Service manual for SAF axles and Suspension Assemblies
Contents
1. 4 the no load stroke at Yee the slack adjuster Ps at 127 mm is approx se 10 15 mm long eet The wheel must rotate Adjusting screw freely with no grating width across flats 19 mm noise Special instructions for automatic slack adjusters are given on the following pages A At 1 2 stroke the angle must not exceed 90 B On full brake application the slack adjuster and axle beam must not come in contact with each other L Inspect piston rod according to technical specification Automatic slack adjuster Type HALDEX When interchanging from a manual to an automatic slack adjuster make sure that you fitt replacement adjuster in accordance with type approval by SAF for your specific axle type Changes to the adjuster arm length are not permissible NOTE The installation of an incorrect type of automatic slack adjuster will result in critical effect of serious overheating the brakes References regarding automatic slack adjuster to SAF axles types are available from your SAF service partner at request see back cover A A 10114GB Edition 0802 Automatic slack adjuster adjustment Type HALDEX 10114GB Edition 0802 Mi Set cams and brake shoes to released position Observe the correct push rod length L as indicated in the SAF specifications Membrane brake chamber Before installing the automatic slack adjuster ensure that the brake chamber push rod isin released position2. By contrast spring brake chambers must be under full operating pressure min 6 bar IM PORTANT If this is not maintained properly the basic setting will be wrong with critical effect of overheating the brakes Grease the camshaft Install anchor bracket 3 being sure to use two fixing bolts 4 do not yet tighten the bolts Install the slack adjuster on the camshaft The arrow 7 points in the braking direction Turn adjusting screw 1 until the bore in the slack adjuster 8 1 coincides with the bore in the clevis end 9 see drawing Grease split pin 8 and secure Install return spring 10 Move the control arm 2 in the direction of the arrow operating direction of slack adjuster up to its end position A without applying excessive force When control arm 2 is in its end position A tighten the fixing bolts 4 For the anchor bracket mounting 11 ensure that the 2 U profiles engage firmly togehter Fit slack adjuster retaining clip on camshaft Axial clearance Adjust 0 5 2 mm using shims Adjust running clearance between brake lining and drum by turning adjusting screw 1 in clockwise direction until the lining fits smoothly against the drum Then back off adjusting screw 1 by 3 4 turn Do not use impact wrenches FUNCTION CHECK If the self adjuster is fFunctionning correctly then a minimum torque of 18 Nm must be felt and a grating noise must be hear
3. Air suspension bag upper 239 40 Nm U bracket see axle type in question 104 200 201 B 10114GB Edition 0802 Air Suspension Series U Item Parts designation Item Parts designation 1 Axle assembly 222 Washer 223 Hex nut 100 Front hanger bracket 228 Shock absorber 230 Hex bolts 104 Spigot flange 232 1 Washer 232 2 Hex nut 200 Hex bolt assembly 232 3 U washer induding items 201 202 233 Mounting plate 201 Hex bolt M30 202 Lock nut M30 234 Air bellows 207 U Profiles 235 1 Hex bolt 208 Eccentric bush 235 2 Lock nut 208 1 Thrus washer 236 Hex bolt 236 1 Self tapping screw 209 Trailing arm spring assembly 237 Spring washer induding items 211 214 239 Hex nut 240 Mounting plate 210 Thrus block 240 1 Air suspension mounting 211 Retainer plate bracket 214 Bearing bush HD 242 Clamping plate 219 Spring seat 220 U bolt kit induding items 221 223 221 U bolt When ordering spare parts quote correct axle identification serial no refer to the axle type plate fal 10114GB Edition 0802 Pivot clamping bolt assembly tightening instruction For spring brackets made of steel the bearing screw connections require no maintenance Further adjustments are not necessary Torque control setting is equal to 1200 Nm For spring brackets made of aluminium the bearing screw connections should be checked i e adjusted in 6 months intervals Torque control setting is equal to 1200 Nm REPAIR It may be necessary e g du
4. The following repair kits are available Designation AT brake calliper RH AT brake calliper LH AT brake calliper RH AT brake calliper LH Brake calliper carrier with guide kit RH Brake calliper carrier with guide kit LH Guide pin group folding bellows Guide pin group steel cap Guide pin group Tappet with boot Brake pad retainer kit per axle Cap for clearence adjuster 4 caps SB 7 Cap for clearence adjuster 4 caps SN 7 All kits available only as complete sets Content Item No incl pads incl pads without pads without pads 61 70 81 62 70 81 80 81 70 66 1 66 2 064 65 65 65 1 D 10114GB Edition 0802 FEB sty Z080 LOA gOyTIOT 2 Adjust dimension A to the same length on both sides Watch toe in approx 4 0 mm Set dimension B to a length of 537 mm The reversing lock must be engaged Check seat of piston rods in stabilizing cylinders applying stabilizing pressure min 2 bar If there is any play adjust C When working on the tracking of the vehicle stabilising pressure must be applied to the cylinders and the air suspension must be adjusted to the correct height Tighten all bolts to the specified torque securing nuts with split pins Attention Make sure there is no load on the axle when lubricating the s
5. 41 95 Cable clamp 41 Plug 96 Hex bolt 97 Clamp 059 Brake assembly 98 Plug including items 64 74 75 99 Rubber grommet ABS When ordering spare parts quote correct axle identification serial no refer to the axle type plate B 10114GB Edition 0802 10114GB Edition 0802 for SAF SK RS RZ 9030 11030 RZ 12030 axles and suspension units steering axle see p 36 37 Service schedule Mileage intervals gt Whichever comes first Time intervals gt after first every every every month 3 months 6 months 12 months Mechanical check Note Torque check wheel nuts after the first 50 km and 150 km and after every wheel removal Torque check all nuts and bolts to recommended setting Check and adjust hub end float if required Pack wheel bearings with fresh grease after 300 000 km or 36 month whichever comes first Check condition of taper roller bearings and replace if necessary Lubricate camshaft bearings after every brake lining replacement however at least every 12 months Visual inspection for wear damage 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 sp
6. 0 21 0 22 0 Assembly tools SAF parts no Axle types 14242 16242 N Hub nut spanner 1012 0011 01 1 012 0013 00 D Hub puller 3 301 0006 02 3 301 0007 01 5 Universal puller for wheel hub 4 434 3822 00 4 434 3822 00 f Bearing inner race 4 434 3815 00 4 434 3816 00 a Wheel bearing oil seal inserter 3 434 3300 00 3 434 3301 00 g Brake shoe clamping device 3 349 1001 00 3 349 1001 00 S Puller for MS bushing 46 mm 1 434 1056 00 1 434 1056 00 g Bushing tool 50 46 mm and 42 38 mm 1 434 1055 00 1 434 1055 00 q Exploded view of K RS RZ 14242 16242 axle assembly Torque wrench settings Use torque wrench The use of impact wrenches is not accepted N 10114GB Edition 0802 Wheel nuts U bolts Spigot hub centred fixing diagonally in M 22x1 5 600 Nm three stages Bolt centred fixing M 24 700 Nm M 22 x 2 430 Nm M 22 650 Nm M 22 x 1 5 430 Nm M 20 500 Nm Production number right direction of travel Shock absorber M 24 400 Nm K RS RZ 14242 16242 Item Parts designation Item Parts designation 01 Axle beam assembly 73 Rivet including items 3 5 6 8 3 Spherical mounting plate 74 Spring clip 5 Ball 75 Return spring 6 Bearing bush 8 Grease nipple with ABS 77 Exciter 010 Camshaft bearing assembly 78 ABS sensor linkage adjustment side 80 1 Protective hose including items 12 15 18 80 2 Clamp 12 Camshaft bearing 80 3 Clamp 15 Hex bolt 18 Bellows 081 Camshaft assembly RH including items 18 3 84 88 1 18 3 Bra
7. 19 including items 65 71 73 22 22 1 25 65 Brake shoe with item 66 3 Spherical mounting plate 66 Cam roller 4 Protection plug 4 1 Protection plug axle tube 70 Lining service group 5 Ball including items 71 72 73 6 Camshaft bearing brake carrier side 71 Brake lining cam roller side 6 1 Riffle bolt 72 Brake lining ball side 6 2 Hex nut 73 Rivet 010 Camshaft bearing assembly 74 Spring clip linkage adjustment side 75 Return spring including items 12 15 18 12 Camshaft bearing with ABS 15 Hex bolt 76 Bracket sensor 18 Bellows 76 2 Hex bolt 78 ABS sensor 18 3 Brake lining wear gauge 19 O ring Hub nut 081 Camshaft assembly LH 20 O ring Stub axle including items 18 3 85 1 88 1 22 Hub nut RH thread 22 1 Hub nut LH thread 082 Camshaft assembly RH 25 Brake cylinder support including items 18 3 85 1 88 1 27 Hub unit complete 85 1 Disc spring with item 27 2 86 Spring clip 27 2 Repair kit including items 87 Washer 27 3 38 39 88 Washer 27 3 Bearing grease 88 1 Spring clip 29 Brake drum with automatic adjustment 30 Wheel bolt assembly 89 1 Automatic slack adjuster including items 31 34 89 2 Anchor plate RH 31 Riffle bolt 89 3 Anchor plate LH 34 Wheel nut 90 Return spring 38 Inner seal ring 38 1 Outer seal ring 091 Dust cover assembly 39 O ring Hub cap including items 92 98 99 92 Dust cover RH 40 Hub cap complete with items 39 41 93 Dust cover LH 40 1 Hub cap complete with pole wheel 94 Plug and items 39
8. A F 36 710 1000 1200 M 24x2 780 1100 1300 M 27 W A F 41 1050 1500 1800 M 27x2 1150 1600 1950 M 30 W A F 46 1450 2000 2400 M 30x2 1600 2250 2700 M 36x2 W A F 55 2450 3450 4150 N Wheel fixing Wheels see appropriate axle maintenance chart TRILEX wheels M 18 270 300 Nm S M 20 320 350 Nm q Q NOTIZEN NOTES NOTE SAF H 10114GB Ecition 0802 SAF NOTIZEN NOTES NOTE g 10114GB Edtion 0802 Australia Austria Belarus Belgium Bulgaria Chile Czech Republic Denmark Egypt Finland France Germany Great Britain Hungary celand srael taly alaysia etherland ew Zealand orway Peoples Republic of China Poland Portugal Romania Russia Republic of Slovakia Slovenia Spain Sweden Switzerland Turkey Yugoslavia SAF Vertretungen Agents Concessionnaires Service Stationen Service Stations Points Service HDTE Heavy Duty Transport Equipment Pty Ltd SAF Hering Rad Ges m b H SAF Representative Office SAF Benelux B V SAF Trade Bulgarien OOD Union Tecnica Automotriz S A C SAF Trade spol s r o Transport Komponenter A S Egyptian Co for Trading amp Construction Oy Arne Stara AB SAF France S A Otto Sauer Achsenfabrik Keilberg KG ILM S Ltd L V Technik Kft Stilling M N Systems Ltd SAF Italia S r l Quality Trailer Components SAF Benelux B V Transpecs Ltd MoRek a s Jinan SAF Axle Co Ltd SAF POLSKA Sp z 0 0 Suspartes Lda S C SAF TRADE RO S
9. Ae ee as aac ela A ina A Ya we DAL 10114GB Edition 0802 General information Tightening instruction for pivot clamping bolt assembly Adjusting the ride height i Braking system checking and adjustment oc ccccccsssscsssssssesssseseesssssseesessesesssssseseensessesesssessoaneseseeeesesseeeea 46 HALDEX automatic slack ACJUSCOM cc ccccsccssssscssssseenssssssnsssssnssssesnssssesnssssennssssennssssennsstsenssssnsssinssenn 48 S ABA automatic slack adjuster Track control Wheel bearings adjustment 51 Torque wrench SOLES cc cccsssssssssssesssssssscussssussessssussseunssseasssunsstessssssssnessonnssossssuassousssiuststussssussstsssasisuassn D2 a 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 ve
10. K 11222 K 9019 K 11019 K Hub end float adjustment is not required Tighten hub nut 140 wrench in the 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 10 dividing line Axle types SK 9030 11030 Tighten hub nut to a torque of 150 Nm at the same time rotating the hub and drum Locate the locking collar onto the dowel on the hub nut noting the position of the dowel in relation to the collar Remove the collar and turn the hub nut 2 1 2 holes anti clockwise Reverse the collar and re locate it onto the repositioned hub nut dowel Fit the lock nut and tighten using a torque of 400 Nm Check whether the hub rotates freely and without excessive end float adjust if necessary H 10114GB Edition 0802 The following tightening torques are only valid if no other values are given in the axle maintenance chart Torque wrenches settings impact wrench not permissible Thread WAF Material fasts 8 8 10 9 12 9 M8 W A F 13 25 35 41 M 8x1 27 38 45 M 10 W A F 17 16 49 69 83 M 10x1 52 73 88 M 12 W A F 19 18 86 120 145 M 12x15 90 125 150 M 14 W A F 22 21 135 190 230 M 14x1 5 150 210 250 M 16 W A F 24 210 300 355 M 16x1 5 225 315 380 M 18 W A F 27 300 405 485 M 18x1 5 325 460 550 M 20 W A F 30 410 580 690 M 20x1 5 460 640 710 M 22 W A F 32 550 780 930 M 22x1 5 610 860 1050 M 24 W
11. complied with and if SAF approved spare parts have been fitted for SK RS RZ 9037 11037 axles Hub end float setting Lubricant Lubricant specification Hub end float adjustment is not required Pack wheel bearings with fresh grease after 500 000 km or 50 month whichever comes first Wheel bearings SAF parts no 4 387 0011 05 Check condition of taper roller bearings and Camshaft replace if necessary SAF parts no 4 387 0011 05 Replace O ring 39 and fit the wheel cap Stub axle After brake relining lubricate camshaft bearings SAF parts no 4 387 0015 06 whilst rotating the camshaft through 360 several SAF fitting paste times Brake anchor bracket ball SAF parts no 4 387 0007 00 Copper paste 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 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 iS X i Hub nuts with LH threads are marked with ze jg 39 k Abe s a groove milled into the hex outside 5 s 4 Q v ZN BRAKE type SNK 367 Max permissible turned brake drum bore 371 0 mm Brake drum bore with max permissible wear 372 0 mm SAF approved brake l
12. ring 39 and fit the wheel cap Hub nut tightening After brake relining lubricate camshaft 360 several times paste Brake type SNK 300 Max permissible turned brake drum bore Brake drum bore with max permissible wear SAF approved brake linings bearings whilst rotating the camshaft through 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 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 nominal size 300 0 d 373 0 mm 304 0 mm 1st oversize 302 0 d 2nd oversize 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 DIN 7338 rivet Brake SAF parts no Brake drum brake lining Brake lini Rivet size brake lining refacing stages in mm rake linings vets Nominal size 1st oversize 2nd oversize number per axle SNK 300 300 0 d 302 0 d 303 0 x 150 1 057 0034 00 15 5 16 7 17 1 1 057 0033 00 16 5 17 7 18 1 x 200 1 057 0025 00 15 5 16 7 17 1 1 057 0024 00 16 5 17 7 18 1 Ass
13. 1 Protective ring 89 3 Anchor plate LH 38 2 Outer seal ring 39 O ring 90 Return spring 40 Hub cap complete with items 39 41 091 Dust cover assembly 41 Plug including items 92 99 92 Dust cover RH 059 Brake assembly 93 Dust cover LH including items 64 74 75 94 Plug 95 Cable clamp 64 Brake shoe assemlby 96 Hex bolt including items 65 71 73 97 Clamp 98 Plug 65 Brake shoe with item 66 66 Cam roller 99 Rubber grommet ABS When ordering spare parts quote correct axle identification serial no refer to the axle type plate N 10114GB Edition 0802 10114GB Edition 0802 for K RS RZ 14242 16242 axles Service schedule E Mileage intervals gt 30 000 km 90 000 km 150 000 km Whichever comes first ne y Time intervals gt month 3 months 6 months 12 months M echanical check Note Torque check wheel nuts after the first 50 km and 150 km and after every wheel removal Torque check all nuts and bolts to recommended setting Check and adjust hub end float if required Lubricate camshaft bearings after every brake lining replacement however at least every 12 months Pack wheel bearings with fresh grease also after every brake lining replacement check wheel bearing wear Visual inspection for wear damage 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
14. R L SAF INTCOM SAF Trade spol s r o Otto Sauer Achsenfabrik Keilberg KG SAF Otto Sauer Achsenfabrik Espana S L Trailax AB Willy Erny AG INTERM OBIL A S SAF Representative Office Otto Sauer Achsenfabrik Keilberg KG Hauptstra e 26 D 63856 Bessenbach Telefon 060 95 301 0 Telefax 06095 301 259 e www saf achsen de 0061 3 93690856 00 43 22 36 6465 00 00 375 17 2849092 00 31 0 342 497889 00 359 58 22491 0056 2 62348 51 00420 632 557188 00 45 75520080 0020 2 2152309 003 58 67818750 0033 1 30880900 00 49 06095 301 0 00 44 1509 600185 00 36 76 493507 00354 5 889797 00972 9 8626030 00 39 045 8250560 00 60 3 61858292 00 31 0 342 497889 00 64 9 9807300 00 47 67 06 35 00 00 86 531 8 8733 61 889 00 48 67216 6560 70 00351 21 2134710 00 40 68 2588 30 007 095 5799400 00421 38 7601834 003 86 530 29213 00 34 93 8468111 00 46 36 169700 00 41 52 3372121 0090 212 285 4364 65 0090 212 2862690 91 00381 13520427 SAF SV10114GB 0802
15. Service manual for SAF axles and a E Service lt Manufacturer Address Body type Chassis no Year of manufacture Registration date in service 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 OTTO SAUER ACHSENFABRIK KEILBERG D 63854 BESSENBACH GERMANY zul Last rio ff Ty max km h star TECH Inae spree _ i vitesse maxi won e OOO N 10114GB Edition 0802 Page SAF axle ingdentificatio Ns nsen ee Se A eather NN 0 Cl SN A 8 NN 0 a ad Ma 2 General service instruction NOUS aa anana SAF axle types SK RS RZ 9042 11242 9037 11037 Service schedule for SAF axle types SK RS RZ 9042 11242 Service chart for SAF axle types SK RS RZ 9042 11242 Spare parts and torque wrench settings SK RS RZ 9042 11242 Service schedule for SAF axle types SK RS RZ 9037 11037 Service chart for SAF axle types SK RS RZ 9037 11037 Spare parts and torque wrench settings SK RS RZ 9037 11037 SAF axle types SK RS RZ 9030 11030 RZ 12030 Service schedule for SAF axle types SK RS RZ 9030 11030 RZ 12030 Service chart for SAF axle types SK RS RZ 9030 11030 R
16. Z 12030 Spare parts and torque wrench settings SK RS RZ 9030 11030 RZ 12030 SAF axle types SK RS RZ 12242 Service schedule for SAF axle types SK RS RZ 12242 Service chart for SAF axle types SK RS RZ 12242 Spare parts and torque wrench settings SK RS RZ 12242 SAF axle types K RS RZ 14242 16242 Service schedule for SAF axle types K RS RZ 14242 16242 Service chart for SAF axle types K RS RZ 14242 16242 Spare parts and torque wrench settings K RS RZ 14242 16242 SAF axle types with disc brakes SK RS RZ 9022 K 11222K 9019K 11019K Service schedule for SAF axle types SK RS RZ 9022 K 11222 K 9019K 11019 Kees 26 Service chart for SAF axle types SK RS RZ 9022 K 11222K 9019K 11019K i Spare parts and torque wrench settings SK RS RZ 9022K 11222K 9019K 110 Trailing steering axles Trailing steering axles ACJUSEMENC ones ess sesssestiensstnestinstteusstinsttiusstinstiinstiunstiestiuntinetinansnnen BO SL 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 AA Air Suspension Series M Pean 38 39 Spare parts and torque wrench settings Air Suspension Series O s iiss coc fase a te cis ie a sa a de dled ailsclladttenaliteed 40 41 Spare parts and PON wrench MRN Air Suspension Series U a attest
17. amper 3 2 Steering knuckle 89 2 Anchor plate RH 527 Blocking cylinder assembly RH 89 3 Anchor plate LH 528 Cylinder screw induding items 4 9 16 17 19 20 22 25 90 Return spring 530 Steering control 501 506 differential 4 Bush 501 Pivot pin including items 5 Ball 502 Pressure plate top 531 533 6 Bearing bush 503 Pressure plate bottom 534 538 541 7 Bearing bush 504 O ring 531 Membrane cylinder 8 Hex bolt 505 Cover plate 532 Bevelled washer 9 Hex nut 505 1 Gasket 533 Push rod 16 Grease nipple 506 Bolt kit 534 Yoke assembly 17 Grease nipple including items 507 508 including items 507 Hex bolt 535 537 18 3 Brake lining wear gauge 508 Spring washer 535 Yoke 536 Clevis pin 20 Bearing bush 512 Tie rod assembly 537 Split pin including items 25 Mounting bracket 513 515 518 538 Hex nut 513 Tie rod tube 539 Bellows 66 Cam roller 514 Ball joint LH 540 Clamp Ball joint RH 541 Clamp 81 Camshaft assembly RH 515 Clamp induding items 18 3 84 88 3 516 Clamping plate 517 Clamping fork Trailing steering axle with LEAD system LEAD damping effect as a function of steering lock angle Steering stabilization is effected via the steering damper i e item 530 Steering control differential is no longer required Adjustment dimension B of the LEAD damper at 537 mm when engaged in the straight line position for the trailing steering axle When ordering spare parts quote correct axle identification serial no refer to t
18. 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 Safety inspection Check wheel brakes for correct adjustment Check service brake and hand brake efficiency Check truck trailer combination for brake compatibility Check service brake pressure to manufacturer s recommendation 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 Special service conditions Vehicles with long standing periods service at specified time intervals Vehicles used under extreme conditions service at suitably reduced intervals 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 for K RS RZ 14242 16242 axles Hub end float setting Lubricant specification Tighten hub nut while at the same time turning the Wheel bearings hub until slight resistance is felt SAF parts no 4 387 0011 05 Now slacken the hub nut by 1 12 of a turn until the Camshaft next locking position is reached Secure with split SAF parts no 4 387 0011 05 pin Stub axle lat i pul
19. d when adjusting screw 1 is backed off Operate the footbrake several times Check whether the brake drum rotates freely check the lining clearance and repeat adjustment procedure if necessary Automatic slack adjuster adjustment Type S ABA Set cams and brake shoes to released position Observe the correct push rod length L as indicated in the SAF specifications Membrane brake chamber Before installing the automatic slack adjuster ensure that the brake chamber push rod isin released position By contrast spring brake chambers must be under full operating pressure min 6 bar IMPORTANT If this is not maintained properly the basic setting will be wrong with critical effect of overheating the brakes Grease the camshaft Install anchor bracket 3 being sure to use two fixing bolts 4 do not yet tighten the bolts Install the slack adjuster on the camshaft The arrow 7 points in the braking direction Turn adjusting screw 1 until the bore in the slack adjuster 8 1 coincides with the bore in the clevis end 9 see drawing For the fixed point mounting ensure that the 2 U profiles engage firmly inside one another Grease split pin 8 and secure Install return spring 10 e Mount slack adjuster on camshaft e Axial clearance Adjust 0 5 2 mm using shims e Adjust control arm e Possible adjustment range for control lever position Slack adjuster up to its end positi
20. e drum fixing flanges Wheel bearing inserter N N 10114GB Edition 0802 Exploded view of SK RS RZ 9042 11242 axle assembly Torque wrench settings Use torque wrench Wheel nuts U bolts Shock absorber The use of impact Spigot hub centred fixing diagonally in M 24 400 Nm wrenches is not accepted M 22x 1 5 600 Nm three stages Bolt centred fixing M 24 700 Nm M 22 x 1 5 430 Nm M 22 650 Nm M 20 500 Nm Production number right direction of travel 09 10114GB Edition 0802 SK RS RZ 9042 11242 Item Parts designation Item Parts designation 01 Axle beam assembly 64 Brake shoe assembly including items 3 6 010 19 including items 65 71 73 22 22 1 25 65 Brake shoe with item 66 3 Spherical mounting plate 66 Cam roller 4 Protection plug 4 1 Protection plug axle tube 70 Lining service group 5 Ball including items 71 72 73 6 Camshaft bearing brake carrier side 71 Brake lining cam roller side 6 1 Riffle bolt 72 Brake lining ball side 6 2 Hex nut 73 Rivet 010 Camshaft bearing assembly 74 Spring clip linkage adjustment side 75 Return spring including items 12 15 18 12 Camshaft bearing with ABS 15 Hex bolt 76 Bracket sensor 18 Bellows 76 2 Hex bolt 78 ABS sensor 18 3 Brake lining wear gauge 19 O ring Hub nut 081 Camshaft assembly LH 20 O ring Stub axle including items 18 3 85 1 88 1 22 Hub nut RH thread 22 1 Hub nut LH thread 082 Camshaft assembly RH 25 Brake cylinder suppor
21. e 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 daims 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 bass for a legal claim Reprinting reproduction or translation in whole or in part is not permitted The issue of this publication inval
22. embly tools SAF parts no 9030 11030 12030 Hub nut spanner 2 012 0023 00 Hub puller 3 301 0010 00 or 4 434 3822 00 Wheel bearing oil seal inserter 3 434 1014 00 Mounting drifter for wheel bearing 3 434 3308 00 Inserter for MS bushing 1 434 1055 00 Puller for MS bushing 1 434 1056 00 Clamping rings for brake drum damping flanges 3 434 1060 00 E 10114GB Edition 0802 Exploded view of SK RS RZ 9030 11030 RZ 12030 axle assembly Torque wrench settings Use torque wrench Wheel nuts U bolts Shock absorber The use of impact Spigot hub centred fixing diagonally in M 24 400 Nm wrenches is not accepted M 22 x 1 5 600 Nm three stages Bolt centred fixing M 24 700 Nm M 22 x 1 5 430 Nm M 22 650 Nm M 20 500 Nm Production number right direction of travel B 10114GB Edition 0802 SK RS RZ 9030 11030 RZ 12030 Item Parts designation Item Parts designation 01 Axle beam assembly 70 Brake lining set including items 3 8 010 22 including items 71 72 73 3 Spherical mounting plate 71 Brake lining cam roller side 5 Ball 72 Brake lining ball side 6 Bearing bush 73 Rivet 8 Grease nipple 74 Spring clip 010 Camshaft bearing assembly 75 Return spring including items 11 13 14 18 i 11 Spherical bush housing with ABS 12 Spherical bearing bush 77 Exciter 12 1 Grease nipple 78 ABS sensor 13 O ring 80 1 Protective hose 80 2 Clamp 14 Hex bolt assembly 80 3 Clamp including items 15 17 15 Hex bolt 081 Camshaft as
23. fter 500 000 km or 50 months whichever comes first Check condition of taper roller bearings and replace if necessary Lubricate camshaft bearings after every brake lining replacement however at least every 12 months Visual inspection for wear damage 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 Safety inspection Check wheel brakes for correct adjustment Check service brake and hand brake efficiency Check truck trailer combination for brake compatibility Check service brake pressure to manufacturer s recommendation 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 Special service conditions Vehicles with long standing periods service at specified time intervals Vehicles used under extreme conditions service at suitably reduced intervals Warranty claims will only be accepted as long as the operating and maintenance instructions have been
24. g diagonally in M 24 400 Nm wrenches is not accepted M 22 x 1 5 600 Nm three stages Bolt centred fixing M 24 700 Nm M 22 x 2 430 Nm M 22 650 Nm M 22 x 1 5 430 Nm M 20 500 Nm 091 9726 Type plate Production number right direction of travel S 10114GB Ecition 0802 SK RS RZ 12242 Item Parts designation Item Parts designation 01 Axle beam assembly 70 Lining service group including items 3 5 including items 71 72 73 3 Spherical mounting plate 71 Brake lining cam roller side 5 Ball 72 Brake lining ball side 6 Camshaft bearing brake carrier side 73 Rivet 6 1 Riffle bolt 6 2 Hex nut 74 Spring clip 75 Return spring 010 Camshaft bearing assembly linkage adjustment side with ABS including items 12 15 18 77 Exciter 12 Camshaft bearing 78 ABS sensor 15 Hex bolt 80 1 Protective hose 18 Bellows 80 2 Clamp 80 3 Clamp 18 3 Brake lining wear gauge 22 Hub nut with dowel 081 Camshaft assembly RH 23 Circlip including items 18 3 85 1 88 1 24 Locknut 25 Brake cylinder support 082 Camshaft assembly LH 27 Hub unit including items 18 3 85 1 88 1 29 Brake drum 85 1 Disc spring 86 Spring clip 30 Wheel bolt assembly 87 Washer including items 31 34 88 Washer 31 Riffle bolt 88 1 Spring clip 34 Wheel nut with pressure plate 89 Mechanical slack adjuser 35 Taper roller bearing 36 Taper roller bearing with automatic adjustment 37 Grease seal 89 1 Automatic slack adjuster 38 Inner seal ring 89 2 Anchor plate RH 38
25. g arm spring assembly 237 Spring washer induding items 211 214 239 Hex nut 240 Mounting plate 210 Thrus block 240 1 Air suspension mounting 211 Retainer plate bracket 214 Bearing bush HD 242 Clamping plate 219 Spring seat 220 U bolt kit induding items 221 223 221 U bolt When ordering spare parts quote correct axle identification serial no refer to the axle type plate 3 10114GB Edition 0802 Air Suspension Series O Torque wrench settings Refer to appropriate axle type maintenance chart for more detailed maintenance instructions Maximum adjustment of hanger bracket using eccentric bush 208 6 mm Tightening directions Tighten spring seat and shock absorber fixings at the ride height Parts are ready to be assembled the threads must not be oiled or greased Pivot clamping bolt assembly Torque tightening procedure Pre tighten to 400 Nm final tightening torque 120 see page 44 120 rotation 2 flats of the nut Shock absorber fixing 232 2 400 Nm Air bag hexagon head bolt steel immersion piston 236 80 Nm Air bag self tapping bolt plastic immersion piston 236 1 20 Nm Air bag mounting bolt 235 2 180 Nm Air suspension bag upper 239 239 40 Nm U bracket see axle type in question 3 10114GB Ecition 0802 Air Suspension Series O Item Parts designation Item Parts designation 1 Axle assembly 222 Washer 223 Hex nut 100 Front hanger bracket 228 Shock absorber 230 Hex bolts 104 Spig
26. h 512 Tie rod assembly 8 Hex bolt including items 513 515 9 Hex nut 518 513 Tie rod tube 16 Grease nipple 514 Balljoint LH 17 Grease nipple Ball joint RH 515 Clamp 18 3 Brake lining wear gauge 25 Mounting bracket LH 516 Clamping plate Mounting bracket RH 518 Bolt kit 81 Camshaft assembly RH including items 519 520 including items 18 3 519 Hex bolt 84 88 3 520 Hex nut 82 Camshaft assembly LH 527 Blocking cylinder including items 18 3 528 Cylinder screw 84 88 3 84 O ring 530 Steering control 84 1 Spacer ring differential 86 Circlip including items 531 533 87 Washer 534 538 541 88 Washer 531 Membrane cylinder 532 Bevelled washer 88 1 Spring dip 533 Push rod 88 3 Bellows including items 535 537 When ordering spare parts quote correct axle identification serial no refer to the axle type plate Fl 10114GB Edition 0802 Exploded view SK RLZ 9030 11030 axle assembly Torque wrench settings Use torque wrench Wheel nuts U bolts Shock absorber The use of impact Spigot hub centred fixing diagonally in M 24 400 Nm wrenches is not accepted M 22 x 1 5 600 Nm three stages Bolt centred fixing y EER Nm M 22 x 1 5 430N m KOPAR M 20 500 Nm 3 1 3 2 For brake and wheel mounting parts refer to the corresponding axle drawing e g SK RS RZ 9030 E 10114GB Edition 0802 SK RLZ 9030 11030 Item Parts designation Item Parts designation Item Parts designation 01 Axle beam assembly with auto
27. he axle type plate FA 10114GB Edition 0802 Exploded view SK RLZ 9037 11037 axle assembly Torque wrench settings Use torque wrench Wheel nuts U bolts Shock absorber The use of impact Spigot hub centred fixing diagonally in M 24 400 Nm wrenches is not accepted M 22 x 1 5 600 Nm three stages Bolt centred fixing M 24 700 Nm M 22 x 1 5 430 Nm M 22 650 Nm 3 1 3 2 88 3 lt 88 1 Q 183 AD 84 1 90 88 87 S For brake and wheel mounting parts 84 E refer to the corresponding axle drawing e g SK RYRZ 9037 H 10114GB Edition 0802 SK RLZ 9037 11037 Item Parts designation Item Parts designation Item Parts designation 01 Axle beam assembly with automatic adjustment 534 Yoke assembly including items 1 1 1 3 89 1 Automatic slack adjuster including items 1 1 Mounting bracket LH 89 2 Anchor plate RH 535 537 1 2 Mounting bracket RH 89 3 Anchor plate LH 535 Yoke 1 3 Reversing lock complete 536 Clevis pin 1 4 Damper connection 90 Return spring 537 Splint pin 538 Hex nut 3 1 Steering knuckle 501 Pivot pin 539 Bellows assembly LH 502 Pressure plate top 540 Clamp including items 4 9 503 Presure plate bottom 541 Clamp 16 20 22 1 25 501 506 504 O ring 505 Cover plate 3 2 Steering knuckle 505 1 Gasket assembly RH including items 4 9 506 Bolt kit 16 20 22 25 501 506 including items 507 508 4 Bush 507 Hex bolt 5 Ball 508 Spring washer 6 Bearing bush 7 Bearing bus
28. hicles 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 tne 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 Jne dally 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 Thes
29. idates all earlier maintenance and repair manuals 10114GB Edition 0802 10114GB Edition 0802 for SK RS RZ 9042 11242 axles and suspension units steering axle see p 30 33 Service schedule ry ry every Mileage intervals gt 30 000 km 90 000 km 150 000 km whichever comes first Time intervals gt every every every month 3 months 6 months 12 months Mechanical check Note Torque check wheel nuts after the first 50 km and 150 km and after every wheel removal Torque check all nuts and bolts to recommended setting 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 Lubricate camshaft bearings after every brake lining replacement however at least every 12 months Visual inspection for wear damage 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 Safety inspection Check wheel brakes for correct adjustmen
30. ine 10 a groove milled into the hex outside BRAKE type SNK 420 Max permissible turned brake drum bore Brake drum bore with max permissible wear SAF approved brake linings Pretighten to 150 Nm whilst rotating drum For final torque continue tightening through Hub nuts with LH threads are marked with 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 d 1st oversize 422 0 nominal size 420 0 424 0 mm 425 0 mm d 2nd oversize 424 0 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 Brake size SAF parts no Brake drum brake lining brake lining refacing stages in mm Brake linings Rivets Nominal size 1st oversize 2nd oversize number per axle SNK 420 dy 420 0 dy 422 0 d 424 0 DIN 7338 rivet x 180 1 057 0060 00 1 057 0061 00 20 6 20 0 21 6 21 0 22 6 22 0 x 200 1 057 0066 00 1 057 0067 00 20 6 20 0 21 6 21 0 22 6 22 0 Assembly tools 9042 11242 SAF parts no 1 012 0024 00 3 349 1001 00 3 434 1040 01 3 434 1043 00 Hub nut spanner Brake shoe clamping device Brak
31. inings BERAL 1561 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 Brake SAF parts no Brake drum brake lining ER DIN 7338 size brake lining refacing stages in mm Brake linings Rivets rivet Nominal size 1st oversize 2nd oversize number per axle SNK 367 d 367 0 d 369 0 d 371 0 x 180 1 057 0068 00 21 1 22 1 23 1 1 057 0069 00 20 5 21 5 22 5 x 200 1 057 0070 00 21 1 22 1 23 1 1 057 0071 00 20 5 21 5 22 5 Assembly tools SAF parts no 9037 11037 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 1059 00 Puller for MS bushing 1 434 1056 00 Bushing tool for MS bushing 1 434 1055 00 E 10114GB Edition 0802 Exploded view of SK RS RZ 9037 11037 axle assembly Torque wrench settings Use torque wrench Wheel nuts U bolts Shock absorber The use of impact Spigot hub centred fixing diagonally in M 24 400 Nm wrenches is not accepted M 22x 1 5 600 Nm three stages Bolt centred fixing M 24 700 Nm M 22x 1 5 430 Nm M 22 650 Nm M 20 500 Nm Type plate Production number right direction of travel B 10114GB Edition 0802 SK RS RZ 9037 11037 Item Parts designation Item Parts designation 01 Axle beam assembly 64 Brake shoe assembly including items 3 6 010
32. ke lining wear gauge 21 Thrust washer 082 Camshaft assembly LH 22 Hub nut including items 18 3 84 88 1 23 Splint pin 84 O ring 25 Brake cylinder support 84 1 Spacer ring 27 Hub unit 85 Seal ring 28 Grooved pin 85 1 Disc spring 29 Brake drum 86 Spring clip 87 Washer 30 Wheel bolt assembly 88 Washer including items 31 34 88 1 Spring clip 31 Wheel bolt 32 Hex nut 89 Mechanical slack adjuster 34 Wheel nut with pressure plate with automatic adjustment 35 Taper roller bearing 89 1 Automatic slack adjuster 36 Taper roller bearing 89 2 Anchor plate RH 37 Grease seal 89 3 Anchor plate LH 40 Hub cap 90 Return spring 059 Brake assembly including items 64 74 75 091 Dust cover assembly including items 92 99 64 Brake shoe assembly 92 Dust cover RH including items 65 71 73 93 Dust cover LH 94 Plug 65 Brake shoe with item 66 95 Cable clamp 66 Cam roller 96 Hex bolt 97 Clamp 70 Lining service group 98 Plug including items 71 72 73 71 Brake lining cam roller side 99 Rubber grommet ABS 72 Brake lining ball side When ordering spare parts quote correct axle identification serial no refer to the axle type plate X 10114GB Edition 0802 10114GB Edition 0802 for SAF Disc brakes axle types SK RS RZ 9022 K 11222 K 22 5 and 9019 K 11019 K 19 5 Periodic checks Service schedule after first x Mileage intervals gt 5 000 km 30 000 km 150 000 km Whichever comes first et after first every every Time in
33. ler and pull hub back against outer SAF parts no 4 387 0015 06 Pack hub cap thread with grease and refit hub cap SAP UENO Rae Check whether the hub rotates freely and without Brake anchor bracket ball excessive end float adjust if necessary SAF parts no 4 387 0007 00 Copper paste Never mix different types or grades of grease Hub nut tightening 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 Ss v X Clean stub axle and apply fresh SAF fitting ze BO gO paste ES N a SX 5 lane 7g Brake type SNK 420 g a N 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 BREM SKERL 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 Brake SAF parts no Brake drum brake lining an DIN 7338 size brake lining refacing stages in mm Brake linings Rivets rivet Nominal size 1st oversize 2nd oversize number per axle SNK 420 420 0 d 422 0 d 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
34. m Green assembly grease 064 l White assembly grease Driving P direction a Disc brake type SB 7 Disc brake type SN 7 SK RS RZ 9022 K 11222 K 9019 K 11019 K Item Parts designation Item Parts designation 01 Axle beam assembly 59 60 Brake calliper assembly 4 Protective plug ABS including items 61 62 65 66 4 1 Protective plug axle tube 70 81 19 O ring 064 Brake pad set 20 O ring including items 63 64 1 64 2 22 Axle nut RH 22 1 Axle nut LH 66 Tappet with boot including items 66 1 66 2 27 Wheel hub unit complete including item 27 2 70 Guide pin group 27 2 Wheel bearing repair kit including items 70 1 70 4 including items 27 3 38 38 1 27 3 Bearing grease with ABS 76 Bracket sensor 29 Brake disc 76 2 Hex bolt 78 ABS sensor 30 Wheel bolt assembly including items 31 34 80 Guide pin group Bush 1 095 1040 00 not included folding bellows 31 Wheel bolt including items 80 1 80 3 82 34 Wheel bolt nut 81 Guide pin group 38 Seal ring steel cap 38 1 Seal ring including items 80 4 80 5 81 1 81 2 83 39 O ring This guide pin group 81 should 40 Wheel cap where possible be used for repairs including items 39 41 40 1 Wheel cap with pole wheel 41 Plug 56 Hex bolt 56 1 Shoulder bolt Important Check the sliding action of the calliper housing for free movement over the total range with pads removed Repair kits for SAF disc brakes SK RS RZ 9022 K 11222 K 9019 K 11019 K
35. matic adjustment 534 Yoke assembly including items 1 1 1 3 89 1 Automatic slack adjuster including items 1 1 Mounting bracket LH 89 2 Anchor plate RH 535 537 1 2 Mounting bracket RH 89 3 Anchor plate LH 535 Yoke 1 3 Reversing lock complete 536 Clevispin 1 4 Damper connection 90 Return spring 537 Splint pin 3 1 Steering knuckle 501 Pivot pin 538 Hex nut assembly LH 502 Pressure plate top 539 Bellows including items 4 9 503 Presure plate bottom 540 Clamp 16 20 22 1 25 501 506 504 O ring 541 Clamp 505 Cover plate 3 2 Steering knuckle 505 1 Gasket assembly RH including items 4 9 506 Bolt kit 16 20 22 25 501 506 including items 507 508 4 Bush 507 Hex bolt 5 Ball 508 Spring washer 6 Bearing bush 7 Bearing bush 512 Tie rod assembly 8 Hex bolt including items 9 Hex nut 513 515 518 513 Tie rod tube 16 Grease nipple 514 Balljoint LH 17 Grease nipple Ball joint RH 515 Clamp 18 3 Brake lining wear gauge 25 Mounting bracket LH 516 Clamping plate Mounting bracket RH 518 Bolt kit 81 Camshaft assembly RH mit Teilen 519 520 including items 18 3 519 Hex bolt 84 88 3 520 Lock nut 82 Camshaft assembly LH 527 Blocking cylinder including items 18 3 528 Cylinder screw 84 88 3 84 O ring 530 Steering control 84 1 Spacer ring differential 86 Lock ring including items 531 533 87 Washer 534 538 541 88 Washer 531 Membrane cylinder 88 1 Spring dip 532 Bevelled washer 88 3 Bellows 533 Push rod When ordering s
36. mbly Use a vacuum cleaner to remove brake dust Never use pressurised cleaning devices or cleaning fluids on the brake drum and hub Ex g X Clean stub axle and apply fresh SAF fitting 3 8S so paste paste J 5 qe 38 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 Brake SAF parts no Brake drum brake lining at DIN 7338 size brake lining refacing stages in mm Brake linings Rivets rivet Nominal size 1st oversize 2nd oversize number per axle SNK 420 d 420 0 d 422 0 d 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 Assembly tools SAF parts no N 12242 D Hub nut spanner 2 012 0023 00 5 Hub puller 3 301 0010 00 f Universal puller for wheel hub 4 434 3822 00 fej Bearing inner race 4 434 3820 00 g Wheel bearing oil seal inserter 3 434 3320 00 x Sealing ring inserter 3 434 1036 00 g Brake shoe clamping device 3 349 1001 00 T Exploded view of SK RS RZ 12242 axle assembly Torque wrench settings Use torque wrench Wheel nuts U bolts Shock absorber The use of impact Spigot hub centred fixin
37. nditions service at suitably reduced intervals 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 for SK RS RZ 9022 K 11222 K 22 5 and 9019 K 11019 K 19 5 axles Hub end float setting lubricant Hub end float adjustment is not necessary Replace wheel bearing grease after 500 000 km or 50 months whichever comes first Check condition of taper roller bearings at grease change and replace if necessary Replace O ring 39 and fit the wheel cap After brake relining observe the following points Inspect the seals on the brake calliper Do not dismantle the wheel bearing assembly Never use high pressure cleaners or cleaning fluids on the brake disc or wheel hub Clean stub axle of any old grease and apply fresh SAF fitting paste Hub nut tightening LH direction of travel LH thread RH direction of travel RH thread Pretighten to 150 Nm whilst rotating wheel hub and disc 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 NOTE Failure to abserve these instructions may result in an accident risk Worn brake linings or excessively worn brake discs result in a reduction in the braking efficiency or in a complete failure of the brake system Thickness of Wear limi
38. ng to the tyre manufacture specifications To avoid excessive tyre wear we recommend having the alignment checked at regular intervals Deviations may be caused by e loose U bolts e spring guide bearing wear e deformation of axle assembly components due to improper use The relevant reference point for alignment is the hub cap centre or stub axle centre 10114GB Edition 0802 A Axle types K 14242 16242 Tighten hub nut while at the same time turning the hub until slight resistance is felt Now slacken the hub nut by 1 12 of a turn until the next locking position is reached Secure with split pin Using hub puller pull hub back against outer bearing Check whether the hub rotates freely and without excessive end float adjust if necessary Pack hub cap thread with grease and refit hub cap tightening it to 400 Nm Axle type SK 12242 Tighten hub nut to a torque of 150 Nm at the same time rotating the hub and drum Locate the locking collar onto the dowel on the hub nut noting the position of the dowel in relation to the collar Remove the collar and turn the hub nut 2 1 2 holes anti clockwise Reverse the collar and re locate it onto the repositioned hub nut dowel Fit the lock nut and tighten using a torque of 400 Nm Check whether the hub rotates freely and without excessive end float adjust if necessary Replace gasket and fit hub cap Axle types SK 9042 SK 9037 SK 9022
39. nths 6 months 12 months Whichever comes first Time intervals gt Mechanical check Note Torque check wheel nuts after the first 50 km and 150 km and after every wheel removal Torque check all nuts and bolts to recommended setting Check and adjust hub end float if required Pack wheel bearings with fresh grease after 300 000 km or 36 month whichever comes first Check condition of taper roller bearings and replace if necessary Lubricate camshaft bearings after every brake lining replacement however at least every 12 months Visual inspection for wear damage 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 Safety inspection Check wheel brakes for correct adjustment Check service brake and hand brake efficiency Check truck trailer combination for brake compatibility Check service brake pressure to manufacturer s recommendation Check air suspension for correct ride height With 2 levelling valves the max permissible bellows pressu
40. on without applying excessive force oa T e Adjust running clearance between brake lining and drum by turning adjusting screw 1 in clockwise direction until the lining fits smoothly against the drum Then back off adjusting screw 1 by 3 4 turn Do not use impact wrenches FUNCTION CHECK e If the self adjuster is functionning correctly then a minimum torque of 18 Nm must be felt and a grating noise must be heard when adjusting screw 1 is backed off e Operate the footbrake several times Check whether the brake drum rotates freely check the lining clearance and repeat adjustment procedure if necessary Fa 10114GB Edition 0802 For axle alignment the air suspension ride height must be adjusted to the values specified by SAF Semi trailers with trailing steering axle Distance A B C max permissible deviation 1 0 mm Toe setting 12 3 0 mm m Camber 12 values apply to unloaded vehicle In the case of self steering axles the stabilizing chambers must be pressurised to 2 0 bar Total toe in 4 0 mm m a Trailer Distance A B C max permissible deviation 1 0 mm Toe setting 12 3 0 mm m Camber 12 values apply to unloaded vehicle The max permissible deviation values for axle aligment are accordi
41. ot flange 232 1 Washer 232 2 Hex nut 200 Hex bolt assembly 232 3 U washer induding items 201 202 233 Mounting plate 201 Hex bolt M30 202 Lock nut M30 234 Air bellows 207 U Profiles 235 1 Hex bolt 208 Eccentric bush 235 2 Lock nut 208 1 Thrus washer 236 Hex bolt 236 1 Self tapping screw 209 Trailing arm spring assembly 237 Spring washer induding items 211 214 239 Hex nut 240 Mounting plate 210 Thrus block 240 1 Air suspension mounting 211 Retainer plate bracket 214 Bearing bush HD 242 Clamping plate 219 Spring seat 220 U bolt kit induding items 221 223 221 U bolt When ordering spare parts quote correct axle identification serial no refer to the axle type plate 10114GB Edition 0802 Air Suspension Series U Torque wrench settings Refer to appropriate axle type maintenance chart for more detailed maintenance instructions Maximum adjustment of hanger bracket using eccentric bush 208 6 mm Tightening directions Tighten spring seat and shock absorber fixings at the ride height Parts are ready to be assembled the threads must not be oiled or greased Pivot clamping bolt assembly Torque tightening procedure Pre tighten to 400 Nm final tightening torque 120 see page 44 120 rotation 2 flats of the nut Shock absorber fixing 232 2 400 Nm Air bag hexagon head bolt steel immersion piston 236 80 Nm Air bag self tapping bolt plastic immersion piston 236 1 20 Nm Air bag mounting bolt 235 2 180 Nm
42. pare parts quote correct axle identification serial no refer to the axle type plate w El 10114GB Edition 0802 Air Suspension Series M Torque wrench settings Refer to appropriate axle type maintenance chart for more detailed maintenance instructions Maximum adjustment of hanger bracket using eccentric bush 208 6 mm Tightening directions Tighten spring seat and shock absorber fixings at the ride height Parts are ready to be assembled the threads must not be oiled or greased Pivot clamping bolt assembly Torque tightening procedure Pre tighten to 400 Nm final tightening torque 120 see page 44 120 rotation 2 flats of the nut Shock absorber fixing 232 2 400 Nm Air bag hexagon head bolt steel immersion piston 236 80 Nm Air bag self tapping bolt plastic immersion piston 236 1 20 Nm Air bag mounting bolt 235 2 180 Nm Air suspension bag upper 239 40 Nm U bracket see axle type in question Fj 10114GB Ecition 0802 Air Suspension Series M Item Parts designation Item Parts designation 1 Axle assembly 222 Washer 223 Hex nut 100 Front hanger bracket 228 Shock absorber 230 Hex bolts 104 Spigot flange 232 1 Washer 232 2 Hex nut 200 Hex bolt assembly 232 3 U washer induding items 201 202 233 Mounting plate 201 Hex bolt M30 202 Lock nut M30 234 Air bellows 207 U Profiles 235 1 Hex bolt 208 Eccentric bush 235 2 Lock nut 208 1 Thrus washer 236 Hex bolt 236 1 Self tapping screw 209 Trailin
43. re difference LH to RH vehicle side is 0 2 bar Special service conditions Vehicles with long standing periods service at specified time intervals Vehicles used under extreme conditions service at suitably reduced intervals 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 for SK RS RZ 12242 axles Hub end float setting Lubricant specification Tighten hub nut 22 to a torque of 150 Nm at the Wheel bearings same time rotating the hub and drum SAF parts no 4 387 0011 05 Locate the locking collar 23 onto the dowel on the Camshaft hub nut noting the position of the dowel in relation SAF parts no 4 387 0011 05 to the collar Remove the collar and turn the hub nut 2 1 2 holes anti clockwise Reverse the collar and Stub axle re locate it onto the repositioned hub nut dowel SAF parts no 4 387 0015 06 Fit the lock nut 24 and tighten using a torque of SAF fitting paste 400 Nm Brake anchor bracket ball Check whether the hub rotates freely and without SAF parts no 4 387 0007 00 excessive end float adjust if necessary Copper paste Replace O ring 39 and fit the wheel cap Never mix different types or grades of grease Hub nut tightening 7 After brake relining lubricate camshaft _ bearings whilst rotating the camshaft through 360 several times Do not disassemble the wheel bearing asse
44. ring repair work to undo the pivot clamping bolt assembly In this case the following combined torque angle tightening method must be used for reassembly Preparatory steps e Carefully clean all mating surfaces of pivot HD bush from oil and grease to prevent damage to rubber joints e Assemble pivot damping bolt assembly as shown in the drawing e Adjust ride height according to vehicle manufacturer s specifications AIR SPRING 1 Pretightening torque Use a torque wrench for pretightening the lock nut to 400 Nm width across flats 46 Pretightening to 400 Nm 2 Angle tightening to final torque Continue turning nut through 120 two flats Correctly following this procedure means no further tightening will be necessary Finish tightening through 120 Use an impact wrench or extend lever to L 2 5m Apply marking and inspect visually FS 10114GB Edition 0802 Air suspension adjusting the ride height Adjust ride height according to vehicle manufacturer s specifications Changes are not permissible because they can lead to damage to axle components The ride height is the distance between the axle beam centre and the lower frame edge Set the angle 2 between the valve lever 1 and link rod 3 so that the valve lever does not reverse at maximum air bellows extension Adjust the ride height using the setting screw 4 NOTE Park vehicle on a flat surface Release hand brake Do not use
45. rings for damage scoring and corrosion Check self steering axle for correct function Check tyre wear and tracking if required Safety inspection Check wheel brakes for correct adjustment Check service brake and hand brake efficiency Check truck trailer combination for brake compatibility Check service brake pressure to manufacturer s recommendation 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 Special service conditions Vehicles with long standing periods service at specified time intervals Vehicles used under extreme conditions service at suitably reduced intervals 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 for SK RS RZ 9030 11030 RZ 12030 axles Hub end float setting Tighten hub nut 22 to a torque of 150 Nm at the same time rotating the hub and drum Locate the locking collar 23 onto the dowel on the hub nut noting the position of the dowel in relation to the collar Remove the collar and turn the hub nut 2 1 2 holes anti clockwise Reverse the collar and re locate it onto the repositioned hub nut dowel Fit the lock nut 24 and tighten using a torque of 400 Nm Check whether the hub rotates freely and without excessive end float adjust if necessary Replace O
46. sembly RH 16 Spring washer including items 18 3 84 88 1 17 Hex nut iss Bellows 082 Camshaft assembly LH 18 3 Brake lining wear gauge including items 18 3 84 88 1 22 Hub nut with dowel 84 O ring 23 Circlip 84 1 Spacer ring 24 Locknut fe A a ring 25 Brake cylinder support ISC spring 27 Hub unit Be pring dip 29 Brake drum asner 88 Washer 30 Wheel bolt assembly 88 1 Spring clip 31 nending items PIGRA with automatic adjustment i 89 1 Automatic slack adjuster 34 Wheel nut with pressure plate 89 2 Anchor plate RH 35 Tapper roller bearing 89 3 Anchor plate LH 36 Tapper roller bearin 37 SERS seal g 90 Return spring 38 Inner seal ring 38 1 Protective ring 091 a oer amy 38 2 Outer seal ring including items 92 39 O rin 92 Dust cover RH 40 Hub ap 93 Dust cover LH Wen eae ty By 94 Plug Pe one with items 39 41 95 Cable clamp g 96 Hex bolt 059 Brake assembly Amp including items 64 74 75 ug 64 Brake shoe assembly 99 Rubber grommet ABS including items 65 71 73 65 Brake shoe with item 66 66 Cam roller When ordering spare parts quote correct axle identification serial no refer to the axle type plate EB 10114GB Edition 0802 10114GB Edition 0802 for SAF SK RS RZ 12242 axles and suspension units steering axle see p 30 33 Periodic checks Service schedule After first ee 5 000 km ey Mileage intervals gt or 130 000 km 90 000 km 150 000 km after first every every every month 3 mo
47. t Check service brake and hand brake efficiency Check truck trailer combination for brake compatibility Check service brake pressure to manufacturer s recommendation 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 Special service conditions Vehicles with long standing periods service at specified time intervals Vehicles used under extreme conditions service at suitably reduced intervals 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 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 Hub nut tightening LH direction of travel LH thread RH direction of travel RH thread one more scale l
48. t including items 18 3 85 1 88 1 27 Hub unit complete 85 1 Disc spring with item 27 2 86 Spring clip 27 2 Repair kit including items 87 Washer 27 3 38 39 88 Washer 27 3 Bearing grease 88 1 Spring clip 29 Brake drum with automatic adjustment 30 Wheel bolt assembly 89 1 Automatic slack adjuster including items 31 34 89 2 Anchor plate RH 31 Riffle bolt 89 3 Anchor plate LH 34 Wheel nut 90 Return spring 38 Inner seal ring 38 1 Outer seal ring 091 Dust cover assembly 39 O ring Hub cap including items 92 98 99 92 Dust cover RH 40 Hub cap complete with items 39 41 93 Dust cover LH 40 1 Hub cap complete with pole wheel 94 Plug and items 39 41 95 Cable clamp 41 Plug 96 Hex bolt 97 Clamp 059 Brake assembly 98 Plug including items 64 74 75 99 Rubber grommet ABS When ordering spare parts quote correct axle identification serial no refer to the axle type plate o 10114GB Edition 0802 10114GB Edition 0802 for SK RS RZ 9037 11037 axles and suspension units steering axle see p 34 35 Service schedule ry Mileage intervals gt 30 000 km 90 000 km 150 000 km whichever comes first Time intervals gt ry month 3 months 6 months 12 months Mechanical check Note Torque check wheel nuts after the first 50 km and 150 km and after every wheel removal Torque check all nuts and bolts to recommended setting Hub end float adjustment not required Pack wheel bearings with fresh grease a
49. t of Thickness of Brake type l nic brake disc A brake disc B linings C Lubricant specification Wheel bearings SAF parts no 4 387 0011 05 Tappet boots and brass bushes SAF parts no 4 387 0016 00 Rubber guide bush 70 3 SAF parts no 4 387 0017 01 Stub axle SAF parts no 4 387 0015 06 SAF fitting paste inmm Disc diameter No of brake pads per axle SB7 22 5 45 lt 37 30 430 4 SB6 19 5 45 30 Item No Tightening torque Nm 377 Spanner size W A F 4 Hexagon outside inside 70 6 70 7 Guide bearing on brake calliper 2 hex socket head screws 290 M16 x 1 5 10 9 14 X Diaphragm combination cylinder 2 hex nuts 210 M16x1 5 24 Brake calliper mounting on axle body M16x1 5x55 Assembly tools Hub nut spanner Puller for wheel hub Lever for wheel hub SAF parts no 1 012 0024 00 4 434 3822 00 1 434 1041 00 N N 10114GB Edition 0802 Exploded view of SK RS RZ 9022 K 11222 K 9019 K 11019 K Torque wrench settings Use torque wrench Wheel nuts U bolts Shock absorber The use of impact Spigot hub centred fixing diagonally in M 24 400 Nm wrenches is not accepted M 22 x 1 5 600 Nm three stages Bolt centred fixing M 22 650 Nm NI 10114GB Edition 0802 up to February 2002 Knorr from March 2002 Knorr M 22x 1 5 430 N
50. teering knuckle bearing Grease the first time after 1 month then every 6 months LEAD systems have no stabilizing cylinders 530 Adjustment dimension B of the LEAD damper at 537 mm when engaged in the straight line position for the trailing steering axle and the reversing block El 10114GB Edition 0802 Exploded view of SK RLS 9042 11242 Torque wrench settings Use torque wrench Wheel nuts U bolts Shock absorber The use of impact Spigot hub centred fixing diagonally in M 24 400 Nm wrenches is not accepted M 22x1 5 600 Nm three stages Bolt centred fixing M 24 700 Nm M 22 x 1 5 430 Nm M 22 650 Nm 3 1 3 2 I 90 g gq 8 For brake and wheel mounting parts 5 081 082 refer to the corresponding axle drawing m e g SK RYRZ 9042 SK RLS 9042 11242 Item Parts designation Item Parts designation Item Parts designation 01 Axle beam assembly 82 Camshaft assembly LH 518 Bolt kit induding items 1 1 1 4 including items 18 3 including items 1 1 Mounting bracket LH 84 88 3 519 520 1 2 Mounting bracket RH 84 O ring 519 Hex bolt 1 3 Reversing lock complete 84 1 Spacer ring 520 Lock nut 1 4 Damper connection 86 Lock ring 87 Washer 522 Bolt kit 3 1 Steering knuckle 88 Washer including items assembly LH 88 1 Spring clip 523 525 induding items 4 9 88 3 Bellows 523 Hex bolt 16 17 19 20 22 1 25 525 Lock nut 501 506 with automatic adjustment 89 1 Automatic slack adjuster 526 Steering d
51. tervals gt month 3 months 12 months Mechanical check Note Torque check wheel nuts after the first 50 km and 150 km and after every wheel removal Torque check all nuts and bolts to recommended setting e 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 Visual inspection for wear damage Check suspension components for wear fluid leakage and damage Check brake linings for wear Inspect all rubber sealing elements on the brake calliper when replacing brake linings Check brake system for leaks operate brakes Check air suspension system for leaks Check air bag for damage Clean piston surface if soiled Check parabolic springs for corrosion and damage Check self steering axle for correct function Check tyre wear and track widths if required Safety inspection Check wheel brakes for correct adjustment Check service brake and hand brake efficiency Check truck trailer combination for brake compatibility Check service brake pressure to manufacturer s recommendation 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 Special service conditions Vehicles with long standing periods service at specified time intervals Vehicles used under extreme co
52. wedges to keep the axle assembly in position for ride height adjustment Fill compressed air system to cut off pressure Levelling valve Frame side member NOTE In the case of air suspensions with two val ves for individual control on either vehicle side it is essential that both sides are adjusted to the same ride height Use two manometers for this purpose The difference in pressure between the LH and RH bellows must not exceed 0 2 bar Fa 10114GB Edition 0802 10114GB Edition 0802 Braking system checking and adjustment S cam brakes with manual slack adjusters Due to normal brake drum and brake lining wear the wheel brakes must be regularly adjusted in order to maintain the full brake cylinder stroke To ensure maximum brake efficiency the clea rance between brake lining and drum must be kept to an absolute minimum To determine this clearance check the brake cylinder stroke while full pressure is applied to the service brake If the path at the yoke end measures more than 2 3 of the maximum cylinder stroke then the brake must be adjusted without delay With a correctly adjusted brake it should be impossible to move the piston rod by hand more than 15 mm Turn adjusting screw to the right until the brake shoes fit closely to the brake drum No load absolutely no play is permis sible between the piston and membrane Turn adjusting screw to 3 SD the left until
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