OPERATING INSTRUCTIONS

INDEPENDENT WHEEL SUSPENSION

RL 75 E/EC
RL 82 EC

FRONT AXLE/TAG AXLE

RL 75 A
RL 82 A

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 Preface

This documentation has been developed for specialized staff trained by ZF Friedrichshafen AG for repair
and maintenance work to be done on ZF-units.
Due to the continuous technical upgrading of the product, however, the maintenance of the unit at your
disposal may require both deviating work steps and differing setting and testing data.

These Operating Instructions are based on the unit’s state-of-the-art at the time of printing.
They were prepared with utmost care in order to avoid errors.
ZF Friedrichshafen AG, however, shall not be liable for any possible errors in figures or descriptions.

ZF Friedrichshafen AG reserves the right to replace these Operating Instructions by a successive edition at
any time without advance notice. Upon request ZF Friedrichshafen AG will advise which edition is the latest
one.

The owner and the user shall be responsible for complying with the safety instructions and for
implementing any maintenance work according to the specified guidelines.

ZF Friedrichshafen AG shall not be liable for any incorrect installation, improper handling, insufficient
maintenance, improperly and incompetently performed work and any consequential damage resulting
thereof.

It is imperative to observe the relevant instructions and manuals of the vehicle manufacturer.

Important information regarding technical reliability and operational safety are highlighted by the following
symbols:

This symbol serves as a reference to special working procedures,

INFO methods, information, use of auxiliaries etc... indicated in these
Operating Instructions.


This symbol identifies situations in which lacking care might lead to
CAUTION damage to the product.

This symbol identifies situations in which lacking care might lead to

DANGER personal injury.

ZF Friedrichshafen AG
ZF Services
Donaustr. 71
D - 94034 Passau

Copyright © ZF Friedrichshafen AG.

This document is protected by copyright. Complete or partial reproduction or dissemination of this document is
prohibited without the consent of ZF Friedrichshafen AG.
Infringements lead to civil and criminal prosecution.
Subject to technical modifications!
Design level 2007/12
4th edition 2015/05
 OPERATING INSTRUCTIONS

1. Grease lubrication of hub bearing

1.1 Grease quality

Approved greases see ZF- List of Lubricants

TE-ML 12.

The ZF List of Lubricants is being continuously updated and can be obtained or viewed as follows:

 in all ZF plants
 in all ZF Service Centers
 Internet: http://www.zf.com

1.2 Maintenance intervals

In this connection refer to the ZF List of Lubricants TE-ML 12.

1.3 Grease change in the hub

 A complete check of the compact bearing including a grease change is also required outside the
maintenance interval, if the following criteria apply:
- Grease overflow at the shaft seal at brake disk side. Check the shaft seals during every
brake disk change.
- Overheated brake parts (e.g. burnt bellows on pressure piece).
Also refer to chapter 4.

Legend:
7
2 6
1 = Steering knuckle assy.
2 = Bearing unit assy.
2a = Bearing outer ring /
bearing inner ring 1
2b = O ring (109x5)* 2d
2c = Cassette-type seal*
2d = Retaining ring
2e = Shaft seal *
3 = Hub with brake disk
4 = Slotted nut 5
4
5 = O ring (155x3) 2e
6 = Locking plate 2a
7 = Cover 3
2b 2c 2a

* These spare parts are available separately, and are supplied as loose parts with the
bearing unit!

Removal

1 Remove hub with brake disk (3)

2 Remove grease from the hub (3), clean hub Remove just the inner rings of the tapered
and bearing inner rings/bearing outer rings (2a). roller bearings from the hub!

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 OPERATING INSTRUCTIONS

Reinstallation


3 Check condition and wear of tapered roller Replace worn or damaged tapered roller
bearings (2a) (inner and outer ring) bearings by a new bearing unit.

4 Thoroughly grease tapered roller bearings (2a)

and fill them with the specified grease quantity.

5 Fill quantity: 96g per hub


6 Install hub Install new shaft seal (2e), cassette-type
seal (2e) and O-ring (2b).


7 Fit wheel head Fit new locking plate (6). Seal cover (7)
with Loctite 574.

All details of operations and setting values required for disassembly and reassembly are included
in the relating Repair Manual (5871.197.002)!

2. Grease lubrication of steering knuckle / control arm / steering lever / relay lever

2.1 Grease quality

Approved greases see ZF List of Lubricants TE-ML 12.

The ZF List of Lubricants is being continuously updated and can be obtained or viewed as follows:

 in all ZF plants
 in all ZF Service Centers
 Internet: http://www.zf.com

A lithium-saponified multi-purpose grease of NLGI class 2 which is mixable with mineral oil (grease
code KP2K-30 acc. to DIN 51825 or ISO-L-XCCHB2 acc. to ISO/DIS 6743-9) is to be used at the
greasing points.

2.2 Grease interval

In this connection refer to the ZF List of Lubricants TE-ML 12.

 The grease intervals must be reduced accordingly (40,000 km or every six months) under extreme
working conditions e.g. dust, wetness, dirt, considerable strains, etc.

 Always lubricate the ZF steering axles with the wheels on the ground, to ensure a correct grease
flow (no jacking allowed).

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 OPERATING INSTRUCTIONS

2.3 Procedure

2.3.1 Lubrication with pneumatic pump or a different automatic lubrication system

When using a pneumatic pump or different automatic lubrication systems, the initial lubrication pressure is not allowed
to exceed 250 bar.
Example: For a pump with a ratio of 1:50 the inlet pressure must not exceed 5 bar
(5 bar x 50 = 250 bar).

Lubricate the greasing points until grease comes out at the seal rings (steering knuckle bearing) and scrapers (control
arm bearing) over the whole circumference.

 Always lubricate with the wheels on the ground, as this is the only way to ensure a correct grease
flow.

2.3.2 Lubrication with a grease gun

Use a grease gun to lubricate the greasing points until grease comes out at the seal rings (steering knuckle bearing)
and scrapers (control arm bearing) over the whole circumference.

 Always lubricate with the wheels on the ground, as this is the only way to ensure a correct grease
flow.

Position of the lubricating nipples:

1 = Steering knuckle bearing (top)

2 = Steering knuckle bearing (bottom)
3 = Control arm bearing (top)
4 = Control arm bearing (bottom)
5 = Relay lever
6 = Intermediate lever

RL 75 E

1 3

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 OPERATING INSTRUCTIONS

RL 75 EC / RL 82 EC
3
1

3
5 6
1

4 2

RL 75 A / RL 82 A
1

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 OPERATING INSTRUCTIONS

3. Check of vertical play in the axle fist

The vertical play existing in the axle fist must be determined as a part of the legally stipulated periodic technical
vehicle inspection. It is necessary to repair the king pin bearing if the vertical play exceeds 1.3 mm.

For further information see Service Information 85/11.

All details of operations and setting values required for the repair are included in the relating
Repair Manual!

4. Check of compact bearing (hub bearing)

4.1 Check intervals

Check the bearing when brake disk is changed, in case of any ABS-fault message and if noise rises with increasing
speed.

4.2 How to check the axial play

Remove the wheels. Loosen the cylindric.l screws on the cover and remove the
cover, so that the steering knuckle becomes visible.

Fix magnetic stand to the hub and position the dial indicator at the circular ring
area at front side of the steering knuckle. Push hub towards the axle with both
hands (do not tilt) and rotate by 20° to 30° in both directions, until the dial
indicator pointer remains fix. Calibrate the dial indicator to zero. Use both hands
to pull the hub away from the axle (do not tilt) and rotate it by 20° to 30°in both
directions, until the pointer remains fix. The difference corresponds to the axial
play. Repeat measurements 3 times and calculate the average. Rotate the
wheel several times between the measurements.

If the measured value exceeds 0.20 mm, the compact bearing is worn and must be replaced.
Please find further information in the Repair Manual.

4.3 How to check grease overflow

Check shaft seal at brake disk side with regard to grease overflow.

 A small quantity of grease (slight collar of grease) is permitted and not to be regarded as leakage.
5. Wheel bolts and wheel nuts
We would recommend you to replace heavily corroded wheel bolts.

 For tightening torques see vehicle manufacturer.

Please take further information from our Service Information.

Never grease/oil the thread of wheel bolts and wheel nuts.

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 OPERATING INSTRUCTIONS

6. Lifting jack points

Do not position the lifting jacks on other points than those marked in the following illustration:

RL 75 E

Lifting jack points

RL 75 EC / RL 82 EC

Lifting jack points

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 OPERATING INSTRUCTIONS

RL 75 EC / RL 82 EC

Lifting jack points

RL 75 A / RL 82 A

Lifting jack points

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