Workshop pocket manual

SAF-axles with air suspension system

 Copyright

In accordance with the law on unfair competition, this workshop pocket manual is classified as an
official document.

All rights reserved by

SAF-HOLLAND GmbH
Hauptstrasse 26
63856 Bessenbach
Germany

This workshop pocket manual contains texts and drawings which, without the express permission
of the manufacturer, may not be

• duplicated,
• distributed or
• disclosed in any other manner, either fully or in part.

Any breach or infringement will result in liability for damages.

XL-AA40000MM-en-DE Rev C • 07/2016 • Errors and changes excluded • © SAF-HOLLAND

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 Table of Contents

Page

Overview of axle types ..................................................................................................................... 4

Type plate ......................................................................................................................................... 5
INTRA torque..................................................................................................................................... 6
Shock absorber installation position ................................................................................................. 7
MODUL torque .................................................................................................................................8
Brake disc wear ................................................................................................................................ 9
3D bushing elasticity ...................................................................................................................... 10
Lifting the vehicle . ...........................................................................................................................11
Inclination of the semi-trailer .......................................................................................................... 12
Wheel interface .............................................................................................................................. 13
Hub unit connectors ....................................................................................................................... 15
Axle nuts . ....................................................................................................................................... 16
Brake calliper connectors ............................................................................................................... 18
Brake chamber connectors ............................................................................................................ 19
No impact wrench . ......................................................................................................................... 20
Greasing the axle stub end ............................................................................................................ 21
Greasing the drum brake . .............................................................................................................. 22

XL-AA40000MM-en-DE Rev C • 07/2016 • Errors and changes excluded • © SAF-HOLLAND

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 Overview of axle types with air suspension system
MODUL with disc brake
INTRADISC

INTRADRUM
MODUL with drum brake
XL-AA40000MM-en-DE Rev C • 07/2016 • Errors and changes excluded • © SAF-HOLLAND
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 Type plate – identifying the axle
The type plate INTRA

Since end of 2012

Identification in case of a missing

type plate
The axle serial number is
embossed on the right of the
axle stub end, as viewed in the MODUL
direction of travel.

XL-AA40000MM-en-DE Rev C • 07/2016 • Errors and changes excluded • © SAF-HOLLAND

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 INTRA torque tensioning instructions

INTRADISC / INTRADRUM servicing the air suspension systems Torque settings

Torque settings Pivot bolt torque Stainless steel / aluminium
Steel hanger bracket specification 1 through 4 hanger bracket
M20x1.5 (AF30) M12 (AF19) 1. Pretightening M20x1.5 (AF30) M12 (AF19)
Nut contact surface, 40 Nm 400 Nm Nut contact surface, 40 Nm
dry: 600 Nm dry: 400 Nm

2. Labelling
for angle
tightening
to 120° (two
edges)

3. Angle
Requires maintenance
tightening
M30 (AF46) M16 (AF24) M30 (AF46) M16 (AF24)
to 120° (two
400 Nm + 120° • 180 Nm with steel 400 Nm + 120° • 180 Nm with steel
edges)
See tensioning plunger piston See tensioning plunger piston
instructions 1 • 80 Nm with plastic instructions 1 • 80 Nm with plastic
through 4 plunger piston through 4 plunger piston

4. Labelling for Caution:

subsequent Maintenance intervals for stainless steel/
Caution:
visual aluminium hanger brackets:
Every time the pivot bolt mounting is tightened
inspection • Initial inspection after 10,000 km or 5 weeks.
to the reference torque, the corresponding
• Additional inspections every 100,000 km or
setting must be labelled.
12 months.
• Control torque: 1200 Nm

Note: Any warranty claim for the INTRADISC / INTRADRUM air suspension system is voided if the mandatory instructions detailed in the
“Maintenance and Repair Manual” are not applied. See www.safholland.com

XL-AA40000MM-en-DE Rev C • 07/2016 • Errors and changes excluded • © SAF-HOLLAND

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 Shock absorbers

Shock absorber installation position

“TOP”
The “TOP” label of the
shock absorber must point
upwards.

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 MODUL torque tensioning instructions
M24 x 2 (AF36) M12 (AF19)
400 Nm 40 Nm

M12 (AF19) 80 Nm
for steel plunger
pistons

Self-tapping
screw
M30 (AF46) K100 x 40 (AF10)
Label the positions of 400 Nm + 120° 20 Nm for plastic
M22 x 1.5 (AF32)
washer, nut, screw. 580 Nm M20 (AF30) plunger pistons
180 Nm

Tensioning instructions: Caution!

1. The bearings of the trailing arm are to be fitted in • Do not apply oil or grease to the thread.
accordance with the maintenance and repair manual. • The screw connections of the steel
2. Position the eccentric washer below the screw head. hanger bracket do not require
3. Raise the vehicle to the correct ride height. maintenance.
4. Pretighten the M30/SW46 nuts to 400 Nm. Label the • The thickness of the coating applied
positions of the washer, nut and screw on the hanger to the screw contact surface between
bracket. shock absorber and hanger bracket
5. Tighten the nut by another 120º (two edges) while and between trailing arm and hanger
holding the screw head firmly against it. bracket must not exceed 45 µm.
6. Perform a visual inspection. Correct the tightening • For galvanised hanger bracket,
angle if necessary. thickness must not exceed 120 µm;
7. When tightening is complete, label the positions of otherwise the no-maintenance feature
the washer, nut and screw on the hanger bracket. ceases.
XL-AA40000MM-en-DE Rev C • 07/2016 • Errors and changes excluded • © SAF-HOLLAND
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 Brake disc wear
Wear on the brake disc and brake pads Typical signs of wear on the brake discs

To assess the friction surface on

Permitted: Cracks Permitted:
the brake pads, the pad retainer
of up to 1.5 mm Uneven disc
must be removed and the brake
maximum (width surface
calliper adjustment must be de-
and depth), which
adjusted.
run to the centre
of the hub

Permitted:
Network-type Not permitted:
cracking Full-length
cracking

Wear limits:
Brake disc: Minimum 37 mm
Brake pad: Minimum 2 mm

XL-AA40000MM-en-DE Rev C • 07/2016 • Errors and changes excluded • © SAF-HOLLAND

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 3D bushing joint elasticity
SAF INTRADISC plus: Permitted joint elasticity of the 3D bushing
When tested with a longitudinal force of 30 kN (approx. 3 t), the 3D bushing of the INTRADISC
plus system can carry out elastic movement in a horizontal direction of ±14 mm maximum, i.e. a
total of 28 mm (image 1).
This elasticity does not indicate that the bushing is damaged; rather, it is required for proper
functioning of the chassis system. However, such values of ±14 mm are reached only during static
inspection and do not occur while driving.
Due to the shape of the 3D bushings, rigidity in a horizontal direction is much higher than in
vertical direction. It is therefore important to ensure proper installation position (image 2).
This high rigidity in a horizontal direction allows for the system’s intentional auto steering
behaviour, whereby tyre wear and the strain on the roads are reduced.

Image 1: Image 2:
Joint elasticity: x = ±14 mm, Follow the “TOP” label for
28 mm total installation position
XL-AA40000MM-en-DE Rev C • 07/2016 • Errors and changes excluded • © SAF-HOLLAND
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 Lifting the fully loaded vehicle
Changing tyres of a fully loaded trailer with INTRA axle.
Lifting points.

P
XL-AA40000MM-en-DE Rev C • 07/2016 • Errors and changes excluded • © SAF-HOLLAND
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 Inclination of the semi-trailer

Ride heights

The ride height of the air suspension axles is to be set to the permitted values as indicated in the
appropriate documentation provided by SAF.

For single axles, a minimum suspension travel of 60 mm must be observed.

For multiple-axle trailers, a minimum suspension travel of 70 mm must be observed.

Exceptions

On multiple-axle trailers with lift

axles, minimum suspension travel
should not drop below 100 mm
on the lift axle in order to maintain
ground clearance.

Maximum inclination of the semi-trailer must

not exceed ±1°.
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 Wheel interface – part 1

Drum brake Disc brake Drum brake

Single tyres Twin tyres

L2min. = 60 mm
For hub centering / mixed centering

For hub centering / mixed centering

L2min. = 46 mm L2min. = 56 mm

Steel wheels
Steel wheels

Centering bushing Centering bushing Spherical centering ring

01095104001 01095103501 Sperical wheel cone

Wheel nut with Wheel nut

Wheel nut with pressure plate M22x1.5/AF32
pressure plate M22x1.5/AF32
M22x1.5/AF32
430 Nm
600 Nm 600 Nm

For wheels with mixed centering / spherical countersink, 2 distance / centering bushings
(installed opposite each other) are needed per wheel hub.

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 Wheel interface – part 2
Single tyres Twin tyres
Aluminium wheels

L2min. = 80 mm
L2min. = 56 mm
For hub centering
Stud hole 26 mm

Wheel nut with

Wheel nut with
pressure plate
pressure plate
M22x1.5/AF32
M22x1.5/AF32
600 Nm
600 Nm
Aluminium wheels

L2min. = 56 mm
L2min. = 56 mm
For hub centering
Stud hole 32 mm

Wheel nut / sleeve

Wheel nut /
nut with
sleeve nut with
pressure plate
pressure plate
M22x1.5/AF32
M22x1.5/AF32
600 Nm
600 Nm

XL-AA40000MM-en-DE Rev C • 07/2016 • Errors and changes excluded • © SAF-HOLLAND

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 Hub unit connectors

Axle type SK RB RB-Integral / BI B9 SI / ZI - 22K11 SI / ZI - 22K01

Tensioning Torque / Torque / Torque / Torque / Torque /
method rotation angle rotation angle rotation angle rotation angle rotation angle
Type of thread M18x1.5 M12x1.5 M14x1.5 M14x1.5 M14x1.5
Type of screw TORX DHS DHS DHS DHS
Size of head E24 AF13 AF15 AF15 AF15
Torque / 50 Nm + 90° 40 Nm + 90° 50 Nm + 120° 50 Nm + 120° 50 Nm + 120°
angle
Reference 450 Nm 130 Nm 180 Nm 180 Nm 180 Nm
torque
Figure

Procedure • Pretightening • Pretightening • Pretightening 50 Nm

50 Nm 40 Nm • Final tightening: 120° in diagonally opposite sequence
• Final tightening: • Final tightening:
90° in diagonally 90° in diagonally
opposite opposite
sequence sequence
Caution • Use screws only once!
• No oil, grease, dirt or other residue in the threaded section!

XL-AA40000MM-en-DE Rev C • 07/2016 • Errors and changes excluded • © SAF-HOLLAND

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 Axle nuts – part 1

Axle type SK RB S/Z/B series

Tensioning Torque / Torque /

method rotation angle rotation angle

Type of thread M72x1.5 M75x1.5

Type of screw Hexagon nut Hexagon nut

Size of head AF85 AF85

Torque / angle 150 Nm + 30° 150 Nm + 30°

Reference torque 900 Nm 900 Nm

Figure

Procedure Tightening the axle nut:

• Left in direction of travel: left-hand thread; right in direction of travel: right-hand thread.
• Pretightening 150 Nm, evenly turn hub unit by 5 turns.
• Final tightening: re-tighten by 1 graduation mark (30°).
• Axle nuts with left-hand thread: outside on collar with milled groove.

Caution • No oil, grease, dirt or other residue in the threaded section!

• Do not use an impact wrench!

XL-AA40000MM-en-DE Rev C • 07/2016 • Errors and changes excluded • © SAF-HOLLAND

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 Axle nuts – part 2
Axle type SK SK

Tensioning Torque / Torque

method rotation angle

Type of thread M120x2 M56x2

Type of screw Hexagon nut Hexagon nut

Size of head AF140 AF85

Torque / angle 150 Nm + 10° -

Reference torque 900 Nm Inside nut: 150 Nm

Outside nut: 400 Nm

Figure

Procedure Tightening the axle nut: Adjusting wheel bearing play:

• Left in direction of travel: left-hand thread; right in • Tighten axle nut AF 85 to 150 Nm while turning wheel
direction of travel: right-hand thread. hub.
• Pretightening 150 Nm, evenly turn hub unit by 5 turns. • Turn back axle nut by 2 ½ holes in the lock disc.
• Final tightening: re-tighten by 1 graduation mark (10°). • Slip on lock disc and lock axle nut using locking pin.
• Labelling axle nuts with left-hand thread: outside on • Tighten lock nut to 400 Nm.
hexagon with milled groove. • Check that wheel bearing and wheel rock run properly.

Caution No oil, grease, dirt or other residue in the threaded section!

XL-AA40000MM-en-DE Rev C • 07/2016 • Errors and changes excluded • © SAF-HOLLAND

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 Brake calliper connectors

Axle type SK RB S/Z/B series

6-hole connection 4-hole connection

Tensioning Torque / Torque /

method rotation angle rotation angle

Type of thread M16x1.5 M18x1.5

Type of screw Hexagon screw DHS

Size of head AF24 AF24

Torque / angle - 120 Nm + 60°

Reference 290 Nm 450 Nm

torque

Figure

Procedure Tighten screws, working from inside to outside. • Pretightening 120 Nm

• Final tightening: 60°, working from inside to
outside

Caution • Ensure correct position of the close tolerance bolt!

• Use screws only once!
• No oil, grease, dirt or other residue in the threaded section!

XL-AA40000MM-en-DE Rev C • 07/2016 • Errors and changes excluded • © SAF-HOLLAND

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 Brake chamber connectors

Axle type Disc brake Drum brake

Tensioning Torque Torque

method

Type of thread M16x1.5 M16x1.5

Type of screw Hexagon nut Hexagon nut

Size of head AF24 AF24

Torque / - -
angle

Reference 210 Nm 210 Nm

torque

Figure

Caution • Tighten screws alternately and uniformly in 2 stages!

• Use nuts only once!
• No oil, grease, dirt or other residue in the threaded section!

XL-AA40000MM-en-DE Rev C • 07/2016 • Errors and changes excluded • © SAF-HOLLAND

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 No impact wrench

Caution:

Do not use an impact wrench. Not for loosening, not for tightening.

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 
XL-AA40000MM-en-DE Rev C • 07/2016 • Errors and changes excluded • © SAF-HOLLAND
 Greasing the axle stub end

Greasing the axle stub end

Note:
2/3
Grease the axle stub end to prevent tribocorrosion.
Apply 1 g of grease.

Note:

• Do not apply oil or grease to the thread.

• No oil, grease, dirt or other residue in the
Only included in the repair kit
threaded section.
Material no. 05 387 0042 01 (1 kg)

XL-AA40000MM-en-DE Rev C • 07/2016 • Errors and changes excluded • © SAF-HOLLAND

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 Drum brake

Brake shoes – greasing ball, camshaft

Note:
Apply copper paste to the bearings
of the cam roller and the anchor
ball.

Material no. 05 387 0014 01 (1 kg)

Wear limits

Brake size Standard limit Wear limit “dmax”

“d”

420 420 425

367 367 372

300 300 304

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XL-AA40000MM-en-DE Rev C • 07/2016 • Errors and changes excluded • © SAF-HOLLAND
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 Contact information

Emergency hotline +49 6095 301-247

Customer service / maintenance

Telephone +49 6095 301-602
Fax +49 6095 301-259
Email service@safholland.de

After market / spare parts

Telephone +49 6095 301-301
Fax +49 6095 301-494
Email originalparts@safholland.de

Web www.safholland.com

SAF-HOLLAND GmbH
Hauptstrasse 26
63856 Bessenbach