32 59 33 07 07 34 9 13 82 68 41 06 18 31 98 70 02 12 50 02 60 39 02 66 16 55 74 45 75 72 74 74 42 02 61 10 45 06 0 26 16 58 35 0 21 22 75 13 21 386 26 16 58 35 www saf axles com Otto Sauer Achsenfabrik GmbH Hauptstra e 26 D 63856 Bessenbach Tel 49 0 60 95 301 0 Fax 49 0 60 95 301 259 www saf axles com ege 930060000000006600000000000000006 Vom Ausland from abroad 43 3 62 27 23 21 32 59 33 07 07 30 21 09 40 19 80 386 26 16 58 35 41 19 08 64 90 42 02 61 10 45 06 00800 72 37 37 84 49 73 33 80 81 58 45 75 72 74 74 34 9 13 82 68 41 372 697 91 96 33 3 88 72 06 43 35 8 93 51 31 33 41 19 08 64 90 44 87 02 42 02 37 30 21 09 40 19 80 36 13 45 17 27 386 26 16 58 35 39 02 66 16 55 74 44 87 02 42 02 37 32 59 33 07 07 372 697 91 96 372 697 91 96 33 3 88 72 06 43 386 26 16 58 35 45 75 72 74 74 32 59 33 07 07 34 9 13 82 68 41 48 6 18 31 98 70 40 2 12 50 02 60 39 02 66 16 55 74 45 75 72 74 74 42 02 61 10 45 06 386 26 16 58 35 90 21 22 75 13 21 386 26 16 58 35 SAF
3. 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 Measured value A1 Measured value B1 Calculation of the toe in and toe out values A1 B1 mm A m FAHRTRICHTUNG S positive value Toe in S negative value Toe out Laser with bracket 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 VS padiasal sioua pue sjuawpuawly 1 10 900Z parepdn 1se1 900Z L0 uonip3 858p LLAS LU um a m N LE ES Q a P LL um Q a SV11484GB Edition 01 2006 Last updated 2006 01 13 Amendments and errors reserved SAF NonStopService 24 e Im Servicefall wahlen Sie bitte immer die Rufnummer Ihres Heimatlandes e In the case of service please always dial the number of your own country Inland home country 03 62 27 23 21 0 59 33 07 07 30 21 09 40 19 80 386 26 16
4. 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 pages 8 to 15 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 25 With aluminium and stainless steel hanger brackets check that the bolts of the spring brackets and shock absorbers are tightened to the prescribed torques as described on page 7 On all units check that the bolts of the U brackets are tightened to the prescribed torques as described on page 7 For steering axles observe also the points on pages 16 and 17 Carry out a general safety check in accordance with the statutory provisions e 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 SAF INTRA with steel hanger bracket M12 WAF19 M20x1 5 WAF30 i 600 Nm 40 Nm 4 V M16 WAF24 180 Nm for steel plunger piston 80 Nm for plastic plunger piston Tightening torques SAF INTRA with aluminium hanger bracket and Stainless steel hanger bracket M12 WAF19 i 600 M16 WAF24 180 Nm for steel plunger piston 80 Nm for plastic plunger piston IA Semer M20 WAF30 180 Nm W
5. the wheel rim Correct the adjustment if necessary For baili brake carier Replace the O ring and fit the wheel cap Copper paste l Replace the brake shoe return springs at every brake pad change SAF Part No 5 387 0014 01 Tighten axle nuts Note during brake repairs Lubricate the camshafts rotating the camshaft through 360 several times 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 Remove old grease from the stub axle and regrease Max permissible axial backlash of hub unit 0 0 20 mm d 1st oversize 302 0 d nominal size 300 0 2nd oversize 303 0 BRAKE SNK 300 Max admissible brake drum machining diameter 303 0 mm Max admissible brake drum wear diameter 304 0 mm Brake lining qualities recommended and approved by SAF SAF 396 BREMSKERL 6386 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 SAF Part No Brake drum brake lining Rivet Brake lining Repair stages in mm DIN 7338 Normal dimension 1st repair stage 2nd repair stage Number per axle SNK 300 d 300 0 d 302 0 d 303 0 x 150 3 057 3133 00 ie ee i x 200 3 057 3124 00 en Assembly tools SAF Part No Axle nut wrench 4 434 3828 00 Puller for wheel hub 3 301 0010 00 Fitting mandrel for wheel bearing and seal ring 3 434 1014
6. thread Pretightening 150 Nm then turn the hub unit slowly by 5 revolutions Final tightening Retighten by 1 increment 30 Marking of the nuts with left hand thread Milled groove on outside of hexagon Max permissible axial backlash of hub unit 0 0 20 mm BRAKE SNK 420 Max admissible brake drum machining diameter Max admissible brake drum wear diameter 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 size Brake lining Repair stages in mm Grease specifications For camshaft SAF Part No 5 387 0011 05 For axle stub end SAF mounting paste SAF Part No 5 387 0021 05 For ball in brake carrier Copper paste SAF Part No 5 387 0014 01 Ou Ou N o H a i a ms a i Oe oe LO E e JS rw al OO et EN OO ew Oo 5 N o st us C st E N 424 0 mm 425 0 mm SAF 396 BREMSKERL 6386 Rivet DIN 7338 Brake lining Rivet Normal dimension 1st repair stage 2nd repair stage Number per axle SNK 420 d 420 0 d 422 0 d 424 0 20 6 3 057 3960 00 21 6 21 0 22 6 22 0 20 6 3 057 3966 00 Assembly tools Axle nut wrench Brake shoe tensioner Puller for wheel hub 21 6 21 0 SAF Part No 4 434 3828 00 3 349 1001 00 4 434 3822 00 22 6 22 0 A
7. 00 Fitting mandrel for wheel bearing 3 434 3308 00 Brass bush mounting mandrel 1 434 1055 00 Brass bush mounting device 1 434 1056 00 13 SV11484GB Edition 01 2006 Last updated 2006 01 13 Amendments and errors reserved SAF SV11484GB Edition 01 2006 Last updated 2006 01 13 Amendments and errors reserved SAF Axle types SK RS RZ 12242 Adjust wheel bearing clearance Tighten the WAF 85 axle nut to 150 Nm turning the wheel hub at the same time Turn back the axle nut by 2 1 2 holes of the lock washer Push on the lock washer and secure the axle nut with the locking pin Tighten the lock nut to 400 Nm Check the running and rock of the wheel bearing The wheel must turn without resistance and no rock may be felt at the wheel rim Correct the adjustment if necessary Replace the O ring and fit the wheel cap 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 Remove old grease from the stub axle and regrease Max permissible axial backlash of hub unit 0 0 20 mm BRAKE SNK 420 Max admissible brake drum machining diameter Max admissible brake drum wear diameter Brake li
8. 1 2006 Last updated 2006 01 13 Amendments and errors reserved SAF Page Identification E 2 3 SAF general safety IRStEuEIeHS ee 5 SAF EECH 6 Usine Re 7 Service schedule 9 4218 SL9 4218 79 4218 7L9 4218 59 4220 SL9 4220 Z9 4220 ZL9 4220 11 4218 SL11 4218 SZL11 4218 711 4218 ZL11 4218 511 4220 SL11 4220 SZL 4220 711 4220 AE NEC E UP WES P750 eee 8 SE er UA PEEL T 9 79 3718 7 59 3718 59 3718 79 3720 ZL9 3720 511 3720 SLTT 3720 7211 3720 ZL11 3720 TT 10 ERA EEN DU RT 11 57 3015 7 77 3015 89 3020 1 79 3020 1709 3020 7 ZT1 3020 FEI 3020 E 12 SK RS RZ 6530 9030 11030 RZ 12030 E 13 SIUE 27H ET 14 L E E E e 15 Tightening torques and adjustment instructions TOISSBI 6 FC TIN E e EBENEN AN REDREEREE mennneernnetsiitaesisaesscacssesescesnsacsiacenta 16 17 General information Check the Drake SOLE E 18 Adjustment of HALDEX automatic slack adjusters essent 19 20 Adjustment of S ABA automatic slack adjusters cccccescscessssesssssscssesscsecessesessesesacsesassesassesassecassusesateesateesateesasensass 21 Tightening instructions for adjustable pivot bot 22 Sale e it UE 23 Tyre changing on fully loaded trailer with INTRA axle ccccceccssssescsscsssecsssecsssseesssesaseecassesessecessecesee
9. 5 Ontrailers 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 particular 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 operati
10. 822 00 SV11484GB Edition 01 2006 Last updated 2006 01 13 Amendments and errors reserved SAF SV11484GB Edition 01 2006 Last updated 2006 01 13 Amendments and errors reserved SAF Axle types 7 3015 277 3015 59 3020 SL9 3020 29 3020 ZL9 3020 211 3020 ZL11 3020 Wheel bearing play wheel bearing grease Adjustment of wheel bearing play not necessary Note during brake repairs Lubricate the camshafts rotating the camshaft through 360 several times 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 Remove old grease from the stub axle and regrease Replace the O ring Replace the brake shoe return springs at every brake pad change Tighten axle nuts On left hand side in direction of travel Left hand thread On right hand side in direction of travel Right hand thread Pretightening 150 Nm then turn the hub unit slowly by 5 revolutions Final tightening Retighten by 1 increment 30 Marking of the nuts with left hand thread Milled groove on outside of hexagon Max permissible axial backlash of hub unit 0 0 20 mm BRAKE SNK 300 Max admissible brake drum machining diameter Max admissible brake drum wear diameter 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 lin
11. A axle Jack positioning points 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 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 E 2 KONTERMUTTER LOCK NUT AUSFEDERUNG EINFEDERUNG F AHRTRICHTUNG A Ir 8 l IRONT Eds i ee F R 0 N T RRC Sg 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 a
12. General Operating and Service Manual Edition 01 2006 Service E 2 i SV11484GB Edition 01 2006 Last updated 2006 01 13 Amendments and errors reserved SAF SAF air suspension system Type INTRA The axle type designation Version identification number and serial number see type plate are required for the warranty procedure SAF air suspension system Type MODUL OTTO SAUER ACHSENFABRIK GMBH SAF D 63856 BESSENBACH GERMANY FX OO OT TT AN 1754524 N SN 284051007 a Identification if the type plate is missing The Serial No of the axle is embossed in the axle end on the right hand side as seen in m the direction of travel 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 ies SAPS Dye eeng eene 147 0460280 Test Report TDBO381 BS fos enn A Anann MH AN 1754524 Ident No Prod No Serial No Example a7 84607 580 284051 007 istae L 0 0 0 0 0 0 y O idk xdade mae Lf 0 ID f O Enter the axle data from the SAF type plate SV11484GB Edition 01 2006 Last updated 2006 01 13 Amendments and errors reserved SAF SV11484GB Edition 0
13. W WHK TERES Cut screw K100x40 WAF10 20 Nm for plastic plunger piston Attention e Threads not to be oiled or greased e Pivot bolt on steel hanger brackets maintenance free e Service intervals for aluminium hanger brackets and stainless steel hanger brackets first check after 500 km further check after every 6 months Spring eye bolt Inspection torque 1 200 Nm Shock absorber bolt Inspection torque 400 Nm SV11484GB Edition 01 2006 Last updated 2006 01 13 Amendments and errors reserved SAF SV11484GB Edition 01 2006 Last updated 2006 01 13 Amendments and errors reserved SAF Axle types S9 4218 SL9 4218 29 4218 ZL9 4218 S9 4220 SL9 4220 29 4220 ZL9 4220 511 4218 SL11 4218 SZL11 4218 211 4218 ZL11 4218 511 4220 SL11 4220 SZL11 4220 211 4220 ZL11 4220 ZZL11 4220 Wheel bearing play wheel bearing grease Adjustment of wheel bearing play not necessary Note during brake repairs Lubricate the camshafts rotating the camshaft through 360 several times 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 Remove old grease from the stub axle and regrease Replace the O ring Replace the brake shoe return springs at every brake pad change Tighten axle nuts On left hand side in direction of travel Left hand thread On right hand side in direction of travel Right hand
14. e SNK 367 SV11484GB Edition 01 2006 Last updated 2006 01 13 Amendments and errors reserved SAF x 180 3 057 3168 00 21 1 20 5 22 1 21 5 23 1 22 5 x 200 3 057 3170 00 21 1 20 5 22 1 21 5 23 1 22 5 Assembly tools SAF Part No Axle nut wrench 4 434 3828 00 Brake shoe tensioner 3 349 1001 00 Brake drum mounting flanges 3 434 1040 01 Puller for wheel hub 4 434 3822 00 Axle types SK RS RZ 6537 9037 11037 Wheel bearing play wheel bearing grease Adjustment of wheel bearing play not necessary Change the wheel bearing grease after 500 000 km or 50 months Inspect taper roller bearing for serviceability at grease changes Replace the O ring and fit the wheel cap 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 Remove old grease from the stub axle and regrease Replace the brake shoe return springs at every brake pad change Tighten axle nuts On left hand side in direction of travel Left hand thread On right hand side in direction of travel Right hand thread Tightening torque 900 Nm Each hub unit must be rotated smoothly at least twice while tightening the bolts Marking of the nuts with left hand thread Mi
15. eesateesaseesasenass 24 Adjustment of the air suspension system ride height 25 PIE HT IERI E 26 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 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
16. ervice brake several times check the free running of the brake drum check the clearance If necessary repeat the adjustment of the slack adjuster SV11484GB Edition 01 2006 Last updated 2006 01 13 Amendments and errors reserved SAF SV11484GB Edition 01 2006 Last updated 2006 01 13 Amendments and errors reserved SAF 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 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 SV11484GB Edition 01 2006 Last updated 2006 01 13 Amendments and errors reserved SAF SV11484GB Edition 01 2006 Last updated 2006 01 13 Amendments and errors reserved SAF Tyre changing on fully loaded trailer with INTR
17. ing form see instructions in the pack Brake size SAF Part No Brake drum brake lining Brake lining Repair stages in mm Grease specifications For camshaft SAF Part No 5 387 0011 05 For axle stub end SAF mounting paste SAF Part No 5 387 0021 05 For ball in brake carrier Copper paste SAF Part No 5 387 0014 01 o o DN o H an a a o CH o c 7 OU a gt gt N O ES 9000 Dy om mo c c N 303 0 mm 304 0 mm SAF 396 BREMSKERL 6386 Rivet DIN 7338 Normal dimension 1st repair stage 2nd repair stage Number per axle SNK 300 d 300 0 d 302 0 d 303 0 x 150 3 057 3133 00 E es E x 200 3 057 3124 00 n Assembly tools SAF Part No Axle nut wrench 4 434 3828 00 Puller for wheel hub Puller for wheel hub 3 301 0010 00 4 434 3822 00 Axle types SK RS RZ 6530 9030 11030 RZ 12030 Adjust wheel bearing clearance Grease specifications Tighten the WAF 85 axle nut to 150 Nm turning the wheel hub at the same time Turn back the axle nut by 2 1 2 holes of the lock washer For wheel bearings SAF Part No 5 387 0011 05 Push on the lock washer and secure the axle nut with the For camshaft locking pin SAF Part No 5 387 0011 05 Tighten the lock nut to 400 Nm For axle stub end Check the running and rock of the wheel bearing SAF mounting paste The wheel must turn without resistance and no rock may be felt SAF Part No 5 387 0021 01 at
18. ions in the pack SAF Part No Brake lining Rivet DIN 7338 Brake lining Brake drum brake lining Rivet Repair stages in mm Normal dimension 1st repair stage 2nd repair stage Number per axle SNK 420 d 420 0 d 422 0 d 424 0 x 180 3 057 3960 00 Be 2 S 2 x 200 3 057 3966 00 ee 2 2 Assembly tools SAF Part No Axle types 14242 16242 1 012 0013 00 3 301 0007 01 Axle nut wrench Puller for wheel hub Universal puller for wheel hub Fitting mandrel for wheel bearing and seal ring Brake shoe tensioner 46 mm dia brass bush driver mandrel 50 46 mm and 42 38 mm dia mounting mandrel 4 434 3822 00 3 349 1001 00 1 434 1056 00 1 434 1055 00 4 434 3822 00 3 434 3301 00 3 349 1001 00 1 434 1056 00 1 434 1055 00 SV11484GB Edition 01 2006 Last updated 2006 01 13 Amendments and errors reserved SAF SV11484GB Edition 01 2006 Last updated 2006 01 13 Amendments and errors reserved SAF Tightening torques Designation Number per axle Tightening torque Ball joint screw M30 340 Nm Reatining clamp screw M12 80 90 Nm Steering damper screw M24 600 660 Nm Lock cylinder screw M6 8 10 Nm Stabilising cylinder screw M16 180 30 Nm Lock nut M20 is locked against the thrust rod Cover p
19. ir 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 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 SV11484GB Edition 01 2006 Last updated 2006 01 13 Amendments and errors reserved SAF SV11484GB Edition 01 2006 Last updated 2006 01 13 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 K NIGSZ APFEN 4 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
20. iven in the SAF specifications e Brake chambers Before installation ensure that the brake chamber is in its starting position e Spring brake chambers on the other hand must be under full working pressure min 6 bar IMPORTANT If this is not observed the basic setting will be wrong e Grease the camshaft e Install mounting point strap 3 be sure to use two mounting bolts 4 e Install the slack adjuster on the camshaft e The arrow mark 7 points in the braking direction e Turn adjusting screw 1 until the bore in the slack adjuster 8 1 is aligned with the bore in the yoke end 9 see figure e With the fixed mounting point ensure that the 2 U profiles engage correctly in one another e Grease cotter pin 8 and secure e Hook in return spring 10 e Fix the slack adjuster on the camshaft Axial clearance Adjust the nominal value of 0 5 2 mm using shims Adjust the control arm Observe the possible setting range for the control lever position Adjust the clearance of the brake lining by turning adjusting screw 1 in clock wise direction until the brake lining is in contact with the brake drum Then back off adjusting screw 1 by 3 4 turn Do not use an impact wrench FUNCTION CHECK If the adjustment coupling is functioning correctly a torque of at least 18 Nm must be felt when backing off adjusting screw 1 a ratchet noise should also be clearly audible Actuate the s
21. ke 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 No clearance between piston and diaphragm permitted in the rest position Adjustment is performed at the adjustment screw WAF 19 Turn the adjusting screw to the right until the brake shoes are firmly up against the brake drum Turn the adjusting screw to the left until the free travel of the slack adjuster at 127 mm is approx 10 15 mm It must be possible to turn the wheel freely without braking without scraping noises Special instructions apply for automatic slack adjusters see adjustment procedure on the following pages A B Angle must not exceed 90 at 1 2 stroke No contact permissible between slack adjuster and axle beam during emergency braking L Observe piston rod length as per the SAF specifications HALDEX automatic slack adjuster Note when changing over from mechanical
22. late screw M8 25 30 Nm Dimension A must be the same observe the toe in approx 4 0 mm m Dimension B is 537 mm engage the reversing lock On versions with pneumatic stabilisation a steering damper must be used On versions without pneumatic stabilisation a steering damper must be used Check Backlash free seating of the piston rods of the stabilising cylinders Apply stabilising pressure min 2 bar to the cylinders Piston and pressure rods must then be backlash free under slight pressure otherwise adjust at C When setting the track width on the trailer the cylinders must be under stabilising pressure and the correct ride height of the air suspension system must have been set Tighten all bolts to the prescribed torque and lock the nuts or insert the cotter pin Note During lubrication work on the steering pin bearing the axle must be relieved raised Lubrication at the bearing points of the king pin bolt for the first time after 1 month then every 6 months SV11484GB Edition 01 2006 Last updated 2006 01 13 Amendments and errors reserved SAF SV11484GB Edition 01 2006 Last updated 2006 01 13 Amendments and errors reserved SAF Check the brake setting Adjustment of S cam brakes with manual slack adjusters The natural wear of the brake drum and bra
23. le nut with the cotter pin Turn back the wheel hub slightly against the front bearing with the wheel hub puller Seal the thread of the wheel cap Screw on the wheel cap Check the running and rock of the wheel bearing The wheel must turn without resistance and no rock may be felt at the wheel rim Correct the adjustment if necessary Replace the brake shoe return springs at every brake pad change Grease specifications For wheel bearings SAF Part No 5 387 0011 05 For camshaft SAF Part No 5 387 0011 05 For axle stub end SAF mounting paste SAF Part No 5 387 0021 01 For ball in brake carrier Copper paste SAF Part No 5 387 0014 01 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 A not permitted on the brake drum and brake hub a 9 Remove old grease from the stub axle and regrease E d E Max permissible axial backlash of wheel bearing EG X g z 2 0 0 20 mm 5S ei Iz BRAKE SNK 420 Max admissible brake drum machining diameter 424 0 mm Max admissible brake drum wear diameter 425 0 mm Brake lining qualities recommended and approved by SAF SAF 396 BREMSKERL 6386 Machine new brake linings to diameter 0 3 mm of the brake drum When riveting on observe the lining form see instruct
24. lled groove on outside of hexagon Max permissible axial backlash of hub unit 0 0 20 mm BRAKE SNK 367 Max admissible brake drum machining diameter Max admissible brake drum wear diameter 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 SAF Part No Brake drum brake lining Brake lining Repair stages in mm Grease specifications For wheel bearings SAF Part No 5 387 0011 05 For camshaft SAF Part No 5 387 0011 05 For axle stub end SAF mounting paste SAF Part No 5 387 0021 01 For ball in brake carrier Copper paste SAF Part No 5 387 0014 01 3 1 0 mm 372 0 mm SAF 396 BREMSKERL 6386 Brake Rivet lining Normal dimension 1st repair stage 2nd repair stage Number per axle cD N co o H ue ar i TF gt EW jO om 2 369 0 2nd oversize Rivet DIN 7338 SNK 367 367 d 369 0 d 371 0 x 150 3 057 3174 00 A 22 1 23 1 x 180 3 057 3168 00 215 225 22 1 23 1 x 200 3 057 3170 00 0 2155 22 5 Assembly tools SAF Part No Axle nut wrench 1 012 0024 00 Brake shoe tensioner 3 349 1001 00 Brake drum mounting flanges 3 434 1040 01 Wheel bearing mounting mandrel 3 434 1058 00 Brass bush mounting device 1 434 1056 00 Brass bush mounting mandrel 1 434 1055 00 Puller for wheel hub 4 434 3
25. ning 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 size Brake lining Repair stages in mm Grease specifications For wheel bearings SAF Part No 5 387 0011 05 For camshaft SAF Part No 5 387 0011 05 For axle stub end SAF mounting paste SAF Part No 5 387 0021 01 For ball in brake carrier Copper paste SAF Part No 5 387 0014 01 N v N e n a ue co De go gt N ol Ost EN DI ON xe oN o st ust C st cC CN 424 0 mm 425 0 mm SAF 396 BREMSKERL 6386 Brake Rivet Rivet lining DIN 7338 Normal dimension 1st repair stage 2nd repair stage Number per axle SNK 420 d 420 0 d 422 0 d 424 0 x 180 3 057 3960 00 Se 2 s 2 x 200 3 057 3966 00 d 1 5 SC 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 Axle types K RS RZ 14242 16242 Adjust wheel bearing clearance Tighten the axle nut turning the wheel hub until a slight resistance is felt Turn back the axle nut by 1 12 turn to the next locking possibility Lock the ax
26. onal 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 6 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 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 SV11484GB Edition 01 2006 Last updated 2006 01 13 Amendments and errors reserved SAF SV11484GB Edition 01 2006 Last updated 2006 01 13 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 pages 9 11 13 14 and 15 Regularly check the camshaft for smooth return and
27. othly at least twice while tightening Grease specifications For wheel bearings SAF Part No 5 387 0011 05 For camshaft SAF Part No 5 387 0011 05 For axle stub end SAF mounting paste SAF Part No 5 387 0021 05 For ball in brake carrier Copper paste SAF Part No 5 387 0014 01 K N K o H gement ua p e D o gt EN jO ot Se 424 0 mm 425 0 mm SAF 396 BREMSKERL 6386 Brake Rivet lining Normal dimension 1st repair stage 2nd repair stage Number per axle SNK 420 d 420 0 d 422 0 d 424 0 2nd oversize Rivet DIN 7338 424 0 x 180 3 057 3960 00 20 6 20 0 21 6 21 0 22 6 22 0 x 200 3 057 3966 00 Assembly tools Axle nut wrench Brake shoe tensioner Brake drum mounting flanges Wheel bearing mounting mandrel Puller for wheel hub 20 6 20 0 21 6 21 0 SAF Part No 1 012 0024 00 3 349 1001 00 3 434 1040 01 3 434 1043 00 4 434 3822 00 22 6 22 0 SV11484GB Edition 01 2006 Last updated 2006 01 13 Amendments and errors reserved SAF Axle types Z8 3718 S9 3718 SL9 3718 Z9 3720 ZL9 3720 S11 3720 SL11 3720 211 3720 ZL11 3720 Wheel bearing play wheel bearing grease Adjustment of wheel bearing play not necessary Note during brake repairs Lubricate the camshafts rotating the camshaft through 360 several times Grease specifications For camshaft SAF Part No 5 387 0011 05
28. re in the slack adjuster 8 1 is aligned with the bore in the yoke end 9 see figure Adjustment of HALDEX automatic slack adjusters L Grease cotter pin 8 and secure Hook in return spring 10 Turn the control arm in the direction of the arrow working direction of the slack adjuster into its end position without using force In this end position of control arm 2 tighten mounting bolts 4 With the fixed mounting point 11 ensure that the 2 U profiles engage correctly in one another NOTE FOR SELF STEERING AXLES Weld on mounting point strap 3 in this position Fix the slack adjuster on the camshaft Axial clearance Adjust the nominal value of 0 5 2 mm using shims Adjust the clearance of the brake lining by turning adjusting screw 1 in clock wise direction until the brake lining is in contact with the brake drum Then back off adjusting screw 1 by 3 4 turn Do not use an impact wrench FUNCTION CHECK If the adjustment coupling is functioning correctly a torque of at least 18 Nm must be felt when backing off adjusting screw 1 a ratchet noise should also be clearly audible Actuate the service brake several times check the free running of the brake drum check the clearance If necessary repeat the adjustment of the slack adjuster Adjustment of S ABA automatic slack adjusters e Cams and brake shoes are in the zero position Observe the correct piston rod length L as g
29. 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 SV11484GB Edition 01 2006 Last updated 2006 01 13 Amendments and errors reserved SAF SV11484GB Edition 01 2006 Last updated 2006 01 13 Amendments and errors reserved SAF e Cams and brake shoes are in the zero position Observe the correct piston rod length L as given in the SAF specifications e Brake chambers Before installation ensure that the brake chamber is in its starting position e Spring brake chambers on the other hand must be under full working pressure min 6 bar IMPORTANT If this is not observed the basic set ting will be wrong e Grease the camshaft e Install mounting point strap 3 be sure to use two mounting bolts 4 e Install the slack adjuster on the camshaft e The arrow mark 7 points in the braking direction e Turn adjusting screw 1 until the bo
30. xle types SK RS RZ 9042 11242 Wheel bearing play wheel bearing grease Adjustment of wheel bearing play not necessary Change the wheel bearing grease after 500 000 km or 50 months Inspect taper roller bearing for serviceability at grease changes Replace the O ring and fit the wheel cap 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 Remove old grease from the stub axle and regrease Replace the brake shoe return springs at every brake pad change Tighten axle nuts On left hand side in direction of travel Left hand thread On right hand side in direction of travel Right hand thread the bolts Marking of the nuts with left hand thread Milled groove on outside of hexagon Max permissible axial backlash of hub unit 0 0 20 mm BRAKE SNK 420 Max admissible brake drum machining diameter Max admissible brake drum wear diameter 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 size SAF Part No Brake drum brake lining Brake lining Repair stages in mm Tightening torque 900 Nm Each hub unit must be rotated smo
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