SAF axles and Suspension Assemblies Service Parts Manual

Service Edition 8/2002 Service manual for SAF axles and Suspension Assemblies

10114GB Edition 0802 Manufacturer.............................................................................................................. Address....................................................................................................................... Body type................................................................................................................... Chassis no................................................................................................................... Year of manufacture................................................................................................. Registration, date-in-service..................................................................................... 2 Vehicle information Spare parts service for SAF axles and suspension systems When ordering spare parts quote correct axle identification serial no., refer to the axle type plate. Please enter the axle identification figures in the type plates shown below so that correct specification are available when required. Type plate for axle beam assembly

Contents Page SAF axle indentification 2 General service instructions 5 Notes 53-54 SAF axle types SK RS / RZ 9042 / 11242 / 9037 / 11037 Service schedule for SAF axle types SK RS / RZ 9042 / 11242 6 Service chart for SAF axle types SK RS / RZ 9042 / 11242 7 Spare parts and torque wrench settings SK RS / RZ 9042 / 11242 8-9 Service schedule for SAF axle types SK RS / RZ 9037 / 11037 10 Service chart for SAF axle types SK RS / RZ 9037 / 11037 11 Spare parts and torque wrench settings SK RS / RZ 9037 / 11037 12-13 SAF axle types SK RS / RZ 9030 / 11030 / RZ 12030 Service schedule for SAF axle types SK RS / RZ 9030 / 11030 / RZ 12030 14 Service chart for SAF axle types SK RS / RZ 9030 / 11030 / RZ 12030 15 Spare parts and torque wrench settings SK RS / RZ 9030 / 11030 / RZ 12030 16-17 SAF axle types SK RS / RZ 12242 Service schedule for SAF axle types SK RS / RZ 12242 18 Service chart for SAF axle types SK RS / RZ 12242 19 Spare parts and torque wrench settings SK RS / RZ 12242 20-21 SAF axle types K RS / RZ 14242 / 16242 Service schedule for SAF axle types K RS / RZ 14242 / 16242 22 Service chart for SAF axle types K RS / RZ 14242 / 16242 23 Spare parts and torque wrench settings K RS / RZ 14242 / 16242 24-25 SAF axle types with disc-brakes SK RS / RZ 9022 K / 11222 K / 9019 K / 11019 K Service schedule for SAF axle types SK RS / RZ 9022 K / 11222 K / 9019 K / 11019 K 26 Service chart for SAF axle types SK RS / RZ 9022 K / 11222 K / 9019 K / 11019 K 27 Spare parts and torque wrench settings SK RS/RZ 9022K/11222K/9019K/11019K 28-29 Trailing steering axles Trailing steering axles - adjustment 30-31 Spare parts and torque wrench settings SK RLS 9042 / 11242 32-33 Spare parts and torque wrench settings SK RLZ 9037 / 11037 34-35 Spare parts and torque wrench settings SK RLZ 9030 / 11030 36-37 Spare parts and torque wrench settings Air Suspension Series M 38-39 Spare parts and torque wrench settings Air Suspension Series O 40-41 Spare parts and torque wrench settings Air Suspension Series U 42-43 3 10114GB Edition 0802

10114GB Edition 0802 4 Contents Page General information Tightening instruction for pivot clamping bolt assembly 44 Adjusting the ride height 45 Braking system - checking and adjustment 46 HALDEX automatic slack adjuster 47-48 S-ABA automatic slack adjuster 49 Track control 50 Wheel bearings - adjustment 51 Torque wrench settings 52

10114GB Edition 0802 for SAF axles and suspension units 1. Instructions and tips for vehicle operation In order to maintain the operation and road safety of the vehicle, the maintenance operations prescribed by SAF must be carried out regularly at the specified intervals (see "Maintenance instructions"). Furthermore, ensure that 1.1 the disc brake is not overheated due to continuous operation as otherwise irreparable damage to the surrounding components – in particular the wheel bearings – cannot be ruled out. This can impair the operational and road safety of the vehicle and represent a serious hazard for man and machine. 1.2 the compatibility of the brakes on the truck-trailer combination is checked. For reliable braking and uniform brake lining wear, the brake systems of the two vehicles must be matched to one another before starting operation 1.3 the parking brake is not applied immediately when the brakes are hot as the resulting different stress fields can damage the brake discs 1.4 the drum brakes are not overheated as this will result in a dangerous reduction in braking efficiency 1.5 the maximum permissible axle loads and speeds are not exceeded 1.6 the cargo is evenly distributed over the loading area and safely secured 1.7 on vehicles with air suspension, the air bags are always fully pressurised before starting a journey 1.8 the prescribed wheel rims and tyre sizes are employed 1.9 the tyres have the prescribed inflation pressure 1.10 your driving style is matched to the road conditions 1.11 axle supports are used when loading/unloading construction machinery 1.12 the use of auxiliary trailer braking facilities (trailer underrun brake) is not permitted. 2. Vehicle safety 2.1 The daily check of the vehicle for road safety before starting a journey is the responsibility of the driver. 2.2 Modifications to the suspension and braking system are strictly forbidden. 2.3 Compliance with the specified permissible axle loads, specifications in the vehicle operating permit, vehicle inspection intervals and the regular maintenance intervals is the responsibility of the vehicle owner. 2.4 We strongly recommend fitting only SAF approved replacement parts and spare parts which are covered by SAF product liability. These products have been thoroughly tested by SAF for safety, functionability and suitability. Fitting of these parts guarantees not only safety on the roads but satisfies the legal operational requirements. SAF is not in a position to judge whether those products from other companies represent a safety risk for SAF axles and systems. 3. Warranty 3.1 Warranty claims will only be accepted as long as the operating and maintenance instructions have been complied with and if SAF approved spare parts have been fitted. 3.2 Warranty claims must be reported to SAF before starting the work. 3.3 The warranty period is 12 months after the vehicle registration date or after the start of operation of the vehicle. 4. Service and spare parts A close-knit service network of SAF partner companies is at your disposal for technical advice on SAF axles and suspension systems as well as for supplying approved SAF spare parts (see back cover or brochure "SAF service stations"). In case of repair we strongly recommend fitting only SAF original parts for those reasons mentioned in point 2.4. SAF axles and suspension units are subject to continuous further development; the data and drawings contained in the manual may therefore differ from the details given in the operating permit. The contents of the manual does not constitute the basis for a legal claim. Reprinting, reproduction or translation in whole or in part is not permitted. The issue of this publication invalidates all earlier maintenance and repair manuals. 5 General service instructions

10114GB Edition 0802 Service schedule Check truck-trailer combination for brake compatibility Check service brake pressure to manufacturer’s recommendation Vehicles with long standing periods: service at specified time intervals Vehicles used under extreme conditions: service at suitably reduced intervals Service schedule whichever comes first Mileage intervals > Time intervals > After first 5,000 km or every 30,000 km every 90,000 km every 150,000 km after first month every 3 months every 6 months every 12 months • • • • • • • • • • Periodic checks Check air suspension for correct ride height. With 2 levelling valves, the max. permissible bellows pressure difference (LH to RH vehicle side) is 0.2 bar. Check wheel brakes for correct adjustment Check service brake and hand brake efficiency Lubricate camshaft bearings after every brake lining replacement, however, at least every 12 months. Hub end-float adjustment not required. Pack wheel bearings with fresh grease after 500,000 km or 50 months, whichever comes first. Check condition of taper roller bearings and replace, if necessary. Torque check all nuts and bolts to recommended setting. Note: Torque check wheel nuts after the first 50 km and 150 km (and after every wheel removal). Mechanical check Visual inspection for wear/damage Safety inspection Special service conditions for SK RS / RZ 9042 / 11242 axles and suspension units (steering axle see p. 30-33) Warranty claims will only be accepted as long as the operating and maintenance instructions have been complied with and if SAF approved spare parts have been fitted. 6 Check suspension components for wear, fluid leakage and damage Check brake linings for wear Check camshafts for free movement Check slack adjusters for correct function Check braking system for leaks (brake applied) Check air suspension for air leaks Check air suspension bellows for damage Check piston surface for contamination and clean, if necessary Check parabolic springs for damage, scoring and corrosion Check self steering axle for correct function Check tyre wear and tracking (if required)

10114GB Edition 0802 for SK RS / RZ 9042 / 11242 axles Hub end-float setting. Lubricant. Hub end-float adjustment is not required. Pack wheel bearings with fresh grease after 500,000 km or 50 month, whichever comes first. Check condition of taper roller bearings and replace, if necessary. Replace O-ring (39) and fit the wheel cap. After brake relining, lubricate camshaft bearings whilst rotating the camshaft through 360° several times. Do not disassemble the wheel bearing assembly. Use a vacuum cleaner to remove brake dust. Never use pressurised cleaning devices or cleaning fluids on the brake drum and hub. Clean stub axle and apply fresh SAF fitting paste. Lubricant specification: Wheel bearings: SAF parts no. 4 387 0011 05 Camshaft: SAF parts no. 4 387 0011 05 Stub axle: SAF parts no. 4 387 0015 06 SAF fitting paste Brake anchor bracket ball: SAF parts no. 4 387 0007 00 Copper paste Hub nut tightening LH direction of travel - LH thread. RH direction of travel - RH thread. Pretighten to 150 Nm whilst rotating drum. For final torque, continue tightening through one more scale line (10 °). Hub nuts with LH threads are marked with a groove milled into the hex outside. Assembly tools SAF parts no. 9042 / 11242 Hub nut spanner 1 012 0024 00 Brake shoe clamping device 3 349 1001 00 Brake drum fixing flanges 3 434 1040 01 Wheel bearing inserter 3 434 1043 00 Brake drum / brake lining refacing stages in mm BRAKE type SNK 420 Max. permissible turned brake drum bore: 424.0 mm Brake drum bore with max. permissible wear: 425.0 mm SAF approved brake linings: BERAL 1541, BREMSKERL 6386 Turn new brake linings to brake drum bore dimension + 0.3 mm. When renewing rivets, observe the manufacturer’s instructions regarding the brake lining. Normalmaß 1. Rep.-Stufe 2. Rep.-Stufe d 0 d 1 d 2 Brake linings Rivets 420.0 422.0 424.0 DIN 7338 rivet number per axle SNK 420 d 0 -420.0 d 1 -422.0 d 2 -424.0 x 180 1 057 0060 00 20.6 21.6 22.6 1 057 0061 00 20.0 21.0 22.0 x 200 1 057 0066 00 20.6 21.6 22.6 1 057 0067 00 20.0 21.0 22.0 4 64 B 8 x 15 Nominal size 1st oversize 2nd oversize Brake SAF parts no, size brake lining Service chart 7 nominal size 1st oversize 2nd oversize

10114GB Edition 0802 Spare parts Exploded view of SK RS / RZ 9042 / 11242 axle assembly Torque wrench settings Use torque wrench. The use of impact wrenches is not accepted. U-bolts: (diagonally in three stages) M 24 / 700 Nm M 22 / 650 Nm M 20 / 500 Nm 091 96 97 98 94 92 93 99 95 94 90 89.1 29 31 30 34 38 27.3 27.2 27 081/082 88.1 88 87 86 85.1 010 38.1 39 40 40.1 41 64 70 72 73 71 65 66 75 059 4.1 74 6.2 6 6.1 18 15 12 18 78 76.2 76 22/22.1 19 20 4 5 01 3 25 Typenschild 89.2 89.3 18.3 8 Wheel nuts: Spigot-hub-centred fixing: M 22 x 1.5 / 600 Nm Bolt-centred fixing: M 22 x 1.5 / 430 Nm Shock absorber: M 24 / 400 Nm Production number (right/direction of travel) Type plate

10114GB Edition 0802 List of spare parts SK RS / RZ 9042 / 11242 01 Axle beam assembly including items 3 - 6, 010, 19, 22 - 22.1, 25 3 Spherical mounting plate 4 Protection plug 4.1 Protection plug (axle tube) 5 Ball 6 Camshaft bearing, brake carrier side 6.1 Riffle bolt 6.2 Hex nut 010 Camshaft bearing assembly, linkage adjustment side including items 12, 15, 18 12 Camshaft bearing 15 Hex bolt 18 Bellows 18.3 Brake lining wear gauge 19 O-ring - Hub nut 20 O-ring - Stub axle 22 Hub nut, RH thread 22.1 Hub nut, LH thread 25 Brake cylinder support 27 Hub unit, complete with item 27.2 27.2 Repair kit including items 27.3, 38 - 39 27.3 Bearing grease 29 Brake drum 30 Wheel bolt assembly including items 31 - 34 31 Riffle bolt 34 Wheel nut 38 Inner seal ring 38.1 Outer seal ring 39 O-ring - Hub cap 40 Hub cap, complete with items 39, 41 40.1 Hub cap, complete with pole wheel and items 39 - 41 41 Plug 059 Brake assembly including items 64, 74 - 75 64 Brake shoe assembly including items 65, 71 - 73 65 Brake shoe with item 66 66 Cam roller 70 Lining service group including items 71, 72, 73 71 Brake lining, cam roller side 72 Brake lining, ball side 73 Rivet 74 Spring clip 75 Return spring with ABS 76 Bracket sensor 76.2 Hex bolt 78 ABS sensor 081 Camshaft assembly (LH) including items 18.3, 85.1 - 88.1 082 Camshaft assembly (RH) including items 18.3, 85.1 - 88.1 85.1 Disc spring 86 Spring clip 87 Washer 88 Washer 88.1 Spring clip with automatic adjustment 89.1 Automatic slack adjuster 89.2 Anchor plate, RH 89.3 Anchor plate, LH 90 Return spring 091 Dust cover assembly including items 92 - 98, 99 92 Dust cover, RH 93 Dust cover, LH 94 Plug 95 Cable clamp 96 Hex bolt 97 Clamp 98 Plug 99 Rubber grommet, ABS Item Parts designation Item Parts designation 9 When ordering spare parts quote correct axle identification serial no., refer to the axle type plate.

10114GB Edition 0802 Service schedule 10 Check truck-trailer combination for brake compatibility Check service brake pressure to manufacturer’s recommendation Vehicles with long standing periods: service at specified time intervals Vehicles used under extreme conditions: service at suitably reduced intervals Service schedule whichever comes first Mileage intervals > Time intervals > After first 5,000 km or every 30,000 km every 90,000 km every 150,000 km after first month every 3 months every 6 months every 12 months • • • • • • • • • • Periodic checks Check air suspension for correct ride height. With 2 levelling valves, the max. permissible bellows pressure difference (LH to RH vehicle side) is 0.2 bar. Check wheel brakes for correct adjustment Check service brake and hand brake efficiency Lubricate camshaft bearings after every brake lining replacement, however, at least every 12 months. Hub end-float adjustment not required. Pack wheel bearings with fresh grease after 500,000 km or 50 months, whichever comes first. Check condition of taper roller bearings and replace, if necessary. Torque check all nuts and bolts to recommended setting. Note: Torque check wheel nuts after the first 50 km and 150 km (and after every wheel removal). Mechanical check Visual inspection for wear/damage Safety inspection Special service conditions for SK RS / RZ 9037 / 11037 axles and suspension units (steering axle see p. 34-35) Check suspension components for wear, fluid leakage and damage Check brake linings for wear Check camshafts for free movement Check slack adjusters for correct function Check braking system for leaks (brake applied) Check air suspension for air leaks Check air suspension bellows for damage Check piston surface for contamination and clean, if necessary Check parabolic springs for damage, scoring and corrosion Check self steering axle for correct function Check tyre wear and tracking (if required) Warranty claims will only be accepted as long as the operating and maintenance instructions have been complied with and if SAF approved spare parts have been fitted.

SAF axles and Suspension Assemblies Service Parts Manual

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