Link 60K AIR Installation Instructions Manual
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Link 60K AIR Installation Instructions Manual

Chassis suspensions, tandem drive suspension
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INSTALLATION
INSTRUCTIONS
60K AIR LINK
®
TANDEM DRIVE SUSPENSION
Link Suspensions of Canada
601 18th Ave
Nisku, AB T9E 7T7 Canada
www.linkmfg.com
QUESTIONS?
CALL CUSTOMER
SERVICE
1-888-472-9326
60K AIR LINK Susp.
11/27/2019

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Summary of Contents for Link 60K AIR LINK

  • Page 1 INSTALLATION INSTRUCTIONS 60K AIR LINK ® TANDEM DRIVE SUSPENSION Link Suspensions of Canada 601 18th Ave Nisku, AB T9E 7T7 Canada www.linkmfg.com QUESTIONS? CALL CUSTOMER SERVICE 1-888-472-9326 60K AIR LINK Susp. 11/27/2019...
  • Page 2 601 – 18 Avenue Nisku, Alberta Ph: 888-472-9326 Fax: 780-955-2386 Email: lsc@linkmfg.com Link Manufacturing Ltd. 223 – 15 Street NE Sioux Center, Iowa 51250 Ph: 800-222-6283 Fax: 712-722-4876 Email: info@linkmfg.com AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...

  • Page 3: Table Of Contents

    Required Tools ........................23 Procedure ..........................24 Install the Shock ........................27 Required Components ......................27 Required Tools ........................27 Procedure ..........................28 Install Restraint Strap ........................ 30 AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...
  • Page 4 Plumbing the Air System ......................43 SECTION 4: SUSPENSION FINAL SETUP ..................44 APPENDIX A: TORQUE SUMMARY TABLE ..................45 APPENDIX B: ..........................46 APPENDIX C: ..........................47 AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...

  • Page 5: Section 1: Component Terminology

    SECTION 1: COMPONENT TERMINOLOGY AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...

  • Page 6: Section 2: Introduction

    INTRODUCTION Description This document is intended to provide general guidelines for the installation of the Air Link system in a new chassis at the OEM level. In this case, the design has been worked into the chassis based on requirements outlined by the OEM (capacity, ride height, spread, etc.).

  • Page 7: Section 3: Assembly

    Walking beam [1][2] (Link Supplied) [1] The walking beam is not available without bushings. [2] Walking beam supplied assembled with bushings in kit. Breakdown above provided for replacement detail. AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...

  • Page 8: Required Tools

    4. Insert the trunnion tube into the center bushing of each walking beam. Note: Trunnion tube must be installed before the walking beams are installed to the axles. AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...
  • Page 9 Warning: Axles and suspension components are heavy. Avoid pinch points during assembly. 8. Align each bushing inner sleeve to the axle hanger bore holes. AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...
  • Page 10 Follow axle manufacturer’s recommended procedures for completing this step. 11. Back off set screws off enough so that the point does not protrude past the inside of the cap. AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...
  • Page 11 Note: Tighten the hardware to secure the connection with no play. Final torque done at alignment stage. See Appendix B. AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...

  • Page 12: Assemble The Axle To The Walking Beams (3"Ø Adapter Bushing)

    [2] Walking beam supplied assembled with bushings in kit. Breakdown above provided for replacement detail. Required Tools ▪ Hammer (Mallet) ▪ Wrench (1 1/2”) ▪ Socket (1 1/2”) ▪ Torque wrench 500 ft-lb minimum ▪ Digital Level ▪ Pliers ▪ Alignment punch AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...

  • Page 13: Procedure

    Note: Trunnion tube is intended to be loose in the center bushing. (Freely rotate and some end to end play). AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...
  • Page 14 7. Slide each straight adapter sleeve through the axle hanger bore holes. 8. Install the slotted nuts and cotter pins. Torque specification: 1200-1250 ft-lb. [1627-1695 Nm] AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...
  • Page 15 Note: Keep the orientation of the end caps straight up and down as shown. This is the neutral position for the eccentric bushing. AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...
  • Page 16 Note: Tighten the hardware to secure the connection with no play. Final torque done at alignment stage. AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...

  • Page 17: Install Frame Mounted Components

    [2] Air Spring Hangers, for the capacity, are typically two sizes. Refer to layout drawing to ensure correct orientation. Required Tools ▪ Socket ▪ Wrench ▪ Ratchet wrench or Air impact tool. AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...

  • Page 18: Procedure

    Note: The suspension is designed to use axle stops at each wheel end to control jounce travel of the walking beam. Link does not typically supply these parts, but they are very important for a functional suspension. 1. Mount the trailing arm hanger to the frame.
  • Page 19 4. Install the upper shock bracket to the frame rail using 2 - 3/4”Ø bolts Gr.8 (or equivalent) Note: The design of the bracket may vary; refer to suspension kit drawing for clarifying details. AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...

  • Page 20: Install The Trailing Arm

    1. Dis-assemble the upper block set on each trailing arm. 2. Use solvent to flush the threaded holes and bolts to remove any remaining anti- seize compound from the manufacturing process. AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...
  • Page 21 5. To ensure the trailing arm spacing is centered on the hanger bushing, the bushing should be flush on the outside trailing arm block. 6. Apply thread locking compound (Loctite 242) on bolts. AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...
  • Page 22 Caution: Ensure caps are tightened square so that the gaps are even across the bushing. Torque specification: 250 ft-lb [339 Nm] AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...

  • Page 23: Install Air Spring

    (Link P/N: 201-02-110) Bolt, Hex, Gr.5, Ø1/2" UNC x 1-1/2” (Link P/N: 201-00-045) Required Tools ▪ Torque wrench 30lb-ft minimum ▪ Socket (3/4") ▪ Socket (1 1/8”) ▪ Ratchet wrench AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...

  • Page 24: Procedure

    3. Secure the air spring top stud to the air spring hangers, using the 1/2ӯ flat washer, lock washer and a standard hex nut. Torque specification: 30 ft-lb [41 Nm] AIR LINK 60k Suspension РInstallation Manual Rev.00 (11/20/2019) Proprietary and Confidential...
  • Page 25 Secure the bottom of the air spring to the trailing arm using the 1/2”Ø flat washers, lock washers and bolts. Torque specification: 30 ft-lb [41 Nm] AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...
  • Page 26 9. Repeat steps 1 through 8 for the opposing air springs. Note: It is easiest to install the forward air springs first, then the rear based on the room in the suspension. AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...

  • Page 27: Install The Shock

    ▪ Torque wrench 250 ft-lb minimum ▪ Socket (1 1/2”) ▪ Socket (1 1/8”) ▪ Wrench (1 1/8”) ▪ Ratchet wrench or Air impact gun ▪ Loctite 242 (Blue) AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...

  • Page 28: Procedure

    Make sure bolt head is orientated to the outside of the suspension. 5. Align the upper shock eye until it lines up with the threaded hole in the frame mounted shock bracket. AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...
  • Page 29 1”Ø Torque specification: 200-250 ft-lb [271-339 Nm] 3/4”Ø Torque specification: 180-200 ft-lb [244-271 Nm] 9. Repeat steps 1 thru 8 for the opposite side of the suspension. AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...

  • Page 30: Install Restraint Strap

    Restraint strap kits are offered for customers who are operating units which can raise the chassis off the ground using outriggers. In these cases, Link offers these straps to provide additional control of the jounce travel of the suspension. For all Air Link suspensions, the shock is designed specifically to control the jounce travel.

  • Page 31: Procedure

    7. Secure the lower cotter pin as in Step 4. 8. Repeat steps 1 – 7 for the restraint strap on the other side of the chassis. AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...

  • Page 32: Install The Height Control Valve Linkage Rod

    Trailing Arm Hangers. The installation below is for Link’s standard valve kit. There are two options for securement hardware (pin connection or bolt connection). Both are shown below for reference. Both are acceptable methods and it will be customer preference and based on the suspension layout.

  • Page 33: Procedure (Height Control Valve Installation)

    Required Components (Pin Connection) Description Quantity Image HCV Linkage Rod Stud, Straight (1/4-20 UNC-2A) Nut, Hex, Gr8 (1/4-20 UNC-2A) Washer, Lock, SAE (Ø1/4") AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...

  • Page 34: Procedure (Pin Connection)

    Torque specification: 80-100 in-lb [9-11 Nm] 4. Loosen the clamp on the p-boot which secures it to the HCV linkage rod. AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...
  • Page 35 Note: This connection can be readjusted during final ride height setting once the chassis has load on 8. Repeat step 1-7 for the opposite side of the suspension. AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...

  • Page 36: Required Components (Bolt Connection)

    Torque specification: 5-10 in-lb [1-2 Nm] Caution: The bolt should only be tightened to remove the play in the connection while still allowing the grommet to rotate on the bolt. AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...
  • Page 37 Torque specification: 5-10 in-lb [1-2 Nm] Caution: The bolt should only be tightened to remove the play in the connection while still allowing the grommet to rotate on the bolt. AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...
  • Page 38 Note: This connection can be readjusted during final ride height setting once the chassis has load on 9. Repeat steps 1-8 for the opposite side of the suspension. AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...

  • Page 39: Install The Walking Beam/Axle Assembly To The Trailing Arms

    Line up the walking beam center bushings into the lower block set of the trailing arms. Warning: Be careful of pinch/crush points that can damage components and injure technicians. AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...
  • Page 40 Tighten the bolts back and forth until full torque to keep the gap even. Torque specification: 250 ft-lb [271 Nm] AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...

  • Page 41: Install Control Rod Components

    Link does offer control rods for customers and some OEMs have organized their own solution. In all cases, Link is willing to work with each OEM to ensure that these control rods are configured to provide an optimum configuration for the Air Link suspension.
  • Page 42 The Air Link suspension system can also be configured with V-Rod control rod designs. Please contact Link to review and provide design feedback for any special OEM configuration request. AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...

  • Page 43: Plumbing The Air System

    Plumbing the Air System The Suspension air system is relatively simple in application. The Air Link suspension system is a height controlled suspension and will adjust the air pressure in the air springs to maintain the design ride height based on the load applied.

  • Page 44: Section 4: Suspension Final Setup

    Please contact Link if a ride height change is needed on any chassis after the suspension is installed so that we can assist in finding the best resolution.

  • Page 45: Appendix A: Torque Summary Table

    HCV mounting bolts Ø1/4" UNC bolt 80-100 [9-11] HCV arm to linkage rod Ø1/4" UNC bolt 5-10 [1-2] Linkage rod boot to L-bracket Ø1/4" UNC bolt 5-10 [1-2] AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...
  • Page 46 APPENDIX B: AIR LINK RIDE HEIGHT ADJUSTEMENT WORK INSTRUCTION AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...
  • Page 47 The information hereon in, refers to Link supplied height control valves. Set-up and adjustment will vary from different height control valve manufacturers. Please refer to the instructions specific to your height control valve.
  • Page 48 Work Instruction LWI 055 REAR SUSPENSION RIDE HEIGHT ADJUSTMENT Issued by: Engineering Date: 06/25/2018 Rev.: 1 Pg. 2 of 6 3. Ensure all ¼” hardware for the height control valves mounting and rod linkages are torqued to specification before starting. Torque specification: 5-10 in-lb [1 Nm] –...
  • Page 49 Work Instruction LWI 055 REAR SUSPENSION RIDE HEIGHT ADJUSTMENT Issued by: Engineering Date: 06/25/2018 Rev.: 1 Pg. 3 of 6 Option 1 - Digital Level (a) Place a digital level on a clean section of the bottom flange of the chassis frame rail near the suspension.
  • Page 50 Work Instruction LWI 055 REAR SUSPENSION RIDE HEIGHT ADJUSTMENT Issued by: Engineering Date: 06/25/2018 Rev.: 1 Pg. 4 of 6 (c) Measure from the frame of the top surface of the trailing arm at the back, behind the second air spring. (d) Subtract the two measurements from one another.
  • Page 51 Work Instruction LWI 055 REAR SUSPENSION RIDE HEIGHT ADJUSTMENT Issued by: Engineering Date: 06/25/2018 Rev.: 1 Pg. 5 of 6 6. Use screwdriver to loosen clamp on P-bolt. 7. Adjust the rod through the P-boot. Note: Orientation of the P-boot is not critical (can be upside down). The key is to ensure that there is rod sticking through the entire length.
  • Page 52 11. Measure the second side of the Air Link® suspension. 12. Repeat steps 6 - 10 for the second side of the Air Link® suspension, then proceed to step 13. 13. Recheck the first side of the Air Link suspension.
  • Page 53 Work Instruction LWI 055 REAR SUSPENSION RIDE HEIGHT ADJUSTMENT Issued by: Engineering Date: 06/25/2018 Rev.: 1 Pg. 7 of 6 REVISION HISTORY Revision Date Details 10/05/2017 Initial release. 11/26/2018 Revise entire document UNCONTROLLED IF PRINTED...
  • Page 54 APPENDIX C: AIR LINK ALIGNMENT WORK INSTRUCTION AIR LINK 60k Suspension – Installation Manual Rev.00 (11/20/2019) Proprietary and Confidential...
  • Page 55 Pg. 1 of 5 PURPOSE ® This publication is intended for vehicles equipped with Air Link suspension that have walking beams with a through pin end connection. Proper axle and wheel alignment will provide prolonged tire life, decreased maintenance on the suspension and driveline components and improved fuel economy.
  • Page 56 Work Instruction LWI 056 THROUGH PIN ALIGNMENT Issued by: Engineering Date: 06/25/2019 Rev.: 1 Pg. 2 of 5 ALIGNMENT PROCEDURE 1. Prior to any alignment measurements and adjustments, park the chassis on level ground. 2. Ensure that the ride height is set correctly. Note: At design ride height, the top surface of the trailing arm must be parallel to the bottom flange of...
  • Page 57 Work Instruction LWI 056 THROUGH PIN ALIGNMENT Issued by: Engineering Date: 06/25/2019 Rev.: 1 Pg. 3 of 5 7. Loosen the two stover nuts just enough to rotate the end caps. Note: Some friction is desired to keep everything in place during alignment. Note: If the truck has been in service, the hardware or end caps may have become...
  • Page 58 Work Instruction LWI 056 THROUGH PIN ALIGNMENT Issued by: Engineering Date: 06/25/2019 Rev.: 1 Pg. 4 of 5 ECCENTRIC END CAP ANGLE CORNER THRUST ANGLE THRUST ANGLE X (IN)* MOVEMENT X (DEG) 0° 0” NEUTRAL VERTICAL (0°) 1/16 0.1° 0.436” FORWARD ANGLED (-22.5°)
  • Page 59 Work Instruction LWI 056 THROUGH PIN ALIGNMENT Issued by: Engineering Date: 06/25/2019 Rev.: 1 Pg. 5 of 5 1/16 0.1° 0.436” REARWARD ANGLED (22.5°) 0.2° 0.873” REARWARD ANGLED (45°) 3/16 0.3° 1.309” REARWARD ANGLED (67.5°) 0.4° 1.745” REARWARD ANGLED (90°) *The thrust angle measurement is based on a wheel base of 250”.

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