Operating manual
Air suspension systems and axles with drum brake
Valid for axle types S / Z
XL-AT11484OM-en-DE
Translation of the original operating
manual
1.1 Dear customer,
This operating manual helps you to familiarise yourself with the products
from SAF-HOLLAND with instructions for their proper use.
The operating manual contains important instructions on how to operate
the product safely, properly and economically. Adherence to it helps
prevent hazards, faults and reduce down-time and increase the reliability
and service life of the product. Read the operating manual through
carefully and follow the instructions accurately.
It must be ensured that all personnel with responsibility for performing
tasks on the vehicle are able to consult the operating manual at all times.
The operating manual must be kept in the glove compartment in the
driver's cabin of the towing vehicle at all times.
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1.1 Copyright
This operating manual is classified as in accordance with the law on unfair
competition.
All rights reserved by
SAF-HOLLAND GmbH Hauptstrasse 26, 63856 Bessenbach, Germany
This operating manual contains 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 damages.
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Content
Content
1 Axle identification........................................................................ 4
1.1 Identifying the axle ................................................................... 4
1.2 Position of the type plate .......................................................... 4
1.3 Identification in case of missing type plate ................................ 5
2 Ordering spare parts..................................................................... 5
3 General information..................................................................... 6
3.1 Liability ..................................................................................... 6
3.2 Warranty and general terms and conditions of business ............ 6
3.3 Environmental protection .......................................................... 6
4 Safety............................................................................................. 7
4.1 Target group ............................................................................. 7
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4.2 Proper use ................................................................................ 7
4.3 Safety instructions and symbols used in the operating manual .. 7
4.4 Marking used for sections of text .............................................. 8
4.5 General safety instructions ........................................................ 8
5 Maintenance Procedures.............................................................. 9
5.1 General maintenance instructions ............................................. 9
5.2 Before each journey .................................................................. 10
5.3 Service schedule ........................................................................ 11
5.4 Wear check on the thickness of the brake lining ....................... 13
5.5 Inspection torque ...................................................................... 15
5.6 Lubricate ................................................................................... 17
6 Jacking point................................................................................. 18
7 Inclination of the semi-trailer...................................................... 19
XL-AT11484OM-en-DE · Edition 03.2011 · Errors and changes excluded · © SAF–HOLLAND 3
1 Axle identification
1 Axle identification
1.1 Identifying the axle
Please have the exact type designation of
the product ready when ordering spare
parts.
The 11-digit number (serial No.) can be
found on the type plate.
AS-0028
Fig. 1 · · Type plate
1.2 Position of the type plate
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AS-0016
Fig. 2 · Position of the type plate, air suspension system type INTRA
AS-0017
Fig. 3 · Position of the type plate, air suspension system type MODUL and floating axles
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2 Ordering spare parts
1.3 Identification in case of missing type plate
The axle's serial No. is embossed on the
axle journal, on the right-hand side,
viewed in the direction of travel (fig. 4,
item 1).
AS-0004
Fig. 4 · Right-hand axle stub end:
Serial No.
The data for ordering spare parts from SAF-HOLLAND can be entered in
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the following field.
Ident No. Serial No.
1. axle
2. axle
3. axle
4. axle
5. axle
2 Ordering spare parts
When ordering original spare parts from SAF-HOLLAND make sure that
you pay attention to the assembly groups of the respective product.
Reproduction parts have a negative effect on the function of the product,
have a shorter lifetime and cause risks and hazards, which SAF-HOLLAND
cannot evaluate. They also increase the maintenance requirement.
For technical consultancy for SAF-HOLLAND products and the provision of
parts, a tight service network of SAF-HOLLAND partner companies are on
hand to help you (see the back page or visit us online at
www.safholland.com).
For further instructions on identifying spare parts refer to our homepage
www.safholland.com in the "After-market" section.
XL-AT11484OM-en-DE · Edition 03.2011 · Errors and changes excluded · © SAF–HOLLAND 5
3 General information
Updates are published on the internet at www.safholland.com as
necessary.
3 General information
3.1 Liability
SAF-HOLLAND's "General Terms and Conditions" apply SAF-HOLLAND.
SAF-HOLLAND does not recognise any liability claims for personal injury or
material damage which are caused by one or more of the following
causes:
• Improper use of the product ⇒Page 7,
• Failure to adhere to the operating manual and the safety instructions
contained in it.
• Arbitrary constructional changes to the product.
• Insufficient maintenance of parts which are subject to wear
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⇒Page 9,
• Improper maintenance work and maintenance work that is not
performed in good time ⇒Page 9,
• the use of any spare parts other than original parts from
SAF-HOLLANDErsatzteilbestellung.ditamap,
• the use of damaged parts,
• disasters due to external influences or acts of God.
3.2 Warranty and general terms and conditions of
business
For information on our current warranties and general terms and
conditions, refer to the "Sales" section of our homepage at
www.safholland.com .
3.3 Environmental protection
All components and consumables used for maintenance and care must be
disposed of in an environmentally friendly manner.
Recyclable components must be cleaned of oil and lubricants and recycled.
When doing so, you must adhere to the disposal instructions for the
respective consumables and the valid national and regional regulations.
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4 Safety
4 Safety
4.1 Target group
The operating manual for the product is restricted exclusively to use of the
product by the user and personnel authorised and instructed by the user.
The user must ensure that the personnel authorised by him receive regular
instruction on the content of the operating manual and in particular the
safety instructions it contains.
4.2 Proper use
The product has been constructed using state-of-the-art technology and in
accordance with the recognised rules of technical safety. However, its use
may result in hazards for the operator or third parts or damage to the
device or other objects of material value. The product must only be used a
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steering axle or fixed axle.
Proper use also includes:
• Adherence to the operating manual and implementation of the
working steps stipulated in the operating manual.
• Adherence to the performance limits ⇒Fig. 1 of the product.
• Adherence to all maintenance and care instructions and additional
inspections.
• The use of the listed consumables ⇒Page 9 and their disposal in an
environmentally friendly manner ⇒Page 6.
Operationally safe function can only be guaranteed if all the instructions,
adjustments and performance limits for the product are adhered to.
4.3 Safety instructions and symbols used in the
operating manual
The following symbols are used to denote particularly important
information and sections of the text. Make 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 injuries.
XL-AT11484OM-en-DE · Edition 03.2011 · Errors and changes excluded · © SAF–HOLLAND 7
4 Safety
Careful!
This safety instruction with the signal word warns of a
possible damage to the product.
Note:
Marking for special user tips and other particularly useful and
important information for efficient work and economical use.
4.4 Marking used for sections of text
• Marking for instructions for actions and information in safety
instructions
1., 2., 3., ... Marking used for working steps
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4.5 General safety instructions
It is imperative to adhere to the following safety instructions for
your SAF-HOLLAND axles and suspensions in order to comply with
operational safety and traffic safety:
Danger!
Risk of serious traffic accidents which may lead to
serious or fatal injuries.
Operation
• You must make sure that the brakes do not overheat, e.g.
due to continuous use. Overheating on drum brakes can
lead to a dangerous reduction of the braking power. On
disc brakes overheating can cause damage to the
surrounding components - in particular the wheel bearing.
This can be seriously detrimental to safety, e.g. can cause
the wheel bearings to fail.
• In case of overheating the parking brake must not be
applied until the brake has cooled down. The brake discs
and brake drums may otherwise become damaged as a
result of different levels of tension arising during the
cooling process.
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5 Maintenance Procedures
Danger!
• When loading and unloading the provided support devices
must be used in order to prevent damage to the axle.
• Adhere to the trailer manufacturer's recommendations for
OFF ROAD use of the installed axles and suspensions. The
SAF-HOLLAND definition OFF ROAD refers to driving on
nontarmacked/concreted stretches, e.g. gravel roads,
countryside and forest roads, on construction sites and in
gravel pits.
The operation of SAF-HOLLAND axles and suspensions in
OFF ROAD use which are not conceived for this purpose
can cause damage and thus compromise traffic safety.
Care
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• 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.
General safety instructions
• You must only use the wheel rims and tyre sizes specified
by the trailer manufacturer. The tyres must always have
the stipulated air pressure.
5 Maintenance Procedures
5.1 General maintenance instructions
Danger!
Risk of serious traffic accidents which may lead to
serious or fatal injuries.
• Maintenance tasks must only be carried out by authorised
specialist workshops and by staff with the appropriate
training.
XL-AT11484OM-en-DE · Edition 03.2011 · Errors and changes excluded · © SAF–HOLLAND 9
5 Maintenance Procedures
Danger!
• The wheel nuts have to be re-tightened with the stipulated
tightening torque values, initially after 50 km and then
after 150 km.
• At the latest 5,000 km after commissioning the semi-
trailer/trailer, the brake systems on the tractor and the
semi-trailer/trailer must be adjusted to each other by way
of a tractor/trailer brake synchronisation in order to ensure
that the brakes perform evenly and the brake pads wear
evenly. Tractor/trailer brake synchronisations should be
performed by specialist brake workshops. On vehicles with
EBS a balancing inspection has to be carried out.
• All components which are not in a serviceable condition
must be replaced.
• The general safety inspection must be performed as per
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legal regulations.
• Daily inspection of the vehicle for traffic safety before
starting the journey is part of the duty of the driver.
SAF-HOLLAND axles and suspensions require continuous
care, inspections and maintenance so that natural wear
and faults can be detected in good time, and in order to
maintain operational and traffic safety.
SAF-HOLLAND recommends that you carry out the
inspections and maintenance tasks described in the
chapter "Maintenance". In case of repairs you must always
follow the SAF-HOLLAND repair instructions and
directions.
5.2 Before each journey
Danger!
Risk of serious traffic accidents which may lead to
serious or fatal injuries.
• The maximum permitted axle load must not be exceeded
and the loaded goods must be positioned with an even
distribution.
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5 Maintenance Procedures
Danger!
• For vehicles with an air suspension system, you must
ensure that the airbags are fully inflated with air. An
incomplete supply of air can cause damage to the axles,
chassis, frame and attachment and compromise traffic
safety.
1. Carry out general visual inspections on the tyres and all parts of the
chassis to make sure they are firmly fastened and check for wear, leaks,
corrosion and damage.
2. Carry out general visual checks on the brakes to make sure they are
firmly fastened and to check for wear, leaks, corrosion and damage.
3. Remove any coarse soiling before starting the journey in order to
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prevent damage to the following traffic.
5.3 Service schedule
Danger!
Risk of serious traffic accidents which may lead to
serious or fatal injuries.
• Maintenance tasks must only be carried out by authorised
specialist workshops and by staff with the appropriate
training.
• In the case of vehicles with extreme operating conditions,
e.g. OFF ROAD or multiple-shift operation, the
maintenance intervals have to be shortened from
12 months/150,000 km to 6 months/75,000 km.
XL-AT11484OM-en-DE · Edition 03.2011 · Errors and changes excluded · © SAF–HOLLAND 11
5 Maintenance Procedures
Maintenance work on the axle
According to the vehicle manufacturer's information
Initially after 1 month or 5,000 km
Every 12 months or 150,000 km
Every 3 months or 30,000 km
Every 6 months or 75,000 km
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Check the wheel bearing unit for leaking
X
grease
Check and, if necessary, adjust ⇒Page 19. X
On aluminium and stainless steel hanger
brackets check the screw connections, pivot
bolts and shock absorbers with the stipulated X
inspection torque ⇒Page 15.
Initially after 500 km.
On MODUL suspensions the U-bolts must be
tested with the respective test torque values X
⇒Page 15.
Test the screw connection for the air bags
with the stipulated inspection torque X
⇒Page 15.
For steering axles lubricate the bearing points
X X
of the king pin bolts ⇒Page 17.
Lubricating the camshaft ⇒Page 17. X
Check the slack adjuster X
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5 Maintenance Procedures
According to the vehicle manufacturer's information
Initially after 1 month or 5,000 km
Every 12 months or 150,000 km
Every 3 months or 30,000 km
Every 6 months or 75,000 km
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Check the wear limits on the brake lining
X X
and drum ⇒Page 13.
General safety inspection as per legal regulations.
5.4 Wear check on the thickness of the brake lining
Danger!
Risk of accidents due to the vehicle rolling away.
• Park the vehicle on firm, level ground.
• Lock the vehicle so that it cannot roll away.
• The test must be performed with the service brake and
parking brake released.
On the slack adjuster the camshaft has a cut-in nut and an attached
indicator for visual inspection of the state of wear on the brake pads.
XL-AT11484OM-en-DE · Edition 03.2011 · Errors and changes excluded · © SAF–HOLLAND 13
5 Maintenance Procedures
AS-0018
Fig. 5 · Installation position of the wear indicator
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Danger!
Risk of serious traffic accidents due to the loss of traffic
safety and operational safety which may lead to serious
or fatal injuries.
• You must ensure that the brakes are fully functional.
• The wear inspection must be performed for each wheel
and on each axle.
• Once the wear limits have been reached, the brake lining
must be replaced immediately by an authorised specialist
workshop and by personnel with the appropriate training.
New
Wear indicator for brake lining thickness
in new condition.
AS-0019
Fig. 6 · Wear indicator, new
condition
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5 Maintenance Procedures
Worn
Wear indicator for brake pad thickness in
worn condition.
If the wear indicator has reached a
horizontal position, an inspection of the
thickness of the brake lining has to be
performed by a specialist workshop.
AS-0020
Fig. 7 · Wear indicator, worn
condition
5.5 Inspection torque
Danger!
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Risk of accidents due to loose screw connections.
• Threads must not be oiled or greased.
• Do not loosen screws.
• Check the inspection torque with a pre-set torque wrench.
If the stipulated inspection torque is not achieved, an
authorised specialist workshop with appropriately qualified
staff must be visited.
SAF INTRA
1 4
2
3 AS-0021
Fig. 8 · SAF INTRA inspection torque
XL-AT11484OM-en-DE · Edition 03.2011 · Errors and changes excluded · © SAF–HOLLAND 15
5 Maintenance Procedures
Inspection torque Width across flats
Item Screw connection
(Nm) (WAF)
–1– M20x1.5 400 30
–2– M30 1200 46
–3– M16 80 24
–4– M12 40 19
SAF MODUL
1
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3
2 4
7
AS-0022
Fig. 9 · SAF MODUL inspection torque values
Inspection torque Width across flats
Item Screw connection
(Nm) (WAF)
–1– M24x2 400 36
–2– M22x1.5 580 32
–3– M30 1200 46
–4– M20 180 30
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5 Maintenance Procedures
Inspection torque Width across flats
Item Screw connection
(Nm) (WAF)
–5– M12 40 19
–6–1) M12 80 19
–7–2) K100x40 20 10
5.6 Lubricate
Careful!
Risk of damage to the camshaft, slack adjuster and king
pin bolt!
• Only use the specified lubricant.
• Lubricate the axle only when unloaded.
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• Only lubricate the specified lubricating points.
Use special lithium complex soap
lubricating grease (SAF-HOLLAND part
number 5 387 0011 04).
• Lubricate the camshaft, slack adjuster
and king pin bolt thoroughly on all
lubricating nipples.
AS-0023
Fig. 10 · Rear lubrication point on
Note: brake spider
The bearings have long-term
lubrication and are
permanently protected from
the penetration of dirt and
spray water by O-ring seals
and rubber sleeves.
AS-0024
Fig. 11 · Front lubrication point on
camshaft bearing
1) For steel airbag pistons
2) For plastic airbag pistons
XL-AT11484OM-en-DE · Edition 03.2011 · Errors and changes excluded · © SAF–HOLLAND 17
6 Jacking point
AS-0025
Fig. 12 · Lubrication point on the
slack adjuster
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AS-0026
Fig. 13 · Lubrication points on the
king pin bolt
6 Jacking point
Raise the vehicle with the jack ⇒Fig. 14 as
shown.
Careful!
Risk of damage to the
AS-0013
axle!
Fig. 14 · Jacking point
The jack must only be
positioned as shown in
⇒Fig. 14 .
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7 Inclination of the semi-trailer
7 Inclination of the semi-trailer
On single axles a minimum suspension travel of 60 mm must be
observed.
On multiple axle trailers a minimum suspension travel of 70 mm must
be observed.
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AS-0014
Fig. 15 · Inclination of the semi-trailer
Careful!
Risk of damage to the vehicle!
The maximum inclination of the semi-trailer must not exceed
1 degree or 20 mm per metre.
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XL-AT11484OM-en-DE · Edition 03.2011 · Errors and changes excluded · © SAF–HOLLAND
Emergency hotline +49 6095 301-247
Customer Service +49 6095 301-602
Fax +49 6095 301-259
Spare Parts +49 6095 301-301
[email protected]
www.safholland.com
SAF-HOLLAND GmbH
Hauptstrasse 26
D-63586 Bessenbach
