SAF EM640023-SPL Installation Manual
Installation Manual
SAF TRAKr
with E-Maschine EM640023-SPL
Pilot series
XL-PS40050BM-en-DE Rev C
Original Installation Manual
Installation Manual
Please note
This installation manual is intended for the exclusive use by trained persons within the commercial vehicle
industry and related workshops.
The content of this manual is not all-inclusive and not legally binding. SAF-HOLLAND GmbH assumes
no liability as a result of its use. All information contained in the manual does neither represent ensured
characteristics of the product nor represent a guarantee. SAF-HOLLAND GmbH reserves the right to make
changes in the interest of technical progress without prior notice.
No liability is assumed as a result of incorrect or inappropriate parts being tted to the product or
the omittance of appropriate tests after the servicing of the product. Use appropriate spare parts’
documentation when obtaining spare parts. Use only genuine SAF-HOLLAND GmbH spare parts in repairs.
This manual is subject to a copyright of SAF-HOLLAND GmbH. All rights reserved. No part of this manual
may be reproduced, copied or translated in any form or by any means without the prior written permission
of SAF-HOLLAND GmbH. Brand names mentioned in this manual are not identied as such in all cases,
but they are nevertheless subject to the provisions of trademark legislation.
The failure of any individual provision of this disclaimer to comply with current legal provisions does not
aect the validity of the remaining provisions.
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Copyright
This installation manual is classied as in accordance with the law on unfair competition.
All rights reserved by
SAF-HOLLAND GmbH
Hauptstrasse 26
63856 Bessenbach, Germany.
This installation manual contains texts and drawings which, without the express permission of the
manufacturer, must not be
• reproduced,
• distributed or
• disclosed in any other manner, either in full or in part.
Any breach or infringement will result in liability for damages.
XL-PS40050BM-en-DE Rev C · Edition 02/2023 · Errors and changes excluded © SAF-HOLLAND GmbH
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Installation Manual
Content
1. General information 4
1.1 Ordering spare parts 4
1.2 Liability 4
1.3 Warranty and general terms and conditions of business 4
1.4 Environmental protection 4
1.5 Target group 4
1.6 Proper use 4
1.7 Rescue data sheet 4
1.8 Safety instructions and symbols used 4
1.9 Marking used for sections of text 5
2. Safety instructions 5
3. General instructions 5
4. Function diagram 7
5. Suspension system 8
5.1 Driving height plate 8
5.2 Lifting thread 8
5.3 Ground strap 9
5.4 Ground concept - equipotential bonding 9
6. Initial gearbox oil lling 9
6.1 Pressure compensation element 9
7. Liquid cooling system for E-Machine 10
7.1 E-Machine cooling connection 11
7.2 Cooling system installation 11
8. Mounting Procedure LVDC Cooling Connector Set 12
8.1 Harting connector side 12
8.2 Super-seal connector side 13
9. E-Machine routing 14
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Installation Manual
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1. General information
1.1 Ordering spare parts
When ordering original spare parts from
SAF-HOLLAND, make sure you accurately identify
the respective product.
Non-genuine parts have a negative eect on the
function of the product, have a shorter lifetime
and cause risks and hazards that SAF-HOLLAND
cannot estimate. It also increases the maintenance
requirement.
SAF-HOLLAND operates a tight service network
of partner companies for technical support of
SAF-HOLLAND products and supply of parts (see
www.safholland.com).
For further instructions on identifying spare parts,
refer to the Aftermarket section of our home page
www.safholland.com.
Updates are published as necessary on the Internet
at www.safholland.com.
1.2 Liability
SAF-HOLLAND‘s „General Terms and Conditions”
apply. SAF-HOLLAND accepts no liability claims
for personal injury or material damage with one or
more of the following causes:
• Failure to observe the proper use.
• Failure to observe the installation manual and
the safety instructions contained in it.
• Arbitrary changes or modications to the product.
• Insucient maintenance of parts that are subject
to wear.
• The use of any spare parts other than original
SAF-HOLLAND parts.
• Use of damaged parts.
• Disasters due to external inuences or force
majeure.
1.3 Warranty and general terms and
conditions of business
valid national and regional regulations.
1.5 Target group
The installation manual of the product is restricted
exclusively to be used by trained personnel from
authorised specialist workshops.
1.6 Proper use
The product has been constructed using stateof-the art technology and in accordance with
recognized rules of technical safety.
However, its use may result in hazards for the
operator or third parties or damage to the device or
other objects of material value.
Proper use also includes:
• Observance of the operating manual and the
installation manual, as well as implementation
of the working steps stipulated in the installation
manual.
• Adherence to the performance limits of the
product.
• Adherence to all repair and care instructions, as
well as additional inspections.
• Use of the auxiliary and operating materials
listed, as well as their environmentally-friendly
disposal.
Operationally safe function can only be guaranteed
if all the instructions, setting and performance limits
for the product are adhered to.
1.7 Rescue data sheet
Note:
The creation and provision of a rescue data
sheet in accordance with ISO17840-2 is under
responsibility of vehicle operator.
Refer to the “Sales” section of our home page
www. safholland.com for information on current
warranties and general terms and conditions.
1.4 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
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1.8 Safety instructions and symbols
used
The following symbols are used to denote
particularly important information and sections of
the text.
It must be ensured that they are always read and
observed before working with the product.
Installation Manual
Danger!
3. General instructions
This safety instruction with the exclamation mark
warns of a possible safety risk or serious and fatal
injuries.
Attention!
This safety instruction with the exclamation mark
warns of possible damage to the product.
Note:
Marking for special user tips and other particularly
useful and important information for ecient work
and economical use.
1.9 Marking used for sections of text
• Marking for instructions for actions and
information in safety instructions
1., 2., 3., ... Marking used for working steps.
2. Safety instructions
Danger!
The installation of the product is restricted
exclusively to trained personnel from authorised
specialist workshops.
Danger!
• Do not move trailer with SAF TRAKr without
poper working cooling system for the
e-machine! Preliminary supply of liquid cooling
system with the onboard vehicle source (+24V,
e.g. permanent power output) can be realized.
• The preliminary supply of the liquid cooling
system for the e-machine is only permitted
for transfer drives to the locations for the
installation of the electric recuperation system.
Make sure that the cooling system is working
during the transfer drives.
• For normal use, the liquid cooling system for the
e-machine must be connected to the electric
recuperation system (see „7. Liquid cooling
system for E-Machine“ on page 10).
Danger!
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The TRAKr gearbox is not lled with oil on
delivery. The oil for the initial gearbox lling
is included in the TRAKr axle delivery. Before
operation the gearbox must be lled with the
supplied gearbox oil:
• Filling gearbox oil SAF Synlube SAE 70W-90
capacity: 0.45 l
• Article number: 03 387 1004 00
• Oil class: SAE 70W-90
See „6. Initial gearbox oil lling“ on page 9.
High Voltage!
• Only specially certied and trained personal
must conduct mounting and repair work on the
TRAKr, its components and the corresponding
trailer.
• The personal has to be trained and certied
according to the national legislation and/or
regulations (e.g. DGUV 209-093 Level 2 S or E
or comparable).
XL-PS40050BM-en-DE Rev C· Edition 02/2023 · Errors and changes excluded © SAF-HOLLAND GmbH
Danger!
The operation of the TRAKr in ADR* vehicles is not
allowed.
*) European agreement concerning the
International carriage of dangerous goods by
road.
Note:
The creation and provision of a rescue data
sheet in accordance with ISO17840-2 is under
responsibility of vehicle operator.
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