PREVOST GKN AXLES LIMITED KIRKSTALL DIVISION Service Manual
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PREVOST GKN AXLES LIMITED KIRKSTALL DIVISION Service Manual

PREVOST GKN AXLES LIMITED KIRKSTALL DIVISION Service Manual

For axle type s82
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CONTENTS
1. DESCRIPTION......................................................................................................................................... 16-3
2. AIR SPRING ............................................................................................................................................ 16-4
2.1
Inspection........................................................................................................................................ 16-4
2.2
Removal.......................................................................................................................................... 16-4
2.3
Installation....................................................................................................................................... 16-4
3. SHOCK ABSORBER ............................................................................................................................... 16-5
3.1
Inspection........................................................................................................................................ 16-5
3.2
Removal.......................................................................................................................................... 16-5
3.3
Installation....................................................................................................................................... 16-6
4. RADIUS ROD........................................................................................................................................... 16-6
4.1
Inspection........................................................................................................................................ 16-6
4.2
Removal.......................................................................................................................................... 16-7
4.3
Bushing Removal ........................................................................................................................... 16-7
4.4
Bushing Installation......................................................................................................................... 16-7
4.5
Installation....................................................................................................................................... 16-7
5.1
Removal.......................................................................................................................................... 16-8
5.2
Installation....................................................................................................................................... 16-8
6. SUSPENSION AIR SYSTEM .................................................................................................................. 16-9
6.1
Description...................................................................................................................................... 16-9
6.2
Inspection........................................................................................................................................ 16-9
6.3
Air Line Test.................................................................................................................................... 16-9
6.4
Air Tank Maintenance..................................................................................................................... 16-9
7. SUSPENSION HEIGHT ADJUSTMENT................................................................................................. 16-9
8. HEIGHT CONTROL VALVE.................................................................................................................. 16-10
8.1
Operation ...................................................................................................................................... 16-10
8.1.1 Loading Position ................................................................................................................ 16-10
8.1.2 Neutral Position.................................................................................................................. 16-10
8.1.3 Unloading Position............................................................................................................. 16-10
8.2
Maintenance ................................................................................................................................. 16-10
8.2.1 Removal and Installation ................................................................................................... 16-11
8.2.2 Air Leakage Test................................................................................................................ 16-11
9. FRONT KNEELING AND HI-BUOY SYSTEM (IF APPLICABLE)........................................................ 16-12
9.1
Principles of Operation ................................................................................................................. 16-12
9.2
Maintenance ................................................................................................................................. 16-12
9.3
Keeling Sense Switch................................................................................................................... 16-13
9.4
Bellows Control and Exhaust Solenoid Valves ............................................................................ 16-13
9.4.1 Removal and Installation ................................................................................................... 16-13
10. HI-BUOY SYSTEM ................................................................................................................................ 16-13
10.1 Principles of Operation ................................................................................................................. 16-13
SECTION 16: SUSPENSION
16-1

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  • Page 1: Table Of Contents

    SECTION 16: SUSPENSION CONTENTS 1. DESCRIPTION............................16-3 2. AIR SPRING ............................16-4 Inspection............................16-4 Removal............................16-4 Installation............................16-4 3. SHOCK ABSORBER ..........................16-5 Inspection............................16-5 Removal............................16-5 Installation............................16-6 4. RADIUS ROD............................16-6 Inspection............................16-6 Removal............................16-7 Bushing Removal ........................... 16-7 Bushing Installation.........................
  • Page 2 Section 16: SUSPENSION 11. LOW-BUOY SYSTEM ........................... 16-13 11.1 Principles of Operation ......................... 16-13 12. "LEVEL-LOW" LEVELING SYSTEM (IF APPLICABLE)............... 16-14 12.1 Principles of Operation ......................... 16-14 13. DRIVE AXLE STABILIZER RESERVOIR (XL-45 CONVERTED VEHICLE) ........16-15 13.1 Lubrication (Fig. 17) ........................16-15 14.

  • Page 3: Description

    Section 16: SUSPENSION 1. DESCRIPTION The vehicle is provided with an air suspension system. The system consists of air springs, height control valves, radius rods, sway bars and shock absorbers (Fig. 1 and 2). The system operation is fully automatic and maintains a constant vehicle height regardless of load, or load distribution.

  • Page 4: Air Spring

    Section 16: SUSPENSION 2. AIR SPRING 1. Safely support vehicle at the recommended body jacking points. The "rolling lobe" type air springs are made from a To gain access to a given air spring, the corre- special compound rubber molded to the proper sponding wheel can be removed as follows: contour and dimensions.

  • Page 5: Shock Absorber

    Section 16: SUSPENSION 6. Build up air pressure in system. air will enter the cylinder tube and make the shock absorber appear defective. Note: To accelerate this operation, air reser- Proceed as follows to check shock absorbers: voirs can be filled from an exterior air supply connected to the accessory tank fill valve or to 1.

  • Page 6: Installation

    Section 16: SUSPENSION 5. Place the lower and upper mounting pin stud nuts and torque them to 70 - 80 lbf·ft (95 - 110 N·m). 4. RADIUS ROD Radius rods are used to secure the axles in the proper transversal and longitudinal positions. Four radius rods are provided on the front axle suspen- sion (three longitudinal and one transversal), four on the drive axle suspension (three longitudinal...

  • Page 7: Removal

    Section 16: SUSPENSION 4. If necessary, use an arbor press or a suitable 4.2 Removal driving tool. Press or drive the bushing into the radius rod end until it extends equally on both 1. Flatten the tab washer which secures the two sides of the rod.

  • Page 8: Sway Bar

    Section 16: SUSPENSION 2. Position the retaining plate. Install the tab 5. With the vehicle at normal ride height, apply oil washer and nuts (or bolts). on threads and tighten all radius rod anchor pin nuts or bolts to 110 - 130 lbf·ft (150 - Caution: Always use new tab washers at 175 N·m).

  • Page 9: Suspension Air System

    Section 16: SUSPENSION 6. SUSPENSION AIR SYSTEM 6.3 Air Line Test With the main air system at normal operating pressure (95 - 125 psi (655 - 860 kPa)), coat all 6.1 Description suspension air line connections and air spring mountings with a solution of soap and water. Air The suspension air system has its own air reser- leakage will produce soap bubbles.

  • Page 10: Height Control Valve

    Section 16: SUSPENSION The appropriate vehicle body height is obtained by Note: The measure should be taken from measuring the clearance of all the air springs under the upper air spring support on sub- installed on the vehicles. All air springs clearance frame to top of the lower air spring support on should be 11.5 ±...

  • Page 11: Maintenance

    Section 16: SUSPENSION 3. Disconnect overtravel lever from link and pull 8.2 Maintenance down lever to exhaust remaining air from air springs. The height control valve requires no periodic maintenance. Height control valve linkage oper- 4. Disconnect air supply and delivery lines from ates on rubber bushings and no lubrication should the height control valve.

  • Page 12: Front Kneeling And Hi-Buoy System (If Applicable)

    Section 16: SUSPENSION ease. It is also used to allow an extra ground 9. FRONT KNEELING AND HI- clearance for particular situations. In normal con- BUOY SYSTEM (IF ditions, the height control valve is in operation and only the hi-buoy can be operated. APPLICABLE) The kneeling system is used to lower front of ve- 9.1 Principle of Operation...

  • Page 13: Principles Of Operation

    Section 16: SUSPENSION 9.3 Kneeling Sense Switch 10.1 Principles of Operation The kneeling sense switch is bolted to the same Refer to the system pneumatic diagram annexed bracket as for the front height control valve, right in the technical publication box provided with the over the steering axle.

  • Page 14: Level-Low" Leveling System (If Applicable)

    Section 16: SUSPENSION Warning: Never move vehicle with selector 12. "LEVEL-LOW" LEVELING knob in any other position than the "DRIVE" SYSTEM (IF APPLICABLE) position. The purpose of the "level-low" leveling system is to adjust suspension in three separate points (front, rear right and rear left) in order to level vehicle body.

  • Page 15: Lubrication (Fig. 17)

    Section 16: SUSPENSION FIGURE 17: DRIVE AXLE STABILIZER RESERVOIR 16034 13.1 Lubrication (Fig. 17) The sight glass indicates if oil must be added to the reservoir. If the small ball in the sight glass is at the bottom of the sight glass then add oil to the reservoir as per the following procedure: 1. Remove connector tube at the top of the res- ervoir to permit air to enter.

  • Page 16: Troubleshooting

    Section 16: SUSPENSION 14. TROUBLESHOOTING MALFUNCTION POSSIBLE CAUSE CORRECTION Bellows deflate over time Defective check valve assembly Replace check valve assembly Defective exhaust valve assembly Replace exhaust valve assembly Leak in air line and/or bellows Replace air line or bellows Defective valve cover, rubber O-rings Replace valve cover, O-rings or gas- or gasket...

  • Page 17: Torque Specifications

    Section 16: SUSPENSION HEIGHT CONTROL VALVE RADIUS ROD BUSHING Make.............Neway Make ............Prévost Quantity used............3 Prévost number .......... 630021 Supplier number........905 54 234 SWAY BAR BUSHING Prévost number........... 630095 Make ............Prévost BELLOWS CONTROL EXHAUST Prévost number .......... 130953 SOLENOID VALVE ASSEMBLY SHOCK ABSORBER AND SWAY BAR LINK Make............Norgren...
  • Page 18 SECTION 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) CONTENTS 1. INTRODUCTION............................16-4 2. STEERING LINKAGE ..........................16-4 2.1 General Description ........................16-4 2.2 Turning Angle..........................16-5 2.3 Steering Linkage Adjustment.......................16-8 2.4 Pitman Arm ..........................16-8 2.4.1 Removal ...........................16-8 2.4.2 Installation ........................16-8 2.5 Drag Link............................16-8 2.5.1 Adjustment ........................16-9 2.6 Bell Crank and Idler Arm......................16-9 2.6.1 Bell Crank and Idler Arm Removal ..................16-9...
  • Page 19 Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) 4.2 Front End Inspection........................16-21 4.3 Front Wheel Camber .........................16-21 4.4 Front Wheel Toe-In........................16-21 4.5 Toe-In Check ..........................16-21 4.6 Toe-In Adjustment ........................16-22 4.7 Front-Axle Caster........................16-22 4.8 Major Damage ...........................16-22 5. AIR SPRING MAINTENANCE (FRONT AIR SPRINGS).................16-24 5.1 Inspection...........................16-24 5.2 Removal.............................16-24 5.3 Installation ..........................16-25...
  • Page 20 Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) LIST OF ILLUSTRATIONS FIG. 1: SUSPENSION AND STEERING LINKAGE ..................16-4 FIG. 2: LOCATION OF CLAMPS........................16-5 FIG. 3: CLAMP POSITIONING ........................16-6 FIG. 4: CLAMP POSITIONING ........................16-6 FIG. 5: CLAMP POSITIONING ........................16-6 FIG.

  • Page 21: Introduction

    Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) left front wheels. The steering linkage consists 1. INTRODUCTION of tie rods connected to the bell crank and the This supplement contains service procedures steering arm at the left side of the coach, and and specifications that apply to the PRÉVOST to the idler arm and steering arm at the right XL converted coach shell vehicles equipped...

  • Page 22: Turning Angle

    Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) 2.2 Turning Angle maximum turning angle mechanically through the two steering stop screws installed on the swivel assembly. The + 0° - 1° turning angle (56° ) mechanical stop is factory adjusted to accommodate the chassis design, and therefore, does not require adjustment on new vehicles.
  • Page 23 Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) FIGURE 4: CLAMP POSITIONING 16039 FIGURE 3: CLAMP POSITIONING 16038 FIGURE 5: CLAMP POSITIONING 16040 16-6...
  • Page 24 Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) FIGURE 6: CLAMPS POSITIONING 16041 16-7...

  • Page 25: Steering Linkage Adjustment

    Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) Warning: Always wear approved 2.3 Steering Linkage Adjust- protection when operating pullers. ment Caution: Do not drive pitman arm on or off Note: Whenever a steering linkage compo- pitman shaft as this can damage the steering nent has been removed and replaced, check gear.

  • Page 26: Adjustment

    Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) Drag link end sockets are equipped with lubri- 1. Bell crank : Disconnect drag link, tie rod and relay rod from bell crank by removing cation fittings and should be lubricated as cotter pins, stud nuts and washers from directed in paragraph "2.10 LUBRICATION ball studs.
  • Page 27 Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) FIGURE 8: BELL CRANK AND IDLER ARM BALL JOINT 16043 5. Install bearing, o-ring and nut. Note : Apply grease on bearing before in- stallation. 5. Firmly tighten nut (Fig. 9). FIGURE 10: BELL CRANK 16045 6. Unscrew nut until bell crank or idler arm...

  • Page 28: Relay Rod

    Each tie rod assembly 9. Apply anti-seize compound PREVOST # consists of three parts; a tube and two socket 640064 on screws' threads. Install the cap end assemblies.

  • Page 29: Steering Arms

    Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) 3. Position ball studs (socket ends of tie rod) 4. Install wheel as directed in Section 13, in holes in steering arm and bell crank or "WHEEL, HUBS AND TIRES" under idler arm.

  • Page 30: Power Steering Hydraulic Pump

    Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) 6. Idler Arm and Crank bell : Lubricate at LX or equivalent). Apply grease gun two fittings, one on the idler arm and the pressure to the fitting until lubricant ap- other on the crank bell, every 6,250 miles pears at the top seal.

  • Page 31: Independent Front Suspension Joints

    Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) ends of the annular spacer are not in 3. INDEPENDENT FRONT contact with each other, the thus formed SUSPENSION JOINTS opening must be located at 180 to the opening of the locking circlip. Pay attention during assembly to ensure that the locking 3.1 Lower and Upper A-Arm circlip eyelets are located at each side of...
  • Page 32 Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) FIGURE 12: BALL JOINT 16047 16-15...

  • Page 33: Lower A-Arm Central Joints (Bt-Sectional Bearing System)

    Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) 3.2 Lower A- Arm Central TABLE 3 Joints (Bt-Sectional Bearing Suitable for Position Axial load F1 System) repair kits (kN) Prévost # 3.2.1 Instructions 611112 Lower A-arm All reference numbers mentioned refer to component parts shown in figure 13.
  • Page 34 Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) FIGURE 13: CENTRAL JOINT 16048 TABLE 5 Suitable ORDER PRÉVOST TOOLS # for repair SEE FIGURE 13 kits Prévost # 611112 683114 683115 683116 683117 683118 683120 683119 16-17...

  • Page 35: Upper A-Arm Ball Joints (One-Part Bearing System)

    Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) 3.3 Upper A-Arm Ball Joints TABLE 6 (One-Part Bearing System) Suitable for ORDER PRÉVOST TOOLS # repair kits 3.3.1 Instructions SEE FIGURE 14 Prévost # All reference numbers mentioned below refer to component parts shown in (Fig.
  • Page 36 Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) FIGURE 14: BALL JOINT 16049 16-19...
  • Page 37 Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) FIGURE 15: STEERING LINKAGE MEASURE 16050 16-20...

  • Page 38: Front End Alignment

    Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) 6. Check king pins for looseness. 4. FRONT END ALIGNMENT 7. Check if the length of the torque rod is Proper front end alignment must be main- 23 9/64" (588 mm) (Fig. 15). Check if the tained to insure ease of steering and provide length relay...

  • Page 39: Toe-In Check

    Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) by keeping the wheels in a straight ahead 4.5 Toe-In Check position. 1. Check the camber adjustment and adjust Caster variations may be caused by bent if necessary. upper suspension arm, lower suspension 2. Hoist the front of the vehicle and spin the arm, or king pin housing.
  • Page 40 Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) FIGURE 16: FRONT END ALIGNMENT DIAGRAM 16051 DIAGRAM SPECS (SEE FIGURE 16) WHEEL CAMBER 1/8° ± 1/4° KING PIN INCLINATION 6,5° (not adjustable) CASTER 2° (not adjustable) TOE-IN 3/32 ± 1/32 inch. 16-23...

  • Page 41: Air Spring Maintenance (Front Air Springs)

    Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) 5. AIR SPRING 5.2 Removal MAINTENANCE Note: Front air springs can be removed with- out removing the entire suspension assembly. (FRONT AIR SPRINGS) 1. Safely support vehicle at the recom- Two "rolling lobe" type air springs are used mended body jacking points and jack up with the independent front suspension, one at body understructure.

  • Page 42: Installation

    Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) FIGURE 18: AIR SPRING AND SHOCK ABSORBER 16053 5.3 Installation Note: To accelerate this operation, air reser- voirs can be filled from an exterior air supply 1. Compress air spring as necessary, then connected to the accessory tank fill valve or to aligning studs with their holes, position air the emergency fill valve.

  • Page 43: Shock Absorber

    Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) 6. SHOCK ABSORBER 6.2 Shock Absorber Installation front shock absorbers double-acting and telescopic type. Shock 1. Check that the shock absorber mounting absorbers ensure a smooth ride and enhance pin is properly torqued (350 - 400 lbf·ft vehicle stability on the road.

  • Page 44: Sway Bar (Front Suspension)

    Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) FIGURE 20: SWAY BAR (FRONT SUSPENSION) 16055 FIGURE 21: SWAY BAR (DRIVE AXLE) 16056 7.1 Sway Bar (Front Suspension) 3. Remove sway bar. Note: Sway bar bushings are slitted to ease their 7.1.1 Removal removal.

  • Page 45: Sway Bar (Drive Axle)

    Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) 2. Torque bushing collar nuts to 70 - 80 lbf•ft 9/64" (588 mm) and relay rod to 22 13/32" (95 - 110 N•m). (569 mm). 3. Torque sway bar link upper nuts to 215 - 225 Caution : Parts must be replaced by ones with lbf•ft (290 - 305 N•m) and lower nuts to 70 - 80...

  • Page 46: Height Control Valve

    Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) Caution: Always adjust on "fill cycle". If it is neces- sary to lower vehicle height, release sufficient air to be well below height, and adjust to height or fill cycle. The normal ride height is obtained by adjusting air spring clearance of both front and rear suspension as follows: FRONT AIR SPRING CLEARANCE...

  • Page 47: Neutral Position

    Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) 9.1.2 Neutral Position 10. "LEVEL-LOW" LEVELING When vehicle body reaches the normal ride SYSTEM (IF APPLICABLE) height, the height control valve overtravel lever The purpose of the "level-low" leveling system is reaches the "neutral"...

  • Page 48: Air Tank Maintenance

    Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) FIGURE 25: AIR TANKS' LOCATIONS 16060 11.2 Air Tank Maintenance Ensure that the accessory air tank is purged dur- ing pre-starting inspection. A good practice is to purge this tank at the end of every working day by the remote air tank drain valve located in the steering compartment (Fig.

  • Page 49: Secondary Air Tank

    Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS)      The primary air tank is located above R.H. wheel of drive axle. To increase primary air tank volume, a supple- mentary air tank is added in series to the primary air tank.

  • Page 50: Air Brakes

    Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) FIGURE 29: REAR VALVE LOCATION (XL-40 & XL-45E) 12010 FIGURE 31: FRONT VALVE LOCATION 12089 These two air valves are fitted with the same valve stems as standard tires, and can be filled by any standard external air supply line.

  • Page 51: Brake Air Chamber

    Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS)     13. BRAKE AIR CHAMBER The front wheels are equipped with "Knorr- Brake pads have to be checked on a regular basis Bremse" brake chambers, used for service brake. depending on vehicle operation. The remaining thickness of the pads should never be less than 3/32 in (2 mm).

  • Page 52: Torque Table

    Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) 16. TORQUE TABLE DESCRIPTION REFERENCE TORQUE (DRY) lbf•ft / N•m Steering Gear to Mounting Bracket Bolt Nut 350-400 475-542 Pitman Arm to Steering Gear Clamp Bolt 275-300 373-407 Drag Link to Pitman Arm Stud Nut* Drag Link to Bell crank Stud Nut* Drag Link Socket End Clamp Bolt Nut 60-80...

  • Page 53: Specifications

    Section 16: SUPPLEMENT INFORMATION ON INDEPENDENT FRONT SUSPENSION (IFS) 17. SPECIFICATIONS Front Axle Brake Chambers Make..........Knorr-Bremse Type..............24 Effective diaphragm area ...24 sq.in. (154,8 sq.cm) Supplier number......BS 3517 II/31651 Prévost number...........641309 Front Axle Air Springs Make......Goodyear Tire and Rubber Diameter..........
  • Page 54 GKN AXLES LIMITED KIRKSTALL DIVISION SERVICE MANUAL FOR AXLE TYPE S82 HUB UNIT AND SWIVEL ASSEMBLY FITTED TO PRÉVOST'S XL CONVERTED COACH SHELL WITH INDEPENDENT SUSPENSION REVISED BY PRÉVOST CAR INC.
  • Page 55 CONTENTS 1. LUBRICATION..............................2 2. Routine Maintenance ............................3 3. HUB UNIT REMOVAL ............................ 3 4. STUB AXLE ASSEMBLY REMOVAL......................3 4.1 Inspection ..............................4 5. REFITTING STUB AXLE ASSEMBLY ......................4 6. SWIVEL BEARING ADJUSTMENT ....................... 4 7. SWIVEL FINAL ASSEMBLY........................... 5 8.

  • Page 56: Lubrication

    1. LUBRICATION Lubricate the top swivel bearing and the bottom swivel bush. They are provided with grease fitting for pressure lubrication (Fig. 1). These grease fittings should be serviced every 6,250 miles (10 000 km) or twice a year whichever comes first. Good quality lithium-base grease NLGI No. 2 (Shell Retinax LX or equivalent) is recommended.

  • Page 57: Routine Maintenance

    12. Drive out hub bearing cups (11 & 64, Fig. 2. ROUTINE MAINTENANCE 8) from hub (8, Fig. 8). 2.1 Hub Bearing Adjustment 13. If hub bearing distance piece (oil seal An inspection should be made after the first wear sleeve) (60, Fig. 8) shows signs of 3,000 miles (4 800 km) and then at intervals wear or corrosion it must be removed and of 25,000 miles (40 000 km).

  • Page 58: Inspection

    11. Check the condition of swivel stop nut 3. Select swivel bearing adjustment shims (33, Fig. 8), and adjusting washer (32, (19, Fig. 8) with total thickness of Fig. 8), removing for replacement if approximately 0.020 inch and place in required.

  • Page 59: Swivel Final Assembly

    FIGURE 3: TOP AND BOTTOM CAP 10018 5. Secure bottom cap (55, Fig. 8) with swivel bottom cap setscrews and washers (53 & 54, Fig. 8) then tighten to 26-32 lbf•ft (33- 35 N•m). FIGURE METHOD CHECKING SWIVEL BEARING ADJUSTMENT 10017 6. Check that tightening torque of top steering arm studs (28, Fig.

  • Page 60: Hub Unit Assembly

    8. Fit hub bearing nut pinch bolt and nut (66 & 5, Fig. 8), tighten finger tight. 9. Adjust 'End Float' as follows : Rotate hub and using a hide faced mallet, knock hub backwards and forwards along axle arm to 'Shock Load' and thus settle bearings in position.
  • Page 61  Check the 'End Float' again, using above procedure, and adjust if outside specified limits. FIGURE 6: TO ADJUST HUB 'END FLOAT' 10021 10. Clean hub cap and hub mating faces (3 & 8, Fig. 8) with Loctite Superclean Safety Solvent no. 706 or other suitable chlorinated solvent then...

  • Page 62: Torque Table

    9. TORQUE TABLE ITEM No DESCRIPTION TORQUE (DRY) lbf•ft / N•m Hub Cap Setscrew 85-103 115-140 Hub Pinch Bolt Nut 24-26 33-35 Wheel Nut 475-525 644-712 Brake Caliper Setscrew 310-340 420-461 Swivel Pin Nut 500-700 678-949 Top Cap Setscrew 51-62 69-84 Top Steering Arm Stud 190-210...

  • Page 63: Parts List

    10. PARTS LIST ITEM No DESCRIPTION QTY/AXLE Hub Cap Setscrew Hub Cap Spring Washer Hub Cap Hub Cap 'O' Ring Bearing Nut Pinch Nut Hub Bearing 'D' Washer Wheel Stud Protective Cover Wheel Stud R.H. Wheel Stud L.H. Pole Wheel Hub Outer Bearing Cup Hub Outer Cone Hub Oil Seal...
  • Page 64 Swivel Bearing Cup Swivel Bearing Cone Swivel Pin 'D' Washer Swivel Pin Nut Top Cap Top Cap Setscrew Spring Washer Top Cap Setscrew Lubricator Lubricator Protective Cap Top Steering Arm Stud L.H. Top Steering Arm Stud R.H. Top Steering Arm (L.H.) Top Steering Arm Nut Brake Caliper Bracket Nut Stop Screw Adjusting Washer...
  • Page 65 Swivel Bottom Cap Swivel Pin Swivel Pin Bottom Bush Swivel Assembly L.H. Swivel Assembly R.H. Brake Caliper Bracket Stud Hub Bearing Distance Piece Brake Caliper Bracket Bolt Brake Caliper Bracket Nut Brake Disc Hub Inner Bearing Cup Hub Inner Bearing Cone Brake Disc Capscrew Bearing Nut Pinch Bolt Hub Bearing Nut...
  • Page 66 FIGURE 8: HUB UNIT AND STUB AXLE 10023...

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