Service Book Manual 191835 - NP 040420 Pedal W20E

SAFIM S6 BRAKE SYSTEM PAGE
RIF. 191835/NP
DESCRIPTIONS 191835NP/1
LAST REVISION 040420

COMPACT S6 braking valve consists of one casting with reduced sizes and easy to install.
Inside the casting there is an accumulator recharge valve and 2 independent braking circuits.
Next to the main body, we have fixed a little block containing a solenoid valve that enables to
control the negative parking brake.
SAFIM supplies an already perfectly adjusted and calibrated system in accordance with the
technical specifications stated by the customer. The customer himself will easily be in a position
to perform further adjustments with the proper screws provided along with the braking valve.
SAFIM Via Livingstone, 6 - 41100 Modena (Italy)

Tel. (0039) 059 894411 Fax. (0039) 059 894444 E-mail: info@safim.it
RIF. 191835/NP

RIF. 191835/NP
CONNECTIONS
B Other service or tank M22x1.5 ISO 6149
N Tank M18x1.5 ISO 6149
P Inlet oil M22x1.5 ISO 6149
F Accumulator pressure switch M10x1 ISO 6149
R1 Accumulator M14x1.5 ISO 6149
R2 Accumulator M14x1.5 ISO 6149
F1-2 Brake pressure switch M10x1 ISO 6149
T1 Brakes M14x1.5 ISO 6149
T2 Brakes M14x1.5 ISO 6149
INSTALLATION REQUIREMENTS
Acc. charging valve pressure: 50-200 Bar
Kind of oil: hydraulic oil according to DIN 51524
Filtering level: NAS 1638 category 8
Oil viscosity: from 1.9° Engler to 5.4° Engler to 50°C
Temperature: -20°C / + 90°C
Inlet oil range: 3-50 Lit /min
IDENTIFICATION PLATE
Each S6 brake system carries an identification
plate showing:
1. Product reference/order number
2. Month and year of manufacture
3. Accumulator recharge pressure
4. Braking pressure

RIF. 191835/NP
ADJUSTMENT 191835NP/4
Warning : all connections must be made with the engine off and the hydraulic
system depressurised. Before carrying out any operations with the engine running,
always make sure that the discharge N and secondary service B connections are
open. Working on the system with the engine running and these connectors closed
may lead to serious injury to personnel and damage to equipment.
The S6 system does not present any particular installation problems. Keep the connectors and
pipe as clean as possible; the presence of foreign bodies and impurities will cause malfunction
and rapid wear of the system components.
Important : in order to bleed air from the system, with accumulators charged and the motor
running, press the brake pedal and open the bleed valves for a few seconds.
If a safety valve is fitted between the feed pump and the brake valve, it must be set at least 30
bar above the maximum accumulator cut out pressure.
If another work port is fed by the B, then it must be protected with its own relief valve.
PEDAL ENTRY SLOT
SAFIM usually supplies S6 units ready-calibrated according to customer

specifications.
Should adjustment be necessary, please follow the instructions given below.
1) Regulation of twin-screw accumulator charging valve Series 11000.
The accumulator charging valve series 11000 with twin coaxial adjusting screws is used to
regulate the recharge point and maximum pressure of an accumulator within a range varying
between +10% and +35% of the recharge pressure.

RIF. 191835/NP
Screw A regulates the recharge pressure of the accumulator readings (minimum pressure),
rotate adjusting screws A and B in a clockwise direction.
A pressure switch should be connected to either outlet R or F before regulating pressure
readings.
When the valve has been operated (engine on), activate the brake pedal to reduce oil pressure
in the accumulator and locate the recharge point on the pressure gauge; modify adjusting
screw’s position A, so that it corresponds to the desired value and fix the screw with the nut.
Regulate the maximum pressure with screw B and then fix it whit the nut.
Attention: tighten screw’s nut A first and afterwards screw’s nut B.
In order to improve the valve’s functioning, the maximum pressure must be at least 5-8 Bar
more than the pressure reading with screw B tightened.
It is important to fit stop C on the adjusting screw in order to prevent screw A from tightening
excessively and thus blocking the pump.
2) Adjusting braking pressure
Connect a pressure gauge (with 250 bar scale) to a brake circuit. Apply the brakes.
Braking pressure depends on pedal stroke.
The braking pressure adjusting screw that has a cross hole, can be found in the valve lower
side: in order to reduce the braking pressure, you have to tighten the adjusting screw (
therefore you get a reduction in the pedal stroke); in order to increase the braking pressure
you have to unscrew the adjusting screw (you get an increase in the pedal stroke).
RIF. 191835/NP
Follow all pressure recommendations to prevent any damage to brakes.
The braking pressure setting parameters are shown in the identification plate (Pos. PF).
3) Adjusting pedal angle
The pedal’s angle is adjusted by the front screw (a). When you have completed all the adjusting
operations, finally block the pedal by the rear screw (b).
4) Checking accumulator efficiency
Accumulators are pre-charged with nitrogen under pressure.
There are two methods for checking accumulator gas pressure:
a. Discharge all hydraulic oil from accumulators before checking. Check accumulator
gas pressure by using a suitable equipment fitted with a pressure gauge.
b. Check gas pressure by inspecting oil pressure. Fit a pressure gauge to the accumulator
coupling pipe and load the accumulators. Switch off the engine and discharge the accumulators
either by applying the brakes several times or by loosening the connection. Pressure will begin
to drop slowly until it suddenly drops to zero.

RIF. 191835/NP
The pressure reading given just before pressure’s suddenly zero sinking is the accumulator gas
pre-charge pressure.
On systems with three or more accumulators the inspection should start from the accumulator
mounted on the charging valve via connections R or F.
In order to control the accumulator in braking circuits R1, R2, either discharge or
disconnect the accumulator from the connected R-F charging valve.
5) Adjusting pressure switches
Increase pressure to the accumulators until you see the dashboard warning light flashing and
then turn the adjusting screw in the direction desired.
Turn it clockwise to switch off the warning light ; turn it anti-clockwise to switch on the warning
light .
Rotate the screw carefully by few degrees if the set pressure has been almost reached.

RIF. 191835/NP
SERVICE PROGRAM 191835NP/8
WARNING: Every brake pedal disassembling/assembling proceeding must be carried

out with the accumulators unloaded. In order to unload the accumulators,
you must press the brake pedals many times with the engine off.
EVERY SIX MONTHS: Check the gas charging accumulator, following procedure n° 4
EVERY YEAR: Check the brakes’ pressure and the accumulators’ recharge pressure.
EVERY WEEK: Check and clean pedal room. The inspection frequency should be
carried out according to the kind of working environment.

RIF. 191835/NP
TROUBLE SHOOTING 191835NP/9
BRAKES
PROBLEM
CAUSE SOLUTION
Braking abrupt and sudden Wrong pressure adjustment Reduce the pressure by turning the
(See instruction manual). adjusting screw under the pedal
whilst checking pressure with
gauge.
Insufficient braking Wrong pressure adjustment Increase the pressure by turning

(See instruction manual). the adjusting screw under the pedal
whilst checking pressure with
gauge.
IMPORTANT: Do not exceed the
maximum allowed braking
pressures.
Brake’s activation and Brake feed and discharge rate is Check that the diameter of the
release are delayed. insufficient. brake pipes is large enough in
relation to length and fluid capacity.
Drain and fill system with correct
Hydraulic fluid viscosity too high. fluid viscosity.
The brakes stay on. S6 System discharge is defective The hydraulic pipe system is not
discharging freely to the tank and
the pressure is feeding back to the
brakes.
Please note that when the pedal is

in rest position, brake ports are
freely connected to the tank port
through the valve.
Brake pedal does not return.
Check the pedal stop adjuster;
there should be a little free
clearance before the pedal begins
to operate the piston.
Check pedal area and clean it from
soil, sand traces, etc..
Keep the floor -mat away from
the pedal.

RIF. 191835/NP
Dashboard warning light Pressure switch setting is wrong. Check the pressure switch on the
does not flash or remains charging valve. Adjust it up to a
on all the time. value that is below the minimum
accumulator pressure, but high
enough to comply with CEE
regulation 9812 and to ensure nr.
braking actions per once
the warning light has flashed.
Braking pressure not The accumulator minimum Check cut in accumulator pressure:
uniform pressure is lower than the it should be higher than max. brake
maximum braking pressure. pressure. Set the accumulator
charging valve (See instructions
pos 1 page 191835NP/14).

RIF. 191835/NP
ACCUMULATOR CHARGING VALVE

PROBLEM CAUSE SOLUTION
Continuous recharging of Nitrogen pre-charging of Drain the oil from the accumulators
accumulators. accumulators too high or too low. and check the nitrogen pressure.
(See instructions in 4 a)
Recharge accumulator gas following
the instructions and specifications
given in the maker’s manual (See
instructions in 4)
Braking capacity too high for Check brake adjustment and/or fit
accumulator volume installed. accumulators with bigger volume.
Feed pump continuously Pump worn. Check the pump. Repair or replace.
under pressure.
Dirt in the valve. Thoroughly check the valve. (See
drawing pos A and page
191835NP/14).
Dismantle and clean if necessary.
Parts should move smoothly. Seals
and seal locations should not be
damaged.
Check that all connections are
properly tightened and that they are
not leaking.
Accumulators will not charge. Foreign body is jamming the Check that all parts move smoothly;
priority valve. check the in-feed valve in particular.
Dismantle and clean if necessary.
(See drawing pos D and page
191835NP/14)
Check the hydraulic connections;
tighten if necessary and remove any
leaks.
If the accumulator charging valve has
been dismantled, check that the stop
ring on the piston in front of the feed
connection has been refitted in the
correct position.
(See pos C). Check the piston’s
direction.
Knocking can be felt at pedal. Sudden, abrupt variations in Brake discharge flow too high.
discharge pressure. Increase the diameter of the
discharge pipe or fit an independent
discharge at the pedal. Consult
Safim.

RIF. 191835/NP

RIF. 191835/NP
ACCUMULATOR SEQUENCE VALVE

The purpose of this valve is to energize the accumulator charging valve by means of accumulator R1
pressure if this is loaded at a useful pressure value.
When pressure is lower than the requested value, this valve closes and protects
R1 accumulator against any fluid leaks from accumulator charging valve and R2 accumulator.
Problems connected to this valve:
PROBLEM CAUSE SOLUTION

Accumulator charging valve The valve is over set Reduce the spring charge by
will charge continuously with removing the spacers, but do not
short in-shots. make this operation, because this
valve has been tested by the
manufacturer and set at 100-110 bar
as agreed with the customer.
Connecting orifice closed Clean the orifice by removing the

conical unit
Pressure lost from Leakage through conical unit or Check conical unit cleanliness, check
accumulator R1 through through a seal. that the seal surface is in good
accumulator charging valve conditions, check O-ring integrity
or R2 accumulator
Suggestions on how to disassemble the sequence valve:

1) Discharge the accumulator. IT IS DANGEROUS TO LOOSEN THE SCREW WHILE THE
ACCUMULATOR IS UNDER PRESSURE.
2) Unscrew plug. Be careful: the spring is loaded!
3) Unscrew lock screw and remove the conical unit, the disc and the seal.
4) Remove the cartridge by pulling it by thread M4.
R1
Orifice
Valve Accumulator
charging valve
Conical unit
Cartridge Spring
R2
M4 Thread
Washers
Lock screw
Plug

RIF. 191835/NP
INSTRUCTIONS FOR 191835NP/14
DISASSEMBLING THE
ACCUMULATOR CHARGING VALVE
CONTROL OPERATIONS POS. 1

Start the vehicle and charge the accumulators.
If oil comes out of the pipe linked with connection “B” (during the accumulators’ recharge), the gear
feeding pump is not damaged.
If no oil comes out of connection “B”, the gear feeding pump must be replaced.
In case the gear feeding pump is not worn, proceed as follows:
cut off pressure from the system; disassemble the connection (if present) on hole “P” in the brake pedal
charging valve and check that the priority piston is in contact with the stop ring (see picture below).
If the priority piston is in contact with the stop ring, check its smoothness in the valve body and proceed
as described in pos. 2.
If the priority piston and the stop ring are not in contact, check the piston’s smoothness itself (it might be
blocked).
In order to take out the priority piston, remove the stop ring and pull the priority piston out.
Remove any dirt traces in the priority piston or in the grooves of the valve body seat.
CONTROL OPERATIONS POS. 2

Unscrewing the closing plug. When assembling it again, lock the closing plug with a 200 Nm tightening
group.
Pull out the piston containing the unidirectional valve, then unscrew the pin valve seat and afterwards
take out the components mounted inside.
Check that there isn’t any dirt on the pin valve tight cone and that the cone is entire and complete.
In case it is damaged, replace it.
Clean all removed parts carefully.
In order to lock the pin valves’ seat use a 6 Nm (max) tightening group and moisten the thread ridge with
LOCTITE brake thread quality medium cod. 242 or use a brake thread with similar features.
CAUTION: No trace of glue should be found on the pin valve tight cone.

RIF. 191835/NP
SPARE PARTS LIST 191835NP/15
Description Ref.
Brake system support pedal 103022/DP
Brake system seal kit SG12512
Pedal rubber 12818
Brake system springs kit ML14240

RIF. 191835/NP
SPARE PARTS LIST 191835NP/16


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SAFIM S6 BRAKE SYSTEM PAGE

LAST REVISION 040420

SAFIM Via Livingstone, 6 - 41100 Modena (Italy)

SAFIM Via Livingstone, 6 - 41100 Modena (Italy)

1. Product reference/order number

2. Month and year of manufacture

3. Accumulator recharge pressure

SAFIM Via Livingstone, 6 - 41100 Modena (Italy)

SAFIM usually supplies S6 units ready-calibrated according to customer

SAFIM Via Livingstone, 6 - 41100 Modena (Italy)

2) Adjusting braking pressure

Follow all pressure recommendations to prevent any damage to brakes.

3) Adjusting pedal angle

4) Checking accumulator efficiency

Accumulators are pre-charged with nitrogen under pressure.

There are two methods for checking accumulator gas pressure:

SAFIM Via Livingstone, 6 - 41100 Modena (Italy)

5) Adjusting pressure switches

SAFIM Via Livingstone, 6 - 41100 Modena (Italy)

WARNING: Every brake pedal disassembling/assembling proceeding must be carried

SAFIM Via Livingstone, 6 - 41100 Modena (Italy)

Insufficient braking Wrong pressure adjustment Increase the pressure by turning

Please note that when the pedal is

SAFIM Via Livingstone, 6 - 41100 Modena (Italy)

SAFIM Via Livingstone, 6 - 41100 Modena (Italy)

ACCUMULATOR CHARGING VALVE

SAFIM Via Livingstone, 6 - 41100 Modena (Italy)

SAFIM Via Livingstone, 6 - 41100 Modena (Italy)

ACCUMULATOR SEQUENCE VALVE

PROBLEM CAUSE SOLUTION

Connecting orifice closed Clean the orifice by removing the

Suggestions on how to disassemble the sequence valve:

SAFIM Via Livingstone, 6 - 41100 Modena (Italy)

CONTROL OPERATIONS POS. 1

CONTROL OPERATIONS POS. 2

SAFIM Via Livingstone, 6 - 41100 Modena (Italy)

SAFIM Via Livingstone, 6 - 41100 Modena (Italy)

SAFIM Via Livingstone, 6 - 41100 Modena (Italy)

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