Air suspensions O/S/A BPW BERGISCHE ACHSEN O S. BPW Original spare parts. Air suspensions series O / SL / AL / AC BPW ORIGINAL SPARE PARTS

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1 PW riginal spare parts Air suspensions /S/A PW ERGISCHE ACHSEN PW riginal spare parts Air suspensions series / / / AC S PW RIGIN SPARE PARTS A

2 PW riginal spare parts Air suspensions Contents Air suspension series Explanation of PW suspension type codes Page Explanation of PW code numbers Trailing arms Straight single leaf trailing arms Cranked single leaf trailing arms Straight double leaf trailing arms Cranked double leaf trailing arms Spring seats, axle clampings Welded axle spring seat assembly Clamped axle spring seat assembly Spring plates, segments Centering bolts, tracking plates Spring Ubolts Spring pivot bolt bearings Spare parts for spring pivot bolt bearings Repair kits Air bags Air bags Ø 300 Air bags Ø 360 Conversion from steel piston to plastic piston Spare parts for air bags Upper air bag attachments, spacers Shock absorbers, attachments Shock absorbers Upper shock absorber attachments ower shock absorber attachments Check straps, attachments Check straps Check strap attachments Hanger brackets, integrated supports Hanger brackets Integrated supports Spare parts for hanger brackets Changing the weldin bushes Ustabilizers rawbar attachments, air tanks Axle lifts EC Air CMPACT (AC) Spare parts for EC Air CMPACT (AC) Twosided axle lift for AC Side axle lift for AC Central axle lift for AC / 4 PWEuft e

3 PW riginal spare parts Air suspensions 10 rawbar attachments, 12 air tanks Hanger brackets, integrated supports , 170/171 8 Shock absorbers, shock absorber attachments Trailing arms Check straps Ustabilizers Axle lifts Spring pivot bolt bearings Air bags Axle clampings Spring plates Tracking plates Spring Ubolts Spare parts for EC Air CMPACT air suspensions see pages PWEuft e

4 Explanation of PW suspension type codes Example: H S F H A 3 / 9010 /12 A F30 EC Trailer axle rake H H.. SN 420 K K.. SN 360 N N.. SN 300 SH SH.. S 4309 / 4345; TS 4309 / 4312 SK SK.. S 3745; TS 3709 S Z I IZ F M H For single wheels, wheels with offset For single wheels, wheels without offset For twin wheels Wheel spiders for TRIEX wheel rims, single wheels Wheel spiders for TRIEX wheel rims, twin wheels Wheel studs M 22 x 1.5 without wheel nuts, order wheel nuts for stud or spigot alignment separately For spigot alignment For hanging boosters Air suspension series Ride height = straight overslung trailing arm M M = cranked overslung trailing arm MN MN = cranked overslung trailing arm 355 MT MT = cranked underslung trailing arm 290 T T = underslung trailing arm = straight overslung trailing arm M M = cranked overslung trailing arm U U = underslung trailing arm = straight overslung trailing arm M M = cranked overslung trailing arm MT MT = cranked overslung trailing arm U U = underslung trailing arm U U = Airlight irect ACAU ACAU = EC Air CMPACT ACAM ACAM = EC Air CMPACT ACM ACM = EC Air CMPACT AC AC = EC Air CMPACT A With axle lift device R With frame ( = ride height mm ) U With Ustabilizer With steering axle, series steering angle max. 40 With selfsteering axle, series steering angle max. 20 Single axle 2 / Tandem axle suspension 3 / Triaxle suspension 6006 to /12 to /40 Axle load (kg) + quantity of wheel studs per hub Steering angle of steering axle 4 PWEuft e

5 Explanation of PW suspension type codes Example: H S F H A 3 / 9010 /12 A F30 EC A C E G K S Alloy hanger brackets Integrated support Hanger brackets with top plate Hanger brackets without top plate Air bags with split piston Screwed on hanger brackets Taper mounted hanger brackets (70 mm wide) T With support ( trailing axle ) V X Y Adjustable hanger brackets With stainless steel hanger brackets Without mounted hanger brackets, hanger brackets separate 30 Air bag Ø 300 mm, for stroke 200 mm (standard) 301 Ø 300 mm, for stroke up to 340 mm 30 K Ø 300 mm, for stroke 150 mm 36 Ø 360 mm, for stroke 200 mm (standard) 361 Ø 360 mm, for stroke bis 340 mm 362 Ø 360 mm, for stroke bis 450 mm 36 K Ø 360 mm, for stroke 180 mm F30 Z Ø 300 mm, central on the trailing arm Without mounted air bags, air bags separate EC Single axle with PW EC hub system 1996 (1998) ECMAXX Weightoptimized ECaxle 2003 EC Plus Weightoptimized axle with PW EC Plus 2003 hub system EC Plus 2 Weightoptimized axle with EC Plus 2 Unit 2007 MAXX Weightoptimized axle with conventional hub bearing system Valid: This spare parts list shows fast moving parts for air suspension bogies of the series.. /.. / tonnes and EC Air CMPACT. For further spare parts see PW spare parts catalogue and / or spare parts lists of the corresponding single axles without bogie parts. parts are embossed with PW Code no. Subject to change (without notice). PWEuft e 5

6 PW riginal spare parts Air suspensions Explanation of PW code numbers Example: digit 21. Air suspension single axle Air suspension single axle without air bags, air bags loose, separate 61. Air suspension single axle Tandem axle air suspension 32. Tandem axle air suspension / triaxle air suspension 62. Tandem axle air suspension Triaxle air suspension Triaxle air suspension Modul without hanger bracket and air bag Axle series H / SH 74. K / SKH 77. N 72. Modul with hanger bracket and without air bag H / SH 75. K / SKH 78. N 73. Modul with hanger bracket and air bag + H / SH 76. Tandem or triaxle suspension K / SKH 79. N digit Axle load Roller bearing earing system kg / Conventional hub bearing system kg / Conventional hub bearing system kg / Conventional hub bearing system kg / Conventional hub bearing system kg / EC Unit kg / EC Unit kg / EC Unit kg / EC Unit kg / EC Plus Unit kg / EC Plus Unit kg / EC Plus 2 Unit kg / Conventional hub bearing system 6 PWEuft e

7 Explanation of PW code numbers Example: digit ( Ref. number 7... ) 01. esignation trailing guide and air bag beam ACAU 02. ACAM 03. ACM 04. AC... Further combinations trailing guide / air bag beam from AC program... Trailing arms resp. trailing arm assemblys from AV program digit ( Ref. number 2... / 3... / 6... ) 001. to to to 839. Premounted air suspension axle without hanger brackets and air bags in the case of ref. number 61.xx.xxx.xxx to 69.xx.xxx.xxx e.g..0xx. = Premounted air suspension axle.x51. = Premounted air suspension axle with trailing arm esignation of ride height and air bag type 220 to 509 in the case of ref. number 61.xx.xxx.xxx 69.xx.xxx.xxx e.g..22x. = 220 mm ride height.44x. = 440 mm ride height Air bag type:.xx0. = PW 30 (Ø 300 mm).xx1. = PW 36 (Ø 360 mm).xx2. = PW 361 (Ø 360 mm).xx3. = PW 301 (Ø 300 mm).xx4. = PW 30 K (Ø 300 mm).xx5. = PW 36 K (Ø 360 mm).xx6. = PW 362 (Ø 360 mm).xx9. = PW 30 / 36 loose separately esignation of wheel bare in the case of ref. number For explanation of code number, see EHKN / ES / ETS digit ( Ref. number 7... ) Consecutive number digit ( Ref. number 2... / 3... / 6... ) 000 Consecutive number PWEuft e 7

8 PW riginal spare parts Air suspensions 1 Trailing arms General PW Trailing arms The trailing arm connects the axle to the vehicle frame via the air suspension hanger brackets and the air bag. PW trailing arms (single or twin leaf) are highly flexible spring steel elements. They are hotrolled from one piece, after which they are shotpeened, cataphoretic dipcoated and zincphosphated. Trailing arms absorb much of the flexural forces and reduce the torsional forces input into the axle beam. Various trailing arm versions permit individual equalisation for example for axle load, track, spring centre, centre of gravity height and driving comfort. In every situation, their stiffness and flexibility are exactly matched to the vehicle and its application. This reduces the stress on the body and ensures that the vehicle achieves a long service life. If single leaf trailing arms are mounted, the catch strap offers the necessary safety reserves if the worst should come to the worst. onglife steelrubbersteel bushes (up to 4 times the service life of rubbersteel bushes) offer maintenancefree mounting of the trailing arm. The axle is precisely located, and tyre wear and operating costs are both reduced. Spare parts for EC Air CMPACT air suspensions see pages PWEuft e

9 Trailing arms 1 Conversion of spring pivot bolt As part of the introduction of new products into series production, the spring pivot bolt connection on all Airlight II air suspensions systems will be changed from M 30 to M 24 from September 2007 onwards. Introducing an M 24 pivot bolt provides greater security due to higher bolt tension being achieved. In addition the surface area of the clamped interfaces is increased. This means the bolted connection has been made even less susceptible to settling. The M 24 spring bolts are Geometcoated, removing the need for additional lubrication on new component assembly. This modification affects all air suspension systems with 70 mm wide trailing arms (all Airlight II versions). All the versions will be changed over to M 24 at the start of series production from week 36 / 2007 onwards. Versions with M 30 spring bolts will no longer be produced from that point onwards. The adaptation to M 24 spring bolts is performed by changing the spring pivot bolt assemblies, the bushes in the air suspension hanger brackets and channel cross members and the steel / rubber / steel bushes in the trailing arms. The geometry of the actual trailing arm is not changed. As an assembly, the trailing arms with steel / rubber / steel bushes for M 24 spring bolts are given the index 2 (example: trailing arm for M 30 spring bolt => trailing arm for M 24 spring bolt). It is possible to adapt from the M 30 spring bolt to the M 24 spring bolt by changing the steel / rubber / steel bush. Steel / rubber / steel bush for spring pivot bolt M 30 PWno Steel / rubber / steel bush for spring pivot bolt M 24 PWno PWEuft e 9

10 PW riginal spare parts Air suspensions ptimised trailing arms and air bag attachment Within the scope of a further development of the Airlight II air suspension, PW will be introducing new optimised trailing arms from 1 July 2010 as well as a centrally bolted air bag PW 30 / 30 K for offset V = 20 mm. A fourhole pattern will be drilled into the new trailing arm and the air bag will be bolted directly onto the trailing arm with a single bolt. In addition to the new centrally bolted air bag, the familiar air bags PW 30 / 30 K and PW 36 / 36 K / 361 can continue to be attached using a steel plate and different offsets. Note: Please note that the new air bag can only be combined with the new trailing arm. It is impossible to mount a new air bag onto an old trailing arm by mistake due to the bolt / hole diameters. From a technical point of view, there are no restrictions to using both versions on the same axle or vehicle. hole pattern for the old air bag hole pattern for the new air bag ld version New version 10 PWEuft e

11 etermining replacement trailing arms The PW code number is punched into the underside of the trailing arm (in the area of air bag) resp. in the range of the rolledin eye of the trailing arm. If this identification is missing or no longer legible, the particular type of trailing arm can be determined based on the shape and the dimensions. Punched PW code number 1. Clarifying design Single layer, 3 trailing arms or twolayer trailing arms Spring pivot bolt Ø 24 or Ø 30 Note the position of the spring bolt (heartshaped pin) in twolayer trailing arms Measure the thickness () of the trailing arm and the width () etermine the offset (K) and the shape (H) Measure dimension 1 (middle of spring bolt to middle of axle) Measure dimensions 2 to 5 1 Ø 24 or Ø 30 H 75 2 (PW 30) 2 (PW 36) (Centre air bag) 1 2 (PW 30) H K K 2 (PW 36) (Centre air bag) 70 Ø Ø 360 Trailing arms with rubber / steel bushes fitted are no longer available. If there is a requirement for replacing them, change to trailing arms with steel / rubber / steel bushes! Ø Ø 360 Rubber / steel bushes cannot be replaced by steel / rubber / steel bushes! Single layer trailing arms with catch plate fitted (with spring screw fitted) are replaced by trailing arms with a loose catch plate. When changing to trailing arms with loose catch plate, use tracking plate or pin. See also page 49 PWEuft e 11

12 PW riginal spare parts Air suspensions 1.1 Trailing arms Straight single leaf trailing arms (PW 30 / 36) 2 (PW 36) (Centre air bag) F Ø Trailing arms with mounted catch plate (with mounted spring screws) see page 11. oose spring screws for trailing arm with centre bolt see page Ø 300 / Ø A 1 A 2 H H A 3 A 4 H H A 5 H A 6 H A 7 H A 8 H 12 PWEuft e

13 Trailing arms 1.1 Straight single leaf trailing arms imensions Fig. H 1 70 mm wide ( ) PW 36 PW 30 2 PW A 2 1 x A 3 1 x F Ø PW Code no. Trailing arm Item 1000 Item 1001 / Suitable catch strap Item 1012 Item 1013 / A 8 1 x mm wide ( ) 3Trailing arm A 7 1 x R R R 100 mm wide ( ) A A 3 1 x A A A 3 1 x * A A 6 1 x A 4 1 x mm wide ( ) 3Trailing arm A 5 1 x R R 1005 ush (steel / rubber / steel) Ø 30 / 60 x Ø 24 / 60 x ush (steel / rubber / steel) Ø 30 / 57 x 102 ush (rubber / steel) 1) Ø 30 / 60 x Plug for catch strap * for steering axle 1) for old trailing arms with rubber / steel bush oose spring screws for trailing arms with centre bolt see page 21. for trailing arm width 70 mm for trailing arm width 100 mm PWEuft e 13

14 PW riginal spare parts Air suspensions 1.2 Trailing arms Cranked single leaf trailing arms, 70 mm wide (PW 36) 2 (PW 30) (Centre air bag) F Ø 75 K Trailing arms with mounted catch plate (with mounted spring screws) see page 11. oose spring screws for trailing arm with centre bolt see page Ø 300 Ø H H 3 H 4 H 5 6 H H 7 H 14 PWEuft e

15 Trailing arms 1.2 Cranked single leaf trailing arms, 70 mm wide imensions Fig. K H 1 70 mm wide ( ) x PW 36 PW F Ø PW Code no. Trailing arm Item 1000 Item 1001 / x Suitable catch strap Item 1012 Item 1013 / ~ 7 1 x x x mm wide ( ) 3Trailing arm x R R R R R R R R R R R 1005 ush (steel / rubber / steel) see page 13 oose spring screws for trailing arms with centre bolt see page 21. PWEuft e 15

16 PW riginal spare parts Air suspensions 1.2 Trailing arms Cranked single leaf trailing arms, 100 mm wide (PW 30 / 36) 2 (PW 36) (Centre air bag) 1005 F Ø 75 K Trailing arms with mounted catch plate (with mounted spring screws) see page 11. oose spring screws for trailing arm with centre bolt see page Ø 300 / Ø H 2 H 3 H 4 H 5 H 6 H 7 H 8 H 9 H 10 H 11 H 16 PWEuft e

17 Trailing arms 1.2 Cranked single leaf trailing arms, 100 mm wide imensions Fig. K H mm wide ( ) PW 36 PW 30 2 PW F Ø PW Code no. Trailing arm Item 1000 Item 1001 / Suitable catch strap Item 1012 Item 1013 / x x x x x x mm wide ( ) 3Trailing arm R R R x R R R R ~ x R R R R 1005 ush (steel / rubber / steel) ush (rubber / steel) 1) Ø 30 / 57 x Ø 30 / 60 x Plug for catch strap ) for old trailing arms with rubber / steel bush oose spring screws for trailing arms with centre bolt see page 21. for trailing arm width 100 mm PWEuft e 17

18 PW riginal spare parts Air suspensions 1.3 Trailing arms Straight double leaf trailing arms 1 2 (PW 30 / 36) 2 (PW 36) (Centre air bag) F Ø H 70 Ø 300 / Ø C 1 H C 2 H C 3 H C 4 H C 5 H C 6 H 18 PWEuft e

19 Trailing arms 1.3 Straight double leaf trailing arms, 100 mm wide imensions Fig. H H mm wide ( ) PW 36 PW 30 2 PW F Ø PW Code no. Trailing arm Item 1000 C C C 1 2 x C C C C / C 2 2 x C C C x C C 3 C C C C C 3 2 x C C C C C Centre bolt Item C 4 2 x C C C 2 2 x C C C C 2 2 x C ush (steel / rubber / steel) Ø 30 / 57 x 102 for trailing arm width 100 mm ush (rubber / steel) 1) Ø 30 / 60 x Hexagon nut (for centre bolt item 1018) M 16 / ) for old trailing arms with rubber / steel bush PWEuft e 19

20 PW riginal spare parts Air suspensions 1.4 Trailing arms Cranked double leaf trailing arms, 100 mm wide 1 2 (PW 30 / 36) (PW 36) (Centre air bag) F Ø H K Ø 300 / Ø H 2 H 3 H 4 H 20 PWEuft e

21 Cranked double leaf trailing arms, 100 mm wide imensions Trailing arms 1.4 PW Code no. Fig. H K H mm wide ( ) PW 36 PW 30 2 PW F Ø Trailing arm Item x / x x x Centre bolt Item ush (steel / rubber / steel) Ø 30 / 57 x 102 for trailing arm width 100 mm ush (rubber / steel) 1) Ø 30 / 60 x Hexagon nut (for centre bolt item 1018) M 16 / ) for old trailing arms with rubber / steel bush oose spring screws for trailing arms with centre bolt Trailing arm thickness incl. catch strap H imensions Centre bolt (Item 1018) PW Code no. H 1 x 40 M 16 x x 48 M 16 x H 1 x 50 M 16 x x 33 M 16 x x 38 M 16 x x 40 M 16 x x 43 M 16 x x 45 M 16 x x 48 M 16 x x 51 M 16 x x 54 M 16 x x 65 M 16 x Hexagon nut (Item 1019) for centre bolt M 16 / PWEuft e 21

22 PW riginal spare parts Air suspensions 2 Spring seats, axle clampings General PW Axle clampings The axle is connected to the trailing arm using the axle connection comprising: spring plates, spring pads, segments and Ubolts. Clamped, positivelocking axle connections ensure an even force transfer into the axle appropriate to the degree of load. This is only possible with square axle beams which therefore offer a long service life. The connection parts are attached at the reinforced corners of the axle beam (no welded connection). ue to the modular construction a servicefriendly repair is guaranteed. Spring plate Catch strap Spring seat Trailing arm Tracking plate Segments Spring Ubolt Welded axle mountings are mainly used with a round axle cross section, steering axles as well as heavyduty air suspension systems. Spring plate Catch strap Trailing arm Spring seat Shaped plate for hole welding Tracking plate Spare parts for EC Air CMPACT air suspensions see pages Protection plates Segment Spring Ubolt 22 PWEuft e

23 Spring seats, axle clampings 2 etermining axle mountings 1. Clarifying design Trailing arm 70 mm or 100 mm wide Axle cross section Ø 127 / 120 / 150 Axle spring seat assembly clamped or welded Round centring ring or square frame with clamped axle mounting Spring seats with centring ring Shock absorber attachment: Spring seat without shock absorber attachment Spring seat with welded pin for shock absorber mounting or spring seat for shock absorber mounting Trailing arm mounted from above or from below Spring Ubolts or screws Ubolt encloses axle beam or is positioned to the side Spring Ubolts or bolts fitted from the top or bottom Singe or double segments Tracking plates Weld on tracking plates after installation and tracking of the air suspension axles on the vehicle at the rear end of the spring seats or spring plates Weld a 4 x 80. o not weld the trailing arms! a 4 x 80 Follow the welding guidelines given in the PW installation instructions! Important for all welding work! The trailing arms, air bags and plastic pipings should be protected against sparks and weld splashes during all welding work. The earth terminal must under no circumstances be attached to the trailing arm or hub. a 4 x 80 PWEuft e 23

24 PW riginal spare parts Air suspensions 2.1 Welded axle spring seat assembly Spring seats for welded axle spring seat assembly Spring seats with welding lug A 1 A 2 A Spring seats with counterlugs Spring seats with segments / / / Spring seats with counterlugs Spring seats with segments 12 / / / / PWEuft e

25 Welded axle spring seat assembly 2.1 Spring seats for welded axle spring seat assembly Spring seats, trailing arm 100 mm wide above mounted Spring seat without shock absorber attachment Exec. A M / V.. Spring seat with shock absorber attachment Exec. R 1.. Spring seat with shock absorber attachment Exec. C R 2.. Item esignation A PW Code no. Fig. PW Code no. Fig. PW Code no. Fig. Spring seats with welding lug, without counterlugs M / V 1 / V 1F / V Spring seat, above x A Spring seat, above x A Spring seat, above right Spring seat, above left Spring seat, above right Spring seat, above left Steering axle x x 1026 Spring seat, above x A 1 A 1 A 1 R 1 / R 13 / R 14 R 2 / R 2 F / R 23 Steering axle x x A 2 Steering axle x x Steering axle x x A 3 A 3 Spring seats without welding lug, with counterlugs / segment 1024 Spring seat, below (counterlug) Ø x x x x x x x x x Steering axle Spring seat, above right Spring seat, above left x x Spring seat, above right Spring seat, above left x X x x x x Spring seat, above Ø x ~ Spring seat, above right Spring seat, above left Ø x x ~ Spring seat, above x ~ Spring seat, above right Spring seat, above left x x x x Plate * Formed piece Shaped plate Segment see page 35 / 39 see page 35 / 39 see page 35 / 39 * eleted in 120 with shaped part (introduced 01 / 05). Further executions upon request. PWEuft e 25

26 PW riginal spare parts Air suspensions 2.1 Welded axle spring seat assembly Spring seats for welded axle spring seat assembly 120 / 150 Spring seats with welding lug Spring seats with counterlugs Spring seats with segments A 1 A 2 A / Ø 127 Spring seats without welding lug Spring seats with welding lug Spring seats with counterlugs Spring seats with counterlugs Spring seats with segments 12 / / / / PWEuft e

27 Welded axle spring seat assembly 2.1 Spring seats for welded axle spring seat assembly Spring seats, trailing arm 100 mm wide below mounted Spring seat without shock absorber attachment T.. / U.. / U.. Item esignation A PW Code no. Fig. PW Code no. Fig. Spring seats with welding lug, without counterlug T.. / U.. / U Spring seat, below x A Spring seat, below x A Spring seat, below Ø x Spring seat, below x A Spring seat, below left Spring seat, below right 120 Steering axle x x A 1 Spring seats without welding lug, with counterlugs / segment 1024 Spring seat, above (counterlug) Ø x x x A 2 A 2 3 Steering axle Spring seat, below left Spring seat, below right x x A 2 / A Spring seat, below left Spring seat, below right x x A 2 / A Spring seat, below Ø x 1 / Spring seat, below x A 2 / A Plate * Formed piece Shaped plate Ø Segment * eleted in 120 with shaped part (introduced 01 / 05). Further executions upon request see page 35 / 39 PWEuft e 27

28 PW riginal spare parts Air suspensions 2.2 Clamped axle spring seat assembly Spring seats for clamped axle spring seat assembly II Trailing arms 70 mm wide, above mounted II Trailing arms 70 mm wide, below mounted Trailing arms 70 mm wide, below mounted / irect air suspension (Airlight irect ) PWEuft e

29 Clamped axle spring seat assembly 2.2 Spring seats for clamped axle spring seat assembly Spring seats, trailing arms 70 mm wide Trailing arms 70 mm wide, above mounted Spring seat without shock absorber attachment Exec. A.. Spring seats with shock absorber attachment Exec. I 1.. Item esignation A PW Code no. PW Code no. 25 Profiled part (Centring frame) 1024 Spring seat, below Spring seat, above right Spring seat, above left * * * x x ) 1x ) 1x x ) 1x ) 1x * Replacement for profile part (centering frame) ) Spring seat with integrated centering bolt Trailing arms 70 mm wide, below mounted Spring seat without shock absorber attachment Spring seats with threaded bolts for shock absorber attachment irect air suspension (Airlight irect ) Spring seats with plates for shock absorber attachment irect air suspension (Airlight irect ) Item esignation A PW Code no. PW Code no. PW Code no. 25 Profiled part (Centring frame) Spring seat, below right Spring seat, below left * * * ) 1x ) 1x x x 1026 Spring seat, below x x 1035 Spring seat x x * Replacement for profile part (centering frame) ) Spring seat with integrated centering bolt PWEuft e 29

30 PW riginal spare parts Air suspensions 2.2 Clamped axle spring seat assembly Spring seats for clamped axle spring seat assembly Trailing arms 100 mm wide, above mounted / / / Trailing arms 100 mm wide, below mounted PWEuft e

31 Spring seats for clamped axle spring seat assembly Spring seats, trailing arms 100 mm wide Clamped axle spring seat assembly 2.2 Trailing arms 100 mm wide, above mounted Spring seat without shock absorber attachment.. Spring seat with shock absorber attachment I 1.. Spring seat with shock absorber attachment I 2.. Item esignation A PW Code no. PW Code no. PW Code no. 25 Profiled part (Centring frame) Spring seat, above right Spring seat, above left Spring seat, above right Spring seat, above left * * * x x x x x x x * Replacement for profile part (centering frame) Further executions upon request x x x x Trailing arms 100 mm wide, below mounted Spring seat without shock absorber attachment U a 150 b Item esignation A PW Code no. Fig. 25 Profiled part (Centring frame) * 1026 Spring seat, below x a Spring seat, below x b 1026 Spring seat, below x c 1026 Spring seat, below x d 150 c 180 d * Replacement for profile part (centering frame) Further executions upon request. Axle mountings with round centring ring are replaced by axle mountings with square centring frame. Change over if replacement is required. Weld new square centring frame onto the axle beam and use spring seats for square centring. Follow the PW welding guidelines! Round centring ring Square centring frame PWEuft e 31

32 PW riginal spare parts Air suspensions 2.2 Clamped axle spring seat assembly Spring seats for clamped axle spring seat assembly Trailing arms 100 mm wide above mounted ouble bar Spring seat Support for Ustabilizer / / / PWEuft e

33 Clamped axle spring seat assembly 2.2 Spring seats for clamped axle spring seat assembly ower spring seats, trailing arms 100 mm wide Trailing arms above mounted ouble bar Spring seat Support for Ustabilizer Ø 31 Item esignation A PW Code no. PW Code no. PW Code no Spring seat x x x x Steering axle Steering axle x x 1024 Support x x Further executions upon request. PWEuft e 33

34 PW riginal spare parts Air suspensions 3 Spring plates, segments Segments Segment above the trailing arm / 33 Segment on the axle beam 43 / PWEuft e

35 28 22, ,5 31,5 22,5 39,5 28, , Spring plates, segments 3 Segments Item esignation imensions PW Code no. Application Fig. Single segments Segment above the trailing arm Trailing arm width 70 mm 1035 Segment Trailing arm width 100 mm Segment on the axle beam 1035 Segment , , ) , ) 120 solid * 120 solid 111, * 150 solid ,5 1) for flattened spring Ubolts (disc brake) * welded on the axle beam PWEuft e 35

36 PW riginal spare parts Air suspensions 3 Spring plates, segments Segments ouble segment, round centring ring, clamped axle spring seat assembly PWEuft e

37 Spring plates, segments 3 Segments Item esignation imensions PW Code no. Application Fig. ouble segments ouble segment, round centring ring, clamped axle spring seat assembly 1035 Segment ) ) for flattened spring Ubolts (disc brake) PWEuft e 37

38 PW riginal spare parts Air suspensions 3 Spring plates, segments Segments ouble segment on axle beam, trailing arm mounted from below, welded axle spring seat assembly 55 ouble segment on axle beam, trailing arm mounted from above, welded axle spring seat assembly PWEuft e

39 Spring plates, segments 3 Segments Item esignation imensions PW Code no. Application Fig. ouble segments ouble segment, welded axle spring seat assembly 1035 Segment ) ) ) for flattened spring Ubolts (disc brake) PWEuft e 39

40 PW riginal spare parts Air suspensions 3 Spring plates, segments Segments, Spring plates ouble segment above the trailing arm ouble segment above the trailing arm for shock absorber attachment with screws ouble segment above the trailing arm for shock absorber attachment with threaded bolts / / / 33 ouble segment above / below the trailing arm for shock absorber attachment with threaded bolts ouble segment below the trailing arm for shock absorber attachment with threaded bolts / Ustabilizer M30 M M24 M PWEuft e

41 Spring plates, segments 3 Segmente, Spring plates Item esignation PW Code no. Application imensions Fig. ouble segments, spring Ubolt next to the axle beam, trailing arms 100 mm wide ouble segment above the trailing arm 1035 Spring plate x = 150 x x = ouble segment above the trailing arm for shock absorber attachment with screws 1035 Spring plate / 150 x = 150 / 180 x / 150 x = 150 / 180 x ouble segment above the trailing arm for shock absorber attachment with threaded bolts 1035 Spring plate / 150 x = 150 / 180 x ouble segment above / below the trailing arm for shock absorber attachment with threaded bolts Spring plate, left / 150 x = 150 / 180 x Spring plate, right No longer available. Use spring plate without thread bolt and weld on thread bolt (see page 92) ouble segment below the trailing arm for shock absorber attachment with threaded bolts / Ustabilizer 1035 Spring plate / 150 x = 150 / 180 x Spring plate, left Spring plate, right / 150 x = 150 / 180 x Further executions upon request. PWEuft e 41

42 PW riginal spare parts Air suspensions 3 Spring plates, segments Spring plates Spring Ubolts mounted from below, trailing arms 70 mm wide ( II) mounted from above Spring Ubolts mounted from below Spring Ubolts mounted from below, spring plate for shock absorber attachment with screws Spring Ubolts mounted from below, spring plate for shock absorber attachment with threaded bolts Spring Ubolts mounted from above, trailing arms 70 mm wide ( II) mounted from below Spring Ubolts mounted from above, spring Ubolt next to the axle beam S 3745 / 4309 / 4345 TS 3709 / 4309 / 4312 Shock absorber front S 3745 / 4309 / 4345 TS 3709 / 4309 / 4312 Shock absorber rear PWEuft e

43 Spring plates, segments 3 Spring plates Item esignation PW Code no. Application imensions Fig. Spring Ubolts mounted from below, trailing arms 70 mm wide ( II) from above mounted Spring plate without shock absorber attachment 1032 Spring plate ) A 92 / 150 A 1032 Spring plate A 92 / 150 A 125 / 150 A 1032 Spring plate ) A 92 / 150 A Spring plate for shock absorber attachment with screws 1032 Spring plate ) A 92 / 150 Ø 24,5 A Spring plate for shock absorber attachment with threaded bolts 1032 Spring plate ) A 92 / 150 A Spring Ubolts mounted from above, trailing arms 70 (100) mm wide ( II) mounted from below Spring Ubolt next to the axle beam 1035 Spring plate x = 150 x 68 Spring Ubolts mounted from above, trailing arms 70 mm wide ( II) mounted from below, TS Spring plate x = 150 x 55 1) No longer available, replaced by spring plates with spherical countersink (see also page 53). PWEuft e 43

44 PW riginal spare parts Air suspensions 3 Spring plates, segments Spring plates Spring Ubolt encloses the axle beam, trailing arms 100 mm wide Spring Ubolts mounted from below, spring plate without shock absorber attachment / without Ustabilizer Spring Ubolts mounted from below, spring plate for shock absorber attachment with screws Spring Ubolts mounted from below, spring plate for Ustabilizer attachment with screws Ø 24, Ø Spring Ubolt next to the axle beam, trailing arms 100 mm wide Spring Ubolts mounted from above, spring Ubolt next to the axle beam Spring Ubolts mounted from below, spring Ubolt next to the axle beam Spring Ubolts mounted from below, spring Ubolt next to the axle beam, spring plate for shock absorber attachment with screws PWEuft e

45 Spring plates, segments 3 Spring plates Item esignation PW Code no. Application imensions Fig. Spring Ubolt encloses the axle beam, trailing arms 100 mm wide Spring plate without shock absorber attachment / without Ustabilizer attachment 1032 Spring plate A 125 / Ø 127 A 125 / A 125 / 180 A Spring plate for shock absorber attachment with screws 1032 Spring plate G A 125 / A 125 / 180 G Ø 24.5 A Spring plate for Ustabilizer attachment with screws 1032 Spring plate A 125 / Ø 127 A 125 / ) 150 A 125 / 180 1) with bore hole for centering bolt Ø 26 Ø 31 A Spring Ubolt next to the axle beam, trailing arms 100 mm wide Spring plate without shock absorber attachment 1035 Spring plate * * x = 150 x = 150 x = 180 x = 180 x * with bore Ø Spring plate for shock absorber attachment with screws 1035 Spring plate = 144 / x = 150 = 187 / x = 150 x Spring plate x = 150 x Ø PWEuft e 45

46 PW riginal spare parts Air suspensions 3 Spring plates, segments Spring plates Trailing arms 70 mm wide Spring Ubolts mounted from above, spring plate for shock absorber attachment with threaded bolts Trailing arms 100 mm wide Spring Ubolts mounted from above, spring plate for shock absorber attachment with threaded bolts Spring Ubolts mounted from above, spring plate for shock absorber attachment with screws PWEuft e

47 Spring plates, segments 3 Spring plates Item esignation PW Code no. Application imensions Fig. Spring Ubolts mounted from above Spring plate for shock absorber attachment with threaded bolts A C X G V Spring plate, right Spring plate, left Trailing arms 70 mm wide Trailing arms 100 mm wide G C A * * X V ) ) G C A X V * Shock absorber attachment bolt Ø 28 (standard Ø 24) 1) Replaced by / 23.0 see below Spring plate for shock absorber attachment with screws 1032 Spring plate G C A X Spring plate, right Spring plate, left ) ) G 2) Replace for / 44.0 New Shock absorber attachment with screw, order screw ( ) separately. C A X PWEuft e 47

48 PW riginal spare parts Air suspensions 4 Centring bolts, tracking plates Centring bolts, tracking plates Single leaf trailing arm without centre bolt ouble or sing leaf trailing arm with centre bolt Weld on tracking plates after installing and tracking of the air suspension axles on the vehicle at the rear of the spring seats or spring plates Weld a 4 x 80. o not weld the trailing arms! 48 PWEuft e

49 Centring bolts, tracking plates 4 Centring bolts, tracking plates Item esignation Remark PW Code no. imensions Single leaf trailing arm without centre bolt ( / M / U / / M / U ) 1040 olt (Centring bolt) Centring bolt Ø 24 x Tracking plate 1041 Plate 120 (Tracking plate) x 98 x x 98 x x 98 x x 98 x x 98 x ouble or single leaf trailing arm with centre bolt ( / M / T / / M / U / / M / U ) Tracking plate 1041 Plate 120 (Tracking plate) x 98 x x 98 x x 98 x x 98 x x 98 x Washer (Centring ring) Centring ring, trailing arm mounted from above, trailing arm mounted from below, spring seat with round hole, axle with round centring ring Ø 24 / 69 x Ø 24 / 71 x Washer (Centring ring) Centring ring, trailing arm mounted from below, spring seat with round hole Ø 24 / 69 x Ø 24 / 71 x Plate (Centring plate) Centring plate, trailing arm mounted from above, spring seat with square hole, axle with square centring ring Ø 24 / 73/60x Ø 24 / 90/55x Ø 24 / 90/72x PWEuft e 49

50 PW riginal spare parts Air suspensions 4 Centring bolts, tracking plates Adjustable tracking plates (Tracking aid) Weld on tracking plates after installing and tracking of the air suspension axles on the vehicle at the rear of the spring seats or spring plates Weld a 4 x 80. o not weld the trailing arms! 50 PWEuft e

51 Centring bolts, tracking plates 4 Adjustable tracking plates (Tracking aid) Item esignation Remark PW Code no. imensions ouble or sing leaf trailing arm with centre bolt ( / M / T / / M / U ) Adjustable tracking plates 1041 Shaped plate (Tracking plate) loc ocking screw M 16 x Hexagon nut M 16 / Adjustable tracking plates Shaped plate 120 / Ø 127 (Tracking plate) Support Hexagon nut M 16 / PWEuft e 51

52 PW riginal spare parts Air suspensions 5 Spring Ubolts Spring Ubolt M 22, trailing arms 70 mm wide Spring Ubolt next to the axle beam M = 550 Nm 1057 M = 550 Nm Spring Ubolt encloses the axle beam Spring Ubolt next to the axle beam Airlight irect 1057 M = 550 Nm M = 550 Nm 52 PWEuft e

53 Spring Ubolts 5 Spring Ubolt M 22, trailing arms 70 mm wide Spring Ubolt for series II, trailing arms 70 mm wide Spring Ubolt next to axle beam Spring Ubolt encloses the axle beam M 22 A M 22 A M 22 A 120 A = 92 Item 1050 PW Code no. 120 A = A = Spring Ubolt flattened flattened flattened flattened round round flattened Spring plate without spherical countersink (with disc) Spring plate with spherical countersink (with spherical disc) M 22 A M 22 A 120 A = 92 Item 1050 PW Code no. 120 A = Spring Ubolt / 262 flattened 1055 Washer Ø 23 / 125 isc (spherical disc) * Ø 23 / 34 x ock nut M 22 / SW 32 / H / 262 round * Spherical disc for spring plates with spherical countersink PWEuft e 53

54 PW riginal spare parts Air suspensions 5 Spring Ubolts Spring Ubolt M 24, trailing arms 100 mm wide Spring Ubolt next to the axle beam * * U with TS M = 650 Nm M = 650 Nm M = 650 Nm M = 650 Nm Spring Ubolt encloses the axle beam M = 650 Nm M = 650 Nm 54 PWEuft e

55 Spring Ubolts 5 Spring Ubolt M 24, trailing arms 100 mm wide Spring Ubolts for series / /, trailing arms 100 mm wide Spring Ubolt next to axle beam Spring Ubolt encloses the axle beam M 24 A M 24 A M 24 A M 24 A M 24 A 120 / 150 A = 125 ( ) 120 A = 152 ( ) 120 isc brakes A = 152 ( ) 150 A = 180 ( ) Ø 127 A = 152 ( ) Item 1050 PW Code no (190) (210) (230) (250) (270) (277) (275) (280) * (280) (292) * (292) (280) (285) (280) (290) (290) (301) (300) (300) (308) * (308) (320) * (320) (331) * (331) (310) (310) (320) (315) (320) (330) (325) (330) (335) (340) (345) (345) (340) (356) (355) (350) (355) (365) (360) (370) (370) (380) (400) (415) PWEuft e 55

56 PW riginal spare parts Air suspensions 5 Spring Ubolts / Hexagon screws Hexagon screws M 24 / M / M M = 650 Nm M = 650 Nm U / U Irekte uftfederung ( / T) M = 650 Nm M = 650 Nm 56 PWEuft e

57 Spring Ubolt / Hexagon screws 5 Hexagon screws M 24 Item esignation Remark PW Code no. imensions Application X Hexagon screw M 27 x M 24 x M 24 x M 24 x M 24 x X Hexagon screw M 24 x M 24 x M 24 x M 24 x Washer Ø 25 / ock nut M 24 / Spare parts for EC Air CMPACT air suspensions see pages PWEuft e 57

58 PW riginal spare parts Air suspensions 5.1 Assembly instructions for clamped axle spring seat assemblies Trailing arms 70 mm wide ( II ), spring Ubolt M 22 Series / M Series U Assembly instructions: Parts are to be assembled in line with opposite illustration, further grease spring Ubolts thread. Spring seats and trailing arm are to be aligned parallel to the axle beam and selflocking nuts are to be equally crosswise tightened until contact to spring plate. Control parallel position of spring seats and trailing arm towards axle beam and hereafter tighten selflocking nuts crosswise in a.m. sequence 1234 until all have achieved a tightening torque of 200 Nm. Using a torque wrench tighten selflocking nuts crosswise in following steps to the tightening torque of 550 Nm. 1) 200 Nm s.a. 2) 300 Nm 3) 450 Nm 4) 550 Nm Hereafter tighten the nuts by another 90 turning angle. M = 550 Nm PWEuft e

59 Assembly instructions for clamped axle spring seat assemblies 5.1 Trailing arms 100 mm wide ( / ), spring Ubolt M 24 Series / M / / M Spring Ubolt encloses the axle beam Ubolt next to the axle beam Series U / U Assembly instructions: Parts are to be assembled in line with opposite illustration, further grease spring Ubolts thread. Spring seats and trailing arm are to be aligned parallel to the axle beam and selflocking nuts are to be equally crosswise tightened until all components are in uniform contact. (The spring seats are only in contact with the radi of the axle beam.) No uneven tightening is allowed due to singlesided tightening of the lock nuts. Using a torque wrench, tighten the lock nuts in several stages crosswise until the specified tightening torque has been reached. M = 650 Nm ( Nm) PWEuft e 59

60 PW riginal spare parts Air suspensions 6 Spring pivot bolt bearings General Spring pivot bolt bearing PW spring bolt mountings connect the trailing arms to the supports / frame. The maintenancefree steel / rubber / steel bushes guarantee that the axles are guided securely and with a stable track in any circumstances. In axle lift devices, the mounting of the lift arm is integrated into the spring bolt mounting, thereby ensuring a safe and longlife function. olt head in square locking device Spring pivot bolt Wearing plates Weldin bush with internal square Rapid axle alignment is possible using PW hanger brackets with integrated track adjustment. Production tolerances on the vehicle can be counteracted or tracking corrected without the need to unfasten the spring Ubolts (axle tracking). Adjustment plates Spring pivot bolt 5 5 Spring bolt with square antirotation lock Since 1995, PW has been using spring bolts and weldin bushes with square antirotation lock on rigid steel supports. In case of wear on bushes with a slot for the hexagon head of the spring bolt that are welded into older supports, change over to the new technology with square antirotation lock. Spare parts for EC Air CMPACT air suspensions see pages PWEuft e

61 Spring pivot bolt bearings 6 New spring pivot bolt bearing from week 18/2004 onwards From week 18/2004 onwards, the functional principle of the loose wear plates (registered utility model EGM U1 ) familiar in Airlight II hanger brackets will also be carried across to the rigid air suspension hanger brackets for 100 mm wide trailing arms. oose wear plates offer the following advantages: Simplified mounting, because the wear plates are not inserted in the bracket until the trailing arm has been positioned in the bracket. This means there is significantly more installation space available at the start of the installation procedure. Preinstalled air suspension modules can therefore be installed in the vehicle frame much more easily thanks to the brackets which are already welded on. A practical design of the wear plates thanks to the insertion offset and height limitation ensures that the installation functions smoothly. Insertion offset Mixed installation is technically possible (brackets with loose wear plates or with welded wear plates). Wearing plates PW uses two different versions of wearing plates. 1. A straight shaped plate for straight hanger brackets, channel crossmembers and frames PW code no.: M M An offset shaped plate for angled hanger brackets, PW code no.: M M 30 Height limitation Spring pivot bolt Ø 24 Since week 30/2007 air suspension modules (Airlight II) will only be obtainable with Ø 24 mm trailing arm bushes and spring pivot bolts. Introducing an M 24 spring pivot bolt provides greater security due to higher bolt tension being achieved. In addition the surface area of the clamped interfaces is increased. This means the bolted connection has been made even less susceptible to settling. The tightening torque (with torque wrench!) for Airlight II channel crossmembers and air suspension hanger brackets is reduced from 900 Nm ( Nm) for the M 30 spring bolt to 650 Nm ( Nm) for the M 24 spring bolt. Shaped plate (M 24) (M 30) with straight hanger brackets, channel cross members, frames Shaped plate (M 24) (M 30) with angled hanger brackets PWEuft e 61

62 l PW riginal spare parts Air suspensions 6.1 Spare parts for spring pivot bolt bearings Spare parts for spring pivot bolt bearings A C l l l X M 24 x 2 d M 24 x 2 d M 24 x 2 E F l 10 l l d M 24 x 2 d M 24 x 2 M 24 x 2 G H I l Ø 6.3 l l M 30 x 2 1 M 30 x 2 M 30 x 2 J K d 39 Ø d M N d d d 62 PWEuft e

63 Spare parts for spring pivot bolt bearings 6.1 Spare parts for spring pivot bolt bearings Item esignation imensions PW Code no. Fig. 1 l d Screw (Spring pivot bolt) M 24 x 2 x C 144 Ø Ø 18 M 24 x 2 x Ø 48 M 24 x 2 x A 166 Ø M 24 x 2 x Ø 56 Ø 18 M 24 x 2 x E Ø 54 M 24 x 2 x A Ø M 24 x 2 x M 24 x 2 x M 24 x 2 x F SW 36 M 24 x 2 x Screw (Spring pivot bolt) M 30 x 2 x M 30 x 2 x M 30 x 2 x G 235 M 30 x 2 x SW 46 M 30 x 2 x M 30 x 2 x H M 30 x 2 x M 30 x 2 x Ø 62 M 30 x 2 x I 40 M 30 x 2 x Ø 52 M 30 x 2 x Ø Slider Ø 30 / 50 x 58 x J Ø Plate Ø (Adjusting plate) 51 Ø Ø K 65 Ø Ø Ø Plate Ø 31 / 72 x Ø Washer Ø 25 / 36 x Ø 36 6 Ø 26 / 60 x Ø 60 Ø 25 / 60 x Ø 25 8 Ø 25 / 62 x Ø Ø 25 / 70 x Ø Washer Ø 31 / 45.5 x M Ø 45.5 Ø 31 / 45.5 x A Ø 56 4 Ø 31 / 57 x Ø 57 Ø 31 / 62 x Ø 62 Ø 31 / 71 x Ø 31 / 71 x * Ø 31 Ø ock nut M 24 x 2 / SW SW 36 M 24 x 2 N M 30 x 2 / SW SW 46 M 30 x Castle nut M 30 x 2 / SW 46 M 30 x Split pin 6.3 x 50 / * hardened Spare parts for EC Air Compact air suspensions see pages PWEuft e 63

64 PW riginal spare parts Air suspensions 6.1 Spare parts for spring pivot bolt bearings Spare parts for spring pivot bolt bearings A C d 1 d d 1 E F d Ø 45 3 d 1 1 d 1 G H I d d 1 d 1 d 1 d J (M 24) (M 30) with straight hanger brackets, channel cross members, frames (M 24) (M 30) with angled hanger brackets K 1 1 d 1 1 d d 64 PWEuft e

65 Spare parts for spring pivot bolt bearings 6.1 Spare parts for spring pivot bolt bearings Item esignation imensions PW Code no. Fig. 1 1 d 1173 Washer Ø 31 / 56 x A Ø 56 Ø ush (Polyamid) Ø 41 / 50 x Ø 50 Ø Ø 42 / 50 / 54 x Ø 54 Ø 50 Ø 42 C Ø 54 / 62 / 58 x Ø 62 Ø 58 Ø 54 Ring Ø 42 / 50 x Ø 50 Ø Graduated bush Ø 24 / 62 / 42 x Ø 24 / 62 / 42 x Ø 42 C Ø 62 Ø 24 / 62 / 42 x Ø 24 Ø 24 / 62 / 40 x Ø 40 Ø 24 / 59 / 54 x Ø 59 Ø 54 Ring Ø 24 / 42 x Ø Ø 30 / 39 x A Ø ush Ø 30 / 42 x Ø Graduated bush Ø 30 / 45 / 40 x Ø 45 Ø 40 Ø 30 Ø 30 / 62 / 42 x C Ø 62 Ø 42 Ø 30 / 62 / 40 x Ø 62 Ø 40 Round wearing plate 1520 Washer Ø 30 / 121 x E Ø 121 Ø Square wearing plate 1520 Plate Ø 56 / 105 x F Ø 56 / 105 x G Ø 56 / 101/140 x F Ø 56 / 101/140 x V2A Ø Plate 62/92 / 101/140 x H /92 / 101/130 x / I 62/92 / 101/140 x Shaped plate Ø 24 / angled bracket Ø 24 Ø 24 / straight bracket J Ø 30 / straight bracket Ø 30 Ø 30 / angled bracket Washer Ø 24 / 110 x Ø 24 / 110 x Ø A Ø 110 Ø 24 / 110 x Ø 30 / 110 x Ø Washer Ø 24 / 36.6 / 50/70 x Ø 70 Ø 50 Ø 24/36 ush Ø 24 / 36.6 / 55/90 x /1 * K Ø 24/ Ø 90 Ø 55 Ø 30 / 42.6 / 55/90 x /1 * Ø 30/42 Washer Ø 24 / 50 / 110 x Ø 110 Ø 24 Ø 30 / 50 / 110 x Ø 100 Ø 30 Ø 30 / 50 / 110 x Ø Washer Ø 24 / 50 / 70 x Ø 24 Ø 30 / 50 / 70 x Ø 70 Ø 30 Ø 30 / 50 / 70 x * last digit 1 = with PW ogo Spare parts for EC Air CMPACT air suspensions see pages PWEuft e 65

66 PW riginal spare parts Air suspensions 6.1 Spare parts for spring pivot bolt bearings Spare parts for spring pivot bolt bearings A Torsion protection with slotted bush, round wearing plate Torsion protection with slotted bush, square wearing plate, pivot bush Torsion protection with square internal lock bush, pivot bush C 1 d 1 d 1 d 1 E F G d SW 50 d X 1 d 1 d H I J d 1 d d d d K M Ø M 18 x 1.5 SW 27 SW 27 d M 18 x 1.5 Ø PWEuft e

67 Spare parts for spring pivot bolt bearings 6.1 Spare parts for spring pivot bolt bearings Item esignation imensions PW Code no. Fig. 1 1 d 1535 ush 1) (Weldin bush) A Torsion protection with slotted bush. No longer available. Conversion to torsion protection with square internal lock bush. Ø 30 / 51 / 56 x Ø Ø 24 / 55 / 67.6 x C Ø Ø 30 / 55 / 73.6 x Ø Ring Ø 30 / 55 x V2A E 55 Ø ush with welded on torsion protection 1540 ush 1) (Weldin bush) Ø 30 / 55 / 63 x V2A F Ø Ø 24 / 36 / 67 x G Ø 24 / 36 / 67 x V2A H 68 Ø 30 / 42 / 74 x G Ø 30 / 42 / 74 x V2A H Ø 24/36 21 Ø 30/42 23 Shaped part 92 x 62 x I Shaped plate (welded on torsion protection) Adjusting plate with welded on torsion protection 1560 Shaped part (screwed on torsion protection) J / K Ø Hexagon screw M 8 x Hexagon screw M 18 x 1.5 x M 1571 Hexagon nut M 18 x 1.5 / SW ) Changing the weldin bushes see pages 170 / 171. Spare parts for EC Air CMPACT air suspensions see pages PWEuft e 67

68 PW riginal spare parts Air suspensions 6.2 Repair kits for spring pivot bolt bearings M = 900 Nm 1154 Twoside axle lift Sidewise mounted axle lift M = 900 Nm M = 900 Nm PWEuft e

69 Repair kits for spring pivot bolt bearings 6.2 Spare parts see pages Trailing arm width 70 mm Thread M 24 M 30 Item esignation imensions S = Steel hanger bracket A = Alloy hanger bracket X = Stainless steel hanger bracket V = adjustable AV = Axle lift device PW Code no. S X V S V A V PW Repair kit PW item A V AV S X V S V A V A V AV Spring pivot bolt assembly Item 1154, 1161, 1165, 1168, ush Ø Ø Screw (Spring pivot bolt) M 24 x 2 x M 24 x 2 x M 24 x 2 x M 30 x 2 x M 30 x 2 x M 30 x 2 x Plate (adjusting plate) Ø Ø Ø Ø Washer Ø 26 / 60 x Ø 25 / 70 x Ø 25 / 36 x Ø 31 / 71 x Ø 31 / 57 x ock nut M 24 x 2 / SW M 30 x 2 / SW Castle nut M 30 x 2 / Split pin 6.3 x 50 / Washer Ø 31 / 56 x ush Ø 42 / 50 / 64 x Graduated bush Ø 30 / 62 / 42 x Shaped plate Ø 24 / angled bracket Ø 24 / straight bracket Ø 30 / angled bracket Ø 30 / straight bracket ush Ø 24 / 36.6 / 55/90 x Ø 30 / 42.6 / 55/90 x ush Ø 24 / 36 / 67 x Ø 30 / 42 / 74 x PWEuft e 69

70 PW riginal spare parts Air suspensions 6.2 Repair kits for spring pivot bolt bearings Twoside axle lift M = 900 Nm M = 900 Nm Sidewise mounted axle lift M = 900 Nm Twoside axle lift M = 900 Nm M = 900 Nm 1161 Sidewise mounted axle lift PWEuft e

71 Repair kits for spring pivot bolt bearings 6.2 Spare parts see pages Trailing arm width 100 mm Item esignation imensions 1152 Spring pivot bolt assembly Item 1154, 1160, 1161, 1165, 1168, 1525 S = Steel hanger bracket V = adjustable AV = Axle lift device Thread M 30 PW Code no. S S S S AV PW Repair kit PW item S AV S V S V ush Ø 30 SRS Ø 30 SR Screw (Spring pivot bolt) M 30 x 2 x 200 / Ø M 30 x 2 x 200 / Ø M 30 x 2 x Slider Ø 30 / 50 x 58 x Plate (adjusting plate) Ø Ø Plate Ø 31 / 72 x Washer Ø 31 / 71 x Ø 31 / 57 x A Ø 31 / 62 x ock nut M 30 x 2 / SW ush Ø 41 / 50 x Ring Ø 30 / 39 x Graduated bush Ø 30 / 62 / 40 x Plate Ø 56 / 101/140 x Ø 56 / 105 x /92 / 101/130 x /92 / 101/140 x Shaped plate Ø 30 / straight bracket Weldin bush Ø 30 / 51 / 56 x Ø 30 / 55 / 73.6 x Shaped part 92 x 62 x ush Ø 30 / 42 / 74 x Shaped plate (welded on torsion protection) Adjusting plate with welded on torsion protection Support S V AV S V AV S V AV S V AV PWEuft e 71

72 PW riginal spare parts Air suspensions 7 PW Air bags General Standard air bag PW Air bags are firmly rolled into the top air bag cover and are bonded onto the clamping plate at the bottom by vulcanisation. The top air bag cover is either bolted onto the frame trussing or else a plate or bracket is welded onto the vehicle frame to attach the bag, depending on the bag version. The air bag cover is bolted onto it using two M 12 securing nuts. The rolling piston is made from glassfibre reinforced plastic with a steel support to give reduced weight and resistance to corrosion. The integrated bump stop protects against damage when the bags are vented. The air bag plate at the bottom is bolted onto the trailing arm using two M 16 securing bolts. Upper air bag attachment Air bag cover umper Air bag Rolling piston (Plastic) (Air bag piston) Air bag plate ower air bag attachment 72 PWEuft e

73 PW Air bags 7 Reduced weight of the Airlight II air suspension with the new air bag 30 / 30 K Gewichtsreduzierung bei der Airlight II uftfederung mit dem neuen Air bag 30 / 30 K Within the scope of a further development of the Im Airlight Rahmen II air einer suspension, Weiterentwicklung PW will be der introducing Airlight II uftfederung new optimised führte trailing die arms PW from ab dem 1 July Juli 2010 as neue well as optimierte a centrally Trailing bolted arms air sowie bag PW einen 30 zentralverschraubten for offset V = 20 Air mm. bag PW 30 / 30 K für / 30 K das Versatz maß V = 20 mm ein. Currently, the air bag is fastened to the trailing ie arm efestigung by means of des a universal algs auf steel der plate enkerfeder inserted erfolgte into the base bisher of über the air eine bag in den piston oden with der possible uftfederglocke offsets 0 / 20 / 60. eingesetzte This steel UniversalStahlplatte plate is attached to mit the den trailing möglichen arm with Versatzmaßen two bolts. von 0 / 20 / 60. Über zwei Schrauben ist diese Stahlplatte mit der In future, the air bag with the most frequently Feder verbunden. used standard offset of V = 20 mm will be bolted Jetzt directly wird onto der the Air trailing bag mit arm dem with am a häufigsten single bolt. A verwendeten fourhole pattern Standardversatzmaß will be drilled into von the V new = 20 mm direkt trailing auf arm. der In enkerfeder addition to the mit new nur einer centrally Screw verschraubt. bolted air bag, ie the neue familiar enkerfeder air bags erhält PW ein 30 Vierfachohrbild. K and PW 36 / 36 K / 361 can continue to be / 30 attached using a steel plate and different offsets. Neben When using dem neuen the new zentralverschraubten centrally bolted air Air bag, bag 15können auch kg are weiterhin saved on die a 3axle bekannten suspension uftfederbälge compared PW 30 / 30 to the K und old PW version 36 (5 / 36 kg K per / 361 module). mit Stahlplatte und unterschiedlichen Note: Please note Versatzmaßen that the new air montiert bag can werden. only be combined with the new trailing arm. ei It is Einsatz impossible des neuen to mount zentralverschraubten a new air bag onto uftfederbalgs old trailing werden arm by gegenüber mistake due der to alten the bolt Ausführung / hole an 15 diameters. kg im 3AchsAggregat (5 kg pro Modul) eingespart. The old air bag with the steel plate can, however, continue Hinweis: itte to be beachten used for all Sie, versions dass der with neue old alg or nur new mit der trailing neuen arm. enkerfeder kombiniert werden kann. From a technical point of view, there are no restrictions to using both versions on the same Eine fehlerhafte Montage eines neuen algs auf axle or vehicle. eine alte enkerfeder ist aufgrund der Schraubenbzw. ochdurchmesser contact in our sales nicht department möglich. will be Your pleased to assist you with planning the er alte alg mit Stahlplatte kann dagegen weiterhin changeover. für alle Ausführungen mit alter und neuer Feder eingesetzt werden. Aus technischer Sicht besteht hinsichtlich einer gemischten Verbauung auf der Achse oder im Fahrzeug keine Einschränkung. Ihr Ansprechpartner im Vertrieb unterstützt Sie gerne bei der Planung der Umstellung. PW 361 PW 36K PW 36 PW 30K PW 30 Upper air bag attachment Air bag cover umper Air bag Rolling piston (Plastic) (Air bag piston) ower air bag attachment PW 30K PW 30 PWEuft e 73

74 PW riginal spare parts Air suspensions 7 PW Air bags Air bag with splitted piston (CombiAir bag) A combination air bag is divided into two parts: The air bag is bolted onto the vehicle frame with the rolling piston while the centring cone is connected to the trailing arm or integrated to the spring seats. When the trailer is lifted, the axle and the cone move downwards. The movement is restricted by the shock absorbers. However, the air bag remains in its rest position. When the trailer is lowered to the ground, the air bag and centring cone once more come together. The bag can neither fold nor crease. Stroke limiting The upward travel is restricted by a bump stop inside the air bag. The downward travel must be restricted under certain application conditions. Upper air bag attachment Air bag cover umper Air bag Rolling piston ( Air bag piston (Steel) ) Centring cone ower air bag attachment Air supply The pressure needed during driving is applied via a compressed air line that is connected to the air bag via the threaded sleeve (M 22 x 1.5) welded into the air bag cover or via a hollow stay bolt (M 18 x 1.5 / M20 x 1.5). M 22 x M 20 x 1.5 M 18 x PWEuft e

75 PW Air bags 7 etermining estimmung replacement von Ersatzuftfederbälgen air bags 1. Clarifying Ausführung design klären StandardAir air bag or oder split geteilter air bag Air bag (combination (KombiAirbag) air bag) Ø 300 PW 30 for für stroke Hub mm mm PW 30 K for für stroke Hub mm mm Ø 360 PW 36 for für stroke Hub mm mm PW 36 K for für stroke Hub mm mm PW 361 for für stroke Hub bis up 340 to mm 340 mm PW 362 for für stroke Hub bis up 450 to mm 450 mm PW 365 for für stroke Hub bis up 380 to mm 380 mm ie The algausführung bag design as well sowie as die the PW Code code no. no. des of the nackten bare air uftfederbalges bag can be read ist auf off jedem from every Air air bag. abzulesen. Example: eispiel: 30 K Code Nummer no. des of air bag only nackten rubber alges part item. Pos Air algausführung bag execution 2. etermining Art des uftanschlusses the type of air feststellen. connection. Air uftanschluss connection an to eingeschweißter weldedin threaded Gewindesleeve in im the uftbalgdeckel air bag cover oder or to an hollow hohlem stay Stehbolzen. bolt. 3. Air algbefestigung bag attachment Top bere air uftbalgbefestigung bag attachment in middle in algmitte of bag oder or offset seitlich to versetzt? the side? Measure age der the oberen position algbefestigung of the top bag am attachment Rahmen on zur the unteren frame algbefestigung in relation to the an bottom der enkerfeder bag attachment ermitteln (er on maximale the trailing seitliche arm (the Versatz maximum zwischen lateral oberer offset und unterer between algbefestigung the top and bottom darf 10 bag mm nicht attachment überschreiten.). is not allowed to exceed 10 mm). ie The obere top and und bottom untere bag algbefestigung attachments must darf nicht not be verdreht installed zueinander with any eingebaut rotational werden! misalignment! V 4. ld uftfederbälge version of alter air bags Ausführung Complete Komplette air uftfederbälge bags of the älterer older version, Ausführung air bags mit with StahlGlocken, aluminium uftfederbälge pistons and internal mit AluGlocken aluminium und support innerer AluAbstützung as well as split sowie bags geteilte with glass älge fibrereinforced GFKKegel plastic (PW 36) taper werden (PW nicht 36) are mehr no geliefert. longer mit available. ei Ersatzbedarf umrüsten auf PW Air bags If mit replacement GFKGlocke. is required, change over to PW air ie bags gängigsten with glass Ersatzteile fibrereinforced für ältere plastic uftfederbälge piston. The mit StahlGlocke most common sind spare weiterhin parts for lieferbar. older air bags with steel piston are still available. PWEuft e 75

76 PW riginal spare parts Air suspensions 7.1 Air bags Ø 300 Air bags Ø 300 Fig. A Fig. bserve position of upper and lower air bag attachment! 1 C d 2 H H 3 4 X X V V Fig. C Air bag with plastic piston 1240 Air bag with plastic piston central screwed CombiAir bag C Y H X V PWEuft e

77 Air bags Ø Air bags Ø 300 Fig. V X H Y C d PW 30 Air bag standard PW Air bag cpl. Item 1200 A A A 1 0 / 20 / A A PW Code no. only Item Air bag piston Item 1210 Item 1210 / 1213 ower plate Item 1220 Centring cone (CombiAirbag) Item * Air bag with integrated air connection in stud bolt 2 0 / 20 / M 18x M 20x * Air bag with split piston (CombiAir bag) C 1 0 / 20 / PW 30 K Air bag standard A A A / 20 / A A A * Air bag with integrated air connection in stud bolt 157 M 20x M 18x / 20 / M 18x M 20x M 20x * Air bag with split piston (CombiAir bag) C C / 20 / C Air bags with steel or aluminium pistons are no longer available. Conversion from steel or alloy piston to plastic piston. PW 30 Conversion kit for 1 air bag PW 30 K Conversion kit for 1 air bag consisting of rolling piston (plastic), air bag plate, and attachment parts Conversion see page Further executions upon request. * Air bag central screwed PWEuft e 77

78 PW riginal spare parts Air suspensions 7.2 Air bags Ø 360 Air bags Ø 360 Fig. A PW 36 / PW 361 Fig. PW 36 K bserve position of upper and lower air bag attachment! 1 C C 2 H H 3 X X 4 V V e.g Fig. C PW 361 (Steel piston) Air bag with steel piston Air bag with plastic piston C H X V e.g PWEuft e

79 Air bags Ø Air bags Ø 360 imensions Fig. V X H C Remark PW 36 Air bag standard PW Air bag cpl. Item 1200 PW Code no. only Item 1205 A 1 0 / A 1 45 / / Plastic piston A A C 1 0 / C 1 45 / / Steel piston C 1 32 / PW 36 K Air bag standard / / Plastic piston / Air bag piston Item 1210 ower plate Item C 1 32 / / Steel piston PW 361 Air bag standard A 1 45 / / Plastic piston C / 55 C C 1 45 / / Steel piston C C 1 32 / PW 36 Airlight irect Types PW 36 and PW 36 K air bags with steel or aluminium pistons are no longer available in some cases. Conversion from steel or alloy piston to plastic piston. PW 36 Conversion kit V = 0 / 55 for 1 air bag consisting of rolling piston (plastic), Conversion kit V = 45 / 80 air bag plate and attachment parts. Conversion kit V = 80 PW 36 K Conversion kit V = 0 / 55 for 1 air bag Conversion kit V = 45 / 80 Conversion kit V = 80 Conversion see page Further executions upon request. PWEuft e 79

80 PW riginal spare parts Air suspensions 7.3 Conversion from steel piston to plastic piston Conversion from steel or alloy piston to plastic piston Air bag with steel or aluminium piston Air bag with glass fibrereinforced plastic piston Types PW 30 / 30 K / 36 and 36 K air bags with steel or aluminium pistons are no longer available in some cases. If replacement is required, change over to the air bag with glass fibrereinforced plastic piston. bserve position of upper and lower air bag attachment! ismantling: Admit as much air into the air bag as possible through the air suspension or rotary disc valve / switching valve. Support the vehicle safely so there is no risk of accident, e.g. place a suitable spacer between the vehicle frame and the trailing arm. Vent the air bag. Remove the compressed air connection. Unscrew top (1240) and bottom (1224) bag attachments and remove the air bag. low compressed air into the hole for the air connection until the bag is completely unrolled. Unscrew and remove locking screw (1222) and take off bottom washer (1220). Unscrew and remove square bolt (1215) using an impact driver and remove piston (1210) from the air bag. Assembly: Screw threaded sleeve (1215) onto the air bag to a tightening torque of 130 Nm. Place bottom base plate (1220) into glass fibrereinforced plastic piston (1210) and screw on loosely using locking screw (1222). Align the top and bottom bag attachment points in relation to one another and tighten locking screw (1222) to a tightening torque of 230 Nm (The air bag must not be twisted after installation in the vehicle!) Install the air bag into the vehicle, tighten the top and bottom attachments to the corresponding tightening torque. Connect the air connections. Check for leaks. Admit air into the air bag, remove the support PWEuft e

81 Conversion from steel piston to plastic piston 7.3 Conversion from steel or alloy piston to plastic piston Air bag PW 30 / 36 max. offset 10 mm H Threaded sleeve (1215) Rolling piston (Plastic) (Air bag piston) (1210) Air bag plate (1220) Inner support screw (1222) V ower air bag attachment (1224) Trailing arm V The maximum lateral offest between the upper and lower attachments must not exceed 10 mm. PW 30 PW 30 K V X PW 36 PW 36 K PW 361 V e.g X Item esignation Remark PW Code no. imensions V X H Application PW Conversion kit cpl PW 30 0 / 20 / PW 30 K PW / 55 PW / PW PW / / 55 PW 36 K / PW 36 K PW 36 K Conversion kit cpl. consisting of: Rolling piston (Air bag piston) (Item 1210) ower air bag plate (Item 1220) Threaded sleeve (Item 1215) Inner support screw (Item 1222) ower attachment screws (Item 1224) PWEuft e 81

82 PW riginal spare parts Air suspensions 7.4 Spare parts for air bags Spare parts for air bags Air bag standard Air bag with split piston (CombiAir bag) Air bag with steel piston Air bag with plastic piston A C a H1 d d H C 1205 d b H1 d K Ø d d c H1 K d1 Ø d H1 K H1 d1 d 82 PWEuft e

83 Spare parts for air bags 7.4 Spare parts for air bags Item esignation Remark PW Code no. Fig. PW 30.. imensions Ø d C esignation of air bag 1205 Air bag, only M M PW N N M A M N 0 0 PW 30 K M N N PW M PW PW M PW 36 K 4881 M A PW M PW M PW 36 Airlight irect PW 36 N 1 K 32 S Item esignation Remark PW Code no. Fig. PW 30 imensions d H1 d1 K Remark 1210 Piston b Steel piston b c * d c * d PW a a b Plastic piston (GFK) Steel piston c Plastic piston (GFK) c PW 36 Airlight irect Plastic piston (GFK) Glass fibrereinforced plastic tapers for split air bags 36 are no longer available. If replacement is required, change over to the PW 30 combination air bag or the normal air bag! Item esignation Remark PW Code no. Fig. PW 30 CombiAir bag imensions d H1 d Centring cone C Piston * piston for central screwed air bag PW 36 Airlight irect ~ PWEuft e 83

84 PW riginal spare parts Air suspensions 7.4 Spare parts for air bags Spare parts for air bags Air bag standard Air bag with steel piston Air bag with plastic piston Air bag with split piston (CombiAir bag) A C d SW d 1215 d d M 16 M 16 E F 1220 PW 30 PW X M 16 V X X V V 84 PWEuft e

85 Spare parts for air bags 7.4 Spare parts for air bags Item esignation Remark PW Code no. Fig. Steel piston 1215 olt imensions 1 d Application PW 30 K PW 30 K PW 30 K / 36 K PW 30 / 30 K A PW PW 30 / 30 K / 36 / 36 K PW 30 / 36 / PW Ring Ø 30 / 55 x 5 for bolt 1 = 48 Plastic piston (GFK) 1215 Threaded sleeve M 16 x 51 / SW 24 PW 30 / PW olt M16/Ø30x40/150/SW32 PW 30 K Air bag with M16/Ø30x40/195/SW32 PW 30 central screw Air bag with split piston (CombiAir bag) 1215 olt PW 36 K PW olt C Ø 30 x 62 / SW 46 PW 36 / PW 36 K 1218 Nut M 16 / SW 19 PW 30 / PW 30 K Shaped part Screw Item esignation Remark PW Code no. Fig. PW 36 Airlight irect Ø 13 / 20 / 59 x M 12 x PW 30 imensions PW 36 N V X Application 1220 Plate F 0/20/ PW 30 / PW 30 K GFK 1220 Washer E PW 30 / PW 30 K PW Plate Washer Attachment central bolt with steel piston 1222 ocking screw Central screw with plastic piston 0/ F 45/80 70/ / /80 70/ E M 16 x 30 M 16 x 35 PW 36 / PW 36 K GFK PW 36 / PW 36 K 1222 Screw M 16 x 115 piston height < 150 mm Attachment trailing arm air bag M 16 x 160 piston height > 180 mm 1224 ocking screw M 16 x 55 M 16 x 65 M 16 x ocking screw M 16 x 61 / SW 22 Air bag with central screw PWEuft e 85

86 PW riginal spare parts Air suspensions 7.5 Upper air bag attachment / spacers Upper air bag attachment / spacers A mm a Ø b M 18 / M Screw in the air bag mm 1243 Ø C Screw in the air bag 1240 H 1250 H 1251 E H 1252 F H PWEuft e

87 Upper air bag attachment / spacers 7.5 Upper air bag attachment / spacers Item esignation Remark PW Code no. Fig. imensions Application Upper air bag attachment Steel frame 1240 ock nut A a M 12 Steel frame 5 22 mm Steel frame / integrated air connection in stud bolt 1241 Hexagon nut M 18 A b M 20 Steel frame 5 22 mm Alloy frame 1243 Spring washer / Hexagon nut M 12 / Ø 20 / SW 30 Alloy frame mm Spacers imensions Item esignation Remark PW Code no. Fig. H Application 1250 Plate PW 30 C PW Support PW PW Support E PW PW Square tube F PW 30 PW 30 / PW 36 PWEuft e 87

88 PW riginal spare parts Air suspensions 8 Shock absorbers General PW Shock absorber The shock absorber reduces vibration in the vehicle body and ensures greater driving comfort and road safety. This is because the wheels stay in contact with the road and dynamic wheel load fluctuations are reduced. PW uses various types of shock absorber to guarantee the best possible damping in each case. In turn, this ground contact is responsible for the tracking stability and braking properties of the vehicle. max. Highvolume PW shock absorbers are adapted to the vehicle, the overall height and the range of applications. Using the split air bag (CombiAir bag + Airlight irect ) with air suspensions, the shock absorber is fitted with an end stop in order to avoid any further axle travel. The rubber bushes of PW shock absorbers ( GEShock absorber ) can be replaced (see page 91). GE Made in Germany Shock absorbers should only be built in and changed per axle. Individual axles can be equipped in different ways within a multiaxle vehicle. 88 PWEuft e

89 Shock absorbers 8 General PW PC PC Stoßdämpfer The PW PW PC PC Stoßdämpfer ( Pneumatic ermöglichen amping eine Control ) shock lastabhängige absorber ämpfung improves und driving gewährleisten properties and unabhängig comfort vom whatever eladungszustand the load. gleichbleibend The hohe best Sicherheit damping, und better hohen road Fahrkomfort. safety, lower maintenance ie stufenlose costs Anpassung given der all these ämpfung reasons, an den you jeweiligen don t need eladungszustand to think long erfolgt and hard durch ein before pneumatisch fitting angesteuertes or retrofitting PW Proportionalventil air am suspension ämpfer. systems with PC. a das PC System auf die Standardluftfederung aufbaut und keine zusätzliche Regelelektronik benötigt, Function lassen sich PC Stoßdämpfer problemlos The in PW disadvantage uftfederungen with conventional integrieren bzw. shock absorbers nachrüsten. is that their characteristics can only be optimally adapted to one loading condition (usually er PC fully Stoßdämpfer laden). PC ist detects in zwei Ausführungen, the actual loading abgestimmt condition auf die via algdrücke the air suspension der uftfederbälge and adapts PW 30 itself und smoothly. PW 36, lieferbar. This improves er Einbau drivingmuss safety auf die at Stoßdämpferlängen the same time as abgestimmt reducing the sein. strainon the chassis and the vehicle, in particular when the ei trailer der Montage is empty ist or auf only ausreichenden partly laden. Freiraum PC zur uftfederstütze is virtually essential zu achten. in highvalue vehicles and when carrying sensitive cargoes. Vehicle maintenance costs are reduced. Funktionsweise The cargo and the carriageway are also subjected to Herkömmliche fewer shock Stoßdämpfer loads. haben den Nachteil, dass die Kennlinie nur auf einen eladungszustand (i.a. Volllast) optimal abgestimmt werden PC is connected to the PW air suspension system and does not require any electronic kann. er PCStoßdämpfer erkennt über die control systems. uftfederung den tatsächlichen elsdungszustand und passt sich diesem stufenlos an. as erhöht die Fahrsicherheit und entlastet gleichermaßen Fahrwerk und Fahrzeug, insbesondere bei leeren oder teilbeladenen Fahrzeugen. einahe unerlässlich ist der PCStoßdämpfer in hochwertigen Fahrzeugen und bei sensiblen adungen. ie Wartungskosten für das Fahrzeug sinken. Auch adegut und Fahrbahn werden deutlich geschont. An PW uftfederungen angeschlossen, kommt der PCStoßdämper ohne jede Elektronik aus. When using PC shock absorbers, a eim Einsatz von PCStoßdämpfern shim must be installed between the muss zwischen Hanger bracket bzw. support or spring seats and each PC, Achslappen also shorter lock nuts must be used. und PC je eine istanzscheibe montiert sowie kürzere Sicherungsmuttern verwendet werden. traction Zug ämpfkraft damping [ N forces ] [ N ] pressure ruck convetional damping stability Konventionelle ämpfer Stabilität Komfort safety Sicherheit driving property traction Zug ämpfkraft damping [ N forces ] [ N ] pressure ruck uftanschluss PC (Proportionalventil) PC damping stability Kontinuierlich verstellbare ämpfer Stabilität Komfort safety Sicherheit driving property speed [ m/s ] speed [ m/s] 0 0,131 0,262 0,393 0, ,131 0,262 0,393 0,524 Geschwindigkeit [ m/s ] Geschwindigkeit [ m/s] PWEuft e 89

90 PW riginal spare parts Air suspensions 8.1 Shock absorbers Shock absorbers Mounting position I II min. max. X Ø 1300 Ø d Ø 24 Mounting position Shock absorber with with steel and rubber bushes Ø 24 / 30 PW Code no. Shock absorber with with steel and rubber bushes Ø 24 / 32 PW Code no. Standard shock absorber (Item 1300) min. imensions max. X d N = Newton at 13 cm/s N = Newton at 52 cm/s N N N N I / / 3000 I ) / / 3000 repl. by I / / 5010 I / / 3000 repl. by I / / 4500 repl. by I / / 3000 I / / 5010 I / / 5000 repl. by I / / 5010 I / / 2150 I II / / 800 II / / 1000 I II ) ) / / 3000 II / / 900 II / / 1000 Remark PC Shock absorber (Pneumatic amping Control) (Item 1300/1301) I for air bag PW 30 I R I for air bag PW 36 Shock absorber with last digit..0 are replaced by shock absorber with last digit..2. 1) Special version 2) reinforced bserve the modified bushes (page 91). 90 PWEuft e

91 Made in Germany GE Shock absorbers 8.1 Spare parts for shock absorbers Rubber bushes only for GEshock absorber Exec. Item esignation PW Code no. imensions Shock absorber with last digit..0 Shock absorber with last digit Steel bush Rubber bush Repair kit bushes Item Steel bush Rubber bush Ø 24 / 30 x Ø 19 / 50 x Ø 24 / 32 x Ø 23 / 50 x GE Made in Germany S A Steel and rubber bushes with Ø 24 / 30 mm are no longer available convert to steel and rubberbushes with Ø 24 / 32 mm. Changing the bushes 1 2 Ø 23,5 Stahlbuchse / Steel bush / ouille en acier Ø 24 / Ø 24 / GE Made in Germany Ø 30 / Ø 32 Gummibuchse / Rubber bush / ouille en caoutchouc Ø 19 / 50 x Ø 23 / 50 x 25 3 = GE Made in Germany ubricate the rubber and steel bush with a 50% soap solution prior to assembly! PWEuft e 91

92 PW riginal spare parts Air suspensions 8.2 Upper shock absorber attachments Upper shock absorber attachment with threaded bolts Shock absorber front Shock absorber rear M = 420 Nm 1330 M = 420 Nm 1330 M = 420 Nm 1330 M = 420 Nm M = 420 Nm 1330 M = 420 Nm M = 420 Nm Item esignation Remark PW Code no. imensions A Shock absorber attachment on threaded bolts, steel hanger bracket / integrated support / frame A 1310 Threaded bolt (steel) (welded to hanger bracket, integrated support or frame) M Threaded bolt (stainless steel) (welded to hanger bracket) Shock absorber attachment on threaded bolts, stainless steel hanger bracket A M ock nut * VM 24 / Shock absorber attachment on threaded bolts, shock absorber rear, attachment to spacer for air bag Item 1255 left Item 1256 right A X Y Support, left Support, right X Y 60 A ock nut * VM 24 / * With PCshock absorber use lock nut washer PWEuft e

93 Upper shock absorber attachments 8.2 Upper shock absorber attachment with screws Shock absorbers next to hanger bracket Steel hanger bracket / integrated support / frame M = 420 Nm M = 420 Nm M = 420 Nm M = 420 Nm M = 420 Nm 1330 M = 420 Nm Item esignation Remark PW Code no. imensions 1315 Hexagon screw = 144 = 155 = 187 Shock absorbers next to hanger bracket, steel hanger bracket M 24 x M 24 x M 24 x M = 420 Nm M = 420 Nm 1) inside dimension of the hanger bracket = 55 mm 2) inside dimension of the hanger bracket = 67 mm Sleeve ush ock nut e.g Ø 25 / 40 x 55 1) Ø 25 / 40 x 67 2) * VM 24 / Shock absorber above the trailing arm, shock absorber at hanger bracket centre Hexagon screw = 72 = 80 = 110 = 125 = 125 = 157 = 177 = 187 Ring (2x) = 67 = 90 ock nut M 24 x M 24 x M 24 x M 24 x M 24 x M 24 x M 24 x M 24 x Ø 25 / 50 x Ø 25 / 42 x * VM 24 / M = 420 Nm M = 420 Nm * With PCshock absorber use lock nut washer M = 420 Nm PWEuft e 93

94 PW riginal spare parts Air suspensions 8.2 Upper shock absorber attachments Upper shock absorber attachment with screws Shock absorber attachment between plates, steel hanger bracket / integrated support / frame Repair solution for shock absorber attachment with retracted supports M = 420 Nm 1330 M = 420 Nm 1330 M = 420 Nm 1330 M = 420 Nm M = Nm M = 420 Nm 1330 M = 420 Nm M = 420 Nm Item esignation Remark PW Code no. imensions Hexagon screw Ring (1x) Ring (2x) ock nut Shock absorber attachment between plates, steel hanger bracket / integrated support / frame M 24 x M 24 x M 24 x Ø 25 / 42 x Ø 25 / 42 x VM 24 / Repair solution for shock absorber attachment with retracted supports 1312 Repair kit (Item 1313, 1315, 1317, 1330) X = X = 121 a 4 a Support Screw ush ock nut X = X = M 24 x 140 / Ø 25 / 40 x VM 24 / X = 121 X = 121 X = PWEuft e

95 Upper shock absorber attachments 8.2 Upper shock absorber attachment with screws Item esignation Remark PW Code no. imensions Hexagon screw Sleeve ush Ring (2x) ock nut Shock absorbers next to hanger bracket, alloy hanger bracket M 24 x M 24 x Ø 25 / 40 x 55 1) Ø 25 / 40 x 67 2) Ø 25 / 42 x VM 24 / ) inside dimension of the hanger bracket = 55 mm 2) inside dimension of the hanger bracket = 67 mm M = 320 Nm M = 320 Nm Shock absorber above the trailing arm, shock absorber at hanger bracket centre, alloy hanger bracket Hexagon screw Ring (2x) Washer (2x) ock nut M 24 x M 24 x Ø 25 / 50 x Ø 25 / VM 24 / M = 320 Nm Hexagon screw ush Ring Washer Ring e.g. Ring ock nut Shock absorbers next to hanger bracket, cast alloy hanger bracket M 24 x M 24 x Ø 25 / 40 x 67 2) Ø 25 / 42 x Ø 25 / Ø 25 / 50 x Ø 25 / 42 x VM 24 / VM 24 / short M = 320 Nm M = 320 Nm Hexagon screw Ring Washer ock nut Shock absorber above the trailing arm, shock absorber at hanger bracket centre, cast alloy hanger bracket M 24 x Ø 25 / 50 x Ø 25 / VM 24 / M = 320 Nm PWEuft e 95

96 PW riginal spare parts Air suspensions 8.3 ower shock absorber attachments ower shock absorber attachment Item esignation Remark PW Code no. imensions Spring seat, right Spring seat, left ock nut / / attachment to spring seats with threaded bolt, shock absorber front see page see page * VM 24 / M = 420 Nm M Shock absorber front, shock absorber attachment to adjustable support Support Hexagon screw Hexagon screw Hexagon nut Sleeve ock nut M 24 x M 16 x 35 / M 16 / Ø 25 / 42 x VM 24 / M = 420 Nm M / M Shock absorber rear 1224 ocking screw see page Support, right Support, left Spring Ubolt ock nut ock nut Item 1320 right Item 1321 left VM 16 x 1.5 / VM 24 / X X M = 100 Nm 1330 M = 420 Nm * With PCshock absorber use lock nut washer PWEuft e

97 H V ower shock absorber attachments 8.3 ower shock absorber attachment Item esignation Remark PW Code no. imensions Support, right Support, left M / M / M Shock absorber rear, attachment to support with threaded bolt Item 1320 right Item 1321 left X A ock nut * VM 24 / * With PCshock absorber use lock nut washer M = 420 Nm ower shock absorber attachment between plates M = 420 Nm H V M = 420 Nm Item esignation PW Code no. imensions 1311 Repair kit cpl. (Item ) 1318 Ring Sleeve 1320 Support H 190 / V 150 H 200 / V 160 H 185 / V 120 H 217 / V 125 H 245 / V 120 H 185 / V Hexagon screw = 56 = 75 = 86 = 90 = Ø 25/42x10 Ø 25/42x15 Ø 25/42x17.5 Ø 25/42x / / 150 M 24 x 110 M 24 x 130 M 24 x 140 M 24 x ock nut VM 24 / PWEuft e 97

98 PW riginal spare parts Air suspensions 8.3 ower shock absorber attachments ower shock absorber attachment Item esignation Remark PW Code no. imensions / / Attachment to spring plate above the trailing arm, spring Ubolts mounted from above Spring plate Hexagon screw ock nut see page M 24 x VM 24 / M = 420 Nm Spring plate Hexagon screw ock nut / / Attachment to spring plate above the trailing arm, spring Ubolts mounted from below see page 43 / M 24 x VM 24 / M = 420 Nm 43 / U Attachment to spring seat above the trailing arm with screw, spring Ubolts mounted from above Spring seat Hexagon screw ock nut see page M 24 x VM 24 / M = 420 Nm / / Attachment to spring plate with threaded bolt welded on, spring Ubolts mounted from above Spring plate, right Spring plate, left ock nut see page 41 see page * VM 24 / * With PCshock absorber use lock nut washer M = 420 Nm 98 PWEuft e

99 ower shock absorber attachments 8.3 ower shock absorber attachment Item esignation Remark PW Code no. imensions Spring plate ock nut / / Attachment to spring plate with threaded bolt welded on, spring Ubolts mounted from below see page * VM 24 / M = 420 Nm Spring plate, right Spring plate, left ock nut T / U / U Attachment to spring plate with threaded bolt, spring Ubolts mounted from above see page 47 see page * VM 24 / M = 420 Nm Spring plate Hexagon screw ock nut T / U / U Attachment to spring plate with screw, spring Ubolts mounted from above see page M 24 x M 24 x * VM 24 / M = 420 Nm * With PCshock absorber use lock nut washer PWEuft e 99

100 PW riginal spare parts Air suspensions 8.3 ower shock absorber attachments ower shock absorber attachment Item esignation Remark PW Code no. imensions Spring plate, left Spring plate, right ock nut T / U / U Attachment to spring plate with threaded bolt welded on, spring Ubolts mounted from below see page 41 see page * VM 24 / M = 420 Nm T / U / U Attachment to spring plate with screw, spring Ubolts mounted from below Spring plate, left Spring plate, right Hexagon screw ock nut see page 41 see page M 24 x * VM 24 / M = 420 Nm T / U / U Attachment to spring plate with threaded bolt screwed on, spring Ubolts mounted from below, shock absorber front Spring plate ock nut Threaded bolt Sleeve * ock nut see page M M 24 / M 30 / = Ø 32 / 38 x * VM 24 / M = 750 Nm 1327 M * not applicable with Ustabilzer 1324 M M = 420 Nm * With PCshock absorber use lock nut washer PWEuft e

101 ower shock absorber attachments 8.3 ower shock absorber attachment Item esignation Remark PW Code no. imensions T / U / U Attachment to spring plate with threaded bolt screwed on, spring Ubolts mounted from below, shock absorber rear Spring plate ock nut Threaded bolt Sleeve ock nut see page M M 24 / M 30 / = Ø 32 / 38 x * VM 24 / M = 750 Nm 1327 M30 M M = 420 Nm / Attachment to spring plate with screw, spring Ubolts mounted from below Spring plate Hexagon screw ock nut see page M 24 x M 24 x * VM 24 / M = 420 Nm * With PCshock absorber use lock nut washer PWEuft e 101

102 PW riginal spare parts Air suspensions 9 Check straps Check straps Item esignation PW Code no. imensions Check straps, standard Check straps, PVC coated 1360 Check strap PWEuft e

103 Check strap attachments 9.1 Check strap attachment with hexagon nuts Screw SC SC Sleeve SC Shaped plate Hexagon nut Return spring 1) / / R / R / R (with frame) Item esignation Remark PW Code no. imensions PW Code no. imensions 1362 Threaded bolt M 30 / 40 x M 30 / 40 x * M 30 / Ø 26 / 2.6 x 148 * no longer available M 30 x M 30 x Ø 34 / 54 x * M 30 / Ø 26 / 2.6 x 148 Check strap attachment with split pins R / R / R / / (with frame) Item esignation Remark PW Code no. imensions PW Code no. imensions 1362 olt Ø 30 / 40 x Screw SC SC M 30 x 218 M 30 x Sleeve SC Ø 34 / 54 x Washer Split pin Return spring 1) / x 45 / 94 Ø 26 / 2.6 x / x 45 / 94 Ø 26 / 2.6 x 148 1) not applicable if check strap length < 1120 mm PWEuft e 103

104 PW riginal spare parts Air suspensions 10 Hanger brackets / integreated supports General PW Air suspension hanger brackets Air suspension hanger brackets transfer all control, braking and acceleration forces from the axle to the vehicle frame. Short, adjustable PW air suspension hanger brackets with integrated shock absorber mounts make installation easier, reduce weight and cut the flexural load on the vehicle s frame. The vehicle manufacturer benefits from straightforward crossbracing options at the interface between the frame and the hanger bracket. PW air suspension hanger brackets are available in steel as well as in highgrade steel and aluminium if required (only Airlight II). Complete frames are no longer available. PW Integrated support Vehicle manufacturers all over the world quickly appreciate the assembly benefits of this module. Whether it s the hanger brackets, the shock absorber attachments or the crossbraces, everything is integrated to save space. Even steering axles can be connected to it without additional preparation. The channel crossmember is available in two versions with an open, narrow hanger bracket for welding or with a cover plate for bolting/riveting onto the vehicle frame. The channel crossmember can even make additional crossmembers unnecessary, depending on the frame design. Track alignment Rapid axle alignment is possible using PW hanger brackets with integrated track adjustment. Production tolerances on the vehicle can be counteracted or tracking corrected without the need to unfasten the Ubolts (axle tracking) PWEuft e

105 Hanger brackets / integreated supports 10 General Mehr Greater Flexibilität flexibility für for Fahrzeughersteller vehicle manufacturers the bolted die Airlight anschraubbare II air suspension Airlight hanger II uftfederstütze bracket from von PW PW With PW the bietet new, mit innovative der neuen, bolted innovativen, Airlight anschraubbaren Airlight hanger II uftfederstütze bracket, PW die is Möglichkeit, offering the II air suspension opportunity kompakte Fahrzeugrahmen of prefabricating ohne compact Hanger vehicle frames without bracketsvorzufertigen, air suspension zu hanger beschichten brackets, und coating erst später, them but in der not Endmontage, attaching the mit axle dem and kompletten suspension Achsaggregat unit until the final zu verbinden. assembly stage. Mit y expanding dieser Erweiterung the Airlight des II Airlight range, II PW aukastens is offering eröffnet vehicle manufacturers PW Fahrzeugherstellern an attractive eine alternative attraktive to the conventional, Alternative zum fully konventionell welded chassis. komplett This geschweißten is because the bolted Chassis. system enn offers das schraubbare clear logistical System and bringt cost klare advantages, ogistik und Kostenvorteile, in particular for insbesondere offsite frame bei production and dezentraler surface Rahmenfertigung coating. Production und is berflächenbeschichtung. air suspension ie Fertigung hanger brackets wird flexibler. will be available made more flexible. The from week 36/2007 onwards. ike all other Airlight II air ie Hanger bracketssind ab KW 36/2007 lieferbar suspension hanger brackets and channel cross und wie alle anderen Airlight II Hanger bracketsund members, they have been designed for use with M 24 Integreated supports beim Serienstart für die trailing arm spring bolts from the start of series Application mit production (see also PW News uft e). M 24 enkerfederbolzen ausgelegt (siehe auch PW News uft d). racing Knotenblech plate 5 5 bolts Schrauben per hanger pro Stütze, bracket, comply Montagerichtung with the mounting beachten! direction! Kundenvorteile: Customer advantages: Einbau Installation des of gesamten the entire Fahrwerks chassis (incl. (inkl. bracket Hanger struts) bracketsverstrebung) by coldjoining technology über Significant Kaltfügetechnik cost and logistical advantages with offsite frame deutliche production Kosten and surface und ogistikvorteile coating (it easier bei dezentraler to transport the Rahmenfertigung vehicle frame without und hanger berflächenbeschichtung brackets) (einfacher Transport der Fahrzeugrahmen ohne Hanger Expansion of production flexibility bracket) For mounting on standard frames with bottom flange Erhöhung der Flexibilität in der Fertigung width as little as 120 mm Montage an Standardrahmen bereits ab 120 mm No Untergurtbreite changes to the frame required, except for the hole pattern außer Suitable dem for ohrbild aluminium keine frame Veränderungen des Rahmens Improved notwendigrepair capability für AluRahmen geeignet verbesserte Reparaturfähigkeit PWEuft e 105

106 PW riginal spare parts Air suspensions 10 Hanger brackets / integreated supports General Shock absorber attachment Hanger bracket with welded bolt for shock absorber attachment (100 mm wide trailing arm) replaced by hanger brackets with hexagon bolt and nut. Adustable hanger brackets Adjustable hanger brackets and channel crossmembers with weldin square frame for spring bolt mounting have been replaced by hanger brackets and channel crossmembers with weldin slot bush. If replacement is required, change over to this new version. From week 18/2004 onwards, the functional principle of the loose wear plates (registered utility model EGM U1) familiar in Airlight II brackets will also be carried across to the rigid air suspension hanger brackets for 100 mm wide trailing arms. Wearing plates PW uses two different versions of wearing plates. 1. A straight shaped plate for straight hanger brackets, channel crossmembers and frames PW code no.: M M An offset shaped plate for angled hanger brackets PW code no.: M M 30 Shaped plate (M 24) (M 30) with straight hanger brackets, channel cross members, frames Shaped plate (M 24) (M 30) with angled hanger brackets It is essential to use new spring pivot bolts when the hanger bracket / integrated support is replaced! bserve modified spring pivot bolt bearing! 106 PWEuft e

107 Hanger brackets / integreated supports 10 estimmung etermining von replacement Ersatz air suspension uftfederhanger brackets brackets ie The PW Sachnummer code number ist embosses in die Stirnseite into the der end Hanger of bracket the hanger bracket. If eingeprägt. this identification is missing or no longer legible, the Falls particular diese Kennzeichnung type of hanger nicht bracket vorhanden can be bzw. nicht determined mehr lesbar based ist, kann on die the entsprechende shape and the dimensions. Hanger bracket anhand der Form und der imensions bestimmt werden. eingeprägte PW Sachnummer Clarifying design Ausführung Hanger bracket bestimmen / integrated support / frame Hanger bracket / Integreated supports / Rahmen Steel, aluminium or stainless steel hanger bracket Stahl, Alu oder EdelstahlHanger bracket Straight boxsection hanger bracket / estesign Gerade hanger bracket Kastenstütze / retracted / estesignhanger hanger bracket bracket / eingezogene Rigid or adjustable Hanger spring bracket pivot bolt mounting Federbolzenlagerung Spring pivot bolt Ø 24 rigid mm oder or Ø adjustable 30 mm Spring Trailing pivot arm 70 bolt or Ø mm oder wide Ø 30 enkerfeder Tall hanger bracket 70 oder (ST) 100 mm breit Höhe Hanger Hanger bracket bracket with shock ( ST ) absorber attachment ( screw / bolt ) Hanger bracket mit Stoßdämpferbefestigung (Screw Position olt) of shock absorber attachment ( / F ) K K ST 120 a StM M FM G F b ST K ST 120 F F age Stoßdämpferbefestigung ( / F ) Spare parts for EC Air CMPACT air suspensions see pages PWEuft e 107

108 PW riginal spare parts Air suspensions 10.1 Hanger brackets Hanger brackets / trailing arms 70 mm wide ( II) A K ST 83 F F Ø ST 83 F F Ø C K F K F ST F Ø ST F Ø 83 E F K K F F ST F Ø ST F Ø Remark: o not apply heat to the suspension hanger brackets to effect any reworking or alignment. amaged hanger brackets should be completely replaced! When exchanging the hanger brackets, new spring pivot bolts and locking nuts are to be used! bserve the welding guidelines as per PW installation instructions! 108 PWEuft e

109 Hanger brackets 10.1 Hanger brackets / trailing arms 70 mm wide ( II) ST = mm ST F Ø Hanger bracket with shock absorber attachment on threaded bolt Hanger bracket with shock absorber attachment with screw imensions Fig. ST K F Adjustable steel hanger bracket, trailing arm 70 mm wide Item 1510 / 1511 / Adjustable Adjustable F Ø Exec. V Exec. V (H) A (w. TP) A (H) A (w. TP) ~A Stainless steel hanger bracket, adjustable, trailing arm 70 mm wide C Cast alloy hanger bracket, adjustable, trailing arm 70 mm wide /170 51/41 olton, adjustable steel hanger bracket, trailing arm 70 mm wide R R R R E F Further executions upon request. (w. TP) = with top plate PWEuft e 109

110 PW riginal spare parts Air suspensions 10.1 Hanger brackets Straight steel hanger brackets / trailing arms 100 mm wide A C F ST ST a b E F K K K F F F ST ST ST 100 a b 100 a b 100 G H I K K ST F ST F 120 a b 120 a b J K Remark: K ST 100 a F b K * New hanger bracket with loose wear plates. Further executions upon request. (w. TP) = with top plate ST 100 a F b o not apply heat to the suspension hanger brackets to effect any reworking or alignment. amaged hanger brackets should be completely replaced! When exchanging the hanger brackets, new spring pivot bolts and locking nuts are to be used! bserve the welding guidelines as per PW installation instructions! No longer available. Change over to hanger bracket with loose wear plates resp. hanger bracket with shock absorber attachment with screw. 110 PWEuft e

111 Hanger brackets 10.1 Straight steel hanger brackets / trailing arms 100 mm wide ST = mm imensions ST Hanger bracket without shock absorber attachment Rigid Hanger bracket with shock absorber attachment on threaded bolt Rigid Adjustable Hanger bracket with shock absorber attachment with screw Rigid Adjustable Fig. ST K F Exec. E/ Exec. E/ Exec. V Exec. E/ Exec. V Item 1510 / 1511 / Standard hanger bracket, trailing arm 100 mm wide G * J * G * G (w. TP) * R A * G * K * H * 85/170 51/ K * * G * G * (w. TP) H 85/170 57/ * * K (w. TP) /170 59/ * A * J * R R E F * * E R F * Further executions upon request. PWEuft e 111

112 PW riginal spare parts Air suspensions 10.1 Hanger brackets Straight steel hanger brackets / trailing arms 100 mm wide A C F ST ST a b E F G H I K K F F ST ST 100 a b 100 a b J K M N Remark: K ST 100 a F b o not apply heat to the suspension hanger brackets to effect any reworking or alignment. amaged hanger brackets should be completely replaced! When exchanging the hanger brackets, new spring pivot bolts and locking nuts are to be used! bserve the welding guidelines as per PW installation instructions! 112 PWEuft e

113 Hanger brackets 10.1 Straight steel hanger brackets / trailing arms 100 mm wide ST = mm imensions ST Hanger bracket without shock absorber attachment Rigid Hanger bracket with shock absorber attachment on threaded bolt Rigid Adjustable Hanger bracket with shock absorber attachment with screw Rigid Adjustable Fig. ST K F Exec. E/ Exec. E/ Exec. V Exec. E/ Exec. V Item 1510 / 1511 / Standard hanger bracket, trailing arm 100 mm wide A M I H * * R * I * (w. TP) ~ I * R H I * H ~ H R R R I * * A C * M * M * C R H I * M * (w. TP) M * * New hanger bracket with loose wear plates. Further executions upon request. (w. TP) = with top plate No longer available. Change over to hanger bracket with loose wear plates resp. hanger bracket with shock absorber attachment with screw. PWEuft e 113

114 PW riginal spare parts Air suspensions 10.1 Hanger brackets Straight steel hanger brackets / trailing arms 100 mm wide A C ST 100 E F ST 100 G H I K F ST 100 a b J K M N Remark: K ST 100 a F b o not apply heat to the suspension hanger brackets to effect any reworking or alignment. amaged hanger brackets should be completely replaced! When exchanging the hanger brackets, new spring pivot bolts and locking nuts are to be used! bserve the welding guidelines as per PW installation instructions! 114 PWEuft e

115 Hanger brackets 10.1 Straight steel hanger brackets / trailing arms 100 mm wide ST = mm imensions ST Hanger bracket without shock absorber attachment Rigid Adjustable Hanger bracket with shock absorber attachment on threaded bolt Rigid Adjustable Hanger bracket with shock absorber attachment with screw Rigid Adjustable Fig. ST K F Exec. E/ Exec. V Exec. E/ Exec. V Exec. E/ Exec. V Item 1510 / 1511 / Standard hanger bracket, trailing arm 100 mm wide * G R M * R G M * * R G M (w. TP) R G * M * M * New hanger bracket with loose wear plates. Further executions upon request. (w. TP) = with top plate No longer available. Change over to hanger bracket with loose wear plates resp. hanger bracket with shock absorber attachment with screw. PWEuft e 115

116 PW riginal spare parts Air suspensions 10.1 Hanger brackets Taper mounted steel hanger brackets, trailing arms 100 mm wide A C F F ST ST 100 a b 120 a b E F G H I K K K F F F ST ST ST 120 a b 120 a b 100 a b J K Remark: o not apply heat to the suspension hanger brackets to effect any reworking or alignment. amaged hanger brackets should be completely replaced! When exchanging the hanger brackets, new spring pivot bolts and locking nuts are to be used! bserve the welding guidelines as per PW installation instructions! 116 PWEuft e

117 Hanger brackets 10.1 Taper mounted steel hanger brackets, trailing arms 100 mm wide ST = mm imensions ST Hanger bracket with shock absorber attachment with screw Rigid Adjustable Fig. ST K F Exec. S Exec. SV Item 1510 / 1511 / 1513 Taper mounted steel hanger bracket, trailing arm 100 mm wide G G * * H * I * * C * H I * H * I H /170 51/ * * New hanger bracket with loose wear plates. Further executions upon request. No longer available. Change over to hanger bracket with loose wear plates resp. hanger bracket with shock absorber attachment with screw. PWEuft e 117

118 PW riginal spare parts Air suspensions 10.1 Hanger brackets Alloy hanger brackets / stainless steel hanger brackets, trailing arms 100 mm wide Alloy hanger bracket, trailing arm 100 mm wide A C Aluminium hanger brackets for 100 mm wide trailing arms are no longer available. Contact PW if replacement is required. F F ST ST Taper mounted stainless steel hanger bracket, trailing arm 100 mm wide E Remark: ST 120 F K ST 120 F o not apply heat to the suspension hanger brackets to effect any reworking or alignment. amaged hanger brackets should be completely replaced! When exchanging the hanger brackets, new spring pivot bolts and locking nuts are to be used! bserve the welding guidelines as per PW installation instructions! 118 PWEuft e

119 Hanger brackets 10.1 Alloy hanger brackets / stainless steel hanger brackets, trailing arms 100 mm wide ST = mm imensions ST Hanger bracket without shock absorber attachment Rigid Adjustable Hanger bracket with shock absorber attachment on threaded bolt Rigid Adjustable Hanger bracket with shock absorber attachment with screw Rigid Adjustable Fig. ST K F Exec. S Exec. SV Exec. S Exec. SV Exec. S Exec. SV Item 1510 / 1511 / Alloy hanger bracket, trailing arm 100 mm wide Aluminium hanger brackets for 100 mm wide trailing arms are no longer available. Contact PW if replacement is required. Taper mounted stainless steel hanger bracket, trailing arm 100 mm wide E E Further executions upon request R R R Stainless steel hanger brackets for 100 mm wide trailing arms are no longer available. Contact PW if replacement is required. PWEuft e 119

120 PW riginal spare parts Air suspensions 10.2 Integreated supports Integrated support / trailing arms 70 mm wide ( II) A K StM M K StM M ST F ST F FM G FM G C K StM M ST F FM G E F StM M ST F StM M ST F FM G FM G G StM M ST F Remark: o not apply heat to the suspension integrated support to effect any reworking or alignment. amaged integrated supports should be completely replaced! When exchanging the integrated supports, new spring pivot bolts and locking nuts are to be used! bserve the welding guidelines as per PW installation instructions! FM G 120 PWEuft e

121 Integrated support / trailing arms 70 mm wide ( II) Integreated supports 10.2 ST = mm ST Integrated support with shock absorber attachment on threaded bolt Integrated support with shock absorber attachment with screw between plates imensions Adjustable Adjustable Fig. ST FM M StM G K F F Ø Exec. CV Exec. CV Integrated support, adjustable, trailing arm 70 mm wide Item A E C / Further executions upon request. PWEuft e 121

122 PW riginal spare parts Air suspensions 10.2 Integreated supports Integreated supports / trailing arms 70 mm wide ( II) A K StM M K StM M ST F ST F FM G FM G C K StM M ST F FM G E F StM M ST F StM M ST F FM G FM G G StM M ST F Remark: o not apply heat to the suspension integrated support to effect any reworking or alignment. amaged integrated supports should be completely replaced! When exchanging the integrated supports, new spring pivot bolts and locking nuts are to be used! bserve the welding guidelines as per PW installation instructions! FM G 122 PWEuft e

123 Integreated supports / trailing arms 70 mm wide ( II) Integreated supports 10.2 ST = mm ST Integrated support with shock absorber attachment on threaded bolt Integrated support with shock absorber attachment with screw between plates imensions Fig. ST FM M StM G K F Adjustable Adjustable F Ø Exec. CV Exec. CV Integrated support, adjustable, trailing arm 70 mm wide Item F C / G / C / Further executions upon request. PWEuft e 123

124 PW riginal spare parts Air suspensions 10.2 Integreated supports Integreated supports / trailing arms 100 mm wide A K StM M K StM M ST F ST F FM G FM G C K StM M ST F FM G E F StM M StM M ST F ST F FM G FM G G StM / M ST F Remark: o not apply heat to the suspension integrated support to effect any reworking or alignment. amaged integrated supports should be completely replaced! When exchanging the integrated supports, new spring pivot bolts and locking nuts are to be used! bserve the welding guidelines as per PW installation instructions! FM G 124 PWEuft e

125 Integreated supports 10.2 Integreated supports / trailing arms 100 mm wide ST = mm ST Integrated support with shock absorber attachment on threaded bolt Integrated support with shock absorber attachment with screw between plates Integrated support with shock absorber attachment screw in support centre imensions Adjustable Adjustable Adjustable Fig. ST FM M StM G K F Exec. C Exec. C Exec. C Integrated support, adjustable, trailing arm 100 mm wide Item A E G F C / Replacement channel crossmembers are now only supplied with adjustable spring bolt mounting. Note the modified spring pivot bolts if replacement is required. Further executions upon request. PWEuft e 125

126 PW riginal spare parts Air suspensions 10.3 Spare parts for hanger brackets, integrated supports, frames Weldin bushes for spring pivot bearings Weldin bushes for steel hanger brackets / integrated supports / frames with unadjustable spring pivot bolt bearing Spring pivot bolt bearing for steel hanger bracket with slotted bushes (torsion protection), welded on wear plates (1520) Spring pivot bolt bearing for steel hanger bracket with square internal lock bushes (torsion protection), welded on wear plates (1520) Spring pivot bolt bearing for steel hanger bracket with square internal lock bushes (torsion protection), loose wear plates (1525) Weldin bushes ( Item 1535 ) no longer available. Conversion to torsion protection with square internal lock bush. Weldin bushes for stainless steel hanger brackets with unadjustable spring pivot bolt bearing Unadjustable spring pivot bolt bearing, stainless steel hanger bracket Weldin bushes for steel hanger brackets / integrated supports with adjustable spring pivot bolt bearing Adjustable spring pivot bolt bearing, hanger bracket with square profile Adjustable spring pivot bolt bearing, hanger bracket with elongated hole PWEuft e

127 Spare parts for hanger brackets, integrated supports, frames 10.3 Weldin bushes for spring pivot bearings Item esignation Remark PW Code no. imensions Weldin bushes for steel hanger brackets / integrated supports / frames with unadjustable spring pivot bolt bearing Washer Weldin bush Round wearing plate, torsion protection with slotted bushes Ø 30 / 121 x no longer available * Plate Weldin bush Square wearing plate, pivot bush, torsion protection with slotted bushes Ø 56 / 105 x Ø 56 / 101 / 140 x no longer available * Plate Weldin bush Shaped plate Weldin bush 1) Spring pivot bolt Ø 24 Spring pivot bolt Ø 30 Square wearing plate, pivot bush, torsion protection with square internal lock bush Ø 56 / 105 x Ø 56 / 101 / 140 x Ø 30 / 51 / 56 x 29 oose wear plates, torsion protection with square internal lock bush see spring pivot bolt bearings Ø 24.1 / 55 / 68 x Ø 30.5 / 55 / 74 x Weldin bushes for stainless steel hanger brackets with unadjustable spring pivot bolt bearing Plate Weldin bush with torsion protection Ring Square wearing plate, pivot bush, torsion protection with square internal lock bush Ø 56 / 101 / 140 x Ø 30.5 / 55 x Ø 30.5 / 55 x Weldin bushes for steel hanger brackets / integrated supports, with adjustable spring pivot bolt bearing Plate Shaped part Adjustable spring pivot bolt bearing, hanger bracket with square profile x 101 x x 101 x x 62 x Shaped plate Weldin bush 1) Spring pivot bolt Ø 24 Spring pivot bolt Ø 30 Adjustable spring pivot bolt bearing, hanger bracket with elongated hole 1540 siehe Federbolzenlagerungen Ø 24.3/36.6 / 68 x Ø 30.3/42.6 / 74 x 23 * Conversion kits see spring pivot bolt bearing page ) Changing the weldin bushes see pages 170 / 171. PWEuft e 127

128 PW riginal spare parts Air suspensions 10.3 Spare parts for hanger brackets, integrated supports, frames Wear plates for alloy hanger brackets Unadjustable spring pivot bolt bearing Adjustable spring pivot bolt bearing Cast alloy hanger bracket Weldin bolts for shock absorber attachment / check strap Weldin bolts for shock absorber attachment Weldin bolts for check strap attachment PWEuft e

129 Spare parts for hanger brackets, integrated supports, frames 10.3 Wear plates for alloy hanger brackets Item esignation Remark PW Code no. imensions Wear plates for alloy hanger brackets with unadjustable spring pivot bolt bearing Washer Washer Unadjustable spring pivot bolt bearing Ø 30 / 50 / 110 x Ø 30 / 50 / 70 x Wear plates for cast alloy hanger brackets with adjustable spring pivot bolt bearing Shaped plate ush Spring pivot bolt Ø 24 Spring pivot bolt Ø 30 Adjustable spring pivot bolt bearing Cast alloy hanger bracket see spring pivot bolt bearings Ø 24.3/36.6 / 55/90 x Ø 30.2/42.5 / 55/90 x Weldin bolts for shock absorber attachment / check strap Shock absorber attachment 1310 Threaded bolt see upper shock absorber attachment page 92 Fangseilbefestigung 1363 Threaded bolt see check strap attachment page 103 PWEuft e 129

130 PW riginal spare parts Air suspensions 11 Ustabilizers Ustabilizer attachments M = Nm M M = Nm 1324 M24 ower Ustabilizer attachmenrt between plates ower Ustabilizer attachmenrt on threaded bolts Item esignation Remark PW Code no. imensions PW Code no. imensions Spring seat Spring plate see page 33 see page 41 / 45 see page Hexagon screw M 30 x ock nut M 30 / SW M 30 / SW Threaded bolt M 24 / M 30 / = M = Nm M = Nm 1168 Upper Ustabilizer attachmenrt between plates Upper Ustabilizer attachmenrt on threaded bolts Item esignation Remark PW Code no. imensions PW Code no. imensions 1156 Hexagon screw M 30 x ock nut M 30 / SW M 30 / SW Threaded bolt M 30 / Ø 45 x PWEuft e

131 Ustabilizers 11 Ustabilizers A Item esignation Remark PW Code no. imensions ock nut ush Shaped plate Grease nipple Hexagon screw VM 10 / Ø 50 / 70 x AM 10 x 1 / M 10 x Ustabilizer (incl. item 1817) A = A = A = A = A = 1300 ush ( Item 1817 ) Ø 30 / 52.6 x Ø 30 / 52.6 x Ø 30 / 52.6 x Ø 30 / 52.6 x Ø 30 / 52.6 x ush Ø 30 / 52.6 x Ø 30 / 60 x Support (incl. item 1817) H = H = H = H = 395 ush ( Item 1817 ) Ø 30 / 52.6 x Ø 30 / 60 x Ø 30 / 60 x Ø 30 / 60 x 68 PWEuft e 131

132 PW riginal spare parts Air suspensions 12 rawbar attachments, spring pivot bolt torsion protections rawbar attachments, spring pivot bolt torsion protections rawbar attachment for welded hanger brackets rawbar attachment for formed hanger brackets / estesignhanger brackets Item esignation Remark PW Code no. imensions PW Code no. imensions 1550 Support (incl. item ) fo bolt Ø for bolt Ø ush without slit Ø 30 / 58 / 65 x Ø 30 / 58 / 65 x ush with slit Ø 30 / 58 / 65 x Ø 30 / 58 / 65 x 36 Welded on torsion protection with steel hanger brackets / integrated supports and axle lift device Item esignation Remark PW Code no. imensions 1560 Shaped plate for SW (welded on torsion protection) Shaped part (screwed on torsion protection) Screwed on torsion protection with steel hanger brackets / integrated supports and axle lift device for SW PWEuft e

133 rawbar attachments, spring pivot bolt torsion protections 12 rawbar attachments, spring pivot bolt torsion protections Fit connecting link disc with welded on torsion protection for adjustable steel hanger bracket / integrated support and axle lift device, hanger bracket with square profile Item esignation Remark PW Code no. imensions 1560 Adjusting plate ith welded on torsion protection Fit connecting link disc with welded on torsion protection for adjustable steel hanger bracket / integrated support and axle lift device hanger bracket with elongated hole = = 57.5 PWEuft e 133

134 PW riginal spare parts Air suspensions 13 Air tanks Air tanks Item esignation Remark PW Code no. imensions PW Code no. Air tank Item 2000 Capacity itre Ø Attachment Item Air tank = Alloy EC Air AIRTANK Air tank Item 2000 Capacity itre Ø Attachment Item Air tank PWEuft e

135 Notes PWEuft e 135

136 PW riginal spare parts Air suspensions 13 Axle lifts General PW Axle lift devices As an option, multiaxle vehicles can be equipped with an axle lift to reduce the wear on the tyres when driving unladen or with a light cargo. PW offers axle lifts for positioning in the middle or at the sides of the axle. Sidewise mounted axle lift A sidewise mounted lift is recommended for lifting the first axle and in vehicles with limited ground clearance, high axle loads or long suspension travel. Central mounted axle lift The lifting device can be arranged in the centre of the axle for lifting the middle (rear) suspension axle or if space is limited. This axle lift device is attached to the frame by crossmembers in the middle of the vehicle. The lift bag forces must also be absorbed by a crossmember. 136 PWEuft e

137 Axle lifts 13 Spare parts for EC Air CMPACT air suspensions see pages ftujt Zentrallift Central lift oth Sowohl the die central mittige axle Achsanhebevorrichtung lift device using a lifting über einen bag and iftbalg the PW als auch central der lift in with bellows Fahrzeugmitte fitted in montierte the middle PW of Zentrallift the vehicle can mit Faltenbalg lift one or heben more suspension eine bzw. mehrere axles and are Aggregatachsen integrated within an und the sind space im of auraum the axle unit. des Achsaggregates Their compact design integriert. means they are preferred Aufgrund for ihrer use kompakten in vehicles auweise with limited werden ground sie bevorzugt clearance bei Fahrzeugen and small tyres mit (e.g. geringer pallet box odenfreiheit trailers with und single kleinen tyres). Reifen (z.. bei einfachbereiften PalettenkastenFahrzeugen) eingesetzt. Zweiseitenlift Twoside axle lift The er Zweiseitenlift doublesided (für lift (for bis airsprung zu 10Tonnenuftfederachsen) to 10 tonnes) benötigt does keinen not need Raum any vor space den axles up in Hanger front bracketsund of the air suspension in der Fahrzeugmitte. hanger brackets Er ist jederzeit or in the nachrüstbar middle of und the überzeugt vehicle. It durch can geringes be retrofitted Gewicht at any und time gute to odenfreiheit. offer the convincing benefits of low weight and good ground clearance. PWEuft e 137

138 PW riginal spare parts Air suspensions 13.1 Sidewise mounted axle lifts Sidewise mounted axle lifts, trailing arms 100 mm wide Sidewise mounted axle lift Standard hanger bracket Taper mounted hanger bracket Adjustable hanger bracket 77 / M = 230 Nm M = 66 Nm M = 230 Nm M = 900 Nm Alloy hanger bracket M = 900 Nm 138 PWEuft e

139 Sidewise mounted axle lifts 13.1 Sidewise mounted axle lift, trailing arms 100 mm wide Item esignation Remark PW Code no. imensions PW Code no. imensions Screw (Spring pivot bolt) Washer Washer ock nut Castle nut Split pin ush Graduated bush Air bag ocking screw ocking screw Steel hanger bracket, torsion protection with square internal lock bush Alloy hanger bracket see page see page Ø 41 / 50 x Ø 30 / 40 / 46 x 31 see page 77 / M 16 x 30 (for welded supporting arm) M 16 x 65 (for solid supporting arm) 1513 Hanger bracket see page see page Shaped plate (welded on torsion protection with steel hanger brackets) Ø 41 / 50 x Ø 30 / 40 / 46 x 31 Solid, screwed supporting arm Supporting arm with bump stop 1610 ifting arm = M Ø 17 M Support (for steel hanger bracket) (for steel hanger bracket) (for alloy hanger bracket) ocking screw ock nut * ump stop = = = M 16 x VM 16 / Ø 80 / M M = 230 Nm * for supporting arm without threaded holes. PWEuft e 139

140 PW riginal spare parts Air suspensions 13.1 Sidewise mounted axle lifts Sidewise mounted axle lifts, trailing arms 100 mm wide Sidewise mounted axle lift Standard hanger bracket Taper mounted hanger bracket Adjustable hanger bracket 77 / M = 230 Nm M = 66 Nm M = 230 Nm M = 900 Nm Alloy hanger bracket M = 900 Nm 140 PWEuft e

141 Sidewise mounted axle lifts 13.1 Sidewise mounted axle lift, trailing arms 100 mm wide Item esignation Remark PW Code no. imensions 1630 ever (for steel hanger bracket) Welded supporting arm with bump stop H Support ever ump stop ock nut (for alloy hanger bracket) / M 12 x Ø 80 / M M H No longer available. Change over to solid lever (page 139) Return spring Plate Ø 3.5 / 23.5 x x 70 x 6 PWEuft e 141

142 PW riginal spare parts Air suspensions 13.1 Sidewise mounted axle lifts Sidewise mounted axle lifts, trailing arms 70 mm wide Sidewise mounted axle lift Standard hanger bracket Integrated support / M = 230 Nm M = 900 Nm 142 PWEuft e

143 Sidewise mounted axle lift, trailing arms 70 mm wide Item esignation Remark PW Code no. imensions Adjustable spring pivot bolt bearing, hanger bracket / integrated support with elongated hole, connecting link disc with welded on torsion protection Sidewise mounted axle lifts Screw (Spring pivot bolt) Plate (adjusting plate) Washer see page ock nut 1175 ush Ø 41 / 50 x Ring Ø 30 / 39 x Air bag see page 77 / ocking screw M 10 x ocking screw M 16 x ocking screw M 16 x Hanger bracket see page Shaped plate Adjusting plate with welded on torsion protection see page Solid, screwed supporting arm Supporting arm with bump stop 1610 ifting arm = Ø Ø 17 M Support ocking screw = M 10 x ump stop PWEuft e 143

144 PW riginal spare parts Air suspensions 13.2 Central axle lifts Central axle lift Central axle lift Steel hanger bracket Alloy hanger bracket / M = 900 Nm M = 230 Nm Supporting arm with threaded holes 1224 M = 230 Nm Supporting arm without threaded holes M = 900 Nm Welded supporting arm with bump stop Welded supporting arm with rubber roller M = 230 Nm M = 66 Nm M = 230 Nm 1640 M = 230 Nm 144 PWEuft e

145 Central axle lifts 13.2 Central axle lift Item esignation Remark PW Code no. imensions PW Code no. imensions Screw (Spring pivot bolt) Washer Washer ock nut Castle nut Split pin ush Graduated bush Air bag ocking screw ocking screw Steel hanger bracket, torsion protection with square internal lock bush Alloy hanger bracket see page see page Ø 41 / 50 x Ø 30 / 40 / 46 x 31 see page 77 / M 16 x 30 (for welded supporting arm) M 16 x 65 (for solid supporting arm) 1513 Hanger bracket see page see page Shaped plate (welded on torsion protection with steel hanger brackets) Ø 41 / 50 x Ø 30 / 40 / 46 x 31 Supporting arm with bump stop Support above the axle 1600 Support /150, Ø 127 Supporting arm with rubber roller Support above the axle 1600 Support /150, Ø 127 Support underneath the axle , Ø Tube Ø 35 / 51 x 102 Solid, screwed supporting arm Supporting arm with bump stop 1610 ifting arm = M Ø 17 M Support (for steel hanger bracket) (for steel hanger bracket) (for alloy hanger bracket) ocking screw ock nut * ump stop = = = M 16 x VM 16 / Ø 80 / M M = 230 Nm * for supporting arm without threaded holes. PWEuft e 145

146 PW riginal spare parts Air suspensions 13.2 Central axle lifts Central axle lift Central axle lift Steel hanger bracket Alloy hanger bracket / M = 900 Nm M = 230 Nm Supporting arm with threaded holes 1224 M = 230 Nm Supporting arm without threaded holes M = 900 Nm Welded supporting arm with bump stop Welded supporting arm with rubber roller M = 230 Nm M = 66 Nm M = 230 Nm 1640 M = 230 Nm 146 PWEuft e

147 Central axle lifts 13.2 Central axle lift Item esignation Remark PW Code no. imensions Welded supporting arm with bump stop H ever (for steel hanger bracket) Support ever (for alloy hanger bracket) ump stop / M 12 x Ø 80 / M ock nut M H No longer available. Change over to solid lever (page 145) Welded supporting arm with rubber roller H ever Roller Ø 25.5 / 110 x Hexagon screw M 16 x Tube Ø 17 / 25 x Ring Ø 25.5 / 35 x ock nut VM H Return spring Plate Ø 3.5 / 23.5 x x 70 x 6 PWEuft e 147

148 PW riginal spare parts Air suspensions 13.2 Central axle lifts Central axle lift with rubber / steel bush Central axle lift with rubber / steel bush M = 66 Nm M = 230 Nm M = 900 Nm 148 PWEuft e

149 Central axle lifts 13.2 Central axle lift with rubber / steel bush Item esignation Remark PW Code no. imensions PW Code no. imensions Screw (Spring pivot bolt) Washer ock nut Castle nut Air bag ocking screw Steel hanger bracket, torsion protection with square internal lock bush Alloy hanger bracket see page see page see page 77 / M 16 x Hanger bracket see page see page Support ump stop ock nut M Spring washer / ever (incl. item 1641) ush Ø 30 / 60 x Return spring Ø 3.5 / 23.5 x 250 PWEuft e 149

150 PW riginal spare parts Air suspensions 13.2 Central axle lifts Central axle lift Central axle lift Support underneath the axle Support above the axle PWEuft e

151 Central axle lifts 13.2 Central axle lift Item esignation Remark PW Code no. imensions 1035 Segment for Spring Ubolt for Washer Ø 25 / Hexagon screw M 24 x 120 / ock nut VM 24 / Support (incl. item 1601) for ush Ø 24 / 50 x Shaped plate Shaped plate ocking screw M 8 x 12 (4x) ocking screw Air bag M 10 x 25 (8x) PWEuft e 151

152 PW riginal spare parts Air suspensions 13.2 Central axle lifts Axle lift (central) with lever Axle lift (central) with lever PWEuft e

153 Central axle lifts 13.2 Axle lift (central) with lever Item esignation Remark PW Code no. imensions 1605 Profile Model no longer available, for further information contact PW Support ump stop Hexagon screw M 10 x 55 / ock nut VM 10 / ever ush Shaped plate Grease nipple Hexagon screw K Ø 50 / 90 x M 10 x 110 / Return spring rake cylinder Spring washer A 12 / Hexagon nut M 12 / Hexagon nut M 16 x 1.5 / Yoke G 16 x olt x 45 x Split pin x Plate Threaded bolt Ring Washer ock nut M 20 / 40 / M 20 x Ø 24.5 / 33.5 x Ø 21 / 51 x M K Air bag (incl. item ) Ring Ring Air bag (only) Washer Ø 205 x Spring washer (24x) 1691 Hexagon screw M 8 x (8x) 1692 Hexagon screw M 8 x (4x) 1693 Hexagon screw M 8 x (12x) PWEuft e 153

154 PW riginal spare parts Air suspensions 13.2 Central axle lifts Central axle lift with support Central axle lift with support 120 Ø PWEuft e

155 Central axle lifts 13.2 Central axle lift with support Item esignation Remark PW Code no. imensions PW Code no. imensions 120 Ø Segment Spring Ubolt Washer Ø 25 / ock nut VM 24 / 980 A A 1600 Support (incl. item 1635) A A Integreated supports (incl. item 1672) ump stop Support ever Threaded bolt Ring Washer ock nut upon request Ø 80 / M M 20 / Ø 24 x Ø 24.5 / 33.5 x Ø 21 / 51 x M Air bag Spring washer / Hexagon screw M 8 x 55 / Hexagon screw M 8 x 22 / PWEuft e 155

156 PW riginal spare parts Air suspensions 13.3 Twoside axle lifts Twoside axle lift, steel hanger bracket with unadjustable spring pivot bolt bearing Twoside axle lift Screwed support with square bar M = 900 Nm Screwed support with elongated hole M = 900 Nm PWEuft e

157 Twoside axle lifts 13.3 Twoside axle lift, steel hanger bracket with unadjustable spring pivot bolt bearing Item esignation Remark PW Code no. imensions Screw (Spring pivot bolt) Washer Washer ock nut ush Graduated bush 1560 Shaped plate (welded on torsion protection) Shaped part (screwed on torsion protection) Trailing arms 100 mm wide see page Ø 42 / 50 / 54 x Ø 30 / 42 / 62 x for SW for SW 46 Screwed support with square bar Screwed support with elongated hole Retrofit kit twoside axle lift (Item 1610, 1611, 1615, 1660) Support, right Support, left Support with elongated hole Contents per axle ever ump stop Cylinder head screw ock nut x 60 x M 6 x VM 6 / Square bar ocking screw Plate ocking screw ock nut x M 8 x M 12 x M 12 x VM 12 / Return spring Ø 22.5 / 2.5 x iaphragm cylinder for axle lift Hexagon nut Type 36, Stroke > 90 mm M 16 x 1.5 See pages 168 / 169 for assembly and installation instructions. PWEuft e 157

158 PW riginal spare parts Air suspensions 13.3 Twoside axle lifts Twoside axle lift, steel hanger bracket with adjustable spring pivot bolt bearing Twoside axle lift Screwed support with square bar M = 900 Nm Screwed support with elongated hole olted, 2part holder M = 900 Nm M = 900 Nm PWEuft e

159 Twoside axle lifts 13.3 Twoside axle lift, steel hanger bracket with adjustable spring pivot bolt bearing Item esignation Remark PW Code no. imensions Screw (Spring pivot bolt) Plate (adjusting plate) Washer Washer ock nut ush Graduated bush Shaped plate Shaped plate (welded on torsion protection) Adjusting plate with welded on torsion protection Trailing arm 70 mm wide Trailing arm 100 mm wide see page see page Ø 42 / 50 / 54 x Ø 30 / 42 / 62 x 22 see page see page Screwed support with square bar, trailing arm 100 mm wide Screwed support with elongated hole, trailing arm 100 mm wide 1609 Retrofit kit twoside axle lift (Item 1610, 1611, 1615, 1660) Contents per axle 1610 Support, right Support, left Support (for steel hanger bracket) Screwed support with elongated hole, trailing arm 70 mm wide 1610 Shaped plate Shaped plate (for steel hanger bracket) olted, 2part holder, trailing arm 70 mm wide Screwed support with square bar, trailing arm 100 mm wide Support, right Support, left Support ever ump stop Cylinder head screw ock nut Trailing arm 70 mm wide x 60 x M 6 x VM 6 / 9808 Trailing arm 100 mm wide x 60 x M 6 x VM 6 / 9808 Screwed support with elongated hole Screwed support with square bar Square bar ocking screw Plate ocking screw ock nut M 12 x VM 12 / x /35 x M 8 x for for 25/ M 12 x Return spring Ø 22.5 / 2.5 x iaphragm cylinder for axle lift Type 36, Stroke > 90 mm 1663 Hexagon nut M 16 x 1.5 See pages 168 / 169 for assembly and installation instructions. PWEuft e 159

160 PW riginal spare parts Air suspensions 13.3 Twoside axle lifts Twoside axle lift, integrated support with unadjustable spring pivot bolt bearing Twoside axle lift M = 900 Nm PWEuft e

161 Twoside axle lifts 13.3 Twoside axle lift, integrated support with unadjustable spring pivot bolt bearing Item esignation Remark PW Code no. imensions Screw (Spring pivot bolt) Washer Washer ock nut ush Graduated bush 1560 Shaped plate (welded on torsion protection) Shaped part (screwed on torsion protection) Trailing arms 100 mm wide see page Ø 42 / 50 / 54 x Ø 30 / 42 / 62 x for SW for SW Support, right Support, left Support with elongated hole Screwed support with elongated hole ever ump stop Cylinder head screw ock nut x 60 x M 6 x VM 6 / ocking screw ock nut M 12 x VM 12 / Return spring Ø 22.5 / 2.5 x iaphragm cylinder for axle lift Hexagon nut Type 36, Stroke > 90 mm M 16 x 1.5 See pages 168 / 169 for assembly and installation instructions. PWEuft e 161

162 PW riginal spare parts Air suspensions 13.3 Twoside axle lifts Twoside axle lift, integrated support with adjustable spring pivot bolt bearing Twoside axle lift M = 900 Nm PWEuft e

163 Twoside axle lifts 13.3 Twoside axle lift, integrated support with adjustable spring pivot bolt bearing Item esignation Remark PW Code no. imensions Trailing arm 70 mm wide Trailing arm 100 mm wide Screw (Spring pivot bolt) Plate (adjusting plate) Washer Washer ock nut see page see page ush Ø 42 / 50 / 54 x Graduated bush Ø 30 / 42 / 62 x Shaped plate see page see page Screwed support with elongated hole, trailing arm 100 mm wide 1610 Support, right Support, left Support (for integreated supports) Screwed support with elongated hole, trailing arm 70 mm wide 1610 Shaped plate Shaped plate (for integreated supports) ever ump stop Cylinder head screw ock nut Trailing arm 70 mm wide x 60 x M 6 x VM 6 / 9808 Trailing arm 100 mm wide x 60 x M 6 x VM 6 / 9808 Screwed support with elongated hole 1635 ocking screw M 12 x ock nut VM 12 / Return spring Ø 22.5 / 2.5 x iaphragm cylinder for axle lift Hexagon nut Type 36, Stroke > 90 mm M 16 x 1.5 See pages 168 / 169 for assembly and installation instructions. PWEuft e 163

164 PW riginal spare parts Air suspensions 13.3 Twoside axle lifts Twoside axle lift, alloy hanger bracket with unadjustable spring pivot bolt bearing Twoside axle lift Screwed support with square bar M = 900 Nm PWEuft e

165 Twoside axle lifts 13.3 Twoside axle lift, alloy hanger bracket with unadjustable spring pivot bolt bearing Item esignation Remark PW Code no. imensions Trailing arms 100 mm wide Screw (Spring pivot bolt) Washer Washer Castle nut Split pin see page Ring Ø 42 / 50 x ush Ø 30 / 42 x Retrofit kit twoside axle lift (Item 1610, 1611, 1615, 1660) Support, right Support, left Screwed support with square bar Contents per axle ever ump stop Cylinder head screw ock nut x 60 x M 6 x VM 6 / Square bar ocking screw x M 12 x Return spring Ø 22.5 / 2.5 x iaphragm cylinder for axle lift Hexagon nut Type 36, Stroke > 90 mm M 16 x 1.5 See pages 168 / 169 for assembly and installation instructions. PWEuft e 165

166 PW riginal spare parts Air suspensions 13.3 Twoside axle lifts Twoside axle lift, alloy hanger bracket with adjustable spring pivot bolt bearing Twoside axle lift M = 900 Nm PWEuft e

167 Twoside axle lifts 13.3 Twoside axle lift, alloy hanger bracket with adjustable spring pivot bolt bearing Item esignation Remark PW Code no. imensions Trailing arm 70 mm wide Screw (Spring pivot bolt) Plate (adjusting plate) Washer Washer Castle nut Split pin Washer see page ush Ø 42 / 50 / 54 x Graduated bush Ø 30 / 42 / 62 x Shaped plate see page Support, right Support, left Support Screwed support with elongated hole, trailing arm 70 mm wide (for alloy hanger bracket) ever ump stop Cylinder head screw ock nut x 60 x M 6 x VM 6 / ocking screw ock nut Screwed support with elongated hole M 12 x VM 12 / Return spring Ø 22.5 / 2.5 x iaphragm cylinder for axle lift Hexagon nut Type 36, Stroke > 90 mm M 16 x 1.5 See pages 168 / 169 for assembly and installation instructions. PWEuft e 167

168 PW riginal spare parts Air suspensions 13.3 Twoside axle lifts Twosided axle lift, installation notes General The PW twosided axle lift is suitable for the following axles and air suspension systems: 9 t airsuspension axles for single and twin wheels 10 t airsuspension axles with single wheels, not however for axles with greater permitted axle loads or for steering axles Air suspension systems with air bag types 30K, 30, 36K, 36 for spring deflections up to 220 mm, not however for longtravel air suspension systems with bag types 301, 361, 362, 365 The twosided axle lift is fitted underneath the air suspension hanger brackets of the axle to be lifted. Please bear in mind the following points when using them: In air suspension systems with raising and lowering, the downward travel of the axles must be limited. The travel limitation can take the form of an air suspension valve with integrated level restriction, a separate shutoff valve or of catch straps. The stroke limiting function must be set so that the axle lift cannot be overloaded at maximum lift. The ride height of the air suspension must be set to a min. upward travel of 100 mm. When the axle is lifted, the tyre damping results in a clearance of approx. 60 mm under the tyres. Make sure there is adequate ground clearance below the axle lift, in particular in air suspension systems with trailing arms located underneath to give a low vehicle height. Make sure the right and left sides of one hanger bracket have a symmetrical setting of the sliding blocks. After mounting the axle lift, check it functions correctly and that there is adequate clearance from the adjacent components. An air pressure of at least 6 bar is required to lift the axle. The permitted operating pressure is 8.5 bar. There is no need for a pressure control valve or a residual pressure holding feature. Free cylinder venting through cross sections without throttle points in the valve installation must be ensured in order to avoid impermissibly high pressure values. Comply with the appropriate statutory regulations when retrofitting an axle lift (e.g. overload protection, German "Kraftkreis", etc.). 168 PWEuft e

169 Twoside axle lifts 13.3 Twosided axle lift, installation notes Perform the following installation steps when retrofitting the twosided axle lift: Take the load off the lifting axle. Unscrew the spring bolt (M 30) and remove it. Install the twosided axle lift as described in the supplied installation instructions. When doing this, only fit the spring bolts loose and do not tighten them yet. Install the diaphragm cylinder with the air connection upwards (M = 180 Nm). Fit plastic plugs into the diaphragm cylinder so the bottom hole is open whilst the top hole is tightly closed. Install the bump stop under the air suspension hanger bracket (channel crossmember) in the position provided for the air suspension (M = 66 Nm). Refer to the technical documents for the corresponding position. Proceed as follows if you do not have the corresponding technical documents: Raise the air suspension using the rotary disc valve or by disconnecting the air suspension linkage. Raise it until the air bags are fully extended. Pivot the axle lift towards the trailing arm by hand, until the plastic buffer makes contact with the trailing arm (the catch plate must be in contact with the trailing arm). In this position, fit the bump stop so it is in contact with the air suspension hanger bracket (channel crossmember). Adjust the air suspension to the nominal ride height with the rotary disc in the "driving" position. Fit the spring bolt antirotation lock. Tighten the spring bolt screw connection to the prescribed tightening torque (M = 900 Nm). Refer to the appropriate installation guidelines for the air suspension installation and valve connection. Perform a trial actuation to test that it is functioning reliably. o not touch any moving parts of the axle lift when doing this. ANGER F ACCIENTS! Check the spring bolt screw connection is firmly seated after the first drive under load. Pos. 1 Pos. 2 Pos. 3 Pos. 4 Pos. 5 Pos. 6 Pos. 7 Axle lifted Min. ride height with lifted axle Axle fully lowered PWEuft e 169

170 PW riginal spare parts Air suspensions Changing the weldin bushes (spring bolt assembly) in PW air suspension hanger brackets for 100 mm wide springs and loose wear plates Perform the following work if the mounting bushes are worn out: 1. Remove the wornout bushes from the side plates 2. Insert new bushes and use spacer sleeve* (112.5) or trailing arm bush ( ) plus mounted wear plates to preload, align centrally and with adjustable hanger brackets horizontally and tackweld Rigid hanger bracket with mounted spacer sleeve* * Not PW tool with mounted trailing arm bush and wear plates Adjustable hanger bracket egin of seam End of seam Weld the bushes 4. When mounting the trailing arms: ightly grease the stud thread and nut contact surface Mount wear plates Tighten locknut M 30 to M = 900 ( ) Nm Important for all welding work! The trailing arms, air bags and plastic pipings should be protected against sparks and weld splashes during all welding work. The earth terminal must under no circumstances be attached to the trailing arm or hub. Welding method: Inert gas welding Weld wire quality G 4 Si 1 (IN EN 440) Mechanical quality values must be equivalent to basic material S 355 J 2 or S 420. Weld thickness a 4 up to a 5 (IN EN 25817) Avoid end cavities and undercutting. * Not PW tool 170 PWEuft e

171 Changing the weldin bushes (spring bolt assembly) in PW air suspension hanger brackets for 70 mm wide springs and loose wear plates Perform the following work if the mounting bushes are worn out: 1. Remove the wornout bushes from the side plates 2. Insert new bushes and use spacer sleeve* (82.5) or trailing arm bush (72+0.5) plus mounted wear plates to preload, align centrally and with adjustable hanger brackets horizontally and tackweld Adjustable hanger bracket with mounted spacer sleeve* * Not PW tool with mounted trailing arm bush and wear plates egin of seam End of seam Weld the bushes 4. When mounting the trailing arms: ightly grease the stud thread and nut contact surface Mount wear plates Tighten locknut M 24 to M = 650 ( ) Nm M 30 to M = 900 ( ) Nm Important for all welding work! The trailing arms, air bags and plastic pipings should be protected against sparks and weld splashes during all welding work. The earth terminal must under no circumstances be attached to the trailing arm or hub. Welding method: Inert gas welding Weld wire quality G 4 Si 1 (IN EN 440) Mechanical quality values must be equivalent to basic material S 355 J 2 or S 420. Weld thickness a 4 up to a 5 (IN EN 25817) Avoid end cavities and undercutting. * Not PW tool PWEuft e 171

172 PW riginal spare parts Air suspensions 14 Spare parts for EC Air CMPACT running gear systems Spring pivot bolt bearing for screwedon gusset plates 75 / AC not supplied by PW PW 30K PW 30 PW 36K PW 36 PW 30K PW PWEuft e

173 Spare parts for EC Air CMPACT running gear systems 14 Item esignation imensions PW Code no Trailing guide H = 60 mm incl. item H = 130 mm ush Ø 24 / 43 / 59 / 132 x Plug 60 x 83.5 x Qty. / Axle ACAU ACAM ACM AC AC 1030 Air bag beam 2 = 380 mm, K = 155 mm = 380 mm, K = 85 mm = 380 mm, K = 10 mm Repair kit axle clamping Item 1050, 1055, Spring Ubolt Washer A ock nut M / SW Standard spring pivot bolt bearing 1150 Repair kit spring pivot bolt bearing Item 1005, 1015, , Spring pivot bolt M 24 x 171 / Ø Plate (adjusting plate) 107 x 85/70 x Washer Ø 25 / 60 x ock nut M 24 / SW Spring pivot bolt bearing for screwedon gusset plates 1155 Spring pivot bolt M 24 x 171 / Ø Plate (adjusting plate) 107 x 85/70 x Washer Ø 25 / 60 x ock nut M 24 / SW Hexagon screw M 18 x 1.5 x Hexagon nut M 18 x 1.5 / SW Air bag cpl. see page 75 / Shock absorber (see page 110) Ø 65 / 75 mm, min.: 287 mm, max. 412 mm, X = 204 mm Ø 65 / 75 mm, min.: 292 mm, max. 432 mm, X = 204 mm Hexagon screw M 24 x / SW Repair kit shock absorber attachment Item Hexagon screw M 24 x / SW ock nut VM Hanger bracket, adjustable Ø 24 / ST 205 / 90 / 85 F 35 / K 77.5, 270 Ø 24 / ST 290 / 90 / 85 F 35 / K 77.5, Washer Ø 59.1 / 170 x PWEuft e 173

174 PW riginal spare parts Air suspensions 14 Spare parts for EC Air CMPACT running gear systems Twoside axle lift, EC Air CMPACT 1640 AC H H = 60 mm Item esignation Remark PW Code no. imensions 1600 Twoside axle lift cpl. ( Item ) H = H = Support Shaped plate olt ocking disc Ø 20 x ocking screw ock nut M 12 x 22 / SW M / SW Repair kit shaped part ( Item ) Shaped part owel Washer Cylinder head screw for H = M A M 10 x 50 / SW (upon request) for H = M A M 10 x 50 / SW iaphragm cylinder ( incl. item 1663 ) Hexagon nut M 16 x 1.5 / SW 24 See pages 168 / 169 for assembly and installation instructions. 174 PWEuft e

175 Spare parts for EC Air CMPACT running gear systems 14 Side axle lift device, EC Air CMPACT AC Item esignation Remark PW Code no. imensions 1156 Screw (Spring pivot bolt) M 24 x 260 / SW Plate (adjusting plate) Washer Ø 25 / 60 x ock nut M 24 / SW ush Ø 40.5 / 50 x Graduated bush Ø 24 / 40 / 62 x Air bag ( incl. item 1224 ) ocking screw see page M 16 x Hanger bracket see page Adjusting plate with antirotation device ifting arm ush Hexagon screw Tube ock nut Ø 32 / 41 x M 20 x Ø 21 / 31 x M 20 PWEuft e 175

176 PW riginal spare parts Air suspensions 14 Spare parts for EC Air CMPACT running gear systems Central axle lift device, EC Air CMPACT AC Item esignation Remark PW Code no. imensions Screw (Spring pivot bolt) Washer ock nut ush Graduated bush Air bag (incl. item 1224) ocking screw M A 31 / M 30 / SW Ø 41 / 50 x Ø 30 / 40 / 62 x 31 see page 75 / M 16 x Hexagon screw M 16 x Hanger bracket see page Support Tube Ø 35 / 51 x ifting arm = 720 mm 1615 Support x ump stop Ø 80 / M PWEuft e

177 Notes PWEuft e 177

178 PW ergische Achsen Kommanditgesellschaft, P. ox 12 80, Wiehl, Phone +49 (0) , PWEuft e