Operating manual

Kögel KTA Trailer axle / KTS air suspension

Use
Dear customer! You have bought the Kögel Trailer Axle or  We always adapt our products to the state of the art in science
KTS air suspension. Thank you! and technology and reserve the right to any technical changes to
design, equipment and accessories.
 This manual was compiled for you, the responsible operator of a No claims can be derived from errors or the information, figures
trailer equipped with a Kögel Trailer Axle or KTS air suspension. and descriptions in these operating instructions!
Please read these operating instructions before your first
drive and before performing any repair / maintenance work.  Please contact us if any issues are not clear or if you need more
Take special care with regard to the safety / warning notes information:
and the instructions regarding the safe operation of the KTA
Kögel Trailer Axle or KTS air suspension. Kögel Trailer GmbH & Co. KG
Kögel Trailer GmbH & Co. KG cannot accept any responsibility Industriestrasse 1
regarding damage and faults resulting from non-adherence to 89349 Burtenbach
these operating instructions! Germany

 Information in these operating instructions will help you minimise Phone +49 8285 88 - 0
mistakes and avoid risks to yourself and others. Fax +49 8285 88 - 17905

 Keep these operating instructions in the driver's cab of the tractor

unit for the entire service life of the product and ensure that a Kögel – 24h – breakdown service – Europe-wide
further copy is available when the trailer is alternately used. tel.: 00800 8285 88-88

 Forward these documents to the new owner / operator when the  We hope you have a pleasant and safe drive with
trailer is sold. Kögel Trailer Axle!
Table of chapters

Chapter 1 Introduction / safety  from Page 5

Chapter 2 Operation  from Page 17
Chapter 3 Spare parts  from Page 31
Chapter 4 Repair /maintenance  from Page 45
Chapter 5 Service / additional information  from Page 59

Kögel Trailer Axle Version 05/2017 3

Contents

1.1. Identification of trailer / axles 7 3.1. KTA spares at a glance 32

1.2. Read before operation / maintenance  8 3.2. Selecting and procuring spares 33

1.3. Intended use 9

4.1. Test and maintenance schedule 46
1.4. Foreseeable misuse 10
4.2. Axle from other manufacturer with KTS 47
1.5. Safety instructions / warnings 11
4.3. Tightening torques 47

2.1. To be considered during operation 18 4.4. Cleaning 55

2.2. Brake wear 20 4.5. Disposal / recycling 57

2.3. Wheel change 24

5.1. Warranty / guarantee 62
2.4. Air suspension 28
5.2. Documentation 62
2.5. Shock absorbers 29

4 Version 05/2017 Kögel Trailer Axle

 1
Introduction / safety
1.1 Identification trailer / axles
1.2 R ead before operation /
maintenance
1.3 Intended use
1.4 Foreseeable misuse
1.5 Safety / warning instructions

Kögel Trailer Axle Version 05/2017 5

 Text mark-up
T Tighten the screw connection to the stipulated torque
The following presentation styles / symbols are used:
> 25 kg Weight greater than 25 kg
►► Action instructions
Perform visual inspection
 List of points
Marking / entry required
 Image captions
Perform greasing / lubrication by hand
>> see Cross-reference
Use a suitable wire brush
1
Component-code / list
Grease gun / lubrication required
# Identity No. / Item order number
Lifting tool / vehicle jack required for jacking up
Important information regarding warranty / liability,
potential damage to the vehicle / trailer / axles Trestle required for securing

Take note of further information in other documentation Clean with a lint-free cloth

General warning of possible risks Use soft-face hammer (plastic)

Tools required for maintenance work Nm Torque wrench required

Secure trailer with wheel chocks

Secure trailer / alert traffic

6 Version 05/2017 Kögel Trailer Axle

1.1. Identification of trailer / axles
Allocate your trailer to the appropriate Kögel Trailer Axle: A 1
Kögel Trailer GmbH & Co. KG
Industriestraße 1 89349 Burtenbach | Germany

WKO _ _ _ _ _ _ _ _ _ _ _ _ _ _
| Germany
KG
Co.
& Burtenbach
GmbH
1 89349 LT
Trailer
aße 22

Version ID 1-
Kögel KTA1 T DBT
Industriestr 1-

01 00 KTA1
ID
Modul
2-
ID
10006
3- 105km/h
ID
00 SGSL06Z
Vmax
01 4-
ID
9.000kg
Version 6357203
no. Stat.
Ident 0002016
No.
Serial
0002016
Germany
in
Made

Ident no. 6357203 ID 2- Modul T DBT 22 LT

Serial No. 0002016 ID 3- 10006

ID 4- SGSL06Z
0002016
Made in Germany Stat. 9.000kg Vmax 105km/h

 Trailer Identification Number (FIN, 17 digits)

 Position of name plate / driving direction
►►Enter the FIN of your vehicle / trailer.
Kögel Trailer GmbH & Co. KG
Industriestraße 1 89349 Burtenbach | Germany

10 Version 01 00 ID 1- KTA1
1
Axle name plate 9 Ident no. 6357203 ID 2- Modul T DBT 22 LT
2
8 Serial No. 0002016 ID 3- 10006 3
The axle data of the Kögel Trailer Axle is provided on the name 7 ID 4- SGSL06Z 4
plate. It is useful for procuring spares / service.
0002016
Stat. 9.000kg Vmax 105km/h 5
Made in Germany
6

 Name plate - data

Axle type / Identity No. Serial No.
Example KTA / 6357203 0002016 1 Axle identification number
2 Brake identification number
1st axle 3 Test axle load
4 Approval number (test protocol)
2nd axle
5 Technical maximum speed Vmax. 105 km/h
3rd axle 6 Max. permitted axle load, static
7 Bar code
►►Read the axle data on the name plates. 8 Serial number
9 Identity number
►►Enter the axle type (Pos. 1), Identity No. (Pos. 9) and 10
[01] Implementation / [00] Revision status
serial number (Pos. 8).

Kögel Trailer Axle Version 05/2017  7

 1.2. Read before operation / maintenance
These operating instructions for the Kögel Trailer Axle are intended
for the operator:
Drivers and trailer operators. This document is intended for repair,
maintenance and spare part procurement by appropriately quali-
fied workshop staff / specialised workshops.
This document is not an instruction manual for the repair or main-
tenance of the Kögel Trailer Axle by drivers and trailer operators.
This document is not an instruction manual for the installation of
the Kögel Trailer Axle into vehicles, its modification or its removal
from vehicles.
Please contact us, the manufacturer, or one of the contract work-
shops of Kögel Trailer GmbH & Co. KG in good time if you plan
subsequent changes to your Kögel Trailer Axle.
Do not perform any independent and unapproved repair or main-
tenance work.
The minimum requirements for performing maintenance and re-
pair work are:
Qualified skills in commercial vehicle technology
Experience with trailer axles for commercial vehicles
Professional commercial vehicle workshop equipment
Access to all tools required
8 Version 05/2017 Kögel Trailer Axle
Recommendation
Accessory parts should only be installed in your Kögel Trailer Axle
after consultation withKögel Trailer GmbH & Co. KG or a contract
workshop of Kögel Trailer GmbH & Co. KG.
Recommendation for instruction
We recommend that drivers be instructed regarding the Kögel Trail-
er Axle before they start to drive with it.
Persons are deemed to have been instructed if they have at least:
completely read the following instructions for drivers / trailer
operators before starting the drive,
proof of participation in instruction sessions (e.g. by the vehicle
manufacturer or the trailer operator) concerning the topics "load"
and "permitted axle loads" and
a valid, official driving permit for this type of vehicle at the start of
the drive.
Notes regarding maintenance and repair
Please take note of the following, information regarding mainte-
nance and repair in addition to the operating instructions:
Kögel Trailer Axle – Workshop manual
1.3. Intended use Intended use includes adherence to the stipulations, descriptions

The Kögel Trailer Axle has been built according to the rules of tech-

and notes in these operating instructions.
1
nology and the acknowledged rules of safety engineering. Matching tractor unit
Technical requirements for the operation of the Kögel Trailer Axle: Intended use includes performing a brake matching
procedure.
Steel or aluminium wheels with hub centring  size 22.5" Unlike drum brakes, disc brakes do not indicate overload to the
Maximum permitted offset of the wheels ET 120 mm driver through a noticeable reduction in the braking effect.
Maximum permitted axle load of 9000 kg Such overload may lead to overheating of the brakes of the tractor
The maximum permitted speed is  105 km/h unit or the trailer. The consequences of overloaded brakes may
Operation only in On-Road mode: Driving on asphalted, include a reduction in braking forces, higher brake lining or brake
concreted, paved tracks / paths. disc wear as well as wheel bearing and axle damage.

An adjustment of the brake force distribution in the total vehicle

22,5" 1
system according to ECE R13 must be performed with load by an
independent brake service after a short run-in period of 1000-
2 5000 km or 14 days after the acceptance of the vehicle and after
3
each change of the tractor unit to ensure optimal distribution of
the brake forces in the total vehicle system.
4
All warranty claims against Kögel Trailer GmbH & Co. KG
120 expire if these instructions are not adhered to and the re-
sults of a brake adjustment for the whole vehicle system
 Requirements for the wheels cannot be proven.

1 Wheel / tyre size: 22.5"

2 Rim with ET 120 mm
3 Rim made of steel or aluminium
4 Wheel nuts with pressure plate for hub centring

Kögel Trailer Axle Version 05/2017  9

 1.4. Foreseeable misuse
The manufacturer: the axle was operated under Off-Road conditions such as on

unmade routes / tracks, in building site areas and gravel pits /
KÖGEL Trailer GmbH & Co. KG landfill areas.
Industriestraße 1
89349 Burtenbach, Germany All resulting risks and exclusions of liability also apply if:
GERMANY
the acceptance was performed by a tester / expert at a technical
declines all liability for damage due to non-adherence - and the test centre or an officially acknowledged organisation,
user shall bear all risks in such cases. approvals by the authorities are available.

Any liability of the manufacturer becomes void if: ►►Inquire with Kögel Trailer GmbH & Co. KG when using the
the axle and its components have been changed without approval. Kögel Trailer axle outside its range of its appropriate use and tech-
the original parts or conversion parts / accessory parts released by nical restrictions.
Kögel Trailer GmbH & Co. KG have been exchanged for other parts. ►►Adhere to the test and maintenance intervals prescribed and doc-
 c hanges were later made to the axle (e.g. holder was welded ument the work carried out.
to the axle pipe). This is classified as a design modification
by Kögel Trailer GmbH & Co. KG and therefore voids the
operating permit.
 unapproved accessories and third-party spares / components
that are not genuine parts from Kögel Trailer GmbH & Co. KG
were attached or installed. The operating permit for the trailer and
possibly the insurance cover become void.
test and maintenance intervals prescribed by the manufacturer
were not adhered to.

10 Version 05/2017 Kögel Trailer Axle

1.5. Safety instructions / warnings Mandatory signs

Pictograms Two-person operation prescribed

1
The following pictograms may be used in these operating instruc-
tions and on the product - and must always be adhered to! De-energise

Danger signs Thoroughly clean hands

General warning of possible risks Ensure good ventilation

Risk of crushing fingers, hands and feet

Personal protective equipment
Risk of crushing for body, body parts
Wear sturdy safety shoes
Risk of burning on hot surfaces
Wear protective gloves
Risk of collision / impact in head area!
Wear protective helmet, head protection
Prohibitory signs
Wear protective goggles / eye protection
Reaching in prohibited!
Wear protective mask, breathing protection
Spraying with high-pressure cleaner prohibited
Wear ear protection
No unauthorised access!
Wear protective clothing
Accessing the surface and area prohibited!
Wear warning vest, warning clothes

Kögel Trailer Axle Version 05/2017  11

 Additional, important pictograms Warning and danger signal words

Problem waste - may not be disposed of with domestic waste DANGER

Risk of environmental pollution / poisoning Indicates immediate danger
Death or most severe injuries may result if this risk is not avoided.
Professional waste oil disposal

Professional scrap tyre disposal WARNING

Contact a physician Indicates a potentially dangerous situation
Death or severe injuries may result if this risk is not avoided.
Immediately rinse the eyes with lots of water

Read the workshop manual CAUTION

Warning / danger instructions structure Indicates a potentially dangerous situation
Small or minor injuries may result if this risk is not avoided.
Warnings against potential dangers can take the following forms:

NOTICE
SIGNAL WORD
Indicates a potential risk of damage to goods
[Pictogram] Source of danger! Damage to the tractor unit or trailer axle system may result if this
Possible consequences - Type of injury! risk is not avoided.
This may pose further risks which are associated with injuries.
►►How do I avoid this - Action instructions.

12 Version 05/2017 Kögel Trailer Axle


Warning and safety instructions are intended for your safety, the
safety of third parties and the safety of your vehicle. The instruc-
tions contain specific information regarding complete or partial
prevention of risks. They will allow you to understand the conse-
quences of the risk and possibly alleviate them.
►►Read and adhere to the warning and danger notes.
Protect yourself and others.
►►Drivers must check in advance whether warning or danger in-
formation regarding this activity is contained in these operating
instructions.
►►Employees of accredited, specialised workshops must check in
advance whether warning or danger information regarding this ac-
tivity is contained in these operating instructions.
►►Also check whether additional information contains warning or
danger notes.
Additional information:
Kögel Trailer Axle - Workshop manual
Kögel - Operating instructions for the respective trailer
Kögel Trailer Axle
Important safety instructions
The Kögel Trailer Axle has been produced according to the cur-
1
rent state of technology. However, not adhering to intended use
may lead to risks to the life and limb of the user or third parties.
Resulting damage to the trailer cannot be excluded.
The following safety instructions are intended to provide you
with preventive
information to
ensure that you know the major sources of risk
allow you to avoid the occurrence of risks and the associated
consequences
make occurring risks detectable as early as possible.
►►Drivers / trailer operators should read the following safety instruc-
tions before starting their first drive and must adhere to them.
We recommend that you update this knowledge regularly and reg-
ularly read these safety instructions during the operating phase.
►►Please note that there might be additional risks that are not yet
known or have not yet occurred.
Always act responsibly and with the appropriate caution
and care!
Version 05/2017  13
 Driving height level regulation
The driving height of the tractor unit and the trailer must be
matched to each other - total vehicle adjustment.
Risk of crushing when lowering / lifting.
►►Keep a safe distance to all moving parts.
►►Ensure that the tractor unit and the trailer are on "driving level"
before starting the drive.
►►Please take note of the warning displays on the combination instru-
ment of your tractor unit. Please take note of any warning sounds.
Bogie connection, suspension and shock absorption
Shock absorbers, air suspension bellows, bearing bushes and wear-
ing discs are subject to high functional wear. The more demanding
the operating conditions, the higher the wear will be. Severe or
complete wear leads to increased accident risk and may damage
the axle system.
►►
Take note of the driving performance of the trailer.
Contact an accredited, specialised workshop to obtain instructions
before starting the drive if you detect unstable driving performance
or a loose nut / screw connection.
►►Have the inspection and maintenance work performed according
to the inspection and maintenance plan by an accredited, special-
ised workshop.
14 Version 05/2017 Kögel Trailer Axle
Wheel head with wheel and hub
Damage, wear and corrosion of the tyres, rim, hub, wheel bolts or
wheel nuts may affect the road safety of the trailer. This increases
the accident risk.
►►Observe the condition and the wear of these safety-related parts.
►►Have the inspection and maintenance work performed in due time
according to the inspection and maintenance plan by an accredit-
ed, specialised workshop.
Brakes
Braking generates friction. Friction generates heat.
The brake system, particularly the brake disc, brake calliper, wheel
hub and rim may get so hot during operation that they pose a risk
of burning.
►►Keep sufficient distance from the hot components of the axle system.
►►Never touch the hot components with bare hands or other body parts.
The braking performance drops off, becomes uneven or fails com-
pletely in the event of wear / faults / malfunctions.
This poses an accident risk.
►►Have the inspection and maintenance work performed according
to the inspection and maintenance plan by an accredited, special-
ised workshop.
Axle lift
Lifting / lowering the axle poses the risk of crushing.
►►Maintain a safe distance to the axles during lowering / lifting.
Straightening work after accident damage
Straightening work on the Kögel Trailer Axle impedes traffic safety.
►►Drivers or trailer operators should not perform straightening work
on an axle. Do not perform an exchange of axles.
►►Always have the exchange of axles performed in an accredited,
specialised workshop.
Accessories
Unsuitable accessories may impede the road safety of the trailer
(e.g. unapproved tyres, rims).
This poses an accident risk.
►►Take note of the approval list issued by the vehicle manufacturer.
Spare parts and components
Kögel Trailer Axles are based on high-quality components.
This is the basis for high road safety. Faulty or insufficiently load-re-
sistant spare parts or screw connection increase the accident risk.
Recommendation:
►►Use Kögel Trailer Axle - genuine spares.
Kögel Trailer GmbH & Co. KG cannot evaluate third-party spares.
The torque values prescribed and load limits permitted for
third-party spare parts are not known to us. Significant deviations
Kögel Trailer Axle
as compared to Kögel Trailer Axle - genuine spare parts are possi-
ble. You are taking a major risk if you do not know the tightening
methods and torques prescribed and the load limits permitted.
1
►►Always have spare part orders and repairs performed in an ac-
credited, specialised workshop.
Your conduct may make a difference
Residual risks may persist, even after considering all specifica-
tions, warnings and risk notifications. Your conduct is essential
for safety.
►►Consider that the technology and the safety systems are subject
to physical limits during the drive and while working on the trailer.
►►Act carefully and responsibly. Consider other persons and do not
take known risks.
WARNING
Straightening work on the axle body!
This may affect road safety.
This poses an immediate accident risk!
►►Only have the repair work on an axle performed or a defective
axle exchanged by qualified staff in a specialised workshop.
Version 05/2017  15
16 Version 05/2017 Kögel Trailer Axle
 2
Operation
2.1 Consider during operation
2.2 Brake wear
2.3 Wheel change
2.4 Air suspension
2.5 Shock absorbers

Kögel Trailer Axle Version 05/2017  17


Kögel Trailer Axle - Workshop manual
►►Have all inspection and maintenance work performed and docu-
mented by qualified employees at specialised workshops.
We recommend having all work on the Kögel Trailer Axles per-
formed by Kögel Trailer GmbH & Co. KG, the manufacturer, or
by one of our contract workshops listed in the Kögel Trailer Axle
- Workshop Manual.
In this way you can prevent potential damage to the axle components
and your trailer and reduce the injury risk for the specialised staff.
WARNING
Inappropriately performed work
on the trailer / axles during operation!
You and other persons might be directly injured!
Damage to the trailer / axles might cause further risks -
increased accident risk!
►►Only perform work on the axle / trailer when you have received
instruction and can provide evidence of relevant skills.
►►Only perform work you are familiar with and that you can per-
form safely.
►►Only have repair work performed by qualified specialised staff in
a specialised workshop.
18 Version 05/2017
2.1. To be considered during operation
►►Ensure that:
Before each drive
The air suspension bellows are ventilated
The air suspension is at the correct driving height (driving level).
Tyres and wheels are undamaged and do not fall short of the
prescribed, technical requirements
The tyre pressure in all tyres is correct and equal
All wheel nuts are present and firmly tightened
The air connection (yellow, red) is correctly connected
ABS / EBS are correctly connected
The air system has no leaks - audible noise
During the drive
The driving behaviour is adapted to the road / weather conditions
as well as the load to be transported
The brakes do not overheat
The parking brake is released
During loading and unloading
►►Check that:
The maximum axle load is not exceeded
The weight of the load is correctly distributed
The tractor unit and the trailer are appropriately supported while
loading or unloading heavy items
Kögel Trailer Axle
In the event of repairs at the roadside ►►Only use suitable and technically fault-free lifting devices with
sufficient carrying capacity and adhere to all valid accident pre-
►►Park the vehicle in a safe place if possible.
vention and safety regulations.
Only experienced staff members who are within the viewing and
►► Warn other roadusers with a warning triangle and / or haz-
hearing range of the operator may attach loads and give instructions
ard lights.
to the operator of the lifting device.
►►Ensure that the work station at the trailer is sufficiently illuminated.
►►Avoid body contact with lubricants.
►► Wear a safety vest. Do not use dirty or used lubricants.

►► Wear suitable clothing, i.e. not torn or loose fitting - safety

clothing. After completing the repair work
2
►►Check the trailer / axles for damage, leaks or faults. Each part
►► Wear protective gloves. that was removed for maintenance or repair work must be re-at-
tached and immediately checked.
►► Wear safety shoes.
►►Appropriately secure the trailer against rolling away. ►► Thoroughly wash your hands.
►►Pack up the warning device (warning triangle).
►► Keep unauthorised people at distance from the hazard area.
►►Remove the wheel chocks and secure them on the trailer.
►►Remain alert while working at the trailer / axle.
Do not work while smoking, if you are tired or under the use of ►►Only continue your drive with the trailer when you are sure that
drugs, alcohol or medication. the repair performed has been appropriately completed.
►►Do not re-use self-locking screw connectors. These must always ►►  sed lubricants and cleaning items must be disposed of in
U
be replaced. an environmentally appropriate manner.
►►Never use worn tools and never leave tools behind on the axles or ►► Waste tyres must be disposed of in an environmentally ap-
on the trailer. propriate manner.

►► Enlist the help of an assistant when working with heavy parts.

►►Use lifting equipment to lift heavy items.

Kögel Trailer Axle Version 05/2017 19

 2.2. Brake wear
The compressed-air disc brake on the Kögel Trailer Axle may con-
tain different devices for monitoring the wear of the brake lining.
These may include one or a combination of the following elements:
Brake lining wear display, visual (standard)
Brake lining wear indicator as a warning display (optional order).
DANGER
Driving with worn brake linings / brake discs
This leads to reduced braking effect or total failure of the brake.
The trailer does not stop - accident risk!
►►Never fall short of the minimum wear limits.
►►Regularly check the state and the thickness of the brake linings /
brake discs.
>> see "4.1. Test and maintenance schedule" on page 46
►►Never drive with worn or defective brakes.
►►Have the brake linings / brake discs replaced by qualified staff in
a specialised workshop in good time before the minimum wear
limit is reached.
►►Check the brake function and the system performance after each
maintenance or installation step and before operating the trailer.
20 Version 05/2017 Kögel Trailer Axle
WARNING
The brake system is pressurised
Working on the brake system may lead to crushing of the
fingers / hands - accident risk!
►►Allow the pressure to escape fully and in a controlled manner
before working on parts under air pressure.
►►Keep a safety distance to moving parts of the brake system, e.g.
to the piston rods of the brake cylinders, levers, etc.
►►Only use suitable and safe tools.
►►Always consider the detailed Kögel Trailer Axle Workshop Manual
when working on the brake system.
Glazed, burnt or oily brake linings must be immediately
exchanged!
Wheel chocks / brake lining
The thickness of a new brake lining is 23 mm.
The minimum wear limit (brake lining thickness) is 2 mm.
Brake discs
The thickness of a new brake disc is 45 mm.
The minimum wear limit (brake disc thickness) is 37 mm.
Inspect the brake disc thickness (visually)
1
The visual inspection may take place with the wheel installed or
removed. The brake lining wear indicator only shows the remaining
thickness of the outer brake lining.
It does not provide an accurate measurement of the lining wear on
both brake linings.
For an accurate brake lining inspection consider the: 2

Kögel Trailer Axle - Workshop manual

2

►► support

►► dirty spots, e.g. brake dust

►► inspect both sides of the axle.

When the shaft has moved in, the brake linings are worn
and must immediately be exchanged.

►►Check the brake lining thickness and its state every 3 months,
even when a brake lining wear display is connected.  Brake lining wear indicator (visual)

>> see Kögel Trailer Axle – Workshop manual

1
Shaft
2
Marking

Kögel Trailer Axle Version 05/2017 21

 Brake lining warning display / indicator (optional) Inspect the brake disc surface (visually)

The brake can be equipped or retrofitted with a brake lining wear
sensor in order to make regular checking of the disc thickness
unnecessary.
The contact is ground away when the brake lining is worn, which
triggers a warning indicator.
The warning display is provided via EBS in the driver's cab or
mounted in a separate display device on the outside of the trailer.
Visual inspection can only take place when the wheel has been
removed.
The visual surface inspection of the brake discs can, for example,
be performed during a wheel change.
The brake discs must be checked for grooves and cracks during
each wheel change.
For an accurate brake disc inspection, see the:

Reliably monitors the brake lining wear Kögel Trailer Axle - Workshop manual

Contains all parts required for one axle (2 brakes)
Easy to install, including installation instructions

►► support.

3 ►► dirty spots, e.g. brake dust

2

4
►► inspect both sides of the axle.
1
►►Adhere to the max. permitted measures for crack and ridge
formations.
 Brake lining wear indicator kit (# 6141515)
a Friction ring width
1 Indicator / contact b Dimension: max. 0.75 x a
2 Brake lining with bracket c Dimension: max. 1.5 mm
3 Cable tie (x2)
4 Brake lining holder / cover ►►Check the thickness of the brake disc when the wheels are removed.
>> see Kögel Trailer Axle – Workshop manual

22 Version 05/2017 Kögel Trailer Axle

 c c c
1 a 2

b
3

2
4 3

4
1 3

 Visually inspect the brake disc surface  Brake disc deformed: severe crack / ridge formation

1
 Cracks running towards the centre of the hub ►►Immediately have the brake discs replaced by a specialised
(max. b permitted) workshop in pairs per axle.
2 Network-shaped cracks (permitted)
3
 Cracks running towards the inner and outer rim of the friction
ring (not permitted - immediately replace the brake disc!)
4 Unevenness / grinding rings (max. c permitted)

Kögel Trailer Axle Version 05/2017 23

 2.3. Wheel change

Take note of the operating instructions issued by the trailer

manufacturer as well as the safety and warning instructions
concerning wheel changes!

WARNING
Carelessness during wheel changes
Wheel changes at the roadside / on unsecured terrain
could impede the traffic flow and the operator might be hit
by moving vehicles!  Secure the trailer
►►Secure the site against road traffic - use warning devices, e.g.
warning triangle, warning signal in the tractor unit. ►►Position the trailer on a level surface - do not park on slopes,
gradients.
►►Wear , , , . ►►Secure the trailer against rolling away.
►►Perform the wheel change rapidly to avoid unnecessary obstruc- ►►Activate the parking brake on the tractor unit.
tion of the traffic and problems for other roadusers.
►►Activate the operating brake of the trailer.
►► Wheels are heavy!
Get the help of an assistant if necessary.
►►Secure the removed wheels to prevent them from rolling away. ►► place support under intact wheels (not under the lifted axle).

For lifting axle:

►►Move the lifting axle down.
Hexagonal wrench for wheel nuts (SW32)
►►Secure the lifting axle against moving up - unplug the EBS cable
Torque wrench
if necessary to prevent automatic upwards movement.
Vehicle jack / trestle

24 Version 05/2017 Kögel Trailer Axle

 200 200

2
 Axle, view from below: Support area for lifting equipment  Lifting the axle

The axle may only be lifted with approved (inspected) lifting
equipment! The vehicle jack must only be positioned at the
sides / support areas approved.
►►Safely position the vehicle jack on firm ground.
Use a firm support surface, as required, to prevent the jack from
sinking in.
►►Lift the axle until the wheel can rotate.
The support surface of the trestle must be equipped with a
support layer, e.g. hard rubber or timber - to prevent possi-
ble damage to the axle body!
►►Secure the axle with a stable trestle.

Kögel Trailer Axle Version 05/2017 25

 1
6 7
> 25 kg

10 3

4 9

8 5
2

1 2 3
1 2 3

 Remove the defective wheel  Mount the spare wheel

1 Wheel bolt / wheel hub 1 Spare wheel

2
Wheel 2 Tightening sequence for wheel nuts ( T 600 Nm ± 30)
3 Wheel nut (M22x1.5 / SW 32) 3 Remove the defective wheel /tyre

►►Remove all wheel nuts. The wheel nuts / wheel bolts must not be lubricated with
oil, paint or lubricant!
►►Lever the defective wheel from the wheel bolts / wheel hub and
secure it against rolling away.
►►Carefully place the spare wheel onto the wheel hub / wheel bolts.
Take note of the rotating direction of the wheels.
►► clean dirty parts.
►►Tighten the wheel nuts by hand.
►► Inspect wheel bolts, wheel hub, brake disk, brake linings ►►Fasten the wheel nuts with the torque specified and in the fasten-
and remove corrosion as required. ing sequence specified (across the diagonals).
►►Check that the wheel bolts are not bent and exchange wheel
bolts as required.

26 Version 05/2017 Kögel Trailer Axle

 6
1

10 1
7

3 2
3

2
8
3 1
9
2 2
5

Nm

 Check the wheel nuts  Aluminium disc wheels

1 Steel rim 1 Wheel nut hub cap (Kögel)

2 Hub-cap indicator (twisting check) 2 Aluminium rim
3 Sensor system for, e.g. tyre pressure, kilometre counter, etc. 3 Wheel hub

WARNING The wheel hub may only be thinly greased with approved
lubricants (wheel hub paste) to prevent seizing / fusing
Risk of wheel coming loose! between rim and hub!
Loose wheel nuts lead to accidents! Aluminium disc wheels are only permitted for hub centring.
►►Re tighten the wheel nuts during initial operation and after driving
approx. 50 km after each wheel change.

►►Check the wheel nuts with max. tightening torque.

►►Place the hub cap indicators onto the wheel nuts as required.
►►Connect the sensor system installed as required.

Kögel Trailer Axle Version 05/2017 27

 2.4. Air suspension

 Complete the wheel change / repair work

►►Lift up the axle. 
►►Remove the wheel chocks, vehicle jack, trestle, warning triangle,
tools, etc. Store it safely.
►►Set the trailer to driving level (air suspension).
►►Adjust the tyre pressure after installation.
The tyre pressure prescribed is specified on the rubber side-wall
of the tyre.
►► Perform a general visual inspection.
►►Take the defective wheel with you - do not dispose of it in the
environment! Secure it in the spare wheel holder.
►►Clean the environment from dirt as required, e.g. tyre remains,
lubrication cloths, etc.
►►Retighten the wheel nuts after approx. 50 km drive.
1 2
 Inspect the air bellows
1 Air suspension bellows (rubber)
2
Piston
Air suspension bellows are subject to permanent wear from the rolling
movement of the bellows wall - which leads to material fatigue.
The bellows wall (rubber) will become hard and brittle over time - which
leads to crack formation in the expansion area as well as bursting.
►► Clean the air suspension bellows and piston.
►► Check for external damage (shearing, holes, cracks,
brittleness, jammed foreign objects, fold formation, etc.).
►►Have the air suspension bellows exchanged in the event of damage.

28 Version 05/2017 Kögel Trailer Axle

2.5. Shock absorbers

Perform the inspection of the shock absorbers when they

2
are dry - not in rainy weather! 1

The shock absorbers must be inspected regularly and after every 3

wheel change.
Defective / leaky shock absorbers have a direct impact on the
handling of the trailer and tyre wear.
2
"Slight sweating" of the shock absorber is permitted and even
desirable for lubrication purposes.
Oil mist is visible on the shock absorber body.  Shock absorber inspection

Rubber bushes are subject to permanent wear. 1 Screw connection

Rubber bushes become hard over time. 2 Rubber bush
►►Turn the shock absorber body to and fro. 3 Shock absorber body
The rubber bushes are worn out if there is noticeable play /
perceptible movement.
►► inspect both shock absorbers on each axle.
►►Have the complete shock absorber exchanged if the rubber
bushes are worn out. ►►Check the shock absorbers for oil leaks.

In case of a slight oil mist or dampness:

The shock absorbers must be installed in the correct instal-
lation position - see markings on the shock absorber.
>> see Image "Shock absorber inspection"
►► Wipe the oil leak away. Drive for 2 days with the trailer
and again check the shock absorbers.
Oil will leak / drip out of leaking shock absorbers. Oil on the
shock absorber body and the components is visible.
►►Have both shock absorbers on the axle exchanged.

Kögel Trailer Axle Version 05/2017 29

30 Version 05/2017 Kögel Trailer Axle
 3
Spare parts
3.1 Spares at a glance
3.2 Selecting and procuring spares

Kögel Trailer Axle Version 05/2017 31

 3.1. KTA spares at a glance

9 10 11 1 2 3

7 6 5

 KTA maximum equipment

32 Version 05/2017 Kögel Trailer Axle

3.2. Selecting and procuring spares

Recommendation:
Spares must be ordered according to the previously installed
version.

►►Identify the spare parts based on the partially embossed Part No.
on the components.
►►Note the entries in Pos. 1, 8, 9 on the name plate on the axle.
>> see "1.1. Identification of trailer / axles" on page 7
 Nameplate sticker on KTA axle body

1 Axle body (axle pipe / wheel end / name plate)

3
2 Wishbone complete (with fastening accessories)
3 Air suspension bellows (D=300 mm)
4 Brake disc (D=430 mm)
5 Brake calliper (right/left)
6
 Diaphragm brake cylinder or spring accumulator
brake cylinder
7 Axle lift
8 Axle support right / left (pre-installed on the trailer)
9 Shock absorbers
10
ABS sensor

11 Axle stop

Kögel Trailer Axle Version 05/2017 33

 Assembly: KTA partially mounted

 KTA partially mounted

Assembly Identity No. Components

1 6141501 Partially mounted KTA (16/../...) with diaphragm brake cylinder
2 6141502 Partially mounted KTA (16/24/ABS) with spring accumulator brake cylinder and ABS sensor
3 6141503 Partially mounted KTA (16/24/...) with spring accumulator brake cylinder

34 Version 05/2017 Kögel Trailer Axle

Assembly: KTA complete

3
5

6 4

1 2

 KTA complete
3
Assembly Identity No. Components
1 6141511 KTA complete (FH260) partially mounted from KTA 6141501
2 6141512 KTA complete (FH260) partially mounted from KTA 6141502
3 6141513 KTA complete (FH260) partially mounted from KTA 6141503

Kögel Trailer Axle Version 05/2017 35

 Individual parts
1 Diaphragm brake cylinder (Type 16") # 6610105*
2 Spring accumulator brake cylinder
(Type 16/24") # 6610104*
3 ABS sensor # 6610108*
14 Wishbone complete assembly # 6357488*
comprising: Spring link # 6610107
Tension pins # 6610106
 Slotted bush bearing # 6610102
 1 Diaphragm brake cylinder 2 S
 pring accumulator brake Flange bearing # 6610103
cylinder
Axle stop # 6612769*
Axle connection assembly*
comprising: Spring plate # 6611016
Spring seats, single unit # 6611017
Spring clamp M22x1.5 # 6611013
Hexagon safety nut M22x1.5 # 6611014

 5 Air suspension bellows with KIT # 6610101*

 3 ABS sensor 4 Wishbone with stop KIT - air suspension bellows:
Hexagon screw M12x160 # 6503632
Washer DIN9021, A13 # 346509
Hexagon safety nut M12 # 346507
6 Shock absorber with KIT # 6611015*
KIT - shock absorber:
Hexagon screw M20x1.5x120 # 6504298
Hexagon screw M20x1.5x110 # 6504371
 Washer DIN125, A21 # 73540
 5 A
 ir suspension bellows 6 Shock absorber Hexagon safety nut M20x1.5 # 6504301
(D=300 mm) * 2 on each axle

36 Version 05/2017 Kögel Trailer Axle

Assembly: Axle body with wheel end

1 2 3 4 5 6

 Axle body sub-assemblies

3
Assembly Identity No. Components 1 Name plate # 6611008
1 6357204 Axle body with wheel end 2 Axle pipe # 6611010

Wheel end, complete # 6357209

3 Hub unit (wheel bearing) # 6610112
O-ring 84x4 # 6610111
4 Brake disc (D=430 mm) # 6610097
Brake disc KIT # 6610098
5 Wheel flange # 6611018
Axle nut Ri # 6611023
Axle nut Le # 6611022
6 Wheel bolt with nut # 6611019

Kögel Trailer Axle Version 05/2017 37

 Assembly: Complete axle body

1 2 3 4

 Complete axle body (with brakes)

Assembly Identity No. Components 1 Axle body with wheel end # 6357204
1 6357203 Complete axle body 2 Brake calliper, right # 6610099
3 Brake calliper, left # 6610100
4 Brake linings x4 (set per axle) # 6611020

Brake calliper screw KIT

Brake calliper screw # 6610109
Brake calliper fitting screw # 6610110

38 Version 05/2017 Kögel Trailer Axle

Assembly: Axle joint

1 2

 Axle joint: Wishbone on axle pipe + axle support on the chassis

1 Axle support, left # 6154698

3
Assembly Identity No. Components Axle support, right # 6154699
x1 6154698 Axle support Left Fastening KIT for each axle support:
x1 6154699 Axle support Right Hexagon screw M24x2.0x170 # 6504299
x2 6357488 Wishbone assembly Hexagon safety nut M24x2.0 # 6504302
Eccentric disk # 6419097
The axle support is attached to the trailer. Axle support washer # 6425334
2 Wishbone assembly # 6357488
Axle connection KIT for each wishbone:
Spring plate # 6611016
Spring seats # 6611017
Spring clamp # 6611013
Hexagon safety nut M22x1.5 # 6611014
3 Axle stop (plastic, clamped) # 6612769

Kögel Trailer Axle Version 05/2017 39

 Assembly: Axle lift

1 2

 Axle lift, mounted

Assembly Identity No. Components 1 Axle lift, complete # 6141493

x2 6141493 Axle lift, complete with 2 Axle lift installation kit # 6141499
Axle lift installation kit# 6141499 comprising: Hexagon screw M12x40 # 346533
Hexagon screw M12x170 # 6504331
Hexagon screw M10x20 # 346946
The axle lift is equipped with double bellows (FD 200-19 P04). Hexagon safety nut M12 # 346507
Washer DIN125, A13 # 346509
Spring ring, A10 # 346927
3 Double bellows, FD 200-19 # 6502824

40 Version 05/2017 Kögel Trailer Axle

Assembly: KTS air suspension with KTA axle body

1 2 3 4 5

 Air suspension / shock absorber

3
Assembly Identity No. Components 1 Shock absorber # 6611015
x2 6611015 Shock absorber with KIT 2 KIT shock absorber see individual parts (page 36)
x2 6610101 Air bellows with KIT 3 Axle stop (plastic) # 6612769
4 Air suspension bellows # 6610101
5 KIT air suspension bellows see individual parts (page 36)

The shock absorber is only designed for use with a flat bed
semi-trailer.
The max. static payload is 9 t.
The axle stop is pre-installed on the wishbone.
The air suspension bellows (D= 300 mm) have a plastic piston.

Kögel Trailer Axle Version 05/2017 41

 Assembly: KTS air suspension
1 Shock absorber # 6611015
KIT - shock absorber
1 2 3 comprising: Hexagon screw M20x1.5x120 # 6504298
Hexagon screw M20x1.5x110 # 6504371
Washer DIN125, A21 # 73540
Hexagon safety nut M20x1.5 # 6504301
2 Axle connection assembly
comprising: Spring plate # 6611016
Spring seats, single unit # 6611017
7
Spring clamp M22x1.5 # 6611013
5 4 Hexagon safety nut M22x1.5 # 6611014
3 Axle stop (plastic) # 6612769
4 Air suspension bellows # 6610101
6 KIT - air suspension bellows
comprising: Hexagon screw M12x160 # 6503632
 KTS assemblies Washer DIN9021, A13 # 346509
Hexagon safety nut M12 # 346507
5
Wishbone # 6357488
Assembly Identity No. Components 6 Axle lift assembly (optional)  # 6141493
consisting of individual components 57 Fastening KIT for each axle support:
x2 --------
(no axle lift) Hexagon screw M24x2.0x170 # 6504299
Hexagon safety nut M24x2.0 # 6504302
The KTS air suspension is used in combination with an axle body Eccentric disk # 6419097
from another axle manufacturer. Axle support washer # 6425334
The installation procedure is the same as for the KTA Kögel
Trailer Axle. Before using a KTS air suspension with an axle body
The KTS air suspension is available with an optional axle lift. from a different manufacturer, always consult with
Kögel Trailer GmbH & Co. KG to determine whether the axle
body is suitable!

42 Version 05/2017 Kögel Trailer Axle

Screw connection list

Pos. Identity No. Components x Pos. Identity No. Components x

Axle support x2 Wishbone x2

1 6504299 Hexagon screw DIN 960-M 24X2.0X170-10.9 1 1 6610107 Spring link 1
2 6504302 Hexagon nut DIN 980-V M 24X2.0-10 1 2 6610106 Tension pins 4
3 6141490 Eccentric disk 1 3 6610102 Slotted bush bearing 1
4 6141491 Axle support disc 1 4 6610103 Flange bearing 2

Shock absorbers x2 Brake calliper x2

1 6504298 Hexagon screw DIN 960-M 20X1.5X120-10.9 1 1 6610109 Brake calliper screw M 16X1.5X55-10.9 5
2 73540 Washer DIN 125-A21.0-ST-A3P 2 2 6610110 Brake calliper fitting screw M 16X1.5X55-10.9 1
3 6504301 Hexagon nut DIN 980-V M 20X1.5-10 2 Brake cylinder x2
4 6504371 Hexagon screw DIN 960-M 20X1.5X110-10.9 1 1 346523 Hexagonal nut DIN 980 M16x Kl. 10 2 3
Air suspension bellows x2 Axle lift x2
1 6503632 Hexagon screw DIN 931-M 12X160-8.8 2 1 346507 Hexagon nut DIN 980-V M 12-10 5
2 346509 Washer DIN 9021-A13.0-ST-DAC 6 2 346509 Washer DIN 125-A13.0-300HV 6
3 346507 Hexagon nut DIN 980-V M 12-10 4 3 346533 Hexagon screw DIN 933-M 12X40-10.9 4
4 6504331 Hexagon screw DIN 931-M 12X170-8.8 1
Axle integration x2
5 346946 Hexagon screw DIN 933-M 10X20-10.9 4
1 6611016 Spring plate 1
6 346927 Spring ring DIN 127-A10-ST 4
2 6611017 Spring seats, single unit 1
3 6611013 Spring clamp, M22X1.5 - 10.9 2
4 6611014 Hexagon safety nut M22X1,5 - 10 4

Kögel Trailer Axle Version 05/2017 43

44 Version 05/2017 Kögel Trailer Axle
 Repair / maintenance
4.1 Inspection / maintenance plan
4.2 A xle from other manufacturer
with KTS 4
4.3 Tightening torques
4.4 Cleaning
4.5 Disposal / recycling
Kögel Trailer Axle Version 05/2017 45
 4.1. Test and maintenance schedule
The maintenance intervals listed below are only guidelines,
since the road conditions in different countries can vary and the
specific use of the trailer axle by different hauliers may also vary.
The intervals and the work required depend on:
Vehicle type, individual use, operating conditions.
This test and maintenance schedule is intended for normal "on-
the-road" use, i.e. use on asphalted / concreted roads.
The intervals must be halved for more demanding operations,
e.g. on unpaved roads and gravel tracks:
Reduce intervals from 12 months to 6 months.
46 Version 05/2017
Under: www.koegel.com/Kundenservice/add-ons/full-service/
you will find an inspection and maintenance list for down-
loading as proof of the work performed.
►► It is important that safety-related screw connections between
T the components are tightened to the specified torque!
 lease note that the intervals are based on km driven and
P
the elapsed time in months.
The actual operating time of the axle unit is decisive.
►►Adjust the intervals according to the actual operating time and
the average operating environment.
►►Shorten the intervals as required.
After a prolonged parking time, the Kögel Trailer Axle must first
be inspected for possible damage during parking.
►►Always perform a pre-drive check.
>> see "2.1. To be considered during operation" on page 18
Kögel Trailer Axle
4.2. Axle from other manufacturer with KTS 4.3. Tightening torques

 Tightening torques with on-board tools

1 2 The values specified can be approximated by placing a pipe onto

a standard wheel nut spanner (on-board tool).

 KTS air suspension with axle from another manufacturer ►►Check the tightening torques as soon as possible with a torque
wrench.
1 Assembly: KTS air suspension
2 Axis from another manufacturer
Tightening torque Pipe length "A" Body weight "G"
Always observe the operating instructions provided by the
axle manufacturer!
700 mm
800 mm
85 - 95 kg
75 - 83 kg
4
Always follow the safety/warning instructions and mainte- 600 - 660 Nm
900 mm 67 - 73 kg
nance intervals!
1000 mm 60 - 66 kg
Refer to the maintenance table on the next page for information on
inspection and maintenance intervals for the KTS air suspension. 820 - 900 Nm 1000 mm 82 - 90 kg

Kögel Trailer Axle Version 05/2017 47

 Inspection and maintenance intervals

Checking point Task / activity Intervals

12 months /
3 months /

6 months /

100,000
25,000

50,000
Assemblies every X months or X kilometres drive
Wishbone
Check the U-bolt screw connection applying First inspection after the first at the latest after
axle pipe T test torque drive with load or 2,000 km

Brake Visual inspection of the parts for damage / wear, safety-related screw connections
Brake lining Check the thickness of the brake lining (wear dimension / minimum lining thickness of 2 mm) X
Check for cracks, damage or wear (minimum thickens of the brake disc 37 mm) X
Brake disc
Check for concentricity errors on the disc (max. concentricity error of the disc 0.15 mm)
T X

Hub screw connection / check the brake disc / retighten X

Check the general state of the brake cylinder (connection, damage, corrosion, leaks) X
Brake cylinder
T Check / retighten the screw connection X

Check the adjuster for correct function (recommended play between the brake linings X
Adjuster and the brake disc: between 0.7 and 1.1 mm)
Check that the sealing plug is present X
Manually check that the brake calliper is moving freely X
Brake calliper Check the air gap X
T Check the seals
Check / retighten the screw connection X

48 Version 05/2017 Kögel Trailer Axle

Checking point Task / activity Intervals
Wheel Visual inspection of the parts for damage / wear, safety-related screw connections
circumference
Wheel hub unit Check for damage or wear X
Tyres Check for damage or uneven wear, measure profile depth, tyre pressure X
Rim Check for damage X
Wheel attachment Check the screw connection / retighten wheel nuts after the first drive under load X
(approx. 50 km) and then after every wheel change to the specified torque / tighten
T across the diagonals

Bogie / suspension Visual inspection of the parts for damage / wear, safety-related screw connections
Frame carrier Check for damage or deformation / corrosion X
(axle support)
Check for damage or deformation / corrosion X
Axle tube
Check that a name plate is attached
Air bellows Check for damage or deformation / wrong attachment X
Air bellows screw Check / retighten the screw connection X
connection

Air valves

Shock absorbers
Check the general condition

Check for leaks / firm attachment

X

X
4
Axle pipe Inspect, retighten the U-bolt screw after 1 year or 100,000 km X
wishbone T connection
then every 2 years
connection
Visual inspection for damage and wear, X
Axle stop replace if deformation / cracks are evident

Kögel Trailer Axle Version 05/2017 49

 9 110+60° T 10 500 T 11 500 T 12 40 T

13 60 T

8 650 T

6 25 T

5 80 T 4 210 T 3 450 ±20 T 2 600 ±30 T 1 700 ±25 T

160+90°

7 650 T *

1 4 3 2
1. Tighten nuts to 500 Nm evenly at diagonals 2. Unscrew approx. 240° (equivalent to 4 edges of the nut)
 Safety screw connections / torques;
* 3. Tighten in several stages until the final torque of 650 Nm is reached
50 Version 05/2017 Kögel Trailer Axle
Safety screw connections

Sub-assembly Connection size Spanner size Torque

group [mm] (SW) [Nm]
1 Axle nut
Axle tube M68 1.5 95 700 ±25 *
2 Wheel nuts - rim
Wheel hub M22 1.5 32 600 ±30 *
160 + 90°
Brake disc 3 Wheel flange / wheel hub attachment M18 1.5 Tx19 or *
450 ±20
4 Brake cylinder
Brake calliper M16 1.5 24 210 *
Axle support 5 Axle lift M12 19 80
Air bellows 6 Axle lift M10 17 25
7 Axle pipe connection 650
Wishbone M22 1.5 32
(lubricated)
Caution! No tightening torque! Check with test torque across the diagonals (1-2-3-4).

Axle support 8 Bearing bolts M24 2.0 36 650

9 Brake calliper
Axle tube M16 1.5 24 110 + 60° *

4
Axle support 10 Shock absorber, top M20 2.0 30 500
Wishbone 11 Shock absorber, bottom M20 1.5 30 500
Frame 13 Air bellows, top 40
M12 19
Wishbone 14 Air bellows, bottom M12 19 max. 60

* Only applies to KTA axle.

When using an axle body from another manufacturer, always observe the applicable specifications!

Kögel Trailer Axle Version 05/2017 51

 Prescribed tightening methods

Safety-related screw connections Requirements for correct screw connections

►►Take note of particularly safety-related screw connections, which
T The tightening torque values must be adhered to when
are marked by .

WARNING

Faulty, inadequately tightened, overtightened or
damaged screw connections!

These screw connections may break or come loose. Com-
ponents of the trailer / axle may be lost - accident risk!
If screw connections are loose, the service life and road-
worthiness of the trailer are no longer assured - your life 
and those of other roadusers are directly put at risk! 
►►Please take note and adhere to the prescribed tightening meth-
ods for screw connections.
►►Do not use lubricants (oil, grease) on the threads of the wheel
bolts / nuts.
►►Replace released screw connections - never reuse them once 
they have been used.
establishing screw connections.
A professional torque wrench is always required for tightening to
a specific tightening torque.
Grease or lubricant must under no circumstances be used on the
threads of the screw connections.
The screw surfaces must be kept free of paint when the trailer
is repainted. The specifications of the component manufacturer
have to be adhered to.
Only high-quality screw connections may be used.
Use only genuine KÖGEL spare parts.
Screw connections from other manufacturers may show
significant deviations from genuine Kögel spares regarding
strength (load limits), quality and the torque required.
These connections could be destroyed during the fastening process.
The following two fastening methods for screw connections have
to be considered:

- Simple torque method

- Torque rotation angle method

52 Version 05/2017 Kögel Trailer Axle

Simple torque method
Nm
 Simple torque method 
Screw connections that are produced using the torque method
may only be released and restored by qualified workshops
The screws and nuts and other connection elements used must be
disposed of once the connection has been released. The units must
under no circumstances be reused, as their structure is damaged.
Tightening with torque
►►Set the torque wrench to the prescribed torque value.
►►Tighten the screw connection with the torque spanner until you
hear a click.
The target value has been reached.
Kögel Trailer Axle
Checking screw connections
 Checking screw connections
►►Mark the position of the nut with a pen (setting a control marker).
►►Set your torque wrench to the control value and carefully try to turn
the nut further until your torque spanner clicks or emits a signal.
►►Check the position of the nut based on the control marker you made.
If the nut has moved even a little, the screw connection is defective.
►►The defective screw connection must be replaced by a new
screw connection.
The screw connection is deemed to be in order if the nut
4
has not moved.
Version 05/2017 53
 Torque rotation angle method

Nm
60°

60°

Nm 60°
 Torque rotation angle method: Step 1  Torque rotation angle method: Step 2

Screw connections that are produced with the torque/angle 2. Fastening with rotation angle
method may only be released and restored by qualified workshops ►►Mark the position of the nut with a pen (setting a control marker).
The screws and nuts and other connection elements used must be
►►Continue to turn the nut / screw through the angle prescribed /
disposed of once the connection has been released. The units must
the prescribed number of nut corners.
under no circumstances be reused, as their structure is damaged. Take note: 60° = 1 nut corner.

1. Preliminary tightening with torque ►►Check the state of the nut and the rotation angle based on the
control marker you made.
►►Set the torque wrench to the prescribed torque value.
If the rotation angle has not been reached:
►►Tighten the screw connection with the torque spanner until you
hear a click. ►►Carefully continue to turn the nut to the target value, then check
The target value has been reached. the rotation angle.

Target value exceeded:

►►Always replace defective screw connections and start procedure
again from step 1.

54 Version 05/2017 Kögel Trailer Axle

4.4. Cleaning
Cleaning of the trailer / axle components improves driving safety,
maintains the value of your trailer and sustains your warranty claims.
It is important to clean and maintain the trailer / axle components
regularly in order to prevent accidents and injuries or damage.
The cleaning and maintenance intervals depend on the intensity of
use, the operating environment and the level of soiling of the trailer.
Axle components contain environmental pollutants such as
oil, grease, acid and brake dust. These may escape into
the natural environment during the cleaning process.
►►Only clean the trailer / axle components at a suitable washing place.
►►Adhere to the local environmental regulations.
Carelessness during cleaning and ignoring the safety
instructions may cause injuries.
The power supply must always be disconnected before any
cleaning work!
►► Thoroughly clean your hands with water / hand-washing
agent after cleaning work.
►►Use a hand protection agent before cleaning work as required.
Kögel Trailer Axle
►►Clean your trailer / axle components immediately with
clean water, e.g. with a high pressure / steam jet cleaner,
after driving on roads with de-icing salt (in winter) and after
transporting fertiliser or other materials that
contain acids or alkaline substances.
►►During the first month of use, only wash the new trailer / axle
components with clean / cold water if possible.
►►Carefully remove grease spots with pure benzine (not petrol).
►►Do not treat the brake hoses with petrol, benzine, paraffin or
mineral oils.
►►Be particularly careful when using water / cleaning agents during
cleaning work and take care that sensitive electronic components
are not exposed to liquids.
CAUTION
Risk of slipping due to wetness!
There is a risk of slipping when cleaning the trailer with
liquids (water, cleaning agents).
►►Wear , , . 4
►►Secure the trailer against rolling away.
►►Do not step under the trailer under wet conditions / if the ground
is damp.
Version 05/2017 55
 NOTICE ►►Move the water jet in a circular pattern -
do not focus it on one point.
Cleaning with aggressive, scouring agents!
►►Be particularly careful when cleaning with a
The surface coating / materials may be damaged or even destroyed high-pressure cleaner and adhere to the conditions.
by chemicals, salts, acids and alkaline substances.
►►Do not use abrasive, corrosive cleaning agents such as petrol, Conditions
steel wool, wire brushes, emery paper, etc. to clean the trailer /
Water pressure max. 50 bar
axle components.
Water temperature max. 80 °C
►►Only use weakly acidic to weakly alkaline
cleaning agents with a pH value of 6-10. General distance between the lance to the surfaces
for round jet nozzles min. 70 cm
►►Only use a soft, clean cloth or brushes.
for flat jet nozzles (25 °) min. 30 cm
►►Use the care products approved for the
for dirt blasters min. 30 cm
respective material, e.g. plastic, aluminium cleaner.
distance to sealing elements min. 15 cm

NOTICE ►►Do not blast directly at the following components:

Cleaning with a high-pressure cleaner / steam jet! Parts of the electrical system (plugs, cables, sensors)
Components, surfaces that are exposed to a water jet with too high Tyres
a pressure at too short a distance or to too high a water temperature Wheel shock absorbers
may be damaged or destroyed. Labelling (name plate, stickers)
►►  ead the operating instructions and adhere to the safety
R Compressed air hoses
instructions of the high pressure cleaning device. Sealing elements (rubber sleeves)

►►Wear , , . Do not clean your new trailer with a high-pressure

cleaner / steam jet cleaner during the first 3 months.

56 Version 05/2017 Kögel Trailer Axle

4.5. Disposal / recycling
The owner and operator of the trailer is responsible for adhering
to the regulations regarding environmentally compatible disposal.

Learn about recycling or ecologically friendly processing of parts

and materials that have been replaced during maintenance and
repair work.

Almost all lubricants used are considered to be chemical waste

that requires disposal by a specialised company that must be
contacted for this purpose.

Axle components contain environmentally hazardous sub-

stances and must never be disposed of with domestic waste.

►►  sed lubricants and cleaning items must be disposed of in

U
an environmentally appropriate manner.

►► Waste tyres must be disposed of in an environmentally ap-

propriate manner.

►►Worn components (brake linings, brake discs, etc.) must be

disposed of according to the local regulations.
4

Kögel Trailer Axle Version 05/2017 57

58 Version 05/2017 Kögel Trailer Axle
 Service /
additional information
5.1 Warranty / guarantee
5.2 Documentation
5
Kögel Trailer Axle Version 05/2017 59
Customer service from Kögel - you can
count on us!
We know what drives you! We offer our customers not only techni- 
cal innovation and Swabian engineering technique but also, and
above all, competent customer service. We provide high-quality
trailers and axles as well as outstanding service: Do you have a
question, need help in defining spare parts or have a complaint?
Kögel will provide you with quick and professional assistance –
you can rely on us!
We want to provide you with the best advice and service. Our
technical customer service will do everything to assist you with
your business objectives, the most important thing for us is your
satisfaction.

Advice:
Our customer service will provide you with advice and support
- Do you have a question? Contact us.
60 Version 05/2017 Kögel Trailer Axle
Kögel Mobile Service: Comprehensive service for forwarding
companies and workshops - Kögel provides mobile support in
many regions. Kögel Mobile Service operators are competent to
answer any questions you may have about the supply of spare
parts for the Kögel product range. The benefits for you include
minimal response times when you need spare parts, on-the-spot
support, reduced freight costs and continuous contact with the
manufacturer. All service vehicles carry an adequate quantity of
the most common spare parts. When you place your next order,
simply ask whether the mobile service is available in your region.
Warranty: Fast and straightforward support with complaints
Contact your chosen Kögel service partner directly or phone the
service number +49 18 05 56 34 35 55 for reliable, quick and
competent processing of your warranty claims.
 Customer service

Phone +49  1805  KOEGEL  55

Phone +49  1805  563435  55
Fax +49  731  9454  23  494
Please provide the following information if service is required: E-mail: aftersales@koegel.com

Axle type Spare parts

Serial number
Visual appearance of the fault Delivery / pickup:
Cause of the fault - if known KÖGEL Trailer GmbH & Co. KG
Boschstraße 25
89079 Ulm
Possible warranty claims expire after interventions with or Germany
removal of parts from the Kögel Trailer Axle / KTS air sus-
pension without our prior written approval. Postal address:
KÖGEL Trailer GmbH & Co. KG
Heuweg 3
89079 Ulm
Germany

Phone +49  1805  563435  36

Fax +49  731  9454  23  679
https://parts.koegel.com
E-mail: parts@koegel.com

24h – breakdown service – Europe wide

Phone 00800  8285  8888

5
Kögel Trailer Axle Version 05/2017 61
 5.1. Warranty / guarantee 5.2. Documentation
Kögel Trailer GmbH & Co. KG will provide you with the support Kögel Trailer GmbH & Co. KG offers full service.
you require for the Kögel Trailer Axle in the event that unexpected Under:
problems should occur during the use of the axle. www.koegel.com/Kundenservice/add-ons/full-service/
you will find the "Maintenance Checklist" report document for the
The user-oriented warranty structure of Kögel Trailer GmbH & Co. KG, prescribed, annual inspection.
which is described in detail at www.koegel.com, is proof that your
purchase has provided you with a reliable partner that will support
you in future.

Claiming your warranty requires the performance of the mainte-

nance work prescribed. Our national and international Kögel ser-
vice network will provide you with appropriate advice and support.
Performance of the maintenance work guarantees problem-free
and fault-free use of your Kögel Trailer Axle in the long term.
We would also like to draw your attention to the maximum permit-
ted axle loads under the boundary conditions defined, which have
to be adhered to without exception.

Please make these maintenance guidelines also accessible to third  Report document
parties who are allowed to use your trailer, in order to avoid possi-
ble problems. ►►Print the report document (size A4 - portrait).
►►Have the necessary maintenance work performed and have the
Our central technical customer service and the country represent- result documented / confirmed.
atives will gladly help you with inquiries.
►►Keep the report document together with the other vehicle docu-
mentation.

62 Version 05/2017 Kögel Trailer Axle

Legal information Your contact

Website: Please note down the details of your direct contact representative
Additional information regarding Kögel Trailer Axle / KTS air
suspension and Kögel Trailer GmbH & Co. KG is provided at
www.koegel.com
_______________________________________
Editor
Please contact the Technical Editing Department of ___________________________________________
Kögel Trailer GmbH & Co. KG directly if you have any
questions or suggestions. ___________________________________________
E-mail: redaktion@koegel.com
___________________________________________
Responsible for the content:
KÖGEL Trailer GmbH & Co. KG ___________________________________________
Industriestraße 1
89349 Burtenbach, Germany ___________________________________________
GERMANY
___________________________________________
Reprint, translation and copying, even of sub-sections, is prohibited without
written approval. ___________________________________________
Printed in Germany  Editorial deadline: 01/05/2017
Regarding the information in this brochure: ___________________________________________
Products may change after the editorial deadline for this printed document.
The information in this brochure must be considered as preliminary. The illustra- ___________________________________________
tions may contain accessories that are not part of the supply. This brochure may
also include types and support services that are not provided in specific countries. ___________________________________________
Ask your Kögel Trailer GmbH & Co. KG partner for binding information regarding
the latest situation. ___________________________________________
5
Kögel Trailer Axle Version 05/2017 63
 EN6612639-1original05-2017
Kögel Trailer GmbH & Co.KG | Industriestraße 1 | 89349 Burtenbach
Phone +49 82 85 88 - 0 | Fax +49 82 85 88 - 17905 | info@koegel.com
www.koegel.com