AirTek AT90 Specifications

front axle & suspension

Overview

Front Suspensions

The Blue Bird All American is equipped with one of two front suspension systems:

Hendrickson™ SofTek.™ The Softek front suspension is a three parabolic leaf spring configuration, and is standard equipment on the Forward Engine All American.

Hendrickson™ AirTek.™ The Airtek front suspension is an air spring suspension used on the Forward Engine All Americans equipped with air suspension option. Two leveling valves maintain ride height at varying axle loads.

Axles

Hendrickson™ SteerTek. The Forward Engine All American is equipped with Hendrickson SteerTek front axles. The SteerTek axle includes an anti-lock brake system and is used in 13,200 and 14,600 lb. capacities on All Americans.

Hendrickson Identification

Appendixes & Other References

Appendix 1. AirTek & SofTek. Hendrickson Publication number 17730-248 covers maintenance, adjustment, and component replacement information on the SofTek leaf spring suspension. Please note that this Hendrickson publication also incorporates information on Hendrickson’s SteerTek front axle and AirTek front air suspension.

The specific Hendrickson axle model installed may be identified by refering to the axle numbers etched near the center front of the axle’s main beam.

Also See: The Hydraulc Brakes chapter of this manual includes a procedure for removing the front disc rotor/hub assembly.

Maintenance

Maintenance of the front axle and suspension consists of periodic general inspection, checking tightness of fasteners, and lubricating grease fittings. Refer to the maintenance charts in this chapter (also included in the Specs & Maintenance chapter) for maintenance inspection intervals. The exploded illustrations in this chapter include torque specifications.

35

HENDrIcksoN

AIrtEk / softEk

1

APPENDIX

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SERVICE MANUAL

36

B

B

Right Side Shown

Left Side Symetrical unless otherwise noted.

G

G

G

G

L

SofTek Front Suspension

A

D

C

SERVICE MANUAL FRonT AxlE & SuSPEnSion

Torque Requirements

key description

A Front Hanger Pivot

B Shackle Bracket Pivot

C upper Shock

D lower Shock

E linkage Rod Assy locknut

F leveling Valve lockout

G Axle Clamp Group nuts

H Air Spring Mounting Stud locknuts (All)

J Shackle Bracket locknuts

Front Axle Alignment Specs

Caster:

Camber:

Cross Caster:

Toe In:

4.5° ± 1.5° positive

± 1.0° (left & right) 2 Total

1.00° max

0.060” ± .030” torque

+- 5%

300 ft.lbs.

300 ft.lbs.

125 ft.lbs.

125 ft.lbs.

11 ft.lbs.

8 ft.lbs.

295 ft.lbs.

25 ft.lbs.

120 ft.lbs.

37

L

38

SERVICE MANUAL

F

H

H

J

J

B

B

E

OUTBOARD

STUD ONLY

H

D

A

E

C

SHOCK LENGTH

@ RIDE HT:

FE=17.25±.25

L

G

AirTek Front Air Suspension


Torque Requirements

key description

A Front Hanger Pivot

B Shackle Bracket Pivot

C upper Shock

D lower Shock

E linkage Rod Assy locknut

F leveling Valve lockout

G Axle Clamp Group nuts

H Air Spring Mounting Stud locknuts (All)

J Shackle Bracket locknuts torque

+- 5%

300 ft.lbs.

300 ft.lbs.

125 ft.lbs.

125 ft.lbs.

11 ft.lbs.

8 ft.lbs.

295 ft.lbs.

25 ft.lbs.

120 ft.lbs.

Front Axle Alignment Specs

Caster:

Camber:

Cross Caster:

Toe In:

4.5° ± 1.5° positive

± 1.0° (left & right) 2 Total

1.00° max

0.060” ± .030”

Ride Height Adjustment

Ride height may be verified by measuring either shock length or air spring height:

1. With leveling valve and linkage installed as shown and air system at 80 PSi or greater, right hand side shock length from centerline of eye to centerline of eye should be 17.25” ± .25” for Forward Engine models.

2. if adjustment is required, loosen leveling valve body mounting fasteners from the frame rail and rotate valve counter-clockwise or clockwise to lengthen or shorten shock dimension.

3. Tighten valve mounting fasteners to 8 ft. lbs.

4. Remove vertical link lower grommet from stud on spring pad, lower valve horizontal arm, and release all air from bag.

5. Reconnect link and verify shock length according to step 1. if measurement is not correct, repeat steps 1 thru 5 until proper ride height is achieved.

6. Repeat steps 1 thru 5 for left hand side.

39

L

Front Axle & Suspension

I nterval

:

M onths

/M iles whichever occurs first

40 operation

Spring Suspension

Inspect visually

Check U-bolt torque •

Lubricate steering grease fittings

Inspect spring pin lock bolts

Inspect shackle bracket pivot bolt

Inspect shocks

Torque shock mounting bolts

Air Suspension

Inspect visually

Check axle to suspension fasteners •

Lubricate steering grease fittings

Inspect pin lock bolts

Inspect shackle bracket pivot bolt

Torque shock mounting bolts

Inspect air spring cushions

Check air spring fasteners

Inspect shocks

Check suspension height

Check ride height control valve bolts

•

•

Check for visual damage. See Hendrickson publication 17730-248.

• Tighten to 285–305 ft. lbs (32–34 Nm).

Use NLGI #2 EP or equivalent.

• Tighten to 380–420 ft. lbs. (515–569 Nm).


• Check for signs of leaks, wear, or damage.

• TIghten to 215 ft. lbs. (25 Nm).

•

•

•

•

• notes

Check for wear, damage, misalignment. See Hendrickson publication 17730-248.

• Tighten to 285–305 ft. lbs (32–34 Nm).

Use NLGI #2 EP or equivalent. Lube with suspension loaded.



• TIghten to 215 ft. lbs. (25 Nm).

Check for wear, abrasions, cuts, or other damage

•

• Check for signs of leaks, wear, or damage.

Shock length, eye to eye: 18.5” ± .25”. (470 ± 6mm).

TIghten to 8–10 ft. lbs. (11–14 Nm).

L

FRonT AxlE & SuSPEnSion

SUBJECT: AIRTEK

®

& SOFTEK

®

Service Instructions for

Blue Bird Buses

LIT NO: 17730-248

DATE: February 2007 REVISION: C

This publication is also available at www.hendrickson-intl.com

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43

TABLE OF CONTENTS

Section 1

Section 2

Section 3

Section 4

Section 5

Section 6

Section 7

Section 8

Introduction . . . . . . . . . . . . . . . . . . . . . . 2

Product Description . . . . . . . . . . . . . . . . 3

Important Safety Notice . . . . . . . . . . . . . 6

Special Tools . . . . . . . . . . . . . . . . . . . . 11

Parts Lists

For Vision Buses

AIRTEK – 10K Capacity . . . . . . . . . . . . . . 12

SOFTEK – 8K/10K Capacity . . . . . . . . . . . 14

For All American Buses

AIRTEK – 14.6K Capacity. . . . . . . . . . . . . 16

SOFTEK – 13.2K/14.6K Capacity . . . . . . . 18

Right Hand Drive Axle . . . . . . . . . . . . . . . 20

Towing Procedure . . . . . . . . . . . . . . . . 21

Preventive Maintenance

Component Inspection. . . . . . . . . . . . . . . . . 24

Lubrication Intervals . . . . . . . . . . . . . . . . . . 25

Kingpin Lubrication. . . . . . . . . . . . . . . . . . . 25

Tie Rod End Lubrication. . . . . . . . . . . . . . . . 26

Tie Rod End Inspection . . . . . . . . . . . . . . . . 27

Clamp Group Re-torque Interval . . . . . . . . . . 29

Tire Inspection . . . . . . . . . . . . . . . . . . . . . . 29

Axle Wrap Liner Inspection. . . . . . . . . . . . . . 32

Shock Absorber Inspection. . . . . . . . . . . . . . 32

Kingpin Bushing Inspection . . . . . . . . . . . . . 34

Steering Knuckle Inspection . . . . . . . . . . . . . 35

Shackle Thrust Washer Inspection . . . . . . . . 36

Front Hanger/Rear Shackle Plate

Surface Paint Wear . . . . . . . . . . . . . . . . . 37

Alignment & Adjustments

Alignment Definitions . . . . . . . . . . . . . . . . . 38

Inspection Prior to Alignment . . . . . . . . . . . . 40

Front Wheel Alignment . . . . . . . . . . . . . . . . 41

AIRTEK Ride Height Adjustment . . . . . . . . . . 43

AIRTEK Height Control Valve Test . . . . . . . . . 45

Steering Stop . . . . . . . . . . . . . . . . . . . . . . . 46

Toe Setting. . . . . . . . . . . . . . . . . . . . . . . . . 46

Spring Eye Re-torque. . . . . . . . . . . . . . . . . . 48

Section 9

AIRTEK ® • SOFTEK ® for Blue Bird Buses

January 2008

Rev. D

Component Replacement

Fasteners. . . . . . . . . . . . . . . . . . . . . . . . . . 50

Spacers. . . . . . . . . . . . . . . . . . . . . . . . . . . 50

AIRTEK Height Control Valve. . . . . . . . . . . . . 50

AIRTEK Air Spring . . . . . . . . . . . . . . . . . . . . 53

AIRTEK Front Leaf Spring Frame Hanger . . . . 57

SOFTEK Front Leaf Spring Frame Hanger . . . . 58

AIRTEK Rear Shackle Frame Bracket . . . . . . . 59

SOFTEK Rear Shackle Frame Bracket. . . . . . . 60

SOFTEK Rubber Axle Stop . . . . . . . . . . . . . . 62

Thrust Washer . . . . . . . . . . . . . . . . . . . . . . 62

AIRTEK Leaf Spring Assembly. . . . . . . . . . . . 63

SOFTEK Leaf Spring Assembly . . . . . . . . . . . 66

Front Leaf Spring Eye Bushing . . . . . . . . . . . 68

Shock Absorber . . . . . . . . . . . . . . . . . . . . . 68

AIRTEK Bottom Axle Wrap . . . . . . . . . . . . . . 70

SOFTEK Bottom Axle Wrap. . . . . . . . . . . . . . 71

AIRTEK Top Axle Wrap (In Chassis) . . . . . . . 72

SOFTEK Top Axle Wrap (In Chassis) . . . . . . . 75

AIRTEK Front Axle Assembly. . . . . . . . . . . . . 77

SOFTEK Front Axle Assembly . . . . . . . . . . . . 78

STEERTEK Axle Removal . . . . . . . . . . . . . . . 79

STEERTEK Axle (Removed from Chassis). . 80

Steering Knuckle Disassembly . . . . . . . . . 83

Kingpin Preparation & Measurement . . . . . 84

Kingpin Bushing Removal . . . . . . . . . . . . 86

Steering Knuckle Bore Measurement . . . . . 87

Kingpin Bushing Installation. . . . . . . . . . . 87

Kingpin Bushing Reaming . . . . . . . . . . . . 88

Kingpin Seal Installation . . . . . . . . . . . . . 89

Steering Knuckle Assembly. . . . . . . . . . . . 90

Tie Rod End and Cross Tube . . . . . . . . . . . . 92

Section 10 AIRTEK Plumbing Diagrams

10K Capacity. . . . . . . . . . . . . . . . . . . . . . . 94

14.6K Capacity . . . . . . . . . . . . . . . . . . . . . 95

Appendix Reference Material . . . . . . . . . . . . . . . . . . A-97

Trouble Shooting Guide . . . . . . . . . . . . . . A-98

Torque Specifications . . . . . . . . . . . . . . . A-100

Front Alignment Specifications. . . . . . . . . A-108

Technical Procedure Publication Quiz . . . . . . . . . . . A-110

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AIRTEK ® •

SOFTEK ® for Blue Bird Buses

SECTION 1

Introduction

NOTE

This publication is intended to acquaint and assist maintenance personnel in the preventive maintenance, service, repair and rebuild of the following Hendrickson equipment as installed on applicable Blue Bird Buses:

■

AIRTEK ® — An integrated front air suspension with the STEERTEK axle.

■

■

SOFTEK ® — An integrated steel spring mechanical suspension with the STEERTEK axle.

STEERTEK — A lightweight, formed and robotically welded steer axle assembly.

Use only Hendrickson Genuine parts for servicing this suspension system.

It is important to read and understand the entire Technical Procedure publication prior to performing any maintenance, service, repair, or rebuild of the product. The information in this publication contains parts lists, safety information, product specifications, features, proper maintenance, service, repair and rebuild instructions for the AIRTEK/SOFTEK

Suspension and the STEERTEK axle.

A Technical Procedure Quiz has been included at the back of this publication. Hendrickson will provide personalized AIRTEK/SOFTEK Technical Procedure Quiz Achievement Certificate to candidates scoring 80% or higher on the test. Simply complete the test and fill in the enclosed answer sheet or write your answers on a separate sheet with the return address, name, phone number, and company name as it will appear on the award to:

Hendrickson

ATTN: Truck Marketing Test Quiz Assessment

800 S. Frontage Road

Woodridge, Illinois 60517

Hendrickson reserves the right to make changes and improvements to its products and

publications at any time. Contact Hendrickson Tech Services at 630-910-2800 or e-mail [email protected] for information on the latest version of this manual.

The latest revision of this publication is also available online at www.hendrickson-intl.com.

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Introduction

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APPENDIX

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17730-248


AIRTEK ® •


SECTION 2

Product Description

BLUE BIRD VISION BUSES

FIGURE 2-1

AIRTEK ® Air Suspension System

Capacity: 10,000 pounds

FIGURE 2-2

SOFTEK ® Mechanical Suspension System

Capacity: 8,000/10,000 pounds

45

FIGURE 2-3

AIRTEK ® Air Suspension System

Capacity: 14,600 pounds

BLUE BIRD ALL AMERICAN BUSES

SOFTEK ®

FIGURE 2-4

Mechanical Suspension System

Capacity: 13,200/14,600 pounds

FIGURE 2-5

RIGHT HAND DRIVE AXLE

17730-248

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46

SERVICE MANUAL

AIRTEK ® •


STEERTEK

— The box-shaped design provides a stiffer axle and resists torsional, longitudinal and vertical loads more effectively than traditional axle beams. Together with the front limbs of the leaf springs, the robotically welded axle beam forms a torsion system, enhancing roll stability characteristics and improving handling.

Axle clamp group — The patented clamp group provides four-sided clamping pressure.

The Clamp Group consists of the following:

■

■

■

Top Axle Wrap

Top Axle Wrap Liner

Top Spring Pad

■

■

■

Bottom Axle Wrap

Bottom Axle Wrap Liner

¾" Bolts, Washers and Locknuts

Adjustable tie rod —To help maximize tire life, the tie rod easily adjusts toe-in/out.

Steering knuckles — The steering and tie rod arms are integrated for increased strength and reduced weight. The unique steering knuckle packaging delivers a maximum of 50° wheel cut. The two piece knuckle design makes servicing the kingpin bushings easier.

AIRTEK

— Winner of the 2001 Automotive News and Cap Gemini Ernst & Young PACE

Award for Product Innovation. AIRTEK is an integrated front air suspension and robotically welded steer axle that work together to form an integrated torsion system. Utilizing a system approach, Hendrickson has engineered and optimized the following components to form a system delivering ride, stability and handling characteristics with reduced weight and maintenance.

Air springs — Exclusive to Hendrickson, the lightweight air springs deliver a soft ride.

The air springs are engineered to support 78% of the vertical load while providing a low spring rate. The quick “snap” design for the 10,000 pound capacity, the bolt on design for the 14,600 pound capacity, and the “push-to-connect” air supply design also provide fast and easy removal and installation.

Leaf spring assembly — With its innovative design, the leaf spring provides superior stability, performance and a soft ride. The patented leaf spring shares loads with the air spring. Durable rubber front and patented rear bushings are greaseless and only require periodic inspections.

SOFTEK

— is an integrated front mechanical suspension and robotically welded steer axle that work together to form an integrated torsion system. Utilizing a system approach,

Hendrickson has engineered and optimized the following components to form a system delivering ride, stability and handling characteristics with reduced weight and maintenance.

Leaf spring assembly — With its innovative design, the leaf spring provides superior stability, performance and a soft ride. Durable rubber front and patented rear bushings are greaseless and only require periodic inspections.

Shock absorbers — AIRTEK/SOFTEK utilizes premium shocks that have been tested and tuned specifically for the suspension system.

Frame brackets — Optimized design delivers weight reduction and proven durability. The front and rear frame brackets are common between the SOFTEK and AIRTEK suspensions.

4

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AIRTEK ® •


TECHNICAL NOTES

1. AIRTEK and SOFTEK are approved for 100% on-highway use; other applications must be preapproved by Hendrickson Sales Engineering. System capacity rating for the suspension represents maximum loads on tires at ground level.

2 The STEERTEK axle for the Vision is available with 69" kingpin intersection (KPI). The STEERTEK axle for the All American is available with 71" kingpin intersection (KPI).

3. AIRTEK suspension weight includes frame and shackle bracket assemblies, main springs, bushings, air springs and air spring bracket, height control system, shocks, upper shock brackets and axle clamp group.

4. SOFTEK suspension weight includes frame and shackle bracket assemblies, steel leaf springs, bushings, shocks, upper shock brackets and axle clamp group.

5. STEERTEK axle weight includes the axle beam, knuckle/steering arm assemblies and tie rod assemblies.

6. AIRTEK and SOFTEK are integral to and available exclusively with the STEERTEK axle. This system is anti-lock braking system (ABS) ready. STEERTEK is compatible with most industry standard wheel ends and brakes. Contact OEM for more information.

7. The STEERTEK axle product identification is etched on the center front of the axle beam providing the following information:

■

Axle part number: Identifies the features of the axle beam.

■

Axle assembly number: Identifies the complete assembly, which includes the steering knuckles and bracket assemblies.

FIGURE 2-6 Front view of STEERTEK axle showing approximate location of Product Identification.

47

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AIRTEK ® •


SECTION 3

Important Safety Notice

Proper maintenance, service and repair are important to the reliable operation of the suspension. The procedures recommended by Hendrickson and described in this technical publication are methods of performing such maintenance, service and repair.

The warnings and cautions should be read carefully to help prevent personal injury and to assure that proper methods are used. Improper maintenance, service or repair may

damage the vehicle, cause personal injury, render the vehicle unsafe in operation, or void the manufacturer's warranty.

Failure to follow the safety precautions in this manual can result in personal injury and/or property damage. Carefully read and understand all safety related information within this publication, on all decals and in all such materials provided by the vehicle manufacturer before conducting any maintenance, service or repair.

NOTE

EXPLANATION OF SIGNAL WORDS

Hazard “Signal Words” (Danger-Warning-Caution) appear in various locations throughout this publication. Information accented by one of these signal words must be observed to help minimize the risk of personal injury to service personnel, or possibility of improper service methods which may damage the vehicle or render it unsafe.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

Additional ‘Notes’ or ‘Service Hints’ are utilized to emphasize areas of procedural importance and provide suggestions for ease of repair. The following definitions indicate the use of these signal words as they appear throughout the publication.

INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN

SERIOUS INJURY OR DEATH.

INDICATES A POTENTIAL HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, CAN RESULT IN

SERIOUS INJURY OR DEATH.

INDICATES A POTENTIAL HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, MAY RESULT IN

MINOR OR MODERATE INJURY, OR PROPERTY DAMAGE.

An operating procedure, practice condition, etc. which is essential to emphasize.

SERVICE HINT A helpful suggestion, which will make the servicing being performed a little easier and/or faster.

Also note that particular service operations may require the use of special tools designed for specific purposes. These special tools can be found in the Special Tools Section of this publication.

6

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17730-248


AIRTEK ® •


SAFETY PRECAUTIONS

FASTENERS

LOOSE OR OVER TORQUED FASTENERS CAN CAUSE COMPONENT DAMAGE, LOSS OF VEHICLE

CONTROL, PROPERTY DAMAGE, OR SEVERE PERSONAL INJURY. MAINTAIN CORRECT TORQUE

VALUE AT ALL TIMES. CHECK TORQUE VALUES ON A REGULAR BASIS AS SPECIFIED.

AIR SPRINGS

AIR SPRING ASSEMBLIES MUST BE DEFLATED PRIOR TO LOOSENING ANY CLAMP GROUP

HARDWARE. UNRESTRICTED AIR SPRING ASSEMBLIES CAN VIOLENTLY SHIFT. DO NOT INFLATE AIR

SPRING ASSEMBLIES WHEN THEY ARE UNRESTRICTED. AIR SPRING ASSEMBLIES MUST BE

RESTRICTED BY SUSPENSION OR OTHER ADEQUATE STRUCTURE. DO NOT INFLATE BEYOND

PRESSURES RECOMMENDED BY AIR SPRING MANUFACTURER, CONTACT HENDRICKSON

TECHNICAL SERVICES FOR DETAILS. IMPROPER USE OR OVER INFLATION MAY CAUSE AIR SPRING

ASSEMBLIES TO BURST, CAUSING PROPERTY DAMAGE AND/OR SEVERE PERSONAL INJURY.

WHEN SERVICING THE VEHICLE OR ATTACHING AN AIR SPRING AND THE VEHICLE IS ON THE

GROUND, PRIOR TO AIRING THE SUSPENSION SYSTEM MAKE CERTAIN THE AIR SPRING

LOCATOR IS INDEXED INTO THE UPPER AIR SPRING BRACKET PROPERLY, AND THE AIR

SPRING IS FULLY SEATED ON THE SPRING TOP PAD. FAILURE TO FOLLOW THESE

INSTRUCTIONS CAN RESULT IN PREMATURE AIR SPRING FAILURE, CAUSE PERSONAL INJURY,

OR PROPERTY DAMAGE.

PRIOR TO AND DURING DEFLATION AND INFLATION OF THE FRONT AIR SUSPENSION SYSTEM,

ENSURE THAT ALL PERSONNEL AND EQUIPMENT ARE CLEAR FROM UNDER THE VEHICLE AND

AROUND THE SERVICE AREA, FAILURE TO DO SO CAN CAUSE SERIOUS PERSONAL INJURY,

DEATH, OR PROPERTY DAMAGE.

LOAD CAPACITY

ADHERE TO THE PUBLISHED CAPACITY RATINGS FOR THE SUSPENSIONS. ADD-ON AXLE

ATTACHMENTS (I.E. SLIDING FIFTH WHEELS) AND OTHER LOAD TRANSFERRING DEVICES CAN

INCREASE THE SUSPENSION LOAD ABOVE THE RATED AND APPROVED CAPACITIES WHICH

CAN RESULT IN FAILURE AND LOSS OF VEHICLE CONTROL, POSSIBLY CAUSING PERSONAL

INJURY OR PROPERTY DAMAGE.

MODIFYING COMPONENTS

DO NOT MODIFY OR REWORK PARTS. DO NOT SUBSTITUTE PARTS OF THE SUSPENSION OR

AXLE COMPONENTS, USE OF A MODIFIED OR REPLACEMENT PARTS NOT AUTHORIZED BY

HENDRICKSON MAY NOT MEET HENDRICKSON’S SPECIFICATIONS, AND CAN RESULT IN

FAILURE OF THE PART, LOSS OF VEHICLE CONTROL, AND POSSIBLE PERSONAL INJURY OR

PROPERTY DAMAGE. USE ONLY HENDRICKSON AUTHORIZED REPLACEMENT PARTS, DO NOT

MODIFY PARTS WITHOUT AUTHORIZATION FROM HENDRICKSON.

SHOCK ABSORBERS

THE SHOCK ABSORBERS ARE THE REBOUND TRAVEL STOPS FOR THE SPRINGS. ANYTIME THE

FRONT AXLE ON AN AIRTEK SUSPENSION IS SUSPENDED IT IS MANDATORY THAT THE SHOCK

ABSORBERS REMAIN CONNECTED. FAILURE TO DO SO CAN CAUSE THE AIR SPRINGS TO

EXCEED THEIR MAXIMUM LENGTH, POSSIBLY CAUSING THE AIR SPRINGS TO SEPARATE FROM

THE PISTON, OR CAUSE A REVERSE ARCH IN THE STEEL LEAF SPRINGS, POSSIBLY RESULTING

IN PREMATURE STEEL LEAF SPRING FAILURE.

49

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AIRTEK ® •


TORCH/WELDING

DO NOT USE A CUTTING TORCH TO REMOVE ANY ATTACHING FASTENERS. THE USE OF HEAT

ON SUSPENSION COMPONENTS WILL ADVERSELY AFFECT THE STRENGTH OF THESE PARTS.

A COMPONENT DAMAGED IN THIS MANNER CAN RESULT IN THE LOSS OF VEHICLE CONTROL

AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE.

EXERCISE EXTREME CARE WHEN HANDLING OR PERFORMING MAINTENANCE IN THE AREA OF

THE SPRING ASSEMBLY AND AXLE. DO NOT CONNECT ARC WELDING GROUND LINE TO THE

SPRING ASSEMBLY OR AXLE. DO NOT STRIKE AN ARC WITH THE ELECTRODE ON THE SPRING

ASSEMBLY OR AXLE. DO NOT USE HEAT NEAR THE SPRING ASSEMBLY OR AXLE. DO NOT NICK

OR GOUGE THE SPRING ASSEMBLY OR AXLE. SUCH IMPROPER ACTIONS CAN CAUSE DAMAGE

TO THE SPRING ASSEMBLY OR THE AXLE CAN FAIL, AND CAN CAUSE LOSS OF VEHICLE

CONTROL AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE.

OFF ROADWAY TOWING

WHEN A VEHICLE IS DISABLED AND EQUIPPED WITH A STEERTEK AXLE, CARE MUST BE TAKEN

TO ENSURE THERE IS NO DAMAGE TO THE SUSPENSION WHEN TOWING THE VEHICLE. THE

USE OF A TOW STRAP IS NECESSARY TO TOW A DISABLED VEHICLE INTO A REPAIR FACILITY

PARKING LOT INTO THE SHOP BAY. THE TOW STRAPS SHOULD BE CONNECTED TO THE TOW

HOOKS PROVIDED BY THE MANUFACTURER AT THE FRONT OF THE BUMPER. IF THE USE OF

TOW HOOKS IS NOT AN OPTION THEN A TOW STRAP MAY BE WRAPPED AROUND THE FRONT

AXLE (SEE FIGURE 3-1) IN A MANNER THAT IS ACCEPTABLE FOR TOWING THE VEHICLE INTO

THE SHOP. DO NOT USE A TOW CHAIN AROUND THE FRONT AXLE OR WITH A SINGLE POINT

LOCATION TO TOW THE VEHICLE, DOING SO WILL DAMAGE THE AXLE, SEE FIGURE 3-2. FOR

DETAILED TOWING INSTRUCTIONS FOR ON-HIGHWAY TOWING SEE SECTION 6.

FIGURE 3-1 ACCEPTABLE FIGURE 3-2 NOT ACCEPTABLE

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1

APPENDIX

PROCEDURES AND TOOLS

A MECHANIC USING A SERVICE PROCEDURE OR TOOL WHICH HAS NOT BEEN RECOMMENDED

BY HENDRICKSON MUST FIRST SATISFY HIMSELF THAT NEITHER HIS SAFETY NOR THE

VEHICLE’S SAFETY WILL BE JEOPARDIZED BY THE METHOD OR TOOL SELECTED. INDIVIDUALS

DEVIATING IN ANY MANNER FROM THE INSTRUCTIONS PROVIDED ASSUME ALL RISKS OF

CONSEQUENTIAL PERSONAL INJURY OR DAMAGE TO EQUIPMENT INVOLVED.

PERSONNEL PROTECTIVE EQUIPMENT

ALWAYS WEAR PROPER EYE PROTECTION AND OTHER REQUIRED PERSONAL PROTECTIVE

EQUIPMENT TO HELP PREVENT PERSONAL INJURY WHEN YOU PERFORM VEHICLE

MAINTENANCE, REPAIR OR SERVICE.

8

17730-248

SERVICE MANUAL

17730-248


AIRTEK ® •


SUPPORT THE VEHICLE PRIOR TO SERVICING

PLACE THE VEHICLE ON A LEVEL FLOOR AND CHOCK THE WHEELS TO HELP PREVENT THE

VEHICLE FROM MOVING. NEVER WORK UNDER A RAISED VEHICLE SUPPORTED BY ONLY A

FLOOR JACK. ALWAYS SUPPORT A RAISED VEHICLE WITH SAFETY STANDS. BLOCK THE

WHEELS AND MAKE SURE THE UNIT WILL NOT ROLL BEFORE RELEASING BRAKES. A JACK CAN

SLIP OR FALL OVER. SERIOUS PERSONAL INJURY CAN RESULT.

AXLE

AXLE CAMBER IS NOT ADJUSTABLE . DO NOT CHANGE THE AXLE CAMBER ANGLE OR BEND

THE AXLE BEAM. BENDING THE AXLE BEAM (SEE FIGURE 3-3) TO CHANGE THE CAMBER

ANGLE WILL DAMAGE THE AXLE AND REDUCE AXLE STRENGTH, AND WILL VOID

HENDRICKSON'S WARRANTY . A BENT AXLE BEAM CAN CAUSE LOSS OF VEHICLE CONTROL,

POSSIBLY CAUSING PERSONAL INJURY OR PROPERTY DAMAGE.

FIGURE 3-3

REPLACE ANY SAFETY DECALS THAT ARE FADED, TORN, MISSING, ILLEGIBLE, OR OTHERWISE

DAMAGED. CONTACT HENDRICKSON TO ORDER REPLACEMENT LABELS.

51

STEERTEK IS A UNIQUE AXLE, IN THAT THE KINGPIN IS CRYOGENICALLY INSTALLED IN THE

AXLE. THE KINGPIN IS A NON-REPLACEABLE COMPONENT OF THE AXLE ASSEMBLY. DO NOT

TRY TO REMOVE THE KINGPIN. IF THE KINGPIN SHOWS SIGNS OF MOVEMENT, CONTACT THE

HENDRICKSON TECH SERVICES DEPARTMENT.

THE REPAIR OR RECONDITIONING OF SUSPENSION OR AXLE COMPONENTS IS NOT ALLOWED

AS SHOWN ON LABEL IN FIGURE 3-3. HENDRICKSON ADVISES REPLACING ALL COMPONENTS

FOUND TO BE DAMAGED OR OUT OF SPECIFICATIONS. ALL MAJOR HENDRICKSON

COMPONENTS ARE HEAT TREATED AND TEMPERED. AIRTEK/SOFTEK COMPONENTS CANNOT

BE BENT, WELDED, HEATED, OR REPAIRED WITHOUT REDUCING THE STRENGTH OR LIFE OF

THE COMPONENT. FAILURE TO FOLLOW THESE GUIDELINES CAN CAUSE LOSS OF VEHICLE

CONTROL, POSSIBLE PERSONAL INJURY, DEATH, OR PROPERTY DAMAGE AND WILL VOID

APPLICABLE WARRANTIES.

IF A VEHICLE EQUIPPED WITH A STEERTEK AXLE IS INVOLVED IN A CRASH, A THOROUGH

INSPECTION OF THE AXLE SHOULD BE PERFORMED NOTING THE CONDITION OF THE AXLE

BEAM, KINGPINS, AND KNUCKLE ASSEMBLIES. IF ANY COMPONENT APPEARS DAMAGED THE

AXLE SHOULD BE REPLACED. IN THE EVENT THE CRASH RESULTED IN EXCESSIVE SIDE LOAD

SUCH AS A BENT WHEEL, HUB, OR SPINDLE, IT IS STRONGLY RECOMMENDED TO REPLACE

THE COMPLETE AXLE ASSEMBLY, CONTACT HENDRICKSON TECHNICAL SERVICES WITH ANY

QUESTIONS. FAILURE TO REPLACE ANY DAMAGED COMPONENTS CAN CAUSE LOSS OF

VEHICLE CONTROL, POSSIBLE PERSONAL INJURY, DEATH, OR PROPERTY DAMAGE AND WILL

VOID APPLICABLE WARRANTIES.

9


1

APPENDIX

L

52

SERVICE MANUAL

AIRTEK ® •


PARTS CLEANING

SOLVENT CLEANERS CAN BE FLAMMABLE, POISONOUS AND CAUSE BURNS. TO HELP AVOID

SERIOUS PERSONAL INJURY, CAREFULLY FOLLOW THE MANUFACTURER’S PRODUCT

INSTRUCTIONS AND GUIDELINES AND THE FOLLOWING PROCEDURE:

1. WEAR PROPER EYE PROTECTION

2. WEAR CLOTHING THAT PROTECTS YOUR SKIN

3. WORK IN A WELL VENTILATED AREA

4. DO NOT USE GASOLINE, OR SOLVENTS THAT CONTAIN GASOLINE. GASOLINE CAN

EXPLODE

5. HOT SOLUTION TANKS OR ALKALINE SOLUTIONS MUST BE USED CORRECTLY. FOLLOW

THE MANUFACTURER’S RECOMMENDED INSTRUCTIONS AND GUIDELINES CAREFULLY

TO HELP PREVENT PERSONAL ACCIDENT OR INJURY

DO NOT USE HOT SOLUTION TANKS OR WATER AND ALKALINE SOLUTIONS TO CLEAN GROUND

OR POLISHED PARTS. DOING SO WILL CAUSE DAMAGE TO THE PARTS AND VOID WARRANTY.

L


1

APPENDIX

10

17730-248


SECTION 4

Special Tools

These shop made tools are designed to install and remove kingpin bushings. Bushing tools are made from cold rolled steel or equivalent. Drawings are for reference only. Hendrickson does not supply these tools.

KINGPIN BUSHING TOOLS

AIRTEK ® •


53

ADJUSTABLE STRAIGHT FLUTE REAMER

17730-248

11

Special Tools

1

APPENDIX

L

54

SERVICE MANUAL

SECTION 5

Parts List

Blue Bird Vision Buses - 10K Capacity

L

Parts Lists

1

APPENDIX

12

17730-248


AIRTEK ® for Blue Bird Vision Buses - 10K Capacity

KEY NO. PART NO.

3

4

1

2

12

13

14

15

16

17

18

9

10

11

7

8

5

6

19a

19b

20

21

22

23

24a

24b

25

26

27

28

29

30

31

32

33

34

DESCRIPTION NO.REQ.

KEY NO. PART NO.

64075-002L Air Spring

60850-001 Air Spring Bracket

59427-008

59935-004

59428-006

64742-001

HCV, Link Mount & Linkage Assembly

(Includes Key Nos. 3-11)

Height Control Valve

HCV Linkage (Replaces 59428-001)

Link Mount Service Kit


*

*

5

5

* 5 ⁄

* 5 ⁄

⁄

16

"-18 UNC Stud - 2.07"

⁄

16

"-18 UNC Stud - 2.44"

16

16

"-18 UNC Hex Nut

" Hardened Washer

* 5 ⁄

16

"-18 UNC Locknut

*¼" Hardened Washer

*¼"-20 UNC Locknut

58913-009L Shock Absorber (Replaces 58913-008)

**¾"-10 UNC Upper Shock Bolt

**¾"-10 UNC Lower Shock Bolt

59946-001

59423-002

60961-163

**¾" Hardened Washer

**¾"-10 UNC Hex Locknut

Shock Spacer

Shock Bracket

Leaf Spring Assembly Service Kit

For vehicles built prior to 11/06

(Includes Key Nos. 19a, 24a, 25)

66805-001

60512-000

64488-002

66510-001

64316-000

64314-000

64159-000

60952-XXX

64905-004

58900-035

58900-033

58900-031

58900-055

58900-053

58900-051

58900-036

58900-034

58900-032

58900-056

58900-054

58900-052

60903-016

60904-002

60961-040

60961-009

Leaf Spring Assembly

For vehicles built after 11/06


Front Hanger (Replaces 64488-000)

**M20 Hex Bolt - 170mm

**M20 Hardened Washer

**M20 Locknut

Rear Shackle Bracket



Rear Shackle Plate

Thrust Washer

Only for vehicles built prior to 11/06

2



**M20 Locknut

Axle Assembly (Includes Key Nos. 30-55) 1

Contact Hendrickson Tech Serv. for Part No.

Axle & Kingpin Assembly 1

4

8

4

6.5", 8.5" Ride Height

LH Lower Steering Knuckle Assembly

150 Ackermann Air Brake



150 Ackermann Hydraulic Brake


1

4

4

2

2

4

2

2


RH Lower Steering Knuckle Assembly







LH Upper Steering Knuckle Assembly

RH Upper Steering Knuckle Assembly

Kingpin Bushing and Bearing Service Kit,

Axle Set

(Includes Kit Nos. 60961-009 & -039)

LH Kingpin Bushing w/Composite Thrust

Bearing Service Kit

(Includes Key Nos.35-38, 40-42, Loctite)

2

2

8

4

2

2

2

2

2

2

2

2

1

1

1

1

1

1

2

2

1

1

35

36

37

38

39

40

Not Shown

41

42

Not Shown

43

44

59828-000

64256-000

60259-002

60259-001

58910-000

60236-001

60937-000

64246-000

45

50

51

52

53

46

47

48

49

54

55

60961-039

59156-000

58937-000

58909-000

60961-043

60961-041

60961-042

66699-003

66699-001

60961-139

60961-137

60961-138

66645-001

66645-002

22962-007

17800-004

60961-069

60238-001

60240-000

59952-003

64722-003

60961-015

60508-000

59845-000

60961-051

60961-052

56

57

58

Not Shown

59

21867-044

21867-045

22962-001

17700-035

18831-021

64516-001

64516-002

60

Not Shown

64536-010

64536-060

64536-050

DESCRIPTION NO.REQ.

RH Kingpin Bushing w/Roller Thrust

Bearing Service Kit


Grease Cap Assembly

Retaining Ring

Kingpin Bushing

Thrust Bearing Service Kit, Axle Set

(Includes Kit Nos. 60961-041 & 60961-042)

4

4

4

LH Composite Thrust Bearing Service Kit

(Includes Key Nos. 38, 40-42, Loctite)

RH Roller Thrust Bearing Service Kit

(Includes Key Nos. 39-42, Loctite)

LH Composite Thrust Bearing

RH Roller Thrust Bearing

Kingpin Shim - 0.047"

1

1

2

Kingpin Shim - 0.005" (As needed for service)

Kingpin Seal

5 ⁄

8

"-11 UNC Socket Head Cap Screw

Loctite (Red) Compound Tube

ABS Sensor Sleeve

***Tie Rod Assembly, 10K, 5.36 Drop


* 7 ⁄

200 Ackermann (Replaces 59948-005)


8

" Castle Nut

***Tie Rod End Service Kit, Axle Set

(Replaces 60961-012)

(Includes Kit Nos. 60961-137 & -138)

***LH Tie Rod End Service Kit


(Includes Key Nos. 46, 48-49)

2

***RH Tie Rod End Service Kit



***LH Tie Rod End (Replaces 64004-001) 1

***RH Tie Rod End (Replaces 64004-002) 1

7 ⁄

8

" Flat Washer

Tie Rod Nut Cotter Pin

2

2

1

2

1

4

4

Stop Bolt Service Kit, One Side


½"-13 UNC Square Head Bolt

½"-13 UNC Hex Jam Nut

Top Axle Wrap

Bottom Axle Wrap

Top/Bottom Axle Wrap Liner Service Kit,

One Side (Includes Key Nos. 54-55)

Top Axle Wrap Liner


Clamp Group Service Kit, One Side


6.5" Ride Height

8.5" Ride Height

¾"-16 UNF Hex bolt

6.5" Ride Height - 10.0"


¾" Flat Washer

¾"-16 UNF 2B Nylon Locknut

Dowel Pin, 8.5" Ride Height - 2.0"

Top Pad

LH

RH

Front Axle Spacer

LH 6.5" Ride Height

LH 8.5" Ride Height

RH 8.5" Ride Height

8

2

2

1

1

8

8

2

1

1

1

2

2

2

2

55

17730-248

13

Parts Lists

1

APPENDIX

L

SERVICE MANUAL

56

Blue Bird Vision Buses - 8K/10K Capacity

9

10

11

11 12

45

1

2

5

4

4 7

4 5

6

8a

50

49

48

18

17

41

4

43

3

17

14

14

17

16

3

4

41

43

25

24

26

13a

30

29

31 32

20

22

34

40

39

37 38

51

26

24

25

45

35

27

30

46

For 8K vehicles

47 built prior to 2/07

12

17 16

9

11

44

42

46

47

19

11

44

42

46

47

10

45

49

7

48

2

4

8a

4

5

6

13a

1

4 5

17 18

46

47

16

17

30

29

16 17

28

30

36

14

17

14

25

24

26

23

21 32

18

31

34

37

38

39 40

26

24

25

33


8b

13b

17

18

51

52

8b

16

17

14

15

15

14

17

18

14

17730-248

L

Parts Lists

1

APPENDIX


SOFTEK ® for Blue Bird Vision Buses - 8K/10K Capacity

KEY NO. PART NO.

3

4

5

1

2

6

7

8a

8b

9

10

11

12

13a

13b

14

15

16

17

18

19

20

21

22

23

24

25

26

DESCRIPTION NO.REQ.

KEY NO. PART NO.

58913-009L Shock Absorber (Replaces 58913-007)





59946-001

59423-002

60961-161

60961-162

Shock Spacer

Shock Bracket

Leaf Spring Assembly Service Kit

For vehicles built after11/06

(Includes Key Nos. 8a, 13a, 14)

8K

10K

66623-001

66624-001

66364-000

60511-000

64488-002

66510-001

64316-000

64314-000

64159-000



8K

10K


8K

10K

Front Hanger (Replaces 64488-000)



**M20 Locknut




60952-XXX

64905-004

Rear Shackle Plate

Thrust Washer

Only for vehicles built prior to 11/06



**M20 Locknut

STEERTEK Axle Assembly



Axle & Kingpin Assembly

6.5", 8.5" Ride Height


58900-035

58900-033

58900-031

58900-055

58900-053

58900-051

58900-036

58900-034

58900-032

58900-056

58900-054

58900-052

60903-016

60904-002

60961-040

60961-009

60961-039

59156-000

58937-000

58909-000

















Axle Set

(Includes Kit Nos. 60961-009 & -039)


Bearing Service Kit

(Includes Key Nos. 24-27, 29-31, Loctite)


Bearing Service Kit


Grease Cap Assembly

Retaining Ring

Kingpin Bushing

2

4

4

1

1

1

1

1

4

1

4

8

4

4

4

2

8

4

2

2

2

2

2

2

4

2

2

27

28

29

Not Shown

30

31

Not Shown

32

33

59828-000

64256-000

60259-002

60259-001

58910-000

60236-001

60937-000

64246-000

34

39

40

41

42

35

36

37

38

43

44

60961-140

60961-141

45

46

47

Not Shown

64804-110

64804-130

22962-001

17700-035

18831-021

64506-000

48

49

50

64519-000

64080-000

Not Shown

51

64536-010

64536-060

64536-050

66164-000

52

60961-043

60961-041

60961-042

66699-003

66699-001

60961-139

60961-137

60961-138

66645-001

66645-002

22962-007

17800-004

60961-069

60238-001

60240-000

59952-003

64722-003

60961-015

60508-000

59845-000

66366-001

DESCRIPTION NO.REQ.


(Includes Kit Nos. 60961-041& -042)









Kingpin Seal

5 ⁄

8



ABS Sensor Sleeve

***Tie Rod Assembly, 10K, 5.36 Drop




* 7 ⁄

8

" Castle Nut

***Tie Rod End Service Kit, Axle Set


(Includes Kit Nos. 60961-137 & -138)

2

***LH Tie Rod End Service Kit



***RH Tie Rod End Service Kit



***LH Tie Rod End (Replaces 64004-001) 1

***RH Tie Rod End (Replaces 64004-002) 1

7 ⁄

8

" Flat Washer 2

2 Tie Rod Nut Cotter Pin





Top Axle Wrap

Bottom Axle Wrap

2

2

2

2



Top Axle Wrap Liner


Clamp Group Service Kit, One side


6.5" Ride Height

8.5" Ride Height

¾"-16 UNF U-bolt



¾" Flat Washer


Dowel Pin, 8.5" Ride Height - 2.0"

Top Pad/Axle Stop Assembly


Top Pad

Rubber Axle Stop

Front Axle Spacer

LH 6.5" Ride Height

LH 8.5" Ride Height

RH 8.5" Ride Height

Thrust Pad Washer

For 8K vehicles built prior to 2/07

Clamp Group Spacer

For 8K vehicles built prior to 2/07

4

4

2

2

1

2

1

1

2

2

8

8

1

1

1

2

1

2

1

4

4

57

17730-248

15

Parts Lists

1

APPENDIX

L

58

SERVICE MANUAL

Blue Bird All American Buses

14.6K Capacity - Left Hand Drive Steertek Axle

L

Parts Lists

1

APPENDIX

16

17730-248


AIRTEK ® for Blue Bird All American Buses - 14.6K Capacity

NO.REQ.

KEY NO. PART NO.

22

23

24

25

26

27

28

29

30

31

15

16

17

18

19

20

21

10

11

12

13

14

3

4

5

1

2

6

7

8

9

32

33

34

35

36

37

38

39

DESCRIPTION NO.REQ.

KEY NO. PART NO.

66865-002L Air Spring

66807-001 Air Spring Bracket

22962-014

17730-015

½" Hardened Washer

½"-13 UNC Nylon Locknut


59013-000

60501-000

22962-028

49983-000

66825-001

**¾"-10 UNC Nylon Locknut

Height Control Valve Assembly


Height Control Valve

¼" Hardened Washer

¼"-20 UNC Locknut

HCV Linkage Assembly

59428-005 HCV Linkage

*

*

*

5

5

5

* 5 ⁄

⁄


16

"-18 UNC Stud - 2.44"

⁄

16

"-18 UNC Hex Nut

⁄

16

" Hardened Washer

16

"-18 UNC Locknut

58913-011L Shock Absorber




59946-006

65000-002

66805-001

64488-002


Shock Spacer

Shock Bracket


Front Hanger


66510-001

64314-000

60952-XXX


**M20 Locknut


Rear Shackle Plate



**M20 Locknut

Axle Assembly (Includes Key Nos. 32-57) 1


Axle & Kingpin Assembly 1

8

4

4

4

4

2

2

2

2

2

4

2

2

2

6

2

2

4

4

4

2

4

4

2

2

4

2

2

2

2

2

2

2

64905-004

64905-007

58900-035

58900-033

58900-031

58900-055

58900-053

58900-051

58900-036

58900-034

58900-032

58900-056

58900-054

58900-052

60903-055

60904-002

60961-040

60961-009

60961-039

59156-000

58937-000

58909-000

6.8", 7.8", 8.8" and 9.8" Ride Height

13.2K

14.6K


















Axle Set

(Includes Kit Nos. 60961-009 & -039)


Bearing Service Kit



Bearing Service Kit


Grease Cap Assembly

Retaining Ring

Kingpin Bushing

1

1

4

4

4

1

1

40

41

42

Not Shown

43

44

Not Shown

45

46

59828-000

64256-000

60259-002

60259-001

58910-000

60236-001

60937-000

64246-000

47

48

49

50

51

52

53

54

55

56

57

58

59

60

61

62

63

60961-043

60961-041

60961-042

64006-002

64006-003

60961-011

60961-027

60961-028

64002-001

64002-002

22962-007

17800-004

60961-069

60238-001

60240-000

59952-026

64722-003

60961-015

60508-000

59845-000

60961-051

60961-146

60961-052

60961-147

21867-044

21867-027

21867-045

21867-035

22962-001

17700-035

18831-022

18831-021

18831-023

66814-001

66814-002

64536-025

64536-050

64536-075

DESCRIPTION

None Req.

2

2

2

17730-248

17

Parts Lists

1

APPENDIX

59

L

60

SERVICE MANUAL

Blue Bird All American Buses

13.2K/14.6K Capacity - Left Hand Drive Steertek Axle

L

Parts Lists

1

APPENDIX

18

17730-248


SOFTEK ® for Blue Bird All American Buses - 13.2K/14.6K Capacity

KEY NO. PART NO.

DESCRIPTION NO.REQ.

KEY NO. PART NO.

3

4

5

1

2

6

7

8

14

15

16

17

9

10

11

12

13

18

19

20

21

22

23

24

25

26

27

28

Not Shown

29

30

Not Shown

31

58913-010L Shock Absorber





59946-001

65000-002

66625-001

66626-001

64488-002

Shock Spacer

Shock Bracket


13.2K

14.6K

Front Hanger


66510-001

64314-000

60952-XXX

64905-002

64905-005


**M20 Locknut


Rear Shackle Plate



**M20 Locknut





6.8", 7.8", 8.8" and 9.8" Ride Height

13.2K

58900-035

58900-033

58900-031

58900-055

58900-053

58900-051

58900-036

58900-034

58900-032

58900-056

58900-054

58900-052

60903-055

60904-002

60961-040

60961-009

60961-039

14.6K


















Axle Set

(Includes Kit Nos. 60961-009 & -039)


Bearing Service Kit



Bearing Service Kit


59156-000

58937-000

58909-000

60961-043

60961-041

60961-042

59828-000

64256-000

60259-002

60259-001

58910-000

60236-001

60937-000

64246-000

Grease Cap Assembly

Retaining Ring

Kingpin Bushing











Kingpin Seal

5 ⁄

8



ABS Sensor Sleeve

1

1

1

4

4

4

1

1

1

1

2

4

4

1

2

2

6

4

2

2

2

2

2

4

4

8

4

1

4

2

2

2

2

32

33

38

39

40

41

34

35

36

37

42

43

44

45

46

47

48

49

50

51

64006-002

64006-003

60961-011

60961-027

60961-028

64002-001

64002-002

22962-007

17800-004

60961-069

60238-001

60240-000

59952-026

64722-003

60961-015

60508-000

59845-000

60961-142

60961-143

60961-144

60961-145

64804-120

64804-130

64804-140

64804-150

22962-001

17700-035

18831-022

18831-021

18831-023

66806-001

66666-000

64080-000

64536-010

64536-035

64536-060

64536-085

64536-025

64536-050

64536-075

DESCRIPTION NO.REQ.

Tie Rod Assembly, 14.6K, 5.36 Drop


* 7 ⁄

150/200 Ackermann

250 Ackermann

8

" Castle Nut

Tie Rod End Service Kit, Axle Set

(Includes Kit Nos. 60961-027 & -028)

LH Tie Rod End Service Kit


RH Tie Rod End Service Kit


LH Tie Rod End

RH Tie Rod End

7 ⁄

8

" Flat Washer


1

2





Top Axle Wrap

Bottom Axle Wrap



Top Axle Wrap Liner


Clamp Group Service Kit, One side


6.8" Ride Height

7.8" Ride Height

8.8" Ride Height

9.8" Ride Height

¾"-16 UNF U-bolt





¾" Flat Washer


Dowel Pin

6.8" Ride Height


4

None Req.

2

2

2



Top Pad/Axle Stop Assembly


Top Pad

Rubber Axle Stop

LH Front Axle Spacer

6.8" Ride Height

7.8" Ride Height

8.8" Ride Height

9.8" Ride Height

RH Front Axle Spacer

6.8" Ride Height

7.8" Ride Height

8.8" Ride Height

9.8" Ride Height

2

2

8

8

2

2

2

2

1

None Req.

2

2

1

1

1

2

2

17730-248

19

Parts Lists

1

APPENDIX

61

L

62

SERVICE MANUAL

Right Hand Drive for Blue Bird All American Buses

13.2K/14.6K Capacity

L

KEY NO. PART NO.

1

2

3

4

5

6

7

67905-402

67905-404

67905-405

67905-407

58900-035

58900-033

58900-031

58900-055

58900-053

58900-051

58900-036

58900-034

58900-032

58900-056

58900-054

58900-052

60904-001

70903-001

60961-040

60961-009

60961-039

59156-000

58937-000

58909-000

60961-043

60961-041

DESCRIPTION NO.REQ.

KEY NO. PART NO.



SOFTEK Standard Drop - 13.2K

AIRTEK Deep Drop - 13.2K

SOFTEK Standard Drop - 14.6K

AIRTEK Deep Drop - 14.6K


















Axle Set

(Includes Kit Nos. 60961-009 & -039)

RH Kingpin Bushing w/Composite Thrust

Bearing Service Kit


LH Kingpin Bushing w/Roller Thrust

Bearing Service Kit


Grease Cap Assembly

Retaining Ring

Kingpin Bushing



RH Composite Thrust Bearing Service Kit


1

1

1

1

1

4

4

4

8

9

10

Not Shown

11

12

Not Shown

13

14

59828-000

64256-000

60259-002

60259-001

58910-000

60236-001

60937-000

64246-000

15

16

17

18

19

20

21

22

23

24

25

60961-042

60239-005

60239-001

60961-010

60961-025

60961-026

64000-001

64000-002

22962-007

17800-004

60961-069

60238-001

60240-000

59952-026

59952-031

64722-003

60961-015

60508-000

59845-000

DESCRIPTION NO.REQ.

LH Roller Thrust Bearing Service Kit


RH Composite Thrust Bearing

LH Roller Thrust Bearing



Kingpin Seal

5 ⁄

8



ABS Sensor Sleeve

Tie Rod Assembly, 13.2K


150/200 Ackermann

250 Ackermann

* 7 ⁄

8

" Castle Nut

Tie Rod End Service Kit, Axle Set

(Includes Kit Nos. 60961-025 & -026)

LH Tie Rod End Service Kit


RH Tie Rod End Service Kit


LH Tie Rod End

RH Tie Rod End

7 ⁄

8

" Flat Washer



(Includes Nos. 20-21)



Top Axle Wrap - 13.2K

Top Axle Wrap - 14.6K

Bottom Axle Wrap


One Side (Includes Nos. 24-25)

Top Axle Wrap Liner


2

2

2

2

2

2

1

1

2

1

2

1

4

4

1

1

2

2

2

NOTE: * Item included in assembly only, part not sold separately.

** Not supplied by Hendrickson, used for reference only. Refer to OEM (vehicle manufacturer) for more information. Hendrickson is not responsible for components supplied by vehicle manufacturer. For assistance with maintenance and rebuild instructions on these components see vehicle manufacturer.

*** Hendrickson supplies different tie rod assemblies and each type may take a different replacement tie rod end kit to service. Prior to ordering, find the part number on the tie rod tube, reference Hendrickson Publication No. SEU-0223 or contact Hendrickson Sales Engineering 630.910.2800

for corre spon ding kit numbers.

NOTE: Quantities of service kit components may vary from amount shown in lists.

Parts Lists

20

17730-248

1

APPENDIX


AIRTEK ® •


SECTION 6

On Highway and On Roadway

Recommended Towing Procedure

Hendrickson recommends that a vehicle equipped with a STEERTEK axle be towed by the

following methods (listed in order of preference) for ON HIGHWAY or ON ROADWAY

applications.

1. Wheel lift method, the ideal towing procedure

2. Towing the vehicle from the rear method

3. Conventional axle fork method

Please read, understand and comply with any additional towing instructions and safety precautions that may be provided by the vehicle manufacturer.

Hendrickson will not be responsible for any damage to the axle, suspension or other vehicle components resulting from any towing method or fixture not authorized by Hendrickson.

Please contact Hendrickson Tech Services at 630.910.2800 or send email to: [email protected] with any questions regarding proper towing procedures for vehicles equipped with a STEERTEK axle.

WHEEL LIFT METHOD—IDEAL

This method provides the greatest ease for towing the vehicle. Lifting at the tires helps reduce the risk of possible damage to the axle, suspension, and engine components during towing operations, see Figure 6-1.

FIGURE 6-1 Wheel lift method

63

17730-248

TOWING VEHICLE FROM THE REAR METHOD

This method is preferred when the proper equipment is not available to perform the wheel lift method and is necessary for wreckers not equipped with an under lift system.

21

Towing Procedure

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SERVICE MANUAL

AIRTEK ® •


AXLE FORK LIFT METHOD

This is an alternative method for towing the vehicle, but requires standard 5" forks, (see

Figures 6-2 and 6-3) and designated lift points inside the axle clamp groups. The following procedure must be used:

■

Place a spacer on the boom, to provide adequate clearance between the oil pan and the boom if necessary. Lift the vehicle in order to place spacer under tires. This will provide sufficient room under the axle to locate forks in the proper position.

■

Install the fork in the boom properly.

■

Position the tow forks directly under the axle, inside the axle clamp groups as shown in Figure 6-2.

FIGURES 6-2 AND 6-3

PROPER TOW FORK LOCATION ON INSIDE CLAMP GROUP ON THE STEERTEK AXLE

■

Prior to lifting the vehicle, ensure that the bottom axle plate is flat in the tow fork to

minimize any gap between the bottom axle plate and the tow fork, see Figure 6-4 and

6-5. It may be necessary to deflate the air in the steer axle suspension, and/or release the tractor brakes. Deflate the steer axle air springs by disconnecting the height control valve linkage and lowering the height control valve linkage arm. This will exhaust the air pressure in the steer axle air springs.

FIGURE 6-4 WITHOUT GAP FIGURE 6-5 WITH GAP

NOTE When lifting a vehicle with an under lift boom, care must be taken not to damage the engine’s oil pan. Vehicles equipped with a front fairing may require removal of the front fairing prior to towing to prevent component damage.

■

■

Lift vehicle and secure the vehicle to the boom.

Install safety straps, it is preferred to use nylon safety straps. Chains have a tendency to bind and may cause damage to the axle.

22

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APPENDIX


AIRTEK ® •


OFF ROADWAY TOWING METHOD

WHEN A VEHICLE IS DISABLED AND EQUIPPED WITH A STEERTEK AXLE, CARE MUST BE

TAKEN TO ENSURE THERE IS NO DAMAGE TO THE SUSPENSION OR AXLE WHEN TOWING THE

VEHICLE. THE USE OF A TOW STRAP IS NECESSARY TO TOW A DISABLED VEHICLE INTO A

REPAIR FACILITY PARKING LOT INTO THE SHOP BAY. THE TOW STRAPS SHOULD BE

CONNECTED TO THE TOW HOOKS PROVIDED BY THE VEHICLE MANUFACTURER AT THE

FRONT OF THE BUMPER. IF THE USE OF TOW HOOKS IS NOT AN OPTION THEN A TOW STRAP

MAY BE WRAPPED AROUND THE FRONT AXLE, (SEE FIGURE 6-6) IN A MANNER THAT IS

ACCEPTABLE FOR TOWING THE VEHICLE INTO THE SHOP. DO NOT USE A TOW CHAIN

AROUND THE FRONT AXLE TO TOW THE VEHICLE, DOING SO WILL DAMAGE THE AXLE AND

VOID WARRANTY, (SEE FIGURE 6-7) .

THE FOLLOWING METHODS ARE NOT RECOMMENDED FOR:

ON HIGHWAY OR ON ROADWAY TOWING

FIGURE 6-6

NYLON STRAPS ARE

ACCEPTABLE FOR

OFF ROADWAY TOWING

65

CHAINS ARE NOT

ACCEPTABLE FOR

OFF ROADWAY TOWING

FIGURE 6-7

17730-248

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Towing Procedure

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AIRTEK ® •


SECTION 7


Following appropriate inspection procedure is important to help ensure the proper maintenance and operation of the AIRTEK ® suspension system and component parts function to their highest efficiency.

/SOFTEK ®

HENDRICKSON RECOMMENDED PREVENTIVE MAINTENANCE INTERVALS

■

The first 1,000 miles

■

On-highway – every 25,000 miles (40,000 km) or 6 months, whichever comes first

COMPONENT INSPECTION

■

■

■

■

■

■

■

■

■

■

■

■

Air spring — Look for chaffing or any signs of spring or component damage.

Clamp group — Check torque on clamp group mounting hardware. Refer to Torque

Specifications in the appendix of this publication.

Fasteners — Look for any loose or damaged fasteners on the entire suspension. Make sure all fasteners are tightened to the specified torque. Refer to Torque Specifications in the appendix. Use a calibrated torque wrench to check torque in a tightening direction. As soon as the fastener starts to move, record the torque. Correct the torque if necessary. Replace any worn or damaged fasteners.

Front hangers and shackle brackets — Check for cracks or loose mounting hardware.

Replace if necessary, see the Component Replacement Section of this publication for replacement procedure.

Operation — All steering components must move freely through the full range of motion from axle stop to axle stop.

Shock absorber — Look for any signs of dents or leakage, misting is not considered a leak. See Shock Absorber Inspection in this section.

Steel leaf spring and wrap leaf assembly — Look for cracks. Check the front and rear bushings for any wear or deterioration. Replace spring assembly if any of the previous conditions are observed. See the Component Replacement Section of this publication for replacement procedure.

STEERTEK Axle — The axle should be free of any nicks or gouges. Inspect for any cracks or dents on axle.

Steering pivot points — Check for looseness at all pivot points. Inspect and lubricate all pivot points. Refer to the Trouble Shooting Guide Section in the Appendix of this publication.

Thrust washers (If equipped) — Look for any signs of excessive wear to the thrust washers, shackles and shackle bracket. See Thrust Washer Inspection detailed in this section.

Tire wear — Inspect tires for wear patterns that may indicate suspension damage or misalignment. See Tire Inspection in this section.

Top and bottom axle wrap liners — Look for any cracking or broken pieces on liner in load bearing areas. See Axle Wrap Liner Inspection in this section.

■

■

Top pad (AIRTEK) — Check for cracks or damage. Replace if necessary, see the

Component Replacement Section of this publication for replacement procedure.

Top pad and bump stop (SOFTEK) — Check for cracks and/or missing rubber bump stops. Replace if necessary, see the Component Replacement Section of this publication for replacement procedure.

■

Wear and damage — Inspect all parts of suspension for wear and damage. Look for bent or cracked parts. Replace all worn or damaged parts.

See vehicle manufacturer’s applicable publications for other preventative maintenance requirements.

24

17730-248 Preventive Maintenance

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APPENDIX

SERVICE MANUAL

NOTE

NOTE


AIRTEK ® •


LUBRICATION INTERVALS

For vehicles equipped with the STEERTEK axle, regular lubrication intervals should be

followed to help prevent premature wear to the kingpin bushings and tie rod ends, see lubrication chart below.

The recommended service lubrication interval is a guideline, the vehicle may require increased lubrication interval depending on severity of operation.

STEERTEK GREASING AND LUBRICATION SPECIFICATIONS

Component Greasing Interval Grease

NLGI

Grade

Outside Temperature

Kinpin Bushings

Tie Rod Ends

Maximum of

25,000 miles

(40,225 kilometers) or 90 days, whichever comes first.

Multipurpose

Grease

2

Refer to the lubricant manufacturer’s specifications for the temperature service limits applicable to your area.

Drag Link See Vehicle Manufacturer

NOTE: Lubrication greases acceptable for use on the STEERTEK axle will carry a designation of

NLGI #2 EP and rated GC-LB or equivalent.

KINGPIN LUBRICATION

On the Hendrickson STEERTEK front axle the kingpin grease fittings are located on the top and bottom of the kingpin grease caps.

1. Place the vehicle on a level floor.

2. Prior to greasing the kingpins on the vehicle, the suspension must be in a loaded condition.

3. Clean off all the grease fittings and grease gun tip with a clean shop towel prior to lubrication.

4. Lubricate the kingpins through the grease fittings on the top and bottom of the steering knuckle, see Lubrication Specification Matrix above.

5. Force the required lubricant into the upper and lower kingpin grease fittings, until new lubricant flows from the upper axle beam and knuckle and the thrust bearing purge location, see Figures 7-1 and 7-2.

Greasing at the lower zerk should purge grease from the thrust bearing shell. Both sides purge in the same area. The left side of the axle has a composite style thrust bearing, see

Figure 7-1 and the right side of the axle has a steel roller thrust bearing, see Figure 7-2, for right hand drive axle configuration the thrust bearings will be the opposite.

FIGURE 7-1 FIGURE 7-2

67

17730-248

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SERVICE MANUAL

AIRTEK ® •


TIE ROD END LUBRICATION

LUBRICATION PROCEDURE

1. Turn the vehicle wheels straight ahead.

2. Wipe the zerk fitting and grease gun tip with clean shop towels.

3. Wipe the seal/boot clean with shop towels.

4. Attach a grease gun to the zerk fitting. Either a hand or pneumatic grease gun is acceptable. If air operated grease gun is used, system air pressure should not exceed 150 psi (1035 kPa).

EXCEEDING THE MAXIMUM AIR PRESSURE TO THE ZERK FITTING CAN CAUSE DAMAGE TO THE

DUST BOOT AND COMPONENT FAILURE.

5. Dirt, water, and discolored old grease should flow from the relief vents or purge holes near the boot crimp or bellows area, see Figure 7-3. Continue to purge grease until fresh grease flows from the purge area.

FIGURE 7-3

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1

APPENDIX

6. If the tie rod end is designed for lube service and it will not accept grease proceed as follows: a. Remove the zerk fitting b. Inspect the threaded zerk fitting hole in the tie rod end and remove any obstructions c. Install a new zerk fitting d. Continue the lubrication procedure e. If the tie rod end will not accept grease following this procedure it will be necessary to replace the tie rod end, (see Tie Rod End replacement in the Component

Replacement Section of this publication)

7. Apply grease until all the old grease is purged from the boot and fresh grease is coming out.

26

17730-248

SERVICE MANUAL

17730-248


AIRTEK ® •


TIE ROD END INSPECTION

INSPECTION PROCEDURE

Before beginning this inspection procedure, the entire system must be unloaded (i.e., the front end of the vehicle must be raised and supported with safety stands).

DO NOT GREASE THE TIE ROD ASSEMBLY BEFORE PERFORMING THE INSPECTION. DOING SO

CAN INHIBIT EFFORTS TO DETERMINE ACTUAL WEAR.

REPLACE THE ENTIRE TIE ROD END IF THE BOOT IS TORN OR MISSING, FAILURE TO DO SO

CAN CAUSE PREMATURE WEAR OF THE TIE ROD END.

1. Block rear wheels of vehicle. Using the bottom of the axle beam or the frame rails, raise the front end off the ground and support with stands.

2. With the engine off, turn the wheels from full left to full right and then return to the straight-ahead position.

3. Check that the boots are in place and completely installed over the tie rod ends.

4. Check for cracking or tears in the boots. Also check the boot seals for damage. Replace the entire tie rod end if the boot is damaged.

THE CORRECT COTTER PIN MUST BE INSTALLED THROUGH THE TIE ROD END WITH THE

CASTLE NUT TIGHTENED TO THE PROPER TORQUE SPECIFICATION IN ORDER TO SECURELY

ATTACH THE TIE ROD. LOSS OF THE COTTER PIN CAN CAUSE THE TIE ROD END NUT TO

BECOME LOOSE AND ADVERSELY AFFECT VEHICLE STEERING AND POSSIBLY RESULT IN TOTAL

LOSS OF STEERING CONTROL.

5. Check that the tie rod end nut is installed and secured with a cotter pin. If the cotter pin is missing, check the nut torque specification and then install a new cotter pin. Always tighten the castle nut to specified torque when setting the cotter pin. Do not back off the nut to insert cotter pin.

FIGURE 7-4

6. Check that the tie rod end is threaded correctly into the cross tube and is engaged deeper than the end of the cross tube slot. The tie rod end must be visible the entire length of the cross tube slot, see Figure 7-4.

7. Check that zerk fittings are installed. Replace a damaged zerk fitting with a new one.

DO NOT USE THE FOLLOWING ITEMS OR METHODS TO CHECK FOR MOVEMENT OF THE TIE

ROD ASSEMBLY. DAMAGE TO COMPONENTS CAN RESULT IF:

■

■

■

A CROW BAR, PICKLE FORK OR 2 x 4 ARE USED.

ANYTHING OTHER THAN HANDS ARE USED TO GRASP THE CROSS TUBE ASSEMBLY (CAN

RESULT IN DAMAGE TO THE CROSS TUBE).

EXCESSIVE PRESSURE OR FORCE IS APPLIED TO THE TIE ROD ENDS OR THE JOINTS OF

THE ASSEMBLY.

69

27


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APPENDIX

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SERVICE MANUAL

AIRTEK ® •


8. By hand or using a pipe wrench, with jaw protectors to avoid gouging the cross tube, rotate the cross tube toward the front of the vehicle and then toward the rear. After rotating, center the cross tube. If the cross tube will not rotate in either direction, replace both tie rod ends, see Figure 7-5.

FIGURE 7-5

NOTE

L


1

APPENDIX

FIGURE 7-6

9. Position yourself directly below the tie rod end. Using both hands, grab the assembly end as close to the tie rod end as possible (no more than 6" or

152.4mm). Apply hand pressure with reasonable human effort vertically up and down in a push-pull motion several times (using approx. 50-100 lbs. of force). Check for any movement or looseness at both tie rod end locations, see Figure 7-6.

FIGURE 7-7

10. If there is any movement in the tie rod assembly, install a magnetic based dial indicator on the Ackermann arm, see

Figure 7-7.

11. Set the dial indicator to zero.

12. Apply hand pressure with reasonable human effort vertically up and down in a push-pull motion several times (using approx. 50-100 lbs. of force). Observe the reading on the dial indicator.

13. If the reading is more than 0.060", replace both tie rod ends at the next service interval.

14. If a tie rod end exhibits 0.125" of movement by hand, the vehicle should be removed immediately from use and the tie rod end be replaced.

According to the Commercial Vehicle Safety Alliance (CVSA), the vehicle “out of service” criteria is: Any motion other than rotational between any linkage member and its attachment point of more than 1 ⁄

Handbook, April 1, 2006.)

8

" (3mm) measured with hand pressure only.

(393.209(d)), (published in the North American Standard Out-of-Service Criteria

28

17730-248

SERVICE MANUAL

FIGURE 7-8


AIRTEK ® •


CLAMP GROUP RE-TORQUE INTERVAL

1. Clamp group locknuts must be torque to specification at preparation for delivery.

2. Clamp group locknuts must be re-torqued at 1,000 miles.

3. Thereafter follow the 6 month/ 25,000 mile inspection and annual re-torque interval.

4. Ensure that the clamp group is properly aligned and the hex bolts/U-bolts are seated in the top pad, and the bottom axle wrap is centered on the top axle wrap, see Figure 7-8.

71

17730-248

5. Check for the signs of component or bolt movement.

6. If signs of movement are present, disassemble the clamp group fasteners, check for component wear or damage and replace as necessary, then install new clamp group fasteners and repeat steps 1 through 5.

FIGURE 7-9

7. Tighten the clamp group locknuts evenly in 50 foot pounds increments to 285-305 foot pounds torque in the proper pattern to achieve uniform bolt tension, see Figure 7-9.

TIRE INSPECTION

The leading causes of tire wear are the following, in order of importance:

1. Tire Pressure

2. Toe Setting

3. Thrust Angle

4. Camber

The following tire Inspection guidelines are based upon TMC (Technology & Maintenance

Council) recommended practices. Any issues regarding irregular tire wear where

Hendrickson is asked for assistance, will require tire and alignment maintenance records, reference TMC’s literature numbers RP219A, RP230, or RP 642.

Tire wear is normally the best indicator of vehicle alignment condition. If tires are wearing too rapidly or irregularly, alignment corrections may be needed. The tire wear patterns described below can help isolate specific alignment problems.

29


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APPENDIX

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SERVICE MANUAL

AIRTEK ® •


FIGURE 7-10

FIGURE 7-11

FIGURE 7-12

The most common conditions of concern are:

■

■

■

Overall Fast Wear (Miles per 32nd)

Feather Wear

Cupping

■

■

■

Diagonal Wear

Rapid Shoulder Wear (One Shoulder Only)

One-Sided Wear

Overall Fast Wear — Fast wear can be described as exhibiting a good, but accelerated wear pattern. It is typically caused by operating conditions, such as mountainous terrain, frequency and severity of turning, abrasive road surfaces in combination with vehicle configurations and their attributes-such as power steering, heavy axle loads, high wheel cuts, setback axles, short wheel base tractors, long wheel base straight trucks. To correct this problem, consult with vehicle and tire manufacturers when specifying equipment or replacing tires. For more information, see TMC RP 219A publication, page 11. For information on how to accurately measure and record tire rates, see TMC RP 230 publication.

Feather wear — Tread ribs or blocks worn so that one side is higher than the other resulting in step-offs across the tread face. Generally, ribs or blocks exhibit this wear. To spot this problem, do the following:

With one hand flat on the tread of the tire and a firm down pressure, slide your hand across the tread of the tire. In one direction, the tire will feel smooth and in the opposite direction there will be a sharp edge to the tread. Typical causes of feather wear include: excessive side force scrubbing, resulting from conditions of misalignment such as excessive toe, drive axle misalignment, worn, missing or damaged suspension components, bent tie rods or other chassis misalignment.

To correct this problem, tires can be rotated to another axle for maximum utilization of remaining tread. Additionally, diagnose the vehicle itself and correct misalignment condition as required. If steer tire feathers are in opposite directions, an improper toe condition is most likely the cause. For more information, see TMC RP 219A publication, page 5.

If feather wear on both steer tires is in the same direction, drive axle or other chassis

misalignment is indicated. If one steer tire shows feather wear and the other steer tire has normal wear, a combination of toe and drive axle or chassis misalignment is indicated.

Cupping — Localized, dished out areas of fast wear creating a scalloped appearance around the tire. Cupping, which appears around the tire on the shoulder ribs, may also progress to adjoining ribs, see TMC RP 219A publication, page 7.

Cupping is usually a result of moderate-to-severe imbalance, improper rim/wheel mounting, excessive wheel end play or other assembly nonuniformity. It can also be due to lack of shock absorber control on some suspension types.

To solve cupping problems:

■

■

Tires – Correct mismount or balance problem. If ride complaints arise, steer tires may be rotated to drive or trailer axle.

Vehicle – Diagnose component imbalance condition, i.e., wheel, rim, hub, brake, drum. Correct as necessary.

30

17730-248

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APPENDIX

SERVICE MANUAL

17730-248


AIRTEK ® •


FIGURE 7-13

Diagonal Wear — Can be described as localized flat spots worn diagonally across the tread at approximately 25-35° angles, often repeating around the tread circumference. For more information, see

TMC RP 219A publication, page 20.

Diagonal wear is usually caused by bad wheel bearings, toe out, mismounting of tire and wheel assembly to axle, and mismatched duals for size and/or inflation pressures. It may start as brake skid.

Diagonal wear is aggravated by high speed empty or light load hauls.

To correct diagonal wear, reverse direction of rotation of the tire. If wear is excessive, true tire. If the source of trouble is the vehicle, diagnose cause and correct as needed.

FIGURE 7-14

Rapid Shoulder Wear (One

Shoulder Only) — Is defined as a tire worn on the edge of one shoulder, sometimes extending to inner ribs. It can progress to diagonal wipeout. For more information, see

TMC RP 219A publication, page 22.

This wear condition is usually caused by excessive toe or excessive camber. These conditions can be created by a misaligned or bent axle and can also be caused by loose or worn wheel bearings.

To correct this type of rapid shoulder wear:

■

Tires – Change direction of rotation of tire. If shoulder wear is severe, remove and retread.

■

Vehicle – Diagnose misalignment and/or mechanical condition and correct.

FIGURE 7-15

One-sided wear — Is excessive wear on one side of tire extending from the shoulder towards the center of the tread. For more information, see TMC RP 219A, page 26.

One-sided wear is usually caused by improper alignment, worn kingpins, loose wheel bearings, excessive camber, excessive axle loads, non-parallel axles, or non-uniform tire and wheel assembly caused by improper bead seating or bent wheel.

To correct one-sided wear:

■

■

Tires – Depending on severity, rotate tires to another axle position or, if worn to minimum tread depths, submit for possible retreading.

Vehicle – Diagnose mechanical problem and correct.

73

31


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AIRTEK ® •


AXLE WRAP LINER INSPECTION

FIGURE 7-16

INSPECTION PROCEDURE

■

Axle wrap liners are installed on the STEERTEK axle to help prevent any type of abrasion on the axle at the clamp group area. Any time an axle wrap is removed it is mandatory that the axle wrap liner be replaced.

■

Liner Crack Criteria:

It is possible for the axle wrap liner to crack during service. If the liner is cracked and all the pieces are intact it is not necessary to replace the liner. If the liner is broken out and there are pieces missing the liner must be replaced immediately, see Figure 7-16. See Axle Wrap replacement in the Component Replacement

Section of this publication.

SHOCK ABSORBER INSPECTION

Hendrickson uses a long service life, premium shock absorber on all AIRTEK and SOFTEK suspensions. When the shock absorber replacement is necessary, Hendrickson recommends that the shock absorbers be replaced with identical Hendrickson Genuine parts for servicing. Failure to do so will affect the suspension performance, durability, and will void the warranty.

FIGURE 7-17

Inspection of the shock absorber can be performed by doing a heat test, and a visual inspection. For instructions on shock absorber replacement see the

Component Replacement Section of this publication. It is not necessary to replace shock absorbers in pairs if one shock absorber requires replacement.

HEAT TEST

1. Drive the vehicle at moderate speeds on rough road for minimum of fifteen minutes.

DO NOT GRAB THE SHOCK AS IT CAN POSSIBLY CAUSE

PERSONAL INJURY.

2. Lightly touch the shock body carefully below the dust cover, see Figure 7-17.

3. Touch the frame to get an ambient reference. A warm shock absorber is acceptable, a cold shock absorber should be replaced.

4. To inspect for an internal failure, remove and shake the suspected shock. Listen for the sound of metal parts rattling inside. Rattling of metal parts can indicate that the shock has an internal failure.

32

17730-248

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APPENDIX


FIGURE 7-18

AIRTEK ® •


VISUAL INSPECTION

Look for these potential problems when doing a visual inspection. Inspect the shock absorbers fully extended. Replace as necessary.

75

NOTE

LEAKING VS. MISTING SHOCK VISUAL INSPECTION

The inspection must not be conducted after driving in wet weather or a vehicle wash; shocks need to be free from water. Many shocks are often mis-diagnosed as failures. Misting is the process whereby very small amounts of shock fluid evaporate at a high operating temperature through the upper seal of the shock. When the “mist” reaches the cooler outside air, it condenses and forms a film on the outside of the shock body. Misting is perfectly normal and necessary function of the shock. The fluid which evaporates through the seal area helps to lubricate and prolong the life of the seal.

FIGURE 7-19

A shock that is truly leaking and needs to be replaced will show signs of fluid leaking in streams from the upper seal. These streams can easily be seen when the shock is fully extended, underneath the main body (dust cover) of the shock. Look for these potential problems when doing a visual inspection. Inspect the shock absorbers fully extended. Replace as necessary.

The AIRTEK/SOFTEK suspension is equipped with a premium seal on the shock, however this seal will allow for misting to appear on the shock body (misting is not a leak and is considered acceptable).

If the shock is damaged, install a new shock absorber as detailed in the Component Replace ment Section of this publication.

17730-248

33


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KINGPIN BUSHING INSPECTION

INSPECTION PROCEDURE (STEERING KNUCKLE LATERAL MOVEMENT)

1. Chock the wheels to help prevent the vehicle from moving. Set the parking brake.

2. Use a jack to raise the vehicle until the wheels are off the ground. Support the vehicle with safety stands.


NOTE

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APPENDIX

3. CHECKING THE UPPER KINGPIN BUSHING. Install the base of a dial indicator onto the axle beam and face the tip against the steering knuckle, see Figure 7-20.

4. Set the dial indicator to “0” zero.

5. Move the top of the tire in and out by applying reasonable constant pressure and then release, see Figure 7-22.

FIGURE 7-22

6. Check the reading on the dial indicator.

If the dial indicator moves more than

0.015", the upper bushing is worn or damaged. Replace both bushings. Refer to the Kingpin Bushing replacement procedure in the Component Replacement


7. CHECKING THE LOWER KINGPIN

BUSHING. Install a dial indicator so that the base is on the axle and the indicator tip is against the inside of the bottom of the knuckle, see Figure 7-21.

8. Set the dial indicator to “0” zero.

9. Move the bottom of the tire in and out. If the dial indicator moves more than

0.015", the lower bushing is worn or damaged. Replace both kingpin bushings. Refer to the Component

Replacement Section of this publication.

If one bushing is worn or damaged, it is mandatory to replace both the top and bottom bushings on that knuckle assembly.

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STEERING KNUCKLE INSPECTION

CHECKING VERTICAL END PLAY (UP AND DOWN MOVEMENT)

The operating spec for vertical clearance on the steering knuckle is 0.008" to 0.030".

1. Chock the rear tires to help prevent the vehicle from moving.

2. Set the parking brakes.

3. Use a jack to raise the vehicle until both tires are 1" off the ground.

FIGURE 7-23

4. Place a dial indicator on each side of the axle as follows: a. Index the wheels slightly (left or right).

b. Place the magnetic dial indicator base on the axle, see Figure 7-23.

c. Place the tip of the dial indicator on the top of the upper steering knuckle

(not on the grease cap).

5. Set the dial indicator to “0” (zero).

6. Lower the jack.

7. If vertical clearance is greater than

0.030", adjust the upper knuckle to obtain clearance specifications, if adjustment does not achieve clearance specification, install shims (Hendrickson part no. 60259-002) between the top of the axle and the bottom of the upper steering knuckle to obtain the proper clearance specification. See Steering Knuckle Assembly in the Component Replace ment Section of this publication for proper shim installation.

8. If vertical clearance is below 0.008", adjust the upper steering knuckle to obtain the proper clearance specification, if adjustment does not achieve clearance specification, remove shims. See Steering Knuckle Assembly in the Component Replacement Section of this publication for proper shim removal.

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NOTE

SHACKLE THRUST WASHER INSPECTION (If Equipped)

SOFTEK Vision 8K capacity vehicles built after 02/2007, and all other vehicles built after

11/2006 are not equipped with shackle thrust washers.

In normal use these components will function satisfactorily, even though the components may show some wear.

FIGURE 7-24

Shackle Bracket

M20 Locknut

Tightening Torque

290-310* ft. lbs.

Washer

Shackle Plate

Thrust Washer

M20 Bolt

Leaf Spring with Bushing

*Specification provided, controlled and subject to change by vehicle manufacturer.

An indication that the shackle thrust washers are worn, or need replacement is when the suspension exhibits one or more of the following conditions:

1. Excessive lateral movement of the spring.

2. The rear spring eye and or thrust washers are in contact with the shackle plates.

3. Normal and unacceptable thickness of the thrust washers (See Figure 7-24) can be measured with a micrometer or a ruler.

■

The normal thickness of a new thrust washer is 3 ⁄

16

" (0.187").

■

■

■

The minimum thickness allowable for a thrust washer is 3 ⁄

32

" (0.090").

If one or more of these conditions is experienced, disassembly of the rear shackle assembly is required to replace the thrust washers.

If one thrust washer is worn out, Hendrickson recommends both thrust washers on that side of the suspension be replaced. Inspect the thrust washers on the other side of the vehicle and replace if necessary. See Shackle Thrust Washer replacement procedure in the Component Replacement Section of this publication.

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FRONT HANGER/REAR SHACKLE BRACKET SURFACE PAINT WEAR

The Hendrickson front suspension systems AIRTEK and SOFTEK equipped on Blue Bird buses, utilize rubber bushings in the leaf springs. These rubber bushings allow the leaf spring to deflect and contact the front hanger and shackle plates when the bus encounters high lateral acceleration (ex. a highway clover leaf). The rubber bushing will center the leaf spring between the legs of the hanger/shackle plates once the vehicle is driven straight.

This function of the rubber bushing may allow the leaf spring to contact the front hanger/rear shackle plate and possibly remove surface paint from the contact area. Surface paint wear does not cause damage that will affect the function or durability of the front hanger/rear shackle plate or their mating components provided a minimum wall thickness is maintained.

FIGURE 7-25

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An indication that the front hanger/ rear shackle plates are worn and require replacement is when the components no longer meet the following minimum requirements:

■

■

Front hanger inboard leg minimum thickness of 9.15 mm and the outboard leg thickness minimum thickness 11.00 mm, see Figure 7-

26.

Rear shackle plate minimum thickness of 5.8 mm, see Figure 7-26.

FIGURE 7-26

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SECTION 8


ALIGNMENT DEFINITIONS

FIGURE 8-1

Ackermann Steering Geometry —

The geometry of the four bar linkage consisting of the front axle beam pivot points, tie rod arms, and cross tube and attempts to provide free rolling of front tires in a turn.

Ackermann geometry is dependent upon the steering axle track-width

ACKERMANN GEOMETRY

and wheelbase of the vehicle.

Improper geometry results in wheel scrub in turns which generally appears as toe wear on the tire.

Center of Rotation

Rear Axle

Usually more wear is present on one side of the vehicle than the other due to the operational route of the vehicle.

Wheel

Base

Bump Steer (Feedback) — The feedback felt through the steering linkage to the steering wheel when a steer axle tire hits a bump in the road. This occurs because the axle-end of the drag link and the axle attachment point of the spring do not travel in parallel circular arcs as the suspension moves up and down. This condition can also be caused by trapped air in the power steering system.

FIGURE 8-2

Camber — The angle formed by the inward or outward tilt of the wheel reference to a vertical line. Camber is positive when the wheel is tilted outward at the top and is negative when the wheel is tilted inward at the top.

Excessive positive camber may cause smooth wear on the outer half of the tire tread. Excessive negative camber may cause wear on the inner half of the tread. Static-unloaded camber angles are built into the axle to put the loaded tire perpendicular to the road.

FIGURE 8-3

Caster — The forward or rearward tilt of the steering axle kingpin in reference to a vertical line. The angle is measured in degrees.

Caster is positive when the top of the steering axis is titled rearward and is negative when the tilt is forward. Proper caster is important for directional stability and returnability. Too much positive caster can cause shimmy, excessive steering effort and is normally a vehicle performance and handling consideration. Uneven positive caster may create a steering pull toward the side with the lower caster. This attribute may be used to compensate for crowned roads.

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FIGURE 8-4

FIGURE 8-6

FIGURE 8-7

KINGPIN

INCLINATION

IN DEGREES

KINGPIN

OFFSET

Kingpin Inclination (KPI) — The inward tilt of the kingpin from the vertical. This front suspension parameter has a pronounced effect on steering effort and returnability. As the front wheels are turned around an inclined kingpin, the front of the truck is lifted. This lifting of the vehicle is experienced as steering effort when the turn is executed and exhibits itself as recovery force when the steering wheel is released.

Kingpin Offset — The distance between the center of the tire patch and intersection of the kingpin axis with the ground. This parameter of front end geometry is important in vehicles without power steering and has a major effect on static steering. If there is no kingpin offset, the tires must scrub around the center of the pin patch when turned in a static condition, resulting in higher static steering efforts.

Steering Arm — The component that connects the drag link to the axle knuckle assembly.

FIGURE 8-5

Thrust Angle, Tracking, or Square

— The angle formed by the centerline of the vehicle frame (geometric centerline) and the direction that an axle points. As indicated by the term “square”, the ideal value for the angle is 0° or when the axle centerline is at 90° or perpendicular to the geometric centerline. Thrust or tracking to the right is positive, and to the left is negative.

A steering correction is required to offset the effect of the thrust angles and keeps the vehicle traveling in a straight line. It results in a lateral offset between the steer and drive axle tires commonly referred to as “dog tracking.”

Tie Rod Arm (Ackermann-Arm, Cross Tube Arm) — The component that transmits steering forces between left and right axle knuckle assemblies through the cross tube assembly.

TOE-IN

Toe-in — is when the horizontal line intersects in front of the wheels, or the wheels are closer together in front than in the back. Toe-in is commonly designated as positive, toe-out as negative. Excessive toe-in wears the outside edge of the tires. Steer axle toe is adjustable to reduce wear to the leading edge of the tire and also to avoid road wander. Toe is adjusted in a static, unloaded condition so that the tires will run in a straight line under a dynamic, loaded condition.

TOE-OUT

Toe-out — Is when the horizontal lines intersect behind the wheels, or the wheels are closer together in back than in front. Toe-in is commonly designated as positive, toe-out as negative. Excessive toe-out wears the inside edge of the tires. Steer axle toe is adjustable to reduce wear to the leading edge of the tire and also to avoid road wander. Toe is adjusted in a static, unloaded condition so that the tires will run in a straight line under a dynamic, loaded condition.

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FIGURE 8-8

Toe-Out on Turns — (See Ackermann Geometry).

Excessive turning angles such as those encountered in pickup and delivery operations may contribute to premature tire wear. Be advised that the greater the turning angles, the more that toe and camber change. If you have any doubt regarding the optimum turning angles for your operation, contact the vehicle’s manufacturer, axle

OEM, tire OEM and alignment equipment manufacturer for advice.

Total Toe — The angle formed by two horizontal lines through the planes of two wheels. Steer axle toe Is adjustable to reduce wear to the leading edge of the tire and also to avoid road wander. Toe is adjusted in a static, unloaded condition so that the tires will run in a straight line under a dynamic, loaded condition.

TOE-OUT TOE-IN

INSPECTION PRIOR TO ALIGNMENT

WHEELS AND TIRES

Examine the following items:

■

■

■

■

■

■

The tires are inflated to the manufacturer’s specified tire pressure.

The steer axle tires are the same size and type.

The lug nuts are tightened to manufacturer’s specified torque.

The wheels are balanced and check for tire to rim runout.

The wheels and tires are free of excessive wear and damage.

Wheel bearing end play is within OEM specification.

FRONT SUSPENSION

Inspect the following:

■

All fasteners are installed and tightened to the specified torque. See Torque

Specification Section in the appendix of this publication.

■

■

■

■

■

Leaf springs are free of wear or damage.

Air springs are free of wear or damage (if equipped).

Shock absorbers are free of wear and damage.

Vehicle ride height for both the front and rear are within specification. Follow manufacturer's guidelines (if equipped).

Front and rear spring mounts for wear or damage.

INSPECT TIE ROD ENDS

Perform the “Tie Rod Inspection” procedure, refer to the Preventive Maintenance Section of this publication.

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REAR AXLE AND REAR SUSPENSION

Rear axle misalignment can cause front tire wear. If the outer edge of one front tire is worn and the inner edge of the other front tire is worn, check the following:

■

■

■

■

■

■

■

Make sure the rear axle (especially a tandem axle) is correctly aligned. Refer to the procedure from the manufacturer of the vehicle or the suspension.

All fasteners including U-bolts (if applicable) are installed and tightened to the specified torque.

The leaf springs are not worn or damaged.

The bushings in the leaf springs are not worn or damaged.

The torque rods (if used) are correctly adjusted (if adjustable).

The frame is not bent or twisted.

Refer to any additional recommendations and specifications from the manufacturer of vehicle on rear axles and suspensions. Reference the TMC (The Technology &

Maintenance Council) Guidelines for Total Vehicle Alignment.

FRONT WHEEL ALIGNMENT

Hendrickson recommends technicians review TMC’s publication TMC (Technology &

Maintenance Council) “Guidelines for Total Vehicle Alignment”.

The AIRTEK/SOFTEK front wheel alignment specification can be found in the Appendix of this publication.

Check the total vehicle wheel alignment when the following occur:

■

Every 80,000 to 100,000 miles, or 12-18 months (normal maintenance).

■

■

■

When the vehicle does not steer correctly.

To correct a tire wear condition.

There are two types of front wheel alignment:

1.

Minor alignment – a minor front wheel alignment is done for all normal maintenance conditions, see below.

2.

Major alignment – a major alignment is done when uneven or excessive tire wear is evident, or response at the steering wheel is sluggish, or the need for major wheel alignment check and adjustment is required, see below.

MINOR FRONT WHEEL ALIGNMENT

Perform the minor front wheel alignment in the following sequence:

1. Inspect all systems that affect wheel alignment. Refer to “Inspection Prior to Alignment” in this section.

2. Check the wheel bearing end play.

3. Check and adjust the vehicle ride height (for AIRTEK) as specified in the Preventive

Maintenance Section of this publication.

4. Check toe-in and adjust if necessary.

MAJOR FRONT WHEEL ALIGNMENT

Be certain to follow wheel alignment inspection intervals as specified by the original equipment manufacturer. Before performing a major front wheel alignment it is recommended that alignment equipment calibration be checked to ensure proper vehicle alignment.

83

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Major wheel alignment is accomplished in the following sequence of operation:

1. Inspect all the systems that influence the wheel alignment. Refer to the “Inspection Prior to Alignment” in this section.

2. Check and adjust the maximum turn angle, (see “Steering Stop Procedure” in this section), see Figures 8-9 and 8-10.

3. If the vehicle has power steering, check and adjust, if necessary, the pressure relief in the power steering system. Refer to vehicle manufacturer’s specifications See Steer

Stops in this section.

4. Verify the turning angle per step 2, (toe-out during vehicle turns or the Ackermann angle). Refer to vehicle manufacturer's specifications.


5. Check the kingpin (or steering axis) inclination (the kingpin inclination is not adjustable). Refer to “Kingpin Inclination”, in the Alignment Definitions in this section.

6. Check the camber angle. Do not attempt to adjust. Refer to “Camber” in the Alignment

Definitions in this section.

AXLE CAMBER IS NOT ADJUSTABLE. DO NOT CHANGE THE AXLE CAMBER ANGLE OR BEND

THE AXLE BEAM. BENDING THE AXLE BEAM TO CHANGE THE CAMBER ANGLE CAN DAMAGE THE

AXLE AND REDUCE AXLE STRENGTH, AND WILL VOID HENDRICKSON’S WARRANTY. A BENT AXLE

BEAM CAN CAUSE LOSS OF VEHICLE CONTROL, POSSIBLY CAUSING PERSONAL INJURY OR

PROPERTY DAMAGE, SEE FIGURE 8-11.

FIGURE 8-11

SERVICE HINT

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7. Check and adjust caster angle. Refer to “Caster” in the Alignment Definitions in this section. The use of two different angle caster shims will not change cross caster. Cross caster is the difference between the caster readings for left and right side of the vehicle.

Prior to checking caster confirm that the vehicle is at its proper ride height front and rear.

The front and rear ride height must be correct to achieve proper caster.

8. Check and adjust toe-in, refer to adjusting the Toe-In under the Alignment Definitions in this section.

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SERVICE HINT


AIRTEK ® •


AIRTEK RIDE HEIGHT ADJUSTMENT

1. Drive the vehicle onto a level surface.

2. Free and center all suspension joints by slowly moving vehicle back and forth several times without using the brakes. It is important when coming to a complete stop to verify that the brakes are released.

3. Chock front wheels.

Hendrickson recommends the following be performed during any type of ride height adjustment to help prevent socket head cap screws from loosening from the height control valve housing, and any subsequent air leaks from the height control valve.

4. Prior to adjusting the height control valve, clean the threads of the ¼" valve mounting fasteners to remove any debris and corrosion.





5. See additional Air Spring Cautions and Warnings in the Important Safety Notice Section of this publication prior to inflating or deflating the suspension system.

It is very important that the leveling valve be cycled completely before and after any ride height adjustments. This cycling of the leveling valve will help to make the adjustment as accurate as possible.

6. Detach the upper rubber grommet of the height control valve linkage from the upper stud and exhaust the suspension system air by lowering the height control valve linkage arm.

7. Re-attach the upper grommet of the height control valve linkage onto the upper stud to fill the suspension system with air. Wait until the airflow to front air springs has stopped.

8. Measure the suspension reference ride height on the shock absorber, see Figures 8-12 and 8-13, measuring from the center of the top mounting bolt to the center of the bottom mounting bolt.

FIGURE 8-12

85

FIGURE 8-13

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9. The different referenced ride height measurements are as specified in the following chart. If the reference measurement is not within ± ¼" of the specification, the ride height MUST be adjusted.

Blue Bird Model

Vision 10K

All American Front Engine

All American Rear Engine

NOTE

FIGURE 8-14

AIRTEK (FRONT)

RIDE HEIGHT

Dimension A

From the bottom of the frame to the center of axle

SHOCK ABSORBER

LENGTH

Dimension B

At ride height with a tolerance of ¼"

COMFORT AIR (REAR)

RIDE HEIGHT

SHOCK ABSORBER

LENGTH

From the bottom of the frame to the bottom of the main support member.


12½"

14 7 ⁄

8

"

14 7 ⁄

8

"

18 9 ⁄

16

"

17¼"

17 15 ⁄

32

"

4 7 ⁄

8

" 22¾"

10. Detach the upper grommet of the height control valve linkage from the stud on the leveling valve arm and exhaust suspension system air, see Figures 8-14 and 8-15.

11. Adjust the height control valve by loosening the ¼" mounting locknuts and pivoting the valve body about the mounting bolt.

It is necessary to place a 3 ⁄

16

" Allen wrench in the head of the mounting bolts while adjusting ride height to prevent movement of the bolts, which can cause air leakage in the body of the leveling valve.

12. Facing the air spring from the outboard side of the vehicle, pivot the valve body clockwise to increase the ride height and counter clockwise to decrease the ride height.

13. Tighten the ¼" mounting locknuts to 8-10 foot pounds, (see Figures 8-14 and

8-15) and repeat steps 4 through 10 until the reference measurement equals ± ¼" of the specification, see Figures 8-12 and 8-13.

14. Remove wheel chocks.

FIGURE 8-15

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AIRTEK HEIGHT CONTROL VALVE TEST

The height control valve test can be done with Barksdale Test Kit (Model 55521).

KIT CONTENTS

QTY.

DESCRIPTION

1

1

1

Gauge

(F3) Fitting

Flush Plug

QTY.

1

1

1

DESCRIPTION

Valve

(T1) Tubing ¼"

Tool

QTY.

2

1

1

DESCRIPTION

Plug

Fitting

O-Ring

HEIGHT CONTROL VALVE TEST INSTRUCTIONS

1. Disconnect linkage from valve handle.

2. Lower height control valve linkage arm down to exhaust air from the suspension system.

3. Remove the tubing from both air spring ports, see Figure 8-16. Place supplied tool around the tubing, press down to pull out tubing. DO NOT CUT THE TUBING.

4. Install the red plugs supplied into the air spring ports.

5. Use needle nose pliers to remove the “flapper” from the valve exhaust port.

FIGURE 8-16

6. Install hex fitting F3 (the one with a small pin protruding) into the exhaust port. To install hex fitting into exhaust port align pin on fitting with slot on exhaust port, push in and rotate clockwise to stop.

7. Connect one end of the tubing (T1) to this port and one end into the test gauge valve.

8. Rotate the test gauge valve handle to test mode, see diagram in Figure 8-16.

9. Rotate handle on valve being tested to fill mode.

10. Observe pressure reading for a period of

30 seconds.

FIGURE 8-17

11. Refer to chart for maximum allowable pressure drop vs. inlet pressure in. 30 seconds, see

Figure 8-17. The valve is good if the pressure drop does not exceed the maximum allowable.

12. Rotate vehicle valve handle to exhaust mode.

13. Rotate test gauge valve handle to test mode. Repeat steps 10 and

11.

14. Replace valve if maximum allowable drop is exceeded.

This test is complete. Remove the test gauge valve and fitting from the exhaust port. Remove the red plugs from the air spring ports. Reconnect the air spring tubing to the valve, ensuring that the air lines are pushed fully into the PTC fittings. Reconnect the linkage to the valve handle. Suspension ride height will automatically return to the correct position.

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NOTE

NOTE

STEERING STOP

ADJUSTMENT PROCEDURE

When the axle or lower steering knuckle is replaced, the steering stop adjustment must be checked.

The steering stop adjustment procedure is as follows:

1. Drive truck onto turntables and chock the rear wheels.

2. Measure the wheel cut. The wheel cut is determined by steering the tires. Wheel cut is measured at the inside wheel only, therefore the tires must be turned to the full lock position for each right hand and left hand direction. Refer to the vehicle manufacturer for exact specifications.

3. Increase the wheel cut by loosening the jam nuts and screw the axle stops in clockwise.

4. Tighten the jam nuts.

FIGURE 8-18

It is very important that the sides of the square head axle stops are set parallel to the axle beam to ensure a good contact point on the axle, see

Figure 8-18.

5. Decrease the wheel cut by loosening the jam nuts and screw the axle stops out counterclock-wise.

6. Tighten the jam nuts to 40-60 foot pounds torque.

7. Measure the wheel cut and check for any interference with related steering components.

ALWAYS CHECK/RESET THE STEERING GEAR BOX POPPET WHEN THE WHEEL CUT IS

DECREASED. FOLLOW MANUFACTURER'S GUIDELINES FOR THE GEAR BOX POPPET RESETTING

PROCEDURE. FAILURE TO DO SO CAN RESULT IN PREMATURE FAILURE OF THE AXLE OR

STEERING KNUCKLE. THIS CONDITION CAN CAUSE LOSS OF VEHICLE CONTROL, PERSONAL

INJURY OR PROPERTY DAMAGE AND VOID WARRANTY.

TOE SETTING

1. Place the vehicle on a level floor with the wheels in a straight ahead position.

2. Raise the vehicle and support the front axle with jack stands.

3. Use paint and mark the center area of tread on both steer axle tires around the complete outer diameter of the tires.

4. Scribe a line through both steer axle tires in the painted area around the complete outer diameter of the tires.

5. Raise the vehicle and remove the jack stands.

6. Set the vehicle on the ground.

Do not measure toe-in with the front axle off the ground. The weight of the vehicle must be on the front axle when toe-in is measured.

7. Use a trammel bar and measure the distance between the scribe marks at the rear of the steer axle tires. Record the measurement.

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NOTE


AIRTEK ® •


8. Install the trammel bar and measure the distance between the scribe marks at the front of the steer axle tires. Record the measurement, see Figure 8-19.

When setting up the trammel bar the pointers should be level with the spindles at the front and rear of the steer axle tires.

9. To calculate the toe setting subtract the front measurement from the rear measurement, the difference between the two will equal the toe-in/toe-out measurement.

FIGURE 8-19

89

10. If the toe measurement is not within the specifications of 1 /

16

" ± 1 /

32

"

(0.060" ± 0.030"), it will be necessary to adjust the toe setting. Refer to the following procedure.

a. Loosen the tie rod cross tube clamp bolts and locknuts.

b. Turn the tie rod cross tube until the specified toe-in distance is achieved.

THE THREADED PORTION OF THE TIE ROD END MUST EXTEND PAST THE SLOTS INTO THE TIE ROD

CROSS TUBE, SEE FIGURE 8-20. FAILURE TO DO SO CAN CAUSE COMPONENT TO FAIL CAUSING

LOSS OF VEHICLE CONTROL AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE.

FIGURE 8-20

17730-248 c. Tighten the bolt and locknut on the tie rod cross tube to 60-75 foot pounds torque.

11. Repeat steps 1-9 until the correct toe setting is achieved.

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SPRING EYE RE-TORQUE

This procedure to re-torque is necessary when replacing

■

Front Hanger

■

■

Shackle Assembly

Steel Leaf Spring Assembly

AIRTEK RE-TORQUE PROCEDURE

FIGURE 8-21

NOTE

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1. Chock the rear wheels of the vehicle to prevent movement.

2. Verify ride height. Adjust if necessary, see AIRTEK Ride Height adjustment procedure in this section.

3. Loosen all six (6) front and rear spring eye bolts, see Figure 8-21.

FIGURE 8-22

DO NOT remove the spring eye bolts.

4. Let the suspension settle.

5. Tighten the front M20 spring eye bolt locknuts to vehicle manufacturer's specifications.

6. Tighten the rear M20 spring eye bolt and shackle bolt locknuts to vehicle manufacturer's specifications.

7. Affix a straight edge to the bottom of the frame rail in front of the air spring, see Figure 8-22.

8. With the vehicle on a level surface measure the distance from the top of the straight edge to the ground on both sides of the vehicle and record the measurements.

9. Measure the difference from one side to the other.

10. Do a road test and repeat measurement steps

7 to 9.

11. If the measurement is less than level. If measurement is more than 3 ⁄

Hendrickson Tech Services.

3 ⁄

8

" the vehicle is

8

" contact

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SOFTEK RE-TORQUE PROCEDURE

FIGURE 8-23

AIRTEK ® •


91

NOTE

1. Chock the wheels.

2. Loosen all six (6) front and rear spring eye bolts, see Figure 8-23.

Do not remove the spring eye bolts.

3. Let the suspension settle.

4. Tighten the front M20 spring eye bolt locknuts to vehicle manufacturer's specifications.

5. Tighten the rear M20 spring eye bolt and shackle bolt locknuts to vehicle manufacturer's specifications.

6. Affix a straight edge to the bottom of the frame rail behind frame hanger, see Figure 8-22.

7. With the vehicle on a level surface measure the distance from the top of the straight edge to the ground on both sides of the vehicle and record the measurements.

8. Measure the difference from one side to the other.

9. Do a road test and repeat measurement steps 7 to 9.

10. If the measurement is less than 3 ⁄

8

" the vehicle is level. If measurement is more than 3 ⁄

8

" contact Hendrickson Tech Services.

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SECTION 9


FASTENERS

Hendrickson recommends that when servicing the vehicle to replace the removed fasteners with new equivalent fasteners. Maintain correct torque values at all times. Check torque values as specified. See Hendrickson’s Torque Specifications in the Appendix of this publication. If non-Hendrickson fasteners are used follow torque specifications listed in the vehicle manufacturer’s service manual.

SPACERS

There are different front axle spacer configurations for each front suspension system. Prior to disassembly of the front axle clamp group, note the orientation and quantity of the front axle spacer(s) (if equipped). It is required that the axle spacers be installed in the same orientation and location as removed to preserve the existing vertical alignment. Refer to the

Parts List Section of this publication.

AIRTEK HEIGHT CONTROL VALVE – 10K

DISASSEMBLY

1. Drain the air from the secondary air tank.






3. Deflate the air springs by removing the height control valve linkage at the rubber grommet and lowering the height control linkage arm. This will exhaust the air pressure in the air springs.

FIGURE 9-1 10K

THE PUSH-TO-CONNECT FITTINGS ARE NON-

SERVICEABLE. IT IS NECESSARY TO CLEAN THE

DIRT AND DEBRIS AWAY FROM THE PUSH-TO-

CONNECT FITTINGS AND THE AIR LINES TO HELP

PREVENT ANY FOREIGN MATERIAL FROM

ENTERING THE AIR SPRING, AIR SYSTEM OR

DAMAGING THE PUSH-TO-CONNECT FITTINGS.

CLEAN PUSH-TO-CONNECT FITTINGS USING

SOAPY WATER AND A SOFT BRISTLED BRUSH AND

DRY WITH COMPRESSED AIR.

4. Remove the air lines from the height control valve, see Figure 9-1. The air lines are push-to-connect. Push in on the air line to release tension, push down on the collar and pull out the air line.

5. Remove the two ¼" mounting nuts and washers.

6. Remove the height control valve.

Air Spring

Leveling Valve Arm

Push-to-connect

Fittings

Air Spring Bracket

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SERVICE HINT


AIRTEK ® •


ASSEMBLY

1. Attach the height control valve on the vehicle frame as shown in Figure 9-1.

FIGURE 9-2 10K

2. Attach the ¼" washers and the locknuts. Do not tighten the locknuts to specified torque until after the proper ride height is attained. Mount the height control valve parallel to flange of the frame, see Figure 9-2.

When replacing or installing nylon air line tubing into quick-connect fittings, it is critical that the end of the air line is cut square. Improper cut of the end of the air line tubing can cause the air line to seat improperly in the quick connect fitting causing air leakage.

FIGURE 9-3 10K

3. Attach the air lines to the height control valve, see Figure 9-3.

To Left Hand

Air Spring

“In” Port

4. Install the height control valve linkage assembly.

5. Adjust the height control valve to proper specifications. See the

Align ment & Adjustments Section of this publication for proper ride height adjustment.

C1 C2

6. Tighten the ¼" locknuts to 8-10 foot pounds torque.

To Right Hand

Air Spring

“Exhaust” Port

AIRTEK HEIGHT CONTROL VALVE – 14.6K

DISASSEMBLY

1. Drain the air from the secondary air tank.






3. Deflate the air springs by removing the height control valve linkage at the rubber grommet and lowering the height control linkage arm. This will exhaust the air pressure in the air springs.

THE PUSH-TO-CONNECT FITTINGS ARE NON-SERVICEABLE. IT IS NECESSARY TO CLEAN THE

DIRT AND DEBRIS AWAY FROM THE PUSH-TO-CONNECT FITTINGS AND THE AIR LINES TO HELP

PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE AIR SPRING, AIR SYSTEM OR

DAMAGING THE PUSH-TO-CONNECT FITTINGS. CLEAN PUSH-TO-CONNECT FITTINGS USING

SOAPY WATER AND A SOFT BRISTLED BRUSH AND DRY WITH COMPRESSED AIR.

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FIGURE 9-4 14.6K

4. Remove the air lines from the height control valve, see Figure 9-4. The air lines are push-to-connect. Push in on the air line to release tension, push down on the collar and pull out the air line.

5. Remove the two ¼" mounting nuts and washers.

6. Remove the height control valve.

Leveling

Valve Arm

Air Spring Bracket

Air Spring

ASSEMBLY

1. Re-install the air fittings into the height control valve. Ensure the Teflon pounds (4-20 Nm).

® thread sealing ring is seated around the base of the fitting’s hex shoulder. Torque to 3-15 foot

2. Install the height control valve to the upper air spring bracket by attaching the ¼" washers and locknuts. Torque to 8-10 foot pounds, see Figure 9-5.

FIGURE 9-5 14.6K

3. Install the air lines to the height control valve. Refer the Plumbing Diagram


Rubber

Grommet

"

Tightening Torque

8-10 ft. lbs.

PRIOR TO AND DURING

DEFLATION AND INFLATION OF

THE FRONT AIR SUSPENSION

SYSTEM, ENSURE THAT ALL

PERSONNEL AND EQUIPMENT

ARE CLEAR FROM UNDER THE

VEHICLE AND AROUND THE

SERVICE AREA, FAILURE TO DO SO

CAN CAUSE SERIOUS PERSONAL

INJURY, DEATH, OR PROPERTY

DAMAGE.

Linkage

Assembly

Height Control

Valve Link

Mount

4. See additional Air Spring

Cautions and Warnings in the Important Safety otice

Section of this publication prior to inflating or deflating the suspension system.

5. Inflate the suspension by connecting the height control valve linkage to the height control valve arm and lower mounting bracket. Verify the air springs inflate uniformly without binding.

6. Remove the frame supports.

7. Remove the wheel chocks.

8. Verify proper ride height adjustment, (see ride height adjustment in the Alignment &

Adjustments Section of this publication).

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AIRTEK AIR SPRING – 10K

DISASSEMBLY

1. Place the vehicle on level floor.


3. Raise the frame.

4. Support the vehicle with frame stands.






OR PROPERTY DAMAGE.






6. Remove the air from the air system by disconnecting the height control valve linkage at the rubber grommet of the height control valve arm and allow the arm to drop. This will exhaust air from the system.

IF THE AIR SPRING IS TO BE RE-INSTALLED; INSPECT LOCK-TABS FOR DAMAGE OR CRACKS

PRIOR TO RE-INSTALLATION. CARE MUST BE TAKEN TO REMOVE DIRT AND DEBRIS FROM THE

PUSH-TO-CONNECT FITTING. FAILURE TO DO SO CAN RESULT IN THE PUSH-TO-CONNECT

FITTING FAILING TO SEAL WITH THE AIR LINE.

7. Disconnect the air line to the air spring.

8. Raise the frame to allow for air spring removal.

9. Separate the air spring from the upper air spring bracket by applying downward pressure on air spring, see Figure 9-6, pushing outward on the lock-tabs outside the bracket, and inward on inlet lock-tabs. This will dislodge the air spring from the upper air spring bracket.

10. Apply upward pressure between the base of the air spring and the top pad. This will dislodge the air spring from the top pad, see Figure 9-7.

11. Remove the air spring.


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SERVICE HINT

ASSEMBLY

1. Insert the air spring into the top pad. Make sure the lock tabs click in place.

2. Compress the air spring and slide into vertical position. There is a locating nodule on the air spring to index the position in the upper air spring bracket.

3. Pull the air spring up into the upper air spring bracket until the air spring snaps into place in the upper air spring bracket. Verify all four lock-tabs are engaged, see

Figure 9-8.

FIGURE 9-8

When replacing or installing nylon air line tubing into quick-connect fittings it is critical that the end of the air line is cut square. Improper cut of the end of the air line tubing can cause the air line to seat improperly in the quick connect fitting causing air leakage.

4. Install the air line into the air spring.






OR PROPERTY DAMAGE.






6. Air up the suspension.

7. Check the air spring for leaks.

8. Check the ride height and adjust if necessary. See Alignment & Adjustments Section of this publication for the proper ride height adjustment.


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AIRTEK AIR SPRING – 14.6K

DISASSEMBLY



3. Raise the frame.







OR PROPERTY DAMAGE.






6. Remove the air from the air system by disconnecting the height control valve linkage(s) at the rubber grommet(s) and allowing the lever(s) to drop. This will exhaust air from the system.

7. If the air spring is damaged and the suspension is deflated, it will be necessary to raise the frame and support the vehicle with frame stands to obtain adequate clearance for air spring removal.

8. Disconnect the ¼" NPT air fitting from the air spring.

9. Remove the lower ½" air spring locknut from the piston stud to remove the air spring from the top pad, see Figure 9-9.

FIGURE 9-9

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10. Remove the ¾" upper air spring locknut from the air spring bracket.

11. Remove the air spring.

ASSEMBLY

1. Compress the air spring and slide into vertical position.

2. There is a locating ½" stud and ¾" threading stud on top of the air spring.

3. There are two studs on the bottom of the air spring. Guide studs through the air spring bracket and properly seat the lower air spring piston into the top axle pad. Secure the

½" locknut to the piston, see Figure 9-10.

FIGURE 9-10

4. Tighten the ¾" upper air spring locknuts to vehicle manufacturer's specifications and the lower ½" lower air spring locknuts to 20-30 foot pounds.






OR PROPERTY DAMAGE.






6. Install the air line into the air spring.

7. Air up the suspension.

8. Check the air spring for leaks.

9. Check the ride height and adjust if necessary. See Alignment & Adjustments Section of this publication for the proper ride height adjustment.


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SERVICE HINT


AIRTEK ® •


AIRTEK FRONT LEAF SPRING FRAME HANGER

DISASSEMBLY



3. Raise the frame.


5. Suspend the front axle from the shock absorbers.






7. Deflate the air springs by removing the height control valve linkage and lowering the leveling valve arm. This will exhaust the air pressure in the air springs.

8. Remove the air lines from air springs.

9. Remove the M20 spring eye bolt, washers and locknut.

A bottle jack may be required to raise the axle slightly to facilitate removal of the spring eye bolt.

10. Remove the frame mounting fasteners from the hanger. See manufacturer's guidelines.

11. Remove the hanger from the vehicle, see Figure 9-11.

FIGURE 9-11

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ASSEMBLY

1. Install the new hanger on the frame.

2. Install new frame fasteners. Follow manufacturer's guidelines.

3. Install the new M20 spring eye bolt from the outboard side of the hanger (see Figure

9-11), washers and locknut.

4. Remove the frame stands and lower frame.

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SERVICE HINT






6. Install the air lines into the air springs.

7. Install the height control valve linkage and inflate the suspension to normal operating pressure.

8. Tighten M20 locknut to vehicle manufacturer's specifications.


SOFTEK FRONT LEAF SPRING FRAME HANGER

DISASSEMBLY



3. Raise the frame.


5. Suspend the front axle from the shocks.

6. Remove the M20 spring eye bolt, washers and locknut.

A bottle jack may be required to raise the axle slightly to facilitate removal of the spring eye bolt.

7. Remove the frame mounting fasteners from the hanger. See manufacturer's guidelines.

8. Remove the hanger from the vehicle, see Figure 9-12.

FIGURE 9-12

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ASSEMBLY

1. Install the new hanger on the frame.


3. Install the new M20 spring eye bolt from the outboard side of the hanger (see Figure

9-12), washers and locknut.

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5. Tighten M20 shackle locknut to vehicle manufacturer's specifications.


AIRTEK REAR SHACKLE FRAME BRACKET

DISASSEMBLY



3. Raise the frame.









8. Remove the air lines from air springs.

9. Remove the rear M20 spring eye and shackle pivot bolts, washers and locknuts.

A bottle jack may be required to raise the axle slightly to facilitate removal of the rear spring eye bolt.

10. Remove the frame fasteners from the shackle bracket. See manufacturer's guidelines.

11. Remove the shackle bracket from the vehicle, see Figures 9-13 and 9-14.

12. Inspect the shackle assembly and both thrust washers (if equipped) for excessive wear or damage. See Thrust Washer Inspection in the Preventive Maintenance Section of this publication. Hendrickson recommends the thrust washers be replaced when this assembly is serviced.

13. If damaged or worn excessively, replace with Genuine Hendrickson Parts as detailed in the Component Replacement Section of this publication.

FIGURE 9-13

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FIGURE 9-14

SERVICE HINT

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ASSEMBLY

1. Install the shackle bracket on the frame.


3. Install the thrust washers (if equipped) and shackle plates with the M20 bolts, washers and locknuts. Snug the shackle bolts. DO NOT tighten.







6. Install the air lines into the air springs.

7. Install the height control valve linkage and inflate the suspension to normal ride height.

8. Tighten M20 shackle locknuts to vehicle manufacturer's specifications, see Figures

9-13 and 9-14.


SOFTEK REAR SHACKLE BRACKET

DISASSEMBLY



3. Raise the frame.



6. Remove the rear M20 spring eye and shackle pivot bolts, washers and locknuts.

A bottle jack may be required to raise the axle slightly to facilitate removal of the rear spring eye bolt.

7. Remove the frame fasteners from the shackle bracket. See manufacturer's guidelines.

8. Remove the shackle bracket from the vehicle, see Figures 9-15 and 9-16.

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AIRTEK ® •


9. Inspect the shackle assembly and both thrust washers (if equipped) for excessive wear or damage. See Thrust Washer Inspection in the Preventive Maintenance Section of this publication. Hendrickson recommends the thrust washers be replaced when this assembly is serviced.

10. If damaged or worn excessively, replace with Genuine Hendrickson Parts as detailed in the Component Replacement Section of this publication.

FIGURE 9-15

103

FIGURE 9-16

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ASSEMBLY

1. Install the shackle bracket on the frame.


3. Install the thrust washers (if equipped) and shackle plates with the M20 bolts, washers and locknuts, see Figures 9-15 and 9-16.


5. Tighten M20 locknuts to vehicle manufacturer's specifications.


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SOFTEK RUBBER AXLE STOP

FIGURE 9-17

8K/10K

Rubber Stop

Top Pad

13.2K/14.6K

REMOVAL

1. Insert a small pry bar between the rubber stop and the inside of the top pad.

2. Apply downward force on the pry bar and pull the rubber stop out of the top pad, see Figure

9-17.

3. Inspect the top pad and frame rail flange for any contact damage.

4. Clean any debris from inside the top pad.

Rubber Stop

Top Pad

INSTALLATION

1. Lubricate the new rubber axle stop with soapy water.

2. Install the rubber axle stop in the top pad.

3. Apply downward force on the rubber axle stop until it is seated firmly in the top pad.

AIRTEK THRUST WASHERS (If Equipped)

DISASSEMBLY



3. Raise the frame.









8. Remove the M20 spring eye and shackle pivot bolts, washers and locknuts.

9. Remove the shackle plates and thrust washers (if equipped).

ASSEMBLY

1. Install the NEW thrust washers (if equipped) and shackle plates with the M20 bolts, washers and locknuts, see Figure 9-14.

2. Remove frame stands and lower frame.

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AIRTEK ® •







4. Install air lines into the air springs.

5. Install the height control valve linkage and inflate the suspension to normal ride height.



SOFTEK THRUST WASHERS (If Equipped)

DISASSEMBLY



3. Raise the frame.



6. Remove the M20 spring eye and shackle pivot bolts, washers and locknuts.

7. Remove the shackle plates and thrust washers (if equipped).

ASSEMBLY

1. Install the NEW thrust washers (if equipped) and shackle plates with the M20 bolts, washers and locknuts, see Figure 9-16.

2. Remove frame stands and lower frame.



AIRTEK LEAF SPRING ASSEMBLY

DISASSEMBLY



3. Raise the frame.







6. Deflate the air springs by removing the height control valve linkage and lowering the height control valve arm. This will exhaust the air pressure in the air springs.

105

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SERVICE HINT

THE PUSH-TO-CONNECT FITTINGS ARE NON-SERVICEABLE. IT IS NECESSARY TO CLEAN THE

DIRT AND DEBRIS AWAY FROM THE PUSH-TO-CONNECT FITTINGS AND THE AIR LINES TO HELP

PREVENT ANY FOREIGN MATERIAL FROM ENTERING THE AIR SPRING, AIR SYSTEM OR

DAMAGING THE PUSH-TO-CONNECT FITTINGS. CLEAN PUSH-TO-CONNECT FITTINGS USING

SOAPY WATER AND A SOFT BRISTLED BRUSH AND DRY WITH COMPRESSED AIR.

7. Disconnect the air lines at the air springs.

8. Suspend the front axle to remove the load from leaf spring assembly.

9. Remove the air spring (see Air Spring disassembly in this section).

10. Remove the front and rear M20 spring eye bolts washer and locknuts. Loosen the M20 shackle pivot bolt.

To ease in the removal of the spring eye bolts, it may be necessary to raise the axle slightly.

FIGURE 9-18

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11. Remove the ¾" clamp group locknuts and discard.

DO NOT USE A CUTTING TORCH TO REMOVE CLAMP GROUP BOLTS OR ATTACHING

FASTENERS. THE USE OF SUCH HEAT ON SUSPENSION COMPONENTS CAN ADVERSELY AFFECT

THE STRENGTH OF THESE PARTS. A COMPONENT DAMAGED IN THIS MANNER CAN RESULT IN

THE LOSS OF VEHICLE CONTROL AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE.

If a clamp group nut fails to come off bolt, cut half way through the bolt with an abrasive cut off wheel, taking care not to contact axle beam or other components. Using an impact wrench, spin the locknut to fracture the bolt and remove.

12. Remove the ¾" clamp group bolts, the top pad, galvanized liner and the bottom axle wrap and liner. Discard the clamp group bolts, see Figure 9-18.

13. Remove the spring assembly.

ASSEMBLY

1. Install the new spring and wrap leaf assembly on the axle. Verify the center bolt is located properly in the top axle wrap and spacer (if equipped), see Figure 9-18.

2. Install the new galvanized liner and the top pad onto the spring.

3. Remove and replace the bottom axle wrap liner located in bottom axle wrap.

4. Install the bottom axle wrap.

5. Install the new ¾" clamp group bolts, washers, and locknuts. New clamp group fasteners must be used when the clamp group is removed, to prevent premature bolt fatigue.

6. Snug the clamp group, DO NOT torque at this time.

7. Raise the axle and the spring assembly into the front hanger and rear shackle assembly.

8. Install the M20 spring eye bolts, washers and locknuts. Snug bolts. Do not tighten.

9. Ensure that the clamp group is properly aligned and the hex bolts are seated in the top pad, and the bottom axle wrap is centered with the top axle wrap, see Figure 9-19.

FIGURE 9-19

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FIGURE 9-20

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SERVICE HINT

SERVICE HINT






12. Install air spring.

13. Install air lines, and air up system.

14. Remove the frame supports and load the front axle with the vehicle weight.

15. Verify proper ride height. See Alignment & Adjustments Section of this publication.

16. Tighten the M20 spring eye bolt locknuts to vehicle manufacturer's specifications.

SOFTEK LEAF SPRING ASSEMBLY

DISASSEMBLY



3. Raise the vehicle.


5. Suspend the front axle to remove the load from leaf spring assembly.

6. Remove the front and rear M20 spring eye bolts washer and locknuts. Loosen the M20 shackle pivot bolt.

To ease in the removal of the spring eye bolts, it may be necessary to raise the axle slightly.

7. Remove the ¾" clamp group U-bolts, washers and locknuts. Discard the fasteners.






8. Remove the top pad, galvanized liner and the bottom axle wrap, see Figure 9-21.

9. Remove the spring assembly.

ASSEMBLY

1. Install the new spring and wrap leaf assembly on the axle. Verify that the center bolt is located properly in the top axle wrap and spacer (if equipped), see Figure 9-21.

2. Install the new galvanized liner and the top pad onto the spring.

3. Remove and replace the bottom axle wrap liner located in bottom axle wrap.


5. Install the new ¾" clamp group U-bolts, washers, and locknuts. The locknuts must be replaced when the clamp group is removed, to prevent premature bolt fatigue.


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FIGURE 9-21

Front Hanger

M20 Bolt

Rear Hanger

M20 Locknut

Tightening Torque

*290-310 ft. lbs.

Shock Absorber

¾" Lower

Shock Bolt

¾" Lower

Shock Locknut

Tightening Torque

*125-135 ft. lbs.

Leaf Spring

M20 Bolt

M20 Washer

Rear Shackle Plate

M20 Locknut

Tightening Torque

*290-310 ft. lbs.

Dowel Pin

Axle Spacer


Top Wrap


¾" Clamp Group Locknut

Tightening Torque

285-305 ft. lbs.

Bottom Axle Wrap

¾" Washer

7. Raise the axle and the spring and wrap leaf assembly into the front hanger and rear shackle assembly.

8. Install the M20 spring eye bolts, washers and locknuts. Snug bolts. Do not tighten.

9. Ensure that the clamp group is properly aligned and the U-bolts are seated in the top pad, and the bottom axle wrap is centered with the top axle wrap, see Figure 9-22.

FIGURE 9-22

* Specification provided, controlled and subject to change by vehicle manufacturer.

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FIGURE 9-23


11. Remove the frame supports and load the front axle with the vehicle weight.


FRONT LEAF SPRING EYE BUSHINGS

The spring eye bushings for the AIRTEK and SOFTEK spring and wrap leaf assemblies are designed to provide extended service life. If premature wear occurs careful consideration must be given to the contributing factor that caused the wear. This must be corrected in order to prevent the new bushing from wearing in the same manner. The front and rear bushings are permanently installed in the spring leaf and are not serviceable. If a bushing wears prematurely, the spring and wrap leaf assembly must be replaced. Follow the procedure for the Front Leaf Spring removal in the Component Replacement Section of this publication.

AIRTEK/SOFTEK SHOCK ABSORBER – VISION (8K/10K)

It is not necessary to replace shock absorbers in pairs if only one shock requires replacement.

DISASSEMBLY

1. Remove the ¾" lower mounting bolt, fasteners, and spacer.

2. Remove the ¾" upper mounting bolt and fasteners.

3. Slide the shock absorber out of the upper bracket and off of the lower mounting bolt.

4. Inspect the shock absorber mounting brackets and hardware for damage or wear, replace as necessary.

FIGURE 9-24

Shock

Absorber

¾" Bolt

¾" Washer

Top Axle Wrap

Spacer

Apply a thin coating of anti-seize compound to the shock absorber lower mounting bolt shank, to the mating face of the axle wrap, and spacer, and to the inside bore of the aluminum top axle wrap

¾" Washer

¾" Lower Shock Locknut

Tightening torque

*125-135 ft. lbs.


ASSEMBLY

1. Install the shock absorber into the upper mounting bracket.

2. Install the upper ¾" shock mounting bolt, washers and locknut.

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FIGURE 9-25

AIRTEK 14.6K

Shock Absorber

Top Pad

3. Apply a thin coating of anti-seize compound to the shock absorber lower mounting bolt shank, to the mating face of the axle wrap and spacer, and to the inside bore of the aluminum axle wrap. This is necessary to help prevent seizing of the bolt to the aluminum axle wrap.

4. Install the lower ¾" bolt from the inboard side to the outboard side of the top axle wrap and attach the spacer, washer, and locknut, see Figure 9-24.

5. Tighten both upper and lower ¾" locknuts to vehicle manufacturer's specifications, see

Figure 9-24.

AIRTEK/SOFTEK SHOCK ABSORBER – ALL AMERICAN (13.2K/14.6K)

It is not necessary to replace shock absorbers in pairs if only one shock requires replacement.

DISASSEMBLY

1. Remove the ¾" lower mounting bolt, fasteners, and spacer.

2. Remove the ¾" upper mounting bolt and fasteners.

3. Slide the shock absorber out of the lower bracket and off of the lower mounting bolt.

4. Inspect the shock absorber mounting brackets and hardware for damage or wear, replace as necessary.

FIGURE 9-26

SOFTEK 13.2K/14.6K

Spacer Shock Absorber

Top Pad

¾" Bolt

¾" Washer

¾" Bolt

¾" Washer

Spacer

¾" Washer


Tightening torque

*125-135 ft. lbs.


¾" Washer


Tightening torque

*125-135 ft. lbs.

ASSEMBLY

1. Install the shock absorber into the upper mounting bracket.

2. Install the upper ¾" shock mounting bolt, washers and locknut.

3. Install the lower ¾" bolt from the inboard side to the outboard side of the top axle wrap and attach the spacer, washer, and locknut, see Figures 9-25 and 9-26.

4. Tighten both upper and lower ¾" locknuts to vehicle manufacturer's specifications, see

Figures 9-25 and 9-26.

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SERVICE HINT

AIRTEK BOTTOM AXLE WRAP

DISASSEMBLY



3. Raise the frame.







6. Deflate the air springs by disconnecting the height control valve linkage and lowering the height control valve arm. This will exhaust the air pressure in the air springs.






7. Remove ¾" hex bolts, washers and locknuts. Removal of the air spring will be required. See Air Spring Replacement instructions in this section. Discard fasteners.

8. Remove bottom axle wrap. It may be necessary to use a dead blow mallet to dislodge axle wrap.

9. Once removed inspect axle wrap for damage. Replace if necessary.

10. Discard used bottom axle wrap liner.

ASSEMBLY

1. Install new bottom axle wrap liner into bottom axle wrap.

2. Install bottom axle wrap on axle.

FIGURE 9-27 AIRTEK

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3. Install new ¾" clamp group bolts, washers and locknuts. Ensure that the clamp group is properly aligned and the hex bolts are seated in the top pad, and the bottom axle wrap is centered on the top axle wrap, see Figure 9-27.

FIGURE 9-28

4. Tighten locknuts evenly to 285-305 foot pounds torque, see Figure

9-28 for proper torque sequence.

5. Install Air spring. See Air Spring assembly in this section.


SOFTEK BOTTOM AXLE WRAP

DISASSEMBLY



3. Raise the frame.







5. Remove ¾" U-bolts, washers and locknuts. Discard fasteners.

6. Remove bottom axle wrap. It may be necessary to use a dead blow mallet to dislodge axle wrap.

7. Once removed inspect axle wrap for damage. Replace if necessary.

8. Discard used bottom axle wrap liner.

ASSEMBLY

FIGURE 9-29 SOFTEK

1. Install new bottom axle wrap liner into bottom axle wrap.

2. Install bottom axle wrap on axle.

3. Install new ¾" U-bolts, washers and locknuts.

Ensure that the clamp group is properly aligned and the U-bolts are seated in the top pad, and the bottom axle wrap is centered with the top axle wrap, see Figure 9-29.

4. Tighten locknuts evenly to 285-305 foot pounds torque, see Figure 9-28 for proper torque sequence.


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AIRTEK ® •


SERVICE HINT

SERVICE HINT

AIRTEK TOP AXLE WRAP (In Chassis)

DISASSEMBLY



3. Raise the frame.


5. Suspend the front axle to remove the load from the spring and wrap leaf assembly.






AIR SPRINGS MUST BE DEFLATED PRIOR TO LOOSENING ANY CLAMP GROUP HARDWARE.

UNCONSTRAINED AIR SPRINGS CAN VIOLENTLY SHIFT, RESULTING IN POSSIBLE PERSONAL

INJURY, DEATH OR PROPERTY DAMAGE.

7. Deflate the air springs by disconnecting the height control valve linkage and lowering the height control valve arm. This will exhaust the air pressure in the air springs.

8. Disconnect the air lines at the air springs.

9. Remove the air spring (See Air Spring disassembly in this section).

10. Support the axle with a jack.

11. Remove the front and rear M20 spring eye bolts, washers and locknuts.

A bottle jack may be required to raise the axle slightly in order to remove spring eye bolts.






12. Remove the ¾" clamp group bolts, washers and locknuts. Discard fasteners.

13. Remove the top pad, the galvanized liner, and the bottom axle wrap.

14. Remove the lower shock mounting bolt.

15. Remove the spring and wrap leaf assembly

16. Strike the axle wrap with a dead blow mallet at the front and rear on the underside of the axle wrap to dislodge it from the axle, see Figure 9-30.

17. Clean and inspect the axle wrap and axle wrap line for cracks or damage, replace each if cracks or damage are present.

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FIGURE 9-30

115

IMPORTANT NOTE

SERVICE HINT

ASSEMBLY

1. Install the new axle wrap liner on the axle.

2. Spray the axle wrap liner and the axle wrap with a silicon lubricant.

3. Position the axle wrap on the axle, see Figure 9-31.

DO NOT STRIKE THE TOP AXLE WRAP WITH A HAMMER. HENDRICKSON RECOMMENDS USING

A PLASTIC DEAD BLOW MALLET WITH CARE WHEN INSTALLING THE AXLE WRAP.

FIGURE 9-31

4. Protect the top surface of the axle wrap with a block of wood, cardboard, or shop towels.

5. Install a bottle jack between the axle wrap and frame rail flange.

6. Jack the axle wrap down into position on the axle, using care to make sure the axle wrap bore indexes the locating bushing on the axle.

14.6K Top

Axle Wrap

Top Axle

Wrap Liner

Axle Wrap

Guide Pin

10K Top

Axle Wrap

Axle

For Flat Floor Models install the intermediate dowel pin into the axle wrap.

7. Install the spring and wrap leaf assembly on the axle wrap (indexing the dowel pin if equipped).

8. Install the galvanized liner and the top pad on the spring and wrap leaf assembly.

9. Remove and replace the bottom axle wrap liner.


11. Install the new ¾" clamp group bolts, washers, and locknuts.


13. Use a jack and raise the axle and spring assembly into the front spring hanger and shackle assembly.

A bottle jack may be required to raise the axle slightly in order to install the spring eye bolts.

14. Install the M20 spring eye bolts in the front spring hanger and rear shackle assembly.

15. Ensure that the clamp group is properly aligned and the hex bolts are seated in the top pad, and the bottom axle wrap is centered with the top axle wrap, see Figure 9-32.

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FIGURE 9-32

FIGURE 9-33

16. Tighten the ¾" clamp group locknuts evenly to 285-305 foot pounds torque in the proper sequence, see Figure 9-33.

17. Remove the jack from the axle.

18. Remove the frame stands.






20. Attach air lines to the air springs.

21. Install shocks. (See shock absorber assembly in this section)

22. Air up system to proper ride height. (See Ride Height Adjustment in the Alignment &

Adjustments Section of this publication).

23. Tighten the M20 spring eye bolt locknuts to vehicle manufacturer's specifications, see

Figure 9-34.


FIGURE 9-34

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SERVICE HINT

SERVICE HINT


AIRTEK ® •


SOFTEK TOP AXLE WRAP (In Chassis)

DISASSEMBLY



3. Raise the frame.


5. Suspend the front axle to remove the load from the spring and wrap leaf assembly.

6. Remove the front and rear M20 spring eye bolts, washers and locknuts. Loosen the

M20 shackle pivot bolt.

A bottle jack may be required to raise the axle slightly in order to remove spring eye bolts.

7. Support the axle with a jack.






8. Remove the ¾" clamp group U-bolts, washers and locknuts. Discard fasteners.

9. Remove the top pad and the bottom axle wrap.

10. Remove the lower shock mounting bolt.

11. Remove the spring and wrap leaf assembly.

12. Strike the axle wrap with a dead blow mallet at the front and rear on the underside of the axle wrap to dislodge it from the axle, see Figure 9-35.

13. Clean and inspect the axle wrap and axle wrap liners for cracks or damage, replace each if cracks or damage are present.

FIGURE 9-35

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ASSEMBLY

1. Install the new axle wrap liner on the axle.

2. Spray the axle wrap liner and the axle wrap with a silicon lubricant.

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SERVICE HINT

FIGURE 9-36

3. Position the axle wrap on the axle, see

Figure 9-36.

DO NOT STRIKE THE TOP AXLE WRAP WITH

A HAMMER. HENDRICKSON RECOMMENDS

USING A PLASTIC DEAD BLOW MALLET WITH

CARE WHEN INSTALLING THE AXLE WRAP.

4. Protect the top surface of the axle wrap with a block of wood, cardboard, or shop towels.

5. Install a bottle jack between the axle wrap and frame rail flange.

6. Jack the axle wrap down into position on the axle, using care to make sure the axle wrap bore indexes the locating bushing on the axle.

13.2K/14.6K

Top Axle Wrap

Top Axle

Wrap Liner

Axle Wrap

Guide Pin

8K/10K Top

Axle Wrap

Axle

7. Install the spring and wrap leaf assembly on the axle wrap indexing the center bolt in the locating hole.

8. Install the top pad on the spring and wrap leaf assembly.

9. Remove and replace the bottom axle wrap liner.


11. Install the new ¾" clamp group U-bolts, washers, and locknuts.


FIGURE 9-37 SOFTEK

13. Use a jack and raise the axle and spring assembly into the front spring hanger and shackle assembly.

A bottle jack may be required to raise the axle slightly in order to install the spring eye bolts.

14. Install the M20 spring eye bolts, washer and locknuts in the front spring hanger and rear shackle assembly.

15. Ensure that the clamp group is properly aligned and the U-bolts are seated in the top pad, and the bottom axle wrap is centered with the top axle wrap, see Figure 9-37.

FIGURE 9-38

16. Tighten the ¾" clamp group locknuts evenly to 285-305 foot pounds torque in the proper sequence, see Figure 9-38.

17. Apply a thin coating of anti-seize to the lower shock mounting bolt.

18. Install shocks. (See shock absorber assembly in this section)

19. Remove the jack from the axle.

20. Remove the frame stands.



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AIRTEK FRONT AXLE ASSEMBLY

FIGURE 9-39

SHOWN AIRTEK 10K

STEERTEK AXLE CLAMP GROUP CONSIST OF THE FOLLOWING COMPONENTS:

■

■

■

Top axle wrap

Top axle wrap liner

Top pad

■

■

■

Bottom axle wrap

Bottom axle wrap liner

¾" Bolts, washers and nylon locknuts

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Height Control

Valve Linkage

Spring Eye Bolt

Leaf Spring

Air Spring

Top Pad

Lower Shock Locknut

LH Upper

Steering Knuckle

King Pin Bushing

King Pin Seal

Axle & King

Pin Assembly

Composite Bearing

LH Lower

Steering Knuckle

Cap Screws

Cotter

Pin

RH Upper

Steering Knuckle

Rear Shackle

Assembly

¾" Bolts

Spacer

Top Axle

Wrap Roller

Bearing

RH Lower

Steering Knuckle

Castle Nut

Bottom Axle

Wrap Liner

Bottom Wrap

¾" Washer

¾" Locknut

Tie Rod Assembly

RH Tie Rod End

LH Tie Rod End

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SOFTEK FRONT AXLE ASSEMBLY

STEERTEK AXLE CLAMP GROUP CONSIST OF THE FOLLOWING COMPONENTS:

■

■

■

Top axle wrap

Top axle wrap liner

Top pad

■

■

■

Bottom axle wrap

Bottom axle wrap liner

¾" Bolts, washers and nylon locknuts

FIGURE 9-40

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STEERTEK AXLE REMOVAL

Refer to Figures 9-39 and 9-40 when replacing the components of the STEERTEK axle.

DO NOT USE A TORCH ON CLAMP GROUP BOLTS OR ANY OTHER PART OF THE AIRTEK

SUSPENSION. IF THE CLAMP GROUP BOLTS WILL NOT COME LOOSE WITH AN IMPACT

WRENCH, USE A CUT OFF WHEEL AND CUT THE SHANK OF THE BOLT. THE USE OF A TORCH

CAN CAUSE DAMAGE TO CERTAIN AIRTEK COMPONENTS THAT CAN RESULT IN THE LOSS OF

VEHICLE CONTROL AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE.



3. SOFTEK equipped vehicles — proceed to step 6.






5. AIRTEK equipped vehicles — Deflate the air springs by disconnecting the height control valve linkage and lowering the height control valve linkage arm. This will exhaust the air pressure in the air springs.

6. Raise the frame.


8. Suspend the front axle with the shocks attached.

9. Remove the front wheels, hubs, brake shoes and backing plate assembly.

10. Disconnect the drag link from the steering arm.


12. AIRTEK equipped vehicles — Remove lower air spring mounting fasteners for both air springs at the axle top pad and unseat from the top pad.

13. Support the axle with a floor jack.

THE REPAIR OR RECONDITIONING OF SUSPENSION OR AXLE COMPONENTS IS NOT ALLOWED.

HENDRICKSON ADVISES REPLACING ALL COMPONENTS FOUND TO BE DAMAGED OR OUT OF

SPECIFICATIONS. ALL MAJOR HENDRICKSON COMPONENTS ARE HEAT TREATED AND TEMPERED.

AIRTEK COMPONENTS CANNOT BE BENT, WELDED, HEATED, OR REPAIRED WITHOUT REDUCING

THE STRENGTH OR LIFE OF THE COMPONENT. FAILURE TO FOLLOW THESE GUIDELINES CAN

CAUSE LOSS OF VEHICLE CONTROL, AND POSSIBLE PERSONAL INJURY OR DEATH OR PROPERTY

DAMAGE AND WILL VOID APPLICABLE WARRANTIES.

14. If the vehicle is equipped with the shock absorbers attached to the top axle wrap, it will be necessary to remove the lower shock mounting locknuts and washers. Remove the shock absorbers from the lower mounting bolts and push clear of spring assembly.


15. Remove the ¾" clamp group bolts, washers, and locknuts. Discard fasteners.

16. Lower the axle and remove from the vehicle.

121

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STEERTEK AXLE (Removed from Chassis)

AXLE DISASSEMBLY

1. Remove the bottom axle wrap and liner from the axle.

2. Strike the top axle wrap with a dead blow mallet at the front and rear on the underside of the axle wrap to dislodge it from the axle, see Figure 9-41.

FIGURE 9-41

SERVICE HINT

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3. After removal of the top axle wrap from the axle inspect for cracks or fretting.

4. Remove the tie rod assembly. See Tie Rod disassembly in this section.

REMOVAL OF THE CAP SCREWS WILL ALLOW THE STEERING KNUCKLE TO SEPARATE FROM THE

AXLE. THE BACKBONE MUST BE SUPPORTED BEFORE REMOVAL OF THESE TWO (2) CAP

SCREWS. FAILURE TO DO SO CAN CAUSE COMPONENT DAMAGE OR PERSONAL INJURY.

5. Remove the two 5 ⁄

8

" socket head cap screws from the steering knuckle assembly.

6. Remove the steering knuckle, thrust bearing, and shims (if equipped).

7. After complete removal of the one side, repeat steps 1-6 for the opposite side of the axle.

8. Inspect the steering kingpin bushings for excessive wear. If worn, replace the kingpin bushings and seals. See the Kingpin Bushing replacement instructions in this section.

AXLE PRE-ASSEMBLY

1. Install the new upper axle wrap liner on the axle. Index the liner with the axle's guide pin, see Figure 9-42.

DO NOT STRIKE THE TOP AXLE WRAP WITH

A HAMMER. DAMAGE TO THE ALUMINUM

AXLE WRAP WILL OCCUR. USE A PLASTIC

DEAD BLOW MALLET WITH CARE WHEN

INSTALLING THE AXLE WRAP.

FIGURE 9-42

Top Axle

Wrap

13.2K/14.6K

Top Axle

Wrap Liner

Axle Wrap

Guide Pin

Top Axle

Wrap-8K/10K

Axle

SECURELY INSTALL THE TOP WRAP TO THE

AXLE. FAILURE TO DO SO CAN CAUSE LOSS

OF CONTROL OF THE VEHICLE, PERSONAL

INJURY OR PROPERTY DAMAGE.

Apply a lubricant (such as an aerosol silicone) to the outer surface of the plastic liner to aid in assembly of the top axle wrap.

Bottom Axle

Wrap Liner

Bottom Axle

Wrap

2. Install the top axle wrap, see Axle Wrap

Assembly instructions located in this section. The axle wrap must be aligned with the guide pin on the axle.

3. At this point in the assembly, do not install anything further on the axle.

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AXLE INSTALLATION

1. Place the new axle on the floor jack and position the axle under the vehicle.

2. Install the axle spacer (if equipped) on the top axle wrap prior to raising the axle into position.

3. Raise the axle into position, see Figures 9-43 and 9-44. Care must be taken at this point to ensure that the front leaf spring assemblies' center bolt is aligned correctly in the top axle wrap.

FIGURE 9-43

AIRTEK 10K AIRTEK 14.6K

123

Leaf Spring

Assembly

Spacer

Rear Shackle

Bracket

Top Axle Wrap

Leaf Spring

Assembly

Dowel Pin

(If equipped)

Spacer (If equipped)

Rear Shackle

Bracket

Top Axle Wrap

FIGURE 9-44

SOFTEK 8K/10K SOFTEK 13.2K/14.6K

Leaf Spring

Assembly

Dowel Pin

(If equipped)

Spacer

Rear Shackle

Bracket

Top Axle

Wrap

Leaf Spring

Assembly

Dowel Pin

(If equipped)

Spacer

Rear Shackle

Bracket

Top Axle

Wrap

4. Verify that the galvanized liner is between the leaf springs and the top pad.

5 Install the new bottom axle wrap liners on the bottom axle wraps.

6. Install the bottom axle wraps on the axle.

7. Install the top pad with the directional identification facing correctly on the vehicle, see

Figure 9-45.

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FIGURE 9-45

FIGURE 9-46

8. Install the new ¾" clamp group bolts, washers and locknuts. Snug the bolts , DO NOT tighten to the specified torque at this time.

9. Ensure that the clamp groups are properly aligned and the bolts are seated in the top pad, and the bottom axle wraps are centered on the top axle wraps, see Figure 9-46.

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12. AIRTEK equipped vehicles:

■

Engage the 10K air springs into the top pad. The bottom of the air spring snaps into the top pad.

■

Engage the 14.6K air springs into the top pad. Install new lower air spring mounting fasteners and tighten to 20-30 foot pounds torque.

13. Install the lower shock absorber connection (if removed). Install the lower shock fasteners and tighten to vehicle manufacturer's specifications.

14. Install the steering knuckles as per the Steering Knuckle replacement instructions in this section.

15. Install the tie rod assembly.

16. Install the 7 ⁄

8

" hardened washers on the Ackermann arm and the castle nuts. Tighten the castle nuts to 185 foot pounds, then rotate until the first castle slot lines up with the cotter pin bore in the tie rod end. Do not back off the nut for cotter pin installation.

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SERVICE HINT

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17. Install the tie rod end cotter pins.

18. Connect the drag link. Install the castle nut. Tighten the castle nut to 185 foot pounds, then rotate until the first castle slot lines up with the cotter pin bore in the drag link. Do not back off the nut for cotter pin installation.

19. Install the drag link cotter pin.

20. Install the brake backing plate assemblies.

21. Install the brakes, hubs, and wheels as per manufacturer’s guidelines.

22. Fill the hubs with the proper lubricant (see manufacturer’s guidelines for recommended lubrication specifications).

23. Raise the vehicle and remove the frame stands.

24. Lower the vehicle.

25. SOFTEK equipped vehicles — proceed to step number 27.

26 AIRTEK equipped vehicles — Reconnect the height control valve and air up the system.

FIGURE 9-47

27. Tighten the ¾" clamp group locknuts evenly in 50 foot pounds increments to 285-305 foot pounds torque in the proper sequence to achieve uniform bolt tension, see Figure 9-47.

28. SOFTEK equipped vehicles — proceed to step number 30.

29 AIRTEK equipped vehicles — Adjust ride height per instructions in the Alignment &

Adjustments Section of this publication.

30. Grease the front steering components as per lubrication guidelines in the Preventive



STEERING KNUCKLE DISASSEMBLY

DISASSEMBLY

See tools needed to remove and install kingpin bushing under the Special Tools Section of this publication.

The steering knuckle disassembly and assembly includes the Kingpin Preparation and

Measurement and Kingpin Bushing Removal process.



3. Raise the frame.


5. Remove the wheel and hub assembly.

6. Remove the brake components from steering knuckle.

7. Remove the tie rod assembly.

FIGURE 9-48

Lightly tap the side of the Ackermann arm with a mallet to separate the tie rod end from the Ackermann arm, see

Figure 9-48.

8. Remove the drag link from the knuckle if necessary.

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REMOVAL OF THE CAP SCREWS WILL ALLOW THE STEERING KNUCKLE TO SEPARATE FROM

THE AXLE. THE STEERING KNUCKLE MUST BE SUPPORTED BEFORE REMOVAL OF THESE TWO

(2) CAP SCREWS. FAILURE TO DO SO CAN CAUSE COMPONENT DAMAGE OR PERSONAL

INJURY.

FIGURE 9-49

9. Remove the 2 socket head cap screws that connect upper kingpin connection to the steering knuckle, see Figure 9-49.

10. Remove the lower steering knuckle from the kingpin by sliding it down the kingpin.

11. Remove the upper steering knuckle by sliding it up off the kingpin.

KINGPIN PREPARATION

AND MEASUREMENT

CLEANING GROUND AND POLISHED PARTS

■

Use a cleaning solvent to clean ground or polished parts and surfaces. DO NOT USE

GASOLINE.

■

Do not clean ground or polished parts in a hot solution tank or with water, steam, or alkaline solutions. These solutions will cause corrosion of the parts.

DRYING THE CLEANED PARTS

■

Parts must be dried immediately after cleaning. Dry the parts with clean paper towels, clean rags, or compressed air. Do not dry bearings by spinning with compressed air.

Damage to the bearings will result.

PREVENTING CORROSION ON CLEANED PARTS

■

Apply a light coating of oil to all cleaned and dried parts that are going to be reused.

Do not apply oil to the brake lining or the brake drums. If parts are to be stored, apply an effective rust inhibitor to all surfaces.

TO HELP PREVENT SERIOUS EYE INJURY, ALWAYS WEAR PROPER EYE PROTECTION WHEN

YOU PERFORM VEHICLE MAINTENANCE OR SERVICE.

SOLVENT CLEANERS CAN BE FLAMMABLE, POISONOUS AND CAUSE BURNS. TO HELP AVOID

SERIOUS PERSONAL INJURY, CAREFULLY FOLLOW THE MANUFACTURER’S PRODUCT

INSTRUCTIONS AND GUIDELINES AND THE FOLLOWING PROCEDURES:

■

WEAR PROPER EYE PROTECTION.

■

■

■

■

WEAR CLOTHING THAT PROTECTS YOUR SKIN.

WORK IN A WELL VENTILATED AREA.

DO NOT USE GASOLINE, SOLVENTS OR OTHER MATERIALS THAT CONTAIN GASOLINE

THAT CAN EXPLODE.

HOT SOLUTION TANKS OR ALKALINE SOLUTIONS MUST BE USED CORRECTLY. FOLLOW

THE MANUFACTURER’S RECOMMENDED INSTRUCTIONS AND GUIDELINES CAREFULLY

TO HELP PREVENT PERSONAL ACCIDENT OR INJURY.

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17730-248


AIRTEK ® •


DO NOT USE HOT SOLUTION TANKS OR WATER AND ALKALINE SOLUTIONS TO CLEAN GROUND

OR POLISHED PARTS. DAMAGE TO THE PARTS WILL RESULT.

THE STEERTEK HAS A UNIQUE AXLE. THE KINGPIN IS CRYOGENICALLY INSTALLED IN THE AXLE.

THE KINGPIN IS A NON-REPLACEABLE COMPONENT OF THE AXLE ASSEMBLY. DO NOT TRY TO

REMOVE THE KINGPIN. DOING SO WILL DAMAGE THE AXLE AND MAY CAUSE LOSS OF VEHICLE

CONTROL, PERSONAL INJURY OR PROPERTY DAMAGE. IF THE KINGPIN SHOWS SIGNS OF

MOVEMENT, CONTACT HENDRICKSON PRODUCT ENGINEERING - TECH SERVICES.

1. Prepare and polish the kingpin by removing all grease and excess debris using a fine grit

(220 grit or higher) emery cloth and parts solvent, see Figures 9-50 through 9-53.


127

FIGURE 9-52 KINGPIN BEFORE CLEANING FIGURE 9-53 KINGPIN AFTER CLEANING

2. Inspect the kingpin for wear or damage. Use a micrometer and measure the upper and lower kingpin in two locations. Positions must be 90º opposed from each other. If the kingpin has less than 1.802" diameter, replacement of the axle is necessary, see

Figures 9-54 through 9-57.

Kingpin minimum dimension is 1.802"


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KINGPIN BUSHING REMOVAL

1. Remove the retaining ring for the grease cap.

2. A hydraulic shop press with a minimum forcing capacity of 2.5 tons (or use an arbor press) will be required.

BEFORE APPLYING HYDRAULIC PRESSURE TO ANY TOOLING SET-UP, ALWAYS CHECK TO BE

SURE THE PRESS PLATE, ADAPTERS, AND COMPONENTS BEING WORKED ON ARE

POSITIONED PROPERLY, I.E. “IN LINE” WITH THE RAM. IMPROPER POSITIONING CAN CAUSE

PERSONAL INJURY OR COMPONENT DAMAGE.

BEFORE APPLYING HYDRAULIC PRESSURE TO REMOVE OR INSTALL THE KINGPIN BUSHING,

SUPPORT THE LOWER STEERING KNUCKLE AS SHOWN IN FIGURES 9-58 AND 9-59.

IMPROPER SUPPORT TO THE STEERING KNUCKLES CAN CAUSE COMPONENT DAMAGE.

3. Use the grease cap to press out the kingpin bushing and seal. Remove the grease zerk in the grease cap or use a hollow driver, (see Figure 9-58) to press out the kingpin bushing.

4. Install the lower steering knuckle upside down in press. Be sure to support the lower steering knuckle assembly so that it sits in-line with the press, see Figure 9-59.

5. Use the same procedure to remove the kingpin bushing in the upper kingpin connection or the steering arm, see Figures 9-58 through 9-60.

6. Clean the parts and inspect for reassembly, see Figure 9-61.


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FIGURE 9-60


AIRTEK ® •


FIGURE 9-61

129

STEERING KNUCKLE BORE MEASUREMENT

Complete the following steering knuckle bore inspection and the measurement instructions prior to installing the kingpin bushing.

1. Measure the upper knuckle bore inside diameter at two locations. Always use an inside micrometer or a telescoping gauge when taking a knuckle bore measurement. Some out-of-roundness at the top and bottom of the bore edges is acceptable. Steering knuckle bore diameter is 1.938" ± 0.003"

2. Measure the upper and lower bore in two positions and at two locations. The two positions must be 90º opposed from each other, see Figures 9-62 through 9-64. If the average measurement is more than the knuckle bore maximum diameter specification, replace the knuckle.

FIGURE 9-62 FIGURE 9-63 FIGURE 9-64

17730-248

KINGPIN BUSHING INSTALLATION

1. A hydraulic shop press with a minimum forcing capacity of 5 tons will be required.

BEFORE APPLYING HYDRAULIC PRESSURE TO ANY TOOLING SET-UP, ALWAYS CHECK TO BE

SURE THE PRESS PLATE, ADAPTERS, AND COMPONENTS BEING WORKED ON ARE

POSITIONED PROPERLY, I.E. “IN LINE” WITH THE RAM. IMPROPER POSITIONING CAN CAUSE

PERSONAL INJURY OR COMPONENT DAMAGE.

2. Install the lower or upper steering knuckle in the press.

3. Install the kingpin bushing from the machined side (axle side) of the lower steering knuckle using a bushing driver, (see driver specifications in the Special Tools Section of this publication). Press in bushing to a depth of no less than 15 /

64

" (0.236") or 6 millimeters and no more than 5 /

16

" (0.32") or 8 millimeters, see Figures 9-65 and 9-67.

4. Following this procedure it is necessary to ream the kingpin bushings to fit the kingpins, (see Kingpin Bushing Reaming Instructions).

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FIGURE 9-65 FIGURE 9-66 FIGURE 9-67

SERVICE HINT

KINGPIN BUSHING REAMING

REAM THE KINGPIN BUSHINGS WITH AN ADJUSTABLE STRAIGHT FLUTE REAMER. (SEE

SPECIAL TOOLS SECTION OF THIS PUBLICATION) DO NOT HONE OR BURNISH THE KINGPIN

BUSHINGS. HONING OR BURNISHING WILL DAMAGE THE BUSHINGS AND VOID WARRANTY.

WHEN INSTALLING STEERING KNUCKLE COMPONENTS IN A VISE IT IS NECESSARY TO

PROTECT THE MACHINED SURFACES FROM GOUGES OR MARRING BY USING BRASS JAWS.

FAILURE TO DO SO CAN CAUSE PREMATURE PART DAMAGE, DAMAGE TO THE STEERING

KNUCKLE COMPONENTS, LOSS OF WARRANTY, LOSS OF VEHICLE CONTROL, CAUSING

PERSONAL INJURY OR PROPERTY DAMAGE.

1. Install the lower steering knuckle assembly in a vise with brass jaws.

It is acceptable to mount the knuckle components in a vise either vertically or horizontally when performing the reaming procedure.

2. Install the reamer into the lower steering knuckle until the blades touch the kingpin bushing.

3. Rotate the reamer with light downward pressure. Rotate the reamer smoothly. Do not apply too much pressure, see Figures 9-68 and 9-69.

FIGURE 9-68 Lower Steering Knuckle in Vise FIGURE 9-69 Upper Steering Knuckle in Vise

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SERVICE MANUAL

NOTE

NOTE


AIRTEK ® •


4. Slide the reamer out of the bottom of the steering knuckle assembly. If it is necessary to remove the reamer from the top, rotate the reamer opposite of cutting rotation.

5. Clean and remove all kingpin bushing material from the steering knuckle assembly.

Take special attention to remove material from the grease channels and dimples.

6. Clean the 5 /

8

" brake backing plate bolts with a wire wheel and run a tap through the threads of the lower steering knuckle assembly and then flush out with brake cleaner and dry with compressed air.

PRIOR TO INSTALLATION ENSURE THAT ALL RESIDUAL LOCTITE ® MATERIAL IS REMOVED FROM

THE MOUNTING BOLTS AND THE THREAD BORES IN THE UPPER STEERING KNUCKLES, AND

NEW LOCTITE 277 OR EQUIVALENT IS APPLIED TO HELP ENSURE THAT THE BOLTS SUSTAIN

THE PROPER TORQUE REQUIREMENT. FAILURE TO DO SO CAN CAUSE LOSS OF VEHICLE

CONTROL RESULTING IN PERSONAL INJURY OR PROPERTY DAMAGE.

The Hendrickson Genuine part, socket head cap screw comes with a pre-applied loctite compound.

7. Install the upper and lower steering knuckle on the kingpin.

8. Check for the proper fit by rotating the knuckle assembly back and forth to verify there is no binding on the kingpin, see Figures 9-70 and 9-71.

9. If the bushing is too tight repeat steps 1 through 8 until the proper clearance is achieved.

Bushing size is to be 0.001" larger than the kingpin size.


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KINGPIN SEAL INSTALLATION

1. Place the steering knuckle assembly in a vise with brass jaws or place on a suitable workbench. The steering knuckle will have the machined surface facing up (axle side up).

2. Lay the kingpin seal into the bore of the steering knuckle. The seal lip should face outward or toward the axle.

3. Use a bushing driver tool and press seal firmly into the steering knuckle assembly.

4. Install the kingpin seal until it makes contact with the kingpin bushing, see Figures

9-72 and 9-73.

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FIGURES 9-72 AND 9-73

STEERING KNUCKLE ASSEMBLY

ASSEMBLY

After replacement of the kingpin bushings it is necessary to re-assemble the steering knuckle assemblies. The STEERTEK axle is equipped with two different thrust bearings installed.

The composite thrust bearing is installed on the left side of the axle. The roller bearing is installed on the right side of the axle, see Figures 9-74 and 9-75, for right hand drive axle configuration the thrust bearings will be the opposite. Do not substitute aftermarket components when servicing.

1. Install the thrust bearing on the lower kingpin with the seal facing up toward axle (the black seal will designate the top side). The composite thrust bearing is installed on the left side of the axle. The roller bearing is installed on the right side of the axle, see

Figures 9-74 and 9-75. For right hand drive axle configuration the thrust bearings will be the opposite.

2. Install the shim on the upper kingpin.

3. Pack the bushing dimples on the upper and lower steering knuckles with multi purpose

Lithium based grease (NLGI Grade 2) before installation, see Figures 9-74 and 9-75.


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4. Install the upper steering knuckle on the upper arm kingpin.

5. Install the lower steering knuckle on the lower kingpin and install the old socket head cap screws loose into the top two threaded holes.

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SERVICE HINT

NOTE

IMPORTANT NOTE


AIRTEK ® •


The easiest way to achieve this is with the grease caps not installed in the knuckle assemblies. This eliminates back pressure. The assembly can then freely slide up and down on the kingpin. If the grease caps are still installed, remove the grease zerks to avoid creating back pressure. Grease zerks will be re-installed at the end of the procedure.

6. Install a bottle jack under the lower knuckle and slightly raise the knuckle until it is

possible to thread in the (3) brake backing plate bolts by hand. These are for guide

purposes only.

7. Snug the two socket head cap screws.

8. Lower the bottle jack so that all the vertical clearance is on the underside of the axle.

9. Affix a magnetic base dial indicator on the axle and place the tip of the dial indicator on top of the knuckle assembly, see Figure 9-76.

10. Zero the dial indicator.

FIGURE 9-76

11. Raise the bottle jack until there is no clearance between the knuckle assembly and the bottom of the axle, slightly lifting the axle.

12. Check the reading on the dial indicator. The specification for vertical travel on the steering knuckle during assembly is 0.008" to 0.011".

13. If the clearance is above 0.011", loosen the socket head cap screws and push down on the knuckle assembly until the proper vertical clearance is achieved. Add (0.005") shim if necessary.

14. If the clearance is below the 0.008", loosen the two socket head cap screws and pull up on the knuckle assembly until the proper vertical clearance is achieved. If the 0.008" minimum clearance is unattainable it may be necessary to remove a 0.005" shim.

The Hendrickson Genuine part, socket head cap screw comes with a pre-applied loctite compound.

PRIOR TO INSTALLATION ENSURE THAT ALL RESIDUAL LOCTITE MATERIAL IS REMOVED FROM

THE MOUNTING BOLTS AND THE THREAD BORES IN THE UPPER STEERING KNUCKLE, AND

NEW LOCTITE 277 OR EQUIVALENT IS APPLIED TO HELP ENSURE THAT THE BOLTS SUSTAIN

THE PROPER TORQUE REQUIREMENT. FAILURE TO DO SO CAN CAUSE LOSS OF VEHICLE

CONTROL RESULTING IN PERSONAL INJURY OR PROPERTY DAMAGE.

15. Remove one old socket head cap screw and replace with new socket head cap screw.

16. Remove second socket head cap screw and replace with new socket head cap screw.

Tighten both socket head cap screws to 175-200 foot pounds torque.

17. Recheck the vertical clearance with the dial indicator or a 0.010" feeler gauge, see

Figure 9-76.

18. Remove the brake spider bolts, they should thread out freely.

19. Remove the bottle jack and continue assembling the wheel ends.

Loctite applied to the three brake spider bolts is a critical procedure to ensure that these bolts sustain the torque requirement of Steering knuckle assembly.

133

17730-248

91


1

APPENDIX

L

134

L

SERVICE MANUAL

AIRTEK ® •


NOTE:

20. Apply loctite to the three brake spider bolts prior to installation into the brake spider.

Tighten bolts to 175-200 foot pounds torque.

DO NOT GREASE KNUCKLES WITHOUT THE BRAKE SPIDER INSTALLED AND TIGHTENED TO

PROPER TORQUE. FAILURE TO DO SO CAN CAUSE COMPONENT DAMAGE RESULTING IN

FAILURE AND LOSS OF VEHICLE CONTROL, POSSIBLY CAUSING PERSONAL INJURY OR

PROPERTY DAMAGE.

21. Install the tie rod end into the lower steering knuckle arm.

22. Tighten the castle nuts to 185 foot pounds torque then rotate the castle nut to the next castle slot and install cotter pin.

23. Install the drag link into the steering arm and tighten to the vehicle manufacturer’s

specifications.

24. Install new o-rings on the grease caps and lubricate o-rings with grease.

25. Install grease caps and new retaining rings.

26. Install brakes, drums, wheels and tires.

27. Remove jack and safety stands.

28. Grease steering knuckles with the vehicle on the floor.

29. Remove wheel chocks.

TIE ROD END AND CROSS TUBE

Hendrickson supplies different tie rod configurations. Prior to ordering find the part number on the tie rod tube. For additional information see Technical Bulletin SEU-0223 or contact

Hendrickson Sales Engineering.

DISASSEMBLY


2. Position the steer axle tires straight ahead.

3. Remove the cotter pin and castle nut.

4. Lightly tap the side of the Ackermann arm to loosen the tie rod end from the Ackermann arm, see Figure 9-77.

FIGURE 9-77

5. Repeat to steps 3 and 4 to remove the other tie rod end.

6. Remove the cross tube and tie rod ends from the vehicle.

7. Mount the cross tube in a soft jaw vice.

8. Remove the hardware from the clamp on the cross tube.

9. Count the exposed threads on the tie rod end being replaced.

10. Remove the tie rod end from the cross tube.

DO NOT HEAT THE CROSS TUBE WITH A TORCH TO FACILITATE THE REMOVAL OF THE TIE ROD

END. THE USE OF SUCH HEAT CAN ADVERSELY AFFECT THE STRENGTH OF THE CROSS TUBE.

A COMPONENT DAMAGED IN THIS MANNER WILL RESULT IN LOSS OF WARRANTY, AND CAN

RESULT IN THE AND LOSS OF VEHICLE CONTROL, AND POSSIBLE PERSONAL INJURY OR

PROPERTY DAMAGE.

11. If the opposing tie rod end is being replaced repeat steps 8 through 10.

92

17730-248 Component Replacement

1

APPENDIX

SERVICE MANUAL

NOTE


AIRTEK ® •


12. Inspect the cross tube for dents, cracks, or thread damage. Replace the cross tube if needed.

ASSEMBLY

1. Lubricate the new tie rod end threads with Anti-Seize.

When installing the cross tube the thread direction of the tie rod ends are as follows:

■

A right hand threaded tie rod end will be installed into the right side Ackermann arm.

■

A left hand threaded tie rod end will be installed into the left side Ackermann arm.

2. Install the new tie rod end into the cross tube, leaving the same amount of threads exposed that were counted on the failed tie rod end prior to removal.

THE THREADED PORTION OF THE TIE ROD END MUST EXTEND PAST THE SLOTS INTO THE TIE

ROD CROSS TUBE, SEE FIGURE 9-78. FAILURE TO DO SO CAN CAUSE COMPONENT DAMAGE,

LOSS OF VEHICLE CONTROL AND POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE.

FIGURE 9-78

135

17730-248

3. Replace the opposing tie rod end if necessary by repeating steps 2 and 3.

4. If replacing opposing tie rod end, it is critical that the cross tube will rotate in the opposing tie rod end.

DO NOT HEAT THE CROSS TUBE WITH A TORCH TO ROTATE THE CROSS TUBE IN THE TIE ROD

END. THE USE OF SUCH HEAT CAN ADVERSELY AFFECT THE STRENGTH OF THE CROSS TUBE.

A COMPONENT DAMAGED IN THIS MANNER WILL RESULT IN LOSS OF WARRANTY, AND CAN

RESULT IN THE LOSS OF VEHICLE CONTROL, AND POSSIBLE LOWER STEERING KNUCKLE

PERSONAL INJURY OR PROPERTY DAMAGE.

5. Install the cross tube into the Ackermann arms.

6. Tighten the castle nuts to 185 foot pounds torque then rotate the castle nut to the next castle slot and install cotter pin.

7. Grease tie rod ends, see Lubrication Chart for required lubricant in the Preventive


8. Set the toe, (see the Toe Adjustment Procedure in the Alignment & Adjustments Section of this publication).


93


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APPENDIX

L

136

SERVICE MANUAL

AIRTEK ® •


SECTION 10

Plumbing Diagrams

AIRTEK SINGLE HEIGHT CONTROL VALVE – 10K


L

Plumbing Diagrams

1

APPENDIX

94

17730-248


AIRTEK ® •


AIRTEK DUAL HEIGHT CONTROL VALVES – 14.6K


137

¼" Nylon Air Line

S.A.E., D.O.T. compliant

Use convoluted tubing over all nylon air lines

“In” Port

“Exhaust”

Port

C2

To Air Spring

C1

To Air Spring

FRONT

¾" Nylon Air Line

S.A.E., D.O.T. compliant

Use convoluted tubing over all nylon air lines

Pressure

Protection

Valve

17730-248

95

Plumbing Diagrams

1

APPENDIX

L

138

SERVICE MANUAL

AIRTEK ® •


L 1

APPENDIX

96

17730-248


Reference Material

This technical publication covers Hendrickson Truck Suspension’s recommended

procedures for our parts/products. Other components play a major role in overall

performance and Hendrickson recommends you follow the specific vehicle manufacturer’s recommendation for care and maintenance. Some recommended procedures have been developed by The Technology & Maintenance Council (TMC) and

Hendrickson supports these recommendations. We have compiled a list of these below.

TMC

To obtain copies of the following RP’s, video’s, or charts, contact TMC at:

TMC/ATA

2200 Mill Road

Alexandria, VA 22314

Phone: 703-838-1763 website: tmc.truckline.com

online ordering: www.truckline.com/store

Important References

TMC RP 214B Tire/Wheel End Balance and Runout

TMC RP 216

TMC RP 219A

TMC RP 222A

TMC RP 230

Radial Tire Conditions Analysis Guide

Radial Tire Wear Conditions and Causes

User’s Guide To Wheels and Rims

Tire Test Procedures for Tread wear, Serviceability, and

Fuel Economy

TMC RP 514

TMC RP 618

TMC RP 620B

TMC RP 708A

TMC RP 642

TMC RP 644

TMC RP 645

Video’s

Pre-Alignment Inspection

Wheel Bearing Adjustment Procedure

Front End Alignment Steering Geometry

Trailer Axle Alignment

Guidelines For Total Vehicle Alignment

Wheel End Conditions Analysis Guide

Tie Rod End Inspection and Maintenance Procedure

TMC T0326

TMC T0372

Other

TMC T0400

Wheel End Maintenance

Tire Pre-Trip Inspection Guidelines

Wheel bearing Adjustment Procedure Wall Chart

139

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APPENDIX

A-97

L

SERVICE MANUAL

140

CONDITION

Worn or damaged kingpins and kingpin bushings

Vibration or shimmy of front axle during operation

Excessive wear on tires or uneven tire tread wear

Vehicle is hard to steer

AIRTEK/SOFTEK

TROUBLESHOOTING GUIDE

POSSIBLE CAUSE CORRECTION

Dirt in system– contaminated lubricant

Incorrect lubricant

Axle not lubricated at scheduled frequency

Incorrect lubrication procedures

Lubrication interval not compatible with operating conditions

Worn or missing seals

Caster out of specification

Wheels and/or tires out of balance

Worn shock absorbers

Worn thrust washers (if equipped) and rear hanger clamps

Broken engine mount

Wheel bearing adjustment

Tires have incorrect air pressure

Tires out of balance

Incorrect tandem axle alignment

Incorrect toe setting

Incorrect steering arm geometry

Worn kingpin bushings

Excessive wheel bearing end play

Wheel bearing adjustment

Low pressure in the power steering system

Steering linkage needs lubrication

Steering knuckles are binding

Incorrect steering ar geometry

Caster out of specification

Tie rod ends hard to move

Worn thrust bearing

Steering gear box internal problem

Polish and inspect kingpin, replace bushing and seals, then follow specified lubrication procedures

Lubricate axle with specified lubricant

Lubricant axle at scheduled frequency

Use correct lubrication procedures

Change lubrication interval to match operating conditions

Replace worn or missing seals

Set proper ride height then adjust caster to specification

Balance or replace wheels and/or tires

Replace shock absorbers

Replace thrust washers (if equipped) and rear hanger clamps

Replace engine mount

Adjust wheel bearing to the vehicle manufacturers specifications.

Adjust tire pressure to manufacturer’s specification.

Balance or replace tires

Align tandem axles

Adjust toe-in to manufacturer’s specification

Repair steering system as necessary

Replace kingpin bushings

Check specified wheel nut torque, replace worn or damaged wheel bearings

Adjust wheel bearing to the vehicle manufacturers specifications.

Repair power steering system

Lubricate steering linkage

Check vertical clearance

Repair steering system as necessary


Replace tie rod ends

Replace thrust bearing

Perform steering gear trouble shooting procedures per steering gear manufacturing guidelines.

L

A-98

1

APPENDIX


CONDITION

Tie rod ends need lubrication

Tie rod ends are worn and require replacement Severe operating conditions

Worn or broken steering ball stud

Drag link fasteners lightened past specified torque

Lack of lubrication or incorrect lubricant

Power steering stops out of adjustment

Suspension has harsh or bumpy ride

Restricted steering radius

Vehicle leans

Vehicle wanders

AIRTEK/SOFTEK

TROUBLESHOOTING GUIDE (CONTINUED)

POSSIBLE CAUSE

Damaged boot on tie rod end

Pump/gear relief valve pressure setting exceeds system specifications

Bent or broken cross tube, tie rod end ball stud or tie rod end

NOTE:

Damaged components require replacement

Steering gear poppets improperly set or malfunctioning

Axle stops improperly set

Severe duty cycle service

Air spring not inflated

Air spring ride height out of specification

Broken or worn leaf spring

Front suspension overloaded

Steering stops not adjusted correctly

Ride height incorrect

Air spring(s) are not inflated

Suspension is not torqued correctly at installation

Leaf spring broken

Excessive weight bias

Caster out of specifications

Incorrect toe setting

Fifth wheel not greased

Air in the power steering system

Rear ride height out of adjustment

Front ride height out of adjustment

CORRECTION

Lubricate tie rod end. Make sure lubrication schedule is followed.

Increase frequency of inspection and lubrication intervals

Replace tie rod end

Adjust power steering system to manufacturer's specified pressure

Check for proper operation or adjust poppets to OEM specifications

Set axle stops to OEM specifications

Increase frequency of inspection and lubrication intervals

Tighten drag link fasteners to the specified torque

Lubricate linkage with specified lubricant

Adjust steering stops to OEM specifications

Check air supply to air spring, repair as necessary

Adjust ride height to proper specification

Replace leaf spring

Redistribute steer axle load

Adjust steering stops to achieve correct wheel cut

Adjust ride height to specification

Repair source of air pressure loss

Perform spring eye re-torque procedure.

See Torque Specification Section of this publication

Replace leaf spring

Contact the vehicle manufacturer or

Hendrickson Tech Services


Adjust toe to specification

Grease fifth wheel

Remove air form the power steering systems



141

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APPENDIX

A-99

L

142

SERVICE MANUAL

AIRTEK for Blue Bird Vision Buses - 10K Capacity

Hendrickson Recommended Torque Values Provided in Foot Pounds

L 1

APPENDIX


NO.

AIRTEK for Blue Bird Vision Buses – 10K

HENDRICKSON RECOMMENDED TORQUE SPECIFICATIONS

COMPONENT QTY.

SIZE

TORQUE VALUE

(in foot pounds)

1 Front Frame Hanger to Front Leaf Spring Eye

2 Rear Shackle Bracket to Shackle Plate

2

2

M20

M20

*290-310

*290-310

3 Rear Shackle Bracket to Spring Eye

4 Air Spring

5 Height Control Valve to Frame

6 HCV Linkage to HCV Arm

7 HCV Linkage to Top Pad

2

2

2

2

2

M20

Self-Locking

¼"

5 /

16

"

5 /

16

"

*290-310

Snap Fit

8-10

10-12

10-12

8 HCV Linkage Grommet to HCV Arm

9 HCV Linkage Grommet to Top Pad

10 Spring Center Aligning Dowel Pin (Flat Floor Bus)

1

1

2

Grommet

Grommet

¾"

Push In

Push In

***Loose Fit

11 Axle Wrap Liners for Clamp Group 2 Formed Snap Fit

DO NOT ASSEMBLE CLAMP GROUP WITHOUT AXLE WRAP LINERS. FAILURE TO DO SO CAN CAUSE

LOSS OF VEHICLE CONTROL, PROPERTY DAMAGE OR PERSONAL INJURY.

12 Clamp Group Hardware 8 ¾" 285-305

ENSURE CLAMP GROUP IS ALIGNED PROPERLY PRIOR TO TIGHTENING HARDWARE. FAILURE TO DO

SO CAN CAUSE LOSS OF VEHICLE CONTROL, PROPERTY DAMAGE OR PERSONAL INJURY.

13 Knuckle Attachment Bolt (Socket Head Cap Screw)

14 Knuckle / Axle Wheel Stop Bolt

4

2 5

5 /

8

"

/

8

" Jam Nut

175-200

40-60

15 Tie Rod Tube to Tie Rod Ends

16 Tie Rod Ends to Lower Steering Knuckle

17 Shocks Eye Bolts

2

2

2

7

5 /

8

"

/

8

" Castle Nut

¾"

60-75

**185

*125-135

• All hardware ¼" and greater is Grade 8 with no additional lubrication.

Frame mount hardware in most cases are Huck style fasteners supplied by the OEM.

NOTE:

* All hardware information in gray in the matrix denotes recommended torques for fasteners originally supplied by the vehicle manufacturer. If Hendrickson supplied fasteners are used, tighten to Hendrickson torque values, if non Hendrickson fasteners are used, follow torque specifications listed in the vehicle manufacturer’s service manual. Hendrickson is not responsible for maintaining vehicle manufacturer’s torque values.

** Torque to 185 foot lbs., advance nut to next hex face to install cotter pin. Do not back off nut for cotter pin installation.

*** Denote items not shown on illustration.

MODEL

Blue Bird

Vision 10K

RIDE HEIGHT

AIRTEK

SHOCK ABSORBER

LENGTH



12½" 18 9 /

16

"

COMFORT AIR

RIDE HEIGHT

SHOCK ABSORBER

LENGTH



4 7 /

8

" 22¾"

143

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APPENDIX

L

SERVICE MANUAL

144

SOFTEK for Blue Bird Vision Buses - 8K/10K Capacity


1.

*290-310

12.

Press Fit

1.

*290-310

12.

Press Fit

11.

*125-135

11.

*125-135

2. & 3.

*290-310

5.

Snap Fit

5.

Snap Fit

11.

*125-135

11.

*125-135

2.

*290-310

3.

*290-310

7.

175-200

7 .

175-200

10.

**185

8.

40-60 6.

285-305

9.

60-75

5.

Snap Fit

6.

285-305


9.

60-75

8.

40-60

10.

**185

2. & 3.

*290-310

L 1

APPENDIX


NO.

SOFTEK for Blue Bird Vision Buses – 8K/10K


COMPONENT



QTY.

2

2

SIZE

M20

M20

TORQUE VALUE

(in foot pounds)

*290-310

*290-310



2

2

M20

¾"

*290-310

***Loose Fit




6 Clamp Group Hardware 8 ¾" 285-305





4

2 5

5 /

8

"

/

8

" Jam Nut

175-200

40-60



11 Shocks Eye Bolts

12 Rubber Axle Stop

2

2

4

2

7

5 /

8

"

/

8

" Castle Nut

¾"

—

60-75

**185

*125-135

Press Fit



NOTE:


** Torque to 185 foot lbs., advance nut to next hex face to install cotter pin. Do not back off nut for cotter pin installation.

*** Denote items not shown on illustration.

145

1

APPENDIX

L

146

SERVICE MANUAL

AIRTEK for Blue Bird All American Buses - 14.6K Capacity


L 1

APPENDIX


NO.

AIRTEK for Blue Bird All American Buses – 14.6K


TORQUE VALUE

COMPONENT QTY.

SIZE

(in foot pounds) (in Nm)

Front Frame Hanger to Front Leaf Spring Eye 2 M20 *290-310 *393-420 1

4

5

2

3

6

7

Rear Shackle Bracket to Shackle Plate

Rear Shackle Bracket to Spring Eye

Air Spring to Air Spring Bracket

Air Spring to Top Pad

Height Control Valve to Air Spring Bracket

HCV Linkage to HCV Arm

2

2

2

2

2

2

M20

M20

¾"

½"

¼"

5 /

16

"

*290-310

*290-310

*20-30

20-30

8-10

10-12

*393-420

*393-420

*27-41

27-41

11-14

14-16

8

9

HCV Linkage to Top Pad

HCV Linkage Grommet to HCV Arm

10 HCV Linkage Grommet to Top Pad


2

1

1

2

5 /

16

"

Grommet

Grommet

¾"

10-12

Push In

Push In

Loose Fit

14-16




13 Clamp Group Hardware 8 ¾" 285-305 386-414

ENSURE CLAMP GROUP IS ALIGNED PROPERLY PRIOR TO TIGHTENING HARDWARE. FAILURE TO

DO SO CAN CAUSE LOSS OF VEHICLE CONTROL, PROPERTY DAMAGE OR PERSONAL INJURY.

14 Knuckle Attachment Bolt (Socket Head Cap Screw) 4 5 /

8

" 175-200 237-271



2

2

5 /

8

" Jam Nut

5 /

8

"

40-60

60-75

54-81

81-102

17 Tie Rod Ends to Lower Steering Knuckle 2 7 /

8

" Castle Nut **185 **251

18 Shocks Eye Bolts 2 ¾"



*125-135 *169-183

NOTE:


** Torque to 185 foot pounds (251 Nm), advance nut to next hex face to install cotter pin. Do not back off nut for cotter pin installation.

MODEL

Blue Bird

All American

Front Engine Model

All American

Rear Engine Model

RIDE HEIGHT

AIRTEK

SHOCK ABSORBER

LENGTH



14 7 ⁄

8

"

14 7 ⁄

8

"

17¼"

17 15 ⁄

32

"

COMFORT AIR

RIDE HEIGHT

SHOCK ABSORBER

LENGTH



4 7 ⁄

8

" 22¾"

147

1

APPENDIX

L

148

SERVICE MANUAL

SOFTEK for Blue Bird All American Buses - 13.2K/14.6K Capacity


L 1

APPENDIX


SOFTEK for Blue Bird All American Buses – 13.2K/14.6K


NO.

COMPONENT




QTY.

2

2

2

SIZE

M20

M20

M20

TORQUE VALUE

(in foot pounds) (in Nm)

*290-310 *393-420

*290-310

*290-310

*393-420

*393-420


5 Axle Wrap Liners for Clamp Group

2

2

¾"

Formed

Loose Fit

Snap Fit



6 Clamp Group Hardware 8 ¾" 285-305 386-414







11 Shocks Eye Bolts

4

2

2

2

4

7

5

5

5

/

8

"

/

8

" Jam Nut

/

8

"

/

8

" Castle Nut

¾"

175-200

40-60

60-75

**185

*125-135

237-271

54-81

81-102

**251

*169-183

12 Rubber Axle Stop 2 —



Press Fit

NOTE:


** Torque to 185 foot pounds (251 Nm), advance nut to next hex face to install cotter pin. Do not back off nut for cotter pin installation.

149

1

APPENDIX

L

SERVICE MANUAL

150

CAMBER 1

LEFT

RIGHT

CROSS

AIRTEK for Blue Bird Buses

FRONT AIR MODULE SUSPENSION ALIGNMENT SPECIFICATION

RANGE

DESIGN SPECIFICATION

0.00º ± 1.0º

- 0.25º ± 1.0º

Max 2.0º

MINIMUM

-1.0º

-1.25º

—

MAXIMUM

+1.0º

+0.75º

—

CAMBER NOTES:

1 The camber angle is not adjustable. Do not bend axle or otherwise try to adjust camber. If found out of specification, notify

Hendrickson Tech Services for further information.

CASTER

LEFT

RIGHT

CROSS 3

1,2 DESIGN SPECIFICATION

4.1º ± 1º

4.1º ± 1º

Max 1.0º

RANGE

10K 14.6K

MINIMUM MAXIMUM MINIMUM MAXIMUM

+3.1º +5.1º +3.1º +5.1º

+3.1º

—

+5.1º

—

+3.1º

—

+5.1º

—

CASTER NOTES:

1 Caster is determined with the vehicle at specified ride height for air suspension or at rated load for mechanical suspension systems. It is critical that the vehicle front and rear ride height is within specifications prior to performing a caster measurement or adjustment. See Hendrickson ride height specifications and procedure.

2 In most cases actual vehicle caster is defined with the frame rails at zero slope. Refer to the vehicle manufacturer’s specifications for correct frame rail slope. (Both the alignment surface and the vehicle’s frame rails should be level during execution of alignment procedures). For vehicles with a positive frame rake (higher in rear) add the frame slope (in degrees) to the caster reading to determine true vehicle caster.

3 The cross caster angle is not adjustable – Do not bend axle or otherwise try to adjust cross caster. If found out of specifications notify Hendrickson Tech Services for further information. Changes to caster can be attained by using caster shims as provided by the vehicle manufacturer or chassis and body manufacturer. Caster shims must match, side to side, to reduce uneven loading to the suspension components. The use of two different angle caster shims will not correct cross caster.

4 Example of caster adjustment: 2.5º RH/3º LH, would require one, 1.0 shim on each side to increase caster and achieve

3.5° RH/4.0° LH, which is in specification. Do not attempt to use uneven shims.

Hendrickson recommends following TMC 2 practices:

TOTAL TOE 2

DESIGN SPECIFICATION¹

1 /

16

" ± 1 /

32

" (0.06" ± 0.03")

MINIMUM

1 /

32

" (0.03")

RANGE

3 /

MAXIMUM

32

" (0.09")

TOE-IN NOTES:

1 Toe-in is to be set and adjusted in the normal vehicle unladed configuration. Actual vehicle curb weight on the ground. Toe should be checked at the tires front and rear tread center, at a distance above ground equal to the tire's rolling radius.

2 In most instances total toe is set by the vehicle manufacturer or body builder. Consult the vehicle manufacturer for specifications.

L 1

APPENDIX


CAMBER 1

LEFT

RIGHT

CROSS

SOFTEK for Blue Bird Buses

FRONT AIR MODULE SUSPENSION ALIGNMENT SPECIFICATION


0.00º ± 1.0º

- 0.25º ± 1.0º

Max 2.0º

MINIMUM

-1.0º

-1.25º

—

RANGE

MAXIMUM

+1.0º

+0.75º

—

CAMBER NOTES:

1 The camber angle is not adjustable. Do not bend axle or otherwise try to adjust camber. If found out of specification, notify

Hendrickson Tech Services for further information.

CASTER

LEFT

RIGHT

CROSS 3

1,2


8K/10K

8K/10K

RANGE

13.2K/14.6K

13.2K/14.6K

MINIMUM MAXIMUM MINIMUM MAXIMUM

4.5º ± 1º 4.5° ± 1.5° +3.5º +5.5º +3.0º +6.0º

4.5º ± 1º 4.5° ± 1.5°

Max 1.0º

+3.5º

—

+5.5º

—

+3.0º

—

+6.0º

—

CASTER NOTES:

1 Caster is determined with the vehicle at specified ride height for air suspension or at rated load for mechanical suspension systems. It is critical that the vehicle front and rear ride height is within specifications prior to performing a caster measurement or adjustment. See Hendrickson ride height specifications and procedure.

2

3

4

In most cases actual vehicle caster is defined with the frame rails at zero slope. Refer to the vehicle manufacturer’s specifications for correct frame rail slope. (Both the alignment surface and the vehicle’s frame rails should be level during execution of alignment procedures). For vehicles with a positive frame rake (higher in rear) add the frame slope (in degrees) to the caster reading to determine true vehicle caster.

The Cross caster angle is not adjustable – Do not bend axle or otherwise try to adjust cross caster. If found out of specifications notify Hendrickson Tech Services for further information. Changes to caster can be attained by using caster shims as provided by the vehicle manufacturer or chassis and body manufacturer. Caster shims must match, side to side, to reduce uneven loading to the suspension components. The use of two different angle caster shims will not correct cross caster.

Example of caster adjustment: 2.5º RH/3º LH, would require one, 1.0 shim on each side to increase caster and achieve

3.50° RH/4.00° LH, which is in specification. Do not attempt to use uneven shims.

Hendrickson recommends following TMC 2 practices:

TOTAL TOE 2

DESIGN SPECIFICATION¹

1 /

16

" ± 1 /

32

" (0.06" ± 0.03")

MINIMUM

1 /

32

" (0.03")

RANGE

MAXIMUM

3 /

32

" (0.09")

TOE-IN NOTES:

1 Toe-in is to be set and adjusted in the normal vehicle unladed configuration. Actual vehicle curb weight on the ground. Toe should be checked at the tires front and rear tread center, at a distance above ground equal to the tire's rolling radius.

2 In most instances total toe is set by the vehicle manufacturer or body builder. Consult the vehicle manufacturer for specifications.

151

1

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L

SERVICE MANUAL

152

L

A-110

1

APPENDIX

Technical Procedure Publication Quiz

1) What three items have the greatest influence on tire wear?

a) Toe b) Air Pressure c) Camber d) Thrust Angle

2) Caster may be increased or decreased using shims or wedges.

True or False

3) Cross caster may be changed using shims or wedges.

True or False

4) You may bend a STEERTEK axle to correct for improper camber settings.

True or False

5) In an unladen vehicle the correct toe setting for the STEERTEK axle is?

a) 0 to negative 1 /

8

" b) 0 to negative 1 /

16

" c) 0 to positive 1 /

32

" d) 1 /

16

" ± 1 /

32

"

6) When reducing wheel cut on the STEERTEK axle it is necessary to check the steering gear box poppets.

True or False

7) The torque requirement for the front and rear spring hanger eye bolts are the same.

True or False

8) When servicing the clamp group a technician should always replace the following items.

a) Hex bolts/U-bolts (Grade 8) and nylon locknuts (Grade C) b) Bottom axle wrap liner c) Upper axle wrap liner, if removed d) All of the above

9) What is the clamp group final torque?

a) 500-550 foot pounds (678-746 Nm) b) 290-310 foot pounds (393-420 Nm) c) 285-305 foot pounds (386-414 Nm) d) 240-275 foot pounds (325-373 Nm)

10) What is the torque sequence for the clamp group? See Figure below.

a) 1,3,2,4 b) 1,4,2,3 c) 1,2,3,4 d) The torque sequence does not matter.

11) For a vehicle equipped with a STEERTEK axle it is an acceptable practice to tow using a tow chain wrapped around the axle.

True or False

12) The front leaf spring eye bushing is non serviceable

True or False


13) To remove the STEERTEK knuckle you must.

a) Drive the kingpin out of the axle bore b) Remove the locking pins before driving the kingpin out c) Remove the two 5 /

8

" socket head cap screws and separate the knuckle assembly d) None of the above

14) What is the maximum allowable specification for lateral movement of the steering knuckle?

a) 0.001" b) 0.075" c) 0.030" d) 0.015"

15) When the AIRTEK ride height is checked, it is not necessary to cycle the leveling valve before check the ride height.

True or False

16) Worn kingpins are easily removed and replaced.

True or False

17) The lower shock eye bolt mounting torque per the vehicle manufacturer is: a) 125-135 foot pounds (169-183 Nm) b) 225-255 foot pounds (305-346 Nm) c) not critical d) none of the above

18) Although the AIRTEK/SOFTEK is low maintenance, it is recommended to do a visual inspection on the axle and suspension every ___________ miles.

a) 100,000 or 1 year b) 25,000 or 6 months c) Never

19) When replacing the rear spring ¾" length hanger bolts, the new bolts should be installed: a) From the outboard side to inboard side for AIRTEK 10K and SOFTEK 8K/10K b) It does not matter what direction the bolts are facing c) From the inboard side to outboard side for AIRTEK 14.6K and SOFTEK

13.2K/14.6K

d) Both a and c

20) The STEERTEK axle combined with the clamp group and stiff front spring limb help to make the AIRTEK torsionally rigid and reduce body roll.

True or False

21) How many grease points are there on the STEERTEK axle?

a) 2 b) 6 c) 8 d) None

22) It is acceptable to replace a failed shock absorber with any brand that will fit.

True or False

23) A shock that is misting is classified as a leaking shock and should be replaced immediately.

True or False

24) Wheel bearing adjustment has no impact on tire wear.

True or False

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SERVICE MANUAL

154

L

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1

APPENDIX

CERTIFICATE

25) Prior to performing a total vehicle alignment the following components must be inspected.

a) Front and rear spring mounts b) Steer axle tires c) Ride height d) All of the above

26) When the clamp group is disassembled the use of a cutting torch is acceptable to help remove seized bolts and nuts.

True or False

27) Prior to steering knuckle re-assembly it is critical that residual Loctite be removed and reapplied from the upper kingpin connection.

True or False

28) AIRTEK is available exclusively with the STEERTEK axle.

True or False

29) To heat test a shock absorber you should drive a vehicle at moderate speeds for fifteen minutes.

True or False

30) If the kingpin bushing is worn, then both bushings on that knuckle need to be replaced.

True or False

31) The unique packaging of the steering knuckle will allow up to ______ degrees of wheel cut on the STEERTEK axle.

a) Maximum of 50° b) 32° c) 87° d) None of the above

32) A pre-alignment inspection reveals a tie rod end is worn out of specification. What is the correct action needed to complete the alignment.

a) Fill the tie rod with grease to absorb excessive play b) Replace the tie rod and reset toe before alignment c) Perform alignment and then replace tie rod end and reset toe d) Align vehicle and do not repair tie rod end

33) The seal on the thrust bearings are installed facing down.

a) True b) False c) Doesn’t matter

34) When servicing tie rod ends it is not necessary to have the part number located on the tie rod tube to order tie rod service kits.

True or False

Hendrickson will provide a personalized AIRTEK/SOFTEK Technical Procedure Quiz

Achievement Certificate to candidates scoring 80% or higher on the test. Simply complete the test and fill in the enclosed answer sheet or on a separate sheet with the return address, name, phone number, and company name as it will appear on the award to:

Hendrickson

ATTN: Truck Marketing Test Quiz Assessment

800 S. Frontage Road

Woodridge, Illinois 60517

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